ML18058B896

Svc Water Sys - Evaluation of Pipe Wall Thinning Down Stream of Valve CV-0826.

ML18058B896
Person / Time
Site:	Palisades
Issue date:	06/17/1993
From:	Hoang P CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML18058B895	List: ML18058B894 ML18058B896 ML18058B897 ML18058B898
References
EA-SP-03316-03, EA-SP-03316-03-R00, EA-SP-3316-3, EA-SP-3316-3-R, NUDOCS 9307060310
Download: ML18058B896 (22)

Text

@ consumers Power l'OWEIUlllfi MICHl&All"S PffOlillESS PALISADES NUCLEAR PLANT ENGINEERING ANALYSIS COVER SHEET EA - S P - O3 ~ 16 - O ?>

Total Number of Sheets 3,_

Title SgA'Y_ICE l&.4lf8. St_SrEM - Ell'.A L !ll1 na& OE e_1PE >VAl:L [tf. INNI tJ..(i;.

/l.Q 'r!l.l!l. ~Vt.EAM QF VAL VE. c ll- 0826.

INITIATION AND REVIEW Calculation Status Preliminary Pending Fi~ Superseded D D D Initiated Init Review Method Technically Reviewed Revr Rev Appd Appd CPCo w/_/. .",., ,% ge9

1. Description Detail 9ual By Date By Alt Cale By Date By Appd P.i~

,_,, ~B'i Review v

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0 Original Issue

p. Hol+N<; q3 *v ~~~

( 9307060310 930701 PDR ADOCK 05000255

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'P PDR Form 3619 10-91

PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 2 Rev# 00

1.0 Purpose

The purpose of this caclulation is to evaluate the structural integrity of a small through wall leak found near the down stream flange of CV0826 valve on line HB23-16" of Service Water system for a temperory non-Code repair permit. The scope of the calculation includes evaluations using the proposed Code Case N-513 "Fracture Mechanics Approach", the Code Case N-480 "Wall Thinning Evaluation Method" and the "Branch Reinforcement Approach" per the proposed Code Case N-513.

2.0 Design Input:

1. Nondestructive Testing Service Thickness Measurement Examination Report, dated 5126/93

2. Drawing M101 SH. 2744, Rev. 2

3. Stress Report EA*SP* 03316-01, S&L File# 9131-00

4. Nondestructive Testing Service Thickness Measurement Examination Report, dated 6/6/93

5. Palisades Plant Piping Class Summary, M-259, Sh. 3HB, Rev. 9.

3.0 Assumptions

• 1. Per the plant NOE personnel, the UT thickness measurement grid (1" by 1 ") for the bottom half of the eroded piping portion starts from the toe of the fillet weld where a pin hole leak was found.

2. Thickness of pipe wall within the flange hub and weld can not be confirmed. This calculation is performed with an assumption that there is no corrosion at the fillet weld interfaces with flange and pipe base metals.

3. Per the conversation between CPCo Licencing and NRC staff (5/27/93 and 6/4/93), the structural integrity of the leaked pipe can be evaluated by the "Wall Thinning Approach" or the "Branch Reinforcement Approach". (See attachment 3)

4.0 Approach

The UT thickness measurement grid dated 5126/93 is a 2" by 2" grid for the pipe bottom half and 2" by 6" grid for the pipe top half. The examined area starts at 1/2" from the slip on flange fillet weld toe, 12" wide on the down stream pipe side and all around the pipe circumference. The thickness measurement show that the eroded area is concentrated at the pipe bottom and very close to the fillet weld toe. A refined grid (1" by 1") was used for the measurement dated 6/6/93. The refined grid covered the pipe bottom half, 4" wide, and butted up the fillet weld toe. The surface plot of the pipe wall thickness adjacent to the pin hole leak is shown in Figures 1 & 2.

Structural integrity of the eroded pipe is evaluated by the following approaches:

~*

PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 3 Rev# 00 4.1.Fracture Mechnics Approach: (Ref. 7.10 and 7.5) a) Flaw characterization:

The stress intensity factor K assuming pipe wall thickness of tmin per the USN RC GL 90-05 is judged to be too conservative for low pressure piping (very small tmin>*

Alternatively, the proposed Code Case N-513 (Ref. 7.10) suggests that the adjusted pipe wall thickness tadj can be chosen such as tmin < tadj < tact where tmin is the Code minimum pressure design pipe wall thickness P*D t * := -D mm 2( 15000 + 0.4-P)

The minimum measured pipe wall thickness (0.141") is conservatively conside_red as the pipe actual wall thickness adjacent to the flaw tact*

In this calculation tadj is chosen such that the characterized flaw length 2a is the 3" length limit. From Figure 3, with the smooth flaw profile and 2a=3", tadj is approximately 0.132".

Therefore, a 3 inch circumferential through wall crack on a 16" OD, 0.132" thick pipe, is the postulated fracture mechanics model.

Note that the predicted pipe wall thickness at the end of the evaluation period is not reqiured for this approach.

b) Applied stress:

The nomimal applied stress s(ksi) for pressure, dead weight and SSE is recalculated from the intensified combined stresses at the valve end (REF. 7.3). Note that thermal load is not considered due to temperature < 150 degree and SSE stress is two times OBE stress.The applied stress is the far field stress (unintensified and no adjustment for pipe wall thickness).

c) Stress intensity factor K: Ref. 7.5 and 7.10 K := l.4*s*F*~o where F := I + A*C l.S + B *C2.S + c *C3.5 D a

c :=--o (it*R)

D - t adi R := ~ D :Mean radius 2

R r:=-o 1 adj The coeficients A,B and C are given in Section 5.2 of this calculation.

- ,-*

PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 4 Rev# 00

• d) Acceptance criteria Where K1 is the material initiation stress intensity. For carbon steel, K 1 :=35000 psi-,Ji;io (Ref. 7.5) 4.2 Wall Thinning Approach:

a) Methodology: (Ref. 7.4)

- The predicted pipe wall thickness at the end of 18 month evaluation period is calculated from the current minimum measured thickness and the wear rate.

- The average wear rate of the past 20 years of the plant operation is calculated from the difference between the maximum pipe thickness tolerance and the minimum measured thichness divided by 20 year.

- The Code minimum pipe wall thickness tmin is calculated as such that axial and hoop stresses meet all Code stress limits.

b) Acceptance Criteria

- The predicted pipe wall thickness to the next outage (18 month appx.) tp shall be greater than tmin.

- The stress limit for pressure hoop stress is Sh (15 Ksi)

- The stress limit for equation 11 (P+WT) is Sh (15 Ksi)

- The stress limit for equation 128 (P+WT+08E) is 1.2Sh (18 Ksi)

- The stress limit for equation 128 (P+WT+SSE) is 2.4Sh (36 Ksi)

• PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 5 Rev# 00 4.3 Branch Reiforcement Approach

• a) Flaw characterization:(Proposed Code Case N-513)

The Code minimum thickness is calculated as:

t * :=

P*D

-D nun 2( 15000 + 0.4*P)

Per the proposed Code Case N-513 (Ref. 7.10), the adjusted pipe wall thickness tadj can be chosen such as 2*tmin < tadj < tnom In this calculation tadj is chosen such that the characterized flaw is entirely contained within a 5 inch diameter circular area. The diameter d of the postulated circular opening is 10". (Ref. 7.10, Section 3.2).

- Applied stress:

The nomimal applied stress s for pressure, dead weight and SSE is recalculated from the intensified combined stresses at the valve end (REF. 7.3). Note that thermal load is not considered due to temperature < 150 degree. SSE stress is two times OBE stress. The nominal stresses are then adjusted for the new pipe thickness before reintensified by the UFT stress intensification factor.

- The required reinforcement area for the circular opening is calculated in accordance with ND-3643.3, Ref. 7.7~

- Stress intensification factor of an equivalent unreinfored fabricated tee (UFT) is calculated using Figure ND-3673.2(b)-1, Ref 7 .8.

c) Acceptance criteria Stress at the postulated circular opening using UFT stess intensification factor shall be within the ND-3650 limits for all service levels .

• PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 6 Rev# 00 5.0 Calculations 5.1 Measured pipe wall thickness:

1 2 3 4 5

.380 .401 .404 .375 .374 G Partial pipe wall thickness plot using the .379 .383 .380 .374 .381 H measured data dated 6/6/93 .202 .394 .373 .374 .373 I

.227 .4 .373 .371 .377 J

.264 .278 .309 .299 .393 K

.141 .301 .313 .342 .365 L M:=

= 0 .. 11 .214 .270 .329 .378 .312 M j = 0 .. 4 .2 .202 .310 .207 .364 N

.166 .4 .318 .374 .396 0 N.l, ( 4 - J*i :=M1,J

.. .25 .379 .402 .381 .375 p Q.l :=M.I, o .383 .377 .375 .372 .375 Q

.389 .408 .380 .376 .380 R M

Figure 1 Surface Plot of Pipe Wall thickness from row G through row R N

• Figure 2 Other View of Surface Plot of Pipe Wall thickness from row G through row R

PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet? Rev#OO 5.2 Calculation using fracture mechanics approach.

a) Flaw characterization:

The Code min wall thickness for design pressure: p =100 D := 16

. *- P*D t nun.-- .

2*( 15000 + 0.4*P) t min =0.053 Envelope the pipe wall thickness to a smooth profile (dash curve in Fig. 3)

Ql := 0.28 Q3 := 0.16 Q :=0.135 Q :=0.12 Q6:=0.115 Q 7 *=0127 .

4 5 Q :=0.16 Q :=0.225 QlO :=0.31 8 9 i := 0 .. 11 tact :=Ms,o tact=0.141 > tadj:=0.132 > tmin=0.053 0.389 .----.--.----.--.------.---r----r----.---..------c::=-..,,/

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tact 0.195

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. ........-:..:. :..::..:- -* -* -*-*-*- -*- *--_-:,_-:_- -,........: -* - . -* - .

t . ------

nun o.___ _.__ _....__ _.__ __.__ __.__ __.__ ___._ ___..__ _..__ _.__ __,

0 2 3 4 6 7 8 9 10 11 i

Figure 3 : Pipe Wall Thickness in cricumferential direction measured near the fillet weld toe. tadj is determined from the smooth wall profile such that the through wall crack length 2a is 3 inches.

PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 8 Rev# 00 b) Applied Stress Nominal stress fields near the flaw (RUNID 03316A.INP EA-SP-03316-01 Rev 0)

At node point 50, analysed pressure P=65 psi i := 1.425 0.75 factor included p :=65 D = 16 t nom :=0.375 s p =693.333 s pwt := 926

- 2241 - s pwt s obe - .

I s sse := 2 *s obe s = 2.702* 103 c) Applied stress intensity K R := 16- t adj The 2a flaw length is about 3" at t adj 2

r. *- -R- al:=-

3 r =60.106 t adj 2 Coefficients A,B,C and D in matrix form

- 3 .26543 1.52784 - 0.072698 0.0016011 a:= 11.36322 -3.91412 0.18619 -0.004099

(

-3.18609 3.84763 -0.18304 0.00403 173.603 r

b - 2 c .=a*b c= -441.331 r

441.908 3

r

PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 9 Rev # 00 C :=_al_ c =0.06 (n*R)

F :=I+ c 0

.cl. 5 + c 1.c 2*5 + c 2.c 3*5 F = 3.194 3 s s = 2.702* l 0 s. *-- - - Ksi 1000 05 K := 1.4* s.f.( n*al)

• K =26.234 Ksi*,Ji;i K(=35 Ksi*,ji;i K<Kro d) Results The applied stress intensity K (26.234) is less then 35 ksi fi;iu Therefore, no Code repair or replacement is required .

• PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 10 Rev# 00 5.3 Wall thinning approach:

a) Minimum measured thickness tmeas :=Ms,o tmeas =0.141 b) Predicted pipe thickness in the next 18 month period

- The average wear rate in the pass 20 years of operation based on the max and min measured thickness.

l.1 2 S*t nom - t meas rate:=-------

20 rate = 0.014 inch per year

- The predicted pipe thickness based on the average wear rate for the next 18 month period 18 t p := t meas - -*(rate) 12 tp =0.12 tp is greater than 0.3*tnom =0.113 inch, therefore tp meet the requirement 3410 of Code Case N-480.

c) Minimum pipe wall thickness required per the Code Case N-480 c.1) Minimum pipe wall thickness required for hoop stress See Section 5.2 (a) of this calculation t min =0.053 c.2) Minimum thickness required for axial stress to meet the Code stress limits Section modulus for thin wall pipe:

Z(t) =n* -D _-

( 2 t) .*t 2

• PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 11 Rev# 00 As analysed stresses based on the original section modulus (Ref. 7.3) s 11 : = 926 s 12B *=2242 5 l 2D = 5 11 + 2 . ( 5 l 2B - 5 11)

- Minimum thickness required to meet Eq. 11 stress limit Stress as a function oft calculated from the ratio of the original section modulus and the reduced thickness section modulus.

Z orig s(t) := s 1r - - Sall = 15000 Z(t)

Solve fort with an initial guess t :=0.01 t min =root( s(t) - Sall' t) t min =0.022

- Minimum thickness required to meet Eq. 128 stress limit.

z s(t) := s 12B ' - -

orig Sall = 18000 Z(t)

Solve fort t min =0.045

- Minimum thickness required to meet Eq. 120 stress limit.

• = s . z orig Sall = 36000 s(t) . 12D Z(t)

Solve fort t min =0.036

• Therefore, the Code minimum pipe thickness is governed by the pressure hoop stress t min := 0.053

PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 12 Rev# 00 c.3) Evaluations using N- 480. 361 O(a) acceptance criteria:

The tp at the end of evaluation period is greater than the Code minimum pipe wall thickness.

. tp =0.12 t min =0.053 t p>t min Therefore, the flaw is acceptable per 361 O(a) of N-480 d) Result:

The flaw wall thinning predicted for the next 18 month period is acceptable per N-480 acceptance criteria 3610 (a).Therefore, code repair is not required. Note that the minimum measured pipe wall thickness in the subsequence inspections shall not be less than 0.3 times pipe nominal thickness or 0.113" per the requirement 3420 of N-480 .

• PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 13 Rev# 00 5.4 Branch reinforcement approach (Proposed Code Case N-513) a) Flaw characterization The Code min wall thickness for design pressure: P=!OO D:=l6

. *- P*D t nun.-- t min =0.053 2*( 15000 + 0.4*P)

= 0 .. 11 2-t min= 0.106 < t adj =0.165 < t nom = 0.375 0.389 ... --******************** .......................................................................................................................................... ***************-** ... ********************* .......... ****---~-

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0.35 \

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0.311 \ /

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0.272 /

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0.233 /

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t nom 0.195 ',, /

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• ---.-~"':'.:-.. *---*-*-*-* *-*-*-*-*- - -* -*-*-*- ----------- -*-*-*-*-*-* .-.:::_________ ----*-*-*-*

0.156 0.117

--- ----

2*t .

___ nun0.078 0.039 O'--~-'-~~--'-~~'--~-'-~~-'-~~'--~---'-~~--'-~~'--~---'-~---'

0 2 3 4 6 7 8 9 10 11 Figure 4 : Pipe Wall Thickness in cricumferential direction measured near the fillet weld toe.The smooth wall thickness profile is used to determine tadj such that t > 2*tmin and the flaw is within a 5 inch diameter circular opening.

From Fig. 4 the pipe wall thickness for the branch reinforcement approach is tadj =0.165 b) The required reinforcement area for the circular opening is calculated in accordance with ND-3643.3, Ref. 7.7.

d := 10  : the postulated circular opening d2 :=d  : the header reinforcement length

available reinforcement area from header

. 2 m

• A req = 1.07-d*t min Areq =0.569 Therefore, the reinforcement area meet the requirement per ND-3643.3, Ref. 7.8

. 2 m :required reinforcement area

PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 14 Rev# 00 c) Stress using UFT stress intensification factor R = D - t adj t adi tadj =0.165 h.*- - -~

2 R

. 0.9 1 uft :=- i uft = 11.884 2

h3 Nominal stress for the original pipe thickness (RUNID 03316A.INP EA-SP-03316-01 Rev 0) p :=65 tnom :=0.375 i = 1.425 0.75 factor included

._ P*D Sp.---- Sp =693.333  : Pressure stress 4*tnom

Pressure plus weight stress

WT stress

_ 2241- Spwt s obe .- . :OBE stress I

For thin wall pipe, the modified nominal stress for pipe wall thickness of tadj can be approximated as follows:

tnom Sobe:= s obe'--.

t adj Reintensified stress using UFT stress intensification factor Eq 11 s 11 =4.883*103 < 15,000 psi Eq 128 4 S 12B =2.358*10 > 18,000 psi

• 4 Eq 120 S l 2D = 4.227* I 0 > 36,0000 psi d) Results: The erroded pipe fails to meet the N-513 UFT evaluation citeria 3.2 (c).

'. *

PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 15 Rev# 00 6.0 Summary and

Conclusion:

Three different approaches were used to evaluate the structural integrity of the pin hole leak on line HB23-16". The results of the evaluations are as the follows:

- Linear Elastic Fracture Mechanics Approach: (Proposed Code Case N-513)

K = 26.234 Ksi fi;i  : Applied stress intensity is less than Kr=35 Ksi fi;i  : Allowable stress intensity

- Wall Thinning Approach: (Code Case N-480) t p =0.12 in  : Predicted pipe wall is greater than t min = 0.053 in  : Required minimum pipe wall thickness

- Branch reinforcement Approach: (Proposed Code Case N-513) 2 A 1 = 1.118 in :total available reinforcement area is greater than 2

A req = 0.569 in :required reinforcement area 3

S 11 = 4.883* IO < 15;000 psi 4

S12B=2.358*10 >18,000psi :Fail 4

s1 2o=4.227*10 >36,0000psi :Fail The structural integrity of the pipe leak was found to be assured by the fracture mechanics approach and the wall thinning approach. The flaw also meet the reinforced area requirement in the proposed Code Case N-513. However, the calculated stresses using UFT stress intesification factor fail the Code stress equations 128 and 120 in the branch reinforcement approach.

The branch reinforcement approach of the proposed Code Case N-513 is judged to be too conservative since the flaw is within 5" circular area but the UFT stress intensification factor is based on the full size opening (16" diameter) .

• On the basis of the above evaluations and discusion we conclude that the structural integrity of the pipe leak on line H823-16" is assured and due to pressure less than 275 psig and temperature less than 200 °F, the leaked pipe is acceptable for a non-weld repair per Ref. 7.5.

- ., '

. '

PALISADES NUCLEAR PLANT EA-SP-03316-03 ANALYSIS CONTINUATION SHEET Sheet 16 Rev# 00 7 .0 References

• 7 .1. Nondestructive Testing Service Thickness Measurement Examination Report, dated 5/26/93. (Attachment 1) ..

7.2. Drawing M101 SH. 2744, Rev. 2 Rev. 2 7.3. Stress Report EA*SP* 03316-01, S&L File# 9131-00 7 .4. Code Case N-480, "Examination Requirements for Pipe Wall Thinning Due to Single Phase Erosion and Corrosion",Section XI, Division 1, 05/10/90.

7.5. USNRC Generic Letter 90-05, "Guidance for Performing Non-Code Repair of ASME Code Class 1,2, and 3 Piping", 6/15/90.

7.6 Nondestructive Testing Service Thickness Measurement Examination Report, dated 6/6/93. (Attachment 2) 7.7 Palisades Plant Piping Class Summary, M-259, Sh. 3HB, Rev. 9.

7.8 ASME B&PV Code, Section Ill, Subsection ND, 1992 7.9 ANSl/ASME 831.1, 1973 7 .10 Proposed Code Case N-513, "Evaluation Criteria for Temporary Acceptance of Flaws in Class 3 Piping",Section XI, Division 1, 08/13/92. (Presented in February 1993 Committee Meeting) .

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I EXAMINATION REPORT Job Location &t.1 (4 /.1£S. A/~e,.I..<<& /!L ,,,,,,,,,r Total Hours Worked ~u NDT Procedure A/nT- U.T -Q:l.. Rev s Ultrasonic Equipment&.;Ame7Eo 4/NSerial No. 000 3SS" Cal Dueo9 -@- £l A/{-d_ Search Unit Size/Frequency ..a .. I .5.. ~ti_;/,,_ Serial Number 1.t.aaf .,

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Material Type Nominal Diameter Item Type A"1~.d!'.'.6

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Item Thickness Measurements Location 1 2 3 4 6 6 7 8 9 10 11 12 13 14 16 16 17 18 19 20 21 A 171. .?.7/ .37~ ..~l'I .379 R . 1/()1/ .~79 .'!177 * '17( .'17'1 c:. . ~~n .379' . '178 ."\79 ,Yoj 0 ,377 .371 . -:rB' -'17'1 . 3'1'1 E .1t1 * .'.Jiln .3~'f

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THICKNESS MEASUREMENT EXAMINATION REPORT CONTINUATION SHEET Project No. -;J " '.11 S - 2'Jt;tJC~ !Examination Report Sheet No. ~di Joate t'l/, -P~- ?3 ~age :z. of ;i.,

Thickness Measurements Item Location 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 M>1

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@) Date Attachment Sheet No)u\ - \

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CONSUMERS POWER COMPANY NONDESTRUCTIVE TESTING SERVICES Examination Report Sheet No M'f> K- DI SUPPLEMENTARY SKETCH WOIMONo ~A Line No. H-B-z~ -llo Item Type/No i: i'J\~]i\wffV\ F~r {'I" A~l~t~

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