ML15190A268

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1400669.312, Rev. 0, Hot Leg Drain Nozzle Weld Residual Stress Analysis
ML15190A268
Person / Time
Site: Palisades Entergy icon.png
Issue date: 05/05/2015
From: Fong M
Structural Integrity Associates
To:
Office of Nuclear Reactor Regulation
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ML15190A274 List:
References
10426669, 1400669 1400669.312, Rev. 0
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Integrity Associates, Incl File No.: 1400669.312V s Project No.: 1400669CALCULATION PACKAGE Quality Program Type: Z Nuclear [] CommercialPROJECT NAME:Palisades Flaw Readiness Program for 1R24 NDE InspectionCONTRACT NO.:10426669CLIENT: PLANT:Entergy Nuclear Operations, Inc. Palisades Nuclear PlantCALCULATION TITLE:Hot Leg Drain Nozzle Weld Residual Stress AnalysisDocument Affected Project Manager Preparer(s) &Revision Pages Revision Description Approval Checker(s)Signature & Date Signatures & Date0 1 -38 Initial Issue Preparer:A-1 -A-2Computer FilesNorman EngNE 5/5/2015 Minji FongMF 5/5/2015Checkers:Charles FourcadeCJF 5/5/2015Gole MukhimGSM 5/5/2015Page 1 of 38F0306-01R2 j an ni hglfn y Associates, Inc.Table of Contents1.0 OBJECTIVE .................................................................................................................. 52.0 TECHNICAL APPROA CH ...................................................................................... 52.1 M aterial Properties ......................................................................................... 52.2 Finite Element Model for Weld Residual Stress Analysis ........................... 62.3 W elding Sim ulation ...................................................................................... 62.4 H eat Inputs .................................................................................................... 62.5 Creep Properties ........................................................................................... 72.6 M echanical Boundary Conditions ............................................................... 73.0 A SSUM PTION S ...................................................................................................... 74.0 W ELD RESIDUAL STRESS AN ALY SIS ............................................................. 84.1 Hot Leg Cladding ........................................................................................ 84.2 Boss W eld .................................................................................................... 94.3 ID Patch W eld ................................................................................................ 94.4 Post-weld Heat Treatm ent ............................................................................ 94.5 Hydrostatic Test ........................................................................................... 104.6 Five N orm al Operating Cycles (N OC) ........................................................ 105.0 RESULTS OF WELD RESIDUAL STRESS ANALYSIS .................................... 115.1 W elding Tem perature Contours ................................................................. 115.2 PW H T Tem perature Results ...................................................................... 115.3 Residual Stress Results ............................................................................... 116.0 CON CLU SION S ................................................................................................... 127.0 REFEREN CES ........................................................................................................ 12APPEN DIX A COM PUTER FILES LISTIN G ............................................................... A -1File No.: 1400669.312 Page 2 of 38Revision: 0F0306-01R2 raful hBgrII Assoiates, Inc?List of TablesTable 1:Table 2:Table 3:Table 4:Table 5:Table 6:Table 7:Table 8:Table 9:Elastic Properties for SA-516 Grade 70 (5 4" Thick) .......................................... 13Elastic Properties for ER308L ............................................................................. 14Elastic Properties for Alloy 600 ................................................................................ 15Elastic Properties for Alloy 182 .......................................................................... 16Stress-Strain Curves for SA-516 Grade 70 (< 4" Thick) .................. 17Stress-Strain Curves for ER308L ........................................................................ 18Stress-Strain Curves for Alloy 600 ....................................................................... 19Stress-Strain Curves for Alloy 182 ...................................................................... 20Creep Properties ................................................................................................. 21File No.: 1400669.312Revision: 0Page 3 of 38F0306-01R2 olu Iran Itegrity Assocates, Inc.List of FiguresFigure 1. Finite Element Model for Residual Stress Analysis ........................................... 22Figure 2. Applied Mechanical Boundary Conditions ........................................................ 23Figure 3. Weld Nugget Definitions for the Boss Weld ..................................................... 24Figure 4. Weld Nugget Definitions for the ID Patch Weld ............................................... 25Figure 5. Applied Hydrostatic Test Pressure and Corresponding End Cap Pressure Loads ..26Figure 6. Predicted Fusion Boundary Plot for Cladding ................................................... 27Figure 7. Predicted Fusion Boundary Plot for Boss Weld .................................................. 28Figure 8. Predicted Fusion Boundary Plot for ID Patch Weld .......................................... 29Figure 9. Time vs. Temperature Curve for PWHT ........................................................... 30Figure 10. Predicted von Mises Residual Stress at 70'F after ID Patch Weld .................. 31Figure 11. Predicted von Mises Residual Stress at 70'F after PWHT .............................. 32Figure 12. Paths for Stress Extraction ............................................................................... 33Figure 13. Residual Stress Comparison at 70'F Before and After PWHT ........................ 34Figure 14. Measured Through-Wall Residual Stresses for PWHT ................................... 35Figure 15. Predicted von Mises Residual Stress at 70'F after Hydrostatic Test ............... 36Figure 16. Predicted Radial Residual Stress + Operating Conditions (5th NOC Cycle) ....... 37Figure 17. Predicted Hoop Residual Stress + Operating Conditions (5th NOC Cycle) ......... 38File No.: 1400669.312 Page 4 of 38Revision: 0F0306-01R2 VjstnwobmrwInte grity MOsOctS, Inc.1.0OBJECTIVEThe objective of this calculation package is to document the weld residual stress analysis for the hot legdrain nozzle at the Palisades Nuclear Plant (Palisades). The weld residual stress analysis is based on thelatest methodology and process developed by Structural Integrity Associates (SI).2.0TECHNICAL APPROACHThe finite element model is obtained from a previous finite element model (FEM) calculation package[1] and the weld residual stress analysis uses the latest weld residual stress analysis methodologydeveloped by SI, using the ANSYS finite element analysis (FEA) program [3].The residual stress analysis consists of a thermal pass followed by a stress pass, where the temperaturedistribution time history from the thermal pass is used as temperature input into the stress pass todetermine stresses. Stress results from the weld residual stress analysis are obtained and saved for futureuse to evaluate flaws which will be performed in a separate calculation package.The finite element model includes all components in the post-nozzle installation stage because newelements cannot be added during an ANSYS analysis run. Since all the weld elements need to beincluded in the initial model, the element "birth and death" technique in ANSYS is used to initiallydeactivate the weld elements, with elements corresponding to the active weld segment reactivated at themelting temperature, thus simulating the weld metal deposition.2.1Material PropertiesThe weld residual stress analysis performed in this calculation uses the material properties specificallydeveloped in a separate calculation package for weld residual stress analyses [2]. Per the materialdesignation used in the FEM calculation [1], the following materials are used:" SA-516 Grade 70:" ER308L:" Alloy 182:Hot leg base metalHot leg cladding (typical weld metal for Type 304)Boss weld and ID patch weld0 Alloy 600 (SB-166): Drain nozzleThe material properties are reproduced in Table 1 through Table 8.File No.: 1400669.312Revision: 0Page 5 of 38F0306-01R2 Cj Msiwiw lae grit y AssoCkiats, Wl2.2 Finite Element Model for Weld Residual Stress AnalysisThe finite element model for the analysis was developed in a previous FEM calculation [1], which wascreated using the ANSYS finite element analysis software package [3]. The base finite element modelfor the weld residual stress analysis is meshed with 8-node solid elements (SOLID 185) in ANSYS. Thisfinite element model is shown in Figure 1.2.3 Welding SimulationThe FEA for predicting the weld residual stresses is performed as a continuous analysis so that the loadhistory from the cladding is carried over the nozzle-to-pipe weld and ID patch weld. Specifically, theresidual stresses and strains at the end of one weld pass are used as initial conditions at the start of thenext weld pass.The procedures for this complex multi-step simulation are encoded in ANSYS Parametric DesignLanguage (APDL) macros which utilize elastic-plastic material behavior and elements with largedeformation capability to predict the residual stresses due to the various welding processes.2.4 Heat InputsThe deposition of the weld metal is simulated by imposing a heat generation function on the elements ofthe FEM representing the active weld, which is applied as a volumetric body heat generation rate. Theamount of equivalent heat input energy, Q (in terms of kJ/inch), is determined from the weldingparameters.Since the welding parameters for the welds are not available, a typical heat input of 28 kJ/inch, with anoverall heat efficiency of 0.8, is assumed for all the welds. The heat efficiency represents a "composite"value reflecting the concepts of arc efficiency, melting efficiency, etc., and is an optimum value toproduce reasonable heat penetration in the analysis.The APDL macros automatically calculate the appropriate time intervals for the thermal pass to ensurethat sufficient heat penetration is achieved, the required interpass temperature between weld passes ismet, and a reasonable overall temperature distribution within the finite element model is achieved. Theresulting temperature time history is then imported into the stress pass in order to calculate the residualstresses due to the thermal cycling of the weld elements using nonlinear, elastic-plastic load/unloadstress reversal relations.The following summarizes the welding parameters used in the analysis:" Interpass temperature = 350°F [4]" Melting temperature = 2500'F (See Section 3.0)* Reference temperature = 70'F (See Section 3.0)File No.: 1400669.312 Page 6 of 38Revision: 0F0306-01R2 V obn fri/Irs gr/flr Assoceis, Inc.0 Heat input for all welds = 28 kJ/in (See Section 3.0)0 Heat efficiency for all welds = 0.8 (See Section 3.0)a Inside/Outside heat transfer coefficient 5 Btu/hr-ft2-°F (See Section 3.0)0 Inside/Outside temperature = 70'F (See Section 3.0)2.5 Creep PropertiesStrain relaxation due to creep at high temperature is considered in the post-weld heat treatment (PWHT)step of the analysis. In general, creep becomes significant at temperature above 800'F; thus, creepbehavior under 800'F will not be considered in this analysis. The creep properties listed in Table 9 aredetennined in the previous FEM calculation [1].2.6 Mechanical Boundary ConditionsThe mechanical boundary conditions for the stress analysis are symmetric boundary conditions at thesymmetry planes of the model, axial displacement restraint at the end of the nozzle, and axialdisplacement coupling at the end of the hot leg piping, as shown in Figure 2.3.0 ASSUMPTIONSThe following assumptions are used in the analyses:" The hot leg cladding material is assumed to be ER308L, which is a typical weld metal forType 304 stainless steel cladding.* The metal melting temperature is assumed to be 2500'F, which is the temperature point wherethe strength of the material is set to near zero [1]." The analysis is performed with a reference temperature of 70'F." The exposed surface of the model is subject to a typical ambient air cooling convection filmcoefficient of 5 Btu/hr-ft2-°F at a bulk temperature of 70'F. The exposed surfaces are defined asthe exterior surfaces of the model, excluding the symmetry planes and the far ends of themodeled piping and nozzle." Since the welding parameters for the welds are not available, a typical heat input of 28 kJ/in, withan overall heat efficiency of 0.8, is assumed for all of the welds." The focus of this analysis is the residual stresses in the drain nozzle boss weld region, while theinteraction between the clad buildup and the hot leg base metal has secondary effects on theregion of interest. Therefore, the clad is assumed to be fully deposited in a single one-layer pass.File No.: 1400669.312 Page 7 of 38Revision: 0F0306-01R2 tituak l lafugrit f Associates, Inc ." The boss weld is represented by a 40-bead process, as shown in Figure 3, with each beadrepresented by a one pass "bead ring" nugget. This approach is a common and acceptableindustry practice when information regarding the bead start/stop position and sequencing areunknown." Similarly, the ID patch weld is represented by a 6-bead process, as shown in Figure 4, with eachbead represented by a one pass "bead ring" nugget.* For model simplification, the penetration hole is present during the deposition of the cladmaterial. This is acceptable since any localized stress with or without the hole would havenegligible impact on the final results.* For convenience, the modeled ID patch weld has the same geometry as the backing ring for theboss weld." Additional assumptions on PWHT are discussed in Section 4.4.4.0 WELD RESIDUAL STRESS ANALYSISThe weld residual stress analysis consists of a thermal analysis to determine the temperature distributionfollowed by a stress analysis to determine the resulting stresses. The analytical sequence describedbelow is used in the finite element analysis, followed by detailed discussions of the steps in Sections 4.1through 4.6:1. Deposit cladding on hot leg pipe inside (ID) surface.2. Install drain nozzle, backing ring, and deposit boss weld.3. Remove backing ring and deposit ID patch weld.4. Post-weld heat treatment, including creep effects based upon experimental data per Table 9.5. Subject the configuration to hydrostatic test.6. Impose five cycles of "shake down" with normal operating temperature and pressure to stabilizethe residual stress fluctuations due to stress redistribution caused by normal operating loads.4.1 Hot Leg CladdingThe clad material is typically welded onto the inside surface of the hot leg pipe, and the nominalthickness of the clad is thicker than the typical thickness for a single weld layer used in the process.However, the focus of this analysis is on the as-welded residual stresses, while the interaction betweenthe clad buildup and the base material during the many actual weld passes is not of interest. Therefore,the clad is assumed to be fully deposited in a single pass.File No.: 1400669.312 Page 8 of 38Revision: 0F0306-01R2

$trucnI~mbIlnfegrify Associates, Inc.At this step, only the hot leg pipe base metal elements and clad material elements are active; all othercomponents are deactivated during the analysis. At the end of the cladding application, the entire modelis cooled to 70'F before application of the boss weld.4.2 Boss WeldThe boss weld connects the drain nozzle boss to the hot leg piping. As shown in Figure 3, the weld iscomposed of 40 nuggets deposited in 20 weld layers. In the absence of detailed weld fabricationinformation, a weld sequence is assumed based on standard welding practice at the time of fabrication.In particular, for every layer, the first nugget is deposited on the hot leg side, the second nugget on thenozzle side.At this step, the drain nozzle elements and backing ring elements are reactivated, and the boss weldnuggets are reactivated sequentially to simulate the welding process. The preheat temperature of the bossweld is 250'F [4]. At the end of the boss weld, the entire model is cooled to 70'F before the applicationof the ID patch weld.4.3 ID Patch WeldThe final weld step is to add the ID patch weld, which replaces the backing ring. As seen in Figure 4, theID patch weld is composed of 6 nuggets deposited in 2 layers.At this step, the backing ring is first deactivated to allow the residual stresses to redistribute, and the IDpatch weld nuggets are reactivated sequentially to simulate the welding process. The preheat temperatureof the ID patch weld is 250'F [4]. At the end of the ID patch weld, the entire model is cooled to 70'Fbefore the post-weld heat treatment (PWHT).4.4 Post-weld Heat TreatmentPWHT is assumed to be performed as per the following procedure outlined in Article N-532 of theASME Code,Section III [7] and the welding procedure [4] for welding on material group P-i:1. Heat welded piping component to 11 50'F [4] at a heating rate of 400'F per hour divided by themaximum metal thickness (100'F per hour for 4 inch thick hot leg) [7, Article N-532.3 (2)].2. Hold at temperature for approximately 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> (lhr/in of weld thickness) [7, Table N-532].3. Allow to cool to 600'F at a cooling rate of 500'F per hour divided by the maximum metalthickness (125°F per hour for 4 inch thick hot leg) at temperature above 600'F [7, Article N-532.3 (5)].4. Air-cool from 600'F to ambient [7, Article N-532.3 (5)].5. A steady state load step is imposed at the end of the PWHT process.File No.: 1400669.312 Page 9 of 38Revision: 0F0306-01R2 jsh1J Inu gnfy* Assoc.iaWs, InO.During the PWFHT, creep behavior is activated for time steps with the maximum temperature above800'F. At the end of the PWHT, the entire model is cooled to 70'F before the application of thehydrostatic test.4.5 Hydrostatic TestA hydrostatic test pressure of 3110 psig (3125 psia) and a temperature of 400'F [8, page 9] are appliedafter the welding. The pressure is applied on the ID surfaces of the hot leg pipe and drain nozzle. End-cap loads, Pend-cap-hl is applied at the free end of the hot leg piping. This is calculated based on thefollowing expression:P x Finside-hiPend-cap-hl " 2 2routside-hl -rinside-h1where,P = Hydrostatic test pressure (ksi)Pend-cap-hl = End cap pressure on hot leg pipe end (ksi)rinside-hi = Inside radius of hot leg pipe (in)routside-hl = Outside radius of hot leg pipe (in)The applied pressure loads on the model are shown in Figure 5.4.6 Five Normal Operating Cycles (NOC)After the hydrostatic test, the assembled configuration is put into service and subjected to five cycles ofshake down to stabilize the as-welded residual stresses. This step involves ramping the model from zero-load to steady-state conditions at normal operating temperature and pressure then back to steady-state at70'F and no pressure five times.The applied operating pressure is 2085 psig (2100 psia) and temperature is 583°F [9]. The temperature isassumed to be uniform throughout the components and operating pressure is applied as an internalpressure on the ID surface, with corresponding end cap pressures calculated using the equation in theprevious section. The term "P" is replaced by the operating pressure in the expression.File No.: 1400669.312 Page 10 of 38Revision: 0F0306-01R2 t baniraI Iatnflr Associates, Inc.5.0 RESULTS OF WELD RESIDUAL STRESS ANALYSISThe ANSYS input files and computer output files for the analyses are listed in Appendix A.5.1 Welding Temperature ContoursThe maximum temperature prediction contours for each weld are created using the macroMapTemp.mac. This type of contour plot is also called a "fusion boundary" plot because it provides anoverview of the maximum temperature on each node throughout the thermal transient for each weldingprocess. The plots are useful in visualizing the melting of weld metal and the extent of heat penetration.The predicted fusion boundary contours for the cladding, the nozzle-to-pipe weld, and ID patch weldapplications are shown in Figure 6, Figure 7, and Figure 8, respectively. The purple color in the plotsrepresents elements at melting temperature (>2500'F); the plots show complete melting of the weldmetal for each weld and slight melting of the base metal along the weld interface.5.2 PWHT Temperature ResultsFigure 9 plots the inside surface temperature curve for the PWHT process. It shows the linear 1 00F/hrheating rate, 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> (240 minutes) hold time at 1150°F, 125°F/hr cooling rate at temperature above600'F, and the air cooling to room temperature of 70'F.5.3 Residual Stress ResultsFigure 10 plots the von Mises residual stresses after welding is complete, but before PWHT. It showsextensive residual stresses of greater than 66.3 ksi in the weld material. However, as shown in Figure 11,after the PWHT the residual stresses in the weld have relaxed significantly, to below 49.2 ksi, but theresidual stresses in the cladding remain essentially unchanged.To further investigate the effects of the PWHT, before and after PWHT residual stresses are extractedalong the two through-wall paths shown in Figure 12. The through-wall residual stresses are comparedin Figure 13, and it shows that there is little to no stress reduction in the clad material, while there issignificant stress reduction in the pipe base metal.The PWIJT results from the FEA trend comparably well with the data in EPRI report TR-105697 [10],which contains a comparable through-wall clad residual stress distribution based on experimentalmeasurements, as shown in Figure 14. The experimental measurements were for a low alloy steel vesselwith a Type 304 stainless steel clad. The data shows tensile stress through the clad thickness and thebase metal near the clad interface, but the stress drops rapidly to compressive values at farther distancesfrom the clad.File No.: 1400669.312 Page 11 of 38Revision: 0F0306-01R2 SWRIuM lati Associates, Inc.Figure 15 depicts the predicted von Mises residual stresses after the hydrostatic test. It shows aninsignificant reduction in maximum stress when compared to the post-PWHT step: 73.749 ksi (Figure15) versus 73.750 ksi (Figure 11), while the overall stress contour remains essentially the same.Figure 16 and Figure 17 depict the combined weld residual plus operating radial and hoop stresses at thefifth stabilization NOC cycle, respectively. The stress results at this step are used in the fracturemechanics evaluations.

6.0 CONCLUSION

SFinite element residual stress analysis has been performed on the hot leg drain nozzle boss weld atPalisades. Stresses at normal operating conditions combined with residual stresses have been obtainedand saved for future use. The stress results will be used in a separate calculation to determine crackgrowth.

7.0 REFERENCES

1. SI Calculation No. 1400669.310, Rev. 0, "Finite Element Model for Hot Leg Drain Nozzle."2. SI Calculation No. 0800777.307, Rev.5, "Material Properties for Residual Stress Analyses,Including MISO Properties Up To Material Flow Stress."3. ANSYS Mechanical APDL and PrepPost, Release 14.5 (w/ Service Pack 1), ANSYS, Inc.,September 2012.4. Combustion Engineering Welding Procedure No. MA-41, Rev.0, SI File No. 1400669.204.5. "Steels for Elevated Temperature Service," United States Steel Co., 1949.6. Publication SMC-027, "Inconel Alloy 600," Special Metals Corp., 2004, SI File No.0800777.211.7. ASME Boiler and Pressure Vessel Code,Section III, 1965 Edition with Addenda through Winter1966.8. Combustion Engineering Specification No. 0070P-006, Rev.2, "Engineering S1pecification forPrimary Coolant Pipe and Fittings," SI File No. 1300086.203.9. Palisades Design Input Record, "Palisades Alloy 600 Flaw Eval DIR 3-4-15 Revl.pdf," SI FileNo. 1400669.201.10. EPRI Report No. TR-105697, "BWR Reactor Pressure Vessel Shell Weld InspectionRecommendations (BWRVIP-05)," September 1995.File No.: 1400669.312 Page 12 of 38Revision: 0F0306-01R2 VjIsbwhtrhI, hglnfy Assacials, IncsTable 1: Elastic Properties for SA-516 Grade 70 (5 4" Thick)Temperature Young's Mean Thermal ThermalModulus Expansion Conductivity (2) Specific Heat (2)(0F) (x103 ksi) (x10-6 in/in/0F) (Btu/min-in-°F) (Btu/lb'°F)70 29.5 6.4 0.0488 0.103500 27.3 7.3 0.0410 0.128700 25.5 7.6 0.0369 0.1381100 18.0 8.2 0.0290 0.1711500 5.0 8.6 0.0218 0.1982500 0.1 9.5 0.0014 0.2042500.1 -0.0 --Notes:1. All values per [2].2. Density (p) = 0.283 lb/in3 [2], assumed temperature independent.3. Poisson's Ratio (u) = 0.3 [2], assumed temperature independent.File No.: 1400669.312Revision: 0Page 13 of 38F0306-01R2 VjjSowburWe /aft*wl Assocalos, Irc.Table 2: Elastic Properties for ER308LTemperature Young's Mean Thermal ThermalModulus Expansion Conductivity (2) Specific Heat (2)(0F) (x103 ksi) (xl0-6 in/in/lF) (Btu/min-in-°F) (Btu/lb-0F)70 28.3 8.5 0.0119 0.116500 25.8 9.7 0.0151 0.131700 24.8 10.0 0.0164 0.1351100 22.1 10.5 0.0189 0.1401500 18.1 10.8 0.0213 0.1452500 0.1 11.5 0.0292 0.1592500.1 -0.0 --Notes:1. All values per [2].2. Density (p) = 0.283 lb/in3 [2], assumed temperature independent.3. Poisson's Ratio (u) = 0.3 [2], assumed temperature independent.File No.: 1400669.312Revision: 0Page 14 of 38F0306-01R2 StnwrW laftegry Asosis, hnc.Table 3: Elastic Properties for Alloy 600Temperature Young's Mean Thermal ThermalModulus Expansion Conductivity (2) SpecificHeat(2)(0F) (x103 ksi) (x10-6 in/in/0F) (Btu/min-in-*F) (Btu/lb-'F)70 31.0 6.8 0.0119 0.108500 29.0 7.6 0.0147 0.120700 28.2 7.9 0.0161 0.1251100 25.9 8.4 0.0192 0.1391500 23.1 9.0 0.0222 0.1482500 0.1 10.0 0.0306 0.1772500.1 -0.0 --Notes:1. All values per [2].2. Density (p) = 0.300 lb/in3 [2], assumed temperature independent.3. Poisson's Ratio (u) = 0.29 [2], assumed temperature independent.File No.: 1400669.312Revision: 0Page 15 of 38F0306-01R2 Vjstnwbra91I tughTir A6ssociats. Inc.Table 4: Elastic Properties for Alloy 182Temperature Young's Mean Thermal ThermalModulus Expansion Conductivity (2) Specific Heat (2)(0F) (xl03 ksi) (xl0-6 in/in/0F) (Btu/min-in-°F) (Btu/lb-0F)70 31.0 6.8 0.0119 0.108500 29.0 7.6 0.0147 0.120700 28.2 7.9 0.0161 0.1251100 25.9 8.4 0.0192 0.1391500 23.1 9.0 0.0222 0.1482500 0.1 10.0 0.0306 0.1772500.1 -_ 1:____0.0 --Notes:1. All values per [2].2. Density (p) = 0.300 lb/in3 [2], assumed temperature independent.3. Poisson's Ratio (u) = 0.29 [2], assumed temperature independent.File No.: 1400669.312Revision: 0Page 16 of 38F0306-01R2 Vjsklfrunkru kIlogrily Associats, IiC @Table 5: Stress-Strain Curves for SA-516 Grade 70 (5 4" Thick)Temperature Strain Stress('F) (in/in) (ksi)0.00128814 38.0000.00187809 42.00070 0.00257329 46.0000.00381110 50.0000.00600383 54.0000.00113553 31.0000.00142679 35.875500 0.00183954 40.7500.00261139 45.6250.00415246 50.5000.00106667 27.2000.00132412 32.550700 0.00166876 37.9000.00228121 43.2500.00354341 48.6000.00116667 21.0000.05116163 22.1251100 0.05915444 23.2500.06794123 24.3750.07755935 25.5000.00300000 15.0000.16717493 15.1251500 0.16992011 15.2500.17268761 15.3750.17547742 15.5000.01000000 1.0000.10961239 1.1252500(2) 0.12781277 1.2500.14689940 1.3750.16683167 1.500Notes:1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.File No.: 1400669.312Revision: 0Page 17 of 38F0306-01R2 asftcraI Ilfgrrly Associates, Inc!Table 6: Stress-Strain Curves for ER308LTemperature Strain Stress('F) (in/in) (ksi)0.00203180 57.5000.02471351 61.56370 0.03107296 65.6250.03861377 69.6880.04747167 73.7500.00140089 36.1430.00714793 40.250500 0.01065407 44.3570.01558289 48.4640.02233857 52.5710.00132488 32.8570.00477547 37.125700 0.00743595 41.3930.01143777 45.6610.01727192 49.9290.00121913 26.9430.00264833 30.1381100 0.00404100 33.3320.00634529 36.5270.01005286 39.7210.00117995 21.3570.05352064 21.5631500 0.05610492 21.7680.05878975 21.9730.06157807 22.1790.01000000 1.0000.10961239 1.1252500(2) 0.12781277 1.2500.14689940 1.3750.16683167 1.500Notes:1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.File No.: 1400669.312Revision: 0Page 18 of 38F0306-01R2 rucWnhitI ugrfty AssociaWs. Inc.Table 7: Stress-Strain Curves for Alloy 600Temperature Strain Stress('F) (in/in) (ksi)0.00157419 48.8000.01658847 55.30070 0.02343324 61.8000.03212188 68.3000.04291703 74.8000.00152069 44.1000.01539220 50.338500 0.02210610 56.5750.03072476 62.8130.04153277 69.0500.00152128 42.9000.01634485 49.000700 0.02334760 55.1000.03227153 61.2000.04338643 67.3000.00155985 40.4000.02275193 44.4751100 0.03004563 48.5500.03888203 52.6250.04943592 56.7000.00092641 21.4000.08827666 22.4751500 0.09785101 23.5500.10796967 24.6250.11863796 25.7000.01000000 1.0000.10961239 1.1252500(2) 0.12781277 1.2500.14689940 1.3750.16683167 1.500Notes:1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.File No.: 1400669.312Revision: 0Page 19 of 38F0306-01R2 V ~SM&,Ifri~rIht, y Associaes, IncGTable 8: Stress-Strain Curves for Alloy 182Temperature Strain Stress('F) (in/in) (ksi)0.00179032 55.5000.03456710 60.11370 0.04292837 64.7250.05257245 69.3380.06359421 73.9500.00164483 47.7000.02976152 52.313500 0.03809895 56.9250.04790379 61.5380.05929946 66.1500.00159574 45.0000.02849157 49.538700 0.03680454 54.0750.04663682 58.6130.05812078 63.1500.00159073 41.2000.03568855 44.4881100 0.04402702 47.7750.05360088 51.0630.06449835 54.3500.00106494 24.6000.11812735 25.3251500 0.12540227 26.0500.13290814 26.7750.14064577 27.5000.01000000 1.0000.10961239 1.1252500(2) 0.12781277 1.2500.14689940 1.375__ __ __ 0.16683167 1.500Notes:1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.File No.: 1400669.312Revision: 0Page 20 of 38F0306-01R2 VjS&InAUMi Intgrfiy Assocates. InO'Table 9: Creep PropertiesMaterial Temperature Creep Strength (ksi) A(OF) al (0.0001%/hr) 02 (0.00001%/hr) (ksi/hr)800 19.0 12.4 1.26E-13 5.40SA-516 Gr. 70 ______900 9.0 6.7 3.59E-14 7.80(Based on carbonsteel) 1000 3.5 2.8 2.43 E- 12 10.32Per[5] 1100 1.4 0.8 2.50E-07 4.11800 33.4 25.0 7.73E-19 7.95ER308L _____900 24.0 17.6 5.67E- 17 7.42(Based onType 304) 1000 17.6 11.5 1.82E-13 5.41Per[5] 1100 11.5 7.1 8.62E-12 4.77Alloy 600 800 40.0 30.0 1.50E-19 8.00Alloy 182900 28.0 18.0 2.87E-14 5.21(Based on 1000 12.5 6.1 3.02E- 10 3.21Alloy 600)Per [6] 1100 6.8 3.4 1.72E-09 3.32File No.: 1400669.312Revision: 0Page 21 of 38F0306-01R2

~SbwbnI Iabgnfy Associafs, ~Figure 1. Finite Element Model for Residual Stress AnalysisFile No.: 1400669.312Revision: 0Page 22 of 38F0306-01R2 Van" bft* ASSOWN, him'sELEMENT'SAxial displacement couplesSymmetry boundary conditionsAxial displacement restraint//Figure 2. Applied Mechanical Boundary ConditionsFile No.: 1400669.312Revision: 0Page 23 of 38F0306-01R2 COW" bft* AMOGWOS, fteFigure 3. Weld Nugget Definitions for the Boss WeldFile No.: 1400669.312Revision: 0Page 24 of 38F0306-01R2

&Vean"a huIqIy Associaes1IncGFigure 4. Weld Nugget Definitions for the ID Patch WeldFile No.: 1400669.312Revision: 0Page 25 of 38F0306-O1R2 V on"~wuu IAfuge Associates, IncGTYPE NUHot leg end cap pressureInternal pressure-7.38152 -5.05007 -2.71862 -.387175 1.94428-6.2158 -3.88435 -1.5529 .77855 3.11 ksiHydrostatic testFigure 5. Applied Hydrostatic Test Pressure and Corresponding End Cap Pressure LoadsFile No.: 1400669.312Revision: 0Page 26 of 38F0306-01R2 SVan"w lWAbry Assocafts, W17- 170 610 1150 1690340 880 1420 1960Predicted fusion boundary plot (Purple -Temperature > Melting)Figure 6. Predicted Fusion Boundary Plot for Cladding(Note: Purple = Temperature > Melting temperature of 2500'F)22302500 OFFile No.: 1400669.312Revision: 0Page 27 of 38F0306-01R2 Van" NWNY Awdeft, knOFigure 7. Predicted Fusion Boundary Plot for Boss Weld(Note: Purple = Temperature > Melting temperature of 2500'F)File No.: 1400669.312Revision: 0Page 28 of 38F0306-01R2 Cjjouiww Iaqg*l Associats, /ncFigure 8. Predicted Fusion Boundary Plot for ID Patch Weld(Note: Purple = Temperature > Melting temperature of 2500'F)File No.: 1400669.312Revision: 0Page 29 of 38F0306-01R2 wbv wV klft ASSiate, k,.125011251000875750Terrperature (F)6251500375-25012501000 1400 1800 2200 26001200 1600 2000 2400 2800Time (min)Figure 9. Time vs. Temperature Curve for PWHTNote:1. PWHT temperature history is for a typical ID node on the model.3000File No.: 1400669.312Revision: 0Page 30 of 38F0306-01 R2 VON" MWW As=Aft Inc.0Figure 10. Predicted von Mises Residual Stress at 70°F after ID Patch WeldFile No.: 1400669.312Revision: 0Page 31 of 38F0306-01R2 Can" &A" Assadates, hY.0Figure 11. Predicted von Mises Residual Stress at 70°F after PWHTFile No.: 1400669.312Revision: 0Page 32 of 38F0306-01R2 itstViiaW& W hgfysociates, InceFigure 12. Paths for Stress ExtractionNotes:1. In the hot leg coordinates, hoop residual stresses along path P1 and axial residual stresses alongpath P2 are extracted for comparison of before and after PWHT.2. The before and after PWHT through-wall residual stresses are compared in Figure 13.File No.: 1400669.312Revision: 0Page 33 of 38F0306-01R2 CAW" MM* Awadates, Inalm807060504030] :+ As-Welded (P1)El PWHT (PI)* As-Welded (P2)A PWHT (P2)IAInU'S..4.'2010-----++0-10-20-30-40-50C-- -----Clad interface++----- ---------------- -----++I .I .I .I .I .I).0 0.1 0.2 0.3 0.4 0.50.6 0.7 0.8 0.9 1 I0.6 0.7 0.8 0.9 1.0Normalized Thickness (x/t)Figure 13. Residual Stress Comparison at 70°F Before and After PWHTFile No.: 1400669.312Revision: 0Page 34 of 38F0306-01R2 Cjsban"u hbp*ft'sociats, him@120Aa A-WeldedOPWHT100 +~- Clad Interface80 +LD7at0A60'400-0 A0 0I20tData fromEPRI TR-1 01 9890-Ino00*Thi*w C4ud Test,Inuufue at Depth0-20 +A-404 4 I I I002 0.4 0.6Distance from Clad Surface (inches)0.81.3Figure 14. Measured Through-Wall Residual Stresses for PWHTNotes:1. Figure is obtained from EPRI report TR-105697 [10].2. Measurements show little to no stress reduction in the cladding after PWHT.3. Measurements show significant stress reduction in the base metal after PWHT.File No.: 1400669.312Revision: 0Page 35 of 38F0306-01R2 Cj~suan" Ibfwgd Assocatps, Inr.GFigure 15. Predicted von Mises Residual Stress at 70°F after Hydrostatic TestFile No.: 1400669.312Revision: 0Page 36 of 38F0306-01 R2 can&*etuw MWfwgly Assocates, WcFigure 16. Predicted Radial Residual Stress + Operating Conditions (5th NOC Cycle)Note: Radial stresses shown in the nozzle axis radial direction.File No.: 1400669.312Revision: 0Page 37 of 38F0306-01R2 VOW&W AdW* AwacWes, Inc.'sFigure 17. Predicted Hoop Residual Stress + Operating Conditions (5th NOC Cycle)Note: Hoop stresses shown in the nozzle axis circumferential direction.File No.: 1400669.312Revision: 0Page 38 of 38F0306-01R2 CAN" Moo* AWsc&M, tesAPPENDIX ACOMPUTER FILES LISTINGFile No.: 1400669.312Revision: 0Page A- I of A-2F0306-01R2 C aj~n"i hiidfy ASSOciates, WncFile Name DescriptionPalisadesHLDrain.INP Input file to create base geometry model [1]MPropMISO.INP Elastic-plastic Material properties inputs [1]Autonugsel.mac Macro that groups elements into nuggetsBCNUGGET3D.INP Weld pass and model boundary definition fileTHERMAL3D.INP Input file to perform the thermal pass of welding simulationTHMPWHT.INP Input file to perform the thermal pass of PWHTSTRESS3D.INP Input file to perform the stress pass of welding simulationCBC.INP Input file to apply mechanical boundary conditionsTHMPWHT-mntr.inp Processed thermal pass load steps for PWHTINSERT3D.INP Input file to perform the stress pass of hydrostatic testWELD#_mntr.inp Processed thermal pass load steps for stress pass # = 1-3*.mac WRS analysis macro files required for analysisTHERMAL3D.TXT Parameter input file for thermal pass of welding simulationSTRESS3D.TXT Parameter input file for stress passGenStress.mac Macro to extract PWHT stress resultsGETPATH.TXT Through-wall stress path definition to extract PWHT stress resultsFile No.: 1400669.312Revision: 0Page A-2 of A-2F0306-01R2

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