ML15198A226
| ML15198A226 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 07/15/2015 |
| From: | Coble M T, Glunt N L Westinghouse |
| To: | Office of Nuclear Reactor Regulation |
| Shared Package | |
| ML15198A232 | List: |
| References | |
| 102-07077-TNW/DCE CN-PAFM-15-20-NP, Rev. 2 | |
| Download: ML15198A226 (38) | |
Text
EnclosureNon-proprietary Documents for Relief Request 53Attachment 3Westinghouse Calculation CN-PAFM-15-20-NP, Rev. 2, PaloVerde Unit 3 RCS Cold Leg Alloy 600 Small Bore Nozzle RepairTransient Stress and Fracture Mechanics Evaluation for OneCycle Operation Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision Shop Order Number Network/Activity PageCN-PAFM-15-20-NP 2 962 143368-0041 1Project Releasable (Y/N) Open Items (Y/N) Files Attached (Y/N) Total No. PagesPalo Verde 3 Half-Nozzle Repair Y N Y 37Palo Verde Unit 3 RCS Cold Leg Alloy 600 Small Bore Nozzle RepairTransient Stress and Fracture Mechanics Evaluation for One CycleOperationAuthor Name(s)Signature / DateScopeNathan L. GluntMatthew T. CobleElectronically Approved*Electronically Approved*Verifier Name(s)Anees UdyawarJustin D. WebbManager NameJohn L. McFaddenSignature / DateElectronically Approved*Electronically Approved*Signature / DateElectronically Approved*Non-Proprietary Class 3Non-Proprietary Class 3ScopeNon-Proprietary Class 3Non-Proprietary Class 3ScopeNon-Proprietary Class 3Non-Proprietary Class 3Carl J. GimbroneElectronically Approved**Electronically approved records are authenticated in the electronic document management system.© 2015 Westinghouse Electric Company LLCAll Rights ReservedWestinghouseWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 2Record of RevisionsRev. Date Revision Description0-A April 14, Draft20150 April 16, Original Version20151 April 17, Removed sentence in Section 5.1.2 per customer request. Change is marked by a revision bar2015 in the left hand margin.2 April 17, Editorial changes and sentence removal per customer request. Changes are marked by a2015 revision bar in the left hand margin.2 See EDMS This -NP version adds proprietary brackets and the proprietary information has beenredacted.4 .14 44 4I IWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 3Table of Contents1.0 Background and Purpose ............................................................................................................................. 42.0 Sum m ary of Results and Conclusions ..................................................................................................... 63.0 References ................................................................................................................................................... 74.0 Calculations ................................................................................................................................................. 94.1 Lim its of Applicability ............................................................................................................ 94.2 Open Item s ........................................................................................................................................ 94.3 M ethod Discussion ............................................................................................................................ 94.4 Discussion of Significant Assum ptions ......................................................................................... 94.5 Acceptance Criteria ........................................................................................................................... 94.6 Input .................................................................................................................................................. 95.0 Evaluations, A nalysis, Detailed Calculations and Results ................................................................... 105.1 General Corrosion Assessm ent ................................................................................................. 105.1.1 M axim um A llow able Bore Size .................................................................................... 105.1.2 General Corrosion Rate .................................................................................................. 105.1.3 General Corrosion for One Fuel Cycle ........................................................................... 115.2 Stress Evaluation and Transient Consideration .......................................................................... 125.2.1 Therm al Transient Evaluation ...................................................................................... 125.2.2 M echanical Load Considerations ................................................................................. 135.3 Fracture M echanics Evaluation .................................................................................................. 145.4 Stress Corrosion Cracking Assessm ent ...................................................................................... 196.0 Listing of Com puter Codes Used and Runs M ade In Calculation ....................................................... 20Appendix A : Supporting Docum entation ...................................................................................................... 23A .1 Palo V erde Unit 3 Operating M ode History (Reference 16) ....................................................... 23Appendix B : Com parison of RCS Piping Transients .................................................................................... 25Checklist A : Proprietary Class Statem ent Checklist ...................................................................................... 33Checklist B: Calculation Note M ethodology Checklist ................................................................................. 34Checklist C: V erification M ethod Checklist .................................................................................................. 35Checklist D : 3-Pass V erification M ethodology Checklist ............................................................................ 36Additional V erifier's Com m ents ......................................................................................................................... 37Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 41.0 Background and PurposeDuring the 3R18 spring 2015 refueling outage at Palo Verde Nuclear Generating Station (PVNGS) Unit3, visual examinations of the reactor coolant pump (RCP) suction safe end revealed evidence of leakagein the annulus between the outer surface of the Inconel 600 instrument nozzle and the bore on the suctionsafe end. The most likely location of the flaw(s) is in the primary water stress corrosion cracking(PWSCC)-susceptible Alloy 82/182 weld and Inconel 600 instrument nozzle, along their fusion lineinside the safe end bore. The Alloy 600 instrument nozzle is attached with a partial penetration weld tothe inside of the RCP suction safe end.The "half-nozzle" repair method will be used to replace a portion of the Alloy 600 one-inch instrumentnozzle. The repair will be made with an Inconel 690 PWSCC-resistant material half-nozzle, which willbe attached to the Palo Verde Unit 3 RCP suction safe end outside diameter. This is an alternative to theASME Section XI [1] requirement, IWB-3142.3, to correct the observed leakage. For the half-nozzlerepair, the instrument nozzle is severed on the outside of the RCP suction safe end. The remaining lowerportion of the instrument nozzle is removed by boring into the suction safe end. The removed portion ofthe Alloy 600 instrument nozzle is then replaced with a section (half-nozzle) of a more PWSCC-resistantRev. 2 Alloy 690 material, which will then be welded to the outside surface of the suction safe end using a 52Mweld filler (see Figure 1). The inner portion of the original instrument nozzle, including the partialpenetration weld, is left in place.The half-nozzle repair has been successfully implemented on 63 Alloy 600 small-bore reactor coolantsystem hot leg nozzles (i.e., pressure taps, sampling line, and resistive temperature device thermowellnozzles) for Palo Verde Units 1, 2, and 3 [5 and 14]. Additionally, the half-nozzle method has been usedat many other Combustion Engineering (CE) designed nuclear steam supply system plants.Westinghouse has previously performed a technical justification and a fracture mechanics investigationinto the feasibility of small diameter Alloy 600/690 half-nozzle repairs in WCAP-15973-P-A [2]. TheNRC has issued a final safety evaluation (SE) [3] that found WCAP-15973-P to be acceptable forreferencing in licensing applications for CE designed pressurized water reactors as long as informationrequired by the SE in is submitted as a relief request. The NRC SE [3] is incorporated into WCAP-15973-P-A [2], and this WCAP report was submitted to the NRC in [18]. The flaw evaluation performed in thisreport will follow guidance from the technical basis and the NRC SE to demonstrate that a flaw(s) in thepartial penetration weld will not grow to an unacceptable size in the suction safe end base metal, for up to18 months of operation.The purpose of this report is to demonstrate the acceptability of the half-nozzle repair for the flawed RCPsuction safe end instrument nozzle at Palo Verde Unit 3 based on a the following assessments:1. corrosion evaluation2. ASME Section XI crack growth evaluation3. stress corrosion cracking assessmentThe flaw evaluation will demonstrate that any flaws in the penetration weld that remain after the half-nozzle repair will not grow to an unacceptable flaw size into the suction safe end carbon steel metalWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 5within the next cycle of operation (18 months). The fracture mechanics justification will be consistentwith revision 1 of Relief Request 31, which was previously submitted and approved for the Palo VerdeUnits 1, 2, and 3 small-bore hot leg Alloy 600 nozzles [5 and 14].This calculation note was created and verified in accordance with Westinghouse Level II ProceduresWEC 3.2.6, WEC 3.3.3 and Level III Procedure ES 3.2.1.Figure 1: RCP Instrumentation Nozzle Repair SchematicWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 62.0 Summary of Results and ConclusionsDuring the spring 2015 refueling outage at Palo Verde Unit 3, visual examinations of the RCP suctionsafe end revealed evidence of leakage in the annulus between the outer surface of the Inconel 600instrument nozzle and the bore on the suction safe end. The most likely location of the flaw(s) is in thePWSCC-susceptible Alloy 82/182 weld and Inconel 600 instrument nozzle, along their fusion line insidethe safe end bore. The Alloy 600 instrument nozzle is attached with a partial penetration weld to theinside diameter of the RCP suction safe end.The half-nozzle repair method will be used to replace a portion of the Alloy 600 one-inch instrumentnozzle with an Inconel 690 PWSCC-resistant material half-nozzle, attached to the Palo Verde Unit 3 RCPsuction safe end outside diameter. The ASME Class 1 pressure boundary and associated nozzleattachment weld will be relocated to the outside surface of the suction safe end. The (assumed) flawedpartial penetration weld and a portion of the existing nozzle will be abandoned in place.Westinghouse has previously performed a technical justification and a fracture mechanics investigationinto the feasibility of small diameter Alloy 600/690 half-nozzle repairs WCAP-15973-P-A [2] and CN-CI-02-71 [6], which the NRC has found acceptable for referencing in licensing applications for CEdesigned pressurized water reactors as long as information required by the SE is submitted as a reliefrequest. The flaw evaluation performed in this report follows their guidance and demonstrates that a flawin the partial penetration weld will not grow to an unacceptable size in the suction safe end base metal, forup to 18 months of operation.The evaluation performed in this report demonstrates the acceptability of the half-nozzle repair for theflawed RCP suction safe end instrument nozzle at Palo Verde Unit 3 based on a corrosion evaluation, onan ASME Section XI crack growth evaluation, and on a flaw stability analysis.The corrosion rate around the instrumentation nozzle bore was determined based on the operating modecorrosion rates of [2] and the plant operating history. Based on the overall corrosion rate, theinstrumentation nozzle bore diameter remains acceptable for the end of life at Palo Verde Unit 3.A comparison was made between the ASME Section XI Code evaluation of hot leg nozzle repairs [2 and6] and the Palo Verde Unit 3 RCP instrumentation nozzle repair, and it was determined that the evaluationin [2 and 6], which was for 40 years of operation, would bound the repair condition for theinstrumentation nozzle and the suction safe end of Palo Verde Unit 3 for at least 18 months. Furthermore,it was demonstrated that the previous relief request and the subsequent NRC SEs [5 and 14], documentingapproval for the Palo Verde Units 1, 2, and 3 small-bore hot leg nozzles, are bounding and applicable forthe RCP suction safe end instrumentation nozzle half-nozzle repair. Therefore, the half-nozzle repair forthe RCP suction safe end is acceptable per Section XI of the ASME Code for at least the next 18 monthsof operation.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 73.0 References1. ASME Boiler and Pressure Vessel Code,Section XI, 2001 Edition with 2003 Addenda.2. Westinghouse Report, WCAP-15973-P-A, Rev. 0, "Low-Alloy Steel Component Corrosion AnalysisSupporting Small-Diameter Alloy 600/690 Nozzle Repair/Replacement Programs," February 2005.(Westinghouse Proprietary Class 2)3. NRC Letter, "Final Safety Evaluation for Topical Report WCAP-15973-P, Revision 01, "Low-AlloySteel Component Corrosion Analysis Supporting Small-Diameter Alloy 600/690 NozzleRepair/Replacement Program" (TAC No. MB6805)," January 12, 2005.4. Combustion Engineering Report, A-CEOG-9449-1242, Rev. 00, "Evaluation of the CorrosionAllowance for Reinforcement and Effective Weld to Support Small Alloy 600 Nozzle Repairs," June13, 2000. (Westinghouse Proprietary Class 2)5. APS Letter, "Palo Verde Nuclear Generating Station (PVNGS) Units 1, 2, 3, Docket No. STN 50-528/529/530, 10 CFR 50.55a(a) (3) (i) Alternative Repair Request for Reactor Coolant System HotLeg Alloy 600 Small-Bore Nozzles (Relief Request 31, Revision 1)." August 16, 2005. (MLAccession No. ML052550368)6. Westinghouse Calculation Note, CN-CI-02-71, Rev. 2, "Summary of Fatigue Crack GrowthEvaluation Associated with Small Diameter Nozzles in CEOG Plants," March 31, 2004.(Westinghouse Proprietary Class 2)7. Combustion Engineering Specification, 00000-PE-140, Rev. 04, "General Specification for ReactorCoolant Pipe and Fittings," May 25, 1977. (Westinghouse Proprietary Class 2)8. Combustion Engineering Report, CENC-1642, Rev. 0, "Analytical Report for Arizona Unit No. 3Piping," May 1984. (Westinghouse Proprietary Class 2)9. Combustion Engineering Specification, SYS80-PE-480, Rev. 02, "Specification for StandardPlantfor Reactor Coolant Pumps," May 2, 1978. (Westinghouse Proprietary Class 2)10. Palo Verde Nuclear Generating Station Units 1, 2, and 3 Updated Final Safety Analysis Report, Rev.17B, January 2015.11. Westinghouse Calculation Note, A-GEN-PS-0003, Rev. 3, "Evaluation of Fatigue Crack GrowthAssociated with Small Diameter Nozzles in CEOG Plants," December 9, 2005. (WestinghouseProprietary Class 2)12. Westinghouse Design Specification, 14273-PE-140, Rev. 15, "Project Specification for ReactorCoolant Piping and Fittings for Arizona Nuclear Power Project," June 25, 2007. (WestinghouseProprietary Class 2)13. CE -KSB Pump Co. Inc. Drawing, E-8111-101-2002, Rev. 00, "Pump Casing -A."Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 814. NRC Letter, "Palo Verde Nuclear Generating Station, Units 1, 2, and 3 -Relief Request No. 31,Revision 1, Re: Proposed Alternative Repair for Reactor Coolant System Hot-Leg Alloy 600 Small-Bore Nozzles (TAC Nos. MC9159, MC9160, and MC9161). ML Accession No. ML062300333.15. Westinghouse Calculation Note, CN-MRCDA-15-13, Rev. 0, "Qualification of Palo Verde Unit 3Reactor Coolant Pump Replacement Instrumentation Nozzle," April 16, 2015. (WestinghouseProprietary Class 2)16. Palo Verde Nuclear Generating Station Document 13-MS-B04 1, "Alloy Steel Corrosion AnalysisSupporting Alloy 600/690 Nozzle Repair/Replacement."17. Westinghouse Policy/Procedure WEC 3.6.5, Rev. 1, "External Computer Software," effective July13, 2013.18. Westinghouse Owners Group Letter, "Westinghouse Owners Group Transmittal of NRC-ApprovedTopical Report WCAP- 15973-P-A (Proprietary) and WCAP- 15973-NP-A, Rev 0, (Non-Proprietary)"Low-Alloy Steel Component Corrosion Analysis Supporting Small-Diameter Alloy 600/690 NozzleRepair/Replacement Programs," (TAC MB6805) (Task 1170)," March 16, 2005.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 94.0 Calculations4.1 Limits of ApplicabilityThis calculation note is applicable to the fracture mechanics evaluation of the Palo Verde Unit 3 RCPsuction safe end instrumentation nozzle half-nozzle repair.4.2 Open ItemsThere are no open items in this calculation note.4.3 Method DiscussionThe purpose of the evaluation contained herein is to demonstrate the acceptability of the RCP suction safeend instrumentation nozzle half-nozzle repair for an operation duration of 18 months (1 cycle). Thetechnical basis for the half nozzle repairs in the hot leg and pressurizer has been performed in WCAP-15973-P-A [2], which has been accepted by the NRC in Reference 3. Furthermore, Palo Verde specifichot leg half nozzle repairs have been performed per [5] for a plant operation duration of 40 years, and hasbeen approved by the NRC as discussed in Reference 14. The approved half-nozzle repair evaluation forPalo Verde 1, 2, and 3 for the hot leg nozzle [5 and 14] will be used as a basis for justification that thePalo Verde Unit 3 RCP suction safe end will remain acceptable for one cycle of operation based on thefracture mechanics evaluation herein. The complete details and results of the evaluation are provided inSection 5.0 of this document.4.4 Discussion of Significant AssumptionsAll assumptions are identified in Section 5.0 of this calculation note.4.5 Acceptance CriteriaThe evaluation of a postulated flaw in Palo Verde Unit 3 RCP suction safe end instrumentation nozzleattachment weld is performed in accordance with the ASME Section XI Code [1], WCAP-15793-P [2],CN-CI-02-71 [6], and the NRC SE [3].4.6 InputThe specific input required for this calculation note are described in the detailed evaluation contained inSection 5.0.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 105.0 Evaluations, Analysis, Detailed Calculations and Results5.1 General Corrosion AssessmentAccording to WCAP-15973-P-A [2], the crevices between the safe end bore and the instrument nozzlematerial will fill with borated water if a half-nozzle replacement/repair is implemented. When used asprimary pressure boundary materials, carbon and low alloy steels are clad with corrosion-resistantmaterials (generally weld-deposited stainless steels) to isolate these materials from the primary coolant,thereby minimizing corrosion and corrosion product release to the coolant. The inside diameters of holes,such as those used for instrumentation nozzles, are not clad because, in the as-built condition, they are notexposed to borated water. During the time when the plant returns to operation from a shutdown condition(i.e., refueling), the crevice region may be filled with aerated water. The oxygen in the water will beconsumed by corrosion of the steel; however, the corrosion rate will be high for the relatively short timewhen the temperature is at a low-to-moderate level. When the plant is operating, the crevice region willRev. 2 be de-aerated, and the corrosion rate is much less than that during the time immediately after startup.5.1.1 Maximum Allowable Bore SizeThe first step in the corrosion evaluation is the determination of the allowable increase in the diameter ofthe carbon steel nozzle bore. The allowable increase in the diameter (because of corrosion) wasdetermined by subtracting the original bore diameter from the maximum allowable diameter. Themaximum allowable hole size was determined in Section 2.4 of WCAP-15973-P-A [2] based on (1) thereduction in the effective weld shear area, and (2) the required area of reinforcement for the nozzle boreholes.A value of [ ]a*c inches of corrosion allowance was determined for the hot leg nozzle per A-CEOG-9449-1242 [4], which is Reference 12 of the WCAP-15973-P-A. Westinghouse Calculation CN-MRCDA-15-13 [15] determined that the actual Palo Verde Unit 3 suction safe end nozzle repair corrosionallowance would be larger than the hot leg nozzle corrosion allowance of [ ]a' inches. Forconservatism, a corrosion allowance of [ ]a'c inches was used herein for the Palo Verde Unit 3 suctionsafe end for the small Alloy 600 nozzle repair. The allowable diametrical hole increase of [ ]a.C inchescan be compared to the corrosion growth of the bore hole calculated for 40 years, as shown below.Therefore, the hot leg nozzle corrosion allowance can be conservatively used for the RCP suction safeend. Similar trends for the other applications of fracture mechanics (i.e., flaw stability and crack growth),as described later in this report, will also demonstrate that the hot leg nozzle evaluations performed forPalo Verde Unit 3 in WCAP-15973-P-A [2] and the relief requests [4 and 15] are bounding for the RCPsuction safe end bore region.5.1.2 General Corrosion RateThe corrosion rate for a carbon steel material (such as that of SA-508, Class 1) for the Palo Verde Unit 3RCP suction safe end is provided in [2]. The corrosion rate in [2], applicable to the half-nozzle creviceregion, is provided 600 small-bore nozzle repairs [5] in order to provide assurance that the allowable holeWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 11diameter for three separate operating conditions: full power operation, startup mode (assumed to be atintermediate temperature with aerated primary coolant), and refueling mode (100'F with aerated primarycoolant). The corrosion rates for each mode of operation are shown in Table 1 in mils per year (mpy).The percentage of time spent in each mode of operation based on [2] is also shown.Arizona Public Service (APS) has committed to track the time at cold shutdown in the previous reliefrequests for hot leg Alloy 600 small-bore nozzle repairs [5] in order to provide assurance that theRev. 2 allowable hole diameter is not exceeded over the life of the plant. The case herein for 18 months is morethan sufficient, as demonstrated below. Based on a review of Palo Verde Unit 3 operation data shown inAppendix A, the percentage of time spent in startup and cold shutdown conditions is bounded by thevalues used in [2].Table 1: Corrosion Based on Mode of OperationMode of Operation Growth Rate [21 Percent Time in Mode [2]Normal Operations 0.4 mpy 88%Startup Conditions 19.0 mpy 2%Cold Shutdown Conditions 8.0 mpy 10%An overall corrosion rate is then determined based on the corrosion rates of the individual operatingmodes and the percentage of time spent in each mode. Using Table 1, the calculated corrosion rate (CR)for Palo Verde Unit 3 is:CR = (0.88)(0.4 mpy) + (0.02)(19.0 mpy) + (0.10)(8.0 mpy) = 1.53 mpyRev. 15.1.3 General Corrosion for One Fuel CycleFor a conservative operation period of 40 years, the total corrosion of the nozzle bore would be:Corrosion = (1.53 mpy) (40 years) = (0.00153 in/yr) (40 yrs)= 0.0612 inches (radially, relative to penetration)= 0.1224 inches (diametrically, relative to penetration)As previously discussed, the allowable increase in hole diameter to the Palo Verde Unit 3 instrumentationnozzle bore is [ ]aJ` inches. Since the expected corrosion in 40 years is only 0.1224 inchesdiametrically, the diameter of the bore would remain acceptable beyond the next 40 years of operation.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 125.2 Stress Evaluation and Transient ConsiderationIn [6], for the technical basis for the hot leg half-nozzle repairs, postulated bounding flaws encompassingthe entire partial penetration weld at small-bore penetration welds in the hot leg piping were assessed forflaw growth and flaw stability as specified in ASME Code Section XI for a plant life of 40 years. This isthe basis for the WCAP-15973-P-A allowable flaw size and crack growth evaluations in [2]. Theseevaluations demonstrated that the postulated bounding flaws, which could have been left in place in theweld remnant after small-bore nozzle repairs, are acceptable. The small-bore instrument nozzle repairsevaluated for the hot leg are similar to the Palo Verde Unit 3 RCP suction safe end small-bore instrumentnozzle repair. Any differences will be assessed herein to justify that the fracture mechanics evaluationperformed for the hot leg nozzle repair would bound the RCP suction safe end small-bore instrumentnozzle repair for the next 18 months of plant operation.Rev. 2 The weld size and bore diameter used in the hot leg half-nozzle repair evaluation are similar to that of thePalo Verde Unit 3 instrumentation nozzle half-nozzle repair in the suction safe end. The thickness used inthe hot leg nozzle repair evaluation is 3.75 inches, as compared to the 3.00-inch thickness for the RCPsuction safe end for Palo Verde Unit 3. This difference is evaluated in Section 5.3 of this report, and isshown to have an insignificant impact on the fracture mechanics analysis.5.2.1 Thermal Transient EvaluationThe RCP suction safe end transients are the same as the cold leg transients documented in [7]. Based on[8], the usage factor for the hot leg piping is [ ]a` and the usage factor for the cold leg piping isI ]a,'. These usage factors are sufficiently small, and the difference between the two usage factors isconsidered to be insignificant; therefore, the transient effects on the RCP suction safe end are expected tobe similar to those on the hot leg.Based on a comparison of the hot leg transient definitions in [71 and the RCP nozzle transients in [9], alltransients except for the Loss of Secondary Pressure (faulted condition) transient are more severe andlimiting for the hot leg than for the RCP suction safe end as shown in Appendix B. The Loss ofSecondary Pressure transient is not required to be considered for the fatigue crack growth because onlythe Level A/B and test transients are considered. However, for the flaw stability evaluation, the Loss ofSecondary Pressure transient should be considered. For the flaw stability evaluation performed in [6], itwas determined that the Loss of Secondary Pressure transient was not the limiting transient used in themaximum allowable flaw size calculation; furthermore, it had a margin of approximately [ Ia,cbetween the applied stress intensity factor and the allowable stress intensity factor (see Section 3.5 of [2]and Section 2.1 of [6]). The difference in the delta temperature and the ramp time of the temperaturechange for the cold leg, as compared to the hot leg transient, is not so severe that it would result in verylarge changes in the existing thermal stresses for the hot leg nozzle. Therefore, the severity of the RCPsuction safe end Loss of Secondary Pressure transient is not sufficient to significantly reduce the marginof [ ]a-c between the applied and allowable stress intensity factors. Therefore, the flaw stabilitycalculation for the hot leg nozzle is sufficient and representative for the RCP suction safe end location.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 135.2.2 Mechanical Load ConsiderationsAn additional consideration in the calculation of the stress field in the vicinity of the crack is the stressdue to mechanical loads. The mechanical load stresses used in [6] and discussed in [2] for the hot legpiping are evaluated in Appendix C of [11]. It is demonstrated by comparison, as illustrated in Table 2and Table 3, that the mechanical load stresses evaluated for the hot leg piping conservatively bound themechanical load stresses in the RCP suction safe end.The pressure load applied to the hot leg and RCP suction safe end is identical. Therefore, the stress ineach is based on the pipe geometry. From Appendix C of [11], the stress in the pipe, based on thick-walltheory, can be calculated as:"=P (Ro2 -R2In the previous equation:P = operating pressure (2,250 psi)Ri= inner radius of the pipeR= outer radius of the pipeThe radii can be calculated by dividing the diameter values given in Table 3 by a factor of two. Theresulting operating pressure stress values are [ ]ac ksi for the hot leg and [ ]a"c ksi for the RCPsuction safe end. The stress in the hot leg pipe due to operating pressure conservatively bounds the RCPsuction safe end stress.The piping mechanical loads used to evaluate the piping stress are the pipe axial load and the bendingmoment. The mechanical loads applied to the hot leg piping and RCP suction safe end are compared inTable 2. The comparison shows that the axial load on the hot leg piping is [ ]ac times greater than theaxial load on the RCP suction safe end. The axial stress area ratios are compared in Table 3. Thiscomparison shows that the axial stress area ratio of [ is much less than the axial load ratio of1].. A similar comparison can be made for the applied bending moments. Table 2 shows that thehot leg bending moment is [ ] ax times greater for normal operating conditions and [ timesgreater for operating basis earthquake (OBE). A comparison of the section modulus in Table 3 shows thatthe section modulus ratio of [ ]'" is less than the minimum bending moment ratio of [ ]a.C Thesecomparisons show that the mechanical loads applied to the hot leg piping, and the resulting stress fieldevaluated in [2 and 6], provide bounding results when compared to the mechanical loads applied to theRCP suction safe end and the stress field that would result from these loads.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 14Table 2: Comparison of Hot Leg Piping and RCP Suction Safe End LoadsLoad RatioHot Leg RCP Suction (Hot Leg/ RCPLoad Type Condition Loads(2 Nozzle Loads(3) Suction Nozzle)NO4(1 [ ]a.c [ ]a a,c [ ]Axial (kips) OBE [ ]a,c [ ]a.c [ ]axcN04_ _ [ ] ac [ ]ac(4) [ ]a,cBending (ft-kips) OBE [ ] a.c [ ] a,c axNotes:1)2)3)4)The NO4 condition corresponds to the loads due to deadweight, normal operating thermal expansion, andfriction.Loads are from [11].Loads are from [12], reported for Assembly P-4 at the "B" end of piping.Equal to the square root sum of the squares of M, and M, moments in [12].Table 3: Comparison of Hot Leg and RCP Suction Safe End Geometric PropertiesRatioRCP Suction (Hot Leg/ RCPDimension Hot Leg(t) Nozzle(2) Suction Nozzle)Inner Diameter (in) [ ] a,c [ a,c _Outer Diameter (in) [ ]a,c [ ]ac -Area (in2) (3) [ ] ac [ ] ac [ ] a,cSection Modulus (in3) () ] a.x [ I ac [ ] acNotes:1)2)3)4)Dimensions are from [11].Dimensions are from [13]; the inner diameter is based on the minimum wall thickness of 76.2 mm (3.0inches).Area is calculated as: n*diameter2/4.Section modulus is calculated as: [it* (outer diameter4-inside diameter4)/64]/(outer diameter/2).5.3 Fracture Mechanics EvaluationAn overall transient stress comparison performed in Section 5.2 determined that the stress evaluation in [2and 6] envelops the Palo Verde Unit 3 suction safe end instrumentation nozzle half-nozzle repair.Therefore, the hot leg transient stresses used in the allowable flaw size determination and fatigue crackgrowth evaluation [2], and used in the basis document [6], would bound the Palo Verde Unit 3 RCPsuction safe end transient stresses.The stress field, geometry, and flaw size are the major contributors to the calculation of stress intensityfactors. Based on the discussion in Section 5.2, the hot leg transient stresses used in the allowable flawsize determination and fatigue crack growth evaluation [21, and used in the basis document [6], wouldbound the Palo Verde Unit 3 RCP suction safe end transient stresses.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 15The stress intensity factor model used in the hot leg nozzle flaw evaluation is based on a hole in a flatplate, with two cracks emanating from the corners. The bounding axial and circumferential flawgeometries are shown in Figure 2 and Figure 3; the stress intensity model is shown in Figure 4. The holediameter used in the hot leg nozzle repair evaluation (diameter = [ ".c inches) from [6] is similar insize to the suction safe end instrumentation nozzle hole diameter (diameter = [ ] ax inches) in [13].This slight difference would have an insignificant effect of the calculated stress intensity factors.Additionally, the difference in the thickness of the hot leg nozzle of 3.75 inches, as compared to the coldleg nozzle thickness of 3.0 inches, will have an insignificant impact on the fracture mechanics analysisand the stress intensity factor calculation. This is because, based on a review on the stress intensity factordatabase used in [6], the influence coefficients used in the stress intensity factor calculation do notsignificantly change between flaw depth-to-wall thickness ratios of a/t = 0.2 to a/t = 0.5. The flaw depthto wall thickness ratio (a/t) of both the hot leg and cold leg is approximately 0.3. Furthermore, accordingto Section 3.5 of [2] and Section 2.1 of [6], there is ample margin between the calculated stress intensityfactors and the allowables to account for any small changes in component geometries.According to Section 3.5 of [2] and Section 2.1 of [6], the limiting transient (with respect to allowablecircumferential flaw size) was the cooldown transient, particularly the end of the cooldown transient. Theend of cooldown is generally limiting due to the low temperature that affects the fracture toughness of thecomponent. The fracture mechanics evaluations in [2] and in its supporting document, [6], wereperformed according to the 1992 Edition of the ASME Section XI Code, where IWB-3612 determinedacceptability for normal and upset condition transients based on the following criterion:K, < KIa/4 10However, for Palo Verde Unit 3, the 2001 Edition with 2003 Addenda Section XI ASME Code is theCode of record. The acceptance criterion for normal and upset condition transients in IWB-3612 in the2001 Edition with 2003 Addenda Section XI ASME Code is based on the following criterion:K, < Kic/410Since Kic is less limiting than Kia, the calculated axial and circumferential flaw stress intensity factors forthe End of Cooldown transient in Section 3.5 of [2] (and Table 2-2 of [6]) would have additional marginover the allowables based on the current Palo Verde Unit 3 ASME Section XI Code year. As documentedin Section 3.5 of [2] and Section 2.1 of [6], an RTNDT value of 60'F was utilized in the allowable stressintensity factor calculation for the hot leg base metal. The use of an RTNDT value of 60'F in [2 and 6] wasconfirmed based on a review of the allowable stress intensity factor for the End of Cooldown transient.For the RCP suction safe end, the RTNDT is 40'F or less according to the RCP suction safe end CertifiedMaterial Test Report and UFSAR Table 5.2-29B [10]. Therefore, the lower RTNDT value of 40°F for thePalo Verde Unit 3 cold leg nozzle would result in a less limiting allowable flaw size than the hot legnozzle RTNDT of 60'F. As such, the allowable flaw size evaluation performed in [2 and 6] for a hot legnozzle repair would be conservatively representative for the Palo Verde Unit 3 RCP suction safe endinstrumentation nozzle since stress intensity factors for the same size flaws would be similar.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 16Therefore, the allowable flaw size evaluation performed in WCAP-15973-P for a hot leg nozzle repairwould be conservatively representative for the Palo Verde Unit 3 RCP suction safe end instrumentationnozzle since stress intensity factors for the same size flaws would be similar.The fatigue crack growth evaluation performed in [2 and 6] demonstrated that crack growth for 40 yearswas small, and that the axial and circumferential flaws remained within the allowables. Table 4 andTable 5 show the crack growth for 40 years of operation to compare with the allowable flaw sizes fromthe generic hot leg piping evaluation (Section 3.4 of [2] and Section 2.1 of [6]) and the Palo Verde-specific hot leg piping evaluation from [5]. Since the stresses, stress intensity factors, and allowable flawsizes used in [2 and 6] are considered bounding for the Palo Verde Unit 3 suction safe endinstrumentation nozzle repair, the amount of fatigue crack growth tabulated in Table 4 and Table 5 for 40years is expected to far exceed the anticipated fatigue crack growth for an 18-month duration in the PaloVerde Unit 3 suction safe end instrumentation nozzle.Table 4: Hot Leg Piping Fad ue Crack Growth from [2] and [61Axial Circumferential CircumferentialDepth or Initial Axial Final Allowable Final AllowableLength (in.) (in.) (in.) (in.) (in.)Depth 0.938 0.984 1.3 1.001 1.3Length 0.762 0.791 1.1 0.802 1.1Table 5: Hot Leg Piping Fatigue Crack Growth Using PVNGS Dimensions [51Axial Circumferential CircumferentialDepth or Initial Axial Final Allowable Final AllowableLength (in.) (in.) (in.) (in.) (in.)Depth 0.950 0.999 1.3 1.017 1.3Length 0.762 0.793 1.1 0.805 1.1Since the fracture mechanics evaluation in [2 and 6] concluded that the half-nozzle repair was acceptablewith respect to Section XI of the ASME Code for 40 years of operation, and since the fracture mechanicsevaluation in [2 and 6] has been found to be bounding for the Palo Verde Unit 3 suction safe endinstrumentation nozzle half-nozzle repair, it is concluded that the flawed Palo Verde Unit 3 suction safeend instrumentation nozzle weld will remain acceptable with respect to fatigue crack growth though thesuction safe end for an operating duration of 18 months.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 17Axial FlawsRjlItFigure 2: Axial Flaw GeometryFigure 3: Circumferential Flaw GeometryWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 18I~-2R -TDCFigure 4: Stress Intensity Factor ModelWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number. Revision PageCN-PAFM-15-20-NP 2 195.4 Stress Corrosion Cracking AssessmentAccording to the NRC SE for WCAP- 15973-P-A [3], the stress corrosion assessment in [2] may be usedin the relief request as long as a review of plant chemistry is conducted to ensure that flaws in the carbonsteel base metal material will not grow by stress corrosion. Stress corrosion and plant chemistryevaluations were previously conducted in [5]. The hot leg nozzle repair relief request determined,through a review of chemistry records and chemistry control procedures, that the plant chemistry waswithin the bounds of the standards of [2] and that the stress corrosion cracking conclusion reached in [2]also applies to the Palo Verde Unit 3 RCP suction safe end. Provided below is an excerpt from the PaloVerde relief request for the hot leg nozzle and the NRC SE [14], which is still applicable for the RCPsuction safe end region.NRC Requirement 1Conduct appropriate plant chemistry reviews and demonstrate that a sufficient level of hydrogenoverpressure has been implemented for the RCS, and that the contaminant concentrations in thereactor coolant have been typically maintained at levels below 10 part per billion (ppb) fordissolved oxygen, 150 ppb for halide ions, and 150 ppb for sulfate ions.APS ResponseA review of plant chemistry records show that the halide /sulfate concentration levels have beenmaintained below 150 ppb for chloride, fluoride, and sulfate over the two operating cycles priorto the repair. Oxygen levels are maintained below 10 ppb during power operation and below 100ppb during plant startups (RCS temperature >250'F). There is no oxygen limit when the RCStemperature is below 250'F.An RCS hydrogen overpressure of > 15 cc/kg is established prior to criticality (hard hold point)and is maintained in a range of 25 to 50 cc/kg in Modes 1 and 2. In Modes 1 and 2, RCShydrogen is a Control Parameter with Action Level 1 outside the range of 25 -50 cc/kg, anAction Level 2, less than 15 cc/kg, and an Action Level 3 less than 5 cc/kg. Chemistryadministrative control procedures do not allow critical reactor operation with the RCS hydrogenconcentration less than 15 cc/kg without immediate corrective action. The nominal operatingband for RCS hydrogen is 25 to 50 cc/kg.Thus the conclusion reached in the Westinghouse TR with respect to stress corrosion cracking,applies to PVNGS.The plant chemistry is expected to be within the standards of [2] for the next fuel cycle; therefore, theconclusion reached in [2] would apply to Palo Verde Unit 3 for that period.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 206.0 Listing of Computer Codes Used and Runs Made In CalculationMicrosoft Excel' is used in this calculation to calculate the SIFs to determine the allowable pressure-temperature limit curves. Excel is considered to be a "general utility program" per WestinghousePolicy/Procedure WEC 3.6.5, "External Computer Software," Section 7.6 (Reference 17).Table 6-1Summary of Computer Codes Used in CalculationCode Code Code Configuration Basis (or reference) that supports use of code inNo. Name Ver. Control Reference current calculation1 MS Excel N/A See note above See note above1 Microsoft Excel is the registered trademark of Microsoft Corporation in the United States and/or other countries.Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 21Table 6-2Electronically Attached File ListingMachineRun Name RunNo. E- U Computer Run Description Date/Time File Type EDMS File Name or File LocationN/A N/A N/A N/A N/A N/AAttachment List for CN-PAFM-15-20 Rev. 0L]axcWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 22Computer Code Checklist 6-1(Completed By Author)No. Self Review Topic1 Are macros, scripts, calculational worksheets, or single-application programs used in theanalysis?2 Have the requirements in WEC 3.6.1 and WEC 3.6.6, if applicable, for the documentationand qualification of the macros, scripts, calculational worksheets, or single-applicationcomputer programs been met?3 Has the range of use for the macros, scripts, calculational worksheets, or single-applicationprograms been verified and documented in the calculation note?4 Have all macros, scripts, calculational worksheets, or single-application program limitationsbeen identified and documented within the calculation note?5 In the case of finite element analysis models, scripts and macros: Are there any commandsor element type limitations identified that apply to this analysis?6 In the case of finite element analysis models, scripts and macros: Have macros(e.g., ANSYS APDL) used in the analysis, been documented in accordance with WEC 3.6.1and WEC 3.6.6?Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 23Appendix A: Supporting DocumentationA.1 Palo Verde Unit 3 Operating Mode History (Reference 16)rMode of Operation (Days)Cycle Date Begin Date End Normal Startup Shutdown Total Days"-> axcF F 4 + 4F F + 4 + 4F F + 4 +/- 4______ F F 4- 4 4F F + 4 + 4F F + 4 +/- 4______ F F 4- 4 4F F 4- 4 + 4+ F + 4 +/- 4I F 4- 4 4+ F + 4 +/- 4F F + 4 4+ F + 4 + 4Vwlord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 24Mode of Operation (Days)Cycle Date Begin Date End Normal Startup Shutdown Total Days+ _____ ________a,ca,c4 4 4L4 4 ++Total DaysWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 25Appendix B: Comparison of RCS Piping TransientsThis appendix contains the plots of the hot and cold leg RCS piping transients from [7]. For all transients,the RCS pressure is identical for the hot and cold leg piping. Therefore, only the differences in transienttemperature profiles need to be considered. The transient list is shown in Figure B-1. The thermaltransients are compared by evaluating the maximum temperature difference and the rate of change of thetemperatures for the hot and cold leg temperatures. The comparison of these values is shown in Table B-1. As can be seen in Table B-1 and Figure B-2 through Figure B-7, all transients are bounded except forthe faulted Loss of Secondary Pressure Transient.Table B-1: Cornaison of Transient Temperatures (1 2)Transient ATht (OF) 8Th,/6t (OF/minute) ATcold (OF) 6ToId/bt (°F/minute) DispositionHeatup r a,c boundedCooldown boundedLoading boundedUnloading boundedStep IncreaseStep DecreasePlant Variation no differenceReactor TripLoss of FlowLoss of Load boundedPlant Leak Test _ _ _ _ _ _no differenceNotes:1) AT = maximum difference in temperature for the hot or cold leg temperature2) 5T/8t = maximum rate of change for the hot or cold leg temperatureWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 26axcacKWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 27-\a,cWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 28a,cWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 29"\ a,cWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 30a,cWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM-15-20-NP 2 316~acI',Word Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 32"a,cWord Version 6.2 Westinghouse Non-Proprietary Class 3WESTINGHOUSE ELECTRIC COMPANY LLCCalculation Note Number Revision PageCN-PAFM- 15-20-NP 2 33Checklist A: Proprietary Class Statement ChecklistDirections (this section is to be completed by authors): Authors are to determine the appropriate proprietary classification oftheir document. Start with the Westinghouse Proprietary Class 1 category and review for applicability, proceeding toWestinghouse Proprietary Class 2 -Non-Releasable and finally to Westinghouse Proprietary Class 2 -Releasable. Theproprietary classification is established when the first criterion is satisfied.Westinghouse Proprietary Class 1FD If the document contains highly sensitive information such as commercial documents, pricing information, legalprivilege, strategic documents, including business strategic and financial plans and certain documents of the utmoststrategic importance, it is Proprietary Class 1. Check the box to the left and see Appendix B of Procedure 1.0 inWCAP-7211, Revision 5, for guidance on the use of Form 36 and the distribution of this document. 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