ML17059A341

Rev 0 to Nine Mile Point Unit 1 CRD Return Nozzle Fatigue Evaluation.

ML17059A341
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Site:	Nine Mile Point
Issue date:	04/30/1994
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MPR-1485, MPR-1485-R, MPR-1485-R00, NUDOCS 9407010168
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P>1MPRASSOCIATES INC.ENGINEERS MPR-1485Revision0April1994NineMilePointUnit1ControlRodDriveReturnNozzleFatigueEvaluation PreyaredforNiagaraMohawkPowerCoryoration 301Plainfield RoadSyracuse, NY132129407010168 940M3PDR.ADOCK05000220P'DR 0

Pi9MPRASSOCIATES INC.EN&INEERSNineMilePointUnit1ControlRodDriveReturnNozzleFatigueEvaluation MPR-1485Revision0April1994Principal Contributors E.B.BirdJ.E.NestellR.S.PaulA.B.RussellPreparedforNiagaraMohawkPowerCorporation 301Plainfield RoadSyracuse, NY13212J.GawlerNMPCEngineer320KINGSTREETALEXANDRIA.

VA22314-3238 703-519-0200 FAX:703.519-0224

Pa1MPRASSOCIATES INC.ENGINEE0SCONTENTSSection1INTRODUCTION

1.1Background

2SUMMARY3DISCUSSION 3.1DesignandOperation 3.2LoadCycleDefinition 3.3Structural Analysis3.4FatigueEvaluation 3.5FractureMechanics

-CrackGrowthRate3.6Experience Survey4REFERENCES 5APPENDICES

~Pae2-13-13-1.3-13-23-33-43-54-15-1APPENDIXAAPPENDIXBAPPENDIXCAPPENDIXDAPPENDIXEAPPENDIXFAPPENDIXGAPPENDIXHAPPENDIXICalculation ofCRDRNozzleThermalandPressureCyclesCRDRNozzleFiniteElementModel,GeometryCRDRNozzleFiniteElementModel,MaterialProperties Calculation ofHeatTransferCoefGcients CRDRNozzleFiniteElementModel,BoundaryConditions andResultsLowCycleFatigueUsageCrackGrowthRateComputerProgramVerification CrackGrowthRateAnalysisCasesImplementation PlanA-1B-1C-1D-1E-1F-1G-1H-1

PA1MPRASS0CIATESINC.ENGINEERS LISTOFFIGURESF~Fiore3-13-23-33-43-53-6~DetcritiooCRDRNozzleDimensions FiniteElementModelFiniteElementModelDetailsCalculated Temperature Distribution Calculated StressIntensity Distribution FatigueCrackGrowth

Pa1MPRASSOCIATES INC.ENG'INEERS Section1INTRODUCTION Thepurposeofthisreportistodocumentafatigueevaluation oftheControlRodDriveReturn(CRDR)nozzleintheNineMilePointUnit1reactorvessel.Thenozzleisafourinchvesselpenetration thatacceptslowtemperature waterfromthecontrolroddrivesystem.Theobjectives oftheevaluation weretoestimate:

1)thelong-term susceptibility oftheCRDRnozzletothermalfatiguecracking, and2)thecrackgrowthrateofapotential flawintheCRDRnozzleovertheremaining lifeoftheplant.Thisevaluation wasundertaken tosupportNiagaraMohawkPowerCorporation (NMPC)effortstoperformanultrasonic inspection oftheCRDRnozzleinsteadofthedyepenetrant inspection specifiebyNUREG-0619.

Thefatigueevaluation oftheCRDRnozzleconsidered thenumberofpressureandtemperature cyclesthenozzlehasexperienced todateaswellasanestimateofthenumberoffuturecycles.Finiteelementstressanalysesofthenozzlewereperformed todetermine thestressdistribution inthenozzleduetothepressureandtemperature cycles.Stressanalysisresultswerethenusedtocalculate nozzlefatigueusageandcrackgrowthrates.1.1BACKGROUND Inthe1970's,anumberofBWRsdetectedsigniTicant crackingoffeedwater andCRDRnozzles.ThecracksintheCRDRnozzleswerecausedbythermalfatigueresulting fromchangesincoldCRDRflowatthenozzles,TheNRCissuedNUREG-0619, "BWRFeedwater NozzleandControlRodDriveReturnLineNozzleCracking,"

(Reference 1)thatidentified interimandlong-term recommendations regarding thisissue,including inspection requirements.

ForNineMilePointUnit1,theinspection requirements includeperforming adyepenetrant (PT)examination oftheCRDRnozzleinternalsurfaceduringtheupcoming1995ref'ueling outage.NMPCplanstoperformanultrasonic (UT)inspection oftheCRDRnozzleinsteadofthedyepenetrant examination basedonthefollowing:

1.Automated UTinspection systemsarenowavailable forperforming accurateinspections fromoutsidethevessel.UTinspection systemsatthetimeNUREG-0619wasissueddidnotprovidesufficient detection orflawsizingcapabilities.

2.TheCRDRnozzlethermalsleevedesign(weldedinplace)makesthenozzlelesssusceptible tothermalfatiguecrackingthantheoriginaldesignsatotherBWRs.Infact,nodamagetotheCRDRnozzlewasfoundduringthe1977in-vessel PTexamination orinanysubsequent examination.

1-1

3.DetailedanalyticmodelingoftheCRDRnozzleshowsthatsmallsurfaceflawswillnotgrowtounacceptable valueswithinspecified operating periods.Thisreportaddresses Item3abovefortheCRDRnozzle.Inaddition, thisreportdocuments theresultsofasurveyofBWRsregarding CRDRnozzleinspection historyandexperience.

Theimplementation planforthistaskisprovidedinAppendixI.1-2

P&qMPRASSOCIATES INC.ENGINEERS Section2SUMMARYThreepressureandtemperature cycleswereidentified fortheCRDRnozzle:startup/shutdown, reactorscram,andhydrostatic test.ThesecyclearedefinedfortheCRDRnozzleasfollows:Startup/Shutdown

-areactorvesselheatup/cooldown betweenpoweroperation andshutdownorstandbyconditions wheretheshutdownisachievedmanuallybyplantoperators.

ReactorScram-astartup/shutdown cyclewheretheshutdownisachievedbyareactorscram.~Hydrostatic Test-reactorvesselpressurization anddepressurization toidentifyleakspriortopowerascension.

Thenumberofcyclesexperienced todate,thenumberofcyclesexperienced sincethe1977PTinspection andtheprojected numberofcyclesinthefuturearelistedbelow.Startup/Shutdown ReactorScramHydrostatic TestNumberofCyclestoDate9610018NumberofCyclesSince1977PTInspection 38279Projected NumberofCyclesperYear5Thereactorscramtransient isthelimitingcycleforCRDRnozzlestresses, Finiteelementmodelingofthethermaltransient showsthatthepeakstressintensity inthebasemetaloccursattheendofthetransient intheboreofthenozzlejustabovetheblendregion.Thepeakstressintensity duetopressureandtemperature wascalculated tobe110ksi.FatigueanalysesshowthatfatigueusagefortheCRDRnozzleisverylow(approximately

0.0 03peroperating

year).Forthecalculated stressandthenumberofcyclesexperienced todate,afatiguecrackwouldnotbepredicted toinitiateinthe2-1

CRDRnozzleatthepresenttime.Considering thecalculated stressandthenumberofcyclesexpectedinthef'uture,afatiguecrackisnotpredicted withinthelifeoftheplant.Fracturemechanics calculations showthatapostulated 1/4inchflawlocatedinthehigheststressedregionofthenozzlewouldnotgrowtoanunacceptable sizewithinthelifeoftheplant.Thepostulated 1/4inchQawiscalculated togrowtoadepthofonly0.4inchesin40years.A0.4inchflawdoesnotexceedtheallowable Qawsizefortheanalyzedsectionofthenozzlewhichisapproximately 0.5inchesbasedoncriteriagiveninSectionXIoftheASMECode.Theallowable QawsizeprovidessigniTicant margintoensurethenozzledoesnotfailbybrittlef'racture.

2-2

PAIMPRASSOCIATES INC.EN&INEERSSection3DISCUSSION 3.1DESIGNANDOPERATION TheNMP-1ControlRodDriveReturn(CRDR)nozzleisa4-inchreactorvesselpenetration locatedatthesameelevation asthefeedwater nozzle.Figure3-1isasectionviewofthenozzlewhichshowsselecteddimensions.

TheCRDRnozzleisequippedwithathermalsleevewhichisweldedtotheCRDRnozzleatthesleeveinletandextendsintothereactordowncomer withacircularplateattheend.Thisdesignisintendedtoprotecttheboreofthenozzleandthevesselwalladjacenttothenozzlefromtherelatively coldCRDRflow.TheControlRodDrive(CRD)Systemprovideswaterfromthecondensate storagetankatatemperature ofabout70'Ftothecontrolroddrivemechanisms tocoolthecontrolroddrives,toreposition rods,andtoscramtherods.Undertypicalplantconditions, thesystemoperatesatalltimeswhenfuelisinthevessel.Duringnormaloperation, flowfromtheCRDpumpsismaintained relatively constantwithaportionoftheflowrecirculated tothecondensate storagetank,about30-47gpmoftheflowusedforcontrolroddrivemechanism cooling,andabout17-35gpm(theremaining flow)returnedtothevesselviatheCRDRnozzle.Someaccidentsequences involving loss-of-offsite powermayresultinsystemshutdownforashortperiodoftime,Theseaccidentsequences arenotconsidered forthisanalysis.

Theflowratedoesnotchangeasaresultofrepositioning acontrolrodsincetheflowdivertedtomovetherodiscompensated bythewaterdisplaced bytheroddrivewhichisroutedtotheCRDRline.AreactorscramresultsinaCRDRnozzleflowtransient.

Duringascram,theCRDRaccumulators discharge todrivethecontrolrodsintothecore.ThisresultsinanincreaseinCRDRnozzleflowto65gpm.Whenaccumulator pressuredropsbelowreactorpressure, CRDRflowrategoestozeroastheaccumulators arerecharged.

Aftertheaccumulators havebeenrecharged, CRDRflowratereturnstothenominal17to35gpm.3.2LOADCYCLEDEFINITION Table3-1liststhepressureandtemperature cycleswhichwereconsidered inthestructural evaluation.

Thenumberofcycleswasdetermined fromplantdataregarding thenumberofplantstartups/shutdowns andscrams.Thecyclesaredefinedasfollows:3-1 0

~Startup/Shutdown

-areactorvesselheatup/cooldown betweenpoweroperation andshutdownorstandbyconditions wheretheshutdownisachievedmanuallybyplantoperators.

~ReactorScram-astartup/shutdown cyclewheretheshutdownisachievedbyareactorscram.~Hydrostatic Test-reactorvesselpressurization anddepressurization toidentifyleakspriortopowerascension.

Thenumberofannualcyclesexpectedinthefutureisconservatively estimated tobe50%morethantheaverageannualnumberofcyclesthatoccurredoverthepast10years.Acalculation ofoperating cyclesispresented inAppendix'A.

33STRUCTURAL ANALYSISStressanalyseswereperformed todetermine thestressesforthefatigueandcrackgrowthrateanalysesdescribed inSection3.4and3.5below.Transient thermalanalyseswereperformed tocalculate thetemperature distribution inthenozzleasafunctionoftimeforthereactorscramtransient.

Steadystatestressesduetopressureandtemperature werecalculated atspecified timeintervals throughout thetransient.

Thesectionsbelowdescribethefiniteelementmodel,materialproperties, boundaryconditions, andresults.33.1FiniteElementModelTheANSYScomputerprogramwasusedtodevelopafiniteelementmodeloftheCRDRnozzle.ThemodelincludestheCRDRnozzleitselfandasufficient lengthofthereactorvesselshellandattachedCRDRpipingtoeliminate interaction betweentheCRDRnozzleandthestructural boundaryconditions appliedtotheedgesofthevesselshellandattachedpiping.Thethree-dimensional nozzle-to-cylinder intersection wasmodeledwithatwo-dimensional axisymmetric modelofanozzleinasphere.Theequivalent spherical radiuswaschosentobe3.2timestheradiusofthereactorvesselcylindertoinsurethatthemaximumhoopstressandstressintensity calculated bytheaxisymmetric modelwouldbecomparable tothoseintheactualthree-dimensional intersection.

AppendixBdocuments thefiniteelementmodel.ThefiniteelementmeshoftheCRDRnozzleisshowninFigures3-2and3-3.33.2MaterialProertiesThemodeloftheCRDRnozzleiscomposedofthreeregionswithdifferent materialproperties.

ThereactorvesselwallisSA302GradeBlowalloysteel.TheCRDRnozzleisanSA336lowalloysteelforgingwithASMECodeCase1236-1fornickeladdition.

ThecladisassumedtobeType308stainless steel.3-2

Temperature dependent materialproperties wereusedinthethermal'a'nd stressanalysesoftheCRDRnozzle.AppendixCdocuments thematerialproperties usedintheanalyses.

399ThermalBoundaConditions Thermalboundaryconditions forthereactorscramtransient arediscussed indetailinAppendices DandEandsummarized below.Thelastportionofthereactorscramtransient wasmodeled.Initially, theCRDRnozzleisatauniformtemperature of525'Fcorresponding tozeroflowthroughtheCRDRnozzleastheaccumulators arerecharged.

Atthestartofthetransient, theCRDRflowrateisstepchangedtoit'snominalvalueof35gpmwithafluidtemperature of70'F.Heattransfercoefficients andbulkfluidtemperatures areappliedtotheinsidesurfaceofthereactorvesselwallandtheboreoftheCRDRnozzle.Allothersurfacesareassumedtobeadiabatic (insulated).

AppendixDisacalculation oftheheattransfercoefficient inth'eCRDRnozzlebore.Theoverallheattransfercoefficient betweentheCRDRfluidandthenozzleborewhichincludestheeffectsofthethermalsleeveandwaterannuluswascalculated tobe100BTU/hr-ft~-'F.

Thisincludestheeffectsofthefluidfilmontheinsidesurfaceofthethermalsleeve,conduction throughthethermalsleeve,andnaturalconvection throughthestagnantfluidlayerbetweenthethermalsleeveandthenozzlebore.Aheattransfercoefficient of1000BTU/hr-ft2-'F wasusedbetweenthebulkdowncomer fluidtemperature andthevesselwall.39.4Structural BoundaConditions Thestructural boundaryconditions forthestressanalysisincludeappliedpressures anddisplacements (Appendix E).Apressureof1250psigwasappliedtotheinsidesurfaceofthereactorvesselwallandtheboreoftheCRDRnozzle.Anegativepressurewasappliedtothesafeendtosimulatetheaxialloadintheattachedpiping.Attheendofthereactorvesselwall,symmetryboundaryconditions areappliedtopermitradialdisplacement andtoprohibitrotation.

Atthesafeend,couplesareusedtoallowtranslation ofthesafeendbuttoprohibitrotation.

39.5ResultsThepeakstressintensity inthebasemetaloccursattheendofthescramtransient.

Figure3-4showsthecalculated temperature distribution attheendofthetransient.

Figure3-5showsthecalculated stressintensity distribution attheendofthetransient.

Thepeakstress(110ksi)inthebasemetaloccursintheboreoftheCRDRnozzleatthebasemetaltocladdinginterface, justabovetheblendintothevesselwall.Theprincipal component ofthestressintensity ishoopstress.3-3

3.4FATIGUEEVALUATION Afatigueevaluation oftheCRDRnozzlewasperformed basedontheloadcyclesdefinedinSection3.2andtheresultsofthefiniteelementstressanalysisdiscussed inSection3.3.Nozzlefatigueusageforcurrentplantoperation conditions wasevaluated onapercyclebasis.Asdiscussed inSection3.2,theCRDRnozzleissubjecttostartup/shutdown cyclesandstartup/scram cycles.Fatigueusagewascalculated forbothofthesecycles.Thenozzlealsoundergoes hydrostatic testing;however,thiscycleisboundedbythepressure-temperature conditions duringastartup/shutdown cycle.Fatigueusageiscalculated by:u=gnNwhere:u=fatigueusagen=numberofcycleswhichoccurN=numberofallowable cyclesbasedonthecyclicstressesAfatigueusageof1.0indicates thatthereisapotential forfatiguecrackinitiation inthenozzle.Theallowable cyclesaredetermined fromtheASMECodeDesignFatigueCurveforCarbon,LowAlloyandHighTensileSteels(Reference 2,FigureI-9.1).Thiscurveprovidesaconservative numberofallowable cyclesforagivenalternating stressrange(safetyfactorshavealreadybeenapplied).

Therefore, useofthiscurvefortheusageevaluation providesaconservative estimateoffatigueusageforthenozzle.Calculation offatigueusageforstartup/shutdown andstartup/scram cyclesaredocumented inAppendixF.Thecalculation isperformed usingthepeakstressintensity rangeonthebasemetalinsidesurfaceofthenozzleforeachofthecycles.Thefatigueusageforthenozzlewascalculated tobe1.963x10~perstartup/shutdown cycleand3.848x10perstartup/scram cycle.Basedonrecentplantoperating history,thereareapproximately fivestartup/shutdown cycles,onehydrostatic testandfourstartup/scram cyclesperyear,whichcorresponds toanannualfatigueusageof0.003.3.5FRACTUREMECHANICS

-CRACKGROWTHRATECrackgrowthofanassumedpre-existing fiawinthenozzleduetothepressureandthermalcyclesdefinedinSection3.2isanalyzedusingthePariscrackgrowthrateequation:

=C(AK)dN3-4

\where:crackgrowthrate(inches/cycle) daGnstressintensity factorrange(ksiPin)C,m=constants (dependent onmaterial, environment, andloading)CandmaretakenfromtheASMEcrackgrowthcurveforsurfaceQawsinawaterreactorenvironment (Reference 2,FigureA-4300-1).

Thestressintensity factorrangeisthemaximumchangeinstressintensity factorduringthegivencycle.Stressintensity factorisafunctionofstressandcracksize.Asdescribed inSection3.3,stresseswereanalyzedbyQniteelementanalysis, UsingtheQniteelementmodelresults,asectionthoughthenozzlewall,passingthroughthepeaksurfacestressesontheinsideandoutsidesurfacesofthenozzle,wasdetermined.

Thissectionislocatedintheblendregionofthenozzleneartothetransition totheboreregion.Athirdorderpolynomial wasQittothestressesthroughthesectionasafunctionofdepththroughthenozzle.Stressintensity factorsweredetermined bythemethodsofReference 3.Stressintensity factorsarecalculated asaf'unction ofcracksizeandthepolynomial coefficients fromthecubicstressdistribution.

Acomputerprogramthatcalculates crackgrowthbasedonthemethoddescribed abovewasdeveloped toanalyzeassumedQawsinthenozzle.Theprogramdescription andveriQcation aredocumented inAppendixG.InputsandresultsofthecrackgrowthanalysisareprovidedinAppendixH.Theresultsofthecrackgrowthanalysis, assuminganinitialQawsizeof0.25inches,areshowninFigure3-6.AsshowninFigure3-6,theassumed0.25inchinitialQawwillgrowtoapproximately 0.40inchesin40yearsofoperation.

TheresultsindicateaverysmallcrackgrowthrateforacrackintheCRDRnozzle.Inaddition, the0.40inchfinalQawsizeislessthantheallowable Qawsizeof0.5inches.Theallowable flawsizefortheanalyzedsectionofthenozzlewasdetermined fromcriteriagiveninSectionXIoftheASMECode[Ref.2].Determination oftheallowable Qawsizeisdocumented inAppendixH.Anallowable flawsizeof0,5inchesprovidessigniQcant margintoensurethenozzlewillnotfailbybrittlefracture.

Theappliedstressintensity factorfora0.5inchflawunderthemostseverestressconditions inthenozzleisapproximately 81ksiIin.Thenozzleisnotpredicted tofailbybrittlefractureuntiltheappliedstressintensity factorexceedsthecriticalstressintensity factorfortheCRDRnozzlematerial.

Atnormaloperating temperatures thecriticalstressintensity factorisapproximately 200ksiIin,whichismorethantwicetheappliedstressintensity factorofthe0.5inchallowable flaw.3-5

3.6EXPERIENCE SURVEYAsurveywasperformed todetermine theexperiences ofotherutilities withregardtoCRDRnozzlecracking.

NUREG-0619 responses totheNRCfromutilities operating BWRplantswerereviewedtodetermine howtheCRDRnozzlecrackingissuewasresolvedateachoftheplants.Inaddition, severalutilities werecontacted todetermine moredetailedinformation aboutinspection practices fortheCRDRnozzle.Theresultsaresurnrnarized below.Reviewofutilityresponses totheNRCindicated thatalmostalloperating BWRscutandcappedtheCRDRreturnline,eitherwithorwithoutflowrerouted'to anothersystem.PlantswithacappedCRDRnozzlearenotrequiredbyNUREG-0619 toperforminspections ofthenozzle(besidesafinalPTinspection requiredpriortocappingthenozzle).However,someplantswereoperatedforextendedperiodsoftimewiththeCRDreturnlinevalvedout,whichNUREG-0619 considers tobeatemporary solution.

Inaddition, oneplant,OysterCreekNuclearGenerating Station,hascontinued tooperatewithCRDreturnlineflowthroughtheCRDRnozzle.OysterCreekistheonlyotherplantbesidesNMPUnit1permitted tooperatewiththeCRDRnozzleinservice,Severalplants,including OysterCreek,werecontacted todetermine information aboutinspection techniques andresultsofnozzleinspections.

Twooftheplantscontacted, DuaneArnoldEnergyCenterandQuad-Cities Station,foundcracksintheCRDRnozzleduringrecentinspections (pastGiveyears).AtDuaneArnold,theCRDreturnlinewasvalvedoutandcappedwithablindflangein1982.Duringavisualinspection oftheCRDRnozzlein1990,evidenceofcrackingwasfoundandafullPTexamination wasperformed.

Acrackapproximately 3incheslongand0.25inchesdeep,justpenetrating intothebasemetalofthenozzle,wasfoundandgroundout.Thenozzleprobablyhadathermalsleeveinstalled priortobeingcapped;however,thetypeofthermalsleeveisunknown.Theplantperformsavisualinspection ofthenozzleeveryoutage,butdoesnotperformanyultrasonic inspections.

QuadCitiesoperatedwiththeCRDreturnlineinavalved-out conflguration until1989whencrackingwasfoundintheCRDRnozzle.Duringthisperiodofoperation, theCRDreturnlinewasvisuallyinspected everyoutage.Asaresultofthecracking, theCRDreturnlinewascutandcappedin1989.Sincethattimenoinspections ofthenozzlehavebeenperformed.

Inbothofthesecases,crackingwasfoundafterasigniflcant periodofoperation withtheCRDRnozzleisolatedfromCRDRflow.Mostlikely,crackinginitiated priortoisolation oftheCRDRflow,butwasnotidentifled untillaterinspections, OysterCreekistheonlyotherplant(besidesNileMilePointUnit1)allowedbyNUREG-0619 tooperatewithflowtotheCRDRnozzle.SimilartoNMPUnit1,OysterCreekappliedforanexemption oftheNUREG-0619 requirements fortheCRDRnozzle,including thescheduled PTexamination.

Basedonautomated ultrasonic

~~~~(UT)examinations oftheCRDRnozzle,whichdidnotidentifyanyindications, Oysterreekwasgivenanexemption fromthenozzlePTexamination untilthenextrefueling outage.Qualiflcation oftheUTsystemwasperformed usingamock-upoftheCRDRnozzle.EventhoughtheUTsystemwasdesignedspecifically forthenozzlegeometry, 3-6

Itherewereseveralproblemsencountered duringsetupofthesystem.MountingthesystemtooklongerthantypicalUTsystemsduetospaceconstraints aroundthenozzle.Inaddition, removalofthemirrorinsulation aroundthenozzleareawasexpensive andtimeconsuming.

Aftertheinspection, anewtypeofremovable insulation wasinstalled toprovideeasieraccessforfutureinstallations.

3-7 0

Table3-1CRDRNozzlePressureandTemperature CyclesDescription 1NormalStartup/Shutdown 2ReactorScram3InitialHydro4Refueling Hydro510yearISIHydroReactorVesselPressure(psi)01030-0103012500187500>>1030-0011330Downcomer FluidTemperature

('F)70-525-70250250250CRDRNozzleFluidTemperature

('F)7070<<525<<70707070NumberofCyclestoDate9615NumberofCyclesExpectedperYear5.03.90.01.00.1

23e~')ASSCQ.SKQIgCULCLI'QTLRe~It$0JiVc48>~~~mt'TTIcuenor.~~tgncuovr.lup~tITb~+prre<v+'.i)aeisa)~'Mi7(Sb~T.IL)Z1VOVreeaaRCr.)4~~q~'-iTYTT,SYSIEIIgETUTPTTuCJLEKSQ'YFigure3-1.CRDRNozzleDimensions

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4hrentawQ~7Qp:PANSYS5.0MAR31199410:40:18PLOTNO.1NODALSOLUTIONSTEP=14SUB=1TIME=3600 SINT(AVG)DMX=1.462SMN=3533SMNB=2569 SMX=96413SMXB=105008 3533138532417334493448135513365453757738609396413'+~~Figure3-5.Calculated StressIntensity Distribution

0.440.420.400.38~0.36~0.34(~p0.32.0.3000.280.260.240.220.20050IIIIIIIITIIIII100150200250300350400Cycles(10cyclesperyear}Figure3-6.FatigueCrackGrowth

PD1MPRASSOCIATES INC.EN&INEEITS Section4REFERENCES 1.NUREG-0619, "BWRFeedwater NozzleandControlRodDriveReturnLineNozzleCracking, November1980.2.ASMEBoilerandPressureVesselCode,1980EditionwithAddenda.3.Buchalet,'C.B.,

andBamford,'.W.H.,

"StressIntensity FactorSolutions forContinuous SurfaceFlawsinReactorPressureVessel,"ASTM-STP-590, 1975.4-1 I'

rpMPRENGINEERS Section5APPENDICES A.Calculation ofCRDRNozzleThermalandPressureCyclesB.CRDRNozzleFiniteElementModel,GeometryC.CRDRNozzleFiniteElementModel,MaterialProperties D.Calculation ofHeatTransferCoefficients E.CRDRNozzleFiniteElementModel,BoundaryConditions andResultsF.LowCycleFatigueUsageG.CrackGrowthRateComputerProgramVerification H.CrackGrowthRateAnalysisCasesI.Implementation Plan5-1

FA1MPRSSOCIATES INC.ENGINEERS AppendixACALCULATION OFCRDRNOZZLETHERMALANDPRESSURECYCLES

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ylLIMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314CALCULATION TITLEPAGEClientNr4~g~oh'5-wW~rn/P~/ggjOr~IMWI7Page1ofI3Projectg~>~mneozan.E-J'WFsSTaskNo.dew-22.fTitle~<ODEC~%MdI/r-/'alculation No.~g~-+gal-dZ8-0/Preparer/Date Checker/Date Reviewer/Date Rev.No.

lx)MPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314RECORDOFREVISIONS Calculation No.Old-2zf-~jPQ-aI Revision<T.~CheckedByP~fib',;Description Page

WMPQMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.ops-z~-685-ol'7S'CheckedByPagePurposeThepurposeofthiscalculation istodocumentthegeometric inputdataforafiniteelementanalysisoftheNiagaraMohawkPowerCorporation, NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.Atransient thermal/stress analysissimulating areactorscramwasperformed.

References 1and2arecalculations whichdocumentthefiniteelementmodelmaterialproperties andboundaryconditions/

results.TheANSYScomputerprogram(Reference 3)wasusedtocalculate thetransient temperature distribution inanaxisymmetric modelofthenozzle.Theprogramwasthenusedtocalculate stressprofilesduetopressureandduetothecalculated temperature distribution.

Theresultsofthisanalysis, intheformofstressdistributions throughthebore/blend sectionofthenozzle,willbeusedinafatigueandcrackgrowthevaluation oftheCRDreturnnozzle.Discussion Figure1isadrawingoftheCRDreturnnozzlewhichshowspertinent dimensions (Reference 4).Thedimensions usedintheanalysisareasfollows:VesselRadiusRVVesselThickness TVCladThickness CLADAngularExtentANG1106.7*3.2inches7.125inches.2188inches8degreesOtherdimensions fromFigure1areasfollows:NozzleBoreNozzleODSafeEndODVesselCutOutR1R2R3R42.061inches4.813inches2A69inches5.563inches8.688inches4.125inches1.344inchesSafeEndH1SafeEndH2SafeEndH3Theradialdimensions forthenozzlebore,R1,andthevessel,RV,aretothebasemetal-cladding interface.

Thesedimensions shouldbereducedbythethickness of

OlxlMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.4785-g~)t-Q,S-OICheckedByP~74uPagethecladding(7/32").Thisdiscrepancy betweenthefiniteelementmodelandthedrawingdimensions shouldhaveanegligible affectonthecalculated stresses.

Figures2and3showtheaxisymmetric finiteelementmodelofthenozzle.The'xisymrnetric modelusesaradius3.2timestheactualradiusofthereactorvessel.Thisistoinsurethemaximumhoopstressandstressintensity fromthemodelwillbecomparable tothoseintheactualthree-dimensional intersection (Reference 5).Theangularextentofthefiniteelementmodelaffectsthenumberofelementsinthemodelandconsequently thecomputerrunningtimeforthemodel.Theangularextentassumedintheseanalysesis8degrees.Thisextentwasselectedbyperforming pressureonlyloadcaseswithmodelsofvaryingextentandevaluating thestressesatthevesselcutline.Thepressureanalysesshowedthat8degreesissufficiently farfromtheCRDreturnnozzlesuchthatthestressdistribution atthevesselcutlineisuniform.Reference 6istheANSYSoutputfilewhichshowsthePREP7echooftheinputdata.References MPRCalculation 085-229-EBB-02, "CRDRNozzleFiniteElementModelMaterialProperties",

Revision0.2.MPRCalculation 085-229-EBB-03, "CRDRNozzleFiniteElementModelBoundaryConditions andResults",

Revision0.3.ANSYScomputerprogramversion5.0.4Combustion Engineering ReportCENC1142,"Analytical ReportForNiagaraMohawkReactorVessel",drawingnumber231-567-7.

5.J.B.TruittandP.P.Raju,ASME-78-PVP-6, "Three-Dimensional VersusAxisymmetric FiniteElementAnalysisofaCylindrical VesselInletNozzleSubjecttoInternalPressure, AComparative Study"6.7.MPRCalculation "Geometry",

tasknumber85-31"LowFlowFeedwater ControlSystem",2/28/83.ANSYSoutputfileNOZZLE.OUT, 87,853bytesdated4-04-943:45:28pm.

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PRIMP'PRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.+g-gag-$3/f-0ZPreparedByCheckedByPageg~PuroeeThepurposeofthiscalculation istodocumentthematerialproperties usedinafiniteelementanalysisoftheNiagaraMohawkPowerCorporation, NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.TheANSYScomputerprogramwasusedtocalculate thetransient temperature distribution inthenozzle.Inaddition, theprogramwasusedtocalculate stressprofilesduetopressureandduetothecalculated temperature distribution.

Thematerialproperties requiredintheanalysesare:ElasticModulusCoefficient ofThermalExpansion ThermalConductivity SpecificHeatPoisson's RatioDensityDiscussion Figure1showsaschematic oftheCRDRnozzleoutline.Thenozzlemodeliscomposedofthreeregionswithdistinctmaterialproperties.

~Region1isthereactorvesselwall.ThevesselwallmaterialisSA302GradeB(Mn-1/2Mo),

Reference 1.~Region2istheCRDRnozzle.ThenozzlematerialisSA336withASMECodeCase1236-1,Reference 1.Equivalent materialisSA508Class2(3/4Ni-1/2Mo-1/3Cr-V) asdiscussed below.~Region3istheClad,assumedtobetype308Stainless Steel.Stainless SteelType304,18Cr-8Nimaterialproperties areaclosematchandareusedinthisanalysis.

Previousfiniteelementanalysesofthefeedwater nozzleused1980ASMECodematerialproperties (Reference 2).Inthatcalculation, acomparison ofmaterialchemicalcomposition betweentheoriginal1964specification andthe1980Codewasmade.Thecomparison showedthatforthevesselwall1980ASMECodematerialproperties wereequivalent.

Thecalculation alsoshowedthattheequivalent material

lxHMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.de-d45'+44-ozCheckedByS~mt~~PageypropertyforthenozzlewasSA508Class2(3/4Ni-1/2Mo-1/3Cr-V).

Thesamematerialproperties usedinthepreviouscalculation forthefeedwater nozzleandvesselwallareusedinthisanalysisfortheCRDReturnnozzleandvesselwallrespectively.

ResultsTemperature dependent materialproperties arelistedinTables1through3forthereactorvesselwall,CRDReturnnozzleandcladdingrespectively.

Attachment AisalistingoftheANSYSmacroMATL.MACwhichisthecomputerprograminputdataformaterialproperties.

(Theinputdataalsolistsheattransfercoefficients.)

Forallthreematerials, adensityof489Ib/ftandPoisson's Ratioof0.3wereused(Reference 3).Thereference temperature forthecoefficient ofthermalexpansion (REFTinfileMATL.MAC) is70'Fforthenozzleandvesselwall.Forthecladdingmaterial, theaveragetemperature betweenthedowncomer andnozzlefluidtemperatures atfullpowerconditions wasusedforthereference temperature toapproximate theresidualstressstateinthecladding.

Specificheatwascalculated fromthermaldiffusivity bythefollowing formula:Cp=K/(Rho*TD)

Where:CpKRhoTDSpecificHeat(btu/Ib-'F)

ThermalConductivity (btu/hr-ft-'F)

Density(Ib/ft)ThermalDiffusivity (ft/hr)References Combustion Engineering ReportCENC1142,"Analytical ReportForNiagaraMohawkReactorVessel",pageA-78.2.MPRCalculation "Material Properties",

tasknumber85-31"LowFeed-waterFlowControl",

2/28/93.3.StandardHandbookForMechanical Engineers, SeventhEdition,pages5-6and6-7.

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-SA302GradeBCarbonMolybdenum (Mn-1/2Mo)

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'::.;',';:(Btb1lb';.,F).jI 7010015020025030035040045050055060029.2029.0428.7728.5028.2528.0027.7027.4027.2027.0026.7026.407.027.067.167.257.347.437.507.587.637.707.777.8323.323.624.124.424.624.724.724.624.424.223.923.5.1047.1070.1110.1142~1173.1203.1235.1264.1286.1313.1343.1361

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-SA336withCodeCase1236-1Equivalent toSA508Class2(3/4¹i1/2Mo-1/3Cr-V) 70100150200250300350400450500550600Mo'du!.'Us~of

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6.416.506.576.676.776.876.987.077.157.257.347.42'IG'ondiictiyity'.:k,I, l'j<:(Btu/hr',-:,,',ft-."':,F(}':,-';:I:.-;,

23.623.723.924.024.023.923.723.623.323.122.722.4K,"m,'(Bi'u/ib;-";,,F}',;",'",:

~1063.1084.~1118.1149.1180.1204.1224.1254.1274.1305.1326.1351ModulusofElasticity valuesarefor1/2-2CrChromeMolybdenum.

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-Stainless SteelType308Type304Properties Usted(18Cr-8Ni)

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r:.>M,odulus:,.",,of;:;:.;.

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ASSOCIATES INC.ENGINEERS AppendixECRDRNOZZLEFINITEELEMENTMODELBOUNDARYCONDITIONS ANDRESULTS

lLimpRMPRAssociates, Inc.320KingStreetAlexandria, VA22314CALCULATION TITLEPAGEClient~~~~gp/~/g+//L/gW/Qg/0/rv/~~///Page1ofgqProjectg~/~~~~opygmyrT/QTaskNo.0Z~Titlego~~p~pYAnted/77@AS~i>ZF~ur-I~Calculation No.~-P29-Ct~d-o3 Preparer/Date az.8.'/Z-Z/-5'yChecker/Date g<g.'7~Reviewer/Date Rev.No.

txrMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No..080=PP9-Fd'rs-y3RevisionRECORDOFREVISIONS PreparedByDescription Page0+1+pv<rrO'JvP

t>IMPRCalculation No.dd~-cVW-ggg-oJPreparedByMPRAssociates, Inc.320KingStreetAlexandria, VA22314Page~PurposeThepurposeofthiscalculation istodocumenttheboundaryconditions andresultsofafiniteelementanalysisoftheNiagaraMohawkPowerCorporation, NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.Atransient thermal/stress analysissimulating areactorscramwasperformed.

References 1and2arecalculations whichdocumentthefiniteelementmodelgeometryandmaterialproperties.

TheANSYScomputerprogram(Reference 3)wasusedtocalculate thetransient temperature distribution inanaxisymmetric modelofthenozzle.Theprogramwasthenusedtocalculate stressprofilesduetopressureandduetothecalculated temperature distribution.

Theresultsofthisanalysis, intheformofstressdistributions throughthebore/blend sectionofthenozzle,willbeusedinafatigueandcrackgrowthevaluation oftheCRDreturnnozzle.Discussion TheCRDsystemprovideswaterfromthecondensate storagetankatatemperature ofabout70'Ftothecontrolroddrivemechanisms tocoolthecontrolroddrives,toreposition rodsandtoscramtherods.Thesystemoperatesatalltimesthatfuelisinthevessel.ExcessfiowfromtheCRDpumpsisroutedtothereactorvesselviatheCRDreturnnozzle.Consequently, flowthroughtheCRDreturnnozzleistypical.NominalCRDreturnflowrateis17to35gpm.Theflowratedoesnotchangeasaresultofrepositioning acontrolrodsincetheflowdivertedtomovetherodiscompensated bythewaterdisplaced bytherod.AreactorscramresultsinaCRDreturnnozzleflowtransient (Reference 4).Duringascram,theCRDaccumulators discharge todrivethecontrolrodsintothecore.thisresultsinanincreaseinCRDreturnflowto65gpm.Whenaccumulator pressuredropsbelowreactorpressure, CRDflowrategoestozeroastheaccumulators arerecharged.

Aftertheaccumulators havebeenrecharged, CRDflowratereturnstothenominal17to35gpm.Thelastportionofthereactorscramtransient issimulated inthiscalculation.

Attimezerothenozzleisatauniformtemperature of525'Fcorresponding tozeroflowthroughtheCRDreturnnozzleastheaccumulators arerecharged.

At1secondintothetransient, theCRDreturnflowrateisstepchangedtothenominalflowrateof35

l41MPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.os%->z1wed-o7PreparedByCheckedBygR~Page~gpmwithafluidtemperature of70'F.Apressureof1250psigisappliedtotheinsidesurfaceofthereactorvesselwallandtheinsideofCRDreturnnozzlethroughout thetransient (nominalreactorpressureis1030psig,scrampressureis1250psig).Detailsofthethermalandstructural boundaryconditions arediscussed below.ThermalBoundaConditions forthereactorscramtransient areshownonFigure1anddiscussed below.AttimezerotheCRDreturnnozzleandreactorvesselwallareatauniformtemperature of525'Fcorresponding tothebulkdowncomer fluidtemperature.

Theoverallheattransfercoefficient betweenthedowncomer fluidandthevesselwallisassumedtobe1000Btu/(hr-ft

-'F).Thisisthevalueusedinprioranalysesforthefeedwater nozzle.At1secondintothetransient, thebulkfluidtemperature intheCRDreturnnozzleisstepchangedto70'F.Theoverallheattransfercoefficient betweentheCRDreturnfluidandthenozzlewallis100Btu/(hr-ft-

'F).Theheattransfercoefficient inthenozzleincludestheeffectsofthefluidfilmontheinsidediameterofthethermalsleeve,conduction throughthethermalsleeve,andnaturalconvection throughthestagnantlayerbetweenthethermalsleeveandthenozzlebore.Reference 5isacalculation oftheoverallheattransfercoefficient betweentheCRDreturnfluidandthenozzleinsidesurface.Theoutsideofthevesselwall,theoutsideofthenozzleandtheradialcutlinesthroughthevesselwallandsafeendaremodeledasadiabatic (noheatflowacrossthesurface).

Structural BoundaConditions includeappliedpressureanddisplacement constraints.

Figure2showstheappliedpressurealongtheinsidesurfaceofthereactorvesselwallandtheinsidesurfaceoftheCRDreturnnozzle.Theappliedpressureonthesesurfacesis1250psig.Apressureisalsoappliedtothesafeendtorepresent theaxialloadintheattachedpiping,Thevalueofthepressureappliedtothesafeendiscalculated asfollows(dimensions arefromReference 1):AintFlAlPend=Where:pi*R12Pint"Aint pi*(R3-R1)=FI/AI13.34in16681.Ibf5.803in2875.psi 0

RMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.oN-d4f-F4ss'-oZPreparedBy7K~PageAintR1PintFlAIR3Pend=Insideareaofsafeend(in)Safeendinsidediameter=2.061inchesInternalpressure=1250psigLongitudinal force(Ibf)Crosssectional areaofsafeendSafeendoutsidediameter=2A69inchesPressureappliedtothesafeend(psi)Figure3showsthedisplacement boundaryconditions appliedtotheendofthereactorvesselwall.Symmetryboundaryconditions areappliedtopermitradialdisplacement alongthecutlinebuttoprohibitrotationofthecutline.Figure4showsthedisplacement boundaryconditions appliedtothesafeend.Couplesareusedtoallowtranslation ofthesafeendcutlinebuttoprohibitrotationofthecutline.ResultsThepeakstressintensity occursattheendofthetransient whensteadystateconditions havebeenreached.Figure5showsthetimehistoryofstressintensity atseveralnodesinthebore/blend region.Thestressesshowninthetimehistoryareatthecladdingtobasemetalinterface.

Figure6showsthecalculated temperature distribution attheendofthetransient.

Thepeakstressintensity inthebasemetalforthetransient occursatnode806intheboreblendregionofthenozzleatthebasemetaltocladdinginterface (Attachment A).Thepeakstressintensity atnode806duetotemperature andpressureis110ksi.Thestressintensity duetopressurealoneatnode806is65ksi.Theprincipal component ofthestressintensity isthehoopstress.Colorcodedcontourplotsofstressdistribution areshowninFigures7through10forpressureonlyloading(timezeroofthetransient).

Figures11through14showstressdistributions attheendofthereactorscramtransient forpressureandtemperature loading.Fourplotsareshownforeachloading:Stressintensity, ASMEcodeorTrescastressintensity, Hoopstress,theZcomponent ofstressfortheaxisymmetric model,~Xcomponent stress,interpreted asasecondhoopstressforthe e0 lLiMpRCalculation No.ogJ-g2g-flag-cgPreparedByZ.N.N~clMPRAssociates, Inc.320KingStreetAlexandria, VA22314Pagespherical modelofthevesselwall,Ycomponent stress,interpreted asaxialstressinthenozzleregion.Figures15and16showthelocations ofnodes806and14.Node806isthepointofmaximumstressintensity attheinterface betweenthecladdingandthebasemetal.Node14isthepointofmaximumstressintensity ontheoutsidesurfaceofthenozzle/vessel intersection.

Astraightline(path)isdrawnfromnode806tonode14andthestressintensity valuesareinterpolated ontothepath(Figure11showstheinterpolation path).Figures17and18showstressintensity alongthispathforthepressureonlycaseandthepressureandtemperature case.Attachment BisatabularlistingofthestressversuspathlengthvaluesforFigures17and18.Attachments CandDprovidetheANSYSinputdataforthethermalandstresspassesoftheanalysis.

Reference 6isthehardcopyoutputfilefortheboththethermalandstresspasses.References 1.MPRCalculation 085-229-EBB-01, "CRDRNozzleFiniteElementModelGeometry".

2.MPRCalculation 085-229-EBB-02, "CRDRNozzleFiniteElementModelMaterialProperties",

Revision0.3.ANSYScomputerprogramversion5.0.MPRCalculation 085-230-ABR-01, "NineMilePointUnit1,ControlRodDriveReturnNozzleThermalandPressureCycles",Revision1.5.MPRCalculation 085-230-ABR-02, "OverallHeatTransferCoefficient ForCRDRNozzleatNMP-1",Revision0.6.ANSYSoutputfileNOZZLE.OUT, 87,853bytesdated4-04-943:45:28pm.

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ANSYS5.0APR7199411:59:26PLOTNO.1NODESTYPENUMPRESP8P<PZgcyylrccf~gag-g<~+~JJu~ZV=1DIST=25.552 XF=25.29YF=347.745~~QJIQ4/pl]eel+~JCMPressureBoundaryConditions r/'Cut6

ANSYS5'APR7199412:03:24PLOTNO.3NODESTYPENUMUZV=1DIST=25.552 XF=25.29YF=347.745+r'I'/III IIIIIIIiIIII~~~~IiiiiiiStructural BoundaryConditions

-RadialSymmetry,~/QU/Z&

ANSYS5'APR7199412:05:05PLOTNO.4NODESTYPENUMCP/OAc.+a!1~ZV=1DIST=25.552 ZF=25.29YF=347.745A"~1';~,~~~~~~~~//IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIStructural BoundaryConditions

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ANSYS5.0APR4199416:33:47PLOTNO.1NODALSOLUTIONSTEP=2SUB=21TIME=3601 TEMPTEPC=9.434 SMN=88.846SMX=523.56288.846100200300400500600ReactorScram,Temperature Profile+/5-u4C-.

~gtt"'~SiSQSySfS)9ANSYS5.0APR4199416:32:56PLOTNO.1NODALSOLUTIONSTEP=1SUB=1TIME=1SINT(AVG)DMX=1.501SMN=1421SMNB=920.904 SMZ=66400SMKB=72225 142186411586123081303003752044740519605918066400PressureOnly,StressIntensity P/6u4E'

ANSYS5.0APR4199416:33:00PLOTNO.2NODALSOLUTIONSTEP=1SUB=1TIME=1SZ(AVG)RSYS=ODMX=1.501SMN=-22178SMNB=-30892 SMX=63262SMXB=68966

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S$.E..eCANSYS5.0APR4199416:33:03PLOTNO.3NODALSOLUTIONSTEP=1SUB=1TIME=1SX(AVG)RSYS=ODMX=1.501SMN=-3074SMNB=-13025 SMZ=42194SMZB=46227

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4+zc:t$a.~ANSYS5.0APR4199416:33:31PLOTNO.7NODALSOLUTIONSTEP=14,'UB

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-595320231000017977259533393041907498835786065837ReactorScram,XComponent Stress

ANSYS5.0APR4199416.33.35PLOTNO.8NODALSOLUTIONSTEP=14SUB=1TIME=3600 SY(AVG)RSYS=ODMX=1.46SMN=-45246SMNB=-61830 SMX=18196SMXB=20255

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82283183383l835$36$37838839$l0$41$42843$44845$46$47$48849ANSYS5.0APR7199412:23:22PLOTNO.1NODESNODENUMZV=1*DIST=1.386

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• XF=2.975*YF=344.095$62917$06l3$89l303$61916944943$07$88l319l304915$60942$08$87l318914l305941$59$86l317l306$58913.7861316l283$57$85$84.789l315l286$56NodeNumbers-ID.788l314l285.78713131284+/pv/CC/4

(x10I01)652612ANSYS5.0APR4199418:06:06PLOTNO.1POST1STEP=1SUB=1TIME=1PATHPLOTNOD1=806NOD2=14CO5735331C453CZV=1DIST=0.75 XF=0.5YF=0.5ZF=0.5CENTROIDHIDDEN41337333329325370.5411.0831~6242.1653.2482.7073.794.3314.8725.414Posi4ion,ID4oODPressureOnlyBiduel7

(x104I'2)110102ANSYS5.0APR4199418:06:26PLOTNO.2POST1STEP=14SUB=1TIME=3600 PATHPLOTNOD1=806NOD2=14957.962887.1+816.23C745.37CZV=1DIST=0.75 ZF=0.5YF=0.5ZF=0.5CENTROIDHIDDEN674.51C603.65532.79461.93391.07101.0832.1653.2484.3315.4140.5411.6242.7073.79Position,IDtoOD4.872ReactorScramTransient

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• • • • • ENTERHELP,ERRORFORANEXPLANATION OFANSYSERRORESTIMATION

• • • • • • • • • • ENDOFINPUTENCOUNTERED

• • • • • EXITTHEANSYSPOST1DATABASEPROCESSOR

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• • • • • ANSYSCOMMANDLINEARGUMENTS

• • • • • MEMORYREQUESTED (MB)=64.0*****INPUTFROMCONFIG.ANS FILEKEYWORDINPUTVALUEVALUEUSEDNUMVPAG512512SIZVPAG1228812288EXTFILE00*****ANSYSDYNAMICMEMORYALLOCATION

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ALLRIGHTSRESERVED.

SWANSONANALYSISSYSTEMS,INC.

ISENDEAVORING TOMAKETHEANSYSPROGRAMASCOMPLETEiACCURATEiANDEASYTOUSEASPOSSIBLE.

SUGGESTIONS ANDCOMMENTSAREWELCOMEDANYERRORSENCOUNTERED INEXTHERTHEDOCUMENTATION ORTHERESULTSSHOULDBEIMMEDIATELY BROUGHTTOOURATTENTION

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3600.0TITLE=ReactorScramTransient GRAPHPLOTKEY=1XAXISLABEL=Position, IDtoODYAXISLABEL=StressIntensity (psi)

Path:C:iNOZZLE File:XPATH.OUT13,436.a..4-04-946:06:28pmDEFINEAPATHFORSUBSEQUENT CALCULATIONS THROUGHNODES:80614Page6a<Z***NOTE***CP=32.130TIME=18:06:17Previousinterpolated pathdatahasbeenerased.ReissuePDEFcommandtointerpolate desireddata.DEFINEPATHINPATHCOORDINATE SYSTEM0DIRECTION MAXMINX6.28552.2798Y348.57344.93Z0.00000E+00 0.00000E+00 TOTALPATHLENGTH=5.4136DEFINEPATHVARIABLESINTASTHENODALDATAITEM=SCOMP=INTROTATEDINTOCOORDINATE SYSTEM0ANDMOVEDTOTHEPATHNUMBEROFPATHVARIABLES DEFINEDIS5***WARNING***CP=37.950Theselectedelementsetcontainsmixedmaterials.

Thiscouldinvalidate errorestimation.

TIME=1806:22SUMMARYOFVARIABLESINTMAX=0.10997E+06 MIN=39107.CUMULATIVE DISPLAYNUMBER2WRITTENTOFILEXPATH.PLT DISPLAYTITLE=ReactorScramTransient RASTERMODE.PRINTALONGPATHDEFINEDBYLPATHCOMMAND.DSYS=01*****ANSYS-ENGINEERING ANALYSISSYSTEMREVISION5.0*****MPRASSOCIATES VERSION=PC 386/48618:06:26APR04,1994CP=FORSUPPORTCALLPHONE703/519-0200 FAXReactorScramTransient 41.680*****PATHVARIABLESUMMARY*****S0.00000E+00 0.112780.225570.338350.451140.563920.67670SINT0.10997E+06 911)rru~i88915.86153.83317.80781.78373.

Patn:File:0.789490.902271.01511.12781.24061.35341'6621.57901.69181.80451.91732.03012.14292.25572.36852.48132.59402'0682.81962.93243.04523.15803.27073.38353.49633.60913.72193.83473.9474406024.17304.28584.39864.51144.6242C:KNOZZLE XPATH.OUT13,436.a..4-04-946:06:28pm76148.74078.72106.70305.68564.66937.65312.63805.62374.60995.59673.58388.57214.56098.54950.53857.53067.52158.51230.50269.49216.48061.46233.44546.43265.42541.41859.41175.40518.39815.39107.39160.41883.44307.46492.Page7Pg8*****ANSYS-ENGINEERING ANALYSISSYSTEMREVISION5.0*****MPRASSOCIATES VERSION=PC 386/48618:06:26APR04,1994CP=FORSUPPORTCALLPHONE703/519-0200 FAXReactorScramTransient 41.740*****PATHVARIABLESUMMARY*****S4.73694.84974.9625507535.1881SINT49026'1915.54876.'57081.59280.

Path:C:(NOZZLE File:XPATH.OUT13,436.a..4-04-946:06:28pmPage8~+85.30095.413661484.63709.*****ENDOFINPUTENCOUNTERED

• • • • • NUMBEROFWARNINGMESSAGESENCOUNTERED=

NUMBEROFERRORMESSAGESENCOUNTERED=

• • • • • PROBLEMTERMINATED BYINDICATED ERROR(S)ORBYENDOFINPUTDATA*****ANSYSRUNCOMPLETED REV.5.0CPTIME(sec)ELAPSEDTIME(sec)47.00047.000PC386/486TIME=18:06:26DATE=04/04/94

4774<P~Fr~i C'ath:C:(NOZZLE File:BCT.INP/SOLUTION OUTRESgALLgALL ANTYPE,TRANS KBC,1TREF,70THOT=525TCOLD=70570.a..3-28-945:13:42pm!1=StepChange,0=RampPage1p//TUNIF,THOT LSELISJLOCgXgRlSFLgALLgCONVg4ggTHOTCMSELISgLIDLSELgU~LOC/XgR1SFLgALLgCONVI5IgTHOTALLSELNSUBST,1TIME,1SOLVESAVELSEL~SgLOCIXgR1SFLDELEgALLfCONVSFLgALL~CONVI4I~TCOLDALLSELUTOTS,ONELTIM,1,1 TIME,3601 SOLVESAVEFINISH!CRDRID!NumberofSub-Load-Steps

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0()vac-Qgc.~Q~RC-K.BXC;'hisprogramcalculates crackgrowthIn~nozzleduetopressureand'hermalcyclesDECLARESUSCrackgrowth (At,Nsbl,PII,P2I,Sdist1,T11,TrII,Sdlst2,T21,Tr21)DECLAREfUNC'I!OH Klt(Al¹,L)DECLAREfUNCTIDHdadxt(dK,R)DIHNSub(5,5),hain(5,5),Peax(5,5),Strdistsn(5, 5),Strdistex(5, 5),Tlein(5,5),Tieax(5,5),12min(5,5),T2eax(5,5)DIHNsubcyc(5),

Repcyc(5),

BO(5),Sl(5),82(5),83(5),RefStr(5)

CQHHOHSNAREDPlCLS~OpenInputandoutputfliesinputfileS

~COrp(ANDS OPENinputflleS FORINPUTAStlflan~LEN(RTRINS(lnputfileS))

outflleS~LEFIS(RIRINS(lnputflleS),

flan-4)+".OUT"OPENoutfileSFOROUtPUTAS¹2'eadinputfileINPUTtl,Aot,NflnalINPUTt1,Rmin,CIRmlnt,C2Rmint,ml,e2INPUT¹I,Reax,C1Reaxt,C2RmaxtINPUTtieFl,f2,F3,F4INPUItl,NstrdlstfoRI~0TONstrdistINPUI'l,80(l),81(l),82(1),83(l),Refgtr(l)

NEXTIINPUT<<I,NcyctypefORI~1TONcyctypeINpUTtl,Repcyc(1),

Nsctrcyc(l) fORJaITONsubcyc(l)

INPUTtl,NSub(l,J)~Pein(l,J),Peax(l,J),Strdistsn(I

~J)~TImin(I,J),T2min(l~J),Strdistex(l

~J),TIeax(I,J),T2eax(l,J)NEXTJNEXTI'onstants Pi~3.I81592Calculate crackgrowthNtot~0At~AotPRINTt2,USING"ttODOUNTILNtot>>NfinalFORI~1TONcyctype<<.ttN'tot; AtFORK~'ITORepcyc(l)

Ntot~Hiot+1fORJ~ITONsubcyc(l)

CALLCrackgrowth(AS, NSub(I,J),hain(l,J),Peax(l,J),Strdlstcn(l, J),Tlmln(l,J),T2eln(l,J),Strdlstex(l, J),Tieax(l,J),T2eax(I,J))NEXTJPRINT<<2,USING"ttOt.ttO"INtot;AtNEXTKNEXTILOOPEND0QLo1Oc0Rp0V'0I)xO~Qto-cC)coCoCDtolOCr)o

CCF(Dd(P-ACE,E,ME.(('~>SUBCrsckGrorrth (A¹,Nsb,Pl,P2,Sdlstl,'ll,Trl,Sdist2,12,Tr2)~Thissubroutine calculates crackgrorrthgiventheInitialcracklength,'hememberofcyclesandthemlnfaaraandmsxfaaaapressures and-'ecperatures.

dtl=Trl-Tl=dt2~tr2-12KlPliKIN(AN,0)+dtleKIN(AN,Sdlstl)L2aI2~Kit(AN,0)+dt2eKIN(AN,Sdlst2)IFKleK2THENKmin~KlKmsx~K2ELSEKein8K2KmsxKlENDIFdKiKesx-KminR~Kmin/Kesxdst~dscgrf(d(,

R)eNab~Af+ds¹FUNCTIONdscgrf(cB:,R)'alculate dscBIgivendKsndRSHAREDhain,Clhainf,C2Relnf,el,e2SHAREDRmsx,CIRmsxt,C2RmsxtIfhain~RmsxTHENClf~ClhalnfC2N~C2ibalntELSESELECTCASERCASEIS<<ReinClf~CIRmlntC2N~C2Rmlnf-CASEIS>>RmsxClt~CIRmaxfC2N~C2ResxfCASEELSEClt~Cllbalnt+(CIResxt-CIReinf)a((R-Rmln)/(Rmsx-hain))C2N~C2lbalnt+(C2Resxt-C2Reint)e((R-hain)/(Rmsx-Rein))ENDSELECTENOIFIFClt~C2NTHEMdscgrt~ClfedKmlELSEcB:tran~(C2N/Clf)(1/(ml-m2))SELEC'tCASEcXCASEISedxtrsndsdxf~CltadKallCASEIS>adKtrsndsdMNC2NadKENDSELECTEHDIFENDFUXC'tlOH FUNCTIONKit(Alt,L)'alculate StressIntensity factor'iven crack'LengthsndstressdistributlonSHAREDFl,f2,f3,F4,80(),81(),82(),83(),Refstr()Klf((PleAIN).5)a(Fla80(L)+F?*81(L)a2aAlf/Pl+f3e82(L)eAlf2/2+F4~83(L)a4eAlt3/3/Pl)/Refgtr(L)

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Ao-NfinalRminC1RminC2Rmfnm1lll2RmaxC1RmaxC2RmaxF1F2F3FIoNstrdistBO(-)'B1(-)B2(-)B3(-)RefStr(-)

McyctypeRepcyc(-)

Nsubcyc(-)

Nsub(-,-)

Pmin(-~-)Pmax(-e-)

Strdistnn(-

T1min(-,-)

T2min(-,-)

strdistmx(-

71max(-,-)

72max(-e-)

1'nitialCrackLength(inches)TotalNwberofCyclestoAnalyzeHinfmmRfactorcorresponding tocrackgrowthconstants FirstParisCrackGrowthLawCoefficient forRminSecondParisCrackGrowthLawCoefficient forRminFirstParisCrackGrowthLawExponentforRminandRmaxSecondParisCrackGrowthLawExponentforRminandRmaxHaxigunRfactorcorresponding tocrackgrowthconstants FirstParisCrackGrowthLawCoefficient forRmaxSecondParisCrackGrowthLawCoefficient forRmaxStressIntensity Hagnification FactorStressIntensity Hagnification FactorStressIntensity Hagnification FactorStressIntensity Hagnification FactorNumberofThermalStressDistributions (Note1)StressDistribution Coefficient StressDistribution Coefficient StressDistribution Coefficient StressDistribution Coefficient Reference PressureorTemperature ChangeforStressDistribution (PrefordTref)NsmterofDifferent TypesofCycles(Note2)NumberofCycleRepetitions (Mote2)NumberofDifferent TypesofSubcycles foraGivenCycle(Note2)NumberofCyclesforaGivenSubcyclePressureatHinisxIaStressStateDuringCycle(psi)PressureatHaxfaunStressStateDuringCycle(psi)ThermalStressDistribution NumberforHinirmmTemperatures FirstNozzleTegperature atHinimmStressStateDuringCycle('F)(Note3)SecondNozzleTemperature atHiniaunStressStateDuringCycle('F)(Note3)ThermalStressDistribution NunberforHaxiaunTemperatures FirstNozzleTemperature atHaxiguaStressStateDuringCycle('F)(Note3)SecondNozzleTemperature atHaxinxmStressStateDuringCycle('F)(Note3)Aroe'roohio.mlira+As~lJ:~cLip&.AlebrIlgIIVIr0(aeerie$horro~a(erre~%)resenes4eessAstlo~4ieuo, a.merc~r.ka~a)iwnmoP5',Pp.en)$'psoF'ela',~<lec~l1e~rp]o8gigere~]gyp'l'uboolclcs s4e~decrsnsr's+

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0' Ao,NfinalRmin,C1Rmin,C2Rmin,m1,m2Rmax,C1Rmax,C2RmaxF1,F2,F3,F4Nstrdist80(0),81(0),82(0),83(0),RefStr(0) 80(1),81(1),82(1),83(1),RefStr(1) 0'08Z080(Nstrdist),

81(Nstrdist),

82(Nstrdist),

83(Nstrdist),

RefStr(Hstrdist)

NcyctypeRepcyc(1),

Nsubcyc(1)

Nsub(1,1),Pmin(1,1),Pmax(1,'1),

Strdistan(1, 1),T1min(1,1),T2min(1,1),Strdistmx(1, 1),T1max(1,1),T2max(1,1)Nsub(1,Nsubcyc(1)),

Pmin(1,Ksubcyc(1)),

Pmax(1,Hsubcyc(1)),

Strdistan(1, Nsubcyc(1)),...,

T2max(1,Nsubcyc(1))

Repcyc(2),

Nsubcyc(2)

Nsub(2,1),Pmin(2,1),Pmax(2,1),Strdistan(2, 1),Tlmin(2,1),T2min(2,1),Strdistmx(2, 1),T1max(2,1),T2max(2,1)(0lu(0CLHsub(2,Nsubcyc(2)),

Pmin(2,Nsubcyc(2)),

Pmax(2,Ksubcyc(2)),

Strdistaa(2, Nsubcyc(2)),...,

T2max(2,Nsubcyc(2))

Repcyc(Hcyctype),

Xsubcyc(H cyctype)Nsub(Kcyctype, 1),Pmin(Ncyctype, 1),Pmax(Hcyctype, 1),Strdistam(Kcyctype, 1),...,T2max(Kcyctype, 1)Nsub(Kcyctype, Nsubcyc(Ncyctype)

),Pmin(Kcyctype, Nsubcyc(Ncyctype)

),...,T2max(Ncyctype, Nsubcyc(Kcyctype)

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tÃMPRENGINEERS AppendixIIMPLEMENTATION PLAN

WMPRASSOCIATESINC.ENGINEERSImplementation PlanforStructural AnalysisofNMP-0CRDRNozzleSpecification No.MPR-085-223-01 Revision0February1994Preparedby:Reviewedby:EdwardBird(MPREngineer)

I1.:,('..'~/;,

JaesNestell(MPREnginedr)

~~/~S~YDateDate'pprovedby:PhillipKasik(MPREngineer) lS-5'-DateApprovedby:.QP.IK(JQ.L'Qr-AcJneGawler(NMPCCognizant Engineer) c~l;-qIDate320KING51REETAI,EXANDRIA, VA22314-323 703-51'.0200 FAX70351r7.0224

r~lMPRASSOCIATES INC.ENGINEERS CONTENTSSectionBACKGROUND PURPOSETECHNICAL APPROACHExperience SurveyThermalLoadDefinition Structural AnalysisFractureMechanics/Fatigue Evaluation INFORMATION SOURCES~Pae10"11-

eASSOCIATES INC.EN&INEEAS BACKGROUND NUREG-0619 requiresNMPCtoperformanin-vessel PTexamononeofthefourfeed-waternozzlesandthecontrolroddrivereturn(CRDR)nozzleduringthenextrefueling outageatNineMilePointUnit1.Thisexamisexpectedtoresultinhighworkerexposure, potential outagedelaysandassociated highcostswithoutcomparable increases insafety.Asaresult,NMPCplanstorequestanexemption fromthisrequirement, basedonthefollowing:

Automated UTinspection systemsarenowavailable forperforming accurateinspections fromoutsideofthevessel.Modifications havebeenmadetothefeedwater nozzles,spargersandfiowcontrolsystemtoeliminate orlessenthefeedwater nozzlecrackingproblemsthatoccurredinthe1970s.~NodamagewasfoundontheCRDRnozzleduringthein-vessel examin1977orduringvisualexaminations thereafter.

~DetailedmodelingandanalyseshavebeendonetoshowthatsmallQawswillnotgrowtounacceptable valueswithinspecified operating periodsforthefeedwater nozzles.PURPOSEThepurposeofthistaskistoevaluatethelong-term susceptibility oftheCRDRnozzletothermalfatiguecracking, determine crackgrowthratesandcriticalcracksizes.NMPCwillusetheresultsofthistasktosupporttheirexemption requestandtoevaluatetheseverityofanyindication foundduringtheautomated UTinspection plannedforthe1995refueling outage.TECHNICAL APPROACHAfourstepapproachwillbeusedtoaccomplish thistask:~Experience Survey~ThermalLoadDefinition

~Structural Analysis~FractureMechanicslFatigue Evaluation

Eachofthesestepsisdescribed below.Theresultsofallfourstepswillbedocumented inasingleMPRreport.Thisworkwillbeperformed inaccordance with10CFR50,AppendixB,usingthelatestapprovedversionofMPR'sQAManual.ExerienceSurveAtelephone surveyofapplicable BWRswillbeperformed todetermine theirexami-nationhistory/frequency andcrackingexperience fortheCRDRnozzle.Surveyinformation willbecollected forweldedthermalsleevedesignssimilartoNMP-1andothernon-welded designs.Thetelephone surveywillincludequestions aboutexami-nationtechniques andtools.Thisinformation isexpectedtobeusefulinevaluating thesensitivity ofthecrackingproblemtothermalsleevedesign.ThermalLoadDefinition TheNMP1operating flowcharacteristics andlogrecordsoftheCRDsystemwillbereviewedtodetermine flowvariations andresulting temperature variations fortheCRDRnozzleduringdifferent CRDoperating conditions, e.g,,duringmovementofthecontrolrodsandscrams,andduringdifferent plantoperating conditions, e.g.,startup,shutdown, andstandby.Themagnitude andfrequency ofthermalandpressurechangeswillbeusedasinputtothestructural modelandtocalculate crackgrowthratesandfatigueusage.Structural AnalsisTheANSYScomputerprogramwillbeusedtodevelopatwo-dimensional axisymmetric finiteelementmodeloftheCRDRnozzle.ThemodelwillincludeasectionofthereactorvesselwalladjacenttotheCRDRnozzle.Theextentofthissectionwillbelongenoughtoeliminate interaction betweentheboundaryconditions appliedtothevesselwallandtheCRDRnozzle.Theradiusofthereactorvesselwallsectionwillbemodeledat3.2timestheactualradius.Thiswillinsurethatthemaximumhoopstressandstressintensity calculated bytheaxisymmetric modelwillbecomparable tothoseintheactualthree-dimensional intersection.

Thermalboundaryconditions, including heattransfercoefficients, willbecalculated fortheloadcycledefinedabove.Theresultsofthepreviously performed feedwater nozzleanalysiswillbefactoredintothiscalculation.

Thetemperature distribution withintheaozzlewillbecalculated asafunctionoftimefortheseboundaryconditions.

Through-wallstressesthatresultfrompressureandtemperature willbecalculated atseveralsnap-shotsintimetoestablish thetimeofpeakstress.Through-wall stresseswillbeusedinthefracturemechanics/fatigue evaluation below.Theoriginalstructural evaluation fortheCRDRnozzledocumented inReference 3isanareareinforcement calculation.

Becausestresseswerenotexplicitly calculated, adirectcomparison tostressesobtainedfromthisanalysisisnotpossible.

FractureMechanics atiueEvaluations Fatigueusageandcrackgrowthrateswillbecalculated forthestresscyclesdetermined inthestructural analysis.

Smallsurfaceflawsofvarioussizeswillbepostulated toexistonthevesselwallandnozzleboreregions.Crackgrowthratesduetolowfrequency pressureandthermalcycleswillbecalculated todetermine howquicklytheseinitialsmallflawscouldgrowtounacceptable sizes.Afatigueusageevaluation fortheCRDRnozzleswasnotperformed fortheoriginalstructural evaluation (Reference 3)ontheupdatedvesselusagereport(Reference 4).Acomparison tothecurrentanalysisisnotpossible.

INFORMATION SOURCESInformation sourcesfortheCRDRnozzlestructural analysisinclude:Combustion Engineering DrawingNo.231-567,Revision7,"NozzleDetails-Vessel."2.ASMECodeforMaterialProperties.

3.Combustion Engineering ReportCENC1142,"Analytical ReportforNiagaraMohawkReactorVessel."4.MPRReport629,"Re-evaluation ofReactorVesselFatigueAnalysisforRevisedOperating Cycles,NineMilePointNuclearGenerating StationUnitNo.1,"August13,1979.-3-