calculation m-dsc-356, evaluation of modified pressurizer ... › docs › ml0521 ›...

Attachment 1

Southern California Edison Calculation M-DSC-356,"Evaluation of Modified Pressurizer Heater Sleeves'

Southem Callfomia Edison Company CALC NO. ICCN NOJ N-3 PAGE TOTAL NO. OF

INTERIM CALCULATION M-DSC-356 PRELIM. CCN NO. 1PAGESCHANGE NOTICE (ICCNY,CALCULATION CHANGE NOTICE (CCN) BASE CALC. REV. UNT| CCN CONVERSION: CALC. REV.COVER PAGE 2 3 CCN NO. CCN- 4SU.1MARY CHANGE _

IM NO 0 YES CALCULATION suBJEcT:Evaluation of Modified Pressurizer Heater Sleeves

CALCULATION CROSS-NDEX ENGINEERING SYSTEM NUMBER/PRIMARY STATION SYSTEM O-CLASSONew/UpdatedIndexIncluded DESIGNATOR 1201 / BBBO ExistIrn Index Is Complete

CONTROLLED PROGRAM OR PROGRAM/DATABASE NAME(S) VERSIONIRELEASE NO.(S)She P ram'ocedure Impact? DATABASE ACCORDING TO El ALSO. USTED BELOW

S0123-XXIV-5.1X NO 0 YES. AR No. 0 PROGRAM 0 DATABASE

1DCFR50.59/72.48 Review:AR No. 031100614__

1. BRIEF DESCRIPTION OF ICCN/CCN:

The purpose of this CCN Is evaluate the acceptability of the fillet weld connection between the Pressurizer heatersleeve and heater sheath using a maximum diametral gap of 0.060-. The maximum gap tolerance of 0.060 Isnecessary to resolve the insertion difficulty encountered subsequent to the implementation of a half-nozzle repair ofthe Pressurizer sleeve. The diametral gap tolerance used in the original construction was O.045 maximum.

Update Cross-IndexUpdate Table of ContentsAdd Attachment Ill to the calculation

This evaluation is applicable to both Units 2 & 3. 62

INITIATING DOCUMENT (ECP. OTHER) AR 031100614-3 Rev. *

2. OTHER AFFECTED DOCUMENTS (CHECK AS APPLiCABLE FOR CCN ONLY);

El YES [ONO OTHER AFFECTED DOCUMENTS EXISTAND ARE IDENTIFIED ON ATTACHED FORM 26-50

3. APPROVED BY: DISCIPLNE/ESC: DEO

So P 6'~o L Cor (rAv?62 ~•j4~ORIGINATOR (Print nime s Vdate) FLS SiSgnatureane)

Approval requires PQS T3EN64 uaon Ved________Approval requires PS T3EN64 Cualfication Verifed:

In~til

Nan'o/M. 137Sk,/ /v<z/9 /cAft/o,IRE (Print namnIaigndate) /

Approval rquire PQS 73EN6t4 OQualicatlcnverIffed: 'V?7n-e-Initial

4. CONVERSION TO CCN DATESCE CDWSONGS

SCE26-122-1 REV.i 4105 [REFERENCE: 50123WtlV-7.15]

Site File CopyM-DSC-356

CALCULATION CROSS-INDEX

Calculation No. M-OSC-356 Sheet of

INPUTS OUTPUTS Does the out- Identify output InterfaceClre.put interlace caic/doc umentnumber and These Interfacing calculations and/or Results and conclusion of the capc/document

responsible docurnents provide Input to the sject s require CCN, ECPa TCNiev., orFiS initals and calculation, and If revised may require calculation are used In these Interfacing Change? tracldng number.

date revision of the subectcaLula. calculations and/or documents.

CalclDocument No. Rev. No. Calc/Document No. Rev. No. YES I NO

1 C-E Report No. CENC-1420, 0I _ Addendum 2 to the Analyticla Reportfor SONGS No. 2 Pressurizer

m - m_

SCE 28-424 RFY. S 4d05 [REFERENCE: 50123-XXrV.7.151

-

ENSInSEAJNG SERVICES. M~:.

ICCN NO.1 9 IPRELIM. CCN NO. N4-3 PAGE -z~-OF I ~

Fcw ONVRSION:77

Madc. btr: Date Ci:n:

Calculation No.: AES-C-5212-1 ,1. L(9 Southesn Caliromia Edinon

SCE No. M-DSC-356, Re. I Checked br Dnte: . P rowct No.:

Title: Evalaulion of Modified Pressutizer Heater -5 q y , AeS 03105212-1 QSleeves - SONGS Units 2 and 3 Revision No.: Documeni Control No.: Sheet No.:

I- 1I 6 ofl083

TABLE OF CONTENTS (CONT'D)

Section

APPENDIXA

Title Page

Heat Transfer Parameters 55 to 57

59 to 60APPENDIX B - Finite Element Load Cases

APPENDIX C - Code Analysis Output 61 to 151

APPENDIX D - ANSYS Input Files 152 to 1083

APPENDIX I Evaluation of Heavier Replacement PZR HeaterElement Assemnbly 1083Ato 1083B

AITACHMENT fl - Bvaluation for Smaller Pad Size

ATTACHMENT EJ - Evaluation of Fillet Weld at the PressurizerHeater Sleeve/Heater Sheath Connection

11-1

'I1-I

I

QA.E17REV 819&

'i-D)SC-32 5 6

M-DSC-356

ATTACHMENT IIIE&TS DEPARTMENT

CALCULATION SHEETICCN NOJPRELIM. CCN NO. N-3 PAGE -+ OF { 5

CCN CONVERSION:ICCN NO. <Project or ECP N/A

Subject See Title SheetCaic No. M-DSC-356

Sheet of

REV ORIGINATOR DATE IRE _ DATE REV ORIGINATOR DATE IRE DATE sr

J. Gaor 05123/05 N. Elakily 05124105 7 12l

ATTACHMENT III - Evaluation of Fillet Weld at the Pressurizer Heater Sleeve/HeaterSheath Connection

1. PURPOSE

The purpose of this calculation is to provide the basis for the acceptability of the fillet weldconnection between the Pressurizer heater sleeve and heater sheath with a maximum diametralgap of 0.060". The maximum gap tolerance is necessary to resolve the heater insertiondifficulty encountered subsequent to the implementation of a half-nozzle repair of thePressurizer sleeve. Allowing a maximum diametral gap of 0.060" would decrease rework timeand reduce total dose to the personnel due to the rework.The maximum diametral gap of 0.045" between the heater sleeve and heater sheath wasprovided in the original ASME Code of Construction [6.1], which included ASME Code Case1361-2 [6.2].

M-DSC-356


CALCULATION SHEETICCN NOJPRELIM. CCN NO. N-3 PAGE E OFI.

CCN CONVERSION: 1I CCNNO. f IProject or ECP N/A

Subject See Title SheetCaic No. M-DSC-356

Sheet of

REV ORIGINATOR DATE IRE DATE REV ORIGINATOR DATE IRE DATE

J. Gaor 05/23105 N. Elakily 05/24105 2A E= = = =0

2.0 SUMMARY OF RESULTS

The results of the evaluations, show that the use of larger diametral gap of 0.060" maximum inthe fillet weld connection between the Pressurizer heater sleeve and heater sheath result instresses and usage factor within the ASME Code Allowable limits. The results of theevaluation are presented in Section 8.0 and a summary of the stress results in the fillet weldconnection is provided below.

The most critical Primary Stress Intensity calculated at the fillet weld connection:

Pm = 7.442 ksi < 9.78 ksi (0.6Sm)PL + Pb = 18.722 < 24.45 ksi (1.5 Sm)

The maximum range of Primary plus Secondary Stress Intensity calculated at the fillet weldconnection:

PL + Pb + Q = 42.38 ksi < 48.9 ksi (3.OSm)

The controlling fatigue stresses and Cumulative Usage Factor at the fillet weld connection for adesign life of 40-year life:

U = 0.40 < 1.0

M-DSC-35 6


CALCULATION SHEETProject or ECP NIA ISubject See Title Sheet

ICCN NO.1PRELIM. CCN NO. N-3 PAGE 6 OF'l

CCN CONVERSION:CCN NO. I.alc No. M-DSC-356Sheet of

REV ORIGINATOR DATE IRE DATE REV ORIGINATOR DATE IRE DATE ix

J. Gaor 05123105 N. Elakily 05o24105 1I93.0 ASSUMPTIONS

None required.

M-DSC-35 6


CALCULATION SHEET

ICCN NO.1 l OI PRELIM. CCN NO. N-3 I PAGE 1 OF IS

CCN CONVERSION:ICCN NO. I/Project or ECP NIA

Subject See Title SheetCaIc No. M-DSC-356

Sheet of

REV ORIGINATOR DATE IRE DATE REV I ORIGINATOR DATE I IRE DATE |J. Gaor 05/23105 N. Elakily 05/24105 il S

IIz

4.0 DESIGN INPUT

A. Original Pressurizer Sleeve:Outside Diameter, OD = 1.66" + 0.0 /- 0.002 [6.3]Inside Diameter, ID = 1.273" + 0.010 / -0.0 [6.3]Sleeve Material: SB 167 Alloy 600 [6.3]Heater Sheath Material: Type 316 Stainless Steel [6.4]Heater Sheath OD = 1.245" +/- 0.007" [6.4]

r, a = mean coefficient of thermal expansion, Sm = Design Stress Intensity Value

B. Replacement Pressurizer Sleeve:OD = 1.66" nom. ( to be fitted to pressurizer hole penetration ) [6.5]ID = 1.298" + 0.0 / -0.005 [6.5)Sleeve Material: SB 166 Alloy 690 [6.5]Heater Sheath OD = 1.245" +/- 0.007" [6.4]

Table 4.2 - Properties of Alloy 690 r6.61Property Temperature, F

100 200 300 400 1500 600 700Ex 106 30.12 29.5 29.1 28.8 28.3 28.1 27.6

a, 10-6 7.8 7.8 7.9 8.0 8.1 8.2 8.3in/in/ 0FSm, ksi 23.3 23.3 23.3 1 23.3 23.3 23.3 1 23.3

Note: The original ASME Code did not list Alloy 690 but was later specified in ASME CodeCase 474. For Alloy 690, the values above are from the ASME Code 1998 Edition, 2000 Addenda[6.6], which were previously specified in Code Case 474-2 (code case was annulled and Alloy690 was included in the ASME Code 1999 Addenda).

M-DSC-3 56


CALCULATION SHEET| ICCN NOJ N N

PRELIM. CCN NO. N-3 PAGE J-OI5

|CCN CONERSION:ICCN NO. IProject or ECP NIA

Subject See Title SheetCaIc No. M-DSC-356

Sheet of

REV ORIGINATOR DATE IRE DATE | REV I ORIGINATOR DATE IRE DATE ox

J.Gaor 05/23105 N. Elakily 05124/05 | | 2Cz

C. Hcater Sheath Material: Type 316 Stainless Steel [6.4] . Note: Sheath material remainsunchanged.

Table 4.1 - Properties of Type 316 Stainless Steel [6.11Property Temper ature, 'F

100 200 300 400 500 600 700Ex 106 28.2 27.7 27.1 26.6 26.1 25.4 24.8psia, 1O6 9.16 9.34 9.47 9.59 9.70 9.82 9.93in/in/OF I I ISm, ksi 20.0 20.0 20.0 19.2 17.9 17.0 16.3

M-DSC-3 56

ATTACHMENT IIIE&TS DEPARTMENT,

CALCULATION SHEET| ICCN NOJ N 3O

PRELIM. CON NO. N-3 PAGE OFI J

CCN CONVERSION:CCN NO. IProject or ECP NIA

Subject See Title SheetCalc No. M-DSC-356

Sheet of

REV ORIGINATOR DATE IRE DATE REV ORIGINATOR DATE IRE DATE C|

J. Gaor 05/23/05 N. Elakily 05124/05 2 II =

5.0 METHOD OF EVALUATION

The fillet weld between the Pressurizer heater sleeve and the heater sheath will be evaluatedusing the same methodology as the original Combustion Engineering (CE) Stress Report[6.7]. The loads and weld cross sectional properties are modified by the ratio of the newdiametral and the original diametral gap. The results of the evaluation will demonstratecompliance with the original ASME Code stress requirements for Class 1 components [6.1].

The original fillet weld connection between the Pressurizer heater sleeve and heater sheathwas constructed in accordance with Code Case 1361-2 which required a maximum of 0.045"diarhetral gap between connecting parts. The 0.045" maximum diametral gap limits thedeflection of the part inside the penetration thereby limiting the bending stresses that can beimposed on the fillet weld.

M-DSC-3 56


CALCULATION SHEET| ICCN NOJ l lO-1IPRELIM. CCN NO. N.3 I PAGEI JQF

CCN CONVERSION:I CCN NO./ lProject or ECP

Subject SeN/A Calc No. M-DSC-356

e Title Sheet Sheet of

REV ORIGINATOR DATE IRE DATE REV ORIGINATOR DATE IRE DATE _

J. Gaor 051231o5 N. Elakily 05/24/05 2 Z= * = ?

6.0 REFERENCES

1. ASME BPVC Section III Code, Rules for Construction of Nuclear Power Plant Components,1971 Edition, 1971 Summer Addenda.

2. ASME Code Case 1361-2, Socket Welds, Section III.3. S023-919-33 Rev. 2, Internal Details for SONGS Unit 2 Pressurizer4. S023-919-2-D58 Rev. 1, Heater Element Assembly5. Drawing No. 41116 Sh. 2 Rev. 3, Primary System Instrument Nozzle Details6. ASME BPVC Section III Code, Rules for Construction of Nuclear Power Plant Components,

1998 Edition through 2000 Addenda.7. C-E Report No. CENC-1420, Addendum 2 to the Analytical Report for SONGS Unit. No. 2

Pressurizer

M-DSC-3 56

A1TACHMENT IIIE&TS DEPARTMENT

CALCULATION SHEET| ICCN NOJ l| PRELIM. CCN NO. N-3 I PAGE -Il OFl

[CCN CONVERSIONCCN NO. IProject or ECP NIA


Sheet of

REV ORIGINATOR DATE IRE DATE REV ORIGINATOR | DATE IRE DATE

J. Gaor 05123105 N. Elakily 05_24/05 EJ,

7.0 NOMENCLATURE

Terms used are as defined in the body of the calculation.

M-DSC-3 56

- -


CALCULATION SHEETProject or ECP NIA ISubject See Title Sheet

ICCN N N PAGE N- O1PRELIM. CCN NO. N-3 PAG_"1 F/

-alc No. M-DSC-356I CCN CONVERSION:

CCN NO. 1 I

Sheet of

REV ORIGINATOR DATE I IRE DATE REV ORIGINATOR DATE IRE DATE | r

J. Gaor 05123/05 |N. Elakily 05/24/05 | |I -M

8.0 CALCULATIONS

The original C-E Analytical Report [6.1] evaluated the sleeve to sheath fillet weld for PrimaryMembrane (Pm), Primary + Secondary (PL + Pb + Q), Shear (r) and Fatigue Usage Factor. Thenew 3/16" fillet weld size has a throat which is reduced from that originally evaluated due to theincrease in gap between the heater sleeve and heater sheath. The increase in gap also increasesthe stress due to the internal pressure.

See Figure 8-1 for the schematic configuration of the heatersleeve to heater sheath fillet weldconnection.

The throat of the fillet weld evaluated in the original C-E Analytical Report was 0.1227". For thenew configuration, the weld throat is calculated as follows:

throat size= (0.619 + 0.1875 - 0.649) X 0.707= 0.111",where: outside radius of heater sheath = 1.238 /2 = 0.619" (min. radius)

inner radius of heater sleeve = 1.298 / 2 = 0.649" (max. radius)fillet weld size= 0.1875".

The applied axial force due to internal pressure is 3.182 kips.

The new applied axial force due to internal pressure becomes,F = 3.14 X (0.649) 2 X 2500 = 3.306 kips

For the Primary Stress Intensity evaluation , Pm, the new stress is calculated by multiplying theoriginal Pm by the ratio of the increase in Force and by the decrease in the throat size of the filletweld. The original Pm = 6.48 ksi, thus, the new Pm is,Pm = 6.48 X (3.306 / 3.182) X (0.1227 / 0.111) = 7.442 ksi,which is less than the allowable of 9.78 ksi ( 0.6 Sm for SS Type 316 at 700 'F)

Therefore, the Primary Stress Intensity criteria is satisfied.

Primary membrane + bending stresses (PL + Pb) were not explicitly calculated in the original C-E Analytical Report since there were no primary bending loads on the fillet weld due to the closetolerance between the sleeve and the sheath. For conservatism, the maximum bending loadscalculated under seismic and pressure pulsation loadings will be included in this evaluation.The maximum bending stress per the original report is 11.28 ksi,(PL + Pb) = 7.442 + 11.28 = 18.722 ksi < 24.45 ksi (1.5 Sm) for SS Type 316

M-DSC-35 6

ATTACHMENT IlIlE&TS DEPARTMENT

CALCULATION SHEETI CCN NOJ I _ /

IPRELIM. CON NO. N-3 IPAGE_''~OF /L2

| CCN CONVERSION:CCN NO. IProject or ECP NJA


Sheet of

REV ORIGINATOR DATE IRE | DATE | REV I ORIGINATOR DATE IRE DATE

J. Gaor 05123105 L N. Elakily 51 24/05 | l lIILI I CZ I II

To calculate the new stress, conservatively, the throat factor will be squared to account forbending across the throat as opposed to pure shear,(PL+ Pb) = 18.722X (3.306/3.182) X (0.1227/0.111)2

= 23.77 ksi < 24.45 ksi (1.5 Sm) for SS Type 316.

Therefore, the Primary membrane + bending stress intensity criteria is satisfied.

For the Primary + Secondary Stress Intensity evaluation, the maximum stress intensity calculatedin the heater sleeve to sheath weld is 30.35 ksi as shown in the original C-E report.The thermal stresses are directly proportional to the modulus of elasticity times the coefficient ofthermal expansion of the material being welded. The comparison of E times ax of the materials isshown below:

Property Temperature, VF

100 200 300 400 500 600 700E a (Alloy 226.8 228.7 230.6 231.0 230.9 230.7 228.8600)E ca (Alloy 235 230.1 229.9 230.4 229.2 230.4 229.1690) .Ea (SS 258.3 258.7 256.6 255.1 253.2 249.4 246.3Type 316) _ _ ___ __ __

The increase in thermal stress is estimated by using the equation below assuming that the weldstress is proportional to the differential expansion between the heater sleeve and the heater sheath.

a / 00 = [ (E. a. - E690 X690) / (Ess ass- E600 Ct600) I

where: a = new stress, o. = original stress

Substituting the values in the equation above, at different temperatures, the ratio of c; / cO istabulated below:

_ -Temperature, OF

Property 100 | 200 |_ 1300 | 400 |500 | 600 | 7000 / C(, 0.74 10.95 1.03 11.02 1 1.08 1 1.02 1 0.98-

Based on the above, the increase in thermal stress when using Alloy 690 sleeve In lieu of the originalAlloy 600 sleeve is less than 10%. For conservatism, the stress due to pressure plus thermal stress willbe Increased by 10%.

M-DSC-3 56


CALCULATION SHEETICCN NOJ I IPRELIM. CCN NO. N-3 PAGE J IOF I

I CCN CONVERSION: lICCN NO. I7 lProject or ECP N/A


Sheet of

REV ORIGINATOR DATE IRE DATE REV ORIGINATOR DATE IRE DATEQ

J. Gaor 05/23/05 N. Elakily 05124105 iZ= = O

The new Primary + Secondary Stress Intensity is,(PL+Pb+Q)=30.35X 1.10X(3.306/3.182)X( 0.1227/0.111) 2

= 42.38 ksi < 48.9 ksi (3.0 Sm)

Therefore, Primary + Secondary stress intensity criteria is satisfied.

For the Primary + Secondary + Peak Stress Intensity evaluation, the maximum stress intensitycalculated in the heater sleeve to sheath weld is 141.75 ksi using a conservative stressconcentration factor of 5.0 as shown in the original C-E report. (Note: the minimum stressconcentration factor for fillet welds to be used for fatigue analysis as given in Code Case 1361-2is 4.0).Using the above ratio for the (PL + Pb + Q), with a pressure increase factor for the trip transientof (2.55 / 2.50), the new Primary + Secondary + Peak Stress Intensity is,

(PL+ Pb + Q +F) = 141.75 X (2.55 12.50) X 1.10 X (3.30613.182) X (0.1227/0.111)2= 201.91 ksi

The allowable number of cycles for alternating stress of 101 ksi is approximately 1750 cycles.For 700 cycles, considering a 40 year design life, the cumulative usage factor may be boundedby (700 / 1750), or 0.40, which is less than the allowable usage factor of 1.0.

M-DSC-3 56

NUCLERR REG AFFRIRS Fax:949-368-7575 Rug 2 '05 12:08 P.02


CALCULATION SHEET|ICCN NOJ AGE CL5'O 1

PRELIM. CCN NO. N-S | PAGE__-OF ..

CCN CONVERSION:ICCN NO. fProject or ECP N/A Cakc No. M-DSC-356

Subject See Title Sheet Shoet of

REV ORIGINATOR DATE IRE DATE REV ORIGINATOR DATE I IRE

J. Gaor I 23I06 N. Elskiy IOW4105 I I = r A

Gap

-1 H-

Heater sleeveAlloy 690

IlItr-.3/16'

HeaterSheath,SS 316

V_

Fiqure 8.1 Schemaic of theheater sleeve to heater sheath fillet weld connection

-DSC,3 5 6

Attachment 2

Figure

"Typical Heater Arrangement"

- - -

5/8" PLATE X- TOP & BOTTOMHEATER SUPPORT PLATES

-IFL5/8" PLATE

REMNANT OF EXISTING SLEEVE,ALLOY 600

INSIDE

I

PRESSURIZERWALL

I

OUTSIDE

"-TEMPERBEAD WELD PADWITH J-GROOVE WELDS

-NEW HEATER SLEEVE,ALLOY 690I.D. = 1.298" (max)

-HEATER SHEATH,SS 316O.D. = 1.245" (NOMINAL)

= 1.238" (MINIMUM)

(NEW HEATER SLEEVE I.D.)

N3/16/

1.298"

miIIIIpF

(HEATER SHEATH O.D.) 1.245"

HEATER ARRANGEMENT(SCHEMATIC)

NOMINAL DIAMETRAL CLEARANCE= (1.298" - 1.245") = 0.053"

MAXIMUM DIAMETRAL CLEARANCE= (1.298" - 1.238") = 0.060" = cMAX

cMAX = 0.060" REQUESTED

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