ML18058B897

Svc Water Sys - Evaluation of Pipe Wall Thinning Down Stream of Valve Mv SW 136

ML18058B897
Person / Time
Site:	Palisades
Issue date:	06/22/1993
From:	Hoang P CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML18058B895	List: ML18058B894 ML18058B896 ML18058B897 ML18058B898
References
EA-SP-03316-04, EA-SP-03316-04-R00, EA-SP-3316-4, EA-SP-3316-4-R, NUDOCS 9307060314
Download: ML18058B897 (23)

Text

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1.0 Purpose

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET EA-SP-03316-04 Sheet2 Rev# 00 The purpose of this caclulation is to evaluate the structural integrity of a small through wall leak found at the down stream butt weld of valve MV SW136 on line HB23-4" of Service Water system for a temperory non-Code repair permit. The scope of the calculation includes evaluations using the proposed Code Case N-513 "Fracture Mechanics Approach", the Code Case N-480 "Wall Thinning Evaluation Method" and the "Branch Reinforcement Approach" per the proposed Code Case N-513.

2.0 Design Input:

1. Nondestructive Testing Service Thickness Measurement Examination Report Sheet MFS-03, dated 6/10/93. (Attachment 1)

2. Drawing M101-SH. 2744, Rev. 2.

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

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

5. Nondestructive Testing Service Thickness Measurement Examination Report Sheet RDW-01, dated 6/2/93. (Attachment 2)

3.0 Assumptions

1. Per the plant NOE personnels, the UT weld crown thickness measurement (Ref. 7.1) at 10:00.

location is near to the pin hole leak. Weld surface irregularities and component configuration prohibited the taking of UT measurements at this location where the material thickness may be thinner than the weld crown thickness. Surface grinding to facilitate additinal UT measurements could not be accomplished to avoid further wall thinning. Therefore, the thickness mesurements used as the basis for the calculation are only an approximation of wall thickness at the toe of the weld.

2. Since the thickness measurement of 0.228" at the valve end (Ref. 7.1) is about the same as the expected thickness at the valve end counterbore, it is assumed that there is no significant erosion or cor-1sion in the valve body.

3. Per the conversation between CPCo Licensing and NRC staff, structural integrity of a pin hole leaked pipe can be evaluated by the "Wall Thinning Approach" or the "Branch Reinforcement Approach" for a non-code repair permit. ( See Attachment 3)

4.0 Approach

./.?~[*

The measured weld thicknesses at several locations around the pipe circumference are plated in Figure 1. The corroded area is concentrated near the 10:00 o'clock location where the pin hole leak was found. There is no significant thickness reduction in the adjacent pipe metal (except location E1, t=0.187 or 0.789 times pipe nominal thickness, Ref. 7.6). Furthermore, there is no indication of erosion/corrosion on the down stream pipe wall. Therefore, the leak may be resulted from corrosion in a local weld area where the weld is not fully penetrated. Structural integrity of the leaked pipe is evaluated by the following approaches:

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET EA-SP-03316-04 Sheet 3 Rev#OO 4.1.Fracture Mechnics Approach:

a) Flaw characterization:

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

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

• :=

-D mm 2( 15000 + 0.4-P) and tact is the actual pipe thickness adjacent to the flaw (tact= 0.19").

In this calculation tadj is chosen such that the characterized flaw length 2a is the 2"

( 15% of the circumference) length limit. From Figure 3, with the smooth flaw profile and 2a=2", tadj is approximately 0.125".

Therefore, a 2" inch Circumferential through wall crack on a 4.5" OD, 0.125" thick pipe, is the postulated fracture mechanics model. The crack length is about from 9:00 to 11 :00 o'clock positions.

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

b) Applied stress:

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

c) Stress intensity factor K:

Ref. 7.10 K := l.4*s*F-J;ao where F :=I+ Acl.5 + B-c2*5 + C-c3*5 0 a

R c :=--o r:=-o (it* R) t adj D-t adi R :=

~ D

Mean radius 2

The coeficients A,B and C are given in Section 5.2 of this calculation.

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET d) Acceptance criteria Where Ki is the material initiation stress intensity. For carbon steel, EA-SP-03316-04 Sheet 4 Rev# 00 KI:= 35000 psi*fi;.u (Ref. 7.5 and 7.10) 4.2 Wall Thinning Approach:

a) Methodology: (Ref. 7.4)

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

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

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

b) Acceptance Criteria

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

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

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

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

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

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET EA-SP-03316-04 Sheet 5 Rev# 00 4.3 Branch Reiforcement Approach a) Flaw characterization:(Proposed Code Case N-513)

The Code minimum thickness is calculated as:

P*D t

• :=

-a mm 2( 15000 + 0.4* P)

Per the proposed Code Case N-513 (Ref. 7.10), the adjusted pipe wall thickness tadj can be chosen such as 2*tmin < tadj < tact In this calculation tadj is chosen such that the characterized flaw is entirely contained within a 2.25 inch diameter circular opening which is half of d=4.5", the diameter of a postulated circular opening. (Ref. 7.10, Section 3.2).

- Applied stress:

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

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

- Stress intensification factor of an equivalent unreinfored fabricated tee (UFT) is calculated using Figure ND-3673.2(b)-1, Ref 7.8.

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

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET EA-SP-03316-04 Sheet 6 5.0 Calculations I:= n-4.5 5.1 Measured pipe wall thickness:

Weld thickness plot using the measured data dated 6/10/93 Location from top (12:00) fraction of the circumference 0

I 12 I

6 1

4 1

7._

x:=

24 I

3 1

2 3._!_

4 1

5*-

6 i :=O.. 8 D :=4.5

OD of the pipe

= n* D

The circumference Distance from the top (in)

Weld thickness(in) 0

.3 1.178

.185 2.356

.094 3.534

.148 x= 4.123

.184 4.712

.362 7.069

.38 10.603

.330 11.781

.33 Rev# 00 0.38 1-1-1--1-1--;::r====r==-1--===i=====r--11-1-1 0.342 0.304 0.266 ti 0.228 0.19 t2 0.152

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0.076 O.D38 0'-_

_.__~ __._ _

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0 2

3 4

6

x.

l 7

8 Figure 1: Measured weld thickness along the circumference.

9 10 11 12

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET 5.2 Calculation using fracture mechanics approach.

a) Flaw characterization:

The Code min wall thickness for design pressure:

D :=4.5 P*D tmin ------

2*( 15000 + 0.4-P) t min =0.015 Envelope the pipe wall thickness to a smooth profile (curve in Fig. 2) z:=0.1..12 vs : = pspline( x, tsm) f(z) := interp(vs, x, tsm,z) tsm EA-SP-03316-04 Sheet 7 Rev# 00 p = 100

.3

.13

.094

.138

.184

.282

.38

.330

.33 From Figure 2, for crack length 2a= 2", the adjusted thickness is approximately 0.125" tmin =0.015 tadj =0.125

< tact =0.19 0.388 r----""T""--r----""T""--..------r------,.--=--.------.---.-------.--.......------.

0.349 0.311 f(z) 0.272 tact 0.233 0.194...................................................................................................................................................................

l adj

--- 0.155 l min0.116 O.o78 0.039 o._ _ _._ __,__ _ _._ __ '-----'---'----'----'---'---------'----'

0.1 1.092 2.083 3.075 4.067 5.058 6.05 7.042 8.033 9.025 10.017 11.008 12 Figure 2 : Smooth weld thickness profile in cricumferential direction. tadj is determined from the smooth wall profile such that the through wall crack length 2a is 2 inches.

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET EA-SP-03316-04 Sheet 8 Rev# 00 b) Applied Stress Nominal stress fields near the flaw (RUNID 03316A.INP EA-SP-03316-01 Rev 0)

At node point 66, analysed pressure P=65 psi p =65 D =4.5 P*D Sp.----

4*tnom s12g-s11 sobe:=----

c) Applied stress intensity K t nom :=0.237 Sp =308.544 s obe = 696.14 s = 3.214* 103 i.= 1.425 0.75 factor included s I I = 2465 s 128 = 3457

Pressure stress

Weight stress

OBE stress

SSE stress

Applied stress R := D - t adj 2

The 2a flaw length is about 15% of the circumference at thickness t adj R

r *-.--

t adj 2

al*=-

2 Coefficients A,B,C and D in matrix form r=l7.5

(

-3.26543 1.52784 -0.072698 0.0016011 a:= 11.36322 -3.91412 0.18619

-0.004099

-3.18609 3.84763

-0.18304 0.00403 9.789 r

b -.-

2 c :=a*b c= -22.081 r

29.69 r3

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET C :=_al_

( 7!* R)

F = l.4 s = 3.214* 103 C=0.146 K := l.4*s.P.(7t*a1)°"

5 K<Kro d) Results s

Ksi s *-.---

1000 K = 11.165 Ksi*fi;i KI :=35 Ksi*fi;i The applied stress intensity K (12.662) is less then 35 ksi fi;io Therefore, no Code repair or replacement is required.

EA-SP-03316-04 Sheet 9 Rev# 00

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET 5.3 Wall thinning approach:

a) Minimum measured thickness t meas:= t2 t meas = 0.094 b) Predicted pipe thickness in the next 18 month period EA-SP-03316-04 Sheet 10 Rev# 00

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

rate:= 0.38- 0.094 20 rate= 0.014 inch per year

- The predicted pipe thickness for the next 18 month period is 18 t p := t meas - -*(rate) 12 t p =0.073 tp is greater than 0.3*tnom =0.71 inch, therefore tp meet the requirement 3410 of Code Case N-480.

c) Minimum pipe wall thickness required per the Code Case N-480 c.1) Minimum pipe wall thickness required for hoop stress Hoop stress due to design pressure P=100 psi. was calculated in section 5.2(a) for the following condition.

P:=lOO D :=4.5 sh:= 15000 tmin =0.015 c.2) Minimum thickness required for axial stress to meet the Code stress limits Section modulus for thin wall pipe:

(

D t) 2 Z(t) :=11* T

• t tnom :=0.237 Z orig : = z ( t nom)

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET EA-SP-03316-04 Sheet 11 Rev# 00 As analysed stresses based on the original section modulus (Ref. 7.3) 3 s 11 = 2.465* 10 3

s 128 = 3.457* IO s 12D := s 11 + 2* ( s 12B - s 11)

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

Solve fort zorig s(t) := s 1 r--

Z(t)

Sall := 15000 t : = 0.01 Initial guess t min =0.036

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

Solve fort Z orig s(t) - s 128"--

Z(t)

Sall := 18000 tmin =0.042

- Minimum thickness required to meet Eq. 12D stress limit.

Solve fort z orig s(t) :=s 12D'--

Z(t)

Sall := 36000 t min =0.027 Therefore, the Code minimum pipe thickness is t min : = 0.042

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET

• c.3) Evaluations using N-480. 361 O(a) acceptance criteria:

EA-SP-03316-04 Sheet 12 Rev # oo The tp at the end of evaluation period is greater than the Code minimum pipe wall thickness.

tp =0.073 t min =0.042 t >t.

p mm Therefore, the flaw is acceptable per 361 O(a) of N-480. tp is also greater than the required thickness per section 3420 of Code Case N-48_0, 0.3 times tnom or 0.071 ".

d) Result:

The flaw wall thinning predicted for the next 18 month period is acceptable per N-480 acceptance criteria 361 O (a).Therefore, code repair is not required: Note that the minimum measured weld thichness in the subsequence inspections shall not be less than 0.3 times tnom or 0.071" per the requirement 3420 of N-480.

f(z) tact t adj PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET EA-SP-03316-04 Sheet 13 Rev # 00 5.4 Branch reinforcement approach ( Proposed Code Case N-513) 0.388 0.349 0.311 0.272 0.233 0.194 0.155 a) Flaw characterization The Code min wall thickness for design pressure:

P*D t

mm*- -2*( 15000 + 0.4-P) tmin =0.015 P ::: 100 D.=4.5 tact : = 0.19 2*t min= 0.03 The postulated circular opening diameter d : = 4.5 From Figure 4, for t adj := 0.135, the flaw is within a d/2=2.25" diameter circular area.

2*t min 0.116 O.D78 0.039 0

0.1 l.l 2.1 3.1 4.1 5.1 6.1 7.1 8.1 9.1 10.l 11.l z

Figure 4 : Pipe Wall Thickness in cricumferential direction measured near the fillet weld toe.The smooth wall thickness profile is used to determine tadj such that t > 2*tmin and the flaw is within a 2.25 inch diameter circular opening.

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

d :=4.5 d2 :=d

the postulated circular opening

the header reinforcement length Al =0.54

. 2 lil A req :: l.07*d*t min Areq =0.072

. 2 lil

available reinforcement area from header

required reinforcement area Therefore, the reinforcement area meet the requirement per ND-3643.3, Ref. 7.8

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET c) Stress using UFT stress intensification factor t adj =O.I35 0.9 1 uft :=-

2 h3 R := D - t adj 2

i uft = 5.754 t adi h *-

~

R EA-SP-03316-04 Sheet 14 Rev# 00 Nominal stress for the original pipe thickness (RUNID 03316A.INP EA-SP-03316-01 Rev 0)

Eq 11 p :=65

._ P*D Sp.----

4*tnom s12B-s11 sobe:=----

t nom :=0.237 i:=l.425 0.75 factor included Sp =308.544

Pressure stress

WT stress

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

tnom S *=s *--

p.

p t d" a ~

tnom Sobe :=sobe*--

t adj Reintensified stress using UFT stress intensification factor SI I= l.20I*I04

< 15,000 psi Eq 128 4

S I2B = l.728*10

< 18,000 psi Eq 120 4

S I2D = 2.256* 10

< 36,0000 psi d) Results:

The leaked pipe meet the N-513 UFT evaluation citeria 3.2 (c).

PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET 6.0 Summary and

Conclusion:

EA-SP-03316-04 Sheet 15 Rev# 00 Three different approaches were used to evaluate the structural integrity of the pin hole leak on line HB23-4". The results of the evaluations are as the follows:

- Linear Elastic Fracture Mechanics Approach: (N-513 )

K = 11.165 Ksi fi;i

Applied stress intensity is less than Ksi fi;i

Allowable stress intensity

- Wall Thinning Approach: (Code Case N-480) t p =0.073 in

Predicted pipe wall is greater than t min : = 0.071 in

Required minimum pipe wall thickness 0.3 *nominal thickness.

- Branch reinforcement Approach: (Proposed Code Case N-513) is greater than Al =0.54

. 2 lil

total available reinforcement area A req = 0.072 in 2

required reinforcement area 4

S 11 =1.201*10

< 15,000 psi

Pass 4

S l2B = 1.728* 10

< 18,000 psi

Pass 4

S 12D = 2.256* 10

< 36,0000 psi

Pass The structural integrity of the pipe leak was found to be assured by the fracture mechanics approach, the wall thinning approach and the branch reinforcement approach.

On the basis of the above evaluations and discusion we conclude that the structural integrity of the pipe leak on line HB23-4" is assured and due to design pressure less than 275 psig and temperature less than 200 °F, the leaked pipe is acceptable for a non-weld repair. (Ref. 7.5).

7.0 References PALISADES NUCLEAR PLANT ANALYSIS CONTINUATION SHEET EA-SP-03316-04 Sheet 16 Rev# 00 7.1. Nondestructive Testing Service Thickness Measurement Examination Report MFS-03, dated 6/10/93. (Attachment 1) 7.2. Drawing M101 SH. 2744, Rev. 2 7.3. Stress Report EA*SP* 03316-01, S&L File# 9131-00 7.4. Code Case N-480, "Examination Requirements for Pipe Wall Thinning Due to Single Phase Erosion and Corrosion",Section XI, Division 1, 05/10/90.

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

7.6 Nondestructive Testing Service Thickness Measurement Examination Report Sheet No. RDW-01, dated 612/93. (Attachment 2) 7.7 Palisades Plant Piping Class Summary, M-259, Sh 3HB, Rev. 9.

7.8 ASME B&PV Code, Section Ill, Subsection ND, 1992 7.9 ANSl/ASME 831.1, 1973 7.10 Proposed Code Case N-513, "Evaluation Criteria for Temporary Acceptance of Flaws in Class 3 Piping",Section XI, Division 1, 08/13/92. (Presented in February 1993 Committee Meeting).

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FIGURE 1 Consumers Power Company Palisades Plant Docket 50-255 P&ID Drawing M-208, Sheet IA July 1, 1993 1 Page

HB-23-24' System

Description:

Service Water Line HB-23-16*

Service water line HB-23-16" taps into the "A" Critical Service Water Header (HB-23-24").

Service water from the "A" Critical Header flows through HB-23-1~' to the Component Cooling Water Heat Exchanger, E-548.

The service water fl9ws through the tubes in E-548 and exits the heat exchanger back into service water line HB-23-16".

The service water goes through cv~o826, E-548 Service Water Outlet Valve and then HB-23-16" taps into the main service water return header pipe, H8-23-24" and discharges to Lake Michigan.

A 4" bypass line around CV-0826, contains a temperature control valve, CV-0822 and a manual isolation valve, MV-SW136.

Normally most of the service water going through E-548 goes through the bypass line, H8-23-4".

As the lake temperature warms during surruner, CV-0826 will be manually throttled open to help keep the temperature control valve, CV-0822 in a mid-point position.

Estimated service water flow rates are 1000 gpm/heat exchanger in the winter to 1500 gpm/heat exchanger in the surruner.

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'f' IOI HB-23-16' HB-23-16' L.0 COMPONENT COOLING WATER HEAT EXCHANGERS FIGURE 1 P&ID Drawing M-208, Sheet lA