DUANE ARNOLD FEEDWATER NOZZLE TEMPERATURE CYCLING · sparger was assembled to the thermal sleeve...
53
NEDC-23677 CLASS II SEPTEMBER 1977 EMPLOYEES ONLY DUANE ARNOLD FEEDWATER NOZZLE TEMPERATURE CYCLING - NOTICE THE ATTACHED FILES ARE OFFICIAL RECORDS OF THE DIVISION OF DOCUMENT CONTROL. THEY HAVE BEEN CHARGED TO YOU FOR A LIMITED TIME PERIOD AND MUST BE RETURNED TO THE RECORDS FACILITY BRANCH 016. PLEASE DO NOT SEND DOCUMENTS CHARGED OUT THROUGH THE MAIL. REMOVAL OF ANY PAGE(S) FROM DOCUMENT FOR REPRODUCTION MUST BE REFERRED TO FILE PERSONNEL. X3~ftI1 4 A~ RECORDS FACILITY BRANCH J. E. CHARNLEY '.4 I '~911.21O ~ -~ GENERAL* ELECTRIC DEADLINE RETURN DATE f7);77 1~ I-
Transcript of DUANE ARNOLD FEEDWATER NOZZLE TEMPERATURE CYCLING · sparger was assembled to the thermal sleeve...
NEDC-23677 CLASS II
SEPTEMBER 1977
EMPLOYEES ONLY
DUANE ARNOLD FEEDWATER NOZZLE TEMPERATURE CYCLING
- NOTICE THE ATTACHED FILES ARE OFFICIAL RECORDS OF THE
DIVISION OF DOCUMENT CONTROL. THEY HAVE BEEN
CHARGED TO YOU FOR A LIMITED TIME PERIOD AND
MUST BE RETURNED TO THE RECORDS FACILITY
BRANCH 016. PLEASE DO NOT SEND DOCUMENTS
CHARGED OUT THROUGH THE MAIL. REMOVAL OF ANY
PAGE(S) FROM DOCUMENT FOR REPRODUCTION MUST
BE REFERRED TO FILE PERSONNEL.
X3~ftI1
4
A~
RECORDS FACILITY BRANCH
J. E. CHARNLEY
'.4 I
'~911.21O ~ -~
GENERAL* ELECTRIC
DEADLINE RETURN DATE
f7);77
1~ I-
NEDC-23677 Class II
September 1977
EMPLOYEES ONLY
DUANE ARNOLD FEEDWATER NOZZLE TEMPERATURE CYCLING
J. E. Charnley
Approved:N. J. Biglieri, Manager Reactor Assembly and Pressure Vessel Design
BOILING WATER REACTOR PROJECTS DEPARTMENT* GENERAL ELECTRIC COMPANY SAN JOSE, CALIFORNIA 95125
GENERAL* ELECTRIC
DISCLAIMER OF RESPONSIBILITY
This document was prepared by or for the General Electric Company. Neither the General Electric Company nor any of the contributors to this document:
A. Makes any warranty or representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this document, or that the use of any information disclosed in this document may not infringe privately owned rights; or
B. Assumes any responsibility for liability or damage of any kind which may result from the use of any information disclosed in this document.
L-2
NEDC-23677
TABLE OF CONTENTS
Page
ABSTRACT ix
1.0 INTRODUCTION 1-1
2.0 SUMMARY AND CONCLUSIONS 2-1
3.0 DISCUSSION 3-1
3.1 Feedwater Sparger and Nozzle Design 3-1
3.2 Instrumentation Installation 3-1
3.3 Monitoring 3-4
3.4 Data 3-5
3.5 Criteria 3-28
3.6 Analysis 3-31
4.0 REFERENCES 4-1
DISTRIBUTION
iii/iv
NEDC-23677
LIST OF ILLUSTRATIONS
Title
Original Geometry
Sensor Locations
Figure
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-21
3-22
3-23
3-24
3-25
3-26
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Cycling
Turbine Trip Recorder 1
Turbine Trip Recorder 2
Turbine Trip Recorder 3
22.4% Power Recorder 1
22.4%
22.4%
50.2%
50.2%
50.2%
73.6%
73.6%
73.6%
84.5%
84.5%
Power
Power
Power
Power
Power
Power
Power
Power
Power
Power
Recorder
Recorder
Recorder
Recorder
Recorder
Recorder
Recorder
Recorder
Recorder
Recorder
2
3
1
2
3
1
2
3
1
2
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Temperature
Illustration of Ordered Overall Range (OOR) Cycle
Counting Approach
Load Spectra
GE Extrapolation of ASME Fatigue Curve
Fatigue Damage Curve
Page
3-2
3-3
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-21
3-22
3-23
3-24
3-25
3-33
3-36
3-38
3-39
v/vi
84.5% Power Recorder 3
N4A(450 ) Nozzle
N4B (1350) Nozzle
N4C (2250) Nozzle
ND (3150) Nozzle
Bounding Curve
NEDC-23677
LIST OF TABLES
Table Title Page
3-1 Maximum Peak-to-Peak Temperature Range in 3-26
Approximately 4-Minute Interval
3-2 May 1977 Startup Map 3-29
3-3 40-Year Design Life Time/Temperature 3-30
3-4 Envelope Spectrum for Fatigue Damage Calculation 3-35
3-5 Cumulative Fatigue Damage 3-4o
vii/viii
NEDC-23677
ABSTRACT
All four Iowa Electric Duane Arnold Nuclear Reactor feedwater nozzles were
instrumented with resistance temperature detectors during the May 1977 outage
and the subsequent startup was monitored. The measured thermal cycling was
significantly less than at reactors which have had significant cracking.
Recommendations for future inspections are presented based on resultant fatigue
damage calculations.
ACKNOWLEDGEMENTS
The author acknowledges the contributions made to this report by the following
individuals:
G. G. Chen
S. A. Delvin
A. B. Fife
J. N. Loofbourrow
K. R. Miller
P. C. Riccardella
C. R. Toye
ix/x -
NEDC-23677
1.0 INTRODUCTION
The inner blend radius of the four Duane Arnold Nuclear Reactor feedwater nozzles
were instrumented with resistance temperature detectors during the scheduled
refueling outage which began in April 1977. The purpose of the instrumentation
was to record the temperature cycling experienced by each feedwater nozzle due
to the mixing of feedwater and reactor downcomer water. This cycling has caused
feedwater nozzle cracking at other BWRs.
The Duane Arnold feedwater nozzle/thermal sleeve/sparger design is unique.
It was postulated that the potential for nozzle cracking at Duane Arnold was
less than at other reactors which have experienced cracking.
This report describes the instrumentation installation, summarizes the data,
gives the criteria for evaluating the data, describes the method of analysis
and presents recommendations for further inspections.
1-1/1-2
NEDC-23677
2.0 SUMMARY AND CONCLUSIONS
The Duane Arnold feedwater nozzle design was specifically exempted from the
General Electric Feedwater Nozzle Interim Examination Recommendation (FNIER)
contained in Service Information Letter (SIL) Number 207, because the feedwater
nozzle thermal sleeve is welded to the nozzle safe end. Therefore, it was
expected that the feedwater nozzles would experience less thermal cycling and
thus significantly less cracking than other BWRs with a similar period of operation.
The feedwater nozzle temperature cycling recorded during the May 1977 startup
was significantly less than that recorded for other BWRs which have a slip
fit between the thermal sleeve and the safe end. Large thermal cycles do not
occur at Duane Arnold at low feedwater temperatures. The peak-to-peak temperature
cycling is between 590 F and 82oF for all conditions with the feedwater temperature
greater than 2000F. At lower feedwater temperatures the cycling is reduced
except during a turbine trip transient.
Iowa Electric supplied the basis for a time/temperature map for the feedwater
system at Duane Arnold. Based on the time/temperature map and on the measured
temperature cycling, a 40-year cumulative fatigue usage factor due to rapid
thermal cycling of 0.20 was calculated. This value is low enough so that feed
water nozzle cracking due to fatigue is not predicted to occur. Should cracking
due to another mechanism occur, then the cracks will propagate slower than
at other BWRs because of the smaller thermal cycles experienced at Duane Arnold.
It is therefore recommended that Duane Arnold remain exempt from FNIER. Periodic
ultrasonic examination of the feedwater nozzles is recommended to assure that
significant cracking due to another mechanism has not occurred. Liquid pene
trant examination of the feedwater nozzle and safe end is not required, unless
the ultrasonic examination detects cracking. To assess the performance of
the thermal sleeve with time, it is also recommended that periodic visual exami
nation of the feedwater sparger and of the weld between the thermal sleeve
and safe end be performed.
2-1/2-2
NEDC-23677
3.0 DISCUSSION
3.1 FEEDWATER SPARGER AND NOZZLE DESIGN
The original Duane Arnold feedwater nozzle/thermal sleeve/sparger design is
unique. The thermal sleeve was field welded to the nozzle safe end. The
sparger was assembled to the thermal sleeve with a maximum diametral clearance
of 0.004 inch. Thus leakage cannot occur between the thermal sleeve and the
nozzle as it can with the original slip fit design at other BWRs. However, leakage can occur between the sparger tee box and the thermal sleeve. Figure
3-1 shows the original design. The original design details are given in
References 1 through 4.
BWR SIL Number 207 "Feedwater Nozzle Interim Examination Recommendation" does
not apply to Duane Arnold due to the thermal sleeve to nozzle weld. Thus,
the type and frequency of feedwater nozzle examinations must be evaluated speci
fically for Duane Arnold. To help establish a basis for this evaluation the
feedwater nozzles were instrumented during the April 1977 refueling outage.
3.2 INSTRUMENTATION INSTALLATION
Ailtech SG725 Resistance Temperature Detector (RTD) (similar to those used
at other reactors) were installed on all four feedwater nozzles. The RTD
platinum-tungsten element is spiral wound and enclosed in a stainless steel
housing, which is filled with MgO insulation. The housing is flanged to facil
itate a spot welding application. The sensor is hermetically sealed, and
includes an integral stainless steel cable. Each RTD was configured into a single active arm, three lead wire, Wheatstone bridge system, and calibrated
at 212 and 5500F. An RTD requires less than 0.4 sec to achieve 90% of its
final value following a step change in temperature from 320 F to 5500F.
The RTD locations are shown on Figure 3-2. The locations were selected based
on the following criteria:
a. General Electric testing of tee-box sparger designs indicated that
maximum cycling on the Duane Arnold feedwater nozzles would occur
on the bottom (6 = 1800) of the nozzle and would occur on the
3-1
-v SPARGER AND THERMAL SLEEVE
4-1/2 in. -. I:
- 1 i
1-3/4 in. 1 in.-4 W 3/8 in.
10.942 D 1-5/8 in. 0.75 in. 2- i
3 in.---* U.) 9.183 9.062 SLIP FIT 9.064 D 9.5 n. 9.125 0
10THERMAL SLEE\/E 0.5MR 3*
TEE BOX 2tk 1-5I 0.188 in. 011 n
1/4 in.NOZZLE 12295513 0
2-/ i. 1 0.522 450 .. -1/4
in
11 3 in. 1-33 101/2in
1 in.
29-1/8 in.i
Figure 3-1. Original Geometry
NEDC-23677
SLIP FIT
TEE BOX
THERMAL SLEEVE
BEST ESTIMATE BLEND 0.50 RADIUS CONTOUR
0.70 0.
TOP 315' 45'
SPARE SENSOR LOCATIONS
ADJACENT SENSOR NOZZLE X 0 PRIME SENSOR
SNA 450 1.45 1800 T1l SNB 1350 0.7 1800 T13 SNC 2250 0.7 1800 T4 2250 BOTTOM 135 SND 3150 0.7 1800 T9
1800 PRIME SENSOR LOCATIONS
NOZZLE SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 4 SENSOR 5 SENSOR 6 X 0 X 0 X 0 X 0 X 0 X 0
(Ti) (T2) (T3) (T4) (T5) (T6 N4C 2250 0.50 0o 0.50 450 0.50 1350 0.50 1800 0.50 2250 0.50 3150
(T7) (T8) (T9) N4D 3150 0.50 00 1.25 00 0.50 1800
(T10) (Tl1) N4A 450 0.50 1800 1.25 1800
(T13) (T12) (T14) N48 1350 0.50 1800 0.50 1350 0.50 2250
RECORDER LOCATION 1 LOCATION 2 LOCATION 3 LOCATION 4 LOCATION 5 LOCATION 6 (Ti) (T2) (T3) (T4) (T5) (T6)
1 N4C1 N4C2 N4C3 N4C4 N4C5 N4C6 (T4) (T9) (T10) (T13) (T12) (T14)
2 N4C4 N4D3 N4A1 N4B1 N4B2 N4B3 (T7) (T8) (T9) (T10) (Tl1)
3 N4D1 N4D2 N4D3 N4A1 N4A2
Figure 3-2. Sensor Locations
3-3
NEDC-23677
nozzle blend radius (X ~ 0.5). Temperature cycling on the nozzle
bore and on the safe end should be significantly less than on the
blend radius.
b. One location (6 = 1800 and X = 0.50) was instrumented on all four
nozzles.
c. The N4C nozzle has six RTDs to determine magnitude of cycling as
a function of azimuthal position.
d. The N4A and N4D nozzles have three and four RTDs, respectively, to
determine magnitude of cycling as a function of location on blend
radius (dimension X).
e. The N4B nozzle has three RTDs to confirm azimuthal dependence as
measured on the N4C nozzle.
f. To allow adequate room for installation, the minimum distance between
a sensor and the thermal sleeve was 0.5 inch.
All 18 RTDs (14 prime labeled T1 through T14 and 4 spare labeled SNA through
SND) were installed without loss. All 18 sensors remained operational during
the entire test. The installation details are given in References 5 through 8.
3.3 MONITORING
The RTDs were attached to strip chart recorders. Figure 3-2 shows how the
sensors are wired to the chart recorders. Recorder Number 1 has the six N4C
RTDs. Thus, it shows the azimuthal variation of cycling. Recorder Number 2
has the common RTD (X = 0.5, 0 = 1800) location, as well as the RTDs along
the bottom half of the N4B nozzle. Thus, it will show the nozzle to nozzle
variation of thermal cycling and the N4B azimuthal cycling variation. Recorder
Number 3 has the N4A and N4D RTDs. Thus, it will show the cycling magnitude as
a function of position along the blend radius. The spare sensors were periodi
cally monitored by replacing prime sensors from a recorder.
NEDC-23677
The entire startup from May 12, 1977 to May 20, 1977 was monitored. The majority
of time the recorders were set on slow speed (0.5 mm/sec). At selected times
the chart speed was increased to 10 mm/sec.
3.4 DATA
3.4.1 Temperature Fluctuations
The entire startup from 2000 hours on May 12,1977 to 1400 hours on May 20 was
recorded. The startup lasted 187 hours and 167 hours of data were obtained.
The missing 20 hours were distributed throughout the startup, and were caused
by various equipment malfunctions. During the initial startup phase the only
significant temperature cycling occurred during the turbine trip. The turbine
trip cycling is shown on Figures 3-3 through 3-5. The highest cycling was
recorded by sensors T4, T9, T10, and T13, which are at the bottom (X = 0.50,
= 1800) of nozzles N4C, NAD, N4A, and N4B, respectively. The maximum cycling
is 115 0F peak-to-peak. As can be seen in the figures, the number of significant
thermal cycles is small and the time during which the cycling occurs is short
(less than 1 hour).
Figures 3-6 through 3-17 show approximately 1 minute of temperature cycling
for four power levels 22.4%, 50.2%, 73.6% and 84.5%, which was the highest
power level achieved during the test. The maximum and minimum peak-to-peak
cycling for each temperature sensor for each power level for a 4 minute interval
are tabulated on Table 3-1 and plotted in Figures 3-18 through 3-21.
Figure 3-22 is a bounding curve of the maximum peak-to-peak cycling using all
the RTDs.
Inspection of Figures 3-18 through 3-22 and Table 3-1 will reveal that:
a. The highest cycling occurs on nozzle N4A (450).
b. The maximum cycling occurs at or near the bottom of all nozzles.
c. The highest cycling value exclusive of the turbine trip transient
was 820F and was recorded by T11 at 22.4% power. Inspection of the
3-5
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3-7
NEDC-23677
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3-17
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NEDC-23677
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NEDC-23677
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3-20
nsp4n.. I.
NEDC-23677
D=> TURBINE TRIP
250 300
FEEDWATER TEMPERATURE (oF)
Figure 3-18. Temperature Cycling N4A(45 0) Nozzle
3-21
160
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100 1--
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T10
T11
1 1 100 150 200 350 400
I I I II
NEDC-23677
= > TURBINE TRIP
200 250 300
FEEDWATER TEMPERATURE (oF)
Figure 3-19. Temperature Cycling N4B (1350) Nozzle
3-22
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w
U
<0
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T13
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I I
NEDC-23677
= > TURBINE TRIP
250 300
FEEDWATER TEMPERATURE (oF)
Figure 3-20. Temperature Cycling N4C (2250) Nozzle
3-23
160
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NEDC-23677
= > TURBINE TRIP
T8
I T7
200 250
FEEDWATER TEMPERATURE (oF)
300
Figure 3-21. Temperature Cycling ND (3150) Nozzle
3-24
160
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NEDC-23677
0 = > TURBINE TRIP - -- => APPROXIMATION OF BOUDING CURVE
USED IN FATIGUE ANALYSIS
-I
L - - - -
I
250 300 350
FEEDWATER TEMPERATURE (oF)
I I I I385 252
T T (0F)
Treactor Tfeedwater(oF)
Figure 3-22. Temperature Cycling Bounding Curve
200 175 165
3-25
140
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20 I-
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NEDC-23677
Table 3-1
MAXIMUM PEAK-TO-PEAK TEMPERATURE RANGE (AT) IN APPROXIMATELY 4-MINUTE INTERVAL
Prior to Turbine Ro Recorder RTD 1200 Hours 5/13/77 Number Number Tfeedwater Treactor
1 2 3 4 5 6
4 9 10 12 13 14
7 8 9 10 11
1
2
3
SNA Spares SNB
SNC SND
154 0F 154 0F 15140F 154 0F 154 0F 154 0F
154 0F 154 0F 154 0F 154 0F 154 0F 154 0F
154 0F 1 540F 154 0F 154 0F 154 0F
15140F' 154F 154 0F 15140F
539 0 F 5390 F 5390F 539 0 F 539 0F 5390F
5390F 5390F 5390 F 539 0F 5390F 539 0F
5390 F 539 0 F 539 0F 5390F 5390F
5390 F 539 0 F 539 0F 5390F
ll Turbine Trip 1830 Hours 5/13/77
AT Tfeedwater Treactor AT
00F 0 15 26 20
0
5 25 40 12 45
8
0 0
22 47 46
149 0F 149 0F 1149 0F 149 0F 14 90 F 140OF
149 0 F 149 0F 149 0F 149 0F 149 0F 1490 F
14 90F 149 0F 14 90F 149 0F 14 90F
1490 F 149 0 F 1490 F 149 0F
NA *
NA NA NAO NAO NAO
NA NA NAO NA NA NA
NA NA NA NA NA
NA NA* NA NA
1o50 F 20 54
110 38 20
115 75
112 30
113 12
15 15 70
110 85
22.4 0330 H
Tfeedwater
2850 F 2850F 2850 F 285 0F 2850F 2850F
2850F 2850F 2850 F 2850 F 2850F 2850 F
285 0 F 2850 F 2850F 2850F 2850F
285 0 F 285 0F 2850 F 285 0 F
4% Power ours 5/14/7
Treactor
537 0 F 5370 F 5370F 5370F 5370F 5370 F
5370F 5370 F 5370F 5370 F 5370F 5370 F
5370F 5370F 5370F 5370 F 537oF
5370 F 5370F 5370 F 5370F
AT Tfe
00F 0
22 29 44 0
31 62 62 34 49 70
0 0 61 64 82
50.2% Power 1500 Hours 5/15/ edwater Treactor
340 0F 340 0F 340 0F 340 0F 340 0F 340 0F
340O0F 340OF 340 0F 340 0F 340 0F 340 0F
340 0F 340OF 340 0F 340 0F 340OF
340 0F 340 0F 3400F 340 0F
540 0F 540 0F 540 0F 5o40OF 540 0F 540 0F
540O F 540 0F 540 0F 540 0F 5400F 540 0F
540 0F 540 0F 540oF 540 0F 540 0F
5400F 540 0F 5o40OF 540 0F
/7773.6% Power
0930 Hours 5/19/77 Tfeedwater Treactor A
0oF 1
15 32 34
0
32 52 54 49 53 51
0 0
54 55 59
3670 F 3670 F 3670F 3670 F 3670 F 3670 F
3670 F 3670F 367 0F 367 0F 367 0F 3670F
3670 F 3670 F 367 0F 3670 F 3670 F
3670 F 3670 F 3670 F 3670 F
542 0F 542 0F 5420F 542 0F 542 0 F 5420F
542 0F 5420F 5420F 5o42 0F 54o20 F 5420F
542 0F 542 0F 5420F 542 0F 542 0F
542 0F 5420F 542 0F 5o42 0F
AT Tfe
30F 3 14 64 43 4
62 59 76
7 21 61
3 4
59 72 59
84.5% Power 1350 Hours 5/20/77 edwater Treactor A
378 0F 3780F 3780 F 378 0 F 3780 F 3780F
3780F 3780F 378 0F 3780F 378 0F 378oF
378 0F 3780 F 378 0F 378OF 3780F
3780 F 3780 F 3780F 3780 F
543 0F 543 0F 543 0F 543 0F 543 0F 543 0F
543 0F 543 0F 5430F 543 0F 5430F 543 0F
5430F 5430F 543 0F 5430F 543 0F
5430F 5430F 543 0F 543 0F
2oF 3 11 60 33
3
59 60 67 22 10 58
1 1
59 67 48
47 22 48 49
RTD readings have been corrected to the actual temperature with the calibration curve.
*The pressure sensors recorded a reactor pressure of 0.0 psig. Thus the reactor temperature is unknown.
3-26
NEDC-23677
raw data (Figure 3-8) will show that the 82oF cycling was infrequent.
Most cycles had peak-to-peak amplitudes substantially less than 820F.
RTD SNA shows that the maximum cycling is restricted to a local region
as well as to one power level.
d. Generally, maximum cycling occurs at X = 0.5 and decreases as X
increases.
e. Cycling is reduced as the feedwater temperature is reduced below
2850F (22.4% power).
f. Generally maximum cycling occurs at 22.4% power.
3.4.2 Time at Temperature
3.4.2.1 Iowa Electric Input
The basic data needed to generate a time temperature map for the feedwater
system were supplied by Iowa Electric specifically for the Duane Arnold plant.
It is tabulated below:
a. Feedwater heaters are on line 100% of the time reactor is operating.
b. There will be 3221 days of outage during the 40-year design life.
c. The startup that was monitored is typical of the 280 slow startups.
d. In addition, there will be 400 fast startups that are similar to
a slow startup, except they take one-half as long.
e. Each shutdown is similar to a startup, except it takes one-tenth
as long.
f. There will be 2 years of operation at 50% power and 2 years at 75%
power.
3-27
NEDC-23677
g. Remainder of the 40-year design life will be spent at a power greater
than 75%.
3.4.2.2 Time/Temperature Map
Table 3-2 contains the time/temperature information for the May 1977 startup.
The values in Table 3-2 should be multiplied by
280 +400 ' 280 + 400 =548 2 10
to obtain the map for all startups and shutdowns in the 40-year design life.
The total number of hours of operation at greater than 75% power can be
obtained in the following manner.
H(>75) = 30(548) + 24 40(365) - (2+2) 365 - 3221 - 548(167)]
24J
= 163,000 hours
H(>75) = Hours of Operation at Greater than 75% Power
The number of hours at 50% power plus the number of hours at 75% power can
be calculated in the following manner:
H(50% to 75%) = (2+2) 365 (24) + 96 (548) = 87,600 hours
Thus, the 40-year design life map is tabulated in Table 3-3.
3.5 CRITERIA
Feedwater nozzle cracks are initiated by cyclic stress. The fatigue usage
factor at the blend radius due to stress cycles considered in the reactor pres
sure vessel stress report9 is approximately 0.6. The ASME Section III allowable
value is 1.0.
3-28
NEDC-23677
Table 3-2
MAY 1977 STARTUP MAP
Treactor - Tfeedwater
500 0F + 250F
450 0F + 250F
Turbine Trip
400 0F + 250F
350 F + 250F
3000F + 250F
250 0F + 25 0 F (~~25% power)
200 F + 250F (50 to 75% power)
1500F + 250F (>75% power)
TOTAL HOURS
NOTE
Treactor
Tfeedwater
Hours of Operation
0
0
1
7
8
21
96
30
167
= Saturation temperature at reactor pressure
= The average temperature of the two feedwater lines
3-29
NEDC-23677
Table 3-3
40-YEAR DESIGN LIFE TIME/TEMPERATURE MAP
Treactor - Tfeedwater Hours of Operation
500 0 F + 250F 0
450 0F + 250F 0
Turbine Trip 550
400 0F + 25 0 F 3,800
350'F + 250F 2,200
300 0F + 250F 4,400
250OF + 250F 11,500
2000 F + 25 0 F 87,600
150'F + 250F 163,000
0 77,300
TOTAL 350,350
3-30
NEDC-23677
Fatigue usage on the blend radius was not explicitly calculated in Reference 9. Fatigue usage was calculated for the nozzle and safe end region. The safe end and the weld of the thermal sleeve to the safe end were investigated in detail as it was known that the fatigue usage would be greater there than at the blend radius. The maximum calculated fatigue usage factor was 0.9 and
occurred on the outside surface of the safe end. Based on a survey of latter
stress reports, the fatigue usage factor on the blend radius is approximately 0.6.
Fatigue usage due to rapid thermal cycling was not explicitly included in the
Duane Arnold design. Thus, a usage factor allowance of up to 0.4 remains for rapid thermal cycling.
If the fatigue usage factor due to rapid thermal cycling can be shown to be
less than 0.4 during the reactor design life, then the feedwater nozzle would
not be expected to experience fatigue cracking. If the fatigue usage factor
was shown to be greater than 0.13 per year (5.0 in 40 years), then cracks would
be expected to have occurred before the next refueling outage. If the fatigue
usage factor is greater than 0.4 and less than 5.0, then the analysis is not conclusive.
3.6 ANALYSIS
Fatigue damage due to rapid thermal cycling is evaluated utilizing the Ordered Overall Range (OOR) cycle counting approach of References 10 and 11, in conjunction with the General Electric extrapolation of the ASME Boiler and Pressure Vessel Code Section III fatigue curve for stainless steel.
3.6.1 Cycle Counting Technique
The subject of fatigue under random loading cycling has been extensively researched in connection with automotive, aerospace and highway bridge applications. Several methods for estimating fatigue damage under random cycling are available in the literature. Some of the methods make use of the statistical character of the
cycle pattern, as characterized by mean and standard deviation of the signal.
Others involve a brute force cycle counting approach in which the fatigue damage contribution of each individual cycle is calculated and summed to estimate
3-31
NEDC-23677
total fatigue damage. Because the thermal cycling from General Electric tests
does not adhere to any consistent statistical distribution (such as normal or
Gaussian), it was found that statistical approaches could not be conveniently
applied, and it was necessary to resort to a cycle counting approach to evaluate
fatigue damage. The OR approach of References 10 and 11 was selected to per
form the cycle counting.
The 0OR is an abbreviated cycle counting approach, which permits selection
of a small number of load reversals which account for a large fraction of the
fatigue damage. Figure 3-23 illustrates application of the approach to a sim
plified load trace. The first step is to select the largest overall range
of a load (or temperature) trace, from the highest peak to the lowest valley
(points F and U in Figure 3-23). Next a screening level of some percentage
of the largest overall range (50% in Figure 3-23) is selected and ranges with
amplitudes greater than the screening level are counted, keeping track of the
sequence in which the reversals occur. Only reversals which occur in a peak
valley-peak-valley sequence are considered in counting ranges greater than
the screening level.
(Note that in Figure 3-23, the range between reversals H and M is actually
larger than the counted range between M and R, but the former range was not
counted because it was not in the correct sequence and would yield a peak-peak
valley-valley sequence in conjunction with the largest overall range.) The
screening level is then reduced incrementally to zero, and a load spectrum
of screening amplitude versus number (or percent) of cycles greater than the
screening amplitude is produced as illustrated at the bottom of Figure 3-23.
The finer the screening level increments, the more accurate will be the repre
sentation of the actual cycling.
The resulting OOR load spectrum can be used to estimate fatigue damage in con
junction with any fatigue curve and cumulative damage law desired. In many
cases, only the upper portion of the load spectrum is required to obtain a
reasonably accurate damage estimate since higher stress cycles tend to dominate
fatigue damage calculations.
3-32
A
RESULTING LOAD SPECTRUM:
0 1 1 I I I I I I I
0 2 4 6 8 10 12 14 16 18 20 22
NUMBER OF RANGES WITH AMPLITUDE > SCREENING LEVEL
Figure 3-23. Illustration of Ordered Overall Range (OR) Cycle Counting Approach
3-33
F
NEDC-23677
SAMPLE LOAD TRACE CONTAINING 21 RANGES* OF VARYING AMPLITUDE
LARGEST OVERALL RANGE: PEAK TO PEAK AMPLITUDE = 40 ksi
50% SCREENING LEVEL: 4 RANGES* WITH AMPLITUDE GREATER THAN 20 ksi
15% SCREENING LEVEL: 12 RANGES* WITH AMPLITUDE GREATER THAN 6 ksi
*(NOTE: NO. RANGES= NO. REVERSALS =
2 x NO. CYCLES)M U
100
80
60
40
20
w 0
z z w w
0
LU
LL 0
I
LU
w15%
NEDC-23677
3.6.2 Envelope Load Spectrum
Based on General Electric tests, an envelope load spectrum has been developed
(Figure 3-24). This envelope spectrum should be applicable, with a reasonable
degree of conservatism, to any temperature trace of the test program. Two of
the highest Duane Arnold cyclic locations have been compared to the envelope
load spectrum. The results are also shown on Figure 3-24. The high power case
falls on the envelope curve and the low power case falls substantially below the
envelope curve. Thus, fatigue damage predictions based on the envelope curve
will be accurate for high power operation and conservative for low power opera
tion. Inspection of the typical temperature traces (Figures 3-6 through 3-17) will reinforce this conclusion. During high power operation there are many
temperature cycles that approach the maximum peak-to-peak cycle; while during
low power operation, most temperature cycles are small compared to the maximum
peak-to-peak cycle.
3.6.3 Fatigue Evaluation Method
The envelope load spectrum of Figure 3-24 has been changed into a table con
taining the number of cycles at various amplitudes (A) as shown in Table 3-4.
Since the test traces analyzed were approximately 240 seconds long, the envelope
spectra of Figure 3-24 results in discreet numbers of cycles at each amplitude per 240 seconds of cycling, and must be scaled up or down to the actual
cycling duration. In the last column of Table 3-4 the cycling has been scaled
up to indicate the number of cycles at various amplitudes per hour of cycling.
Note that a factor of two has been applied in transferring the envelope spectrum
from Figure 3-24 to Table 3-4 to translate from reversals to cycles (two reversals/cycle).
The last column of Table 3-4 can now be used to compute fatigue damage per
hour of cycling at any peak stress level by summing the damage from 15 cycles
of amplitude equal to 98% of the peak stress level, 3.0 cycles of amplitude
equal to 93% of the peak stress level, etc.
For consistency with ASME code design procedures and General Electric design
requirements, the design fatigue curves of Figure 3-25 were used in performing
the damage calculations. The austenitic stainless steel fatigue curve of Figure
3-34
NEDC-23677
Screening
Amplitude
A (%)
100
96
90
86
80
70
60
50
40
30
20
10
*At Amplitude = A
3-35
Table 3-4
ENVELOPE SPECTRUM FOR FATIGUE DAMAGE CALCULATON
Total Number*
Number of of Cycles
Cycles A A% (240 sec)
0
98 1
1
93 2
3
88 2
5
83 5
10
75 8
18
65 10
8
55 12
40
45 15
55
35 25 80
25 25
105
15 75
180
Number*
of Cycles
(hr)
15
30
30
75
120
150
180
225
375
375
1125
DUANE ARNOLD DATA AT 84.5% POWER
O DUANE ARNOLD DATA AT 22.4% POWER
I I I I I I I I10
I i iI I I I I I I II II I I I I I I I 1
100
NUMBER OF RANGES IN 240 sec TRACE WITH AMPLITUDE GREATER THAN A
Figure 3-24. Load Spectra
100
80 b-
O
0
0
60 [-
O
O
0
40 I- 0
20 I-
0
I
10001
NEDC-23677
3-25 was used as the Duane Arnold feedwater nozzles are clad. Peak stress
amplitudes were calculated as follows.
Sa = -alternating : -ATpp(%) (Treactor - Tfeedwater 20
Where: - = 375 psi/OF for stainless steel cladding
ATp-p(%) =Peak-to-peak AT (in percent of available
temperature differential)
Treactor - Tfeedwater = Available temperature differential (OF)
Figure 3-26 is a plot of fatigue damage from the above equation for several
values of ATp-p(%).
The damage curve of Figure 3-26 represents a convenient design tool for evalua
tion of the thermal cycling data. The peak-to-peak cycling anplitude in percent
can be obtained from the test data and, in conjunction with the load map of time versus feedwater to reactor temperature differential, can be used to enter
the appropriate damage curve and predict cumulative fatigue usage.
3.6.4 Fatigue Evaluations
The fatigue damage due to the bounding temperature cycling curve (Figure 3-22) and the 40-year design life time temperature map (Table 3-3) can now be calculated using Figure 3-26. The calculation is summarized in Table 3-5. The highest cycling value and associated percent cycling for each 4250 F interval
was assumed constant for the entire interval (Figure 3-22). The cumulative
fatigue usage factor due to rapid thermal cycling in 40 years is 0.2. The
total 40-year fatigue usage factor for all identified cycles is 0.2 plus 0.6
or 0.8, which is less than the ASME Code allowable value of 1.0.
3-37
NEDC-23677
100 10 2 10 10 10 106 10 10 10 10
CYCLES
Figure 3-25. GE Extrapolation of ASME Fatigue Curve
3-38
C
U0
I
NEDC-23677
1.0
0.1
50% CYCLING
.E
> 40% 0
0
O 0 0
001 -30%
2
0
(9 25%
LL
20%
0.001 17%
15%
0.0001 5000 4000 3000 200'
Treactor - feedwater oF)
Figure 3-26. Fatigue Damage Curve
3-39
1000
NEDC-23677
Table 3-5
CUMULATIVE FATIGUE DAMAGE
Fatigue Damage
Peak-to- Damage per
Discrete Value Interval Peak Percent per 40-Year
Treactor - Tfeedwater Treactor - Tfeedwater Cycling Cycling 1000 hr Life
375 0F 400 0F + 250F 500F 13% 0.0001 0.0004
3250F 350OF + 25 0F 630F 19% 0.00016 0.0004
2750F 300 0F + 250F 750 F 27% 0.00065 0.0028
252 0F 250 0F + 250F 82OF 33% 0.0019 . 0.0219
175 0F 200 0F + 250F 760F 43% 0.00065 0.0569
175 0F 150OF + 250F 760F 43% 0.00065 0.1060
Turbine Trip* 115 0F NA 0.023 0.0127
TOTAL 0.2011
*Percent cycling is not known for the turbine trip event. Damage during turbine
trip was calculated by assuming a value of percent cycling and using Figure 3-26.
This is exactly correct as figures could be directly plotted as a function of
maximum peak-to-peak cycling directly without the need of obtaining the percent
cycling.
3-40
NEDC-23677
The method of analysis has both conservative and nonconservative steps. The
most significant of these are:
Conservatisms:
a. RTD measurements used as metal surface temperature, whereas metal
surface temperature fluctuations are lower than sensor temperature
fluctuations.
b. Fatigue damage curve was generated with a bounding load spectra
C. Fatigue calculation used a bounding temperature cycling curve
d. The highest temperature cycling in each +25 0 F interval of the bounding
curve was used for the entire interval.
Nonconservatisms:
a. A limited number (18) of RTDs were used
b. All locations of the nozzle could not be measured
c. A limited data base (one startup) was used
d. Some temperature cycles are so rapid that the RTDs may not have
reached full value
The RTDs will measure a temperature that closely approximates the metal surface
temperature. Tests performed by General Electric indicate that the recorded
cycling is approximately 10% higher than the actual metal surface cycling.
As shown on Figure 3-24 the Duane Arnold data at high power, where most of
the fatigue damage occurs, falls essentially on the bounding load spectra curve.
The bounding temperature cycling curve and the interval approximation of it
were intentionally used to balance the nonconservatism due to a limited number
of RTDs and the limited data base.
3-41l
NEDC-23677
Based on General Electric tests, the locations of the feedwater nozzles that
are expected to experience the highest temperature cycling were instrumented.
It is judged that the probability of other nozzle locations having higher cycling
is small.
The temperature cycling is slow enough so that the RTDs recorded at least 90% of
the maximum cycling.
Therefore, it is judged that the cumulative fatigue usage factor of 0.2 is as
accurate as can reasonably be calculated.
3-42
i
NEDC-23677
4.0 REFERENCES
1. Chicago Bridge and Iron Co. Drawing Special Forgings Nozzles N4A through
N4D VPF 2655-238.
2. Chicago Bridge and Iron Co. Drawing Feedwater Nozzle VPF 2655-99.
3. Chicago Bridge and Iron Co. Drawing Thermal Sleeves for Feedwater Nozzles
VPF 2655-100.
4. General Electric Co. Drawing, Reactor Assembly 197R608.
5. General Electric Co. Specification 21A2110, Feedwater Nozzle Instrumentation
Program.
6. General Electric Co. Drawing 768E476, Feedwater Nozzle Instrumentation
Connection Diagram.
7. General Electric Co. Drawing 768E462, Feedwater Nozzle Instrumentation
Installation Kit.
8. General Electric Co. Field Deviation Disposition Requests 1001-1010, Feed
water Nozzle Instrumentation Program - DAEC.
9. DAEC Reactor Pressure Vessel Stress Report VPF 2655-330.
10. H. 0. Fuchs, et al., "Shortcuts in Cumulative Damage Analysis," Society
of Automotive Engineers, Paper No. 730565, 1973.
11. D. V. Nelson and H. 0. Fuchs, "Predictions of Cumulative Fatigue Damage
Using Condensed Load Histories," Society of Automotive Engineers, Paper
No. 750045, February 1975.
4-1/4-2
NEDC-23677
DISTRIBUTION
Name M/C
N. J. Biglieri 752
J. E. Charnley (3) 747 H. Choe 589
F. E. Cooke 747
M. Costandi (10) 873
C. W. Dillmann 752
A. B. Fife 747
J. D. Gilman 712
D. R. Heising 743
L. K. Holland 150
J. Jacobson 713
I. R. Kobsa 7147
K. R. Miller 712
R. H. Moen 589
J. L. Rash 682
R. R. Roof (6) 126
H. T. Watanabe 682
NED Library (5) 328
VNC Library Vol
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