generation® george gellrich lusby, md 20657 · lusby, md 20657 410 495 5200 office 717 497 3463...

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~Exe!.on Generation® George Gellrich Site Vice President Calvert Cliffs Nuclear Power Plant 1650 Calvert Cliffs Parkway Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear Regulatory Commission ATTN: Document Control Desk Washington, DC 20555 Calvert Cliffs Nuclear Power Plant, Unit No. 1 Renewed Facility Operating License No. DPR-53 NRC Docket No. 50-317 Subject: Information Concerning Dissimilar Metal Weld in Pressurizer Safety Relief Nozzle-to-Safe-End Weld References: 1. Letter from N. L. Salgado (NRC) to G. H. GelrInch (CCNPP), dated February 24, 2011, Relief from the Requirements of the ASME Code 2. Letter from D. T. Gudger (Exelon) to Document Control Desk (NRC), dated February 25, 2016, Report Concerning Dissimilar Metal Weld Flaw in Pressurizer Safety Relief Nozzle-to-Safe-End Weld In Reference 1, Calvert Cliffs Nuclear Power Plant, LLC was granted a relief from certain requirements of the American Society of Mechanical Engineers Code for dissimilar metal weld repairs. Reference 1 required that certain information related to a repair performed using this Code relief be provided to the Nuclear Regulatory Commission prior to entry into Mode 4 following the weld repair. A dissimilar metal weld on the Unit 1 pressurizer safety valve line was repaired during the current refueling outage using techniques approved by the subject Code relief. Attachments (1) and (2) contain the required weld overlay sizing analysis and the weld overlay material and size dimension drawing. The attached information, when combined with information previously submitted in Reference 2, meets the requirement to submit the required information prior to Unit 1 entry into Mode 4 conditions.

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Page 1: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

~Exe!.on Generation®George GellrichSite Vice President

Calvert Cliffs Nuclear Power Plant1650 Calvert Cliffs ParkwayLusby, MD 20657

410 495 5200 Office717 497 3463 Mobilewww. exeloncorp .comgeorge.gellrich~exeloncorp.com

March 5, 2016

U. S. Nuclear Regulatory CommissionATTN: Document Control DeskWashington, DC 20555

Calvert Cliffs Nuclear Power Plant, Unit No. 1Renewed Facility Operating License No. DPR-53NRC Docket No. 50-317

Subject: Information Concerning Dissimilar Metal Weld in Pressurizer Safety ReliefNozzle-to-Safe-End Weld

References: 1. Letter from N. L. Salgado (NRC) to G. H. GelrInch (CCNPP), dated February24, 2011, Relief from the Requirements of the ASME Code

2. Letter from D. T. Gudger (Exelon) to Document Control Desk (NRC), datedFebruary 25, 2016, Report Concerning Dissimilar Metal Weld Flaw inPressurizer Safety Relief Nozzle-to-Safe-End Weld

In Reference 1, Calvert Cliffs Nuclear Power Plant, LLC was granted a relief from certainrequirements of the American Society of Mechanical Engineers Code for dissimilar metal weldrepairs. Reference 1 required that certain information related to a repair performed using thisCode relief be provided to the Nuclear Regulatory Commission prior to entry into Mode 4following the weld repair. A dissimilar metal weld on the Unit 1 pressurizer safety valve line wasrepaired during the current refueling outage using techniques approved by the subject Coderelief. Attachments (1) and (2) contain the required weld overlay sizing analysis and the weldoverlay material and size dimension drawing. The attached information, when combined withinformation previously submitted in Reference 2, meets the requirement to submit the requiredinformation prior to Unit 1 entry into Mode 4 conditions.

Page 2: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

Document Control DeskMarch 5, 2016Page 2

Should you have questions regarding this matter, please contact Mr. Larry D. Smith at(410) 495-5219.

Respectfully,

George H. Gellinch

Site Vice President

G HG/KLG/psf

Attachments: (1) Full Structural Weld Overlay Sizing for the Four-Inch PressurizerSafety/Relief Valve Nozzles

(2) Drawing 12024-0051 SH0001

cc: NRC Project Manager, Calvert CliffsNRC Regional Administrator, Region INRC Resident Inspector, Calvert CliffsS. Gray, MD-DNR

Page 3: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

ATTACHMENT (1)

FULL STRUCTURAL WELD OVERLAY SIZING FOR THE FOUR-INCH

PRESSURIZER SAFETY/RELIEF VALVE NOZZLES

Calvert Cliffs Nuclear Power PlantMarch 5, 2016

Page 4: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

" DESCRIPTION¶ OF CONFIGURATION AND REPAIR PRocEss ""The safety and relief ~alve nozles a're lociated in •the ulppe head of th~e pre~surzer and are fabricated

with SA-50S Class 2 [7, Sectionhs 2-2-4 and 2-2-51 an~d are fitted with a SA-1 82 F3 16 Safe end [7,Sections 2-2-4 and 2-2-5]. The dissimilar metal weld (DMW) which joins the pressurizer safety/reliefnozzles to the saf'e ends are fabricated using Alloy 821182 [10] nickel batsed weld metal.

The full structural overlay repair wiillbe performed using primary watet stress c:orrosion cracking(PWSCC) resistant Alloy 52M material depos~ited aro.und the circumference of dhe configuration. Theoverlay material will be deposited using the machine gas tungsten arc welding (GTAW) process. For theAlloy 52M weld overlay filler metal, the sele~cted material is. SB-166, Rod & Bar, Alloy 690 (S8Ni-29Cr-gFe) [6]. * ,. .. . .

ASME CODIE CRITER.A "The applicable ASME Code, Section XI edition for Calvert Cli~ffs Nuc~lear Power Plant, Units. Iand 2 is

the 2004 Edition [3] per Section 1.4 of Reference 1 1. The basis for FSWOL sizing is the ASME Code,Section Xl, Code Case N-740-2 [ I] and the ASME Code, Section XI, Division 1, Class 1 [31 rules forallowable flaw sizes in austenitic .and ferritic piping (IWB-364.0). The ASME Code, Section.X11 CodeCase N-740-2 [1] incorporates the weld repair by overlay approach documented in Code Case N-504-3[4], and the temper bead welding app~roach documecnted in Code Case N-638-1 [8], and applies these tosimilar and dissimilar metal welds. To determine the overlay thickness, Code Case N-740-2 refers to therequirements of ASME Code, Section XlIWB-3640. IWB-3640 at' the applicable Code refers toAppendix C, which contains the specific methodology for meeting the allowable flaw sizes. Theoverlays are to be applied using the OTAW process, which is a nonflux process. Therefore, forcirumferential flaws, the source equations in Appendix C, Section C-5320 (limit load c:riteria) are thecontrolling allowable flaw size equations for *combined loading (membrane plus bending) and

membrane-only loading. These equations are valid for flaw depth-to-thickness ratios for flaw lengthsranging from 0 to 100% of the circumference as defined in Section C-5320 of Appendix C. Forpurposes of designing the overlay, a circumferential flaw is assumed to be 100% through the originalwall thickness for the entire circumference of the item being overlaid.

!o/

Page 5: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

........ :-.:,

The overlay is sized by iusing the souirce equations iii Siection C-5320 [3]. :, .'The allowable bending strs's unider combined membrane plus bending loads is given by the equation:

i .. .. . •.: . .. . S F--~.-o l --LS J IJ ... . C-5321.

where..3 . ..... •=2>(2:)iP In e,f or(+/3) ,,

The allowable rm..brahe stress is given, by. thie equation ........ .

where,:

and

o' C-5322.-°. • (a G' 2qzl. : . . .. •

9' = arcsin{0.5(.•)sin 0],

S, = allowable b ending strss for a circumfer'entially flawed pip~e . .....aeb = bending "stressat incipient pl ti.t .c colla"pse ?" .:.:: "i" :. ' : + "S~in = safety factor for membrane i+'Strssbased on Service Lev'el as shown in Table 1 [3, C-26211SF,, = sf'ety factor for bendiig stress based on Service Level• as sown in Table 1 [3, C.262 I]

a =fotlwall thicns icue vra hcnsi h+•'' '•::+'t, = toalowable thicknes (snclude ovrlay thicknmessn this clawed)i

=alloabl membrane stress a in foiri pastircwnfrollype flwe pipe : :': .. "+""Ou = membrlawanle st 3,s atiniiguet plas10-i] 18°ollapse 0 l irufretalfaO = halflflaw angtea[3,xFigurefC-43d10i1] inIY o rfrad an10sfl ci.um.renia flaw:

•,= angletoeneutral axismoryflawedpipe intresadihefans oai~

.+= flow stress = (s, + sa)/2 [3, C-8200(a)J +' .. .. ..Si, •=Specifiedvalue for materiafl .yield strengt [6] at th!e. evaluation (operating) temperature

s.= specified valu~e for material ultimate strength [6] at the evaluation (operating) temperature

Safety factors are provided in Appendix C of Section Xl for evaluation of flaws in austenitic stainlesssteel piping. The safety factors used for the weld overlay sizing are shown in Table 1 and are taken fromC-2621 [31.

2' II

Page 6: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

Table 1: Safety Factors for Sizing- Circumferential Flaw

Service .. Membrane Stress Safety Bending Stress,, Level'•+!•• Faictor S,. 8P Saifet Fac~tor, SFb• .

A 2.7 2.3.....B 2.4 2.0... C 1.• ].8 . 1.6

D 1.I.3 .. 1.4

The overlay thickness must be established so that ithe flaw assu~mption herein meets the allowable.flaw depth-to-thickness ratio requirement of te source equatons [3, C-5320], for the thickness of theweld-overlaid item, considering primary ebrane-plus-bending stresses, as well as membr'ane onlystresses, per the source equations defined previously. Since the weld overlay is austenitic materialand applied With a. nonflux welding process, which has hiigh fracture toughness, the limit load failuremode .is applicable [3, Figure C-42i0-1 for nonflux welds] ad, hence, limit load e•,ijiaitioifi•'•'•••techniques are used here.

The non-overlaid piping stresses for use in the equa~tion! are, usually obtained from the applicablestress reports for the items to be overlaid. However, in this calculation, since the stresses are notprovided, they are calculated based on; forces• and moimenta at the welds using equations from C-2500of Section XI, Appendix C as described below.i

Primary membrane stress (o'm) is given by:

Cm= pD/(4t), where:

p = maximum operating pressure for the.Sevicee.Level being considered ,••iD =- outside diameter of the component including the oveirlay. •t =t'hickness, consistent with the locatio•n ati whichl theo0Utside diameter is taken -

Sincluding the overlay (note that any inside diameter (ID) cladding is not counted

Primary bending stress (ci)is given by:i -• -;. .:.' •: "-:

Gb=DM/(2[), where: .... :' .. • ; :'

D =outside diameter othcmpnnt includng t eo lyd = inside diameter consstent •with the point at which the outside diameter is taken

..."(note that ID cladding is not counted towar'd the inside, diameter)• i..Mb =resultant moment for theappropriate primary load combination for each Service

Level (square root of the sum of the squares (SRSS) of three moment componentsin X, Y, and Z diections) ,".

I =' moment of inertia, (ir/64) (D4'-d 4). " ; .. .. " . -. - .

Page 7: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

The contribution of axial .and shear forces to piping, stress (other than force couples contributing tomoments) is not included basd on C-2500 of Section XI, Appendixt C [3]; . .•,, -,, ,

The following l!oad co~mbinations are u~sed for" the full structural weld overlay. These are equivalent tothe load • co m bin ation s d efin ed in R eference ::2 (P age 13) v • •: : . . •- . "... • •. , , .; ,,. i .

",' service Level A (ormal): Pressure (P)'+Deadweight (DW)..* •... .•'•.-.....:."-SerVice Level B (upset)•:• •' P +, OW S[kSS(Relief valve di.scharge transient (PORV) +

Operating basis..eart.hquake (ORE))Service Level C (Emergency): P + DW + SRSS (PORV•i+ Delgignbasis earthqual~e (DBE))Service Level D (Faulted): P ± ,. DW..+ SRSS (Safety v alv3e discharge: transient (SRV) or Once

:: •, ":......• :7! :,•, ••- 'through core cooling transient (OTCC) + DBE)•,•, :

Reference 2 (Page 13) states that the dynamic loads (pORV, OBE, DeE, SRV, OTCC) are combined,

Service..Le~el* .A., B, C, and D in the ASM• Code [3] are alternatively referred as Normal, Upset,--Emergency, and FaUlted conditions, respectively, in- this evajuation. .Per ASME Ccse, •Section XI,,:..C-5-3 11. for theCombined Loading case, test conditions! shall be included with the Service L•eve B LoadCombination. However, the hydro~static pressure test is notoapplic:able to the weld ov¢erlay: repair and isnot included in the FSWOL design. In addition, the leak test requitement per, ASME Cod; ,Section XI,IWB-5220 is included, in the design of the FSWOL sincee the.leak test pressure (2250 ps.ia given in :Table I-1, Pressure Vessels of Reference 7) is the same as the operating pressure of 2250 psia[Table I- I, Pressure veisael, of ReferenceT],. Tlicefore, no aidditional test condition nieeds to be ::.included with the Service Level B Load Combination,•• .. ::-.•..:•; •,•-••.-:•.:!-. '-

The weld overlay sizing is an ite rative process, in which the allowable stre~sse are calculated and then•compared to the stresses in the overlaid component. 'If de stresses in the component are larger thian theallowable stresses in the component then the overlay thicknss is inc~reased, and theprocess Is repeateduntil it converges to an overlay thickness which meets the allowable Stresses.

The thickness of the weld overlay is determined through an iterative process• The thickness of the ...overlay (t01) is assumed resulting in total thicktness of(t,+-t01) where t• is the original pipe tlickness,,The applied flaw size-to-thickness ratio based on~ aFSWOL (flawed through the original pipe wall,thickness, tp) is tp/(tp + t01). The allowable stresses are then determined from the source equations(see Section 3.0). If this allowable stress value is greater than the calculated stress for the overlaidcomponent, the overlay thickness (to,) is reduced. On the other hand, if the allowable stress value is lessthan the calculated stress for the overlaid component, the overlay thickness (td) is increased. Theprocess is repeated until the assumed overlay thickness results insa stress ratio of the calculated stress tothe allowable stress that is equal or less than 1.0. As the maximum allowed value for alt is-0.75 [3, C-5320], t01 is initially set as t,,/3. If the overlay thickness of tp/3 meets the allowable stresses forpure membrane and combined membrane plus bending stresses, then no more iterations are performed.If the allowable stresses are not met, then the overlay thickness is increased until the ratio of thecomputed stress to the allowable stress is less than or equal to 1.0.

Page 8: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

WELD OVRA(Umc'S M• "-

The operatng pressure ([7, Table lI•.!i d~enislons [5 and overlay thicknes. ar shown in Table 4. At

the thickness 6ftheIlD I•bittrlng)e seFgik•il). An• Ihitial, alt value of (f.75 (thu limiti~ng value

3600 flaw .resiits lr.!# I f .aWleng t.i • i•io 6f 1.0. Fi• 1 sf~ows the locations for fallstructurai we•l- o"•rlay (FSWit)•sizinj: ;;•-••..... }... • .... '

• "•" "/ i i•.';i'•,IA /lB " .". .. . .. .. . .. . . ... . . . . - ' -.. . .. 3.. . . ! . . . . .

• "l ii 1 "'" If I " L ] i lJJ

... ..RE iE. V A..• .. ..J.Z ...L.. .. '•..... W .. .AFE...• - E... . ()

I I I

- - - .r

FigUre 1: Locationa Exanited for FSqwoL Sizing . . .

•"Table 4: Di~mensions fo'r Overlay Slzh•.I :'-: -"•. .. :•

Lo~atranlA, Loaton 1 B L..atlon 2"

_______ (,dbtt.) (uo buttef Weidp, p$1g 2235 2235 2235.

tr 1 , In 1.313 t.094 1.313lt 0. o75 0.75 0.75

toll In 0.38 0.3515 0.4a0tprplii, In 1.78 1.48 1.75D:lo, In e.938 e,792 8.93e

t, !n€4 105.5 93,38 108.855Pipe + Owdy___ _______

The final calculated membrane stresses (cv,,n) and bending stresses (at) at each service level for the pipe +overlay configuration are shown in Table 5. This table also shows the ratio of the membrnme stress (arm)to the flow stress (C'r) at the selected Locations. The material properties are evaluated at the normaloperating temperature of 6530 F (7, Table I-I] using Section 11, Part D of the ASME Code [6].

SO /

Page 9: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

• ~~~Table 5: Calculgted Stresses •, *=

•., Locution "A .... t... 18• Lo iati '

.of, psI 53744. 83744 53.744______ am/o•= .O.,•lt 0.048 0,041

A " No.=rm~al ~bmpsi 7...... 01 . ... . 78.5 ..... 701

B ,. Up~set db, ps~iI ... '1553 . 17••t.40 1f •553

0 Faulted 0 b, pai.. .. 2108 . 238. .210.8

Table 6 shows the allowable stresses as determ•ined fro~m the source equations discussed in Section 3.0.The membrane and bending stresses from Table 5 are compared to the allowable stresses as shown bythe ratios in Table 6. The limiting cases for the membrane and bending stresses arc shown in bold. Inthe limit load analyses, the flow stress of the Alloy, 52M weld overlay material is used, consistent withthe assumption of a full 360° flaw through the original pipe wall for the design of the full structural weldoverlay ... " ' . " ' "" " ..

~5oI~ ii

Page 10: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

T a b le" . 6 :- . A l l o w a b l e. . .. : . ' . , "S t- ..re s"se a.. .' " .a n d, C a l c u l a t e d, S t r e;s- -s, ..to.. A...Tb l e 6 : A l o w b l ore s e bnl elc lS t r e sss R a t ioal es~eu R a i o

_______ p ~ t.•Si 052470. .~0,166 0.5247

_____ ______________ 0;!142e' '0..h66 . l0.428

Letel A Normal S,, psi 4920 738! ... 7921

Lewilc Emergency 8t, p8i 1474118146 1240 7.4

LewI 0 Faitlted Si, psi 14733S .. .. 4 22f' .. 14733

0...•t,., .....Lewi B [ Upse~t o•h/S, 0.3957 J 0,.4648 0.3957LewiC [ Emereny om/St 0.2967- . .•. 0.3488'-' J 0'.2967'Lewei O Fautd Gtn1 t 0.2143 0,2518 0.2143

Notes: o,' -Bending strss at IncipIent plasti"c colapse [-3, C,5320]3So-Allowable ldidgn tes ['3, C.5320];,. :.. •S.-Allowable membrane stress [3, C-5320],e" -Membrane stress at incipient plastic collapse [3, C-5320]

...(All terms defined InSection3'.0).,. .:.:

The weld overlay length must consider three requirements: (I) length required for structural••.'

reinforcement, (2) length required for preservice examination access of the overlaid weld, and"(3)limitation on the area of the nozzle surface that can be. overlaid,

Structural ReinforcementStructural reinforcement requirements are expected to be satisfied if the weld overlay length is 0.75.J'•

on either side of the susceptible weld being overlaid [1], where R is outside radius of the item arnd t is thenominal thickness of the item at the applicable side of the overlay. However, to assure ASME Code,Section III, NB-3200 [9] compliance, detailed shear stress calculations are instead performed todetermine the minimum required structural length.

7oF Ii

Page 11: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

The sc~tio, .alpng thel lengt h of the overlay is ovaluated for axial shear due to transfer of axial load andmoment from •he.overla~id. item. to.the overay.• S•uipargrph NW-3 227.2 [9] imitsf pure shear due toDesign L~oadings, Test Load'in' or; an" Service Level loadings except Service Level D to 0.6Smn.Therefore, O.6s,~i~i ds for serIce Levels A, l, and .C. •or Service Level D (Faulted) coniditions, thestress intensityI im•it is theilesserof 4m or 0,7s• [,[NB-3225 andI Appendix F], equivalent to the lesserof 1.ZSm, or, o.35Su• br shear stres,•Thpe v'alues ire shown in Table 7 for the safe end, nozzle and weld

Shear stress• around the~circumferencee at the overlay-base material interface due to axial force andmoment loading equals: -!.. .... . ..

w here: " l: • "• ' .. . : ".... .." ... ... . . . . ..=outside radius of overlaid item at crack ! !. ... i :I

L i=' length of ovrlay at outside surface of overlaid item on one side of crack,4= shear area, ,2iR 0L., " ....

P, = pressure, psig.<. : '. • .:,- . . .M. = resultanit momment from piping interf'ace loads at crack.. ..

Thus =€- PiiR02/(2azR 0L) +M(dL)', .... ' " ": '...' '"

Solvhing for L and equating r with tlhe allowable shear stress (Sdtw yields: .

L [PR11 2 + 4/(•l2)]/Sio, where:. , " . .

= 0.63.(Service Levels A, B nd C) .":i• . .

=Lesser of 1 .2Sm and 0,358. (Service ILevel D).'

The evaluation for required length is documented in Table 7 for the-pressurizer sa~fety/relief valvenozzles and safe ends. The overlay weld metal is also evaluated (at the s;mallest diameter) as it maycontrol if the base metal has a higher value Of Sin. The greater yalue of the required Overlay length willbe taken. The material properties are evaluated at the normal operating temperatur of 6530F [7, Table1-11 using Section II, Part D of the ASME Code [6]. • '• :•' . ...

f'ro /1

Page 12: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

.• Table 7: Mniamum Required Ov/erlay Length•: •'r

' •••''- ..., i •'•"Location 1A,1B • Location 2. Location.A16162

R0, in i 3.03 3.03 3.03

Material.Class 28'0 SA-182 F316 Alloy 52M

Sen•csLewi A O.6St,• kal ...... 18.02 9.. .95 ..... 13.98"

Ser~ce ~l i C0.6Sm, kela• •. 16..4.02 ... .9.95 ... : 13.98•-..

-SI4Ce LeVil D •-1;2Smi ksl . .. 32.04-. +•+++ 19.90 ,.27.90,

Ser•¢ae Level D0O.35S0, icat 28• 25.13 28.00 ...Serdce Leel A 1, in 0.258 0,415 0.298Sar~ce Level B L, in 0.315 0.807• 0.361Sdnice Level C L•, In 0.350 0.563 0.401Senecae Level 0 L, In 0.201 0.283 0.202

The required overlay length is c:alcUlated at Locations IA, IB, and 2 along the• nozle and safe endconfiguration (see Figure 1). N•ote that these locations are evaluated twice; wite WOL metal and nozzleand safe end base metal (see Table 7). The design drawing implements'a configuration that meets all thedesigned FSWOL thickness and length requirements.

The lengths shown in Table 7 ensure adequate shear stress transfer along the length of the weld overlay.Service Level C is the most limiting of all cases. This length is sufficient to trasf'er the imposed loadsand maintain stresses (sheary'within the appropriate ASME Code allowable limits.

In addition) to the necessary shear transfer length, the overlay must be inspectable by PDI qualified UTmethods. Any additional length determined to be necessary by the UT personnel for proper PDI'qualified inspection will be noted on a design drawing.

Preservice Examination

Weld overlay access for preservice examination requires that the overlay length and profile be such thatthe overlaid weld and any adjacent welds can be inspected using the required NDE techniques. Thisrequirement could cause the overlay length to be longer than required for structural reinforcement. Thespecific overlay length required for preservice examination is determined based on the examinationtechniques and proximity of adjacent welds to be inspected.

9~F ii

Page 13: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

.. Area Limitation on NozzleThe total weld overlay surface area is limited to 500 in2 [1, Section 1-1] (this value will be specified inthe relief request) on the nozzle (ferritic base material) when using amhiei~t temperature temper beadwelding to apply the 0Verlay. Using an outside diameter of 6.0625", the maximum length is limited to500/ (nD0) -- 26.25" on the ferritic steel nozzle material. The required overlay length on the nozzle isless than this limit (see Table 7).

SMaximum Overlay Sizing

This calculation documents the minimum overlay thickness and length necessary fbr structuralrequirements. Additional thickness and length may be added to addr~ess Inspectability and crack growthconcerns. [n addition, a maximum overlay thickness (typically an additional 0.25") and a maximumoverlay iength Will be determ.ined. The determination of the maximum length is based onimplementation factors and is intended to be large enough so as to not unnecessarily constrain theo•verlay process. These dimensions Will be indic~ated on a, subsequent design drawing to create a "box"within •which the •overlay is analyzed. In the subsequent analy~es, the finite element models use thegeometry (minimum or maximum) that will produce conservative results.

DI, SCUSSIONS AND CONCLUSIONSTable 8 antd Figure 2 summarize the m!inium requird overlay dime nsions. This calculation documentsthe development of a weld overlay design for the* pressurizer safety/relief valve nozzle-to-safe end•DMWs at the Calvert Cliffs Nuclea Power Plant, Units ! and 2. The design meets the requirements ofthe ASME Code, Section •XI, C•ode Case N-740-2 [1] and AsME Code, Section XI, Appendix C [3] for afull structural Weld overlay.

The weld overlay sizing presented in Table 8 is based upon the primary loadings documented inSection 4.0 and using the criteria from the ASME Code, Section Xl, Appendix C. The Overlaythicknesses and lengths listed in Table 8 meet ASME Code stress criteria.

Table 8: Minimum Required Overlay Dimensions

I Location Thickness(in Lnt l)INozzle Side of DMW (IAIIB) I 0.438 I 0.401

Safe End Side of DMW (2 0.438 0.564

Figure 2: Full Structural Weld Overlay Geometry, Minimum Dimension. (SchematicRepresentation)

/0 or Ii

Page 14: Generation® George Gellrich Lusby, MD 20657 · Lusby, MD 20657 410 495 5200 Office 717 497 3463 Mobile www. exeloncorp .com george.gellrich~exeloncorp.com March 5, 2016 U. S. Nuclear

REFERENCEs •••'• .. ,:;:. , •'"•.:!. ;

1 .. ASME Boiler and Pressure Vessel Coda, Code Case N-740-2, "Full Structural Dissimilar.:•:Metal Weld Overlay for Repair"or Mitigaition of Class, 1, 2, and .3 Item's, Section• XI, "'

2. Calvert Cliffs Design C~alculaition No. CA05999, "Unit 2 Pressurizer Reiief Va'lve Class I•Analysis,"! Rev.~ 0, S][ File No.0801014.216..

Nuclear Power Plant C o6nents •2004 Edition .... " .... ': ..

4. ASME Boiler and Pressure Vessel Code, Code Case.N-504-3, "Alternative Rules forRepair of Cliasse's 1: 2, anid -3 ,usfenitlii Stainle~ss Steel Piping,'Section Xi, Division 1."

5. Calvert Cli ffs Drawiing N'o. 1i209-12, R•:V. 2, "Nozle Details for 6750-M-485-15-4, 96"i.D. P ressurizer," SI File Nqo. 001014.215. ":

6. ASME Boiler and Pr-essure Vessel Code, Section 11, part D, Material Properties, 2004Edition.

7. Combustion Engineering Book No. 72367, "Instnuction Manual, Pressurizer, Calvert CliffsStation" Si File No. 0'801014.213. .. .. .. :...

8. ASM'E Boiler aid Pr~essur Vessel Code', Code Case N-638-1, "iSimil~ar ad Dissimilar

Section XI, Division I ." -- , • . .:.. :. • :••,.

9. ASME Boiler and Pressure Vessel Code, Section 111, Rules for Construction of NuclearFacility Component~s, 2004 Edition. . ... ... •.... ... . ... ... . ..

10. CCNPP Table 21-4, "Unit I Alloy 82/182 Full Penetration Welds," SI File No.0801014.205. • , - o .. .•••.:: " :'. : •: ,.• . '.•

11. Attachment (1) to Constellation Eniergy Letter to USNRC, December 29, 2008, "FourthInterval Inservice Inspection Program Plan for Calvert Cliff's Nuclear Power Plant Units 1and 2," Rev. 0, SI File No. 0801014.211.

12. CCNPP Design Specification No. 8067-31-4, "Project Specification for a PressurizerAssembly for Calvert Clifis 1 & 2," Rev. 12, Feb 2006, SI File No. 0801014.212.

)13r 2/

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ATTACH MENT 2

DRAWING 12024-0051 SH0001

Calvert Cliffs Nuclear Power PlantMarch 5, 2016

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