Y . Exhibit C 4 NEP-12-02 4 Revision i 1 ' Page1of2 COMMONWEALTH EDISON COMPANY CALCULATION TITLE PAGE CALCULATION NO. NED-P-MSD-090 PAGE NO.: 1 X SAFETY RELATED REGULATORY RELATED NON-SAFETY RELATED CALCULATION TITLE: Flaw Evaluation for 02AS-S4 Weld in Quad Cities Unit i Loop A Recirculation System STATION / UNIT: Quad Cities 'Jnit i SYSTEM ABBREVIATION: RR EQUIPMENT NO.:(IF APPL.) PROJECT NO.:(IF APPL.) | | l REV:0 STATUS: QA SERIAL NO. OR CHRON NO. DATE: 3 /t 9 /3(, I Ap e cov.d 7148o7 ~~ l , PREPARED BY: Guy H. DeBoo lle . O Uf-b DATE:3/to/9 A | / J |- ! - - | REVISION SUMMARY:InitialIssue | | | ELECTRONIC CALCULATION DATA FILES REVISED: (Name ext / size /date/ hour: min / verification method / remarks) | DO ANY ASSUMPTIONS IN THIS CALCULATION REQUIRE LATER VERIFICATION YES_NO X REVIEWED BY: Hien O. Do uw u- DATE: %f 151/*16 \ o REVIEW METHOD: ,(eA tutmew . COMMENTS (C OR NC):. N C. . . _ , APPROVED BY: l) A k f DATE: o/eelg w w- - q i<j 9604100154 960404 PDR ADOCK 05000254 p PDH
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Y.
Exhibit C4 NEP-12-02
4 Revision i 1'Page1of2
COMMONWEALTH EDISON COMPANYCALCULATION TITLE PAGE
CALCULATION NO. NED-P-MSD-090 PAGE NO.: 1
X SAFETY RELATED REGULATORY RELATED NON-SAFETY RELATED
CALCULATION TITLE: Flaw Evaluation for 02AS-S4 Weld in Quad Cities Unit i Loop A Recirculation System
STATION / UNIT: Quad Cities 'Jnit i SYSTEM ABBREVIATION: RREQUIPMENT NO.:(IF APPL.) PROJECT NO.:(IF APPL.)
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REV:0 STATUS: QA SERIAL NO. OR CHRON NO. DATE: 3 /t 9 /3(, I
Ap e cov.d 7148o7 ~~
l,
PREPARED BY: Guy H. DeBoo lle . O Uf-b DATE:3/to/9 A |/ J |- !- -
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REVISION SUMMARY:InitialIssue|
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ELECTRONIC CALCULATION DATA FILES REVISED:(Name ext / size /date/ hour: min / verification method / remarks)
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DO ANY ASSUMPTIONS IN THIS CALCULATION REQUIRE LATER VERIFICATION YES_NO X
REVIEWED BY: Hien O. Do uw u- DATE: %f 151/*16\ o
REVIEW METHOD: ,(eA tutmew . COMMENTS (C OR NC):. N C.. .
_ ,
APPROVED BY: l) A k f DATE: o/eelgw w- -
q i<j
9604100154 960404PDR ADOCK 05000254p PDH
}>*
Exhibit CNEP-12-02
4 RGvision 1*
Page 2 of 2
COMMONWEALTH EDISON COMPANYCALCULATION TITLE PAGE
CALCULATION NO. NED-P-MSD-090 PAGE NO.: 2
REV: STATUS: QA SERIAL NO. OR CHRON NO. DATE:
PREPARED BY: DATE:
REVISION SUMMARY:
ELECTRONIC CALCULATION DATA FILES REVISED:(Name ext / size /date/ hour: min / verification method / remarks)
DO ANY ASSUMPTIONS IN THIS CALCULATION REQUIRE LATER VERIFICATION YESNO
REVIEWED BY: DATE:
REVIEW METHOD: COMMENTS (C OR NC):
APPROVED BY: DATE:
ELECTRONIC CALCULATION DATA FILES REVISED:)(Name ext / size /date/ hour; min / verification method / remarks)j
)DO ANY ASSUMPTIONS IN THIS CALCULATION REQUIRE LATER VERIFICATION YESNO
l
)REVIEWED BY: DATE:
iREVIEW METHOD: COMMENTS (C OR NC):. {APPROVED BY: DATE:
REVIEWED BY: DATE:
REVIEW METHOD: COMMENTS (C OR NC):.
APPROVED BY: DATE:
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Exhibit C4 NEP-12-02
Revision 1-
COMMONWEALTH EDISON COMPANYCALCULATION TABLE OF CONTENTS
PROJECT NO.CALCULATION NO.NED-P-MSD-090 REV. NO. O PAGE NO. 3DESCRIPTION PAGE NO. SUB PAGE NO.
TITLE PAGE I
IREVISION SUMMARY 2
TABLE OF CONTENTS 3
PURPOSE / OBJECTIVE 4
METHODOLOGY ANDACCEPTANCE CRITERIA 4-5
ASSUMPTIONS 5
DESIGN INPUT 6-9
REFERENCES 9-10
CALCULATIONS 11-18
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SUMMARY AND CONCLUSIONS 18
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ATTACHMENTSA LMT UT Test Report 02AS-S4 8 pages
B NDIT SO40-QH-0264-00 2 pagesi D IGSCC Growth 6 pages
The purpose of this calculation is to evaluate the flaw detected in weld 02AS-S4 onQuad Cities Unit 1 Recirculation A loop pump suction line. This flaw was found,
during the augmented IGSCC inspection program, which is based on NRC GL-88-01. The flaw exceeded the applicable acceptance standards for austenitic steelsdelineated in IWB-3514 of the 1989 ASME Section XI Code, Reference 1, and isevaluated using the methodology and acceptance criteria specified in Reference 1,IWB-3640, to establish its acceptance for continued service.
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Methodology and Acceptance Criteria:
The piping report, Reference 4, identifies the material used for the piping containingthe flaws as SA403 WP304 austenitic stainless steel. Therefore, the evaluation andacceptance requirements of IWB-3640 are applicable to the evaluation of this flaw.The rules of IWB-3641 of ASME Section XI,1989 Edition are applicable becausethe following conditions are met:
(a) Piping / fitting NPS 2 4 with the flaw within Vit of the weld.
(b) Piping / fitting materials are made of wrought stainless steel, Ni-Cr-Fe alloy.'
(c) Materials have a specified minimum yield strength less tha'n 45 ksi.
(d) Material S values are given in Table 1-1.2 of Section lil,1989 Edition. <
As required in IWB-3641 of Reference 1, flaw growth analyses are performed onthe flaw to determine the maximum growth due to fatigue and stress corrosioncracking mechanisms for an evaluation period of at least four (4) operating years(35040 hours). The calculated maximum f aw dimension at the end of theevaluation period is compared with the calculated maximum allowable flawdimensions for both normal operating / upset conditions and emergency / faultedconditions to determine the acceptability for continued service.
REVISION 0
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COMMONWEALTH EDISON COMPANY*
CALCULATION NO. NED-P-MSD-090 PAGE NO. 5
The flaw growth analyses are performed for fatigue crack growth following the |
n:ethodology of Reference 1 Appendix C and for IGSCC following the methodology l
of NUREG-0313, Reference 6. The fatigue crack growth is based on the |normal / upset operating events expected to occur during the evaluation period with !
the transient definition and transient stresses developed for Dresden Unit 3Recirculation system used in this evaluation. The IGSCC crack growth rate isdeveloped using the residual stress distribution and operating loads with the da/dtrelationship defined in Appendix A of Reference 6. The evaluation period for the
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flaw growth analyses was determined as the time necessary for the flaw depth to |grow to approximately the IWB-3640 acceptable depth limit.
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The bounding normal / upset and emergency / faulted design basis load combinationsare used to define the applied stress values used in this evaluation. Thesebounding applied stress values are used to establish the acceptable crack size ;
which must be greater than the end of evaluation flaw size. Because these flaws iare located adjacent or within the weld material as defined in Figure IWB-3641-1 of '
Reference 1, the critical flaw size h defined using the criteria for a submerged arc lweld, SAW. |
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IAssumptions:
1) Quad Cities Unit 1 and Dresden Unit 3 recirculation system pressure and thermal Itransient responses to normagupset transient events are identical. This is a lreasonable assumption because both units are fabricated from materials with '
identical material properties for thermal expansion and from identical fittinggeometries, and are operated using similar procedures.
2) The welding process used to fabricate this weld is conservatively defined asSAW, submerged arc weld.
3) Five startup/ shutdown events were assumed to occur during the evaluationperiod with a single idle loop restart occurring between each startup andshutdown. While this places some limitation on operation over the next fuelcycle, the fatigue crack growth studies show that fatigue crack growth is minimal.Thus, this limitation can be reevaluated if the 5 cycle limit is approached.
REVISION 0
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COMMONWEALTH EDISON COMPANY'
CALCULATION NO. NED-P-MSD-090 PAGE NO. 6
Design input:
Flaw Characterization:
Weld 02AS-S4 (Reference 3) contains the following circumferentially oriented flaw inthe 28" OD pipe to elbow weld of the loop A recirculation pump suction. A cross-section of this weld is provided in Figure 1.
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IFlaw Depth Length Circumferential LocationNo. Clockwise from Top
1 0.206" 1.25" 11.75"
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This flaw is located on the elbow side of the weld and is ID connected. Themeasured wall thickness is 1.27" at the location of the flaw.
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REVISION O
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CALCULATION NO. NED-P-MSD-090 PAGE NO. 7
Flaure 1 Weld 02AS-S4
OD 28.0"| t=1.27"
Flaw Depth.=0.206"|
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N 11.75"I'
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1.25" '
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! REVISION O
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COMMONWEALTH EDISON COMPANY;
CALCULATION NO. NED-P-MSD-090 PAGE NO. 8'
Loading :
Input dat? for the piping beam type loads is provided in Reference 5. The loadsprovir'ad are leadweight (WT), thermal and OBE seismic (OBE). In accordance withthe C.'.iad Citi as FSAR, SSE is twice OBE. The loads provided are the axial force andbending mor,ients at the weld. Input data for pressure and temperature are taken fromthe Clns 1 piping calculations for Dresden Unit 3, Reference 7.
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iWeld 02AS-S4 Looo A Recirculation Pumo Suction- I
Maximum Temperature = 550*F Maximum Pressure = 1000 psig
Fa (lbf) Mb (ft-lbf) Mc (ft-Ibf)
Weight 6463 -1395 -8306
Thermal 4585 15183 100606
OBE 6672 10580 1562
Fatigue Load Definition:
The normal / upset design basis transient events are defined in Reference 7 for this line.The thermal gradients defined for this line are zero except for the restart of an idlerecirculation loop. Using an as welded butt weld, the Reference 7 thermal transienttemperatures for this event is:
AT (*F) ATa(*F) T.(*F) T6(*F) ;i
Restart -44.75 -27.01 Note 1 Note 1
Note 1: This is not a gross structural discontinuity, therefore the T. and To terms are not considered.
REVISION O
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COMMONWEALTH EDISON COMPANY-
CALCULATION NO. NED-P-MSD-090 PAGE NO. 9
Materials:1
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As defined in Reference 3, the flaw is located on the elbow side of the weld. Thematerial for this fitting is SA403, WP304. From Reference 2, S for this materialism
2conservatively defined as 16,900 lbs/in at 550 F. The following material propertiesat 500 F are used in the evaluations:
E = 25.8 x 10' psi4a = 9.4 x 10 in/in/ F
v = 0.3
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The use of E and a at 500 F (vs. 534 or 550 F) will not affect the conclusions reached'
Piping Membrane and Bending Stress for Crack Growth of the Loop A RecirculationPump Suction Weld 02AS-S4:
Normal and Upset Conditions:
P mn ;* 8 Pn + 8 Wm + 8 Tm P mn = 5511.8 * psi|
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P bn :: 8 Wb + 8 Tb P bn = 1938.8 * psil
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For Fatigue and IGSCC Crack Growth the total Membrane plus Bending stress is used as a membrane stressfor conservatism: )
P mn + P bn = 7450.6 * psi
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Axial Residual Stress Through Wall Distribution for the Loop A Recirculation PumpSuction Weld 02AS-S4:
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!Residual Stress Through Wall Distribution per NRC NUREG-0313 Rev 2 to be used for the crack |growth calculations: )
o o := 1.0 o | := 30000.0 psi |
c 1 := -6.910
e 2 := 8.687 ,
1
|e 3 := -0.480
c 4 := -2.027
o R(x) := a g. a g + c j-(x) + e 2-(x)2 + 8 3-(x)3 + e 4-(x)d'
x := 0.0. 0.1.1.0 This is the through wall ratio x/t
REVISION O
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COMMONWEALTH EDISON COMPANYJ,
CALCULATION NO. NED-P-MSD-090 PAGE NO.15.
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43 10
R(x)42.5 10
x psi
2*10" T 30000
\ U 11555.54
1.5 10 U -1245.1) U -9616.5
4 (10 U -13700.7
\0R(*I \ / U -14098.1
\ [ ' U -11551.5P88
\ / U -6950.5~
0 ' U -1330.2 ,
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U 4129.1-5000
d-1*10
\ /d
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-1.5 10|
#-2 100 0.1 s.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
(b)Axial Residual Stress Distribution
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|GSCC Crack Growth Calculation for the Loop Recirculation Pump Suction Weld02AS-S4: ;
The crack growth due to IGSCC is calculated using the previously calculated residual stress and thecombined pressure, weight and thermal stresses acting on the present flaw depth of 0.206" for a 3600 l
circumferential flaw. The crack growth rate, daldt = 3.590 x 10 K,2.1st in/ hour, specifed in NUREG-0313,4
Reference 6, was used to project the flaw depth. The calculations, documented in Attachment C, wereperformed using the PC-CRACK program, Reference 8.
After 44000 hours, the flaw grows from 0.206" to a depth of 0.712" as a result of stress corrosion crack growth ,
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which produces an all ratio of 0.561, As recommended in NUREG-0313, Reference 6, the flaw icngth isprojected by increasing the ori inal aspect ratio, lla, by the factor that the depth has increased to calculate the0projected aspect ratio. The fisw lengths for the two flaws are projected below.
1 1 a jfa 1 := 0.206.in i 1 := 1.2 Sin a jf := 0.712 in I jf:= q ,1 1 jf 1 jf = RN
The flaw is projected to be a jf = 0.712*in in depth and I jf = 14.9'in in length.
The projected flew length to circumference ratio is:
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I if= 0.17
Fatigue Crack Growth Calculation for the Loop A Recirculation Pump Suction Weld;
02AS-S4: i<
|The fatigue crack growth is calculated using the provously calculated thermal transient stress, the residual
istress and the combined pressure, weight and thermal stresses The range sets defined for this evaluation
]include 5 startup and shutdown events with 1 idle loop restart event occurring during each startup and shutdown '
cycle. The fatigue crack growth was calculated using the PC-CRACK program, Reference 8, and the fatiguecrack growth rate specified in Appendix C of Reference 1. The fatigue crack growth was based a 3600 1
circumferential flaw model with two initial crack depths. The projected end of evaluation period flaw depth of0.712" and the current fisw depth of 0.206" to establish the bounding fatigue crack growth condition. These
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calculations are documented in Attachment D. 1
A review of these evaluatens shows that the fatigue crack growth for both initial flaw depths is insignificant andtherefore does not contnbute to the final end of evaluation period flaw size.
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ASME Section XI Acceptance Criteria for the Loop A Recirculation Pump Suction ,
Wold 02AS-S4: l
After 44000 operating hours (5 years) the fisw size has been projected to be a maximum 0.712" in depth for17% of the circumference of the weld.
The following calculations determine the code acceptable flaw size for the bounding normal / upset loadcombinaten and the bounding emergency / faulted load combination
REVISION O
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COMMONWEALTH EDISON COMPANY !~ t
CALCULATION NO. NED-P-MSD-090 PAGE NO.17 |.
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Table IWB-3641-5 For Submerged Arc Wolds (SAW), Applied Stress Ratio:1
Piping Membrane Stress for the Loop A Recirculation Pump Suction Weld 02AS-S4:
1
Normal and Upset Conditions:
P mn : 8 Pn + 8 Wm + 8 OBEm + 8 Tm P mn = 5574.4 * psi
Emergency and Faulted Conditions:
P mf ;* 8 Pf + 8 Wm + 8 SSEm + 8 Tm P mf = 5G36.9 * psi
Piping Bending Stress Loop A Recirculation Pump Suction Weld 02AS-S4:
Normal and Upset Conditions:
P bn : 8 Wb + 8 OBEb P bn = 336.4 * psi
Emergency and Faulted Conditions:
P bf 8 Wb + a SSEb P bf = 524.6 psi
Thermal Expansion Stress:
P , := a Tb P , = 1790.5 * psi
|Applied Stress Ratio in SAWS for the Normal / Upset Condition per Table IWB-3641-5:
fD \oM := 1.08 + 0.0091 - 24 l M = 1,116
Y" )
P,P mn + P bn + 3
SR n := M. SR n = 0.4333 m
REVISION O4
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COMMONWEALTH EDISON COMPANY.
CALCULATION NO. NED-P-MSD-090 PAGE NO.18
From Table IWB-3641-5, the acceptable alt ratio for a flaw length less than 20% of the circumference and an :
applied stress ratio of 0.60 or less is 0.60, therefore the acceptable fisw depth, a , for the normal / upset 1
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conditions is
a nc := 0.60-t n a nc = 0.762 *in
which is greater than the projected and of evaluation period flaw depth of a jf = 0.712 in
Applied Stress Ratio in SAWS for the Emergency / Faulted Condition per Table IWB-3641-6:
PeP mg + P bf + 3
SR g := M. SR g = 0.492Sm
From Table IWB-3641-6, the acceptable alt ratio for a flew length less than 20% of the circumference and an |
applied stress ratio of 1.2 or less is 0.60, therefore the acceptable flaw depth, ag, for the emergency / faulted
conditions is the same as the normal / upset condition. Therefore, the acceptable flaw depth for the end ofevaluation period flaw length of
1 jf = 14.9*in is a nc = 0.762 *in
which is greate.' than the projected and of evaluation period flaw depth of a jf = 0.712 in i
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Summary and Conclusions:
The evaluation for the multiple flaws found in the 02AS-S4 weld of the Loop A Recirculation Pump suction line esacceptable for 44000 hours of hot operating time. This evaluation was performed using methodology andacceptance criteria of IWB-3640 of the ASME B&PV Code, Sechon XI, Reference 1. The end of evaluationperiod flaw sizes considered crack growth from IGSCC and fatigue mechanisms, and calculated the IGSCCgrowth as speedied in NUREG-0313, Reference 6. The end of evaluation period flaw depths were shown to beless than the acceptable flaw depth as defined by rid-3641 of Reference 1.
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REVISION O (FINAL) (o2As-s4.uco)
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Comed*
Pig) 18 ef 20.Proccduro No. HDT-C-2 R:v. 22 S:rptemb;r, 1995
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ULTRASONIC CALIBRATICN FORM HDT-CF-C2,
STATION /UtlIT: _1A6 0. t'r t u I QL DA. PACE: / OF f,
| PROCEDURE: HDT- M REV. '2. 2. CALIBTATION SilEET / [*[3D DATE: OL d. % |
EIAMINATION HETil D " *
STRAICilT BEAH: M A AtiCLE BEAHearlal y circumferential _/ l -' [[,2
A. I. Gernhman Proinct Enaineer N [ #a 3*/f 96n, % ._ z. r -,
Status of information: $ Approved for Use UnverifiedO snoin.oring audoom.nt
Method and Schedule of Verification for Unverified NDITs:
Description of Information:
Anforence: ABB Reactor Recirculation Piping Report Q1-RRCI 01C, Rev 14, transferredto S&L on 06-09-93, filed under RMD-067693, Rev. 00
1. Per your request, this HDIT transmits the forces and moments on the Loop A RPV suctionassale (between the pipe and the nossle safe end) from the above reference.
N.P. 510 (loads in LBS, moments in FT IAS)
14 cal Coordinates Used (F.= Axial Force with positive force indicating compression.F,o Vortical Force, %s Torsional Moment, %= Vertical Moment)
is Normal operation w/RWCU in service; 1H 2 is Normal Operation w/o RWCU in service;TN 1TN 3 is Shutdown of RR line w/R98CU; ohE is the maximaam of (X+Y) or (E+Y)
Purprse of issuance:To transmit forces and moments at NPs $10 and CA1B on the RR Piping
Source of information:s m above reference Att*chment a
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Distribution: NED-P-MSD-090g,,, ion o
| NEDCC CHRON DG A. I. Gers % - 23 33| R. C. Lindberg - QUA D. Bianc! ud - 23
ProiIct No, ioo04-o01 File No.: a/A CHRON No.: N/A
2. Per your request, this NDIT also transmits the forces and acaents on the elbowend (located on the riser) of the first elbow off the Loop A RPV suctionnozzle fr a the above reference,
u.P. cAin (loade in Las, moments in FT-Las)
Loc 1 Coordinates Used (F,= Vertical Axial Force with positive force indicatingccepression, F.&F,a Horizontal Forces, %= Vertical Torsional Moment, %&%s HorizontalMoments)
TH 1 is Normal Operation w/RWCU in service; TH 2 is Normal Operaticm2 w/o RWCD in service;TH 3 is Shutdown of RR line w/ANCUs CBE is the maximum of (X+Y) or (z+Y)3. Par your request this NDIT also transmits the following infor1mation: l
)1Pipe and nossle material: A358 304
Pipe geometry: D.= 2 0 . 0 0 * t,=1. 203 ' i
|Nassle safe end geometry: D,=2 8 . 375 " t =1.223 "Maximum Operating Temperature: T,=54 6 ' F
Anschment 8
NEIM-MSD490Revision 082 Final
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pc-CRACK(C) COPYRIGHT 1984, 1990
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STRUCTURAL INTEGRITY ASSOCIATES, INC.|SAN JOSE, CA (408)978-8200
VERSION 2.1 :I
i Date: 1-Mar-1996Time: 11:53:17.83
LEAST SQUARE CURVE FIT OF STRESS PROFILE !
02BS-S12 RESIDUAL
TERM COEFFICIENTCO 3.045E+01C1 -1.780E+02 l'
C2 2.154E+02C3 -6.963E+01
COEFFICIENT OF DETERMINATION R^2= 0.9991CORRELATION COEFFICIENT = 0.9983
X VALUE Y VALUE Y CALC DIFF0.000E+00 3.000E401 3.045E+01 -4.531E-011.250E-01 1.190E+01 1.143E+01 4.706E-012.500E-01 -1.250E+00 -1.678E+00 4.277E-013.750E-01 -9.620E+00 -9.684E+00 6.425E-025.000E-01 -1.370E+01 -1.341E+01 -2.937E-016.250E-01 -1.410E+01 -1.366E+01 -4.401E-017.500E-01 -1.155E+01 -1.126E+01 -2.891E-018.750E-01 -6.950E+00 -7.025E+00 7.540E-021.000E+00 -1.330E+00 -1.769E+00 4.394E-011.125E+00 4.130E+00 3.691E+00 4.389E-011.250E+00 8.100E+00 8.540E+00 -4.401E-01