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I 1 M P R ASSOCIATES, INC.
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GPU MUCLEAR CORPORATION
OYSTER CREEK NUCLEAR GENERATING STATION *
TORUS SHELL THICKNESS MARGIN MPR-953
Prepared for GPU Nuclear Corporation Parsippany, New Jersey
October 1986
WASHINGTON. D.C. 20036
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202-659-2320
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M P R ASSOC~ATES. INC.
CONTENTS
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Page Sect? on
1.
2.
3 .
4.
5 .
INTRODUCTION
1.1 Purpose
1,2 Background
1.3 Scope
SUMMARY
Df scu ss ION 3.1 Stress Margin
3.2 Other Sources of Margin
3.3 1983 Inspections and Repair
REFERENCES
APPENDICES
Appendix A - Stress Margin.
Appendix B - Other Sources o f Margin
Appendix C - 1983 Inspec t ion Reports
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M P R ASSOCiATES INC.
Section 1
I NTRODUCTlON
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1.1 PURPOSE
This report presents the results o f analyses to determine the margin i n the thickness o f the Oyster Creek torus shell. The torus she71 thickness margin is determined i n order t o determine t h e corrosion allowance for the inside and outside surfaces of the torus shell.
1 . 2 BACKGROUND
In accordance w i t h the requirements of NUREG-0661, "Safety Eva1 uation Report, Mark I Containment tong-Term Program," the Oyster Creek torus was reanalyzed f o r newly defined loads for postulated p lan t accidents and transients. these analyses, plant modifications were designed and installed i n 1983 t o reinforce the existing torus structure. straps and midbay saddles,
As a result o f
These modifications included she? J hoop
As part o f these modi f ica t ions , the original coatings on the inside and outside surfaces o f the torus shell were removed. revealed pitting corrosion on the inside surface o f the shell below the water line. Repair criteria were established which defined an acceptable ef fec t ive metal toss due t o corrosion based OR Mark I Program stress analysis resufts. Corroded areas not meeting the cri teria were repaired by weld overlay.
Inspections o f the torus she?? in 1983
After installation of the torus structural modifications and weld repafr, the inside surface of the torus shell was recoated with a protective coating. No
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coating was appl ied to the outside surface o f the torus shell. Material Nonconformance Report (MNCR), Reference (I), identified general corrosjon
In 1986, a
on the outside surface of the torus shell. Accordingly, wall thickness measurements were taken t o determine the metal loss due to the observed corrosion, and analyses were performed t o determine a corrosion allowance for the torus she1 I .
1.3 SCOPE
The scope o f this repor t i s t o document t h e basis for margin in the torus shell thickness which may be considered as a corrosion allowance, This scope includes:
Review o f Mark 1 Containment torus stress analysis results t o determine the minimum thickness f o r which the torus shell would meet ASME Code allowable stress values. This inctudes formally documenting the analyses and corrosjon a1 lowance criterfa used.
Review o f the manufacturers' material certificates t o determine actual p l a t e thickness and strength.
Determination o f underthickness tolerance permi t ted by the ASME Code.
Review of the 1983 GPUN torus inspection reports to determine the maximum depths of pftting corrosion which. were not weld repaired.
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Section 2
SUMMARY
Torus she1 1 thickness margins have been determined based on calculated stresses, actual materi a7 properties, actual plate thicknesses, and ASME Code pemftted undertolerance. Results are presented in Table 2-1, Also t abu la t ed in Table 2-1 are t h e maximum corros'ion depths l e f t i n the torus shell following the 1983 inspections and repairs.
As shown in Table 2-1, the calculated stress margin exceeds the maximum corrosion depth lef t in the torus shell f o r a71 regions o f the torus. The difference between the stress margin and maximum corrosion depth can be considered a s ' a corrosion allowance. The mater1 a? property and ASME Code permitted undertolerance margins could be used to j u s t i f y add i t iona l corrosion allowance i f needed,
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TORUS SHELL LOCATION
Torus Shell Thickness Margin (inch) haximua Depth of Cormsion
Material Pmaertv Plate Thickness ~%%$ Left in TONS Shell After Stress Margin Mkgl.6 . Margin Undertolerance 1983 Repairs
General Shell 0.060 0.013 0 0.010 0.040
Adjacent to Ring Girder
0.013 1/ Within 1" o f SRV
Within 1" o f NcnSRV
Between 1-8" Away
Sqiporting R i n g Girders 0.061-
Supporting Ring Girders 0,076' 0 . a ~
From A l l Ring Girders 0.103 0,013
0 0 .a10
0 0.010
0 0.010
0.050
0.ow
0.040
Adjacent t o Saddle Flange
Within I" of Saddle f lmge
Between 1-8" Away From Saddle flange
0.W
0.151
0.013 0 0.010 0.035
0.013 0 0.010 0.040
Adjacent to oru us Straps within 1" o f Straps 0.057 0.013 0 0.010 0.U4D
Remainin Portion of setween Straps 0.060 0.013 0 0.010 0 . M
A' This m a r in applies to ring gfhkrs w i t h center SRV supports attached, which am more hi ly loaded than all other SRV sup ortin ring glrgers. This margin is mservatively considered here ko apply to ring girders wi P h sliding or rigid SRV suppoxts a&ache!.
g' This is the margin for ri girders with rigid SRV supports. This m a r in iS mnservetively considered hem to apply t o non-SRV supporting ring girders, 3nce nan-SRV supporting ring girders are loa ? ed less than SW suworting ring girders.
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M PI? ASSOCIATES. INC.
Section 3
DISCUSSION
3.1 STRESS MARGIN
. Structural reanalyses o f the Oyster Creek torus were performed i n 1982 t o demonstrate that the torus met the stress analysis criteria o f the Mark I Containment Long-Term Program, Results o f these reanalyses are documented i n References (2 ) and ( 3 ) .
A plan view o f the Oyster Creek torus i s shown in Figure 3-1. Preliminary analyses o f the torus identified the need for reinforcement o f t he lower half o f t h e shell. As a result, hoop straps and a mid-bay saddte, shown l’n Ffgure 2-2, were added t o the torus. Final analyses included the e f f e c t s of the structural modifications.
Using t h e stress analysis results o f the Mark I Containment Long-Term Program, ca7culattons were performed to determine the minimum she31 thickness required to meet applicable ASME Code allowable stress values. are contained i n Appendix A and tabulated i n Table 2-1. determined for the general shell and for the she77 near discontinuities such as the ring gjrder, saddle flange, and hoop straps, difference between nominal shell thickness and the minimum required thickness.
Results o f these calculations Stress margins were
Stress margin is defined as the
3 . 2 OTHER SOURCES OF MARGIN
Three other potential sources o f shell thickness margin were considered, are :
These
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' Material property margfn
Plate thickness margin
ASME Code permitted undertolerance
An evaluation of these additional sources o f margin was performed and i s contained i n Appendix B and tabulated i n Table 2-1.. Results o f these evaluations are summarized 'as follows: .
The m i n i m u m tensile strength o f the plates used i n the Oyster Creek torus is 75 ksi compared t o a rnln.lmum specified tensile strength o f 70 k s i for the A212 Grade B material. AssumSng the allowable stress i s proportional t o the materia? strength, thSs excess material strength .Is equivalent to a shell thickness margln o f 0.013".
Spot measurements of actual p l a t e thickness show it t o be only s l igh t ly greater t h a n nominal, thickness.
Paragraph N€-2124(b) o f the ASME Code (Reference ( 4 ) ) permits an undertolerance equal t o the lesser o f 6 percent o f the ordered thickness o r O.OIOil, Q.0109' i s cont ro l l ing . This ASME Code permi t ted undertolerance may be considered t o be a source o f additional thickness margin.
* No additional margin can be attrfbuted t o actual plate
For the Oyster Creek torus shell with a nominal thickness o f O.385lf, .
3.3 1983 INSPECTIONS AND REPAIR
In 1983 the entire inside and outside surfaces o f the torus shell were cleaned t o bare metal and visually inspected. The inspections revealed p i t t i n g corrosion on the inside surface o f the shell below the waterline, observed on the port ion of the shell above the waterline.
No visible corrosion was
The corroded areas and depths o f corrosion were documented f o r each bay (see Appendix C). Repair cr i ter ia were developed t o provide a mfnimum of 0.020" margfn based on Mark I program stress analysis results. potential sources of margln, e.g., actual material properties o f the plate, actual plate thickness, and permissible ASME Code undertolerance on plate thickeness.
No credit was taken f o r other
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The repair criteria were as follows:
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Torus Shell Region Acceptable Metal Loss
Due t o Pittinq C o r n x i o n (Inch)
1, General. Shell 0.040
2. Near Ring Girder
a. b.
Within 1” o f Rfng Glrder 11g-8t1 Away From Ring Girder
3. Near Saddle Weld
a. Nithin 1” o f Weld b, 1*’-8’f Away From Weld
0.050 0.080
0.035 0.090
Weld repajr was performed i f the average e f f e c t i v e metal ?oss due t o pitting corrosion exceeded the above depths. Thus, the above meta l losses represent the
maximum metal losses that may have been left in the torus shell following the 1983 inspections and repairs
3-3
FIGURE 3-1
PLAN VIEW UY STER CREEK' TORUS
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1 \ HOOP STRAP \ YRiNG
OUTER SUPPQ .COLUMN
FIGURE 3-2 ELEVATlON VlEW
TORUS SHELL AND HOOP STRAPS
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I Section 4
REFERENCES
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4.
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GPU Nuclear Corpora t i on Materi a1 Nonconformance Report Number 86-285 dated June 17, 1986.
MPR report MPR-718, "Oyster Creek Nuclear Generating Stat ion - Mark I Contaiment Long-Term Program - Analysfs o f Torus Shell" dated August 1982.
MPR report MPR-722, ''Oyster Creek Nuclear Generating Stat ion - Mark I Containment Long-Term Program - PI ant Unique Analysis Supplemental Report'' dated July 1983.
American Society o f Mechanical Engineers, ASFIE Boiler and Pressure Vessel Code, Section 111, Rules for Construction o f Nuc7ear Power Plan t Components, Divis ion 1. 1977 Edit ion w i t h Addenda through Summer 1977.
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M P R ASSOCIATES. !NC.
1
Section 5
AP P ENOX CES
Appendix A - Stress Margin
Appendix B - Other Sources o f Margin Appendix C - ,1983 Inspection Reports
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M P R ASSOCIATES. INC.
APPENDIX A
Stress Margin
PURPOSE
The purpose of t h i s appendix i s t o determine the thickness margin i n the Oyster Creek torus shell based an stress.
DISCUSSION
Torus shell stresses were evaluated as part o f the Mark I Containment Long-term Program f o r Oyster Creek (Reference (1)). p l a n t unique load combinatSons as defined i n Reference (2 ) . The results o f t h e stress analyses are contained in References (3) and (4) and are summarized i n Table A-I . exists i n the 0.385" [nominal) thick she11 is as follows:
These stresses were calculated for many
The approach t o determining whether a stress margin on thickness
(A) Membrane Stresses
Membrane stresses vary inversely w i t h thfckness. Therefore a ratio o f calculated membrane stress to allowable st ress can be used t o determine the minimum required wall thickness as follows:
1 Minimum Required Wall Thickness I = ( Calculated Mernbr ane Stress Allowable Membrane Stress 0 . 3 a ~
(
Wall thickness margin based on membrane stress i s therefore calculated as follows: .
Margin = 0,385" - Minimum Required Wall Thickness
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.(B) . Bending Stresses
Bending stresses vary inversely w i t h t he square o f the thickness. a ratio of calculated bending stress t o allowable stress can be used t o determine the minimum required wall thickness as follows:
Therefore,
2 1 Calculated Bending Stress
A I 7 owabl e Stress Minimum Required Ma71 Thickness
0.385" I = ( (
Wall thickness margin based on bending stress i s also calculated by subtract- ing the minimum required wall thickness from t h e 0.385" nominal H a l l t h i c k - ness.
T a b l e A - 1 sumnarizes the calculated stresses and allowable stresses for primary membrane stress (Pm), local primary membrane stress (Pl), and primary membrane plus bending stress (Pm + Q or PI j . Q ) , for each region o f t h e torus shell. These calculated and allowable stresses were obtained from the results o f the Mark 1 Containment Long-term Program (Reference (1)) , Also tabulated i n Table A-1 are the torus shell margins based on stress calculated using the equations shown above. For simplicity, the membrane por t ion o f these stresses was conservatively assumed to be pure bending stress.
As shown in Table A-1, t h e thickness margin i n several she77 regions (described below') i s much smaller than i n other regions, documents calculations performed t o reanalyze the stress calculations from
(Note t h a t membrane p l u s bending stresses are listed i n Table A-1.
The remainder of t h i s appendix
Reference (1) to determlne if stresses i n these regions were calculated conser- vatively, and if so, then stresses were recalculated more realist ically. Torus shell thickness margins are t hen determined based on these more r ea l i s t i c calculated stresses.
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The particular areas which were reanalyzed i n th is task are listed below, along w i t h a description of the reanalysis effort:
0 She 1 1 Between Straps
The or ig ina l calculations o f the general primary membrane stress in- tensity i n the shell between straps was reviewed t o determine any sources of conservatism which could be removed t o reduce the stress. One source o f conservatism (Reference (4 ) , p. 20) found i n the original calculation was the use o f safe shutdown earthquake loads t o envelope both operating basis earthquake and safe shutdown earthquake. A second source of conservatism was the algebraic sumnation o f the earthquake results with the tfme dependent loss of coolant accident (LOCA) results (Reference f4), p. A-16) whlch implies the loads are i n phase. A less conservative square root-sum o f squares sumnati an of these dynamic loads i n acceptable, A t h i r d source of conservatism i s the use of an enveloping stress extrapolation factor (Reference (5)).
Additional torus stress analyses performed to remove the conservatisms discussed above are documented i n Reference (61, Section 1 o f t h i s appendix, 5ased on these calculations, the shell between the straps has a thickness margin of 0.060".
Shell a t Saddle Flange Edge
Two sources of conservatism found i n the original evaluation are the use o f a conservative stress extrapolation factor and the absolute summing of LOCA and seismic stresses. Reference (7) , Section 2 o f this appendix, contains further evaluations o f stresses in the she'll a t t he saddle flange I n which these conservatisms were removed. Based on these calculations, the torus shell adjacent t o the saddle flange has a margin o f a t least U.06Ol1 within one inch of t h e saddle flange. Between 1 inch and 8 inches away from the saddle flange the margin is 0.151".
Shell a t Rins Girder
One source o f conservatism i n the original evaluatlon is the use of conservat 5 ve s bress extrapol a t i on factors. Reference ( 8 ) , Sect i on 3 of t h i s appendix, contains further evaluations o f these stress extrapola- t i o n factors at the r ing girder. shell has a margin of 0.06Ii1 with in one inch adjacent t o ring girders wi th Safety Relief Valve (SRV) attached pip ing , and 0.079" within one inch o f r ing girders without attached SRV piping. inches away from the ring girder the margin i s 0.103".
Based on these calculations, the tarus
Between 1 inch and 8
A-3
I I . REFERENCES
{I) MPR-718, "Oyster Creek Nuclear Generating Station Mark I Containment Long-Term Program, Analysis of Torus She1 1," August 1982.
(2) MPR Calculation, "Calcu7ation o f Overall Stresses i n Torus Shell and Comparisons to Allowed Stress," By R.C. Trench, Dated 7/29/82.
(3) MPR Calculation, Yknrnary o f Stresses i n She'll Monftor Elements," By R C. Trench, Dated 7/15/82,
(4) MPR Calculation, "Load Combinations for Evaluation of Torus Shell Using Program TORSHST," by B.R. Bernier, Dated 6/3/82,
(5) MPR Calculations, "SEF f o r Membrane Stress Intensity i n S h e l l Between Straps," by T.E. Greene, Dated 6/17/82.
(6) MPR Calculation, "Torus Shell Thickness Margin i n Shel l 5etween Straps,'# by M.J. Kennedy, Dated 9/26/86.
(7 ) MPR Calculation, "Torus Shell Thickness Margin a t Saddle Flange," by M. J, Kennedy, Dated 9/25/86.
( 8 ) MPR Calculation, "Torus Shell Thickness Margin a t Ring Girder," by M.3. Kennedy, Dated 9/19/86.
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TABLE A-l
Torus Shell Thqckness Margin Calculated Based on Stress L/
Calculated ASME Calculated Allowable Torus Shell
Type o f Service Stress Stress Thickness Margin Location Stress Level (Ksi) (Ks i ) ( i n )
Clean She'll Pm A/B 14.3 19,3 0.100 c 14.4 .35.6 0.229
She1 1 Between Pm A/B 19-1 19.3 0.004 Straps C 19.1 35.6 0.178
Shell at Edge Pm+Q A/B 50-3 69.5 0.057 o f Straps
Shell at T i p Pt A/B 22-2 29.0 0.090 of Straps c 22.2 53.4 0.225
- . .
Shell at Saddle Fl A/B 17.6 . 29-0 0.151 F1 ange C 30.9 53,4 0.162
Pl+Q A/B 57.4 69-5 0,035
Shell at Saddle P I 1 A/B 15.0 29-0 0.186 C . 15.1 53.4 0.276
Pl+Q A/B 24.2 69.5 0.158 Flange Tips
Shell at Ring PI A/B 24.2. 29.0 0.064 Girder c 31.7 53.4 0. I56
Pl+Q A/B 67 ,7 69.5 0.005
Shell at Column P I A/B 15.5 29.0 0.179 Connection C 23.1 53.4 0,218
PI+Q AI8 25.4 69.5 0.171
Shell a t Vent PI A/B 8-4 29.0 0.273 Penetration C 8.4 53.4 0.324
Pl+Q A/B 10-7 69.5 0.234 ~-
Notes
1' Calculated and allowable stresses for each shell region are obtained from Reference 1.
2/ Calculated stresses shown for the shell 'at r i n g girders are for the shell at ring girders without attached piping. Stresses i n the shell near r i n g girders w i t h attached pip ing are considered.separate1y i n Section 3 o f this appendix-
m
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APPENDIX A
Section I
MPR Calculation Entitled "Torus Shell Thickness Margin in Shell Between Straps," by M, J, Kennedy dated September 26, 1986.
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NE3213.10 Locd Primary Membrane Stress. Cas- sn es arise in which a membrane stress produced by pressure or otter mechanical loading and associated wit!! a primary or discontinuity effect produces excessive distortion in the transfer of load to other portions of the structure. Conservatism requires that such a stress be classified as a local primary mem- brane stress even though it has some characteristics of
r -
the minimum miburface radius of curvature and t is the minimum thickness in the region considered. Regions of local primary stress integsy involving axisymmetric membrane stress distributions which exceed 1.1 Sw shall not be closer in the m e n m f
Rt, where R is defined as (RI + R2)i2.and r is de med as ( r l +r2)/2, where and f Z are the minimum thicknesses at each of the regions
-.--- T E Z i i a a n 2.5 --7- >.--
considered and R, and Ro are the minimum midsur- face radii of curvature at these region; where the membrane stress intensity exceeds 1.1 S,. Discrete regions of local p n m q membrane stress intensity, such as those resulting from concentrated loads acting on brackets, where the membrane stress intensity exceeds 1.1 S, shall be spaced so that there is no overlapping of the areas in which *e membrane stress intensity exceeds 1.1 S,.
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Project: e3-toCp
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07/10/06 11:41:19
M P R ASSOClATES, INC.
I 1
I
APPENDIX A
Section 3
MPR Calculation Entitled "Torus Shell Thickness Margin a t Ring Girder," by
M, 3, Kennedy dated September 19, 1986.
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MPR ASSOCIATES, INC. to50 Connectlcut Ave.. NW - Washington, DC 20036
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r050 Connectlcut Ave.. NW - Washtngton. DC 20036
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MPR ASSOCIATES, INC. I050 Connecticut Ave., NW - Washington, DC 20036
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v v 7 E .I Gs Calculated by: wj(% Date: 9 1 r ~ l QG
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83- \ob Project:
- - . __ ._ -- - . . . 07/10/06 11:41:19
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I M P R ASSOCIATES, INC.
I I APPENDIX B
Other Sources o f f.,drgi n I !I Contents
MPR Calculation Entitled "Other Sources o f Margin," by M. J. Kennedy dated I September 26, 1986.
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07/10/06 11:41:19
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MPR ASSOCiATES, lNC, 1050 Connecticut Ave., NW - Washington, DC 20036
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1 I I I I I kI-. I I I 1 f I I I I
NE2W
(a) Materid outside the limits of size br thickness given in any specification in Section 11 may be used if the material is in compliance with the other requirements of the specification and no size iimita- tion is given in this Subsection. In those specifications
Material Size Ranges and Tolerances
in which chemical composition or mechanical proper- ties are indicated to vary with size or thickness, any material outside the specification range sMl be required to conform to the composition and rnechani- caI properties shown for the nearest specified range [NA-3766.6(a)(I)J.
(b) Plate material shall be ordered not thinner than the design thickness. Vessels, except for piping, made of plate furnished with an undertolerance of not more -ban the lesser value of 0.01 in. (0.25 mm) or 6% of the. lordered thickness may be used at the f u U design pres- *sure for the thickness ordered. If the specillcation to which the plate is ordered allows a greater undertoler- ance, the ordered thickness of the material shall be sufficiently greater than the design thickness so that the thickness of the material furnished is not more than the lesser of 0.01 in. (0.25 mm) or 6% under the design thickness.
(c) If pipe or tube is ordered by its nominal wall thickness, the manufacturing undertolerance on wall thickness shd1 be taken into account. The manufac- turing undertolerances are given in the several pipe and tube specifications Iisted in the applicable Tabks in Appendix I. After the minimum wdl thickness is determined (NE-3641.1), it shall be increased by an amount sufficient to provide for the manufacturing undertolerance dlowed in the pipe or tube spec- ification.
-
,06(35A) = 4023fA i o ' 0 ,v7;&4* KY &&7M = .d/&
07/10/06 11:41:19
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MPR ASSOCIATES, ifiC. I050 Connecticut AVB.. NW - Washington, OC 20036
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M P R ASSOCIATES. INC. I
APPENDIX C
1983 Inspection Results
GPU Nuclear Corporation f i el d Change Request Number c-015357 dated November 12, 1983
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hal Resolution:
b /p . -- ... . - Q Design Verification I
SECTION V
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