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CHAPTER
35
FUNCTIONALITY AND
OPERABILITY CRITERIA
Stephen R. Gosselin and Guy H. DeBoo
35.1
INTRODUCTION
35.1.1
Objectives
35.1.2
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35.2
MECHANICAL COMPONENTS
AND FAILURE MODES
Typical failure modes for SSCs can be determined from extensive industry experience reported in the Nuclear Plant Reliability
Data System (NPRDS), Licensee Event Reports (LERs), and
other industry studies.
35.2.1
Piping Components
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FIG. 35.1
three safety classes. Over 1/3rd of the failures occurred in nonsafety pipe which are normally not reported to the regulatory
authorities. The Class 1 piping failures are dominated by stress
corrosion cracking in BWR piping and Class 2 piping failures are
primarily associated with vibration fatigue, thermal stratification
and FAC mechanisms. The Class 3 failures are dominated by corrosion mechanisms. In all causes piping reliability is not a function of design safety class; but, is dominated by service loading
and degradation mechanisms not specifically addressed in the
ASME Section III design standards.
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FIG. 35.3 PIPING FAILURE TRENDS IN COMMERCIAL NUCLEAR POWER PLANTS COVERING
THE PERIOD BETWEEN 1970 THROUGH 2007 [38].
FIG. 35.4 U.S. PIPE FAILURE DATA BY DEGRADATION MECHANISMS AND OTHER
CAUSES [36].
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35.2.2
35.2.3
Pumps
Supports
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35.2.4
Valves
35.3
OPERABILITY/FUNCTIONALITY
EVALUATIONS
35.3.1
Conditions requiring functionality evaluations are usually identified through the inservice inspection and testing programs and
augmented inspection programs such as GL 88-01 intergranular
stress-corrosion cracking (IGSCC) and flow-accelerated corrosion
(FAC) inspection programs. Some examples of conditions identified by the inservice inspection and testing programs are wallthinning from an FAC mechanism, snubber failures and pipe or
nozzle cracking from fatigue and IGSCC mechanisms, leakage
exceeding TS limits for valves, and excessive pump vibrations. In
some instances, a system-operating excursion subjects a system
and its components to an unanalyzed condition that requires an
evaluation.
Unanticipated operating events require operability evaluations.
Examples of such events include fluid transients such as
steam/water hammer and steam/vapor bubble collapse; temperature and pressure excursions; and thermal stratification. Flowinduced system vibration from pump operation, cavitation, twophase flow conditions and acoustic pressure waves are known to
lead to snubber wear, piping erosion, and fatigue failure, especially
in socket-welded fittings.
Functionality evaluations are required for temporary loading
conditions such as lead shielding, rigging for maintenance or
modification installation and scaffolding support. The loading to
be considered in conjunction with the temporary loads is dependent on the system operating status while the temporary condition
exists. The seismic load is not considered with the temporary condition if the affected system is declared out of service and the
systems seismic failure does not undermine the ability of other
systems or components to perform their safety functions.
A functionality evaluation is required for as-built/as-found conditions that are not consistent with the design-basis configuration.
Examples of these conditions include support system discrepancies, which might consist of such missing, damaged, or failed
supports as weight supports that slide off their stanchions, a snubber failing to activate and provide the required restraint, or support members found to have missing or undersized welds.
Additional or unwanted restraints, such as snubbers that lock up
or exceed the drag force restrictions, or a support design with
insufficient rotational clearance, are all examples of other supporting system discrepancies.
35.3.2
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analysis;
test or partial test;
operating experience; or
engineering judgment.
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35.4
The ASME B&PV Code Section III [8], Section XI [7], and the
ASME O&M Code [9] all contain requirements directly and indirectly related to the operability of components. The Section III
rules encompass requirements for the design, construction, stamping, and overpressure protection for nuclear plant items. These
rules are for new construction and give consideration to mechanical and thermal stresses caused by cyclic operation; they typically
do not address deterioration that might occur in service because
of radiation effects, corrosion, erosion, or other material degradation mechanisms. The rules of this section are not applicable to
valve operators, controllers, position indicators, pump impellers,
and other nonpressure-retaining items (except for those within the
scope of Subsection NF), as well as motor drives and instruments.
Functional acceptability aspects of some components are not
mentioned in Section III; for other components, a disclaimer
statement is provided. Such a disclaimer is provided for valves,
for example, stating that Code valve design acceptability requirements are not intended to ensure functional adequacy of the
valves. However, rules are provided for pressure-relief valves that
cover set pressure, lift, blowdown, and closure (NX-7000) [8].
The rules of Section XI and the O&M Code, on the other hand,
are more directly related to various aspects of component operability. These Codes define inspection and testing requirements to
identify degraded and nonconforming conditions for SSCs. Each
defines the acceptance criteria and evaluation methods.
The following paragraphs itemize some specific stipulations
applicable to pumps and valves from the O&M Code and vessels
and piping from Section XI. The pumps and valves covered by
these stipulations are components required for the following conditions:
(1) shutting down the reactor to the cold shutdown condition;
(2) maintaining the reactor in a cold shutdown condition; and
(3) mitigating the consequences of an accident.
35.4.1
Valves
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35.4.2
Pumps
35.4.3
Snubbers
35.4.4
Piping
The rules of Section XI [7] define requirements for the evaluation and acceptance of degraded piping components. These
requirements have been developed for piping that is flawed or
degraded from a corrosion mechanism and are used to demonstrate the piping fitness for service when subjected to design-basis
loads. (More detailed information regarding the flaw evaluation
requirements for piping is found in Chapter 29 of this book.) For
the specific case of through-wall flaws in Class 3 moderate-energy piping in which the maximum operating temperature does not
exceed 200F and the maximum operating pressure does not
exceed 250 psig, Code Case N-513 [25] specifies flaw evaluation
methods and acceptance criteria to justify the temporary acceptance of this condition. The USNRC has approved the use of this
Code Case in the revision of 10CRF50.55a [11].
35.4.5
Reactor Vessel
The rules of Section XI [7] define requirements for the evaluation and acceptance of flaws and radiation embrittlement the reactor vessel. These requirements are used to demonstrate the vessels fitness for service when it is subject to design-basis loads.
(More detailed information regarding flaw evaluation requirements is found in Section 29.) Appendix E of Section XI Code [7]
provides evaluation methods and acceptance criteria for the reactor vessel when it is subject to pressure in excess of the pressuretemperature limits required by 10CFR50.60 and Appendix G of
10CFR50 [11]. Meeting the requirements of this appendix ensures
adequate structural integrity for returning the vessel to service.
The Appendix E evaluation method reduces some of the margins
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FIG. 35.8
such vessel pressure-temperature limits do not have this additional margin for their structural integrity assessments.
35.5
OPERABILITY EVALUATION
METHODS
PUMP VIBRATION LIMITS (Source: Fig. ISTB-5200-1 of the ASME O&M Code)
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FIG. 35.9 LOWERBOUND KLA AND KLC TEST DATA REACTOR VESSELS (Source: Fig. A-4200-1, Appendix A of the ASME
B&PV Code)
35.5.1
Piping Systems
other building-filtered loads evaluated by response spectra methods. Section III, Appendix N [8] provides detailed descriptions of
these alternative, more rigorous methods that may be used to
determine system responses to seismic and other building-filtered
dynamic loads. Also, the combination of dynamic loading
responses from different events permits the use of the square
rootsum-of-the-squares method. This combination method is justified when the predominant frequencies of the events being combined are sufficiently separated to make the probability of simultaneous maximum responses for each event very unlikely [6].
Finally, the load cases used in the evaluation should be consistentwith and limitedthose loads that can realistically occur
during the period of operation when the piping system is in the
degraded or nonconforming condition.
35.5.2
Supports
35.5.3
Valves
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35.5.4
Items (1) and (2) of the preceding list use the loads for their
respective nozzles. Items (3)(6), however, use the combined
effects of weight, dynamic inertia, operational loads (e.g., as
motor torque in a pump), and all nozzles.
In many cases, particularly on Class 2 and 3 vessels, item (2) is
the limiting component; for this item, the local stress analysis of
the shell should be reviewed. Such analyses are typically done
using the methods of WRC Bulletin 107 [21] and WRC Bulletin
297 [22]methods for which vendors occasionally use the total
through-wall stress (i.e., membrane bending, or using WRC
Bulletin 107 terminology N, membrane force terms M, and
bending moment terms) when comparing the nozzle stress to the
primary local membrane allowable, rather than just the membrane
(N, terms) component. For Service Level D conditions, local membrane effects should be checked in the shell at the shell nozzle junction, but not local membrane plus local bending (PL Pb Q).
The requirements for local checks are taken directly from
Appendix F of the ASME Boiler and Pressure Vessel Code [8].
35.5.5
Specific Inspections
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35.6
B1
(35.2)
Pmax 2Pa
(35.3)
(M A + M D)
PmaxD
+ B2
6 2Sy
2t
Z
Pmax 2Pa
(35.4)
(35.5)
(35.6)
MA
PD
+ 0.75i
6 Sy
4t
Z
MA
PD
+ B2
6 the greater of 1.5Sm or Sy
2t
Z
SHORT-TERM OPERABILITY
ACCEPTANCE CRITERIA
The acceptance criteria presented here are currently being considered by the ASME Section XI Task Group on Operability for
publication as a Code Case [18]. These proposed criteria are
based on industry evaluations of the margins present in the analytical methods and also in the acceptance criteria used for design of
the SSC. For example, for piping systems these industry investigations have lead to alternative evaluation methods and acceptance criteria for seismic and other building-filtered loads during
normal and upset conditions.
The development of the criteria provided here was based on
ASME Section III, Appendix F [8] criteria and is augmented with
industry testing programs for application to specific piping system
components.
35.6.1
B1
MA
PD
+ B2
6 the greater of 1.5 Sh or Sy
2t
Z
(35.7)
(M A + M D)
PmaxD
+ B2
6 greater of 3 Sh or 2Sy
2t
Z
Pmax 2Pa
(35.8)
(35.9)
35.6.2
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35.6.2.1 Component Standard Supports. Component standard supports are supplied by support manufacturers with defined
load capacities. The following criteria will be used to determine
the operability of these components when they are subject to
Service Level D/faulted condition loads as defined in Table 35.1.
(a) The manufacturers ultimate tested load divided by a safety
factor of 1.5 except for the side load on U-bolts, which
should be 3.0. In determining this limit, the allowable
should be modified by the temperature effects on the material ultimate strength.
(b) The manufacturers allowable load for Service Level D.
(c) The manufacturers allowable load for Service Level A multiplied by either of the following:
(i) the lesser of 2 or 1.167 (Su /Sy) when Su 7 1.2 Sy or
(ii) 1.4 when Su 6 1.2Sy.
If the criteria in the preceding list cannot be met, the criteria in
the paragraphs that follow for linear-type supports can be used to
demonstrate the operability of the standard component.
35.6.2.2 Linear-Type Supports. For linear-type supports,
ASME Section III, Appendix F, paragraph F-1334 [8] provides the
basis for the operability criteria. The following limits summarize
the criteria of this subparagraph, although not all of the criteria
specified in this subparagraph are presented here.
For Tension Stress, Ft min(1.2Sy, 0.7Su) except at pinholes,
which use min(0.9Sy, 0.5Su).
For Shear Stress, Fv min(0.72Sy, 0.42Su).
For Bending Stress, Fb (f ) Sy for compact sections where
(f ) the plastic shape factor. For noncompact sections, see
Appendix F, paragraph F-1334.4(c) [8].
For Compression, Fa min(Ft, 0.67Scr).
For Combined Axial Tension and Bending, the stress of members
subjected to both axial tension and bending must be proportioned to
satisfy the requirements of equation (35.10), which follows.
fby
fa
fbx
+
+
1
Fa
Fbx
Fby
(35.10)
Where
Fa the smaller of 1.2Sy or 0.7Su
For Combined Axial Compression and Bending, the stresses of
members subjected to both axial compression and bending must
be proportioned to satisfy the requirements of equations (20),
(21), and (22) of ASME Section III, NF-3322.1(e)(1) [8]. The
NF-3322.1(e)(1) equations are modified to use the Fa, Fb, and F e
definitions of Section III, Appendix F, paragraph F-1334.5 [8].
35.6.2.3 Structural Bolts. Structural bolting will meet the
requirements of Section III, Appendix F, paragraph F-1335. For all
structural bolts, the average tensile stress computed on the basis of
the average tensile stress area will not exceed the lesser of 1.0Sy and
0.7Su. The average shear stress will not exceed the lesser of 0.6Sy and
0.42Su. For high-strength structural bolts (Su 7 100 ksi at operating
temperature), the maximum stress at the periphery of the cross section caused by direct tension plus bending but excluding stress concentrationswill not exceed Su. If structural bolts are subject to
combined tensile and shear loads, the tensile and shear stresses must
be proportioned so that the following equation is satisfied.
f 2t
F 2tb
f 2y
+
F 2yb
(35.11)
Ft 5/3
Fy
b
+ a
b 1.0
Fto
Fyo
(35.12)
35.7
LONG-TERM OPERABILITY
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35.8
35.9
NOMENCLATURE
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35.10
REFERENCES
22. WRC 297, Mershon, J. L., Mokhtarian, K., Ranjan, G. V., and
Rodabaugh, E. C. (1987). Local Stresses in Cylindrical Shells Due to
External Loadings on NozzlesSupplement to WRC Bulletin 107
(Revision 1), Welding Research Council, Bulletin 297, New York.
23. ANSI B31.1, Power Piping; The American National Standards Institute.
2. Kot, C. A., Srinivason, M. G., and Hsiek, B. J., Margins for the InPlant Piping System Under Dynamic Cooling, Seismic Engineering,
PVP-Vol. 220, The American Society of Mechanical Engineers, 1991.
25. ASME Boiler and Pressure Vessel Code Section XI, Division 1, Code
Case N-513, Evaluation Criteria for Temporary Acceptance of Flaws
in Class 3 Piping; The American Society of Mechanical Engineers.
4. ASME Boiler and Pressure Vessel Code, Section III, Division 1, Code
Case N-411-1, Alternative Damaging Valves for Response Spectra
Analysis of Class 1, 2, and 3 Piping; The American Society of
Mechanical Engineers.
26. ASME Boiler and Pressure Vessel Code Section XI, Division 1, Code
Case N-640, Alternative Reference Fracture Toughness for
Development of P-T Curves for ASME; The American Society of
Mechanical Engineers.
11. U.S. CFR, Title 10, Energy, Part 50, Domestic Licensing of
Production and Utilization Facilities, Regulations Effective Jan. 2000.
33. Cooper, W.E., 1992. The initial Scope and intent of the Section III
Design Procedures, Paper presented at PVRC Workshop on Cyclic
Life and Environmental Effects in Nuclear Applications, January 1992.
34. Gosselin, S.R., F.A. Simonen, P.G. Heasler, and S.R. Doctor, 2007.
Fatigue Crack Flaw Tolerance in nuclear Power Plant PipingA
Basis for Improvements to ASME Code Section XI Appendix
L, NUREG/CR-6934, U.S. Nuclear Regulatory Commission,
Washington, D.C.
35. Simonen, F.A. and S.R. Gosselin, 1999. Life Prediction and Monitoring
of Nuclear power Plant Components for Service Related Degradation,
J. Pressure Vessel Technology, Vol. 123, pp. 58-64, February, 2001.
36. Lydell, B.O.Y., 2007. PIPExp-2007 High Level Summary of
Database Content as of July 31, 2007, SPI-R-2007-01.07, SigmaPhase Inc., Vail, AZ, August 6, 2007.
37. Lydell, B., Huerta, A. and Gott, K., 2007, Progress with the
International Pipe Failure Data Exchange Project, PVP2007-26278,
Proc. 2007 ASME Pressure Vessel and Piping Division Conference,
July 2226, 2007, San Antonio (TX).
38. Lydell, B., Huerta, A. and Gott, K., 2008, Characteristics of Damage
& Degradation Mechanisms in Nuclear power Plant Systems,
PVP2007-61914, Proc. 2008 ASME Pressure Vessel and Piping
Division Conference, July 2731, 2007, Chicago (IL).
39. Olson, D.E., B.J. Voll, and H.T. Tang, 1994, Behavior and Failure
Mode of Standard Components Beyond their Design Condition:
Recommendations for Support Evaluation and Reconciliation
Criteria, PVP-Vol. 285, Codes and Standards for Quality
Engineering, American Society of Mechanical Engineers, N.Y.