Influence on structure and fracture mechanics evaluations of a BWR feedwater nozzle following weld overlay repair

This present paper summarizes applying weld overlay repair on the feedwater nozzle in a boiling water reactor, and evaluates the influence on the structure and fracture mechanics of the component. The requirements for utilizing a full structural weld overlay, including the weld overlay design, effects of welding residual stresses (WRSs), impacts of weld shrinkage, prediction of potential flaw growth, and influence on ASME Code Section III design evaluations, are further defined in ASME Code Case N-504-2. In order to confirm the effectiveness of the weld overlay design of the nozzle, the WRSs following overlay installation were determined using engineering simulation software. The impacts of weld shrinkage from overlay welding are also addressed. The shrinkage stresses were evaluated via a numerical model of the attached piping system to ensure the design margins of the pipe structure. Since the weld overlay technique is well known to be effective in mitigating crack initiation or cracking to leakage, a fatigue crack growth prediction under ASME Code Section XI must be conducted to address the fatigue qualification of the affected component. The ASME Code Section III construction qualification of the whole nozzle region must consider the applicable thermal transient stresses, structural discontinuities, and bimetallic effects that are caused by the weld overlay. This investigation proves that the current stress analyses of the nozzle and the pipe structure are not significantly affected by the added overlay mass, so the structural integrity of the component can be ensured, meeting the requirements of ASME Code Case N-504-2.