ML051940467

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Attachment 2-B, FAI/04-86, Revision 0, Test Report for Phase 2 of Experimental Investigation of Post Air Intrusion Into ECCS Suction Piping for Palo Verde Nuclear Generating Station
ML051940467
Person / Time
Site: Palo Verde  Arizona Public Service icon.png
Issue date: 02/11/2005
From: Berger W, Hammersley R, Henry R
Fauske & Associates
To:
Office of Nuclear Reactor Regulation
References
FAI/04-86, Rev 0
Download: ML051940467 (107)
v • d • e


Text

ATTACHMENT 2-B3 FAIIO4-86, Revision 0 Test Report for Phase 2 of Experimental Investigation of Post RAS Air Intrusion Into ECCS Suction Piping for Palo Verde Nuclear Generating Station (Prorietary)

REDACTED VERSION

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l EAREDACTED VERSION Westinghouse Non-Proprictary Class 3 FAI/04-86 Page 1 of 106 Rev. 0 Date: 02/ 11,05 FAUSKE & ASSOCIATES, INC.

CALCULATION NOTE COVER SHEET SECTION TO BE COMPLETED BY AUTHOR(S):

Calc-Note Number FAI/04-86 Revision Number 0 Title Test Report for Phase 2 of Experimental Investigation of Post-RAS Air Intrusion Into ECCS Suction Piping for Palo Verde Nuclear Generatinz Station Project Number or Project Arizona Public Service (APS) Shop Order APS005

Purpose:

This report documents the scaled integral experiments (Phase 2) that were conducted to investigate a past plant operability question regarding the possibility of air initially residing in the horizontal segment of the sump suction line being swept into the pump suction header and ECCS pumps. The nature ofthe two phase flow patterns in the ECCS suction piping was also investigated.

Results Summary:

References of Resulting reports, Letters, or Memoranda (Optional)

]

Author(s): Completion Name (Print or Type) Signature Dale

.AS Robert J. Hammerslev February 11. 2005 Robert E. Henry Q'- E.d February 11, 2005 SECTION TO BE COMPLETED BY VERIFIER(S):

Verifier(s): Completion Name (Print or Type) Sienature Date William E. Berger 0/1 /it1 Februarv II. 2005 Independent Review or Method of Verification: Design Review . Alternate Calculations X , Testing Other (specify)

SECTION TO BE COMPLETED BY MANAGER:

Responsible Manager: Approval Name (Print or Type) Signature Date R. E. Henry February 11.2005 5 2005 Fauske & Associates, Inc.

All Rights Reserved

REDACTED VERSION FAI/04-86 Page 2 of 106 Rev. 0 Date: 02/11/05 CALC NOTE NUMBER FAI/04-86 PAGE 2 CALCULATION NOTE METHODOLOGY CHECKLIST CHECKLIST TO BE COMPLETED BY AUTHOR(S) (CIRCLE APPROPRIATE RESPONSE)

1. Is the subject and/or the purpose of the design analysis clearly stated?........................................................................................................Y 3 NO 7 NO N/A
2. Are the required inputs and their sources provided? ............. .......................
3. Are the assumptions clearly identified and justified? I ....................................... NO NIA
4. Are the methods and units clearly identified? ................................................... ( .. ) NO N/A
5. Have the limits of applicability been identified? . N/A (Is the analysis for a 3 or 4 loop plant or for a single application.)
6. Are the results of literature searches, if conducted, or other background data provided? .. (:2YE` NO N/A
7. Are all the pages sequentially numbered and identified by the calculation note number? ...................................................................... .......... NO
8. Is the project or shop order clearly identified? ................................. _. NO
9. Has the required computer calculation information been provided? ........ ............. YES NOC
10. Were the computer codes used under configuration control? .................. ............. YES NOCED Il. Was the computer code(s) used applicable for modeling the physical and/or computational problems identified? .YES NO 3 (i.e., Is the correct computer code being used for the intended purpose.)
12. Are the results and conclusions clearly stated? ............................................ . NO
13. Are Open Items properly identified ...........................

. YES NO

14. Were approved Design Control practices followed without exception? ............. YES NO (Approved Design Control practices refers to guidance documents within Nuclear Services that state how the work is to be performed, such as how to perform a LOCA analysis.)

9 ....NO NMA

15. Have all related contract requirements been met? ..................... .......................

NOTE: If NO to any of the above, Page Number containing justification

PROPRIETARY FAI/04-86 Page 3 of 106 REDACTED VERSION Rev. 0 Date: 02111/05 FAL/04-86 Test Reportfor Phase 2 of Experimental Investigation of Post-RAS Air Intrusion Into ECCS Suction Pipingfor Palo Verde Nuclear GeneratingStation PreparedFor:

irizona Public Service PreparedBy:

Fauske & Associates, LLC 16 W070 West 83rd Street Burr Ridge, Illinois 60527 TEL: (630) 323-8750 FAX: (630) 986-5481 November, 2004

PRPRETRYFAI/04-96 Page 4of 106 REDACTED VERSION Rev. 0 Date: 02/11/05 ABSTRA CT This report documents the Phase 2 scaled experiments that were conducted to investigate a past operability question for the Palo Verde plants regarding the possibility of the air initially residing in the horizontal segment of the sump suction line being swept into the vertical downcomer anrd subsequently into the ECCS and Containment.Spray (CS) pumps. The Phase 1 tests (FAI, 2004a) addressed [ ] The nature of the two phase flow pattern produced [ ] for the High Pressure Safety Injection (HPSI), Low Pressure Safety Injection (LPSI), and CS systems was investigated in these Phase 2 tests.

Test cases were also included with the HPSI and CS pumps running at the time of RAS with the Low Pressure Safety Injection (LPSI) started later. In general these tests demonstrated that most of the air was pulled through the HPSI suction line before the LPSI pump was started. For most of these tests the HPSI pump was assumed to fail and was shutdown when the flow decreased to one-half of the initial value. Some tests were performed to address the possible operator action of keeping the CS pump on one train and shutting down the CS pump on the other train in favor of the LPSI pump if HPSI were to fail on both trains. With this event sequence, stopping the CS pump enabled the air in the lower header to rise up through the downcomer, pass backward through the check valve and be discharged into the sump thus eventually rising to the containment atmosphere.

Consequently, there was no air in the header when the LPSI pump was started.

FPROPW REDACTED VERSION FAI/04-86 PageS of 106 Rev. 0 Date: 02/1 1/05 PURPOSE This report documents the scaled integral experiments (Phase 2) that were conducted to investigate a past operability question regarding the possibility of air initially residing in the horizontal segment of the sump suction line being swept into the pump suction header and ECCS pumps. The nature of the two phase flow patterns in the ECCS suction piping was also investigated.

REDACTED VERSION-,,

FAI/04-86 Page 6 of 106 Rev. 0 Date: 02/1 1/05 INPUTDA TA AND ASSUMPTIONS The Phase 2 experiments were configured and conducted per the approved test plan (FAI, 2004b). The initial conditions, major components, and key dimensions for these tests are described in the test plan.

+ROPR*ETAMF-REDACTED VERSION FAI/04-86 Page 7 of 106 Rev. 0 Date: 02/1 1105 TABLE OF CONTEN.TS Paoe CALCULATION NOTE COVER SHEET . ........................................... .

CALCULATION NOTE METHODOLOGY CHECKLIST ............................................ 2 TITLE PAGE ............................ ......................... 3 ABSTRACT.................................................................................................................................. 4 PURPOSE..................................................................................................................................... 5 INPUT DATA AND ASSUMPTIONS ........................... 6 TABLE OF CONTENTS ............................ . . 7 LIST OF FIGURES ............................ . . 9 LIST OF TABLES ............. . . 12 1.0 PHASE 2 TEST OBJECTIVES .... 13 1.1 Technical Issue .. 13 1.2 Experimental Objectives .. 13 2.0 PHASE 2 TEST FACILITY .... 15 2.1 Physical Arrangement .. 15 2.1.1 Configuration 2A .14 2.1.2 Configuration 2B .8 2.1.3 Configuration 2C .21 2.2 Instrumentation .. 26 2.3 Scaling Considerations .. 28 2.3.1 Two-Phase Flow Pattern Considerations .28 2.3.2 Vertical Scaling of Two-Phase Downward Flow .29

REDACTED VERSION FAI/04-86 Page 8of 106

.Rev. 0 Date: 02/1105 2.3.3 Scaling of the Initial Air Volume and the Isolation Valves ..................... 33 2.3.4 Materials .......................................... 37 3.0 PHASE 2 INITIAL CONDITIONS AND TEST MATRIX . . . 39 4.0 PHASE 2 TEST RESULTS . . .43 4.1 Configuration 2A .. 43 4.1.1 Key Observations .43 4.1.2 Discussion of Results .49 4.2 Configuration 2B .. 94 4.2.1 Key Observations .94 4.2.2 Discussion of Results .94 4.3 Configuration 2C .. 96 4.3.1 Key Observations .96

5.0 CONCLUSION

S ........... 101

6.0 REFERENCES

.. ........... 105 APPENDIX A: Phase 2 Configuration 2A Test Results . . . .....................................A-I APPENDIX B: Phase 2 Configuration 2B Test Results ........................................ B-I APPENDIX C: Phase 2 Configuration 2C Test Results . . . .....................................C-1 APPENDIX D: [

.................. D-I APPENDIX E: [

]....................... E-I

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REDACTED VERSION FAI/04-86 Page 9 of 106 Rev. 0 Date: 02/11/05 LIST OF FIGURES

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PROPRIETARY.--

REDACTED VERSION FAI/04-86 Rev. 0 Page 12of 106 Date: 02/11/05 LIST OF TABLES Page Table I Test Dimensions .17 Table 2 Instrumentation for Phase 2 Test ...................... 27 Table 3 Phase 2 Test Matrix for Configuration 2A .40 Table 4 Phase 2 Test Matrix for Configuration 2B .41 Table 5 Phase 2 Test Matrix for Configuration 2C ............................  :.:.:.;.:.;.42 Table 6 Phase 2 Configuration 2A Test Results and Observations .44 Table 7, Phase 2 Configuration 2B Test Results and Observations .46 Table 8 Phase 2 Configuration 2C Test Results and Observations .47 Table 9 Summary of Tests for Reproducibility .90

PROPRtETAfy-REDACTED VERSION FAI/04-86 Page 13 of 106 Rev. 0 Date: 02/11/05 1.0 PHASE 2 TEST OBJECTIVES 1.1 Technical Issue The Palo Verde Nuclear Generating Station (PVNGS) has identificd a concern. Specifically, all three units have sump recirculation flow paths to the Emergency Core Cooling System (ECCS) pumps which contain a pocket of air trapped between the sump isolation Motor Operated Valves (MOVs) (butterfly valves) and check valve that could potentially be forced into the operating pump suction upon an initiation of a Recirculation Actuation Signal (RAS) during a design basis event.

PVNGS has requested analysis of this concern to determine:

(I) If any air volume between the inboard sump isolation valve and the downstream check valve could be forced into the suction of the operating High Pressure Safety Injection (HPSI) and Containment Spray (CS) pumps upon openingofthe sump isolation valves at the time of RAS.

(2) The impact on pump performance if any amount of air from the sump suction piping is injected into the operating pumps.

1.2 Experimental Objectives Phase I testing (FAI, 2004a) demonstrated that the flow demand on the containment sump pump suction line following RAS was sufficient [

] Therefore, Phase 2 experimental investigation was initiated at FAI to investigate the two-phase flow patterns [

] The objectives of the Phase 2 testing were to investigate the extent of air transport to the HPSI and CS pumps as well as the LPSI pump for those accident sequences where this could be started. Full scaling testing of the pump performance for the resulting air intrusion will be performed in a Phase 3 test facility at Wyle Laboratories in Huntsville, Alabama. In the Phase 2 testing, the

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RE ~ E ON, FAI/04-86 Page 14 of 106 Rev. 0 Date: 02/I1/OS

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] The Phase 2 tests were configured and performed in accordance with the approved test plan (FAI, 2004b).

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FA1104-86 Page 15 of 106 REDACTED VERSION Rev. 0 Date: 02/11/05 2.0 PHASE 2 TEST FACILITY 2.1 Physical Arrangement 2.1.1 Configuration 2A

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The use of 4 inch diameter (Schedule 40) pipe to represent the 24 inch diameter (Schedule 20 and 30) pipe in the plant defined a linear scale ratio of approximately 1/6 (FAI, 2004b). Thus, the balance of the suction line pipe lengths and valve locations also used a 1/6th scale unless there were other considerations [

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Figure 1: Phase 2 Test Configuration 2A for Post-RAS Air Intrusion.

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] Both the HPSI and CS pumps are single stage centrifugal pumps in the test apparatus. For the plants, the HPSI umps are eight stage centrifugal designs.

Table I Test Dimensions

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.. .... I Figure 3: Phase 2 Test Configuration 2B for Post-RAS Air Intrusion.

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U 2.1.3 Configuration 2C

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REDACTED VERSION FAI/04-86 Rev. 0 Page 26 of 106 Date: 02/11/05 2.2 Instrumentation The test instrumentation is similar for all three test configurations and is indicated in Figures 1, 2 and 3 and listed in Table 2. A personal computer (PC) [

] was used to collect data during the transient following the opening of the isolation valves as well as the subsequent steady state recirculation flow that followed. Each data channel was sampled at a rate of once per [ ] which is much faster than the hydraulic transient which takes tens of seconds.]

] Each experiment had the following data recorded:

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REDACTED VERSION FAI/04-86 Rev. 0 Page28of106 Dale: 02/11105 Digital movie cameras were used to record the flow patterns in the clear piping sections. General observations in the clear pipe sections were made and noted by the test engineers. These observations were particularly important to characterize the water-air flow patterns in the various suction pipes.

2.3 Scaling Considerations The test plan (FAI, 2004b) presented the scaling assessment for the Phase 2 tests. The scaling assessment addressed [

] The scaling considerations are discussed below.

2.3.1 Two-Phase Flow Pattern Considerations

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PROPRrETA REDACTED VERSION FAI/04-86 Page 39 of 106 Rev. 0 Date: 02/11/05 3.0 PHASE 2 INITIAL COVDITIONS AND TEST MA TRIX The range of initial conditions were as follows:

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The test matrices for Configurations 2A, 2B and 2C as provided in the Phase 2 Test Plan (FAI, 2004b) are reproduced in Tables 3, 4 and 4 respectively. With the observations of the initial tests, the test matrix was expanded during the testing program to investigate specific phenomena as well as demonstrate reproducibility of the results. The expanded test matrix executed in the Phase 2 testing is presented in Section 4.0, Phase 2 Tests Results. A cross reference is provided between the expanded test matrix and the test matrix from the test plan. Key observations for each test include the two-phase flow pattern [ ] Other observations include Relative to elevation of center line of the lower horizontal header for the HPSI, CS and LPSI pump suction lines.

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REDACTED VERSION FA1104-86 Page 43 of 106 Rev. 0 Date: 02/11/05 4.0 PHASE2 TESTRESULTS The test data and digital movies of the Phase 2, Configurations 2A were reviewed for the tests specified for this configuration in the Phase 2 Test Plan (FAI, 2004b). After reviewing and discussing the results from the original twelve tests for Configuration 2A with APS and Westinghouse personnel, it was decided to expand the Configuration 2A test matrix to 29 tests.

Table 6 summarizes the results for all 29 of the Configuration 2A tests [

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FAI/04-86 Page 49 of 106 Rev. 0 Date: 02/11/05 REDACTED VERSION 4.1 Configuration 2A 4.1.1 Kev Observations The key observations for the Phase 2 air intrusion tests relate to the specific test objectives, i.e. (I) to investigate the air delivery rates to the HPSI and CS pump suctions and (2) document the associated two-phase flow patterns. Observations from the 29 tests performed in Configuration 2A of the Phase 2 testing are as follows:

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4.2.1 Kev Observations 4.2.2 Discussion of Results 4.2.2.1 General Comments These scoping tests included 8 experiments with the principal difference being the predetermined LPSI flow rate. Table 7 summarizes the results for all tests including the as-tested flow rates for both pumps and the corresponding Froude numbers in the different piping segments.

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5.0 CONCLUSION

S The following conclusions were derived from the three Phase 2 configurations for the integral 4 inch diameter scaled experiments representing the Palo Verde sump suction line behavior.

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6.0 REFERENCES

FAI, 2004a, "FAI/04-65, "Test Report for Phase I of Experimental Investigation of Post RAS Air Intrusion Into ECCS Suction Piping for Palo Verde Nuclear Generating Station," September.

FAI, 2004b, FAII04-74, "Test Plan (Phase 2) for Experimental Investigation of Post-RAS Air Intrusion Into ECCS Suction Piping for Palo Verde Nuclear Generation Station," December.

FAI, 2005, FA1104-79, "Test Report: Phenomenological Studies for the APS Containment Suction Line," January.

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