ML071980284

Meeting Slides for Category 1 Working-Level Meeting with PPL to Discuss Steam Dryer Analysis, Licensing, Design Approach, and Power Asension Test Plans

ML071980284
Person / Time
Site:	Susquehanna
Issue date:	07/19/2007
From:	Susquehanna
To:	Office of Nuclear Reactor Regulation
Guzman R, NRR/DORL, 415-1030
References
Download: ML071980284 (27)

Text

Non-proprietary Version Susquehanna Steam Dryer Replacement NRC Meeting June 29, 2007 Rockville, MD PP Non-proprietary Version Steam Dryer Replacement Ppi Agenda

- Overview of SSES CPPU Steam Dryer Licensing and Design Approach

- Corrective Action Status

- Replacement Dryer Design Overview

- Steam Dryer Instrumentation Plan

- Power Ascension Test Plan/Start-Up Limits 2

I

Non-proprietary Version Overview

" Steam dryer licensing basis is conservative and meets ASME fatigue limit of 13,600 psi

• The as fabricated replacement steam dryer will have reduced stress intensities and increased margins to the ASME fatigue limit

" The revised FEM provides results less that the ASME fatigue limit

" Replacement dryer designed for CPPU conditions

- (( 1]

- Improved dryer joint/weld design and fabrication techniques

- Design and fabrication conducted under 10CFR50, Appendix B

" Unit 1 steam dryer instrumented for 107% CLTP

- Demonstrates structural adequacy of new steam dryer design

- Validates steam dryer. analysis tools

" Power ascension test program

- Slow and deliberate

- Confirms no acoustic resonances at 114% CLTP

- Allows validation of analysis and steam dryer design prior to full CPPU I operation

- Confirms acceptability of steam dryer up to full CPPU conditions

- Provides for communication to NRC Non-proprietary Version CPPU Dryer Licensing Approach

• Based on conservative steam dryer design

- Stresses benchmarked to 1985 strain gagedata

- Assumes same weld details as used on current dryer

- Does not include fabrication stress reduction techniques

• Power ascension test plan overview

- Acceptance criteria based on 13,600 psi ASME fatigue limit MSL start-up limit curves based on submitted stress report

- Unit 1 steam dryer instrumented (strain, pressure, & acceleration) for operation up to 107% CLTP

- Unit 1 107% CLTP acceptance criteria (values) based on final fabricated steam dryer and steam dryer instrumentation data

- MSL start-up limit curves validated by steam dryer instrument data and revised as necessary

- Unit 1 and Unit 2 full CPPU acceptance criteria based on validated MSL start-Up limit curves

• Summary reports provided to NRC

• Post implementation inspections 4

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Non-proprietary Version CPPU New Dryer Design Approach

• Based on specific Susquehanna plant steam dryer data New steam dryer design

- Improved structural design

- Designed and fabricated under 10CFR50, Appendix B

- Fabrication utilizes stress reduction techniques Approach will be validated

- Start-up testing

• Measure actual dryer stresses and loads

. Validate ACM load definition

- Periodic inspections Design, of Record

- Revised stress analysis incorporating data from steam dryer instrumentation

- Incorporate stress reduction fabrication details into revised analysis

- Updated stress analysis becomes the steam dryer design basis Non-proprietary Version GE CORRECTIVE ACTION

-REPORT Susquehanna Steam Dryer Finite Element Model Input Condition 6

3

Non-proprietary Version Corrective Action Overview Support lug locations misplaced

- Under lifting rods for most dryers

- Negligible impact on component mode shapes

- Minor impact on dryer stresses Corrective actions to assure quality

- Internal GE reverification of FE model

- PPL/3rd party review of FE model

- No additional discrepancies found-7 Non-proprietary Version 8

4

Non-proprietary Version

((I 9

Non-proprietary Version 10 S

Non-proprietary Version

))

11 C Non-proprietary Version orrective Action impact - Support Lug Stress Results Impact Limiting Component

-((I Minimum stress margin at full CPPU

- [I1 12 6

Non-proprietary Version REPLACEMENT STEAM DRYER OVERVIEW 13 Non-proprietary Version Replacement Steam Dryer Overview Utilized OE from Quad Cities and Dresden replacement steam dryers Overall Design Approach

- Maintain basic geometry Load definition development remains applicable

- 1985 instrumented dryer measurements

- 2006 main steam line measurements

- MSIV slow closure testing 14 7

Non-proprietary Version Replacement Steam Dryer Overview Overall Design Approach

- Improve fabrication details to reduce or eliminate stress intensities

" Eliminate surface cold working

" Weld factor optimization

- Full penetration welds

- Minimize plate thickness mismatches

" Move or eliminate welds from high stress locations

" Use extruded and preformed sub-components

" Solution anneal sub-components

" Design and fabricated under 10CFR50, Appendix B 15 Non-proprietary Version Current Susquehanna Dryer 16 8

Non-proprietary Version Replacement Susquehanna Steam Dryer 17 Non-proprietary Version 18 18 9

Non-proprietary Version 20 10

Non-proprietary Version 21 Non-proprietary Version 22 11

Non-proprietary Version 23 Non-proprietary Version 24 24 12

Non-proprietary Version 2]

25 Non-proprietary Version 2]

26 13

Non-proprietary Version STEAM DRYER INSTRUMENTATION PLAN 28 14

Nan-proprietary Version Steam Dryer Instrumentation Plan (PLA-6176)

Vibration Measurement Program Goals

• Validate'the structural adequacy of the replacement steam dryer design under CPPU conditions for first two steps (107% CLTP)

• Validate load definition and structural analysis models used for the full CPPU analysis

• Validate the main steam line strain gage limit curves Non-proprietary Version Steam Dryer Instrumentation Plan

, Steam dryer strain gages

- Primary instrument for monitoring structural response (Unit 1, first two CPPU steps)

• Steam dryer accelerometers

- Monitor dryer rocking, mechanical vibration from recirculation pump vane passing frequency (Unit 1, first two CPPU steps)

- Provides backup to strain gages for structural response Steam dryer pressure sensors

- Benchmark pressure load definition (Unit 1, first two CPPU steps)

- Provides backup to strain gages Main steam line strain gages

- Primary instrument for monitoring structural response (Unit 1, third and fourth CPPU steps and all Unit 2 steps) 30 15

Non-proprietary Version I]

31 Version 3on-proprietary 32 16

Non-proprietary Version 3]

33 Non-proprietary Version 34 17

Non-proprietary Version I3 35 Non-proprietary Version 36 36 18

Non-proprietary Version I]

37 Non-proprietary Version

((

I]

"38 19

Non-proprietary Version 1]

39 Non-proprietary Version Main Steam Line Sensor Summary

" Two locations monitored per steam line

" Four strain gauges per location

" Total of 32 strain gages installed on four steam lines per unit 40 20

Non-proprietary Version Main Steam Line Strain Gauge Locations Up-tm S9o L.

Gage Location Dowasuum5S".

Gagc Location Dead-He~aded Leg Direto Length MSL A (f) MSL B (ft) MSLC (f) MSL 0 (ft)

Distance from steam dome to 22, 22.B 22.. 228 upstream SG locatio (L,)

Di.tencý fron ntnerndo.e to . 52,7 49.6 40.3 52.6 do-w-nsnemSG location (L2)

Distr from steam dome todead- 54.4 NA NA 54.4 h 8eaded0 looa tion(LO(

Length of dead-eaded leg (L) 24.1 NA NA 24.2 41 Non-proprietary Version Main Steam Line Strain Gauge Acceptance Criteria

" Based on 80% CLTP slow MSIV closure data and 100 CLTP data

" Base data is used to develop baseline curves for each MSL location

" Limit curves developed from baseline curves

- Baseline factored by ratio of ASME endurance limit to peak dryer stress intensity

- Bias and uncertainty included in calculation of peak stress

- Assessments based on frequency dependent uncertainty factors

- The baseline factor is calculated for multiple high stress locations to assureit is limiting 42 21

Non-proprietary Version POWER ASCENSION TEST PLAN 43 Non-proprietary Version Power Ascension Test Plan (PLA-6176) 3 Main Elements

- Slow and deliberate power ascension

" Defined hold points

" Time allowed for monitoring and analysis

- Monitoring, analysis, and trending program

- Steam dryer instrumentation

- Main steam line strain gages

- Piping accelerometers

. Moisture carryover

- Post CPPU monitoring and inspection program to verify dryer and piping performance above CLTP conditions 44 22

Non-proprietary Version Power Ascension Test Plan Slow Deliberate Power Ascension

- Obtain baseline observations at 100% CLTP

- Maximum hourly power increase restriction -1 %

CLTP per hour (-34.8 MWt)

- During power increases, obtain steam dryer instrument (Unit 1 only), main steam line strain, and piping vibration data at each 3.5% power ascension step.

- Each 3.5% power ascension step (-122 MWt)

- Compare strain and vibration data to acceptance criteria

- Obtain/ evaluate moisture carryover data

- Perform plant walk downs

- Review data evaluation and walk down results 45 Non-proprietary Version Power Ascension Test Plan Steam Dryer Monitoring and Analysis

• Level 1: Allowable Stress Exceeded (13,600 psi)

- Action - Reduce power level to previous acceptable level

• Level 2: Low Margin to Allowable Stresses (11,000 psi)

- Action - Hold at current power and re-evaluate

" Steam dryer pressures and MSL strain measurements used to validate and benchmark analytical tools

" Unit 1, 3 rd and 4th steps and all Unit 2 steps monitored using MSL strain measurements

- MSL limit curves updated after benchmark against steam dryer instrument data 46 23

Non-proprietary Version Power Ascension Test Plan Steam Dryer Monitoring and Analysis

" MSiV Slow Closure Test

- Measurements taken at -80% CLTP to simulate 107% CLTP Benchmark composite pressure load definition used in FEA

- Measurements taken at -85.5% CLTP to simulate 114% CLTP

• Confirm the "no acoustic resonance" prediction

• Confirm power scaling factor used to calculate full CPPU stresses

" Increased Core Flow

- Measurements taken at 107% CLTP power, increased core flow range 100 - 108 MIb/hr

• 1 or 2 Mlb/hr steps

• Benchmark and evaluate recirculation vibration load definition used in FEA

• Moisture Carryover

- Moisture carryover measurements taken at each 3.5% power ascension step over 100% CLTP

• Acceptance criterion < 0.1% by weight

• Action - Hold at current power level and re-evaluate 47 Non-proprietary Version Power Ascension Test Plan Steam Dryer Monitoring and Analysis Unit 1 at 107% CLTP

- Validate, benchmark load definition and structural analysis analytical tools

- Validate, benchmark CPPU scaling factor

- Limit curves will be validated on Unit 1 measurements at 107% CLTP

- Validated MSL power ascension limit curves will be used for ascension to 114% CLTP for Unit 1 3rd and 4 th steps, and all Unit 2 steps

- Monitored using MSL strain measurements 48 24

Non-proprietary Version Power Ascension Test Plan Post CPPU Monitoring and Inspection Program

- Moisture Carryover and Plant Parameters

• Per station operating procedures

- Strain gage/Accelerometer Monitoring

• Dryer, MSL data collection as appropriate during remainder of operating cycle as long as instrumentation remains operable

- Steam Dryer Monitoring and Inspection

" Plant parameter monitoring during operation

• Dryer inspections during refueling outages per BWRVIP-139

" Inspections and Walk Downs 49 Non-proprietary Version Power Ascension Test Plan NRC Communication Written reports on steam dryer upon completion of test program for each CPPU fuel cycle will be forwarded to NRC staff

• Relevant data collected at each power step

• Comparisons to performance criteria (design predictions)

• Steam dryer structural integrity monitoring evaluations

• Evaluations or corrective actions required to obtain satisfactory dryer performance

- Reports will be provided for

• Unit 1 at 107% CLTP

" Unit2 at 114% CLTP

" Unit I at 114% CLTP 50 50 25

Non-proprietary Version Power Ascension Test Plan Summary Slow and deliberate power ascension

- New Steam Dryers

- Dryer on Unit 1 instrumented for 107% CLTP uprate

- Steam dryer strain gages used for Unit 1 107% CLTP acceptance criteria

- MSLs on both units instrumented

- Methods benchmarked to in-plant measurements before proceeding to full CPPU

- Main steam line strain gages used for Unit 1 114% CLTP and Unit 2 114% acceptance criteria

- Provides feedback to the NRC Non- roprietary Version Susque anna Steam Dryer Program Summary

" Steam dryer licensing basis is conservative and meets ASME fatigue limit of 13,600 psi

" The as fabricated replacement steam dryer will have reduced stress intensities and increased margins to the ASME fatigue limit

" The revised FEM provides results less that the ASME fatigue limit

" Replacement dryer designed for CPPU conditions

- (( 1]

- Improved dryer joint/weld design and fabrication techniques

- Design and fabrication conducted under 10CFR50, Appendix B

" Unit 1 steam dryer instrumented for 107% CLTP

- Demonstrates structural adequacy of new steam dryer design

- Validates steam dryer analysis tools

" Power ascension test program

- Slow and deliberate

- Confirms no acoustic resonances at 114% CLTP

- Allows validation of analysis and steam dryer design prior to full CPPU operation

- Confirms acceptability of steam dryer up to full CPPU conditions

- Provides for communication to NRC 52 26

Non-proprietary Version Additional Questions?

53 27