ML12277A176
| ML12277A176 | |
| Person / Time | |
|---|---|
| Site: | Prairie Island  |
| Issue date: | 10/04/2012 |
| From: | NRC/RGN-III |
| To: | |
| Atif Shaikh | |
| References | |
| Download: ML12277A176 (37) | |
Text
P i i I l d N l
G ti Pl t
Prairie Island Nuclear Generating Plant (PINGP)
Unit 2 Unit 2 Steam Generator Replacement (SGR)
Project NRC Region 3 Presentation g
October 4, 2012
Purpose The purpose of this meeting is to discuss the Prairie Island Nuclear Generating Plant (PINGP) Unit 2 steam Island Nuclear Generating Plant (PINGP) Unit 2 steam generator replacement activities including design, licensing, fabrication, installation and oversight.
2
Att d
Attendees
- Karen Fili, Vice President Nuclear Capital Projects
- Scott Marty, Director Unit 2 SGR Project Richard Pearson Unit 2 SGR Project Engineering Supervisor
- Richard Pearson, Unit 2 SGR Project Engineering Supervisor
- Gene Eckholt, Project Licensing Manager
- Glenn Adams, Project Licensing Lead Engineer 3
M ti A
d Meeting Agenda
- Overview
- Design and Planning R
l t St G
t (RSG) D i
Replacement Steam Generator (RSG) Design Engineering Design and Analysis Radiation Protection
- Steam Generator (SG) Removal and Installation
- Post Installation Verification and Testing X
l E O
i ht
- Xcel Energy Oversight
- Regulatory Interface 4
O i
P j
t S Overview - Project Scope Replace two Unit 2 original Westinghouse Model 51 Replace two Unit 2 original Westinghouse Model 51 steam generators with new AREVA Model 56/19 RSGs Two piece replacement through existing equipment hatch similar to Unit 1 similar to Unit 1 5
O i
P j
t S Overview - Project Scope
- Run Animation 6
O i
P j
t S Overview - Project Scope Project includes off-site disposal of the two original steam generators Immediate preparation and packaging for off site disposal similar to Unit 1 U1 OSG Upper Part leaving U1 OSG Lower Part being U1 OSG Upper Part leaving PINGP in late 2004 prep for rail shipment at PINGP in late 2004 7
O i
P j
t I iti ti Overview - Project Initiation
- Project initiated for economic issues including:
Increasing repair costs Increasing repair costs Potential need for planned mid-cycle inspections, forced outages Increasing outage time g
g Reduction in plant output Replacement energy costs 8
O i
P ti i t
Overview - Participants Project Management - Xcel Energy Xcel Energy Project Management & oversight personnel Project Management & oversight personnel RSG Engineering & Fabrication - AREVA AREVA NP SAS Engineering & Licensing support AREVA NP Engineering & Licensing support AREVA NP Major forgings - Japan Steel Works Tubing - SANDVIK Steel Installation Contractor - SNC - Lavalin SNC Lavalin (SLN) - Babcock & Wilcox Nuclear Energy Engineering and construction services required for Steam Generator removal and installation 9
O i
S h d l Overview - Schedule
- Fabrication and Delivery First lower part hydrostatic test completed and ASME Pre-Service Inspection in process O
h d l f
it d li S
i 2013 i
On schedule for on-site delivery Spring 2013 using on-site barge landing and haul routes from Unit 1 project 10
RSG Components F
i A
d J
2006 RSGs Delivered Receipt of Forgings Pour 1st RSG Forging Current Timeline SGR Outage Forgings Award - June 2006 Full Contract - August 2006 to PI p
g g
and Tubing at Manufacturer OSG Disposal g
g January 2010 SGR Outage Fall 2013 U2 SGR Installation Services Contract Award Dec 2009 Contract Award 4th Qtr 2011 Establish other support contracts and Temporary Facilities PHASE 2 PHASE 1 N-4 N-3 Detailed Engineering (ECs)
PHASE 2 PHASE 1 2006 2007 2008 2009 2010 2011 2012 2013 Outage Outage N-2 Outage N-1 Outage Laser Scanning Precision Conceptual Verification &
Walkdowns Work Packages Complete 11 Measurements Final Design Verification
D i
d Pl i
RSG D i
Design and Planning - RSG Design RSG Design Designed and fabricated by AREVA NP SAS (Paris / Chalon France)
SAS (Paris / Chalon, France)
Two (2) piece ASME Section III Class 1 Nuclear Pressure Vessel - to be N-stamped in field N-stamped in field Alloy 690 (TT) tubing material Final Girth Closure Weld located at top of transition cone Basic design for Unit 2 is same as Unit 1 12
D i
d Pl i
RSG D i
Design and Planning - RSG Design Steam outlet nozzle flow restrictor integral to RSG elliptical head Level sensing line pressure stabilizers Anti-stratification device in feedwater ring to reduce thermal stratification effects Low Delta-P deck plate Stainless Steel (SS) Feedwater Ring with J-tube outlet nozzles and welded with J tube outlet nozzles and welded inlet thermal sleeve Loose Parts Trapping Screen to protect tube bundle region 13 tube bundle region
D i
d Pl i
RSG D i
Design and Planning - RSG Design Tube Bundle Recirculation Connection for Cold Shutdown Chemistry Control 5 sets of SS Anti-Vibration Bars (AVBs) with 9 contact points SS Quatrefoil Tube Support Plates SS Quatrefoil Tube Support Plates (TSPs)
Additional handholes at tubesheet and at two elevated TSPs at two elevated TSPs 14
D i
d Pl i
RSG D i
Design and Planning - RSG Design RSG Design (continued)
OSG RSG Thermal Output (MWt) 825 825 Thot/Tcold/Tave (nom.) (deg F) 590/530/560 590/530/560 Number of Tubes 3388 4868 RSG Design (continued)
Number of Tubes 3388 4868 Tubing OD/WT (in.)
0.875/0.050 0.75/0.043 Heat Transfer Area (sq. ft.)
51,500 61,281 Performance Coefficient UA (10E6 Btu/hr-F) 67.52 81.93 RCS Fl B
t E ti t
(10E6 RCS Flow - Best Estimate (10E6 lbm/hr) 38.39 38.51 RCS Pressure (psia) 2250 2250 Steam Flow (10E6 lbm/hr) 3.54 3.57 Full Load Steam Outlet Pressure (design normal operating) (psia) 750 806.8 Max. Moisture Carryover (%)
0.25 0.1 Operating Weight (lbf) 801,073 802,055 15
D i
d Pl i
RSG D i
Design and Planning - RSG Design L
L d f U it 1 RSG Lesson Learned from Unit 1 RSG A small number of tubes exhibited wear scars at some TSP and AVB locations Comprehensive investigation was completed in numerous fields Comprehensive investigation was completed in numerous fields such as:
Design, fabrication and installation Evaluation of Non-Destructive Examination (NDE) techniques Review of operating experience Wear simulations to attempt to reproduce wear at TSPs A single root cause could not be determined Increase in depths of wear scars from 1R24 to 1R25 was limited Increase in depths of wear scars from 1R24 to 1R25 was limited, suggesting a trend to stabilization. The Operational Assessment of the growth provided justification for no inspection until 1R28 Outage 16
D i
d Pl i
RSG D i
Design and Planning - RSG Design RSG Improvements related to wear scars TSP Procurement - Reinforcement of flatness controls TSP Manufacturing Recording of reworked holes TSP Manufacturing - Recording of reworked holes and additional dimensional data TSP Assembly - Record and control parallelism, require slight contact at locking wedges and check peripheral gaps peripheral gaps Tie Rod Assembly - Group to have same length between TSP and tie rods and tightened from the center to the exterior AVB P t
Additi l
d d AVB Procurement - Additional recorded measurements 17
D i
d Pl i
RSG D i
Design and Planning - RSG Design Other RSG Improvement compared to Unit 1 Secondary Manway Davit Arm Design - Improved design to address binding design to address binding Feedwater Ring Inspection Port Design -
Changed gasket, torque and locking washers to address loose screws and damaged gaskets AVB Anti Lift Off Device Design - Lockwashers are bigger to address binding on screw threads Tubesheet drilling is now performed after the tubesheet assembly to the lower shell section An extended lip is integrated into the tubesheet, eliminating a cylindrical ring section and one circumferential weld in the channel head 18
Design and Planning -
Design and Planning Fabrication Test Examples Materials and NDE per ASME Section III RSG Vessel Primary Side Hydrostatic Test Tubing Examinations At Tubing Mill Per ASME Section III Section XI per EPRI NDE Guidelines, bobbin full length, Rotating Pancake Coil (RPC) low row u-bends At AREVA - Chalon France At AREVA Chalon, France Helium Leak Test of tube-to-tubesheet weld Tube Expansion Profilometry Pre-service Eddy Current Testing (ECT) 19 Pre service Eddy Current Testing (ECT) including RPC of expansion transition
D i
d Pl i
RSG D i
Design and Planning - RSG Design I d t
L L
d Industry Lesson Learned San Onofre Tube Leak A combination of unpredicted, adverse thermal hydraulic diti d i ffi i t
t t f i
th t b b
dl conditions and insufficient contact forces in the upper tube bundle caused fluid-elastic instability which was a significant contributor to the tube-to-tube wear, resulting in the tube leak Due to modeling errors, the San Onofre replacement generators t d i
d ith d
t th l h d li i
were not designed with adequate thermal hydraulic margin Applicability to PINGP Fluid Elastic Instability risk evaluated with AREVA CAFCA4 (thermal-hydraulic data) and GERBOISE (vibration) codes (thermal-hydraulic data) and GERBOISE (vibration) codes AREVA CAFCA4 showed thermal-hydraulic results up to 4 times higher velocity than Mitsubishi FIT III Code (Reference SONGS AIT Report)
Even with conservative Connors and damping coefficients, the absence of fluid-elastic instability of the RSG tube bundle is demonstrated 20 y
Unit 1 ECT during first cycles showed no tube-to-tube contact or wear
D i
d Pl i
RSG D i
Design and Planning - RSG Design Industry Lesson Learned (continued)
Industry Lesson Learned (continued)
San Onofre Tube Leak - PINGP versus SONGS AREVA design and fabrication, not Mitsubishi Tubes made by Sandvik not Sumitomo Tubes made by Sandvik, not Sumitomo PINGP AVB design is different and does not include the SONGS retainer bar design that caused wear PINGP RSG tube bundle ~ half the size of SONGS PINGP square pitch value larger than SONGS triangular PINGP has u-bend region increasing pitch incrementation No divider plate repairs for PINGP RSGs PINGP U1 RSG Operating History PINGP U1 RSG Operating History
< 10 tubes preventively plugged since 2004 No challenges to tube structural integrity 21
D i
d Pl i
EC P k
Design and Planning - EC Packages Engineering Change (EC) Packages One (1) EC Package applicable to the design and analysis of the RSGs prepared by Xcel Energy analysis of the RSGs prepared by Xcel Energy Sixteen (16) EC Packages applicable to removal and installation activities prepared by SNC-Lavalin divided by system (RCS FW MS etc ) or Lavalin divided by system (RCS, FW, MS, etc.) or activities (Rigging, RSG Assembly, etc.)
EC Packages are reviewed in accordance with EC d 10 CFR 50 59 EC process and 10 CFR 50.59 22
D i
d Pl i
EC P k
Design and Planning - EC Packages 23
B k
Break 24
SG R l
d I t ll ti SG Removal and Installation Heavy Loads Outside Lift System (OLS) utilizes gantry arrangement g
y g
with hydraulic jacking mechanism OLS designed seismic II over I to reduce risk to non-safety related Condensate Storage Tanks and Containment Structure Containment Structure Based on design and distance OLS can not striking D5/D6 building 25 striking D5/D6 building
SG R l
d I t ll ti SG Removal and Installation Heavy Loads Inside lifting utilizes the existing 230-ton capacity g
p y
Polar Crane and an Engineered Lift evaluation per ANSI B30.2 Unit 1 and Unit 2 common systems in containment evaluated for impacts and actions taken to address actions taken to address (photo from Unit 1 SGR) 26
SG R l
d I t ll ti SG Removal and Installation Heavy Loads On-site transport routes are load tested prior to SG component transport p
p SG load drop analysis is performed for the radiological consequences related to a drop of the SG 27
SG R l
d I t ll ti SG Removal and Installation R di ti P
t ti Radiation Protection RCS Pipe End Decon Shielding Plan under development ALARA Plan under development 28
SG R l
d I t ll ti SG Removal and Installation Security Opening of the equipment hatch requires establishing a temporary security barrier, a common outage evolution Components will enter Protected Area (PA)
Components will enter Protected Area (PA) through existing PA boundary gates 29
P t I t ll ti V
ifi ti d T ti Post Installation Verification and Testing Pre SGR Outage Data Collection Pre-SGR Outage Data Collection Reactor Coolant System (RCS) baseline flow Reactor Coolant Pump (RCP) baseline vibration Baseline of Plant Process Monitoring points Baseline of Plant Process Monitoring points Construction Tests Construction NDE - RT, MT, PT, VT Pre-service In-Service Inspections Instrument Calibration Steam Generator Hydrostatic Test - Secondary P i
/S d
S t
I S
i L
k T t
Primary/Secondary System In-Service Leak Test Requires NDE be performed in accordance with ASME Section III, 92 or later 30
P t I t ll ti V
ifi ti d T ti Post Installation Verification and Testing Startup Testing Startup Testing Measure RCS Flow RCP Vibration / Motor Amperage Chemistry Adjustments Chemistry Adjustments Hot Shutdown Testing Verify RCS Flow Measure RCP Vibration Measure RCP Flow Coastdown Monitor Instruments & Controls Operation O
t SG Bl d
S t
Operate SG Blowdown System Measure / Adjust RSG Support Hot Gap Conditions Measure Rod Drop Times 31
P t I t ll ti V
ifi ti d T ti Post Installation Verification and Testing E
t d P T
ti E
l ti Expected Power Testing Evolutions Verify expected design parameters Monitor Primary and Secondary Chemistry y
y y
Parameters First Stage Turbine Pressure Downstream Instrument Calibrations st u e t Ca b at o s Main Steam Flow Calibration Moisture Carryover Testing M
it St Li D
i T
Monitor Steam Line Drain Traps Monitor SG Blowdown 32
O i ht AREVA Oversight - AREVA NUPIC joint utility audit 2009: Xcel Lead NUPIC joint utility audit - 2009: Xcel Lead NUPIC joint utility audit - 2011: Xcel participant Xcel Nuclear Oversight (NOS) visit to Japan Steel Works g
(
)
p to witness tubesheet Ultrasonic Test (UT)
Full time Xcel NOS representative at St. Marcel fabrication facility Full time Xcel NOS representative at Sandvik Project and Subject Matter Expert visits for project meetings Primary Side Hydrostatic Test Eddy Current meetings, Primary Side Hydrostatic Test, Eddy Current Test (ECT) and UT witness and Radiography Test (RT) radiography review 33
O i ht SNC L li
/ B&W NE Oversight - SNC-Lavalin / B&W NE X
l NOS 2009 A dit Xcel NOS 2009 Audit Xcel NOS 2012 Audit - SNC-Lavalin Engineering Xcel SGRP Engineering Staff oversight Xcel SGRP Engineering Staff oversight Modification development by External Design Organization Owners Acceptance and EC approval by Xcel Energy Project Engineering Staff 34
R l t I t f
LAR Regulatory Interface - LARs License Amendment Request (LAR): Unit 2 exception from Containment Integrated Leak R t T
ti (ILRT)
Rate Testing (ILRT)
Revise Technical Specification (TS) 5.5.14, Containment Leak Rate Testing Containment Leak Rate Testing Basis: ASME testing better than ILRT Precedent: PINGP Unit 1 for 2004 SGRP Implementation: Prior to SGR Outage 35
R l t I t f
LAR Regulatory Interface - LARs LAR: U1/U2 SG Program Changes Revise TS 3.4.19, SG Tube Integrity Revise TS 5.5.8, SG Program Revise TS 5.6.7, SG Tube Inspection Report Revise TS to recognize U2 with Alloy 690TT tubes Eliminate SG repair criteria (associated with OSGs)
Adopt TSTF-510 to SG Program Same SG Program to both units g
Implementation: In conjunction with SGR Outage 36
SGR P j
t SGR Project Q&A Closing Remarks 37