Text

NRR E-mail Capture - Draft Bypass Test Plan
	ML12297A392
Person / Time
Site:	Crystal River
Issue date:	10/23/2012
From:	Westcott D; Progress Energy Co
To:	Farideh Saba; Division of Operating Reactor Licensing
References
	Download: ML12297A392 (45)
	v • d • e

NRR-PMDAPEm Resource From: Westcott, Daniel [Daniel.Westcott@pgnmail.com]

Sent: Tuesday, October 23, 2012 11:22 AM To: Saba, Farideh Cc: Herrin, Dennis W.; McDaniel, Sarah

Subject:

draft bypass test plan Attachments: ALION-PLN-ENER-8706-02 Rev 0C- NRC DRAFT.pdf - Adobe Acrobat Pro.pdf

Farideh, Attached is the draft test procedure for our call on November 1st.

Dan 1

Hearing Identifier: NRR_PMDA Email Number: 513 Mail Envelope Properties (66C0930ED750B74E80B0F51A1F24D99A1A7126AC4E)

Subject:

draft bypass test plan Sent Date: 10/23/2012 11:21:37 AM Received Date: 10/23/2012 11:25:19 AM From: Westcott, Daniel Created By: Daniel.Westcott@pgnmail.com Recipients:

"Herrin, Dennis W." <Dennis.Herrin@pgnmail.com>

Tracking Status: None "McDaniel, Sarah" <Sarah.McDaniel@pgnmail.com>

Tracking Status: None "Saba, Farideh" <Farideh.Saba@nrc.gov>

Tracking Status: None Post Office: WN000074.oak.zone1.progress-energy.com Files Size Date & Time MESSAGE 98 10/23/2012 11:25:19 AM ALION-PLN-ENER-8706-02 Rev 0C- NRC DRAFT.pdf - Adobe Acrobat Pro.pdf 3207630 Options Priority: Standard Return Notification: No Reply Requested: No Sensitivity: Normal Expiration Date:

Recipients Received:

TECHNICAL DOCUMENT COVER PAGE Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page 1 of 19 Document

Title:

Crystal River 3: Bypass Fiber Quantity Test Plan Project No: 261-8706 Project Name: Crystal River 3 Top Hat Strainer Bypass Testing for ENERCON Client: ENERCON Document Purpose/Summary:

This document presents the Alion Test Plan for the Crystal River 3 Top Hat Strainer Bypass Testing measurement. All design inputs are based on the Enercon Design Inputt LLetter [Ref. 10].

This test plan is prepared Safety-related in accordance with the Alion Science and Technology Innovative Technology Solutions Operation Nuclear Quality Assurancee Program.

Prog D

Total Page Count: 43 pages R

X AF Design Verification Method:

Design Review T

Alternative Calculation tion Qualification Testing Professional Engineer (if required) Approval: Date Matthew G. Jursich Prepared By:

Printed/Typed Name Signature Date David Jurjevich Reviewed By: David Daily Printed/Typed Name Signature Date Approved By: Megan Stachowiak Printed/Typed Name Signature Date Form 3.3.1 Revision 2 Effective Date: 2/28/07

REVISION HISTORY LOG Page _2__ of _19_

Document Number: ALION-PLN-ENER-8706-02 Revision: 0C Document

Title:

Crystal River 3: Bypass Fiber Quantity Test Plan D

Instructions:

Project Manager is to provide a brief description of each ch document revision including ach inc rationale for the change R

ts used and, if applicable, identification of source documents d for the change.

REVISION DATE Description 0A AF 10-5-2012 DRAFT Issu Issue 0C 0C T10-16-2012 16--2012 16 20 See Cover Page Incorporated cli Incorporated Incorpora 4.2, 4.3, 4.4.

1 and At C

A lar client comments in Sections 1, 2.0, 3.1, 3.2, 3.4, 3.5, 4.1, 4.4 4.5, 4.6.1, 4.6.2, 4.10, 5.0, 7.2, 8.1, 8.3.1, 11.0 and Appendix Attachment A.

Clarified debris generation and transportation in Section 4.3 and Appendix 1. Re-worded assumption in Section 3.5. Changed purified water to deionized/demineralized in Section 4.6.2. Clarified last fiber addition regarding concentration in Section 5.0 Form 6.1.3 Revision 1 Effective Date: 2/28/07

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 3 of 19 TABLE OF CONTENTS 1.0 Background........................................................................................................................................................... 6 2.0 Test Objectives ................................................................................................................................................... 6 2.1 Strainer Design ............................................................................................................................................... 6 2.2 Fiber Bypass Testing...................................................................................................................................... 7 3.0 Technical Approach ........................................................................................................................................... 7 3.1 Overview of Testing Strategy ..................................................................................................................... 7 3.2 Debris Load Definition ................................................................................................................................. 8 3.3 Scaling of Debris Quantities for Testing .................................................................................................. 8 3.4 Filter Bags ........................................................................................................................................................ 8 3.5 Assumptions .................................................................................................................................................... 9 4.0 ......

Test Description ................................................................................................................................................. 9 4.1 Scaling and Selection of Prototype ............................................................................................................

.................... 9 4.2 Debris and Flow Scaling .............................................................................................................................

.............................. 10 4.3 ............................

Fiber Debris Size Distribution .................................................................................................................. 10 4.4 4.5 4.6 T

Debris Preparation-Fiber ..........................................................................................................................

Debris Introduction ....................................................................................................................................

Hydraulic Test Conditions ........................................................................................................................

10 11 11 4.7 4.8 4.6.2 Water Temperature and Chemistry AF ..........................................

4.6.1 Strainer Approach Velocity ..................................................................................................................

ry ..................................................................................................

stry ..............................

4.6.3 Water Level .............................................................................................................................................

4.6.4 pH ...............................................................................................................................................................

4.6.5 Turbidity ...................................................................................................................................................

Debris Type ..................................................................................................................................................

Test Control .................................................................................................................................................

11 11 11 11 11 12 12 5.0 6.0 7.0 8.0 4.9 4.10 7.1 7.2 D

Preparation ....................................................................................................................................................

R Test Procedures Debris Addition............................................................................................................................................

Test Matrix .........................................................................................................................................................

res................................................................................................................................................

Test Equipment and Specifications ifications............................................................................................................................

Equipment Specifications Specificatio ............................................................................................................... 14 Test Equipment andd Accuracy Accu 12 12 13 13 14

.................................................................................................................. 15 Test Acceptance Criteria................................................................................................................................ 16 8.1 Fiber Bypass .................................................................................................................................................. 16 8.2 Head Loss ...................................................................................................................................................... 16 8.3 Testing Stabilization Criteria ..................................................................................................................... 16 8.3.1 Step Stabilization Criteria ..................................................................................................................... 16 8.3.2 Final Stabilization Criteria ..................................................................................................................... 17 8.4 Test Termination ......................................................................................................................................... 17 9.0 Test Documentation and Records ............................................................................................................... 17 10.0 Debris Handling Requirements ..................................................................................................................... 18 11.0 Quality Assurance Requirements ................................................................................................................. 18 12.0 References .......................................................................................................................................................... 19

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 4 of 19 LIST OF FIGURES Figure 2-1: Strainer and Test Tank Layout .................................................................................................................. 7 Figure 4-1: Alion Hydraulic Test Tank Diagram......................................................................................................... 9 LIST OF TABLES Table 5 Bypass Test Matrix .................................................................................................................................... 13 LIST OF APPENDICES Appendix 1 - Calculation of Testing Parameters ........................................................................................

.......................................... (3 pages)

LIST OF ATTACHMENTS TTACHMENTS HMENT T

Attachment B - Table 3-2 of NUREG/CR-6808 AF Attachment A - Design Input Letter ..............................................................................................................

R-6808 ............................................................................................

ale.......................................

Attachment C - Vortex Strength Scale .............................

(9 pages)

(1 page)

............................................................................................................(1 page)

Attachment D - Material Safety and Data Sheets .....................................................................................(10 pages)

DR

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 5 of 19 ACRONYMS AND DEFINITIONS inches (length)

°C Degrees Celsius

°F Degrees Fahrenheit Alion Alion Science and Technology CFR Code of Federal Regulations CR3 Crystal River 3 cm centimeter D Diameter dp differential pressure ECCS Emergency Core Cooling System stem FE Flow Element GL gpm GSI Generic Letter T

gallons per minute (f Generic Safety Issue (flow) ssue ue low ft HDFG in ITSO kg LDFG AF Feet (of water)

High Density inch Innovative er) sity ty Fiberglass Fiberg ovative Technology Solutions Kilogram Low Density Fiberglass Fibergla Fiberg Solu Operation D

lb LOCA R

MSDS NII PCI PWR QA DS Pound Loss oss o of Coolan Nationa Per Perfo Coolant Accident Material Saf SSafety Data Sheet National Instruments Performance Contracting, Inc.

Pressurized Water Reactor Pr Quality Assurance S or sec second TB Turbidity USNRC/NRC United States Nuclear Regulatory Commission

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 6 of 19

1.0 BACKGROUND

The design of the Emergency Core Cooling System (ECCS) at the Crystal River Nuclear Power Plant provides a suction source for the ECCS pumps, allowing the ECCS to operate in a containment recirculation mode. If a Loss-of-Coolant-Accident (LOCA) inside containment were to occur, it could generate debris that, if transported to and deposited on the containment sump screens, could pass through the screens and affect downstream components and/or the ability to maintain long term core cooling.

The United States Nuclear Regulatory Commission (NRC) Staff has identif ident identified Generic Safety Issue (GSI) rmance." To this rmanc

-191, "Assessment of Debris Accumulation on PWR Sump Performance." t end, on September 13, urized Wate 2004, the NRC issued Generic Letter (GL) 2004-02 to Pressurized Water React Reactor (PWR) Owners for 2.0 TEST OBJECTIVES T

grade ECCS performance action to ensure that LOCA-generated debris does not degrade perform performance.

the screen perforated area using:

AF The objective of this test program is to measure x Prototype strainer hydraulic tankk testing x 5-micron nominal inline filters pre and post-test weights re the mass of the rs to capture bypassed bypa fibrous debris that passes through th fibrou fifiber and subsequently take the difference of x Incremental fiber loading DR 2.1 Strainer Design gn ding to o ensure conservative conservati measurement of fiber bypass A single-ring top hat will be installed in the Alion test tank , see Figure 2-1. The top hat is 38 in length and has a net surface area of 14.70 ft2 [R

((Ref. 10].

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 7 of 19 T

2.2 Fiber Bypass Testing Alion will perform a fiber bypass AF Figure 2-1: Strainer trainer ner and Test Tank LLay asss test on a prototypical Layout prototypic section of the sump strainer to measure the 3.0 D

maximum fiber bypass quantity R

TECHNICAL APPROACH ntity tity through the th test str will be performed in thee Alion Test tank located strainer that is comprised of one top hat. The testing locat in Warrenville, Illinois.

The discussion of technical approach iimplemented in this plan includes the following:

x an overview of testing strategy tra x debris load definition x scaling of plant quantities for testing x filter bags x assumptions 3.1 Overview of Testing Strategy The technical approach implemented in this test plan is to measure the bypassed fiber quantity for a prototypical ECCS strainer using test conditions that conservatively maximize fiber bypass. Alion will perform bypass testing for Enercon in accordance with the requirements of the project plan [Ref. 14].

A representative approach velocity will be passed through a prototypical strainer. Incremental fiber additions simulate the worst-case scenario for fiber bypass by minimizing the concentration, which prevents early bed formation. To account for the installation tolerance of 1/16 for any gaps or

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 8 of 19 openings between connecting components of the strainer that provide entry to the strainer internals, a 1/16 gap will be included between a portion of the test Top Hat and the plenum. Bypassed fiber will be captured using downstream 5-micron filter bags via a 100% pass through alignment in the flow stream, so that bypassed fiber can be captured and measured. See Section 3.4 for filter bag preparation, processing and measuring. The test report will show the measured bypassed fiber quantities per addition and the total quantity of bypassed fiber.

3.2 Debris Load Definition Debris load definition is provided by the Enercon Design Input Letter, which identifies the fibrous debris source terms for the current plant configuration. The single debriss type ppredicted to be destroy post-LOCA at Crystal River is NUKON [Ref. 10]. The debris sourcee terms are sca scaled for the test article in Appendix 1. NUKON will be utilized during testing to represent plant fibrous resent the plan fibrou debris (see Section Debris Preparation [Ref. 12]. T 4.7). NUKON fines and smalls will be created according to the current revision revisio o of the NEI ZOI Fibrous 3.4 Filter Bags The filter bags used for this test AF 3.3 Scaling of Debris Quantities for Testing est sting ting Scaling of debris quantities is detailed in Appendix pendix ix 1.

1 st will be 5-micron mesh me size, which will capture bypassed NUKON D

particles/fibers, which typically R

ALION-SPP-LAB-2352-70 lly havee a diameter of 7-micron ereby facilitating high characteristic length, thereby filters will be dried and weighed before an hig capture cap 7 and are expected to have a much longer efficiencies. Before use and in accordance with 2-70 [Ref. 3], the filters will be prewashed to remove any loose material. The and after testing to calculate the amount of NUKON that was captured in the filter bags during the test. Alion lab procedure ALION-SPP-LAB-2352-70, "Filter Bag Preparation and Processing ProceProcedure, will be the procedure utilized to measure the collected NUKON.

At least seven filter bags will be prepared before the test. During testing one filter bag will be set up to capture NUKON, another used as a control and the remaining filter bags will be switched out one at a time for each fiber addition. Also, filter bags may be replaced as required to maintain acceptable filter bag differential pressure. Filter bags will be dried with set drying times until the difference in weight change between drying sessions is minimal. The test procedures will specify drying time intervals and the weight change differential.

Prior to testing, another set of cleaning filter bags shall be used to completely filter out any latent debris that would affect the post-test mass of the testing filter bags.

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 9 of 19 3.5 Assumptions The following assumption is made:

x The effective surface area of the strainer is 1139 ft2 [Ref. 10]. However, testing will be performed using a scaling ratio based on a 1050 ft2 strainer. This incorporates margin into the results for tag/label sacrificial area.

x The fiber from each addition collects on the screen prior to the next addition and does not remain suspended in the tank volume.

4.0 TEST DESCRIPTION The test will be performed at the Alion Hydraulics Laboratory located Warrenville, IL. A diagram of a ocated in Warre typical test tank instrumentation setup is illustrated in Figure 4-1 4-1..

FT Figure 4-1: Alion Hydraulic Test Tank Diagram 4.1 Scaling and Selection of Prototype A prototype section consisting of one Top Hat will be tested in the tank. This assures a 1 to 1 scaling ratio for dimensions and perforated plate hole size including gaps installed at the base of Top Hats at the plenum. The height of the gap between the plenum and Top Hat will be 1/16 inch (+1/32, -0). The total length of the gap on the interior perimeter of the Top Hat (i.e., adjacent to a plenum cover plate)

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 10 of 19 will be 11-7/16 (+/- 1/16), which may be placed on any single interior side of the Top Hat. The distance between the test Top Hat and the cover plate adjacent to the gap on the interior perimeter of the Top Hat will be 1/4 (+1/16, -0). Also, the total length of gap on the exterior perimeter of the Top Hat (i.e., at the edge of the plenum) will be 7-9/16 (+/- 1/16). The effective surface area of the strainer is 1139 ft2 [Ref. 10]. However, testing will be performed using a scaling ratio based on a 1050 ft2 strainer. This incorporates margin into the results for tag/label sacrificial area. The other test parameters are scaled and are included in Appendix 1.

4.2 Debris and Flow Scaling All testing parameters will be based on the project inputs outlined in the th Design D Input Letter [Ref. 10].

These parameters will be scaled based on the ratio of testing strainer area to plant net effective area.

This scaling factor and its use in determining test parameters are shown in Appendix Append 1. Screen scaling is A

1 to 1, meaning that test conditions can be determined directly by this ratio. T d by taking plant con conditions condit and scaling them 4.3 Fiber Debris Size Distribution AF The fiber debris size distribution given in the design the fibrous debris as large pieces, small esign input letter ((Ref.10] for NUKON debris classifies fines. For the tests outlined in this document, mall pieces, and fines two fibrous debris classifications willll be used, fines charac

[Ref.11] and smalls characterized ed as Classes 4-6 zed characterized as Classes 1-3 in NUREG/CR-6224 4-6 in NUREG/CR-6224.

NU Classes 1-3 fines will be used D

to represent the latent debris R

strainer, with 13% remaining ris source letter [Ref. 10], 92% transport rce term for all tests.

nsport to the strainer.

strain For te For the fines generated in the design input Fo the small pieces generated, 20% transport to the maining as smalls and 7% of the smalls eroding to fines.

4.4 Debris Preparation-Fiber n-Fiber Debris will be prepared according ding tto the NEI ZOI Fibrous Debris Preparation procedure [Ref. 12]. This procedure produces the required size distribution of fiber fines and smalls that are easily transportable and readily disperse in the testing medium. Fines are defined in the NEI procedure document [Ref. 12]

as readily suspendable in water and are Classes 1 through 3 while smalls are class 4 and 5 of Table 3-2 of NUREG/CR-6808 [Ref. 13]. Table 3-2 is in Attachment B. All fiber will be Performance Contracting, Inc.

(PCI) NUKON single side baked between 6 and 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months . Fibrous fines will be cut, weighed out and separated using a commercially available pressure washer, and then verified to meet the correct classification of fiber sizes. Fiber fines are then combined to maintain a fiber mass to volume ratio less than or equal to 0.21 lbs/gal. Fibrous smalls will be cut for the appropriate mass for each specific addition, soaked in water and stirred with a hand paddle until the pieces are fully saturated and separated from each other. Samples of fiber smalls and fines will be examined and photographed using a light-board, or equivalent device, to ensure fiber preparation is consistent with the guidance provided in Reference 12.

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 11 of 19 4.5 Debris Introduction Debris will be introduced into the tank in areas of high velocities near the pump return line. This will allow the flow within the tank to carry the debris to the Top Hats. Adjustable tank internal mixing will be added to areas of low velocities. Batches of fiber will be added in increments that ensure the concentration in the test tank is less than or equal to the plants concentration. The plant concentration is calculated in Appendix 1.

Fiber additions are included in the test matrix in Section 5.0.

4.6 Hydraulic Test Conditions 4.6.1 Strainer Approach Velocity velocity to be modeled to during testing is 0.0185 T

Plant and prototype strainer surface areas for which the

[Re Ref.f. 10] and specified Appendix testing flow rate is given in the design input letter [Ref.

185 ft/s.

he approach velocity is used to calculate the A 1. The approach s The equivalent flow rate for the approach velocity is 122 gpm.

AF 4.6.2 Water Temperature and Chemistry hem hemistry The water temperature will be maintained ntained above 60 °F during durin the course of the test. Temperature shall not exceed the maximum limit of 110 °F. Deionized/demineralized Deionized/d Deionized/de water will be used and the chemistry D

will not be monitored or controlled during this deionized/demineralized water.

R 4.6.3 Water Level wate t test other than initially verifying the use of The pool water level for thee bypass ttest will be initially set at 54 inches. If vortexing occurs, a vortex suppressor will be installed or the he water level will be increased. Any required actions will be recorded in the test logs. The water level will be recorded during testing and increase with each debris addition.

Test tank water may be removed to mix the next debris addition and re-introduced into the test tank.

Test tank water may be discarded after visually verifying there is no fiber within the water to ensure there is room for further debris additions.

4.6.4 pH pH will not be monitored or controlled during this test.

4.6.5 Turbidity The tank liquid may be sampled for turbidity when determined by the test engineer. Turbidity measurements will be recorded for informational purposes only.

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 12 of 19 4.7 Debris Type The low density fiberglass insulation quantities that transport to the strainer will be accurately represented by NUKON. NUKON, provided by PCI, is specified as the plant fibrous insulation. The as-fabricated density of NUKON is 2.4 lb/ft3 and the fiber diameter is 7 microns [Ref. 8]. Attachment D contains Material Safety Data Sheet (MSDS) information.

4.8 Test Control All testing actions and control must be noted in the test log. This includes flow adjustments, debris addition (beginning and completion), stirring (including the duration of the stir), and all other acts that be every affect the testing environment. The test logs shall be able to describe ev everything about the test without recourse to the test engineer.

4.9 Preparation AF The flow rate of the system should be maintained at - 10 gpm, +20 gpm of the prescribed value.

Stabilization criteria for each subtest are given in Section on 8.0 8.0.

x T

The test tank must be arranged and equipped A sparger system will be installed becomes re-suspended.

(see Figure 2-1):

d ass per the following ((se alled on the return line to aid in the suspension of the debris within the water. Mechanical mixers may be utilized in low velocity areas to ensure settled debris shakedown testing can be conducted to ensure that the

d. Hydraulic shakedow x DR eate adequate turbulence return flow will create al pressure tubing The differential tu tubing, bot to suspend the test debris.

both the High and Low lines must be securely fastened inside ent vibrations tthat cause noisy signals. Furthermore, the Low side must be the tank to prevent securely fastened to the plen plenum to prevent ambient leakage.

The National Instruments LabVIEW' data acquisition program must be programmed to match the test parameters, such as screen area and correct orifice plate conversion (see Section 7.0). Imperial units will be displayed and recorded in the test logs and data during testing.

The debris batches of Section 5 must be prepared according to the test matrix and the latest NEI debris preparation procedure [Ref. 12]. The debris preparation documentation from Reference 3 will be included with the execution of this Test Plan.

4.10 Debris Addition All debris will be added in two places directly over the sparger system which will allow the flow within the tank to carry debris to the Top Hat. This will allow for equal debris bed growth on the top hat.

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 13 of 19 The debris must be added in a controlled manner as to not disturb the debris bed through unnecessary turbulence.

Also, visual observations shall be made to ensure that a vortex does not form during the testing. If a vortex does form, water shall be added to the tank to raise the water level until no vortices are observed or a vortex suppressor may be installed.

5.0 TEST MATRIX To maintain the correct debris concentration below that of the plant and to maintain the correct fiber mass to volume ratio given in the NEI debris preparation proceduree [Re [Ref. 112], the volume of water per addition is specified. The six gallons of water added to the testt tank per pe stage will satisfy both criteria above while maintaining practical testing actions during testing.

ing. It is worth noting that the last addition T

for each fiber size will have a different concentration because the addition rrep amount of scaled test fiber for that size classification.

represents the remaining Stage Flow Rate DR NUKON Fines NUKON Smalls Table 5 Bypass Test Matrix Tank Volume Tank Level evel Nom Nominal Bed Concentration (ft3/gal) lbs/gallon Added Gallons AF

Thickness (NEI Added (GPM) (lbs) (lbs) (gal) l) (in))

(in) Criterion)

F.1 122 0.157 0 21 2175 54.00 54 0.053 0.00003 0.03 6 F.2 122 0.157 0 2181 81 54.16 0.107 0.00003 0.03 6 F.3 122 0.157 0 2 2187 54.32 0.160 0.00003 0.03 6 F.4 122 0.030 0 2193 54.48 0.170 0.000006 0.00 6 S.1 122 0 0.036 36 36 2199 54.64 0.182 0.00001 0.01 6 6.0 TEST PROCEDURES The Alion Test Program has developed generic test procedures for debris preparation, fill and start-up testing, and head loss testing. These generic test procedures are applicable, and the current revisions at the time of testing will be used to perform the testing specified in this test plan. Generic test procedures are listed in References 2 through 7.

The Test Lab Safety Procedure, ALION-SPP-LAB-2352-21 [Ref. 7] shall be followed at all times.

The general sequence of the test is as follows:

1. Prepare test filter bags in accordance with procedure ALION-SPP-LAB-2352-70 [Ref. 3].

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 14 of 19

2. Verify the tank has been cleaned in accordance with ALION-SPP-LAB-2352-45 [Ref. 4] and filled according to ALION-SPP-LAB-2352-44 [Ref. 5].

3. Verify the tank is setup correctly and dimensional variations from the general layout included in Figure 2-1 and Figure 4-1 are approved by the Project Manager and/or Test Coordinator.

4. Debris shall be prepared in accordance with the latest NEI debris preparation Procedure [Ref.

12].

5. Photographs of typical samples of prepared debris will be taken.

6. For cleaning purposes, filter bags shall be used to filter water in the tank for at least 5 turnovers prior to adding any debris at a cleaning flow rate greater than the test flow rate to ensure that no residual debris interferes with the measured bypass quantities.

tities tities.

7. Strainer bypass testing will be performed in accordancee with test t specific procedures and the spe Test Matrix described in Section 5 of this Test Plan.

permits. T

8. Photographs of the debris bed and any non-attached hed settled debris must

9. At the conclusion of testing, process test filter bags in accordance a

mus beb taken when visibility with ALION-SPP-LAB-2352-7.0 70 [Ref. 3].

AF

10. Drain and clean the Test Tank in accordance ALION-SPP-LAB-2352-45 [Ref. 4].

TEST EQUIPMENT AND SPECIFICATIO SPECIFICATIONS SPECIFICATION 4].

dance with Test Tank Ta Draining and Cleaning Procedure, D

This section details the test specification In addition, the test equipment R

7.1 Equipment Specifications ecifica ecifications The equipment employed during testing data acquisition system is used requirements in which the test instrumentation must conform.

cation requirement pment used and the accur accuracy of each instrument are discussed.

testin and their associated accuracies are given in Section 7.2. The testi sed tto collect flow rate, differential pressure, and temperature data throughout the performance of the test. This system also allows for the creation of graphs of the data as well as tables of the raw data.

Due to instrument noise and combined instrument uncertainties, the data that is displayed via LabVIEW' (version controlled by [Ref. 1] and verification controlled by [Ref. 2]) is a floating-average, averaged over the previous 10 data points, with each data point recorded every 2 seconds. This averaging may lead to small discrepancies in instrument readouts. In such a case, the most conservative measurement for any given instrument will be recorded in the test logs. For instance, the lowest flow rate, highest differential pressure, and highest temperature shall be recorded in the test logs.

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 15 of 19 7.2 Test Equipment and Accuracy The details of the equipment used and the calibration of the following instruments in this testing are identified and controlled in the Test Program Description, ALION-PLN-LAB-2352-003, Hydraulic Testing of Debris Program

Description:

Test Tank [Ref. 1] and Alion Test Equipment Verification Procedure [Ref. 2]. The following is a summary of the equipment used in this testing:

x Scales and Balances, as needed (balances verified prior to use) o 0 to 150 lbs range, +/- (1% of reading + 0.1 lbs) o 0 to 610 grams range, +/- 0.02 grams o 0 to 6 kilograms range, +/- 0.002 kilograms o 0 to 10 kilograms range, +/- 0.006 kilograms x Pressure transmitters, as needed o 0 to 100 inches of water range, +/- 0.17% % accuracy of upper ran range o 0 to 250 inches of water range, +/- 0.17% 7% accuracy of upper ra range o 0 to 300 inches of water range, +/-- 0.25% % accuracy accura of upper uppe range o 0 to 25 psi range, +/- 0.25% accuracy curacy of upper range ran o 0 to 50 psi range, +/- 0.25% % accuracy uracy of upper range rang x Flow orifice o 70 gpm to 900 gpm, +/- +/- 0.25 % of measured meas velocity v

x Thermocouples o 32 °F to 16522 °F range, +/-- 3 °F, LabV nge, +/ LabVIEW' verified to +/-5%

x Temperature probe obe o -40 °F to 1999 °F range, +/- +//- (0.1%

(0 reading + 2 °F) o -50 to 300 00 °C range, +/- 1 °°C x NI LabVIEW' dataa acquisition system, (version controlled by [Ref. 1])

o Real-time analog og data da acquisition system, allowing continuous display of test parameter values and trends. Data is sampled every two seconds, and averaged over the previous 10 data points. Test data is recorded for each instrument in a simple spreadsheet for later analysis.

x 5-micron nominal filter bags x Digital Caliper o 0 to 6 inches, +/- 0.001 inches x Commercially Available Tape Measure o 0-25, 1/16th inch divisions o 0-12, 1/32th inch division up to one foot, 1/16th inch division after one foot

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 16 of 19 8.0 TEST ACCEPTANCE CRITERIA In accordance with the test objective, the acceptance criterion for this testing is to conduct the fiber bypass test in accordance with applicable test procedures outlined in this document and to successfully collect and record data. The duration of the test shall be no shorter than 13 hours1.50463e-4 days 0.00361 hours 2.149471e-5 weeks 4.9465e-6 months .

8.1 Fiber Bypass Fiber that bypasses the test strainer will be collected continuously throughout the test, examined and quantified at the conclusion of testing.

8.2 Head Loss Head loss measurements will be recorded continuously throughout out the th test and a are used to determine the stability of the debris bed before ending the test.

T To prevent structural failure to the prototype or tankk system, a head loss lim imposed during testing. Above this head loss, the Testt Module, tank lilimit of 6 ft-water will be ta pump, and other components may AF exceed this value. If the head loss approaches maintain a value slightly less than the limit.

8.3 Testing Stabilization Criteria The head loss measurements for teria t.

efore, the head loss acro become susceptible to fatigue or failure; therefore, es this value, the flow rat or this test will be continuously contin r

rate across the debris bed should not of the system may be reduced to recorded by the data acquisition system.

DR times are based on waterr level and flow ra Criter 8.3.1 Step Stabilization Criteria m

The test will be monitored by lab personnel and measurements here are multiple stabilization throughout the test. There stabiliza sta will additionally be recorded manually points throughout the test, each with a particular bility. The criteria are listed in the following sections. Note that pool turnover level of required stability.

rate, and must be calculated separately for each addition.

At least 5 pool turnovers must occur after the end of the debris addition and before the beginning of the next debris addition.

At the completion of each fiber addition step in the test matrix, settled debris shall be agitated manually with the intent to ensure that debris reaches the strainer module and that no significant quantities of debris are allowed to settle elsewhere in the tank environs. However, manual agitation shall continue only until further manual stirring has no noticeable effect on the system head loss or the amount of settled debris. Agitation may be provided through use of a wooden oar or through temporary adjustment of the mechanical mixers. Supplemental agitation shall be conducted carefully to avoid disturbing the debris bed on the strainer module.

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 17 of 19 8.3.2 Final Stabilization Criteria Manual agitation of settled debris will be done to ensure all debris reaches the strainer. Additionally, head loss stabilization may be required by the test coordinator. The test can be considered complete after the following criteria are satisfied:

x The bypass test has to have run for at least 13 hours1.50463e-4 days 0.00361 hours 2.149471e-5 weeks 4.9465e-6 months .

x A minimum of 6 hours6.944444e-5 days 0.00167 hours 9.920635e-6 weeks 2.283e-6 months have elapsed since the last debris batch was added to the tank.

x During the first 2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months of the 6-hour hold, the filter bags m must be switched out every 30 minutes (this results in at least 4 filter bags being used for this step) and once every hour after the 2-hour hold.

x T

Two consecutive filter bags appear to be clean during or after the 6-hour fiber, etc.). These filter bags cannot be the filter 6-hour hold.

6-hou hold (e.g. No visible 6-h er bags changed out dur ter during the first 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months of the 8.4 Test Termination equipment damage or personal injury:

a) The head loss across the AF The following cases require that the testt be immediately y:

ediately terminated terminat termina and the pump secured OFF to avoid he debris bed should not exceed 6 ft-water. If reached, the flow rate will D

be reduced as specified R

maintain the head secured OFF.

ecified in the test ead loss below 6 ft b) Any catastrophic system te procedure.

proced ft-water, ft-wate

-wa If reducing the flow rate as specified fails to the test must be terminated and the pump must be failure, such as loss of power or equipment malfunction (for which no stem failur spare is available), will req require test termination if deemed necessary by the Project Manager or Test Coordinator.

9.0 TEST DOCUMENTATION AND RECORDS The test specific procedure and Test Matrix provide the instructions for performing the required test steps and the associated signatures provide documentation for the performance and witnessing of critical steps. The test specific procedure also provides a test log, which is used to document significant points during the performance of the test.

The Test Equipment Verification Procedure [Ref. 2] provides the means to verify the calibration and setup of each instrument before testing to ensure error-free data acquisition. Furthermore, the procedure is run again near the end of testing to check for instrument failure or inaccuracies produced during testing.

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 18 of 19 Other test laboratory procedures are provided in Section 6.0.

The test logs are used to track the overall progression of testing and not used as safety-related measurements. The data file recorded by the data acquisition system is used for all stabilization calculations, post-test analysis, trending, and application. The Fiber Bypass Report will further clarify how the test data can be utilized.

10.0 DEBRIS HANDLING REQUIREMENTS This test plan identifies a test matrix using fiberglass. All appropriate MSDS shall be followed and the following will be used when handling (preparing, mixing, and adding into th test tank) the materials:

to the x Safety glasses with side shields or goggles, x Cloth or Tyvek laboratory coat, x Dust mask with a N95 rating similar to 3M Model del 82 8210, x Latex, nitrile or neoprene gloves (leak checkk gloves oves before use),

x mme mmended),

Long-sleeved shirt and long pants (recommended),

x Fire extinguisher with water, foam, carbon bon dioxide or dry ppo powder, and x Filled eye wash station in proximity mity to debris.

bris.

None of the testing debris is directly rectly harmful under nnormal no testing use (submerged in the test tank water); therefore, the above personnel sonnel safety equipm equipment is unnecessary between debris additions or preparation.

11.0 QUALITY ASSURANCE REQU REQUIREMENTS loped, implem The test program is developed, impleme implemented, and maintained in accordance with the Alion Science and nology Solutions Operation (ITSO) Quality Assurance (QA) Program for Technology Innovative Technology nuclear safety-related services. Those processes that affect the quality of the output are identified and controlled by project specific procedures.

The goal of the testing program is to develop bypass data that may be used to support safety related analyses; therefore, the data shall be obtained and developed in accordance with the Alion ITSO 10CFR50 Appendix B QA Program. Although this test is designed to measure the quantity of fiber that bypasses the strainer, head loss data will be monitored to ensure strainer integrity is maintained and therefore the Alion QA program will be followed. Materials, parts, and components used by the testing program do not perform safety related functions and are not designated for installation and use in nuclear facilities. The data developed from the testing program, however, will be used to validate the performance and/or form the basis for design of components installed in a nuclear facility. Measuring and test equipment is calibrated in accordance with the ITSO QA Program.

Crystal River 3: Bypass Fiber Quantity Test Plan Document No: ALION-PLN-ENER-8706-02 Revision: 0C Page: 19 of 19 It should be noted that the performance or critical characteristics of the test apparatus and equipment are not the same as that required for a nuclear safety-related system (i.e. not withstand a design basis accident); however, to ensure a quality output, the input and process will be controlled in a quality manner. Those processes that affect quality will be identified and controlled by project-specific procedures. Those processes that affect quality are preparation of test specimens, measurement and test equipment (procurement, calibration, and data collection), and test operation.

The fit, form, and function of materials, parts, and components used for testing and analysis by Alion are controlled by specification to ensure the required design characteristics are established to duplicate onfor onforma and/or model safety-related nuclear components. Certificates of conformance and compliance may be aterials, parts, or components. Debris used to document specification or design compliance for materials, materials tested are supplied commercially from original equipment pment manufacturers.

manufac

12.0 REFERENCES

T AF Current revisions of all Alion procedures shall be used

1. ALION-PLN-LAB-2352-003 - Hydraulic Revision 6, 1/9/09 used.

draulicc Testing of Debri

2. ALION-SPP-LAB-2352 Test Equipment Verification

3. ALION-SPP-LAB-2352-70, 70, Verificat Ve 0, Filter Bag Preparation Debris Program

Description:

Test Tank, Procedure Preparatio and Processing Procedure D

4. ALION-SPP-LAB-2352-45

5. ALION-SPP-LAB-2352-44 R AB-2 AB-23 2 Test Tank Draini 2352 Test Tank AB-2352-46

6. ALION-SPP-LAB-2352-46 AB-2352-21

7. ALION-SPP-LAB-2352-21

8. NEI 04-07, Volumee 1, Rev. 0, December 2004

- Tes Test Lab 1, Pressurized Pressuri Pressur 4

Draining and Cleaning Procedure Ta Fill Procedure

- Test Tank Debris Head Loss Procedure L Safety Procedure Water Reactor Sump Performance Evaluation Methodology,

9. NEI 04-07, Volume 2, Safety Evaluation by the Office of Nuclear Reactor Regulation Related to NRC Generic Letter 2004-02, Rev. 0, December 6, 2004

10. Enercon Design Input Letter, FPC-121-LTR-001 Revision 2, October 15, 2012 (Included as Attachment A)

11. NUREG/CR-6224 Parametric Study of the Potential for BWR ECCS Strainer Blockage Due to LOCA Generated Debris., October 1995

12. Nuclear Energy Institute, ZOI Fibrous Debris Preparation: Processing, Storage and Handling Revision 1, January 2012

13. NUREG/CR-6808 Knowledge Base for the Effect of Debris on Pressurized Water Reactor Core Cooling Sump Performance, February 2003

14. ALION-PLN-ENER-8706-01, Revision 0, Crystal River 3 Top Hat Strainer Bypass Testing for ENERCON

Crystal River 3: Bypass Fiber Quantity Test Plan Page:

Document No: ALION-PLN-ENER-8706-02 Revision: 0C 1-1 of 1-3 Appendix 1 - Calculation of Testing Parameters Inputs:

Net surface area of 48 in test top hat = 14.70 ft2 [Ref. 10]

CR3 total plant strainer screen area 1139 ft2 net [Ref. 10]

Maximum Sump Flow Rate during Recirculation = 8696 gpm [Ref. 10]

NUKON Insulation =10 ft3 [Ref. 10]

Latent Fiber = 30.0 lbm [Ref. 10]

Maximum Containment Water Volume = 71936 ft3 [Ref. 10]

Strainer Area Obstructed by Miscellaneous Debris = 89 ft2 [Ref. 10]

Tank volume = 37.5 gallons/inch (approximately) +150 gallonss (piping volu volume)

Determination of Test Tank Flow Rates T AF The total strainer area obstructed by miscellaneous ft2. Therefore, the total surface area follows:

Crystal River 3 Plant strainer net effective ws:

aneous debris identified fective screen area = 113 iden in i the Design Input Letter is 89 1139 ft2 - 89 ft2 = 1050 ft2 D

Scaling factor (Test Surface Area / Plant Strainer Scre R

The testing flow rate and approach velocity are The Approach Velo ar Screen Area) = 14.70 ft2 / 1050 ft2= 0.014 a determined by the following formulas:

Velocity is determined by the following formula:

App. Velocity = Plant Flow (g (gpm) / (Plant Strainer Area (ft2)

7.48 gallon/ft3

60 sec/min)

App. Velocity = 8696 gpm / (1050 ft2

7.48 gal/min

60 sec/min)

App. Velocity = 0.0185 ft/s The Scaled Test Tank Flow is determined as follows:

Scaled Test Tank Flow = Plant Flow x Scaling Factor Scaled Test Tank Flow = 8696 gpm

0.014 Scaled Test Tank Flow Rate = 121.7 gpm The flow is rounded up to the nearest gpm for practicality in testing therefore, 122 gpm will be used.

Crystal River 3: Bypass Fiber Quantity Test Plan Page:

Document No: ALION-PLN-ENER-8706-02 Revision: 0C 1-2 of 1-3 Table A1-1: Scaling of Flow Rate Plant Strainer Net Approach Scaled Test Tank Scaling Ratio Effective Screen Area Velocity Flow (gpm)

(ft2) (ft/s) 0.0140 1050 0.0185 122 Determination of Plant Concentration and Batch Size The plant concentration is determined by taking the total debriss transported tran to the sump divided by the maximum containment water volume. This concentration on is maintained mainta th throughout testing with T ze. The initial batch (F.1) is calculated below.

the exception of the last debris batches for each debris size.

herefore the amount of NUKON required to The water level changes with each addition and therefore maintain the plant concentration also changes. Seee thee following calculations:

calculation AF Plant Concentration = Total Transported Debris bris (ft3) / Maximum Containment tion = 15.9 Plant Concentration 5.9 ft / (71936 ft 3

Plant Concentration = 00.0000 Initial Batch Size = Initial C

f

7.48 gal/ft )

3 0.00003 ft3 / gallon tial Tank Volume

Plant 3

Water Volume (gal)

Pla Concentration

NUKON Density D

Initial Batch Size = [(54 inches R

nches

37.5 gallons/inch This batch size will model the gallon Initial

) +150 gallons]

0.00003 ft3/gallon

2.4 lb/ft3 tial Batch he fiber suspended s

B Size = 0.16 lb in the sump pool.

Determination of Scaled Mass Values for Test Debris Loads To determine the mass of NUKON for testing, NUKON plant quantities are scaled by volume then multiplied by the density of NUKON (2.4 lb/ft3). The debris transport fractions are taken from the Enercon Design Input Letter [Ref. 10]. The bed thickness is determined by dividing the scaled volume by the strainer surface area (14.70 ft2).

For the fines generated in the design input letter [Ref. 10], 92% transport to the strainer. For the small pieces generated, 20% transport to the strainer, with 13% remaining as smalls and 7% of the smalls eroding to fines. The latent debris source term is documented in the Enercon Design Input Letter is treated at LDFG and will be scaled in the same manner as NUKON above.

Crystal River 3: Bypass Fiber Quantity Test Plan Page:

Document No: ALION-PLN-ENER-8706-02 Revision: 0C 1-3 of 1-3 Table A1-2: Scaling Fiber for Test Quantities Volume Scaled Volume Material Scaled Volume Transport Debris Type Transported to Tran Transported to Density Surrogate Mass Generated (ft3) Fraction 3 Sump (ft3) Sump (ft ) (lbs/ft3) (lbs) 0.13 (Smalls) 1.04 00.015 0.036 8

NUKON 0.07 (Fines) 0.56

.56 0.008 2.4 0.019 2 0.92 (Fines) 1.84 0.026 0.062 Latent Fiber*

30.0 1.0 (Fines) 12.55 0.175 2.4 0.420 (lbs)

TOTAL: 15.9 T

0.224 TOTAL: 0.537

Latent fiber is treated as LDFG and scaled directly from the he mass given as aan input in the Enercon Design Input Letter [Ref. 10]. The volume is calculated using the density of NUKON.

Table A1-3: Test Tes Matrix F

Nominal NUKON UKON Tank Stage Flow Rate (GPM)

NUKON Fines (lbs)

Smalls Sm Volume Tank Level A Bed Thickness Concentration (ft3/gal) lbs/gallon Added Gallons Added (lbs)

(l (gal)

(g (in)

F.1 122 0.157 0 2175 2

R 54.00 0.053 0.00003 0.03 6 F.2 122 0.157 0 2181 54.16 0.107 0.00003 0.03 6 F.3 122 0.157 0 2187 54.32 0.160 0.00003 0.03 6 F.4 122 0.030 0 D 2193 54.48 0.170 0.000006 0.00 6 S.1 122 0 0.036 2199 54.64 0.182 0.00001 0.01 6