ML13086A550
| ML13086A550 | |
| Person / Time | |
|---|---|
| Site: | Calvert Cliffs  |
| Issue date: | 03/01/2013 |
| From: | Sellers C - No Known Affiliation |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| CCNPP-CHLE-002, Rev 0e | |
| Download: ML13086A550 (1) | |
Text
CHEMICAL EFFECTS HEAD LOSS EXPERIMENT (CHLE)
TEST PROTOCOL for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002, Revision Oe March 1, 2013 Prepared by: Reviewed by:
Craig D. Sellers Stephen Kinsey & Josh Wargo
Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013 REVISION HISTORY Log Revision Description Od Issue for NRC Review Oe Address S&L and Henni comments
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Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013 1.0 Purpose ......................................................................................................................................................................... 1 2.0 Overall experim ental protocol ............................................................................................................................. 1 3.0 Specific Protocol Topics ......................................................................................................................................... 2 3.1 Experim ental Facility Design .......................................................................................................................... 2 3.2 Debris Preparation and Introduction ..................................................................................................... 8 3.2.1 Fibrous Debris ............................................................................................................................................. 8 3.2.2 Particulate Debris ....................................................................................................................................... 8 3.2.3 Coatings ......................................................................................................................................................... 8 3.2.4 Reactive Materials ...................................................................................................................................... 8 3.3 Fluid Chem istry ..................................................................................................................................................... 9 3.4 Fluid Temperature ............................................................................................................................................... 9 3.5 Head Loss M easurem ent ...................................... ..................................................................................... 9 3.6 Shakedown Testing .......................................................................................................................................... 10 3.7 Baseline Testing .................................................................................................................................................. 10 3.8 Chem ical Effects Head Loss Testing ..................................................................................................... 10 4.0 Method for A pplying Results ............................................................................................................................. 11 4.1 Large Temperature Dependent Chemical Effects Head Loss .................................................... 12 4.2 Small Temperatu re Dependent Chem ical Effects ......................................................................... 13 4.3 No Chem ical Effects ........................................................................................................................................... U Deleted: 13 5.0 References ................................................................................................................................................................. 14 Deleted: 14 List of Fileures Figure 1: Schem atic of Proposed CH LE Facility ................................................................................................... 3 Figure 2: Loop Fill, Heat-Up and Debris Bed Build ............................................................................................. 4 Figure 3: Reaction Cham ber Fill ........................................................................................................................................ 5 Figure 4: Loop Venting .......................................................................................................................................................... 6 Figure 5: Loop Run .................................................................................................................................................................. 7 Figure 6: Debris Bed Differential Pressure ................................................................................................................. 12 List of Tables Table 1: Detector Debr is Beo Composition .......................... ....................................................................... 9 ii
Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013 1.0 PURPOSE The purpose of this document is to describe the protocol planned to be implemented for the chemical effects head loss experiments (CHLE) for the Calvert Cliffs Nuclear Power Plant (CCNPP).
This document presents the methods for performing the experiments, the processes for which the test conditions for each experiment will be established, and the methods for applying the experimental results. The plan for performing these experiments is described in a separate document.
2.0 OVERALL EXPERIMENTAL PROTOCOL The overall concept for the experiments is a long-term integrated chemical effects test with head loss measured throughout the test. A 30-day test duration is considered long-term for this experimental program.
Materials used in the test will be representative of the materials submerged in the containment pool and/or exposed to containment spray. These include destroyed insulation, qualified/unqualified coatings, concrete, latent debris and other miscellaneous materials in containment. The material quantities will be scaled such that ratio of the test fluid volume or mass to the volume or mass of materials immersed in the pool fluid or the surface area of materials exposed to pool or spray fluid is consistent with the ratio of the volume or mass of the post-LOCA pool to the submerged material volume or exposed material surface area at CCNPP. This will maintain consistent chemistry concentrations.
The test chemistry will begin with the initial post-LOCA pool chemistry expected at CCNPP. A scaled quantity of sodium tetraborate decahydrate (NaTB) buffer will be allowed to dissolve in the test chamber to simulate the dissolution of buffer in the plant. Strong acids from the radiologic decomposition of water and electrical cables' may be added periodically to the test at a rate similar to which these acids are expected to be produced at CCNPP. No additional chemical or pH control will occur. The test chemistry will be allowed to evolve as it would in the post-LOCA environment at CCNPP. Water chemistry will be periodically sampled and tested for chemical contents.
The test temperature conditions will replicate the CCNPP post-LOCA temperature profile for the specific break conditions being simulated in the experiment. The last portion of the test will be used to investigate low temperature chemical effects by reducing the temperature in stages until room temperature is achieved.
1 The radiologic decomposition of water and electrical cable insulation and resulting production of strong acids assumes significant core damage. The assumption of core damage is not consistent with successful ECCS performance.
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Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013 Head loss will be monitored throughout the test using a fiber and particulate debris bed formed on a flat perforated plate that has proven to be a good detector of head loss caused by chemical effects
[Ref. 1]. The debris bed will not necessarily be representative of the debris bed expected on the sump strainer or within the reactor core at CCNPP but it will include similar fibrous material. The flow rate through the debris bed will yield a higher approach velocity than that expected at the CCNPP sump strainer and fuel assemblies. The flow rate used will be specified to increase the sensitivity of the debris bed for identification of head loss due to chemical effects.
3.0 SPECIFIC PROTOCOL TOPICS 3.1 Experimental Facility Design The planned design of the experimental facility includes the following major components:
- 1) Reaction Chamber - This chamber contains the material coupons and buffering agent and is used to simulate the containment pool for the long-term test. Test chamber allows for full submergence of coupons as well as exposure to nozzles simulating containment spray.
- 2) Vertical Head Loss Loop - This loop contains the flat perforated plate and debris bed across which chemical effects head loss will be detected.
- 3) Heat Exchanger Loop - This loop contains a cool-down heat exchanger to investigate the potential for chemical precipitation in the shutdown cooling heat exchangers.
- 4) Primary Heater - This heater controls the temperature of the reaction chamber and heats recirculation fluid from the head loss and heat exchanger loops prior to injection into the reaction chamber.
- 5) Recirculation Pumps and Valves - The reaction chamber, vertical head loss loop, and heat exchanger loop have independent recirculation pumps with valves to control flow direction.
- 6) Initial Solution Preparation Chamber - This chamber contains the initial borated water solution simulating the reactor coolant and safety injection fluid and will be discharged into the reaction chamber at the beginning of each experiment to simulate the LOCA.
A schematic diagram of the planned loop is shown in-Figure 1below. Four different operation modes of the loop are shown in Figure 2.through Figure (6. Deleted: Figure 2 Deleted: 2 Deleted: Figure 6 Deleted: 6 Page 2 of 14
Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013 I i I i j 1 i
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Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013 i I I S I 4 I S I I I IS*ToPT7NA - TA1 RFVWW HEACrIDNCHAIWjEH SCILLITIO PI4EPTIALO
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Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013 IREACTICN CHrW-BERFILL Page 5 of 14
Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013
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Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013 Deleted: ¶ Note: This is an early figure and does not include a pressurized reaction tank or a heat exchanger loop.
V Page 7 of 14
Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013 3.2 Debris Preparation and Introduction 3.2.1 Fibrous Debris Fibrous debris, other than the fiber in the vertical head loss loop debris bed, will be cut from new bats of material, boiled to release the binders, dried, and weighed to the quantity specified in the test plan. The fiber samples will be placed in stainless steel mesh containers or otherwise secured to prevent fiber migration into the vertical head loss or heat exchanger loops which could affect head loss in the debris bed. The objective is to limit the impact on head loss to that head loss caused by chemical effects.
3.2.2 Particulate Debris Particulate debris will have no unique preparation process and will be placed in stainless steel mesh containers or otherwise secured to prevent migration into the vertical head loss or heat exchanger loops which could affect head loss in the debris bed. The objective is to limit the impact on head loss to that head loss caused by chemical effects.
3.2.3 Coatings Epoxy and alkyd coatings debris generated from exposure to the break iet.xill be prepared by I Deleted: Qualified coatings and unqualified coatings exposed to the break jet debris applying the coating to a flexible surface.,peeling off the flexible surface after drying, dhthgAJW I Deleted: and pulveriz*d. The objective will be to produce as small a chip or particle as possible. The chips and/or particleswill be weighed and placed in stainless steel mesh containers or otherwise secured J Deleted: removed from the flexible surface I to prevent migration into the vertical head loss or heat exchanger loops which could affect head loss in the debris bed. Inoreanic zinc coatings debris generated from exposure to the break let will be simulated by using inorganic zinc coated coupons with a surface area equivalent to the surface area of the guantitv of 10 um spherical particles calculated to be produced for each break, The objective is to facilitate corrosion and dissolution and limit the impact on head loss to that head loss caused by chemical effects.
Unqualified coatings not exposed to the break jet will be applied to a coupon of substrate similar to that which they are applied at CCNPP. The coupons coated with the surface area specified in the test plan will be introduced into the reaction chamber prior to initiation of each experiment. These coated coupons will be allowed to dissolve and/or corrode normally in the experimental solution.
3.2.4 Reactive Materials Coupons of reactive materials (aluminum, galvanized steel, copper, and concrete) will be placed in the reaction chamber prior to initiation of each experiment. These coupons will be allowed to dissolve and/or corrode normally in the experimental solution.
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Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013 3.3 Fluid Chemistry The fluid chemistry will be established in the initial solution preparation chamber and will match the borated water solution expected at the beginning of the LOCA. This includes any expected lithium hydroide.and/or silica concentrations.
The NaTB buffer will be placed in the reaction chamber prior to the initiation of each experiment and will be allowed to dissolve naturally in the experimental fluid. Strong acids from the radiologic decomposition of water and electrical cables may be added periodically to the test at a rate similar to which these acids are expected to be produced at CCNPP. No additional chemical or pH control will occur.
3.4 Fluid Temperature The fluid temperature will match the sump temperature profile specified in the test plan with a variance of +/-57F.
3.5 Head Loss Measurement Chemical effects head loss will be indicated by measurement of head loss across a debris bed. The debris bed formed on the flat plate screen is intended to provide a highly efficient filtering media capable of readily identifying the head loss impact of potential precipitates on a qualitative basis.
Since the head loss that is being monitored during the course of the test is meant to provide only a qualitative indication of chemical effects impact, the composition of the bed is designed more for filtering and not as a prototypical debris bed for CCNPP. The goal in the debris bed formation is to establish a stable head loss prior to the beginning of the integrated test.
Table 1: Detector Debris Bed Composition Substance Quantity (in grams)
NUKON 16 +/- 0.1 Silicon carbide 80 +/- 0.1 The debris loading for this particular configuration results in a particulate to fiber mass ratio of 5:1.
This detector debris bed was developed during vertical loon head loss testing in late 2008 and early 2009 [Ref. 11. The debris bed was found to provide repeatable head loss results and was sensitive to detecting head loss from chemical precinitates.
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Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision 0e, March 1, 2013 The debris mixture is prepared as follows:
- 1. Blanket NUKON will be double-shredded to produce fines:
- 2. The fiber will be boiled for 10 minutes in RO water:
- 3. The boiled fiber will be immediately drained and rinsed with cold RO water:
- 4. A 2-liter volume of liquid will be taken from the loop:
- 5. The total fiber amount for the test is added to the loop liquid volume to form a suspension and held at 135 + 5 -F:
- 6. The suspension will be agitated using a hand mixer (set at high speed) for four minutes;
- 7. The test engineer will visually examine the resulting slurry and insure that no clumps ot wetted insulation exist*
- 8. Once the slurry agitation is comolete, the susoension is aeltated using a stirrine rod:
- 9. Particulate is added to the fiber slurry and agitated using a stirring rod and visually examined to ensure no clumping of either debris type:
- 10. Agitation continues until slurry is added to the test looM The debris mixture is introduced into the column at the flanged opening above the screen. The debris slurry fiber-particulate mixture from the mixine container must be added slowly to the onening in the column over a period of one minute. The slurry mixture shall be poured slowly around the internal peripher of the opening to facilitate uniform bed thickness formation. While pouring the mixture. the slurry shall be agitated with a stirring rod in the container and in the column to ensure homoeeneitv of the mixture.
3.6 Shakedown Testing A number of shakedown tests will be performed to verify correct design of the test facility and to demonstrate effective and repeatable performance of the head loss column and debris bed.
3.7 Baseline Testing A Baseline test will be performed with the appropriate fluid chemistry but without the insulation debris and potentially reactive materials which will provide non-chemical effects long term head loss across the test temperature range.
3.8 Chemical Effects Head Loss Testing A chemical effects head loss is defined as any change in head loss not attributable to expected non-chemical effects reasons. Such reasons are changes in fluid viscosity and density with changes in fluid temperature.
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Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision 0e, March 1, 2013 Another reason is the gradual steady increase in debris bed head loss observed in most long term head loss tests. This is termed debris bed degradation. The cause of this gradual head loss increase is debris bed compaction and the subsequent decrease in porosity.
The chemical effects head loss experimental test will be performed with the appropriate fluid chemistry and the potentially reactive materials which will provide total long term head loss across the test temperature range. Differences in this test and the baseline test will be deemed chemical effects head loss.
4.0 METHOD FOR APPLYING RESULTS As discussed earlier. CCNPP performed vertical loop head loss testing in late 2008 and early 2009
[jeL1] during which the detector debris bed was developed. A test was performed to demonstrate the sensitivity of the detector debris bed to chemical effects head loss. This test was performed at 135 OF using a screen approach velocity of 0.028 ft,/sec. and 0.55 grams of sodium aluminum silicate chemical precipitate surrogate prepared according to the WCAP-16530 specifications added to the loop. This amount represented approximately 1-ppm of sodium aluminum silirate.
The debris bed differential pressure results of this test are shown in Figure 6. The differential pressure across the debris bed increased from approximately 0.2 ft-water to 8 ft-water. This is a 3900% increase in differential pressure due to the introduction of only 1-ppm of surrogate precipitate and clearly demonstrates the sensitivity of the detector debris bed.
Our proposed method for anplying the results of the current test program is to scale the head loss observed in large-scale prototypical strainer head loss testing using WCAP-16530 surrogate precipitates based on the chemical effects head loss observed in these integrated chemical effects head loss tests. The criterion for laree chemical effects head loss will be a 100% increase differential pressure. This is conservative as it represents less than 2.5% of the increase in differential pressure observed due to the introduction of only 1-ppm of WCAP-16530 surrogate precipitate on the detector debris bed, Page 11 of 14
Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision 0e, March 1, 2013 10 140 8 120 6 0 01 0>
a- 4 so 2 60 0 40 0 2 3 4 5 Time [hr]
Filgm6: Debris Bed Differential Pressure 4.1 Large Temperature Dependent Chemical Effects Head Loss ....
One form of result that is not expected but must be recognized as possible is a large chemical effects I
Deleted: The method depends for applying on the form the testThree of the results.
possible forms of results are foreseen:¶ head loss on the detector debris bed at a specific temperature. Large chemical effects head loss is defined as a detector debris bed head loss increase of greater than 100% as compared to the baseline test head loss with no chemical effects. For example, head loss through the debris bed initially 1 ft-water that increases to 2 ft-water for a reason that cannot be explained by density and/or viscosity changes with temperature or by long-term bed degradation, would be considered a large chemical effects head loss.
In this case, CCNPP will apply the WCAP- 16530 chemical effects test head loss to the CCNPP suction strainer at all temperatures at or below the temperature at which the chemical effects head loss is observed. This WCAP-16530 head loss impact will be based on prototype strainer hydraulic testing using surrogate precipitates generated in accordance with the WCAP-16530 model.
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Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision 0e, March 1, 2013
, Deleted: Itis noted that the A CCNPP prototypical strainer hydraulic test simulating a olant confiouration similar to the cUrrent Deleted: ing CCNPP-2 conflurationproduced strainer debris bed head loss value.-wate.prior to the introduction of WCAP-16530 surrogate precipitate, The head loss increase d to. water,*fi= Deleted less than 10 the introduction of 13.9-prpm of WCAP-16530 surrogate precipitate which is an approximate Delete 33
% increase.
Deleted: ft The detector debris bed responded with a 3900% increase in head loss from 1-pom of WCAP- Deleted:
16530 precipitate. The concentration of preclnitate oredicted by WCAP-16530 for CCNPP is \ Deleted: s greater than S-ppm. Therefore applying this total WCAP-16530 head loss when a >100% increase Deleted: over 690 mbar(
in detector debris bed head loss is conservative. Deleted: >223 Deleted: It 4.2 Small Temperature Dependent Chemical Effects Deleted:)
Deleted: 68800 One possible form of result that is more likely to be observed than the large impact is a small Deleted: st rained chemical effects head loss on the detector debris bed at a specific temperature. Small chemical Deleted: 2 effects head loss is defined as a detector debris bed head loss increase of greater than or equal to Deleted: ft 10% and less than or equal to 100% compared to the baseline test. Deleted: 6 Deleted: It In this case, CCNPP will apply a ratio of the WCAP-16530 chemical effects test head loss to the Deleted: 2 CCNPP suction strainer at all temperatures at or below the temperature at which the chemical Deleted: ft effects head loss is observed. The ratio will be the percentage increase in chemical effects head loss Deletd: 6 observed over the non-chemical effects head loss observed. Deleted: ft Deleted: 2 Chemical Effects Strainer Head Loss = % head loss increase due to chemical effects observed Deleted: ft in test x WCAP-16530 head loss.
- Deleted: f For example, if the head loss through the detector debris bed in the test is initially 1 ft-water but Ib' Deleted: The CCNPPprototypical strainer hydraulic tessting produced strainer debris bed increases to 1.5 ft-water for a reason that cannot be explained by density and/or viscosity changes S head lossval water) prior ues lessthan 10 mbar (-0.33 ft-to the introduction ofWCAP-16530 with temperature, head loss increase due to chemical effects would be a 50% increase. Thus, if surrogate over pr, ecipitates. The head loss increased to 690 rob, ar (>23 ft-water) which is an during the CCNPP prototypicalUan hydrautlic testing the stabilized strainer head loss prior to approximate 6800% increase. Therefore introduction ofintroduction.of.CA..16..0.p..c.pt.tes....ajl=
WCAP-16530 precipitates was.0.0jn-water and after introduction of WCAP-16530 applying a head loss ba., ercentage of this total WCAP-16530 ed on a >0% to 100% increase in precipitates it stabilized at 23owater,_the strainer head loss attributable to chemical effects now r detector deb ris bed head loss is conservative. For example, has ed on the -0.33 ft-water debris bed becomesgA ~jn-water
+ 0.5*(32.-jn-water -,.80j-water) =,Z.Q.n-water. head loss obhserved during prototypical strainer testing a 20' %increase in detector debris bed head loss translates into 0.33 +0.2*(23 - 0.33) =
4.3 :Jjjjg]*Chemical Effects 4.86 which isa 1400% increase in debris bed head loss.¶ One form of test results is thatl b chemical effects head loss or in-vessel chemical reaction is ¶ observed. A head loss variation of less than +10% compared to the baseline test is considered Deleted: no I.neaj~gbchemical effects head loss. If this is the result, chemical effects can be ignored at CCNPP. O Page 13 of 14
Chemical Effects Head Loss Experiment (CHLE)
Test Protocol for Calvert Cliffs Nuclear Power Plant CCNPP-CHLE-002 Revision Oe, March 1, 2013
5.0 REFERENCES
- 1. Design Calculation CA07055, Rev. 0001 (ALION-REP-CCNPP-7311-001, CCNPP Chemical Effects Vertical Loop Head Loss Test Report, Revision 2).
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