ML14127A361

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Chemical Effects Plans for Integrated Testing Presentation for the May 21, 2014 Public Meeting
ML14127A361
Person / Time
Site: Calvert Cliffs  Constellation icon.png
Issue date: 05/03/2014
From: Sellers C
Exelon Generation Co
To:
Office of Nuclear Reactor Regulation
Morgan N
References
Download: ML14127A361 (36)
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Calvert Cliffs Chemical Effects Plans for Integrated Testing Eighth Discussion With NRC Staff May 14, 2014

Agenda

  • Introductions
  • Objectives for Meeting
  • Introduction to CCNPP Program for Vic Cusumano
  • Discussion of Autoclave Chemical Effects Test Results
  • Discussion of Integrated Chemical Effects Testing Plans
  • Discussion of Small-Scale Debris Penetration Testing Plans
  • Schedule for Future Periodic Meetings 1 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

CCNPP Attendees

  • Tom Konerth - Supervisor Mechanical & Civil Design
  • Ken Greene - Licensing Engineer
  • John Swailes - Project Manager GSI-191
  • Craig Sellers - Project Manager RI GSI-191
  • Andy Henni - Lead Design Engineer RI GSI-191
  • Steve Kinsey - Chemical Effects Testing
  • Eric Federline - Chemical Effects Testing
  • Jim Landale - PRA Lead RI GSI-191 2 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Objectives of this Meeting

  • Introduce CCNPP Risk Informed GSI-191 Resolution Project
  • Discuss Autoclave Test Results

- CCNPP-CHLE-005 High Temperature Tests

- CCNPP-CHLE-006 Metals Tests

- CCNPP-CHLE-010 Concrete & Insulation Tests

  • Discuss Integrated Chemical-Effects Head Loss Experiment (CHLE) Test Plans

- CCNPP-CHLE-002

  • Discuss Small Scale Penetration Test Plans
  • Establish Schedule for Future Meetings
  • Capture Staff Issues and Concerns 3 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Introduction to CCNPP RI GSI-191 Project SECY-12-0093 Option 2

  • Parallel Risk-Informed and Deterministic Resolution

- Refined Testing and Analysis to Support Deterministic Resolution

- Risk-Informed Testing and Analysis Partnered with STP

- Replacing Fibrous Insulation as Needed to Support Closure

- Close by 12/2019 4 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Introduction to CCNPP RI GSI-191 Project (Continued)

  • Plant Modifications Completed to Date

- Aluminum Minimization

  • Mineral Wool Replacement
  • Aluminum Scissor Lift Removal
  • Scaffold Removal

- NPSH Assurance

  • New Large Strainer with Structural Reinforcement

- Multiple Large-Scale Strainer Head Loss Tests

- Extensive Chemical Effects Testing Demonstrating Minimal Chemical Effects Head Loss

  • Refueling Cavity Drain Enlargement
  • Recirculation Suction Header Temperature Instrumentation

- Insulation Debris Reduction

  • Removal of Much Mineral Wool
  • Removal of Much Generic Fiberglass
  • Removal of Some Calcium Silicate and Double-Banding of that Remaining in ZOI

- Buffer Replacement

  • Replaced TSP with NaTB 5 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Introduction to CCNPP RI GSI-191 Project (Continued)

  • Downstream Effects

- Ex-Vessel

  • Replaced HPSI Pump Cyclone Separators

- In-Vessel

  • 2007 Strainer Bypass Testing
  • Current On-Going Activities

- Testing

  • Integrated Chemical Effects Testing

- Extensive Interaction with NRC Staff

- Establish Agreement on Methods/Protocols and Acceptance of Results

  • Strainer Penetration (Bypass) Testing
  • Strainer Head Loss Testing, as Required
  • Re-Evaluation of Downstream Effects 6 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Introduction to CCNPP RI GSI-191 Project (Continued)

- Industry Activities

  • Partner in STP RI GSI-191 Resolution Project

- Best-Estimate Calculations

  • Containment Water Mass
  • Pool Temperature Profiles for VS, S, M, L, and VL LOCAs
  • Debris Generation, including CRUD Generation
  • Debris Transport
  • Pool Lithium Concentration
  • Pool Strong Acid Production
  • Pool pH
  • Submerged Concrete
  • Calculations Support Risk-Informed and Deterministic Resolution Approaches

- Risk-Informed Analyses

  • Hybrid LOCA Frequency
  • Initial Risk-Assessment Quantification
  • Participant in PWROG Comprehensive Analysis and Test Programs

- Member of PWROG GSI-191 Challenge Board

- Participating with PWROG GSI-191 TIGER Team 7 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Introduction to CCNPP RI GSI-191 Project (Continued)

Overview of On-Going Chemical Effects Test Program

  • Objective

- Demonstrate Minimal Chemical Effects

- Identify Chemical Effects Head Loss on Detector Debris Bed

- Determine Time and/or Temperature at Which Chemical Effects Head Loss Occurs, or Not

  • Approach

- Long-Term Integrated Chemical Effects Tests

- Circulate Flow Through Repeatable and Sensitive Detector Debris Bed

- Extensive Autoclave Testing to Refine Design of Experimental Protocols

  • Begin with Design Basis Chemical Effects Tests

- DEGB LBLOCA Conditions w/Post 2014 RFO Insulation Replacement Configuration

- Post 2018 RFO Insulation Replacement Configuration, as required

  • Potential Negligible Chemical Effects Outcome

- Permits Deterministic Resolution of GSI-191

  • Risk-Informed Testing, As Necessary

- Medium & Small Break Chemical Effects Testing, as Necessary

- Consistent with STP RI Approach 8 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Introduction to CCNPP RI GSI-191 Project (Continued)

Details of CCNPP Chemical Effects Test Program

  • Autoclave Test Program - 52 Autoclave Tests

- CCNP-CHLE-005 High Temperature Experiment [Complete]

  • Address Initial High Temperature (>195°F) Portion of LOCA (<10 hours)

- CCNPP-CHLE-006 Metals Experiments [Complete]

  • Single and Synergistic Corrosion Effects of Differing Metal Combinations
  • Determine Most Appropriate Metals for Integrated Tests

- CCNPP-CHLE-007 Alkyds Coating Experiments [In-Progress]

  • Investigate Chemical Effects Impact of Alkyd Coatings

- CCNPP-CHLE-010 Concrete Experiments [Complete]

  • Single and Synergistic Corrosion Effects of Concrete and Insulation

- CCNPP-CHLE-011 Long-Term Experiments [In-Progress]

  • Determination of Duration for Long-Term Integrated Experiments
  • 10-Day Autoclave Simulation of Full Integrated Test
  • Tests Completed

- No Increased Filtration Times Observed

- Chemistry Analysis Pending 9 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Introduction to CCNPP RI GSI-191 Project (Continued)

Details of CCNPP Chemical Effects Test Program (Continued)

  • Integrated Chemical Effects Head Loss Experiment (CHLE)

- Use CCNPP-Specific Chemistry Conditions

- Use CCNPP-Specific Materials

- Materials Scaled Appropriately by Volume or Surface Area

- Autoclave Test Results Influenced Design of Experimental Protocols

- Simulate Bounding Sump Temperature Profile

- Circulate Solution Through Detector Debris Bed

- Stepwise Temperature Reduction at End of Experiments 10 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Autoclave Testing Results

  • Contamination Issue
  • CCNPP-CHLE-005 High-Temperature Test Results
  • CCNPP-CHLE-006 Metals Test Results Synergistic Interactions Filtration Results
  • CCNPP-CHLE-010 Concrete & Insulation Test Results 11 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Autoclave Testing - Contamination Issue Zinc Contamination Carryover Autoclave Cleanliness Samples - Zinc

  • Discovered 12/17/13 3000
  • Testing Stopped
  • Cleanliness Criteria Established
  • Cleaning Procedure Qualified 2500
  • Autoclave 1

- No Zn Until 12/5/13 Test 2000 Zn Concentration (ppb)

Autoclave

  • Autoclave 2 1 1500

- First Zn 10/16/13 2 3

  • Autoclave 3 4 1000

- First Zn 10/16/13

  • Autoclave 4 500

- First Zn 9/27/13 0

9/23 10/13 11/2 11/22 12/12 1/1 1/21 2/10 3/2 Sample Date 12 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

High Temperature Portion of LOCA - CCNPP-CHLE-005

  • Initial Portion of LOCA Temperature Profile in Sump > 195°F
  • Autoclave Testing Compared Initial LOCA Profile to Sustained 195°F
  • Zn, Cu, and Ca Releases Comparable at 195°F
  • How to Read Charts

- Red Line, Round Mark: Concentration at Time for Temperature Profile > 195°F

- Black Line, Square Mark: Concentration at Time for Temperature Maintained at 195°F

- 80 Minute: Concentration After 30 Minutes in Borated (Un-buffered) Water (Acidic)

- Green Dashed Line: Temperature Profile from 80 to 600 minutes

- Time = 0: Concentration when Autoclave Reaches 280°F

  • Same Time Delay Applied to 195°F Tests

- Final Concentration of Red Line is at 195°F 13 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

High Temperature Portion of LOCA (Continued)

Ca, Zn, and Cu Releases Comparable at 8000 290 195°F Zinc 270 Concentration (ppb) 6000 250 WCAP-16530 Predicts >40,000 ppb Ca Temp (F) 230 4000 4000 290 210 190 270 2000 Profile 195-Ave 170 3000 Concentration (ppb) 250 CHLE-005 Temp 0 150 Calcium -80 110 300 490 680 870 1060 1250 1440 Temp (f) 230 2000 Time (min) 210 1000 290 190 1000 270 Profile 195-Ave 800 170 Concentration (ppb)

CHLE-005 Temp Copper 250 0 150 600 Temp (F)

-80 110 300 490 680 870 1060 1250 1440 230 Time (min) 400 210 190 Profile 200 195-Ave 170 CHLE-005 Temp 0 150

-80 110 300 490 680 870 1060 1250 1440 Time (min) 14 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

High Temperature Portion of LOCA (Continued)

  • Al, Si, Mg, & Pb Concentrations Lower at Constant 195°F
  • Al, Mg, and Pb Concentrations are Low (<1.5 ppm) in Either Temperature Profile
  • WCAP-16530 Predicts >65,000 ppb Al and >170,000 ppb Si, Silent on Mg and Pb 2000 290 25000 290 Silicon 270 Aluminum 270 Concentration (ppb) Concentration (ppb) 20000 1500 250 250 Profile Temp (F) Temp (F) 230 15000 230 1000 195-Ave 210 10000 210 CHLE-005 Temp 190 190 500 5000 170 Profile 195-Ave 170 Temp 0 150 0 150

-80 110 300 490 680 870 1060 1250 1440 -80 110 300 490 680 870 1060 1250 1440 Time (min) Time (min) 800 290 1600 290 Magnesium 270 270 Lead Concentration (ppb) Concentration (ppb) 600 1200 250 250 Temp (F) Temp (F) 230 230 400 800 210 210 190 190 200 400 Profile 195-Ave Temp 170 170 Profile 195-Ave Temp 0 150 0 150

-80 110 300 490 680 870 1060 1250 1440 -80 110 300 490 680 870 1060 1250 1440 Time (min) Time (min) 15 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Autoclave Testing of Metals - CCNPP-CHLE-006

  • CCNPP Performed Many Autoclave Tests of Metals
  • Various Combinations
  • Objectives were:

- Investigate Single and Synergistic Corrosion Effects of Differing Metal Combinations

- Determine Which Metals are Appropriate for Integrated CHLE Tests

  • 48 Hour Tests with Insulation Debris Materials
  • CHLE-006 Tests Used More Severe Temperature Profile than CHLE-005 Tests Which Unexpectedly Resulted in Higher Dissolved Concentrations of Metals
  • Filtration Results Show No Indication of Precipitates Adversely Impacting Filtration Times and Therefore not Affecting Head Loss 16 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Autoclave Testing of Metals (Continued)

  • Results

- The Following Metals Used in Containment Will Be Included in Integrated Tests

- Interactions Observed

  • Zinc & Aluminum
  • Zinc & Magnesium
  • Zinc & Silicon

- Presence of Zn in Solution With Insulation, Concrete, and Marinite Reduces Release of Al, Mg, and Si

  • High Zn Concentration from Metallic Zn Coupons as Surrogate for Inorganic Zinc-Rich Coatings (IOZ )

17 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Autoclave Testing of Metals (Continued) 60000 280 Presence of Zn in Solution Reduces 260 Release of Al, Mg, & Si 50000 Si Concentration (ppb)

Silicon 240 40000 Temp (F) 220 30000 200 8000 280 20000 180 260 10000 160 Al Concentration (ppb) 6000 240 With Zn No Zn Temp 0 140 Aluminum -100 400 900 1400 1900 2400 2900 Temp (F) 220 4000 Time (min) 200 5000 280 180 260 Mg Concentration (ppb) 2000 4000 160 Magnesium 240 Temp (F)

With Zn No Zn Temp 3000 220 0 140

-100 400 900 1400 1900 2400 2900 2000 200 Time (min) 180 1000 160 With Zn No Zn Temp 0 140

-100 400 900 1400 1900 2400 2900 Time (min) 18 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Autoclave Testing of Metals (Continued)

Filtration Results

  • 68 Filtration Sample Times
  • Average Filtration Time <20 Seconds
  • One Sample > 60 second Filtration 50 Time [144.2 s] 45

- 8 Hour Sample Followed by 3 40 Filtration Time (s) 35 Sample Times ~10 Seconds 30

- Clearly Anomalous 25

- Suspected Fugitive Debris from 18 20 Mesh Baskets 15 8 hr

- Data Point Not Plotted 10 24 hr 5 32 hr 0 48 hr

  • No Indication of Difficult to Filter Precipitates Test Number - Description 19 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Autoclave Tests of Concrete and Insulation - CCNPP-CHLE-010

  • The Following Autoclave Tests Were Run
  • Insulation and Concrete
  • Insulation Only
  • Concrete Only
  • Results
  • Al, Ca, Mg, and Si Released from Both
  • Tests Very Repeatable
  • No Synergies Observed
  • Plant-Specific Concrete to be Used in Integrated Tests 20 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Plans - Test Facility Schematic Vertical Head Heat Exchanger Loss Column Loop Loop Heating &

Cooling 21 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Facility - Photos Initial Prep Tank Primary Reaction Chamber Vertical Head Loss Loop Heat Exchanger Loop 22 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Plans - Reaction Chamber Layout Submerged Coupons in Center Below Recirculation System to Assure Flow Across Coupons and Tank Mixing 23 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Plans - Reaction Chamber CFD

  • Pump Recirculation to Assure Flow
  • CFD Simulation Across Coupons and Tank Mixing 24 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Plans - Reaction Chamber CFD CFD Shows Mixing and Dissolution of Buffer Buffer Basket 25 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Facility Schematic - Initial Prep Lineup 26 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Facility Schematic - Debris Bed Build 27 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Facility - Reaction Chamber Fill 28 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Facility - Loop Venting 29 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Facility - Long-Term Operation 30 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Plans

  • Plant-Specific Chemistry
  • Plant-Specific Materials

- Use Best Estimate (BE) Concentrations - Mineral Wool Insulation

- Bounding Range: 2575 - 2897 ppm

  • Equivalent for

- Best Estimate (BE): 2740 ppm (PD)

  • Nukon
  • Thermal Wrap
  • Sump Lithium Concentration
  • Generic Fiberglass

- Bounding Range: 0.036 -0.974 ppm

  • Temp-Mat

- BE: 0.50 ppm (Average) - Lead Shielding Blankets

  • Materials Provided by Lancs Industries
  • NaTB Buffer Concentration

- Marinite Board Fire Barrier

- 16,500 lbm NaTB Installed

- BE Water Mass for LBLOCA: 4,099,799

  • Materials from CCNPP Warehouse lbm - Concrete

- BE Water Volume @195°F: 509,998

  • Materials from CCNPP Demolition gallons - Galvanized Steel & Copper

- Test Water Volume @195°F: 750 gallons

  • Materials Conforming to Same ASTM Stds

- NaTB: 24.26 lbm

- Coatings

  • Strong Acids
  • Inorganic Zinc Coated Coupons

- HNO3 & HCl Added at Rate Produced

  • Epoxy Coating Excluded

- 30 Day Total Added Before Stepwise

  • Alkyd Coatings TBD (Autoclave Testing in Cooldown Progress)

- Assures Higher pH for Release and Lower pH for Potential Precipitation 31 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Plans (Continued)

  • Temperature Conditions
  • Final Step-Wise Temperature Reduction
  • Duration Determined Based on Results of
  • Duration of Plateaus Based on Time for CCNPP-CHLE-011 Autoclave Test Detection in Debris Bed 150 Test Temperature Profile 140 280 130 255 120 Temperature (F) 230 110 Temp (F) 205 180 100 155 90 130 80 105 70 80 0 24 48 72 96 120 144 168 192 216 240 60 Time (hr) 50 240 245 250 255 260 265 270 275 280 Test Temperature AOR Sump Temperature Time (Hr)

Test Temperature 32 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Integrated CHLE Test Plans (Continued)

Modeling of Marinite Modeling of Zinc-Rich Coatings

  • Marinite Fines Debris Historically Treated
  • Failed Inorganic Zinc Coatings Historically as 10 µm Spheres for Hydraulic Treated as 10 µm Spheres for Hydraulic Characteristics Characteristics
  • Modeling as such in Chemical Effects
  • Modeling as such in Chemical Effects Testing Results in Non-Prototypical Surface Testing Results in Non-Prototypical Surface Area of Solid Marinite Area of Metallic Zinc
  • Calvert Cliffs Proposed Approach
  • Calvert Cliffs Proposed Approach

- Marinite Fine Debris Tested using 1/2 - IOZ in ZOI and Degraded Qualified IOZ Thick Marinite Board with 50% of the Tested using Cured/Aged IOZ Coated Surface Area as 44 µm Spheres Coupons with 2x Surface Area of

- Marinite non-Fines Tested using 1/2 Thick Destroyed or Degraded Coatings Marinite Board with Postulated Surface Area Submerged or Sprayed 33 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Small-Scale Penetration Test Plan

  • Sensitivity Tests

- Water Chemistry

  • Tap Water
  • Borated Buffered DI Water
  • Buffer Type
  • Buffer Concentration

- Water Temperature

  • Controlled Room Temp
  • Elevated (180°F)

- Fiber Mixture

  • Nukon
  • Nukon, Temp-Mat, Min Wool, Cocktail

- Approach Velocity

  • Prototypical Strainer

- Fabricated from Similar Perforated Plate

  • Continuous Filtration
  • Performed Jointly with Arkansas Nuclear One

- 3 Different Pocket Geometries

  • 400 mm Deep (ANO)
  • 200 mm Deep (ANO & CCNPP)
  • 100 mm Deep (ANO) 34 Calvert Cliffs Chemical Effects - Plans for Integrated Testing

Future Meetings

  • June 2014

- Chemical Effects Autoclave Test Results

  • CCNPP-CHLE-007 Alkyds Test
  • CCNPP-CHLE-011 Long Term Test

- Final Chemical Effects Screening Test Protocol

  • Ready to Launch CCNPP-CHLE-002 Integrated CHLE Tests

- Small-Scale Penetration Test Results

  • Ready to Launch Large-Scale Penetration Tests 35 Calvert Cliffs Chemical Effects - Plans for Integrated Testing
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