ML16152A123
| ML16152A123 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 06/01/2016 |
| From: | Ameren Missouri |
| To: | Division of Operating Reactor Licensing |
| Klos L, NRR/DORL/LPLIV-1, 415-5136 | |
| References | |
| Download: ML16152A123 (36) | |
Text
1 Callaway Energy Center Strainer Testing for GSI-191 06/01/2016 Callaway Energy Center Strainer Testing for GSI-191 Ameren Missouri Nuclear Regulatory Commission Rockville, MD
2 Callaway Energy Center Strainer Testing for GSI-191 DESIRED OUTCOMES
- Generate a mutual understanding of testing to resolve GSI-191
- Keep staff informed of Callaway Energy Center GSI-191 Resolution Project progress
3 Callaway Energy Center Strainer Testing for GSI-191 OVERVIEW
- Risk-Informed Approach
- Plant Characteristics
- Debris Loads
- Fiber
- Particulates
- Solution Chemistry
- Testing Process
- Overview
- Specific Approach
- Staff Feedback
4 Callaway Energy Center Strainer Testing for GSI-191 PRIORITIES FOR UNDERSTANDING Test Process Steps
- 1. Form chemical surrogate in laboratory grade water
- 2. Determination of thin-bed condition by visual inspection
- 3. Strategies for reducing Non-Q coating burden Test Attributes
- 1. Treatment of small debris
- 2. Strainer geometry (no curb around test module)
- 3. Flow history with respect to spray and precipitates
- 4. Particulate surrogate
5 Callaway Energy Center Strainer Testing for GSI-191 CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191 Risk-Informed Approach
6 Callaway Energy Center Strainer Testing for GSI-191 TWO TEST SERIES FOR STRAINER PERFORMANCE
- Head loss testing
- Fiber penetration testing
- All test procedures, instrumentation, and materials are developed and procured/dedicated Safety Related to support deterministic portion of RoverD
7 Callaway Energy Center Strainer Testing for GSI-191 INFORMATION PROVIDED
- Information provided for NRC review
- Test specification
- Test plan
- Presentation
8 Callaway Energy Center Strainer Testing for GSI-191 TEST SCHEDULE
- Shakedown June 7, 13
- Head loss tests 1, 2 and 3 June 20, 27 July 5
- Fiber penetration tests 1 and 2 July 11, 18
- NRC staff observation Recommend 2nd head loss test (June 27)
9 Callaway Energy Center Strainer Testing for GSI-191 Plant Characteristics CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
10 Callaway Energy Center Strainer Testing for GSI-191 PLANT CHARACTERISTICS
- Nukon fiberglass on RCS and equipment
- RMI on steam generators
- Non-Q coatings
- TSP dry buffer system
- PCI strainer modules in vertical stacks
- EOP used to ensure submergence
- Full strainer area ~3300ft2
- Test module scale ~10.5%
11 Callaway Energy Center Strainer Testing for GSI-191 INDEPENDENT SUMP TRAINS
12 Callaway Energy Center Strainer Testing for GSI-191 Test module equals full short stack RECESSED STRAINER MANIFOLD
13 Callaway Energy Center Strainer Testing for GSI-191 Debris Loads (Fiber)
CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
14 Callaway Energy Center Strainer Testing for GSI-191 BASIC TREATMENT OF FIBER
- ZOI consistent with approved methodology
- Erosion consistent with approved methodology
- Transport consistent with guidance and Drywell Debris Transport Study (DDTS)
- All fines assumed to transport
- Small Fiber
- Add small-fiber (as small fiber) after all fines
- NEI guidance for fiber debris preparation and handling
15 Callaway Energy Center Strainer Testing for GSI-191 CEC BREAK SPECTRUM Every break has unique debris Every break has a frequency
~600k weighted samples of size and direction at all welds About 4600 lbm of Non-Q coating Traditional DBA loads near upper right RoverD fiber goal near 300 lbm DBA Loads RoverD Fiber Failures (critical welds)
Bounding Particulate
16 Callaway Energy Center Strainer Testing for GSI-191 Debris Loads (Test Particulates)
CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
17 Callaway Energy Center Strainer Testing for GSI-191 Coating Debris Quantity CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
18 Callaway Energy Center Strainer Testing for GSI-191 MAX CEC COATING DEBRIS (FOR TEST PLANNING)
- Estimates based on max DEGB at independent locations
- Present test load larger than 2008 test load
- High particle-to-fiber mass ratios for most breaks Coating Type Total Debris Volume (ft³)
Test Mass Typical 2008 Surrogate (lbm)
Test Mass SiO2 Surrogate (lbm)
Acrylic/Epoxy 21.8 435 379 IOZ 13.1 629 228
19 Callaway Energy Center Strainer Testing for GSI-191 STRATEGIES TO REDUCE PARTICULATE IMPACT 1.
Test particulate loads that bound RoverD critical welds 2.
Choose a second RoverD-type limit for particulates (next slide) 3.
Reduction of coating particulate 4.
Justify some Non-Q failure as chips
20 Callaway Energy Center Strainer Testing for GSI-191 ROVERD-TYPE LIMIT FOR PARTICULATES RoverD Fiber Failures (critical welds)
Second RoverD-type criterion for coatings (ex 5200 lbm)
Preliminary risk estimate of CDF
= 3.3e-7 per yr No increase in critical weld count (approx 55 welds)
RoverD Particulate Failures (critical welds)
21 Callaway Energy Center Strainer Testing for GSI-191 Particle Surrogate CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
22 Callaway Energy Center Strainer Testing for GSI-191 CANDIDATE PARTICULATES 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x PCIpaint 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x SiO2-Agsco-325 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x 2008 Pulverized Paint 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x Tin-AcuPowder-115 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x Walnut Flour 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x SiO2-Agsco-70 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x SiO2-MinuSil5 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x SiO2-MinuSil10
23 Callaway Energy Center Strainer Testing for GSI-191 SURROGATE SELECTION PROCESS 1.
Calculate the CEC particulate volume for damaged organic and damaged IOZ coatings (Q and Non-Q) 2.
Examine the corresponding particle distribution obtained using typical 2008 surrogates 3.
Match the particle distribution using available silicates 4.
Confirm the small and large diameter components with physical descriptions consistent with guidance
24 Callaway Energy Center Strainer Testing for GSI-191 CLOSE COMPOSITE 10
-1 10 0
10 1
10 2
10 3
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
particle diam (µm) fraction <= x SiO2-Agsco-70 + SiO2-MinuSil5 Typical 2008 Composite Silicate Composite
25 Callaway Energy Center Strainer Testing for GSI-191 Solution Chemistry CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
26 Callaway Energy Center Strainer Testing for GSI-191 TEST SOLUTION
- Penetration test solution
- pH during early fiber ingestion (first pool turn over)
- Quickest TSP dissolution is ~105 min
- Headloss test solution
- Solution pH determined by RoverD fiber target (likely LBLOCA)
Condition Initial pH Max Steady State pH Estimated TSP basket s wetted at start of recirc Time to recirculation Estimated turn over time SBLOCA 4.6-4.7 4.7 - 7.5 Less than 10 min 133 min
~2 hours LBLOCA 4.6-4.7 7.1 -7.3 Less than 5 min 12.5 min
~0.5 hour5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br />
27 Callaway Energy Center Strainer Testing for GSI-191 PRECIPITATE
- Precipitate type
- AlOOH and Ca3(PO4)2
- Precipitate quantity
- Multiple batches that range from 24-hr chemical to NPSH failure
28 Callaway Energy Center Strainer Testing for GSI-191 Testing Process CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
29 Callaway Energy Center Strainer Testing for GSI-191 FACILITY DESCRIPTION Tank test configuration to maximize transport NEI fiber debris preparation WCAP-16530 chemical surrogate preparation Alden debris introduction Time-lapse video P, level, T (120F), pH spot checks
30 Callaway Energy Center Strainer Testing for GSI-191 TEST LOOP P&ID
31 Callaway Energy Center Strainer Testing for GSI-191 GENERIC HEAD LOSS TEST Step 1
- Conventional debris up to target (batches)
Step 2
- EOP flow reduction Step 3
- Bed stability checks Step 4
- Chemical surrogate add (batches)
32 Callaway Energy Center Strainer Testing for GSI-191 GENERIC PENETRATION TEST
Purpose:
Characterize quantity of fiber passing through strainer module as function of load
- Single pass fiber with 100% downstream capture
- Two tests at max velocity for pH effect
- Alden process for sample collection, filter dry, weigh
33 Callaway Energy Center Strainer Testing for GSI-191 TEST SPECIFIC - PRECIPITATE
- Precipitate produced per WCAP-16530 protocol in same laboratory grade water used for borated/buffered solution
- Test velocity and precipitate load addition
- After fiber/particles, add 24-hour Ca3(PO4)2 load, reduce velocity, batch all additional chemicals
34 Callaway Energy Center Strainer Testing for GSI-191 THIN-BED CONFIRMATION BY INSPECTION
- Consistent with Pilot plant 2008 thin-bed confirmation
- Supported by high particle-to-fiber mass ratios
- Supported by experience with thin-bed protocol
- Optional 3rd test for performance characterization or replicate
35 Callaway Energy Center Strainer Testing for GSI-191 OLD TEST VS NEW TEST Near-field settling in flume Wood chipper fiber Walnut flour overestimated required debris volume by 20%
Tap water Debris batches
- Fiber fines, walnut flour, tin, fiber fines, large debris
- Batches did not have similar fiber-to-particulate ratios Surrogates
- Walnut shell flour, tin, chips, and fine, small, large LDFG Maximum transport in tank NEI prep fiber Particulate scaling conserves volume
- Increases IOZ by x3 Buffered borated water Has no epoxy chips Particulate and fiber fines introduced simultaneously
- Batches have similar fiber to particulate ratios Surrogates
- Silicates for all coating, LDFG fines and smalls 2007 Test 2016 Test
36 Callaway Energy Center Strainer Testing for GSI-191
SUMMARY
AND FEEDBACK
- Improve quality assurance and repeatability by forming chemical surrogates in laboratory-grade water
- Non-Q coatings are the dominant challenge for successful strainer testing
- Staff invited to attend head loss testing to confirm formation of thin bed at high particulate-to-fiber load
1 Callaway Energy Center Strainer Testing for GSI-191 06/01/2016 Callaway Energy Center Strainer Testing for GSI-191 Ameren Missouri Nuclear Regulatory Commission Rockville, MD
2 Callaway Energy Center Strainer Testing for GSI-191 DESIRED OUTCOMES
- Generate a mutual understanding of testing to resolve GSI-191
- Keep staff informed of Callaway Energy Center GSI-191 Resolution Project progress
3 Callaway Energy Center Strainer Testing for GSI-191 OVERVIEW
- Risk-Informed Approach
- Plant Characteristics
- Debris Loads
- Fiber
- Particulates
- Solution Chemistry
- Testing Process
- Overview
- Specific Approach
- Staff Feedback
4 Callaway Energy Center Strainer Testing for GSI-191 PRIORITIES FOR UNDERSTANDING Test Process Steps
- 1. Form chemical surrogate in laboratory grade water
- 2. Determination of thin-bed condition by visual inspection
- 3. Strategies for reducing Non-Q coating burden Test Attributes
- 1. Treatment of small debris
- 2. Strainer geometry (no curb around test module)
- 3. Flow history with respect to spray and precipitates
- 4. Particulate surrogate
5 Callaway Energy Center Strainer Testing for GSI-191 CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191 Risk-Informed Approach
6 Callaway Energy Center Strainer Testing for GSI-191 TWO TEST SERIES FOR STRAINER PERFORMANCE
- Head loss testing
- Fiber penetration testing
- All test procedures, instrumentation, and materials are developed and procured/dedicated Safety Related to support deterministic portion of RoverD
7 Callaway Energy Center Strainer Testing for GSI-191 INFORMATION PROVIDED
- Information provided for NRC review
- Test specification
- Test plan
- Presentation
8 Callaway Energy Center Strainer Testing for GSI-191 TEST SCHEDULE
- Shakedown June 7, 13
- Head loss tests 1, 2 and 3 June 20, 27 July 5
- Fiber penetration tests 1 and 2 July 11, 18
- NRC staff observation Recommend 2nd head loss test (June 27)
9 Callaway Energy Center Strainer Testing for GSI-191 Plant Characteristics CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
10 Callaway Energy Center Strainer Testing for GSI-191 PLANT CHARACTERISTICS
- Nukon fiberglass on RCS and equipment
- RMI on steam generators
- Non-Q coatings
- TSP dry buffer system
- PCI strainer modules in vertical stacks
- EOP used to ensure submergence
- Full strainer area ~3300ft2
- Test module scale ~10.5%
11 Callaway Energy Center Strainer Testing for GSI-191 INDEPENDENT SUMP TRAINS
12 Callaway Energy Center Strainer Testing for GSI-191 Test module equals full short stack RECESSED STRAINER MANIFOLD
13 Callaway Energy Center Strainer Testing for GSI-191 Debris Loads (Fiber)
CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
14 Callaway Energy Center Strainer Testing for GSI-191 BASIC TREATMENT OF FIBER
- ZOI consistent with approved methodology
- Erosion consistent with approved methodology
- Transport consistent with guidance and Drywell Debris Transport Study (DDTS)
- All fines assumed to transport
- Small Fiber
- Add small-fiber (as small fiber) after all fines
- NEI guidance for fiber debris preparation and handling
15 Callaway Energy Center Strainer Testing for GSI-191 CEC BREAK SPECTRUM Every break has unique debris Every break has a frequency
~600k weighted samples of size and direction at all welds About 4600 lbm of Non-Q coating Traditional DBA loads near upper right RoverD fiber goal near 300 lbm DBA Loads RoverD Fiber Failures (critical welds)
Bounding Particulate
16 Callaway Energy Center Strainer Testing for GSI-191 Debris Loads (Test Particulates)
CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
17 Callaway Energy Center Strainer Testing for GSI-191 Coating Debris Quantity CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
18 Callaway Energy Center Strainer Testing for GSI-191 MAX CEC COATING DEBRIS (FOR TEST PLANNING)
- Estimates based on max DEGB at independent locations
- Present test load larger than 2008 test load
- High particle-to-fiber mass ratios for most breaks Coating Type Total Debris Volume (ft³)
Test Mass Typical 2008 Surrogate (lbm)
Test Mass SiO2 Surrogate (lbm)
Acrylic/Epoxy 21.8 435 379 IOZ 13.1 629 228
19 Callaway Energy Center Strainer Testing for GSI-191 STRATEGIES TO REDUCE PARTICULATE IMPACT 1.
Test particulate loads that bound RoverD critical welds 2.
Choose a second RoverD-type limit for particulates (next slide) 3.
Reduction of coating particulate 4.
Justify some Non-Q failure as chips
20 Callaway Energy Center Strainer Testing for GSI-191 ROVERD-TYPE LIMIT FOR PARTICULATES RoverD Fiber Failures (critical welds)
Second RoverD-type criterion for coatings (ex 5200 lbm)
Preliminary risk estimate of CDF
= 3.3e-7 per yr No increase in critical weld count (approx 55 welds)
RoverD Particulate Failures (critical welds)
21 Callaway Energy Center Strainer Testing for GSI-191 Particle Surrogate CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
22 Callaway Energy Center Strainer Testing for GSI-191 CANDIDATE PARTICULATES 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x PCIpaint 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x SiO2-Agsco-325 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x 2008 Pulverized Paint 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x Tin-AcuPowder-115 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x Walnut Flour 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x SiO2-Agsco-70 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x SiO2-MinuSil5 10
-1 10 0
10 1
10 2
10 3
0 0.2 0.4 0.6 0.8 1
particle diam (µm) fraction <= x SiO2-MinuSil10
23 Callaway Energy Center Strainer Testing for GSI-191 SURROGATE SELECTION PROCESS 1.
Calculate the CEC particulate volume for damaged organic and damaged IOZ coatings (Q and Non-Q) 2.
Examine the corresponding particle distribution obtained using typical 2008 surrogates 3.
Match the particle distribution using available silicates 4.
Confirm the small and large diameter components with physical descriptions consistent with guidance
24 Callaway Energy Center Strainer Testing for GSI-191 CLOSE COMPOSITE 10
-1 10 0
10 1
10 2
10 3
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
particle diam (µm) fraction <= x SiO2-Agsco-70 + SiO2-MinuSil5 Typical 2008 Composite Silicate Composite
25 Callaway Energy Center Strainer Testing for GSI-191 Solution Chemistry CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
26 Callaway Energy Center Strainer Testing for GSI-191 TEST SOLUTION
- Penetration test solution
- pH during early fiber ingestion (first pool turn over)
- Quickest TSP dissolution is ~105 min
- Headloss test solution
- Solution pH determined by RoverD fiber target (likely LBLOCA)
Condition Initial pH Max Steady State pH Estimated TSP basket s wetted at start of recirc Time to recirculation Estimated turn over time SBLOCA 4.6-4.7 4.7 - 7.5 Less than 10 min 133 min
~2 hours LBLOCA 4.6-4.7 7.1 -7.3 Less than 5 min 12.5 min
~0.5 hour5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br />
27 Callaway Energy Center Strainer Testing for GSI-191 PRECIPITATE
- Precipitate type
- AlOOH and Ca3(PO4)2
- Precipitate quantity
- Multiple batches that range from 24-hr chemical to NPSH failure
28 Callaway Energy Center Strainer Testing for GSI-191 Testing Process CALLAWAY ENERGY CENTER STRAINER TESTING FOR GSI-191
29 Callaway Energy Center Strainer Testing for GSI-191 FACILITY DESCRIPTION Tank test configuration to maximize transport NEI fiber debris preparation WCAP-16530 chemical surrogate preparation Alden debris introduction Time-lapse video P, level, T (120F), pH spot checks
30 Callaway Energy Center Strainer Testing for GSI-191 TEST LOOP P&ID
31 Callaway Energy Center Strainer Testing for GSI-191 GENERIC HEAD LOSS TEST Step 1
- Conventional debris up to target (batches)
Step 2
- EOP flow reduction Step 3
- Bed stability checks Step 4
- Chemical surrogate add (batches)
32 Callaway Energy Center Strainer Testing for GSI-191 GENERIC PENETRATION TEST
Purpose:
Characterize quantity of fiber passing through strainer module as function of load
- Single pass fiber with 100% downstream capture
- Two tests at max velocity for pH effect
- Alden process for sample collection, filter dry, weigh
33 Callaway Energy Center Strainer Testing for GSI-191 TEST SPECIFIC - PRECIPITATE
- Precipitate produced per WCAP-16530 protocol in same laboratory grade water used for borated/buffered solution
- Test velocity and precipitate load addition
- After fiber/particles, add 24-hour Ca3(PO4)2 load, reduce velocity, batch all additional chemicals
34 Callaway Energy Center Strainer Testing for GSI-191 THIN-BED CONFIRMATION BY INSPECTION
- Consistent with Pilot plant 2008 thin-bed confirmation
- Supported by high particle-to-fiber mass ratios
- Supported by experience with thin-bed protocol
- Optional 3rd test for performance characterization or replicate
35 Callaway Energy Center Strainer Testing for GSI-191 OLD TEST VS NEW TEST Near-field settling in flume Wood chipper fiber Walnut flour overestimated required debris volume by 20%
Tap water Debris batches
- Fiber fines, walnut flour, tin, fiber fines, large debris
- Batches did not have similar fiber-to-particulate ratios Surrogates
- Walnut shell flour, tin, chips, and fine, small, large LDFG Maximum transport in tank NEI prep fiber Particulate scaling conserves volume
- Increases IOZ by x3 Buffered borated water Has no epoxy chips Particulate and fiber fines introduced simultaneously
- Batches have similar fiber to particulate ratios Surrogates
- Silicates for all coating, LDFG fines and smalls 2007 Test 2016 Test
36 Callaway Energy Center Strainer Testing for GSI-191
SUMMARY
AND FEEDBACK
- Improve quality assurance and repeatability by forming chemical surrogates in laboratory-grade water
- Non-Q coatings are the dominant challenge for successful strainer testing
- Staff invited to attend head loss testing to confirm formation of thin bed at high particulate-to-fiber load