ML17306A467

Summary of 920205 Meeting W/Util Re 5 Yr Fuel Enhancement Program & Other Fuel Related Issues.W/Attendance List & Handout

ML17306A467
Person / Time
Site:	Palo Verde
Issue date:	02/11/1992
From:	Trammell C Office of Nuclear Reactor Regulation
To:	Office of Nuclear Reactor Regulation
References
NUDOCS 9202210282
Download: ML17306A467 (70)

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UNITED STATES NUCLEAR REGULATORY COMMISSION WASHINGTON, D. C. 20555 February 11, 1992 Docket Nos.

50-528, 50-529 and 50-530 LICENSEE:

Arizona Public Service Company FACILITY:

Palo Verde Nuclear Generating Station

SUMMARY

OF MEETING HELD ON FEBRUARY 5,

1992, REGARDING THE 5-YEAR FUEL ENHANCEMENT PROGRAM AND OTHER FUEL-RELATED ISSUES On February 5, 1992, the NRC staff met with representatives of Arizona Public Service Company (APS) in which the licensee presented its 5-year fuel enhance-ment program and other fuel-related issues.

The meeting was held pursuant to notice issued on January 28, 1992.

A list of attendees is shown in Enclosure 1.

Copies on nonproprietary viewgraphs are shown in Enclosure 2.

1.

2.

3.

4.

5.

6.

The 5-year fuel enhancement program consists of the following elements:

Fuel assembly design improvements.

Fuel pellet design improvements.

The use of erbium as a distributed burnable poison.

Axial blankets.

Increased burnup and enrichment limits.

Advanced alloy program, corrosion resistant cladding.

Details of these enhancements are contained the viewgraphs in Enclosure 2.

Other fuel-related issues are the reload technology transfer program wherein APS personnel have acquired the training and skills to perform reload evaluations, including Chapter 15 transient and accident analyses; an upcoming Core Operating Limit Report amendment request (per Generic Letter 88-16);

and four core analysis method improvements contained in the Unit 1, Cycle 4 reload analysis which is currently under review.

The NRC staff requested that APS give NRC a one-year notice of intent to submit an application for the use of erbium, and a minimum time of six months for review.

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Regarding the technology transfer program, the NRC staff stated that we would like to review this program in more detail than was presented at the meeting.

A generic letter has been issued on this subject (Generic Letter 83-11, "Licensee Qualification for Performing Safety Analyses in Support of Licensing Actions," February 8, 1983).

The material contained in APS'eload Capability Report appeared to contain the type of information that NRC will need for its review.

Enclosures:

As stated Criminal signed by Charles M. Trammell, Sr. Project Manager Project Directorate V

Division of Reactor Projects III/Iv/V Office of Nuclear Reactor Regulation CC:

See next page DISTRIBUTION:

Docket File NRC & Local PDRs PDV r/f T. Hurley/F. Miraglia J. Partlow B. Boger M. Virgilio T. Quay C. Trammell D. Foster OGC(15B18)

E. Jordan(HNBB 3?01)

NRC Participants ACRS(10)(P315)

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Shankman(17G21)

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Zimmerman, Region V

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Regarding the technology transfer program, the NRC staff stated that we would like to review this program in more detail than was presented at the meeting.

A generic letter has been issued on this subject (Generic Letter 83-11, "Licensee Qualification for Performing Safety Analyses in Support of Licensing Actions," February 8, 1983).

The material contained in APS'eload Capability Report appeared to contain the type of information that NRC will need for its review.

A. i~

Charles M. Trammell, Sr. Project Manager Project Directorate V

Division of Reactor Projects III/IV/V Office of Nuclear Reactor Regul ation

Enclosures:

As stated CC:

See next page

1n C

II

Hr. William F.

Conway Arizona Public Service Company Palo Verde CC:

Nancy C. Loftin, Esq.

Corporate Secretary 8 Counsel Arizona Public Service Company P.

O.

Box 53999, Hail Station 9068

Phoenix, Arizona 85072-3999 Jack R.

Newman, Esq.

Newman 8 Holtzinger, P.C.

1615 L Street, N.W., Suite 1000 Washington, D.C.

20036 James A. Beoletto, Esq.

Southern California Edison Company P. 0.

Box 800

Rosemead, California 91770 Senior Resident Inspector U.S. Nuclear Regulatory Commission HC-03 Box 293-NR Buckeye, Arizona 85326 Regional Administrator, Region V

U. S. Nuclear Regulatory Commission 1450 Maria Lane Suite 210 Walnut Creek, Cal ifornia 94596 Ignacio R. Troncoso Senior Vice President El Paso Electric Company Post Office Box 982 El Paso, Texas 79960 Roy P.

Lessey, Jr.,

Esq.

Bradley W. Jones, Esq.

Arkin, Gump, Strauss, Hauer and Feld El Paso Electric Company 1333 New Hampshire Ave., Suite 400 Washington, D.C.

20036 Hr. Charles B. Brinkman, Manager Washington Nuclear Operations ABB Combustion Engineering Nuclear Power 12300 Twinbrook Parkway, Suite 330 Rockvi lie, Maryland 20852 Hr. William A. Wright, Acting Director Arizona Radiation Regulatory Agency 4814 South 40 Street

Phoenix, Arizona 85040 Chairman Haricopa County Board of Supervisors 111 South Third Avenue

Phoenix, Arizona 85003

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5-Year Fuel Enhancement Pro ram:

A. Introduction B. Fuel Assembly Design Improvement Program C. Fuel Pellet Design Improvements D. ERBIA Burnable Absorber Program E. Axial Blankets F. Increased Burnup and Enrichment Limits G. Advanced AlloyProgramlCorrosion Resistant Claddin H. Integrated Schedule for Program Implementation Other Fuel-Related Issues:

A. Reload Technology Transfer B. Fuel Analysis Capability C. Core Operating LimitReport Submittal (G.L. 88-16)

D.. Unit 1, Cycle 4, and Unit 2, Cycle 4 Methods Improvem ents

Purpose To provide the NRC with the current APS plan and schedule for the implementation of fuel design enhancements P

To provide the NRC with a status of current APS fuel related programs

- P Improve fuel cycle economics while maintaining margin of safety:

~ Improve utilization of fuel resources

~ Achieve higher burnups with fewer fuel assemblies

~ Increase enrichment limit

~ Maintain flexible operation at full power with more thermal margin thereby offsetting higher power peaking

~ Utilize Erbium to achieve thermal margin 8 MTC goals

~ Improve clad to achieve higher burnups

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Fuel Assembly Design Improvement Program Fuel assembl desi n im rovements:

Guardian Grid willreduce debris failures Self-locking plenum spring willincrease free volume in fuel rod

Guardian Grid Design Characteristics:

Filtering features added to Inconel bottom grid k Grid lowered and fuel rods retained in down position 4 Greater than 90l. filtering effectiveness

-Benefits:

I Move cladding away from highest wear positions 4 Provide a debris filter and trap

Isometric View of Guardian'Grid (Conceptual Drawing)

Fuel Rod with Grooved End Cap Spring Tab x

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Lower End Fitting Flow Hole Guardian'Design Showing Debris Straining Features (Conceptual Drawing}

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Debris Straining Features Fuel Rod Ouwd 1

Guardian Grid 16x1 6 Design Ob ectives:

4 Dramatically reduce susceptability to debris-induced failures 4 Maintain or improve fuel assembly pressure drop l'aintain reconstitutable feature P Maintain fuel rod performance capability 4 Maintain mechanical integrity Status:

Supplied in 1991 for 14x14 plants 4 Currently under development for ABB-CE 16x16

Self Locking Plenum Spring Design Desi n Characteristics:

4 Short fuel rod plenum spring f Accomodates differential thermal expansion and radiation-induced dimensional changes between the pellet column and cladding tube Benefits:

Significant reduction in spring volume Status:

Feasibility study complete Manufacturing qualification to be completed in 1992

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Fuel Pellet Design Improvements Characteristics:

l Modified dish and chamfer 4 Increased density l Slightly larger diameter Benefits:

4 Increased fuel loading improves fuel costs k Susceptibility to densification during irradiation is minimized

Fuel Pellet Design Improvements Status:

P APS willauthorize fuel design improvements in near future Im lementation:

P No regulatory/licensing/analysis concerns identified P Subject design changes can be implemented under 10 CFR 50.59 without resulting in an unreviewed safety question P May be implemented at any time P UFSAR changes willbe made as required P Design changes willbe documented in future Reload Analysis Reports

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Erbia Burnable Absorber Program A

lication:

Integral with the U02 Low concentration; typically 1.5 wt lo 4

In typically 20'lo of reload fuel pins Erbium Characteristics:

Rare earth similar to gadolinium Er203 is compatible with U02 and with Zr 4 Thermal conductivity/melting point impact on U02 similar to that of Gd Neutron cross-sections much lower than Gd, similar to boron

Erbia Burnable Absorber Program Benefits:

Increased thermal margin:

~ Eliminates displacement of fuel

~ Reduces local peaking 1'mproved fuel cycle economics 4 Improved MTC and power distribution control for low leakage, extended cycles Conse uences:

4 Small impact on thermal conductivity and UO melting point

~ No reduction in enrichment required

Erbia Burnable Absorber Program Status:

k Material Property Evaluation complete 4 Critical experiments at RPI test reactor show excellent agreement with predictions 4 Lead Fuel Assembly Program currently in progress at SONGS-2 and Calvert Cliffs-2

Erbia-Urania Development Program 4 Pellets were successfully fabricated for lead fuel assemblies using standard methods 4 The effect of Erbia additions on melting point and thermal conductivity was consistent with expectations:

~ Negligible effect on melting point

~ Small effect on thermal conductivity consistent with available data on Gadolinia-Urania k Other pellet characteristics including density, Erbia homogeneity, etc, were satisfactory and consistent with Gadolinia experience

Erbium Lead Test Assemblies k Calvert Cliffs (Unit 2 Cycle 9) - 4 assemblies:

~ Startup achieved May 1991

~ Burnup is now approximately 6.8 GWD/MT

~ Pieliminary core follow looks good 1 San Onofre (Unit 2 Cycle 6) - 4 assemblies:

~ Startup achieved November 1991

~ Burnup is now approximately 1.9 GWD/MT

~ Willprovide direct comparison with B C -Al 0 I

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Axial Blankets Application I Essentially a low axial leakage fuel management (axial leakage reduced by factor of 2 to 3) 4 Natural uranium pellets loaded into top and bottom of fuel rod I Approximately 20 cm blanket (10'/o core volume)

I'mount and axial placement of burnable absorbers may be modified from non-blanket designs Axial Blankets Status/Schedule 1 Proven fuel design technology (PWRs and BWRs}

I No regulatory/licensing/analysis concerns identified May be implemented at any time sufficient thermal margin is available to accomodate increased axial peaking

Axial Blankets Benefits 4 Lower average feed enrichment I Reduced fuel costs 4 Effectively shorter core improves axial stability Axial Blankets Consequences 4 Increases axial peaking l'mall impact on MTC 4 Small impact on CEA trip reactivity insertion curve 4 Minimal effect on planar radial peaking {Exy}

4 Minimal effect on CEA worths nQfease Ue UfnU an nric men imi s Fuel IF

Increase Fuel Burnup and Enrichment Limit Status:

Docketed methodology supports peak rod average burnups to 52 GWD/MT PVNGS currently licensed for maximum enrichment of 4.05 wt'/o U-235 Benefit:

increased limits provide greater fuel management flexibilityresulting in reduced fuel costs Spent Fuel Pool Expansion In Conjunction With Increased Enrichment Limit Current spent fuel pool, new fuel pit, and fuel handling equipment criticality analysis:

~ 4.3 wt% with fuel stored in checkboard array

~ 4.0 wt% with fuel stored in high density mode with poison inserts P

Pool capacity for fuel stored in checkerboard array will be met in 1994/1995 P Alternatives currently under consideration for expanding capacity:

~ Credit boron

~ Take credit for burned fuel and license regions

~ Poison inserts P Licensing changes willbe submitted to the NRC High Burnup Fuel Performance P Performance areas addressed by ABB-CE Material Evaluation Programs include:

~ Corrosion

~ INechanical properties

~ Dimensional stability

~ Fuel performance:

- Smelling

- Gas release

~ PCI P The ABB-CE database addresses these concerns to:

~ Peak-rod average burnups of 63 GND/MT

~ Peak-assembly average burnups of 57 GND/MT

~ Fast fluences of 13 x 1021 n/cm2 (E ) 0.821 Mev)

P For high temperature plants like Palo Verde, clad corrosion continues to be a controlling issue for high burnup operation

Dimensional Stability P Related performance areas include:

~ Fuel rod and assembly growth

~ Fuel rod cladding creep

~ Fuel rod channel closure P Data sources:

~ Ongoing surveillance programs on commercial power reactor fuel

~ Ongoing test reactor programs

~ Palo Verde Unit )

I P No unforeseen or abrupt changes in fuel rod or assembly dimensional stability have been observed after extended burnup operation P No mechanical limitations on current 8 future PVNGS designs in achieving burnups up to 60 GWD/MThave been identified to date 0

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Pellet-Cladding Interaction p PCI has not been a problem for modern PWR fuel P Programs include ramp tests:

~ CE/KWU/DOE Ramp Test Program at Petten

~ Super ramp and super ramp extension

~ Over ramp P Supplemental information from Halden Reactor Base Program P Program includes a wide range of variables: fuel pellet/rod design characteristics, Burnups, and power histories Results have been used to establish failure thresholds, as well as provide additional benchmark data for development of fuel performance models for fission gas release, and fuel swelling behavior Operating guidelines have been effective in preventing PCI failures in modern PWRs I

PCI willnot be a problem for Palo Verde to achieve burnups to 60 GWD/MT

Summary Increased enrichments and burnups are planned to provide fuel management design flexibilityfor purposes of producing improved fuel cycle economics Burnups to 60 GWDlMThave been achieved with no decrease in fuel reliability Power reactor LFA programs and test reactor experiments have provided information necessary to develop fuel performance models for high burnup application High.burnup design methodology has been approved by the NRC and is being employed in current reload fuel batches in other ABB-CE plants to rod average burnups of 60 GWDIMT Corrosion and its related effects remain an important issue for PVNGS

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Status:

Advanced AlloyProgram p Zr-4 clad corrosion recognized as fuel rod life limitin high temperature plants like Palo Verde APS currently measures clad film oxide thickness in PYNGS Unit 1 at the end of each cycle APS currently utilizes Zr-4 clad with controlled chemistry and optimized annealing process Tech Spec changes were submitted to the NRC on 12/20/91, which willallow up to 80 fuel rods in two assemblies to be irradiated in Unit 3, Cycles 4, 5, and 6

~ Assemblies contain rods with chemistry variants outside of Zr-4 ASTM specification Reactor Coolant Temperature Comparison Zircaloy Corrosion Ranking Plant Goesgen Ringhals -2 North Anna -1 Grohnde EDF 1300 MWe Palo Verde - 1 2 8 3 EDF 900 MWe Ringhals -3 and 4 ANO-2

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SONGS -2 and 3 Maine Yankee Calvert Cliffs-1 and 2 Fort Calhoun St. Lucie -2 Inlet Temp.

('0 555 546 556 556 559 565 548 543 555 553 552 548 543 549 Outlet Temp.

('0 615 611 620 6f5 625 621 613 613 613 611 602 599 599 600 Status of Advanced AlloyDemonstration Program P Tube fabrication completed P Mechanical properties meet Zr-4 requirements P Activities related to fuel rod fabrication are in progress P Safety Evaluation Report submitted to NRC P Insertion of demonstration assemblies targeted for Palo Verde Unit 3 Cycle 4 November 1992 startup

Corrosion Demonstration Program at Palo Verde Unit 3 on Alternate Cladding Variants 4 Plan to irradiate several cladding variants for three cycles at Palo Verde Unit 3 beginning with Cycle 4:

~ Zr-4 compositional variations beyond ASTM specification limits

~ Alternate Zr-based alloys ne rae ce ue or

- roramm emen a ion Summary 5-Year Fuel Enhancement Program:

~ Fuel Assembly Design Improvement Program

~ Fuel Pellet Design Improvements

~ ERBIA Burnable Absorber Program

~ Axial Blankets

~ Increased Burnup and Enrichment Limits

~ Advanced AlloyProgram/Corrosion Resistant Cladding I

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Preliminary Integrated Schedule For Fuel Enhancement Implementation U2CSanalyslswith'new pellet BeglnhbonU2CS new PHtet Ship U2 CS fuH to PVNGS Begin U2CS operagon Submit clad Tech Spec change Receive NRC approval on clad LFAs Begin fab advanced clad LFAs Ship fuelg:As1o PVNGS Unit3 Begin U3 C4 operation with LFAs Complete 1st cycle ops with clad BGEE complete 24ma cyde w/Er LFAs SONGS potential batch of Er APS begin U2 C6 design with Er SONGS complete Er LFAcore follow PVNGS Begin U2C6 with batch of Er Ucenstng submittal forSFP expansion Require SFP expansion: 3 of4 Require SFP expansion: 4 of4 U3C5 feb with Guardhn G 5 LS Guardian Grid/Sprtng ln U3 C5 129r.

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9/97V Activity "3992 '-'-'=':- 1993::=;:::-.,I JAS DJ F A

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NB YNLGPTVC 1997 II. Other Fuel Related Issues 4 APS has completed Reload Technology Transfer with ABB-CE k

APS staff has demonstrated capability to utilize ABB-CE methods to perform reload and plant support functions k

Technical specification changes willbe submitted to NRC in near future which willremove cycle-specific data from technical specifications for inclusion in a unitlcycle specific Core Qperating LimitReport Discuss physics methods improvements submitted to the NRC in December 1991 eoa ec noo rans er

Reload Technology Program Ob ectives:

4 Acquire qualified methods for specific events analyses l Qualify engineering staff 4 Acquire qualified computer codes How:

I'BB-CE/APS Reload Technology Transfer Program

Reload Technology Transfer Program Qverview Option in 1986 APS - CE Fuel Fabrication Contract Sco e:

g Reload engineering technology obtained:

~ Physics Analysis

~ Fuel Performance

~ Core Thermal Hydraulics

~ Non-LOCA Transient Analysis

~ COLSSlCPC Analysis f Reload engineering technology excluded:

~ LOCAAnalysis

~ Fuel Mechanical Design

~ Fuel Fabrication

~ Reload Software Generation Reload Technology Transfer Program Overview Option in 1986 APS - CE Fuel Fabrication Contract Pro ram:

Three Phases:

J.'lassroom lecture 4 On the job training {OJT) 4 Independent analysis Goal:

P Acquire and maintain reload technology capability Provide improved plant support 4 Develop "partnership" with ABB-CE Develop capability to utilize alternate fuel vendor Summary of Independent Analysis Ob ective:

P To demonstrate that APS has been adequately trained in ABB-CE Reload Engineering Methods

~ APS engineers perform independent reload analysis

~'ABB-CE independent review and approval of.all calculationsiresults and Reload Capability Report (i.e. Topical Report)

~ Submittal of Reload Capability Report or other

'ocumentation to NRC for approval as required Criteria:

f Results of APS analysis were equivalent to ABB-CE findings

Status:

Reload Technology Transfer Reload Capability Report is currently in review by ABB-CE f Upon final approval by ABB-CE, APS willdiscuss with NRC to determine required level of review/

approval by the NRC Schedule and level of review willbe determined by option{s} selected for utilization of capability:

~ Plant support

~ Unit/cycle-specific reload analysis

~ "Partnership" with ABB-CE

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APS Fuel Analysis Capability k Benefits of APS fuel analysis capability:

~ Optimized plant operating space

~ In-house control of reload analysis design basis

~ Improved plant engineering support

~ Increased plant "ownership"

~ Improved technical audit capability

~ Potential "partnership" with ABB-CE Optimized Plant Operating Space i

Palo Verde specific in-house designs with operating space optimized for Palo Verde's unique needs 4 Enhanced direct interface between analysis engineer and operations l Improved thermal margin I

Fuel vendors may strive for the "bounded" reload design that can encompass several utilityissues

Enhanced Engineering, Licensing and Operations Support 4 Direct and rapid response to plant issues l Comprehensive understanding of the design and licensing basis of the plant 4 Increased ability to independently complete safety significant documents:

~ JCQs

~ 10 CFR 50.59s

~ Nuclear Safety Assessments

~ Technical Specifications Plant "Ownership" Increased f Cannot "own" the plant unless design/analysis basis from which it was built is understood 4 Reduced reliance on vendors Reduced impact of the vendor becoming non-viable 4 Abilityto perform in-house reloads ensures utility maintains "ownership" of the plant

Improved Technical Audit Capability APS Nuclear Fuel Management Department {NFM)is responsible (design authority} for review and approval of all fuel vendor documentation for changes As design authority for fuel-related products, APS NFM Department must fullyunderstand and concur with all fuel-related changes proposed by the fuel vendor

~ Superficial review is not acceptable considering safety significance of transmitted material

~ Independent technical review is possible only ifengineers have extensive training on fuel vendois methods and codes Strong technical review will help to identify and minimize errors

ABB-CE/APS Partnership P Current degree of "partnership" currently exists:

~ Reload fuel management development

~ Plant support analysis verification and review

~ Loan APS engineers to ABB-CEforpeak reload analysis and plant support efforts P ABB-CE and APS are working to formalize "partnership" to integrate resources into planned and emergent workloads Development of ABB-CE/APS Partnership 1986 CE Reload Fuel contract is currently under renegotiation P ABB-CE and APS are working to formalize a "partnership" Resource Sharing:

~ Increase pool of trained engineering resources available to meet peak demands

~ Improve utilization of ABB-CE and APS engineering staff

~ Provide continued on the job training and relevant work experience for APS and ABB-CE engineering staff APS maintains fuel analysis capability consistent with ABB-CE ore era in Iml eor umia fvel2C

Core Operating LimitReport (COLR)

Submittal (G.L. 88-16) 4 APS willsubmit technical specification changes for the removal of cycle-specific data from technical specifications in the near future:

~ COLR was developed for currently operating/upcoming cycles.

(Unit 1 Cycle 4, Unit 2 Cycle 4, & Unit 3 Cycle 3)

~ Submittal is in accordance with Generic Letter 88-16 and similar to those previously submitted on other dockets Implementation is in accordance with G.L. 88-16. An implementation plan for defining details outside the scope of G.L. 88-16 is under development

~ Controlling document

~ Review and approval of COLR

~ Placement in Control Room

nl nl ce, an ce e

o s m rovemen s Benefits of APS Fuel Program 4 Maintain current margin of safety C

4 4 Improve fuel reliability 4 Increase core design flexibility 4 Increase plant "ownership-" and improve technical oversight 4 Improve fuel cycle economics I

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