ML18354A413
| ML18354A413 | |
| Person / Time | |
|---|---|
| Site: | Palisades  |
| Issue date: | 04/26/1979 |
| From: | Consumers Power Co |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| Download: ML18354A413 (22) | |
Text
1. 0 2.0
~
~
~
ca.d.1.c:J P4ff'° p.ut te~
- t1 I to Skcvrn -
- \\en.tha...krr K,_p~
6-pcn-r tlv CJC/ 4.. 10,f-9 PALISADES PLANT STEAM GENERATOR REPAIR REPORT TABLE OF CONTENTS
&-zss 5G-flfl Page LIST OF EFFECTIVE PAGES
'Vpcb.nd tJ.-'Zlo-l'J LOEP-1 INTRODUCTI~ SUl~'4ARY, AND CO CLUSIONS cc..p 1-1 1.1
SUMMARY
$k S'IEAM GENERA~PAIR PROGRAM 1-2 1.1.1 REP~R ALTER 4~vEs 1-2
- 1. 1. 2 REivIO~L ANDf{'~PIACEMENT OF THE STEAl:-1 1-3 GENE;R~'I'~R 7
s.* FROM CONTAINMENT
\\,
- 1. 1. 3 STE&'l1 G 1
B\\RATGR CHARAC'IEldSTICS 1.1.4 SAF~E~TED CONSIDERATIONS 1.1.5 ALZ':fo CONSI~RATIONS
- 1. 1
- 6 OF 1 SITE RADIOLOGICAL CONSEQUENCES 1.1.7
- NIQUE ASPECT~F PROGRAM
- 1. t'.a/sTEAM GENERATOR \\.ISPOSAL
- 1. 2 IDENTIFICATION OF PRINCI~ AGENTS
- 1. 3 10 i.FR 50. 59 CONSIDERATIOJs
- 1. 4 C~CLUSIONS REPdCEMENT COMPONENT DESIGN 2.1lcoMPARISON WITH EXISTING <DMPON~NT DESIGN I 2.2.1 PARAMETRIC COMPARISON
\\
~
2.1.2 PHYSICAL COMPATIBILITY WITH EXISTING STEAJ.'4 GENERATOR AND SY STEi"1S \\
2.1.3 ASME CODE APPLICATION
\\
2.1.Q REGULATORY GUIDE APPLICATION i
1-3 1-4 1-4 1-4 1-4 1-5 1-5 1-6 1-6 2-1 2-1 2-1 2-2 2-2 2-3
PALISADES PIANT SGRR 2.2 COMPONENT DESIGN_!MPROVEMENTS 2-5 2.2.1 DESIGN FEATURES TO IMPROVc PERFORMANCE 2-6
- 2. 2. 2 DESIGN FEATURES TO IM PROVE MAINTENANCE 2-11 AND INSPECTION 2.3 §HOP TESTS AND I~~TIONS 2-12 2.4 STORAGE CRITERIA_gQE NEW STEAM GENERATORS 2-12 3.0 BALANCE-OF-PLANT SY§!EM_!10DIFICATIONS 3-1
- 3. 1 BLOWDOWN SYSTEM 3-1 3.2 RECIRCULATION SYSTEM 3-1 3.3 ~PLING SYSTEM 3-2 3.~ PRIMARY HEAD DRAINS 3-2 3.5 ~I~ RANGE LEVEL INDICATION 3-3 4.0 RE.PLACEMENT PROGRAM AND PROCEDURES 4-1 4.1 CONSTRUCTION~NSIDERATICNS 4-1 4.1.1 SITE PREPARATION 4-1 4.1.2 RIGGING 4-5 4.1.3 RIGGING LOAD SUPPORTS 4-9 4.1.4 CONSTRUCTION-REIATED INCIDENTS 4-9 4.1.5 CONTAINMENT STRUCTURAL CDNSIDERATIONS 4-10
- 4. 2 EQUIPMENT AND MATERIAL REM.OVAL AND REPLACEMENT 4-16 4.2.1 - MECHANICAL EQUIPMENT 4-16 4.2.2 INSTRUMENTATION 4-16 4.2.3 ELECTRICAL EQUIPMENT 4-17 4.2.. 4 PIPING 4-22 ii
FIGURE NO.
2.2-1 2.2-2 2.2-3 2.2-4 2.2-5 2.2-6 2.2-7 2.2-8 2.2-9 2.2-10 2.2-11 3.1-1 3.1-2 3.3-1 3.3-2 3.4-1 3.5-1 4.1-1 4.1-2 4.1-3 4.1-4 4.1-5 4.1-6 4.1-7 4.1-8 4.1-9 4.1-10 4.1-11 4.1-12 4.1-13 4.1-14 4.1-15 4.1-16 PALISADES PLANT SGRR LIST OF FIGURES TITLE REPLACEMENT STEAM GENERATORS FLOW DISTRIBUTION BAFFLE TUBE SUPPORT PLATE AND FLOW BAFFLE BOTTOM BLOWDOWN DUCT ASSEMBLY TUBE SUPPORT TYPES EGGCRATE ASSEMBLY BEND REGION TUBE SUPPORT TUBE SUPPORT UPPER ASSEMBLY STEAM GENERATOR -
FLOW RESTRICTOR NOZZLE PRIMARY HEAD DRAINS EXISTING BLOWDOWN AND RECIRCULATION SYSTEM MODIFIED BLOWDOWN AND RECIRCULATION SYSTEM EXISTING TURBINE ANALYZER PANEL FOR SAMPLING SYSTEM MODIFIED TURBINE ANALYZER PANEL FOR SAMPLING SYSTEM PRIMARY HEAD DRAIN SYSTEM WIDE RANGE LEVEL TRANSMITTER SITE PLAN BARGE SLIP OLD STEAM GENERATOR STORAGE FACILITY PLAN VIEW OLD STEAM GENERATOR FACILITY SECTIONS AND DETAILS CONTAINMENT LAYDOWN AREAS GENERAL ARRANGEMENT PLAN VIEW, SH.1 GENERAL ARRANGEMENT PLAN VIEW, SH.2 GENERAL ARRANGEMENT SECTION A-A GENERAL ARRANGEMENT SECTION B-B DOWN-ENDING STEAM GENERATOR ONTO SLEDS LOWERING STEAM GENERATOR FROM ELEVATOR PLATFORM ONTO TRANSPORTERS STEAM GENERATOR IN HOISTED POSITION, SECTION VIEW STEAM GENERATOR ON TRANSPORTER BETWEEN STORAGE AND CONTAINMENT STEAM GENERATOR ON TRANSPORTER BARGE TO STORAGE OFF LOADING STEAM GENERATOR FROM BARGE, PLAN VIEW OFF LOADING STEAM GENERATOR FROM BARGE, viii
e PALISADES PLANT STEAM GENERATOR REPAIR REPORT LIST OF EFFECTIVE PAGES Page Latest Identification Amendment i
0 ii 0
iii 0
iv 0
v 0
vi 0
vii 0
viii 0
ix 0
x 0
LOEP-1 0
LOEP-2 0
LOEP-3 0
'9 LOEP-4 0
LOEP-5 0
1-1 0
1-2 0
1-3 0
1-4 0
1-5 0
1-6 0
2-1 0
2-2 0
2-3 0
2-4 0
2-5 0
2-6 0
2-7 0
2-8 0
2-9 0
2-10 0
2-11 0
2-12 0
2-13 0
Tbl 2.1-1 0
Tbl 2.1-2 0
Tbl 2. 2-1 0
Fig. 2.2-1 0
e Fig. 2. 2-2 0
Fig. 2.2-3 0
Fig. 2. 2-4 0
LOEP-1
'9 PALISADES PLAN'I SGRR Paqe Latest Identification Amendment Fig. 2.2-5 0
Fiq. 2. 2-6 0
Fiq. 2.2-7 0
Fig. 2. 2-8 0
Fiq. 2.2-9 0
Fig. 2. 2-10 0
Fig. 2.2-11 0
3-1 0
3-2 0
3-.3 0
Fiq. 3.1-1 0
Fiq.. 3. 1-2 0
Fig. 3.3-1 0
Fiq.. 3. 3-2 0
Fiq. 3. 4-1 0
Fig. 3.5-1 0
4-1 0
e 4-2 0
4-3 0
4-4 0
4-5 0
4-6 0
4-7 0
4-8 0
4-9 0
4-10 0
4-11 Q,
4-12 0
4-13 0
4-14 0
4-15 0
4-16 0
4-17 0
4-18 0
4-19 0
4-20 0
4-21 0
4-22 0
4-23 0
4-24 0
4-25 0
4-26 0
e 4-27 0
4-28 0
4-29 0
LOEP-2
Paqe Identification Fiq. 4.3-3 Fig. 4. 3-4 Fiq. 4.3-5 Fig. 4. 3-6 Fiq. 4. 3-7 5-1 5-2 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 Table 6. 2-1
'I' able 6. 2-2 Table 6.2-3 Table 6.2-4 Table 6.2-5 7-1 7-2 1-3 7-4 7-5 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 Table 8.4-1 Table 8.8-1 9-1 9-2 9-3 10-1 PALISADES PLANT SGRR Latest Amendment LOEP-5 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
PALISADES PLANT SGRR
, techniques and American Society of Mechanical Engineers Boiler and Pressure Vessel Code (ASME Code) editions.
1.1.4 SAFETY-RELATED CONSIDERATIONS To be. provided later.
1.1.5 ALARA CONSIDERATIONS Personnel exposure will be maintained "as low.as is reasonably achievable" (ALARA) throughout the steam generator repair program.
Estimates of the exposures to personnel involved in the various repair alternatives have been developed using projections of work activity durations, manpower levels, and expected radiation levels.
1.1.6 OFFSITE RADIOLOGICAL CONSEQUENCES Radiological evaluations of the gaseous and liquid releases attributable to the steam generator repair have been conducted.
The effects of the releases are less than those associated with normal operation of the facility on the basis of the discussion in Section 6.2.2.
1.1.7 UNIQUE ASPECTS OF PROGRAM As presently contemplated, there are no unique engineering or construction aspects of the Palisades Plant steam generator repair program.
The repair program, including the fabrication of replacement units, will utilize conventional nuclear industry manufacturing and construction methods.
The shop fabrication of the steam generators will be conducted in accordance with standard shop practices.
The closure of the temporary construction opening in the containment will be performed in a manner similar to that used to close the original containment construction opening.
The transport and rigging of the steam generator will utilize proven techniques.
In short, the repair program will rely on fabrication and construction practices or techniques which have been previously qualified* for* similar applications.
1-4
PALISADES PLANT SGRR 1.3 10 CFR 50.59 CONSIDERATIONS To be provided later.
1.4 CONCLUSION
S To be provided later.
/
1-6
j.
- k.
PALISADES PLANT SGRR Regulatory Guide 1.84, Code Case Acceptability -
ASME III Design and Fabrication (August 1977)
Regulatory Guide 1.85, Code Case Acceptability -
ASME III Materials (August 1977) 2.2 COMPONENT DESIGN IMPROVEMENTS The replacement steam ge:nerator design incorporates the traditional Combustion design features and.design improvements that have evolved through several generations of steam generator designs in response to the operational steam generator problems that have occurred in the nuclear industry.
The replacement steam generators will essentially duplicate the physical, thermal, and hydraulic characteristics of the original ~nits while incorporating a combination of features proven in field operation and design improvements to mitigate operational problems.
The heating surf ace has been selected to provide thermal performance which would match that presently installed and to respond to plant thermal transients in the same manner as does the existing unit.
The design will provide improvements in thermal/hydraulics, notably in secondary flow distribution.
These improvements are intended to minimize flow stagnation, steam blanketing, and harmful solids accumulations.
It is important to avoid harmful solids deposits in contact with heat transfer tubing in the steam generators.
Furthermore, flow baffles have been included to minimize solids dropout on the tubesheet.
The blowdown arrangements are designed to take advantage of the improved flow distribution, making significant improvements in the effectiveness of blowdown in removing harmful solids deposits.
The tube support system utilizes the traditional Combustion eggcrate tube support, with its low flow resistance, support against vibration and wear, and resistance to tube denting or lateral tube deformation.
The bend region tube support system also uses the standard Combustion approach, with double 90 degree bends and support assemblies of interlocking strips.
The design provides positive restraint against vibration and resistance to tube deformations during LOCA, steam line break, and seismic events.
The tube support system provides rugged, positive 2-5
PALISADES PLANT SGRR support while minimizing flow resistances and the possibility of local dryout of steam blanketed regions.
Access openings and inspection ports are provided to enable inspection of tubes, tubesheet, and support surfaces within the tube bundle as well as at the periphery of the bundle.
2.2.1 DESIGN FEATURES TO IMPROVE PERFORMANCE 2.2.1.1 Thermal Performance In order to minimize the effect on plant transient performance, heat transfer tubes of 3/4 inch outside diameter and.042 inch average wall thickness (consistent with Combustion's System 80 design) will be provided in such quantities and lengths on the replacement units that the product of their area (A) and heat transfer coefficient (U) equals the product of the original area and original
The total cross-sectional flow area of the heat transfer tubes will be equal to the cross-sectional flow area of the tubes in the original units.
The control of these parameters on the replacement units allows the hydraulic impedance to primary flow to essentially correspond with that of the original steam generators.
2.2.1.2 Flow Distribution Baffle For*the replacement steam generators, Combustion will include a flow distribution baffle just above the tubesheet secondary face.
The flow baffle assembly shown schematically in Figure 2.2-2 causes the recirculating flow from the downcomer to be directed radially across the tube bundle, maintaining relatively high fluid velocities throughout the tube bundle region.
The tube bundle on the replacement units has an open region in the center of the steam generator approximately 42 inches in diameter around the primary stay, where tubes are omitted.
The flow baffle causes radial flow to completely penetrate the tube bundle before exhausting into the open region of the tube bundle.
Appropriate baffling is included in the divider lane to prevent tube bundle bypass and to ensure maximum velocities at the tubesheet.
While the flow baffle is a perforated plate, Combustion does not anticipate that denting will occur in the flow baffle for the following reasons:
2-6
- a.
- b.
PALISADES PLANT SGRR The flow baffle is constructed of Type 405 stainless steel, a corrosion-resistant material which is not expected to undergo the rapid transformation of plate material to magnetite, which caused the denting problem in the carbon steel tube support plates.
Corrosion tests are ongoing in Combustion's laboratories to verify the corrosion phenomena and the resistance of Type 405 stainless steel to that phenomena.
The annular gap sees a high velocity flow-through situation which will keep the gap continually flushed.
The tube support plates contained large flow holes in addition to the annular gaps, causing washing of the gaps to be minimal or nonexistent.
The differing flow arrangements between the original Palisades Plant steam generator tube support plates and the replacement steam generator flow distribution baffle are illustrated in Figure 2. 2-3.
- 2.2.1.3 Blowdown Capability The potential blowdown capabilities for the replacement steam generators complement the hydraulics associated with the flow distribution baffle and enhance solids control within the operating steam generator.
With the incorporation of a flow distribution baffle, recirculating fluid flows exist at velocities sufficiently low to allow the dropout of solid particles only in the center open region of the tube bundle or very near to this region.
In this region, free of heat transfer tubes, blowdown ducts that take suction in a circular pattern adjacent to the innermost tubes are provided.
Figure 2.2-4 shows the schematic arrangement of the blowdown'duct and its relationship to the tube bundle.
At the end of each circumferential section of the blowdown duct, a transport duct (with no blowdown openings) carries the blowdown fluid across the divider lane discharging.through intersecting holes drilled in the tubesheet to a 6-inch Schedule 80 blowdown nozzle.
See Section 3.1 for a description of the connecting blowdown system.
The internal blowdown ducts and tubesheet blowdown connections for the replacement units have been sized to accommodate future higher blowdown capabilities than those available on the original steam generators.
2-7
PALISADES PLANT SGRR 2.2.2
- DESIGN FEATURES TO IMPROVE MAINTENANCE AND INSPECTION 2.2.2.1 Handholes The replacement steam generators will include four 6-inch h~ndhole openings on the lower and intermediate shells to facilitate inspections.
The lower two handholes will be positioned just above the tubesheet and have provisions for viewing the top surf ace of the flow distribution baffle through the tube bundle shroud.
The upper handholes are located just above the eggcrate in the tube lane and are adjacent to the bend region of the tube bundle.
These handholes will also incorporate the provision for viewing through the tube bundle shroud (see Figures 2.2-1 and 2.2-10).
2.2.2.2 Inspection Ports Two 2-inch inspection ports will be,added to the replacement units just above the tubesheet secondary face to provide
~
- accessibility to the tubesheet surface and to allow use of an inspection device such as a horoscope to observe tubes.on either side of an opening between two particular tube rows.
2.2.2.3 View Ports In addition to the access openings described above, the replacement units will also contain a small number of tube holes through the fubesheet for visual inspection vertically through the tube bundle.
These extra tube holes, plugged during normal operation, could allow a horoscope application and could provide broader inspection coverage within the tube bundle.
2.2.2.4 Primary Head Drains To facilitate draining of the steam generator primary head before maintenanc.e or inspection activities in this area, the replacement units incluqe a drain nozzle (see Figure 2.2-11) on both the inlet and outlet plenums of the primary head.
See Section 3.4 for a description of the connecting drain system.
2-11
PALISADES PLANT SGRR TABLE 2.1-1 STEAM GENERATOR COMPARISON DATAm
- Original ReplacE:ment steam steam
\\ I A. Primary Side Generators Generators
~
- 1. Thermal power, MWt 2450 2450 2
- Design pressure, psi 2500 2500
- 3. Design temperature, OF 650 650 4
- Cold leg temperature, OF 547.8 547.8
- 5. Hot leg temperature, o.F 598.5 598.5
- 6. Coolant flow, 10~ lb/hr 62.25 62.25 7
- Calculated pressure drop, psid 30.5 29.5 8
- Normal operating pressure, psi 2100 2100 B. Secondary Side
- 1. Design pressure, psi 1000 1000
- e
- 2. Design temperature, OF 550 550 3
- Flow rate, 10~ lb/hr 5~281 5.281 4
- Stearn outlet pressure; psi 770 770 5
- Feedwater temperature, OF 429.1 429.1 C. Dimensions 1
- Evaporator outside diameter, in 164 164 2
- Stearn drum outside diameter, in 239-3/4 239-3/4 3
- Overall length, in 709.78 740.00 4
- Tubing outsid~ diameter, in 0.750 0.750 5
- Tubing wall thickness, in
.048
.042 D. Hydrostatic Pressure 1
- Primary, psi a 3125 3125
- 2. Secondary, psi a 1250 1250 E. Weights and Volumes 1
- Complete vessel dry, lb 924,596 937,381
- 2. Vessel c. G. dry, in 345.32 343.5
- 3. Secondary fluid 0% power, lb 209,180 208,965
- 4. Secondary fluid 100%
power, lb 129,164 138,254 Note:
111 Values are per steam genera tor, except I tern A.1,
n
\\!
PALISADES PLANT.SGRR TABLE 2.1-2 REPLACEMENT STEAM GENERATOR DATA 111*
Safety Analysis A.
Primary Side
- 1.
- 2.
- 3.
- 4.
- 5.
- 6.
- 7.
- 9.
Thermal power, MWt Design pressure, psi Design temperature,°F Cold leg temperature,°F Hot leg temperature,°F Coolant flow, 106 lb/hr Calculated pressure drop, psid Normal operating pressure, psi B.
Secondary Side
- 1.
- 2.
- 3.
- 4.
- 5.
Design pressure, psi Design temperature,°F Flowrate, 106 lb/hr Steam outlet pressure, psi Feedw.ater temperature, °F C.
Weights and Volumes
- 1.
- 2.
- 3.
- 4.
NOTE:
Complete vessel dry, lb Vessel C.G. dry, in Secondary fluid 0% power lb Secondary fluid 100%
power, lb 2530 2500 650 542.5 595.4 62.5 29.6 2100 1000 550 5.491 770 435 937,381 343.5 208,965 136,863 Design 2650 2500 650 547.8 598.5 70.0 36.1 2250 1000 550 5.786 770 438 937,381 343.5 208,965 134,441 111 Valves are per steam generator, except Item A.1.
Upper, inter-mediate, and cone shells Lower shell Tubesheet forging Tube support plates PALISADES PLANT SGRR TABLE 2.2-1 STEAM GENERATOR MATERIALS Original Steam Generators SA-302, Grade B alloy steel SA-516, Grade 70 carbon steel SA-508, Class II alloy steel SA-36 carbon steel Replacement Steam Generators SA-533, Grade A, Class I alloy steel SA-533, Grade A, Class I alloy steel SA-508, Class III alloy steel Eggcrate tube supports A-570, Grade D/
A-176, Type 409 A-303-64, Grade D stainless steel carbon steel Primary head Primary head clad Tubesheet clad Heat transfer tubing Flow distribution baffle Secondary head Nozzles/primary stay SA-302, Grade B alloy steel Stainless steel Inconel SB-163 Inconel SA-533, Grade B, Class I alloy steel Stainless steel Inconel SB-163 Inconel SA-240, Type 405 stainless steel SA-516, Grade 70/ SA-516, Grade 70 SA-302, Grade B carbon steel carbon steel/
alloy steel SA-508, Class II alloy steel SA-508, Class III alloy steel
PALISADES PLANT STEAM GENERATOR REPAIR REPORT REPIACEMENT STFJ.\\M GENERATORS Figure 2.2-1
FLOW BA!=FLE 7UBSHEET PALISADES PLANT STEAM GENERATOR REPAIR REPORT FI.ON DISTRIBUTION BAFFLE Figure 2.2-2
ORIGINAL
..5TEAM GENERATOR
.7G5 11NOM DI~
f t TUBE SUPPORT PL~T*E W\\TH JNTERSTITIAL FLOW HOLES
. REPLACEMENT STE~M GE.NERATO~
FLOW BAFFLE FLOW THRO DESIGN PALISADES PLANT STEAM GENERATOR REPAIR REPORT TUBE SUPPORI' PLATE AND FI.CW BAFFLE Figure 2.2-3
DNt Dt:.R U..NE..
'B~FFLING---'
.t31.0WOOWN r,i O,QAJll oucr SECTION A-A" BL..O WDO W/\\/
O<..ICT Fl.OW OIST,tl/'3UTION
/3.AFFt.e SLOWDOWN NOZ..
PALISADES PLANT STEAM GENERATOR REPAIR REPORT BOTroM BIDWDam oucr ASSEMBLY Figure 2.2-4
I II I PALISADES PLANT STEAM GENERATOR REPAIR REPORT STFJ\\M GENERATOR -
FIDW RESTRICJ.roR NOZZLE Figure 2. 2.;...10
_J
PALISADES PLANT SGRR 3.5 WIDE RANGE LEVEL INDICATION A differential pressure type level transmitter will be added to each new steam generator to provide steam generator wide range level indication of about 44 feet.
The top head of the new steam generators will have a 1-inch nozzle at el 671', which will be used for the low-pressure sensing line connection.
The high-pressure sensing line will be connected to pressure taps at el 627' (see Figure 3.5-1).
With this addition, an operator can determine the water level in the secQndary side of each steam generator during wet layup (or similar operations) beyond the range measurable with the present level indicators (about 15 feet).
The new level indicating system is functionally independent, both electrically and mechanically, of any safety-related systems.
The sensing lines will be in accordance with ASME Code Section III, Class 2 and seismic Category I classifications.
The transmitter will be located in a low radiation zone.
The transmitter output will electrically connect to a new indicator in the main control.room' and will.
not be ~sed to automatically initiate or terminate any action.
3-3
__J
PALISADES PLANT SGRR 6.0 SAFETY EVALUATIONS 6.1 FSAR EVALUATIONS 6.
1.1 INTRODUCTION
To be provided later.
6.1.2 NON-LOCA ACCIDENTS To be provided later.
6.1.2.1 Excessive Feedwater To be provided later.
6.1.2.2 Excessive Load Increase To be provided later.
6.1.2.3 Loss of Load To be provided later.
6.1.2.4 Loss of Feedwater Flow To be provided later.
6.1.2.5 Steam Line Break To be provided later 6.1.2.6 Steam Generator Tube Rupture To be provided later 6.1.3 LOSS-OF-COOLANT ACCIDENT EVALUATION To be provided later.
6.1.4 CONTAINMENT PRESSURE ANALYSIS To be provided later.
6.1.5 FSAR EVALUATION CONCLUSIONS
(
To be provided later.
6-1
_J