ML19310F002

Forwards Big Rock Point Core Spray Sparger & Steam Baffle Design Rept & Append 3&4.Rept Describes Improved Flow Distrib Characterisics.Recommends Confirmation Test Be Performed Prior to Installation

ML19310F002
Person / Time
Site:	Big Rock Point File:Consumers Energy icon.png
Issue date:	11/27/1978
From:	Legate R GENERAL ELECTRIC CO.
To:
Shared Package
ML19310F003	List: ML19310F002 ML20027A408
References
NEDC-21974, NEDC-219747, NUS3234, NUDOCS 7811270099
Download: ML19310F002 (500)

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~. _ ' - T$, n .- -t. Accrovec: R. J. Brancon, Manager Ocerating P! ant Engineering 6.. NUCLE AR ENERGY ENGINE E AiNG DIVtSiON = GE NE R AL E LE CTP 60 COvr AN v 5AN JOSE. CA LIF ORNI A 95125 GEN ER AL h ELECTRIC

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NEDO 21974 TABLE OF CONTENTS Page ABSTRACT. ... i x ACKNOWLEDGEMENTS.... .....xi 1. INTRO DU CTIO N. ..1-1 1.1 Purpose of Report. .1-1 1.2 Backgrounc. .1-1 1.3 Design Aporoach. .1-1 2. DESIGN B ASIS....... .... 2-1 2.1 The Repair Program - Coces. .2-1 2.2 Pnor Satisf actory Performance .2-1 2.3 New Performance Requirements. .2-2 3. DESIGN FEATURES... ...... 3-1 3.1 New Components -Sparger. .3-1 3.2 New Matenals - Sparger. .3-2 3.3 New Components - Steam Baffle.. .3-2 3.4 New Materials - Steam Eaff!e. .3-3 4. DESIGN VERIFICATION.. ....... 4-1 a.1 The Design Venfication Program. .41 4.2 The Test Program. .4-1 4.2.1 Test B11-1 Sparger Flow Distnbution Test. . 4-1 4 2.2 Test B11-2 Single Nozzle Bench Flow Tests.. .4-2 4.2.3 Test 811-3 Single Nozzle Pattern Test. .4-2 4 2.4 Test B11-4 Single Nozz!e Pattern Test in Air. .4-3 4.2.5 Test B11-5 Sparger Ring Development Tests. .4-5 4.2.6 Test B11-6 Sparger Dimensional Check. .4-6 4 2.7 Test B11-7 Core Coc!ing Confirmatior Test. .4-6 4.2.8 Test B11-S Sparger Ring Sensitivity Tests. .4-24 5. CONCLUSIONS... ....S-1 APPENDICES 1. BIG ROCK POINT - STEAM BAFFLE AND CORE SPRAY SPARGER DESIGN SPECIFICATION - GE 22A5589, REV 2, OCT 1978.. ..A-1 2. BIG ROCK POINT CORE SPRAY SPARGER AND STEAM B AFFLE STRESS AN ALYSIS, REV 1................... ..............B-1 3. THE BIG ROCK POINT SPARGER RING TEST PROGRAM, NUS 3234. SEPT 1978.. .......C-1 4. THE BIG ROCK POINT SPARGER RING TEST PROGRAM, ADDENDUM,14US 3234, OCT 1978... ...............D-1 2:6- -IV-

% Eat:19u LIST OF TABLES Table Page 4-1 Sensitiv:ty Test Program .4-25 s.

NEDC 21974 LIST OF FIGURES Figure Page 3-1 Sparger Water inlet - Original Design. .3-2 3-2 Sparger Water Inlet - Rectacement Design. .3-4 4-1 Measured Flow Distribution Sample of Portion of B11-4 Test Gnd. Nozzle 58. .4-4 4-2 Test Series B11 Core Cooling Confirmation. 75 psi Vessel Pressure. Combined Steam Entry. .4-8 4-3 Test Series B11 Core Cooling Lenfirmation. 75 psi Vessel Pressure. Bottom Steam Entry. .4-9 4-4 Test Series 811 Core Cooling Confirmation. 50 psi Vessel Pressure. Combined Steam Entry. .4-10 4-5 Test Series B11 Core Cooling Confirmation. 50 psi Vessel Pressure. Bottom Steam Entry. .4-11 -6 Test Series B11 Core Cociing Confirmation. 25 osi Vessel Pressure. Combined Steam Entry. .4-12 4-7 Test Series B11 Core Cooling Confirmation. O psi Vessel Pressure. CombinM Steam Entry. .4-13 4-8 Test Series B11 Core Cooling Confirmation. Atmospheric Air .4-14 4-9 Channels Receiving Less Than Design Flow Rate. .4-15 ^10 Measureo Flow Rates. Channel A.. . 4-1e 4-11 Measured Flow Rates. Channel B .4-1T 4-12 Measured Flow Rates. Channel C. .4-18 4-13 Measureo F!cw Rates. Channel D. .4-19 4-14 Measured Flow Rates. Channel E. .4-20 4-15 Measured Flow Rates. Channel F. .4-21 4-16 Measured Flow Rates. Channel G. .4-22 4-17 Measured Flow Rates. Channe! H. .4-23 n.

NEDC 21974 ABSTRACT This report cescrices the design effort undertaken to provide e core aoray sparger having improved flow cistribution characteristics for the Big Rock Point (BRP) Boiling Water Reactor. The design of the core sprsy sparger (hereinafter called "the soarger) was based on an expenmental testing program. A fullsize sparger was installea in a specially constructea test vessel of a configuration simulating the BRP reactor vessel. With this test equipment it was possible to perform tests duplicating the range of sparger operating conditions including sparger flow and reactor vesselcressure and steam environment. Testing consisted cf etfect-ing an operating concition in the test vessel, actuating the core soray system and measuring the flow of water received by the individual simulated fuel buncles in the test vessel. During a series of developmental tests the no::le aiming pattern was adjusted until an actimum flow distnbution was octained. Sucsequently, a series of des!gn configuration tests were conducted to estaclisn a cata base. Finally a senes of sensitivity tests were performed to evaluate the system sensitivity to (1) factors which might De introduced in lactication of the new sparger and (2) conditions that might occur as a result of installation of the new soarger in the BRP reactor vessel. Tne existing (old) sparger ; known to nave two camagea elbows: an expected less than cotimum core coverage; and an imprec:se doc-umentation of the existing pattern. This reolacement was under-taken to correct this situation. The sparger and the steam batfle are not known to nave any other defects after 17 years of service, therefore, the new sparger and steam Def!Ie are essentially re-placements in kind .a .w

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1.0 INTRODUCTION

1.1 Purpose of Report Tne pur;cse of inis rescriis :c cescrice in cetaJ ine scc;e anc resu::s of ine cr: gram c ces;gn a rea core scra) scarger (scarger, f or *ne Big RccW Pcmt,EPP) Scihng Wa:er Peacic" Tn's rescri a!so cescnces t e cesign of ne ERP Steam Eaffle, cat'lei T e ca+f e mil ce reciacec to mmim:ce personnel racrat en excesure anc to ease f; up prociems carmg sparger reciacement

1.2 Background

Tne ERP reactor nas !Ao core scray systems: me rmg sparger system (suoject of inis report) anc the recuncant core spray sys:em Tne cesign anc repiacement of :ne recun-cant system nas ccmcletec cu"ing 1977 The recuncant system was ces.gnec excer-mentaHy usmg a test f ac:hty constructe for this exper: mental program. The test f ac,hty provices reactor vessel pressure cver *ne sparger ccerating range. The f acdity crovices ine cacacmty for full scale sparger test:ng in a steam environment. Cne :m;criant ocservation f rom :ne recuncant core scray sys:em expenmental crogram was !nat tne core scray f!cw distr cut;cn from a s*eam test was cifferentinan a s:milar:est m air. Censumers Power Company mace a decision to cudc an exact cuphcate of ine existmg scarger anc test it in tne steam f acility to cetermme the acecuacy cf *ne ex:stmg nng scarger. The test results snowec :nat the core scray c:stncut:cn coulc ce imcrevec. anc ces gn of a new scarger w as initiatec. 1.3 DeC3n Approach TLe casic accroach was to reaim :ne 36 scarger nozctes. A comprenenswe stucy was uncertaken to evaluate. frcm an engineermg anc cost stanc;cmt. the feasic:hty of severai ccsste!e realmmg meinccs witnin ne ces.gn restramts. Cesign restra:nts mcluced a. Surf ace rac:at;cn levei cn sparger anc caff!e estimatec to ce a ER. sS 7 3... v s, 2, -. a i i,s a i a a-s c - * ^ c. ^ = r - c r ~^ " *. c ^ ^ s *. u c '. e d y ^ a +* 'l c =~' *.~^ ^ rt .s c.w v. .-p w v Olate. c. Ccncern :nat cc!c wors:rg cf nczcie e! cows cy cencmg couic incuce,nter-granular s:ress corrosion cracking. d Ccncern that metal galhng may occur Anen turning uniucricatec inreaced connec* ions. Ces;gn al*ernat:VCs cors:ce"ec Assur"mg **at the rearming Aculo ce accomphshec Arth (1) tne sparger remammg n ciace m ine vesse! anc (2) *ne scarger ceing removec from ine vessel, tne fchc Airg ai:E"nathes Ae'e evalLatec: a. Er.nc eic Cws *U reair"~ c. Ins:ali flow cefiec cr3 cn eacn noccle: 1

' EDC 21974 c. Remove existing nczzfes arc elco As and replace hitn new components: c P'ug ex: sting r.ozzfes and instail new elecws and new nczz!es. Tnese aiternatnes were ejectec The more s:gnificant negative consicerations are suminarizec teicw a. Peaim cy tencmg. (1) Wou!c cause strain narcening anicn could induce intergranular stress corrosien cracking (IGSCC). (2) Could cnmp elbow affecting nozz!e ficw (3) Could crack tack welc. Inspect;cn is cifficult. c Install ceflectors to reaim; n) Could cause a crevice condition wnicn cc alc incoce IGSCC (2i Wouic require uncerwater structural weld L c. Remove existing elbows anc nozzles anc replace (1) Physical lengins of the elbows are too snort for remote cuttirw (2) Woulc ce cifficult to reinstall with correct a; ming ang!e. c. Plug existing nozzles-mount new e! bows anc nozzies: (1) Would cnange scarger thermal.nycraulic ciaracteristics 2) Would recuire underwater anthng. tapping anc welcing (3) Difficult to reinstall aitn correct aiming angle. Tne feasibility stucy a!so accressed replacing tne sparger anc ret. sing the existing baffle. This acOrcacn would assure cor ect sparger nczzle aiming wnich coula ce venfled by severai prcven means pnor to installation in the reacter vessel Tne reuse of the existing baffle au snown to hawe several cisaavantages and several advantages. The cisacvan-tages inciacec (1) cersonnel ractating exposure cunng sparger removal and rep! ace-ment anc 42) a poss:cihty that the new sparger Aculd not fit tne existing caffle. The acvantages inc!uced (1) lower hardware costs by not replacing the caffle anc (2) nozzle aiming pattern will nave teen vented by test. Basec on their concen, for minimum radiation for personnel minimum nsk. and minimum cutage cntical patn t4me. Consurners Power Company elected to purchase a ew caff!e as Aell as a new scarger. t2

N E DC-21974 2.0 DESIGN BASIS 2.1 The Repair Program-Codes The BRP Steam Baffle and Core Spray Sparger are to be replaced in accordance with the requirements of ASME Section XI.1971 Edition. Winter 1972 Addenda. The replacement will be undertaken to provide a new core spray sparger having improved core flow distribution characteristics with guidance for Replacement and Pepair taken from IWA 7000 of ASME Section XI.1974 Edition. Summer 1976 Addenda. The BRP Reactor Vessel was designed f abricated and N-stamped in accordance with the ASME Boiler and Pressure Vessel Code. Section I.1959 Edition. Code Cases 1270N. 1271 N and 12373N were specified The vessel was N-stamped in 1961. The Reactor Vessel was constructed in accordance with the requirements specified in the Design Specifica-tion DP19889 (GE). The BRP core spray sparger was designed and fabricated in accordance with the re-autrements of AS A B31.1-1955.Tne steam baffle was designed in accordance with sound engineering practices with a one-fourth scale testing program to verify the hydraulic design. The replacement core spray sparger is to be designed and fabricated in accor-dance with ASA B31.1-1955. The steam baffle is to be an identical replacement except that materials and material processes will be as described below. Welding to the pressure vessel will not be required for this replacement. Welding of the sparger sections, studs and hold down bolts will be performed in accordance with ASME Section (1.1971 Edition. Winter 1972 Addenda. All welding material will meet the requirements of NB-2400. ASME Section Ill.1977 Edition. Summer 1977 Addenda. All welds will be examined by liquid penetrant within the limits afforded by the access and structure. This non-destructive examination will be in accordance with ASME Section III. 1974 Edition. Summer 1975 Addenda. NB-5000. Welds mace to prevent loosening nuts from bolts will be visually examined and shall be subjected to a mechanical proof load test. All materials used for the new steam baffle will meet the requirements of applicable ASTM or ASME material specifications with additional requirements specified to minimize susceptibility to intergranular stress e errosion cracking. 2.2 Prior Satisf actory Performance The BRP Reactor has been in operation approximately seventeen years.The ring sparger core spray system has not been actuated during this period, However, it has been subjected to the reactor environment with no observed design problems. The baffle similarly has been in the reactor environment for approximately seventeen years. A caffle-plate latch modification was incoroorated early in plant life when the baffle plates were found 17 the open Oosition. Two specimen oaskets were welded to the baffle support plate in ine early sixties Each baffle Olate door was originally built having two handles. One handle was removed from each Daffle plate in 1977 to remove an inter-21

N E DC-2 i s,4 ference to flow from the new reoundant core spray system. The Caffle in its present configuration nas no known cesign prctiems. 2.3 New Performance Requirements Basec on a recent eva!uation by Corisumers Power Company the available sparger flow rate versus reactor pressure cnaracteristics have been established as Pressure (psig) Flow Rate (gpm) 75 292 50 359 25 416 5 456 0 466 Consumers Power Company also establisnec, as a goal. the core spray flow rate for each fuel tundle. This information is shown on Page 8 of the Design Specification. GE 22A5589. (See Appendix 1 ). Tne maximum allowable leax rate for the piping connecting the core spray noz:!e thermal sleeve to the sparger has been estaclished at 8 gpm. Though not a new perfor-mance requirement. a reauirement has been established in the design to incorporate featt res that will enable the owner to verify that the core spray nozzle alming points do not shift during the operating life of the plant. This verification can be done during selected refuehng outages. 22

N E CC21974 3.0 DESIGN FEATURES 3.1 New Components - Sparger Tne new sparger nas been designed to duphcate the thermal nydraulic characteristics of the existing sparger. Dimensionally the new sparger will ce a dLohcate of the sparger that was used in the flow distnoution cevelopment tests cescribed in Section 4. There are, nowever three design changes f rom both the exist;ng sparger and the test sparger. The first is a cnange in the configuration of the elbows connecting the new ring sparger to the thirty six nozzles. On the original sparger inese elbows were either a 15 cegree or a 30 cegree bend.1.2 inch pipe elbow. Use of these elbows needlessly restricted flexibility for the precise aiming of the individual nuzzles. Tne elbows used on the test sparger are swivel jointed. fu;l flow.12 inch elbows that allow nozzle aiming within a range of 25 degrees. The saivel jointed elbows cannot be used for the final con iguration because the f riction lock device used to hold their p:e-set position was judged 10 have insufficient resistance to accidental cnange in aiming angte. The elbows used witn the new sparger are mitre cut prec:sion elbows Each elbow is faoricated to preciseiy aim the nozzle. These elbows allow three dimensional aiming flexibility. The intersect point with the upoer core plane by a projection of the nozzle flow axis is held to be within a circ le naving a 14 inch radius The seconc design change is a new feature of the nozzle usec on the new sparger. The new cesign nozzle cocy is one piece wnile Ine nozzles on tne existing sparger have a two piece cocy The two pieces of the old nozzle are threaced 'ogether and tack welded These tack welds interfere with the tool used to venfy corre.:t nozzle aiming angle. The new one oiece body nozzles. naving a closely controlled o'.tside diameter, eliminate the interference proolem and assure that the nozzle aiming argle can be precisely venfied. The nozzle intenor configuration has only minor dif ferences resulting f rom the one piece design. The third change concerns the sparger water inlet. The onginct sparger has a single water inlet througn a 2 inch tee. See Figure 31. Welced to tne tee is a 2 Nn long 2 iacn pipe ccuphng. The coucling is provided with a flanged end designed to mate with a second couphng. The two couphngs are held togetner w!!n a Marmon clamp. This joint cesign has been changed for the following reasons: (al nemote reinstallation of the Marmon clamp is not con;idered feasible. (b) The onginalinstallation cf the ~ connector. a senes of pices and elbows joining the sparger inlet to the core spray Sparger thermal sleeve. was a field fitup operation. As a result of the initial field fitup operation the true dimensions of the connector are unknown. therefore, an icentical replacement connector cannot be pref abncateo. (c) Ref erring to Figure 3-1. it can ce seen that the old cesign requires that the f aces of the flanges on eitner end of the connector be parallel with their mating fianges it is not expected that this condition could be duplicated during a remo, assembly coeration. 31

N E D C-21974 SP ARGER ._ Y.., \\ \\ TEE l - COUPLINGS / YARMCN CLAMP s \\ 45 E LBOWS VARMCN ~ CLAMP \\ 4_ w 90' E LBCW Figu e 3-1 Sparger Wa:er inlet - Original C es:gn. 3-2

N E DC-21974 For the reasons outhned above the connector design has been changed. Figure 3-2 shows schemaiiCally the essential features of the new design. Ine ball joint provices a water tignt;oint at the sparger inlet and provices a joint which need not b; parallel with the sparger. It aiso provides a means of assuring parallelism at the other end Decause by rotating the connector below the ball joint and si'.1ultaneously correctly positioning the thermal sleeve the lower Marmon type flanges can te made 'e parallel. The slip joint provides a means to adjust the length of the connector. A new heavy duty Marmon type clamp has been designed to replace the one piece strap type Marmon clamp presently used to join the connector coupling to the thermal sleeve coupiing. The new design is needed Decause remote installation of the one piece clamp is not feasible. The new two piece design provides relative ease of installation and an increased margin of safety f rom stress considerations. The new connector design has three potentialleak pattu. One is at the ba!-! oint. a second J is at the slip joint and the third is at the thermal sleeve Marmon clamp joint. As stated in the new performance requirements section. Paragrapn 2.3, the max mum a!!Owable leak rete is 8 gallons per minute. Tests at General Elec^nc show the following typical ieak rates for the three joints: Identification Leakage Rate (gpm) Ball joint 0 Slip joint 0.8 max Marmon joint 0.06 max TOTAL 0.86 max Thus the new connector design meets the design requirement. 3.2 New Materials - Sparger There are no known materials probtems with the existing sparger. Experierce with Boihng Water Reactor components has shown that some heats of Type 304 stainless steel are susceptible to Intergranular Stress Corrosion Cracking (IGSCC) in the as-welded condmon. The existing sparger and the connector were fabricated using Type 304 austenitic stain less steel. Type 316 austenitic stainless steel (having carbon content limited to a maximum of 0 02 e) has been used for the new replacement components.The Type 316 material has tne same physical properties as the Type 304 material, however. tests by General Electric have shown that susceptibility to IGSCC is significantly reduced by using Type 316 stainless steel. Thus, the replacement sparger and connector are considered to be better oonsidering IGSCC than the existing sparger and connector. 3.3 New Co,ponents - Steam Baffle The new oaffle has Deen designed tc De a direct replacement unit for the existing baffle. All components have the same configuration except as cescribed below: The baffle is clamped to the reactor vessel by eight " studs"(GE Drawing No.137C7221). The stud design has Deen slightly changed to accomrnocate remote installation tech-niques. The changes inclu7 a tacered lead-in for wrench locating which lengthens the 33

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N E D C-21974 part out dces not affect the working lengtn. and four hcles in the base to provice tie points for a stud insertion tool. The toit pre-loac nas teen recucea from 100 ft-Ibs to 55 f tats. Tne new pre-! cad produces a loacing whicn is acceotatle using ASME Section lil Design Rules. The sparger ring is c!amped to the baffle using eight J-bolts '(Reference GE Drawing No. 16782245). These J-bolts have also been recesignec to accommodate remote assembly As with the stud cesign, the J-ocit mocification involves adding a wrench locating lead-in ano does not affect the working lengtn of the part. The caffle plate latch modification, incorporated in earlier modifications, nas been incorporated in the new cesign. The principle of the original modification was retained. The design details were modified because it was convenient to do so and imoroved performance could be expected. 3.4 New Materials - Steam Baffle There are no snown matenals problems with the existing baffle. The baffle, like the sparger. has teen designed using ASTM specification Type 316 austenitic stainless steel rather than Type 304 used in the existing baffle. 353-6

• EDC-21974 4.0 DESIGN VERIFICATION 4.1 The Design Verification Program Des:gn venficm:en of tre scarger core scray cistncuticn nas teen accomolisnea cy fuil sca!e test;ng Design venfication of the sparger anc caffle structural anc mater:al cnarac-tenstics nas teen acccmplisnea cy stress analysts f see Accencix 2 ) anc incepencent reaew cy cualifiec incecencent rev: ewers.

4.2 The Test Program The core scray distncution for the new scarger has resulted from a planned senes Of tests There were eignt test senes. The Test Report ( Appendix 3. Section 3) dccuments the complete ::escnption of the full scale 'est f acility. The test f acility provicec the capatility to test a fuH size scarger over a range of sparger operat:ng conditions inc!ud-mg sparger f!cw reactor pressure and a steam environment. Several of the ect!ier tests were concucted in tne laDortery using a cencn type setuo. The lateratory f acilit:es are also cescnbec :n the test recort The sec' ions that follow summanze the test Objectives and the test results Cf the eight test senes The 'est report is referenced frecuently to cirect the reacer to the location of tne test cata teing ciscussed. To simphfy ;centification. tne tests herem are numcered ?ne same as :n the test report. 4.2.1 Test B11-1 Sparger Flow Distribution Test Tne sparger flow cistntution test was performed to demonstrate an essentially equal rate of ficw from eacn of the 36 noz:!es en the sparger. Confirmation of ecuality gave evicence that there aere no unknown tnermal nydcauhc cnaractenstics assoc:ated with the sparger ring. The test procecure anc *est acparatus are desentec in Accencix 3. Sage 3.19 The test results are summanzed as f 0Hcws' Adjustec !cw ficw (303 gprrn Hignest ficw 8.99 gpm Average f!Ow 3.75 gpm Lowest flow $ 52 gprn Maximum ceviat;cn - 2.74c : - 2. 63 = = ACjusted htgn ficw (470 gpm; Hegnest f!cw 1415g;m A.erage f!cw 13.72 gpm Lowes' flow 13 38 gem Maximum ceviation - 313*: - 2.46

NE DC-21974 4.2.2 Test 811-2. Single Nozzle Bench Flow Tests Tne s:ngie nc 2!e cencn flow test Aas performec to cemonstrate an essentially ecual rate of flow from eacn incivicual no: ie to De used in sparger tests. (This test Aas in f act cerformec pncr to the Test B11-1 ) Confirmaticn of this ob;ective aas necessary to crovice a casis for the evaivation of the flow rate of the ncz:ms Anen usec m tne previossly cescncec Sparger Pcw Distnbution Test.The test croceaure anc test appara-tus are cescncea in Appendix 3. Fage 3-29 Test results are summanzed be ow-At 25 psig sparger pressure 38 no les tested) Higr est flow 71 gpm Average flow 6 34 gpm Lowest flow 6.7 gpm Maximum ceviation f rom average -3 S c - 2.150 At 42 psig sparger pressure (2 no:2!es tested) Measured flow = 9 3 gpm At 65.9 psig sparger pressure i2 nor:les tested) Measured flow = 11.5 gpm 4.2.3 Test B11-3 Single Noz.!e-Pattern Test Tne single nozz!e pattern test had two main cojectives. First. it was intenced to cefine t9e effect of vanc us steam oressure concitions on tne nor:le flow pattern anc second. it was mtendec tnat the test results tculd show that flow cistncution was not significantly alterec Oy tre convenient spnerical ball icint eloows which would ce used in future testing rather tnan the mitre-cut e!Oows to ce usec cn the new sparger. The test results cic not com;letely satisfy the test cbjectives Tne test apoaratus cescnbec in Appencix

3. Degmnmg en Page 3.33 concists of the f ull scale test f acility. The cross sectienec area of the mstrumented water collecting fuel channels were the same as a full size fuel cnannel. Most of 'he flow from one nozzle positioned at sparger neignt above the fuel cnannels was collectec in cnly four channels. The coarseness of the measuring system resultec in data that dic not adecuately define the flow cattern. The cata did snow that inere is no obvious cifference il results Ahen testing with either the schencal tall e! bow or the mitre cut elbow. However. it can net be stated that there is no difference Test resu'ts are shown in Appendix 3. beginning on Page 3.34.

Upon evaluating the test cata anc notmg the inconclusive results. it was cecided that the cverah design venf tcation could test be servec by prcceeding with the remaining pre-planned tests This cec:s;on was basec on tnree consicerations: the amount of time required to mccify the facihty to provide a finer ficw distribution measunng systern. the expectation nat maividual noz:!e flow cistnbutions woulc ce significantly alterec cy a2

NE OC 21974 interaction affects cf steam f!ow ano ac;acent no:2!e f!OWS. anO the re5u'!s cf Test 811-4 (see f urther ciscussion in Section 4.2 4; 4.2.4 Test 811-4 Single No::le Pattern Test in Air Test B11-4 was des gnec to measure the flow distrioution from incmcual no :tes Anen tested in air. These tests were COncuctec in tre laOoratory curing the time perioc Test B11-3 was temg performec :n the test f acihty. For the B11-4 tests. tne col lector system nac a relat:vely f:nc gt:c The conectors were 4 4 inch squares as compared to the 7 4 7.4 inch squares of the coarse gnd used in Test B11-3. The B11-4 test procecure anc test apparatus are shown in Appencix 3 deginning on Page 3 39 Tne test results are summarized in Aapencix 3 teginning on Page 3 40 The nor:!e useo on tre scarger is cesigned to have a full cone spray pattern.The no :Ie has a 15; cischarge angle whicn results in a ring of water, at collector etevaticn. hav.ng a ciameter of acproximately 15 incn when ficwed at a height of 50 inches above the conectors These approximate cimensions are based solely on gecmetric consic-erations. The grapnical presentation of test data shows that the nor:les produce a flow pattern which is an annuiar nng of water with a hollow center. For the fol!cwing discus-s:on a portion of the B11-4 test gnd is recrocucea in Figure 4-1 using measured cata rather than the visual snac:ng tecnnique used in the test report. The measurec cata gracnically presentec are the no :le 58 test resul's snown in Appendix 3 cn Page 3 43. It shoulc ce notea that pom: -A was the physic, center of the test grid. 3 ?s 337 A 3.93 4 13 i AiVING PcINT A If we postulate this test having been performud using an 3 8 inch gric and tre water collected in each grid section to be the total of that collected in the four smaller channels occupymg the space, we see a otstricution for the grid carkened in the acove figure as follows. 43

NE DC 21974 i l i 0 0 O.5 l 0.25 0 25 i 0 l 8 9 10 11 12 13 I i I i i I i i i 3.12 15 l 1.12 0 94 l 1.5 0 25 i i 16 17 18 19 20 21 l l i D j i I { l i I 0.12 0 88 i 0.25 0.25 0.88 0.25 { l j 4 I, 24 25 26 27 l 28 29 l A E 0 25 1.5 0.31 0.25 i 1.25 OE2 22 23 34 35 36 37 l' C I i O 0 62 1.5 1 44 1.19 0 19 40 41 42 43 44 45 ) l 1 ) O I O 0.25 0 69 0 0 { 48 49 50 El 52 53 i LEGEND. 0.25 - -lNCHES OF W AT[R 26 - -COLLECTION GRID LOCATION A A4 MING PCtNT F gure 4-1 Measurea F!cw D:stribution Samcie of Portion of 511-4 Test Grid. Nc::!e 59. 1

N E DC-21974 Similar:y. if we acstu: ate that due to some uncefined effect the center of the nc :te flow cattern is cisplaced to peints B 'C. o r D". totalhng the f ow within ne carsenec 8 8 ;ncn gncs crocuces the fcilowing prierns: l i i l l 16' 1.62 2 81 2.75 1.06 i 1 i f f f I 2 37 3.50 2.75 1.06 0 62 3.S8 AIMING point B AIMING PotNT C AIMING point o The Cistnbutions are sinkingly similar to those cotained in Test 511-3 where the large gno (7 4 - 7 4) was used in a steam environment. 4.2.5 Test B11-5 Sparger Ring Development Tests The purpose of tms test series cas to expenmentally develcp a sparger no le aiming pattern to test reproduce the desired flow districution of the cesign specification. lt was also a reOuirement that the resultant pattern De readily reptoducible Cn the new sparger. Cor:sidenng that (1) tne sparger in plan view is octagonal in snape (2) the sparger coes not lie in one plane but has in f act. a 19 cegree bend f rom the horizontal plane. and (3) the nozz'es are not uniformly spaced around the sparger. it was expected that the nor !e elbows would te space onentec in three dimensions. Further. considenng that a one cegree rotation of the no: le results in a displacement of the flow pattern center of approximately one inch at the intersect point on the core surface. it was cecidea that noz !e aiming would De best achieved by projecting a hght beam from the nor:le to a target piaced on tne core surface rather tnan trying to measure angles in tnree cimen-sions The !ignt team trave!s a patn that is the crojection of the no :le flow axis. Exper;ence with this technique nas snown that the nozzle aiming (light bearr intersect point).s reproducicle witnin a arcte having a diameter of one inch er less. The test facihties for test 811-5 are descnced in Appendix 3. Section 3.7. The test crocecures are containec in Appencix 3. beginning on Page 3.45. Tne test results are given in Accendix 3. teg1nning on Page 3.48. Figure 3.72. " aiming pattern No.1 Refernna to aimmg pattern No.1 it can be seen that the aiming points were cesenbed in tacular form. and also by diagram. The x" locations show the intencec intersect ocint f or the hght ceam.The numbers around and just inside ihe circle represent the az:rnutnallocation of the no les. It might te noted that the sparger has an axis of geomeinc symmetry about the 0-160' axis. (0 is shown in the lower left corner.)It can also te seen that the aiming point pattern is generally symmetrical about the sparger axis cf symmetry When a test run was comp!etea the test results were made availacle in tne form shown in Page 3 49 of the test report. In these presentations the sparger O' pos:t:en :s always at the lower lef t ocsition Looking at Figure 3.73 on Page 3.49 we see s

N E DC 21974 meacurec channe! f ca for 31 of ine 34 active cnannels in the core. At : east two channels hac macecuate fiow ishown as zero). Figure 3 7.5 on Page 3 51 snows aiming pattern 1A For this test a tota! cf erght noccies were reaimec to provide flow to the ceficient t.nanne!s Pesults of nis enange are s* wn in Figure 3.7 6 en Page 3 52. Flow to the ceficient cnannels aas improved 3ut still cid not meet the cesign gcal Also it can ce seen that :nis resultec in one cnannel near !ne core center now navmg a measured flow of less than ine ces' rec 2 gpm Tne test-asaluate-reaim cycle aas continued until a pattern acDreaching the CDtimum flow cistr:Oution for the water available was Octainec, at whicn time test series 811-7. Core Cochng Configuration Test. sas begun. The results of inis test series is discussec in Section a 2.7 et this report. 4.2.6 Test B11-6, Sparger Dimensional Check Tes 511-6 was concucted pncr to beginning Test 511-5. In performing Test B11-6 a numter of precise measurements were made te venfy that the test scarger met the GE drawing dimensional requirements for the new sparger This test was deemed necessary because it is niencec that the new sparger be. 50 f ar as is practical, an exact cuplicate of the fmal test scarger configuration. Duplicate spargers should have cuplicate flow cistncution cnaractenstics. The test recuirements and test crocedure are given in Appencix 3 on Page 3 63. The measurements taken are given in Appendix 4 initial measurements showed that tne sparger cic not conform to the crawing recuire-ments Tne sparger was rewcrked as requirec.The reported c;mensions were taken af ter +he reworx and are substantially identical to crawmg recuirements. 4.2.7 Test B11-7 Core Cooling Confirmation Test Tne core ccchng confirmation test was a senes of 58 tests cesignec to confirm tnat the scarger flcw cistribution satisfied cesign repuirements. The tests performed are sum-marizec as felicws: Vessel Sparger Sparger Orientation Pressure Flow (section over Steam Entry (psig) (gpm) instrumented channels) Condition 0= ; 90: 180: 270= Combined Bottom 75 292 2 2 2 2 x 75 292 2 2 2 2 x 75 292 23 x 50 259 2 2 2 2 x 50 359 2 2 2 2 x 25 415 2 2 2 2 x C-5 455 2 2 2 2 x AiA 455 2 2 2 2 4C

NEDC 21974 NOTE: - A m; ca::ern m s Accen x 3 c ge 3 m a mm ng ca::en F ;;;erax 3 Pace 3 65> m

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'G Arpenca 3 Page 3 59) Aiming pattern '1 I was used for 2 test :uns in one azimuthal position. Because the results Were not considered sufficient in quantity to provide a basis for conclusion. they are not ncludec in the fcilowing discussions. Aiming patterns '1F and '1 H ' used for a total of 56 test runs. are considered to be equivalent based on test resuits. A small change was made in the location of aiming points 5. B,14 and 17 to provide physical symmetry about the sparger axis of symmetry. The aiming coints of nozz!es 8 and 14 were adjusted 0.37 inches. for nozz!es 5 and 17 aiming points were acjusted 1.85 inches. The test apparatus. test requirements and test procedures f or Test B11-7 are described in Appendix 3. Page 3.54 The test results. using all of the raw date. are summarized in Figures 4-2 througn 4-8 of inis report. In each of the figures the graphical outline represents the test vessel core grid. ln each grid. the desired flow rate, average measured flow rate, ano number of flow measurements are presented as shown in the illustration below: CESIRED F low R ATE 4;pm) AVEP AGE YEASuPED$ LOW R ATE (gp H NUMBER OF CLCW V E ASLF EY E NTS Analysis of Figures 4-2 through 4-8 revealed 6 fuel charinels having an average measured flow rate less than the desired ficw rate goal for at least one test condition. The locations of the six channels ( A througn F) and a summary of the average flow rates measured in eacn channel for eacn test condition are shown on Figure 4 9 Channels identifiec as G and H have average flow rates greater than the design flow rate but nave at least one measured value tess than the design value by more than 4 e. Figures 4-10 througn 4-17 graphically illustrate pressure vs. ficw rate cata cased On both average anc the minimum flow rates measured during the tests.

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3

- - 4. c ,s n b. c -. 3 r,..a y .p.3,.-,,.,, e - oi s .M .iv so < e - scT o.c s tav Ern v ;N u Figure 4-9. Channels Receiving Less Than Design Flow Rate. -,= e, a

N E DC-21974 7 CHANNEL A 6 YE ASLRED F LOW l [ -. A ' E R A G E * - A ( A C N L Y Q - AV ER AGE" - COVPINE D STE AV E NTR Y T OP + E C"TC#) 0 A V ER A GE * - B OTTOM STE AM ENTR Y ONLY g - V Alfr. vi F LO N 's-CWN AT 50 A ND 75 as.4 CNL v i

• SE. ElGUR E 4-9 5

l 4 2_. I; At C ME ASLRED FLOW C s 3 N N N N t DESIAEC FLOW / / MINIMUM MEASURED E LOW l l I I I i I l I g 3 25 50 60 75 100 PA ESSURE fmigi Figure 4-10. Measured Flow Rates. Cnsanel A. Lie

NEDC 21974 7 CHANNELB 6 ME ASLRED FLOW d - A V ER AGE * - air CNL v Q A V ER AG E * - COVE tN E O ETE Af

• EN'R Y TOP + ECT7 0Vi

- A V E R AC E" - ECTTOM STE AM E NTR Y CNLY A -.lNivLvrLOW SHOWN AT 50 AND 'i 00: w - ONL I

• SEE FiGL AE 4 9 5
• THIS PCINT REPRESENTS A VEASUREMENT TH AT is LNCONSISTANT WITH ALL VEASUREMENTS FOR ALL OTHER 7 ESTS.

4 Ee 3:0 A s G '.4 E A SL R E O F.C a 3 *-~ g I s a 1 i C ESIRED F LOW A w

• /

V6NIMUM VE ASURE D F LCW - 1 I l I I i I l l g 0 25 50 70 75 100 PR E SSU A E :4.ca F'gure 4-11 MESSureC Flow RB!eS. CnBnnel B. 17

N E DC-21974 7 CHA?vNE C / 6+ MEAELRE D E LOA d y AtERAGE*-AiRONLV O - A V ER A GE * - CC'/B:NE O ST E AM ENTR Y 'T OP + E DTTOM, C - AV ER AGE * - BOTTOM STE Av ENTR Y ONL v A - MINIMUM F LOW (SHOWN AT 50 AND 75 ps,q ONLY)

• EE E F IGUR E 4-9 5

4 4-2 %= s 0 3 A v G 'zE ASUR E D F LOW \\ n N N n 2 DESIR ED F LOW h N O N VINIMLM VE ASUR EO F LCW N %^- 1 1 I i 3 25 50 75 700 PR E SSL,R E Wsm: Figure J-7 2. Measurea Flow Rates. Channel C 4.:5

NEDC 21974 7 CHANNEL D 6 VE AsumED Low -. e cER AGE

• _ air Or,L v O

AvEF AGE - c veined sTE Av EsTay .T OP - E C TT Dr/, - A V EP AG E' - ECTTOM ST Et.'A E NT A v ON Lv g - min 1MLM E LOW SsOnN AT 50 AND 75 m ;; C*,Lv i (I sEE riGuaE Aa 5 - t } aw- = ?:: 4 3O s e AV G V E ASL ; E D F LL.' Q 3 m_ \\ Nd 9 DESIR ED F LOW / N 4 8 4 14 l 91NIMLM VE ASUR ED F LOW w I i 1 l 1 l l l i l 3 3 25 50 68 75 1 00 DA ESSUP E ipugi ?!gure 4-13. Measurec !cw Rates. Chanrel D. .:. c

N E D C-21974 ? CHANNE L E 6-ME AEURE D F LOW d a w EP AGE' - air ONts C - A V E R A G E " - COMS:N E D STE AV E NTR Y ' TOP + ECTTOYi O - av ER^cE - BOTTeu STe Av ENTR v cNov g - VWNLMrLOW 'SCWN AT 50 AND 75 asq CN L v i

• S E E F IG U R E t. ?

5-L 4 I 2 L 5 E 3 av VE ASLRED c;CW I I 6 y DESIRED FLOW 9 i l g 3 25 50 75 '00 pa rSSURE foua) F;gure 4-74 Measurec' Flow Rates. Cnenne! E. 23

NEDC 21974 7 I i

I I

i C H A fi N E L E 6-ME ASLRED F LOW d - AkEAAGE*-AiPCNLf

O A' ER t.C E * - COYBtN E D STE AN1 E NTR Y

<?OP+ BC.M OV t O - M E R A C E' - 50TTCV ST EM/ E NT A v ONLv A - Y tN:f.wr,' r L Cw :ssCW N AT 50 A N D 7 5 psg C *,L v j

• SE E F IGLR E a-9 j

l 5-1 r n 4 - g Av0'AEastpECFLCe. l i= %f d ) i 3~ ,i C w DEstRED FLCW i 1 - l i I f g D 25 50 75 100 PRESSURE :mmi r ig u re ~,~,a 5. Measurea iow mates. pnenne., r. r v 4 :1

NEDC 21974 I I I l l CHANNEL G l 6-l ME ASURED F LOW I C AV ER ACE * - CO*/BiNED STE AM ENTRY A VER AGE * - AIR ONL v Q. 'T OP + B O TT O*/ l O - AV ER A GE * - BOTTOM STE AM ENTR Y CNLY A - VINIMLM r LOA 15HCWN AT EO AND 75 s a CNLY a l

• SEE riGURE 4 9 l

5-- 4- ? O i t l l N w I \\ 'l i 3~ { \\ I g l Av 3 '/ E aSL A E D P LOW j g i \\ \\6 s& ~ ^ DESIRED F LOW I' % l 4 ,,N ...Em= E 0 F co I I I l 1-I I I I l i l i l 0 0 25 50 57 75 100 PR E SSUR E tosig) Figu re 4-7 6. Measurea Flow Rates. Channel G. 4 22

NEDC-21974 7 l i CHANNELH t t l I ME ASLPED F LOA 6 I 6 - A V ER AGE * - A( A CNL

• l O

A s ER AGE' - COV61NED STE AM E NTPV I l iTOP + ECTT C AU I O - A V E R AGE * - ECTTOM STE AM E NTA Y Of LY 4 l l 3 - MINIMUM F LOW SHCwN AT EC AND 75 usq CNLY)

• SE E FIGLR E 4 9 i

I 5h h 4 - ? \\ 5 \\ \\ 3l \\ N MINIMUM ME ASURED F LCW O AVG ME ASLFED F LCW w O N i \\ l N O s_ DESIRED F LOW f % 1 w I I I t I 'r I i I I i. r I 3 I I l l I O O 25 50 68 75 100 PP ESLURE (:mg) figur? J-1I ME'BSUfeC fiOW RBIES. Channel H. 123

l 4.2.8 Test 811-8 Sparger Ring Sensitivity Tests j The sparger ong sensitivity tests were performea to obtain data to assess the sensitivity a of core spray cistncution to small effects sucn as sparger manufacturing tolerances. ] neal!ation fituo, nng ce-centenng, and errors in nozzle aimmg A tota! of 22 tests were g perf t *mec inciucmg two control tests tnat were repeats of normai tests performed d cur ng 'ne confirmation test senes B11-7 Each incividual test introcuced a cond tion to ] produce a greater error than can be reahzed dunng sparger installation. Fur example the j sparger cannot ce positioned off center in the reactor ves' el oy more inan 14 incn = tecause the raffle has a 14 incn nominal clearance to the vessel wall, nowever for twe of the sensitivity tests the sparger was positioned 12 incn off center. Test conditions are hsted on Tabie 4-1. A cescriction of the ec;uipment and f aciiiced is given in Apoencix 3 on Page 3 76. Test results are c;iven in Appencix 3 on Pages 3.78 tnrough 3.99 The results of Tes 31 through 16 conf rm that the sparger spray cistnoutton wa',vmually unaffectec.Tnis re; att was expected because the net effect of the test conditio is did not alter the core spray t 'stricution pattern but only displaced the pattern relative ta the core. g For Tests 17 ana 1F (wo rozz!es were intentionally misaligned relative to aiming pattern 1H The aiming gwnt for norte 8 was displaced 1.85 inches away from tne core control

ocation. The aimmg point for nozz e numcer ' was displaceo 518 inches toward tne ngnt nanc edge of the channel containing its onginal aiming point.The tests resulted in a shgnt cegracation of tne core spray distribution for both the steam and air tests. As a result of this finding the aiming point tolerance for all nozzles on the new sparger will be hmitec to 12 mch. Tests 19 and 20. which removed and replaced all nozz!es at random.

croduceo results that show core spray distnoution is affected by Ine innerent nonuniformity of the flow pattern of the individual nozzles as was observed during Tests B11-3 anc B11-4. It is this nonuniformity that is believed to result in the asymmetnc core spray cis:r.bution. although the sparger has m;rror symmetry. It is conc!uced that the new sparger can be expected to have a core spray distnbution very close to that of the test soarger inclusive of considenng manufactunng and installa- = tion tolerances. It is planned trat nozzles for the new sparger be installed on the test l sparger for a fmal confirmati.an test senes. Tests will be performed to cetermine if the e nonuniformity observed fcr Tests 19 and 20 of the B11-8 sensitivity test exists for the prccuctico nozz!es. If these tests incicate that this nonuniformity coes exist for the 3 procuction nozz!es. the testec nozzles from an acceptable core scray distnoution w'il ce i cteaned and mstallec on the new sparger in a tocation identical to their !ucation on the test sparger If the testing moicates that the nonuniformity does not exist for the procuc-tien nozz!es, tne nozz es will ce install d on the production sparger in a rancom cattern. j i N 5 J 9 5 i 4 24 I

• _j. kl

[*' 'O [ h d' f.. g ( I 1 I h ' d ( 9 pq.

N E DC-21974 Table 4-1 SENSITIVITY TEST PROGRAM Test Vessel Pressure Sparger Flow N o. (PSIG) (gpm) Steam Entry Sparger Position 1 75 292 Comoined O' - Normal 2 AlR 466 O' - Normal 3 75 292 Comoined O' - Raise 180' position 1 2"- provide four point support 4 75 292 Combined O' - Raise 180 position 1" - provide four point succort 5 75 292 Comoined O' - Raise O' position ' 2" - provide four po:nt support 6 75 292 Comoineo O' - Raise 90 position '2" - provide four point support AIR 466 0 - Raise 180' position ' 2" S AIR 466 0' - Raise 180' position 1" 9 AIR 466 O' - Raise 0; position ' 2" 10 AIR 466 0' - Raise 90' position ' 2" 11 75 292 Combined Sparger level - Oc 90' 180= 270' sparger locations clockwise by 1' from corresponding vessel position. Sparger centered in vessel over core 12 AIR 466 Same as run 11 13 75 292 Combined Soarger level - 0=-180' sparger position in line with O-180' on vessel. 90' and 270'sparger axis ' 2" toward vessel 90' location 14 AIR 466 Same as run 13 15 75 292 Comoinec Soarger level - 90'-270' sparger in line with 90'-270' on vessel. O' ano 180'sparger axis ' 2" toward vessel O' location 4 25

TJ.DC-21974 Table 4-1 SENSITIVITY TEST PPOGRAM (Continued) Test Vessel Pressure Sparger Flow No. (PSIG) (gpm) Steam Entry Sparger Position 16 AIR 466 Same as run 15 17 75 292 Comoined Soarger level - Normal O' azimuthal-Aiming pattern 1H except nozz!e 8 at 4 B-B 75 and nozzle 4 at 9.0- A.S 18 AIR 466 Same as run 17 Note: 1 rotat.on = 94incnes 19 75 292 Combined Same as Test #1. Prior to ' unning remove all 36 nozzfes. Rep ace in random fashion. Verify that no nozzle has been reinstalled in its onginal location. Record location for each nozzle. 20 75 292 Comcined Same as Test el and #19. It is intended that the nozzles ce removed and replaced a second time. 21 25 292 Combined Same as Test #1 22 25 292 Combined Same as Test #1 except rotate sparger to 270= azimuthal location 4-26

N E DC-21974

5.0 CONCLUSION

S A new core spray soarger for BRP nas Deen designm m en has the same therrnal hydraulic anc cimensional characteristics as coes the BRP 9 sparger tested at NUS. A new steam Daffle has been designec for BRP as an icentit~ replacement unit f or the extsting baffle. The new sparger and the new baffle have been constructed f rom materials proven to ce less susceptible to Intergranular Stress Corrosion Cracking than the origi-nal construction material. The confirmation and sensitivity tests demonstrate that an optimum nozz!e aiming pattern was being approached and that further testing and modifications would only result in a small gain for the time and expense incurred. The nozzle aiming pattern is judged to be acceptable since the flow cistricution met the estaclisned goal over the greater part of the pressure range failing to comotetely meet the goal only at the lowest and highest pressures. Because the spray flow distribution was shown to be affected by indivicual nozzle cnaracteristics. it is recommended that a final confirmation test be conducted using procuction nozzles: and after the final confirmation test the nozzles bt located on the new sparger in the same location. if the testing incicates that this is required. If during the final confirmaticn testing of the procuction nozzles. it can be demonstrated that the incivicual nozzle characteristics do not affect the core spray flow distribution. a random location of the production nozz!es is acceptable. 5152}}