ML20040G849
| ML20040G849 | |
| Person / Time | |
|---|---|
| Site: | McGuire, Mcguire  |
| Issue date: | 02/08/1982 |
| From: | Parker W DUKE POWER CO. |
| To: | Adensam E, Harold Denton Office of Nuclear Reactor Regulation |
| References | |
| NUDOCS 8202160532 | |
| Download: ML20040G849 (46) | |
Text
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DUKE POWER COMPANY Powen Bentonwo L
422 Socin Cut:acu Srazzr. CnAntorre, N. C. 28242 4
v.e,p.cs.oc,
February 8, 1982 Tctc~o c-4.c4 7o4
$7 cam P#CDuCTION 373~4C63 Mr. Harold R. Denton, Director 19 I
Office _of Nuclear Reactor Regulation U. S. Nuclear Regulatory Commission ISliCGpjy..-
N Washington, D. C.
20555 y
Attention:
Ms. E. G. Adensam, Chief 2 S 79$b k Licensing Branch No. 4 rgy !g+4 Re: McGuire Nuclear Station
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Docket Nos. 50-369, 50-370 Q-
/
Dear Mr. Denton:
Attached are five copies of a report entitled " Response to Request from NRC - Additional Test and Status on Model D Steam Generators". This is the Non Proprietary version of the report subm*.tted on January 29, 1982.
The supporting documentation outlining the basis for the Proprietary desig-nation of the original report is provided in the submittal of January 29,.
1982.
Please advise if~there are any questions regarding this matter.
Ve y truly your,
i 6,
William O. Parker, J.
GAC/jfw cc: w/o attachment Mr. P. R. Bemis Mr. James P. O'Reilly, Regional Administrator Senior Resident Inspector U. S. Nuclear Regulatory Commission McGuire Nuclear Station Region 11 101 Marietta Street, Suite 3100 Atlanta, Georgia 30303 So /
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8202160532 820208
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e DUKE POWER COMPANY MCGUIRE UNIT 1 RESPONSE TO REQUEST FROM NRC ADDITIONAL TEST AND STATUS ON MODEL D STEAM GENERATOR PREHEATER
1.0 INTRODUCTION
This report presents information requested from Duke Power by the NRC in a letter dated 1/7/82 from Robert L. Tedesco to Mr. William O. Parker, Jr., on Docket No. 50-369. Specifically, the report updates the Novem-ber 20, 1981 presentation to the NRC by discussing the cu rent Westing-house evaluation program (analysis and test) with progress to date.
Included in the program description are design modifications under con-sideration. Data from operating plants with model D steam generators is presented and correlated. McGuire 1 operating criteria was submitted previously by letter dated January 26, 1982. The Westinghouse position on startup programs for upcoming plants is also described.
-__-+_s~.
o Proprietary Class 3 2.0 WESTINGHOUSE EVALUATION PROGRAM The Westinghouse progra*m to evaluate the model D steam generator pre-heater tube wear mechanism focuses on two objectives. These are: (1) to develop a design modification to eliminate the tube wear mechanism, and (2) to define a power-time envelope and feedwater configuration for operation of unmodified plants. The major portion of the testing to date has been on the simulated D-3 design. The difference between D-2 and D-3 steam generators is presented below.
r The design of the D-2 impingement plate is different from that on the D-3.
Flow model test work. has shown that the differences in the plate design do change the detailed flow pattern at the entrance to the tube bundle but not the probable nature of the wear mechanism.
[]a,c.e Of inunediate interest to both the D-3 and D-2 is the characteristics of the wear phenomena, the tube vibration characteristic, the rate of wear and the correlation of velocity to wear. The intent of this report is to provide a summary review of the logic and status of the Westinghouse program _rather than final conclusions.
2.1 MODIFICATIONS DESIGN Before meaningful design modifications can be developed, it is necessary to. understand the mechanism of the tube wear experienced at Ringhals 3 and Almaraz 1.
The objective of this part of the program is to define the characteristics of the mechanism in terms of flow rate, tube motion j
(mode / frequency) and amplitude of the motion. From this definition of the mechanism, design guidelines are to be specified with respect to j
velocity profiles, damping characteristics and the effects of support l
configuration changes. This phase of the work is taking advantage of both air and water model tests to determine individual tube velocities, l
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s Proprietary Class 3 and shaker tests and analysis to study tube / baffle plate damping and tube vibration characteristics. From the data so derived vibration threshold conditions are being determined.
Preliminary design modification concepts continue to be studied. Con-sideration is being given to concepts which may be applicable in modi-fying the flow distribution into the inlet of the tube bundle, methods to increase tube damping and methods to increase individual tube sup-ports.
The prime phases of the design modification program can be summarized as following:
o Definition of excitation mechanism o
Tube response model verification o
Design modification concept selection A summary of the status of each program and sub-program to cate is pre-sented below.
2.1.1 EXCITATION ECHANISM DEFINITION Flow Mapping - Tests aimed at defining the magnitude, direction and j
distribution of the flow entering the tube bundle with the 03 impinge-l ment plate installed at Alaraz and Ringhals have been completed. Test models used in this investigation were (a) 1/7 scale air (b) 1/6 scale water and (c) 2/3 scale water. Tests results from the air and water tests compare well. An example of the flow distribution obtained in each of the three models is provided in Figure A-1.
The similarity of l
flow distributions obtained in the air and water tests supports the use of the air flow test results in the initial phase of flow velocity-tube wear correlation activity. Direct flow mapping for the D-2 impingement plate installed at McGuire 1 is complete using the 1/7 scale air test.
1535Q:1
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Proprietary Class 3 Results frcrn the 2/3 scale model water test using the D3 impingement plate []a,c.e An example of a tube bundle inflow map obtained from the 2/3 scale water model is provided in Figure A-2.
This map illustrates the potential available for reducing the tube bundle inflow velocity by introducing features to better distribute the flow.
In order to better understand the phenomena occuring in the Pre-Heat steam generato, the mean square MAXIMUM TANGENTIAL VELOCITY at each tube location has been compared against eddy current were indications of the tubes.
[]a,c.e The various []a,c.e for each location are provided in the table on Figure A-3.
Plots of estimated []a,c.e versus column number for Rows 49, 48 and 47 are presented in Figures A-4, A-5, and A-6, respectively.
Because of the unique and varying flow conditions experienced by each tube (particularly behind and in the neighborhood of the impingement plate and impingement plate supports), no attempt has been made to draw a smooth curve through the data points.
This data has been used to correlate velocity squared with regions of damage and regions of no damage. The flow will also be used to develop hydraulic forcing functions. No mode shape weighting of the local velocity was used in this analysis since a dynamic analysis of the tube motion has indicated that a single mode will not adequately describe the tub,e motion. The initial conclusion based on this correlation is that, wear does not occur below approximately 9 feet per second.
Data obtained from the 1/6 scale water flow model operated at the West-inghouse R D Center has been evaluated, providing the inlet flow dis-tribution. A vector diagram was made that shows the horizontal velocity 1535Q: 1 W~
Proprietary Class 3 in the inlet region in a horizontal plane at an elevation of 4.5" (full scale) above the centerline of tne impingement plate (Figure A-7).
[]a,c.e
[]a,c.e An overall assessment of the flow velocity field in the D3 inlet plenum can be made by reflecting on the results from the various tests to date. Several points can be made as follows:
1.
[]a,c.e 2.
[]a,c.e 3.
The presence of momentum effects is also shown in test data obtained from the Swedish State Power Board (SSPB) Full Scale Inlet Test where time variation of the flow velocity was observed.
4.
Control of inlet momentun is reflected in' two of the design concepts being considered. []a,c.e Pressure Pulse Mapping Pressure pulse mapping in front of the tube bundle in the Westinghouse ARD 2/3 Scale Water Test with the as-built D3 impingement plate in con-junction with a 4 hole and 31 hole flow limiter was completed. []a,c.e Tube Support Definition Infomation that statistically characterizes the fabricated tube and support geometry has been identified providing true positioning and alignment offsets of tubes and supports for a Model D3 Steam Generator.
These alignments were compared to those used in the static and dynamic tube analyses and were consistent. The U-tube static model runs which superimpose normal operation tube loadings have been completed.
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The purpose of these tests is to detemine the damping characteristics of the steam generator tubes when they are vibrated in a prototype manner with prototype boundary conditions. The vesulting measured damping udll be used in the flow induced vibration analysis. []a,c.e Flow Induced Vibration Analysis A multi span (ynamic analy:is model has been constructed using the' WECAN computer program. The model utilizes annular gap elements at the sup-port plate locations and is thus able to simulate orbital tube response. The gap elements can be offset to simulate support plate mal-alignment. The use of this model eliminates many of the restric-tions and assumptions necessary in modai analysis.
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[]a,c.e Figure A-10 shows the three-dimensional model. A sample of the displacements is given in Figure A-11.
These displacements cor-relate well with the field wear scar locations.
Flow-Induced Vibration Tests Shakedown testing of the 0.417 scale combined flow and vibration model showed that the pump motor did not have sufficient horsepower to provide the required flow rate. A maximum flow rate of 60 percent of the scale nominal full power flow rate was obtained prior to shutdown. Prepara-tions are in progress to replace the pump motor with one of sufficient power to test with a flow rate of about 30 percent above the flow l
1535Q: 1
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i Proorietary Class 3 required for dynamic simulation. During the shutdown, the olearances between selected tubes and baffles will be modified to reflect the upper end of the clearance tolerance range utilized in the fabrication of the D3 units. This will provide for a more conservative test capability.
Results of this test are anticipated to be useful in correlation with field data obtained from accelerometers at Almaraz to provide a defini-tion of the vibration mechanism and an acceptable operating power level.
2.1.2 TUBE RESPONSE MODEL VERIFICATION Wear Scar-Mode Shape Analysis Tube war scar analyses have been completed and the results have been incorporated into the flow induced vibration model as part of the ini-tial conditions (plate offsets).
2.1.3 MODIFICATION Westinghouse is developing the following design modifications to be applied to steam generators which require the modifications based on results of field data analyses and laboratory tests.
Conceptual Design Several conceptual design modification approaches to minimize the poten-tial for the tube wear concern are being developed. These include (1) flow control features fitted in front of the tube bundle, (2) vibration control bars for rows 49 through 46, (3) internal tube dampers, and (4) feedwater systems and modifications to direct the flow to the auxiliary feedwater nozzle.
A fifth approach under development and considered for use in combination with any of those above involves modification of the reverse flow limit-ing device mounted in the main feedwater nozzle. The current design consists of a plug with four venturi openings. []a,c.e 15350:1
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[]a,c.e A 1/7 scale model test article of the new configuration will be fabricated for testing.
A layout drawing of the second concept, []a,c.e The installation of anti-vibration bars (AVB's) is another method being considered by Westinghouse in order to eliminate the tube wear mecha-nism. The AVB's will be an integral part of the slotted flow bar design, extending 3 rows into the tube bundle.
Based on results of short :, pan testing of internal tube support con-figurations, []a,c.e An additional short span test has been added to investigate tube support dampening due to relative motion between the tube and the tube support.
Test set-up is in progress.
Selected Modification Analysis The flow induced vibration podel has been modified to reflect the effects of the design modification support. In addition, the gap stiff-ness values have been increased by a factor of three in an effort to make them more realistic.
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Proprietary Class 3 2.2 OPERATING PLANT POWER-TIME ENVELOPE AND FEED CONFIGURATION At this time a conservative position has been taken by Westinghouse limiting long-term power operation prior to the design modification, for Ringhals 3, Almaraz 1 and McGuire 1 to 50 percent on the main nozzle coupled with periodic edcty current' inspection. The' objective of this part of the current program is to quantify the degree of conservatism with respect to the long-tem limit of 50 percent power on the main nozzle and to evaluate the long-term use of the main feed bypass line and auxiliary feedwater nozzle. From this program, it is anticipated that a higher power level / time envelope and feed configuration may be defined for plant operation prior to long-tem modification.
A major step to meeting this objective is to develop a comprehensive tube wear correlation. This correlation will consider sensitivity to such variables as local flow velocities, individual tube loading, manu-facturing tolerances and time. Work has been completed on developing a preliminary velocity wear envelope. []a,c.e Eddy current data from McGuire Unit I will be correlated with D-2 impingement plate flow velocities if indications are found.
In parallel with this effort, work is also in progress to develop wear-load-time correlations and even-tually to consider the implications of tube support plate manufacturing tolerances on long-tem wear characteristics. These parallel programs will be combined to define a comprehensive tube war correlation.
In order to define an allowable main nozzle flow - time envelope and the associated recommendations for flow control it is also important to consider the implications of wear on the long-tem integrity of the tubes. The allowable operating envelope for tube wear control will be defined by using the tube wear correlation in conjunction with the limiting tube wall thickness reduction studies.
The total power level of the plant can be increased above the limits on the main nozzle by also feeding through the main feed bypass line to the 1535Q:1
o Proprietary Class 3 auxiliary feedwater nozzle.
In order to achieve significant power increases in this manner, it is necessary to modify the system operation and system design on the majority of plants. In addition, long-term operation of the auxiliary nozzle requires analysis of the impact on the steam generator both for steady-state and transient operation. These studies are inc.luded in this program to define the power-time operating envelope and feed configuration for unmodified plants.
The current status of the programs to define the power-time operating envelope for the short-term is presented below.
2.2.1 TUBE WEAR RATE CHARACTERIZATION Tube Wear Mapping Mapping of the tube wear data from both 'the Ringhals 3 and Almaraz 1 plants has been completed. A typical plot of the maximum wear depths encountered along a row of tubes is provided in Figure B-1.
Similar mapping versus wear (or lack of wear) for the Model D-2 impingement plate will be undertaken as data becomes available.
Tube Flow-Wear Correlation
[]a,c.e Flow Induced Vibration Analysis Flow dependent hydrodynamic oscillating loads have been calculated and are shown in Figures B-4 and B-5 for vortex shedding and fluid elasti.c excitation, respecti vely. These results will be used as input to the single tube vibration tests and the flow induced vibration analysis.
1535Q: 1
Proprietary Class 3 Single Tube Vibration Test This test is to be conducted to obtain tube reaction forces at the sup-port interface. The tube will be supported in a manner as indicated by the wear scar profiles seen from the Ringhals 3 tube.
[]a,c.e A conceptual design has been developed to measure the reaction forces using piezo-electric force transducers at the supports. Figure B-6 describes the measuring device concept.
Sliding' Wear Tests Four sliding wear test rigs will be designed to test tube-support plate couples in an ambient All Volatile Treatment (AVT) water environment.
The test facility will simulate orbiting motion of the tube within its support at various contact loads to provide accelerated wear data.
[]a,c.e The objectives of these tests are to obtain wear rates which will be used to define acceptable operating power levels prior to the implementation of the repair modifications. Figure B-7 shows a test matrix for this program.
2.2.2 MODEL VERIFICATION Operating Plant Wear Scar Analysis Analysis of wear scar data was based on Ringhals 3 tubes row 49, column 55 and row 49, column 66. []a,c e r
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[]a,c.e 2.2.3 UPPER BOUND MAIN N0ZZLE FEED LIMITS Allowable Tube Wall Thickness Reduction Preliminary fatigue calculations have been performed for a tube [
]a,c.e The fatigue calculations considered both the reduction in tube cross-section and the stress concentration introduced by the scar. The resulting fatigue usage for the worn tube was found to be
[]a,c.e 2.2.4 SYSTEMS OPERATION Main Feedwater/ Main Feedwater Bypass Split Flow Operation Plant operation with feedwater flow to both the m'ain nozzle and the auxiliary nozzle has been investigated as a means of achieving higher power levels than would be possible with flow to the main nozzle only.
Long-term operation in this uude requires the impact on the steam generator to be considered and modification made to the system operations and design.
An evaluation is in progress for a generic feedwater system modification which can be adjusted for plant specific application. This modification will be designed with the objective of providing the optimum flow split for maximum power level operation. The modification is []a,c.e 1535Q:1
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Proprietary Class 3 3.0 OPERATING PLANT DATA There are currently four Westinghouse operating plants which have pre-heat steam generators.
. Ringhals Unit 3 a 3-loop plant rated at 2785 MWT with D-3 steam generators.
Almaraz Unit a 3-loop plant rated at 2785 MWT with D-3 steam generators.
KRSK0 a 2-loop plant rated at 1882 MWT with D-4 steam generators.
McGuire Unit 1 a 4-loop plant rated at 3425 MWT with D-2 steam generators.
Table 3-1 lists the steam generator parameters for ea h of these plants. With respect to the issue under consideration, the main param-eters are pre-heater. From a point of view of design and flow configu-ration, Ringhals 3, Almaraz 1 and McGuire 1 have similar designs and as such, experience and data obtained from each of these plants may be applicable to all three plants. It will be noted that the flow rates at McGuire 1 are slightly below that for Almaraz 1 and Ringhals 3 by virtue of the reduced loading per steam generator on a 4-loop plant compared to that of a 3-loop plant.
With respect to the model identity of D-2 versus D-3, there are two differences:
o The D-3 has a flow distribution plate between the tube sheet and the bottom preheater baffle, the D-2 does not. This does not influence the mechanism under consideration.
1535Q:1
Proprietary Class 3 I
o The design of the D-2 impingement plate is different from that on the D-3.
Flow model test work has shown that the differences in the plate design does change the detailed flow pattern.at the entrance of the tube bundle but not the nature of the mechanism.
[]a,c.e In summary, it is concluded that the data and experience gained at Ringhals, Alamaraz and McGuire may be applicable to all three plants.
Analyses and tests to confirm the degree of applicability are ongoing.
Of insnediate interest are characteristics of the wear phenomena, the tube vibration characteristic, the rate of wear and the correlation of velocity to wear.
1535Q:1
i i
4.0 EFFECT OF DESIGN MODIFICATIONS ON UNIT 1 AND UNIT 2 SCHEDULE McGuire I will be shut down no later than the 15th of February for an eddy current inspection of all four (4) steam generators.
Duke Power and Westinghouse will mutually develop the program for the subsequent period of power operation. This program will be based on the results of the eddy current inspection, correlation of operating experience from other plants, and the status of the Westinghouse overall program.
It is anticipated that this power program.will be adopted for McGuire 1 until any necessary modifications are made to the steam generators. At this time, it is not possible to define the schedule or details for potential steam generator modifications. The modification schedule will be dicta-ted by the Westinghouse program and the power needs of the Duke system.
In the case of McGuire 2, Duke Power's program will again be influenced by the Westinghouse modification schedule.
In the event that any neces-sary steam generator modifications cannot be made prior to plant start-up, Duke Power will proceed with a prudent startup program. The-details of that program will be based on our knowledge at that time.
~
5.0 WESTINGHOUSE SUGGESTED SPECIAL STARTUP TEST PROGRAM The startup program for individual plants in the future will be a func-tion of the data and experience gained from operating plants and the status of the Westinghouse program at the time of the specific plant startup.