ML20081K147

Forwards Response to Request for Addl Info on Sbwr Design, Addressing Details of Tests Intended to Confirm Structural & Functional Integrity of Certain Components

ML20081K147
Person / Time
Site:	05200004
Issue date:	03/20/1995
From:	Quinn J GENERAL ELECTRIC CO.
To:	Borchardt R NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM), Office of Nuclear Reactor Regulation
References
MFN-043-95, MFN-43-95, NUDOCS 9503280420
Download: ML20081K147 (3)

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GENuclearEnergy MR $8 75 ven k165 San Jose. CA 95125-1014 '

408 925-1005 (phone) 408 925-3991 (facsimile)

March 20,1995 MFN 043-95 Docket STN 52-004 Document Control Desk U. S. Nuclear Regulatory Commission Washington DC 20555 Attention: Richard W. Borchardt, Director Standardization Project Directorate

Subject:

Response to NRC Request for Additional Information on The Simplified Boiling Water Reactor (SBWR) Design, RAI 210.13 Attached is GE'S response to RAI 210.13, which addresses details of tests intended to confirm the structural and functional integrity of certain SBWR components.

Sincerely, 1lkU O Y ,

) k James E. Quinn, Projects Manager LMR and SBWR Programs Enclosure cc: P. A. Bochnert (NRC/ACRS)

1. Catton (ACRS)

S. Q Ninh (NRC)

J. I-l. Wilson (NRC) 2S008G 9503290420 950320 PDR ADOCK 05200004 '

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Attachment to MFN 043-95 RAI Number: 210.13 Question:

The response to RAI ECGB.14 needs further clarification. No detail descriptions are provided regarding how various categories of design loads were analytically predicted; ,

how to ensure that the prediction of loads were ahvays on the conservative side; how l component stress and fatigue evaluation were performed; and how tests will be conducted to verify design adequacy for mechanical components, including reactor vessel and internals, heat exchangers, and the IC. The response to RAls SRXB.38,39,40 and 42 indicated that the tests conducted at PANDA, PANTHERS, GIRAFFE, the 1 Massachusetts Institute of Technology, and the University of California at Berkeley are intended for thermal-hydraulic performance and are not for the purpose of defining mechanical loads or verifying component design adequacy. Provide more detailed descriptions to address the above concerns, and verify that detail stress reports and load definition documents are available. l In addition, provide information regarding details of any tests which are intended to  !

verify structural or functional integrity of mechanical components, including testing plans, test procedures, sensor types and locations, and basis to ensure conclusive l comparisons of test results with analytical predictions. Will flow-induced vibrations be l monitored in some of the planned tests? What is the basis to ensure conclusive obsenations by performing nondestructive examinations after completion of only one-third of the required isolation condenser operational cycles. as indicated in the response to RAI ECGB.14?

GE Response:

Following the transmittal of responses to RAIs ECGB.14 and SRXB.38, 39,40 and 42, GE received and responded to RAls 900.48-900.61 which have essentially the sarne content as RAI 210.13 regarding details of tests intended to confirm the structtNal or functional integrity of components. Please refer to letter number MFN-209-93, from J. E. Leathennan to J. N.

Wilson, dated November 24,1993.

Provided below are responses to each of the questions included in RAI 210.13. In some cases the responses reference the responses to RAls included in the letter referenced above.

The Isolation Condenser (IC) and the Passive Containment Cooling System (PCCS) condenser designs have been validated by detailed analyses in accordance with the ASME Section III code. The analytical prediction of design and service level loads, the fatigue evaluation and the calculation of component stresses for the IC and the PCCS are documented in the ANSALDO Stress Reports, which are available for review in San Jose. In addition, the responses to RAls 900.48 and 900.61 summarize the analyses that were performed for these components.

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Response'to RAI 210.13 (continued)

The structural design objective of the IC structural tests is to assure that the loads used in the design envelop the loads expected during the SBWR service conditions. The-test matrix required to meet the structural test objectives is' designed to:

1. Envelop all thermal-hydraulic loading conditions expected during the tests to assure that load estimates from the tests include the largest temperature gradients and the fastest thermal transients with prototype pressure loads.

2. Include sufficient number of load cycles to reveal any thermal ratcheting where the elastically calculated stress levels exceed the ASME Code shakedown limits so that the measured deformations can be used to envelop the ASME alternative shakedown analysis approach.

Test requirements and sensor types and locations are provided in the test specification 23A6999, Rev. 3. The PANTIIERs IC test plans and procedures document will be issued later this year.

The output of key structural measurements will be compared to the analysis results documented in the ANSALDO Stress Reports. The responses to RAIs 900.53, 900.55, and 900.57-900.60, provide details on these tests and on how the test results will be compared with the analytical predictions. The exister.ce of flow-induced vibration will be monitored duririg the tests as described in the test specification and in the responses to rah 900.53 end 900.58.

The original basis for performing nondestructive examinations after completion of only one-third of the required IC operational cycles vvas that the IC should be tested for greater than the number of service level conditions expected to occur between In Service Inspections. GE has since determined that 20 load cycles, with a large fraction of the cycles to include thermal-transients, will be sufficient to meet the structural test objectives as well as uncover unexpected vibrations or. crack initiations at welds. Therefore, the number of " normal" IC operation cycles has been reduced from 45 to 20. Plus, the number of reactor heatup/cooldown cycles has been reduced from 85 to 5. The purpose of these tests is to gather structural measurements to demonstrate conservatism in the structural analyses. In addition, the adequacy of the proposed inservice inspection procedures will be confirmed by performing NDE tests prior to and after tests have been completed.

The design adequacy of the RPV and internals is validated by detailed analyses performed in accordance with the ASME Section III code. A comprehensive vibration assessment program for reactor internal structures and core support structure components subject to flow induced vibration will be implemented during initial startup testing for the first SBWR RPV. This program will consist of vibration analysis, a vibration measurement program, er inspection program and a comparison of the analytical results and the test results.

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r. GENuclear Energy Geerali:eene C:. :ry 115 Cur:re? Ave :,e se hse. CA 9512$

November 24,1993 MFN No.209 93 Docket STN 52-004 i

Document Control Desk U.S. Nuclear Regulatory Commission Washington DC 20555 -

Attention: Jerry N. Wilson, Director Standardization Project Directorate

Subject:

NRC Requests for Additional Information (RAls) on the Simplified Boiling Water Reactor (SBWR) Design

Reference:

Requests for Additional Information (RAIs) for the SBWR Design, Letter from M. Malloy to P. W. Marriott Dated September 28,1993 The reference requested additionalinformation on the SBWR Design. In fulfillment of this request, GE is submitting responses to RAIs 900.48-900.61.

Sincerely,

,:::?:3 J. E. Leatherman SBWR Licensing Manager ,

MC-781, (408)925-2023 l

gjlSD3 N 40)p r

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bec: J. A. Beard P. F. Billig '

R. H. Buchholz R. W. Burke, Sr. (EPRI)

S. A. Delvin D. L Foreman E. M. Lynch M. Malloy (NRC)

P. W. Marriott W. A. Marquino T. R. McIntyre F. A. Ross (DOE) .

SBWR File MC-781 1

LTRBK nt?

RAI Number: 900,48 Question:

Discuss the ASME Code classification of the IC-related piping and tubing and its relevance to the stress levels to be confirmed by the tests. Discuss how the test results will be used with other piping loads (e.g., seismic) to verify that the stress allowable limit of 1.5 Sm will be met for the steam supply line. In addition, discuss how the thermal gradient effects though the pipe wall and the number of cycles are considered in the design and verified in the test for the portion of piping and tubing submerged in the IC pool. If any of this submerged ,

piping is not ASME Code Class 1, discuss how the test results will be used for establishing its design.

GE Response:

The ICS piping located inside the containment up to and including the IC flow restrictors are classified as ASME Code Section III, Class I components. The IC and piping located outside the containment, downstream of the flow restrictors are classified as ASME Code Section III, Class 2 components. During the testing, in order to limit the loads that will be transferred by the piping connected to the Isolation Condenser, a guide or lugs will be provided at the ends of the supply and drain lines, below the bottom of the Isolation Condenser pool. During the detailed design and analysis of the IC supply and return piping, the pipe applied loads on the Isolation Condenser will be calculated and shown to be within the IC interface requirements. ,

The IC and attached piping up to the containment penetration anchors have been designed and analyzed in accordance with the requirements for ASME Code Section III, Class 1 and 2 components. The analysis results for the IC and attached piping, confirm that the stresses are less than their ASME Code allowable values. The purpose of the structural test instmmentation, is for diagnostic use if something should fail, and to gather information on actual stresses for future comparison with the calculated analysis results.

A detailed analysis of the IC and attached piping and supports has been performed using the ANSYS finite element computer program. The IC stress reports document the analytical results which confirm that the design meets the ASME Section III Class 1 Sc 2 requirements. The following loads were considered in the analysis: differential pressure between the primary and '

secondary side, differential thermal expansion due to non-uniform temperature distributions, deadweight, dynamic loads, including earthquake, LOCA and DPV/SRV effects. The thermal gradient effects along the pipe, and through the pipe wall have been calculated for steady state and transient conditions. The calculated thermal gradient effects have been included in the ASME stress and fatigue analyses, documented in the IC stress reports. A fatigue analysis was performed for the IC, in accordance with the requirements of ASME Section III, Appendix XIV.

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4 The number of cycles considered in the design and analysis, is based on a i combination of BWR operational plant history, and consideration of the unique  !

SBWR features which result in additional IC operation in place of alternative systems.

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. RAI Number: 900.49 Question:

Are the IC connecting pipes (i.e., steam supply line and drain line) and valves representative of the actual piping and valves to be installed in the SBWR plant?

If they are not entirely similar, explain the applicability of the test results to the actual piping and valves to be installed in the SBWR plant.

GE Response:

All parts of the PANTHERS IC, including the steam supply and drain piping which would be outside of the SBWR containment or part of the containment penetrations are full-scale. The remaining piping and valves in the steam supply and drain lines are not full-scale. The elevation difference between the

. PANTHERS IC pool tank and the simulated RPV water level is representative of SBWR. The piping irreversible hydraulic losses have been specified to be the same as required for SBWR and the condensate drain valve is required to meet the same leakage and opening time ~ requirements as the SBWR valve. Since the performance part of the tests is steady-state, GE considers these requiremenu to be sufficient to characterize the IC performance. There is no plan to use the test results for design of the SBWR piping and valves.

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l R I Number: 900.50 Question:

I Are the tests always conducted with saturated dry steam with a quality greater than 99.8 percent? Discuss how a constant steam quality can be maintained l throughout the tests since the test pressure varies from 70 to 1375 psig.

l GE Response:

The intention is to conduct all of the PANTHERS IC tests with. essentially dg steam at the IC inlet during the period of steady-state performance measurement. It is recognized that during the transient period following opening of the IC drain valve there may be some liquid cargover to the IC, but these periods will not be used to characterize the IC heat transfer performance.

The IC can be supplied with nearly dry steam for a wide range ofinlet pressure. The simulated reactor pressure vessel (RPV) is maintained at saturated conditions by injecting steam into the lit t uid inventory at the bottom-of the vessel. Moisture cargover to the IC is reduced to a minimum by a steam separator /dger in the top of the simulated RPV.

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. l RAI Number: 900'51 .

Question:

Detailed drawings that identify sensor locations are not provided. Explain the' criteria used to select the type and location of these sensors and show their.

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locations in drawings.

GE Response:

Sensor locations for the PCC test facility will be shown in the SIET document ,

number SIET 00094RI91, " PANTHERS-PCC TEST FACILITY DESCRIPTION", 4 which is in draft form but is not yet issued. Flow rate, temperature and pressure measurement locations were selected to ensure that a good measurement can  !

be made of the parameters necessary to characterize the PCC thermal and hydraulic performance. Tube wall thermocouples are attached to attempt to measure the wall temperature differential for comparison with the heat transfer correlation used for design. Structural instrumentation, type and location, was ,

selected based on the stress analysis of the unit. The structural instruments are located in regions of the expected highest stresses, displacements or

, acceleration, These instruments are placed primarily for the purpose of providing diagnostic information in the event that the PCC performs in an unexpected manner.

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Rhl Number: 900.52 Question:

Will modal survey tests be conducted on the IC assemblies prior to the planned flow tests? (Such information will be helpful for investigating the behavior response under vibratory loadings.)

GE Response:

l There are no plans to perform modal suney tests on either the IC or the PCC condenser. i l

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Rhl Number: 900.53 Quesdon:

What are the acceptance criteria for the measurements received from the sensors when monitoring the test responses? For instance, how will it be verified that flow-induced vibrations (FIVs) are not a problem? Will spectral analyses of monitored data be conducted to examine the vibraton behavior of responses especially if severe FIV or water hammer loadings occur?

GE Response:

The output of key structural measurements (identified in Tables 4-2 and 4-4 of the test specification 23A,6999 Rev 1) will be compared to values determined in the ASME Code,Section III stress analysis to confirm that the stresses do not exceed the calculated design stresses. Some accelerometer and strain gauge data will be reviewed to assess the presence of FIV and/or waterhammer.

Spectral analyses of the monitored data may be conducted if severe FIV or waterhammer loadings occur. -

The PANTHERS PCC will be tested using experimental

• tress analysis cyclic tests in accordance with ASME Code Section III, Appendix II, Article II-1000, Subarticle II-1500. The criterion forjudging the structural adequacy of the PCC prototype is the following: The PCC does not leak due to structural tailure when pressurized to the design pressure after being subjected to 5-times the number of pressure and temperature cycles for which it was designed.

When the structural cyclic testing has been completed, the PCC will be pressurized with air to the design pressure (7.6 bar g) and the pressure maintained for 15 minutes. If no leaks due to structural failure are observed, the structural adequacy of the PCC for the SBWR will be considered as confirmed.

The PCC structural tests are not considered necessag for proof of the PCC structural integrity since a stress and fatigue analysis has been performed according to ASME code rules. The PCC structural tests are also not included in the testing being performed for the SBWR certification program.

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RkI Number: 900.54 Question:

What level of sensitivity or accuracy is expected for the proposed leak detection '

method? Discuss the objective of the leak test and any follow-up actions that might need to be taken when defined limits or acceptance criteria are exceeded.

GE Response:

The testing performed to satisfy the PANTHERS IC test objectives related to Leak Detection Methods (Paragraph 6.1.1.4 of GE doc. 23A6999) will help in the evaluation of some proposed methods ofleak/ break detection for SBWR. The test data will help to denne the expected sensitivity and accuracy of these methods.

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RAI Number: ~900.55 l 1

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Section' 1 of the test specification. states that the purpose of the tests is to confirm  !

the structural adequacy of the Ansaldo-designed hardware for use in the- l SBWR. The test specification includes the facility requirements, test l procedures, and structural data to be collected but does not provide the stnictural  !

acceptance criteria. .;

l Provide the structural acceptance criteria and the methodology for.satisfymg .  ;

the criteria in order to confirm the structural adequacy of the PCC system.  !

GE Response: ..

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' The output.of key structural measurements (identified in Tables 4-2 and 4-4 of the test specification 23A' 6999 Rev.1) will be compared to values determined in the ASME Code,Section III analysis to confirm that the stresses do not exceed the calculated design stresses. '

The PANTHERS PCC will becyclically tested using experimental stress  ;

analysis cyclic tests in accordance with ASME Code section III, Appendix II, 3 Article 11-1000, Subarticle II-1500. The criterion forjudging the structural  ;

adequacy of the PCC prototype is the following: The PCC does not leak due to .

structural failure when pressurized to the design pressure after being subjected .  ;

1 to 5-times the number of pressure and temperature cycles for which it was designed. j When the structural cyclic testing has been completed, the PCC will be  :

pressurized with air to the design pressure (7.6 bar g) and the' pressure maintained for 15 minutes, if no leaks due to structural failure are observed, the unit will considered structurally acceptable for the SBWR.

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RAI Number: 900.56 Question:

Section 4.1.1 of the test specification states that a full-size PCC unit will be provided to be mounted inside the tank simulating the PCC poolin SBWR.

Provide the details for mounting the PCC unit inside the PCC tank.

GE Response:

The PCC prototype is bolted to the floor of the PANTHERS PCC pool tank and to the structural members supporting the Door of the tank. The lower header of each of the two PCC modules has two welded support " saddles" which are bolted to the floor. The single inlet pipe and the two drain / vent pipes have mounting flanges which are also bolted to the floor of the tank. A SIET report

" PANTHERS-PCC TEST FACILITY DESCRIPTION", SIET 00094R191, now in draft form contains figures showing the mounting details. Figures 10,19 and 23 of the draft are attached.

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RhI Number: 900.57 Quesuon:

Section 4.1.4.3 of the test specification states that Module B is instnimented in only a few positions for comparison with Module A and for confirmation of symmetrical performance. However, the measurements specified for Module B are thermal hydraulic (See also Table 4-2) only and do not include any l structural response measurements. Provide the structural response measurements that will be included for Module B for comparison with Module A and for confirmation of symmetrical structural response.

GE Response:  ;

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Section 4.14.3 of the test specification describes one of the structural measurements as the surface temperature at selected locadons. Module B has 10 themocouples located similarly to thermocouples on Module A. No other structural measurements are planned for Module B.

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RAI Number: 900.58 Question:

Section 4.1.4.3 of the test specification states that acceleration measurements will be made for the purpose of evaluating the vibration characteristics and detection ,

of possible condensation / water hammer loads. Specify the time interval at which the structural responses, such as accelerations and displacement-measurements, will be taken.

GE Response:

i The accelerometer output will be recorded in analog format during the approximate 10 -15 minute steady-state period of each test run. The data will be i briefly examined following the test to assess the existence of any significant FIV or waterhammer loads. Further analysis of the data can be performed later if necessary. Strain and displacement measurements are intended for steady state values (not dynamic loads) and will be sampled at 15 second intervals (as described in the test specification Table 4-2) duridg the 10 - 15 minute recording period.

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RAI Number: 900.59 Question:

l Table 4-2 of the test specification shows that the location for the measurement of permanent strain at the upper header /tubejunction for Module A is position number 5. However, Figure 4-4 indicates that the location of upper header / tube junction for Module A is position number 4. Clarify the location for the permanent strain measurement at the upper header /tubejunction for Module -

A.

GE Response:

The " Position Number" stated in Table 4-2 for the permanent strain measurement at the upper header /tubejunction of Module A is incorrectly shown as "5". The correct " Position Number" for this measurement is "4".

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RII Number: 900.60 Question:

Table 4-2 of the test specification gives the required structural measurements for the PCC test. In some cases, multiple measurement locations will be utilized, but these positions are not clearly specified in Table 4-2. For example, Table 4-2 doe:, not specify the five positions for the measurement of acceleration at mid-lengti, car tube. Provide the position location for measurements to be taken at a multiple number of positions.

GE Response: ,

The location of the measurements is shown in better detail in the SIET document number 00157ST92 (draft) " TECHNICAL SPECIFICATION FOR IC &

PCC INSTRUMENTS INSTA.LLATION", and Ansaldo Componenti drawing VN00015-A-B-25, rev.1, which were included in earlier transmittals.

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RAI Numi..er: ' 900.61 -

Question:

The PCC test description (Section 3.4.2), of the test specification states,"The tests will include sufficient pressure / temperature cycles (five times the number of .

cycles used for design) to confirm the structural integrity." Discuss the adequacy of five times the number of design cycles for the severe accident condition. Also, discuss how the number of cycles us'ed for_ design was established.

GE Response:

It is not intended that the PCC testing will confirm the structural adequacy of the PCC design for severe accident conditions. The evaluation for severe accident conditions will be done by analysis. The LOCA pressurization cycles planned for the PANTHERS tests, have a peak pressure of 55 psig, which is well below the 110 psig design pressure. The design pressure of the PCC is twice that of the containment structure (55 psig). The PANTHERS leak test pressure is 110 psig, but the leak tests will be performed with air and will not result in any thermal cycling.

The number of cycles selected for the PCC design assumes that the unit will undergo 60 containment leak tests in its life and should survive one LOCA and one automatic RPV depressurization (essentially the same as a LOCA).

The PANTHERS PCC will be tested using experimental stress analysis cyclic tests in accordance with ASME Code Section III, Appendix II, Article 11-1000, Subarticle 11-1500. The criterion forjudging the stmctural adequacy of the PCC prototype is the following: The PCC does not leak due to structural failure when pressurized to the design pressure after being subjected to 5-times the number of pressure and temperature cycles for which it was designed.

The PCC structural tests are not considered necessary for proof of the PCC structural integrity since a stress and fatigue analysis has been performed according to ASME code rules. The PCC stmctural tests are also not included in the testing being performed for the SBWR certification program.

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