ML20084T358
| ML20084T358 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 12/31/1973 |
| From: | TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML20084T280 | List: |
| References | |
| NUDOCS 8306230138 | |
| Download: ML20084T358 (67) | |
Text
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Rec'd w/1tr. dtd. 5 74 REllTRN TO DIRECTORATE OF REGULATORY OPERATIONS 1913 BROWNS FERRY UNIT 1 TORUS EXPERIENCE RETURN TO DmMRATE OF REGULA1 DRY OPERATIONS llIW' uNSo '$lbl.'?,3
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h 1 1973 BROWNS FERRY UNIT 1 TORUS EXPERIENCE k
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f - 1 TABLE OF CONTENTS IlffRODUCTION 1 PART I - DETAILED SEQUENCE OF EVENTS 3 PART II - STRESS PROGRAM 9 APPENDIX A - STRESS RESULTS FROM RELIEF VALVE DISCHARGE 21 I-
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1-U LIST OF ILLUSTRATIONS No. Title 1 Relative Location of the Eleven Relief Valve Tailpipes Inside the Torus 2 LVDT Locations l 3 Displacement of the LVDT's for the Third Opening of Relief Valve 19 f (November 18) i 4- Arrangement of the Lubrite Plates and the Embedded Base Plates 5 Clearance Between the Lubrite Plates and the Babedded Base Plates
).
6 Location of the Ten Additional LVDT's 7 Displacement of the LVDT's for the Second Relief Opening of Relief Valve 19 (November 30) l 8 Displacement of the LVDT's for the First Opening of Relief Valve 19 (November 30) 9 Displacement of the LVDT's for the Second Opening of Relief Valve 4 (November 30) 10 Torus-Ring Header Support Modification 11 Displacement of the LVDT's for the Third Opening of Relief Valve 19 (December 8) 12 Displacement of the LVDT's for the Second Opening of Relief Valve 4-(December 8) f 13' Jacking Bracket Added for Lifting the Torus Cradles 14 Displacement of the LVDT's for the Third Opening of Relief Valve 19 (December 24) 15 Displacement of the LVDT's for First Opening of Relief Valve 19 (December 24) 16 Displacement of the LVDT's for the Second Opening of Relief Valve 19 (December 24) 17 Displacement of the LVDT's for the Second Opening of Relief Valve 4 (Decemioer 24) 18 Displacement of.the LVDT's upon Opening Relief Valve 19 (December 29) 19 Relative Location of Relief Valves 30, 41, 5, 23, 4, and 42
-20 Displacement of the LVDT's upon Opening Relief Valves 30, 41, 5, 23, 4,_42 Simultaneously 21 Displacement of the LVDT's upon Opening Relief Valves 30, 41, 5, 23, 4, 42 Simultaneously 22 Relative Location of Relief Valves 4,'18, 19, 30, 31, and 41 l 23~ Displacement of .the LVDT's upon Opening Relief Valves 4, ~ 18, and 19 Simultaneously v
, . . . .. . . . .. . . . . . . . . . . . . . . =
LIST OF ILLUSTRATIONS (Continued)
No. Title 24 Displacement of the LVDT's upon Opening Relief Valves 4,18, and 19 Simultaneously 25 Torus Testing Summary 26 Torus Testing Summary 27 Summary of Test Program 28 Summary of Test Program (Continued) 29 Summary of Valve Operations 30 Clearance Between the Lubrite Plates and the Embedded Base Plates 31 Relief Valve 19 Test Data - December 3, 1973 32 Relief Valve 19 Test Data - December 3,1973 33 Relief Valves 4 and 19 Data - December 8,1973 34 Stresses Indicated on Strain Gauges - December 8, 1973 35 Strain Gauge Locations 36 Strain Gauge Locations 37 Strain Gauge Locations 38 Strain Gauge Locations 39 Strain Gauge Locations 40 - Stress in Torus Plate 41 Location of Relief Valve Line Discharge 42 Relief Valve Line Extension Arrangement 43 Browns Ferry Unit 1 Suction Header Shock Suppressors vi
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9 INTRODUCTION .
This report-addresses the observations, testing, modifications, and test data evaluation on the Browns Ferry 1 torus which occurred since November 8,1973.
This subject was discussed in a Joint AEC/IVA/GE meeting at the Browns Ferry site on January 16, 1974. The later sections of this report contain some evaluation details not available at that time.
The report is divided into two sections: Part I is a detailed description of the sequence of events which occurred at Browns Ferry 1. In this section the displacement instrumentation results are used to quantitatively describe the per-formance of the Browns Ferry 1 torus before and after each of the action steps t
which were taken to reduce the response of the structure to the relief. valve air t
clearing transient. Part II is a description of the stress levels measured i
'during this testing, an evaluation of the short- and long term sig n ifi cance of these stress levels, and a description of the additional action required to reduce the stresses produced during the air clearing transient to a level which will be acceptable for 40-year plant operation.
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1 PART I - DETAILED SEQUENCE OF EVENTS 1.1 IDENTIFICATION OF THE PROBLEM During startup testing of the main steam relief valves at Browns Ferry Nuclear
) Plant on November 8, 1973, significant noise was heard coming from the torus 1
area when the relief valves were opened. Figure I shows the relative location of the eleven relief valve tailpipes inside the torus. Three relief valves (19, 22, and 31) discharge into the center bay area with a " ram's-head" type discharge. The remaining eight relief valves discharge adjacent to the sup-port cradles with an elbow type discharge. Each elbow is attached to a torus support beam to eliminate thrust loading on the tailpipe.
On Novmeber 11, a drywell and torus entry was made to inspect for possible evidence of vibration or damage. No damage was found, but it was noted that one relief valve discharge pipe had vibrated against the floor grating within the drywell. Clearance was increased to eliminate this interference.
I Instruments were installed on the torus to measure acceleration and record audio level. On November 15, two relief valves (19 and 41) were opened one at a time. The accelerometer data recorded was inconclusive. Audio levels recorded were about 120 db whenever the valve was open. It was agreed to delay further testing until better instrumentation could be installed.
In a telephone conversation with GE-San Jose personnel on November 16, TVA described to CE the observed movement of the Unit 1 torus and torus-ring header which occurred when the relief valves discharged to the torus. It was agreed that better instrumentation (LVDT's) was necessary to accurately measure j the observed torus and torus-ring header movement.
Six LVDT's were installed on the torus to measure the torus and torus-ring header deflection. Figure 2 shows their location (LVDT-7 was added at a later date). On November 18, one relief valve (19) was opened three times with at least 30 minutes between openings. The LVDT's confirmed the visual 3
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obs.rvation made on November 15. Figure 3 shows the displacement of the six LVDT's for the third opening. The torus-ring header moved upward 1.03 inches. (
Support cradle 13 moved upward 0.16 inch and downward 0.10 inch. Af ter adjust-f ment was made for torus support movement, the deflections measured on the torus skin appeared high, but within the range predicted in GE NEDO-10859 (Steam Vent [
!- Clearing Phenomena). -
1.2 TEMPORARY SHIMMING I
i During the November 18 tests, it was noted that several torus support saddle j feet were not in full contact with their support pads. The arrangement of the
< Lubrite plates and the embedded base plate is shown by Figure 4. The clearance l between the Lubrite plates and thc embedded base plates is shown by Figure 5 (those in apparent contact were marked OK) .
l To correct this problem, a shimming procedure was submitted by GE-San Jose for l TVA approval on November 21. The shimming was proposed to be done in two stages. l The first stage provided that while the plant was still operating temporary
- shims would be installed closing the gap as much as possible without jacking on j the torus or disturbing the embedded support plates. The second stage was pro- (
posed to be accomplished during a scheduled outage with the reactor cooled down
- and depressurized. During the second stage, the temporary shims would be r removed and jacks used to preload the support cradles.
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! An Abnormal Occurence Report was submitted to the AEC on November 28 describing
- - the vibrations in the torus and torus-ring header upon opening relief valves and noting that not all torus support saddle feet were in full contact with their support pads. ,
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- On November 27, the LVDT's were reinstalled on the torus (LVDT-7 added) to l
measure the torus and torus-ring header deflections, and one relief valve (19)
I was opened twice with about 30 minutes between openings. The purpose of this test was to determine the effectiveness of the shims. The results indicated no I apparent reduction in the vibration, but more extensive instrumentatioa was j needed for positive confirmation.
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Ten additional LVDT's were added to measure torus and torus-ring header deflec-tion. Figure 6 shows their location. On November 30, relief valves (19 and 4) were each opened twice with about 30 minutes between openings to confirm that the shims had not reduced vibration. The results are shown in Figure 7 for the second opening of valve 19. Comparing Figure 7 to Figure 3 indicates that the l only significant effect of the temporary shims was to prevent the downward move-ment uf the support cradle (LVDT-5, note reversal of polarity). Figure 8 shows.
the torus and torus-ring header deflections during the first opening of relief [
valve 19.. Comparing Figure 8 to Figure 7 indicates an apparent increase in
< deflection during the second opening which was 30 minutes after the first open-ing. Figure 9 shows the deflection during the second opening of relief valve 4.
Comparing Figure 9 to Figure 7 indicates that the torus skin deflections were less when relief valve 4 was opened.
Following the November 30 testing, we concluded that:
( 1. The temporary shims prevented downward movement of torus supports but did i
not prevent significant lifting at torus (temporary shims did not remove spring effect).
i
- , 2. We still had significant header movement and vibration.
- 3. Vibration from the second cpening of the same valve was more severe than from a
the first opening if the openings were about 30 minutes apart.
- 1.3 TORUS RING-HEADER SUPPORT MODIFICATION l-In an attempt to' reduce torus-ring header movement, the torus-ring header support w.s modified to prevent vertical movement of the header relative to the support (Figure 10). Starting on December 3 and again on December 8 relief valves 4, 19, and 31 were opened one at a time with about 30 minutes between openings.
The purpose of these tests was to evaluate the effect of the torus-ring header support modification and to provide additional data in preparation for possible -
further corrective action. During the December 8 testing, 48 strain gauge chan-nels in addition to the previous 17 LVDT channels and one additional' channel
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were used to record data. Figures 11 and 12 show several of the LVDT deflections upon' opening relief valve 19 the third time and valve 4 the second time. The torus-ring header movement was found to be acceptable, particularly in the area where the torus support saddle feet and the support pads were in contact with the base plates and were supporting load.
Following the December 8 testing, we concluded that:
- 1. The modified header movement was now acceptable.
2.
The torus lift was still excessive, indicating a need for better shimming and other possible changes. l 1.4 PERMANENT SHIMMING Between December 15 and 19 (during e scheduled outage) each torus support saddle l was jacked, permanently shimmed, and loaded to ensure adequate load distribution.
The jacking bracket added for lifting the torus cradles is shown in Figure 13.
During the same outage, the three " ram's-head" discharge pipes were shortened approximately 2 feet (on relief valves 19, 22, and 31).
The LVDT's were reinstalled plus one additional channel, and 47 strain gauges were installed with some at new positions. On December 24, relief valves (34, 22, 19, 4, and 31) were opened one at a time with about 30 minutes between openings.
The purpose of these tests was to evaluate the effect of the permanent shimming.
Figures 14,15,16, and 17 show the LVDT deflections upon opening relief valve 19, each three times, and valve 4 on a second opening. Comparing Figure 14 to Figure 11 indicates that the cradle movement was about the same.
Following the December 24 testing, we concluded that:
1.
Torus wall and header movement was reduced.
- 2. Torus lift reduction was inconclusive.
- 3. The effect of repeated opening was no longer apparent.
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1.5 MULTIPLE VALVE OPENING At this point, additional data were needed to evaluate the effectiveness of the permanent shimming and the distribution of stresses during multiple valve open-ings. Relief valves 19, 31, 34, and 41 were opened on December 28 and 29 to start collecting this data. Figure 18 shows the LVDT deflections upon opening relief valve 19. It was noted that during these tests both the torus movement and stresses were considerably less than recorded during earlier tests. The reason for this shakedown was not apparent.
On January 4, 1974, relief valves 30, 41, 5, 23, 4, and 42 were opened simul-taneously. Figure 19 shows the location of the valves. Opening the six valves simulated valve operation during a pressure transient. Figures 20 and 21 show that the torus lift was insignificant.
On January 11, additional tests were conducted to record and evaluate the torus movement during multiple valve openings. During this testing, relief valves 4,18, and 19 were opened simultaneously because these three valves were located in an area (see Figure 22) known to possess more severe response f characteristics. Figures 23 and 24 show the LVDT deflections during this opening. The measured deflections were considered acceptable.
On January 16, a meeting was held with representatives of GE, TVA and AEC at Browns Ferry to inform AEC concerning the details of this problem. Figures 25, 26, 27, 28, and 29 show a summary of the relief valve testing program which was discussed. A confirmatory test program is planned for the Unit 2 torus to establish the adequacy of jacking and shimming procedures.
1.6 IN-SERVICE INSPECTION t
TVA will perform a visual in-service inspection once per fuel cycle of areas inside and around the outside of the suppression chamber as an interim measure.
The need for the inspection will be reevaluated after completion and reporting of all modifications.
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l 1.7 UNIT 2 TORUS Investigation of the Unit 2 ' torus revealed that several torus support cradles adequate bearing was not being realized between the Lubrite and the embedded base plates.
In'some cases the lack of bearing was evidenced by a significant gap between the plates as shown in Figure 30.
4 A procedure to jack, permanently shim, and equalize the load on the Unit 2 cradle supports was prepared by GE-San Jose. Af ter approval by TVA, the cradle supports were permanently shimmed.
The Unit 2 torus-ring header supports are being modified to prevent vertical movement of the header relative to the 'supports.
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SPECIAL TEST VAaVE at INSTR SHIMS SUPPORT INSTRUCTION OATE RUN NO. RUNID PiO. (rrun) TYPE-CHAN PURPOSE ADDED MODIFIED 1 11/15/73 1 HPCI ACCE L 1 DETERVINE SOURCE OF NO NO 2 l HPCl41 AUDIO-1 VIBRATION REPORTED IN 3 1 19 CONTROL ROOM BY OPP 4 41 5 41 6 19 7 19 11/18/73 1 1 19 0 LVDT4 PROVIDE QUANTITATIVE NO NO 2 18 19 70 CONFIRMATION OF VISU AL 3 Ill 19 30 OBSERVATIONS ON 11/15/73 11/27/73 1 IV 19 0 LVOT-7 TEST E FFECT OF SHIMS Y ES NO 2 V 19 35 2 11/30/73 1 VI 19 0 LVDT 17 PROVIDE CONFlRMATION YES NO 2 VII 19 34 OF 11/27/73 RESULTS WITH 3 Vill 4 30 MORE EXTENSIVE 4 IX 4 29 INSTRUMENTATION 12/3/73 1 X 19 0 STR AIN DETE RMINE STRESS YES YES 2 XI 19 25 GAUGES -12 EFFECTS OF SUPPORT CHANGE 3AND4 12/8/73 1 Xll 19 0 STRAIN PROVIDE FURTHER CON- YES YES 2 Xill 19 30 GAUGES 48 FlRMATION OF PREVIOUS 3 XIV 19 30 LVDT-18 OBSERVATIONS WITH MORE 4 XV 4 38 EXTENSIVE INSTRUMENTA. S XVI 4 13 TION AS PREPARATION FOR 6 XVil 31 0 FIN AL FIX 7 XVill 31 30 8 XIX 31 29 Figure 25. Torus Testing Summery
SPECIAL TEST at INSTR SHIMS SUPPOR T PE RM ANE NT INSTRUCTION DATE R UN NO. RUNID VALVE NO. Imm) TYPE O4 AN PURPOSE ADDED MODIF!ED SH!MS 13 12/24/73 1 XX 34 STRAIN TEST EF FECTS OF NA YES YES I 2 XXI 22 GAUGES PE RM ANE NT SHIMS 3 XXIt 19 0 LVDT-19 4 XXt!! 19 30 5 XXIV 19 30 6 XXV 4 30 7 XXVI 4 30 8 XXVil 31 19 12/28/73 1 XXVill 31.41 STRAIN TEST MULTIPLE NA YES YES 41 65 GAUGES 4I VALVE OPENINGS 2 XXIX LVDT 19 12/29/73 3 XXX 19 ME ASURE TORUS NA YES YES 4 XXXI 34 CRADLE MOVEMENT 20 1/4/74 1 XXXil 18 0 STRAIN DETE RMINE STRESS NA YES YES I 2 XXXill 30 38 GAUGES DURING MULTIPL5 3 XXXIV 5 27 LVDT-19 VALVE LIFTS 4 XXXV 23 12 5 XXXVI 42 13 C XXXVil 18,30 16 7 XXXVI!! 30,41 35 1/5/74 8 XXXIX 30.41,5 0 9 XL 30,41,5.23 30 to XLI 30.41,5,23,4 37 11 XLil 30.41.5.23.4.42 43 21 1/11/74 1 XLill 31 0 STRAIN PROVIDE FURTHER NA YES YES 2 XLIV 18.~10 38 GAUGES #I CONFIRMATION OF
'. XLV 31.41 22 LVDT-19 PREVIOUS 1 '
XLVI 31,41 30 OBSE RVATIOt!S
. XLVil 19 31 f 3 XLVill 19 30 7 XLIX 4.18 30 8 L 18.19 30 9 LI 4.19 30 10 Lil 4.19,18 33 Figure 26. Torus TestingSummary
INSTR CHANNELS TEST DATE STATUS
- LVDT SG OTHER TOTAL RUNS VALVE NO.
11/15/73 A 2 3 19 3 41 11118/73 A 6 3 19 11/27/73 B 7 2 19 11/30/73 8 17 2 4 2 19 12/3/73 C 24 2 2 19 12/8/73 C 18 48 2 4 3 19 3 31
'A- ORIGINAL B - TEMPORARY SrilMS C - TEMPORARY SHIMS AND MODIFIED SUPPORT Figure 27. Summary of TestProgram l
l l l l l 1
TEST DATE TOTAL RUNS' VALVE NO. 12/24/73 2 4
. 19 1 22 1 31 1 34 12/28/73 1 41 1 31,41 12/29/73 1 19 1 34 1/4/74 1 5 1 18 1 23 1 30 1 42 1 18,30 1 30,41 1/5/74 1 5,30,41 1 5,23,30,41 1 4.5.23,30,41 1 4,5.23,30,41,42 1/11/74 2 19 1 31 1 4,18 1 4,19 1 18,19 1 18,30 2 31,41 1 4,18,19 TOTAL 58 'ALL RUNS WITH PERMANENT SHIMS AND MODIFIED SUPPORT 19 - LVDT CHANNE LS 47 -STRAIN GAUGE CHANNELS Figu,r 28. Summary of TestProgram (Continued) l
i VALVE NO. TOTAL OPE NINGS 4 11 5 5 18 6 19 24 22 1 23 4 30 8 31 8 34 2 41 12 42 2 83 Figure 29. Summary of Valve Operations
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I 1800 0.081 0.164 0.210 OK 0.116 7 4 5 0.210 OK 0.045 3 0.076 6
.106 OK OK OK 0.182 020 0.087 K 0.12 0.182 0.214 OK 0.229 0.375 0.333 0.146 0.160 I
0.082 OKp OK 900 270o OK OK 16 g- OK % og 9 0.185 0.162 0.093 OK 15 054 OK 10 0352 0.209 0.246 OK* OK .168
'O.225 \ 0.231 14 gg OK K 0.110 OK 13 12 OK OK OK OK OK OK 00 Figure 30. Clearance Between the Lubrite Plates and the Embedded Base Plates (Those in Apparent ContactAre Marked OK)
l PART II. STRESS PROGRAM 1.1 DATA FROM STRAIN GAUGE MEASUREMENTS Starting with the December 3 testing, twelve channels of strain gauge informa-tion were added and recorded. Relief valve 19 was opened twice with about 30 minutes between openings.
. Figures 31 and 32 show the locations of strain gauges as well as the' data col-1ected and reduced to stress values for these runs.
On December 8, testing was continued with runs opening valves 4,19, and 31 one at a time at approximately 30 minute intervals. Readings from forty-eight channels of strain gauge information were included in the data taken. The locations <ef these strain gauges are as shown in Figure 33 and in Figure 34. Indicated stresses from these gauges can also be seen in Figure 34. On December 24, further testing was conducted consisting of runs opening valves 34, 22,19, 4, and 31 one at a time at about 30 minute intervals. Figures 36, 37, 38, and 39 show the locations of the strain gauges connected for this phase of the testing and Figure 34 shows the resulting stress indications. 1.2 MULTIPLE VALVE OPENING On December 28, two runs were made. The first consisted of a simultaneous open-ing of valves 31 and 41. The second being a single opening of valve 41. The locations of the strain gauges connected and read can be seen in Figures 34, 36, 37, and 38. Figure 34 also shows the resulting stresses read. On' January 4,1974, testing was resumed consisting of single valve openings of valves 18, 30, 5, 23, and 42 and multiple valve openings consisting of the following combinations: i 9 , 4
Run 6 Valves 18 and 30 7 30 and 41 8 30, 41, and 5 9 30, 41, 5, and 23 10 30, 41, 5, 23, and 4 11 30, 41, 5, 23, 4, and 42 The results and location of these gauges can be seen in Figures 35, 36, 37, 38, _ and 39.. Testing was resumed and completed on January 11 with strain readings being taken for the following series of single- and multiple-valve openings: Run 1 Valves 31 2 18 and 30 3 31 and 41 4 31 and 41 5 19 6 19 ; 7 4 and 18 j 8 18 and 19 9 4 and 19 l 10 4, 19 and 18 Locations of the gauges connected during these runs and the stresses indicated can be seen in Figures 35, 36, 37, 38, and 39. 1.3 STRAIN MEASUREMENTS 1 1 The containment structures at Browns Ferry were designed to meet the ASME B&PV Code, Section III, for metal containment structures. The relief ~ valve discharge produces loadings which were not available at the time the structure was designed and erected. In evaluating the capability ot the structure to accommodate these
. loads, it' is logical to use the Code as a basis of acceptability.
10
In the ASME Code, there are different levels of allowable stress intensity depending on the source of the stress. In addition to two stress intensity levels, there is a stress intensity range and there is a cyclic (fatigue) level of acceptability. With respect to the controlling criterion for the life of the plant, the most stringent of these conditions is the one which measures the fatigue life of the structure. The strain measurement program carried on during the torus testing does form a basis for fatigue (cyclic) analysis of this structure. 1.4 STRAIN MEASUREMENTS PROGRAM Beginning with the testing initiated on December 3, strain measurements were made as well as the previously discussed displacement measurements. The' results of all the strain gauge measurements starting with the December series are - d shown on Figures 34 and 35. In order to make it possible to follow this dis-l cussion more readily, a brief description of each strain gauge location is O given in the first column on these summary sheets. 1.5 DECEMBER 8 TESTING As noted in the previous discussion on LVDT results, relief valves 4, 19, and 31 were opened one at a time. Comparing runs 1, 2, and 3 for relief valve 19 it can be seen that the third run produced stresses approximately 50% higher than the first two runs for a few of the measurement points. The runs were approximately 30 minutes apart. The reason for this increase is not apparent. On an absolute basis the indicated stress of 30,000 psi in the torus wall at the 6 o' clock position of the header nozzle was considered to be unacceptable for total plant life. The 25,500 psi stress in the header support structure at cradle.15, while high, was probably acceptable. All other indicated stresses are reasonable and acceptable. 11 4
Opening valves 4 and 31 did not produce results which were as high as those observed from opening valve 19. Logically, it could be expected that valve 4 would produce higher stresses at the 45 degree nozzle than valve 19 because the discharge point is closer to the 45 degree nozzle and valve 4 has a discharge elbow rather than the " ram's head" discharge of valve 19; the elbow discharge l will produce higher loads. However, the stresses are all in an acceptable range. Relief valve 31 discharge bears the same geometric relationship to the nozzle at 315 degrees as valve 19 bears to the 45 degree nozzle. Comparing correspond-ing stresses it can be scen that valve 31 produced relatively modest stresses at the 315 degree nozzle (%9500 psi) compared with the stresses at the 45 degree nozzle from valve 19 (s20,000 to 30,000 psi). Clearly the torus struc-ture was not behaving in a linear mode on December 8. 1.6 DECEMBER 24 TESTING As described previously, the torus was permanently shimmed between December 15 and 19. Also the three " ram's head" discharges were raised approximately 2 feet. Again, valves 4, 19, and 31 were discharged in a series of tests. The results for valve 19 were somewhat lower than the results from December 8, particularly when comparing highest values. Also there was no increase in stress with repeated openings. When valve 4 was opened, the results which were obtained were essentially the same as those obtained on December 8. On the basis of valve 19 values, it was expected that valve 4 values would be lower than in the earlier tests. Additionally, when valve 31 was opened the values obtained were not significantly different from the earlier test. 1.7 MULTIPLE-VALVE OPENING Despite the fact that the stress values from single-valve openings were not dramatically lowered from earlier values, it was decided to proceed with mul-tiple v ~.ve testing. Note that the observed single-valve values were satisfactory. 12 I I
Beginning on December 28, valves 31 and 41 were opened together. All indicated stresses were satisfactory except for the value of 28,770 psi at the 6 o' clock position on the 315 degree nozzle. Also on December 28 valve 41 was opened by itself. The 12,400 psi stress at the 6 o' clock position is also higher than was expected. Aside from these two stresses, however, the remainder of the stresses is con-sistent with the results from December 24. As noted in the discussion on torus movement, there did appear to be signs of " shakedown" in the torus response. Additional and extensive multiple valve testing was carried out on January 4 and on January 11. In summary, the results, from a stress standpoint, were dramatically lower and very consistent. The structure was now behaving in a predictable manner. A review of the tabulated stresses shows values for multiple valve operation which are satisfactory. The highest values were obtained in run 10 with valves 4,18, and 19 opened together. As discussed previously, these three valve dis-charges are located in an area known to produce severe response characteristics. The stresses recorded are deemed to be acceptable for the interim operating period. As discussed elsewhere, the discharge for valve 19 (as well as valves 22 and 31) is to be moved as a part of the modification program. The major contributor to the stresses shown appears to be from valve 19; moving the discharge will pro- . vide maximum stress levels consistent with the limits required for unrestricted lifetime plant operation. 1.8 CYCLIC ANALYSIS I 1.8.1 Introduction 6 i l The original design of the Browns Ferry containment structure did not include cyclic loading analysis. The cyclic loadings which were specified in the design , i i 13
M 1 documents were restricted to the earthquake loadings. The total number of sig-nificant seismic events at a given point in the structure were few enough that cyclic analysis would not have been a controlling design condition. As dis-cussed later in this section, the design results from such events are trivial. 'I With the initiation of the extensive test program at Browns Ferry Unit 1, the need for cyclic analysis was reexamined. It is clear that with the expected
; operation of relief valves, the need for an appraisal of cyclic performance is '
i important in assessing the capability of the structure. 1.8.2 Analysis for Stress J j An examination of the data obtained during the testing at Browns Ferry shows that the dynamic stresses of interest are those in the torus shell plate at j the juncture of the large suction header nozzle and the shell plate. Other locations where strain measurements were taken show values which are consis-tently lower than the values used in this analysis. I In order to do a cyclic analysis it is necessary to know the stress conditions i for each of the anticipated loading conditions and to know how many of each
; loading condition can be reasonably expected in the life of the plant.
TI.e stress condition for each loading condition has been determined from the test data as described in the following discussion: l Examination of test data reveals that the maximum dynamic stresses occur at i the 6 o' clock position at the 45 degree nozzle. In order to represent con-I ditions as they are expected to be af ter the structural and mechanical changes l are made in the torus, only data acquired af ter December 24 have been used. Also, data have not been used if it resulted from the discharge of valves 19, 22, or 31 since these valve discharges are to be moved as part of the modification program. . During the torus testing at Browns Ferry, a maxtmum of six valves were dis-l l charged simultaneously. As a result there is stress data available from the 14
i I test program which covers the discharge of up to six valves. However, during the life of the plant all eleven valves will discharge simultaneously on a num-l ber of occasions. There fore , the test data have been extended to predict the { stress picture when all eleven valves discharge. The chart of stress versus number of valves discharging is shown in Figure 40. The data utilized and the methods utilized in preparing the chart are discussed in Appendix A. 1.8.3 Relief Valve Actuation During the life of the plant it is predicted that relief valve actuation will be reliably encompassed by the following schedule: No of Valves Actuations in Discharging Simultaneously 40 Years 1 350 2 300 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 - 11 80 Total Events Involving at Least 1 Valve 800 This prediction is based on consideration of possible plant operating and inci-dent conditions during approximately 40 years. Also, it presumes that prompt relief trip will be installed early in the plant life. 1.8.4 _ Cyclic Analysis Having made a prediction of valve actuation and knowing (on a calculational basis) the corresponding dynamic stresses at a point, it is possible to 15
calculate the cumulative usage factor, U. The analysis reported here is in accordance with the method outlined in paragraph NB-3222.4 Analysis for Cyclic Operation, ASME B&PV Code, Section III. The dynamic stresses used in the cyclic analysis must be modified to account for the fact that the stresses reported in Figure 40 are stresses approximately 1-1/2 inches from the juncture of the torus shell plate and the nozzle. The stresses have been increased by 25% to account for the higher stresses at the point of interest. The effect of the local structural discontinuity has been accounted for by using a stress concentration factor of three. It is at:sumed that in each event there are eight significant stress cycles. This assumption is based on review of the test records. Table 1 is a summary of the calculations. Due to predicted relief valve discharge, the cumulative usage is satisfactory. However, to this calculated usage there must be added the effects of other cyclic loadings at the point in question. The only other loadings which could be significant are seismic loadings. Consider in the life of the plant two earthquakes each producing 15 cycles at peak values and 15 cycles at half-peak values. Based on preliminary reanalysis, assume conservatively that the earthquake stress ranges from -10,000 psi to
+5,000 psi for maximum values.
Half maximum will then be -5,000 psi to +2,500 psi. Then: n - 15 Salt j j = 3 (10,000 + 5,000)/2 = 22,500 psi n
= 15 Salt 2= 3 (5,000 + 2,500)/2 = 11,250 psi N = 60,000, N = 10 6 Ueq = n /Nj + n2/N2 ~ +
6" 60,000 10 Tht.re fore , the cyclic usage contribution from the seismic events is trivial, and the plant is completely adequate for cyclic conditions. 16
Table 1 CYCLIC STRESS ANALYSIS No. of Valves Resulting Stre~ss 1.25 Stress _ Discharging N U (Figure 41) = Salt /3 Salt (ASME Fig. I-9.0) (P") (n/N) 1 5,600 7,000 21,000 80,000 350 x 8 0.035 2 7,800 9,750 29,250 22,000 300 x 8 0.109 3 9,600 12,000 36,000 11,500 10 x 8 0.007 4 11,100 13,875 41,625 7,000 10 x 8 0.011 5 12,300 15,375 46,125 5,000 10 x 8 0.016 6 13,500 16,875 50,625 3,800 10 x 8 0.021 7 14,600 18,250 54,750 3,200 O 10 x 8 0.025 8 15,600 19,500 58,500 2,700 10 x 8 0.030 9 16,500 20,625 61,875 2,200 10 x 8 0.036 10 17,400 21,750 65,250 1,900 - - 11 18,200 22,750 68,250 1,700 80 x 8 0.376 Cumulative Usage Factor U = 0.666 s
1 1.8.5 Effect of Testing In addition to the usage calculated above for the normal plant operation, Browns Ferry Unit 1 has been subjected to an unusually large number of relief valve discharges because of this extensive test program. Table 2 is a summary of the cyclic usage resulting from all the testing from December 3,1973, through January 11, 1974. This contribution to cyclic usage is only 0.108. . The total cyclic usage, therefore, becomes U = 0.108 + 0.666 = 0.774 for Browns Ferry Unit 1. 1.9 MODIFICATIONS B 1.9.1 Relief Valve Line Extensions The modifications that are being made to the relief valve piping within the torus are indicated in Figure 41. Relief valves 19, 22, and 31 have " ram's heads" which presently terminate in the middle of the respective torus bays from which they emerge from the drywell. This location is indicated by the diamond shaped symbol in Figure 41. After modification, the arrangement'of the relief valve line exits is shown by the triangle symbols for the eleven valves. Figure 42 shows the support arrangement for one of the longer relief valve lines which will be moved from the middle of one of the torus bays. Shock suppressors will be used on these lines but are not shown on these figures. 1.9.2 Addition of Shock Suppressors to ECCS Suction Header The critical area for high stresses in the torus is around the suction header nozzle penetrations into the torus because of the structural discontinuities. Seismic events cause an additional load on this nozzle and the installation of shock suppressors can minimize the seismic loadings. Modifications are being made such that a pair of 10 kip shock suppressors will be located at each of the suction nozzle penetrations in the torus as shown in Figure 43. ' I 18
I Table 2
SUMMARY
OF CYCLIC USAGE RESULTING FROM TESTING ) Run Stress 1.25 Stress Salt N U, 12-3/1 18870 23587 70761 1600 0.005 12-3/2 26400 33000 99000 670 0.012 8/I 20145 25181 75543 1350 0.006 12-8/2 19840 24800 74400 1400 0.006
; 12-8/3 30000 37500 112500 480 0.017 12-8/4 10800 13500 40500 7800 0.001 12-8/5 23276 29095 87285 950 0.008 12-8/6 10522 13152 39456 8500 0.001 12-8/7 10950 13687 41061 7500 0.001 12-8/8 10577 13221 39663 8500 0.001 12-24/1 4101 5126 15378 360000 0 m
12-24/2 4243 5304 15912 300000 0 12-24/3 19394 24242 72726 1500 0.005 12-24/4 16466 20582 61746 2300 0.003 12-24/5 17438 21797 65391 2000 0.004 12-24/6 11177' 13971 41913 7000 0.001 12-24/7 12605 15756 47268 '4900 0.002 12-24/8 9299 11624 34872 12500 0.001 12-28/1 8265 10331 30993 19000 0 12-28/2 5475 6844 20532 90000
. - 0.
Subtotal 0.074 19
Table 2 (Continued) Run Stress 1.25 Stress Salt N U 1-4/1 5275 6594 19782 100000 0 1-4/2 3956 4945 14835 420000 0 1-4/3 2744 3430 6 10290 10 0 1-4/4 6 3320 4150 12450 10 0 1-4/5 3117 6 3896 11688 10 0 1-4/6 6267 7834 23502 50000 0 1-4/7 6593 8241 24723 43000 0 1-4/8 7462 9327 27981 27000 0 1-4/9 10321 12901 38703 9300 0.001 1-4/10 12098 15122 43366 5600 0.001 1-4/11 14552 18190 54570 3200 0.003 1-11/1 7736 9670 29010 23000 0 1-11/2 3452 4315 12945 10 6 0 1-11/3 5806 7257 21771 70000 0 1-11/4 7216 9020 27060 32000 0 1-11/5 17642 22052 66156 1900 0.004 1-11/6 20934 26167 78501 1200 0.007 1-11/7 9280 11600 34800 12500 0.001 1-f1/8 17469 21836 65508 2000 0.004 1-11/9 17741 22176 66528 1900 0.004 1-11/10 24208 30260 90780 850 0.009 Subtotal 0.034 From Sheet 1 0.074 Total usage from testing 0.108 l ' I 20
E =30 X106 1 - u = 0.7 u = 0.3 1 + u = 1.3 REttEF VALVE 19 TIME 1005 HOURS RUN 1 DATE 12/3/73 X 104 STRAIN GAGE ei e2 c3 ej+e3 (et + e3I /1 - #
- MAX ' MIN 1+u ROSETTE NO.1 +350 +230 +150 (1,2, AND 3) +500 +714 2157 +13,065 +8,355 ROSETTE NO.2 +570 +380 - 40 (4,5. AND 6) +530 +757 $501 +18.870 +3,840 ROSETTE NO.3 (7. 8. AND 9)
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t . .y:
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'I
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2700 f Figure 36. Strain Gauge Locstions , I e i i _ ..., - .. - . .. ~-
'LVDTC TM (C
% - -d
% 0. 7,m .
,o ,o ,r(o) f
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'40
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+ "
1
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c
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l-- _ 45 6' Mn M oc s2 , Figure 37. Strain Gauge Locations
2 m. t /4 in.
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20 21* Oc l , l16* 2 0 CLOCK
'f3 0 *17 (FS) 9 O' CLOCK U 10' l *22 (Fs) 3O' CLOCK f f /4 in.
5 6O' CLOCK g R-R pp I de 00* 50 61* 61 82 30 in. 1-1/2 TYP - O , , , , , , L o (6 ,,,. $., 2 64 96 92 ~ 3 90 85 Be 53
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*72 47 Y.y Of TAIL A DETAIL 8 Figure 38. Strain Gauge Locations
/
f
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/ - , .
h B/G H
% d' d' i B/G 23 (0) 20 (L) LDM =
= ,. , ,
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AD-AD AE-AE @M 100 AK j AK '- (l ,, ,, M h M WELD db j ev a 2 g AG-AG Figure 39. Strain Gauge locations i I ?
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19 l 18 - 17 - 16 - i5 - .
- 14 -
3
.a M 13 -
o Z S e g 12 - 5 o d 11 o e ' g 10 - 5 . @ 9 - 8 - 450 NOZZLE AT 6 O' CLOCK - CU o VALUES FROM TESTS 7 -
@ CALCULATED VALUES t
( 6 - 1 1 @ l 5 - I I I I I I I I I I 0 O 1 2 3 4 5 6 7 8 9 10 11 NUMBER OF VALVES DISCHARGED SIMULTANEOUSLY r-Figure 40. ' Stress in Torus Plate
. . - - _ = .
I i 4 1800
' 5 , , 42
/ ',
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23 / 34 i 22 i _ -... B
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, h BEFORE MODIFICATION 6 AFTER MOOlFICATION
! :c:.
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Figure 41. Location of Relief Valve Line Discharge j t _ _
l l! lIll ll l)lII Q i n. 0
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s w 8 L W i SOD N
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%.' G NEU S I
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t A BDW ( - XEONE c c W' - H
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s.\ i n u 0 0 d 6 y t f 0 1 1
, . . m m. . . . . . . ..m _
t d 1 PREVIOUSLY INSTALLE D 1 SHOCK SUPPRESSORS i 1800 i 2250'
,ky,
'1350 f
,,[
.:it ~,
-Jc a
o 112030' 247030' j . 6 f t 0 in. i e ft 6 in. e
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j 900 - - 2700
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, ... -g t .
450 3150 30 in. DI A SUCTION HE ADER i 1 figure 43. Browns Ferry Unit 1 Suction Header Shock Suppressors b i' L
f 4 APPENDIX A - STRESS RESULTS FROM RELIEF VALVE DISCHARGE li l 9 The chart of Figure 40 was obtained by extending the data obtained from dis-charging one through six valves to include up to eleven valves. This was done r by assuming that the data would be best represented by the curve: y = ax ,b It had been established that the data would not realistically fit the straight line expression y = a + bx, where a = 0. The data does not support the require-ment that the stress is zero when no valves are being discharged. Assuming an t exponential function overcomes this deficiency. Therefore: y = axb (A-1) where:
- = number of valves discharged y = stress level at 6 o' clock at 45 degree nozzle and a and b are constants to be determined.
, Taking the logarithm of:
- log y = log a + b log x (A-2) 4 or:
Y = A + BX (A-3) where: l
- Y = log y l A = log a B=b i X = log x 21 I
i Equation A-3 is a linear equation which can be - c- 1 for a "best fit" analysis of the available stress data. Table A-1 is a summary of the calculations used to derive the extended data. The values in the y column are taken directly from the dynamic stress data reported elsewhere with the values rounded up to the nearest 500 pai. Table A-1 CALCULATED EXTRAPOLATION DATA 2 x, y X Y XY X 1 5.500 0 0.7404 0 0 2 9.500 0.3010 0.9777 0.29429 0.09060 3 7.500 0.4771 0.8751 0.41751 0.22762 4 10.500 0.6021 1.0212 0.61486 0.36252 5 12.500 0.6990 1.0969 0.76673 0.48860 6 15.000 0.7782 1.1761 0.91524 0.60560 N=6 2.8574 5.8874 3.00863 1.77494 Substituting in the normal equations: B = ( - X EY 2 NE (X ) - (EY)2 B = 0.49/64 A = -B Eh Eh A = 0.74567 Equation A-3 therefore becomes: Y = 0.74567 + 0.49464 X Substituting in this equation readily provides the results of number of valves discharging and the resulting stress. These are tabulated below and are shown in Figure 40. 22
No. of Valves Resulting Stres 1 5600 psi 2 7800 psi 3 9600 psi 4 11100 psi 5 12300 psi 6 13500 psi 7 14600 psi 8 15600 psi 9 16500 psi 10 17400 psi 11 18200 psi
.s f
23/24
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