ML071930316

Chemical Effect Head Loss Test Specification

ML071930316
Person / Time
Site:	Palo Verde
Issue date:	03/12/2007
From:	Sporri M CCI
To:	Office of Nuclear Reactor Regulation
Golla J, 415-1002
Shared Package
ML071930304	List: ML071930316 ML071930365
References
800456 Q.003.84.781, Rev 0
Download: ML071930316 (74)

Text

Anweisung Specification REVISIONSSTAND

/ REVISION STATUS Rev. No. Seite Nr. /

Page No. Art der Revision /

Nature of revision 0 1 - 28 Erstausfertigung /

First edition 1 2 Bemerkungen /

R e m a rks: Rev. 0 Page 2 of 28 Pages Q.003.84.781

Anweisung Specification Table of contents Page 1. Scope and Purpose 5 1.1 Purpose 5 2. References 6

3. General Description of the CCI Test Loop 7 3.1 Main Test Loop Data 8 3.2 Modification of Test Loop for Palo Verde Testing 9 3.2.1 Chemical Effect Testing 9 4. Test Description 10 4.1 Clean Head Loss Test 10 4.2 Chemical Effect Head Loss Test (Test 2 and 3) 10 4.3 Test Matrix 10 5. Test Parameter 11 5.1 Calculation of Scaling Factor 11 5.2 Calculation of Flow Rate 11 5.3 Calculation of Plant Specific Debris 12 5.4 Calculation of Test Specific Debris 13 5.5 Procedure for Precipitant Generation 14 6. Test Performance 15 6.1 Chemical Test Performance: Main Steps 15 6.2 Chemical Test Performance: Chemical Steps 16 7. Chemical used to Generate Precipitates 18 7.1 Chemicals Used in Testing 18 7.2 Boric Acid 18 7.3 Trisodium Phosphate (TSP) 18 7.4 Sodium Aluminate 19 7.5 Calcium Chloride 20 7.6 Sodium Silicate 21 Rev.0 Page 3 of 28 Pages Q.003.84.781

Anweisung Specification

8. Debris Preparation 22 8.1 Nukon Insulation 22 8.2 Thermolag 22 8.3 Nukon and Alpha Cloth 23 8.4 Reflective Metal Insulation (RMI) 23 8.5 Paint Chips 24 8.5.1 Epoxy Material Description (from APS) 24 8.6 Latent Debris 26 9. Documentation 27

10. Enclosures and Exhibits 28 List of Tables T a b l e 1: M a i n T e s t L o o p D a t a 8 T a b l e 2: T e s t m a t r i x: t y p e o f t e s t s 10 T a b l e 3: S c a l i n g f a c t o r 11 T a b l e 4: F l o w r a t e s f r o m p l a n t 11 T a b l e 5: T u r n o v e r o f t e s t l o o p w a t e r 11 T a b l e 6: D e b r i s m a s s a m o u n t a t p l a n t s u m p 12 T a b l e 7: D e b r i s m a s s a m o u n t f o r h e a d l o s s t e s t s 13 T a b l e 8: C h e m i c a l A d d i t i o n T a b l e 14 T a b l e 9: A l l o w a b l e p H R a n g e f o r C h e m i c a l A d d i t i o n 14 List of Figures Figure 1: Outline of MFT facility for Pa lo Verde testing (3 modules shown) 9 List of Pictures Picture 1: Multi Functional Test Loop (MFT-Loop) 8 Picture 2: Representative sample of shredded and crumpled SS RMI Foil 23 Picture 3: Latent debris 26 Rev.0 Page 4 of 28 Pages Q.003.84.781

Anweisung Specification

1. Scope and Purpose A series of chemical tests is being per formed to quantify the impact on screen /

debris bed head loss due to precipitates which may form in the post-LOCA containment sump pool. Based on the Westinghouse Owner's Group (WOG) chemical effects evaluation, Docum ent No. WCAP-16530-NP, Revision 0, the primary precipitates which may form ar e sodium aluminum silicate (NaAlSi 3 O 8) and aluminum oxyhydroxide (AlOOH).

In lieu of aluminum oxyhydroxide, aluminum hydroxide (Al(OH)

3) will be precipitated in the chemical test. Although aluminum hydroxide has a slightly diffe rent crystal structure than aluminum oxyhydroxide, it is chemically equi valent to aluminum oxyhydroxide.

In addition, as some calcium will dissolve in the post-LOCA sump per the WCAP and Palo Verde has utilizes TSP for a buffer, some calcium precipitates will form.

Laboratory testing is being performed in or der to assure the correct chemical compositions are be used in the larger sca le chemical tests. These tests will be outlined in this specification. The te sts will be compared to the WOG evaluation in order to assure the results are withi n an acceptable range of the WOG results.

All testing and evaluations will be perform ed in accordance with CCI's Nuclear QA Manual [3].

The units used in this specificat ion are based on European (SI) standard.

1.1 Purpose The purpose of this specification is to define the test requirements for determination of head loss across the new sump strainer and to provide information on the following: Description and main data of the CCI Mu lti Function Test Loop (MFT) for the strainers C h e m i c a l P r e p a r a t i o n Test debris preparation T e s t p r o c e d u r e Rev.0 Page 5 of 28 Pages Q.003.84.781

Anweisung Specification

2. References

[1] APS Specification, 13-MN-1003, Rev.

0 inclusive CCI compliance matrix dated 07.04.2006

[2] NEI Report 04-07, Pressurized Water Reactor Sump Performance Evaluation Methodology, Rev. 0, December, 2004

[3] SER [1, volume 2], p. VI-16 Appendix VI

[4] Westinghouse Owners Group Document No. WCAP-16530-NP, Rev. 0

[5] CCI N-III Quality Assurance Manual, Rev. 5.1

[6] "Palo Verde Bypass, Transport and Head Loss Tests" CCI Document No.

Q.003.84.779 Rev. 0

[7] "Input to CCI Chemical Head Loss Tests for Palo Verde", APS document, 2 nd November 2006, including Ref 3: PVNGS Calculation 13-MC-SI-0016, "Trisodium Phosphate Basis Calculation" [8] "Palo Verde Chemical Laboratory Bench Top Test" CCI Document No.

Q.003.84.780 Rev. 0

[9] Niutec document no. 2007.0132.01 "CCI Palo Verde Chemical Testing: "Amounts of purchased c hemicals", dated 02/28/2007

[10] Niutec document no. 2007.0132.01 "CCI Palo Verde Chemical Testing: "Amounts of debris in lab bench tests", dated 02/28/2007

[11] CCI drawing 103.129.565 Rev. B

[12] CCI drawing 900229-1CH Rev. C Rev.0 Page 6 of 28 Pages Q.003.84.781

Anweisung Specification

3. General Description of the CCI Test Loop The CCI multi functional test loop is a cl osed recirculation loop with test channel piping, pump and measuring devices as shown in Figure 1.

The water recirculation in the loop is realized by means of a centrifugal pump measured with a flow meter that has a capacity up to 200 m 3/h. The test will be performed between 10 and 30°C. The flow ra te is adjustable by means of the frequency controlling of the rpm of the pump motor. Additionally the flow rate can be pre-adjusted by means of va lve in the up stream line.

The water flow rate is measured usi ng a KROHNE magnetic inductive flow meter. The head loss across the strainer is measured by means of a KELLER differential pressure transducer.

The temperature of the water is m easured using a Ni-CrNi Thermocouple K.

All instrumentation (temper ature measurement, pressure transmitter, flow meter etc.) is certified by a qualified laborat ory according to accepted standards with SCS Certificates (SCS = Swiss Calibration Service).

A CCI strainer segment with 40 representative pockets is placed in the Plexiglas channel before the loop is filled with water. The 40 pocket specimen has a vertical orientation while the water fl ow is horizontal into the pockets. The specimen is 10 pockets high (120 mm height per pocket) by 4 pockets wide (84 mm per pocket) and the pockets are 400 mm deep. The distance of the test pockets above the floor is approx. 30 mm. Side blades and top blade are made on solid steel while the bottom blade is perforated.

For specific testing due to the different water levels the top pocket rows can be blocked off. In order to keep the fibers suspended, a steel sheet may be inserted between the Plexiglas modules. This sheet can be raised and lowered to create a flow disturbance on the bottom of the channel to keep the debris suspended until they transfer to the strainer.

The minimum submergence of the test module is 1 cm. After adding the prepared debris the water level will be higher. For tests with a large amount of debris the water level must be lower ed between the test steps to prevent overflowing of the test loop while tests with a few debris the minimum submergence may be adjusted to a higher level.

The fibers that bypass the strainer can be collected by a fine mesh screen downstream of the strainer in case of bypass testing with fibers only.

Water sample can be taken downstream of the test strainer. The tap is located on the horizontal return pipe on the side in horizontal orientation.

Rev.0 Page 7 of 28 Pages Q.003.84.781

Anweisung Specification 3.1 Main Test Loop Data Max. feasible depth of test loop water 1.4 m 4.59 ft Max. test pool dimensions 8.0 x 0.4 m 26.25 x 1.31 ft Amount of Plexiglas modules 8 each 1m long 8 each 3 ft long Range of variable flow rate 0 - 200 m 3/h 0 - 880 gpm Range of water temperature 10 - 30°C 50 - 86 °F Range of tested head loss 0 - 360 mbar 0 - 12 ft H 2 O Table 1: Main Test Loop Data Picture 1: Multi Functional Test Loop (MFT-Loop)

Rev.0 Page 8 of 28 Pages Q.003.84.781

Anweisung Specification 3.2 Modification of Test Loop for Palo Verde Testing 3.2.1 Chemical Effect Testing The Chemical Effect Tests will be done with 3 Plexiglas modules. In the plant the bottom of the lowest strainer pocket will be 9" [12] off the floor due to the false floor on which the strainer sits and on the st rainer feet. This "curb" in front of the strainer will be simulated by blocking t he lowest pocket row (120 mm). The test strainer sits 30 mm over the flume floor.

This together gives a simulating of 6" (120 +30 mm) which is conservative compared to the 9" at the plant, however thus allowing plant specific meas urement of "lift over curb".

1 2 3 Figure 1: Outline of MFT facility for Palo Verde testing (3 modules show n) Rev.0 Page 9 of 28 Pages Q.003.84.781

Anweisung Specification

4. Test Description 4.1 Clean Head Loss Test Clean Head Loss Test, means a test without debris. The head loss of the "virgin" strainer will be measured. To get the head lo ss characteristic of the test module the test will be executed with different flow rates below and above of nominal flow rate.

4.2 Chemical Effect Head Loss Test (Test 2 and 3)

Chemical Effect Head Loss Test means a test with the maximum of deposited debris at the screen surface of the strainer. The volume of each type of debris is given by the client [6] and recalculated to the scale of the test module (Table 7).

Additional the chemical amounts [7] recalculated to test loop (Table 8) will be added. For chemical testing the most lim iting conditions will be used for testing. Test 5 from [6] (Stone flour uses fo r alkyd paint, aluminium paint and latent debris. Qualified epox y coating as dus t (<0.6mm) Unqualified coating as fines (0.6mm to 2.0mm))

or its repetition Test 5A from [6] (Epox y dust (<0.6mm) uses qualified epox y coating, alkyd paint and aluminium pain

t. Unqualified epoxy coating as fines (0.6mm to 2.0mm). Sand uses for latent debris (28% with particle size of 0.5mm to 2.0mm, 35% with particle size of 0.075mm to 0.5mm and 37% as stone flour)).

Test 6 from [6] (Stone flour uses fo r epoxy coating, alkyd paint, aluminium paint and latent debris)

RMI had not transported in the transport te sting at the highest flow velocity.

Therefore RMI will not be used for chemical testing.

4.3 Test Matrix The following table shows the test matrix with the relevant parameters. The test water temperature is the tem perature of the tap water. Th e order of the test is not fixed and can be varied. Reference for the values is [6].

T e s t no.5 5A 6 F u ll Load 3142 11600 ac c o r d ing to [6]F u ll Load 3142 11600 F u ll Load (gpm)T y pe of T e s t c o r r e s pond t o Sc r een Ar ea Plant c o r r e s pond t o F l o w Rate Pla n t (ft 2)3142 11600 ac c o r d ing to [6]ac c o r d ing to [6] Table 2: Test matrix: ty pe of tests Rev.0 Page 10 of 28 Pages Q.003.84.781

Anweisung Specification

5. Test Parameter 5.1 Calculation of Scaling Factor The table below shows the screen area of t he new suction strainer [12] and the screen area of the test module [

11] used in the test loop.

The filtering surface of the real insta llation is conservatively reduced by the sacrificial area of the label s and the Alpha / Nukon cloths.

The scaling factor is the result of the division of the two areas.

Pla n t, S c r een Ar ea Un it (S I)Scr een A r ea Plant Scr een Ar ea Te s t l o o p Scaling F a c t o r 31 42 f t 2 (-400 f t 2) (m 2)254.7 4.5 56.9 Table 3: Scaling factor The amount of fiber and particulate as well as the flow rate will be recalculated from the plant to the test condition by the scaling factor.

5.2 Calculation of Flow Rate The relevant flow rates from the plant will be converted and recalculated to the test loop condition.

Sy s t em Un i t (U S, SI)Flow Rate (US)Plant Flo w Ra te (S I)Plant Fl ow Ra te (S I)T e s t L oop De s i gn Flow Rate (g p m , m 3/h)1160 0 263 5 46.3 3 Table 4: Flow rates from plant At those flow rates the complete turnover of the system will be:

T u r nove r W a t e r Le ve l @ 1.25 m Un i t (S I)W a ter Filling T e s t Lo op Ti m e fo r 5 T u r n over Ti m e fo r 1 5 T u rnover T e s t loo p 3 m by 0.4 m (L , m i n)1700 11.0 33.0 Table 5: Turnover of test loop w a ter Rev.0 Page 11 of 28 Pages Q.003.84.781

Anweisung Specification 5.3 Calculation of Plant Specific Debris The table shows the debris values and densit ies as used by the previous tests [6]

and their conversion to mass values.

T y pe of Debr i s Un it (U S , US, US)Volum e (US)Pl ant Sum p Dens ity (US)Mas s (US) Pl a n t Su m p Ins u lati on Nu k on Fiber (ft 3 , lb/f t 3 , lb)8.25 2.4 19.8 0 T h er m o lag 33 0 (ft 3 , lb/f t 3 , lb)3.88 56.7 220.00 RM I T r a n s c o (0.00 2")(ft 2 , lb/f t 3 , lb)2502 9 493.2 2057.30 RM I Mirr or (0.002")(ft 2 , lb/f t 3 , lb)419 493.2 34.4 4 Coating Q u alif ied IO Z (ft 3 , lb/f t 3 , lb)2.42 442.9 1071.75 Un qualif ied IOZ (ft 3 , lb/f t 3 , lb)1.41 442.9 624.45 Q u alif ied Epox y (ft 3 , lb/f t 3 , lb)2.09 98.5 205.87 Un qualif ied E pox y (ft 3 , lb/f t 3 , lb)3.19 98.5 314.22 Un qualif ied A l k y d (ft 3 , lb/f t 3 , lb)0.28 98.5 27.5 8 Un qualif ied A l um in um (ft 3 , lb/f t 3 , lb)1.12 98.5 110.32 La te nt D e br is Fi b e r (ft 3 , lb/f t 3 , lb)12.5 2.4 30.0 0 Par t ic ulate (ft 3 , lb/f t 3 , lb)1.01 167.4 168.74 Da m age d IO Z (ft 3 , lb/f t 3 , lb)0.01 442.9 4.4 3 Table 6: Debris mass amount at plant sump The influence of labels or large tr ansportable debris to the head loss is considered in the way that the reduction in filtering surface (see [6]) results in a lower scaling factor and therefore in a hi gher amount of fiber and particulate for the testing.

Rev.0 Page 12 of 28 Pages Q.003.84.781

Anweisung Specification 5.4 Calculation of Test Specific Debris The plant specific values are convert ed to SI-dimensions and divided by the scaling factor to the test specific amounts.

The Chemical Tests uses the debris amounts below:

De bri s N a m e Un i t (S I)M a ss (S I) Te s t 5 M a ss (S I) Te s t 5 A Mas s (S I) Te s t 6 Ins u lati on Nu k o n (k g)0.397 0.39 7 0.39 7 T h er m o lag 33 0 (k g)1.755 1.75 5 1.75 5 Coating / Par t icula t e Co ati n g IOZ (k g)13.56 4 13.56 4 13.5 6 4 Ep ox y Coatin g as Dus t (k g)1.642 2.74 2 Ep ox y Coatin g as Fines (k g)2.506 2.50 6 Sand (k g)0.84 8 Sto ne Flou r (k g)3.215 0.49 8 10.2 6 5 Table 7: Debris mass amount for head loss tests For the head loss test the mass of the debris will be used as the measurable parameter.

Rev.0 Page 13 of 28 Pages Q.003.84.781

Anweisung Specification 5.5 Procedure for Precipitant Generation The procedure recommended for preparing prec ipitates in the test loop is as follows. The chemical quantities to be added are determined based on laboratory testing [8] [9].

100% Chemical A ddition A m ount Test 1 Test 2 Boric Acid 42.964 kg 42.964 kg T r isodium Phosphate T SP 7.093 kg 7.093 kg Sodium Aluminate Solution 36%

4.737 kg / 3.294 L 4.737 kg / 3.294 L Calcium Chloride Solution 34%

0.273 kg / 0.205 L 0.273 kg / 0.205 L Sodium Silicate Solution 38%

3.528 kg / 2.592 L 3.528 kg / 2.592 L Table 8: Chemical Addition Table For all steps requiring pH measurement it will be done with indicator paper and a portable pH meter at the loop and then verified in the lab.

The boric acid an d TSP quantity will be added and dissolved prior to addition of any debris. After debris addition and stabilization of head loss, 40% of all chemicals will be added. Then the steps will be repeated to total 70%, 100%, 120%, and 140% values.

The pH values for each chemical addition will be performed per table below.

Chemical Addition Step Allow able pH Range 40% 6.0 - 8.1 70% 6.0 - 8.1 100% 7.5 - 8.1 120% 7.5 - 8.1 140% 7.5 - 8.1 Table 9: Allow able pH Range for Chemical Addition Rev.0 Page 14 of 28 Pages Q.003.84.781

Anweisung Specification

6. Test Performance 6.1 Chemical Test Performance: Main Steps For the chemical tests, preparatory works and clean head loss testing occurs prior to performance of the main test steps. During chemical testing a chemist can be consulted for unexpected issues or behavior.

The main steps will be performed as follows:

1. After filling the pool with water the recirc ulation is started. The water level is chosen in order to fully submerge the test at 1 cm. The water volume will be measured using a flow gauge at the water source.

2. Flush the pressure taps feeding the pr essure transducer to ensure that there is no particulate debris build-up/blockage and / or air bubbles inside.

3. Add boric acid per Table 8 to the test loop to prepare a boric acid solution with a boron concentration of approxim ately 4'400 ppm as B based on the filling of the pool and the water amount of debris preparation. This will prepare a slightly acidic solution.

4. Measure pH in test loop. The pH should be between 4.5 and 5.5, but is not critical. The key parameter is the boron concentration which should be 4'400 ppm as B. The pH and water temperature will be measured after approximately 5 turnovers to ensur e a homogenous mixture and a 500 mL water viscosity sample will be taken.

5. Add TSP per Table 8 to the test bas ed on the filling of the pool and the water amount of debris preparation.

6. Measure pH in test loop. The pH s hould be per Table 9, but is not critical.

The key parameter is the boron conc entration which should be 4'400 ppm as B and the Trisodium phosphate concentration which should be 3'900 ppm as TSP. The pH and water temperatur e will be measured after approximately 5 turnovers to ensure a homogenous mixture and a 500 mL water viscosity sample will be taken.

7. Next the debris addition will occur into the test compartment. The debris will be weighed and mixed into a homogeneous mixture in buckets and then poured into the test pool. The debris is to be introduced in front of the strainer.

8. Measure pH in test loop and head loss due to the debris addition. After the head loss has stabilized by the criterion of 1% change in 30 minutes or the test engineer states to continue, the values will be recorded and a 500 mL water viscosity sample will be taken.

Rev.0 Page 15 of 28 Pages Q.003.84.781

Anweisung Specification

9. The chemicals will be added in additions of 40%, 70%, 100%, 120%, and 140% of solution amounts following the details outlined in Table 8.

--> Following the steps outlined in Section 6.2.

Measure the head loss due to the chemical addition until stabilization of a 1%

change in 30 minutes period for the complete chemical addition or the test engineer states to continue, the va lues will be recorded and testing can proceed with the next addition.

--> Repetition of Step 9 for next chemical addition

10. Measure the head loss after the last chemical addition until stabilization of a 1% change in 30 minutes for two consecutive 30 minute periods for the termination criteria or the test engineer states to continue, the values will be recorded and testing is done.

11. The amount of total debris which is added for each test will be recorded.

Also, the amount of settled debris in the tank needs to be quantified.

6.2 Chemical Test Perfo rmance: Chemical Steps The chemical steps will be performed as follows:

1. Carefully add the sodium aluminate soluti on to the test loop. This chemical is alkaline and caution must be exercis ed in its handling. Caution must be exercised because there will be a neutraliz ation reaction that will generate heat. This will create the potential for spattering if done too quickly.

Note: a precipitate will form immediately after the addition of sodium aluminate.

2. Measure pH in test loop. The pH and water temperature will be measured after approximately 5 turnovers to ensure a homogenous mixture and a 500 mL water viscosity sample will be taken.

3. Carefully add the calcium chloride solution to the test loop. This chemical is alkaline and caution must be exercised in its handling.

4. The pH and water temperature will be measured after approximately 5 turnovers to ensure a homogenous mixture and a 500 mL water viscosity sample will be taken.

5. Carefully add the sodium silicate solution to the test loop. This chemical is alkaline and caution must be exercised in its handling. It is important that sodium silicate solution is added last so that it can preferentially react with any aluminum instead of precipitating silica.

6. The pH and water temperature will be measured after approximately 5 turnovers to ensure a homogenous mixture and a 500 mL water viscosity sample will be taken.

Rev.0 Page 16 of 28 Pages Q.003.84.781

Anweisung Specification

7. The pH will be compared to that obt ained in the laboratory bench test to ensure that it is in the appropriate r ange (Table 9). For pH values outside of the expected range, the caus e must be identified. If the pH is less than as specified in Table 9, sodium hydroxide should be added to the test loop.

If the pH is greater than specified in Table 9, a small amount boric acid should be added to the test loop.

If the pH is much greater that spec ified nitric acid must be added to the test loop.

8. After the addition of all chemicals and a minimum of 15 turnovers to ensure a homogenous mixture, the pH and wate r temperature will be measured and a 500 mL water viscosity sample will be taken.

The pH should per Table 9. If t h e p H e x c e e d s t h e v a l u e p e r , p H a d j u s t m e n t w i t h a c i d w i l l b e necessary.

T a b l e 9 9. Take a 1500 mL grab sample of the liquid in the test loop from the tap downstream of the strainer and measure the test temperature. The sample will be analyzed for suspended solids and dissolved phosphate, aluminum, calcium and silica. The pH and water viscosity will also be recorded.

Additionally, the sample will be analyzed to ensure that precipitant production in the loop is within the WOG recommended concentration limit for prototypical settling. The samples will be shaken until they can be analyzed.

The precipitant size, settling rate, and filterability will be measured for the precipitants in the grab sample. A dditionally, the sample will be measured for dissolved boron.

Rev.0 Page 17 of 28 Pages Q.003.84.781

Anweisung Specification

7. Chemical used to Generate Precipitates 7.1 Chemicals Used in Testing All precipitates required for the Multi-F unctional Test Loop (MFT) Chemical Filter Performance Test will be freshly precipitated in the test loop for use in the test.

This will avoid the potential for differences in crystal structure caused by aging and will best simulate precipitates formed under containment sump conditions.

The chemicals to be added to the test l oop to generate the requi red precipitates are given below. A commercial/industrial grade is appropriate for all of these chemicals.

Note: Actual amounts of each chemical used in the MFT tests will be determined based on the Laboratory Test results outlined in [8].

The Material Safety Data Sheet (MSDS) must be reviewed and understood by all persons performing work or witnessing the testing. The MSDS for each chemical used in the testing is attached in Section 10.

7.2 Boric Acid Boric acid (H 3 BO 3) will be added to the test loop to match the post-LOCA containment sump chemistry. For Palo Verde, a boric acid concentration of 4'400 ppm as B will be used [7]. The volume of water added to the test loop will be measured and the amount of Bo ric Acid added will be calculated and recorded based on that volume and the Boric Acid chemical assay. A calibrated flow gauge is located on the water pipe that will be used to fill the test loop. The volume of water added for each test will be measured from this gauge. There will be some water added to the loop after the addition of debris. This amount of water will be calculated and the boron level will be adjusted accordingly.

The MSDS must be consulted and is attached for viewing in Section 10.

7.3 Trisodium Phosphate (TSP)

Trisodium phosphate (TSP) will be added to the test loop to match the post-LOCA containment sump chemistry. Fo r Palo Verde, a concentration of 3'900 ppm as TSP will be used [7]. The volume of water added to the test loop will be measured and the amount of TSP added will be calculated and recorded based on that volume and the TSP chemical assa

y. A calibrated flow gauge is located on the water pipe that will be used to fill t he test loop. The volume of water added for each test will be measured from this gauge. There will be some water added to the loop after the addition of debris. This amount of water will be calculated and the TSP level will be adjusted accordingly.

Rev.0 Page 18 of 28 Pages Q.003.84.781

Anweisung Specification The MSDS must be consulted and is attached for viewing in Section 10.

Trisodium phosphate (TSP) is the source of phosphate in the Chemical Filter Performance Test. Phosphate will precipitat e mainly as Tricalcium phosphate.

TSP is commercially available as a solid. An accurate assay is required to establish the phosphate content.

For this testing anhydrous TSP by C hemira GmbH is used, 40.5-43.4% P 2 O 5. The MSDS must be consulted by the i ndividuals performing the procedure and is attached for viewing in Section 10.

Section 7.3.2 of WCAP-16530-NP recomm ends limiting the concentration of calcium phosphate precipitate to a maximu m of 5 g/l to achieve prototypical settling behavior. The actual value of TSP needed to produce the required mass of phosphate will be determined from the laboratory testing.

The concentration of calcium phosphat e produced in the MFT test will be compared to the WOG recommended concentrati on limit for prototypical settling.

The precipitate size, settling rate, and filt erability of all precipitates in the MFT Chemical Test will be determined.

7.4 Sodium Aluminate Sodium aluminate [7] is the source of al uminum to simulate aluminum dissolution in the Chemical Filter Performance Test.

This chemical will result in the most representative mixture bec ause it will not add other c hemical elements that would not be found in the containment su mp. Aluminum will precipitate as both sodium aluminum silicate and as aluminum hydroxide.

Sodium aluminate is commercially available as a solid or as a concentrated liquid. Either form is suitable for the te st, but an accurate assay is required to establish the aluminum content in either case.

For this testing a liquid 36% sodium aluminate chemical solution produced by Chemira GmbH containing 16% Al 2 O 3 , 20% Na 2 O with a density of 1.4 +/- 0.02 g/cm 3 will be used as the source of dissolved aluminum in the test.

Sodium aluminate is manufactured by reacting hydrated alumina with caustic soda. As a result, solutions are caustic with pH values over 12. The solution will be corrosive and should be properly handled with appropriate personnel protection. The MSDS must be consulted and is attached for viewing in Section

10. Rev.0 Page 19 of 28 Pages Q.003.84.781

Anweisung Specification Precipitation of aluminum hy droxide is accomplished by lowering the pH to 8.1 or less (based on Palo Verde chemistry). The boric acid concentration in the test loop (based on the containment sump chem istry) will provide an excess of boric acid for the amounts of aluminum hydroxide to be precipitated.

Section 7.3.2 of WCAP-16530-NP recomm ends limiting the concentration of aluminum hydroxide precipitate to a maxi mum of 11 g/l to achieve prototypical settling behavior. The actual quantity of sodium aluminate needed to produce the required mass of aluminum will be dete rmined from the laboratory testing.

The concentration of aluminum hydrox ide produced in the MFT test will be compared to the WOG recommended concentrati on limit for prototypical settling.

The precipitate size, settling rate, and filt erability of all precipitates in the MFT Chemical Test will be determined.

7.5 Calcium Chloride Calcium chloride (CaCl

2) [7] is the source of calcium to simulate calcium dissolution in the Chemical Filter Perfo rmance Test. Calcium may co-precipitate with other metals.

Calcium chloride is commercially available as a solid or as a concentrated liquid.

Either form is suitable for the test, but an accurate assay is required to establish the calcium content in either case. The liquid form is more convenient for use in the test and is available in various strengths.

A 34% calcium chloride (nominal of 35 wt % CaCl

2) solution produced by Chemira GmbH with an approx imate density of 1.30 g/cm 3 will be used for the test. The MSDS must be consulted by the individuals performing the procedure and is attached for viewing in Section 10.

Rev.0 Page 20 of 28 Pages Q.003.84.781

Anweisung Specification 7.6 Sodium Silicate Sodium silicate [7] is the source of silica to simulate silica dissolution in the Chemical Filter Performance Test. S ilica will precipitate as sodium aluminum silicate.

Sodium silicate is commercially available as a solid or as a concentrated liquid.

Either form is suitable for the test, but an accurate assay is required to establish the silica content in either case. The liquid form is more convenient for use in the test and is available in various strengths.

For this testing a 37 - 40% liquid sodium silicate solution (27.3 wt % SiO

2) produced by Chemira GmbH with a density of 1.34 - 1.38 g/cm 3 will be used.

The MSDS must be consulted by the i ndividuals performing the procedure and is attached for viewing in Section 10.

Section 7.3.2 of WCAP-16530-NP recomm ends limiting the concentration of sodium aluminum silicate precipitate to a maximum of 11 g/l to achieve prototypical settling behavior. The act ual value of sodium silicate needed to produce the required mass of silica will be determined from the laboratory testing.

The concentration of sodium aluminum silicate produced in the MFT test will be compared to the WOG recommended concentrati on limit for prototypical settling.

The precipitate size, settling rate, and filt erability of all precipitates in the MFT Chemical Test will be determined.

Rev.0 Page 21 of 28 Pages Q.003.84.781

Anweisung Specification

8. Debris Preparation 8.1 Nukon Insulation The original fibers specified by the c lient [1] will be used for the testing. The fibers will be supplied by the client. The preparation of the fibers will follow the steps below: The fibers will be freed from the jacketing (if jacketed). Then the fibers will be baked by placing them in an oven with a regulated temperature of 300°C for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> prior to testing.

The fibers will be hand cutting in pieces of approx. 50 x 50 mm.

The dry material gets weighed The fibers get split in batches of 3 to 4 dm 3 (0.1 to 0.14 ft

3) Each batch gets soaked in 2 l of water (1/2 gal)

Their adherence will be decomposed by a high pressure water jet with a capacity of 100 bar and with the jet in a distance of +/- 0.05 m to the water surface, during approx. 4 min for each batch.

It will be ensured by visual means that the insulation is decomposed into the water in suspended fiber pieces smaller than 10 mm ("). Several batches can be mixed together to a main batch (portion) according to the test description.

8.2 Thermolag The Thermolag used for testing is actual material used at the PVNGS site. For this test the Thermolag will be prepared by removing the wire backing, and then crushed /ground by mechanical means into a fine powder. Thermolag does contain a small amount of fibers, but will be treated as 100% particulate for testing purposes.

The size distribution for the Thermolag powder was measured by sieving:

47 g has a size >2.0 mm 550 g has a size of 1.0 mm to 2.0 mm 392 g has a size of 0.075 mm to 1.0 mm 4 g has a size of <0.075 mm The Thermolag will be mixed together with the fibers in the water bucket after decomposition of the fibers.

Rev.0 Page 22 of 28 Pages Q.003.84.781

Anweisung Specification 8.3 Nukon and Alpha Cloth Nukon cloth and Alpha cloth (from here on refe rred to solely as Nukon cloth) are assumed to be durable and if subjected to a high energy line break, only a small amount of the cloth will be shredded into i ndividual fibers. The majority of the cloth is assumed to retain its original dimensions, but may be torn in multiple locations. For head loss testing, the cloths are considered in the sacrificial area.

8.4 Reflective Metal Insulation (RMI)

Stainless steel foil with a thickness of 0.05 mm (0.002") will be used simulate RMI. A commercial shredding company will tear and crumple the RMI using a mechanical process in order to approximate the sizes [3].

Picture 2: Representative sample of shredded and crumpled SS RMI Foil The scale of the ruler is centimeter.

The RMI will be added simultaneously with other debris (a homogenous debris mixture) to the test loop.

Rev.0 Page 23 of 28 Pages Q.003.84.781

Anweisung Specification 8.5 Paint Chips In this testing epoxy paint chips will be used for the qualified and unqualified epoxy coatings. These paint chips have been generated from coating types that are used in the plant or equivalent coat ings. The amount of paint chips will be supplied by the client according to [1].

Unqualified Alkyd and unqualified Aluminum coating would be modeled as stone flour. Qualified IOZ, unqualified IOZ and damaged IOZ coatings would be modeled as zinc dust (raw material of IOZ coating).

The paint chips, stone flour and zinc dust are mixed together with the fibers in the water bucket after decomposition of the fibers.

8.5.1 Epoxy Material Description (from APS)

PVNGS Engineering requested PVNGS maintenance to "Manufacture" epoxy coating chips for use in containment su mp strainer performance testing. The maintenance coating group manufactured t he chips using Amerlock 400 that is produced by Ameron.

The Amerlock 400 was applied by spray to large sheets of plastic inside the PVNGS coating facility. The epoxy was applied per the manufacturer's instruction. The large sheets of plasti c were stretched flat, however there were some wrinkles. The wrinkles caused t he epoxy to dry in various thicknesses.

The epoxy was allowed to cure for one week and was then removed from the plastic sheets by hand. The thickness of nineteen random samples of the epoxy chips was measured. The thickness of the epoxy ranged from 5.4 mils to 36.5 mils with an average (m) value of 15.7 m ils and a standard deviation (s) of 9.4 mils. The thickness measurements in mils we re 5.4, 6.3, 6.9, 7.2, 8.3, 8.3, 9.3, 10.9, 12.4, 14.2, 15.7, 16.4, 17.6, 19.4, 20.3, 22.8, 23.

1, 36.5, and 37.4. Based on this sample, approximately 70% of the coating quantity manufactured will have a thickness less than 20.4 mm (m+0.5s). The average thickness value for epoxy coatings in the debris generati on evaluation (Calculation 2005-06160, Rev. 1) is 19 mils (1.5 mil sealer with 17.

5 mil topcoat). Since the majority of the manufactured epoxy coatings have thick nesses near the coating thickness used in the plant, the manufactured epoxy coati ng is considered representative of the epoxy coating currently in the Palo Verde containment.

The epoxy was then placed in an oven and cured at a temperature between 200 and 300°F for 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> or more. The large epoxy chips were then mechanically reduced into smaller pieces. The epoxy was then sieved into various sizes as needed for testing. Then some of the epoxy chips were further reduced in size Rev.0 Page 24 of 28 Pages Q.003.84.781

Anweisung Specification by a ball mill to obtain the finer sizes.

The Los Angeles (L.A.) abrasion tester was used as the ball mill due it availability.

The various sizes (noted by 'X') of epoxy to be used for testing is as follows: Large chips X > 0.25" X > 6.35 mm Chips #8 sieve < X < 0.25" 2.36 mm < X < 6.35 mm Fine #30 sieve <X < #10 sieve 0.6 mm < X < 2.00 mm Dust X < #30 sieve X < 0.6 mm The lab used for processing the epoxy material has current commercial qualification for the type of material handling performed; however the lab's QA program is not 10CFR50, Appendix B cert ified. CCI will perform an independent verification of material si ze under their QA program.

Attachments:

a) Amerlock 400 product data sheet b) Memo from Ameron on material densit y and curing at elevated temperature c) Sieve report from Amec for t he various epoxy size distribution d) Amec commercial qualification reports Rev.0 Page 25 of 28 Pages Q.003.84.781

Anweisung Specification 8.6 Latent Debris CCI has used a stone flour COOP product in the past for strainer performance testing which comes very close to this kind of debris. The size spectrum analysis its Sv value is 0.776 m 2/cm 3 , corresponding to a sphere diameter of 7.7 µm. This is a recently measured value which is bounded by the 10 µm.

The quantity of particulates is defined by volume. However, we measure the particulate quantity for the tests by weight. For the head loss, besides the above value of Sv, the representative volume quantity is important. Therefore, the volume quantity has to be converted to weight by the density of the surrogate particulates.

The surrogate particle material density was measured to be:

2680 kg/m 3 (167.4 lb/ft

3) The particulates are mixed together with the fibers in the water bucket after decomposition of the fibers. They do not need decomposition, since they already come in a form of flour and distribute instantly.

Picture 3: Latent debris Rev.0 Page 26 of 28 Pages Q.003.84.781

Anweisung Specification

9. Documentation The records of these tests shall be collected and attached to the strainer replacement QC documentation.

Each test record shall identify: C o m p o n e n t t e s t e d Date, hour of test Test specification no. and revision Test equipment no./ data recorder no.

Test number according to test specification Type of observation Test parameters (flow rate, fiber and par ticulate quantities (dry weight), water temperature, head loss)

Quantity of debris which transport to t he strainer vs. quantity of debris which settles in flume (measur ement can be approximate)

Location of debris settlement in flume (f ar from strainer, near strainer, etc)

Action taken in connection with any deviations noted Person evaluating test results The test report shall include:

Attached test records Photographs of debris prior to mixing Photographs of settlement Photographs of pockets with debris layers after the tests Assumptions, data, descriptions, evaluations and conclusions.

I n s t r u m e n t a t i o n cert ification certificate MSDS of used material Rev.0 Page 27 of 28 Pages Q.003.84.781

Anweisung Specification Rev.0 Page 28 of 28 Pages Q.003.84.781

10. Enclosures and Exhibits Material Safety Data Sheets (MSDS) a) MSDS Boric Acid b) MSDS Trisodium phosphate c) MSDS Sodium Aluminate d) MSDS Calcium Chloride e) MSDS Sodium Silicate f) MSDS Nitric Acid g) MSDS Sodium Hydroxide