ML102920509

Presentation to Pnsc Containment Update & Discussion of Repair Options

ML102920509
Person / Time
Site:	Crystal River
Issue date:	11/16/2009
From:	Geoffrey Miller Nuclear Generation Group, Progress Energy Florida
To:	Office of Information Services
References
FOIA/PA-2010-0116
Download: ML102920509 (7)

Text

Steam Generator Replacement (SGR) Opeening (between Buttresses 3 and 4)

Crystal River Unit #3 Presentationto PNSC Containment Update & Discussion of Repair Options SGR Opening November 161 2009 Dimensions Presented by Garry Miller 0 Liner 23' 6" 2W'9" 0 ConcreteOpening 25'G'. 2T0

,,J Progress Energy SProgress enlly Hydro-Demolition & Liner Removal Sequence Delamination Close-up 1 F7 7F 3F Condition Assessment Techniques Location of the Delamination Completed or Planned Impulse Response (IR) Scanning of Containment Wall Surfaces w Comprehensive on external exposed surfaces w Representative sampling inside buildings L 0.

i Core bores 4

w Use to cross-check IR results w Includes visual inspection/documentation of surface inside the bored hole i IWL visual inspection of containment external surface (affected areas) i Dome Inspections

" IR scans in selected area

" Core bore samples in repaired and non-repaired areas

" Physical survey (compared to 1976 results)

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Containment "Unfolded" - Buttress 2 to 5 Containment "Unfolded" - Buttress 5 to 2 Updated No, 16'" Mosaic IR Overlay scaleis approximate Updae.a I' 2000 10o Etu-s -2 G.-s 03 03no Burs 05 noSNS

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ALL Core Bores Core Bores Buttress spans 2 4- 5 (asof Nov 14002009) Buttress Spans 5 1 - 2 (as of Nov 141" 2009) i i._:iiiiiiiiiiiiiiill iiiiil~i --. ....

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Root Cause Analysis - P11 Metrics Root Cause Analysis Un-refuted FailureModes as of Nov 9gh2009 Field Data Acquisition 80 E~telnl Events

• Impulse Response (IR) Scans 70 Opyrtiol-l Eelrts

• Boroscopic Inspections 60

• Core bore holes

• Im*elraeqrtoe Corrrr-tndonll~llCi~

• Inside the delaminated gap 40 40 fl e MI--orOOo Shrinknge.Creep..nd Serrkl nt

• Visual inspections 30 .. Chreich"r EnoioonreWneRY tri~trcoddAgingr

• Delamination cracks at SGR Opening 20 natdeqtuareUse WrConcrete

• Larger fragments from concrete removal process

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• Containment external surface 0 Hi0htLo I Stress Progirss liergy SProgressbrqy A .

Root Cause Analysis Root Cause Analysis Field Data Acquisition (continued) Field Data Acquisition (continued)

• Nearby energized tendons lift-off (vertical and i Core bores laboratory analysis horizontal) . Petrographic Examination w Modulus of Elasticity and Poisson's Ratio

• Containment ID measurements w Density, Absorption, and Voids

• Strain gauge measurements w Compressive Strength, Splitting Tensile Strength, and Direct Tensile Strength

• Linear variable displacement transducer (LVDT) gap monitoring 0 Building Natural Frequency N&... Progress EQergy I"40 b*ProgressEitorgy MPR 3D FE Model Model Features 180 degree Symmetric model w Symmetry plane @ 150 degrees midway Between Buttress 3 & 4 / I & 6 w 1AOpening, Ia Damage &1/2hHatch Modeled Explicitly Concrete Model

" Brickelements forallcomponents r Dome and Base modeled independently DESIGN BASIS ANALYSIS " Simplifiedring beam and buttress geometry o Constraint equations used to joindome and ringgirder for meshing efficiency w Constraint equation used to model sloped surfaces ofthe hatch Liner Model

, Shell mesh withvariable thickness w Shared nodes withcontainment inner surface Tendon Modeling

" Hoop tendons modeled explicitlyforrelease and re-tensioning

" VerticalTendons modeled explicitlyfor release and re-tensioning o Dome tendons modeled independently withforces ported to global model

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MPR 3D FE Model MPR 3D FE Model Model Features(continued) Load Cases

• LE* AN I Live and Dead Loads I Wind (110mph @ 30' increasing to 179 mph @ 166'10")

I Tornado Wind (300 mph) i Tornado pressure (external pressure of 3 psig) i Tornado Missiles (35' utility pole or 1 ton car @ 150 mph)

I Seismic (OBE - 0.05 and SSE - 0.10)

Temperature Loads I Accident Pressure (55 psig) i Accidental Containment Spray Actuation Press (-2.5 psig)

~$Pr-lfessitarg MPR 3D FEEModel Specific Analysis to be Performed Repair Attributes i Incorporates and is compatible with Root Cause Analysis I Existing Design Cases I Planned Analysis for Comparison Sequence findings

. Gravity (.95 G) w Dead Load , Tendons IReDaigvll* W!9 tta,9 tHgirlboad Steps w Internal Dead Load (200 puff) w Remove Hoop + Vertical Tendons w Tendons (1635 kips / tendon) in SGR Opening Incorporates Life of Plant Considerations u Include losses w Remove SGR Opening . Long Term Surveillance and/or Maintenance Requirements w Internal Pressure (55.0 psi) , Delamination(l) w License Renewal

. Wind Pressure (0.568 psi) w Remove Additional Hoop & Vertical Tendons I Constructability Seismic Accident Thermal Replace the SGR Plug(2) w RepairiM

. Re-tension Tendons w SAVE Path Dependent Model for Starting point to Run 5 Controlling

(/ 1 Rtt°IOu se r usc¢onr, ti umlw aminaun*3 Design cases r - - Ito1eplan SGRc rlug, marrar tervosrgv Repair Alternatives Repair Alternatives Considered "use-as-Is" and "Anchorage Only" Use-as-Is I Use as Is - Rejected w Degraded safety related structure Anchorage Only . Design margins are reduced I Cementitious Grout Anchorage Only- Rejected w Containment and delaminated layer willnot structurally perform as monolithic shell I Epoxy Resin u Would function as two independent shells pinned together w Detensioning is not expected to close the delamination gap (greater than 2"in some places)

Delamination Removal and Replacement u Would require some competent fillmaterial be added w Anchorage plate washers (acting to distribute the load) would have minimal separation creating dilficulty in the field

" Tendons are not always equally spaced

" Rebar mat interference at targeted anchorage locations 123Pgress Enetgy ~. lt r~ress F t~y

Repair Alternatives Repair Alternatives "Cementitious Grout" "Cementitious Grout" i Cementitious Grout - Rejected I Cementitious Grout - Rejected (continued) w Will not be able to penetrate all of the fissures observed along w Mock-up test needed to validate tendon duct integrity (leak the delaminated surface tightness against grouting injection) u Test may indicate leak tightness is not assured u Creates un-repaired weak planes, affecting tensile capacity w Requires anchorage to resist grout injection pressures( >20 w Multi-fissure segmented cracking and dislodgement could block psig), and this has all of the same difficulties as detailed in the adjacent areas from being filled "Anchorage Only" repair u This anchorage system limits access to effectively perform IR scans to ensure complete grout coverage w Mock-up testing to simulate all of the in-situ conditions is problematic Physical properties of grout would require detailed evaluation u Examples - Cleanliness of surfaces, parallel fissures and/or verification to prior to use u Would likelyrequire in-situ testing that would be difficult to control " Many grouts are blended for geotechnical applications in the field " Tensile strength of typical grouts is significantly lower than epoxy resins 25 Progteas Energy IGG N; Progress Etengy Repair Alternatives Repair Alternatives "Epoxy Resin" "Epoxy Resin" i Epoxy Resins - Rejected i Epoxy Resins - Rejected (continued) w Not viable in gaps greater than /" due to exothermic reaction . Mock-up testing to simulate all of the in-situ conditions is u Delamination gaps are well beyond this limit,including > 2" in some problematic locations " Examples - Cleanliness of surfaces, parallel fissures mWould likely require in-situ testing that would be difficult to control w May not be able to penetrate all of the fissures observed along the delaminated surface u Creates un-repaired weak planes, affecting tensile capacity w Requires anchorage to resist epoxy injection pressures (8 to 20 psig), and this has all of the same difficulties as detailed in the w Raising the injection pressure to improve penetration in fissures "Anchorage Only" repair

" Anchorage becomes more difficult u This anchorage system limits access to effectively perform IR scans

" Tendon conduit integrity becomes more difficult to ensure complete coverage w Mock-up test nee ded to validate tendon duct integrity (leak tightness against epoxy injection) u Test may indicate leak tightness is not assured 27~ ProgressErnegly etj~ý ~Progresst ben Repair Alternatives Repair Alternatives Repair and Replacement Repair and Replacement I Delamination Removal and Replacement - Selected I Repair and Replacement - Selected (continued) w Delamination Removal Challenges w Need to secure and verify same constituents to use the existing

" Safe removal of delaminated concrete at elevated heights qualified design concrete mix (for the SGR Opening)

" Avoiding collateral damage to tendon conduits

" Minimize damage to the remaining substrate to minimize concrete w Concrete Placement bruising and to provide a favorable bonding surface " Needs to construct ganged forms for placing the pours

" Requires verification planar fissures are removed " Need to determine method to anchor the forms

" Elevations create work execution challenge

. Requires new radial reinforcement design (anchored to the substrate) w Will require treatment of planar fissures (if encountered) at periphery

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Boroscopic Photos Boroscopic Photos DelaminationGap Dimensions DelaminationGap Dimensions Buttress 3-4, CellK Core 55 Buttress 3-4 CellH,Core #82

[*,*s*.4*ce,,**:,**] [ ss 3-4,tellX, Core,#80 S, Progress Eqrgy Boroscopic Photos Boroscopic Photos Debris in the Delamination Gap Debris in the DelaminationGap SButress 3-4, Ce~lZ ,Core If 78 ] [Butress 3-4, Cell Y, CoreM6, Sotss 3-4, CellH,Core f1u.] B tess

- 3 4 Cel H Core 82]

133 C Nrorss Energy Boroscopic Photos Boroscopic Photos Fissuresin the Delamination Gap Fissuresin the DelaminationGap Butes 3-4. Top of SGR Opening ] Buttress 3-4. Tp of (3R Opning Buttress 3-4 CellJ Core #7 Buttress 3-4,CellM,Core#1 UprLeftCorner Looking West t Upr Le."Cme

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