ML020980319
| ML020980319 | |
| Person / Time | |
|---|---|
| Site: | Prairie Island  |
| Issue date: | 03/19/2002 |
| From: | Office of Nuclear Reactor Regulation |
| To: | |
| References | |
| Download: ML020980319 (60) | |
Text
Committed to Nuclear Excellence Prairie Island Nuclear Generating Plant Steam Generator Replacement Project Unit 1
.N.C Present.ton NRC Presentation March 19, 2002
SGR Project Presentation - Attendees March 19, 2002 Nuclear Management Company Ken Albrecht - Project Manager Richard Pearson - Project Engineer, Design Oley Nelson - Safety Analysis
"* Framatome ANP Alain Laux - Project Manager
"* Framatome ANP Inc.
Mary Beth Baker - Project Manager, Licensing
"* Steam Generating Team (SG Larry Davis - Project Manager Scott Marty - Project Engineer, Installation Terry Higgins - Project Engineer, Licensing Gene Eckholt - Licensing Supervisor Jean Paul Billoue - Technical Manager Scott Beckham - Lead, Accident Analysis
- T, Ltd)
Mark Ceraldi - Lead Engineer, Licensing NRC Presentation March 19, 2002 NMC Committed to Nuclear Eclec 2
Committed to Nuclear Excellene SGR Project Meeting Agenda
"* Project Overview
"* Component Design
"* Licensing Approach
"* Installation Plan
"* Future Meetings Ken Albrecht - Project Manager Richard Pearson - Project Engineer, Design Oley Nelson - Safety Analysis Scott Marty - Project Engineer, Installation Ken Albrecht - Project Manager NRC Presentation March 19, 2002 3
- Condition of Unit 1 SGs
"* Justification for Replacement
"* Project Participants
"* SGR Project Organization
"* Project Milestone Schedule NRC Presentation March 19, 2002 SG R Project Overview Ken Albrecht Committed to Nuclear Excellence 4
PINGP Unit 1 SG Plugging History (thru January 2001)
NMCer-jj Committed to Nuclear "Excellenc Total Tubes/SG = 3388 sw/a_
450 400 350 300 250 200 150 100 50 1990 92 94 96 98 2001
-- -#12SG
- -m#11SG 5
NRC Presentation March 19, 2002 mm-m m
mmm m
I I
I 0
Om m
mW-
NMCle Committed to Nuclear "Excellenc PINGP Unit 1 SG Status (thru January 2001)
Total Tubes Defective
- 11 SG 817
% Tubes Defective
% Equivalent Plugged 5.05%
12.26%
- 28 sleeves = 1 plug 8.65% Average 6
NRC Presentation March 19, 2002 0
24%
1076 47%
NMC Committed to Nuclear"Excellence Justification for Replacement Economic - No Safety Concerns:
Increasing repair costs Potential need for planned mid-cycle inspections, forced outages Increasing outage time Reduction in plant output Replacement energy costs NRC Presentation 7
March 19, 2002
Committed to Nuclear" Project Participants RSG Engineering & Fabrication Framatome-ANP selected as RSG vendor
- Engineering & licensing support - Framatome-ANP
- Major forgings - Japan Steel Works
- Tubing - SANDVIK Steel Installation Contractor The Steam Generating Project Management Team (SGT, Nuclear Management Company
- Project management & oversight personnel NRC Presentation March 19, 2002 Ltd.)
8
SGR Project Organization NMClrce Committed to NucleaIr xeI l J -- T SGRP QoNQC OVERSIGHT NRC Presentation March 19, 2002 9
Project Milestone Schedule Committed to Nuclear Excellence Polar Cr Installation Contract February '01 KNovember 2001 Fat I
O March '02/N OJune ication Begins September '04 SGR Outage D'eml~ivery at PINGP M~ai,'Mlp ajor Forgings Comple
'02 Tubing Complete I
i 1
2001 2002 2003 2004 NRC Presentation March 19, 2002
-H 10 January '01 Refueling Outage N-2 Walkdowns November '02 Refueling Outage N-1 Walkdowns &
rane Mod Fabrication Contract August '00 I
2000
NMCIii Committed to Nuclear Excellence Component Design Richard Pearson 11 NRC Presentation March 19, 2002
Committed to Nuclear Excellence RSG
- Improved tubing material.
Component Alloy 690 (TT) vs. 600 (MA)
° Maximum heat transfer surface area
° Up to 10% plugging at maximum fouling conditions & normal power levels
- Design accommodates potential power uprate conditions NRC Presentation March 19, 2002 o RSG Design Philosophy 12
NMCIeI*
Committed to Nuclear"Excellenc RSG Component RSG Design Philosophy
"* High efficiency steam moisture removal
"* Water level stability
"* Mitigation of thermal stratification effects
"* Elimination of water hammer risks
- Mitigation of tube bundle vibration
"* Compatible with existing external interfaces - No major modifications
"* OSG operating experience reflected in design NRC Presentation 13 March 19, 2002
NMCle Committed to Nuclear "Excellence RSG Component o RSG Design Basis
- Safety Related and Non-Safety Related Design Bases Unchanged NRC Presentation March 19, 2002 14
NMC e Committed to Nuclear Excelle[ce RSG Component
"* Two-Piece Design
"* ASME Section III Vessel
"* Use of Code Cases 2142 and 2143 for Nickel Alloy Welding of Partition Plate NRC Presentation March 19, 2002 15
NMCerele Committed to Nuclear "Excellenc Framatome-ANP Experience 9
Supplied 272 Steam Generators Worldwide 0 75 RSGs 19 for Foreign Utilities 56 for EDF 0 Facility Capable of Producing 14 SGs per Year 0 Maintained N and NPT Stamp Certifications for > 20 Years NRC Presentation March 19, 2002 16
Committed to Nuclear EDFExperience Unit C.O.
SG R1-R2 PWSCC IGA/SCC IGANSCC OD Wear - Loose TSP Def.
Other Total name Tube Roll Trans.
@TSP level
@ Sludge circ. Fatigue parts Frag TS-TSP cause plugged SGR Mat.
Rugged Rug.d Plug.d Plug Cumulated number of plugged tubes Y-SG Dates cracked cracked cracked d
Dam 1 79-90 69-0- 0 0-0-0 0
0-0-0 0
0-0-0 0
0 5-0 0
0 0 - 0 0
5 Dam 1 80-95 6901T 0-0 0-0-0 0
0-0-0 0
0-0-0 0
0 0-0 1
0 0-0 2
3 Tri 1 80-98 690Tr 0-0 0-0-0 0
0-0-0 0
0-0-0 0
0 0-0 4
0 0-0 5
9 Tri 2 80-97 690T-0-0 0-0-0 0
0-0-0 0
0-0-0 0
0 0-0 0
0 0-0 1
1 Tri 3 81-02 690TT- 0-0 0-0-0 0
0-0-0 0
0-0-0 0
0 0-0 0
0 00-0 Gra 1 79-94 690TT 0-0 0-0-0 0
0-0-0 0
0-0-0 0
0 0-0 0
0 0-0 4
4 Gra 2 80-96 690TT 0-0 0-0-0 0
0-0-0 0
0-0-0 0
0 0-1 0 04 0
0-0 2
6 Gra 4181-00 69oTrh 0-0 0-0-0 0
0-0-0 0
0-0-0 0
0 0-0 0
0 0-0 2
2 SLB 1 83-95 690TT 0-0 0-0-0 0
0-0-0 0
0-0-0 0
0 0-0 5
0 0-0 3
8 Pen 2 Nov-92 690TT 0-0 0-0-0-0 0
0-0-0-0 0
0-0-0-0 0
0 13-0 8
0 0-0 4
24 Gol 2 Mar-94 690Th 0-0 0-0-0-01 0
0-0-0-0 0
0-0-0-0 0
0 1-0 10 0
0-0 2
13 Cho 1 May-00 690TT 0-0 0-0-0-0 0
0-0-0-0 0
0-0-0-0 0
0 0-0 0
0 0-0 12 12 Cho 2 Sep-00 690TT 0-0 0-0-0-0 0
0-0-0-0 0
0-0-0-0 0
0 0-0 1
0 0-0 2
3 Civ 1 2000 690TT 0-0 0-0-0-0o 0-0-0-0 0
0-0-0-0 0
0 0-0 1
0 0-1 11 13 Civ2 2000 690Th 1 0-0 0-0-0-0 0
0-0-0-0 0
0-0-0-0 0
0 0-0 0
0 0-0 6
6 Other causes: plugged tubes for reasons such as magnetic anomalies, rolling anomalies, etc..
NRC Presentation March 19, 2002 17
Committed to Nuclear Excellence Framatome Model 56/19 RSG
° Thermal-hydraulics design provides optimum velocity profile, circulation and water level stability.
- Stainless steel broached tube support plates for straight sections.
1 Five sets of AVBs support the U-bend region of tubing to reduce gaps.
- Full tube-to-tubesheet expansion process.
° Improved wrapper support system.
NRC Presentation 18 March 19, 2002
Framatome Model 56/19 RSG Committed to Nuclear Excelle
- Enhanced bolting design & graphite gaskets for leaktight access openings.
. Easy access to upper internals and top of tubesheet.
0 Clear tube lane & top of tubesheet for sludge management.
l Additional inspection handholes at key locations.
l Steam outlet flow restrictor integral to RSG elliptical head.
0 High-efficiency moisture separators utilized.
NRC Presentation 19 March 19, 2002
Committed to Nuclear Excellence RSG Component Structural Design
- ASME Section III Normal/Upset/Faulted Conditions Load Combinations
- Normal
- Normal & OBE
- Normal & DBE
- Normal & Pipe Rupture
- Normal & DBE & Pipe Rupture NRC Presentation 20 March 19, 2002
Committed to Nuclear Excellence RCS Structural Model RCS Structural Evaluation
"* OEM (Westinghouse) - Analysis of Record
"* Framatome-ANP, Inc. providing new RCS analysis with RSG
"* Deadweight, thermal expansion & seismic loading
"* Develop loads on components & structures due to pipe breaks
"* Leak-Before-Break (LBB) will be maintained with RSG NRC Presentation 21 March 19, 2002
RSG/OSG Comparison Committed to Nuclear Excellene RSG OSG Thermal Output (MWt) 825 825 Thot/Tcold/Tave (nominal)
(deg F) 590/530/560 590/530/560 Number of Tubes 4868 3388 Tubing OD/ID (in.)
0.75/0.6642 0.875/0.775 Heat Transfer Area (sq. ft.)
61,281 51,500 Performance Coefficient UA (106 Btu/hr-F) 81.93 67.52 RCS Flow (best estimate) (106 lbm/hr) 38.51 38.39 RCS Pressure (psia) 2250 2250 Steam Flow (106 Ibm/hr) 3.57 3.54 Full Load Steam Outlet Pressure (design normal operating) (psia) 806.8 750 Maximum Moisture Carryover
(%)
0.1 0.25 Operating Weight (lbf) 802,055 801,073 Primary Side Volume (cu ft) 1127 1089 Secondary Side Liquid Mass (Ibm)
Hot Zero Power 159,100 157,123 100% Power 107,100 107,420 NRC Presentation March 19, 2002 22
NMC-Committed to Nuclear Excellence SG Program Elements Related to RSG Design
- Assessment of potential degradation mechanisms Inspection Integrity assessment Maintenance and repairs Maintenance of secondary-side integrity Secondary-side water chemistry Foreign material exclusion NRC Presentation 23 March 19, 2002
Committed to Nuclear Excellence Audit/Surveillance Activities NMC Supplier QA Program
"* Plans & controls audit activities of SGR Project Suppliers
"* Monitors compliance with Supplier Quality Programs
- Procurement & Fabrication activities and schedule
"* Performed Framatome-ANP surveillance Participated in Framatome-ANP audits of sub-vendors JSW, Sandvik, FOMAS
"* Participated in NUPIC audit of Framatome-ANP Inc.
"* Performed audit of SGT PINGP Site QA Audit Group
° Annual Project Team Audit NRC Presentation 24 March 19, 2002
Committed to Nuclear Excellene Fabrication Oversight
- Sandvik - Purchasers Authorized Representative (PAR) on site at Sandvik Steel
"* Japan Steel Works - visits by Project
"° Fomas - visits by Project Team
" ANI NRC Presentation March 19, 2002 Team 25
Committed to Nuclear Excellence Fabrication Status Framatome ANP Chalon-Saint Marcel
"* Expected to receive all major component forgings by end of March, 2002
"° Currently the first tubesheet is being drilled SANDVIK
- Pre-production qualification tubing
- Production tubing run started NRC Presentation March 19, 2002 run complete 26
Committed to Nuclear Excellence Licensing Approach Oley Nelson 27 NRC Presentation March 19, 2002
Committed to Nuclear"Excellence 10CFR50.59 Scope 28 NRC Presentation March 19, 2002
NMC Committed to Nuclear Excellence" USAR Accidents & Other Analyses
- Licensing Basis
- Evaluation
- Chapter 14 Process Transients & Accidents
- Potential NRC Reviews NRC Presentation March 19, 2002 29
NMCla Committed to Nuclear "Excellenc USAR Chapter 14 Licensing Basis
"* PINGP Licensed in 1974
"* Not SRP plant
"* Approved to conduct safety analysis 1983 NRC Presentation March 19, 2002 30
Committed to Nuclear"Excellenc Holder of Analysis of Record
" NMC
- All Chapter 14 Analyses
- except,
"° Westinghouse
- Long Term Core Cooling NRC Presentation March 19, 2002 31
Committed to Nuclear Excellence Safety Evaluation Process
"* Identify key SG parameters
"* Compare the OSG and RSG parameters
"* Assess RSG impact USAR remains bounding, or
- Analyze using NRC-approved methodology NRC Presentation March 19, 2002 32
Committed to Nuclear Excellene Key Design Parameter Comparison
"* Small increase in secondary operating pressure
"* Small increase in RCS volume
"* Smaller SG tube ID
- Higher tube bundle heat transfer rate NRC Presentation March 19, 2002 33
Committed to Nuclear Excellene Accident Evaluations Impact on Fuel Criteria
"* Reactivity coefficients are not affected
"* Power distributions are not affected
"* Rod Worth is not affected
"* Min RCS Flow will not change
"* USAR Transients Bound RSG - except MSLB NRC Presentation 34 March 19, 2002
NMClea Committed to Nuclear "Excellenc Accident Evaluations Impact on Primary Pressure
"* Cooldown events
- Not an issue
"* Heatup events
- UA f benefit
- USAR Transients bound RSG NRC Presentation March 19, 2002 35
Committed to Nuclear Excellene Accident Evaluations Impact on Secondary Pressure
° Cooldown events
- Not an issue
- Heatup events
- UA 1t adverse impact
- Reanalyze limiting events NRC Presentation 36 March 19, 2002
Committed to Nuclear Excell/ene Accident Evaluations Impact on Containment Analysis MSLB
- UA f adverse impact
- Secondary mass approximately same
- Reanalyze event
- Volume T adverse impact
- Reanalyze event NRC Presentation 37 March 19, 2002
NMC Committed to Nuclear Excellene Accident Evaluations Impact on Dose
"* Number of failed pins not affected
"* TS activity limits not affected
"* Smaller Tube ID beneficial for SGTR NRC Presentation March 19, 2002 38
RMCCdt Committed to Nuclear Excellene RCCA Withdrawal at Power Secondary System Pressure 0 UA ft transfers more energy 0 Expect SG Safeties to limit pressure NRC Presentation March 19, 2002 39
NMC '
Committed to Nuclear Excellene Loss of External Electric Load Secondary System Pressure
"* UA f transfers more energy
"* Expect SG Safeties to limit pressure NRC Presentation March 19, 2002 40
Committed to Nuclear Excellence MSLB - Core Response
"* UA ft -larger cooldown
"* Modeling tube uncover - benefit
"* May not need to perform sub-channel analysis NRC Presentation March 19, 2002 41
NMC-Committed to Nuclear Excellence MSLB - Containment Response
- UA f transfers energy at a higher rate NRC Presentation March 19, 2002 42
NMC l Committed to Nuclear Excelle[e LOCA - Containment Response
- Small increase in RCS Volume NRC Presentation March 19, 2002 43
Codes Used for Reanalysis
"* LOCA & Non-LOCA Transient Analysis:
- RELAP5/MOD2 - B&W
"* LOCA and SLB Containment Response CONTEMPT NRC Presentation March 19, 2002 Committed to Nuclear Excellene 44
NMC '
Committed to Nuclear Excellence Potential NRC Reviews Submit at least 1 year prior to SGR Outage:
0 Revised SG surveillance requirements for Unit 1 0
Revised TS analysis methodology
- ASME Code Case relief NRC Presentation March 19, 2002 list for Unit 1 45
USAR Chapter 14 Core and Coolant Boundary Protection Committed to Nuclear Excellene Accident RCCA Withdrawal Subcritical RCCA Withdrawal-At Power (DNB, primary pressure)
RCCA Withdrawal-At Power (secondary pressure)
RCCA Misalignment - Static
& Dropped Chemical Volume & Control Malfunction Startup of Inactive RC Loop FW System Malfunction Heat Removal USAR 14.4.1 14.4.2 14.4.2 14.4.3 14.4.3 14.4.5 14.4.6 Effect of RSG Disposition Doppler & rod worth unaffected UA f] - beneficial (if any impact) for DNBR Doppler & rod worth unaffected UA f - beneficial (if any impact) for DNBR UA beneficial for primary pressure UA f - analyze secondary pressure Static power distribution unaffected Doppler & rod worth unaffected UA f - beneficial (if any impact) for DNBR RCS volume T - beneficial Bounded by other transients FW conditions unaffected Secondary pressure T - beneficial NRC Presentation March 19, 2002 E
E A
E E
E E
46
Core and Coolant Boundary Protection Accident Excessive Load Increase Loss of RC Flow Coastdown Loss of RC Flow - Locked Rotor Loss of External Electrical Load (DNB, primary pressure)
Loss of External Electrical Load (secondary pressure)
Loss of Normal Feedwater Loss of Offsite Power USAR 14.4.7 14.4.8 14.4.8 14.4.9 14.4.9 14.4.10 14.4.11 Effect of RSG Disposition Steam load increase unaffected RC AP I - beneficial UA ft - beneficial for primary pressure Secondary pressure bounded by other transients Power distribution unaffected UA ft - beneficial for primary pressure UA f - beneficial (If any impact) for DNBR UA ft - analyze secondary pressure liquid mass T at low level trip - beneficial Considered as part of LNFW, 14.4.10 NRC Presentation March 19, 2002 USAR Chapter 14 NMC e Committed to Nuclear "Excellenc 47
Accident Fuel Handling Accidental Release - Liquid Accidental Release - Gas Steam Generator Tube Rupture Steam Pipe Rupture (SLB)
SLB Containment Response SLB Dose RCCA Ejection USAR Chapter 14 Standby Safety Features Analysis USAR Effect of RSG 14.5.1 Unaffected by RSG 14.5.2 Not analyzed in USAR 14.5.3 Unaffected by RSG 14.5.4 Tube ID I beneficial for dose SG available volume I vs. Tube ID benefit for overfill 14.5.5 UA f - analyze for core response 14.5.5 UA 1t
- analyze 14.5.5 Different steam release to RHR cut-in 14.5.6 UA 1t - beneficial for primary pressure Doppler & Rod worth unaffected NRC Presentation March 19, 2002 NMC-Committed to Nuclear Excefllene Disposition E
N/A E
E A
A E
E 48
Nuc Committed to Nuclear "Excellec USAR Chapter 14 Reactor Coolant Pipe Rupture Analysis Effect of RSG Disposition Large Break LOCA - PCT Large Break LOCA Containment Small Break LOCA - PCT Anticipated Transient Without Scram 14.6 App. K 14.7 14.8 Tube flow resistance, - beneficial Tube plugging limit I - beneficial Primary inventory delta < 1.5%
Natural circulation T beneficial UA 1t beneficial for ECCS flows Beneficial and/or no effect NRC Presentation March 19, 2002 Accident USAR E
A E
E 49
NMCeEln Committed to Nuclear "Excellenc Installation Plan Scott Marty NRC Presentation March 19, 2002 50
Committed to Nuclear Excellence Installation Contractor The Steam Generating "eam SGT, Ltd.
Washington Group International, Inc./
Duke Engineering & Services, Inc.
Company Completed or In Progress
"* Point Beach Units 1 & 2
"* DC Cook Unit 2
"* St. Lucie Unit 1
"* Indian Point 2
- Calvert Cliffs Unit 1 Future
"* Calvert Cliffs Unit 2
"*Oconee Units 1, 2 & 3
"*Callaway NRC Presentation March 19, 2002 51
NMCla xe Committed to Nuclear"xcellence Arrival at PINGP - May 2004 RSGs arrive by barge in May 2004.
Average date for first tow over last 30 years is March 19th. Latest date was May 11, 2001 due to spring floods
° Off load using a rubber tired, multi axle, self propelled modular transporter OSG Arrival circa 1968 NRC Presentation March 19, 2002 52
Steam Generator Removal/Replacement Unit 1 Equipment Hatch Shield Blocks
" Two piece replacement through the existing equipment hatch with new lower assembly and new steam dome
"* One cut per RCS nozzle with narrow groove automatic welding of RCS
"* Removal /IReplacement methods similar to OSG Installation Two piece construction with field weld at the transition cone upper girth joint SG upper & lower assembly transported through the equipment hatch and up-ended SG assembly load handling with existing 230t capacity polar crane.
Engineered Lifts will be utilized with maximum expected load < 250t NRC Presentation March 19, 2002 53 NuMCea Ij Committed to Nuclear "Excellenc
Committed to Nuclear Excellence Steam Generator Removal/Replacement II 9 IPJ1Il
i4i
" Minimal piping changes: Blowdown piping re-route due to RSG nozzle relocation for thermal hydraulic considerations
"* Additional wide range water level taps
" Girth weld joint optimized for OD welding. Automatic weld process is being considered
"* No concrete removal is anticipated NRC Presentation March 19, 2002 2
j I I.l.
V.
K 54
NMC Committed to Nuclear Excellence 2001 Unit 1 [N-2] Outage
"*Polar Crane Inspections
"*Photogrammetry Measurements As-built dimensions of primary and secondary nozzles and support pads to verify RSG Design Rigging constraints: Polar Crane, Equipment Hatch and Vault Walls
"*Laser scanning of equipment chase for input to rigging studies
"*Walkdowns to obtain input information for design and construction and formulate conceptual plans
" *Primary weld joint UT measurements NRC Presentation 55 March 19, 2002
Committed to Nuclear"Excelle 2002 Unit 1 [N-I] Outage
"* Polar Crane
- Modifications per Whiting Corporation to restore crane to 230t capacity
- Re-rope crane per Whiting Inspection Services recommendation
"* Additional Laser scanning of equipment chase with equipment hatch open for input to rigging studies
"* Walkdowns to verify conceptual installation plans and design change packages NRC Presentation 56 March 19, 2002
NMC Committed to Nuclear Excellence Radiation Protection - ALARA
"* OSG Lower Assembly
- Water level will be controlled to provide shielding during removal
- Shield plates will be installed over all openings
"* Shielding
- RCS pipe ends. Pipe end decon is being evaluated RTD bypass manifold
- Other locations
"* Mock-up Training
- Channel head entry / work
- RCS pipe work NRC Presentation 57 March 19, 2002
NMC Committed to Nuclear Excellence J
Post Installation Testing
" RCS and SG support thermal monitoring program to verify RCS thermal expansion
" RSG Secondary side post installation testing in accordance with ASME Section III to support vessel ASME "N" stamping RCS Primary side post installation testing in accordance with ASME Section XI
"* Secondary side piping and nozzle welds post installation testing in accordance with ASME Section Xl NRC Presentation 58 March 19, 2002
NMC '
Committed to Nuclear Excellence Current Status
"* Preliminary Rigging Studies: Inside and Outside Containment. 3-D modeling of equipment chase
"* Meetings with RSG Fabricator to resolve interface issues related to RSG design and installation
"* Installation Contractor is developing project specific procedures
"* Collecting and Evaluating Industry SGR Lessons Learned Participated in Kewaunee SGRO Ongoing visits to Calvert Cliffs SGT database of Lessons Learned Interface with Plant Outage Planning NRC Presentation 59 March 19, 2002
Suggested Future Meetings NMCla Committed to Nuclear Excllenc Ken Albrecht - Project Manager
"* Fall2002
"* Spring 2003
"* Spring 2004 Fabrication Licensing & Fabrication Update Pre-installation 9 Others if needed NRC Presentation March 19, 2002 60