ML20072K093

Discusses Small break-auxiliary Feedwater Level for 205FA Plants

ML20072K093
Person / Time
Site:	Crane
Issue date:	08/01/1978
From:	Cartin L BABCOCK & WILCOX CO.
To:	Duerson S BABCOCK & WILCOX CO.
References
TASK-07, TASK-7, TASK-GB GPU-2210, NUDOCS 8307020238
Download: ML20072K093 (32)

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THE BABCOCK & WILCOX COMPANY POWER GENERATION GROUP To l

S. H. Duerson, Project Management a

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From L. R. Ca* tin, Plant Integration (2835) sos ses.s File No.

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205/145FA Plants Subj.

Date Small Break - Auxiliaff Feedwater Level August 1, 1978 l v ni. i i.,.................

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Re: 1)

R. C. Jones to S. J. Engel, " Auxiliary Feedwater Steam Generator Overfill Problem," Standard Plant 205, T.3.4, March 14, 1977.

L. R. Cartin to S. H. Duerson, "Small Break Auxiliary'.Feedwater,"

2)

All 205 Plants, September 15, 1977.

3)

N. H. Shah to D. H. Roy, " Status of 205FA Small Break LOCA Analysis,"

Standard 205FA, T3.4, March 30, 1978.

4)

A. F. McBride/E W. Swanson to D. H. Roy, "A Brief History of ECCS Steam Generator Level Requirements for 205FA Plant Design,"

March 28, 1978.

5)

D. H. Roy to B. A. Karrasch, " Auxiliary Feedwater Level Control for 205FA Plant," April 27, 1978.

6) E.h.SwansontoDistribution,"AuxiliaryFeedwaterLevelControl,"

All 205's, April 27, 1978.

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7)

E. W. Swanson to Distribution, " Steam Generator Level Taps,"

All 205's, May 3, 1978.

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E. W. Swanson to Distribution, " Steam Generator Level Taps," WPPSS

,.y G and Others, May 11, 1978.

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E. W. Swanson to Distribution, "Small Break Auxiliary Feedwater,"

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205 Plants, June 27, 1978.

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10) CI/A No. 88-4616-00, NSS032.

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L. H. Bohn to C. D. Thompson, " Steam Generator Level Taps," 21R11, May 31, 1978.

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J. H. Taylor's letter to S. A. Varga of the NRC, dated May 26, 1978.

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13)

J. H. Taylor to Distribution, " Preliminary Report of Safety Concern PSC 10-78," April 12, 1978.

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-14)

B. A. Karrasch to Distribution,-" Plant Integration Activites on ECCS E

-Small Break Analysis," June 20, 1978.

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Cartin to Duerson Page Two Small Break - Auxiliary Feedwater Level August 1, 1978 a

15)

E. W. Swanson to Distribution, " Auxiliary Feedwater Level Control,"

Standard, October 11, 1977.

16)

L. R. Cartin to S. H. Duerson, "Small Break - Auxiliary Feedwater,"

All 205FA Plants, June 26, 1978.

Presently, B&W has an NRC approved Small Break Analysis for the 205FA plants (BAW-10074, Rev.1). Analysis work to support the development of BAW-10074 was performed primarily in 1972, and this topical has served as the licensing basis for BSAR-205 and all backlog 205FA plants under both the so-called interim and fiaal (10CFR50.46 and Appendix K) acceptance criteria. This analysis assumed credit for filling the steam generators to approximately 40 feet with auxiliary feedwater (AFW) to aid in condensing steam in the hot leg; condensation permits depressurization of the loop resulting in increased HPI flow and serves to increase the total system liquid inventory.

Since the issuance of BAW-10074, systems to actuate and control the addition

'of AFW have evolved. Steam line breaks (SLB), loss of feedwater transients

.(LOFW), feedwater line breaks (FWLB), and LOCA's have all placed requirements on the C&I associated with the AFW system. FOGG logic to mitigate the SLB and FWLB transients and control of AFW to a six foot level, for anticipated transients (LOFW) and design basis events, to reduce thermal loadings on the steam generators and to eliminate the necessity for operator action (to limit potential overcooling transient and to prevent overfill of the steam generators by AFW) is now part of B&W's Standard Design. These modifications were made to achieve licensability of B&W's product line with the tentative approval of ECCS subject to confirmation by analysis to be performed in the future.

The need to perform a confirmatory analysis was initially sited in March, 1977 (Reference 1).

Preliminary plans were then established (Reference 2) in September, 1977 to initiate this analysis and to lay the groundwork in the l

l event design modifications to the AFW C&I are required.

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Reference 3 presents the results of the initial analysis by ECCS of small breaks for the 205FA plants. These results indicated,that a partial core uncovering would occur for breaks on the order of 0.05 f t'.

The principle changes in the analysis, reistive to BAW-10074, which produce this result were:

1.

The control of auxiliary feedwater (AFW) addition by the SRCI to maintain

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a nominal six foot level in the secondary side of the steam generators.

1 (BAW-10074 utilized a forty foot level control setpoint.)

2.

A more realistic simulation of primary to secondary system interaction (spacial heat transfer effects due to transient water volume / level changes within the primary-secondary tube bundle region) during the small break LOCA.

3.

The Appendix K requirement to incorporate leak models which distinguish between the subcooled and saturated blowdown regimes of the LOCA transients.

The combined effects of the above factors necessitate a need to consider alternate design provisions to enhance mitigation of the small LOCA's.

Since Reference 3 was issued, several activities have taken place; principle ones are:

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i Cartin to Duerson Page Three Small Break - Auxiliary Feedwater Level August 1, 1978 1.

Alternatives which could provide acceptable small break consequences in-cluding discharge models, criteria changes, operator action, larger HPI pump capacity, AFW level setpoint, use of the dump to sump equipment, etc. have been reviewed for potential use.

It was concluded that an adjustment (higher) in the AFW level control setpoint is the only viable option in that the remaining remedies are either not very beneficial, not licensable, not backfittable, or disallowed under 10CFR50.46 and Appendix K.

2.

An historical overview (Reference 4) was prepared in an attempt to put in perspective the evolution of B&W's present AFW control system (six foot level control setpoint) and the specific problems (maintenance of hot shutdont following non-LOCA transient, overfill and overcooling transients) for which it is designed to solve.

3.

The addition sud control of A W to a high level requires a change of monitoring and control instrumentation, including additional high level taps in the steam generator. However, of first priority was the addition of taps since installation is less expensive in the shop p,rior to stress relief than afterwards and that shop installation is much less. expensive than field installation.

(Rough estimates were that the new taps would cost $2-3,000 each in the shop versus about $100,000 per NSS in the field.)

Because of the installation cost difference, it was deemed beneficial (References 5 and 6) to add new taps to those generators in the shop now to avoid the complication of field installation. References 7-9 provide a su==ary of the specific design activities and decisions that have taken place. Level taps have been added on the WPPSS contract (see Reference 8),

and a CI/A proposing additional taps on PASNY has been prepared. Action on 4

other contracts has not been initiated since fabrication schedules do not call for final stress relief for at least ene year; design changes on these plants will be made following fim decisions on C&I requirements.

4.

The addition of level taps on steam generators in the field has been studied; it was determined to be feasible using flange connections. Cost estimates from the B&W Construction Company (Reference 11) have been formally requested based on preliminary design concepts.

5.

A re-analysis was perfomed of the 0.5 f t break by ECCS utilizing an l

improved small break, modeling techniques (Reference 12) developed during l

the resolution of PSC 10-78 (Keference 13). This evaluation utilized all three model changes described in Reference 12.

The results, however, merely confirm the conclusion drawn in Reference 3 that equipment changes are necessary to mitigate the consequences of a small LOCA. A presentation of the analytical findings has been given to the Section Manager of Plant Design, and Dr. Roy does concur thr.t sufficient work has been perfomed to demonstrate that the six foot auxiliary feedwater control setpoint in conjunction with the ECCS is unacceptable for small break mitigation.

A fomal summary of the calculation is being prepared now.

I With completion of Item 5 above, efforts to establish and imple=ent an acceptable AFW control system must be initiated. To achieve this end, a five-phase program l

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Cartin to Duerson Page Four Small Break - Auxiliary Feedwater Level August 1, 1978 is described below. This program is structured to include work which has taken place to date'and future activites that are required.

Phase I. - Problem Identification The analysis efforts (ECCS) to show that system design changes are necessary to enhance the mitgation of small breaks form the bulk of this phase of the program. These efforts will be essentially complete following documentation of the most recent analyses. Funding to date has been provided by TVA (Charge No. 04212A15). To cover past and anticipated efforts of Phase I, 450 manhours and 6 CDC hours will be required in addition to the 1000 manhours and 25 CDC hours provided in 0412A15.

Phase I has identified two principle factors which created the small LOCA problem. The first was the loss of a high (forty foot) AFW level control i

setpoint. The second was a previously unexpected result of the FAC. To meet the FAC, B&W Evaluation Models incorporated the use of leak correlations to distinguish between the subcooled and saturated blowdown per%ods of a LOCA.

However, no specific analyses were performed then (1974) to identify the specific consequence of this model change. Based on the work performed to resolve PSC 10-78, it is suspected that the six foot AFW level control setpoint-could be shown to be acceptable under pre-FAC guidelines. Confirmation of this fact could form the basis for partial cost recovery of analysis cost.

Your assistance in evaluating the feasibility of this cost recovery path is requested. Further analysis cost to confirm that the FAC contributed to creation of the small break concern is anticipated to be approximately 100 manhours and 8 CDC hours.

Phase II.

AFW Level Determination An acceptable AFW 1evel control setpoint is believed to be one which provides the foll: ring:

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Small LOCA mitigation. -

2.. Acceptable long-term consequences during all Chapter 15 events which utilize AW (SLB, FWLB, ' etc.).

l 3.

Thermal ~ stresses within the design capability of the IEOTSG during over-l cooling events (tube to shell AT is the primary concern).

To meet the above, the control setpoint must be minimized (as low as possible) to meet items 2 and 3, but-high enough to provide LOCA mitigation.

l To establish an acceptable AFW level, it is proposed that ECCS, Control Analysis (CA), and Safety Analysis (SA) perform invetigative analyses simultaneously.

~ These efforts (graphically displayed in Figure 1), are aimed at identifying:

-1.

The sensitivity of AFW level on the small break transient.

2.

The potential impact of a high AFW level on design overcooling event and the 1092 spec.

- 3.

Maximum AFW level control setpoint requirements (based on Engineering N

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Cartin to Duerson Page Five Small Break - Auxiliary Feedwater Level August 1, 1978 judgement) from an accident analysis standpoint (Chapter 15 event).

With the above information and some preliminary feedback from Mt. Vernon of the acceptability of higher AFW 1evels on select overcooling event (hand calculations to be performed by CA), a preliminary AFW level control setpoint can be chosen.

From a LOCA standpoint, sufficient analyses will be performed to demonstrate the adequaqr of the selected level across the full small break spectrum; licensing submittals (updates to small break topical report) can then be deferred with good assurance of acceptable results.

Phase III. AFW Level Confirmation j

Phase II analysis efforts will provide an acceptable AFW level setpoint and possibly a range depending on the sensitivity shown in LOCA calculations.

Insight gained by the initial evaluations by CA, SA and Mt. Vernon will also provide a better understanding of additional analyses that will be required to confirm that the AFW level setpoint is acceptable from a steam generator integrity standpoint and for other accident analyses. Anticip,ated Phase II activites and costs are shownon Figure 1.

It is not possible to identify the scope of work required by Mt. Vernon at this time because the impact of a higher AFW control setpoint on overcooling transients, tube to shell AT, etc.,

is not known. The preliminary review by Mt. Vernon of select overcooling events (hand calculations to be performed by Control Analysis) with a high AFW level should provide sufficient guidance during the AFW level control setpoint selection process to limit the amount of actual stress analyses which must be performed.

Phase IV.

Equipment Changes InadditionkodeterminationofanacceptableAFW1evelcontrolsetpoint, C&I equipment changes will be required. Questions which must be resolved are:

1.

How many level taps must be added to the steam generators?

2.

When must new equipment be ordered for plants approaching the OL stage of licensing?

3.

What are the instrument error requirements with AFW controlled with full range level instrumentation?

4.

When and how are equipment changes to be implemented on steam generators already in the field?

Per Reference 14, Plant Integration will proceed to determine the most economical (minimum hardware change), licensable approach utilizing a higher SRCI level control for steam generators in the field. A major output of this effort will be the number of taps to be installed in the field. A basis for selling an upgrade of the present two-channel SRCI steam generator level control system to a four-channel ESFAS system will also be developed. This activity will serve as a possible vehicle for partial cost recovery since an upgraded system will improve plant availability / reliability, provide protection from AFW overfill TZY'.M.

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Page Six Cartin to Duerson Small Break - Auxiliary Feedwater Level August 1, 1978 o

i (see Reference 15 for discussion of the problem) and aid in prevention of main feedwater overfill. The principle stimulus for this activity is the belief that the use of a four-channel (ESEAS) control scheme may be more desirable General than upgrading the two-channel, SRCI to a protection-grade system.

instrumentation requirements (range, accuracy, etc.) will also be developed based on Phase II and III analysis results. The above' level of effort will be required to establish the necessary groundrules to proceed with equipment change CI/A's and procurement activities. Actual C&I change cost will be identified per the issuance of CI/A's.

Lastly, level taps must be installed on the steam generators in the shop and possibly on units already in the field. If field installation is required, an FOAK level tap must be designed; installation techniques and costs must be developed; and appropriate CI/A's processed once the actual number of taps to be installed are known. Figure 1 also presents the potential cost identi-fied for this activity.

i Phase V.

Licensing - Small Break Submittal Following design confirmation of a AFW control system, a revision to the ECCS small break evaluation model will be required to incorporate analytical techniques to accurately predict steam generator performance during the small break transient.

A spectrum analysis will eventually be required followed by an update to BAW-10074.

TVA or WPPSS licensing schedules will ultimately control when this work is performed. At this time, however, it is anticipated to begin no later than fourth quarter of 1979. Anticipated costs are shown in Figure 1.

Summarv The five-phase program described above and in Figure 1, incorporates all known

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aspects of the AFW level problem known today. Changes in the scope of the The costs program are extremely likely as additional problems are identified.

shown in Figure 1 are essentially a "best guess" hased on our knowledge today, and they are consistent with those previously supplied per Reference 16.

Costs associated with equipment changes (design plus hardware costs) are notThese identified in Figure 1 since requirements for the hardware are not known.

type costs will be identified as the program proceeds.

Attached also, is a non-CPR work request and WA's to cover Phases I, II and These activities are essential for the parts of Phase IV for the 205 FA plants.Your assistance in securing the necessary funding t program to proceed.

these work activities is requested.

Lastly, the above program has been prepared specifically for the 205FA pisnts.

possess the same problems and similar activicks will be B&W 145FA plants do As per our discussions previously, the anticipated funding levels required.

(analysis) which may be required for the 145FA plants are:

ECCS approximately 3000 manhours /100 CDC approximately 700 manhours / 5 CDC Others T21"O9

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Cartin to Duerson Page Seven Small Break - Auxiliary Feedwater Level August 1, 1978 No work is anticipated for this plant type for at least one year. Input from the 205FA plant resolution program will tend to minimize analysis and hardware development costs.

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-B. L. Brooks J. R. Burris W. A. Cobb J. F. Cuvilier

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. 4!-CPR WORR REQUEST FORM Phase I = 1450/31 = $56K Top Rate WA #0412A15 e' NCTR #

7 r/S Manhours 2560 X

=$ 52,480 Contract or Rish Program CDC llours 49 X

=$ 41,650 No. -

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Contract or Risk Program Total /Affceted Contract =$ 94,130 Phase II'

.R-39-ECCS/R42 ECCS Edwe Name 90s rces e-,n p..a._

i,,xiliary reedwater Level Total Min. Impact

$598,000 WA Nos.

SeeAttachedRiskAssessmenk**

• E*"

8' Steam Generator (529)

Control Analysis (393) ECCS (394)

Plant Integration (352) Safety Analysis (325)

Mt. Vernon Mech. Design Unit (s) Licensing (346)

Cost Center Organization requesting work: URF originator Plant Desien Note: WA for Mt. Vernon is not attached.

PM Risk (Hardv Duerson)

Manhours requested include 200

-manhours for their activities.

Other Cause:ECCS Analysis assumes a high steam eenerator level to assist small break mitigation: this program vill:

(1) Add high level measuring taps, l

(2) Determine the ECCS level needed, (3) Define upper li=its for level per Safety Nature of Work:

See Attached WA's and WPD's.

Work is result of:

Inadequate W3S Cost Base Line Without Contingency Inade'quate WBS Scoce Base Line Without Contingency Error or Change which Invalidates Previously Co=pleted O

New information: Recent ECCS analysis indicates the as; designed xx Othersix foot level is not sufficient; the previous forty foot level assumption is not compatible with other design needs.

Has PM. reviewed and concurred with need and non-CPR status? xxYes No Should Standard Plant W3S be revised?

Yes xx No l

List WA No(s). and dollar value for each WA which has bee'n identified l.

as offset:

l 64 ;

J

/ 7 7/

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Uni,t Manager

/Dade SectionMandei-C h 7)

IIELP STAMP OUT T2189c.:

PROFIT DECRADATION

-. _. - - -,. - _ _ _ - - _ -.. - _.. -. - _. - -.. - -. -. -. -.. -. - _ -. - - _ -