DCPNRC_003210April 10, 2012
ENCLOSURE 4
Presentation Slides "AP1000® First Plant and First Three Plant Tests Comprehensive Vibration
Assessment Program (CVAP) Instrumentation and Analysis Plans"
(Non-Proprietary)
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Agenda
" Purpose
" Background and previous submittals
" Description of changes and implications
* Current approach and methodology for complying withRG 1.20, Rev. 2
" Near Term Submittals
" Closing Questions, Comments
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Purpose
* Summarize the technical aspects of the AP1000 CVAPprogram
" Obtain NRC comments in preparation for the submittal oftwo reports in April:- Vibration Analysis Plan for AP1 000 CVAP
- AP1000 CVAP Measurement, Test and Inspection Plan
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Background and Previous Submittals
" The AP1000 DCD describes CVAP in section 3.9.2
* The details of the CVAP Pre-Hot Functional Test (Pre-HFT)report are provided in two referenced technical reports- WCAP-15949-P, Rev. 2 (APP-MI01-GER-001, Rev. 2)
- WCAP-1 6687, Rev. 1 (APP-GW-GLR-001, Rev. 0)
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WCAP-15949-P,Rev.2
" Describes Analysis- Comparison with and scaling from previous CVAPs and tests
- Modal results based upon system model
- Analysis results and margins
" Measurement Plan- Table of sensors
" Test conditions
" Table and Figure for Inspection
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WCAP-16687-P, Rev 1
Expected and Allowable Sensor Responses- For Hot Functional Test (HFT) conditions
- HFT pressure and temperature
- 4 RCPs, 100% speed
- No core or core simulator (with justification)
- Table of sensors
- Table and figure for inspection
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Pre-HFT Report Conclusions
*RVI evaluations demonstrate acceptable margins toendurance limits
e Expected and allowable sensor responses provided for onetest condition
" Measurement Plan and Inspection Plan defined
* Report methods and results were based upon the RVIdesign and operating conditions at that time
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Description of Changes and Implications
Design change APP-GW-GEE-411 changed the in-coreinstrumentation (ICI) system from the "Upper MountedInstrument Assembly" design to the "Instrument GridAssembly" (IGA) design
- Allowed lCIs to be stored in the upper internals (shielded) duringoutages
- Allowed reduction in the number of RV closure head penetrations forICs from 42 to 8
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Instrument Grid Assembly
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Impact of IGA on CVAP
" IGA consists of multiple tubes and supports in the RVUpper Head
" The AP1000 utilizes cooling nozzles to provide flow fromthe down-comer to the upper head.
" The increased potential for flow induced vibration effectshas prompted the need for:- More detailed predictive methods and
- Incorporating the hydraulic resistance of the core to achieveprototypic velocities in the upper head
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Impact of IGA on CVAP...
" Predictions are based on analyses and utilize detailedassembly models
" HFT will use flow restrictors to simulate the hydraulicperformance of the fuel and provide prototypic upper headvelocities
" Number of sensor locations on the IGA is 31, comparedwith 5 on UMIA
" Specify pre-HFT and post-HFT inspection locations for theIGA
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Other Significant Updates for CVAP
" Sensor predictions will be provided for multiple testconditions (RCS pressure & temperature, RCP pumpspeed, pump operating configurations)
* Predictive analyses will address uncertainties.
" Total number of sensors increased from 51 to 97
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US Regulatory Requirements
" NRC Requirements- General Design Criteria (GDC) 1 and 4 in Appendix A to 1 OCFR50- 10CFR50.34 (documentation requirements)
- Requirements can be met by following guidance provided in RG1.20, Rev. 2
" DCD Rev. 19- Commits to following RG 1.20, Rev. 2
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RG 1.20, Rev. 2
" Objective- Verify the structural integrity of reactor internals for flow induced
vibrations prior to commercial operation
" Major Elements of CVAP- Predictive analysis
- Test and Measurement
- Inspections
- Documentation
- Predictive analysis report (Pre-HFT report)
- Preliminary test report
- Final (Reconciliation) report
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RG 1.20 Plant Design Categories
* "Prototype"- Unique or first of a kind design
- Has to go through analysis, test, measurement and inspection
- Sanmen 1 will be "Prototype" prior to CVAP test
" "Valid Prototype"- A "Prototype" plant that has successfully gone through CVAP
- Sanmen 1 will be classified as "Valid Prototype" after thesuccessful CVAP
* "Non-Prototype Category 1"- Subsequent plants similar in design to "Valid Prototype"
- Requires analysis and either measurement or-inspection
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Predictive Analysis
* Objective is to consider all flow induced forcing functions,predict response of reactor internal structures anddemonstrate that they meet the acceptance criteria
* Forcing Functions- Vortex shedding
- Turbulence induced
- Pump induced
- Vessel motion
* Velocity field either by CFD or simplified methods
* Turbulence induced forcing function using standardcorrelations
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Predictive Analysis Contd.
* Structural Response- Finite element models for major assemblies
- Modal analysis
- Forced response analysis
* Acceptance Criteria
- Alternating stress intensity at limiting location is limited to fatigue curvevalue at 1011 cycles in the ASME Boiler and Pressure Vessel Code, SectionIII, Appendix 1-9.0
" Simulation models - FEM or CFD validated and benchmarked
- Grid sensitivity studies
- Modal and damping test
- Scale model test for CFD
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Predictive Analysis Contd.
e Testing- IGA
- Mock up test to measure fundamental frequencies and damping
- IGA Hydraulic Test
- Quarter scale, quarter symmetry
- Most of the major structural components modeled
- Core Barrel
- Full scale modal test if possible
- Data from the legacy scale model tests, CVAPs, HFTs
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Predictive Analysis Contd.
* Biases and Uncertainties- Biases and uncertainties will be assessed for each major step of the
analytical and test process
- They will be combined mathematically to derive a overall uncertaintyfor the predictions
- Comparison with the CVAP test measurements will provide the final"end to end" uncertainty
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Measurements
* Different types of sensors utilized- 31 accelerometers (7 external),- 53 strain gages,- 5 dynamic pressure transducers (2 on IGA and 3 on core barrel),- 8 Linear Variable Displacement Transducers (LVDTs) - 4 on upper
support/IGA and 4 on Core Shroud radial keys
* Sensor location criteria- DCD Commitment- Critical to safety- New component- High stress areas- Analytical model validation- Based on previous experience
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Measurement Contd.
* Sensor Specifications
- Static Pressure: 2250 psig design, 3300psig maximum
- Operating Temperature: 5570F design, 68 0F to 600°F maximum
- Surrounding Medium: Water with HFT required Primary Chemistry
* Sensor Sensitivity and Measuring Range
- All sensors will have enough sensitivity and measurement range to adequatelycapture all meaningful sensor data.
" Sensor Reliability /
- In order to assure high reliability, sensors that have been used in similar testsare selected. They will be tested and calibrated prior to use
" Sensor Redundancy
- Additional sensors are carefully selected to still be able to get meaningful dataeven in the event of sensor failure
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Sensor Mounting
* Mounting hardware requirements:- Designed to withstand the HFT test conditions
- Installation and removal will be performed by qualified installers
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Mounting Hardware Considerations
* Mount sensors as close to the locations of interest aspossible
e Measurement quality not adversely affected by sensorattachment method
" Prevent cable failure and limit cable vibration
* Prevent loose parts
* No damage to RVI
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Permanent Modifications for CVAPa,c
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Test Conditions
" Cover expected range of pump RPM, coolant temperatures,and flow rates from the initial zero flow condition to hotstandby temperature, pressure and flow conditions
" Transients involving various pump speeds and pumpoperating configurations
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Inspections
" CVAP requires detailed visual inspections of reactorinternals pre and post test to ensure no damage hasoccurred
" Visual examination is performed:- On critical surfaces to see if there are any cracks
- On welds to see evidence of cracks
- On interface surfaces to see evidence of wear or distress
- On fittings to see if they are tight
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Documentation
e CVAP documentation per RG 1.20, Rev. 2
- Predictive analysis report to be submitted prior to the test
- This report provides best estimate structural response predictions andacceptance criteria
- Also, provides measurement, test and inspection plans
- Preliminary test report at the conclusion of CVAP test
- Includes measurement results, inspection results
- If all acceptance criteria are met, plant is allowed to load fuel
- Final reconciliation report
- This report reconciles any and all significant differences betweenanalytical predictions and measurements
- This provides an end to end estimate of uncertainty for the program
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WCAP-1 7534Vibration Analysis Plan for API 1000 OVAP" The Analysis Plan provides:
- Methodology for predicting dynamic response of internal structuresdue to all flow induced loads for normal operating and transientconditions
- Methodology for determining the expected and acceptable responseof sensors to demonstrate the structural integrity of reactor internals
" Consistent with RG 1.20, Rev. 2 requirements
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WCAP-1 7534 Vibration Analysis Plan Contd.
* Details for:- Assessing various forcing functions for all internals
- Turbulent buffeting, pump induced pulsations, vortex shedding,vessel motion
- Computational Fluid Dynamics (CFD) models benchmarked byscale model test used to obtain velocity fields for Upper Head
- Correlations and models used for Lower and Upper Internals regions
- Finite element structural models for modal analysis and forcedresponse analysis
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WCAP-1 7534 Vibration Analysis Plan Contd.
" Methodology for determining expected structural responseof internals using detailed ANSYS assembly models.
" Methodology for uncertainty analysis to evaluate the overalluncertainty in the predictions for comparison with CVAPmeasurements
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WCAP-1 7584 AP1 000 CVAP Measurement,Test and Inspection (MTI) Plan
" Provides criteria for selecting components for measurementand inspections
" Provides typical sensor types and locations based uponexisting analyses and experience
" Provides transducer specifications to ensure accurate andreliable measurements
* Provides requirements for the Data Acquisition System(DAQ)
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WCAP-17584 Measurement, Test andInspection (MTI) Plan Contd." Provides criteria for type of pre- and post-CVAP test
inspections and locations
" Provides proposed CVAP test conditions
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CMarch27,2012 Proposed Licensing Process For CVAP Analysis, Test Performance Reports, and Removal of License Condition a, c
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CVAP Submittal Summarya,c
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