u.s. epr leak-before-break (lbb) methodology
TRANSCRIPT
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1> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
U.S. EPR Leak-Before-Break (LBB) Methodology
AREVA NP Inc. and the NRCJune 26, 2008
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2> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Introduction
Russ WellsLead Licensing Engineer, Chapter 3
Regulatory AffairsNew Plants Deployment
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3> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Agenda
> Meeting Objectives (R. Wells)> EPR LBB Approach and Methodology (A. Nana) > Summary (A. Nana)> Combined License Information (COL) Items
and ITAAC (R. Wells)> Surge Line Stratification (T. Bhagwagar)
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4> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Meeting Objectives
> Provide an overview of the LBB approach on three piping systems for U.S. EPR
> Provide clarifications and responses to initial comments/questions
Identify key internal references for audit review
> Respond to questions regarding NRC confirmatory LBB analysis
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5> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
U.S. EPR LBB Approach
Ashok NanaLead Engineer for LBB Analyses
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6> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Overview
> Three high-energy piping systems are identified for LBB
Main coolant loop (MCL) piping• Hot leg, cold leg and crossover leg
Pressurizer surge line (SL), andMain steam line (MSL) piping inside containment• From steam generators to first anchor point location at
Containment Building penetration
3 LBB Piping Systems
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7> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Isometric View Showing MCL and SL Piping
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8> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Plan View of MCL Piping
See FSAR Tier 2 Fig. 3.6.3-1
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9> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Elevation View of MCL Piping
See FSAR Tier 2 Fig. 3.6.3-2
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10> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Layout of SL Piping
See FSAR Tier 2 Fig. 3.6.3-3
Note: PZR Nozzle DM Weld will be revised to indicate it is a shop weld
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11> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Layout of MSL PipingInside Containment Portion to 30JMK10BQ110
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12> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
LBB Applicability
> Application of LBB limited to piping – “not-susceptible” to failure from various degradation mechanisms in service
Demonstrate – probability of fluid system rupture is “extremely low”Demonstrate/address following issues are not a concern:
• Pipe rupture due to water hammer• Creep damage• Degradation by erosion, erosion/corrosion, due to unfavorable flow
conditions and chemistry• Corrosion resistance of piping• Fatigue cracking or failure of piping system • Thermal aging and thermal stratification• Potential indirect sources of pipe rupture• Piping material not-susceptible to brittle cleavage type failure• Failure prevention and detection
LBB - applied to Class 1 & 2 or equivalent piping systems
Addressed in FSAR Tier 2 Section 3.6.3.3
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13> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Overall LBB Methodology
> Typical LBB analysis considers applied loadings in piping system – these are known, such as for operating plants
> The LBB analysis performed for U.S. EPR is consistent with methods and criteria of NUREG 1061, Vol. 3 and SRP 3.6.3
> In this approach the final LBB results are in the form of “Allowable Load Limit” (ALL) diagrams
If applied loading points lie within the ALL window, LBB is justified – with appropriate LBB safety margins already considered in window
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14> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Typical ALL Diagram Considering Various Axial Loads
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15> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Overall LBB Methodology
> Like typical LBB analysis, it involves:Phase I: performing leak rate analysis – to obtain leakage crack sizes (ℓ) with recommended margin of 10 on leak detection capabilityPhase II: performing detailed flaw stability analysis –• Considering safety margin of two on leakage crack size or
(2ℓ)
> Like typical LBB analysis, for consideration of selection of location for LBB, it involves:
Pipe or nozzle geometryBase and weld metal materialsOperating pressures and temperatures
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16> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Overall LBB Methodology
> In typical LBB analysis - actual loads are known: Only those locations that have least favorable combination of stress and material properties needs to be demonstrated for LBB
> In the ALL diagram approach: A significant number of initially assumed normal operating loadings are considered in the leak rate analysis Corresponding maximum allowable moment loads are then determined through flaw stability analysis
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17> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Identification of LBB Location
> Considering geometry, materials and operating conditions.
If any of the three parameters change it is identified as an LBB locationExample - Following this process of selection, five locations are determined for the MCL piping:
• 1) RV outlet nozzle region at hot leg• 2) SG inlet nozzle at hot leg• 3) SG outlet nozzle• 4) Crossover leg, RCP outlet nozzle, cold leg, RV inlet• 5) RCP inlet nozzle region
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18> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Phase I - Leak Rate Analysis
> Perform leak rate analysesFor MCL & SL piping – In-house code KRAKFLO used
• Benchmarked for subcooled & saturated liquid conditionsFor MSL piping – SQUIRT code used
• Benchmarked for saturated steam conditionsVarious assumed normal operating loads are considered.
• Moment loadings ranging from a small fraction of the yield strength to gradual increments of loadings above yield strength of the material
• Axial load due to pressure• Low external pipe axial load conservatively assumed
Leakage flaw sizes are then determined considering a factor of 10 times the leak detection capability flaw sizeFatigue flaws postulated at all locations. Lower bounding limit curve or minimum moment curve is generated
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19> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Leak Rate Analyses
> For the MCL Piping:Loadings ranged from pressure only case to small increments in loadings of 2.5E6 in-lbs up to 20E6 in-lbs.From 20E6 in-lbs to 50E6 in-lbs; increment increased to 5E6 in-lbsFrom 50E6 in-lbs to 140E6 in-lbs; increment increased to 10E6 in-lbs
> A family of curves of:Leak rate versus crack lengths are thereby established for each loading condition
• Leak rates ranging from 1 to 10 gpm are shown for a typical location
> For MCL, with leak detection capability of 0.5 gpmTherefore, desired leakage crack sizes are for 5 gpm
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20> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Leak Rate Versus Crack Length – SG Inlet Nozzle
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21> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Minimum Moment Vs Crack Length Curve
For 5 gpm Leak Rate
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22> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Minimum Moment Curve
> The leak rate analyses help establish the Minimum Moment Curve
Minimum moment corresponds to deadweight, steady state pressure and thermal expansion moment for normal operation.
Lower Bound Limit Curve
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23> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Materials & Material Properties
> The MCL and SL are fabricated from F304LN stainless steel (SS) and 308/308L SS welds
Safe ends F316LNDissimilar metal welds (DMW) – Alloy 52/52MAll welds fabricated using GTAW processAttached RV nozzles – SA-508 Grade 3 Class 1Attached SG & PZR nozzles – SA-508 Grade 3 Class 2
> RCP casings – SA 351 CF3> MSL piping – SA 106 Grade C carbon steel matl.
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24> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Materials & Material Properties
> Material Testing Program:
> Material properties of comparable materialsObtained from industry literature
> For MSL – used experimental data
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25> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
J-R Curve for 2.75T CT Specimens
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26> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
J-R Curve for 1.5T CT Specimens
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27> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
J-R Curve for Alloy 52 Fusion Line
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28> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
J-R Curve for RCP, Nozzles & Alloy 52
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29> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
J-R Curve for SA 106 Grade C - MSL
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30> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Phase II – Flaw Stability Analysis
> Perform flaw stability analyses – Applied J> Circ. T-W crack in straight pipe solution
For MCL & MSL piping – Used EPRI/GE method for axial tension & bending solutionFor SL piping – Used EPRI/GE method for bending solution
• Effect of axial load also considered through determining Meq
> Detailed J-Tearing analysis is performedSince a margin of two is recommended between leakage crack size, ℓ, and critical crack size, 2ℓ
• Leakage crack sizes from Phase I are doubled for flaw stability analysis i.e. flaw size, a = ℓ
For normal operating + SSE loadings – since absolute sum load combination is considered, a factor of 1.0 on loadings is applicable
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31> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Illustration of Instability Point in J/T Analysis
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32> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Phase II – Flaw Stability Analysis
> At each applied minimum moment load, maximum allowable moment load considering a factor of two on leakage crack size is determined.
> Joining these loci of points creates the Upper Bounding Limit Curve called the ALL diagram for a given LBB location
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33> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Phase II – Flaw Stability Analysis
> From Phase I - leak rate analysis Lower Bound or Minimum Moment Curve is determined
> From Phase II –J-T analysis method Upper Bound or Maximum Moment Curve is established
> Combining the results from the above analyses results in an ALL diagram
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34> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
ALL Diagram for SG Inlet Nozzle – Various Axial Loads
0
20000
40000
60000
80000
100000
120000
140000
0 20000 40000 60000 80000 100000 120000 140000
Minimum Moment, in-kips
Max
imum
Mom
ent,
in-k
ips
2000 kips2500 kips3000 kipsMin. Moment
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35> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
ALL Diagram – Showing Allowable LBB Zone
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36> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
LBB Demonstrated
> For each major segment of piping system Locations identified for LBB
• Geometry, materials, and operating conditionUnique ALL diagramActual loads when available – compared against the associated ALL diagramIf all the loads fall in the ALL LBB zone – LBB is demonstrated
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37> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Preliminary Loads - SG Inlet Nozzle
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38> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Preliminary Loads – MSL (SF=2)
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39> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Preliminary Loads – MSL (SF=1.7)
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40> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Preliminary Loads – SL (SF=2.0)
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41> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Summary
> LBB analysis conforms to GDC 4 and applicable regulatory guidance
> LBB can be successfully demonstrated for the entire piping system
> Benefit of this approach – LBB analysis would not need to be re-performed due to future structural loads re-analysis.
> ALL diagram concept – very convenient for structural analysts to verify that LBB requirements continues to be met for the given piping system
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42> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
COL & ITAAC
Russ Wells
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43> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Regulatory Implementation of LBB Approach
> As noted in previous slides, the U.S. EPR LBB approach is intended to be a “bounding approach” for purposes of the design certification application (FSAR Tier 2 Section 3.6.3)
> Verification of this bounding approach is accomplished through COL information items and ITAAC
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44> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
LBB COL Information Items
> COL Information Item 3.6-3 (FSAR Tier 2 Section 3.6.3)
A COL applicant that references the U.S. EPR design certification will confirm that the design LBB analysis remains bounding for each piping system and provide a summary of the results of the actual as-built plant specific LBB analysis, including material properties of piping and welds, stress analyses, leakage detection capability, and degradation mechanisms.
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45> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
ITAAC
> FSAR Tier 1 Table 2.2.1-5—RCS Inspections, Tests, Analyses, and Acceptance Criteria
An analysis exists that assesses the LBB capability of the piping and equipment listed in Table 2.2.1-1
An analysis will be performed.
The piping and interconnected component nozzles listed in Table 2.2.1-1 have been evaluated for LBB
Acceptance Criteria
Inspection, Test or Analysis
Design Commitment
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46> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Stratification in Surge Line
Tehemton BhagwagarSupervisory Engineer RCS and Class 1 Piping
Analysis
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47> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Surge Line Stratification
> Low potential for thermal stratification in U.S. EPR surge line due to:
Improved geometry• Continuous 5 degree slope from the PZR to the HL to prevent
water stagnation• Vertical take-off from the HL with a 6.7D length to minimize
turbulent penetrationImproved system operation • Continuous spray bypass flow at normal operation to suppress
turbulent penetration• The PZR-to-HL temperature difference is minimized during
plant heat-up by initiating in-surges via the CVCS system
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48> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Surge Line Stratification in Operating Plants
SL Stratification Results for a Westinghouse PWR
Source: “An Investigation of Thermal Stress Ranges Under Stratification Loadings,” T.H. Liu and E.L. Cranford, Westinghouse Electric Corporation, published in Journal of Pressure Vessel Technology, Transactions of the ASME, Vol. 113, May 1991, page 330
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49> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Surge Line Geometry for a Westinghouse PWR
Source: “An Investigation of Thermal Stress Ranges Under Stratification Loadings,” T.H. Liu and E.L. Cranford, Westinghouse Electric Corporation, published in Journal of Pressure Vessel Technology, Transactions of the ASME, Vol. 113, May 1991, page 326
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50> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
SL Stratification Results for a B&W PWR
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51> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Surge Line Geometry for a B&W PWR
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52> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
SL Stratification Results for a French PWR
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53> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Surge Line Geometry for a French PWR
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54> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Surge Line Geometry for U.S. EPR
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55> NRC Audit Leak-Before-Break June 26, 2008AREVA NP INC.
Questions?