AP600/AP1000 Test Programs
Stephen M Bajorek Ph DStephen M. Bajorek, Ph. D.Office of Nuclear Regulatory Research
United States Nuclear Regulatory CommissionPh : (301) 415 7574 / smb4@nrc govPh.: (301) 415-7574 / [email protected]
AP1000 Design Workshop
Slide 1
August 2007
Basis for ECC Experimental Testingg
AP600 passive safety systems unique.New components:PRHR Heat Exchanger (HX)Core Makeup Tank (CMT)Automatic Depressurization System (ADS)Passive Containment Cooling System (PCCS)
Uncertainty in system behavior.Natural circulation and core cooling by gravity
injection rather than forced convection.
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AP600 Test Program Objectivesg j
Simulate AP600 thermal hydraulic phenomenaSimulate AP600 thermal-hydraulic phenomena and behavior of passive safety systems.
Provide high quality data to validate computer codes for safety analysiscodes for safety analysis.
Provide information to verify componentProvide information to verify component design and performance.
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AP600 Test Programg
New AP600 safety features & thermal-hydraulics required tests:To obtain data for model development, new correlationsTo simulate AP600 T/H conditions
ExamplesCore Make p Tank (CMT) TestsCore Makeup Tank (CMT) Tests
Automatic Depressurization System (ADS) TestsPassive Residual Heat Removal (PRHR) Tests( )DNB Tests Integral Effects Tests for Long Term Cooling
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AP600 Test Programg
New AP600 components required:Verification of design basis conditionsDemonstration of operation
ExamplesPassive Containment System (PCS) water distribution tests
PCS wind tunnel testsPCS wind tunnel testsADS sparger / IRWST testsReactor coolant pump (RCP) high-inertia rotor testsp p ( ) gCheck valve tests
Slide 5
Passive Containment Cooling System Tests
Air Flow Pressure Drop Measured air flow annulus loss coefficients
Test Objectives
coefficients
Water Film Formation Tests Plate wetting characteristics with and without coatings
Heated Plate Tests Investigated water film stabilityHeated Plate Tests Investigated water film stability
Bench Wind Tunnel Tests To show wind from any direction enhances air flow
Condensation Tests Heat transfer coefficients on various surfaces; effect of helium on HTC.
Large Scale PCS Tests Data during PCS operation on a scaled structurestructure.
PCS Water Distribution Tests Demonstrated effectiveness of water distribution on containment dome / sidewall.
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PCS Wind Tunnel Tests Measured wind-induced pressure and loading on containment shield building.
AP600 Containment Tests
AP600 L S l H tAP600 Large-Scale Heat Transfer PCS Test
Wind Tunnel Test
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PCCS Test Results
Large Scale PCS TestRelations between heat removal, containment pressure, water flow
rate and air velocity Internal noncondensable gas/steam distribution and mixing
Wind Tunnel TestsShield building, air inlet/outlet geometry ensures wind aids natural
circulation air flowcirculation air flowWide range of site topographies examined
Water Distribution TestsC t i t f ti f fi dContainment surface coating performance confirmed
Wetted area versus water flow rate with worst case surface defects quantified
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Separate Effects TestsSeparate Effects Testsfor
AP600 Passive Core Cooling
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ECC Separate Effects Tests
PRHR Heat Exchanger Tests Determined heat transfer characteristics
Test Objectives
PRHR Heat Exchanger Tests Determined heat transfer characteristics of the PRHR HX and mixing characteristics of the IRWST.
ADS Phase A Confirmed the capability of the sparger d d t i d d i ff tand determined dynamic effects on
IRWST structure.
ADS Phase B Simulated operation of ADS Stages 1,2, and 3.
Core Makeup Tank Tests To verify gravity drain behavior of the core makeup tank over a full range of flow rates and pressures. Verify operation of tank level instrumentationoperation of tank level instrumentation.
DNB Tests To extend the existing critical heat flux correlation for Westinghouse fuel assemblies at lower flow conditions.
Slide 10
ADS Phase B Tests
Key Features Separate Effects Test Full-scale, prototypic hardware
Purpose of Tests: Obtain data for code verification Evaluate valve/piping package Obtain piping load dataObtain piping load data
ADS Test Results: Pressure pulses at ADS sparger measured and used to confirm
IRWST structural designIRWST structural design. Sparger design confirmed by full-flow tests. Full-scale ADS pipe/valve package critical flow with DP and flow
quality measurements
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quality measurements.
Core Makeup Tank Testsp
Key FeaturesySeparate effects test at full pressure and temperatureVessel 10-ft high with 2-ft diametergSimulated cold leg and pressure balance lines
Purpose of TestsPurpose of TestsEvaluate CMT performanceEvaluate CMT level instrumentationEvaluate CMT level instrumentationObtain T/H data for code verification
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CMT Test Results
Data for model development / assessment:Data for model development / assessment:Natural circulationSteam injection/mixing in cold CMTSteam condensation on walls & water surfaceConduction through thick steel walls
Thermal stratificationThermal stratificationCondensate mixing with cold waterHot liquid flashing during depressurization
CMT operation smooth, no water hammer
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PRHR Heat Exchanger (HX) Testsg ( )
Key Features3 tubes, instrumented650 F (616 K) / 2250 psig (15.6 MPa) conditionsBaffles used to simulate various tube bundle locations
and typesFull-height IRWST with scaled volume350 kW power supply
Purpose of Test:Obtain thermal-hydraulic data for code validation
Slide 14
Demonstrate IRWST temperature profile(s) during heatup.
PRHR HX Test Results
Data obtained over full range of RCSData obtained over full range of RCS pressures, temperatures, water flow rates and IRWST temperatures and water levelsIRWST temperatures and water levels.
IRWST heatup temperature profile p p pcharacterized.
Westinghouse used these data to develop models / correlations for safety codes.
Slide 15
DNB Tests
Key Features:Separate effects test covering range of fluid conditions anticipated
during AP600 DNB relate Condition I and II transients. Three 5 5 14 ft (f ll length) heated rod b ndle test assembliesThree 5x5, 14 ft. (full length) heated rod bundle test assemblies.
Purpose of Tests:Purpose of Tests:Determine the critical heat flux (CHF) performance of the AP600
fuel assembly design, particularly at low flow conditions. Measure the effect of intermediate flow mixer (IFM) grids at low
flow conditions.
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DNB Test Results
DNB tests provided data to extendDNB tests provided data to extend Westinghouse fuel DNB correlation to AP600 / AP1000 low flow conditionsAP1000 low flow conditions.
Tests demonstrate that sufficient DNB margin exists in AP600 / AP1000 design (DNBR > 1.3)
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Component Design Tests
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AP600 Component Design Testsg
Component Design Tests conducted to provideComponent Design Tests conducted to provide verification of new / modified components:
RCP/SG Channelhead - shows no SG to pump flow anomaliesRCP journal bearing - to determine rotor drag lossesRCP high inertia rotor - to minimize rotor drag lossRCP high inertia rotor - to minimize rotor drag lossRPV internals test - Scaled model at Univ. of Tennessee to
demonstrate no lower plenum flow anomaliesCheck valve - to determine flow versus pressure drop for
prototypic valves
Slide 19
Integral Effects TestsIntegral Effects Testsfor
AP600 Passive Core Cooling
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ECC Integral Effects Testsg
Integral tests performed to better understand system performance, interaction between components, and overall safety margin.
Westinghouse (AP600) integral tests:SPES-2SPES 2 APEX (Advanced Plant EXperiment)
NRC also performed independent, confirmatory tests:ROSA-AP600
APEX
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APEX
AP600 Full Height, Full Pressure, Integral Systems Test (SPES)Integral Systems Test (SPES)
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SPES Integral Systems Testsg y
Full-height, full-pressure tests conducted at the g , p1/395th scale SPES-2 facility in Italy. Facility models AP600 RCS at full power operation.p pIncludes:
CMTsCMTsAccumulators
PRHRPRHRIRWST
ADS
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ADS.
SPES Integral Systems Testsg y
Purpose of SPES-2 tests:Obtain thermal-hydraulic data at high pressure for
safety code validation.
SPES-2 Test Matrix Addressed: Small Break LOCA Effect of break size and location Effect of non-safety systems
Steam Line BreakSteam Line BreakSteam Generator Tube Rupture (SGTR)Design basis with/without active systems
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Design basis with/without active systems SGTR with inadvertent ADS actuation
SPES Integral Systems Test Resultsg y
Passive safety system operation (with single failure) prevented core uncovery for all small LOCAs (up to 8-inch DEG).
SGTR: RCS depressurized and flow to SG terminated by passive systems without operator action or non-
f t tsafety systems. SGTR and Large Steam Line Beak do not result in ADS
actuationactuation. No adverse interactions between passive and non-
safety systems
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safety systems.
SPES-2 Matrix Test S00303
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Pressurizer pressure
SPES-2 Matrix Test S00303
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Passive Injection Flows
AP600 1/4 Scale, Long Term Integral Systems Test (APEX)Systems Test (APEX)
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APEX Integral Systems Testsg y
APEX is a 1/4 height, low pressure test facility at Oregon State University. Max pressure = 400 psig (2.86 MPa)
APEX includes: CMTs
A l tAccumulatorsPRHR IRWSTIRWST ADS
Slide 29
APEX Integral Systems Testsg y
APEX Test Matrix Addressed:Small Break LOCABreak size (1/2 inch to 4-inch DEG DVI)Break size (1/2 inch to 4 inch DEG DVI)Break location (CL, DVI, CMT, IADS actuation)Tests with/without non-safety systemsTests with/without non safety systems
Long Term CoolingComplete IRWST draindownComplete IRWST draindown
Transition to containment sump injectionContainment backpressure simulation
Slide 30
Containment backpressure simulation
APEX Test Results
Provided thermal-hydraulic data for safety code assessment. (Facility scaling found to be acceptable for AP600 and most AP1000 scenarios.)
Passive safety system operation (with single failure) prevented core uncovery for all small LOCAs. y
Transition from IRWST to long-term containment sump recirculation occurred at appox 8 hourssump recirculation occurred at appox. 8 hours.
Limiting PRA success criteria identified by tests with
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g ymultiple failures.
APEX Test SB01
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Pressurizer Pressure
APEX Test SB01
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Passive System Injection Flows
ROSA-AP600 Integral System Testsg y
For AP600 Design Certification the NRC also gperformed independent, confirmatory tests after modifying the ROSA facility. y g y
ROSA-AP600 is a full height, high pressure test facility operated by JAERI.
ROSA-AP600 included CMTs, Accumulators, PRHR, IRWST and ADS although there were
Slide 34
several non-prototypic features.
ROSA-AP600 Facilityy
Slide 35
ROSA-AP600 Test Results
Provided thermal-hydraulic data for safety code assessment. (Facility scaling found to be acceptable for AP600 and most AP1000 scenarios.)
Passive safety system operation (with single failure) prevented core uncovery for all small LOCAs.prevented core uncovery for all small LOCAs.
Data from ROSA C-shaped PRHR proved to be very useful in validating safety codes for PRHR HX performance.
Slide 36
ROSA-AP600 DEDVI Results
Two-phase level Two-phase level remained above core
No cladding heatup
Slide 37
APEX-AP1000 Integral Testsg
Both Westinghouse and the NRC performed tests in a modified version of APEX (known as APEX-AP1000) to investigate phenomena not not well-scaled for AP1000 and to confirm AP1000 system performance. Westinghouse: Design basis testsNRC: Beyond design basis tests
APEX-AP1000 facility, tests and results to be di d i i
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discussed in separate presentation.
AP600/AP1000 Test Programsg
AP600 and AP1000 are supported by extensive pp ytest programs. These programs provided data for code assessment and demonstration of plant & component performance.
Nearly all AP600 tests apply to AP1000. Additional tests performed in APEX-AP1000 pfacility to account for potential deficiencies in supporting database.
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pp g
