PWR Materials Management Program (PMMP) Executive ...€¦ · PWR Materials Management Program...

© 2016 Electric Power Research Institute, Inc. All rights reserved.

David Czufin (TVA), Executive Chair

Robin Dyle (EPRI), PMMP Program Manager

Tuesday, August 30, 2016

PWR Materials Management

Program (PMMP) Executive

Committee Meeting

Date: August 26, 2016

2© 2016 Electric Power Research Institute, Inc. All rights reserved.

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AgendaTime Topic Lead

8:00 am Introductory Remarks and Agenda Review D. Czufin, TVA

8:15 amGeneral Topics

February 2016 Action ItemsR. Dyle, EPRI

8:30 am

Material Reliability Program (MRP) Business

2016 Budget status, including changes

2017 Budget update

2018 Budget for endorsement

Industry Highlights and Operating Experience

B. Rudell, Exelon

A. Demma, EPRI

10:00 am Morning Break All

10:20 am

Steam Generator Management Program (SGMP) Business

2016 Budget status, including changes

2017 Budget update

2018 Budget for endorsement

Industry Highlights and Operating Experience

J. Stevens, Luminant

H. Cothron, EPRI

11:50 am 2018 Budget review D. Czufin, TVA

12:00 pm Lunch - Crescent City Ballroom (Mezzanine Level) All

1:00 pm

MRP Technical Topics

Baffle Former Bolts

RPV Updates

Peening

B. Rudell, Exelon

A. Demma, EPRI

2:00 pm Member satisfaction survey S. Chengelis, EPRI

2:15 pmSGMP Technical Topics

Sherlock, Triton and Fluid Elastic Instability, Foreign Object Wear prediction

J. Stevens, Luminant

H. Cothron, EPRI

3:15 pm Review of action items D. Czufin - All

3:30 pm Adjourn


Action Items from January 2016

General Items

– Program leads explore options to support DNP

SGMP

– Consider decreasing of guideline review frequency to support DNP

– D. Czufin took to contact the utility that had not provided OE

– Report on monthly MAPC call when FEI data is available

– Review the STP root cause and make recommendations to PMMP

– Develop a checklist to use in dealing with emerging issues

MRP

– Provide a description of the long-term impact of xLPR – compare funding versus the value

– Provide a comparison of the old budgeting process and the RFA approach

– Quickly determine if MRP-367 should be updated for 80 years


PMMP MembersLast Name First Name Account Role

McLachlan Mark Ameren Missouri

Lloyd Mark American Electric Power, Inc.

Thiele Bryan Arizona Public Service Co. Alternate

Cadogan Jack Arizona Public Service Co.

Adams Matt Dominion Generation

Downing Parker Duke Energy Corp. EOC

Khan Ajaz EDF Energy Nuclear Generation, Ltd.

Sims William Entergy Operations, Inc.

Basso Tom Exelon Corporation

Bologna Richard FirstEnergy Nuclear Operating Co. EOC

Gil Rudy Florida Power & Light Co. EOC

Lim Jaesoo Korea Hydro & Nuclear Power Co., Ltd.

Tran Chung Luminant Holding Company LLC

Nimick Jan Pacific Gas & Electric Co.

Rajkowski Leonard PSEG Power, LLC

Williams George South Carolina Electric & Gas Co.

Adams Brad Southern Nuclear Operating Co. EOC

Connolly James STP Nuclear Operating Company

Czufin David Tennessee Valley Authority (TVA) Chairman

McCoy Jaime Wolf Creek Nuclear Operating Corp.

Khanifar Aziz Xcel Energy Services, Inc.


August 2016

Materials Program Changes


PSCR Organizational Update

PSCR Scope– PSCR takes overall responsibility for materials testing, characterization, and

modeling

– Direct support of the needs of issue programs

– Better alignment in strategic plans and seamless integration in R&D

– Funded by issue programs and current PSCR (base + TI) funding streams

– Additional staff to support the restructuring

PSCR Leadership– TAC Chair: Jim Cirilli, Exelon

Vice Chair: open

– Technical Chair: Ian Armson, Rolls Royce

EPRI Program Manager: Anne Demma

– TG Lian has been assigned to support EPRI engagement in Europe


Materials Organizational Chart – August 2016

Al Ahluwalia

Kyle Amberge

Brian Burgos

Paul Crooker

Tim Hardin

Craig Harrington

Mike McDevitt

Peter Chou

Gabriel Ilevbare

Raj Pathania

Cem Topbasi

Jean Smith

David Steininger

Jim Benson

Brent Capell

Rich Guill

Sean Kil

Rick Williams

Bob Carter

John Hosler

Wayne Lunceford

Amardeep Mehat

Nathan Palm

Chuck Wirtz

Dana Couch

Steve McCracken

Nick Mohr

Artie Peterson

Ben Sutton

Jon Tatman

Stacey Wells

Kurt EdsingerMaterials

Open

MRP

Helen Cothron

SGMPAnne Demma

PSCR

Andy McGehee

BWRVIPGreg Frederick

WRTC

Anna Deshon

Robin Dyle

David Gandy

Jennifer Ma

Chuck Welty


Together…Shaping the Future of Electricity


Bernie RudellMRP Chairman, Exelon

Anne DemmaProgram Manager, EPRI

PMMP Executive Committee MeetingTuesday, August 30, 2016

Materials Reliability

Program



Presentation Topics

2016 Budget Status and Deliverables

2017 Budget

2018 Preliminary Budget and RFA structure

Guidelines Status

Industry and Regulatory Issues and PWR OE

2016 Meetings and Workshops


2016 and 2017 Budgets

2016 and 2017 budgets were endorsed by the PMMP at the

February 2016 meeting

2016-17 Greybook was finalized in April 2016 and sent to

members

– Ahead of new prioritization for 2018

2018 Strategic Plan developed (retires Greybook)


2016 Budget Overview (February 2016)

2016 (k$)

Feb. 2016

Base and Strategic Gap Funding 3,318

Estimated Carry Forward 114

Supplemental Funding 11,459

Total Available Funding 14,891

Total Projects 11,179

Program Management 3,600

Total Planned Expenses 14,779

Contingency / Fund Balance 112


2016 Budget Overview (April 2016)

2016 (k$)

Feb. 2016










2016 MRP Budget Overview (August 2016)

2016 (k$)



Sector Emergent Issue Funding 1,000






Contingency 0


Preliminary 2016 Spend Plan on BFB issue

2016 Funding Source

Emerging Issue Funding k$ 1,000

MRP contingency funding k$ 100

BTP 5-3 and Appendix G delays due to FAVOR Delay k$ 50

Dynamic strain project delay k$ 50

Total Funding k$ 1,200

2016 Spending Plan

General support k$ 97

Focus Area #1 - Cause/EOC, IG, Reg. Interface k$ 149

Focus Area #4 – Inspection/NDE k$ 70

Focus Area #5 – Irradiated Mtls (BFB) Testing k$ 903

Focus Area #6 – Aging Mngmt Prog Assessment k$ -

Total Spend Plan k$ 1,219


2016 Key Planned Deliverables

Topical Report for PWSCC Mitigation by Surface Stress Improvement (MRP-335

Rev. 3)

Basis for ASME Section XI Code Case N-838—Flaw Tolerance Evaluation of

Cast Austenitic Stainless Steel (CASS) Piping Components (MRP-362 Rev. 1)

Effect of Lithium Concentration on IASCC Initiation in Irradiated Stainless Steel

(MRP-413)

Management of Thermal Fatigue in Normally Stagnant Non-Isolable RCS Branch

Lines (MRP-146, Rev. 2)

PWR Supplemental Surveillance Program (PSSP) Capsule Fabrication Report

(MRP-412)


2016 MRP Planned Deliverables (1 of 2)

Product ID Title

Item

Type

Planned

Completion

Date Status

3002007392 MRP: Topical Report for PWSCC Mitigation by Surface Stress Improvement (MRP-335 Rev. 3) Report 2/29/2016 Completed

3002008359 MRP: Effects of Surface Peening on the Inspectability of Nondestructive Evaluation Report 4/15/2016 Completed

3002007383MRP: Basis for ASME Section XI Code Case N-838—Flaw Tolerance Evaluation of Cast Austenitic

Stainless Steel (CASS) Piping Components (MRP-362 Rev. 1)Report 4/30/2016 Completed

3002008636MRP: Development of Probability of Detection Curves for UT of Dissimilar Metal Welds (MRP-262,

Rev. 2)Report 5/2/2016 Completed

3002008082 MRP: Effect of Lithium Concentration on IASCC Initiation in Irradiated Stainless Steel (MRP-413) Report 6/30/2016 Completed

3002008084MRP: Specification Guideline for PWSCC Mitigation by Surface Stress Improvement (MRP-336,

Rev. 1)Report 6/30/2016 Completed

3002007897 MRP: Revised Technology for Reactor Vessel J-groove Weld Surface Examination (MRP-410) Report 7/1/2016 Completed

3002007934 MRP: Administrative Procedures (MRP-130, Rev. 4) Report 7/22/2016 Completed

3002007851MRP: Summary of JSME Thermal Fatigue Assessment Guideline and Comparison with MRP

Management Guideline (MRP-408)Report 9/5/2016 Completed

3002007852 MRP: Benchmark of Thermal Fatigue Management in France (MRP-409) Report 9/5/2016 Completed


2016 MRP Planned Deliverables (2 of 2)

Product ID Title

Item

Type

Planned

Completion

Date Status

3002007850MRP: Environmentally Assisted Fatigue Testing of Stainless Steel Under Non-isothermal and

Complex Loadings (MRP-407)Report 9/30/2016

On

Schedule

3002007964 MRP: PWR Supplemental Surveillance Program (PSSP) Capsule Fabrication Report (MRP-412) Report 9/30/2016On

Schedule

3002008083 MRP: Basis for PWSCC Mitigation by Surface Stress Improvement (MRP-267, Rev. 2) Report 9/30/2016 Completed

3002007853MRP: Management of Thermal Fatigue in Normally Stagnant Non-Isolable RCS Branch Lines (MRP-

146, Rev. 2)Report 10/30/2016

On

Schedule

3002007960MRP: Screening, Categorization, and Ranking of Reactor Internals Components for Westinghouse

and Combustion (MRP-191, Rev. 1)Report 10/31/2016

On

Schedule

3002007849 MRP: PWSCC in Alloys 600 and 690: Quantitative Assessment of Crack Initiation Time (MRP-406) Update 11/18/2016 Completed

3002007948 MRP: PWR Bottom Mounted Nozzle Exam Zone Definition & Basis Development (MRP-411) Report 11/18/2016On

Schedule

3002007955MRP: Aging Management Strategies for Westinghouse and Combustion Engineering PWR Internal

Components (MRP-232, Rev. 2)Report 12/16/2016

On

Schedule

3002007933 MRP: Inspection Data Survey Report (MRP-219, Rev. 12) Report 12/18/2016On

Schedule

3002007951 MRP: RPV Integrity Primer (MRP-278, Rev.1), A Primer on Theory and Applications Report 12/18/2016On

Schedule


MRP 2017 Budget Overview

2017 (k$)

Jan. 2016










MRP 2018 Budget Overview

2018 (k$)










MRP Reorganized Projects into 10 Research Focus Areas

RFA Description

1 Reactor Vessel Internals Assessment, Modeling and Inspection

2 Reactor Vessel Internals Irradiated Materials Testing

3 Alloy 600/690 Management, Mitigation, and Inspection

4 Reliability of CASS Pressure Boundary Components

5 Pipe Rupture Probability Assessment

6 Stainless Steel Degradation Mechanism Studies

7 Fatigue Management (Thermal and Vibration Fatigue)

8 Replacement Materials Testing (Alloy 690/52/152)

9 Reactor Pressure Vessel Integrity

10 Environmentally Assisted Fatigue


0

0.5

1

1.5

2

2.5

3

1 9 7 2 3 10 8 4 5 6

IC Score vs RFA

IC S

core

RFA #

Higher priority RFAs

– #1 Reactor Vessel Internals Assessment, Modeling and Inspection

– #9 Reactor Pressure Vessel Integrity

– #7 Fatigue Management (Thermal and Vibration Fatigue)

Middle priority RFAs

– #2 Reactor Vessel Internals Irradiated Materials Testing

– #3 Alloy 600/690 Management, Mitigation, and Inspection

– #10 Environmentally Assisted Fatigue

Lower priority RFAs

– #8 Replacement Materials Testing (Alloy 690/52/152)

– #4 Reliability of CASS Pressure Boundary

– #5 Pipe Rupture Probability Assessment

– #6 Stainless Steel Degradation Mechanism Studies

MRP IC members RFA Prioritization Results


MRP 2018 Budget by RFA

RFA DESCRIPTION RFA BUDGET

($K)

% OF MRP

BUDGET

1 INTERNALS ASSESSMENT, MODELING AND INSPECTION 2,011 19

2 INTERNALS IRRADIATED MATERIALS TESTING 2,044 20

3 ALLOY 600/690 MANAGEMENT, MITIGATION, AND INSPECTION 646 6

4 RELIABILITY OF CASS PRESSURE BOUNDARY 175 2

5 PIPE RUPTURE PROBABILITY ASSESSMENT 875 8

6 STAINLESS STEEL DEGRAD MECH STUDIES 50 0

7 THERMAL AND VIBRATION FATIGUE 1,225 12

8 REPLACEMENT MATERIALS TESTING (ALLOY 690/52/152) 1,350 13

9 REACTOR PRESSURE VESSEL INTEGRITY 1,450 14

10 ENVIRONMENTALLY ASSISTED FATIGUE 500 5

TOTAL 10,326 100


MRP 2018 Budget by RFA and Project


EPRI MRP NEI 03-08 Guidelines


MRP NEI 03-08 Active GuidelinesDoc Number Product ID Document Title Date Level

MRP-126 Rev 0 1009561 Generic Guidance for an Alloy 600 Management Plan Nov 2004 Mandatory

MRP-146 Rev 1 1022564 Management of Thermal Fatigue in Normally Stagnant Non-Isolable RCS Branch Lines Jun 2011 Needed

MRP-146S Rev 0 1018330Management of Thermal Fatigue in Normally Stagnant Non-Isolable RCS Branch Lines – Supplemental

Guidance Jan 2009 Needed

MRP 2015-019 N/AMRP-146 and MRP-192 Interim Guidance

NEI 03-08 Needed & Good Practice Interim Requirements for Management of Thermal FatigueMay 2015 Needed

MRP-192 Rev 2 1024994 Assessment of RHR Mixing Tee Thermal Fatigue in PWR Plants Aug 2012 Good Practice

MRP-227-A1022863

MRP 227-A, Pressurized Water Reactors Internals Inspection and Evaluation Guidelines Dec 2011 Mandatory

MRP-227 Rev 1 3002005349 Pressurized Water Reactor Internals Inspection and Evaluation Guidelines Oct 2015 Mandatory

MRP 2014-006 N/A MRP-227-A Interim Guidance to inspection requirements of Westinghouse Control Rod Guide Tubes Feb 2014 Needed

MRP-228 Rev 1 1025147 MRP-228 Inspection Standard for PWR Internals Dec 2012 Needed

MRP-228 Rev 2 3002005386 MRP-228 Inspection Standard for PWR Internals Dec 2015 Needed

MRP 2013-023 N/A MRP-228 Interim Guidance for Ultrasonic Examinations of Reactor Internal Baffle-Former Bolting Oct 2013 Needed

MRP-384 Rev 0 3002002963 Guideline for Nondestructive Examination of Reactor Vessel Upper Head Penetrations Sep 2014 Good Practice

MRP 2016-021 N/A BFB Interim Guidance for Tier 1 Plants (4-loop downflow) Jul 2016 Needed

http://www.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000000001009561



https://membercenter.epri.com/Programs/061145/cockpit library/MRP Letters/2015 Letters/MRP 2015-019.pdf



http://membercenter.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000003002005349

http://membercenter.epri.com/programs/061145/cockpit library/MRP Letters/2014 Letters/MRP 2014-006.pdf



http://membercenter.epri.com/programs/061145/cockpit library/MRP Letters/2013 Letters/MRP 2013-023.pdf

http://membercenter.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000003002002963


MRP Guideline Deviations


1 MRP Guideline Deviation as August 22, 2016

Associated with a component replacement

Once MRP-146, Revision 2 is approved, this will not be a

deviation anymore


Industry & Regulatory Issues and

recent PWR Materials OE


Industry Challenges Quasi-Laminar Flaws / Hydrogen Flaking Issue (Doel 3 RPV issue) - Will be discussed in Technical

Topics Presentation

– MRP participated in the meeting organized by the Belgium regulator on this subject in January 2016

– MRP is assessing the impact of the new information on the previous probabilistic analysis (MRP-367) and will update report as needed

Potential Non-conservatism of Branch Technical Position 5-3 Methods to Estimate Initial Toughness of RPV Steels - Will be discussed in Technical Topics Presentation

– NRC agrees with MRP-401/ BWRVIP-287 that issue is not immediate safety concern but is performing analyses to determine if BTP must be revised

BMN Volumetric Examination

– Agreement reached with NRC in 2013 to pursue Code Case to incentivize but not require volumetric exams, however eventually tabled

Reactor Vessel Internals: Baffle-Former-Bolt Cracking - Will be discussed in Technical Topics Presentation

– During spring 2016 outages, Indian Point 2 and Salem 1 found large quantities of degraded baffle-former-bolts that required replacement, resulting in extended outages

– The findings raised concern regarding industry preparedness to respond when such degradation is discovered and the impact on the rest of the fleet


Regulatory Issues

Received a fee waiver for NRC’s review of MRP-227-Rev.1,

PWR Internals Inspection and Evaluation Guidelines

Development work for MRP-227 Rev 2 to address GALL SLR

has established an acceptable timeline with NRC to maintain

generic reference of MRP-227-A in GALL SLR

MRP-335, R3, the technical basis for optimized inspection

intervals for Alloy 600 locations based on PWSCC mitigation

by peening was submitted to the NRC for a safety evaluation

(SE)


PWR Materials OE since January 2016 NPC Meeting 2016

– Axial flaw in DM weld at 4” Pressurizer Safety Nozzle, MSIP mitigated in 2006, was determined to be deeper. Root cause concluded flaw depth was miss sized in prior exams. Repaired by Full Structural Weld Overlay

> NDE Alert letter issued

– BFB Inspection results in high % failed in two Westinghouse 4-Loop down flow units

> An Industry BFB FG has been established with MRP and PWROG participation

– Thermal Fatigue Exams reveal flaws in two units

> Not an “emergent issue” as this was addressed in recent interim guidance -Thermal Fatigue FG has the lead on following assessment of these issues

– Evidence of leakage at a Cold Leg RTD Instrument Nozzle

> ET revealed an axial PWSCC flaw in nozzle, opposite j-groove weld. Repaired RTD nozzle with a Mechanical Nozzle Clamp per Code Case.

– RV Head CRDM/Nozzle Exams identified two shallow off axis indications just below the toe of the J-groove on one nozzle – repaired by grinding to PT white results

> Not an “emergent issue” – another Cold Head experience.

– ISI identified an acceptable by evaluation flaw in a 14” RHR return line off the hot leg

> Final Owner causal determination to be reviewed for disposition


2016 MRP Meetings & Workshops


2016 Meetings

Event Date Location

MRP TACs and IC MeetingJune 6-10

Westin Hotel

Westminster, CO

International Light Water Reactors

Material Reliability Conference & Exhibition 2016

– Workshops: Aug. 1

– Conference Presentations: Aug. 2-4

– Annual Exchange with NRC: Aug. 4

August 1-4

Hyatt Regency

McCormick Place,

Chicago, IL

EPRI Nuclear Power Council Meetings

– PMMP Meeting (Aug 30)

– MAPC Meeting (Aug 31)

Aug. 29–Sept. 1 New Orleans, LA

MRP TACs and IC Meeting November 14-18Eilan Hotel,

San Antonio, TX


2016 MRP International Workshops & Visits

Jan Feb Mar Apr

May Jun Jul Aug

Sept Oct Nov Dec

Visits to Kyushu and

Shikoku, IGALL meeting

and MRP Japan

Workshop: April 4-8,

Osaka & Tokyo, Japan

MRP Workshops and

Visits: Ringhals and EDF

October 10-14, Sweden

MRP Workshops: KHNP,

Sept. 20-22 with SGMP

and NDE in Korea

MRP Reactor internals

workshop: KHNP, May

16-17, Korea

Nuclear Sector Japan

Seminars: Oct. 25-26,

Tokyo, Japan

MRP Workshop Focused

on LR (LTO in Spain):

June 15-17, Spain


Committee Membership and Leadership


Program Organization and Leadership

Materials Reliability Program

(IC)

Rudell, Exelon

Hoehn, Ameren

Demma, EPRI

Regulatory Interface

Richter, NEI

Dyle, EPRI

Support TAC

Hoehn, Ameren

Childress, Duke Energy

Burgos, since Aug. 1 (replaced

McDevitt who retires Sept. 30)

Inspection TAC

Smith, Exelon

Doss, Duke

Spanner, EPRI

Mitigation & Testing

TAC

Efsing, Ringhals

Koehler, Xcel Energy

Smith, EPRI

Assessment TAC

Sims, Entergy (Will step down

After Peening SER)

Wells, Southern Nuclear

Amberge, EPRI

Materials Review Visits




Jim StevensSGMP Chairman, Luminant

Helen CothronProgram Manager, EPRI

PMMP Executive Committee MeetingTuesday, August 30, 2016

Steam Generator

Management Program



Presentation Topics

2016 Budget Status and Deliverables

2017/2018 Budget

2016 Events

Guidelines Status

Industry Challenges and Regulatory Issues

Operating Experience

SGMP Membership Changes


2016 Budget and Deliverables


2016 Budget

2016

($K)

Funding (Base + Supplemental) $ 6,538

Carryforward $ 150

Total Available Funding $ 6,688

Total Planned Expense $ 6,538

Total Fund Balance $ 150


Summary of 2016 SGMP Deliverables

3 Guideline Documents

– NEI 03-08 mandatory and needed elements

8 Technical Reports

1 Software Product

1 Technical Transfer

1 Database Update

Triton Version 1


2016 SGMP Delivered Products

Deliverable Name PID #

Committed

Date

Delivered

Date

Generic Elements of U-Bend Tube Vibration Induced Fatigue Analysis for Westinghouse Model

44F Steam Generators 3002007562 June-16 April-16

Generic Elements of U-Bend Tube Vibration Induced Fatigue Analysis for Westinghouse Model

51F Steam Generators 3002007565 June-16 May-16

Model Assisted Probability of Detection Software using R (MAPOD-R) Revision 2 3002007857 Sept-16 May-16

Steam Generator Integrity Assessment Guidelines, Revision 4 3002007571 July-16 June-16

Pressurized Water Reactor Steam Generator Examination Guidelines, Revision 8 3002007572 July-16 June-16

Assessment of Lead Induced Stress Corrosion Cracking Inhibitor Effectiveness 3002007860 June-16 June-16

Correlating Primary-to-Secondary Leakage with Probability of Burst 3002007607 June-16 June-16

Alternatives to Hydrazine for PWR Secondary Chemistry Control; Evaluation of

Diethylhydroxylamine (DEHA) 3002007608 June-16 June-16

Steam Generator Foreign Object Handbook, Revision 2 3002007858 Aug-16 July-16


2016 Planned Deliverables

Deliverable Name PID #

Committed

Date

Delivered

Date

Development of Algorithms for Automated Analysis of SG Eddy Current Data 3002007710 Nov-16

Assessment of Processes for Implementation of Auto Data Analysis Systems 3002007712 Oct-16

Steam Generator In Situ Pressure Test Guidelines, Revision 5 3002007856 Nov-16

Steam Generator Degradation Database (SGDD) Version 7.3 3002007880 Dec-16

Pressurized Water Reactor Chemistry Knowledge Transfer, Volume 2 - Secondary System

Purification 3002007911 Aug-16

Triton Steam Generator Thermal-Hydraulics Code; Version 1.0 3002005515 Dec-16


Steam Generator Integrity Assessment Guidelines

NEI 03-08 Mandatory, Needed and Good Practice Elements

Updated with latest research results and operating experience

Major changes

– Guidance for performing assessments with less than 100% inspection

– Guidance for inspection scope, expansion scope and integrity assessments when

small numbers of indications are identified

– Recommendation for examination of the channel head

– Recommendation to perform eddy current noise monitoring

Report 3002007571 published June 2016 – Implementation Date August 2017


PWR Steam Generator Examination Guidelines

NEI 03-08 Needed and Good Practice Elements

Updated with latest research results and operating experience

Major changes

– Guidance for automated data analysis

Single pass system endorsed for Alloy 690TT

– Guidance for measuring and monitoring eddy current noise

Report 3002007572 published June 2016 – Implementation Date August 2017


2017/2018 Budget

2017

($K)

Funding (Base + Supplemental) $6,538

Carry Forward $150

Total Available Funding $6,638

Total Planned R&D Expense $6,538

Total Fund Balance $150


SGMP 2017/2018 Research Focus Areas

Research Focus Areas

Prop.

2017

Costs

($K)

Maintenance of SGMP (Technique and Personnel Qualification, Guidelines,

Databases, Tech Transfer) 3302

Understanding Wear Mechanisms 1176

Chemistry and Fouling 646

Managing Corrosion Mechanisms 510

Development of ECT Improvement 648

State of the Art Software for Understanding Flow Conditions 256


2016 Events


2016 SGMP Events

Event Date Location


– PMMP & MAPC meetingsFeb 8-11 Austin, TX

Steam Generator Task Force Meeting Feb 3 Washington DC

SGDD Training: Data Entry May Webcast

SGDD Training: Reporting May Webcast

SGMP TAG Meeting (June 7-9)

– SGMP IC Meeting (June 8 and 9)

– NDE TAC Meeting (June 7)

– E&R TAC Meeting (June 7)

– TS TAC Meeting (June 7)

June 7-9 Salt Lake City, UT

35th Steam Generator NDE and Tube Integrity Workshop July 17–20 Clearwater Beach, FL

Steam Generator Task Force Meeting Aug 17 Washington, DC


2016 SGMP Events

Event Date Location


– PMMP Meeting

– MAPC Meeting

Aug 29 -Sept 1 New Orleans, LA

SGDD Training: Data Entry Nov Webcast

SGDD Training: Reporting Nov Webcast

SGMP TAG Meeting (Dec 6-8)

– SGMP IC Meeting (Dec 7-8)

– NDE TAC Meeting (Dec 6)

– E&R TAC Meeting (Dec 6)

– TS TAC Meeting (Dec 6)

Dec 6-8 New Orleans, LA


SGMP Guidelines


SGMP Guideline Status and Revision Schedule

Guideline Title Current

Rev #

Report # Last Pub

Date

Implementation

Date(s)

Interim

Guidance

Review

Date

Comments

SG Integrity

Assessment

Guidelines

4 3002007571 June 2016 8/31/2017 None 2020

EPRI SG In Situ

Pressure Test

Guidelines

4 1025132 Oct 2012 10/10/13 NoneN/A

Rev 5 in progress

PWR SG Examination

Guidelines

8 3002007572 June 2016 8/31/2017 None 2020

PWR SG Primary-to-

Secondary Leakage

Guidelines

4 1022832 Sept 2011 4/11/2012

7/11/2012

None N/A Revision will begin

2016


SGMP Guideline Status and Revision Schedule

Guideline Title Current

Rev #

Report # Last Pub

Date

Implementation

Date(s)

Interim

Guidance

Review

Date

Comments

PWR Primary Water

Chemistry Guidelines

7 3002000505 April 2014 1/28/2015 None 2018

PWR Secondary Water

Chemistry Guidelines

7 1016555 Feb 2009 8/20/09

11/20/09

SGMP-IG-13-01

SGMP-IG-14-01

N/A Rev 8 in progress

Steam Generator

Management Program

Administrative

Procedures

4 3002005168 Mar 2015 3/9/2016 None N/A

Steam Generator

Degradation Specific

Flaw Handbook

2 3002005426 Nov 2015 N/A None N/A


NEI 03-08 Deviations

• Three long-term deviations

– Two Steam Generator Examination Guidelines, R7

–Single party auto analysis

–Steam Generator Integrity Assessment Guidelines, R3

–Use of site-specific sizing indices

• Two short term deviations

–Steam Generator Examination Guidelines, R7

–PSI prior to hydro

–Secondary Water Chemistry Guidelines, R7

–Exceeding control parameters during startup


Industry Issues


Industry Issues

Assuring High Performance of Single Party Auto Analysis Systems

Foreign Object Wear

– Detection of FOs

– Inspection Scope

– Estimating Wear rates from FOs

Cracking in Alloy 600TT Steam Generator Tubes

Wear in Replacement Steam Generators

Need for a State of the Art Thermal Hydraulic Code


Regulatory Issues

NRC has accepted SGMP Research Conclusions Regarding Divider

Plate Crack Propagation

– Staff Interim Guidance Letter

NRC will review published guidelines in 2016 to ensure all their

technical issues have been resolved

– Most of the technical issues have been incorporated into the guidelines;

however, not all of them are requirements

Single pass auto analysis

Site-specific equivalency of generic eddy current technique

qualifications

In plane fluid elastic instability




Operating Experience Update

South Texas identified a 0.09 volt volumetric indication in

Alloy 690TT tubing during a steam generator inspection in

2015

Utility has completed the apparent cause and determined

that if the indication is not a false call, the degradation is

most likely pitting corrosion

They will be taking action in the future to address pitting

corrosion in their hard sludge pile

SGMP will be conducting research 2017/2018 investigating

pitting corrosion in Alloy 690TT tubing


Committee Membership Changes


SGMP IC Membership

Position Name Company TAC Start Date End Date

IC Chair Jim Stevens Luminant TS Jan-2014 Dec-2016

IC Vice Chair, TAG Chair John Arhar PG&E E&R Jan-2014 Dec-2016

NDE TAC Chair Dan Folsom TVA NDE Jan-2014 Dec-2016

E&R TAC Chair Pat Fabian PSEG E&R Jan-2014 Dec-2016

TS TAC Chair Larry Miller Dominion TS Jan-2016 Dec-2018

At Large Member Scott Redner Xcel NDE Jan-2014 Dec-2016

At Large Member Lee Friant Exelon E&R Jan-2014 Dec-2016

At Large Member Pat Wagner WCNOC NDE Jan-2015 Dec-2017

At Large Member Ken Johnson Duke TS Jan-2015 Dec-2017

At Large Member Warren Leaverton APS E&R Jan-2015 Dec-2017

At Large Member Steve Brown Entergy NDE Jan-2015 Dec-2017

At Large Member Daniel Mayes Duke E&R Jan-2015 Dec-2017

Larry Miller has changed positions and will no longer be in SGMP

Vice Chairman is leading while TS TAC identifies a replacement




2018 Budget Review

“Presentation Placeholder”


Brian Burgos, Technical Leader, Principal, EPRI

Kyle Amberge, Technical Leader, Principal, EPRI

Tim Hardin, Technical Executive, EPRI

Paul Crooker, Technical Leader, Principal, EPRI

Anne Demma, Program Manager, EPRI

Bernie Rudell, MRP Chairman, Exelon

PMMP Meeting, New Orleans, August 30, 2016

MRP Technical Topics



Topic 1 - Baffle-Former Bolt

Focus Group (BFB FG) Update


Background


Westinghouse NSSS Internals

Control Rod Guide Tube

Outlet Nozzle

Core Barrel

Thermal Shield

Former Plate

Hold Down Spring

Lower Core Support Plate

Vessel Head

Pressure Vessel

Inlet Nozzle

Upper Support Plate

Lower Core Plate

Bottom-Mounted

Instrumentation Column Body

Lower Support Column Body

Upper Core Plate

Baffle Plate

Upper Support Column


Baffle-Former Assembly

Example

Baffle-Former

Bolt

Locations

Thermal

Shield

Core Barrel

Baffle Plate

Former Plate

Source: ML15331A264


Baffle-Former Assembly Details

Baffle

Baffle Plate Edge

Bolt

Baffle to Former Bolt

(Long & Short)

Corner Edge Bracket Baffle

to Former Bolt

Core Barrel to Former Bolt

Core Barrel

Former

Source: ML15331A179


Coolant Flow Configurations

Source: ML073190376


Timeline

Note: UT deployed as it became available and qualified for the various sites

1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

DC Cook finds degraded

bolts by visual inspection

First UT baffle-former bolts

(BFB) inspections in French

PWR CP0 units and first

cracks found

Indian Point 2,

Salem 1 find

degraded bolts

(visual+UT)

Ginna performs

first MRP-227

inspectionsFirst degraded

baffle-former bolts

found in U.S.

WCAP-13266: BFB

Program for the

Westinghouse Owners

Group - Plant

Categorization

NRC Information

Notice 98-11

on BFBsMRP publishes

assessment of

French BFB OE

(MRP-03)

NRC

reviews &

approves

MRP-227

Westinghouse

Technical Bulletin

TB-12-5, related to

the DC Cook OE

MRP publishes

Reactor Internals

Inspection

Guidelines

(MRP-227)


Guidance


Past Operating Plant Experience

EDF 1989-Present

Joint Owners Group Program 1998-2000

Industry MRP-227-A Inspections (through end of 2015)

B&W and International Plants


EDF Experience 1989-PresentBaffle bolt failures reported - Limited to CP0 design

• 3-loop (converted to upflow), with significant plant-to-plant variability (CPY design <5 indications over life of plant)

EDF Periodic bolt replacement of failed original bolts, and periodic replacements included previously replaced bolts• Maintain sufficient number of “healthy bolts” to push next inspection to 10 years (based on projection model)


Joint Owners Baffle Bolt Program (15-22 EFPY)

Sponsored Inspections of four plants (1998-2000)• Point Beach Unit 2: 2-loop, Upflow (converted) , Type 347SS

• 8% UT Indications

• Partial replacement program

• Farley Unit 1: 3-loop, Upflow (converted), Type 316SS• No UT Indications

• Proactive replacement of minimum pattern

• Ginna: 2-loop, Downflow, Type 347SS• 9% UT Indications (Of these, 14 were sent for metallurgical examination. Results showed

no indications of cracking, so this 9% likely contains a number of false calls)

• Partial replacement program

• Farley Unit 2: 3-loop, Converted Upflow (downflow at time of inspection), Type 316SS• No UT Indications

• Proactive replacement of minimum pattern

NO 4-LOOP PLANTS EXAMINED


Industry MRP-227-A Baffle-Former Bolt Inspections (25-35 EFPY)through end of 2015

• Point Beach Unit 1: 2-Loop, Upflow (converted), Type 347SS

• 1st Inspection: No UT Indications

• Point Beach Unit 2: 2-Loop, Upflow (converted), Type 347SS

• 2nd Inspection: 2% Additional UT Indications

• Ginna: 2-Loop, Downflow, Type 347SS

• 2nd Inspection (partial inspection of 123 original bolts and 56 replacement bolts): 1 Additional UT Indications (Partial Replacement – 25 bolts)

• Prairie Island Unit 1: 2-Loop, Downflow, Type 347SS

• 1st Inspection: 6% UT Indications

• Prairie Island Unit 2: 2-Loop, Downflow, Type 347SS


• Surry Unit 1: 3-Loop, Downflow, Type 347SS

• 1st Inspection: <1% UT Indications

• Surry Unit 2: 3-Loop, Downflow, Type 347SS


• Robinson: 3-Loop, Downflow, Type 347SS


• Turkey Point Unit 3: 3-Loop, Downflow, Type 347SS

• 1st Inspection: No UT Indications in 305 of 1088 bolts inspected

NO 4-LOOP PLANTS EXAMINED


• Oconee Unit 1, Type 304SS• No relevant UT indications - Four BFBs uninspectable due to large welds on locking bars

• Oconee Unit 2, Type 304SS• No relevant UT indications - One BFB uninspectable due to UT probe not seating properly

• Oconee Unit 3, Type 304SS• One BFB identified with crack-like indications - One BFB uninspectable due to UT probe not seating properly

• Crystal River Unit 3, Type 304SS• No relevant UT indications - UT performed due to visual indication from baffle-to-baffle bolts

• Doel 1: 2-Loop Downflow, Type 316SS• 1st Inspection: 2% UT Indications

• Doel 2: 2-Loop Downflow, Type 316SS• 1st Inspection: <1% UT Indications

• Krsko: 2-Loop, Downflow (prior to inspection), Type 316SS• 1st Inspection: <1% UT Indications

• Tihange 1: 3-Loop, Upflow (converted), Type 316SS• 960 of 1088 bolts inspected in each of the following inspections


• 2nd Inspection: 3% UT Indications

• 3rd Inspection: No confirmed UT Indications (5 bolts either not inspectable or not interpretable)

B&W and International Plant Results


Observations from Broader OE

Prior to the recent OE at Cook Unit 2, Indian Point Unit 2, and Salem Unit 1 (discussed later in the presentation), the following observations can be made:

• Bolts with UT indications tend to be randomly distributed

• Distributions are consistent with expectations of IASCC failures

• Quantity and distribution of bolts with indications bounded by historical generic safety assessment generated in mid-1990s (WCAP-15328)

• Industry response to replacement of bolts with indications has been positive


Recent Operating Plant Experience

DC Cook 2 - 2010

Indian Point 2 - 2016

Salem 1 - 2016


DC Cook Unit 2 (2010 / 22 EFPY) (4-Loop Downflow

Configuration)

Fuel failure in peripheral assembly attributed to wear against broken bolt head

Bolt heads and lock bars found on lower core plate

Visual inspections revealed 18 degraded bolts on single plate

– Additional bolts removed from plate with visual indications to define extent of localized degradation (approx. 40 bolts

in single patch)

– Additional test bolts removed from symmetrical locations to evaluate potential for degradation on other plates (all of

these test bolts were found to be intact)

No UT inspections performed in 2010 (at that time UT was not qualified or optimized

for the Cook 2 bolt design)

Degraded and test bolts replaced

Westinghouse issued Technical Bulletin TB-12-5

100% Visual inspection conducted in 2012 with no additional indications


Indian Point Unit 2 (2016 / 31 EFPY) (4-Loop Downflow

Configuration)

Degraded bolts/lock bars noted in visual exams performed prior to MRP-227 100% UT exams that were planned to occur during this outage

Markings on periphery of neighboring fuel assembly identified (no fuel failure).

Inspections identified 227 with visual degradation or UT indications

– Includes 14 that were not inspectable

UT indications were clustered

– Spanned various quadrants

– Multiple groups of 10+ adjacent failures / At least one cluster of 50+ adjacent failures

Observed failure pattern likely exceeds MRP-227 expansion criteria and exceeds WCAP-17096 engineering acceptance criteria

Site-specific response

– Performed Acceptable Bolting Pattern Analysis (ABPA)

– Performed Replacement Bolting Pattern Analysis

– Performed engineering evaluations supporting Unit 3 Extent of Condition Evaluation

– Performed engineering evaluations supporting Unit 2 Assessment of Potential Safety Impacts

– Performed baffle-former bolt removal and replacement

– Quarantined select bolts for potential future testing


Salem Unit 1 (2016 / 28 EFPY) (4-Loop Downflow Configuration)

Conducted visual exams every other refueling outage in response to DC Cook Unit 2 OE and TB-12-5; MRP-227 exams were not planned until 2017

Degraded bolts/lock bars noted in visual exams followed by doing UT exams

Loose/protruding bolt heads resulted in fuel fretting and one fuel assembly leaker

Inspections identified 182 with visual degradation or UT indications– Includes 18 that were not inspectable

UT indications were clustered– Concentrated to a few adjacent octants

– Multiple groups of 10+ adjacent failures / At least one cluster of 50+ adjacent failures

Observed failure pattern likely exceeds MRP-227 expansion criteria and exceeds

WCAP-17096 engineering acceptance criteria

Site-specific response– Performed Acceptable Bolting Pattern Analysis (ABPA)

– Performed Replacement Bolting Pattern Analysis

– Performed engineering evaluations supporting Unit 1 Justification for Past Operation

– Performed engineering evaluations supporting Unit 2 Extent of Condition Evaluation

– Performed baffle-former bolt removal and replacement

– Quarantined select bolts for potential future testing


Conclusions from Recent OE

These three plants share a common plant design

configuration (4-loop downflow), bolt design, and bolt

material

Bolts with visual or UT indications tend to be clustered

Distributions seem to indicate the presence of a mechanism

causing adjacent bolts to become more susceptible to

failure


US Trends – BFB FG Industry OE Database

Exam Req’d by

MRP-227A

0

50

100

150

200

250

0 5 10 15 20 25 30 35 40

Nu

mb

er

of

Assu

med

Deg

rad

ed

Bo

lts

EFPY at Inspection

Current EFPY Range

No of Assumed Degraded Bolts-Tier 1




BFB FG Activities


Industry Response

The Industry Baffle-Former Bolt Focus Group (BFB FG) was formed

in May 2016 to support an integrated approach among industry

organizations to address recent operating experience

- AREVA

- EPRI

- PWROG

- Utility Staff

- Westinghouse

- Others

Six focus areas with key

actions defined


Near Term Industry BFB FG Actions Completed

Supported presentation to NSIAC on 5/23/2016– Westinghouse Technical Bulletin TB-12-5 remains valid

Provided Industry Alert Letter from the PMMP Chairman to PWR site VPs on 6/1/2016– Expect that NEI 03-08 Interim Guidance will require the 4-loop plants

identified in the Westinghouse TB-12-5 bulletin to perform UT inspections of all the BFBs or replace an acceptable pattern of bolts at their next outage.

– Consideration should also be given to proceeding with procurement of replacement bolts prior to issuance of interim guidance due to potentially long manufacturing lead times.

Westinghouse NSAL 16-01 issued 07/05/16 and revised 08/01/16

AREVA CSB issued 07/14/16


Near Term Industry BFB FG Actions Completed

Issued NEI 03-08 “Needed” Interim Guidance on 7/25/2016 regarding

BFB inspections for Tier 1 plants as identified in Westinghouse NSAL

16-01

Assessed Fall 2016 and Spring 2017 outage seasons for developing

a contingency plan for tooling and BFB material needs

– Fall 2016: 3 planned MRP-227 UT inspections (1 of 3 is a Tier 1a plant) and 1

VT-3 inspection (Tier 1b plant)

– Spring 2017: 2 planned MRP-227 UT inspections (both Tier 1a plants), 1

planned UT inspection (non MRP-227 but a Tier 1a plant), and 1 VT-3

inspection (Tier 1b plant)

Initiated Hot Cell Post Irradiation Examinations of Indian Point 2 BFBs

– Microscopic examinations have begun and are currently underway


Planned BFB FG Activities through Mid-2017

Finalize BFB OE database by adding international data and UT inspection results from 2016-2017 exams in the USContinue with Hot Cell PIE work for IP2 and SAL1Provide additional NEI 03-08 Interim Guidance for the remainder of U.S. PWR fleet (2-loop and 3-loop plants) later in Fall 2016 or early 2017 Establish fundamental understanding of BFB failure mechanism(s) and develop potential changes to MRP-227 inspection guidance as needed– Re-inspection frequency for UT exams

– Allowance for proactive BFB replacement to manage aging


Topic 2 - RPV Integrity Updates





Appendix G P-T Curve

Small Surface Flaw Issue





Background

In August 2012, NRC informed industry of a concern regarding potentially high Conditional Probability of Failure (CPF) for RPV when a small inside-surface circumferentially-oriented flaw is postulated during cooldown2012-2013 MRP performed independent FAVOR analyses

(MRP-368)2014: MRP work continued, seeking to define a potential solution

to ensure safety goals (CPF < 1E-6) are met under all conditions2014: BWRVIP began investigation of impact of shallow surface

flaws on BWR leak test conditionsBefore work could be completed, computational anomalies in the

FAVOR software were identified– MRP informed NRC in August 2014

NRC plans to issue revised FAVOR by end of September 2016


Future Work on Small Surface Flaw Issue

Cladding residual stresses “drive” this issue and FAVOR handles cladding

stresses using a Stress Free Temperature (SFT) approach

– Stresses are zero at the SFT and increase as vessel temperature decreases

To date, both the NRC and industry analyses have used SFT = 488°F ─ a

conservative value

– Derived from measured of the circumferential stress component, which acts on an

axial flaw

However, the small surface flaw is a circumferential flaw

– In the basis work for the Alternate PTS Rule, NRC determined that the only feasible

through-clad flaw in an RPV is a circumferential flaw

After revised FAVOR code is released, MRP & BWRVIP will resume work to

resolve the small flaw issues using a lower SFT appropriate for the

circumferentially-oriented small surface flaw

– A significant reduction in CPF is possible, mitigating issue


Branch Technical Position 5-3 Issue


Background

NUREG 0800 Branch Technical Position 5-3 provides to estimate RTNDT and Upper Shelf Energy (USE) when drop weight (TNDT) and/or weak-direction Charpy V-notch (CVN) test data are not available

In 2014 potentially non-conservatisms in BTP 5-3 were identified

MRP/BWRVIP and PWROG conducted projects to address potential non-conservatisms in BTP

– MRP/BWRVIP evaluated conservatism of the BTP methods and assessed safety significance of nonconservatisms (MRP-401/BWRVIP-287)

Probabilistic fracture mechanics (PFM) analyses showed there is negligible risk to PWRs from use of existing BTP through 60 years of operation

– PWROG’s “Material-Orientation Toughness Assessment” (MOTA) showed existing P-T curve methods for PWRs have available conservative margin to offset BTP in most cases


Present NRC Position & Activity on BTP 5-3 Issue

There has been ongoing engagement with NRC on this issue

NRC agrees that “no PWRs need to update their P-T limits and PTS evaluations for 60 years of operation” (NRC Report at ASME XI WGOPC, May 2016)

NRC has tasked ORNL to perform analyses similar to those in MRP-401/BWRVIP-287 to address operation through 80 years of operation– To be completed by end of 2016

No decision has been made regarding whether or not BTP 5-3 will be revised– Likely depends on results of ORNL 80-year analyses


Future MRP Work on BTP 5-3 Issue

When the new version of FAVOR becomes available, MRP

plans to update MRP-401/BWRVIP-287

– Sensitivity studies performed with the beta version (Fall 2015) of

FAVOR indicate that certain changes made in the code will

increase CPF and negatively impact the conclusions of MRP-

401/BWRVIP-287

– Updating the analysis using the lower SFT previously discussed

may yield more favorable results for 80 year analyses


Update on GE Procedure for Estimating Initial RTNDT (1/2)

GE developed an alternate methodology for determination of Initial RTNDT for materials in BWR vessels, similar to BTP 5-3Technical basis was documented in 1994 BWR Owner’s Group

report (NEDC-32399P), which was reviewed & approved by NRC When BTP 5-3 issue was raised in 2014, NRC said its review

would also include the adequacy of the GE procedureEPRI review of NEDC-32399P identified a concern that the

technical basis did not include any data for forgingsBecause 9+ PWRs have used GE procedure to estimate Initial

RTNDT of nozzle forgings, MRP co-funded BWRVIP project to evaluate GE procedure for forgings– GE Hitachi generated a draft report offering qualitative arguments for the

conservatism of the procedure for forgings because test data necessary for qualitative analysis were not available


Update on GE Procedure for Estimating Initial RTNDT (2/2)

In January 2016 public meeting, NRC expressed its position that GE procedure is potentially nonconservative for base metal (both plates and forgings)

Because NRC position broadens the issue, BWRVIP then initiated project to more broadly evaluate the conservatism of the GE procedure

– Project is in progress

– Similar to approach in MRP-401/BWRVIP-287, project will determine the uncertainty associated with use of the GE procedure and then assess impact on vessel shell failure risk

– Report will combine work from GE Hitachi with this effort

PWRs are not relying on this effort to address potential concern for PWR nozzles; PWROG PA-MSC-1091R3 (Demonstrate Appendix G Margins for PWR RPV Nozzles and Beltline) will be used to address nozzle issue by using a generic SA-508 fracture toughness


Doel 3 Quasi-laminar Flaw Issue


Status of Issue and Plans

In 2013 MRP-367 assessed the relevance of the ~8,000 quasi-laminar flaws (hydrogen flaking) reported at Doel 3 in 2012

– For the limiting U.S. forged-ring PWR, safety goals are met when similar flaking is assumed for operation through 60 years

In 2014 Electrabel conducted another, more sensitive UT to ensure all flaws were detected

– Result: More reported flaws (~13,000)

MRP plans to update MRP-367 for (1) new flaw cartography and (2) address 80 years of operation

In late 2015, NRC tasked ORNL to review MRP-367

– ORNL provided draft report to NRC in late 2015 which NRC is still reviewing

– NRC will provide feedback to MRP by mid-September 2016 regarding whether or not any ORNL comments are consequential for planned MRP-367 update

– Update of MRP-367 will proceed after feedback from NRC is received


Topic 3 - Status on PWSCC Mitigation

by Peening


PWSCC Mitigation by Peening- Complete MRP Program in 2016

Technical Readiness & MRP R&D

ASME CodeNRC Safety Evaluation

Implementation

Peening LWRs in Japan

• Both PWRs and BWRs

• PWRs mitigated during RFOs

• Laser and Water Jet Technologies

• Nozzles, J-Groove Welds and DMWs

MRP R&D Program Complete

• PWSCC Initiation Testing

• Residual Stress Relaxation

• Vendor Technical Basis Information

Documentation and Guidance

• Technical Basis

- MRP-267, Rev 2 – published 2016

• Topical Report (MRP-335, Rev 3)

- Incorporate SE into -A revision

within 3 months of SE issue date

• Utility Implementation Guidance

- MRP-336, Rev 1 – published 2016

Dissimilar Metal Butt- Welds (DMWs)

• Code Case N-770-5

Reactor Pressure Vessel Head

Penetration Nozzles (RPVHPNs)

• Code Case N-729-5

In-service peening of:

• RV outlet and inlet nozzles

• Bottom-mounted nozzles

• Reactor vessel top head penetration

nozzles

– RPVHPN mockups for post-peening

UT inspectability demonstrations

1 complete for laser process

2 in-progress for spares

MRP-335 Rev 3 Safety Evaluation

(SE) for Optimizing Inspections

after Mitigation

• Technical Documents submitted to

NRC

• Fee Exemption and Acceptance

Reviews

• Requests for Additional Information

• SE

– NRC anticipates issuing by 9/30

– OMB Assessment - in-progress

Plant Applications

- 8 PWRs planning to mitigate Alloy 600/182 components by peening:

2016 - Byron-2 (completed spring 2016), Braidwood-1, Wolf Creek, ANO-1

2017 - Callaway, Byron-1, Braidwood-2, ANO-2

- 3 additional PWRs in planning, but funding not approved

Palisades, Indian Point-3, Indian Point-2




BACKUP SLIDES on

BAFFLE FORMER BOLTS ISSUE


Extent of Condition / Interim Guidance / NRC Interfacing

(Focus Area #1)

Primary objectives in the short term:– Developed an OE database and analyze for trends to identify potential

relationships between known failures and plant design/operating conditions

This will be a significant input in developing additional Interim Guidance

– Issue initial NEI 03-08 Interim Guidance to MRP-227/228 in the Fall 2016 timeframe

Potential update to Interim Guidance in 2017 based on OE from Fall 2016 and Spring 2017 refueling outages and other focus group activities

– Confirm refueling outage schedules for the next 2 years to feed into Focus Area #3 (Repair / Replacement needs)

This is needed to develop planning for both UT and replacement tooling and inventory assessment of typical BFB designs

– Support interfacing between regulatory authorities and industry groups


Plant/Fleet Operating Experience Assessment

(Focus Area #2)

Primary focus is on the development of the Westinghouse NSAL and the

AREVA Customer Service Bulletin

– NSAL issued 7/5/16 and revised 8/1/16

– AREVA CSB issued 7/14/16

Assisted in the development of an operating experience assessment

Will continue to review OE


Repair / Replacement (Focus Area #3)

Recent OE at IP2 and Salem 1 identified issues related to replacement tooling availability– Delays in BFB replacement tooling were experienced due to limited availability of equipment

Ongoing evaluations are underway for vendor capital and/or PWROG tooling investment– What is the appropriate amount of tooling needed

– How do the outages overlap in Fall 2016/Spring 2017

– Are modifications or changes needed to the existing equipment for production or reliability

Material availability assessment completed – Both vendors have bolting material to fabricate roughly 1,500 BFBs

– Items under consideration

Are increased machining rates required to potential provide sufficient bolts in a timely manner if required

Is a common bolt design possible to allow for faster machining rates


Inspection / NDE (Focus Area #4)

Current NDE UT methods are identifying defects

Review bolting UT results for lessons learned relevant to the protocol

Provide input to Focus Area #5 on recommended NDE examinations of bolts received from IP2 and Salem 1– Recommended PT prior to Destructive Examination

Evaluate the ability to correlate UT signals with measured crack size from destructive examination– May be impractical with multiple bolt designs and varying vendor UT

techniques

– Internal hex head bolts and locking devices are particularly difficult to UT


Irradiated Testing Support (Focus Area #5)

Short-Term Testing (2016)

• Work to support Indian Point and Salem root cause and operability analyses

Intermediate-Term Testing (2016)

• Testing with fleet-wide applicability resulting from the OE

Long-Term Testing (2017+)

• Evaluation of IASCC susceptibility of BFB materials with respect to dose and time

• IP2 has shipped 32 bolts to the Westinghouse Hot Cell Facility (received 6/29/16)

• Shipment of Salem bolts (6+) to follow

• Ginna bolts (6) to be shipped in August 2016


Aging Management Assessment (Focus Area #6)

Focus Area #6 is taking a long term approach toward understanding

the mechanisms and adjusting the guidance of MRP-227 as required;

for example:

– Review previous aging management assessments and compare to recent OE

– What materials/structural models best replicate observed OE and what do they

predict for the future

Evaluation of repair/replacement modifications

– Account for these within MRP-227 (re-inspection criteria)

– Relative effectiveness of options over the long term

Recommend adjustments to WCAP-17096 methodology as

appropriate




2016 Nuclear Sector

Member Satisfaction



Member Satisfaction - Background

EPRI has captured member satisfaction

feedback in various forms for many years

Current member satisfaction survey

adopted by Board in 2006

Results reviewed regularly with Board

– one of Corporate Performance Indices (CPIs)

Member feedback used to drive

continuous improvement across EPRI

Helps prioritize efforts

– focus on areas with greatest impact on

satisfaction


Nuclear Member Satisfaction Survey Results

Overall Performance

Ease of Doing Business

Technical Program Value

Overall Satisfaction

2015 Results

2010-2015 Trend

92.3%

Overall

PerformanceEase of Doing

BusinessTechnical

Program Value

86.1%

93.2%

92.4%

75%

80%

85%

90%

95%

100%

2010 2011 2012 2013 2014 2015

• Impact of research on improving my business

• The program's strategic priorities and directions

• Quality of research results

• Relevance of research carried out by the program

• Technical staff expertise

Top ranked aspects of EPRI Experience

Who completed the Survey


Category Initiative Timeframe

Research and

Development

• Research Focus Areas

• Project Overview Forms

• Quality Management ProgramImplemented 2016

Tech Transfer

• Executive Summary

• Onsite EPRI updates/regional meetings

• International workshops

• International NPC

• Digital Strategy (ongoing)

Implemented 2016

Simplification

• On-line Pricing

• Invoice Review

• New Pricing Model

Implemented 2016

Website• New Search Engine

• Member Center ImprovementsImplemented 2016

Improvement Initiatives

Listening and Responding to the Feedback of our Members


Digital Delivery Enhancements

Becomes


Becomes

Digital Delivery Enhancements


New Search Engine

The search engine gets smarter over

time based on use.

It tracks what people search and where

they go with the results.

The more the search engine is used, the

faster it learns.

As it learns, features such as relevance

and search term recognition will

dramatically improve, and as a result

improve your search experience.

You make the search engine better by

using it!


Survey instrument

Key components …

1. Who you arewithout a name and organization, we can’t

count your input!

2. Number of years you have been an Advisor

3. How we’re doing

4. How you assess EPRI value

5. Key improvement in ease of doing business

6. Value you have received from this Program


Survey instrument

Key components

7. Rate each statement based on how

satisfied you are

8. Rank the top 5 statements as

indicated in the instructions

9. Would you recommend EPRI

10.If you are not satisfied with us in any

area, please tell us why

9

10

7

8




2015 Nuclear Member Satisfaction Scores, By Area≤86% 87%-90% ≥91%

Program AreaSurveyed

Co's% Response

Overall

Performance

Technical

Program Value

Ease of Doing

Business

Overall

SatisfactionTotal

Nuclear Sector Council 19/39 48.7% 94.4% 96.6% 81.1% 93.3% 91.3%

Materials Degradation / Aging 18/40 45.0% 91.5% 92.1% 84.2% 92.1% 90.0%

Fuel Reliability 15/40 37.5% 89.5% 91.4% 89.5% 89.5% 90.0%

Used Fuel and High-Level Waste Management 16/40 40.0% 96.8% 96.0% 90.5% 97.8% 95.3%

Nondestructive Evaluation 13/40 32.5% 90.0% 92.7% 81.8% 90.0% 88.6%

Equipment Reliability 30/40 75.0% 91.0% 91.2% 83.8% 90.7% 89.2%

Risk and Safety Management 16/40 40.0% 92.2% 94.4% 91.1% 91.1% 92.2%

Strategic Initiatives (ANT and LTO) 20/40 50.0% 95.0% 95.7% 90.7% 95.7% 94.2%

Chemistry, Low-Level Waste and Radiation

Management15/40 37.5% 94.4% 94.4% 88.8% 95.8% 93.3%

Total 92.3% 93.2% 86.1% 92.4% 91.0%


Helen Cothron

SGMP Program Manager

PMMP Executive Committee Meeting


SGMP Technical Topic Status of High Impact

Activities



Presentation Content

Sherlock Project

Triton

In-Plane Fluid-Elastic Instability Testing


Sherlock – Test Program Using Two Retired Steam

Generators

2 SGs with complementary degradations of interest and design

Cruas 4 Paluel 2

Design Areva (Recirculating)

Tube bundle U-tubes – Alloy 600TT (Vallourec)

TTS Mechanical rolling + kiss rolling

Operating time ~30 years (more than 200.000 h)

NPP 900 MWe 1300 MWe

Φ tubes 7/8" 3/4"

Chemical Cleaning 2007 (HTCC) None

Water Coolant River Sea

Secondary chemistry Morpholine low pH Ammonia high pH

SG Replacement 2014 (done) In progress


Status of Sherlock Project

2010-2013

• Setting up• Choice of SGS, Choice of topics, Partnership

2014

• NDT during SG replacement (Cruas)• Primary side & Secondary side

2015

• NDT during SG replacement (Paluel)

• Primary side & Secondary side

2016 -2018

• Preparing works in Storage Building + Lab/ prototype works• Finalize examination programs, Find sub-contractors, etc

2018-2019

• Works in storage building• Decontamination, Sampling, NDT

2019-2023

• Laboratory Examinations• Visual, Mechanical, Metallurgical, Chemical exams


EdF Changes to the Project

• Recent changes in French regulations resulted in:

• Increased work necessary to adapt the SG storage building to comply with the regulation for the decontamination and sampling steps

• Large increase in the total project budget

• EDF financial difficulties have lead to a reduction in the Sherlock project budget (as well as the budget for many other EDF projects)

• To comply with budget constraints, the project scope will be modified to include the examination of only the Cruas SG

The expectation is that most of the initial project objectives can be met

EdF, AREVA, and EPRI are renegotiating the agreement– Expect project to be extended to 2023


Triton – State of the Art Steam Generator Thermal-

Hydraulics Code

Simulates velocities, void fractions, temperatures,

secondary side pressure

Thermal hydraulic conditions affect:

– Flow induced vibration, wear, and fatigue

– Deposit formation

– Foreign object assessments

– Thermal performance

Results of thermal hydraulic code output can be used to

inform:

– Uprates

– Fouling assessments

– Tube plugging


Status

Alpha-1 version released November 2014– Recirculating SG’s with and without preheaters

Alpha-2 version released February 2016– Once-Through Steam Generators (OTSG’s)

– Preheater and support plate customization

– Options for heat transfer and momentum correlations

– Post-processing capabilities

Beta version planned for June 2016– Did not pass software testing

– New beta version released August 2016

Version 1.0 planned for December 2016


In-Plane Fluid-Elastic

Instability Tests Status Air Flow tests complete

– Objective was to develop a basic understanding of in plane vibration to prepare for two-phase Freon tests

– Able to demonstrate in-plane fluid elastic instability

– What we learned Applying a small preload suppresses in-plane

vibration - Need to validate with two-phase conditions

Still unsure how significant out of plane vibration affects in plane vibration initiation –Need to validate with two-phase conditions

Number of supports (one vs two) more important than gap size

Coupling is important to initiate in-plane FEI –all tubes should be flexible


In-Plane Fluid-Elastic Instability Tests

Status

Planning stages for two-phase Freon tests underway– Use two support configurations and

the most relevant two-phase flow conditions, demonstrate in-plane fluid elastic instability

– Meeting with expert panel August 10-11, 2016

Test configuration is still under discussion

One test with a hold point

– Tests will cost more than expected

Negotiating the cost

CNL may share the cost


Tube Bundle

Layout


9 Air Flow Tests Completed Prior to Hold Point

Test Series No.

Tube Support Condition (AVB Cassette)

Number of

Flexible

Tubes

Tube

Support

LocationDiametral

Clearance (in)

Tube to Support

Setup

Dry or

Wetted

1 N/A N/A N/A All n.a.

2 0.040" Centered Dry All #1

3 0.040" Centered Dry One (C4) #1

4 0.040" Centered Dry All #1, #2





9 0.005" Centered Dry One (C4) #1


6 Additional Tests Performed After Hold Point

Test Series No.

Tube Support Condition (AVB Cassette)

Number of

Flexible

Tubes

Tube

Support

LocationDiametral

Clearance (in)

Tube to Support

Setup

Dry or

Wetted

10 0.010” Centered Dry One (C4) #1

11 0.010” Centered Dry All #1

12 0.010” Light Preload Dry One (C4) #1

13 0.010” Light Preload Dry All #1

14 0.010” Centered DryThree (2C,

3D, 4C)#1

15 0.010” Centered Dry

Seven (2C,

3B, 3D, 4C,

5B, 5D, 6C)

#1


Tubes Exhibiting Out-of-Plane FEI in the Lowest Mode at Approximately 2.9 Hz


Tubes Exhibiting Out-of-Plane FEI in Both the 1st and 2nd Modes at

Approximately 2.9 Hz and 8.1 Hz

Watch this tube


Tubes Exhibiting Out-of-Plane FEI in Both 1st and 2nd Modes Then Tripped to

In-Plane FEI

Initiation of IP-

FEI was

unpredictable


Typical Vibration Results

In-Plane Fluid Elastic Instability was observed in the air flow tests - typical results for vibration vs.

flow velocity

1. Stepwise

increasing

flow

2. Sudden

onset of IP

FEI

3. Stepwise

decreasing

flow

4.

Cessation

of IP FEI

5.

Threshold

Velocity


Schedule

Air-Tests Completed

– Expert panel will finalize the two-phase Freon test configuration after reviewing final air test report

Meeting was held at CNL in August

– Discussed air test results and made preliminary recommendations for Freon test matrix

0.020” gap, one AVB support, all flexible tubes

Options to be discussed include using a smaller AVB gap and one additional AVB support

Prepare for Freon Tests

– Some design is complete

– 2016 funding is depleted

– Further design, fabrication, setup, and testing will be completed 2017

– Tests conducted early 2018




James Benson

Technical Executive

PMMP Meeting


Steam Generator Foreign

Object Wear Estimation

Model Development



SG Foreign Object Experience


SG Tube Leak Events Due to Foreign Objects (US)

Source: EPRI SG Degradation Database (2016 is partial data)

2

1 1

3

2

1 1 1 1 1 1 1 1 1 1 1

0

1

2

3

4


SG Tubes Repaired Due to Foreign Objects (US)

Source: EPRI SG Degradation Database (2016 data represents a partial year)

3 2 2 3 4

15

4

1519

59

15

3931

60

78

54

35

17 15

57

70

48

17 15

4 23 11

6

10

1

4

6

3

2

28

4414

42

38

2

45

16

6

31

14

22

1

2 30

20

40

60

80

100

Num

be

r o

f T

ub

e R

epa

ire

d

Year

FO WEAR FO PREVENTIVE


Spiral Wound Cable Sheath at Byron 2

in 2002

Wire at ANO 2 in 2005

Objects Retrieved at South Texas

Project 1 in 2005

Large Nut in an Unknown SG

Examples of Foreign Objects Removed From SGs

Reference: Steam Generator Management Program: Steam Generator Foreign Object Handbook,

Revision 1, EPRI, Palo Alto, CA: 2016. 3002007858


Foreign Object Tube Wear Summary

TYPE OF FOREIGN OBJECT EVENT NUMBER OF EVENTS

LEVEL I EVENTS (<40%TW) 205

LEVEL II EVENTS (40-99%TW) 50

LEVEL III EVENTS (P-S LEAKAGE) 20

TOTAL NUMBER OF FO EVENTS 275

NUMBER OF FORCED OUTAGES 11

54.9%36.4%

5.5%

1.1% 1.8%0.4% TTS

Top of TSP

Freespan

Upper Tube End

Baffle Plate

Unknown

Axial Location of Foreign Tube Wear

Reference: Steam Generator Management Program: Steam Generator Foreign Object Handbook, Revision 1, EPRI, Palo Alto,

CA: 2016. 3002007858


Summary of Un-Retrieved Secondary Side FOs

Reference: Steam Generator Management Program: Steam Generator Foreign Object Handbook, Revision 1, EPRI, Palo Alto,

CA: 2016. 3002007858


Background

Foreign objects (FO) continue to enter into steam generator (SG) tube bundles

Some FOs can cause tube wear, which may lead to P/S leakage

Once FOs are identified by FO Search and Retrieval (FOSAR) equipment or by

Eddy Current Testing (ECT), utilities evaluate the need for removal

Removal of all identified FOs from the SG is not always warranted or possible

– FO will not cause tube wear (e.g., soft material)

– FOSAR vendor may be unable to retrieve (e.g., equip not capable or available)

– Worker radiation dose vs. risk to SG

In 2009 and 2010, EPRI developed FO Prioritization Strategies which utilities and

SG vendors have applied in making decisions on FO retrieval efforts

– Qualitative estimate of potential that a FO will cause tube wear

– To date, the strategies being used by the industry appear to be effective (i.e., No SG tube

integrity issues from FOs left in the SG)


Current FO Ranking Criteria Based on Operational Risk

Category 1 - High Priority: The object may cause wear greater than the maximum acceptable

wear depth before the next tube inspection. The most effort should be put to removing objects that

fall into this category.

Category 2 - Medium Priority: The object is not expected to cause wear greater than the

maximum acceptable wear depth before the next tube inspection. However, objects that fall into

this category may lead to long-term performance issues if not removed.

Category 3 - Low Priority: The object is not expected to cause significant tube wear. Less effort

may be made in removing objects that fall in this category.

EPRI Project EP-P27664 / C13136 - Steam Generator Foreign Object Critical Areas: Westinghouse Model F Steam Generator (/home/thakkajg/athos-ModelF/TAPE11.3958.3 / TAPE7.vgub)

122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62

ROW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

59 74.1 74.4 74.7 75.1 75.6 76.0 76.6 7 0

58 71.7 71.1 70.2 70.1 70.2 70.3 70.5 70.7 71.0 71.1 71.4 71.7 72.0 72.4 72.9 15 0

57 72.1 71.2 70.3 69.6 68.8 68.0 67.6 67.6 67.6 67.8 67.8 67.8 67.9 68.1 68.2 68.5 68.7 69.1 18 0

56 72.3 71.7 70.6 69.9 68.9 67.9 67.0 66.3 65.5 65.1 64.9 64.9 64.7 64.4 63.8 63.3 62.7 62.4 62.2 62.1 62.4 21 0

55 70.6 70.1 70.1 69.3 68.3 67.3 66.3 65.5 64.6 63.7 62.8 61.1 59.7 58.6 57.6 56.8 55.9 55.2 54.6 54.2 53.8 53.6 53.6 12 11

54 70.4 69.8 69.2 68.7 68.9 67.9 67.0 66.5 65.6 64.7 63.7 61.6 59.4 57.4 55.7 54.1 52.7 51.6 50.4 49.5 48.6 47.8 47.1 46.5 46.0 45.7 45.4 12 15

53 71.3 70.4 68.9 68.0 67.6 66.8 66.0 65.4 64.6 63.7 61.6 59.1 56.8 54.6 52.6 50.7 49.0 47.5 46.2 45.0 43.8 42.8 41.8 40.9 40.1 39.4 38.9 38.5 38.2 11 8

52 71.0 70.0 68.3 66.9 65.9 65.2 64.5 63.6 62.0 59.3 56.8 54.3 52.2 50.0 47.9 46.0 44.3 42.7 41.3 40.1 38.8 37.6 36.5 35.5 34.6 33.7 33.0 32.4 31.8 31.4 9 7

51 70.5 69.2 67.5 66.2 65.1 64.0 63.0 60.9 57.8 54.9 52.3 50.0 47.7 45.5 43.6 41.6 39.9 38.2 36.9 35.6 34.5 33.3 32.0 30.8 29.8 28.8 27.9 27.1 26.4 25.8 25.3 8 6

50 71.6 70.8 69.5 68.5 66.9 65.3 64.0 62.7 60.3 57.0 53.9 51.0 48.4 45.9 43.5 41.3 39.3 37.5 35.7 34.2 32.7 31.4 30.2 29.3 28.2 27.2 26.4 25.6 24.8 24.2 23.7 23.2 22.8 22.4 9 5

49 68.7 69.8 68.6 67.2 65.9 64.4 62.9 60.5 57.0 53.5 50.4 47.4 44.7 42.1 39.8 37.5 35.5 33.7 32.0 30.3 28.9 27.7 26.9 26.2 25.5 24.7 23.8 23.1 22.3 21.8 21.2 20.7 20.3 20.0 19.8 8 4

48 67.8 66.9 67.6 66.9 65.4 64.4 63.2 61.3 57.6 53.9 50.6 47.3 44.2 41.3 38.7 36.3 34.1 32.0 30.1 28.3 27.1 26.2 25.3 24.4 23.7 22.9 22.2 21.5 20.7 20.0 19.4 18.9 18.4 18.0 17.7 17.5 17.2 8 4

47 69.4 68.3 66.0 64.9 63.9 62.9 61.8 58.6 54.8 51.2 47.8 44.6 41.5 38.6 35.7 33.2 30.9 28.9 27.0 25.8 24.9 24.0 23.2 22.3 21.4 20.7 19.9 19.2 18.5 17.8 17.2 16.6 16.2 15.8 15.5 15.2 15.0 14.9 7 4

46 69.2 67.6 65.3 63.5 61.9 60.3 56.1 52.3 48.7 45.4 42.0 38.9 36.0 33.3 30.6 28.2 26.2 24.9 23.9 22.8 22.0 21.2 20.4 19.5 18.7 17.9 17.1 16.4 15.7 15.1 14.5 14.1 13.7 13.4 13.1 12.9 12.8 12.8 6 4

45 72.7 70.9 68.8 66.6 64.8 62.3 58.4 54.0 50.1 46.3 42.9 39.8 36.7 33.7 31.0 28.4 26.1 24.6 23.2 22.1 21.1 20.1 19.2 18.5 17.8 17.0 16.2 15.3 14.6 13.8 13.1 12.7 12.6 12.5 12.4 12.4 12.4 12.4 12.4 12.4 4 4

44 73.6 72.2 70.1 68.0 66.0 63.4 58.3 52.9 48.1 44.4 40.9 37.5 34.6 31.8 29.0 26.4 24.9 23.4 21.9 20.5 19.4 18.4 17.6 16.7 16.0 15.3 14.7 13.9 13.3 12.9 12.6 12.2 11.9 11.9 11.9 11.9 11.9 12.0 12.1 12.1 12.2 6 3

43 72.5 71.7 70.9 69.5 66.9 64.3 58.5 53.1 47.9 43.1 39.0 35.7 32.5 29.7 27.2 25.4 23.8 22.3 20.9 19.5 18.1 16.8 16.0 15.1 14.3 13.7 13.6 13.3 13.0 12.6 12.2 11.8 11.5 11.1 11.2 11.2 11.3 11.4 11.5 11.7 11.9 12.0 5 3

42 71.5 70.5 69.8 69.2 67.6 65.0 59.0 53.3 48.0 43.1 38.4 34.3 30.8 28.0 25.4 24.1 22.8 21.4 19.9 18.6 17.2 15.9 14.6 13.6 13.0 12.9 12.9 12.8 12.6 12.4 12.0 11.6 11.2 10.8 10.4 10.5 10.6 10.7 10.9 11.1 11.3 11.6 11.8 6 3

41 70.0 69.5 68.6 67.9 66.2 64.0 59.3 54.0 48.5 43.3 38.6 34.2 30.0 26.4 24.3 22.8 21.4 20.3 19.2 17.8 16.4 15.1 13.8 12.7 12.2 12.2 12.2 12.1 12.1 12.0 11.9 11.4 10.9 10.5 10.1 9.6 9.7 10.0 10.2 10.4 10.6 10.9 11.2 11.5 6 3

40 68.5 67.6 65.5 63.4 61.3 58.4 54.1 50.0 45.8 41.2 36.5 32.3 28.3 24.7 22.3 20.5 19.3 18.2 17.3 16.5 15.5 14.3 13.1 12.6 12.0 11.5 11.5 11.5 11.4 11.4 11.5 11.3 10.9 10.5 10.0 9.5 9.2 9.5 9.8 10.1 10.4 10.7 11.0 11.3 11.6 5 4

39 68.2 66.9 64.5 62.3 60.3 57.0 52.6 48.4 44.5 40.8 37.0 32.8 28.6 25.1 22.8 20.6 18.6 17.2 16.2 15.2 14.5 13.8 13.2 12.6 12.1 11.6 11.1 10.9 10.8 10.8 10.8 10.9 10.7 10.4 10.1 9.8 9.5 9.2 9.5 9.8 10.0 10.3 10.6 10.9 11.2 11.4 5 3

38 69.8 67.5 64.1 61.3 59.1 56.0 51.4 47.2 43.1 39.3 35.8 32.5 29.0 25.8 23.3 21.0 18.9 17.0 15.3 14.1 13.3 13.1 13.2 12.8 12.2 11.7 11.2 10.7 10.2 10.2 10.2 10.3 10.4 10.5 10.4 10.0 9.8 9.5 9.3 9.5 9.8 10.0 10.3 10.5 10.7 11.0 11.3 4 4

37 68.5 65.8 62.2 58.6 55.1 50.4 46.1 42.1 38.2 34.6 31.2 28.1 25.8 23.9 21.7 19.4 17.3 15.4 13.7 12.3 12.2 12.3 12.4 12.3 11.9 11.4 10.9 10.3 9.8 9.7 9.9 10.0 10.2 10.3 10.1 10.0 9.8 9.6 9.4 9.6 9.8 10.0 10.2 10.4 10.7 10.9 11.1 3 4

36 74.5 71.2 67.7 64.2 60.6 56.2 50.3 45.3 41.2 37.3 33.7 30.2 27.0 24.9 23.2 21.8 19.9 17.8 15.8 13.9 12.3 11.6 11.3 11.5 11.6 11.7 11.5 11.0 10.5 10.0 9.7 9.7 9.8 9.9 10.0 10.0 10.0 9.9 9.7 9.6 9.5 9.6 9.8 10.0 10.3 10.4 10.6 10.8 10.9 5 3

35 73.1 69.8 66.5 63.0 59.0 52.5 46.6 41.1 36.6 32.9 29.4 26.2 23.9 22.3 20.8 19.3 18.0 16.3 14.3 12.9 12.1 11.3 10.6 10.6 10.7 11.0 11.0 10.8 10.4 10.1 9.8 9.6 9.7 9.8 9.8 9.8 9.8 9.7 9.7 9.8 9.8 9.9 10.1 10.2 10.4 10.5 10.6 10.7 10.8 4 3

34 73.7 71.7 68.8 65.4 61.5 55.3 49.0 43.1 37.7 32.9 28.8 25.5 23.2 21.5 19.9 18.4 17.0 15.8 14.5 13.5 12.7 11.9 11.2 10.4 9.8 10.0 10.2 10.6 10.7 10.5 10.2 9.9 9.7 9.7 9.7 9.7 9.8 9.8 9.8 9.9 10.0 10.1 10.3 10.4 10.4 10.5 10.5 10.6 10.6 10.6 5 2

33 71.8 69.5 67.2 64.0 58.4 51.7 45.5 39.8 34.6 29.9 25.6 22.7 20.8 19.2 17.7 16.2 14.9 13.7 13.4 13.2 12.6 11.9 11.0 10.3 9.5 9.2 9.7 10.1 10.6 10.5 10.2 10.0 9.8 9.7 9.8 9.8 9.8 9.8 9.9 10.0 10.2 10.4 10.6 10.6 10.6 10.6 10.6 10.5 10.5 10.5 4 3

32 69.5 68.9 66.6 64.3 61.0 54.6 48.3 42.3 36.7 31.6 27.0 23.3 20.9 18.7 17.0 15.6 14.2 12.9 12.6 12.6 12.6 12.3 11.8 11.0 10.2 9.6 9.0 9.2 9.6 10.2 10.5 10.3 10.1 10.0 9.9 9.9 10.0 10.0 9.9 9.9 10.0 10.2 10.5 10.8 10.8 10.8 10.7 10.6 10.5 10.4 10.4 5 2

31 68.9 68.3 65.8 63.7 60.9 55.5 50.2 44.7 39.0 33.6 28.6 24.5 22.0 19.6 17.2 15.2 13.6 12.3 11.9 11.9 11.8 11.8 11.8 11.4 11.0 10.4 9.9 9.3 8.8 9.1 9.7 10.3 10.4 10.4 10.2 10.2 10.1 10.1 10.1 10.0 9.8 10.0 10.3 10.6 11.0 11.1 11.0 10.9 10.7 10.6 10.5 10.3 5 2

30 69.4 67.6 65.1 62.8 60.4 55.6 50.2 45.2 40.3 35.6 30.7 25.9 23.2 20.7 18.3 16.1 13.9 12.0 11.2 11.2 11.1 11.1 11.1 11.1 11.2 11.2 10.8 10.3 9.8 9.1 8.6 9.2 9.9 10.6 10.6 10.5 10.4 10.3 10.3 10.2 9.9 9.8 9.9 10.3 10.8 11.1 11.3 11.2 11.0 10.9 10.7 10.5 10.3 5 3

29 68.3 65.3 62.3 59.6 56.0 50.6 45.3 40.4 35.8 31.5 27.3 24.4 22.0 19.6 17.3 15.1 12.9 11.6 10.8 10.5 10.4 10.4 10.4 10.4 10.8 11.3 11.3 10.9 10.3 9.6 8.9 9.1 9.8 10.4 10.8 10.7 10.6 10.5 10.3 10.1 T T 10.1 10.5 10.9 11.3 11.6 11.4 11.2 11.0 10.8 10.6 10.3 3 4

28 68.1 66.2 63.1 60.1 57.2 51.2 45.8 40.8 36.1 31.7 27.5 24.4 22.7 20.7 18.6 16.2 14.1 12.6 11.8 10.9 10.1 9.7 9.7 9.8 10.2 10.6 11.0 11.4 11.4 10.8 10.2 9.6 9.3 9.8 10.3 10.8 10.9 10.7 10.7 10.6 10.3 T T 10.4 10.7 11.1 11.4 11.8 11.5 11.3 11.1 10.8 10.5 10.1 4 3

27 67.3 64.1 61.1 57.9 53.3 47.4 41.9 36.8 32.1 27.9 24.2 22.3 20.6 18.9 17.4 15.4 13.7 12.7 11.9 11.0 10.2 9.5 9.1 9.4 9.9 10.3 10.7 11.1 11.6 11.6 10.9 10.4 10.0 9.9 10.3 10.6 10.9 10.8 10.8 10.7 10.7 10.6 10.6 10.6 10.8 11.2 11.5 11.8 11.6 11.4 11.1 10.7 10.3 9.9 3 3

26 67.2 65.2 62.0 58.9 55.4 49.6 44.0 38.7 33.6 28.7 24.5 22.1 20.3 18.6 17.0 15.5 14.1 13.3 12.9 12.0 11.1 10.4 9.7 9.3 9.3 9.6 10.0 10.4 10.8 11.3 11.7 11.6 11.0 10.6 10.3 10.3 10.6 10.8 10.9 10.9 10.9 10.9 10.8 10.8 10.8 10.9 11.2 11.5 11.8 11.5 11.3 10.8 10.3 9.8 9.4 3 3

25 66.5 63.2 60.0 56.9 51.8 46.2 40.8 35.7 30.9 26.4 22.6 20.2 18.4 16.8 15.3 13.9 13.0 12.8 12.5 12.1 11.3 10.5 9.9 9.6 9.4 9.4 9.7 10.1 10.6 11.0 11.4 11.8 11.6 11.1 10.8 10.6 10.7 10.8 11.0 11.0 11.0 11.0 10.9 10.9 10.9 10.8 10.7 10.8 10.9 10.7 10.5 10.0 9.5 9.0 8.6 2 4

24 68.2 64.9 61.3 58.0 54.2 48.6 43.2 38.0 33.2 28.4 24.2 21.5 19.2 17.0 15.2 13.7 12.4 12.1 11.9 11.9 11.7 11.1 10.7 10.2 9.8 9.6 9.5 9.5 9.9 10.3 10.7 11.1 11.5 11.8 11.6 11.3 11.2 11.0 11.1 10.9 10.9 10.9 11.0 11.0 10.6 10.3 10.0 9.8 9.9 10.0 10.1 9.8 9.3 8.8 8.3 7.8 3 3

23 67.6 64.1 60.4 56.5 51.3 45.8 40.5 35.5 30.8 26.4 22.9 20.6 18.3 16.2 14.1 12.3 11.5 11.2 11.0 10.9 10.8 10.8 10.5 10.2 9.8 9.6 9.5 9.5 9.7 10.0 10.4 10.8 11.1 11.6 12.0 11.9 11.6 11.6 11.4 11.2 10.9 10.8 10.5 10.2 9.7 9.4 9.1 9.0 9.1 9.2 9.4 9.1 8.6 8.1 7.7 7.2 3 3

22 70.3 66.9 63.4 60.0 55.5 49.2 43.4 38.1 33.3 28.8 24.6 22.0 19.6 17.4 15.3 13.4 11.9 11.2 10.4 10.1 9.9 9.8 9.9 10.1 10.1 9.7 9.5 9.4 9.5 9.6 9.8 10.0 10.4 10.8 11.2 11.9 12.3 12.2 11.9 11.9 11.6 11.0 10.4 9.7 9.4 8.9 8.6 8.4 8.3 8.3 8.5 8.7 8.4 8.1 7.6 7.1 6.7 3 3

21 69.9 66.5 63.1 59.5 53.8 47.5 41.6 36.2 31.4 27.0 23.6 21.1 18.7 16.5 14.5 12.6 11.8 11.0 10.3 9.5 8.9 8.9 9.2 9.5 9.6 9.6 9.4 9.3 9.4 9.5 9.6 9.7 9.9 10.4 10.9 11.5 12.2 12.6 12.3 12.2 11.5 10.7 9.9 9.2 8.6 8.2 7.8 7.7 7.6 7.6 7.8 8.0 7.8 7.6 7.1 6.6 6.2 3 3

20 69.5 66.1 62.9 58.7 52.0 45.8 39.9 34.6 29.8 25.4 22.7 20.2 17.9 15.8 13.7 12.4 11.7 11.0 10.3 9.6 8.9 8.8 8.7 8.9 9.1 9.1 9.2 9.3 9.3 9.3 9.4 9.4 9.5 9.8 10.3 10.9 11.5 12.3 12.5 12.0 11.0 10.1 9.4 8.7 8.1 7.7 7.2 7.0 6.9 7.0 6.9 6.9 6.7 6.5 5.9 5.4 5.0 3 3

19 69.0 65.9 62.7 57.2 50.3 44.1 38.2 32.9 28.1 24.3 21.7 19.2 17.0 14.9 13.0 12.4 11.7 11.0 10.3 9.6 9.2 9.1 8.9 8.8 8.8 9.1 9.4 9.5 9.3 9.1 9.1 9.3 9.4 9.5 9.6 10.2 10.9 11.4 11.9 11.6 10.7 9.7 8.9 8.3 7.8 7.4 6.8 6.2 5.9 5.7 5.5 5.4 5.3 5.1 4.6 4.2 3.9 3 2

18 71.7 68.8 65.8 61.9 55.5 48.8 42.5 36.6 31.4 26.6 23.3 20.6 18.3 16.0 13.9 12.6 12.1 11.5 11.0 10.4 9.8 9.6 9.4 9.3 9.1 9.1 9.3 9.6 9.8 9.7 9.3 9.2 9.2 9.4 9.4 9.4 9.5 10.0 10.2 10.4 10.7 10.4 9.5 8.6 7.9 7.4 7.0 6.2 5.3 4.7 4.5 4.2 4.1 4.0 3.9 3.5 3.2 2.9 4 2

17 70.9 68.0 65.2 61.2 54.0 47.2 40.9 35.1 29.9 25.4 22.5 19.8 17.3 15.0 12.9 12.2 11.7 11.3 10.8 10.2 10.1 9.9 9.7 9.5 9.3 9.4 9.6 9.9 10.1 10.1 9.9 9.7 9.5 9.5 9.5 9.5 9.3 8.8 8.9 9.1 9.3 9.5 9.3 8.5 7.6 6.8 6.2 5.2 4.4 3.8 3.4 3.2 3.0 2.9 2.8 2.5 2.3 2.1 4 2

16 72.7 70.1 67.2 64.3 59.4 52.3 45.7 39.3 33.6 28.3 24.4 21.5 18.8 16.4 14.1 12.4 11.9 11.4 10.9 10.5 10.1 10.0 10.0 10.0 9.8 9.7 9.7 9.8 10.0 10.2 10.3 10.5 10.3 10.1 10.0 9.8 9.7 9.1 8.4 7.8 7.8 8.0 8.3 8.6 8.3 7.3 5.9 5.0 4.2 3.5 3.0 2.7 2.4 2.1 2.0 1.9 1.7 1.4 1.3 4 3

15 72.0 69.3 66.6 63.6 57.2 50.1 43.6 37.5 32.0 26.8 23.6 20.6 18.0 15.4 13.2 12.1 11.5 11.0 10.6 10.1 9.9 10.0 10.0 9.9 9.9 9.9 9.9 9.9 10.0 10.0 10.3 10.4 10.6 10.6 10.6 10.4 9.8 9.0 8.2 7.5 6.9 6.8 7.1 7.5 7.6 6.6 5.2 4.1 3.4 2.8 2.3 2.1 1.7 1.4 1.1 1.0 0.8 0.6 0.5 4 2

14 71.2 68.8 66.1 62.6 55.1 48.0 41.5 35.5 30.0 25.5 22.4 19.6 17.0 14.5 12.3 11.8 11.2 10.7 10.2 9.8 9.9 9.9 10.0 9.9 9.9 10.0 10.0 9.9 9.9 9.9 10.1 10.3 10.5 10.8 11.0 10.9 10.0 9.0 8.1 7.5 6.8 6.2 6.0 5.9 6.0 5.5 4.7 3.5 2.7 2.2 1.8 1.4 1.0 0.7 0.5 0.4 0.3 0.2 0.1 4 2

13 70.6 68.2 65.5 60.7 53.1 46.0 39.6 33.6 28.2 24.2 21.2 18.4 15.9 13.5 11.9 11.4 10.9 10.4 10.0 9.7 9.8 10.0 10.0 10.0 10.0 10.1 10.0 10.0 9.9 9.9 10.1 10.3 10.4 10.7 11.1 10.7 10.1 9.2 8.3 7.6 7.0 6.3 5.2 4.5 4.2 4.2 3.9 3.2 2.3 1.6 1.1 0.8 0.6 0.4 0.2 0.2 0.1 0.0 0.0 4 2

12 72.6 70.1 67.8 65.0 58.7 51.2 44.3 37.8 31.9 26.5 23.0 20.0 17.4 14.8 12.4 11.5 11.1 10.7 10.3 9.8 9.8 9.8 9.9 10.0 10.0 10.1 10.1 10.1 9.8 9.7 10.0 10.1 10.2 10.5 10.6 10.7 10.1 9.5 9.0 8.4 7.7 7.1 6.1 4.9 3.8 3.1 2.9 2.9 2.6 1.8 1.1 0.8 0.6 0.5 0.3 0.3 0.3 0.3 0.3 0.3 4 2

11 72.1 69.6 67.3 64.6 57.0 49.5 42.4 36.0 30.2 25.2 22.0 19.0 16.5 13.8 11.5 11.2 10.9 10.6 10.3 10.0 10.0 10.0 10.1 10.1 10.1 10.1 10.2 10.1 T T 9.9 10.0 10.1 10.3 10.5 10.3 9.6 9.0 8.5 8.1 7.7 6.9 5.7 4.6 3.5 2.7 2.2 2.0 1.8 1.3 0.9 0.7 0.7 0.7 0.7 0.6 0.7 0.8 0.9 1.0 4 2

10 71.1 69.2 66.9 63.8 55.5 47.9 40.9 34.5 28.7 24.1 21.0 18.1 15.5 12.9 11.0 10.9 10.8 10.6 10.4 10.2 10.2 10.3 10.3 10.3 10.2 10.2 10.1 10.1 T T 9.8 9.8 9.9 10.0 10.1 9.7 9.1 8.6 8.2 7.7 7.3 6.6 5.4 4.3 3.4 2.6 1.9 1.5 1.3 1.1 0.9 0.8 1.0 1.2 1.4 1.4 1.3 1.3 1.4 1.6 4 2

9 69.6 68.0 65.8 61.8 53.7 46.2 39.4 33.1 27.3 23.1 20.1 17.3 14.6 12.0 10.7 10.7 10.8 10.7 10.6 10.5 10.5 10.5 10.4 10.4 10.3 10.2 10.0 9.9 9.9 9.8 9.7 9.6 9.6 9.7 9.7 9.1 8.5 8.1 7.7 7.3 7.0 6.1 5.1 4.2 3.4 2.7 2.1 1.5 1.3 1.1 1.1 1.2 1.5 1.8 2.1 2.1 1.9 1.8 2.0 2.2 4 2

8 68.3 66.8 64.7 59.7 51.8 44.5 37.6 31.5 25.8 22.2 19.2 16.5 13.7 11.1 10.4 10.6 10.8 10.8 10.8 10.8 10.7 10.7 10.6 10.5 10.3 10.1 9.9 9.7 9.6 9.6 9.5 9.5 9.4 9.4 9.1 8.5 8.1 7.7 7.3 7.0 6.4 5.5 4.8 4.0 3.3 2.8 2.2 1.9 1.5 1.3 1.4 1.9 2.1 2.1 2.4 2.7 2.7 2.4 2.5 3.0 3 2

7 67.1 65.6 63.8 57.8 50.1 42.8 36.1 30.0 24.6 21.3 18.2 15.6 12.7 10.1 10.1 10.4 10.8 11.0 11.1 11.1 11.0 10.9 10.8 10.6 10.3 10.0 9.8 9.5 9.3 9.3 9.3 9.4 9.4 9.2 8.5 8.1 7.7 7.4 7.1 6.8 6.0 5.3 4.6 3.9 3.3 2.9 2.5 2.1 1.8 1.7 1.7 2.0 2.5 3.0 3.1 3.5 3.5 3.2 3.2 3.9 3 2

6 65.8 66.2 64.7 62.8 56.1 48.5 41.2 34.7 28.8 23.7 20.4 17.3 14.6 11.6 9.4 9.8 10.3 10.8 11.2 11.5 11.7 11.8 11.9 11.9 11.4 10.8 10.1 9.7 9.3 9.1 9.1 9.3 9.4 9.5 9.2 8.5 8.0 7.5 7.1 6.9 6.5 5.9 5.2 4.5 3.9 3.4 3.1 2.8 2.4 2.1 2.1 1.9 1.9 2.5 3.3 3.7 3.7 4.3 4.2 3.6 4.3 4 2

5 66.0 65.8 64.4 62.3 54.6 47.1 40.0 33.6 27.8 23.0 19.6 16.6 13.8 10.7 8.9 9.5 10.4 11.0 11.5 12.0 12.3 12.7 13.0 13.2 12.6 12.0 11.3 10.7 9.8 9.5 9.5 9.6 9.5 9.7 9.3 8.8 8.3 7.8 7.4 7.0 6.4 5.8 5.2 4.6 4.1 3.8 3.6 3.3 2.9 2.6 2.3 2.3 2.1 2.2 3.2 4.5 4.6 4.4 4.3 3.1 3.3 4 2

4 65.1 65.5 64.3 61.7 53.2 46.0 38.9 32.6 26.9 22.3 19.0 16.0 13.0 9.8 8.5 9.5 10.6 11.4 12.1 12.6 13.2 13.7 14.2 14.8 13.9 13.3 12.5 11.6 10.6 10.6 10.8 11.2 11.4 11.5 11.1 10.4 9.5 8.3 7.9 7.5 7.1 6.5 5.8 5.1 5.1 4.9 4.4 4.0 3.7 3.3 3.0 2.8 2.5 2.5 2.8 3.8 4.6 4.6 2.8 2.8 2.4 4 2

3 64.3 61.1 57.2 52.8 46.9 42.4 37.4 31.6 26.1 21.7 18.5 15.4 12.2 9.8 8.8 9.7 11.0 11.8 12.7 13.3 14.1 14.7 15.6 16.3 15.5 14.8 13.9 12.7 11.9 12.4 12.9 13.3 13.8 14.3 14.5 14.6 14.4 13.9 13.2 12.3 11.1 9.4 7.4 6.7 6.9 6.7 6.6 6.2 5.5 4.5 4.6 4.4 3.9 3.4 3.2 3.2 3.8 3.5 3.6 2.6 1.6 3 2

2 62.6 51.1 39.7 29.1 25.1 23.2 20.7 18.3 15.9 15.0 14.8 14.0 12.9 13.2 11.8 10.9 11.3 12.2 13.1 13.7 14.3 14.9 15.5 16.3 15.6 15.8 16.7 16.0 14.7 14.2 14.8 15.7 16.6 17.7 19.0 20.2 21.1 21.6 21.7 22.1 22.5 22.2 21.1 19.4 17.6 15.2 12.4 9.4 9.1 8.8 9.2 9.0 7.8 6.8 5.1 3.8 3.6 3.8 3.5 2.1 1.1 3 1

1 60.3 41.6 25.6 13.1 10.3 10.3 9.5 8.6 7.8 8.8 10.8 12.4 12.8 13.0 12.1 11.6 10.4 9.2 7.8 7.6 8.1 8.8 9.5 11.3 14.0 16.1 16.9 16.2 15.0 14.2 14.8 15.7 16.7 17.9 19.4 20.7 21.5 22.2 22.4 22.8 23.0 22.4 21.1 19.2 17.3 14.9 12.2 9.3 9.2 9.1 9.5 9.2 7.9 6.6 4.9 3.6 3.4 3.4 3.1 3.1 1.1 2 2

Number of Tubes: 327 187

Total Tubes (SG Each Side): 654 374

% of Total Tubes (SG Each Side): 11.6 6.6

6.6

xx 60 >rV2 45 lbf/ft

2

xx rV2 < 45 lbf/ft

2

60> rV2

45

TUBE LANE

xx rV2 60 lbf/ft

2

rV2

60

Total Tubes (SG Each Side): 654 374

% of Tubes (SG Each Side): 11.6

Zone Map—Bounding Triangular Pitch SG Model Zone Map—Representative Square Pitch SG Model Ref: Steam Generator Management Program: Foreign Object Prioritization Strategy

for Triangular Pitch Steam Generators. EPRI, Palo Alto, CA: 2010. 1020989

Ref: Steam Generator Management Program: Foreign Object Prioritization Strategy for

Square Pitch Steam Generators. EPRI, Palo Alto, CA: 2009. 1019039.


Excerpts from Foreign Object Prioritization Strategy for

Square Pitch Steam Generators, May 2009 (#1019039)

“The process described … provides a basis for defining retrieval efforts and should not be used to determine final acceptability of any objects remaining inside the steam generator.”

“Final acceptability is a function of many parameters, including actual object size, minimum wall thickness requirements, duration between inspections, and the actual object location, along with specific details regarding the steam generator in question.”

“All of those plant-specific features must be addressed in order to demonstrate final acceptability of any objects found in the secondary side of the steam generator.”


Steam Generator Foreign Object Wear Estimation Model

Development

Project Objective

To develop a practical and simple model for calculating FO-induced tube wear vs.

time

Project Tasks

Perform detailed measurements of fluid forces acting on FOs in SG tube arrays

Develop a model for estimating SG tube FO wear

Perform model testing and validation based on field data

Develop a hybrid model that incorporates current FO Prioritization Strategy

Develop a functional specification to incorporate the model into a SG FO wear

estimation software tool


Expected Benefits of a Model to Predict SG Tube Wear Rates

Caused By Foreign Objects

To provide input to an evaluation to determine acceptability if, for any reason, a

particular FO were to remain in the SG.

To assist in the evaluation of potential tube wear and to determine the length of

time that specific FOs can remain in the SG before removal may be required.

To produce results to confirm if the current industry methodology is conservative

and, if so, utilities could use it, as written, without performing an additional

assessment (i.e., validates the current approach)


SG Foreign Object Wear Model Development Work Flow

FO Force Experiments CFD analysis

FO Database

Development of FO Drag and Lift Force Coefficients

Model development


14

Water Flow Test Loops

x

z

U

Force measurement

system in test section

FO

flow

Initial Test Loop

Max Flow: 1.0 m/s

New Test Loop

Max Flow: 1.5 m/s


Force Data: Mean Drag Coefficient Correlations

Re : Reynolds numberpU dr

212

; : projected area; :pitch velocitydrag

d p p

p p

FC A U

U Ar

Plate-like FOs Rod-like FOs

2 : Equivalent cylinder to object surface area ratio ( ( ))

: object projected area / object length

c dc

o

p

SS d l

S

Ad

l


PLANT EXAMPLE : Robinson SG - Machining Remnant (Plate-like FO)

Mode 1: 126 Hz (approx.)

pinned

Model (Simple 1D ‘torsional’)


Robinson FO Case

Define FO Geometry

and Analysis Parameters

Results output

3D animation

Monte-Carlo simulation


Program: 3D Animation (Robinson FO)

3DAnimation

animation speed= 1/10 × real speed

animation amplitude= 4 × real amplitude


19

FO Wear Estimation:

Monte Carlo Simulation Results (Robinson FO)

Highest probability 100%TW:

70 to 150 days

• Actual time to 100%TW:

115 days (approx)

Highest probability 40%TW:

20 to 40 days


SQUARE ARRAY ROTATED SQUARE ARRAY

FO Location and Flow Direction Effects Based on CFD


Project Review Meeting with SG Vendors

Meeting Date: Feb 2, 2016

Participants: Areva, Westinghouse, B&W

Purpose of Meeting: To obtain vendor feedback on the value of a tool that can

provide an estimate of FO tube wear

Vendor Feedback:

– All 3 vendors indicated that they expect that the project could provide benefit to

the industry

– The experimental FO force information would be beneficial for performing FO

assessments

– A wear assessment tool would provide additional information/confirmation for

making FO removal decisions


Planned Deliverables

Technical Report

– Hybrid FO Wear Model development

– Underlying theory & experimental data

– Model validation

FO tube wear software specification

– Software would be intended to incorporate the Hybrid FO Wear Model into a

software product


Conclusions

FO wear has been the leading cause of SG tube leaks in recent years

FOs in steam generators should be retrieved to satisfy structural integrity performance criteria, unless it can be supported by engineering analyses that tube wear from FOs would not challenge SG tube structural integrity

Prior EPRI reports, containing FO Prioritization Strategies, provide a basis for defining retrieval efforts, but state that they should not be used to determine final acceptability of any objects remaining inside the steam generator

This project is intended to provide a tool that will determine FO-induced tube wear rates based on specific FO dimensions and SG flow conditions

The wear rate calculations are expected to provide the SG engineer with additional information to make FO removal decisions



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