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o NRC Attendees
o Licensee Project Team Attendees
o Dominion Surry Nuclear Station – Licensee
o Gary Miller (Licensing)
o Janean Sealey (Projects)
o John Henderson (Design Manager)
o Lars Gordon (Engineering)
o Structural Technologies, LLC – CFRP Material Manufacturer
o Jason Alexander, Anna Pridmore and Leo Nadeau
o Simpson Gumpertz & Heger (SGH) – CFRP Designer
o Rasko Ojdrovic
o Public Attendees
2
Presentation Agenda
3
Purpose of Today’s Meeting
4
Overview of CFRP Process and Procedure
o No excavation
o Standalone design (no reliance on
host pipe)
o Rapidly implemented
o Targeted or continuous repairs
o Minimal diameter reduction and
effect on flow
5
Overview of CFRP Process and Procedure
7
Scope of Proposed Alternative Request
8
Scope of Proposed Alternative Request
o Affected piping in Surry Power Station Units 1 & 2
o 96” diameter Circulating Water System Inlet Piping (CW) from the Station
Inlet Canal to the Main Steam (MS) Condenser and 24”, 30”, 36”, 42”, and
48” diameter Service Water (SW) System pipe headers from the CW system
to the supply lines to the Recirculation Spray Heat Exchangers.
o All of these lines are concrete encased and buried. The concrete
encasement of the piping systems was designed as a Seismic Category l
structure and provides the seismic support for these pipes. The piping was
fabricated in accordance with American Water Works Association (AWWA)
C201 “Standard Specification for Electric Fusion Welded Steel Water Pipe”
with carbon steel materials conforming to American Society for Testing
Materials (ASTM) A-283 Gr. B. The piping was designed and installed in
accordance with ANSI B31.1 -1967 “Power Piping Code”.
o A detailed listing of the piping sections to be replaced will be provided,
which identifies the pipe number, size, configuration, preliminary
construction schedule and function.
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Scope of Proposed Alternative Request
11
Scope of Proposed Alternative Request
Components Affected- Unit 2
12
Scope of Proposed Alternative Request
13
Scope of Proposed Alternative Request
14
Technical Basis
Enclosures Included in Alternative Request
o ASME Code Components Affected (Enclosure 2- scope, schedule,
definition of terms)
o Material inspection and controls (Enclosure 3- materials
inspections, controls and qualification testing)
o Design basis (Enclosure 4- drawings), (Enclosure 5- calculations)
(Enclosure 6- design specification)
o Installation (Enclosure 7- sample project installation procedures )
o Examination and Testing (Enclosure 8- sample project quality plan
and QA/QC forms)
o Qualifications and Training (Enclosure 9- sample qualification and
training package)
o Operational Experience (Enclosure 10- successful and failed
applications)
o In-service Inspection (Enclosure 11- sample in-service inspection)
15
Technical Basis
Material Inspection and Controls
16
Technical Basis
Material Inspection and Controls
o Saturating epoxy: 100% solids epoxy used to saturate the glass and
carbon fiber fabrics
o Primers: low viscosity 100% solids epoxy used to promote adhesion
between host pipe and CFRP
o Thickened epoxy: silica fume mixed with epoxy and used to create
smooth surface
o Structural reinforcing fabric: unidirectional carbon fiber fabric
o Non-structural fabric: glass fiber fabrics used as dielectric barrier,
intermediate layer and water barrier
o Finish layer: thickened epoxy used to provide resistance to abrasion,
chemical, flow, debris, etc.
o Termination materials: corrosion resistant metal expansion rings with
rubber gaskets used to mechanically press CFRP against pipe at ends of
repair(optional)
17
Technical Basis
Material Inspection and Controls
Epoxy
o Two-part
o Ambient cure thermoset
o 100% solids
o Volatile organic compound (VOC)
compliant
18
Technical Basis
Material Inspection and Controls
Primer
o Low viscosity epoxy providing an
adhesive bond for the thickened
epoxy.
Saturating epoxy
o Used to impregnate the
reinforcing fabrics.
Thickened epoxy
o Typically made up of the
saturating epoxy and silica fume
mixed together in accordance
with the manufacturer’s
procedure. The thickened
epoxy filler is used to even out
Application of primer coat the pipe substrate and it is also
used in between layers of CFRP.
19
Technical Basis
20
Technical Basis
Material Inspection and Controls
o CFRP liner is designed to take all the loads acting on the host
pipe without reliance on the host pipe for structural integrity
except at the termination locations.
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Technical Basis - Design Basis
Water Research Foundation (WRF) Research Projects
(2011-2015)
o Full-scale tests
o Hydrostatic pressure
o Three-edge bearing
o Laboratory tests
o Shear bond strength
o Degree of cure
o Water-tightness
o Finite element analysis (FEA)
of CFRP-lined pipe
o Based on Simpson Gumpertz
& Heger research including
Water Research Foundation
project #4352, 4510 and 4592 23
Technical Basis - Design Basis
Full-Scale Hydrostatic Pressure Tests
54 in.
pipe
48 in.
pipe
24
Technical Basis - Design Basis
25
Technical Basis - Design Basis
Finite Element Analysis (FEA) Validation
Sequential
analysis of buried
CFRP-lined pipe
that continues to
degrade
Buckling analysis
26
Technical Basis - Design Basis
Material Verification & Testing
o Witness panels – ASTM D3039
o Validate tensile strength
o Validate elastic modulus
o Validate ultimate strain
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Technical Basis - Design Basis
Shear Bond Strength on Steel Substrate
28
Technical Basis - Design Basis
Degree of Cure
o Cure Testing – ASTM E2160
o Differential scanning calorimetry (DSC) on epoxy
%𝐶𝑢𝑟𝑒
𝐻𝑡 − 𝐻
=
𝐻𝑡
29
Technical Basis - Design Basis
Progression of Cure
Varies by material
Need minimum
85% cure before
placing pipe back
in service
30
Technical Basis - Design Basis
Water-tightness Test
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Technical Basis - Design Basis
Water-tightness Acceptance Criteria
o Depending on layers of CFRP installed, dedicated water-
tightness layer or coating will be utilized
Specimen without water-tightness Specimen with water-tightness
layer, with multiple weeps at 150 psi layer, with no leaks at 400 psi
32
Technical Basis - Design Basis
Durability Testing
o Material adjustment factors established for each CFRP system through long-
term exposure, testing for the retained strength, and extrapolating the test
results out to the design life for the system (50-year service life).
o Time effect factor accounts for the creep rupture strength of CFRP.
33
Technical Basis - Design Basis
Determination of Material Properties
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Technical Basis - Design Basis
Multi-Ply Strength
o Strength depends on the number
of layers.
o Calculate the load-deformation
relationship for an n-layer
laminate by increasing
deformations until the first lamina
fails, and continue up to ultimate
load.
o Ultimate tensile strength of the n-
layer laminate is the ultimate load
divided by the initial area of the
laminate.
o Repeat sufficient number of times
to obtain the probability density
function (PDF) of tensile strength
of the multi-ply laminate.
35
Technical Basis - Design Basis
Factor of Safety
o Based on reliability analysis in WRF 4352 report
o Provide a desired probability of failure of 10-6 per calendar
year in accordance with NEI 96-07
o Desired minimum reliability index is 3.9
37
Technical Basis - Design Basis
Combined Stress
38
Technical Basis - Design Basis
Combined Circumferential Stress
41
Technical Basis - Design Basis
Sample Drawing Package
Sample CFRP layup for different pipe diameters
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Technical Basis - Design Basis
Sample Drawing Package
Schematic cross section of pipe and overlaps
(Not to Scale)
43
Technical Basis - Design Basis
Sample Drawing Package
Schematic detailing for different pipe configurations
(Not to Scale) 44
Technical Basis - Installation
Pre-installation requirements:
47
Technical Basis – Examination and Testing
o Project Oversight
o Multiple Owner Representatives
o Design Engineering Representative
53
Technical Basis - Qualifications and Training
54
Technical Basis - Operational Experience
Recent Nuclear Piping CFRP OE
57
Technical Basis – Surry Operational Experience
Surry Unit 1 CW 96-inch Discharge
58
Technical Basis – Surry Operational Experience
Unit 1 - CC SW 42-inch Discharge End Cap
CC SW
30-inch
Risers
59
Technical Basis – Surry Operational Experience
Unit 1 CC SW 30-inch Riser
60
Technical Basis - In-service Inspection
o For CFRP piping installed under this ISI Alternative, Inservice
Inspection requirements will include the following:
o Demonstration of CW and SW system integrity in accordance with
the Inservice Inspection Program for buried CW components by
documenting adequate flow through the 96-inch CW piping and
the major SW supply piping.
o Internal visual inspection of CFRP piping performed on a refueling
frequency.
o The visual inspection will include the following activities.
o Determination of the extent of biological fouling, sediment
buildup, and corrosion (including microbiologically influenced
corrosion-MIC)
o Assessment of the effectiveness of biofouling control mechanisms
o Monitoring the material integrity of metallic components, CFRP,
concrete, concrete to concrete, concrete to steel joints, Weko-
Seals, and other joint seals 61
Duration of Proposed Alternatives
62
Precedents
63
References
64
Regulatory Procedure
65
Questions
66