OUTAGE PLANNING & EXECUTION AT C-2 Shahid … · OUTAGE PLANNING & EXECUTION AT C-2 Shahid Bashir, Manager (Planning) C-2. ... List of shutdown jobs ... I&C Maintenance, Electrical

Effective Outage

Management

OUTAGE PLANNING & EXECUTION AT C-2

Shahid Bashir,

Manager (Planning)

C-2

Salient Design Features

C-2

Plant Design Parameters

No of Loops 02

Reactor core rated thermal power 998.6 MWt

Gross electric power output 325 MWe

Operating temperature 280 oC - 302 oC

Operating Pressure 15.2 MPa

Design life 40 years

Commercial Operation 18-05-2011

PART-I

OUTAGE PLANNING

C-2

Outage Management

(Other Than RFO)

Planned Outages:

• Notified / Scheduled at least 04 weeks in advance.

• Managed by normal plant organization.

Unplanned Outages:

• Managed by normal plant organization.

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Outage Management

Other Than RFO

List of shutdown jobs

• Readily available

• Updated by Planning div.

• Available on LAN

• Assessment / Preparation by relevant work units

• S/D jobs categorized

Short Hot S/D (<2 days) Longer Hot S/D (2 to10 days)

Cold S/D (5 to 10 days) Longer S/D (>10 days)

S/D Planning Meeting

• Meeting held within 04 hrs after Unplanned Outage

• Decision of Plant mode

• Line of action for safe and early startup

• List of Present Shutdown Jobs issued within 03 hrs

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Outage Management

RFO

• Refueling Outage planning and preparation is initially done by normal plant organization. Outage Execution Organization is established 5 to 6 Months before start of refueling outage which takes over the responsibility for planning, preparation and execution of refueling outage.

Administrative Procedure for Refueling Outage

• Defines the organization, responsibilities and processes for preparation, execution and follow-up of refueling outage.

• Defines Interfaces between different groups of plant and with contractors.

• specially focus on safety, quality, scheduling of activities and coordination between various parties involved.

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Refueling Outage Preparation…

Months

Before Start

of RFO

Activity

12 - Start preparation work

- Issue schedule of preparation work

11 Assign key Outage Management Personal

(COC, OC, DOCs, OM)

10 Define and issue Outage Goals / Objectives

08 - Identify Outage work Scope

- Budget estimate / Allocation of Funds

- Preliminary Level-1 Schedule

- Purchase orders

Preparation Schedule

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…Refueling Outage Preparation…

Months Before

Start of RFO Activity

06 Outage Scope freeze

05 - Award of major contracts

-Establish Outage Execution

Organization

03 Prepare ALARA Plan, Industrial Safety

Plan

02 Administrative procedures, Technical

procedures, quality plans, shutdown

safety plan and temporary

services/facilities plan


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Months

Before Start

of RFO

Activity

01 - Work Control Documents

- Level-I and Level-II Schedules

- Outage - Hand Book

- Logistics Arrangements

- Spare parts procured and checked

1/2 - Complete Pre-outage work

- Complete Training


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…Refueling Outage Preparation… Progress Review

Time

Before

Start of

RFO

Activity

11 Months Monthly Review Meetings

04 Months Fortnightly Review Meetings

02 Months Weekly Review Meetings

01 Week Daily Outage Coordination Meetings

03 Days Daily Planning Meetings

• Special Meetings with Contractors whenever necessary

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WCP (Pumps)

VWN

VER

SCW (Pumps)

WES (Pumps)

TBV

DHC

Fans at Roof

Coolers of Rotor/Stator

Open Cycle Pumps

Systems on which Preventive Maintenance can be perform during

normal Plant Operation to optimize the RFO work load

DDT

WRP

SLW

SBR

SDC

PWP

SNG Compressors

SCA Compressors

SAM

VSA


Outage optimization strategy C-2

Train Isolation Concept

• WES

• SCW

• EEG, VDC

• Essential Chillers

• VCH

} α OR β

C-2 RFO Planning Scheme

Lo-Lo Level Maintenance

Train Switch Over

…Refueling Outage Preparation… C-2


• Critical Path Schedule for activities on critical path including refueling, ISI , Maintenance, Modifications, tests and operational activities

• Level – I Schedule giving the sub-activities of all critical path activities in detail.

• Level – II Schedule giving the implementing schedules of all outage jobs including refueling, ISI , Mechanical Maintenance, I&C Maintenance, Electrical Maintenance Modifications, Tests (Surveillance and Startup).

Outage Schedules

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Assessment is made for the following:

• Manpower

• Duration

• Spare Parts / Materials / Consumables

• Cost

• Procedures

• Training

• Special Tools / Equipment

• Testing (Pre and Post)

• FME

• Temporary Services/Facilities Support from other work groups

*Plans are prepared where necessary


Assessment and Planning of Outage Jobs

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Training

• General Employees Training for all external manpower (Foreign & Local) on plant layout, organization, radiation protection, industrial safety, work control, emergency planning & preparedness and plant security.

• Special Training to Plant personnel as required.

Quality Assurance

• QA Audit (Review of Procedures, Quality Plans, QA Programs and manuals)

• QA Surveillance Plan for Selected Activities.


Shutdown Safety Plan

• Safety assessment is performed and a comprehensive shutdown safety plan is prepared.

• Ensures availability of key safety functions and maintain defence in depth during the outage. – Decay Heat removal

– Reactor coolant system inventory control

– Electrical Power Sources

– Spent fuel pool cooling

– Containment Closure

• Describes the active equipment that would be available to support the key safety functions.

• Defense in depth operational requirements and scheduling criteria are mainly based on technical specifications.


PART-II

OUTAGE EXECUTION

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Refueling Outage Execution…

Daily Meetings and Progress Reporting

• Daily Outage Coordination Meeting

• Daily Planning Meeting

• Daily Progress Report

• Weekly Progress Report

Schedule Updating

• Schedule is updated daily on the basis of progress, plant

condition and adjustment required by different work units

and contractors.

• 3 day Rolling Schedule is issued daily.

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…Refueling Outage Execution…

Work Control

• Responsible Persons apply for work authorizations, radiation work permits & industrial hazard permits

• Work authorizations are issued by MCR. After isolation of systems / equipment by Operation and preparation of necessary permits by Safety & Health Physics,.

• Equipment are tested after normalizing systems in the presence of relevant contractor personnel and relevant Plant responsible personnel.

• A centralized database management system for monitoring of WA status along with experience feed back window.

• Plant administrative procedures for work control, testing and acceptance are followed.

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…Refueling Outage Execution…

1) Operational Activities

• Operation Division performs operation activities according to schedule including: – Plant shutdown

– SRC oxidation operation

– Change of plant condition

– SRC water level variation

– Monitoring status of safety and support systems

– Functional surveillance tests

– Isolation of systems/ equipment

– Preparing and issuing work authorizations

– Restoration of systems/equipment after maintenance

– Line up for tests

– Post maintenance tests

– Start-up tests and plant start-up.

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2) Maintenance Activities

• Responsible Persons perform following activities:

– Arrange issuance of spare parts, consumables, tools

etc.

– Arrange Work Authorizations/necessary permits

– Execute the jobs on CNPP scope.

– Supervise the execution for contracted jobs

– Arrange quality control inspections according to

quality Plan

– Acceptance of equipment after maintenance.

…Refueling Outage Execution… C-2

3) Modifications • Performed by relevant maintenance

divisions/contractors

• Monitored by relevant System Engineers of Tech. Div.

• Responsible Persons of maintenance for different jobs (contracted jobs & jobs to be done by CNPP)

• Arrange issuance of spare parts, consumables, tools etc. Arrange Work Authorizations/ necessary permits

• Execute the jobs on CNPP scope.

• supervise the execution for contacted jobs

• Arrange quality control inspections according to quality plan and acceptance of the equipment.

• Final acceptance of the jobs is done by Technical Division.


4) Surveillance Tests

• Calibration & checking by maintenance.

• Functional Tests by operation with the participation of Maintenance and Technical.

• Final acceptance by Technical Division.

5) ISI Activities

• Responsible Persons perform following activities: – Arrange issuance of spare parts, consumables, tools

etc.

– Arrange Work Authorizations/necessary permits

– Execute the jobs on CNPP scope.

– Supervise the execution for contracted jobs

– Arrange quality control inspections according to quality Plan

– Acceptance of equipment after ISI.


6) Radiological Protection

• Radiation Protection Section provides radiation protection services.

• Entry into radiation controlled area (RCA) is allowed only against radiation work permits.

• Protective clothing and dosimeters are provided to all radiation workers before entry into RCA.

• ALARA plans are prepared and implemented for major hot jobs.

• Rubber areas are established where required.

• Radioactive waste is collected and stored according to waste management plan.


7) Quality Control

• Quality Plans

• QC Inspections by Work Units

• QC Inspections by QA & Assessment Division

• QC Inspections by Regulatory Body

8) Quality Assurance

• Planned Surveillance of Selected Jobs.

• General Surveillance

• Non-Conformance Management (NCNs, NCRs, Deficiency Reports)

9) Nuclear Safety Oversight

• Outage management is responsible for ensuring implementation of Shutdown Safety Plan.

• Operators are responsible for monitoring and maintaining the status of safety and safety support systems according to shutdown safety plan.

• Nuclear Safety surveillance is carried out by Technical Division.


Return to Service

• Outage Management ensures that the plant is ready

for return to service by verifying the following:

– Close out of all Work Authorizations

– Testing and acceptance of equipment.

– Systems returned to normal operating configurations.

– Completion of Surveillance and startup tests.

– All equipment is operable when required prior to mode

changes.

– Engineering issues and other commitments have been

closed out properly.

• Check lists are prepared and completed as

necessary.

…Refueling Outage Execution C-2

PART-III

OUTAGE FOLLOW-UP

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Refueling Outage Follow-up… • Experience feed back Report

– Work Units

– Contractors.

• Critique Meetings – Problem encountered

– Lesson Learned

• Refueling Outage Report – Outage preparation

– Outage execution

– Outage jobs statistics

– Major jobs

– Comparison of planned verses achieved outage goals and Critical Path Milestones

– Major problems encountered & corrective actions taken

– Good practices and lessons learned.

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…Refueling Outage Follow-up

• Refueling Outage Report on Radiation Protection

– Radiation protection activities performed

– Dose records

– Contamination control

– Waste management

– Deficiencies observed and lessons learned.

• Actions on feed back from previous refueling outage are identified and responsibilities for implementation are assigned.

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