Power Uprate Lessons Learned Point Beach Nuclear Plant 2011 Units 1 & 2

Power Uprate Lessons LearnedPoint Beach Nuclear Plant2011 Units 1 & 2

Kelly Oetting

BOP System Engineer

FSRUG 2012 Conference

January 23-26, 2012

2

Power Uprate Lessons Learned

Power Uprate Scope

• Westinghouse 2 – Loop PWR, Unit 1 1970, Unit 2 1972

• 545 MWe to 637 MWe

• 1540 MWth to 1800 MWth

• 17%

• Approximately 35 Major Modifications for Each Unit

• Dozens of Smaller Supporting Modifications

3


Unit 2 Diagram

4


Unit 1 Diagram

5


Duration

• Unit 2 – 120 Days (3/1/11 - 6/19/11)

• Unit 2 – Power Ascension Testing 12 Days (6/19/11 – 7/1/11)

• Unit 1 – 75 Days (10/3/11 – 12/17/11)

• Unit 1 – Power Ascension Testing 12 Days ( 12/17/11 - 12/29/11)

• The Difference…..Mostly Lessons Learned!

6


Lessons Learned Major Categories

• Preparation

• Resources

• Foreign Material Exclusion (FME) Control / Chemistry Control

• Testing

• Configuration Control

• Technical Conscience

• Component Specific Lessons Learned

7


Preparation

• Design Packages – Are They ready? Design Final?

• Work Packages Planned?

• Parts On-Site/Available?

• Spare Parts On-Site/Available?

• Testing Packages Complete/Ready?

• Test Equipment Identified/On-site/Available?

• Pre-Outage Work Complete? (scaffolding, insulation, rigging, etc..)

• Is Your License Amendment Approved?

8


Resources

• Contractors – Majority of Work – Remember…They Eventually Leave

• Early DEDICATED in-house resources for design reviews and approvals

• Need dedicated in-house resources from Engineering, Operations, Maintenance, Procedure Writers, Document Control, Drafting

• Procedure reviews – Who’s doing it? Need knowledgeable people – HUGE resource drain (50% of system engineer’s time during outages)

• Don’t forget in-house participation in testing, especially I&C

• Who will do the equipment database and vendor manual updates?

• Resources Spare Parts Management, out with the old – in with the new

• Resources PM updates

• Routine System Engineering Duties May Have To Wait

9


Foreign Material Exclusion (FME) Control / Chemistry Control

• Na, F and Fe values above CEI limit for 25 days (U2) 10 days (U1)

• GMAW weld rod, sodium silicate binding agent

• Management Buy-In for Clean-Up Plans

• Specific Acceptance Criteria (quantitative not qualitative)

• Better physical barriers (covers, tape)

• Watch out for weld blanket (fraying and dye)

• Remove anti-rust coatings prior to installation

• TIG for root pass

• Smoke exhaust ventilation

• Flushing (high pressure wash & high volume wash)

• Grinding wheels – fibers plugged start-up strainers

• Start-up strainer design (mesh size? Back flush capability?)

• Consider a start-up polisher (trailer)

10


Testing

• Get Involved Early• Get the Right People Involved (In-House and Outside Expertise)• Predicted Values May Not Match Actual – Have A Plan To

Evaluate• How Will As–Left Setting Be Documented?• SQA Program?• Software Setup and Tuning Parameters Specified in Design?• Factory Acceptance Testing Specified in Design?• Bench Cal and Test Prior to Installation – huge time savings

between U2 to U1• Equipment Tagging Complete PRIOR to Testing• Finish ALL of the Start-Up Testing• Don’t remove test instrumentation early• FWH level optimization (knee test)

11


Configuration Control

• NAMS/PASSPORT Software not the most user friendly

• CRNs – Changes to original design package – cross reference not enough

• Revise original design package to show final configuration if possible

• Detailed titles and descriptions for CRNs

• Make sure CRNs for 1st Unit incorporated on the 2nd Unit

12


Technical Conscience

• Summit Fever!

• Accountants vs. Engineers

• Schedule Impact vs. Long Term Reliability

• Flushing (strainers, duration, chemistry requirements)

• Accepting Poor Workmanship (condenser wall)

• Spend a Little More for Increased Reliability (ES Exp Jnts)

13


Component Specific Lessons Learned

• Ensure Vendors Actually Meet The Agreed Upon Specifications

• Pumps; 30+ runs at manufacturer before pump acceptable (vibs, curve shape, alignment)

• Pump thermal growth nowhere close to calculated, measure it. (Essinger Bars, Rotalign, etc..)

• Pump nozzle loads required significant piping rework (vendor couldn’t accept piping designer’s higher values)

• Pump oil leaks due to thrust disc drive nut – wrench flats machined in wrong location

• Supplied Pump/Motor coupling keys too large, didn’t match half keys used for component balancing

• New Motors: Rotors made in China, failed on the test stand, rework; 5 new rotors had to be manufactured, shop in China never made 3600 rpm motors before

14


Component Specific Lessons Learned(cont.)

• Rewound motors: lower starting amps and torque, longer acceleration time caused rework for calculations and over current relay settings

• Valves – trim not sized correctly, valves full open at 100% pwr

• Skid mounted piping welds not per code or lacked vendor provided evaluation and poor quality

• Skid mounted components not rated for ambient conditions

• Skid mounted dp instruments piped backwards

• Small bore piping cracked socket weld, use 2:1 weld leg configuration

• Painters will paint everything, even moving parts

• Vendor manuals and drawings not updated timely

• Controller power supply failures caused mid outage design change for feed reg valve

• Swapping from backup to primary feed reg valve controller, need to wait 15 seconds and follow specific sequence or valve will go full shut – software glitch

15


Component Design Change Details

Before EPU After EPU

Feed Pump Bryon Jackson - DVS Sulzer – CD/BBS

# Stages 1 1

Rated Speed 6000 rpm 3600 rpm

Speed Increaser Yes – 3.367:1 No – Direct Drive

Design Flow 7800 gpm 9300 gpm

Design Head 2180 ft 2200 ft

Mini Recirc 500 gpm 4000 gpm

Feed Pump Motor Westinghouse TECO

Horsepower 5000 6200


16


Component Design Change Details(cont.)


Condensate Pump Byron Jackson – 24 KXH Flowserve – 28 APKD

# Stages 7 7


Design Flow 4720 gpm 5700 gpm

Design Head 800 ft 760 ft

Condensate Pump Motor Westinghouse TECO

Horsepower 1250 1500


17




#1 & #2 LP FWHs Westinghouse (shell)Southwest Eng. (tube bundle)

Yuba

Length 41 ft 9 in 49 ft

Diameter 68 in 79.25 in

Heat Transfer #1 147,500,000 Btu/hr 141,100,000 Btu/hr

Heat Transfer #2 116,700,000 Btu/hr 126,600,000 Btu/hr

#3 LP FWHs Westinghouse (shell)Southwest Eng. (tube bundle & channel

head)

Yuba

Length 42 ft 8 in 42 ft 8 in

Diameter 42.75 in 49 in

Heat Transfer 153,500,000 Btu/hr 184,300,000 Btu/hr

18




#4 LP FWHs Struthers Wells Yuba

Length 34 ft 38 ft 4 in

Diameter 46 in 52 in


#5 HP FWHs Yuba Yuba

Length 53 ft 2 in 48 ft

Diameter 51 in 59 in


19




FWH Level Control Valves Copes Vulcan Copes Vulcan / SPX

Controller Masoneilan - pneumatic Yokogawa US1000-11

Positioner Moore 72 - pneumatic Fisher DVC 6010

Transmitter Float – part of controller Rosemount Guided Wave Radar 5300 Series

20




Heater Drain Tank Level Control Valves

Copes Vulcan Copes Vulcan / SPX

Controller Foxboro - pneumatic Yokogawa UT55A

Positioner Moore 72 - pneumatic Fisher DVC 6010

Transmitter Foxboro - pneumatic Rosemount Guided Wave Radar 5300 Series

Feedwater Regulating Valves Copes Vulcan Copes Vulcan / SPX

Actuator Copes Vulcan RA Hiller

Controller Foxboro 62 HB - pneumatic Yokogawa YS-1700

Positioner Bailey Model AP-4 - pneumatic FisherDVC 6005 base unit

DVC 6025 feedback unit

Feedwater Isolation Valves ( new) Did Not Exist Flowserve Gate Valve

Actuator Hiller - piston double acting

Documents

Power Uprate Lessons Learned Point Beach Nuclear Plant 2011 Units 1 & 2