Sub-Chapter 19.1 - Plant Commissioning Programme

7/21/2019 Sub-Chapter 19.1 - Plant Commissioning Programme

1/13

HPC-NNBOSL-U0-000-RES-000018 Version 1.0

Plant Commissioning Programme

NOT PROTECTIVELY MARKED

NNB GENERATION COMPANY LTD

HINKLEY POINT C PRE CONSTRUCTION SAFETY REPORT

SUB CHAPTER 19.1

PLANT COMMISSIONING PROGRAMME

PART OF CHAPTER 19, COMMISSIONING

Version 1.0

Date of Issue 14 May 2012

Document No. HPC-NNBOSL-U0-000-RES-000018

Next Review Date TBA

Produced by

(Company/Organisation)NNB GenCo


2/13

Text within this document that is enclosed within curly brackets {} is AREVAor EDF Commercially Confidential Information (CCI) or Personal Information (PI)and has been removed.


3/13




TABLE OF CONTENTS

0 INTRODUCTION ................................................................................................................. 4

0.1 Purpose............................................................................................................................... 4

0.2 Scope .................................................................................................................................. 4

1 PRE-OPERATIONAL TESTING (NON-ACTIVE COMMISSIONING)................................. 5

1.1 Phase I Individual System Tests.................................................................................... 51.1.1 Construction Tests............................................................................................................ 51.1.2 Individual System Tests.................................................................................................... 5

1.2 Phase II Pre-Core Loading Testing................................................................................ 51.2.1 Pre-Core Loading Testing................................................................................................. 61.2.2 Cold Functional Testing (CFT).......................................................................................... 6

1.2.3 Hot Functional Testing (HFT)............................................................................................ 71.2.4 Activities Managed via the Commissioning Programme............................................... 71.2.5 Preparation for Fuel Load................................................................................................. 8

2 INITIAL START-UP AND OPERATIONAL TESTING (RADIOACTIVE COMMISSIONING)8

2.1 Phase III Power Escalation Testing ............................................................................... 82.1.1 Initial Start-up..................................................................................................................... 92.1.2 Operational Testing (Power Raise Tests)........................................................................ 9

3 REFERENCES AND ABBREVIATIONS........................................................................... 10

3.1 References........................................................................................................................ 10

3.2 Abbreviations ................................................................................................................... 10

4 FIGURES........................................................................................................................... 12

LIST OF FIGURES

Figure 1: Plant Commissioning Programme (Overview)...............................................................12Figure 2: Plant Commissioning Programme (Principles) ..............................................................13


4/13




0 INTRODUCTION

0.1 Purpose

Commissioning tests serve as a progressive transition between erection, installation andthe start of normal operation of the various plant systems. These tests may take place atthe manufacturers or suppliers works, on specific test facilities or on the power station

site. The choice depends on the type of equipment, level of a systems integration thatcan be simulated off-site (e.g. Instrumentation and Control (I&C) systems) and on theability to obtain specific conditions on-site (e.g. for qualification of accident transients)[Ref 1].

The method of defining commissioning tests is chosen with the following objectives:

To ensure that plant commissioning does not compromise nuclear and/or industrialsafety,

To demonstrate that all statutory inspections and testing are completed inaccordance with UK codes and regulations,

To ensure that all operational aspects of system functions are tested, including safetyclassified functions, taking into account and credit for, manufacturers, and/or off-site)tests,

To serve as the basis for designing operational test documentation.

The main purpose of commissioning tests is to ensure that plant systems will performaccording to their design intent and satisfactorily meet the required safety function asstated in the safety case.

The test programme is based on reference documents that define and describe thesystems related functional aspects and specifications. This reference material isobtained from manufacturers information, plant systems manuals and designspecifications.

0.2 Scope

A phased approach is employed for plant commissioning. It is conducted from thecompletion of erection activities to full power commercial operation. It is organised intotwo test categories [Ref 2 and 3] and is carried out in three main phases:

Pre-operational tests (Non-Active Commissioning)


5/13




programme will be prepared after the design phase is completed. Plant testing will onlycommence once this programme of testing is approved [Ref 4].

The structure of the commissioning process is shown at Figure 1 and Figure 2.

Progression through the individual stages of testing identified in this document will besubject to QA hold-points and procedural requirements to ensure that all testing pre-requisites have been met. Plant and systems will be functionally tested and willdemonstrate compliance with test criteria prior to being required for subsequent tests.

1 PRE-OPERATIONAL TESTING (NON-ACTIVECOMMISSIONING)

1.1 Phase I Individual System Tests

Phase I includes initial construction and individual system tests:

Initial energisation of components and first start-up of equipment,

Functional testing of plant and equipment as individual systems and/or groups ofsystems without fully integrated testing with the reactor coolant system or relatingauxiliary systems and the secondary-side systems.

1.1.1 Construction Tests

These tests cover construction and installation checks leading up to first energisation

with process fluid and electrical supplies.

Pre-commissioning testing is a verification of installation and construction. Typicalactivities are checking motor insulation, pipe and equipment cleanliness, input/outputtesting of Instrumentation and Control (I&C) systems. This is a carried out as aconstruction function prior to handover for start of commissioning. The responsibility forcarrying out this work is emphasised in the contract document. There is a specificattachment specification covering commissioning activities.

1.1.2 Individual System Tests

This stage is done on a system-by-system or sub-system by sub-system basis,depending on the erection sequence, safety and planning requirements. These testsmust be finished when the system or sub-system is required for overall inactive testing.

Basic functional testing at system level is carried out in the Pre-Operational test phase


6/13




o Hot functional tests of the reactor coolant system,

o Secondary-side systems,

o Preparation for fuel load.

These tests are completed prior to loading nuclear fuel into the reactor vessel.

1.2.1 Pre-Core Loading Testing

Pre-start-up testing activities are expected to be as follows:

CEC (Chasse en Cuve) Dynamic Flushing into the VesselThe main safety systems which connect to the Reactor Coolant System (RCP [RCS])are flushed using water pumped from a large storage tank. This process is completeonce the internal pipework and equipment cleanliness meet the required criteria.

EFCO (Essai Functionnel Cuve Ouverte) Open Vessel Functional TestsThese tests are conducted with an open reactor pressure vessel, without the reactor

closure head in place. Safety Injection Systems (RIS [SIS]) are then functionally testedby injecting water directly into the primary circuit. Flow rates and control functions aretested. Carry out the initial operation and testing of Residual Heat Removal System(RIS/RRA [SIS/RHRS]) and Containment Spray (CAE).

Open Vessel Functional Test main steps would include:

Establish Reactor Coolant Pump seal injection to maintain seal cleanliness,

Pump water into the vessel to prove RIS/RRA [SIS/RHRS] flow orifices are of the

correct size,

Test RIS/RRA [SIS/RHRS] configurations and prove hydraulic characteristics of thesystem,

Accumulator discharges, functional Safety Injection Low and High Pressure pumps,

Verify RIS/RRA [SIS/RHRS] and CAE flow rates and control functions,

Loss of Offsite Power and transfer to Emergency Diesel Generator supplies (BAS).

1.2.2 Cold Functional Testing (CFT)

The Primary Circuit Cold Functional Test period is defined as that period, which for thefirst time, provides an opportunity for integrated system operation and testing of primarycircuit components and associated support systems with the reactor closure head inplace


7/13




Performance of primary hydro pressure test to verify leak tightness and integrity ofRCP [RCS] and high pressure pipework sections,

Initial preparations of the RCP [RCS] and related systems for the start of HotFunctional Testing.

These tests will prepare for Hot Functional Testing.

1.2.3 Hot Functional Testing (HFT)

The objective of Hot Functional Testing is to perform a series of individual integratedstation tests for which elevated pressures and temperatures are required in the RCP[RCS], prior to the initial charge of nuclear fuel. Full operational pressure andtemperature conditions are achieved from energy input by Reactor Coolant Pump (RCP)circulation and pressuriser heater operation. These conditions enable the reactormonitoring, control, safety and support systems to be operated and tested under normaloperating conditions.

This testing is selected to demonstrate, within plant limitations, that the operation of eachengineered system to support integrated plant operation will meet its design and safetyrequirements. This includes plant endurance running, chemical conditioning, reliabilitymonitoring and demonstration of human-machine interface from the Main Control Room(MCR) and at other local control stations. Power Station operations personnel wouldoperate and manoeuvre the plant in accordance with station operating procedures. Themain tests are to demonstrate the ability of the following:

To heat up plant to normal, operating conditions,

Passivation and chemical conditioning of the RCP [RCS],

To monitor, control and safely operate at normal operating conditions,

Reactor protection and safety systems to function correctly,

To safely cool down to ambient conditions from MCR and other control locations,

The station operating procedures to safely manoeuvre the plant,

Reliability and endurance running of the station under normal operating conditions.

1.2.4 Activities Managed via the Commissioning Programme

Due to the operating status and configuration of plant and availability of staff, certain keyactivities that are required as part of the preparation for start-up will be carried out underth t l f th ll i i i t Thi ll b t f th l t


8/13




ILRT is to demonstrate that the leakage integrity of the primary containment towithstand the calculated Design Basis Accident (DBA) pressure load that challengesthe primary containments leak tightness capability.

1.2.5 Preparation for Fuel Load

The post-HFT / pre-Fuel Load period is when preparations are being made to ensure allstructures, systems and components required to support the initial charge of nuclear fuelinto the RPV are in a satisfactory state. Activities carried out during this period are asfollows:

Final construction, inspection and testing of those systems not required for HFT, butare required for fuel load,

Post HFT In-Service Inspection (ISI) of the RPV,

Complete testing to fuel handling machine and associated equipment,

Boration of primary circuit systems in preparation for fuel load.

Activities may be brought forward or carried out in parallel to mitigate risk to later stagesof testing. Activities will be planned such that they do not impact on the systematicconfidence building approach to commissioning nor breach any consent hold points.

2 INITIAL START-UP AND OPERATIONAL TESTING(RADIOACTIVE COMMISSIONING)

2.1 Phase III Power Escalation Testing

Phase III includes fuel load, cold and hot pre-critical tests, initial criticality, and powerascension up to commercial operation. A demonstration run will also be conductedduring this test phase.

These tests include:

Standard start-up tests, which are designed to verify the correct operation of theplant and compliance with the design intent.

Testing that is repeated at different power levels during power ascension testing (e.g.core physics and control systems tests) to confirm that the design assumptions arevalid and support the safety analysis.

O ti d d t t ill Th th l t ti ti


9/13




The programme will evolve from experience gained during plant commissioning andinitial operation together with feed-back (lessons learned) from similar EPR plants.

2.1.1 Initial Start-up

Following preparation for fuel load, fuel is received, inspected and stored in the fuelpond, ready for loading. The fuel is loaded into the reactor core using the fuel handingequipment. Following verification of the core the upper internals and reactor head arereplaced. The reactor head is then secured and the reactor assembly is completed.

The reactor coolant system is then filled and fully vented to remove residual air. TheRCPs are then started to heat the RCP [RCS] up to nominal operating conditions.

Following fuel load there is a period of pre-criticality testing, which includes control rodmotion/drop tests. Initial criticality and low power physics testing follow for example asfollows:

Low power physics testing to verify design assumptions,

Evaluation of protection settings based on core physics test data,

Nuclear instrumentation testing.

2.1.2 Operational Testing (Power Raise Tests)

Specific tests are performed during power raise testing and are generally grouped intothree categories.

System tests, At-power physics tests,

Transient tests.

There is normally a period of continuous full power commercial operation before the finalrating certificate is issued.

2.1.2.1 System Tests

Power raise tests are normally structured to manoeuvre the plant to ever increasingpower levels and plateaus. The plant is then stabilised while a series of tests are carriedout. A number of tests are carried out during each plateau. These tests are designed toconfirm proper operation at lower core power levels before subjecting the plant to morerigorous testing at higher power levels.

The major power plateaus can be at a nominal reactor power of 30 48 75 and 100 per


10/13




2.1.2.2 At-Power and Transient Testing

An example of typical at-power tests are as follows:

Calibration of nuclear instrumentation,

Primary and secondary calorimetric testing,

RCS flow checks,

Reactor protection testing,

Physics testing,

Verification of plant behaviour during high power transients,

Transient testing; remote shut down, turbine trip, turbine load rejection, station blackout/turbine trip, reactor trip and National Grid response testing.

3 REFERENCES AND ABBREVIATIONS

3.1 References1

1. GDA PCSR Sub-Chapter 19.1 (2009) EDRMS.UKEPR-0002-191

2. Strategy for Commissioning EDRMS.NSL/B/TECH/10/279

3. Compliance Statement and Forward Work Plan LC21 Commissioning EDRMS.NSL/B/TECH/10/417

4. LC21 Commissioning, HSE T/INS/21 Issue 1 Public.

3.2 Abbreviations

Term / Abbreviation Definition

CAE Containment Spray

CEC (Chasse En Cuve) Dynamic Flushing into the vessel.

CFT Cold Functional Testing

DBA Design Basis Accident


11/13




Term / Abbreviation Definition

ISI In-Service Inspection

LC Licence Condition (ONR)

MCR Main Control Room

NNB Nuclear New Build

SSC Structures, Systems and Components

PSI Pre-Service Inspection

RCP [RCS] Reactor Coolant System

RCP Reactor Coolant Pump

RIS [SIS] Safety Injection System

RIS/RRA [SIS/RHRS] Safety Injection System/Residual Heat Removal System

RPV Reactor Pressure Vessel

SOT Structural Over-Pressure Test


12/13




4 FIGURES

Figure 1: Plant Commissioning Programme (Overview)

OFF SITE TESTING ON SITE COMMISSIONING

PREOPERATIONAL TESTING (NONACTIVE COMMISSIONING) START UP TESTING (RADIOACTIVE COMMISSIONING)

PHASE I SYSTEM TESTS PHASE II PRE CORE LOADING TESTS PHASE III POWER ESCALATION TESTSFACTORY

ACCEPTANCE

TESTING(FAT)

FACTORY

INTEGRATION

TESTING(FIT)

CONSTRUCTION

AND ERECTIONI.1

SETTING

TO

WORK

(STW)

I.2

SITE

ACCEPTANCE

TESTING

(SAT)

I.3

SITE

INTEGRATION

TESTING

(SIT)

II.1

COLD

FUNCTIONAL

TESTING

(CFT)

II.2

PREPARATION

FOR HOT

FUNCTIONAL

TESTING

II.3

HOT

FUNCTIONAL

TESTING

(HFT)

II.4

PREPARATION

FOR FUEL

LOAD

III.1

FUEL

LOAD

III.2

PRE

CRITICALITY

TESTING

III.3

CRITICALITY

TESTING

III.4

POWER

ESCALATION

TESTING

UNCONTROLLED WHEN PRINTED

NOT PROTECTIVELY MARKEDPage 12 of 13


13/13




Figure 2: Plant Commissioning Programme (Principles)

UNCONTROLLED WHEN PRINTED

NOT PROTECTIVELY MARKEDPage 13 of 13

Documents

Sub-Chapter 19.1 - Plant Commissioning Programme