Transcript Reestablishing CM at Browns Ferry 1 and Watts Bar 2

TENNESSEE VALLEY AUTHORITY
WATTS BAR NUCLEAR PLANT
Ed Freeman
Engineering Manager
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Project History
• May 1971- Application for Construction Permits for
WBN Unit 1 and 2 requested
• January 1973 - Construction Permits for WBN Unit 1
and 2 issued
• October 1976 - Application for an Operating License for
WBN Units 1 and 2 Requested
• June 1982 - Safety Evaluation Report for Operating
License for WBN Units 1 and 2 (NUREG – 0847)
issued
• September 1985 - NRC “Show Cause” Letter to TVA
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Project History
• Late 1985 - WBN Unit 2 Construction Suspended
• May 1989 - Nuclear Performance Plan (NPP) Describes
Actions to Identify and Correct Problems at WBN
• December 1989 - Safety Evaluation Report WBN NPP
WBN Unit 1 (NUREG-1232)
• November 1990 - NUREG-0847 Supplement 5 issued
• October 1995 - FSAR Amendment 91 issued
• November 1995 - Low Power Operating License for
WBN Unit 1 issued
• February 1996 - Operating License for WBN Unit 1
issued
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Project History
• July 2000 - TVA Formally Deferred WBN Unit 2
• January 2007 – Detailed Scoping Estimating Planning
Study
• July 2007 - NRC Staff Requirements Memorandum
• August 2007 - TVA Board Approves 5 Year Program for
Completion of Construction of WBN Unit 2
• August 2007 - Construction Reactivation Letter
• July 2008 - Construction Permit Extension
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Installation Status
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Major structures complete
System and component installations are substantially complete
Approximately 6600 pipe hangers installed
Substantial amount of instrument tubing incomplete
Electrical cables 90+% pulled and terminated
Some major components used in operating units – RCP’s,
Charging Pump, Aux Feedwater Pump, RHR Heat Exchanger
• Equipment condition is good
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Issues Related to Configuration Control
• Construction was stopped with incomplete documentation of
installation status
• Some QA records were lost or incomplete
• Cable pull and termination cards were missing
• ASME data package assembly had not begun
• 79-02/-14 piping and hanger program documentation missing
or not completed
• Operating units tended to use parts or whole components for
maintenance replacements
• Very few as constructed drawings done
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Objective for Completion
• Sound design supported by analysis
• Plant configuration that matches the sound design
• Construction completion statements or walkdown data for the
configuration
• QA records for equipment and material
• ASME N-5 and N-3 forms signed off for applicable systems
• Refurbishment records establishing “as new” equipment
condition
• Completed and successful test procedures documenting
performance objectives met
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Configuration Recovery Process
• Design Baseline Verification program
– Review existing calculations produced for the licensing of U1,
prepare a new U2 calc or make adjustments to the calculation for
two unit operation
– Review the original design documentation against current design
standards and practices
– Review/regenerate design criteria and system descriptions for
every system
– Program reviews (ie – Appendix R, EQ, 79-02/-14) for
compliance status and objectives
– Compare U1 existing design against U2 walkdown information
– Review documentation of installations for incomplete or missing
records
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Configuration Recovery Process
• Field walkdowns
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Operational modes/flow diagrams
“Pipe Tight” for Turbine Building
Piping Isometrics
Pipe Hanger detailed walkdowns (B31.1 and 79-02/-14)
ASME N-5 regeneration
Conduit installation and supports
Cable Tray supports
Cable terminations
Some cable signal tracing
Instrument Panels
HVAC ductwork
Embedded Plates
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Configuration Recovery Process
• Walkdown information compared to U1 configuration control
drawings, U1 design changes, U2 as designed drawings to
determine the gap between installed and desired configuration
• Engineering packages issued for the gap
• Engineering Document Construction Release issued for
incomplete construction or changes to existing design
• Process has controls for working in the vicinity of an operating
unit
• Addresses ASME N-5 completion issues and deficiencies
• Construction closure process insures correct installation
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WBN Unit 2 Refurbishment
• Refurbishment/Restoration - Performance of activities to restore a
component to its former good condition.
• Inspections - disassembly to the extent necessary to verify or
measure critical attributes (which may be affected by time),
cleanliness, conditions of bearing or seating surfaces or components.
• Cleaning - Removal of dirt and other contaminants using
pressurized air, water, approved solvents, etc., as necessary.
System/component flushes, as part of the startup testing program,
may be credited where applicable.
• Lubrication - Removal of old grease/oil from reservoirs, bearings,
and other lubricated components and replacement with vendor
specified or other engineering approved lubricants.
• Parts Replacement - Replacement of all “soft” parts which would
degrade over time, such as gaskets, packing, elastomers, etc.
• “Passive Refurb” – Inspection of structures, piping, physical
attributes to verify no significant pre-service degradation
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Preoperational Testing
• Component testing to demonstrate installation/refurbishment
of individual items
• Full RG 1.68 testing program
– Individual system functionals
– System performance tests
• Flushing program/System cleanliness
• Integrated Safeguards Testing April 2011
• Integrated Leak Rate Testing July 2011
• Cold Hydro May 2011
• Hot Functional August 2011
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Turnover to Operations
• Turnover process will include a validation that:
– Required design calculations and other documents are
complete and unverified assumptions have been closed
– Design packages have been completed in the field
– As constructed and configuration control drawings have
been issued
– Special programs and corrective actions for previous
construction deficiencies have been completed
– Refurbishment is complete
– Preoperational testing is complete
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Watts Bar Unit 2 Project Status
• Tracking to complete within the 60 month schedule
• Critical path - delivery of key equipment – Control systems,
valves, pumps
• Engineering and licensing activities are on schedule
• FSAR amendment has been submitted
• Construction bulk work is gaining momentum
• CCW and annunciator systems turned over for startup testing
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WBN2 Construction Completion Status
FY 2007
FY 2008
FY 2009
FY 2010
FY 2011
FY2012
FY 2013
OND J F MAM J J A SOND J F MAM J J A SOND J F MAM J J A SOND J F MAM J J A SOND J F MAM J J A SOND J F MAM J J A SOND J F MA M
DSEP
Ready for Fuel Load
April 2012
Construction Reactivation letter
TVA Board Decision
Regulatory Framework
Full Power
Operation
October
2012
Detailed Project Schedule
Commence Principal Construction Activities
Major Engineering Complete – March 2010
FSAR Amendment / OL Update
Turbine on Turning Gear – October 2010
U2 Emergency Plan Drill – May 2011
Integrated Safeguards Testing – Apr 2011
Primary Hydro – May 2011
Fill Ice Condenser – July 2011
Licensing Activity
Hot Functional – August 2011
Significant Project Milestone
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Questions?
?
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