Transcript Presentation to CNRB Meeting #583 Turkey Point Engineering
Power Uprate Lessons Learned Point Beach Nuclear Plant 2011 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
Power Uprate Lessons Learned
Unit 2 Diagram
4
Power Uprate Lessons Learned
Unit 1 Diagram
5
Power Uprate Lessons Learned
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
Power Uprate Lessons Learned
Lessons Learned Major Categories
• • • • • • •
Preparation Resources Foreign Material Exclusion (FME) Control / Chemistry Control Testing Configuration Control Technical Conscience Component Specific Lessons Learned
7
Power Uprate Lessons Learned
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
Power Uprate Lessons Learned
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
Power Uprate Lessons Learned 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)
Power Uprate Lessons Learned
• • • • • • • • • • • •
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)
10
Power Uprate Lessons Learned
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
11
Power Uprate Lessons Learned
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)
12
Power Uprate Lessons Learned
• • • • • • •
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
13
Power Uprate Lessons Learned
• • • • • • • • • •
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
14
15
Power Uprate Lessons Learned Feed Pump
# Stages Rated Speed Speed Increaser Design Flow Design Head Mini Recirc
Component Design Change Details
Before EPU
Bryon Jackson - DVS 1 6000 rpm Yes – 3.367:1 7800 gpm 2180 ft 500 gpm
After EPU
Sulzer – CD/BBS 1 3600 rpm No – Direct Drive 9300 gpm 2200 ft 4000 gpm
Feed Pump Motor
Horsepower Rated Speed Westinghouse 5000 1789 rpm TECO 6200 3582 rpm
Condensate Pump
# Stages Rated Speed Design Flow Design Head
Power Uprate Lessons Learned
Component Design Change Details
(cont.) Before EPU After EPU
Byron Jackson – 24 KXH 7 1180 rpm 4720 gpm 800 ft Flowserve – 28 APKD 7 1188 rpm 5700 gpm 760 ft
Condensate Pump Motor
Horsepower Rated Speed Westinghouse 1250 1190 rpm TECO 1500 1189 rpm 16
#1 & #2 LP FWHs Power Uprate Lessons Learned
Component Design Change Details
(cont.) Before EPU
Westinghouse (shell) Southwest Eng. (tube bundle)
After EPU
Yuba Length Diameter Heat Transfer #1 Heat Transfer #2 41 ft 9 in 68 in 147,500,000 Btu/hr 116,700,000 Btu/hr 49 ft 79.25 in 141,100,000 Btu/hr 126,600,000 Btu/hr
#3 LP FWHs
Length Diameter Heat Transfer Westinghouse (shell) Southwest Eng. (tube bundle & channel head) 42 ft 8 in 42.75 in 153,500,000 Btu/hr Yuba 42 ft 8 in 49 in 184,300,000 Btu/hr 17
#4 LP FWHs
Length Diameter Heat Transfer
Power Uprate Lessons Learned
Component Design Change Details
(cont.) Before EPU After EPU
Struthers Wells 34 ft 46 in 174,000,000 Btu/hr Yuba 38 ft 4 in 52 in 229,498,000 Btu/hr
#5 HP FWHs
Length Diameter Heat Transfer Yuba 53 ft 2 in 51 in 334,776,179 Btu/hr Yuba 48 ft 59 in 411,333,000 Btu/hr 18
FWH Level Control Valves
Controller Positioner Transmitter
Power Uprate Lessons Learned
Component Design Change Details
(cont.) Before EPU
Copes Vulcan Masoneilan - pneumatic Moore 72 - pneumatic Float – part of controller
After EPU
Copes Vulcan / SPX Yokogawa US1000-11 Fisher DVC 6010 Rosemount Guided Wave Radar 5300 Series 19
Power Uprate Lessons Learned
Component Design Change Details
(cont.) Before EPU
Copes Vulcan
After EPU
Copes Vulcan / SPX
Heater Drain Tank Level Control Valves
Controller Positioner Transmitter Foxboro - pneumatic Moore 72 - pneumatic Foxboro - pneumatic Yokogawa UT55A Fisher DVC 6010 Rosemount Guided Wave Radar 5300 Series
Feedwater Regulating Valves
Actuator Controller Positioner Copes Vulcan Copes Vulcan Foxboro 62 HB - pneumatic Bailey Model AP-4 - pneumatic Copes Vulcan / SPX RA Hiller Yokogawa YS-1700 Fisher DVC 6005 base unit DVC 6025 feedback unit
Feedwater Isolation Valves ( new)
Actuator Did Not Exist Flowserve Gate Valve Hiller - piston double acting 20