ML041970664

Summary of Category 1 Meeting with Omaha Public Power District Re Significant Projects Planned for the Next Two Outages at the Fort Calhoun Station

ML041970664
Person / Time
Site:	Fort Calhoun
Issue date:	07/15/2004
From:	Kennedy K NRC/RGN-IV/DRP/RPB-C
To:	Ridenoure R Omaha Public Power District
References
Download: ML041970664 (34)

Text

UNITED STATES NUCLEAR REGULATORY COMMISSION R E G I O N IV 611 RYAN PLAZA DRIVE, SUITE 400 ARLINGTON, TEXAS 76011-4005 July 15, 2004 R. T. Ridenoure Vice President Omaha Public Power District Fort Calhoun Station FC-2-4 Adm.

P.O. Box 550 Fort Calhoun, NE 68023-0550

SUMMARY

OF CATEGORY 1 MEETING WITH FORT CALHOUN STATION

Dear Mr. Ridenoure:

This refers to the meeting conducted in the Region IV office on July 8, 2004. This meeting was held to discuss significant projects planned for the next two outages at the Fort Calhoun Station. Specifically, during the 2005 refueling outage, the Fort Calhoun Station will replace the main condenser and moisture separators and implement the first phase of modifications to install a rapid refueling package. During the 2006 outage, the Fort Calhoun Station will replace the reactor pressure vessel head, the pressurizer, and the two steam generators and will complete the installation of the rapid refueling package. In addition, the Omaha Public Power District is constructing an independent spent fuel storage installation at the Fort Calhoun Station and plans to load the first storage casks in the spring of 2006.

In accordance with 10 CFR 2.390 of the NRC's "Rules of Practice," a copy of this letter and its enclosures will be available electronically for public inspection in the NRC Public Document Room or from the Publicly Available Records (PARS) component of NRC's document system (ADAMS). ADAMS is accessible from the NRC Web site at httD://www.nrc.uov/readinu-rm/adams.html (the Public Electronic Reading Room).

Should you have any questions concerning this matter, we will be pleased to discuss them with you.

Sincerely, Kriss M. Kennedy, Chief v

Project Branch C Division of Reactor Projects

Enclosures:

I.Attendance List

2. Licensee Presentation

Omaha Public Power District cc w/enclosures:

John B. Herman, Manager Nuclear Licensing Omaha Public Power District Fort Calhoun Station FC-2-4 Adm.

P.O. Box 550 Fort Calhoun, NE 68023-0550 Richard P. Clemens, Division Manager Nuclear Assessments Fort Calhoun Station P.O. Box 550 Fort Calhoun, NE 68023-0550 David J. Bannister Manager - Fort Calhoun Station Omaha Public Power District Fort Calhoun Station FC-1-1 Plant P.O. Box 550 Fort Calhoun, NE 68023-0550 James R. Curtiss Winston & Strawn 1400 L. Street, N.W.

Washington, DC 20005-3502 Chairman Washington County Board of Supervisors P.O. Box 466 Blair, NE 68008 Sue Semerena, Section Administrator Nebraska Health and Human Services System Division of Public Health Assurance Consumer Services Section 301 Centennial Mall, South P.O. Box 95007 Lincoln, NE 68509-5007 Daniel K. McGhee Bureau of Radiological Health Iowa Department of Public Health 401 SW 7th Street, Suite D Des Moines, IA 50309

Omaha Public Power District Electronic distribution by RIV:

Regional Administrator (BSMI)

DRP Director (ATH)

DRS Director (DDC)

Senior Resident Inspector (JGK)

Branch Chief, DRPIC (KMK)

Senior Project Engineer, DRPlC (WCW)

Staff Chief, DRPITSS (PHH)

RlTS Coordinator (KEG)

Dan Merzke, Pilot Plant Program (DXMZ)

RidsNrrDipmLipb DAMS: a y e s NO Initials:

Publicly Available 0 Non-Publicly Available 0 Sensitive Non-Sensitive RVAzua;df KMKennedy

• GW 71 HI04 71 \5I04

ENCLOSURE 1

~~

NRC PUBLIC MEETING ATTENDANCE 1 LICENSEUFACILlTY Omaha Public Power District Fort Calhoun Station I DATER7 ME July 8,2004; 12:OO Noon (CST) lli LOCATION Training Conference Room Region IV Office I NAME (PLEASE PRINT) 0RGANlZATl0N

I NRC PUBLIC MEETING AlTENDANCE .

LICENSEUFAClLlTY Omaha Public Power District Fort Calhoun Station DATERIME July 8,2004; 12:OO Noon (CST)

LOCATION Training Conference Room Region IV Office NAME (PLEASE PRINT) ORGANIZATION II I

ENCLOSURE 2 I'

Fort Calhoun Station Major Projects Omaha Public Power District I

Presentation to the Nuclear Regulatory Commission, Region IV July 8,2004 7lW2004 l I Introduction Ross Ridenoure Vice President flw

- 7/8/2004 gpeB 2 1

I I Introduction H OPPD participants H Purpose of meeting '

Introduce project management teams Discuss the what, why, and when of upcoming major projects at Fort Calhoun Station o Provide milestone information for planning of NRC inspection resources Discuss successful management of projects and plant operations 7/8/2004 w 3 I Meeting Agenda H 12:OO to 1 5 0 (Major projects except ISFSI)

Safety & Engineering - Ralph Phelps o Projects Overview - Sudesh Gambhir NSSS Component Replacement Overview - Ron Short o NSSS Component Design/Fabrication - Jay Cate NSSS Installation - Ron Bayer H 150 to 2:OO: Break H 2:OO to 3:OO o ISFSI - Sudesh Gambhir & Ken Erdman Closing remarks by OPPD and NRC 2

I Main Thing

.r P activities at FCS support the Mal1]Thing:

4 Safe,event-free, cost-competitive nuclear production of electricity for OPPD rn Failure to prepare is preparing to fail.

-John Wooden Core Principles rn Critical self-assessments are broad and lasting Human Performance is exemplary Operations are event-free throughout the organizat ion rn Initiatives in high visibility areas have strong performance rn Cost-effective producer of electricity rn Excellence in materiel condition 3

I Ladder of Accou nta biIity A Above the Lin Make It Happen! u Accountable Find a Solution! Behaviors Things Happen Own It! BECAUSE OF Victim Behaviors Things Happen Personal Excuses TO YOU Blame Others Unaware andlor Unconscious I I 7/8/2004 7 Safety and Engineering Ralph Phelps Division Manager - Nuclear Engineering 4

I Safety Nuclear Safety 8 P Top ,priority u Managing current engineering issues o Required inspections of RV Head, Pressurizer, and Steam Generators rn Radiological Safety o Control of Restricted High Radiation Areas o ALARA dose for required inspections and repairs o Source term reduction I

Safety Industrial Safety Safety Ion 1 initiative Improvement in Lost Time Accident record w Project Safety Major component replacements o Increased contractor population through 2006 7/8/2004 10 5

I My Safety Pledge I WlLLnowta fellow employees.

I AM making a new and fresh commitment to safety, my safety attitude, safety awareness at home and work.

7/8/2004 11 Engineering Engineering support of Project Teams o NED Strategic Plan o Matrixed personnel o Subject Matter Experts o Station Modification Acceptance & Review Team Engineering training/qualification of contractors 6

Overview Sudesh Gambhir Division Manager - Nuclear Projects 7/8/2004 13 Replacement (06)

Alive to 2033 &

8 Work Force DeveloDmenl i:

z.!j!.eadenhlD Leadership Academy i/j jj- Succession Planning 4 Maturlng Work Force 1:

1: ,:

w v 7/8/2004 14 7

Project Goals rn Nuclear safety/quaIity Q First time quality in everything we do Industrial safety o No one injured w Excellent communications Improved plant performance o Reliability I

7lBnW4 l5 I I Challenges

, Maintain Operational Focus o Keep the Main Thing the Main Thing Be Responsive to Operations & Maintenance needs I

~

o Maintain NRC Confidence

I rn Design Review for Major Projects Successfully Execute the Projects CI First time quality o On Budget On Schedule o Use of Plant Operating Experience 4 Tribal Knowledge o Ownership I

7/8/2004 16 8

I Vendor Performance (Staffing for Success)

Vendor Selection (best athlete approach)

Team/Relationship Building Clear Expectations/Training/Pre-job Briefings Oversight and Monitoring o 2 resident representatives at manufacturer o Executive oversight meetings Accountability rn Integration with plant staff 9

I (What Risk Management & Mitigation can go wrong & What are the consequences) rn Risk = Probability x Consequences rn Risks and mitigation strategies o Vendor Performance -+ Use operating experience o Installation + Identify first of a kind evolutions o Nuclear --+ Maintenance Rulehse of PRA o Outage -+ Use Outage Risk Assessment Model o Budget + BWG Consulting assessment o Other (weather, transportation, etc.) + Included in Budget risks 7/8/2004 19 Power Uprates w Extended Power Uprate (EPU) project is indefinitely deferred Replacement components sized for up to 17% power uprate rn Appendix K 1.6% power uprate o CROSSFLOW problems being addressed o Submittal of revised amendment request could occur later this year 10

Balance of Plant Improvements r Plantcomputer & simulator upgrades - 2005 w Condenser module replacement - 2005 w Moisture separator refurbishment - 2005 rn Low,pressure turbine replacement - 2006 w Unit transformer replacement - 2006 flw 7/8/2004 @ppB 21 I 2005 Big Outage Preparation w Site team fully integrated with no silos w Roles and responsibilities crystal clear w Relentless preparation & exhaustive reviews w Detailed contingencies w No missed milestones w Contractor oversight plan w Practice, practice, practice: On-line work behaviors the same as RFO work behaviors I

11

NSSS Components Replacement Projects Ron Short Manager - NSSS Refurbishment Project 7/8/2004 23 Scope Replace Steam Generators - 2006 RFO Replace Pressurizer - 2006 RFO Rep1ace Reactor Vessel Head - 2006 RFO Install Rapid Refueling Package o New Missile and Neutron Shields in 2005 RFO (Phase 1)

Remainder in 2006 RFO (Phase 2) 7/8/2004 24 12

II " RSGS Vendors Involved 1 1.

Mitsubishi Heavy Industries (MHI): Design, Fabrication, and Deliyery A mitsubishi

' Framatome ANP (Areva):

LicensingKafety Analysis O Bechtel: Installation RRVH R MHI: Design, Licensing, Fabrication, and Delivery (Westinghouse is Licensing subcontractor)

TBD: Installation I 7/8/2004 25 I Vendors Involved RPZR MHI: Design, Licensing, Fabrication, and Delivery A mitsubishi (Westinghouse is Design and Licensing subcontractor)

Bechtel: Installation RRP R Westinghouse: Phase 1 Design, Fabrication, and Installation o TBD: Phase 2 Design, Licensing, Fabrication, and Installation 13

1 Schedule w N-1 RFO: February 25 - April 21,2005 rn NSSS components delivery: May 15,2006 o Barge delivery preferred o Rail is alternate method w SGRO: September 8 - December 7,2006 7/8/2004 21 1 NRC Inspection Procedures Steam Generator Replacement:

o 50001 - Steam Generator Replacement Inspection Head Replacement:

o 71007 - Reactor Vessel Head Replacement Inspection General o 57050 - NDE Visual Examination Procedure Review/Work Observation/Record Review o 57060 - NDE Liquid Penetrant Examination Procedure ReviewNVork Observation/Record Review o 57080 - NDE Ultrasonic Examination Procedure ReviewNVork Observation/Record Review 14

Licensing Act ions Non-TS changes requiring NRC approval (per 50.59) have not been identified to date i Minor 'Technical Specifications changes Relief Request: ASME Section XI leak rate testing for Containment following restoration of opening I

Component Design and Fabrication Jay Cate NSSS Component Lead 15

1 1 Replacement Steam Generators I (RSG) FabricatiodDesign Features Improved molsture separation design Integralmain steam flow restrlctor Forged low alloy steel shells dad layup reclrculatlonnozzle improved feedring design Advanced AVE deslgn and material Alloy 690 thermally treated tubing Stainless steel tube support plater Hydraulic expansion of tubes in the tube stwet Improved primary and secondary side access lectropollshedprlmary channel head Improved bonom blowdown system design Flat bonom primary channel head dulgn 7/8/2004 31 I I 16

I Replacement Pressurizer (RPZR)

Safe End Manway Added Heater Sleeve Repair Pads Larger Support Skirt Acceos Holes I 7/8/2004 Surge NOZZIR - &#

Safe End 33 I Replacement RV Head (RRVH)

FabricationlDesign Features Flange eliminated CEDM Penetratlons (redundant below Grayloc penetntione removed)

One Piece Forging improvements Alloy 690 Penetration Weld -Alloy 690 Equivalent Buttering Jgroove weld 7/8/2004 W PPg A%Zz 34 17

7/8/2004 35 NSSS Component Supplier Responsibilities rn Mitsubishi Heavy Industries (MHI) contracted to supply RSGs RPZR, RRVH

+ Design

+ Material procurement Component fabrication

+ Delivery to Fort Calhoun 7/8/2004 36 18

Major Sub-suppliers of MHI RPZR Design - Westinghouse

' #HeavyForgings - Japan Steel Works RSG Tubing - Sumitomo Metals Industries Various other forging/material/serices sub-suppliers - all accepted under MHI Quality Assurance Program Component Installation Ron Bayer NSSS Installation Manager 19

I Component InstalIat ion 2 Phase Approach I Phase 1 Perform engineering studies to determine optimum installation method Identify risks and propose mitigation o Identify first of a kind evolutions for further action Phase2 Perform detailed installation engineering o Perform detailed planning I

7/8/2004 39 Component Installation Octagon opening allows removal of the fewest tendons 7/8/2004 40 20

+I Component Installation Inside Lift System (W

u UsedforSG movements Double Runway System o Outside rails supports ILS o Inside rails used to transport components out of and in to Containment Closing Containment Opening Reinstall Contai nment Liner Reinstall Tendon Sheathing ReinstaII Rebar Pour Concrete to Close Opening Re-tension Tendons Code pressure testing 7/8/2004 42 21

I' RRP/RRVH InstaIlat ion 7/8/2004 43 RRP/RRVH Installation RRVH installed with rapid refueling enhancements o Retractable utility bridges, integral fans 0 Missile & neutron shield installation 2005 RFO Concept similar to Seabrook, Wolf Creek, others RRVH largely assembled prior to 2006 RFO Limited laydown space in Containment Difficult to reuse old components Unique CEDM design (rack & pinion) m OEM vendor (Westinghouse) as technical lead 22

I End of First Presentation Questions/discussion Independent Spent Fuel Storage Installation Sudesh Gambhir Nuclear Projects Division Manager Ken Erdman Project Manager 7/8/2004 46 23

I Site Interface w Contractor controls w Interface with other projects w Operating Experience 7/8/2004 47 Spent Fuel Storage w FCS to lose full core off-load storage capability following the 2006 RFO rn Contract for fuel storage components and transfer services awarded to Transnuclear, Inc.

rn Transnuclear to provide special equipment and experienced personnel for fuel transfer under OPPD management rn Work on Independent Spent Fuel Storage Installation(ISFSI) is underway rn Each of 10 storage modules to hold container with 32 fuel assemblies W Initial load of storage casks scheduled for spring 2006 24

Storage Pad I 7/6/2004 49 NRC Inspection Procedures 60851- Design Control Of ISFSI Components 60852 - ISFSI Component Fabrication by Outside Fabricators 60853 - Onsite Fabrication of Components and Construction of an ISFSI 60854 - Preoperational Testing of an ISFSI 60855 - Operation of an ISFSI 60856 - Review Of 10 CFR 72.212(b)

Eva1uations 25

I ISFSI Project Phases ISFSl Construction Civil Site Work o Protected Area Development o ISFSllPlant Integration Dry Cask Storage System Fabrication Fuel Transfer 7/8/2004 51 I ISFSI Construction Schedule Civil Site Work Site Excavation and Structural Fill:

July 15 - September 1,2004 Concrete Pours and Final Grade Surfacing:

September 1 - October 31,2004 (IP 60853) 7/8/2004 52 26

ISFSI Construction Schedule Protected Area Development rn Engineering & Facility Change:

, June 28 - December 14,2004 rn Security Equipment Procurement:

December 15,2004 to March 31,2005 rn Construction of Security Fence, Support Building, LighUCamera Towers, etc.:

April 15 to October I,2005 7/8/2004 53 1 ISFSI Construction Schedule ISFSVPlant Integration rn Installation/Assembly of HSM:

July 1 - December 31,2005 rn Test of Cask Temperature Monitoring System: c December 200x- January 31,2006 rn Final Interfacemesting of ISFSI Security Systems :

5' December 2004 - January 31,2006 27

Dry Cask Storage System Fabrication Canister Fabrication Vendor Selection:

July 1, 2004 Dry Storage Canister Fabrication/Delivery:

January - December, 2005 Storage Module Fabrication/Delivery:

March - December, 2005 7/8/2004 55 Fuel Transfer Schedule Establish Load Campaign Responsibilities and Process Procedures:

June 16,2004 - January 31,2005 NRC Dry Run and Project Document Review:

February 2006 Initial I O Canister Load Campaign:

March - June 2006 28

Conclusion Questions Discussion Closing Remarks - W. Gary Gates J

7/8/2004 57 29