ML043430091
| ML043430091 | |
| Person / Time | |
|---|---|
| Site: | Saint Lucie, Turkey Point  |
| Issue date: | 12/06/2004 |
| From: | NRC/RGN-II |
| To: | |
| Shared Package | |
| ML043430077 | List: |
| References | |
| Download: ML043430091 (75) | |
Text
1 Nuclear Engineering Nuclear Engineering NRC / FPL Interface Meeting NRC / FPL Interface Meeting December 6, 2004 Region II Atlanta, Georgia ENCLOSURE 2
2 Agenda O Opening Remarks R. Kundalkar O Engineering Performance B. Hughes /A. Zielonka O Corrective Action C. Bible O Equipment Reliability A. Pell O Life Cycle Management W. Busch O Materials Management R. Gil O 2004 Hurricane Season B. Hughes O Summary R. Kundalkar
3 Nuclear Engineering Organization D. RYBCZYK EXECUTIVE SECRETARY B. HUGHES MANAGER ST. LUCIE SITE ENGINEERING A. ZIELONKA MANAGER TURKEY POINT SITE ENGINEERING P. FREEMAN MANAGER SEABROOK SITE ENGINEERING J. MOABA MANAGER MAJOR PROJECT ENGINEERING GROUP (MPEG) S/G, RX Vessel C. VILLARD MANAGER NUCLEAR FUEL D. TOMASZEWSKI MANAGER LIFE CYCLE MANAGEMENT S. HALE MANAGER SBK UPRATE / MSRs J. GARCIA CHIEF NUCLEAR ENGINEER C. BIBLE MANAGER SPECIAL PROJECTS R. S. KUNDALKAR VICE PRESIDENT NUCLEAR ENGINEERING
4 Engineering Performance St. Lucie / Turkey Point Engineering B. Hughes / A. Zielonka
5 WANO Weighted Overall Performance 75 80 85 90 95 100 1998 1999 2000 2001 2002 2003 2004 PSL1 PSL2 Industry Median 75 80 85 90 95 100 1998 1999 2000 2001 2002 2003 2004 PTN 3 PTN 4 Industry Median Data Through 9/04 St. Lucie Turkey Point PERCENTAGE
6 Engineering Department Indicators and Goals (1) All green by NRC criteria (2) FPL criteria more stringent (3) Unit 3 EAC significant improvement Green Red Unit 1 - 0.0 Unit 3 - 0.0 Unit 2 - 1.7 Unit 4 - 0.9 Unit 1 - 0.6%
Unit 3 - 0.4%
Unit 2 - 0.5%
Unit 4 - 0.5%
C.
Safety System Unavailibility - HPSI (1)(2)
<0.75%
>5%
Unit 1 - 0.4%
Unit 2 - 0.4%
Unit 3 - 0.2%
Unit 4 - 0.2%
D.
Safety System Unavailibility -AFW (1)(2)
<1.0%
>6%
Unit 1 - 0.5%
Unit 2 - 0.7%
Unit 3 - 0.4%
Unit 4 - 0.6%
E.
Safety System Unavailibility - RHR (1)(2)
<0.75%
>5%
Unit 1 - 0.6%
Unit 2 - 0.6%
Unit 3 - 0.5%
Unit 4 - 0.4%
F.
NRC Violations due to Engineering
<2
QA Findings
<2
>6 3
1 Unit 1 - 1.13E-5 Unit 3 - 1.64 E-5 Unit 2 - 4.01E-5 Unit 4 - 2.15 E-6 I.
OSHA Recordable Injuries 0
2 0
0 Outage 7%<
Outage 26%<
Non-Outage 11%<
Non-Outage 10%<
K.
Reactivity Events Due to Engineering 0 Major
<4 Minor
>5 Major
> 8 Minor 0 Lvl 1 0 Lvl 2 0 Lvl 1 0 Lvl 2 Unplanned Scrams Per 7000 Hours A.
<1
>6 J.
ALARA 10% <Budget
>5% Over Budget H.
Wano FRI 5 E-4
>2.0 E-2 B.
Safety System Unavailibility - EAC (1)(2)(3)
<1.25%
>5%
Turkey Point Actuals Nuclear Safety Focus (Data Through 9/30/04)
St. Lucie Actuals Goals Indicators
7 Engineering Department Indicators and Goals Green Red A.
Condition Report Evaluations (Late) 0 Late
>5 Late 0
1 B.
Condition Report Action Items (CAQ SITRIS ACTIONS Late) 0 Late
>5 Late 0
0 C.
Condition Report Action Items (Non CAQ SITRIS ACTIONS Late) 0 Late
>11 Late 0
0 D.
Self Assessments 1 in 6 mos
<2 per year 2
5 E.
System Walkdowns 90%-100% W/D Complete
<70% W/D Complete 100%
100%
F.
Drawing/VTM/TEDB Changes 0-2 Late 10 Late 0
18 (1) (2)
St. Lucie Actuals Goals Indicators Problem Identification and Correction (Data Through 9/30/04)
Turkey Point Actuals (1) No safety significant items late.
(2) No late priority 1 drawings, all were priority 3 and 4 drawings.
8 Engineering Department Indicators and Goals Green Red A.
Engineer Initial Training Not Started Within 12 Months of Hire
<1
>6 0
0 C.
Plant Modification Revisions due to ENG Error 0
5 4
0 D.
Procurement Engineering Backlog
( >4 Weeks Old)
<2
>11 0
121 B.
Training Performance Indicators GREEN Quality of Engineering (Data Through 9/30/04)
St. Lucie Actuals Goals Indicators RED GREEN GREEN Turkey Point Actuals
9 Engineering Department Indicators and Goals Green Red Unit 3 - 95.5%
Unit 4 -99.17%
B. Thermal Performance Indicator
>99.70%
<99.5%
Unit 1 - 99.98%
Unit 2 - 99.91%
Unit 3 - 99.9%
Unit 4 - 100%
C. Refueling Outage Duration
<30 Days
>35 Days Unit 1 35 Unit 3 66 (1)
Unit 1 - 0.1%
Unit 3 - 2.16%
Unit 2 - 4.24%
Unit 4 - 1.35%
100.00%
D. Forced Loss Rate 18 Month Running Average 0% - 1%
>2.0%
A.
Summer Capacity Factor
>99.8%
<98%
St. Lucie Actuals Goals Indicators Cost/Plant Operation Performance (Data Through 9/30/04)
Turkey Point Actuals (1) Special Reactor Head Replacement Outage for Turkey Point (Goal < 65 days)
10 Engineering Performance NRC Performance Indicator On Reactor Trips: Green to White O Causes O Actions O Status of Corrective Actions O Future Initiatives
11 Corrective Action C. Bible
12 Corrective Action O Performance Improvement Initiatives
- Programmatic
- Organizational
- Strategic O Examples
13 Performance Improvement Initiatives O Programmatic Improvements
- Electronic Condition Report system
- Equipment Reliability Improvement Program
- Utilizing enhanced troubleshooting procedure
- Form multi-discipline team
- Obtain Industry Experience and Vendor Input
- Develop Fault Tree and Cause Validation Matrix
14 Performance Improvement Initiatives O Organizational Initiatives
- Performance Improvement Departments
- Corporate equipment reliability manager
- Increased engineering staffing levels O Improved focus on equipment reliability O More proactive approach for equipment health O Dedicated corrective action program coordinator O Engineering FIX IT NOW rapid response teams
15 Performance Improvement Initiatives O Strategic Initiatives
- Equipment Reliability
- Preventative Maintenance Optimization
- Breaker Reliability
- Life Cycle Management
16 Performance Improvement Initiatives O
Increased number of condition reports O
Increased sensitivity to initiate condition reports for unexpected/unwanted conditions O
Increased identification of opportunities for improvement O
Open corrective action backlog remaining constant O
New trending tool developed, training in progress Turkey Point Condition Reports Originated Site-Wide 2866 5201 0
1000 2000 3000 4000 5000 6000 1Q04 2Q04 3Q04 4Q04 2003 CRs Generated Quarterly 2004 CRs Generated Quarterly 2003 Cumulative Total 2004 Cumulative Total Turkey Point Open Corrective Actions 414 459 501 583 634 707 766 756 750 788 631 521 592 534 567 0
100 200 300 400 500 600 700 800 900 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03 Jan-04 Feb-04 Mar-04 Apr-04 May-04 Jun-04 Jul-04 Aug-04 Sep-04
17 St. Lucie Unit 2 Auxiliary Feedwater Pump Overspeed O Event
- Steam driven pump tripped on overspeed while starting O Design
- Two electric driven pumps
- One steam driven pump
- Pump has two steam admission valves from A and B steam headers
- Steam admission valves open independently based on respective steam generator level
18 St. Lucie Unit 2 Auxiliary Feedwater Pump Overspeed O Root Cause
- Design of AFAS start logic
- Staggered pump start results from different timing on actuation of two steam admission valves causing governor instability
- Staggered starts were not tested during monthly surveillance's
- Design of steam supply piping
- Condensate in steam supply challenges governor when second steam admission valve opens
19 St. Lucie Unit 2 Auxiliary Feedwater Pump Overspeed Unit 2 AFW 2C Turbine Supply/Drain Piping MS Hdr 2A MV-08-13 V08130 SE-08-2 V08663 MV-08-3 V08884 MS Hdr 2B MV-08-12 V08163 SE-08-1 V08660 V08883 2C AFW Turbine V08165 V08622 V08661 V08618 V08619 V08600 V08662 V08177
20 St. Lucie Unit 2 Auxiliary Feedwater Pump Overspeed 2C AFW Pump Overspeed Trip Gov ernor Unstable for Condition OS Linkage Problem Buffer Springs Incorrect Tappet Nut/Head lever Governor Oil Incorrect OS Actuation Incorrect Engagement Worn Mating Faces Bent/Damaged Stem Cam Plate Binding Low Lev el Temperature Gov ernor Valve Binding Valve binding Condensate in Steam Supply Turbine at Full Speed Staggered Start Stability Adjustment CR 03-4548 Attachement 23, Page 1 of 4 2C AFW PUMP OVERSPEED FAULT TREE ANALYSIS Contamination Looseness in linkage Stem spring coil bound
21 St. Lucie Unit 2 Auxiliary Feedwater Pump Overspeed 2C AFW Pump Turbine Trip Fault Validation Matrix Potential Cause Potential Fault Validation Results Root Cause Measure trip tappet/head lever engagement (0.030-0.060) 0.038 Tappet/head lever engagement Agitate linkage to test health Agitated linkage and could not get mechanism to trip Ruled Out- 0.038 within spec.
Condition of head lever/tappet nut surfaces Inspect head level/tappet nut surfaces Surfaces in good condition Ruled Out based on inspection and agitation test.
Overspeed linkage vibration/wear Incorrect OS actuation Replicate event to see if actual overspeed occurs.
Test duplicated valid OS - max turbine speed 5200 rpm, OS setpoint - 4690 rpm Ruled Out base on test results Bent/damaged stem Inspect for bent stem.
Monitor during operation.
Manual stroke.
Vendor and SCE observed operation, no indication of improper operation.
Ruled Out based on inspection and operational performance.
Valve binding Check for smooth stroke by manual actuation Inspection performed; no indication of adverse condition.
Manual stroke Sat.
Ruled Out based on inspection and operational performance.
Cam plate binding Monitor during operation.
Manual stroke.
Vendor and SCE observed operation, no indication of improper operation.
Ruled Out based on inspection and operational performance.
Looseness or free play of linkage Check for looseness or free play Vendor and SCE inspected linkage. No looseness noted.
Ruled Out Governor valve binding/improper operation Spring coil bound on closing Check to determine if spring is coil bound Vendor observed operation, spring not coil bound Ruled Out
22 St. Lucie Unit 2 Auxiliary Feedwater Pump Overspeed 2C AFW Pump Turbine Trip Fault Validation Matrix Oil level adequate Check Oil Level 3/8 below top of sightglass.
Verified correct during test runs.
Ruled Out.
Correct buffer springs Check springs Checked with Woodward that correct springs are installed.
Ruled Out, stable operation achieved with current springs.
Oil Temperature/
Viscosity Verify correct oil for operating range.
R&O 32 oil is acceptable to temperature as low as 40 oF.
Temperature ruled out as contributor.
Governor mis-adjusted Review traces for divergent speed behavior Test traces indicated that adjustment was needed.
Potential Contributor Load Change challenges governor.
Perform testing to determine possibility of load change causing instability No abrupt load changes were witnessed during tests.
Ruled out based on testing.
Staggered start causes governor instability Review surveillance data, previous events and current test data.
Governor response satisfactory during single start scenarios and staggered start scenarios without condensate. Turbine vulnerable to overspeed when upset at nominal speed.
Potential Root Cause Governor Unstable for Condition Condensate in steam supply challenges governor.
Perform replicate testing to determine presence of condensate Testing demonstrated that water present during start sequence.
Potential Root Cause
23 St. Lucie Unit 2 Auxiliary Feedwater Pump Overspeed O Interim Corrective Action
- Adjusted governor compensating needle valve and verified proper operation with extensive testing replicating staggered starts
- Optimized condensate removal and heating of piping
- Perform staggered starts during monthly surveillance's O Final Corrective Action
- Modify AFAS start logic to simultaneously open both steam admission valves (Currently planned for unit outages in 2005)
24 Turkey Point 4A EDG Lockout O Event
- 4A EDG lockout relay actuated while EDG was in the standby condition
- Initial indications pointed to a problem with the Electronic Speed Switch (ESS)
O Design
- ESS receives input from magnetic speed sensor on engine flywheel and provides relay outputs of engine speed to various components
- Power source for ESS is shared with EDG annunciator panel power supply
25 Turkey Point 4A EDG Lockout O Root Cause
- ESS sensed electrical noise from faulty annunciator panel power supply as pulses from speed circuit magnetic pickup
- Power supply filtering capacitor failed O Corrective Action For Similar Power Supplies
- Replace 4B EDG and Unit 3 and 4 control room J panel capacitors
- Establish PM for 8 year replacement of filtering capacitors
26 Turkey Point 4A EDG Lockout EDG 4A Annunciator Power Supply (PS-1) Root Cause Matrix Cause Validation/Action Steps Expected Results Actual Results Status Failed PS1 inverter section Replace PS1 inverter section False speed indication would clear. Annuciator power would be restored Annuciator power supply failed; Fuse 2 on new inverter opened. Obtain good replacement inverter with new parts.
Complete Troubleshoot for failed component on original PS1 inverter Failed open C1 capacitor would not filter feed back noise. In Progress Inverter input capacitor (C1-1200 mfd) found open circuited.
Complete Troubleshoot for failed component on replaced PS1 inverter Identify failed components Found a mounting screw (larger than normal) shorting transistor to chassis Complete Failed PS1 rectifier circuit Implement TSA to isolate inverter and test PS1 rectifier circuit with 120 Vac.
Annunciator circuits function properly Annunciator circuits function properly Complete Failure of annunciator cards or circuitry.
Implement TSA to isolate inverter and test PS1 rectifier circuit with 120 Vac.
Annunciator circuits function properly.
Annunciator circuits function properly.
Complete Excessive loading from annunciator.
Use temporary power supply.
Measure load currents.
Load currents within specification.
Load currents within specification.
Complete
27 Turkey Point 4A EDG Lockout EDG 4A Lockout Due to Electronic Speed Switch Actuation - Root Cause Matrix Failure Mode: Electronic Speed Switch (ESS)
Cause Validation/Action Steps Expected Results Actual Results Status Noise on magnetic pickup Disconnect magnetic pickup from ESS.
False speed indication would remain False speed indication remained. NOT A CAUSE Complete Failed ESS Bench check ESS. Replace ESS.
ESS bench checks out good.
False speed indication would clear.
ESS bench checks good. False speed indication remained. NOT A CAUSE Complete.
Noise on 125 Vdc power supply Contact vendor and OE to determine susceptibility to noise.
ESS not susceptible to noise.
Both vendor and OE (VC Summer) indicate that ESS can give false speed indication with noise on input power.
POTENTIAL CAUSE Complete Measure noise (ripple) on 125 Vdc.
Approximately 1-3 Vac peak to peak.
Acceptable with annunciator circuit isolated. POTENTIAL CAUSE Complete Identify noise source. Most likely source is the annunciator circuitry since false speed signal cleared when Annuciator 125 Vdc power supply fuse blew.
Failed power supply Failed Power Supply Complete
28 Turkey Point Unit 3 Cable Failure O Event
- After Unit 3 was shutdown for 20 days, valve PCV-456 (PORV) unexpectedly opened when its control switch was placed in auto
- Investigation revealed that instrument cable had shorted conductors where cable/conduit passed over 3B Hot Leg RCS piping
- Majority of cables over 3B and 3C Hot Legs were degraded, cables in all other locations were in good condition O Design
- Various cables/conduits are routed in close proximity to RCS piping
29 Turkey Point Unit 3 Cable Failure O Cause
- Cable accelerated aging due to temperature
- Root Cause 8 Conduits routed in enclosed areas 8 Limited heat dissipation capability 8 High heat sources
- Contributing Factors 8 Normal Containment cooling ventilation register found failed closed 8 Insulation gaps and deficiencies 8 Uninsulated pipe stubs on RCS piping
30 Turkey Point Unit 3 Cable Failure
31 Turkey Point Unit 3 Cable Failure
32 Turkey Point Unit 3 Cable Failure Pressurizer Pressure Channel PT-3-445 Cable Failure to CR 2004-11329 Page 1 of 8 Failure Mode Tree PROBLEM FAILURE MODE FAILURE MODE FAILURE MODE FAILURE MODE See Attached Failure / Mode See Attached Failure / Mode See Attached Failure / Mode See Attached Failure / Mode Cause Cause Cause Cause Damaged / Failed Cable Jacket, Insulation & Shields found in Conduit 3C226 (conduit located near /touching 3B Hot Leg Pipe Insulation)
Heat / Temperature Aging Radiation Bad Cables /
Misapplication Chemical Attack
33 Turkey Point Unit 3 Cable Failure O Corrective Action
- All active cables above and in close proximity to Hot and Cold Legs of RCS piping were removed, visually inspected and replaced
- Sample inspection of cables in other locations in proximity to high temperature piping (i.e.
RCS intermediate legs, blowdown lines, main steam, feedwater, letdown and pressurizer)
34 Turkey Point Unit 3 Cable Failure O Corrective Action (continued)
- Insulation deficiencies corrected
- Normal Containment cooling ventilation register restored to service
- Temperatures obtained on 11/27/04 at RCS temperature of 533 degrees; resulted in highest conduit temperature of 124 degrees.
- Dataloggers installed to obtain temperature readings over an operating cycle
- Operating experience report issued
- Operability assessment for Unit 4 issued
35 Conclusions O Equipment Performance Improvements
- Programmatic
- Organizational
- Strategic O Starting to See Positive Benefits
- Increased number of Condition Reports
- Improved root cause analysis
36 Equipment Reliability A. Pell
37 Equipment Reliability Equipment Reliability Improvement Program (ERIP)
O Key Success Factors from INPO 01-004 Achieving High Equipment Reliability - A Leadership Perspective O
In 2004, > 200 Formal Actions Completed YTD O
Implements INPO AP-913, Equipment Reliability & 10 NRC Part 50.65 Requirements for Monitoring the Effectiveness of Maintenance at Nuclear Power Plants Performance Monitoring y System Performance y Component Performance y Predictive Trending Results y Operations Rounds Monitoring y Monitor Testing & Inspection Results Scoping and Identification of Critical Components y Common Scoping Criteria y Identify Important Functions y Identify Critical Components y Identify Noncritical Components y Identify Run-to-Failure Components PM Implementation y Preventive Maintenance (PM) y Document Equipment As-Found Equipment Condition y Equipment Condition Feedback y Standard Postmaintenance Test Corrective Action y Corrective Maintenance y Failure Cause & Corrective Action y Prioritization of Equipment Problems Life-Cycle Management y Long-Term Strategy for System and Component Health y Prioritization of Improvement Activities y Integration of Long-Term Plans with the Station Business Strategy Continuing Equipment Reliability Improvement y Development and Use of PM Templates y Continuing Adjustments to PM Task and Frequency Based on Station and Industry Equipment Operating Experience y Documentation of the PM Technical Bases y Consideration of Alternative Maintenance Strategies to Ensure Reliable Equipment y Continuous Improvement from Plant Staff Recommendations
38 Equipment Reliability NAP-407, Equipment Reliability O Responsibilities defined for each Station Organization O Defined Priority Actions for System Health & Equipment Reliability Excellence in Equipment Reliability Maintenance Equipment Performance Standards Chemistry Programs &
Controls Work Management Long Term Equipment Reliability Prevention of Equipment Failures
39 Equipment Reliability System Health Reporting O
Assesses System Health and incorporates:
INPO AP-913, Equipment Reliability Process Description 10 NRC Part 50.65 Requirements for Monitoring the Effectiveness of Maintenance at Nuclear Power Plants - Maintenance Rule O
Action Plans defined for improving System Health Highest Priority established for Red & Yellow WOs O
Key Performance Measures & Indicators track progress Top 10 Equipment Issues at each Station System Health Metrics Equipment Reliability Indicator O
Action Plans reviewed by Plant Health Committees &
40 Equipment Reliability System Health Improvement in 2004 System Health - Turkey Pt. & St. Lucie Status thru end of 3rd Quarter 2004 27.5 31.1 33.9 36.7 44.3 45.9 43.9 41.9 20 16.3 15.5 13.6 8.5 6.6 6.5 7.65 0%
20%
40%
60%
80%
100%
4Q03 1Q04 2Q04 3Q04 Last 12 Months Red Yellow White Green
41 Equipment Reliability Breaker Program - St. Lucie 4 KV Breaker Replacement
- SF6 breakers selected
- Simple operating mechanism with less failure modes
- Reduced required maintenance
- SL1-19 Installation
- Extensive OE review to minimize potential issues
- Maintenance and testing on key interfaces
- Additional oversight dedicated to Project
42 Equipment Reliability Breaker Program The result:
6 Non Safety breakers installed with no issues
43 Equipment Reliability Breaker Program 4 kV and 6.9 kV Breakers Plan for Breaker Replacements ACTIONS PLANT OUTAGE 2004 2005 2006 REPLACE 4C 4160 BREAKERS PTN 9
PTN4-21 REPLACE 6 NNS 4.16 kV BREAKERS PSL 6
SL1-19 REPLACE 3C 4160 BREAKERS PTN 10 PTN3-21 REPLACE 24 UNIT 2B TRAIN 4.16kV BREAKERS PSL 24 SL2-15 REPLACE REMAINING UNIT 1 4.16/6.9kV BREAKERS PSL 50 SL1-20 REPLACE REMAINING UNIT 2 4.16/6.9kV BREAKERS PSL 39 SL2-16
44 Equipment Reliability Breaker Program O St. Lucie Outdoor Switchgear Floor Repair
- 2B4 floor repaired in March 04
- No problems encountered upon return to service
- Turkey Point 4.16 KV switchgear interface
- Ensured interface/tolerances were correct on all GE Magna-Blast breakers
- Utilizing the new Operations and Maintenance Procedures to optimize the breaker interface
45 Equipment Reliability Preventive Maintenance Optimization (PMO)
- PMO Phases in 2004
- Criticality Determinations (FID) - Complete
- Standard Equip Clearance Boundaries (FEG) -
Complete
- Maintenance Feedback System & Database -
Complete
- Upcoming PMO Phases
- PM Scheduling & Integration
- Key: Living Program &
Ownership going forward Maintenance Feedback 3
10 7
19 10 12 43 71 180 230 157 10 17 14 6
14 11 4
4 3
2 0
9 4
2 2
1 7
10 5
7 4
1 4
5 6
7 11 16 14 10 16 9
119 255 292 431 265 247 231 148 194 5
16 8
18 9
29 5
0 14 7
9 10 5
0 50 100 150 200 250 300 350 400 450 500 Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sept Oct F e e d b a c k Failed Close to Fail Good Above Average Excellent Feedback Return Rate 100%
97%
98%
98%
98%
94%
100%
100%
100%
100%
100% 100% 100%
46 Equipment Reliability Summary O Extensive Fleet ERIP Actions completed across the Fleet O Improvements made in plant performance O In 2004, FPL successfully put into place an Equipment Reliability Improvement Program O ERIP is a 3-5 year program - Were clearly not complete
- Future work remains in driving change throughout station organizations, culture, and behaviors
- Key improvements required include long term modifications/actions
- Feedback, indicators, monitoring process loops required for sustainability
47 Life Cycle Management Warren Busch
48 Life Cycle Management O Program to Cope with Obsolescence of Components and Systems O Implements a Long Term Strategy to Improve Reliability and Reduce Maintenance and Training Costs O Projects to Replace I&C Systems and Electrical Components are in process O Systems not supported by OEM and Parts Unavailable
49 Life Cycle Management O Standard Platform Approach to I&C System Replacements
- Distributed Control System, Foxboro I/A
- Safety Related Platform, Triconex O Redundancy and Diversity Even for Non-Safety Systems
50 Life Cycle Management O St. Lucie Digital Data Processing System Replacement
- Both units in service (May 2003, March 2004)
51 O
Incore Detectors/Linear Heat Rate Monitoring Life Cycle Management
52 Life Cycle Management O
Calorimetric Power Determination
53 Life Cycle Management O Major Projects In Process
- Qualified Safety Parameter Display Systems
- License amendments for on line implementation
- Emergency Response Data Acquisition and Display Systems
- Feedwater and Steam Dump Control Systems
- License amendments for Steam>Feed and turbine trip reactor trip setpoint at Turkey Point
54 Life Cycle Management O Turkey Point Project Plans Unit Activity 2004 2005 2006 2007 2008 2009 2010 2011 PTN 3 Plant Data Netw ork Installation PTN 3 QSPDS PTN 3 ERDADS PTN 3 FW Controls & Steam Dumps PTN 3 Aux FW Controls (QR80 & C281 Cabinets)
PTN 3 Secondary Pneumatic / Turbine Bldg PTN 3 Reactor Protection System/ESFAS PTN 3 RCS, CVCS & Balance of HAGAN PTN 3 Critcal Equipment Monitoring PTN 3 Annunciator PTN 3 Balance of Controls (HVAC,AUX System Controls)
PTN 3 Rod Control PTN 3 Process/Area Rad Monitoring PTN Simulator PTN 4 Plant Data Netw ork Installation PTN 4 QSPDS PTN 4 ERDADS PTN 4 FW Controls & Steam Dumps PTN 4 Aux FW Controls (QR80 & C281 Cabinets)
PTN 4 RCS, CVCS & Balance of HAGAN PTN 4 Secondary Pneumatic / Turbine Bldg PTN 4 Critical Equipment Monitoring PTN 4 Annunciator PTN 4 RPS/ESFAS PTN4 Balance of Controls (HVAC,AUX System Controls)
PTN 4 Rod Control PTN 4 Process/Area Rad Monitoring 2004 2005 2006 2007 2008 2009 2010 2011 PDN FW CONTR & SD'S RPS/ESFAS SEC PNEU TB Crit Equip Monitor AFW CONTROLS P/ARM BOC ROD CONTROL Annunciator RCS/CVCS/Bal PDN FW CONTR & SD'S QSPDS RPS/ESFAS SEC PNEU TB Crit Equip Monitor AFW CONTROLS P/ARM BOC ROD CONTROL Annunciator RCS/CVCS/Bal SIMULATOR RVCH RVCH ERDADS ERDADS QSPDS SIMULATOR SIMULATOR SIMULATOR
55 Life Cycle Management O St. Lucie Project Plans Unit Task Title 2004 2005 2006 2007 2008 2009 2010 2011 PSL 1 DDPS/SOE/PDN (Installed Spring 2004)
PSL 1 DIGITAL FW CONTROLS /RCP Indicators/DCS PSL 1 QSPDS PSL 1 DCS RACEWAYS PSL 1 ERDADS PSL 1 Turbine Building Heater Drains PSL 1 DEH Control System & RTGB 101 PSL 1 CEPEDS/Core Mimic (RTGB 103 &104)
PSL 1 Condensate and Cooling Water (RTGB 102)
PSL 1 RPS/ESFAS PSL 1 RCS & CVCS Control (RTGB 3-6)
PSL 1 Critical Equipment Monitoring PSL 1 Annunciators PSL 1 CEA Control System PSL 1 Process/ Rad Monitoring PSL 2 DDPS/SOE/PDN (Installed Spring 2003)
PSL 2 DCS RACEWAYS PSL 2 ERDADS PSL 2 QSPDS PSL2 DIGITAL FW CONTROLS (DFWC)
PSL 2 Turbine Bldg Heater Drains PSL 2 ADS/Core Mimic (RTGB 203 &204)
PSL 2 DEH Control System PSL 2 Condensate and Cooling Water (RTGB 202)
PSL 2 RCS & CVCS Control (RTGB 3-6)
PSL 2 RPS/ESFAS PSL 2 Critical Equipment Monitoring PSL 2 Annunciators PSL 2 CEA Control System PSL 2 Process/ Rad Monitoring PSL Simulator QSPDS Cond/CoolingWater ERDADS RACEWAYS TB HTR DRNS CEPEDS RPS/ESFAS Crit Equip Monitor CEA Annunciators P/ARM P/ARM RCS/CVCS RACEWAYS ERDADS QSPDS Cond/Cooling Water ADS CEA DEH TB HTR DRNS RPS/ESFAS Crit Equip Monitor Annunciators RCS/CVCS SIMULATOR RVCH DEH RVCH RVCH DFWC/RCP DFWC RVCH SIMULATOR SIMULATOR SIMULATOR
56 Materials Management R. Gil
57 Materials Management O Alloy 600 and other materials issues continue to be a focus area O Bottom Mounted Instrumentation (Turkey Point)
- Bare metal visual (BMV) completed at Turkey Point Unit 4
- No Leaks
- Performed Unit 3 UT - No indications
- Committed to perform Unit 4 UT during spring 2005 Turkey Point Unit 4 BMI Visual
58 Materials Management O Small Bore Instrument Nozzles (St. Lucie)
- Hot leg and pressurizer BMVs performed each outage
- Replacing on prioritized basis
- Unit 2 Hot Leg and pressurizer nozzles already replaced O Pressurizer Heater Sleeves (St. Lucie)
- Unit 1 PZR to be replaced in fall 2005
- Plan to replace Unit 2 PZR sleeves in 2007
- BMV inspections per WOG recommendations
59 Materials Management O Butt Welds (St. Lucie)
- Augmenting ISI with bare metal visuals
- Mitigation options being evaluated O Reactor Head Penetrations
- All four heads UT inspected
- St. Lucie Unit 2 repaired two cracked penetrations
- No leaks or wastage identified
- Turkey Point 3 head replaced
- Plans in place to replace three remaining heads
60 External Corrosion Management O Challenge at both sites
- Open structures/ coastal salt laden environment O Mechanical piping health reports developed
- Increased management oversight
- Action plans for improvement
- PSL: Red, PTN: White O System health reports
- Material condition status attribute
- Walkdown report of degradation
- Action plans for improvement
61 External Corrosion Management O Established external corrosion coordinator at each site O Feedback on degradation precursors from System Engineering walkdowns O External corrosion (XCI) monitoring program for insulated piping O Protective coating maintenance program in place at both sites
- Improvement in tracking process being pursued
62 Conclusions O FPL continues to be active industry participant O All Alloy 600 locations at FPL plants have been identified and plans are in place, or actively being developed, to provide long-term resolution O Improvements in overall material condition programs being actively pursued
63 2004 Hurricane Season B. Hughes
64 2004 Hurricane Season Charley Frances Jeanne
65 Transmission & Substations
66 Transmission & Substations O Execution Strategy
- System Stability
- Energize Every Substation Bus
- Restore Customer Service
67 Transmission & Substations CHARLEY Aug. 13, 2004 Sections Locked Out Distribution Substation Out Transmission Structures Affected Trans. Structures Down Transformer Failures 44 14 220 75 145 1
Trans. Structures Leaning Breaker Failures Number of Days to Restore 8
2 FRANCES Sept. 3, 2004 108 54 150 56 94 1
20 2
JEANNE Sept. 25, 2004 80 30 129 48 81 1
14 2
68 Integrated Supply Chain O Resources O Logistics O Material
69 Results.... A Great Success ONTARIO QUEBEC TX OK AR LA NM AZ CA NV UT CO KS MO IA NE SD ND MT WY ID OR WA MN WI IL IN FL MS AL GA SC NC TN KY VA WV OH MI PA NY ME VT NH MA RI CT NJ DE MD Peak external resources reached over 7,400:
39 states and Canada 43 utilities 66 line contractors
70 A Mammoth Logistical Success O
26 staging sites established
- Several sites used more than once O
On average we housed, fed and supported over 14,000 workers daily providing
- 38,000 meals
- 20,000 gallons of water
- 7,500 trucks with 180,000 gallons of fuel per day O
Over 1,800 truckloads of material delivered and utilized in the field:
- 1,700 miles of wire
- 13,200 poles
- 11,100 transformers
- 416,000 splices
71 Nuclear
72 Key Challenges O Damage assessment (X2)
O Recovery and restart (X2)
O Nuclear security O Access to the site O Water intrusion O Secondary water chemistry O Turkey Point outage O Regulatory permission to restart O Employee personal impact O Fatigue, stress and morale
73 Key Successes O Recovery organization O No personnel injuries or human performance errors O Excellent operating crew performance O Good use of operating experience O Met all security requirements O Teamwork
74 Impact on Nuclear Plants O Extensive Hurricane preparation at both sites O Dedicated Hurricane /
Emergency Plan staffing O Two dual-unit outages O Loss of all offsite power at St. Lucie during Jeanne O St. Lucie outage rescheduled O Infrastructure damage
75 Restoring Power...
Restoring Lives