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
Nuclear Engineering NRC / FPL Interface Meeting December 6, 2004 Region II Atlanta, Georgia 1
ENCLOSURE 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 2
Nuclear Engineering Organization R. S. KUNDALKAR VICE PRESIDENT NUCLEAR ENGINEERING D. RYBCZYK EXECUTIVE SECRETARY B. HUGHES A. ZIELONKA P. FREEMAN MANAGER MANAGER MANAGER ST. LUCIE TURKEY POINT SEABROOK SITE SITE ENGINEERING SITE ENGINEERING ENGINEERING J. MOABA C. VILLARD D. TOMASZEWSKI MANAGER MANAGER MANAGER MAJOR PROJECT ENGINEERING NUCLEAR FUEL LIFE CYCLE MANAGEMENT GROUP (MPEG) S/G, RX Vessel S. HALE J. GARCIA C. BIBLE MANAGER CHIEF MANAGER SBK UPRATE / MSRs NUCLEAR ENGINEER SPECIAL PROJECTS 3
Engineering Performance St. Lucie / Turkey Point Engineering B. Hughes / A. Zielonka 4
WANO Weighted Overall Performance St. Lucie Turkey Point 100 100 95 95 PERCENTAGE 90 90 85 85 80 80 75 75 1998 1999 2000 2001 2002 2003 2004 1998 1999 2000 2001 2002 2003 2004 PSL1 PSL2 Industry Median PTN 3 PTN 4 Industry Median Data Through 9/04 5
Engineering Department Indicators and Goals Nuclear Safety Focus (Data Through 9/30/04)
Goals St. Lucie Turkey Point Indicators Green Red Actuals Actuals Unit 1 - 0.0 Unit 3 - 0.0 A. Unplanned Scrams Per 7000 Hours <1 >6 Unit 2 - 1.7 Unit 4 - 0.9 Unit 1 - 0.6% Unit 3 - 0.4%
B. Safety System Unavailibility - EAC (1)(2)(3) <1.25% >5%
Unit 2 - 0.5% Unit 4 - 0.5%
(1)(2) Unit 1 - 0.4% Unit 3 - 0.2%
C. Safety System Unavailibility - HPSI <0.75% >5% Unit 2 - 0.4% Unit 4 - 0.2%
Unit 1 - 0.5% Unit 3 - 0.4%
D. Safety System Unavailibility -AFW (1)(2) <1.0% >6% Unit 2 - 0.7% Unit 4 - 0.6%
Unit 1 - 0.6% Unit 3 - 0.5%
E. Safety System Unavailibility - RHR (1)(2) <0.75% >5% Unit 2 - 0.6% Unit 4 - 0.4%
F. NRC Violations due to Engineering <2 >6 2 NCV's 4 NCV's G. QA Findings <2 >6 3 1 Unit 1 - 1.13E-5 Unit 3 - 1.64 E-5 H. Wano FRI 5 E-4 >2.0 E-2 Unit 2 - 4.01E-5 Unit 4 - 2.15 E-6 I. OSHA Recordable Injuries 0 2 0 0 Outage 7%< Outage 26%<
J. ALARA 10% <Budget >5% Over Budget Non-Outage 11%< Non-Outage 10%<
0 Major >5 Major K. Reactivity Events Due to Engineering 0 Lvl 1 0 Lvl 2 0 Lvl 1 0 Lvl 2
<4 Minor > 8 Minor (1) All green by NRC criteria (2) FPL criteria more stringent (3) Unit 3 EAC significant improvement 6
Engineering Department Indicators and Goals Problem Identification and Correction (Data Through 9/30/04)
Goals St. Lucie Turkey Point Indicators Actuals Actuals Green Red A. Condition Report Evaluations (Late) 0 Late >5 Late 0 1 Condition Report Action Items (CAQ SITRIS B. ACTIONS Late) 0 Late >5 Late 0 0 Condition Report Action Items (Non CAQ C. SITRIS ACTIONS Late) 0 Late >11 Late 0 0 D. Self Assessments 1 in 6 mos <2 per year 2 5 90%-100% W/D <70% W/D E. System Walkdowns 100% 100%
Complete Complete F. Drawing/VTM/TEDB Changes 0-2 Late 10 Late 0 18 (1) (2)
- 1) No safety significant items late.
- 2) No late priority 1 drawings, all were priority 3 and 4 drawings.
7
Engineering Department Indicators and Goals Quality of Engineering (Data Through 9/30/04)
Goals St. Lucie Turkey Point Indicators Actuals Actuals Green Red Engineer Initial Training Not Started A. <1 >6 0 0 Within 12 Months of Hire B. Training Performance Indicators GREEN RED GREEN GREEN Plant Modification Revisions due to C. 0 5 4 0 ENG Error Procurement Engineering Backlog D. <2 >11 0 121
( >4 Weeks Old) 8
Engineering Department Indicators and Goals Cost/Plant Operation Performance (Data Through 9/30/04)
Goals St. Lucie Turkey Point Indicators Actuals Actuals Green Red Unit 3 - 95.5%
A. Summer Capacity Factor >99.8% <98% 100.00%
Unit 4 -99.17%
Unit 1 - 99.98% Unit 3 - 99.9%
B. Thermal Performance Indicator >99.70% <99.5% Unit 2 - 99.91% Unit 4 - 100%
Unit 1 Unit 3 C. Refueling Outage Duration <30 Days >35 Days 35 66 (1)
Forced Loss Rate 18 Month Running Unit 1 - 0.1% Unit 3 - 2.16%
D. 0% - 1% >2.0%
Average Unit 2 - 4.24% Unit 4 - 1.35%
(1) Special Reactor Head Replacement Outage for Turkey Point (Goal < 65 days) 9
Engineering Performance NRC Performance Indicator On Reactor Trips: Green to White O Causes O Actions O Status of Corrective Actions O Future Initiatives 10
Corrective Action C. Bible 11
Corrective Action O Performance Improvement Initiatives
- Programmatic
- Organizational
- Strategic O Examples 12
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 13
Performance Improvement Initiatives 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 14
Performance Improvement Initiatives O Strategic Initiatives
- Equipment Reliability
- Preventative Maintenance Optimization
- Breaker Reliability
- Life Cycle Management 15
Performance Improvement Initiatives Turkey Point Condition Reports Originated Site-Wide 6000 Increased number of 5000 5201 condition reports 4000 3000 2866 Increased sensitivity to 2000 1000 initiate condition reports for 0 1Q04 2Q04 3Q04 4Q04 unexpected/unwanted 2003 CRs Generated Quarterly 2004 CRs Generated Quarterly conditions 2003 Cumulative Total 2004 Cumulative Total Increased identification of 900 Turkey Point Open Corrective Actions opportunities for 800 766 756 750 788 improvement 700 634 707 631 592 Open corrective action 600 583 567 534 521 501 500 backlog remaining constant 459 414 400 New trending tool 300 developed, training in 200 100 progress 0 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 16
Auxiliary Feedwater Pump Overspeed Event
- Steam driven pump tripped on overspeed while starting 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 17
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 18
Auxiliary Feedwater Pump Overspeed Unit 2 AFW 2C Turbine Supply/Drain Piping MS Hdr MS Hdr 2A 2B SE-08-2 SE-08-1 V08663 V08660 MV-08-13 MV-08-12 V08130 V08163 V08884 V08883 MV-08-3 2C AFW Turbine V08661 V08622 V08165 V08600 V08618 V08662 V08619 V08177 19
Auxiliary Feedwater Pump Overspeed CR 03-4548 Attachement 23, Page 1 of 4 2C AFW PUMP OVERSPEED FAULT TREE ANALYSIS Incorrect Tappet Nut/Head Engagement lever OS Linkage Worn Mating Faces Problem Incorrect OS Actuation Looseness in linkage Bent/Damaged Stem Gov ernor Stem spring coil Valve Binding bound Valve binding Cam Plate Binding 2C AFW Low Lev el Pump Overspeed Temperature Governor Oil Trip Contamination Buffer Springs Incorrect Gov ernor Unstable for Condensate in Condition Steam Supply Staggered Start Stability Adjustment Turbine at Full 20 Speed
Auxiliary Feedwater Pump Overspeed 2C AFW Pump Turbine Trip Fault Validation Matrix tential Cause Potential Fault Validation Results Root Cause erspeed linkage Tappet/head lever Measure trip tappet/head 0.038 Ruled Out- 0.038 within ration/wear engagement lever engagement (0.030- spec.
0.060)
Agitate linkage to test health Agitated linkage and could not get mechanism to trip Condition of head Inspect head level/tappet Surfaces in good condition Ruled Out based on lever/tappet nut surfaces nut surfaces inspection and agitation test.
Incorrect OS actuation Replicate event to see if Test duplicated valid OS - max Ruled Out base on test actual overspeed occurs. turbine speed 5200 rpm, OS results setpoint - 4690 rpm vernor valve Bent/damaged stem Inspect for bent stem. Vendor and SCE observed Ruled Out based on nding/improper Monitor during operation. operation, no indication of inspection and eration Manual stroke. improper operation. operational performance.
Valve binding Check for smooth stroke by Inspection performed; no Ruled Out based on manual actuation indication of adverse condition. inspection and Manual stroke Sat. operational performance.
Cam plate binding Monitor during operation. Vendor and SCE observed Ruled Out based on Manual stroke. operation, no indication of inspection and improper operation. operational performance.
Looseness or free play of Check for looseness or free Vendor and SCE inspected Ruled Out linkage play linkage. No looseness noted.
Spring coil bound on Check to determine if spring Vendor observed operation, Ruled Out closing is coil bound spring not coil bound 21
Auxiliary Feedwater Pump Overspeed 2C AFW Pump Turbine Trip Fault Validation Matrix vernor Oil level adequate Check Oil Level 3/8 below top of sightglass. Ruled Out.
stable for Verified correct during test runs.
ndition Correct buffer springs Check springs Checked with Woodward that Ruled Out, stable correct springs are installed. operation achieved with current springs.
Oil Temperature/ Verify correct oil for R&O 32 oil is acceptable to Temperature ruled out as Viscosity operating range. temperature as low as 40 oF. contributor.
Governor mis-adjusted Review traces for divergent Test traces indicated that Potential Contributor speed behavior adjustment was needed.
Load Change challenges Perform testing to determine No abrupt load changes were Ruled out based on governor. possibility of load change witnessed during tests. testing.
causing instability Staggered start causes Review surveillance data, Governor response satisfactory Potential Root Cause governor instability previous events and current during single start scenarios test data. and staggered start scenarios without condensate. Turbine vulnerable to overspeed when upset at nominal speed.
Condensate in steam Perform replicate testing to Testing demonstrated that Potential Root Cause supply challenges determine presence of water present during start governor. condensate sequence.
22
Auxiliary Feedwater Pump Overspeed 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 Final Corrective Action
- Modify AFAS start logic to simultaneously open both steam admission valves (Currently planned for unit outages in 2005) 23
Turkey Point 4A EDG Lockout 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)
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 24
Turkey Point 4A EDG Lockout Root Cause
- ESS sensed electrical noise from faulty annunciator panel power supply as pulses from speed circuit magnetic pickup
- Power supply filtering capacitor failed 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 25
Turkey Point 4A EDG Lockout Attachment 2 EDG 4A Annunciator Power Supply (PS-1) Root Cause Matrix Cause Validation/Action Steps Expected Results Actual Results Status Failed PS1 inverter Replace PS1 inverter section False speed indication Annuciator power supply Complete section would clear. Annuciator failed; Fuse 2 on new power would be restored inverter opened. Obtain good replacement inverter with new parts.
Troubleshoot for failed Failed open C1 capacitor Inverter input capacitor Complete component on original PS1 would not filter feed back (C1-1200 mfd) found open inverter noise. In Progress circuited.
Troubleshoot for failed Identify failed components Found a mounting screw Complete component on replaced PS1 (larger than normal) inverter shorting transistor to chassis Failed PS1 rectifier Implement TSA to isolate Annunciator circuits Annunciator circuits Complete circuit inverter and test PS1 rectifier function properly function properly circuit with 120 Vac.
Failure of annunciator Implement TSA to isolate Annunciator circuits Annunciator circuits Complete cards or circuitry. inverter and test PS1 rectifier function properly. function properly.
circuit with 120 Vac.
Excessive loading from Use temporary power supply. Load currents within Load currents within Complete annunciator. Measure load currents. specification. specification.
26
Turkey Point 4A EDG Lockout Attachment 2 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 Disconnect magnetic pickup False speed indication would False speed indication Complete pickup from ESS. remain remained. NOT A CAUSE Failed ESS Bench check ESS. Replace ESS bench checks out good. ESS bench checks good. False Complete.
ESS. False speed indication would speed indication remained. NOT clear. A CAUSE Noise on 125 Vdc power Contact vendor and OE to ESS not susceptible to noise. Both vendor and OE (VC Complete supply determine susceptibility to Summer) indicate that ESS can noise. give false speed indication with noise on input power.
POTENTIAL CAUSE Measure noise (ripple) on 125 Approximately 1-3 Vac peak to Acceptable with annunciator Complete Vdc. peak. circuit isolated. POTENTIAL CAUSE Identify noise source. Most Failed power supply Failed Power Supply Complete likely source is the annunciator circuitry since false speed signal cleared when Annuciator 125 Vdc power supply fuse blew.
27
Turkey Point Unit 3 Cable Failure 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 Design
- Various cables/conduits are routed in close proximity to RCS piping 28
Turkey Point Unit 3 Cable Failure 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 29
Turkey Point Unit 3 Cable Failure 30
Turkey Point Unit 3 Cable Failure 31
Turkey Point Unit 3 Cable Failure Pressurizer Pressure Channel PT-3-445 Cable Failure Attachment 1 to CR 2004-11329 Page 1 of 8 Failure Mode Tree PROBLEM Damaged / Failed Cable Jacket, Insulation & Shields found in Conduit 3C226 (conduit located near /touching 3B Hot Leg Pipe Insulation)
FAILURE MODE FAILURE MODE FAILURE MODE FAILURE MODE Heat / Temperature Radiation Bad Cables / Chemical Attack Aging Misapplication See Attached Failure / Mode See Attached Failure / Mode See Attached Failure / Mode See Attached Failure / Mode Cause Cause Cause Cause 32
Turkey Point Unit 3 Cable Failure 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) 33
Turkey Point Unit 3 Cable Failure 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 34
Conclusions O Equipment Performance Improvements
- Programmatic
- Organizational
- Strategic O Starting to See Positive Benefits
- Increased number of Condition Reports
- Improved root cause analysis 35
Equipment Reliability A. Pell 36
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 PM Implementation y System Performance y Preventive Maintenance (PM) y Component Performance y Document Equipment As-Found y Predictive Trending Results Equipment Condition y Operations Rounds Monitoring y Equipment Condition Feedback y Monitor Testing & Inspection Results y Standard Postmaintenance Test Scoping and Identification of Corrective Action Critical Components y Corrective Maintenance y Common Scoping Criteria y Failure Cause & Corrective Action y Identify Important Functions y Prioritization of Equipment Problems y Identify Critical Components y Identify Noncritical Components y Identify Run-to-Failure Components Continuing Equipment Reliability Improvement y Development and Use of PM Templates Life-Cycle Management y Continuing Adjustments to PM Task and Frequency Based on y Long-Term Strategy for System and Component Health Station and Industry Equipment Operating Experience y Prioritization of Improvement Activities y Documentation of the PM Technical Bases y Integration of Long-Term Plans with the Station Business y Consideration of Alternative Maintenance Strategies to Ensure Strategy Reliable Equipment y Continuous Improvement from Plant Staff Recommendations 37
Equipment Reliability NAP-407, Equipment Reliability Responsibilities defined for each Station Organization Defined Priority Actions for System Health & Equipment Reliability Maintenance Prevention of Equipment Equipment Performance Failures Standards Excellence in Equipment Reliability Long Term Chemistry Equipment Programs &
Reliability Controls Work Management 38
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 &
VPs 39
Equipment Reliability System Health Improvement in 2004 System Health - Turkey Pt. & St. Lucie Status thru end of 3rd Quarter 2004 100%
8.5 6.6 6.5 7.65 16.3 15.5 13.6 20 80%
60%
41.9 Red 43.9 45.9 Yellow 44.3 White Green 40%
20%
33.9 36.7 31.1 27.5 0%
4Q03 1Q04 2Q04 3Q04 Last 12 M onths 40
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 41
Equipment Reliability Breaker Program The result:
6 Non Safety breakers installed with no issues 42
Equipment Reliability Breaker Program 4 kV and 6.9 kV Breakers Plan for Breaker Replacements ACTIONS PLANT # OUTAGE 2004 2005 2006 PLACE 4C 4160 PTN 9 PTN4-21 EAKERS PLACE 6 NNS 4.16 kV PSL 6 SL1-19 EAKERS PLACE 3C 4160 PTN 10 PTN3-21 EAKERS PLACE 24 UNIT 2B PSL 24 SL2-15 AIN 4.16kV BREAKERS PLACE REMAINING UNIT PSL 50 SL1-20
.16/6.9kV BREAKERS PLACE REMAINING UNIT PSL 39 SL2-16
.16/6.9kV BREAKERS 43
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 44
Equipment Reliability eventive Maintenance Optimization (PMO) Maintenance Feedback
- PMO Phases in 2004 500 Feedback
- Criticality Determinations 450 Return Rate 431 (FID) - Complete 400 350 100%
- Standard Equip Clearance Feedback 300 100% 98% 98% 97% 100% 292 100% 100% 100% 100% 100% 98% 94%
Boundaries (FEG) - 250 230 255 265 247 231 Complete 194 200 180 157 148 150 119
- Maintenance Feedback 100 71 System & Database - 50 4 7 10 4 1
19 17 5 14 10 3
9 29 16 10 7 2 4 6 0 3 12 9 5 10 43 18 10 14 9 14 11 16 95 10 47 8 7 111 1614 7 4 2 6 5 5 2 0 Complete 0 t v c n b ar r ay n l g pt t
- Upcoming PMO Phases Oc No De Ja Fe M Ap M Ju Ju Au Se Oc
- PM Scheduling & Integration Above Average Excellent
- Key: Living Program &
Ownership going forward 45
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 46
Life Cycle Management Warren Busch 47
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 48
Life Cycle Management Standard Platform Approach to I&C System Replacements
- Distributed Control System, Foxboro I/A
- Safety Related Platform, Triconex Redundancy and Diversity Even for Non-Safety Systems 49
Life Cycle Management O St. Lucie Digital Data Processing System Replacement
- Both units in service (May 2003, March 2004) 50
Life Cycle Management O Incore Detectors/Linear Heat Rate Monitoring 51
Life Cycle Management O Calorimetric Power Determination 52
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 53
Life Cycle Management O Turkey Point Project Plans nit Activity 2004 2005 2006 2007 2008 2009 2010 2011 TN 3 Plant Data Netw ork Installation PDN RVCH TN 3 QSPDS QSPDS TN 3 ERDADS ERDADS TN 3 FW Controls & Steam Dumps FW CO NTR & SD'S TN 3 Aux FW Controls (QR80 & C281 Cabinets) AFW CO NTRO LS TN 3 Secondary Pneumatic / Turbine Bldg S EC PNEU TB TN 3 Reactor Protection System/ESFAS RPS /ES FAS TN 3 RCS, CVCS & Balance of HAGAN RCS /CVCS /Bal TN 3 Critcal Equipment Monitoring Crit Equip Monitor TN 3 Annunciator Annunciator TN 3 Balance of Controls (HVAC,AUX System Controls) BOC TN 3 Rod Control RO D CO NTRO L TN 3 Process/Area Rad Monitoring P/ARM TN Simulator SIMULATO R SIMULATO R SIMULATO R SIMULATO R RVCH TN 4 Plant Data Netw ork Installation PDN TN 4 QSPDS QS PDS TN 4 ERDADS ERDADS TN 4 FW Controls & Steam Dumps FW CO NTR & SD'S TN 4 Aux FW Controls (QR80 & C281 Cabinets) AFW CONTROLS TN 4 RCS, CVCS & Balance of HAGAN RCS /CVCS /Bal TN 4 Secondary Pneumatic / Turbine Bldg S EC PNEU TB TN 4 Critical Equipment Monitoring Crit Equip Monitor TN 4 Annunciator Annunciator TN 4 RPS/ESFAS RPS/ESFAS TN4 Balance of Controls (HVAC,AUX System Controls) BOC TN 4 Rod Control ROD CONTROL TN 4 Process/Area Rad Monitoring P/ARM 2004 2005 2006 2007 2008 2009 2010 2011 54
Life Cycle Management O St. Lucie Project Plans Unit Task Title 2004 2005 2006 2007 2008 2009 2010 2011 SL 1 DDPS/SOE/PDN (Installed Spring 2004) RVCH RVCH SL 1 DIGITAL FW CONTROLS /RCP Indicators/DCS DFWC/RCP SL 1 QSPDS Q SPDS SL 1 DCS RACEWAYS RACEWAYS SL 1 ERDADS ERDADS SL 1 Turbine Building Heater Drains TB HTR DRNS SL 1 DEH Control System & RTGB 101 DEH SL 1 CEPEDS/Core Mimic (RTGB 103 &104) CEPEDS SL 1 Condensate and Cooling Water (RTGB 102) Cond/CoolingWate r SL 1 RPS/ESFAS RCS/CVCS SL 1 RCS & CVCS Control (RTGB 3-6) RPS/ESFAS SL 1 Critical Equipment Monitoring Crit Equip Monitor SL 1 Annunciators Annunciators SL 1 CEA Control System CEA SL 1 Process/ Rad Monitoring P/ARM SL 2 DDPS/SOE/PDN (Installed Spring 2003) RVCH RVCH SL 2 DCS RACEWAYS RACEWAYS SL 2 ERDADS ERDADS SL 2 QSPDS QSPDS SL2 DIGITAL FW CONTROLS (DFWC) DFWC SL 2 Turbine Bldg Heater Drains TB HTR DRNS SL 2 ADS/Core Mimic (RTGB 203 &204) ADS SL 2 DEH Control System DEH SL 2 Condensate and Cooling Water (RTGB 202) Cond/Cooling Water SL 2 RCS & CVCS Control (RTGB 3-6) RCS/CVCS SL 2 RPS/ESFAS RPS/ESFAS SL 2 Critical Equipment Monitoring Crit Equip Monitor SL 2 Annunciators Annunciators SL 2 CEA Control System CEA SL 2 Process/ Rad Monitoring P/ARM SL Simulator SIMULATO R SIMULATO R SIMULATO R SIMULATO R 55
Materials Management R. Gil 56
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 Turkey Point Unit 4
- Committed to perform Unit 4 UT BMI Visual during spring 2005 57
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 58
Materials Management Butt Welds (St. Lucie)
- Augmenting ISI with bare metal visuals
- Mitigation options being evaluated 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 59
Management Challenge at both sites
- Open structures/ coastal salt laden environment Mechanical piping health reports developed
- Increased management oversight
- Action plans for improvement
- PSL: Red, PTN: White System health reports
- Material condition status attribute
- Walkdown report of degradation
- Action plans for improvement 60
Management Established external corrosion coordinator at each site Feedback on degradation precursors from System Engineering walkdowns External corrosion (XCI) monitoring program for insulated piping Protective coating maintenance program in place at both sites
- Improvement in tracking process being pursued 61
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 62
2004 Hurricane Season B. Hughes 63
2004 Hurricane Season Charley Frances Jeanne 64
Transmission & Substations 65
Transmission & Substations O Execution Strategy
- System Stability
- Energize Every Substation Bus
- Restore Customer Service 66
Transmission & Substations CHARLEY FRANCES JEANNE Aug. 13, 2004 Sept. 3, 2004 Sept. 25, 2004 ections Locked Out 44 108 80 Distribution Substation Out 14 54 30 ansmission Structures Affected 220 150 129 Trans. Structures Down 75 56 48 Trans. Structures Leaning 145 94 81 Transformer Failures 1 1 1 reaker Failures 8 20 14 umber of Days to Restore 2 2 2 67
Integrated Supply Chain O Resources O Logistics O Material 68
Results .... A Great Success Peak external resources reached over 7,400:
39 states and Canada 43 utilities 66 line contractors NH WA VT ME ONTARIO QUEBEC MT ND MN MA OR WI NY RI ID SD MI CT WY PA NE IA NJ OH NV IL IN DE UT WV VA CO KS MO MD CA KY NC TN OK AR SC AZ NM MS AL GA TX LA FL 69
A Mammoth Logistical Success 26 staging sites established
- Several sites used more than once 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 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 70
Nuclear 71
Key Challenges Damage assessment (X2)
Recovery and restart (X2)
Nuclear security Access to the site Water intrusion Secondary water chemistry Turkey Point outage Regulatory permission to restart Employee personal impact Fatigue, stress and morale 72
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 73
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 74
Restoring Power ...
Restoring Lives 75