ML101120176
| ML101120176 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 04/22/2010 |
| From: | Duke Energy Carolinas |
| To: | Office of Nuclear Reactor Regulation |
| Stang J, NRR/DORL, 415-1345 | |
| References | |
| Download: ML101120176 (29) | |
Text
Major Project Plans April 22, 2010 Oconee Nuclear Station
Objectives
Provide history and context regarding completed projects, risk improvements, and organization capabilities.
Provide technical information, status, and projected risk improvements associated with Oconee projects of regulatory interest.
Reaffirm Dukes commitment to Oconee projects of regulatory interest.
2
Agenda
Background
ONS Refurbishment
Steam Generator and Reactor Head Replacements
Active Projects
Reactor Protective System / Engineered Safeguards Protective System
Tornado
Natural Phenomena Barrier System
High Energy Line Break
Fire Protection transition to NFPA-805
Protected Service Water
Commitments
Closing Remarks 3
Background
ONS Refurbishment
Digital Upgrades
Integrated Control System (1998)
Water Treatment System (2000)
Automatic Feedwater Isolation (2002)
Keowee Hydroelectric Stations Exciter and Governor (2004)
Main Turbine Control System (2004)
Control Rod Drive System (2008)
Turbine Supervisory Instrumentation (2008)
Main Generator Voltage Regulator (2008)
Expandable Process Control System (2008)
Main Feedwater Pump Control System (2010, 2011)
Reactor Protective and Engineered Safeguards Protective Systems (2011 - 2013) 4
Background
ONS Refurbishment
Emergency Core Cooling Systems / Emergency Operating Procedure Improvements
High Pressure Injection Pump recirculation flow
Low Pressure Injection cross-tie / flow restrictors
Reactor Building Spray
Other Upgrades - examples
Emergency Feedwater Control Valve Instrument Air Upgrades
Battery Replacements: Vital, Power, Standby Shutdown Facility, & Keowee
Keowee Underground Cable Replacement
Electrical Penetration Replacements
600 V Electrical Distribution System Upgrades
Security System Upgrades
Reactor Building Sump Strainers (~100 ft2 to ~5000 ft2)
Steam Generator / Rx Vessel Head Replacements
Combined Cost: $1.3 Billion 5
Completed Projects Risk Improvement 2.0E+03 1E-03 Estimate Oconee CDF - Historical 1.8E+03 1.6E-04 1.6E+03 SSF &
TB Flood Mods Core Damage Frequency ( /yr. )
1.4E-04 1.4E+03 1.2E+03 Oconee 1.2E-04 IPE 1.0E+03 1.0E-04 Rev. 2 PRA Rev. 3 Ext. Flood:
8.0E-05 8.0E+02 PRA Fragility Analysis 6.0E-05 6.0E+02 4.0E+02 4.0E-05 2.0E-05 2.0E+02 1.0E-06 0.0E+00 Post-TMI 1986 1990 1997 2003 2006 6
Active Projects RPS/ES
Regulatory Status
License Amendment Request (LAR) submitted 1/31/2008
Safety Evaluation Report (SER) issued 1/30/2010
Inspection Planning for Site Acceptance Testing and installation
Project Status
Unit 1 installation Spring 2011
Unit 2 installation Fall 2013
Unit 3 installation Spring 2012
Risk Benefit
Not quantified - Addresses long term obsolescence
Cost
$ 225 M 7
Active Projects Tornado
Regulatory Status
Tornado LAR submitted 6/30/2008; Review in progress
Fiber Re-enforced Polymer LAR submitted; 6/1/2006
Approved for re-enforcing Block Walls only; 3/26/2008
Re-submitted for Brick Walls 6/29/2009; NRC review in progress
Project Status
Natural Phenomena Barrier System (NPBS); construction in progress
Protected Service Water System; design & construction in progress
Main Steam Isolation Valves (w/ tornado protection); design in progress
SSF Equipment Doors Upgrade; design in progress
Risk Benefit
Small (low E-06 / yr) - actual risk improvement
Cost
$ 155 M (NPBS only) 8
Active Projects Natural Phenomena Barrier System Project Status
Complete
Control Room North Wall
SSF / CT-5 Trench Intersection
SSF Generator Fuel Oil Vent
Ongoing
Borated Water Storage Tank (BWST) Foundations
Remaining
Fibrwrap Installations
BWST Superstructure and Steel Siding 9
Active Projects High Energy Line Break
Regulatory Status
LARs submitted; Unit 1 6/2008; Unit 2 12/2008; Unit 3 6/2009
NRC review in progress
Project Status
Feedwater and Main Steam Pipe Weld Inspections; complete
East Penetration Room Flood Modifications; complete
Protected Service Water System; design and construction in progress
Main Steam Isolation Valves; design in progress
Letdown Cooler Isolation Valves Upgrade; scoped, slotted, awaiting LAR approval
Control Complex Ventilation Isolation; scoped, slotted, awaiting LAR approval
High Pressure Injection Suction Header Isolation Valves Upgrade; scoped, slotted, awaiting LAR approval
Turbine Building column re-enforcements; scoped, slotted, awaiting LAR approval
Condenser Circulating Water Stop Gate Upgrade; scoped, slotted, awaiting LAR approval
Risk Benefit and Cost primarily attributed to PSW project 10
Active Projects NFPA--805 Transition NFPA
Regulatory Status
Letter of intent submitted February 2005
Initial LAR submitted May 31, 2008
Incomplete - preliminary Fire PRA & modifications not determined
Followup LAR submitted October 31, 2008
Based on RG 1.205, revision 0
Revised LAR submitted April 14, 2010
Incorporates Requests for Additional Information (RAIs)
Will be template for RG 1.205, revision 1, submittals
Project Status
Protected Service Water System; design and construction in progress
Turbine/Auxiliary Building Wall Fire Barrier Upgrade; scoped, slotted, awaiting LAR approval
Purge Inlet Room/Auxiliary Building Fire barrier Upgrade; scoped, slotted, awaiting LAR approval
Blockhouse Pressure Relief Shafts Upgrade; scoped, slotted, awaiting LAR approval
General Area/Hazard Fire Detection improvements; scoped, slotted, awaiting LAR approval
Breaker Coordination Study; scheduled to complete 8/2010
Program Implementation Team; in place
Risk Benefit
Small - actual risk improvement from PSW project
Cost
$ 20 M (not including modifications) 11
Active Projects Main Steam Isolation Valves
Regulatory Status
Tornado and HELB LARs dependent on commitment to install
Separate LAR will be required - targeted for 12/2011
Project Status
Initial Scope Approved
MSIV procurement specification being developed
Detailed Scope being developed
Risk Benefit
Very Small (<1E-06 / yr) - actual risk improvement
Cost
~$ 400 M 12
Active Projects Protected Service Water
Background
Oconees Licensing Basis evolved over time; became complex and open to interpretation.
Higher Risk Licensing Basis issues were on paths to resolution
Emergency Feedwater
Emergency Power
Seismic
Lower Risk Licensing Basis issues remained to be addressed
Tornado
High Energy Line Break (outside containment)
Appendix R (Transition to NFPA-805) 13
Active Projects Protected Service Water Background, contd
Standby Shutdown Facility (SSF)
Designed to meet Appendix R, Turbine Building Flood (internal), and Sabotage.
Maintains Units in Mode 3 from outside the Main Control Rooms
Damage Control Measures used to cooldown and restore long term DHR
Later credited for Station Blackout and Tornado
Single train, with support system interdependencies
Most Risk Significant set of systems at the Station
SSF Risk Reduction Team focused on reliability / availability improvements 14
Active Projects Protected Service Water
Background, contd
Issaqueena Team Chartered
Provide framework for resolution of Licensing Basis Issues
Reduce Overall Station Risk
Reduce Risk Worth of SSF
Concept for PSW (Protected Service Water)
Integral to licensing approach for Tornado, HELB, and Fire Protection
Duplicates functions of SSF using equipment in the Auxiliary Building
Supplies alternate power to SSF equipment
Feasibility/Constructability Analyses
Initial Scope/Licensing approach development
Final Scope/commitment to construct
Design/Licensing/Construction ; in progress.
Licensing / Design Basis at risk; LARs not approved.
Non-Seismic CDF Improvement: 20-25% risk reduction.
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Protected Service Water Mechanical Scope Remove abandoned Diagram for PSW Keowee mechanical eqpt Mechanical Scope to make space for new Keowee PSW electrical eqpt.
Turbine Bldg New PSW Primary New Piping to U 3
( 2000 HP ) & Booster Condensate System
( 50 HP ) Pump for Test Line U1 & 2 U 2 CCW U 3 Ctrl Ctrl Rm Suction Rm New Piping to U 2 New Piping CCW for Pump Test / Min Flow Aux Bldg New Piping &
New Piping &
Isolation Vlvs Isolation Vlvs U1 U2 U3 RX Bldg Rx Bldg Rx Bldg 16
Protected Service Water Civil & Electrical Power Scope Keowee Diagram for PSW Install new circuit breakers for PSW Civil & Electrical Power Scope ACB - 9 ACB - 10 13 . 8 KV Power Feeder Circuit Existing Underground 15 KV Cable /Reels Keowee 13 . 8 KV PSW Power Feed 100 KV CT - 4 Xfmr Lee line to Blockhouse Central Pwr to U 1 /2 /3 PSW AB Turbine Loads & Backup Power to the following AB Eqpt :
Bldg 1 ) U 1 / U 2 / U 3 HPI Pumps Power Feed 2 ) U 1 /U 2 / U 3 Vital I & C From Lee Battery Chargers . Line New PSW Xfmr Auxiliary & Switchgear Bldg Bckup Pwr to U 1 / 2 /3 Pzr Htrs Bldg U1 U2 U3 RX Bldg Rx Bldg Rx Bldg Backup Pwr for SSF Diesel Generator SSF CT-5 Xfmr 17
Protected Service Water Instrument & Control Scope Diagram for PSW Keowee Instrumentation & Control Scope Re - route Keowee Emergency Start Cables out of Turbine Bldg U1 & 2 Blockhouse MCR Ctrls for New PSW Turbine Bldg MCR Ctrls for New Pmp , Sw itchgear & U 1 / U2 PSW U 3 Specific Eqpt .
Specific Eqpt .
New PSW Xfm r
& Sw itchgear U1 & 2 U 2, 125 U 3 Ctrl Bldg U 1, 125 U 3 , 125 VDC Bus Ctrl Rm VDC Bus Rm VDC Bus Aux Bldg Re - route Vital I & C Prim ary & Backup Pow er Cables out of Turbine Bldg 18
Protected Service Water Project Status
Complete
Most of duct bank outside protected area
PSW Building Foundation
100kV Substation
Unit 1 (Fall 2009) - all except HPI transfer switches and power panels
Ongoing
Equipment Manufacturing
Duct Bank Construction
PSW Building
Unit 2 outage (Spring 2010) - will install portions of Main Control Board additions & some HPI mechanical scope
Auxiliary Building piping, cable tray, and hangers
Remaining
Unit 1, 2 & 3 Refueling, Keowee, and Standby Shutdown Facility outages
PSW Building and Equipment Installation
PSW Duct Bank and Cable Installation
Aux Service Water Demolition and Install PSW Pump
SSF Alternate Power Supplies
System Testing 19
Natural Phenomenon Barrier System Protected Service Water Projects
Projects have been Managed Task with a contractor providing engineering and procurement specifications. Another contractor is the constructor and responsible for equipment / material procurement.
Currently transitioning most remaining construction to Self Perform using supplemental personnel.
Quality and Adherence to Standards is top priority and have not been compromised to achieve schedule. Numerous Stop Work and Stand-Downs to drive standards improvement.
Initial schedule based on much higher production rates.
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Natural Phenomenon Barrier System Protected Service Water Projects
Improvement plans in place to reduce human performance issues and rework.
oversight, risk awareness, human performance, procedure use and adherence, security, productivity, engineering quality and safety culture
All critical equipment expedited.
Outage work based on equipment availability.
Work added well past outage schedule milestones.
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Focus
Maintaining healthy SCWE
Continuous reinforcement that we will not compromise safety and quality standards even with aggressive scheduling
Improving worker human performance and schedule predictability
Ensuring quality manufacturing and on time delivery of materials and equipment
Finalizing design
Transferring construction work from contract constructor
Strong oversight of remaining work to be completed by contract constructor 22
Work Windows
Work Windows needed to complete the project:
Spring 2010 - Unit 2 Outage
Fall 2010 - Unit 3 Outage
Spring 2011 - Unit 1 Outage
Summer 2011 - Keowee Outage
Fall 2011 - Unit 2 Outage; Outage SSF Outage
Spring 2012 - Unit 3 Outage
Station Aux Service Water Outage - Adjacent to last unit outage to transition to Protected Service Water.
Schedule Commitments
NPBS - 7/2011
PSW - 7/2012 23
Tornado Commitments Current New Complete No. Commitment Due Date Due Date (Y/N) 1T U3 Control Room North Wall Modification. 5-2009 - Y 2T SSF Diesel Fuel Vent Modification. 12-2007 - Y SSF and CT-5 Trenches Intersection Modification SSF Trench at north 3T 6-2008 - Y end of SSF (TORMIS).
4T Natural Phenomena Barrier System Modifications. 12-2010 7-2011 N 5T Fiber Reinforced Polymer (FRP) LAR for strengthening selected 6T 11-2006 - Y masonry walls for tornado wind and P.
7T Tornado Mitigation Strategy LAR. 6-2008 - Y 8T PSW/HPI modifications. 12-2010 7-2012 N 9T Missile inventory program developed. 12-2007 Y Notify NRC management of significant changes in the scope and/or As necessary until As necessary until 10T N completion dates of the commitments. 12-2014 7-2016 11T U1:12-2012 U1:12-2014 12T Installation of MSIVs. U2:12-2014 U2:12-2015 N 13T U3:12-2013 U3: 7-2016 Fiber Reinforced Polymer (FRP) LAR for strengthening selected "brick" 14T 6-2009 - Y masonry walls for tornado wind and P.
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HELB Commitments Current New Complete No. Commitment Due Date Due Date (Y/N)
Implement an inspection program for the Aux Bldg MS and FW girth 1H 11-2006 - Y and accessible attachment welds.
U1: 6-2008 Implement an inspection program for other Aux. Bldg high energy 2H U2: 12-2008 - Y piping critical crack locations at welds.
U3: 6-2009 Initial ASME Section XI ISI interval UT of the Aux. Bldg MS and FW 3H 7-2008 - Y girth welds and accessible attachment welds.
Initial ASME Section XI ISI interval UT of other Aux. Bldg high 3-2012 No change Y 4H energy piping critical crack locations at welds.
Implement an inspection program for accessible piping base metal 11-2006 - Y 5H downstream of the FW isolation valves located in the EPR.
Implement an inspection program for accessible piping base metal U1: 6-2008 6H of other Aux. Bldg high energy piping critical crack locations not at U2: 12-2008 - Y welds. U3: 6-2009 Initial ASME Section XI ISI interval UT inspection of piping base 7H 11-2006 - Y metal downstream of FW isolation valves located in the EPR.
Initial ASME Section XI ISI interval UT inspection for accessible 8H piping base metal of other Aux. Bldg high energy piping critical 3-2012 No change Y crack locations not at welds.
Implement an inspection program of accessible attachment welds at 9H 11-2006 - Y the terminal ends inside the FW guard pipe.
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HELB Commitments Current New Complete No. Commitment Due Date Due Date (Y/N)
Initial visual inspections of accessible attachment welds at the terminal 10H 6-2007 - Y ends inside the FW guard pipe.
Inspect and repair the Unit 2 East Penetration Room electrical penetration termination enclosures to their correct configuration.
11H 11-2006 - Y Missing and/or damaged covers, gaskets, and fasteners will be repaired or replaced.
Inspect and repair the Unit 1 East Penetration Room electrical penetration termination enclosures to their correct configuration.
12H 12-2006 - Y Missing and/or damaged covers, gaskets, and fasteners will be repaired or replaced.
Inspect and repair the Unit 3 East Penetration Room electrical penetration termination enclosures to their correct configuration.
13H 11-2006 - Y Missing and/or damaged covers, gaskets, and fasteners will be repaired or replaced.
Create an inspection plan to select a portion of Units 1, 2 and 3 14H enclosures to open and inspect for signs of internal debris and 11-2006 - Y corrosion.
Revise station procedures and processes as needed to ensure 15H penetration termination enclosures are maintained in their correct 3-2007 - Y configurations.
Complete the design and installation of flood outlet devices for the Unit 16H 11-2006 - Y 1 East Penetration Room.
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HELB Commitments Current New Complete No. Commitment Due Date Due Date (Y/N) 17H Complete the design and installation of flood outlet devices for the Unit 11-2006 - Y 2 East Penetration Room.
18H Complete the design and installation of flood outlet devices for the Unit 11-2006 - Y 3 East Penetration Room.
19H Complete the design and installation of flood impoundment and 12-2007 - Y exterior door flood improvement features for the Unit 1 East Penetration Room 20H Complete the design and installation of flood impoundment and 12-2007 - Y exterior door flood improvement features for the Unit 2 East Penetration Room.
21H Complete the design and installation of flood impoundment and 12-2007 - Y exterior door flood improvement features for the Unit 3 East Penetration Room.
22H U1: 6-2008 23H HELB LB and Mitigation Strategy LARs. U2: 12-2008 - Y 24H U3: 6-2009 Notify NRC management of significant changes in the scope and/or As necessary As necessary 25H N completion dates of the commitments. until 3-2012 until 7-2016 27
Other Projects
Alloy 600 Remediation
Buried Piping
SSF Generator
Keowee Major Maintenance
Replacement Rx Head NDE
Feedwater Pump Turbine Controls
24 Month Fuel Cycle
Valve Controller Replacements (Pneumatic replaced with Digital)
Keowee / Toxaway Relicensing 28
Action Items and Closing Remarks
We have provided history and context regarding completed projects, risk improvements, and organization capabilities.
Provided technical information, status, and projected risk improvements associated with current Oconee projects of regulatory interest.
Reaffirmed Dukes commitment to Oconee projects of regulatory interest.
29