ML18102A362

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Discusses 960828 Meeting W/Pse&G in Hancocks Bridge,Nj to Present Licensee Integrated Test Program to Be Implemented During Restart of Salem Unit 2.List of Attendees & Copy of Slides Presented at Meeting Encl
ML18102A362
Person / Time
Site: Salem  
Issue date: 09/03/1996
From: Larry Nicholson
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To: Eliason L
Public Service Enterprise Group
References
NUDOCS 9609100306
Download: ML18102A362 (91)
v • d • e


Text

I'**,

'1ij, September 3, 1996 Mr. Leon R. Eliason Chief Nuclear Officer & President Nuclear Business Unit Public Service Electric and Gas Company P. 0. Box 236 Hancocks Bridge, New Jersey 08038

SUBJECT:

SALEM MANAGEMENT MEETING ON AUGUST 28, 1996

Dear Mr. Eliason:

On Wednesday, August 28, 1996, members of the Public Service Electric & Gas Company (PSE&G) met with the U.S. Nuclear Regulatory Commission (NRC) at the Salem Generating Station, Hancocks Bridge, New Jersey, to present their Integrated Test Program to be implemented during restart of Salem Unit 2. This meeting was requested by the licensee.

We found the meeting very informative in understanding the development and implementation of your Salem startup testing program. is a list of the meeting attendees. Enclosure 2 is a copy of the slides that were presented during the meeting.

Docket Nos. 50,..272/50-311

Enclosures:

1.

List of Attendees

2.

Slides 9609100306 960903 PDR ADOCK 05000272 p

PDR ORIGINAL SIGNED BY:

Larry E. Nicholson, Chief Projects Branch 3 Division of Reactor Projects

Mr. Leon R. Eliason cc w/encl:

L. Storz, Senior Vice President - Nuclear Operations E. Simpson, Senior Vice President - Nuclear Engineering E. Salowitz, Director - Nuclear Business Support D. Garchow, General Manager - Salem Operations C. Schaefer, External Operations - Nuclear, Delmarva Power & Light Co.

J. Benjamin, Director - Quality Assurance & Nuclear Safety Review D. Powell, Manager, Licensing and Regulation R. Kankus, Joint Owner Affairs A. Tapert, Program Administrator R. Fryling, Jr., Esquire M. Wetterhahn, Esquire P. MacFarland Goelz, Manager, Joint Generation Atlantic Electric Consumer Advocate, Office of Consumer Advocate William Conklin, Public Safety Consultant, Lower Alloways Creek Township Public Service Commission of Maryland State of New Jersey State of Delaware

Mr. Leon R. Eliason Distribution w/encl:

Region I Docket Room (with concurrences)

Kay Gallagher, DRP Nuclear Safety Information Center (NSIC)

D. Screnci, PAO NRC Resident Inspector L. Olshan, Program Manager, NRR W. Dean, OEDO J. Stolz, PDl-2, NRR M. Callahan, OCA Inspection Program Branch, NRR (IPAS)

PUBLIC DOCUMENT NAME:

g:\\branch3\\salemmgt.mtg To receive a copy of this document, indicate in the box:

"C" = Copy without attachment/enclosure "E

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" = Copy Wit attachmenttr,nc. osure "N" =

a copy OFFICE RI: ORI{. I I

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OFFICIAL RECORD COPY I

PSE&G LIST OF PRINCIPAL ATTENDEES LICENSING/DESIGN BASES Dave Garchow, General Manager, Salem 1 & 2 Gary Overbeck, Director, Systems Engineering Mike Rencheck, Manager, Salem System Engineering Gene Nagy, Systems Engineer Max LeFavre, Nuclear Business Relations Carl Fricker, Supervisor, Salem Plant Assessments Robert Hoffman, Licensing Gabe Salamon, Supervisor, Salem Licensing Chris Bakken, Operations Manager Nick Conicella, Manager, Salem Station Projects Richard Cooper, Director, Division of Reactor Projects, (DRP)

James Wiggins, Director, Division of Reactor Safety, (DRS)

Larry NicholsG;i, Chief, Projects Branch 3, DRP Eugene Kelly, Chief, Systems Engineering Branch, DRS Charles Marschall, Senior Resident Inspector, Salem Lenny Olshan, Senior Project Manager, NRR Roy Fuhrmeister, Electrical Engineering Branch, DRS Jon Greene, NRC Contractor OUTSIDE P. Milford, News-Journal Co./Delwarare Joseph F. Janccha, Atlantic Energy Patricia MacFarland Goelz, Atlantic Energy Rich Pinney, New Jersey Dept. of Environmental Protection ENCLOSURE 1

ENCLOSURE 2 SYSTEM READINESS REVIEW PROGRAM

~ I STARTUP AND POWER ASCENSION PHASE

SYSTEM READINESS OVERVIEW

=>SYSTEM READINESS~REVIEW PROGRAM

  • Phase I - Initial System Readiness Review
  • Phase II - Restart Activity Monitoring
  • Phase III - Final System Readiness Review
  • Phase IV - Startup and Power Ascension

SYSTEM READINESS OVERVIEW

=>INITIAL SYSTEM READINESS REVIEW (PHASE I)

  • Salem Units 1 & 2 - 46 Systems each
  • Multi-Discipline Teams - System Manager Lead
  • General Review design basis and licensing basis documentation
  • Open activities assessment
  • Comprehensive system walkdown

SYSTEM READINESS OVERVIEW

>RESTART ACTIVITY MONITORING.(PHASE II)
  • Review open corrective action items
  • Evaluation of emergent action items for Restart applicability
  • Coordinate scheduling of system work activities
  • Systems Indexed Database System (SIDS)

SYSTEM READINESS OVERVIEW RESTART ACTIVITY MONITORING (PHASE II)

  • Development of Startup System Test Plans
  • Preparation for System Window closure
  • Preparation for Final System Readiness Reviews
  • System Manager regularly scheduled walkdowns
  • SIDS database update & evaluation of exceptions to completed work

SYSTEM READINESS OVERVIEW

=>FINAL SYSTEM READINESS REVIEW (PHASE III)

  • Initiate review of Startup System Test Plans
  • System Readiness Walkdowns - System Manager & Operations
  • Macro-review of appropriate UFSAR sections
  • Presentation of Final System Readiness Report, prior to Restart
  • System Readiness Review Board (SRRB)
  • Management Review Committee (MRC)

SYSTEM READINESS OVERVIEW

=>STARTUP AND POWER ASCENSION (PHASE IV)

=>System Manager

  • Completes SAAP-35 System Affirmation Forms
  • Continuously monitors system readiness, emergent corrective maintenance activities and condition reports
  • Completes regularly scheduled system walkdowns
  • Monitors to completion, work items scoped Power A.scension within SIDS
  • Establishes baseline system performance monitoring, tracking and trending

SYSTEM READINESS OVERVIEW STARTUP AND POWE~ A.SCENSION (PHASE IV)

  • PROGRAM OVERVIEW
  • PROGRAM PHILOSOPHY
  • DEVELOPMENT PHASE
  • PLANNING PHASE
  • IMPLEMENTATION PHASE
  • POST STARTUP CRITIQUE
  • TEST SCHEDULE PICTOGRAMS

}-

STARTUP AND POWER ASCENSION PROGRAM

~PROGRAM OVERVIEW

  • Objective
  • Safe, Controlled, Deliberate Salem Restart

STARTUP AND POWER ASCENSION PROGRAM PROGRAM OVERVIEW I

=>Program Key Elements:

=>

Development Phase (System Engineering)

  • System Test Plan Development
  • Review by Test Review Board (TRB)
  • Review by Station Operations Review Committee (SORC)
  • Approval by General Manager Salem Operations (GM-SO)

STARTUP AND POWER ASCENSION PROGRAM PROGRAM OVERVIEW I

  • Program Key Elements:

Planning Phase

  • NAAP-5 "Special Test" Test Managers
  • Establish Test Team
  • Test Implementation Strategy
  • Contingency Plans

STARTUP AND POWER ASCENSION PROGRAM PROGRAM OVERVIEW;

  • Program Key Elements:

=>

Implementation Phase (Operations Department)

  • Startup & Power Ascension Management and Support Organization
  • Assessment Hold Points and Criteria for continuing Restart
  • Management Observation Program during Startup and Power Ascension evolutions
  • NAAP-5 "Special Test" Test Managers
  • Post-Test Review of Special Tests by TRB

STARTUP AND POWER ASCENSION PROGRAM

=>PROGRAM PHILOSOPHY

=>Management Review Committee (MRC) Approved Concept

  • Utilize Existing Processes (NAAPs-5, 8, 9)
  • Program Described by SC.TE-TI.ZZ-OOOl(Q),

"Startup And Power Ascension Program"

  • Test Review Board (TRB) established as Pre-SORC screening for System Test Plans (STPs) and Special Test Procedures

STARTUP AND POWER ASCENSION PROGRAM PROGRAM PHILOSOPHY

) QA/NSR Oversight of Restart Test Program
  • Evaluation of Test Review Board Process is ongoing
  • QA/NSR has selected 13 Tests to review in detail
  • Basis for 13 Selected Tests:
  • M-Rule Risk Significant Systems, plus Feed & Condensate, and Station Air
  • Generic implications/Applicability of a large number of components
  • Complexity of Test/Problem/Solution
  • For the selected 13 Tests, QA/NSR will:
  • Review the test procedure in detail
  • Observe performance of the test
  • Review test results/ Acceptance Criteria

{,.:

STARTUP AND POWER ASCENSION PROGRAM PROGRAM PHILOSOPIJY

=>Test Phases

  • Phase I : Component level testing, covered under NAAP-9 or NAAP-8
  • Phase II : System level testing, covered under NAAP-8 or NAAP-1
  • Phase III : Integrated functional testing, i.e. Manual SI, Mode-Op Testing (Surveillance/Periodic Tests)
  • Phase IV : Mode & Power Ascension Testing

STARTUP AND POWER ASCENSION PROGRAM SPECIAL TEST PREPARATION AND PLANNING FLOW CHART System Manager Develop System Test Plan TRB Review of Test Plan Develop Identify Test._-"., Contingency Equipment Plan Perform Shift Briefing Perform Test DEVELOPMENT PHASE SORC Review of Test Plan Develop Startup Schedule NAAP-5 GM-SO I

I I

Follow Normal Testing t Np NF Processr

  • 1--1---------"

PLANNING PHASE Operations and Test Team Training Establish

  • --- Criteria For Acceptance IMPLEMENTATION PHASE Test NO Initiate AR/CR and Retest Accordingly Prepare

---Post-Test ---

Report Pre Plan Test Briefing TRB Review Test TRB Review of Implementation Strategy NO Initiate AR/CR and Retest Accordingly Test Manager Form Test Team END

STARTUP AND POWER ASCENSION PROGRAM

=>DEVELOPMENT PHASE

=:)System Test Plan Development & Content

  • Table 1 : Matrix of DCPs/DCRs
  • Purpose/Scope vs. Testing which validates new design
  • Table 2: Matrix of Work Orders (WO's)
  • Work Scope vs. Post-Maintenance Test (PMT) and/or Operations Retest (RT)
  • Table 3 : Industry Experience and Commitments
  • Potential items (OEFs, ATS, Lessons Learned) which have or may result in testing

STARTUP AND POWER ASCENSION PROGRAM DEVELOPMENT PHASE I

  • System Test Plan Development & Content
  • Table 4 : Additional Testing/Startup And Power Ascension Testing
  • Recommended additional testing vs. basis for test
  • Post fuel-load testing identified by design changes (Table 1 DCPs/DCRs)
  • Required Mode for performance of each test
  • Duration required for each test
  • Summary : An argument as to why the system is ready for Startup based on testing

STARTUP AND POWER ASCENSION PROGRAM DEVELOPMENT PHASE I

=>System Test Plan Types

  • System Test Plans ( 46 Total)
  • Integrated Functional Test Plan (Phase III)
  • Power Ascension Test Plan (Phase IV)

STARTUP AND POWER ASCENSION PROGRAM DEVELOPMENT PHASE I

=>System Test Plan Review/Approval

  • Engineering Supervisor
  • Operations SRO - System Team Member
  • Maintenance - System Team Member
  • Test Review Board Chairman
  • SORC Chairman
  • General Manager Salem Operations (GM-SO)

STARTUP AND POWER ASCENSION PROGRAM DEVELOPMENT PHASE:

=>Test Review Board Members

  • Chairman - Startup Testing Manager
  • System Engineering Supervisors
  • Design Engineering Supervisors
  • Operations SRO (Retest Supervisor)
  • Maintenance (Staff Engineer, Testing background)
  • In-Service Test Group (IST) Supervisor
  • Installation Test Group (ITG)
  • Startup Test Engineer (Startup Group)

STARTUP AND POWER ASCENSION PROGRAM DEVELOPMENT PHASE I

=>Test Review Board Charter

  • Ensure the adequacy, consistency, and proper test methodology for:
  • Startup System Test Plans
  • DCP Tests & Special Tests
  • One-Time Special Test Procedures
  • Work Order Post-Maintenance Test (PMT) and/or Ops Retest (RT)

Activities

  • Recommend approval to SORC for System Test Plans and Special Test Procedures
  • Identify testing that constitutes Special Tests or infrequently performed tests or evolutions

STARTUP AND POWER ASCENSION PROGRAM DEVELOPMENT PHASE

=)Types Of Tests
  • DCP "Special Tests" (NAAP-8)
  • Station Procedures used as one-time tests (NAAP-1)
  • Surveillance/Periodic Testing
  • Reactor Engineering Testing
  • Work Order PMT /RT Activities

STARTUP AND POWER ASCENSION PROGRAM DEVELOPMENT PHASE I

  • Types Of Tests

=> NAAP-5 "Special Tests"; Tests or Evolutions (DCP or Station Tests) which:

  • Are not permitted by normal operating procedures
  • Infrequently performed surveillances (> 18 month periodicity) which are not practiced or simulated in training exercises
  • Place plant systems outside normal parameters or configurations
  • Have potential to significantly impact plant conditions
  • Complexity of the activity places the plant at increased risk
  • Plant startups after extended outages
  • Major design modifications involving reactivity control, power production, and power transmission systems

STARTUP AND POWER ASCENSION PROGRAM DEVELOPMENT PHASE I

=>Test Approvals

  • DCP Special Tests; Review is part of the DCP package/process
  • Station Procedures; Review is part of the procedure package/process

STARTUP AND POWER ASCENSION PROGRAM SPECIAL TEST PREPARATION AND PLANNING FLOW CHART System Manager Develop System Test Plan Identify Test Equipment Perform Shift Briefing TRB Review of Test Plan Develop Contingency Plan Perform Test DEVELOPMENT PHASE SORG Review of Test Plan Develop Startup Schedule NAAP-5 GM-SO I

I I

Follow Normal Testing ~.Np Np Process rf--L-------_J PLANNING PHASE Operations and Test Team Training Establish

--- Criteria For Acceptance IMPLEMENTATION PHASE Test NO Initiate AR/CR and Retest Accordingly Prepare

>--Post-Test ---

Report Pre Plan Test Briefing TRB Review Test TRB Review of Implementation Strategy NO Initiate AR/CR and Retest Accordingly Test Manager Form Test Team END

STARTUP AND POWER ASCENSION PROGRAM

=>PLANNING PHASE

~ I

) NAAP-5 "Special Test" Test Managers
  • Establish Test Team
  • Pre-Test Planning
  • Identify Test Equipment
  • Perform Test walk down/rehearsal
  • Develop Contingency Plans
  • Develop Pre-Test Shift Briefing

STARTUP AND POWER ASCENSION PROGRAM PLANNING PHASE c I

  • NAAP-5 "Special Test" Test Managers
  • Simulator Training
  • Establish Criteria for acceptability
  • Present Special Test implementation strategy to TRB
  • OEF Training

__J

STARTUP AND POWER ASCENSION PROGRAM OEF TRAINING (EXAMPLES):

  • SER 24-89 (Seabrook); Failure to manually scram the reactor when startup test conditions were exceeded
  • SER 8-90 (Shearon Harris); Nonconservative Nuclear Instrumentation and Reactor Trip setpoints during plant startup with a new "low leakage" core
  • SER 4-96 (St. Lucie); Inadequate technical review resulted in failure of Reactor Coolant Pump seal and degradation of backup seals
  • SER 3-96 (Quad Cities); Failure to perform reactor scram and Turbine Trip when test limits were exceeded
  • SOER 91-01; Summary of above events involving the Conduct of Infrequently Performed Tests/Evolutions

STARTUP AND POWER ASCENSION PROGRAM SPECIAL TEST PREPARATION AND PLANNING FLOW CHART System Manager Develop System Test Plan TRB Review of Test Plan Identify Test Develop Equipment *--- Contingency Plan Perform Shift Briefing Perform Test DEVELOPMENT PHASE SORC Review of Test Plan Develop Startup Schedule NAAP-5 Follow Normal Testing I

NO GM-SO I

NO Process PLANNING PHASE Operations and Test Team Training Establish a--i~ Criteria For Acceptance IMPLEMENTATION PHASE Test NO Initiate AR/CR and Retest Accordingly Prepare

>---Post-Test ---

Report Pre Plan Test Briefing TRB Review Test TRB Review of Implementation Strategy YES NO Initiate AR/CR and Retest Accordingly Test Manager Form Test Team 6

STARTUP AND POWER ASCENSION PROGRAM

=>IMPLEMENTATION P.HASE

=>Startup & Power Ascension Management and Support Organization

  • Established to provide experience, safety focus, and resources to enhance the ability to conduct a safe and conservative startup

STARTUP AND POWER ASCENSION PROGRAM Ops Manager Startup Test Manager Shift S/U Testing Engineer Startup & Power Ascension Management And Support Organization NSS Shift Crew (RP, Chem, EO's, RO's)

General Manager so SNSS

= Shift Support Organization

-**-.. -**-**-* -**-**-**-**-* -*-**-**-**-* -**-**~

1 : ! !

i Shift Plant Manager Shift Outage Manager i

i Outage Manager r- --*- ---*- -**-* --**-**-.L - -T *---*-* -*-**---*-----*--*-* -* --* -*- -T ----

~~----'-~~

Shift Proc.

Rep.

Shift Maint.

Rep's Shift Outage Coord.'s Director Sys.

Engineering Shift Eng.

Support Manager i

Engineering Support

STARTUP AND POWER ASCENSION PROGRAM IMPLEMENT A TI ON PHASE

~ '

  • Startup & Power Ascension Management and Support Organization

=>Outage Management Team

  • Outage Manager
  • Shift Outage Manager
  • Around the clock control of the Outage Control Center
  • Outage Control Center
  • Staffed by Maintenance, Engineering and Procurement Department representatives, providing expertise to analyze and resolve emergent issues during startup
  • Outage Coordinators
  • Oversight and coordination of plant work activities

STARTUP AND POWER ASCENSION PROGRAM IMPLEMENTATION PHASE

  • Startup & Power Ascension Management and Support Organization
) Startup Support Team
  • Shift Plant Manager
  • On-shift (24-hr) direct representative of the GM-SO
  • Supports Senior Nuclear Shift Supervisor (SNSS) while maintaining overall perspective of startup process
  • Shift Engineering Support Manager
  • On-shift (24-hr) direct representative of the Director - System Engineering
  • Maintaiu.., overall perspective of Engineering support and controls on-shift Engineering resources

STARTUP AND POWER ASCENSION PROGRAM IMPLEMENTATION PHASE

  • Startup & Power Ascension Management and Support Organization
  • Startup Support Team
  • Startup Testing Manager
  • Reports directly to the Operations Manager
  • Supports Senior Nuclear Shift Supervisor (SNSS) during Startup and Power Ascension test activities
  • Provides focus and single point contact needed to coordinate overall Startup & Power Ascension Test Program
  • Shift Startup Testing Engineer
  • On-shift (24-hr) presence to implement the Startup and Power Ascension Test Program at the direction of the Startup Testing Manager
  • Sequencing Procedure implementation

STARTUP AND POWER ASCENSION PROGRAM IMPLEMENT A TI ON PHASE

=>Startup and Power Ascension Sequencing Procedure

  • Sequences all Startup and Power Ascension tests
  • Establishes Startup and Power Ascension Program Holdpoints
  • Will be written and approved per NAAP-1
  • Associated 10CFRS0.59 Safety Evaluation will be written to assess the aggregate effect of all Startup and Power Ascension test activities

STARTUP AND POWER ASCENSION PROGRAM IMPLEMENTATION Pa~sE

=:)Hold Points and Criteria for continuing Restart

=:)Plant Performance Hold Points: Allows time for a deliberate decision to be made by the Shift Plant Manager that the sequence should progress to the next set of activities in the schedule

  • The decision is based on satisfactory plant performance and test results, and effective resolution of open and emergent issues
  • This ensures that all information is considered (i.e. material condition, completion of necessary corrective maintenance actions, personnel performance, responsiveness of support activities, etc.)

STARTUP AND POWER ASCENSION PROGRAM IMPLEMENT A TI ON PllA.SE

  • Hold Points and Criteria for continuing Restart

=>Plant Performance Hold Points:

  • Cold Shutdown (Mode 5), Tave <200 Deg F
  • Hot Shutdown (Mode 4), Tave <350 Deg F
  • Hot Standby (Mode 3), Tave >350 Deg F, Sub-critical
  • Startup (Mode 2), Critical, Power <5°/o
  • Power Operation (Mode 1), Power >So/o
  • Prior to exceeding 25% Power
  • Prior to exceeding 47°/o Power
  • Prior to exceeding 90°/o Power
  • Final Plant Performance Review

STARTUP AND POWER ASCENSION PROGRAM IMPLEMENT A TI ON PHASE

  • Hold Points and Criteria for continuing Restart

=>Assessment Hold Points: Permits a systematic management review and assessment of plant and personnel performance to ensure that the plant and the organization are ready to proceed with the startup plan

  • The assessment process includes a SAAP-34 planned assessment by the line organization and an independent assessment by the Quality Assessment Department
  • These planned assessments are conducted during the ascension to the hold point and provide input to the department manager's recommendation to the General Manager to continue with the schedule
  • Assessment Criteria to be developed from the station self assessment diagnostic performance standards, criteria and attributes

STARTUP AND POWER ASCENSION PROGRAM IMPLEMENTATION PHASE

  • Hold Points and Criteria for continuing Restart
) Assessment Hold Points:
  • Prior to Mode 2 (Startup)
  • Prior to exceeding 25°/o Power
  • Prior to exceeding 90°/o Power
  • Final Assessment Review

STARTUP AND POWER ASCENSION PROGRAM IMPLEMENTATION PHASE

=>Management Observation Program during Startup and Power Ascension evolutions

  • Frequency and Focus Areas of routinely scheduled SAAP-34 Management Observations shall be based on input from the Startup Testing Manager and the Startup and Power Ascension Program
  • In addition to normal processing and trending analysis, the results of these observations shall be reported directly to the GM-SO ~nd the Startup Testing Manager

STARTUP AND POWER ASCENSION PROGRAM IMPLEMENT A TI ON PHASE

=:) NAAP-5 "Special Test" Test Managers
  • Provide Management Oversight for Special Test (Note: Shift Plant Manager performs this function when Test Manager is not available)
  • Performs Shift Briefing prior to Special Test
  • Prepare Post-Test Report
  • Present Post-Test Report to TRB

STARTUP AND POWER ASCENSION PROGRAM

=>POST STARTUP CRIIlQUE

  • Startup Testing Manager leads a critique of the startup
  • Review identifies, communicates and addresses any lessons learned, considering both problems encountered and positive experiences
  • Ensures that these experiences are incorporated into future Salem startups

STARTUP AND POWER ASCENSION PROGRAM PRE CORE LOAD TESTS

  • ECCS Hi-Head CL Flow Balance
  • Manual ESF Actuation - Safety Injection
  • ECCS Int-Head CL Flow Balance
  • Manual ESF Actuation - CISA
  • ECCS Int-Head HL Flow Balance
  • Manual ESF Actuation - CISB
  • 2A DG & Vital Bus Mode-Op Test
  • Cntmt Spray System Auto Actuation
  • 2B DG & Vital Bus Mode-Op Test
  • SSPS Train A Functional Test
  • 2C DG & Vital Bus Mode-Op Test
  • SSPS Train B Functional Test
  • Letdown Isol Bypass Ckt Test
  • CAACS/EACS Integrated System Test
  • SIG Blwdn Smpl Isol Bypass Ckt Test

STARTUP AND POWER ASCENSION PROGRAM

~ :

PRE CORE LOAD TESTS

  • P250 Computer Inverter Test
  • Component Cooling Sys Flow Balance
  • Alt Shtdn Sys (ASDS) Inverter Test
  • CH Chiller Capacity Test
  • Chilled Water System Flow Balance
  • Battery Charger Functional Test
  • FHV Pressure Control Damper Test
  • ABV System Functional Test
  • FHV Exhaust Fan Auto-Start Test
  • CA V System Flow Balance
  • FHV Htng Coil Hot Wtr Flow Balance
  • CA V Ductwork Leak Test
  • Station Air Compressor Functional Test

STARTUP AND POWER ASCENSION PROGRAM PRE CORE LOAD TESTS

  • ADFCS Hardware/Software Test
  • DG Starting Air & Turbo Boost Test
  • SGFP Trip/Turbine Runback Functional
  • DG Jacket Wtr & Cutri Pol Heater Test
  • SGFP Speed Control Functional Test
  • DG Breaker Close Permissive Functional
  • CCP Gear Oil Cooler Performance Test
  • EHC Reference & Setter Display Test
  • Boric Acid/Primary Water Register Test
  • EHC Governor Valve Calibration Test
  • PDP Relief Valve Functional Test
  • Main Gen Stator Runback Logic Test
  • Rad Monitoring System Computer Test

STARTUP AND POWER ASCENSION PROGRAM PRE MODE 4 TESTS

  • ABV Initial Flow Balance
  • Primary Water Makeup Control Test
  • Switchgear Area (CA V) Air Balance
  • VCT Level Control Test
  • Battery & Security Exhaust (CA V) Test
  • Steam Dump Control Test
  • Fire Damper (CA V) Functional Test
  • Rod Speed & Direction Control Test
  • C02 Damper (CA V) Functional Test
  • RVLIS - Rx Clot Pump Combinations
  • MSR/MSCDT Control Circuit Test

STARTUP AND POWER ASCENSION PROGRAM MODE 4 THROUGH MODE 3 TESTS

  • Circulating Water Sys Integrated Test
  • Rx Clot Sys RTD Cross-Calibration
  • Condensate Pump Performance Test
  • Pressurizer Bypass Spray Flow Setting
  • Ltdwn HX Temperature Control Test
  • Pressurizer Pressure Control Test
  • Ltdwn Pressure Control Test
  • Pressurizer Level Control Test
  • RVLIS - Rx Clot Pump Combinations
  • Centrifugal Charging Flow Control Test
  • Atmos Relief Viv (MSlO) Dynamic Test

STARTUP AND POWER ASCENSION PROGRAM

~ I MODE 4 THROUGH MODE 3 TESTS

  • 21 AFW Pump & Valve Auto-Start Test
  • Hot Shutdown Panel Functional Test
  • 22 AFW Pump & Valve Auto-Start Test
  • Steam Dump Control Test
  • 23 AFW Pump Manual Start Test
  • Steamline Baseline Leak Test
  • AFW Control Valve Functional Test
  • Plant Vent Rad Monitor (R41) Test
  • ARPI Baseline Scaling Data Collection
  • Main Stm Line Rad Monitor (Nl6) Test

STARTUP AND POWER ASCENSIO-N PROGRAM

~ I ZERO POWER (MODE 2) TESTS

  • Reactivity Computer Checkout
  • Isothermal Temp Coefficient Calculation
  • NIS Trip Setpoint Adjustments
  • Boron Endpoint Determination
  • SGFP Recirc Cutri Viv Dynamic Test
  • Rod Swap Reactivity Measurement Test
  • SGFP Speed Control Tuning
  • Rod Worth Measurements

STARTUP AND POWER ASCENSION PROGRAM POWER ASCENSION (MODE 1) TESTS

  • ABV System Flow Balance
  • Rod Speed & Direction Control Test
  • Turbine Stop Viv Belleville Setting
  • Secondary Plant Level Control Tuning
  • Bleed Stm Coil Drain Wtr Column Test
  • SGFP Recirc Cntrl Viv Dynamic Test
  • Secondary Plant Performance Test
  • Heater Drain Pump Disch Cutri Viv Test
  • Incore Flux Mapping
  • Turbine Control Valve Baseline Curve

STARTUP AND POWER ASCENSION PROGRAM

~ I POWER ASCENSION (MODE 1) TESTS

  • SGFP Speed Control Tuning
  • Incore/Excore NIS Calibrations
  • ADFCS Process & Load Swing Tests
  • NIS Trip Setpoint Adjustments
  • Rx Coolant Sys Flow Measurements
  • SGFP Trip & Auto Turbine Runback
  • Statepoint Data Collection
  • Calorimetric Tests
  • Target Axial Flux Diff Measurement

STARTUP AND POWER ASCENSION PROGRAM POST-STARTUP TESTS

  • Secondary Plant pH Chemistry Control (Iron Transport)
  • Spent Fuel Cooling System Performance Baseline

POWER LEVEL 100 90 75 70 50 35 25 15 5

0 POWER ASCENSION PROFILE

  • AFP Out of Service (2% Power)
  • ADFCS STP Level/FeedOow/DP Perturbations (7.5% Power)

Hold Point 2

4

  • Flu1. Mapping
  • Calorimetric
  • Reset NIS Trips (60°/e Power)
  • ADFCS STP Level/FeedOow/DP Perturbations (47% Power)

Flux Mapping (25% Power)

  • Turbine O/S Tests
  • Turbine Bellville Washer Setup
  • Sync Turbine
  • ADFCSSTP Level/FeedOow/DP Perturbations (15% Power)

Hold Point SGFP STP 25°1. Load Swing (90% Power)

  • ADFCSSTP 10% Load Swings (47% Power)

(37% Power) 6 8

10 12 14 DURATION (DAYS)

ADFCS STP 10% Load Swing (100% Power)

  • Calorimetric
  • Core Conditioning
  • RCS Flow Measurements
  • ADFCS STP Level/FeedOow/DP Perturbations (100% Power) 16 18 SGFP STP 40% Load Swing (90% Power)

SGFP STP SGFP Trip (Runback to 60%)

(90% Power)

+30 Days

+60-90 Days

  • Secondary System pH Chemistry Control 20 22 24

PLANT HARDWARE ISSUES

=>HARDWARE INTERVENTION ACTION PLAN

=>Objective

  • Identify the most significant hardware challenges to reliable, event free operation, and prioritize plant systems to ensure proper focus and resources

PLANT HARDWARE ISSUES HARDWARE INTERVE:N1TION ACTION PLAN

=>Initial System Screening Criteria

  • Power production losses attributed to system in past 18 months
  • Corrective maintenance man-hours applied to system in past 18 months

PLANT HARDWARE ISSUES HARDWARE INTERVENTION ACTION PLAN

~Final System Screening Criteria

  • Reliability (Overall System Health)
  • Incident Reports, Corrective Maintenance Work Orders, Problem Reports)
  • Operability (Potential challenges to plant safety)
  • Backlogs (Predictor of future system failures)
  • Open DEFs, Corrective & Preventive Maintenance Work Orders, Problem Reports)
  • Power Losses (Losses/Reductions in power output)
  • Megawatt-Hours lost

PLANT HARDWARE ISSUES HARDWARE INTERVENTION ACTION PLAN

=>Eight "Focus Systems" were identified

  • RCP - Reactor Control and Protection System
  • CVC - Chemical and Volume Control System
  • DG - Diesel Generator System

=>These eight focus systems caused 45 of 54 forced outages since 1988 (83°/o)

PLANT HARDWARE ISSUE, (RCP) Reactor Control and Protectio~ System

=>Problem Statements

  • Poor reliability, system has caused several power reductions or reactor trips
  • Inadequate preventative maintenance
  • Inadequate module testing
  • Lack of module configuration control

PLANT HARDWARE ISSUES (RCP) Reactor Control and Protection System

=>Problem Resolutions

  • Hagan Refurbishment and Replacement Project (Hagan R & R)

(Total Module Upgrade):

  • Refurbishment; module upgrade to latest Westinghouse revision
  • Replacement; obsolete modules replaced with NUS modules
  • Comprehensive Preventive Maintenance Program has been established and will be implemented prior to Restart
  • New procedures for control of the upgrade process, bench testing, calibration, and module configuration control

PLANT HARDWARE ISSUES (RCP) Reactor Control aQp Protection System

=>Key Startup and Power Ascension Test Activities

  • Elevated temperature 50 Hour burn-in period
  • Loop channel calibrations after installation
  • Time response testing
  • "Special Testing" of process control loops

PLANT HARDWARE ISSUES (RCP) Reactor Control and Protection System

  • Key Startup and Power Ascension Test Activities
  • Process Control Loop Special Tests:
  • Primary Water Makeup Control
  • Volume Control Tank (VCT) Level Control
  • Rod Speed & Direction Control
  • Letdown Heat Exchanger Temperature Control
  • Letdown Pressure Control
  • Pressurizer Pressure Control
  • Pressurizer Level Control

PLANT HARDWARE ISSUES (CN) Feedwater and Condensate System

==>Problem Statements

  • Feedwater flow control at low power required extensive manual operations, and contributed to several reactor trips
  • SGFP actuator high vibration has led to power reductions and shutdowns

PLANT HARDWARE ISSUES (CN) Feedwater and Con(l~nsate System

=>Problem Resolutions

(redundant, reliable, controls in automatic from 2°/o to lOOo/o power)

  • Improved SGFP Recirc Control Valve design; replaced/relocated valves and reconfigured control to provide modulation
  • Installed new SGFP '1ctuators and digital speed control system

PLANT HARDWARE ISSUES (CN) Feedwater and Condensate System

=>Key Startup and Power Ascension Test Activities

  • SGFP Recirc Control Valve static and dynamic testing
  • SGFP Speed Control System/Main Turbine Runback Testing:
  • Dynamic tuning of SG:FP Speed Control System (<5°/o & 47% Power)
  • ADFCS component level testing:
  • ADFCS hardware & software Factory Acceptance Test (FAT)
  • ADFCS system logic Special Test Procedure

PLANT HARDWARE ISSUES (CN) Feedwater and Condensate System

  • Key Startup and Power Ascension Test Activities
  • ADFCS system level testing:
  • ADFCS process transient response Special Test Procedure (7°/o, 15°/o, 47°/o and 100°/o Power):
  • Open Loop Feedwater Flow Perturbation (FW Cntrl Viv Demand 10°/o step increase)
  • Open Loop DP Perturbation (Stm Press/FW Press DP)

(SGFP Speed Demand 5°/o step decrease)

  • Closed Loop S/G Level Setpoint Perturbation (SIG Level Setpoint 5o/o step increase)
  • Closed Loop DP Perturbation (Stm Press/FW Press DP)

(DP Setpoint 20 psi step increase)

PLANT HARDWARE ISSUES (CN) Feedwater and Condensate System

  • Key Startup and Power Ascension Test Activities
  • Integrated Plant testing:
  • 10°/o decreasing, then lOo/o increasing load swings from 47°/o Power
  • 10% decreasing load swing from 100°/o Power
  • 25°/o decreasing load swing from 90% Power
  • 40°/o decreasing load swing from 90°/o Power

PLANT HARDWARE ISSUES (CN) Feedwater and ConcJ~nsate System

  • Key Startup and Power Ascension Test Activities
  • Integrated Plant testing:
  • SGFP Trip from 90% Power

PLANT HARDWARE ISSUES (MS) Main Steam System~ l

=>Problem Statements

  • Atmospheric Relief Valve (MSlO) Controls have been unreliable
  • Steam Trap failures have led to destructive water hammer and plant inefficiency

PLANT HARDWARE ISSUES (MS) Main Steam System ~ :

=>Problem Resolutions

  • Incorporated Atmospheric Relief Valve (MSlO) Controls into ADFCS
  • Modified MSR Steam Supply Valve interlocks to allow recovery following an MSR Trip
  • Replaced Steam Traps with fixed orifices, each with a bypass, strainer and temperature indicator arrangement

PLANT HARDWARE ISSUES (MS) Main Steam System, I

=>Key Startup and Power Ascension Test Activities

  • Functional testing of Turbine Bypass Valves to demonstrate proper sequencing, and control loop response in both Pressure Control and Tave Control modes
  • MSR Logic and Interlock Functional Test Procedure
  • Utilize Turbine Bypass Valves for temperature control during plant heatup to demonstrate resolution of excess cooldown issue
  • Static testing of the Atmospheric Relief Valves

PLANT HARDWARE ISSUES (MS) Main Steam System, ;

  • Key Startup and Power Ascension Test Activities
  • Pressure setpoint perturbations in the Pressure Control 1\\11ode (Mode 2/3)
  • Main Turbine load swings (Runbacks) in the Tave Control Mode
  • 10°/o load swings from 47°/o and lOOo/o Power
  • 25°/o load swing from 90°/o Power
  • 40°/o load swing from 90°/o Power
  • SGFP Trip from 90°/o Power (30°/o load swing to 60°/o Power)
  • Dynamic testing of the Atmospheric Relief Valves (ADFCS Special Test)

PLANT HARDWARE ISSUES (CW) Circulating Water System

>Problem Statements
  • Poor reliability, controls and instrument setpoints not properly coordinated to provide reliable integrated system operation
  • Traveling Screens incapable of handling large amounts of river debris, this has resulted in operational impacts and plant trips
  • Condenser Waterbox structural damage due to waterhammer following pump starts

PLANT HARDWARE ISSUES (CW) Circulating Water System

=>Problem Resolutions

  • Modified Circulating Water Pump (Circulator) start permissives to reduce system pressµre transients
  • Traveling Screens were provided with larger motors, new type baskets, increased operating speeds, and additional spray nozzles for debris removal
  • Revised Circulator, Traveling Screen, and Bearing Lube setpoints to provide improved integrated system operation
  • Modified Screen Wash and Bearing Lube strainer and strainer control circuit

PLANT HARDWARE ISSUES (CW) Circulating Water System

=>Key Startup and Power Ascension Test Activities

  • Functional testing of Circulator, Traveling Screen, Screen Wash and Bearing Lube system component control circuits
  • Special Test Procedure demonstrates integrated system functional operation (Examples:)
  • Verifies Circulator Discharge Valve interlock on Circulator start
  • Verifies Screen Wash Pump auto-start interlock on Circulator start
  • Verifies Traveling Screen speed increase on high differential pressure
  • Verifies Bearing Lube Pump start permissives
  • Records process parameters under various system configurations to establish system baseline

PLANT HARDWARE ISSUES (CVC) Chemical and Volume Control System

=>Problem Statements

  • Volume Control Tank (VCT) hydrogen pressure control valve is unreliable
  • Centrifugal Charging Pump (CCP) flow control valve is susceptible to cavitation damage under low Reactor Coolant System pressure conditions
  • Full closure of the CCP flow control valve under low charging flow conditions can damage Reactor Coolant Pump seals
  • Positive Displacement Charging Pump (PDP) relief valve lifts during PDP operation, and during start of a CCP
  • CCP speed increaser gear oil cooler has excessive tube corrosion

PLANT HARDWARE ISSUES (CVC) Chemical and Volume Controi System

=>Problem Resolutions

  • Replaced VCT hydrogen pressure control valve with more suitable design
  • Replaced CCP flow control valve assembly with an enhanced anti-cavitation trim design for more reliable flow control
  • Added a pneumatic limit relay to the control air circuit for the CCP flow control valve to prevent full valve closure
  • Replaced PDP relief valve with a more suitable design, and relocated a check valve to provide isolation from the CCPs
  • Replaced CCP speed increaser gear oil cooler with new titanium tube and shell cooler for improved corrosion resistance

PLANT HARDWARE ISSUES (CVC) Chemical and Volume Control System

) Key Startup and Power Ascension Test Activities
  • CCP flow control valve functional and AOV diagnostic testing
  • CCP flow control valve Special Test Procedure to verify proper minimum flow

("min-stop" limit)

  • PDP relief valve functional test to demonstrate valve remains seated during PDP operation and CCP starts
  • CCP gear oil cooler performance testing
  • VCT hydrogen pressure control valve functional and AOV diagnostic testing

PLANT HARDWARE ISSUES (DG) Diesel Generator System

=>Problem Statements

  • Component failures due to high vibration have challenged DG availability
  • Starting Air and Turbo Boost Air System components degraded due to corrosion
  • Starting Air and Turbo Boost Air System compressor pressure switches/setpoints provide inadequate margin between compressor start and relief valve setpoint

PLANT HARDWARE ISSUES (DG) Diesel Generator System *

=>Problem Resolutions

  • Jacket Water Pump discharge piping replaced with tubing, flex hoses were added/replaced, and components otherwise isolated from vibration
  • Starting Air and Turbo Boost carbon steel piping and valves replaced with stainless steel, relief, check and manual valves provided with soft seats
  • Replaced air start motors, pulsation dampers, aftercooler and moisture separator, added new afterfilters, new strainers, and removed air dryer/filter
  • Replaced Air Compressor pressure switches and provided flexible tubing connections to eliminate vibration induced setpoint drift

(.

PLANT HARDWARE ISSUES (DG) Diesel Generator System

==)Key Startup and Power Ascension Test Activities

  • Vibration testing to ensure sensitive components have been isolated
  • Functional Testing of new Starting Air and Turbo Boost System components
  • DG 1-Hour Run and 24-Hour Endurance Run surveillance tests
  • DG Auxiliaries, Starting Air and Turbo Boost Air check valve surveillance tests
  • DG Mode-Op surveillance tests (Load Acceptance Testing):
  • Accident Loading Sequence (Safeguards Mode 1)
  • Blackout Loading Sequence (Safeguards Mode 2)
  • Blackout Accident Loading Sequence (Safeguards Mode 3)

PLANT HARDWARE ISSUES (SW) Service Water System

=:)Problem Statements

  • Service Water Pump strainers allow large debris to pass through system
  • Service Water Pumps degraded due to inadequate material selection and NPSH below pump design requirements
  • Large header piping requires repla,cement due to erosion/corrosion degradation
  • Minimum-flow recirculation lines have high vibration following piping replacement/rerouting
  • Service Water strainer failure due to waterhammer induced by backwash valves

PLANT HARDWARE ISSUES (SW) Service Water System

~Problem Resolutions

  • Service Water Pump strainers are being refurbished to correct clearances
  • Service Water Pumps are being replaced with pumps of improved material and design better suited to meet the actual operating condition
  • Large header piping is being replaced via ongoing replacement project
  • Existing recirculation line orifices were re-sized, new orifices installed, and valve controller setpoints modified to reduce line vibration
  • Si:rainer Backwash Valves are being replaced with more suitable design

PLANT HARDWARE ISSUES (SW) Service Water System

=>Key Startup and Power Ascension Test Activities

  • Functional testing to demonstrate proper recirculation line flow rates and vibration levels
  • Functional testing to demonstrate proper normal system flow rates
  • Strainer Backwash Valve functional and AOV diagnostic testing
  • Strainer Backwash Valve dynamic functional testing to demonstrate resolution of the waterhammer issue

PLANT HARDWARE ISSUES (RC) Reactor Coolant System

=>Problem Statements

  • Reactor Coolant Pump (RCP) motor oil collection system does not meet Appendix R requirements
  • RCP motor oil levels fluctuate, and oil "misting" occurs creating a hazard
  • Pressurizer Power-Operated Relief Valve (PORV) seat leakage
  • Pressurizer pressure control unable to control pressure with proportional heaters i

PLANT HARDWARE ISSUES (RC) Reactor Coolant System

=>Problem Resolutions

  • RCP motor oil collection system was modified to satisfy Appendix R requirements
  • RCP upper oil pots were modified to eliminate level fluctuation and oil misting problems
  • PORV trim materials were replaced to eliminate seat leakage
  • Pressurizer Spray and Bypass Spray Valves were replaced (last outage)

PLANT HARDWARE ISSUES (RC) Reactor Coolant System

=>Key Startup and Power Ascension Test Activities

  • 24-Hour RCP runs to demonstrate stable motor oil levels and bearing temperatures
  • Follow-up RCP oil pot inspections during subsequent containment entries to ensure long-term resolution of the oil misting issue
  • PORV seat leakage test
  • Pressurizer Bypass Spray Valve flow test
  • ~
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