ML19308C383

Startup Svcs & Training Activitives During 1977

ML19308C383
Person / Time
Site:	Davis Besse, Crystal River, Crane
Issue date:	12/31/1977
From:	Spangler W BABCOCK & WILCOX CO.
To:
References
TASK-TF, TASK-TMR NUDOCS 8001230353
Download: ML19308C383 (6)

Text

-

d%k

% n) g Startup services and training.

t J l@-

activitives during 1977.

%g g

W. H. Spangler Manager. Plant Startup Services Nuclear Power Generation Division Lynchburg, Virginia During 1977 B&W's Startup Services organization DAVIS-BESSE 1 STARTUP assisted in the startup of three plants, Crystal River-3, Davis-Besse-1, and Three Mile Island-2.

Major milestones of the DB 1 startup are shown in This paper provides a brief recap of the completion Figure 2. As points of reference, the hydrostatic of the CR-3 startup and discusses the progress test of the Reactor Coolant System was completed of startup activities at DB 1 and TMI 2, along on September 9,1976, and the unit acceptance with generic conclusions that can be made re-test was scheduled for March 1,1978.

garding plant startups. Also included is a descrip-compiete soon testingrun.t acceptance tion of what B&W is doing to qua'ify its personnel compiete 75r. testing to meet new regulatory requirements made ef-corr.prete 40s testing-fective in 1977. In addition, new developments in Comoiete 15r. testing-simulator training are presented.

--RCS hydro in ta cr I

-Complete HFT Fuet lead CRYSTAL RIVER 3 STARTUP

- 7.0

-30 4u 7.t 8ie n25)

Major milestones of the CR-3 startup are shown f'

4a to in Figure 1.The Reactor Coolant System.[iy4ro-

, static. Test was completed on November 23,1975.

Mj",hoyr to usngpr u

Fuelloading was completed on December 4,1976, a'nd criticality, was achieved on January 14,1977.

Fi,ure 2 Davis.Besse.1 piant s:artuo milestones.

~

With successful completion of the Unit Acceptance Test, power _escal_ation testing was completed on Figure 3 shows the makeup of the overall startup April 26,1977, task force overlayed on the major milestones of startup. Note that personnel reductions began just Complete 100r. testing' unit acceptance-after fuel loading, however, the major reduction Complete 75r testing-in manpower did not occur until three months complete 40r. testing-following fuel loading. The dotted line in Toledo Complete 155. testing-Edison Company (TECO) statistics shows the Complete ZPPT-anticipated staffing for normal operation. Thus, initial enticahty-those in excess of 194 are considered to be dedi-RCS hydro Complete HFT Fuel load cated solely to plant startup and then only because of startup.

I i

i e

a e

12 2

- 3.8 0 1.3 2.8 3.8 1.8 3.3 4.6 The breakdown of responsibilities for the Months prior __ Months after startup is shown in Table 1. TECO retained overall to fuel loading fuel loading responsibility for the startup, for those activities l

Figure 1 Crystal River. 3 c ant startup miles:enes.

associated with normal plant operation, and the 8001 230353 1

]

L

conduct of startup testing. TECO contracted B&W personnel for tasks associated with startup plan-Initial criticality Fuel loa d -* -

ning and startup test management, for techm. cal d

advice and consultation on the NSS systems, and Beg 350" RCS hydro-rt *q overall plant startup. TECO contracted the assist-f300 ance of others for those tasks associated with p

{

g construction acceptance checkout, cleanup, and testing.

250" g

k200--

___J-Figure 4 shows a breakdown of '.ne types of B&W g /

startup activitics and the assistane2 of B&W and h150 Others

/

Ant i ated operating centages for each type of activity add up to greater 5

g' statt n 100 g

than 100% because of the combined involvement 3o.,

Toledo Edison Company in many activities.)

Activity Totals 32.9 %

'1973 ' 1974 ' 1975 1976 1977 78 6 %

4.6 f. 3 7

Tests um 280 y 76.7%

Figure 3 Davis Besse 1 sta-tuo personnel.

Cleaning & flushing 67%

30 7 28.2T.

Inspection & checkout m

99 l 70.7 T.

41.4 %

Table 1 Davis-Besse.1 plant startup responsibilities Installation 3%,97, 38 7

Y

.3T.

50%

55 447 TECO Note: Totals of percentages add up to more than 1007.

• Overall plant startup because of combined involvement in many activities e Administer QA/QC program i

iTECO El'2 Others B&W

• Administer safety tagging and clearance program Figure 4 Davis Besse-1 rdant startuo activitics.

• Operate and maintain permanent plant equipment

. Calibrate alt instruments Figure 5 shows the participation of TECO and

• Develop startup procedures B&W in the preparation of procedures, e Perform startup testing B&W Types of crocedures Total written

• Test program manager 11.9f.

Operating 464 ySchedule startup and test programs

• Provide technical advice consultation, and 89 8'". r 21.8T.

direction on all NSS systems Surveillance & test

'/ m 1 499

+ Provide technical direction and assistance 99 6T.

r 0.4 T.

in plan! startup Emergency and

'// X////3'A 991

. Assist in individual component and system announcator alarm

- 99.3r.

checkout, testing, an1 turnover Maintenance 0.7 f.

129

• Guidance on instrumentation and controls

- 2 0 '".

98 0 %

calibration and tuning Computer alarm I

i 1506 1

• Develop startup procedures point i

. Perform startup testing E TECO i

iB&W j

Others Note: Totals of percentages add up to more than 100%

3"'

+ Provide technical direction and overati coordination of construction testing and plant startup Figure 5 Davis.Besse.1 startup procedu es.

i r

+ Perform construction testing Table 2 identifies the major difficulties en-

. Assist in individual component and system checkout, countered while comp eting each startuP milestone.

l testing, and turnover ese es not have eW Maying

. Assist in conduct and documentation of plant system flusning and cicaning effects. nd it is not practical to assign a delay i

period associated with each. They do, however, aid in explaining particularly long phases in the i

startup.

28

L e

! 5 12 34 84W pramed startsc scheese i,

ii i 1

234 5

Table 2 Davis Bessel problems durmg startup oconee.

1 234 i 5

Oconw 2 i

Milestone Problems in completing milestone g p 5

RCS hydro e Turnover ofincomplete systems three Moe 6sianca e'

12 34 5 HFT e HPl pumplube oilsystem Arkar' San Nuclear One 1 CCCC")

e Plant constructen not complete 1234 5 ocmee 3 CICJ Fuelicadmg

• Surveillance specimen holder tubes 8 2 34 5

e internals guide blocks Syge,p g,,g,,,

e Aunihary feedwatersystem 1

2 34 5 e Reactor vessel nead 0 rergs crystal River-3 i

ii 1

+ Auxihary buildmg penetration sealant t 23 4! $

e Fuelhandhng eavipment Davis-Besse l 1

1 three M,ie ssiend-2 f M We) e Startup source handhng tool i 2 3 l

e staton groundmg Metns prer pk,,

ontns after

+ Nuclear instrumentaten ug:e,,

to fuel cao fueiKao

~

e Radiaten monitormg system i comece ecs n.e,evew w e Ertremely cold weetner-lost time

@*700',7 *.'

l...

1 o 5 10 15 2o 25 Initial criticahty e incore detector guide NNs NMi f

+ Plant construction not comple's

= - - -

• Hot weather - lack of system power Figure 6 B&W NSS startuo history.

e Design of pressurizer rehef valve loop seals Unit acceptance e Steam-feedwater rupture control system Complete unit acceptance test _

• Mam feedwater pumps and controls e Aunhary feedwater pumps and controls

• TurDme stop valves and controls initial criticality -

+ Condenser tube leak (drain inomgement)

- - - - - - - - + - -

• Cold weather - need for power from 0B-1 Complete HFT-

+ Electromatic rebet valve

+ Main steam code safety valves RCS hydro]

s

~5 ?ipmg and valve vibratens i

Fael load e Turbme typass valves l

j l

e Feedwater system pipmg

- 7.0

-35 0 (1.5) ~~% S - '6.Q e interface between custom designed i

secondary plant and ICS tunmg

[

/

e On hne computer Months r.rcr-*

- Months tfter to 1W4 loadmg fuel loading Figure 7 Thruc Mile Islar4;-2 plant startuD milestone's.

Figure 6 shows a comparison of the startup of DB 1 to previous B&W NSS startups. This startup was particularly long in the phases between hot W

RCshydro functional testing and initial criticality (7.5 Begin HFT months);and between the compiction of zero 50 gl=/,'#

• - End HFT power physics testing and the completion of the f

[

M/

saw /

157o power testing plateau (2.3 months). The re-maining phases look very similar to previous l4o.

/

.itartups. The primary reason for lengthy delays g so.j identified were construction problems. The Others i

difficulties in completing the 157o plateau testing 3 20-were primarily with the Steam /Feedwater Rupture 3 --

' q Control System and the Auxiliary Feedwater 10 g'gN 1

System, which are both first-of.a-kind systems.

1977 1978 THREE MILE ISLAND-2 STARTUP Startup of TMI-2 has progressed as shown by the Figure a Three Miie isiend-2 startvo personnei.

major milestones presented in Figure 7 The RCS Hydrostatic Test was completed on June 6,1977, The breakdown of responsibilities for the and fuelloading was scheduled for February startup program is shown in Table 3. GPU retained 1,1978.

oyerallrespousibility fotthe_planningananage.

Figure 8 shows the numbers of personnel ment, r.nd direction of_ star _ tup. testing. Metro-7volved solely with plant startup from General politan Edison Company (Met. Ed.) will be Public Utilities (GPU), B&W, and other support operating the plant and was therefore given the organizations.

responsibility to operate all equipment during 29

. i Tyoes ot procsdures t69 5

Total written

[75 8'** 2G' 1is Tatie 3 Three Mde Islano operatmg

-unit 2 plant startup responsedities Survedlan:e t. test r

iP 380

( 23.5f.

76 Fe 34 GPUtMET EO Emergency

• Overall plant startup Maintenance Q Ioor, 34

• Test pregram manager 97 8f'

• Administer QA/QC program Controiroom alarm response v///</ W <<< w i 1250

• Admmister safety taggmg and clearance program

• Ocerate and maintain permanent plant equipment

• Calcrate all instruments after turnover i

i B&W (M GPUandothers

• Perform startup testing

p. Schedule startup and test programs Figure 9 Tnree Mav Istand 2 startwo crocedures.

• Calibrate and tune instrumentation and controls

• Coordinate startup procedure development B&W Table 4 Three Mite island-unit 2 problems during startup

• Provide technical advice. consultation, and direction on all NSS systems y,lestone Prob! ems in completine mdestone

• Provide technical direction and assistance in RCS hydro e PressurizerheaterclosureO rings plant startup

. Control rod drsve cicsures

• Assist in individual component and system

• Survedlance specimen hoider tubes checkout, testing. and turnover

• Internals guide blocks

• Develop startup procedures HFT

+ Plant constr action not complete

• Reactor vessel head 0. rings Others

. Phosphate enntamination of OTSG's

• Provide technical directron and overall coordination

, inadeauate supply of demineralized water of construction testing and plant startup

• RC pump seal damage h* Demineralizer resin rec ~@

• Perform construction testmg RC pump casing gasFets

• Assist in individual component and system checkout.

• Ausdiary steam system shared with unit 1 testmg.and turnover

_- -p + Changein pnmeconstruction contractor

• Assist in conduct and documentation of plant system Fuelloadmg

• Reactor coolant pump casing gaskets flushing and cleaning

• Plant cleanup and painting celayed until

• Perform pre operational cabbration ot all mstruments busy post.HFT pericd

• Fuelhandimgeauipment

• Develop startup procedures startup. GPU has contracted the assistance of GENERIC CO,NCLUSIONS B&W in the preparation of a large portion of the NSS related procedures and surveillance related Based on experiences in 1977, two conclusions procedures necessary to meet requirements of the generic to the startup of a nuclear steam system Standard Technical Specifications, in addition to can be drawn:

providing advice and consultation on the NSS systems. GPU contracted the assistance of other

• The need for additional manpower at the support organizations for those tasks associated job sites during the startup period is contin-with construction acceptance checkout, cleanup, uing to grow because of expanding documen-an testing.

tation requirements and the more extensive testing programs now beine required. B&W Figure 9 shows the assistance B&W and is continuing to meet utility needs in these

- oths.rs provided to GPL..m preparation of the areas by makint available increated numbers of various types of startup procedures.

personr$el with broadened scope of capabihtv Table 5 shows B&W startup assistance personnel Table 4 identifies the major difficulties en-ass gned for the three most r.. ent plant start-countered m, completing each startup milestone.

ups at various periods.

The plant startup at TMI.2 is not far enough

~

• Utilities continue to become committed to start-

'along that many conclusions can be drapor that effectwe cMwith previous start.

up schedules prepared early in the project that ups can be made later prove to be unrealistic because of construc-u tion constraints. Loading fuel in the core prior

~

30 S

A formal screening pro;: ram to assure the to the tirme the plant is ready for criticality reliability of a'l B&W personnel permitted un-severely limits access to complete construction.

escorted access to nuclear power plants. The pro-In addition, pressure on startup personnel to gram is managed by the B&W Security Depart-achieve unrealistic schedules often results in ment and meets the requirements of ANSI N18.17.

sidous mistakes being made that ultimately All B&W personnel subject to field assignment are cause additional delays. Two recent examples given thorou;;h physical examinations to assure of this type of mistake are: flushing a demin-their suitability to work in the nuclear power plant eralizer resin bed into the cooling water systers, environment, including medical certification to and contamination ci the reactor vessel, work in environments where face masks are re-internals and tr:osfer canal while shot blasting quired. The examinations meet the requirements containment concrete surfaces. There needs to of NUREG 0041 and are documented as shown be an industry-wide effort to enablish anci in Figure 10.

feamtam redism m pr'o7crRhedillmg.

el *-r;4e.n;

,e' 8.A 9 *:" W

• 8-~

' ~ ~ ' *

• • " N Table 5 Baw startup assistance personnel Plant

m...n u.

.t:we

.u.

6apaw emo Discipline

~ CR.3 DB.1 TMl4_

m

.y,,

u.,

Startup test program manager 1

1

... u.

5 a

-an Reactor performan,ce engineer 3

23

• ',; ; ~'

Gengt startup consu! tant Test coord.nator 2

4

,' g Test engineer 8

Shift augmenter 4

Scheduler 2

2 O'

Chemo nuclear engineer 1

1 1

'a*-

- tai'-**t"r.

Reactimeter operator 2

Instrumentation and controls engineer 1

1 F vedure writers 3

3 e

4--

c+

PERSONNEL QUALIFICATIONS

' "~"

New personnel qualifications are continuing to

' be imposed upon the industry. Some of the more

~

~

,,,,,,,,,,,,,,,,n, recent are-

..o.a.suu,u

'

• Security Requirements NUREG 0220 ANSI

. w a n. ~ wn..

T_ ' ' ' ~

ag o M

1. U ti!.At e to i ' ~

l.a..m n:.wm N18.17 Reg. Guide 1.17 tan _. - - -....-

Operating Plant Personnel Qualifications ANSI 18.1 1.8

- - ~~

- -~

Figure 10 WJical certification recora Qualifications of Inspection, Examination, and A program has been instituted to certify Testing Personnel for Construction Phase B&W personnel to the highest possible ANSI ANSI N45.2.6 Reg. Guide 1.58 qualifications commensurate with educational A

background and experience. Each individual Requirements for Special Physical Examinations will have a summary of his/her history readily for Those People Who Are Expected to Work available along with documentation certifying While Wearing Face.\\lasks (NUREG 0041) the expertise and level to which he or she is (Reg. Guide S.15) qualified.

The following actions are being taken by Formal training programs are being instituted B&W to train and qualify personnel so as to be to qualify people for the various levels of Non-of m'aximum assistance to utilities during start-Destructive Testim: work to meet the requirements up, refuelin;;, or maintenance outages.

of ANSI N45.2.6.

a a\\,o

@.. \\

31

,g g g (N.

, sy gp l

Di) hM i

y

,--q yv y.-

--,-------y-%

,,m

-,--w-

o

-TRAINING SIMULATOR IMPROVEMENTS and to replace the current Integrated Control Synem and its analog equations with digital Training on the B&W Simulatorisin heavydemand.

equations in an on.line computer.

The facility is essentiaEy booked for the first two shifts during 19'iS. To maintain and improve the TRAINING VI A VIDEO TAPES quality of training avaEable with the B&W Simula-tor, we are currently in the process of making We have developed nine video tapes under the major changes to improve the accuracy of repre-sponsorship of the Operr. tor Licensing Branch of sentation of the Rancho Seco core during Cycle 2.

the Nuclear Regulatory Commission. These tapes Thsse revisions will enhance the ability to damon-represent the B&W plant response to various state axial power imbalance control, core quadrant methods of control and to certain casualty condi.

power tilts from asymmetrical control rod condi.

tions. Specifically, they include the plant response tions, the different reactivity effects resulting from to automatic Integrated Control System action a single control rod movement as compared to a plus the three major manual modes of operation.

group of control rods and the reactivity differ-The casualty tapes cover loss of a single feedwater ences reflected from a dropped control rod versus pump, loss of all reactor coolant pumps, and steam an ejected control rod.

generator tube leak. Each is approximately twenty minutes long and is provided with an instruction Using an auxiliary computer in the Simulator, manual for assistance to the student. The tapes we will implement a back track capability which are fast moving and will maintain the student's will allow the Simulator to be restarted at those interest while they are in use. We are continuing conditions that existed during the time from I with this series on control and casualty tapes, and to 30 minutes prior to reset. This reset func-are beginning a maintenance series starting with tion will allow students to repeat operations reactor coolant pump seals and control rod drives.

with different actions or to rapeat the same actions with a different operator. The auxiliary computer will implement expanded plant computer capa-bility including the plotting of eight selected variables on a strip chart recorder, color CRT Acknowledgements display of plant status and alarms, and new alarms and event recorders. The simulator pro-The author gratefully achnowledges the gram will be further revised during a summer contribution and support of.ilr. Jach l

outage to implement a more complete repre.

Evans, Davis Besse 1 Station Superintendent, sentation of the Rancho Seco secondary plant in the preparation of this paper.

I 32 b