ML20094M747
| ML20094M747 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 04/12/1983 |
| From: | CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| Shared Package | |
| ML19258A087 | List:
|
| References | |
| CON-BX21-035, CON-BX21-35, FOIA-84-96 PROC-830412, NUDOCS 8408150716 | |
| Download: ML20094M747 (100) | |
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TEST PROGRAM STATUS AND REVISION 12 - TEST SCHEDULE b
PREPARED BY: TECHNICAL DEPARTMENT MIDLAND ENERGY CENTER CONSUMERS POWER COMPANY April 12, 1983 4
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t-i TABLE OF CONTENTS 1.
INTRODUCTION
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II.
TEST PROGRAM SCHEDULE STATUS (AS OF 3-31-83)
- 1. System Turnovers 2.
Testing Activities Summary
- a. Electrical
- b. Instrumentation and Control
- c. Nuclear Eteam Supply Systems
- d. Auxiliary Systems
- e. Feedwater/ Condensate
- f. Turbine /HVAC
- g. Process Steam
- h. Programmatic Testing 3.
Procedure Development
- a. Status - Procedure Development and Approval
- b. Status - Tests Completed III. PROJECT TEST SCHEDULE - REVISION 12 A.
Rev 12 Test Schedule Philosophy
- 1. 95% of Unit 1 testing will be performed prior to Unit 2 Fuel Load
- 2. Inherent time frames are built into the merged schedule to absorb Punchlist Open Items following major Milestone Testing.
- 3. No two Unit 1 & 2 Milestone events are required to be performed simultaneously (except ILRT and HFT).
- 4. Separation of Fuel Loads.
- 5. LLRT/ILRT/ SIT are performed nearly piggy-back during the same time frames.
- 6. Integrated ESFAS Test would be a common Test Phase.
- 7. Rev 11 disadvantages have become less significant in Rev 12
- 8. Initial Turbine Roll - Milestone added to allow early testing prior to HFT.
B.
"ev 12 Test Program Plans
- 1. Planned Activities Leading to the Next Target Milestones
- 2. Auxiliary System Flushes into Reactor Vessel i
- 3. Refueling Canal Hydro and Wet Fuel Handling Test
- 4. React or Coolant System Cold Hydro
- 5. Feedwater System Flush
- 6. Ccadenser vacuum
- 7. Initial Turbine Roll
- 8. Hot Functional Testing i
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- 10. Integrated Safeguards Features Actuation System Test
- 11. Fuel Load C.
Manpower-for Rev 12 List of Figures and Tables Figure 1 - Actual System Turnovers and Rev 12 Demand Turnover curve Table 1 - Procedure Development and Approval Status Report Figure 2 - Procedure Development - Curve of Actual vs Goal Table 2 - List of Tests Completed Figure 3 - Curve of Testing Completions - Actual and Rev 12 Projections Figure 4 - Plan for two unit startup, Rev 12 Table 3 - Rev 12 Listing of Test Procedures and Time Frames for Completion.
Figure 5 - Manpower Curves 4
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CASE LOAD FORECAST REPORT - APRIL 1983 TEST PROGRAM
'I; INTRODUCTION This report contains; 1.
The status of the Test Program Schedule as of March 31, 1983, and 2.
Revision 12 of the Test Schedule based upon the Two-Unit startup concept.
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The basic premise in the development of this schedule is to estab-11sh a safe, organized, and logical approach to meeting the Project Objectives in a timely manner without sacrificing quality.
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.s Generic Checkout DISCIPLINE Percent Complete Electrical 83 I&C 37 Turbine /HVAC 24 Feedwater/ Condensate 25 NSSS 4
Auxiliary System 8
Process Steam 15 Total 45%
In summary, 45% of the Systems (850) in the Plant have been initially checked out, and 4% of required Tests (Preop,-Acceptance, Flush, and Specific) have been performed.
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s II.
TEST PROGRAM SCHEDULE STATUS The status of the Test Program Schedule as of March. 31,1983 is present-ed in this section in terms of System Turnovers, what we have accom-plished so far in the Test Program, and where we are relative to Test Program Milestones leading to initial fuel load.
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System Turnovers - Summary Total scoped Systems (approximate) -
850 543 Total System Turnovers Accepted 307 Remaining System Turnovers
% conplete = 543 = 64%
850 Figure i shows a graph of actual number of systems accepted thru.
March 31, 1983. It also shows the remaining system turnovers based upon Revision 12 Turnover demand dates. The numbers in parenthesis-show ACTUAL % complete.
2.
TESTING ACTIVITIES
SUMMARY
The status of the Test Program Network as of 3-31-83 is presented below.
It should be noted that " checkout complete" as reported in this Section may not be necessarily 100% complete due to remaining panchlist open items such as design changes, corrective actions, and turnover exceptions requiring checkout and/or retest.
- a. ELECTRICAL SYSTEMS 321 of 371 Electrical Systems have been turned over to CPCo.
(87 ?).
E[1 % have been initially checked out and energized. No
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Preoperational tests or Acceptance Tests have started.
Significant activities completed and/or in progress include:
BOTH UNITS' MAIN POWER XFMRS and STATION POWER XFMRS have been turned over and checked out. The Common Startup Power XFMRS are energized and in operation. Final " Pre-energize" testing will be performed in 1983. Backfeed from 345 KV Sys:em is dependent on Turnover of Main Generator Protection and Microwave Systems.
all 6.9 KV BUSSES, 4.16 KV Busses, have been energized; maj or portions of 480 VAC Load Control Centers, 460 VAC Motor Control Centers, 250 VDC Motor Control Centers, 125 VDC* Control Power Panels,120 VAC Instrument Power Panels, and 480 VAC Distribution -
Panels have also been energized and are in operation.
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QA overinspection of class lE cable routing-is 91% complete.
Electrical Reactor Building penetration repairs and replacement resulting from rodent damage and faulty Bunker-RAYMO modules is 95% comp'lete.
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37% of I&C Systems h'a've'been checked.ou_t._
No Pre-operations / Acceptance Tests have started. Six specific procedures have been completed.
Significant Activities completed and/or in progress include:
Plant computer installation, checkout, energization, and vendor acceptance test are complete. Computer points input verification is in progress and will continue throughout the Preoperational Test Program.
Unit Control Room Annunciator Cabinets (both Units), Evaporator Building Annunciator Logic cabinets, and Radwaste annunciator logic cabinet, have been energized and logic verification completed. The HVAC Annunciator logic cabinet has been energized.
l Non-Nuclear Instrumentation (NNI Cabinets and Modules both units)
The electrical checkout and initial energization of NNI j
l cabinets are complete.
Incore Monitor Remote Analog Peripherals (both un,its) - partial I&C checkout is complete. The Incore Guide Tube Clearance checks have been ecenleted.
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5 CRD Stator Prainstallation check was completed on both Units.
ICS cabinets and Modules (both units) - The electrical ' checkout
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is complete, the pre-turnover calibration of modules is complete; initial energization of ICS cabinets is in progress including the Evaporator System Development Demand (ESDD) Cabinets.
Instrument Racks - (Note: Each instrument rack represents one system) - Electrical checkout and energization, of the following instrument racks are complete:
Balance of Plant Instr. Rack 1C-49, 2C-49 1C-53, 2C-53 1C-166, 2C-166 0C-180 2C-146
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0C-343 Radwaste Instrument Rack DC-167 Evaporator Instrument Rac1r OC-168 OC-281 4
Analog Isolation Cabinets 1C46, 2C46 - Electrical l,and I&C check-out are complete.
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-- Digital Isolation Cabinets 1C47, 2C47 - Electrical and I&C checkout are complete.
Process Steam Transfer Instrument Rack, lhdluding power-supply ~ ____
~ and peripheral - electrical checkout, I&C checkout of power supply, and energization of Instrument Racks OC391 and OC386 are complete.
Boron Recovery and Liquid Waste Programmatic Controller System including remote I/O Cabinets - Prepower checks, and electrical checkouc of I/O cabinets are complete, ladder checks are 4
essentially complete except for design changes requiring retest.
Radwasta Gas System Programmatic Controller System including remote I/O cabinets - prepower checks, Part 1 - Power ON prelimi-nary checks, and Part 2 Ladder checks are complete.
C.
Nuclear Steam Supply Systems (NSSS) 14 of 56 systems have besa turned over to CPCo (or 25_ %.)
e No Preop or Acceptance Tests have been started. One specific procedure (Unit 2 Decay Heat Removal Initial Pump',Run) has been completed.
Significant Activities corpleted or in progress 'nclude:
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7 Turbine Bypass Valves - Unit 1 Electrical and I&C checkout complete; Unit 2 electrical checkout cot lete.
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Unit 1 Reactor Vessel Internals Modification is in progress Unit 2 Reactor Vessel Internals Modification complete; the HFT Flow screen is installed / attached to the PLENUM; the CRD dummy guide assemblies being installed in the PLENUM.
lt Unit 2 Reactor Coolant Pump Motors - partial electrical checkout l
complete; all 4 RCPM's have been bumped for proper rotation and ~
Pre'arations are anti-rotation devices have been installed.
p underway for initial motor runs.
Unit 2 Decay Heat Removal System (portions in the Auxiliary 1
Building) - Electrical and I&C checkout are essentially complete; Initial Pump Runs-Recire Mode, complete; Gravity flush to suction i
of DH Pumps and Velocity Flush of lines from pump discharge to BETST recire lines complete.
l' Unit 2 Makeup System (High Pressure Injection Pumps) - Gravity flush to MU pump suction complete; two of the 3 HPI pump motors j
have been run and preparations are underway to run the third HPI
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pump motor.
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8 Unit 1 & 2 Boronometer - Electrical checkout complete.
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~ Unit 2 - Boric Acid Addition - The mix tank has been cleaned; electrical and I&C checkout in progress
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& [ Hydrazine and Lithium hydroxide - Electrical 1&C, and
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Unit mechanical checkouts complete. Nitrogen blow to hydrazine drums Unit 2 flush to suction of L10H and Hydrazine Pumps complete.
complete.
Unit 2 RB Spray suction piping - partial flush complete.
Unit 2 Borsted Water-Storage Tank Outlet Piping - Flush to The BWST Circulation pump initial i
suction of DH pumps complete.
I run complete.
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- d. AUXILIARY SYSTEMS 26 of 84 Auxiliary systems have been turned over to CPCo (H %).
Preformance of two flush procedures (Unit 1 & 2 FH Bridge Air 4
System Flush) and one Specific Procedure (Receipt of Dummy Fuel Assemblies and Control Rods) have been completed.
inude:
Significant Activities completed and/or in progrest m
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Service Water Sluice-Gates -ISO checkout complete; electrical checkout in progress.
component cooling water - Portions of the system (B-Loop) required to provide cooling water to the RCP motors have been checked out and flushed; this includes piping to the CCW and Decay Heat Coolers and DH Pump Seal Coolers.
Reactor Building Vent Header - Electrical checkout of valves complete.
Radwaste pump seal water / headers - electrical checkout complete.
Filter Handling - Electrical checkout complete.
Primary Mixed Bed demineralizer - Electrical checkout complete.
New Fuel Elevator - electrical checkout complete.
Spent Fuel Pool Handling Bridge - electrical checkout complete 4
- Unit 1 Reactor Building Fuel Handling (FH) - electrical and I&C
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checkout complete, portions associated with Dry thdexing Preoperational Test-(Milestone 1A) complete 1
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- Unit 2 Reactor Building Fuel Handling - Electrical and I&C checkout complete, portions associated with Dry Indexing Preoper-
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ational Test (MILESTONE 2A) complete Unit 1 FH Transfer Mechanism - I&C checkout complete; Fuel Transfer Hydraulic System Flush in progress
- Unit 2 FH Transfer Mechanism - Electrical and I&C checkout
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'ctmp-lete-,ATransfer Hydraulic System Flush in progress.
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Service Water System - electrical c/o Main Header valves in
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progress, I&C checkout of common Header to the Turbine Building Service Water complete; electrical checkout Unit 1 & 2 Turbine Building Service water complete; electrical checkout Unit 2 Turbine Building service water complete.
Initial Pump and/or motor runs completed to date include: Primary Water Storage Transfer and Vacuum Pumps (Motor only), service water Travelling screens, four cf the five service water pump motors, four of the five service water strainers, and one of the CCW pumps.
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Feedwater/ Condensate Systems J.,
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55 of 100 systems have been ture d ever t "PCo (55 1 m_
R 11-Performance of one Specific Procedure (Aux Boiler Initial Operation and Boilout) and 6 Flush Procedures, described below, have been completed.
Significant Activities completed and/or in progress include:
Unit 2 Condensate supply and Low Pressure Feedwater Heating -
Electrical, I&C, and mechanical checkouts complete; condensate pumps initial run complete.
Unit 1 & 2 Hotwell makeup and Rejection - Electrical and I&C
__ EIE5ut complete-excep.t.for.Xnit. 2_I&C_cheekout which is in che progress.
Unit 1 & 2 Main Condenser - I&C checkout complete.
Unit 1 & 2 Condenser Hotwell sampling - Electrical checkout complete.
Common Feedwater crossconnect - electrical C/0 complete.
Unit 2 Condensate Demineralizers and Associated Systems -
4 Electrical and I&C C/0 in progress.
Makeup Demineralizers - al) checkouts complete, sysrcm is functional.
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Demineralized Water Storage and Transfer - all checkout essentially complete; system is functional and providing primary source of Flush Water; Flushes associated with the. storage and transfer header branch lines to all hose stations, and Unit 1 & 2 Reactor Building piping, complete.
Makeup Demineralizer Chemical Storage and Transfer - all system checkout and flushes complete; system is functional.
Condensate storage (common system) - partial electrical and I&C checkout complete, flush to Unit 182 Auxiliary Feedwater Pump F
recire lines complete.
Unit 1 Condensate Storage - Tank has been cleaned; I&C C/0 complete.
Unit 2 Condensate Storage - all system C/0 complete except for electrical C/0; tank has been cleaned; flush from tank to Hotwell complete (Milestone 2E).
Condensate Transfer - For the common system, all electrical and s
I&C C/0 complete; condensate jockey and transfer pumps have been run; flush of the system is complete.
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Unit I system electrical and I&C C/0 complete.
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s 13 Ammonium Hydroxide Storage and Transfer - The common unit electrical and I&C C/0 complete; chemical addition pumps have been coupled. The Unit 1 & 2 systems electrical and I&C C/0 complete.
Hydrazine Addition System - Unit 1 & 2 Electrical and I&C C/0 complete.
Hogging / Exhaust Piping Vacuum Relief - Unic 1 & 2 I&C C/0 complete.
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Circulating Water Supply - Unit 1 & 2 initial m' tor run of o
circulating water pump motors complete.
Water Box Scavenging - Unit 1 & 2 Electrical and I&C C/O complete.
Acid Storage, Supply, Distriuution - Electrical checkout.
complete; pumps have been coupled.
Auxiliary Boiler - all system C/O complete; both boilers have 4
been fired and Auxiliary System flushes completed; boiler tuning
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and load test is in progress.
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Auxiliary Boiler St cam Distribution - all system C/0 co:nplete steam blow of main headers complete.
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Air Compressors / Instrument Air Dryer - all system C/0 complete
- compressors are functional; presently clearing punchlist open items; air blows main header complete.
Service Air Distribution - all system C/O of the Unit 1, 2 and common headers complete; air blows te subheaders and branch lines in progress.
- Instrument Air Distribution - All system C/0 complete; Instrument.
air is available to Evap Bldg. Miscellaneous Buildings, Dow pump house Turbine Building (both units) -and portions of the
_ ~ ~ ~ ~ Auxiliary Building._.
Fire Water Supply / Distribution - System C/0 complete; Diesel Fire and electric pump initial runs is complete.
System is supplying
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site fire water protection.
Transformer Deluge - I&C C/0 complete.
Carbon Dioxide Fire Protection - I&C and Electrical C/0 in progress on those portions that are turned over.
4 Building Deluge Protection - Electrical and I&C R/0 for portions of the system turned over is complete.
e 15 Hose Station Protection - Checkout of Hose Stations complete (to Warehouse 1. Turbine Building. Reactor Building, and Miscellaneous Buildings.
blow / purge of system Nitrogen System - System C/0 complete; N2 complete; the distribution system is undergoing redesign work and therefore flushing will have to be done over.
- Natural Gas Evap Bldg Lab - System C/0 complete; flush of system complete.
Vacuum Fume Hood (Evap Bldg Lab) - Elect C/0 and piping flush complete.
Acid and Caustic Waste - Unit 2 sumps have been cleaned; I&C and electrical C/0 complete; initial pump run of Neutralizing sump pump complete.
f.
Turbine /HVAC Systems 76 of 150 systems have been turned over to CPCo (50%).
Performance of one Acceptance Test (D G Electric Hea,t Test) and 6 Flush Procedures as described below have been completed.
Significant activities completed or in progess include:
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l Unit 1 & 2 Turbines - System C/0 complete; Turbine has been placed on turning gear.
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Unit 1 & 2 Turbine Generator Bearing tube Oil Supply - System C/0 complete; 011 flush complete; system functional.
Generator H and CO - Unit 1 & 2 I&C C/0 complete; 2
2 preparations under way to perform Generator Air Drop Test.
Unit 1 & 2 Hydrogen Seal Oil - System C/0 complete except for I&C C/O. Oil flush complete.
Turbine Lube Oil Storage, Transfer, and Purification (Unit 1, 2,
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and Common) - All system C/0 complete; oil flush complete; system functional.
Cooling Pond Makeup Screens / Screen Wash - System C/0 complete:
system is functional.
Ccoling Pond Makeup, traveling screens, sluice gates, trash racks - Cooling Pond has been filled with water, checkout of screen wash pumps, screens, makeup pumps, sluice gate, valves complete.
Cooling Pond blowdown system checkout Lg in progress.
Hot Water Supply / Chemical Treatment - Electrical C/0 complett-initial motnv run of hot water pumpn complete, i
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Plant Hot Water Heat Systems - Unit 1 & 2 Turbine Building electrical C/0 and initial motor runs complete; electrical C/0 Auxiliary Bldg Hot Water heat ecaplace; Unit 2 elederical. I&C C/0 and initial motor runs complete; affice Service Building electrical. I&C C/0 complete including. initial motor runs; 4
Intake, Hypochlorination, Service Water Building electric heat-system C/0 complete; Unit 1 & 2 Diesel Generator Bui.. ding electric heat - system C/0 complete - The Diesel Generator Building Electric Heat Acceptance Test is complete.
Reacter Buidling Hot Water Heat (Unit 1, common) electrical C/0 4
complete; Process Evaporntor Hot Water Heat electrical C/O including initial motor runs complete; Auxiliary Building Safeguard Room Electric Heat - electrical and I&C C/0 complace i
(common Unit; Unit 1 - electrical C/0 in progress); Cuard House 3 electric Heat - I&C and electrical C/0 complete.
j Turbine Building Chilled Water - Unit 1 & 2 I&C C/0 complete; chilled water pump motors were run and coupled; the system J
flushes are in progress.
Office / Service Building Chilled Water - Electrical and I&C C/0 complete; strrtup of chillers and pumps complete; proof flush is complete.
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Office / Service Building HVAC - System C/0 complete, air balancing and setting of dampers complete.
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Chlorination Building HVAC, Cooling Pond MU Building HVAC, Cooling Pond Intake Building HVAC, Guard House HVAC, and Pond Blowdown Building HVAC - System C/0 is complete.
Evaporator Building HVAC, Circulating Water Intake Building HVAC, 011y Waste Treatment Building HVAC, and Dow Condensate Return Pump House HVAC - electrical C/0 in progress.
Refuel Pool Air Supply (Unit 1) - electrical c/o in progress.
Domestic Water Storage, Transfer, and Heating - System c/o complete'and system is functional.
Hydrogen Supply - Electrical and I&C C/0 complete; purging H2 system with nitrogen complete (common system); Unit 1 & 2 H2 system is functional up to the Main Generator and to the RCS MU Tenk.
Oily Waste System - Common Unit electrical and.I&C c/o complete.
Unit 1 electrical and I&C c/o complete and flush.is complete; l
Unit 2 electrical and I&C c/o complete.
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o-19 Turbine Bolt Heater Panels - Both Unit I heater panels have been-turned over; one of the panels have been checked out.
Four of the Unit 2 Heater panels have been turned over; of,these 1 heater panel has been checked out.
- g. Process Steam i
12 of 15 Process Steam Systems have been' turned over to CPCo (80%). Performance of one Flush Procedure (Demineralized Water Supply) has been completed.
Significant Activities completed and/or in progress include:
Steam to HP Evaporator - I&C C/0 complete, electrical C/0 in progress.
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condensate Return / Unit 2 Condenser. HP steam to Dow Isolation j
Valves - I&C C/0 complete LP Steam to Dow Isolation Valve - I&C C/0 in progress.
Process Steam Blowdown to Dow - Electrical and I&C C/0 complete; motor run has been performed and coupling of pump to motors complete.
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Condensate Chemical addition - electrical c/o complete; HP I
chemical Feed flush, sodium sulfite chemical feed flush and j
l associated pump runs complete.
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- condensate Supply / Vacuum Deaerator - system c/o complete; Dow DemineraIized Water Tank (2.5 million gal) is filled with water for flushes; initial demin pump run and flush complete, evap dearator feed pump initial run complete.
t Feedwater Supply - Electrical, Mechanical, and I&C C/0 is near completion; initial motor run of HP Feed Pump motor is complete.
i Iron removal (Condensate Return) - Mechanical and I&C c/o i
complete.
Iron Removal sump - system c/o and iron removal sump pump run complete.
HP Boilers - Initial checkout, start up, and testing complete, all 3 boilers have been fired up.
- Process steam plant st aple I&C c/o complete.
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Programmatic Testing 3 of 5 systems were accepted by CPCo (60%)
Significant activities completed and/or in progress include:
The Unit 1 & 2 Reactor Building Tendon Test Facility has been turned over as well as the Unit 2 RB Structural Integrity Test Facility.
3.
Procedure Development
- a. The status of Procedure Development and Approval required for the Test Program is summarized below and detailed breakdown 'of each Procedure type and Discipline is shown on Table 1.
s STATUS - PERCENT OF TOTAL Procedure Type Drafts In Review &
Not Approval Total Written Cycle Approved Preoperational Test
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Procedure
.s 268 23%
56%
21%
Acceptance Test Procedures 178(
29%
38%
33%
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-22 Flush Procedures 168 2%
20%
69%
Specific Procedures 119 13%
21%
66%
Generic" Procedures 46 4
22%
74%
729 16%
33%
45%
(Total)
(Not)
(in)
(Approved)
(Written)
(Review)
Our goal is to have all Procedures approved by March 1984.
Figure 2 shows a curve of Procedure Development - Actual vs
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Scheduled. Based upon Rev 12 Test Schedule, we project that procedures required to support Testing Activities will be developed and approved at least 2 months before,the scheduled test start date.
- b. The status of Test Program Procedure Performance completions is summarized below and shown in detail in TABLE 2 and Figure 3.
PROCEDURES COMPLETED None Preoperational Tests completed -
2 Preoperational Tests started /not complete -
d Acceptance Tests completed -
1 0
Acceptance Tests started (not complete) i 16 Flushes completed -
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17 Specific Tests completed -
9 Specific Test started (not complete) -
23 Generic Tests / Checkout - Checkout procedures are performed for all components, subsystems, controls, and similar items to ensure that they function properly and are installed correctly prior to the start of system Preoperational or Acceptance Testing. Due to the nature of checkout (i.e. required for electrical, mechanical, and I&C), the status of checkout is presented below only as an approximate. The " completion" status is assumed that the
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checkout activity in itself is complete but there may be punchlist items that are still open and require checkout testing.
In addition, the following guidelines were assumed in reporting checkout complete:
Electrical - system is checked out and energized Mechanical System - electrical, I&C, and mechanical C/0 are complete e
I&C - electrical and I&C C/0 are complete
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.s Generic Checkout DISCIPLINE Percent Complete
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Electrical 83 I&C 37 Turbine /HVAC 24 Feedwater/ Condensate 25 NSSS.
4 Auxiliary System 8
Process Steam 15 Total 45%
In summary, 45% of the Systems (850) in the Plant have been initially checked out, and 4% of required Tests (Preop, Acceptance, Flush, and Specific) have been performed.
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ks III. Project Test Schedule - Rev 12 A.
Rev 12 Test Schedule Philosophy The Rev 12 Test Schedule Philosophy is basically the same as Rev 11 relative to the dual Unit startup concept and is sum arized in this section. Figure 4 shows Rev 12 Test seqlence through commercial operation for both Units.
1.
The majority (95%) of Unit 1 preoperational testing will be performed prior to Unit 2 Fuel Load.
This will relieve Unit 1 preoperational testing of restraints and delays due to Unit 2 license operating restrictions (technical specifications and surveillance testing).
This will increase Unit 2 availability.for power production owing to fewer interferences from Unit 1 preoperational testing.
I Inherent timeframes are built into the merged schedule to absorb I
2.
corrective design and/or maintenance following major periods of 9
integrated initial plant operation and preoperational testing.
Historically, nuclear plant test programs have suffered lengthy delays immediately following the Cold Hydro Test Phase and the Hot Functional Test Phase due to equipment or other operational failures. These failures have in the past slowed and in many 4
cases stopped critical path progression onto the next succeeding scheduled event (s) until repairs and/or design problems were resolved. These timeframes are shown on Figure 2 as " Resolve Punchlist Items- ".
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3.
No two Unit 1 and Unit 2 milestone events are required to be performed simultaneously.
It is impractical to focus site activities on more than one (1) major Unit 1 and Unit 2 milestone activity at the same time.
The Midland Site is currently being staffed to permit simultaneous component testing with each Unit but not for simultaneous integrated milestone testing. To do so would require two of every resource including the Testing Group, Operations Group, Bechtel, B&W, and CPCo Management support.
4 However, one major change in this philosophy is that, on Rev 12 the ILRT on one Unit is now scheduled to be performed simultaneously with HFT on the other unit. Since Testing manppver required to perform ILRT is different from HFT, and since there is no system nor technical relationship between ILRT on one unit and HFT on the other unit, we believe that these two events can occur in parallel,.
I 4.
Separation of Fuel Loads Unit 1 and Unit 2 Fuel Loads are separated in :ime to support the Dow requirements with regard to process steam availability.
5.
LLRT/ILRT/ SIT are performed nearly piggy-back during the same tLeeframes.
Containment leak rate and structrual integrity testing would benefit by capitalizing on the commonality of equipment, personnel, and vendor support required to perform these tests.
6.
The integrated ESFAS Test would be a common test phase.
4 The safeguards system for the Midland Project is essentially a common system in that each plant is designed to respond to the others safeguards action. As such, this particular milestone test for each J
plant will include the other plant to the extent that_neither could
~~
provide sustained powet during conduct of the test.
Thus, ESFAS testing will be performed for each plant at approximately the sacc i.imei:ame to avoid duplication of effort and interiuption of pov.
produc t ion from the "on-line" plant.
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7.
Several disadvantages with the Rev 11 schedule at the time it was developed have become less significant in terms of the Rev 12 schedule. These are:
.The potential problem of Spent Fuel Pool area work a.
interferring with fuel receipt would be less significant.
s Receipt and storage of new fuel on site imposes a number of restrictions on the fuel storage facilities (spent fuel pool area). Typically, this means all activities are limited to
~
either fuel handling itself or to routine maintenance of fuel' handling related equipment. Usually, the license for receipt and storage of "special nuclear materials" (fuel) specifically prohibits construction activity or any other dirt generating i
or heavy maintenance work which could potentially affect cleanliness or structural integrity of the new fuel.
i j
Based upon Rev 12, only 7 systems remain to be turned-over. to support fuel receipt. The potential problem of receiving and storing Unit 2 fuel conflicting with construction of Unit 1 (construction access to the inside of the containment) is now much less significant due to large amount of construction work j
~
l completed. There is no longer the problem associated with
}
Tendon tensioning on the Unit 1 RB interferring with fuel receipt because the Tendon tensioning is complete.
b.
Construction has a better chance of achieving the turnover demand dates since there are only 307 of 850 turnovers remaining.
In addition, the CCP concept is predicated on quality work which would result in a more complete system at the time of turnover, i.e. less construction deficiencies.
4
~~
The feedwater and condensate system will not have to be laid c.
up for a long time between chemical cleaning and the start of HFT.
I d.
We have more time to redner backlog punchlist t. gen items.
I i
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=
Three temporary high pressure boilers 8.
Initial Turbine Roll were installed in 1982 and fully tested to primarily allow early testing of the Process Steam Systems which will result in considerable schedule gains during powe'r escalation testing of Unit 1.
The Temporary High Pressure Boilers will also be capable of supplying steam co support Secondary Plant Testing including Initial Turbine Roll. Early Testing of the Secondary Steam Side of the plant and the Main Turbine will result in overall test schedule gains in the secondary side of the Plant. A Turbine Roll Milestone (TR) has been added to the Test Sequence which is required to be accomplished approximately 1 to 2 months prior to HFT. The Pre EFT Schedule Gains is expected from being able to perform early testing of relief valves, initial steam leak tests, steam blows and flushes of Secondary Side Systems.
B.
REV 12 TEST PROGRAM PLAN This section describes the Test Program Plan Revision 12, both in narrative form discussing the Testing highlights and Tabular / Chart forms showing details of the Test Program.
Figure 4 shows the Rev 12 Test Program Schedule Sequence showing the major milestones leading to initial fuel load and commercial opera-tion.
Figure 5 shows the full-blown Test Schedule in Tabular form listing the projected start dates for Preoperational, Acceptance, and Specific tests as well as nyst en flushes.
- -m uo*
n;
.s 30 The narrative presented below pertain to Unit 2; however, due to similarities between the two units, it is applicable also to Unit 1.
- 1. Planned Activities Leading to the Next Target Milestones (B-Auxi-liary System Flushes and G-Feedwater System Flushes)
The major thrust during this period is to complete system check-outs and flushes for the 543 systems now in the hands or CPCo (as of 3-31-83).
In addition, approximately 60 System Turnovers.and subsequent checkout and flushing activities are projected to occur during this time frame.
In the electrical area, turnover of the remaining electrical power systems and subsequent energization are scheduled to provide permanent power to run the mechanical systems. Backfeed from the 345 KV lines through the Station Transformers will be a major event to ens 2re that sufficient power is available to support major test events and their power load requirements, and allow testing of the electrical systems.
In the I&C area, the major effort will be devoted to completing I&C checkout of instrument racks, cabinets, modules, and annunciators that have been turned over to CPCoy The majority of the remaining I&C system turnovers are scheduled during this time frame to allow as mueli checkout as possible in suppor t of Mechan-
!cci systems checkout and stattup. Verif$ cation of input / output
~
o 31 s
s signals to the plant computer, annunciators, indicators, and controls will be an on-going process.
In the primary systems area, seven (7) systems remain to be turned over to support Milestone B-Auxiliary System Flushes into the Reactor Vessel. The major objective during this period is to checkout and flush the individual auxiliary systems which support the Reactor Coolant System (RCS). These include the DH Removal, High Pressure Injection, RCP seal injection, RC makeup, Core Flood, RCS letdown, and portions of the Reactor Co'olant System Cold leg piping.
In the secondary side of the plant, the major testing activities involve checkout and flushing of the entire condensate system and Seven (7) Systems remain to be turned over to the Demerators.
allow the next target Milestone (G) to start, which is the Main Feedwater Flush.
In the Evaporator Building, major activities in 1983 will include complete checkout and flush of Secondary and Tertiary Systems; complete flushing after remaining five (5) systems are turned I
over to CPCo; complete Tunnel modifications, and initial piping heatup using the HP Boilers.
l
_. _ _ _ --.. _ _ _.. _ -.... _ _ ~ _. _ _ _. _.
32
- 2. Milestone B-Auxiliary System Flushes into Reactor Vessel' This Milestone involves flushing of the low and high pressure injection, and Core Flooding lines into the Reactor -
Vessel. Other activities scheduled to be performed / completed during this period include:
- Reactor Vessel internals modification and final clean up i
- Reactor Vessel internals pre-HFT baseline inspection l-
- Reactor Cooling Pump Motor initial runs, seal installation, alignment and coupling to pumps.
- After flushes to the RV, setting the Core Support Assembly and filling the KV up to the flange level.
j i
f
- Conducting the Reactor internals Vent Valve Test, and surveillance specimen holder tube test.
i
- 3. Milestone C - Refueling Canal Hydro and Wet Fuel Handling Test The Milestone will verify the integrity of the Re, fueling Canal and the seal plate, and the FH equipment and fuel index test with refueling e=nal w ter.et Its fril level (simuirsir,7 -tfuelitg operations).
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3-33 Following CANAL Hydro, several key e.ents take place in prepara-tion for RCS COLD Hydro. Some of the activities include the following:
- Set Plenum in Reactor Vessel
- Install RV Head and Tension Studs
^
- Couple Control Rod Drive Mechanism lead screws and install closures.
4 5
- Fill and Vent Reactor Coolant System
- Draw Pressurizer Bubble, and Run Reactor Coolant Pumps.
- 4. Milestone D - RCS COLD HYDRO During this test, the RCS is pressurized to 125% of design pressure to verify system integrity. Durina the Hydro phase, miscellaneous tests will be conducted such as:
- RCP Flow Tests I
- HU/HPI/LPI/CF System Tests
- Secondary Side, Stram Gn.nrator Hydra Tes!
34 5
-t l
e I
Following Unit 2 RCS depressurization, test and manpower' emphasis i
vill be shif ted to Unit 1.
At this point, resolution of punchlist open items will be vigorously pursued and remaining RCS insulation will be installed in preparation for nit 2 HFT.
- 5. Milestone G - Feedwater System Flush Following the Condensate System flushes and Turnover of the l
Feedwater System, the Deaerator will be filled and the Feedwater l
Booster Pumps will be used to flush the f aedwater system includ-ing piping through the condensate domineralizers. Other activ-ities during this time period include:
1.
- Turnovers, checkout, and flush of remaining systems required for drawing vacuum in Condense and initial Turbine roll.
- 6. Milestone H - Condenser vacuum Drawing a vacuum in the condenser involves the checkout and operation of the air ejectors, vacuum pumps, and the Circulating Water System. Any air inleakage to the condenser will be iden-tified and required at this time prior to HTT. The permanent Auxiliary Boilers or tempotary HP Boilers will EE operated to provide ntsam to the gland real steau system and blanketing steam o, 61,c K,i t ' e s e Lc parat on rehrater, tube side. the HP Heater 9
~. _ _
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' s 35 o
Vents, drains and level control sytem will be in operation. The Turbine will be placed on turning gear with support systems such as Seal and tube oil, and cooling water, in operation.
o
- 7. Milestone TR - Initial Turbine Roll
~
l Due to the availability of the HP Boilers, the Main Turbine initial roll can be accomplished independent of the Reactor t
Coolant System and Steam Generators. To support initial Turbine roll the Condensate and portions of the Feedwater System have to be in operation and the Condenser in a vacuum.
In addition, the following systems have to be functional:
s Main Turbine Steam Supply and drains.
i Moisture Separator Rehester supply and drains f
Stator Cooling i
I Turbine EHC System Main Turbine Supervisory Instrumentation Main Generator Protection Microwave System 4
4
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- 8. Milestone J - Hot Functional Testina k
During RFT, operation of the NSSS and secondary sy. stems is integrated for the first time: The test will be conducted at ambient conditions, heatup, hot shutdown conditions (2.155 psig and 532F), and cooldown. A significant number of Preoperational and Acceptance Tests will be conducted during this time.
I
- 9. Milestone K - Intearated Leak Rate Test i
1 l
The ILRT involves pressurising the Containment above the Design Bases Accident Pressure and conducting a leak integrity check to ensure that the building and penetrations are air tight and i
capable of isolating the structure in the unlikely event of an l
accident involving release of radioactivity. Prior to this test, the Local Leak Rate Test of all containment penetrations will be conducted. Based upon the two-Unit startup concept, the ILRT for Unit 1 will precede Unit 2 ILRT.
- 10. Milestone L - Intearated Safemuards Features Activation System Test UponcompletionofHTTandILRT,thenextmajoraijestoneisthe SFAS Test. The prerequisites for this test involves
- kractor Vessal ner..! vewava)
~
t 37
- RV internals removal
- Turnever, checkout, and testing of all system / components that receive a signal from the STAS cabinets.
During the SFAS test, operation of all emergency core cooling systems is checked. An emergency condition will be simulated which will cause the plant's automatic safeguard systems to start in response to the signal. The Diesel Generators, EPI and LPI pumps, and containment spray pumps will be actuated.
Required flow conditions will be verified as well as the order in which systems respond and the length of time elapsed before the re-
~
sponse is initiated.
- 11. Milestone M thru O - Fuel Load and Post Fuel Load Activities This phase of the Test Program is called the Startup phase and will not be described in this report.
For planning purposes.
Figure 2 shows the Major Milestone Target dates beyond Fuel Load, and shows a duration of approximately 4.3 months from Fuel Load to Commercial Operation (UNIT 2) and approximately 6 months for Unit 1.
~~
.O f
38 C. Manpower Requirements - Revision 12 Figure 5 shows manpower resource curves for Test Engineers, operators, electrical checkout (ECO) personnel. ISC Tech 71cians, Maintenance Mechanics, Maintenance electricians, and Chemistry and Health Physics Technicians required to support Revision 12 of the Test Schedule.
The Midland Plant has been staffed to support the Dual Unit Startup Plan. The resource availability for each of the above resources has been superimposed on the appropriate curves.
It is also worth noting that a separate organization, Construction General Service Organization (CGS 0), will perform the majority of work associated with Post Turnover Punchlist items. The present load of CGSO personnel is:
Non-Manual -
55 l
i Manual (Crafts) 100 Breakdown of Manual 55 Pipefitters and Welders
~
35,
Electricians 10 Laborers l
o I
39 In terms of shift work, the estimated durations in the Test Schedule were assumed as follows:
~
.. ~
~
1.
The majority of Post Turned-over activities were assigned a 5-day work week, 8 hrs / day.
2.
Mainline Activities and Milestones (such as RCS initial fill and vent, RCS Hydro, HFT, etc.) AND key systems (such as Auxilia'ry Systems required to support RCS Hydro) were assigned a 7 day work week, 24 hrs / day.
3.
The majority of System Flushes and initial fill and vent operations requiring Operations support were assigned a 7 day t
work week, 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> / day.
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TURNOVER s
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s REMAINING TURNOVERS (307)
TURNED.0VER SYSTEMS-(543)
-l 64%
3'6%
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AUX 3%
- ELECT 6%
ELECT 38%
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% COMPLETE
= 64 SYSTEM TURNOVERS BY DISCIPLINE - (3 31-88)
t UNIT 2 HYDRO UNIT 2 FUEL LOAD 12%
19%
UNIT 1 HYDRO S.E.P.
FUEL RECEIPT PROCESS STEAM 5~*
UNIT 1 HFT 19%
UNIT 2 HFT 34%-
REMAINING SYSTEMS = 307 REMAINING SYSTEMS P,Y MILESTONES - (3-31-83)
- - -, -. -. ~. - -,,,
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i REVISION 12===
=
SYSTEf'S ACCEPTED = 544 0F 8 5C TOTAL.
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/
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i 4
o STARTED /NOT COMPLETED
_ COMPLETE _
PRE-OPERATIONAL TESTS 0
-2 ACCEPTANCE TESTS 1
0 SYSTEM FLUSHES 16
~
17 SPECIFIC TESTS 9,
23 TOTAL 26 42 TOTAL TESTS REQUIRED (EXCLUDING GENERIC TESTS) 683
% TEST COMPLETE =
4
~
TESTS CO'MPLE1 ED - (3-31-83)
l r
GENERIC CHECKOUT DISCIPLINE PERCENT COMPLETE l
l l
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~
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AUXILIARY SYSTEM 8
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rg) 8p MANPOWER CURVES REFER TO HANDOUT MATERIAL, FIGURE 5 d
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POST TURNOVER EXCEPTION WORK CONSTRUCTION GENERAL SERVICES ORGANIZATION MANPOWER NON-MANUAL 55 MANUAL PIPEFITTERS & WE G ERS
- 55 ELECTRICIANS
- 35 LABORERS
- 10 100 k
e L
(g
- g j) g.6 Pops & t A1
~
Bechtel Associates Professional Corporation
~
777 East Eisenhower Parkway a5056 Ann ArcorMengan wenaeress:P.O. Box 1000, Ann Arcor. Micnigan 48tC6 vember ah'@W naut n MVPANY BLC-11923 R E P' E I V E Consumers Power Company 1945 West Parnall Road DEC 0 81981 Jackson, Michigan 49201 Attention: Mr. R.C. Bauman FIELO QuaulY AaaVRANCE Design Production Manager M10 LAND, MICHIGAN
Subject:
Midland Plant Units 1 and 2 Consumers Power Company Bechtel Job 7220 Strength Test of Cable Tray and Raceway Support Material File:
C-1201 w/A
Reference:
Bechtel letter BLC-11695,10/23/81, Curtis to Bauman Consuuer Power Company's comments in response to the referenced letter were received and resolved. (Telephone conversation between Richard Oliver of CPCo and P.V. Regupathy of Bechtel).
Final Electrical Raceway Support Tests Report, parts 1 and 2 are enclosed Part I contains engineering analysis and summary of test results. Part 2 consisting of four volumes contains test data.
Please note that, on the basis of analysis of test results, the report concludes that the electrical raceway supports as installed are adequate.
Very truly yours,
$k L.H. Curtis Project Engineer SLS/SDG/dkj(C)
,11/20/2 Attachments:
1.
Electrical Raceway Support Test Report, Part 1 2.
Electrical Raceway Support Test Report, Par,t 2 (4 volumes) cc:
(all w/a 1):
D.B. Miller
, i /'
T.J. Sullivan ~
n.t.
_.4 w.
i ///QQ C/.'I..i' R.A. Wells l
3.'3.L*L; ~1..... -
N o'
I',-." c'
~ \\ f's _ L/ i Q, / f Written Resa ne C
[c,,.
t 1