ML053550267

Service Water Project Update Presentation on 12/07/2005

ML053550267
Person / Time
Site:	Catawba
Issue date:	12/07/2005
From:	Duke Energy Corp, Duke Power Co
To:	NRC/RGN-II
References
Download: ML053550267 (58)

Text

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~Dulce r"power Catawba Nuclear Station Service Water Project Update December 7, 2005

Participants Name Title Dhiaa Jamil Site Vice-President - CNS Bill Pitesa Station Manager-CNS Regis Repko Engineering Manager-CNS Dan McRainey Project Director - Nuclear Service Water Project 2

Agenda

• Opening Remarks Dhiaa Jamil

• Station Performance Regis Repko

- Reliability / Predictability

- Equipment Performance

- Safety System Results

- Plant Equipment Items / Improvements

• Service Water Project Status Bill Pitesa

- Low Pressure Service Water

- Water Treatment System

- Mock-Up Piping

- Nuclear Service Water Lake Intake Piping

- 12 Day Nuclear Service Water Outage

- Resource Plan

• Miscellaneous Items and Closing Remarks Dhiaa Jamil 3

2005 In Review

• Duke and Cinergy Merger

• Senior Site Management Changes

• ISFSI Construction

• Technical Training Programs Accreditation Renewed

• MOX Lead Test Assemblies Installed

• Industry Recognition for Thermal Efficiency (BTU/kwh) and Generation Efficiency ($/kwh)

• Lowest Duke Dose for an Outage with SG Inspection and Lowest CNS Outage Personnel Contamination Events

• No Licensee Event Reports

• Green Performance Indicators and Violations

• No Reactor Trips

• Improvements in Equipment Reliability 4

2005 Unit 1 Power History 110---- - - - - - -

100 90 -

80 -,

70 e

~ 60 -.

Q Q.

C e

u 0

50 -

Q.

Main Feedwater Pump 1B seam seal LO "

repair 30 -

20 -

1EOC15 Outage 10 -

0---*-+--..---,

111105 1/28105 2/24."05 3/23,105 4119/05 5i161Q5 6/12/05 7/91'05 8/5/05 911105 9128105 10125105 11.'21105 5

2005 Unit 2 Power History 110 ,-----------------------.-

100 ----------------1,---------------------1 90 -

70 40 30 '

20 Main Turbine EHC Fluid leak

'0 o .,,- ., .:,-.- - ---.------------------l---.-----.- -- .

1/1105 1128105 2124!O5 3/23105 4/19/05 5/16"05 6/12/05 7,19/05 815,105 9f1l05 9128/05 10/25.105 1 "/21l05 6

Agenda

• Opening Remarks Dhiaa Jamil

• Station Performance Regis Repko

- Reliability / Predictability

- Equipment Performance

- Safety System Results

- Plant Equipment Items / Improvements

• Service Water Project Status Bill Pitesa

- Low Pressure Service Water

- Water Treatment System

- Mock-Up Piping

- Nuclear Service Water Lake Intake Piping

- 12 Day Nuclear Service Water Outage

- Resource Plan

• Miscellaneous Items and Closing Remarks Dhiaa Jamil 8

Reliability I Predictability 2003 2004 2005 through October Unplanned Lost 15.7 16.8 3.8 EFPD (does not include outage extensions)

Outage Extension 22 6.6 3 Days Lost Gen days to 23.8 17.5 2.5 equip. failures (on-line & outage) 9

Equipment Performance 2003 2004 Nov '04-Oct '05 All MRFF* 55 42 29 (12 month total)

HSS* MRFF 28 20 11 (12 month total)

All UTSE* 102 77 53 (12 month total)

HSS UTSE 58 36 21 (12 month total)

• MRFF - Maintenance Rule Functional Failure HSS - High Safety Significance UTSE - Unplanned Technical Specification Entry 10

Equipment Performance

• Significant Improvement in Component Cooling Heat Exchanger Performance

- Chemical addition capability

- De-chlorination

- HX performance monitoring

- Results:

II 2002 to 2003: 2-3 months (stainless steel Hx cleaning)

III 2004 to present: 6-8 months (both stainless steel and brass Hx cleaning)

• Direct Effect on Safety System Unavailability 11

Unit 1 Safety System Unavailability Emergency Power - Unit 1 HPI- Unit 1 1.50% 3.00%

1.20% 2.50%

2.00%

0.90%

1.50%

0.60%

1.00%

0.30% 0.50%

0.00% 0.00%

2003 2004 2005 2003 2004 2005 RHR -Unit 1 Emergency Feedwater - Unit 1 1.50% 1.50%

1.20% 1.20%

0.90% 0.90%

0.60%

0.60%

0.30%

0.30%

0.00%

0.00%

2003 2004 2005 2003 2004 2005 12

Unit 2 Safety System Unavailability Emergency Power- Unit 2 HPI* Unit 2 2.50% 3.00%

2.00% 2.50%

2.00%

1.50%

1.50%

1.00%

1.00%

0.50%

0.50%

0.00% 0.00%

2003 2004 2005 2003 2004 2005 RHR* Unit2 Emergency Feedwater* Unit 2 2.00% 1.50%

1.70%

1.20%

1.40%

0.90%

1.10%

0.80% 0.60%

0.50% 0.30%

0.20%

0.00%

-0.10% 2003 2004 2005 2004 2005 13

Plant Equipment Items I Improvements

• Diesel Generator batteries replaced

• Digital Feedwater Control card upgrades

• Proactive 7300 card replacements

• Electrical generator rewinds

• 2 reactor coolant pump motor refurbishments

• U1 emergency feedwater check valve relocated

• Emergency feedwater heat trace system improvements

• U1 gas intrusion resolved

• Refueling water storage tank instrumentation lightening protection

• 10 year vessel ISI

• Reactor vessel bottom mounted instrument inspection

• Fire Protection isolation valves replaced

• Low Pressure Service Water (RL, non-safety) pipe replacements

• Monitoring and Trending of raw water heat exchangers

• All containment spray heat exchangers replaced

• Lake intake pipe cleaned and coated 14

Agenda

• Opening Remarks Dhiaa Jamil

• Station Performance Regis Repko

- Reliability / Predictability

- Equipment Performance

- Safety System Results

- Plant Equipment Items / Improvements

• Service Water Project Status Bill Pitesa

- Low Pressure Service Water

- Water Treatment System

- Mock-Up Piping

- Nuclear Service Water Lake Intake Piping

- 12 Day Nuclear Service Water Outage

- Resource Plan

• Miscellaneous Items and Closing Remarks Dhiaa Jamil 15

Service Water Project Status Low Pressure Service Water

• System provides makeup to cooling towers, cools turbine and generator auxiliaries, containment chillers and secondary system pump motors

• Carbon steel piping became degraded from corrosion - cooling capacity was marginal during hot weather

• Restoration is to replace piping with High Density Polyethylene Piping (HDPE)

• Cooling Tower makeup has new control valves and HDPE piping headers

• Turbine/Service building distribution piping changed to HOPE

• New HOPE main supply header installation in progress and will be in service by April 2006 16

Low Pressure Service Water Supply Header Connections to Unit 1 17

New Low Pressure Service Water Supply and Return Piping to Containment Chillers 18

Low Pressure Service Water 32" HOPE Pipe Installation 19

Water Treatment System 20

Service Water Project Status Water Treatment System

• New System to chlorinate the supply and then de-chlorinate the disch~rge to the lake or Standby Nuclear Service Water Pond (SNSWP)

• Allows higher concentrations of chlorine for greater biofouling control and reduced Hx Fouling

• De-chlorination prevents exceeding NPDES discharge limits

• Treats both Nuclear Service Water and Low Pressure Service Water

• Portions of System have been placed in operation

• Low Pressure Service Water Chlorination to be operational by May 2006

• Effectiveness of chemical controls for Nuclear Service water will be monitored by sample coupons 21

Chlorination Building For Nuclear Service Water 22

Sample Coupons 23

Sodium Bi-Sulfite Tank (De-Chlorination) 24

De-Chlorination Equipment Skids 25

De-Chlorination Sam Ie Buildin 26

Mock-up Piping 27

Service Water Project Status Nuclear Service Water Mock-U Pi

• Developed mock-up piping -300 Feet of 42 inch pipe and 100 feet of 30 inch pipe

• Demonstrated Capability of Equipment

- High Pressure Water Cleaning

- Abrasive Blast

• Proved the clean and coat process

• Trained Craft and Inspection Personnel

• Logistical Improvements Identified

- Handling of Coating Equipment

- Removal of Abrasive Material

- Sequence of Support Personnel (QC, Fire Watch, Hatch Attendant)

• Contingency plans

- Safety Training For Medical Emergency Response Team

- Weld Repairs 28

Mock-Up Piping 29

Mock-Up Piping 30

Nuclear Service Water Lake Intake Piping 31

Service Water Project Status Lake Intake Piping

• Clean/Coat Nuclear Service Water Lake Intake Piping (400 feet of 48" piping)

• Built Two Snorkels in the Nuclear Service Water Pump House

• The Snorkels provide:

- a QA1 boundary between the SNSWP & Lake Wylie while the plant uses the SNSWP for Nuclear Service Water cooling water

- alternate access & egress path for personnel working inside the Nuclear Service Water Lake Intake Pipe

• Built Cofferdam at Lake Intake to dewater and allow access 32

Service Water Project Status Lake Intake Pi in Dia ram SEE VIEW "s-s" 33

Snorkel Components Being Fabricated 34

Snorkel Preassembled for Testing 35

Cofferdam Construction 37

Causeway from the Catawba Park to the Cofferdam 38

Cofferdam Viewed from Boat Ramp at Catawba Park 39

Service Water Project Status Lake Intake Piping Clean/Coat Process

• Coating material has Extensive Service History Within Nuclear Industry and Duke Power

• QA Receipt of Material and Level B Storage of Material

• Coating Manufacturer provided Training and Qualified Coating Contractor

• QA/QC Service Level 1 Inspections of Entire Process

• Process Steps

- High Pressure Water Cleaning

- Weld Backing Ring Removal

- 100 % Engineering Condition Inspection

- Biocide Treatment of Welds

- Establish Environmental Controls

- Abrasive Blast

- Apply 3-Coat Plastocor Coating System

- Robotic Video Inspection 40

Service Water Project Status Lake Intake Pi in Results

• All internal pipe and weld surfaces were inspected by a team of engineers to verify that wall thickness remained above a minimum value required by the applicable design criteria

• Engineering calculations determined that the existing piping was designed with a large amount of margin (a factor of 5) over what was required. A wall thickness of 0.625 inches piping was installed and the minimum required is 0.125 inches.

• The Engineering Inspection results indicated that ALL welds exceeded the minimum required thickness with results as follows:

- 30 welds were considered in very good condition with less than 1/8 inch metal loss

- 16 welds were considered in good condition with between 1/8 inch and ~ inch metal loss

- 9 welds were found with localized spots of greater than ~ inch metal loss but still with acceptable metal wall thickness

• No repairs were necessary to restore the welds to required wall thickness 41

Nuclear Service Water Pipe Prior to Initial Cleaning 42

Nuclear Service Water Flange Initial Cleaning 43

Lake Intake Pipe Before Cleaning Lake Intake Pipe After High Pressure Water Cleaning 44

ILake Intake Pipe After Abrasive Blast I Lake Intake Pipe After Final Coating 45

12 Day Nuclear Service Water Outages 46

Service Water Project Status 12 Day Nuclear Service Water Outages

• Two 12 Day Nuclear Service Water Outages Scheduled to Begin January 2006

• Currently Pre-fabricating Piping

• Laser Scanning Being Used to Obtain As-Built Conditions

• Work To Be Done

- Clean/Coat Welds in Nuclear Service Water Supply Header Piping from Pump House to Auxiliary Building

- Auxiliary building Isolation Valves and Crossover Piping

- RN Pump House Isolation Valves and Crossover Piping

- Diesel Generator Isolation Valves and Crossover Piping 47

---

~---

Service Water Project Status 12 Day Nuclear Service Water Outages

• Sequence

. for clean/coat of welds in supply piping requires:

- System drain

- High Pressure Water Clean and vacuum

- Establish Environmental Conditions

- Engineering weld inspection and repair (as required)

- Abrasive Blasting for surface preparation

- QC surface prep inspection

- QA 1 coating application (hand trowel application) of only pipe welds 48

11/30/05 Service Water Project 1 Extended LCO MO 6

'A' Train LCO 0207:00 0605:00 0365:5et up for LCO (material, equipment, pipe culling, etc) 1411:00 07005:CD100064 1 A DIG RN pipe and valve replacement 1411:00 0405:Replace piping and ~

061. 1413:00 07005:GD200141 2 A DIG RN pipe and valve replacement 061 1413:00 0406:Replace piping an ~

061. 1610:00 07005:CD500062 RN pump strainer piping upgrade 061.£~{00 0409:Removepiping and valves 0408:Replace piping a~d valves ~

081~:00 1610:00 06111:00 i1iill***********1418:00 i!Il, 07005J:;D500063 Add isolation valves & spools to RN discharge header 061M:00 0911:00 0411:Remove piping and valves 07 1"1:00 1418:00 110410:Replacepiping andvalyes ~

06100 1512:00 l 07~05:CD500175 Replace 1 s 2 RN 67A 061"3:00

" 0413:Remove piping and valves 07 "3:00 1512:00 0412:Replace piping and valves -~

~

06 "':00 06 11:od06 15:00 0380:0pen manways ~

16111:00 07005:CD500376 Clean & coat RN piping from pump structure to aux bldg 0615:00 os 15:00 0381:Hydro laser piping IIIIIIIII 0915101015:00 0435:Dry pipe 1103:001215:00 0386:Weld repair ~

1215l>01315:00 0383:Abrasive blast weld areas . . ,

1315:001415:00 0437:Clean pipe ~

14 15:001503:0 0384:lnspect for coating ~

1503:~16d3:00 0385:Coat welds 1603:0 16 11:00 0387:C1ose manways 1611:001623:00 08003:0PS Clear tags and fill 'A' train ~

1623:001705:00 0432:0P5 Flush RN system ~

17 05:0~ 17 14:00 0366:RN testing and flow balance

11/30105 Service Water Project 2 Extended LeO JANUARY FEBRUARY

~~ruM~ffiMW~ruM~ffiM~~ruM~ffiM~~ruM~ffiM~~ruM~ffiM~~

1 I 2 I 3 I 4 I 5 16_1 7 1 8 I 9 I 10 1 11 IJ_~ U~I 14 1 15 116 1 17 U8 JJ] L20 121J22 123124125 1 261271 28 1 29 1 30131 L--1_LI:L3_LAJ5J 6 I:

'B'Train LCO 1807:00 22 d5:00 0377:Set up for LCO (material, equipment, pipe cutting, etc) 22 05:00,22 11:00 36 0376:0PS Tag and drain for 'B' train LCO 22111:00 2924:00 137 0375:CD100064 1 B DIG RN pipe and valve replacement 22 1 :0023 23:00 jl:

0417:Remove piping and valves 2323:00 2924:00 0416:Replace piping and alves @.,~~\ J

~=

3003:00 40 0374:CD200141 2 B DIG RN pipe and valve replacement l 22 1 :0023 23:00 41 0419:Remove piping and valves 1

• 42 43 0373:CD500062 RN pump strainer piping upgrade 0421:Remove piping and valves 22111:00 221~7:00 2323:00 0418:Replace piping and yalves ~~'%%.\%K~",,~,@l 3003:00

\

3020:00

~

J 44 241+7:00 30 20:00

~

45 0420:Replace piping and valves 46 0372:CD500063 Add isolation valves & spools to RN discharge header ~1~

2821:00

\ j 22111:00 ~3:00 47 0423:Remove pipin9 and valves 2821:00 48 221h:00 2915:00 0371:CD500175 Replace 1 & 2 RN 69B 221~3:00 0425:Remove piping and valves 2323:00 2915:00 51 0424:Replace piping and valves 11 52 0369:CD500376 Clean & coat RN piping from pump structure to aux bldg ~

2211:00

• 01111:00 11 11 54 53 2211:0~2215:00 0395:0pen manways ~

22 1iiO 0394:Hydro laser piping Y i 2515:00 2515:002615:00 55 0438:Dry pipe ~

26 03:QQgy 03:00 156 0393:Engineering inspection IIIJiI 26 15:0027 03:00 0439:lnstalltemporary covers Iii§ oloo I':

27 28 15:00 0392:Weld repair ~

2815:002915:00 59 0391:Abrasive blast weld areas ~

2915:003015:00 160 0440:Clean pipe ~

,I" 3015:003103:0 0390:lnspeel for coating ~

31 03:0001 03:00 0389:Coal welds ~

I,:: 01 0388:Close manways 03:0~1 11:00 1

0111:000123:00 1 164 0368:0PS Clear ta9S and fill '6' train . ,

01 23:0002 05:00 65 0430:0PS Flush RN system ,

0205:0002 14:00 166 0367:RN testing and flow balance

• Service Water Project Status 12 Day Nuclear Service Water Outages

• Project Contingency Plans:

- Start Date could be delayed in case of severe weather

- Welding resources and equipment available in case weld repairs are required

- Additional coating equipment available

- Coating scope reduction plan in place

- Back-out plans for pipe replacements

- Additional environmental control equipment available 51

Service Water Project Status 12 Day Nuclear Service Water Outages

• Operational Risk Mitigation Plans Include:

- Minimize maintenance activities on opposite train equipment

- Protect and increase monitoring of opposite train equipment

- Affected train DGs to be maintained "available"

- Component Cooling Water (CCW) system to be in cross train alignment during train outages

- Continuously staff the Standby Shutdown Facility 52

Service Water Project Status 12 Day Nuclear Service Water Outages

• Operational Risk Mitigation Plans Include:

- Changes have been made to loss of power procedures to address local throttling of AFW flow

- Changes will be made to plant procedures for the ability to cross tie the CCW headers

- Operations use of Configuration Risk Management Program to control and limit activities at the station

- Outage Control Center will be staffed during each train outage 53

Service Water Project Status 12 Day Nuclear Service Water Outages

• Operational Risk Mitigation Plans Include:

- Operators will do just in time review of loss of service water and loss of CCW procedures

- No maintenance will be allowed in the switchyard

- Outage will be during the time of year with lower risk of severe weather

- Increased focus by all plant personnel (OPS, Maintenance, Engineering and Management) due to awareness of risk significance

(

54

Pre-Fabrication of Piping For The 12 Day Nuclear Service Water Outages 55

Pre-Fabrication of Piping For The 12 Day Nuclear Service Water Outages 56

Resource Plan 57

SWP Resource Plan

• Resources To Support SWP:

• $ 285 million in projected project cost

• Secured raw metal materials

• 12 day outage prefab ongoing at Catawba, McGuire, and Oconee

• 355 craft and craft supervision

• 90 professional staff

• 127 service contractors

• End of year peak will be 572 58

SWP Resource Plan

• Contractor Oversight Improvements:

• Initially, SWP contractor oversight did not keep pace with the rapid growth of the project organization

• Corrective actions were implemented in response to observations and incidents

• Improvements were made to the contractor oversight plan

• Additional SWP oversight resources have been provided

• Communications and integration between the SWP team and the station organization are significantly improved

• Dedicated contacts within Operations and Work Control established for SWP

• Management observations targeted at SWP activities increased 59

Agenda

• Opening Remarks Dhiaa Jamil

• Station Performance Regis Repko

- Reliability / Predictability

- Equipment Performance

- Safety System Results

- Plant Equipment Items / Improvements

• Service Water Project Status Bill Pitesa

- Low Pressure Service Water

- Water Treatment System

- Mock-Up Piping

- Nuclear Service Water Lake Intake Piping

- 14 Day Nuclear Service Water Outage

- Resource Plan

• Miscellaneous Items and Closing Remarks Dhiaa Jamil 60