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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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Low Pressure Service Water Supply Header Connections to Unit 1 17

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

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Low Pressure Service Water 32" HOPE Pipe Installation 19

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Water Treatment System 20

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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

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Chlorination Building For Nuclear Service Water 22

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Sample Coupons 23

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Sodium Bi-Sulfite Tank (De-Chlorination) 24

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De-Chlorination Equipment Skids 25

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De-Chlorination Sam Ie Buildin 26

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Mock-up Piping 27

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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

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Mock-Up Piping 29

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Mock-Up Piping 30

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Nuclear Service Water Lake Intake Piping 31

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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

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

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Snorkel Components Being Fabricated 34

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Snorkel Preassembled for Testing 35

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Cofferdam Construction

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37

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Causeway from the Catawba Park to the Cofferdam 38

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Cofferdam Viewed from Boat Ramp at Catawba Park 39

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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

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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

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Nuclear Service Water Pipe Prior to Initial Cleaning 42

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Nuclear Service Water Flange Initial Cleaning 43

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

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

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12 Day Nuclear Service Water Outages 46

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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

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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 *

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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

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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

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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

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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

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

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

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Resource Plan 57

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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

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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

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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