ML063340006
| ML063340006 | |
| Person / Time | |
|---|---|
| Site: | Farley  |
| Issue date: | 11/29/2006 |
| From: | Division of Nuclear Materials Safety II |
| To: | Southern Nuclear Operating Co |
| References | |
| Download: ML063340006 (72) | |
Text
SNC Farley Units 1 & 2 Status November 29, 2006 NRC Region II Status Meeting 1
Agenda 3/4 Introduction 3/4 Farley Project Overview - Lewis Sumner 3/4 Farley Site Status - Randy Johnson 3/4 Licensing Status - Doug McKinney 3/4 Problem Identification and Resolution -
Paul Hayes 3/4 Major Focus Areas- Sonny Bargeron 3/4 Open Discussion - ALL 2
Farley Project Overview Lewis Sumner 3
0 100 200 300 400 500 600 700 800 900 Nov-04 Dec-04 Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 FNP Unit 1 Oct-05 Equip Nov-05 Dec-05 HU Jan-06 Feb-06 Mar-06 Apr-06 May-06 Average Daily Power Level Jun-06 Jul-06 November 17, 2004 - October 31, 2006 Aug-06 Sep-06 Oct-06 4
0 100 200 300 400 500 600 700 800 900 Apr-04 May-04 Jun-04 Jul-04 Aug-04 Sep-04 Oct-04 Nov-04 Dec-04 Jan-05 Feb-05 Mar-05 Apr-05 FNP Unit 2 May-05 Jun-05 Jul-05 Aug-05 Equipment Sep-05 Oct-05 Nov-05 HU Dec-05 Jan-06 Feb-06 Mar-06 Apr-06 Average Daily Power Level May-06 April 14, 2004 - October 31, 2006 Jun-06 Jul-06 Aug-06 Sep-06 5 Oct-06
INPO Index INPO Performance Indicator Index 100 95 90 85 Percent 80 75 70 65 A pr05 M ay05 Jun05 Jul05 A ug05 Sep05 Oct05 No v05 Dec05 Jan06 Feb06 M ar06 A pr06 M ay06 Jun06 Jul06 A ug06 Sep06 Monthly Index Values Unit 1 - Index Value Unit 2 - Index Value Plant - Index Value Year End Target 6
Forced Loss Rate 12.0 11.0 10.0 9.0 8.0 7.0 Percent 6.0 5.0 4.0 3.0 2.0 1.0 0.0 Apr05 M ay05 Jun05 Jul05 Aug05 Sep05 Oct05 No v05 Dec05 Jan06 Feb06 M ar06 A pr06 M ay06 Jun06 Jul06 A ug06 Sep06 Cycle Based Averages (18 or 24 Months)
INPO 100% Performance Level Unit 1 - Monthly Cycle Avg Unit 2 - Monthly Cycle Avg Year End Goal Level Action Level 7
Industrial Safety Accident Rate - Plant Value 2.0 Industrial Safety Accident Rate per 1.8 1.6 1.4 1.2 1.0 200,000 Hours Worked 0.8 0.6 0.4 0.2 0.0 A pr05 M ay05 Jun05 Jul05 A ug05 Sep05 Oct05 No v05 Dec05 Jan06 Feb06 M ar06 A pr06 M ay06 Jun06 Jul06 A ug06 Sep06 Cycle Based Averages (18 or 24 Months)
INPO 100% Performance Level Industrial Safety Accident Rate (Cycle Based)
Action Level 8
NRC PI - Safety System Functional Failures 0
1 Safety System Functional Failures 2
3 Green 5 4
5 6
7 8
Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 12 Month Rolling Sum Note: Yellow/Red No Threshold White > 5 Green 5 Unit 1 Data Unit 2 Data Action Level 9
NRC PI - Mitigating System Performance Index, Cooling Water System 1.0E-07 Green 1.0E-06 Mitigating System Performance Index 1.0E-06 White > 1.0E-06 OR PLE = Yes 1.0E-05 (MSPI) Value Yellow > 1.0E-05 1.0E-04 Red > 1.0E-04 1.0E-03 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Rolling 36 Month Values Green 1.0E-06 White > 1.0E-06 OR PLE = Yes Yellow > 1.0E-05 Red > 1.0E-04 Unit 1 Data Unit 2 Data Action Level 10
NRC PI - Reactor Coolant System Specific Activity 0%
10%
% of Technical Specifications Limits 20%
30%
Green 50%
40%
50%
60%
70%
White > 50%
80%
90%
100%
Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Note: Red No Threshold Monthly Maxim um Yellow >100% White > 50% Green 50% Unit 1 Data Unit 2 Data Action Level 11
NRC PI - Emergency Response Organization Drill/Exercise Performance 100%
95%
Green 90%
90%
85%
% Of Opportunities 80%
White <90%
75%
70%
65%
60% Yellow <70%
55%
50%
Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 24 Month Rolling Values Note: Red No Threshold Green 90% White <90% Yellow <70% Plant Data Action Level 12
NRC PI - Alert and Notification Reliability 100%
99%
98%
97%
% Of Opportunities 96%
95% Green 94%
94%
93%
92% White <94%
91%
90%
Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 12 Month Rolling Values Note: Red No Threshold Green 94% White <94% Yellow <90% Plant Data Action Level 13
Collective Radiation Exposure - Unit Values 200 180 160 140 120 Rem 100 80 60 40 20 0
A pr05 M ay05 Jun05 Jul05 A ug05 Sep05 Oct05 No v05 Dec05 Jan06 Feb06 M ar06 A pr06 M ay06 Jun06 Jul06 A ug06 Sep06 12 Month Normalized Unit Values*
INPO 100% Performance Level Unit 1 - Actuals Unit 2 - Actuals Action Level 14
NRC PI - PA Security Equipment Performance Index 0.00 0.02 0.04 Green 0.08 0.06 Index Value 0.08 0.10 0.12 White > 0.08 0.14 0.16 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 12 Months Rolling Averages Note: Yellow/Red No Threshold White > 0.08 Green 0.08 Plant Data Action Level 15
NRC PI - FFD/Personnel Reliability Program 0
1 Reportable Events Caused By Green 2 2
Programmatic Failures 3
White > 2 4
5 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 12 Months Rolling Sum Note: Red No Threshold Yellow > 5 White > 2 Green 2 Plant Data Action Level 16
Engineering Realignment 2006 17
Organizational Chart: Technical Support Technical Support Engineering Fuels Licensing 18
Organizational Chart: Licensing Nuclear Licensing Vogtle Licensing Farley Licensing Hatch Licensing PRA Services License Renewal 19
Organizational Chart: Engineering Engineering VP Plant Support Engin. Services Engin. Admin. Serv. Config. Mgmt. Common QA Prog.
20
Organizational Chart: Plant Support Plant Suppt. Mgr.
Farley Support Hatch Support Vogtle Support Design Change Team Design Change Team Design Change Team RER Team RER Team RER Team Elec./I & C Elec./I & C Elec./I & C RER Team RER Team RER Team Mech/Civil Mech/Civil Mech/Civil Proj/Planning Team Proj/Planning Team Proj/Planning Team 21
Organizational Chart: Configuration Management Config. Manager Admin. Asst.
Design. Config. -
Minor Mods. Hatch E Fin Farley E Fin Vogtle E Fin DCP /Design.
Config. As Found 22
Organizational Chart: Engineering Services Engin. Serv. Mgr.
M & IS Equip. Reliab. Engin. Prog. Mgr.
- Seismic
- Stress
- Fire Protection
- Dry Cask Storage
- Security
- Environmental Qualification 23
Organizational Chart: Engineering Programs Engin. Prog. Mgr.
Admin. Asst.
Seismic/
Stress Fire Protection Dry Cask Storage Security Environ. Qualif.
24
Organizational Chart: Equipment Reliability Equip. Reliab. Mgr.
Admin. Asst.
Components - Mech. Components - Mech. Equipment Reliab. Components - Elec. Turbine Gen.
25
Farley Project Overview:
2006 TIP Award 26
27 Pandemic Plans Avian Flu H5N1 Panic or Pandemic ?
Threats to Avian Flu Business H5N1 Continuity Human Flu Pandemic 28
Pandemic Plans What are we trying to do here?
3/4 Agree that our SNC focus is to keep nuclear units on-line SNC Decision Matrix Pandemic Progression - Example - SRO Decision Cycle SNC Pandemic Threat Level Gradually Progresses 3/4 Acknowledge the uncertainty of a Low Guarded Elevated High Severe widespread pandemic Reaches SNC Reaches SNC In response, create a flexible plan Threshold Threshold Implement initial preparations: Implement the plan: Implement the plan:
3/4 that accommodates an uncertain
- Notify SROs
- Sequester SROs
- Identify SROs
- Vaccinate SROs
- Establish site quarters
- Acquire vaccination meds
- Buy hand sanitizer
- Double clean restrooms event Plan ahead: Plan ahead: Plan ahead:
- Notify SROs
- Sequester SROs
- Unit shutdown
- Vaccinate SROs
- Establish site quarters
- Consolidate SROs at site
- Prioritize unit shutdowns
- Consider outside assistance 3/4 When the pandemic does happen, z Focus resources where they will do the most good; with frugality z Put forces and resources in reserve as much you can 29
Pandemic Plans SNC Mission and Implementation Statement in the event of a pandemic SNCs Mission in the face of a pandemic threat To continue the uninterrupted maximum generation and delivery of electrical energy from the nuclear reactors at all three sites, considering mandated minimal staffing levels that are on-hand for an extended period of time and that there are no allowable compromise of the public health, public safety or violations of then-in-effect regulations in doing so.
Implementation The specified task would be to keep electricity flowing uninterrupted at maximum loads for all six nuclear units.
- Implied in that is the suggested establishment of minimum manning documents for not only numbers of employees present for duty but minimums assigned in several duty functions.
- Falling below these pre-established minimums at any location might necessitate voluntary derate or even shutdown of selected nuclear units, in a logical, stepwise manner.
- Likewise, there may be a hierarchy of necessary plant services and necessary Corporate services beyond which nuclear unit operations would not be prudent, regulatorily allowable or even possible 30
Pandemic Plans Event-driven Decision Matrix SNC Decision Matrix Pandemic Progression - Gradual versus Rapid SNC Pandemic Threat Level Gradually Progresses Low Guarded Elevated High Severe Implement Implement Implement Implement Plan Plan Plan Plan Reaches SNC Reaches SNC Reaches SNC Reaches SNC Threshold Threshold Threshold Threshold Pandemic explodes Low High Severe Implement Implement Plan Plan Implement Reaches SNC Plan Reaches SNC
-- Example -- Threshold Implement Threshold Plan 31
Farley Site Status Randy Johnson 32
Positioned for the Future 3/4 Both unit's steam generators replaced in 2000 & 2001 3/4 Completed construction and placed in service new mechanical draft cooling towers in 2003 & 2004 3/4 Replaced both unit's reactor vessel heads in 2004 & 2005 3/4 Completed Dry Cask Storage facility and completed first campaign in 2005.
3/4 License renewal approved- Spring 2005. Unit 1- 2038. Unit 2- 2041 3/4 New 20,000 sq. ft. Maintenance Training facility opened in summer 2006.
3/4 In 2006, completed extensive repair effort on fire protection impairments related to Kaowool & large penetration seals 33
Licensing Status Doug McKinney 34
Licensing Status 3/4 1 LER in 2006 (MSIV failure to close) 3/4 CDBI, ISFSI, EP, MSIV Special Inspection are completed NRC inspections 3/4 MSPI Verification, Initial Exam, Outage are future NRC inspections 3/4 NRC approval requests - snubber relief request, room cooler TS, SSPS TS, Weld Overlay Alternative, 10 year ISI /IST, Personnel Access Hatch 35
Triennial Fire Inspection Actions 3/4 Re-validate safe shutdown analysis and develop database 3/4 Manual operator actions review 3/4 Circuit analysis review 3/4 Communications, emergency lights, diagnostic instruments 3/4 Complete by end of 2007 3/4 Next Farley Triennial Fire Audit 3/2008 36
Problem Identification and Resolution Paul Hayes 37
Problem Identification & Resolution Problems Identified Through -
3/4 Corrective Action Program 3/4 System Health Reports 3/4 Equipment Reliability Board (ERB) 3/4 Major Issues List 3/4 Long Range Plans 3/4 Life Cycle Plan 38
Life Cycle Plan 3/4 Provides overview of plant projects 3/4 Integrates planned improvements and outage durations 3/4 Ensure budget review and assessment against other plant needs 39
Major Issue List 3/4 30 Issues 3/4 Directs Problem Resolution Focus for Primarily Short/Medium-Term Issues 3/4 Monthly Meetings Ensure Management Visibility 40
Focus Areas 3/4 HHSI 3/4 4KV Breakers 3/4 ECCS Sump 3/4 Service Water Issues 3/4 Alloy 600 3/4 Plant Computer Replacement 3/4 MSIVs 3/4 Main Steam Line Vibration 41
HHSI Pump Casings Replacing all 6 casings. First replacement planned for March 2007.
Charging Pump Gassing 3/4 Significant Event and LER 12/05 3/4 Attributed to large swing in VCT pressure 3/4 Ops procedures enhance to monitor for VCT pressure fluctuations 3/4 Participating in WOG program to study gas void formation/behavior 3/4 INPO assist visit investigated events and made recommendations regarding automatic pressure control, checking system for additional high points, adding charging pump discharge vents, etc 3/4 Restoration of automatic VCT pressure control under investigation.
42
4 KV Breakers 3/4 Expediting replacement with C-H.
3/4 Unit 1 & 2 SW breaker design issued and breakers procured.
3/4 Implementation begins in Dec 06 3/4 Other Safety Related bus breaker DCP preparation in-progress.
3/4 P.O. for additional breakers to be issued in Dec 06 43
ECCS Sump 3/4 Modifications scheduled for U2R18 and U1R20 (2007) 3/4 Continue to respond to emerging criteria such as chemical effects 44
Service Water Issues 3/4 Replacement of all 10 SW pumps starting with 2E.
3/4 No reliance on booster pumps for lube and cooling.
45
Alloy 600 3/4 Inspection planned for U2R18 (Spring 07) 3/4 Weld overlays planned for U1R20 (Fall 07) 3/4 Unit 2 overlays planned for 2010 46
Plant Computer Replacement 3/4 Replacement completed for Unit 1 and the simulator 3/4 Unit 2 complete by February 2007 47
MSIVs 3/4 Component refurbishment and enhancements scheduled for upcoming outages 3/4 Computational Fluid Dynamics (CFD) assessment to be performed by Weir Valve. Should be complete in early 2007.
48
Main Steam Line Vibration 3/4 Initiated Engineering Study to assess recent OE and technology to determine if improved techniques available.
49
Major Focus Areas Sonny Bargeron 50
2007 Overview 3/4 Spring and Fall outage 3/4 INPO Non- Operations Accreditation Renewal 3/4 INPO Evaluation 3/4 LO Initial Training Exams 3/4 MSPI Margin Recovery 51
Outage Plans Unit 2 Spring Outage Plans Reactor Coolant Pump Inspections:
- 18 month motor inspection on A & B
- Shaft cracking UT Inspection on all pumps
- Seal inspection on B
- 10-year motor change-out on C Alloy 600 Inspections:
- UT of 4 Pressurizer nozzles 52
Outage Plans Unit 2 Spring Outage Plans 3/4 Containment Sump Screen Modification 3/4 Secondary-side Inspections of all Steam Generators including Upper Internals and Feedring 3/4 Inspection and Refurbishment of all 6 Main Steam Isolation Valves 3/4 Main Power Transformer Replacement (#1 & #3) 53
Outage Plans Unit 1 Fall Outage Plans 10 year Reactor Vessel ISI 3/4 Rx vessel inspection 3/4 RCS loop to vessel alloy 600 weld UT ( HL & CL) 3/4 Rx Vessel bottom mounted incore penetration weld UT (alloy 600)
Pressurizer Alloy 600 weld mitigation 3/4 Surge line 3/4 Spray line 3/4 3 safety lines 54
Outage Plans Unit 1 Fall Outage Plans 3/4 Containment Sump modification 3/4 Replace two Main Power Transformers 3/4 High Pressure Turbine Rotor Out inspection with a Rotor Swap 3/4 Secondary-side Inspections of all Steam Generators including Upper Internals and Feedring 3/4 MSIV inspection / refurbishment 55
INPO Non- Operations Accreditation Renewal 3/4 Engineering, Maintenance & Chemistry pipelines 3/4 January Evaluation 3/4 Maintenance training facility z Lab mockups 3/4 Flow loop simulator z Practical factor training z Dynamic learning activities 56
INPO Evaluation 3/4 Next evaluation July 2007 3/4 Accomplishments z Focus on equipment replacements z Material condition z Workforce ownership z Conservative decision making z Low rad exposure z Timely resolution of equipment problems 57
INPO Evaluation 3/4 Improvement Needed z Operations planning input z Recognition of error likely situations z Component mis-positioning z Lifting & Rigging 58
LO Initial Training Exams 3/4 HL - 30 (10/06 Exam) - 1 RO & 3 SRO 3/4 HL - 31 ( 10/07 Exam) - 7 RO & 7 SRO 3/4 HL - 32 ( 10/08 Exam) - 8 RO & 8 SRO 59
MSPI Margin Recovery 3/4 All NRC indicators currently green 3/4 Two indicators with zero margin to white z U1 CCW z U2 MDAFW Developed action plan to recover margin 60
U1 CCW Margin Recovery 3/4 1 failure to start in 2006 ( handswitch contacts) 3/4 Fail to start or Run will result in white MSPI 3/4 Recovery focused on handswitch &
breaker replacements 61
U2 MDAFW Margin Recovery 3/4 1 failure to run in 2004 due to oil leak requiring pump stop 3/4 1 fail to start will result in white MSPI 3/4 Recovery focused on breaker replacement, handswitch replacement, and gasket improvement 62
Questions 63
4kV Safety Related Breakers Overview and Planning 64
Most Recent Issues By Year 3/4 2000 (2 issues) z Dirty hand switch contacts z unknown 3/4 2002 (1 issue) z Dirty hand switch contacts 3/4 2004 (4 issues) z Dirty hand switch contacts z Four bar linkage damaged 3/4 2005 (3 issues) z Dirty hand switch contacts z Loose stop bolt z Unknown 3/4 2006 (6 issues) z Charging motor (2 issues were out-of-spec - not failures) z Guide rail notch too narrow (2-DL03) z Roller/Trip latch gap out of spec high (Root Cause 1-DL05) z 2 issues are in-progress (1-DH03, 1-DK05) 65
Bus Arrangement FROM FROM TO 230 KV 230 KV 230 KV SWITCHYARD SWITCHYARD SWIT CHYARD UNIT 1 MAIN G ENERATO R START UP START UP XF M R XF M R UNIT AUX UNIT AUX 1A 1B XFM R XF M R 1A 1B 1H 1K 1F 1G 1L 1J 1E 1D 1C 1B 1A RIVER SERVICE CCW CCW SERVICE RCP RCP WATER WAT ER WAT ER CCW RIVER Charging Charging RIVER RCP WATER WATER SERVICE SERVICE RIVER WAT ER RHR RHR WATER RIVER WAT ER WAT ER AFW AFW CHARGING CT MT SPRAY CT M T SPRAY ESP Simplified SERVICE WAT ER Unit-1 4160v Normal Alignment (Unit 2 is similar) 66
Most Recent Root Cause (1-DL05) 3/4 During a routine train swap, the breaker for the 1C SW pump was momentarily closed but tripped free (open) 3/4 Root cause investigation attributed the failure to age and degradation of existing Allis-Chalmers breakers which exhibited:
z Excessive gap distance between the latch roll and the trip latch z Bending of the back plate. This is the mounting plate for the stop bolt.
67
Internal Operating Mechanism for Allis Chalmers MA350 68
Interim Action Plan 3/4 Analysis of high duty breakers on expedited schedule z Complete with exception of 2-DK04 (scheduled 11/28) , 1-DG02 (feeder breaker for 1R21) 3/4 Extend analysis to include all safety related breakers 3/4 Replacement of SW breakers with new vacuum breakers 3/4 Use the healthy breakers from SW replacements in F & G (after PM performed) 3/4 Expedite DCPs for Unit 1 & 2 F & G replacements 69
Long Term Plan 3/4 Total replacement of existing obsolete Allis-Chalmers MA350 breakers with Cutler Hammer vacuum breakers z Unit 2 DCPs (F &G) due by March, 2007 z Unit 2 replacements complete by Spring 2007 z Unit 1 DCPs (F &G) due by June, 2007 z Unit 1 replacements complete by end of 2007 3/4 Increased tracking by serial number of breaker locations and number of cycles 70
Breaker Operation Closed SAT Trip Free 71
Questions 72