ML053550267
| 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
r"powerCatawba Nuclear Station Service Water Project Update December 7, 2005
_.----------
Participants NameDhiaaJamilBillPitesaRegisRepko Dan McRainey Title Site Vice-President-CNS Station Manager-CNS Engineering Manager-CNS Project Director-Nuclear Service Water Project 2
Agenda*Opening Remarks*Station Performance-Reliability/Predictability-EquipmentPerformance
-SafetySystemResults-PlantEquipmentItems/Improvements
- Service Water Project Status-LowPressureServiceWater-WaterTreatmentSystem-Mock-UpPiping
-NuclearServiceWaterLakeIntakePiping-12DayNuclearServiceWaterOutage-ResourcePlan
- Miscellaneous Items and Closing Remarks Dhiaa Jamil Regis Repko Bill Pitesa Dhiaa Jamil 3
2005 In Review*Dukeand Cinergy Merger*Senior Site Management Changes*ISFSI Construction
- Technical Training Programs Accreditation Renewed*MOXLeadTest Assemblies Installed*Industry Recognition for Thermal Efficiency (BTU/kwh)and Generation Efficiency
($/kwh)*LowestDukeDoseforan Outage with SG Inspection and Lowest CNS Outage Personnel Contamination Events*No Licensee Event Reports*Green Performance I ndicators and Violations*No Reactor Trips*Improvements in Equipment Reliability 4
2005Unit1 Power History 110----------100 90-80-, 70...e60-.Q Q.-C e u 50-...0 Q.Main Feedwater LOPump1Bseamseal
" repair 30-20-10-1EOC15 Outage 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
2005Unit2 Power History 110 ,-----------------------.-
100----------------1,---------------------1 90-70 40 30'20MainTurbineEHC 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*Station Performance-Reliability/
Predictability
-Equipment Performance-SafetySystemResults-Plant EquipmentItems/Improvements
- Service Water Project Status-LowPressureServiceWater
-Water Treatment System-Mock-UpPiping
-NuclearServiceWaterLakeIntakePiping-12Day Nuclear Service Water Outage-ResourcePlan
- Miscellaneous Items and Closing Remarks Dhiaa Jamil Regis Repko Bill Pitesa Dhiaa Jamil 8
'----
Reliability I Predictability 2003 2004 2005 through October Unplanned Lost 15.7 16.8 3.8EFPD(doesnot include outage extensions)
Outage Extension 22 6.6 3 DaysLostGendaysto 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(12monthtotal)
HSS*MRFF 28 20 11(12monthtotal)
All UTSE*102 77 53(12monthtotal)
HSS UTSE 58 36 21(12monthtotal)
- MRFF-Maintenance Rule Functional FailureHSS-HighSafety SignificanceUTSE-UnplannedTechnical Specification Entry 10
Equipment Performance
- Significant Improvement in Component Cooling Heat Exchanger Performance
-Chemical addition capability
-De-chlorination-HX performance monitoring-Results: II2002to2003:2-3months (stainlesssteelHx cleaning)III 2004topresent:6-8 months (both stainlesssteelandbrass Hx cleaning)*DirectEffecton Safety System Unavailability 11
Unit1 Safety System Unavailability 2005 2004 HPI-Unit1 Emergency Power-Unit1 1.50%3.00%1.20%2.50%0.90%2.00%1.50%0.60%1.00%0.30%0.50%0.00%0.00%2003 2004 2005 2003 RHR-Unit 1 Emergency Feedwater-Unit1 1.50%1.50%1.20%1.20%0.90%0.90%0.60%0.60%0.30%0.30%0.00%2003 2004 2005 0.00%2003 2004 2005 12
Unit 2 Safety System Unavailability Emergency Power-Unit2 HPI*Unit 2 2.50%3.00%2.00%2.50%1.50%2.00%1.00%1.50%1.00%0.50%0.50%0.00%0.00%2003 2004 2005 2003 2004 2005 RHR*Unit2 Emergency Feedwater*Unit2 2.00%1.50%1.70%1.20%1.40%1.10%0.90%0.80%0.60%0.50%0.30%0.20%-0.10%0.00%2004 2005 2003 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 vesselISI*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 intakepipecleaned and coated 14
Agenda--*Opening Remarks*Station Performance
-Reliability
/Predictability
-Equipment Performance
-SafetySystemResults-Plant EquipmentItems/Improvements
- Service Water Project Status-Low Pressure Service Water-Water Treatment System-Mock-Up Piping-Nuclear Service WaterLakeIntakePiping-12Day Nuclear Service Water Outage-Resource Plan*MiscellaneousItemsandClosingRemarksDhiaaJamilRegisRepko Bill PitesaDhiaaJamil 15
Service Water Project Status Low Pressure Service Water*Systemprovides makeuptocoolingtowers,cools turbine and generator auxiliaries, containmentchillersand secondary systempumpmotors*Carbonsteelpipingbecame degraded from corrosion-cooling capacity was marginalduringhot weather*Restorationisto replacepipingwithHighDensity Polyethylene Piping (HDPE)*Cooling Tower makeuphasnewcontrolvalvesandHDPEpiping headers*Turbine/Service building distributionpipingchangedtoHOPE
- NewHOPEmain supply header installation in progressandwillbeinservicebyApril 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 supplyandthen de-chlorinate thetothelakeor Standby Nuclear Service Water Pond (SNSWP)*Allows higher concentrations of chlorine for greater biofouling controlandreducedHxFouling
- De-chlorination prevents exceeding NPDES discharge limits*Treats both Nuclear Service WaterandLow Pressure Service Water*Portions of Systemhavebeenplacedin operation*Low Pressure Service Water Chlorinationtobe operationalbyMay 2006*Effectiveness of chemical controls for Nuclear Service waterwillbe 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-ChlorinationSamIeBuildin 26
_._.-_.---------Mock-up Piping 27
Service Water Project Status Nuclear Service Water Mock-U Pi*Developed mock-uppiping-300 Feetof42inchpipeand100 feet of30inchpipe
- Demonstrated Capability of Equipment-High Pressure Water Cleaning-Abrasive Blast*Provedthecleanand coat process*TrainedCraftandInspection Personnel*Logistical Improvements Identified
-Handling of Coating Equipment-Removal of Abrasive Material-Sequence of Support Personnel(QC,FireWatch,Hatch Attendant)
- Contingency plans-Safety TrainingForMedical Emergency Response Team-WeldRepairs 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 WaterLakeIntakePiping (400 feet of48"piping)
- Built Two Snorkelsinthe Nuclear Service WaterPumpHouse*The Snorkels provide:-a QA 1 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 CofferdamatLakeIntaketo dewater and allow access 32 SEE VIEW"s-s"---------'----------
Service Water Project Status Lake IntakePiinDiaram 33
Snorkel Components Being Fabricated 34
Snorkel Preassembled for Testing 35
_.------------
Cofferdam Construction
, , 37
Causewayfromthe Catawba Parktothe Cofferdam 38
Cofferdam ViewedfromBoatRamp at Catawba Park 39
Service Water Project Status Lake Intake Piping Clean/Coat Process*Coatingmaterialhas Extensive Service History Within Nuclear Industry and Duke Power*QA ReceiptofMaterialandLevelB StorageofMaterial
- Coating Manufacturer provided TrainingandQualifiedCoating Contractor
- QA/QCServiceLevel1 Inspections ofEntireProcess
- Process Steps-HighPressure Water Cleaning-WeldBackingRingRemoval-100%EngineeringConditionInspection
-Biocide Treatment of Welds-Establish Environmental Controls-Abrasive Blast-Apply 3-Coat PlastocorCoatingSystem
-Robotic Video Inspection 40
Service Water Project Status Lake IntakePiin Results*All internalpipeandweld surfaces were inspectedbyateam of engineers to verifythatwall thickness remained above a minimumvaluerequiredbythe applicabledesigncriteria
- Engineering calculations determinedthattheexistingpipingwas designedwithalarge amount ofmargin(a factor of 5)over whatwasrequired.Awall thicknessof0.625inchespipingwas installedandthe minimumrequiredis0.125inches.*The EngineeringInspectionresultsindicatedthatALL welds exceeded the minimum required thicknesswithresultsasfollows:-30 welds were consideredinverygoodconditionwithlessthan1/8inchmetalloss-16 welds were consideredingoodconditionwith between 1/8inchandinchmetalloss-9 weldswerefoundwithlocalizedspotsof greater thaninchmetallossbutstillwith acceptablemetalwall thickness*Norepairswere necessarytorestoretheweldstorequiredwall 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
I Lake Intake Pipe After Abrasive Blast ILakeIntakePipe After Final Coating 45
_.------.--12 Day Nuclear Service Water Outages 46
Service Water Project Status12Day Nuclear Service Water Outages*Two12Day Nuclear Service Water Outages ScheduledtoBegin January 2006*Currently Pre-fabricating Piping*Laser ScanningBeingUsedtoObtain As-Built Conditions
- WorkToBeDone-Clean/Coat Welds in Nuclear Service Water Supply HeaderPipingfromPumpHouseto Auxiliary Building-Auxiliary building Isolation Valves and Crossover Piping-RNPump House Isolation Valves and Crossover Piping-Diesel Generator Isolation Valves and Crossover Piping 47
Service Water Project Status12Day Nuclear Service Water Outages*Sequence for clean/coat of welds in supply piping.requires:-System drain-High Pressure WaterCleanandvacuum
-Establish Environmental Conditions
-Engineering weld inspectionandrepair(as required)-Abrasive Blasting for surface preparation-QC surface prep inspection-QA1 coating application(handtrowel application) of only pipe welds 48 1 6 MO 1610:00 16111:0007005:CD500376Clean&coatRNpipingfrompumpstructuretoauxbldg 1512:001610:0007005:CD500062RNpumpstrainerpipingupgrade 1413:0007005:GD2001412A DIGRNpipeandvalvereplacement 1413:00Service Water Project Extended LCO 1411:0007005:CD1000641A DIGRNpipeandvalvereplacement 1411:00os 15:00 0915101015:000435:Drypipe 061.061 061.0605:000365:5etupforLCO(material,equipment,pipeculling,etc)0409:Removepipingandvalves0408:Replacepiping valves0406:Replacepipingan 06111:00 1418:00 i1iill***********
i!Il, 07005J:;D500063Addisolationvalves
&spoolstoRNdischargeheader 061M:00 0911:000411:Removepipingandvalves 061"3:00"0413:Removepipingandvalves 06"':00*1611:001623:0008003:0PSCleartagsandfill'A'train1623:001705:00 0432:0P5FlushRNsystem171714:000366:RNtestingandflowbalance 06100 1512:00 lReplace1 s2RN67A 1103:001215:000386:Weldrepair1215l>01315:000383:Abrasiveblastweldareas
.., 1315:001415:000437:Cleanpipe14 15:001503:00384:lnspectforcoating0385:Coatwelds 1603:01611:00 0387:C1ose manways0611:od0615:000380:0penmanways0615:00 0381:Hydrolaserpiping IIIIIIIII0405:Replacepipingand 0207:00*'A'TrainLCO07"3:000412:Replacepipingandvalves07 1"1:00 1418:00 110410:Replacepiping andvalyes11/30/05 11/30105 Service Water Project Extended LeO 2 JANUARY FEBRUARY 1 I 2 I 3 I 4 I 5 16_1718I9I10111141151161 17 U8 JJ]L20 121J22 123124125 1 261271281291 30131 L--1_LI:L3_LAJ5J 6 01111:00*3020:003020:003003:00 3003:00 2924:00 2924:00 2915:00 2915:00 2821:00 2821:00 22 d5:00*241+7:000420:Replacepiping and valves221:002323:000417:Removepipingandvalves 2323:000416:Replacepipingandalves J
0421:Removepipingandvalves 22111:000423:Removepipin9andvalves0425:Removepipingandvalves 2323:000424:Replacepipingand valves 221h:00 0371:CD500175Replace1&2RN69B 22 05:00,2211:000376:0PSTaganddrainfor'B'trainLCO 22111:000373:CD500062RNpumpstrainerpipingupgrade 22111:000375:CD1000641B DIGRNpipeandvalvereplacement10374:CD2001412B DIGRNpipeandvalvereplacement l221:002323:000419:Removepipingandvalves 2323:000418:Replacepipingandyalves J\j0372:CD500063Addisolationvalves
&spoolstoRNdischargeheader
\26 15:0027 03:00 0439:lnstalltemporary covers Iii§27 oloo2815:000392:Weldrepair2815:002915:000391:Abrasiveblastweldareas2915:003015:000440:Cleanpipe3015:003103:00390:lnspeelforcoating3103:000103:000389:Coalwelds0111:000388:Closemanways 1 0111:000123:000368:0PSClearta9Sandfill'6'train
., 01 23:0002 05:00 0430:0PSFlushRNsystem
, 0205:0002 14:000367:RNtestingandflowbalance*
2211:000369:CD500376Clean
&coatRNpipingfrompumpstructuretoauxbldg0395:0penmanways22 1iiO 2515:000394:Hydrolaserpiping Y i 2515:002615:000438:Drypipe26 03:QQgy 03:000393:Engineeringinspection IIIJiI 1807:000377:SetupforLCO(material,equipment,pipecutting,etc)'B'TrainLCO I: 136 37 jl: 40*41 42 43 44 45 46 47 48 51 1152 1153 11 54 155 56 I': 159 60 , I" I,:: 1 164 165 66
Service Water Project Status12Day Nuclear Service Water Outages*Project Contingency Plans:-StartDatecouldbe delayed in case of severe weather-Welding resources and equipment available in caseweldrepairsarerequired
-Additional coating equipment available-Coating scope reductionplanin place-Back-out plans for pipe replacements
-Additional environmental control equipment available 51
Service Water Project Status12Day Nuclear Service Water Outages*OperationalRiskMitigationPlansInclude:
-Minimize maintenance activities on opposite train equipment-Protect and increase monitoring of opposite train equipment-AffectedtrainDGstobe maintained"available"-Component Cooling Water (CCW)systemtobeincrosstrain alignment during train outages-Continuously staff the Standby Shutdown Facility 52
Service Water Project Status 12 Day Nuclear Service Water Outages*Operational Risk MitigationPlansInclude:
-Changes have been made to loss of power procedures to address local throttling of AFW flow-Changeswillbe made to plant procedures for the abilitytocrosstiethe CCW headers-Operations use of Configuration Risk Management Programtocontroland limit activitiesatthestation
-Outage Control Centerwillbestaffed during each train outage 53
Service Water Project Status 12 Day Nuclear Service Water Outages*OperationalRiskMitigationPlansInclude:
-Operatorswilldo justintime review of loss of service waterandloss of CCW procedures-No maintenancewillbeallowedinthe switchyard
-Outagewillbeduringthetime of year with lower risk of severe weather-Increasedfocusbyallplant personnel (OPS, Maintenance, Engineering and Management)dueto 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:*$285millionin projected project cost*Securedrawmetal 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 peakwillbe572 58
SWP Resource Plan*Contractor Oversight Improvements:*Initially,SWP contractor oversightdidnotkeep pacewiththe rapid growth of the project organization
- Corrective actions were implemented in response to observations and incidents*Improvementsweremadetothe contractor oversight plan*Additional SWP oversight resourceshavebeen provided*Communications and integrationbetweentheSWPteamand the station organization are significantly improved*Dedicated contacts within Operations and Work Control established for SWP*Management observations targetedatSWP activities increased 59
Agenda*Opening Remarks*Station Performance
-Reliability
/Predictability
-Equipment Performance-SafetySystemResults-Plant EquipmentItems/Improvements
- Service Water Project Status-LowPressureServiceWater
-Water Treatment System-Mock-UpPiping
-Nuclear Service WaterLakeIntakePiping-14Day NuclearServiceWaterOutage-ResourcePlan
- Miscellaneous Items and Closing Remarks Dhiaa Jamil Regis Repko Bill Pitesa Dhiaa Jamil 60