CPSES-200500361, Annual Operating Report for 2004

Annual Operating Report for 2004

ML050680291
Person / Time
Site:	Comanche Peak
Issue date:	02/25/2005
From:	Madden F TXU Power
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
10CFR50.36, CPSES-200500361, RG-1.016, Rev. 4, RP-85, TXX-05033
Download: ML050680291 (15)

Text

A TXU

'wC Power TXU Power Mike Blevins Comanche Peak Steam Senior Vice President &

Electric Station Chief Nuclear Officer P.O. Box 1002 (E01)

Glen Rose, TX 76043 Tel: 254 897 5209 Fax: 254 897 6652 mike.blevins~txu.com Ref: #10CFR50.36 CPSES-200500361 Log # TXX-05033 RP-85 February 25, 2005 U. S. Nuclear Regulatory Commission Attn: Document Control Desk Washington, DC 20555

SUBJECT:

COMANCHE PEAK STEAM ELECTRIC STATION (CPSES)

DOCKET NOS. 50445 AND 50-446 ANNUAL OPERATING REPORT FOR 2004 Gentlemen:

Attached is the CPSES Annual Operating Report for 2004 prepared and submitted pursuant to guidance provided in C.1 b of U.S. NRC Regulatory Guide 1.16, Revision

4. The attachment also submits the annual Occupational Radiation Exposure Report as required by Technical Specification 5.6.1 contained in Appendix A to the Comanche Peak Steam Electric Station Unit 1 Operating License NPF-87 and Unit 2 Operating License NPF-89.

mTaS A member of the STARS (Strategic Teaming and Resource Sharing) Alliance Callaway

• Comanche Peak

• Diablo Canyon

• Palo Verde

• South Texas Project s Wolf Creek

TXX-05033 Page 2 of 2 This communication contains no new licensing basis commitments regarding CPSES Units 1 and 2. Should you have any questions, please contact Douglas Snow at (254) 897-8448.

Sincerely, TXU Generation Company LP By: TXU Generation Management Company LLC Its General Partner Mike Blevins By: /222%

red W. Madden Director, Regulatory Affairs DWS Attachment c - B. S. Mallett, Region IV W. D. Johnson, Region IV M. C. Thadani, NRR Resident Inspectors, CPSES

Attachment to TXX-05033 COMANCHE PEAK STEAM ELECTRIC STATION ANNUAL OPERATING REPORT 2004 TXU Generation Company LP 1

Attachment to TXX-05033 TABLE OF CONTENTS 1.0 Summary of Operating Experience 2.0 Outages and Reductions in Power 3.0 Personnel Exposure and Monitoring Report 4.0 Irradiated Fuel Inspection Results 5.0 Outage Related Single Radioactivity Release or Radiation Exposure to an Individual that Accounts for More than 10 Percent of Allowable Annual Values 2

Attachment to TXX-05033 1.0

SUMMARY

OF OPERATING EXPERIENCE The Comanche Peak Steam Electric Station (CPSES) is a dual unit pressurized water reactor power plant, supplied by Westinghouse Electric Corporation. It is located in Somervell County in North Central Texas approximately 65 miles southwest of the Dallas-Fort Worth Metropolitan area. Each generating unit core was originally designed for a warranted power output of 3411 Megawatt thermal (MWt). This output, combined with the reactor coolant pump heat output of 14 MWt, gives a warranted NSSS output of 3425 MWt, which is the license application rating. Both units rated thermal power was subsequently increased to 3458 MWt, which represents a 1.4 percent increase in core output (from 3411 to 3458 MWt). The reactor coolant pump heat output considered in the safety analysis was increased to approximately 16 MWt for both units. All safety systems, including the engineered safety features, are designed for operations at a maximum NSSS output of 3579 MWt and an associated maximum core output of 3565 MWt.

1.1 CPSES UNIT 1 CPSES Unit 1 achieved initial criticality on April 3, 1990. Initial power generation occurred on April 24, 1990, and the plant was declared commercial on August 13, 1990.

Since being declared commercial, CPSES Unit 1 has generated 118,003,248 net Megawatt-hours (MWH) of electricity as of December 31, 2004, with a net unit capacity factor of 81.36% (using MDC). The cumulative unit and reactor availability factors were 87.38% and 90.37%, respectively, as of December 31, 2004.

On March 27, 2004, the unit began a power ramp down for its tenth refueling outage.

The unit entered the refueling outage on the same day. During the refueling outage, 93 fresh fuel assemblies were loaded for Cycle 11. The refueling outage lasted 37 days 19 hours2.199074e-4 days <br />0.00528 hours <br />3.141534e-5 weeks <br />7.2295e-6 months <br /> and ended on May 4, 2004. Unit 1 reached 100% power on May 11, 2004.

During the refueling outage, the major work scope completed included:

• RCCA wear and swelling measurements

• Guide Tube Support Pin Replacement

• Alloy 600 inspections (Rx Head, BMI, Other RCS locations)

• 100% eddy current testing of the "U" tubes in all four steam generators

• Replace Low Pressure Turbines with upgrade turbines

• Install Upgrade on the Main Turbine/Generator Shaft Lift Oil System

• Perform 5-year inspection on Diesel Generator

• I&C Digital Upgrade to T/G Controls and Protection/Control Room Upgrade Figure 1.1 provides the generation profile of the average daily net electrical output of Unit 1 for 2004. Table 1.1 is a compilation of the yearly and total summaries of the operating data.

During this reporting period there were no failures or challenges to the Safety Valves.

3

Attachment to TXX-05033 1.2 CPSES UNIT 2 CPSES Unit 2 achieved initial criticality on March 24, 1993. Initial power generation occurred on April 9, 1993, and the plant was declared commercial on August 3, 1993.

Since being declared commercial, CPSES Unit 2 has generated 97,094,153 net Megawatt-hours (MWH) of electricity as of December 31, 2004, with a net unit capacity factor of 84.39 % (using MDC). The cumulative unit and reactor availability factors were 89.03% and 91.94%, respectively, as of December 31, 2004 There was no refueling outage for Unit 2 during 2004.

Figure 1.2 provides the generation profile of the average daily net electrical output of Unit 2 for 2004. Table 1.2 is a compilation of the yearly and the total summaries of the operating data.

During this reporting period there were no failures or challenges to the Safety Valves.

2.0 OUTAGES AND REDUCTIONS IN POWER 2.1 CPSES UNITI Table 2.1 describes unit operating experience including unit shutdowns and provides explanations of significant dips in average power levels for CPSES Unit 1.

2.2 CPSES UNIT 2 Table 2.2 describes unit-operating experience including unit shutdowns and provides explanations of significant dips in average power levels for CPSES Unit 2.

3.0 EXPOSURE AND MONITORING REPORT .

The personnel exposure and monitoring report for CPSES is provided in Table 3.0.

4.0 IRRADIATED FUEL INSPECTION RESULTS 4.1 CPSES UNIT I Visual examinations of Unit 1, Cycle 10 fuel assemblies were performed by inspection personnel by viewing the assemblies from the edge of Spent Fuel Pool #1 as assemblies were off-loaded from the core. Some randomly selected fuel assemblies were examined using underwater camera equipment which was performed concurrently with the poolside visual exams. All fuel assemblies appeared to be in good condition with no anomalies observed. In general, only light residual crud levels on the assemblies were observed which were consistent with crud patterns observed during previous refueling outage inspection campaigns.

Results of RCCA Examinations Performed During lRF10:

4

Attachment to TXX-05033 During the refueling outage (lRF10), Unit 1 control rods (RCCAs) were inspected by Westinghouse for cladding wear and rod tip swelling to determine the condition of the control rods prior to reaching their original design end of life (12 EFPY), which would occur during Cycle 11. The inspection results indicated minimal clad wear and no tip swelling and were therefore cleared for one more cycle of operation.

However, during the above inspections, it was discovered that RCCA R522 was missing one control rodlet (out of the 24 rodlets per RCCA). It was subsequently determined that the rodlet had separated from the RCCA hub and dropped into the corresponding guide tube of host assembly L1I sometime during either refueling outage 1RF09 RCCA shuffling, Cycle 10 operation, or during lRF1I RCCA inspections. A review of the results of the core flux maps performed during Cycle 10 did not reveal any discernible indications as to if or when the separated rodlet event occurred during the cycle. No known similar event has been reported in the industry. The limited clad wear and lack of any tip swelling observed during the inspections suggested that degradation of the RCCAs was not a factor in the separation of the rodlet. Additional detailed underwater camera visual inspections were performed on R522 in August, 2004 to support the Westinghouse root cause investigation. These inspections confirmed that the rodlet was still fully intact, including the threaded portion of the top end plug that screws into the RCCA hub finger. The root cause investigation concluded that this event was the result of an isolated manufacturing defect that allowed the rodlet to progressively unscrew from the hub during reactor operations.

Spare control rod R508, which had seen previous service in Unit 1, was re-inspected for wear and tip swelling prior to its use as the replacement for R522 in Unit 1, Cycle 11.

4.2 CPSES UNIT 2 There were no irradiated fuel inspections performed on Unit 2 fuel in 2004 5.0 OUTAGE RELATED SINGLE RADIOACTIVITY RELEASE OR RADIATION EXPOSURE TO AN INDIVIDUAL THAT ACCOUNTS FOR MORE THAN 10 PERCENT OF ALLOWABLE ANNUAL VALUES CPSES Units 1 and 2 did not experience any single release of radioactivity greater than 10% of an allowable dose limit during an outage or forced reduction in power of over 20% of designed power level during 2004.

During 2004 Unit 1 conducted a refueling outage (see section 1.1). During the outage activities, no individual received radiation exposure exceeding 10% of an allowable dose limit in a single exposure event. Exposure is tabulated in Table 5.0.

5

Attachment to TXX-05033 FIGURE 1.1 COMANCHE PEAK STEAM ELECTRIC STATION - UNIT 1 GENERATION PROFILE AVERAGE DAILY UNIT POWER LEVEL for 2004 1,400 1,200 1,000 a) 800 600 400 200 0

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC 6

Attachment to TXX-05033 TABLE 1.1 COMANCHE PEAK STEAM ELECTRIC STATION - UNIT I ANNUAL ELECTRIC POWER GENERATION DATA (2004)

YEAR CUMULATIVE Hours RX was Critical 7,917.00 111,102.43 RX Reserve Shutdown Hours 0 2870.89 Hours Generator On-line -7,877.88 110,194.10 Gross Thernal Energy Generated (MWH) 26,958,967 366,392,267 Gross Electric Energy Generated (MWH) 9,372,228 123,293,888 Net Electric Energy Generated (MWH) 9,018,126 118,003,249 RX Service Factor (%) 90.13 88.10 RX Availability Factor (%) 90.13 90.37 Unit Service Factor (%) 89.68 87.38 Unit Availability Factor (%) 89.68 87.38 Unit Capacity Factor (%, using MDC net) 89.27 81.36 Unit Capacity Factor (%, using DER net) 89.27 81.36 Unit Forced Outage Rate (%) 0 2.80 7

Attachment to TXX-05033 FIGURE 1.2 COMANCHE PEAK STEAM ELECTRIC STATION - UNIT 2 GENERATION PROFILE AVERAGE DAILY UNIT POWER LEVEL for 2004 1,400 1,200

---

- -- 119

_

- -- V - X T

• ,

_ _ _ w ,-

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1,000 800 3/20 Turbine Stop and Control Valve Testing, OPT-217 I

6/1I Turbine Stop and Control Valve 9/3 TurbihIC Stop and Control Valve

( Testing, C)PT-217

-

.

10/08 Loss of Heater Drain now, I

11/03 Runback from operator error when recovering from repairs to restore 'A' phase generator Testing, OPT-217 - I 2LT-2589A potential signal to and Turbine Turbine Control Stop and (EHC).

600 Control Valve Testing, OPT-217 400 200 0

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC 8

Attachment to TXX-05033 TABLE 1.2 COMANCHE PEAK STEAM ELECTRIC STATION - UNIT 2 ANNUAL ELECTRIC POWER GENERATION DATA (2004)

YEAR CUMULATIVE Hours RX was Critical 8,784.00 89,620.05 RX Reserve Shutdown Hours 0 2,366.46 Hours Generator On-line 8,784.00 89,070.28 Gross Thermal Energy Generated (MWH) 30,232,082 297,308,796 Gross Electric Energy Generated (MWH) 10,439,312 101,220,422 Net Electric Energy Generated (MWH) 10,038,851 97,094,153 RX Service Factor (%) 100.00 89.58 RX Availability Factor (%) 100.00 91.94 Unit Service Factor (%) 100.00 89.03 Unit Availability Factor (%) 100.00 89.03 Unit Capacity Factor (%, using MDC net) 99.38 84.39 Unit Capacity Factor (%, using DER net) 99.38 84.39 Unit Forced Outage Rate (%) 0.00 2.80 9

aI Attachment to TXX-05033 TABLE 2.1 COMANCHE PEAK STEAM ELECTRIC STATION - UNIT I UNIT OPERATING EXPERIENCE INCLUDING SHUTDOWNS AND POWER REDUCTIONS DURING 2004 METHOD OF TYPE SHUTTING DOWN F: FORCED DURATION* THE REACTOR OR NO DATE S: SCHEDULED (HOURS) REASON REDUCING POWER CORRECTIVE ACTION/COMMENTS 1 040211 F NA A NA On February 11, 2004 at 1629 a Unit I turbine EHC control system DC to DC converter failed. Failure of lof 2 EHC controllers to hydraulically isolate when intentionally deenergized resulted in an unplanned load rejection from 95% to about 71% reactor power. This meets the criteria for an NRC unplanned 20%

transient. Unit was stabilized at approximately 86% reactor power. Following repairs, the unit returned to full power on February 12, 2004 at 0224 and finished the month in that status. (Reference SMF-2004-000508) 2 040327 S 907.13 C 2 On March 27,2004 at 0900 the unit began downpower to enter I RFI0. Unit was tripped perprocedure at 1215 entering MODE 3. Unit entered MODE 6 March 30, 2004 at 2010. Unit exited MODE 6 after core reload April 24, 2004 and entered MODE 5 at 0039. On May 2, 2004 Unit entered MODE 2 and reactor was critical at 1615. Unit entered MODE I on May 3,2004 at 1154. Unit was synchronized to grid on May4, 2004 at 0723 ending IRF10. Duration of 37 days and 19 hours2.199074e-4 days <br />0.00528 hours <br />3.141534e-5 weeks <br />7.2295e-6 months <br />. The unit returned to full power on May 11, 2004 at 1023.

I) REASON 2) METHOD A: EQUIPMENT FAILURE (EXPLAIN) E: OPERATOR TRAINING AND LICENSE EXAMINATION I: MANUAL B: MAINT OR TEST F: ADMINISTRATIVE 2: MANUAL SCRAM C: REFUELING G: OPERATIONAL ERROR (EXPLAIN) 3: AUTOMATIC SCRAM D: REGULATORY RESTRICTION H: OTHER (EXPLAIN) 4: OTHER (EXPLAIN)

• INDICATES SHUTDOWN HOURS/OTHERWISE "NA" FOR NOT APPLICABLE 10

4.

Attachment to TXX-05033 TABLE 2.2 COMANCHE PEAK STEAM ELECTRIC STATION - UNIT 2 UNIT OPERATING EXPERIENCE INCLUDING SHUTDOWNS AND POWER REDUCTIONS DURING 2004 METHOD OF TYPE SHUTTING DOWN F: FORCED DURATION* THE REACTOR OR NO DATE S: SCHEDULED (HOURS) REASON REDUCING POWER CORRECTIVE ACTION/COMMENTS 1 041008 F NA A NA On October 08, 2004 at 1340, the unit reduced power to -60%

reactor power in response to a reduction in heater drain flow when a level transmitter failed. This meets the criteria for an NRC unplanned 20% transient While at reduced power, discretionary testing of the turbine stop and control valves was performed at about 75% reactor power. Unit returned to full power on October 9, 2004 at 0306. (Reference SMF-2004-003413) 2 041103 F NA G NA On November 03, 2004 at 1830 the unit experienced an unplanned runback to about 61% reactor power. This meets the criteria for an NRC unplanned 20% transient Upon restoring the Phase A generator potential feed to the turbine control system after maintenance, the turbine speed target setpoint had not been reset as required by procedure and the runback occurred as designed.

(Reference SMF-2004-003639)

I) REASON 2) METHOD A: EQUIPMENT FAILURE (EXPLAIN) E: OPERATOR TRAINING AND LICENSE EXAMINATION 1: MANUAL B: MAINT OR TEST F: ADMINISTRATIVE 2: MANUAL SCRAM C: REFUELING G: OPERATIONAL ERROR (EXPLAIN) 3: AUTOMATIC SCRAM D: REGULATORY RESTRICTION H: OTHER (EXPLAIN) 4: OTHER (EXPLAIN)

• INDICATES SHUTDOWN HOURS/OTHERWISE [NA0 FOR NOT APPLICABLE 11

Attachment to TXX-05033 TABLE 3.0 COMANCHE PEAK STEAM ELECTRIC STATION - UNITS I AND 2 2004 PERSONNEL EXPOSURE AND MONITORING REPORT

1. Personnel Total Person rem Work & Job Function Station Utility Contract Station Utility Contract Reactor Operations & Surveillance Maintenance&Construction 94 0 62 0245 0.000 0.139 Operations 192 0 129 2.032 0.000 0246 Health Physics & Lab 44 0 52 1.029 0.000 0.468 Supervisory & Office Staff 15 0 1 0.066 0.000 0.001 Engineering Staff 70 0 28 0201 0.000 0.028 Routine Plant Maintenance Maintenance & Construction 151 0 439 4.711 0.000 24.568 Operations 129 0 32 3.334 0.000 0.337 Health Physics & Lab 42 0 89 1.663 0.000 7.593 Supervisory & Office Staff 7 0 1 0.054 0.000 0.079 Engineering Staff 43 0 144 0.536 0.000 47.928 In-service Inspection Maintenance & Construction 7 0 24 0.014 0.000 0.496 Operations 8 0 4 0.123 0.000 0.054 Health Physics & Lab 2 0 6 0.013 0.000 0.054 Supervisory & Office Staff 0 0 0 0.000 0.000 0.000 Engineering Staff 13 0 57 0.948 0.000 4.416

• Special Plant Maintenance Maintenance & Construction 22 0 100 0.447 0.000 1.958 Operations 27 0 5 0.259 0.000 0.026 Health Physics & Lab 5 0 8 0.071 0.000 0274 Supervisory & Office Staff 2 0 0 0.011 0.000 0.000 Engineering Staff 9 0 49 0.130 0.000 5.112 Waste Processing Maintenance & Construction 12 0 15 0.011 0.000 0.176 Operations 13 0 6 0.137 0.000 0 243 Health Physics & Lab 25 0 14 0.470 0.000 0.074 Supervisory & Office Staff 0 0 0 0.000 0.000 0.000 Engineering Staff 2 0 0 0.032 0.000 0.000 Refueling Maintenance & Construction 49 0 123 1.054 0.000 1.678 Operations 38 0 8 1.363 0.000 0.033 Health Physics & Lab 26 0 63 0.917 0.000 3.539 Supervisory & Office Staff 2 0 1 0.012 0.000 0.004 Engineering Staff 16 0 91 0.231 0.000 16.732 Totals Maintenance & Construction 335 0 763 6.482 0.000 29.015 Operations 407 0 184 7.247 0.000 0.939 Health Physics & Lab 144 0 232 4.161 0.000 12.002 Supervisory & Office Staff 26 0 3 0.143 0.000 0.083 Engineering Staff 153 0 369 2.077 0.000 74.217 GrandTotals 1065 0 1551 20.111 0.000 116256

• Steam Generatorreplacement walkdowns

• Design Mfodifications 13

Attachment to TXX-05033 TABLE 5.0 2004 COMANCHE PEAK STEAM ELECTRIC STATION - UNITS 1 AND 2 OUTAGE RELATED RADIATION EXPOSURE TO AN INDIVIDUAL FOR A SINGLE MAINTENANCE ACTIVITY WHICH EXCEEDS 10 PERCENT OF AN ALLOWABLE ANNUAL DOSE LIMIT*

Individual's Maintenance Sinele Event Total Annual Activity Department Exposure (mrem) Exnosure (mrerm)

N/A N/A NIA N/A No activities exceeded the allowable 10 percent dose limit.

• Subject annual dose limit is 5000 mrem deep dose equivalent 14