ML19327B217

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Forwards Description of Electrical Enhancement Plan to Upgrade Understanding of Plant Electrical Design Basis. Configuration Which Existed Prior to Recent Changes Under Evaluation to Verify Design Capability
ML19327B217
Person / Time
Site: Crystal River Duke Energy icon.png
Issue date: 10/20/1989
From: Widell R
FLORIDA POWER CORP.
To:
NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
Shared Package
ML19327B218 List:
References
3F1089-16, NUDOCS 8910270125
Download: ML19327B217 (20)


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. October 20, 1989 3F1089-16 -

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U.S. Nuclear Regulatory Commission Attn: Document Control Desk

. Washington, D.C. 20555 Sub-lect: Crystal River Unit 3 .;

Docket No. 50-302 i' Operating License No. DPR-72 Electrical Enhancement Plan

Dear Sir:

Please find attached five copies of a description of the plan FPC E

has developed to upgrade our understanding of the CR-3 electrical p design basis. This includes two primary features: a rescheduling

! of our existing. Configuration Management (CM) plans to be initiated

! immediately and expansion of the present CM program calculation review to include a full revalidation of the CR-3 electrical I distribution systems. FPC considers this to be an extremely l thorough program and believes the schedule to be appropriate to l' produce a high quality product. We will review this with your l staff at our November 1, 1989 meeting and anticipate incorporating l any' improvements your staff may recommend.

L During our recent meeting at the CR-3 Site and previous conversations it is apparent that concerns regarding overall plant safety with the known electrical issues still exist within the NRC  !

staff. FPC hereby communicates our basis for considering the plant l to remain well supported by the present electrical systems design ,

and is safe to operate while our revalidation efforts are being completod. i The EDG's are both capable of supplying sufficient emergency AC power for all likely events. A large LOCA concurrent with a loss of offsite power scenario can load the "A" EDG to approximately 3112 KW which is within its 30 minute rating. The probability of such a scenario is 4.8 E-8 per 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> period as modeled in the recently reviewed CR-3 PRA. The operator action to reduce loading below 3000 KW is the removal of EFP-1 which is not needed in such scenarios. Further, CR-3 has been analyzed against the NRC's leak-0910270125 891020 PDR ADOCK 05000302 i j

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' GENERAL OFFICE: 3201 Thirty fourth Street South e P.o. Box 14042 . St. Petersbur0, Florida 33733 * (813) 866- 51 y A Florida Progress Company

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L October 20, 1989 3F1089-16 Page 2 before-break criteria and a GDC-4 exemption issued. Therefore, such LOCA's are no longer credible events.

The existing CR-3 station batteries are capable of supplying needed DC loads. The DC loads are now distributed in a configuration such l that actual loads are less than tested loads. The configuration I which existed prior to recent changes are being evaluated to verify design capability. Nevertheless current DC supplies are adequate.

l The CR 1/2 startup transformer is the backup offsite power supply and the alternate AC source for our plant design. It requires manual action from the CR-3 control room to lineup this configuration. The limitation on its capacity when large loads are I

started is clearly annunciated in the control room and expeditious actions can be taken to alleviate the situation. Thus, the source availability is not significantly impeded.

These issues represent compliance and design concerns which warrant the attached actions. They do not compromise plant safety. The actions FPC has planned'for Refuel 7 will constitute significant improvements and the attached reviews will provide additional confidence that not only are the systems adequate but that significant margin is available and operator burden is lessened.

We look forward to discussing the attached plans with the staff and I are strongly committed to a cooperative effort at better understanding the CR-3 electrical design. We welcome staff input to assure mutual confidence is built by the results of these j reviews.

l-l Sincerely, 1

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l Rolf C. Widell, Director Nuclear Operations Site Support RCW/KRW/wla xc: Regional Administrator, Region II Senior Resident Inspector l

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Enclosure #1

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l L FLORIDA POWER CORPORATION L

ELECTRICAL SYSTEM

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DESIGN BASIS

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RECONSTITUTION EFFORT FOR

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CRYSTAL RIVER 3

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OCTOBER 20,1989 1 e

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ELECTRICAL SYSTEM DESIGN BASIS RECONSTITUTION t

  • The following discussion provides an overview of the Design Basis Reconstitution effort for Crystal River 3. In addition, specifics are provided as to the expected scope to be encompassed by this effort.for the three primary Electrical Systems.

DESIGN BASIS RECONSTITUTION OVERVIEW The Design Basis Reconstitution effort at Florida Power Corporation is a comprehensive and thorough process directed by the Configuration Management Plan (CMP) dated September 7, 1988 (This '

plan was provided to the NRC at the NRC/FPC management meeting held ,

at Crystal River 3 on October 18, 1989.) This plan is the written >

document accepted by FPC management as the overall scope of work for the Nuclear configuration Management section of the Nuclear Operations Engineering and Projects Organization. Two of the seven programs in the CMP relate directly to the design basis reconstitution effort.

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Program No. II, " ENHANCED DESIGN BASIS DOCUMENT (EDBD) PROGRAM",

I describes the plan of action for developing Enhanced Design Basis l Documents. This program was developed based on INPO report  ;

j " Recommendations on Design Basis Documentation in the Nuclear

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Utility Industry" and will address previously identified weaknesses of the existing CR-3 Design Basis Documents such as:

. incorrect / incomplete source reference documentation, i.e.,

doce.ments that contain the basis for design parameters

. lack of systems interface requirements identification

. lack of margins identification

. referenced calculations not verified / checked The resultant EDBD will integrate the CR-3 design requirements and design related licensing commitments into a single document for each identified system and will include appropriate design basis information to support both Safety and Key Operational functions (see attachment 1 for sample EDBD) . The EDBD Program has been designed to produce a user-oriented document while achieving the following objectives.

. Provide an effective and reliable source of design basis information.

. Ensure the accuracy, reliability, consistency, and credibility of the available CR-3 calculations used as references in the EDBD's.

. Ensure the availability of documentation to support (document the basis for) parameters identified in the EDBD's.

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. Provide assurance that the design related licensing co.mmitments are reflected in the EDBD. '

. ' Ensure that key engineering requirements and assumptions critical to plant safety are identified in the EDBD.

4 The process for implementing the EDBD Program is described in detail in the Configuration Management EDBD Plan revised 9/20/89.

(The plan has recently been revised to incorporate enhancements l based on the two pilot EDBD's developed earlier this year.) The -i process for developing an EDBD is very methodical and extensive and can be summarized as follows: ,

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1. Develoo System Loaic Tree Diaarams (see attachment 2 for samole Loaic Tree) . The Logic Trees are the first stage in j the development of the EDBD's. They are developed to outline  ;

-(in an easy to understand visual format) the legal j E requirements, safety functions, implied system parameters, and l component functional requirements for the system. This is accomplished by reviewing in-depth system specific documents )

! and identifying the safety requirements and the key parameters  !

and components which are necessary for the system to achieve j its design safety function. J l 2. Identify. Retrieve, and Cataloc Potential EDBD Inout Sourceg. l l The existing CR-3 Design Basis Documents and FPC files, SEEK j

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system, microfiche, etc. are reviewed to identify sources of information which will support the EDBD development. These L sources are also input into a PC-based relational database ,

l program to provide better traceability and accessibility  ;

l during the EDBD development. Additional sources identified l after this initial review are also input into this program for  !

l future reference. The following types of documents are considered for review for identifying input sources.

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l' - Existing Design Basis Documents

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Analysis Basis Documents  ;

I - Calculations and Analyses  !

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CR-3 Licensing Basis 1

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NSSS/A-E Design Criteria, Standards, Specifications, and Design Reports

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Special Project Reports  ;

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NSSS/A-E Correspondence l

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Modification / Design Change Packages l

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Drawings

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Procurement Documents

3. Inout Source Document Review. All documents identified as potential input sources are reviewed to determine their contribution to the EDBD. A form "EDBD Source Data Sheet" is completed to document its applicability and to further characterize the contents of the document into design basis topics. I

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4. EDBD Prenaration. Utilizing the Logic Trees and information i

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from the applicable source documents, the EDBD is prepared in draft form. Two guidance documents, " Format and Content i Guidelines" and " Writers Guide", which are part of the EDBD l

  • Plan are used to develop the EDBD. This ensures that all the I appropriate topics, are addressed and provides for consistency j

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in the presentation of the information.

5. EDBD Review. 'In addition to the typical design control review performed by the EDBD contractor organization, the EDBD draft i receives a review by the FPC System Engineering group as a minimum and others as deemed necessary.

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6. Problem Identification. As with any process for which design information is being retrieved, reviewed, and dispositioned, I there is potential for problems that cannot be readily resolved. These types of problems are identified during the EDBD development as an Open Item Report. Problems that imply )

a potential safety concern or are suspected design basis i issues will be handled in accordance with FPC Nuclear Operations Department Procedure NOD-17, " Design Basis Issues '

Resolution".

7. EDBD Final Issuance and Control. After all comments to the draft EDBD are reconciled, a " final" document is approved. ,

The EDBD is distributed into the Design Basis Document manual replacing the existing Design Basis Document for the respective system. The manual is a controlled document which is distributed to various individuals / departments throughout

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Nuclear- Operations including Enginecring, Operations, l

Licensing, Training, and Quality Programs. Maintenance of the

  • L Design Basis Document is controlled by Nuclear Engineering Procedure NEP-216, " Design Basis Document".

The systems included within the present scope of the EDBD Program were selected based upon their safety classification, importance to safety, the FPC PRA model, and interviews with operations personnel. Thirty-seven systems have been identified and are scheduled to be developed as shown on the EDBD systems schedule (see attachment 3). To date, the two pilot systems (Main Steam and Decay Heat Removal) have been completed and issued, and the second group of systems (Core Flood, Emergency Feedwater/EFIC, Reactor Coolant, and Makeup & Purification) is under development with an earlier than expected completion of January 1990. In addition, the three primary electrical systems (AC Power, DC Power, and Emergency Diesel Generator) were authorized for an early start, and completion is expected for these systems by March 1990. The schedule as shown on the attached chart is intended to be a baseline for budgeting and manpower planning. It should be noted that the schedule and/or sequence may change to accommodate or coordinate with other activities as was the case with the electrical systems.

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1 The second program in the Configuration Management Plan that relates directly to the design basis reconstitution effort is Program No. III, "EDBD FIELD VALIDATION PROGRAM". This program is intended to validate that the plant actually conforms to the EDBD and its source documents. The program was essentially modeled

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after the NRC "SSFI" technique. The following . objectives are expected to be achieved as a result of this program.

. Systems are capable of performing the safety functions q required by their design baties.

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. Testing is adequate to demonstrate that the systems are I capable of performing their safety functions, l

.. Ensure agreement between FSAR, Tech Specs, Procedures, EDBD's,

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. Operator and maintenance technician training is adequate to e ensure proper operations and maintenance of the system.

. Human. factors considerations relating to the selected systems (e.g., accessibility and labeling of valves) and the systems

(' supporting procedures are adequate to ensure proper system i operation under normal and accident conditions.

The Field Validation effort is performed by a dedicated team of individuals located at the plant site. After an EDBD is completed, the Field Validation team systematically breaks the document down

'into sections. The system and component parameters are listed individually on a form " PARAMETER VALIDATION SHEET" which must be

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completed to document validation of the parameter. During the validation, walkdowns are performed, discussions with plant personnel are held, and plant procedures and drawings are compared 3 to the as-built plant. In addition, the source documents (references) are validated on a " REFERENCE VALIDATION SHEET".

l Discrepancies found as a result of the validation effort are I

recorded on a Validation Problem Report (VPR) and referred to the

. FPC supervisor for disposition. Discrepancies that appear to be I

significant and represent a suspected design basis issue are handled in accordance with Nuclear Operations Department procedure NOD-17, " Design Basis Issues Resolution". The schedule for the Field Validation is simply to follow the completion of EDBD itself.

The validations for the two pilot systems are presently underway with completion expected by December 1989.

ELECTRICAL SYSTEMS SPECIFICS l As a result of the recent discoveries of several problems in the i electrical area, FPC believes it is prudent to accelerate the

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schedule for the design basis reconstitution for the Electrical Systems. The above described programs (EDBD Development and Field

. Validation) will be applied to the AC Power, DC Power, and l Emergency Diesel Generators systems on a priority basis. In l

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d addition, a comprehensive Electrical Calculation Enhancement effort will be performed as described in Enclosure 2, " Electrical Calculation Enhancement Program". The scope of equipment and L components expected to be addressed by the EDBD effort is l

l AC Power l' 230KV Substation CR-3 Startup Transformer CR-1&2 Startup Transformer 4160V Non-segregated Phase Bus Duct 4160V and 480V Switchgear Including Breaker

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Control and Protective Relaying 480V Motor Control Centers AC Distribution Panels 120V Vital AC Power and Control Cable

! Cable Raceway and Separation 1

Electrical Penetration Assemblies l' DC Power Batteries L Battery Chargers

[' DC Ground Detection Disconnect Switches and Bus Duct DC Distribution Panels Emeraency Diesel Generators

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Diesel Engine Electric Generator Fuel Oil Transfer Controls l

i Jacket Coolant Loading Air Cooler Load Shedding -

L Lube Oil Generator Protection '

l Compressed Starting Air Engine Exhaust ELECTRICAL SYSTEMS EDBD SCHEDULES As mentioned above, the EDBD effort for the Electrical Systems were authorized for an early start. These efforts were initiated as of October 7, 1989 (original schedule had 11/90 start for Emergency L Diesel Generators and 7/91 start for AC and DC power). The Logic Tree phase of the effort is presently under development with completion expected in December 1989. The Logic Trees will provide a better definition for the full scope of equipment necessary to be addressed as part of the EDBD. The final EDBD's for these systems are expected to be completed and issued in March 1990. The respective Field Validation efforts will then begin with the last l system to be completed by October 1990.

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SUMMARY

In' summary, FPC believes the Configuration Management efforts (EDBD

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Enhancements) will baseline the electrical systems design bases and i

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provide the appropriate information' for proper operation,

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maintenance, and design control related to these' systems.

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FLORIDA POWER CORPORATION

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ELECTRICAL CALCULATION u

ENHANCEMENT PROGRAM l

l OCTOBER 20, 1989

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SUMMARY

FPC is initiating an' Electrical Calculation (EC) Enhancement Program for the purpose of identifying and implementing specific activities which will ensure

the continued design adequacy and regulatory compliance over the life of the Plant. This effort is an extension of the Configuration Management Program described in Enclosure #1.

I When Crystal River #3 was designed the traditional electrical calculations were done by hand to sunort the procurement of the electrical equipment. Small loads were grouped together to facilitate the calculations. Revisions to the plant normally impacts the groups which by themselves do not impact the accuracy of the calculations. Major up-dates were done as required.

FPC is actively involved in such programs as Safety Performance Improvement Program (SPIP) and Technical Specification Improvement Program. FPC has also improved our Design Review, Root Cause Analysis, Vendor Information, Operating Experience Review and related processes. During these activities FPC has found cases of electrical calculations containing errors. The types of errors are:

. Calculations not in enough detail

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. Incorrect assumptions '

. Incorrect equipment timing 41

. Error in Power Factor The Enhancement Program will revalidate the design activities performed in support of the CR3 AC and DC Distribution System. This program will also pull together the various revalidation activities that have been performed to-date and will be performed during Refuel VII on Emergency Diesel Generator. FPC will utilize state-of-the-art computer software to configure and model AC and DC distribution systems which will enable CR3 to perform on-line Short Circuit, Voltage Drop and Load Flow Analyses.

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' DETAILED DESCRIPTION 0F THE EC EM4ANCEMENT PROGRAN t-FPC is assigning this' program to key personnel in the Engineering Staff with strong support by our Licensing Group, Protective Relay Department, and contract support. An organizational chart of the program is attached.

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l.ICENSING FPC will perform an in-depth review against all Crystal River #3 Licensing documents, NRC Generic Letters, Bulletins, Notices. This effort will assure that the - CR3 Electrical Distribution Systems reflect and comply with ' the CR3

!. Regulatory Requirements. l AG <

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1 FPC will configure the Crystal River #3 AC Electrical System on a Personal

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Computer dedicated in the Electrical area for this program implementation. The following calculations / activities will be performed on this machine: _

. Data Base of "as installed" data: j

. Nameplate data of motors, transformers, will be read in the field. .

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. Manufacturers rating of relays, cables, inverters, and panel boards will be developed.

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. Field validation of protective devices installed configuration. l

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. The length of each power circuit taken from the marker tapes j when the cables were installed, will be documented. )

. Short Circuit Calculations to ANSI C37.010 to the following levels will be performed, (see Attachment #1):

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. 4160 Volt Buses

. 6900 Volt Buses b '

. 480 Volt Switchgear Buses

. 480' Volt Motor Control Centers

. 480 Volt Motors

. 120 Volt Breaker Panels

. Voltage Drop Calculations to the following levels will be performed, (see Attachnent #2):

. 4160 Volt Buses

.- 6900 Volt Buses e 480 Volt Switchgear Buses

. 480 Volt Motor Control Centers

. 480 Volt Motors

. 120 Volt Motor Control Circuits .

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. Load Flow Calculations to the following levels will be performed, _ .

(see Attachment #2)

. 4160 Volt Buses

. 6900 Volt Buses e 480 Volt Switchgear Buses

. 480 Volt Motor Control Centers

. 480 Volt Motors

. 120 Volt Breaker Panel (Primary side of transformer)

Please note that Attachments 1 and 2 are Preliminary. The Attachments represent loads in " Typical" format. It is FPC's intent to analyze all  ;

loads on a given bus, except for some non-safety related loads which will be lumped in groups.

Also included in the program will be a review of all power cables to insure their selection for current carrying capabilities is correct. The voltage drop within 3

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2 the control circuits of motor control circuits will also be reviewed. This-is (g . especially important'since each Motor Control Center control circuit has its own control transformer providing an additional impedance. This effort will be done by models that bound groups of circuits and individual circuits as needed.

The major AC Electrical Components will also be certified to insure their size and rating is proper. This includes:

Start-Up Transformer Non-Segregated Bus Duct Switchgear.

Reactors Inverters The main distribut' ion system provides power for the safety related and non-safety related loads. 'Therefore, both are included in the scope of this' work as -

- necessary to support the safety related equipment. Specific activities that can

- be segregated'into safety vs. non-safety and do not impact the safety related -

. equipment are not being committed to. An example of this is a control circuit of a non-safety related motor operated valve.

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FPC will use computer technology to support the calculation / activities to be 1

1 I performed as part of the DC portion of the enhancement. i

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A data base for DC equipment will be developed similar to that described in the

, AC section.

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. Nameplate data of motors, chargers, will be read in the field. ,

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. Manufacturers ratings of relays, cables, panel boards, and batteries will be developed from manufacturer data.

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e Field validation of protective devices installed configuration.

. The length of each power circuit taken from the marker tapes when the cables were installed will be documented.

A short circuit analysis will be done to establish the fault current on the downstream side of all protective devices. This will be done at the 250 volt and 125 volt level. (see Attachment #3) j A voltage drop analysis will also be performed to all safety related equipment.

This includes fuse panels, motors, motor control circuits. (seeAttachment#4)- j A load flow analysis will be done to the same level as the voltage drop analysis.

1 Please note that Attachments 3 and 4 are Preliminarv. The Attachments represent loads in " Typical" format. It is FPC's intent to analyze all loads on a given I panel, except for some non-safety related loads which will be lumped in groups. l l

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Also included in the program will be a review of all power cab 1es to insure their selection for current carrying capabilities is correct. '

The major DC components will also be verified to insure their size and rating are proper. This includes:

Batteries Battery Chargers Each battery will be analyzed to determine all the equipment that will operate and their operating times for a loss of offsite power and no diesel generator.

This analysis will be for a duration of two hours. With this analysis a discharge profile will be developed for each battery half (125VDC) and the resulting voltage.

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L This analysis will be performed with the new safety related batteries being installed during Refuel VII. FPC has scheduled a project to add a non safety N related battery to the plant. This will allow the large non-safety related loads to be removed from the existing safety related batteries. The computer model of the CR3 DC distribution system will be utilized to size the new non safety related batteries which are scheduled for installation prior to Refuel VIII.

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The computer model will also enable FPC to calculate the discharge profiles based on the loads left on the existing safety related batteries. The DC coping capability required by the FPC station blackout assessment will be reevaluated to reflect the new safety related and new non-safety related batteries. l G90RDINATION The AC and DC protective devices used at Crystal River #3, will be reviewed to insure they are rated for the intended service. This includes continuous and fault. conditions. This coordination will be done for all safety related

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equipment and non-safety related equipment that impacts safety related equipment.

The protective devices associated with the 230KV substation, start-up transformer, 4160 volt level and 6900 volt level will be evaluated by the Florida Power Relay Department.

The protective devices associated with the 480 volt switchgear will be reviewed including coordination curves.

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Breakers and fuses used at the 480V Motor Control Center, 120VAC Vital Bus Panels,125VDC, 250VDC will be individually verified.

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EMERGENCY DIESEL GENERAT9RS (EDG)

The Diesel Generator has received rigorous analysis within the last two years.

The analyses have been maintained and will be updated with modifications that effect it due to MARS being installed during Refuel VII. The revalidation activities performed to date and those planned for Refuel VII were reviewed with the NRC staff during our meeting held on 8/31/89. This program will pull together these activities and will evaluate the results of EDG revalidation against the output of above described program. No other analysis is being considered.

FIELD TEST FPC will use test data when it is available to support the calculations.

Also some instrumentation will be added to gather additional field data as necessary to support the project. l SCHEDULE ,

The attached schedule is based on FPC's preliminary assessment of the project scope. This schedule assumes that FPC will be able to procure an acceptable software program to model the AC and DC systems at CR3. If FPC must develop the software in-house, the completion date of the project may be impacted. FPC will '

keep the staff informed of this critical milestone as well as our progress on the entire program.

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ELECTRICAL CALCULATION DHWICEMENT PROGRAM  ;

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PROJECT MANAGER

' ENGINEER

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i FPC FPC

LICENSING NUCLEAR CONTRACTOR (S) CONfRACTOR(S)

ENGINEERING l

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ESTABLISH THE CR3 . SELECT SOFTWARE . PROTECTIVE RELAY DC ACTIVITIES ELECTRICAL REGULATORY . DEVELOP DATA BASE CALCULATIONS & . SHORT CIRCUIT REQUIREMENTS . AC CALCULATION CURVES & SETTINGS . VOLTAGE DROP 4

. SHORT CIRCUIT (480V & LOWER) . LOAD FLOW

. VOLTAGE DROP . CABLE AMPACITY

. LOAD FLOW . VERIFY PROTECTIVE i RELAY SETTING (4160V .

. VERIFY PROTECTIVE AND HIGHER) l RELAY SETTING (480V l AND LOWER)

! . OL LOAD RELAY

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. VERIFY CABLE AMPACITIES l FPC/ CONTRACTOR (S) FPC FPC

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SUPPORT CONFIGURATION MANAGEMENT RELAY DEPARTMENT

. GATHER FIELD DATA . INTERFACE . PROTECTIVE RELAY CALCULATIONS,
CURVES, SETTING (4160V & HIGHER)~

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ELECTRICAL CALCULATION ENHANCEMENT PROGRAM ,._..

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- ACTIVITY 1989 . 1990

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START PROJECT & ASSIGN WORK' X X f REVIEW AND ESTA.BL!SH _ _ __ ._ ,_; . _ .

  • LICENSING BASIS X X X i

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SELECT SOFTWARE'AC ~ ~ ~

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BUY AND RECEIVE ._.

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GATHER ALL FIELD DATA - AC & DC X X ~

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GATHER AL'L DESIGN DATA - AC & DC ~ X' X X X X X' ~X~X X ~ ~

VALIDATE PROGRAMS X X LOAD DATA BASE X' X ~ X X ~ ~ X ~ X [X 1

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EPUT COMPONENT DATA'INTO MODEL X X ~ X X X ' X'~~X '.

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PERFORM SHORT CIRCUIT ANdLYSIS ~~ ~ X" X^ 'X

! PERFORM VOLTAGE DROP ANALYSIS _. .__ . XiX'[X PERFORM LOAD FLOW ANALYSIS ~

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i POWER CABLE REVIEW ~ ~ ~

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CONTROL CIRCUIT VOLTAGE DROP X X REVIEW MAJOR AC COMPONENTS X X

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