ML17347A587

Performance Rept,1986. W/870515 Ltr

ML17347A587
Person / Time
Site:	Saint Lucie, Turkey Point, 05000000
Issue date:	12/31/1986
From:	Dickey J, Woody C FLORIDA POWER & LIGHT CO.
To:	Grace J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
References
NUDOCS 8706300996
Download: ML17347A587 (30)

Text

REGULATORY INFORMATION DISTR IBUTIQN SYSTEM (R IDS )

ACCESSXQN NBR 8706300996 DOC. DATE: 86/12/31'OTARXZED'O DOCKET F*C IL: 50-000 Generic Docket 05000000 50-250 Turkey Point Plant. Unit 3> Florida Power and Light C 05000250 50-251 Turkey Point Plant> Unit 4> Florida Power and Light C 05000251 50-335 St. Lucie Plant> Unit 1> Florida Power Zc Light Co. 05000335 50-38'P St. Lucie Plant. Unit 2. Florida Power 8< Light Co. 05000389 AUTH. NAME AUTHOR AFFILIATION.

DICKEY> J. W. Florida Powe~ ~c Light Co.

WOODY> C. O. Florida Power Zi Light Co.

RECIP. NAME RECIPIENT AFFILIATXON GRACE. J. N. Region 2> Office of Director'UBJECT:

"Performance Rept> 1986." W/870515 ltr:.

DISTRIBUTION CODE: IE01D COPIES RECElVED: LTR ENCL SIZE:

TITLE: General (50 Dkt)-Insp Rept/Notice of Violation Response NOTES:

RECIPIENT COPIES RECIPIENT COPIES ID CODE/NAME LTTR ENCL ID CODE/NAME LTTR ENCL PD2-2 PD 1 NcDONALD> D 2 2 TQURIGNY> E 2 2 INTERNAL: AEOD 1 1 DEDRO ENF LIEBERMAN 1 NRR ROE> N. L NRR/DOEA DIR 1 NRR/DREP/EPB NRR/DREP/RPB 2 2 NRR/DRIS DIR N~R JPMAS/ILRB 1 OGC/HDS2 G 1 1 RES DEPY GX RGN2 FILE 01 1 EXTERNAL: LPDR 2 2 NRC PDR NSIC 1 TOTAL NUMBER OF CQP IES REQUIRED: LTTR 23 ENCL 23

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ivlay 15, 1987 Dr. 3. N. Grace Regional Administrator, Region II U. S. Nuclear Regulatory Commission 101 Marietta Street Suite 2900 Atlanta, GA 30323

Dear Dr. Grace:

The enclosed "Nuclear Performance Report 1986" provides an overview of Florida Power 2 Light Company's (FPL) nuclear operations and performance for 1986. The utility and its customers depend on safe, reliable, economical power from our four nuclear units. Continued excellent overall performance enabled nuclear power to fill more than 32% of our customers'lectrical energy demand.

During 1986, safety remained the primary goal of FPL's Nuclear Energy Department. Achievements in this and other strategic areas such as training, maintenance, and reliability came as a direct result of our Quality Improvement Program. V/e are proud of our accomplishments and confident of continued improvement.

Sincerely, Group Vi esident Nuclear rgy an FPL Group company

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Introduction or the nuclear power indus-try in the United States, 1986 was a year of signifi-cant achievement.

Although overshadowed world-wide by the events at Chemobyl, the nation's growing number of nuclear facilities powered past the 1,000th reactor-year of safe operating experience. More than 16 per-cent of the country's electricity approximately 405 billion kilowatt hours was generated by nuclear energy in 1986.

It was the largest amount of nuclear generat-ed electricity produced by any nation in the world.

Second only to coal as a source of electricity in the U.S., nuclear energy is a vital and growing component of power supply. During 1986, five additional nuclear plants achieved full commer-cial operation, bringing the number of U.S. plants currently licensed for operation to 106.

Nuclear power in the United States has saved the equivalent of more than 5.6 billion barrels of oil. Savings in fuel costs to utility customers dur-ing the past decade alone are estimated to be as much as $ 63 billion.

Along with providing such savings, the U.S nuclear industry has maintained a total and on.

going obligation to safety an obligation un.

matched in scope and success by any other industry.

Contents Letter from Nuclear Operations V.P.

The Nuclear Role at FPL Safety Turkey Point Plant St. Lucie Plant 10 Reliability Economics 13 The Quality Program 14 Policy Deployment 16 Letter from Nuclear Energy Group VP. 17 Nuclear Milestones Organization 19-20

The FPL Commitment When Florida Power & Light Company's first nuclear power plant began operation in 1972, the company's commitment to the use of nuclear energy was made clear and put in precise order: to provide safe ... reliable ...

and economical power to its customers.

Fifteen years and171 billion kilowatt-hours later with a record of excellent safety, high reliability and indisputa-ble economic savings that commitment continues to be the focal point of FPL's nuclear operation.

During 1986, safety remained the overall goal of FPL's nuclear energy department. Driven by a program empha-sizing quality in every aspect of its operations, the de-partment's quest for improvement reached into other strategic areas as well. Achievements in training, mainte-nance, reliability, organizational development andregula-tory interaction came as a direct result of the company's Quality Improvement Program.

Performance is the final indicator of a successful pro-gram. Our increased use of data to monitor and measure virtually every detail of operations allows us to present an objective and documented .view of our total performance.

It is performance, rather than programs, by which we seek to be measured. And when judged by performance, our success is clearly evident.

This report is a review of the 1986 activities of the nu-clear energy department ià Dickey Vice President Nuclear Operations

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'I mamr'j IIIIIIIINH I I1II p) uclear power generation has become a key element in FPL's successful strategy of developing a dependa-

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~ ,I ble and diversified fuel mix to produce the most eco-nomical power for its 2.8 million customers.

Among all the fuel options available to FPL NRC Resident Inspector Perk Bibb checks plant nuclear, oil, natural gas and purchased coal statusin the st. Lucie Unit 1 controlroorn. Jack Crienjak (not shown) is the NRC senior resi.

power nuclear power is by far the most eco- dentinspector.

nomical. Electricity generated by nuclear energy costs only about one-third as much as that gen-erated by burning oil, despite recent lower oil prices.

FPL's nuclear facilities consist of two units at its Turkey Point plant in south Dade County, Flori-da and two units at the St. Lucie plant located on Hutchinson Island near Ft. Pierce, Florida. Turkey Point Units 3 and 4, which began operation in 1972 and 1973 respectively, are rated at 666 megawatts each. St Lucie Units1 and 2, which became operational in 1976 and 1983 respective-ly, have a rated capacity of 839 megawatts each.

In 1986, the four nuclear units produced 32 percent of customers'lectrical demand, saving an estimated $ 274 million in fuel costs. Each Tur-key Point unit is capable of displacing about

, i'~i@ 28,000 barrels of oil per day, while the St. Lucie units can displace about 32,000 barrels each.

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',Pl: equivalent of more than 273 million barrels of oil, a savings of $ 4.6 billion in fuel costs. It is expect-ed that nudear power will continue to provide about one-third of customers'lectrical needs during the next few years. Considering that the " ~ St. Lucie

If';ic<<g original cost of the four units was $ 2.5 billion, nuclear energy has proven to be a wise and pru-I'>si> t~i" dent investment for FPQ customers.

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1986 Generating Capacity By Fuel Type (Summer Capacity of 13,088 MW) 100%

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~ Fossil Steam (59.9%) 21 Units Nuclear (22.0%) 4 Units Gas Turbine (l4,5%) 48 Units mm Combined Cyde (3.6%) 2 Units

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1986 Generation By Fuel Type (Total Energy Sales 54.3 Billionkwh)

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')4')')ll Instrument and ControlSupervisor Jorge Riveron (right) and Instrumeot and Control Specialist Bill Cazenby check the operation of the newly installed Unit 4 alternate shutdown panel at Turkey Point. The Unit 3 panel willbe placedin service during the 1987 refueling outage.

The FPL Nuclear Energy Department

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The nuclear energy department consists of 1,536 employ-ees working under the guidance of a management team with outstanding credentials. (see back fold-out)

There are 662 plant employees at the St. Lucie plant, FBB~

695 at Turkey Point and 179 staff personnel at offices in Juno Beach, Florida.

During 1986, FPL's four nuclear units achieved a com-bined average equivalent availability of 70.9 percent com-pared to a U.S. industry average of 60.3 percent.

Three of the units, Turkey Point 3 and both St. Lucie units, operated at an average equivalent availability of 84 percent. Turkey Point 4 was not in operation for a total of 240 days in 1986. During this period, many designmodTii-cations were installed. By implementing many of the les-sons learned by the industry since original construction, these modifications will bring the plant nearer to today' standards.

The four nuclear units produced 18.5 billion kilowatt-hours of electricity during 1986.

Turkey Point Plant (see page 9)

IIIIIININI 3l'uno Beach office complex - This is the site of the nuclear energy, power plant engineering, prolect management and power plant construction de.

partments. These key staff departments support operation of the ltukey Point and St. Lucie nuclear units. St. Lucie Plant (see page 10)

he health and safety of employees and the pub-lic is the top priority of the nuclear energy de-partment. Since 1979, FPL has added more than

$ 600 million in capital improvements to its nu-clear plants. The majority of these additions were for new safety features required by the Nuclear Regulatory Commission (NRC) in such (

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areas as fire protection and modifications related to lessons learned from the Three Mile Island v(

accident.

( 1 Training Professional training is es-pecially significant to as-sure the highest margins of safety. In 1986, the depart-ment's operating andmain-tenance budget for techni- OO cal training was $ 13.5 million, with a capital im-provement commitment of $ 175 million for training centers and plant-specific simulators.

More than 1,400 employees participated in these training programs in 1986, including 61 who passed NRC-administered examinations.

By the end of 1986, ten performance-based technical training programs at each plant had been developed to meet the criteria of the Na-tional Academy for Nuclear Training. Four of the programs at each plant were accredited by the National Nuclear Accrediting Board during the year and the remaining six programs at each plant are expected to be accredited by mid-1987.

Nuclear Operatcv Tommie Todd inspects a valve on a high pressure safety Both plants became branches of the National injection pump.

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'brkey Point Trainin Building Completed for occupancy Dec. 18 198b, this St. Lucie Trainln Building This 51000 square. foot buildingnearedcomple-5<000 square. foot uilding was also a part of PEP. (5ee pg, 9) tionin 1986 wit occupancy scheduled by February 198Z .

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Academy for Nuclear Training when the first pro-grams were accredited.

New training facilities were constructed at both plants. The 51,000-square-foot buildings in-clude classrooms, laboratories, libraries and of-fices for the training staff and will house full scale plant control room simulators to be deliv-ered in 1987. The additional facilities allow for the expanded technical and skills training required I I!

by the ten performance-based technical training s"'0 ~ ~ ~

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I I management system was implemented during  !

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I ta It auelct 1986. The initial phase dealt with materials con- V ~ IIV,'l!!t t ',

figuration control, designed to monitor and as- ,I sist in the maintenance of over 15,000 training documents.

A four-level instructor certification program was also implemented in 1986. Level 1, on-the-job instructor/evaluator training, was completed by 135 plant supervisors and training staff mem-bers. This training focused on "how to" tech-niques for providing consistent, systematic and IV quality training in the plant environment. Levels \

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'2 and 3, technical instructor and program coordi-

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nator, are scheduled for completion in 1987. Level 4, program supervisor, will follow in 1988.

Radwaste Supervisor Lew LaGarde (n'ght) and Senior Radiation Protection Man Chris Breviginspect a spent resin container prior to shipment.

Organizational development The nuclear energy management development program, begun in 1984, continued during 1986 with I

20 senior employees placed in rota- - -

positions. The purpose of the Q'ionai I

t 'I program is to maintain a succession .', Q Q,.v,'v plan and improve the overall effec-tiveness of the nuclear energy team.

As an extension of the fitness for duty program, a two-phase drug testing policy was established in 1986.

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Phase 1 included an initial mandatory drug screening test for all nuclear energy vice presidents, directors, man-agers and department heads.

Phase 2 included random drug screening tests for all salaried employees with authorized unescorted access to vital and radiological controlled areas at St. Lucie or Turkey This siren on Hutchinson Island was activated during the federal alert and Point The testing also included all positions in the first notification system demonstration. phase of the program.

Cecil Wethy, Turkey Point plant site vice president:

'7he age of the Turkey Point nuclear units presents us with a major challenge. Many of our projects involve upgrading the design of a number of systems to present requirements. In addition, equipment replacement to address plant aging and to employ new technologyis necessary to ensure high reliabilityin the future. Our top priorityjob at Turkey Point aside from safety, is to maintain effective interaction with our regulators. This is essential for success in implementing the many changes required."

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~C+p feggy During 1986, the Turkey Point plant produced its 100bil.- .erations and manage the changes and modifications nec-lionth kilowatt-hour of electricity. Located on Biscayne essary to bring the plant to current standards. Included in Bay in south Dade County near Homestead, the plant has this continuing program are enhancements to:

saved customers an estimated $ 2.7 billion in fuel costs since beginning operation in 1972. ~ site facilities The Turkey Point units have performed remarkably well ~ operations during their 14 years of operation. They have a combined ~ procedures lifetime capacity factor of 66 percent compared to the in- ~ configuration controls dustry average of 60.3 percent In the key performance ~ training indicator of forced outage rate over the life of the plant, ~ management actions both units have been outstanding. The forced outage rate ~ licensing programs for Unit 3 is 8 percent, with Unit 4at 6.7 percent Thecur- ~ quality programs rent annuai national average is 177 percent. ~ maintenance In 1984, the performance enhancement program (PEP) ~ technical specifications.

was established at Turkey Point to upgrade overall site op- ~ operability of safety systems

Turkey Point Plant All PEP tasks continued to be completed on schedule during 1986. One project, procedure upgrade, has had a significant impact on improving operations and mainte-nance. Since 1984, 639 new procedures have been devel-oped, bringing the total number to 1,164. Another project was an integrated schedule designed to address all planned plant modifications. With priorities assigned based on future safety impact and cost/benefit analysis, schedules are produced according to priority and the available resources. The system, when approved by the NRC, will provide an agreed-upon method to makesched-uled commitments for safety-related modifications and efficiency improvements. The preliminary five-year inte-grated schedule now consists of about $ 200 million of work on almost 500 selected projects.

1986 improvements resulting from PEP

~ auto trips reduced . 53 percent fi

~ personnel exposure reduced............ 25 percent

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radioactive waste shipped reduced....... 47 percent plant changes and modifications completed ..... 230 zt ft d~>>

~ procedures developed . 180 Turkey Point Unit 3 Outage Director Ron Hogue discusses detailed plans for comprehensive motor operated valve maintenance scheduled for the Unit 3 outagein early igB7 OO ~

~ 0 aaa Turkey Point Plant ~ X ~ 14 Performance Enhancement Program Tasks VSNR0 500 USNI+

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~ PEP Tasks Target PEP Completed Task r

NRC Resident Inspector Kurt Van Dyne (center), NRC Senior Resident In.

spector Russ Brewer(left) and NRC Resident Inspector John McDonald con.

duct dailyinspectionin the Turkey Point controlroom.

9.1

tg' pxI During 1986, a systematic review of selected safety Mechanics Bob Skiner (kneeling),

John Lewis (left) and Foreman systems and a changeover to modified standard technical Gary Sharpe inspect the diesel specifications were initiated. These projects were devel- generator fuelandoil flilteis. Mod.

iflication of the emergency diesel oped to ensure conformance to current design require- generator system was a major ac-ments and regulatory criteria. In the overall facilityevalua- tivityduring the Turkey Point Unit 4 extended outage during tgBLL tion in the systematic assessment of licensee performance (SALP) report, the NRC concluded that "...

these initiatives are of far greater magnitude and scope than any similar initiatives at other utilities ... They not only benefit Turkey Point but are expected to serve as a model for other utilities."

Equipment modifications and design configuration is-sues were the dominant factors in extending the outage of Unit 4. In all, 230 plant changes and modifications were completed at Turkey Point during 1986. Significant changes and upgrades were made in emergency diesel generator loading, the component cooling water system and the auxiliary feedwater system.

Designed to coexist with its environment, Turkey Point's 12,700-acre plant site continues to be the home for Turkey Point Plant Manager Chris Baker reviews progress of Unit 4 outage such rare and endangered species as the American croco- with Joe Kappes, maintenance superintendent.

dile and bald eagle. Most of the land is dominated by mangrove swamps maintained in their natural state to serve as a wildlife preserve. Additionally, 2,500 acres of the original site were deeded to the state of Florida in 1972 and that land today is part of the Biscayne National Park.

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System Engineer Kent Clotfelter (left), Shift Technical Advisor Martin Bowskill (center) and Operations Support Gioup Supervisor Julio Balaguero inspect the component cooling water system in preparation for flow bal.

ancing tests. Expedited testing was required as part of theselectsafetysys- Senior Nuclear Plant Operator Charlie Cullop tags component cooling water tem review prior to returning Ttirkey Point Unit 3 to operation. Unit 4 was system equipment. This plant. wide equipment identification and fabeling offline forits refueling outage. program is part of the Turkey Point perfonnance enhancement project.

9-2

Radiological safety and emergency planning FPL's overall radiological exposure has dropped 65 percent since 1983.

Another measure of the depart-ment's radiological improvement is the continued reduction in low level radioactive waste shipped, O'0 which has been reduced 62 per- H, cent since 1983.

In 1986, the department's radiation dosimetry process-ing program was accredited by the U.S, Department of Commerce National Bureau of Standards, under the na-tional voluntary laboratory accreditation program (NVLAP). Dosimetry is the process by which personnel ex-posure to radiation is carefully monitored. FPL is one of gp,,

only 13 utilities accredited under NVLAP in all eight cate- I gories of consideration.

The emergency preparedness program continued to be effective as demonstrated by successful tests of emer-gency plans and favorable evaluations by the Federal Emergency Management Agency, the NRC and the Insti-tute of Nuclear Power Operations (INPO).

(Right) Startup department Instrument and Control Supervisor Milton Jor.

dan (left) and technical department Engineer Art Martinez inspect the spent fuel pool area. As a result of a Quality Improvement Program teams decontamination program, the spent fuelarea is now fullyaccessible with.

out protective clothing. The teaminvestigated the problem of areas of ex.

cessive contamination throughout the plant. As a result, a standardized de.

contamination program was created with established goals and priorities.

In addition to Jordan and Martinez, team membersincluded John Brooks, Pat Hughes, Dave Ingram, Don Vetromile and Virgil Wager.

Nuclear Energy Nuclear Energy Solid Radioactive Waste Shipped Collective Exposure Per Unit (PWR Only) 20 1000 16 R 14 700 12 I 600 I. 10 g Soo 8

200 100 1984 1985 1986 1984 1985 1986

~ Industry Average

~ FPLOata ~ Industry Average

~ FPL Data NOTE: Industry Average represents waste generated

Ken Harris, St. Lucie plant site vice president:

"St. Lucies exceptional operating record has been recognized by the Nuclear Regulatory Commission, which has subsequently reducedon-site inspections. Both St. Lucie units have drawn international at ten-tion as being among the best performing nuclear plantsin the world.

The team focus now willturn toward operating and maintenance cost control."

At the end of 1986, the St Lucie plant marked 10 years tion of operational data rated St Lucie 2 as the best of 19 of record-setting commercial operation. new units to come on line during the 1983-85 period.

Since the startup of St. Lucie 1 in 1976 (Unit 2 began Even though this unit had a refueling outage during 1986, service in 1983 following an industry record construction it still finished the year with an 84 percent capacity factor.

schedule of six years), the plant has generated more than In recognition of the planQ exceptional operating re-68 billion kilowatt-hours of electricity. In displacing the cord, the NRC in 1986 named St Lucie as one of only two equivalent of more than 109 million barrels of oil, the units nuclear facilities in an 11-state southeast region and one have saved FPL customers an estimated $ 1.9 billion in fuel of only five in the country eligible for reduced on site in-costs. spections.

St. Lucie 1 achieved a capacity factor for 1986 of 97 In the NRC systematic assessment of licensee perform-percent and was listed by the publication Nucleonics ance (SALP),the level of performance at St Lucie was Week as the best performing unit in the country. Accord- graded as "high" with major strengths identified in areas ing to Utility Data Institute, both St. Lucie units were of plant operations, maintenance, surveillance, licensing among the ten lowest in cost of generating units in the activities and training and qualifications effectiveness-. No nation. A report by the NRC office of analysis and evalua- major weaknesses were identified.

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St. Lucie Plant During 1986, 286 plant changes and modifications were completed. These were necessary to meet chang-ing regulatory requirements and to ensure continued high equipment reliability in the future.

UJ, Key performance indicators included a 46 percent re- 3 ~QIGGIG GIIGIIiI GLOI duction in automatic trips since 1984, a reduction in per- . GG- ~; CIQGIII11IIPli sonnel exposure of 63 percent from the previous year gg ~

.,I ~m~Gaaa~gyjlxiri" Gi aGaa'gr'I" and a reduction of 17 percent in radioactive waste P rr shipped. There was just one equipment related trip during 1986.

In addition to its performance records, St Lucie has also become noted for its environmental contributions.

About one-fourth of the 1,132-acre property is used for plant facilities, transmission lines and canals. The remain-ing mangrove swamps, marshlands and'beaches are maintained in their natural state. Some 160 species of birds and 25 different kinds of animals live at St Lucie and Assistant Nuclear Plant Supervisor Earl Libby Peft), Reactor Control Oper-ators John Hauger /center) and John Giles review upcoming shift activities are regularly monitored by the utility. Two parks are main- in the St. Lucie tJnit 2 control roonL tained for use by the public and the site's landscaping complements its natural surroundings. Conservation ac- lv tivities include "turtle walks" that offer the public a chance to view the nighttime nesting rituals of giant log- 22~~NW 3P gerhead, leatherback and green sea turtles.

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St. Lucie Plant Technician Sue Bromstrup draws a sample from the water St. Lucie Plant Manager Dave Sager Ireft) confers with Site Vice President treatment plant. Ken Ham's.

10.2

Turbine Operator Elliott Sumner (left),

Foreman Roger Thorn.

as (center) and Me-chanic Eugene Floyd prepare for the 18.

month preventive maintenance on thein-strument air dryer dur-ing the 1986 refueling outage at St. LucJe Unit 2.

4V St. Lucie Plant Manager Dave Sager (seated) and Operations Superinten.

dent John Barrow review plant performance data.

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FPL Construction Su.

pervisor Gordon Olson (left), Catalytic'ngi.

neer John Whitney center) and Pipe Fitter eman Bob Morgan plan piping work for the moisture reheater tube bundle replace.

ment during the St. Plant Security Coordinator Bill White (left), Wackenhut Lieutenant Jim Lucie 1 refueling out. Wampler (center) and Wackenhut Captain Frank Finch review the St. Lucie age scheduled for Feb. site secunty system changes which willresult, from the installation of the ruary 198Z intake area intrusion detection sonar system.

10.1

Maintenance he role of maintenance is vital in nuclear plant relia-bility and among 1986 achievements in that area was the development of an analytically-based preven-tive maintenance program 0 at the Turkey Point plant The goal of the program is to improve plant ln the charging pump room, Electrician Aldo safety and availability through high-tech analysis Ramirez checks the Turkey Point Unit 4Bcharg.

to allow for preventive rather than corrective ing pump motor in preparation for reassembly.

maintenance. New techniques include thermog-raphy, vibration analysis, computer data bases, statistical quality control and analysis related to component aging.

Implementation of a nuclear job planning sys- Nuclear Energy tem was also completed during 1986. The com- Equivalent Availabi%fy puterized network provides a centralized loca- 100%

. tion for all information regarding plant work orders. The system is interfaced with a total equipment data base that contains information 80 on components at each plant site.

A maintenance self assessment, using the In.

stitute for Nuclear Power Operations (INPO) maintenance guideline document as a reference, was completed at both plants in 1986. In addi-tion, a tracking system to monitor action items was installed as part of the program. FPL was the first utility in the country to complete the self as-20 sessment Unit scrams, or automatic shutdowns of the 10 reactor, decreased substantially in 1986. This was 1984 1985 1986 accomplished through the formation of quality improvement teams which analyzed all unit re- ~ Industry

~ FPL Data Average actor scrams since 1980 and then developed countermeasures for prevention. As a result, the -

EQUIVALENTAVAILABIUTY Equivalent availability is the ratio average number of scrams per unit decreased of the total power a unit could have producetL considering actual equipment and regulatory limits, to its rated capacity from 51 to 3.5. expressed as a percentage.

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I Senior Plant Technician Jeff Cook (standing) and Electrician Mike Waters conduct vibration analysis on the St. Lucie Unit 1B steam generator feed pump motor. Such analysis is a key component of the new analytically-based preventive maintenance program.

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Nuclear Energy Unplanned Auto Scrams 10 ie4i 7 I c t 6>( ()

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Reactor Operators Dave Kem (on ladder) and Bruce Poole perform receipt Z inspection of fuel for the Unit 2 refueling outage. A Quality Improvement Program team has been formed to improve the overall fuel cycle from re-ceipt to operation and final storagein the spent fuel pool.

Nuclear Energy Forced Outage Rate 20%

12 10 8

1984 1986

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~ FPLData Industry Average FORCED OUTAGE RATE - Forced outage figures reflect the percentage of time units are off line due to forced events when they could otherwise be producing power. Forced events are unplanned equipment failwes or other conditions that result in units being taken off line on short notice.

Senior Plant Technician Ralph Akerman conducts thermographic analysis on the St. Lucie Unit 1 isolated phase bus duct. Such high technology analysis is a part of the increased emphasis on analytically. based preventive maintenance.

12

he performance of the nu- Thermal Performance clear energy department 12 contributed significantly to FPL's overall financial per-formance during 1986.

The total nuclear non- ~ 11 fuel operation and mainte-nance expenses in 1986 5 were approximately $ 183 million. FPL's 1986 av-erage total nuclear production costs including Cl 4

fuel was 20.9 percent less than the 1985 industry e 10 average. tndustry data for 1986 was unavailable at the time of this printing.

The Florida Public Service Commission (PSC) also allowed recovery of $ 216 million in jurisdic- 9 tional costs associated with the replacement of the Turkey Point steam generators during 1981 to 1984 1985 1986 1983. During two days of hearings held by the PSC, testimony showed that the events requiring the replacement of the steam generators were

~ 'PL Average industry Average THERMAL PERFORMANCE - Thermal performance is usually beyond FPL's control The commission deter-

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measured by heat rate, or Btu per kilowatt hour. A low heat rate reflects emphasis on thermal efficiency and attention to detail in mined that the costs were prudently incurred for maintenance. An efficient or "well tuned" plant enables the benefit of the company's customers. operators to detect abnormal trends and correct them early. The minimum heat rates attainable are also a function of plant design.

Total Nuclear Production Costs (FPL to Industry Average Comparison) FPL Nuclear Fuel Savings 4g00 20 4,600 18 16 4,200 4.1 4,000 Oq 10

.8 I 3800 3,600 8

Fuel Cost 1984 1985 1986 1983 1984 1985 1986

~ FPL Average Industry Average

~ Total Customer Fuel Savings

n 1981, FPL launched a company-wide Quality Im-provement Program (QIP) O designed to provide the tools necessary to help produce innovative solu-tions to complex p roblems.

The program's quality concepts have been es-pecially valuable to the nuclear energy depart-ment, where higher standards have been on-going goals. The application of statistical quality control techniques, as emphasized in the quality improvement process, has become essential to the everyday operations of the nuclear program.

QIP consists of three distinct and separate areas:

Teams During 1986, the nuclear energy department j~ kkks had 141 teams dealing with a wide variety of problem and opportunity areas. Utilizing prob-lem solving techniques taught in extensive train-ing programs, more than 850 department em-ployees participated on teams. By determining the root causes of problems and formulating cor-rective actions, team members continually im-prove performance. A QIP team, the "QKT's "increased the efficiencyof the method ofcommu.

nicating with plant operations and support personnel during offwork An example of one such team success during hours. The Turkey Point team included (left to right) Dru Tenneli, Pat Boyd, 1986 was the development of a new, simplified Margie Ot tilige, Gyneth Rhodes and Dawn Costa. Connie Herd was also a member of the team.

control rod split pin replacement operation at Turkey Point 4. Through vendor and FPL team ef-forts, the reactor's 102 guide tube split pins were replaced in 18 days nearly five days ahead of schedule, under budget and with no rework, a first in the industry.

Other quality team achievements during 1986 icoc 'lt i as r tali included new emergency operations proce-dures, significant radwaste reductions, improved electrical power availability for refueling activi-ties and enhanced refueling outage planning.

Turkey Point Plant Manager Chris Baker reviews the "qualityin daily work" flag system with his staff.

The Quality Program Quality in daily work (Q/OW)

Emphasizing continually improving work performance, this component of the quality program begins with a thorough identification of job responsibilities for each in-dividual. Standards to measure performance and to set goals are then developed for each position. Once the work process has been shown to meet its objectives, the

/ tr / process may be standardized for the entire work unit.

gy, The QIDW process promotes systematic control and improvement in any task to which it is applied. A process is established for day-to.day work performance whichre-quires that day-to-day work be planned, done, checked, and if the objectives have not been met, acted upon.

FPL's quality improvement efforts are based on a re-spect for people in the work place, customer satisfaction, the use of data for management direction and quality performance on a daily basis. The quality program has emerged as the single most important element in the way FPL operates as a company.

The use of quality improvement principals to achieve significant savings in operations costs, increase customer satisfaction and improve communication and coopera-tion among employees has attracted international atten-tion. To date, more than 500 organizations in the U.S. and Europe including 24 electric utilities have attended special seminars held at FPL to leam more about the program.

The nuclear energy staff QIP team satisfied the national voluntary laborato.

ry program requirement for dosimetry acueditation. The team developed quality control training programs, dose algonthms and required proce.

dures. The benefit was immediate assessment of worker radiation expo.

sure measured at the highest standards of accuracy. Team members were I Nuclear Energy Analyst Mike Fedotowsky (left), Technician Pat ti Tims (cen. ji ter) and Senior Specialist Sandy Perle. Also on the team was Regina Belcher.

Policy deployment As FPL's corporate "roadmap," policy deployment requires that each department concentrate on a few select areas of performance improvement. Success in these priority is achieved by a corporate-wide focus geared to 'reas providing solutions and developing opportunities. With an emphasis on data gathering, the policy deployment process demands that improvement actions be constant-ly monitored and measured with follow-up corrective ac-tion taken when necessary.

The policy deployment goals of the nuclear energy de-partment are to: (1) improve regulatory performance (2) 5 The St. Lucie QIP "INPO" team promoted a concentrated plant wide effort improve unit reliability (3) plan andmanage operating and to raise the overall St. Lucie INPO rating ofplant processes and procedures.

maintenance expenses within approved budgets. Specific The 886 INPO evaluation found ten "good practices," a significant im.

provement over previous evaluations. Team members included (front row, plant and staff annual plans then are supported by proj- left to right) Chns Burton, Russ Cox, BillAlfera,Rick Wagoner(backrow, left ects aimed at accomplishing the mid-term plans. (see pol- to right), Lamar McLaughlin, Doc Mercer, Hany Bishop, Dennis Wyatt;Bob May ew and Ed Burgess. Other team members were Alan Hilland Andy icy deployment diagram) Pauley.

15

~ ~ %1 1987 POL!CY DEPLOYMENT During the next decade. we want to To become and be recognized as the safest, become the best managed CIWric utilityin best performing nudear utility, through the United States and an excelfe'nt teamwork and commitment to excegence.

company overaK and be recognized as sud<<

CORPORATE NUCLEAR ENERGY MIDTERM STAFF MIDTERM PLAN PLAN

~ Achieve custome satisfaction hnprove regubtory perfannance

~ Shape the environment ~ Improve Nxt reKabihty

. Strerqthen organizational effectiveness ~ Pbn and manage operating and

~ Effecuve utilizatian of resoirces maintenance expenses within the approved budget CORPORATE SHORT-TERIVI PLAN

'1 r

~ Improve reliability of electric service ~ Reduce INPO fincgngs to 61 ~ hlrove safety system ~ Reduce NRC findings

~

hnprove public canfidence in or safety ~ Reduce NRC findings to 47 availabgty/refiabTityi i ~ Reduce RIPO fe&gs, programs Reduce SCRAMS to I2 ~ Improve tNPOrelatiansivps Reduce forced outagedays..o; '" .

'i~'>>

~ 5trengthen FPks effectiveness in dealing ~ Reduce unpbnned days off Kne to 18',.

~ Reduce pbnt outages -'Reducedurp4nned outageso with special interest groups, govern Maintain operating and mainteQnce ~ Urllitapeathg and maht8Qnce -Reduce aprtal and 06Mbudget varbnces-mental bodies and regu4tory agencies expenditures to vnthin>> 4% to -5% " veiancesto+4%to -So/oofbudgeted'.

Effective deployment of resources(capital anlouAt and operating expenses) ' Reduce skin and dothing c rrtaminations

~ Continue to emphasize the safe, relbbfe I

and effeent operation of nudear power pbnts A'<< ~ ",:.'; <<>q,,,P~O+g V aa<< CKI .4 ic CrF'-'p

'p'vro$Pp'

~ hstructor development and certifiation ~ Reduce the number of auxTiQry feechvater hnplement quaKty instructions project . system faut ts by 50'/o from ig86 bvef tfroughaut administrative procekres

~

Improve the quality assirance ~ Reduce the rxxnbe of diesel generator ~ Pracehre upgrade program departmenth ability to provide FPE with fAts by 25'/o from 686 fevels ~ aaytiagy based preventive effective self regubtion of its nudear ~ Trahing program acaeditatkn project AQiAteQAce

~ QIP team to prepare for and coordrQte Implement bNQn pefarmance

~ Pea th physics improvement program INPOeva!uation evaluation system

~ Engheering degree program for hcensed - ~ Qgo team to arQIyze data, frxf and correct ~ INFO team opeatars auses of contaminaticns(skin and - N5 reKabiKty

~ Reduce number of unusual events dothing) ~ Equipment bbeKng

~ Enhance QCPS baseline to ensrre ~ Reduce automatic trips to three per unit ~ On line secondary chenistry monitor commitments are indudedin procedures ~ Reduce outage extereons . htegrated outage managenent and

~ Control selected EACS to + 4% to

~

and iratructions hnprove handling of Aaroradiologial - Sho ~ Oxygen ingress reduction environmental hsues ~ RC5 valve upgrades

~ Steamgenerator refiabTity project ~ RCP seal upgrade

~ Improve corrosion envronment of ~ Budget consol and pbnning secondary system ~ AFW Engineering Program

~ Submit Technical Specifiation amend ~ Design Basis Reconsutution ments to increase mstrumentzeion sN.

veil4nce htevah

~ Reduce number of automatic reactor tnps

~ Improve praductivity utrTization of pbnt maintenance workers through improved Job pbnfxng

~ Reanalysis and relicense PTN to hw concentration boric acid

~ Seismic hazard/alternate load methodology Manpower pbnning system Dagy cost accounthg system

Simply stated, our job is to provide safe, reliable and least cost energy to our customers.

These three goals are not mutually exclusive. They must be. achieved in concert and while they present for-midable challenges, we are demonstrating that superior performances are possible in each area.

A part of our Quality Improvement Program concen-trates on always bringing performance into proper focus.

Part of such a focus is the need to track performance and communicate openly and effectively with fellow employ-ees. The demands of a flawless performance call for anin-creased awareness on the part of each employee in every area of operation anything short of this is not meeting our personal commitment to quality.

During 1986, Florida became the nation's fifth most populous state as 113,000 new customers joined the FPL system. The state is projected to become the fourth largest in 1987.

To meet such growing demands, the nuclear energy department must continue to build on its quality-conscious philosophy and efficiency-oriented operation.

As a vital component of the FPL power system, we must continue to find ways to improve as we are called upon to generate the needs of a new generation of customers.

We must use the considerable accomplishments of 1986 to springboard to new and unprecedented heights in nuclear performance, for while we are proud... we are not yet satisfied.

CO. Woody Group Vice President Nuclear Energy

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World Nuclear Milestones 1951 First nuclear power generation began in the United States (experi.

mental breeder reactor BR-1, 100 megawatts).

1954 First nuclear power plant began commercial operation in USSR (5 megawatts).

1956 First British nuclear power plant began commercial operation (Calder Hall, 35 megawatts).

First Asian nuclear reactor constructed in India.

1957 International Atomic Energy Agency established.

First U.S. Nuclear power plant began commercial operation (Shippingport, 60 megawatts).

First Japanese nuclear power plant began operation (JRR 1, 50 ~'

megawatts).

1958 U.S. nuclear powered submarine Nautilus crossed the Arctic Ocean underwater.

1959 First nuclear. powered commercial ship, the Savannah, was launched.

1960 Dresden Nuclear Plant began operation(U.S., 180 megawatts).

Yankee Nuclear Plant began operation (U.S134 megawatts).

1965 FPL President McGregor Smith announces that a nuclear power plant will be built at Turkey Point.

II 4 1967 First French nuclear power plant began operation (Chooz A, 310 ~

EEF i ~

megawatts).

1969 First Federal Republic of Germany nuclear power piant began oper.

ation (Obrigheim KWO, 340 megawatts).

Turkey Point Facts and Milestones Nuclear steam supply systems, designed by Westinghouse Electric Corpora.

tion, have pressurized water reactors (PWR) with three steam generators.

Secondary plants, designedby Bechtel Power Corporation, use six stages of feedwater heaters.

Turbine generators, designedby Westinghouse, have one high pressure and two low pressure turbines.

Turkey Point construction permit received ............... April 27, 1967 Turkey Point 3 operating license received ................. July 19, 1972 Start of commercial operation . Dec. 4, 1972 Turkey Point 4 operating license received ................ April 10, 1973 Start of commercial operation Sept. 7, 1973 Turkey Point steam generators replaced ................. May 16, 1983 Turkey Point generates 100 billionth kilowatt.how ........ Aug. 30, 1986 Fuel cycles: Unit 3, 10th cycle; Unit 4, 11th cycle St. Lucie Facts and Milestones

. RK Nuclear steam supply systems, designedby Combustion Engineering, have pressurized water reactors (PWR) with two steam generators.

Secondary plants, designed by Ebasco Services, use five stages of feedwater heaters.

Turbine generators, designed by Westinghouse Electric Corporation, have one high pressure and two low pressure turbines.

St. Lucie1 construction permit received ...................

Operating license received March 1, 1976 Start of commercial operation . Dec. 21, 1976 St. Lucie 2 construction permit received .. May 2,1977 Operating license received April 6, 1983 Start of commercial operation . Aug. 8, 1983 St. Lucie 1 named as top nuclear generating performer in the free world . Oct. 21, 1985 Fuel cycles: Unit 1, 7th cycle; Unit 2, 3rd cycle 18