ML093020671

Brunswick Nuclear Plant Emergency Diesel Generators - Progress Energy

ML093020671
Person / Time
Site:	Brunswick
Issue date:	10/22/2009
From:	Progress Energy Carolinas
To:	NRC/RGN-II
Shared Package
ML093020640	List: ML093020650 ML093020671
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Download: ML093020671 (24)

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Brunswick Nuclear Plant Emergency Diesel GeneratorsNRC Region II VisitOctober 22, 2009 Agenda lAC Power Reliability lEDG Historical Performance lEDG Performance Indicators lEDG #4 Governor lOrganizational Lessons and Actions from Recent Events 2

AC Power Reliability 3Completed ActionsInstalled new 230 kV supply breakers for SATsInstalled new Unit output breakersReplaced SWYD CCVTs & Lightning ArrestorsInstalled new local 230 kV capacitor banks for voltage support on Unit 2Installed new Main Transformers -Outfitted with continuous gas monitoring instrumentationImproved material condition of spare SATReplaced sudden pressure relaysReplaced no load disconnect switches Improved PMs on Iso-Phase and Non-Seg Bus Inspected Non-Seg Bus flex linksEstablished standard preventive maintenance program for busesInstalled permanent SAMA diesel generators on Unit 2Planned ActionsInstall new local 230 kV capacitor banks for voltage Support on Unit 1Install permanent SAMA diesel generators on U1Unit Auxiliary Transformer (UAT) ReplacementReplace remaining transmission line breakers Replace Line Insulators at a rate of ~150 sets per year during each unit Completed ActionsReplaced 2 transmission line breakersReplaced 145 poles and 341 insulator sets Revised Transmission Interface Agreement to specify plant involvement/coordination of work activitiesUnder EvaluationReplace SATs w/auto load tap changing transformersUpgrade 2/3 logic for Aux Transformer Emergency Power Reliability 4Installed two backup diesel powered generators (SAMA diesel generators) to power the 125 VDC batteriesImproved CDF by 68% on Unit 1 and 66% on Unit 2 5EDG Historical Performance2007 Reliability Study wOperations wMaintenance wEngineering wTechnical Training2007 Reliability Study 6 wLicensing wProcurement wIndustry Representative wVendor RepresentativeMulti-discipline team assembled to review EDG issues and develop short and long term action planINPO Assist lMSPI Reliability data lVendor Input/Industry OE lMaintenance Rule Functional Failures, 2000-2006 lBNP Equipment Reliability List lEDG NCRs, 2003-2006 lEDG Planned and Unplanned Out Of Service (OOS) times, 2003-2006 lEDG Corrective Work Orders, 2003-20062007 Reliability StudyInputs Used in Analysis 7 lEDG Material Costs, 2003-2006 lEDG Self Assessment & Benchmarks, 2003-2006 lEDG NRC Findings, 2003-2006 lEDG Nonconformances lEDG items on Long Range Plan lSystem Engineer brainstorming sessions EDG Actions Action 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 EDG #2 exhaust bellows Allen Bradley relays Jacket Water TCVs SAMG DGs Capacitor leakEDG PM evaluationsUltra Low Sulfur FuelLatent design issuesHuman perform issues High qual potentiometersGEMCO control switches Replace EDG #1 bearingCollector ring Starting air config/quality Exciter/voltage regulator Governor upgrade Piston replacement (est) 8 CompletedWorkingScheduled EDG Performance Indicators 9

Brunswick Unit 1Emergency AC Power System NRC Performance Indicator MSPI (36 Months) September 2009 Status: 87% Margin Remaining in Green10 Brunswick Unit 2Emergency AC Power SystemNRC Performance Indicator MSPI (36 Months)September 2009 Status: 86% Margin Remaining in Green11 MSPI EDG Failures12 5 4 3 2 1 o ...j£--2004 2005 2006 2007 2008 2009 BNP Ind (Aug) Avg/EDG Avg/EDG ft _______ 1"' _____ _

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0.001 o o o -Planned -Unplanned EDG #4 Governor 14 EDG #4 Governor lEDG #4 removed from service for 6 year preventive maintenance:

w4.5 days planned unavailability wCommenced 7 day LCO on both units lDuring Post Maintenance Testing, EDG #4 failed to start due to governor failure.

lGovernor testing, tuning, support component replacement, and oil flushing occurred for the replaced governor -resulting in the expiration of the LCO prior to completing testing.15 EDG #4 Failure Analysis lFME on Pilot Plunger restricted movement lTwo possible sources for particles:

wInternal Wear Particles wExternal Source (FME) lFactors for wear of internal parts wOil analysis did not indicate abnormal wear of internal parts wInspection of internal parts during disassembly did not indicate wear lPotential Source(s) of FME:

wVendor maintenance on Pilot assembly without flush wOn-site testing/installation or oil addition/flushing activities.16 Evaluation of Governor17Pilot ValvePlungerCompensation Land(FME binding location)

Evaluation of Governor18Pilot Valve PlungerCentering SpringCompensation Land FME on Pilot Plunger 19 Organizational Lessons and Actions from Recent Events (2007-2009) lTechnical Rigor wTechnical Task Risk/Rigor procedure wEngineering Product Quality Procedure revision wTrending and Monitoring lPost Maintenance Testing Process Improvements wPMT specificity based upon safety related function20 Organizational Lessons and Actions from Recent Events (2007-2009) lWork Management wSensitivity to risk significant work wOutage Control Center Use wReadiness Reviews lParts Quality Interim Actions (pending permanent corrective actions) wFME requirements for vendors in Purchase Orders/Contracts wIncreased vendor surveillance wInterim EDG Spare Parts controls inspection/testing/FME inspections wReview near term EDG maintenance plans21 Organizational Lessons and Actions from Recent Events (2007-2009) lEDG Reliability Review Update wValidate Corrective actions taken from events since 2007 are bounding and comprehensive wReview problems/failures since 2007 wReview Industry Operating Experience since 2007 wBenchmark other utility EDG Reliability plans wRevise as needed near/long-term reliability improvement strategy22 Organizational Lessons and Actions from Recent Events (2007-2009) lEDG Maintenance Strategy Improvements:

wNear Term Evaluate options to address extension of 7 day LCO:

uReduces overall unavailability to complete work uImproved efficiency of work planning wLonger Term -Evaluate options to address long duration LCO for EDG major overhaul/repairs uAdditional on-site emergency AC capability uAC distribution alignment wCommon Mode Failure Strategy for Maintenance implementation23 Questions?24