TENNESSEE VALLEY AUTHORITY WATTS BAR NUCLEAR PLANT Ed Freeman Engineering Manager 1 Project History • May 1971- Application for Construction Permits for WBN Unit 1 and 2 requested • January 1973 - Construction Permits for WBN Unit 1 and 2 issued • October 1976 - Application for an Operating License for WBN Units 1 and 2 Requested • June 1982 - Safety Evaluation Report for Operating License for WBN Units 1 and 2 (NUREG – 0847) issued • September 1985 - NRC “Show Cause” Letter to TVA 2 Project History • Late 1985 - WBN Unit 2 Construction Suspended • May 1989 - Nuclear Performance Plan (NPP) Describes Actions to Identify and Correct Problems at WBN • December 1989 - Safety Evaluation Report WBN NPP WBN Unit 1 (NUREG-1232) • November 1990 - NUREG-0847 Supplement 5 issued • October 1995 - FSAR Amendment 91 issued • November 1995 - Low Power Operating License for WBN Unit 1 issued • February 1996 - Operating License for WBN Unit 1 issued 3 Project History • July 2000 - TVA Formally Deferred WBN Unit 2 • January 2007 – Detailed Scoping Estimating Planning Study • July 2007 - NRC Staff Requirements Memorandum • August 2007 - TVA Board Approves 5 Year Program for Completion of Construction of WBN Unit 2 • August 2007 - Construction Reactivation Letter • July 2008 - Construction Permit Extension 4 Installation Status • • • • • • Major structures complete System and component installations are substantially complete Approximately 6600 pipe hangers installed Substantial amount of instrument tubing incomplete Electrical cables 90+% pulled and terminated Some major components used in operating units – RCP’s, Charging Pump, Aux Feedwater Pump, RHR Heat Exchanger • Equipment condition is good 5 Issues Related to Configuration Control • Construction was stopped with incomplete documentation of installation status • Some QA records were lost or incomplete • Cable pull and termination cards were missing • ASME data package assembly had not begun • 79-02/-14 piping and hanger program documentation missing or not completed • Operating units tended to use parts or whole components for maintenance replacements • Very few as constructed drawings done 6 Objective for Completion • Sound design supported by analysis • Plant configuration that matches the sound design • Construction completion statements or walkdown data for the configuration • QA records for equipment and material • ASME N-5 and N-3 forms signed off for applicable systems • Refurbishment records establishing “as new” equipment condition • Completed and successful test procedures documenting performance objectives met 7 Configuration Recovery Process • Design Baseline Verification program – Review existing calculations produced for the licensing of U1, prepare a new U2 calc or make adjustments to the calculation for two unit operation – Review the original design documentation against current design standards and practices – Review/regenerate design criteria and system descriptions for every system – Program reviews (ie – Appendix R, EQ, 79-02/-14) for compliance status and objectives – Compare U1 existing design against U2 walkdown information – Review documentation of installations for incomplete or missing records 8 Configuration Recovery Process • Field walkdowns • • • • • • • • • • • • Operational modes/flow diagrams “Pipe Tight” for Turbine Building Piping Isometrics Pipe Hanger detailed walkdowns (B31.1 and 79-02/-14) ASME N-5 regeneration Conduit installation and supports Cable Tray supports Cable terminations Some cable signal tracing Instrument Panels HVAC ductwork Embedded Plates 9 Configuration Recovery Process • Walkdown information compared to U1 configuration control drawings, U1 design changes, U2 as designed drawings to determine the gap between installed and desired configuration • Engineering packages issued for the gap • Engineering Document Construction Release issued for incomplete construction or changes to existing design • Process has controls for working in the vicinity of an operating unit • Addresses ASME N-5 completion issues and deficiencies • Construction closure process insures correct installation 10 WBN Unit 2 Refurbishment • Refurbishment/Restoration - Performance of activities to restore a component to its former good condition. • Inspections - disassembly to the extent necessary to verify or measure critical attributes (which may be affected by time), cleanliness, conditions of bearing or seating surfaces or components. • Cleaning - Removal of dirt and other contaminants using pressurized air, water, approved solvents, etc., as necessary. System/component flushes, as part of the startup testing program, may be credited where applicable. • Lubrication - Removal of old grease/oil from reservoirs, bearings, and other lubricated components and replacement with vendor specified or other engineering approved lubricants. • Parts Replacement - Replacement of all “soft” parts which would degrade over time, such as gaskets, packing, elastomers, etc. • “Passive Refurb” – Inspection of structures, piping, physical attributes to verify no significant pre-service degradation 11 12 13 Preoperational Testing • Component testing to demonstrate installation/refurbishment of individual items • Full RG 1.68 testing program – Individual system functionals – System performance tests • Flushing program/System cleanliness • Integrated Safeguards Testing April 2011 • Integrated Leak Rate Testing July 2011 • Cold Hydro May 2011 • Hot Functional August 2011 14 Turnover to Operations • Turnover process will include a validation that: – Required design calculations and other documents are complete and unverified assumptions have been closed – Design packages have been completed in the field – As constructed and configuration control drawings have been issued – Special programs and corrective actions for previous construction deficiencies have been completed – Refurbishment is complete – Preoperational testing is complete 15 Watts Bar Unit 2 Project Status • Tracking to complete within the 60 month schedule • Critical path - delivery of key equipment – Control systems, valves, pumps • Engineering and licensing activities are on schedule • FSAR amendment has been submitted • Construction bulk work is gaining momentum • CCW and annunciator systems turned over for startup testing 16 WBN2 Construction Completion Status FY 2007 FY 2008 FY 2009 FY 2010 FY 2011 FY2012 FY 2013 OND J F MAM J J A SOND J F MAM J J A SOND J F MAM J J A SOND J F MAM J J A SOND J F MAM J J A SOND J F MAM J J A SOND J F MA M DSEP Ready for Fuel Load April 2012 Construction Reactivation letter TVA Board Decision Regulatory Framework Full Power Operation October 2012 Detailed Project Schedule Commence Principal Construction Activities Major Engineering Complete – March 2010 FSAR Amendment / OL Update Turbine on Turning Gear – October 2010 U2 Emergency Plan Drill – May 2011 Integrated Safeguards Testing – Apr 2011 Primary Hydro – May 2011 Fill Ice Condenser – July 2011 Licensing Activity Hot Functional – August 2011 Significant Project Milestone 17 18 19 20 21 22 23 Questions? ? 24