Power Uprate Lessons Learned
Point Beach Nuclear Plant
2011 Units 1 & 2
Kelly Oetting
BOP System Engineer
FSRUG 2012 Conference
January 23-26, 2012
Power Uprate Lessons Learned
Power Uprate Scope
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Westinghouse 2 – Loop PWR, Unit 1 1970, Unit 2 1972
545 MWe to 637 MWe
1540 MWth to 1800 MWth
17%
Approximately 35 Major Modifications for Each Unit
Dozens of Smaller Supporting Modifications
Power Uprate Lessons Learned
Unit 2 Diagram
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Power Uprate Lessons Learned
Unit 1 Diagram
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Power Uprate Lessons Learned
Duration
• Unit 2 – 120 Days (3/1/11 - 6/19/11)
• Unit 2 – Power Ascension Testing 12 Days (6/19/11 – 7/1/11)
• Unit 1 – 75 Days (10/3/11 – 12/17/11)
• Unit 1 – Power Ascension Testing 12 Days ( 12/17/11 - 12/29/11)
• The Difference…..Mostly Lessons Learned!
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Power Uprate Lessons Learned
Lessons Learned Major Categories
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Preparation
Resources
Foreign Material Exclusion (FME) Control / Chemistry Control
Testing
Configuration Control
Technical Conscience
Component Specific Lessons Learned
Power Uprate Lessons Learned
Preparation
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Design Packages – Are They ready? Design Final?
Work Packages Planned?
Parts On-Site/Available?
Spare Parts On-Site/Available?
Testing Packages Complete/Ready?
Test Equipment Identified/On-site/Available?
Pre-Outage Work Complete? (scaffolding, insulation,
rigging, etc..)
• Is Your License Amendment Approved?
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Power Uprate Lessons Learned
Resources
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Contractors – Majority of Work – Remember…They Eventually Leave
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Early DEDICATED in-house resources for design reviews and
approvals
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Need dedicated in-house resources from Engineering, Operations,
Maintenance, Procedure Writers, Document Control, Drafting
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Procedure reviews – Who’s doing it? Need knowledgeable people –
HUGE resource drain (50% of system engineer’s time during outages)
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Don’t forget in-house participation in testing, especially I&C
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Who will do the equipment database and vendor manual updates?
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Resources Spare Parts Management, out with the old – in with the new
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Resources PM updates
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Routine System Engineering Duties May Have To Wait
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Power Uprate Lessons Learned
Foreign Material Exclusion (FME) Control / Chemistry Control
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Na, F and Fe values above CEI limit for 25 days (U2) 10 days (U1)
GMAW weld rod, sodium silicate binding agent
Management Buy-In for Clean-Up Plans
Specific Acceptance Criteria (quantitative not qualitative)
Better physical barriers (covers, tape)
Watch out for weld blanket (fraying and dye)
Remove anti-rust coatings prior to installation
TIG for root pass
Smoke exhaust ventilation
Flushing (high pressure wash & high volume wash)
Grinding wheels – fibers plugged start-up strainers
Start-up strainer design (mesh size? Back flush capability?)
Consider a start-up polisher (trailer)
Power Uprate Lessons Learned
Testing
• Get Involved Early
• Get the Right People Involved (In-House and Outside Expertise)
• Predicted Values May Not Match Actual – Have A Plan To
Evaluate
• How Will As–Left Setting Be Documented?
• SQA Program?
• Software Setup and Tuning Parameters Specified in Design?
• Factory Acceptance Testing Specified in Design?
• Bench Cal and Test Prior to Installation – huge time savings
between U2 to U1
• Equipment Tagging Complete PRIOR to Testing
• Finish ALL of the Start-Up Testing
• Don’t remove test instrumentation early
• FWH level optimization (knee test)
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Power Uprate Lessons Learned
Configuration Control
• NAMS/PASSPORT Software not the most user friendly
• CRNs – Changes to original design package – cross
reference not enough
• Revise original design package to show final
configuration if possible
• Detailed titles and descriptions for CRNs
• Make sure CRNs for 1st Unit incorporated on the 2nd Unit
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Power Uprate Lessons Learned
Technical Conscience
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Summit Fever!
Accountants vs. Engineers
Schedule Impact vs. Long Term Reliability
Flushing (strainers, duration, chemistry requirements)
Accepting Poor Workmanship (condenser wall)
Spend a Little More for Increased Reliability (ES Exp Jnts)
Power Uprate Lessons Learned
Component Specific Lessons Learned
• Ensure Vendors Actually Meet The Agreed Upon
Specifications
• Pumps; 30+ runs at manufacturer before pump
acceptable (vibs, curve shape, alignment)
• Pump thermal growth nowhere close to calculated,
measure it. (Essinger Bars, Rotalign, etc..)
• Pump nozzle loads required significant piping rework
(vendor couldn’t accept piping designer’s higher values)
• Pump oil leaks due to thrust disc drive nut – wrench flats
machined in wrong location
• Supplied Pump/Motor coupling keys too large, didn’t
match half keys used for component balancing
• New Motors: Rotors made in China, failed on the test
stand, rework; 5 new rotors had to be manufactured,
shop in China never made 3600 rpm motors before
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Power Uprate Lessons Learned
Component Specific Lessons Learned
(cont.)
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Rewound motors: lower starting amps and torque, longer acceleration
time caused rework for calculations and over current relay settings
Valves – trim not sized correctly, valves full open at 100% pwr
Skid mounted piping welds not per code or lacked vendor provided
evaluation and poor quality
Skid mounted components not rated for ambient conditions
Skid mounted dp instruments piped backwards
Small bore piping cracked socket weld, use 2:1 weld leg configuration
Painters will paint everything, even moving parts
Vendor manuals and drawings not updated timely
Controller power supply failures caused mid outage design change for
feed reg valve
Swapping from backup to primary feed reg valve controller, need to
wait 15 seconds and follow specific sequence or valve will go full shut
– software glitch
Power Uprate Lessons Learned
Component Design Change Details
Before EPU
After EPU
Bryon Jackson - DVS
Sulzer – CD/BBS
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6000 rpm
3600 rpm
Yes – 3.367:1
No – Direct Drive
Design Flow
7800 gpm
9300 gpm
Design Head
2180 ft
2200 ft
Mini Recirc
500 gpm
4000 gpm
Westinghouse
TECO
Horsepower
5000
6200
Rated Speed
1789 rpm
3582 rpm
Feed Pump
# Stages
Rated Speed
Speed Increaser
Feed Pump Motor
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Power Uprate Lessons Learned
Component Design Change Details
(cont.)
Before EPU
After EPU
Byron Jackson – 24 KXH
Flowserve – 28 APKD
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Rated Speed
1180 rpm
1188 rpm
Design Flow
4720 gpm
5700 gpm
Design Head
800 ft
760 ft
Westinghouse
TECO
Horsepower
1250
1500
Rated Speed
1190 rpm
1189 rpm
Condensate Pump
# Stages
Condensate Pump Motor
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Power Uprate Lessons Learned
Component Design Change Details
(cont.)
Before EPU
After EPU
Westinghouse (shell)
Southwest Eng. (tube bundle)
Yuba
41 ft 9 in
49 ft
68 in
79.25 in
Heat Transfer #1
147,500,000 Btu/hr
141,100,000 Btu/hr
Heat Transfer #2
116,700,000 Btu/hr
126,600,000 Btu/hr
Westinghouse (shell)
Southwest Eng. (tube bundle & channel
head)
Yuba
Length
42 ft 8 in
42 ft 8 in
Diameter
42.75 in
49 in
153,500,000 Btu/hr
184,300,000 Btu/hr
#1 & #2 LP FWHs
Length
Diameter
#3 LP FWHs
Heat Transfer
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Power Uprate Lessons Learned
Component Design Change Details
(cont.)
Before EPU
After EPU
Struthers Wells
Yuba
Length
34 ft
38 ft 4 in
Diameter
46 in
52 in
Heat Transfer
174,000,000 Btu/hr
229,498,000 Btu/hr
#5 HP FWHs
Yuba
Yuba
53 ft 2 in
48 ft
51 in
59 in
334,776,179 Btu/hr
411,333,000 Btu/hr
#4 LP FWHs
Length
Diameter
Heat Transfer
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Power Uprate Lessons Learned
Component Design Change Details
(cont.)
Before EPU
After EPU
Copes Vulcan
Copes Vulcan / SPX
Controller
Masoneilan - pneumatic
Yokogawa US1000-11
Positioner
Moore 72 - pneumatic
Fisher DVC 6010
Transmitter
Float – part of controller
Rosemount Guided Wave Radar 5300
Series
FWH Level Control Valves
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Power Uprate Lessons Learned
Component Design Change Details
(cont.)
Before EPU
After EPU
Copes Vulcan
Copes Vulcan / SPX
Controller
Foxboro - pneumatic
Yokogawa UT55A
Positioner
Moore 72 - pneumatic
Fisher DVC 6010
Transmitter
Foxboro - pneumatic
Rosemount Guided Wave Radar 5300 Series
Feedwater Regulating Valves
Copes Vulcan
Copes Vulcan / SPX
Actuator
Copes Vulcan
RA Hiller
Controller
Foxboro 62 HB - pneumatic
Yokogawa YS-1700
Positioner
Bailey Model AP-4 - pneumatic
Fisher
DVC 6005 base unit
DVC 6025 feedback unit
Did Not Exist
Flowserve Gate Valve
Heater Drain Tank Level Control
Valves
Feedwater Isolation Valves ( new)
Actuator
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Hiller - piston double acting