Power Uprate Lessons Learned Point Beach Nuclear Plant 2011 Units 1 & 2 Kelly Oetting BOP System Engineer FSRUG 2012 Conference January 23-26, 2012

2 Power Uprate Lessons Learned Power Uprate Scope Westinghouse 2 – Loop PWR, Unit , Unit MWe to 637 MWe 1540 MWth to 1800 MWth 17% Approximately 35 Major Modifications for Each Unit Dozens of Smaller Supporting Modifications

3 Power Uprate Lessons Learned Unit 2 Diagram

4 Power Uprate Lessons Learned Unit 1 Diagram

5 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/ /29/11) The Difference…..Mostly Lessons Learned!

6 Power Uprate Lessons Learned Lessons Learned Major Categories Preparation Resources Foreign Material Exclusion (FME) Control / Chemistry Control Testing Configuration Control Technical Conscience Component Specific Lessons Learned

7 Power Uprate Lessons Learned Preparation 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?

8 Power Uprate Lessons Learned Resources Contractors – Majority of Work – Remember…They Eventually Leave Early DEDICATED in-house resources for design reviews and approvals Need dedicated in-house resources from Engineering, Operations, Maintenance, Procedure Writers, Document Control, Drafting Procedure reviews – Whos doing it? Need knowledgeable people – HUGE resource drain (50% of system engineers time during outages) Dont forget in-house participation in testing, especially I&C Who will do the equipment database and vendor manual updates? Resources Spare Parts Management, out with the old – in with the new Resources PM updates Routine System Engineering Duties May Have To Wait

9 Power Uprate Lessons Learned Foreign Material Exclusion (FME) Control / Chemistry Control 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)

10 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 Dont remove test instrumentation early FWH level optimization (knee test)

11 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

12 Power Uprate Lessons Learned Technical Conscience 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)

13 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 couldnt accept piping designers higher values) Pump oil leaks due to thrust disc drive nut – wrench flats machined in wrong location Supplied Pump/Motor coupling keys too large, didnt 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

14 Power Uprate Lessons Learned Component Specific Lessons Learned (cont.) 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

15 Power Uprate Lessons Learned Component Design Change Details Before EPUAfter EPU Feed PumpBryon Jackson - DVSSulzer – CD/BBS # Stages11 Rated Speed6000 rpm3600 rpm Speed IncreaserYes – 3.367:1No – Direct Drive Design Flow7800 gpm9300 gpm Design Head2180 ft2200 ft Mini Recirc500 gpm4000 gpm Feed Pump MotorWestinghouseTECO Horsepower Rated Speed1789 rpm3582 rpm

16 Power Uprate Lessons Learned Component Design Change Details (cont.) Before EPUAfter EPU Condensate PumpByron Jackson – 24 KXHFlowserve – 28 APKD # Stages77 Rated Speed1180 rpm1188 rpm Design Flow4720 gpm5700 gpm Design Head800 ft760 ft Condensate Pump MotorWestinghouseTECO Horsepower Rated Speed1190 rpm1189 rpm

17 Power Uprate Lessons Learned Component Design Change Details (cont.) Before EPUAfter EPU #1 & #2 LP FWHsWestinghouse (shell) Southwest Eng. (tube bundle) Yuba Length41 ft 9 in49 ft Diameter68 in79.25 in Heat Transfer #1147,500,000 Btu/hr141,100,000 Btu/hr Heat Transfer #2116,700,000 Btu/hr126,600,000 Btu/hr #3 LP FWHsWestinghouse (shell) Southwest Eng. (tube bundle & channel head) Yuba Length42 ft 8 in Diameter42.75 in49 in Heat Transfer153,500,000 Btu/hr184,300,000 Btu/hr

18 Power Uprate Lessons Learned Component Design Change Details (cont.) Before EPUAfter EPU #4 LP FWHsStruthers WellsYuba Length34 ft38 ft 4 in Diameter46 in52 in Heat Transfer174,000,000 Btu/hr229,498,000 Btu/hr #5 HP FWHsYuba Length53 ft 2 in48 ft Diameter51 in59 in Heat Transfer334,776,179 Btu/hr411,333,000 Btu/hr

19 Power Uprate Lessons Learned Component Design Change Details (cont.) Before EPUAfter EPU FWH Level Control ValvesCopes VulcanCopes Vulcan / SPX ControllerMasoneilan - pneumaticYokogawa US PositionerMoore 72 - pneumaticFisher DVC 6010 TransmitterFloat – part of controllerRosemount Guided Wave Radar 5300 Series

20 Power Uprate Lessons Learned Component Design Change Details (cont.) Before EPUAfter EPU Heater Drain Tank Level Control Valves Copes VulcanCopes Vulcan / SPX ControllerFoxboro - pneumaticYokogawa UT55A PositionerMoore 72 - pneumaticFisher DVC 6010 TransmitterFoxboro - pneumaticRosemount Guided Wave Radar 5300 Series Feedwater Regulating ValvesCopes VulcanCopes Vulcan / SPX ActuatorCopes VulcanRA Hiller ControllerFoxboro 62 HB - pneumaticYokogawa YS-1700 PositionerBailey Model AP-4 - pneumaticFisher DVC 6005 base unit DVC 6025 feedback unit Feedwater Isolation Valves ( new)Did Not ExistFlowserve Gate Valve ActuatorHiller - piston double acting