TENNESSEE VALLEY AUTHORITYWATTS BAR NUCLEAR PLANT

Ed Freeman

Engineering Manager 1

• 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

Project History

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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DSEP

TVA Board Decision

Full PowerOperationOctober 2012

FY 2007 FY 2008 FY 2009 FY 2010O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M

FY 2011 FY2012 FY 2013

FSAR Amendment / OL Update

Ready for Fuel Load

April 2012

Regulatory Framework

Construction Reactivation letter

Licensing Activity

Significant Project Milestone

Major Engineering Complete – March 2010

Detailed Project Schedule

Commence Principal Construction Activities

Turbine on Turning Gear – October 2010

Primary Hydro – May 2011

Hot Functional – August 2011

Integrated Safeguards Testing – Apr 2011

U2 Emergency Plan Drill – May 2011

Fill Ice Condenser – July 2011

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WBN2 Construction Completion Status

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Questions?

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