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This book was motivated by the desire to further the evolution of a concise book on Power Plant Engineering. Keeping in focus the importance of this subject in GATE and ESE, we have done a proper study and thereafter developed the content of the book
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Koeberg Nuclear Power Station: Plant Life Extension and Ageing Management 1st NNR Regulatory Information Conference – Pretoria, Centurion
Date: 05 October 2016 Presenter: Kabelo Moroka
Topics to be covered • Brief Description • Global Trends in Nuclear Power • Periodic Safety Re-Assessment • Life Extension Modifications
• Ageing Management • Ageing Management Matrix • References for identifying Ageing • Long Term Operation Initiatives
2
Brief Description (Koeberg) • 2 x 2775 MW Pressurized Water Nuclear 3 Loop Reactors (PWR) • Nuclear Steam Supply Systems (NSSS) constructed by Framatome, now AREVA • ASME III Design • 2 x 975 MW Electrical with house load consumption 45MW • Conventional Plant constructed by Alstom • Original 40 year design assumption • Started Commercial Operation in 1984/1985. • Original Design assumed a 40 year operational life.
Good operational and maintenance practices has allowed for the assumed life to be extended to 60 years. 3
Brief Description (Koeberg) conti..
Nuclear Plant
Emergency Systems
The Koeberg Plant Design Consists of 3 main areas to be considered: • Conventional Plant • Nuclear Plant • Emergency Systems
Conventional Plant
• The used nuclear fuel has to stay on site for 5 to 15 years after shut down. • The operational life of some parts of the Nuclear plant will therefore be extended to 75 years.
In 2010 Eskom Board approved Business Case for Extending Koeberg Life to 60 years
4
Global Trends in Nuclear Power • 225/435 NPPs have been in operation for more than 30 years and 63 for more than 40 years (as of 2014)*
Plant Life Extension Extending plant life is considered in two areas: 1. Updates to the design • • • •
Original Koeberg design was approved by the regulator. Regulator approves all changes to the design. Design has to be updated for extending the life of the plant. Regulator has to approve all Time Limited Ageing Analysis (TLAAs) as part of the design update.
2. Ageing Management • Regulator has continuous oversight of ageing management processes. • Some ageing management processes are approved by the regulator. • Plant requires regulatory approval for startup at the beginning of each cycle. • This approval includes assurance that ageing has been addressed.
6
Periodic Safety Re-Assessment • Koeberg is compared against the EDF reference plant. • 1st Safety Reassessment was performed and implemented.
• 2nd Safety Reassessment was performed and is in the process of being implemented. • External Events Safety Reassessment was performed with implementation starting. • The resultant modifications are implemented as part of the strategy of continued improvement in safety and to maintain alignment to international standards. 1985
1990
1995
2000
SRA I
After Fukushima, NNR Instructs External Event PSR
2005
2010
Plant Upgrades
2015
SRA II
EESRA 7
2020
Plant Upgrades
2025
SRA III
Plant Upgrades
2030
Life Extension Modifications • Only modifications that result in once off intervention to operate beyond 40 years are considered to be associated with Plant Life Extension. • Anticipated once off interventions: o Steam Generator Replacement (In Progress) o Refueling Water Tank Replacement (In Progress) o Reactor Vessel Head Replacement o Control Rod Drive Mechanisms o Switchboards Replacement o Condenser Tube Replacement o Feed heater Replacement
o Power Cable Replacement
8
Ageing Management
• Ageing Management considerations starts at design stage – specific intention (40yrs) • Designer builds in measures to counter known and potential degradation: Material selection Provides maintenance/operations instructions (analysed envelopes) Monitoring suggestions Required Plant Programmes (minimum)
Ageing Management cont.. During the life of the plant, operators and utilities: • Respect the design and operating envelopes • Perform testing and monitoring • Identify operational deficiencies (unknown at design) • Investigate operating experience (OE) - Internal and External • Adjust design and operating envelopes
• Adjust the monitoring and establish additional ageing management programmes • Perform plant modification
At about midlife questions start:
Asset management – Are we going to make it? Life extension – Additional requirements to operate beyond the assumed life?
Ageing Management cont.. To answer the questions we respond in two ways:
1. Strategic Objectives as per: • Nuclear Licence • Corporate directives & policies • International Clubs • Nuclear Safety • Economics • Lifetime (40yrs, plan for 60) • Environmental impact
Ageing Management cont.. 2. Determine Actual Limitations • Worldwide this is needed for asset management purposes as well as regulator demands • Two broad approaches have been identified: USA - Ongoing operational regulator requirements (including maintenance rule)
Design description SAR/ DSE Comparison with actual plant Operations Procedures / OTS Maintenance & Monitoring Maintenance Bases ISI / IST Transients FAC BAC SRSM Etc. Aspects linked to: 1. Nuclear Safety 2. Production
AMP Confirms all degradation catered for
2025 (40y)
Age degradation
Ongoing Improvement
2045 (60y)
PLEX Business case: Already Identified replacement of expensive equipment e.g. SG, PTR & RPVH plus others as per Life Of Plant Plans
Ongoing Comparisons & Improvement
verified by 10yr SRA CURA/ NEXCO
Need specific intervention Can continue without intervention, risk is with Eskom (financial)
Ageing Management cont.. Specific Intervention Options US based
B. European Based (Recommended)
C. Unique
Try to emulate US by adapting Licence Renewal Process
Perform Special PSR as per IAEA guidance that covers:
1.
Continue all programmes
1. Plant Design
2.
Review EPRI IMT & GALL
2. Actual condition of SSCs
Develop unique suite of requirements with NNR ( can use various inputs e.g. EDF VD series)
3.
Compile a LR application
3. Environmental Qualification
4.
Commit to some replacements and resolutions plus new programmes( e.g. Maintenance Rule)
Will require special indepth review and justification plus studies
Ageing Management Matrix • The Ageing Management Matrix (AMM) contains a list of structures and components (SCs) and the ageing mechanisms applicable to the components. • The EDF ageing matrix was used to derive the initial Koeberg AMM. • An assumption was made that for the initial matrix, the ageing concerns of EDF and Koeberg are similar enough to adopt and allow for adaptation to the Koeberg AMM.
• The AMM is continuously updated when new international or internal ageing concerns are identified. • Where the ageing degradation mechanism is not addressed a gap is identified and tracked until resolution.
• Establish if adequate measures are in place to manage the identified ageing • Determine inspection, monitoring, justification by analysis, maintenance, testing, replace, etc. • Track "gaps" where ageing is not being sufficiently managed
• Documents specific ageing and integrity concerns and adopted strategy. • Identifies intended actions to achieve accepted objective. • Document items that do not require further evaluation as there are no ageing concerns.
Ageing Management Matrix Time Limited Ageing Analysis (TLAA)
Nuclear Technical Plan (NTP)
• Documents the Assumptions and Subsequent Calculations to conclude on Integrity.
• Specifies the Replacement and Refurbishment Projects.
16
References for identifying ageing EDF • Koeberg reference plant • Alignment with EDF Ageing Matrix
IAEA • Industry Links and proven practices • IGALL used for validation of AMM and AMPs
FROG • OEM (Hosted by Framatome, now AREVA) • All AREVA constructed plants participate
PWROG • Technology Reference • Most utilities operating PWRs participate
EPRI • Science Links • Many utilities across the world contribute
