GE HitachiNuclear EnergyGE HitachiNuclear EnergyNuclear EnergyNuclear Energy

Life Extension and P UPower Uprates

James CarnealProgram Manager -New Product IntroductionNew Product Introduction

2011 LB60 W k h2011 LB60 WorkshopFebruary 22-24, 2011

Washington, D.C.

OutlineEPU Fundamentals and Economics

120

110•EPU Fundamentals and Economics•How do you achieve EPU•EPU: higher steam quality, FW, Steam flows.

ReactorOperatingDomain

100

g q y, ,•Economics

•Primary concerns with EPUCore Flow (%) 1

00

$•Impact on Reliability, Design, Materials•Typical EPU Mods/Pinchpoints

I t f EPU Pl t Lif E t i

BreakevenROI

$

time•Impact of EPU on Plant Life Extension•Current EPU Experience•Survey of Literature

Investmenttime

Survey of Literature•What are primary concerns

2

EPU Fundamentals

3

EPU Fundamentals

How EPU is achieved:EPU l i th i il bl i th• EPU reclaims the margins available in the original plant design configuration – more realistic state-of-the art analysis

methodologies.

• Higher performance equipment is installed to• Higher performance equipment is installed to maintain safe plant operation. – The majority are in the Balance-of-Plant

& T bi /G t& Turbine/Generator areas.

4

EPU Fundamentals

Economics:• The utility’s decision on power uprate is

$• The utility s decision on power uprate is

based on a cost/benefit evaluation– must meet the financial metrics &

l t t t lInvestment

BreakevenROI

time

long-term asset management plan.

• Regulatory approval to operate anRegulatory approval to operate an additional 20 years – a large positive factor in the

cost/benefit evaluationcost/benefit evaluation.

5

EPU: Operational DomainMELLLA+ EPU

SPU

MEODwer

120

110

MELLLA+ = MELLLA Plus

SPU = Stretch Power Uprate

EPU = Extended Power UprateMEOD

ELLLA ICF

rmal

Pow

OLT

P)

Reactor

100

MEOD = Max. Ext. Op. Domain

SPU = Stretch Power Uprate

Cor

e Th

e(%

O ReactorOperatingDomain ELLLA = Extended Load Line

Limit Analysis

ICF = Increased Core Flow

OLTP = Original Licensed Thermal

Core Flow (%) 100

C OLTP = Original Licensed Thermal Power

• EPU will reduce both ends of the core window at rated power conditions.

6

• Min core flow state point will “increase”• Max core flow state point will be reduced

EPU: Mass Flow

FW flowSteam flow

Plenum Pressure

C FlJP Pressure

Core Flow

•EPU results in increased Feedwater flow/Steam flow:EPU results in increased Feedwater flow/Steam flow:•Core flow: small effect since Recirc flow.

•EPU effect: 1-2% increase in core dP•<1% increase in JP SJ dP

7

1% increase in JP SJ dP• Reduction in maximum core flow capability

JP/EPU: EPU without Core flow increase?Example #’s from BWR/5-251, CLTP 105%

CLTP and ICF (105% CF)

EPU (120% OLTP, 104% CF)

Steam Flow / FW 15 1 17 7Steam Flow / FW Flow (Mlb /hr)

15.1 17.7

Core Flow (Mlb /hr)

114 (7.5*steam) 112.7 (6 3*steam)(Mlb /hr) (6.3 steam)

Steam Quality @ core exit

13.2% 16.2% (+3%)

•Example calculation: •Core flow is 6.3 times more than steam/FW flow.

core exit

•Steam quality is +3% more than OLTP.•112.7/ 17.7 * 3%=19.0% more steam for same core flow.

•EPU achieved by increasing quality at core exit• multiplied by (recirc flow/steam flow) ratio

8

• multiplied by (recirc flow/steam flow) ratio.

EPU Economics• Typical 120% power uprate :

– cost approximately $250MM to $500MM.

Pl t i d l t f t• Plant economic and plant safety:– better reliability/availability performance – more robust and advanced designs of equipment upgrades/

l treplacements.

• 7 plants at 150MWe uprate = 1 new 1100 Mwe plantCost: $1 75B to 3 5 B versus $10+B– Cost: $1.75B to 3.5 B versus $10+B

BreakevenROI

$

time

9

Investmenttime

Primary Concerns

10

Impact on Reliability & Design Li it

Safety Limit

Limits

Regulatory Margin

Operating Limit

O ti EPUMargin erosion due to:- New Operating

Operating Margin EPU

NormalOriginal Power

Conditions- Power Uprate- Aging Affects

Normal Operation

11

Impact on materialsss

Original material curve

40 d d ti

ng S

tres 40 year degradation

80 year degradation

Alte

rnat

in

EPU

A

Cycles

ODB

• Need to gage material life.

Cycles

12

Need to gage material life.

Summary of Typical EPU Mods1) NSSS1) NSSS- Steam dryer replacement/modifications- Power Range Neutron Monitoring system2) BOP upgrade/replacement) pg p- Feedwater heaters- Condenser tube staking- Condensate pump and/or motor

Condensate demin filter

- Feedpump motor and/or blade- Iso-phase bus duct- Torus attached piping

Switchgear

3) Turbine/Generator upgrade/replacementHigh pressure turbine replacement

- Condensate demin filter- Moisture-separator reaheater

- Switchgear- Cooling tower fan

- High pressure turbine replacement- Generator rewind- Hydrogen cooler for generator

• Most utilities will include other hardware modifications to maintain equipment reliability, availability and/or higher efficiency.

• This is important to successful long-term EPU operation.

13

This is important to successful long term EPU operation.

Non Hardware-Related Pinchpoints 1) Set point changes

– calibrate to the new 100% rated thermal power condition2) Reactor vessel overpressure design limit2) Reactor vessel overpressure design limit3) Core thermal-hydraulic stability4) Containment pressure/temperature limit5) ATWS reactor vessel overpressure and containment P/T limit6) RPV mechanical stress limit

Notes:Notes: A) Except for item 1, the remaining pinch points are addressed by using refined

methodologies to meet the respective safety criteria. For example use TRACG (3 D) vs ODYN (1 D method) for items 2 and 5– For example, use TRACG (3-D) vs. ODYN (1-D method) for items 2 and 5.

• GEH has not experienced a hardware mod/replacement resulting from the pinch points

14

resulting from the pinch points.

Impact of EPU on PLEX

15

World Nuclear Plant Age10/13/2009Year 60+

10/13/2009Year 40

10/7/2009Year 15

9/29/2009Start-up

10/13/2009Year 25

Mid-LifeNew Older Extended-Life

4040

30

nts (

Wor

ld)

30

ants

(Wor

ld)

Due to length of

10

20

Num

ber o

f Pla

n

10

20

Num

ber o

f Pla

gLE, plants will start as early as current

01 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41

Age/ Years In-Service0

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41

Age/Years In-Service

current regulations allow.

16Source: IAEA

Factors Impacting EPU Planning

• Equipment reliability/availability • Plant Life Extension

• Licensing safety margins requirementsH d biliti

Operational MarginsEPU Pinch Points

• Plant Life Extension• Hardware capabilities

Control System Capabilities

D i B i D t ti

• Data Rates / Data Quality / Data Availability• Digital upgrades improve Safety Margin

• Completeness/Quality• Retrievability

Design Basis Documentations

Other Planned Initiatives• Technical rework

Project Management• Utility/Vendors interface

17

• Licensing constrainty

• Resources

Extended Power Uprate Experience120

8/00 6/05

11/06

5/06 5/06

8/02

100

110

Power

(%)

6/93 8/96 10/98 11/98 11/98 12/01 12/01 11/02 5/02 6/02 6/02 5/06 5/06 1/03 5/06

8/99

90

Ther

mal

80

KKM

KKL

Montic

ello

Hatc

h 1Ha

tch 2

eArn

oldes

den 2

esde

n 3

Clint

onns

wick 1

nswick

2Cit

ies 1

Cities

2Co

frent

es VYVarious plants

Licensed Limit

Mon Ha HaDu

ane

Dres

Dres C

Brun

swBr

unsw

Quad

CQu

ad C Co

fVarious plants

18

Current EPU Experience• Several EPU projects were performed with 60-year

plant life assumptions

• No resulting plant modifications linked to the 60 year assumption have been experienced

S f t li i it i ( h CUF 1 0) t ith• Safety licensing criteria (such as CUF<1.0) are met with current or improved methodologies• Some plants are very close to operational limit, and additional actions

may be necessarymay be necessary

• Is the trend going to be the same for +60 plant life condition?

19

Literature Survey- Potential EPU ImpactsImpacts

• RPV and Internals embrittlement• Increased fluenceIncreased fluence• Potential regulatory changes

• Water availability/conservation• Cable Aging

• Impact varies with plant specific application• Concrete exposed to high temperature and radiation • Weld Techniques – Repair of irradiated materials

O h N h i l• Other Non-technical:• Lack of cohesive domestic Research Infrastructure.• Shortfall in trained workers at all levels. • Public Opinion and Policy• Public Opinion and Policy.

d th li t20

and the list goes on…

Strategic OpportunityStrategic Position

Opportunity

• Clear Utility cost-benefit… life versus NPP.

• Increased Federal regulation (NRC and

Define … Measure … Timeline

g (EPA).

• GEH will be engaged with industry, regulatory and customers for PLEX.Analyze … Design … Verify

Acquire OEM dataStrategy& White Paper

NPI High ROI ST Projects

ID future MT, LT Projects

Acquire OEM/field dataPlant failure survey

Economic assessmentMaterials/life cycle management

Timeline

Strategic Plan MT, LT ProjectsWeibull analysis

y g y

Initial Goal: 80 Year Life Asset Management Strategy and White Paper• Clear strategic direction based on data analysis• Clear cost/benefit analysis of future potential markets

21

Clear cost/benefit analysis of future potential markets• Multi-Generational Product Plan from short-term to long-term

What will be Life Limiting?120

110

• Currently no known generic issue that will limit plant life to less than 80 years

ReactorOperatingDomain

100

p y

• Industry must develop technical bases for high risk life limiting issues

Core Flow (%) 100

• Individual plants must assess their risk and

Breakeven

$

- Maintain mitigation/contingency plans for high risk issues, and Maintain life c cle and aging

Investment

BreakevenROI

time

- Maintain life cycle and aging management to avoid obsolescence

22

QUESTIONS ?

Th k !Thank you!