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
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
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
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resulting from the pinch points.
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
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• 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