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LICENSEE: Arizona Pubfd S €8rkpany
Palo Verde Nuclear Generating Station, Unit 2
SUMMARY OF THE MAY 24,2000, MEETING TO DISCUSS STEAM GENERATOR REPLACEMENT AND POWER UPRATE ISSUES
On May 24, 2000, the U.S. Nuclear Regulatory Commission's (NRC's) staff, and the Palo Verde Nuclear Generating Station, Unit 2 licensee, Arizona Public Service Company, met in Rockville, Maryland, to discuss steam generator replacement and power uprate issues planned by the licensee for Palo Verde Unit 2. The licensee plans to replace both Unit 2 steam generators during the Fall 2003 refueling outage with generators being fabricated in Milan, Italy, by Ansaldo. The new steam generators have an improved steam dryer design, have 26 percent more heat transfer area, and use Inconel 690 steel for the tubes. Construction and quality assurance activities were discussed during the meeting, as well as the plans to transport the generators through Mexico to the site. A recent example of the licensee's activities in the quality assurance area was the rejection of almost 3000 steam generator tubes because they were manufactured 1.5 millimeters shorter than the specified length.
The licensee is planning to take advantage of the increased steam generator capacity by .requesting NRC approval of a power uprate for Unit 2. The licensing submittals associated with the power uprate proposal would revise the appropriate sections of Chapters 6 and 15 of the Updated Final Safety Analysis Report, and would revise the Technical Specifications. The staff noted that, when using generically approved computer codes to conduct the safety analyses, all conditions placed on the use of these codes should be specifically addressed in the licensee's submittals.
Enclosure 1 is the list of attendees for the meeting, and Enclosure.2 is a copy of the slides presented by the licensee.
It was agreed at the conclusion of the meeting that the staff and the licensee will meet in
approximately 6 months to discuss progress on these issues.
/RA/
Docket No. STN 50-529
Enclosures: 1. List of Meeting Attendees 2. Licensee's Meeting Slides
cc w/encls: See next page
Mel B. Fields, Project Manager, Section 2 Project Directorate IV & Decommissioning Division of Licensing Project Management Office of Nuclear Reactor Regulation
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Palo Verde Generating Station, Units 1, 2, and 3
cc:
Mr. Steve Olea Arizona Corporation Commission 1200 W. Washington Street Phoenix, AZ 85007
Douglas Kent Porter Senior Counsel Southern California Edison Company Law Department, Generation Resources P.O. Box 800 Rosemead, CA 91770
Senior Resident Inspector U.S. Nuclear Regulatory Commission P. O. Box 40 Buckeye, AZ 85326
Regional Administrator, Region IV U.S. Nuclear Regulatory Commission Harris Tower & Pavillion 611 Ryan Plaza Drive, Suite 400 Arlington, TX 76011-8064
Chairman Maricopa County Board of Supervisors 301 W. Jefferson, 10th Floor Phoenix, AZ 85003
Mr. Aubrey V. Godwin, Director Arizona Radiation Regulatory Agency 4814 South 40 Street Phoenix, AZ 85040
Ms. Angela K. Krainik, Director Regulatory Affairs Arizona Public Service Company P.O. Box 52034 Phoenix, AZ 85072-2034
Mr. John C. Horne Vice President, Power Generation El Paso Electric Company 2702 N. Third Street, Suite 3040 Phoenix, AZ 85004
Mr. David Summers Public Service Company of New Mexico 414 Silver SW, #1206 Albuquerque, NM 87102
Mr. Jarlath Curran Southern California Edison Company 5000 Pacific Coast Hwy Bldg DIN San Clemente, CA 92672
Mr. Robert Henry Salt River Project 6504 East Thomas Road Scottsdale, AZ 85251
Terry Bassham, Esq. General Counsel El Paso Electric Company 123 W. Mills El Paso, TX 79901
Mr. John Schumann Los Angeles Department of Water & Power Southern California Public Power Authority P.O. Box 51111, Room 1255-C Los Angeles, CA 90051-0100
Mr. Gregg R. Overbeck Senior Vice President, Nuclear Arizona Public Service Company P. 0. Box 52034 Phoenix, AZ 85072-2034
August 18, 1999
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LIST OF ATTENDEES
PALO VERDE NUCLEAR GENERATING STATION, UNIT 2
STEAM GENERATOR REPLACEMENT AND POWER UPRATE ISSUES
NRC/APS
MAY 24, 2000
ARIZONA PUBLIC SERVICE COMPANY
David Mauldin Carl Churchman Paul Clifford Richard Bernier Mohammad Karbassian Kevin Neese Ron Pontes Larry Joy Ted Erikson
WESTINGHOUSE
Bill Gardner Richard Bradshaw
BECHTEL
Eric Ocsterle Andrew Matyas
McGRAW HILL
Elaine Hiruo
NRC
Dick Wessman Mel Fields Chu-yu Liang Steve Dembek Anthony Attard John Tsao
Enclosure 1
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Palo Verde Steam Generator Replacement
And Power Uprate Project
Presentation To The
Nuclear Regulatory Commission
May 24, 2000W1
........
m C,
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Palo Verde Steam Generator Replacement And Power Uprate. Project
"Project Update
Carl Churchman SGR Project Director
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Objectives
* Provide status of SG replacement and power uprate project
+ Discuss oversight activities
* Provide details of project management
+ Discuss recently identified modifications
+ Discuss results of safety analyses
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Objectives
* Review installation plan
+ Provide update on licensing activities
* Provide an overview of upcoming activities
* Discuss integrated schedule
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Agenda
Introduction Project status & oversight ABBICE transition Safety Analyses Configuration
management
Modifications Installation plan Licensing activities Future activities
Carl Churchman Carl Churchman Rick Bradshaw Paul Clifford Mo Karbassian
Mo Karbassian Ron Pontes Dick Bernier Carl Churchman
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RSG Fabrication Status
* Tubing e Fabrication in progress
• Delivery to be in July and September 2000
* Tubesheet#1 e Drilling in progress
- > 75 percent complete
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RSG Fabrication Status
* Tubesheet#2 • Stub barrel welded to tubesheet
• Drilling to start mid-June 2000
* Lower and intermediate shells • Fabrication in progress for both SGs
* Eggcrate supports • Fabrication of templates in progress
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4-
RSG Fabrication Status
+ Economizer flow distribution plate #1 • Drilling in progress
* Primary channel heads * Support skirts attached • Stainless steel cladding in progress
* Primary nozzles "• Cold leg: stainless steel cladding in progress "* Hot leg: Safe ends attached
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RSG Transportation
+ Status of transportation plan
+ Status of permits
* Status of infrastructure improvements
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Oversight Activities
* Audited ABB Chattanooga in May 1999 • Seven findings
- Software control, design control, internal audit program, corrective action program
* Source verification performed in February 2000 "* ABB resolved all identified issues and
implemented appropriate corrective actions
"* Audit findings are closed
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Oversight Activities
* Audited ABB Windsor in August 1999 Eight findings - Software control/design control - Weakness QA audits/auditor training - Corrective actions
* APS has accepted corrective actions proposed by ABB
+ Implementation of corrective actions was verified during week of May 15, 2000
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Oversight Activities
* Audited Ansaldo Milan in June 1999 Wisconsin Public Service Corp. participated
Six findings "o Weak and ineffective corrective action • ~/,
"o Non-compliance ANSI Standard "o Procurement control
"o Compliance with cleaning spec (WPSC) "o Documentation of witness points
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Oversight Activities
* Audited Ansaido Genoa in June 1999 Wisconsin Public Service Corp. participated
Two findings "o Procurement control "o Corrective action program
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Oversight Activities
+ APS and WPSC have accepted corrective actions proposed by Ansaldo
* Ansaldo implementing corrective actions. to audit findings
+ Ansaldo has appointed a new QA director * Implementation of corrective actions to be
verified in June 2000
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Sandvik Oversight Activities
* Ansaldo audited Sandvik in March 2000 with APS in an oversight capacity * Results generally satisfactory with two minor
findings - Document control - Records storage temperature controls
* APS/Ansaldo quality team review scheduled for July/August 2000
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Sandvik Oversight Activities
* Short tubes * 2895 tubes fabricated 1.5mm short * Error related to use of incorrect drawing * Tubes to be replaced by Sandvik to meet
specifications
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BNFL Acquisition of ABB Nuclear *BNFL/Westinghouse announced the acquisition of ABB's Nuclear Businesses Worldwide on May 2, 2000.
*ABB Nuclear Companies will be integrated into and operated as part of Westinghouse.
* In USA: Westinghouse Electric Company
CE Nuclear Power LLC.
* No changes to the PVNGS RSG Project Team, QA, Technology, or Schedule are anticipated.
*BNFL
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Safety Analyses
SUFSAR Chapter 15 Transient Analysis "* CENTS code "• Analytical limits "* Methodology changes "* Sample from uprate submittal
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Safety Analyses
*CENTS will replace CESEC-III as the primary tool for Chapter 15 non-LOCA transient analysis.
SCENTS will be used to predict global changes in RCS pressure during the CEA ejection event. STRIKIN-II will continue to be used to predict local conditions (i.e., fuel enthalpy and DNBR).
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Safety Analyses
Initial conditions at full power Values Include appropriate uncertainties
Power
Inlet temperature Pressurizer pressure
RCS mass flow rate ?ressurizer level SG level Axial power distribution
MTC Primary to secondary leakage
= 4070 MWt = 548 to 566TF = 2100 to 2325 psia = 95% to 116% of design = 24% to 59% = 4% to 92% NR = -0.20 to +0.20 ASI = -0.20 to -4.0 E-4 delta-rhoIPF = 720 gpd I SG
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Safety Analyses SMethodology changes
e The following methodslassumptions changes will be applied to both the current plant configuration (Units 113) and Unit 2 RSG/uprate
- Dose calculations will assume a decontamination factor of 100 (partition factor of 0.01) forthe intact SG /
- Post-trip MSLB will employ a more detailed reactivity calculation, including moderator density feedback in the hot channel
- More realistic IOSGADV+LOP event analyzed separately from limiting AOO with SF (i.e., LOF from SAFDL)
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Safety Analyses
SMethodology changes (cont.) - Single RCP sheared shaft with LOP will
assume that, at 60 minutes, the operator either closes the stuck open ADV or reestablishes level in the affected SG
- SGTR+LOP will credit EOP-based isolation of affected SG
- SGTR+LOP+SF will employ calculated flashing (based on local conditions) for leakage into affected SG
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Safety Analyses
0 Sample from uprate. submittal • Outline and contents of the safety analysis
portion of the submittal is based on a composite of the PVNGS UFSAR and the Farley uprate submittal
• Inadvertent opening of a SGADV - Identification of causes and event
description - Acceptance criteria
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Safety Analyses
SSample from uprate submittal (cont.) • Inadvertent opening of a SGADV (cont.)
- Description of analysis - Input parameters, initial conditions, and
assumptions
- Results - Conclusions
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Safety Analyses
Table 7.3.1.4.5.A: Sequence of Events for IOSGADV+LOP Event
Time (sec) Event Value
3876 3990 3876 3990 MVIt M"t MWt MWt
0.00 0.00 Inadvertent opening of SG#1 ADV -- -
0.00 0.00 Core Power (% RTP) 100 100
0.00 0.00 Hot Channel Minimum DNBR 1.72 1.72
147.9 176.5 SG pressure reaches MSIS/Trip setpoint (psia) 850 915
149.1 177.7 Reactor/Turbine trip
Loss of Offsite Power
149.7 178.3 Scram CEAs begin falling _ _ -_
151.2 179.7 Minimum DNBR > SAFDL > SAFDL
153.5 182.1 MSIVs Closed -_ _ _
352.7 329.3 SG#2 MSSV Bank I Open (psia) 1303 1303
Begin Oscillating
463.9 428.3 RCS pressure reaches SIAS setpoint (psia) 1750 1750
919 1005 SG#1 Empties -_
1800 1800 Operators manually close SG#1 ADV .
1800 1800 Operators initiate cooldown (min) 30 30
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Major Activities
SU2R10 (spring 2002) • Remove interfering commodities from
bioshield wall • Polar crane preparations (based on U2R9
inspection) • SG2 auxiliary crane supports • Modify second containment spray pump
impeller
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Major Activities
SU2CII (summer 2002 - fall 2003) "• Craft access facility "• Outside lift system
"• Haul route
"* RSG preparations
* U2R11 (fall 2003) "o Bioshield wall modifications "• Replace steam generators
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PVNGS - 2Rl I Steam Generator Replacement Outage Summary Schedule
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STEAM GENERATOR REPLACEMENT LEGEND
5 SIG REPLACEMENT CONTRACTOR PROCESSING, OFFICE & BREAK AREA FACILITY (EXISTING) SIG REPLACEMENT CONTRACTOR WAREHOUSE FACILITY (EXISTING)
Q REPLACEMENT SIG OFFLOADISTORAGE LOCATION
CONTAINMENT ACCESS, CRAFT ASSEMBLY AREA & POD/OUTAGE MANAGEMENT FACILITY
S OLD SIG STORAGE LOCATION
SIG CONTRACTOR SECURITY ACCESS V FACILITY
SEMERGENCY PERSONNEL HATCH) 100
® FAB SHOP, WELD TEST SHOP & MOCK-UP FACILITY (EXISTING)
4 LAYDOWN AREA
@CONTRACTOR PARKING AREA
DECONTAMINATION FACILITY / Im '00
NOTES:
1. SECURITY GATE TO BE REWORKED TO FACILITATE SG MOVEMENT INTO PROTECTED AREA.
2. CONTRACTOR TRUCK/SMALL EQUIPMENT ACCESS TO PROTECTED AREA
May 9,2000
STEAM GENERATOR REPLACEMENT
SITE FACILITIES
STEAM GENERATOR REPLACE ENT LEGEND
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EQUIP. HATCHY TRAILER. SADDLES. & SG '
AKPRUNWAYO f I., 2'-7 3/8m !.JACK POD. TYP.
1-- /2.-- I/. -'-7 1/___*L.-8-7-1/2;,
I I i
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4J
JBUC SERVICE COMPANY GENERAL ANGSMENT HANDLI]NG SGs % o
NERATOR REPLACEMENT OUTSIDE CONTAINMENT __98_90 ______ VERDE NUCLEAR 2. SKETCH 05.04-4 |___ __ __ ___
i II
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0 Uý . S. (2)
SECONDARY
MANWVAY
~SNUDBERLUa- I Mr CLEAR
-RECIRC
RUNWAY RAIL STRUCTURE
DOWNCOUER FEEDWATER
ELEVATION
i'vkMist" MIN
I
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.- 33'-3 3/4"
* POL.AR CRANE (EXISTING)
Ix
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in
ta
in
W--.§ -Th -f. DRA of=* I Umaa I~mu A@ -L -ý ... i ARIZON
CATS eT AUC
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Licensing Activities
+ APS had planned a two phase submittal in August 2000 and February 2001
* APS will combine into one submittal in June 2001
* Request approval in June 2002 * U2C12 fuel design to commence in
September 2002 based on SER from NRC
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Potential Technical Specification Changes
+ Definition of rated thermal power
* Low SG pressure reactor trip setpoint
+ Low SG pressure MSIS setpoint
* Peak containment pressure,
* Operating range for cold leg temperature at 100 percent power
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Test Program
* Review UFSAR Chapter 14 for applicable testing
* Use existing Surveillance Test Procedures as applicable
* Test program and results to be described in start-up test report in accordance with the PVNGS TRM
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PVNGS Unit 2 SGRP I Integrated Level One Schedule for RSG & Power Uprate 1997 1998 1999 2000 2001 1 2002: 2003 1:20041
U2i0
Design & Document Phase
U2RU
Fabrication of RSGs9Ansaldo Energla $.p.a. In Milan. Italy
U2RMO
12W07 I102
Uprate Scoping
4*08
Award Eng. Contract I Obtain Infrastructure Permits Transport to
nalize Trnsportaion Route Intervention Modification Transport
Study Complete, 'wC RSGs II Engineering=%,
APS & CE RSG I Uprate Engineering Analysis Analysis R IDSI20o *1e01
NRC Evaluation /Approval of Uprate Submittal &01
RSG & Power Uprate Modification Engineering & Installation W2
Venice
to PVNGS
Arrive At PVNGS *9)02
1109 110
Signed Installation Phase I Contract With Bechtel
Spray Pond Temp Transmitter Uprate Eng SP Temp Trans Uprate Installation .11013 W01 , 3102MSIo"
Main Transformer Cooling Eng. Main Transformer Cooling Installation
Cooling Tower Wnd Vane Eng.
"Cooling Tower Wind Vane Installation ED Control Valve Eng. ED Control Valve Insllatklo 1i02~~5102 12I 22I
Containment Spray Pump impeler Modilfication Engineering
Containment Spray Pump Modliled Impeller Installation SOte P12W 0Iaa 20n . Site Preparations for Installation
309 III i mosU2R8 - Laser Piping Templating U2R9 - Design Verification Wlldowne U2R 10. elo-shield VAll Mods logo/Iraqi W • •2ems0MS
Prepare/Issue U2RIO DCP*s Prepare/Issue U2RIOV1P's SG Level Transmitter Installation
SO Level Transmitter Design Eng SG Level Transmitter Installation P 5001 3002000502
PreparelIssue Const. Proc. Prepare/Issue U2Ri I Vi's3I01 Pe Ae Ae-01
Insalal Protected Ares Access. Nort
U2R11, Replace SGO
s52 Tm
Prepare/Issue U2R1 I DCPas
"Design/Consruct OSG Storage/NSG Storage Facilities
North Annex Remodeling Install Downcomer Slowdown Electlcal Modification S..I ,
Avarded To Awalkdo
M3211
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STEAM FLOW, Ibule•
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001i;1 ODE 0 1 006 009 ODE 0
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3PID~309'H1411
0051 0S' W0E1 006 009 WOE 0
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'IA\Vq 06,6E
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sasi~euv S, aWP
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Safety Analyses
* Sample from uprate submittal (cont.) Conclusion
For the IOSGADV+LOP event, all of the acceptance criteria are met. The peak primary and secondary pressures remain below 110 percent of design at all times, thus ensuring the integrity of the RCS and main steam systems. The minimum hot channel DNBR remains above the SAFDL, thus ensuring fuel cladding integrity. Offsite radiological consequences remain within a small fraction of 10 CFR 100 guidelines.
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Configuration Management
CENP Analysis
S&L Analysis
Palo Verde Modification Packages
lAW 81 DP-OEE1 0
4-
Bechtel Analysis
Bechtel Installation Standards
PVNGS Impact Process 81 DP-OCC26
RSG Design Specification
02MN-725
Ansaldo Design & Analysis
u ,, !
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Configuration Management
I
Mod Pkg #1
Mod Pkg #3
Mod Pkg #2
Mod Pkg #4
Mod Pkg #1
Mod Pkg #3
Mod .Pkg #2
Mod Pkg #4
N,
Master Mod Pkg
Power Uprate Mod
I
SGR Mod
. II I
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Control Of Design Inputs
41Analysis
Bechtel Analysis
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Containment Spray Modification
* Increase in calculated containment peak pressure has decreased pump head margin
* Pumps would be marginally acceptable * Approximately 8 PSID margin is desired at
test flow rate
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Containment Spray Modification
*Alternate flow rate instrument with less uncertainty will be used to regain ~4 PSID
* Modifying pump impeller profile will regain the remaining desired margin • Vendor guidance will be used
* One pump to be done in 2R9 * One pump to be done in 2R10
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Bechtel Engineering Schedule Palo Verde Unit 2 SGRP
Page 1 of 1 5111/00
1999 2000 2001 2002 2003
soJF A JJAso NID JJIFI AJIJAIAIsAINDJFMAM JIJIA1sloINIDJIFI+II JIJIAISoNID N-2 :: iN1 { ;SGRO
Walkdown Plans 3/ $/2t./ 101"!6
POWER UPRATE ENGINEERING... J 1 0 .. Primary Systems Analysis 1/3 !! - 8/1 Jun 19.'00: Prelim Branch Line Reaction Loads ~~~~~~~ ....... P m a y S s m .A n l s s ..................... ...... .. ..I.............. ..... ....... Ba c ..n .e ~ .o d .. .... "... . . .. ...
Secondary Systems Analysis 1 1,/21 July 31, '00: Prelim RSG Nozzle Reaction Loads
Containment Structural Analysis 3/10.- 10/,. 4
N-1 MOD PACKAGES i K. Prepare 30% Packages6 5. *"- .......15 Prepare 70% Packages 2.8 6----44/16: "Prepare 100% Packages 5/220--07-17: I S5/22 I•! 7117! Sept 4,'01: N-1 +
Issue Final Packages ....... 8/7. 8/28 Sackagep .. N i e . ..................... ........ .. .. ........... .. .. ...
PRE-OUTAGE MOD PACKAGES .. ... .......... ........... .. ..i .... .. ........ . .... ........ ....... .. .... .. .. • • • P r e p a r e.7.%.P.ck a g e s.......................................................... . ..... .............. . . ................ .. ............ . . ......................... ............... . Prepare 30% Packages ' 3 .... 7/./ i
Issue...Final..Packages. .Aug 16,'02: Pre-Outage-+
.Issue Final Packages .. 150" Packages Complete ... .. ..... ....... .. ......... ...... ...... ... ... ........ ................... ........ .... ...... .. .. .................. .... .......... .......... ................. ........ .i .. .... .... ... . .. ..... .............. .... ... ......... SGRO MOD PACKAGESj
Prepare 30% Packages . .7/13 Prepare 70% Packages 5/7 3f2 I P ......... 00%.... ......Packag es .... -.. J.2 , 0:.R.............. . ...... ... ....... ... .. .... . .... .... ..... .. F e .. a r... e- .1 0 0.%..o. .......... ..Pa c k....... ........ .... ...... ......" ........................ ........ .... +....... .... .. ... , ... .... ..... .... 1.7 ... ......... ... .. .. ... .... .......... .O e c 2 0 , '0 2 : S G R O ,
Issue Final Packages .1 . Packages Complete
POST-OUTAGE MOD PACKAGES I .
Prepare 30% Packages . . .. .. .. ... 22 Prepare 70% Packages 7/22 *-19/13 Prepare 100% Packages 7... ! 10/7 1- 18 ... . ... . ........ + . ... .... .... . . ..... ........ • .. . .... .. .D e c 2 0 , '0 2 : P o s tIssue Final Packages 12/2 l2/13 DcOutagePosC Outage Pkgs Cmplt
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0~
CD
U~)
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SGR Implementation Phase -Functional Organization -
5/18/00
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Major Activities
* U2R9 (fall 2000) • Laser templating of piping in containment • Design walkdowns in containment • Polar crane inspections
* Modify one containment spray pump impeller
* U2C10 (winter 2000 - spring 2002) • Personnel access and north side sally port
Art •