Unit Commissioning of “Belene” NPP (Bulgaria)

Unit Commissioningof “Belene” NPP (Bulgaria)

Varna, 2010

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1. Principles of NPP commissioning

Necessary permissive documents: Permission from the relevant Nuclear Regulatory Bodies of the Bulgarian Republic and other competent state bodies for the implementation of the Commissioning Program

Valid rules, norms and standards, as specified in the Contract«Power Unit Commissioning Program” Program shall comply with the

requirements concerning the execution of procedure of licensing and authorization for safe use of nuclear energy

Main categories of activities at NPP unit completion of construction and in Commissioning period erection works, commissioning

works, operation of the accepted objects

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1. Principles of NPP Commissioning (continuation)

Commencement of Activities- Construction and erection readinessof buildings, systems and NPP Units

Completion - Integrated Tests of power units

Activities performed - Individual tests of the installed equipmentFunctional tests and Integrated Tests of the

systems and equipmentя systems and equipmentReactor physical start-up Power start-up and design power development

освоение проектной Integrated tests of the unit equipmentКонечная цель Confirmation, that the systems (components)

of power unit and a unit as a whole areimplemented and operate in compliance withthe design and deficiencies are corrected.

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BPP Belene Unit 1 Commissioning Schedule

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2. Phases of NPP Commissioning

Phase А0 Preparatory PhasePhase А Pre-commissioning adjustment worksPhase B0 Receipt and initial storage of nuclear fuel at NPP

sitePhase B1 Initial core loading with nuclear fuel and tests

in sub-critical state

Phase B2 First criticality and tests at the minimum controllable power level;

Phase C1 Power start-up, power development to 50 % andunit handover to trial operation

Phase C2 Trial operation of the powerunit, including development of nominal

thermal power and integrated tests of the power

unit.

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3. Phase А0 − «Preparatory Phase»

Activities at Phase А0 «Preparatory activities»

Preparatory phase covers the activities making provisions for the subsequent NPP power unit commissioning phase:

organizational support of the subsequent commissioning phases;

technical support of the subsequent commissioning phases;

material support of the subsequent commissioning phases;

adjustment works with temporary power supply of the systems and equipment providing for erection and adjustment works at Phase A “Pre-commissioning adjustment works”.

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3. Phase А – «Pre-commissioning adjustment works»

The structure of Phase А «Pre-commissioning adjustment works»

Phase А «Pre-commissioning adjustment works», based on the requirement of commissioning safety assurance and/or optimization of NPP commissioning technology, a power unit commissioning Phase A “Pre-commissioning adjustment works” is divided into stages, in its turn Phase А3 is split in two phases А3-1 and А3-2

Stage А1 – «Individual and functional tests of the power unit equipment and systems»;

Stage А2 – «Tests of hermetic enclosure system»;

Stage А3 – «Cold-hot run-in of Reactor Plant”;

Stage А4 – «Inspection of the main equipment of Reactor Plant”.

Phase А-3.1 stage А3 – Hydrostatic tests of the primary and secondary circuit, circulation flushing of the primary system and cold run-in of the Reactor Plant;

Phase А-3.2 stage А3 – «Hot run-in of Reactor Plant equipment”.

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3. Phase А – «Pre-commissioning adjustment works»The structure of Phase А activities «Pre-

commissioning adjustment works»1 Cold tests, including:

Stage A “Pre-commissioning and adjustment works”: based on the requirement of commissioning safety assurance and/or optimization of NPP commissioning technology, a power unit commissioning phase may be split up into stages.

Stage А1 – Individual and functional tests of the power unit equipment and systems, including adjustment works on the first-priority and supporting systems;

Stage А2 – Tests of hermetic enclosure system;

Stage А3 Phase А3-1 – Hydrostatic tests of the primary and secondary systems for strength and leak-tightness, circulation flushing of the primary system and cold run-in of the Reactor Plant.

Stage А4 – Inspection of the main equipment of Reactor Plant after hot tests at nominal primary system parameters ;

2 Phase A-3.1 Stage A3-Hydraulic tests of the primary and the secondary circuits, including circulation flush of the primary circuit and “cold” run of Reactor Plant equipment;

3 Phase A-3.2 Stage A3- “Hot” run of the Reactor Plant equipment.

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3. Phase А – «Pre-commissioning adjustment works»

Criteria of Completion of Stage A “Pre-commissioning adjustment works”

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the scope of works defined by the phase program is completed;

inspection of the main and auxiliary equipment is completed, identified non-conformance eliminated;

refueling machine integrated tests are completed, the machine in handed- over to service;

preparation of power unit for Phase B1 – Initial core loading with nuclear fuel and tests in sub-critical state – is completed.

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3. Phase В0 – «Receipt and initial storage of nuclear fuel at NPP site»

Objectives of Phase B0

incoming inspection of nuclear fuel;providing for nuclear fuel integrity;fuel accounting and provisions for its safe storage;integration of the initial core loading with nuclear fuel.

Completion criteria of Phase B0all the works determined by the requirements of the phase program are

completed;verified characteristics of the systems and equipment comply with the

requirements of technical documentation;fresh nuclear fuel is prepared for transfer to the Reactor Building and loading

into reactor in accordance with the requirements of the initial core loading program.

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3. Phase В1 – Initial core loading with nuclear fuel and tests in sub-critical state


safe initial loading of fuel assemblies into the core;filling the primary circuit with the coolant of the quality required by the design;

reactor assembling and a complex of works on verification and putting into service of safety systems and systems of normal operation of the power unit, including provisions for reactor plant, systems and equipment parameters’ values required before the reactor is brought to the critical state;

tests in sub-critical state in accordance with the phase programme and provisions for availability for Phase В2 – «First criticality and tests at the minimum controllable power level»

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3. Phase B1 “Initial core loading with nuclear fuel and tests in sub-critical state”

activities:

Completion criteria of Phase B1

the core is loaded with regular fuel assemblies and CPS control rods;the reactor is assembled;the primary circuit is filled with the coolant of the required quality;the primary circuit is heated-up to the nominal parameters;

safety systems and systems of normal operation of the power unit tested and put into service, provisions are made to ensure that parameters of the reactor plant, systems and equipment are in line with those required before the reactor is put into critical state;

integrated tests of Reactor Control and Protection System are completed;the tests defined by the phase programme are fulfilled in full scope

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3. Phase В2 – First criticality and tests at the minimum controllable power level


make provisions for and conduct reactor start-up in a safe and prescribed manner;

determine the major physical characteristics of the reactor core;verify the compliance of neutron-physical characteristics of the reactor core

with the design specificationsverify the compliance of reactivity-affecting systems with the design

specifications;verify the compliance of emergency reactor protection system effectiveness

with the design specifications;tests to checkup thermo-hydraulic characteristics of the Reactor Plant and

validate the indications of Reactor Plant parameters’ monitoring and recording system and calibration of Neutron Flux Monitoring System.

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3. Phase В2 – First criticality and tests at the minimum controllable power level

Completion criteria of Phase В2

the reactor reached criticality and reactor power increased to 1% of the nominal;

tests and experiments on obtaining experimental data of neutron-physical characteristics of the reactor core defined by the phase programme of the unit first criticality are implemented, and their compliance with the criteria established in the tests programmes are verified;

the tests to verify the design thermal-hydraulic characteristics of the reactor plant, and validate the indications of Reactor Plant parameters’ monitoring and recording system and calibration of Neutron Flux Monitoring System by reactor thermal power have been completed.

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3. Phase С1 – Power start-up, power development to 50 % and unit handover to

experimental operation

Objectives of Phase С1increase of reactor power from minimum controllable power level to the

power level providing for initiation of electric energy generation and successive power development to the level of 50 % of the nominal;

verification of reactor core neutron and physical characteristics compliance with the design values;

verification of the actual parameters of the equipment and systems for compliance with the design specifications in steady state and transient conditions, to ensure safe and reliable operation of the power unit equipment;

identification and logging of phenomena and processes for which no provisions are made in the design and which may have impact on serviceability of power unit equipment and systems;

checkup of stable operation of the main equipment of NPP power unit at thermal power level of 50 % of the nominal during 72 hours;

acceptance of NPP power unit to trail operation.

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3. Phase С1 «Power start-up, power development to 50 % and unit handover to

experimental operation»

Completion criteria of Phase С1determined actual characteristics of the core, verified compliance of the said with

design specifications;

verified compliance of the actual parameters and characteristics of the systems and equipment with the requirements of the manufacturing plants and design specifications;

verified safe and reliable operation of NPP power unit systems and equipment in steady state and transient conditions in compliance with the design specifications;

completed tests of the system and equipment defined by the test programmes, the results meet the acceptance criteria;

successive power development of NPP unit from the minimum controllable power level to the power level of 50% of the nominal;

verified stable operation of the main power unit equipment at thermal power level of 50 % of the nominal during 72 hours;

power unit is accepted to experimental operation;

NPP power unit is prepared for implementation of Phase С2 «Trial operation of the power unit, including development of nominal thermal power and integrated tests of the power unit».

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3. Phase С2 – Trail operation of the power unit, including development of nominal

thermal power and integrated tests of the power unit

Phase С2 “Experimental operation of the power unit, including development of nominal thermal power and integrated tests of the power unit” is part of the complex of Belene NPP commissioning activities and is split up into the following 2 stages:

Stage С2-1 «Unit power development from 50 to 100 % of the nominal power»;Stage С2-2 «Integrated tests of power unit at nominal power».

Objectives of Stage С2-1at thermal power of 75 and 100 % verify the compliance of the actual parameters and

characteristics of the systems and equipment with the design specifications in steady-state and transient conditions of power unit to make sure of reliable and safe operation of equipment;

identify and log the phenomena and processes for which no provisions are made in the design and which may have impact on serviceability of power unit equipment and systems at power levels of 75 and 100% of the nominal.

stabilization of the primary and secondary parameters. Determination of FA status by radiation-chemical analysis method.

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3. Phase С2 “Trial operation of the power unit, including development of nominal

thermal power and integrated tests of the power unit”

Completion criteria of Phase C2-1 “Development of nominal thermal power”

successive power development of NPP unit to minimal power levelinclusive is completed;

determined actual neutron and physical characteristics of the reactor; verification of reactor core neutron and physical characteristics compliance with the design values;

determined actual parameters and characteristics of NPP power unit unit equipment and systems, verified compliance of the said with design specifications; verified safe and reliable operation of NPP power unit systems and equipment in steady state and transient conditions in compliance with the design specifications;

Trial Operation of NPP power unit as well as all testes, provided for in the phase program, are completed.

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3. Phase С2 – Experimental operation of the power unit, including development of

nominal thermal power and integrated tests of the power unit.

Stage С2-2 «Integrated tests of power unit at nominal power»Decision on initiation of Phase C2-2 shall be taken by Commissioning Management Committee following verification and validation of the power unit availability based on:

report of the Working Committee on completion of activities for Phase “Development of nominal power of power unit” (C2-1);

report of the Working Committee on availability of NPP power unit for Integrated Tests.

Objectives of Stage С2-2Demonstration of stable operation of equipment and the power unit as a whole during 72 hoursintegrated test of the joint operation of power unit equipment, I&C, automatic regulation, monitoring and control systems of APCS while the unit is operating at nominal thermal power in base-load mode during 72 hours;verified stable operation of the main power unit equipment and the power unit as a whole at thermal power level in the base mode during 72 hours;Integrated Tests of the power unit shall be carried out continuously during 72 hours of the NPP power unit operation at nominal thermal power in a base mode.

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3. Phase С2 – Experimental operation of the power unit, including development of

nominal thermal power and integrated tests of the power unit.

Completion criteria for Integrated Tests of NPP power unit (Phase С2-2)

Integrated Tests completed in full scope as prescribed by the integrated tests programme;

verified continuous reliable operation of equipment and the power unit as a whole during 72 hours meting the design specifications;;

while the integrated tests of NPP power unit were conducted :- safety limits and conditions as stated in Technical Specifications of

Belene NPP Units 1 and 2 were observed;

- over the total period of integrated tests at the nominal power level the primary and secondary water chemistry was in line with the normative requirements;

- the equipment and overall power unit parameters were within the authorized limits specified for power unit operation at nominal power level.

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4. Commissioning Management Structure

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5. Responsibility and Obligations of the SidesDuring Commissioning of Power Unit

Duties and responsibilities of Contractor

commissioning of NPP power units prior to completion of Integrated Tests of each power unit and quality assurance of works;

provision of experience and qualified personnel to fulfill the obligations regarding commissioning of Belene NPP Units 1 and 2;

supply of commissioning documentation and the appropriate reports that will be required to fulfill the obligations regarding commissioning of power units;

organization, management and coordination of construction and erection works and adjustment works to fulfill the commissioning schedule,;

handling the executive and reporting documentation;

technical supervision of Employer’s operation personnel activities before the commencement of Phase B1.

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5. Responsibility and Obligations of the Sides During Commissioning of Power Unit

Duties and responsibilities of Contractor

development and coordination with the Employer of commissioning documentation in the scope determined by the Contract terms and conditions, correction of “as-built” commissioning documentation at NPP site prior to commencement of commissioning activities based on consideration of integrated tests of the power unit;

Participation of the Employer’s personnel in commissioning activities and tests on systems, equipment and components of NPP and futher maintenance and repair of NPP power unit systems and equipment by the personnle of the Employer;

organization of work and technical supervision of the activities of the Employer’s operation personnel before the commencement of Phase B1;

providing technical support to the Employer’s operation personnel at phase B1 and at further commissioning stages;

providing technical support to the Employer in preparation of materials to obtain licenses and authorizations from Bulgarian Nuclear Regulatory Agency and for registration of pipelines and equipment;

Assignment of required personnel to NPP Site for activities carrying out.23

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Duties of the Employernuclear and radiation safety of Belene NPP from the point of nuclear fuel

arrival at Belene NPP site;determination of the need for and obtaining of all licenses and

certificates from the Regulatory Authorities of the Republic of Bulgaria that should be obtained by the Employer in compliance with the Country Law; organization, management and disciplinary control and coordination of qualified operation personnel;

establishment of working committees and sub-committees;timely review and approval of commissioning documentation submitted

by the Contractor;Responsibilities for inadequate performance of its staff and consequences

of such inadequate actions;coordination of the power units’ operation personnel the network

dispatching service personnel performance during adjustment and tests activities in power units commissioning period;

provision of all power resources and expendables required for commissioning.

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Obligations by the EmployerProviding to the Contractor of the operational and maintenance

personnel, which is qualified, certified and has permit to work, to operate under technical guidance and with technical support of the Contractor; the working place of the personnel shall be equipped with everything required;

Providing the Contractor (from pre-commissioning stage till integrated test of the power units), at his request, with everything required for fulfillment of the Contractor’s obligations;

Providing the Contractor’s specialists at NPP Site with shop-floors and laboratory facilities required for work; providing of the premises with all communal services to be ensured under the Contract;

Ensuring operation of the laboratories for metal control, radiochemical laboratories, water-chemical laboratories, and fulfillment of medium chemical analyses during putting of NPP units into operation.

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Duties and responsibilities of I&C Supplier –AREVA NP GmbH

Development of I&C Design;I&C manufacturing, factory acceptance tests and supply; I&C pre-commissioning and commissioning activities; Training and qualification of pre-commissioning and commissioning personnel

of the Contractor and the Employer, performing I&C pre-commissioning and commissioning activities, temporary operation and maintenance;

Preparation of pre- commissioning, commissioning and operational documentation for I&C maintenance of the scope of AREVA NP GmbH supply;

Supply of required instruments and devices required for carrying out activities for I&C on temporary importation terms;

Completion of start- up group with qualified and attested pre-commissioning, commissioning, operation and maintenance personnel from AREVA NP GmbH-supervisors for organization, supervision and technical supervision for I&C pre-commissioning within the scope of AREVA NP GmbH supply;

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5.Responsibility and Obligations of the SidesDuring Commissioning of Power Unit

Duties and responsibilities of Belene NPP Designer - General Designer (AEP)

Accepted technical solutions, which determine reliability and safety of the Contract NPP to be checked during NPP commissioning, provision of compliance of operational characteristics with the provisions approved in the Contract;

Timely taking-over of pre-commissioning, operational documentation, engineering procedures as well as documentation for erection operations –flushing programs(blow-downs), hydraulic tests of the systems and equipment, individual tests, specifications and drawings of temporary elements for flushing (blow-downs) as stipulated in the design within the framework of the Contract NPP;

provision of designer’s supervision at all stages including power unit commissioning in order to confirm compliance of works and results of inspections and tests with the design requirements;

Introduction of modifications and alterations into detailed design documentation according to the results of NPP pre-commissioning activities and commissioning, as build documentation revision at Belene NPP Site in compliance with the results of pre-commissioning activities prior to Preliminary Acceptance of NPP power units for operation;

Development of technical corrective measures for removing found non- conformances or issue of conclusion on possibility of power unit operation with irregularities after performance of measures required and documentation revision;

Development of Final Report for FSAR and revision of FSAR in the Contractor ‘s responsibility

scope considering the results of commissioning activities.

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Responsibility of Scientific Supervisor of NPP and Rector Plant Projects - RNTs «Kurchatov Institute»;

Scientific supervision of NPP and Reactor Plant Projects;Revision of achievement of NPP design feasibility study and operational

indexes;Participation in the development of design documentation for NPP and FSAR,

additional design materials for Reactor Plant and power units as a whole, technological regulation of NPP safety operation;

Arrange of scientific and technical tasks related to radiation and nuclear safety, which occurred at all stages of NPP life-time;

Decision making for principle technical issues, safety issues, selection of main parameters of the reactor plant and reactor core, fuel cycle which are obligatory for RP Designer and NPP Project Designer;

Adjustment of modification of RP and NPP design characteristics.

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5.Responsibility and Obligations of the SidesDuring Commissioning of Power Unit

Duties and responsibilities of Designer of RP for Belene NPP-OKB Gidropress

Accepted technical solutions, which determine reliability and safety of the RP to be checked during NPP commissioning, provision of compliance of operational characteristics with the provisions approved in the Contract;

Participation in the development of design documentation for NPP and FSAR, additional design materials for RP and power unit as a whole , technological regulation of safety operation of Belene NPP;

provision of designer’s supervision at all stages including power unit commissioning in order to confirm compliance of works and results of inspections and tests with the design requirements;

Introduction of modifications and alterations in design documentation of the RP according to the results of pre-commissioning activities;

Development of technical corrective measures for removing found non-conformances or issue of conclusion on possibility of power unit operation with irregularities after performance of required measures and documentation revision;

Safety, operability, efficiency and reliability of the RP; Achievement of RP design feasibility study and operational indexes; Achievement of the required level of nuclear, radiation, fire and technical safety;Introduction of modifications and alterations in the documentation according to

pre-commissioning activities results .

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5. Responsibility and Obligations of the PartiesDuring Commissioning of Power Unit

Division of responsibility during completion of erection works and taking over the equipment to pre-commissioning, carrying

out of pre-commissioning on the process systems and equipment

Procedure of pre-commissioning on the pre-commissioning systems and equipment is implemented during two stages:

Individual tests, completion of which is the end of works on the erection of the equipment;

Functional tests and integrated system and equipment testing; Sequence of work performance:

Individual tests;Taking over of the equipment and system (part of the system) to the Pre-

commissioning Department of Commissioning Directorate for conducting of pre-commissioning with the issuance of the protocol about taking over to pre-commissioning;

Implementation of pre-commissioning on the given system (carrying out of the functional tests and integrated system testing).During individual tests of the equipment the following is carried out:Idle running tests of the rotate equipment (pumps, fans, compressors and etc.);Adjustment of the emergency gears;Operability check of the fittings;Process systems and equipment tests for stability and tightness (hydraulic and pneumatic tests).

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5. Responsibility and Obligations of the Parties During Commissioning of Power Unit

Division of responsibility during individual tests of the equipment

Subcontractors of the erection works are responsible for:Ensuring of the safe conditions of implementation of the individual tests of the equipment, post-

erection clearance for stability and tightness of the process equipment and pipelines;Assembling and dismantling of the temporary elements, temporary service sites; Implementation of the individual tests of the equipment; Implementation of the tests of the process equipment and pipelines for stability and tightness; Implementation of the post-erection clearance of the process systems and equipment, and

opening and closing of the manual driven valves; Fitters operations on maintenance of temporary circulation circuits; Tuning of hanger-support system of pipelines; Fitting on tuning of emergency gears;Preparation of the equipment to the external and internal examination before and after post-

erection clearance and equipment and systems run, opening and closing of equipment hatches, collectors and tanks, filter cleaning;

Equipment maintenance;Primary equipment loading with the process media and sorbents and implementation of

hydraulic (pneumatic) tests after loading;Timely removal of the ascertained assembly defects;Imposition of the thermal insulation, mapping of the protective covering;Preparation and issuance of the reporting documentation on the works performed.

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5. Responsibility and Obligations of the Parties During Commissioning of Power Unit

Division of responsibility during individual tests of the equipment

The Subcontractor of pre-commissioning works (Commissioning Directorate) is responsible for:

Program and test methods development;Monitoring and technical management during individual tests of the equipment by

subcontractors erection organizations.Operational Personnel (operational personnel of the Employer in the framework of its responsibility during technical management of the

Contractors operational personnel) is responsible for:Permission of the erection and pre-commissioning organizations to the

implementation of the individual tests of the equipment, post-erection clearance and tests for stability and tightness of the process equipment and pipelines;

Preparation of the equipment to the individual tests; Implementation of the on-line switching of the equipment and electrify fittings

during individual tests of the equipment and tests for stability and tightness of the process equipment and pipelines.

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Division of responsibility during functional tests and integrated system and equipment testing

Erection companies are responsible for:Elimination of defects and discrepancies, occurred during NPP commissioning, including

integrated testing of the power units, ensuring of support during commissioning of the power units under technical management and supervision of the Contractor, attracting manufacturers supervisor of the main equipment;

Assembling and dismantling of the devices, temporary systems and equipment, required during works of NPP commissioning;

Implementation of the repair works and works connected with the replacement, reconstruction and updating of the systems and equipment.

The Subcontractor of the pre-commissioning works is responsible for:Implementation of tests, pre-commissioning on the systems and equipment of the power unit

in accordance with the programs and methods;Quality assurance during commissioning in accordance with the requirements of POKAS-

ВЭ;coordination of pre-commissioning works;

Participation in the acceptance of the systems and equipment for pre-commissioning, organized by the Employer in accordance with the requirements of the special procedure;

Technical recommendations and instructions, written instructions and orders during commissioning;

Preparation and issuance of the reporting documentation on the results of pre-commissioning.

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Division of responsibility during functional tests and integrated system and equipment testing

Operational Personnel (operational personnel of the Employer in the framework of its responsibility during technical management of the Contractors operational personnel) is

responsible for: Ensuring of the conditions for the safe implementation of pre-commissioning, including

the inspection of the system and adjacent systems status and inspection of equipment under voltage in the area of pre-commissioning;

Permission of the personnel of the pre-commissioning organizations to the pre-commissioning on the systems and equipment according to day and shift tasks;

Implementation of the on-line switching on all the systems and equipment of BeleneNPP, beginning from the stage of prestart adjustment works;

Current technical maintenance of the equipment; Preparation of the systems and equipment to the technical maintenance and repair by

own forces and contractors erection organizations, attracting manufacturers supervisor of the main equipment;

Permission of the erection personnel for the elimination of the occurred erection defects; Implementation of the periodic testing of the equipment, being temporary operated;Preparation of the process systems and equipment for pre-commissioning.

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6. Documentation Required for Power Unit Commissioning

«Guide on Organization of Commissioning Activities» and schedule for commissioning, along with a list of activities, executors, and dates of work fulfilment;

Lists of commissioning documentation, operation and maintenance instructions, technical-organizational procedures for commissioning;

Technical-organizational procedures for commissioning;

Commissioning programs;

Power unit commissioning schedules;

Programs of post-erection cleaning and individual tests;

Commissioning documentation in accordance with the approved list;

Operational and maintenance instruction in accordance with the approved list;

Quality Assurance Programs for NPP Commisioning (POKAS- C);

Quality Assurance Programs for NPP Operation (POKAS - O).

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Unit Commissioning of “Belene” NPP (Bulgaria)

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