POWER August 2010 - 52

NUCLEAR POWER
10. Motivating the team. Bruce A Executive Vice President and Chief Nuclear Officer
Norm Sawyer watches as Executive Vice President, Project Management and Construction
John Sauger addresses participants at the Bruce A's Return to Operations workshop. Sauger
directed his remarks to the operations staff: " It's going to take a Herculean effort. We expect
you guys to help us, to pull us across the finish line. You own the plant; you need to take it back
from us. " Courtesy: Bruce Power
Milestone Countdown
The process of recommissioning Units 1
and 2 began in April 2010 when representatives
from across the site spent the day with
key members of the Restart Team (Figure
10). Using the successful restart of Units
3 and 4 as a guide, management stressed
the importance of a smooth transition from
reconstruction to operations for Units 1
and 2. Other management representatives
recalled the " glory days " of the station's
operating record during the 1980s, when
the units were among the top performers in
the world, and reiterated that they strongly
believe Bruce Power will soon establish
new industry reliability records.
" There has never been another project
Accuracy Counts; So Does
Accomplishment
The Project Controls Team, in consultation
with other project groups, establishes
the project schedule and major milestones,
such as the logical order of tasks and timelines
for the various plant systems to return
to service. This team works closely
with work crews to identify and overcome
obstacles encountered during construction
and commissioning, training and turnover,
and operations. Nevertheless, challenges
are inevitable for a project of this scope. At
Bruce A, one challenge is keeping up with
the myriad accountability tasks.
One critical item on the RTS program
plan is the required closeout of a long list of
pending design change notices (DCNs) before
start-up can begin. By September 2009
the rate at which contractors were closing out
DCNs was unacceptable. The average time
for closing out a DCN was approximately
a thousand days, meaning that another 550
years would be required to finish the project.
Instead of maintaining that status quo, a 90day
limit was placed on delinquent DCNs,
and the pressure was on the RTS staff to
pick up the pace. Through process streamlining,
such as grouping like items together
to achieve economies of scale, the staff was
able to reduce DCN closeout time to about
75 days. There are still more than a thousand
DCNs to finish before fuel can be loaded
into the reactors.
The RTS process is driven by a staff of
about 60 people who verify the DCNs by
ensuring that all the supporting documentation,
necessary training, on-site inspec52
tions
and verifications, remedial re-work
when required, and signoffs are complete
before systems are declared safe and available
for service. The transparency of the
RTS program, and specifically the DCN
process, is extremely important because
the CNSC uses it as the basis for regulatory
staff to determine whether fuel can be
loaded in Unit 1 and 2 reactors.
The Project Controls Team reports that
never in the 1,635-plus days of the project
(at the time of POWER's plant visit in
April) have so many deliverables and associated
milestones been squeezed into three
months as was the case in the first three
months of 2010. For example, during those
three months the project:
■ Completed all delinquent DCNs older than
90 days. The lead time was then further
ratcheted down to eliminate DCNs older
than 45 days.
■ Launched the New Safety Leadership and
Human Performance Programs to empower
field supervisors with more decisionmaking
authority.
■ Completed commissioning activities for
66 new motor control centers.
■ Completed a record 350 work packages in
a single week. One of those work packages
alone required approximately 1,800 valves
to be aligned, restored, or replaced.
■ Exceeded the 1,000 project tasks-perweek
barrier. A climb to 1,500 tasks per
week is under way.
■ Removed the legacy asbestos discovered
under the turbine deck plates in both Units
1 and 2.
www.powermag.com
quite like this in the Canadian nuclear industry, "
said John Sauger, Bruce Power's
executive vice president for project management
and construction. " We're proud to
be blazing a path for others to follow, and
I thank everyone who has brought us this
far. But our work is far from over. Our job
now is to put these reactors back together,
to do it safely, and to deliver a first-class
product. "
The RTS program is also designed to
ensure orderly transfer of the plant from
construction to operation. When all the
equipment has been installed and successfully
tested and all the DCNs have been
processed as a precursor to CNSC approval,
then the final commissioning steps begin
for each unit:
1. Load fuel (currently scheduled before
year-end 2010 for Unit 2)
2. Remove the " guaranteed shutdown state "
designation
3. Refill the primary heat transport system
4. Turbine operation
5. Turbine synchronization to the grid
6. Full reactor power
7. Specific commissioning tests
8. Normal operation and follow-up to monitor
plant performance and new or updated
programs after return to service
At the end of May, the project team continued
moving forward to meet the remaining
milestones. Fuel loading and associated operations
will precede synchronization to the
power grid by approximately five months.
Units 1 and 2 are scheduled to return to commercial
service by early 2012. When they do,
they and their fellow Bruce units will supply
about one-quarter of Ontario's power and
will have a longer life expectancy than anyone
anticipated two decades ago. ■
-James M. Hylko (jhylko1@msn.com) is
a POWER contributing editor. Dr. Robert
Peltier, PE is editor-in-chief.
POWER | August 2010
http://www.powermag.com

POWER August 2010

Table of Contents for the Digital Edition of POWER August 2010

Contents
POWER August 2010 - Cover1
POWER August 2010 - Cover2
POWER August 2010 - Contents
POWER August 2010 - 2
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