darlington refurbishment 2017 q3 report · the darlington refurbishment project, ... we’d be a...
TRANSCRIPT
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OPEN AIRLOCKS AND INSTALL SHIELDING
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REMOVE INTERFERENCES AND INSTALL WORK PLATFORM
SEVER PRESSURE TUBES AND BELLOWS
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REMOVEEND FITTINGS
INSPECT AND INSTALL CALANDRIA TUBES
REMOVE PRESSURE TUBES
INSPECT AND INSTALL FUEL CHANNELS (PRESSURE TUBES, BELLOWS AND END-FITTINGS)
REMOVE CALANDRIA TUBES
INSTALL FEEDER TUBES
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End fittings made by Laker Energy Products.
THE UNIT 2 DARLINGTON REFURBISHMENT SCHEDULE
BROTECH DEVELOPS SKILLED TRADES TO DELIVER ON THE DARLINGTON REFURBISHMENT PROJECTBarrie-based Brotech Precision CNC Machining is not
only producing precision components for Darlington
Refurbishment; it’s also helping build the skilled workforce
of the future.
In the last two years, Brotech has doubled its size,
going from 25 to 50 employees, most of whom are
machinists specializing in precision machining for the
nuclear, aerospace and defence industries. And just this
year, Brotech made a $1 million building and equipment
investment to meet the needs of OPG’s Darlington
Refurbishment project.
“We’re a shop that depends on seal-tight, efficient
processes to ensure consistently high quality service and
components,” says Jerome Horowitz, the company’s Vice
President. “If we didn’t work like that, we wouldn’t have
been able to grow or support the needs of our customers
the way we have been.”
Another reason for Brotech’s success is its long-standing
partnerships with Georgian College and the Ontario Youth
Apprenticeship Program, says Horowitz.
“Brotech ends up employing one or two students from each
program per year,” he says. “We want to train people to
build the expertise our customers need.”
We believe Nuclear will play a big role in our business for
the next 30 or more years.”
POWERING FORWARDDELIVERING RESULTS
A year after Ontario Power Generation took its
Unit 2 nuclear reactor off-line, in Oct. 2016 Darlington
Refurbishment – Canada’s largest clean energy
project – remains on time and on budget.
Last October, OPG and our more than 200 project
partners kicked off refurbishment of all four nuclear
reactors at the Darlington Nuclear Generating Station.
Since then, the project has been powering forward
and delivering results on this 10-year large-scale
initiative.
After successfully removing all 960 feeder pipes from
the Unit 2 at the end of our third quarter, Ontario
Power Generation is progressing into the next stage:
removal of reactor components. This work activity
will continue until the spring of 2018 as part of the
40-month Unit 2 refurbishment schedule.
Innovation and ExpertiseOver the last year, our project partners located across
Ontario have contracted more than 4,000 workers
to support Refurbishment. Some project partners
like Brotech Precision CNC Machining in Barrie and
Laker Energy Products in Oakville have increased
staffing and invested in infrastructure and high-tech
equipment to meet the demands of the project.
As this $12.8 billion project progresses the Darlington
Refurbishment team is working together to develop
innovative approaches to get the work done safely
and with quality while improving efficiencies when it
comes to cost and time.
In this report, you’ll learn more about the status of
the Darlington Refurbishment Project, and how it’s
providing another 30 years of safe, clean and reliable
energy for Ontarians.
Message from Dietmar Reiner,
Senior Vice President, Nuclear Projects
OCT 15, 2016BREAKER OPEN
PROJECT COMPLETE FEBURARY 27, 2020
SHUT DOWN REACTOR
DEFUEL REACTOR
INSTALL BARRIERS TO ISOLATE UNIT 2 FROM STATION CONTAINMENT
PRESSURE TEST
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LOAD FUEL AND REMOVE EQUIPMENT
HEAT UP AND LOW POWER TESTING
HIGH POWER TESTS AND CONNECTION TO THE GRID
Segment 4: Load Fuel, Test and Restart Reactor Segment 3: Install Reactor Components Segment 2B: Remove Reactor Components Segment 2A: Prepare for Reactor Component RemovalSegment 1: Defuel Reactor and Isolate from the Station
PROGRESS AS AT SEPTEMBER 30, 2017SEGMENT 2B DEC 17 START
SEGMENT 3 JUNE 2, 2018 START
SEGMENT 4 AUG 7 2019 START
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LAKER INCREASES STAFF TO SUPPORT DARLINGTON REFURBISHMENTLaker Energy Products, an OPG project partner, recently
doubled its staff to support the Darlington Refurbishment
Project.
Laker supplies Refurbishment with key CANDU reactor
components, including end fittings, liners, channel
closures, and feeder material, which are critical to
the mid-life restoration of the Darlington Nuclear
Generating Station.
As a result of the planned work to support Darlington
Refurbishment, Laker purchased and moved to its current
manufacturing plant in 2015. The larger facility allowed
Laker to triple its machining capacity. It also enabled
Laker to increase staff to 90 people, with an expected
increase to over 100 staff before the end of the year.
“These are highly skilled, technical jobs – experienced
CNC (Computer Numerical Control) machinists, welders,
engineers, engineering technologists,” said Chris Hughes,
President of Laker Energy Products. “If not for Darlington
Refurbishment, we’d be a much smaller company.”
Visit www.opg.com to watch a video about how Laker
staff’s passion for perfection and precision are powering
Darlington Refurbishment.
SEGMENT 2B DEC 17 START
REMOVE FEEDER TUBES
PROJECT PILLAR PERFORMANCEOPG’s project pillars measure the organization’s success in
maintaining high standards in terms of worker safety, quality of
work, our ability to stay on schedule and adhere to overall project
cost. Here is an overview of our project pillar performance during
the third quarter of 2017 (July 1 – September 30, 2017).
SAFETYWorker safety has been excellent. To date, 2,829 days have been worked
without a lost-time accident. Since the previous quarter, the All-Injury Rate
(AIR) has increased (indicating declining performance) from 0.41 to 0.45 in
September. This is a result of four minor medically-treated injuries. AIR is a
measure of injuries per 200,000 hours worked. Despite the increased AIR,
this figure is far better than infrastructure industry performance in Ontario.
Radiological safety performance on this project has been excellent, with
zero unplanned exposures.
SCHEDULEThe project remains on track to complete Unit 2 refurbishment as scheduled.
COSTUnit 2 cost performance has improved from the previous quarter mainly
due to rigorous cost and schedule controls. The forecast to complete Unit 2
remains within the approved budget of $3.417 billion, including contingency.
ENVIRONMENTEnvironmental performance has been excellent with no reportable
spills or infractions. Emissions are better than target and well below all
regulatory limits.
QUALITYNo regulatory non-compliance events on Unit 2 or quality related system
failures resulting in loss of generation or impacts on the high confidence
critical path schedule.
Darlington Refurbishment
project partners have
agreed to fill at least
20 per cent of their
talent pools supporting
the project with trades
apprentices, in accordance
with OPG’s commitment
to stakeholders.
A worker training to use remote control technology
at the Darlington Energy Complex.
WORKING OUTSIDE THE BOXThe Darlington Refurbishment Project relies on the expertise of a diverse group of highly skilled trades, many whose
professions have been around for generations. But as technology has evolved, so too has the know-how to do the
work.
Boilermakers on the project, for example, are severing pressure tubes remotely, using joysticks and live images of
the work area on a computer screen. This approach allows them to be more precise as they control the tooling
mounted on work platforms, improving their ability to get the job done with greater quality.
A recent report from BuildForce Canada indicates that the Darlington Refurbishment Project, along with the Bruce
Power Major Component Replacement slated to begin in 2020, will help push stronger demand for highly skilled
trades, including boilermakers, electricians, labourers, carpenters, millwrights, pipefitters and ironworkers. To get the
job done safely and efficiently, they’ll need to be trained using the latest techniques and tooling.
“In many cases, project partners have designed one-of-a-kind tooling specifically for the Darlington Refurbishment
Project,” said Roy Brown, OPG Senior Director of Projects, Re-tube and Feeder Replacement. “So in addition to
drawing on the knowledge of generations past, tradespeople working on a complex project like ours need to have
the leading-edge technical skills to use those tools.”
A Brotech employee uses a
new Mazak Integrex machine
at their facility in Barrie
POWERED UP FOR REFURBISHMENT AND CONTINUED OPERATIONSPROJECTS AT A GLANCE
TURBINE GENERATOR WORK UNDERWAYTurbine generators are key to power production: the water heated in the reactor
generates steam in the boilers. This steam then turns one high pressure and three
low pressure turbines, which are coupled to an electric generator to produce power.
They receive regular maintenance during outages at OPG, but Unit 2 refurbishment
offers a rare opportunity for the complete disassembly, inspection and overhaul of
the unit’s turbine generator.
“It’s quite exciting that the turbine is now in a state of disassembly that it hasn’t been in since construction of the power
plant,” said Peter Moore, OPG Project Manager. “We now have the chance to replace and do a deeper inspection of
critical parts.”
Parts scheduled for replacement include the generator stator cooling hoses; the high voltage bushings under the
generator that carry the power to bus bars and out to the transmission lines. Workers are also installing protection rings
to repair erosion on the steam turbines.
Work on the Unit 2 turbine generator is being completed by OPG staff and our project partners, the Joint Venture
group (SNC Lavalin Nuclear — Aecon Construction) and Alstom Power Canada Inc. Most of the trade and professional
labour working on this project are from Ontario, and a significant quantity of parts and materials are being sourced
within the province.
Worker oversees one of three low pressure
turbine sections being placed on roller stands
to perform a series of inspections.
Each of the turbine’s
four rotors weighs in
excess of 200 tonnes!
WWW.OPG.COM
Worker inspecting the turbine over speed trip assembly that safely shuts the turbine down if it exceeds its maximum operating speed.
@opgpics Ontario Power Generation@opg
Ontario Power Generation (OPG) produces almost half of the electricity that Ontario homes, schools, hospitals and business rely on each day. After decades of reliable power generation, OPG’s Darlington Nuclear Generating Station is receiving a mid-life refurbishment
that will benefit Ontarians for another 30 years.
To learn more about Darlington Refurbishment, the largest clean energy project in Canada, visit our website at www.opg.com and subscribe to the Darlington Refurbishment newsletter.
Have questions? Contact us at [email protected].