STPNOC – South Texas Project - Units I & IIInstallation of Leading Edge Flow Meters

Replacement of Feedwater Heat Exchangers

BHI Energy | Specialty Services Showcase Project Report

Spring 2015

BHI Energy was contracted by STPNOC to replace feedwater heaters and install leading edge flow meters (LEFM’s) over (3) outages. LEFM’s were being replaced in (2) extended power uprate (EPU) outages for each unit. Both complex projects were critical to achieve an increase in power output at each unit thus generating a significant return on investment for STPNOC.

Project Description – Replacement of leading edge flow meters and venturisScope Description

Two machine GTAW welding systems working in parallel to install welds on a leading edge

flow meter

The scope per unit included (4) 18” dia. x 15’ long bolt-in venturis, and (4) 18” dia. x 48” long, 1.375” wall, carbon steel Cameron Leading Edge Flow Meters

There were (3) welds per LEFM – (1 lead in, and 1 on each side of transducers) – LEFM’s and Venturis were installed in the horizontal position All welds were completed with machine gas tungsten arc welding (GTAW) - GTAW for root/hot/and weldout, with prep counter bored to within 5 thousandths of an inch (using consumable inserts and J-preps) This project was a full service approach including cut-out, machine ing, rigging, rigging path development, fit-up, GTAW machine welding, preheat and post weld heat treating BHI provided supervisors and carpenters (6/shift) for Excel modular scaffolding management to provide efficiency in parallel with FWH work BHI provided insulation removal, and re-installation of new insulation

BHI Energy’s overall approach to critical projects such as these is as follows:

Top notch project management, from drawing review to estimation to project execution The most talented field supervision in the industry with the capability to deliver complex projects ahead of schedule and under budget in what can be a complicated nuclear environment The best craft available, hand-picked by our teams and traveled from outside the local area under BHI Energy’s Specialty Welding Agreements with the International Trades. This resource based supple ments the local are craft that can be utilized to concentrate on the balance of the outage scope High tech tooling when required to overcome critical challenges in safety, work access and overall qualityThe above approach can be described as our Gold Standard for complex projects.

BHI Energy Approach

BHI provided an experienced project team including seasoned project management, union craft who have trav-eled with BHI to implement many of these projects, and a home office leadership oversight and intrusion to assure schedule, quality and safety management.

Provided clearance, scaffolding, insulation removal, hanging of rigging points Markedcut lines, sever piping, removed venturis in series (sequenced), and installed venturis (sequenced) while completing ID overlays on feedwater piping Cut piping for LEFM’s while venturis were being worked Final cuts on LEFMs after venturis were installed 2 LEFM’s were installed in parallel, with associated preheat and post weld heat treating Shear wave ultrasonic inspection for all completed welds

The work and schedule was completed in 18 days. The LEFM crew consisted of 35 craft/shift (70 craft total on site). 15 to 18 craft/shift were required for LEFM’s. 14 craft/shift for Venturi flange installation and small bore welding. There were (30) pipefitters/welders utilized, with the balance being machinists, laborers, firewatch, QC, and heat treaters. Craft were brought in from outside the area so that local labor and project quality would not be impacted.

A venturi being moved through the rigging pathOnto a specially fabricated rail

Project Challenges

An aggressive schedule of nineteen (19) days for (4) LEFM’s and associated venturis ID of existing piping did not match new LEFM’s. This added 3 days of weld build up on the piping Safety concerns due to major equipment moves, cutting, rigging, fit-up and welding Tight access to remove and rig-in new Venturis Attracting craft for STP. This was a remote plant location, with limited outage hours worked, lower craft hourly scale, and abundance of work in the oil and gas sector nearby which challenged labor supply

Project Description – Replacement of feedwater heaters

Scope Description

(2) Low pressure – Unit II – 21 day schedule (2) High pressure – Unit I – 21 day schedule (project not executed at this writing) (2) High pressure – Unit II – 21 day schedule (project not executed at this writing) A full service approach included scaffold, insulation removal/reinstall, machining, heat treating, visual and penetrant testing, and all welding All level tree piping instrument determination and re-termination Excel modular scaffold builds for FWH’s and LEFM’s, and removal of all insulation, including reinstalling pre-form insulation on the feedwater heaters Rigging and moving of components by long time vendor partner Barnhart Crane & Rigging Shielded metal arc welding (SMAW) for all large bore piping (GTAW for small bore) (8) Large bore piping welds and 180 small bore piping welds per heater Brand new level tree piping installed for all heaters

BHI Energy Specialty Services Approach

BHI Energy’s project team developed an aggressive replacement schedule with a continuous hands-on field man-agement and workforce effort. The BHI Energy | Specialty Services management, supervision, and specialty union workforce had extensive component repair and replacement experience. BHI offered a strategic full-service approach to successfully support the project schedule, quality and safety goals. Upfront project award and project planning assured project readiness and success. Project planning and scheduling Single or double cut of large bore piping Pinning of spring cans, replacing some with new, including resetting the loads on all All welding, utilizing SMAW processes, for P1, P4, P5A, P5B, and P8 materials, with and without, post weld heat treatment of larger nozzles All pipe machining and end preparation

The heaters were installed and the system pipe tight and all work completed and demobilized off site in 20 days. The project schedule worked seven (7) days per week, two (2) rotating twelve (12) hour shifts per day.

The entire crew consisted of (90) total BHI Energy | Specialty Services supplied personnel consisting of a Site Manager, a Night Manager, Superintendents, Assistant Superintendents, Foremen, Safety Coordinators, Machinists, QC inspectors, heat treaters, of which roughly (30 total) were welders and pipefitters. Up-front project planning consisted of a (6) months in advance Site Manager. A Project Superintendent, QC, and all supervision arrived (6) weeks in advance of the project start date.

(6) total feedwater heaters will be installed over (3) refueling cycles – 2 per outage

Project Challenges

A fixed schedule of (21) days for (2) heaters in each of three outages Safety concerns due to major equipment moves, cutting, rigging, fit-up and welding HP heaters had interferences tubing, support, small bore piping Attracting craft for STP. This was a remote plant location, with limited outage hours worked, lower craft hourly scale, and abundance of work in the oil and gas sector nearby which challenges labor supply Coordination of electrical, I&C activities and scaffold movements could have created schedule delays

BHI Energy Approach

BHI provided an experienced project team including seasoned project management, union craft who have trav-eled with BHI to implement many of these projects, and a home office leadership oversight and intrusion to assure schedule, quality and safety management.

Provided clearance, scaffolding, insulation removal, hanging of rigging points Markedcut lines, sever piping, removed venturis in series (sequenced), and installed venturis (sequenced) while completing ID overlays on feedwater piping Cut piping for LEFM’s while venturis were being worked Final cuts on LEFMs after venturis were installed 2 LEFM’s were installed in parallel, with associated preheat and post weld heat treating Shear wave ultrasonic inspection for all completed welds

The work and schedule was completed in 18 days. The LEFM crew consisted of 35 craft/shift (70 craft total on site). 15 to 18 craft/shift were required for LEFM’s. 14 craft/shift for Venturi flange installation and small bore welding. There were (30) pipefitters/welders utilized, with the balance being machinists, laborers, firewatch, QC, and heat treaters. Craft were brought in from outside the area so that local labor and project quality would not be impacted.

Mechanical Integrity Issues and Project Challenges Resolved

This project was an Extended Power Uprate initiative (EPU). The existing feedwater heaters were experiencing significant degradation due to initial design deficiencies and internal erosion over the life of the heaters. The new heaters accommodate greater throughput volume, which translates to greater plant megawatt output. Replace-ment of leaking tubes was also addressed wholesale heater replacements. The replacement heaters were also made of a more resilient material that would provide much greater efficiency and longer asset life.

Why Select BHI Energy | Specialty Services (Project Value Recognized)

BHI was selected by STPNOC because of our ability to provide all services including welding, electrical, I&C activi-ties, insulation and scaffolding management. BHI’s project management organization assured integrated control of all activities, schedule management, project controls, quality assurance and safety compliance worked closely with our team supervision.

2005 Newpoint Parkway | Lawrenceville, GA 30043 678.205.1025

A nuclear industry leader, having replaced the most industry feedwater heaters in the past (10) years Extensive piping replacement and LEFM installation team experience Utilization of the same vendor for LEFM’s and FWH’s is a value for STP, creating synergies and project efficiencies Successful history at STPNOC replacing feedwater heater bundles On site relationships were accustomed to and trusting of BHI Energy leadership, supervision, and project management team BHI Energy is a trusted long-term service provider, having provided radiation protection and staff augmenta tion services at STP for many years

For LEFM installation, 90% of the insulation had to be replaced or fabricated due to the new LEFM spool design. The scaffolding needed to be modified 6-8 times and a couple of these mods includ-ed taking down the scaffold tower and building it back on each unit. The towers were 25’-30’ tall and 30’ square with multiple working decks completely surrounding the piping for this project. The use of Excel Modular Scaffolding saved countless hours and cost based on its unique design and efficiencies.The management of the safety and quality programs, with such an aggressive work schedule, was expected to be a challenge because of all of the project activities. Assurance of program compliance consisted of BHI Energy | Specialty Services site management’s close monitoring of work activities and resource controls, including detailed and informative safety and pre-job briefings at every shift change.

Experienced BHI Specialty craft, managed with an integrated project managed approach