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OPG personnel inside the turbine hall at the Darlington Nuclear Generating Station.
Q1 2018
A REPORT ON CANADA’S LARGEST CLEAN ENERGY PROJECT
DARLINGTON REFURBISHMENT
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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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THE UNIT 2 DARLINGTON REFURBISHMENT SCHEDULE
Tetra Tech is one of more than 200 companies
across Ontario working on the Darlington
Refurbishment project. The company’s power
division, which also supports Pickering Nuclear,
provides a range of services — from engineering
and project management to scheduling and
training — using innovative 4D, virtual and
augmented reality approaches.
“The Darlington Refurbishment has opened up
new potential for our next generation of technical
staff to sit next to their peers in support of this
significant project,” said Tetra Tech’s president,
Pat Marchione. “Since the project will result in
Darlington continuing to produce economical
and clean base load power for Ontarians for an
additional three decades, ensuring that
institutional and technical knowledge is passed
along is so important.”
Passing on this knowledge — sharing lessons
learned and so improving efficiencies — is the
kind of approach that is helping the project
complete work safely, with quality, on time and
on budget.
Since joining the effort in 2013, staffing levels at
the Pickering-based company’s power division
have more than doubled, in large part as a result
of its work on the Darlington Refurbishment.
The Darlington Refurbishment, Canada’s largest clean
energy project, continues to track on time and on budget,
as Unit 2 reactor reassembly gets underway.
We experienced a successful first quarter in 2018
highlighted by arriving at the halfway mark on the Unit 2
schedule and the green lighting of Unit 3 refurbishment.
Both of these milestones serve to reinforce our
stakeholders’ confidence in our project team’s ability to
safely complete the refurbishment of all four reactors
at Darlington Nuclear on time and on budget. During
this quarter, OPG and our project partners completed
the removal of all 960 end fittings, 480 pressure tubes
and 480 calandria tubes from Unit 2. The removed
components have been shipped to OPG’s state-of-the-art
Re-Tube Waste Processing Building where they are being
prepared for long-term safe storage.
We have now begun installing new and refurbished
components in Unit 2. Other work is also underway,
including refurbishing our fuel handling equipment,
rebuilding or replacing nearly 1,000 valves and overhauling
our turbines and generators, both which help produce
electricity.
In this report, you’ll learn more about some of the
exciting milestones we’ve reached on the Darlington
Refurbishment project in our first quarter, and how we’re
delivering results for 30 more years of safe, clean and
reliable energy.
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
SEGMENT 2B DEC 17 START
SEGMENT 3 MAY 3, 2018
SEGMENT 4 AUG 7 2019 START
PROGRESS AS AT MARCH 31, 2018
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Peter Gowthorpe, Director of Laveer Engineering, third from right, receives
a plaque from Ted Gruetzner, OPG’s Vice President of Stakeholder Relations.
SEGMENT 2B DEC 17 START
REMOVE FEEDER TUBES
PROJECT PILLAR PERFORMANCEOPG’s project pillars measure the organization’s success
in maintaining high standards in worker safety, quality of
work, and adhering to schedule and overall project cost.
Here is an overview of our project pillar performance
during the first quarter of the year (January 1, 2018 —
March 31, 2018).
SCHEDULEUnit 2 remains ahead of schedule.
COSTUnit 2 refurbishment costs are slightly below plan.
The life-to-date cost for Unit 2 remains within the
approved budget.
SAFETYNo lost time injuries and three minor Medically
Treated Injuries occurred. Since Unit 2 breaker open
in Oct. 2016, 8 million hours have been worked safely.
QUALITYThere have been no quality-related events in the
quarter.
ENVIRONMENTEnvironmental performance has been excellent with
no reportable spills or infractions in Q1. Emissions are
better than target and well below all regulatory limits.
REDESIGNED TOOLSET HELPS REFURBISHMENT STAY ON TRACK
An important step in reactor disassembly is the removal of annulus spacers from six of the reactor’s fuel channels so they can be sent for
analysis. When the time came to plan for execution of the task on the
Darlington Refurbishment project, project partner Promation found
that Laveer Engineering had the expertise in retrieval tool design
and development OPG was looking for.
“Promation had the lead on the project, but felt that we could
provide the design and development required to make the project
a success,” said Peter Gowthorpe, Director of Laveer Engineering, a
custom tooling and engineering company based in Burlington, Ont.
Annulus spacers (or garter springs) play a critical role in maintaining
a gap between the pressure tube and calandria tube inside a unit’s
fuel channel, preventing contact between the two components.
Removal of these springs is intricate work, which involves collecting
the spacers by using an annulus spacer retrieval tool.
Gowthorpe said, “We’re taking lessons learned and applying them to
both projects and relationships.”
By utilizing a modified tool, the Darlington Refurbishment team
was able to safely remove 24 spacers from the fuel channels inside
Darlington’s Unit 2 reactor, ahead of schedule.
Learn more! Visit www.opg.com to watch a new Darlington
Refurbishment project video titled ‘Building Together’, which explains
what’s happening right now, during the reactor reassembly phase.
ON TRACK FOR SUCCESS
OPG and Bruce Power
signed a Memorandum
of Understanding in
2015, confirming their
commitment to ongoing
collaboration towards
improving efficiencies
in both organizations’
refurbishment programs.
A worker training in front of the full-scale replica of a reactor calandria face at
the Mock-up and Training Facility at OPG’s Darlington Energy Complex.
Even before project execution began, the Darlington
Refurbishment team sought, gathered and incorporated
industry knowledge and experience pertaining to
both nuclear and other mega-projects into its project
planning.
This information, combined with what has been learned
during refurbishment of Unit 2 — the first Darlington unit
to undergo its mid-life overhaul — is being leveraged to
ensure the safe and efficient execution of the project.
For example, a full-scale nuclear reactor mock-up was
built at the Darlington Energy Complex after operating
experience from other projects showed that schedule
and cost could be negatively impacted by a lack of
trained workers and tooling compatibility.
“The Darlington mock-up has definitely paid for itself,
allowing workers to hone their skills in a non-nuclear
environment before moving into the actual reactor,”
said OPG’s Mike Allen, Senior Vice President, Nuclear
Refurbishment. “It’s played a crucial role in this project
remaining on time and on budget.”
Knowledge gained during Unit 2’s refurbishment is
helping shape plans for Unit 3’s overhaul, set to begin
in 2020.
“We are continuous learners,” said Bill Owens, Vice
President of Unit 3 Refurbishment Execution. “That
means constantly striving to find better ways to do
what we do. And in turn, that means better value for the
province as we move forward on Canada’s largest clean
energy project.”
LESSONS LEARNED LEAD TO COST SAVINGS ON REFURBISHMENT
Pickering Mayor
David Ryan tests
virtual reality
glasses at an event
recognizing Tetra
Tech’s work on
the Darlington
Refurbishment
project, March 2018.
INNOVATION AT WORK
PLANNING FOR THE FUTURE
UNIT 3 GETS GREEN LIGHT FOR REFURBISHMENTIn February, OPG recognized reaching the halfway mark on the Unit 2 refurbishment schedule and the green lighting of
Unit 3 refurbishment at an event at the Darlington Energy Complex.
“The go-ahead to move forward with the next unit is a testament to the hard work and dedication of the Darlington
Refurbishment team,” said OPG President and CEO Jeff Lyash. “I thank OPG’s employees, the community and our many
partners across the province for the hard work that’s gone into the planning of this project.”
The Unit 3 Refurbishment team is leveraging the opportunity to incorporate lessons learned from Unit 2. Detailed planning and
engineering replications are underway and on track. Planning schedules are under development and will focus on integration
and coordination with ongoing work on Unit 2 refurbishment and across the station. Additionally, a thorough assessment of
risks and opportunities is being reviewed, including the resource challenges of undertaking two units simultaneously.
The refurbishment and continued operation of Darlington up to 2055 will contribute a total of $90 billion to Ontario’s GDP
and increase employment across the province by an average of 14,200 jobs annually, including over 2,600 jobs onsite at
Darlington. Refurbishment will also secure 3,500 megawatts of affordable, reliable and emissions-free power: the equivalent
of taking two million cars off the road.
“Darlington is an essential source of electricity in Ontario and plays a key role in our economy,” said Lyash. “The station has
delivered clean, reliable, low-cost power since 1990, and we are continuing to deliver on our commitment to complete this
project on time and on budget.”
Members of the Darlington Refurbishment project
recognize Unit 2 and Unit 3 milestones at an event,
February 2018.
WWW.OPG.COM @opgpics Ontario Power Generation@opg
Ontario Power Generation (OPG) produces almost half 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 Project Newsletter.
Have questions? Contact us at [email protected].
Feeder tubes manufactured by BWXT at a Whitby, Ont. warehouse prior to shipment to the Darlington Nuclear Generating Station, for OPG’s Darlington Refurbishment project.