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Reni Zlateva TECHNICAL SUPPORT DIVISION KNPP, POWER PRODUCTION 2 Vienna, October 03-06, 2006

Vienna 03-06.10.2006. 1. Introduction. Where is KNPP situated?. . Vienna 03-06.10.2006. 2. The construction of Units 5 and 6 of Kozloduy NPP began in the early 80s. Their design characterizes with:Two-loop mono-units with installed electrical capacity of 1000 MW each, WWER-1000 type, B-320 modelProtective steel-reinforced concrete containmentDefence in-depth conceptPrinciples of triple redundancy, physical separation and preservation of the system functions in case of single failureAn13

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Reni Zlateva TECHNICAL SUPPORT DIVISION KNPP, POWER PRODUCTION 2 Vienna, October 03-06, 2006

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    1. Vienna 03-06.10.2006 Reni Zlateva TECHNICAL SUPPORT DIVISION KNPP, POWER PRODUCTION 2 Vienna, October 03-06, 2006

    2. Vienna 03-06.10.2006 1

    3. Vienna 03-06.10.2006 2 The construction of Units 5 and 6 of Kozloduy NPP began in the early 80s. Their design characterizes with: Two-loop mono-units with installed electrical capacity of 1000 MW each, WWER-1000 type, B-320 model Protective steel-reinforced concrete containment Defence in-depth concept Principles of triple redundancy, physical separation and preservation of the system functions in case of single failure Analogical control and protection systems Digital information system Introduction BASIC DATA

    4. Vienna 03-06.10.2006 3 Implementation of a new redundant power supply • Digital control of the turbine and second circuit systems (ASUT) • Accelerated unit unloading, which resulted in significant improvements of the performance of emergency protections • Increase of dynamic stability of the units in case of transients • Development and implementation of a full-scale simulator for operational staff training Introduction INITIAL MODIFICATIONS

    5. Vienna 03-06.10.2006 4 The main objectives of Units 5 and 6 Modernization Program (MP): To provide level of safety of the Units in compliance with the current international norms and standards To enhance operation reliability To enhance units’ efficiency To extend units’ operational lifetime with 15-20 years beyond their design life Units 5&6 Modernization Program MAIN OBJECTIVES

    6. Vienna 03-06.10.2006 5 The Modernization Program was developed on the basis of: A broad scale analyses of the units' status. The recommendations for the units made by: Chief designer International missions at the plant Conclusions from the summarized operational experience of Kozloduy and other plants with WWER-1000/B 320 type Units 5&6 Modernization Program BASIS FOR PROGRAM DEVELOPMENT

    7. Vienna 03-06.10.2006 6 212 technical measures Classification of the measures per areas of improvement Measures to improve the safety of Units 5&6 through implementation of new design solutions Studies and additional analyses Measures for improvement of reliability through replacement of equipment with expiring design life and critical equipment Measures to improve performance efficiency and operating conditions Measures related to preparation for equipment decommissioning Units 5&6 Modernization Program STRUCTURE

    8. Vienna 03-06.10.2006 7 Phase 1 – “Engineering” Consist of collection and submittal of input data, development of Terms of Reference, specifying Kozloduy NPP requirements for the new systems, conceptual designs and equipment specifications for the measures without site works Phase 2 – “Implementation” Includes development of detailed design documentation, manufacturing and delivery of equipment, installation and tests, licensing and commissioning Units 5&6 Modernization Program PHASE APROACH

    9. Vienna 03-06.10.2006 8 Units 5&6 Modernization Program PHASE APROACH

    10. Vienna 03-06.10.2006 9 Units 5&6 Modernization Program PHASE APROACH PHASE 2 - IMPLEMENTATION

    11. Vienna 03-06.10.2006 10 Units 5&6 Modernization Program CONTRACTORS

    12. Vienna 03-06.10.2006 11 The funds envisaged for implementation of the modernization program amount to a total of 491M € - about 135M € is the funding that Kozloduy NPP directly has invested into the modernization program, and about 356M € was raised through credit agreements with various credit institutions, such as: EURATOM for financing the work to be performed by Framatome ANP CITIBANK for financing the work to be performed by Westinghouse ROSEXIMBANK for financing the work to be performed by Atomenergoexport Units 5&6 Modernization Program PROJECT FINANCING

    13. Vienna 03-06.10.2006 12 Modernization and Investment Division (M&l): The main contact point to the contractors being responsible for all technical coordination as well as interface, planning, communication, and contract performance issues The organization of the M&l Division - a multi-discipline matrix type comprising experts in various engineering fields - planning, studies and analyses, quality assurance, contract administration, cost management, communications and documentation control Units 5&6 Modernization Program PROJECT MANAGEMENT

    14. Vienna 03-06.10.2006 13 1998-2000: The basic engineering phase 2002: Three studies and eleven measures with installation of equipment were implemented on both units 2003: The number of entirely completed measures increased to 98 (46.2% implementation rate) 2004-2005: 90% completion of Modernization Program including: Replacement of electrical, mechanical and a part of I&C equipment of safety-systems on both units Replacement of monitoring and a part of control systems with new digital ones Implementation of new diagnostic systems 2006- 2008 : 21 measurements completion including Replacement of process control systems Units 5&6 Modernization Program IMPLEMENTATION

    15. Vienna 03-06.10.2006 14 ECK measures • Replacement of mechanical equipment • Electrical equipment and systems modernisation • Implementation of I&C systems and new diagnostic systems • Operational conditions improvement • Enhancement of unit fire protection Westinghouse measures   • Computer Information System • Radiation Monitoring System • Turbine control system • Primary and Secondary circuit control systems Kozloduy NPP measures • Reactor Protection System • Neutron Monitoring Systems Replacement of I&C equipment Units 5&6 Modernization Program IMPLEMENTATION

    16. Vienna 03-06.10.2006 15 Measure 12332 – Implementation of a system for detection of loose parts - KÜS Automatically record of primary circuit noises Alarm of events classified as relevant events Localization of events Measure 12333 – Implementation of a system for quick detection and localization of leakage from primary circuit  - FLUES Up-to-date computerized system High accuracy = 1kg/h Alarms Self- calibration Units 5&6 Modernization Program DESIGN FLAW ELIMINATION

    17. Vienna 03-06.10.2006 16 Measure 12362 – Implementation of a system for monitoring of thermal cycles on coolant system piping - FAMOS Analysis of weak places of primary and secondary circuit pipes Pipe temperature values record Graphical images for quick assessment Alarm Measure 13011 – Installation of hydrogen detection and recombination systems  H2 quantity monitoring and alarms H2 recombination and control it’s quantity below < 4% Units 5&6 Modernization Program DESIGN FLAW ELIMINATION

    18. Vienna 03-06.10.2006 17 Units 5&6 Modernization Program DESIGN FLAW ELIMINATION Measure 11311 – Install a steam-gas mixture detector in the reactor vessel  Direct measurement of water quantity in the reactor vessel Optimal alarms Short response time (< 30s) Measure 23251 – Installation of an automated system for cold overpressure protection  (COP) Interlocks and pressure relief valves modifications Teleperm – controller Three independent channels

    19. Vienna 03-06.10.2006 18 Units 5&6 Modernization Program DESIGN FLAW ELIMINATION Measure 43213 – Delivery of equipment for TV-monitoring of systems equipment Under-water system SUSI for monitoring of main coolant pipes and pipes with diameter about 450 mm, reactor vessel and in-core devices High manoeuvrability Radiation-proof electrical and mechanical components Quick installation - reinstallation Measure 10111 – Replacement of boron meters type NAR-B with boron meters type NAR-12 to ensure continuous measurement with required accuracy, speed and automatic calibration  Replacement of the existing boron meter (NAR-B) with a new one which: Provides better precision, reliability and response time Is capable of measuring the B-10 concentration with an alarm signal

    20. Vienna 03-06.10.2006 19 Units 5&6 Modernization Program DESIGN FLAW ELIMINATION Measure 10221 – Install an integrated, continuous reactivity measuring system - AKR 03 Incorporated in AKNP-07 Includes signal converters, analysis, processing and information retrieval means Self-diagnostic Malfunction alarms Measure 10222 - Installation of a core subcriticality measurement system (SKP): Incorporated in AKNP-07 Highly sensitive sensors Self-diagnostic and malfunction alarms Stationary ionisation chambers

    21. Vienna 03-06.10.2006 20 Units 5&6 Modernization Program EQUIPMENT RELIABILITY ENHANCEMENT Measure 10121 – Replacement of the neutron monitoring system (AKNP) with a more sophisticated system (AKNP-07-02) after its operation life runs out Use of up-to-date high reliably equipment Precise measurement of neutron flux value in different operating modes of the unit Neutron flux value memory

    22. Vienna 03-06.10.2006 21 Units 5&6 Modernization Program EQUIPMENT RELIABILITY ENHANCEMENT Measure 14211 – Replacement of pressure sensors "Sapphire"  Sensors characteristics: Analog and digital output signals Error limits 0,1% - 0,15% Wide temperature range of performance Alarm Produced by high corrosion-proof alloy Hydraulic hits proof - up to 150%

    23. Vienna 03-06.10.2006 22 Units 5&6 Modernization Program EQUIPMENT RELIABILITY ENHANCEMENT Measure 14151 – Replacement of the "Hindukush" and CM-2M systems (In-core Instrumentation System)  Use of redundant configurations of high-reliable software and hardware devices (instrumentation devices, work stations with «UNIX - Solaris 8» operation system, network) Improvement of sensors construction and data processing for in-core neutron detectors and coolant temperature sensors Redundant configurations

    24. Vienna 03-06.10.2006 23 Units 5&6 Modernization Program EQUIPMENT RELIABILITY ENHANCEMENT Mesure 14131 – Replacement of the “Titan” system “Ovation” computer information system (CIS) Implementation of modern digital technology and module-based project with redundant configurations Nuclear application programs for monitoring of important parameters of the main equipment and calculations Practically unlimited possibilities of storing and archiving information of unit processes Self-diagnostic and malfunctions alarms Flexibility for future modernizations and expansions without having to shutdown the unit

    25. Vienna 03-06.10.2006 24 Units 5&6 Modernization Program EQUIPMENT RELIABILITY ENHANCEMENT Mesure 14190 – Replacement of UKTS The new unit process control system (UKTS) based on Westinghouse’s Ovation family of hardware and software products provides the following functions: Automatic and Remote Manual Control, Local Manual Control Protections and Interlocks Alarms Access Control Self-diagnostic Flexibility for future modernizations and expansions without having to shutdown the unit through: implementation of modern digital technology implementation of a design with divided functions redundant configurations technically-friendly maintenance due to self-diagnosis functions and module-based project

    26. Vienna 03-06.10.2006 25 Units 5&6 Modernization Program EQUIPMENT RELIABILITY ENHANCEMENT ????? 14191 – Replacement of ASUT Common platform and communication network with the other information and control systems (CIS and UKTS) Larger access to unit data and capability of technological processes and event analyses Implementation of modern digital technology Redundant configurations Digital systems ??????-D??S implementation Use of servo-regulators Woodward-SPC for turbine control Self-diagnostic and malfunctions localization

    27. Vienna 03-06.10.2006 26 Units 5&6 Modernization Program IMPLEMENTATION

    28. Vienna 03-06.10.2006 27 UNITS 5 AND 6 MODERNIZATION PROGRAM STATUS

    29. Vienna 03-06.10.2006 28   Huge scope of activities Modernization program performance during the scheduled time for routine annual maintenance Participants are representatives of various Bulgarian, Russian, West-European and US companies whose modernisation activities involve complicated interrelations both among them and with the existing or newly Installed equipment at the plant The close cooperation between contractors' teams and plant specialists working on the Project Thus, despite the fact that the program is being implemented by contractors of different culture and experience, applying different codes and standards - European, American, Bulgarian and Russian, a unified safety approach has been achieved, ensuring their compatibility and harmonious integration into the design of the upgraded units.  

    30. Vienna 03-06.10.2006 29 UNITS 5 AND 6 MODERNIZATION PROGRAM SUCCESS INDICATORS Time schedule management: Implementation of the full scope of planned improvements according to the defined outage schedules and reduction of outage duration Financial resources management: Strict adherence to specified budget frame Cost optimization resulting in overall implementation of the Program by 2% lower than the planned budget

    31. Vienna 03-06.10.2006 30 IMPORTANCE OF MODERNIZATION PROGRAM FOR KOZLODUY NPP The Modernization Program: Ensures long-term safe and effective operation of Units 5& 6 Improved equipment reliability and grid stability Serves as a basis for plant design lifetime extension Provides basic knowledge and experienced personnel for Belene NPP project implementation Reliable power output thanks to: Reduced scope of repair of equipment components of high defect rate Reduced duration of stoppages caused by control logic defects Transition to risk oriented outages resulting in: Reduction of planned outage windows duration Decrease of repair and maintenance cost Increase of produced electrical power Competitive behavior of Kozloduy NPP at the free energy market

    32. Vienna 03-06.10.2006 31 IMPORTANCE OF MODERNIZATION PROGRAM FOR KOZLODUY NPP Valuable experience gained in managing different aspects of large and complex investment projects: Analyses and enhancement of design status Organization and implementation of complex interfaces with new or existing equipment Development of new operational and maintenance documentation Management of modified units configuration Advanced knowledge on modernization of VVER -1000/?-320 units Training of plant personnel for operation of new equipment in compliance with the new requirements Development of open-minded thinking and adaptability

    33. Vienna 03-06.10.2006

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