HPC-NNBOSL-U0-000-RES-000018 Version 1.

Plant Commissioning Programme

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NNB GENERATION COMPANY LTD

HINKLEY POINT C PRE CONSTRUCTION SAFETY REPORT

SUB CHAPTER 19.1

PLANT COMMISSIONING PROGRAMME
PART OF CHAPTER 19, COMMISSIONING

1.0

Version
Date of Issue

14 May 2012

Document No.

HPC-NNBOSL-U0-000-RES-000018

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2012 Published in the United Kingdom by NNB Generation Company Limited (NNB GenCo), 90 Whitfield Street - London, W1T
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Plant Commissioning Programme

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TABLE OF CONTENTS
0

INTRODUCTION ................................................................................................................. 4

0.1

Purpose............................................................................................................................... 4

0.2

Scope .................................................................................................................................. 4

PRE-OPERATIONAL TESTING (NON-ACTIVE COMMISSIONING)................................. 5

1.1
Phase I Individual System Tests.................................................................................... 5
1.1.1 Construction Tests ............................................................................................................ 5
1.1.2 Individual System Tests .................................................................................................... 5
1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5

Phase II Pre-Core Loading Testing................................................................................ 5

Pre-Core Loading Testing ................................................................................................. 6
Cold Functional Testing (CFT).......................................................................................... 6
Hot Functional Testing (HFT)............................................................................................ 7
Activities Managed via the Commissioning Programme ............................................... 7
Preparation for Fuel Load ................................................................................................. 8

INITIAL START-UP AND OPERATIONAL TESTING (RADIOACTIVE COMMISSIONING)8

2.1
Phase III Power Escalation Testing ............................................................................... 8
2.1.1 Initial Start-up..................................................................................................................... 9
2.1.2 Operational Testing (Power Raise Tests) ........................................................................ 9
3

REFERENCES AND ABBREVIATIONS........................................................................... 10

3.1

References........................................................................................................................ 10

3.2

Abbreviations ................................................................................................................... 10

FIGURES ........................................................................................................................... 12

LIST OF FIGURES
Figure 1: Plant Commissioning Programme (Overview) ...............................................................12
Figure 2: Plant Commissioning Programme (Principles) ..............................................................13

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INTRODUCTION

0.1

Purpose
Commissioning tests serve as a progressive transition between erection, installation and
the start of normal operation of the various plant systems. These tests may take place at
the manufacturers or suppliers works, on specific test facilities or on the power station
site. The choice depends on the type of equipment, level of a systems integration that
can be simulated off-site (e.g. Instrumentation and Control (I&C) systems) and on the
ability to obtain specific conditions on-site (e.g. for qualification of accident transients)
[Ref 1].
The method of defining commissioning tests is chosen with the following objectives:
x

To ensure that plant commissioning does not compromise nuclear and/or industrial
safety,

To demonstrate that all statutory inspections and testing are completed in

accordance with UK codes and regulations,

To ensure that all operational aspects of system functions are tested, including safety
classified functions, taking into account and credit for, manufacturers, and/or off-site)
tests,

To serve as the basis for designing operational test documentation.

The main purpose of commissioning tests is to ensure that plant systems will perform
according to their design intent and satisfactorily meet the required safety function as
stated in the safety case.
The test programme is based on reference documents that define and describe the
systems related functional aspects and specifications. This reference material is
obtained from manufacturers information, plant systems manuals and design
specifications.

0.2

Scope
A phased approach is employed for plant commissioning. It is conducted from the
completion of erection activities to full power commercial operation. It is organised into
two test categories [Ref 2 and 3] and is carried out in three main phases:
x

Pre-operational tests (Non-Active Commissioning)

o Individual System Tests Phase I,
o Pre-Core Loading Tests Phase II.

Initial start-up and operational tests (Radioactive Commissioning)

o Power Escalation Tests Phase III.

Plant commissioning tests cover all testing performed on the installed plant and
equipment. Safety-classified Structures, Systems and Components (SSC) are
specifically tested to ensure correct operation as specified in the design requirements.
The following description gives a preliminary overview of the plant commissioning
programme. Only the main test phases are listed, as a detailed commissioning
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programme will be prepared after the design phase is completed. Plant testing will only
commence once this programme of testing is approved [Ref 4].
The structure of the commissioning process is shown at Figure 1 and Figure 2.
Progression through the individual stages of testing identified in this document will be
subject to QA hold-points and procedural requirements to ensure that all testing prerequisites have been met. Plant and systems will be functionally tested and will
demonstrate compliance with test criteria prior to being required for subsequent tests.

PRE-OPERATIONAL TESTING (NON-ACTIVE

COMMISSIONING)

1.1

Phase I Individual System Tests

Phase I includes initial construction and individual system tests:
x

Initial energisation of components and first start-up of equipment,

Functional testing of plant and equipment as individual systems and/or groups of

systems without fully integrated testing with the reactor coolant system or relating
auxiliary systems and the secondary-side systems.

1.1.1 Construction Tests

These tests cover construction and installation checks leading up to first energisation
with process fluid and electrical supplies.
Pre-commissioning testing is a verification of installation and construction. Typical
activities are checking motor insulation, pipe and equipment cleanliness, input/output
testing of Instrumentation and Control (I&C) systems. This is a carried out as a
construction function prior to handover for start of commissioning. The responsibility for
carrying out this work is emphasised in the contract document. There is a specific
attachment specification covering commissioning activities.

1.1.2 Individual System Tests

This stage is done on a system-by-system or sub-system by sub-system basis,
depending on the erection sequence, safety and planning requirements. These tests
must be finished when the system or sub-system is required for overall inactive testing.
Basic functional testing at system level is carried out in the Pre-Operational test phase.
Some systems testing will not be completed in this phase, with necessary overlap into
the Operational testing phase. This allows the phased start of systems in support of the
wider commissioning and start-up programme.

1.2

Phase II Pre-Core Loading Testing

x

Phase II includes the initial integrated tests:

o Dynamic flushing and open vessel functional tests,
o Cold functional and hydrostatic tests of the reactor coolant system,

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o Hot functional tests of the reactor coolant system,
o Secondary-side systems,
o Preparation for fuel load.
These tests are completed prior to loading nuclear fuel into the reactor vessel.

1.2.1 Pre-Core Loading Testing

Pre-start-up testing activities are expected to be as follows:
CEC (Chasse en Cuve) Dynamic Flushing into the Vessel
The main safety systems which connect to the Reactor Coolant System (RCP [RCS])
are flushed using water pumped from a large storage tank. This process is complete
once the internal pipework and equipment cleanliness meet the required criteria.
EFCO (Essai Functionnel Cuve Ouverte) Open Vessel Functional Tests
These tests are conducted with an open reactor pressure vessel, without the reactor
closure head in place. Safety Injection Systems (RIS [SIS]) are then functionally tested
by injecting water directly into the primary circuit. Flow rates and control functions are
tested. Carry out the initial operation and testing of Residual Heat Removal System
(RIS/RRA [SIS/RHRS]) and Containment Spray (CAE).
Open Vessel Functional Test main steps would include:
x

Establish Reactor Coolant Pump seal injection to maintain seal cleanliness,

Pump water into the vessel to prove RIS/RRA [SIS/RHRS] flow orifices are of the
correct size,

Test RIS/RRA [SIS/RHRS] configurations and prove hydraulic characteristics of the

system,

Accumulator discharges, functional Safety Injection Low and High Pressure pumps,

Verify RIS/RRA [SIS/RHRS] and CAE flow rates and control functions,

Loss of Offsite Power and transfer to Emergency Diesel Generator supplies (BAS).

1.2.2 Cold Functional Testing (CFT)

The Primary Circuit Cold Functional Test period is defined as that period, which for the
first time, provides an opportunity for integrated system operation and testing of primary
circuit components and associated support systems with the reactor closure head in
place.
Activities include: filling and venting of the RCP [RCS] through integrated operation
under limited elevated pressure and temperature conditions to support hydrostatic
testing of the primary circuit. The main steps are as follows:
x

Initial filling and venting of the RCP [RCS],

Preliminary Chemical and Volume Control System (CVCS [RCV]) mid loop testing,

Establish RCP [RCS] solid water control,

Initial Reactor Coolant Pump operation,

Warming RCP [RCS] for primary hydro pressure test,

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x

Performance of primary hydro pressure test to verify leak tightness and integrity of
RCP [RCS] and high pressure pipework sections,

Initial preparations of the RCP [RCS] and related systems for the start of Hot
Functional Testing.

These tests will prepare for Hot Functional Testing.

1.2.3 Hot Functional Testing (HFT)

The objective of Hot Functional Testing is to perform a series of individual integrated
station tests for which elevated pressures and temperatures are required in the RCP
[RCS], prior to the initial charge of nuclear fuel. Full operational pressure and
temperature conditions are achieved from energy input by Reactor Coolant Pump (RCP)
circulation and pressuriser heater operation. These conditions enable the reactor
monitoring, control, safety and support systems to be operated and tested under normal
operating conditions.
This testing is selected to demonstrate, within plant limitations, that the operation of each
engineered system to support integrated plant operation will meet its design and safety
requirements. This includes plant endurance running, chemical conditioning, reliability
monitoring and demonstration of human-machine interface from the Main Control Room
(MCR) and at other local control stations. Power Station operations personnel would
operate and manoeuvre the plant in accordance with station operating procedures. The
main tests are to demonstrate the ability of the following:
x

To heat up plant to normal, operating conditions,

Passivation and chemical conditioning of the RCP [RCS],

To monitor, control and safely operate at normal operating conditions,

Reactor protection and safety systems to function correctly,

To safely cool down to ambient conditions from MCR and other control locations,

The station operating procedures to safely manoeuvre the plant,

Reliability and endurance running of the station under normal operating conditions.

1.2.4 Activities Managed via the Commissioning Programme

Due to the operating status and configuration of plant and availability of staff, certain key
activities that are required as part of the preparation for start-up will be carried out under
the control of the overall commissioning arrangements. This allows best use of the plant
conditions presented during this phase.
x

Pre-Service Inspection (PSI) of the Reactor Pressure Vessel (RPV) before CFT,

Primary Circuit hydrostatic test.

Containment Structural Over-pressure Test (SOT) and Integrated Leak Rate Test (ILRT)
are also carried out during this phase.
x

SOT is to demonstrate that the primary containment structure and its closures have
the ability to withstand successfully a test pressure and that the structure behaves in
accordance with design predictions.

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x

ILRT is to demonstrate that the leakage integrity of the primary containment to

withstand the calculated Design Basis Accident (DBA) pressure load that challenges
the primary containments leak tightness capability.

1.2.5 Preparation for Fuel Load

The post-HFT / pre-Fuel Load period is when preparations are being made to ensure all
structures, systems and components required to support the initial charge of nuclear fuel
into the RPV are in a satisfactory state. Activities carried out during this period are as
follows:
x

Final construction, inspection and testing of those systems not required for HFT, but
are required for fuel load,

Post HFT In-Service Inspection (ISI) of the RPV,

Complete testing to fuel handling machine and associated equipment,

Boration of primary circuit systems in preparation for fuel load.

Activities may be brought forward or carried out in parallel to mitigate risk to later stages
of testing. Activities will be planned such that they do not impact on the systematic
confidence building approach to commissioning nor breach any consent hold points.

INITIAL START-UP AND OPERATIONAL TESTING

(RADIOACTIVE COMMISSIONING)

2.1

Phase III Power Escalation Testing

Phase III includes fuel load, cold and hot pre-critical tests, initial criticality, and power
ascension up to commercial operation. A demonstration run will also be conducted
during this test phase.
These tests include:
x

Standard start-up tests, which are designed to verify the correct operation of the
plant and compliance with the design intent.

Testing that is repeated at different power levels during power ascension testing (e.g.
core physics and control systems tests) to confirm that the design assumptions are
valid and support the safety analysis.

Operating procedures and test surveillances. These are the normal station operating
procedures widely used during the start-up tests. These procedures and
surveillances are validated and used during this time. Fault and accident procedures
are validated during the plant commissioning. The off-normal procedures for faults
and design basis accidents are validated on the replica simulator prior to plant
testing.

First of a Kind (FOAK) testing is performed in order to verify an un-proven or

innovative concept, which has not yet been validated. Such tests may require
additional specific instrumentation capable of confirming theoretical data.

Tests which gradually exercise the plant in a progressively searching and onerous
manner.

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The programme will evolve from experience gained during plant commissioning and
initial operation together with feed-back (lessons learned) from similar EPR plants.

2.1.1 Initial Start-up

Following preparation for fuel load, fuel is received, inspected and stored in the fuel
pond, ready for loading. The fuel is loaded into the reactor core using the fuel handing
equipment. Following verification of the core the upper internals and reactor head are
replaced. The reactor head is then secured and the reactor assembly is completed.
The reactor coolant system is then filled and fully vented to remove residual air. The
RCPs are then started to heat the RCP [RCS] up to nominal operating conditions.
Following fuel load there is a period of pre-criticality testing, which includes control rod
motion/drop tests. Initial criticality and low power physics testing follow for example as
follows:
x

Low power physics testing to verify design assumptions,

Evaluation of protection settings based on core physics test data,

Nuclear instrumentation testing.

2.1.2 Operational Testing (Power Raise Tests)

Specific tests are performed during power raise testing and are generally grouped into
three categories.
x

System tests,

At-power physics tests,

Transient tests.

There is normally a period of continuous full power commercial operation before the final
rating certificate is issued.
2.1.2.1 System Tests
Power raise tests are normally structured to manoeuvre the plant to ever increasing
power levels and plateaus. The plant is then stabilised while a series of tests are carried
out. A number of tests are carried out during each plateau. These tests are designed to
confirm proper operation at lower core power levels before subjecting the plant to more
rigorous testing at higher power levels.
The major power plateaus can be at a nominal reactor power of 30, 48, 75 and 100 per
cent. Typical tests at these power levels are as follows.
x

Radiation surveys,

Core instrumentation response testing (flux maps, Xenon oscillations),

Verification of plant behaviour during low power transients,

Further Evaluation of protection settings based on core physics test data.

Raising reactor power step by step is supported on the secondary side by taking steam
via the atmospheric steam generator dump system, then to condenser steam generator
dump system and finally to the turbine leading to the synchronisation of the alternator
and raising electrical power output to 100 per cent full power.
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2.1.2.2 At-Power and Transient Testing
An example of typical at-power tests are as follows:
x

Calibration of nuclear instrumentation,

Primary and secondary calorimetric testing,

RCS flow checks,

Reactor protection testing,

Physics testing,

Verification of plant behaviour during high power transients,

Transient testing; remote shut down, turbine trip, turbine load rejection, station black
out/turbine trip, reactor trip and National Grid response testing.

REFERENCES AND ABBREVIATIONS

3.1

References 1

3.2

1.

GDA PCSR Sub-Chapter 19.1 (2009) EDRMS.

UKEPR-0002-191

2.

Strategy for Commissioning EDRMS.

NSL/B/TECH/10/279

3.

Compliance Statement and Forward Work Plan LC21 Commissioning EDRMS.

NSL/B/TECH/10/417

4.

LC21 Commissioning, HSE T/INS/21 Issue 1 Public.

Abbreviations
Term / Abbreviation

Definition

CAE

Containment Spray

CEC

(Chasse En Cuve) Dynamic Flushing into the vessel.

CFT

Cold Functional Testing

DBA

Design Basis Accident

DIN

Division Ingnierie Nuclaire

EFCO

(Essai Functionnel Cuve Ouverte): Open Vessel Functional Tests

FOAK

First of a Kind

GDA

Generic Design Assessment

HFT

Hot Functional Testing

I&C

Instrumentation and Control

ILRT

Integrated leak Rate Test

BC may show a more recent version, version history can be used to locate specific versions.

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Term / Abbreviation

Definition

ISI

In-Service Inspection

LC

Licence Condition (ONR)

MCR

Main Control Room

NNB

Nuclear New Build

SSC

Structures, Systems and Components

PSI

Pre-Service Inspection

RCP [RCS]

Reactor Coolant System

RCP

Reactor Coolant Pump

RIS [SIS]

Safety Injection System

RIS/RRA [SIS/RHRS]

Safety Injection System/Residual Heat Removal System

RPV

Reactor Pressure Vessel

SOT

Structural Over-Pressure Test

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FIGURES

Figure 1: Plant Commissioning Programme (Overview)

OFFSITETESTING
FACTORY
ACCEPTANCE
TESTING
(FAT)

FACTORY
INTEGRATION
TESTING
(FIT)

CONSTRUCTION
ANDERECTION

ONSITECOMMISSIONING
PREOPERATIONALTESTING(NONACTIVECOMMISSIONING)
PHASEISYSTEMTESTS
PHASEIIPRECORELOADINGTESTS
I.1
I.2
I.3
II.1
II.2
II.3
II.4
SETTING
SITE
SITE
COLD
PREPARATION
HOT
PREPARATION
TO
ACCEPTANCE INTEGRATION FUNCTIONAL
FORHOT
FUNCTIONAL
FORFUEL
WORK
TESTING
TESTING
TESTING
FUNCTIONAL
TESTING
LOAD
(STW)
(SAT)
(SIT)
(CFT)
TESTING
(HFT)

STARTUPTESTING(RADIOACTIVECOMMISSIONING)
PHASEIIIPOWERESCALATIONTESTS
III.1
III.2
III.3
III.4
FUEL
PRE
CRITICALITY
POWER
LOAD
CRITICALITY
TESTING
ESCALATION
TESTING
TESTING

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Figure 2: Plant Commissioning Programme (Principles)

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