Darlington Refurbishment 2017 Q3 Report · the Darlington Refurbishment Project, ... we’d be a much smaller company.” Visit to watch a video about how ... Darlington Refurbishment

Q3 2017

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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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].