Streamlining Outage Efficiency at a Pennsylvania Nuclear Power Plant

Nuclear power plant outages demand efficiency, safety, and a high level of coordination to execute time-critical tasks and bring plants back online quickly. When a Pennsylvania nuclear power plant faced excessive critical path time due to outdated steam line plugs and a unique control rod blade transportation and storage requirement, the plant’s leadership engaged Preferred Engineering (PE) to support two custom solutions: a more efficient main steam line plug system and a control rod blade rack, specifically designed to meet tight requirements. These tools were essential for supporting the plant’s streamlined outage objectives (Figure 1). [caption id="attachment_228800" align="aligncenter" width="739"]

1. Installation team onsite. Courtesy: Preferred Engineering[/caption]

Optimizing Steam Line Plug Performance to Save Time

The plant’s existing main steam line plugs (MSLPs) had become a persistent source of delay, prompting the team to seek out a standard plug solution known for reliability and efficiency. Preferred Engineering’s main steam line plugs were selected due to their established use in reducing installation time and improving critical path alignment across the customer’s nuclear fleet. The MSLP design provides a passive, dual-seal mechanism, adding an extra layer of protection without requiring constant energy input. The plug’s stainless-steel construction and compatibility with varied nozzle geometries proved essential for the plant’s maintenance schedule, minimizing the need for additional handling steps and simplifying decontamination procedures. Additionally, the MSLP installation tool allows for rapid deployment from the refueling floor, enabling plant operators to install two plugs in less time and with fewer manual steps. This efficiency directly reduces handling complexity, improves plug reliability, and trims down critical path time—benefits that played out in real time during the plant’s recent outage.

Customizing a Control Rod Blade Rack to Meet Tight Operational Demands

Control rod blade storage and handling are complex aspects of outage planning. The Pennsylvania nuclear plant had a specific need for a rack that could transport and store 20 control rod blades while adhering to both spatial constraints and seismic standards. It was vital for these blades to be safely stored in a way that prevents accidental damage during outage operations. The timeline for delivery and installation was short, with only eight weeks from design to implementation. Preferred Engineering’s team worked closely with plant leadership, conducting a thorough assessment of outage requirements to deliver a fully customized blade rack (Figure 2). This collaboration enabled quick engineering to build the storage solution in the short timeframe, which was then integrated seamlessly into the plant layout. [caption id="attachment_228803" align="aligncenter" width="259"]

2. Installed control rod blade rack. Courtesy: Preferred Engineering[/caption] To meet all safety requirements, the custom rack complied with seismic standards and was easy to maneuver for quick placement. Every aspect of the design, from the tight spatial fit to the material resilience enabled the control rod blades to be handled with confidence and efficiency. Chris Bohn, sales engineer at Preferred Engineering, noted, “We understand that downtime is a costly part of doing business for a nuclear plant. When a plant is offline for maintenance or refueling, that’s revenue lost. So, designing products like these to minimize that downtime is our top priority. By focusing on a tailored blade rack design, we were able to help the plant’s team stay on track with their outage plan and maximize their efficiency.”

Forward-Looking Benefits

With these solutions implemented, the plant achieved a smoother, faster outage process with reduced critical path time, maximizing overall outage efficiency. Beyond the immediate outage, the standardization of these MSLPs and the custom control rod blade rack are expected to support operational stability in future maintenance cycles. This case study illustrates the impact of specialized, responsive outage solutions, reinforcing the need for tailored tools that support safe, timely, and efficient outage execution. Through collaboration and engineering expertise, Preferred Engineering worked with the plant to provide solutions that allowed them to stay on schedule, minimize critical path challenges, and operate more effectively. Steven Mitchell is vice president of Preferred Engineering.