Browns Ferry Nuclear Plant#Unit 1

The nuclear power plant is named after a ferry that operated at the site until the middle of the 20th century. (Brown's Ferry)

Browns Ferry was TVA's first nuclear power plant; its approval occurred on June 17, 1966 and construction began in September 1966. In 1974, the time of its initial operation, it was the largest nuclear plant in the world. It was the first nuclear plant to use units capable of generating more than 1 gigawatt of power.{{cite web

| url= https://www.tva.com/energy/our-power-system/nuclear/browns-ferry-nuclear-plant

| title= Browns Ferry Nuclear Plant

| publisher= Tennessee Valley Authority (TVA)

| access-date= 2008-11-18

| archive-date= 2015-10-12

| archive-url= https://web.archive.org/web/20151012200505/https://www.tva.com/Energy/Our-Power-System/Nuclear/Browns-Ferry-Nuclear-Plant

| url-status= dead

}} The lake provides main cooling, and 7 additional Mechanical Draft "helper" cooling towers assist during limitations on water temperature.{{cite web |title=BROWNS FERRY NUCLEAR PLANT UNIT 1 SEISMIC IPEEE REPORT, TVANBFN-01 -R-005 |url=https://www.nrc.gov/docs/ML0502/ML050210124.pdf |date=October 7, 2004 |publisher=NRC |quote=The residual heat removal service water intake structure is a single structure serving all three units. The reinforced concrete chimney stands 600 feet high and varies in diameter from 62 feet at the base to 6 feet at the top}} The 600 ft concrete chimney vents gases.{{cite web |last1=Jonsson |first1=Asgeir |last2=Smith |first2=John W. |title=Design of Browns Ferry Chimney |url=https://cedb.asce.org/CEDBsearch/record.jsp?dockey=0016923 |website=Journal of the Power Division |pages=437–447 |date=1970}}

In 2006, the Nuclear Regulatory Commission (NRC) renewed the licenses for all three reactors, extending their operation for an additional twenty years past their original 40-year licensing period.

TVA employs 1,500 people at the plant, making it the second largest employer in Limestone County, Alabama after only the Toyota-Mazda factory near Greenbrier{{citation |title=It's official: Toyota-Mazda announce Alabama factory |url=http://www.al.com/business/index.ssf/2018/01/its_official_toyota-mazda_anno.html |publisher=AL.com |date=11 Jan 2018}}{{citation |title=Major Employers |url=http://www.lceda.com/doing-business/facts-and-data/major-employers |access-date=2018-03-01 |publisher=Limestone County Economic Development Association}}

During the January 2024 Snowstorms, the Browns Ferry Plant reached its capacity of 3,954Mw, and was serving 2 million customers within the Tennessee Valley area.{{Cite web |title=Instagram |url=https://www.instagram.com/p/C2Ko42dAk3R/?igsh=c2Vpbmh6MTQ5azAx |access-date=2024-01-17 |website=www.instagram.com}}

On August 16, 2017, the NRC approved TVA's request for a 14.3% uprate of each reactor's output. Each unit's gross electrical output was 1,155 MW_e (1,101 MW_e net), but after power uprates during refueling outages in Fall 2018 for Unit 1, Spring 2019 for Unit 2, and Spring 2018 for Unit 3, the gross electrical output for each unit was increased to 1,310 MW_e (1,256 MW_e net). The uprate for Unit 3 was completed in July 2018,{{cite news|last=Flessner|first=Dave|date=2018-07-24|title=TVA boosts power output at newest Browns Ferry reactor|url=https://www.timesfreepress.com/news/business/aroundregion/story/2018/jul/24/tva-boosts-power-output-newest-browns-ferry-reactor/475591/|work=Chattanooga Times Free Press|location=Chattanooga, Tennessee|access-date=2018-11-16}} and in January 2019 for Unit 1.{{cite news|author=|title=Browns Ferry 2 taken offline for power uprate|url=https://www.neimagazine.com/news/newsbrowns-ferry-2-taken-offline-for-power-uprate-7027439|work=Nuclear Engineering International Magazine|date=March 7, 2019|access-date=2019-08-30}} The final uprate, for Unit 2, was completed in August 2019, completing the $475 million project.{{cite news|author=|title=TVA completes nearly $500M upgrade at Browns Ferry nuclear plant|url=https://www.power-eng.com/articles/2019/08/tva-completes-485m-upgrade-at-browns-ferry-nuclear-plant.html#gref|work=Power Engineering|date=August 8, 2019|access-date=2019-08-26|archive-date=2019-08-26|archive-url=https://web.archive.org/web/20190826050656/https://www.power-eng.com/articles/2019/08/tva-completes-485m-upgrade-at-browns-ferry-nuclear-plant.html#gref|url-status=dead}}

The electrical power increase of each unit was facilitated by the maximum operating thermal output of each reactor being increased from 3,458 MW_th to 3,952 MW_th.{{cite web|url=https://www.nrc.gov/reading-rm/doc-collections/news/2017/17-037.pdf|title=NRC Approves Extended Power Uprate for Browns Ferry Nuclear Plant|date=August 16, 2017|website=www.nrc.gov|publisher=Nuclear Regulatory Commission|access-date=October 19, 2017}}

The graph represents the annual electricity generation at the site in GWh.

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text: Browns Ferry Nuclear Plant

{{More citations needed section|date=August 2020}}

{{stack|File:Browns Ferry Unit 1 under construction.jpg}}

Unit 1 is a 1,256 MWe net BWR/4 built by General Electric. Construction started on Unit 1 on September 12, 1966{{cite web |url=http://tva.com/75th/pdf/tva_timeline_by_year.pdf |title=TVA timeline by year |publisher=Tennessee Valley Authority |access-date=5 August 2009 |url-status=dead |archive-url=https://web.archive.org/web/20100804060602/http://www.tva.com/75th/pdf/tva_timeline_by_year.pdf |archive-date=4 August 2010 }} and first powered up for testing on December 20, 1973. Commercial operation began on August 1, 1974.{{cite news |author=|title=Browns Ferry No. 2 N-Unit Test Approved|url=https://tennessean.newspapers.com/clip/57880858/browns-ferry-no-2-n-unit-test-approved/|page=6|work=The Tennessean|location=Nashville, Tennessee|agency=Associated Press|date=August 9, 1974|access-date=2020-08-23|via=Newspapers.com}} It was licensed to operate through December 20, 2013.{{cite web|url=https://www.nrc.gov/info-finder/reactors/bf1.html|title=Browns Ferry Nuclear Plant, Unit 1|year=2017|website=www.nrc.gov|publisher=United States Nuclear Regulatory Commission|archive-url=https://web.archive.org/web/20170502112159/http://www.nrc.gov/info-finder/reactors/bf1.html|archive-date=May 2, 2017|url-status=live|access-date=August 21, 2017}} Unit 1 was shut down for a year after a fire in 1975 damaged the unit. The unit was subsequently repaired and operated from 1976 through March 3, 1985, when all three Browns Ferry units were shut down for operational and management issues.

Starting in 2002, TVA undertook an effort to restore Unit 1 to operational status, spending $1.8 billion USD to do so. The NRC approved the restart of Unit 1 on May 15, 2007 and the reactor was brought up to criticality on May 22.{{cite web|url=http://www.tva.gov/news/releases/aprjun07/restart.htm|title=TVA Restarts Browns Ferry Unit 1|date=May 22, 2007|website=www.tva.gov|publisher=Tennessee Valley Authority|archive-url=https://web.archive.org/web/20070615003835/http://www.tva.gov/news/releases/aprjun07/restart.htm|archive-date=June 15, 2007|url-status=dead|access-date=August 21, 2017}} During initial testing after restart, on May 24, 2007, a leaky hydraulic control pipe in the turbine hall burst, spilling about {{convert|600|USgal}} of non-radioactive fluid, and the newly restarted reactor was temporarily powered down. Reactor power-up and tests resumed on May 27 and the unit started supplying power to the electricity supply grid on June 2, 2007, reaching full power on June 8. The Browns Ferry restart was estimated to pay for itself in five years.{{cite web|last=Blair|first=Elliot|url=https://www.bloomberg.com/apps/news?pid=20601103&sid=agGMCRlWdMyU&refer=us|title=New Reactor Costs Daunt U.S. Utilities as TVA Restarts Old Unit|publisher=Bloomberg|date=2007-07-09|access-date=2011-03-28}}

On May 4, 2006, NRC issued a renewed license, adding twenty years to operate through December 20, 2033.

Unit 1 generated 9,801 GWh of electricity in 2017, achieving a capacity factor of 101.62%.

Image:Puf.jpg foam used to fill a cable tray penetration at a power plant in Nova Scotia (subsequently removed and replaced with firestop mortar).]]

On March 22, 1975 a fire started when a worker using a candle to search for air leaks accidentally set a temporary cable seal on fire. At Browns Ferry, foamed plastic, covered on both sides with two coats of a flame retardant paint, was used as a firestop. The fire spread from the temporary seal into the foamed plastic, causing significant damage to the reactor control cabling in the station.{{cite news | url=https://news.google.com/newspapers?id=bGstAAAAIBAJ&sjid=U4oFAAAAIBAJ&pg=6822,845656 | title=Nuclear risk-benefit ratio needs a much closer look | date=April 4, 1979 | access-date=August 19, 2020 | author=Fisher, Brad | newspaper=The Tuscaloosa News | via=Google News | quote=The fire burned for seven hours, damaging scores of cables that provide the control room staff their eyes and ears to the two 1.1 million kilowatt reactors. Core cooling systems, pumps, dials and switches were knocked out by the fire. But plant workers found a way to press the auxiliary pumps into service, which kept the reactor cooled and allowed for a safe shutdown of the reactors after about 15 hours.}}

An NRC bulletin explained the circumstances of the fire.

The fire started in the cable spreading room at a cable penetration through the wall between the cable spreading room and the reactor building for Unit 1. A slight differential pressure is maintained (by design) across this wall, with the higher pressure being on the cable spreading room side. The penetration seal originally present had been breached to install additional cables required by a design modification. Site personnel were resealing the penetration after cable installation and were checking the airflow through a temporary seal with a candle flame prior to installing the permanent sealing material. The temporary sealing material was highly combustible, and caught fire. Efforts were made by the workers to extinguish the fire at its origin, but they apparently did not recognize that the fire, under the influence of the draft through the penetration, was spreading on the reactor building side of the wall. The extent of the fire in the cable spreading room was limited to a few feet from the penetration; nonetheless, the presence of the fire on the other side of the wall from the point of ignition was not recognized until significant damage to cables related to the control of Units 1 and 2 had occurred.{{cite web|title=IE Bulletin No. - 75-04A: Cable Fire at Browns Ferry Nuclear Plant|url=https://www.nrc.gov/reading-rm/doc-collections/gen-comm/bulletins/1975/bl75004a.html|publisher=United States Nuclear Regulatory Commission|date=April 3, 1975}}

This later resulted in the Nuclear Regulatory Commission making significant additions to the standards for fire protection through the publication of 10CFR50.48 and Appendix R. According to the Nuclear Information and Resource Service, the newly restarted Unit 1 does not comply with these standards.{{Citation needed|date=August 2020}} Unit 3 was not affected by the accident. This event was pivotal not just for firestopping in the nuclear field, but also in commercial and industrial construction. While the nuclear field went to installations of silicone foam, a wider array of firestops became prevalent in non-nuclear construction.{{Citation needed|date=August 2020}}

Unit 2 is a 1,259 MWe net BWR/4 built by General Electric that originally came online on August 2, 1974, and is licensed to operate through June 28, 2034. Unit 2 generated 8,396 GWh of electricity in 2017, achieving a capacity factor of 86.81%.

Unit 2 returned to service in 1991, after all three reactors were shut down in 1985.{{cite web|url=https://www.power-technology.com/projects/browns_ferry/ |title=Browns Ferry Nuclear Power Plant, Alabama, USA|date=2007|website=power-technology.com|publisher=Verdict Media Limited|access-date=2018-11-16|quote=All three units of the Browns Ferry plant were actually shut down in 1985, but they retained their NRC operating licences. Unit 2 came back on line in 1991, and Unit 3 in 1995 at a cost of US $1.8bn, which was also the estimated cost of restarting Unit 1.}} During a drought in August 2007, Unit 2 was shut down for one day because water temperature in the Tennessee River rose too high for the water to be used for cooling and then discharged back into the river.Mitch Weiss, [http://www.wral.com/news/state/story/2343605/ Drought Could Force Nuclear Plants to Shut Down], Associated Press, January 23, 2008, retrieved from WRAL-TV website, April 7, 2009

Beginning in 2005 Unit 2 was loaded with BLEU (Blended Low Enriched Uranium) recovered by the DOE from weapons programs. This fuel contains quantities of U-236 and other contaminants because it was made from reprocessed fuel from weapons program reactors and therefore has slightly different characteristics when used in a reactor as compared to fresh uranium fuel. By making use of this fuel, which would otherwise have been disposed of as waste, the TVA is saving millions of dollars in fuel costs and accumulating a database of recycled uranium reactions in LWR use.[http://www.tva.gov/news/releases/octdec05/tva_bleu.htm TVA press release] {{webarchive |url=https://web.archive.org/web/20060925141920/http://www.tva.gov/news/releases/octdec05/tva_bleu.htm |date=September 25, 2006 }}

Unit 3 is a 1,260 MWe net BWR/4 built by General Electric that originally came online on August 18, 1976 with a capacity of 1,105 MWe net, and is licensed to operate through July 2, 2036. Unit 3 returned to service in 1995 after all three units were shut down in 1985 for maintenance and repairs. Unit 3 generated 9,651 GWh in 2017, achieving a capacity factor of 99.70%. The power update of 155 MWe was completed in July 2018.

TVA decided to shut the entire plant down and keep it shut down indefinitely in order to focus on making improvements to all three units in order to bring it back into regulatory compliance following extremely negative assessments from the NRC.{{cite report|author1=United States General Accounting Office|author-link1=Government Accountability Office|title=Nuclear Regulation: Efforts To Ensure Nuclear Power Plant Safety Can Be Strengthened

|date=13 August 1987|page=40|publisher=United States General Accounting Office|url=https://www.gao.gov/products/RCED-87-141|access-date=20 May 2018|format=PDF|oclc=878522216|id=RCED-87-141}} Unit 2 finally resumed operation on May 24, 1991, with Unit 3 following it on November 1, 1995, although Unit 1 did not resume operation until June 2, 2007.

Cooling tower #4 (which was {{convert|90|feet}} wide, {{convert|300|feet}} long, and four stories tall) was destroyed in a fire caused by sparks from the electrical cooling fans in the tower hitting the abnormally dry redwood slats within the tower on May 10, 1986. During normal operation, water was kept flowing near-continuously over the redwood slats within the tower, but after close to two months of inactivity, the slats were very dry and extremely flammable.{{cite book|last1=Mahaffey|first1=James|title=Atomic Accidents: A History of Nuclear Meltdowns and Disasters: From the Ozark Mountains to Fukushima|publisher=Pegasus Books|isbn=9781480447745|edition=1st|date=2014-02-04}}{{cite news|title=Fire Destroys Cooling Tower at Nuclear Plant|url=https://www.apnews.com/5f7a9c16bd2454ab3bafa2df4e8eacc6|access-date=21 May 2018|work=AP News|date=11 May 1986|archive-date=22 May 2018|archive-url=https://web.archive.org/web/20180522041421/https://www.apnews.com/5f7a9c16bd2454ab3bafa2df4e8eacc6|url-status=dead}} $5 million of damage was done.{{cite news|title=Blaze Heavily Damages Unused Cooling Tower At Nuclear Plant|url=https://www.apnews.com/883b146491db3a85e86f02cc4d95387c|access-date=21 May 2018|work=AP News|date=23 May 1996|archive-date=22 May 2018|archive-url=https://web.archive.org/web/20180522041457/https://www.apnews.com/883b146491db3a85e86f02cc4d95387c|url-status=dead}}

Cooling tower #3 (which was in the process of being refurbished at the time) was heavily damaged in a fire on May 23, 1996, with about 80% of the tower destroyed.

At 11:05 AM on August 19, 2006, Unit 3 was manually scrammed due to loss of both the 3A and 3B Reactor Recirculation pumps. The initial investigation found the Variable Frequency Drive (VFD) microprocessors non-responsive. The root cause of the event was that the VFD controls malfunctioned due to excessive traffic on the connected plant Integrated Control System (ICS) network. Corrective actions included installing network firewalls that limit the connections and traffic to the VFD controllers.{{Cite web |title=TENNESSEE VALLEY AUTHORITY - BROWNS FERRY NUCLEAR PLANT (BFN) - UNIT 3 - DOCKET 50-296 - FACILITY OPERATING LICENSE DPR - 69 - LICENSEE EVENT REPORT (LER) 50-296/2006-002-00 |url=https://www.nrc.gov/docs/ML0629/ML062900106.pdf |access-date=April 28, 2022 |website=U.S. Nuclear Regulatory Commission}}

File:Crumpled transmission towers after 2011-04-27 tornado near Browns Ferry Nuclear Power Plant.jpg

At 5:01 PM on April 27, 2011, all three reactors scrammed due to loss of external power caused by a tornado in the vicinity of the plant. Control rod insertion and cooling procedures operated as designed with no physical damage or release of radiation. Diesel backup generators provided power after a brief period of outage. An NRC Unusual Event, the lowest level of emergency classification, was declared due to loss of power exceeding 15 minutes. Additionally, a small oil leak was found on one generator. Due to widespread transmission grid damage from the storms, Browns Ferry was unable to produce power for the grid and significant blackouts occurred throughout the Southeastern United States.[https://www.nrc.gov/reading-rm/doc-collections/event-status/event/2011/20110428en.html#en46793 NRC: Event Notification Report for April 28, 2011][http://www.tva.gov/news/releases/aprjun11/storm.htm TVA: Power Restoration Updates] {{webarchive |url=https://web.archive.org/web/20110502025725/http://www.tva.gov/news/releases/aprjun11/storm.htm |date=May 2, 2011 }}

A drain line leaked 100-200 gallons of water containing tritium levels above acceptable EPA drinking water standards. The leak was fixed within three hours of when it was discovered and was largely contained within the plant area.

{{cite web|title=Tritium Leak|date=11 January 2015 |url=http://www.timesfreepress.com/news/local/story/2015/jan/11/tvreports-tritium-leak-browns-ferry/282080/}}

The Nuclear Regulatory Commission found that 5 contract workers failed to conduct roving fire watch patrols as required by NRC. As a result, Tennessee Valley Authority was fined $140,000 for failing to maintain adequate fire watches in 2015 at Browns Ferry.

{{cite web|title=TVA fined $140,000 for fire violations at Browns Ferry Nuclear Plant; from google (brown ferry nuclear plant drought) result 7|date=29 November 2016 |url=http://www.timesfreepress.com/news/business/aroundregion/story/2016/nov/29/tva-fined-140000-fire-violations-browns-ferry-nuclear-plant/400229/}}

The 2010 U.S. population within {{convert|10|mi}} of Browns Ferry was 39,930, an increase of 12.3 percent in a decade, according to an analysis of U.S. Census data for msnbc.com. In 2020, the population within {{convert|50|mi}} was about 1.4 million, an increase of 43 percent since 2010. Cities within 50 miles include Huntsville (28 miles to city center).{{Cite web |date=2011-04-14 |title=Nuclear neighbors: Population rises near US reactors |url=https://www.nbcnews.com/id/wbna42555888 |access-date=2024-08-16 |website=NBC News |language=en}}{{Cite web |author=Staff Reporter |date=2022-07-05 |title=Nuclear Power plants in Alabama - A competitive and clean energy Source |url=https://skillings.net/nuclear-power-plants-in-alabama-a-competitive-and-clean-energy-source/ |access-date=2024-01-17 |website=skillings.net |language=en-US}}

According to an NRC study using geological data from 1989 to 2008 which was published in August 2010, the estimated risk of an earthquake intense enough to cause core damage to reactor one was 1 in 270,270, and for reactors two and three, the risk was 1 in 185,185.{{Cite web |date=2011-03-16 |title=What are the odds? US nuke plants ranked by quake risk |url=https://www.nbcnews.com/id/wbna42103936 |access-date=2024-08-16 |website=NBC News |language=en}}{{cite web|url=http://msnbcmedia.msn.com/i/msnbc/Sections/NEWS/quake%20nrc%20risk%20estimates.pdf|title=SAFETY/RISK ASSESSMENT RESULTS FOR GENERIC ISSUE 199, "IMPLICATIONS OF UPDATED PROBABILISTIC SEISMIC HAZARD ESTIMATES IN CENTRAL AND EASTERN UNITED STATES ON EXISTING PLANTS"|date=September 2, 2010|archive-url=https://web.archive.org/web/20170525170632/http://msnbcmedia.msn.com/i/msnbc/Sections/NEWS/quake%20nrc%20risk%20estimates.pdf|archive-date=May 25, 2017|url-status=dead|access-date=August 21, 2017|df=mdy-all}}

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{{commons category-inline}}

• [http://www.tva.gov/ TVA Website]
• {{cite web

| url= http://www.eia.doe.gov/cneaf/nuclear/page/at_a_glance/reactors/brownsferry.html

| title= Browns Ferry Nuclear Power Plant, Alabama

| date= August 19, 2008 | publisher= Energy Information Administration, U.S. Department of Energy (DOE)

| access-date= 2008-11-18 }}

• {{cite web

| url= https://www.nrc.gov/info-finder/reactor/bf1.html

| title= Browns Ferry 1 Boiling Water Reactor

| date= February 14, 2008 | work= Operating Nuclear Power Reactors

| publisher= U.S. Nuclear Regulatory Commission (NRC)

| access-date= 2008-11-18 }}

• {{cite web

| url= https://www.nrc.gov/info-finder/reactor/bf2.html

| title= Browns Ferry 2 Boiling Water Reactor

| date= February 14, 2008 | work= Operating Nuclear Power Reactors | publisher= NRC

| access-date= 2008-11-18 }}

• {{cite web

| url= https://www.nrc.gov/info-finder/reactor/bf3.html

| title= Browns Ferry 3 Boiling Water Reactor

| date= February 14, 2008 | work= Operating Nuclear Power Reactors | publisher= NRC

| access-date= 2008-11-18 }}

• [http://www.ccnr.org/browns_ferry.html The Fire at the Brown's Ferry Nuclear Power Station], by David Dinsmore Comey, 1976.
• [http://www.nirs.org/press/06-20-2007/1 NIRS Investigation Finds That "New" Browns Ferry-1 Reactor Still Doesn't Meet Fire Protection Regulations Its 1975 Fire Caused] Nuclear Information and Resource Service, June 20, 2007.
• [https://web.archive.org/web/20070930024100/http://www.al.com/newsflash/regional/index.ssf?%2Fbase%2Fnews-30%2F1187315674106070.xml&storylist=alabamanews TVA reactor shut down; cooling water drawn from river too hot]
• [http://frwebgate3.access.gpo.gov/cgi-bin/waisgate.cgi?WAISdocID=1957518962+71+2+0&WAISaction=retrieve Reactor Fire Protection 10CFR50.48]{{dead link|date=November 2016 |bot=InternetArchiveBot |fix-attempted=yes }}, NRC Summary
• [http://content.usatoday.com/communities/greenhouse/post/2012/06/climate-change-makes-nuclear-coal-power-plants-vulnerable/1#.T9L_lt18V50 Climate change causes nuclear, coal plant shutdowns] June 4, 2012 USA Today, regarding the effects of global warming

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