Darlington Nuclear’s Unit 1 successfully refurbished months ahead of schedule

Key Takeaways:

• The refurbished Unit 1 at the Darlington Nuclear Generating Station will provide 875 MW of clean energy for over 30 years, powering 875,000 homes and helping meet Ontario’s forecasted 75% electricity demand increase by 2050.
• The $12.8 billion refurbishment project is expected to generate $90 billion in economic benefits and create 14,200 jobs annually over its lifespan, with 96% of costs spent within Ontario, significantly boosting the provincial GDP.
• Completed five months early, Unit 1’s refurbishment showcases Ontario’s ability to deliver large-scale, complex nuclear projects safely, on time, and on budget, highlighting the expertise of a 6,000-member workforce, including skilled tradespeople and industry partners.

The Whole Story:

Ontario has completed the refurbishment of Unit 1 at the Darlington Nuclear Generating Station five months ahead of schedule.

Refurbishing and returning Unit 1 to service provides 875 megawatts (MW) of power for the next 30-plus years, enough to power 875,000 homes.

“Ontario needs more electricity – 75% more by 2050 – to power new homes, historic new investments and an electrifying economy,” said Stephen Lecce, Minister of Energy and Electrification. “Delivering this massive clean energy project five months ahead of schedule is a testament to the incredible knowledge and skill of Ontario workers and positions us for success as we build out our plan to meet the soaring energy demand over the next 25 years.”

The Darlington Refurbishment Project is one of Canada’s largest energy projects. The refurbishment of Unit 1 involved the successful removal and replacement of major components of the reactor and its associated equipment including pressure tubes, calandria tubes and feeder pipes, as well as inspection and upgrades of the Turbine Generator equipment.

According to an independent report by the Conference Board of Canada, the entire $12.8 billion project, and the subsequent 30 years of station operation, are expected to generate a total of $90 billion in economic benefits for Ontario and create 14,200 jobs per year. With 96% of project costs spent in the province, for every $1 spent on the project, Ontario’s GDP will increase by an average of $1.40.

“Unit 1 is the third unit we will have refurbished months ahead of schedule, safely and with quality,” said Ken Hartwick, OPG President and CEO. “Through the planning, dedication, skill and innovation of OPG and its project partner team, including hundreds of skilled tradespeople, we are now in year 9 of this 10-year refurbishment project execution phase, clearly demonstrating we can complete large, complex nuclear projects on schedule and on budget.”

According to Ontario’s Independent Electricity System Operator (IESO), the province’s demand for electricity is forecast to increase by 75% by 2050, the equivalent of adding four and a half cities the size of Toronto to the grid. Continued operation of the Darlington Nuclear Generating Station during that period will help tackle the rising demand while reducing emissions, taking the equivalent of two million cars off Ontario’s roads per year.

The project involved the removal and replacement of major reactor components, including pressure tubes, calandria tubes, and feeder pipes, as well as inspection and upgrades of the turbine generator equipment. The work was carried out by a team of approximately 6,000 people from OPG and its vendor partners, including skilled tradespeople, project management professionals, and support services personnel.

The team comprised members from various unions, such as the International Brotherhood of Boilermakers, United Brotherhood of Carpenters and Joiners, International Brotherhood of Electrical Workers, and several others.

Since the project began in 2016, OPG has applied thousands of lessons learned on each subsequent unit to achieve major efficiencies and schedule savings. This includes an industry-first combined pressure tube and calandria tube removal process.

Unit 1 now joins Darlington’s Units 2 and 3, which were successfully refurbished in 2020 and 2023, respectively, as OPG’s latest nuclear success story.

Unit 4, the final unit undergoing refurbishment, is currently in the reactor rebuilding phase and progressing on schedule to be completed by the end of 2026 to wrap up the ambitious 10-year, $12.8-billion mega-project.