Solutions for Nuclear Power

Transcription

1 Solutions for Nuclear Power SOLUTIONS FOR Seismic Retrofits Blast Mitigation Steel & Concrete Pipes Walls, Slabs & Floors Security Facilities Steel & Concrete Tanks Columns & Beams Contact us: John O Leary Mobile: Kevin Hawks Mobile: John Solon Mobile: George Mathes mobile

2 Solutions for Nuclear Power Introduction to Next Next is a specialty construction firm focused on providing innovative solutions specifically to the nuclear power industry. The primary focus of our work involves utilizing high strength composites to provide cost effective, low plant impact solutions to infrastructure problems relating to: Structural degradation due to age and corrosion Load or design criteria changes Seismic qualification or upgrades Blast mitigation Ballistic Protection Asset Protection from corrosion issues Company personnel have extensive experience in providing these solutions in the industrial marketplace and over 40 years experience providing customer driven solutions to the nuclear power market. The experience of the owners and employees of Next Composite Solutions includes: Specific project experience in every operating Nuclear Power Station in the United States Significant experience in the international nuclear market including work in China, South Korea, Japan, Europe and South America. Successful completion of hundreds of shutdown projects throughout the US Nuclear market Extensive experience operating under 10CFR50 Appendix B Quality Programs Experience operating in high radiation areas Completion of testing and qualification programs for innovative solutions for the nuclear market Over 25 years experience providing solutions to a wide variety of industries using high strength composites, including providing these solutions in the nuclear power market Expertise in corrosion protection solutions for aggressive environments Background Next Composite Solutions, Inc was formed by SCG and members of its partner companies to provide solutions to the Nuclear Power Market. SCG, Inc., an industrial specialty construction company, has been performing structural, seismic, and blast upgrades using carbon fiber reinforced polymers (CFRP) since 2007, installing well over 2 million square feet of material in that time. For work in the nuclear power market, SCG partnered with other contractors and engineers who specialized in servicing the nuclear market. When SCG s contracting partner decided to exit the marketplace, several of their employees who had worked on CFRP related work opted to stay connected to both CFRP and the nuclear market and joined up with SCG to form Next Composite Solutions, Inc. While Next offers a similar array of products and services to SCG, the business is focused entirely on the nuclear power market. Safety At Next, we believe safety is the driver for success on every project. Our composite experts have been operating in heavy industry and have completed extremely challenging projects in hazardous environments without a single recordable incident in almost 9 years and spanning hundreds of thousands of man-hours. We employ a full time Safety Director with certifications from OSHA, MSHA, NIOSH, and the American Red Cross, and operate an aggressive program that is focused on preventive safety practices vs. reactive ones. Each Next project, regardless of size or scope, has a Site Specific Safety Plan that addresses the specific hazards associated with the site and work scope. While the company is very focused on providing value based solutions to the industry, we have also adopted policies to support performance at the highest levels of Quality and Safety.

3 Solutions for Nuclear Power Nuclear Power Market After the accident in 2011 at Fukushima, the NRC identified 11 highest priority tier 1 activities to enhance U.S Reactor safety: Carbon fabrics for blast hardening and structural repair of concrete and/or steel infrastructure such as floor slabs, beams and columns, pipes and tanks. Basalt fabrics for structural repair where non-conductive material is required. Properties include no wicking and an insulator for temperature and sound. Carbon Fabric Basalt Fabric Enhancement of Nuclear Plant Systems often requires complex solutions for: Existing structures needing upgrade for seismic qualification Backup cooling systems Component supports not meeting seismic/structural requirements Infrastructure at lifecycle limit requiring upgrade or replacement Ballistic protection work For many of the projects requiring seismic upgrades, plants are faced with conventional options. The Next Team offers an alternative for many projects using Carbon Fiber Technology. Composite Solutions: Next provides innovative solutions that are engineered and tailored to a client s specific problem. In that process, we match products to applications to find the best and most cost effective solution. Advanced materials such as composite fabrics are often very effective alternatives for repair and rehabilitation work. Next works with the following composite materials: Glass fabrics (both E-glass and S-glass) used for axial confinement and applications requiring lower strength materials. Non-conductive. Kevlar fabrics used for blast mitigation and ballistic protection. Benefits: Composite Solutions offer many benefits over traditional Options. Very strong and very light-weight, easy to handle, can be inserted into confined areas. Low overall costs compared to traditional concrete and steel methods. Often materials can be installed without requiring a plant outage schedule. Corrosion resistant, long lasting. Glass Fabric Kevlar Fabric High chemical resistance. Additional coatings can be applied as a topcoat for additional protection. High sustainability rating due to low energy needed to install and due to extended life-cycle of existing infrastructure. Laminates Carbon, basalt and glass for beam reinforcement, concrete crack repair and rebar replacement.

4 Solutions for Nuclear Power Protecting Assets: After years of exposure, critical infrastructure assets can undergo surface damage and eventually structural damage due to chemicals, abrasion, and other external impacts and must be repaired. Next utilizes composite systems to rehabilitate sites with both surface and structural damage. These repairs normally include a carefully selected coating material that is matched to the constraints of the application. Next uses a three-step process to insure the match of coatings to the application provides the optimal solution: Classify Application Type Identify Process Constraints Factor in Economic Constraints Step 1: Classify Application We use 3 broad categories in this step to classify the type: Dry Conditions (such as columns). Condensing Vapors/Splash (such as walls, roof surfaces). Continuous Immersion (such as tanks). Step 2: Physical Constraints Each application is constrained by temperature extremes, acidic versus alkaline chemistry, abrasion and other exposures. Each of these must be defined and used to select materials. Quality Each of our projects offers unique challenges and requires extreme attention to detail. Whether the result of the project is structural reinforcement, chemical containment or continued plant operation, the quality of our installations has enormous life safety, environmental and economic impact. To meet these demands, we utilize a detailed system of engineering review, detailed project instructions, and both in-house and third party quality control inspection. Each crew is equipped with state of the art equipment for monitoring project conditions, and performing inprocess and final inspections. Performance The ultimate measure of a construction company is performance. Completing projects on time, on budget, to specification and with zero accidents is always the goal at Next. We rely on a skilled, trained and experienced workforce to achieve consistently high standards in field performance. To backup our site operations, we have invested heavily in information technology, material science and testing, and state of the art communication systems. Each project undergoes a complete review before the first boots are on site. This review includes safety Step 3: Economic Constraints The solution must fit the life cycle needed, costs must be aligned with benefits and budgets Coating & Lining Options: Next has access to extensive testing on coatings and related products to verify properties and to develop detailed field installation procedures that include manufacturers recommendations. Depending on the specific coating selected for an application, Next is fully certified in the following types of installation equipment that may be required: Rolled and sprayed-on products. Heated Plural Component sprayers. Flame-gun applied products. issues, schedule, material handling, and logistics. During the review, metrics are established for continuous measurement of project progress in each key area.

5 ! Nuclear!Plant!! Support Facilities Seismic Rehabilitation!! Composite Solution:! After the Fukushima accident, the NRC developed a three-tiered prioritization of activities to enhance U.S. reactor safety. Tier 1: Near Term Tier 2: Mid Term Tier 3: Longer Term 11 areas Identified 3 areas identified 13 areas identified Tier 1 - Seismic Reevaluations To reanalyze potential seismic effects using presentday request for information to determine if safety upgrades are needed. CALCULATION SHEET Page: 10 of 102 uke Energy Revision: 0 Calc. No.: MNS S01 cguire Nuclear A Station major Energy Company performed the Tier 1 Prepared Seismic By: R. Kanitkar Reevaluations for one of its Nuclear Plants. One area that eismic Evaluation was & identified; FRP Strengthening the support of Existing buildings Masonry Walls CMU block Reviewed walls By: K. Lanham required strengthening. Various methods of reinforcement ted were Yes evaluated and No CFRP X was the selected solution Date: 03/20/2014 Seismic Upgrade using Carbon Fiber Seismic engineering determined the reinforcement requirements for the CMU block wall strengthening. Testing was performed to verify material strength of CFRP samples using pull tests. These tests provided a final calibration of the CFRP design. Five block walls were then prepped and CFRP was applied per the design documents. Figure 3: Partial Elevation for Line 32 CMU Block Walls Common in Support Buildings Seismic compliant structures using CFRP methods and materials. Very cost effective.! Simplified installation. No safety issues and no change orders. No need for an outage event to perform the work.

6 !!!!!NEXT Steel%Mill Cooling Water Basins Seismic Rehabilitation The eight Cooling Tower Basins were all experiencing wall cracking and leaks. The initial cause of the cracking was determined to be inadequate horizontal reinforcing allowing shrinkage cracks to appear. A seismic event furthered the opening of the cracks. There had been numerous attempts to address the problem by either patching or injection. These repairs had met with limited success for a variety of reasons with most of the cracks continuing to leak. Composite Solution: Apply CFRP composite materials to repair/stitch cracks and to strengthen walls in place of rebar. Engineering established the amount of materials needed for seismic and structural requirements. The repair included; clean and remove damaged concrete, seal leaks, treat and apply carbon fiber to to crack areas, and finally, to apply carbon fiber to wall surfaces. The repaired system was then coated for UV protection. The basins have been completely rehabilitated by this comprehensive repair. The solution brought each basin into compliance with seismic and structural requirements. The final result provides long term structural integrity and repairs leaks permanently.

7 U.S. Army Basic Combat Training Center of Excellence, Fort Jackson, SC Seismic & Blast Retrofit for the Oliver Dental Clinic The Oliver Dental Clinic Building at Fort Jackson was retrofitted for both blast and seismic considerations. The existing building is comprised of lightly reinforced CMU with interior steel framing. Problem: The existing CMU walls required strengthening for seismic loading in both in-plane and out-of-plane shear capacities. The building also required strengthening for anticipated blast loading in the CMU out-of-plane capacity rating. Composite Solution: Installed carbon FRP according to seismic and blast engineering analysis to bring the building into compliance with Federal and Military standards. Extensive QC services were performed to insure that the retrofitted materials performed as specified. The building was brought into compliance with blast and seismic standards using advanced composites. The advantages of using FRP resulted in an accelerated schedule done within a very effective budget.

8 60 PCCP Water Main Montreal Water System Strengthening and Rehabilitation The AquaDuc Cathedral 60 D water main was approaching failure and required emergency repairs. Pre-stressing wire failure and internal cracks were noted in a 200 section. 200 surface abrasive blast Composite Solution: Teamed with Construction ATA, a Montreal based contractor, the pipe repair was analyzed and an FRP based repair was engineered to meet the water system s structural and regulatory requirements. Following City review and approval, the pipe surface was water blasted and the pipe joints (every 20 ) were repaired and reinforced with FRP. 200 PCCP with FRP Next, the pipe was wrapped internally with a 2-layer high strength carbon fiber system (FRP) to replace lost hoop strength in accordance with the engineering documents. In the final step, an NSF topcoat was applied. The FRP system restored the lost hoop strength without loss of pipe flow and pressure capacity. In addition, the work was completed using existing pipe access areas within the 10 day shutdown period. 200 PCCP with topcoat

9 Plastics Manufacturer Steel Pressurized Water Pipe CFRP Repair & Testing The Problem: Engineers for a major manufacturer in Mt. Vernon, IN, wanted to determine if high strength composites could be used to perform fast, non-intrusive repairs to pressurized steel pipe. A test was designed using a severely damaged piece of 18 diameter steel pipe. The pipe section had lost wall thickness of 50% to 100% due to corrosion. As can be seen, the pipe was completely corroded through leaving a number of holes including one large 2 x 4 hole. Repair Solution: First the corrosion was removed using abrasive blasting. The large holes were covered with light gauge sheet metal and attached with silicone caulk. Then, a multi-layer carbon fiber system was applied to the pipe. The system included a galvanic insulator and three layers of heavy ounce fabric. The system was installed wet on wet to simulate field repair conditions. Testing: The pipe section was transported to the plant for testing. Hydro-testing equipment was connected to the pipe segment. Pipe fitters checked all fittings prior to pressurizing the pipe segment treated with carbon fiber reinforcement. After filling the pipe with water, pressure was gradually increased in 50 psi increments with a five minute dwell time at each interval. Once the pressure reached 200 psi, the dwell time was extended to 60 minutes. There was no breech in the carbon fiber reinforcement and there was no pressure drop. The pipe showed no signs of damage or leaking when sustained pressure of 200 psi was applied. The high strength carbon fiber repair system proved to be a viable repair method that would provide ease of installation, replacement strength for the steel lost through corrosion, a water-tight seal under design pressure, and significant new corrosion resistance.

10 Steel%Mill% Piping Rehabilitation The piping was weathered with about 60% showing signs of rust. The remaining 40% appeared to have tight mil scale. The pipe required cleanup and the application of a protective coating to prevent rust and mil scale. Repair Solution: The repair system used multiple coats and flake to provide a permeation resistant membrane coating to prevent rust and mil scale. The repair method began with abrading the mil scale with 40 grit sand paper to roughen the surface. Next the pipe surface was cleaned with high-pressure water to remove dirt and loose rust. SCG then applied 1 coat at 5 to 7 mils of a surface tolerant epoxy by brush and roller. For the final step, SCG applied a second coat at 2 to 4 mils of high solids poly-urethane. Durable repair developed specifically for this environment that met the required shutdown constraints.

11 Metals'Smelter' 9 D Hot Gas Duct Strengthening & Rehabilitation Structural and integrity reinforcement of secondary bypass duct from furnace Hot Gas Duct H Problem: Severe corrosion of carbon steel hot gas duct resulting in danger of structural collapse and through holes causing EPA reportable releases. Replacing duct would cause extended plant shutdown. Corrosion level of existing steel had reached the level where weld repairs created further damage, and support structure was not designed for additional weight of alloy cladding. Replacement and alloy cladding were also price prohibitive for construction costs and not feasible given plant downtime for extended shutdown. Plant had not considered CFRP repairs as traditional systems have temperature limitations of approximately degrees F. This duct cycled from approximately 120 degrees F to 440 degrees F when the furnace was in bypass mode.

12 Composite Solution: By using alternative resins for CFRP and utilizing an insulating barrier layer prior to application of carbon fiber, a CFRP repair provides a structural and integrity repair that was installed without a plant shutdown. Working with our engineering and materials partners, a testing protocol was developed to prove whether the modified CFRP system would retain its structural properties through long term temperature cycling of the duct. Once the test protocol was complete, samples of the composite system were created and thermally cycled to replicate the plant and duct operating conditions. Post cycling testing actually provided increased structural capacity and no degradation to the system. Design and Installation Challenges: After the testing program produced a viable system, the design process included dealing with long sections of duct that were originally designed to be self supporting but now lacked structural integrity, and to transfer strength of the CFRP system across stiffeners, flanges and ports on the duct. The entire duct was modeled using both a 3D Finite Element Analysis and Global Beam. Analysis in order to capture the behavior of the duct and to validate the repair strategies. The installation process was equally complex, as furnace scrams would send the surface temperature of the duct soaring 300 degrees without warning. The plant operation also created significant challenges for the resin curing process, as materials were force cured during duct operation. The result of the testing, design and successful installation is a first of its kind, Patent Pending system for using CFRP to structurally repair high temperature systems. The cost of the repair was a fraction of the alternatives in construction cost, and did not require a single day of plant shutdown, providing an immeasurable economic benefit.

13 Pulp and Paper Mill 50 D Steel Tank Strengthening & Rehabilitation Before Repair Description: The scope of work was to repair and strengthen a 50 diameter steel tank by 160 tall. The steel tank was operated by a pulp and paper plant. The tank wall had severe corrosion caused by the corrosive effects of the tank s contents. The tank was constructed of steel walls that were assembled in rings. The rings varied in thicknesses ranging from 3/4 thick for the bottom and ¼ for the top rings. There were over 900 through holes in the tank. The tank was critical to normal plant operations. Composite Solution: A carbon fiber composite system was designed to strengthen the existing steel tank. The installation work was performed with the tank in service. First, all holes in the tank were patched with thin sheet metal and epoxy. Surface Primed Logo Here Finished Tank The hoop strength in the walls that was lost due to corrosion was added back with the carbon fiber composite. Carbon Coordination between the plant operations and maintenance staff and the installation team led to a successful repair with no production impacts. The tank was wrapped in carbon fiber in less than 30 days.

14 The Kress Building Historical Building Yuma, AZ Column Strengthening The building on Main St. in the historic section of downtown Yuma was being renovated. The project required an increase in the load capacity of structural columns to support renovations and addition of the new The Top of the Kress roof-top bar and lounge. Composite Solution: First, the building load capacity, including the planned renovations, was analyzed and an FRP based system was engineered to meet the increased structural requirements. Next, the column surfaces were prepped for the addition of FRP. The work included adding a radius on the corners of the square column shape, abrasively cleaning the surface and priming the concrete. In the final step, each column was wrapped with the carbon fiber system (FRP) to provide confinement strengthening in accordance with the engineering documents. The building central column structure was strengthened using carbon fiber technology to support the increased load required by the planned renovations. The work was completed in 10 days allowing other planned construction activities to proceed on schedule. Before: 1 st Floor Carbon Fiber strengthening Before 3 rd Floor Final Installation

15 Agri Business Steel Supports & Catwalk Thermal Plastic Coating Restore structural strength and add protective coating to a catwalk and steel pipe bridge support that is above several acid storage tanks Steel beam after surface prep Composite Solution: A field applied polyethylene coating was installed using a proprietary flame applicator that melts a powder form of the material onto the surface creating a pin-hole free, completely acid resistant protective coating. The process required surface prep: abrasive blast to remove corrosion and previous coatings, and reinforcement with carbon fiber where steel loss was sufficient to require structural reinforcement. Extremely durable acid resistant coating developed specifically for steel and concrete surfaces. Due to the method of application, the process is an instant cure, thus allowing the systems repaired to be back in service immediately. Flame application Flame application Finished Beam with Coating

16 Chemical Plant Acid Sump Containment Rehabilitation Restore integrity of containment area around piping and acid pumps. Problem: Ground water hydrostatic pressure had opened leaks in the containment area. The containment was also being attacked by chemical exposure. Composite Solution: Leaks were sealed by the injection of moisture cured urethane foam on 3 centers around the perimeter. Coving was added on vertical surfaces. CFRP was installed to prevent future cracking. The final step added a coating for chemical protection. Damaged acid sump area Injection points Completely sealed containment area, restored concrete with chemically resistant coating for longer life. Installing cove Acid pump finished area Finished acid sump area