Using Engineering 3D Models for Engineering Support of Nuclear Power Units Decommissioning

Transcription

1 47А, Pokrovka Street, Moscow Russian Federation, Tel: +7 (499) Using Engineering 3D Models for Engineering Support of Nuclear Power Units Decommissioning

2 Russian Nuclear Power Plants: Location Map 10 NPPs, 33 Units, ICAP = MW Ленинградская АЭС Кольская АЭС Билибинская АЭС Калининская АЭС Курская АЭС Смоленская АЭС Балаковская АЭС РБМК-1000 ВВЭР-1000 ВВЭР-440 БН-600 ЭГП-6 Нововоронежская АЭС Ростовская АЭС Белоярская АЭС

3 Planned Shutdown Dates for Nuclear Power Units (Generations 1 and 2) to Be Decommissioned

4 Stages of Nuclear Power Unit Decommissioning, Based on the Approved Decommissioning Concept Preparation Stage Preparation for nuclear power unit decommissioning 1st Stage Preparation for nuclear power unit surveillance 2nd Stage Nuclear power unit surveillance Dismantling "clean" turbine island equipment Dismantling slightly and medium-active equipment Dismantling highly active (localized) equipment Dismantling buildings and structures 0 Year of final shutdown +6 years +10 years +100 years

5 Need to Create Local Nuclear Power Plant Unit Decommissioning Databases (Information Systems) Time gap between personnel involved in final decommissioning stages and personnel involved in final operating phase of a nuclear power unit will be years (1-2 generations). Paper-based design documentation developed in the 1960s s wears out and becomes unfit for further use. By 2020, 19 nuclear power units will reach end of design service life. 13 nuclear power units will reach end of prolonged service life. Thereby, without a systematic approach to informational support for preparation activities and nuclear power unit decommissioning, efficient implementation of decommissioning process may become critical in years.

6 Application Areas for Nuclear Power Unit Decommissioning Databases Preserve and communicate information about NPP unit configuration with a long-term perspective, facilitate personnel training and visual data presentation for future generations of personnel - dozens of years from now. Simulate complex nuclear- and radiation-dangerous operations. Integrate radiation environment data, forecast nuclear waste volumes, provide informational support for nuclear waste handling during decommissioning. Plan and manage decommissioning projects, optimize time schedules, taking into account existing restrictions.

7 Creating an As-Built Asset Information Model with Engineering and Radiation Data Basic data: Documentation Reengineering Data input based on attributive characteristics Gamma Scanning Determining equipment hot spots Laser Scanning Collecting topological information with a millimeter accuracy 1. As-built engineering 3D model with superimposed radiation situation 2. Actual physical structure of the plant 3. Weight and dimensions, component materials, other characteristics degree panoramic photo, other data of comprehensive engineering and radiation survey 5. Digital documentation archive 6. Intelligent process diagrams

8 Lifecycle of an As-Built Engineering and Radiation Model Информация доступна всем участникам ВЭ As-Built Engineering and Radiation Model of the Asset The model is used for planning and simulation of decommission work Plant shut down Beginning of decommissioning Create Comprehensive engineering and radiation survey Update Decommission activities (dismantling, radioactive waste utilization, etc.)

9 Applied Technologies: Laser Scanning Laser scanning is a technology providing a people-independent way of obtaining actual reliable topological information about the asset condition to fractions of a millimeter. It has been in active use since the end of the 90s in such areas as oil &gas industry, metal industry for collecting initial information for the purpose of modernization and reconstruction of production plants. It was initially developed in France in the late eighties for recovery of documentation for nuclear plants. Main characteristics Accuracy: Range: Scanning time: Number of points: from 1 mm up to 2500 m 2-3 min up to several million

10 Laser Scanning. As-built Model Creation Technology Point Cloud Scans As-built 3D model Combining scans based on reference points (marks) Applying a uniform coordinate system Purging low-quality measurement data Modeling (converting point clouds to solid models)

11 Laser Scanning. Topological Information Quality Comparison 3D model of Leningradskaya NPP, building 401, turbine island (based on design documentation)

12 Laser Scanning. Topological Information Quality Comparison 3D model of Leningradskaya NPP, building 401, turbine island (on the basis of laser scanning)

13 Laser Scanning. Topological Information Quality Comparison In most cases the existing plant documentation significantly differs from the actual configuration, which causes considerable disparities of design and actual volumes of the radioactive waste, complicating decommissioning

14 Documentation Reengineering

15 Documentation Reengineering. Basic Data

16 Documentation Reengineering Digital archive contents Raster files Specs Drawings 3D Model

17 Examples of Completed Projects 47А, Pokrovka Street, Moscow Russian Federation, Tel: +7 (499)

18 Project Results: Decommissioning Information System for Novovoronezhskaya NPP, Units 1 and 2

19 Engineering 3D Site Model of Novovoronezhskaya NPP, as a Part of the Respective Decommissioning Information System

20 Engineering 3D Site Model of Bilibinskaya NPP, as a Part of the Respective Decommissioning Information System

21 Engineering 3D Site Model of Leningradskaya NPP, as a Part of the Respective Decommissioning Information System

22 Engineering 3D Site Model of Kurskaya NPP, as a Part of the Respective Decommissioning Information System

23 Engineering 3D Site Model of Kurskaya NPP, as a Part of the Respective Decommissioning Information System 23

24 Engineering 3D Site Model of Kolskaya NPP, as a Part of the Respective Decommissioning Information System

25 Engineering 3D Site Model of Kolskaya NPP, as a Part of the Respective Decommissioning Information System 25

26 Engineering 3D Site Model of Smolenskaya NPP, as a Part of the Respective Decommissioning Information System

27 Beloyarskaya Nuclear Power Plant 47А, Pokrovka Street, Moscow Russian Federation, Tel: +7 (499)

28 Using Laser Scanning at Beloyarskaya NPP Project characteristics Plant: Customer: Turbine island of units 1,2 of Beloyarsk. NPP Joint Stock Company «Research & Demonstration Center Decommission Nuclear Reactors» Work time: 2012 Duration of scanning: 1 week Duration of creation of IMS of a turbine island 2 months Cost: ~10 million RUB.

29 Laser Scanning at Beloyarskaya Nuclear Power Plant

30 Laser Scanning at Beloyarskaya Nuclear Power Plant

31 Laser Scanning at Beloyarskaya Nuclear Power Plant

32 Laser Scanning at Beloyarskaya Nuclear Power Plant

33 Laser Scanning at Beloyarskaya Nuclear Power Plant

34 Gamma Survey of Beloyarskaya NPP turbine island

35 Integration of comprehensive engineering and radiation survey data into 3D engineering model. Points of radiation control Results of measurements of a radiation background in rooms of the turbine island on elevation level , ,

36 Integration of comprehensive engineering and radiation survey data into 3D engineering model. Points of radiation control

37 Integration of comprehensive engineering and radiation survey data into 3D engineering model. Points of manual radiation control

38 Comprehensive engineering and radiation survey data integration into 3D engineering model. Points of manual radiation control

39 Decommission Scheduling and Simulation Using as-build radiation IMS Dismantling work plan for main equipment, pipelines and piping components of turbine unit No.1 of Beloyarsk. NPP Initial state - Before dismantle Final state After equipment removal

40 Work objectives: Simulation Model for Dismantling AMB-100 Reactor Structures at Beloyarskaya Nuclear Power Plant Lowering costs and increasing implementation safety of a chosen decommissioning option for a particular nuclear power unit. NEOLANT has developed: a software suite which enables to model process steps of dismantling graphite stack of AMB-100 reactor and train human operators of the dismantling robot (BROKK); in accordance with the dismantling technology, a graphical and physical model of the AMB-100 reactor was created, with all contained objects, such as graphite stack blocks, cast iron blocks of the reflector, casing pipes of the control and protection system etc.

41 Three different attachment for the BROKK robot are in use: Simulation Model for Dismantling AMB-100 Reactor Structures at Beloyarskaya Nuclear Power Plant Graphite stack is dismantled by a BROKK robot, which can be lowered into the reactor well and moved there with the help of a special structure carousel. Using the gripping and manipulating device, the robot lifts and lowers floor plates, covers of containers for dismantled blocks and sawn-off pieces of casing pipes of the control and protection system, grabs pieces of cracked blocks. With the grapple, the robot grips and lowers graphite blocks, using holes in their middle. Using the buzz saw, the robot saws off upper parts of casing pipes of the control and protection system which hinder from extracting the blocks with the grapple. Implemented solid-state physics: objects are prevented from penetrating each other; gravity force is applied to objects; movements of caterpillars, manipulators and attachments of the robots. Software suite has a two-screen configuration: Window with a 3D model, visualizing a dismantling scenario. Graphic interface window with additional control options for modeling, camera positioning, capturing, playback of captured scenarios etc. The suite has two functional performance modes: simulation and playback.

42 Simulation Model for Dismantling AMB-100 Reactor Structures at Beloyarskaya Nuclear Power Plant The process of creation and application of the simulation model revealed a range of problems in the developed dismantling technology: 1. Changing attachments It s impossible to change attachments automatically, because it is not possible to position the robot arm with the needed degree of precision, when the BROKK robot is being controlled by using camera images. Graphite dust will settle on the contacts of the automatic attachment changing device, making the change of attachments impossible. A technology modification was suggested, using three robots with necessary attachments already in place. 2. Difficult to work with stationary cameras A set of stationary cameras does not provide a wide enough field of view to perform some operations (mainly extracting blocks from the reactor well). Cameras positioned on the carousel show almost nothing of what is under the stack. Therefore, a free camera was used while working with the 3D model, but it can not possibly be applied in the real dismantling process. Hereupon, it was considered necessary to review the camera positioning scheme, based on the analysis of required angle shots, by simulating dismantling operations on the simulation model.

43 Simulation Model for Dismantling AMB-100 Reactor Structures at Beloyarskaya Nuclear Power Plant 3. Low percentage of blocks which can be extracted with the initially suggested technology Some graphite stack blocks proved to be impossible to extract for one of the reasons: Carousel structure was in the way. Robot arm was not long enough to reach some blocks. The technology check revealed that only about 30% of the blocks are extractable: Blue blocks are extractable. Yellow blocks can t be extracted because of the carousel. Another carousel structure was suggested with a massive round plate which has a sliding opening (circular and radial slide). If three or more blocks are stuck together, they are impossible to extract, because the BROKK robot arm has not enough lifting power. A solution was suggested: splitting block conglomerates, which required: using an additional robot with a special pick hammer attachment; or making sure that the grapple is strong enough to use it for this purpose as well.

44 Summary

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