AREVA: Experience in Dismantling and Packing of Pressure Vessel and Core Internals
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2 AREVA: Experience in Dismantling and Packing of Pressure Vessel and Core Internals Jan Hendrik Bruhn GmbH/ IBRZ-G Varna, June 10 th 2010
3 Content General Requirements for Dismantling Projects Stade NPP PWR RPV Internals Segmentation and Packing Wuergassen NPP BWR RPV and Internals Segmentation and Packing - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.3
4 Chapter 1 General Requirements for Dismantling Projects
5 Radiation protection requirements Engineering Requirements Optimized dismantling, cutting and packing performance Appropriate design of the equipment Provision of shielding due to high radiation Selection of appropriate cutting techniques Fulfillment of segmentation and packing requirements Minimization of secondary waste Time scheduling Production control Detailled work sequences Parallel activities Detailed planning Preparation & mock-up tests Cutting & packing plan On-site performance - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.5
6 Cutting Techniques (1) Cold cutting processes Mechanical Sawing Milling Shearing Nibbling Unscrewing Grinding Drilling Wire sawing (rope, diamond) Etc. Hydraulic Water abrasive suspension slicing (WASS) Nitrojet cutting Etc. Thermal cutting processes Thermal Torch cutting Powder flame cutting Laser cutting Plasma cutting Oxygen lance Petrogen cutting (gasoline-oxygen) Etc. Electro-thermal Electric discharge machining (EDM) Contact arc metal cutting (CAMC) Etc. - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.6
7 Cutting Techniques (2) Main advantages of cold cutting No considerable generation of secondary waste No generation of aerosols and hydrosols Appropriate cutting speeds Reliable technologies Radiation resistant applications Generated chips can be collected easily - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.7
8 Concrete Example: Water Abrasive Suspension Slicing Advantages of Water Abrasive Suspension Slicing Cutting simple as well as complex geometries Easy to operate and reliable cutting technique Cutting up to 200 mm stainless steel Independent of water depth and oxide layer No generation and release of aerosols Generates easy to handle and packable fragments Proven and effective water purification system in use Replacement of single filter cartridges is not required - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.8
9 Chapter 2 Stade NPP PWR RPV Internals Segmentation and Packing
10 Dismantling Projects Stade NPP PWR General Information Dismantling and packing of RPV Internals ( ) Remote controlled underwater segmentation and packing Parallel dismantling on 3 locations Total mass of 85 tons Primary waste characterization Packing and conditioning for final storage Water purification - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.10
11 Components to be Cut and Packed Upper Core Internals Core Support Structure Core Barrel with Upper Core Internals Core Barrel - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.11
12 Pool Layout Water Purification System Storage cask Baskets LCI Turn Table Crosscut Saw Baskets Water Pot Mobile Bridge with Jib Cranes RPV Working Platform Mobile Aux.Bridge Storage Rack UCI Mobile Crane Bridge Survey of the working area at Stade NPP Storage Rack Storage Cask Water Purification System - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.12
13 Crosscut Saw Dismantling and Cutting operations in the Spent Fuel Pool Basket Interim Storage Rack Upper Core Internals View at Support Columns and Upper Core Plate - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.13
14 Cutting and Packing of Control Rod Guide Assemblies - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.14
15 Loading of a MOSAIK Cask Copyright by GNS Transport of the Cask into the Spent Fuel Pool Copyright by GNS Positioning of the cask at the pool bottom Copyright by GNS Loading of the Cask Copyright by GNS Mounting of the Cask Cover - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.15
16 Chapter 3 Wuergassen NPP BWR RPV and Internals Segmentation and Packing
17 Dismantling Projects Wuergassen NPP BWR General Information Application for shut down and decommissioning by phases Order for dismantling of control rod guide tubes & jet pumps Project completion Order for dismantling of hook bolts of the steam separator Project completion Order for dismantling of cyclones of the steam separator Project completion Order for dismantling of remaining RPV-internals Project completion Order for dismantling of cylindrical part of RPV Project completion 09/ / / / / / / / / / / Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.17
18 Control Rod Guide Tubes & Jet Pumps Order: 11/2003 On-site performance: 09 12/2004 Total material: 22 tons Disposal in 200-l drums Cut through a jet pump by band saw Storage of cut pieces into drums Nibbling of cut tubes - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.18
19 T-Bolts Segmentation & Disposal 40 pieces T-bolts (8 t) Dismantling from the steam separator Cutting into segments by use of band saw equipment Disposal into 200-l drums 40pcs.; length 5,70 m - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.19
20 Steam Separator Cyclones Order receipt: 10/2005 Engineering, procurement of tools: 7 months Cutting & packing: 7 months Total mass : 35 tons Volume reduction: The cut segments were flattened down by an underwater press Disposal of cut segments into 200-l drums - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.20
21 Remaining RPV Internals Order receipt: April 2006 End of project: Dec Additional cranes Working platform Housing Total mass: About 55 tons On-site dismantling in two phases: Phase 1: Movable internals inside the set down pool (Dec Oct. 2007) Phase 2: Rigidly mounted internals in situ (Mar. Dec. 2008) Sawing platform Post processing platform Phase 2 - Arrangement Revolving stage on RPV flange with adhered post segmentation platform - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.21
22 On-site Impressions Dismantling of remaining RPV Internals Phase 1 Phase 2 WASS operation inside working tank Postsegmentation of core spray tube First cut on core shroud Sawing platform and mast Loaded drum Loaded drum Final cutting of an ejector pump retainer Cutting of core spray tube by jigsaw Diffusor separator - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.22
23 RPV Dismantling Technical Data RPV data Total weight of cylindrical part: 320 Mg Height: 15m Cut segments: 252 pcs. Packing for final storage Konrad Container Type II: 19 Konrad Container Type III: 10 Applied cutting techniques Water Abrasive Suspension Slicing Water pressure: 2000 bar Jet diameter: 0,8 mm Material thickness: 137 mm Cutting speed: 20mm/min Band saw (for RPV flange) Cutting height: 1100mm Flange thickness: 425 mm - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.23
24 Cutting Sequence Decontamination, post segmentation and recycling Packing into Konrad container - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.24
25 Optimized Packing Plan - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.25
26 Overview on installed Infrastructure Shielding plate Complex RPV crane (handling tools and dismantled pieces) Rail systems and cranes for transportation (remote-operated) Rail system and cranes for container loading and conditioning (remote-operated) Installation of cranes and auxiliary equipment (e.g. steel structure) for transportation of RPV segments and packing into containers - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.26
27 On-site Impressions RPV Dismantling Vertical segmentation of RPV flange Positioning of RPV segment for transport to container loading station Gripper removing RPV segment Packing of RPV segment into Konrad container - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.27
28 Dismantling Projects Reference List Nr Activity NP Plant Country Year 1 Dismantling and cutting of commissioning instrumentations Several plants Germany Separation of a core flux measuring casing Gundremmingen C Germany Cutting of a thermal shield BR 3 Mol Belgium Dismantling and packing of core instrumentation assemblies Biblis A and B Germany 1993, 2000, Dismantling of PTR tubes inside the fuel pool, Unblocking of a stuck fuel bundle, Placing of blind hole bores at the fuel pool liner Koeberg 1 and 2 South Africa 2000, Cutting of windows into the set down ring of RPV internals Trillo Spain Dismantling, cutting and packing of control rod guide tubes and jet pumps Wuergassen Germany Dismantling, cutting and packing of T-bolts Wuergassen Germany Dismantling, cutting and packing of cyclones and stand pipes Wuergassen Germany Dismantling, cutting and packing of RPV internals Wuergassen Germany Dismantling, cutting and packing of RPV (cylindrical part) Wuergassen Germany Dismantling, cutting and packing of RPV internals Stade Germany Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.28
29 Any reproduction, alteration, transmission to any third party or publication in whole or in part of this document and/or its content is prohibited unless AREVA has provided its prior and written consent. This document and any information it contains shall not be used for any other purpose than the one for which they were provided. Legal action may be taken against any infringer and/or any person breaching the aforementioned obligations. - Bulgarian Nuclear Energy - J.H.Bruhn - Varna, June 10th GmbH Proprietary - - p.29
30 - End of Presentation - AREVA: Experience in Dismantling and Packing of Pressure Vessel and Core Internals Jan Hendrik Bruhn GmbH/ IBRZ-G Varna, June 10 th 2010
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