ML031530713

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April 18, 2003 - RIC 2003 Presentation - F1 - David A. Heacock - Region II Breakout
ML031530713
Person / Time
Site: North Anna Dominion icon.png
Issue date: 04/18/2003
From: Heacock D
Dominion
To:
Office of Nuclear Reactor Regulation
References
RIC 2003
Download: ML031530713 (37)
v • d • e


Text

RIC 2003 Region II Breakout - Session F1 North Anna Unit 2 Reactor Vessel Head Replacement David A. Heacock Site Vice President April 18, 2003

Agenda

  • Design and Licensing
  • Challenges
  • Lessons Learned
  • Regulatory Interface North Anna 2 RV Head Replacement 2

Typical Penetration North Anna 2 RV Head Replacement 3

North Anna 2 RV Head Replacement 4 Design and Licensing

  • Reconcile code of record - RCC-M to Owners Requirements

- NAPS-2 not a Code Stamped Vessel

- Friction weld on CRDM penetration tubes

- Acceptability of French QA program

- Assemble reconciliation package

- Assemble code data package

- Perform stress analyses North Anna 2 RV Head Replacement 5

Design and Licensing

  • Develop design engineering packages

- Engr. Transmittal to allow Head Set

- DCP for new RV Head

- DCP for modified Service Structure

- 3 DCPs in phases for Access Opening

  • Obtain concurrence from NRC:

- 50.59 approach for replacement head

- Containment testing approach

- NRC Final Review of documentation packages North Anna 2 RV Head Replacement 6

READY FOR LIFT TO TRANSPORTER North Anna 2 RV Head Replacement 8 SETTING CUTTING EQUIPMENT ON PLATFORM CUTTING EQUIPMENT IN OPERATION CUTTING EQUIPMENT IN OPERATION

EXPOSED REBAR FIRST CUT COMPLETE - WAITING FOR REBAR REMOVAL

North Anna 2 RV Head Replacement 11 AND CRDM REMOVAL

  • Key points:

- Preserve latch housing integrity

- Prevent damage to latch housing thread North Anna 2 RV Head Replacement 12

MACHINING & LIQUID PENETRANT TEST

  • Key points to insure weld quality:

- to remachine the weld edge

- to meet the base metal North Anna 2 RV Head Replacement 13

LATCH HOUSING WELD INSERT TACK WELDING Casing Fuse insert Penetration X

North Anna 2 RV Head Replacement 14

OLD HEAD ON PLATFORM READY FOR LIFT

NEW HEAD ON PLATFORM TOP HAT BEING REMOVED NEW HEAD READY FOR MOVE INTO CONTAINMENT ReBar Being Reinstalled Building Concrete Forms eBar Installation omplete Concrete Forms Complete

New Head Assembly Moving New Head to Cavity Transportation

  • 30 days required for submitting transportation plan in France and U.S.
  • U.S. Customs pre-staged for clearance
  • Russian heavy-lift aircraft retained to move head from Lyon to Richmond
  • Specialized trucks used to move head in France and the U.S.

North Anna 2 RV Head Replacement 22

50.59 Determination

  • NAPS-2 is not a Code Stamped Vessel
  • It was designed and licensed to Owners Requirements
  • Replacement head has been evaluated to conform to Owners Requirements, hence --
  • The project was performed under 50.59
  • No formal NRC approval was required North Anna 2 RV Head Replacement 23

50.59 Determination

  • Approach discussed with NRR in early October in a series of telecons
  • Public Meeting held at Dominion on October 29, 2002
  • NRC concurred with approach, but ---
  • NRC formally requested an opportunity to review the documentation packages
  • NRC also visited French regulator and mfgr North Anna 2 RV Head Replacement 24

50.59 Determination

  • NRC advised that the main challenges would be related to:

- QA Program reconciliation

- Use of friction welding specifically excluded by ASME Section III

- Reconciliation of RCC-M Code to Owners requirements North Anna 2 RV Head Replacement 25

QA Program

  • QA Audit team dispatched to France from 10-21 to 10-31
  • Mapping from French QA program to 10CFR50 App. B program was direct
  • French program derived from US program
  • QA audit report concluded that French QA program was satisfactory (met App. B)

North Anna 2 RV Head Replacement 26

Friction Weld

  • Penetration tube to CRDM adapter weld used friction welding process
  • Basically, hold one piece still; spin the other very fast; push them together and they fuse
  • Used successfully in over 40 French vessel heads; significant history with no events
  • French code and process requirements very well refined North Anna 2 RV Head Replacement 27

Friction Weld

  • Basis of reconciliation was effectiveness of French program
  • US Codes not well-defined as a basis of comparison (Sect III N/A; Sect IX weak)
  • Backed up reconciliation with extensive pre-service examinations (UT and LP)

North Anna 2 RV Head Replacement 28

Code Reconciliation

  • Identified all applicable ASME manufacturing and pre-service requirements that define Owners Requirements

- Applicable portions of ASME III (68) and special provisions of design specification

  • Mapped all documentation into those requirements and identified deltas

- Used ASME 95 with 96 addenda as basis

- Performed a reconciliation to ASME III (68)

North Anna 2 RV Head Replacement 29

Code Reconciliation

  • Reconciliation basis was then developed for each delta
  • NOTE: French code was developed from ASME.
  • There was a high degree of correlation between the codes
  • The factory does both RCC-M and ASME work so parallel quals existed for workers North Anna 2 RV Head Replacement 30

Stress Analyses

  • Westinghouse provided inputs for dead load, seismic and LOCA loads
  • Westinghouse provided design inputs on physical interface equipment

- Vessel Head

- Lifting Ring North Anna 2 RV Head Replacement 31

Stress Analyses

  • French approach relies on acceptability of the computer code and focuses on outputs
  • U.S. approach expects documentation of methodology to create a stand-alone report North Anna 2 RV Head Replacement 32

Disposal

  • Envirocare contracted to take possession of old RV head
  • WMG provided truck transportation across the U.S. to Utah
  • Costs to store on site or dispose were fairly close
  • Need to consider capital vs. O&M North Anna 2 RV Head Replacement 33

Lessons Learned

  • Do not attempt to do this job this way !!!
  • Take firm control of your documentation packages; special attention to resources and planning of engineering efforts is necessary.
  • Use of experienced company personnel is a must
  • Use of experienced prime contractors is a must North Anna 2 RV Head Replacement 34

Lessons Learned

  • Define the lines of communication among the project team members and to the Station
  • Strong and flexible project planning -

coordinate the prime contractors and outage planning

  • Establish a presence in the prime contractors offices including the mfgr.
  • Clear communications with the regulator North Anna 2 RV Head Replacement 35

Regulatory Interface

  • Constant and effective communications from NRC
  • Efficient NRC Task Team documentation reconciliation reviews
  • On-site NRC inspection activities well coordinated
  • Excellent cooperation by the NRC North Anna 2 RV Head Replacement 36

Comments or Questions?

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