ML060260383
| ML060260383 | |
| Person / Time | |
|---|---|
| Site: | Palisades  |
| Issue date: | 12/21/2005 |
| From: | Nuclear Management Co |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| Download: ML060260383 (37) | |
Text
An Overview of the Palisades Reactor Head Replacement Project Presented by NMC to NRC Staff December 21, 2005 NRC Region III Headquarters Lisle, Illinois
1 Agenda Agenda
- Purpose
- Mission Statement
- Project Organization
- Project Status
- Engineering
- Quality Oversight
- Summary
- Conclusion
2 Purpose Purpose
- Communicate the scope and status of the Palisades Reactor Head Replacement Project (RHRP) to NRC Region III
- Provide NRC with information necessary for planning inspection activities of the Palisades RHRP project
3 Mission Statement Mission Statement Replace the NMC Reactor Head Closure Systems in a world-class manner and with a team that fulfills the customers expectations for safety, reliability and cost effectiveness
4 Background on NMC Head Replacements Background on NMC Head Replacements
- Multi-site capital project for NMC
- Common fabrication organization
- NMCs Fleet approach allows for the transfer of operating experience to our current head replacement projects
- Site specific installation organizations
- Key personnel, experiences and resources are being utilized on Palisades head replacement
5 Project Organization Project Organization Lyle Bohn Sr. Vice President Paul Harden Site Vice President Sherry Bernhoft Director of Projects Dwight Mims Site Director Hank Hoelscher Fleet Manager Reactor Vessel Head Replacements Ron Bloomfield Site Manager Reactor Vessel Head Replacement Steve Forsha Lead Quality Oversite Jim Pfefferle Lead Fabrication Group Mike Sellman NMC CEO/CNO Mark Reddemann Vice President of Nuclear Assessment James Wong Site RHRP Responsible Engineer Darrel Turner Manager of Projects Leo Ganser NOS Program Manager
6 Head Replacement Lessons Learned Head Replacement Lessons Learned
- NMC Fleet
- J-groove weld quality
- Head drop analysis issues
- Industry
- Vendor oversight
- Containment restoration
7 Project Status Project Status
8 Project Status Project Status
- Scope
- New reactor pressure vessel head (nearly like-for-like)
- New control rod drive mechanism (CRDM) pressure housings, supports and in-core instrument (ICI) closures
- Through-the-wall replacement
- Schedule
- Installation in Fall 2007 (est. 50 days)
- N-1 walkdowns in Spring 2006
9 Design Design
- Babcock & Wilcox Canada (BWC) is the designer of the replacement head
- Westinghouse (WEC) supplied Certified Design Specification
10 New Reactor Head Fabrication New Reactor Head Fabrication
- Contracted with BWC to supply replacement reactor vessel head (RVH)
- Head forged at Japan Steel Works
- Head forging recently arrived at BWC shop
- CRDM nozzle tubing by Valinox
- July 2007 head delivery to Palisades site
- QA data package available 30 days after RVH arrival on site
- Fabrication schedule available
11 New Reactor Head Fabrication New Reactor Head Fabrication
12 Head Components Head Components
- WEC fabricating / supplying:
- 45 CRDM pressure housings
- Seismic supports for pressure housings
- 8 ICI Grayloc closures
- New designed incore instrumentation assemblies (compatible with Graylocs)
- Components will be installed at Palisades site
- Fabrication schedule available
13 Design Change Assessment Design Change Assessment
- Other WEC Services
- Licensing support, Design Change Package (DCP) support, etc.
- Reactor head-related DCP and 10 CFR 50.59 reviews to be completed by September 2006
- NMC leading these activities
- These activities conducted on site
14 Construction & Installation Activities Construction & Installation Activities Currently negotiating with prime contractor to perform/support:
- Pre-outage assembly of new RVH
- Containment construction opening/close/test
- Rigging and heavy loads handling
- In-containment disassembly/reassembly of RVH
- Old RVH disposal
15 Pre Pre--Outage Assembly Outage Assembly
- Off Load from BWC truck
- Place new RVH in dry fuel storage (DFS) building
- Install seismic supports
- Install Grayloc closures
16 Containment Construction Opening Containment Construction Opening
- Plant reaches Mode 5
- Remove affected tendons
- Relax adjacent/surrounding tendons
- Remove concrete, rebar & tendon sheaves
- Reactor defueled
- Remove liner plate
17 Containment Construction Close/Test Containment Construction Close/Test
- Concrete test pour
- Liner plate prepared/reinstalled
- Install new rebar and solid tendon sheaves
- Install new tendons
- Install forms and pour concrete
- Tension tendons
- Perform Containment Integrated Leak Rate Test (ILRT)
18 Rigging & Heavy Loads Rigging & Heavy Loads Pre-Outage:
- Head drop analysis recently completed
- Evaluate and prepare haul routes
- Evaluate containment lay-down area floor loading
- Analyze & establish required heavy load safe paths in containment
19 Rigging & Heavy Loads (cont Rigging & Heavy Loads (contd) d)
- Major lifts
- Place old RVH in shipping container
- Lift Old Head in shipping canister off runway
- Transport new RVH from DFS; lift to runway; up-end inside containment
- Other
- Transfer RVH lift rig & service platform from old to new RVH
20 In In--containment RVH Activities containment RVH Activities
- Project will receive old RVH when still on vessel flange
- Remove CRDM support tubes (clean and store)
- Remove CCW lines to CRDM pressure housings
- Remove RVH lift rig and service platform
- New RVH will be rigged into containment and set on vessel flange (defueled)
- Above components will be installed on new RVH
21 Old RVH Disposal Old RVH Disposal
- Currently evaluating:
1.
Leaving CRDM pressure housings on old RVH, or 2.
Removing the CRDM pressure housings prior to shipping off site
- Expect this decision by January 31, 2006
- Expect old RVH to be shipped off site very soon after removal from containment
- Duratek already contracted to dispose of old RVH
22 Construction & Installation Activities Construction & Installation Activities
- Currently negotiating construction/installation contract
- Anticipate installation contract awarded by January 31, 2006
- Anticipate Integrated Project Plan completed by April 30, 2006
- Installation-related DCPs and licensing packages will be completed by March 31, 2007
23 Licensing Requirements Licensing Requirements
- RHRP planned to be completed in accordance with 10 CFR 50.59
- Additional NRC reviews or prior approvals not anticipated
24 Key Dates Summary Key Dates Summary January 31, 2006: Installation contract awarded April 2, 2006: Refueling Outage begins; N-1 walkdowns performed April 30, 2006: Integrated Project Plan Rev. 0 completed September 2006: RVH Design Change Packages (DCPs) and 10 CFR 50.59 reviews completed March 2007: Installation DCPs and 10 CFR 50.59 reviews completed July 2007: New reactor head arrives at Palisades site September 8, 2007: Refueling/RVH Replacement Outage begins (50 day duration)
25 Engineering Engineering
26 Replacement Head Scope Details Replacement Head Scope Details
- Single-piece forging
- Strip cladding
- Alloy 690 tubing and weld material required
- Alloy 600 Prohibited
27 Applicable ASME Codes Applicable ASME Codes Replacement Reactor Vessel Head
- Sections II, III, V - 1998 Edition thru 2000 Addenda
- Section IX - Latest Edition
- Section XI - 2001 Edition thru 2003 Addenda Containment Liner and Concrete
- Section XI - 1998 Edition thru 1998 Addenda
28 Applicable Regulatory Requirements Applicable Regulatory Requirements
- U.S. NRC Regulatory Guide 1.28, Rev. 3 -
Quality Assurance Program Requirements
- U.S. NRC Regulatory Guide 1.37 - Quality Assurance Requirements for Cleaning of Fluid Systems and Associated Components of Water-Cooled Nuclear Power Plants
- U.S. NRC Regulatory Guide 1.38, Rev. 2 -
Quality Assurance Requirements for Packing, Shipping, Receiving, Storage, and Handling of Items for Water-Cooled Nuclear Power Plants
29 Nondestructive Testing Nondestructive Testing
- Section III, ASME 1998 Edition thru 2000 Addendum
- Section XI, ASME 2001 Edition thru 2003 Addendum
- Implemented NRC flaw evaluation criteria
- Utilized NRC acceptance criteria for preservice examination
- Verified examination capabilities with NDE and repair mockups
30 Quality Oversight Quality Oversight
31 Quality Oversight Quality Oversight
- NMC Project Oversight Plan
- Establishes the program oversight and responsibilities for the project
- Supplier qualification
- Fabrication oversight
- Installation oversight
- Release and receipt inspections
- Status reporting
32 Resident Oversight Resident Oversight
- Resident oversight personnel for NMC
- Monitoring work activities at:
- Japan Steel Works - Head forging
- Valinox - Inconel 690 head adapters
- Patriot Forge - Head adapter flanges
- Babcock & Wilcox Canada - Head manufacture
- Ionics - CRDM housings
- Verify critical attributes at witness and hold points
- Follow-up on nonconformances and corrective actions
- Review of quality documentation as work is completed
33 Quality Assurance Audits Quality Assurance Audits
- NMC project follow-up audit of Westinghouse in December 2005
- Nuclear Procurement Issues Committee (NUPIC) audit of Babcock & Wilcox Canada in first quarter 2006
- Project audit planned for Babcock &
Wilcox Canada during 2006
- Project self-assessment
34 Summary & Conclusion Summary & Conclusion
35 Summary Summary
- Palisades Sale - no anticipated effects on this project
- NMC has monitored fabrication of five replacement heads and completed head replacement at four sites
- Fabrication of the Palisades replacement head is ongoing
- Planning and engineering for installation of replacement head at Palisades is underway
36 Conclusion Conclusion
- We appreciate this opportunity for NMC to update the NRC on our head replacement activities
- We will continue to work with the site resident inspectors to keep them apprised of our schedules