ML103210347
| ML103210347 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse  |
| Issue date: | 11/16/2010 |
| From: | FirstEnergy Nuclear Operating Co |
| To: | NRC/RGN-II |
| References | |
| Download: ML103210347 (58) | |
Text
FirstEnergy Nuclear Operating Company Reactor Vessel Head Replacement Meeting with Nuclear Regulatory Commission November 16, 2010 Davis-Besse Nuclear Power Station
2 Agenda
Desired Outcomes for Meeting
Background for Reactor Vessel (RV) Head Replacement
Project Scope Accelerated for 2011 Reactor Vessel Head Replacement
Project Organization/ Milestones / Controls
New RV Head Status and Pre-Service Inspection Results
Integrated Head Assembly Features & Schedule
Shield Building & Containment Access Openings
Heavy Loads, Haul Routes, and Storage of Old RV Head
Installation of New RV Head / Removal of Old
ALARA Planning
Quality Assurance Oversight Plan
Closing Summary
3 Desired Outcomes
Demonstrate FENOCs continued overriding commitment to ensure the safe and reliable operation of Davis-Besse
Provide the NRC a comprehensive understanding of the scope and schedule for activities supporting the October, 2011 replacement of the Reactor Vessel (RV) Head
Provide the NRC with a good understanding of the current status of preparations for the RV Head replacement
Address questions and develop an understanding of the actions necessary to support the NRCs Inspection of the RV Head replacement activities
FirstEnergy Nuclear Operating Company Reactor Vessel Head Replacement Meeting with Nuclear Regulatory Commission November 16, 2010 Davis-Besse Nuclear Power Station
2 Agenda
Desired Outcomes for Meeting
Background for Reactor Vessel (RV) Head Replacement
Project Scope Accelerated for 2011 Reactor Vessel Head Replacement
Project Organization/ Milestones / Controls
New RV Head Status and Pre-Service Inspection Results
Integrated Head Assembly Features & Schedule
Shield Building & Containment Access Openings
Heavy Loads, Haul Routes, and Storage of Old RV Head
Installation of New RV Head / Removal of Old
ALARA Planning
Quality Assurance Oversight Plan
Closing Summary
3 Desired Outcomes
Demonstrate FENOCs continued overriding commitment to ensure the safe and reliable operation of Davis-Besse
Provide the NRC a comprehensive understanding of the scope and schedule for activities supporting the October, 2011 replacement of the Reactor Vessel (RV) Head
Provide the NRC with a good understanding of the current status of preparations for the RV Head replacement
Address questions and develop an understanding of the actions necessary to support the NRCs Inspection of the RV Head replacement activities
4 Background for Reactor Vessel Head Replacement Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Clark Price - Director, Special Projects
5 Background for Reactor Vessel Head Replacement
Unused Midland Head placed in service 2004
Original schedule for combined new Reactor Vessel (RV) Head replacement with OTSGs in 18RFO
16RFO RV Head Inspection and modification
FENOC Commitment to replace RV Head in October, 2011
Confirmatory Action Letter to shut down no later than October 1, 2011 and replace Reactor Vessel Head Installation of Unused Midland Head
6 Project Scope Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Joe Rogers - Manager, Steam Generator Replacement Project
7 Project Scope Accelerated for October 2011 Reactor Vessel Head Replacement
Reactor Vessel (RV) Head Delivery and Integrated Head Assembly Construction
Replacement Control Rod Drives
Containment Access Facility
Temporary Assembly Building
Old Steam Generator Storage Facility Reactor Vessel Head Replacement
8
Containment Shield Building Opening & Closure
Containment Vessel Opening & Closure
RV Head Lift Transfer System
Haul Route Analysis
Other associated Plant Modifications
- Head Vent Piping
- Component Cooling Water Cooling
- Polar Crane Upgrade
- Permanent Aux Crane (Palfinger)
Project Scope Accelerated for October 2011 Reactor Vessel Head Replacement
9 Project Organization Chart Technical Buyer Bruce Nolan Security Specialist Dan Klink Regulatory Compliance Pat McCloskey Licensing Henry Hegrat SVP, Fleet Engineering Danny Pace Director, DB Special Projects Clark Price Manager, Steam Generator Project Joe Rogers VP, Fleet Oversight Karen Fili Vendor Oversight Lead Dave Wahlers Engineering Lead Theo Swim Radiation Protection Lead Jim Lochotzki Project Controls Supervisor Bill Hayes Installation Lead Jim Barron Component Lead Dave Gerren Installation Lead Dave Atkinson Site VP, DB Nuclear Barry Allen Bechtel Project Manager Glenn Campbell AREVA Project Manager Mike Epling Installation Oversight Lead Steve Steagall Quality Oversight Project Support Lead Karen Dunn
10 Completed Project Milestones
Order placed for new Reactor Vessel Head 1/31/2002
Head fabrication complete and NPT stamped 4/22/2004
Initial purchase order issued for transport of head 4/5/2010
Head replacement moved to Fall 2011 mid-cycle outage 6/23/2010
Pre-service Inspection of head complete 9/17/2010
Inspection & packaging for transport 10/11/2010
RV Head Transported from Chalon to Antwerp (Port of Exit) 10/15/2010
Transport ship departed from Antwerp for Cleveland 11/5/2010
11 Planned Project Milestones
New Reactor Vessel Head arrives on site Late November 2010
Temp Assembly Building (TAB) construction complete 5/15/2011
Access Opening design change package issued 5/30/2011
Begin Pre-outage Mobilization May 2011
Containment Access Facility (CAF) construction complete 6/30/2011
New RV Head (& Vent Line) design change package issued 7/21/2011
Integrated Head Assembly design change package issued 7/29/2011
Old SG Storage Facility (OSGSF) construction complete 9/15/2011
IHA ready to move into Containment 9/20/2011
Mid-Cycle Outage begins 10/1/2011
Move old RV Head to OSGSF Late October 2011
12 Project Oversight
Executive Oversight Committee
Weekly conference calls with AREVA and Bechtel
Monthly meetings with AREVA and Bechtel
Full time on-site project presence at AREVAs Lynchburg, VA facility
Integrated design development review meetings
Integrated schedule development review meetings
Dedicated Fleet Oversight to Project
Readiness Reviews and Challenge Meetings
- Task Readiness
- Formal Project Integrated T-6 / T-3 / T-1 readiness reviews
13 New Reactor Vessel Head Status Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Dave Gerren - Project Component Lead
14 New Reactor Vessel Head Status
Reactor Vessel Head fabrication completed in 2004 at the AREVA Chalon Factory and maintained in storage until September, 2010
A pre-service inspection of the head was completed in September, 2010
RV Head was prepared for shipment and left the Chalon Factory on October 11, 2010
RV Head was loaded on a sea transport in Antwerp, Belgium on November 3, 2011 Reactor Vessel Head Replacement
15 New Reactor Vessel Head Status
RV Head arrival into Cleveland is scheduled for late November
RV Head will be transported by a roadway heavy hauler to the on-site head storage facility
- The Ohio Special Hauling Permit has been approved
- The heavy hauler has completed a route survey
RV Head will be placed in the head storage facility and remain there until the Temporary Assembly Building is ready to receive the RV Head and components to begin assembly 2002 - Reactor Vessel Head Transport
16 New Reactor Vessel Head Status
Integrated Head Assembly (IHA) fabrication to commence in January, 2011
RV Head to be transported to the Temporary Assembly Building (TAB) in early June, 2011
CRDM hardware and IHA sub-components to begin shipping in early June, 2011
RV Head and IHA to be fully assembled by September 20, 2011
17 Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Dave Gerren - Project Component Lead Replacement Reactor Vessel Head Pre-Service Inspection (PSI) Workscope
18 Workscope
ASME Section XI - Pre-Service Inspection (PSI)
- The PSI examinations were performed and documented in accordance with ASME Section XI (1995 Edition through the 1996 Addenda) and ASME Code Case N-729-1 as modified by 10 CFR 50.55a
Additional Examinations
- Additional examinations were performed to provide a more complete base line for reference during future examinations. This history provides a unique fingerprint for each CRDM penetration Replacement Reactor Vessel Head Pre-Service Inspection (PSI) Workscope
19
Section XI Scope
- CRDM nozzle to flange welds, peripheral locations
- Volumetric or Surface examination required
ASME Code Case N-729-1 Examinations
- Examination of the CRDM Nozzle and RV Head J-Groove Welds
- Visual and Volumetric examinations required
Additional Examinations Performed
- Several augmented examinations performed to enhance ISI base line data.
- This history provides a unique fingerprint for each CRDM penetration Replacement Reactor Vessel Head Pre-Service Inspection (PSI)
20
Required Exams Performed
- Nozzle to flange weld - Liquid Penetrant (PT) performed on all peripheral nozzles
- Nozzle base material - Ultrasonic Examination (UT) exam on all nozzles
- Bare Metal Visual Examination of the RV Head surface, including the intersection with the CRDM Nozzles to be completed once the RV Head is on the head stand in Containment
Augmented Exams Performed
- Nozzle to flange weld - PT extended to all nozzles
- Nozzle to flange weld - UT performed on all nozzles
- Nozzle to flange weld - ID Eddy Current Testing (ET) performed on all welds
- Nozzle base material - ID ET performed on all nozzles
- Nozzle base material - OD ET performed on all nozzles
- J-groove weld - ET performed on all welds
- Additionally, the interference fit region of the nozzles was evaluated for the ability to perform a leak path inspection in subsequent ISI exams Replacement Reactor Vessel Head Pre-Service Inspection (PSI) Results
21 Replacement Reactor Vessel Head Pre-Service Inspection (PSI)
22
Required Exams Result Summary
- Examinations resulted in no detectable degradation indicative of planar flaws (UT) and no relevant indications (PT)
Augmented Exams Result Summary
- No relevant UT, PT indications or eddy current responses indicative of planar degradation were found in any of the augmented examinations
- Minor non-relevant surface anomalies and geometry conditions were detected and documented Replacement Reactor Vessel Head Pre-Service Inspection (PSI) Results
23
Control Rod Drive Mechanism (CRDM) Nozzles
- Manual UT & PT examinations were performed on 69 dissimilar metal welds (Nozzle to Adapter weld) in the CRDM penetrations
- Examinations resulted in no recordable indications (UT) and no relevant indications (PT)
- An Eddy Current Testing (ET) rotating probe technique was used to examine the full length of the inside diameter (wetted surface) of the nozzles which included the inside diameter of the dissimilar metal weld for each nozzle
- No eddy current responses indicative of planar degradation were found in the ET examinations Replacement Reactor Vessel Head Pre-Service Inspection (PSI) Results
24
Control Rod Drive Mechanism (CRDM) J-Groove Welds
- An eddy current array probe technique was used to examine the wetted surfaces of the J-Groove weld and outside diameter of all nozzles
- No eddy current responses indicative of planar degradation were found in the ET examinations
- Minor non-relevant surface anomalies and geometry conditions were detected and documented
- These eddy current responses may be compared to those of future in-service examinations Replacement Reactor Vessel Head Pre-Service Inspection (PSI) Results
25 Replacement Reactor Vessel Head Pre-Service Inspection (PSI) Results
Control Rod Drive Mechanism (CRDM) Nozzles
- Automated UT examinations were performed on all 69 CRDM penetrations to provide a baseline for future in-service inspections
- The examination identified no recordable crack indications from the penetration tube base material
26
Automated Ultrasonic Examination (UT) Observation of Fabrication Indications
- Several fabrication indications were recorded at or near the fusion zone of the weld to help with future examination efforts (fingerprinting)
- The number of fabrication indications recorded during this baseline examination is within the range of indications observed on other baseline and in-service examinations for this configuration using the same UT techniques Replacement Reactor Vessel Head Pre-Service Inspection (PSI) Results
27
Nozzles #3 and #16
- Two nozzles (CRDM penetrations 3 & 16) were observed to have unique UT back wall patterns
- Signal patterns represent a change in the tube to RV Head contact pressure in the region of the nozzle interference fit
- The back wall reflector issue was entered in the corrective action program and determined to be an acceptable condition Replacement Reactor Vessel Head Pre-Service Inspection (PSI) Results
28
Conclusion
- The Replacement RV Head PSI successfully performed required NDE in accordance with ASME Section XI and ASME Code Case N-729-1 as modified by 10 CFR 50.55a
- No unacceptable conditions were identified
- The data has been documented and archived for reference use during subsequent ISI exams
- A bare head exam will be performed once the IHA is fully assembled and on the head stand in containment and will be added to the PSI report Replacement Reactor Vessel Head
29 Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Dave Gerren - Project Component Lead Integrated Head Assembly Features & Schedule
30 Integrated Head Assembly Features & Schedule
Design Features
- Integral Control Rod Drive ventilation fans
- Attached foldable cable trays
- Use of the current lift pendant system
- Integral permanent shielding for the head flange area
- Large inspection opening doors
- One-piece removable shielded work platform
- Improved electro-polished head vent to hot leg piping routed out the side of the service structure
- New Control Rod Drive Mechanisms, stators, position indication tubes and cables
- The new Integrated Head Assembly weight is bounded by the existing analysis
31 Hinged cable trays Six fans at flange level Improved shielding with 1 1/2 inch thick steel Re-routed head vent line Removable shielded work platform Integrated Head Assembly Features & Schedule
32
Head Vent Line Modification
- The head vent line modification will re-route the vent line away from the CRDMs just below the head insulation
- The replacement piping will be electropolished to reduce future source term
- The vent line will have a welded connection to the nozzle on the head This will require removal and replacement of the nozzle at location 21 with a prefabricated pipe in the Temporary Assembly Building
- Pre-service inspection of this nozzle will be performed in the Temporary Assembly Building Integrated Head Assembly Features & Schedule
33 Integrated Head Assembly Features & Schedule
Impact on normal and shutdown operations
- RV Head will operate similar to the existing RV Head, however will simplify disassembly/ reassembly for maintenance and refueling, reducing personnel dose
- Improved access opening will be provided to ease inspections and maintenance
- New replacement CRDMs will improve equipment reliability
34 Shield Building & Containment Access Openings Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Jon Hook - Design Engineering Manager
35 Shield Building & Containment Access Openings
Overview
- Containment is provided by two independent structures that share the same foundation
- Shield Building Reinforced concrete structure completely encloses the containment vessel
- Containment Vessel Steel plate structure 6 annular space between the shield building and containment vessel
36
Codes
- Normal American Concrete Institute (ACI) Codes were used in the design and installation
- ACI 318-63 Building Code Requirements for Reinforced Concrete
- ACI 301 Specifications for Structural Concrete for Building
- ACI Manual for Concrete Practice Parts 1, 2, and 3 1968
- ACI Manual of Concrete Inspection
- ACI 307-69, Specification for the Design of Reinforced Concrete Chimneys
- ASTM C-150 Standard Specification for Portland Cement Ohio Building Code Note: The Shield Building is a reinforced structure, therefore recent industry issues with Post-Tension Structures are not applicable to Davis-Besse
- Containment Vessel
- ASME Boiler and Pressure Vessel Code,Section III for Class B Vessels, 1971 Shield Building & Containment Access Openings
37 Shield Building & Containment Access Openings 20 FT 33.5 FT 22 FT SHIELD BUILDING CONSTRUCTION OPENING
Restoration of Openings
- Concrete will be removed via hydro demolition
- Concrete and rebar will be restored to design configuration
- Use of an on-site batch plant will be used
- Containment Vessel
- Original liner plate will be reinstalled
- Visually inspected and Radiography inspected
- Integrated Leak Rate Test will be performed upon completion
38
Conclusion
- The access openings and restoration of the Shield Building and Containment Vessel are very similar to what was done in 2002 for the reactor head replacement
- The access openings will be restored to meet the design requirements
- A similar process will be used to replace the Steam Generators in 2014 Shield Building & Containment Access Openings
39 Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Theo Swim - Project Engineering Lead Heavy Loads, Haul Routes and Storage of Old Reactor Vessel Head
40 Heavy Loads and Haul Routes
Evaluate and Prepare Haul Routes Highway to Head Storage/ Temporary Assembly Building (TAB) Location TAB to Containment Containment to Storage Facility
Lift/Transfer system
Heavy load lift plans
Evaluate floor loadings
Current head drop analysis
41 Heavy Loads and Haul Routes
42 Storage of Old Reactor Vessel Head
Transportation to OSGSF (Old Steam Generator Storage Facility)
OSGSF Location
OSGSF Design
OSGSF Construction Schedule
- OSGSF Design Package to be issued February 2011
- Contractor Mobilization / Begin Construction March 2011
- OSGSF construction complete September 2011
43 Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Joe Rogers - Manager, Steam Generator Replacement Project Installation of New RV Head /
Removal of Old
44 New Head Installation Schedule Project Work Window: Mode 5 to Heatup to Mode 4
Enter Mode 5
Establish Shield Building Opening
Disassemble Old Head & Move to Temp Head Stand
Offload Fuel
Establish Containment Vessel Liner Opening
Transport New Head to Head Stand
Transfer Lifting Pendants from Old Head to New Head
Transport Old Head to Outside Work Platform, then to Old SG Storage Facility
Restore Containment Liner Integrity
Reload Fuel
Move New Head to Reactor Vessel
Perform Head Reassembly
Perform Integrated Leak Rate Test
Restore Shield Building opening
Heat up and Enter Mode 4
45 Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Doug Noble - Radiation Protection Manager ALARA Planning
46
Staffing Augmentation
Dose Control
Contamination Control
Temporary Decontamination Facility ALARA Planning
47
Total resource needs not significantly greater than normal refueling (approximately 70 Radiation Protection (RP) Technicians)
Permanently assigned RP Technicians and Supervisors (FENOC and Contract)
Davis-Besse ALARA Specialist assigned to RV Head Replacement Project Staffing
48 Dose Controls for Old Head
Based on controls used in 13th Refueling Outage and industry benchmarking (8 facilities to date)
Shielding applied to reactor head, service structure and other components
Establish Radiological Controlled Areas around travel path inside and outside Containment
Radiation Protection will escort the removed RV Head during transportation to Old Steam Generator Storage Facility
49
Use of Containment Purge Ventilation to ensure negative pressure at Reactor Head Access
Cover/Bag Head and Service Structure in Containment
Continuous air monitors Contamination Control
50
Primary use for 18th RFO Steam Generator Replacement preparations
Will use during 17th Mid-Cycle Outage for structural steel removed for SGRP
Purpose is to reduce radioactive waste/materials (structural steel and tools)
Located inside Protected Area Temporary Decontamination Facility Example of A Temporary Decontamination Facility at Another Nuclear Site
51
Industry leading performance expected through effective ALARA planning
No unplanned exposures and
No loss of control of radioactive materials Conclusion
52 Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Quality Assurance Oversight Plan Dave Wahlers - Vendor Oversight Lead
53 Quality Assurance Oversight Plan Reactor Vessel Head
Fleet Oversight Topics to be Discussed
- Activities Witnessed during fabrication
- Activities Witnessed after removal from Long-Term Storage
- Activities Remaining to be performed upon arrival at Davis-Besse
- Phased Approach of the Quality Assurance Oversight Plan
54 Quality Assurance Oversight Plan
Activities Witnessed During Fabrication
- Ultrasonic Examination (UT) of base forging
- Liquid Penetrant (PT) Examination prior to hydrostatic test
- Hydrostatic Test
- Liquid Penetrant (PT) Examination after hydrostatic test
- Attachment of ASME Name Plate
55 Quality Assurance Oversight Plan
Activities Witnessed After Removal from Long Term Storage
- Cleanliness condition after removal of storage coating
- Application of protective coating shipping coating
- Traceability of components
- Final packaging and shipment preparations
Activities Remaining to be Performed
- Visual inspection upon arrival in United States
- Receipt inspection upon arrival at Davis-Besse
- Final Quality Assurance Data Package Review
56 Quality Assurance Oversight Plan
Phased Oversight Approach of Reactor Vessel Head Replacement Project Activities
- Design and Planning
- Reactor Vessel Head and Integrated Head Assembly
- Reactor Vessel Head Removal and Replacement
- Post-Installation Verification and Testing
57
Conclusion Fleet Oversight will continue to assess both off site and on site activities associated with the replacement RV Head Project at Davis-Besse to ensure that they are performed in accordance with applicable requirements in a safe and controlled manner Quality Assurance Oversight Plan
58 Closing Comments Safe Plant Operations Safe Plant Operations Reliable Plant Operations Reliable Plant Operations Cost-Effective Plant Operations Cost-Effective Plant Operations Clark Price - Director, Special Projects