ML19242B738

To Plant Steam Generator Repair Rept

ML19242B738
Person / Time
Site:	Palisades
Issue date:	08/03/1979
From:	Youngdahl R CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML18043A930	List: ML18043A928 ML19242B738
References
PROB-790803, NUDOCS 7908090354
Download: ML19242B738 (65)

Text

{{#Wiki_filter:CO:ISU'ERS POWER C0!GA'IY PALISADES PLAIIT STEAM GEIERATOR REPAIR REPORT Docket 50-255 License DPR-20 At the request of the Cc= mission and pursuant to the Atomic Energy Act of 195L and the Energy Reorganization Act of 197L, as amended, and the Co=nission's Rules and Regulations thereunder, Consumers Power Company submits the " Palisades Plant Steam Generator Repair Report," Revision 3, July 1979, which describes the potential repair progras based on complete replacement of the existing steam generators if major repairs beccee necessary. CO:ISUMERS POWER COMPA'IY By R C Younedahl (Siened) R C Youngdahl, Executive Vice President Sworn and subscribed to before me this 3rd day of August 1979 Dorothy H Eartkits (Sirned) Dorothy H Eartkus, :iotary Public Jackson County, Michigan My co=niscion expires March 20, 1933 s ',. b g-Cl} D 7908090 3 6#/

PALISADES PLANT SGRR REMOVE INSERT vi Rev 2 vi Rev 3 vii Rev 2 vii Rev 3 viii Rev 1 viii Rev 3 x Rev 2 x Rev 3 Figure 3-3-2 Rev 0 Figure 3-3-2 Rev 3 Table 4-3-2 Rev 0 Table 4-3-2 Rev 3 (Sheet 1 to 2) (Sheet 1 to 2) Appendix C C-1-1 Rev 3 Table C-1-1 (Sheet 1 to 12) Table C-1-2 (Sheet 1 to 3) Table C-1-3 (Sheet 1 to 14) Table C-1-4 (Sheet 1 to 3) Table C-1-5 (Sheet 1 to 3) C-2-1 Rev 3 C-3-1 Rev 3 C-3-2 Rev 3 C-3-3 Rev 3 Figure C-3-1 Rev 3 Figure C-3-2 Rev 3 Figure C-3-3 Rev 3 Figure C-3-4 Rev 3 C-4-1 Rev 3 C-5-1 Rev 3 C-5-2 Rev 3 C-5-3 Rev 3 C-6-1 Rev 3 C-6-2 Rev 3 C-7-1 Rev 3 Table C-7-1 Rev 3 C-8-1 Rev 3 C-8-2 Rev 3 C-9-1 Rev 3 C-10-1 Rev 3 \\ s ( )

PALISADES PLANT SGRR 8.o REPLACEMENT OF STEAM GENERATOR 8-6 EVAPORATOR SECTIONS 8.7 MAN-REM CONSIDERATIONS 8-6

8.8 CONCLUSION

S 8-7 9.0 COST BENEFIT ANALYSIS FOR THE DECONTAMINATION, 9-1 STO RAG E, AND DISPOSAL OF THE OLD STEAM GENERATORS CONSIDERING ALARA

9.1 INTRODUCTION

9-1 9.2 STEAM GENERATOR IN-PLACE DECONTAMINATION 9-1 9.3 STEAM GENERATOR STORAGE AND DISPOSAL 9-2 9.3.1 LONG-TERM STEAM GENERATCtt STORAGE 9-2 ONSITE 9.3.2 IMMEDIATE SHIPMENT BY BARGE 9-2 9.3.3 SHORT-TERM STORAGE WHILE UNITS ARE 9-3 CUT UP FOR SHIPMENT (WITHOUT DECONTAMINATION) 9.

3.4 CONCLUSION

S 9-3

10.0 REFERENCES

10-1 APPENDIX A - RESPONSE TO NRC QUESTIONS OF 4/17/79 A-1(a)-1 2 APPENDIX B - RESPONSE TO NRC QUESTIONS OF 4/19/79 B-1(a)-1 APPENDIX C - RESPONSE TO NRC QUESTIONS OF 5/16/79 C-1-1 3 s' J C'h (J ' Revision 3 July 1979

PALISADES PLANT SGRR LIST OF TABLES TABLE NO. TITLE 2.1-1 STLAM GENERATOR COMPARISON DATA 2.1-2 REPLACEMENT STEAM GENERATOR DATA 2.2-1 STEAM GENERATOR MATERIALS 4.2-1 ELECTRICAL EQUIPMENT AND INSTRUMENTS TO BE TEMPORARILY REMOVED 4.2-2 480 V MOTOR CONTROL CENTER 809 LOAD TABULATION 4.2-3 TEMPORARY AND PERMANENT ELECTRICAL LOADS ASSOCIATED WITH STEAM GENERATOR REPAIR AND THEIR CORRESPONDING POWER SOURCE 4.3-1 TYPICAL PORTABLE SURVEY INSTRUMENT SPECIFICATIONS 4.3-2 MAN-REM ASSESSMENT FOR REGLACEMENT 4.4-1 ACTIVATED CORROSION PRODUCTS AFTER SHUTDOWN 4.4-2 MAN-REM ASSESSMENT FOR OFFSITE DISPOSAL 6.2-1 ESTIMATES OF AIRBORNE RELEASES TO ENVIRONMENT DURING STEAM GENERATOR REPAIR EFFORT 6.2-2 COMPARISON OF GASEOUS EFFLUENT RELEASES 6.2-3 ESTIMATED SPECIFIC ACTIVITY OF LAUNDRY WASTEWATER 6.2-4 ESTIMATED RADIOACTIVE LIQUID EFFLUENT RELEASED DURING THE STEAM GENERATOR REPAIR 6.2-5 COMPARISON OF RADIOACTIVE LIQUID EFFLUENT RELEASES 8.4-1 STEAM GENERATOR REPAIR ALTERNATIVE COSTS 8.8-1 COMPARISON OF MAJOR REPAIR ALTERNATIVES B-2-1 GENERAL CORROSION RATE IN FAULTED VOLATILE CHEMISTRY MODEL BOILER ENVIRONMENTS B-2-2 TUBE SUPPORT MATERIALS COMPARISON CORROSION 2 TESTING AT HEAT TRANSFER / SUPPORT LOCATION (MODEL BOILER TESTING) C-1-1 MANUAL WELDING OF RC PIPE WITH MACHINE CLADDING C-1-2

SUMMARY

OF MANHOURS FOR ALL TASKS BY LOCATION C-1-3 MACHINE WELDING OF RC PIPE WITH REMOTE VIEWING C-1-4

SUMMARY

OF MANHOURS FOR ALL TASKS BY LOCATION C-1-5 MAN-REM ESTIMATE C-7-1 MAN-REM ESTIMATE (PREPARATION, INSTALLATION, REMOVAL, AND STORAGE) 1 (l).3 vii Revision 3 July 1979

PALISADES PLANT SGRR LIST OF FIGURES FIGURE NO. TITLE 2.2-1 REPLACEMENT STEAM GENERATORS 2.2-2 DELETED 2.2-3 DELETED 2.2-4 BOTTOM BLOWDOWN DUCT ASSEMBLY 2.2-5 TUBE SUPPORT TYPES 2.2-6 EGGCRATE ASSEMBLY 2.2-7 BEND REGION TUBE SUPPORT 2.2-8 TUBE SUPPORT 2.2-9 UPPER ASSEMBLY 2.2-10 STEAM GENERATOR - FLOW RESTRICTOR NOZZLE 2.2-11 PRIMARY HEAD DRAINS 3.1-1 EXISTING BLOWDOWN AND RECIRCULATION SYSTEM 3.1-2 MODIFIED BLOWDOWN AND RECIRCULATION SYSTEM 3.3-1 EXISTING TURBINE ANALYZER PANEL FOR SAMPLING SYSTEM 3.3-2 MODIFIED TURBINE ANALYZER PANEL FOR SAMPLING SYSTEM 3 3.4-1 PRIMARY HEAD DRAIN SYSTEM 3.5-1 WIDE RANGE LEVEL TRANSMITTER 4.1-1 SITE PLAN 4.1-2 BARGE SLIP 4.1-3 OLD STEAM GENERATOR STORAGE FACILITY PLAN VIEW 4.1-4 OLD STEAM GENERATOR FACILITY SECTIONS AND DETAILS 4.1-5 CONTAINMENT LAYDOWN AREAS 4.1-6 GENERAL ARRANGEMENT PLAN VIEU, SHEET 1 4.1-7 GENERAL ARRANGEMENT PLAN VIEW, SHEET 2 4.1-8 GENERAL ARRANGEMENT SECTION A-A 4.1-9 GENERAL ARRANGEMENT SECTION B-B 4.1-10 DOWN-ENDING STEAM GENERATOR ONTO SLEDS 4.1-11 LOWERING STFAM GENERATOR FROM ELEVATOR PLATFORM ONTO '!MNSPORTERS 4.1-12 STEAM GENERATOR IN HOISTED POSITION, SECTION VIEW 4.1-13 STEAM GENERATOR ON TRANSPORTER BETWEEN STORAGE AND CONTAINMENT 4.1-14 STEAM GENERATOR ON TRANSIORTER BARGE TO STORAGE 4.1-15 OFF LOADING STEAM GENERATOR FROM BARGE, PLAN VIEW 4.1-16 OFF LOADING STEAM GENERATOR FROM BARGE, 1 'O r c e 9- \\ J/ viii Revision 3 July 1979

PALISADES PLANT SGRR LIST OF FIGURES 4.2-4 PRIMARY COOLANT PIPING CUT POINTS 4.2-5 MAIN STEAM PIPING CUT POINTS 4.2-6 FEEDWATER PIPING CUT POINTS 4.2-7 BLOWDOWN PIPING CUT POINTS 4.2-8 STEAM GENERATOR UPPER SUPPORT DETAILS 4.3-1 ACCESS CONTROL (EL 590'-0" AND EL 611'-0") 4.3-2 ACCESS CONTROL (EL 649'-0") 4.3-3 PRIMARY COOLANT PIPING CONTACT RADIATION SURVEY 4.3-4 AVERAGE RADIATION FIELDS 10 WEEKS AFTER SHUTDOWN 4.3-5 RADIATION SURVEY (EL 607'-6") 4.3-6 MAXIMUM DOSE RATE INSIDE STEAM GENERATORS 4.3-7 GENERAL RADIATION FIELD NEAR STEAM GENERATOR PIPING A-1(b)-1 STEAM GENERATOR REPLACEMENT SCHEDULE 2 A-1(b)-2 STEAM GENERATOR RETUBING C-3-1 PRIMARY COOLANT PIPING CUT POINTS C-3-2 MAIN STEAM PIPING CUT POINTS C-3-3 FEEDWATER PIPING CUT POINTS 3 C-3-4 BLOWDOWN PIPING CUT POINTS a 595 x Revision 3 July 1979

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PALISADES PLANT SGRR TABLE 4.3.2 (SliEET 1) MAN-HEM ASSESSMENT Fok REPLACEMENT (The manhour and man-rem estimates have been revised refer to Table C-1-1 to C-1-5.) Average Atea m keductlon Area Estimated m Radiation Man-Rem Factor Man-Hem Manhouts in Field Dose (Man-kem) (Shielding and/or Dose Work Area Radiation Field (rem /hr) Unshielded Decontamination) (Man-Rem) 1. outside of power plant building but within secutity fence 213,300 .5x10* 1.06 1.0 1.06 2. Checking In and out through security and healt.h pysics, as well as time spent suiting up, cleaning up, and moving to and from work area for personnel working in radioactive areas 55,300 .0025 138.25 1.0 138.25 3. Inside contaisuhent near new construction opening 3,550 0.001 3.55 1.0 3.55 4. Within 6 feet of outhide of reactor coolant pipe or bottom of steam generator before removal of steam generators 5,050 0.03 151.5 1.0 151.5 5. Within 6 feet of outside of reactor coolant pipe after steam generator's removal 19,100 0.01 191.0 1.0 191.0 23,400 Al 234.0 Al 234.0 A1 6. Within 6 feet of outside of reactor coolant pipe or bottom of steam generators with partial enposure to inside of reactor coolant pipe v3 before steam generator's removal 750 1.0 750.0 0.05 37.5 ,J ~ (,71 7. Within 6 feet of outside of reactor coolant pipe with partial exposure to inside of reactor coolant pipe after steam generator's temoval 4,400 1.0 4,400 0.05 220.0 m 1 8. Inside reactor coolant pipe 4,500 40,500 4070.0 (6;) 200 A1 9.0 1,800 A1 0.1 100.0 Al 300 A2 2,700 A2 270.0 A2 / 9. Low radiation area within containment 41,250 0.001 41.25 1.0 41.25 4,200 A2 .005 A2 21.0 A2 21.0 A2 Reviulon 3 July 1979

PALISADES PLANT SGhk TABLE 4.3.2 (SHEET 2) MAN-REM Ad.,Eb'; TENT FOR REPLACEMENT (The manhour and man-rem estimates have been cuanged ref er to Table C-1-1 to C-1-5.) Average Area m Reduction Area Estimated m Radiation Man-Rem Factor Man-Rem Manhours in Field Dose (Man-Rem) (Shielding and/or Dose Work Area Radiation Field (tem /hr) Unshielded Decontamination) (Man-Rem)

10. Within 6 feet of ?ap half of original steam generators 1,100 0.005 5.5 1.0 5.5

11. Within 6 feet of top half of new steam generators 8,050 0.001 8.05 1.0 8.05

12. Operating floor of containment 15,800 0.005 79.0 s.2 15.6

13. Inside containment, above polar crane 1,150 0.001 1.15 1.0 1.15

14. Auxiliary building near clean resin tank and cooling water tank 750 0.001 0.75 1.0 0.75

15. Auxiliary building near blowdown tank 6,700 0.001 6.7 1.0 6.7

16. Spent fuel pool floor 2,750 0.005 13.75 1.0 13.75

17. Within 6 feet of the bottom half of new steam generators 3,700 0.010 37.0 1.0 37.0

18. Within 6 feet of the outside of the teactor vessel 50 1.0 50.0 1.0 50.0

19. Next to the existing steam generators outside of the containment 1,000 0.02 20.0 1.0 20.0 Total 4,993 Al 1,666 A2 1,193 Note:

m The three man-rem estimates given for work area 8 (Inside of reactor coolant pipe) are presented because of three welding techniques under consideration. The ALARA considerations will be the factor determining which technique is g3 eventually used. The total time estimated for cutting, welding, and inspecting inside ttae teactor coolant pipes is

• " n 4,500 manhours.

One altcInative (A1) is a technique, presently being investigated for feasibility, utilizing manual ~' [ welding from the outside of the piping. Using this method, only 200 manhouts out of a total of 4,500 would be required v inside primary coolant piping. The temailaing 4,300 manhouls wculd be spent within 6 feet of the reactot coulant pipe (work area 5). The second alternative (A2) is an automatic welding technique for the cladding from anulde the piping utilizing remote viewing. This method r egulled 300 m snhour s inside the piping, and the tem 42ning 4,200 manhouts would be spent in a low radiation area in the containment (werk area 9). t. v~ Revision 3 July 1979

SGRR C-1 PALISADES PLANT SGRR C-1 Provide the following additional information regarding ALARA considerations (Sections 1.1.5 and 4.3.5): (1) Duration of exposure associated with anticipated replacement / repair tasks (2) Repetition rate of the tasks (3) Numbers of work force exposed during each task (4) Occupational exposures associated with antici-pated replacement / repair activities

RESPONSE

Tables (C-1-1 through C-1-5) provide the requested additional information. The manhour and corresponding man-rem estimates have changed from the original presented in Table 4.3.2. The changes are based on modifications to the welding techniques, described as Alternative (A7) and Alternative (A2), and further development of work packages. The new exposure estimates are as follows: 1,547 to 2,803 man-rem (A1), based on manual welding the reactor coolant pipe carbon steel portion and machine welding the cladding (with remote viewing), and 1,537 to 2,663 man-rem (A2) based on machine welding (with remote viewing) both the carbon steel and cladding. The man-rem range reflects two analyses, for 140 and 42 days after shut down for the commencement of primary system pipe cutting. These estimates do not include a contingency. It should be noted that Work Area 8, which represents manhours spent inside the reactor coolanc pipe, has been expanded to appropriately differentiate radiation field levels before and after local decontamination. C-1-1 Revision 3 July 1979 B i- - E/15

i r PALISA0t.S PLANT SGRR TABLE C-1-1 (Sheet 1) MANUAL WELDING OF RC PIPE WITl! MACilINE CLADDING NUMBER AVERAGE OF NUMBER TIMES TASK DURATION OF TASK NUMBER DESCRIPTION (llOURS) PERSONNEL

• LOCATION PERFORMED MANilOURS COMMENTS 1

Scaffold, cut, and remove con-180 6 1 1 1,080 struction opening linet plate. 83 6 2 1 498 2 Install new liner plate for con-233 6 3 1 1,398 struction opening, including 100 6 2 1 600 fitup, scaffolding welding, etc. 3 Cover and uncover spent fuel pool 270 7 16 0 1,890 (protective cover). 116 7 2 0 812 240 7 1 0 1,680 f 4 Cut reactor coolant pipe. 15 2 4 12 360 Inside radiation 15 2 6 12 360 control envelope 17 2 2 12 408 12 2 9 12 288 5 Machine weld preparation on ends 58 2 7 18 2,088 12 weld preps of reactor coolant pipes. 35 2 2 18 1,260 would be on decon-23 2 9 18 828 taminated pipe and 6 on pipe attached to reactor. 6 Rig, iltup, line up, and tack in 28 5 7 12 1,680 qf' place reactor coolant pipe closure 17 5 2 12 1,020 spools. 11 5 9 12 660 ',

• Refer to Table C-1-5 u

PALISADES PLANT SGRR TABLE C-1-1 (Sheet 2) MANUAL WELDING OF RC PIPE WITl! MACllINE CLADDING NUMBER AVERAGE OF NUMBER TIMES TASK DURATION OF TASK NUMBER DESCRIPTION (1100RS) PERSONNEL *l.OCATION PERFORMED MAN!!OURS COMMENTS 7 Weld hot leg reactor coolant 131 4 5 4 2,096 Manual welding 8C pipe (carbon steel). 2 1 8C 4 8 level 131 4 9 4 2,104 113 4 2 4 1,800 8 Clad hot leg reactor coolant 2 1 8C 4 8 Utilizing machine pipe (stainless steel) 50 2 9 4 400 welding with re-30 2 2 4 240 mote welding 9 Weld cold leg reactor coolant 89 4 5 8 2,864 Manual welding pipe (carbon steel). 2 1 8C 8 16 Manual welding 91 4 9 8 2,896 77 4 2 8 2,448 10 Clad cold leg reactor coolant 2 1 8C 8 16 Machine welding pipe (stainless steel) 45 2 9 8 720 with remote 28 2 2 8 448 viewing 11 Stress relieve reactor coolant 22 4 5 12 1,056 pipe. 2 1 8C 12 24 22 4 9 12 1,056 20 4 2 12 960 J' __ O J

• Refer to Table C-1-5

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PALISADES PLANT SGRR TABLE C-1-1 (Sheet 3) MANUAL WELDING OF RC PIPE WITil MACllINE Cl. ADDING NUMBER AVERAGE OF NUMBER TIMES TASK DURATION OF TASK NUMBER DESCRIPTION (110URS) PERSONNEL

• l.0 CATION PERFORMED MANil0URS COMMENTS 12 X-Ray and NDT reactor coolant 1/2 1

8 48 24 Leave pill guide pipe. 4 2 5 120 1,960 in place 8C when 3 2 2 120 720 possible in order 1 2 9 120 240 to reduce exposure. 13 Install cleanliness plugs in 1/2 1 8A 6 3 reactor coolant pipe prior to 1 2 4 6 12 cutting pipe. 14 Clean inside of reactor coolant 1 1 BC 12 8 pipe after welding. 15 Cover steam generator reactor 1 4 8B 6 24 coolant nozzles 1 4 1 6 24 1 4 9 6 24 4 2 7 6 48 (Seal weld only) 16 Cover ends of reactor coolant 1 4 8B 18 72 pipe spools (temporary). 2 4 7 18 144 1/2 4 1 18 36 1 4 2 lb 72 c."$ 11 Rig reactor coolant pipes to 3 4 5 6 72 U' decontamination area. 1 4 2 6 24 / (? -J

• Refer to Table C-1-5

PALISADES PLANT SGRR TAliLE C-1-1 (Sheet 4) MANilAL WELDING OF RC PIPE WITil MACllINE CLADDING NUMBER AVERAGE OF NUMBER TlHES TASK DURATION OF TASK NUMiiER DESCRIPTION (llollRS) PERSONNEL,

• I.OCATION PERFORttED M ANilOllR S COf1MENTS 18 Measure reactor coolant pipe 4

3 5 12 144 closure spools. 1 3 2 12 36 19 Remove insulation from steam 38 4 2 2 304 generators. 32 4 4 2 256 25 4 9 2 200 32 4 10 2 256 20 Reinsulate new steam generator. 180 4 2 2 1,440 120 4 9 2 900 150 4 11 2 1,200 150 4 17 2 1,200 21 Remove and replace reactor 5 2 2 12 120 coolant pipe insulation. 3 2 4 12 72 5 2 5 12 120 3 2 9 12 72 22 Cut, remove, bevel, e rect, weld, 260 3 2 2 1,566 stress relieve, and insulate main 277 3 9 2 1,662 steam lines at top of steam 40 3 10 2 240 generator. 148 3 11 2 888 148 3 12 2 888 / 23 X-Ray and NDT main steam line. 40 2 2 2 160 (6 weld) t' 25 2 9 2 100 CD 65 2 11 2 260

• Refer to Table C-1-5

O PALISADES PLANT SGitR TABLE C-1-1 (S'eet 5) F1ANUAL WELDING OF RC i.'E WITil FtACllINE CLADDING N Ut!IlER AVERAGE OF NUtiBER tit 1ES TASK DURATION OF TASK NUttBER DESCRIPTION (llOURS) PERSONNEL.

• LOCATION PE RFO R11ED t1ANilOURS C0tlF1ENTS 24 Cut, bevel, erect, weld, stress 162 2

2 2 648 refleve, and insulate feedwater 107 2 9 2 428 line. 25 2 10 2 100 245 2 11 2 980

5 X-Ray and NDT f eedwa ter line.

20 2 2 2 80 (4 welds) 45 2 11 2 180 26 Remove and replace miscellaneous 60 4 2 1 240 small pipe near steam generators. 50 4 4 1 200 40 4 9 1 160 50 4 17 1 200 27 flove component coeling water 75 4 2 1 300 tank and clean resin tank out of 50 4 9 1 200 way and reinstall. 125 4 14 1 500 28 Install blowdown, tank, pump, and 40 3 2 1 120 insulatlon. 20 3 9 1 60 W 67 3 15 1 201 29 Install new blowdown piping 122 6 2 1 732 inside containment. 13 6 4 1 78 92 6 5 1 552 L 177 6 9 1 1,062 D

• Refer to Tabic C-1-5

pal.ISADES PLANT SGRR TABl.E C-1-1 (Sheet 6) MANUAL. WEl.DIf1G OF RC PIPE WITil f1ACllINE CLADDING liUM BER AVERAGE OF NUttBER TlHES TASK DURATION OF TASK MMBER DESCRIPTION (llOURS) PERSOf4NEL

• l.OCATION PERFORt!ED M ANilOllRS CutlMENTS 30 Install new blowdown piping 193 6

2 1 1,158 outside containment. 128 6 9 1 768 322 6 15 1 1,932 31 Remove electrical inside con-37 4 2 1 148 tainment so steam generator can 63 4 4 1 252 be removed. 25 4 9 1 150 32 Reinstall electrical inside 90 8 2 1 720 containment. 60 8 9 1 480 75 8 11 1 600 75 8 17 1 600 31 Install electrical for new 92 4 2 1 368 blowdown system. 12 4 9 1 48 173 4 15 1 692 32 4 17 1 128 34 Install and remove equipment 30 2 2 1 60 9'[ required to monitor position of 10 ,f reactor and steam generators 130 1 9 1 130 during weldup of reactor coolant 20 2 17 1 40 pipe. 20 2 18 1 40 ( O,

• Refer to Table C-1-5

PALISADES PLANT SGRR TABI.E C-1-1 (Sheet 7) MANilAL WEl. DING OF RC PIPE WITil t!ACillNE CLADDING Nllt!BER AVERAGE OF Nt!M BER Tit!ES TASK DllRATION OF TASK Nljt!BER DESCRIPTION (llollRS) PERSONNEL

• LOCATION PERFORFtED t1 ANilOllR S CO!!MENTS 35 Mobilize, install cages.

1,075 20 1 1 21,500 Remove dome and buttress facle, relax tendons, remove tendons, chip concrete, cut rebar and tendon sheathing for containment construction opening. 36 Replace opening on contalnment, 1,275 15 1 1 19,125 including the following: Replace tendon sheathing, rebar, concrete and tendons, stress tendons and replace dome and buttress facia, demobi1ize. 37 Construct and remove barge slip. 829 14 1 1 11,606 38 Foundations for rigging equip-692 12 1 1 8,304 ment, including sheetpiling, earthwork, concrete foundations and removal of foundations (at \\ containment building). 39 Mobile heavy lift rigger. 100 15 1 1 1,500 40 Assemble 4 crawlers. 150 10 1 1 1,500 /

• Refer to Table C-1-5

O PAI.lSAbr.S IL\\NT SGRR TAh!.E C-1-1 (Sheet 8) flANUAl, WEl. DING OF RC PIPE WITil MACillNE CLADDING NUMBER AVERAGE OF NUMBER TIMES TASK IlURATION OF TASK NUMBER DESCRIPTION (llollRS) PERSONNEL,

• l.0 CATION PERFORMFD MANiloliRS COMMENTS 41 Assemble jacking frame at barge.

62 12 1 1 744 42 Assemble jacking frame at con-78 12 1 1 936 tainment. 43 Pteassemble equipment for inside 78 12 1 1 936 containment. 44 Install lifting equipment inside 112 15 2 1 1,680 containment. 158 15 12 1 2,370 105 15 13 1 1,575 45 Remove existing steam generators 23 15 1 2 690 from containment (rigging). 26 15 2 2 780 44 15 4 2 1,320 19 15 19 2 570 46 Transport and store existing 31 10 19 2 620 steam generators. 6.5' --q 47 Receive and ballast barge. 20 5 1 1 100 v 48 Offload, store, load, and trans-158 10 1 2 3,160 / port new steam generators. (. d 49 Rerig as required to install. 16 15 1 2 480 r

• Refer to Table C-1-5

PALISADES PLANT SCRR TABLE C-1-1 (Sheet 9) MANUAL. UEl. DING OF RC PIPE UlTil MAClflNE CLADDING NUMBER AVERAGE OF NUMBER TIMES TASK DURATION OF TASK Nl!MBER DESCRIPTION (ll0URS) PERSONNEL

• l.0 CATION PERFORMED MANilollRS COMMENTS 50 Install new steam generators.

19 15 1 2 570 21 15 2 2 t>30 37 15 12 2 1,110 12 15 17 2 360 31 Remove all external rigging 225 15 1 1 3,375 equipment from site. 52 Remove all rigging equipment 75 15 2 1 1,125 from containment. 105 15 12 1 1,57S 70 15 13 1 1,050 53 Remove internal rigging equip-63 15 1 1 945 ment from site. 54 Miscellaneous rigging 150 5 1 1 750 55 Steam generator stora e building. 406 10 1 1 4,0(20 3 n 56 Cut and remove top support of 8 5 10 1 40 steam generator. 5 5 2 1 25 /. 3 5 9 1 15 a57 Remove shims other steam 6 4 10 1 24 generator top support. 4 4 2 1 16 2 4 9 1 8

PALISADES Pl.AIJT SGRR TABLE C-1-1 (Sheet 10) MAfiUAL WEl.Dif4G OF RC PIPE WITil flACll!!JE Cl.ADDif1G f;UtiliER AVERAGE OF fJUM BER TIMES TASK DURATION OF TASK fJ UtlHE R DESCRIPTION (ll0URS) PERSOfif4El.

• l.0C AT 10f1 PERFORMED fl AIJ110UR S COMMENTS 58 Remove hyttraulic snubbers.

4 5 10 8 160 3 5 2 8 120 1 5 9 8 40 59 Unbolt existing steam generator. 4 3 4 2 24 3 3 2 2 18 1 3 9 2 6 60 Remove shims at steam gene rat or 15 3 4 2 90 base. 9 3 2 2 54 6 3 9 2 36 61 lio l t down steam generators. 10 3 5 2 60 6 3 2 2 36 4 3 9 ') '> 4 62 Reshim bottom steam generator 50 3 5 2 300 (sliding base). 30 3 2 2 180 20 3 9 2 120 s_: '. -Q 63 Replace top steam generator 120 3 11 2 720 support. 72 3 2 2 432 48 3 9 2 288 64 Re shim top steam generator 40 3 11 2 240 F supports. 24 3 2 2 144 16 3 9 2 96

• Refer to Table C-1-5

PALISAIJES PLANT SCRR TABl.E C-1-1 (Sheet II) MANUAL WEl. DING OF RC PIPE 'JITil MACillNE CLADDING N t'M B E R AVERAGE OF Nt!M HE R TIMES TASK DURATION OF TASK NUMBER DESCRIPTION (llOURS) PERSONNEL.

• LOCATION PFRFOkttED MANilOURS COMMENTS 65 Reinstall steam generator hy-30 4

11 8 960 draulic snubbers. 18 4 2 8 576 12 4 9 8 384 66 fliscellaneous pipe operations 1 25,088 Welders tests, (welders tests, material 2 7,030 training, material hangling, scaffolding, training, 4 952 handling and fabri-lunt;ers and supports, line 5 3,699 eation of tents are testing, cleanup, tents). 8 20 in 1.ocation 1. Re-9 6,982 ma i nde r o f ma nhou r s 10 552 were allocated on 11 1,088 the basis of piping 12 413 manhours in each 15 914 locatlon. 17 87 67 Dist ributables (startup, 1 11,436 Welders tests and cleanup, scaffolding, welders 2 13,298 miscellaneous in tests other than pipe fitters, 3 1,003 Area 1. Remainder miscellaneous). 4 1,526 of manhours allo-5 4,883 cated on the basis J 6 131 of direct manhours [- 7 1,613 excluding Area 1. ~ 8 51 9 9,766 10 5t27 11 2,921

• Refer to Table C-1-5

Pall 5 PLAriT SGRR TABLE C-1-1 (Sheet 12) ftAliUAL WELDitJG OF RC PIPE WITH !!ACillNE CLADDitiG fil!!!BER AVERAGE OF fiUtihE R TlttES TASK DURATION OF TASK NUFt BE R DESCRIPTION (llOllRS) PERSONtiEL

• LOCATION PERFORftED ttANilullRS Cor!51EliTS 67 (Cont inued) 12 2,616 13 1,090 14 218 15 1,526 16 785 17 1,090 19 480 68 Nonata nua l 1

99,160 Office personnel and 2 6,511 50% of engineers and 3 53 supe rvision's man-4 1,110 hours are in Location S 2,872

1. 1.

Remainder of taan-6 16 hours by discipline 7 85 were allocated to the 8 14 proper location based 9 5,770 on direct manhours 10 426 expended in that loca-11 1,176 tion by discipline. 12 895 f'] 13 149 For exarnple: The man-14 11 hours for electrical v 15 1,143 engineers and supts 16 141 were allocated based 17 401 on the electrical c-19 67 direct hours expended cf' on each task at each location.

• Refer to Table "-1-5

I Ahi t 4-02 ( ',in e t () M'Mf t A14 Y e st' M Af; tit Wid S l e ak Al l T A' K S HV l i ta A l l s pPl MANI! Al. WF i lsl M. t it k t A("Il X Fi M >l AN T C.S. P i l't WI fil H Al ll l N F. (1Aliolw; Ar;D kin a l t. V i t W I Ni T A."K ro i. I 2 3 4 t, 1 M 9 to il 11 Il 14 15 16 il 1H 19 I 49M j,tifte t 2 htH1 1,'l98 1 1,#,Mu Mlf 1,M90 4 4#,M 16 0 It.o 2MM !,2 till 2,t iM M M/M 6 1,ulu 1, t, M o e,t.o / I,Miwi 2,09h M 1,104 8 240 M 4tni 9 2,44M 1,Ph4 16 1,H96 to 4 '. M lh 120 11 9 688 1.0 % 1 '. 1,0 % 12 Ilo 9ho 24 240 il 12 1 14 M l$ 14 4M 14 24 16 le, 11 l' 4 11 11 14 11 IM is. 144 19 lo ". 2$6 7tvl 2$6 lo I,440 9hu I,/ou I,/i ni 2l llo 12 iln Il 22 1,$h0 1,662 240 MMN MMM ll Ital IllO 2 ha i 24 h4M 42M lO0 9 Mi s 2$ M46 1 M11 lh 140 200 160 foo )I li ll l 28MB $1 M B <^, i s. "me 4 A

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PALISADES PLANT SGRR TABl.E C-1-3 (Sheet 1) MACilINE WELDING OF R.C. PIPE WITil REMOTE VIEWING NIIMBER AVERAGE OF NIIMBER TIMES TASK DURATION OF TASK N t1M BE R DESCRIPTION (llollRS) PERSONNEL

• LOCATION PERFORMED M ANil0URS COMMENTS 1

Scatfold, cut, and remove 180 6 3 3 1,080 construction opening liner plate. 83 6 2 1 498 2 Install new liner plate fo r con-233 6 3 1 1,398 struction opening. Including 100 6 2 1 600 fitup, scaffolding, welding, etc. 3 Cover and uncover spent fuel 270 7 16 0 1,890 pool (protective cover). 116 7 2 0 812 240 7 1 0 1,680 4 Cut reactor coolant pipe. 15 2 4 12 360 luside radiation con-15 2 6 12 360 trol envelope 17 2 2 12 408 12 2 9 12 288 5 Machine weld prep on ends of 58 2 7 18 2,088 12 weld preps would reactor coolant pipes. 35 2 2 18 1,260 he on decontaminated 23 2 9 18 828 pipe and 6 on pipe ,."T attached to reactor. _..C' 6 Rig, fitup, lineup and tack in 28 5 7 12 1,680 place reactor coolant pipe 17 5 2 12 1,020 closure spools. I1 5 9 12 660 C

• Refer to Table C-1-5

pal.lSADES PLANT SGRR TABl.E C-1-3 (Sheet 2) MACllINE WELDING OF R.C. PIPE WITil REMOTE VIEWING NUMBER AVERACE OF NilMBER TIMES TASK DURATION OF TASK NUMBER DESCRIPTION (flollRS) PERSONNEL.

• l.0 CAT I ON PE R FO RME D MANilOURS COMMENTS 7

Weld hot leg reactor coolant 4 2 7 4 32 Utilizing machine pipe (carbon steel). 3 1 8C 4 12 welding with remote 234 1 5 4 935 viewing. 146 3 2 4 1,753 273 3 9 4 3,276 8 Clad hot leg reactor coolant 2 1 8C 4 8 Utilizing machine pipe (stainless steel) 50 2 9 4 400 welding with remote 30 2 2 4 240 viewing. 9 Weld cold leg reactor coolant 4 2 7 8 64 pipe (carbon steel). 2 1 8 8 16 160 1 5 8 1,280 100 3 2 8 2,400 186 3 9 8 4,464 10 Clad cold leg reactor coolant 2 1 8C 8 16 Machine welding pipe (stainless steel). 45 2 9 8 720 with remote viewing. 28 2 2 8 448 .-g I'_ n) 11 Stress relieve reactor coolant 22 4 5 12 1,056 pipe. 2 1 BC 12 24 22 4 9 12 1,056 20 4 2 12 960 / 1 y

• Refer to Table C-1-5

PALISADES PLANT SGRR TAliLE C-1-3 (Sheet 3) MACllINE WEl. DING OF R.C. PIPE WITil REMOTE VIEWING NUMfiER AVERAGE OF NUMliER TIMES TASK DURATION OF TASK NUMBER DESCRIPTION (flollRS) PERSONNEL.

• LOCATION PERFORMED MANilollRS COMMENTS 12 X-Ray and NDT reactor coolant 1/2 1

8C 48 24 Leave pill guide in pipe. 4 2 5 120 1,960 place BC when possi-3 2 2 120 720 ble in order to re-1 2 9 120 240 duce exposure. 13 Install cleanliness plugs in 1/2 1 8A 6 3 reactor coolant pipe prior to 1 2 4 6 12 cutting pipe. 14 Clean inside of reactor coolant 1 1 8C 12 8 pipe after welding. 15 Cover steam generator reactor 1 4 8B 6 24 coolant nozzles. 1 4 1 6 24 1 4 9 6 24 4 2 7 6 48 (Seal weld only) 16 Cover ends of reactor coolant 1 4 8 11 18 72 pipe spools (te.mporary). 1 4 7 18 144 v._) 1/2 4 1 18 36 'm 1 4 2 18 72 v 17 Rig reactor coolant pipes to 3 4 5 6 72 decentami na tion area. I 4 2 6 24

• Refer to Table C-1-5

PALISAI)ES PLANT SGRR TABLE C-1-3 (Sheet 4) MACilINK WELOING OF R.C. PIPE WITil REtlOTE VIEWING NtJMBER AVERAGE OF NUMBER TIMES TASK DURATION OF TASK NUMBER DESCRIPTION (flollRS) PERSONNEL

• LOCAT ION PERFORMED MANHollRS COMMENTS 18 Measure reactor coolant pipe

'4 3 5 12 144 closure spools. 1 3 2 12 36 19 Remove i nsulat ion f ro.a steam 38 4 2 2 304 generators. 32 4 4 2 256 25 4 9 2 200 32 4 10 2 256 20 Reinsulate new steam generator. 180 4 2 2 1,440 120 4 9 2 960 150 4 11 2 1,200 150 4 17 2 1,200 21 Remove and replace reactor coolant 5 2 2 12 120 3 2 4 12 72 pipe insulatton. 5 2 5 12 120 3 2 9 12 72 22 Cut, remove, bevel, erect, weld, 260 3 2 2 1,560 n stress relieve, and Insulate main 277 3 9 2 1,662 'l'd steam lines at top of steam 40 3 10 2 240 'f generator. 148 3 11 2 888 148 3 12 2 888 / -j

• Refer to Table C-1-5

pal.!SADES Pl. ANT SCRR _T Abl.E C-1-3 (Sheet 5) MACllINE WEl. DING OF R.C. PIPE WITil REMOTE VIEWING NUMBER AVERAGE OF NUMBER TIMES TASK Dl] RATION OF TASK NIIMBER DESCRIPTION (110URS) PERSONNEL, *I.OCATION PE RFORt1ED M AN UOli = . z I: w l' v. H-Z> l l We aE l I I lm a w a j l : : : ~r==e:- ,tm ~ z=acarx4

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l A til E C-1 -4 ( Sliv e t 1) SilMM ANY OF M ANitollR S 'toH Al.l. TASKS BY liu Al' ION WF i lll Ntl OF kEAClHN OWilANT PirE BY mat ill M W i lli REMOlE VaFWINf; TASK No. 1 2 3 4 5 6 1 8 9 to 11 12 13 14 15 16 Il lH 19 I 54 /No 55 4,ht o 56 25 15 40 51 8 24 lb 58 110 40 160 59 lH 24 6 60 54 90 16 6I th 60 24 62 1H0 10 0 120 61 4 11 2H8 110 f,4 l '. 4 96 240 65 5/h 184 4hti Siel>t ot a l H 2,lif l 15,109 2,47H 2,6 f,4 5,4/9 160 4,056 2tl1 19,453 H2O 6,0/8 5,941 2,625 500 2,H25 1,906 2,5/H 40 1,190 e.6 25,uSH h,991 1,064 1,954 211 20 H,158 54) I,lul 4 14 91) HI Ti.t a l Directs lui,u/9 1/,701 2,41H 3,72H 1,41) 160 4,21) 21/ 27,Hil I,16 1 7,1 15 6,111 2,625 500 1,75H 1,906 /, ti l 5 40 1,190 61 11,400 l l, lH5 1,001 1,526 1,052 til I,744 - al,466 567 2,911 2,hlh 1,090 218 1,516 1H5 1,090 4HO

t. H 99,160 6,4 11 51 1,191 1,648 16 2 18 61 6,75) 420 1,191 911 l '. 9 11 1,158 141 4til

t. /

Total I l l,til9 51 HIH 1,5 6'e 6,445 11,111 507 b,255 2MH 46,010 2, 1 518 I I,2 /e / 9,904 1,H64 129 6,422 2,812 4,loh 40 1,1 ) / 6 ,N a 0

i pal i S Alae, I'l /Mr St;PR 'lAh!.E C-t-5 ( Silf t.T l) PIM1-RFil 1Sl'IttA TE (/) (1) INEIm.ated Manhours in ihol l a t i on F i e l.1 A rea Fl.in-Item Dose Average 1411ation f l e lil (H.inmil Welling) ( H i. h ine We l.ll ng ) (Han-Rem) W..tk Area (l or.it i on ) (rem /hr) A, A, (Hannal Weliling) (Hohine We l.l l u g )

1. Outsl.le of powrr plant 1,n l lil i n g len t within security f e n..

.5x 10 217659 217619 1.1 1.1

2. (:her li i n g in a n.1 ent t ies ough serior i t y an.!

laealsh physics as well as t im. sp nt soitIng up, c le.an l og up a n.1 ma.vlog io a n.l f:om work ascas foi personnel working in s a.lloar t I ve asca. .0025 52143 5201H 130.3 1 10 1. I n s i st e i on t a inment near new ionstructton opening. 001 15 14 l'> l4 3.5 1.5

4. Within 6' of outst.le of reactor coo l.in t p i p.

or leottom of ste.im g. net.ator prior to removal ol' s t e.im genetators. .0 10 -.050 6276 6445 188.3 - 111.H 195.1 - 322.3

5. Wit hin 6' out a l le of reactor

.oolant pipi aftet st eam generator's removal. .010 -.030 19678 1211) 196.8 - 590.1 621.) - 164. 0 6 Within 6' of out s lite of reactor i ool. net p i p. or l>ot t om of st eam genes st or s wis h l'ar t ! al e x ps,us e to ins i le of reactor iool,uit p i pe puloi to st e.nu genera t os 's s e niov e l. .050 - 0.100 507 507 25.4 - 50.7 25.4 - 50.7

7. Wit hin b' of ont s tile ut ac. actor ioolant p i pe wit h par t i il exposure to insl.le o' re.otor ioolant p i pi.ifter ste.im generator's t emov.i l.

050 -.100 5658 6255 281 - 454.H ll2.H - 625.5 s -g -g / - (.. /

l'Al.l S ADI S l't.Atir SCRR I Alti li f;-l 5 (Sill <L T 2 ) HAN-HI H 13TitlAllC (1) (1) I.t imat eil Hanluinr a in Hallallon Field Area Han-lr or c ont a inment. 005 010 '> H 61 9904 49.3 'lH.7 49.5 - 99.0 l 1. I ns t ile e on t.a l omen t. .s t po l.a r ciane elevatlon. .001 lH6 7 IH64 3.9 5.9

14. Anxillasy lintl.llng ne.er c! car renin tank an.1 sooling wates t.nik.

.001 //9 //9 0.7 0.I

15. Anx i l l.a r y bo l id i ng nr.ir lilowdown tank.

.001 640ll 6442 6.4 6.4 16 Spent fnel pool floor. .005 1812 /H 12 14.2 14.1

17. Within 6' of the 1.o t t ism l. il f o f new s t..im gene r.i t o r, (in p l. ire).

.010 -.0 10 4106 4106 41.1 - Il1./ 41.1 - 115./ <s 49 js %s 9 / v L,J v

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SGRR C-2 PALISADES PLANT SGRR C-2 Describe the designated contamination control envelopes and your plan to maintain occupational exposure within these envelopes "ALARA." Include also dose rates, exposure times, and numbers of workers involved in the tasks (Section 4.3.3).

RESPONSE

The contamination control envelopes will be used for the cutting of reactor coolant piping (Task 4). Although the design of the envelopes has not been finalized, the envelopes will include a high efficiency filtration system. The flow of air within the envelopes will preclude the escape of contaminants through the tent openings used for entering and exiting the area. Each of the 12 cuts on primary coolant piping will require two workers approximately 15 manhours. It is e.stimated that 720 man-hours will be spent within the control envelopes, with an average radiation field of 30-50 mr/hr. This results in an estimated 21-36 man-rem of occupational exposure. As cescribed in the Repair Report, Section 4.3-1, personnel in-volved in work within areas with a high level of contamination will wear two sets of protective clothing. Respiratory protection will be required in accordance with Palisades health physics procedures. Sneet lead, lead wool blanket, or other shielding will be used where possible in accordance with ALARA guidelines. ~O '\\ CO) ji-C-2-1 Revision 3 July 1979

SGRR C-3 PALISADES PLANT SGRR C-3 Provide a diagram showing the radiation surveys around the steam generator replacement / repair activities. Include similar radiation surveys for Figures 4.2-4 through 4.2-7. Include a table showing the whole body dose received during the inspection and plugging of the degraded steam generator tubes for 1976, 1977, and 1978.

RESPONSE

1. Figures 4.3-3, 4.3-4, and 4.3-5, which are included in the Steam Generator Repair Report, show radiation surveys around the steam generators at various times after shutdown. The fields specified are representative of those expected for the replacement repair activities. It should be noted that the fields specified in Figure 4.3-5 are expected to decrease significantly at the time that pipe cutting begins, considered to be 42-140 days post-shutdown for study purposes. The decrease will follow the general radiation field near the steam generator piping shown in Figure 4.3-7. Figures 3: 2-4 through 4.2-7 have been modified to include general treld information in areas where replacement / repair activities will occur and are now designated as Figures C-3-1 through C-3-4. 2. As requested, Tables C-3-1 and C-3-2 show the whole body dose received for inspection and plugging steam generator tubes during 1976 and 1978, respectively. TABLE C-3-1 PALISADES PLANT - RADIATION DOSE

SUMMARY

STEAM GENERATOR WORK 1976 Activity 1976 Exposure 1. ECT Personnel Inside steam generator (without shielding) 16.5R Outside steam generator 19.3R Total (received over a period of 21 days) 35.8R 2. Insert and remove shielding Inside steam generator 17.8R Outside steam generator 2.0R Total 19.8R 3. Insert templates Inside steam generator 25.3R Outside steam generator 2.8R total 28.lR 4. Brushing and rolling Inside steam generator 37.6R Outside steam generator 4.3R Total 41.9R S \\r \\ C-3-1 Revision 3 eo, July 1979 s v\\ l '

SGRR C-3-2 PALISADES PLANT SGRR Activity 1976 Exposure 5. Insert plugs Inside steam generator 28.8R Outside steam generator 2.9R Total 31.7R 6. Weld plugs Inside steam generator 54.4R Outside steam generator 15.3R Total 69.7R 7. QC inspection of above operation Inside steam generator 23.6R Outside steam generator 1.6R Total 25.2R 8. Engineers support of above operations 10.7R Exposure accumulated inside steam generator 204.0R Exposure accumulated outside steam generator 48.2R TOTAL ACCUMULATED EXPOSURE 262.9R NOTE: The exposure designated inside and outside steam generator are only estimates (although the total for each operation is accurate), since inside steam generator data is extracted from high radiation dose summary sheets which also include some outside steam generator work. The net result is that the inside steam generator data reads slightly higher and the outside steam generator data reads slightly lower than actually occurred. Radiation exposure to engineers is not included in this breakdown. TABLE C-3-2 PALISADES PLANT - RADIATION DOSE

SUMMARY

STEAM GENERATOR WORK 1978

• 1978 Exposure Organization / Activity (Level 9 R/hr 3.5 R/hr) 1.

Consumers Power Company Repairmen a. Manway cover removal / vacuuming 5.6 b. Dam installation 45.0 c. Surge line shielding + miscellaneous 5.5 d. Flooring /RSS hot legs 8.5 e. Flooring, struts, tracks, bridge , r "{ A cold leg 14.3 s B cold leg 22.5,p C, '., 1 - C-3-2 Revision 3 July 1979

SGRR C-3-3 PALISADFS PLANT SGRR Activity

• 1978 Exposure f.

Tracks, bridge A hot leg 6.1 B hot leg 6.3 g. General maintenance 1.9 h. Tube plugging A cold leg 3.1 A hot leg 1.6 B cold leg 3.9 B hot leg 1.8 i. Equipment removalflegcleanup 6.8 j. Dam removal 4.6 k. Manway cover replacement 4.9 1. Cont cleanup 2.6 145.0 2. HP coverage 6.0 3. NDT lab / contractors 44.3 4. CE - Setup 2.4 Deplugging A cold leg 7.4 A hot leg 4.3 Sleeving 14.9 29.0 Total exposure

• 224.3 Man-rem NOTE:
• These exposures are based on dosimeters and TLDs.

Source is containment entry logs. These numbers should only be considered close approximations. D \\/j s C',c n C-3-3 Revision 3 July 1979

I<t 57M. 6EN E-50 A ~ (E5Q-8 /S TYR 8 UT CPPOSITE General Field l /-/ANO) 20-30 mr.!hr .- \\ CUT PC/NT ,/ l\\ CUT PC/NT 4 g ",c' p,p,y c, ( 'l NEAR SIDE $ \\ i FAR SIDE 35 arf nr ) General Field 35 mr/hr 3 0 /. O. P / 8 //V 6 T/ eneral Field f NEAR S/DE $ 2 ~ )/ FA R S/DE CU T POINT h NEARS /DE $ FA RS/DE EL EVA TION PALISADES PLANT STEAM GENERATOR REPAIR REPORT PRIMARY COOLANT PIPING CUT POINTS Figure C-3-1 Revision 3 ,3 July 1979 A s \\' (,0, J

FU TL;R E L OC A TICN - N ') I i .'._e r-5 N < _) # Cil I/ PRES E.'. ~ 4 CCA T,'1 V -! ~ - Cencral Field t m f , _ -C/N _ _ 5-10 mr/hr x .v (') Ca? =0!N 7 ui* / ~4D / I f 3 6 " MAIN STEAV l , h. v i: in D Z 37M SE, / ' E-SOA lE-50s /3 TrA 2& " CPPOSITE HAND) EL E VA TION PALISADES PLANT STEAM GENERATOR REPAIR REPORT MAIN STEAM PIPING CUT POINTS Figure C-3-2 Revision 3 N ;3 f' July 1979 s. ( j '; )

5 STkt. GEN. E-50 A T (E-50 8 /S TYR BUT OPPOSITE \\ HAND) General Field f. 5-10 mr/hr CUT POINT i i xl y.- T i - Cl.) T PC/Nl~ / I i 1 /8" }~EEDWATER P/AN PAL?SADES PLANT STEAM GENERATOR REPAlR REPORT FEEDWATER PIPING CUT POINTS Figure C-3-3 Revision 3 f July 1979 3 ', O i , r'.

General Field fCU T POIN T 5-10 mr/hr ~ 2 SURFACE ,gBlQWDOWN LINE General Field 5-10 mr/ hr [ S TAV gin i SQA EL E VA 7/0 N STM GEN E-SO B /S TYR, B UT OPPOSITE HANC C u T PC/N T 2 " EOT TOM y g*

8. CWD 0 wW L INE 35 mr/hr General Field with Manways Covered I

l ?- *7 EL EVA TION ,- :. c \\,j 9C TA T[3 30 ' CL C C/ w/SE O "' PALISADES PLANT STEAM GENERATO9 REPAIR REPORT BLOWDOWN PIPING CUT POINTS Figure C-3-4 Revision 3 July 1979

SGRR C-4 PALISADES PLANT SGRR C-4 Discuss briefly how you would avoid imbalance of the permanent ventilation systems due to the additional construction -related ventilation equipment (portable fans, hoods and filters, etc).

RESPONSE

Additional construction - related ventilation equipment will be used to supplement the permanent ventilation system and will remove fumes associated with welding and cutting operation as well as ventilating temporary enclosures. Significant imbalance of the permanent ventilation system is not expected since the construction related ventilation equipment will exhaust inside the containment after filtration, and/or have relatively low flowrate. However, should imbalance of the permanent ventilation system occur, balance can be restored by controlling the dampers on the permanent ventilation system. i C-4-1 Revision 3 July 1979

SGRR C-5 PALISADES PLANT SGRR C-5 Your description of compliance with Regulatory Guide 8.8, "Information Relevant to Ensuring that Occupational Ex-posure at Nuclear Power Stations Will Be As Low As Reasonably Achievable", Revision 3, June 1978, states that the follow-ing considerations were not implemented: 1. Radiation zones in the containment work areas, identifying the exposure levels in each work zone. C.2.(a) 2. Streaming or scattering of radiatior. from installed shielding, such as plugs in open er.ded pipe lines following cutting. C.2.b.(4) 3. Outleakage of airborne contamination from the contain-ment due to steam generator replacement / repair activities when the equipment hatch is open. 4. Cperating experiences should be recorded, evaluated, and reflected in the selection of replacement instrumen-tation. C.2.(c)(3) 5. Provision to be implemented to minimize exposure of station personnel in performing code inspection, such as removable insulation, smooth welds, etc. (C.2.(i)(11) 6. An adequate emergency lighting system can reduce potential exposures of station personnel by permitting prompt egress from high radiation areas if the station lighting system fails. 7. A staff member who is a specialist in radiation protection assigned the responsibility for contributing to and coor-dinating ALARA efforts in support of operation that could result in substantial individual and collective dose levels. 8. ... Station work c.reas to limit the average concentration of radioactive material in air to levels below... in Appendix B, Table 1, Column of 10 CFR Part 20. C.2.d Provide justification for not implementing these provisions of Regulatory Guide 8.8, and demonstrate that alternative precautions you have taken will provide comparable levels of protection. I, ',' h ,] s C-5-1 Revision 3 July 1979

SGRR C-5-2 PALISADES PLANT SGRR

RESPONSE

The philosophy of the radiation protection group is to maintain the occupational dose to all personnel as low as is reasonably achievable (ALARA). This has been stated as a policy in the Palisades Plant Radiation Protection Manual. In order to ensure that the various provisions of Regulatory Guide 3.8 are evaluated adequately, a third party ALARA review of the repair effort has been utilized. The reviewers' responsibilities are to develop ALARA " checklists" to be used in conjunction with the work pack-age descriptions for each of the repair tasks. The "cnecklists" will evaluate and recommend any measure found appropriate to maintaining the personnel exposure ALARA as defined in Regulatory Guide 8.8 (Revision 3). Although the detailed work packages are presently in the develop-ment stage, each of the following specific provisions will neces-sarily be given complete consideration for use during any re-placement / repair activity: 1. The identification of exposure levels in any work zone is presently implemented per Palisades Plant health phyLics procedures. The Repair Report Section 4.3.5.4 describes the low background radiation waiting areas that will be used near each containment work area. As specified, special signs, tape, or rope-off areas will be utilized to designate these zones. Inter-mediate zones could be utilized, if found ALARA, as individual work packages are developed. 2. The effective streaming or scattering of radiation from installed shielding, such as plugs in open ended pipe lines, can be minimized through the use of local decontaminating of pipe stubs, use of temporary shielding, or exposure control by controlling ingress or egress to work areas. (See Repair Report Sections 4.3.5.2 and 4.3.5.3). All of these ALARA techniques are being evaluated for use with the individual work packages per third party ALARA review described above. ] { r; v C-5-2 Revision 3 July 1979

SGRR C-5-3 PALISADES PLANT SGRR 3. In addition to the temporary enclosure on the construc-tion opening, airborne radioactivity inside containment during the steam generator repair effort will be con-trolled, monitored, and ultimately released via the plant vent stack. The air will be drawn through the hatches and construction opening and exhausted by the purge system via the plant ventilation stack, thus precluding airborne radioactive particles or gases from leaving containment openings utilized for construc-tion activities. (See Repair Report Section 4. 3. 3). 4. Continuous air monitors, area radiation monitors, and portable survey instruments will be used in ac-cordance with Palisades Plant health physics procedures. Daily and weekly operational checks, calibration, and response settings will be implemented and recorded as required per Palisades Plant health physics procedures. 5. Appropriate provisions will be implemented to minimize exposure of station personnel in performing code in-spection, such as removable insulation, smooth welds, etc. Design features to improve maintenance and in-spection are discussed in the Repair Report Section 2.2.2. 6. An emergency lighting system will be available for the steam generator replacement activities. 7. A staff member who is a specialist in radiation protection will be assigned to the responsibility for coordinating ALARA efforts. 8. Special measures will be implemented to minimize and control the average concentration of radioactive material in air to below those specified in Appendix B, Table 1, Column 1 of 10 CFR Part 29. In addition to temporary enclosures in areas where cutting will occur, containment air will be conditioned for the removal of airborne radioactivity by use of filters. C-5-3 Revision 3 July 1979

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SGRR C-6 PALISADES PLANT SGRR C-6 Explain what steps you plan to take to help main-tain doses ALARA in this project. Indicate what use will be made of contaminations tents, lead wool blankets, gloveboxes, remote cutting and welding equipment, temporary shielding and venti-lation systems. Also indicate what equipment will be mocked-up for training purposes.

RESPONSE

An independent ALARA review of the steam generator repair effort has been utilized to make recommendations for maintaining doses ALARA (see question C-5). The ALARA recommendations made will be incorporated into the various work packages. Each of the following items will be used where appropriate to maintaining doses ALARA. 1. Contamination Tents - The cutting of primary coolant piping will be contained within specially designed contamination control envelopes. The envelopes will be provided with high efficiency filtration. 2. Temporary shielding in the form of; lead wool blankets, lead shield plugs and sheet lead will be used where effective to maintaining doses ALARA. Experience has shown that lead wool blankets can effectively reduce streaming around shield plug and sheet lead fittings. 3. Gloveboxes - As yet, there are no repair / replace-ment activities described, which can effectively use glovebox enclosures for maintaining doses ALARA. As work procedures develop, glovebox techniques will remain a viable option. 4. Remote cutting and welding equipment - Automatic welding machines with remote viewing will be used for welding operations made to interior located stainless steel cladding. Measuring equipment for determining the location of reactor vessel and steam generator during weld-up and cutting opera-tions will utilize remote indicators. Although the cutting techniques have not been finalized, the ALARA considerations will be one of the determining factors for final selection. _ng 'l} LGL C-6-1 Revision 3 July 1979

SGRR C-6-2 PALISAGES PLANT SGRR 5. Ventilation Systems - Local construction related ventilation equipment will be used to supplement the permanent ventilation system and will remove fumes associated with welding and cutting operation as well as controlling the airborne contamination existing in the temporary enclusures. 6. Mock-tips of reactor coolant pipe, and the steam generator primary head as well as the actual cutting and welding equipment will be utilized for training and work planning. n 'l e 3

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C-6-2 Revision 3 July 1979

SGRR C-7 PALISADES FLANT SGRR C-7 Provide a table Jhowing the occupational col-lective whole body dose estimates for the fol-lowing ;hases of the steam generator replacement repair acitivities: (1) preparation, (2) removal, (3) installation and (4) storage. Discuss briefly your procedure for calculating these doses, taking into account the dose reduc-tion measures proposed to maintain doses as low as reasonably achievable (ALARA), including local decontamination, temporary lead shielding, pre-job planning, pre-job training and use of remote tools where practicable.

RESPONSE

Table C-7-1 provides the requested information. The table groups the various tasks into preparation, removal, installation, and storage phases of the replacement / repair effort. The man-rem i.3 the product of (man-hours) X (average radiation field) for ;ach task. It should be noted that each task consists of man-hours accumulated in several locations, and each location has a corresponding radiation field. A description of locations and average radiation fields is presented in Table C-1-5, credit taken for decon-tamination and temporary shielding is incorporated into the radiation field estimates. Reduction factors for shielding and/or decontamination are presented in the repair report, Table 4.3.2. C-7-1 Revision 3 July 1979 n y\\ c{,)

l'Al l S A105 l'1ANI' StRR I Alit t C 1 f1AN-kitt ESTlHATE (l'r ep.a r a t i on, I ns t.e l l.it ion, Re.moval, an.1 Storage) .In, tall.etion. S t o s. ige- 'l a tik No. Ptils ttin-Rem Tasi,,___ _ Howevat . tb. tills Hin-Rem Task No. tills it sn - kcas l'a i i..e r.a t i on No. Hits Han-th m Tasti i 1,5/H J.12 1 1,416 ll. !t. 2 1,991 2.90 46 6/O II.4 1 4, 181 11.58 Il 15 1/. l6 5 4,17h 111.69 55 4,0h0 0.01 64 140 1.60 15 110 16.51 6 1, 16 0 69.H5 15 /I,500 0.II 16 114 1 9. 68 7 6.00H 12.I) ll l l, t.o h U 06 19 1,0lb 10./1 8 64H 2.HH 11 H,10 4 0.01 21 l15 1.0/ 9 H,//4 44.HH 19 1,'00 0.01 21 4/6 912 to 1, l H '. 5.28 40 1,500 0.01 /4 5// 1,91 ll 1,09h 19.0H 41 /44 0.01 26 240 4.05 11 1,9'4 51.44 41 9 th 0.01 11 JOO 1.00 14 11 .42 550 8. t.H 17 96 .78 41 9 th 0.01 il^ 1, lho 5/.95 18 INO l.51 44 5,h15 11,62 45 4/ 100 0.01 56 H0 . I '. 10 4,H00 9.60 48 1,160 0.01 57 4H 14 11 269 1.(N) 49 4HO O.01 5H 110

1. H) 22 4,761 14.21 59 4H

.19 23 $/0 1.16 (1) (l) 165.2H 60 lHO l.01 24 1,5f9 1.13 25 2t 0 16.18 26 560

5. 17 27 100 1.25 28 lH 1

.80 29 1,414 85.00 30 1,H5H H.67 12 2,400 10.R ll I,l l6 I.ll 14 l 'lO 2.6 16 19,ils 0.09 50 1,670 10.12 p 51 1, l / 5 01 3 - I. 52 l,150 11.11 L $1 945 0.01 5 '. 159 0.01 61 1 O O.81 3 62 f.00 4.05 -', 7 6) 1,440 1.24 64 4HO l.08 V 65 1,910 4. 12 Nul.t ot a l 6/.491 199.66 9,lHS 154.4l H9,9HL) 454.09 4, t.H O 11.4/ t.6 2 5,115 H 15.H7 66_ 1,584 4. e. / _ 66 10,116 _ 6 0.91. 'l o t a l Ill r et ta M /, i' 9 1/5.4H 10, /h s 58.10 l l o, l ut, Sl' 4, #.H O 11.41 i Dist thotables 61 22,591 124 2,1/9 15.7H 2H,416 156.3 1,108

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/ }. H 6 ___ _. . _ 6, 36. H.91 61,600 _ 9 2. _l }. /,h is I fi I e l'o t.s l 159.441 4 / l. 14 19,612 182.46 100~,512 161. f.6 H,5/1 11.01 (I) liri mt.un i n.a t l on / Sh i e l.l l nr. I ns t ia l l a t l on

SGRR C-8 PALISADES PLANT SGER C-8 Discuss your cutting and welding operations and cleanup of surface contamination in respect to "ALARA" guide-lines (Section 4. 3. 3).

RESPONSE

We note that a definite schedule has not been set for the cutting and welding, that experience is being gained by way of similar operations at other plants, and that detailed work plans have not been completed. The final operations will reflect applicable experience, and ALARA consider-ations. The following is an outline of operations under consideration at this time. 1. Cutting of Reactor Coolant Pipe Since the Palisades reactor coolant pipe is carbon steel w/ stainless steel cladding, a plan is to utilize a track mounted oxygen-acetylene torch to cut the pipe. Consideration is also being given to mechanically cutting the pipe in order to minimize the pipe lost during the cutting process and to facilitate the machining operation. The cutting operation will be accomplished in an enclosure to limit spread of contamination. 2. Handling of Pipe to Decontamination Area After the pipe has been cut, temporary shield plugs will be secured to each open end of the reactor coolant pipe and the short pieces of pipe moved to a decontami-nation area. The temporary shield plugs will be mechanically attached to' the pipe in order to reduce the number of welding and cutting operations. 3. Field Machining of the RC Pipe Attached to Reactor and Reactor Coolant Pumps Temporary shield plugs will be inserted a short distance into the pipe. The pipe between the shield plug and the end of the pipe will then be decontaminated to the extent practical. The pipe weld preparations would then be field machined. C-8-1 Revision 3 July 1979 _v r]e/ J

SGRR C-8-2 PALISADES PLANT SGRR 4. Field Machining of the Short Pieces of Reactor Coolant Pipe Af ter the new steam generator has been placed, the dimensions between the existing reactor coolant pipe and the new steam generator nozzles will be transferred to the short pieces of reactor coolant pipe and the pipe weld preparations machined. 5. Welding of RC Pipe After set-up of the reactor coolant pipe the joints may be welded by one of the following methods: 1. Manually weld the carbon steel portion of the reactor coolant pipe and utilize an automatic welding machine with remote viewing for welding _ the stainless steel interior cladding. 2. Utilize an automatic welding m:. chine with remote viewing to weld both the carbon steel and stain-less steel interior cladding. 6. Clean-up of Surface Contamination Loose surface contamination will be removed manually from the outside of reactor coolant pipe pieces, prior to cutting operations and again, prior to removal from contamination control envelopes. Plastic or other impervious sheeting will be used to cover pipe pieces before relocating to decontamination area. C-8-2 Revision 3 July 1979 ra:-

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SGRR C-9 PALISADES PLANT SGRR C-9 Your estimated dose renge of 1,200 to 5,000 man-rem for the steam generator replacement / repair activities is too wide to assure that occupational exposure will be as low as reasonably practicable. Justify the high end of the range as being ALARA. Experiences with other designs indicate the feasibility of performing such work with substantially lower total doses than the high end of range you have predicted.

RESPONSE

As presented in the task description (Question C-1), there are two welding techniques being considered for reactor coolant pipinc. One technique utilizes manual welding of reactor coolant carbon steel pipe with a machine weld-up of the stainless steel cladding. This technique would result in an estimated 1,547-2",808 man-rem for the repair. The second technique utilizes a machine weld-up of both carbon steel pipe and stainless steel cladding. This alternative results in an estimated 1,537-2,663 man-rem for the repair effort. The high end of the range presented in Table 4.3.2, 5,000 man-rem, resulted from a manual weld-up of carbon steel pipe and cladding entirely from the inside. Due to the technical feasibility of the two welding techniques described above, this third alt-ernative is no longer con-sidered ALARA and has since been eliminated. C-9-1 Revision 3 July 1979 .r c3;,

SGRR C-10 PALISADES PLANT SGRR C-10 Provide a rough breakdown of the activities, person-hour occupancies, and projected dose rates which are used in deriving the esti-mated total of 40,250 man-rems per unit for retubing in place (Section 8.7).

RESPONSE

Refer to Appendix A of the SGRR response to Question A-2, as transmitted to the USNRC by the Consumer Power Company letter dated June 11, 1979. That analysis is currently under reevaluation. c'] n L" ,I C-10-1 Revision 3 July 1979}}