ML20014E610
| ML20014E610 | |
| Person / Time | |
|---|---|
| Issue date: | 01/14/2020 |
| From: | Oleary J Office of Nuclear Regulatory Research, Next Composite Solutions |
| To: | |
| Nove, Carol | |
| References | |
| Download: ML20014E610 (15) | |
Text
NRC Presentation CFRP In Safety Related Piping Systems Alternative Approaches in Design, Materials and Implementation Presented by John OLeary Next Composite Solutions, Inc 115 Second Ave, Edwardsvile, IL 618.692.1905 www.nextcomposites.com
NRC Presentation
Introductions
- John OLeary - President Next Composites
- Next Composite Solutions
Problem Solving Focus Commodity Solutions Product Driven Minimal Difficulty Increasing Difficulty Complex Problems Solution Driven N
E X
T When standard solutions arent feasible 3 quick examples to illustrate this focus NRC Presentation
Major internal Corrosion High Temp (450 to 500 F)
Large Diameter (84D)
Elevated 80 above haul route
- 1 - Hot gas Duct Repair NRC Presentation Extensive engineering & testing Avoided shutdown and lost revenue Lowered installation costs No increase in structural supports CFRP External wrap Extensive corrosion
Badly corroded warm water discharge pipe -
48 to 66 diameter Usually fully immersed in the river Large gaps in the pipe Discharge Pipe gap!
- 2 - River Headworks Pipe Replacement CFRP External wrap NRC Presentation Gap Fixed with Carbon Fiber Pipe Project was capitalized!
(Existing pipe was abandoned in-place)
Much Shorter schedule (2 months vs 2 years)
Gap fixed with Carbon Fiber Pipe CFRP Replacement Pipe Installed Full replacement Engineered CFRP system
Example #3 - Nuclear Plant Condensate Pipe Repair 36 pipe, 50 LF High temp - 370 F High pressure - 670 psi with 770 psi transient Thin-wall discovered during outage UT Testing - min wall identified A full design package completed in accelerated timeframe Over 50 of degraded pipe (thin-wall) repaired Full certification achieved under PCC 2 following installation under to convert from temporary to permanent Completed in 6 days (within outage schedule)
NRC Presentation High Temp CFRP System Developed
Nuclear Power Specific Innovative, Solution Driven Projects NRC Presentation
Seismic Upgrade of Block walls Our CFRP Team - Single Source for engineering and installation Seismic audit identified block wall upgrades needed CFRP solution permitted minimal construction impacts Obstruction Mitigation Locations of Carbon Fiber Strips Width of Carbon Fiber Strips Structural Connection Details Nuclear Power Station NRC Presentation Carbon Fiber reinforcement Result: Cost effective Seismic Compliant structures using CFRP methods and materials
Damaged large reinforced concrete Girders Significant deterioration due to exposure to run-off from heat exchangers on the floor above.
After removal of bad concrete Unit 2 Unit 1 Turbine Building Girder Repair NRC Presentation Nuclear Power Station Unit 1 - after removal of damaged concrete Addressed limited access Met extreme loading requirements Offered significantly lower costs Minimized impact on plant operations Fire protection provided Rebuild with special high strength Grouts and CFRP
CW Pipe - 24 Diameter Previously repaired leak near flange. We were requested to provide a CFRP repair alternative.
Unable to move replacement spool into repair area.
Cooling Water Piping Repair NRC Presentation Nuclear Power Station Provided EC & CRFP Calculations Removed previous repair and prepared surface Repaired pipe with CFRP per engineering drawings Inspected and tested final repair CFRP Design, Full EC Package and Implementation Completed in 14 days
Corrosion threatening structural foundations Very limited access Damage approx. 3+ into sump wall No option to completely drain and stop inflows Turbine Room Sump Repair NRC Presentation Nuclear Power Station Required extensive testing program to prove material properties and solution viability Installed coffer dam to isolate repair Preformed soundings to remove bad concrete Replaced damaged piping Repaired with specialized Grouts Added CFRP to repaired sump wall surface
NRC Presentation Identifying root causes Listening to plant concerns Avoiding material or system bias The Lincoln Effect (competing ideas within the team)
Each solution vetted across all relevant disciplines Assembling a Solution Driven Team For buried pipe:
Replacement options Repair options Alternative materials &
technologies Next Composites Team Kinectrics AES - Nuclear Engineering KL Structures - Composites Experts SAK - Tunneling & Lining Experts Fyfe - Composite Materials DZ - General Construction/Logistics/Support Audubon - Corrosion Science Experts
NRC Presentation Team has been involved in nuclear buried pipe work since 2003 Completed studies and white papers for SR piping options including CFRP beginning in 2010 Expanded team to provide wider array of solutions to meet SR requirements Developed collaborative approach to developing test plans for alternative solutions with in house 400,000 sf laboratory Each alternative passes multi-discipline crucible before presentation to Owner Ultimately no single solution to SR pipe repair replacement Buried Pipe - A Fresh Look
NRC Presentation Some concerns:
One size fits all approach Limited temperature and size range Pushes entire industry to single product Cannot address enormous quantities of smaller diameter pipe Functionally limited to 30 & up Service Water Systems Requires full replacement value design. With newer UT technology full replacement is not always required Extremely high barriers to entry limits competition and drives up cost Pre & post testing often does not represent field installation Eliminates innovation as material and testing capabilities continue to expand CFRP SR Code Case
NRC Presentation CFRP is an effective tool to address SR systems but has limits Approach to restoring nuclear infrastructure needs to be solution based to keep industry economically viable Broader view focused on all disciplines produces better results Team approach widens solutions and eliminates false starts Conclusion For an example of how the team approach works, we invite you to our joint presentation at the EPRI BPIG Meeting February 17-20 which will include:
Joint presentation between Next/Kinectrics team and Major Projects Group at an active plant Multi-discipline review, analysis and recommendations for Buried SR Piping System Materials analysis, testing plans and FOAK technologies for addressing aging SR Piping