ML20198S568

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Partially Deleted Rev 6 to Edcr 93-303, Reactor Vessel Internals Segmentation Component Removal Program 1993
ML20198S568
Person / Time
Site: Yankee Rowe
Issue date: 08/02/1993
From:
YANKEE ATOMIC ELECTRIC CO.
To:
Shared Package
ML20198S170 List:
References
FOIA-98-175 93-303, 93-303-R06, 93-303-R6, NUDOCS 9901110363
Download: ML20198S568 (52)
v • d • e


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-g ENGINEERING DESIGN CHANGE REQUEST EDCR NO.:

93-303 NUCLEAR SERVICES DIVISION PLANT:

YNPS YANKEE ATOMIC ELECTRIC COMPANY W.O.:

9571 EDCR TITLE:

REACTOR VESSEL INTERNALS SEGMENTATION COMPONENT REMOVAL PROGRAM 1993 I

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l@!Hjgi duut/41 M w 7/r7/93 LEADENGINEk DATE AND REVIEW

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F[i/93 ENGINEERING ER DATE A

2A, 41 COMPONENT REMOVAL MANAGER DATE k

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CTMANAGkR DATE 99p]11g3981217 BLOCK 98-175 PDR R79\\31 990lll0.$VS salp

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Page 2 of 52 EDCR 93-303 g

L REACTOR INTERNALS SEGMENTATION 1.0

  • EXECUTIVE

SUMMARY

On February 26, 1992, YNPS permanently ceased power operations and YAEC

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initiated decommissioning planning and other plant closure activities.

The I

Decommissioning Plan for the facility is currently scheduled for submittal to the Nuclear Regulatory Commission by October 1993.

i Beginning in October 1992, YAEC began evaluating the feasibility of l

removing and disposing the plant's steam generators, the pressurizer, and the reactor vessel internal components.

This evaluation was prompted y

i primarily by the extension of access to the Barnwell Low-Level Radioactive l-Waste Facility through June 1994, and included significant interaction with the NRC.

As a result of this interaction and lessons learned from the Shoreham Decommissioning experience, the NRC provided guidelines and clarification on the nature and extent of activities that can be accomplished prior to NRC approval of the Decommissioning Plan (Reference (1)).

In addition, access to the decommissioning fund to pay for these activities was granted (Reference (2)).

The NRC has approved the use of the 10CFR50.59 process in Reference (37) for the CRP activities.

g This EDCR covers the removal, packaging, and transporting off-site of the reactor internals and thermal shield from the reactor vessel, as well as the site preparations necessary for internals segmentation.

Yankee Atomic Electric Company (YAEC) shall provide overall supervision and coordination for all tasks of the Component Removal Program (CRP) and shall be responsible for the following tasks specific to the internals segmentation program:

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I Storage of internal components unsuitable for Low Level Waste (LLW) disposal will be covered by EDCR 93-304.

Shield tank cavity preparation prior to internals segmentation is covered by EDCR 93 305.

Removal, transportation, and disposal of the four steam generators and pressurizer is covered by EDCR 93-302.

The work for this EOCR will be performed in accordance with the established engineering design change request procedures (WE-100), project procedure (YPP-006), and all applicable plant procedures.

Overall project management for the work is presented in the " Component Removal Project Management Plan t

(CRP)," Reference (3).

A milestone schedule for the work is presented in Section 5.3 herein.

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The safety evaluation, contained in Enclosure (A), addresses all aspects of i

the above component removals and shipment as they relate to:

(3) potential 4

impact on Yankee Plant safety-related systems, structures, and components:

and (2) environmental impacts, i

A breakdown of estimated costs associated with this EDCR for removal and disposal of the reactor internals is contained in Section 10 of the CRP Management Plan.

The cost control process, as addressed in this plan, will be followed to track expenditures and scope changes.

Based on this review, the segmentation and removal activities described in this EDCR do not result in an unreviewed safety question and, therefore, may be performed under the provisions of 10CFR50.59.

In addition, they will be conducted in conformance with the criteria and guidance provided by the NRC regarding activities prior to NRC approval of the decommissioning plan for the Yankee Nuclear Power Station.

NRC review of this EDCR is anticipated.

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l EDCR 93-303 i

i Page 5 of 52 2.0 TABLE OF CONTENTS

. [1 Pace 1.0 EXECUTIVE

SUMMARY

1,

2 l

2.0 TABLE OF CONTENTS..

5 1

'8 3.0, DESIGN CRITERIA.

9 3.1 Quality Assurance 9

i 3.2 Technical 12

4.0 DESCRIPTION

OF CHANGE...

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4.1 Background

13 4.2 Scope and Intent 14 EP

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5.0 RESOURCES.

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l 5.1 Organizations Responsible for the Detailed Design 49 i

5.2 Cost Management 51 5.3 Schedule 51 6.0 OPEN ITEMS 52 TABLE OF ABBREVIATIONS AND ACRONYMS USED IN EDCR 93-303.

6 ENCLOSURES i

l (A)

SAFETY EVALUATION l

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(B)

LICENSING AND CONTROLLED DOCUMENTS AFFECTED r

(C)

CALCULATIONS f

(D)

PROCEDURES (E)

EQUIPMENT PROCUREMENT INFORMATION 1

E.1 PCI Equipment Deliverables E.2 Electrical Modifications - Bill of Materials E.3 CNSI Equipment Deliverables (F)

DRAWINGS / SKETCHES / TABLES f

(G)

REFERENCES (N>

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EOCR 93-303 Page 6 of 52 TABLE OF ABBREVIATIONS AND ACRONYMS USED IN EDCR 93-303 l

A Amps j

AC

. Alternating Current 3

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As low As-Reasonably Achievable ANSI Amer.ican National Standards' Institute ARM lg ;

Area Radiation Monitor J.,

. AVL Approved Vendors List

- BKR.

Breaker '(circuit)

C.

Centigrade temperature CAD ~

_ Computer-Aided Drafting CE' Cognizant Engineer i

lCFH_

Cubic Feet per-Hour

.CFM Cubic' Feet per-Minute

.CFR.

Code of Federal Regulations

-_ C i Curie-CNC Computer Numerically Controlled CNSI.CNS Chem Nuclear Services, Inc.

CRD Control Rod Drive 1

CRP Component Removal Program CY Connecticut Yankee s

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ECN-Engineering Change Notification

~EDCR' Engineering Design Change Request

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. EPA Environmental. Protection' Agency J'

.ER Environmental Report i

B F

Fahrenheit Tempr,ature FERC

' Federal Energy Regulatory Commission

FSAR-Final: Safety Analysis Report FTCC Fuel Transfer Control Console GEIS Generic.Eny'ironmental Impact Statement-

'GTCC-Greater Than Class C HEP 1 High Efficiency Particulate Air (filter).

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. HIC High Integrity Container HRP.

High Radiation Package l

a Inc

~ Incorporated KVA Kilo (1000) Volts Amps l

KW.

Kilo (1000) Watts b

LCSA-Lower Core Support Assembly LLRW Low Level Radioactive Waste h-

~LLW

-Low Level Waste

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EDCR 93-303 Page 7 of 52 TABLE OF ABBREVIATIONS AND ACRONYMS g

USED IN EDCR 93-303 p

(Continued)

MCB Main Control Board 1

MCP Main Coolant Pump MD Maintenance Department MDM Magnetic Discharge Machining I

ml Milliliter MPC Maximum Permissible Concentration MR Material Request NNS Non-Nuclear Safety NPDES National Pollution Discharge Elimination System NRC Nuclear Regulatory Commission 1

NSSS Nuclear Steam Supply System NST Neutron Shield Tank I

O&M Operations and Maintenance ODCM Off-Site Dose Calculation Manual

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PAS Primary Auxiliary Building PAG Protective Action Guidelines PCI PCI Energy Services Inc.

Plasma Cutting Table

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PCT POL I

Possession Only License PORC Plant Operations Review Committee PPM Parts Per Million PVS Primary Vent Stack i

PWR Pressurized Water Reactor 0A Quality Assurance i

R/HR Rems per Hour RP Radiation Protection i

RSS Reactor Support Structure SFP Spent Fuel Ptol SRM Staff Requirements Memorandum SSC Systems Structures, and Components STC Shield Tank Cavity f

STCMC Shield Tank Cavity M5nipulator Crane TBCC Tool Boom Control Console

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TCR Temporary Change Request TLG TLG, Inc.

USMC United Shoe Machinery Corporation V

Volts VC Vapor Cont:iner A79\\31 i

n EDCR 93-303 Page 8 of 52 TABLE OF ABBREVIATIONS AND ACRONYMS j

USED IN EDCR 93 303 (Continued)

W Westinghouse, Inc.

WMG WMG, Incorporated H

YAEC Yankee Atomic Electric Company YOOAP Yankee Operational Quality Assurance Program j

YPP Yankee Project Procedure l

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EDCR 93-303 Page 9 of 52 3.0 DESIGN CRITERIA 3.1 Ouality Assurance 3.1.1 OA Procram Reauirementr.

The reactor vessel internals including the thermal shield are classif.ied Non-Nuclear Safety (NNS) per the Yankee Nuclear Power Station (YNPS) " Equipment Classification of Systems, Components, and Structures Guide,"

(Reference (4)).

To ensure proper control and quality

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for the component removal work, however, a specified a

level of Quality Assurance will be implemented.

The OA effort is detailed in the design, procurement, and implementation procedures of this EDCR 93-303. as well as the project specification (Reference (5)).

Packaging of radioactive waste for transport is

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controlled via the Yankee Ouality Assurance Program.

The following 0A Program attributes are the minimum requirements to be met during the implementation of work performed in.accordance with this EDCE.

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a.

Orcanization The project for the segmentation of the Yankee

.g reactor internals is the responsibility of the Yankee j

Atomic Electric Company.

Organizational interfaces and responsibilities are delineated for Yankee, PCI.

and Chem Nuclear in their respective project management plans (References (3). (16) and (23)).

b.

Desian Control

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J Controls shall be established for systems necessary for the segmentation.

Modifications to the Owner's f

control air and electric power systems necessary to L

support the segmentation process shall be implemented i

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under the Owner's existing design control process in accordance with approved procedures.

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l EDCR 93-303 Page 10 of 52 c.

Procurement Document Control Procurement of services for segmentation and changes thereto shall be controlled and shall address the follo6'ing as a minimum:

1.

Use of an approved contractor.

2.

Criteria for acceptance of secvices.

d.

Instructions. Procedures, and Drawinas Plant modifications, segmentation, packaging, and cask handling shall be accomplished utilizing procedures approved by the Owner.

This shall include special process procedures, as well as work control documents, that provide instructions accompanied with pertinent technical data to perform a specific task.

e.

Document Control J

i, The issuance of and changes to procedures, drawings, and specifications soall be accomplished in accordance with an approved document control program.

f.

Control of Purchased Material. Ecuipment. and Services The adequacy of the Contractor's Quality Assurance Plan has been verified prior to mobilization.

Both PC] and Chem Nuclear are on Yankee's Approved i

Vendor's List (AVL)..

The Contractor shall be capable of performing the specified tasks in accordance with the original Specification (Reference (5)).

g.

Identification and Control of Material. Parts and Components Measures shall be established by administrative or physic'l means to account for segmented materials and cut locations.

These controls shall be sufficient to provide traceability of dose profile data to a specific segment and to assure that segmented material can be easily identified for future shipment.

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l' All chemicals used on the job.shall be controlled in accordance with the Owner's Cnemical Control Program.

AP 0031.

h.

Control of Special Processes Special processes..such as welding and remote underwater cutting, shall be performed by trained and i

qualified personnel utilizing qualified procedures.

I Cutting procedure qualification shall be accomplished through mockup demonstration.

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0A Records rm,

Records shall be maintained, as a minimum, for the

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1.

Segmentation procedures.

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2.

Procurement documents.

3.

Surveillance, audit, and assessment records.

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Qualification records.

.5.

All radwaste packaging activities.

3.1.2 Plant Specific The following programmatic requirements apply to this design change:

Yankee Atomic Electric Company (YAEC) Engineering Manual Change No. 36 (January 29. 1993).

YAEC.0uality Assurance Manual (Y00AP-1-A), Ctsnge p

No. 31.

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-Yankee Project Procedures.

The following additional requirements are applicable to the equipment modifications required for this EDCR:

h YR EEG 51 Revision 2. " Power Cable, Control Cable, and Switchboard Wire," dated'May 7, 1987.

YAEC 1153, Revision 0, " Recommendation for Wire and i

Cable Installation and. Handling."

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Structural / mechanical / electrical /l&C modifications will be implemented in accordance with the requirements of R79\\31

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Section 4.0. herein, and the detailed implementation procedures contained in Enclosure (D) hereto.

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All contractors will work under their own OA plan, which I

has been reviewed and approved by Yankee, as it is apnlicable to each work activity, All Contractor work under this EDCR will be reviewed and approved by Yankee via YNSD and plant PORC review cycles before implementation.

3.2 Technical The technical design criteria for this modification meets or a

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exceeds the requirements of the Yankee plant.

The following

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standards or documents have been applied to this modification.

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4. 0*

DESCRIPTION OF CHANGE 4.1

,Backoround

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1 On February 26. 1992, the YNPS permanently ceased power operation.

I and YAEC initiated decommissioning planning and other plant I

closure activities.

YAEC's preliminary decommissioning plans included placing the plant in a safe storage condition until the year 2000, or until a suitable Low Level Radioactive Waste (LLRW)

I burial f agility with sufficient capacity for the estimated 95,000 ft of LLRW becomes available.

The Decommissioning Plan for the facility is currently scheduled for submittal to the Nuclear Regulatory Commission (NRC) by October of 1993.

Beginning in October 1992, YAEC began evaluating the feasibility of removing and disposing of the plant's steam generators, the l

pressurizer, and the reactor vessel inte nal components.

This evaluation was prompted, in part, by the 1992 extension of access to the Barnwell f acility for the period between January 1,1993

,1 and June 30, 1994 The scope of the project was determined based on a careful evaluation of several factors, including impact on future decommissioning activities, duration of burial facility access, and total project costs.

The feasibility evaluation process included significant interaction with the NRC to establish a basis for completing certain decommissioning activities prior to NRC approval of the decommissioning plan for the facility.

The NRC Commissioners issued guidance to the NRC staff on decommissioning activities in the form of a Staff Requirements Memorandum (SRM) on January 14. 1993, Reference (6). The guidance allows YAEC to proceed with the component removal project without approval of the facility Decommissioning Plan. The SRM includes clarificatio on the nature and extent of activities that can be accomplished prior to NRC approval of the Decommissioning Plan.

The SRM also addresses access to the decommissioning fund to pay for these activities.

YAEC performed comprehensive reviews to verify that all aspects of the Component Removal Project would be in compliance with the SRM guidance and all other applicable regulatory and plant licensing requirements.

These reviews were transmitted to the NRC via

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References (7), (8), and (9).

The NRC. in Reference (2), approved YAEC request to withdraw-f'unds from the decommissioning trust R79\\31 I

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EDCR 93 303 Page 14 of 52 fund, prior to NRC approval of the Decommissioning Plan, for the removal of the four steam generators, pressurizer, and reactor vessel internals.

By letter, dated July 15,1993~ (Reference 37), the NRC concluded that YAEC has addressed all of the SRM criteria, and the staff does not object to the proposed component' removal activities.

4.2 Scone and Intent This CDCR, 93 303, provides for the segmentation of all of the

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reactor internals including the thermal shield..

This EDCR also L

provides for the packaging and removal of those internal 10 components which can be disposed as low level waste (LLW) as defined in 10CFR61.

With the exception of Shield Tank Cavity (5TC) preparation, all design and preparation activities as well as on-site work associated with internals segmentation are within L

the scope of this EOCR, All design work will be performed in accordance with the established YAEC engineering design change y

request procedure (WE-100) and Yankee Project Procedure YPP-006 or L) the equivalent in the vendor's approved 0A program.

All on-site work shall be performed in accordance with plant or vendor j

procedures which'have'been either developed or modified appropriately, and have been reviewed and approved.

PCI, Inc. will be responsible for the segmentation of the internals. This responsibility entails development of a segmentation plan and procedures consistent with the packaging plan, development.of segmentation tooling and control of debris and off gas byproducts that result from the segmentation process, performance of the internals segmentation, and rigging and loading of the segmented pieces and associated debris (References (5) t and (10)).

l Chem-Nuclear Systems, Inc. (CNSI), in conjunction with their subcontractor WMG will be responsible for characterization of the

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internals, development of the packaging plan, and packaging, transport and disposal of the segmented components acceptable for LLW disposal (Reference (11)).

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5 Yankee Atomic Electric Company (YAEC), in addition to providing overall coordination to the Component Removal Program (CRP), will be responsible for site preparation and coordination and storage of components that are not suitable for LLW disposal.

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EDCR 93-303 Pege 15 of 52 STC preparation is covered separately under EDCR 93-305.

g Packaging and storage of internal segments not acceptable for LLW

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disposal will be covered under EDCR 93-304 i

4.3 Description of Reactor Internals Segmentation Work 4.3.1 I

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internals as being separated into nineteen separate t

subassemblies as follows:

Item Component 1

Control Rod Drive Shafts (24) 2 Core Holddown Spring f

3 Guide Tube Holddown Plate 4

Guide Tube Support Plate 5

Control Rod Guide Tubes (24) 6 Incore Instrumentation Assembly 7

Upper Core Support Barrel 8

Upper Core Support Plate l

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EDCR 93-303 Page 16 of 52 Item Component 9

Lower Core Support Barrel 10 Secondary Core Support (4) 11 Thermal Shield Clamp (4) 12 Thermal Shield 13 Core Baffle I

14 Core Barrel 15 Lower Core Support Plate 16 Core Radial Support Ig 17 Shroud Tube Top Plates (4)

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18 Shroud Tubes (24) i 19 Shroud Tube Lower Plate

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EDCR 93-303 Page 49 of 52 5.0 RESOURCES 5.1 Oraanizations Responsible for the Detailed Desian 5.1.1 1,mplementino Oroanizations - General The Yankee Component Removal Program will be implemented in accordance with all applicable Yankee Plant YNSD, and l

Yankee Project programs and procedures. The overall project management plan for the work is presented in Reference (3).

The Component Removal Project is a matrix organization comprised of personnel from the Yankee Project, the Yankee Plant, and other YNSD departments.

5 As part of the Component Remova'l Program. this EDCR 93 303 addresses the work package for all on-site work associated with segmentation and packaging of the reactor internals.

Refer to Section 4.0 for a detailed description of the change.

The YNSD cognizant engineers (C. Child /W. Jones) will l

maintain overall responsibility for design, procurement, and tencor/ contractor technical interface, f.1.2 Yankee Proiect (YNSD)

Mechanical Enaineerina This group is responsible for the overall coordination of this design change.

They will perform or supervise the performance of all detailed mechanical / structural evaluations required for this

EDCR, They will provide on-site support during implementation of this EDCR.

Svstems Enoineerina This group is responsible for establishing system design interfaces within the scope of the EDCR. They will review the systems implementation procedures.

and plant operating procedures.

Electrical and I&C Enaineerina This group is responsible for the electrical and 1&C modifications required for component removal.

A?9\\3;

EDCR 93-303 Page 50 of 52 5.1.3 PCI. Inc.

PCI will perform all the services necessary to:

a.

Develop a Segmentation Plan, b.

Fabricate and qualify segmentation tooling.

l c.

Train and qualify segmentation personnel.

d.

Perform segmentation.

e.

Filter shield tank cavity water.

f.

Provide debris control.

g.

Collect and process off gases.

l h.

Load liners and provide specialized rigging and support equipment.

i.

Provide an underwater camera system to assist in remote activities.

5.1.4 Chem Nuclear Systems. Inc, j

Chem Nuclear will perform all the services necessary to:

l y

a.

Characterize the reactor vessel internals.

I b.

Package, transport, and dispose of the reactor vessel l'

internals.

5.1.5 Yankee Plant Site Oroanization

'L Yankee Plant Coanizant Enaineer i

The Plant Cognizant Engineer. B. E. Smith, is responsible for the coordination of all work at the Yankee Plant required to implement thi'. design change.

This includes the preparation of plant installation and test procedures and review of l,.

contractor rigging plans.

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EDCR 93-303 Page 51 of 52 lI Maintenance Department (MD) l The plant MD is responsible for assisting with l

electrical interfaces, and the preparation, review.

l and approval of the implementation. procedures required by this EDCR unless specifically noted otherwise.

l The plant MD will perform removal of internals from the vessel in accordance with existing Yankee i

I procedures (Enclosure (D)), which will be modified to meet the segmentation internals storage requirements.

l l

The plant MD will install the explosive meter sampling arrangement discussed in Section 4.3.2.5, I

5.1.6 Plant Operations Plant Operations will prepare procedures and perform the required systems alignment to fill. maintain, and drain

]

down the cavity, as required by this EDCR in accordance j

with procedures identified in Enclosure (D).

I p

5.1.7 Radiation Protection

['

The plant staff, augmented by outside RP Contractor l'

personnel, will provide all required RP services for this EDCR.

Scope includes development of ALARA plans for the

[

work.

ALARA techniques have been integrated to the t

maximum extent possible during the early planning and sequencing of the component removal work included in this EDCR 93 303.

5,2 Lost Manacement l:

A breakdown of the-estimated costs associated with this EDCR for the removal and disposal of the reactor. internals is contained in Section 10 of 'the CRP Management Plan, Reference (3).

The cost control process,. as addressed in this plan, will be followed to track expenditures and scope changes.

5.3' Schedule The following key milestone dates have been established for internals segmentation:

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