ML060260383

12/21/05 Public Meeting Summary Powerpoint Slides

ML060260383
Person / Time
Site:	Palisades
Issue date:	12/21/2005
From:	Nuclear Management Co
To:	Office of Nuclear Reactor Regulation
References
Download: ML060260383 (37)

Text

An Overview of the Palisades Reactor Head Replacement Project Presented by NMC to NRC Staff December 21, 2005 NRC Region III Headquarters Lisle, Illinois

Agenda

• Purpose

• Mission Statement

• Project Organization

• Project Status

• Engineering

• Quality Oversight

• Summary

• Conclusion 1

Purpose

• Communicate the scope and status of the Palisades Reactor Head Replacement Project (RHRP) to NRC Region III

• Provide NRC with information necessary for planning inspection activities of the Palisades RHRP project 2

Mission Statement Replace the NMC Reactor Head Closure Systems in a world-class manner and with a team that fulfills the customers expectations for safety, reliability and cost effectiveness 3

Background on NMC Head Replacements

• Multi-site capital project for NMC

• Common fabrication organization

- NMCs Fleet approach allows for the transfer of operating experience to our current head replacement projects

• Site specific installation organizations

- Key personnel, experiences and resources are being utilized on Palisades head replacement 4

Project Organization Mike Sellman NMC CEO/CNO Mark Reddemann Paul Harden Lyle Bohn Vice President of Nuclear Assessment Site Vice President Sr. Vice President Dwight Mims Site Director Sherry Bernhoft Leo Ganser Director of Projects NOS Program Manager Darrel Turner Manager of Projects Steve Forsha Hank Hoelscher Fleet Manager Lead Quality Oversite Reactor Vessel Head Replacements Ron Bloomfield Site Manager Reactor Vessel Head Replacement James Wong Site RHRP Responsible Jim Pfefferle Engineer Lead Fabrication Group 5

Head Replacement Lessons Learned

• NMC Fleet

- J-groove weld quality

- Head drop analysis issues

• Industry

- Vendor oversight

- Containment restoration 6

Project Status 7

Project Status

• Scope

- New reactor pressure vessel head (nearly like-for-like)

- New control rod drive mechanism (CRDM) pressure housings, supports and in-core instrument (ICI) closures

- Through-the-wall replacement

• Schedule

- Installation in Fall 2007 (est. 50 days)

- N-1 walkdowns in Spring 2006 8

Design

• Babcock & Wilcox Canada (BWC) is the designer of the replacement head

• Westinghouse (WEC) supplied Certified Design Specification

• WEC providing design and advisory services to BWC (fabricator) and NMC 9

New Reactor Head Fabrication

• Contracted with BWC to supply replacement reactor vessel head (RVH)

• Head forged at Japan Steel Works

• Head forging recently arrived at BWC shop

• CRDM nozzle tubing by Valinox

• July 2007 head delivery to Palisades site

• QA data package available 30 days after RVH arrival on site

• Fabrication schedule available 10

New Reactor Head Fabrication 11

Head Components

• WEC fabricating / supplying:

- 45 CRDM pressure housings

- Seismic supports for pressure housings

- 8 ICI Grayloc closures

- New designed incore instrumentation assemblies (compatible with Graylocs)

• Components will be installed at Palisades site

• Fabrication schedule available 12

Design Change Assessment

• Other WEC Services

- Licensing support, Design Change Package (DCP) support, etc.

- Reactor head-related DCP and 10 CFR 50.59 reviews to be completed by September 2006

• NMC leading these activities

• These activities conducted on site 13

Construction & Installation Activities Currently negotiating with prime contractor to perform/support:

- Pre-outage assembly of new RVH

- Containment construction opening/close/test

- Rigging and heavy loads handling

- In-containment disassembly/reassembly of RVH

- Old RVH disposal 14

Pre-Outage Assembly

• Off Load from BWC truck

• Place new RVH in dry fuel storage (DFS) building

• Weld 45 CRDM pressure housings to new RVH

• Install seismic supports

• Install Grayloc closures 15

Containment Construction Opening

• Plant reaches Mode 5

- Remove affected tendons

- Relax adjacent/surrounding tendons

- Remove concrete, rebar & tendon sheaves

• Reactor defueled

- Remove liner plate 16

Containment Construction Close/Test

• Concrete test pour

• Liner plate prepared/reinstalled

• Install new rebar and solid tendon sheaves

• Install new tendons

• Install forms and pour concrete

• Tension tendons

• Perform Containment Integrated Leak Rate Test (ILRT) 17

Rigging & Heavy Loads Pre-Outage:

- Head drop analysis recently completed

- Evaluate and prepare haul routes

- Evaluate containment lay-down area floor loading

- Analyze & establish required heavy load safe paths in containment 18

Rigging & Heavy Loads (contd)

• Major lifts

- Place old RVH in shipping container

- Lift Old Head in shipping canister off runway

- Transport new RVH from DFS; lift to runway; up-end inside containment

• Other

- Transfer RVH lift rig & service platform from old to new RVH 19

In-containment RVH Activities

• Project will receive old RVH when still on vessel flange

- Remove CRDM support tubes (clean and store)

- Remove CCW lines to CRDM pressure housings

- Remove RVH lift rig and service platform

• New RVH will be rigged into containment and set on vessel flange (defueled)

• Above components will be installed on new RVH 20

Old RVH Disposal

• Currently evaluating:

1. Leaving CRDM pressure housings on old RVH, or

2. Removing the CRDM pressure housings prior to shipping off site

• Expect this decision by January 31, 2006

• Expect old RVH to be shipped off site very soon after removal from containment

• Duratek already contracted to dispose of old RVH 21

Construction & Installation Activities

• Currently negotiating construction/installation contract

• Anticipate installation contract awarded by January 31, 2006

• Anticipate Integrated Project Plan completed by April 30, 2006

• Installation-related DCPs and licensing packages will be completed by March 31, 2007 22

Licensing Requirements

• RHRP planned to be completed in accordance with 10 CFR 50.59

• Additional NRC reviews or prior approvals not anticipated 23

Key Dates Summary

• January 31, 2006: Installation contract awarded

• April 2, 2006: Refueling Outage begins; N-1 walkdowns performed

• April 30, 2006: Integrated Project Plan Rev. 0 completed

• September 2006: RVH Design Change Packages (DCPs) and 10 CFR 50.59 reviews completed

• March 2007: Installation DCPs and 10 CFR 50.59 reviews completed

• July 2007: New reactor head arrives at Palisades site

• September 8, 2007: Refueling/RVH Replacement Outage begins (50 day duration) 24

Engineering 25

Replacement Head Scope Details

• Single-piece forging

• Strip cladding

• Alloy 690 tubing and weld material required

- Alloy 600 Prohibited

• Automated gas tungsten arc welding process used for J-groove welds 26

Applicable ASME Codes Replacement Reactor Vessel Head

• Sections II, III, V - 1998 Edition thru 2000 Addenda

• Section IX - Latest Edition

• Section XI - 2001 Edition thru 2003 Addenda Containment Liner and Concrete

• Section XI - 1998 Edition thru 1998 Addenda 27

Applicable Regulatory Requirements

• U.S. NRC Regulatory Guide 1.28, Rev. 3 -

Quality Assurance Program Requirements

• U.S. NRC Regulatory Guide 1.37 - Quality Assurance Requirements for Cleaning of Fluid Systems and Associated Components of Water-Cooled Nuclear Power Plants

• U.S. NRC Regulatory Guide 1.38, Rev. 2 -

Quality Assurance Requirements for Packing, Shipping, Receiving, Storage, and Handling of Items for Water-Cooled Nuclear Power Plants 28

Nondestructive Testing

• Section III, ASME 1998 Edition thru 2000 Addendum

• Section XI, ASME 2001 Edition thru 2003 Addendum

• Additional NDE requirements imposed by NMC for Alloy 690 tubing and J-groove welds

- Implemented NRC flaw evaluation criteria

- Utilized NRC acceptance criteria for preservice examination

- Verified examination capabilities with NDE and repair mockups 29

Quality Oversight 30

Quality Oversight

• NMC Project Oversight Plan

- Establishes the program oversight and responsibilities for the project

• Supplier qualification

• Fabrication oversight

• Installation oversight

• Release and receipt inspections

• Status reporting 31

Resident Oversight

• Resident oversight personnel for NMC

- Monitoring work activities at:

• Japan Steel Works - Head forging

• Valinox - Inconel 690 head adapters

• Patriot Forge - Head adapter flanges

• Babcock & Wilcox Canada - Head manufacture

• Ionics - CRDM housings

- Verify critical attributes at witness and hold points

- Follow-up on nonconformances and corrective actions

- Review of quality documentation as work is completed 32

Quality Assurance Audits

• NMC project follow-up audit of Westinghouse in December 2005

• Nuclear Procurement Issues Committee (NUPIC) audit of Babcock & Wilcox Canada in first quarter 2006

• Project audit planned for Babcock &

Wilcox Canada during 2006

• Project self-assessment 33

Summary & Conclusion 34

Summary

• Palisades Sale - no anticipated effects on this project

• NMC has monitored fabrication of five replacement heads and completed head replacement at four sites

• Fabrication of the Palisades replacement head is ongoing

• Planning and engineering for installation of replacement head at Palisades is underway 35

Conclusion

• We appreciate this opportunity for NMC to update the NRC on our head replacement activities

• We will continue to work with the site resident inspectors to keep them apprised of our schedules 36