RESULTS OF FULL SCALE TESTING OF THE REMOTE DISMANTLING IN GREIFSWALD NPP. Ralf Borchardt Energiewerke Nord GmbH

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1 RESULTS OF FULL SCALE TESTING OF THE REMOTE DISMANTLING IN GREIFSWALD NPP Ralf Borchardt Energiewerke Nord GmbH

2 Verify suitability for operation Prooftesting of technology Performance data of each cutting technique - cutting data - tool stand time - waste production Performance of auxiliary systems - ventilation - water cleaning facility Personnel training - collection of operation experience Prooftesting objectives

3 12 TEST COMPLEXES (e.g. cutting and handling technique for R.P.V.) 45 TEST MEASURES (e.g. operation on the post cutting place) 274 TEST PROCESSES (e.g. cutting on the cylindrical part with band saw) 2500 TEST STEPS (e.g. driving band-saw in work position) Structure of test program

4 Reactor Pressure Vessel - Band saw for horizontal cuts Wall thickness: - Band saw for vertical cuts 140 mm carbon-steel with - Oxygen burner 9 mm stainless cladding - Oxygen core lance - Angle grinder Reactor internals - Band saw for horizontal cuts Wall thickness: - Band saw for vertical cuts mm stainless-steel - Plasma burner Cutting Tools Dry cutting area

5 Experience Test with 15 different types of blades Best blades for cutting are: Bi-metal blades hardness of the carrier material - Carbon steel > 970 Vickers HV - Austenitic steel > 1000 Vickers HV 1 blade 8 to 15 cuts Band - saw Dry cutting area Blade change after 5 or 8 cuts

6 Experience Cutting speed - 1 to 10 mm/min - 5 to 15 mm/min Saw blade speed - 18 to 22 m/min Band - saw Dry cutting area Tooth pitch horizontal cutting to 1.4 tpi start to cut to 2.0 tpi tendon cut vertical cutting to 3.0 tpi

7 Advantages Very reliable operation Low aerosol production Dry cutting is possible Disadvantages Only simply geometries Low performance Band - saw Dry cutting area

8 Experience Is needed for cutting - the blades after a stick - the first two vertical cuts at the R.P.V. ring Cut speed - 10 to 25 mm/min Change the gas mixture of Oxygen / Ethen Oxygen burner Dry cutting area

9 Advantages High cutting performance Disadvantages Strong aerosol production Not suitable for standard cutting task Oxygen burner Dry cutting area

10 Experience Is needed for cutting the first two vertical cuts at the reactor internals ring Cut speed - 25 to 45 mm/min Plasma burner Dry cutting area

cutting area Strong aerosol production Is not possible to use

11 Advantages High cutting performance Hole cutting is possible for wall thickness up to 80 mm Disadvantages Plasma burner Dry cutting area Strong aerosol production Is not possible to use for cutting the R.P.V. Bottom Not foreseen as main cutting method

12 Advantages Hole cutting is possible Disadvantages Remote handling is very complicated for horizontal cuts Strong pollution Not suitable for standard cutting task Oxygen core lance Dry cutting area

13 Reactor internals Cylindrical parts Wall thickness: - Band saw for horizontal and vertical cuts mm stainless-steel - CAMC device - Plasma burner Plates Wall thickness: - CAMC device - Plasma burner mm stainless-steel - Wire saw - WASJ Tubes and pipes - CAMC device Wall thickness: - Plasma burner 8-15 mm stainless-steel - Fret saw Cutting Tools Wet cutting area

14 Experience Test with 10 different types of blades Best blades for cutting are: Bi-metal blades hardness of the carrier material > 970 Vickers HV 1 blade 8 to 10 cuts Blade change after 6 cuts Underwater Band saw Wet cutting area

15 Experience Cutting speed - 10 to 30 mm/min Saw blade speed - 18 to 25 m/min Tooth pitch to 3.0 tpi Underwater Band saw Wet cutting area

16 Advantages Very reliable operation Controlled water pollution Disadvantages Only simply geometries Low performance Underwater Band saw Wet cutting area

and 8 mm electrodes on stainless steel Stability of

17 Experience Material of the cutting electrode - strengthened graphite with carbon-fibres Test with 5 and 8 mm electrodes on stainless steel Stability of the 8 mm of electrode is better CAMC device Wet cutting area

18 Advantages Good for cutting materials with a wall thickness 80 to 300 mm and complicated geometries Disadvantages CAMC device Wet cutting area Strong water pollution Particle size smaller than 10 µ m Short stand time of the filters in the water cleaning facility

19 Experience Machine torch PB-S100 WU - Wall thickness up to 80 mm Angle machine torch PB-S47 WU O/L 90 - Simple und double walled pipes - Wall thickness up to 16mm Underwater plasma burner Wet cutting area

20 Advantages High cutting performance Very reliable operation Disadvantages Underwater plasma burner Wet cutting area Strong water pollution Particle size smaller than 10 µ m Short stand time of the filters in the water cleaning facility

21 Advantages Controlled water pollution Disadvantages Limited applicability Low performance Fret saw Wet cutting area

22 Advantages It is possible to cut austenitic material with a wall thickness of up to 300 mm Disadvantages Wire saw / WASJ Wet cutting area Remote handling is very complicated Cutting methods must already be taken into account at the basic planning

23 R.P.V. nozzles Carbon steel with stainless steel cladding Annular water tank Carbon steel and concrete R.P.V. insulation Carbon steel and stone wool - Milling machine - Wire saw - Angle grinder Cutting Tools Cutting area - reactor cavity room

24 Advantages Very reliable operation Low aerosol production Disadvantages Limited applicability Low performance Milling machine Cutting area - reactor cavity room

Experience The cutting of the annular water tank filled with concrete is possible Cutting time per cut - 5 6 hours Wire speed - 25

25 Experience The cutting of the annular water tank filled with concrete is possible Cutting time per cut hours Wire speed m/s Water consumption - 5 m³ per cut Wire store - 25 m Diameter of wire and 10 mm Wire saw Cutting area - reactor cavity room

26 Advantages High cutting performance Very reliable operation Disadvantages Strong pollution Remote handling is very complicated Wire saw Cutting area - reactor cavity room

27 Reactor component Preferential cutting tools Back up cutting tools RPV Band saw Oxygen burner Reactor cavity lower activated part - Cylindrical ring Band saw Plasma burner Protection tube unit lower activated part - Cylindrical ring Band saw Plasma burner Preferential cutting tools Dry cutting area

28 Reactor component Preferential cutting tools Back up cutting tools Reactor cavity higher activated part - Cylindrical ring Band saw Plasma burner Reactor cavity bottom - Upper plate CAMC Not planned - Lower plate Plasma burner CAMC - Tubes Plasma angle bur. Fret saw/camc - Cylindrical ring Band saw Plasma burner/ CAMC Preferential cutting tools Wet cutting area

29 Reactor component Preferential cutting tools Back up cutting tools Protection tube unit higher activated part - Upper plate CAMC Not planned - Lower plate Plasma burner CAMC - Tubes Plasma angle bur. Fret saw/camc - Small pipes CAMC/Plasma angle burner Preferential cutting tools Wet cutting area Shearing tools Core basket - Cylindrical ring Band saw Plasma burner - Bottom plate CAMC Not planned

30 Reactor component RPV nozzles - Main cooling pipes - Measuring nozzle RPV insulation non activated part Annular water tank incl. RPV insulation activated part Preferential cutting tools Milling machine Band saw Angle grinder Wire saw Back up cutting tools Not planned Milling machine Shearing tools Not planned Preferential cutting tools Cutting area reactor cavity room

31 Fundamental suitability of the components and facilities proven Essential changes of the technique during the test phase: 100 Essential changes of the technique after completion of the model dismantling: 80 Numerous optimisations in the sequence of operation Main statements of the full range testing

32 cut duration in hours Cut duration for horizontal cuts on the R.P.V number of cut Results of personnel training

33 END of the presentation Thank you for your attention!

dismantling > Cutting techniques for decommissioning nuclear facilities and conditioning of nuclear waste Innovation Our solutions for

dismantling > Cutting techniques for decommissioning nuclear facilities and conditioning of nuclear waste Innovation Our solutions for Cutting techniques for decommissioning nuclear facilities and conditioning of nuclear waste Innovation Nuclear facilities consist of a variety of different components that are made of different materials