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EWN – Energiewerke Nord GmbH
Germany
“Dismantling of the turbine hall
at Greifswald NPP”
planning issues and practical work
IAEA training course on advanced cutting technologies 05 - 08 Sept. 2011
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Dismantling of the turbine hall
Contents
1. General facts on the turbine hall dismantling
– Summary on dismantling work 1996 - 2007
2. Training for manual dismantling at EWN
3. General licensing (planning) approach
4. Dismantling planning for the turbine hall (supervised area)
– Main strategies
– Detailed planning and boundary conditions
5. Practical dismantling execution
– Realisation of the work on selected examples
Contents
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Dismantling of the turbine hall
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Turbine hall dismantling - masses and work duration
Total amount of material in the turbine hall Per unit: 10.1 thousand Mg
Sum of units 1 - 5 50.7 thousand Mg
Radiological classification of materials in turbine hall units 1-4 Category I (not contaminated material) 39% of overall mass
Category II (suspected material) 59% of overall mass
Category III (contaminated material) 02% of overall mass
Material to be stored/disposed as radioactive wastes About 0.5% of the overall mass (ca. 250 Mg)
Averaged dismantling duration for a twin unit: about 4 years
1 year dismantling and
3 years cutting
General facts on turbine hall dismantling
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Turbine hall dismantling - resources, capacities and costs
Averaged annual staff requirements (1996 – 2007)
44 EWN Staff (on site work organisation, dismantling, cutting, transport)
And 6 workers from external companies
Averaged productivity (1996 – 2007)
50 kg/man-hour (dismantling and cutting)
This results in (for the turbine halls 1- 6 and remaining supervised
area):
1.1 million man-hours (including planning, overheads, etc.)
51.5 million € (including planning, overheads, etc.)
● Personnel cost: 46.8 million € (91%)
● Direct cost: 4.7 million € (09%).
General facts on turbine hall dismantling
6 EWN – training for manual dismantling
EWN training for manual dismantling
Dismantling of units 7 and 8 (clean, 80% completed)
Performed between 1991 and 1994
Can be regarded as “full scale testing”
(no radiological limitations)
Testing of different cutting tools
(mechanical, thermal)
Applicability for different
material and thicknesses
Advantages/ Disadvantages
(e.g. space requirements,
speed, dust creation,
reliability/ safety, auxiliaries)
Involved staff: former maintenance
and technical (operational) staff
Qualification: on the job
7 EWN – training for manual dismantling
EWN training for manual dismantling
Prerequisites/ preconditions:
Available technical staff with knowledge
from operation/maintenance
“Full scale testing area”
“No restrictions” for selection of tools
Results:
Real dismantling work performed
Staff with confidence, experiences, skills
Choice of tested dismantling tools
readily available on the market
List of applicable tools and their areas
of application (part of dismantling instruction)
There was no requirement (by the authority)
to proof “special” staff qualification for manual
dismantling
(there is a sufficient degree of trust)
8 EWN – training for manual dismantling
EWN training for manual dismantling
Staff training/ adaptive qualification for decommissioning
Company specific adaptive qualification performed internally by several
Departments (for 43 workers from Greifswald and Rheinsberg NPPs in 1994)
Three weeks theory - lectures/ seminars (Bolded items - with examination): EWN disposal concept (project structure, residual material managem., licensing)
Health, labour and fire protection
Radiation protection (Basics, access regime, zoning concept, personal dosim.)
Environmental protection (Legal basis, hazardous wastes, material handling)
Decontamination (Basics, decontamination procedures/processes, experiences)
Cutting procedures (shearing, sawing, grinding, thermal cutting, plasma
cutting)
Waste management (Waste streams and treatment facilities, storage and
disposal)
Transport and lifting equipment and fittings
One week practical exercises Operation of transport/lifting devices, measurement devices for rad. protection
First aid practise, operation of manual fire extinguishers
9 EWN – training for manual dismantling
EWN training for manual dismantling
Staff training/ adaptive qualification for decommissioning
Company specific adaptive qualification performed internally by several
Departments (for 43 workers from Greifswald and Rheinsberg NPPs in 1994)
Results:
(Internally) certified specialised staff:
Operators of ground based transport/ lifting devices, Riggers and
Executioners
Thermal/ plasma cutter
First-aider
Staff prepared for further external qualification/examination
E.g. decontamination worker
10 EWN – training for manual dismantling
Training results: Principle dismantling technologies
Mech. cutting techniques for steel, non-ferrous metals, plastics (examples)
Devices/techniques Application range
Hand operated sawing techniques
1. Band saw with pneumatic or electric drive 120 mm
2. Reciprocating saw (sword saw) 130 mm
3. Reciprocating saw (jig saw) with clamping & feed device 440 mm
4. Small sized metal saw with electrical drive 34 mm
Portable working tools for pipes and vessels
1. Tube cutter with electrical drive Up to Ø 25 mm x 1 mm
2. Tube saw with pneumatic drive Up to 40 mm depth
3. Tube cutter fixed externally on the tube with hydraulic drive Ø 152 mm - 622 mm
4. Tube milling machine with pneumatic drive Ø 1515 mm, 45 mm depth
Hand operated shears for tubes and vessels
1. Shears with electrical drive (nibblers) High alloyed steel up to
5 mm, others up to 10 mm
Stationary working tools for tubes and sectional steel (profile steel)
1. Hydraulic shears Sectional steel up to 50 mm
11 EWN – training for manual dismantling
Training results: Principle dismantling technologies
Thermal cutting techniques for different materials (examples)
Devices/techniques Material Application range
Oxyacetylene cutting
1. Oxygen cutter (machine & manual) C-steel Up to 300 mm
Plasma cutting
1. Manual and machine driven cutters S-steel, Al Up to 75 mm
2. Machine driven cutter with media:
compressed air, H2, O2, N2, argon
High alloyed steel Up to 80 mm under water
Powder injection flame cutting
1. Powder injection flame cutting S-&C-steel, cast iron Up to 300 mm
Thermic lance
1. Thermic lance (Core lance) Different materials Up to 2000 mm
Laser cutter
1. Manual and machine driven cutters
with compressed air
S-steel, C-Steel Up to 10 mm
Contact arc metal cutting
1.Manipulator driven cutting device conductive materials Limited by current and
electrodes dimensions
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Licensing - Overview
Licensing procedure integrated in the general staged
approach
Different parts of the TH are covered by different
part licenses, e.g: G01.1 (Dismantling in supervised area units 1 to 6)
G03 (Dismantling controlled area units 1 and 2)
G04 (Dismantling controlled area units 3 and 4)
G06.3/4 (Dismantling of remaining buildings and
systems)
Mainly stepwise application and realisation as
reserve/alternative to dismantling in the controlled
area TH5/6 about 60 PCDs
TH3/4 and TH 1/2 about 10 PCDs
OVERALL LICENCE
G01 (30. June 1995)
Part licence
(e.g. G03, G04) Part licence
(e.g. G03, G04) Part licence
(e.g. G03, G04)
PCD-0 PCD-1
PCD-2
Dismantling instructions
EWN licensing/ planning approach
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General licensing/ planning approach
Results (in view of dismantling)
We have PCD 0, 1, 2
A general framework established with the overall licence (general rules,
applicable methods and technologies, overall safety report)
An approved scope for decommissioning (dismantling scope)
A general description of work
Defined links with licensing authority (authorized experts) for controls
General timeframe
We have (internal) dismantling instructions
A detailed and binding
sequence of work if necessary
A concrete association of
materials and technologies
in exceptional cases only
Subject of detailed planning
(no need for approval)
EWN licensing/ planning approach
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Main strategies for planning
Shut down and separation of systems
System by system (controlled area: same approach)
Dismantling planning and realization
Unit by unit (controlled area: room by room)
Subdivision into sections based on physical location and accessibility e.g.
Generator-transformer unit
Turbine and condenser
Big vessels (pre-heaters, feed water tanks)
Small technological equipment (small pipes, pumps, drives, valves, …) top down
Steel constructions (supports, stages, stairs)
I&C equipment
Building structures (concrete parts)
EWN Dismantling planning
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Main strategies for planning
Main strategies for material categories
Category III materials (contaminated materials)
Dismantling into as big as possible parts (under control area conditions)
Sorting, packaging and transport to ZLN or ZAW (centralized treatment places for contaminated materials)
Category II materials (suspected materials)
Dismantling into dimension of boxes
Use of centralized storage/cutting places in the turbine hall
Packaging and transport to free release measurement facility
Category I materials (non-contaminated materials)
Dismantling into as big as possible parts
Use of centralized storage/cutting places in and outside the machine hall
Conventional removal/release of materials
EWN Dismantling planning
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Main strategies for planning
Main dismantling strategies
Dismantling technologies Use of maintenance and repair procedures as basis for dismantling
instructions
Cutting points = assembling connections (e.g. flanges) -> results in e.g. 3 m long pipe sections for lifting with cranes
Cutting of bolts instead of unscrewing if possible, cutting of equipment
Centralized cutting places = main working places Usage of “free” space between the units (former repair/maintenance and
storage areas)
Dismantling into as big as possible parts: Depends on suitability and availability of lifting and transport equipment
E.g. complete components (tanks, vessels) to be lifted by cranes
Depends on type of equipment to be dismantled Tubes up to Ø 50 mm and connected equipment: general cutting to dimensions
and weight suitable for manual transports
EWN Dismantling planning
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Main strategies for planning
Detailed planning and boundary conditions
Availability of lifting and transport capacities
Turbine hall cranes for big components
Transport ways, openings
Transport means (trailers)
Accessibility of equipment to be dismantled
Work load of cutting places and storage capacities
Availability of material management equipment
Free release capacities
Availability of work force
Parallel work in different units
EWN Dismantling planning
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Main strategies for planning
Detailed planning and boundary conditions
Approach implemented up to about September 2006
Dismantling focuses on controlled area
Dismantling in the turbine hall depends on available (remaining) resources
“New” approach since about September 2006
New aim:
To empty the turbine hall as soon as possible and to prepare the turbine hall for reuse
Consequences
Installation of storage places outside the turbine hall for Cat. I and II materials in the controlled areas of unit 5 to 1 and “open air”
Removal of bigger parts for storage
Additional transports outside the turbine hall
Complete disconnection of dismantling from cutting
EWN Dismantling planning
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Centralised cutting places
Cutting place with band saw
Dismantling of the turbine hall – practical work
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Centralised cutting places
Manual cutting at cutting pace
Dismantling of the turbine hall – practical work
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New storage places
Storage places in controlled areas of units 5 - 1
Dismantling of the turbine hall – practical work
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New storage places
Open air storage of turbine hall equipment (Nov. 2006)
Dismantling of the turbine hall – practical work
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Big component dismantling
Removal of main generator stator
Dismantling of the turbine hall – practical work
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Big component dismantling
Dismantling of a turbine – steam pipes
Dismantling of the turbine hall – practical work
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Big component dismantling
Dismantling of turbine components
Dismantling of the turbine hall – practical work
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Big component dismantling
Dismantling of a turbine condenser
Dismantling of the turbine hall – practical work
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Big component dismantling
Dismantling of a turbine condenser
Dismantling of the turbine hall – practical work
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Big component dismantling
Dismantling of a feed water tank
Dismantling of the turbine hall – practical work
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Big component dismantling
Dismantling of complete vessels
Dismantling of the turbine hall – practical work
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Dismantling of smaller parts
Dismantling or remaining equipment top down
Dismantling of the turbine hall – practical work
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Dismantling of smaller parts
Removal of cable trays - fire protection containing
asbestos
Dismantling of the turbine hall – practical work
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Concrete demolition
Demolition of turbine desk
Dismantling of the turbine hall – practical work
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Concrete demolition
Demolition of turbine desk
Dismantling of the turbine hall – practical work
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Concrete demolition
Dismantling of the turbine hall – practical work
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Concrete demolition
Demolition of concrete floor (channel cutting)
Dismantling of the turbine hall – practical work
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Concrete demolition
Preparation of new wall openings (doors)
Dismantling of the turbine hall – practical work
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Concrete demolition
Removal of building structures
Dismantling of the turbine hall – practical work
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Concrete demolition
Removal of building structures
Dismantling of the turbine hall – practical work
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Dismantling of the turbine hall
Recreation of the floor for reuse
Dismantling of the turbine hall – practical work
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