dismantling techniques applied at mzfr - · dismantling techniques applied at mzfr e. prechtl...
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1
Wiederaufarbeitungsanlage Karlsruhe Rückbau- und Entsorgungs- GmbH
The The DecommissioningDecommissioning Project Project MultiMulti--PurposePurpose Research Research ReactorReactor
( MZFR ) ( MZFR )
Dismantling Techniques applied at MZFR Dismantling Techniques applied at MZFR
E. PrechtlProjekt MZFRWAK GmbH
Research Reactor Decommissioning Demonstration Project (R²D²P)IAEA Workshop “Decommissioning Technologies”
Forschungszentrum Karlsruhe 6 – 10 Juli 2009
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2IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Nachhaltiger Rückbau: NPP and Prototype NPP and Prototype ReactorsReactors in Germany in Germany ( > 20 ( > 20 MWeMWe ))
Nuclear Facilitiesin the formerresponsibility of Karlsruhe Research Center and EWN, sinceJuly 1st 2009: EWN
NPP in Operation: 17
NPP and Prototype Reactors underDecommissioning: 15
NPP and Prototype Reactors in safeEnclosure: 3
Prototype NPP complete dismantled: 2
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3IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
FR 2 Research Reactor
Safe enclosure
Central Waste Treatment
Department
HDB
Compact Sodium-Cooled Nuclear
Reactor
KNK
Multi-Purpose Research ReactorMZFR
Karlsruhe Reprocessing Plant
WAK(VEK)
Superheated Steam Reactor at Karlstein
Green field
HDR
Green field
NiederaichbachNuclear Power Station
KKN
DecommissioningDecommissioning Projects on Site of Projects on Site of thetheKarlsruhe Research CenterKarlsruhe Research Center
( incl. ( incl. DismantledDismantled FacilitiesFacilities KKN and HDR, State of Bavaria )KKN and HDR, State of Bavaria )
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4IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Type: Pressurized water reactorHeavy water moderated and cooled
Power: 200 MWth, 57 MWel (242 fuel elements)
Erection: 1961 - 1965
Operation: 1965 – 1984Purposes: → Development and testing of nuclear
materials→ Testing of heavy water systems→ Testing of fuel elements→ Staff training
Decommissioning: 1987 – 2013
Decom. Strategy: Dismantling and Removal in 8 steps (= 8 partial licences)
Objective: Green field (IAEA Level 3)
MultiMulti-- PurposePurpose Research Research ReactorReactor ( MZFR ):( MZFR ):BasicsBasics
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5IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Perform the work safely(radiological and non-radiological)
Dose minimization(but as low as reasonably achieviable „ALARA“)
Cost reduction as much as reasonably possible
Waste minimization
„KIS“- principle ( keep it simple )
MZFR MZFR DecommissioningDecommissioning: : Fundamental Goals of DismantlingFundamental Goals of Dismantling
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6IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
The Main Basic The Main Basic ObjectivObjectiv: : SafetySafety
Radiation Protection: workers, population, environment
Technical Safety:selecting and developing dismantling techniquesselecting and developing handling techniques
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7IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
TypicalTypical RadiologicalRadiological and and Non Non –– RadiologicalRadiological HazardsHazards
High Dose RatesKontaminationChemical exposure: asbestos, etc. Welding and cutting: fireOperation of heavy equipment and power toolsErgonomics: heavy equipment, lifting, etc.Explosives: facility, demolitionEnvironmental conditions: heat, cold, wet, slippery, limited visibilityConfined spaces
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8IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
The activity level of the systems, componentsand partsThe selection of technologies depends also on the space conditionsThe physical/chemical properties of the systemsand comp. to be dismantled (e.g. metal, concrete) Radioisotopes and contamination layerThe type of isotopes present (Co60, H3, …)
MZFR Dismantling TechnologiesMZFR Dismantling Technologies
There is no single technique to address all dismantlingboundary conditions on the MZFR decommissioningproject, the techniques depends on
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9IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Remote controlled dismantling (dry)for large and activated RPV components (metal):Band saw; > 500 T€
Autogenius burner(flame cutting under air);~ 50 T€
MZFR Dismantling Technologies MZFR Dismantling Technologies ( ( contcont‘‘dd ))
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10IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
MZFR Dismantling Technologies MZFR Dismantling Technologies ( ( contcont‘‘dd ))
Remote controlled dismantling (dry) foractivated metals and concrete (bioshield):RC jackhammer (excavator), with tools: ~ 1.500 T€
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11IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Under water remote controlled dismantling(thermal and electrical tec. for high activated metals):
Plasma Cutting (UW); toolcarrier, equipment: ~ 1.000 T€
CAMC (Contact arc metal cutting (UW), adapted: ~ 100 T€(without tool carrier)
MZFR Dismantling Technologies MZFR Dismantling Technologies ( ( contcont‘‘dd ))
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12IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
MZFR Dismantling Technologies MZFR Dismantling Technologies ( ( contcont‘‘dd ))
Mech. hand held tools (activated and cont. metals) :Orbital saw (< 1 T€)
Hydraulic cutter (~ 2 T€)
Nibbler (tanks, ~ 5 T€)
Angle grinder(decontamination, < 500 €)
Mechanical saws (< 1 T€)
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13IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
MZFR Dismantling / MZFR Dismantling / DecontaminationDecontamination Technologies Technologies
Contaminated concrete:Diamant wire saw (~50 T€)
Scarifier (~10 T€)
Hammers drills, Comb. Hammer (> 1 T€)
Air needle scaler (> 1 T€)
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14IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Controlled AreaRad. Prot. Area
MZFR Plant, 1987MZFR Plant, 1987( ( ActivityActivity InventoryInventory approxapprox. 5.0 E16 Bq ) . 5.0 E16 Bq )
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15IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Controlled AreaRad. Prot. Area
MZFR Plant MZFR Plant ((contcont‘‘dd))
1992
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16IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Controlled AreaRad. Prot. Area
1992
MZFR Plant MZFR Plant ((contcont‘‘dd))
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17IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Controlled AreaRad. Prot. Area
1996
MZFR Plant MZFR Plant ((contcont‘‘dd))
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18IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Controlled AreaRad. Prot. Area
1998
MZFR Plant MZFR Plant ((contcont‘‘dd))
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19IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Controlled AreaRad. Prot. Area
1999
1964: Pressure test at the manufacturer’s
MZFR Plant MZFR Plant ((contcont‘‘dd))
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20IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Controlled AreaRad. Prot. Area
2001
MZFR Plant MZFR Plant ((contcont‘‘dd))
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21IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Controlled AreaRad. Prot. Area
MZFR Plant, 2009MZFR Plant, 2009( ( ActivityActivity InventoryInventory approxapprox. 2.0 E13 Bq ). 2.0 E13 Bq )
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22IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
• Mass: RPV – Total mass approx. 403 Mg
• Dimensions: Height: 7.7 m, Ø: 4.4 m
• Geometrical Conditions: Dismantling in present position(from top to bottom and from outside to inside)
• Dose Rate: DLCore-inside ≥ 11 Sv/h (01/1999)
• Radioactivity Inventory: Approx. E 16 Bq ( key nuclide: Co-60 )
• Packaging and Disposal: 178 casks and containers(104 type II Konrad containers and 74 MOSAIK casks), interim storage at the Central Waste Treatment Department (HDB)
RPV Dismantling: RPV Dismantling: ConditionsConditions at at thethe BeginningBeginning( Jan. 1999 )( Jan. 1999 )
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23IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Ventilation area
Packingarea
Band saw1: In intervention
area2: In dismantling
position
Dismantling table
RPV lid
Intervention area
Dismantling area
InstallationsInstallations on on ReactorReactor Building Level +10 m Building Level +10 m
Staffentrance
Lifting, moving, and sawing RPV componentsCut-off piecesSecondary waste
2 1
Ventilation
Repositorycasks .
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24IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Manual Dismantling of all Manual Dismantling of all ComponentsComponentsaboveabove thethe RPV RPV ( Dez. 1999 ( Dez. 1999 –– Feb. 2000 )Feb. 2000 )
BiologicalShield
Dismantling of• absorber rods, • guiding tubes, • measurement systems, etc.
Criteria: dose rate < 500 µSv/h
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25IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
On the reactor lid: Dismantling of the absorber rod drives
On the reactor lid: Cutting of measurement tubes on the RPV lid
Manual Dismantling of all Manual Dismantling of all ComponentsComponentsaboveabove thethe RPV RPV ( Dez. 1999 ( Dez. 1999 –– Feb. 2000 )Feb. 2000 )
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26IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
RemoteRemote OneOne--piecepiece Removal of Removal of thethe RodRod––shapedshapedComponentsComponents insideinside thethe RPV RPV ( April ( April –– Sept. 2000 )Sept. 2000 )
BiologicalShield
Coolingchannels, guidingtubes, etc.
272 components
212 local transfers and transports to HDB (cuttingin a hot cell)
Difficulty: 5 unremovablecooling channels
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27IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Five Five UnremovableUnremovable CoolingCooling ChannelsChannels: : Solution of Solution of thethe ProblemProblem
Leaving in core positionPlanning of back-updismantling technology:
Solution: Dismantling in theunderwater campaign(2004) with the hydraulicshears
BiologicalShield
Typical hazard: fragmentation
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28IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Removal and Removal and RemoteRemote Dismantling of Dismantling of thethe RPV LidRPV Lid( Band Saw, April ( Band Saw, April –– JulyJuly 2002 )2002 )
6: Manipulator system
1: Crane2: Support system3: Dismantling table4: Band saw5: Reactor
Longitudinal sectionof the dismantlingarea in reactorbuilding
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29IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Dismantling of the RPV lid bolts: Cutting off the 2 bolts, that could not be loosenened
PreparationPreparation of Removal and of Removal and RemoteRemoteDismantling of Dismantling of thethe RPV LidRPV Lid( Band Saw, April ( Band Saw, April –– JulyJuly 2002 )2002 )
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30IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Removal and Removal and RemoteRemote Dismantling of Dismantling of thethe RPV LidRPV Lid( Band Saw, April ( Band Saw, April –– JulyJuly 2002 )2002 )
BiologicalShield
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31IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Part I: Pulling up, transporting, and putting down onto the base structure
OptimizationOptimization of Safe Handling and of Safe Handling and Training, Trials, and Demonstration Training, Trials, and Demonstration withwith 1:1 Dummy 1:1 Dummy
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32IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Part II: Removal of the upper filler piece with base structure to core position (in case of interventions)
Training, Trials, and Demonstration Training, Trials, and Demonstration withwith 1:1 Dummy 1:1 Dummy
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33IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Upper Spacer
Removal and Removal and RemoteRemote Dismantling of Dismantling of thethe Upper Upper SpacerSpacer( Band Saw, ( Band Saw, DecDec. 2002 . 2002 –– April 2003 )April 2003 )
BiologicalShield
Optimizing the type of saw bandOptimizing the chip sucking systemOptimizing the grippers
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34IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
40 t – Dismantling Crane
Sledge 1 withManipulator
RotatingRing
Sledge 2 with Tool Carrier and Plasma
Burner
Bridge Manipulator
Mast with2 Sledges
Tests and Qualifikation in an external Mock- up
Drying Unit
UnderwaterUnderwater Dismantling Equipment Dismantling Equipment ( ( ““WetWet dismantlingdismantling““ ))
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35IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Moderator Tank
RemoteRemote Dismantling of Dismantling of thethe Moderator Tank Moderator Tank ( RC Plasma ( RC Plasma CuttingCutting System, Sept. 2004 System, Sept. 2004 –– JuneJune 2005 )2005 )
BiologicalShield
1. Mock-up tests with dummies
2. Real remote dismantling
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36IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
CoolingChannels
CuttingCutting of of thethe RemainingRemaining Five Five CoolingCooling ChannelsChannelsunderunder Water Water ( RC ( RC HydraulicHydraulic ShearsShears, Nov. 2004 ), Nov. 2004 )
BiologicalShield
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37IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Experience with Sediments Experience with Sediments and Slag Residuesand Slag Residues
Deposits between the upper round cover plate and stagnation sheets
Optimization of the cutting process
Deposits and slag residues on the moderator tank bottom:
Development of new tools
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38IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Segmentation of the Cylindrical Wall of the Segmentation of the Cylindrical Wall of the Moderator Tank: Experience with the Cladding Moderator Tank: Experience with the Cladding
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39IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Cleaning of the Moderator Tank Bottom Cleaning of the Moderator Tank Bottom before Cuttingbefore Cutting
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40IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
11.01.200511.01.2005
14.01.200514.01.2005
The Importance of the The Importance of the WaterWater--Purifying SystemPurifying System
Change of filter Change of filter cartridges of the cartridges of the
waterwater--purifying purifying systemsystem
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41IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Thermal shield( five segments )
BiologicalShield
RC Dismantling of RC Dismantling of thethe Thermal Thermal ShieldShield( Plasma ( Plasma CuttingCutting System, System, JulyJuly –– OctOct. 2005 ). 2005 )
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42IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Boundary conditions: • Increase in wall thickness:
From 70 mm up to 130 mm• Gap between TS and RPV
body: Only 20 mm, filledwith slag and sediments
• No gap between TS and lower spacer (support)
Thermal shield
RPV body
Special Special RequirementsRequirements forfor RemoteRemote DismantlingDismantlingof of thethe Thermal Thermal ShieldShield, Segment No. Five, Segment No. Five
((contcont‘‘dd))
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43IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
BackBack--upup Dismantling Dismantling TechniqueTechnique““ContactContact Arc Metal Arc Metal CuttingCutting““ ( CAMC ) ( Nov. 2005 )( CAMC ) ( Nov. 2005 )
Teaching, Cutting,
Preparation, Result:
((contcont‘‘dd))
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44IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Lifting and Lifting and RemoteRemote Dismantling of Dismantling of thetheLowerLower SpacerSpacer ( Band Saw, Jan. ( Band Saw, Jan. -- JulyJuly 2006 )2006 )
RPV body
Lower spacer (two pieces)BiologicalShield
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45IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Removing of the upper RPV insulation (11/2000)
Removing of the lower RPV insulation(03/2007)
RemovingRemoving of of thethe RPV RPV InsulationInsulation
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46IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Computer simulationRPV flange
Dismantling of Dismantling of thethe CylindricalCylindrical Part of Part of thethe RPV RPV ( ( AutogenousAutogenous BurnerBurner and Band Saw, and Band Saw, JuneJune –– Nov. 2007 )Nov. 2007 )
RPV
Real dismantling
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47IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Dismantling area
Dismantling of Dismantling of thethe RPV RPV BottomBottom( Band Saw, Nov. ( Band Saw, Nov. –– DecDec. 2007 ) . 2007 )
RPV bottom
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48IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
MockMock-- up up dismantlingdismantling equipmentequipment in in thethe turbineturbine hall:hall:excavatorexcavator withwith dismantlingdismantling toolstools
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49IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
MockMock-- up up dismantlingdismantling equipmentequipment in in thethe turbineturbine hall:hall:excavatorexcavator withwith dismantlingdismantling toolstools ((contcont‘‘dd))
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50IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
DecontaminationDecontamination WorkWork in in thethe Pool Pool StorageStorage BuildingBuilding
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51IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
DecontaminationDecontamination WorkWork in in thethe Pool Pool StorageStorage BuildingBuilding
DecontaminationDecontamination of of thetherecirculationrecirculation ventilationventilation
shaftsshafts
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52IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
DecontaminationDecontamination of of thethe ConcreteConcrete ShieldingsShieldings
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53IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
DismantlingDismantling and and DecontaminationDecontaminationin in thethe AuxiliaryAuxiliary BuildingBuilding
DismantlingDismantling of of thethe 200 m200 m33
liquid liquid wastewaste tank No. 4 (of 4)tank No. 4 (of 4)
MillingMilling of of thethecontaminatedcontaminatedscreedscreed
DismantlingDismantlingof of thethe tank tank basesbases
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54IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
DismantlingDismantling and and DecontaminationDecontaminationin in thethe AuxiliaryAuxiliary Building: Building: completedcompleted areasareas
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55IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Waste Management: Containers, Waste Management: Containers, boxesboxes and and drumsdrums((forfor lowlow activeactive oror contaminatedcontaminated wastewaste ))
2020‘‘ Container andContainer and
1010‘‘ ContainerContainer200 l drum 200 l drum
Transport Transport boxesboxes
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56IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Waste Management: Waste Management: RepositoryRepository CaskCask Type PSC Type PSC –– V1V1( different ( different shieldingsshieldings forfor lowlow and and middlemiddle activeactive wastewaste ))
Shielding lid Concrete nozzle17
00
1600
Net weight: 14.5 Mg Max. Weight: 20.0 Mg
Price: 15 – 20 T€
Wall shielding[mm]:
Steel: 10 Concrete: 180 Steel: 70
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57IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Lid with shielding
Outer wall:cast iron withspheridiodalgraphit160 mm
Leadshielding: 60 / 80 mm
Net weight: 8.30 MgLoad: 0.52 MgPrice: 40 – 50 T€
1500
1060
Waste Management: Waste Management: RepositoryRepository CaskCask Type MOSAIKType MOSAIK( ( middlemiddle activactiv wastewaste ))
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58IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
concept plan detail planning real(1995) (ab 1999) (2008)
Primary waste (disposal): approx. 403 MgSecondary waste (treatment): approx. 95 Mg, (approx. 80 Mg
contaminated water)Tertiary waste (new installations), decont. or reuse: approx. 250 Mg
Waste Waste MinimizationMinimization StepStep 7 7 ““RemoteRemote Dismantling Dismantling of of thethe RPV incl. RPV incl. InternalsInternals““
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59IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
10851177
145219
318
0
Plan Real
6.SG 7.SG 8.SG
CollectiveCollective Dose, Dose, StepsSteps 6 to 8 [mSv] 6 to 8 [mSv] ( as of 31.12.2008 )( as of 31.12.2008 )
6.SG: Dismantling primary system
7.SG: Remote dismantling RPV
8.SG: Dismantling bioshield and plant decontamination
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60IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
CollectiveCollective Dose of Dose of StepStep 7: RC Dismantling RPV + 7: RC Dismantling RPV + InternalsInternals( as of 31.12.2008 )( as of 31.12.2008 )
Plan: 1177 mSv, Ist: 318 mSv (27%)
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61IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
nderungsanzeigen MZFR Gesamt / nur 7 SG von 1999 - 2008
hr Anzahl (7. SG) Gesamt1999 0 172000 14 382001 16 332002 7 332003 4 172004 6 232005 3 62006 4 122007 8 262008 0 8
0
17
14
38
16
33
7
33
4
17
6
23
3
64
12
8
26
0
8
02468
10121416182022242628303234363840
Anzahl
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008
Jahr
Änderungsanzeigen MZFR Gesamt / nur 7. SG von 1999 - 2008
7. SG
Gesamt
ModificationsModifications / Revision / Revision ProceduresProcedures underunder thetheAtomicAtomic LawLaw ((SupervisorySupervisory AuthorityAuthority ApprovalApproval) )
( 01/1999 ( 01/1999 –– 12/2008 )12/2008 )
Total: 208
Step 7 (RPV-Dis.): 62
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62IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
970 Mg 400 MgMass of reactor
pressurevessel
11,500 MgMass of conta-minated systemand installations
3,500 Mg
157,000 Mg 44,000 MgMasses of buildings
2.6E17 Bq 3.6E16 Bq
Activity afterdefueling
DWR: 1300 MWel MZFR: 57 MWel
ComparisonComparison of MZFR Data of MZFR Data withwith ThoseThose of a of a ReferenceReference PWRPWR--TypeType Power Power ReactorReactor
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63IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Special Experience from MockSpecial Experience from Mock--up Testing and up Testing and the Underwater Cutting the Underwater Cutting
Elaboration, optimization, and implementation of the dismantling concept and objectives in close cooperation with industry, university and research institutes
Simulation of all cutting steps as a basis of a safe cutting procedure as well as for high availability and performance during mock-up tests and real cutting
3-D-simulation to demonstrate collision-free operation and accessibility of all cutting areas as well as implementation of locking and interlocking systems
Allow sufficient time for testing and training on a mock-up
Implementation of a powerful control unit for the process, parameter variations and documentation
High cutting flexibility by separate use of tool carrier and manipulator system
Elaboration and optimization of maintenance plan and repair strategies
Short technical examination periods of documentation and equipment for all relevant cutting steps in close cooperation with the independent experts starting with mock-up testing
Development of back-up techniques
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64IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
8 partial atomic licences: High quality of application documents
New technical developments and designs necessary
High activity inventory: Remote dismantling techniques (mechanical and underwater thermal dismantling techniques)
Complete dismantling of the highly activated reactor
Mock-ups and simulations
Treatment of H3-contaminated concrete structures
Expected total collective dose: < 1 man Sv
Project costs: Approx. EUR 320 million
MZFR MZFR DecommissioningDecommissioning Project: Project: Short Short SummarySummary
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65IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Criteria for selection of dismantling tools and techniquesStaff safetyRadioprotection optimizationWaste minimization Cost reduction
Further criteria :Installation durationReliabilityMaintenance Waste minimizationReplacement equipment disposabilityNo primary criteria is the cutting speed
DismantlingDismantling TechniquesTechniques SummarySummary
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66IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
Dismantling technologies are based on methods and processes applied in conventional areas
Special developments and optimizations are required to fulfilspecial boundary conditions and to reduce the costs
Remote dismantling of highly activated and contaminated RPV components is the technically most challenging step
Early planning and demonstration of the interaction of thehandling system and dismantling technologies in test rigsreduce the dismantling times and, hence, the costs
Advanced planning tools (3D simulation, modern control and robot techniques) increase the overall system availability
Experience gained from the dismantling of prototype facilitiesmay well be used for the dismantling of industrial NPPs
ConclusionsConclusions
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67IAEA Workshop, Karlsruhe Research Center, July 6th – 10th, 2009, E. Prechtl
The MZFR The MZFR –– Site Site todaytoday ………… and in and in thethe nearnear FutureFuture
ThankThank YouYou forforYourYour AttentionAttention !!