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Advanced Nuclear Power<br />

T H E M A G A Z I N E O F F R A M A T O M E A N P<br />

N O 6 January 2003<br />

<strong>Life</strong> <strong>Cycle</strong><br />

<strong>Management</strong><br />

The Power<br />

of Experience


C O N T E N T S<br />

Advanced Nuclear Power<br />

N O 6 January 2003<br />

Framatome ANP<br />

Worldwide Offices<br />

Tour Framatome ANP<br />

92084 Paris La Défense Cedex<br />

France<br />

Tel: +33 1 47 96 00 00<br />

Fax: +33 1 47 96 36 36<br />

FRinfo@framatome-anp.com<br />

3315 Old Forest Road<br />

Lynchburg, VA 24501<br />

USA<br />

Tel: +1 434 832 3000<br />

Fax: +1 434 832 0622<br />

USinfo@framatome-anp.com<br />

Freyeslebenstr. 1<br />

91058 Erlangen<br />

Germany<br />

Tel: +49 9131 18 95374<br />

Fax: +49 9131 18 94927<br />

DEinfo@framatome-anp.com<br />

3 Perspectives<br />

Industry Insights<br />

4 The Worldwide Trend Towards<br />

Partnering Agreements<br />

6 Sustainable Development:<br />

The Johannesburg Summit<br />

Cover Story<br />

8 <strong>Life</strong> <strong>Cycle</strong> <strong>Management</strong>:<br />

The Power of Experience<br />

Features<br />

12 Optimizing the CI to Get<br />

More Power Out of Your PWR<br />

13 Better Fuel Utilization and<br />

Higher Plant Availability at BWRs<br />

with TELEPERM XS<br />

14 Trillo: Standby Offsite Power System<br />

Connection Upgraded<br />

4<br />

EDITORIAL STAFF<br />

Publisher<br />

Nicolas Brun<br />

Editor-in-Chief<br />

Susan Hess<br />

Managing Editor<br />

Martha Wiese<br />

Creative Director<br />

Bill Warner<br />

Regional Editors<br />

Jacqueline Buysse, Christine Fischer,<br />

Martha Wiese<br />

Graphic Design<br />

O’Connor Group<br />

Contributing Writers<br />

Pierre Boermans, David Brown, Patrick<br />

Clay, Jean-Jacques Crosnier, Manfred<br />

Erve, Eberhard Fischer, Gilles Goyau,<br />

Jean-Marie Grandemange, Ambros<br />

Hauser, Johannes Höbart, Robert Horbach,<br />

Hubertus Lindacher, Jean Oullion,<br />

Fernando-Mario Roumiguière, Günter<br />

Scherer, Wilfred Stoll, Ferdinand Uano<br />

Innovation & Technology<br />

15 Robot Facilitates CVCS Replacement<br />

16 New Tools Facilitate Reactor Inspections<br />

18 SIPLUG Online 3: First Modules<br />

Now in Operation at Neckar<br />

18 Engineering Databases Improve<br />

Reload Analysis Process Time<br />

19 Tailor-Made Measurement System<br />

Provides Consistent Results<br />

Departments<br />

20 Equipment and Services<br />

21 Contracts<br />

22 Events and Meetings<br />

22 News in Brief<br />

On the cover: Electricité de France’s Flamanville plant,<br />

located on the seaside “La Manche” in northwest France.<br />

TELEPERM XS is a trademark of Framatome ANP.<br />

TELEPERM is a trademark of Siemens. SIPLUG and<br />

ADAM are registered trademarks of Siemens.<br />

16


Perspectives<br />

Nuclear Power: It’s An Exciting Time<br />

This is an exciting time to be in the nuclear industry. Capacity factors<br />

are the highest they have ever been and still rising. Outage durations<br />

are falling and nuclear electricity production costs are low in<br />

comparison with some other forms of generation. Because of our reliable record<br />

of operation, the public attitude in some parts of the world has improved.<br />

Low production costs and energy security issues are fueling a renewed emphasis<br />

on nuclear power. The nuclear industry is responding with plant life extensions<br />

and power uprates. Even though many plants have been<br />

operating for 20 years or more, given the current conditions,<br />

these plants are valuable assets that need to be preserved.<br />

Nuclear utilities are facing modernization challenges,<br />

particularly in the areas of component repairs and replacement<br />

and electrical and I&C upgrades. As a result of low<br />

production costs and high capacity factors, nuclear power<br />

plants can generate the revenue necessary to make these<br />

modernization investments.<br />

8<br />

6<br />

To meet these modernization challenges, nuclear plants are looking to service<br />

providers for assistance in helping them evaluate the existing condition of their<br />

plant and the aging mechanisms at work to make recommendations on what<br />

needs to be done to achieve long-term operational success. They are expecting<br />

suppliers to develop the most economical and safe solutions and to guide them<br />

in prioritizing these issues based upon susceptibility to failure, aging, repair<br />

versus replacement options and replacement lead-times, to name a few. These<br />

large and diverse scopes are leading some utilities to form long-term alliances<br />

with a vendor.<br />

In addition to preserving their existing assets, utilities have begun the long-term<br />

planning for new nuclear power plants to meet future electricity needs with<br />

safe, reliable, and environmentally friendly generation. Multiple technologies<br />

are in development around the world and it is generally believed that a new<br />

nuclear power plant will be contracted within years.<br />

For those of us who have been in this business for a number of years, the recent<br />

turn of events is not only invigorating but also a welcome recognition of all<br />

the industry’s hard work over the years to prove the viability and necessity for<br />

nuclear power generation as a part of the energy mix.<br />

Thomas A. Christopher<br />

President & CEO<br />

Framatome ANP, Inc.


Industry Insights<br />

The Worldwide Trend Towards<br />

Partnering Agreements<br />

In the past, plant operators dealt with<br />

a multitude of low-cost suppliers.<br />

There might be 300 for plant support<br />

work, another 100 for outage support<br />

plus 800-1000 miscellaneous parts/<br />

materials/services vendors. Each of these<br />

required requests for proposal (RFP)<br />

to be developed and bids to be evaluated.<br />

Before deregulation, the performance<br />

risk was assumed by the rate payers<br />

and there was a guaranteed rate of<br />

return for the utilities. Today, all that<br />

is changing.<br />

Today, the number of utilities establishing<br />

alliances or partnering arrangements<br />

is mushrooming. Dependence<br />

on a particular vendor or group of<br />

vendors allows the utility to improve<br />

the overall operations of their plants<br />

through cost reductions, risk sharing<br />

and other benefits.<br />

The consolidation in the nuclear utility<br />

industry has led to the formation of<br />

multiple types of partnering arrangements.<br />

Some are between utilities and<br />

a single vendor, some are between a<br />

utility and a consortium of vendors,<br />

some are a group of utilities that have<br />

banded together to achieve volume<br />

discounts for services and components,<br />

and another is an arrangement<br />

in which a single company operates<br />

multiple plants for different owners.<br />

Drivers<br />

Driven by increasingly competitive<br />

operating environments and a growing<br />

shortage of qualified service people,<br />

utilities see partnering arrangements as<br />

a way to build long-term relationships<br />

that will not only enhance the performance<br />

of their plants but reduce<br />

their operating costs as well.<br />

Although cost is an important factor,<br />

it is not always the main one. Nuclear<br />

and personnel safety always are of<br />

the highest importance but reducing<br />

outage lengths and enhancing plant<br />

performance also are key drivers.<br />

Improving the allocation of critical<br />

resources, reducing fixed costs, particularly<br />

in the areas of purchasing and<br />

engineering staff support, and better<br />

pre-outage planning are important<br />

benefits derived from partnership-type<br />

relationships. The concept is that a<br />

vendor with a vested interest in the<br />

operation of the plant and who shares<br />

in the risks and rewards will provide<br />

better service. In addition, utility<br />

and vendor teams that work together<br />

over a period of time develop a mutual<br />

understanding and work habits that<br />

result in smoother, safer, and more<br />

cost-effective performance.<br />

Typical Workscopes<br />

Full scope outage services including<br />

refueling, steam generator inspections<br />

and services, pump and motor services<br />

and RV head inspection and repair<br />

are a few of the workscopes usually<br />

covered by partnering arrangements.<br />

However, fuel, mechanical components,<br />

plant modifications, valves, I&C/<br />

electrical systems and welding work<br />

also can be included. The initial length<br />

of an alliance tends to be between<br />

three and five years with options for<br />

continuation based upon performance.<br />

Regular Evaluation<br />

is Essential<br />

An evaluation mechanism with preestablished<br />

criteria for performance is<br />

a key feature of alliances. These criteria<br />

usually are in the areas of safety, longterm<br />

cost reduction goals, production<br />

targets, quality, schedule, radiation<br />

dose reduction and overall cost goals.<br />

The parties mutually agree to the goals<br />

and their evaluation at the beginning<br />

of the alliance and participate equally<br />

in the analysis.<br />

Many partnering arrangements feature<br />

incentives, such as specific personnel<br />

safety and cost reduction goals,<br />

performance improvement criteria,<br />

adherence to established budgets or<br />

quality standards, established by both<br />

4 Advanced Nuclear Power N O 6 January 2003


parties. Both share in the risks and<br />

the rewards, so each has an incentive<br />

to beat the established goals.<br />

Other types of performance measurements<br />

include industry plant ratings<br />

and rankings, safety standards,<br />

and cost of production.<br />

Illustrations: Glasgow Media<br />

Conclusion<br />

An increasingly competitive marketplace<br />

will drive the need for low-cost<br />

operations and maximum output by<br />

all nuclear power plant operators.<br />

Thus, the trend towards partneringtype<br />

relationships will continue. These<br />

long-term relationships are a<br />

win-win situation for both parties.<br />

There is a greater willingness to invest<br />

in resources for long-term continuous<br />

improvement that will decrease the risk<br />

and increase the reward for the utility,<br />

the vendor and the entire industry.


Industry Insights<br />

Sustainable Development: The Johann<br />

Nuclear power contributes to sustainable development<br />

by generating power without creating air pollution<br />

Sustainable development sees<br />

human beings, in the words<br />

of philosopher Cornelius Castoriadis,<br />

as “the gardeners of the planet,”<br />

cultivating and enjoying the earth’s<br />

riches in our lives today, while taking<br />

care to avoid damaging or exhausting<br />

its resources.<br />

History<br />

In 1987, the UN established a<br />

Commission on Environment and<br />

Development, chaired by then<br />

Prime Minister of Norway, Mrs. Gro<br />

Harlem Brundtland. A report was<br />

issued that came to be known as<br />

“Our Common Future” which alerted<br />

the world to the urgency of making<br />

progress toward economic development<br />

that could be sustained without<br />

depleting natural resources or harming<br />

the environment.<br />

The 1992 UN Conference on<br />

Environment and Development<br />

(UNCED) in Rio de Janeiro drew<br />

30,000 people from around the world<br />

who gathered to address the issue<br />

of environmental decline. Out of that<br />

meeting, a new word was coined –<br />

eco-efficiency. “The hope was that<br />

eco-efficiency would transform human<br />

industry from a system that takes,<br />

makes, and wastes into one that<br />

integrates economic, environmental,<br />

and ethical concerns.” The Atlantic<br />

Monthly, June 1998<br />

Five years later, what is now the<br />

World Business Council for Sustainable<br />

Development, a group of 48 industrial<br />

companies, focused their efforts on<br />

what businesses could gain from a<br />

policy of reduce, reuse and recycle.<br />

An outgrowth of this has been the very<br />

real economic benefits that companies<br />

can achieve through altering the way<br />

they design and manufacture their<br />

products and how they handle byproducts<br />

and wastes. An example is<br />

3M who calculated that they saved<br />

$750 million (748.8 Euros) through<br />

pollution-prevention alone.<br />

The 2002 World Summit on<br />

Sustainable Development (WSSD),<br />

held in Johannesburg and attended<br />

by more than 40,000, is the latest<br />

worldwide meeting to address this<br />

important concept. To illustrate how<br />

far it has come, Nitin Desai, the summit’s<br />

Secretary-General, commented,<br />

“Development is now as sexy as the<br />

environment, absolutely.”<br />

Photo courtesy of Entergy Corporation<br />

Business and<br />

Sustainable Development<br />

The Sustainable Development Research<br />

Institute, headquartered in Canada<br />

defines sustainable development as “an<br />

integration of the ecological imperative<br />

to stay within the carrying capacity of<br />

the planet, the economic imperative to<br />

provide an adequate standard of living<br />

for all, and the social imperative to<br />

develop forms of governance that promote<br />

the values people want to live by.”<br />

CEOs at the recent WSSD took a<br />

similar position. Sustainable development<br />

is increasingly viewed as the key<br />

to future growth, and companies such<br />

as DuPont, Shell, Renault, Toyota, etc.<br />

are taking a pro-active stand in its<br />

favor. Moreover, although usually spoken<br />

of in terms of its environmental<br />

aspect, these companies recognize that<br />

to be successful, sustainable development<br />

encompasses every aspect of their<br />

business. US and European business<br />

schools have begun offering sustainable<br />

development courses, proof that there<br />

is a need for managers who understand<br />

the full potential of the concept.<br />

The Role of<br />

Nuclear Power<br />

In a speech presented on Oct. 23rd in<br />

Ottawa, Canada, Joe Colvin, President<br />

and CEO of the Nuclear Energy<br />

Institute in the US stated, “This new<br />

century, I am convinced, will see the<br />

realization of nuclear energy’s potential<br />

to contribute to worldwide sustainable<br />

development, helping to provide<br />

electricity to some two billion people<br />

who do not yet have access to it in<br />

their daily lives, and doing so while<br />

preserving our global environment.”<br />

Not only does nuclear energy generation<br />

protect the environment from air<br />

pollutants (it emits virtually no greenhouse<br />

gases), it promotes the economical<br />

development of other complementing<br />

forms of energy such as hydrogen.<br />

6 Advanced Nuclear Power N O 6 January 2003


esburg Summit<br />

Framatome ANP’s<br />

Commitment<br />

Anne Lauvergeon, head of the <strong>AREVA</strong><br />

<strong>Management</strong> Board, (the parent company<br />

of Framatome ANP) attended<br />

the summit in Johannesburg where<br />

she participated in a “Business Day”<br />

panel discussion on “Accountability<br />

and Transparency.” Commenting<br />

on why she attended, she said, ”I am<br />

personally committed to sustainable<br />

development and see it as an outstanding<br />

opportunity for industries such<br />

as ours to take responsible action. A<br />

company working in a highly technological<br />

field such as nuclear energy,<br />

traditionally focused on security,<br />

quality, and safety aspects, must be<br />

more attentive to the potential impact<br />

of its activities on the environment<br />

than other companies.” One of the<br />

reasons she attended is because the<br />

company has begun implementing a<br />

process, based upon the measurement<br />

of a series of indicators that can be<br />

reported to its stakeholders. Sustainable<br />

development principles are implied in<br />

the total quality approach, with selfassessment<br />

in areas such as customer<br />

satisfaction, human resources management,<br />

corporate citizenship and<br />

enhancement of quality of life in each<br />

community in which the company<br />

operates.<br />

at the recent World Summit was<br />

struck by seeing Greenpeace team up<br />

with the World Business Council on<br />

Sustainable Development (WBCSD)<br />

to open the door to address concerns<br />

such as climate change. Indeed,<br />

the most important result of the<br />

Johannesburg Summit may well be<br />

the progress it generated in building<br />

new bridges.


Cover Story<br />

<strong>Life</strong> <strong>Cycle</strong> Managem<br />

Aging is a universal phenomenon.<br />

Over time, everything and everybody<br />

must face the inexorable deterioration<br />

that aging causes. The majority of nuclear<br />

power plants in the world have been<br />

operating for 20 years or more and many<br />

plants are facing equipment and system<br />

degradation that is affecting the economic<br />

operation of their facilities. Over that<br />

same time period, materials properties<br />

have been improved that offer longer life<br />

with reduced corrosion susceptibility,<br />

safety requirements have increased, and<br />

welding and NDE techniques have<br />

improved. Utilities, whether considering<br />

extending the service life of their plants<br />

or looking for improved operations in<br />

increasingly competitive markets, are<br />

looking to life cycle management to assist<br />

them in making the right decisions.<br />

The<br />

A Proven Process<br />

<strong>Life</strong> cycle management (LCM) is a<br />

proven, effective process for extending<br />

plant life in an integrated and costeffective<br />

manner that prioritizes and<br />

allocates resources to the critical systems,<br />

structures and components. The normal<br />

operation of a plant or component<br />

exposes it to temperatures, mechanical<br />

loads, and environmental issues that<br />

result in aging mechanisms such as<br />

irradiation, fatigue, corrosion, fretting,<br />

cracking, etc. Over time, operation<br />

is affected.<br />

Managing those factors that contribute<br />

to aging and physical degradation can<br />

have a dramatic impact on a nuclear<br />

utility’s bottom line. Millions of dollars<br />

can be saved in avoidable operation and<br />

maintenance costs over the extended<br />

operating life of the nuclear fleet. In<br />

fact, LCM programs completed at four<br />

US plants resulted in long-term savings<br />

of $15M (15.5 Euros) to $30M<br />

(29.5 Euros) per plant.<br />

Benefits of LCM<br />

• Reduces unplanned outages<br />

due to equipment failure<br />

• Reduces operating costs<br />

• Mitigates risks of components<br />

critical to power generation<br />

• Improved equipment<br />

reliability and availability<br />

• Prioritization of competing<br />

options for capital while<br />

meeting emergent needs<br />

• Prioritization of plant<br />

modifications and planning<br />

for implementation<br />

• Estimation of capital upgrades<br />

and development of a longrange<br />

plant improvement plan<br />

<strong>Life</strong> <strong>Cycle</strong><br />

<strong>Management</strong> is a<br />

Balancing Act<br />

LCM is a balancing act between short<br />

and long-term strategic goals and the<br />

extended life of the plant. It encompasses<br />

a complex and interconnected<br />

group of features including financial<br />

models, long-term aging strategies,<br />

preventive maintenance programs and<br />

obsolescence planning tools. The key<br />

is a complete understanding of the<br />

aging processes, the life-limiting<br />

situations, and the establishment of<br />

thresholds. This knowledge, applied<br />

to the definition and qualification<br />

of suitable corrective and preventive<br />

actions, facilitates the risk/benefit<br />

analyses that result in the most costeffective<br />

decisions.<br />

8 Advanced Nuclear Power N O 6 January 2003


ent<br />

Power of Experience<br />

Conclusion<br />

Experience, historical data on individual<br />

plants over time, and a thorough<br />

understanding of the aging mechanism<br />

and physical degradation and their<br />

effect on components and systems are<br />

the primary tools for life cycle management.<br />

Combining the accumulated<br />

knowledge and experience of the<br />

French, German and US engineering,<br />

manufacturing and R&D provides<br />

a complete set of LCM tools ranging<br />

from those dedicated to the detailed<br />

evaluation of a given aging process<br />

to those providing global plant management<br />

support to electricity utilities.<br />

Framatome ANP has been helping<br />

customers manage their assets from<br />

the time the plant was built to the<br />

present. The result is a set of powerful<br />

management tools that draw on lessons<br />

learned and detailed data that have<br />

saved customers millions of dollars in<br />

unplanned outages and maintenance<br />

costs while maximizing plant value.<br />

(See the following case studies.)<br />

RPV Integrity Assessment:<br />

Indispensable for Safe<br />

and Reliable Long-Term<br />

Plant Operation<br />

The integrity of the reactor pressure<br />

vessel (RPV) is essential for<br />

safe and reliable plant operation and<br />

especially for plant life extension. The<br />

residual life of the RPV can determine<br />

the overall life of the whole nuclear<br />

power plant. Advanced techniques are<br />

used to verify the RPV integrity<br />

throughout the planned or prolonged<br />

life of the plant and to provide a good<br />

basis for cost-effective implementation<br />

of preventive and corrective measures,<br />

if necessary. The following two examples<br />

of RPV safety integrity assessments<br />

use fracture mechanics tools.<br />

Example 1:<br />

A substantial part of the PWR-RPV<br />

integrity assessment is related to the<br />

pressurized thermal shock (PTS)<br />

analysis. The safety of the RPV during<br />

a loss of coolant accident (LOCA)<br />

has to be proven over the entire life<br />

of the component. Framatome ANP<br />

is a leader in performing RPV safety<br />

analyses, a multidisciplinary effort that<br />

involves, among other things, highly<br />

sophisticated and detailed thermalhydraulic<br />

analyses and structural<br />

analyses including fracture mechanics<br />

assessments. This work has been<br />

performed by Framatome ANP for<br />

RPVs in the following plant design<br />

types: Siemens, EDF 900 MWe plants,<br />

Westinghouse, and Russian VVER<br />

440 MWe and 1000 MWe plants.<br />

Example 2:<br />

The allowable defect size is a major<br />

criteria for the safety assessment of<br />

RPVs and thus for lifetime prediction<br />

of this component. For the RPV<br />

main coolant pump nozzle of the<br />

Swedish BWR nuclear power plant<br />

Forsmark 1, new devices had to be<br />

developed for the non-destructive<br />

examination (NDE) because of limited<br />

accessibility. To calibrate these new<br />

devices, fracture mechanics calculations<br />

were performed to minimize nondestructive<br />

testing. Allowable defects,<br />

postulated to be located in the weld<br />

of the pump nozzle at the bottom<br />

of the BWR RPVs, have to be safely<br />

detected by NDE inspection. To<br />

achieve realistic conditions, the residual<br />

stresses must be defined as necessary<br />

input for these fracture mechanics<br />

calculations. Framatome ANP has developed<br />

comprehensive models, based<br />

on numerical tools, to simulate the<br />

welding process using the real welding<br />

parameters. The number of weld<br />

beads and the appropriate mechanical<br />

boundary conditions with adjacent<br />

materials must be considered. Based<br />

on the outcome of the fracture mechanics<br />

assessment, the maximum allowable<br />

defect sizes are conservatively defined.<br />

The NDE method can be tailored to<br />

specific needs, and the optimal NDE<br />

inspection intervals can be derived.<br />

Temperature field in the RPV wall and the resulting stresses in<br />

the nozzle region during cold water injection in the primary circuit,<br />

(temperatures in °C; stresses in MPa)<br />

Advanced Nuclear Power N O 6 January 2003 9


Cover Story<br />

Preventing Thermal<br />

Fatigue in Nuclear<br />

Components<br />

Preventing thermal fatigue begins<br />

during the design phase, particularly<br />

for safety-related components and<br />

those subjected to severe loading conditions.<br />

A list of loading conditions to<br />

which the various systems may be subjected<br />

is established early in the design<br />

phase. An in-service analysis is performed<br />

to ensure that design assumptions<br />

are correct under operating conditions.<br />

If there is a significant discrepancy,<br />

the design assumptions must be<br />

reassessed. Designs based on analysis<br />

of potential load conditions have been<br />

proven to prevent fatigue crack initiation,<br />

however unforeseen complex<br />

loading and insufficient monitoring<br />

can lead to a risk of fatigue damage.<br />

The cracking of an elbow in the residual<br />

heat removal (RHR) system at<br />

Civaux 1 is an example of unforeseen<br />

loading. This system includes a mixing<br />

area for the hot fluid from the reactor<br />

coolant system and a fluid cooled by<br />

an exchanger, designed to evacuate the<br />

maximum residual heat from the core,<br />

following a power operation. Fatigue<br />

cracks appeared in this system when it<br />

was used for long periods of time<br />

during unit startup.<br />

To determine the cause of the damage<br />

to avoid the risk of such an incident<br />

affecting other systems of similar design<br />

and to adjust the basic surveillance<br />

Configuration of the N4 residual<br />

heat removal system zone<br />

affected by fatigue and internal<br />

degradation of the elbow<br />

highlighted by liquid penetrant<br />

examination.<br />

and preventative maintenance programs,<br />

both the loading applied to the component<br />

and the component material<br />

resistance must be analyzed. Tests or<br />

digital simulations using software such<br />

as Star-CD to determine local fluid<br />

temperature distributions and Systus<br />

software to identify the resulting structural<br />

stresses are used to evaluate the<br />

loading applied to the component.<br />

These analyses lead to suggestions for<br />

improved operation, or improved design<br />

in the event of equipment replacement.<br />

The structure’s resistance capacity<br />

depends on both the material of which<br />

it is made and the manufacturing<br />

process used (surface condition, residual<br />

stresses, etc.). Metallurgical assessments<br />

and fatigue test programs performed<br />

on typical specimens can highlight<br />

such effects, leading to a better<br />

understanding of the remaining service<br />

life of existing structures and the precautions<br />

to be taken during the manufacture<br />

of replacement equipment<br />

for an extended service life. Assuring<br />

the absence of fatigue on equipment,<br />

in particular under high-cycle thermal<br />

fatigue situations, is critical to the<br />

operation of nuclear power plants. It<br />

requires multi-disciplinary skills (thermal-hydraulics,<br />

mechanical engineering,<br />

materials, inspection, repairs, etc.)<br />

to control the risk of damage over<br />

the long-term.<br />

Example of a<br />

simulated fluid<br />

mixing zone and<br />

determination<br />

of the resulting<br />

stresses<br />

LCM on One System<br />

Leads to Big Savings<br />

One of Framatome ANP’s successful<br />

life cycle management<br />

(LCM) projects focused on a US<br />

plant’s turbine controls. Following a<br />

complete assessment of the plant’s<br />

operating systems, it became clear that<br />

significant operating improvements<br />

and cost savings potentially could be<br />

achieved by targeting the plant’s existing<br />

electro-hydraulic turbine control<br />

(EHC) system.<br />

Following Framatome ANP’s LCM<br />

procedures, the team identified the<br />

EHC system boundaries and examined<br />

its critical equipment and components.<br />

The system’s operation and maintenance<br />

history was reviewed and then compared<br />

with other similar systems at other<br />

plants to uncover any anomalies.<br />

Analysis<br />

An engineering analysis of the most<br />

critical components was completed to<br />

determine its susceptibility to failure.<br />

For example, some vital components<br />

such as relay cards seemed to indicate<br />

a high susceptibility to failure that<br />

could cause the system and the plant<br />

10 Advanced Nuclear Power N O 6 January 2003


to be taken off line. The current analog<br />

system was obsolete and in fact, the<br />

existing EHC system’s vendor had indicated<br />

that it no longer would provide<br />

technical support after 2005. Due to its<br />

obsolescence, there was a shortage of<br />

spare parts for the existing system and<br />

this situation could only worsen.<br />

Additionally, there were limits to the<br />

existing system’s ability to gather data<br />

online and monitor system performance.<br />

The Action Plan<br />

Once the analysis was completed, the<br />

team evaluated the data and began to<br />

map out alternative programs for the<br />

operation and maintenance of the<br />

EHC system, taking into account the<br />

economic impact of each alternative.<br />

Based on the results of this exercise, an<br />

action plan, deemed the most effective<br />

at the best overall cost, was developed<br />

into a formal proposal and presented<br />

to the plant.<br />

The action plan called for replacing<br />

the existing analog EHC system with<br />

a redundant digital control system<br />

that would reduce the single-failure<br />

susceptibility, allow on-line maintenance,<br />

provide more thorough monitoring<br />

and trending of system performance,<br />

and potentially eliminate some existing<br />

EHC system components.<br />

It was estimated that this course of<br />

action would save the utility approximately<br />

$15 million (15.05 million<br />

Euros) in operation and maintenance<br />

costs over the remaining life of the<br />

plant. This example illustrates only<br />

one small segment of plant operation<br />

but the impact of LCM cannot<br />

be disputed.


Features<br />

Optimizing the CI to Get<br />

More Power Out of Your PWR<br />

Up to now nuclear power plant<br />

operators and suppliers have<br />

focused, for the most part, on optimizing<br />

the Nuclear Island (NI) as well as the<br />

turbine generator set to obtain more<br />

power out of their plants and to enhance<br />

plant safety and availability. Little<br />

attention has been paid to the fact that<br />

the Balance of Plant (BOP) – also<br />

known as the Conventional Island (CI) –<br />

also offers many opportunities for<br />

increasing net electric output at relatively<br />

low cost and with short payback periods.<br />

The CI is a highly complex network<br />

of pipes, process components, and<br />

instrumentation & control systems<br />

that serve the sole purpose of efficiently<br />

and reliably converting thermal energy<br />

to electricity. At many plants, electric<br />

output can be increased by up to 4%<br />

through a variety of carefully coordinated<br />

measures without having to increase<br />

the thermal output of the reactor.<br />

To effectively exploit these hidden<br />

resources in the CI, a supplier is needed<br />

who knows the plant from “core to<br />

condenser” and is experienced in analyzing<br />

and assessing power plants in<br />

their entirety – for this is the only way<br />

to prevent modifications from having<br />

undesirable effects on other systems.<br />

Turnkey Expertise<br />

is the Key<br />

Most of today’s nuclear power plants<br />

were built according to the Architect-<br />

Engineer (AE) model where one company<br />

supplied the nuclear steam supply<br />

system or the NI, several companies<br />

supplied the BOP systems and all of<br />

their various tasks were coordinated by<br />

the AE. This often resulted in individual<br />

BOP systems being improved without<br />

the plant as a whole being optimized.<br />

Framatome ANP, with its wide-ranging<br />

expertise in turnkey plant construction,<br />

follows a holistic approach: it treats<br />

the entire BOP as a single entity – the<br />

CI – while carefully accounting for its<br />

interaction with the NI at one end and<br />

the conditions of the main heat sink<br />

at the other. Also, the company systematically<br />

analyzes all CI systems and<br />

components that impact plant output.<br />

In this way, the entire plant can be<br />

optimized in terms of power production,<br />

while at the same time ensuring<br />

high plant availability and efficiency.<br />

First Reference Project<br />

Framatome ANP currently is performing<br />

a CI optimization study, based on this<br />

holistic approach, for the first time<br />

for a Japanese client. The study, started<br />

in June 2002, should be completed by<br />

March 2003. Working in close cooperation<br />

with the customer, possible areas<br />

for improvement are being identified,<br />

based on the present status of the plant.<br />

Technical recommendations for<br />

increasing plant efficiency are being<br />

developed with close attention paid to<br />

their cost/benefit ratio.


Better Fuel Utilization and Higher Plant<br />

Availability at BWRs with TELEPERM XS<br />

During the 2002 refueling outage<br />

at Philippsburg 1 (a German<br />

900 MWe BWR unit that went on<br />

line in 1980) core power distribution<br />

monitoring was improved and a new<br />

control rod sequence controller (CRSC)<br />

installed. This new CRSC, along with<br />

several new modules for local core<br />

monitoring, will enable the plant to<br />

meet today’s rigorous demands for high<br />

availability, optimum fuel utilization,<br />

state-of-the-art controls and automation<br />

of test routines. The new instrumentation<br />

& control (I&C) equipment consists<br />

of the digital safety I&C platform<br />

TELEPERM XS TM and a PC serving<br />

as the CRSC.<br />

Plant Restart In-Service<br />

Testing is Easier<br />

Not only does the use of TELEPERM<br />

XS provide more precise information<br />

and more accurate assessments of the<br />

current condition of the reactor core,<br />

but the high level of test automation<br />

and the ease of operator control<br />

and monitoring greatly relieve the<br />

workload on plant operating personnel.<br />

The introduction of the new CRSC<br />

in conjunction with TELEPERM XS<br />

has reduced significantly the effort<br />

required for in-service testing during<br />

restart of the plant after a refueling<br />

outage. This can shorten outages by<br />

up to half a day.<br />

Framatome ANP’s combined expertise<br />

in the fields of fuel design, process<br />

engineering, I&C technology, and<br />

software development led to the creation<br />

of this solution. Extensive plant<br />

know-how and project management<br />

capabilities were combined to successfully<br />

install and place the CRSC in<br />

operation in just seven days.<br />

Monitoring Power<br />

Distribution and Core<br />

Stability<br />

In the new modules installed for local<br />

core monitoring, the 132 signals<br />

received from the in-core neutron flux<br />

detectors of the local power-range<br />

monitors are compared against predefined<br />

limits. If the limits are exceeded,<br />

appropriate countermeasures are<br />

initiated. The limits are individually<br />

adjusted by the software to match local<br />

burnup conditions – as determined by<br />

the advanced core monitoring computer,<br />

FNR, a module integrated into<br />

the process computer system – and<br />

are continuously corrected to account<br />

for the present coolant mass flow<br />

and reactor power level. Therefore, it<br />

allows the reactor operator to operate<br />

the reactor in a fuel-efficient manner<br />

for optimum fuel utilization.<br />

Another new feature of the core<br />

monitoring equipment is the capability<br />

for monitoring core stability. As a result,<br />

the neutron flux oscillations typically<br />

observed in the initial portion of<br />

BWR power-flow maps can be reliably<br />

detected. Through the implementation<br />

of suitable countermeasures, these<br />

oscillations can be suppressed before<br />

scram limits are exceeded, thus contributing<br />

to increasing overall plant<br />

availability.


Features<br />

Trillo: Standby Offsite Power System<br />

Connection Upgraded<br />

During this year’s annual refueling<br />

outage at the Spanish nuclear power<br />

plant Trillo, a new 220-kV standby offsite<br />

power system connection was installed.<br />

In addition, modifications were made<br />

to the previous offsite connection for<br />

auxiliary power supply. The functions<br />

performed by the new connection were<br />

demonstrated successfully through<br />

numerous individual tests. An integral<br />

test also was performed to verify simultaneous<br />

switchover of all four redundant<br />

auxiliary power trains from the main<br />

offsite power system to the standby system<br />

with the reactor at hot standby.<br />

The owner of Trillo awarded an order<br />

to Framatome ANP to upgrade the<br />

plant’s standby offsite power system<br />

connection for auxiliary power supply.<br />

The new 220-kV standby connection<br />

would take over the functions performed<br />

by the plant’s previous 132-kV<br />

standby connection. This 132-kV<br />

connection would serve in future as a<br />

second standby offsite power system<br />

connection.<br />

Complex Electrical<br />

Modifications Completed<br />

The scope of the order covered all<br />

of the electrical equipment including<br />

the necessary modifications to the<br />

safety-related and non-safety-related<br />

instrumentation and control (I&C)<br />

systems as well as planning for the<br />

associated civil work and piping system<br />

modifications. The electrical supplies<br />

and services included:<br />

• Two 220/10/10-kV transformers,<br />

each rated for 76 MVA<br />

• 220-kV cables<br />

• Equipment for power system<br />

transfer and transformer protection<br />

• Extensive process engineering<br />

investigations and electrical system<br />

calculations<br />

Preparations for the upgrade took<br />

two years. The actual on-site work was<br />

completed within 30 days during the<br />

2002 outage. The project marked the<br />

first time that a digital process control<br />

system – TELEPERM TM XP from<br />

Siemens – was implemented at Trillo.<br />

This provides a reference for upgrading<br />

other plant systems with digital I&C<br />

in the future.<br />

The excellent cooperation with the local<br />

engineering company EMPRESARIOS<br />

AGRUPADOS, S.A. also contributed<br />

to the success of the project.


Innovation & Technology<br />

Robot Facilitates CVCS<br />

Replacement<br />

Due to the discovery of a thermal<br />

cracking phenomenon in<br />

residual heat removal (RHR) system<br />

mixing zones in 1999, Electricité de<br />

France (EDF) launched an extensive<br />

program to identify potential areas for<br />

similar degradations, such as the safety<br />

injection nozzle, the surge line nozzle,<br />

and the Chemical and Volume Control<br />

System (CVCS) nozzle. At the same<br />

time, EDF wished to qualify the tools<br />

and methods for replacing a complete<br />

spool piece that included the CVCS<br />

nozzle, and examine the removed<br />

spool piece using both non-destructive<br />

and destructive tests.<br />

In early 2001, EDF awarded<br />

Framatome ANP a contract to replace<br />

a primary (cold leg) spool piece at<br />

Fessenheim 1 with a CVCS nozzle.<br />

To reduce critical path time, this operation<br />

was performed at the same time<br />

as their steam generator replacement<br />

since the basic cutting, pipe end and<br />

pump casing decontamination, beveling<br />

and welding techniques as well as the<br />

tools used are similar to the ones used<br />

for the steam generator replacement.<br />

Special Equipment<br />

Required<br />

The workscope consisted of two<br />

cuts made at the level of the existing<br />

welds of the primary loop, one at the<br />

pump connection and the other at<br />

the mid section of the pipe. The removal<br />

as well as the installation of the<br />

spool piece, required specific handling<br />

devices due to the limited access.<br />

To perform the final grinding and<br />

associated non-destructive examination<br />

(NDE) of the inner part of the<br />

welds located on the primary pipe, in<br />

line with the dosimetric objectives<br />

of the operation, Framatome ANP<br />

Performing grinding tests with ARTUR on a mock-up in<br />

preparation for deployment<br />

developed and qualified a new robotic<br />

manipulator named ARTUR. This<br />

system has two parts, a crawler and an<br />

arm that are introduced separately<br />

through the primary pump and assembled<br />

inside the casing. Once both<br />

units are assembled, the manipulator is<br />

driven automatically to its operating<br />

position for the grinding, cleaning and<br />

performance of liquid penetrant test.<br />

New Welding System<br />

Developed<br />

In addition, Framatome ANP developed<br />

and qualified an automated welding<br />

process to perform the welds of the<br />

2", 3" and 4" (5.08 cm, 7.62 cm, and<br />

10.16 cm) lines connected to the<br />

primary coolant system. The aim of<br />

such a fully automated welding process,<br />

beyond the limitation of the dosimetry,<br />

is the re-qualification of the circuits<br />

to the French regulatory specifications<br />

without hydro-testing the primary loop.<br />

Work began at the Fessenheim nuclear<br />

power plant on May 18th, and the<br />

primary coolant system was returned<br />

to the utility on September 21st.<br />

Three steam generators and the primary<br />

pipe spool were replaced and other<br />

main maintenance operations were<br />

performed during the plant outage.<br />

ARTUR and the new welding process<br />

performed successfully and the primary<br />

coolant system was re-qualified<br />

without the hydro-test.


Innovation & Technology<br />

New Tools Facilitate<br />

Reactor Inspections<br />

Blade Probe Tool Meets New NRC Requirements<br />

for Volumetric RV Head Inspections<br />

First-of-a-kind work always<br />

carries risks but when the Nuclear<br />

Regulatory Commission (NRC)<br />

recommended in August that high<br />

risk plants do an inspection in their fall<br />

outage starting in September, there<br />

weren’t many choices. That is what<br />

happened to multiple US nuclear plants.<br />

Until the NRC recommendation was<br />

issued, most of the reactor vessel (RV)<br />

head inspections were visual inspections.<br />

However, as a result of the recent<br />

findings at the Davis-Besse plant, the<br />

NRC determined that more complete<br />

inspections were needed.<br />

The NRC issued Bulletin 2000-02 on<br />

August 9, 2002 recommending that<br />

plants with high susceptibility to<br />

cracking and leaking of the RV head<br />

nozzles perform 100% volumetric<br />

blade probe ultrasonic testing (UT)<br />

examinations.<br />

No one had ever performed 100%<br />

volumetric blade probe UT examinations<br />

on thermal sleeved nozzles. The<br />

blade probes used in the past would<br />

not work for this type of inspection.<br />

Market Awareness<br />

Pays Off<br />

Fortunately, Framatome ANP anticipated<br />

that the NRC was going to issue<br />

another bulletin and that they would<br />

require the ultrasonic inspection<br />

of the RV head. In fact, the company<br />

began work in early June to develop<br />

a tool to perform this task. Knowing<br />

that the Bulletin would result in a<br />

demand for inspections at multiple<br />

plants in a short timeframe,<br />

Framatome ANP expedited its efforts<br />

to perfect the design and to build<br />

multiple sets.<br />

Sumo Rocky manipulator<br />

provides easy access for<br />

blade tool check-out<br />

“The industry required some fast<br />

answers to a very difficult problem –<br />

complete volumetric interrogation<br />

of a complete reactor head penetration<br />

set,” commented Steve Huntington,<br />

US Vice President Outage Services.<br />

“Our NDE engineering group was able<br />

to meet the challenge and provide<br />

inspection robots for all three PWR<br />

designs: Babcock & Wilcox (B&W),<br />

Westinghouse (W) and Combustion<br />

Engineering (CE) in less than four<br />

months. Our customers are benefiting<br />

now from this effort as exams are<br />

completed and units are returned<br />

to service.”<br />

Tool Ready for<br />

Fall Outages<br />

By leveraging French blade tool design<br />

technology and incorporating lessons<br />

learned from field experience, a new<br />

Blade probe is easily installed<br />

on the tool<br />

tool was designed, built and tested in<br />

roughly three months.<br />

To date this fall, Framatome ANP<br />

has completed inspections at three<br />

plants with others underway. The tool<br />

has been proven for use on W and<br />

B&W plants with thermally sleeved<br />

RV heads. In addition, the company<br />

designed a similar but different tool<br />

used in CE plants this fall.<br />

This experience, when combined with<br />

the spring 2002 and fall 2001 outage<br />

campaigns, establishes Framatome ANP<br />

as the most experienced provider of<br />

reactor vessel head examination services<br />

worldwide. By investing ahead of time<br />

and staying engaged in the industry’s<br />

issues, Framatome ANP had new<br />

tooling ready for its customers when<br />

they needed it.


New Ultrasonic Tool Reduces Site Support<br />

for Reactor Vessel Inspections<br />

In the spring of 2003, a new remotely<br />

operated manipulator system will be<br />

introduced for ultrasonic examinations<br />

of PWR reactor vessels. This system,<br />

one of the first Framatome ANP projects<br />

designed to integrate the strengths of<br />

the three regions (France, Germany and<br />

the US) will support full 10-year,<br />

intermediate and follow-up ultrasonic<br />

and visual vessel inspections with<br />

minimal disruption of outage activity.<br />

Called the Trans-World Reactor<br />

Vessel Examination System (TWS),<br />

the six-degree-of-freedom robot and<br />

all in-containment components can<br />

be transported to the canal floor<br />

either through the equipment hatch<br />

or through most personnel hatches.<br />

Once assembled and checked out,<br />

the lightweight manipulator can be<br />

lowered into the vessel with either an<br />

auxiliary crane or with the building<br />

polar crane. The manipulator braces<br />

itself against the reactor vessel wall,<br />

and is ready to begin scanning.<br />

project includes enhancements to the<br />

French Civa Cuve analysis package<br />

that facilitates UT data analysis and is<br />

required for the French code examinations.<br />

The TWS project also includes<br />

development of an advanced I&C<br />

system that will be integrated into the<br />

existing French and German manipulators<br />

as well as controlling the new<br />

six-degree-of-freedom robot.<br />

“The Transworld System will revolutionize<br />

PWR reactor vessel examinations,”<br />

said Steve Huntington,<br />

Framatome ANP’s Vice President Outage<br />

Services in the US. By combining the<br />

engineering and non-destructive<br />

examination (NDE) expertise of the<br />

three regions, we have designed a tool<br />

that will perform complete US vessel<br />

exams in less than two days, and<br />

provide inspection accuracy never<br />

seen before.”<br />

TWS: The Tool for<br />

Reactor Inspection<br />

The TWS reduces vessel occupation<br />

time (VOT) and minimizes site<br />

resource requirements for ultrasonic<br />

examination of reactor vessels. Phasedarray<br />

technology reduces total scan<br />

distances to achieve shorter examination<br />

times. The robot’s compactness,<br />

modularity and configuration flexibility<br />

combine to make this one of the<br />

easiest and fastest tools to install and<br />

remove from the vessel. These innovative<br />

features are designed to make<br />

the TWS the premier reactor vessel<br />

inspection tool of the industry.


Innovation & Technology<br />

SIPLUG Online 3: First Modules<br />

in Operation at Neckar<br />

The first drawout-type switchgear<br />

modules equipped with Framatome<br />

ANP’s SIPLUG ® Online 3 valve<br />

diagnostics system were placed in service<br />

in July 2002 at the German PWR<br />

plant, Neckar. Since then, around 90<br />

switchgear modules containing this<br />

innovative technology have been operating<br />

successfully. Neckar now can diagnose<br />

its valves on line, with the resulting<br />

data sent via the plant’s local network<br />

to office PCs for further analysis.<br />

Therefore, plant personnel can monitor<br />

the performance of a valve and its actuator<br />

in real time. Then, if necessary, a<br />

decision can be made on the type of<br />

maintenance work that will be needed –<br />

paving the way for condition-based<br />

maintenance. By reducing the number<br />

of individual valve and/or actuator tests,<br />

considerable savings in both time and<br />

cost can be achieved.<br />

Installation of the SIPLUG Online 3<br />

components directly at the valve<br />

switchgear enables the old drawout<br />

switchgear modules to be easily replaced<br />

with new ones equipped with SIPLUG<br />

while the plant is on line. More of<br />

the diagnostics modules already<br />

delivered by Framatome ANP, will be<br />

placed in operation soon.<br />

The order received from the operator of<br />

Neckar Nuclear Power Station covered<br />

the supply of a valve diagnostics<br />

system consisting of Framatome ANP’s<br />

SIPLUG Online 3 measuring system<br />

module along with the standard<br />

ADAM ® software for data analysis and<br />

trending (“ADAM” is an acronym<br />

based on the German words for<br />

“Valve Diagnostics and Evaluation<br />

Method”). Over the next two years,<br />

a total of 1,500 SIPLUG modules will<br />

be installed in both units, Neckar 1<br />

and 2.


Tailor-Made Measurement<br />

System Provides Consistent<br />

Results<br />

DC Cook determined that their<br />

manual surveillance test for<br />

the reactor building ice condenser lower<br />

inlet doors produced inconsistent results.<br />

They asked Framatome ANP to develop<br />

a new test device to improve the accuracy,<br />

ease, and repeatability of the 40 degree<br />

hinge frictional force portion of the<br />

Technical Specification surveillance test<br />

for these doors.<br />

The lower ice condenser door force<br />

measurement system measures and<br />

displays the holding, opening, and<br />

closing forces of the doors in a -10° C<br />

(15° F) ice condenser environment.<br />

The new test equipment features<br />

an integrated digital force gauge and<br />

distance measuring gauge that is<br />

connected to an industrial freeze-proof<br />

laptop PC. The laptop electronically<br />

converts the digital signals from<br />

the gauge to provide an immediate,<br />

accurate readout and logs the digital<br />

signals. In addition, Framatome ANP<br />

also created a full-scale mock-up<br />

of a pair of ice condenser lower inlet<br />

doors that DC Cook will use as a<br />

technician training platform.<br />

Framatome ANP completed the design,<br />

procurement, mock-up, testing and<br />

qualification of the system within the<br />

given three-week timeframe.


Departments<br />

Equipment and Services<br />

Fast Help<br />

for Neckar 2<br />

During a routine reactor coolant<br />

pipe inspection at the German<br />

PWR unit Neckar 2 during this<br />

year’s refueling outage, an unexpected<br />

discovery was made. A loose thermal<br />

sleeve inside a safety injection nozzle in<br />

the cold leg of one of the four reactor<br />

coolant loops was found using<br />

Framatome ANP’s SUSI underwater<br />

inspection vehicle. A robotic inspection<br />

vehicle deployed through the safety<br />

injection line up to the loop confirmed<br />

the damage. The plant operator subsequently<br />

contracted Framatome ANP<br />

to repair the sleeve as quickly as possible.<br />

The company immediately put together<br />

a team of experts (component designers,<br />

material specialists, manipulator experts<br />

as well as inspection and repair specialists)<br />

and worked out suitable retrieval<br />

and repair procedures along with a<br />

new inspection concept for the other<br />

three loops. All of these were evaluated<br />

in less than a day in discussions with<br />

the plant operator. The licensing<br />

authorities insisted that, as far as possible,<br />

as-built conditions be restored. At<br />

the same time, efforts got underway –<br />

with the support of Framatome ANP’s<br />

material specialists – to determine the<br />

cause of the damage. In just one week<br />

– working around the clock – all of the<br />

repair and inspection equipment had<br />

been built and field personnel trained<br />

on mock-ups.<br />

The entire scope of work was completed<br />

on schedule in just three weeks.<br />

Neckar 2’s management praised the<br />

work carried out by the Framatome<br />

ANP/intelligeNDT team in repairing<br />

the thermal sleeve. Wilfried Gehrig,<br />

Neckar 2’s project manager, found that<br />

the excellent cooperation between<br />

Framatome ANP’s service personnel and<br />

their project team played a particularly<br />

important role in this success.<br />

Steam Generators Chemically<br />

Cleaned at Neckar 1<br />

Benefits of chemical cleaning: higher steam pressure, lower<br />

coolant temperature and higher plant output<br />

During this year’s annual refueling<br />

outage at the German unit<br />

Neckar 1, Framatome ANP chemically<br />

cleaned all three steam generators,<br />

one after the other, on their secondary<br />

sides. The entire cleaning campaign had<br />

an impact of less than six days on the<br />

critical path of the outage. The objective<br />

of the chemical cleaning was to remove<br />

all hard deposits from the tubesheets<br />

as well as all deposits from the outside<br />

surfaces of the tubes to extend steam<br />

generator service life and to assure<br />

long-term component integrity. After<br />

cleaning was complete, it was possible<br />

– in response to a requirement<br />

imposed by the Authorized Inspection<br />

Agency – to retrieve a number of<br />

foreign objects from inside the steam<br />

generators that were embedded in<br />

the hard tubesheet deposits and that<br />

represented a risk of fretting damage<br />

to the tubes.<br />

The customer chose Framatome ANP’s<br />

High-Temperature Chemical Cleaning<br />

(HTCC) process, the most widely used<br />

chemical cleaning process in the world,<br />

for this project. The high degree of<br />

cleanliness achieved with this process<br />

was verified through a visual inspection<br />

performed after all cleaning steps were<br />

completed. Chemical cleaning also<br />

resulted in a significant improvement<br />

in steam generator heat transfer. After<br />

cleaning, steam pressure at Neckar 1 was<br />

approximately 1.5 bar higher, yielding<br />

a 0.9% increase in plant electric output<br />

at the same reactor thermal output<br />

as before. This was accompanied by a<br />

drop in primary-side temperature of<br />

around 0.5°C (.9°F) which will reduce<br />

the thermal loads on the fuel assemblies.<br />

The steam generator cleaning campaign<br />

at Neckar 1 is expected to increase<br />

power production and therefore revenue,<br />

as well as reduce fuel consumption.<br />

20 Advanced Nuclear Power N O 6 January 2003


Departments<br />

Contracts<br />

Long-Term Service<br />

Contract for<br />

Angra 1 and 2<br />

ELETRONUCLEAR (Eletrobrás<br />

Termonuclear S.A.), operator<br />

of Brazil’s nuclear power plants, Angra 1<br />

and 2, awarded a long-term service<br />

contract to Framatome ANP. The fiveyear<br />

contract, won in the face of stiff<br />

international competition, encompasses<br />

service and maintenance work for<br />

the two units that will be performed<br />

during their respective annual refueling<br />

outages. The majority of the work<br />

will be carried out at Angra 1.<br />

In addition to services related to<br />

refueling and radiation protection,<br />

Framatome ANP’s scope of activities<br />

includes assistance for maintenance<br />

work on the reactor coolant pumps<br />

and motors and valve actuators, other<br />

large pumps and pump motors as<br />

well as electrical components. Support<br />

for inspections and non-destructive<br />

material examinations also are included<br />

in the contract. This contract expands<br />

Framatome ANP’s services to include<br />

Angra 1 (a Westinghouse-built 657<br />

MWe PWR that started commercial<br />

operation in 1984) and positions<br />

Framatome ANP as a competent service<br />

partner in the Brazilian market.<br />

The first maintenance activities for<br />

Angra 1 were performed, to the<br />

customer’s full satisfaction, during the<br />

annual refueling outage in July 2002.<br />

As in the past, Framatome ANP<br />

and ELETRONUCLEAR personnel<br />

worked closely together.<br />

Alliance Formed for I&C Upgrade<br />

TXU Energy’s Comanche Peak<br />

Steam Electric Station formed an<br />

alliance with Framatome ANP to oversee<br />

the planning and installation of the<br />

instrumentation and controls (I&C)<br />

upgrade from analog to digital technology<br />

at both of the Comanche Peak<br />

units. Framatome ANP will provide<br />

the engineering services and equipment<br />

to upgrade I&C systems with the<br />

industry standard TELEPERM XS<br />

platform for safety-related applications<br />

and the TELEPERM XP platform<br />

for non-safety applications.<br />

In September 2002 the German utility<br />

E.ON contracted Framatome ANP<br />

to perform the in-service inspections<br />

on the reactor pressure vessels (RPVs)<br />

for all five of its PWR plants between<br />

2002 and 2010. These inspections<br />

include mechanized ultrasonic examinations<br />

of the lower section of the<br />

vessel as well as the RPV closure head<br />

including the vessel head ligaments.<br />

The contract establishes a new contractual<br />

relationship with the Unterweser<br />

and Brokdorf plants and extends the<br />

scope of existing contracts with<br />

Grafenrheinfeld, Isar 2 and Grohnde –<br />

resulting in a total of eight additional<br />

RPV inspections.<br />

“This is not simply a contract for<br />

Framatome ANP to perform services at<br />

Comanche Peak,” James Kelley, TXU<br />

vice president and chairman of the<br />

alliance said. “This is a blueprint for<br />

Framatome ANP and Comanche Peak<br />

to work together in a spirit of partnership<br />

that benefits all concerned.”<br />

Upgrading the turbine generator of<br />

unit 2 will be performed during their<br />

fall 2003 outage and similar work on<br />

unit 2 will be performed in the spring<br />

2004 outage.<br />

E.ON Awards Long-Term Contract for<br />

Ultrasonic Inspection of All of Its RPVs<br />

Framatome ANP, as one member<br />

of a consortium working on the<br />

dismantling of the experimental fast<br />

reactor at Dounreay in the United<br />

Kingdom, has been awarded additional<br />

work. The Dounreay reactor operated<br />

from 1958 to 1977. Dismantling<br />

began in the early 1980s.<br />

The consortium, operating within an<br />

alliance with the United Kingdom<br />

The first such inspection was performed<br />

in the fall of 2002 at Unterweser by<br />

an inspection team from intelligeNDT<br />

(a subsidiary of Framatome ANP). An<br />

extensive inspection program for examining<br />

the lower section of the RPV – a<br />

critical path activity – was completed<br />

in the scheduled time to the customer’s<br />

utmost satisfaction. In fact, intelligeNDT<br />

set the world record of 3.5 days for<br />

inspection of the RPV lower section at<br />

Germany’s Convoy-series PWRs.<br />

This new contract underscores E.ON’s<br />

interest in maintaining a long-term<br />

relationship with a reliable partner for<br />

this important reactor service.<br />

Framatome ANP Wins Contract Extension<br />

for Dounreay Reactor Dismantling<br />

Atomic Energy Authority (UKAEA),<br />

is composed of Framatome ANP,<br />

Cogema’s subsidiary SGN, and three<br />

British companies: Strachan &<br />

Henshaw, Atkins Nuclear and Alstec.<br />

In this new contract, Framatome ANP<br />

will design and supply tools for the<br />

remote-controlled removal of the<br />

remaining fuel elements (977 rods)<br />

from the Dounreay reactor core.<br />

Advanced Nuclear Power N O 6 January 2003 21


Departments<br />

Events and Meetings<br />

7th International<br />

Customer Seminar<br />

Held by Technical<br />

Center in Saint<br />

Marcel<br />

On October 17-18, 2002, the<br />

Saint Marcel Technical Center<br />

held its first customer seminar since<br />

the integration of the Framatome<br />

and Siemens engineering resources as<br />

well as test facilities and laboratories.<br />

Numerous visitors from countries all<br />

over Europe attended and were given<br />

an overview not only of the Technical<br />

Center’s broad spectrum of products<br />

and services, but also of ongoing<br />

French and German projects and<br />

development work. For example, work<br />

is underway on material issues involved<br />

in optimizing plant life management.<br />

In addition, the visitors viewed recent<br />

activities in thermal-hydraulic studies<br />

and component testing.<br />

In the labs and manufacturing facilities<br />

at Saint Marcel and Le Creusot, the<br />

two Technical Center sites in France,<br />

customers then received up-to-date<br />

information on such topics as advanced<br />

welding techniques, ultrasonic inspection<br />

probe fabrication, and experiments<br />

in the fields of corrosion as well<br />

as fluid and structural mechanics.<br />

Since 1995, six other seminars have<br />

been held in Erlangen and Karlstein,<br />

the Technical Center’s sites in Germany.<br />

Ultrasonic probe manufacture<br />

being demonstrated in Saint<br />

Marcel<br />

Departments<br />

News in Brief<br />

Framatome ANP Receives ISO 9001:2000 Certification<br />

Framatome ANP has just received<br />

ISO 9001:2000 certification for all<br />

four of its business groups and for its<br />

three regions: Germany, France and<br />

the US. To date, only 10% of companies<br />

worldwide have been awarded this<br />

new ISO certification. The 2000<br />

version explicitly integrates customer<br />

satisfaction as a measure and demands<br />

continuous quality improvement.<br />

This certification applies to all of<br />

Framatome ANP’s activities worldwide<br />

and guarantees that the same processes<br />

will be implemented by Framatome<br />

ANP, regardless of the location<br />

providing the services. Preparation for<br />

this certification required standardized<br />

practices across all regions and units,<br />

and developing solutions that best<br />

harnessed synergies and that will<br />

facilitate joint projects. The result is<br />

simplified processes and improved<br />

efficiency that will mean better service<br />

for Framatome ANP’s customers.<br />

22 Advanced Nuclear Power N O 6 January 2003


Departments<br />

News in Brief<br />

FBFC International Attains OHSAS 18001 Certification<br />

FBFC International, a Framatome<br />

ANP subsidiary, is the first<br />

unit of the <strong>AREVA</strong> group to attain the<br />

Occupational Health and Safety<br />

Assessment Series (OHSAS) 18001<br />

certifications at the end of December<br />

2001.<br />

The OHSAS standard, in force<br />

since 1999, was developed with the<br />

assistance of different co-operating<br />

organizations such as the British<br />

Standards Institution, Bureau Veritas<br />

Quality International, Den Norske<br />

Veritas and SGS Yarsley International<br />

Certification Services.<br />

The specifications were developed<br />

in response to customer demand<br />

for a recognizable health and safety<br />

management system standard against<br />

which their own management<br />

systems could be assessed and certified.<br />

Legal obligations were a minimum<br />

but the specifications also include the<br />

installation of a system of continual<br />

improvements in overall occupational<br />

health and safety performance in<br />

line with the unit’s policy.<br />

OHSAS 18001 was designed to be<br />

compatible with the ISO 9001 (quality)<br />

and ISO 14001 (environmental)<br />

norms, already obtained by FBFC<br />

International several years ago.<br />

The first renewal audit for the<br />

OHSAS standard and the second<br />

renewal audit for the ISO 14001<br />

standard was completed in October<br />

at FBFC International. In addition,<br />

a unit of the fuel business group,<br />

FBFC International also is ISO<br />

9001: 2000 certified.<br />

Illustration: Glasgow Media<br />

US Nuclear Parts Center Celebrates 25 Years of Service<br />

In 1977, a Babcock and Wilcox small<br />

parts function was moved from<br />

Akron, Ohio to Lynchburg, Virginia.<br />

At that time, the Nuclear Parts Center’s<br />

(NPC) main business was providing<br />

parts to the NSSS plants being built<br />

by B&W. Over time, a new, specialized<br />

facility was built and the business<br />

was expanded to include all types of<br />

reactors. NPC became the exclusive<br />

nuclear parts distributor for multiple<br />

suppliers, and also manufactured<br />

certain parts and refurbished others.<br />

Framatome ANP’s NPC is celebrating<br />

its 25th anniversary this year. Its mission<br />

is the same as originally expressed<br />

by its first manager, Lou Weissert who<br />

stated, “NPC exists to meet our customers’<br />

needs for reliable spare parts<br />

delivered on schedule, and in that<br />

process, to contribute to the profit and<br />

growth performance of the company.<br />

We should accept nothing less<br />

than having the best reputation for<br />

performance in the spare parts<br />

business as viewed by our customers.”<br />

NPC customers now depend on NPC<br />

to inventory a wide variety of spare<br />

parts so they are available when needed,<br />

reducing their storage costs, and for<br />

helping to solve problems 24 hours a<br />

day, seven days a week. To facilitate<br />

customer contact, an NPC Customer<br />

Inquiry System (NPC-CIS) is available<br />

at: www.us.framatome-anp.com.<br />

Nuclear Parts Center employees<br />

are committed to maintaining<br />

and improving their exemplary<br />

reputation for performance<br />

Advanced Nuclear Power N O 6 January 2003 23


Everything<br />

you want<br />

and nothing<br />

you don’t.<br />

That’s a<br />

solution<br />

beyond.<br />

Maintaining the vital I&C and electrical systems in a nuclear plant is beyond<br />

hardware. It’s more than software. It’s planning and engineering that ensures<br />

everything is integrated, that it fits — within your existing requirements<br />

and your budget. It’s getting exactly what you need how you need it — from<br />

flexible, system-specific upgrades to fully engineered, comprehensive packages<br />

that will help you safely and effectively make megawatts for the life of the plant.<br />

As a premier I&C and electrical solutions provider worldwide, Framatome ANP<br />

puts you in control of your plant’s performance by offering more. Our strength<br />

lies in engineering expertise and state-of-the-art technology, implemented<br />

in nuclear plants throughout the world. Our results speak for themselves,<br />

using engineering and technology to improve performance and reduce costs.<br />

If you want more from your control and electrical systems, just ask.<br />

We are your gateway to<br />

global technologies and<br />

responsive, proven<br />

service. Our extensive<br />

I&C and electrical<br />

solutions reduce costs<br />

and extend plant life. We<br />

deliver real solutions that<br />

maximize your plant’s<br />

performance today<br />

and beyond. That’s value.<br />

And that’s our promise.<br />

Tom Weir, Senior VP<br />

I&C and Electrical<br />

Systems<br />

©2002 Framatome ANP, Inc.<br />

Celebrating 25 years of Success<br />

1977-2002<br />

www.us.framatome-anp.com<br />

Framatome ANP, COGEMA and FCI now form the <strong>AREVA</strong> Group, the world leader in the nuclear energy and interconnect sectors.<br />

SM<br />

Ask for more.<br />

ANP:U-083-V1-02-ENG

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