• SONGS 1 Cask Handling System


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SONGS 1 Cask Handling System
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INTRODUCTIC )NS
47
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+ SCE team:
* Jim Reilly Director of Unit 1 Decommissioning
* Dave Pilmer Manager, Unit 1 Licensing
* Riyad Qashu Supervisor Analysis Group
* Torrey Yee Consulting Engineer
* Paul Gyswyt Senior Civil Engineer
May 22, 2003 SONGS Unit 1 2
1
BACKGROUND
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4+ SONGS 1 undergoing active decommissioning
4 ISFSI required to support SONGS 2&3 operation
+ ISFSI located at Unit 1 portion of site
+ Recent NRC questions at other sites on cask handling issues
O Need to address cask handling issues before schedule is
impacted
May 22. 2003 SONGS Unit) 3
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SONGS Unit 1 Plant Boundaries 5
SONGS Unit 1 Cask Handling System
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I+ Project Scope for the SONGS Unit 1 Cask Handling System to
Comply with NUREG-0612/0554 Requirements:
"Single Failure Proof' Turbine Gantry Crane
t * Retrofit and Seismically Qualify
a Ederer eXtra-Safety And Monitoring (X-SAM) Trolley
* Replace Existing Trolley
. North Extension Building Structure
* Upgrade for "Single Failure Proof' Gantry Crane
May 22. 2003 SONGS Unit 1 6
3
NUREG-0612 Evaluation
+ Guideline # 1: Gantry Crane Safe Load Paths
* Drawings define transfer cask path
* No safe-shutdown SSCs or spent fuel below path
* Plant procedures define the transfer cask load path
* Operator training reinforces the transfer cask load path
* Markings clearly show transfer cask load path on Turbine
Building and Fuel Storage Building
* Second person is assigned to "walkdown" the path and
guide the crane operator in the gantry cab
May 22. 2003 SONGS Unil) 7
PLAN
Transfer Cask Load Path
8
4
Transfer Cask Load Path
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Transfer Cask Load Path
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NUREG-0612 Evaluation
+ Guideline #2: Load Handling Procedures
* Procedures assure required actions and precautions related to
cask handling are well understood by operator
* Gantry Crane Operation Procedure
* Radio remote for trolley/hoist control
* Back-up pendant precautions
* eXtra-Safety And Monitoring trolley safety features
* Transfer Cask Control Procedure
May 22. 2003 SONGS Unit 1 12
6
NUREG-0612 Evaluation
+ Guideline # 3: Gantry Crane Operator Training
* 12 hours of training ensures joumeyman operator familiarity
with equipment and plant procedures
* Reduce occurrence of crane operator errors
* Crane operator qualification process
May 22. 2003 SONGS Unit 1 13
NUREG-0612 Evaluation
+ Guideline #4: Special Lifting Devices
Adequate safety margins and proper installation and use.
* Two special devices: Yoke and Yoke Extension
* Design Criteria per ANSI N14.6
* 10:1 ultimate factor of safety
* Prior to use visual, dimensional, nondestructive exams
* Procedures for storage and handling of devices
+ Guideline # 5: Lifting Devices ( Standard Rigging)
* Use 10:1 ultimate factor of safety margin
* Proper installation and use.
May 22, 2003 SONGS Unit 1 14
7
__ Yoke
Exten sion
Hook Special Lifting Devices 15
NUREG-0612 Evaluation
* Guideline #6: Cranes (Inspection, Testing, and Maintenance)
* Gantry Crane Inspection
* Welding and Dimensional Checks
* Gantry Crane Load Testing prior to use
* 125% of 105 Tons = 262,500 pound test weight
Gantry Maintenance Current prior to first lift
* Load bearing components are in proper working order
* Wom or damaged parts are identified and replaced
* SONGS Inspection & Testing Procedures:
* Maintenance and Inspection of Cranes
* Rigging Standards, Prior to Use Inspections
* Inspection and Testing of Special Lifting Devices
May 22, 2003 SONGS Unit 1 16
8
NUREG-0612 Evaluation
+ Guideline # 7: Crane Design
* Conformance to design guidelines ensures industry standards
are meet.
* CMAA - 70
* Structural, Mechanical, & Electrical Requirements
* Crane specific considerations, i.e. bumpers
* NUREG-0612 Appendix 'C'
* Modification of Existing Crane
* NIJREG-0554, "Single Failure Proof Cranes for Nuclear
Power Plants"
May 22. 2003 SONGS Unit 1 17
NJREG-0554 Evaluation (NUREG-612 Appendix 'C')
+ Allowable Stress Limits
* Stresses are maintained below yield, anywhere in the
individual members, when they are exposed to maximum
load lifts during SSE.
May 22. 2003 SONGS Unit 1 18
9
NUREG-0554 Evaluation (NUREG-612 Appendix 'C')
+ Control & Hold the Load During SSE
Handling System Seismically Qualified
* Gantry Crane/Building Coupled Structural Analysis
* Trolley Mechanical/Structural Analysis
X-SAM
EDR-1, Topical Licensing Report
May 22, 2003 SONGS Unit 1 19
NUREG-0554 Evaluation (NUREG-612 Appendix 'C')
+ Automatic Controls and Limiting Devices
X-SAM Components Design
* Malfunction can not prevent the crane from stopping or
holding the load
+ Dual Reeving
* X-SAM concept includes a dual reeving system
* Two independent sets of reeving
* Hydraulic load equalization system
* Cushions sudden motion from one wire rope failure
May 22,2003 SONGS Unit 1 20
10
NUREG-0554 Evaluation (NUREG-612 Appendix 'C')
+ Sensing Devices for Overspeed, Overload, Overtravel
* X-SAM Failure Detection System
* Detects the loss of mechanical continuity in the hoist
* Improper rope spooling
* Drum overspeed
* Detects actuation of Energy Absorbing Torque Limiter
* Limits load imposed on the reeving system from:
* Load hang-up
* Two-blocking
* Load Cell senses overloads during hoisting
May 22, 2003 SONGS Unt 21
NUREG-0554 Evaluation (NUREG-612 Appendix 'C')
+ Design for 'Two-Blocking"
* The X-SAM utilizes a Hoist Integrated Protective System
* Prevents overload of hoist components, i.e.wire rope.
+ Independent, emergency path for stopping and holding the
load in the event of any single, credible failure in the hoist
drive system.
+ Hoisting Drum Design for Shaft or Bearing Failure
* Drum Safety Structure
* Separate hub and stub assembly
* Restraint structure to prevent drum gear and emergency
brake from disengaging
May 22,2003 SONGS Unit) 22
11
NUREG-0554 Evaluation (NUREG-612 Appendix 'C')
4 Safety Devices, i.e. Limit Switches
* Safety devices such as trolley and gantry travel mechanical
stops
* Dual and separate upper limit hoist switches
* One vertical lower limit hoist switch
* Trolley end of travel limit switches
+ Static and Dynamic Load Tests
* 125% load testing
* 100% full performance load testing
Afy 22. 2003 SONGS Unit 1 23
STRUCTURAL ANALYSIS
+ CRANE DESCRIPTION
* The gantry is 47' tall, 40' center span, box girder
construction
* Originally designed for 115 tons and currently rated for 100
ton capacity lifts
* The deck is pre-stressed reinforced concrete slab
* The gantry crane runway/deck is supported by a steel frame
structure
* The Gantry Crane movement is restricted to the Turbine
Building North Extension
May 22, 2003 SONGS Unit 1 24
12
STRUCTURAL ANALYSIS
+ SEISMIC CLASSIFICATION
* The North Extension is Seismic 'A'
* The Gantry Crane is Seismic 'B', upgraded to Seismic 'A'
. The Trolley is a "Single Failure Proof' Seismic 'A'
May 22. 2003 SONGS Unit 1 25
Turbine Gantry Crane 26
13
STRUCTURAL ANALYSIS
+ DESIGN CRITERIA
SONGS 1 Seismic Design Basis
The allowable stress limits are maintained below yield, to prevent
permanent deformation of the individual structural members when
exposed to maximum load lifts during SSE. SONGS 1 Design Criteria
provided allowable stresses below yield:
* Tensile 0.96 Sy
* Compression 0.96 Sy
* Shear 0.57 Sy
m Column buckling per AISC
a Plate buckling per AISC and CMAA
. Maximum lifting load 105 tons
May 22. 2003 SONGS Unit) 27
STRUCTURAL ANALYSIS
I STRUCTURAL ANALYSIS METHODOLOGY
* Modal response spectra analysis @ 5% damping
Geometry was based on as built dimensions
I * Standard three dimensional FEA using a combination of
beam, plate, and mass elements
* Trolley and lifted load were modeled as rigid mass
* Gantry and building were modeled with beam elements
* Deck was modeled with plate elements
* Gantry (local stress) was modeled with plate elements
* Coupled model of gantry and building
May 22 2003 SONGS Unit 1 28
14
STRUCTURAL ANALYSIS
* Boundary conditions
* Trolley wheels were modeled as pin connections
* The gantry wheels were modeled as pin-connections to
rails in the E-W, and up-down. To prevent the up/down
motion L-shaped hold down restraint were added
* Sliding of the gantry is allowed N-S, and is bounded by a
spring load equals 0.3(normal load)
* Computer programs used:
• SAP 2000
* GT-STRUDL
* ANSYS
May 22. 2003 SONGS Unit 1 29
STRUCTURAL ANALYSIS
* Analyzed a total of 14 hook positions
E * Used the maximum induced forces and moments from any
i position to calculate stress
May 22, 2003 SONGS Unit I
30
15
North Extension Building Mods
31
Gantry ANSYS Model - Overall
16
Gantry ANSYS Model - Detail
STRUCTURAL ANALYSIS
i RESULTS SUMMARY
. Added to the building two columns and two brace beams
. Strengthened 7 building connections
* Added 12 hold-down restraints to the gantry
. Strengthened gantry girders, joints and columns
. Reinforced gantry wheel trucks
. Increased number of trolley rail clips
. Met design criteria
May 22. 2003 SONGS Unit 1 34
17
Gantry ANSYS Model - Overall
Trolley Rail Clips - Gantrex
36
18
Cask Drop Consequences
+ Safety analysis does not postulate cask drop because crane meets
NUREG-0554 single-failure-proof criteria
+ Consequences of hypothetical cask drop
* Cask drop causes all fuel rods to rupture and breaches
confinement of internal gases
* Puff release made directly to atmosphere
* Atmospheric dispersion using 5th percentile most adverse
conditions (consistent with SAR accident dose calculations)
* Source term bounds all Unit 1 fuel (calculated for 10 years'
decay)
MaY 22, 2003 SONGS Unit 1 37
Cask Drop Consequences
+ Krypton-85 is only gaseous isotope remaining (iodines and
other noble gases have decayed away)
+ 30% gas activity is released
| + Dose receptor is at the closest point of exclusion area
boundary at plume centerline
+ Hypothetical dose consequences:
* Whole body gamma immersion dose is 9.35 mrem
* Beta skin immersion dose is 777 mrem
May 22. 2003 SONGS Unit 1 38
19
Safety Analysis for Cask Handling
+ Ensure Safe Storage of Spent Fuel in Pool
+ Ensure Safe Transfer of Spent Fuel to the ISFSI
May 22, 2003 SONGS Unit 1 39
Safety Analysis for Cask Handling
| + Protection of Spent Fuel in Pool
* No heavy load lifts over the spent fuel pool
* Cask Pool is physically separated from spent fuel pool
* Single Failure Proof Crane to prevent load drops
* Hypothetical load drop in cask pool would not cause
spent fuel to be uncovered
* Crane upgraded for Design Basis Earthquake
May 22. 2003 SONGS Unit 1 40
20
Safety Analysis f or Cask Handling
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SONGS 1 Spent Fuel Pool
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Safety Analysis for Cask Handling
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SONGS 1 Spent Fuel Pool
42
21
Safety Analysis for Cask Handling
+ Safe Transfer of Spent Fuel
* Single Failure Proof Crane to prevent load drops
* Transfer Cask is qualified for maximum drop height of 80
inches
* Crane and Turbine Building upgraded for Design Basis
Earthquake
* Decontamination Area modified to prevent potential
overturning of the Transfer Cask
May 22. 2003 SONGS Unit 1 43
Licensing Process
+ Licensing Process
* Submit amendment to Unit 1 Safety Analysis Report (DSAR)
* Crane qualification being increased from 100 tons to 105
tons
* Ederer X-SAM single failure proof trolley
* Lifting devices have 10:1 safety factor
* Structural enhancements to gantry frame
* Structural enhancements to support building
* Structural enhancements to gantry rails
* Seismic restraints applied to gantry wheels
May 22. 2003 SONGS Unit 1 44
22
Schedule
: Schedule
* Submit SAR amendment by August 15, 2003
* Request 3 month NRC review
* SER issued by November 15, 2003
* Unit 1 cask handling dry runs commence March 15,
2004
* Unit 1 spent fuel handling from March 25 to August 27,
2004
lav 22, 2003 SONGS Unit 1 45
M,
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23
CONCLUSION
+ "Single Failure Proof' Turbine Gantry Crane
+ Seismic Building Upgrades
+ Maintained NUREG-0612 "Defense-In-Depth"
Approach
Mfay 22. 2003 SONGS Unit 47
24


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