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Dismantlement Technologies
Lawrence E. BoingArgonne National LaboratoryDecommissioning Program
Outline
Reasons for dismantlement
Typical applications
– Segmentation
– One piece removals
Parameters for selecting a specific technology
Mature technologies
Evolving technologies
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Dismantling
Dismantling is defined as the removal of equipment or structures (clean or radioactive) typically to allow for the completion of the decommissioning process (or of the contracted work scope) by use of any of or some combination of thermal, mechanical, or electrical removal methods
In some cases no dismantling will be required to complete decommissioning and in other cases only minimal dismantling will be required; dependent upon desired end‐state
Some techniques useful ex‐situ while others are useful in‐situ
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Reasons for Dismantling
Removal of components or structures – partially or completely
Removal of highly activated items Size reduction Decontamination Packaging and/or shipping constraints
– Is intact/one‐piece a viable removal option ?– Is entombment in place a viable option ?
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Typical Applications
Metal structures and components
Concrete structures and foundations
Tanks, equipment, piping and pumps
Gloveboxes
Concrete shielding
Pressure vessels including RPVs
Reactor vessel internals
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DOE-Fernald Site / Plants 2 and 3
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DOE-Fernald Site Plants #2 and #3 were “Large Industrial Radiological Facilities”
Tokamak Fusion Test Reactor
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TFTR Facility at DOE-PPPL, Princeton, NJ circa 1997
One of a Kind Structures
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Former Vit Cell @DOE - West Valley PFP Glovebox @ DOE-Hanford
Technique Selection & Optimization
Material to be cut– Type, thickness and geometry– Reinforcement if concrete– Reactionary forces
Environment– Type of facility– In air or underwater– Contamination / activation
levels and dose rates– Pollution controls ‐ air and
water
Waste generation Schedule / lead time / cost Highly unlikely that only
one technique can be used for the project
– Review, evaluate and learn from what others have already done !
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100
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thickness steel (mm)
cutting speed (cm/min)Plasma cutting
flame cutting
arc sawgrinding
mech. saw
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1
10
100
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thickness steel (mm)
Aerosols (g/m) flame cutting arc saw
grindingplasma cutting
mech. saw
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thickness steel (mm)
cutting speed (cm/min)Plasma cutting
flame cutting
arc sawgrinding
mech. saw
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10
100
0 10 20 30 40 50
thickness steel (mm)
Aerosols (g/m) flame cutting arc saw
grindingplasma cutting
mech. saw
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BR-3 Decommissioning Project in Belgium
Training & Mock-Up Testing
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Typical Cutting Scenarios
High contact dose rates
– More remote, semi‐remote, standoff type approaches
Low contact dose rate, but high contamination levels
– More hands on, size reduction station approach, worker protective equipment issues
Low dose rate and contamination levels
– Production rate priority, safety aspects are classic industrial safety ones
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One-Piece Removal
Reactor vessels, steam generators, heat exchangers and pressurizers (25 ton – 1100 ton)
Factors to consider– Burial rates – RPV ‐ $4‐7 M USD– Characterization data– Safety analyses– Transportation issues– Preparations ‐ inside and outside facility ‐ dredging
Use of fillers and coatings– Grouts – used as a void filler– Poly‐urea coatings – used as a fixative over shrink wrap
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Tent Erection
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Small Research Reactor One-Piece Component Removal
Heat Exchanger from the 5 MW CP‐5 Research Reactor
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La Crosse NPP RV
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Trojan NPP RPV Package
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Big Rock Point NPP Reactor Vessel
Shipped to Barnwell Site for disposal
Shipping container: 25’ long, 13’ diameter with walls up to 7” thick
Vessel and canister were filled with 114,000 pounds of concrete
Entire package weighed over 565,000 pounds
October 7, 2003 – left plant site
October 30, 2003 – arrived @ disposal site
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Use of Insta-Cote™ SE at Rocky Flats
Sprayable rapid‐curing polyurea elastometer – DOT strong tight container
16 oversized waste items ‐ included 3 large machine tools – up to 25’ x 10’ x 9’ weighing 150 tons
Used 10‐axle ‘low‐boy’ trailer for shipment for disposal at Envirocare
Used on Supercompactor and Repackaging facility equipment
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Use of Insta-Cote™ at Rocky Flats (ctd)
Special base unit of molded material
Poly‐urea coat base unit & add waste item
Plastic sheet wrap the waste item and shrink wrap item with heat gun & inspect to ensure 100% coverage of item
Repeatedly poly‐urea coat the item up to a thickness of ¼”
Used as a lock‐down agent during demolition
http://www.instacote.com20
Dismantlement Technology Groupings
Dismantlement Technology Groupings
Metal Cutting Technologies
– Mechanical
– Thermal
– Electrical
– Other
Concrete Cutting Technologies
– Mechanical
– Thermal
– Other
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Metal Cutting Technologies
Mechanical
Thermal
Electrical
Others
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Mechanical Metal Cutting Technologies
Shears and nibblers
Saws ‐ circular, reciprocating and band
Abrasive wheels
Diamond wire
Milling
Circular cutters
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Common Saws
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Circular Saw Port-a-Band Saw
Nibblers by Trumpf
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Shears
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High Speed Clamshell Pipe Cutter
Can make remote cuts up to 250 feet away
No applied heat or flame results in no smoke generation
Does not generate airborne contaminants
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Plunging Pipe Crimper/Cutter
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Rancho Seco RPV Head Segment
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Diamond wire sawing used to perform cutting operations
TFTR Vacuum Vessel Segments
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Special Designs
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Cable Tensioning for Structural Demolition
Cable tensioning – pull structures down with cables attached to supporting structural members – being used at many DOE sites
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Thermal Metal Cutting Technologies
Plasma Arc (Electrical/Gas) Torch Oxy‐fuel Torch Controlled Explosives
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Plasma Arc Cutting Technology
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•Torch is an energy converter from an electric arc (pilot arc) to a plasma gas (usually Argon) and a second arc is transferred to the work piece.
• Conversion process is only about 50% efficient – the balance is radiant light and sound.
extracted from www.plasmateam.com website
Controlled Explosive Demolition
Uranium mill structural demolition, Canada
USDOE
– Hanford Site, Production Reactor stacks
– Nevada Test Site, Test Cell A Shield wall structure
– INL Site, Numerous decommissioning sites
– Fernald Site, Building structures
Maine Yankee NPP Containment Building demolition, USA
Commercial NPS ‐ Cooling towers 36
Explosive Demolition of the IET Exhaust Line -INEEL
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Electrical Metal Cutting Technologies
Metal Disintegration Machining (MDM)
Electrical Discharge Machining (EDM)
Arc Saw
Electric Arc Gouging
Consumable electrode cutting (in development)
Contact arc metal cutting (in development)
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Other Metal Cutting Technologies
Abrasive Water Jet (AWJ) Laser
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AWJ Cutting was used for several NPP reactor internals size reduction Tasks – San Onofre, Connecticut Yankee and Maine Yankee
Test Results – Laser Cutting
Laser Type Cutting Capability (thickness)
Speed (in mm / minute)
Power (in kW)
Condition Source
CO Laser 30‐150 mm(SUS‐304)
10‐260 21 UW NUPEC
CO laser 200‐310 mm(SUS‐304)
20‐30 21 In Air NUPEC
YAG laser 281 mm(CS / insulator / Al)
100 7.5 In Air NUPEC
YAG laser 40 mm(SUS)
100 7.5 UW NUPEC
YAG laser 3 mm(SUS lining)
2500 0.5‐1.0 In Air NUPEC
Chemical Oxygen Iodine Laser (COIL)
23 mm(SUS‐304)
0.5 1.0 UW RANDEC
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Concrete Cutting Technologies
Mechanical
Thermal
Other
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Mechanical Concrete Cutting Technologies
Diamond Wire Saw
Other Saws
Hydraulic or Pneumatic Hammers / Hoe Rams
Crushers and Shears
Rock Splitters
Wrecking Ball
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Diamond Wire Cutting
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Diamond Wire Cutting (cont’d)
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Battelle Columbus Labs Decommissioning Project
Brokk
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BROKK 330
Brokk End Effectors
46Breaker Hammer Scabbler
Concrete Crusher Bucket Grapples with rotator
BROKK Technical DataWeight(lbs)
Work Area Radius(inches)
Reach Overhead
w/att (inches)
TransportWidth x Length x
Height(inches)
Min‐Max Lift Capacity (lbs)
Model 40 794 w/att +66
95 96 24 x 47 x 37 264‐1056
Model 90 2050 w/att+265
142 156 31 x 72 x 48 374‐1452
Model 180 4190 w/att +550
179 186 31 x 98 x 54 814‐4400
Model 250 6750 w/att +660
236 252 47 x 142 x 59 ‐‐‐‐‐
Model 330 9240 w/att +1200
256 264 59 x 154 x 60 1650‐8250
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Demolition of former Pu Production Facilitiesat Rocky Flats
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www.demcodemolition.com
Thermal Concrete Cutting Technologies
Flame Cutting
Oxygen Lance
Explosives
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Other Concrete Cutting Technologies
Abrasive Water Jet
Lasers
Concrete Fracturing Products / Expansive Grout – similar products sold under a variety of names– Bristar
– Bustar
– DEXPAN
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Abrasive Water Jet
Abrasive Water Jet Cutting ‐used extensively for size reduction/cutting of concrete structures and a wide spectrum of other materials in various industries
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Concrete Fracturing Products
A non‐explosive controlled demolition agent
Expansive Grout – similar products sold under a variety of names used for fracturing the concrete and then rubblizing it further
– Bristar, Bustar, DEXPAN
Useful in areas with smaller sized concrete pad structures or in areas where noise and shock techniques (explosive demolition) are not viable
Mix with water, pour into drilled holes, expand and demolish; 18,000 lbs / cubic inch expansive strength when mixed with water
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Remote Technologies
Use of Remote Technologies Reduce Personnel Radiation Exposures to ALARA
Reduce Personnel Exposure to Harsh Conditions – Underwater, Radiation, Temperature, Accessibility
General Types
– Manual Human Placed Devices
• Long Handled Tools or Diver Deployment
– Master‐Slave Manipulators
– Power Manipulators – use servo systems to amplify the operator force ‐ARTISAN
– Tele‐robots – similar to Power Manipulators only joystick / remote controlled ‐ NEATER
– Wheeled vehicles and travelling robots54
Long Handled Tool End-Effectors
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From www.hydro-lek.com website
1. Tore Jet Lance2. Grabber / Clamper3. Sheer4. Rotary Disk Cutter5. 5-Function Manipulator
Efficiency Considerations
Human Entry versus Remote Equipment
– Must Consider Operating Efficiencies and Other Supporting Needs to Implement
• Support services required and access factors – ventilation, containments, decontamination capability and rigging features
• Radiological, industrial safety and environmental impacts
• Schedule and costs including lead time and maintenance needs
Remote Equipment Cost versus Personnel Exposure
– One person‐rem of exposure = $1,000 to $25,000 or higher in some cases – is geographic dependent
– Remote equipment is very expensive with training and maintenance difficult and time consuming
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Use of Divers
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Large Remote Dismantling Tooling
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Mast Type Deployment
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Robotic Systems
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Dual Arm Work Platform
Robotic system used where exposure levels prevent prolonged human exposure
Max lift capacity of 240‐lbs at full extension of 78”
Tether supplies hydraulics, power and control signals
Deploys a variety of tools and equipment
50% cost savings compared to manual dismantling
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Demolition Lessons Learned
Fixative applications are effective
Misting devices and water sprays are effective at controlling contamination
Dispersion modeling used to help establish radiological boundaries
Surgical demolition is difficult work
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Innovative Processes
Some recent emerging dismantlement technologies include more evolutionary than revolutionary technologies:
– Lasers – needs further development
– Tele‐operated Systems – various industrial
– Oxy‐gas Cutting System ‐ construction
– Liquefied gas cutting
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Conclusions
Large variety of dismantling tools available spanning a wide range of costs
The tool needs to be evaluated for the job taking into consideration ‐ safety, radiation dose, environmental impacts and other site specific parameters
Remote operations can and will bring numerous problems along with them
‘Keep it simple stupid’ or the ‘KISS Concept’ is your best friend
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Suggested Reading
IAEA Technical Reports Series #395
IAEA Technical Reports Series #440
Health Physics Society ‘1999 Summer School on Decommissioning’
European Commission ‘Decommissioning Handbook’
U S Department of Energy ‘Decommissioning Handbook’
American Welding Society, ‘Welding Handbook, Volume 2, Welding Processes’
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MECHANICAL METAL CUTTING TECHNOLOGIES
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PROCESS ADVANTAGES DISADVANTAGESSHEARS & NIBBLERSBlade/PunchCutting HeadElectric, Hydraulic, Pneumatic Powered
First Controlled CuttingVery Low Waste GenerationRemote OperationCuts Mild Steel & Stainless SteelIn Air & Underwater
Limited Thickness CutLimited Material TypeReaction ForcesSpace Envelope
SAWSCircular BladeReciprocating BladeBandElectric, Hydraulic, Pneumatic Powered
Controlled CuttingLow Waste GenerationNo Off-gas or FumesManual or RemoveOperationIn Air & Underwater
Limited Thickness CutLimited Material typeReaction ForcesSlow CuttingBlade StickingBlades Wear
ABRASIVE WHEELSCircular WheelCutting headElectric, Hydraulic Pneumatic Powered
Manual or Remote OperationIn Air & Underwater
Limited Thickness CutLimited Material TypeReaction ForcesAirborne/Underwater ParticlesPossible SparkingBlades Wear Quickly
MECHANICAL METAL CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGESDIAMOND WIREWirePulley SystemWater Lube SystemElectric, Hydraulic Powered
Cut Various ShapesCuts Very Thick ObjectsRemote Operation
Requires 360 Degree AccessWater DischargeWire Sticking & BreakingSlow Cutting
MILLINGMilling HeadMilling Support FrameLube SystemElectric, Hydraulic Powered
Cuts Intricate GeometriesControlled CuttingRemote OperationIn Air & Underwater
Limited Thickness CutSlow CuttingTool Sticking & BreakingLubricant DischargeReaction Forces
CIRCULAR CUTTERSOD or ID MountedCircular Saw TypeSingle Point TypeCircular Machine FrameElectric, Hydraulic, Pneumatic Powered
Cuts Hollow Circular ShapesControlled CuttingRemote OperationLow Reaction Forces
Limited Thickness CutSlow CuttingBlade or Bit Sticking & Breaking Lubricant Discharge
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THERMAL METAL CUTTING TECHNOLOGIESPROCESS ADVANTAGES DISADVANTAGES
PLASMA ARCTorchElectric Power SupplyGas SourceMotion Control
Fast Controlled CuttingManual or Remote OperationCuts Thick PlatesCuts Carbon & Stainless SteelIn Air & UnderwaterLow Reaction Forces
Off-gas & FumesVery Murky WaterDebris ControlLimited Geometries
OXY – FUEL TORCHTorchElectric StarterGas SourceMotion Control
Fast Controlled CuttingManual or Remote OperationCuts Thick PlatesCuts Carbon SteelIn Air & UnderwaterLow Reaction Forces
Off-gas & FumesVery Murky WaterDebris ControlLimited GeometriesDoes not Cut Stainless Steel
CONTROLLED EXPLOSIVESShaped Explosive ChargeIgnition System
Fast Cutting Remote ApplicationCuts Thick SectionsCuts Any MetalIn Air & Underwater
Off-gas & FumesDust ControlDebris ControlShock & VibrationPlacing Charges
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ELECTRICAL METAL CUTTING TECHNOLOGIESPROCESS ADVANTAGES DISADVANTAGES
MDMElectrodeCutting HeadElectric Power SupplyFlush SystemMotion Control
Cuts Various ShapesCuts Very Thick ObjectsRemote OperationControlled CuttingIn Air & UnderwaterLow Reaction Forces
Off-gas & FumesVery Murky WaterDebris Control Slow CuttingFlush Discharge
EDMElectrodeCutting HeadElectric Power SupplyFlush SystemMotion Control
Cuts Various ShapesCuts Intricate GeometriesControlled CuttingIn Air & UnderwaterLow Reaction ForcesSample Cutting
Some Off-gas & FumesVery Slow CuttingFlush Discharge
ARC SAWCircular Blade ElectrodeCutting HeadElectric Power SupplyMotion Control
Cuts Various ShapesControlled CuttingIn Air & UnderwaterLow Reaction Forces
Off-gas & FumesSlow CuttingDebris ControlFlush System in Air
ELECTRIC ARC GOUGINGConsumable ElectrodeGas or Water Source
Manual OperationIn Air & UnderwaterLow Reaction Force
Off-gas & FumesDebris Control
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OTHER METAL CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGES
ABRASIVE WATER JETFocusing NozzleWater SourceAbrasive SourceHigh Pressure Generator
Cuts Thick PlateRemote OperationControlled CuttingIn Air & UnderwaterLow Reaction Forces
Abrasive WasteDebris Control
LASERLaser Beam GeneratorBeam & Focus OpticsGas SourceCutting NozzleMotion Control
Remote OperationControlled CuttingLow Reaction Forces
In Air OnlyDebris ControlExpensive EquipmentUsually Thin PlatesSlow cutting – but improving
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MECHANICAL CONCRETE CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGES
DIAMOND WIREWirePulley SystemWater Lube SystemElectric, Hydraulic Powered
Cut Various ShapesCuts Very Thick ObjectsCuts Through RebarRemote Operation
Requires 360 Degree AccessWater DischargeWire Sticking & BreakingSlow Cutting
SAWSCircular BladeElectric Hydraulic Powered
Controlled CuttingLow Waste Generation No Off-gas or FumesManual or Remote OperationIn Air
Limited Thickness CutReaction ForcesSlow cuttingBlade StickingBlade WearDifficult Rebar cutting
HAMMERSChisel/Spade BitHammer DeviceHydraulic or Pneumatic Powered
No Off-gas or FumesManual or Remote OperationIn Air
Uncontrolled CuttingDust & Debris ControlSlow & Labor IntensiveWorker FatigueVibrationRebar Not Cut
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MECHANICAL CONCRETE CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGES
CRUSHERS / SHEARSJawsHydraulic PoweredDelivery Device
No Off-gas or FumesRemote OperationIn Air
Non ExplosiveLow Tech Solution
Semi-Controlled CuttingDust & Debris ControlReaction ForcesVibration & Shock
SPLITTERSRock SplitterHydraulic CylinderHydraulic Powered
Non ExplosiveVibration ForceNo Reaction ForcesRemote OperationLow Tech Solution
Semi-Controlled CuttingRebar Not CutSlow MethodHole Drilling
WRECKING BALLBallCrane or Boom
Non ExplosiveInexpensiveLow Tech Solution
Uncontrolled CuttingRebar Not CutReaction ForcesVibration & Shock
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THERMAL CONCRETE CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGESFLAME CUTTINGTorchOxygen SourcePowdered Iron/AluminumElectric Ignitor
Remote OperationConcrete & Rebar CutNo Reaction Forces
Off-gas, Fumes, SmokeSemi-Controlled Cutting
OXYGEN LANCEConsumable Lance (Pipe with Rods)Oxygen SourceElectric Ignitor
Cuts AnythingManual Operation
Off-gas, Fumes, SmokeSemi-controlled Cutting
CONTROLLED EXPLOSIVESExplosive ChargesIgnition System
Fast CuttingRemote ApplicationCuts Thick SectionsIn Air & Underwater
Off-gas & FumesDebris ControlShock & VibrationCharge PlacementDrill HolesRebar Not out
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OTHER CONCRETE CUTTING TECHNOLOGIES
PROCESS ADVANTAGES DISADVANTAGESABRASIVE WATER JETFocusing NozzleWater SourceAbrasive SourceHigh Pressure Generator
Cuts Thick PlateRemote OperationControlled CuttingIn Air & UnderwaterLow Reaction Forces
Abrasive WasteDebris Control
LASERLaser Beam GeneratorBeam & Focus OpticsGas SourceCutting NozzleMotion Control
Remote OperationControlled CuttingLow Reaction Forces
In Air OnlyDebris ControlExpensive EquipmentUsually Thin PlatesSlow cutting – but improving
EXPANSIVE GROUTGrout MixtureConcrete Drill
Low tech processEasy to UseInexpensive
Slow processLabor intensive
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