Zion Nuclear Power Station Decommissioning Project

N OLUTIONSOIZ S LLCAn EnergySolutions Company

Zion Nuclear Power PlantDecommissioning Project

Bill SzymczakFormer ZS Nuclear Fuel Specialist

ANS/NE – Chapter Meeting – June 2015

Z NOI S ITULO ONSAn EnergySolutions Company

LLCPRESENTATION OVERVIEW

I. Status Update (6/8/2015 ZCAP Meeting)II. Zion Nuclear Power Plant BackgroundIII. Zion Decommissioning Project PlanningIV. Regulatory RequirementsV. 3 Major Phases of WorkVI. Zion Project Schedule

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LLCI. Status Update - 2015 Work Activities

• Fuel Transfer Operations (Complete January 9)• GTCC (Complete March 6)• License Termination Plan Submitted to NRC and Accepted

for Review• Unit 2 Rx Vessel Segmentation• Unit 1 Rx Vessel Segmentation• Crib House Demo (2nd Quarter)• Unit 2 Large Components• Unit 1 Large Components (4th Quarter)• Complete Turbine Building Unconditional Release Surveys• Start Turbine Building Demolition (4th Quarter)

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LLCReactor Vessel Segmentation

• Unit 1 and Unit 2 Lower Internals Complete

• Unit 1 and Unit 2 Cavities have been drained and decontaminated. Paint fixative applied to cavity walls and floor.

• Unit 2 reactor vessel segmentation started

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Cutting on Lower internalsUnit 1


LLCWaste Operations 2015

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• Class A waste disposal – 338,000 lbs of 3.2 M lbs. shipped

• Class B&C waste disposal complete – 37 of 37 casks shipped


LLCDisbursements and Balances

ZionSolutions Nuclear Decommissioning TrustBalance Roll Forward – Cash Basis

As of March 31, 2015

($ millions)Beginning Balance $ 801.4

Earnings - Net of Taxes & Fees 123.6

Disbursements (633.7)

Ending Balance $ 291.3


LLCMajor Expense Categories

Majority of Expense IncurredAs of March 31, 2015

Project ManagementProcurement of Casks & Canisters for Dry Fuel StorageWaste DisposalPlanning & Preparation for Spent Fuel StorageUnit 1 & 2 Internals SegmentationISFSI Pad Design & ConstructionPlant Maintenance & SecurityAsbestos RemediationUnit 1 & 2 Containment Preparation & SupportFuel Transfer OperationsUnit 1 & 2 Reactor Vessel


LLCII. Zion Nuclear Power Plant Background

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Zion Nuclear Power Station1. Two Westinghouse PWR Units, 1085 MWe each2. Operated 1973-19973. Shut down 1998 / SAFSTOR4. Decommissioning and Dismantling

(D&D) activities started 2010September 2010

Containment Building

FuelBuilding

AuxiliaryBuilding

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SAFSTOR Mode1. Fuel was maintained in Spent Fuel Pool2. >> 5 Year Wait – Fuel Assembly Cool Down Before Allowed to Move

to Dry Storage3. Spent Fuel Pool part of an Independent Nuclear Island

2,226 Fuel Assemblies9

II. Zion Nuclear Power Plant Background (con’t)


LLCII. Zion Station Decommissioning

September 2010

The ZNPS Part 50 License transferred from Exelon to ZionSolutions to decommission ZNPS including the transfer of fuel to dry cask storage

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LLCII. Zion Decommissioning (cont.)

A. Asset Sale Agreement between ZionSolutions & Exelon1. ZionSolutions (ZS) acquired the assets of Zion Station

(Nuclear Decommissioning Trust Fund)2. Leased the land from Exelon3. Took possession of spent nuclear fuel but not ownership (2228 F/As)4. Transferred the Part 50 NRC licenses for Zion Station from Exelon to

ZionSolutions5. Assumed full responsibility for licensed activities6. Assumed all liabilities and obligations for radiological

decommissioning and site restoration7. Return Independent Spent Fuel Storage Installation (ISFSI), reduced

Part 50 licensed area and land to Exelon by 2020

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LLCII. Zion Decommission Project Planning (con’t)

B. Project Organization1. Retained existing Exelon employees to support operation and

maintenance of the plant including operations of synchronous condenser which ceased operation in 2011

2. Adopted existing Exelon Zion Station procedures, emergency preparedness, training, and security plans

3. Established job functions at Zion using ZS and contractor including Exelon personnel & staffed with experienced personnel

C. Project Control1. Based on lessons learned from past D&D projects2. Baseline project controls tied to financial reporting system to track costs3. Report monthly on cost schedule variances and earned value4. Accountability reviews by corporate and external stakeholders including

Exelon

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Zion Nuclear Power Station Decommissioning Schedule Milestones• 2010/2012 Decommissioning planning, order dry cask system, design and

construct ISFSI, components removal in the containment building.• 2012/2013 Preparation to transfer spent nuclear fuel into dry storage

canisters• 2013/2014 Reactor Vessel internals segmentation complete• 2014/2015 Complete transfer of spent nuclear fuel & GTCC casks to ISFSI• 2015 Complete segmentation of Reactor Vessels• 2015 Take the plant cold and dark• 2016 Complete removal of contaminated equipment• 2016 Complete demolition of the Turbine and support buildings• 2018 Complete all major demolition• 2018-2019 Complete site restoration and Final Status Surveys• 2020 Complete Project

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II. Zion Decommission Project Planning (con’t)


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A. Regulatory Related Activities• Interface with Regulators• Revise Updated Final Safety Analysis Report (UFSAR) which became

Defueled Safety Analysis Report (DSAR)• Revise Technical Specifications, Emergency Plan and Security Plan to

reflect ZionSolutions Quality Assurance Project Plan• Develop D&D Plan – Post-Defueled Safety Analysis Report (PDSAR)

(10 CFR 50.82 (a)(4)(i))• Revise Records Management Process• Decommissioning Trust Fund Periodic Reporting • License Termination Plan

III. Licensing

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B. Decommissioning Licensing Activities• Dry Cask Storage Licensing Support - key areas:

• NAC MAGNASTOR/MAGNATRAN Licensing• ISFSI Licensing• FHB Crane SF Upgrade

• DOT (Department of Transportation) permits for large components and radwaste shipments

• Construction Permit for Rail Spur• Demolition Permits• Hazardous Paint Removal• Air Quality Permit for Dust Control• Underground Storage Tank Removal• Air Emissions Source Removal• FAA (Federal Aviation Administration) & FCC (Federal Communications Commission)

Notifications• Coast Guard buoy permits• NPDES (National Pollutant Discharge Elimination System) permit modifications/ renewals• Sanitary/Water treatment permits

III. Licensing (con’t)

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1. Waste Management2. Spent Fuel Management3. D&D Work

IV. 3 Major Phases of Work

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LLCWaste Management

1. Overview (estimated)• 3.2 MM ft3 Class A• Equipment, piping, debris,

secondary waste, (Clive Disposal )• 1.3 MM ft3 recycle materials• Copper, steel, rebar• 4,200 ft3 Class B/C• RV Internals• 700 ft3 GTCC• RV internals

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LLCWaste Management (con’t)

2. Status of shipping campaigns currently underway:• Waste Class B and C materials • Class B/C waste shipped to date 30 liners (as of 2/18/15)• Scheduled completion by the end of May, early finish estimated around

mid-March of 2015• Waste Class A materials• Class A waste shipped to date is more than 276k ft3

• Concentrating on removal of unique waste streams (special nuclear material, sources, odd shaped large components)

• Continues on for balance of project

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2. Containers for Waste Shipments & Methods of Transport• Various containers are being utilized for shipments of Radioactive

Materials:– Casks

•Specialty container, shipped on a truck– Intermodals

Commercially available containers shipped on rail (primary) and truck (secondary)

– Sea-landsCommercially available containers shipped on rail (primary) and truck (secondary)

– Gondolas•Commercially available containers shipped on rail only

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Gondolas

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Intermodals

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First cars shipped to Clive, UT Nov/Dec 2012

Reactor coolant pump motor

Low Level Waste22



Intermodal coming out of containment

Disposal site Clive UT

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A. Fuel Integrity Inspection1. Inspected for damaged fuel – included

historical records review, 100% visual inspections, and vacuum sipping inspections (1368 FAs)

2. Top nozzle repair required for stress corrosion cracking in Westinghouse fuel

Spent Fuel Management

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LLCSpent Fuel Management (con’t)

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• ITTRs (Instrument Tube Tie Rod) installed in 1451 assemblies• The ITTR solution ensures:

• - The structural integrity of the fuel assembly• - Allows the storage of core components in the fuel assembly• - Allows continued fuel handling by “normal means

EDM Upper Nozzle Tie Rod InstallationANS/Best of DD&R 2012 - Panel


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B. Spent Fuel Types1. Damaged Fuel (>pinhole leaks) – placed in damaged fuel canister2. Low Burn-up Fuel3. High Burn-up Fuel (> 45,000 mwd/mtu) – placed in damaged fuel canister

C. Spent Fuel Storage/Transportation Canisters/Casks – NACD. Spent Fuel Transfer ProcessE. ISFSI & Heavy Haul Path

1. Plan, Locate, Design – Location along from active D&D area2. Construct3. Regulatory Oversite

Spent Fuel Management (con’t)

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Z NOI S ITULO ONSAn EnergySoluitons Company

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F. Fuel Transfer Operations1. Fuel Transfer Operations (FTO) craft and supervision underwent

classroom, OJT, and mock-up training2. 4-10 person crews working 4 days on - 4 days off3. FTO worked 24 hours, 7 days per week4. 54 week campaign with maintenance and weather contingencies –

completed in 52 weeks5. Roughly 1 canister every 6 days6. First fuel canister placed on the pad on January 6, 20147. Challenged with non-nuclear union workforce

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I. Fuel Transfer Operations (Typical process of a canister)1. Day 1 Prepare canister for over-pack and locate into fuel handling

building2. Day 2 Load fuel into the canister3. Day 3 Weld the canister4. Day 4-5 Vacuum dry and backfill the canister with helium5. Day 6 Stack-up and transport the canister to the independent spent fuel

storage installation (ISFSI)

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H. Zion Dry Cask Storage – NAC Components• NAC MAGNASTOR System (home for 2228 fuel assemblies)

– 2 MTCs (MAGNASTOR transfer casks) w/adapter plates & lift yokes– VCT (vertical cask transporter) & LPCRT (low profile cask rail transporter)– 61 fuel & 4 GTCC VCCs (vertical concrete casks) constructed– 31 TSCs, 30 TSCDFs, 4 GTCC TSCs– 99 DFCs (damaged fuel cans) (includes 2 spares)– 2131 TSC fuel spacers (1890 – bottom spacers/241 top spacers)

MAGNASTOR System 61 Fuel + 4 GTCC

Canister – 37 FAsVertical Concrete CaskTransfer Cask

2 Transfer Casksfor SNF and GTCC


296/18/2015 sssss


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ZS Dry Cask StorageNAC Components

VCC Construction Pad

VCT with VCC

MAGNASTORTRANSFER

CASK (MTC)

TSCs

LIFT YOKE

CASK DECON PIT


30306/18/2015 sssss


LLCGTCC Waste Summary

• Approx. 94,000 lbs. of GTCC Waste• Approx. 460,000 Curies• Approx. 220,000 Curies of Co-60• Maximum dose rates 13,000 R/hr (130

Sv/hr)• Multiple lifts >200,000 lbs

• Unit 2: July 15 to October 9, 2014• Unit 1: January 9 to March 6, 2015• Used Experienced FTO personnel• 4.1 Person Rem Est per Unit.• Unit 2: 2.6 Person Rem; • Unit 1: 3.6 Person Rem• Zero Injuries

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ISFSI Physical Facility – completed Fall 2013 • 2 -148’ x 68’ concrete pads & 35’ wide alleyway• Monitoring Building• Security Systems

ISFSI Construction


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Fall of 2013March 2015 - 61 Fuel Casks plus 4 GTCC casks on the pad


336/18/2015


LLCD&D Activities

A. Labor Force TrainingB. Containment Activity

1. Containment Opening 2. Interference Removal3. Vessel Segmentation

C. Auxiliary BuildingD. Turbine BuildingE. Office Building

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Containment Access Opening

D&D Activities (con’t)

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ContainmentPre-stressed Tendon

Removal


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Rx Cavity Decontamination

Pressure Washing Painted w/Lag Kote Sealant


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RV Internals / RV Segmentation Project• Contractor is Siempelkamp Nuclear Services• Mechanical cutting of Reactor Vessel

Internals (RVI)• Oxy-propane cutting for Reactor Vessel

– Stade and Karlsruhe reactor experience in Germany

– Equipment fabricated and on-site• Units 1 & 2 RVI

– Upper and Lower internals complete• Unit 2 Reactor Vessel Segmentation

equipment setup in process, segmentation to start in April 2015


The Reactor Vessel shown with the Reactor Vessel Internal is a cylindrical shell with a welded

hemispherical bottom head.


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VRS Assembled Inside Unit 2 Cavity Prior to Filling39

Reactor Vessel Internals Segmentation


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Cutting on upper internals from Unit 2

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Volume Reduction Station Segmenting Unit 2 Control Rod Guide Tubes


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41Waste Basket Loaded With Control Rod Guide Tubes



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42Unit 1 Lower Internals Being Removed From RV



LLCDecommissioning End State

1. Site At Completion of Decommissioning (End State)• Zoned for Heavy Industrial Use• Above grade buildings demolished and removed (to a minimum 3’ below

grade)• Basement areas backfilled and land areas returned to natural contours• Roadways and rail lines will remain• Intake and discharge piping from and into Lake Michigan will remain• Some buried piping will remain• Adjacent facilities/structures to remain:

ComEd Switchyard (to the West) ISFSI Complex (to the Southwest) ISFSI Warehouse (to the Southwest) Microwave Tower (to the South) Sewage Lift Station

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LLCDecommissioning End State(con’t)

Site At Completion of Decommissioning (End State)

“The 10 CFR Part 50 license will be reduced to the area around the ISFSI and the rest of the site released for unrestricted use. The site will be transferred back to Exelon under the Part 50 license when decommissioning is complete.”

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ZION YEAR 2020

ZION TODAY

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- END -


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The presenter would like to acknowledge the effort and work of Linda Chou, ZS Nuclear Licensing Specialist who provided me the base materials for this presentation.

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ACKNOWLEDGEMENTS


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BACKUP SLIDES


LLCRadiation Protection/License Termination

TERMINOLOGY

MARSSIMNUREG-1575, Multi-Agency Radiation Survey and Site Investigation Manual:Provides guidance on planning, conducting, evaluating and documenting Final Status Surveys (FSS) and Source Term Surveys (STS) for demonstrating compliance with dose or risk-based regulations. Also provides guidance for Characterization Surveys, Radiological Assessments and Remedial Action Support Surveys.MARSSIM surveys are performed on soil, systems and structures earmarked to remain at the time of license termination.

MARSAMENUREG-1575, Supplement 1, Multi-Agency Radiation Survey and Assessment of Materials and Equipment:Provides guidance on planning, conducting, evaluating and documenting radiological disposition surveys for the assessment of materials and equipment (M&E). MARSAME guidance will be used for Unconditional Release Surveys of secondary side structures, systems and components.

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TYPES OF RADIOLOGICAL SURVEYS

License Termination

Unrestricted Use of Zion Site

Characterization Surveys

Contamination Verification Surveys

Unconditional Release Surveys

Radiological Assessments

Remedial Action Support Surveys

Final Status Surveys

Source Term Surveys

Radiation Protection/License Termination (con’t)

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LLCRadiation Protection/License Termination (con’t)

2. Fill Material (CCDD/Sand)• Beneficial reuse of concrete from demolition of

structures > 588 ft. elevation and some material < 588 ft.• Candidate concrete is surveyed in accordance with

MARSAME• Concrete is size-reduced to 10” minus; Rebar and other

non-concrete materials is removed• Prior to staging, containerized material is subject to µR

survey and truck monitor• Staging area is isolated and controlled and periodic

surveillances are performed• Recent NRC inspection of Unconditional Release

(MARSAME) Program

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LLCRadiation Protection/License Termination (con’t)

3. Demonstrating Compliance with Radiological Criteria• The site release criteria for Zion Station are the radiological criteria for

unrestricted release specified in 10 CFR 20.1402– Dose Criterion: The residual radioactivity that is distinguishable from

background radiation results in a TEDE (Total Effective Dose Equivalent) to an average member of the critical group that does not exceed 25 mrem/year, including that from groundwater sources of drinking water; and

– ALARA (As Low As Reasonably Achievable) Criterion: The residual radioactivity has been reduced to levels that are ALARA.

• Section 4 of the License Termination Plan (LTP) demonstrates compliance with the ALARA Criterion

• Section 6 of the LTP demonstrates compliance with the Dose Criterion

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LLCV. Zion Project Schedule

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LLCV. Zion Project Schedule (con’t)

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Documents

Zion Nuclear Power Station Decommissioning Project