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Westinghouse Proprietary Class 3 © 2015 Westinghouse Electric Company LLC. All Rights Reserved.Westinghouse Non-Proprietary Class 3 © 2015 Westinghouse Electric Company LLC. All Rights Reserved.
Nuclear Materials Research at the Westinghouse Hot Cells:
Supporting Fleet Operations for 40 Years
Paula FreyerFellow Engineer
Materials Center of Excellence
Westinghouse Electric Company LLC
NSUF Users MeetingTuesday, June 23, 2015
A Proud NSUF Partner Laboratory
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Westinghouse Laboratories - Areas of Expertise• 40 yrs experience in shipping, handling and evaluating
activated/contaminated materials/components• Mechanical performance testing and microstructural
characterization• Autoclave facilities for comprehensive corrosion
evaluations• Irradiated property measurements• Custom design/fabrication of irradiated materials
testing hardware/loops
2013-15 AP1000 Surveillance Capsule Fabrication
1960s Surveillance Capsule Fabrication
16 new capsules shipped to China
16 new capsules shipped to VC Summer 2 & Vogtle 3
16 new capsules fabricated for VC Summer 3 & Vogtle 4
• Nuclear materials R&D and technology/product development
• Fuel crud and steam generator sludge analysis
• Reactor pressure vessel surveillance capsule design, fabrication and testing
• Irradiated component failure analysis
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3
Westinghouse Hot Cells
• One of only 3 commercially available hot cell facilities available in the US
• Evaluation of materials with atomic numbers 1 through 96
• 5 hot cells• Multi-functional, routinely re-
configured to meet the needs of each specific program
• High and Low Level cells built in 1975 – have operated continuously since opening
• A and M cells built in 1994
• Extensive complimentary facilities/capabilities
High Level Cell - 1976
Today
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Westinghouse Hot Cells
•In-cell:• cutting, grinding, milling, machining• tensile, Charpy, fracture toughness, slow
strain rate and fatigue testing• metallography and scanning electron
microscopy• ultrasonic and eddy current measurements• welding• dimensional and density measurements• hydrogen analysis
Low level hot cell (left) and high level hot cell (right)
A and M hot cells
*SEM hot cell not shown
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Additional Key Facilities
Corrosion Laboratory
• 22 fully automated autoclaves– 34.5 MPa (5,000 psi) and
482°C (900°F)
– 4 with load frames with capabilities up to 2,720 kg (6,000 lbs)
• Numerous specimen geometries and autoclave conditions utilized
• Corrosion, wear, SCC initiation, and SCC growth
Materials Performance and Characterization Laboratories
• Metallography
• Scanning electron microscopy
–4 SEMs including dual beam FIB, XEDS, EBSD, ‘ultra-hot’ SEM, large chamber
• Scanning transmission electron microscopy
–FEI CM30, 300 KV, LaB6, XEDS
• Auger electron spectroscopy
• X-Ray Diffraction
–micro-diffraction and residual stress measurements
• Full analytical chemistry facilities
–GC, UV-VIS, FTIR, TGA, Raman, IC, ICP-MS, microwave digestion
• Mechanical testing
–multiple frames (100,000 lbs)
Custom Testing Facilities
• Advanced Fuel Crud Deposition Test Loop
• LOCA Debris Blockage Test Facility
• Thermal Hydraulic Testing High Bay
• Zinc Effects Test Loop
• Wear Test Rig
• High Temperature Steam Oxidation Unit
• Reactor Coolant Pump Seal Testing Laboratory
• Laser Welding Facility
Routinely design and fabricate unique testing facilities for our customers
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LOCA Debris Blockage Test Facility
Examples of Unique Capabilities
High Temperature Steam Oxidation Unit
Reactor Coolant Pump Seal Testing Laboratory
Core Inlet Blockage Intermediate Test Loop(under construction)
6
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Laboratory Customers and Hot Cell Services
• Westinghouse Product Lines• Operating Plants Business• New Plants and Major Projects• Nuclear Fuel and Components
Manufacturing• Decommissioning, Decontamination and
Remediation• Westinghouse Subsidiaries and Affiliates• US and International Utilities• US and International Universities• US and International Laboratories• EPRI• DOE and DOD• PWROG• International Organizations (e.g.,
International IASCC Advisory Committee)• Other commercial organizations,
manufacturers, etc.
• Laboratory facilities originally established to meet Westinghouse needs
• Today, wide range of ‘outside’ customers
• From ‘dirty’ failure analysis work to advanced R&D
• NSUF Partner Laboratory since July 2013
• Available for program collaborations and materials/specimen processing
MissionProvide experimental evidence
to support materials and processing solutions for our
customers and to support industry technical initiatives.
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Wide Range of Hot Cell Evaluations
• Small to large programs• Rapid turn-around (few days) to
multi-year• 24/7 coverage for emergency
evaluations• Wide range of customers• Vast diversity of
components/specimens for study, inspection and testing/evaluation
• Commercial reactor components• Test reactor irradiated components• Tiny parts/pieces to large
components• High radiation level and/or high
contamination level
In-Cell Inspections of Commercial PWR Baffle
Bolt
In-Cell Crack Growth Rate Test Assembly
In-Cell Ultrasonic Measurements of
EBR-II Highly Irradiated 304
Stainless Steel
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In-Cell Eddy Current Examination of ~800 lb Retired Reactor Head Segment with Full
Penetration
Specimen Machining
Three Examples…Hot Cell Projects*
In-Cell Irradiated Charpy Specimen Reconstitution
1. Failure Analysis
2. Effect of Service Exposure on Materials
3. Fundamental Science Evaluation
* Contract hot cell work for a
variety of outside customers
Specimen from PWR Baffle Plate - In-Cell Fracture Toughness
Machining and Testing -
a
cb
a
b
c
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Three Examples…Studies of Highly Neutron Irradiated Stainless Steels
Dose rates@ ~0.5” (R/hr) dpa ranges
>5,000 ~20 – 25
~1,000 ~0 – 80
~1,500 ~0 – 35
Description
1. Highly irradiated 347 SS baffle bolts from a commercial PWRa
2. Highly irradiated 316 SS flux thimble tubes extracted from 3 commercial PWRsb
3. Highly irradiated 304 SS neutron reflector hex blocks from EBR-IIc
Reference Point: Lethal Dose - LD50/60 ~350 R
a “Examination of Baffle-Former Bolts from D.C. Cook Unit 2,” 16th International Conference on Environmental Degradation of Materials in Nuclear Power Plants, Aug 11-15, 2013, Asheville, NC, in press.
b “Hot Cell Crack Initiation Testing of Various Heats of Highly Irradiated 316 Stainless Steel Components Obtained from Three Commercial PWRs,” 13th International Conference on Environmental Degradation of Materials in Nuclear Power Systems 2007 Apr 19-23, Whistler, British Columbia, Canada.
c Extensively published and presented in 2012-2015 (see next slide for partial publication list)
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Highly Irradiated DOE/EBRII ‘Hex Blocks’
• Work extensively published with additional papers currently being prepared
• For detailed technical information, please see (among others):
• Ultrasonic NDE for Irradiation-Induced Material Degradations, Isobe, Etoh, Sagisaka, Matsunaga, Freyer, Garner and Okita, 21st International Conference on Nuclear Engineering, Jul 2013.
• Void Swelling and Resultant Strains in Thick 304 Stainless Steel Components in Response to Spatial Gradients in Neutron Flux-Spectra and Irradiation Temperature, Garner, Freyer, Porter, Wiest, Knight, Okita, Sagisaka, Isobe, Etoh, Matsunaga, Huang and Wiezorek, Proceedings of 16th International Conference on Environmental Degradation of Materials in Nuclear Power Systems - Water Reactors, Asheville, NC, Aug 2013.
• Development of a Nondestructive Inspection Method for Irradiation-Induced Microstructural Evolution of Thick 304 Stainless Steel Blocks, Etoh, Sagisaka, Matsunaga, Isobe, Garner, Freyer, Huang, Wiezorek and Okita, Journal of Nuclear Materials, Sept 2013.
• Using UT to Assess Neutron-Induced Damage, Isobe, Etoh, Sagisaka, Matsunaga, Freyer, Garner and Okita, Nuclear Engineering International, April 2014, 36-39.
• Transmission Electron Microscopy of 304-Type Stainless Steel after Exposure to Neutron Flux and Irradiation Temperature Gradients, Wiezorek, Huang, Garner, Freyer, Sagisaka, Isobe and Okita, Microscopy & Microanalysis, Hartford, CT, Aug 2014, pp 1822-1823.
• Measurement of Depth-Dependent Swelling in Thick Non-Uniform Irradiated 304 Stainless Steel Blocks using Nondestructive Ultrasonic Techniques, Garner, Okita, Isobe, Etoh, Sagisaka, Matsunaga, Freyer, Huang, Wiezorek and Porter, Fontevraud 8, Avignon, France, Sept 2014.
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1. Failure Analysis - Background
• Fall 2010 refueling outage – baffle former bolt pieces found on D.C. Cook Unit 2 lower core plate
• Critical lab response during commercial plant outage (24/7 coverage)
• Failure evaluations: bolts, bolt pieces (heads and shanks) and lock bars delivered to Westinghouse Hot Cell
• Intact bolt examinations
Initial In-Cell Visual Inspections of As-Received Components
Sectioning and Metallography of Highly Activated Components
Examples of As-Received Components
Intergranular IASCC on Failed
Baffle Bolt
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1. Failure Analysis – Response and Results
Failed Bolt Evaluations:•Non-destructive evaluations (VT)
•Cross-sectional metallography/light optical microscopy
•SEM fractography•Hardness testing•Chemical analysis
Intact Bolts Evaluations:•Non-destructive evaluations (VT, PT, UT)
•Cross-sectional metallography/light optical microscopy
•Hardness testing•Chemical analysis•Tensile loading
Identification of Failure
Mechanism(s)
Support Apparent
Cause Analysis
Support Justification for
Return to Operation
• Funded by utility• Rapid turn-around response required
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2. Effect of Service Exposure on Materials - Background• Components removed from operating
reactors• Real behavior • Neutron irradiated = depth of
penetration machine realistic sized specimens for relevant data generation
• Study of materials structure and properties after known service exposure• Key property measurements (e.g.
tensile, slow strain rate, IASCC initiation)
• Correlate with microstructural changes
• Provide the mechanisms and database for following and predicting plant internals aging
In-Cell Machining of ~104 Test Specimens from Thimble Tubes Then Testing to Obtain Real
Performance Data
Highly Irradiated Flux Thimble Tubes Removed
from 3-Different Commercial Plants
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Finished O-ring ready for autoclave testing (shown
attached to a split mandrel)O-ring edge being machined down to target length using carbide cutting tool on lathe
ObjectivesDevelop a property database for the 3 heats of material, comprehensive analysis of this test data, and development of predictive equations for the forecasting of IASCC as a function of stress, dpa and material heat.
Complex Scope• dpa profile determination (plant-specific
transport calculations)• Tensile (18)• Slow strain rate (9)• O-ring crack initiation tests (76)• Detailed ANSYS 3-D FE stress analysis of
the O-ring specimen geometry and test loading conditions
• In-depth microstructural characterization
Six O-rings loaded into fixture for subsequent IASCC initiation testing under PWR simulated environmental conditions
2. Effect of Service Exposure on Materials – Program Objectives & Scope
• Funded by 10-member international consortium (International IASCC Advisory Committee)
• ~3 year program
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104-data point O-Ring IASCC database has led to the largest IASCC crack initiation database world wide for highly irradiated
stainless steels
• Crack initiation portion of the scope: 80% of specimen failures occur rapidly, i.e., within ~150 hours (6 days)
• Suggests that under adequate stress, crack initiation in sufficiently irradiated materials will occur rapidly
• Apparent ‘stress threshold’ controlled by irradiated yield strength: saturates by ~ 26 dpa
• No significant effect of material heat
• Applicability of results: predict IASCC behavior in highly irradiated stainless steels (i.e., reactor internals)
• This type of relevant property data: basis for Plant Life Extension technology
2. Effect of Service Exposure on Materials – Results & Implementation
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#3
#5
• Swelling of 304 SS neutron reflector hex blocks from EBR-II exposure
• US-Japan program conducted with:• The Ministry of Education, Culture, Sports,
Science and Technology (MEXT)• University of Tokyo• Nuclear Fuel Industries Ltd.• Radiation Effects Consulting• Idaho National Lab• Westinghouse Hot Cell• University of Pittsburgh & University of Wisconsin
• Objectives:• Quantify irradiation-induced microstructural
changes in thick section austenitic stainless steels as a function of dpa and Tirr
• Support Japanese development of nondestructive inspection technique to measure same above changes
3. Fundamental Science Evaluation - Background
~8
.5”
As-Received Hex Blocks
In-Cell Dimensional Measurements to Quantify Physical Distortion due
to Swelling
• Funded by MEXT• ~9 month program
~1 to 35 dpa
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• Detailed non-destructive UT:• ~25,000 UT data scans!
• Detailed destructive characterization:• Dimensional swelling measurements
• Precise sectioning of into >225 sub-sections
• Immersion density
• Machining to obtain appropriate surface finish and obtain flat and parallel surfaces
• Custom design and build of immersion density equipment for hot cell measurements of ~ 1 lb coins
• ICP-MS chemical analysis
• Metallography, GS
• Shear punch tests (specimen prep)
• TEM characterization of 14 material conditions (~75 high quality foils)
• Void/precipitate/dislocation/loop densities
3. Fundamental Science Evaluation - Techniques
Two of Several Coins Precision Cut from
Blocks
Immersion Density Set-up for Large Coins
Voids of 1-10 nm
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3. Fundamental Science Evaluation - Key Results
Note: 3.2% swelling maximum determined ultrasonically
Extensive in-cell sectioning and immersion density measurements of
high dose coins to determine swelling of individual pieces
Believed to be the most comprehensive ultrasonic evaluation AND microstructural characterization ever performed for highly
irradiated 304 stainless steel.
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• Key characterization of swelling under known service conditions in thick components• Complex distribution of swelling observed
• Material shows maximum of ~ 3% swelling
• Exceptionally sensitive UT data successfully obtained in-cell• Ultrasonic techniques demonstrated to be a
valid method of measuring average void swelling across thick components
• Development of an in-situ measurement tool appears to be possible
• TEM and immersion density agree well with anticipated swelling distribution
• Basis for analysis of commercial plant exposed samples, etc.
3. Fundamental Science Evaluation - Findings and Implications
Key enabler in delivering the results of this complex multi-national program ……
The Westinghouse Hot Cells are now a proud NSUF Partner Laboratory!
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Current Activities – Precision Machining of Hex Blocks for INL
• Contract for INL/Sebastien Teysseyre
• Same highly irradiated EBR-II hex material (~35 dpa)
• Modified 1/4T CT specimens: currently machining practice trials with new milling machine
• In-cell welding of 4 leads per CT specimen
• 2 round tensiles and 4 thin plates for subsequent microscopy are completed
First fabrication of CT specimens with crack propagation through known swelling gradients
Machining of EBR-II Hex Block Materials for Crack Growth Studies of Heavily Voided Microstructures
Thank you to our customer, Sebastien Teysseyre of INL, for permission to discuss this work.
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22
Current Activities – Precision Machining of Hex Blocks for INL
1.19”
3F3-T 3F3-B
63 mR/hr at 12”(~ 9 R/hr at 1”)
61 mR/hr at 12”(~ 9 R/hr at 1”)
Tensile Specimens Completed
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23
Current Activities – Precision Machining of Hex Blocks for INL
Practice Machining Trails on Unirradiated Material Outside of Cell Using New Milling Machine for Modified 1/4T CT Specimens
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24
Current Activities – Precision Machining of Hex Blocks for INL
Four (4) Modified 1/4T CT Specimens After Machining Completed
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25
Current Activities – Precision Machining of Hex Blocks for INL
Machining completed on four modified 1/4T CT specimens.
Welding of leads onto specimensis on-going.
Machining of EBR-II Hex Block Materials for Crack Growth Studies of Heavily Voided Microstructures
63 mR/hr at 12”(~ 26 R/hr at 1”)
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26
Current Activities – Precision Machining of Hex Blocks for INL
Dose Rates on Final Machined Specimens
Note a: Measured at 24" using Bicron Surveyor 2000 MeterNote b: Measured at 12" using Thermo Scientific Teleprobe FH 40Note c: Calculated from 24" measured value using
http://www.radprocalculator.com/InverseSquare.aspxNote d: Calculated from 12" measured or calculated values using
http://www.radprocalculator.com/InverseSquare.aspx
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27
Current Activities – Canadian Nuclear Laboratories, Chalk River
Focused Ion Beam (FIB), Electron Backscatter Diffraction (EBSD)* and Transmission Electron Microscopy (TEM) of Highly Irradiated
Inconel X-750 Spacers from CANDU Reactors
* Because the FIB milled specimens were thin, transmission EBSD, or more accurately, transmission Kikuchi diffraction (TKD) was used to collection the patterns.
• Work is on-going but nearing completion
• Four (4) specimens of highly irradiated material (~65 dpa)
• Preliminary results required 25 working days after specimen receipt at Westinghouse Laboratories
• Each FIB specimen to contain a grain boundary (GB)
• TEM analysis includes characterization of:
• cavities (i.e., He bubbles), dislocation loops, and precipitates at GBs/within grains
• quantitative size distribution of cavities at GBs/within grains• quantitative density determination for cavities at GBs/within grains• qualitative description of chemistry/phase distribution • denuded zone width• GB misorientation
Thank you to our customer, Malcolm Griffiths of Chalk River, for permission to discuss this work.
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Current Activities – Canadian Nuclear Laboratories, Chalk River
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29
Current Activities – Canadian Nuclear Laboratories, Chalk River
Location of FIB prepared specimen for first of four as-received samples
Low magnification electron induced secondary electron image
Ion induced secondary electron FIB channeling contrast image
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30
Current Activities – Canadian Nuclear Laboratories, Chalk River
Under focused bright field TEM image of a grain boundary and surrounding
region from sample GS4 1:00
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31
Current Activities – Canadian Nuclear Laboratories, Chalk River
Experimental quantitative results to be used as inputs to cavity model(s)
developed by ORNL
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32
Role of Materials and Hot Cell Laboratories in Commercial Technology
Westinghouse relies on a high level of knowledge of the behavior of irradiated
materials to support the industry
Irradiated Materials’ Structure and
Properties• Measure material properties• Characterize microstructure
after irradiation exposure
Establish Industry Database
• Industry assessment of materials degradation
• Update of potential for failure
• FMECA (failure mode, effects and criticality analysis) assessments
Aging Management Guidelines• Industry proposal for informed
guidelines• NRC acceptance of guidelines – criteria
and thresholds• License renewal inspections and
evaluations, planning and recommendations
Irradiated Component Structure and Property
• Component failure analysis• Remaining margin
assessment• Surveillance programs
Plant Aging Management Support• Development of plant
relicensing support plans• Response to NRC RAIs
(requests for additional information)
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33
Understanding Irradiated Materials Behavior – Applications to Reactor Vessel Internals
Understanding “scientific effects” provides the basis for interpreting commercial plant operating
experience and developing guidelines
?
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34
Considerations for Basic Science and Technology Development
• Development of industry relevant positions call for the continued development of basic mechanistic understanding
• Experimental efforts call for dedicated laboratory facilities to evaluate irradiated materials
• Westinghouse has in-place facilities to support development of quantitative data characterizing irradiation effects on plant relevant materials
• Sharing of knowledge is necessary to develop open, reliable and scrutinized positions
• Participation in development of the basic knowledge base directly supports participation in future industry relevant technology programs
– Westinghouse participation in collaborative or sponsored programs continues to build the knowledge base to support our largest customer, commercial nuclear power plants
Westinghouse Laboratories established to support commercial industry initiatives but we also heavily support “basic knowledge programs” for numerous
non-commercial customers
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35
Schedule and Costs• Hot cell work: ~ 5 to 10x as long as work outside
of cells (depending on complexity)• Time is money: hot cell work costs 5 to 10x as
much as work outside of cells (depending on complexity)
• Include ‘risk’ in your cost and schedule – something almost always goes wrong/breaks/is delayed
Lessons Learned
Document What You Do• Document everything you do in writing in a note book with dates, issues,
raw data results, etc.• Take photographs (we take hundreds) as work progresses – invaluable in
report to customer and/or to review years later • Include a familiar scale in your photographs – a ruler, a dime, etc.
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36
Hot Cell (and Outside of Cell) Equipment• Always use calibrated equipment – must
know that measurements are correct!• Difficult to find hot cell ready equipment
(generally, cost is high and only partly satisfies our needs) – we buy standard equipment and custom modify it ourselves for hot cell use
• Understand the limits of your manipulators
• can’t open a zip lock bag• limits on how high/low manipulators
can reach• limited manipulator gripping force
and limit on lifting (weight) capability
Lessons Learned
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37
Hot Cell (and Outside of Cell) Equipment (continued)• Make good use of in-cell cameras
connected to outside cell video monitors to get a close up view of work being done (because your eyes are always a minimum of ~5 feet away depending on your cell window thickness)
• Cheap disposable cameras• Shielding equipment in-cell so it lasts
longer (i.e., cameras)• Use pneumatics and hydraulics as
opposed to mechanical rotation/movement (i.e., pneumatic vice) - saves wear and tear on wrists and manipulators
Lessons Learned
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Communication and Valuable Test Material• Communicate with Radiation Safety Office
and/or Radiological Safety Organization – you need their support for work to progress smoothly
• Excellent communication with your customer required to not waste valuable test material and expensive hot cell labor hours
• Practice trials and/or mockups outside of cell and then practice trials inside of cell using ‘junk’ material is very important!
Lessons Learned
General but Important!• Include radiological disposal costs• Mixed waste – extremely expensive to dispose of - minimize generation and
include costs to get rid of it!
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• Extensive expertise in testing and evaluations of irradiated materials
• Proficiency in one-of-a-kind, first-of-a-kind testing and evaluations
• Three examples of completed programs in hot cell testing of highly irradiated stainless steels
• Two examples of current programs• Critical importance of generating relevant
test data on components removed from actual reactors
Thank you for your attention and….
Summary
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And We Do It All Safely - ALARA
NRC Yearly Whole Body Limit = 5 R
Westinghouse Yearly Whole Body Limit = 500 mr
Current background field in our Hot Cells ~ 1,000 R/hr
with specific areas/components ~ 5,000 R/hr
Westinghouse Hot Cells have been in continuous operation for nearly 40 years and have completed approximately 800 hot cell jobs –
we have never had a ‘stop work event’.
Site: >15 years without a lost time incident.
Attributed to our excellent safety practices and the exceptional skills of our staff.