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Patent 2766583 Summary

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(12) Patent: (11) CA 2766583
(54) English Title: METHODS AND APPARATUS FOR HANDLING MATERIALS FOR RETUBING OF A NUCLEAR REACTOR
(54) French Title: DISPOSITIF ET METHODES DE MANIPULATION DE MATERIAUX DESTINES AU RETUBAGE D'UN REACTEUR NUCLEAIRE
Status: Granted
Bibliographic Data
(51) International Patent Classification (IPC):
  • G21C 17/017 (2006.01)
  • G21C 19/10 (2006.01)
  • G21C 21/00 (2006.01)
(72) Inventors :
  • FRANCIS, CHRIS DUDLEY (Canada)
  • CHUNG, SUNG HWAN (Canada)
  • MURDOCH, BRYAN JOHN (Canada)
(73) Owners :
  • ATOMIC ENERGY OF CANADA LIMITED (Canada)
(71) Applicants :
  • ATOMIC ENERGY OF CANADA LIMITED (Canada)
(74) Agent: NORTON ROSE FULBRIGHT CANADA LLP/S.E.N.C.R.L., S.R.L.
(74) Associate agent:
(45) Issued: 2020-03-24
(22) Filed Date: 2012-01-16
(41) Open to Public Inspection: 2012-07-17
Examination requested: 2016-10-20
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data:
Application No. Country/Territory Date
61/433,398 United States of America 2011-01-17

Abstracts

English Abstract


A method of calandria tube volume reduction during calandria tube replacement.
The method
includes the steps of removing at least one of an end fitting, a pressure
tube, a calandria tube, and
a garter spring from a nuclear reactor at the reactor face; placing at least
one of an end fitting, a
pressure tube, a calandria tube, and a garter spring into a flask at the
reactor face; transporting
the flask away from the reactor; removing at least one of an end fitting, a
pressure tube, a
calandria tube, and a garter spring from the flask; and performing volume
reduction on the at
least one of an end fitting, a pressure tube, a calandria tube, and a garter
spring.


French Abstract

Une méthode de réduction de volume du tube de cuve lors du remplacement du tube de cuve. La méthode comprend les étapes pour retirer au moins un raccord dextrémité, un tube de force, un tube de cuve, et un ressort bracelet dun réacteur nucléaire à la face du réacteur; placer au moins un raccord dextrémité, un tube de force, un tube de cuve et un ressort bracelet dans un château de transport à la face du réacteur; éloigner le château du réacteur; retirer au moins un raccord dextrémité, un tube de force, un tube de cuve et un ressort bracelet du château de transport; et réaliser une réduction de volume sur au moins un raccord dextrémité, un tube de force, un tube de cuve et un ressort bracelet.

Claims

Note: Claims are shown in the official language in which they were submitted.


CLAIMS
What is claimed is:
1. A method of calandria tube volume reduction during calandria tube
replacement,
the method comprising:
removing at least one of an end fitting, a pressure tube, a calandria tube,
and a
garter spring from a nuclear reactor at the reactor face;
placing the at least one of the end fitting, the pressure tube, the calandria
tube,
and the garter spring into a flask at the reactor face;
transporting the flask to a location inside a vault away from the reactor;
removing the at least one of the end fitting, the pressure tube, the calandria
tube,
and the garter spring from the flask; and
performing volume reduction on the at least one of the end fitting, the
pressure
tube, the calandria tube, and the garter spring.
2. The method of claim 1, wherein performing volume reduction further
comprises
performing volume reduction inside the vault containing the reactor, and
wherein
performing volume reduction includes transferring the contents of the flask
into a
separate waste container.
3. The method of claim 2, further comprising transporting the waste
container away
from the reactor by transporting the waste container outside of a building
containing the
reactor.
4. The method of claim 3, further comprising returning the waste container
to the
reactor.
5. The method of claim 1, wherein the end fitting is removed in
substantially one
piece.
23

6. The method of claim 1, wherein the pressure tube, the calandria tube,
and the
garter spring are removed as substantially one piece.
7. The method of claim 1, wherein removing the at least one of the end
fitting, the
pressure tube, the calandria tube, and the garter spring from the nuclear
reactor at the
reactor face comprises mounting an empty flask onto the reactor face.
8. The method of claim 1, wherein transporting the flask away from the
reactor
comprises lifting the flask with a crane onto a trolley.
9. The method of claim 1, wherein transporting the flask to the location
inside the
vault away from the reactor comprises placing the flask onto a trolley system
within a
building containing the reactor.
10. The method of claim 2, further comprising transporting the waste
container away
from the location inside the vault away from the reactor by loading the waste
container
onto a truck using a gantry.
11. A method of calandria tube volume reduction during calandria tube
replacement,
the method comprising:
removing at least one of an end fitting, a pressure tube, a calandria tube,
and a
garter spring from a nuclear reactor at a reactor face;
placing the at least one of the end fitting, the pressure tube, the calandria
tube,
and the garter spring into a flask at the reactor face;
transporting the flask outside a vault containing the reactor;
removing the at least one of the end fitting, the pressure tube, the calandria
tube,
and the garter spring from the flask; and
performing volume reduction on the at least one of the end fitting, the
pressure
tube, the calandria tube, and the garter spring.
24

12. The method of claim 11, wherein transporting the flask outside the
vault
containing the reactor further comprises transporting the flask outside of a
building
containing the reactor.
13. The method of claim 11, further comprising returning the flask to the
reactor.
14. The method of claim 11, wherein the end fitting is removed in
substantially one
piece.
15. The method of claim 11 , wherein the pressure tube, the calandria tube,
and the
garter spring are removed as substantially one piece.
16. The method of claim 11, wherein removing the at least one of the end
fitting, the
pressure tube, the calandria tube, and the garter spring from the nuclear
reactor at the
reactor face comprises mounting an empty flask onto the reactor face.
17. The method of claim 11, wherein transporting the flask away from the
reactor
comprises lifting the flask with a crane onto a trolley.
18. The method of claim 11, wherein transporting the flask away from the
reactor
comprises placing the flask onto a trolley system within a building containing
the
reactor.
19. The method of claim 18, wherein transporting the flask away from the
reactor
further comprises loading the flask onto a truck using a gantry.
20. The method of claim 11, wherein performing volume reduction includes
transferring the contents of the flask into a separate waste container.
21. The method of claim 1, wherein transporting the flask to the location
inside the
vault away from the reactor comprises: moving the flask over a platform hatch
using a
work table, lifting the flask with a crane, and moving the work table away
from a path of
the flask.

22. The method of claim 1, wherein performing volume reduction comprises:
reducing the at least one of an end fitting, a pressure tube, a calandria
tube, and a
garter spring into pieces.
23. The method of claim 22, comprising: placing the pieces into a waste
transfer
flask.
24. The method of claim 11, wherein transporting the flask outside the
vault
containing the reactor comprises: moving the flask over a platform hatch using
a work
table, lifting the flask with a crane, and moving the work table away from a
path of the
flask.
25. The method of claim 11, wherein performing volume reduction comprises:
reducing the at least one of an end fitting, a pressure tube, a calandria
tube, and a
garter spring into pieces.
26. The method of claim 25, comprising: placing the pieces into a waste
transfer
flask.
27. The method of claim 25, comprising: reducing the at least one of an end
fitting, a
pressure tube, a calandria tube, and a garter spring into the pieces in
parallel.
26

Description

Note: Descriptions are shown in the official language in which they were submitted.


CA 2766583 2017-05-15
Attorney Docket No. 027813-9032-CA00
METHODS AND APPARATUS FOR HANDLING MATERIALS FOR RETUBING OF A
NUCLEAR REACTOR
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U. S. Provisional Patent
Application No.
61/433,398, filed January 17, 2011.
BACKGROUND
[0002] The present invention relates to methods and apparatus for retubing
of a nuclear
reactor.
[0003] More specifically, the invention relates to methods and apparatus
for handling
materials for retubing of a nuclear reactor such as a CANDUTm-type nuclear
reactor. The
CANDUTm ("CANada Deuterium Uranium") reactor is a pressurized heavy-water
moderated,
fission reactor capable of using fuels composed of natural uranium, other low-
enrichment
uranium, recycled uranium, mixed oxides, fissile and fertile actinides, and
combinations thereof.
SUMMARY
[0004] In one embodiment, the invention provides a method of calandria tube
volume
reduction during calandria tube replacement. The method includes the steps of
removing at least
one of an end fitting, a pressure tube, a calandria tube, and a garter spring
from a nuclear reactor
at the reactor face; placing the at least one of an end fitting, a pressure
tube, a calandria tube, and
a garter spring into a flask at the reactor face; transporting the flask to a
location inside the vault
away from the reactor; removing the at least one of an end fitting, a pressure
tube, a calandria
tube, and a garter spring from the flask; and performing volume reduction on
the at least one of
an end fitting, a pressure tube, a calandria tube, and a garter spring.
[0005] In another embodiment the invention provides method of calandria
tube volume
reduction during calandria tube replacement. The method includes the steps of
removing at least
one of an end fitting, a pressure tube, a calandria tube, and a garter spring
from a nuclear reactor
at the reactor face; placing the at least one of an end fitting, a pressure
tube, a calandria tube, and
a garter spring into a flask at the reactor face; transporting the flask
outside a vault containing the
1

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Attorney Docket No. 027813-9032-CA00
reactor; removing the at least one of an end fitting, a pressure tube, a
calandria tube, and a garter
spring from the flask; and performing volume reduction on the at least one of
an end fitting, a
pressure tube, a calandria tube, and a garter spring.
[0006] In another embodiment the invention provides a material handling
system for use
during retubing of a nuclear reactor. The material handling system includes a
track system
including a plurality of track sections, wherein the track sections include at
least one curved track
section. The system also includes a trolley having a cargo bed, at least two
wheel trucks
operatively coupled to the cargo bed, and a guide mechanism for interacting
with the track
system, wherein at least one of the wheel trucks pivots relative to the cargo
bed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Various aspects of the invention will become apparent by
consideration of the
detailed description and accompanying drawings.
[0008] Figure 1 shows the general flow of a full End Fitting (EF) flask
from a platform
tooling.
[0009] Figure 2 shows the general flow of an empty EF flask to the platform
tooling.
[0010] Figure 3 shows an embodiment of a trolley.
[0011] Figure 4 shows an embodiment of a trolley with a PT-CT-GS flask.
[0012] Figure 5 shows an embodiment of a trolley with an EF flask.
[0013] Figure 6 shows an embodiment of a straight rail and sole plate
section.
[0014] Figure 7 shows an embodiment of a rail and sole plate layout in the
reactor building.
[0015] Figure 8 shows an embodiment of a trolley side shift assembly.
[0016] Figure 9 shows the complete track system and identifies the section
that is shown in
detail in Figures 10A and 10B.
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CA 02766583 2017-02-02
Attorney Docket No. 027813-9032-CA00
[0017] Figure 10A shows a trolley side shift assembly connecting a first
trolley track.
[0018] Figure 10B shows the trolley side shift assembly connecting a second
trolley track.
[0019] Figure 11 shows an embodiment of a truck gantry.
[0020] Figure 12 shows an embodiment of a buffer nest.
[0021] Figure 13 shows an embodiment of a buffer nest with two EF flasks.
[0022] Figure 14 shows an embodiment of a buffer nest with one PT-CT-GS
flask.
[0023] Figure 15 shows an embodiment of a flatbed nest.
[0024] Figure 16 shows an embodiment of a two flatbed nests on flatbed
trailer holding two
EF flasks each.
[0025] Figure 17 shows an embodiment of a two flatbed nests on flatbed
trailer with one PT-
CT-GS flask each.
[0026] Figure 18 shows an embodiment of a flatbed trailer schematic.
[0027] Figure 19 shows an embodiment of a flatbed trailer with tooling
mounted thereon.
[0028] Figure 20 shows an embodiment of a building extension (box shown in
bottom center
of drawing).
[0029] Figure 21 shows a material handling tooling layout for an EF flask.
[0030] Figure 22 shows an embodiment of a shuttle flask.
[0031] Figure 23 shows an embodiment of an end fitting shield plug removal
tool with a
shuttle flask attached thereto.
[0032] Figure 24 shows an embodiment of EF Pulled into EF flask.
[0033] Figure 25 shows an embodiment of EF Removal Tooling Retracted and EF
in EF
flask.
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[0034] Figure 26 shows an embodiment of Removal of a Full EF flask from the
Platform
Tooling.
[0035] Figure 27 shows an embodiment of Installation of an Empty EF flask
to the Platform
Tooling.
[0036] Figure 28 shows an embodiment of a layout of an EF removal tool set.
[0037] Figure 29 shows an embodiment of a Removal of a full CT-PT-GS flask
from the
platform Receive tooling.
[0038] Figure 30 shows an embodiment of an Installation of an empty CT-PT-
GS flask to the
platform receive tooling.
[0039] Figure 31 shows an embodiment of a CT-PT-GS flask.
[0040]
[0041] Figure 32 is a perspective view of a reactor core of a nuclear
reactor.
[0042] Figure 33 is a cut-away view of the fuel channel assembly.
DETAILED DESCRIPTION
[0043] Before any embodiments of the invention are explained in detail, it
is to be
understood that the invention is not limited in its application to the details
of construction and the
arrangement of components set forth in the following description or
illustrated in the following
drawings. The invention is capable of other embodiments and of being practiced
or of being
carried out in various ways.
[0044] The following is a description of one or more embodiments of methods
and apparatus
for handling materials for retubing of a nuclear reactor such as a CANDUTM
reactor.
[0045] Figure 32 is a perspective of a reactor core of a nuclear reactor 6.
The reactor core is
typically contained within a vault that is sealed with an air lock for
radiation control and
shielding. A generally cylindrical vessel, known as a calandria 10, contains a
heavy-water
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CA 02766583 2017-02-02
Attorney Docket No. 027813-9032-CA00
moderator. The calandria 10 has an annular shell 14 and a tube sheet 18 at a
first end 22 and a
second end 24. The tube sheets 18 include a plurality of bores that accept a
fuel channel
assembly 28. As shown in Figure 32, a number of fuel channel assemblies 28
pass through the
tube sheets 18 of calandria 10 from the first end 22 to the second end 24.
[0046] Figure 33 is a cut-away view of the fuel channel assembly 28. As
illustrated in
Figure 33, each fuel channel assembly 28 is surrounded by a calandria tube
("CT") 32. The CT
32 forms a first boundary between the heavy water moderator of the calandria
10 and the fuel
bundles or assemblies 40. The CTs 32 are positioned in the bores on the tube
sheet 18. A CT
rolled joint insert 34 within each bore is used to secure the CT 32 to the
tube sheet 18.
[0047] A pressure tube ("PT") 36 forms an inner wall of the fuel channel
assembly 28. The
PT 36 provides a conduit for reactor coolant and the fuel bundles or
assemblies 40. The PT 36,
for example, generally holds two or more fuel assemblies 40 and acts as a
conduit for reactor
coolant that passes through each fuel assembly 40. An annulus space 44 is
defined by a gap
between the PT 36 and the CT 32. The annulus space 44 is normally filled with
a circulating
gas, such as dry carbon dioxide, helium, nitrogen, air, or mixtures thereof.
The annulus space 44
and gas are part of an annulus gas system. The annulus gas system has two
primary functions.
First, a gas boundary between the CT 32 and PT 36 provides thermal insulation
between hot
reactor coolant and fuel within the PTs 36 and the relatively cool CTs 32.
Second, the annulus
gas system provides an indication of a leaking CT 32 or PT 36 via the presence
of moisture,
deuterium, or both in the annulus gas.
[0048] An annulus spacer or garter spring 48 is disposed between the CT 32
and PT 36. The
annulus spacer 48 maintains the gap between the PT 36 and the corresponding CT
32, while
allowing the passage of the annulus gas through and around the annulus spacer
48. Maintaining
the gap helps ensure safe and efficient long-term operation of the reactor 6.
[0049] As also shown in Figure 33, an end fitting 50 is attached around the
fuel channel
assembly 28 outside of the tube sheet 18 at each end 22, 24. At the front of
each end fitting 50 is
a closure plug 52. Each end fitting 50 also includes a feeder assembly 54. The
feeder assemblies
54 feed reactor coolant into or remove reactor coolant from the PTs 36. In
particular, for a single
fuel channel assembly 28, the feeder assembly 54 on one end of the fuel
channel assembly 28

CA 02766583 2017-02-02
Attorney Docket No. 027813-9032-CA00
acts as an inlet feeder, and the feeder assembly 54 on the opposite end of the
fuel channel
assembly 28 acts as an outlet feeder. As shown in Figure 33, the feeder
assemblies 54 can be
attached to the end fitting 50 using a coupling assembly 56 including a number
of screws,
washers, seals, and/or other types of connectors.
[0050] Coolant from the inlet feeder assembly flows along a perimeter
channel of the end
fitting 50 until it reaches a shield plug 58. The shield plug 58 is contained
inside the end fitting
50 and provides radiation shielding. The shield plug 58 also includes a number
of openings that
allow the coolant provided by the inlet feeder assembly to enter an end of a
PT 36. A shield plug
58 located within the end fitting 50 at the other end of the fuel channel
assembly 28 includes
similar openings that allow coolant passing through the PT 36 to exit the PT
36 and flow to the
outlet feeder assembly 54 through a perimeter channel of another end fitting
50 at the opposite
face of the reactor 6. As shown in Figure 32, feeder tubes 59 are connected to
the feeder
assemblies 54 that carry coolant to or away from the reactor 6.
[0051] Returning to Figure 33, a positioning hardware assembly 60 and
bellows 62 are also
coupled to each end fitting 50. The bellows 62 allows the fuel channel
assemblies 28 to move
axially. The positioning hardware assemblies 60 are used to set an end of a
fuel channel
assembly 28 in either a locked or unlocked position. In a locked position, the
end of the fuel
channel assembly 28 is held stationary. In an unlocked position, the end of
the fuel channel
assembly 28 is allowed to move. A tool can be used with the positioning
hardware assemblies
60 to switch the position of a particular fuel channel assembly 28.
[0052] The positioning hardware assemblies 60 are also coupled to an end
shield 64. The
end shields 64 provide additional radiation shielding. Positioned between the
tube sheet 18 and
the end shield 64 is a lattice sleeve or tube 65. The lattice tube 65 encases
the connection
between the end fitting 50 and the PT 36 containing the fuel assemblies 40.
Shielding ball
bearings 66 and cooling water surround the exterior the lattice tubes 65,
which provides
additional radiation shielding.
[0053] Material handling refers to tooling whose primary function is to
move and manipulate
shielded flasks containing radioactive materials that are being removed from
the reactor and
6

CA 02766583 2017-02-02
Attorney Docket No. 027813-9032-CA00
transported to the waste processing facility. The secondary function of the
material handling
tooling is to assist in the movement of face tooling and materials during
retube operations.
[0054] Material handling tooling consists of a system of trolleys, rails,
rail switching
equipment, nests and cranes used to manipulate and transport flasks and other
equipment to and
from the opposing faces of the reactor. The tooling is designed to be used in
conjunction with the
reactor area (RA) cranes.
[0055] The material handling equipment is in "production" operation during
three series: the
End Fitting (EF) Removal series, the calandria Tube Insert (CTI) Removal
series, and the
Pressure Tube-calandria Tube-Garter Spring (PT-CT-GS) Removal series. The
material
handling method is the same whether the PT and CT are removed together or
separately.
[0056] Material handling tooling is installed prior to the EF Removal
series (during the PT
and Bellows Cut series) and removed after completion of the PT-CT-GS Removal
series. The
exception is the truck gantry which will be installed at the beginning of the
retube outage and
continue to function for the duration of the outage.
[0057] There are eight major components to the material handling system 1:
a trolley 200,
trolley rails 216 and sole plates 234, a trolley side shift assembly 244, a
truck gantry 260, a
buffer nest 262, a flatbed nest 264, a flatbed trailer 274, and a weather
enclosure 286.
[0058] Figure 1 shows steps 1-4 (below) of the general procedure at the
reactor 6 for all three
removal series. Figure 2 shows the reverse process (labelled below as steps 6-
8 and annotated on
Figure 4 with reference numerals 105-108) for returning an empty flask 202,
204, 206 from the
truck to the face of the reactor 6. In general, the procedure includes: (1) At
reference numeral
101, an empty flask 202, 204, 206 is mounted on the removal tooling 290 at the
face of the
reactor 6. The EF flasks 204 will need to reach both vaults 4, whereas the
longer PT/CT flask
202 only needs to reach the nearer vault 4. (2) At reference numeral 102, the
empty flask 202,
204, 206 is filled with radioactive materials from the removal series. This
now becomes a full
flask 202, 204, 206. (3) At reference numeral 103, the full flask 202, 204,
206 is unloaded from
the removal tooling 290 to the trolley 200 using the RA crane. The fuel
channel platform (FCP)
(or retube platform, RTP) 292 may be positioned at floor level to facilitate
and simplify flask
7

CA 02766583 2017-02-02
Attorney Docket No. 027813-9032-CA00
movements. (4) At reference numeral 104, the full flask 202, 204, 206 is taken
out of the reactor
vault 4 to the truck loading area 248 via trolley 200. (5) At reference
numeral 102, using the
truck gantry 260, the full flask 202, 204, 206 is removed from the trolley 200
and loaded onto the
first buffer nest 262. (6) At reference numeral 106, an empty flask 202, 204,
206 is removed
from the second buffer nest 262 and placed on the trolley 200 using the truck
gantry 260. (7) At
reference numeral 107, the trolley 200 moves from the truck loading area 248
to the reactor face
with the empty flask 202, 204, 206. (8) At reference numeral 108, the cycle
starts again from
Step 1 (i.e. reference numeral 101).
[0059] Radioactive material is contained within the shielded flasks 202,
204, 206 at all times
when removed from the reactor face.
[0060] While the removal operations are occurring on the reactor face, and
while the trolley
200 is moving back and forth from the reactor 6 and the truck loading area
248, the operators in
the truck loading area 248 will be working in parallel. Empty flasks 202, 204,
206 arriving on
the truck will be moved to the first buffer nest 262 in advance. When full
flasks 202, 204, 206
arrive on the trolley 200, they will be unloaded to the second buffer nests
262 instead of being
loaded directly to the truck. The buffer nests 262 are much closer to the
trolley stop position and
this minimizes the time to exchange full flasks 202, 204, 206 for empty ones.
This in turn
minimizes the waiting time at the face for empty flasks 202, 204, 206 to
arrive.
[0061] In general, the procedure at the truck loading area 248 includes:
(1) A truck from the
processing facility containing empty flasks 202, 204, 206 will enter the truck
loading area 248 in
the reactor 6 and park. (2) The doors on the weather enclosure 286 will be
closed so that the
entire truck is protected from the elements. The cover 280 for the flatbed 274
will be rolled back
and the empty flasks 202, 204, 206 on the flatbed nests 264 will be unsecured
for hoisting. (3)
Using the truck gantry 260, an empty flask 202, 204, 206 will be hoisted and
moved from the
flatbed nest 264 to the first buffer nest 262. For CTI and EF flasks 204, two
flasks can be placed
in a single buffer nest 262. (4) A trolley 200 with a full flask 202, 204, 206
from the reactor 6
arrives in the truck loading area 248. (5) The full flask 202, 204, 206 on the
trolley 200 will be
loaded onto the second buffer nest 262. (6) The empty flask 202, 204, 206 will
be loaded from
the first buffer nest 262 onto the trolley 200 and sent back to the reactor 6.
(7) The full flask
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202, 204, 206 on the second buffer nest 262 will be loaded and secured onto
the flatbed nest 264.
(8) Repeat Steps 3 to 7 until there are no more empty flasks 202, 204, 206.
(9) When the flatbed
nest 264 is full of full flasks202, 204, 206, the cover 280 on the flatbed 274
will be closed and
the truck will leave for the processing plant. (10) The truck arrives at the
processing plant and
the full flasks 202, 204, 206 will be removed and empty flasks 202, 204, 206
will be loaded.
(11) The truck returns to the reactor 6 with empty flasks 202, 204, 206. (12)
Repeat from Step 1.
[0062] In some embodiments, there are at least two trucks running in
parallel at all times in
order to minimize flask wait times.
[0063] At all times, exchanging flasks 202, 204, 206 on incoming trolleys
200 will be the
highest priority. To this effect, hoisting operations to load or unload the
truck may not be as
efficient in order to keep operations at the reactor 6 moving as quickly as
possible. Additionally,
the buffer nests 262 in the truck loading area 248 allow hoisting operations
to be flexible.
Hoisting can continue while trolleys 200 are moving through the vault 4 or
while operations
happen on face.
[0064] Figures 3, 4, and 5 illustrate trolleys 200 that are used to convey
flasks 202, 204, 206,
tooling and other materials from one end of both faces of the reactor 6 to the
truck loading area.
Flasks 202, 204, 206 and other loads are lowered onto the bed of the trolleys
200. Each trolley
200 has locating and positioning features to prevent loads from moving once
placed on the
trolley 200 (e.g. nests 208 for stabilizing loads as shown in Figures 3, 4, 5,
and 12-14). The
trolleys 200 also include a guide mechanism 210 for interacting with the track
system 212, where
the guide mechanism 210 may include flanged wheels 214 that rest on parallel
rails 216.
Alternatively, the guide mechanism 210 may include a carriage attached to the
trolley 200, where
the carriage is in contact with a rail to guide the trolley.
[0065] In one embodiment, trolleys 200 move on flanged wheels 214 captured
on tracks
similar to railroad tracks. In various embodiments, the trolleys have two
pivoting axles to allow
tight turns to be made on curved tracks. In other embodiments, the wheels of
the trolley are not
be flanged and instead the trolleys have wheels (e.g. castered wheels) that
run on the floor of the
building. The non-flanged wheels may roll directly on the floor of the
building or on plates or
other surfaces provided (e.g. to provide a smooth and level surface).
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[0066] In various embodiments, the trolleys 200 are powered by electric
motors 224 (e.g.
mounted adjacent to wheel trucks 230 under the trolley 200 as shown in Figure
3), which may be
manually controlled by an operator holding a pendant with a deadman trigger.
In general,
trolleys 200 are equipped with brakes which automatically engage when not in
motion to act as a
parking brake, as well as an emergency brake when releasing the deadman
trigger on the
pendant. The bed 228 of each trolley is quickly configurable with nests 208
for carrying flasks
202, 204,206, tools or other miscellaneous loads. In various embodiments, a
standard trolley
design will be used to carry all materials. Each trolley 200 has a cargo bed
228 and at least two
wheel trucks 230 (e.g. see Figure 3), where at least one of the wheel trucks
230 pivots relative to
the cargo bed 228 in order to permit the trolley 200 to move on curved track
portions.
[0067] Under normal operation, one trolley 200 is allocated for
transferring all flasks 202,
204, 206 from one face of the reactor 6 and one trolley 200 will be allocated
for transferring all
the flasks 202, 204, 206 from the other face of the reactor 6. Details of the
trolley operations and
movements are found in the individual removal sections.
[0068] In various embodiments, trolleys 200 are capable of towing/pushing
other trolleys
200 in case of motor failure. The trolleys 200 also have the capability of
being winched along
the tracks in case of manual contingency operation.
[0069] In various embodiments, a track system 212 (e.g. see Figure 1)
including a plurality
of track sections 232 is installed in the reactor building 2. As discussed
below, the plurality of
track sections 232 may include curved sections 232B to allow the track system
to be installed
without having to remove existing reactor structures.
[0070] In some embodiments, trolleys 200 move on rails 216 similar to
railroad tracks. In
those embodiments in which a rail or rails 216 are employed (e.g. a pair of
rails for use with
flanged wheels or a single rail or multiple rails used to guide castered
wheels as described
above), the rail or rails 216 may be mounted to a large sole plate 234 which
includes a track
section sub-assembly. In addition to straight sections 232A (shown in Figure
6), curved sections
232B of track have been incorporated as well in order to avoid removing
existing reactor
structures. In general, where two (or more) rails 216 are used to accommodate
flanged wheels

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214 or to guide a carriage attached to the trolley 200, the rails 216 are
installed parallel to one
another at a fixed distance apart.
[0071] Each sole plate 234 will be equipped with quick jacking mechanisms
for levelling as
well as quick floor lagging provisions. This combined with the rails 216
preassembled onto the
sole plates 234 will allow for maximum efficiency and ease of installation.
Each of these track
sections 232 will be fully connected and tested prior to installation in the
reactor 6, resulting in a
minimum of on-site set up and adjustment. The vault floor will require inserts
placed into the
floor in advance of installation of the sole plates 234.
[0072] Sole plates 234 in the airlock 246 will not be lagged inside the
airlock area but
clamped just outside of the airlock envelope. The clamping allows for quick
removal of the sole
plates 234 in the airlock 246 in the event the airlock 246 needs to be closed.
[0073] As shown in Figure 7, there is one main line 240 which stretches
from one face of the
reactor 6 through the airlock 246 and out into the truck loading area 248.
This main line 240
contains docking stations at the trolley side shift assembly 244 and at the
end of the rail in the
truck loading area 248.
[0074] A secondary line 242 stretches through a side of the vault 4 through
the walkway.
The trolley 200, EF flasks 204, and CTI flasks (not shown) are small enough in
diameter to fit
within the side doorways with clearance.
[0075] The trolley side shift assembly 244 (Figure 8) is a track switching
mechanism used to
connect trolleys 200 from either face of the reactor 6 to the main line 240.
Additionally, due to
the tight space constraints with the long PT-CT-GS flask 202, the direct,
linear motion of the side
shift is required to bring the flask 202 within the envelope of the RA crane.
In general the side
shift assembly 244 is mounted near the reactor 6 to permit access to both
faces of the reactor 6
and to permit a trolley 200 on one track section to be loaded and unloaded
while another trolley
200 moves past to the other side of the reactor 6 (e.g. Figure 1).
[0076] This mechanism consists of a large slide plate 252 with two sets of
trolley rails 216
mounted on it. The first set of rails 216 is straight and the second set of
rails 216 is curved to
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provide a larger turning radius for the trolleys 200 operating from one of the
reactor faces. The
slide plate 252 is mounted on precision linear bearings (not shown) and rails
254 and is driven by
a ball screw powered by a motor 258. The slide plate 252 will move and align
either the first
trolley track or the second trolley track with the main line 240 out of the
airlock 246 (see Figure
8).
100771 When the trolley 200 associated with the second reactor face is
aligned to the main
line 240, the trolley 200 aligned with the first reactor face is within the
corresponding RA crane
reach envelope. This allows the trolley 200 associated with the first reactor
face to be loaded or
unloaded from the reactor face while the trolley 200 associated with the
second reactor face
passes through. When the trolley associated with the first reactor face is
aligned to the main line
240 the trolley associated with the second reactor face must wait until the
side shift is performed.
[0078] The trolley side shift assembly 244 is controlled by an operator
using a simple
pendant with a deadman trigger. The side shift movement 244 will only continue
while the
operator presses the deadman trigger. The ball screw drive motor 258 is
equipped with a brake
which automatically engages when not in motion to act as a parking brake as
well as an
emergency brake when releasing the deadman trigger on the pendant. The trolley
side shift
assembly 244 is designed to be brought into the vault 4 as a single piece and
installed as a
complete turnkey sub-assembly.
[0079] The truck gantry 260 (Fig= 11) is a new installation to be erected
in the area just
outside of the shielding door of the airlock 246. This is the main gantry used
in loading and
unloading all trucks coming in the docking bay 248 of the reactor building 2.
Due to the close
proximity to the vault airlock 246, the docking bay 248 will handle the
majority of tools and
materials used for the duration of the retube operations.
[0080] The gantry 260 is included in the Material Handling section of this
proposal but will
be installed at the beginning of the retube outage and used throughout the
entire retube operation
as the main truck load/unload crane.
[0081] The main function of the gantry 260 during the removal series is to
load and unload
flasks 202, 204, 206 from the trolleys 200, buffer nests 262 and the flatbed
nest 264. In addition,
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the gantry 260 will be used to place and remove trolleys 200 onto the tracks
212 as well as
materials and tooling used on face during the removal series.
[0082] This gantry 260 is a custom frame gantry which will have travel in
two axis as well as
the hoist. The gantry 260 will be made modular and designed for quick assembly
without the use
of heavy machinery. The gantry 260 is fully certified as an overhead lifting
device.
[0083] Lag studs will have to be pre-installed into the floor in the truck
loading area 248
prior to the gantry 260 being brought on site.
[0084] The buffer nest 262 (Figure 12) is a static cradle designed to hold
a single CT-PT-GS
flask 202 (Figure 14) or two EF flasks 204 (Figure 13). The buffer nest 262
provides a place to
temporarily place a flask 202, 204, 206 so a trolley 200 or the flatbed nest
264 can be cleared.
[0085] The buffer nests 262 are heavy duty weldments which contain rough
positioning
features 268 used to place the different flasks 202, 204, 206 in repeatable
locations. The
positioning features 268 have much greater clearances than those used on the
trolleys 200 or
tools to allow for quick placement and pick up of flasks 202, 204, 206. The
buffer nests 262 will
require lagging to the ground to prevent accidental movement. In some
embodiments, there are
two buffer nests 262 positioned close to the trolley docking position in the
truck loading area
248.
[0086] Lag studs will need to be pre-installed into the floor in the truck
loading area 248
prior to the buffer nests 262 being brought on site.
[0087] The flatbed nest 264 (Figure 15) provides a frame in which to secure
flasks 202, 204,
206 for transport via truck. The flatbed nest 264 is bolted to the bed of the
flatbed trailer 274 and
will remain in place for the duration of the removal series. The flatbed nest
264 is designed to
hold one CT-PT-GS flask 202 (Figure 16) or two EF flasks 204 (Figure 17) each.
Two flatbed
nests 264 can be mounted in a single flatbed trailer 274.
[0088] Similar to the buffer nest 262, the flatbed nest 264 is a heavy duty
weldment which
contains positioning features 276 used to place the different flasks 202, 204,
206 in repeatable
locations. The positioning features 276 are similar to those used on the
trolleys 200 or removal
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tools to prevent movement of flasks 202, 204, 206 during truck transport. The
flatbed nest 264
also contains a quick chain winch tie-down system which will be integrated
into the flask design.
All tie-downs will be manually actuated. These will be custom tailored to the
flasks 202, 204,
206 so that securing and releasing the flasks 202, 204, 206 from the nests 264
will take a
minimum of time and effort.
[0089] The nests 264 need to be installed into the flatbed trailers 274
prior to the beginning
of the removal series.
[0090] The flatbed trailer 274 (Figure 18) is used to transport flasks 202,
204, 206 between
the reactor building (RB) 2 and the processing plant. The flatbed trailer 274
is a drop deck roll-
tight trailer which is custom-modified to carry extremely heavy loads. The
trailer 274 has a roll-
tight cover 280 which is a retractable fabric and metal frame bellows cover.
The cover 280 can
quickly be rolled over the bed 282 of the trailer 274 providing a weatherproof
enclosure around
the load during transport. It can then be unrolled to provide full top and
side access to the load.
An embodiment of the flatbed trailer 274 is shown in Figure 19.
[0091] In other embodiments, provisions are made for mounting the flatbed
nest weldments,
such that the flatbed trailer 274 will hold a pair of flatbed nests 264.
[0092] In some embodiments, trucks backing into the RB 2 outside of the
truck loading door
284 cannot now drive fully inside the existing reactor 6 due to unloading
clearance requirements.
This means that the loading door 284 would remain open to the elements for
extended periods.
To prevent this scenario, a weather enclosure 286, or building extension
(Figure 20), to the truck
docking area 248 will be constructed so the entire truck can be housed inside
an enclosure and
the RB 2 can be isolated from the elements. This construction will include any
reinforcement of
the ground outside and inside the building loading dock 248, as well as guides
and bumpers to
facilitate the quick entry and exit of the trucks.
[0093] In some embodiments, an electric winch is used to move trolleys 200
or to actuate the
trolley side shift assembly 244 in case of motor or ball screw failure.
Regular mounting points
along the track 212 or trolley side shift assembly 244 will be provided to
connect the winch.
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[0094] In some embodiments, a ratcheting come-along is used to move
trolleys 200 or to
actuate the trolley side shift assembly 244 in case of complete power failure.
Mounting points
along the track 212 or trolley side shift assembly 244 will be provided to
connect the come-
along.
[0095] Figure 21 shows the rail layout from a plan view of the RB 2. In the
illustrated
embodiment, the rail layout includes a main line 240 (through airlock 246), a
secondary line 242
(through a vault corridor), a trolley side shift assembly 244 , an airlock 246
, a truck loading area
248 , a truck gantry 260, a buffer nest 262 , a flatbed nest 264 , a flatbed
trailer 274 , and a
weather enclosure 286.
[0096] The material handling system 1 and flasks 204 can be used in the end
fitting removal
series, as described below. In this series all EFs 50 are removed from the
reactor 6. The EF
removal tooling 290 on the platforms 292 are identical. The EFs 50 are removed
simultaneously
in a staggered fashion from both reactor faces to accommodate EF flask trolley
vault traffic.
[0097] A single channel cycle involves removing an EF 50 from a lattice
site and placing it
into a shielded flask 204, inserting a lattice sleeve assembly 65 (LSA),
removing the full flask
204 from the vault 4, and installing an empty flask 204 back onto the removal
tooling 290. The
cycle can begin by starting at the bottom row and working up the reactor face.
In parallel, the
full flask 204 is being delivered to a volume reduction facility. In various
embodiments, the
volume reduction facility is located away from the reactor face, which may
still be within the
reactor vault 4 or which may be outside of the building 2 containing the
reactor 6. There the
flask 204 is emptied and returned in queue for reinstallation on the removal
tooling 290.
[0098] In one embodiment, the PT 36, CT 32, and GS 48 are placed in the
flask 202, which
is then rotated on the platform 292. The platform 292 is subsequently lowered
to floor elevation.
The volume reduction equipment is stationed on the floor beside the platform
292. The contents
of the flask 202 are pushed into the volume reduction machine and volume-
reduced components
fall into a flask that sits beneath the volume reduction machine. In general,
the flask on the
platform for the PT/CT/GS remains on the platform for the duration of the
removal sequence,
whereas the flask beneath the volume reduction machine is replaced when full.

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[0099] The EF Removal Series can be divided into automated and manual
operations. The
automated operations may be controlled remotely from the retube control center
(RCC) or
locally from pendants and are those associated with the face operation with
the tools on the
heavy work table 300 (HWT). This is for ALARA (as low as reasonably
achievable) purposes,
so that people may be kept away from the highly radioactive operations as much
as possible.
The manual operations are those associated with the hoisting and
transportation of flasks 202,
204, 206 and lattice sleeves 65.
[00100] The layout of the tools on the RTP 292 is shown in Figure 28. These
tools include an
FIWT 300 , a pallet 302 , a lattice tube shield plug insert removal tool (LS-
SPIRT) 304 , an EF
flask 204 , an EF retrieval head 306 , and EF shield 308 , an LSA 310, and a
vision system 312.
In various embodiments, these tools may be moved by the vault trolley system
201 and hoisted
by the RA crane for vault transitions.
[00101] The process for removing an EF 50 from a lattice site and placing it
into an EF flask
204 is as follows. Not all of the listed steps are required; for example,
steps (8) and (9) may be
omitted. In various embodiments, all of the operations are carried out using
automated tooling.
(1) Prerequisites include: (a) The EF flask 204 is mounted to the pallet 302,
and a LSA 310 is
mounted to the EF flask 204; and (b) The RTP 292 is at the designated row. (2)
The HWT 300
moves to bring the vision system 312 in front of the designated EF 50. (3) The
vision system 312
calculates the offsets for fme alignment and then the HWT 300 moves to align
the EF removal
tooling 290 to the EF 50. (4) The pallet z-drive advances the EF shield 308
over the EF 50, and
the pallet's Serapid drive advances the EF Retrieval Head 306 into the EF 50.
(5) The EF
retrieval head 306 grips the EF 50. (6) The pallet's Serapid drive pulls the
EF 50 into the flask
204 (Figure 24). (7) The pallet z-drive retracts the EF Shield 308 from the EF
50, the EF
Retrieval Head 306 un-grips the EF 50, and the pallet's z-drive retracts the
head 306 out of the
EF flask 204 back into the guide tube 314. (Figure 25). (8) The HWT 300
indexes in the x-
direction to align the vision system 312 to the open channel. (9) The vision
system 312 shoots
the outboard journal ring and CTI to establish the x-, y-, pitch-, and yaw-
coordinates for the
lattice site. These values are stored for use by all other automated series
that follow. The vision
system 312 does not have to be shot again unless there are problems with the
tool accessing the
site because of alignment issues. (10) The HWT 300 indexes in the x-direction
to align the axis
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of the LS SPIRT 304 with the lattice site. (11) The LS SPIRT 304 advances to
install the LSA
310 into the lattice site. (12) The LS SPIRT 304 retracts fully.
[00102] Replacement of a full EF flask 204 with an empty EF flask 204 at the
platform
tooling is a manual process that requires the use of the vault RA cranes,
vault trolley system 201,
and truck loading facility. The removal of the full EF flask 204 from one side
is shown in Figure
26, and the installation of the empty EF flask 204 to the side is shown in
Figure 27.
[00103] Before beginning the procedure, one empty trolley 200 is waiting to be
loaded on the
side shift mechanism 244 and the RTP 292 is aligned at the designated row. In
various
embodiments, the procedure for a flask replacement can include some or all of
the following
steps: (1) The platform 292 is lowered to the floor, and the HWT 300 moves to
a predetermined
location. (2) Personnel enter the platform 292. (3) The shielded doors on the
full EF flask 204
are closed and the LSA supports are folded in. (4) The crane is positioned
over the full EF flask
204. (5) The crane hook and guide cables are installed on the full EF flask
204. (6) The RA
crane and guide cables are used to hoist the full EF flask 204 to another
section of the RTP 292.
The full EF flask 204 is rotated while hung on the crane to achieve the
correct orientation to be
placed on the trolley (Step 1 at reference numeral 110 in Figure 26). (7) The
full EF flask 204 is
lowered onto the trolley 200 and the RA crane and cable guides are
disconnected. (8) The trolley
200 with the full EF flask 204 is side shifted using the trolley side shift
assembly 244. The
trolley 200 now lines up with the tracks 240 exiting out the airlock 246 (Step
2 at reference
numeral 112 in Figure 26). (9) The trolley 200 is driven through the airlock
246 to the truck
loading area 248 (Step 3 at reference numeral 114 in Figure 26). (10) The
truck gantry 260 and
cable guides are connected to the full EF flask 204. The full EF flask 204 is
hoisted and moved
to a second buffer nest 262. The gantry 260 and cable guides are disconnected
(Step 4 at
reference numeral 116 in Figure 26). (11) The truck gantry 260 and cable
guides are connected
to the empty EF flask 204 in a first buffer nest 262. The empty EF flask 204
is hoisted and
moved to the trolley 200. The gantry 260 and cable guides are disconnected
(Step 1 at reference
numeral 118 in Figure 27). (12) The trolley 200 with the empty EF flask 204 is
driven through
the airlock 246 to the trolley side shift assembly 244 at the reactor face
(Step 2 at reference
numeral 120 in Figure 27). (13) The trolley with the empty EF flask 204 is
side shifted so it is
within the RA crane envelope (Step 3 at reference numeral 122 in Figure 27).
(14) The LSA
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310 supports are extended and the LSA 310 is manually loaded onto the EF flask
204 using the
LSA loading mechanism (in other embodiments the LSA 310 is mounted to the
flask 204 in an
earlier step). (15) The RA crane and cable guides are connected to the empty
EF flask 204. (16)
The EF shield 308 should be in its forward position to provide clearance for
the EF flask 204.
(17) An empty EF flask 204 is loaded on the pallet 302 (step 4 at reference
numeral 124 in
figure 27). (18) The operator manually retracts the EF Shield 308 and couples
it to the EF flask
204. (19) All operators leave the RTP 292, and the platform 292 is raised from
floor level to the
designated row.
[00104] The procedure for replacing an EF flask 204 on the other side of the
reactor 6 is very
similar to the side discussed above. Trolleys coming and going to the other
side will not need to
be side shifted and pass directly through on the curved track section 232B of
the trolley side shift
mechanism 244. EF flasks 204 from the other face will travel on a secondary
line 242 which is
laid in another area of the vault 4. This secondary line 242 is connected to
the main line 240 out
of the airlock 246 at the trolley side shift assembly 244.
[00105] Additional work is performed in the truck loading area 248 to prepare
and clear flasks
202, 204, 206 from the buffer nests 262 and the truck. These processes are
performed in parallel
with work on the face and during trolley movement on the track 212. Operations
in the truck
loading area 248 are described elsewhere in this document.
[00106] Replacement of a full CT-PT-GS flask 202 with an empty CT-PT-GS flask
202 at one
platform receive tooling is a manual process that requires the use of the
vault crane, vault trolley
System 201, and truck loading facility. The removal of the full CT-PT-GS flask
202 is shown in
Figure 29, and the installation of the empty CT-PT-GS flask 202 is shown in
Figure 30. The
process is as follows: (1) One empty trolley 200 is waiting to be loaded on
the side shift
mechanism 244, and the RTP 292 start at the designated row, and no workers are
on the RTP 292
(Step 1 at reference numeral 126 in Figure 29). (2) The platform with the
Guide Tooling remains
at its current location. The other platform is lowered to the floor, and the
HWT 300 moves to a
predetermined location. (3) The shielded doors on the full CT-PT-GS flask 202
are closed. (4)
The crane is positioned over the full CT-PT-GS flask 202 and the crane hook
and guide cables
are installed on the full CT-PT-GS flask 202. (5) The vault crane and guide
cables are used to
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hoist the full CT-PT-GS flask 202 to another section of the RTP 292 (Step 2 at
reference numeral
128 in Figure 29). The full CT-PT-GS flask 202 is rotated while on the crane
to achieve the
correct orientation to be placed on the trolley 200 (Step 3 at reference
numeral 130 in Figure 29).
(6) The full CT-PT-GS flask 202 is lowered onto the trolley 200 and the vault
crane and cable
guides are disconnected (Step 4 at reference numeral 132 in Figure 29). (7)
The trolley side shift
assembly 244 is used to line up the trolley 200 with the tracks 240 exiting
out the airlock 246
(Step 5 at reference numeral 134 in Figure 29). (8) The trolley 200 is driven
through the airlock
246 to truck loading area 248 (Step 6 at reference numeral 136 in Figure 29).
(9) Connect the
truck gantry 260 and cable guides, lift the full CT-PT-GS flask 202 off
trolley 200, rotate and
hoist to a first buffer nest 262 (Step 7 at reference numeral 138 in Figure
29) and to a first flatbed
nest 264 (Step 8 at reference numeral 140 in Figure 30). Disconnect the gantry
260 and cable
guides. (10) Connect the truck gantry 260 and cable guides, lift the empty CT-
PT-GS flask 202
from a second flatbed nest 264 and second buffer nest 262 (Steps 1 and 2 at
reference numerals
142, 144 in Figure 30) , rotate and hoist to the trolley 200 (Step 3 at
reference numeral 146 in
Figure 30). (11) Disconnect the gantry crane and cable guides and drive the
trolley 200 with the
empty CT-PT-GS flask 202 to the reactor face (Step 4 at reference numeral 148
in Figure 30).
(12) Using the trolley side shift assembly 244, move the trolley 200 with the
empty CT-PT-GS
flask 202 to within the vault crane envelope (Step 5 at reference numeral 150
in Figure 30). (13)
Connect the vault crane and cable guides, hoist the empty CT-PT-GS flask 202
from trolley 200
to Tool. The CT-PT-GS flask 202 is rotated while on the crane to achieve the
correct orientation
to be placed on the tool (Steps 6-8 at reference numerals 152, 154, 156 in
Figure 30). (14) The
platform 292 is raised from floor level to the designated row, and the other
platform is moved to
the designated row if required.
1001071 A CT-PT-GS flask 202 is shown in Figure 31. In various embodiments,
the
functional requirements of the CT-PT-GS flask 202 are as follows: (1) Houses a
single CT 32
and partial length PT 36, and four GSs 48. (2) Ends can be opened to permit
loading and
unloading operations. (3) ALARA shielding (including shielded body 316 and
shielded door
318), permitting manual hoist and transport operations when the ends are
closed. (4) The inner
surfaces shall permit easy cleanup. (5) The outer surfaces shall decontaminate
easily to permit
transport. (6) As much as possible the design shall not allow radionuclides to
fall out to the
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environment or contaminate the outside of the flask 202 when the ends are open
during loading
and unloading operations. (7) Contamination control to prevent the escape of
radionuclides
from the inside to the environment when the end have been closed, particularly
during hoisting
and transport operations. (8) Guidance for the Serapid chain ram and CT
Retrieval Head when
they are advanced and retracted by the pallet 302. (9) Lift points 320 for
hoisting and attachment
points for guide cables. (10) Include a brake mechanism for the second pull
with the CT
Retrieval Head. (11) Mount securely to the top of the pallet 302. (12) Allow
transport via
trolley system 201 in the vault 4 and truck to on-site volume reduction
facility. (13) Interface
with tooling at the volume reduction facility for unloading. (14) Designed for
storage in type-A
container outside. (15) Function as an accessory to the pallet 302.
[00108] In various embodiments in which personnel are working with the CT-PT-
GS flask
202, the shielding 316, 318 is designed for minimal radiation exposure to the
personnel when the
flask 202 is filled. Its features are designed with ALARA principles in mind,
such that
personnel minimize the amount of time they are in close proximity to the CT-PT-
GS flask 202
during hoisting and transport activities. Manual operations on the CT-PT-GS
flask 202 include
opening and closing the shielded doors 318, locking and unlocking the shielded
doors 318,
rigging for hoisting, hoisting to and from the trolley system 201, pallet 302,
and truck, and
transport on the trolley system 201.
[00109] The Brackets 322 incorporate contact points that guide the CT-PT-GS
flask 202 into
precise alignment on the pallet 302 during installation. The pallet 302 and CT-
PT-GS flask 202
are designed with adequate clearances to allow for easy installation and
removal of the CT-PT-
GS flask 202.
[00110] The CT-PT-GS flask 202 includes features that function with the
automated system.
These include an electromechanical brake mechanism on the body 316 of the
flask 202 that
engages with the CT Retrieval Head during the second pull, and sensors on the
doors 318 to
indicate if they are open or closed. These devices use a quick disconnect for
installation and
removal of the CT-PT-GS flask 202.
[00111] In one embodiment, the body 316 is made from carbon steel and the ends
318 are
made from lead. In other embodiments, the flask 202 comprises a lead-filled
steel shell. It is

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designed to be maintenance free during a retube outage, and requires
maintenance in between
retube outages.
[00112] Remove End Fittings / SP & Flasking
[00113] After the pressure tubes 36 are cut the end fittings 50 are removed.
The inboard end
of the end fitting 50 contains a portion of the pressure tube 36 from the
pressure tube cutting
operation, also the fuel channel shield plug 58 and liner tube are located in
the end fitting 50 and
positioned at their design location. Because these components are highly
radioactive a shuttle
flask 206 is used to provide the required shielding to reduce exposure to the
worker. The shuttle
flask 206 is lowered onto a trolley 200 and rail system 212 using a crane. The
shuttle flask 206 is
then transferred to the End Fitting Transfer Station (EFTS) located in the
vault 4 where the EF
50 is transferred to a Large Waste Transfer Flask (LWTF).
[00114] In various embodiments, the shuttle flask 206 is lifted off the EFSP
removal tool 324
with the Fuel Machine Bridge crane, then the shuttle flask 206 is moved over
the FCP hatch with
the Fuel Machine carriage. This can be a bottle-neck due to the special care
required to lift and
move a 10 Ton weight across the platform 292 to the hatch with very slow
speed. The process is
optimized by moving the shuttle flask 206 over the hatch using the heavy work
table 300. Once
the flask 206 is lifted with the crane, the heavy work table 300 can be moved
out of the way and
the flask 206 lowered to the vault floor. This simple change can reduce
complication and save
time as the heavy work table 300 can transport the shuttle flask 206 with a
higher speed and less
risk. The operation involving a 10 Ton object moving across the platform 292
in mid air can thus
be eliminated.
[00115] In those embodiments in which the End Fitting / SP Removal & Flasking
series is
performed at a high production rate, the optimization of the processes and
tools as outlined
contribute to minimizing the amount of time required to complete the work,
resulting in lower
costs and lower radiation exposure to workers.
[00116] The primary function of the EFTS is to safely transfer the EF 50 from
the shuttle flask
206 into the Large Waste Transfer Flask (LWTF). At the reactor face, the EF 50
is removed from
the lattice site and pulled into the shuttle flask 206 with the EFSP removal
tool 324. The shuttle
21

CA 02766583 2017-02-02
Attorney Docket No. 027813-9032-CA00
flask 206 is then lowered onto the shuttle flask trolley 200 located on the
Fuelling Machine (FM)
vault floor, using the FM bridge crane. The shuttle flask trolley 200 is used
to transfer the shuttle
flask 206 to the FM maintenance lock. Once in the maintenance lock, the
shuttle flask 206 is
lifted from the trolley 200 and lowered onto the EFTS using the FM Maintenance
Lock crane.
One of the main components of the EFTS is the End Fitting Ram, which pushes
the EF through
Flask-to-Flask Interface (FFI) into the LWTF. The FFI is an interface that
connects the shuttle
flask 206 and the LWTF that shields the operator from unnecessary radiation
doses.
[00117] Remove Pressure Tubes & Flasking
[00118] The main objective of the Pressure Tube Removal & Flasking series is
to pull the
pressure tube 36 from the fuel channel 28 and into a volume reduction machine
that will cut the
pressure tube 36 into small pieces and place those pieces into an attached
small waste transfer
flask. Pressure tube removal series begins at the bottom row and works up to
the next above
row, from the lattice site near the middle of the calandria 10 to the
periphery channels. Each
VRS removes approximately half of the pressure tubes 36.
[00119] In the embodiment disclosed herein, the VRS is performed outside of
the reactor vault
4 such that the crushing machines can be larger and the crushing process can
be performed in
parallel, increasing the production rate. In those embodiments in which the
Remove Pressure
Tube series is performed at a high production rate, the optimization of the
processes and tools as
outlined contribute to minimizing the amount of time required to complete the
work, resulting in
lower costs and lower radiation exposure to workers.
[00120] Thus, the invention provides, among other things, methods and
apparatus for handling
materials for retubing of a nuclear reactor 6.
22

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

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Administrative Status

Title Date
Forecasted Issue Date 2020-03-24
(22) Filed 2012-01-16
(41) Open to Public Inspection 2012-07-17
Examination Requested 2016-10-20
(45) Issued 2020-03-24

Abandonment History

Abandonment Date Reason Reinstatement Date
2017-12-11 FAILURE TO PAY FINAL FEE 2018-12-10

Maintenance Fee

Last Payment of $263.14 was received on 2023-12-21


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Next Payment if small entity fee 2025-01-16 $125.00
Next Payment if standard fee 2025-01-16 $347.00

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Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $400.00 2012-01-16
Maintenance Fee - Application - New Act 2 2014-01-16 $100.00 2014-01-03
Maintenance Fee - Application - New Act 3 2015-01-16 $100.00 2015-01-13
Maintenance Fee - Application - New Act 4 2016-01-18 $100.00 2016-01-04
Request for Examination $800.00 2016-10-20
Maintenance Fee - Application - New Act 5 2017-01-16 $200.00 2017-01-04
Maintenance Fee - Application - New Act 6 2018-01-16 $200.00 2017-12-15
Reinstatement - Failure to pay final fee $200.00 2018-12-10
Final Fee $300.00 2018-12-10
Maintenance Fee - Application - New Act 7 2019-01-16 $200.00 2019-01-15
Maintenance Fee - Application - New Act 8 2020-01-16 $200.00 2020-01-10
Maintenance Fee - Patent - New Act 9 2021-01-18 $204.00 2021-01-08
Maintenance Fee - Patent - New Act 10 2022-01-17 $255.00 2021-12-16
Maintenance Fee - Patent - New Act 11 2023-01-16 $254.49 2022-12-16
Maintenance Fee - Patent - New Act 12 2024-01-16 $263.14 2023-12-21
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
ATOMIC ENERGY OF CANADA LIMITED
Past Owners on Record
None
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Office Letter 2020-02-10 1 55
Representative Drawing 2020-02-18 1 21
Cover Page 2020-02-18 1 53
Cover Page 2020-03-18 1 53
Abstract 2012-01-16 1 16
Description 2012-01-16 21 1,013
Claims 2012-01-16 5 144
Drawings 2012-01-16 24 710
Representative Drawing 2012-03-13 1 31
Cover Page 2012-07-10 1 63
Drawings 2017-02-02 24 688
Claims 2017-02-02 3 88
Description 2017-02-02 22 1,178
Abstract 2017-02-02 1 16
Amendment 2017-05-15 9 229
Description 2017-05-15 22 1,104
Claims 2017-05-15 4 93
Special Order - Green Revoked 2018-02-20 1 52
Reinstatement / Amendment 2018-12-10 8 245
Final Fee 2018-12-10 8 246
Claims 2018-12-10 4 126
Examiner Requisition 2019-02-04 3 201
Special Order 2016-10-20 1 53
Assignment 2012-01-16 5 165
Amendment 2019-08-02 11 400
Claims 2019-08-02 4 128
Examiner Requisition 2016-11-02 4 220
Special Order - Green Granted 2016-10-24 1 31
Amendment 2017-02-02 72 3,079
Examiner Requisition 2017-02-15 4 193