Framtome Magazin 4/02 - AREVA

Advanced Nuclear Power
T H E M A G A Z I N E O F F R A M A T O M E A N P
N O 4 May 2002
FOCUS
Nuclear
Components:
Making
the Right
Decision
OTHER
HIGHLIGHTS
>> Digital Turbine I&C
Improves Plant
Availability
>> HTP X5 Fuel
Assemblies for PWR
Plants: Advanced
Economic and Reliable
Design
>> Choose the Leader For
All Your RV Head Needs
>> Jeumont SA, Highest Quality
From a World Leader in
Component Manufacturing

The Future for Nuclear
Component Manufacturing
After having focused on the Projects & Engineering, Nuclear Services, and Nuclear
Fuel business groups in previous issues, this fourth edition of Advanced Nuclear Power
concentrates on the role of and challenges facing Framatome ANP’s Mechanical
Equipment business group.
This business group is made up of two French entities; the Chalon Saint Marcel
plant that fabricates only nuclear heavy components, and Jeumont SA, a wholly-owned
Framatome ANP subsidiary, that specializes in reactor coolant pumps and
motors and control rod drive mechanisms. With over 272 steam generators,
113 reactor vessels, 68 pressurizers, 220 reactor coolant pump motors and
4,400 control rod drive mechanisms to their credit, these two entities clearly
position Framatome ANP as a leading global nuclear component manufacturer.
After a long period of new reactor manufacturing, the market has entered a phase
of plant service life extension and component replacement. Our mechanical engineering
market – previously dominated by EDF investments – has opened up and become more
competitive. The US, in particular, has a high potential for replacement components
over the next ten years due to aging plants and plant life extensions. The nuclear
renaissance, expected in the future, will create renewed demand for heavy components.
Customers today, due to market deregulation and a more competitive environment,
demand new types of contracts with their suppliers; contracts that are financially
attractive, simpler and more comprehensive. Clients increasingly are interested in all-
inclusive service packages covering supply of replacement components, the replacement
operation itself and the associated engineering and licensing studies. Framatome ANP,
with outstanding manufacturing capabilities, engineering and licensing, installation and,
equally important, the follow-on service and maintenance, can meet these requirements.
Joël Pijselman
Senior Executive Vice-President
C O

N T E N T S
10
FOCUS
Nuclear
Components:
Making the
Right Decision
4Projects & Engineering
4 Digital Turbine I&C Improves Plant Availability
5 Kozloduy 3 and 4: Assessing Remaining Service Life of Systems,
Components and Structures
8 Mechanical
Equipment
8 Jeumont SA, Highest
Quality From a World
Leader in Component
Manufacturing
20
Nuke Notes
6 Nuclear Fuel
6 HTP X5 Fuel Assemblies for
PWR Plants: Advanced Economic
and Reliable Design
14 Mark-B12 Fuel: A Fuel for
All Seasons
15
Nuclear Services
15 Framatome ANP Responds
to Emergency Scope
16 Choose the Leader for All
Your RV Head Needs
18 COMBO: A New System for
Continuous Measurement of
Boron Concentration
19 Oskarshamn 1: New Fuel
Pool Connections Installed
During Plant Operation
>> Framatome ANP Now Wears AREVA Group Colors
As you probably noticed, Framatome ANP – an AREVA and Siemens
company – has a new logo. It is now in the form of a red stylized “A”
that is the AREVA logo. The “A” symbol denotes the common identity of
all the AREVA Group companies and reinforces Framatome ANP’s role
in the creation of the new world leader in nuclear power.

Projects & Engineering
>>
Example:
Overspeed Protection
Digital Turbine I&C
Improves Plant Availability
Increasing use is
now being made of
Framatome ANP’s digital
instrumentation and
control (I&C) platforms,
TELEPERM XS and
TELEPERM XP, for
upgrading I&C equipment
provided for turbine
protection and control.
Testing TELEPERM XS turbine
control equipment (2-channel
configuration)
The new turbine I&C equipment
reduces the number of high-maintenance
hydraulic components. Turbine speed
is monitored by three channels and
the emergency stop valve is actuated
by a 2-out-of-3 logic. The channels are
automatically functionally tested at
cyclical intervals, ensuring that faults
are detected in a timely manner.
The most recent examples include
the replacement of the turbine
control system at Biblis, Units A and
B (Germany) and at Oskarshamn 3
(Sweden). In addition, replacement of
the turbine protection equipment
at Biblis B, Brunsbüttel, Philippsburg 1
and Grafenrheinfeld (all in Germany),
Gösgen (Switzerland) and Forsmark 3
(Sweden) were performed by Framatome
ANP. Other German nuclear power
plants as well as a plant in the US
have expressed interest in using the
TELEPERMTM XS safety I&C equipment
and TELEPERM XP process
control system at their turbine generator
sets.
The new system-wide implemented
multi-channel configuration in
conjunction with replacement of
hydraulic components (i.e. replacing
the hydraulic turbine-trip device
with a turbine-trip block with three
integrated solenoid valves) has been
proven to increase the availability
of the turbine generator set and thus of
the plant as a whole. In addition,
a multi-channel configuration is
provided for the I&C equipment and
mechanical components for turbine
control functions.
Test via turbine
test equipment
For turbine applications,
TELEPERM XS and TELEPERM XP
not only provide the necessary multichannel
capability (for 2-, 3- or 4channel
configurations), but also meet
the requirements essential for efficient
turbine control, such as fast response,
good dynamic behavior and highprecision
control. In the case of
TELEPERM XS, for example, this is
due to the fact that the I&C platform
originally was designed to meet the
requirements associated with reactor
protection and control, such as multichannel
capability, seismic resistance
and electromagnetic compatibility.
Fulfillment of these requirements by
the TELEPERM XS platform has
been verified through qualification to
the standards of the German Nuclear
Safety Standards Commission (KTA)
as well as generic approval from the US
Nuclear Regulatory Commission for
US-oriented markets. New turbine I&C
systems, employing TELEPERM XS
and TELEPERM XP, profit just
as much from the excellent design
features and capabilities of Framatome
ANP’s digital I&C.

Projects & Engineering
Kozloduy 3 and 4: Assessing
Remaining Service Life of Systems,
Components and Structures
Since deregulation of the
European energy market,
demands that nuclear
power plants should meet
uniform safety standards
are growing louder and
louder. Over the years,
one of the aims of the
Bulgarian VVER plant,
Kozloduy, has been not
only to upgrade individual
features of the plant
pertinent to safety (based
on IAEA recommendations)
but also to generally bring
all plant components,
systems and structures
in line with internationally
recognized safety standards,
essentially creating
a new VVER 440 reactor
design. Because this
approach involved various
exemplary and innovative
efforts, it serves as a
model for pioneering a
new safety philosophy.
Developing an Aging-
Management Program
A custom-tailored aging management
program is an extremely interesting
option in this context as it contributes
towards maintaining plant safety at a
high level over the plant’s entire design
service life and beyond. At the same
time, it also is reasonable to expect
economic advantages resulting from
higher reliability and availability.
With this in mind, a special program
was jointly developed by experts
from Kozloduy and Framatome ANP
and is being implemented by a
consortium formed of Framatome
ANP and the Russian company,
Atomstroyexport. The primary goals of
the program are to:
• perform an independent assessment
of the remaining service life of plant
components, systems and structures
that conforms to international
experts’ acceptance criteria,
• identify the need for further investigations
or analyses in certain cases,
• find solutions for improving safety
that are economical at the time.
Part of a Comprehensive
Backfitting Program
The aging-management program is part
of a comprehensive backfitting project
for Units 3 and 4 of the Kozloduy
plant and comprises three phases:
• In the first phase, the remaining
service life of representative
components, systems and structures
(relevant to safety and availability)
is determined at both plant units,
using state-of-the-art techniques.
• In the second phase, a computerized
system is developed to handle
all relevant component and system
data – both original construction
data and data recorded during plant
operation (e.g. loads and environmental
conditions) – as well as
information obtained from in-service
inspections and replacement activities.
• In the final phase, an aging-management
program is generated to
detect, evaluate and mitigate relevant
aging degradation mechanisms and
to identify locations in the plant
where they are likely to occur.
The 18-month project is scheduled
for completion in June 2002. So far,
the customer is very satisfied with
the way the project is progressing and
with the promising results obtained
to date.

Nuclear Fuel
>>
HTP X5 Fuel Assemblies for
PWR Plants: Advanced Economic
and Reliable Design
Recent years have
witnessed a continuous
rise in the performance
requirements for nuclear
fuel assemblies: nuclear
plant operators today
want the highest possible
reliability with optimum
fuel utilization and flexible
operation. Framatome
ANP has successfully
achieved these goals with
the development of its
HTP X5 fuel assembly
for PWRs.
Designed for Enrichments
up to 5 wt.% U-235
Optimum fuel utilization and maximum
fuel assembly reliability are key factors
for reducing nuclear fuel cycle costs
and thus enhancing the competitiveness
of nuclear power. The employment
of higher-enriched fuel and high
operational reliability of fuel assemblies
in reactors with demanding power
histories were two of the main objectives
in fuel assembly development.
Framatome ANP’s new fuel assembly,
HTP X5 (High Thermal Performance
eXtended up to 5 wt. %) for PWRs is
designed for enrichments of up to 5 wt. %
U-235 and permits fuel assembly
burnups of around 70 MWd/kgU and
fuel rod burnups of up to 75 MWd/kgU.
Our HTP X5 fuel assembly: Leader in fuel economy and reliability
Comprehensive Experience
in the Use and Management
of HTP Fuel Assemblies
By the end of 2001, 3,340 HTP
fuel assemblies were installed in 22
PWR plants built by various vendors
in Europe, Asia and the US, predominantly
in reactors using 17x17 lattice
fuel assemblies. A maximum fuel
burnup of 56 MWd/kgU was achieved
with these assemblies. Despite the everincreasing
rate of achieved burnup,
the operating performance of these
fuel assemblies has been exceptional.
High Reliability Despite
Continuously Increasing
Discharge Burnups
The continual increase in discharge
burnup is clear testimony to high
reliability. In the last 20 years, the
average discharge burnup of peak
reload batches of PWR fuel assemblies
has risen by more than half to over
50 MWd/kgU. With the advanced
HTP fuel assemblies now already in
use, discharge burnups of 55 MWd/kgU
will be achieved in the near future.
The materials and design of the HTP
fuel assembly have been optimized
such that within two annual cycles,
burnups of some 35 to 40 MWd/kgU
are possible without any operational
limitations.
Over a number of operating
cycles, the superiority of the HTP line
contact fuel rod support has been
proven, even at positions in the reactor
6 Advanced Nuclear Power N O 4 May 2002

core in which failed rods were frequently
encountered in assemblies
equipped with traditional spring-anddimple
spacers. No rod failures have
occurred since the HTP fuel assemblies
were installed at these locations.
HTP X5 Characteristics
The term, “HTP,” refers to both a
spacer type and the entire fuel assembly
design, equipped with this spacer
as a main component.
Spacers:
The unique, innovative design of
Zirconium HTP spacers combines fuel
rod support and coolant flow mixing
in a single component. The curved
flow channels increase coolant mixing
and improve thermal-hydraulic
behavior. The line-contact fuel rod
support across four double lines
ensures a large contact area and thus
optimum resistance to grid-to-rod
fretting: No fuel rod damage due to
fretting has been observed over
a period of 15 years. In the HTP X5
fuel assembly, the innovative Inconel
spacer derived from the HTP
spacer design is used at the bottom
spacer position where high loads
are incurred.
Bottom end fitting:
To contain debris and thus prevent
fretting damage to the fuel rods, the
fuel assembly bottom end fittings are
optionally fitted with an integrated
debris filter or with FUELGARD TM .
Cladding tubes:
Increased requirements placed on
advanced reactor operation require
cladding tube materials with excellent
corrosion resistance, low hydrogen
uptake and assured mechanical properties.
Our advanced M5 TM cladding is
designed to fulfill all PWR operational
requirements even under the most
demanding plant conditions
(temperature, void, power history etc.)
up to the maximum burnup one can
achieve with 5 wt. % U-235.
“New Generation
Fuel Assembly”
Framatome ANP conducted extensive
testing and lead design programs
Nuclear Fuel
working closely with its customers,
to enable continuous improvements
in fuel economy and reliability.
Working with customer needs,
Framatome ANP will develop,
through the “New Generation PWR
Fuel Assembly” project, a new PWR
fuel assembly design based on previous
design experience and operational
feedback in the coming years.

Mechanical Equipment
>>
Jeumont SA, Highest Quality
From a World Leader in
Component Manufacturing
The strong market
share of Jeumont SA
and its total integration
of design and manufacturing
processes in
its business lines gives
the company a clear
competitive advantage
vis-à-vis operator
availability, reactivity and
quality requirements.
Jeumont, a wholly-owned
Framatome ANP subsidiary, has
more than 220 reactor coolant pumps
and 4,400 control rod drive mechanisms
(CRDM) in operation worldwide.
Although much older than its
parent company – it was created at the
end of the 19th century – Jeumont
has held a Westinghouse license since
the beginning of the 1970s to manufacture
reactor coolant pumps, reactor
coolant pump motors and control rod
drive mechanisms (CRDMs). Its com-
Vertical integration plus many years experience ensures CRDM quality
ponents are providing outstanding
service worldwide in France, the US,
Asia and South Africa. The company
has never ceased striving continuously
to improve the performance and
service life of nuclear power plants
worldwide.
Improved Design Results
in 100 Percent Availability
The vertical integration of all its
industrial processes enhances Jeumont’s
ability to ensure the high quality
and consistency of all its products.
In addition, dedicated workshops for
pumps, motors, CRDMs and shaft
seals ensure that the most experienced
engineers and technicians work
in their area of specialization for the
highest quality product.
Based on specifications drawn up
by Framatome ANP engineering
teams, Jeumont designs, manufactures
and tests complete and coherent reactor
coolant pump sets that optimize
cost effectiveness and time schedules.
8 Advanced Nuclear Power N O 4 May 2002

Over the years, many innovations have
resulted in a pump availability rate of
100 percent without replacing main
motor components. Integrated sensors
(to measure vibrations, flow, temperature,
etc.) for in-service monitoring,
and intermediary spool pieces on all
types of pumps facilitate and reduce
maintenance by avoiding motor
removal. A new stator design eliminates
rewind and replacement. Updated
oil pumping systems improve bearing
performance. All these design
improvements help Jeumont pumps
easily withstand more than 4000
startups.
Increased Service Life
of CRDMs Benefits
Plant Operators
After Framatome ANP designs and
validates the use of CRDMs, the
Jeumont facility completes the detailed
manufacturing design and the manufacturing
itself, all on the same site.
Using original basic specifications,
the company significantly improved
the manufactured models, for example
by increasing service life from 2.5
million steps to almost 8 million.
Furthermore, these products require
no maintenance, allowing users to
constantly adapt to the power increases
required by the grid. These design
and operational features enable
operators to run their units with load
follow over a 60-year service life.
The Prestigious “N Stamp”
from ASME
In December 2001, Jeumont was
awarded N and NPT certification by
the American Society of Mechanical
Engineers (ASME). This certification
enables the company to manufacture
reactor coolant pumps and CRDMs
in accordance with third-party
manufacturer specifications
to position Jeumont as the
supplier of choice for reactor
coolant pumps and motors
and CRDMs.
The North American
Market
Jeumont delivered reactor
coolant pump motors
and spare stators and has
performed and continues to
perform upgrading and
maintenance operations at
more than eight US power
plants. The creation of a
hot workshop on the US
Lynchburg (Virginia) site,
similar to Europe’s largest
hot workshop, Somanu
in France, is just one
aspect of the close working
relationship between
Jeumont and Framatome
ANP in the US.

F O C U S
>>
Nuclear
Components
Making the Right Decision

Most nuclear plants
throughout the world were
built more than 20 years
ago. It is not unusual
for major components to
begin experiencing age
and corrosion-related
problems. Nuclear plant
executives increasingly
are facing tough decisions
that are complicated by
the prospect, at least in
the US, of extending
their licenses another 20
years. Deregulation is
one factor driving nuclear
power plants to increase
their output, reduce costs
and operate at peak
efficiency. As a result, the
market for replacement
components is growing.
For example, in 2001,
there were approximately
$75 million to $100
million in orders in the US.
Forecasts call for orders
to increase to approximately
$200 million
for the next three years.
Until recently, when normal wear
or corrosion-related problems
surfaced, the decision to repair was
relatively easy. Today, however, these
aging plants are being forced to spend
increasing amounts of time and effort
in analyzing the pros and cons of
repairing or replacing. If repair is performed,
how long will it last? Is it
cost-effective? Over what time period?
If the plant intends to extend its
license another 20 years, what impact
does that decision have on the repair/
replacement equation? If a decision is
made to replace a component, then
the issue becomes managing the
existing component in such a way that
maximum efficiency is maintained
during the time it takes to
F O C U S
Accumulator under construction at the Chalon Saint Marcel facility
manufacture the new component.
Framatome ANP is the premier supplier
in the world who can help plant
management through the entire process:
initial inspection and analysis, evaluation
and cost/risk analysis, engineering
for the actual manufacturing and
installation of a replacement component.
Replacement Often Most
Cost Effective
Components that are particularly susceptible
today are reactor vessel (RV)
heads and steam generators (SG). The
susceptibility of Alloy 600 to water
corrosion causes numerous problems
for these components. In the past, one
solution for SG problems was plugging
tubes or sleeving tubes to restore
their efficiency. However, only so
many tubes can be plugged before
capacity is affected. In addition,
inspection (and repairing) of tubes at
every outage significantly impacts
cost and schedule. Since the original
SGs were installed, improved materials
for tubes have been developed that
are less susceptible to corrosion.
These new developments directly
impact the analysis of the repair
versus replacement equation.
Many plants are opting to
replace major components rather
than continuing to inspect and repair
them because of the overwhelming
positive impact to their operational
budgets, particularly if the plant
intends to file for license renewal.
Two US Plants Opt for
Replacement
Callaway, a US plant owned and
operated by AmerenUE, recently
ordered four steam generators from
Framatome ANP to be delivered
in 2005. When asked why they chose
Framatome ANP, Tim Herrmann,
Superintendent Engineering Steam
Generator Replacement and Project
Manager for SGR, commented,
“Framatome ANP offered an innovative
design that supports our needs
and enhances our plant… We came
to Framatome ANP with one frame
of reference and left with a different
and better solution.”
Callaway’s steam generators
will be manufactured in Framatome
ANP’s Chalon Saint Marcel manufacturing
plant, the foremost reactor
component supplier in the world, with
90 units manufactured and installed.
Advanced Nuclear Power N O 4 May 2002 11

F O C U S
Reactor
vessel leaving
Chalon Saint
Marcel for
installation at
Civaux
12 Advanced Nuclear Power N O 4 March 2002

Callaway personnel, while visiting
that facility, were impressed with the
attention to detail, the clean room,
and the constant inspection and analysis
during each step of the manufacturing
process. Since Chalon Saint Marcel
has established a web server for communicating
design specifications, engineering
documentation and manufacturing
progress, customers can access
information on their particular component
in real time.
In 1999, the Chalon Saint Marcel
plant delivered a reactor pressure vessel
as well as three steam generators and a
pressurizer to the Ling Ao Unit 1 station
in China and another to the Ling
Ao Unit 2 station in 2000. They completed
construction of the two Civaux
1450 MWe N4 units in 1997 and
1999. They currently are fabricating
two replacement steam generators for
Prairie Island that will be delivered in
2004. Of the 28 new LWRs (non VVER)
that have been started up since 1990,
13 were built by Framatome ANP.
Chalon Saint Marcel
Manufactures Only Nuclear
Components
Established in 1975, the Chalon Saint
Marcel facility has fabricated over 400
PWR heavy components, including
reactor pressure vessels and internals,
steam generators (272), pressurizers
(68), reactor vessel closure heads
(113), accumulators, piping for reactor
coolant systems and component support
structures. Due to the facility’s
flexible design, the demands of multiple
customers, i.e. multiple types of
components, can be manufactured
simultaneously.
Because the facility has continuously
manufactured only nuclear components,
all R&D efforts focus on
improving the technology, welding
techniques, and materials used in the
components. In particular, the
Technical Center specializes in welding
and related technologies as well as
metallurgy and surface treatment.
Their non-destructive examination
(NDE) innovations and technologies
ensure minutely detailed inspection of
all component parts and welds. The
Center also analyses corrosion chemistry
and develops new materials to
minimize its effects.
Design automation, engineering
and manufacturing are the key to the
Chalon Saint Marcel’s reputation for
F O C U S
quality and service. Deep-drilling
machines for tubesheets, multi-spindle
drilling machines for tube support
plates and automated broaching
machines ensure uniformity and
consistency. Controlled access and
pressurized clean rooms for the tube
installation process (tubing, welding,
hydraulic expansion, etc.) ensure that
no foreign materials are introduced
into the steam generators during the
manufacturing process.
Framatome ANP’s wealth of
worldwide experience in service,
engineering and maintenance helps
customers effectively manage their
aging plants. If replacement components
are required, the premier nuclear
heavy component manufacturing
facility in the world can manufacture
them to the customer’s specification
at a competitive cost, deliver it on
time, and ensure that the installation
requires minimum outage time.
Framatome ANP, through its extensive
experience and expertise, can assist
customers beginning with the decision
analysis process through purchasing,
licensing, manufacturing, installation
and follow-on service for the life
of the component.

Nuclear Fuel
>>
Mark-B12 Fuel :
A Fuel for All Seasons
Recently, the first batch of
Framatome ANP’s new Mark-B12
fuel assembly design was delivered,
loaded and is now operating at Three
Mile Island. A second batch has been
delivered to Davis-Besse for loading in
their upcoming cycle later this year.
The new design features the
advanced alloy M5TM fuel rod cladding
and guide tubes proven to experience
lower growth and lower corrosion
than previous designs using Zircaloy 4.
M5 guide tubes also are expected
to reduce fuel assembly distortion and
thereby allow smoother insertion of
control rods, a critical factor in plant
operation and shutdown.
“The M5 alloy used in cladding
and structure supports higher burnups,
and longer fuel cycles,” said Dennis
Gottuso, manager of North American
Business and Product Development
for Framatome ANP. “We feel that we
are supporting nuclear power by
developing designs that meet and
exceed our customers’ needs.”
“With the challenging two-year
cycles we are designing for TMI,
we were pushing Zirconium (Zr)-4 to
its limits,” said Bob Jaffa, Senior
Engineer for Exelon Nuclear. “M5
cladding gives us much-needed margin
to corrosion limits and we are optimistic
that the M5 guide tubes and the
Mark-B12 holddown spring will reduce
distortion. Also, the heavier uranium
loading in the Mark-B12 better suits
our cycle design needs. For the long
run, we want to be in position to
have a core loaded with fuel capable
of extended burnups when burnup
extension becomes a reality.”
The Beginning
Years of research and development in
new materials preceded the debut of
the Mark-B12 fuel assemblies. First
“An improved fuel design for B&W reactors with better fuel economy and superior corrosion and debris resistance.”
came the search for an alloy that could
withstand severe operating conditions
that would be required in the future –
a future we now see all too clearly.
Higher neutron fluxes, heat fluxes,
and extreme temperatures are the order
of the day as plants strive to increase
capacity and availability to the grid.
Beginning more than a decade
ago, Framatome ANP and its partner
Cezus, narrowed their alloy search
from 20 to six alloys for continued
research and testing. The M5 alloy
underwent a rigorous development
program that identified and controlled
critical constituent and processing
parameters. The resulting alloy
microstructure is highly stable and
provides the best in-reactor cladding
and structural component performance
of any zirconium alloy tested. The M5
is a ternary Zr-1% Nb-0 alloy that out
performed the other test alloys under
the required, severe conditions such as
high lithium, high power density, high
temperature, and sub-cooled boiling.
In addition, the M5 alloy was
found to be such a reliable product that
Framatome ANP went on to use it
in producing guide tubes for reactors.
The Future: Here at Last
The nuclear power industry is
changing daily, and plant owners and
operators are watching their financial
margins closely, looking to uprate,
run at higher peaking rates, and to
keep plants running longer. Thanks to
the thinner M5 cladding and “fatter”
fuel pellets, the Mark-B12 is able to
“go the distance.”
“The uranium loading for this
fuel was increased 5 percent over previous
designs to support longer operating
cycles and higher burnups. The Mark-
B12 can help reduce batch size for
fuel, and allow plant operators flexi-
bility in operations,” Gottuso said.
“M5, the cladding that helps the Mark-
B12 achieve its high performance is not
only available for B&W-type plants,
but also for Westinghouse, and soon,
Combustion-Engineering plants
as well,” said Gottuso. “Our goal is
to provide the nuclear power industry
with the most advanced fuel that can
not only meet the industry’s needs,
but improve the operability of any
PWR.”

Framatome ANP Responds
to Emergency Scope
In October 2001, during a bobbin
eddy current inspection (ECT) of
steam generator tubing at AmerGen’s
Three Mile Island (TMI), Unit 1,
located in Pennsylvania, wear indications
were discovered in the B generator
on four tubes at the secondary face of
the upper tubesheet. The four tubes
surrounded a tube that previously
was plugged.
Since the wear indications were
significant, the ECT analysts surmised
that the cause might be a severed tube.
Once the plug was removed from the
upper tubesheet, a visual inspection
confirmed that the tube had indeed
severed at the upper tubesheet
secondary face.
To understand the cause,
AmerGen decided to remove tube
samples (tube harvest) so that a
destructive examination could be done
for failure analysis. Framatome ANP
received a call on Friday, October 19,
2001 asking for help. Since this was a
first-of-a-kind (FOAK) effort, a team
was quickly formed and a preliminary
plan was mapped out to accomplish
the tube harvest.
The plan involved removing the
SG secondary manway cover and
elliptical wrapper cover to gain access
and allow removal of tube sections
from the secondary side. Cutting the
sections would take place from the
primary side but retrieval and accountability
of the pieces would be from
the secondary side.
The team developed tooling,
mockups, video and other support
items in 4 days. The site team went
through training in Lynchburg and
the final execution plan was completed
in 3 days. One week after the initial
request, the team deployed to site
to begin equipment staging and
Special remotely operated
tool designed especially for
the TMI tube harvest.
setup, and site training.
Tube section removal work
began on October 28th. The team
encountered stuck studs on the
secondary manways, and the studs on
the elliptical wrapper cover had never
been removed since plant startup.
The team also discovered tube sections
that had swelled considerably larger
than design. Furthermore, the nonharvested
section of the tube had to be
left in a condition suitable for future
operation. The sections removed
were ECT tested as a baseline for the
laboratory destructive exams including
metallurgical evaluation and pressure
testing. The entire process, even with
the stuck studs and swelled tubing,
was completed in two days.
The process removed all of the
planned tube sections except one;
the only section not removed was
a 4" (10 cm) long section of the tube
within the upper tubesheet region.
This section was roll expanded in
place to capture it and prevent it from
becoming a loose part. Based on
subsequent testing and analysis of the
Nuclear Services
Close–up of the clamp on the
special tool to hold the tube
in place during the operation.
other sections removed, it turned
out that removal of this 4" section was
not necessary. Testing and analysis
revealed the cause to be attributed to a
combination of three factors; 1) Tube
expansion from water within the tube,
2) OD intergranular attack (IGA) and
3) Flow-induced vibration from high
cross flow. Identification of the cause
of this failure was key to AmerGen’s
plan for mitigation that allowed for
the plant’s return to power operation.
Rich Freeman, steam generator
program engineer at TMI, commented,
“Framatome did a very good job of
preparing and executing the removal
of these tubing sections from the secondary
side of our generator. Removal
of these sections was important and
helped us to discern the cause of our
tubing degradation.”

Nuclear Services
>>
Choose the Leader
for All Your RV Head Needs
Framatome ANP has supplied
more replacement RV heads with
improved design features than
any other manufacturer
Over the last several years, an
increasing number of PWR
plants have experienced stress corrosion
cracking in the area of their control
rod drive mechanism (CRDM) nozzles
and their accompanying welds. The
problem first was discovered in France,
and lately highly susceptible US
plants are being required by the NRC
to perform inspections and make
repairs if problems are found.
Framatome ANP was involved
with this problem since its inception.
As a result, the company has the most
experience and has developed specific
inspection and repair technologies,
tailored to each plant type, to address
the problem. Of the 27 inspections
performed to date in the US,
Framatome ANP completed 24 and
has another seven scheduled for spring
2002. This past fall, inspections
were performed on eight RV heads,
representing three different designs:
four Westinghouse plants, three
Babcock & Wilcox plants and one
Combustion Engineering (CE) plant.
Because of this in-depth experience,
Framatome ANP can perform not
only the inspections and repairs,
but also assist customers in analyzing
the factors that must be taken into
account to make sound decisions
about which option, including replacement,
makes the most economical
and operational sense.
16 Advanced Nuclear Power N O 4 May 2002

Minimal Dose Inspections
for All Types of Plants
During the fall 2001 outages, different
technologies were used, sometimes
in combination to complete the
inspections. Innovative remote tooling
enabled low-dose bare head visual
and head penetration nozzle ultrasonic
(UT) inspections. Rotating UT,
delivered from under the RV head,
supported nozzle flaw characterization.
In spring 2002, the company
will introduce an ultrasonic inspection
technique that verifies the existence of
the leak path forming at the interface
between the outer surface of the
CRDM nozzle and the reactor head
base material adjacent to the nozzle
outer surface. Based on empirical data
taken from Framatome ANP’s database
of 128 nozzle inspections from seven
plants, the leak path UT technique
is equivalent to or better than the
bare head visual inspection performed
to identify leaking nozzles. This
innovation will save dose and time.
Speedy Repairs Reduce
Outage Time
In addition, specialized equipment
was designed to reduce dose levels by
automating the procedures for repairing
CRDM nozzles. In the fall outage
alone, 24 CRDM nozzles and eight
thermocouples were repaired at four
different plants using the remote ID
temperbead repair technique. To maximize
the life of the repair, Framatome
ANP uses a remediating technique
on the weld heat-affected zone.
Using a Midland head mock-up
at Framatome ANP’s testing facility in
Lynchburg also enabled the company
to design specialized tools and techniques
for both inspection and repair
as well as train personnel prior to
deployment. For example, a method
to raise the insulation of the RV
head at one customer’s plant enabled
a bare head inspection and eliminated
the need to perform an underhead
inspection.
Replacement: A Viable
Option For Long-Term
Operations
Companies experiencing the highest
number of flaws are seriously considering
replacing their RV heads. Since
the delivery time for a replacement
RV head is longer than one cycle,
Framatome ANP, working in partnership
with the customer, develops
innovative solutions that reduce lead
time for replacement heads.
Framatome ANP was contracted
to supply three RV head replacements
in the US. These will be fabricated
in the Chalon Saint Marcel plant. This
plant is fully qualified and has never
missed a delivery schedule in over 35
years of continuous manufacturing of
heavy nuclear components. To meet
customer requirements, the facility can
manufacture either single or two-piece
heads and fit up is warranted to mate
with existing plant equipment with
no impact to the reactor vessel flange,
RV stud or CRDM operations. Most
importantly, of the 113 RV heads
manufactured and delivered, none
has experienced crack initiation in the
CRDM J-groove weld. For that reason,
Framatome ANP offers a warranty
on all replacement RV heads.

Nuclear Services
>>
COMBO: A New System for
Continuous Measurement of
Boron Concentration
In PWRs, a boric acid solution
is added to the reactor coolant to
control reactivity. As core burnup
increases, the boric acid content
in the coolant is gradually reduced.
Monitoring of the boron concentration
in systems conveying reactor coolant
for purposes of reactivity control is
important for plant safety, particularly
when the plant is in the shutdown
condition and during core loading.
Framatome ANP has developed
a system called COMBO (continuous
measurement of boron concentration)
that is installed on a pipe or vessel,
with no system modifications necessary.
This makes COMBO ideal for backfitting
as well – in all types of PWRs.
On-Line Monitoring
Offers Advantages
Today, it is standard practice to
measure boric acid concentration in
PWR coolant on a non-continuous
basis via chemical analysis (titration),
necessitating extensive laboratory
support. However, continuous monitoring
has a number of advantages:
• On-line monitoring of boron
concentration in the reactor coolant
system and reactor auxiliary systems
enables operating crews to respond
much more rapidly to disturbances,
thereby delivering an important
safety enhancement.
• Plant economy is improved due to
shorter shutdown and startup
times, and to reduced personnel
and material resources.
Positive Operating
Experience Already Gained
in the Field
The system performed for the first
time at Grafenrheinfeld (Germany)
from 1996 to 1999. The measuring
equipment, characterized
by its small dimensions and ease
and speed of installation, was installed
directly on the main piping of the
volume control system.
A total of 18 COMBO systems
have been monitoring boron concentration
in the coolant treatment
and cleanup system at the VVER-type
PWR units, Mochovce 1 and 2
(Slovak Republic) since 1998 and
1999, respectively. Plants equipped
with VVER-type reactors, in particular,
have a greater need for boron
monitoring in the reactor auxiliary
systems due to the system design and
configuration specific to these plants.
A further COMBO system was
installed in 2002 at Isar 2 (Germany)
for monitoring the fuel pool.

Between October 1 and 15, 2001,
Framatome ANP installed
two new penetrations in the wall of
the fuel pool at Sweden’s oldest
nuclear power plant – the 445MWe
BWR unit Oskarshamn 1. The
penetrations, which have a nominal
diameter of 8" (DN 200), are needed
for connecting the fuel pool to
the residual heat removal system that
has been redesigned as part of
Oskarshamn’s ongoing “MOD” modernization
program. The purpose of
the new connections is to provide the
plant with two additional fuel pool
cooling trains that can be placed in
operation if the system normally used
for pool cooling should fail.
Since the entire reactor core will
be unloaded to the fuel pool when
the unit is shut down in 2002 for the
main scope of the modernization
work, the two penetrations had to
be installed while the plant was still
on line. Because the fuel pool cooling
system extracts the pool water from
the upper region of the pool for
cooling, it was not possible to lower
the water level in the pool. Hence
all activities had to be carried out
underwater using a special caisson to
provide a dry working area at the
pool wall. Thanks to the experience
and knowledge gained from a similar
project performed in 1997 at the
Swiss nuclear power plant Gösgen,
the work was able to be completed
much faster than expected – in 15
days instead of the 23 days originally
planned. According to Anders
Ahrenius, sub-project manager for
the plant operator, OKG Aktiebolag,
the decisive factor here was “the
excellent work done by the team
from Framatome ANP.”
The main goal of the MOD
project is to bring Oskarshamn 1 in
line with today’s safety standards and
to enable the unit to continue generating
power economically for many
years to come. The complete modernization
program that spans several
years, is scheduled for completion by
the fall of this year.

Brazil
Angra 2: Integrated
Maintenance Service
Minimizes First Refueling
Outage Duration
Framatome ANP received a broad-scope
order for service work to be performed
during the first annual refueling outage
(in March 2002) at the Angra 2 nuclear
power plant. In addition to service
work on the reactor floor and for the
fuel assemblies, maintenance work also
will be performed on valves, pumps
and pump motors. The emergency
diesel generating units, electrical and
I&C systems, HVAC systems, and
reactor coolant pumps of the 1309 MWe
PWR plant also will undergo a
comprehensive inspection.
All major inspection work will be
performed in close cooperation with
the Brazilian partner and customer, the
state-owned Eletrobrás Termonuclear
S.A. (ELETRONUCLEAR), as
well as experienced subcontractors
from Germany and Brazil. In total,
more than 1,000 specialists will be
involved in the outage. Thanks to the
integrated service concept developed
by Framatome ANP and the strong
commitment of the utility, manpower
and time scheduling for all companies
and independent experts involved
is coordinated for an outage duration
of less than thirty days. The services
package also includes non-outagerelated
maintenance activities that will
be performed throughout the year
2002 with the plant on line.
Looking Ahead to Angra 3
One year after the start of commercial
operation at Angra 2, the Brazilian
government authorized the plant owner
and operator, Eletrobrás Termonuclear
S.A. (ELETRONUCLEAR), to start
preparing for the resumption of
NukeNotes
construction work at Angra 3. Initial
tasks consist of nuclear and environmental
licensing, adapting supply
contracts and negotiating required
financing. ELETRONUCLEAR
already has invested US $750 million
in this project. Completion of Angra 3
is estimated to cost another US
$1.7 billion.
The contract for Angra 2 and 3 was
awarded in 1976 under the terms of the
German-Brazilian intergovernmental
agreement on cooperation for the
peaceful use of nuclear energy. However,
money shortages caused work on
Angra 3 to be halted in the mid-1980s.
Angra 2 and 3 are both PWR units
of the 1300 MWe class.
Canada
Steam Generator
Secondary-Side Cleaning
at Pickering B
Framatome ANP performed the
steam generator secondary-side
chemical cleaning of Units 5, 6 and 8
of Pickering B Nuclear Power Station,
a CANDU plant operated by Ontario
Power Generation (OPG). The main
goal of the cleaning project was to
prevent or significantly reduce boiler
tube degradation caused by corrosion
product deposition.
Our patented, high-temperature
cleaning process was selected on
the basis of its short application time
and high efficiency, and because it does
not require any plant modifications.
All 36 steam generators were
cleaned during maintenance outages
within less than 12 months. More than
18,849 lbs. (8550 kg) of deposits were
removed. This was the third steam
generator cleaning project successfully
performed for OPG.
Cleaning of the Unit 7 steam
generator secondary sides is scheduled
for early 2003, again using Framatome
ANP’s proven high-temperature process.
China
Ling Ao Unit 1
Achieves First Criticality
On Schedule
Six years ago Framatome ANP and its
Chinese partners established a schedule
for the Ling Ao nuclear power units
being constructed in China. Ling Ao
Unit 1 achieved first criticality on
February 4, 2002, a few days ahead of
schedule. Zero power core compliance
tests were passed on February 7, thus
allowing power escalation.
Ling Ao control room
20 Advanced Nuclear Power N O 4 May 2002

Chinese Safety
Authority NNSA Approves
18-Month Fuel Cycles
for Daya Bay NPP
Daya Bay Units 1 and 2 received a
licensing permit from National Nuclear
Safety Administration (NNSA) in
December 2001 to operate both plants
in 18-month fuel cycles, beginning
with cycle 9. This approval is the
culmination of three years’ engineering
work performed by Framatome ANP
with participation by Nuclear Power
Institute of China (NPIC) and
Guangdong Nuclear Power Joint
Venture Company Limited (GNPJVC).
Cycle 9 specific reload safety evaluations
of both Units and recent start-up tests
results for Unit 2 also met the safety
criteria, confirming the generic safety
demonstration.
New design tools, such as
SCIENCE for nuclear design and
CATHARE for LOCA analyses now
being licensed in China, probably will
open future opportunities for nuclear
power plant performance optimization
and for a continued successful
collaboration.
France
Safety Injection Valve
Replacement
Framatome ANP received an order
from Electricité de France (EDF) for
the replacement of a safety injection
check valve and the up-stream elbow,
at Fessenheim 1 in 2002. This unusual
replacement follows inspections,
during which indications were found
in the seat of the valve and in the
first weld of the elbow.
A soft chemical decontamination
process will be implemented to
reduce man Rem exposure. Due to the
elbow replacement, the fit-up sequence
will use a Romer 3D arm that will
be positioned on the valve flange.
This manipulator will provide accurate
measurements, to ensure correct
positioning of the cutting and beveling
of the spool piece. This technique was
successfully used for a Residual Heat
Removal System partial replacement.
Once everything is properly positioned,
an automatic tungsten inert gas (TIG)
welding technique, assisted by video
surveillance, will be implemented. A
volumetric inspection will be performed
at the end of the operation.
Japan
UF6-UO2 Conversion
Contract for FBFC
FBFC, a wholly-owned Framatome
ANP subsidiary, signed a multiyear
contract with the Japanese company
Nuclear Fuel Industries Ltd. (NFI) for
conversion services. This operation
consists in transforming uranium
hexafluoride (UF6) – enriched in
Europe – into UO2 powder. Delivery
is scheduled to begin in 2002.
Sweden
Nuke Notes
Modernization of Control
Rod Control System
Completed at Forsmark 3
Framatome ANP has modernized
the control system of the control rod
drive mechanisms (CRDM) with
the TELEPERM TM XS digital safety
instrumentation and control system
at Forsmark 3 Nuclear Power Station,
a BWR plant that went into operation
in 1985. This is the first time
TELEPERM XS has been implemented
in the CRDM control system of an
ABB Atom (now Westinghouse Atom)
nuclear power plant. The new control
system provides increased availability,
better and more timely information on
plant conditions, and automatic,
screen-aided CRDM maintenance.
In addition to the highly automated
control system for the drive mechanisms
of the 169 control rods and the related
new calibration functions, the plant
was backfitted with new switchgear and
several PC-based auxiliary systems.
Framatome ANP also supplied a
maintenance database, a local operating
station and a workshop system. The
operation and monitoring functions
were implemented using the
TELEPERM XP instrumentation
and control system.
Advanced Nuclear Power N O 4 May 2002 21

Nuke Notes
South Africa
New Industrial Partners
Continuing its strategy of local
development in South Africa,
Framatome ANP has acquired major
shareholdings in two local companies:
• Lesidi Nuclear Services (LNS) to
assemble the resources required
for maintenance operations and
project management,
• Signum Design and Engineering
Consultants to perform
modification studies.
These investments move Framatome
ANP closer to ESKOM, its customer
and the operator of both Koeberg
units, designed by Framatome ANP.
In addition, it conforms with South
Africa’s policy of developing local
enterprises, while guaranteeing that
the customer receives quality service.
Koeberg nuclear power plant
Taiwan
First Decontamination
Performed
In autumn 2001, Framatome ANP
successfully completed its first
decontamination project in Taiwan at
Unit 1 of Kuosheng Nuclear Power
Station, a BWR plant. Both reactor
coolant recirculation loops and the
internals of three reactor coolant
recirculation pumps were decontaminated
using our world-renowned
Chemical Oxidation-Reduction
Decontamination (CORD ® ) UV
process together with Framatome
ANP’s Automated Mobile/Modular
Decontamination Apparatus
(AMDA ® ). The average decontamination
factors achieved in the two
RCC loops were calculated to be 50.8
and 35.5, respectively, and for the
RCC pump internals to be 127,
76 and 69.
The Framatome ANP CORD ®
UV process is characterized by its high
efficiency and low waste generation,
as only chemicals are used that break
down into water and carbon dioxide
under ultraviolet light. For plant
operators, this translates into a
considerable reduction in personnel
occupational exposures and low waste
treatment costs.
United States
Integration of Fuel Services
Proceeds Smoothly
When the nuclear power operations of
Siemens merged with Framatome in
January 2001, the fuel manufacturing
facilities in Richland, Washington
and Lynchburg, VA were combined.
The past year has been devoted to an
in-depth analysis of both operations to
determine the most efficient method
to maximize operations while continuing
to provide advanced technology
and service to customers.
A plan has been developed to consolidate
several operations that will be
implemented over the next three years.
By going slowly and deliberately and
by developing step-by-step, detailed
work plans and schedules, Framatome
ANP is committed to ensuring ontime
delivery of NCR-free assemblies,
even if it means maintaining duplicate
lines until the transition is complete.
A key ingredient in the plan is
customer participation. Customers will
be kept aware of each step, will have
the opportunity to provide input to
the plan in an on-going manner
and can contribute their ideas and suggestions
for minimizing disruptions.
Framatome ANP is committed to
continuing its normal R&D efforts
and maintaining its schedules and
quality as it goes through this process
to provide the best fuel available in
the US today.
22 Advanced Nuclear Power N O 4 May 2002

Framatome ANP, Inc.
to Purchase Duke
Engineering and Services
Framatome ANP Inc. signed an
agreement to purchase Duke
Engineering and Services Inc., a
subsidiary of Duke Energy located in
Charlotte, North Carolina. Duke
Engineering is a leading engineering
and technical services firm with
1,250 employees, headquartered in
Charlotte, NC.
The purchase will include three
Duke Engineering business groups.
The Nuclear Group focuses on
nuclear engineering, plant upgrades,
instrumentation and control and spent
fuel storage engineering. The Federal
Editorial Staff of Advanced Nuclear Power magazine:
Annie Wallet – Publisher
Susan Hess – Editor-in-Chief
Martha Wiese – Managing Editor
Bill Warner – Creative Director
Regional Editors – Christine Fischer, Vincent Join-Lambert, Martha Wiese
Graphic Design – O’Connor Group
Contributing Writers:
Franz Ammann, Wolfgang Breyer, Yvonne Broy, Dominique Ebalard, Manfred Erve, Yves Fanjas, Ernst Gell, Gilles Goyau,
Michel Jaubert, Sabine Kueny, Linda Leech, Isabelle Morlaes, Thierry Piérard, Jens Reinel, Frank Schindhelm,
Arnd Schüßler, Joachim Specht, Martha Wiese
Framatome ANP-Worldwide Offices
Tour Framatome
92084 Paris La Défense Cedex
France
Tel.: +33 1 47 96 00 00
Fax: +33 1 47 96 36 36
info@framatome-anp.com
Group provides engineering and site
management for several Department
of Energy nuclear sites. The Energy
and Environmental Group serves the
hydro, gas transmission and fossil
energy markets.
Framatome ANP Inc.’s President
and CEO, Tom Christopher said,
“The synergy between Framatome
ANP Inc. and Duke Engineering will
be excellent because of Duke
Engineering proficiencies and our
strategic goals in the energy industry.
As the world leader in nuclear engineering,
nuclear fuel and nuclear services,
this addition enables us to significantly
broaden our business portfolio
in the US.”
Bruce Williamson,
Duke Energy, and
Tom Christopher,
Framatome ANP, Inc.
at the signing
3315 Old Forest Road
Lynchburg, VA 24501
USA
Tel.: +1 434 832 3000
Fax: +1 434 832 0622
info@framatech.com
Freyeslebenstr.1
D-91058 Erlangen
Germany
Tel.: +49 9131 18 95374
Fax: +49 9131 18 94927
info@framatome-anp.de
The following are trademarks of Framatome ANP: ALLIANCE, Fuelgard, M5, Mark-BW, and TRAPPER. TELEPERM is a trademark of Siemens.
Nuke Notes
Framatome ANP/Entergy
Team to Perform License
Renewal at D. C. Cook
Framatome ANP, teamed with Entergy,
was awarded the contract for license
renewal work at American Electric
Power Company’s D.C. Cook nuclear
power plant. The work will be implemented
over several years culminating
in the preparation and presentation of
the license renewal documentation to
the Nuclear Regulatory Commission
(NRC) for approval.
Aside from responsibility for
license renewal work at all Entergy
nuclear power plants, the team also was
awarded a similar contract at FirstEnergy
Corporation’s Davis-Besse plant.
Advanced Nuclear Power N O 4 May 2002 23
©2002 Framatome ANP, Inc.

U4-V1-02-ENG
ENHANCING YOUR COMPETITIVENESS
At Framatome ANP, an AREVA and Siemens company,
we’re constantly working to help your nuclear plant
operate more efficiently, safely, and economically.
With a worldwide team of nearly 13,000, we deliver
advanced technology and responsive services to
improve your performance and profitability. From
comprehensive outage services management to
the most innovative tooling and technology, we offer
the expertise to reduce your outage times. Our
YOU’RE RIGHT TO ASK FOR MORE.
www.framatome-anp.com
I&C modernization
at Beznau, Switzerland
high burnup fuel for both BWR and PWR plants
provides increased margins and extreme reliability.
And you can count on our field proven digital I&C,
replacement components and vast engineering knowhow
to deliver competitive solutions for successful
plant modernization and uprates. So whatever your
plant needs are, let us put the power of experience
to work enhancing your competitiveness.
Framatome ANP, COGEMA and FCI now form the AREVA Group, the world leader in the nuclear energy and interconnect sectors.