Full-scope BWR Services

Westinghouse BWR Services: A Full Complement

of Service Solutions for Your BWR Plant Needs
Westinghouse Electric Company, the
worlds pioneering nuclear power
company, supplied the first
commercial pressurized water
reactor (PWR) in 1957 at Shippingport,
Pennsylvania (USA). Today,
Westinghouse is a fully integrated,
worldwide supplier of both pressurized
water reactor (PWR) and boiling water
reactor (BWR) services.

Grounded in Experience
Toshiba and ABB nuclear technology,
Westinghouse operating experience, and career
BWR technical talent have converged to make
Westinghouse one of the worlds premier BWR
service organizations, focused on your operating
plant success through safe and reliable
operation maximized power outputand
improved outage performance.
Since 1980 Westinghouse has supplied products
and services to BWR nuclear plants around the
world and has helped these plants meet the
ever-present challenge of improving availability,
performance and safety.

In 2000 ABBs nuclear businesses (ABB Atom) were

integrated into Westinghouse Electric Company and
renamed, Westinghouse Atom ABB. This acquisition
further expanded Westinghouses BWR capabilities
and market presence. Six years later, Westinghouse
was acquired by Toshiba Corporation, one of the
worlds largest global nuclear power organizations.
Toshiba has made significant investments in BWR
technology and is now widely regarded as an
industry leader in state-of-the-art BWR technology.

Westinghouse experience plus Toshiba and

ABB technology a winning combination
for BWR plant success.
= Locations where
BWR Services work
is being performed

Nivelles, Belgium
Shoreview, MN
Lake Bluff, IL
Burr Ridge, IL
Seattle, WA
Richland, WA
San Jose, CA

Windsor, CT
Cranberry Twp., PA
Monroeville, PA
Madison, PA
New Stanton, PA
Rockville, MD
Charlotte, NC

Dallas, TX
Glen Rose, TX

Vsters, Sweden
Tby, Sweden

Spartanburg, SC
Rock Hill, SC

Hamburg, Germany
Mannheim, Germany
Orsay, France
Lyon, France
Marseille, France
Madrid, Spain
Terragona, Spain

Tokyo, Japan
Kobe, Japan

Chattanooga, TN

Global Technology and

Process with
Local, Operationally Excellent
Implementation

Pretoria, Republic of South Africa

Cape Town, Republic of South Africa

Westinghouse, a leading supplier to the nuclear power industry, has personnel at locations around the world
supplying technology-based and experience-proven products and services to the BWR fleet. With 139 operating
units, Toshiba and Westinghouse today represent the largest worldwide nuclear operations experience base, with
BWRs making up more than 20 percent of their combined original equipment manufacturer (OEM) fleet. Toshibas
17 BWR plants in Japan and Westinghouses 9 BWR OEM plants (original ASEA-Atom NSSS) in the Nordic
region provide a global OEM experience base. Westinghouse has expanded its investment in BWR support in
recent years with the addition of BWR-focused engineering offices in San Jose, California; and Charlotte,
North Carolina (USA).
In 2009, the company officially opened its
U.S. Boiling Water Reactor Service Center in
Chattanooga, Tennessee (USA). At this unique
service site, customers, industry representatives
and employees receive training on the safe
maintenance and refueling of boiling water reactors in U.S., and some European, nuclear power
plants. The Service Center features a full-scale
BWR cavity with vessel, internals, spent fuel
pool and refueling bridge, two 33-ton cranes and
an undervessel mock-up.

outage services
Westinghouse has a proven track record of successful outage services at BWR plants
worldwide. Westinghouse works with customers to identify and address key performance
improvement areas to limit variability in outage cost and schedule.

Refueling

Reactor disassembly/reassembly
Fuel movement
In-core and canister fuel sipping
Vessel maintenance

Refueling Equipment and

Fuel Handling
Design, manufacture and installation of
fuel-handling equipment and outage-critical
cranes, including maintenance, upgrades
and modernization through Westinghouse
subsidiary PaR Nuclear
Stud carousel
Stud tensioning equipment
Multi-lift tool (Westinghouse Patented)
- Increases efficiency of control rod blade
exchange and shuffle
Asset management

Fuel and Fuel Services

Control Rod Blades
- Supply
- Storage optimization (cutting)
- Visual
- Profilometry

Advanced BWR fuel

Fuel receipt and inspection
Reload engineering
Channel inspection
- Bow
- Length
- Oxide
- Coupon samples
ShuffleWorks
Pool-to-Pad and Dry Cask Spent Fuel

Storage Services including spent fuel
canister welding

In-Vessel
Non-destructive Examinations (NDE) to meet
BWR Vessel Internals Program (BWRVIP)
guidelines including reactor vessel and
internal components, such as shroud and
jet pumps

Undervessel
Instrumentation and Control system
maintenance
Control Rod Drive Mechanism (CRDM)
exchange and rebuild
Hydraulic Control Unit (HCU) maintenance

BEFORE

AFTER

BEFORE

Tooling

Chemical Decontamination
and Cleanings
Full System Decontamination (FSD) with fuel
removed or fuel in
Reactor recirculation system decontamination
Reactor water cleanup system
decontamination
Residual heat removal system
decontamination (online or
during outage)
Fuel pool cooling system decontamination
(online or during outage)
In-situ and fixed base capabilities for reactor
coolant pump decontamination
Cleaning of biologically fouled systems
Back-washable filtration

Temporary Fuel Pool Cooling

Systems
Ranging from 5MBTU/hr to 40MBTU/hr

Emergent Issues Response

Operability determination
Loose/lost parts analysis
Emergent reactor internals repair
Reactor pressure vessel nozzle
repair/mitigation

AFTER

Ability to refurbish and test both contaminated

and clean refuel tooling
- Contaminated tooling at Waltz Mill facility
- Clean tooling at Chattanooga facility
Development of tooling to support emergent
outage needs

Rotating Equipment Services

Pump and motor replacement, including

reactor recirculation pumps and motors
Turbine generator inspection and
maintenance services
Contaminated motor refurbishment

Internals Repair
Innovation
Jet Pump RS-1 weld cracking
has occurred at several BWR
nuclear plants in the United
States and Asia. These
instances generally have
been intergranular stress
corrosion cracking related;
Jet Pump RS-1 weld repair
however, the cracking has
been accelerated due to fatigue loading brought
on by vibrations in the jet pump assembly.
Westinghouse recently repaired two (2) RS-1 welds.
The repair design employs slots and pockets that
have been Electrical Discharge Machined (EDM)
into the pipe wall to secure a clamp. The clamp
structurally replaces the functionality of the
RS-1 weld.

inspection
Westinghouse provides a complete line of inspection services utilizing state-of-theart equipment and technologies. Among the more recently launched technologies is
an in-vessel visual inspection (IVVI) device designed to improve the quality of visual
inspections, while providing significant critical path savings during refueling outages.

In-service Inspections

IVVI (in-vessel visual inspection)

Automated reactor pressure vessel inside
diameter (ID)
Manual reactor pressure vessel outside
diameter (OD) shell welds, nozzle to shell
welds, nozzle inner radius area
Automated core shroud Ultrasonic Testing
(UT) examination
Jet pump diffuser/adapter ID UT
Dryer ID/OD visual inspection
Top guide visual inspection
Below core plate inspection
Bottom head drain inspection
Flow-Accelerated Corrosion (FAC) exams
Feedwater nozzle inspections

WISE (Westinghouse Intelligent Streaming

Examination) inspection data internet
platform for streaming of IVVI and other

inspection data to remote locations

Automated and Manual

Balance-of-plant Examinations
Piping
Supports

Inspection Equipment

DUIT Double-up inspection tool for

vessel internals visual inspections in
parallel with fuel movement and reactor
maintenance activities

Ultrasonic Testing display of reactor

pressure vessel component examination

DUIT
The double-up inspection tool (DUIT) is an
in-vessel visual inspection (IVVI) device designed
to improve the quality of visual inspections in
boiling water reactors while providing significant
critical path savings during refueling outages.
The DUIT tool is specifically designed to
perform the visual inspections in parallel with fuel
movement and reactor maintenance activities
without interfering with the other operations that
require the refueling or auxiliary platforms.

Rotating Equipment Services

Westinghouse offers a complete line of

turbine generator specialty inspections,
including rotor bore, retaining ring, phased
array blade attachment, and comprehensive
general turbine generator non-destructive
examination (NDE) inspections

Retaining ring scanner

mitigation
Westinghouse mitigation products provide proactive approaches to preventing
issues and avoiding costly repairs.

Fluid Dynamics-based
Resonance

Underwater Laser Beam

Weld Repair

Westinghouse has the capability to test and

analyze the effect of vortex shedding, which
results in unwanted acoustic resonance.
Mitigation approaches have been developed,
from changing the flow field to addressing the
resonance directly. Installation of an Acoustic
Side Branch (ASB) modifies the resonance that
exists in the standpipes connecting the main
steam lines (MSLs) to the safety relief valves
(SRVs). The addition of the ASB to the standpipe
shifts the resonant frequency of the standpipe,
thereby eliminating the acoustic standing wave
generated by vortex shedding at EPU flow
conditions. This provides a dampening effect
on the acoustic energy input into the system.

Fully automatic viable underwater repair

option

Mitigating effect of ASB on resonance

before and after installation

Underwater Laser Beam

Welding Process
In the past, underwater welding was typically
performed manually or using mechanized
welding equipment and an arc welding
process. Today, the welding and machining
group of Westinghouse has added
laser beam welding to its toolbox as a viable
underwater repair option for use in the
nuclear power industry.

Debris Trap
The Westinghouse BWR Debris Trap prevents
debris from entering the reactor pressure vessel
(RPV) where it may cause fuel failures or control
rod drive (CRD) malfunction. The axial
centrifugal separator isolates and captures
debris, preventing the debris from returning back
into the main liquid flow. The captured debris is
removed via an access connection.
Main features:
High separation performance
No moving parts
Low-flow resistance

In-line installation (inside or outside

containment)
Low maintenance removal of debris from
the debris trap occurs
during routine maintenance outage
Removes debris as opposed to just stopping
it at some point in the system
Can trap smaller size debris than the
fuel filters

Laser Peening

Laser peening process

Laser peening of core shrouds provides a
long-term solution to relieve stresses that
contribute to core shroud cracking.This
mitigation helps to avoid potential shroud
modifications, which add additional hardware
to an already congested annulus. Laser
peening can also be performed on CRD stub
tubes and many other in-vessel welds.

replacement
Westinghouse replacement parts ensure continuous operation. To address
long-term performance and upgrade needs, Westinghouse provides engineering,
procurement and construction/installation services for component replacement
and installation.

REPLACEMENT COMPONENT
SERVICES
Westinghouse supplies qualified replacement
parts and components, including motors,
switchgear, motor control centers, process
control modules, relays and molded case circuit
breakers. Services include:
Class 1E and safety-related parts and
components
Engineering, operational and technical support
Balance-of-plant spares
Replacement breakers for competitor
equipment
Replacement of existing instrumentation and
control (I&C) systems with state-of-the-art-
digital control systems

REACTOR EQUIPMENT
REPLACEMENT AND
INSTALLATION
Component Replacement and
Installation
Design, engineering, fabrication and installation
of major components, including:

Steam dryer
- Proven capabilities and extensive
experience More than 200 years of
operation without failure
- Polygon structural design ensures a
symmetrical loading of the dryer, reducing
steam flow velocities, which minimizes
structural dynamic loads
- Drain channels are integrated into the dryer
framework, eliminating the need for added
drain channels and welds
- Demonstrated performance at Extended
Power Uprate conditions, including superior
moisture carry-over performance
- Acoustic and structural analyses
- Instrumentation and data acquisition
- State-of-the-art proprietary analysis tools
- Electric Power Research Institute (EPRI)
Boiling Water Reactor Vessel Internals
Project (BWRVIP)-endorsed
methodologies
- Repair
- Segmentation of existing dryer
Steam separator
- High performance (low moisture input to
steam dryer)
- Low pressure drop
Reactor internals
Core shroud
Primary system modifications
Control rod blades

Valve refurbishment and replacement

Core spray piping
Jet pump components (beams, inlet mixer)
Shroud head bolt replacement
Feedwater heater
Piping replacement
Moisture separator reheater
Condenser

Engineering, Procurement and

Construction

Project management
Design engineering
Installation/rigging
Cutting and welding

Digital Technologies
Field Programmable Gate Array (FPGA) safety
upgrades
Safety and monitoring system upgrades
Information and control system upgrades
Full-scope I&C solutions for new build
Control Room solutions
Alarm management system solutions
Computerized procedure system solutions
Simulator system and subsystem solutions

Replacement / modifications to electrical,

safety and control systems to support
extended power uprates
Vintage I&C systems support operation

Rotating Equipment Services

In partnership with our majority owner,

Toshiba Corporation, Westinghouse can
provide complete turbine generator component
replacement including HP turbines, LP
turbines and generators.

Hybrid Control Room Upgrades

Instrumentation and Controls System
Replacements

Common platforms based on standard

products from ABB and Emerson are
typically configured in redundant
manners to reduce single points of failure.
These platforms are the basis for our safety
and control system upgrades.

Instrumentation and Control

(I&C) Services
Field services and installations
Asset management and aftermarket support
Equipment qualification and commercial
dedication

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repair

(engineering, analysis, and modifications and repairs)

Westinghouse provides analytical solutions to your engineering challenges in a variety of disciplines
including: flow, vibration, structural, radiological, components, systems, transient, seismic, setpoints and
containment. Innovative repair or modification techniques are employed to address emergent issues and
extend plant life.

Engineering
Plant Modification Engineering
Services
Westinghouse has the global knowledge, reach
and experience to provide total engineering
solutions across the entire nuclear plant, beyond
traditional nuclear steam supply system (NSSS)
services.
Component installation services
Design change packages
Installation engineering
Balance-of-plant system analysis and
optimization
On-site screening and data collection
Interference analysis
Construction management and procurement
support
Scoping/feasibility studies
NSSS specialty and general construction
support
Balance-of-plant construction management

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Power Uprate Support

Steam line/dryer acoustic analysis

Main steam line strain gauge installation
Structural response (load combinations)
Power ascension real-time stress analysis
Mitigation of acoustic resonance
Feasibility studies
Steam dryer acoustic load definition
Systems evaluation and modification
Licensing support
Implementation support
NSSS analysis
Aging management and license renewal

Steam Dryer Acoustic Technology

Westinghouse provides a state-of-the-art
approach to define steam dryer acoustic loads
and evaluate dryer structural integrity. This
approach takes into account conditions at current
licensed thermal power and potential uprated
conditions, as required by regulatory guidelines.
Endorsed by EPRIs BWR Vessel Internals
Project (BWRVIP) and used on recently

approved BWR Extended Power Uprates
(EPUs)
Power ascension (real-time stress analysis)
Mitigation of acoustic resonances
Modification/replacement
Regulatory support
Auxiliary services (strain gauge and
accelerometer installation)

Steam dryer acoustic load definition

testing apparatus

Steam Dryer Technology

and Replacement
The Electric Power Research Institutes
BWR Vessel and Internals Project
(BWRVIP) the industry users group that
focuses on BWR vessel internals has
authored a topical report, BWRVIP-194:
Methodologies for Demonstrating Steam Dryer
Integrity for Power Uprate. The report is based
on Westinghouse technology acquired from
Continuum Dynamics Inc. (CDI).

Steam Dryer Typical Flow Paths

The purpose of BWRVIP-194 is to delineate

the methodology in a single document to allow
generic U.S. Nuclear Regulatory Commission
(NRC) approval. This will permit plants using
the methodology to experience faster
acceptance times for power uprate applications.

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Analysis
LOCA Analysis
LOCA analysis is performed using the

Westinghouse BWR Emergency Core
Cooling System (ECCS) evaluation model.
This model uses the GOBLIN series of
codes and complies with U.S. Nuclear
Regulatory Commission (NRC) 10CFR50,
Appendix K requirements. Westinghouse can
perform analyses and evaluations covering
the following LOCA-related areas:
- Fast and slow transients
- Stability
- Loss-of-coolant accident (LOCA), and
containment analysis

Containment Analysis
Westinghouse has more than 30 years of
experience in performing nuclear plant
containment analyses, has developed and
licensed analysis codes and also
effectively used industry codes, such as
GOTHIC and RELAP, to provide solutions
for a number of issues at nuclear plants.
- Offer improvements in peak temperature
and pressure over traditional methods
- Minimize the need for design changes
- Provide relief in environmental
qualification requirements
- Enable lower pressure for containment
leak testing

Transient Analysis
POLCA-T advanced 3D kinetics transient
code

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Fast and slow transients

Determination of Minimum Critical Power
Ratio (MCPR)
Full 3D core model for more realistic

Anticipated Transient Without Scram (ATWS)
and core stability analyses
Reactivity Insertion Accident (RIA) analyses

Neutron Fluence Analysis

Westinghouse offers NRC-approved Neutron

Fluence Analysis methodology for reactor
pressure vessel and internals. The
methodology has a low uncertainty error
band and requires no bias to be applied to
the calculated results. It has been used in
the United States and Europe.

Plant Performance Improvement

Outage optimization
Feedwater debris trap
Radiological gas management
Emergent engineering issues
Laser peening
Alternate decay heat removal
WESTEMS thermal fatigue management/
monitoring, equipment lifetime monitors
Valve diagnostics/maintenance
Sump strainer products, chemistry analysis of
consumable materials
Fuel storage rack evaluation
Fuel drop analysis
Fuel bundle analysis
Reactor vessel internals stress analysis

Gas Voids Analysis

Westinghouse capabilities covering the entire
range of NRC requirements listed in GL-2008-01
include the following:
Licensing basis
Design basis
Testing
Corrective actions

Risk Applications and Methods

Probabilistic Risk Analysis (PRA) scope and

technical adequacy
PRA regulatory assistance
PRA operational assistance
PRA standards upgrades and peer review

GOTHIC Analysis Capabilities

Many years of thermal-hydraulic transient
analysis experience, coupled with experience in
the development and licensing of applications
involving GOTHIC, have made Westinghouse
uniquely qualified to develop, qualify and license
models to perform analyses for a wide range of
applications.

Westinghouse gas transport test loop

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Modification and Repairs

In-Vessel
Over the past 20 years, Westinghouse has
successfully performed more than 100 repairs
on BWR reactor pressure vessels and internal
components worldwide. Westinghouse has the
capability to perform the following:
Core plate plugs (new or replacement)
Core spray sparger repair
Core spray piping repair
Jet pump sensing line repair
Jet pump riser repair
Jet pump slip joint clamp mitigation
Jet pump swing gate repair
Jet pump main wedge replacement
Jet pump aux (auxilliary) wedge installation
Jet pump RS-1 repair
Laser seal weld repair
Laser clad weld repair
Core shroud tie rod repair
In-core monitor housing repair
CRD (Control Rod Drive) housing/ stub tube
repair or replacement
Shroud repair (other than tie rod)
Reactor vessel drain line repair
Steam dryer repair

Capability for On-site or Off-site

CRD Rebuild

Ability to rebuild CRD assemblies on site or

off site, if desired
Off-site CRD rebuild facility offering receipt,
storage and rebuild capability

Rotating Equipment Services

Safety-related and/or contaminated pump and
motor refurbishment and remanufacture at
Waltz Mill site
Field service and repairs on pumps and

motors
Turbine generator stator and rotor turnkey
rewind services.

Cutting and Welding

15

NSSS Repairs and Modifications

- Torus repair
- Jet pump riser
- Nozzle overlays
- Balance-of-plant repairs and modifications
- Feedwater piping
- Valve refurbishment

Contaminated reactor recirculation

pump motor in the shop for
remanufacture

additional services
Westinghouse offers additional services to meet your specialized needs.

Training Capabilities
Westinghouses U.S. BWR Service Center in
Chattanooga, Tennessee (USA), is used to train
Westinghouse employees, customers and
industry representatives on the safe maintenance
and refueling of boiling water reactors in U.S.,
and some European, nuclear power plants. The
facility features a full-scale BWR cavity with
vessel, internals, spent fuel pool and refueling
bridge, two 33-ton cranes and an undervessel
mock-up.

From its Waltz Mill Site in Madison, Pennsylvania

(USA), Westinghouse provides BWR Nuclear
Instrumentation System (NIS) and Traversing
In-core Probe System (TIPS) training that can
be held at the customer location. Westinghouse
is currently planning to add integrated plant
operations training to its BWR portfolio, ranging
from an introduction to BWR to Senior Reactor
Operator (SRO) certification equivalency.

Plant Decommissioning and

Dismantling (D&D) and Waste
Management
Full engineering, licensing and work
supervision
Decommissioning study
Nuclear facility decommissioning plans
Reactor vessel and internals segmentation
and packaging
Reactor vessel internals removal
Main component dismantling
Primary and balance-of-plant decontamination
Waste treatment and conditioning: equipment
design and manufacturing
Control rod blade segmentation

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New Advanced Boiling Water

Reactor (ABWR) Plant Design
Engineering

Design certification
Safety analysis
Licensing
Structural analysis
Airplane impact analysis

Probabilistic risk assessment

Systems analysis
Seismic analysis
Plant equipment and procedures
Pre-service Inspection/In-service Inspection
(PSI/ISI) program
Reactor pressure vessel loading
Instrumentation and control systems

U.S. BWR Service Center in Chattanooga, Tennessee (USA)

Westinghouse ... meeting your BWR nuclear plant needs.

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CONTACT INFORMATION
For more information about Westinghouses BWR services, please visit our web site at:
www.westinghousenuclear.com/bwr
88969A_August 2011