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Hot Tapping
Pipeline Pigging
PSI - Offshore |
US Toll Free
1-888-839-6766
International
1-918-447-5100
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Your Source for Piping Solutions.
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By Les Pierce
TDW Senior Application Specialist
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Nuclear power plants, unlike any other industrial facilities in the United States, come under the direct jurisdiction of the Federal Government's Nuclear Regulatory Commission. The intrinsic nature of their technology and function requires that the highest quality products and field services be provided for inclusion in any part of a reactor's energy generation process. Nuclear power plants refuel their reactors on a regular schedule. During refueling, the reactor itself is shut down; however, the remaining cooling system in the plant must maintain service during the process.
If you think shutting down and then re-starting a nuclear reactor to repair a problem is a complex and involved process, you would be correct. If you think that taking a power generation reactor off line for any period of time would be an expensive proposition, you would be correct again.
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Recently, a long time TDW customer knew a full year in advance that a
36" butterfly valve had to be replaced. The problem they faced was that the valve in question was an inter-connect between two operating reactors. Unit 1 was scheduled to be shut down for refueling, but unit 2 had to stay on stream. The defective valve prevented shutdown of unit 1 without also having to shut down unit 2. The potential cost of taking unit 2 offline for several days to switch out valves would amount to $1 million dollars per day in lost power generation revenue.
Nuclear power plant
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A TDW field applications representative was contacted early in the planning process. After several site meetings and a detailed job walk-through it was determined by both TDW and nuclear plant personnel that valve replacement could be performed without taking unit 2 down. The solution presented by TDW was the utilization of a 36" by 24" TDW folding-head STOPPLE®. The folding STOPPLE plug process permits the introduction of a temporary isolation tool into the "LIVE" pipe system. Once in place, the STOPPLE Plug facilitates a temporary blockage "down steam" of the desired work area and permits the "up steam" portion of the system to remain in service.
The 36" STOPPLE plug would have to be performed on one of the levels below ground. Due to available space and the height of the pipe, the process required hand rigging of all TDW equipment from ceiling supports and attachment to the line at an angle of 15 degrees below horizontal. The planning process included detailed drawings of the TDW fitting to be used along with support engineering data that applied to B31.1 power plant code. A complete set of detailed written specifications and site-specific procedures was developed by the local TDW service center. Included were individual drawings for each piece of TDW equipment going into the plant along with dimensions and weights.
Installed STOPPLE® plug at Nuclear power plant.
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Several follow up meetings were conducted to establish an hour-by-hour work schedule along with the manpower loadings and support services required for TDW to accomplish its work. The job required two field technicians, each working a 12-hour shift.
TDW equipment was delivered to the nuclear plant on a Friday and by Monday morning the equipment was moved inside to lower levels and positioned for utilization at the work site. A TDW SANDWICH® valve was rigged into position. Nearly an entire 12-hour shift was required to elevate the valve onto a TDW cam flange fitting. The next shift mounted a TDW model 1200 Hot Tapping Machine. A hot tap was successfully completed, the SANDWICH valve closed, and the model 1200 dismounted. Hot tapping in nuclear facilities often requires the flushing of hot tap "chips" through the tapping machine. The flushing process at this particular location was accomplished by utilizing an existing 4" valve connection between the TDW tapping assembly and the defective 36" valve.
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The following shift installed the 36" x 24" folding STOPPLE plugging machine onto the SANDWICH valve. The STOPPLE plug was firmly set during the next shift according to prescribed scheduling. The 36" line was successfully isolated .
A new valve was placed in position and the customer was able to change out the defective 36" valve during a single shift. TDW then re-pressurized the pipe system and removed the STOPPLE plug from the 36" pipe. A TDW completion plug was set and the SANDWICH valve removed. A blind flange was installed to complete the operation.
The customer was pleased with TDW's performance. They plan to continue using TDW as their preferred vendor based, not only upon the success of a hot tapping and plugging process that literally saved the plant millions of dollars in reactor down time, but also because of over 100 similarly successful nuclear plant applications TDW has performed within the previous 10 years.
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Visit us at www.tdwilliamson.com or call 918-447-5500 or 800-695-0535.
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Introducing the addition of Mechanics Training class for 2006. This class covers preventive maintenance, routine inspection and repairs for TDW Hot Tapping and Plugging (HT&P) equipment. The first 2.5 days cover tapping machines. The second 2.5 days cover plugging. Customers with tapping machines only may leave after completion of the tapping portion. Classes run from 8 a.m. until 5 p.m. each day. The fee is $475 for each portion.
T.D. Williamson, Inc. continues to provide the most comprehensive hot tapping, plugging and pigging instruction available in compliance with Department of Transportation covered tasks, standards and requirements. Rigorous hands-on training and operator qualification LineMaster™ programs are TDW's commitment
to the industry.
LineMaster Training assists you with ensuring that your technicians are trained at
the highest level available. In our state-of-the-art facilities and with our pressurized simulated pipeline, TDW's LineMaster Training program is an in-depth series of classes designed to fulfill DOT Pipeline Safety Operator Qualification rules. To meet DOT requirements, training programs must include classroom time, written exams and hands-on simulated conditions. TDW's LineMaster Training meets these requirements.
TDW LineMaster Training is the best in the business. The company you've trusted with your piping maintenance needs for more than 80 years has the experience to train your technicians and operators effectively and efficiently.
| 2006 LineMaster Training |
March
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Locations
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| Mechanics Training - New |
6 - 10 |
Tulsa, OK - USA |
| Job Planning / FTG Design |
15 - 16 |
Tulsa, OK - USA |
| Transmission |
27 - 30 |
Tulsa, OK - USA |
New European Program call:
32-67-28-36-44 |
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Nivelles, Belgium |
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April
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Locations
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| Gas Distribution Class |
3-6 |
Tulsa, OK - USA |
| Transmission |
17-20 |
Tulsa, OK - USA |
| Gas Distribution Class |
24-27 |
Tulsa, OK - USA |
New European Program call:
32-67-28-36-44 |
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Nivelles, Belgium |
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Class Information and Registration Form
For more information, contact TDW at 918-447-5100 or toll-free at 888-839-6766.
Or call your local TDW representative.
New European LineMaster Training Program in Nivelles, Belgium contact Anne.Roberfroid@TDW.be or Call 32-67-28-36-44
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Don't forget to visit TDW's booth at upcoming trade shows. We are attending several in the next few months, including:
Please check the entire 2006 show listing on the website.
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