In 2017, a decision was made to permanently shut down Kori Unit 1, and preparations began to be made for its decontamination and decommissioning. The dismantling of the biological shields concrete, reactor vessel (RV), and reactor vessel internals (RVI) is crucial to the nuclear decommissioning process. These components were radiologically activated by the neutron activation reaction occurring in the reactor during its operational period. Because of the radioactivity of the RV and RVI of Kori Unit 1, remotely controlled systems were developed for cutting within the cavity to reduce radiation exposure. Specialized equipment was developed for underwater cutting operations. This paper focuses on modeling related to RVI operations using the MAVRIC code and the dose calculation for a diver entering the cavity. The upper and lower parts of the RVI are classified as low-level radioactive waste, while the sides that came into contact with the fuel are classified as intermediate-level radioactive waste. Therefore, the modeling presented in this paper only considers the RVI sides because the upper and lower parts have a minimal impact on the radiation exposure. These research findings are anticipated to contribute to enhancing the efficiency and safety of nuclear reactor decommissioning operations.

In South Korea, the replacement of steam generators began with Kori Unit 1 in 1995, and to date, 20 steam generators have been replaced and are currently stored in intermediate storage facilities. In the future, additional decommissioned steam generators may arise due to measures like the extension of the lifespan of nuclear power plants. In Korea, technological development for dismantling steam generators is underway, and there is no track record of actual dismantling. Although the replaced decommissioned steam generators are stored in intermediate facilities, for site recycling purposes, steam generators, which have relatively lower radiation doses compared to reactor heads and other primary equipment, should be prioritized for dismantling. While there are various specifications for steam generators, those dismantled and stored domestically are of the Recirculation Type. They can be classified into three types: the Westinghouse type WH-51 used in Kori Unit 1, the Fra-51B used in Han-ul Units 1 and 2, and the OPR-1000 used in Han-ul Units 3 and 4. The quantity of U-Tubes varies depending on the specification, but the radiation is concentrated in the primary side components, the U-Tube and Chamber. Since the parts related to the secondary side are not contaminated, they can be disposed of independently after classification. To dismantle a steam generator, it is of utmost importance to first create a scenario regarding where and how the dismantling will take place. Through the analysis of the advantages and disadvantages of each scenario, the optimal timing, location, and cutting method for dismantling should be researched. Furthermore, based on those findings, the best scenario should be derived through an analysis of worker radiation exposure and dismantling costs. To achieve this, a 3D simulation software developed by Cyclelife Digital Solutions under the French EDF was utilized to conduct simulations based on different dismantling schedules and methods. As a result, the optimal scenario for dismantling the steam generator was derived.

Thermal cutting processes that can be applied to dismantling nuclear power plants include oxygen cutting, plasma cutting, and laser cutting. According to the global trend, research projects are being carried out in various countries to upgrade laser cutting, and many studies are also being conducted in Korea with plans to apply laser cutting processes when dismantling nuclear power plants. However, with the current technology level of the laser cutting process, the maximum thickness that can be cut is limited to 250 mm. Therefore, in this study, a laser-oxygen hybrid cutting process was implemented by adding a laser heat source to the oxygen cutting process that can cut carbon steel with a thickness of 250 mm or more (RV, beam, column, beam, etc.) when dismantling the nuclear power plant. This has the advantage of improving the cutting speed and reducing the cutting width Kerf compared to conventional oxygen cutting. In this research, the laser-oxygen hybrid cutting process consisted of laser cutting to which Raycus’ 8 kW Fiber Laser power source was applied and oxygen cutting to which hydrogen was applied with Fuel Gas. The oxygen torch was placed perpendicular to the test piece, and the laser head was irradiated by tilting 35° to 70°. The effects of cutting directions on quality and performance were studied, and cutting paths were selected by comparing cutting results. Thereafter, it was confirmed that there is an optimal laser output power according to the cutting thickness by studying the effect on the cutting surface quality by changing only the laser output power under the same cutting conditions. The results of this study are expected to be helpful in the remote cutting process using laser-oxygen hybrid cutting when dismantling domestic nuclear power plants in the future.

Wolsong Unit 1 nuclear power plant, which was permanently shut down in 2019, has a 678 MWe calandria vessel of the CANDU-6 type pressurized heavy-water reactor model. The calandria inside the vault is a horizontal cylindrical vessel made of stainless steel with a length of 7.8 m and a thickness of 28.6 mm. For the entire dismantling processes of a nuclear power plant, dismantling works cannot be performed using only one cutting technology and method, and when performing dismantling of a calandria vessel, various systems and components can be used for cutting and dismantling. The calandria vessel is located in a concrete compartment called a vault, and in order to safely dismantle the calandria vessel, the spread of radioactive contaminants from inside of the vault to the outside must be prevented. We designed dismantling processes using the laser cutting method to dismantle the calandria vessel and end shields. We must minimize the risk of internal radiation exposure to workers from aerosols derived from the thermal cutting processes. Therefore, we need a way to prevent secondary contamination from spreading outside the vault and within the reactor building. The path through which radioactive contaminants move is that the flying airborne products generated during the cutting process inside the vault where the calandria is located do not stay in place but spread outward through the opening of the RM-Deck structure at the top. Therefore, facilities or devices are needed to effectively prevent the spread of radioactive contaminants by blocking the expected movement path. By using these facilities or devices, it is possible to prevent the movement of radioactive aerosol particles between the location of the worker and the location of the cutting area where the calandria is located, thereby preventing internal exposure through the worker’s breathing. In addition, by using these, the cutting area where airborne pollutants are generated can be designed as an isolated work space to prevent the spread of radioactive contaminants. In this study, we propose a method of facilities for confining radioactive aerosol particles and preventing the spread of contamination when thermal cutting of the calandria vessel within the vault.

The potential impact of hypothetical accidents that occur during the immediate and deferred dismantling of the Kori Unit 1 steam generator has been comprehensively evaluated. The evaluation includes determining the inventory of radionuclides in the Steam Generator based on surface contamination measurements, assuming a rate of release for each accident scenario, and applying external and internal exposure dose coefficients to assess the effects of radionuclides on human health. The evaluation also includes calculating the atmospheric dispersion factor using the PAVAN code and analyzing three years of meteorological data from Kori NPP to determine the degree of diffusion of radionuclides in the atmosphere. Overall, the effective dose for residents living in the Exclusion Area Boundary (EAB) of Kori NPP is predicted, an it is found that the maximum level of the dose is 0.034% compared to the annual dose limit of 1 mSv for the general public. This implies that the potential impact of hypothetical accidents on human health discussed above is within acceptable limits.

For licensees who face the decommissioning project for the first time, even if they can utilize their experience in operation, they should be well prepared and assessed for the risks of dismantling activities reflecting the characteristics of decommissioning. This can be included in the risk management of the decommissioning project, but what we want to discuss in this study is the evaluation of the industrial risk of the actual work before the dismantling work is carried out. We would like to focus more on the review of dismantling activities subject to industrial risk assessment and a series of processes for risk assessment. The dismantling work plan will need to obtain approval from the supervisory department before work on the Systems, Structures, and Components (SSCs) can be carried out. At this time, risk assessment may be included among many safety-related required documents, which are divided into radiological and non-radiological risks. The target activities at Level 1 level can include preparation for dismantling and maintenance of facilities, dismantling big components, removing the contamination of concrete structures, managing radioactive waste, etc. In addition, it can be composed of preparation work, removal of connections, lifting/installation, cutting, radiation/radioactivity measurement, and withdrawal as detailed work stages of each item’s activities. For domestic nuclear decommissioning projects, two major performance organizations, licensees and contractors, must be considered. Regarding risk assessment, the licensee will have a supervisory department controlling decommissioning activities and an HSE department at the site, and a process will need to be established in consideration of the contractor’s work organization. Therefore, activities in the risk assessment process may be established. In this study, risk assessment was reviewed as safety-related matters to be considered when carrying out the dismantling work. Safety-related risk assessment is a necessary procedure for performing practical dismantling activities, and this should be considered well in advance. Therefore, work activities and criteria were established for risk assessment, and the performance process was assumed to apply them. In terms of the performance organization and the responsibilities and roles of the processes to be performed by each organization were constructed, and this can be referred to in the process of preparing for the decommissioning project.

Laser cutting has been recognized as one of key techniques in dismantling nuclear power plants as it has several advantages such as a remote operation and a reduced secondary waste. However, it generates a significant amount of aerosols that can pose a health risk to workers and further induce environmental pollution during the cutting operation. Thus, understanding the aerosol characteristics generated by the laser cutting is crucial for implementing an effective cutting operation and reducing the exposure to these hazardous particles. In this work, we established a methodology to collect the aerosols and investigate their properties in the laser cutting operation. We built an integrated laser cutting system for aerosol analyses, consisting of a high-power laser cutting module, a metal sample holder, an aerosol collector, and a closed chamber. We expect that this system will offer an opportunity for in-depth understanding of the aerosol properties, by connecting it with desired type of aerosol analysis platforms, and further safe dismantling operation of the nuclear power plants.

An important goal of dismantling process is the disassembling of a spent nuclear fuel assembly for the subsequent extraction process. In order to design the rod extractor and cutter, the major requirements were considered, and the modularization design was carried out considering remote operation and maintenance. In order to design the rod extractor and cutter, these systems were analyzed and designed, also the concept on the rod extraction and cutting were considered by using the solid works tool. The main module consists of five sub-modules, and the function of each is as follows. The clamping module is an assembly fixing module using a cylinder so that the nuclear fuel assembly can be fixed after being placed. The Pusher module pushes the fuel rods by 2 inches out of the assembly to grip the fuel rods. The extraction module extracts the fuel rods of the nuclear fuel assembly and moves them to the consolidation module. The consolidation module collects and consolidates the extracted fuel rods before moving them to the cutting device. And the support module is a base platform on which the modules of the main device can be placed. The modules of level 2 can be disassembled or assembled freely without mutual interference. For the design of fuel rods cutter, the following main requirements were considered. The fuel rod cut section should not be deformed for subsequent processing, and the horizontally mounted fuel rods must be cut at regular intervals. The cutter should have the provision for aligning with the fuel rod, and the feeder and transport clamp should be designed to transfer the fuel rods to the cutting area. The main module consists of 6 sub-modules, and function of each is as follows. The cutting module is a device that cuts the fuel rods to the appropriate depth for notching. The impacting module is a device that impacts the fuel rods and moves them to the collection module. The transfer module is a device that moves the fuel rods to the cutting module when the aligned fuel rods enter the clamp module. The clamping module is a device to clamp the fuel rods before moving them to the cutting module. The collection module is a container where the rod-cuts are collected, and the support module is a base platform on which the modules of the main device can be placed. The module of level 3 can be disassembled or assembled after the cutting module of level 2 is installed, and the modules of level 2 can be disassembled or assembled freely without mutual interference.

When decommissioning a nuclear power plant, a large amount of radioactive waste is generated simultaneously. Therefore, efficient treatment of radioactive waste is crucial to the success of the decommissioning process. An utility or decommissioning contractor of NPP often build separate radioactive waste treatment facilities (RWTF) to handle this waste. In Korea, RWTFs are planned to be built for the decommissioning of the Kori Unit 1 and Wolsong Unit 1. In this study, we introduce an application case of using process simulation to derive the optimal layout design and investment plan for a radioactive waste treatment facility. In particular, the steam generator is the largest and most complex device processed in RWTF. Therefore, it is necessary to reflect the large equipment processing area that can treat steam generators in the design of RWTF. In this study, Siemens’ Plant Simulation® was used to derive an optimization plan for the dismantling area of large equipment in RWTF. First, a virtual facility was built by modeling based on the steam generator dismantling process and facilities developed by Doosan Enerbility. This was used to pre-validate the facility investment plan, discover wasteful factors in the logistics waste streams, and evaluate alternatives to derive, validate, and apply appropriate improvement alternatives. Through this, we designed a layout based on the optimal logistics waste streams, appropriate workstations, and the number of buffer places. In addition, we propose various optimization measures such as investment optimization based on optimal operation of facility resources such as facilities and manpower, and establishment of work standards.

Reactor pressure vessels and steam generators generated in the process of dismantling nuclear power plants or replaced steam have various shape and occupy a considerable amount of the disposal site when disposed of in original shape. For the development of domestic technologies related to the disposal of large wastes, it is necessary to secure technologies for reducing large radioactive metal wastes, including technologies such as decontamination, cutting, melting, and residual radioactivity evaluation. Cases of disposal of steam generators in Europe and the United States were investigated. Except for u-tubes, steam generators are less contaminated or easily decontaminated, so it is possible to reduce the volume of waste subject to final disposal by exempting a significant amount through appropriate treatment. Korea Hydro & Nuclear Power Co. is currently temporarily storing 24 steam generators at 41.6 billion won. This paper presents a method to exempt more parts of the steam generator and reduce the volume of waste by properly combining mechanical cutting thermal cutting and melting to dispose of the steam generator. Currently the decontamination and dismantling industries of nuclear facilities are gradually expanding around the world. Therefore, it is necessary to localize the treatment technology for metal waste generated during maintenance and dismantling. The result of this study can be used to establish waste reduction and disposal method for dismantling steam generators.

Kori Unit 1, Korea’s first commercial nuclear power plant is preparing to dismantle after 40 years of power supply. However, unlike the public dose assessment for nuclear power plants in operation, the dose assessment for the public due to abnormal events during the decommissioning of nuclear power plants is insufficient. Therefore, in this study, the steam generator chamber is selected as hypothetical events target among metal waste, which is a major radioactive material generated during the decommissioning of nuclear power plant. In addition, the possible abnormal event scenarios and effective does to public in the Exclusion Area Boundary due to the released radioactive materials are predicted during the disassembly and transportation of the steam generator. For the source term that can be released during the dismantling of the steam generator, the inventory of each radionuclide is evaluated based on the smear test results of the steam generator replaced in Kori Unit 1 in 1998. To evaluate the diffusion of radioactive material, the atmospheric dispersion factor (χ/Q, sec/m3) is calculated through the PAVAN code of the US NRC using the meteorological data of the Kori nuclear power plant for 3 years from 2019 to 2021 according to IAEA recommendations. For the assessment of the public dose, the external dose coefficient and inhalation coefficient of the ICRP and the inhalation rate of the NRC Regulatory Guide 1.3 are referred. It is confirmed that the effective dose to the public in the Exclusion Area Boundary due to the abnormal event during the dismantling of the steam generator is much lower than the effective dose standard value of 250 mSv for 2 hours after the event in the Exclusion Area Boundary.

Dry head end process is developing for pyro-processing at KAERI (Korea Atomic Energy Research Institute). Dry processes, which include disassembling, mechanical decladding, vol-oxidation, blending, compaction, and sintering shall be performed in advance as the head-end process of pyro-processing. Also, for the operation of the head-end process, the design of the connecting systems between the down ender and the dismantling process is required. The disassembling process includes apparatus for down ender, dismantling of the SF (Spent Fuel) assembly (16×16 PWR), rod extraction, and cutting of extracted spent fuel rods. The disassembling process has four-unit apparatus, which comprises of a down ender that brings the assembly from a vertical position to a horizontal position, a dismantler to remove the upper and bottom nozzles of the spent fuel assembly, an extractor to extract the spent fuel rods from the assembly, and a cutter to cut the extracted spent fuel rods as a final step to transfer the rod-cuts to the mechanical decladding process. An important goal of dismantling process is the disassembling of a spent nuclear fuel assembly for the subsequent extraction process. In order to design the down ender and dismantler, these systems were analyzed and designed, also concept on the interference tools between down ender and dismantler were considered by using the solid works tool.

Since nuclear power plant (NPP) dismantling carries the possibility of radiation exposure from a hazardous environment, it’s important to minimize that by using a remote manipulator et al. However, due to complexity of nuclear facilities, it’s necessary for operators to increase their proficiency by operating in advance in a virtual environment. In this research, we propose a virtual manipulator system using a haptic device for NPP’s reactor vessel internals (RVI) dismantling which can realistically manipulate.

Currently, dismantling technology for decommissioning nuclear power plants is being developed around the world. This study describes the cutting technology and one of the technologies being considered for the RV/RVI cutting of Kori Unit 1. The dismantling technology for nuclear power plants include mechanical and thermal methods. Mechanical cutting methods include milling, drill saw, and wire cutting. The advantages of the mechanical method are less generating aerosol and less performance degradation in water. However, the cutting speed is slow and the reaction force is large. Thermal cutting methods use heat sources such as plasma arcs, oxygen, and lasers. The advantages of thermal method are fast cutting speed, low reaction force and thick material cutting. On the other hand, they have problems with fume and melt. Among them, the cutability of the oxygen cutting method is better in carbon steel than in stainless steel. In order to cut the RV/RVI of the Kori Unit 1, the applicability of fine plasma, arc saw, and band/ wheel saw is being reviewed. For RV cutting, the applicability of arc saw and oxy-propane is being considered Because RV is mostly made of carbon steel. However, since the flange is cladded with stainless steel, the use of mechanical methods such as wire saws should be considered. In the case of RVI, since it has a complicated shape and is made of stainless steel, it seems necessary to review various cutting methods. In addition, it will be necessary to minimize radiation exposure of workers by cutting underwater cutting.

This study is for evaluation and optimization of workers’ radiation exposure for dismantling Reactor Vessel (RV) at Kori unit 1 in connection with its decommissioning process for the purpose of establishing Radiation Safety Management Plan. This is because the safety of workers in a radiation environment is an important issue. The basis of radiological conditions of this evaluation is supposed to be those of 10 years after the permanent shutdown of Kori unit 1 when dismantling work of Reactor Vessel would suppose to be started. Dose rates of work areas were evaluated on the basis of spatial dose rate derived from activation level calculated by MCNP (Monte Carlo N-Particle Transport) and ORIGEN-S code. RV are radiated by neutrons during operation, creating an environment in which it is difficult for operators to access and work. Therefore, the RV must be dismantled remotely. However, due to work such as installing devices or dismantling surrounding structures, it is not possible to completely block the access of workers. Accordingly, the exposure of workers to the RV dismantling process should be assessed and safety management carried out. The dismantling process of Kori unit 1 RV was developed based on in-situ execution in atmospheric environment using the oxigen-propane cutting technology as the following steps of Preparation, Dismantling of Peripheral Structures, Dismantling of RV and Finishing Work. For evaluation of exposure of RV dismantling work, those processes of each steps are correlated with spatial dose rates of each work areas where the jobs being done. Results of the evaluation show that workers’ collective dose for RV dismantling work would be in the range of 536–778 man- mSv. The most critical process would be dismantling of upper connecting parts of RV with 170–256 manmSv while among the working groups, the expert group performing dismantling of ICI (In-core instrumentation) nozzles and handling & packaging of cut-off pieces is evaluated as the most significantly affected group with 37.5–39.4 man- mSv. Based on the evaluation, improvement plan for better working conditions of the most critical process and the most affected workers in terms of radiation safety were suggested.

Prior to dismantling a nuclear facility, full site characterization should be carried out to identify basic data for various stages of decommissioning, such as deregulation of sites and structures, selection of decontamination technology, decommissioning methods, and waste management and disposal. Radiological characterization is implemented through information collection, on-site measurement, sampling and analysis, and theoretical calculations and proven codes for radioactive material at the time of decommissioning of the nuclear facility. There are issues in that it takes a lot of time and money to collect and analyze samples for characterization of contaminated sites and radioactive structures. Therefore, in the entire process of decommissioning a nuclear facility, a technology that can quickly measure the radiological characteristics of various decommissioning objects and wastes on site is required. In this project, the utilization of gamma cameras that can be analyzed in the field for quick and accurate characteristic evaluation at the dismantling site was studied. A gamma camera, iPIX from Canberra (Now it became Mirion Technology), was tested in this study. It is a unique gamma imager, which have a CdTe sensor with TIMEPIX chip and a coded aperture collimator, quickly locates and identifies low to high level radioactive sources from a distance while estimating the dose rate at the measurement point in real time. It also can be combined with CZT sensor which called iPIX-NID (nuclide Identification) provides users with clear understanding of radionuclides presence with no need of any spectroscopic knowledge. iPIX with iPIX-NID convert the gamma camera into a hot-spot detector with radionuclide information. To verify the applicability of a gamma camera in Nuclear power plant, it was implemented to Kori unit-1 which was permanently shut down from 2017. Various Systems were observed at restricted area including reactor cooling system, boron recovery system, residual heat removal system, containment spray system, and etc. The locations of hot spots were clearly revealed by iPIX and these results can be used for selecting the locations of destructive samples and help to decide the conservative decision making. Condensate water systems in turbine building were also observed by a gamma camera and showed no nuclide. Based on this preliminary gamma camera applications, further investigation and tests will be carried out to Kori Unit-1.

The dismantling of the reactor pressure vessel has been carried out at a number of commercial nuclear power plants, including the Zion nuclear power plant in the United States and the Stade nuclear power plant in Germany. The dismantling method for the reactor pressure vessel is either in the air or in the water, depending on the utility. In general, a mechanical cutting method is used when dismantling the reactor pressure vessel in the water. And when dismantling a nuclear reactor pressure vessel in the air, the thermal cutting method is applied. However, there is no case of dismantling commercial nuclear reactor pressure vessel by applying a mechanical method in the air. In this study, when a nuclear reactor pressure vessel is dismantled by applying a mechanical method in the air, the applicability was evaluated by testing it using a demonstration mockup of Kori Unit 1. For the evaluation, the mockup was made in the actual size of Kori Unit 1. Mechanical cutting devices used the band saw and the circular saw. In the test, the cutting of the reactor pressure vessel was performed remotely by reflecting the working conditions of the decommissioning site. The band saw cutting method was applied to vertical cutting, and the circular saw cutting method was applied to horizontal cutting. In order to dismantle one cut-off piece, mockup test was performed according to a series of dismantling processes, it consists of preparatory work, vertical cutting process, horizontal cutting process, packaging process and finishing work. The cutting speed of the band saw is 3–10 mm·min−1, and the cutting speed of the circular saw is 2–4 mm·min−1. As a result of the test, when the mechanical cutting method was applied, as is known, the kerf width was smaller than when the thermal cutting method was applied. The cut surface showed a clean state without drag lines generated during thermal cutting. However, the working time was much slower than when the thermal cutting method was applied.

The remote dismantling system proposed in this paper is a system that performs the actual dismantling process using the process and program predefined in the digital manufacturing system. The key to the successful applying this remote dismantling system is how to overcome the problem of the difference between the digital mockup and the actual dismantling site. In the case of nuclear facility decommissioning, compensation between the virtual world and the real world is difficult due to harsh environments such as unsophisticated dismantling sites, radiation, and underwater, while offline programming can be proposed as a solution for other industries due to its sophisticated and controllable environment. In this paper, the problem caused by the difference in the digital mockup is overcome through three steps of acquisition of 3D point cloud in radiation and underwater environment, refraction correction, and 3D registration. The 3D point cloud is acquired with a 3D scanner originally developed in our laboratory to achieve 1 kGy of radiation resistance and water resistance. Refraction correction processes the 3D point cloud acquired underwater so that the processed 3D point cloud represents the actual position of the scanned object. 3D registration creates a transformation matrix that can transform a digital mockup of the virtual world into the actual location of a scanned object at the dismantling site. The proposed remote dismantling system is verified through various cutting experiments. In the experiments, the cutting test object has a shape similar to the reactor upper internals and is made of the same material as the reactor upper internals. The 105 successful experiments demonstrate that the proposed remote dismantling system successfully solved the key problem presented in this paper.