Industrial Projects
Nuclear Facilites
Taiwan Power Lungmen Nuclear Plant
Vogtile Nuclear Plant Prudence Audit
Construction Remediation for Midland Nuclear Station
ComEd Byron Station Cooling Tower
ComEd Glass Fiber/Concrete Wall Investigation
ComEd Quad Cities Service Building
ComEd Zion Service Building
ComEd Quad Cities Laundry, Tool, and Dry Waste Storage Building
ComEd Morrison, Zion, and Mazon Emergency Operations Facilities
ComEd Zion Training Facility
ComEd Standardized Training Facility
Nuclear Research
ComEd Emergency Preparedness Support
ComEd Nuclear Plant Life Extension
Argonne National Lab - CRADA
Argonne Vitrification of Low-Level Waste
Bibliography on Radwaste Solidification
Non-CFC Decontamination Systems Report
Radioactive Waste Oil Recycling Report
Recycling of Ion-Exchange Resins Using Off-Site Regeneration Draft Report
Robotics Engineering Support
CRDM Robot
HACES Robot
Decommissioning of Yankee Rowe Nuclear Plant
ComEd Control Board Photo Drafting for Dresden and Quad Cities
Miscellaneous Industrial Projects
ComEd Chicago South Hydome Maintenance Facility
ComEd Dresden Corporate Chemistry Building
ComEd Quad Cities Chemistry Lab
ComEd La Salle Chemical Feed System
Industrial Excess Landfill
Rocky Flats Liquid Nitrogen Tank
Chicago Incinerator Laboratory Expansion
The following are brief descriptions of relevant industrial design, including nuclear facilities and chemical facilities:
Nuclear Facilities
Taiwan Power Lungmen Nuclear Plant
TECHKNOW assisted Adtechs Corp. in preparing the preliminary design and construction cost estimates for the Radioactive Waste Processing System and Building for the proposed two unit Lungmen plant. Our radwaste engineers prepared system descriptions, selected equipment and obtained pricing for the equipment. We prepared quantity estimates for civil, structural, architectural and electrical materials so that a lump sum price could be bid to the owner.
Nuclear Prudence Audit
TECHKNOW served as a primary consultant to Georgia Power Company during a management prudence audit of the Vogtle Nuclear Power Plant. Strategies for the defense of past management decisions, project control systems and project cost and schedule performance were prepared by TECHKNOW. The firm's consultants assisted in management of the defense effort throughout the preparation and hearing stages of the audit. This support included identifying the consequences of Nuclear Regulatory Commission regulatory changes on the construction, licensing and startup of Plant Vogtle. Arguments and evidence, showing a substantial regulatory impact on the engineering and documentation effort, labor and material costs, and startup testing schedule for the plant, were prepared by senior TECHKNOW consultants.
Construction Remediation for Midland Nuclear Station
TECHKNOW was responsible for the technical management of the $250 million soils remediation project at Midland Nuclear Project for Consumer Power Company. Most of the project involved underpinning two large buildings which included the construction of tunnels, freeze wall and underpinning constructed to very close tolerance.
ComEd Byron Station Cooling Tower
TECHKNOW was retained by Commonwealth Edison Co. to conduct an investigation of a louver failure in Byron Nuclear Station's cooling tower. The continued performance of the natural draft cooling tower is critical to station performance, as it is the main component of the station's cooling system. TECHKNOW applied expertise in cooling towers, as well as root cause analysis, to investigate the failure and develop recommendations to prevent future failures. Recommendations were provided to revise winter operating procedures and institute practices to minimize ice buildup in the winter season.
ComEd Glass Fiber/Concrete Wall Investigation
Commonwealth Edison Co. retained TECHKNOW to provide structural material recommendations for buildings at several nuclear power stations. For ease and speed of construction, TECHKNOW proposed use of a new prefabricated glass fiber concrete wall. TECHKNOW also conducted an investigation, including analysis and testing of thermal behavior and performance under weather variations, of this innovative material. A quality assurance review of vendor testing and calculations was also performed by TECHKNOW. The panels were installed and are performing well.
ComEd Quad Cities Service Building
Techknow designed the $10 million service building addition and renovation at ComEd's Quad Cities Nuclear Power Station as part of a design build team. Techknow prepared all architectural, structural, HVAC, plumbing, fire protection, and electrical and communication designs for the project. Included in the project are new HVAC systems, additional electrical power systems, including four 1600 amp switchboards, communication system and remodeling of locker rooms, shop area and office space. The new addition is a four story structural steel building connected to the exiting service building.
ComEd Zion Service Building
Techknow designed the $4 million service building renovation at ComEd’s Zion Nuclear Power Station as part of a design build team. Techknow prepared all architectural, structural, HVAC, plumbing, fire protection, and electrical designs for the project. Included in the project are new HVAC systems, a weld shop ventilation system, additional electrical power systems, communication system and remodeling of locker rooms, shop area and office space.
ComEd Quad Cities Laundry, Tool, and Dry Waste Storage Building
The Laundry, Tool and Dry Waste Storage Building is a two story building located west of the Unit 1 Turbine Building at the Quad Cities Station. The project is being constructed under a design/build contract. The building contains 21,730 square feet of sorting and storage space. Including in the building are a hot machine shop, decontamination facility, respirator facility, dry active waste storage, compactor/sorting area and clean and dirty storage. Provisions for handling and storage of radioactive waste containers include bridge and monorail cranes for handling the containers, HEPA filter in the ventilation system, connection to the gaseous monitoring system, floor drain system connection to radwaste treatment and special epoxy coatings on walls and floors. TECHKNOW is performing all structural, HVAC, civil and electrical engineering and architecture design for the project.
ComEd Morrison, Zion, and Mazon Emergency Operations Facilities
TECHKNOW performed architectural interior design and provided construction details to remodel the Emergency Operations Facilities (EOF) in Morrison, Zion, and Mazon, Illinois. Executive conference rooms and audiovisual areas were constructed in existing buildings. The audiovisual facilities would allow for ease of operation for executives during emergencies and emergency training exercises. Special requirements for this project included sound proofing, air conditioning for the audiovisual area, and specialized lighting consideration.
ComEd Zion Training Facility
Techknow, designed the $2 million renovation of the Training Facility at the Zion Nuclear Power Station for ComEd. Techknow prepared all architectural, structural, HVAC and electrical designs for the renovation which includes the installation of control room simulator. The HVAC ducts for classrooms at the facility require extensive modification and a new HVAC roof top unit and duct system and halon fire protection system is being installed for the new simulator. New lighting will be installed in classrooms and the simulator and computer areas along with new cabling for the communication and security systems.
ComEd Standardized Training Facility
Techknow designed four standardized training facilities worth over $22 million as part of a design build team for ComEd's Byron, Braidwood, Quad Cities, and Dresden nuclear power stations. Techknow prepared all architectural, structural, HVAC, plumbing, fire alarm and suppression, civil, electrical and lighting designs. The firm also designed ties-ins from the main plant to the new buildings for the sewage, potable water, fire protection, computer and communications systems at all four sites. Each building has extensive electrical systems including redundant power and a UPS for the control room simulator and its computers. Computer and telephone communication systems included the use of fibre optic cable and type 1 cable. Roof top units and a VAV system with in-duct heaters is used to heat and cool the building in which most of the ductwork is exposed. Indirect and direct florescent lighting is used in classrooms and office areas. A sprinkler fire protection system protects classroom, shop and office areas and a Halon system protects the simulator and computer areas.
Nuclear Research
ComEd Emergency Preparedness Support
TECHKNOW supported Commonwealth Edison Co. in the development and conduction of offsite emergency response training programs. Training modules prepared for the client included Radiation Monitoring and Decontamination, Traffic and Access Control and Executive Training for county and municipal officials. Other modules included Registration Center Operations, as well as specialized training for bus drivers, police dispatchers and the news media. TECHKNOW emergency planning specialists also conducted training and updated county emergency plans. Assistance was provided for control and evaluation of county activities during the 1990 Quad Cities Station Emergency Exercise, which was evaluated by the Federal Emergency Management Agency and the Nuclear Regulatory Commission.
ComEd Nuclear Plant Life Extension
Commonwealth Edison Company commissioned TECHKNOW to prepare a report on Nuclear Plant Life Extension for their older BWR and PWR nuclear plants. This report required development of a list of activities for the client to perform at each nuclear station during 1989 to extend the life of the power plants. TECHKNOW prepared activity categories and assigned priorities for client actions supporting plant life extension. Recommendations for action were presented to the company's Production Services Department.
Argonne National Lab - CRADA
TECHKNOW and Argonne National Laboratory (ANL) worked on a cooperative research and development agreement (CRADA). The mission of the CRADA is to develop a chemical processing system for treating high-level radioactive contaminated waste material such as that stored in the underground tanks on the Department of Energy's Hanford Reservation. The development effort combined TECHKNOW's process technology and plant design capabilities with ANL's extensive experience and expertise in planning and performing demonstrations involving highly radioactive hazardous materials.
Vitrification of Low-Level Waste
TECHKNOW cooperated with Argonne National Laboratory (ANL) on a proposal for the Electrical Power Research Institute (EPRI) on the vitrification of low-level radioactive waste. Vitrification, which is the process of making a glass from waste, is ideal for dealing with the the wet wastes which would leach out of other waste media.
This team combined TECHKNOW 's project management experience and background in utility radwaste and the commercial glass industry with ANL's extensive experience with glass as a radioactive waste form.
Bibliography on Radwaste Solidification
TECHKNOW prepared a selected bibliography on radwaste solidification. This bibliography was thorough, reflecting current industry trends, as well as landmark developments.
Non-CFC Decontamination Systems Report
TECHKNOW's white paper, "Two Non-CFC Decontamination Systems: 1. Carbon Dioxide Pellets, 2. Superheated Water," reflected the growing trend among nuclear utilities for nondestructive cleaning methods which did not produce additional waste. Frequently, the solvents used in common cleaning techniques are hazardous and, when radioactive, become a mixed waste, the disposal of which is problematic at best.
Radioactive Waste Oil Recycling Report
TECHKNOW's white paper, "Recycling of Radioactive Waste Oil: Is It Practical ?," is a comparison of several methods nuclear utilities use to process radioactive waste oil. The purpose of this paper was to assess the possibility and potential usefulness of recycling radioactive waste oil instead of discarding it as low-level waste. The paper was revised and resubmitted one month after completion to revise current NRC rulings.
Recycling of Ion-Exchange Resins Using Off-Site Regeneration Draft Report
TECHKNOW has prepared several white papers and technical bulletins for the Electric Power and Research Institute (EPRI) in the field of low-level radioactive waste. The first, "Recycling of Ion-Exchange Resins Using Off-Site Regeneration," dealt with the difficulties associated with the disposal of spent ion-exchange resins.This paper was also presented as a keynote speech at an EPRI sponsored meeting.
Robotics Engineering Support
TECHKNOW provided support to robot manufacturer, PCI Energy Services, by performing structural analysis for robotic equipment. One project involved development of a robot to cut and remove the heat shield in the reactor at Connecticut Yankee Nuclear Power Plant. TECHKNOW analyzed the structural support required for the robotic equipment.
Engineering expertise was also provided for design and development of the CRDM Robot, a machine which removes control rod drives from beneath BWR nuclear power reactors. This work included analysis of the range in force resulting from the robotic arm being in different positions. Subsequently, TECHKNOW designed components for the robotic arm, that ensured complex structural elements matched client requirements. The prototype robot was instrumented and tested by TECHKNOW to ensure that actual impact forces were less than assumed in the design.
CRDM Robot
TECHKNOW performed a structural analysis of PCI's CRDM Robot. The CRDM Robot is a new machine designed to remove control drives from beneath nuclear power reactors.
We analyzed the robot taking into account the range in forces resulting from the robotic arm being in different positions. From this analysis we designed customized components whose complex structural elements matched the client's requirements.
HACES Robot
TECHKNOW designed the structure for HACES, a robot which is a hanging automated cutting machine being used a TMI Unit 2. The robot hangs from the top of the reactor and includes a remote controlled plasma torch and a television camera which operates under water. HACES' purpose is to cut and remove debris from the bottom of the reactor.
Decommissioning of Yankee Rowe Nuclear Plant
TECHKNOW is designing structures to support plasma underwater robotic cutting equipment. The robotic equipment will be used to cut up the reactor internals for safe removal and disposal. The structural support is designed to keep critical deflections to a minimum for proper equipment operation. Our work is being performed for PCI Energy Services, a Westinghouse subsidiary.
ComEd Control Board Photo Drafting for Dresden and Quad Cities
TECHKNOW is preparing 70 drawings of the control boards at the Dresden and Quad Cities Stations using photo drafting. In photo drafting a very clear and distinct photograph is taken of each control board panel. Enlargements are printed to the desired scale from the original negatives and assembled in a photo mosaic which is then reproduced on mylar drawing film to form the original drawing. Various manual drafting steps are performed to produce the final drawing of the control board.
The principal use of the new drawings will be to show new design and control future modifications to the control boards. Secondary uses are for training, human factors evaluation and comparison of the simulator to the control boards.
In order to take accurate pictures quickly, with least interruptions to the control room operations, TECHKNOW designed and fabricated a unique light aluminum frame which can be quickly assembled and disassembled to mount the camera and the lighting. This unique frame allowed the camera to be moved (horizontally and vertically), tilted and leveled to take many pictures from the same frame position. After taking the pictures at one location, the whole frame can be moved to another location.
Miscellaneous Industrial Projects
ComEd Chicago South Hydome Maintenance Facility
This facility was designed in close cooperation with the transportation department which is the primary user. ComEd's transportation department and architectural group as well as TECHKNOW reviewed the maintenance facilities to get ideas for improvements. The most beneficial of which were incorporated into the facility design.
ComEd Dresden Corporate Chemistry Building
This facility was built to house the Station and Corporate Chemistry Labs and offices. The facility is a two-story, 12,500 square foot building with laboratories located on the ground floor and the offices on the second floor. CECo decided to use a design/build concept for bidding the facility and hired TECHKNOW to provide the specification and other drawings to go for a firm lump sum design/build bid. TECHKNOW's scope of work included the general arrangements, preliminary foundation investigation, electrical, HVAC design, fire protection, plumbing, telecommunications, grounding, potable water and security lighting. The design of this facility included specialized piping, electrical, and HVAC needs of a hot lab facility.
ComEd Quad Cities Chemistry Lab
TECHKNOW's white paper, "Recycling of Radioactive Waste Oil: Is It Practical ?," is a comparison of several methods nuclear utilities use to process radioactive waste oil. The purpose of this paper was to assess the possibility and potential usefulness of recycling radioactive waste oil instead of discarding it as low-level waste. The paper was revised and resubmitted one month after completion to revise current NRC rulings.
ComEd La Salle Chemical Feed System
Techknow performed the complete detailed design of the new chemical feed system, including piping and equipment, for injecting biocide and silt dispersant into the circulating and service water systems at ComEd's La Salle County Nuclear Power Plant. The system includes one 10,000 gallon hypochlorite and two 6,200 gallon sodium bromide and polyacrylate storage tanks, two pump skids and calibration stations, and extensive piping to the injection points. The tanks, pump skids and calibration stations are housed in a new building near the existing screen house. Techknow designed the foundations and electrical, heating, ventilating and fire alarm systems for the preengineered building. Redundant electrical power for the building and pumps is designed to be connected to two existing motor control panels. Techknow prepared specifications an drawings for the new chemical feed building and chemical feed system equipment and a definitive scope construction cost estimate and complete bill of material for the project.
Industrial Excess Landfill
The landfill gas collection and treatment system consists of: two perforated pipe horizontal gas collection headers from the horizontal collection system below the landfill cap; above ground collection pipes from seven gas extraction wells; and two gas treatment skids each with a condensate trap, gas analyzer, gas scrubber, particulate filter, variable speed blower, detonation arrester and a refractory lined flare. Liquid from the gas scrubber and condensate trap flows through pipes to a 1000 gallon underground storage tank. Well head valves and the flare skids are controlled by a programmable logic controller (PLC) which also monitors well head pressure and BTU and VOC content of the gas. The two skids and PLC are enclosed in a preengineered building. The PLC is located in an air conditioned room. The quantity of landfill gas is from 0 to 1200 SCFM and consists of Methane 30% to 65%, Carbon Dioxide 35% to 70%, VOC and Radon. The flare operates at a temperature of 2000 deg. F.
Rocky Flats Liquid Nitrogen Tank
TECHKNOW prepared and conducted an engineering analysis for a double walled 60,000 gallon cryogenic storage tank, to store liquid nitrogen at -370 degrees C for the Rocky Flats Arsenal, a U.S. Department of Energy weapons production facility. This analysis ensured tank integrity for all loads including seismic and adherence to ASME Codes. The project required expertise in mechanical engineering codes and standards, namely the ASME Boiler and Pressure Vessel Code, the AISC Specification and the ASME Code for Pressure Piping which served as the safety standard bases for the tank assembly of inner and outer vessels and piping system. For analysis, TECHKNOW utilized the NISA finite element computer program and Autopipe, a pipe analysis program.
Chicago Incinerator Laboratory Expansion
The Chicago Incinerator is one of the few facilities licensed by the State of Illinois to incinerate hazardous chemical wastes. TECHKNOW performed architecture, electrical engineering, structural engineering and plumbing design for the new 900 square foot receiving laboratory in an existing building. In the receiving laboratory, samples of chemicals received at the incinerator are chemically analyzed and test burns performed. The construction work included demolition of existing interior work, installation of new ceramic tile floor, painting, ceiling and lighting, new electrical service, new HVAC equipment and ductwork, piping for water and gas supply, drains and vents and installation of counters and laboratory equipment. TECHKNOW coordinated the City of Chicago building permit application.
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