sosny research and development company

Sosny Research and Development Company

Nuclear Safety Solutions

© Sosny R&D Company, 2016

2www.sosnycompany.com

MANAGEMENT DIVISIONS

Purchase Management Department

Pilot Production Facility

• Sosny Research and Development Company was set up in Dimitrovgrad in 1992.

• Sosny R&D Company has three offices in three Russian cities: Moscow, Dimitrovgrad, and Elektrostal.

• The Company employs a staff of 250 persons.

Director

Scientific Supervisor

Technical Director

Director of Dimitrovgrad Office

Chief Design Engineer

Chief Process Engineer

Deputy Director for Quality Management and Licensing

Design Department

Process Engineering Department

Automatics Department

Research and Development Department

Process Safety Analysis Department

Design and Development Divisions

Transportation Department

International Relations Department

Legal Control Department

Economics and Controlling Department

The Company's leading experts have many years' experience in SNF research, research reactor operation, and development of equipment for nuclear industry

First Deputy Director


o Procedures and equipment for SNF and RW managemento Nuclear and radiation safety analysis

o Equipment for nuclear power plants and nuclear installations

o Transport of radioactive material

o Equipment for SNF loading and transportation

o Equipment for nuclear fuel production and radiochemical reprocessing of spent fuel

o Research and development

o Automated instrumentation and control systems

o Inspection standsfor NPP

Sosny R&D Company is actively involved in almost all stages of the nuclear fuel cycle

Activities


Quality Management System. Licenses and Certificates

Sosny's quality management system is based on ISO 9001:2008 requirements and confirmed by International Certificate of Registration issued by NQA (National Quality Assurance Limited, Great Britain).

Sosny’s quality management system is confirmed by certificates for nuclear fuel cycle facility decommissioning management, design and development for nuclear industry issued by National Commission for Nuclear Activities Control (CNCAN), Romania and the Paks NPP, Hungary.

Sosny R&D Company has all necessary licenses for design and development of equipment for nuclear power plants, nuclear material buildings and facilities, and nuclear fuel cycle facilities.


Procedures and Equipment for SNF Management

Bringing damaged SNF to the safe controllable condition.

Development of methods and tools for handling the spent fuel to transport it to a reprocessing or disposal site.

Nuclear and radiationsafety analysis of the procedures and equipment developed.

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Paks Project• A procedure and equipment for removal of the destructed VVER-440 SNF from the Unit 2 cleanup tank at the

Paks NPP, Hungary, as well as canisters for interim storage and transport of the spent fuel were developed.• A procedure and equipment for drying the SNF-containing canisters were developed.• The SNF was removed from the cleanup tank (2006-2007) and the SNF-containing canisters were dried up

(2013).

o Tools

o Equipment for drying SNF-containing canisters

o Working frame

o SNF-containing canisters with pressurizers for gas release

o Operator's control panel


Vinca Project• A procedure and equipment were developed to withdraw the TVR-S type SFAs from aluminum barrels and

reactor channels used for their storage in the cooling basin of the Vinča Institute, Serbia for more than 20 years, and to load them into canisters.

• A new higher-capacity packaging for the transport of the damaged SNF was developed and fabricated.• 8030 TVR-S type SFAs were repackaged into canisters.

o Untight SNF canisters and baskets for SKODA VPVR/M cask

o Equipment and tools for cutting aluminum barrels and reactor channels, loading the SNF into canisters, handling the canisters and loading them into casks

o Working frame with video surveillance, lighting and radiation monitoring systems


Bilibino NPP (2010-2011)• In view of the forthcoming commissioning of the Bilibino NPP and to enhance safety of accumulated SNF stored

at the NPP, a procedure and equipment were developed for the facility for cutting and loading EGP-6 SFAs into canisters to be shipped to a reprocessing facility.

• Equipment, tools, mockups and prototypes were developed and fabricated to try out the main EGP-6 SNF handling operations at the facility for cutting and loading EGP-6 SFAs into canisters. The mockup equipment was successfully tested at the experimental stand at Sosny R&D Company.

• Preliminary safety analysis of the technology and equipment was performed and received positive expert assessment from IPPE and ATOMENERGOPROEKT, Moscow.

o Experimental stand for verification of non-standard engineering solutions and operation try-out

Unloading area

o Safety analysis

o Remote cutting of SFA and air-tightening of canister

Area for loading into canisters

Inspection area


Bilibino NPP (2013-2014)• Engineering survey of the construction site for the canister preparation facility (CPF) was conducted at the Bilibino NPP.• Conceptual designs of the major equipment were developed for the area for SFA cutting and loading into canisters,

interim accumulation area and SRW preparation area.

• Environmental impact assessment and public hearings were conducted.

• Statements of Work were developed for the design of equipment for the area for SFA cutting and loading into canisters, interim accumulation area and SRW preparation area.

• A Statement of Work for the design of the canister preparation facility and remodeling of the central hall to accommodate the equipment for the facility for cutting and loading SFAs into canisters was developed.

• A declaration of intent (DOI) and a justification of investments (JOI) in construction of the facility for cutting and loading SFAs into canisters were developed.

o Flow chart of SFA preparation for shipment at the facility for cutting and loading into canisters


RBMK SNF Management• Equipment and procedure for loading non-conforming RBMK SNF and its transportation from Unit 2 of the Leningrad NPP

to Mayak PA were developed.• Ampules for a trial shipment of non-conforming SFAs were developed and fabricated. A pilot shipment of the SFAs from

the Leningrad NPP to Mayak PA was completed.• Special ampules were developed for regular shipments of non-conforming RBMK-1000 fuel rod bundles from the

Leningrad NPP to the reprocessing plant. • Preparation of the Leningrad NPP for regular shipments of non-conforming RBMK-1000 SFAs

to Mayak PA is underway.

o Test of equipment for trial shipment of SFAs to Mayak PA o Test of mock-up ampule

o Grapple for fuel rod bundle


Removal of Spent Nuclear Fuel from IPPE• Inventory of the SFAs and fuel rods to be removed was taken in the dry storage facility at IPPE (various fuels with

different uranium and plutonium compositions).• SNF canisters were developed, fabricated and delivered.• Equipment for loading the SNF was developed, fabricated and mounted in the hot cell.• Branch railways on the IPPE site were repaired. A transport plan of the shipment was developed. Shipments of

the SNF in TUK-19 and TUK-108 to Mayak PA for reprocessing were organized.

loading into canisters

o Equipment for SFA tilting, cutting, and


Liquid SNF Management• A procedure and equipment for loading highly-enriched liquid SNF from the IIN-3M reactor at Foton JSC,

Uzbekistan, into the interim storage canisters were developed.• Safety of the procedure and equipment was justified.• The equipment was fabricated, tested and installed at the IIN-3M reactor site.• In September 2015 the liquid spent fuel was shipped to Russia to be reprocessed at the Mayak PA

radiochemical plant.o Equipment for discharge and temporary storage of uranyl sulphate solution of IIN-3M reactor facility at Foton, JSC

o Transport canister for liquid spent fuel and transfer cask for loading the canisters into SKODA VPVR/M cask


AMB SNF Management• The AMB SNF cutting procedure and equipment for the Cutting and Encapsulation Division (CED) of Mayak PA

including handling the SRW was developed.• Preliminary and concept designs of some types of the main and auxiliary equipment for the CED, as well as its

configuration were developed.• Equipment for remote operations in the CED cutting pools.• Sosny experts participated in preparing the CED design estimates, which were positively assessed by

Glavekspertiza of Russia.

o Main specific features of cutting of the AMB SFA-containing cartridges

o Configuration of CED equipment


Safety analysis• Sosny's Safety Analysis Department conducts comprehensive safety analysis of the procedures and

equipment developed, including: nuclear and radiation safety, fire and explosion safety, design analysis, risk analysis, safety analysis reports (SAR).

• The calculations are made by state-of-the-art software (ANSYS, LsDYNA, MCU-RFFI/A, MMKFK-2-BASE, TDMCC) certified by regulatory authorities in due course. All experts dealing with the safety analysis have relevant certificates.


Automated Instrumentation and Control Systems

Process instrumentation and control systems at nuclear facilities. Process video surveillance systems including those used in high-radiation conditions.SSCR alarm system.Automated radiation monitoring systems. Nuclear material, radioactive substances and radioactive waste control and accounting systems.

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Automated Radiation Monitoring Systems

o SAP TRMD main screen

SAP TRMD is designed for the following: radiation monitoring data acquisition and processing; mode control of the equipment influencing background radiation in the premises; assessment of the doses received by the personnel during decommissioning of specific premises, systems, or equipment; provision of informational contents of radiation monitoring; timely decision making regarding organizational, engineering, or protective measures to prevent exposure to the personnel and contamination of the rooms.

o Equipment for radiation monitoring data collection o Database server rack

• Sosny R&D Company completed development, fabrication and commissioning of a subsystem for automated processing of task related monitoring data (SAP TRMD) for the Beloyarsk NPP.


Automated Radiation Monitoring Systems• Sosny R&D Company upgraded radiation monitoring systems for Units 1 and 2 of the Beloyarsk NPP to ensure

radiation safety in preparing for phase 1 decommissioning.

The ARMS upgrades included: optimization of the scope of radiation monitoring with account taken for regulatory documents, current production targets and future tasks regarding preparation of Units 1 and 2 for decommissioning, selection and justification of the software, high- and low-level equipment, development of the preliminary and final designs and getting the general designer's approval; getting a positive expert assessment by Scientific and Engineering Center for Nuclear and Radiation Safety, development and verification of the software, fabrication, testing and delivery of the high-level ARMS.

o Simplified block diagram of ARMS

o Data display on ARM monitors

Automated workstation forNRS engineer

Database server

o Low-level equipment

o Acceptance tests of high-level equipment


Automated profilometry and eddy current facility for a hot cell at the SSC RIAR material testing facility

The facility is designed to examine cylindrical objects with the outer diameter 4-20 mm and up to 1.5 m long. The cross dimensions of the object under examination are determined by a contact method using two linear transducers with T-shaped probes. For profilometry of the objects with a non-cylindrical profile, the facility design allows changing the probes for spherical ones and adjusting the probe position relative to the object axis. Eddy-current testing is performed using plug-in eddy-current transducers of differential and absolute types. The facility has a modular design for a possibility to change its configuration for various research activities.

o Information and control system

o Profilometry module

o In-cell part of the profilometry facility

o Software interface


Transport of Radioactive Material

Transport of power-grade reactor SFAs to a post-irradiation examination facility.

Transport of Russian-origin non-irradiated and spent nuclear fuel from foreign research reactors to a reprocessing plant.

Transport of Russian research and power-grade reactor SNF to a reprocessing plant.

Organization of shipments of low enriched fuel to research reactors.

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Transport of Radioactive Material• To organize a shipment, our experts perform fuel inspections, certification of the shipment, paperwork control,

supervision of loading the fuel into shipping casks, personnel training in handling the packages and loading equipment.

• Logistics experts elaborate new transport plans.o A sea vessel was refitted, certified and assigned INF-2 class.

o A transport plan involving ferry crossing over the Black sea was developed to deliver empty TUK-19 casks.

o Since 2002, Sosny R&D Company has participated in organization of more than 30 RRRFR shipments including SNF air shipments.

o Railway transporters were designed and fabricated for shipment of TUK-140 and TUK-1410.


Equipment for SNF Loading and Transport

Procedures and equipment for loading SFAs into shipping casks.

Equipment for shipping the SNF by various conveyances.

Certification of foreign casks for the use in Russia.

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SNF Loading Equipment• Procedures and equipment for loading the SNF into TUK-19 and SKODA VPVR/M casks:

o Transfer cask for loading SFAs into SKODA VPVR/M cask. Used together with a support plate, an adaptor and other ancillary equipment.

o Transfer cask for loading SFAs into TUK-19 cask. Equipped with an automatic grapple for loading/removal of Type 50 basket.


SNF Transport Equipment

TUK-145/C package is the world’s first Type C package for the transport of research reactor SNF by air.

• Transport overpacks for multi-modal shipments of the spent nuclear fuel in TUK-19 casks and energy absorbing containers for TUK-145/C packages were developed, fabricated and certified in Russia and abroad.

o TUK-145/C for the transport of radioactive material with no limitation on activity by any transport mode. TUK-145/C includes an energy absorbing container filled with hollow titanium balls and a SKODA VPVR/M cask.

o Transport overpack for multi-modal shipments of the TUK-19 casks including a special freight large-capacity 20-ft ISO container.


Equipment for Production of Nuclear Fuel and Radiochemical Reprocessing of Spent Fuel

Development of equipment for polyfunctional radiochemical research complex at SSC RIAR. Development of equipment for NPP unit for reprocessing fast reactor SNF. Development of equipment for special line of the centralized plant for preprocessing fast and thermal reactor SNF.

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Polyfunctional Radiochemical Complex (PRC)• Technical Assignment for development of the PRC and design of a research complex at SSC RIAR.

Glavgosekspertiza of Russia gave a positive assessment of the PRC design.• Design documents for shielding, lifting and transfer equipment for the complex were developed. • A mockup versatile process module (PVM) with the PRC transfer hub, video surveillance and lighting system

was fabricated and delivered. • Detailed design documents were elaborated to fabricate mockup process equipment for the SFA cutting and

fuel rod fragmentation cell.• A conceptual control and monitoring system for the PRC hydrometallurgical line, a list of in-process monitoring

points of the SNF aqueous reprocessing, and recommendations on technical requirements and the use of low-level control and monitoring equipment were developed.

o Test stand at SSC RIAR o Mockup VRM


Laboratory Equipment for NPP nuclear fuel cycle facility (NPP NFCF)

• Mockup laboratory equipment for verification of separate production processes and hydrometallurgical reprocessing and intended for the special line of the centralized fast reactor SNF reprocessing plant was developed and fabricated.

o Equipment for thermal treatment of mixed uranium-plutonium nitride spent fuel

o Unit of centrifugal extractors

o Plutonium dioxide and fissionable material dissolver

o Equipment for deposition of transplutonium and rare-earth

elements

o TUK-155 for the transport of specimens to a material testing facility


Radiochemical Equipment• Laboratory equipment for verification of engineering solutions to reprocessing of the nitride SNF in hot cells was

developed and fabricated, i.e.: SNF thermochemical reprocessing and dissolution, gas purification of the main reprocessing operations, decladding of the fuel rods with liquid metal, metal recycling, electrorefining on a liquid cadmium cathode, reprocessing of depositions and removal of salt ingots.

o SNF and FM dissolver

o SNF thermoreprocessing equipment

The equipment is developed to try out new schemes for fast reactor SNF reprocessing for further commercialization of the closed fuel cycle technologies.

o Gas purification equipment

o Equipment for fuel rods decladding with liquid zinc

o Zinc distillation equipment


Complex of experimental facilities for development of nitride fuel fabrication technology

• In 2015 a complex of experimental facilities consisting of 18 gloveboxes with inert atmosphere was fabricated and delivered to Siberian Chemical Combine (Seversk) to perform technological operations of nitride powder synthesis and nitride fuel pellet fabrication.

• “Electromechanical laboratory press” experimental equipment designed and fabricated by CHAMPALLE SAS (France) was delivered to Siberian Chemical Combine.


Equipment for Nuclear Power Plants and Nuclear Facilities

Design of equipment and systems for nuclear power plants and nuclear facilities.

Fabrication and delivery of equipment and systems for nuclear power plants and nuclear facilities.

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Equipment for Nuclear Subcritical Facility (NSF)

• Elements of the NSF vessel and pools, internals (reflectors, SFA racks, neutron channels, neutron-generating targets), elements of the shield and cooling systems, equipment for SFA and target storage in the pools, transfer casks were fabricated and delivered to KIPT, Ukraine.

• Automated I&C systems for the NSF, ARMS, and SCRAS were developed and delivered.

o Testing of the pool tank

o Testing of fuel handling machine o NSF vessel

o Transfer cask

o Automated radiation monitoring workstationso Neutron-generating targets


Assay equipment • A package of documents for large-scale manufacturing of an automated

system for non-destructive assay (ASNDA) of the BN-800 fuel elements was developed and a prototype system was fabricated to ensure:▫ measurement of outer diameter,▫ gamma radiation monitoring,▫ cladding defects detection,▫ cladding thickness variance detection.

o Transfer module

o Data measuring system

The system has a modular design and includes a set of grapples, radiation-resistant TV system for process surveillance, a set of certified standards.The design of the system allows for performing several types of measurements simultaneously. The configuration of the system can be changed, if required; the measuring modules can be replaced remotely.The software ensures diagnostics, adjustment and configuring of the system, making and running measurement programs, view, analysis, and preprocessing of the results.

o Standard specimens


Inspection Stands

o Assembling of equipment for inspection facility

o Commissioning of the TVSA-T inspection and repair stand at the Temelin NPP

• Sosny R&D Company participates in developing power reactor SFA inspection and repair stands, as well as in mounting the equipment and NPP personnel training. The equipment and procedures enable non-destructive assay of the spent fuel in NPP storage pools, namely: SFA visual examination, dimensional measurements, cladding leak tests (CLT), and eddy-current defectoscopy.

• In 2009, an ultrasonic CLT and eddy-current defectorscopy system for the VVER-1000 TVSA inspection and repair stand was delivered to the Kalinin NPP.

• In 2009, acceptance tests of an ultrasonic CLT system for the VVER-1000 TVSA-T inspection and repair stand were conducted at the Temelin NPP, the Czech Republic. In 2011, two leaky SFAs were successfully inspected.

• In 2015 controlling and measuring equipment for four SFA inspection facilities for Leningrad NPP-2 and Novovoronezh NPP-2 was fabricated, tested and delivered.

o CLT manipulator containing 52 ultra-sonic sensors


Research and Development

Research, development, and engineering support of SNF handling projects.

Analytical and methodical studies.

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AMB Fuel Studies• To develop a procedure for handling the AMB SNF at the Beloyarsk NPP and to justify safety of the SNF

preparation for the shipment to a reprocessing plant, Sosny experts participated in the following studies:▫ condition and corrosion behavior of the AMB SNF including determination of the composition, quantity

and activity of the corrosion products on the SFA storage tubes, determination of the rate of radionuclide deflation from the tube surfaces, and sizing of the SNF corrosion products;

▫ grain-size distribution in filings and FP release into water during AMB SNF cutting operation,▫ FP release into the environment from the water and dried surfaces.

• The method for SNF drying and fire and explosion safety of the dried SNF during storage were justified.

• R&D work was done to develop a technology and procedure for the AMB fuel reprocessing.

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o Grain-size distribution in filings and FP release into water during SNF cutting operation The data are required to estimate exposure to the personnel, nuclear safety analysis, optimization of the cutting modes, and development of spillage collecting tools.

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o Fragment of SFA storage tube


Expert Activities

Photos from the site www.irid.or.jp

By invitation of Hironori Nakanishi, Director General of the Agency for Natural Resources and Energy of Japan and in concurrence with Rosatom State Corporation,A. Leshchenko, an employee of Sosny R&D Company, participates in the international group of experts established at the International Research Institute for Nuclear Decommissioning in Japan (http://www.irid.or.jp/en/index.html).The mission of the expert group is to consult Japanese colleagues onelimination of accident consequences and decommissioning of the Fukusima-1 Nuclear Power Station, as well as to provide recommendations on the current and long-term activities basing on the collaborative viewpoint and personal experience of the group members.


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Pilot Production Facility


Pilot Production FacilitySosny R&D Company has established a pilot production facility to fabricate the equipment designed by the Company's engineering design divisions to be used then at Russian and foreign nuclear facilities. Here the fabricated equipment is assembled, adjusted, tested, and equipped with monitoring and control instruments.


CONTACT US

MOSCOW OFFICE: Office B 405, bldg. 11, Derbenevskaya Quay, Pollars Business Centre, Moscow, 115114 Tel.: +7 (495) 913-67-15Fax: +7 (495) 913-67-16E-mail: [email protected]

DIMITROVGRAD OFFICE: 4a Dimitrov St, Dimitrovgrad, Ulyanovsk region, Dimitrovgrad, 433507Tel.: +7 (84235) 3-98-29 Fax: +7 (84235) 3-83-28E-mail: о[email protected]

ELEKTROSTAL OFFICE:13a Zagonov St, Elektrostal, Moscow region, 144009Tel.: +7 (49657) 9-21-28Fax: +7 (49657) 9-21-30E-mail: [email protected]

Buildings of Dimitrovgrad Office

Pollars Business Center

© Sosny R&D Company, 2016

sosny research and development company

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