The SIJ Transactions on Industrial, Financial & Business Management (IFBM), Vol. 2, No. 3, May 2014 Innovative Technology and Management are the Key of Sustainable Project Development Ahmed Stifi*, Akramullah Aminy** & Sascha Gentes*** *Karlsruhe Institute of Technology, Institute of Technology and Management for the Decommissioning of Nuclear Facilities, Karlsruhe, GERMANY. E-Mail: Ahmed.stifi{at}kit{dot}edu **Karlsruhe Institute of Technology, Institute of Technology and Management for the Decommissioning of Nuclear Facilities, Karlsruhe, GERMANY. E-Mail: akramullah.aminy{at}kit{dot}edu ***Karlsruhe Institute of Technology, Institute of Technology and Management for the Decommissioning of Nuclear Facilities, Karlsruhe, GERMANY. E-Mail: sascha.gentes{at}kit{dot}edu Abstract—The demand for sustainable project delivery is generally growing steadily all over the world. Particularly, the perceived increase in understanding and implementing the term “sustainability” is nowadays a special feature of our engineering industry. The research team within the Institute of Technology and Management for the Decommissioning of Nuclear Facilities trusts that the use of ecological, environmental and innovative technologies and the application of innovative management methods are key to achieving sustainability in decommissioning projects. The main aspect in this respect is the elimination of waste from a technical and executive point of view. The paper will introduce two different research projects, i.e. “decontamination of tubings” and “lean management for decommissioning projects”. Since the decommissioning of nuclear facilities is a rather new activity in many countries, this paper will first outline the decommissioning process. Keywords—Decommissioning Process; Decontamination; Lean Management; Nuclear Facilities; Petrol and Gas Industry; Pipelines Sustainability; Waste Elimination. Abbreviations—Naturally Occurring Radioactive Material (NORM); Office of Statewide Health Planning and Development (OSHPD); Phased Plan Review (PPR); Technologically Enhanced Naturally Occurring Radioactive Material (TENORM); German Name of the Institute of Technology and Management for the Decommissioning of Nuclear Facilities (TMRK); Target Value Design (TVD). I. INTRODUCTION T HE story of nuclear energy started in the fifties with the first nuclear power plant in the USA. The American Atomic Energy Act determines the operation life for nuclear power plants by a maximum term of 40 years; however, an extension by an additional 20 years is possible [Rothwell & Rust, 1997]. With these constraints in mind, i.e. the operation time and the maximum lifetime of nuclear power plants, it becomes clear that in the next couple of years numerous power plants will reach their end-of-life time. Therefore, the nuclear industry will increasingly be faced with task of taking these facilities out of the service [The OECD Nuclear Energy Agency (NEA), 2002]. II. SUSTAINABILITY AND DECOMMISSIONING OF NUCLEAR FACILITIES The term “sustainability” was brought to the world’s attention by Brundtland and her team within the report: “Our ISSN: 2321-242X common future” in 1987. According to her, the definition of sustainable development is “development that meets the needs of the present without compromising the ability of future generation to meet their needs” [Report of UN World Commission on Environment and Development, 1987]. Ten years later, a report by the panel of the National Academy of the Public Administration for the U.S. Department of Energy introduced the sustainability principle as “No generation should deprive future generations of the opportunity for a quality of life comparable to its own” [Report by a Panel of the National Academy of Public Administration for the U.S. Department of Energy, 1997]. Focusing on this principle and knowing that the decommissioning of nuclear facilities is a long term project with an impact on the near and far future urges the researcher and industry to deal with decommissioning processes in sustainable manners. But what is “decommissioning”? The decommissioning of nuclear facilities is the final phase in their lifecycle, after siting, design, construction, commissioning, and operation [International Atomic Energy Agency, 2013]. It is a complex © 2014 | Published by The Standard International Journals (The SIJ) 95 The SIJ Transactions on Industrial, Financial & Business Management (IFBM), Vol. 2, No. 3, May 2014 process involving planning and operation of decontamination and dismantling of facilities, and demolition of building and structures to achieve site remediation. It includes the management of the resulting radioactive waste which should be safely stored in a final disposal facility. Across their activities the decommissioning process takes into account the aspects of health, safety of the operating staff and public, as well as the protection of the environment. Bearing all these features in mind, decommissioning projects are required to be sustainable projects. The research teams within the Institute of Technology and Management for the Decommissioning of Nuclear Facilities (TMRK) are working on a “framework of sustainable decommissioning”, i.e. a model considering six factors that influence the impact of decommissioning on the environment. The framework of sustainable decommissioning is depicted in the following star model, figure 1. and making defective products [Koskela et al., 2013]. The identification and elimination of waste will create value. This philosophy of creating value without waste is the basis of lean management which origins from the manufacturing industry. As mentioned before, the decommissioning process is highly complex in terms of legal requirements, approval processes, executing work and its related supervision. Figure 2 shows an example for sequences of a decommissioning process and its time frame (in years). -5 -4 -3 -2 -1 0 1 2 After Operation Operation 3 4 5 6 7 8 9 10 11 Decommissioning of Nuclear Facilities Approval and Planning Process of Decommissioning Phase 1 Phase 2 Phase 3 Phase 4 Environment Human Figure 2: Sequences of Decommissioning Process (In Years) Economy Time Technology Management Within her case study Freund et al., (2011) investigated the sub process, i.e. the approval process as illustrated in figure 3. The German legal rules strictly separate the design and planning of decommissioning done by facility operators from the review process done by the Ministries and independent experts. Information Inquiry Safety Currently, there are many ongoing research projects within TMRK covering almost all aspects of the decommissioning star model. For example, the “FoRK” research project deals with the technical, economic, social and political consequences of the decommissioning of nuclear facilities at a regional and local level, while the “IRMKA” research project studies and analyses international best practices in terms of the technology and management of the decommissioning of nuclear facilities. Yet another research project deals with safety aspects by monitoring and controlling the path of radioactive materials. MANAGEMENT FOR DECOMMISSIONING OF NUCLEAR FACILITIES The research team trusts that the elimination of waste is the key concept to develop a sustainable decommissioning project. The term “waste” within this paper does not only refer to the commonly occurring waste in nuclear facilities which should be treated and transferred to final disposal facilities. However, TMRK uses the definition of waste as defined by Taiichi Ohno published in his book in1978: “Toyota Seisan Hoshiki”: overproduction, time on hand, transportation, processing itself, stock on hand, movement ISSN: 2321-242X Instructions, VV Information Report Application Documents Inquiry Professional authorities / Federal state authorities Experts/ Consultant (GRS) Statement Statment Figure 1: Framework of Sustainable Decommissioning III. Information Ministry of environment, nature conservation and Nuclear safety (BMU) Advisory Council (ESK, SSK, RSK) Application Documents Permit authority (Ministries) Experts/ Consultant (TÜV) Expert opinions Statement Official Notices of Approval Application Operator Public Figure 3: Approval Process of Decommissioning Within the case study different parties involved in the approval procedure were interviewed. These include the authorities, operators, and experts. Freund also combined the interviews with findings of literature reviews on lessons learned from earlier decommissioning projects which provided information on time and budget overruns. She indicated that the wastes within the approval process are: Formal mistakes in application documents Important existing information gets lost Information for examining the application documents and setting up experts’ recommendation is missing Huge batch size, for example the licensing applications consist on average of 120 documents Waiting time for first statement of experts, approximately 5 month © 2014 | Published by The Standard International Journals (The SIJ) 96 The SIJ Transactions on Industrial, Financial & Business Management (IFBM), Vol. 2, No. 3, May 2014 Poor coordination between different parties and departments Sometimes, the extremely detailed license documents create obstacles even for a small change in the execution Freund looked for tools and methods that can detect, avoid, and prevent such mistakes or “wastes”. In the literature review, she found that the application of Lean Management to similar cases and with similar obstacles and problems was investigated. Lean Management was for example implemented by the Facilities Development Department of the Office of Statewide Health Planning and Development (OSHPD) in the USA, which is responsible for the approval of all hospital construction. OSHPD changed its review from an isolated process, similar to the described decommissioning process above, into a Phased Plan Review (PPR) in which the collaborative and open communication between the integrated team members are the key factors of success [Freund et al., 2011]. Freund found that applying Lean Management principles to the decommissioning process can help eliminating the waste within the process. Learning, for example, is an important principle of Lean Management. In decommissioning projects, short learning cycles should be implemented in order to obtain positive effects of detected wastes. Beside this, the principle of flow is very essential in Lean Management. The flow of the approval process can be improved by decreasing the batch size, i.e. the bulky application documents. This can be achieved through dividing the decommissioning project into several subprojects for approval purposes, which is legally possible [in Germany]. Furthermore, the improvement of cooperation and coordination between all involved parties is one of the main Lean Management features. With the help of Lean Management principles, the operator, authorities, and experts can work together in a multidisciplinary team to deliver a joint project [Freund et al., 2011]. Moving to the next sub processes, The application of Lean Management tools like the Target Value Design (TVD) to the design process and use of the Last Planner System (LPS) by execution process will help in achieving a sustainable decommissioning process. IV. TECHNOLOGY FOR DECOMMISSIONING OF NUCLEAR FACILITIES While the previous section discussed the waste in the process itself, this section is discussing the physical waste. The decommissioning of a nuclear power plant is producing considerable amounts of radioactive contaminated waste. Contamination of materials and components of nuclear facilities results from various physical and physical-chemical processes. Contamination of metal may be found in the upper layer of surfaces (thickness of µm) while in concrete building structures contamination may have penetrated deeper (few cm or even more). The process of removal of contamination from the surfaces of structures, equipment, and different ISSN: 2321-242X components is called “decontamination” [European Commission-Coordination Network on Decommissioning (EC-CND), 2009]. Techniques for decontamination are already available, such as washing, heating, chemical or electrical action, mechanical cleaning or other techniques. When selecting the suitable decontamination technique, several criteria should be considered like the nature of contamination, the contaminated materials, time and cost, and of course the safety, environmental, and social issues. Considering these factors in its research, TMRK aims to develop innovative and sustainable techniques for decontamination purposes. One research project of TMRK deals with the Problem of contaminated tubing from the petrol and gas industry due to Naturally Occurring Radioactive Material (NORM). NORM can be found everywhere on the earth and thus contributes to the background of radiation. Especially in deep geological formations there are several ways in which NORM can be released, e.g. through the process of extracting material from the earth. During the extracting process of oil and natural gases from underground reservoirs, high amount of water and chemicals are used to simplify the extracting. Because of this NORM becomes soluble in the transported fluid and is thus taking out of the formation. The transportation of the liquid from the underground through pipes and tubings leads to an alteration of the temperature, pressure and ph-values which consequently leads to a precipitation of NORM and other materials [Smitht, 1992]. This precipitated material, consisting of barium, calcium, strontium sulfate and also toxic as well as radioactive substances will accumulates to scales inside tubings and other installations of apetrochemical facility [Kolb & Wojcik, 1985; Johnson et al., 1999; Hamlata et al., 2013]. Due accumulation of NORM in scales, the tubings became radioactively contaminated. During the decommissioning of a petrochemical facility the tubes are pulled out of the ground. Since the tubings are radioactivity contaminated by the so called “Technologically Enhanced Naturally Occurring Radioactive Material” (TENORM), decontamination is needed in order to reuse the tubings. The radioactive contamination of pipelines in the petrol and gas industry is an example where the result of a research project will be applied in order to decontaminate tubings in the nuclear facilities. Currently used decontamination methods in this field are based on water jet- and abrasive blasting technologies which produce high amounts of secondary waste. For example: 7 km of tubings contain an amount of 15 t of scales. The decontamination of these 7 km of tubings using sand blasting yields approximately 30-50 t of mixtures (muddy and fixed deposits), hence increasing the total of contaminated waste on average by a factor of 3 [Report of the German Federal Office for Radiation Protection, 2011]. Dealing with this problem, the TMRK research team developed a new sustainable decontamination technology for tubings in order to avoid additional secondary waste. The characterization of the scales has shown that they are hard and brittle and can be removed by applying a defined mechanical force to spall them [Aminy et al., 2010]. Based © 2014 | Published by The Standard International Journals (The SIJ) 97 The SIJ Transactions on Industrial, Financial & Business Management (IFBM), Vol. 2, No. 3, May 2014 on this Problem analysis considerations for alternative decontamination techniques have been made and the following challenges have been identified in order to transform this idea into a sustainable concept: Developing an appropriate tool carrier for producing high frequency vibration and shock, which intended to be used in arrow space boundary conditions of tubing. Development of a suitable tool, for transmitting the energy of the tool carrier on the tubing scales and for extracting the same from the tubing. Conducting preliminary investigations to identify influencing factors of the whole removal process. Determination of the exact effect of influence factors and optimization the entire process. In order to qualify this new decontamination technique different types of deposits have been formed inside the tubing and relevant factors of influence, namely the hardness and thickness of the deposits, the geometry of the used tool, the distance between the tool and the inner wall of the pipe, and the rotation parameters (frequency and mass of the imbalance of the vibrator) were investigated. The results of this research project confirm the fundamental function of decontamination of tubings by means of vibration. However, to carry out experiments within a suitable time frame and without any radiation hazard, new attempts have been investigated by using modern simulation technologies which enable researchers to investigate complicated processes and procedures virtually as well as to examine its efficiency, adaptability and repeatability in an ecologically and environmentally manner; Figure 4 [Stifi et al., 2012]. ACKNOWLEDGMENT The majority of TMRK’s research projects, like the using of vibration technique for decontamination of tubings, are sponsored by the German Federal Ministry for Education and Research (BMBF). REFERENCES [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] Figure 4: Decontamination of Tubings using Vibration Technique [Stifi et al., 2012] V. CONCLUSION The paper intended to highlight the role of management and technology by developing a sustainable decommissioning. It shows that all parties, facility operators, authorities, experts and communities are involved in the sustainable decommissioning process and their decision to undertake it in a sustainable way is a key issue. Also, the paper shows the role of research institutes in the decommissioning process. Research institutes are well equipped with the skills and facilities to develop sustainable management tools and sustainable technologies. Therefore, the early involvement and good cooperation between research institutes and industry is important for developing sustainable decommissioning processes. ISSN: 2321-242X [11] [12] [13] [14] [15] G. Rothwell & J. Rust (1997), “On the Optimal Lifetime of Nuclear Power Plants”, Journal of Business & Economic Statistics, Vol. 15, No. 2. The OECD Nuclear Energy Agency (NEA) (2002), “The Decommissioning and Dismantling of Nuclear Facilities, Status, Approaches, Challenges”. Report of UN World Commission on Environment and Development (1987), “Our Common Future”, WCED. Report by a Panel of the National Academy of Public Administration for the U.S. Department of Energy (1997), “Deciding for the Future: Balancing Risks, Costs, and Benefits Fairly Across Generation”. International Atomic Energy Agency (2013), “Planning, Management and Organizational Aspects of the Decommissioning of Nuclear Facilities”, TECDOC-1702; IAEA 2013. L. Koskela, T. Bølviken & J. Rooke (2013) “Which are the Wastes of Construction?”, 21th Conference of the International Group of Lean Construction (IGLC-21), Fortaleza; Brazil. C. Freund, F. Gehbauer & S. Gentes (2011), “Decommissioning of Nuclear Power Plants – Can Lean Methods Help to Improve the Highly Complex Design and Planning Processes?”, 19th Conference of the International Group of Lean Construction (IGLC-19), Lima; Peru. European Commission-Coordination Network on Decommissioning (EC-CND) (2009), “Dismantling Techniques, Decontamination Techniques, Dissemination of Best Practice, Experience and Know-how”, Final Report. K.P. Smitht (1992), “An Overview of Naturally Occurring Radioactive Materials (NORM) in the Petroleum industry”, Environmental Assessment and Information Sciences Division, Argonne National Laboratory, 9700 South Caas Avenue, Argonne, Illinois. M.S. Hamlata, H. Kadib & H. Fellagb (2003), “Precipitate Containing Norm in the Oil Industry: Modelling and Laboratory Experiments”, Applied Radiation and Isotopes, Vol. 59, No. 1, Pp. 95–99. R. Johnson, K.P. Smith & J. Quinn (1999), “The Application of Adaptive Sampling and Analysis Program (ASAP) Techniques to Norm Sites”, Argonne National Laboratory Environmental Assessment Division, Argonne. W.A. Kolb & M. Wojcik (1985), “Enhanced Radioactivity due to Natural Oil and Gas Production and Related Radiological Problems”, The Science of the Total Environment, Elsevier Science Publishers B.V, Pp. 77–84, Amsterdam. A. Stifi, P. Kern, A. Aminy & S. Gentes (2012), “Technology and Management for Decommissioning of Nuclear Facilities – A Report from Germany”, European Nuclear Conference, Manchester; UK. Report of the German Federal Office for Radiation Protection (2011), “Mengenaufkommen an NORM-Rückständen für das deutsche Entsorgungskonzept”, SR 2416 Bonn. A. Aminy, S. Gentes & F. Ambos (2010), “Decontamination of Tubings using Vibration Technology”, Conference of the American Nuclear Society, Decommissioning, Decontamination & Reutilization, Idaho, USA. © 2014 | Published by The Standard International Journals (The SIJ) 98 The SIJ Transactions on Industrial, Financial & Business Management (IFBM), Vol. 2, No. 3, May 2014 Ahmed Stifi has received his Bachelor of Science degree in Civil Engineering from University of Aleppo in 2001 and his Master of Science degree in Construction Management from Technical University of Darmstadt in 2007. After 4 years of international work experience at large-scale construction projects like “City-Tunnel Leipzig”, “The World Island & the Palm Deira”, “5000 Unit Housing and Infrastructure Project in Libya” and “International Airport project” he attended the researcher teams at Karlsruhe Institute of technology in 2012 and currently he is working as a senior researcher at Institute of Technology and Management in Construction where he is pursuing his Ph.D. His area of interest is Lean Construction and Construction & ReConstruction of Nuclear Power Plants. Sascha Gentes has received his diploma and doctorate degrees in Civil Engineering from the University of Karlsruhe. He is since 2004 Lecturer at Fachhochschule Karlsruhe for “Calculation”, at Hochschule für Technik in Stuttgart for „Contractor’s Cost Management“, and at Universidade Federal do Parana, in Curitiba, Brasil. Since 2008 he leads the department of Technology and Management for the Decommissioning of Nuclear Facilities within Institute of Technology and Management in Construction. Prof. Gentes is the head of research and development department of the company sat. Kerntechnik GmbH in Germany and he published up to date more than 60 various research papers. Akramullah Aminy has received his Master of Science degree in mechanical engineering from the University of Karlsruhe and he is currently working as research assistant at Karlsruhe Institute of Technology in the area of product development. ISSN: 2321-242X © 2014 | Published by The Standard International Journals (The SIJ) 99