Tilted fuel assembly retrieved from Palisades plant

Holtec is working to return the single-unit pressurised water reactor, removed from service in 2022, back to operation. It began the process of fuel loading in late August, but on 21 September announced that fuel loading was on hold after a fuel assembly tilted from its upright position after it had been placed and the fuel-handling machine grapple had been disengaged.

The specially designed Fuel Movement Device was developed to support the controlled lifting and transfer of the tilted assembly. US Nuclear Regulatory Commission (NRC) approval was required to use the specialised recovery methodology, with the regulator issuing a one-time use emergency revision to the plant's licensing basis to facilitate the operation after carrying out a review to confirm that the activity could be carried out safely and in compliance with its regulatory requirements.

_{A special fuel handling device was made to remove the assembly (Image: Holtec)}

The device, together with a custom-engineered fuel transfer canister, provided a solution to a fuel-handling challenge that could not be addressed using conventional refuelling equipment, Holtec said. The Palisades team used the device to lift the fuel assembly from its position within the reactor vessel and placed it into the fuel transfer canister. The canister lid was installed and secured within the reactor cavity before the canister was safely transferred to the plant's used fuel pool, where the recovered assembly is now stored. The operation was supported by extensive engineering evaluations, equipment testing, detailed execution planning, and disciplined performance by the recovery team.

"When we encounter a challenge, what matters is how we respond," said Fadi Diya, Holtec International's Chief Nuclear Officer. "Our team approached this recovery with the same commitment to safety, technical rigor, and teamwork that has guided our work throughout the restart. We developed a solution, executed it safely and error-free, and demonstrated the depth of expertise across our organisation. I’m proud of this team and grateful for the dedication they bring to Palisades every day."

With the recovery operation complete, the Palisades team continues its progression toward the plant’s return to service, including the completion of fuel loading, required testing, inspections, and operational readiness activities, the company said.