ML051330051
| ML051330051 | |
| Person / Time | |
|---|---|
| Site: | Quad Cities  |
| Issue date: | 04/22/2005 |
| From: | Tsukida R General Electric Co |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| 26A6492-NP, Rev 2 | |
| Download: ML051330051 (36) | |
Text
ENCLOSURE 2 ATTACHMENT 2 "Steam Dryer Vibration Instrument Installation Procedure," GE Specification 26A6492-NP, Revision 2, Non-Proprietary, dated April 22, 2005
0 GE Nuclear Energy 26A6492-NP I REV. 2 SH NO. I OF 35 _
REVISION STATUS S}IEET DOCUMENT TITLE STEAM DRYER VIBRATION INSTRUMENT INSTALLATION PROCEDURE LEGEND OR DESCRIPTION OF GROUPS TYPE: INSTL SPEC FMF: QUAD CITIES 2 (PROCEDURE)
MPL NO: N/A I - DENOTES CHANGE SAFETY-RELATED CLASSIFICATION CODEQ REVISION C FEB 21 2005 0 RMCN05632 MAR 29 2005 1 I RS TSUKIDA I RJA RMCN05957 ENGR: RS TSUKIDA APR 22 2005 2 RS TSUKIDA RJA RMCN06057 MADE BY APPROVALS GENERAL ELECTRIC COMPANY 02/03/05 02/21/05 175 CURTNER AVENUE R. TSUKIDA R. TSUKIDA SAN JOSE CALIFORNIA 95125 CHKD BY: ISSUED 26A6492-NP FEB 21 2005 NA RJ AHMANN CONT ON SHEET 2 MS WVORD (2/98)
26A6492-NP SH1NO. 2 W GE Nuclear Energy l REV. 2 OF 35 _
IMPORTANT NOTICE REGARDING CONTENTS IN THIS DOCUMENT Pertaining to Proprietary Nature of this Document The only undertakings of the General Electric Company (GE) respecting information in this document are contained in the contract between Exelon and GE, and nothing contained in this document shall be construed as changing the contract. The use of this information by anyone other than Exelon, or for any purpose other than that for which it is intended is not authorized; and with respect to any unauthorized use, GE makes no representation or warranty, express or implied, and assumes no liability as to the completeness, accuracy, or usefulness of the information contained in this document, or that it use may not infringe upon privately owned rights.
This document contains information that is the property of GE and/or its suppliers and subcontractors.
It is furnished to you in confidence and trust. Information contained herein shall not be reproduced, disclosed to others, or used for any purposes other than those designated by GE. However, this does not alter in any way the rights and obligations defined by applicable contracts.
This is a non-proprietary version of the document 26A6492-P, which has the proprietary information removed. Portions of the document that have been removed are indicated by an open and closed bracket as shown here (( )).
Relating to General Contents Work step sequences in this procedure may be changed or altered at the discretion of the GE Project Manager or responsible Site Engineer, provided they do not affect quality or violate any approved specifications and may need further review by station work planning and refueling personnel.
Unless a +/- tolerance is specified, gauges and measurement devices do not need to be calibrated.
Gauges are for reference only. "Approximately" in this procedure is defined as roughly +/- 10% of necessary gauge reading. When instruments requiring calibration are needed, the instrument identification number and calibration due date will be documented on the appropriate work document, and may require review by site station work planning and refueling personnel.
- GE Nuclear Energy [Z6A6492-NP REV. 2 SH NO. 3 OF 35 INSTRUMENTED STEAM DRYER INSTALLATION 1.0 SCOPE
1.1 Purpose
The purpose of this document is to detail the procedure for completing the installation of the Flow Induced Vibration instrumentation during the installation of the new steam dryer and reactor vessel head at the Quad Cities Unit 2 site. The vibration instrumentation, partially installed at the dryer fabrication shop, is then transported to the site (not covered in this procedure). This document covers from the receiving inspection sensor checkout to post-installation checkout of all sensor prior to final reactor head closure at the Quad Cities site. Reactor re-assembly procedures is covered in other document. The dryer vibration instrumentation is associated with the steam dryer vibration and acoustic pressure measurement during reactor startup operation.
The final installed configuration shall be documented and included in the Design Record File.
1.2 The scope shall include preparation of final installation of the new steam dryer's vibration instrumentation and final testing at the Quad Cities site.
1.3 The final site preparations shall include mast and vibration instrumentation installation and any modifications or testing up to and including the reactor instrument nozzle flange bolting, covered in this document.
2.0 APPLICABLE DOCUMENTS 2.1 Applicable Codes. Standards. The following documents form a part of this installation procedure to the extent specified herein.
2.1.1 ASME Boiler and Pressure Vessel Code, Section 111, forNuclear Power Plant components.
2.1.2 ASME Boiler and Pressure Vessel Code,Section IX, Welding Qualifications 2.1.3 National Electrical Manufacturer's Association (NEMA) Standards 2.1.4 Any Applicable Local Codes, Standards, Requirements, and Procedures required by the Quad Cities site.
0 GE Nuclear Energy 26A6492-NP REV. 2 SH NO. 4 OF 35 2.2 Reference Documents. The following documents may assist the user 2.2.1 23A6395, Reactor Internal Vibration Instrumentation Design Specification 2.2.2 209A7243P004, Clip for Vibration Test Instrumentation 2.2.3 112D4859, Test Brackets, Conduit Clamps with Bolted Latch 2.2.4 352B2248 Mounting Pads (2"x3",I"x2"), Conduit Clamp/Accel Mounts 2.2.5 143-104-000-D60 1, Pressure Transducer Type CP- 104 2.2.6 143-211 -000-D072, Pressure Transducer Type CP-2 11 (Internal) 2.2.7 809-104-000-DOI 1, Floating Clamp Nut Type MA- 104 (for CP-21 1) 2.2.8 144-901 -000-D50 1, Accelerometer Type CA-901 2.2.9 KHC-I0-120-G9, Kyowa Strain Gage (with 321SS Flange) 2.2.10 Reuter-Stokes Outline RS-E8-1000-208 String Assembly A (A,B,C,D) 2.2.11 Reuter-Stokes Outline RS-E8-1000-209 String Assembly B (E,F,G,H) 2.2.12 Reuter-Stokes Outline RS-E8-1000-210 String Assembly C (J,K,L,M) 2.2.13 234C6971, Mast Assembly with Welded Parts 2.2.14 284X898, Mast Master Parts List 2.2.15 234C7084, Mast Assembly with Parts List 2.2.16 234C7001, Mast Base Arrangement on the Dryer (Dryer Weld) 2.2.17 343A2292, Lock Washer for Mast Clamp (Matl Inconel X-750L) 2.2.18 QC2 Penetration Bolt & FIV Sensor String Design Spec.
2.2.19 QC2 FIV Instrument Flange Design Specification 2.2.20 E8-1000-203-81, Reuter-Stokes Washer for Penetration Bolt 2.2.21 E8-1000-208-74, Reuter-Stokes Nut for Penetration Bolt 2.2.22 26A6159, Dyn Press & Vib Monitor Sys, RPV Penbolt Assy Design Spec 2.2.23 P50YP102, Arc Welding, Austenitic Stainless Steel Process Specification 2.2.24 21A8675, Resistance Spot Welding (RSW) of Strain Gages 2.2.25 26A5975, Instrument Flange Design Specification 2.2.26 P5OYP211, Cleaning and Cleanliness Control of Reactor Sys Components 2.2.27 P5OYP215, Capacitor Discharge Resistance Spot Welding (RSW) 2.2.28 E50YP38, Resistance Spot Weld, Peel Test 2.2.29 234C7124, Pressure Sensor Mount Bracket (6" cover, I-slot, CP-104) 2.2.30 234C7125, Pressure Sensor Mount Brkt (6" cover, 2-slots, CP- 104/CP-211) 2.2.31 234C7126, Pressure Sensor Mounting Pad for Dryer Hood Covers (flat ring) 2.2.32 234C7127, Presssure Sensor Mounting Pad for Dryer Skirt Covers (RI 19.5")
2.2.33 234C7128 Sh 1, Pressure Sensor Mounting (CP104 inside cover) 2.2.34 234C7128 Sh 2, Pressure Sensor P23 Skirt Mounting Pad for CP-104 2.2.35 352B2245, Nut Lock CP-211 for Floating Clamp Nut at P13, P14 2.2.36 EEI-10-1010010, Flange Mockup Stand (Tripod type stand) 2.2.37 E8-1000-208-81, Instrument Flange (with 3 holes on 3.00" B.C.)
2.2.38 26A6484 Functional Test Procedure for Sensors in String Assembly 2.2.39 26A6499 Data Acquisition System Installation and Test Procedure 2.2.40 26A6274 Steam Dryer Fabrication Specification 2.2.41 E8-1000-203-72, Reuter-Stokes Gasket for Penetration Bolt
26A6492-NP SH NO. 5 GE Nuclear Energy IREV.2 OF 35 _
2.3 Supplemental Documents. The following documents may assist the user to understand the installation and testing procedure to the extent specified herein.
2.3.1 GE-NE-0000-0030-1244-01, Steam Dryer Instrumentation Philosophy 2.3.2 124D 15 18, New Steam Dryer, Top Assembly 2.3.3 26A6380, Dryer Hammer Test Specification 2.3.4 105E3902, Instrumentation and Data Acquisition Wiring Diagram 2.3.5 26A6366, FIV Sensors, Signal Conditioner & Data Acq Sys for Dryer Test 2.3.6 352B2191, Penetration Bolt A, Sensor String Drawing 2.3.7 352B2192, Penetration Bolt B, Sensor String Drawing 2.3.8 352B2193, Penetration Bolt C, Sensor String Drawing 2.3.9 25A5900, Foreign Material Exclusion Design Specification 2.3.10 WPS-8.43.3/PQR-27, Weld Austenitic SS and Inconel 2.3.11 22A4202, Rx Assy, Welding, Cleaning, Exam, and Storage Specification 2.3.12 26A5734, Reactor Internals Modifications, Fabrication Specification 2.3.13 Welding of CP- 104 (P23) to Mounting Pad Attached to Skirt with Hole 2.3.14 26A6443, New Steam Dryer Installation Specification 2.3.15 Reuter-Stokes E8-1000-208-l l OX Conduit Clamps (A=1, B=2V, C=2H) 2.3.16 Steam Dryer with Vibration Instrumentation Modification Drawing (later) 2.3.17 Kyowa Strain Gage - Construction, Features and Gage Installation 3.0 MATERIALS REQUIRED (AT QUAD CITIES SITE) 3.1 The following Table I is a list of items required for installation of the steam dryer.
TABLE 1 - List of Required hardware and Equipment ID ITEM DESCRIPTION Ref ID Dwg# Qty Supplier/Resp Notes 1 New Dryer w/ Instruments+Mast 234C6821 f[ General Electric (Draft) 2 Mast Assembly and Parts List 234C7084 General Electric 3 Mast Mounting Fastener-Screw I 343A2289 General Electric 4 Mast Mounting Fastener-Screw 2 343A2290 General Electric 5 Special Hex Nut (Jam Nut) 343A2291 General Electric 6 Mast Clamp, Star Washers, X-750L 343A2292 General Electric No tack weld
___reg
___ ____ 'd 7 Mast Mounting Fastener-Screw 3 343A2293 General Electric 8 Washer, I"ODx.53"lDx.09" 304L 343A2294 General Electric 9 Penbolt (Nuts, Gaskets, Washers) E8-1000-208-98 Reuter-Stokes 2 of each per kit 10 Instrument Flange Spec (new 3- 26A5975 Reuter-Stokes I spare as
_ hole) backup I Mockup Flange Supt Std xv/ Clamps N.A. General Electric 12 Penbolt Nut Crowfoot N.A. General Electric 13 Flange Lifting Bail N.A. General Electric 14 Instr Nozzle N6A Fig Fasteners N.A. Exelon Site Suppl. Re-use from disassy 15 RPV Hd/Gasket/Studs/lnsulation N.A. Exelon Site Suppl. Re-use from I 11 disassy
0 GE Nuclear Energy 26A6492-NP 1REV. 2 SH NO. 6 OF 35 _
3.2 Table 2 is a list of requested equipment/material, for use at site during installation.
TABLE 2 - List of Equipment and Materials at Site ID ITEM DESCRIPTION REF ID/DWG No. QtO SUPPLIER/RESP NOTES I Torque Wrench, 3/4" Drive, 0-250 fl-lb. N.A. I Exelon Site Supplied With Calibrat'n Certs 2 Tack Welder and Weld Rods, Cert A.R. N.A. AR Exelon Site Supplied Re-use from disassy 3 O/H Crane, Rigging, Slings, N.A. AR Exelon Site Supplied Re-use from disassy Shackles,etc 4 RPV Head/GasketlStudsflnsulation N.A. AR Exelon Site Supplied Re-use from disassy 5 Work Platform/Planks for Top of Dryer N.A. AR Exelon Site Supplied Re-use scaffold plank 6 Ladder or Work Scaffold w/ Planks N.A. AR Exelon Site Supplied Top Mockup Access 7 Personnal Protective Device, Rad Monit. N.A. AR Exelon Site Supplied Site/OSHA Re mts.
3.3 Table 3 is a list instruments and materials installed on the newv steam dryer at the vendor's shop. Quantities listed are total supplied at the vendor shop, not as-built.
TABLE 3 - List of Installed Vibration Hardware ID ITEM DESCRIPTION REF ID / D'G NO. Qty SUPPLIER/RESP NOTES 1 VIB Sensor String wI Certificate RS-E8-1000-208 (( Reuter-Stokes Certs with QC 2 VIB Sensor String w/ Certificate RS-E8-1000-209 Reuter-Stokes Certs with QC 3 VIB Sensor String w/ Certificate RS-E8-1000-210 Reuter-Stokes Certs with QC 4 5 Tube (Conduit) Bracket Assembly 112D4859G002 Reuter-Stokes Need as-built qty 5 4 Tube (Conduit) Bracket Assembly 112D4859G003 _ Reuter-Stokes Need as-built qty 6 3 Tube (Conduit) Bracket Assembly 112D4859G005 Reuter-Stokes Need as-built qty 7 2 Tube (Conduit) Bracket Assembly 112D4859G004 Reuter-Stokes Need as-built qty 8 Conduit Clamp (Single Tube) E8-1000-208-1 10A Reuter-Stokes Need as-built qty 9 Conduit Clamp (Double-Vertical) E8-1000-208-1I OB Reuter-Stokes Need as-built qty 10 Conduit Clamp (Double-Horizontal) E8-1000-208-1 IOC Reuter-Stokes Need as-built qty I Pad 3- Permanent 2"x3"x114" 304L 352B2248P003 General Electric Certs with QC 12 Pad 4- Permanent l"x2"x114" 304L 352B2248P004 General Electric Certs with QC 13 Clips - for RSWelding Ml Cable 209A7243P004 General Electric Certs with QC 14 Mast Bracket for Press Assy (P26) 234C6976 General Electric 15 Mast Bracket Assy (Conduit Clamp) 234C6983 General Electric 16 Mast Gusset Bracket (5-Cond Clamp) 234C6987 General Electric X _ _ _ _
17 Mast Base (Main Base on Bank D) 234C6996 General Electric 18 Long Gusset Base (Base on Bank C) 234C6997 General Electric 19 Union Support Bracket (Block Hl) 234C6982 General Electric 20 Pad 2-Mast Mounting Bases 234C6994 General Electric _
21 Pad 1-Mast Gusset Mounting Base 234C6995 General Electric 22 Mast Base Arrangement-Dryer Weld 234C7001 General Electric 23 Cover Plate 6" Dome (single slot) 234C7124 General Electric Certs with QC 24 Cover Plate 6" Dome (dual slot) 234C7125 General Electric Certs with QC 25 Sensor Mounting Pad (flat ring) 234C7126 General Electric Certs with QC 26 Sensor Mounting Pad (skirt RI19.5") 244C7127 General Electric Certs with Qf; 27 Skirt Pad, Mounting (P23, CP104) 352B2246 General Electric Certs with QC 28 Nut Lock CP21 I (Inside P13, P14) 352B2245 11 General Electric
26A6492-NP SH NO. 7 0 GE Nuclear Energy IREV. 2 OF 35 4.0 RESPONSIBILITIES 4.1 The Installer shall accept responsibility for one's work. The Installer shall comply with the requirements of this document and the supporting documents listed herein.
4.2 The Installer shall take responsibility for coordination of one's work with others, including the coordination of work planning and radiation monitoring with the Plant Owner.
4.3 The Installer shall be responsible for providing any specialized handling, alignment, and installation equipment, as may be necessary to perform this work, except as otherwise agreed to by the Plant Owner.
4.4 The Installer shall supply qualified personnel for supervision and for performing the required tasks to complete the installation of the new instrumented steam dryer.
5.0 REQUIREMENTS (PRE-INSTALLATION) 5.1 The new steam dryer work area for the final installing of the vibration instruments shall be reviewed for safety and compliance with site practices and procedures.
5.2 The dryer shall have safe access for personnel (i.e. erecting scaffolding, handrails, or providing ladders for access, etc). The top shall be reviewed for use of a work platform (perhaps same as used at vendor's shop or aluminum scaffolding planks if acceptable).
Handrails and other personnel protective safety devices and items, including radiation monitors, shall be provided as required.
5.3 Overhead crane(s) shall be operable and available for use during the vibration installation, along with slings, shackles, chainfalls, rope and other rigging devices.
5.4 The top of the dryer shall be accessible for re-mounting vibration instrumentation routed on top of the dryer and up along the mast and finally up through the nozzle to the instrument flange of nozzle N6A. The top work platform requires some sections be removable for any required work access or inspection.
5.5 The area shall be approved for potential welding and tack welding fasteners and for any resistance spot welding (RSW) of clips for mineral insulated (Ml) cable or strain gages if required. Tarps or other site approved material shall be used to control debris generated from any required welding and final installation.
5.6 The dryer surface and installed vibration instrumentation should minimize contact wvth non-reactor approved materials. This includes tooling, test equipment, hand tools,
26A6492-NP SH NO. 8
- GE Nuclear Energy l EV. 2 OF 35 rigging, lifting devices, etc. Follow station FME system or procedure which may include a specific area designated to control such items.
5.7 Immediately after vessel head removal, it is critical to check the blank instrument flange seal of nozzle N6A. This is to verify the new supplied instrument flange has the correct small tongue groove for proper seal with supplied gasket when the reactor vessel head is re-installed later in the outage. Verify it with the correct supplied instrument flange or immediately send the spare blank unmachined flange to a machine shop to have it properly machined before vessel reassembly.
5.8 An aluminum mockup instrument flange (with the three penetration bolt slots) is used with the flange mockup support stand for proper positioning, orientation and elevation.
The stand is a tripod, temporarily attached to brackets on top of the dryer using SS C-clamps. Note orientation is not critical, original design had penetration-B bolt hole facing -0 degree azimuth, penbolt-A facing the -120 deg azimuth and penbolt-C hole facing the -240 degree azimuth. The mockup is designed with a nozzle opening of
)). See mockup flange support (tripod) and the new instrument flange for N6A nozzle below.
- 6A6492-NP SIH NO. 9 GE Nuclear Energy REV. 2 OF 35 Dryer with Mockup Flange Support Stand Temporarily Attached C0/
0 GE Nuclear Energy 26A6492-NP REV. 2 SH] NO. 10 OF 35
((
Nozzle N6A Instrument Flange
f 26A6492-NP SH NO. I I GE Nuclear Energy IREV. 2 OF 35_
5.9 Receiving the steam dryer from the fabricator with partially installed vibration instrumentation due to the height of the mast and sensor strings at the site will require re-installing the sensor strings, mast, final torque and clamp conduit clamps. Once received, all protective transport tiedown and support hardware must be removed and receiving inspection performed. Use 3/8" or 1/2" double braided nylon rope and tackle or chainfall and dynamometer to slowly and carefully raise the string assembly only one time, without applying excessive tension or bending of any conduit, from the horizontal to the vertical position.
5.10 A second crane is required to raise the mast assembly for installing into brackets welded to the dryer, using screws for attachments. The mast has an estimated total assembly weight including base and fittings of approximately 345 pounds.
5.11 An overhead lift system (approximately 1000 pound capacity) is required to raise the mockup flange support stand (tripod) into position, clamped to brackets on top of the dryer.
5.12 Installation Staging. Tooling, tools, mast and parts, mockup flange support stand, instrument flange with three (3) penetration bolt holes and associated equipment shall be staged for installation.
5.13 Receiving Inspection. Perform functional receiving inspection per Reference 2.2.39 for all sensors installed on the new steam dryer prior to final installation.
5.13.1 Perform receiving inspection of strain gages and record test results.
5.13.2 Perform receiving inspection of accelerometers and record test results.
5.13.3 Perform receiving inspection of pressure transducers and record results.
5.13.4 Receiving inspection report shall be given to QC for record keeping.
5.14 Preparation for Installation.
5.14.1 Prepare installation activity and review safety work plan, schedule.
5.14.2 Clean the dryer surface per specification of Cleaning and Cleanliness Control of Reactor Systems Component before installing and maintain cleanliness during and following final installation, including any foreign material exclusion (FME) concerns, Reference 2.3.9.
5.14.3 Confirm safe working area ready with platform and scaffolding setup.
26A6492-NP SH NO. 12 k0 GE Nuclear Energy IREV. 2 OF 35 5.14.4 Complete required training of conduit benders, welders, RSW personnel if required, torquing, any electronic test equipment, and other required tasks.
5.14.5 Stage available materials with certification (i.e. mounting pads, cable clips for spot welding, conduit clamps, pads, proper weld rods issued for stainless or Inconel welding, torque wrench/crowfoot for penbolt nut, etc).
5.14.6 Review daily work plan, pre-job review, schedule, any specific site or project safety issues/procedures, any required personnel protective equipment, etc.
5.14.7 Quality - QA performed by QC Inspectors, note hold points for inspection and signoffs/acceptance before proceeding to final inspection.
5.14.8 Check if any special work permits are required, such as firewatch or burn permit for welding/RSW, etc.
5.14.9 Review top view of the dryer in Attachment A2, Figure A2-1 and note sensor locations. Also note the dryer orientation and dryer bank identification from Bank A through Bank F (from 90 to 270 deg side) and tie bar numbering from I to 5 (from 0 deg to 180 deg side).
5.14.10 Attachment A2, Figure A2-2 is a top view showing the N6A instrument nozzle flange in relation to the mast on Bank C. Confirm nozzle N6A is (( )) from center of vessel head on 0 deg azimuth. Location of the mockup flange center may be checked using a plum bob. The nozzle center is (( )) to the mast center.
Also see Detail B in Attachment Al, Figure 2. Attachment Al Figure 3 shows the
(( )) N6A instrument nozzle elevation.
5.14.11 Complete welder qualification for Austenitic Stainless and Inconel welds only if required.
5.14.12 RSW qualification peel test is required, only if any modification or more Ml cable clips are required, testing per Reference 2.2.28, peel tests per paragraph 4.1.4.
5.14.12.1 A minimum of 6 peel tests required to qualify procedures.
5.14.12.2 A minimum of 3 peel tests to qualify each RSW operator.
5.14.12.3 Peel tests performed and accepted per criteria per Reference 2.2.28.
5.14.12.4 Production clip RSW peel testing to be performed at every production start and stop.
26A6492-NP SH NO. 13 GE Nuclear Energy 1REV.2 OF 35 5.14.12.5 All peel test coupons shall be visually inspected and conform to requirements, Reference 2.2.28, paragraphs 4.1.3 and 4.1.4. QC shall document and put into records package.
AM Do 1 0 1 Fl:
4 SPOT WELDING SEQUENCE 5.14.13 ((
))
5.14.14 Prepare mockup stand for supporting nozzle and instrument flange. Note proper orientation and attachment of the flange, penbolt-B facing -0 deg azimuth.
5.14.15 Check the dryer mast Master Parts List Reference 2.2.15 for required hardware.
26A6492-NP SH NO. 14 GE Nuclear Energy I REV. 2 OF 35 _
5.14.16 Do not use any temporary SS bolts used at the vendor's shop for fitup. Use only the new supplied SS bolts for one time use only, With wvashers and special hex nut (am nut), with no final tack weld required.
5.14.17 The RPV head and head gasket must be elevated or supported such that tag lines of steel cable or rope can pass through the nozzle out the bottom of the vessel and through the vessel gasket.
5.14.18 Hardware installation sequence and parallel work procedures may be changed with the approval of the site responsible engineer or site project manager, provided the change does not compromise quality or integrity in providing dryer vibration data during reactor startup operation.
26A6492-NP SH NO. 15 GE Nuclear Energy IREV. 2 OF 35 6.0 INSTALLATION PROCEDURE (Mast, Strings, Dryer, Flange, RP%7, Insulation)
Review mast assembly, parts list, instructions, bolt torque, location and orientation on top of dryer bank, vertical angular position and tolerances shall be specified on drawings or contact responsible engineer. The mast installation shall be coordinated with slow and careful one time lifting of the sensor strings and installing the instrument flange on the mockup stand (tripod), used to support the three vibration strings for final string installation, performed with the new steam dryer. The final reactor pressure vessel head is installed per a separate Reactor Re-assembly Procedure.
6.1 ((
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6.2 ((
6.3 ((
6.4 ((
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6.5 ((
6.6 ((
6.6.1 ((
0 GE Nuclear Energy 26A6492-NP I REV. 2 SH NO. 16 OF 35 _
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Penetration Bolt with Gasket, Washer and Nut Installed 6.7 ((
Il
26A6492-NP SH NO. 17 GE Nuclear Energy REV. 2 OF 35 6.8 (( 11 6.9 6.10 [I II 6.11 ff MAST ON TOP OF DRYER
26A6492-NP SH NO. 18 GE Nuclear Energy I REV. 2 OF 35 6.12 ((
1]
3-WAY PENBOLT MOCKUP FLANGE 6.13 ((
6.14 ((
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26A6492-NP SH NO. 19 GE Nuclear Energy REV.2 OF 35 6.15 ((
6.16 f[
11 6.17 ff
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6.18 ff 6.19 ((
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6.19.1 ((
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11 6.19.3 ((
26A6492-NP SHi NO. 20 GE Nuclear Energy l REV. 2 OF 35 6.19.4 The recommended and minimum bend radii for Ml cable are given below:
Sensors MI Cable OD Recommended Minimum IBend inch (mm) Bend Radius Radius inch (mm) inch (mm)
Pressure Transducers _ [I Accelerometers Strain Gages I]I I]II Note 1: Going below the minimum bend radius can lead to sensor failure. QC needs to verify. GE and Exelon need to approve any deviations.
Note 2: Bending of Ml cable has to be made carefully and should not be repeated in the same area.
Note 3: Do not bend Ml cable within 0.2" (5 mm) from the enlarged connection near strain gages to prevent damage to the silver brazing.
Note 4: RS-E8-1000-2xx calls out min bend radius of 1.0" for MI cable.
Note 5: Use recommended cable bend radii as much as possible unless there are circumstances that can not be overcome or there are compelling reasons.
6.20 ((
6.21 Final check shall be made to assure all sensors strings are firmly attached, all excess conduit and cables are securely attached. Spot check clamps are secured with bolts locked with bent tabs. Check the pressure transducer on the mast (P26) and its cable are firmly attached. QC to make final check to assure all items are secure.
6.22 Update the final inventory listing of installed vibration string mounted hardware, by counting the number of cable clips, conduit clamps by type, pads by type, the mast mounting screws, "star tab locking" washers, flat washers and jam nuts used.
6.23 The dryer cleanup may require'general cleanup of any loose debris or materials.
26A6492-NP SH NO. 21 GE Nuclear Energy IREV. 2 OF 35 6.24 Photographs may be used to document the final installation configuration. Digital stills are preferred over film for convenience by including them in the final report.
Videotaping is not required.
6.25 Final installed sensors are to be functionally tested prior to reactor vessel head re-installation per Reference 2.2.39, with results recorded and given to QC.
6.26 QC to approve final instrumentation installation of the three sensor strings before proceeding.
6.27 Prepare each penetration bolt for installation of the instrumented dryer into the vessel.
6.28 Remove the mockup flange support stand from the dryer to install the dryer strongback.
6.29 Unspool the LEMO connector and approximately 50 feet of cable for each penbolt.
6.30 Remove the mockup flange requires removing the temporary nuts and washers. Use two wrenches to keep the penbolt from tuning, one on the upper penbolt flats and the other wrench or crowfoot wrench to untorque the penbolt nut. Penbolt rotation can damage the sensor strings with some components brazed. Remove the nut and both washers of each penbolt. Support the cables from above. Discard the temporary SS nut if used and the temporary flat SS washer but save the recessed SS washer for reuse.
Continue for all 3 penbolts.
6.31 Remove each penbolt from the temporary aluminum flange. Some rotation of the penbolt mockup flange assembly may be required to remove each penbolt. After all three penbolts have been removed, discard the mockup flange, loosen and lift legs, remove the C-clamps and support cables along with the mockup support stand (tripod).
The 3 penbolt string assemblies and spools of cables are supported from above.
6.32 All items cleared from the dryer. Final documentation for vibration installation shall be completed. Final dryer cleaning performed, and dryer now prepared for installation.
6.33 Install the new instrumented steam dryer. Refer to the new Steam Dryer Installation Specification, Reference 2.3.14. This requires rigging for installation into the RPV, fitup, removal from the RPV, final field adjust the lifting lugs, torquing the captive nut and proceed with final installation of the instrumented steam dryer into the RPV, after final documentation and cleaning. The installer must carefully monitor and control the proper slack to assure no hangup during installation or removal of the dryer and later strongback removal from the dryer.
6.33.1 Lifting the dryer with the mast and all instrumentation will have approximately 20" interference with the bridge of the overhead crane without bending the 3 string
26A6492-NP SH NO. 22 0 GE Nuclear Energy REV. 2 OF 35 assemblies and spooled cable, perhaps requiring one or more mast conduit clamps to be released and later reinstalled, torqued and locking-star washer tabs bend to secure the clamp from personnel basket and use of FME tarp to catch any potential dropped lose part. The dryer installation to be completed before continuing.
6.34 Remove the steam dryer strongback per reactor re-assembly procedure. This requires supporting the sensor strings and cables from above. Note: Do not let the LEMO cables get wet.
6.35 Install two zoom pan and tilt cameras to assist installer in monitoring the next sequence of vessel head installation. Camera-I shall be determined by the installer for best view from inside, near the bottom or below the N6A nozzle, to best monitor the movement of the RPV head until the head is near orjust onto the vessel studs. It can be removed and remounted or have camera-2 mounted above on the RPV head strongback, to monitor the final lowering and pulling of the strings up through the nozzle. It will be critical to assist the installer in coordinating the lowering of the RPV head by the crane operator.
6.36 Re-install the RPV head for closure of the vessel. Refer to QC-2 reactor re-assembly procedure to install the strongback onto the RPV head.
6.37 Prepare sensor strings for vessel closure. Use three stainless steel wire ropes (-1/8" dia SS cables as tag lines for the final installation). Insert from top down through the N6A nozzle and routed to the penbolt, loop through the bottom of the penbolt between the conduits and back up through the nozzle and out, and attach both ends together. Each tag line is looped for ease in later removal. Continue for the second wire/cable to 2nd penbolt and finally a 3rd looping wire/cable to the final penbolt.
6.38 Unspool the LEMO connectors and approximately 50 feet of cable for each penbolt and loosely secure to the steel tag line, used as a strain relief when pulling up on the three penbolt bundle. Care should be taken not to apply excessive tension to the cables.
Complete for all three penbolt strings.
6.39 Bundle all three penetration bolts assemblies together, with smooth tapered clamshell device or add duct tape to minimize or eliminate any edge hangup during installation without damage, so all three can be safely inserted by pulling up and through the
(( )) of the N6A nozzle opening. (Alternate: tie all 3 penbolts together with one tagline).
Special Note: Penbolt C, L-string, LEMO connectors AI and A2 must be taped to force stagger one behind the other to clear the penbolt opening, (( )) in the instrument flange. This is the only location as all other cables have sufficient connector stagger.
26A6492-NP SIH NO. 23 W GE Nuclear Energy I REV. 2 OF 35 6.40 Install the RPV head aasket, referring to the separate outage procedure 6.41 The RPV head must be installed onto the correct 'essel stud with N6A facing 0 deg.
The RPV head movement must be carefully coordinated with the installer in providing proper slack or tension in the bundled tag line(s) to the bundled three penbolt string.
6.42 The RPV head must not be rotated during installation without careful coordination with the installer of the strings monitoring from the remote camera. Once the RPV head is over the head studs in the proper orientation, carefully and slowly lower over the vessel head so the installer can take up slack in the tag lines. Note, RPV head rotation, exessive tagline slack or excessive tension can cause damage the penbolt strings or mast. Once the head is engaged in the short vessel stud, it will eliminate further rotation of the RPV head.
6.43 Maneuver and lower the RPV head carefully and slowly, coordinated with the installer using the camera monitor to take up slack in pulling the three bundled sensor strings up through the instrument nozzle N6A.
6.44 Once the RPV head is set and instrument flange is installed, the RPV must not be lifted without potential damage to the instrument strings.
6.45 The cables must be "threaded" through the penetration hole in the instrument flange.
6.46 Install the instrument nozzle flange gasket.
6.47 Separate the three penetration bolts for instrument flange installation.
6.48 Carefully pull the LEMO connector and cables through the proper hole in the instrument flange. Remove any tape or device attached to provide single smooth stagger of LEMO Al and A2 through the flange opening.
6.49 Attach the flange bail or use wire rope or cable to carefully lower the instrument flange into position while guiding each of the 3 penbolts through the proper hole and also aligning the 12 flange bolts. Minimize flange rotation to prevent damage to any conduit attached to the penbolt. Flange installation orientation is not critical.
6.50 Install the 12 instrument flange bolts. Torque to required torque specified in a separate reactor re-assembly procedure. Clean area of any lubricant.
6.51 Next remove any tape or any smboth insertion device installed, cut and remove cable or wire while holding onto the top of the first penbolt.
0 GE Nuclear Energy 26A6492-NP l REV. 2 SH NO. 24 OF 35 6.52 Then install the SS washer, Reference 2.2.21. Note orientation, with the recess installed facing up towards the nut.
6.53 ((
6.54 Calibrate the torque wrench input to provide a crowfoot output of ((
)) Use this value to torque the penbolt nut below, without use of any thread lubricant.
6.55 Take care when tightening the nut such that the penetration bolt does not rotate by using a wrench to hold the flats on the penbolt end while the certified and calibrated torque wrench with crowfoot is used to tighten the penbolt nut (Reference 2.2.22) to a final torque of 153 +/- 2 ft-lbs. QC to verify. Continue with all three penbolts. Record the three torque readings.
CROWFOOT FOR PENBOLT NUT 6.56 Continue with reactor re-assembly. Re-install the mirror insulation. Add appropriate insulation of the bundled 42 cables exiting the N6A instrument flange to retain reactor heat.
6.57 The 42 cables should be untwisted and all run in parallel with acceptable cable bundling towards the jumper to Junction Box I, outside the manway. Periodic suitable bundled cable ties and support is acceptable. A cable tray is not required.
6.58 A final resistance measurement of each sensor shall be performed prior to startup. The results shall be recorded and given to QC.
6.59 A final check shall be made to locate all hardware and any anomalies noted and the area cleared. Final test data shall be recorded and a copy given to QC for project file
S GE Nuclear Energy l 26A6492-NP l REV. 2 SH NO. 25 OF 35 record keeping. Red line changes shall capture the final procedure and locations, inventory list updated, to maintain as-built records, documented on the modification drawing.
6.60 QC to confirm all data and status approved to confirm continuing. This concludes the installation procedure of the new instrumented steam dryer. The next phase is system checkout, in preparing to record data during startup.
A26A6492-NP S1HNO. 26 GE Nuclear Energy REV. 2 OF 35 7.0 QUALITY ASSURANCE Quality Control Representatives shall provide surveillance and document the work performed for this modification, as necessary, to assure that the requirements of these procedures have been met.
This modification shall be accomplished under an Exelon approved QA program.
The completed (as-built) modification shall be documented by sketches and photographs.
Videotaping is not required for visual inspection. As-built documents (e.g. captured inspection images, sketches or drawings) of the final modificatin configuration shall be filed in the GENE design record file.
Any deviations, substitutions, modifications of materials, engineering procedures or design shall be submitted by the installer to GENE Engineering for concurrence.
7.1 Sensor Records: The following records should be prepared for each sensor.
7.1.1 As-installed sketch or drawing. The as-installed location and orientation of all sensors should be confirmed by a description, sketch, or updated drawing, documenting location and orientation, or a statement that they are in accordance with issued drawings. Photographs shall be taken of all sensors, their mounts, locations and routings, showing mounting hardware (cable clips and conduit clamps) to document the final configuration.
7.1.2 Sensor data sheets and calibration information.
7.1.3 Sensor element and insulation resistance recorded at different times during the installation 7.2 QA shall provide a final report of all documents filed for record keeping.
7.3 The steam dryer with vibration instrumentation installed and transported and with final instrumentation installed on the new steam dryer at Quad Cities shall also be performed per the GENE QA requirements, in addition to the requirements of the Quad Cities site.
7.4 The project QA report shall include documents of installation and any testing in documenting the final dryer configuration, plus the reporting of any non-conformance documentation.
7.5 Final report shall be provided follIowing the completion of the project.
I26A6492-NP SH NO. 27 GE Nuclear Energy REV. 2 OF 35 STEAM DRYER ['IBRATIONASTRINGS Attachment A Figures (Computer Aodlel Layouts, Sketches)
These are listed for reference in viewing computer model showing string routing on the dryer:
Attachment Al Figure I - Layout of instrument nozzle, mast and top of dryer, elevation of (( )) from bottom of instrument flange to top of tie bars on the new steam dryer.
Figure 2 - Top view layout with Detail B showing dimensions from mast to instrument flange, with (( )) offset to Instrument Nozzle N6A.
Figure 3 - Elevation view showing instrument nozzle flange mating surface to RPV opening, with
(( )) opening and elevations of (( )) to flange top.
Attachment A2 Figure A2. 1 - Dryer Sensor Locations - Top View Figure A2.2 - Vessel Dryer - Top View Figure A2.3 - Dryer Sensor Locations - Elevation View of 90 Degree Face Figure A2.4 - Dryer Sensor Locations - Elevation View of 180 Degree Face Figure A2.5 - Dryer Sensor Locations - Elevation View of 270 Degree Face Figure A2.6 - Dryer Sensor Locations - Elevation View of 0 Degree Face 4
26A6492-NP SH NO. 28 GE Nuclear Energy IREV. 2 OF 35 STEAMIl DR YER VIBRATIOA' STRINGS Attachmewt A, Figures (ComputerAModel Layouts, Sketches)
These are listed for reference in viewing computer model showing string routing on the dryer:
Attachment Al
((
Figure I - Layout of instrument nozzle, mast and top of dryer, elevation of (( )) from bottom of instrument flange to top of tie bars on the new steam dryer.
4
26A6492-NP SH NO. 29 GE Nuclear Energy REV. 2 OF 35 Attachment Al
((
11 Figure 2 - Top view layout with Detail B showing dimensions from mast to instrument flange, with (( )) offset to Instrument Nozzle N6A.
l 1]
Figure 3 - Elevation view showing instrument'nozzle flange mating surface to RPV opening, with R[ )) opening and elevations of (( )) to flange top.
0 GE Nuclear Energy 26A6492-NP REV. 2 SH NO. 30 OF 35 ATTACHMENT A2 FIGURE A2-1: DRYER SENSOR LOCATIONS - TOP VIEW 1]
I
0 GE Nuclear Energy 26A6492-NP REV. 2 SH NO. 31 OF 35 FIGURE A2-2: VESSEL DRYER - TOP VIEWNI 180- -o0 INSTRUMENT NOZZLE FLANGE NGA 90-
'OP VIEW
0 GE Nuclear Energy 26A6492-NP REV. 2 SH NO. 32 OF 35 FIGURE A2-3: DRYER SENSOR LOCATIONS - 900 FACE
[I I]
26A6492-NP SHl NO. 33 l GE Nuclear Energy REV. 2 OF 3 I FIGURE A2-4: DRYER SENSOR LOCATIONS - 1800 FACE
0 GE Nuclear Energy 26A6492-NP REV.2 SF1 NO. 34 OF 35 FIGURE A2-5: DRYER SENSOR LOCATIONS - 2700 FACE
26A6492-NP SH NO. 35 GE Nuclear Energy I REV. 2 OF 35 FIGURE A2-6: DRYER SENSOR LOCATIONS - 0° FACE