Text

Response to Request for Additional Information Control of Heavy Loads Near Spent Fuel
	ML19030A698
Person / Time
Site:	Salem
Issue date:	07/21/1978
From:	Librizzi F; Public Service Electric & Gas Co
To:	Stello V; Office of Nuclear Reactor Regulation
References
	Download: ML19030A698 (58)
	v • d • e

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r*nrElnf n-rrmv nJlCt<ET FU [ COPV Public Service Electric and Gas Company 1~~lfil~i4~i. ~e~cfflk.- N~J. w0710r Phone 201/430-7000 July 21, 1978 Director of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Washington, D.C.

20555 Attention:

Mr. Victor Stello, Jr., Director Division of Operating Reactors Gentlemen:

CONTROL OF HEAVY LOADS NEAR SPENT FUEL NO. 1 UNIT SALEM NUCLEAR GENERATING STATION DOCKET NO. 50-272

.... /'~

PSE&G hereby transmits its response to your request for c*

information concerning control of heavy loads near spent fuel, dated May 17, 1978.

Should you have any further questions in this regard, please do not hesitate to contact us.

4Il 39 The Energy People Very truly yours,

~)1 / _;_'

/F--~~

F. P. Librizzi/ II General Manager -

Electric Production

~~\\\\

95-0942

QUESTION 1 Provide a diagram which illustrates the physical relation between reactor core, the fuel transfer canal, the spent fuel storage pool, and the set down, receiving or storage areas for any heavy loads moved on the refueling floor.

ANSWER This information has been provided in FSAR Figures 1.2.,...2, 1.2-3, 1.2.,...4 and 9.7-2.

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I QUESTION 2 Provide a list of all objects that are required to be moved over the reactor core (during refueling), or the spent fuel storage pool.

For each object listed, provide its approximate weight and size, a.diagram of the movement path utilized (including carrying height) and the frequency of movement.

ANSWER No loads heavier than the equivalent weight of the spent fuel assembly are moved over the spent fuel pool during refueling.

Objects that are required to be moved over the reactor core during refueling are described in the FSAR in response to Question 9.58.

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QUESTION 3 What are the dimensions and weights of the spent fuel casks that are or will be used at your facility?

ANSWER The actual dimensions and weight of the cask to be used at Salem is currently unknown.

The largest cask that can be used is approximately 88" in diameter, 204.5" long and weighs approx-imately 200,000 lbs. when loaded.

P78 61 49

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I QUESTION 4 Identify any heavy load or cask drop analyses performed to date for your facility.

Provide a copy of all such analyses not previously submitted to the NRC Staff.

ANSWER The physical arrangement of the Fuel Handling Building is such that the transfer pool is separated from the spent fuel pool.

The cask can travel only over the transfer pool.

For this reason, no cask drop analysis was required, nor was any performed.

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QUESTION 5 Identify any heavy loads that are carried over equipment required for the safe shutdown of a plant that is operating at the time the load is moved.

Identify what equipment could be affected in the event of a heavy load handling accident (piping, cabling, pumps, etc.) and discuss the feasibility of such an accident affecting this equipment.

Describe the basis for your conclusions.

ANSWER No heavy loads are handled over equipment required for the safe shutdown of the plant during the movement of fuel from the reactor cavity to the spent fuel pool or vice versa, or the move-ment of a cask.

The handling of fuel is all within the reactor cavity, fuel transfer canal and spent fuel pool.

The cask is moved only within certain areas of the fuel handling building.

No equipment required fo~ safe shutdown is located in any of these areas.

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QUESTION 6 If heavy loads are required to be carried over the spent fuel storage pool or fuel transfer canal at your facility, discuss

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the feasibility of a handling accident which could result in water leakage severe enough to uncover the spent fuel.

Describe the basis for your conclusions.

ANSWER A heavy load handling accident could not result in water leakage severe enough to uncover the spent fuel.

The maximum load car-ried over the spent fuel pool is that of a fuel assembly.

With the proposed increased capacity spent fuel rack modification installed, it is not possible to drop a fuel assembly on the spent fuel pool liner plate.

Other fuel handling accident con-siderations have been addressed in our February 14, 1978 submit-tal concerning the proposed spent fuel rack modification.

A spent fuel shipping cask drop could perforate the fuel trans-fer pool liner plate.

However, such an event would not result in loss of water from the storage pool, since the two are physical-ly separated as shown in FSAR Figure 9.7-2.

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QUESTION 7 Describe any design features of your facility which affect the potential for a heavy load handling accident involving spent fuel, e.g., utilization of a single failure~proof crane.

ANSWER The design of the Fuel Handling Building is such that it is physically impossible for a load greater than 5 tons to be carried over the spent fuel pool.

This is a result of both the physical arrangement of the Fuel Handling Building and load limits on the fuel handling crane.

Administrative con~

trols prohibit loads greater than that of a fuel assembly to travel over the spent fuel pool.

The maximum height at which a fuel assembly can be carried is restricted by limit switches on the crane to 15 inches over the top of the spent fuel racks.

The spent fuel racks have been designed to absorb the energy released by a fuel assembly dropping from 15 inches above them.

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QUESTION 8 Provide copies of all procedures currently in effect at your facility for the movement of heavy loads over the reactor core during refueling, the spent fuel storage pool, or equipment required for the safe shutdown of a plant that is operating at the time the move occurs.

ANSWER The Station Maintenance Department Procedure MSC entitled "Reactor Vessel Head and Internals Removal and Installaiion" is attached.

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QUESTION 9 Discuss the degree to which your facility complies with the eight (8) regulatory positions delineated in Regulatory Guide 1.13 (Revision 1, December, 1975) regarding Spent Fuel Storage Facility Design Basis.

ANSWER The Spent Fuel Storage Facility design conforms with the Regulatory Guide as described in the FSAR in response to Questions 9.10, 9.22 and 9.48, with the exception that the high radiation level instrumentation does not actuate the filtration system.

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1.0 PtrRPOSE f.'.J-_:~:-:::::~.:1;;c:=:

D::::;.._:;:::~2~::-

P?.8C::::~:..-P-E:.MSC REJ..C?OR VESS:::::... EE;._;: J.* x::

r:\\T:S~\\.hLS REMOVJ>..L AND INSTALLATION 1.1 The purpose of this procedure is to give the basic steps required to prepare the reactor vessel, reactor vessel internals and the refueling cavity for the fuel assembly and RCC element replacement.

2. 0 PRECAUTIONS 2.1 The radiation exposures shall be held as low as practicable during the refueling operation.

2.2 2.3 Hand tools used within the proximity of the open reactor must be fastened with a line to prevent their being lost inside the reactor vessel.

All personnel should be careful to avoid exposure to the underside of the reactor closure head.

2.4 The following items are not to be used when working on components of.the primary system:

1.

Carbon steel wire brushes

2.

Chlorinated solvents, e.g. trichlorethylene.

3.

Unapproved masking tape (other than use on protective clothing) 3.0 PREREQUISITES 3.1 The Reactor Coolant System has been brought to refueling shutdown conditions in accordance with Plant Operating Instruction I-3.9 and Refueling Instruction I-2.7.2.

3.2

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The follc~ins to~ls, fixt~reE and e~uip~ent have b8en chec~e~ for praF~= operation in accorcance ~iL~ instructions cor.tained in Volur:.e !I, Cha?te::- 9, a.r.C. reacy for use:

Eouipment

a.

~anipulator Crane

b.

Polar Crane

c.

Fuel Transfer System

d.

Drive Shaft Unlatching Tool

e.

Internals Lifting Rig

f.

Irradiation Sample Handling Tool

g.

Vessel Head Lifting Device

h.

Spring Scale

i.

Load Cell

j.

Load Cell Adapter

k.

Part Length Drive Shaft Unlatching Tool

1.

Stud Tensioners

m.

Stud Nut and Washer Carriers

n.

Spent Fuel Pit Bridge

o.

Spent Fuel Assembly Handling Tool

p.

RCC Change Fixture

q.

Guide Tube Cover Handling Tool

r.

Thimble Plug Handling Tool

s.

Part Length Drive Shaft Retainers

t.

Stud Hole Plugs

u.

Stud Hole Plug Handling Fixture

v.

Reactor Vessel Flange Protector

w.

Burnable Poison Rod Handling Tool Plant !ten l\\urrber FHSTFT FHSTDT FHSTIR FHSTIS FHSTHR FHSTSC FHHELC FHMELC FHSTPT RC.M.EST FHSTFT FH,STCF FHSTGT FHSTTP FJ:n.IBSP FID!EPF FHSTIR FHSTPH Rev. 0 l

cc 3.3

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MSC Special Preca~tions

a.

Care sho~ld be exercise~ when taking measure-ments for the elonsation readings for stucs to elirr.inate time consur:;ins corrections.

b.

No hammer blows shall be employed on the vessel or closure head.

c.

For bolt-up procedures prior to nuclear oper-ation, a vessel temperature of 70°F rnust be obtained before the closure studs are pre-stressed and the vessel is partially pressurized only (partial pressurization not to exceed 600 psig).

This minirnw;. temperature must be main-tained until after the closure head is unbolted.

A vessel te~perature of 99°F minimurr, must be main-tained before increased pressurization of the vessel above 600 psig.

For future pressurization after nuclear operation of the vessel, a temper-ature correction must be made for changes in the NDT of pressure containing parts.

d.

If partial bolt-up and partial pressurization are required, the vessel, closure head, and closure studs must be maintained at a minimum temperature of 70°F before even a partial bolt-up may be begun.

A partial bolt-up, which results in an average stud elongation not exceeding 0.013 +/- :g~~ inches, may be accomplished pro-vided the 70°F minimum temperature of the vessel, closure head ana closure studs is maintained.

This stud preload is adequate to properly seat the closure head for an internal pressure not exceeding 600 psi.

No pressure

-2a-Rev. 0

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c

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r..ay be appliec to tne vessel U."lless t~e ter..pe:::--

ature is 70°F, anc such pressur~ shall not exceed 600 psi unless the tenperature is 99°F or above.

For partial bolt-up see Table V.

After partial bolt-up has been achieved and the temperature has been raised to a minimum of 99°F, operational bolt-up may be accompliEhed in accordance with Table II.

e.

Keep all studs, nuts and washers in matched numbered sets and install them in the appro-priate holes in the reactor vessel.

Replace top closing screws {Pc. 049-04) in studs after tensioning operation is completed.

f.

Stud tensioners should not be pressurized

unless the stud tensioner puller bar is

.. completely engaged on assembled stud.

g.

The water level in the vessel should not be raised closer than six (6) inches to the vessel mating surface prior to tensioning the first six (6) stud bolts in bolt-up operations.

This is to preclude the possibility of trapping water between the two metallic 0-rings.

3.4 All Supervisors using this procedure shall read Mainte-nance Procedure MllF, nTool & Misc. Items, Cleanliness and Closure Inspection Control"; and, subsequently, insure th~t each person he supervises understands the cleanliness and tool control requirements to be used when performing the steps within this procedures.

The Supervisor shall sign his name, dating the signature, under the REMARKS section of this procedure's cover sheet signifying that the above actions have been completed.

-2b-Rev.* 5

4.1 Removal of Reactor Head and Internals

{l)

Disconnect, remove and store the rod drive cooling air supply system.

(2)

Remove and store the missile shield above the Steam Generato~s.

(3)

Disconnect the electrical cables from the rod drive mechanisms and store.

NOTE:

Do not disconnect the electrical cables for the part-length rods at this point.

(4)

Have the Performance Department dismantle the equip~ent on all instrumentation parts in accordance with the instruction outlined in References A-2.

(5)

Remove and store the reactor head removable insulation.

(6)

Install seal and lower the reactor vessel cavity seal ring to rest atop the support ring.

(7)

Secure the reactor vessel seal ring.

(8)

Lower the Stud Tensioners and all other necessary tools and equipment required to unbolt and remove the closure head, to the reactor flange elevatqr using the polar crane.

-~-

Rev. 0

MBC

( 9) that th~ re~ctor coolant system water level is crainec to four (4) inches below th~

reactor vessel closure seal line.

(10)

Have Performance Dept. retract all flux detectors ana thi~bles. Also remove the metal impact monitor system on Stud 132.

(11)

Attach the stud tensioners to the hoists on the head lifting device.

NOTE:

Care must be exercised when raising the stud tensioners to avoid contacting the head flange or the studs.

(12)

To unbolt the heac fro~ hydrostatic test conditions utilizing 0-rings, a three (3) pass procedure is recommended at the following pressures:

PASS lst 2nd 3rd PUMP PRESSU?-E 7100 psi 4700 psi O psi To unbolt the head from operating conditions utilizing 0-rings, a two (2) pass procedure is recommended at the following pressures:

PASS lst 2nd PUMP PRESSURE 4700 psi 0 psi Prior to each reauction of pressure the tensioners shoula be brought up to pressure until it is founa that the nuts are free and can be backed off.

The nuts should be backed Rev. 0

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MBC off ab~ut o~e t~~~ (equivalent to a~out six turns of the te:isio::-ie::- handle) and the pressure decreasea slov:ly.

When the desire:d intermediate pressure is reached, close the release valve on the tensioners and again seat the nut.

This will leave a lower inter-mediate load in the stud.

The order in which the tensioners are applied for disassembly is exactly the same order in which the tensioners were applied for bolt-up.

See Colu~~ 1, Tables I and II.

(13)

Remove the stud tensioner from the vessel flange, and place on the operating deck.

NOTE:

Care must be exercised when removing the stud tensioners to avoid contacting the head flange or the studs.

(14)

Raise the studs until they are clear of the head using a spring scale to assure that at least one-half of the stud weight is taken by the tensioner hoists.

When the studs are clear of the head, block them in that position.

NOTE:

Three studs 120° apart will have to be removed and placed into the stud carriers, then placed on the operating deck.

Install the alignment pins in flange holes 12, 28, and 44.

Install the three (3) sleeves and bottom tightly in ~heir respective holes using the sleeve wrench and torque to approxi-mately 40 ft. lbs.; the sleeves are identified by their respective hole number.

Assemble the collars and bearing plates to the alignment

-s-Rev. 0

UOf"'

pins usi~g th8 hex h~ad belts.

Install the 0-rings in the 0-ring grooves of the align~s~t pins using a lubricant.

Install the eye bolts in the top of the alignment pins.

Carefully install the assembled alignment pins into the proper holes being careful not to damage threads or bearing surfaces.

Engage the threads of the collar with the threads of the sleeve.

Use the bar to tighten the alignment pins to approxi-mately 25 ft. lbs. torque.

(15)

Install all refueling cavity underwater lights.

(16)

Remove all remaining tools and equipment from refueling cavity.

Check canal and cavity for cleanliness.

(17)

Remove and store the control rod drive mechanism seismic support columns.

( 18)

Erect a platform bridge on the head-lifting*

rig walkway for access to the part length drive mechanism.

(19)

Unlatch the part-length RCC element drive shafts from their respective part-length RCC elements using the Part-lencrth Drive Shaft Unlatching Tool suspended from the polar crane hoist.

(Refer to Part-length Control Rod Drive Shaft Unlatching Procedure.)

Secure the part-length drive shafts in the up position.

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Rev. 0

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MSC (25)

Lift the reactor closure head approximately 24 inches, checking for levelness as it is being lifted.

Chck guice studs to determine if binding is occuring.

PRECAUTION; Raciation measurements must be taken during this operation around the vessel flange to assure safe radiation limits.

(2 6)

Using a flashlight, verifl' that the RCC element drive shafts are free in the mechanism housings and were not raisec with the closure head.

This can be verified by source range nuclear instru-(2 7)

(2 8) mentation.

Evacuate all personnel from the refueling cavity.

Coordinate with Operations Dept. to flood the refueling cavity to a level just below the closure head.

(29)

Continue lifting the head and raising the water level as the head is being lifted, keeping the head above the water level.

CAUTION; Watch for any sudden increase in load, which would indicate binding or an interference.

-B-Rev. 0

UOf" (30)

Place two new reactor vessel closure gaskets around the closure head storage pad, before lowering head on to it.

(31)

As the water level approaches the top of th.e cavity, lift t.he reactor closure head out of the refueling cavity and place it on the storage pad.

PRECAUTION:

All personnel must be kept clear of the vessel head during movement across the operating deck.

The underside of the head is highly radioactive.

(32)

Raise the water level in the refueling cavity to the proper refueling level and turn on underwater lights.

PRECAUTION:

Lights must not be turned on until submerged in water.

(33)

Unlatch the RCC element drive shafts from their respective RCC elements using the Drive Shaft Unlatching Tool suspended from the manipulator crane hoist.

(Refer to Control Rod Drive Shaft Unlatching Tool Operating Instructions.)

NOTE:

Observe the top of the drive shafts for evidence of magnetic particle buildup on the disconnect button.

The particles will be attracted to components of the Drive Shaft Unlatching Tool and may cause the tool to jam or malfunction.

Therefore, these particles must be removed with a swab or magnet before using the tool.

-a-Rev. 0

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Re~ove drive shaft fro~ upper internals using the crive shaft unlatching tool.

(Refer to Control Ro~ Drive Shaft Vnlatc~i~g Tool Oner~tinc Instrvctiohs.)

(34)

Attach load cell to internals lifting rig and remove lifting rig from storage location using the polar crane.

(Re fer to Internals Removal and Installation Procedure.)

NOTE:

Prior to removal of the lifting rig f rorn the storage location, verify that the reactor vessel flange protector is securely fastened to

'the lifting rig.

(35)

Lower the internals lifting rig over the vessel guide studs until the rig is seated on the reactor internals.

(36)

Release the reactor vessel flange protector from the lifting rig.

(Refer to Internals Removal and Installation Procedure.)

(37)

Attach the lifting rig to the internals.

(38)

Slowly raise the internals asse~bly observing the total load indicated on the load cell.

(Est.

weight 147,500 Upper Internals, 341,500 Lower Internals.)

CAUTION:

Watch for any sudden increase in load, which would indicate binding or an interference.

(39)

Continue to raise the internals assembly slowly until it is clear of the reactor vessel.

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UOI"'

(~0)

J.:::vE t!-,E-i:-;t£:rr:c.ls a:::se:-:-~ly laterally to desisnat8d storage stand.

(41)

LowEr the intern~ls asserr~ly into the storage stand.

(42)

Remove load cell from lifting rig.

(Refer to Internals Lifting Rig Ooerating Instructions.)

(43)

Open fuel transfer system gate valve in the spent fuel pit.

(44)

Remove fuel a.ssemblies and RCC elements from the reactor as required.

(45)

If needea, remove the specified nu.'Tlber of irraciatio::-i sa:.:ple holder assemblies using the Irradiatior. Sa~ole Handling Tool attached to the plar.t crane.

(Ref er to Irradiation Samole Ea~dlinc Tool Oneratino Instructions.)

NOTE:

See Reactor Vessel Radiation Surveillance Program Report for sample removal schedule.

4.2 Installation of Internals and Reactor Head (1)

Close fuel transfer system gate valve in the spent fuel pit.

(Refer to Fuel Transfer System Operatinq Instructions.)

(2)

Attach load cell to internals lifting rig using the polar crane.

(Refer to Internals Lifting Rig Operating Instructions.)

(3)

Raise the upper internals assembly slowly out of stand.

Rev. 0

MBC

(')

Move intEr~als esse~bly lat~rally over reacto~.

(5)

Lower the internals slo0ly over the guide studs and into reactor vessel, while observing the total louc indicated on the load cell.

CAUTION:

Watch for any sudden decrease in load, which would indicate binding or an interference.

(6)

Continue to lower the internals assembly slowly until the internals are seated in vessel.

(7)

Disconnect the internals lifting rig from the internals asserr~ly and connect the reactor vessel flange protector to the rig.

(Refer to Internals Removal and Installation Procedure.)

(8)

Remove the internals lifting rig and reactor vessel flange protector, and store in proper location.

(9)

Remove load cell from lifting rig.

(10)

Relatch the RCC element drive shafts to their respective RCC elements using the drive shaft unlatching tool suspended from the manipulator crane hoist.

(Refer to Drive Shaft Unlatchino Tool Operating Instructions.)

(11)

Unfasten and remove the two used reactor vessel closure gaskets from the closure head.

NOTE:

The gaskets must be cut in half and then removed from the storage pad area.

(12)

Clean and inspect the surface of the two new reactor vessel gaskets. Rev. 0

(13)

Thoro~s~ly clea~ an~ inspect closure hea~

flange sealing surface.

(14)

Install and attach t~o new reactor vessel gaskets to the closure head.

(15)

Thoroughly inspect, clean, and lubricate stud threads.

a.

Remove all foreign substances from the studs, nuts, and washers.

To remove rust preventativ~, redistilled ethyl alcohol is suggested as a cleaner.

Special attention should be given to the threads and all mating parts of the studs, nuts, and washers.

b.

Lubricate threads and all bearing surfaces of studs, nuts, and washers with Molykote, Type Z, applied by brushing or wiping.

CAUTION:

Do not permit the Molykote to contact Ni-Cr-Fe alloy or stainless steel surfaces.

c16)

Raise the reactor vesse 1 closure head from its support pad using the polar crane and the lifting device.

(17)

Check closed the fuel transfer system gate valve in the spent fuel pit.

(18)

Lower the vessel closure head over the reactor vessel as the water level in the refueling cavity is lowered, and turn off underwater lights.

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MSC

l.

The u:-,6s:r*,*:E:tc:r lis;:-,~s shoulc be tu::::-:-iec off while they are still belo~ the refuelins ~ater level.

2.

Do not allow the closure head to come into contact with the refueling water.

3.

Watch for any sucden decrease in load which would indicate binding or an inter-ference.

(19)

Continue lowering the closure head to within one foot of the reactor vessel flange, and turn off all underwater lights.

(20)

Drain all the water from the refueling c~nal.

(21)

Clean reactor vessel mating surface.

(22)

Lower the reactor vessel head until it is seated on the reactor vessel.

(23)

Replace fuel transfer tube blind flange.

(24)

Remove the head lifting device sling assembly.

(25)

Wash down walls of the refueling cavity and equipment with demineralized water as required.

(26)

Lower the stud tensioners and all other necessary reactor vessel closure head replacement tools and equipment from ~he operating deck to the reactor flange elevation using the polar crane.

(27)

Remove all stud hole plugs.

(28)

Remove the guide studs and store.

(29)

Lower the stud carriers to the refueling canal. Rev. 0

MSC (30)

Install the bottom closing screws in the bottom of the closure stud bolt and the stud lifting eye in the top of each stud bolt.

(31)

Attach the stud lifting eye (Pc. 449-07) to the spring scale and lift the closure stud bolts.

Lower the bolt and engage in the matching stud hole in the vessel flange.

Tighten each stud by hand until it bottoms, then use special (32)

(33) wrench to back off one full turn.

Care should taken not to damage threads when installing the studs.

Install matching washers over each stud with convex side up.

Engage matching nuts on studs and tighten snugly with special nut wrench (Assy. 449-12, Figure 5).

After all 54 studs are installed, the nuts and washers snugged up against the flange, take*

depth readings of the distance between the top of the stud and the top of the measuring rod which is inserted in the hole provided in the center of the studs.

Record the dial indicator readings in Column l of Table III or Table IV, depending on the purpose of bolt-up.

Table III is provided for hydrostatic bolt-up while Table IV is provided for operational bolt-up..

Rev. 1

MSC NO';'E:

':Ll~re:e (3) mec.su:::-::..ns :::-ocs are furr.is!-:e~.

One (1) measuring rod is to be marked hMaster" and rnust be used at all times when the stud elongations are being measured with the dep~h micrometer for determining elongations which will be recorded in tables.

The three (3) measuring rods are for use with the tensioners.

It should be noted that a measuring rod must be present in the studs being tensioned if the dial gages on top of the tensioners are used.

4.3 Tensicning Procedure (Hydrostatic and Operational Conditions).

NOTE:

The following supplements the Biach Industry, Inc. Maintenance Manual for the 2,350,000 lb.

tensioners, Model No. 2-5055 (Sec. 15) and is based on actual bolt-up experience gained in bolting up for hydrostatic testing.

The recommended bolt-up procedure for hydrostatic testing is a three (3) pass procedure with an adjusting pass or partial adjusting pass to bring elongations for all stud bolts into the desired tolerance range.

Operational bolt-up should be a two (2) pass procedure with an adjusting pass to correct the elongations for individual stud bolts which are out of the desired tolerance range. Rev. 0

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4.3.1

h.

J-lydro~t:itic PrcloaJ *.7854 x 31.:::S x (180.475)~ = 79,942.000 lbs.

Bolt-Up Contin~i.:ncil'S *.10 x 79,9~.:!.008 = i,99.::1,'200 lbs.

Total= 87,936,'200 lbs.

PH= Hydrostatic Prt:loJd per Stud= 87 9 ;~*

2.0Q = J,6~8,4~8 B.

Operational Pressure Prclo:id -.7854 x 2500 x (180.475)2 = 63,953,60~ lbs.

Bolt-Up Contingencies*. I 0 x 63,953,60~ = 6,395,360 Tot:il = 70,348,96~ lbs.

P0 =Operating Preload per Stud= 7o.34g4962 = 1,302,758 lbs.

C.

Stud Elongations (Hydro!:tatic & Operational) 4.3.2

- nrt ET= Total Stud Elongation Required= 1;;!:

whcrc:L =distance between bottom thread in nut and top thread m the vessel 0<.1ngc plu~ l.'25 x nomin*1l stud di.:irn:!ter = 39.750 ind1i.:s A= Min. Cross Sectional Arca of Stud= 35.3 Sq. In.

E= 30 x 106 psi (M:iterial A-540 B-24)

Ptt =Hydrostatic Load per Stud= 1,628,448 Lbs.

P0 =Operational Load per Stud= 1,30~,758 Lbs.

Hydrostatic Elongation ET= J,628.448 lbs. (39.750 inclH's) = 0.061 inches min.

35.3sq.in.t30 x 100)

For the hydrostatic test bo!Htp to contain :i pressure of 31 :!5 psi (cq u~1l to l.:!5 x th.*sign prcssm~). the nomin:.il stud ~long:ltion should bi.: 0.0C13 in. t.002 in. since it is impossible to tension all studs exactly the s;1mc amount. This nomin:tl eton,gation c:in readily be obtainl.'d to this accuracy :md will allow no stud to be tensioned kss than thL' 0.0(1 I in.

JL'quirL'd whih: 0.0(15 in. clong.ation docs not ovi.::rstrcss the studs. lt is dcsir<.1bk for thl! i.l\\'cr:igc clon~;1ti0n for ull fifty-four (54) studs to hi.:

. within t 0.00 I in. of the nominal clong:ttion but obt;lining this uccur:1cy m;iy he tillll' consuminl:! :.ind is not ;1hsolutl'ly lll'L'l'ss:.iry. T:1hk Ill provilkS spaL*c for dd1.:rmining. donl!:.itions :id1icwd ~md m:1king com*ctions for out of tolcr:mcc conditions.

~17-Rev. 0

MSC

~. 3. 3

4. 3. 4 Eo: J.302./Sf lh. <~9.750 in.)= o.040 inch min.

35.3 sq. in. c.;u x JCJl>J For operational bolt-up to contain a pressure of 2500 psi (dL*sign pressure) the nomin:il clong:ition should be 0.051 !.002 in. This nominal elon_gation can be readily. obtaim:d to this accuracy and will allow no stud~ to be tensioned less than the 0.049 in. required while 0.053 in. does not overstress the studs. lt is desirable for all fifty-four (54) studs to be within "': 0.00 J in. of the nominal elong:ition since operating conditions will stress studs over long periods of time. Tabk IV provides space for dctennining elongations achieved and corrections for out of toleraT'ce conditions.

Bolt-llp and Tensioner Operation A.

For installation and operation of the stud tensioners consult the Instruction and Maintenance Manual for Bi:ich tensioner Model 2-5055.

CAUTION Stud tensioners should not be pressuriz.ed unless the stud tensioners puller b:ir is completely eng:iged on an asst:mbled stud.

B.

Pull should be accomplished in sets of three (3) studs at the pump pressuri..'s and in the sequence shown on Table I for hydrost:itic conditions and Table II for operating conditions.

CAUTION Maximum hy.c.lr*mlic pump pressure shall not exceed 9500 psi.

The elong::itlon requir.:d to produce the required pre-stress in thl' stud bolts is !_!in:n in Column 7, Tnblc I. for hydrost::itic bolt-up.

and Column 6, Tabli! 11. for oper;1tional bolt-up. Adjusting pump prcss1m.*s arc t?ivcn in Column 6,* TJblc I, and Column 5.

Table JI. in the rcspcL*tiw bolt-up procl'dures. Thl'Sl' mljusting pump prl'ssurl'S should hl* usl'<l for all slue.ls whiL'h ;m~ out or thl'

~lonl!ation tokranL'l' h:1ml. Noll' th;1t th1.* adjustinl! pump Jlrl'SSlll"L'S ;fr1.* thns1.* whkh corrl'spn1lll to thl' nominal don~ation desirl'd. and arL' not tl11.* pump prl'ssml's which thl' Uiadt ~l;11rnal Rev. 0

MSC cun*c, Stud Elc1;1~*~tion (i:-i) vcrst1s Pump Pr:.:ssUJL' (psi). i:i~i:;*t-..:<.

Wili p~OdllC*' ~!1 1.?J01;;:::.ition grc::t.:r in m;:i~nitudc th:.ll'l thL' <lc~ircJ

\\'aluc. Followin~ tlii:; mL"tliuJ or ;,,idju~tm::11t will rninimi7.l' the possibility of stuJs goin;.: out ol tolcr:.ince on the high siJ:! of thi:

tolerance band durinf! the acljustin~ p:.i::.s. It h::is b:.:cn d.::tL'rminL'c.l th::it a stud out of tolerance on th(' low side of the tol~r.inc.:L: m:.iy be adjusted easier than a stud that is over-tensioned. This limitation on auju!->ting pressun:s becomes incrc:isin~ly import<ml for the hydro~tatic boll-up ir. th::it the stud nuts an: difficult to break loose when stud elongation exceeds the elon~ation tolerance.

It should be noted that if it is necessary to reduce the elongation of any stud, the tensioner slio~!ld be attached anc.l pumped to a pressure greater than the previous oil pressure used (approximately l 00 psi greater) until it is found that the nut is free and can be backed off and rot;:ited in a counterclockwise direction. The nut should be backed off about o:ie turn

(equivalent to about six (6) turns on tensioner handle). Reduce the pump pressure to the adjustin,; pump pressure desired and turn the nut b;ick up, se.iting it firmly against the washer.

C.

Aftn all out of tolernnce studs h::ivc been adjuskd, dial indicator readings should be takrn for all remaining studs and ent.:rt'd into Column 4, Table III or T<ible IV (whichever is :.ipplii.:.ibk) ::ind elongations recorded in Column 5. This is necessary sin cl' elongations for other studs than those adjusted m:iy movt>

slightly during the adjusting procedure. To obtain :m accur;:itc average elongation, this is absolutely necessary.

EXAMPLE Assume bolt-up to operating rl!quiremcnts of 0.051 in. ~.00~.

T<.ibulation of elong:itions obt:iincd by use of Table IV shows that five (5)-wic:kly di~pcrsi:d bolts are_o_ut_of_the required tolerance b~md. Four (4) or these stud bolts are below tht! minimt1m tolcra11ce iimit -{0-;046 in.* 0.045 in., 0.047 in.. 0.03.:.l in.). Oni.: (I) stud bolt is found to be

ibovi: the m.iximum tokran1.:c limit (0.055 in.). Bring the elongations into lokr;in1.:e :.is follows:

Note In

.itljustin~ individual studs, usi.: only one ( 1) tensioner with the JHL'Ssur1: hoses for the two (2) other tensioners disrnnrn.'clcd. Rev. 0

(

4.3.5

4. 3. 6 MSC For the Four (4) Stud Dolts 13clow the-Minimum Tolcr~ncc Jbngc:

A.

Attach tensioner to each stud ~md pumr to the ::icljusting pressure (7000 psi) !>flown in Column 5, Table II. Turn the nut sc::iting it firmly against the washL:r, n.:duc~* pressure, disenpgc puller b:ir and n:mo\\'C tensioner.

B.

After the four studs have been retensioned take depth readings to determine if the adjust elongation is within the tolerance range (0.051 in. -t.002 in.).

For the One ( l) Stud Bolt Above The MaximtJm Tolerance R~nge:

A.

Refer to the Biach curve, Elongation vs. Pump Pressure and determine the pump pressure required to break the nut loose on the "over-tensioned" stud. This pressure will be approxi:n3tcly 100 psi greater th~n that pressure corresponding to th_. e!nn~:ition present in tl1C' stud. In this case the pressure required to loo~cn the stud nut will be approximatdy 7900 psi.

B.

Attach tensioner and pump to the pressure determined (7900 psi) or slightly greater until it is found that th~ nut is free and can be backed off. The nut should be b;:ici\\t.'d off about one turn. Reduce th~ pump pressure to 7000 psi and turn the nut back up, seating it firmly ogainst the wash~r.

C.

Take depth readings to determine if the subject has bt.'en brought into tolt!rance rang~

(0.051 in.'!.00~ in.).

Note After all of the "out-of-toler:mce" studs have been adjusted, take depth readings for all fifty-four (54) studs and enter in Column 4, Table I\\'.

Determine the adjusted elongations (readings in Column 4 minus the readings in Column l) and enter in Column 5. All studs should now be in the toler;Jnce range.

D.

Refer to Section 4.1 (12) for unbolting procecure. Rev. 0

Dinl ln:!i:ator r

01.'plh Readings Stud C

r

~

. Measuring Rod

--- Bottom Closing lnscrt FIGURE 10, STUD ELONGATION MEASURING DEVICE Rev. 0

~

0).

n I

N N

I 0

0 1

! I I

SET I

NO.

I l

3 4

s 6

7 8

9 10 11 12 J3 14 ts 16 17 18 2

3 FIRST PASS PUMP STUD PRESSURE NUMBERS (PSI)

I, 19, 37 5200 10,28,46 5,23.41 14 32 50 12,30.48 3, 21, 39 8,26,44 4950 17,35.53 7,25,43 16,34.52 2,10,38 11,29,47 6,24.42 4700 13,33.51 4, 22._40 13,31.49 I

9.27,45 I

13,36,54

~

4

~

l*

SECOND PASS PUMP PRESSURE (PSI) 7ROO i

I 7'100 I

7000 I

' I I

h 5

THIRD PASS PUMP PRESSURE (PSI) 92fJO RROO R-100.

~

TABLE 1-HYDROSTATIC nOLT-UP

\\. '

6 1

ADJUSTING DESIRED PASS PUMP qESIDUAL PRESSURE ELO;'JG/\\TION

\\

(PSI)

(11\\!CHES)

R*IOO o.or._\\ *~.co2 I

I v

~

CX>

n I

w I

~

Ill <

0 o*

1 SET NO.

I 2

3 4

s 6

7 8

9 10 II 12 13 J4 IS 16 17 18 2

STUD NUMBERS I, 19, 37 10,28,46 S,23,41

14. 32. 50 12,30,43 3, 21, 39 8,26,44 17.35,53 7,25,43 16,34,52 2,20,38 11,29,47 6,24,42 IS,33,51 4,22,40 13,31,49 9.27,45

18. 36, 54 REMARKS 3

4 5

6 ADJUSTING FIRST PASS SECOND PASS PASS DESIRED PUMP*

PUMP PUMP RESIDUAL PRESSURE PRE~;suRE PRESSURE ELONG/\\ TION (PSI)

(PSI)

(P~I)

(INCHES) 5200 7800 7000 o.o.; 1 ~.on~

I v

4950 7400 I

i 4700 7000 i

I TABLE II* OPERATIONAL BOLT-UP

ELONGATIO:J DATA SHEET FOR HYUi\\OST;.. TIC LQ/,D

r

'r

":I 4

5 I

o:,!.. !..

t.'..:.c1u:.*1 Cf Di AL

, *,

r

. r -

F' ~ ~

~,\\rU1... _..1 ** :

V.-

1 c.~.

IN1Tl!-.!.... D!/..L tr,'S'iCt.. Tc;:;

fiES?C*:J~.L H~L):c;... TOR

, ELO':G. ;..Fit:=

00 Ji~::;::/-.-~ CJ~. I R E.L.G1 i..

1G f....f=IER E LC:*.' :;.. :.. T l C ~..

1 F: =-~~ ! ~.. *::;.!.. Fl E F.:

AD..:*'""'~:-.*;,'.E;....

h0.

R::,,......,_

3~D ?/..S.S

~~.... r, 1. r**"" {::- i l i

.L.DJ. P/.>.ZS I

(.::,. 'i )

_,.....u:.*.u

..;i\\ "'-' I r-*..J.::>

I 2

3 4

5 6

7 8 I 9

JO 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 18 29 30 31 32 33 I

34 TAULE Ill -

ELC\\~GATION DAT~ SllEJ;T rott l,l\\'()lt0Sl>\\11C LOAD MSC Rev. 0

~-

ELO~"'GATIOT~ DATA SHEET FOR HYDROSTATIC LOJ...8

-~

2 3

4 5

(

DIAL Af.~OUNT OF DIAL AMOUr'n OF RES.

INITIAL Dl/-.L l~,'DICATOR RESIDUAL INDICATOR EL0~,

1 G...t.FTER

(

...)

.J STUD NO.

35 3G 37 3S 39 40 41 42 43 44 45 46 4i 4S 49 so SI 52 53 54 I

MSC INDICATOR READlr~G AFTER ELOr*~GATION READING AFTER ADJUSTr:, EIH READING 3RD PASS 3RD PASS (2-1)

ADJ. PASS (4-1}

SUM=

Avcra"e Re>idual Elon°ation :Sum Col. S =

l>

c 54 DATE

~~~~~~~~~~~~~

TADLE Ill (Continued)

ELONGATION DATA SHEET FOR HYDROSTATIC' LOAD Rev. 0

ELONG/'.TtOr*J D/,Tt.. SHEET FGP. o;'EF:ATIO:~AL LQ/,D 1

2 3

~

5 Dl.l-L 1-.;.... C;l.J1-.'T (Jf-Dlf...L 1t..:::;~

1 ::T Gi-Fi;;S.

INITIAL DIAL lhlDIC.t.. TOR RESiDU:...L INDIC.t.. TOR ELC:*.:G. ;..r:TER STUD WDlCATOn READl;~G AFTER EL o~:GA TI o:*J RE.£...D!i~G AFTEP.I

/.'.DJU:Tr:.Er~T NO.

RE.!-.Dli :s 2iJD PASS 2i,1D P.L.SS (2* 1)

ADJ. i*ASS (4-1) 1 2

3 4

5 6

7 8

9 10 11 I

12 I

13 14

~i 15 16

. --.17

.. - 18

-19

-20

-21..

--i2 23 24 25 26 27 28 29 30 31

) (

J2 I

33 34 TAUL[ IV ELONGATION l>ATA SllEET FOR OPERATIONAL LOAD

.., n,...

-?t:-

R~v. 0

e -*

ELOI JG..C.. TIOrJ DATA SHEET FOR OPERt.. TIOr~AL LOAD 2

3

.4 5

Dl/\\L t.r.',ou;:1 OF DIAL Ar.'iOJ: :Tor-RE::S.

. INITlt..L Dl!... L INDICATOR RESIDUAL INDICATO~

ELO~*:G. AFTER STUD INDICt..TOR READ!r\\!G AFTER E LO~,'GATIOiJ READING AFTER ADJUSTr.~ENT NO.

READl~JG 21-..)D PASS 21\\!DPASS (2-1)

ADJ. PASS (4*1) 35 36 3?

38 39 40 41 42 I

43 44 45 46 4?

4S

~ {

~. - 49

_.1*"

50 51 52 53 54 SUM=

A\\*erage Rei.idual Elongation= Sum Col. S =

54 SUPERVISOR I

)\\

TADLE IV (Continued)

ELONGATION DA TA SI II::ET FOR OPERA Tl ON AL LOAD MSC Rev. 0

j 4

i

~

\\.

~

l

~ '

1 1 l l l

1

(

f 1

+---------

I ADJUST11:G FIRST P/...SS PASS DESIRED PUHP PU!*1P RESID01J..

SET STUD FRESSUilE

'PRESSURE ELOl:G/..TIO!~

lW.

l*~;:~~=~~S

_,(_P_ S ~ L __ -~- _ _:i(.::..P.=....S T:..::....._ )t----..+--><-...I~"*'C...-:1...:..;::

~)

2200 1800

- ~-. 013*':** :&61 _

1 1, 19, 37 2

10, 28. 46 3

5. 23. 41 4

.l~t 32, 50 --+-=+--------- ----. ----'---*---**-

~.. -...

--+---+----*--

_ 5 1,2.,. _3 Q""" _4-=S"----4----=2=0_0::;.-=-0--~--*-'--*--1------1----*

6 3, 21, 39

- ~-----1---*-'--* - __

-+--_

7 8

26 44

-.L... l__

- _____._,_ ___ ~------+-----+----

8 17, 35, 53

L-- -----*** ------ --*--

1800 9

7, 25, 43

'-----------------...__-~---**--___.._

__,l,_ --- -*

10 i6, 34, 52

~-------!--*---

~----* ______,____ *-*

11 12 2, 20, 38 11 29 4 7

.. J.

13.

14 6

24 42

_____, ___,l._

~5) 33, 51 _

--- ---~ -

. 15..

~s ~2, 40 16, 13, 31, 49

- - ----- *--* ~..... - ----L-- -.. -- _............ - *- -*

17 9, 27, 45

- *-----*- --........ ------+---+---**-

18 18, 36, 54 REMA!tKS:

TABLE V, PARTIAL BOLT-UP T'I-**

n I

I

1 f

(

MSC Two lifting eyes have been Frovidcc.,; in i.he top plate of the tcn!:ioners for lifting c.nd.shii::ng each tc1'sioner. Two knobs have been f-:rovicic:C:. 2 t the bottom of the LCnsioners to allov: an operator to guiC:,c the.ensior.err.

a~ they are -tin[;' lowereC:: over the asscmblecJ stuc3 and nut.

5.2 Hoses

Two ten.!:iioner hoses anc1 a long ~upply hose have been Froviaco for the high pressure connection t:etween the pumping unit and the tensioners.

'Io co!'.nect the hose, remove the oust cap whi.ch i:rotects the body half of.he coupling on the tensioners and i.he pump ano push t.he male tip, which is on the ho~e, into the coupling. Scre\\v on the collar aL the way until it bottoms. Force is not necessary as the collar is almost a free

-!it and shoulci spin on. 'Ihe collar must bottom.

Similar hoses ha\\'e been provided fo:- the pneumatic return ::;ystem of the tensioner.s. 'Ibey have been provioec with quick couplings for convenience in co:mecting. The long hose connects from the FUr.1p to the first tensioner, ano the other N.ro hoses connect l::.etween the tensioners.

5. 3

Connecting the tensioners to ttucis:

A.

Lower the tensioners, each tensioner being guidec'l by an operator.

The tensioner must go c.own over the ~tu~ an6 nut until the housing rests on the flange. 'Ihe te.a.-isioner locates on the two aojacent nuts.

B.

At this time the drive sleeve for the nut will be ricing on the top of the nut ancl the puller bar will be supported by it's spring !;Uppo::-t mechanism.

C.

Turn the Ci rive sleeve by turning the cirive gear hancile. The iirive gear shoulci be turneci clockwise. When the c.iriving teeth of tile drive £leeve n-iatch up with the slots of the nut, the ~rive sleeve will clrop into place and ce ready for turning the nut. When engaging the urive sleeve v.*ith ~he nut, it &houl9 always be turned clockwise, even when unbolting.

D.

Cirasp the hancwheel at &:he top o! the puller bar and carefully feel for the thread engagement :,etween the puller bar cockct and the stucl. Rev. 0

E. J.dtc:- t}-,c tL::-e:O:~[ h::.vc e::-.;~f'.E:L, screw o::-. fr.c r:-u!lc.:r t.a:r un~J t.Le holdint; nut L:ott0:-:'1$ on the: spherical v:ashe:rs.

F. Beicl: off the puller ta*r about 1/1:. turn.

G. \\.'/hen this operatio:. haE been perforrnccl on all of the tensione:rs, they are ready to be pressurized.

H. '!'he holc1ing nut has been ~ecu:re~ to the puller bar t.y means of the locking assemblies. It has been set.so that there is a clearance of about 1 /2" betv.*een the bottom of the puller bar arui the top v! t.lie ~tu2.

'!'his allows !or minor variations in the height of the.:.;tuC:.

Cf>.UTIOI~:

A te:-.sioner should not be pressurized unless it is connected to a stud.

The reason for this is that the tensioner does not have any positive stop and therefore could be damaged.

To guard against this happening accidentally, each tensioner is eqcirped ~ith a ~~rr.~ng whistle.

~hen the tensioner is within 1/ f." of it's full stroke it opens a valve which allo\\..'S air to be discha~gec into a warnir.g ~histle. This whistle emits a very loud, shrill sound anc is a clecr warning to the pu::ip operator that a te:.sioner is about to reach maxil:luw stroke.

'When he hears this "'~istle pu..-:ping must be stopped it:u:ieciately anc the tensioner should be allo~ed to retract.

5.3.l Pressurizing the tensioners:

MBC

'This f;ection CJescribes the. procedure for any one tensioning. The actual pressures anti the sequence are c.escribed in the section on Programming.

1. The oesired pres£ure £hould be \\.leterminecJ from the cha:-ts. Operate the pump until the.1 equired pressure has been :..eacheo. Then ::;top pumping.

2. Turn the c:;rive gear in a clockwise airection. This will turn the drive sleeve and in turn v:'.ill rotate the nut. '!'his takes up the !:lack that has been produced by the elongation of the stud. When the nut bottoms, ::eat it with a firm twist on the cirive gear.

3. *If desired, the taking up of the slack can be '°~one as the tensioner elongates the !;tucl £0 that, in effect, the nut is always bottoming against lhe spherical washer. V:hen the desired.pressure has been rcachccl, the nut !:hould be &eated as c,escribed above. Rev. 0

(

5.4

{

MSC

5. 3. 2

~.

Re:le.::..sc the p*;.;::-:-.;:. p:ressu::-e and unscrev.' t:-1e

?'..:..l~e:r

(

bar.

The tensioners can then be lifted off ana shifted to the next set of studs.

Pneumatic Return System As the return system has to push the tensioners back to the starting point, it is suggested that the release valve on the pump be left open as the tensioners are being shifted to the next set of studs.

This will allow ample time for the return system to perform it's operation.

The tensioner has fully r~tracted when the piston extension ring is flush with the top plate surface.

It is recor..r,1enC.ec1 that this be checked every time before starting another tensioning operation.

Visual checking is entirely adequate.

Prograr.ur.ing Procedure 5.4.1 Three sets of charts are included.

One shows stud elongation in inches, the second shows the unit load in psi, and the third shows total load in pounds.

Each chart has two lines, one showing the condition under tension and the second or lower line showing the residual held by the nut.

The chart for stud elongation was determined by actual test and observing the elongation on the tensioner dial indicator.

Four equally spaced strain gages were mounted on the body of the stud and these readings were also taken during test.

These were then translated into stud unit load and stud total load. Rev. 0

(

e e

5. 4. 2 5.4.3 The fcllc~ins iE a~ illu~tratio~ as to ho~ to use the charts:

Assume that a certain total load is required.

Using the chart for "Total Load" find the total load and read across to the lower line marked

~Residual". Then read down to find the required pump pressure.

This means that after pumping to this pressure, tightenins the nut, and releasing the pressure, the load remaining will be the required total stud load.

A similar procedure can be used for stud unit load and stud elongation.

Procedure for any one pass:

As there are 54 stucs and 3 tensioners, assume the stuas divided into three equal seg~ents each having 18 studs and nu."rbered consecutively from one to eighteen.

A suggested sequence would be as follows:

1, 10, 4, 13, 7, 16, 2, 11, 5, 14, 8, 17, 3, 12, 6, 15, 9, & 18.

By following this sequence, the tensioners are shifted around so that they are between tensioned studs and thus produce uniform loading.

Of course, other sequences can be worke6 out.

Multi-Pass Procedure:

As the vessel head will be tightened using at least two passes for the operational load and three passes for the hydro-test load, this means that on the initial pass all studs are tensioned to some pre-determined percentage of the final load.

On a two-pass program they would then be brought up to full load on the second pass.

With a three-pass program, three steps would be used.

-~,-

R4:>u _ n

For a t~o-pas5 progra~, it is su5geste~ that the first pass be at 75% of the required load with the second pass at full load.

For a three-pass program, the first pass might be at 60l of the required load, the second pass at 80% of the required load, and the third pass at full load.

After the final pass some readjustment of the first few sets of studs will probably be necessary as they will have lost some of their te~sion as adjacent studs were tensioned.

For the operational load, a modified final pass is suggested with the first few studs at higher than the final loa6, the next few at somewhat less and the re~aincer at the required full load.

This results in very even final loading with probably no adjustment being necessary.

As the values have been estimated, adjustments in the prograrr. can be made during the course of the initial bolt up.

In order to try out this program, it is suggested that when bolting up to the hydro-test load, the first time, a two-pass program with a modified second pass for t6e operating load be used initially with readings taken after the second pass.

Then the final pass can be at the required full load for hydro-test.

This procedure will give the necessary data for determining the proper pressure values for the operational load so that they will be available for the very first time the operational load is required.

5.4.4.

'TABLE OF VALUES Pump Pressures:

Requireu Hydro-TE:st.Stud Loac, l, 626, OOO{J Required Oper2tir:g Stu~ Load, 1, 300, OOOf;'

For the Hyc:;o-Test Lo2~

Three Pass P1*ogr'-m 1st pass 2nd pass 3:rd pC.t:E For the Operati:;;E Lo2c 2-pass progr2m

.lstpass 2nd pass 3-pass prot;ram lstpass 2nd pass 3rd pass Modified Final Pass for Ofc:rating Load First six sets of.:.:*tllds (! J !>tuds}

Second ~ix sets of ;.tuci5 (18 stucls)

Thi:ro six ~ets of ::tucls (18 stllds}

5, 000 psi on pump 6, 700 psi on pur.1p 8, 300 pci on pump 5, 000 psi on Fump 6, 600 psi on pump

.{, 000 psi on pump 5, 400 psi on pump 6, 600 fSi on pump 7, ~00 psi on pump 7, 000 psi on pump 6, 600 psi on pump Rev. 0

5.5

(

ProceCJ~Te for Looser.in[ Nuts:

5. 5.1 After bol!ing up to either the hyd::-o-tcst or the opel"ational loa~. the tendon(:rs can ue use::C: for ciisassembhnf;. This can be either a 2-pass or a 3-pass process for i..he hydro-test load.

u~ing a 2-pass program, all !'..:tuds would have their load 4*eciuced to about 2/3 of ~heir load on the 1st pass ar.d then the load would be rec;uced altogether on the second pass. On a 3-pass program, the loacs would be ieduceC: to JO%, 60%, and to zero.

The order in "vhich the tensioners are applied for uisasscmbly is exactly the same as the orc~er in which the studs are tensioneci. The tensioners are applie(; to L'le !:tucis in ihe t*sual manner. When screwing on the puller bar, however, a gap of about 3/16 11 should be left between the bottom of the holding nut an~ the top surface of the spherical washer set.

The easiest way is to sc re\\v on the puller bar until the holding nut bottoms on the r.pherical '\\*vasher and then back off 1-1 /2 turns. This is to allow for die contr~ction of tl1e stuc:; th2t will occur when the le.ad is rcdi.::cco.

The tensioners are brought up to Fressure until it is found that the nuts are free ancJ can be backed off by turning the handle counter-clock-wise. The

nuts should be backed off about one turn which is equivalent of 6 turns of the

handle.

The l el ease valve on the pumping unit should i.ie cracked open sot.hat the pres sure dee rea se s slowly. !hen the c.es ired inte rmeciia te lower pressure has been 1 eacheci, close the :t elease valve, then turn the handle to again seat the nut. Then the release valve can be opene~ anc let Lhe pressure go to zero.

This will leave a lower intermediate load in the stud.

The tensioner can now be zemoved and shifted to the next set of ntuds.

Continuing in this way all stucis can l.)e brought to a i*ecJuced level of loading.

On the final pass the load will be recluced to zero an~ it will be found that the nuts are free.

MSC Rev. 0

{

\\

(

I

- -.i

~. -~*.. I..

. t-*...

I

! ** r-**.

~:~=:_;_!_~-:~= !.:::=-:..=-..-:-!===-~1:=-:::*~-==~=:i:~::-_:_T:=.-=:- =.:*:*.:=:.-:_:::..:==..--~::.-*Li.:--_:.~

- - !~~ -:--,--* ~---;*-.-*i*----~- --... -;----'--:--*--~-.;. -~~-.-~1-*.:....-~-- ****-***+--.-***

--*-- *1* -**- --

- - --~--l-----

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5.5.2 5.5.3 5.5.4 5.5.5

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5.5.6 5.5.7 5.5.B 5.5.9

(

MBC Remove the stuc tensioners fror:i the vessel flange using the small electric hoists.

PRECf..lITIO:~:

Care must be exercised when removing the stud tensioners to avoid contacting the head

. flange or the studs.

Raise the stud tensioners using the plant crane and store on the operating deck.

Loosen the reactor cavity seal ring and raise seal ring (6 inches).

Remove and store seals.

NOTE:

The environment around the reactor vessel flange during plant operation is detrimental to the seal material.

Therefore, the seals should be stored in a location that is not subjected to the reactor vessel environment during plant operation.

Reinsert all flux mapping system detectors and thimbles.

Install the control rod drive mechanism seismic support columns.

Erect access platform on the head lifting rig walkway.

Connect the electrical leads to the Part-Length control rod drive mechanisms. Rev. 0

...I

(

MSC 5.5.lC Re ~*O"

-.-+.:.l _,...._,_

-.,,...; *r

'1-.-.ft r t c:

.... e: pc.;- -

.*::-** c...__\\c si.c.-

e ainer_, anc relatch the part-lc~gt~ RCC element drive sh~fts to their respective: elements, using the: part-length drive shaft unlatching tool suspended fro~

the polar crane hoist.

(Ref er to Part-Ler.~th Control Roe Drive.Shaft Unlatc~ing Tool Onerating Instructions.)

5.5.lJ Remove and store the access platform.

5.5.12 Dismantle the equipment on all instrumentation ports in accordance with the instructions outlined in Appendix B-2 and install conseals.

5.5.13 Install the reacto~ closure head insulation.

5.5.14 Connect all remaining electrical leads to RCC element drive mechanisras.*

5.5.15 Replace missile shield and supports.

5.5.lG Replace and reconnect the rod drive cooling air supply system.

5.5.17 Begin filling and venting the reactor coolant system.

(See M-4, Filling anc Venting the Reactor Coolant Svstem.)

5.5.18 Clean up the area around the reactor vessel closure head and the bottom of the refueling cavity. Rev. 0

(

MSC Append i>: A-2 Preparation of Instru~cntation Ports Prior to Refueling

1.

Disconnect thermocouples.

2.

Re~ove jack screws, item 5, W drawing 685J561.

J.

Remove split ring, item 4, ~drawing 685J561.

Remove jack screw plate, item 3, W drawing 685J561.

5.

Remove clamp, item 6, _E drawing 685J561.

6.

Remove ~ale flange, item 1, ! dra~ing 685J561.

7.

Remove conoseal gasket, item 8 1 W dra~ing 685J561.

8.

'Remove conoseal gasket, item 7 1 W dra... *ing 68SJ561, using the Conoseal Gasket Removal Tool, item 16, W drao.*ing 685J561.

- 9.

Place masking tape over gasket seating surfaces.

10.

Install 0-ring, item 202, ! drawing 686Jl27 at top of thermocouple support column, jtems 36, 37, 38, 39, and 40

_E drawing 686J217.

11.

Install protective sleeve, itl!m 41, ]. drawing 686Jl27.

12.

Install protective sleeve locking spring, item 37, W dra'l<.'ing 686Jl27. Rev. 0

APPENDIX B-2 INSTRU1'~~T PORT ASSE.M.ELY GENERAL INFORMATION

1.

Remove CRDM Cooling Guards

2.

Remove thermocouple tray.

3.

Remove protective sleeve locking spring.

4.

Remove protective sleeve.

5.

Remove 0-Ring.

6.

"Neolube" thread lubricant must be applied to all male and female threads.

Allow "Neolube" to dry thoroughly before assembly.

7.

Where "slings" or lifting devices might contact the surface of components, adequate blocking must be provided.

8.

All components must be thoroughly cleaned before and after assembly.

9.

Visually examine all parts prior to assembly for any damage.

10.

Following installation in accordance with procedure (616A210) page 42-45:

a.

Reconnect thermocouples

b.

Install thermocouple tray

c.

Install CRDM Cooling Guards Rev. 2

-<_,.....;r e*

(

l.

NOTE:

Cl~anl~ess is of the utmost importan,in a conoseal joint.

Assemble joint using clean white lint-free gloves.

Vhen the Seal Plug is used instead of the TheI':locouple Support Col um:-., follow this s~. procedure, replacing t!-:e words Thermocouple Support Column" in Steps '4, 5, 19, and 20 with the words "Seal Plug", and deleting Step 8.

Clean lower conoseal gasket as shO\\o"n !n W Drawing "Instrumentation Port Column, Seal Loading, and Hydrostatic Test Assembly" with acetone, making sure all surfaces and edges are free from any dust, dirt, or nicks and scratches in excess of 32 RMS.

2.

Place cleaned lower conoseal gasket on cleaned fetI>ale conoseal flange cf Port Column.

CAUTION: 'When placing this ccooseal gasket, be certain that the apex of the cone formed by the conoseal gaske:

points toward the!££. of the vapor container.

See view in~ Drawing "Instrumentation Port Column, Seal Loading, and Hydrostatic Test Assembly".

J.

'4 *

s.

Clean upper conoseal gasket as shown in detail, W Drawing "Instru-mentation Port Column, Seal Loading, and Hydrostatic Test Asse~bly 11 witb acetone, making sure all surfaces and edges are free from any dust, dirt, or nicks and scratches in e.xc~ss of 32 ll~S.

Clean conose.al surface of Thermocouple Support Column with ace~one, making sure all cotTlers and surfaces are free from dust, dirt, or other foreign contamination.

Place cleaned upper conoseal gasket on cleaned surfaces of Therm.:icouple Support Column..'CAUTION:

Whee placing this ccnosea:

gasket, be certain that the apex of the cone formed by the ~onoseal gasket ~oints toward the bottom of the vapor container.

See view in W Drawing "Instrumentation Port Column, Seal Loading, and Hydro-static Test Assembly."

62-e-3 W ~inghouse Electric Corporation

~-

616 A 210 Cr. l

(

\\:::.;

Page 2 of 5 TITLE~~~~~~~~CO==-NO:.:::.:S=EAl:.::..~A=S~S~EMB=-=L~Y=--=S~P~E~C~IF~I~C~A~T~IO~N:.o.-~~~~~---~--------------------f DIVISION

- ..,i..,....... *

**"" S*8~0

- Ort NUCLEAR ENERGY SYS~

~L.ANT LOCATION PITI'SBURGH, PA.

21

.:.: I I

Rev *

-=~?-.

(

6.

7.

Clea= :.ale collleal flar.ge of port colu:::r. wi~a~etone

.c.~..:!..=g certa::.n that :fl. corners and surfaces are fre.,,from dirt, dust, o~ a::.;* other foreigo cor.ta.::.inatioo.

~nen L~e seal plug is e::p!oyed fo=

hydrostatic testing, assemble the seal plug, conoseal anc port column as follows:

(a)

Place the seal plug vith upper conoseal gasket in the male flange.

(b)

Insta1l the seal plug locking plate.

8.

Place weld ring on female flange.

Place male flange. onto female flange until male flange rests on the lO'l.ler conoseal gasket.

Apply "Neolube" to all clarip contact surfaces &nci to inclined surfaces of the male and !emale conoseal flar.ges, as shovn on Dr~ing "Instrumentation Port Col~, Seal

Loading, and Hydrostatic Test Assembly".

Assemble the clamp around*the male-female flange joint, and hand tigh:en the clamp bolts.

9.

Remove cooling.shroud plate at locations near Thermocouple Assemblies where interference may exist. Rang axial loading ram assembly, @Drca;ing 882D291, from crane.

All~ loadi:ig

ram, Item 1 1 @Drawing 882D291, to rest 6c locking flange, Item 3,

@Drawing,882D291, when hanging from crane.

10.

Locate axial loading ram assembly, Drawing 882D291, over male flange.

11.

Lower axial loading device assembly, Drawing 882D291 until loading ram, Item l, @Drawing 882D291, rests on male flange, as shovn in @Drawing "Inst1-umentation Port Column, Seal

Loading, and Hydrostatic Test Assembly".

Continue lowering axial loading device uutil the locking flange, Item 3,

~

Dra~ing 882D291, can be engaged in the female flange of the Port Column.

62-e-4 v,t_.,ringhouse Electric Corporation fW\\_

s1s A 210, Gr. 1 I

I

~*::

w I

CONOSEAL ASSEMBLY SPECIFICATION

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Page 3 of 5 TITLE~~~~~~~~~~~~~~~~~~~--------~~----~~~~~----------------------1 OIVISION NUCLEAR ENERGY SYSTEMS

~ANT LocAT10N Pittsburgh, Pa.

" 1....... MB C..,*.! '..48 ~~~

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13.

E.=.ga.g.:-

li.>c~ f.:.a:lge, Ite::. 3,

~~ :0:-a... *ing.:;)29!,.!.:-: the: !e:.=..;...:i:

flange cf the Port Col~ by rotating locki.ng fla.nge *p?roxi::l..ately 15° such that the protrusions are just inside the n~tches en the fe:::.ale flange.

Insert ra::, as shown ir. ~* Dra"t.."ing ":&:ns tru::ier: tati.c:'l Port Seal L.:;acing, at1ci Hydrostatic Test A.sse~bly".

r-,**--

14.

Apply between 5,720 psi t~ 6,390 psi to the loading ra:, !:e= l,

15.

.l.6.

17.

@DraTJing 882D.291.

CAUTION:

Apr:lv ::.hll load gradua.Uv.

Maiotain this rfll:l load Yhile adjusting the cla:::p eo that the cla.t:p bolts ar2 located such that the axial loading d~vice can be removed after the claz:p is tighteoec, as shown on i,:::.: Drawing "Ins t:-u:nentatico Port Column, Seal Loading, and liyd:-oitati.:: Test Asseobly,

Tighte~ belts on cale-fe:ale Flange Cla.~p unifor.:ily, in incre::ien:s of ap?roxi:nately 5 to 10 ft. lb. t~rque, unt~l final torque (120-128 ft. lb.)

val~e is attained.

Release pressure c:i loading ra:ti and re:nove.

18.

Rotate the axial loading device to t~e unioclted position as shown on Dra'Jing "Ins,trucenta tion Port Column, Seal Load;.ng, and Hydrostatic Test Assembly",

and remove.

CAt."I'ION: KEE.P H.A.'ms FREE OF FIXTURE DL"'R.!NG REMOVA:..

19.

Install jack screw plate, as sh~ iti @Dr..-ing "I:is:nme:itation Port Column, Seal Loading, and Hydrostatic Test Assembly", over Thermocouple Support Column.

20.

Ins tall split ring, as shown in same driNing, to Thermocouple Support Colucn.

62-e-5 W; \\inghouse Electric Corporation Tn~~

CONOSEAL ASSEt:f,LY SPECIElCAilON

~-

616 A 210, Gr. 1

\\51 Page 4 of 5 CIVtStOl'f NUCLEAR ENERGY SYSTEMS

~~~--------------~

Pi ttsburgn, Pa.

~ANT LOCATION I

'RP.V. 2 I

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2 I~

=

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21.

r~sta11 jack screws to jack screw c1a:e.

2.

7i;hter-: jack screws ur.iforn.1y (appro.xir.-.ately 5-10 in. 1b. pe,.

screw) staggerin~ across :he pattern until fina1 torque (95-~::

in. lb.) is obtained. This assures a leve1 raise of the p~J;.

23.

Follow this procecure for all instrumentation ports.

62-e-6

(

c

~I ----~----L-~~---------------------------------------------.-------------------

3 *. Jstinghouse Electric Corporation

IYl'.___6_16~A _2 __

10 __ G

__ r __

. _1 _

TtTU CONOSEAL ASSEMBLY SPECIF'ICATION

~

Pa of 5 o1v1s10,..

NUCLEAR ENERGY SYSTEMS

~-* * "J~..... ~

~NT Loe:A,., 0..,

Pi ttsburcn. Pa.

ML19030A698

Text

5.2 Hoses

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