ML19210E399

Cycle 1 Refueling Outage Rept,Section 2.20

ML19210E399
Person / Time
Site:	Crystal River
Issue date:	11/27/1979
From:	FLORIDA POWER CORP.
To:
Shared Package
ML19210E396	List: ML19210E395 ML19210E399
References
NUDOCS 7912040502
Download: ML19210E399 (27)

Text

.

4 2.20 B-0TSG REPAIRS A. Pre-Outage Planning Milestones The pre-outage planning effort for the 3-0TSG Repairs was *,

initiated in September 1978 with a B&W/FPC meeting to ,

discuss repair goals. The results of this meeting were 5 that B&W was directed to continue the development of remote repair equipment assuming that a full repair would In addition, 3&W be done at the next ref ueling outage.

In M was asked to aevelop a surveillance program.

parallel, FPC would evaluate its final decision on the extent of repairs.

On Janusry 15, 1979, W. P. Stewart gave the following direction to B&W confirming FPC's of ficial position on repairs:

' . (1) Perform a limited video inspection of selected tubes (2) Open the 120 lane tubes (3) Open/deburr 1000 random tubes for future eddy -

current testing (4) Implement a surveillance program ,

(5) Video inspect all worked tubes (6) Complete development of all remote tooling Planning for the refueling outage progressed along this direction. In parallel, remote tooling development had continued and a demonstration was held on January 23, 1979 for FPC. *his showed that the development ef fort was progressing, but needed f urther work for the equipment to be fully accepted for use in the OTSG. After more efforts at tooling development and refinement, another demonstration was held on March 26, 1979. This resulted in a basic acceptance of the remote equipment for use, with the exception of the

' main welding unit. Suggested improvements were then made on the main welding unit and this too became acceptable.

Sica preparation efforts began in earnest the first week of April 1979 with the arrival of the tooling equipment and B&W personnel. Boilermakers were hired starting April 9,1979, in order to start a two week mock-up

' training ef fort. In addition, set up of support f acilities (e.g. , power supplies, control center , etc. )

was conducted at this time.

All work to be done on the 3-0TSG was covered by Work

?.eques ts for each major task. The work package (Wo rk Request, RWPs , clearances, etc.) were prepared in advance

and submitted to planning by late March 1979. Pre-outa:;e planning, based upon inputs from 3&W and estimates by the site activity coordinator, showed the 3-0TSG repair effort would run from April 25, 1979 to May 22, 1979, for

., t 1475 065 V.'

2.20-1 7912040 "A So2

E a total of twenty-eight (28) days (see Attachment 2.20-A). The effort was originally planned to be off-critical path. However, the last pre-outage schedule resulted in the B-0TSG effort as critical path by a slight margin. The schedule for this effort was *

'{F reduced from a thirty-seven (37) day schedule initially submitted by B&W.

B. Summary of Work Accomplished Attachment 2.20-B summarizes the as-built schedule for W

l the B-0TSG repair ef fort. The following is a brief narrative of repair efforts performed during the outage:

1. Equipment far the effort was staged to the RB equipment hatch on 4/25/79 in preparation for RB access.

2. The motor home control center was set up on 4/26/79.

~

3. The lower primary manway removal co=menced on y 4/28/79 and was completed en 4/29/79. The J-leg and g.

drain hole screens were then installed. '"h e ,

temporary lower manway cover installation was completed on 4/30 - 5/1/79.

4 The upper primary nanway was removed on 5/3/79. A demineralized water flush was conducted but had no '

affect on general area radiation levels (4R/hr general area).

5. The eddy current sky hook and c.2mera for general I scan was installed on 5/1/79. The eddy current 5 manipulator was then installed with a camera to perform freeze frame shots of the lane tubes. This was completed on 5/3/79.

6. The freepath equipment was mounted on the eddy current manipulator and the freepath commenced on j 5/4/79. As of 5/7/79, a total of 1,017 tubes had y been checked, but only 178 would accept the 0.500" gauge. Because of the high rejection rate, g freepathing was halted in favor of using the milling g machine.

7. Ring girder installation commenced late on 5/7/79, but ran into delays due to improper fitting of the marking template and inadequate ID of the tubes being used for the holddown cam locks.

Modifications were made and the ring girder installation completed on 5/9/79. After corrections to problems with the milling machine air connections and setup of the vacuum, spotfacing of the 1:ne tubes commenced on 5/10/79. 'Ihe first 18 tubes were I

=- -

3475 056 g

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I spotfaced with a non-radiused type cutter. A radiused cutted was installed and spotfacing j continued through 5/11/79. At this time, the S crossbc brace was removed to gain more outer periphe" access. On 5/12/79, the right angle milling head was installed and lane tube spotfacing completed.

8. Tube end opening for the eddy current sample was 3

'E commenced ou 5/12/79. This effort went extremely slow due to lack of good maneuverability of the equipment. The tube end opening was halted on

. 5/15/79 in order to get on with welding the lane tubes. At this point, only 146 cubes were opened, but a recurr. to tube end opening was planned, if the schedule pe ceit, at a later date. Prior to milling j nead removal, the original 18 spotfaced tubes were d' respotfaced with a radiused cutter.

9. Setup for lane tube welding commenced on 5/16/79 with the deburring of all spotfaced tubes. The heaters were then installed and the open lane area was heated to 300-350*F and maintained for 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> j 15 minutes. Af ter cooling down, the heaters were d removed and the roll expander installed early on 5/17/79. All but five (5) tubes were roll expanded at the upper 1/8" and these five were accepted as is.

10. The NED welder head was installed late on 5/17/79.

j However, the welding ef fort immediately ran into 3'

problems and delays due to such things as test block holder inadequacy, pilot assembly alignment, camera and cable problems, and lack of good argon cover gas. By 5/21/79, the NED welder head was removed .

and replaced with the Copley, backup welder head.

This unit also ran into problems with argon and a j control problem. These were solved by securing the S ventilation to minimize cross flow and discovering a grounding problem on the control unit. A B satisfactory test block weld was finally made on g 5/23/79. Tube to tube heat welding commen :ed on 5/24/79.

11. On 5/23/79, filling of the FTC for fuel shuffle was started and a gasket leak on the temporary lower manway cover was discovered. Draindown and removal of the cover was required. The cover was removed on 5/24/79, at which time velding was halted to

. eliminate the possibility of the " chimney af fect" causing argon cover gas problems. A new gasket was installed and the temporary cover replaced late on 5/24/79.

I TA75 067 2.20-3

12. Tube to tube sheet welding vss reinitiated early on Y 5/25/79. Additional problems were encountered with -

the filler ' wire fusing in the wire guide tube and several other items. Welding was again started early on 5/26/79 and all but five (5) tubes which vere inaccessible, were completed on 5/27/79. .

13. Setup for manual welding was then initated and the .

manual welds on the five (5) inaccessible tubes -

• completed on 5/28/79. However, there was some concern by one of the welders about adequate fusion.

The liquid penetrant rig and cameras were installed on 5/29/79 to initiate the PT ef fort and perform a ,

visual inspection. The visual examination was conducted on 5/29/79 and resulted in sixteen (16) tubes requiring repairs. Four (4) of these tubes had the weld deposited outside the tube and had no contact with the tube itself (Tubes 77-14, 75-13, 75-14 and 75-15). In addition, it appeared that these four tubes were recessed below the newly spotfaced area of the tubesheet. Weld repairs started on 5/30/79 by manual grinding and rewelding.

The decision on the four (4) tubes mentioned above was to respotface the tubesheet flush to the top of .

the tube and reweld. This was completed on 5/31/79.

14. The final visual inspection and video taping of the 92 reworked lane tubes was conducted on 6/1/79. The PT examination was then started and completed with some delays on 6/2/79. Three (3) tubes were required to be repaired as -s result of PT examinatien.

Based upon equipment performance and schedule considerations, it was decided to halt f urther OTSG repair work at this time.

15. The ring girder removal was started on 6/2/79 and was completed on 6/3/79. All pieces were wiped down, bagged and rarked, and placed by the RB equipment hatch .aydown area.

16. The upper tubesheet was vacuumed and cleaned on 6/3/79. Tubes for the surveillance program equipment were opened and the surveillance program initiated. The curveillance . program was completed en 6/6/79 with no major problems. A final video scan of the upper tubesheet was made af ter twoval of all equipment.

1:. The recirculation flush system was set up on 6/5/79, and flushing was initiated on 6/6/79. However, leaks in the recirculation flush system finally t forced abandoning this approach. A desineralized 2.20-4

water flush was initiated on 6/7/79 and ran for 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br />. ' final QC inspection and Chem / Rad Cl* leach test found the upper head acceptable.

18. The lower head of B-0TSC was drained on 6/7/79 and the temporary manway cover removed on 6/8/79. The

,I-leg and drain hole screens were removed and the lower head was vacuumed. However, a few loose chips remained and in the process of trying to remove g them, muslin clochs were inadvertently used instead j of lint-free rags. Since the muslin was caly used in limited areas, it was decided that solvent cleaning of the lower head could not be justified due to the high radiation exposure. The B-0TSG was turned over to FPC mechanics for closeup on 6/8/79.

19. The upper head was closed up on 6/9-10/79 and the I lower head on 6/8-12/79. This ended that actual repair effo rt.

20, on 6/8/79, in preparation for removal of the repair I equipment, a team entered the R3 to verify appropriate markings on the pieces. At this time, g the ring girder equipment was found missing. An J intensive search was initated and on 6/9/79 some of the major pieces were located on a large wooden LSA shipping crate. On 6/13/79, authorization was given

j. to inspect se led waste drums and four consecutive 4 drums were found to contain ring girder parts.

Howeve r , the waste drums before and after these four were already shipped and were not reclaimable. On 6/27/79, two more major ring girder pieces were found in the contaminated s torage trailer in incorrectly marked bags. All available pieces of

j. the ring girder equipment have been cataloged and .

ME placed in storage as of 6/28/79 (refer to Attach =ents 2.20-F, G, and H).

C. Schedule A comparison of Attachments 2.20-A and- 3 will show that j the actual duration of the repair efforts was 21 days su longer than the original estimated schedule. Some of the more significant delay items encountered are explained sa below:

, 1. Shutdown delays (e.g. , SPs on RCV-8, DHV-3 and 4 operation) in turn delayed start of the OTSG work.

(~1.0 days)

2. Scaffolding and tent erection at the upper and lower manways due to coordination and manpower experience problems. (~1.0 days) 5 u?s 069 2.20-5

I 3.' Manway cover removal and replacemenc problems.

Lower manway removal was hampered by sticking nuts and replacement by problems with the new stud g tensioner. Upper manway and inspection cover g replacement also ran into days. 42.0 days) .-

4 Removal of OTSG insulation also took longer than scheduled for unknown reasons. Qv0.5 days)

The temporary manway cover installation was delayed g' 5.

due to problems with initial fitup and then the g leaking gasket requiring removal, replacement and reinstallation. 41.5 days)

6. Setup of the eddy current manipulator due to equipment problems and some handling / installation problems. b0 5 days)

7. Gauging of the 1000 random tubes due to some equipment problems and the fact that many of the primary identified tubes would not pass the 0.500" probe. This required additional time spent hunting for backup tubes. (~0.5 days) -

8. Ring girder installation due to various problems with tube ids required for holddown devices, camera f unctions , milling head operation, and vacuum operation (~1.5 days) ,

9. Spotfacing of lane tubes due to more time anticipated for operation, especially with milling g heau changeout and crossbar removal for access to f outer periphery. W1.0 days) i

10. Tube end opening for eddy current sample due to pr-blems noted in 9. above plus lack of hardware maneu,erability and larger than anticipated number to be apened. W3.0 days)

11. Welding of spotfaced tubes due to massive welding unit problems. 68.0 days)

12. Manual repairs of reject welds due to larger number of rejects than expected. Qv2.0 days)

13. Penetrant testing of welds mainly due to loss of penetrant and time to replace. G.A.75 days) 14 Ring girder removal due to excessive tangling of control cables and need to wipe down and bag these la highly contaminated pieces. 6 25 days)

15. Surveillance program due to sinor setup problems and f need for some retakes. 40.5 days) 3 05 ON 2.20-6 ,

16. Recirculation flush due to the leaky recirculation system. (~0.25 days)

The above totals-24.25 days of delay time.

There were some items that were completed ahead of schedule and saved schedula time, such as:

1. J-leg screen installation. 40.1 days) g 2. Skyhook installation. (~. 2 days)

J 3. Freeze frame inspection. 41.5 days)

4. Heater installation and tubesheet heating. 90.2 days)

5. Tube end deburring. (s0.4 days)

6. Wire brushing of welds. 40.5. days) 7 Video inspection of weld reworks. (4 .2 days)

8. Upper tubesheet vacuuming. @0.3 days) 9 Lower head cleaning. 40. 3 days)

These schedule savings total coa 3.7 days. The net result between delays and savings is the -21 days delay in the overall repair ef fort. In looking at the delay items, the following breakdown should be noted:

- 78% to repair equipment problems

- 20% to miscellaneous problems and setup delays 2% to surveillance program problems D. Personnel This repair ef fort was perfecsed mainly by a B&W crew using boilermaker craf t labor. The basic organization and staffing is shown in Attachment 2.20-C. The two week mockup training session was essentially conducted on a one shift / day, six day / week schedule. Once actual repair ,

efforts started, the crews were shifted to three shif ts/ day, seven day / week for the duration of the job.

Due to the high radiation levels in the OTSG, craf: labor had to be used for mest of the non-technical work in order to minimize exposure to the B&W technicians. This 4

required an extensive training program for the boilermakers. The training program consisted of video tape trainicg aides and hands-on mockup training or q equipment setup and teardown. In addition, boilermaker

,] welders were trained and qualified to perform manual weld repairs if required. Attachment 2.20-0 provides a breakdown of the man rem exposure for the repair efforts, which to taled~ll2.8 Res.

In general, the use of this labor force worked fairly well, and it is recommended that its use be continued for any future repair ef forts. One point should be noted, that any manway cover removal and replacement was done I 1475 071 2.20-7

with FPC mechanics and this should be continued since they are felt to be better qualified for these efforts.

E. Procedures All repair procedures for this ef fort were written on-site by B&W Construction Company and issued as field construction procedures. The pec:edures to cover the surveillance program were written as a PRR to MP-134 The source document for these procedures was the B&W Field Change Authorization #3062 which was converted into MAR #79-4-68.

In general, this approach worked well and for this type {

5 of effort, with B&W providing the technical expertise, is probably the best approach. The only real procedural problem that arose during the repair effort involved the use of the muslin cloth during the lower head cleanup.

The repair procedures did not adequately specify how to

. clean up the lower head nor what materials should and should not be used in the primary system. This needs to be corrected in future repair procedures. Attach-ment 2.20-E provides an index of the procedures used for this repair effort.

F. Parts and Tools The special tooling used for the repair effort was g designed by, and procured from, B&W. The original design WI goals for the equipment were to perform a major repair ef fort as remotely as possible. The repair equipment essentially consisted of the following items:

1. Eddy current manipulator for use in freeze frame photography and with an air cylinder and 0.500" g gauge for tube end gauging. W

2. Grinding machine for use in large scale tube end and/or weld removal (not used this outage).

3. Ring girder machine with se.raight-on and right angle heads for tube machining. Cutters are capable of g both spotfacing and/or tube ID opening. 5

4. Welding head that mounts on ring girder machine with N power supplies. Used for performing the tube to tubesheet weld.

5. Brushes for mounting in milling machine head for g tube end debarring and weld brushing. 5

6. Roll expander for mounting on ring girder for expanding the top 1/8" of tube end.

E 2.20-8

7. Heaters for drying out the crevice area.

8 Penetrant testing rig for applying phosphorescent dye pe ne trant for remote PT examination of new welds.

9. Tempotary lower manway cover with nozzle and valve to be connected to a pump for a recirculation flush of the tubes.

10. Surveillance inspection equipment for use in obtaining high resolution pictures of the welds for the surveillance program.

11. Vacues system

12. Control cables and special penetration cover for

. Penetration 120 in order to allow use of control center exterior to containment.

With the exception of installation, removal and repairs, the above equipment is remotely operable from outside the OTSG. Items 3, 4, 5, 6 and 8 above are operated from a control center which was housed in a vehicle located on the west end of the Turbine Building. Control cables 4400') were run from the 3-0TSG through containment Penetration 120 and then through the chemical cleaning penetration at the west end of the Inte r=ediate Building to the control center.

As noted in Section C above, problems with the repair equipment resulted in -782 Qvi9 days) of the total repair effort delays. The sajor problems in this area were the welder units and the ring girder itself. The welaer unics' problems appeared to center on the following areas:

1. Sturdiness of the hardware / handling.

2. Electrical feedback and grounding problems.

3 Proper operation of the indexing / centering finger and controls.

4 Control of argon cover gas.

With respect to the ring girder operation, ths main problem area appears to be lack of maneuverability. For angular rotation, it is required that the front cross brace be installed in order to provide rigidity to the rails during movement. However, when performing work in the outer periphery region of the tubesheet, the f ront cross brace must be removed for access. Thus, any a extensive outer periphery work requires repeated, time consusing OTSG entries to install and remove this cross E brace. The multitude of control cables are also an interference problem. Since they are not self-tanding,

~

1475 OB 2.2C-9

g ring girder movement can cause them to go slack and hangup on the unit or to go too tight. Either of these can restrict movement, cause pulling apart at connectors, or cause misalignment of cameras. In addition, the number of cables running in through the =anway are h

W interference problems for the men making entries, which -

can result in cable pulling problems as described above.

The remaining delays caused by repair equipment problems can mainly be written of f to first-of-a-kind pro'ulems and .

were not extensive. The one exception is the ,

recirculation flush system using the temporary lower manway cover. The delays this setup caused due to leakage problems far overshadowed any potential benefits of the system. Since the demineralized water flush from the upper head proved to be efficient, both for last -

outage and as a backup for this outage, it is recommended that the recirculation flush system, including the temporary manway cover, not be used in the future.

Presently, the repair equipment is in storage at Crystal ,

River Unit 3. The following attachments provide the present status of the equipment and storage locations:

- Attachment 2.20-F "A" Ring Girder Unit Parts Status

- Attachment 2.20-G "B" Ring Girder Unit Parts Status

- Attachment 2.20-H Repair Equipment Storage Locations G. Comments and Reco==endations Based upon the results of the repair ef fort and the status of the equipment to date, the following comments and recommendations are offered:

1. As noted in Section F above, the repair equipment ~1s in various storage locations. Some of the equipment must be maintained in a controlled environment, which should be monitored. In addition, any movement of the equipment needs to be noted for f uture retrieval. Thus, a system for periodic g monitoring of the equipment status (location and E environment) should be set up for at least the next cycle.

2. Based upon the problems encountered with the repair E equipment, it is suggested that B&W be asked to generate a recommended list of improvements. A g meeting of all parties should be held to discuss the 3 course of action on equipment improvements and for replacement of damaged or missing pieces.

3. B&W is presently reviewing the results of the surveillance program conducted during the outage.

The report on the surveillance program still needs to be submitted by B&W. In addition a dete::2ination E

2.20-10 1475 074 ,

needs to be made as to whether or not to submit the results of the surveillance to the NRC, in what format, and by whom.

4 The resolution to the four tubes that were suspected of being relaxed was based upon some interim test results. These tests showed that the new welds are satisfactory for the next cycle of operation.

However, a more extensive testing program needs to 1 be initiated in order to permit continued operation

j with these welds in service af ter the next outage.

In addition, a decision as to what inputs on this subject should be given to the NRC needs to be made.

5. Future repair procedures need to be more specific as to what materials should not be used in the OTSG in q order to prevent a reoccurrence of the muslin cloth j incident. This fact needs to be f ed back to B&W for future procedure generation and needs to be enforced during PRC review of the procedures.

6. A decision needs to be made as to the extent of repairs to be conducted at the next refueling outage.

Items that need to be considered are as follows :

d "3

- Surveillance inspection program

- Additional tube end opening for eddy current testing

- Extent repair equipment is to be maintained for a possible major repair

- Necessary repair techniques if additional work needs to be done on the four suspect relaxed tubes

• It is suggested that a meeting of interested parties needs to be held soon af ter this outage in order to discuss these topics and lay out the f uture repair p rog ram.

7. Misplacement of a large amount of the ring girder equipment and eventual loss of a number of pieces points to a need for better control and staging of contaminated equipment. Procedures need to be j generated in order to impose a retter control system in order to minimize future losses.

5

8. Delays in =anway cover removal and replacement point to a need for improved procedures, equipment and/or training. This needs to be pursued for next outage.

I 1475 075 2.20-11

I I

RESPONSIBLE RECOMMDDED DEPT / PERSON COMP. DATE ACTION ITEM

1. Monthly Monitoring Maintenance /G. Westafer Monthly starting of Repair Equipment Chem Rad /G. Perkins 8/1/79 to next Status. B&W/ U. P. Ellsberry outage

2. Equipment Improve- Engineering / J. Colby 9/1/79 .

ment / Replac ement B&W/J. Janis l I!

Meeting.

3. Submittal of B&W/J. Janis 9/1/79 Surve'.llance f Insrection Report.

Determination of Engineering /J. Colby 9/15/79 {a Input to NRC. Licensing /B. Simpson

4. Establish Testing Engineering /J. Colby 9/1/79 y Program for Tube B&W/J. Janis l Welds. .

Determination of Engineering /J. Colby 9/15/79 {E Input to NRC. Licensing / B. Simpson

5. Update Future Repair B&W/J. Janis By next refueling Procedures to outage Reflect Materials Restrictions.

6. Future Repair Engineering /J. Colby 9/15/79 Program Meeting. B&W/J. Janis

7. Contamina t ed Equipment Control Chem Rad /G. Perkins Maintenance /G. Westafer By next refueling outage f

Procedures.

8. Improvements in Maintenance /G. Westafer By next ref ueling Manway Cover outage

. Removal / Replacement.

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a las M . E he kst M Saw W W M id M M M let blit lain M Attachment 2.20-C - Repair Effort Organ 12ation OTSG Coordinator J.Ullfone St.cretary J.S. Shetler Video B&U.CC Support Project Hgr.

P. Abbott R. Spruifl 1

NPCD Shift Craft Coordination Labor C. Cox lut Shift L.K. Prince 1 Field Supt.

(2300-0800)

- - - - - - --- - 1 Foreman - - - - - - - 2 T: h. Specialists 7 Boilerinakers 4

2nd Shift J. Conklin 1 Field Supt.

(0700-1600) - - - - - - - - - -

1 Fo reman --- --- 3 Tech. Specialista 8 Boilermakers 1 Project Engr.

00 3rd Shift O. I.1ndsey 1 Field Supt.

0500-M00) - - -- - - - -- - 1 Foreman - - - - - - 3 Tech. Specialists 8 Boilermakers

y ATTACHMENI 2.20-D B-0TSG REPAIR MAN-REM EXPOSURE WORK DESCRIPTION EXPOSURE (MREM) RWP Misc. Support 187 065 Work Outside Lower Head 740 064 Install Screens in Lower Head 1944 066 .

Install Skyhook & E.C. Manipulator 5924 067 Perform Freeze Frame Photography 2304 067 Remove Skyhook & E.C. Manipulator

& Install Ring Girder 27585 285 Gage 1000 Tube Ends 4908 076 (40%)

Spotface Lane Tubes 1840 076 (15%)

Deburr Tube Ends 613 076 (05%)

Open ids of "X" Tube Ends 4908 076 (40%)

Heat Tubesheet 966 077 (05%)

Roll Expand Tubes 1932 077 (10%)

Install Welder & Weld Tubes 39186 077, 386, 429 Inspect & Repair Welds (Manual) 8177 429 (25%)

Pr Inspect Welds 3990 429 (25%)

Vacuum Upper Tubesheet 407 082 Flush Upper Tubesheet & Tubes 1080 069 Clean Lower Head / Remove Screens 1707 086 Perform Surveillance 3910 This figure was derived by computation  !

Search Waste Drums 515 -

515 TOTAL

• 112,823 -

• This total cgrees with the total exposures of all 3&W individuals employed in the performance of the OTSG repair.

B 1475 082 E

ATTACHMENT 2.20-E INDEX OF B-0TSG REPAIR PROCEDURE CRR-2 Installation and Removal of Skyhook and Eddy Current Manipulator CRR-2 Inspection of Tubes to be Used for Ring Girder Holddown CRR-2 Installation and Removal of the Ring Girder Assembly and Milling Vacuum System CRR-2-15 '- Installation and Removal of J-leg Screens CRR-2 Sp:.:i teing and Opening of Designated Tubes CRR-2 Deburring of Machined Tubes CRR-2 Heating and Expanding of Tubes to be Welded CRR-2 Installation of Welding Equipment and Remote Welding and Brushing of Spotfaced Tubes CRR-2 Installation of PT Equipment and PT Inspection of Welded Tubes CRR-2 Installation and Removal of Shielding, Manual Welding of Outer Row Tubes and Reworking of Rejected Tubes CRR-2 Installation and Removal of Temporary Lower Manway Cover

< and Recirculation Flush System PRR to MP-104 - Surveillance 7.nspection 5 . ,

3 5 1475 083 ,

5 4

i ATTACHMENT 2.20-F "A" RING GIRDER UNIT PARTS STATUS

1. "Y" Axis Ring Segment In Storage Trailer

2. "Z" Axis

3. "W" Axis

4. "X" Axis

5. "X" Plus Box Frame Half

6. "X" Minus Box Frame Half

7. Rear Brace

8. Front Brace

. 9. Rear Spring Support

10. Machining Table

11. Machining Carriage

12. Theta Encoder

13. "R" Drive Motor

14. "X" Drive Motor

15. "Z" Drive Motor ' In Storage Trailer

16. Theta Drive Motor Missing

17. Theta Brake

18. "R" Drive Encoder

19. "Z" Cear Rack

20. '"Z" Encoder .

g

21. "X" Encoder

22. Hydraulic System In Storage Trailer

23. Air Motor Assembly

24. Tool Cutting Head

25. Angle Drive Gear Head I

1475 084 .I

.I

ATTACHMENT 2.20-F (Cont'd)

26. Drive Shaft In Storage Trailer

27. Stif fener Bar *

28. Rear Zoom Camera

29. Rear Tool Head Camera Missing

30. Front Tool Head Camera

31. Light Bar In Storage Trailer

32. Swivel Bracket "

33. C1ble Tray In Storage Trailer

34. Manway Support for cable Tray "

Roll Expander Air Manifold Roll Expander Expansion Unic Missing Liquid Penetrant Test Unit Partial in Storage Trailer Liquid Penetrant Test Unit Cameras (2) ,

In Storage Trailer Corner Mount Pan & Tilt Camera Missing Overhead Pan & Tilt Camera In Storage Trailer Welding Units (2 NED)

.s (1 Copley) In Storage Trailer & Warehouse

} .

Freepath Equipment in Storage ( Auxiliary Building)

Surveillance Equipment In Storage Trailer Motorhome/ Control Center In Storage at Copley Backup Ring Girder In Storage (Warehouse)*

• Detailed Inventory on Separate Document ,

I J 1475 085 5

s ATTACHME!C 2. 20-C "B" RING GIRDER UNIT PARTS STATUS PART NO. # OF PCS. DESCRIPTION STATUS 1-4 8 ea. Ring Segments Storage at FPC Warehouse 5 1 ea. Box Frame Half 6 1 ea. Box Frame Half -

7 1 ea. Rear Brace (1) 8 1 ea. Front Brace With A Unit in Contamin-ated Storage Trailer 9 1 ea. Rear Spring Support Storage at FPC Warehouse .

10 1 ea. Machine Table 11 1 ea. Machine Carriage 12 1 ea. Theta Encoder ,

13 1 ea. "R" Drive Motor 14 1 ea. "X" Drive Motor 15 1 ea. "Z" Drive Motor 16 1 ea. Theta Drive Motor 17 1 ea. Theta Brake 1 ea. "R" Drive Encoder 18 f

~

19 1 ea. "Z" Gear Rack 20 1 ea. "I" Encoder 21 1 ea. "X" Encoder 22 1 ea. Hydraulic System (1)(2) 23 1 ea. Air Motor Assembly Stand in FPC Warehouse (Motors & Manifolds used on A Unit & are missing)

(1)(2) 24 1 ea. Tool Cutting Head With A Unit in Contamin-ated Storage Trailer (Needs Repair) 25 1 ea. Rt. Angle Drive Cutting Head Storage at FPC Warehouse E

1475 086 E

3 ATTAC10tEttr 2.20-G (Cont'd)

PART NO. # OF PCS. DESCRIPTION STATUS (1) 26 1 ea. Drive Shaft With A Unit in Contamin-ated Storage Trailer 27 1 ea. Stiffener Bar Storage at FPC Warehouse 28 1 ea. Camera Bracket 29 1 ea.

30 1 ea.

(1)(2) 31 i ea. Light Bar Bracket with A Unit in Contaminated Storage Trailer (Needs Lights)

(I) 32 1 ea. Swivel Bracke t With A Unit in Contamin-ated Storage Trailer (1)(2) 33 1 ea. Cable Tray With A thic in Contamin-aced Storage Trailer (Needs Repair) 34 1 ea. Cable Tray Manway Sup port Not Supplied on B Unit

- NOTE: (1) Parts requiring replacement to maintain 3 thit as a mock-up unit.

(2) Parts requiring repairs to make B Unit operational.

3 E

1475 087 I

R 1

ATTACHMENT 2.20-H REPAIR EQUIPMENT STORAGE LOCATIONS I. IN ENVIRONMENTAL STORAGE TRAILER R

DESCRIPTION TAG #

ITEM #

Air Dryer 31 1

1 2 Weld Cables Machining Carriage for Ring Girder 16 3

Pump 13 4

Light Cords and Welding Imads 7 I

5 9

6 hp Air Hose 15 7

Vacuum Cleaner Hose 11 8

Coaxial Cables 17 9

Air Hose 23 10 Velding leads 19 11 Cable 22 12 Hose Connectors 18 13 Assorted Nuts & Bolts 21 14 Camera Cables a 15 Templets and Clearcom Headphones 4 16 Conductor 14 ads for Heaters 14 17

18. Stress Reliever Heater Power Supply 29 Stress Reliever Heater Power Supply 30 19 Air Compressor 27 20 Barberton Welder Power Supply 25 21 Copley Welder Power Supply 33 22 23 Assorted Extension Cords and Connections 1 24 Machining Table for Ring Girder 6 E

1475 088 [

8 f

ATTACHMENT 2.20-H (Cont'd)  ;

~

ITEM $ DESCRIPTION TAC #

25 Box of Temp. Manway Spacers 20 26 Tripod for Candy Cane 10 ,

i 27 Manual Welding Supply 28 28 Welder Stand 5 i

29 Barberton Welding Head 3 30 Copley Welding Head '2 31 Black Light for PT 12 32 Junction Bcx and Cables for Welder 22 33 Camera Ranger for Overhead Pan & Tilt 32 34A Ri ng Girder Parts:

343 GIRDER PART # DESCRIPTION 1 "X" Axis Ring Segment 2 "Z" Axis Ring Segment 3 "W" Axis Ring Segment 4 "W" Axis Ring Segment 5 X "Plus" Box Frame 6 X "Minus" Box Frame

- 7 Rear Brace 8 Front Brace 9 Rear Support Spring 15 "Z" Drive Motor .

22 Hydraulic System 31 Light 3a r 32 Swivel 3 racket 33 Cable Tray 34 Tray Manway Support

-- Roll Expander Manifold "~

-- Parts for Pr Test Equipment l

II. Fr0 RED IN MECHANICS ' TRAILER L

F-DESCRIPTION:

- -- Vacuum System for OTSG Work

-- Temp. OTSG Manway Cover (Contaminated) ,

(These items could not be stored in Environ = ental Trailer because of lack of space) 1A75 089 1

I

y ATIACHME!(I 2. 20-H (Coae'd)

III. ENVIRONMENTAL WAREHOUSE EQUIPMENT STORAGE BOX # DESCRIPTION ..

1 Welding Console, #1, NED (Barberton) 2 Welding Console, #2, NED (Barberton) 3 Power Supply, for Welder, NED (Barberton) 4 Spare Parts, "B" Ring Girder 5 Rails , "B" Ring Girder R

6 Pilot Assembly for #1 Weld, NED (Barberton) 7 Spare Parts, Welder, NED (Barberton) 8 Circulating Tank for Belt Grinder 9 Electrolytic Etcher .

(A) 10 Belt Sander (B) 10 Hose Assembly 11 Welding Head, #1, NED (Barberton) 12 Not Listed -- Stored in Mock-up Area 13 Tubesheet Grinder, Spare Parts 14 Cut Off Saw 15 Temp. OTSG Manway Cover 16 Circulating Pump for Cut Off Saw

- Tubesheet Grinder Oper. Console (2 boxes)

- Air Manifold for Grinder v/0ilers and Filters I

-- Assorted Cable Harness for Tubesheet Grinder

- Centerpost for Tubesheet Grinder

-- Grinder Arm, #1

- Grinder Arm, #2

-- Box (2 ea.) Trionics Digital Electronic Readout Panels (for Grinder) 1475 090 g

ATTACHMENr 2. 20-R (Cont'd)

BOX # DESCRIPTION renetration Cover w/ Adjustable Passchru Port Box Electronic Equipment Box Spare Parts for Grinder IV. IN MCCK-UP AREA WIRE CACE 30X f DESCRIPTION 12 Ring Girder Cables, Arc Cables and Vacuum Hoses 3 (Spool) Spare Pan and Tilt Cable 4 (Spool) NED Welder Cable, Spare 5 (Spool) NED 300' Spare Welding Cable

~

V. STORED IN INCLIS, SPOOL # DESCRIPTION 1 400' Ring Girder Assembly Control Cables 2 400' Welding Control Cables 6

1475 091 ~

u S

I

,