ML19344A821
| ML19344A821 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry, Turkey Point  |
| Issue date: | 06/30/1976 |
| From: | Parris H TENNESSEE VALLEY AUTHORITY |
| To: | Schwencer A Office of Nuclear Reactor Regulation |
| Shared Package | |
| ML19344A817 | List: |
| References | |
| REF-GTECI-A-36, REF-GTECI-SF, TASK-A-36, TASK-OR NUDOCS 8008220300 | |
| Download: ML19344A821 (250) | |
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.0-2 ";6 T..i a 12 in roepense to 7.. A. Purple'a lect er of .Iuna 1 ', l'.J3, ..e Jan.sa 7.. '. atsen requesting a docunented c :apari en of t:ta arot- 2 Fe- ,' .ruclear lant reactor building cr .ne denien, cas -inc, and
. sintenanca requirencnts trith the posicions 'iven in the docu:;2at entitled "': ranch Technical Position ATC53 c-1 c.verhond :1r.dline "stirls for :Tuclaar Ftr.mr ?lant.s." :'.ncl uad 2:2 .', ' ec tan of our evaluation.
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EECLOSURR ..- EVAWATIC:T OF RF. ACTOR WII.DI!!G CRA!!T' AT Ti!E ERCWNS FERRY UUCLEAR PLAUT IN CO:: PARI::C:i ':'O '.3!S UUC:."AR REGUI.ATC!G CC:0'!I3IO: 'S DCCU:~ENT ENTITLED "BRAUCH TEC:C:ICAL l'C31TICi Al'C.:H 9-1, DVAILMAD HIJ:DLIUG S'iGTDIC IVR HUCIFJdt l'CWEit l'LAUT3" DATED APRIL 19'(5 Comments are on section B, catitled " Branch Technical Position," and are nu=bered the sc=e as items in this section. , General. The ecuipecnt was designed in such a =anner that no single cor.:ponent fail. electrical or =cchanical, could cause dropping or other uncontrollable hoisting or lowering of the 1 cad. The.desi5n features which provide this protection are cutlined in paragraph 12.2.2 5 2 of the Final Safety Analysis Report (FSAR). 1.a. The performance specifications for construction and per=cnent plant use were identica.l. The loal combinations and nilowabic stresses are Ci ven in tabics 1: 2-114 and 12.2-15 of the FSAR. 1.h. Due to the location of the crane in a nonpressure confining part of the reactor building, the girders were of a scaled desicn with no need for venting and drainage provisions. The possibility of extensive surface condensatien was provided for by cleaning, pri=ing, and painting all structural surfaces in an approved tanner, using nonhygrescopic clectrical insulation, plating cri tical mechanical parts and ter.inals of clectrical devices, and installing motor space heaters. All stnictural portions of the bridge and trolle'y were fabricated frca A36 steel in accordance with AISC specifications. Fracture toughness tests were not performed since the lowest expected operatin.3 te=peratures are 0 F during construction and 65aF as permanent plant equipment. l.c. These criteria were met and are elaborated on in paracraph 12.2.2 5 of the FSAR. l 1.d. No nondestructive excmination (UDE) of welds was made at the time of l fabrication. Subsequent load testing at 125 percent of rated capacity has proved their soundness. ; 3.e. As stated in paragraph 12.2.2 5.3 of the FSAR, all operating stress l levels are far below the endurance limits of the matericis used. A ' fatigue analysis was not Airther considered. l 1.f. All welding was done in accordance with the AWS Standard Code for Welding in Duilding Construction. All welds requiring preheat and postlicat were donc by procedures which specified the required to:::peratures. 2.n. See FSAI: paragraph 12.2.2 5 2 for details of co:::plicace.
2 h13 ::ce: F3/a paracraph 12.2.2.5.2 for details of conrpliance. P... An e>. t"s m i. v" i nv"n t ory o f :.pa re pa r t,. nn.1 at:uel:ual p3 anL nai nLentmee e go . pent. will (d. low in-place cresir:. to be i..aoe or amy creditable component f.d3ure. , 33 1 Mal load attachment points are provided on the main load block as chown in figure 12.2-22d of the FSAR. Each attachment is designed with a safety factor of 5 cr.d proof tested to 2V withcut permanent deformation. Win is consistent with the criteria of paragraph 3.g. of Branch Technical Poatien APC3B 9-1. 3.b. Several clings are provided for heliling verious covers and shield pluca. The :.iini:nm cafety facter for these niings is 1,.86 based on the actual load to be lifted. Eedundant design was no; used since none of the loads using slings are handled over the open reactor. Chere are two lifting devices that may be used with the reactor building crane over an open reactor pressure vessel. These devices are the dryer-separator sling and the reactor pressure vessel head strongback. Both devices consist of four legs independently suspended from a central fixture. The devices can withstand the failure of any one leg and still support their rated capacity, with a safety factor of at least 3. The dryer-separator sling has a safety factor of 5.55 based on rated capacity. The reactor pressure vessel head strongback has a safety factor of h based on rated capacity. Both devices have been tested to 125 percent of their rated capacity. 3.c. The redundant reeving system is shown in figure 12.2-22d of the WAR. The maximum full load hoicting speeds are: main hcok 5.33 FFM and auxiliary hook 22.6 ??M. E=pty hook speeds of 275 percent of these values are provided by the tapered speed load characteristic of the General Electric Company's Maxspeed drives. "hese values are in the "siow" rance for their re:pective captcitics as recommended by the Cranc Manufacturers Association of /cerica (CyAA) Specification 70 and are considered safe maximum speeds. l 3_. q. The reeving system for the main hoist shc .n in figure 12.2-22d of l the FGAR is dual and maintains vertical balance and aliCnment with both ropes intact. E:.ther system.has a factor of safety gree.tcr than 3 based on full load l cnpacity. In the unlikely event of a rope failure, the vertical alignment shifts so tl.nt the load c_ ter of gravity is under the center of support of the remaining rope system. Extensive tests cn thic reeving system have chevn that the lotui shift caused by a rope failure is cdequately cuchioned by the rope elasticity and the equalizing cylinder to. hold the induced stresses well belou ulti:.: ate vilues. The tests on this reeving system verc~ conducted by the University of Tenneccee Mechanical Engineering Department under contract from TVA. Tac results of these tests indicate that the m=cimum linc loa.1 resulting from a rope failure would not execed 43,300 pounda,
- b. line load is based on handling a 70-ton l cank and having one rcpe to fail in the highcot position of the hook l Vith a fixed equalizint; cylinder. Under this condition the remaining rope would htve a :.afety f:.ctory of 3.'s based on the breaking :trength of the rope. In the stabilized position with onc rope failed, the load can still be hoicted with the remaining rope.
3 The rcovInt; on the eux111ary hook is a two-rope whip-style system which provides a ::afety factor of 3.13 based on the breaking strength of the rope when handling rated load with one rope. 3.c. Both the head and load block have physically separate sheave systems for the two ropes. A load belance is thus established on that portion of the blechs associated with the unfailed rope system. The main hoist rape is 1-1/4 inches in diameter, 6 by 37, EIFS, an:1 TGC; and the auxilia / hoist rope is 5/8 inch in diameter, 6 by 37, corrosM-resistant steel, and IL'C. Impact loading allowance, which includes acceleration and deceleration effects, was taken as 15 perec-' of the trolley live loads. For the main hoist with rated design load, the dynamic stress in the lead line is 15.6 percent of its brecking strength and the static stress is 14.1 percent. The dynamic and static stress for the auxiliary hoist rope is 16.3 percent
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of its rated breaking strength. The line speeds for full lead hoisting are: main hoist 32 HM anci auxiliary hoist 22.6 H M. Each of these speeds can increase by a factor of 2 75 with empty hook conditions. 3.f. The maxirum fleet angle frc= dm to lead sheave is 2.86 degrees. In the high hook position the maximum fleet angle between sheaves is 4.15 degrees. This angle decreases to the suggested 15 degrees within 8 feet 3 inches of hook travel. A minimum amount of handling is done near the high hook position. The equalising device is a double-ended hydraulic cylinder as shown in figure 12.2-22:1 of the FSAR. Thi:: is a modified beam type with internal l damping. The equalisation rate is limited to 6 inches per minute by a ~ velocity fuse arrangement in the case of a rope break. 1 No reverse bends are u::cd in this reeving system. The running sheaves are 27 3 and 24.1 times the rope dia:cter and the equalising sheaves are 20.1 times the rope dicneter. This is in accordance with CMAA Specification 70 which allows ratios of 24 to 1 and 12 to 1, respectively. M. As shown in table 12.2-15 of the FSAR, an mechanical parts are designed with a safety factor of 5 under normal conditiens. The hooks were proof tested to 200 percent rated capacity with subsequent magnetic particle exa:.ination prior to installation. After installation, a complete 125 percent load test was performed on the crane. No static load tests were perfomed on the reeving system at the manufacturcr's plcnt.
le M. The intent of these criteria is met by the safety features listed in paragraph 12.2.2.5 2 of the FSAR. . M. The adjustable torque Etit cn the hoist drivesOur is set at 200 percent experience indicates of the full lead torque of the shunt wound motors. that 200 percent is decirable to obtain adequate acceleration of loads. The techanical and structural parts were decigned en the basis of 275 percent full load motor torque under stall conditions. M. Load hancup i: con crvatively provided for by deciGning for 275 percent full load motor torque at stall while the actual value is 200 percent. Redundant limit switches of different design are provided to stop the upward motion of the hook in the event of cperator negligence. No shock-absorbing device is provided. M. See paragraph 12.2.2.5.2.c and 12.2.2 5 2.d of the FSAR for statement of co=pliance. 3 1. The calculated power requirement and the motor rating for the main hoist are identical at 50 horsepower. The auxiliary hoist motor is rated at 7.5 horsepover wh'.le the calculated requirement is 7.45, an oversize of 1.1 percent. M. All aspects of these criteria are complied with. 3.n. The intent of these criteria was =et by checking the centractor's submitted de icn drawings and co=putations and providing shear bars and/or tapered dovels to secure ccchanical ec=ponents. 3.o. These features are inherent in the General Electric Cc=pa'.y's Maxspeed DC adjustable voltage syste=s used on both hoist and travel drives. -
-M. The next larger standard size =otor above that calculated was selected. Travel drive sizes are based on acceleration time as well as running torque and this practice was followed in sizing these drives.
Inching is inherently provided in the variable speed DC drives provided for the travel motions. The bridge is provided with one 50 percent brake for normal stopping and a 100 percent torque bral e for holding. Both trciley brakes are 75 percent torque brakes. There brake torque ratin; alc cencrally in accordance with CMAA Specificaticn 70 when it is considered that this crane is both a floor and cab controlled machinc. An adjuntable timo delay is provided for each backup brake. All brakes are actuated on interruption of power for any reacon.
e O , 5 All brakes have provision for manual operation and none are foot operated. No drag brakes are used. All bridge whccls and all trolley wheel.: are within a machining tolerance of 10.010 inch of the same diameter. The maximum trolley speed is 30 35 FFM, and the maximum brid6 e speed is 54.1 FP11. 3.c. The bridge mounted cab has co=plete operating and emergency - controls. A auplicate set of controls for all functions except the =ain hoist is provided on a bridge counted retractable pendant. An emergency stop switch is provided at bcth statiens and at three locations on the operating floor. Ee % heir;t is equipped with two overhoist limit switches and one down ' travel livit switch'. A mechanical overspeed switch, set to trip at 125 percent of maxi.e. rated speed in either direction, is provided for each hoist. The bridge and trolley are cach provided with two limit switches wired in series which decelerate the drives to creep speed between the limit switch actuators and the m im travel. Four bridge bu:.pers and two trolley bumpers of the spring type are provided. 3.r. All limit switches, overspeed switches, overcurrent relays, etc., are provided as safety backup devices and t.re not intended for nor=al operati.d use. 3.s. The maxi =um working load (MRL) and the design rated load (DRL) are identical. I 3.t. The construction and pemanent plant requirements were the same. s A thorough perfomance test and 125 percent capacity load test were made l prior to use as permanent plant equipment. Visual inspection was the only HDE process used on the crane after it was erected. M. An operating and maintenance nanual satisfying the intent of this l paragraph was supplied by the cranc manufacturer. i
. h.a. An extensive acceptance test was conducted in order to verify that the performance and safety devices were functional as designed.
An ongoing crane inspection and preventive maintenance progrs= incorporating I l checklists, NDE, etc., is carried on by TVA for all nuclear plant safety related cranes. Records of proof tests on hooks are maintained in the permanent records file at the plant. l I F
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6 4.b. The acceptance tests included complete performance tests at no-load, 50 percent,100 percent, and 125 percent rated capacity. Two-blocking is protected against by redundant overhoist limit switches and is not considered a creditable occurrence.
- No load hangup test was performed. This possibility was provided for by designing the structural and mechcnical parts of the crane for 275 percent of motor full load torcue at stall. The allowable stress for this condition was o.9 yield which gives a safety factor of more than 2 based on ultimate.
h c. The WL capacity will be maintained at 100 percent of DRL capacity. O o
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/36 GM BFNP 24
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14.4 Discuss the consequences of dropping the refueling cask into the spent fuel storage peol from the standpoint of loss of poul water and damage to the stured spent fuel. Discuss the analysis of the resulting offsite doses due to ruptured fuel rods. What ineasures are planned to prevent the movement of the retuehng cask over the spent fuel and the accidental dropping of the cask? Since it is planned to transfer spent fuel from the Unit 1 or Unit 2 fuel storage pools to the Unit 3 fuel storage pool, consider the effects cf an accidental dropping of the fuel cask on interme'diate structures or f
; components. ;
y s.
; RESPONSE The sefuehng cask he .g system has been designed to prevent credible f ailures from causing the dropping of the cask in a manner that would cause unacceptable consequences. (This is analaguous to the design of reactos protection systems, which are designed to prevent credible f ailures from preventmg reactor shutdown when required.)
The controls of the overhead electric traveling crane, the mechanical portions of the crane, the structural portions of the crane except the trolley cross gif ts ar.d bridge girders, and the structural assembbes for supporting the cask by the crane yoke and cask trunnions are designed to accept single failures without droppmg the cask. The cross-girts and bridge girders are as co6 trvatively designed as the bWiding steel that supports the crane. All the equipment is designed to withstand the DBE without failure whether or not the cask is being handled. Section 12.2.2.5 of the FSAR contains a description of the reactor building crane, including its safety features, a safety evaluating ar'd a summary of the inspections and tests of the crane. Details of the smgle f ailure protection built into the casw system are given in section 12.2.2.5.2, which describes the safety features. Tornado considerations also are taken up in the response to Question 12.17 of March 25,1971. Spent fuel f rom the Browns Ferry Nuclear Plant will be shipped in a cask weighing about 60 tons and having a capacity of 18 BWR fuel assembhes. Heavier casks, howevt , may be used in the future. The cask will be shipped by rail from the fuel reprocessmg plant to Athens, Alabama, where the cask support frame will have trailer wheels affixed to it. The trailer then wili be moved by highway to the plant site. OutsioO the equipment airlock entrance to the reactor building, the exclusion frame around the cask will be 24 removed, and the cask hosed down to remove road dirt. The trailer then will be backed into the airlock,which is long enough to receive the tractor trailer between the doors. When the outer door has been closed, the inner door will be opened and the trailer backed into the space below the hatch between the RS-R6 and the to column lines (see FSAR Figure 1.66). On the elevation 664 feet floor (FSAR Figures 1.6-2 and 1.611), heavy items that would obstruct cask movement wit be relocated using the reactor building crane. The cask rotator, cask yoke, and the two sets of safety cables then will be attached to the reactor building crane hook and lower block assembly as shown m FSAR Figure 12.2 22c. The hook and yoke with the safety cables will be lowered to the refuehng cask. The movable blocks and power screws on the fuel cask yoke, shown m Figure 014.41, will be used to securely clamp the yoke to both cask lif tmg trunnions. One ciamp on one cask trunnion will support the cask. Af ter the cask has been raised to a vertical position,it will be freed from the support frame and lif ted to elevation 664 feet. Sections of handrail are to be removed from the edge of the hatch, and the cask moved out over the floor with about 6 inches of clearance between the cask and the floor. The safety cables would allow the cask to drop only
; approximately 3 inches if the hook or rotator unit were to f ail; however, a cask dropped without restraint from a height of 6 inches would not penetrate the floor at anf location.
If there is to be a delay before the carn is to be placed m a fuel storage pool, the cask will be stored in the washdown areas of either umt 1 or unit 3. if the cask is to be detached from the crane, tiedown cables, capable of preventmg seismic overturn, will be affsmed tretween the cask and floor. -o Q.14.4-1
BFNP.24 East-west movement of the cask is to be carried out en the space between cr.lumn lines s and t (FSAR Figures 1.&2 and 1.611). Clearance between the cask and floor will be maintained at approximately 6 inches during any 24 mov: ment. Handrails are to be removed as necessary to permit passage of the cask, and replaced af ter the cask has passed. ,
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When II is m seadiness for loading of spent fuel, the cask will be moved adjacent to the cask storage area of the r;spective $el pool, and the bolts removed from the cask head. The cask will be centered approximately on the north southlenterkne of the sturage area in the pool and necessary sections of the handrail removed. At a height of 6 inches above the floor, the cask will be moved out over the pool until it is approximately centered over the storage area. The cask then will be lowered into the pool to the approximate center of the storage a ea. This area is def ned by a 1 inch thick staisiless steel plate welded to the pool floor liner. The cask htting yoke will be desengaged from the cask trunnions and lifted out of the water, bringing with it the cask head. As the submerged items emerge from the pool, they are to be rinsed with demineralized water. Absorbent paper will be placed on the floor to catch any dripping water along the path of movement of the yoke and head to a place out of the way south of column line s, and the handrails replaced. Spent fuel is to be moved from the storage racks to the cask using the refuehng platform.When loading.wh.ch takes about 3 hours, is completed the cask head will be lowered into place by means of a procedure similar to that used for placement of the cask. It should be noted that the safety cables between the yoke and lower block assembly will still be en place. The cask yoke will be clamped to the cask hf ting trunnions, the cask head bolted on, and the cask hited clear of the pool, agam using a demmerahred water rense. Absorbent paper will be used to catch any dripping watIr during movement of the cask over the floor. The loaded cask then is to te moved to a position m front of the spent fuel cask decontamination facility located south of the unit 2 reactor between column hnes RIO and R11. Here the safety cables shown in Figures 12.2 22c and Q14.41 will be removed to permit cask rotation.The cask must be raised about 2 feet 10 inches above the floor before it is moved into the decontamination f acihty. This is the only part of the procedure that will allow a cask to be lif ted without the safety cables. A cask dropped freely from a height of 2 f t 10 in,within this floor area will cause permanent deformation of the floor slab but the slab has the structural capabihty of withstanding this drop. Cask decontamination will be conducted as described in sub-section 10.4.10 of the FSAR. Thereaf ter, the cask will be moved out of the decontamination facihty, and the safety cables replaced.The cask then will be moved to either the unit I or the unit 3 washdown areas for .ny pre shipment tests that may be required. Tiedown cables are to be aflexed if the cask is disengaged from the crane. When ready for shipment, the cask will be moved to the hatch between the R5 and R6 column lines and lowered to the support frome on the trailer. Then the cask will be shif ted to a horizontal position, the yoke unclamped and lif ted free, and the process nf securing the cask to the support frame completed. The trailer will be moved out of the equipment airlock, and final piepas ations for shipment made. The cask then will be transported to Atnens, Alabama, for loading onto the rail car.
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BFNP 24 1 -
. LUGS FOR SAFETY CABLES I{ '
4 . g p/ p- y FUEL CASK YOKE i) () POLE W/ UNIVERSAL AND SOCKET
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BROWNS FERRY HUCLEAR PLANT { FINAL SAFETY ANALY515 REPORT l - Fuel Cask Yoke FIGURE O.14.4-1 (Added by Amendment 24) l l p
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a f- /q BFNP-67
- 10. 3 SPENT F UEL S'IVPAGE This section presents a description of the spent fuel storage facilities presently insEalled at7hTplant. Due to projected shortages of storage space, modifications to the spent fuel Storage racks have been proposed and approval of the modified
$pck design by NRC is pending. With the installation of high dbnsity feel storage racks in the existing spent fuel pools, the storage capacity of each fuel pool will be increased from 1,000 to 3,471 fuel assemblies, providing space for storage of approximately f our and one-half full core loads.
10.3.1 Power Generation Obiective The objective of the spent fuel storage arrangement is to provide specially designed underwater storage space for the spent fuel assemblies which require shielding during storage and handling. ; 10.3.2 Power Generation Design Basis
- 1. Spent f uel storage racks for each reactor shall be supplied !
to accommodate 140% of the full core load of fuel assemblies.
- 2. Spent f uel storage racks shall be designed and arranged so that the f uel assemblies can be efficiently handled during refueling operations.
- 10. 3. 3 Saftty Design Basis
- 1. The fuel array in the f ully loaded spent fuel racks shall be subcritical by a substantial margin.
- 2. Each spent f uel storage rack loaded with fuel and the tiedown lugs for the racks shall be designed to withstand earthquake loading to minimize distortion of the spent fuel storage arrangement.
10.3.4 Description The spent f uel stcrage racks provide a storage place at the bottom of the fuel pool for the spent fuel received from the reactor vessel as shown in Figure 10.2-1 of subsection 10.2. The racks are full length, top entry and are designed to maintain the spent fuel in a space geometry which precludes the possibility of criticality under normal ar;d abnormal conditions. Normal 10.3-1 1 _
BFNP-67 conditions exist when the spent fuel is stored at the bottom of the fuel pool in design storage position. Abnormal conditions may result from an earthquake, or mishandling of equipment. _ Each gtandard spent fuel rack shown in Figure 10.3-1 is 66.5 in. long,g182.62 in. tall, occupies 2 ft of the pool length, and etc7es 20 f uel assemblies with 11.75 X 6.6 in. center-to-center se p. tration. The racks are made of aluminum and are bolted to the fuel pool floor. All racks are built with a common mounting dimension in order to facilitate rack rearrangement or replacement, and can be moved without draining the pool. Storage racks are provided for 140% of tne reactor core load. The maximum refueling batch size that is expected to be in the fuel pool is 35% of a core load. Theref ore, total core unloading of any of the cores can be accommodated at any time. Spaces between normal fuel storage positions are designed so that it is not possible to insert a fuel assembly, either deliberately or by accidental drop, in any position not intended as a fuel , storage position. Safety curtains, made of aluminum, are ' installed between adjacent spent fuel storage racks to serve as structural members, to prevent accidental insertion of fuel bundles between adjacent racks, and to maintain minimum spacing between adjacent racks for geometric reactivity control. Each spent fuel storage rack and fixture loaded with fuel is designed as a seismic Class I structure to resist sufficiently l the response motion at the installed location within the l cupporting structures for the design basis earthquake (see ! Appendix C) . Tnere are three spent f uel storage ' pools; one per unit. Each i fuel storage pool is designed so that no single failure of l structures or equipment will cause inability 1) to maintain : irradiated fuel submerged in water, 2) to re-establish normal ) fuel pool water level, or 3) to safely remove fuel from the 1 plant. In order to limit the possibility of pool leakage around l pool penetrations, each pool is lined with stainless steel. In ! Eddition to providing a high degree of integrity, the lining is , designed to withstand abuse that might occur when the spent fuel chipping cask is moved about. No inlets, outlets, or drains are provided that might permit the pool to be drained below appro,ximately 10 ft above the top of the active fuel. Lines , , extending below this level are equipped with syphon breakers, j l check valves, or other suitable devices to prevent inadvertent ) l 10.3-2 l 1
BFNP-67 pool drainage. Interconnected drainage paths are provided behind the liner welds. These paths are designed to 1) prevent pressure buildup behind t he liner plate, 2) prevent the uncontrolled loss of contaminated pool water to othcr relatively cleaner _ locations
,within the secondary containment, and 3) provide expedient liner
-leak detection and measurement. These drainage paths are formed jy welding channels behind the liner weld joints and are designed
;to permit free gravity drainage to the equipment drain tank.
A transfer canal is provided to join the dual pools of units 1 and 2. This transfer canal is the same depth as the transfer slot between the reactor well and the fuel pool. The transfer canal has a gate on each end so that the fuel pools can be isolated if needed. The transfer canal can also be drained if necessary. This canal enables fuel assemblies or channels to be transferred between the two units. It also permits storage of fuel and irradiated objects in one pool if it becomes necessary to empty the other pool. A diamond plate walkway is provided for personal crossing, and is removable in small lightweight sections. When the diamond plate is removed, safety rails are installed. A further description of the physical characteristics of the reactor well and its relationship to the spent fuel pool is given in subsection 4. 2, " Reactor Vessel and Appurtenances Mechanical Design," and subsection 5.2, " Primary Containment System." 10.3.5 Safety Evaluation The design of the spent f uel storage racks provides for a subcritical anultiplication f actor (k ef0 for both normal and abnormal storage conditions. For normal conditions, k eff is equal to or less than 0.90. Normal conditions exist when the fuel storage racks are located at the bottom of the pool covered with a normal depth of water (about 23 f t above the stored fuel) for radiation shielding with the maximum number of fuel assemblies in their design storage position. The spent fuel is covered with water at all times by a minimum depth required to provide sufficient shielding. Under abnormal conditions, k eff will not exceed 0.95. Abnormal conditions may result f rom an earthquake, accidental dropping of equipment, or damage caused by the horizontal movement of fuel handling equipment without first disengaging the fuel from the hoisting equipment. Tnese calculations were done using a two dimens.onal, three group, diffusion theory code with a water temperature of 65 C. 10.3-3 i
BFNP-67 Water temperatures of 20*C and 65'C were analyzed to assurc that 65'C was tne most reactive under normal conditions. In order to insure that the design bases stated above are met, the Bollowing normal and abnormal loading conditions were analyyed with results as shown. The fuel positions taken into account under normal conditions were: k
- c. normal positioning in the spent fuel storage array 0.843
- b. eccentric pcsitioning in the spent fuel storage array 0.835 l l
- c. two bundles placed side by side while ;
separated from the storage rack area by 12 inches of water 0.692 1
- d. three bundle tee array separated from the j storage rack area by 12 inches of water 0.792
- e. three bundle linear array separated from the storage rack area by 12 inches of water 0.747 1
The fuel positions taken into account under abnormal conditions were: k
- a. moving fuel bundle between work rack and storage rack 0.882
- b. moving f uel bundle in aisle between storage racks 0.843 l
- c. geapple drop displacing two fuel bundles 0.884
- d. four bundle square array separated f rom the I storage rack area by 12 inches of water 0.856 l l
l 10.3-4 ; s
BFNP-67 10.5 Fuel Pool Cooling and Cleanup System 10.5.1 Power Generation Obiective The . Fuel Pool Cooling and Cleanup System shall be designed to remove the decay beat from the fuel assemblies and maintain fuel pool water within specified temperature limits. 10.5.2 Safety Design Basis The fuel pool cooling and cleanup system shall be designed to remove the decay heat from the fuel assemblies and maintain fuel pool water within specified temperature limits. 10.5.3 Power Generation Design Basis
- 1. The Fuel Pool Cooling and Cleanup System shall minimize corrosion product buildup and control water clarity, so that :
the fuel assemblies can be ef ficiently handled underwater, l
- 2. The Fuel Pool Cooling and Cleanup System shall minimize I fission product concentration in the water which could be released f rom the pool to the reactor building environment.
- 3. The Fuel Pool Cooling and Cleanup System shall monitor fuel pool water level and maintain a water level above the fuel sufficient to provide shielding for normal building occupancy.
- 10. 5. 4 Description The Fuel Pool Cooling and Cleanup System for unit 1 is shown in Figure 10.5-1. The system cools the fuel storage pool by transferring the spent fuel decay heat (see Table 10.5-1) through beat exchangers to the Reactor Building Closed Cooling Water System. Water purity and clarity in the storage pool, reactor well, and dryer-separator storage pit are maintained by filtering and demineralizing the pool water through a filter-demineralizer, which is shown in Figure 10. 5-2. System performance under various operating conditions is shown in Figure 10.5-3.
1 The system for each fuel pool consists of two circulating pumps connected in parallel, two heat exchangers, one common filter-domineralizer subsystem, two skimmer surge tanks, and the required piping valves, and instrumentation. Each pump has a design capacity equal to or greater than the system design flow 10.5-1 I -
BFNP-67 rate and is capable of simultaneous operation. Four filter-demineralizers are provided, (one spare unit snared between the three active units) each with a design capacity equal to or greater than the design flow rate for a fuel pool. The. pumps circulate the pool water in a closed loop, taking suction from the surge tanks, circulating the water through the heat exchangers and filter demineralizer and discharging it through diffusers at the bottom of the fuel pool and reactor well. The water flows from the pool surface through skimmer weirs and scuppers to the surge tanks. The fuel pool pumps and heat exchangers are located in the reactor building below the bottom of tne fuel pool. The f uel pool filter-demineralizers, which collect radioactive corrosion and fission products, are located in the radwaste building. The fuel pool concrete structure and metal liner are designed to withstand earthquake loads per project seismic requirements as a Class I system (see Appendix C) . Fuel pool water is continuously recirculated. The heat exchangers are designed to remove the decay beat load of the normal discharge batch of spent fuel. The heat exchangers in the Residual Heat Removal System are used in conjunction with the Fuel Pool Cooling und Cleanup System to supplement pool cooling in the event that a larger than r.ormal amount of fuel is stored in the pool. Makeup water for the system is transferred from the condensate storage tank to the skimmer surge tanks to make up evaporative and leakage losses. The reactor well and dryer-separator pit are filled for refueling by pumping water from condensate storage to the reactor vessel via the condensate and feedwater lines. The water is pumped by a condensate pump and is passed t,hrough a condensate filter-demineralizer enroute to the reactor vessel. Following refueling the water is drained to the condenser hotwell, from which it is pumped by a condensate pump through a condensate filter-demineralizer and then to condensate storage. The circulation patterns within the reactor well and storage pool are established by the placement of the diffusers and skimmers so as to sweep particles disJodged during refueling operations away from tne work area and out of the pools. The normal flow pattern may be altered by taking suction from the bottom of the dryer-separator storage pit to control particles dislodged frem parts transferred to the dryer-separator storage pit. Suction may also be taken from the bottom of the reactor well. A portable, l l l 10.5-2
BFNP-67 submersible-type, underwater vacuum cleaner is provided to remove crud and miscellaneous objects from the pool valls and floor. Pool water clarity and purity are maintained by a combination of filtering and ion exchange. The filter-demineralizer maintains total dissolved heavy element content (Cu, Ni, Fe, Hg, etc.) at 0.1; ppm or less with a pH range of 6.0 to 7.5 f or compatibility with aluminum fuel racks and other equipment. Particulate material is removed from the circulated water by the pressure precoat filter-demineralizer unit in which finely divided powdered ion exchange resin serves as a disposable filter medium. The resin is replaced when the pressure drop is excessive or the ion exchange resin is depleted. Backwashing and precoating operations are controlled from the radwaste building. The spent filter medium is flushed from the elements and transferred to the waste backwash receiver tank by backwashing with air and condensate. New ion exchange resin is mixed in a precoat tank and transferred as 3 slurry by a precoat pump to the filter where the solids deposit on the filter element s. The holding pump maintains circulation through the filter in the interval between l the precoating operation and the return to normal system i operation. 1 The filter-demineralizer units are designed to operate with water flowing at normal 2 gpm/sq f t. Powdered ion-exchange resin or resin mixed with cellulose is used as a filter medium. The holding element for the filter material is a stainless steel mesh, mounted vertically in a tube sheet and replaceable as a unit. Venting is possible from below the tube sheet and from the upper head of the filter vessel. The upper head is removable for installation and replacenent of the holding elements. The filter vessel is constructed of phenolic resin-coated carbon steel. A post-strainer is provided in the ef fluent stream of the filter-demineralizer to limit the migration of the filter material. The filter holding element is capable of withstanding a differential pressure greater than the developed pump head for the system. Tne ion exchange resin is a mixture of finely ground, 300 mesh or less, cation and anion resins in proportions as determined by service requirements. The cation resin is a strongly acidic polystrene with a divinylbenzene cross-linkage. The resin is supplied in the fully regenerated hydrogen form. The anion resin is a otrongly basic, Type I, quarternary ammonium polystyrene with a divinylbenzene cross-linkage. The resin is supplied in a fully regenerated hydroxide form. 10.5-3
, _ _ --. r--,
BFNP-6 7 The maximum pressure drop across the filter and associated process valves and piping at the time for filter media replacement should not exceed the value shown in Table 10.5-1. A holding pump is connected to each filter-demineralizer. This pump starts automatically to maintain sufficient flow through the filter media to retain it on the filter elements during loss of system flow. The holding flow rate is 0.1 gpm/sq f t of filter area. The backwash system is used to completely remove resins and accumulated sludge f rom the filter-demineralizers with a minimum volume of water. Backwash slurry is drained to a local waste backwash receiver tank. The precoat system is designed to rapidly apply a uniform precoat of filter media to the holding elements of a filter-demineralizer. The precoat tank is carbon steel coated with phenolic materials and sized to provide adequate volume for one precoating. An agitator is furnished with the tank f or mixing. One centrifugal precoat pump and associated piping and valves are provided to precoat any filter-demineralizer and recirculate the water to the precoat tank or l suction side cf the precoat pump at a rate of 1.5 gpm/sq ft of l I filter area. The precoat system is also capable of cleaning or decontaminating any filter-demineralizer unit with a detergent or . citric acid solution. The filter-demineralizer units are located l separately in shielded cells. Sufficient clearance is provided I to permit removal of the filter elements from the vessels. Each cell contains only the filter-demineralizer and piping. All inlet, outlet, recycle, vent, drain, and other valves are located on the outside of one shielding wall of the room, together with necessary piping and headers, instrument elements and controls. Penetrations through shielding walls are located so as not to compromise radiation shielding requirements. The system instrumentation is provided for both automatic and remote-manual operations (see Figure 10. 5-4) . Fuel pool skimmer surge tank high, low, and low-low water level switches are provided. The high and low level switches provide level change indications in the control room, the pump room, and on the refueling floor. The low-low switch stops the circulating pumps when surge tank reserve capacity is reduced to the volume which can be pumped in 1 minute with one pump at rated capacity. Control of flow to or f rom the reactor well is accomplished manually during refueling. A level indicator mounted at the valve rack is provided to monitor reactor well water level during refueling. A pool high-low water level switch operates a local indicator light and sounds an alarm in the cont rol room whenever the level is either too high or too low. The trip point is adjustable over the range of skimmer weir adjustment. 10.5-4
BFNP-67 The pumps are controlled f rom the pump room. Pump low suction pressure automatically turns of f the pumps. A pump low discharge pressure alarm indicates in the main control room and on the ref ueling floor. The controls for the remote controlled valves which discharge the fuel pool water to the condenser hotwell, condensate storage tank, and waste surge tank are located on a rack in the pump room. The open or closed condition of each of these valves is indicated by lights in the pump room. The flow rate through each of the filter-demineralizers is indicated by flow indicators in the pump room and on the radwaste panel. The flow indicators on the pump room panel can be seen by the operators f rom the vicinity of the fuel pool cooling system control valves. A high rate of leakage through the refueling bellows assembly, drywell to reactor seal, or the fuel pool gates is indicated by lights on the operating floor instrument racks and is alarmed in the main control room. The filter-demineralizers are controlled from a panel in the radwaste building. Differential pressure and conductivity inctrumentation is provided for each filter-demineralizer unit to indicate when backwash is required. Suitable alarms, dif f erential pressure indicators, and flow indicators are provided to monitor the condition of the filter-demineralizers.
- 10. 5. 5 Safety Evaluation Maximum normal heat load of spent fuel stored in the pool is the sum of the decay heat released by the average spent fuel batch discharged from the equilibrium fuel cycle at the time the last assembly enters the pool, as calculated from the equilibrium refueling time estimate, plus the heat being released by the batch discharged at the previous refueling. The maximum possible heat load is the decay heat of the full core load of fuel at the end of the fuel cycle plus the remaining decay heat of the spent fuel discharged at the two previous refuelings. The Residual Heat Removal System is operated in parallel with the Fuel Pool Cooling and Cleanup System to remove this head load. The Fuel Pool Cooling and Cleanup System can maintain the fuel pool water temperature below 125'F when removing the maximum normal heat load from the' pool with the reactor building closed cooling water temperature at its maximum. The fuel pool water temperature may be permitted to rise to approximately to 150*F when larger than normal batches of spent fuel are stored in the pool. If it 10.5-5
BDiP-67 appears tnat the f uel pool temperature will exceed 125'F, the Fuel Pool Cooling and Cleanup System is connected by operator action to the Residual Heat Removal System. This increases the cooling capacity of the Fuel Pool Cooling and Cleanup System so that a water temperature below 1500F is maintained. The flow rate is designed to be larger than that required for two complete water changes per day of the fuel pool or one change per day of the fuel pool, reactor well, and dryer-separator pit. The maximum system flow rate is twice the flow rate needed to maintain the specified water quality. There are no connections to a fuel storage pool which could allow the fuel pool to be drained below the pool gate between the reactor well and the fuel pool. A check valve is provided in each pipe outside the pool to prevent the pool water from being siphoned out of the pool and uncover the spent fuel. Two dif f users are placed in both the reactor well and the fuel pool to distribute the return water as ef ficiently and vith as little turbulence as possible and to minimize stratificatica e' either temperature or contamination. Flow cont rol valves a- the operating floor enable the operator to achieve optimum recirculation patterns to control and maintain the specified water quality and operational conditions. The circulating pump motors are powered from their corresponding I unit 480-volt shutdown board. G ese boards receive power They from the diesel generators on loss of normal auxiliary power. are considered nonessential loads and will be operated as required under accident conditions. % 1 l 10.5.6 Inspection nni Testine l No special tests are required because at least one pump, heat exchanger, and filter-demineralizer are continuously in operation while fuel is stored in a pool. The spare unit is operated periodically to handle abnornal heat loads or to replace a unit for servicing. Routine visual inspection of the system components, instrumentation, and trouble alarms are adequate to verify system operability. i 10.5-6 , l _
BFNP TaWe 10.51 FUEL POOL COOLING AND CLEANUP SYSTEM SYSTEM SPECIFICATIONS System Functson System Specification Rated Core Thermal Power . ..... 3.293 MW , Total Pool.Well, and Pit Volume .... 106.881 cu f t Fuel Storage Pool Volume . . . . . . . 51.340 cu f t System Design Flow (I pump) ....... 600 gpm Maximum Flow (2 pumps) ....... 1.200 gpm Design Heat load .... . . . 8 B X 10' Btu /hr, Temperature 125'F Maximum Possible Heat Load . . 27.6 X 10' Btu /br. Temperature 150*F Pump Characteristics (1 pump) . 600 gpm. 330 f t TDH Heat Exchanger-Capacity .. . 4.4 X 10' Btu /hr/Hz. Filter Demineralizer ... . . . 270 sq f t. 000 gom 20 psi man dp (dirty) Holding Pump Flow . . ... . 27gpm Precoat Flow ....... .... 405 gpm
p u P J .
~
TEN! ESSEE VALLEY AUTHORITY BR0m;S FERRY NUCLEAR PLA:.T T1 u e- 'i, LA 1
. ,1 4 .
89 . m MECHANICAL MA!hTENANCE INSTRUCTION 1
- r1 b^ REMOVAL AND REPLACDCT OF,2EACTOR PRESSURE
' VESSEL CLOSURE HEAL l.I UNITS 1, 2, AND 3 7
- J I -
..n ,m <J ] ,a l
J m l Approved: N PYanti Superintendent l J
' Date: secto+cr 7. 1976
.J
- Revision
}-
' \, ^ . i
EF 2C4I 1 1 6/29/76 2 w TA3LE OF COIiTI'~fS
- D Fe,e no.
1 . 1
.3 Purp o s e -- - - - - - - - - - - - - - - - - - - - - - - - - - - -- -- - - - - - - - - - - - - - - -
1 1 Referenees ------------------------------------------- Prerequisites ----------------------------------------- 1 Description of PJ7 C1csure Head ---------------------- 2 Figure Ho. 1, 0-Eing Gasket Fastening Detail -- 4 a.
- b. Figure no. 2, Stud Location Oratting ----------- 5
- c. Fi6ure no. 3, Stud Assy. L "ise. retails ------ 7
- d. FiCure no. h, Stud, Uut a '.-?nsher retails ------ _6 Special Tools (Assently, risassembly & Cperational Instructions) --------------------------------------- 9 10
- a. Figure I*o. 5, List of Tools -------------------
;r
- b. Tensioner Lifting Rig Assembly --------------- 9 1
.J c. Stud Tensioner ------------------------------- 13
- d. Figure No. 6, Stud Tensioner Draving ---------- 14
- e. Stud Pandling Tool ---------------------------- 17 l Special Ihintenance Instructions ---------------------- 18 -
J
- a. Relaxing or Tensioning Studs ---------------- - 18 9
- b. Removal of Reactor Vessel closure Head -------- 18 m
Preparation For Work ---------------------------------- 20 q , J Removal of Reactor Vessel Head ------------------------ 22
-~~
9
- a. Figure No. 7, Location of Dr* p rell Vent Eucts -- 23 w
- b. Figure Eo. 8, Head Spray Pipe F1ance Locntions- 25
- c. Figure No. 9, Head Vent Fipe F1ance Locations - 27
.d. Figure No. 12, Special Elind Flance for Head
. .!, Nozzles -------------------a----------------- 26 1
D
* * * * * * - '+' * **ther _ e-e- amemme . , , , , , , , , , ,,, , ____ _
c ee-mempease ---- * ,, BF MMI 1 1 J 6/29/76
!I TABLE OF CONTENTS
.i
's Page No.
.{ ,
'I ------------------- 22 Removal of Reactor Vessel Head (Continued)
------------------------------ 30
- e. Venting of Closure Head
------------------------------ 31
- f. Unionding closure Studs 1
39
- g. Data Sheet MMI-1, Stud Unionding Data for Operational Closure --------------------------------------------
l; ------------------------------ 53
- h. Lif ting of Closure Head
------------ 54
. i. Figure No. 11, RPV Seal Surface Protector i ----------------- 55 Removal of Studs In Line With , Refueling Canal
---------------- 58 C Replacement of Studs Af ter Refueling Operation
- 8. J
---------------------------- 60 Replacement of Reactor Vessel Head
---------------------------------------- 60
; a. Prerequisites
---------------------------.----- 61
- b. Preparation for Work q
------------------------------ 61
- c. Installing Closure Head 63
- d. Installing Washers & Nuts Onto Closure Studs ---------
d
-------------- 65 Tensioning Closure Studs for Operational Closure f7 67 I) a. Mea'suring Stud Elongation from Stud Reference Surf ace -
----u-------------------------------- 67
- b. Tensioning Studs l )
, )'
~*
- c. Data Sheet MMI-2, Stud Tensioning Data for Operational 70 Closure --------------------------------------------
l '! {J d. - Data Sheet MMI-3, Stud Elongation Data for Operaticnal 85 ; Closure , 94 " ~"^ l' ----------.---- 92 lj Installation of Head Attachments and Insulation ' @N L , O - O
- ft
. f ** 's .
~- .- . . . - . . . - . .. .. , . . , , _ . _ , ,
. 6/29/76
~~ ' ,
D TABLE OF COI.*IEI;TS 9 1 a Page I:o. 1 93 J Post Maintenance Chechout --------------------------------------
- s. Figure 13, loc:. tion For ::ea urin; vessel Flange 95 r,1 - Temper ature -----------------------------------------
L 96
- b. Data Sheet IC'I '4, Inspectors Check Sheet r
Ji Appenlix: . 4 Table 20!I-1, 'Most Conservative' !!ini=r. Cold Bolt-up 96 [ Temperatures t . D
# . D*. . 9 . ,
i r T Ir t s t e L v. I in S , Q.. . . .. .... .,,.................. ........ 3 , f V b. - 4 l
.l
e g Page 1 y -
- EF 10!I 1 12/16/77 p -
L TEICTESSEE VALLEY NJTP.ORITY EROU::S FERRY UCCLEAR PLX;T 9 liEC11M;ICAL !!AI:;TEMM;CE INSTISCTION 1 i i 1
~
U nTS 1, 2, AND 3 d t Purpose C i , To specify the nethod of renoval and replacc=cnt of the reactor pressura vessel ['l l it closurc head for all units at Bro;.ns Tcrry Mucle.'r Plant for opera;ienal pur7cs:s. q J ' References
- 1. Babcock and Wilcox Riactor Prc'asure '.*essel Instruction Mar.ual.
- 2. Instruction Manual for Class II Stud Tensioner, Diamond Poter Specialty Corp.
*3. Babcock and Uilcor. Drawing Numbers 122879E and 1228SCE-6 (Figure No. 3 and 4)
] and 122376:;-7.
I b 4. Technical Specifications, 3.6-A-3, 4.6. A-5. .
~
- 5. GEK-9646, Volume I, page 3-1 thru page 3-11.
- 6. CE Ictter number Br 4572 (
Subject:
RPV Head Vcating prior to head rcroval), m .-
- 7. GE LAYDC',Ci DRAWING (Dwg. I;o. 719E507) . . ..
^
- 8. BFNP System Operating Instruction No. 1.
II 9. G01 100-7. . . 10, 45D to T. C. Campbell from A. J.11111er, dated 9-26-77, subject "Recoval of
] Silver Residue from RPV 0-Ring Seal Weld". . _
.)
7 Prerecuisites J
- 1. Reactor in shutdosm mode and cooled to below 200 F. and at or above the q
j appropriate yearly minimum cold head stud tensioning temperatures given q in Table }Dil-1. , i
- 2. Drywell shield plugs removed and stored in designated areas on the operating 7 floor, see Mechanical Maintenance Instruction 24. l s
- 3. Drywell head removed and stored, see licchanical Maintenance Instruction 2. l
- 4. Drywell flange protectors installed, see 10112.
i
- 5. " Hold" order cust be obtained on the head spray line (FCV-74-78 or 74-77) and l
- other equipment? deemed necessary by the shif t engineer for removal of the RPV'.
- Revision: ./_ .
/ - ~ . . .. ... .... -. _ . . . . _ _ . _ . . , _ . _ , _ _ . _ ,.,
~ 7 <* . J Page P
" BF MC l = ,
6/29'/76 Prerecuisites (Continued)
, 6. Reactor Building overhead crane operable.
- 7. visually inspect all lifting and ricsinc, tools and devices to ascertain (1 they are in serviceable ecndition.
b Check the head laydown area and make certain it is clear and free of 8. obstructionf. and ready to receive the RF7 head.
., 9 Check the studj tensioner lifting stroncback, stud tensioners (h), and stud tensioner pcrer pack to ascertain they are in serviceable condition. (See Ref. 2.
- 10. Ascertain RFV flance protector is in the i= mediate area and in serviceable condition.
~
- 11. Ascertain new head "0" rings are in place in the head pedestal area.
n L, Il 12. Check piping and head insulation laydown area and make certain they are clean U and free of obstructions.
- 13. Ascertain qualified personnel and monitoring equipment is available to perform radiation survey before, during, and after head removal operation.
]
J Description of RpV Head The closure head assembly is a weld:ent conciating of a hemispherical done secnent plate, hemispherical sub-assembly sectent plate and a flance forcinc. The s hemispherical sec=ent plates are fabricated of nancanese - molybdenum stcel. I J 'The flance forcing is AST:4 A-503 CL. 2 steel conforming to AS:S Code Case l?32-2
' clad with veld deposited Ni-Cr-Fe alloy on the casket face. The closure head forging Gasket face is machined to accommodate two silver plated, Inconel 0-rinc For fastening gaskets and the 24 setP of , wire clips, backing plates and screws.
details see figure no. l (figure no. 1 on pace b). TSc flange of the for,~ine w ,.
*4
f .. . - L I Page 3
. BF EtI 1
. 6/29/76
'l
')
Descrittien of EpV Head ( utinued) is bored through to receive 92 closure studs. Stud hole no. 1 is located J approxinately 3 deg; s y cinutes clockwise frca the W-axis. See figure I L no. 2 for stud location diagram (figure no. 2 on pace 5 ). "he dome ses.ent
'+ of the closure head contains one vent no::le and two (2) instrument nozzles U (1 used as head spray). The vent no::le is flangeri cr.d .is 3 7/8" nom I.D. and ] is located in the center of the do=e ses=ent. The two instrument no: les are u
flangedandare513/16"nomI.D.andarelocatedantheW- ~ Y axes a distance of 4 feet on either side of the dc=e center. The closure' head has four (h) lifting lugs per=anently attached for handling the head. 17 The closure head is secured to the vessel flange by c2 closure stud assemblies. Each assembly consists of a 6"-8N-3A special threaded stud, with a nominal 6-1 j inch diameter, a nut having eight castellations at the top, a set of lapped 1 and matched sphericci vashers, top and bottom inserta, vessel flance stud hole bushings, and bottoming sleeves. The studs, nuts and washers are steel stc= ped a l in matched sets with nu=bers of the preassigned vessel flange stud holes and are J fabricated of alloy steel AST!! A-540 Gr. B-23 or 24 conforming to AS:s code cose 1335-2, Para. 4, Class 3. The studs and bushings are given a manganse - phosphate p coating to improve their anticalling characteristics and to improve their resis-U tance to rusting. Dag Dispersion 156 or Never See:c co= pound is used to lubricate
. stud and bushing exteinal threads. Stamped numbers on studs are Manufacturer's Le!
numbers. Studs, vachers, and holes are =crked by a vibra-tool to assure matched
.vasher-stud-hole mating at instanetton. l U
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CLOSURE HEAD 4 , p Figure 1 0-Ring Gasket Fastc'ingn Detail , U T-($ - li , 7 l It
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-O GulOE CAP LOCATION figurc 2 Stud Location Din',rs c t
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- 6/29/76 d
n W Description of P,F7 Heed (Continued) h the length of the stud 'n Each stud has a one-inch dic=eter center hole throu6
" to receive a stud elongation = case. ring rod. S e hole vill also acco modate an electrical stud heater (not supplied.) The battc= insert is used to close the bottom of the stud ard serves as a seat for the stud elor.gation nescuring rod.
/ of The top insert is used to close the top of the stud and prevents entr-foreign =atter. Vapor holes are drilled through both the top and bottom
~
inserts. The 92 removable bushings are staked in place in the vessel flange The bottoming sleeve acts as a stud-seating spacer in the vessel
)J stud holes.
Each stud has a threaded length sufficient to accommodate a hydraulic stud hole. A st'ud handling tool is used to install and remove the studs stud tensioner. a from the vessel. " Figure No. 2 shows the numbering sehene for closure studs and figures nt=ter u 3 and 4 show the closure assembly. 9 w Stud guide caps and t.' read protectors are utilized on the studs for guidance
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and protection of stud threads during head re= oval and installation. 1 J w 7 ?. n
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4* Page 9 1 BF KII 1 J 6/29/76 u Special Tools: ( A s senb1't. Disassembiv and Oeerational Instructionsl "3 The special tools supplied by the Sabcock & Wilcox Co=pany are listed in J The identification and function of each figure no. 5 (figure no. 5 on page 10). J tool are given in the table. L Tensioner Liftine Eir Assemblr The lifting rig assc=bly is a combination of a tensioner handling and spacin
, The ric frame and a hydraulic and pneu=atic distributor for the tensioners.
is designed to suspend four (h) tensioners veighing approximately P500 p T::e ri6 S each and to spe.ce them exactly CO apart on a 29.'-3-1/h" bolt circle. ide e is also tubed to distribute hydraulic fit.id for tensioning operations to prov circuit 7 air for piston return after tensioning operations, and with a bleed
,j to retum any primary seal leakaSe to the reservoir of the punping unit.
J The lifting rig is t " knock down" design allowing assembly and disassembly required. 1 i lates at the The rig is composed of a center tute assembly havin6 suspens on p " top, a mounting block at the bottom, an integral canifold, and " hydraul The mounting
" bleed", and " air" tubing channeled downward through the tube.
7 block at the bottom is matchmarked for easy assembly of the horizontal e: n: bly of , . . , , , 1: and the suspension plates at the top are matchmarked for ease of asser. i the angic ar=s. Wire rope assemblies are fastened to the upper suspension pinte f t ha*inc throat and these wire ropes are desicacd to fit a large sister hook dimensions of 6" vidth and 11" depth. 1 P . I e, e
. + - .;..........__....__ ,
g; actor Pr ',sure Vessel Pare 10 B F I&it 1 g(29,yg (Q
.a List of Special Tools Supplied by ,
The Br.bcock & 1!ilcox Cenpany I L . Use Homencl at;..e Part flo. Qty. Pd 5, r,tud Ten . .iner E-87 For installation Diamond PcGer Specicity 1 set 3,550,00.. ;b. and removal of n (1 contre unit. Corp. per Dwg. 700496-1046. " closure stud: with h ti .nioning riechanit:r- and 1 li fting. r. g) , IE-89 1 for liftinc and Stud llon:-ing Tool handlinc c1ccure (See Apin. dix A, (Diamond Pcwer Specialty studs Section .. .) Corp, per ug. SK-15h890) FK-68 1 For obtaininc Ucpth Cc;.1, Starrett
. dial reading of stud clongation U 92 For :r.casuring 5%-90
f!.casuriN Rod stud clonCation d . s. IE-92 & E-lb4 1 For inctallatien g Guide C' - and Dolt Assy and removal of B closure head Guide CDs and Bolt Assy E -93 & E -145 1 For installatien
- and removal of
- closure head E-94 & 15-146 1 For installation .
Guide Cap and Bolt Assy and removal of closure head I *"I I'rotector Assy MK-95 & E-96 ' 92 For protection of closure stud threads during installatien or rcr:: oval of g closure head g lE-1! 7 89 For protection of
""i l'rotector Assy 6 closure ctud
& E-118 4
threads durinr.
- - installation or removal of
'[e .I '. ' .
closure head
- 9 .-
d ' F I G u rc e IJ o . 5 C . . e. r- - ( .C #)
i- Pnco 11 .
- BFfaC 1 d -
PARTS LIST AND SPECIAL TOOLS 6/29/76 Homencl$ture Part No. Qty. Use 1 Bushing Urench D.ig. 9h983C. 1 For $nctallaticr.
'. (includes IC-034 a 235) and rc..e oval cf bushinr, (!7.-63,'
- in reactor '.c: sci closure stud holce Castellated !!at ' Trench 1%-902 per D.c. 10193CD 1 For rotatinc clocure nut e
Stud Wrench }E-901 1 For rotat.in;
- per Dwg. 101989D closure stud
~
'T Sec1 Surface Protector FZ-239 1 For prett:ctica cf 4 per Dwg. 109270C reactor vcesc1
< shc11 ficnce s u l p surface whan exposcd if . Metal Tool Box - l' For shippinc and stort.(;e of hand tools e REGULAR TOCL LIST j Nomenclature Quantity 4 Hammer, Ball Peen 2 q Screwdriver (Plain) 6" 2 Screvdriver (Flain) 8" 2
'J Wrench, adjustable 10" *1 Wrench, adjustable 12" 1 1 U Pipe Wrench, 18" '
1 + W Pipe Wrench, 24" . . 1 Wrenches, Slugging 17/16"thru113/16" i each f Wrench, Allen 3/4" 2 b Ratchet,3/4" drive 2 Extension, 3/4" drive, 15" long - 2
- 1 Sockets,3/4" drive,2" ,
2 Tj AirDrills,3/4" drive 2 1 Hacksaw Flashlicht, 2 or 3 cell 1 o - -" n Box End Wrenches ,1 7/16" thru 1 13/16" 2 9 , t '
, . j
- 1 i.
Fica: s .00. = 5 , I bpEET 1 ch 1
- s. .
' e
N - a .. Pnce 12 B F ! CIT 1 h< 6/29/76 Tensioner Liftinc Ein A=cembiv (Continued) 1 The horizontal beams serve as ecnpre.ssion members for the fra e and also a: I the individual tencioner distribution channels. Is p, The horizontal and angle ams are matchmarked and may be readily acce . bled to k the center assembly by bolting and pinning these =cm'ocre in place. The h hydraulic, bleed, and air tubes are tagged to aid in proper connection during 8g riS assembly. 1 L After the =echanical and tubing connections have been made on all four (L) ens of the rig, the adjusting cables can be attached between cach pair of a==. Shece
. cablcc can then be adjusted to set cach am 00 from the adjacent ams. The 'I hydraulic and pneum; tic heses can then be attached to the proper fittings at < the end of each frame am.
1 q Each frame am has a support plate welded at its extremity with two leveling A I cable plates located in the center of this support plate. The stud tensioner
- assembly should be connected to the end of the ams of the rig by the wire q
y rope assemblies provided for the sucpension of the tensioner assemblics. The four (4) cables vill allow complete leveling of the tensioner ascemblics when Jr suspended from the rig, h wemm- nen levenn, the tensioners en the ri . the cour m e.ebou.s .. __ _ lJ threaded int- the tencioner cover nlate c"ould be thrc9c4 dwn '.o p L complete encarement. The tensioner chould then be leveled.
' usinn a carpenter's icvel, by backing out the eyebolts as required. j I
,"I ql In no case should an. evebolt he disenesced more than 1/4" from the fullv em nced nosi tion, i
- )
Page 13 BF KE 1 l 6/29/76 Tensioner Liftinr Fir Asse=bly (Continued)
~'
The air line and bleed line can be connected directly to the tensioner without any further preparation. 1 J - The inlet hydraulic, bleed, and air lines should be connected.to the =r.nifold 7 j asse: ably at the ports which are labeled " AIR", "ELEED", and "HYD" as a cuide for q , proper connection. J
] Stud Tensioner '
J The Stud Tensioner is a device for use in tightening and loosening bolted flange M I ,j connections having large studs. Figure no. 6 shows a cross-sectional viev, "he
,, z.tensioner elongates the stud to a predeternitied length, permitting the holding
'b nut to be threaded down or backed off by the nut turning transmission. This procedure provides fast, precise stud tightening without torque, bendinc of l studs, or galling of tPJeads. p The tensioner is basically a hydraulic jack, which exerts an axial pulling force on the stud. The tensioner cylinder is supported over the stud by a pedestal which straddles the holding nut and washers and rests on the upper surface of I the flange. The piston is connected to a hollow dravbar. The encocement nut n [ which threads onto the stud rests on the internal flange at tM bottom of l
. ... . the drawbar. Flexibility for alignment of the tensioner and the stud is assured l by spherical surfaces at two points; one being the contact surfaces of the spherical vachers between the cylinder and the pedestal; the other, the contact surfaces between the dravbar and the self-aligninc engagement nut. The encacement nut is driven throuch a gimbal connection to allow alignment. Support links between spherical vashers and the suspension links between the cylinder and the pedestal allow self-centering of the pedestal when the tensioner 4
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6/29/76 1 Stud Trnsioner (Continued) l is 3 avered into position over the stud. A buffer ring at the bottom end of the J drawbar acts as a centering guide for the tensioner assembly and also provide i
,; protection aCainct stud thread damage.
)
The encaS,cment nut in the drawbar is a light-weicht connector bet ecen the i drawbar and the stud and rests on the top thread of the stud (vithout damage to the thread) during tensioner engagement. During this o'peration, none of a the tensioner unit weight is on the threads. The engagement nut is easily threaded on through the ginbal connection by a sheave wheel and bevel gear h
~lL drive.
li u The turning gear of the nut turning transmission is a ring with external b gear teeth and internal lugs. The lugs mate with the castellations in the
!* holding nut. The nut turning transmission engeges the turning cear to o
tighten or loosen the holding nut. The cauce holder and guide assembly has a lower flance with a spherical radius which mates with the internal chamfer in the top of the stud, a floating 1 internal rod which rests on the top of the stud cloncr, tion rod, and a gauge E holder at the top. With an elongation gauge (dial indicator) properly installed 5 'q in the holder, the relative motion betveen the top of the stud and the botten
'of the stud (cloncataan) can be read directly on the cloncation cauge.
.-g 3 In operation, the enc 26c=ent nut is threaded onto the stud and hydraulic 4 , pressure is applied to the underside of the piston. The cylinder then exerts a' downward force throukb the ephcrical vachers and the pedestal to the flance. hie piston exerts an upward force through the drawbar and the enCBCement nut e 4
-- - -- .... .~ .
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=
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. BF MMI 1 J 6/29/76 7 '
J Stud Tencioner (Continued) - . - - - - - - to the stud, elongating the stud. The holding nut is then turned down te a J firm coat against the spherical vanhers. When the hydraulic pressure is p released frc= the tensioner, the load on the st':d in tran:ferred to the J holding nut. . P'j
<a There is a resulting loss of load on the stud due to cenpression of the nuts, 7
J. yachers, ana f1ange, and the oright dending of the nut and ctud threee=. The 775-ten tensioner acac=bly has a piston area of 218.5" end develops a
} pulling force of 1,580,000 pounds at 7250 pai vorking pressure. 1,580,000 a
- pounds is the de:ign =1xi==n applied stud locd for tencioning or loosening P
L5 the stud: for hydrotest stud loading conditions. A slight incresce in prescur'e above 7250 psi may be required when loosening a stud that has been tencioned at 7250 psi. However, at 7500 psi operating pre:sure all nuts vill turn l freely, provided that the proper bolting =equence has been followed and s provided the stud and nut threads are not seized. The =aximum de:icn
= pressure in 7500 psi.
CAUTION: Do not exceed 7500 usi oneratinc cre sure. a The tensioners are operated from a single pover unit acce=bly counted on a G The cart locates the operating components at a comfortable j, four-wheeled cart. elevraion and also provide: a storace area for hoses, hydraulic fittings. etc. J The hydraulic systen is basienlly an air operated hydraulic pump syste: con-j' i. trolled by a four-vay valve.
- NOTE: The number of cycles that each stud tensioner undergoes vill be recorded
, - on stud loading and stud unloading data sheets.
.~_,. .
.~.
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PaSe 17 n BF M1I 1 y 6/29/76 3 Stud !!andlint Tool .
.J The Stud liandling Tool is a device which facilitates the incertion and renovel of the heavy stud used on large bolted closure. It is designed for handlin;;
q studs veichinc approximately h80 pounds. having an 8-pitch thread, and with up to 12 inchc= of thrend encage .ent. The tool requires approximately 50 SCD: of air at 100 psi inlet pressure. a '1he stud clevis and keeper asse .bly threads into the top of the stud and locks
=
in p*..ac e . The transfer yoke is pinned to the stud clevis and provides a neanc
~
by which the stud can be transferred from a crano to the stud handling tool. The
. stud hook engages one leg of the transfer yoke to cupport and tran:fer torque to
, the stud, and is pinned to the drive cerev. The drive sercy is driven by a motor reducer assembly capable of exerting approximately 50 foot pounds at 50 O rpsi. 'Ihe drive cerev provides 12" of '; ravel a .d has an 8-pitch thread. "here-
'~
. fore, there is no vertical move c.ent of the screw nut, guide pl tte, and spring;
{ assemblies during stud incertion or re~. oval.
.The motor reducer assembly is =ounted to the handle plate having tuo handles.
l
- one being an on-off " deadman" hand valve. A direction control valve is alto I 4J I mounted to thi= plate to evitch the motor rotational direction for insertion or removal of the stud. An air lubricator is provided between the " deadman" valve and control valve.
,n .
,The remainder of the tool above the he.ndle plate consist of the lifting eye, ubalance springs, Cuide rods, and the spring support and shield assembly. The
; springs are completely enclosed by a protective cover, and the amount of D .
[] Pnge 18 e EF W.I 1 6/29/76 F g Stud Handlin.~ Tool (Continued)
, spring deflection can be detcrmined by the location of the lover crige of the " guide plate relative to the hard stop tag fastened to the spring cover. '?
U There are three balance springs, each having a sprint rate of cpproxinatcl:. 1 25 pounds per inch. The stud balance springs are preloaded to approri=ctely J 500 pounds. A standard stud veiching 430 pounds (pluc the.1?50 veicht of the J tool on the spring:) vill cause the stud balance sprinCs to furt::er deflect 1 one to two inches, floating the *'eicht of the stud. The guide rode hace a e shoulder vhich acts as a mechanical stop for the springs. [] Special Maintenance Instruction: I,t bd . Relaxinn or fencienin~ Studs Closure studs are relaxed or tensioned using a staggered sequential pattern.
}
J These patterns must be followed accurately. Rapid loocening vill resylt in the inability to loosen como stud =. If this happens. the studs must bc re-tightened the proper amount. Tensioning of the stud chall take place only d when the vessel and head metal temperatures are at or above the apprepriate m
!i yearly minimum conservative ccmperatures civen in Table XMI-1.
b 1 J 2. W
--Renoval of Reactor Vessel Clocurc !! cad EARTII!!GS:
0 '
. 1. Prior to performing any inspection or maintenance operation on the renetor
r 4 Page 19
' BF M4I 1 6/29/76 LI '
L .
,b Rc5 oval of Ecnetor Vessel Closure Head (Continued) l.
C VARNIUCS: (Continued)
- 1. (Continued)
]l I
r vessel, carc shall be taken to prevent personnel in.',ury through radiation
; or pressure and temperature.
.a
- 2. The 'in'ter$'a'l'curfaces of the reactor vessel co=c in contact tith radio-L active prinary coolant; therefore, redioactive caterials may be present h
However, the r.ain durin6 operation and for long periods after shutdown. 0; L radiation problem is due to the components becoming ' radioactive by activation of the ccterial. Personnel vorhing on or near the reactor vessel or head must be thoroughly fn=iliar udth the hazards involved cnd le b --- thould not perfora eny maintentnce prior to conculting the applicable fg instructions. d The reactor vessel is desicned to operate at high temperatures, $bo 7,, and 3 6 hich fluid pressure, 1005 psig. Hich te=perature and possrble steam Ice' g could cause injury to personnel prior and cubsequent to reactor vessel i startup.
- 4. The reactor veccc1 must be decrescurised before maintenance is atte-nted.
D, not Refer to Enuitment M9 nun 1. Reference 1. for necesesry procedures. loosen mechanicns until water temperature is below 200 F. . end prescure it reduced to O esin.
-- - -- CAUTIONS:
- 1. No velding, burning, chippinc, crinding, are strikes, inadvertant impects.
1 notches, grooves, or stress concentratiors chall be permitted on the I, --...rcactor head and shcIl at any time.
*i g- ,
I e 8 A.
o , 0 . . Page 20 BF MMI 1 D 6/29/76
,] Removal of Ecactor '.'essel Closure Head (Cuntinued) _
a
. CAtTIIONS: (Continued)
~
2 Care shall be taken to prevent the contamination of the internal vessel and core surfaces by the dropping of part pieces, tools, rags, or other debris q ,b into the reactor vessel and internals when cpen for any reason. Lights er 1 other equi;=ent used shall be attached to externe.lly secured lanyards to J ensure retrieval. Lights shall be such that breakage would not contaninate the vessel, internals, or core interior. Equipnent parts shall be velded,
, taped, or otherwise secured to prevent accidenta.1 disassembly into the vessel and internals.
- 3. Maintain a fon::al inventory list of all parts, equipnent, and loose objects carried by personnel and check off the list (Ster co=pletion of work to r'
b ensure that itens are not left in the reactoi vessel and internals. r, 4. If any item is dropped into the reactor vessel, it shal'. be reported to the supervisor 1: nediately. a Preparation for Work
- 1. Assenble all rigging, tools and equip =cnt required for re=oving the head.
4 Include the following:
- a. Head StronBback .
, b. Four color-coded stud tensioners with pt:=p unit w c. Lifting rig assembly for tensioners
- d. Nut and washer racks in the reactor well
- e. Special 4" and 6" blind finnges (located in Befueling Floor tool cace) j .f., 1" 900#, 2" 900# and 6" 9006 blind flanges (located in Refuelinc Floor tool
- - - cage) . . - . - - - - . __
4l ma se
. l m .
1 4 - l 4
b
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Paro 21 BF RfI 1 6/29/76 Pre. arction for ' fork (Continued) - l J
- 2. Check oil level in the tensioner lubricator to the pu=p to make cure it is 0 ' sufficient.
' 3 Insure that fluid reservoir on the tensioner power unit asce-bly is . ^.:11. ~
Uce STO-1 oil for filling reservoir. Turn control-valve on power unit a::embly to " release" position to accure
] 14 that pistons are "botto=ed" in all tensioners. Trapped air nuet be bled . by depressing the ball in the hydraulic connector on the tencioner.
- 5. All hydraulic lines must be bled prior to making hydraulic connections to the stud tensioners to remove entrained air. These hydraulic lines can be bled by turning down (clockwise) the air sequence valve on the hydraulic power unit assembly until the air flov to the pu=p is restricted sufficiently
*1 d .to prevent pu=p cperation. Therefore, then the control valve on the hydrau-lic power unit is turned to the " tension" position, there vill be pressure on the entire hydraulic circuit equal to the inlet pressure to the power unit assembly. All hydraulic connections should be nade fros the power unit ascembly to the manifold on the lifting rig assenbly and to the 0 hoses which connect to the tenaioners. All shut-off valves in the hydraulic
- circuit located in the manifold assembly should be fully opened. With the valves open and all hydraulic connections made. turn the hydraulic power b unit control valve to the tension position. Depreen the ball on the end u
of the hydraulic hose to allow air to be bled completely from the _-.~... .. hydraulic tubing system. 'lhis can be easily done by depressint' the end of the fitting against the bottom of a small pan alloving the g -*
<J system to biced air until only hydraulic fluid is ps sing through the end 7 of the high prc sure connections. This procedure should be repent.ed en d
each of the hydraulic connection: which connect directly to the stud-J tensioner asse=bly, i
_m Page 22 BF 1011 1 9/28/76 Preparation for Work (Continued) P s ~~5. (Continued) When 'the bleeding operation of the hydraulic lines is complete, the connections may be made between the stud tensioner assembly and the hydraulic supply lines and the rig is ready for attachment to the sister hook and fundling of the tensioner asse=blies. m
- 6. Check all lifting cables and connections for wear.
s .
- Removal of Reactor Vessel Head
- WARNING: Before removine head nozzle flance bolts, reactor vessel must be at 0 psig and vessel temoerature must be at or above the acerooriste w
yearly minimum tensionine temoeratures ziwn in Table m!I-1, but not more than 2000 7. Verify that MC7 10-5N is closed or water level is below flance then ooen valves FC7 3-98 Ind FCV 3-99. Personnel i.. 5 the reactor well will wear the soorocriate orotective clothine and I fresh air ecuiement orior to the flanze bol: removal. and until released L. by health physics eersonnel. Acorceriate ndiation monitoring practices will be in effect.
- 1. Release drywell vent ducts (A, B, and C) from sidg joints. Ducts shewn in J figure no. 7 (figure no. 7 on page 23). N0'rE: Dicts are perrianently
' mounted to mirror insulation framework.
b
- CAUTION: 1. Do not open the access hatches covering ventilation ducts unless the drywell ventilation blocars are. inoperative and 3 the area around the ducts has been'acaled with tape. ;
j Do not open the hatches covering piac flanges unicss the j 2. hatch has been sealed from below with plastic and tape. ; Af ter installation of the drywell head., all sealing material is
" to be removed.
- 2. Remove insulation from all head piping. Move pip insulation to the piping Q
I.J laydown area (area shown on GE drawing 719E507). w
- 3. ' Remove insulation collars at pipe pencerations (r places) on top of P.rv head 6..
insulation acka r,c. y
- Revision: ,
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Page 24
- EiWs
..q Removal of Reactor Vessel licad (Continued)
" *4. Install locking pins in the four (4) RPV head piping spring hangers to lock in the preset load. -
*5 . Remove bolts from the 6" head spray pipe flanges at points 1 and 2 as shown
' L.[i in figure no. 8 (figure no. 8 shown on page 25). Attach lifting slings (threc point lifting suspension) to pipe and building cranc-5 ton hook and transport to piping laydoun area. (tv'AR'!ING : Install snecial 6 blind flance at noint 2 immedi5tely upon removine head scrav pipe finnee to prevent the esccoe of Install 6" blind flange at point 1, radioactive cases from the RPV head). close and bolt hinged cover at point 1. 1
*6. 2" and 1" pipe flanges at points 1, 2, and 3 as shown in J Remove bolts from 4",
figure no. 9 (figure no. 9 shown on pages 27, 28, and 29). Attach lifting slings g C (three point suspension) to pipe and building crane 5 ton hook and transport the piping to the piping laydewn area. Install special 4" blind flange at point no. I { a. immediately; see warning in item no. 4 above. Install 2" blind flange at point 1 i no. 2 and a 1" blind flange at point no. 3. Close and bolt platfom hinged' J covers at points 2 and 3. Coer ends of piping with plastic bags. 3 1
*7. The RPV head (mirror) insula
- ion package is an assembly consisting of a steel
[j beam framework to which insulation protected by a metal skin (mirror finish) U is attached; also attached to the framework is three drywell ventilation 7 j (return air) ducts; see figure no. 7 (figure no. 7 shown on page 23). The assembly framework has four lifting lugs pe manently attached, to these d- lifting lugs attach lifting cables and also attach cables to the 125 ton
- hook of the building crane. Lift insulation assembly straight up (use e
extreme caution while lifting assembly to prevent damage) until the assembly l cicars the reactor well and all obstructions on the refueling floor, then transport assembly to the RPV head insulation laydoun area (arca shown on q J
" CE drawing 719E570).
i j - [ { '
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.~ - rl ** . Y Page 30 ) - BF M11 1 i 3/21/78 3, Removal of Reactor Vessel Head (Continued)
-l
*7. (Continued)
~
NOTE: At this point the RPV head should be free of all attachments and should be ready to begin the removal of the ettid nuts. g f. Ventinc of Closure Hecd Prerequisites
- 1. Recirculation pumps operating at 40*'. speed to avoid stratified areas in the f ,
vessel and maintain an equal. water temperature distribution.
-2. Reactor Water Cleanup System operating continuously at greater than 400 gpm.
~
- 3. The Reactor Building "chort stack" ventilation exhaust system in operation.
. 4. There must be provision set up for close coordination and communications bet reen j' the refueling floor and the main control room during the head venting operation.
Assure normal condenser vacuum is in operation c ae main steam system. 5. h Head Ventine Procedure
~
;1
+ As soon as all reactor head nuts are detensioned, the reactor water temperature i
should be lowered to and maintained at approximately 900F, The water level should be raised to approximately two feet below the flange elevation at this time. Ascertain from control room personnel that the proper vacuum it in oper-tion 1 and open the gate valve on the 4" head vent special flange. A " tea ke * .te" type whistle should be heard at this point. If it is not, close the vr sve and notify 1 the control room immediately.. If it is, hold this configurati ,n for 2 hours. 1 - This should purge any radioactive gases that could be trapp d under the head. NOTE: Control room personnel should continuously monitor the. reactor building "short
'q.
si stack" reading during the venting operation. If the reading approaches the 4 6 point where isolation of the Reactor Eutiding Ventilation System and
. .J .E.
f, . 1 *Revis. ion :_n '<
; ,. F
9 i , W - Page 31 BF MMI 1 6/29/76 7 Head Ventine Procedure (Continued) J NOTE: (Continued) initiation of the Standby Gas Treatment System will occur, 'close and secure the gate valve. If it is necessary to halt the venting operation, the
- control room shall inform the refuel floor when the stack monitor has returned to normal and the venting procedure is ready to continue.
u
, Unioading Closure Studs Unioading Closure Studs After Operational Closure Using Hydraulic Tensicners -
1 CAUTION: Tensioning of the closure studs (for unloading of the studs) af ter opera-J tion, or for any other reason shall be performed ONLY when the vessel flange and head metal temperatures are at or above the appropriate yearl:, r3 minimum temperature given in Table MMI-1 as measured by control room J . instrumentation TR 56-4 and TR 68-37 on pancis 9-47 and 9-4 respec tively, I and by a hand pyrometer. (See figure 13 on page 95 for location point L to measure vessel flange temperature.) NOTES:
- 1. Stud loosening must be gradual as shown in this procedure. Rapid loosening bJ will result in the inability to loosen some studs. If this happens, the w studs must be re-tightened the proper amount.'
- 2. Per the following information, clean all surfaces to avoid dislodging any r}
IJ fo reign matter into holes of studs, closure head, and vessel.
-m.__... __ _
WARNING: Improper mechanical or chemical cicaning of surfaces may result in excessive local corrosion'of those surfaces when placed in contact with
]a __
primary coolant. The resultant corrosion products taken into solution in the primary coolant could become highly radioactive, thus complicating J the maintenance of any component due to the hazards of exposing men to m high icvels of radioactivity. a
1
,j .. . .
n Page 32
" BF 1S11 1 6/29/76 1
j Unioading Closure Studs (Continued) r CAUTION: Extreme care shall be obse.rved to prevent dirt, foreign particles , etc., from entering the reactor system and lodging between bearing surfaces of Il parts operating with cxtremely small clearances, causing excessive wear L or seizure. i n Y U ll - n u w J J n e d e h 7
; o, g . -
n u i U ' n 10 1 i L
Page 33 , BF 1011 1 6/29/76 Unloadine Closure Studs (Continued)'
' Components shall be cleaned to the extent that no contamination is visible
~
to a person with normal visual acuity, natural or corrected, under a lighting level of at least 50 foot-candles. Areas which cannot be visually inspected due to inaccessibility or geometry shall be evaluated by wiping the surface n with a wet or d'ry', lint-free cloth until all traces of foreign material are
~~
9 . removed and the cloth remains clean after use. a Irridescent temper films resulting from heat treatment and tightly adherent black oxide films that occur on the back side of welds need not be removed. n Rust of any type or amount shall not be allowed. If rusting does occur, the
-. surface shall be cleaned to remove the rust or rust-producing condition and any visible surface contamination.
O Cleanliness shall be maintained by packaging components or subassemblics in polyethylene bags if they are to be stored. n All instructions for the cleaning of surfaces in this instruction refer to a a condition of maximum cleanliness. The cleaning is to be perfor=cd as follows: Clean all metal surfaces as necessar'/ by swabbing with clean, white, lint-free cloths saturated with acetone followed by swabbing with 0 clean, white, lint-free cloths saturated with distilled water. Dry with
~~'--- - - .- cican, white, lint-free cloths. The cleaning must be such that no foreign w matter can be seen af ter cleaning, particularly in the root area of the l threads. Cleaning the stud bolts' threads may be done with an approved J
thread chase. Care must be taken not to damage the threads, m i a 0
g a. <.
} Page 34
- .BF MMI 1
$ 6/29/76 0 .
), .
,Unioading Cl osure Studs ~ (Continued) 9 s
- 3. This procedure requires the simultaneous use of the set of four
- 701364-1845 hydraulic tensioners, the 701124-1846 powcr unit assembly, 3
and the 701334-1842 lif ting rig asserbly as manufactured by the Diamond Power'Specialt'y Corporation.
-The use cf any other quantity of tensioners I
=
or any other type of equipment invalidates the tensioning sequence and I pressure set forth herein. 02 studs (MK-61; Figur e t
. 1. Remove the top insert (MK-67; Figure No. 3) from the
!. 8 No. 3) and inspect the accessible portions of the exterior of the studs, 5 nuts, and washers and the interior of the stud center holes for finish, Clean as necessary. The cleaning must be such that no 4 - dirt, oil, etc. . I area forei'gn matter. can be seen af ter cleaning, particularly in the root s { of the threads. 4 CAUTION: Constantly exercise due care throughout all steps of this . g
' procedure to prevent damage to threads and surfaces'of all
- parts and components and to assure cleanliness at all times.
s NOTE: A QC' inspector must make appropriate verifications on all data sheets.
' 2. As shown in data sheets MHI-1, a total of two passes are required to loosen and remove the nuts (MK-62) from the 92 studs. A first pass 1 r
consisting of 23 sequences of four studs each and a second pass consisting of 23 sequences of four studs each. The four studs in each See figure 2 for stud locations. sequence are located 90 degrees apart. 8
- 3. Assemble, connect, and operate the hydraulic tensioners, lif ting rig, and
'I- power unit assembly in accordance with instructions.
s. E e .
.D
. i
.* e J '. .
Page 35 f BFICH 1
'L 6/29/76 m - 4 . _ - . . . _.
Unloading Closure Studs (Continued) m - NOTES:
~
- 1. Till the power unit assembly filter-regulator-lube asse bly to I the visible rim of the bowl with turbine oil, STC-1.
~
- 2. Set the power ur.it assedbly control valve in the center'positica and
-~~ .
fill the 3-gallon capacity reservoir to the level indicatci vith 1 . Chevron RPM Delo Super 3 a 3 Connect operating air supply of 55 SCFM at 100 psi inlet pressure J to operating air inlet of power unit assedbly vith at least a 1/2-
' - inch supply line. Use of a s= aller size supply line vill not allor a
the pump to operate at full capacity. ei Make certain the oil pressure ccge is calibrated.
;j h.
5 Put air pressure on reservoir, vent oil hoses by depressing ball 7,
' check in fittings letting oil leak cff in a backet.
- 6. Exercise all tensioners independently; check over travel alarms.
7 Open valves and exercise all h tensioners.
- 8. Lift tensioners - check that they hang perpendicular.
9 Remove the two angle "stora6e feet" from each tensioner, and remove the 0 guide handles from the storace feet and insert handles into the front bolt holes on each side and at the base of the tensioner. f L
- 10. Move power unit to operating position (Southwest quadrant of reactor well on refueling floor); see laydawn drawing.
" N. Color code the four tensioners so that one is marked with red, the second In all with green, the third with yellow, and the fourth with blue. } . .r3 J
1
Page 36 BP 1011 1 im ' 3/21/78 Unloadine Closure Studn (Continued) J
~
- 4. (Continued) succeeding steps, confine the use of each tensioner to 23 consecutive studs
,) in the following manner:
Tensioner Code Confine to Studs _l Red (Southwest quadrant) 1 through 23 7 ' J Green (!iorthwest quadrant) 24 through h6 Yellow (!!ortheast quadrant) 47 through 69 Blue (Southeast quadrant) 70 throush 92 r 's. 5 Install the hydraulic tencioners for first pass unloading of the set of '9,
.
- four studs in Sequence 1 of data sheets 1011 1 w
., 6. Turn the tensioner engaging cheave wheel clockwise until the dravbar
" bottom contacts the nut (!E-62). Then back off from nut by two co=plete
~
1 countercicekvise turns of the tensioner sheave wheel to provide 1/8"- gap from the nut. This gap is required to allow for stud contraction , 7 vhen the load is reduced on the stud. Otherwise, the nut could not be J released vhen the hydraulic pressure is reduced. - 0 9 b. e i sd a . b
- Revision. . '
' .U.
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. ... - ~ . __ _ -... .
. Page 37 EF ICfC 1 , 3/21/78
., Unloadinn Closure Studs (Continued)-
- 7. - Obtain a hydraulic pu=p pressure as indicated in column 4 of data sheet 7 *M MI 1.
J NOTES: 7 j 1. The required pump pressure shall be taken directly from the hydrau-lie dial cage counted on the pover unit cart. d 2. Four turns of the nut turning tran mission crank handle equal approxi-mately one turn of the stud nut (1E-62). (The exact ratio is 3.96: 1 for an axial nut travel of 0.lP5-inch.)
- 8. Rotate the nut turning transmission crank handle clock. rise 450 degrees v
.,
- as shown in Column 5 of data sheets m1I-l-1.
u 9 Release the tensioner hydraulic pressure end remove the hydraulic tensioners from the set of four studs in Sequence 1.
- 10. Repeat steps 5 through 9 for the first pass unloading of each set of four
- studs in Sequence 2 through 23 as shown in data sheets IctI-11. This complet'es the first pass unloading.
- 11. Install the hydraulic tensioners for the second pass unloading of the set i
- of four studs in Sequence 1 of data sheets MMI-l-1.
- 12. Turn the tensioner engaging sheave wheel clockwise until the drawbar bottom contacts the nut (IE-62). Then back off from nut by four conpletc counterclockwise turns of the tensioner sheave wheel to provide 1/4-inch
- gap from the nut. This cap is. required to allow for stud contraction when the load is reduced on the stud. Otherwise, the nut could not be released a
when the hydro.lic pressure is reduced.
- 13. Obtain a hydraulic pu=p preocure as indicated in Column it of data sheets
- 1911 - 1 .- 1.
u 1
- Revision: ~
- d. :;
1 Page 38-
'n '. .
BF }tti 3/21/78 Unionding Clonure Studs (Continued)
"1-
- 14. Rotate the nut turning transmission crank handic clockwisc 2160 decrecs
>.s s
. (6 full turns) as shown in Column 5 of data sheets 1:5!I-1-1.
J 15. Release the tensioner hydraulic pressure and remove the hydraulic tensioners F from the set of four studs in Sequence 1. -
- 16. Repeat steps 11 through 15 for the second pass unloading of each set of fcur studs in Sequence 2 through 23 as shown in data sheate M 1. This ccrpletes
]
the second pass unloading. - J
- 17. Remove all nuts (!K-62) from the 92 studs (by rotating the nuts approximately m 135 to 140 turns counter clo,chwise) and remove the spherical washers ('- - 64 a
and FK-65). Place all nuts and their associated spherical washers in the racks provided. 5:ove nut racks out of reactor ucil and to the nut rach laydown arta (6E dug 719E570) using the overhead cranc (5 ton hook). J NOTE: The studs, nuts and washer sets are serially nurabered in accordance t-itF q ~.the hole location in which they are installed or with the associated stud. L 181. For each stud with the exception of studs No.1, No. 31, and No. 61 (sce y figure 2 for stud location diagram), carefully lower the thread protector assembly (see figure 3), comprised of thread protector sleeve (>K-95), thread protector cap (>K-96), captive 1 1/4' inch - 7 UNC - 2A x 3 1/4 inch long, 3/4-ine,h hex socket head cap screw (>K-148), and washer (>K-147), over the stud
.and down between the stud and the closure head stud hole. When the thread of captive screw (FK-148) contacts thread in top of stud,' insert vrench through hole in unsher (FK-147), and fully seat thread protector assembly ov2r stud by turning scrcu hand tight.
- NOTE: If fuel is to be traasfebed between the vessel and the spent fuel 1 -
pool, the four studs in line uith the refueling canal (page 55) should n be removed prior to closure head removal and concurrent with installing thread protectors on the other studs.
.,) 19. For cach of studs No. 1, No. 31, and'No.,bl (sce figure 2 for stud.locatica ] . diagram), carefully louce the alternate thread -protector asucably (see figure 3),
j .. < . encvtaton: y. - - .3--
Page 38A
.) '
BF F2rI 1 ' J ~~ 3/21/78 Unionding closure Studs (Continued)
'1 d- comprised of thread protector sleeve (tK-95) and thread protector cap q (tK-96), over the stud and down between the stud and tle closure head stud
,).
hole. Install a guide cap and bolt assembly (dX-92 & -144, FK-93 & -145, P} l n
- t. .
LJ ' J 7
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- Adde ndtim,
ler w~ wf ~ O O Q C3 C3 O O O O [~- 3 Q- Q3 O Q . Q ' BF 20!! l 3/21/78 . TENNESSEE VALLEY AUTl!ORITY BROM:S FERRY NUCLEAR PLANT
. MECi!ANICAL !!AINTEMANCE DATA Si!E'JT 1011-1-1 UNIT NO.
Stud Unloading Data for Operational Closure (Sheet 1 of 10) DATE
.REACYOR PRESSURE VESSEL' 1 2 3 4 5 '6 I
Degrecs
- Cog. Engineer I Saqu :r.:.e Stud Tencior.er !!yd. Pur.p Crank- Initi d/f:!9 No. :!o. . Color Per.soure IEn:!1e QC Incp:: Luc t Code (psi) Turns Initial /Date FIRST PASS UNLOADING I
1 Red i (1) 1 24
/
Green 6000 450 l 47 Yellow / ! Blue 70 12 Red / [ (1) 2 35 Green 6000 450 58 Yellow / 81 Blu2 6 Red
/ .
(1) 3 29 + Green 6000 450 52 Yellow / , 75 Blue ' il7 Red / fl (1) 4 '40 creen 6000 450 l) 63 Yellow /
/ 86 Bli:e l
. - t! l 0 21 ---
Red / l (1) 5 44 Cccen 6000 450 67 Yellcw / 90 Blue , N D'f', (1) R:quirec 00 inspector signoff. See page 50. i
U U C 'O C C C C C O Q
. . Q .
3/21/78 TEN::ESSEl; VAI.I.EY !.UTIiORITY . IIROW;4S FERRY 1:UCLEAR l'LANT .
. . ?!ECilANICAL t!AIllIE!!ANCE
; . DATA SilEET Dil-1-1 -
. . UNIT NO.
', Stud Unioading Data for Operational Closure
'(Sheet 2 of 10 ) DATE REACTOR PRESSURE VESSEL 1 - 2 3 4 5 6 Degrecs Hyd. Pur p Crank
- Cog. Engineer Scquence Stud. Tensioner
, 1:o . No. Color Pressure, llandle Initial /Date Code . (psi) Turns 4 Red .
Creen 6 27 6000 450 . 50 Yellow /
, 73 P hie 9 Red i 7 32 creen 6000 450 55 Yi.11ow /
78 nlue 14 Red - 8 37} creen 6600 450 . 60 Ycilow ,
/
83 II] t:e - 19 Red ' 9 - 42 Green . 6600 450
. 86 Yellow /
Illue 23 Red 10 46 Creen 6600 450 69 Yellow / 92 Bit:e si:c9l::Lon: \'%,
I O O O '. O C'"3 Q- O Q C' O C C O Q LJ C , 3; ] C*O 3/21/78 , TENNESSEE VALLEY AUTl!ORITY '. t , BROUNS FERRY UllC1. EAR PLANT l ' '
!!ECl!ANICAL t!AINTENANCE DATA SilCET Mil-1-1 UNIT NO.
. Stud Unionding Data for Operational Closure .
(Sheet 3 of 10) DATE REACTOR PRESSURE VESSEL , 2 3 4 5 6 1 - Pegreen Stud Ilyd. Pump Crank
- Cog. Engineer Sequence Tensioner I
No. No. ' Color Prcosure llandic Initial /Date I Code (ps1) Turns j . .
' 3 Red
'l . 11 26 Green 6600 450 .
/
49 Yellow l 72 Elne . 7 Red r < 30 Green 6600 450
' ~ ' 12 /
i 53 Yellow ff 76 Blue 10 Red l ' 1 *. J3 33 Green 6600 450
' ' ~
Yellow / l 56
.} 79 B lt:e - ,
b , 13 Red *
' 14
.. 36 Green 6600 450 59 Yellow /
- 82 Blue 16 Red 15 39 Green 710L 450 62 Yallow /
C5 1:1 ie 3 i
't i
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I
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- a. e C C CI '. E'S ESKP C7
. . - . , N
~
TENNESSEE VAI.I.EY AUT110RITY . ER0m1S FERRY 11UCLEAR PLAliT I!ECilAMICA1. MAINTE!!ANCE DATA S11EET I" tI-1-1 UNIT NO. Stud Unloading Data for Operational closure (Sheet 4 of 10 ) DATE REACTOR PRESSURE VESSEL 4 5 6 i 1 2 3 _. j
- Degrecs 11yd. Pump Crank , Cog. Engineer i Sequence Stud Tensioner l No. I*o . Color Pressure Itandic Initial /Date Coile (psi) Titrns
~
'. 20 Red :
I 16 43 Creen ', 7100 450 - 66 Yellow / ) 89 niec j _ 2 Red 7100 450 17 25 Green * ' 48 Yellow . / 71 Blue , l, I 5 Ped I 18 28 Green , 7100 450 , 51 Yellow -
/
74 Elue . , S Red
, 19 31 Green 7100 450
' Yellow /
54 ! 77 Blue t I l 11 Red i 20 3 ". Green 7500 450 57 Yellow / i 80 - lilac l 1 re n . . . . < - ,, .. . L . .A. -
ifj e
.. *~;o ,iQ,O GT . ~.I M G $2 T C L.a O s- C :: k 'I5 A:2 C7 TENNESSEE VAI. LEY AUTITORITY
- BROWNS FERRY 133CI, EAR PLANT MECI A!!ICAL !!AINTENANCE
- DATA SI!ECT FDII-1-1 UNIT No.
Stud Unloading Data for Operational Closure DATE (Sheet 5 of IQ REACTOR PRESSURE VESSEL 5 6 3 4 .
' 1 2 Der, recs Crank
- Cog. Engineer Stud Tensioner flyd. Pump Sequence Color Pressure llandle Initial /Date No. No. Turns Code (ps!)
15 Red Crcen 7500 450 21 38 / 61 Yellow 84 T.lue 18 Red Green 7500 450 22 41 / 64 Yellow 37 Blue s 22 Red Green 7500 450 . 23 45 / 63 Yellow 91 Blue - - i e
- Revision: _
v \, . __
- 'O C C C3 d C3 h . .. a C- 3 a a a dEyb ; a p 3/21/78 -
TENNESSEE VALI.F.Y AUT!!ORITY , BROWNS FERRY NUCLEAR PLANT
!!ECHANICAI. !!AINTENANCE ,
DATA Sl!EET M:iI-1-1 UNIT NO, Stud Unionding Data for Operational Clocure DATE
' (S!tect 6 of 10)
SECOND PASS UNI.OADING ' REACTOR PRESSURE VESSEL 6 2 3 4 5 , 1 Der,rces Cog. Enginee - Scquence Stud' Tensioner liyd. Pump Cranh ,Initini/D.- _c No. No. C'oler Pressure it :ndl e QC Inspcctor Code (psi) Turn *, Initial /D.c a_
~ /
1 . Red *- 3600 2160 (1) 1 24 Green 47 Yellow / 70, n i ,i, Red
/
12
- Green 3600 2160 (1) 2 35
/
SS' Yellow 81 n1ue f R2d
/
6 . Green 3600
- 2160
- ' s s. (1) 3 29 Yellow /
'. 52 75 Blue .. _ _ _ _
/
17 Red Green 3600
- 2160 (1)./4 40
/
63 Yellov SG Elue Red / 3600
- 2160 (1) 5 [21 44 l 67 Green Yellow /
Bluc i 90 __. 3 (1) Requirec QC inspector signoff. See page 50.
- g . .
O
~*P.itsion: 1. %
7
C C C C i. ._J C' J_C O y Q a a ,f[hg 3/21/73 i r
~ TENNESSEE i/ ALLEY AUTliORITY 11R0t?NS FERRY NUCLEAP PLANT
.. l ' 110C11/.111 CA:) ':.t AI tra.<AN CE
- l'ATDATIO tlVEEIW4I1 1-1 ,
j l , StugtUdIUf!!'dtidiht!t Datnf 8t'Og4Eht'fdnEl"CI68ure i
~ * '
(:~h(shedt gi d[010) . D AT5AT z._.. _ _
<;ir.c.n : An<: li :1 or.n l::c ret.U.02TG222:.MURIN3SEL r'
! 1 2 2 - 3 3 4 _ .__. _ _5_ _g __ 6...._._
u... D6hfcco ' '* Co'g
' ' . 'th giti c e r I;cqSegttence ' "d ted
- T'Td*tt:f6ncr li dllyii'.':' Pump Cr 'C'r ank
?'a .;:o . ' ! . ',' o , i: IC61or l' ' P rddurc U"IfdSdle
initie.1/Date
. ' ' ' : i.
' re.'enae ( p .613i) 'i n ;orns , , . . _ , _ , , ,
~ I 1 4 ~ 1:iJed
- 6 27 ,c Gscan t> < S 6 00 ,!!2160 (1) J 2 y (tellow / /
/, 7 50 _
__ ' i E l v '; _ . __ _ _i _7 i 73_ __ - . . _ . _ . . .
/
I
' 12 9 ' It. . Red 7 32 c . Green 3ME600 4 *- 21'2160 l (1) 2 ': >
/ /
"~
. 55 7.%:llow
70 ..-_._ '.nlua _ _ _ . _ _ _ _ . . _ . _ _ .__ _ _ _ _ . _ _ .
I
/
r, 14 r ..Ged , 37 c.. Green 36tB600
<
- 21,2160 (1) 3 8 79
<a 60 y mallow //
1 33 . _ . . .
- ..nlee_ __ , __ . _ . _ _ _ _ _ _ _ _ .._, - . _ _ _ _ . _ . _ _ _ _ . .
i i 19 1:,..Re d
/
17 9 f. o 42 (;i Cr.cen 3 ram.00 * '71/2.160 (1) 4 Y /f r, 1, 65 y..ipilow
, ,pluc
,.g 08 M ,' 23 l' 1:cd
/
369#,00
- 21'2160.
(1) 5 10 [t/ '. 46 CiOrten
's Wilow _ _ /._, f .
69 _ l .__ _ _ (1) 'ee,i:i re n (;' in: :or r.!.nori. p:. .o 5 . ~. .
, .\
#4?.<:vi s ton :,__/ N _
rage to O C' C C C C O C 'O L. J [. .'.3 C C LJ L ._ J Q 50 C - C-l
' 3/21/78 ,
f i 1 TENNESSEE VAI. LEY AUTif0RITY
- I, BRO'JNS PI;RitY i:UCLEAR PLAtiT t.
!!ECl!AriiCAL IfAINTENANCE I DATA S1!EET 121I11-1 :
UNIT NO. -l j Stud Unloading Dcta for Op.1 rational Closure
;(Sheet 8 of 10) DATE REACTOR PRESSURE VESSEL 4 5 6
.1 2 3 1
- i Degrees .
Crank
- Cog. Engineer !
Sequence Stud
- Tensioner Ilyd. Pu ap 1:a . I'o . Color Pressure llandle Initial /Date Code (psi) Titrns _
3 Red . 11 26 Green 4400 *(2) 2160 49 Yellow / 72 Elne 7 Red
*(2) 2160 12 30 Green -
4400 i 53 Ye110w / n 76 Ulue , 1 . 10 1:cd 13 33 Green /.00 "(2) 2160 '
"' 55 Yellow /
7'] Blue - l o .. 13 ! R.cd l 14 Green 4400 ' *(2) 2160 j 261 59 Yellow / 32 Elue i 16 Red 15 34 Creen , 4400 *(2) 2160 62 Yellow /
, 35 - Blue l 1 _ _ _
*Re- 's ton: s6 %_
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. . . . . . . - ~ . . .;.... . . . . . . .
EROWiG FritRY IiUCLE/.R PLANT MECllAtlICAL I!AINTENANCE DATA SilEET 1011-1-1 UNIT NO.. Stud Unioading Data for Operational Closure
-(Sheet 9 of 10)
DATE REACTOR PRESSURE VESSEL . ; .
.1 -.
.2 3 4 5 6 , ,
Degrecs Sequer.cc Stud' Tensioner Ilyd. Pump Crank
- Cog. Engineer No. No. Color Pressure ' 11andic Initial /Date Code (pst) Turns _ ,_
20 - Red
. 16 43 .Creen 4400 *(2) 2160 66 Yellow /
89 Blue 2 Red -
, 17 25 Creen -
5600 *(2) 2160 48 Yellow -
/
71 Blue . 5 Red
. 13 28 Green 5600 *(2) 2160 l
51 Yellow / 74 Blue , 8 Red
~
19 31 Green 5600 1--(2) ~2160 54 Yellow / 77 Blue t 11 Red 20 34 Creen
- 5600 'T2) 2160
, i , 57 Yellow /
\ , 60 - Illue l \ --
.,
- Revision: .
_s
O U / ".17 E.T C D Q Q c ,;,,; a g g
- :: i TENNESSEE VALLEY AUT110RITY BR0b'NS FERRY NUCLEAR PLANT
!!ECI:A!!ICAL liAlliTEi:ANCE
- DATA Sl!EET }D11-1-1 .
UNIT NO. __ Stud Unloading Data for Ogierational Closure DATE (Sheet 10 of 10) i REACTOR PRESSURE VESSEL 3 4 5 6 1 2 De,~,re c a Ilyd. Pump Crank
- Cog. Engineer Sequence Stud Tensioner No. Color. Pressure liandle Initial /Date No.
Code (psi) Turns , 15 - Red Green 5600 *(2) 2160 21 33
/
61 Yellow 84 Blue 18 Red 5600 *(2) 2160 22 41 Creen
/
64 Yellow-87 Blue 22 Red Green 5600 *(2) 2160 23 45
/
68 Yellow 91 Elue ,
/
t'
- Revision: t. .
,' ~
Page 49 BF FMI 1 Stud Unionding Data for Operational closure (Continued) [1 Li }; umber of cycles that cach stud tensioner underwent during stud unloading:
] Scrial !!u-ber Cycles j
l _ a , N 4 W Recorded on equipment history card. Yes No l'y *t:0TE: If total number of cycles exceeds: 1402, the draw bar should be replaced, r u 2802, the engagement nut should be replaced. Trouble Report 1 umber Verification that during the first five sequences of the first pass unloading (data shcot page 39) that the hydraulic pump pressure was 6000 psi and tha: D the crank handles were turned 450 or 1-1/4 turns as specified on the data sheet. I QC Inspector Date 0 yerification that during the first five sequences of the second pass unloading
, (data sheets page 44) that the hydraulic pump pressure was 3600 psi and that
- the crank handles were turned 2160 or 6 turns as specified on the data sheet.
a J QC Inspector Date 9
- Y Q _
. 1-M *
~
- j. . ,.
.t Page 50 l \'
^g3 BF MM1 1 3/21/78 3
' Unloadint' Clocure Studs
[- (Continued) i l9 '19. (Continued) I3
! and 15-94 & -146) onto the thread protector assembly and into the stud by 1
I inserting the threaded end of the bolt (:Z-144, ;M-145, and !G-146) through c i the hole in the thread protector cap (MK-96) and into -the stud. Fully seat I o the thread protector and guido cap assembly onto the stud by turning the
' bolt'and guide cap hand tight.
; NOTE: Any guide cap and b61t may be installed into any one of the three studs, No. 1, No. 31, and No. 61. The assemblics are not pre-f I, assigned to the studs.
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Page 51 BF 1211 1
- 6/29/76 r}
U r . IJ J m 6 J Lif tine of Closure Head
- 1. Per preceding instructions, unload closure studs, remove nuts and spherical washers from studs, and install thread protector assemblics and guide caps on
[r]t the studs. Prior to attaching the head lif ting strongback to the overhead
'1 J crane (125 ton hook) orient the hook such that the side painted red is in the r~ plant north direction. Verify that the two hook pins on the sling hook box are i,
d retracted onto the pin supports. Lower crane hook into the slot on the hook box such that the side of the hook box painted red is in the plant north direction. ri {j Locate the semi-circular groove in each hook pin so that it is facing downward. The rod ends, turnbuckles, lifting clevis assemblics, head lifting lugs and the strongback ends will be painted with a color code of Blue, Red, Green, and Yellow. Orient the assemblies such that all of the parts painted blue are together, all red parts are together etc. Adjust the turnbuckle bolt end gap to the w following for head handling. J N ee ..e. J J
g . . . .
,Page 52 BF FMI 1 0 9/28/76 p
Lifting of closure Head (Continued)
~
- 1. (Continued)
- TURNBUCFLE BOLT CAP
~
j
- 3 BLUE (EAST) RED (UCPJH) GREEN (CEST) YELLOW (SOLT:1)
" Unit No. 1 10 15/32" 10 13/32" 10 5/16" 10 11/16" Unit No. 2 11 7/16" 9 1/8" 10 1/4" 9 13/16" Unit No. 3 *10 1/2" *10 3/16" *10 11/32" *10 9/32"
- 2. Attach lif ting rig to the overhead crane (125 ten hook) ind to the four (4) n lifting lugs (1K-210; Figure 2) on the closure head.
U NCYrE: Handling and lif ting of the head is to be performed using only the lifting lugs (FK-210) on the head. No other attachment points or methods are to be employed fro lif ting or landling the closure head. I L 3. Take a strain on the head lifting rig, and verify that it does not ride or r< bind against any component or part of the closure head. Verify that the b head will be level with respect to the vessel whez t.Se head is lif ted. U WARNING: Use extreme care during all lifting and handling operations of u the closure head to prevent damage to vmt pipe, instru=entation nozzles, and closure head seating surfa:es and to the closure q studs. J
- Revision: '
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Page 53
;{ DF F04I 1
; 3/21/78 Liftint, of Closure Head (Continued)
,; 14 I'.anually guiding the closure head, carefully lift it to a height of at 4
1 cast 7-feet to clerir closvre stud thread protector assemblies and [ guido caps. CAU'"IO? : Do not allou closure head to ride or Mnd on closure stud cuide i I .j caps or thread protectors. Othentice, the studs =ay be deneged. I J 8
- 5. Lift closure head and transport it to assembly area support stand.
L, 3 q 6. After head is lifted from RFV and transported to the laydown area and before 1 , j ,; any other operation can begin, the RFV flange seal surface protector must be installed. Assemble the eight (8) segments of the seal surface protector as b shoun on figure no.11 (figure no.11 shovn on page 54) on the refuelin:-
- f. floor using necessary precautions to protect the protector from da-ece and le keep the protector cleen. Using a four-leg lifting sling, attach one leg to
,] cach U-shaped lifting ro'd (E-2140) and hoist protector assembly to a suitable working height. At this point clean both the reactor vessel pJ flange seal surface and the seal surface protector por the cicaning instruction shown on page 33 of this instruction. Hoist seal surface protector over the reactor vessel flange and canually cuiding the protee' tor t
y assembly, lover it into position on the vessel flance seal surface. Fctove y lifting sling from protector assembly lifting rods (IE-210). 4
- 7. For removal of 0-ring gaskets (!E-215 and IE-216; figure 3), love: closure
[
,9 head to a suitable vorhing height, set it on support stand, if available, and maintain tension on lifting rig.
D
.g 8. Remove cach of the two 0-ring caskets ( %-215 and 5-216)-from the gaskets' grooves in the closure head scating surface by loosening captive screws
- ~~
* (IE-218) and rotating the retainer clip to disengage the slots in-
- I.
- Revision;__ .
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O . Page 55
~ BF 1211 1 F 3/21/78
~ Lifting of Closure Head (Continued)
- 8. (Continued)
J cach gasket. Sec figure 1 and detail "C" of figure 3 for a typical vicw of the fastening and for 0-ring gasket and fastener details. 9. For removal and replacc= cat of damaged fasteners, see Appendix A. 7 j 10. Per preceding instructions en cicaning, examine for cicanliness and, as necessary, clean the following: closure head internal surfaces, closure J head seating surfaces, vire clips (:E-217; figure 3), captive screus a ('E-218; figure 3), backing plates (BZ-219; figure 3), and 0-ring gaskets ( E-215 and MK-216; figure 3).
- Silver residue in RPV 0-ring seal well may be rimoved with an Arkansas stone and kerosene followed by standard acetone 1 cleanup as described on page 33.
L.l 11. Remove the 3/4-inch square, braided asbestos packing (MK-21; figure 3) q from the 267-7/8-inch diameter by 1/8-inch deep groove in the top of the u reactor vessel flange surface. i Removal of Studs In Line Uith Refueling Canal J When fuel from the spent fuel pool is to be installed or removed from the vessel, the four vessel closure studs in line with the refueling canal must be removed t from the vessel fitngc. Removal of these studs is as follows: 1. l The four (4) studs to be removed during refacling operations are stud nos. h -58, 69, 70, and 71, for Unit 1 and stud nos. 22, 23, 24, and 25 on Units. l 4 2, and 3. I For location of studs sco Stud Location Diagram, Figure No 2 P on page 5. 1
*2 Remove the thread protector assembly, if installed, from each of the four l
r studs by turning the 3/4-inch hex socket head cap screw (FE-148; figurc 3) } ( _ . - - - - - out of the threads at the top of the stud center hole. Simultaneously,
- move the thread protector assembly up the stud. ,
When the screw (MK-148) . is disengaged from the cud, lift the thread protector and remove it from t pud, and from the reactor well to the refueling floor.
*Eevision:_ f,[b w -
w Pag 7 56 BF ?D1I 1 r 3/21./73 [ . 'l Removal of Studs In Line With Ecfueline Canal (Continued) 'J Assemble stud handling tool (FE-89) and connect to a 50 SCFM air supply 3. having a 100 psi pressure.
- 4. Drive the stud handling tool motor and drive screw downward for the full d travel on the drive screw. Reverse the direction control valve.
Assemsle the temporary platform used to work from to remove the studs. Move
' 5.
the platform from the refuel floor to the stud area in the reactor uell. (NOTE: Platform is stored on the refuel floor along the west wall near the tovi rack.)
- 6. Loosen the stud using stud wrench ('n-901) uith a steady even pull.
- NOTE: It may be necessary to use a hammer and brass bar to strike the s ud on t- l to break the threads loose. Do not damage tep of studs or usser threads.
- 7. Thread the stud clevis and keeper assembly into the top of the stud, and a
lock into place.
- 8. Prc1:ad the balance springs by raising the crane until the bottom of the stud lifting tool guide plate is in line with the "hard stop" indication.
J (The stud will now have a 50 to 100 pound upward preload.)
- 9. Drive the handline tool motor and drive screw upward to remove the stud from the vessel stud hole (approximately 75 full turns). When the last ,
thread comes out of engagement, the stud aill " pop up" approximately a 3/4-inch to prevent damage to the lead thread. Reverse the direction I a control valve. 1 1
'NorE: The drive screw is driven at approximately 50 ft. Ibs. torque at l
50 rpm.
~
- 10. Store the studs in the head stud storage rack.
a
- 11. Using the reactor building auxiliary crane, transport the head stud rack 1
-~ ~ ~~~
to its storage area on the operating floor. I r'
- Revision: f f 0 *he
%m -
m . l w . I Page 57 l
' BF mtI 1 u
" ~
6/29/76 0 (Continued) Removal of Studs In Line With Refueling Canal _
- 12. . Examine for cicantiness and, as necessary, clean the reactor vessel flan and flan;;c seal surfaces.
Remove, disassemble and store temporary platform. 13. D . j
- D t
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- U
- D U
- D
- D D
D 0 0 .
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4 Page 58 Bl' ID11 1 3/21/78 a.
.* Replacement of studs After Refueling Operation
]
Inspecting Closure Stuou (Scc figure 3.) N Before the closure studs (FK-61) are installed in the vessel, inspect all AJ
-+ accessibic portions of the studs and bushings (15-63) for finish, dirt, oil, etc. Thereaf ter, whenever the closure head or the nuts (!K-62) are removed from the vessel (as during refueling), all accessibic portions of the studs are to be inspected. Whencver a stud is removed from the vessel, the d
) accessible portion of the bushing is to be inspected.
If needed, the studs may be cicaned by brushing with acetone and 18-8 stainicss p steel brushes, not previously used on any other tyoe surface, or by using an epproved thread chase. Such cleaning must be performed without causing damage to i the threads. Clean studs (>K-61), nuts (3%-62), washers (:Z-64 and 1[-65), and
.?
bushings (IK-63), as necessary. The cleaning must be such that no foreign matter 1 l can be seen after c1 caning, particularly in the root area of the threads. [+ Af ter c1 caning, lubricate the studs lightly with Dag Dispersion No.156 or ::ever-
' Secze compound.
I
- To in'scrt a stud:
{ . l '. Verify bushings and bottoming sleeves are in place. _ { Verify that the stud holcs are thoroughly cican. [
- 2.
1
'f Assembic the te=porary platform or use the service platform to work from to
*3.
lj P install the studs. Move platform from the refuel ficor to the stud n ea in the reactor vc11. I NOTE: Platform is stored on the refuci floor along the west vall near the
. . tool rack.)
3 i
\' l vision:0 ' , a m x )
I < . e - i q - Page 59 BF FD11 1 h' 6/29/76
'1 ___ . _.
Replacement of Studs Af ter Refueling Oncration (Continued) Il 4. With the threaded plugs removed from the tops of the studs, use the crane k and the head studhole handling tool to lift each stud out of the 1 N rack. 4.. .-- -. . Iv i c 1 1 t i 9 3
'I i
i 2&
.' 4 .
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~
l << . Page 60 BF 1011 1 11/9/76 Replacer.cnt of Studu Af ter Refuelin:t 0;-r 2tien (Contir.ued)
- 5. ~ Drive the motor and drive screw up':ard to provide the required insertion travel on the drive screw. Reverse the direction centrol valve.
- 6. Engage the etud uith the teol.-
7
" Lover the stud to within 1/2" to 1" of first thrcsd engcgement.
7. t 8. !!anually depress the tool :.nd stud to brin;; the first threa3 into centact. ,J
" Jog" the hand valve to engc;c the first thread or two. (The stud will 9
now have an approximate 50 pound upward preload).
- 9. Fully insert the stud.
- 10. Install thread protectors on studs.
- 11. Re=ove, disassecble, and c' tore temporary platform.
a Replacement of Reacter Vessel 1:ead a Prerequisites
- 1. The installation of the dryer and separator must be complete.
- 2. The reactor well and equipment storage pool drained and decontaminate 1.
,1 W 3. Studs, nuts and washers cleaned and ready for installation. All stud threads lubricated lightly with Dag Dispersion No. 156, or "Kever Secae" cc=peund.
- 4. Obtain a release from the shif t engineer for the installation of the vessel head. All core verifications must be completed.
- 5. New vessel h'.ad "0" rings installed.
D 6. Valves fCV 3-93 and FCV 3-99. closed.
- 7. Check studs for installetion of thread protectors and see that guide cap and bolt assemblies have been installed on studs nos. 1, 31, and 61.
.8. RPV flange seal surface protcetor cust be recoved, disassembled and stored. Flange scal surfaces cleaned an indicated on page 33.
D 9. Service platform support removed if previously installed. i 1
*10. Instruments LS 3-189, PA 3-139, PI 3-190 and PS 3-190 must *be calibrated and
~
working correctly. Signoff on Data Sheet :c:I l-4, rage 97.
- Revision p1-*N. / ('s l.P
Page 61
- 6/29 6 l4 ;
(C 1ntinued) Re_ placement of Peactor Vessel Head Preparation for !!ork installing a. 1. Assemble and check all rigging, tools, and equip =ent required for I' Include the following:
+he head.
- a. Head Strongback, r .
b. Check stud tensioners and power pack to see that they arc in a 9 serviceable condition. d Check the tensioner lifting devier. to see that it is in a serviceable c. T
- 1 condition.
d. Check the Starrett dial indicator depth gage fer operational readiness. o 1 e. Have on hand 75 feet of 3/h" square braided, John-Manville 8398 ga material. fO . 9 5 8 Installing Clcsure Head h .)
- 1. Properly orient the lifting rod, turnbuckle and clevis assemblies as s o page 51.
Attach the reactor building crane,125 ton hook, to the head stro 2 for v Adjust the turnbuckle bolt gaps to the gaps shown on the table o g the respective unit. u Con:tantly exercise due care throughout the steps of this precedure
" CAtJfION:
to prevent damage to surfaces of all parts and co:ponents and to 8 k assure cleanliness of surfaces at all times T 2. Attach lifting rig to the four lifting lugs on the closure head. J Handling and lifting of the head is to be performed using only the NOTE: No other attachment points or 1.ethods are
# lifting lugs on the head.
to be employed for lifting or handling the closure head.
- f e
~~
.go- . j e- . m Pace 62 BF MMI 1 6/29/76 I J Installine Clocure' Head (Continued)
- 3. Take strain on the head lifting rie and verify that it does not ride or bind against any component or part of the clo:ure head. VeriOf that 4W1 1
j head is level with respect to tne vessel. Loecr head and ed,'ust as
' necessary to 1 cycl.
'!~
WAPJIING: U:e extreme care during all liftint, and handling operations 9 of the closure head to prevent damace to vent pipe, instrument j nozzics, and closure head seating surfaces an-1 to the closure 1* studc.
- 4. For installation of O-ring gaskets (MK-215 and I'K-P16: figure ?), liff
{ La head to a suitabic working height, rest on support stand, if available. c. and maintain tencien on lifting rig. La. 5 Exsnine gaskets and gasket groove for cleanliness and cican as necessary, s 6. Install cach of the tuo 0-ring caskets (MK-215 and MK-216) into the corresponding Casket Brooves in the closure head scating curface.
'l J WARNING:
Uso extreme care during lifting and handling operations
'1 to prevent damage to 0-ring gaskets (MK-215 and "X-P16).
4 J
- 7. Examine the vessel scaling surface and cican as necescary.
- 8. Fit the' 3/h-inch square, braided a:bestos packing (MK-P1: figure ') into the 276-7/8-inch diancter by 1/8-inch deep groove in the top of the reactor vessel flanc.c surface outs 3de the studs.
9 9 Lift tre closure head, manipulate head into the proper orientation . l. u over thc. reactor vencel, and verify that head ic 1cyc1 with respect
't to the vessel. (if not 1 cycl. remove and lower head and ad,'rct as necessarytolevel,)
1 J . l J
Pace 63 BF ME 1 6/29/76 0 q g Insta111nr Closure !!ead (Continued) Slovly lower the
. l'O . AliCn closure head on guide studs !!o=, 1, 31. and 61.
closure head and manually guide into position so that guide capped studs 7 penetrate the closure head stud holes. j
- 11. Continue loverin- the head into position over the closure stud thread a
protectors. and seat the closure head on the vescel until full veicht of head is resting on vessel as evidenced by slach in the liftirc ric. g CAUTIO!!: So not allow closure head to ride or bind on closure stud Other .* ice. the studn may be a guide caps or thread protectors. j. damaged. ,
- 12. Renove lifting rig frca closure head lifting lugs and transport to its lp-proper laydown position.
l f' l Installinn Washer and nuts onto Clocure Studs (See figure: 3 and 4.) lJ L CAUTIOM: Constantly exercise due care throughout the steps of this pro-n cedure to prevent damage to threads and surfaces of all parts and U components and to assure cleanliness of surfaces at all times, . n y for assedbly onto matching numbered stude, group together all lihe 1. nusbered castellated nuts (MK 62: figure 3), convex spherical vosher: f (MK-65), and concave spherical vachers ( E 64). Eyamine the nuts and washers for cleanliness and cican as necessary as indicated en pace D e no. 33. .. I'o. 1. No '1. end w
- 2. Remove the guide cap and bolt assemblies from stud Lift end m Mo. 61 by turning out the bolt and cuide cap from each stud.
x . remove the alternate thread protector as cmblies from the three studs. m l l I a 1 l
rt J .. 7 Pare 64
. DF 201I 1 6/29/76 1
Installine. Un hers and !uts onto Clocure Stud: (Continued) 3 Remove the thread protector a:sembly from each of the remaininc 80 stud:: a by turning the 3/4-inch hex socket head cap screw (MK-lLS: figure 3) 1 j out of the threads a.t the top of the stud center hole. Simultancoucly nove the thread protector a:se.51y up the stud. When the screw (MK-lh8) i: disengaced from the stud, lift the thread protector and renoce it from the stud. Move the 89 stud thread protectors, the 3 citernate thread protectors and the 3 guide caps and bolte a==emblice froa c.: re9etor vell
- to their proper storage arca on the refueling floor.
- 4. Using Dag Dispercion 156 or "UcVer Seeze" co= pound lightly lubricate the bottom curface and the spherical face of spherical vachers (M:-6h) and the
) top curface of Opherical vachers (MK-65). ~
- 5. Install match marked concave spherical washer (>E-64), flat surface doun,
! over the appropriate stud to rest on the surface of the closure head, i CAUTION: Do not drop washer on studs. Lower siculy. 6._ Install the match marked convex spherical washer (MK-65), convex surface down, over the stud so that curved surfaces of the sphericx . whsbers (HK-64 and lIK-65) are mating. .
- 7. With caste 11ations up, thread match marked nut (MK-62) onto the stud.
Continue rotating nut (for a total of approximately 135 to 140 full turns) to seat against spherical vasher (MK-65). Seat the nut !.and tin'c.t.
- 8. Repeat steps 5 through 7, as applicable, to install spherical vacher cet:
and nuts onto all 92 stude. - -- 9 Examine the 92 neasurinc rode (MK-90; ricure 3) and clean as neccccar:- .t o the hole in each of the 92 stude, insert a measurinc rod and carefrily ).wcr the rod to rest on the bottoa insert ("K-7?; firure ?) of the sted. Po NW DROP RCD I::TO SWD.
. 1
- - _. _ . . .. ~
't. ,
- P g3 65 -
t .. . BFWI1 )" 3/21/78 [P , Pt.r c 6. E Instniting Unnhern and truta onto clocure Studs (Centinued) l'T'"C 1 5/29/h r 9. (Continued) ]" .. .
. nc h ..of . l. ~*MW rndrJ:iust _rc=31n.fr3in Atuds 'for 2 Tours prfor to obtaining y .
n6 c16nsstforiticadintis r ~tY"aIT64 the: to icacli"d 'stabiliz'c5 temperature.
~ ~
i sifi51 ' 1 b;. turni:.,- . .t
- . : n :.. .s; :.: :.:c . .2;i .: ::r:- .:.. ' . r '. ~
-[ Tcnnion,ine Clonurt- Stedn Ifnin 11vdraulic Tencionere for Onerationni Closure . g, ~ . . . . . . . . . .. .. . . . .. .: -..
..- r. : .:. .
Clocure stud tensioning (clongation) as cet forth in - - this procedure and as delineated % ::.c i.. :: :.:: . ~ . . . :. :. : . ' - - . :. : : 3- ..- - :: in Data Sheet }0iI-2, requires a tensioning pass of four sequences of four studs cach c.ictn . L:2 d i r :- .. - .. ;_J . .e : r - rt:r -: r: : - , :r- ., to cent the o-rings (14-215 cad 1!K-216), t. ten a first pass of 23 sequences to tension I t .; n . . . .r . . , . . , _ .. . . . , . . . . . . . , . . . . . . .
. . , , ., g ..
a all ctuds to initial clongation values, and, finally, cecond pass of 23 ccquences pre .c e . :: : :. . ' . :- ' --i 5. : :. : r.nd :. :: :. .;:t- - :.ic: f r -- . e r-i s - . :.: .- to tencion all studo to a final target elongation of 0.046 (+0.004/-0.002)-inch. - to t..ci: . r: 2 .- :'-~: : :_: : . . .e r: . . _: NOTE: A Q.C. inspector must make appropriate verifications on all data sheets.
,. 14 . L:.:.nr ' q Ii:. 2r. ' - ; = : :: ..ever ice:' ::-.:. . 1:. . :1:7 1. :r .: .c - :
CA1TTIC::S J oo,2:. ur::.:e :.n- .s :-hcr_::1 fe.0c Of ::ns-;- . . :.cr3 T - I. ' : .i .. .. 1. Loading (tensioning) of the closure studo for any reason, shall be perforned q top :.u-f:.:: :: ::.".:r' :.1 < ir: ' ~: - ij
- 5. OULY..,.chen,the sa .: . . . . . . . . .ycccel.
. - . . . .ficng:e
. . . :and :. r head. :. :.metal. ::.:.tr.speratures
- . .. :st..are ;.::a.uat orc: above the q Ep. , ,. . . .propriate ninf=um .tenatoning'-tcuperatures in. Tabic ~10n 1 'as 'incastfred by y CM7 - . :: c-. :. : - - : : :. . -- u:. _:... ..
conEof room instrumentation TR 56-4 and Ta 68-37 on pancic 9-47 and 9-4 , p 6. Ins tr.11 ::.c c ;c! :.r::t d :; :: snSer:: .. .; er '
- . 5; . c f c st r; .: . l
! respectively, and by a hand pyrometer. (See Figure No.13 on page 95, for w dc=., over :'. c;.L s: : :. t . :. r:e ? . " r i : . u r:
- . . :7 :r.
- location point to measure vessel flange and-head temperatures.
] (R:-U. nd : :-i3 tre :::ir. ,
tJ 2 Closure stud tensioning (clongation) as set forth in this procedure is 7., Uith c:.c .e11:. icn:. p. nre n:.: b ".r: : . nu . :~'- on .: 1. c.
- a obtained by ucing hydraulic pump pressures catablished by tent data.
. Contin.0 re:ci! - 7"- :r - . : *.1 e f : -- - _ ; c' ;?' '
11 Accurate stud elongation is theoretically pocsibic using only the
, turn:.' ;e : ::.: :. :.i:.: . :: . .r. ; .1 W.:..t :
..,. Ea . . t. -1 l l
hydraulic pressures as an index of tensioning. Ilouever, the clongation
=
- 6. P.cper - :cy: ~ ..r. '. :.: - --: f c n ..t . : : :: :r ar. -
.c r -
taeasurceents muct be made and recorded for comparison with results and l y . .. . . . . 1 an2 nut: en .. :. . _ _ tr. e. : . . a 9 D:azzine tne "~' nercuri - r8 .'"C m : fi . . r o '" a- ' M . .- er v er:- '
~
f': Le the :: ole ir i.-c c: of .;.c n . :d e. 1:::cr- n c n m i: rH -
' cra e 1 : ' -' r n the r<W .o ces, on .. c bo;;m J n:cri (: : ' : i .:re ii c e : "<! .
*Revimra: :'. : TJ . h. .
l 4 h 6 f
+= =1' 41 ..
Pac 2 66
~ BF !?iI 1 6/29/76 p
Tensioninc Closure Studs tJainc Hydraulic Tensioners for Oncrational Closure b (Continuea) CAUTIO!!S (Continued) s
- 2. (Continued) for ana17tice1 interpretation = of stud tensioning. Incomp1ete eate com L
r1 delay the tensioning and can prevent analyses of the data. Elongation u measurements also serve as an index of correct progression of stud tensioning and as confirmation that studs are correctly loaded rat the end of all tensioning passes. s WARHII!G: This procedure requires the simultaneous use of the set of four 701364-18hs, hydraulic tensioners, the 701124-1846 power unit
- [] assembly, and the 701334-1842 lifting rig assembly as =anufactured
.~ The use of any other by the Diamond Power Specialty Corporation.
the quantity of tensioners or any other type of equipment invalidate:: ten::ioning sequence and pressures set forth herein. im
~
- 1. Zero dial depth gage (E-88). For each stud in turn, seat the gage on the stud reference surface (as shown in figure 3), and obtain the initial no-load elongation gage reading of each stud. Record the readings in L column 3 of rata Sheet IMI-3.
CAUTION: Frior to taking elongation measurement, the measuring rod p U temperature should equal the stud temperature. As much as two hours may be required to obtain this equalisation of temperatures. 7 J xOrm
' l. Measurements a c to be made as follows: Take measurements in numerical
~
order, but record measurements by appropriate sequence and stud nuubers. 1
**+=>++e ea==me.%.e. ,e , ,
* .me_
m , ~
. Face 67 BP t'BtI 1
] 6/29/76 J 1 4 Meacurinc, Stud Elencation from Stud Reference Surface _ 1 m L
- l. Clean the elongation gcce (??:-88; figure ').
a. CAlffICI{: Do not handle the ga6e by the dial indicator head. J
- b. Zero the cage (:2:-83), insert crce pin into stud center hole, and set i the sage hou:ing on the top of the stud (that is, the etud referer.cc
.J n
surface) with the Gage pin contactinC the measurin6 rod. L
- c. Gently rock the cage bach and forth and rotate it, if necessary, until 1y seated en the a minimu . reading is obtained with the gace fi2 :
stud reference surface. d, Read the cage and record the indicated eloncation of the stud in tbc
' appropriate column of Data Sheet 12tI-3.
J CAUTICU: A gi' ten ncasuring rod must rc=ain in the same. tud throu-hout If mencuring
, all sequences of any one tencioning procedure.
u rods are rc=oved from the studs and interchanced, the initial Erroneous elongation mens':rements no-load references are lost. vill result.
"1 I in subsequent etcp: of this a
- 2. Sequoice and Colu=n identification procedure ref er to Data Sheet!2il-2. Stud Tensionine, Ihtn. unicss othervice noted,.
m
- 3. A QC inspector cust ocke appropriate verifications on all data sheets.
7 Tencioninn Studs ,, J 2. Assemble, connect, and operate the hydraulic tencioners. liftinc rir, and power unit acce=bly in accordance with manufacturer's instructionn. e
~
Pago 68 BF (".fI 1 F.if.29..D.6 12 . . 6/29/% l Tensionint' Studs (Continued)
- 2. y., Con.tinued.
- z . ). .. .... - . . . . . .
. . . . . e.
nue *efcr: tc " r~E
- HOTES t
h 1. Fill the power unit a==cably filter-regulator-lube accembly to the jJ vicible rim of the bowl with turbine oil, STO-1. 6.
- 2. Set the power unit asser.bly control valve in the center position a
L an fi.ll f.,h.e.3. ca.d. .- gallon: capa. city: recervoirto the level indicated g, . . . . l . . .
-iL-a.aa....
- .~. ~-
- C .. ....: h.Chevro. -:1.Ep:0Delo - - - " - - - Surgr:3;c i; ; .0 i'
k3. ZercConnee . .j; operatin;:.- -- air cupply of-55.SCn:nat Ico:pfii'iMet pre :ure' - L ti? Watin~n .Pc inie.'s of pe.rer.. unit-se:ie:ob1yi#it3"gt.1,;,7.g g;'2 ine:. stMYe' ine .. uf,e _ogc 7, u,,,=1:te. supe 17.cirne'#rireset a11cv the a -:;
- c. [eE:f -:US ".".tf avpq11;.c:ga_ci,tyc. tr.i :: : . c 1. . if . c: c- c r,. .
~
[ r.Eir *c. N*d3 tEnf o?CTInso i .that om inaREi'ki'th yeb,"the'second r.b(( Edd.N.'... third.yith, yellow, and the fourth with blue. In all L. D Nh. ic.. steps; confine the-uccioficachiteht'ioh'e? to"53' c'on'c'eNtive studscppi in @e.m.f.o.lle. c, . - - - - vin 3 =annert s';.cc . !' :!-3.
, . . . . ~.
~'
L Cf.,._. .. .... . Tensioner. Code' rei ..:: Conflhei o'Studi t l
~ ~
I}ed, fSouthwost : quadrant);cn:1:teoubi'23" '- -[ . ..
.' .:.ee
' ~"
.3~'" -
G7 penc (J'o:1thwes.tig:adrant.) r 2fhthro'udFU6:
~~. ,"
l ~"
'" ~~" e.
Kp.}Jpy:.p* p r.theaste qun:ircht-): k7 ~Wrbif C 'hY l IQ~ut ~ ^ ~. ~(Scuthe:tst
~ ' quadrant) 70 through 92
.J ',- .a. 'b P C"' '-'
- 4. Zero he ten
- 2. $cquen v.pipper-d.inL . - - - - depth- c.ar.en.i: r in crit 0~ '02 -
- e
\ .. . .
~n..
. .,a
'5. In subsequgn.t.ctep prow . + -- ..nfter-the-four:hidiaulici ~eni:lohere nre 3natalled t
L
- n. . on the.gt o o..c t .dc.
. and-prio.r to applying hydraulic precsure, une the tencioner g .. a....
dgl dg g.ge. cr.d;::c_axurs.it,he:;i;::i;t:itG,* T2Nr lilaWelWFatTo:i"io ,'re p~O'h 'suiri.' '
' Record thq"readinC:.'in 'O Colu::n 4 of Data Sheet }Dil-2.
. Tencientr~ -
1C"E 5 0=er" * ' i N 5 ~ g, Ar.ne-ble, eonuc,... ang on,. 1~ ente the h"irf'UliC 1" E C C OTd * C U " ,'", * #... .. r,-a. .. ' e" ~ " ~ ' " ' ~ ~ ~ i n .* ' r. t c t i on '. . L] power unit cenn--blT J O - - ~ __ _ _ . _ , , . .
Pace 69 BFltG 1 0 - 6/29/76 Tensioninn Stud: (Continued) f 6. An initial elongation of 0.Ol9-inch for Sequences A and B, and 0.021-inch L for Sequences C and D in required to properly seat the 0-rinC Cacketc 1 Perfor= this cloncation in a four-cequence procedure J (15-215 and :s-216). as indicated in step: 7 through 10.
- -7 .
Use the hydraulic tensioners to simultancou:ly stretch the set of four studs in Sequence A of Data Sheet MMI-2 at a pump pressure of PPCO poi es required in Column 5 Turn the control valve from " tension" to " neutral" and recheck pre:sure. Turn the nut turning transmission crank handle counterclockwise until the nut is botto :ed on the spherical vn hcre.
- Approximately 30 foot-pounds torque on the crank (a charp rap vith the l crank) vill ceat the nut. Turn the control valve to "releace" to reduce d.
the pump pressure. 0 Using the tensioner cace, measure the elongation of each of the four studc Record the cace readings in prior to moving the hydraulic tencioners. Compare Column 6, and calculate and record the cloncations in Column 7. the calculated elongation in Column 7 vith the elongation predicted in A Column 8 to indicate that stud loading in progreccing as expected. l difference of + 0.0014-inch is acceotable.
~
0 CAUTI0tlS
- 1. If one of the' four tensioner gace readings in different from the next closest reading by more than 0.0014-inch, it is probably an i IIovcVer, if the inaccurate reading and should be dicrccarded.
readinc.s of' n liven tensioner are repeatedly found to be inaccurcte
" a faulty tencioner' or inadequnte sentinr, of the nut by the ten' ioner F operator may be the cause.
i L
~
C' C ~' C L. i Q Q' Q .Q Q' y a g g P.a C,c 5 TF.UNESStz VAI. LEY AUTl!OltLTY , BR0tc;S PERR7 NUCLEAR PLANT .
!!CC!!At;ICAL MAINTENANCE
. . DATA S!!EFr N11-1-2 ,
UNIT NO. A
- Stud Tensioning Data for operational Closure .
.l ,
DATE
+ (Sheet 1 of 11)
A 6 7 8 9-1 2 3 4 5 i . ; (1) Sequence Calculated Elongation
- Cog. Engineer; Stud Tensioner Pre-Load Ilyd. Punp Ec<!nence Gage Reading Pressure Elongation Elongation Change Iifslal/Date Nc. No. Color Change (2) Predicted Co<Je , (ps1) . Cane Ucading QC Inspector
- In rist/Date (3) 0-RING SEATING PASS .
l 1 Red 2200 0.019 (1) A (3) 24 Green .
/
3 47 Yellow a
. 7 i
- y. 70
- Elue I
I 12 E.d 2 t00 0.019 l f ;
' (1) 3 (3) 35 Graen -
58 ^
; . Yellow ,
r i f>1 P.lue " - ~ ~ t l ' 'j (1) C (3) g 24
. I 1 ' n!
O. - m j 4600 i c i 0.021 ,
',7 Y.211.2
-j i /
7G Blue . l _ _l 12 Rad l Creen 4400 0.021 i (1) D (3) 05 7 j SS Yellow / 81 E.lue
~1) All clor.;-ation ec. :.urecents (in it:chen) are to bc ecdc with tensio:.cr genes.
".) Cxo.:re calculu.I ci.,ng..tico c.ha.10e (Coluir.n 6 ninua Colurh 4) with clennation predicted (Column 3) to indi. c..e :hnt stu i ct.d in r. 13 progrer.:Ing ..a c:.p.cted ( 0.004 inch in acceptable.)
- .i .-- ntion ta .;mrce:entr (in f::ches) cre to be m.th with tensiccer r,a;;cs.
chan;;c (Colt: an 6 riinus Colu :;t 4) with cicar;ation predicted (Colme.n 3) to inJb ':e tha ; s tu 3 . !) C- rc c..lculat e.1 21., ,::.t f e;: 8
..- ! <. : 6 c:- :.c.u.i (y o .00.<, kich 1. c c.:c p .:-ble . ) 1: I:cri ton: ,'x' s
Q ['_.1 C*C' *C L----. C [b C,O [ i 'J C .*'i L), "O O C 2;Q ,
* . . 3'21/78
/ l l
TE:iNERSEE VAI.LFY AUTiiORITY .
. ,l
~
. EP.0*GS l'ERRY NUCLEAR PLANT ;
MECllANICAL !!A1"TENANCE
'g , , i
' D.\TA 51!EET M".1-1-2 UNIT 1:0. :
- f Stud Tensioni51g Data for Operationsi Cicoure'! ,
DATE (Sh ee r. 3 of 11) t 6 7 8 9 3 4 S
- 1. -
2 (1) Sequence Calcuinted El.onr,a tion
- Cog. Er.gineer icqacuca Stud Tenslener Prc-Load'- Ilyd. Putnp Elongation Elongatien CI:nngc ~
'~e.
. No. Color Gn.,e Kccding Frenserc ,
Car.ng r (2) Tredicted g (1 dital!DateO Its:ec: (pcl) Cace Reading l Ccda . . . .I A...'.s a...,64-21 nca . .. 0.065 / , 7500 (1) 5, ,(3) 44 Green
- 67 Y.- 11c - . '
i---.-.--
/ .
'r 99 L1x '
l i
.4 i cd 0.065 /
Green 75,00 __ s-6 27 : 50 Yellow
/ 8
.. , 73 Blue -
. _2 3
a 1 l o n ..g 7500 ,' O.065 / !
' Creen 7 : 32 .
55 Yellow Blue
- _ ,, /
i 73 _...
]
14 Ecd . . 0.065 / 37 Gracn . 7500 8 60 Yellow i. Blue _/ _ C3 __ 19 32d ; 0.065 -
/ l 42 Green 7500 9
(25 Yello.i ,
/
83 31cc ~ l (1.) .\11 clor.c. tle a m nsure: ents (inch:nge inches) are to be n.:de with tensioner gages. (Col mn 6 minus Coltein' /.) with clonf.ation predicted (Column 8) to in.!!c'% t!.it stud (2) C"cPc c.2icuirted elongation Ic..:'iq. is progressing as exp[.;ted (+ 0.'004 indh in neceptatie.) D
-* (*- .,c .,.,, c [ ,, . . , c3 blievision: ] '- N .
r- O - Q I-: u y y 1 C C C C Q E~U Q I-C~~3 O- C
- C-""3 r
l U '9 .. 3/21/73
- i. .
'
- TF.S:!CS5r.E VA1.1.ET AUT110RITY i:E0'i.I.i H:RI:'l :Wi:L1:A2 FL/P -
IIECi!.T'Mt.L ::Jsli:TE!!!::CP. Dt.T.\ 'ill*ffir :';I-1-2 UNIT NO.
. i Stud Tensioning Data for Onerational Closure
., , Dr.TE i (Sheet 4 of 11)
!t 8 9
' 7 2
3
..._ ',. , 4 .
5 6 1 *Cor. Engineer I (1) Sequence Calculated Elongation Pre'-Load! !!yd'. Pue:p Ir.! tial/Ccte i f;;;uenes Stud ' Tensicner Pressure Elongation Elengation Chant,c
!?o , !;o. Color Car,c Reading Change (2) Predicted l i (psi) Car.e Reading _
- Crn'n
- I 23 . Red ' 0.064 ,
creen ; 7300 . 10 46 ,
/
t 69 . Ycilou , o> m. ,. i . 3
- Red . 0.062 i*
Green ; 7100 11 26 .
/ ;
49 Yellow !
,1 72 Lit:e
~
7 i'ed ' O.060
. Green 6900 ,
12 30 i Yellow / 53 . 76 . Clue . . l* 10 red . 0.059 Green ! 6700 , 13 33 Yellow
- - /
56 , 72
- Dlue .
13 Red 0.057 Green
- 6500 '
'14 36 '
Yellow / 59- . Blue 62 ;
, l
,1 ) All clangation :tc.2:.urce.cnts (in inches) are to be made with tensioner gar,cs.4) with clongat. ion predicted (Column 8) to lad:c..te Lt...t
(:.) Carpare calculated clon,.ction change (Colu:.:n 6 minus Colurri lo. r!':'., a is prer.re: r.inr. as enieted' (i,0.004 inch in acceptabic.) *P.cv i c ioni_ ', G .
)
O 's-A Q Q O O Q Q 1 .-)
* ~
O O .O C~3 'C'3]" 3 O C."']
- 3'/21/78
+ .
TE;CiESSEt: V.'iLLEY N.:T!!0P.ITY .
. ER01. S TEit:?? ?"'CLE.'.R P* A'iT IIECILANICM. ?:AIIITEliA::CE DATA SIIEET :U!I- 1-2 U:-:IT : 0. _.
Stud Tensicni!r.g Date for Operational Clocure DAT
. (Sheet 5 o f 11 '
. .. .. i* 7 3 9 4 5 6 _ _ ,
1 2 3 1 :
-l Calculated Elcagetion *.~oc. Engineer Tena*coer P re-I.oad Hyd. Puup (1) Sequence
- a.qu
- nen Stud Elongation Elongation Change Inftial/Date Sc. ? c, . Color Cage Reading Prescure Precticted (psi) Gace Ecading Chanr.c (2)
Code 16 Red . 0.055 33 Creen 6300 15 8 62 icilov . - . - _ f c3 l' Blue - l i 20 EEd , ~ 0.054 43 Creca 6200 16 : Yelic,w ./ i 66 , 59 Blue . l' 2 Fed . 0.053 25 Crccn 6000 , 17 l'
- 7e !!cti _ . . . .
l l 71 Dice - m . 5 Ecd 0.052 28 Creen 5900 la 51 Lilow -
/
74 Clue
- I 8 Pcc -
0.050 31 Green 5700 I 19 - a 54 Yellow I $ 77 U100 l l , a
. ( r , s
) ~J.1 cl on ;n ie 1 rea .t:re .cntr. (in inches) are to be made uf th ten:1cncr ganen. t.2 that Lc0 chan:;c (Colurn 6 minuc Coleun 4) with clon; ation predicted (Column 8) to indi (2) r.c -r r;n .; iculate d cloar,a:J on
! < .. ! ' - 4. - prm-rr nr i :n no < x; cr ted (F 0.004 inch is acuzpt.3h?c.)
~
D
,. nevis ion : kx .%
- ...,si
c-%'h C O C C O Q C :i c..:2 a a a w a a T/21/73 TENNESSEE Vt.LI.EY .AUTi!ORITY Enci??'S FERRY liUCIS.R PLANT HECHANIC/.L ?!AINTE!!ANCE DATA S* LEET M11-l-2 UNIT NO. - i ~ Stud Tensioning Pate for Operational Closure DATE - (Sheet 6 of II) 9
' ' ~ 6 7 8 3* 4 5 .
1 2 3 i i g I
-- f I
l're-to nd ;lpi. ; c.g I'l)
>, S: gecncc-Calculcted i T.1 . 3c.:1.,n !*
- Cog. Engineer l
?-r . . e c . l S t. : 3 l T :
- 9.r
' e.: r Gr.;j Pee:dit ; I ccancre Elcnytisa Eicncetica '; U. n ' : . :1/;.v.e i i
.. ; . ; '. " ;. . i .
Cli nge (2) i Predi,trd - I, .: : . ' (p.si) Ga :c n . din;. I _ . . . . - - 11 P.c d O.049 Ceeea 5600' 20 - 34 57 .
- liow /
60 l Blue - , 15 ned 0.048 33 Green 5500 21 61 Y211ou --
/
l
$4 I,iue l
' 18 Red I 5400 0.048 22 41 Gre: n 64 Ye11cw ,
/
S7 Elue ., j 22 Red ; L 5300 0.047 23 45 Green 63 Yellow / l 91 Blue ,
- / p g I ;
(In inches) cre to be made with tensioner na;;cc. (1) All elonnation ecacurc=cnt:; channe (Colutan 6 minus Coluza .4) with clongation predicted (Column 8) to indle. te that stud (2) Conr. ore calculated cientation g DC) i c ' i :- i n pmp .. : :! .-., . e,pe'ue.1 (+ 0.004 indh 1.2 cceepr, hic.)
-- :t'.:i n Lcn: . . ' ' -
I C C C C C C C .' .i ] O O Q w ("Z J CFZQ O O-I/21/78 TENNESSEE VALLEY AUTl!ORITY ERC'el:iS FERRY NUCLEAR PLA;;T - IIECilANICAL !!AII:TE :A!;CE DATA S!!EET M:17.-l-2 UNIT NO. , Stud Tensioning Data for Operationni Closure DATE (Sheet 7 of 11) 7 8 9
' 4 5 6 1 2 3 r
- E* "8 " #
(1) Sequence Calculated Elongation Stud Tensicner frc-Load Ilyd. Punp Change In't inl/Uste Secuence Pressurc Elongation Elongation Nc. No. Color Cage Reading Cane Reading Change (2) Predicted NC Inspector (3) (psi) Code Initial /Dtte SECOND PASS LOADI!!G F 1 Red 0.018 / Creen 5400 (1) 1 (3) 24
/
47 Yellow ___
,' 70 Blue 12 Red 0.016 /
Green 5400 (1) 2 (3) 33 58 Yellow /
. 81 Plua j .
6 Red 0.016 / Green ,5300 j (1) 3 (3) 29 .
' 52 Yellow -
/
! 75 Blu2 .
17 Red
- 0.012 /
Green 5300 (1) 4 (3) 40 63 Yellow /
! E6 Blue
' m (1) All .11orfation maasurements (in irches) are to be made with ter.cioner gages. . s t s.-
(2) Co 9:cx calculate I clongation CI830Ec (Colue.n 6 ninus Colu2:a 4) with clongation predicted (Colu:rn 8) to in
;c . ..ic i s pre;;re ;9!rm es e:<p[tted (10.004 indh in acceptable.) ,0 Vision: I.f-Q
@ WT II - .O C C:~2 O EZ2 O O O C .~.~3 O O C L_.s LC :yy a e- 2
/ 6,m -
- -~
I TE!.7:E57;C LL.H Ai'TUCS LTT ' I!ROUll3 F'JRRY I4UCLEAR PLANT
~
!! CittIIICAL !!AIi;TENM!CE T '.TA SiiCEf 101-1-2 UNIT 2:0.
Stud Tensioning Data for Operationni Closure DATE (Sheet S of 11) 7 8 9 4 5 6 __ 1 '2 .3 : Elongation
- Cog E.gineer Prc-Load Hyd. Pump (1) Sequence Calculated ,
'2luence Stud Tensioner Elongation Elongation Change In' r I:ti/Dat e No. !!o. Color Gage Reading Pressurc Change (2) Predicted OC Insnector__, (psi) Canc Reading code l' Initi al/ D.:te 21 Ped . 5200
. 0.011 /
(1) 5 (3) 44 Green 67 Yellcw *
/
00 Blue : 4 Ecd 0.008 / 27 Creen 5300 6 50 Yellow / 73 Elue -- 9 Pc1 0.006 / 32 Green 5200 , 7 55 Yellow / 73 Elec , I 14 ned 0.003 / 37 Green 5200 , S 60 Yellow / 23 Blue _ _. 19 Ced 0.002 / 1:2 Green . 5200 9 65 Yellow
/
E3 Blue L.- -
'U All clongation men.;urements (in inchec) are to be cade with tensioner gancs.
(Column 6 ninun Colu n 4.) with ciengation predicted (Column 8) to inditate that stud
- 2) Cerpare calculated c!cngation change ~ '
1 ndDy is progrer. to;; na. .:xpccted (+ 0.004 indh in acc :ptabic.) . Revision: IU.. -
Q Q W r_j f .-- y . 7 g Q 8 C C LJ -C L) ! '_) . 3/21/78 . TENNESSEE VALI.1:Y AUTI:0R1TY BRO'a'NS FERI:Y NiiCLTAR PLANT . MECiiANICAL ltAINTENANCE DATA SilEET 1211 2 . UNIT MO. _ i Stud Tensioning Data for Operational Closure DATE (Sheet 9 of 11)
~~
7 8 9 _. 4
*~
5 6 t 1 3 1 l I
,- 1*
i h i
- Cog Enginger l liyd. Puup I,1) Sequence Calculnted E2cnption '
It'Jtal/ Late I t is
.. . . - ; r.c a : Stud [ *'c r i c e.c r
. .Prc-Lord Elongation Elonnatica C :ance
". I !!o . C::19 e Case Rat. ding Prc::surc ! Chr.nge (2) Precticted (psi) { Gage needing l Cnide 23 red 0.001 45 Grc n 5200 13 69 Yellow /
92 E! ue . 3 Red 0.002 26 Green 5200 11 Yellev I 49 / 72 , Blue. 7 Red 0.001 30 Green 5200 12
' 53 Ycilow /
- 76 Elue *
~
f 10 Fed 0.002 33 Green 5200 . 13 I , 56 ' Yellow / 79 Elue , 13 Red [ 5200 0.002 14 35 Creen l /
, 5 'i .
Yellow T.lue i -- I l 82 ( s i (1) All clen:;ntion trasurer.:ents (in inches) are to bc =sde with tensioner ga;cs. change (Column 6 ininus Colunu 4) (2) Cou;:src calculate ! along., tion
'. .v . .,, f a prccrm cI: ; , . e.:pek:t.ed (10.004 indh 1. necept:ab3 e.) ; Revision:y.
$ ~ s:. '" _
.: ,3 3 m~. . .- .-
- g. a w.
a _. _ ,7 __;_.g . 2 4..a 4 ,, ,
* ' a/ 21s'7s TENNE 3SEE VALT.EY AUT!!ORITY '
nnotC!S FERPY IiUCLEAR PL/.NT MEC!!ArilCAL ?!.\1tlTENAllCE DATA SliEET 1211 2 UNIT NO. Stud Tensioning Data for. Operational Closure DATE
' (Sheet 10 of 11) 6 7 B- _, 9 _
.3 4 5 1 2 1 l i
Calculated Elongatir,n
- Cog. Engierer Studg~ g Tensioner Prc-Load ilyd. Pump ,(1) Sequence Sequca:a Elongation Elonnation Chanc,c Ir.iricl/Date No. No. ' Color Cage Reading Pressure i Chen,,e (2) Predicted Code (psi) ] Gar.e itending 16 i Ped 0.003 30 cre n 5200 15 62 Yelicv _ . _ _ . -
/
P5 l' Clue -
':0 it .!
0.002
-' !. ;- f: tn 5200 l l j . i l' Ie- i . t :
; .. _ L
. , . ; i -. .
- ...t.. . ..
I 2- t n::d 0.003 i 25 i Green 5200 1- i-
; !. 3 LIMu / -
I 71 Tilue . t 5 ned 0.002 Green 5200
'18 28 51 Yellov -
l l 74 Elua - r ' g S Red 0.003 31 Creen 5200 19 Yellow 5 *. r, i alue
./
, I l' .
(1) All elontmtica :.easure- ents (inchange inches) are to be made with te.nsioner gages. (Colu.n 6 minus Column.4) with clongation predicted (Column 8) to indic1 c that stud' ( ?. ) Cc .; arc enleviate*! c'enr.atien i, : . ,! ; ; p r. . . n. .; : .. . v.. .,n[cted ($ 0.00's inc .'.. neccernble.i s frik vi:;i.on:_;y'- ,_
*"* E.*T' d .1;i' & y g ,. _
~^* ~
~- M .m- - xv- -
TEN!1ESSEE VALLLY AUT110RITY - BROWNS FERRY NUCLEAR PLANT ItEC11AMICAL SAI:iTENAI4CE DATA S!!EET MMI-1-2 UNIT NO. Stud Tensioning Data for Operational Closure DATE (Sheet 11 of 11)
~ 7' S 9 5 6 3 4 1 1 2 1 (1) Sequence Calculateu Elongation *
- Cog. Ensbeer
'Tensioner Prc-Load liyd. Pump Change Initial /Date
-Secuence Stud l'rcsnure Elongation. Elor.gation
;o. Mo. Color Cage Reading Cacc Reading Change (2) Predicted 4
(psi) Code 11 Red . 0.002 Green 5200 20 34 Yellov I 57 l 80 Blee . 15 Red 0.002 , Cccen 5200 21 33 61 Yellow ./ - I. 84 Blue IS Rad 0.002 Green 5200 -
.22 41 64 Ye}}ov '/
87 Blue . 22 Red 0.002 Green 5200 23 45 63 Yc11ov - l 91 Blue - - _ _ This insures a supply of forms cnd a This ta' ale should 1c recoved, reproduced and used during closure operations. " reco:d file. to *:^r I?. q E TH'.S F01't FOR A:Tt* VESSEL OTilFR T!!X:. TitAT S:10_:. ! ON FRO::T COVER.
.1) All nica:ctD- ra nc e.:enent s (in inchec) cre to be inade with tencioner gagec.(Colne:a 6 minus Col .::an ,4) uith clo
'2) Ce r . .: . r.
<:a'. .;ul:c.c.I eI cn: a t ina chan."e
- m. ed t.:d (-:- 0. 00f. f redh is accept.abic.)
\
4%p_ e- ,'t , - - ! r. g . .
- Revi n i.on :
j , ,
._.w . c. : .
o. Page 81 BF tt!!I 1 - 6/22/77 w TENTESSCE VALLEY AUTitOn1TY ERO'.!:;S ITPJW MUCLEAR PLA!TI l J l!ECll'd:ICAL !!AL::TE ld:CE 1:STRUCTIO:: 1 DATA S!!CET "11-1-2 p Stud Ten::ioning Data for Operational Closure h Number of cycle, that each stud tensioner underecnt during stud tensioning: Li Cycles Seri.,1 *.rbor l . w 1 1 J 0 Yes No e Recorded on equipment history card. ti I
- NOTE: If total number of cycles exceeds: 1402, the draw bar should be replaced, er 2802, the engagement nut should be rep 12:-
; Trouble report number u;
Verification that during 0-ring seating pass saquences A, B, C, & D that tha
' hydraulic pressure was as specified on the data sheet (pa;c 70) and that the calculated elongation change agreed with the elongatica change predicted within
+0.004 inches.
e
,w QC Inspector Date l'i i
U Verification that during the first five sequences of the first pass loadin; (data sheets pages 71 and 72) that the hydraulic pump pressure was as specified on the data shoct and that the calculated clongation change agreed with the clongation y change predicted within + 0.004 inches. L-
~
D J QC Inspector Date I Verification that during the first five sequences of the second pass loadin - (data b sheets pages 76 and 77) that the hydraulic pump pressure uns as specified en the data sheet and that the calculated elongation change agreed with the elongatien 1 change predicted within 3 0.004 inches. d , 1
- Revision: r f///
OI
~-
Date QC Inspector J
r w Page 82
" BF ICfI 1
- 6/29/76 n
[j Tensionin.c Studs (Continued) CAUTICNS (Continued) 1, J 2. Rotate the nuts on the studs only when the gage reading is exactly I} ac specified for the given sequence and has been held for a period U of 5-10 seconds. Otherwise, the stud leadings may exceed the l
; required amount and cause underloading and overloading of the , other studs. " NOTES
- 1. The required pump pressure shall be taken directly from the hydraulic dial gage mounted on the power unit cart.
t' 2 Four turns of the nut turning transmission crank handle equal y approximately one turn of the stud nut (MK-62). (The cyact
- ratio is 3.96:1 for an axial nut travel of 0.195-inch.)
1 3 Fully record all data required by Data Sheet MMI-2 andMMI-3 for J comparison with predicted results and for analysis of closure stud tensioning. Incomplete dita delay the tensioning and can g prevent analyses of the data.
- 8, Use the hydraulic ter.sioners to simultaneously stretch the set of four ' studs in Sequence B of Data Sheet NMI-2 following the instructions of u
step 7. 9 Use the hydraulic tensioners to shruitaneously stretch the set of four u studs in Sequence C of Data Sheet m11-2 at a pump pressure of bltOO psi as required in Column 5 Seat the nut with a sharp rap of the crank he+ die; release the pump pressure: using the tensioner gare, measure L i
;, .t3 ' stud elongation of each of the four studs prior to moving the c ': ': o
. hydraulic tensioners; record the ence readings in Column 6; and calculat e and record the clongations in Column 7. Compare the calculated clongation e
q in Colum 7 with the clongation predicted in Colwnn 8. [_
Pace 83 BF !CtI 1 6/29/76 Pq
~
u Tensioninc Studs (Continucd) 1 10. Use the hydraulic tensioners to simultaneously stretch the set of four j studs in Sequence D of Data ShectMMI-2 follouing the instructions of 9[j step 9 Proceed to Sequence 1 for the first pa s. Use the hydraulic tensionern 11.
=
to simultaneously stretch the sequence of four studs, equally spaced 90
' degrees apart; obtain the pump preccure indicated for the Sequence in a
Column 5; seat the nut with a sharp rap of the crank; release the pu o pres =ure; using the tensioner gace, ceasure the stud elonration c. ' .e a four studs prior to moving the hydraulic tensioners; record the rare
- readings in Colu=n 6; and calculate and record the eloncations in F1 Column 7. Compare the calculated clongation in Column 7 sith the .i ~ elongation predicted in Column 8.
NOTE: The maxi ==n de ign pressure on the hydraulic tensioncrc is 7500 psi. This pressure represents a stud clongation of aporoximately
" O.ll2-inch. If a preocure of 8000 psi is exceeded n. relief valve is actuated.
]
Do not rotate the nut if pu=p pressure exceed: 7500 psi. CAUTION: Otherwise, excessive stud loading would result. a
- 12. Repeat step 11 for cach of the Sequences 2 through P3 to cenplete the n
L first pass.
~
NOTE: On unit nv.1 the clearance between studs no. ol and no. 9P is closer than on the other studs. Some difficulty =ay be crperienced w in positioninC tensioner on these studs. novever, the tensioner enn - be pocitioned on these studo. Also difficulty may be exnerienced in
, u seating the tensioner on stud no.,89, howcVer, the tensioner can bc 0 - sented on this stud. _. . . . - %. s _ _ _ _ _ _ _ _ _ _
e . I* *
. . - - Pag = 84 1
BF }DII 1 ' 6/19/78 t
- t- Tensionine Studs (Continued) }
The relationship between pump pressure and stud clongation as shown NOTE: ' Therefore , in manufacturer's stud tension manual is approximate. ' a[ stud clongation measurements must be made for cach set of four
!]
l}; studs at cach tightening sequence shown in Data Shect ' 5Dil-1-2 (and hiongation measurements of all studs must be taken after the 3DIl 3) - second pass'is completed as shown in Data Sheet
- 13. Proceed to Sequence 1 for the second pass. Use the hydraulic tensioners .
to simultaneously stretch the sequence of four studs, equally spaced 90 1 s degrecs apart; obtain the purp pressure indicaced for the sequence in Column 5; seat the nut with a sharp rap of the crank; release the pump 3 J pressure; using the tensioner gage, measure the stud clongation of the
' four studs prior to moving the hydraulic tensioners; record the gage readings in Cole =n 6; and calculate the elongation and record in Column 7.
Compare the calculated clongation in Column 7 with the elengation predicted
, in Colu=n 8. .
" ' 14. Repeat step 13. for each of the Sequences 2 through 23 to complete the second pass.
= .
c 15. After the second pass has been completed, obtain the clongation gage reading of each of the 92 studs using the dial depth gage (:E-88) on the w stud reference surface. Record the readings in Coltran 5 of Data Sheet 0 )tII-1-3, Calculate the clongation of each stud by subtracting the no-load gage reading (Colu=n 3; Data Sheet 1DE-1-3) f rom the second pass gage reading Calculate the
- (Column 5; Data Sheet 1::11-1-3) and record in Column 7.
average for the four Colucn 5 readings on Data Sheet IDII-1-3 and record in
'* Column 8. This average is to be within the tolera:ce of the turget clonga-tion. As noted in step 7, if any of the four readings in a sequence
- Revision -
C Q Q Q Q C- 3 O O C- Jar.<C C C I O 'O O Q O r.F 1011 1 3/21/78 , t
~
Reactor Pressure Vassel TENNESSEE VALLEY AUTl!ORITY - BROINS FERRY NitCLEAR PLANT MECIIANICAL MAINTEI ANCE - DATA S11CET 1211- 1-3
' ~
UNIT NO. _. Stud Elongation Data for Operational Closurc ' DATE (Shee: I of 6) 9 10 11 12 13 4 5 6 7 8 2 3
- 1. _ -
SECOND PASS COI;!!ECTED (If Req'd.)
. Initial -
Elon;.a- Avg. Elonga- Avg. . l1c-Lor.d Elonga- QC tion Calcu- Elonga- QC tion Calcu-Elonga- QC Calculated Insp. tion . In:;p . * (Col. 5 lated tion Insp. (Col. 9 lated cc. - l l t ie. Minus Elonga- Cage Verifi- Minu:; Elenga- By Cage Verifi-u.e:ce Stud 4 Cage Verifi-Reading cation Col. 3) tion Reading cation . Col. 3) tion Initial /Date
, jic. . __ ,Q. 1: -ding cation 1 '
1 24 !, , 47 / I 7o , 12 . 2 ;3. -
! 53 * /-
.f ,
!. 01 ~
f e 3 29 . 52 .
/:
75 . 17 > 4 40 ' 63 . f-E5 - f P 21 - 44 5 , 67 f I90 l % - C 1
..m c,n y- 4
O C O O C O O C'"3 L.-.J C."3 C3 C C' 3 C3 C C-J~ 3S*-C 3 BF ?I11 1 C- C (" C/21/78' ,- Reactor Pressure Vessel TENUESSEE VALLEY AUT110RITY - BR0talS FERRY NUCLEAR PLANT MECl!ANICAL IIAINTENANCE - DATA SilEET 101I 1-3 UNIT NO. Stud Elongation Datn for Operar'unal Closurc DATE (Sheet 2 of 6) ,. 9 10 11 12 13 4 S 6 7 8 I 2 3 _
~
CORRECTED (If Req'd.) SECOND PASS
- f. io-Lend Initial .
Elongs- Avg. Elonga- Avg. tion Calcu-- Elongs- QC tion Calcu-Elonga- QC Elongs- QC Calculated Insp. . tion Insp. *(Col.D lated tion Insp. (Col.9. lated h- tion Cage Verifi- Minus Elonga- By Cage Verifi- Cage Verifi- Minus Elonga-Initial /Date nnce Stud . Reading cation . Col. 3) tion Mo. Uc.. dine cation Reading cation Col . 3) tion je . t. 6 27 ' j 50 - 73 I I . 9 1 i, 7 32 53 .
/
73
! 14 8 37 60
/
83 t i 19 9 42 65 7 b3 I t 11
! 23 .
30 46 69 /
)
..t 2q9 5 A
! U C' G G C y a y y '- 1"
~ w L & .. ..-a c a. .
. , . , 7.
Reactor P:cesuEe Vessel TENNESSEE VALLEY AUTliORITY - BR0k'NS FERRY NUCLEAR PLANT MECl!ANICAL MAINTE"ANCE - DATA SitEET KtI-1-3 UNIT NO. Stud Elongation Data for Operational Closure DATE
. (Sheet 3 of 6) 10 11 12 13 6 7 8 9 2 3 4 5 1 .
CORRECTED (If Req'd.) SECOND PASS Initial Avg. Elonga- Avg. Elonga-No-Load Calcu- Elonga- QC tion Calcu-QC tion Elonga- QC Elonga-tion Insp. (Cal. 9 lated Calculated tien Insp. tion Insp. *(Col.5 lated Elonga- By h- Elonna- Ga;;c Verifi- !!ines
.: : .cc Stud l* Ga;c Verifi- Cage Reading Verifi-cation lifnus Col. 3) tion Rending carton Col. 3) tion p itial/Date l
"o. Pending cation 3
11 26 4') / 72 q [ 7 . 12 1 30 - l 53 / l 75 t
- 1) '
a : 23 56
/
n t l 13 1 *. 35 59 . / S2 - la 13 39 E2 i 3
. . r .. g en : N
C' C-C - C L~2 CJ -Q- C- T a a t,_j C C C C~"'] C CC [' O' Ca
. BI'10:I 1 ;y .,,.
TENNESSEE VALLEY AUT!!0RIT - BRGIGS FERRY 2;UCLEAR FLA';T Reacter l'rassure iisse'. . MECliANICAL !!AINTENANCE - DATA S!!EET ID!I-1-3 UNIT NO. 1 i Stud Elongation Data for Operational Closure DATE
. (Sheet 4 of 6 )
10 11 12 13 6 7 8 9 1 2 3 4 5 1
' CORRECTED (If Reg'd.)
SECOND PASS i Initial - Avg.. Elonga- Avg.
- o-Load , ElonCa- Calcu-Elonga- QC tion Calcu' Elonga- QC tion Elo:.r;a- QC 2 lated tion Innp. (Cal. 9 laced Calculated
?
.a- tion Insp. tion Insp. (Col.5 Elongs- By Verifi- ?!1nus Elonga- Cage Verifi- !!inus 2.:: ice Stud Cage Verifi- Canc Col. 3) tion Read int: cation _ Col. 3) rion Initial /Date Rnadinc Reading _ cation
,,". . i !?o . cation 20 16 43 f,5 /
69
~
l l 2 -
; 17 ! 25 j
/
iS ,
'I .
, __ I, 71 l- 5
.3 j 2a i 51 /
74 i 8 ; 19 31 Si / ! 77 . 4 i i 11 - 20 24
^ /
9 p - 1N - 4
*%vis ion : _
")- ~ O C C'~1 O O O- O O G2 C C: GJ C L O O_'_' :M' O M Reactor Pressure Vessel TENNESSEE VALLEY AUT110RITY - BROWNS FERRY NUCLEAR PLANT MECIIANICAL MAINTENANCE - DATA SilEET 1Dil-1-3 ' UNIT NO.
Stud Elongation Data for Operational Closure DATE
. (Sheet 5 of 6) 10 11 12 13 6 7 8 9 2 3 4 5 1
'T CORRECTED (If Req'd.)
SECOND PASS Initial Elonga- Avg. Elonga- Avg. Uo-Load Calcu- Elonga- QC tion Calcu-Elonga- QC tion Elonga-. QC lated Insp. (Col. 9 la tc.! Calculated h- tion Insp. tion Insp. *(Col.5 tion
!!inus Elenna- By Verifi- Minus Elongs- Cage Verifi-Cage Verifi- Cage 131tial/Date_
esnce Stud g Reading cation Col. 3) tion Reading cation Col . 3) tion
'n. "n. ! Re..d!ng ention 15 21 33 61 /
E4 13 22 41 64 .
/
37 22 , 23 45 t 68 / C1
\ /
/ -
I _ h . . .
/
.\.
- r. . . .
.1,,, :
P~T.,
a-O O O O O C ~3 C~3 O w a a
- BF MMI 1
! 6/29/76 I
Reactor Prec3ure Vessel i TENNESSEE VALLEY AUT110RITY - BRO'a'NS FERRY NUCLEAR PLANT MECilANICAL MAINTENANCE - DATA SilEET MMI-1-3
- UNIT NO.
Stud Elongation Data for Operational Closure DATE (Sheet 6 of 6) j I Notes: All dimensions are in inches. (MK-88). All measurements are to be made from stud reference surface using hand held dial depth gage Target elongation for operational closure is 0.046 (+ 0.004/-0.002) inch. is to be The four readings for each sequence (Column 7 or Column 11) are to be averaged, and the averageIf l l i the within + 0.004 inch and - 0.002 inch of the target elongation.is more than + 0.004 i g. average (average the remaining three readings). l 8 Verification that the average calculated elongation (Ref. data sheets pages 85 through l 89)ofin0.046 co umn or 12 for all sequences has been computed accurately and is within the specified to erance .
+ .004 inches. .
- 002 t
- a. I
' (QC Inspector)
The preceding data is correct and accurate. Date Foreman in Charge of Maintenance Date ___
. . Fis2 91 i
. ..- BF PEH 1 6/19/78 Tensioninn Studs _ (Centinued)
- 15. (Continued) is more tihan 10.004-inch from the next closest reading, it should not bc I included when calculating the average (average the re-taining three readings
) ]
In nahing an adjustment to correct the clongation of an individual y NOTE: i stud per Sequence 16 and 17, all tensioners are to be attached and However, only the stud all studs of the Sequence are to be pulled. being corrected vill receive an adjustment to the nut. 16. If the average stud clongation (Column 8 of Data Sheet ID11-1-3)for any sequen follows: of studs execeds the target elongation, it must be loosened as D Attact the stud tensioners to the set of four studs and pu=p the Ll a. k 1 tensiorers to 5800 psi or until the nut turning transmission cran J handle can be turned, b. Loosen the nut by turning the crank handle clocin:ise ? SD Jegrecs. u
- c. Reduce the pump pressure to 5100 psi, and seat the nut with a charp, 7 counterclockwise rap of the crank handle.
3 -
- d. Remove the tensioner load; then remove the tensioners.
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- 17. If the average' stud clongation (Column 8 of. Data Sheet ISII-1-3) for any d
sequence of studs is less than the target elongat!m, it must be tightene W . . as follows: L a. Attach the stud tensieners to the set of four srdds and raise the pump pressure to 5100 psi, 1 f: a b. Scat the nut with a sharp, countercicckwise rap cf the crank handle.
- c. Remove the tensioner load; then rc=ove the tensioners.
*18.
After all corrections have been completed, obtain tha clongation gage r d of cach of the 92 studs using the dial depth gage (r.-SS) on the stu f Record the readings in Colu=n 9 of Data Sheet ?SE-1-3 L' reference surface. a
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- Revision _gy r ,c// G_
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1 .(1;s-s , P;g2 92 BF ME 1 6/19/78 a n t Aw _ q <
' ning Studq (Continued) ! "l
- j (Continued) i es *:alculate the clongation of each stud by subtracting the no-load gage
- ) b t LJ (Column 9) and l
readinr, (Column 3) from the corrected pass gage reading
$ p
- Calculate the average for the d eccord in Co1 urn 11of Data Shcot 10H-1-3.
Ecur readingc in Colu=a 11of Data Shcot 30!I-1-3 and reed in column 12. As al} This average ic to be within the tolerance of the target clongation.
] noted in step 7, if any of the four readings in a sequence is more than -I j should not be incirled 10.004-inch from the next closest readings, it I i
- when calculating the ::verage (average the remains three readings).
When the target clonga?.ica of all studs is achieved, remove censuring 3 i rod from each stud, install center hole insert and torque to 25 foot-j , pounds. Remove and store stud tensioning rigging and equipment.
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I n11ation of Head Attachments and Insulation Head insulation is stored in 5 Install RPV head (mirror) insulation package.
- Attach lifting cables to the 3 '
the head insulation package laydown arca.
' insulation package lifting hooks and to the 125 ten hook of the building
-r. Lower insulation
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overhead crane. Move insulation over the reactor head. (use extreme care in lowering insulatien so as not to damage insulation or head attachments) over reactor head and line up insulation package on guid pins. Lower insulation package (make certain lugs on insulation scating ring mates with lug pockets on the insulation) until package seats on the ,
- seating ring.
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Page 93 BF 1911 1 I 3/21/78 m Installation of !! cad Attachments Insulation (Continued) r1 O NOTE: Personnel working on top of insulation should be instructed to walk on the insulation francwork only (D0 NOT WALK OR LW TOOLS AND/OR EQUIPMENT ON Tile INSULATICN). p, 2. Install 6".IIcad Spray piping, see figure no. 8. Unbolt and open hinged cover, Il remove blind flanges at points 1 and 2. Install.new gaskets in flanges a t points 1 and 2. Piping is located in piping laydown area. From laydown arca move piping by building overhead crane to reactor head, position piping and y install flange bolts. Torque the flange bolts to 300 f c. Ibs.
-j NOTE: Difficulty may be experienced in removing the old gasket from the flanges. A suggested method is driving a nail with a ham =er into the gasket on an angle (approx. 30 ) and grabbing the nail with vise-grips and pulling up until gasket clears the gasket groove. ,z U 3. Install head vent and instrument piping asse=bly, see figure no. 9.
Unbolt and open hinged covers at points 2 and 3. Remove blind flanges p) ( at points 1, 2, and 3. Install new gaskets on flanges at all three points. I%. Torque, the 4" flange bolts to 300 ft. Ibs. and 2" and 1" flange bolts to 200 e ft. lbs. (Piping assembly is located in piping laydown area. From laydown area l J move piping by building overhead crane to the reactor head, position piping and install flange bolts.)
- 4. Remove locking pins from the four (4) RPV head piping spring hangers and check the preset load.
- 5. Post Maintenance Checkout D a. Notify the shift engineer to start the vessel hydro test in accordance with General Operating Instruction 100-7. Release "llold" order.
- b. During the hydro test the follouing points should be leak checked and the results recorded oa the Data Sheet M'II-1-4 (sce page 96 for Data q Shect) item no. 7. ,
yf , 43 , P
*Rcviniun j ~W -
V ~ Pagt 94 BF MMI 1
' 3/21/78 i
O - Installation of !! cad Attachments Insulation _ (Continued) p *S . (Continued) s
- b. (Continued) 7 Head spray pipe flange connections (2 places).
1. j
- 2. Instrumentation pipe flange connection.
7 d 3. Vent pipe flange connections (2 places).
*(l)4. Vessel and head flange joint. ]L *6 Install insulation collars at' pipe penetrations (2 places) on top of insulation package. ,
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*T. Install drywell vent duct slip joints to connect vent ducts (3) mounted on insulation package with ducts under hinged covers at points A, B, and q C as shown in Figure No. 7.
y Remove all tools and equipment from the reactor well and properly decontaminate
*8 I Store stud tensioning rigging and equipment. Store head strongback and them.
U rigging. Store all other tools and equipmant in their proper place. s NOTE: Ascertain that all debris and waste has been disposed of properly, and that the reactor well and refueling floor areas are clean and orderly.
*9 Complete Data Sheet 1011-4 and forward to the mechanical maintenance supervisor.
*10 Notify shift engineer that head installation is complete, and you are ready 4
to install the drywell head (see MMI-2 for drywell head replacement procedure) and the reactor well shield plugs (see MMI-24 for shield plug installation 9 .procedurc).
" * (l) This inspection is not to be made unless PA 3-189 indicates that the inner scal is leaking and the temperature between the RPV head and the mirror insulation
)
is not excessive for personnel entry. m
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T te Face 95 BF ICII 1
- 3/21/78 J
l J M, l 'J . q-J 1 a 7 Reactor Precoure Vc cel Head
) -
11JeadTemperatureReading 7 To Ec Taken In This Arca J Head Fir.nge m m i
' Vessel Flange J
n
- a m -
,4 Weld Joint Q .<. m Reactor Vescel Wall esselTempgramrcToEc Taken In Tlus Arca 4
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- VESSEL FLANCE AND llEAD TE 7CRATUPS !EASURING LOCATION a n f TICURE NO. 13 ,
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Page 96 " BF leil 1
'3/28/78 0
TENNESSEE VALLEY AUTIIORITY
- --BROWNS FERRY NUCLEAR PLA.;T DATA SHEET 1C4I-1-4 s
" Reactor I! cad Insocetors Check Sheet Satisfactory
- Verified ny Task Description Yes 1:o Initials /Date l
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- 1. Head cicanliness inspceted.
- 2. Head "0" rings properly installed.
, 3. Head' lifting strongback inspected.
E 4. Head lift and installation on. vessel. m
- 5. Head stud washers and nuts installed in accordance with procedure.
- 6. Head studs properly tensioned.
.- 7. Hydro test performed. -' Requires QC inspector sign-off.
See page 97,
- a. Head spray pipe flange connections (2 places) - leak checked.
- b. Instrumentation pipe flange _
connection - leak checked. _ . , 1d c. Vent pipe flange connections l (2 places) - leak checked. (1)d. Visually inspect head and vessel , flange joint - leak checked.
- 8. Mirror insulation package installed, r
- 9. Mirror insulation collars at piping penetrations installed.
1 d 10. All piping insulation installed. i
- 11. Vcatilation ducts (3) installed. ,
f l a
- ' NOTE: Any item cheeked no, give detailed explanation in the comments as section to why
" of this report or on a separate sheet attached to this report, the item was unsatisf actory and ehat corrective action was taken.
'6 (1) This inspection is not to be made unicss PA 3-109 indicates that the inner scal in leaking and the temperature between the RPV head and the mirror J ,
funular en in not excenive for personnel entry. M- ._
l ' Page 97 3 BF IC4I 1
- 3/28/78 w Data Sheet 1t41-1-4 (Continued) ,
Instruments LS 3-189, PA 3-189, PI 3-190 and PS 3-190 are calibrated and working
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J correctly. q Verified By Instrument Mechanic Date 1 a , CO?OE TS : t U - i, ma 7 J n d
.. APPROVAL SIC:!ATLRES:
7 Date
- Verified By lJ Cognizant Engr.
Foreman Date Maintenance Supervisor Date 1 s Verification that the results of *.he final hydro test specified on data sheet page 96, Item 7 revealed no visible leakage.
, ,a # QC Inspector Date l
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*s 's <, *nevision:
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J Page 98
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. BF !"II 1 6/29/76 O TE:li;ESSEE VALLCY ALTORITY kI BHC'.C:S IF2.RY .JCLEAR FLA:!T
!' TABLE ICII-l L
'MOST CC:!SER' IATR /E' :G;D"Ci COLD BOLT-UP TE'IPERATURES P
L Yer.r Tentarcture ( 7.) Ye:r Tenner 2ture ' . J 1973 100 1993 129
. 1974 100 ,
199h
; ic75 100 1935 132 1976 100 1996 133 1977 1c6 1997 134 1978 107 1993 l?5 ^
1979 108 1999 136 1950 110 2000 136
!' 1931 111 2001 130 l O- 1982 113 2002 140 1933 llh 2003 141 198h 116 2004 1h2
, 1935 117 2005 143 j 1936 119 2006 14h .
1567 120 2007 145 ; 199S 122 2COS lh6 l 1939 123 20C9 1h8 1 1990 125 2010 149 1991 126 2011 150 9 1992 120 2012 151 J q NOTE: f*TI calculated ncing the fittin;; function (TSAR Firure h.2.5): ( n ".'T 'A = j 12228 - 1475 loc (dt) - hk.5 D ec (dt)J' + 3C0 F. The r:aximu . errecte i integrated fluence or 3.6 x 10 7 nyt was tveraced over the 40 year pir.::'. 4 life. (FSAIi4.2-5) l J . P U -
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. OPage 99
' BF KE 1
+ i 12/16/77
- TENNESSEE VALLEY AUTP.ORITY BROWNS FERRY NUCLEAR FI t;T l
1 . MECHANICAL Ril:;TENCE INSTRiJCTION 1 J i < 4
, APPENDIX A
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, FIMOVAL A::D REPLACEMENT OF RPV HEAD FLANGE "0"-RING GASL".I FASTENERS i i .
" 1.0 Purposa- l
. t1 .
l. J l' This instruction provides the procedure for. properly inspcctin;, removin., I fastencri and replacing the reactor pressure vessel head flange "o"-ring gasket when they are damaged. This'instructica should be performed during refueling outages on an as-nceded basis while the REV head is removed from the vessci. 3 . . 3 .
._2.0 Prerecuisites a .__ 1. Reactor in shutdown mode. _
- 2. RPV head on appropriate RPV head pedestal.
p . u -
- 3. "0"-rings removed from flange. -
This
- 4. RPV head flange protector (1) in place in area being worked on.
protector is used to eliminate any possible damage to the " sealing a d surface" of the flange. , 1 l
. NOTE: Extreme care must be taken to eliminate damage to the RPV head flange sealing surface.
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- 5. Health physics survey completed and appropriate SWP issued.
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- 6. It may be necessary to use tent and HEPA filter before performing any 9 /
vork on flange of RPV head _ J l
, ( )(Thin hard board with holes cut out for access to fastenere u; -11v 4' long.)
J 3.0 Tools.$ Parts, and Ecuiement List . .
- 1. Sma11' machinist ha-ner.
- 2. 5/16" cold chiscl. .
- 3. Drill motor and #25 and #49 drill bits.
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- Addendum: . ,._ b M_
- - - - -._.- _ - _. m..- __. ._ __ __
*Page 100 BF IB1I 1 9 12/16/77
[ ' p 3.0 Tools. Parts, and Eauipment List (Continued)
#r 4. Ease Out.
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- 5. Thread taps.
. 6. Phillips head rarewdriver. '
1 l j\ .7. Small vise grips.
- 8. , Acetone.
- 9. Clean rags. -
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- 10. Liquid wrench.
- 11. Approved duct tape, 2" wide. ,
- 12. Machine oil. -
- 13. Center punch. . -
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i 14. Never seeze (nuclear grade). .-
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. 15. . Flange protector. _
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- 16. Small grinder.
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-l6 4.0 ' Description of "0"-Ring Gasket Fasteners m
The "o"-ring tasket fastener assembly consists of 24 sets, each unit., of rr backing plate, screw, and a wire clip or flat stamped metal clip as shown in Figure 1, page 4. The purpose of the fasteners are to hold es.*o silver plated,
.)' t inconci "o"-ring gaskets in place in their respertive grooves located on the .
! i 3
RPV head flange during assembly and disassembly operations. - - jf , 5.0 Removal of Damaged Fasteners l j1 i IL 1. Upon removal of used inconel "o"-rings frem flange, inspect each "o"-ring l l I lhj fastener assembly for possibic damage. . i
- 2. Determine how many fasteners need replaced and obtain them from Power
[. Stores. - ' 3- - g - g.f .u i *
' Addendum: Y/ - -
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II ~sO OPage 101 BF FDII - ( '
- 12/16/77 4
5.0 Removal of Damated Fasteners (Continued) , ,_
'3 . Install flange protector, with cut-outs, on flange where work is to be performed by use of approved duct tape.
D 4. Chisel the. damaged fastener backing plate off using 5/16" cold chisel 4 The bachin;;
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and smsll nr.chinist ha=mer by tapping lightly on one side.
' plate is held on flange by ts.'o small tack walds.
- 5. Remove screw with phillips screwdriver.or if. screw head is broken, use
) -
vise grips to recove remaining screw shank. If screw shank cannoc be
, gripped, center punch exposed end of screw and drill to a depth of 3/4"
] with #49 drill bit. Use Ease Out to re=ove remaining screw pieces. If 3 " remaining screw cannot be rer.oved by Ease Out, use 025 drill bit and 1
- i
- drill to a depth of 9/16" and re-tap the hole, #10-24 m:C-23 :: 9/16" deep.
l I) 6. i 01'ean hole out by using coatressed air. -
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6.0 Installation of New Fasteners
. 1. Apply Never Sceze to threaded hole with cotton swab, being careful not
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1 to get it on surface adjacent to hole. L; <.
- 2. ' Assemble fastener, fit up and weld to flange per Dh'P No. GI8.43-0-1.
Cognizant engineer should verify fitup before welding.
,QC hold point. ~ Sign off on Data Sheet FBII-1-5, number 1. ', 3 Crind. veld smooth to assure ample clearance between screw shank and slot in backing plate to prevent binding of screw when withdrawn. Visually inspect velds. Cognizant engineer to verify. QC inspector to verify. .
Sign off on Data Sheet 1DrI-1-5, number 2. -
- 4. . Remove flange protector and clean arcas where tape is removed with . '
acetone and clean rags. -
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- g. .' 5
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.o [* Addendum:
'N .1 c=
o D .. CPage 102 O BF FL11 1 12/16/77 ' TENNESSEE VALLEY AUTi!ORITY " BROLl::S TERRi' :!UCLEAR PL.*J!T w-MECHANICAI, E\I::TE!!A::CE I!!STRUCTIC:s 1 j APPE!! DIX A q l I i j.
! DATA COVER SIEET ~
= I
- 6 Unit
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RE LTAE A"D REPLACE.'E:.T OF PJ/ HEAD FL//.:C-E "0"-RI::G GASTIT FASTE ~ERS m
- i .
U 1.0 The RPV head flange "o"-ring gashet f::teners hcvc teen inspected and replaced
, as needed. All verifications have bec.n cade and all associated work co=picted.
2 l Verified by J Cognizant Engineer / Date u j Responsibic Section Supv./ Date , 7 i
'wh I
2.0 The data package consisting of:
- a. FMI-1-5 dc.ca sheet - 1 sheet. .
- b. TR # -
l I 4 These have been reviewed and found acceptable. l I
- QA Inspector / Date "1 .
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- Addendum: .
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n o CPage 103 1 d BF 1011 1 12/16/77 a l
/
TENNESSEE VALLEY AUTHORITY
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BROWS FERRY NUCLEAR PL'JT ,
/ MECILANICAL l'AI::TE"A?:CE II;STRUCTICN 1 '
9 \ ; APPENDIX A a, . DATA SHrET :cII-1-5 f7 .
- 1. Verificat. ion that fasteneE(s) *sroperl* fit up and in correct positica l befor'e welding. -
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4 . , Cognizant Engineer Date J Q.C. Inspector . Date , r .
- 2. Verification that f astener welds visually inspected for proper a=ount of weld
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and ground correctly. .
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Cognizant Engineer Date l-
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. Q.C. Inspector Date t
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- 3. Welder qualification procedure identification n
Verification that the welder is qualified. a Q.C. Inspector Date
' 4. Trouble Report Nu=ber .
)a . l - s . , . R b ~* Addendum: /' i a\ i I
1 Y TE!!!ESSEE VALLny ggE0R ,, f BRO' ASS FEPay ;%CLusR p 1 i i k f l 2
)
FECHriICAL PAI:,rE:ZCE 1;STRUCTIC: l DRWELL HEAD REM 0"AL KO REPLACE"E::T : UNITS 1, 2, A';D 3
- l 1
I I i Approved: / -- _[ldntSuperintendent i 1 J Senter.ber 7, 19 h Date: _ 1 J
- Revision q
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TE!OESSEE VALLEY AUTHORITY BROUNS FERRY NUCL"AR PLAh7 MECllA IICAL MA1:1TENANCE II:STRUCTIO:t 2 m DRWELL LEAD RE: MAL AND REP 1/ ~,EMENT d' I
Purpose:
To prescribe the procedure for the rc= oval, storage, and replacement L. of dryvell top heads at Browns Ferry Nuclear Plant rm
References:
- 1. Final Safety Analysis, Technical Specifications, Section 4.7.A.f.
a
- 2. Pittsburgh-Des Moines Steel Co., Operation and Maintenance n
L Manual for Drywell and Suppression Chamber Containment Vessel, p October,1968, i m Prercouisites - Head Re oval:
' 1. The reactor must be shutdown and cooled to below 212 F. ~
- 2. Permission must be obtaint.d from the Shift Engineer prior to breaking primary containment.
j 3. Secondary containment integrity estsblished and standby gas treatment g system operable. L 4. The drywell must be purged and a breathabic at=osphere existing. 7 5. The drywell pressure must be at atmospheric pressure. w
- 6. The reactor mode switch must be in the shutdown mode position.
m y 7. A g ;cial work per=it must be issued if radiation survey requires. 8 .- A hold order cust be issued on the nitrogen supply valve.
- 9. Drywell shield plugs must be removed.
' 10. Reactor building overhead crane operable. -
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- 11. Refueling platform positioned at the end of the fuel storage pool, n
y deenergized and a hold order issued to the supervisor in charge of
'q head removal or track stops installed to prevent moving the platform E c er the vessel.
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Par.c 2
, BF 101I 2 U
- 6/23/78 "1
) Prercouisites (Continued)'
- 12. Visually inspect all lif ting and rigging tools to v:certain they arc
] , a in serviceable condition.
- 13. Check the head laydown area and make certain it is clear and free of obs tructions.
1 a 1.4. Impicment provisions of Append'x A for use of impacts or hydraulic torque wrenches for head bolting or unbolting. T J
, Tools. Parts and Ecuiement List .
*- * -I. Tools 4. r.
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1 required.
- 1. Ingersoll Rand Series 578 " Slugger Impaccool" with tail hose.
a 1 required.
- 2. Hex socket (3 7/8") for item no.1.
Impact wrench with tail-hose, 1" drive. 2 required. o 3.
- 4. Hex socket (3 7/8") for item no. 3. 2 required.
Impact wrench with tail-hose, 3/4" drive. 2 required.
5.
r' 6. Adapters for item no. 5 to adapt from L= pact vrenches to item 4. L ggD\ 3 7/8" Hex socket. , Hammer (Slugger) wrench, 3 7/8". 2 required.
- 7. ~
Hammer, sledge, 4 lb. with 12" handle. 2 required. p 8. t' U 9. Thread taps, 2 1/2" - 8 unc. 2 required.
- 10. Die nuts, 2 1/2" - 8 unc. 2 required. ,
*11. Hose (air) rubber,1 inch, 50 feet long, 4 sections with oilers and r
j regulator stands. I required.
- 12. Regular machinist hand tool set.
I required.
*13. Ingersoll Rand Hydraulic Torque Control Unit TWPE-1.
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*14. Ingersoll Rand Hydraulic Torque Wrench TU3 or TW4. Up to 4 required
.L with hoses and fittings. I
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II. Parts
- 1. Outsid "o" ring (endless), 5/8" diamete:r (.625" t .015") 32' - 7 5/8" de q g r.h . I required.
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, Paga 2A
- - - BF ME 2 6/9/78 D. Tools, Parts and Ecuinment 1,ist (Continued)
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- 2. Inside "0" ring (endless), 5/8" diameter (.625" t .015") 32' - 5 1/8" develop length. ,1 required.
III. Equip =ent
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- 1. Acetene. 2 gals. required.
- 2. Racs, clean, white, lint-free. 2 bundles required.
; 3. Tape, duct 2" vide. 2 rolls required. ' k. Tape, fiberglass 11/2" vide. 2 rolls required.
5 Tape, =asking 1 1/2" vide. 1 roll required.
; 6. Bacs, plastic, approx.. size 6" vide x 8" long. 200 required.
- 7. Brushes, fiber,round11/2"diameterxh"long. 6 required.
L 8. Brushes, fiber, disc type, 6" die =eter x 11/2" vide, suitable to be power driven. 4 required. *
- 9 Never-See:e thread co= pound or equivalent. 1 can required "I
J peceription: , The drywell top head is attached to the dryvell vessel by two hundred
.']
and eight (208) 2-1/2" dic=eter bolts and nuts and sealed by two 5/8" dic=eter n b . .Nordell rubber "O" ring seals. The two grooves for the "O" rings are located in the flance half. Drilled passa6cs leading to the area between the "O" ring
- provide a means of testing for "O" ring leakage when the flange is assembled.
' Four lifting lugs are provided on the head for removal. A drilled ring located above the upper flange half provides a location for temporary stornse of the removed flange bolts.
J Removal of Drr.rell Head: Bolt Rc= oval - Remove the two hundred and eight drywell. head bolts and P ' Lj washers. No particular bolt loosening sequence is required due to the size and thickness of he head flange. Place the, bolts in the drilled ring which I
- Revision: 4 7-
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- Pace 23 BF IC:I 2 5/7 /73 a . .
Re. m oval of D .rell Hend: (Continued) is velded to the tessel head cbove the flance. Figure A shouc the method
- of tc.mporary storage. ~l m
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- Dolt Brachet M
, s eq ' ' ' ' ' A
- Head F1Anse
] f .
F .. . W.d ..
,, \ ~
'VCOCC1 El#GC Stainle:n Steci
nut tcck velded _
- 2 picces
- FIGURS A-0 -
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1 4 j l j .
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- Addendum:
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BF MII 2 6/23/78 , i m . (Continued) d Removal of Drvwell Head: , 9 Bolts tasy be removed using an Ingersoll Rand Series 578 "Slugg'cr Impaccool"
~
vith a number IR 15062 (3-7/8") hex socket or with an Ingersoll Rand hvdraulic torque control unit T'.'PE-land hydraulic torque wrenches W3 or W?.. Head Lift: If CAUTIO::: 1.if ting the head may cause airborne radiation en the refuel floor. there is airborne radiation in the drywell or loose contamination in the 1 cavity, the dryvell blowers should be secured until the drywell head is d lif ted and the mirror insulation removed and the bulkhead doors closed. T Attach the head strong back as shown in Figure B. Match the color coded turnbuckles with the colored head lugs. p '
~Drywell and RFV Head E., *
- Strongback
- w. oK,
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o , e el n la f - u Lt. .M.
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J jj ......" y -- _ JON 3 0WT5 FIGURE B Lift the head clear of the vessel. Using the turnbuckles, keep the head I < ring sticking to the head flange face. in a level position. Check for "0" i. 1 I Support Feet: t i Six head support feet are provided on storage bracket on the head. These C r
} lg feet can be installed prior to setting the head down. They are provided to i*
prevent damage to the top head flange when setting it down and are stored on 4 brackets on the side of the head. j cMove the vessel head to the lay down area. Remove the support feet from 4 their storage brackets. Place and pin them on the head flange joint below each of their. hat.h Figure C shows the method of installation, 3
- Revision: ,h h **
Page 4 ,
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' 6/19/72
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Stora.3e Bracket 6 Each
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Dryvell !! cad > , r-
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I!ead F1cnge dZ; ,7ig Support Foot 6hd
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FIGURE C -EAD FLA!!GE SUPPORT FOOT IIiSTALLATION 3 i J .. . m m NOIE: The head flange cust be uniformly supported by the support feet or other suitable means whenever it is set down. Uneven footing warps the
-)
U head and if allowed to remain in a warped position for an extended period l' of time, it will deform and replacement on the lower flange will be difficult k or impossible, as the bolt holes will not line up. a 11ead Lavdown: Figure D shows the location for the laydown of a drywell head.
' '(Figure D on next page.)
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- EF MMI 2 6/23/78 a
1 REPLACE"E!"r OF TOP HEAD . sid Prerequisites - Head Reclacement: 7 j l. Reactor vessel head, head piping, and insulation in position.
- 2. Ventilation openings in drywell to reactor vessel head area open.
O b3 Clean Lower Flange Surface - Wipe the lower flange surface and the exposed areas of the "O" rings with a cloth saturaec'd with acetone. L CAUTION: Acetone is highly fla=nable and is toxic in poorly ventilated
.- areas. Allow no fla=e or sparks around area where acetone is used.
ring surf ace while cleaning. If damaged areas exist, report
- Inspect the "0" u these to the supervisor. The "0" ring joint must pass a local leak rate test.
]
"O" Ring Replacement - If the head "0" rings are replaced, the following
'- procedure shall be followed:
~'
[lLJ l. Remove old "0" rings from lower flange.
- 2. Clean groove with acetone. Do not use scrapers or tools which might damage the "0" ring seating surface.
j --
, 3. Obtain new "0" rings '-
Description:
Outside Ring "0" ring 5/8" dia. nom. (.625 1 015) 32' 7 5/8" length (splice in field if required). Inside Ring "O" ring 5/8" dia. nom. (.625 i .015) 32' 5 1/8" g length (splice in field if required)
- NOTE: (If field solice is recuired) "0" ring should be cut on a 45 angle for splicing.
a W
- Revision: i r
M 1 J
1 .. J Page 8 BFFDE 2
' 8/25/76 ' Rig Drywell Head - Att'ach the head strongback to the head and adjust the ' turnbuckle gap dimensions as given in Table MMI 2-1 on page 10.
Af ter the drywell head strongback turnbuckle gap is set, lift head and check 1 j the level. 1 Supnort Feet - Rc=ove the six support feet from the flange and replace thcc on J their hangers.
~
Clean Unoer Flance - Wipe the upper flange face with a cloth and acetone. Inspect the face and make certain it is clean, free of foreign material, and suitable for setting in place.
.i
- Reposition Head n
[j Operate the crane to transport the drywell head until it is positioned over the lower flange. Lower che head to within 12 inches (approx.) of the flange. Check J both flanges for cleanliness and for proper "O" ring placement.
~
NOTE: Four match marks on the flanges are provided on the head and s vessel to insure that the head is returned to the.same position on the vessel mating flange as it was located before 9 removal. Do not try to line up the head using the bolt holes for a reference--USE THE MATCH MARFJ3. a Carefully lower the head to within 3/4" + 1/4" of the lower flange. C1 caning Head Bolts - The bolts and nuts must be. clean prior to assembly because 9 the nuts are made of stainless steel and dirt will cause the threads to gall when m assembled. The head bolts must be wiped cican using a cloth and acetone threads. J
- Revision: - -
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- l 0
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CP:go SA v, ' BF MMI 2
. 5/6/74
~
5 Cleanine Head Bolts - (Continued) . should be cleaned using a non-cetallic brush and acetone. The nut threads should
]
,a . also be cleaned using a round, ncn-metallic brush and acetone. N(YTE: The head bolts have been given a special phosphatizing and baked-on 9 dry lubricant film. Do not wire bruch or clean these bolts by any j means which would re=ove this surface treatcent.
=
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- Pag 2 9
- f. .
BF tell 2 L - 6/23/78 Lubrication Head Bolts and Washers - Apply a l'ight coating of Never Seeze 9- compouad to the entire head bolt and nut for lubricating and rust preventative . p apNe s . m 6 *Asscnble Bolts and Muts - Start 208 bolts. Carefully lower the drywell head Snug all 1 onto the flange making certain the he:.d and flange meet uniformly. a the bolts (bolts are considered snug when there is a metal contact between i If bolts are hard to turn, DO NCTI FORCE THEM. If bolts nut and flange). j are forced, they will only gall in the stainless steel nut and be ruined. I hey will have to be removed by sawing and drilling. If the bolt g ts tight
' in the nut, back it out and reelean threads. Do not snug bolts using a han er .
a wrench. cte: A QC inspector must make appropriate verification on 111 data sheets. 1 Torauine Head Bolts - It is desired that all bolts be torqued so that each is a stressed to 21,200 psi. Calculations using a working bolt stress of 21,200 psi
- show that when properly tightened the 2-1/2" dia=eter bolts elongate .00645".
n Either an impact tool or a hydraulic torque wrench can be used to obtain proper y-.-- . . _ stretching of the stud bolts as verified by. Appendix A.
.
- Impart Tool Method - Af ter snugging, tighten for 5 seconds with the i= pact o
tools and then turn an additions 1 20 as nc,ted by covement of the socket. Check for loosened bolts and repeat this sequence on loose bolts. When all bolts have been rotated 20 (af ter the .* second tightening sequence), turn an additional 10 if possible. l 6 . m
-Revision:
. V _
. . P g; 9A
- BF MMI 2 6/23/78 9
b . Bolts are identified with a 3/8" high stamped number on the top cf the hexhead.
~ As bolts are torqued, they shall be checked of f on Data Sheet Sil 2-1. - *1f the gasketed seal does not meet the leak. e criteria, additional torque may Record the be applied to any segment of the flange to obtain required sr.al.
f] b af f.ected bolt numbers under " Corrective Action Taken," page 13. n
- Hydraulic Torcue Method (usually 2 up to 4) tighten bolts to torque value Us,ing hydraulic torque wrenches 0
established by Appendix A at intervals of 180 , 120 or 90 depending upon 7
,.j number of wrenches used.
Simultaneously torque 2, 3, or 4 bolts at above intervals and sequence around a advancing one bolt at a t. per section until all bolts are torqued. If gasketed seal does not meet the leakage criteria all bolts are to be _ 2
- tightened using a 57. increase in torque value, rounded to a convenient gauge reading. Additional torque may be applied to any sag =ent of the flange to q
obtain the required seal. Record the affected bolt numbers and determine bolt elongation by use of Appendix A using a test bolt with equivalent torque value. Record under corrective action taken. D Verify proper torque setting of hydraulic control unit per Appendix A NOIE: a every 208 bolts during the torquing sequence. N N h'
- Revision: ) i _
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I
- Page 10 BF FSE 2 t
6/23/78 l ' 4 o I 1 ! l . 4 ~' Post Maintenance Check Out - Section 4.7. A f of the Technical Specificatio , Primary Containment, requires that bolted doubic gasketed seals be tested l h refueling J whenever the seal is closed after being opened and at least at eac ~ , ring scaled drywell outage. This requirement is applicabic to the double "0" s. head. Acceptable Icakage criteria and frequency of testing is specified in q " the surveillance requirement. 1 U The pervisor responsible for replacement of the drywell head is respon "0" ring seals. He shall r' for requesting the results section to check the i i J review the test results to assure that the head meets the leakage cr ter a.
" DRYWELL HE!.D TUR'3UC11E CAP DI?'ENSIONS_
, u' Turnbuckle Gao Dinensions Unit No. 3 a Unit No. 1 Unit No. 2 1 Turnbuckle No.
*3"
*1 7/16" m
1 (Red) (North)* *2 1/4" _ _ j
*1 S/8" *1 7/16" _
2 (Green) J
*2 3/8" _
q
*2 7 /8" *3 9/16"
*2 1/2"
- 3 (Yellow)
*1 7/8" *3 7/16"
*3 1/4"
] 4 (Blue)
J TABLE ISE 2-1 a
.q Y_'),
- Revision: __
h m s 1 J
. , Page 11
BF :D:I 2
. 11/5/75 TC."!!ESSEE VALL*-Y, AlsTdORn7 . .
BROWI:S IT.RRY !;UCL:'.43 FL/J;T - 1 , DRWELL HEAD R::FLACDCIT i DATA SHEET 202 2-1
.) '
Unit 1*c: , , Date: *
- TORQUED SATISFACIORILY
i Finnre Eolt Tichtenin: -
" *I!SPECTOR'S
- OR'S *INSEC W,'S Bolt Bolt 307g I:?ITIAL/DATE 1?ITIAL/DATE II?ITIAL/DA2
, No. i ..o n . ..o - 1 27 53 r 2 28 54 s 3 29 55 4 30 56 1
5 31 57 J . 6 32 . 58 l 7 33 59 8 34 60 9 35 61
'J 62 10 36
~
n 37 1 63 12 38 64 n . 13 39 65
.- 14 40 66 is
- 41 67
.. ; 16 k2 68 17 43 69
) 18 44 :
70 19 45 i 71 . 1 20 46 ? 72 21 47 73 1 22 48 74
'J 75 23 49 24 50 , 76 - .
25 51 , 77
,- 26 52 78 J 0 e
T~ 4
- Revision X' '
- a. Page 32 1
. . o r,P YMI 2 11/5/75 1 ** DATA P!P"'" 'a'T 2-1 (Contint:cd) t'O 8
p Bolt *1NSPECTOR'S Bolt *1NSPECTOR'S Bolt
*INSPEC':OR' S INITIAI./DATE no, INITIAL /DATE J no, _
INITIAL /DATE ,3, n2 145-79 h,j 80 H3 . 146 81 n4 ,147' 3 t 82 ns 148 n6 149 I 83
} 84 n7 150
~a n8 . 151 85 152
"]l4 86 n9 153 87 120
+- 88 ul 154 n2 155
; 89
' 156 90 123
>l 157 j 91 124 l 92 125 i 158 i.
126 l 159
) ,.m. 93 127 160 y'# 94 161 95 128 ,
~$ 129 l 162 96 '
130 163 ik 577 _ 164 98 131 132 165
- 99, ,
1 166 j 100 133 101 134 167 i 102 - 135 168 . J 103 136 169 - 104 137 170
]" 138 0 171 105 172 q 106 139 107 140 173' 108 141 174 109 142 175
.)
}
'110 143 176 .
].. J/~s'y -
/ 144 177
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- Revision $g.(I'le _,
. _ ~ - - _. __ _ _ .
.. . rage 2; .
BI', tDil 2 l' o l 6/9/78
,, DATA SitEET L'JC 2-1 (Continued)
},
a ..
' ~
Bolt { Bolt ', Bolt f. No. ;
.p No.
No. . t 199 178 189 - . 200 i 179 19o ~ ... 201 180 191
' 202 181 192 lI: 203 ' .l' 182 193 204 s 183 _
194 _ 205 195 j 184 206
- ., 185 196 '
207 l 186 197 _ 208 _ 187 198 _ ll 188 T, . 3 Yes No ____ Head seal leak tested caticfactoril'/ Corrective Action Taken: (Ifrequired) 13 -
- !. i .
,w r- .
6' . h, . Trouble Report Number ,, *
,d ,
L, Signatures: e
- Date:
4 9 - . . Forc nn Date:
- b Mechanictd F.ain .. Supv.
k :
- Verification that the belts are torqued as specified on page 9er 9A.
.t: -
L
.: Date
.QC Inspector
~
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.x ... . . . . . ...
E
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- Revision: p v J. ,
- 1 - .._~7.-
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cPIge 14
] ,
BF ntI 2 3 .. . 6/9/78 TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT
}ECllANICAL MAINTENANCE INSTRUCTION 2 APPENDIX A
; TESTING OF TOOLS USED IN DRWELL IC.J.D REPLACDENT
, 1.0 Nrpose
'l#
To verify torquing ability of i= pact tools used when replacing the 3 drywell head. To ensure hydraulic torque wrenches used when replacing J drywell head arc operating correctly. It is desired that torquing stress the bolt to 21200 PSI (.00645" elongation). Either section or both may be used. Use separate Data Sheets if both sections are used. . 2.0 References
- 1. Mcchanical Maintenance Instruction 2 fj
,j 3.0 Prcrcouisites
- 1. Impact tools operationally tested. (Section A)
- 2. Regulator stands for air lines. (Section A) 4.0 Precautions
- 1. After testing do not use impact on other work prior to drywell head torquing.
5.0 Tools, Parts, and Eculoment List
. 1. Ingersol Rand Series 578 (Section A) l
" Slugger In:pactool" with tail hose. 1 1/2" drive. 100' 1" air hose.
n j 2. Ingersol Rand Hydraulic Torque Wrencies,' control panel, hoses and fittings
, for_ number of wrenches to be tested. (Section B) 0
!J 3. 3 7/8" socket w/ adaptor to impactool and marked with a 20 interval. I'
. . 4. Test stand l S. Four "C" clamps CAddendum: _
Pcg2 15
-* DF Ifil 2
- . 6/23/78 P.,
u 5.0 Tools. Parts, and Ecuinment List (Continued)
- 6. 3 drywell head bolts ] -
j
- 7. Soap stone markers 6.0 Procedure q A. Impact Tools
- 1. Clean dry.iell head bolts. Apply a thin cost of never see:
l lubricant or an equivalent to the threads. J
- 2. Measure drywell head bolts and record initial length on Data n-
. Sheet 1.
.* g. . ,,
*3. Snug bolt, (metal to metal contact).
d *4. Tighten bolt with impact for 5 seconds G 75 PSI regulator pressure. One man should count the 5 seconds using one thousand one, one
] J thousand two . . . one thousand five method. Measure bolt length.
Pl Record on Data Sheet 1. u q 5. Mark test stand using soapstone or suitable marker in line with Ic ling (clockwise direction) 20 = ark cn 3 7/8" socket.
- 6. Tighten bolt wit!- 1 l'/2" drive impactool until trailing 20 line on the socket is aligned with soapstone cark. Measure bolt length.
Record on Data Sheet 1. 7., Advance socket one half the marked distance using method in Step 4 i This should be equal to approximately a 10 advance or a total 1 movement after snugging of 30 0.
'~
- 8. Measure and record bolt length. If the elongation is not between
.005" and .0065" increase or decrease regulator pressure accordin;1y, J
loosen bolt and repeat steps 3 through 8. Record the pressure and 1 J all length measurements on Data Sheet 1. B. Hydraulic Torque Wrenches
}"
- 1. Clean drywell head bolts. Apply a thin cost of never see: lubricant "I or an equivalent to the threads.
J o nevision r 1 I /
e
*p:gs 16 BF }D:I 2 6/9/78
. 6.0 Procedure (Continued) .
B. Ilydraulic Toreue Wrenches (Continued) . d 2. )!easure drywell head bolts and record initial length on Data j Sheet 1. 0
. 3. 11and tighten bolt.
- 4. Set 5700 foot pounds on gauge located on power module control
] Lock control knob with wing nut. panel by rotating control knob.
' 5. Put power vrench on bolt on test stand. Use 3 7/8" socket.
- 6. Actuate advance and retract switches 'on pendant unit until no 1
w rotation of bolt occurs. m
)!casure and record bolt length. If elongation is not between ' 7. '
006" and .0065" increase or decrease gauge reading accordingly n loosen bolt and repeat steps 3 through 7. Record gauge reading U
" - and all length measurements on Data Sheet 1.
LJ m 7.0 Resul t_s x When testing impactools each impactool will be tested on three bolts When testing the hydraulic torque using the same regulator pressure. 0 , unit three bolts will be tested using the same torque value. The bolt elongation will be between .005" and .0075", prior to use an reinsta11atio of the drywell head. If elongation data is outside this range repeat section A or B as applicable. 1 i
~
Addendum:
. l
*r:,a ;
nU DATA SIIEET 1 hP M!I 2 l
#/9/7s .-
1 e- *Icst Sequence No. w o.. . . . . [., .f . . 1 A Date
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e t .....:
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1 o ~ 5~ MECHANICAL MAINTENANCE INSTRUCTION 10
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REACTOR VESSEL STEAM DRYER AND SEPARATOR RDiOVAL AND REPLACDENT
'T E 1
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- UNITS 1, 2 OR 3
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f I a 4 1 i, LL Approved: i II /97h. ( i Plaqt' Superintendent j - k Date: March 18, 107$
- Revision
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- t i UF IC!I 10 TABLE OF COI.'fE:iTS 1 -
Pare 110. 1 1 Purpose ------------------------------------------------------- a 1
Reference:
p! ------------------------------------------------- 1 Prerequicite: i. L. Tools Pequired ------------------------------------------------ 2
------------------------------------ 2 a Performance of :!.11ntenance Step 1, Installation of Service Platforn Support ------ 2 a.
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- b. Figure 2, Service Platform Support -------------------- 3
- c. Figure 1, Service Platform Support Strongback --------- 5
- d. Step 2, Removal of the Steam Dryer Asse-bly ----------- 7
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Figure 3, Dryer and Separator Sling ------------------- 8
- e. s -
Ticure 4, Steam Dryer Lifting ------------------------- 11
~ f.
s Stop 3, Instc11ction of Service Platfen -------------- 19 6
- h. Figure 5, Service Platform ---------------------------- 16
- i. Figure 6, Service Platform Sling ---------------------- 17 n.
Ll j. Step 4, ' Installation of Stcas Line Flugs -------------- 18
- k. Figure 7, Steam Line Plug ----------------------------- 19 Figure 8, Steam Line Flug and Installation Tool 91
- 1. -------
Figure 9, Leucring Steam Line Plus -------------------- 24
- m. 1
- n, Step 5, Ec= oval of Shroud Head and Separator Accy. ---- 23 1
1
# o. FI Eure 10, Shroud Head Bolt Wrench -------------------- ?O fI p. Figure 11, Shroud Head Hold-Down Holt ---------------- ?1 L'
Figure 11A, Shroud Head Hold-Doun Bolt Orientation ----
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- q. Step 6, Installatien of Shroud Head and Separator Assy.- 35 1
- r. Step 7, Removal of Stcan Line Plugs ------------------- 37 l l
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q Page 14 BF ICfI 10 J N9/73 Perfomance of l'aintenance (Continued)
- 1. Installation of Service Platfom Support (Continued)
Descrittien (Continued) 9 The service platform support consists of circuir steel track seg.ents connected with bolts. The ends of the track sec=ents are enbossed uith matching numbers to facilitate proper assembly on the vessel flar.ce. I Each track sec=ent is provided with clanpc which secure the platfo= support to the reactor vessel. The clamps are tightened against the side of the veccel directly below the flange by means of bolts fitted with toggle pads. Cable slots are provided in each track secnent to acco modate U electrical cables and air hoses used in reactor servicing operations. The U bottom surface of the track segnents are faced with a soft covering for 3 d vessel flange protection. Installation Instructions . Prior to use, chect ":e surfaces of all the platfom segments for scars, dents or protective cover deterioration that would damage the vessel flange surface. Repair or replace as required. i
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D Before and after use, vipe thorou6hly cican of foreign matter. 1
" l KOTE: The reactor vessel flange must ba % :, ;hly c1 caned prior to i m ; installing the service,platfor .,uppt .
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Page 6 BF }D1I 10 , 4/29/74 _D. .e Performance of Maintenance (Continued)
- 1. Installation of Service Platform Support (Continued) ,
Installation Instructio q (Continued) Conne'ct the service platfor= support strongback (Figure No.1) to the F L auxiliary crane hook. l'1 .] *0rient the strongback adjacent to a platform cupport segment that has the threaded connections (2 segments). Turn the strongback and place it on the support segment aligning the tab on the segment with the slots in the strongback. Insert ball-lock pins through each of the slots in the strongback to
-- engage the hole in the platform support segment tab. .
NOTE: The platfora support segment is transported in the horizontal J position when properly positioned relative to the strongback.
.,
- Transport the support segment to the reactor vessel and carefully lower it p on to the vessel flange, orienting the segment so that one end is in line y
- r.
with the separat.or guide pin. -
'L. NO_TE : .The segment contains openings to allow electrical cables and air hoces to pass to the vessel interior. Orient all cables through these openings.
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- Disconnect the strongback and retrieve the other support segment that is i-identical to the first segment.
7 d NorE: The ends of the support seg=ents are identified with match numbers 1 to [litate proper asscebly. I
- Revision:
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i Page 6A BF FD1I 10
- 4/29/74
\ . . . Performance of ?!aintenance (Continued) (CentinucI)
- 1. Installation of Service Platform Support I
Insta11atien Instructions (Continued) 1'Ircnsport : 2 support segment to the reactor vessel and ccrofully louer from the first it on to the vessel flange, orienting it opposite OSO Transport the remrining segments (2) segment) frem the other segment. f to the reactor vessel and carefully lower them on to the vessel flange. Do not tighten
*
- Install connecting bolts and secure the captured sc:nws.
' bolts until all bolts have been started.
3 Confirm that the cables are located in the openings and that support bridge blocks are all in place. U y, . V .
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. 'Page 7 BF M4I 10 10/7/7b J Perfo r v.cc of "nintencnce (Continued)
- 1. Tnctallation of Service Platform Surnort (Continued)
In tallatien I. tructions (Continued) When all cery. cats are acce.mbled together tightcn the cla=ps to cecure the su.rrort in the proper erfcate. tion. Ed
~
- 2. Renoval of the Stec;n Drycr Acceably -
a The re:noval of the reactor pressure vessel head freed the dryer as it was F held in Tlace by hold-dem luss incide the vessel head. Prior to attaching { the dryer and ceparator cling to the 125 ton hook of the everhead crane (see s L Figure No. 3), orientate the crane main hooh such that the sid'c painted red p is in the ple.nt north-west direction. Verify that the two hook pins on the slin; 3. hook box are retracted cnto the pin stOports, Loter the crane hook into the slot on the hook bcx such that the cido of the hook box painted red is in the plant north direction. locate the ceni-circular groove in cach hook pin so that it is facing downward. The cabic turnbuckle and cling cochet accc ablic a vill be painted uith a color code of Blue, Red, Green, and Yellow. Crientate L the asce=blies cuch that all of the parts painted blue are together, all red parts are together, etc. Adjust the turnbuckle end ga_o to the following for
~
dryer handling.
- Turnbuckle Bolt Gao 9
! ED (50 I EI,1G (S$ GI'E. 'I (!i^IO T'" (M n i Unit 1 17 1/2"' 17 9/16" 17 1/2" 17 3/S"
-- l l, 17.419"' 17.S56" 17.982" 18.104"
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Page 9 l i BF ICTI 10 9/9/75 ] f I 1 h Perfor:ance of Maintenance (ce 'nued) . t t
- 2. Removal of the Steam D2/er / r.embl- (Continued) l
( NOTE: The above orientation arrange =ent is to assure the dryer is handled in a level plane during each handling operation. "he orientation a-d turnbuckle gap =casurements shall be recorded on data sheet I?'I 10-1 1 ) " Data 1, see page 47. .
' i Using the pin insertion tool, push one of the hook pins through to the stop, secure the ball lock pin through the opening, in the end of the hook pin tc
. secure the hook pin in place. Insert the second hook pin in a similar canner and secure the ball. hook pin. Adjust the crane hook until it seats securely into the recess in the hook pins.
! l
- a. Dryer and Separator Sling Operational Test
- NOTE: Check air hose and fittings per DFM No. BF75M10 With one technician on the refueling floor holding the sling control box,
{ and with the sli.g suspended, test-operate the sling to de=onstrate its . operational readiness: m 1 LJ Connect the control box to a source of 100 psi service air fro = the [ 7 refueling floor, i i 3: . i .: With the control box air control valve in the INSERT position, check the 1 four pressure gauges on the control box ar.d verify that all four liftin-pins have inserted through the sockets. , l
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- Revision: .
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s Peca 10 l BF IM 10 1 4/9/73 Performance of Worh (Continued)
- 2. Removal of the Steam Dryer A sembly (Continued)
~
- a. Dryer and Separator Slins Operationcl Test (Continued)
U Move the control box air control valve to the D~ TRACT pocition. C4ck i .rc hac been relieved. pressure gnuges to verify that control pre Check that the four lifting pins have retracted out of the lifting socket =.
- b. Dryer Recoval Manually guide the dryer-separator sling vhile loucring co that the four sockets seat over the lifting lugs. Move the control box cir centrol valve to the I:! SERT pocition to insert the four lifting pins throuch a s p
the cocket and lifting luss (see figure no. 4). CAlTIIOII: Verify that all four pre :uze cacos indicate precsure to n assure that the lifting pins are fully inserted. Carefully lift the sling to verify that the load is being lifted evenly. E
$ Raise the dryer assembly out of the reactor vessel until the botton edge of the dryer assembly skirt is in position to clear the curb 'of the drycr-separator canal. Transport the dryer assembly to its storage area in the vest end of the dryer-separator pit. Lower the drfer h+
assembly onto the floor of the dryer-separator pit. Slachen th>. sling i a, cables, r WARITII!G: RADIATIO:I F M .RD o The stesa dryer a scably must be kept vet with domineralized I water to prevent airborne centanination until such tine as the
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- 4 -
4/9/73 3
;j Perfor-ance of Ucrk (Continued)
- 2. Eencal Of 'Ihc Steas Drycr Asse=bly (Continued) ,
" Dryer Eemoval (Continued) b.
Disconnect the sling frcn the dryer cssembly by moving the centrol box control valve to IXTPJiCT. Check that c11 four pins have retract.ed b by verifying that all four pressure gauges indicate zero pressure, s Lift the sling and verify that the sling has disensaced frca the cr/er
~
asse=bly lifting lugs. l' b 3. Installation of Service Pir.tfor: IT Prerecuisites lJ
- a. Service Flatform Feuer Connection and Chechout s
Confim that the disconnect ON/0FF switch is in the OFF position. [ Connect the cervice platfom power supply plug to the cervice plctrom receptacle. 5 E Place the disconnect switch in the CU position. 3 Check service platform drive operation by first depressing the for:ard pushbutton, confining that the platfom rotates as 1cng as the button 4 is depressed. Check service platfom reverse operation by depressing the reverse pushbutt: a confirming the platfom rotates in the rever.;c direction as long as the i button in held depressed. T NOTE: If the jib crane is not to be used, the Reactor I!anual Centrol , 4 J System operation requirca that the du==y plus #738 (Al5) be inserted into receptacle #736 (A:c.). N Jib Crane'Pouer Connection cnd Checkout i Confim that the cervice platform rover connection and chechout is cc plct e. h.
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Pace 13 s BF K'l 10
. 4/9/73 Performance of 'Jork (Centinued) 3 Installation of Service Platfern (Continued) .
i Prerectisites (Continued)
- a. Service F12tferr Faver Cannectic7 and Chechout (Continued)
Jib Cranc Power Connection end Chechout (Continued) If the dunny plug #738 (AX5) was installed in s'ervice platform receptacle 736 (A:.:1), then rcreve it. Connect the =echanically coupled jib crane pouer supply and interlocking ]1, plugs to the service platfor: receptacles. Depress the jib crane pcuer 03 sultch and confirm the power light s illuminates. p
!J Unlock the jib crane trolley frcm the cast and proceed to test operate the trolley, and hoist in accordance with the manufacturer's instruction
, NOTE: The hoist up travel limit switches should be re-checked at this
" , time to confirm or estchlish limits that are compatible with the operations to be perfor=cd.
l
- b. Maintenance Instruction For Service Flatform Jib Crane Prior to each use, visually inspect the hoist cable and cable connections.
1 Repair or replace at the first indication of frayed vire strands. g
' Prior to use, check the security of all lock pins and threaded connections.
J Tighten and secure, as required. 7 f s.
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Before and after use, vipe thoroughly clean of forcicn matter. a m
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- o-8 Page lh g DF 10 I 10 4/9/73 l.
4 Perfor ?.nce of York (Continued)
! 3 Instalhtien of Service Platfom (Centinued)
Prcrecuisite: (Continued) l '5 b. l'aintens .cc Inctructicn Fcr Ee--z!cc Ph:rer- Jib Crane (Continued) Prior to use, check noving parts for bind-free operation c.nd indicacic . of near. Repair or replace as required. Inspect electrical cable and connections for *ndications of vaar or defects. Repair or replace as required, t Prior to use, test-operate to verify that all parts and control interlocks [1 I function as required. Adjust, repair, or replace as required, s
'l i Check that the drive notor: are properly lubricated. See the : nufacturer's instructions supplied with the notors.
Check all velded connections for prepar security. Ecpair as required. Visually inspect all structural me:bcrc for signs of any damage that could h i be detrL: ental to the tool operation. y 1 Confim that the service platfom support is in place on the vecsci flance and ready to accept th; service platfc= (see figure no. 2 on page 4). Thoroughly inspect the service platfo n (figure no. 5) to confi = that I] all conpenent cre recurely fastened cnd loose parts are renoved frer. the f' platfom.
s. l - Pace 15 EF M 10 [' ' ' 4/29/74 [ Perferzance of Ucrh (Continued)
- 3. Instc11ation of service platform (Continued) ,
Prereauisites (Continued) f .
- b. Ihintenance Instructics Fcr Service Platfor Jib Crane (Ocntinued)
Confirm th .t the platfor is clean and free of any foreign natter. I) y NOTE: The jib crane is not nomally used for the dryer cnd sepcrater removal'and replacesent,-but if the jib crane is required for other service operations to be performed, it should be installed f e on the service platfor= before the pictfom is transported to the reactor vessel. D.. L Installation
- Connect the service platfora sling (figure 6) to the reactor building :. tin f]' ,
crane, 125 ten hr.oh. If jib crane has been removed, the 5 ton hook may be used. Transpart the platfom.to the reacter vessel. 1 J- Check that all electrical cables are located in the service platform support Openi.1cs and t .e respective bridges insta ed. . o Carefully lower the service platfom while aligning the ple.tform wheels with the support rails. 1 J 3
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lh n 1 o i 3 ' a 1 S 1 1 Figure G SE11VICli PLATf0 C; SLING r1 . O n U DESC!tlPTION r,
; The service platforn sling is used for the transport of the service L platfora and service platfern support, when connected together. The sling employs three cal.lcs with a safet y hook at the end of each. The cables are y joined by an oval cyc for use with a crane hool. A turnbuck]c is provided u in the cable which connecir, to the lif ting lug in the center of the short side of the rectan;;ulnr opening in the service platfora for adjusting the q leg length as required to lercl the load. The sling has a rated capacity of g 14000 puunds (6356 kilograns) uith leg angles at 15 to the vertical.
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- . 4/9/73 j .
?erfor~.ance of Work (Continued)
- 4. Installation of Steam Line Plugs .(hTA).-
Descriution The ste:= line plug (Figurc 7) is used to seal the steca lines to prevent
] the flow of water from the reactor well into the etesn lines during cc. ticing of safety / relief valves, main steam icolation valves, or other confonente of the main steen lines. -
1
, A square The steam line plug consists of a cylindrical plug uith tuo ceals.
a i flange on one end of the plus is curved to seat egainst the concave surface l of the reactor vessel vall. The choulder behind the flange, and the guard l i {, - 4 t at the oppecite end of the plug, are sized to fit the inside diameter o'f i the reactor vessel steam outlet nozzle. An infir. table, reinforced-rubber I primary seal surround: the plug bet.:cen the guard and the shoulder, and a plyable, neoprene 0-ring secondary seal ic seated on the shotider behind d the square flange. b i A vent-pipe penetrates a plate within the steam line plug to allow the steam line to be vented when the plug is inctalled. The inflatable ccal i is pressurized by service air from the operating floor throu6h a globe .~ valve and prescure gauCe mounted to a plate which hangs from the safety
~ railing c.t the operating floor level. A 50-foot air hoce connects the hanger plate with the air line attached to the steam line plug vent pipe. The air line penetrates the wall of the plug to apply air to the inflatable scal, w
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P:gs 20 BF >MI 10 10/25/77 Performance of Work (Continued) 4 4. Installation of Steam Line Plugs (4 EA) (Continued) Description (Continued) y The steam line plug is installed and removed by use of the reactor building 3 crane 5 ton hoist and the steam line plug installation tool. The bail handle b near the top of the vent pipe sids i: bandling and is used to lash the steam d line plug to the safety railing once the plug is installed in the reactor. An actuating pole with a J-hook or L-hook attaches to the steam line plug p . ly handle for manipulating the plug underwater.
-fs The steam line is sealed by installing the steam line plug, inflating the primary seal, and then draining water frem the steam line to create a
- pressure differential acrosa the steam line plug or establishing a vacuum through the condenser with the techanical vacuum pumps. A threaded cover q
J is installed at the top of the vent pipe so that reactor water cay be raised to a level above the vent pipe during refueling or reactor vessel servicing 6 operations while the steam line plug is installed. 1 Installation Of The Steam Line plug 1 Pre-Installation Instructions CAUTION: Close and obtain hold orders for valves FCV 71-2, 71-3, 73-2, and 73-3 prior to plug installation. NhrE: - Perforc* DP>I No. BF75>110 prior to installation.
] Remove the reactor pressure vessel head and steam dryer assembly.
< Install the service platform support and service platform. The corner
[ opening of the service platform provides sufficier.t space for the steam y n line plug to be Icwered into or removed from the vessel. The corner ) j plate may be removed for steam line plug accese 1: desired.
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- 7/2/74 lj ---
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Performance of Work (Continued) L 4. Installation of Steam Line Plugs (4 EA) (Continued) Pre-Installation Instructions (Continued) w Refer to Figure 8 and attach the steam line plug inctallation tool to the steam line plug as follows: t b f L . m i n$ , w i b
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l g . Page 22 H EP IMC 10 4/9/73 'm , P Ferron-ence of Pork (Continued)
- 4. Installation of Steam Line Plugs (4SA) (Continued)
Installation Of The Stets Line Plue (Continued) .
.71 g Pre-Installetien Instrecticns (continued) f*0TE: The steps for attaching the installation tool to the steam linu N) pluc are the set.:e for transportint; the steam line plugs from the storage area to the refuelins floor edjacent to the reactor pressure vessel outlet nozzics and for the installation of the steem line plugs.
(1) Open the two istches on the steam line plug installation tool fra :e. B (2) Insert the two blocks at the botton of the toc 1 frame into the front - s of the steam line plug and position the steca line plug vent pipe into the vertical channel frame of the tool. (3) Clo::e the two latches on the tool frar.e te hold the vent pipe in place. (4) With the reactor building crane (5 ton hook), lift the stea= line plug. Il NOTE: When the steam line plug is suspended with the installation g i tool, the load must be balanced so that the plug is very near j ? the horizontal plane. If unbalanced, lover the stee, line j plug to the floor and move the sling shackles at the top of the tool to alternate holcs to achieve proper belnnee. f n ij n Check the 0-rin; seal on the steam line pluc, and verify that it is properly
.y scated against the shouldcr of the plu6
'a Transport cach stean line plug to the edce of the reactor uell in the
] location of the stena outlet nozzle to be plucced and hanc the steam line plug hanger plate on the safety railing at this location.
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I} L . . , PnGe 23 BF !?H 10 n - 4/9/73
-! J .u Il Perforr.ance of "ork (Continued) 4J '
- 4. Installation of Steam Line Flucs (hEA) (Continued) m
-] Installation Of The Steam Line plun (Continued)
- [] Pre-Installa.tien Instruct'lons (Continued) b Verify that the globe valve is closed and connect the 100 psi f i-
=: : service air supply frem the refuelinc floor connection box to the inlet side
- LJ of the globe valve on the he.nger plate. J . 9 Uncoil the air hose on the hanger plate as required to thread the air hose G through a cable slot in the service platform support adjacent to the n* reactor crossure
~
vessel steam outlet nozzle, a s -
?1 fJ wa Rotate the service platfor= so the corner opening is above the steam outlet 7 nozzle.
J u Installation Instructions Operate the auxiliary hoist to carefully lover the steam line plug into the L reactor vell, throuch the corner opening in the service platform, and adjacent to the reactor pressure vessel steam outlet nozzle to be plu;ced (see Figure 9). NOTE: Stop lowering uhen the top of the veat pipo is easily accessib'le to technicians on the service platform. e
'l Connect the air hose passing under the service platform support to the 4 J air line at the top of the vent pipe on the steam line pleg.
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1- . A Page 25 BF l'l!I 10 0' - 4/9/73 u 9 J Perfomance of Work (Continued) I
- 4. Installation of Steam Line Plugs (hEA) (Continued)
Installation I.structions (Continued) $L CAUIIC::: In parfo ming the follouing stop, do not execed 30 psig pressure. Pressure in exces:: of this value could de :ase the pri .ary rj seal on the pluc. lJ At the hanger plcte, open the globe valve and apply service air to the steam line plug until 30 psi is sho'm on the prc::sure gauge r_nd ir::: ediately close the globe valve. D 9 Fron the sertice platfom, visually inspect the inflatable primary seal'on G the stcan linc plug, and veri?/ that it is evenly round with no air leaks, b bulces, or other indications of a potential failure. ' u Upon satisfactory ccr:pletion of the visual inspection, disconnect the air supply, and use the Globe valve to bleed all air from the inflateble seal on the plus. I-
' With the seal fully deflated, reconnect the air supply line, and operate the p
i.
' auxiliary hoist to lotter the steam line plug to the elevation of the reactor '! pressure vessel steen outlet noccic to be plucced.
b Using the actuating pole with a suitable J-hook or L-hook attachecnt, enpge the handling ' car on the bottom front of the plug and carefully guide' the stecn line plus into the steam outlet noznic. i
~
PagG 26
- kOfhh/h Performance of '..*crk (Centinued) -
- 4. Installation .of. Steam Line ? lugs (hEA) (Continued)
Installation Inst-uc+.icns (Continued) m NOTE: This step =ust be performed by a technician on the service platform, e standing straight in line with the stes: outlet no:=le to be plugged, n (i CAUTICU: Eaising the plug with the auxiliary hoist when the plug is fully or partially inserted will result in da: age to the plug. If the elevation of the plug is incorrect, use the actuating pole to I pull the plug away from the reactor pressure vessel wall. Care-fully raise the plus with the hoist and use the actuating pole to push on the plus while slowly lowering the hoist. I:=ediately ) q l
'; stop the hoist when the plug enters the stea= outlet nozzle.
Lo
; Push the plug into the nozzle until the 0-ring seal contacts the reactor u
pressure wall a nd hold the steam line plus in this position. T l Open the globe valve and pressurize the inflatable seal on the plug to
*a maxi =u= of 30 psig. The air pressurc =sy be reduced after the separator
*is re=oved. If the air pressure is re=oved from the inflatable seal, the
- main steam line drains should 'ce opened and a caution order issued to
;n
- control a.nd monitor leak.ase into the =ain stea= line. Tie the steam line
- y plug vent pipe off in the vertical position.
l NOTE: The steam line plu; vent pipe, with the air line and air hose, should
'l be closely parallel uith the reactor pressure vessel wall. Tie a J
suitable len;th of nylon rope to the h:ndle at the top of the vent l pipe, pass the line through the cable slot in the service platfor: D support en the reactor pressure vessel fl.anze, and tie the opposite end i of the line to one of the reactor pressure vessel studs to =aintain this position. D k'
*Refision - Q. I C "
Pcgm 27 BF PSG 10 10/25/77 . [] -U Performaneo of Ucrk (Continued) . ,
- 4. Installation of Steam Line Plugs (4 EA) (Continued)
U Installation Instructions (Continued) Free the steam line plug fro = the installation tool by using the actuating a pole and J-hock or L-hook to raise and disengage the two latches on the tool. Pull the tool away from the stes= line plug in a horizontal directien. Remove the cover from the vent pipe on the plug. p Follow the procedures established at Browns Ferry Nuclear Plant and
- establish a vacuum through the condenser with the mechanical vacuum pumps or draia the steam line of water; see Operating Instruction No. 1.
7 NOTE: Draining the steam line will cause a pressure differential across J the inflatable primary seal on the plug, and will cand to push the plug deeper into the reactor pressure vessel no::le, causing the secondary 0-ring seal to seat. When the square flange on the front ' i- of ,the plug is approximately.1/2-inch from the reacter pressure vessel wall, the 0-ring seal is seated.
.g At the hanger plate, disconnect the air supply, and use the globe valve to bleed all air from the inflatable seal on the plug.
At this point, the 0-ring seal is the only thing sealing the steam line. Verify that the leakage rate through the steam line is not greater than can be tolerated 'during the work period. To verify the leakage rate, perform the following steps. D 0 D l '
- Revision:
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Repeat the previous step:: to install the required number of steau line n.J Au,.lv.r.,.=. ,.. .,. . . o . .. . , .'. . e .^ . '... ~ s e .e '. ' .e . .k. . e ... ;i. ~ .'.. ' . = .e v. '. '. . . .~. . =..e . e. ' . ' . ' . = .
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Upon;cc pletion of the required stena line plug installation::, verify that
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1 the vent pipe covers are in place and that the air hoses are against the g th e .'o '. i. . . '..., e _ e , e . reactor prescurc vessel 1.all and restricted from novement. 9 -5. Removal of Shroud Head and Separator Assembly Removal Prerecci::ites F Stecn dryer assemb3 removed.
\
Servi sunnert installed. e
*Revirien: -
hlitt.O: '.-
. % ~~ ) !, 6 The fQel pool cates in place and the dryor coparator canal block:: re=oved and
(
- stored (rce lNI 2k) in the designated areas of the operat.ing floor. i n '
e 1 4 l
\
C* Page 29 EF ME 10 . 4 /29/74 Perfor- nnee of 'Jork (Continued)
- 5. Rc= oval of Shroud Ecad and Separator I,::ceably (Continued) .
Renoval Prercquiniter (Continued) WAE!II:0: P.ADIJ.T1::: H.'" died 4
- Fuel novenent in the fuel ctorage pool near the fuel pool cater must be suspended .hile the water level in the reactor well is
~ lovered to and maintained at the PEI flange level and work is in I e progress. The fuel pool gates have no chielding to prevent radio- ) active exposure of personnel in the reactor well. 1 Renovel Instructions 1
- j.
- NOTE: Four craftsmen, each with a chroud head bolt vrench (see figure no.10),
, are required on the cervice platform to perfom the follo ring step. , Position personnel at the 2 trapdoora and the two removal section platfom. w
- Unlock an'd completely loosen all 48 shroud head hold-dam bolts (see figure no. ' -
using the shroud head bolt vrench (figure 10). See Figure 11 NOTE for explanati. of locking and unlocking shroud head bolts. Complete data sheet mII-10-2 as bolts are loosened and unlocked. See figure 11A for bolt orientation. J With all hold-down bolts loosened, remove the service platform (cce step 5 on n J page 41) and place it on the opera +1rg floor usin,; the cranc and serrice platfo'.- 5 sling. m Li During the following step, the pneumatic control box =uct be held NOTE: i while the sling is transported. - L P Recet the dryer cnd separator cling ac cably turnbuckles to the follm ir-J gap for chro@ p. cad and ccparator handlinc. l t/ ( E
- Revision: .2 2 W j- .._ .
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Fip,ure Ii Shroud !! cad !!ald-Do.m l'olts
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. 4/9/73
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TI N . 7 sp.ouo Hua Hou.o-Da Ear Louma Dinsemi Fis oc.c ff A P%
q * . j .. P ga 33 BFbeE 10 10/25/77 f - ha Performance of Uork (Continued) . .
- 5. Removal of Shroud Head and Seoarator Assembiv (Continued) h Removal Instructions (Continued)
J Turnbuckle Bolt Cap BLUE (SET i RED (5'.O I CREEP C n ! ELLC*: r~ t1 U Unit 1 17 1/2" 17 9/16" 17 1/2" 17 3/S" m 17.419" 17.856" 17.982" 18.104" L Unit 2 J Unit 3 *17 1/2" *18 3/8" *18" *18 3/16" Record the turnbuckle bolt gap dimensions on the data sheet DE 10-1 on page 47. Connect the dryer-separator sling to the crane hook (see figure no. 3 on page 8.) ( Transport the sling over the reactor well. a Test operate the dryer-separator sling before making any connection to the asse=bly. j Manually guide the sling so that the bell-housings seat over the assc=bly lifting lugs. Connect the sling to the asse=bly lifting lugs by moving the sling control bay w control valve to the INSERT position to insert the four lifting pins through the bell-housings and lifting lugs. Verify that the pins have inserted through the bell-housings by observing line pressure on the four control box pressure gauges. . F
- CAUTIC:I: Lo not atte:pt to raise the separator unless all the hold do n 1
u bolts have been unlocked and verified ce data sheet 10-2. Raise the asse:bly s2fficiently to verify free nove:ent.
- Revision: & r b
e o', L . FacQ 34 DF IM 10 { ~ 4/9/73 7 Perfer:-ance of Uork (Continued)
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- 5. Remove.1 of Shroud Head und Separator Acce bly (Continued) m
. Removal In.struction:: (Continued) .s Flood the reactor vell and dryer-cerarator storece pit to the level of d the fuci storage peol.
NOTE: Tne following = top may be co .nenced " hen water han reached t_ point a approximatel'/ eig'it feet above the partition between the drycr-ceparator canal and the reactor voll. i Raise the chroud head an:1 separator ascembly out of the reactor vessel until a
'the bottom cd 6 e of the assembly is in pocition to clear the partitien of the u
' ~
dryer-ceparator canal. m id Trancport the ascc=bly under water to its storage arca in the dryer-repart. tor storage pit. y ... J 4 Lower the assc=bly onto the floor of the dryor-separator storage pit. Slachen the sling cable::. Disconnect the assembly from the drycr-ceparator sling by moving the control box control valve to I2 TRACT, check that the pressure cauges indicate zero pressure, l J Lift the cling, and verify that the sling hac dicencaged froa the accembly , D -lifting Jugs. Decontaminate sling by vashing down with domincrali:>ed vater i g prior to removing slins fron over the fuel pool. L
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i - . ..- ._. _ t l '
- 7. 7
'paic'35-
'* *sF Ifff 10 s
'1/9/73 4
Perfor :ence of Work (Continued)
~ a.
- 5. . Removal of shroud Head and separator Assenb1r (c6ntinued) l Removal Instructions (Continued)
Transport the dryer-cepsrator cling.to it: 6 tora;c area on the operatin-t
~
floor. 4, Disconnect the sling frca the crane- 1.oo'-i. -
,.c. :: :." :
I
- 6. Installation of shroud Head and separator Asce.:bly
.. .... .~ . - .
Installation prerecuisite: -- -"~~- -
'~
Reactor .tell and dryer-reparator storhe?pli:. flooded' to'the nor-al icvel of i the fuel storace pool. Fuel pool cates remove:i. s . I fj Jet pu=p inict/..tixer inctallation cor.pretM,~ i? 7 'p~pIica$le. a l Fuel asse.nbly installation complete, if appliceble. - k . . , . . . . . . , . ..:.---. -~ ** Dryer-separator canal plugs removed. i . . - q . ,:,. :- -: c .rt. ~r 2 *' - c. 0, Installation In=tructions Attach the dryer-separator sling to the reactor building crane 195 ton hook 1 . follodnc the precedure outlined in Stop 5.
} ... : ;.57, c- -. -4 ,
t ! Transport ..:e sling to the dryer-separator"sl.aorage ~p'it. N i l - s 1.1; a-
- 7. .- - -
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- BF E41 10 .
,y 4 /29/74 e
,Perfomince o f 'brh (Continued)
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lJ
- 6. Installation of Shroud !! cad and Separator Assembly (Continued) .
Installation Instructions (Continued) , .q t Louer the sling down into the drycr-separator pit and guide the sling so a that the four bell-housings seat over che separator asse=bly lif ting lugs. e Connect the sling to the assembly by moving the sifag control box control valve to the INSERT position to insert the four lifting pins through the bell-housings and lif ting lugs. Check that all four pressure gauges indi-cate line pressure.
- Verify that the shroud head bolt flats are properly oriented (see figure no. 11, page 31).
J
- Raise the. assembly approximately six feet above the storage pit floor L:- to clear the lower portion of the dryer-separator canal.
f9 b Transport the assembly through the dryer-separator canal and center it over the reactor vessel. Lower the assembly and manually rotate to align the tuo slotted pads on L the assc=bly with the two shroud held gu'ide rods in the reactor vessel. y With the guide rods captured by the two slotted pads, lower the assembly until
- it is properly scated on the upper shroud. The alignment pins on the assemblj engage the s roud during the last feu inches of travel.
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- Revision: '
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J. . . . . . . . . .
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B Page 37 m BF DiI 10 a 11/5/75 n Perforr.ance of k'ork (Continued)
- 6. Installation of Shroud Head and Separator Assembly (Continued)
Installation Instructions (Continued) *
, Disconnect the dryer-separator sling from the assembly by moving the sling j
J control box control valve to the EXTPACT position. Lift the sling and verify that it has disengaged 'from the separator asse=bly lifting lugs. Raise the sling out of the reactor vessel. Install the fuel pool gates. Lower water level one foot below the teactor' pressure vessel flange. !
'nstall the service platfor= with jib crane removed (see step 3 of this l instruction), Use main building crane 5 ton hook.
J
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Tighten and lock all 48' shroud head hold-down bol'ts (see figure no. 11 on page 31) using the shroud head bolt wrench (see figure no. 10 on page 30).
- Torque shroud head bolt nuts to 50 ft./lbs. plus only an amount necessary to insure the next engage =ent position of spring loaded retainer on nut, 0
(see figure no.113 on page 37A for proper' retainer position). Insure that
=
I
.J spring loaded retainer has secured the shoud head bolt nut by atte=pting to loosen nut. Complete data sheet 51I-10-2 as bolts are tightened and locked. See figure 11 NOTE for explanatio of locking and unlocking shroud q head bolts. See figure 11A for bolt orientation. A QC inspector cust y make appropriate verification on data sheet mil-10-2.
m 7. Removal of Steam Line Plues(4 each) L .L . With the reactor water level below the_ reactor pressure vessel flange, and the service platform acd the service platform support installe'd on the
- Revision: 3 .-
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- Page 37A l .
BF P.MI 10 i p l . 1/6/75
. SHROUD HEAD
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Page 33 BFICH 10 l 4/9/73 h-L Forfo m ance of York (Continued)
- 7. Eenoval of stee., Line pluce (4 each) (Continued)
Ee.moval Inntruction: Stem Line plu:- (Continued) reactor prcucure vesrcl flange, rotate the service platfor.; :o that the corner opening is positioned to pez=it re . oval of the stcas line plu m ' (refer to Figure 9). a Rc=ove the cap fro:n the stec.m line plu6 vent pipe. O With the stc= line plug installation tool c.ttached to the 5 ton hoist, a operate the hoict r.s required to cuspend the installation tool through the service platfom corner opening in:cdiately in front of the stec:a line plus vent pipo. Veri _^/ that the tool latches are open. liinually orient the tool co that the two' blocks at the bottom of the tool n'
,i U .
frame are inserted into the front of the stcca line plus, and the plv; vent pipe is installed into the vertical channel of the tool frane (refer to Fi6ure 8). Close the two latches on the tool to hold the vent pipe in place. 1 Open the hr.nger plate globe valve end fully vent the prinary coal, p Disconnect the air supply connector at the top of the vent pipe. U
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. rs .j . PQce 39 BF K4I 10 .l - 4/9/73 Ferfor'tence of Uork (Continued) J
- 7. Re= oval of Stenn Line Fluce (h each) (Continued)
Re oval In::tructionn Ste,n Linct P".in (Continued)
" Gather up the cir hece end coil it at the hancer plate for storage, and ~
i untic the vent pip 2. NOTE: The follouing ctop:: chould be perfomed with a technician on the a service platfem , standing straight in line with the stecr. ifne J plug to be removed. l J Using extreme care, opere.te the 5 ton hoist in the dqi; tode to lift the tool. As soon as the tool starts to lift the plus, stop the hoist, s - n L2 While lechnce acrocs the secondary 0-ring seal fills the steam line, engacc the actuating polc vith a suitable J-hook or L-hook attach =ent. NOTE: The steam line plug vill be recting freely in the reactor pres:ure vessel noz::lc when the steam line is conpletely filled with rater. The leakage can be increa:ed by manually manipulating the vent pipe 0 - IJ to unceat the 0-ring seal. If conditions permit and radiation levels p are closely monitored, the reactor Vater level may be louered to the J 1evel of the steam line p1'ucs, the pluce removed, and the steam lines refilled as the reactor water levc' is broucht back up to just below the reactor pressure vessel D nge.
;*.ove the 5 ton hoist hori: ontally and ::imultancoucly u::e the actuating pole to pull the plus out of the reactor pressure ve::sel nozzle.
J .
. o. Ticac-40 IW ::.:n:10 1
- k
' /.9/73 J &
Phfomance
~~nn -
-of* Wd, : ~(Continue.4)
I. Ec:aovel:o*@enn.J4ne :pitr2:: '(4 -eaeli) /(Continued) ' Eenove.1 In.,ctuteticn 'Ste:. rLine ~Pl'.m (~Centir.neli) ~ Cen,:t!;c pir; .b crpletely .f.Yco cf .the no.:clu .and vert'icnl clearr.nce 10 a assure $,-riisengete inc actucting pole cud, ucins the c'.n:iliary noist, lift 7 i the aten t li.:A pluc straight. up T.rd throur.,h .the :o: en carner. of "i.hc cerrice a pl .tfo19.ad. . cut.cof the reac!; orc r_ . 12. . ...:m :- . u ... 1 i Transport the stcrr.1 line plus to a decont:::ination arca and reaove the J inste.1).ati.o.r; t toL. . c . ; . .: 5 :::. .:ir. it. - l :- . : d .- : : h. . 2:L:Tr: :: :* .:.s pL.: . . :- '.c :.:i: . . j -. i.: cc: c:. .:. ?- . s Ecpeat preceding steps as recuired to rezove the rc..:ainin; etcc 2 line plu.;n. L. .
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F ncn,all..ctee.:t ?ine-pluce hym b ten f .rpr.oved cad.htcarper.ted..tt), t'.e deccpta:.ip sion e;rea, clean .t.ad dry. .thp:.s in ,pr.qnr.atio t- for. torcse.- . a v e r el n r r:<. . . r- ft.: :. . t "- 1P. 5 c:n-21 . 2: - fil l:." ?i ". * -- r.
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Storanc .a let : .,- . c_n n In::e:.pf; t; -
.11, - ._ . : ; i . :
Tne cteg:62 Mmluce nr.ecstorp:I.in r copl,.Mryc.2.rer to extenfrinc;11fc' of i. the rubber fas! npoprec.c. parls.:..Ihe2sica;; lintrp11:cf.cre :itorbd ::ith the ent pipe coyer 30.se nbly instal 15:d, mid resting bn-the. ::quate fitnge and tha guard. The henrerglgtc.tr.f.are placed f.ey:t;.tp the pIly;s. .; rr u::: r- -- CAUTIN!.:.::The pri27.ry peal shev1& be presn:rined ::c.fficiently to prevent c'.arp crea::cs in the rutber scal. Tne sc tl is inflated by conncetin; nort'- tir:2.to tho;isic,t:r$rir ofilhe.clobt v}.1te: o .,1te:hant;cr plaw,3.no
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_s to p.:ppctring;-th,e globervclyettn. t il-the.pri-. arf: scal ds-dhfic.tod to the size of the guard (sce Ficure 7). Close the globe valve at this n point and di:: connect the service air line. Place a plug in tv.c
- inlet cide of the globe valve to keep cut forcicn natter.
.. . . _ . .. . .... . . . . . . _ ~ _ . . _ . .
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PaGa 41 BF 'OE 10
- 0 . 4/9/73 i Perfomence of ',7orlt (Continued)
- 8. P.caoval of Service Platfo m .
- 0 Thoroughly in
- pect the sertice platfom to confim that all cc:nponents 1 + are =ccurely factoned and loose parts are recoved froc the pictform.
. .} - .llW Disconnect the certice platfom poner supply pluc. O Connect the service platfom sling to the reactor building crane (125 ton hook). Move crane over reactor ve::cl and lover slinc to position over platfom. s i. L Connect cling to the certice ple.tfo m lifting brackets (3). D Carefully lift sertice platfom from the pictfom cupport rails to a !a height of one foot above rail. Inspect certice platfom to a:sure that w there are no connections that would prevent the lift of the platfor=. Continue lift until platfom has c1 cared all obstructions and then Il transport the platfom to the proper ntorage area on the refuelins floor g (see GE Duc. 719rso7 for location cf storc;e area). Lover pintfom to its storage area, remove sling from both the platfo m and the crane. 0 l l Store lifting cling and platfom auxiliarf aquipment. ! l0 1 D
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bd Pcgs 42 BF ltMI 10 7 9/28/76 J .
. Performnce of Work (Continued)
- 9. Instal'1ation of Steam Dryer As:sembly 0 Installation Prerecuisites The shroud head and separator assembly installed.
]
J t The dryer-separator pit and reactor well drained, i J Steam line plugs removed (if previously installed). Service platform remeved (if previously installed). m Installation Instructions a ' Reset the dryer-separator sling assembly turnbuckle to the following gap for the Steam Dryer Asse=bly. 7 YELLG: C; Turnbuckle Bolt Gap BLUE (SE) ' RED (53 GREE'I C7.0 Unit i 17 1/2" 17 9/16" 17 1/2" 17 3/8" 7 d Unit 2 17.419" 17.856" 17.982" 18.10?." Unit 3 *17 1/2" *18 3/8" *18" *18 3/16" Attach the dryer-separator sling to the reactor hsilding crane 125 ton hook. -fJ With technician holding the sling control box, pcsition the sling over the dryer assembly. Test operate the dryer-separator sling before making any connections to the i dryer assembly.
- Revision:
a 9 W
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Face 43 BFffE 10 0;. 4/9/73 perforaance of l'ork (Continued) 9 Inntallation of steam tryer Acceably (Continued) . Inetallatio1 I".r.truction (Continued)
-- Verify that the centrol box control valve is. in the I"CFACT position and that the four lifting pins on the sling are retrected out of the bell-housinc.
r L Lover the sling Co..a into the dryer-separator pit and manually guide clinc a so that the four bell-housings cest over the steam dryer accer.bly lifting lugs. .D 'bb Connect sling to the dryer ascenbly by noving the control box control valve to the I:*5 2 T po ition to insert the fo r liftinc pins through the bell 2 J houtings and lifting lugs. D Verify that the pins have inserted through the tell-housings. D . Raise the dryer assenbly approximately 6 feet off the floor of the dryer-separator pit. 0 Transport the dryer ascenbly through the dryer-separator canal and center it over the reactor rell. Louer the dryer asceably vr.til the lo:cr edG e of the dryer shirt is lerel with the RTV flanse.
!& nun 11y align the dryer as.sc. ably so that the tuo croove: 180 degrccu sinrt on the drycr-separator sling are alir.ned vith the shroud head r;uide rods in the reactor vecccl.- Lofer the dryer asse bly into pince.
w . .. . . . p Tete W 17 !'.11 10 bl9ll.5 9 Ferro.mr:r.cn of !!ork- (Continted) u 9 Inctn110:icn of :P.cau tryer Assembly (continued) , m w i Installt.ticn Inr:treeticnc (Continued) Dispoanect the c.1.ing. tTon the; dryer netw.ily by : ovin; the clics control q bo:e c9;)prol. val.:o. to the DTFACT:porition;. verify tMt the. pics; nave . retracted thrcuc.1 the bell-hour.,ings. .w Lift. the clin 6, n;@ verify that the clirc ha:: disengage.d from the dryer ass,r.blye lifting lugs. Tr.an6 pert;the clitc;.to -its storack. e.re* and .diteugace- it.frov. the.s:rrno. - hoch ."~'~ - ri .Or. .: . .. r ,.. .':. r 1..' ..,, -17.- .: - ,- .L : .. .'
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D 10. Ec 2cycli.p-f.Eervice Flat <fo: i Support Loose:1,the clenpS t?.at ceCbre the Support to the veG el.
. ; ;. - - . .. . . ,, . ,; ., . 7. - ; .. . ... ,.... . . , -, g. ,. 2.
Regoce, po.nr.ectin; bp.its and secure the capture scrers, f i i Congeet- the. service:phtforn ;upport- stroccback, to the: cranc .,5; ton-hook.- . 1 1 l
. . . . <.. . . ~ . . . .
Lover the stroncback to a position adjacent to a platform support sci- ent, athluo ri,ont:,the otrop beckcto: the; ccc/.tcni.. 4...: =;v,.1 < rc e<.: 10.? de.- c - rt
*in t he Cr^ r- r - - r: . :: t '.: - c.re all " . . - ' ' th: rSto- - '.t riluiCL : +
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'n: rw :r te: vc- t1. i :ct?
- he t'r.v: - .rre : 1: ' .ai o I c cr .
D . Face h5
- BF tr I 10 4/9/73 Perfor.w.ce of t'ork (Continue 1)
- 10. Ec:aoval of Service Platfc1= Support
- Turn the strongbach and place it on the cupport sciaent alicning the tch on the cep:ent with the clots in the stro-.gback.
Insert bell-loch pine through each of the slot: in the strongbac% to engate the hole in the platfor:a seF;: cat t;b (see figure no.1, on pere 5).
~
NOTE: Tae platfc:a cupport scgnent in transported in the horicontal pocition ifnen properly positioned relative to the stroncback. I Transport the platfor:a cupport sognent to the ctorage crea. (See GE laydown drawing, dt.c. no. 719E307). y g Lover support seg.:ent and dicconnect the stronsbach fron the cepent and retrieve another e n::ent. l When all segraents have been removed and prior to storage, the seg=ents should be thoroughly cleaned and inspected for = cars, dents or protective cover l deterioration that would damage the vessel flange surface. Repair or replace as required.
~l Post h*ork Reenirenents Drain Dryer-Separntor pi' (if full of water).
I Deconte.minate Drycr-Separator pit, obtain releace fro Ecalth Physics rection.
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4
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O It. Page 46 4 DF l"'1 10 hlo, ftn-
's 4
Pont Ucrh F:T d rcr.c: t ( cr. cinued) {4 In tall Erycr-30pirator Cr.nal Bloct: , cee :C" Eh. ' 1: O Decontar.in;ic re:etor 1.cll, all tools e.n?. e pi, c.:t ured in the afore; oir.c ll instruction, cnd obtsin release frc? Healt'.; 7.:ynic: section. 4 II w Ec: ove or st:re in the uronar place all tools and equir.:ent used in the operation. 1
'4 f, Release " Hold" order with shift engineer.
4 h s
; Cor.plete date. cheetc or =2he vrit t e. repcrt cozering the operation.
8
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,s Drycr and f,crerator Elim Turnbuchle Cr.3 "ca.T.:re nent gi' Incocction Decry tine the drycr-:.cMrr.tcr stronc.back ,in connected to the dryer-sc :r.rator sling the turnbue?:le cap rhould bc ::easured and recor: led belev after the unit ht.s been" levelcd. r ,,, . g I i
- Turnbuckle Bolt Ca.p 1__L, Ih. g.ie. w.2 _._. ._t:. _- .__' .J. C.
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_ _i-- <z .i ,. , f . - s ' _- n'- (? 'icr.~-eter Te$ d3 n. in h';ndrc .'.s ,.- Dryc:>. 7,101. ~~ g, . 1 4 Unit 1 '.'-r - .?or ;.iet-
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Insp0ct the cli::c points linted bele. : Satisfactory Yes to L' ire cable ropes (check for broken, frcyed, etc. strras) Cable eyes (check for tent, cracked, bro %cn cycs) 1 Cable cicvis c.nd clevis pin:: (check for ite-ts t.s as above)
] Tarat. enlos (c..eex foe tdrc .i coa.u t, ion, t:ut ,
crac::ed, etc.) __ --_
" Revision: ;/ _ 7'~
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.4 I
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g a. Face h6 n 3F !ct ic U 11/5/75 Data Sheet lC!I 10-1 (Continued) Co=:ents: f:. b D Approval Sirnatures 1 Cate (;-erson Loing :no inspection tr.:i ;2e.surint:) n :e
.i w (. cre:.an)
(:.:aintenance Supervisor) D
- Trouble Report Nu=ber -
D D D . D
- Revision:. < / ), /
4 a[ __ ( _ ... .
Pasa 49 g BF MMI 10 Q - 10/25/77 m, TEI.7iESSE: VALLE.* AU'""40EIN
'- BRC; INS EERY TUCLEAR PLAI.T SHECUD EAD HOLD-LC'.it 30LT LOCE;G A?;D U!iLOCC;G DATA SELT !M 10-2 t*- iO. DATE s
Lockea Unlockea Locked Unicef.c: 1 Position Position Position Position
- Q J q ] % J l $,, . +.7 C h *QC 3oit h *QC h +;;
e Check iIns:ectorl Check lIncrector l ::cleer Check iInstector Check I:nser 25. p 26. i u
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- 27. l
- 28. !
s -) , 29 j _ 30.
,, 31.
32. 4 I4 l., 33. 34 ii 35. l ' I. i, 36. 1 o, 37. i, 38.
- i. 39
) i 40.
1, 41. __ i t. h2. __
.,, 43.
h4 45.
- 46. -
- 47. -
48. O M
- Verification that the shroud head bolts are torqued to 50 ft.-lb.
QC Inspector Date
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/D !ECEICAL 2.*AE TE /J:C3 E!STRUCIC?i 24 REIOVAL K;D FIFLACRZiT, 72AC"tR LEL SHIELD PLUGS, DRm-S!?ARATOR FIT CE!AL ELOCi2 /C;D FUEL FOCL CXT/J. ELCC13 0 VUIil" 1, 2, OR 3 0
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BF MMI 24 s ,, S/6/74 TABLE OF CONTENTS
, Page No.
J Purpose
- ------------------------------------------------------- 1
.- s Re ferences ---------------------------------------------------- 1 J ,
Prerequisites ------------------------------------------------- 1 Reactor Well Shield Plugs ------------------------------------- 1 Description ---------------------------------------------- 1 0 Plug Re= oval --------------------------------------------- 2 Figure No. 1, Upper Level Plugs -------------------------- 3 ) Figure No. 2, Lower Level Plugs -------------------------- 5 Plug Replace =ent ----------------------------------------- '4 Dryer-Separator Canal Blocks ---------------------------------- 6 Description ---------------------------------------------- 6 l
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9 1 i Block Removal -------------------------------------------- 6 J , Block Replacement ---------,------------------------------ 8 figure No. 3, Canal blocks ------------------------------- 7 Fuel Pool Canal Blatks -- ------------------------------------- 9 0- Description ---------------------------------------------- 9 Block Removal -------------------------------------------- 9 Block Replacement -- ------------------------------------- 9 1 i J 11 Figure No. 4, Canal Blocks ------------------------------- l l Post Work Requirements ---------------------------------------- 10 l Data Sheet MMI 24-1 ------------------------------------------- 12 O e.' Data Sheet MMI 24-2 ------------------------------------------- 14 l ,. . e 9 ! e e
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P:ge 1 BE FCil 24 h 3/16/76 TENNESSEE VALLEY AUTHORITY ' q BROWNS FERRY UUCLr.AR PIRIT FECHANICAL PAINTE::ANCE I::STRUCTION 24
*IIITC 1, 2, C..3 REMOVAL AND REPL\ CEMENT, REACT 02 WELL SHIELD PLUGS, DRYER-SEPARATOR PIT CANAL ] BLOCKS AND FUEL POOL CANAL BLOCKS F
Purpose a To specify the sequence and method of removal and replacement of the reactor well shield plugs, the dryer-separator pit canal blocks and the fuel pool canal blocks. References
, 1. TVA Drawing No. 485934
- 2. TVA Drawing No. 48M966
- 3. IVA Drawing No. 48N967
- 4. TVA Drawing No. 44N334 7
j 5. General Electric Drawing No. 719E507 (laydown drawing) q Prereaufsites lJ
- 1. Notify shift engineer prior to any work being done on plugs or blocks.
- 2. Obtain radiological survey of area prior to start to determine conditions and protective requirements.
, 3. Reactor building overhead crane must be operable, n 4. Reactor must be in the refuel or shutdown mode.
'S. The dryer-separator shield plugs shall not be removed or inserted unless (1) the n
u drywell head is on the drywell, or (2) all of the fuel is removed from the l I reactor preusure vessel and stored in the fuel pool with the fuel pool water tight gates in place isolating the spent fuel pool from the reactor well. . 6. The transportation of the dryer-separator shield plugs over an open reacter pressure vessel with or without fuel in the vessel is prohibited.
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P:st 2 BF MMI 24 12/23/75 Reactor tiell Shield Plu:.s (Continued) Desc ri p tion (Continued) the refueling floor. There are two leve of plugs, an upper level and a lower 1cvel. Each plug level is made up .I a three (3) s q,r.cnt plug. The D b plug sepents are numbered, with sepent: ' . , 2, and 3 makin;; up the upper level, while segments 4, 5, and 6 eake up the le .r level. The ic,wer level has the plug seaan rotated 30 CC'.J from the upper les. . seams; this prevents radiation from
*eseqing thru the sea:ns. Large lifting ; e are provided ,fcr underwater attach-ment to the plugs.
Plur Pemoval Connect the shield plug removal sling "G' 'crk 13 to the ove'rhead crane (125 con hook) and to the four (4) lifting device f the upper ' level plug sepent no. 1. See figure no. 1 on page no. 3. Slo.:1y lift plug, usic , caut!.on, to a Lc t that will clea. all obstructions. Transport plug sepent to the northwest - 2e of the dryer-reparator pit (see GE drawing no. 719E507-laydown drawing, : the exact location). 9 f1 b Carefully lower plug segment to the floc evel and unhook rl.ing from plug secccat. Position crane over plug segment no. 2 c- hook crane sling to lifting devices I of plug no. 2. j Slor y lift plug, using caution, to a he. .c that will clear all obstructions.
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Page 4 I BF M'il 24 fl 7/22/72 y . 4 Plun Renoval (Continued)
- a
- Transport plug scgnent to the southwest side of the dryer-separator pit (see
- GE drawing :0. 719E507 laydoun drawing, for exact location). The area of the C concrete flocr en t';ich the plugs will rest should have 4" x 6" continuous eacdon L Carefullj louer cribbing, covered with 3/4" plywood; or an equivalent cribbing.
F plug segment to the floor level and unhock sling from plug segment. 1 Continue the removal of plugs in numerical order until all six plug segnents are removed and stcred in the proper storage area. Straight plug segments are stored on the refuel.ing fleer on the northwest side of the dryer-separatcr pit, s. tile tha r1 ! curved segments are stored on the southwest side of the dryer-separater pit (see t
! GE drawing ::o. 719E507 laydewn drauing, for exact location). See figure :o. 2 r,
i :for lower level plugs. o.4 NOTE: Plugs must be rc=oved in numerical sequence 1, 2, 3, 4, 5, 6 and data sheet IO I 24-1 ccepicted. [ L Plue Reclacement Position cranc over curved plug segment storage area. Connect the shield plus sling to the overhead cranc (125 ton hook) and to the four (4) lif ting devices of plug segment :so. 6. 1 l Lift plug seg cnt, using caution, to a height that vill clear all obstructiens. Transport plug segment to a position over the reactor well. i l 1 1 a
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; Page 6 BF ?MI 24 l 7/22/75
' Plun ReplacerenJ (Continued).
Lower plug segment and manually guide segment to the proper location as shown in figure No. 2 on page 5. Continue plug replacenent in reverse numerical crder until all plug seg=ents are in their proper location and orientatica is correct. (See figure I:o.1
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for upper level plugs c.nd figure No. 2 for lo :cr level plugs.) NOTE: Plug scgnent replacement sequence is 6, 5, 4, 3, 2, and 1. Assure that 0 plug regnents are fitted together properly. Co=plcce data sheet :01124-2. Drver-Separator Canal Blocks
! Description 1he drycr-separator pit and the r eactor well are divided by a recavable block I
ivall . The wall censists of four (4) stacked blocks that are fitted together by the tongue and groove ecthod. Each block is fabricated fro: mild steel plate and then filled with concrete.
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The blocks have permanent lifting lugs fabri-
, cated into the blocks.
l Block Renoval Connect the shield plug sling "G" Mark 13 to the overhead cranc (125 ton hook) and to the four (4) lif ting devices of block "A". See figure No. 3 on pa;c 7.
' lowly lift block, using caution, to a height of 6 feet above the floor 1-. vel.
Transport block to the proper laydown area (see GE drawing No. 719E507 laydo.en drawing, for the exact locatica).
. 'Tue area of thi concrete flocr on which the blocks vill res: sheald have 1" .6"
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Page 8 BF FefI 24 6/6/75 Block Removal (Continued) Carefully lower block to the floor and unhook sling from block. I 3' Continue the operation until all blocks are removed and stored in the proper storage area. NOT": Blocks must be removed in alphabetical sequence A, B, C, and D. Complete data sheet FD1I 24-1 k Block Replacement h
- NOTE: See prerequisite no. 5.
Position crane over block "D" and hook shield plug sling
"G" Ffark 13 to the overhead crane (125 tone hook) and to the four (4) lifting devices on block "D".
I 1
't Lift block, using caution, to a height of 6 feet above the floor level.
(4 1, Transport block to a position over the curb between the reactor well and l dryer-separator pit. ' Lower block and manually guide block to the proper location as shown in figure no. 3 on page 7. 0 Continae the operation until all blocks are in place, as shown in figure no. 3. HQIL- Block replacement sequence is D, C, B, and A. Assure that blocks are properly fitted together. Complete data sheet FSII 24-2. y _ e
Page 9 EF 10:124 Q 7/22/75
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Fuel Pool canal Blocks Description _ The The fuel pool and the reacter well are divided by a renovable block wall.
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wall consists of four (4) stacked blocks that are fitted together by the tengue a and groove tethed. Each bloch is fabricated fren mild steci plate and then
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filled with concrete. The blocks have permanent lifting lugs fabricated into the blocks. Bloch Renoval 9 i
,. ,' Connect the thic1d plug sling "F" :: ark 14 to the overhead crane (125 ton hock) l and to the four (4) lif ting devices of block "E". See figure I;o. 4 on page 11.
! Slowly lif t block, using caution, to a height of 6 feet above the floor IcVel, e
- Transport block to the proper laydown area (see GE drawing ?o. 719E507 laydewn drawing, for exact location). The area of the concrete floor on which the blocks
'will rest should have 4" x 6" continuous wooden cribbing covered with 2/4" plywood, or an equivalent cribbing. Carefully louer block to the floor and unhook sling frem block. Continue the operation until all blocks are renoved hndstoredintheproperstoragearea.
NOTE: Blocks cust be removed in alphabetical sequence E, F, G and H. Cer:ple te data sheet 1011 24 - 1. O . Block Reolaccnent Position cranc over block "H" and hook shield plug sling "F" Mark 14 to ti-c everhead crans (125 ton hook) and to the four (L)1if ting devices on bicck "h. Lif t block, ustra caution, to a height of 6 feet above the flocr icvel. .rres-port block to a position ever the curb between the reactor well and fuel ncal
. area. Lower bleek and :nually cuide block into the prc: cr location. Ce : . ; :ue the operation Y l
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.,* SF MMI 24 f - 5/6/74 J -
Block Replacement
']L (Continued) until all blocks are in place, as shown in figure no. 4.
rt [] NOTE: Block replacement sequence is H, G, F, and E. Assure that blocks are _. .-. properly fitted together. Complete data sheet MMI 24-2. F t . F . lw Post Work Recuirements . m Store shield plug sling in its sling storage area, a Notify shif t engineer when work is completed. , s n i e W ( p . lJ . t*. D .- 0 - 3 J n M n , >- L
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