ML20027B523
| ML20027B523 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 09/15/1982 |
| From: | Davidson D CLEVELAND ELECTRIC ILLUMINATING CO. |
| To: | Schwencer A Office of Nuclear Reactor Regulation |
| References | |
| REF-GTECI-A-36, REF-GTECI-SF, RTR-NUREG-0612, TASK-A-36, TASK-OR NUDOCS 8209210202 | |
| Download: ML20027B523 (100) | |
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u ii P o DoX 5000 - CLEVELAND. oHlo 44101 - TEL EPHONE (216) 622-9800 - tLLUMINATING BLDG - 55 PUBLIC SoVARE Serving The Best Location in the Nation Dilwyn R. Davidson Nsf [Ic$ctnino Ano CONSTRUCTION Se tember 15,1982 Mr. A. Schwencer, Chief Licensing Branch No. 2 Division of Licensing U. S. Nuclear Regulatory Commission Washington, D. C.
20555 Perry Nuclear Power Plant Docket Nos. 50-440; 50-441 Response to Draf t Technical Evaluation Report--Control of Heavy Loads (NUREG-0612)
Dear Mr. Schwencer:
This letter and its attachment provides responses to the recommendations in the draf t technical evaluation report, " Control of Heavy Loads," and the concerns raised in an August 11, 1982, conference call between CEI, the NRC staff and Idaho National Engineering Laboratory (INEL). These responses address the re-commendations of INEL in the draf t technical evaluation report dated May 1982.
It is CEl's present position to be in full compliance with the guidelines of NUREG-0612 prior to fuel load.
We believe this information will resolve the open items and provide the basis for the NRC safety evaluation report on this subject.
If you have any questions, please let me know.
Very truly yours, Dalwyn 1. Davidson Vice President System Engineering and Construction DRD:mb cc: Jay Silberg, Esq.
QN John Stefano Max Gildner Nick Fioravante Fred Clemenson 820921oO_od-6 l
- y.. 0 GUIDELINE RECOMMENDATION
- 1) Safeload Paths a) Load paths should be clearly marked on the floor (Section 2.3.1) in the areas where the load is to be handled.
b) Analyze and justify alternate load paths.
c) Maintain analysis and criteria used for hazard elimination available for review.
RESPONSE
a) The load path will be clearly marked on the floor in the area where the load is to be handled and appropriate procedures will be implemented, b) No alternate load paths are presently defined in the Perry Equipment Removal scheme; however it is currently under evaluation. The Plant Operations Review committee will designate individuals authorized to approve procedural variations, typically the maintenance or shif t supervisors.
c) The analysis and criteria used for hazard elimination will be maintained on file and available for review. Also the PNPP Equipment Removal scheme and Special Handling / Safe Load Path procedures will be maintained on file and available for review.
1 GUIDELINE RECOMMENDATION
- 2. Load Handling Procedure Load handling procedures should be submitted for (Section 2.3.2) review. This should include further information on whether the cranes are employed to lift the loads onto or off the dollies, and on whether the cranes are employed as mechanical mules to move the loaded dollies.
RESPONSF.
The load handling procedures are being written and will be open for revie;/ on site when they are complete. Attached is a draft copy of Control of Heavy Loads procedures, MAP-1301. Additional procedures on crane operating guidelines, and guidelines for rigging are provided for your information. Dollies are not used in the movement of heavy loads.
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OMIC: MAP-1301 Page:
1 Rev.: 0 THE CLEVEIAND ELECTRIC ILLUMINATING COMPANY PERRY NUCLEAR POWER PLANT OPERATIONS MANUAL TITLE:
CONTROL OF HEAVY LOADS REVISION O
EFFECTIVE DATE JBA J
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- PREPARED:
J. P. Goecker SUBMITTED:
PERRY PLANT DEPARTMENT REVIEWED:
NUCLEAR Q.A. DEPARIMENT PORC REVIEW AND RECOMMENDATION FOR APPROVAL MEETING NUMBER:
APPROVED:
MANAGER - PERRY PLANT DEPARTMENT APPROVED:
MANAGER - NUCLEAR Q.A. DEPARTMENT
OMIC: MAP-1301 Page: 11 Rev.:
0, Draft 3 Control of Heavy Loads MAP-1301 Table of Contents Section Title Pjype 1.0 PURPOSE 1
2.0 SCOPE 1
3.0 RESPONSIBILITIES 1
4.0 REFERENCES
1 5.0 DEFINITIONS 2
5.1 Category A Load 2
5.2 Category B Load 2
5.3 Category B Load 2
5.4 Heavy Load 2
5.5 Safe Load Path 2
6.0 DETAILS 3
6.1 General 3
6.2 Precautions 4
6.3 Handling of Category A Equipment 5
6.4 Handling of Category B Equipment 6
6.5 Handling of Category C Equipment 6
6.6 Special Requirements for Loads Handled in the 6
Steam Tunnel 6.7 Special Requirements for Loads Handled in the 7
Emergency Service Water Pump House 6.8 Special Requirements for Handling the Portable 7
Refueling Shields (1 & 2F15E0010) 6.9 Records 7
7.0 ATTACHMENTS 7
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OMIC: MAP-1301 Page:
1 Rev.:
0, Draft 3 1.0 PURPOSE 2
- To provide controls for movement of " Heavy Loads" over or near safe
'f shutdown equipment, such that possible failure of lif ting devices will have a minimal effect on plant safety.
2.0 SCOPE This ibstruction applies to the handling and movement of safety related equipment and heavy loads (greater than 1048f) in the vicinity of safe shutdown equipment. In addition it specifically addresses those load movements requiring administrative procedure control as identified in the Summary Conclusions of the PNPP Control of Heavy Loads Study.
3.0 RESPONSIBILITY j
3.1 The General Supervisor Maintenance Section has the overall respon-sibility for ensuring that the guidelines of this procedure are followed. He shall ensure that Maintenance Section Personnel fully understand their responsibilities.
3.2 The Maintenance Section Operations Engineers and Supervisors have the responsibility of ensuring that the requirements of this proce-dure are adhered to.
When necessary they shall provide guidance to the personnel performing the work.
3.3 The Maintenance Planners and Associate Maintenance Planners have the responsibility of ensuring that the requirements of this proce-dure are incorporated in work packages as applicable.
3.4 All Maintenance Section personnel are responsible for ensuring that the requirements of this procedure are followed when necessary.
When the safety of a load handling event is in question or the requirements of this procedure may be violated, load movement shall be suspended until the problem is resolved.
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4.0 REFERENCES
4.1 ANSI /ASME N45.2.15-1981 Hoisting, Rigging and Transporting of Itens for Nuclear Power Plants.
3 4.2 Control of Heavy Loads Study - Perry Nuclear Power Plant Units 1 & 2; CAI Report No. 2329; Docket Nos. 50-440, 50-441.
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a OMIC: MAP-1301 Page: 2 Rev.:
0, Draft 3 4.3 Equipment Removal Scheme - Perry Nuclear Power Plant Units 1 & 2.
4.4 PNPP Ops. Manual Chap. OM9A:GMI-004 Guidelines for Rigging.
4.5 NUREG-0612 Control of Heavy Loads at Nuclear Power Plants.
4.6 Perry Nuclear Power Plant FSAR.
4.7 ANSI N14.6-1978 Standards for Special Lifting Devices...
4.8 ANSI B30.9-1971 Slings 5.0 DEFINITIONS 5.1 Category A Load A load which requires special lif ting equipment and detailed handling procedures because of large size and weight.
Shall include but not be limited to: Reactor Vessel, Major Reactor Vessel Components, Spent Fuel Casks and other subassemblies of large size and weight.
5.2 Category B Load A load which may be handled with conventional equipment, but requires special procedures because of susceptibility to damage.
Shall include but not be limited to:
Reactor Vessel Head, Recir-culation Pumps and Internals and Safety-related instrument cabinets and control boards.
5,3 Category C Load A load which may be handled with conventional equipment using sound rigging practices. The requirements of OH9A:
GMI-004 " Guidelines for Rigging shall be followed.
5.4 Heavy Load Any load carried in a given area af ter the plant becomes operational that weighs more than the combined weight of a single spent fuel assembly and its associated handling tool. (1048#)
5.5 Safe Load Path A path defined for transport of a heavy load that will minimize adverse effects, if the load is dropped, in terms of releases of radioactive material and damage to safety systems. This path should be administratively controlled by procedures and/or clearly outlined by markings on the floor where the load is to be handled. It may also be enforced by mechanical stops and/or electrical interlocks.
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OMIC: MAP-1301 Page: 3 Rev.:
0, Draft 3 6.0 DETAILS 6.1 General
- 6. l.1 Perry Nuclear Power Plant equipment arrangements in general have been designed to minimize damage due to drops of heavy loads.
By strict adherence to the load handling practices outlined in this instruction, the following criteria of NUREG-0612 " Control of Heavy loads at Nuclear Power Plants" will be satisfied:
1.
Releases of radioactive material resulting from damage s
to spent fuel due to the accidental drop of a heavy load will not produce doses in excess of the limits of 10 CFR part 100.
2.
Damage to the Reactor Vessel or spent fuel pool following accidental dropping of a heavy load will be limited so as not to result in water leakage that would uncover the fuel.
3.
Damage to equipment in redundant or dual safe shutdovu paths from the accidental dropping of a heavy load will be limited so as not to result in the loss of required safe shutdown functions.
6.1.2 Safe load paths have been established for most Perry Plant equipment. These paths are shown in the Perry Plant Equipment Removal Scheme and the Perry Plant Control of Heavy Loads Study.
Those areas of the plant housing fuel or safe shutdown equip-ment have been evaluated and found free of hazards due to heavy loads as defined by NUREG-0612 except for:
1.
Steam Tunnel - loads may be lif ted in the Steam Tunnel only during cold shutdown. This restriction is necessary since damage to both the Main Steam and Feedwater lines could occur simultaneously. See Section 6.6.
2.
Emergency Service Water Pump House - loads lif ted in the ESW pump house, especially one of the ESW pumps, over redundant system components shall be controlled to the requirements of Section 6.7.
3.
Reactor Building - the portable refueling shield shall not be moved over the Reactor Vessel. See Section 6.8.
6.1.3 Lifting Devices 1.
Special lif ting devices used for the movement of " Heavy Loads" shall meet the requirements stated in NUREG-0612 Article 5.1.1 Guidelines 4 and ANSI N14.6-1978.
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OMIC: MAP-1301 Page: 4 Rev.:
- 0. Draft 3 2.
Lif ting devices that are not specially designed, used for the movements of " Heavy Loads", shall meet the requirements stated in NUREG-0612 Article 5.1.1 Guideline 5 and ANSI B30.9-1971.
The devices above shall be used in conjunction with PNPP Opera-tions Manual Chapter OK9A:
GMI-004 - Guidelines for Rigging.
6.2 Precautions 6.2.1 Refer to the PNPP Heavy Loads Study and Equipment Removal Scheme to determine the proper load path. Deviations from these paths are allowable only through a written approved procedure.
6.2.2 Carefully select the rigging equipment, ensuring its capacity is sufficient to safely handle the load. An adequate safety margin shall be established to minimize the possibility of rigging gear failure if load hangup should occur.
In addition, the downgrading effects of off-vertical hitches shall be factored in to the rigging geat-selection.
6.2.3 All hoisting equipment shall be tested in accordance with accepted industry standards. Test results shall L: documented and retained.
6.2.4 Visually inspect each item to ensure it is in satisfactory condition.
Equipment that is damaged or has not been properly maintained, shall not be used.
6.2.5 Prepare the load set-down area.
Blocking, pads and other items necessary to ensure safe storage shall be staged.
6.2.6 Ensure that satisfactory clearance exists along the load path for load movement. Take action as necessary to ensure clear-ance is established.
6.2.7 Provide protection for instruments and other sensitive compo-nents on or in the vicinity of the load to ensure they are not damaged during load movement.
6.2.8 Attach rigging equipment to the load, using sound rigging prac-tices. Avoid kinks and twists in rope, chains and slings.
6.2.9 When disassembling safety-related components, the removed piece shall be expeditiously cleared from the component.
It shall only be suspended for as short a period of time as possible, be securely staged in its laydown area and adequately protected.
4 OMIC: MAP-1301 Page: 5 Rev.:
0, Draft 3 6.2.10 Lift and move the load cautiously and smoothly.
Rigging equip-ment failures, damage to the load or damage to other equipment shall be immediately reported to the Lamediate supervisor.
6.2.11 Any rigging equipment which is accidentally overloaded shall be removed from service and inspected per the requirements of the appropriate instruction.
6.2.12 No load, regardless of weight, shall pass within 5 f t, of:
a.
A filled New Fuel Vault Rack or Containment Fuel Rack, which could cause an impact force greater than 4000 f t. lbs.
b.
A filled Fuel Bldg. Rack, which could cause an impact force greater than 4349 ft. lbs.
c.
An open reactor vessel, with fuel installed, which could cause an Lnpact force greater than 28113 ft. lbs.
6.3 Handling of Category A Equipment NOTE:
The handling of Category A items shall be in accordance with written approved procedures and associated instruc-tions or drawings. The procedures shall include the items listed below as a minimum.
6.3.1 The requirements of Section 6.2 above shall be included and satis fied.
6.3.2 A person shall be designated in charge of the handling opera-tion by the applicable Supervisor.
He shall have demonstrated satisfactory abilities in supervision of hoisting, rigging and transporting activities.
6.3.3 The rigging equipment to be used shall be identified and its selection based on its ability to handle the load.
6.3.4 Instructions for load handling and movemen*. shall be clearly i
listed.
Check points which require docuoantation by specific
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individuals shall be included.
6.3.5 Load indicating devices shall be used where the primary source of hoisting power has the capability of imposing excessive l
loads on the component or item being handled.
6.3.6 Procedural variations shall be approved and documented. A person shall be designated to act in emergency situations (Normally the person in charge). He shall document such action after the fact.
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1 OMIC: MAP-1301 l
Page: 6 Rev.: 0 Draft 3 6.4 Handling of Category B Equipment f
i NOTE:
The handling of Category B items shall be in accordance i
with written, approved procedures and associated instruc-tions and drawings.
The procedure shall include the fol-lowing as a adnimum.
6.4.1 The requirements of Section 6.2 above shall be satisfied.
6.4.2 The rigging equipment to be used shall be identified ana its selection based on its ability to handle the load.
i 6.4.3 Instructions for load handling and movement shall be clearly listed. Check points which require documentation by specific individuals shall be included.
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6.4.4 Procedural variations shall be approved and documented. A person shall be designated to act in emergency situations (Normally the person in charge). He shall document such action af ter the fact.
6.5 Handling of Category C Equipment 6.5.1 The rigging equipment shall be properly maintained.
6.5.2 Category C items shall be handled by experienced personnel utilizing good rigging and safety practices.
Manufacturer's load charts and general safe rigging manuals shall be available.
6.6 Special Requirements for Loads Handled in the Steam Tunnel 6.6.1 Heavy loads handled in or through either Steam Tunnel'shall be controlled to the requirements of Category B equipment and the requirements below.
6.6.2 Procedures for handling equipment in the Steam Tunnel shall contain the following precaution:
"This component shall not be lifted or transported unless the Reactor is in cold shut-down condition."
6.6.3 Permission of the applicable Unit Supervisor must be obtained prior to load handling in the Steam Tunnel.
6.6.4 Signs of high visibility shall be permanently posted within each steam tunnel stating the following:
" Permission of the Unit Supervisor must be obtained prior to lifting and trans-porting loads within the steam tunnel.
Load handling shall be controlled by written, approved procedures.
Ref. PNPP Control of Heavy Loads Study; GAI Report No. 2329, Docket Nos. 50-440, 50-441.
0 OMIC: MAP-1301 Page:
7 - LAST Rev.:
0, Draft 3 6.7 Special Requirements for Loads Handled in the Emergency Service Water Pump House 6.7.1 Heavy loads handled in the Emergency Service Water Pump House shall be controlled to the requirements of Category B equipment.
and the requirements below.
6.7.2 The floor of the ESW Pump House shall be clearly marked with (later) paint indicating the paths to be followed for load mov emen t.
These paths shall be identified as applicable within the handling procedure.
6.7.3 The permission of Shift and Maintenance Supervisor (later) is required for movement of loads within the ESW Pump House.
6.7.4 Movement of heavy loads (especially one of the ESW pumps over redundant safe shutdown equipment) must be minimized and shall be strictly controlled.
6.7.5 Signs of high visibility shall be permanently posted within the ESW Pump House and in the cab of the ESW Crane, stating the following: Permission of Shift and Maintenance Supervisor (later) must be obtained prior to lif ting and transporting loads within this building. Load handling shall be controlled by written, approved procedure and must follow the marked paths.
Ref. PNPP Control of Heavy Loads Study; GAI Report No. 2329; Docket Nos. 50-440, 50-441.
6.8 Special Requirements for Handling the Portable Refueling Shields (1 & 2F15E0010) 6.8.1 Movement of the Portable Refueling Shields within the Reactor Building shall be controlled by the refueling procedure. That portion of the procedure pertaining to shield movement must conform tc the requirements for handling Category B equipment.
6.8.2 The refueling procedure shall contain the following precaution:
"The Portable Refueling Shield shall not be permitted to pass over or renain suspended in close proximity to the Reactor vessel.
6.9 Records None 7.0 ATTACEMENTS None i
THE CLEVELAND ELECTRIC ILLUMINATING C031PAhT PERRY NUCLEAR PO'IER PLANT OPERATIONS MANUAL MAINTENANCE SECTION INSTRUCTION NUMBER OM9A: GMI-0004 REVISION O
EFFECTIVE DATE_
TITLE: GUIDELINES FOR RIGGING PREPARED:
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I N.%)TJTLE/ DATE R EVIEk'ED:
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MAISTES.GCE SECTION - NAME/TITLF/DATE P EVI E'a'ED:
NQAD - PROGRAM QUALI'IY SECTION - SAME/ TITLE /DATE 7" A
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MAISTENANCE SECTION - NA}!E/ TITLE /DATE PPD:
AD?11NISTRATIVE SECTION - NAME/ TITLE /DATE MAINT. SEC. l ADS!IN, EFFECTIVE REY.
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OM9A:GMI-004 Pags: i Rev : 0 LIST OF INCOMPLETE ITDiS At the time this procedure was written, information regarding the items listed belov vere incomplete. These items are designated as "(Lster)" within the procedure.
As the information becomes available, the procedures will be revised.
Ns.
Page Section Item Completed 1
9 9.0 Manufacturer Load Tables 2
3 4
5 6
7 8
9 10 11 12 13 1 !.
15 16 17 18 19 20
1 OM9A:
GMI-0004 Page:
1 of 9 Rev.:
0 GENERAL GUIDELINES FOR RIGGING 1.0 PURPOSE 1.1 To provide guidelines for load handling to ensure it is conducted in a safe manner.
2.0 SCOPE 2.1 This instruction applies to the use of chain hoists, rope hoists, slings, shackles and eyebolts when rigging in all areas of the Plant Complex.
3.0 PRECAUTIONS 3.1 Any person using rigging gear shall be familiar with the equipment and its care.
If adjustments or repairs are tecessary, or if any damage is known or suspected, it shall be promptly reported. Damaged or defective rigging gear shall not be used.
3.2 The rated capacity of any piece of rigging gear shall not be exceeded unless an authorized test is being conducted.
3.3 If a piece of rigging equipment is accidentally o'verloaded, it shall be immediately removed from service and thoroughly inspected. This inspec-tion shall include as a minimum the applicable Preventive Maintenance Requirements.
A written signed report shall be completed stating the date and cause of overload, results of inspections, any repairs made and whether the equipment was returned to normal use or rejected.
3.4 Either the PNPP Equipment Removal Scheme or the PNPP Heavy Loads study shall be referenced to determine the proper load path. Deviations from these paths may require special controls.
3.5 Upper and lower limit switches shall not be used as normal operating controla.
OM9A: GMI-0004-Pags:
2 of 9 Rev.:
0 3.6 Personnel shall not intentionally pass under or work below a suspended load.
If it is necessary to work while partly under a load, it should be adequately blocked or cribbed to prevent dropping or shifting.
4.0 REQUIRED EQUIPMENT 4.1 Necessary rigging gear.
5.0 INSTRUCTION 5.1 General Rigging Guidelines 5.1.1 Equipment Selection 5.1.1.1 Determine the approximate weight of the load. The PNPP Equipment Removal Scheme, PNPP Heavy Loads Study, nameplate data, vendor manuals or other suitable means may be used.
5.1.1.2 Decide on the hitch to be used. The shape and bulk of the load must be accommodated as well as weight.
5.1.1.3 The selected rigging equipment shall have suitable characteristics for the working environment and suitable capacity to safely handle the load. Rated capacity charts should be referenced to ensure the sling will handle the load using the selected hitch at the pull angle determined by the sling length.
l 5.1.1.4 Slings shall be long enough to provide the maximum practical angle between the sling leg and horizontal l
(or the maximum practical angle at the hook if vertical angles are used).
l L
OM9A: GMI-0004 Page:
3 of 9 Rev.:
0 5.1.1.5 The rigging equipment shall be carefully inspected prior to use per the requirements of this instruction.
See Section 5.2.
5.1.2 Attaching the Load 5.1.2.1 Determine the load's center of gravity and lift from above this point whenever possible. The load shall be balanced and adequately supported to prevent slippage.
5.1.2.2 Hoist chains shall not be wrapped around the load.
5.1.2.3 Ensure sufficient headroom exists to sufficiently lift the load.
5.1.2.4 Pad sharp corners and angles on the load to prevent excessive strain on the rigging gear at the point of contact.
5.1.2.5 Slings shall be securely attached to the load. They shall not be shortened with bolts, knots or other unapproved methods. Kinks and twists shall be avoided.
5.1.2.6 Shouldered eyebolts shall be installed so that the shoulder firmly butts against the load. When necessary shims or washers may be used to provide the shoulder with a firm base.
5.1.2.7 Slings or other approved devices shall be properly seated in the saddle of the hook.
5.1.2.8 Provide protection for instruments and other sensitive components on or in the vicinity of the load to ensure they are not damaged during load movement.
t OM9A: GMI-0004 Page:
4 of 9 Rev.: 0 5.1.2.9 Guide loads with tag lines when possible.
5.1.3 Moving the Load 5.1.3.1 The hoist operator shall not engage in any operation which will divert his attention while involved in rigging activities.
5.1.3.2 The hoist operator shall have clear unobstructed access to the lifting mechanism at the point of lift and along the path of travel.
5.1.3.3 Personnel shall stand clear of the load.
Loads shall not be passed over personnel.
5.1.3.4 Do not shock load rigging gear.
Inch slowly into load engagement and avoid sudden stops and starts.
5.1.3.5 Initially lift the load a few inches and check for proper load balance.
Proceed with the lift only when assured that slipping or tilting will not occur.
5.1.3.6 When a load approaching the hoist's capacity is being handled, the brakes shall be tested by lifting the load several inches and checking the braking action.
The lift may be continued only after the operator is assured the brake will hold properly.
5.1.3.7 Lift and move loads slowly and cautiously, ensuring that all obstructions are cleared. Rigging equipment failures, damage to the load or other equipment shall be immediately brought to the attention of the Immediate Supervisor.
OM9A:
GMI-0004 Paga:
5 of 9 Rev.:
0 5.1.3.8 When possible, loads shall not be left suspended at the end of a work shift or for extended or unattanded periods.
If it is necessary to leave a load suspended, specific precautions must be.taken to provide protec-tion against accidental load dropping. The operating mechanism or chain should be secured.
NOTE:
Loads shall not remain suspended over safety or quality-related equipment unless controlled by an authorized, written procedure which outlines the necessary safety precautions.
5.1.3.9 When possible, the load shall be properly staged and protected to prevent damage.
Openings on the load and disassembled components should be protected to prevent entry of foreign material.
5.1.4 Restoration 5.1.4.1 Do not pull slings from under a load when the load is resting on it.
Block the load up to remove the sling.
5.1.4.2 Reinspect all gear to ensure no damage occurred during the lift.
5.1.4.3 Properly clean and store all equipment.
5.2 Inspections of Equipment Prior to Use 5.2.1 Hoists and Come-A-Longs 5.2.1.1 Ensure proper and adequate lubrication.
OM9A: GMI-0004 Page: 6 of 9 Rev.: 0 5.2.1.2 Check the load hook for distortion or cracks.
5.2.1.3 Check the load chain or rope for abnormalities.
5.2.1.4 Ensure free and proper operation.
5.2.1.5 Do not use if any of above abnormalities exist.
5.2.2 Hooks 5.2.2.1 Check for twisting more than 10' from plane of unbent hook.
5.2.2.2 Check for throat opening greater than 15% of normal.
5.2.2.3 Check for cracks, nicks or gouges.
5.2.2.4 If a hook latch is provided, ensure it engages properly.
5.2.2.5 Do not use if any of the above abnormalities exist.
5.2.3 Wire Rope Slings 5.2.3.1 Ensure there is no evidence of corrosion, heat damage or internal damage.
5.2.3.2 Check for broken wires. There shall be no more than 6 broken wires in any one lay or 3 broken wires in one strand in one lay.
5.2.3.3 Check for kinking, crushing, bird caging or other distortion.
5.2.3.4 Ensure end attachments are not cracked, worn or otherwise deformed.
OM9A: GMI-0004 Paga:
7 of 9 '
Rev.:
0 5.2.3.5 Do not use if any of the above abnormalities exist.
4 5.2.4 Synthetic Web Slings 5.2.4.1 Check for evidence of burning or melting.
5.2.4.2 Check for snags, punctures and tears.
5.2.4.3 Check condition of stitching and end fittings.
5.2.4.4 Do not use if any of the above abnormalities exist.
5.2.5 Wire Mesh Slings 5.2.5.1 Check for lack of flexibility due to distortion of the mesh fabric.
5.2.5.2 Check for broken wires in_any part of the mesh or reduction in wire diameter of 25% due to corrosion or.
15% due to abrasion.
5.2.5.3 Check for distortion of handles and broken welds / brazed joints along the sling edge.
5.2.5.4 Do not use if any of the above abnormalities exist.
5.2.6 Shackles 5.2.6.1 Ensure the pin threads freely into the body and is not bent.
5.2.6.2 Ensure the body is not twisted.
5.2.6.3 Check for cracks.
OM9A: GMI-0004 Pags:
8 of 9 Rev.:
0 5.2.6.4 Do not use if any of the above abnormalities exist.
5.2.7 Eyebolts 5.2.7.1 Ensure the threads are not damaged and the pin is not bent.
5.2.7.2 Check for cracks and distortion of the eye.
5.2.7.3 Do not use if any of the above abnormalities exist.
6.0 POST-MAINTENANCE CRITERIA 6.1 Visually inspect all equipment for damage.
6.2 Clean equipment and return to proper storage.
7.0 ACCEPTANCE CRITERIA t
i 7.1 No deficiencies exist which hinder safe use of the equipment.
8.0 REFERENCES
8.1 ANSI B30.9-1971, Slings.
8.2 ANSI B30.10-1975, Hooks.
8.3 ANSI B30.16-1973, Overhead Hoists.
8.4 OSHA 1910.184, Slings.
8.5 PNPP Equipment Removal Scheme.
S.6 OMIC: MAP-1301, Control of Heavy Loads.
OM9A: GMI-0004 Page:
9 of 9 Rev.:
0 9.0 LIST OF ATTACHMENTS Later - Equipment Manufacturer Load Tables 304/H/9/ba 4
4
1.
THE CLEVELAND ELECTRIC ILLUMINATING COMPANY PERRY NUCLEAR POWER PLANT OPERATIONS MANUAL MAINTENANCE SECTION INSTRUCTION NUMBEROM9A: GMI-0003 REVISION 0 EFFECTIVE DATE 4
l TITLE: CRANE OPERATING GUIDELINES
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ADMINISTRATIVE SECTION - NAME/ TITLE /DATE REV.
MAINT. SEC.
ADMIN. EFFECTIVE NO.
PREPARED PPD REVIEW QA REVIEW APPROVAL SEC.
DATE 1
2 3
4 5
6 7
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OM9A: GMI-0003 Pegs:
1 of 8 Rev:
0 CRANE OPERATING GUIDELINES 1.0 PURPOSE 1.1 To provide guidelines for crane operation to ensure all load handling is conducted in a safe manner.
2.0 SCOPE 2.1 This instruction applies to the operation of the overhead cranes in the Unit 1 and 2 Turbine Buildings, Circulating Water Pump Houses and the Service Water Pump House.
3.0 PRECAUTIONS 3.1 Crane Operators shall be qualified in accordance with the requirements of OMIC: MAP-0201.
3.2 The rated capacity of either the main or auxiliary hoist shall not be exceeded unless an authorized, controlled load test is being conducted.
3.3 Refer to the PNPP Equipment Removal Scheme to determine the proper load path. Deviations from these paths may require special controls.
1 3.4 Ensure that satisfactory clearance exists along the load path for load movement. Action shall be taken as necessary to obtain the necessary clearance.
4.0 REQUIRED EQUIPMENT None.
5.0 INSTRUCTIONS 5.1 Conduct of Crane Operators
OM9A: GMI-0003 Pags: 2 of 8 Rev:
0 5.1.1 Crane Operator trainees must be under the direct supervision of qualified operator or other designated person when operating any overhead crane.
5.1.2 When physically or otherwise unfit, the operator shall not engage in operation of the equipment. This shall also apply if the operator is under the influence of alcohol or medication which may cause drowsiness or at the discretion of the man's immediate Supervisor.
5.1.3 Operators shall not engage in horseplay or any other activity which may divert attention when involved in operation of the equipment.
5.1.4 Operators shall be familiar with the equipment and its care.
Known defects or needed repairs shall be promptly reported.
The operator shall inform his relief of any uncorrected defects at shift change.
5.1.5 Operators shall ensure that inspections are conducted at the required periodicities.
5.1.6 The Operator shall ensure that crane controllers are off and no workers are on or adjacent to the crane before closing the mainline disconnect.
5.1.7 Crane controls shall be tested at the beginning of each shift.
5.1.8 The Operator is responsible for those operations under his direct control. When safety is in doubt, the Operator shall consult his Supervisor for resolution prior to handling the load.
5.1.9 Operators shall respond to all hand signals from the designated person directing the lift.
However, STOP signals shall be obeyed regardless of the source.
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OM9A: GMI-0003 Pags:
3 of 8 Rev:
0 5.1.10 The crane warning device shall be sounded each time before moving either the trolley or the bridge and intermittently when approaching personnel.
5.2 Operating Guidelines 5.2.1 Complete the DAILY - PRIOR TO USE inspection. Discrepancies shall be noted and corrected as soon as possible.
5.2.2 Guidelines for attaching the load.
5.2.2.1 The hook shall be brought over the load in a manner to prevent swinging.
5.2.2.2 The hoist rope should be vertical and the hook block centered over the load. Off-center lifts or side pulls require special authorization.
5.2.2.3 The hoist rope shall be free from kinks or twists and
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not wrapped around the load.
5.2.2.4 If there is a slack in the rope condition, it shall be ensured that the rope is still properly seated on the drum and in the sheaves.
5.2.2.5 The load shall be well secured.
l 5.2.2.6 No loose items shall remain on the load during load movement.
5.2.3 Guidelines for load movement.
5.2.3.1 One person shall be designated as in charge of the lift. He shall communicate with the crane operator using the standard hand signals identified in ANSI B30.2.0-1976, Figure 5 (Attachment 2).
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OM9A: GMI-0003 Pags: 4 of 8 Rev:
0 For special cases where additions to or modifications of these hand signals are required, the special signals shall be agreed upon and thoroughly under-stood by both the signal person and the operator.
These signals shall not conflict with the standard hand signals.
Two way radios may be used when making lifts in areas of low visibility.
NOTE:
A STOP signal shall be obeyed regardless of the source.
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5.2.3.2 Inch slowly into.'.oad engagement. Ensure proper load balance prior to raising to the desired height.
i, 5.2.3.3 When a load at or near hoist capacity is to be lifted, test, the hoist brake as follows:
a.
lift the load a few inches, b.
allow the load to remain suspended for several minutes.
c.
If the brake slips or fails to hold, it shall be adjusted or repaired before load handling is continued.
5.2.3.4 The warning bell shall be sounded before load move-ment and intermittently when approaching personnel.
Loads shall not be moved over people.
5.2.3.5 Accelerate and decelerate all load movements slowly.
5.2.3.6 Care shall be taken to ensure the load does not contact obstructions.
OM9A: GMI-0003 Pags:
5 of 8 Rev:
0 5.2.3.7 The natural lag in load movement will cause the load to swing past the vertical centerline when motion stops. Operators must expect and learn to gauge this swing to minimize the pendulum action.
5.2.3.8 Suspended loads should not remain unattended. The operator should remain at the controls to take action in case of brake failure.
6.0 POST MAINTENANCE REQUIREMENTS None.
7.0 ICCEPTANCE CRITERI/,
4 None.
8.0 REFEkENCES 8.1 ANSI B30.2.0-19"/6, Overhead and Gantry Cranes.
l 8.2 OSHA Chap. XVII, Part 1910.179, Overhead and Gantry Cranes.
-8.3 P&H Overhead Crane Operation and Maintenance Manual.
8.4 Whiting' Overhead Crane Operation and Maintenance Manual.
DW31/A/5/rd
OM9A: CMI-0003 Page 6 of 8 Rev:
0 Attachment.1 OVERHEAD CRANE DAILY INPSECTION CHECKLIST
'l.
Ensure runways.and rails are clear.
- 2. Ensure lighting on the bridge and in the cab are proper.
- 3. Ensure the bridge, trolley and cab are clean. There should be no loose debris or tools in any of the afore-mentioned arcan.
- 4. Inspect wire rope for corrosion, broken wires, bird caging, kinking and diameter reduction.
- 5. Inspect hook (s) for cracks or abncrmalities.
- 6. Check gearcase oil levels.
- 7. Check for fluid leakage on lines, tanks and ralves.
- 8.
Check all controls for proper operation.
- 9. Check controls for improper adjustment which could inter-fere with operation.
- 10. Ensure brakes operate properly.
- 11. Check hook limit switches for hoist (s) to be used.
- Perform each shift the crane is in operation.
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OM9As CMI-0003
.Pags 7 of 8 i
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Attachment l' l
(Continued)
- 12. Check operation of warning devices.
- 13. If provided, check settings of load weight indicator.
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OM9A: CMI-0003 Page: 8 of 8 Rev:
0 AMERICAN NATIONAL STANDARD OVERHEAD ANO CANTRY CR ANES ANSI 830.2.0-1976 (TOP RUNNING BRIOGE, MULTIPLE GIROER)
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w GUIDELINE RECOMMENDATION
- 3. Crane Operator Qualifications NO RECOMMENDATION (Section 2.3.3)
RESPONSE
Although not specifically requested, a draft copy of the procedure used in the qualification of crane operators is being submitted for ~the staffs' review (see attached MAP-0201).
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0 THE CLEVEIAND ELECTRIC ILLUMINATING COMPANY
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PERRY NUCLEAR POWER PLANT OPERATIONS MANUAL TITLE:
QUALIFICATION OF CRANE OPERATORS REVISION O
EFFECTIVE DATE m
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e PREPARED:
J. P. Goecker SUBMITTED:
PERRY PLANT DEPARTMENT REVIEWED:
NUCLEAR Q.A. DEPARTMENT PORC REVIEW AND RECOMMENDATION FOR APPROVAL MEETING NUMBER:
I-APPROVED:
MANAGER - PERRY PLANT DEPARD1ENT APPROVED:
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MANAGER - NUCLEAR Q.A. DEPARDiENT i
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OMIC: MAP-0201 Page: 11 Rev.:
- 0. Draft 3 Qualification of Crane Operators MAP-0201 Table of Contents Section Title Page 1.0 PURPOSE 1
2.0 SCOPE 1
3.0 RESPONSIBILITIES 1
4.0 REFERENCES
1 5.0 DEFINITIONS 2
5.1 Heavy Load 2
5.2 Safe Load Path 2
6.0 DETAILS 2
6.1 Administrative Requirements for Operator 2
Qualification 6.2 Crane Operator Conduct 3
6.3 Qualification as Standard Crane Operator 4
6.4 Qualification as Special Handling Crane Operator 6
6.5 Records 7
7.0 ATTACHMENTS 7
7.1 Attac hment 1, Standard Crane Operator 8
Qualification Card 7.2, Special Handling Crane Operator 10 Qualification Card
OMIC: MAP-0201 Page: 111 Rev.:
- 0. Draft 3 List of Ef fective Pages_
f V~
Deaft Revision g
3 0
MAP-020L-i thru -
MAP-0201-iii 3
0 MAP-0201-1 thru MAP-020L-11 I
J SCOPE OF REVISION _:
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OMIC: MAP-0201 Page:
1 Rev.:
0, Draft 3 1.0 PURPOSE To establish a uniform method of training operators of overhead cranes to ensure crane operations are conducted in a safe manner.
2.0 SCOPE This procedure applies to Maintenance Section personnel involved in the operation and use of the various overhead traveling cranes at the Perry Site.
3.0 RES PONSIBILITIES 3.1 The General Supervisor Maintenance Section has the overall respon-sibility for ensuring that the requirements of this procedure are followed. He shall ensure that Maintenance Section Personnel fully understand their responsibilities.
3.2 The Maintenance Section Operations Engineers and Supervisors have the responsibility of ensuring that Crane Operators are qualified to the requirements of this procedure. They shall ensure that the Crane Operators conduct crane operations in a responsible and safety conscious manner.
In addition they shall take necessary action to resolve any questions or problems related to load handling and safety.
3.3 Crane Operators qualified to the requirements of this procedure, are responsible for ensuring that all crane operations under their cogni-zance are conducted in a safe, responsible manner. They shall ensure through inspections that the equipment is in a proper state of usability. They shall bnmediately.'.deatify the need for any repairs and shall ensure' that all preventive. aintenance is completed as necessary.
4.0 REFERENCES
4.1 Harnischfeger P&H Crane Service and Operation Manuals 4.2 Whiting Crane Service and Operation Manuals 4.3 ANSI B30.2-1976 Overhead and Gantry Cranes
OMIC: MAP-0201 Page:
2 Rev.:
- 0. Draft 3 4.4 ANSI /ASME N45.2.15-1981 Hoisting, Rigging and Transporting of Items for Nuclear Power Plants 4.5 NUREG-0612 Control of Heavy Loads at Nuclear Power Plants 4.6 Perry Nuclear Power Plant - Control of Heavy Loads Study.
GAI Report #2329.
4.7 PNPP Equipment Removal Scheme 4.8 OMIC: MAP-1301, Control of Heavy Loads 4.9 ANSI B30.9-1971 Slings 4.10 ANSI N64.6-1978 Special Lifting Devices 5.0 DEFINITIONS 5.1 Heavy Load Any load carried in a given area af ter the plant becomes operational that weighs more than the combined weight of a single spent fuel assembly and its associated handling tool.
(1048f) 5.2 Safe Load Path A path defined for transport of a heavy load that will minimize adverse effects, if the load is dropped, in terms of releases of radioactive material and damage to safety systems. This path should be administratively controlled by procedures and/or clearly outlined by markings on the floor where the load is to be handled. It may also be enforced by mechanical stops and/or electrical interlocks.
6.0 DETAILS 6.1 Administrative Requirements for Operator Qualification Immediate Supervisor shall insure requirements met and sign indicating same on qualification card.
6.1.1 Experience Requirements 1.
Must be a Nuclear Mechanic Grade II or above.
2.
Must be knowledgable about crane maintenance and inspection requirements.
OMIC: MAP-0201 Page:
3 Rev.:
0, Draft 3 3.
Mast have a generally alert and safety conscious attitude.
6.1.2 Physical Requirements 1.
Must be at least 18 years of age.
2.
Must read and speak English fluently.
3.
Vision, with or without corrective lenses, must be at least 20/30 Snellen in one eye and 20/50 in the other.
This may be determined from the Operator's most recent eye exam.
4.
Hearing with or without correction must be good.
5.
The Operator shall not be afflicted with any known heart conditions which might cause a sudden loss of ability to react.
6.
Shall have no physical impairment which could affect his abilities to meet the demands of equipment operation.
7.
Should have. normal depth perception, field of vision, reaction time, manual dexterity, and coordination.
6.2 Crane Operator conduct 6.2.1 Crane Operator Trainees must be under the direct supervision of a qualified operator or other designated person when operating any overhead crane.
6.2.2 When physically or otherwise unfit the operator shall not en-gage in operation of the equipment.
This shall also apply if the operator is under the influence of alcohol or medication which may cause drowsiness or at the discretion of the man's Immediate Supervisor.
6.2.3 Operators shall not engage in horseplay or any other activity which may divert their attention, when involved in operation of the equipment.
6.2.4 Operators shall be familiar with the equipment and its care.
Known defects or needed repairs shall be promptly reported.
The operator shall inform his relief of any uncorrected defects at shif t change.
6.2.5 Operators shall ensure that inspections are conducted at the required intervals.
OMIC: MAP-0201 Page: 4 Rev.:
0, Draft 3 6.2.6 The Operator shall ensure that crane controllers are off and to workers are on or adjacent to the crane before closing the mainline disconnect.
6.2.7 Crane controls shall bs tested at the beginning of each shift.
6.2.8 The Operator is responsible for those operations under his direct control. When safety is in doubt the Operator shall consult his Supervisor for resolution prior to handling his load.
6.2.9 Operators shall respond to all hand signals from the designated person directing the lif t.
However, STOP signals shall be obeyed regardless of the source.
6.2.10 The crane warning device shall be operated each time before moving either the trolley or bridge and intermittently when approaching personnel.
6.2.11 Before leaving the crane unattended, the operator shall land any attached load, place controllers in the "off" position and open the main line device of the specific crane.
6.2.12 If power goes off during operation, the operator shall imme-diately place all controllers in the "off" position. Prior to reuse of the crane, operating motions shall be checked for proper direction.
6.2.13 Contacts with runway stops or other cranes shall be made with extreme caution. The operator shall do so with particular care for the safety of persons on or below the crane, and only af ter making certain that any persons on the other cranes are aware of what is being done.
6.2.14 Before the operator performs any maintenance work on the crane, the operator shall lock, tag or flag the main switch (see Paragraph 2-2.3.2) in the deenergized position.
6.2.15 Persons boarding or leaving overhead cranes should do so caly at authorized locations and designated boarding entrances.
6.2.16 Before closing the main device, the operator shall see to it that all controllers are in the "off" position.
6.3 Qualification as Standard Crane Operator (See Attachment 1)
Qualification as a Standard Crane Operator applies to prospective operators of the Unit 1 & 2 Turbine Building Crance, Circulating Water Pump House Cranes and the Service Water Pump House Crane.
OMIC: MAP-0201 Page: 5 Rev.:
0, Draft 3 6.3.1 Each prospective operator shall complete a qualification card in accordance with the guidelines below.
The qualification card shall be maintained in the operator's training file for the full length of his employment at Perry Nuclear Power Plant.
6.3.2 Part A - Reference Material 1.
The prospective operator shall be trained to ANSI B30.2.0-1976, ASME/ ANSI N45.2.1.5-1981 and ANSI B30.9-1971.
This may be done by review of each manual or through classroom training.
2.
The completion signature may be obtained by discussion with the operator's immediate supervisor, the classroom instructor or other designated person.
6.3.3 Part B - Safety Requirements and Control Equipment 1.
Read and understand the guidelines for Operator conduct found in Section 6.2 of this procedure.
2.
Become familiar with the control equipment associated with the crane through reading and/or classroom training.
3.
Completion signature may be obtained as in Section 6.3.2.2 above.
6.3.4 Part C - Classroom Training (Optional) 1.
If available during qualifications attend any organized classroom training applicable to crane.use, maintenance or safety.
6.3.5 Part D - Operation Training 1.
Operate the crane under the direction of a qualified oper-ator or other designated person until familiar and confi-dent with controls.
2.
Signature may be received from same.
6.3.6 Part E - Operation Demonstration 1.
Conduct an operational ability demonstration to the satis-faction of bnmediate Supervisor or other designated person.
2.
Demonstratica shall include but not be limited to:
a.
Energizing the crane.
OMIC: MAP-0201 Page:
6 Rev.: 0 Draft 3 b.
Conducting a daily prior to use inspection, including the testing of all controls.
c.
Operating the crane along a predetermined path with no load on the hook following hand signals and spotting the hook at a predetermined position.
d.
If available handling a small load as in Step e above.
e.
De-energizing the crane.
3.
Completion signature may be obtained from the person ob-serving the demonstration.
6.3.7 Part F - Written Exam 1.
Satisfactorily complete a written exam covering the infor-mation discussed in Parts A - E above. This shall be ad-ninistered by the PPD Training Unit.
6.3.8 Part G - Certification 1.
Receive an interview from General Supervisor Maintenance Section or designated person covering any or all aspects of the areas above.
2.
Receive certification signature from same.
6.4 Qualification as Special Handling Crane Operator (See Attachment 2)
Qualification as Special Handling Crane Operator applies to prospec-tive operators of the Unit I and 2 Reactor Building Polar Cranes, the Fuel Handling Building Crane and the Emergency Service Whter Pump House Crane. Load handling with these cranes involves movement of safety related equipment and heavy loads in the vicinity of safe shutdown equipment as addressed in NUREG-0612. Therefore, additional training and control is necessary.
6.4.1 Each prospective Special Handling Crane Operator shall have been previously qualified as a PNPP Standard Crane Operator.
A Special Handling Crane Operator qualification card shall be completed as outlined in Section 6.3 with emphasis on the additional items listed below.
6.4.2 Part A - Reference Material 1.
The prospective operator shall be trained to the require-ments of OMIC: MAP-1301, Control of Heavy Loads, PNPP Con-trol of Heavy Loads Study and ANSI N14.6-1978.
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OMIC : MAP-0201 Page:
7 Rev.:
0, Draft 3 6.4.3 Part D - Operation Training 1.
Crane Operation Training shall include discussion of iden-4 tified " heavy loads" and " safe load paths".
6.4.4 Part E - Operation Demonstration 1.
The Operational Ability Demonstration shall include crane travel along one or more of the safe load paths defined in the PNPP Heavy Loads Study and MAP-1301.
6.4.5 Part F - Written Exam 1.
A written exam shall be satisfactorily completed covering all areas on the qualification card, including additional information identified in 6.4.2 - 6.4.4 above.
6.4.6 Part G - Certification 1.
Interview from General Supervisor Maintenance Section or designated person shall include special requirements for handling heavy loads.
6.5 Records 1.
Standard Crane Operator Qualification Card.
2.
Special Handling Crane Operator Qualification Card.
7.0 ATTACHMENTS 7.1 Attachment 1 - Standard Crane Operatar Qualification Card.
7.2 Attachment 2 - Special Handling Crane Operator Qualification Card.
O'M1Cs MAP-0201 Page:
8 Rev.:
0, Draft 3 Form: MAP-0201-1 STANDARD CRANE OPERATOR QUALIFICATION CARD Applies to: Turbine Building Cranes, Circulation Water Pump House Cranes, Service Water Pump House Crane.
NAME QUAL. DATE SECTION TITLE PHYSICALLY QUALIFIED A.
REFERENCES 1.
Applicable Crane Operator & Service Manuals 2.
ANSI B30.2-1976 Overhead & Gantry Cranes 3.
PNPP Equipment Removal Scheme 4.
ANSI B30.9-1971 Slings 5.
ANSI /ASME N45.2.15-1981 Hoisting, Rigging and Transporting items at Nuclear Plants Signa ture Date B.
SAFETY REQUIREMENTS & CONTROL EQUIPMENT 1.
Operator Conduct & Safety 2.
Crane control equipment & safety devices Signa ture Date C.
CLASSROOM TRAINING ATTENDED Title Instructor Date
OMIC: MAP-0201 Page: 9 Rev.: 0 Draft 3 (Cont.)
Form: MAP-0201-1 D.
OPERATIONAL TRAINING Signa ture Date E.
OPERATIONAL DEMONSTRATION Signa ture Date F.
WRITTEN EXAM CRADE Signa ture Date G.
CERTIFICATION INTERVIEW Signa ture Date
i 1
OMIC: MAP-0201 Pcgo:
10 Rev.:
0, Draft 3 Form: MAP-0201-2 SPECIAL HANDLING CRANE OPERATOR QUALIFICATION CARD Applies to:
Rx. Bldg. Polar Cranes, Fuel Handling Bldg. Crane, ESW Pump House Crane.
NAME QUAL. DATE SECTION TITLE PHYSICALLY QUALIFIED A.
REFERENCES 1.
Applicable Crane Operator & Service Manuals 2.
ANSI /ASME N45.2.15-1981 Hoisting, Rigging & Transporting items at Nuclear Plants 3.
PNPP Control of Heavy Loads Study 4.
NUREG-0612 - Control of Heavy Loads at Nuclear Power Plants 5.
OMIC: MAP-1301 Control of Heavy Loads 6.
ANSI B.30.2-1976 Overhead and Gantry Cranes 7.
ANSI B.30.9-1971 - Slings 8.
ANSI N14.6-1978 - Special Lifting Devices Signa ture Date B.
SAFETY REQUIREMENTS & CONTROL EQUIPMENT 1.
Operator Conduct & Safety 2.
Crane control equipment & safety devices Signa ture Date J
CMIC: MAP-0201 Peg 2 11 - IAST Rev.:
0, Draft 3 (Cont.)
Form: MAP-0201-2 C.
CLASSROOM TRAINING ATTENDED Title Instructor Date D.
OPERATIONAL TRAINING Signa ture Date E.
OPERATIONAL DEMONSTRATION Signa ture Data F.
WRITTEN EXAM GRADE Signa ture Date G.
CERTIFICATION INTERVIEW Signa ture Date
GUIDELINE RECOMMENDATION
- 4. & 5. Special Lif ting Devices Special lifting devices and their associated ' problems (Section 2.3.4) and are sufficiently important and a special section Lif ting Devices should be written to show CEl's compliance with the (Section 2.3.5) guidelines concerning these devices. This write-up should address the NUREG 0612 specification that the allowable offsite radioactive release applicable to heavy loads as 25% of the guideline exposures outlined in 10CFR Part 100.
The information on special lif ting devices and lif ting devices should include both the maximum static, and dynamic load stress of each loading device compared with the calculated and tested load strength. In addition, each sling should be properly identified as to its' lifting capacity, applicability to specific load handling operation, and if appropriate, restriction of its' use to specific cranes.
RESPONSE
Details of CEI's compliance with ANSI N14.6-1978 and ANSI B30.9-1971 will be provided by Decembrer 1982. Each sling will be properly identified as to its' lif ting capacity, applicability to specific load handling operations, and if appro-priate, restriction of its' use to specific cranes.
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P CUIDELINE RECOMMENDATION
- 6. Cranes (Section 2.3.6)
The crane inspection, testing, and maintenance program should be written with special atttention to the specification of ANSI B30.2-1976 and the limitations placed on the program by the plant operating conditions.
RESPONSE
The crane inspection, testing, and maintenance program is written in detail in the Perry Maintenance Section procedures. For example, the Reactor Polar Crane Monthly Preventive Maintenance, Reactor Polar Crane Quarterly and Semiannual Preventive Maintenance, and Reactor Polar Crane Yearly Preventive Maintenance procedures (see attached) are written in detail and reference ANSI B30.2-1976.
CEI will meet the specifications of ANSI B30.2-1976.
THE CLEVELAND ELECTRIC ILLUMINATING COMPANY PERRY NUCLEAR POWER PLANT OPERATIONS }'ANUAL MAINTENANCE SECTION INSTRUCTION NUMBER _0'19B:PMI-0015 REVISION O EFFECTIVE DATE TITLE: REACTOR POLAR CRANE MONTHLY PREVENTIVE MAINTENANCE PREPARED: d
>lo 6//6/g2, NMfE/ TITLE / DATE REVIEJED:
MAINTENANCE SECTION - NAME/ TITLE /DATE REVIEWED:
NQAD - PROGRAM QUALITY SECTION - NAME/ TITLE /DATE APPRO7ED:
MAINTENANCE SECTION - NAME/ TITLE /DATE PPD:
ADMINISTRATIVE SECTION - NAME/ TITLE /DATE REV.
MAINT. SEC.
ADMIN. EFFECTIVE NO.
PREPARED PPD REVIEW QA REVIEW APPROVAL SEC.
DATE 1
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OM9B:PMI-0015 Page 1 of 15 Rev. O RX POLAR CRANE MONTHLY PREVENTIVE MAINTENANCE 1.0 PURPOSE To provide guidelines for conduct of monthly preventive maintenance on the Reactor Polar Cranes. Use of this instruction and attention to detail by operators and maintenance personnel, will serve to maintain these cranes in their desired high state of operability.
2.0 SCOPE This instruction applies when performing monthly preventive maintenance on:
1L51E0001 Unit 1 Polar Crane 125/10 Ton 2L51E0001 Unit 2 Polar Crane 125/10 Ton The enclosed requirements shall be satisfied once per month when the crane is regularly used (several times per month) and prior to use when the crane has been idle for an extended period of time (greater than 6 months).
3.0 PRECAUTIONS AND LIMITATIONS 3.1 Only qualified crane operators may operate the crane and its associated equipment.
3.2 The crane shall be positioned such that the maintenance will minimally interfere with other operational activities. No maintenance may be performed with the crane resting over critical equipment.
OM9B:PMI-0015 Pags 2 of 15 Rev. 0 3.3 During preventive maintenance, power shall be isolated and the associated breaker safety tagged in accordance with PAP-1104, unless periodic operational checks are required. When power is not isolated, the operator shall remain in the cab to ensure that the controls are not operated without authorization.
3.4 Warning or out of order signs should be placed on the crane or en the floor directly below.
3.5 After inspection and adjustments, the crane shall not be operated until all guards have been replaced, safety devices reactivated and tools removed.
3.6 If any unsafe or abnormal conditions are discovered, the person in charge shall be notified.
4.0 REQUIRED EQUIPMENT 4.1 Basic hand tools.
4.2 Vacuum cleaner'or air supply.
4.3 Calipers.
4.4 Feeler Gauges.
I j
4.5 Mobil Vactra Oil BB.
4.6 Mobil Oil DTE Extra Heavy.
l l
5.0 INSTRUCTIONS I
i
OM9B:PMI-0015 Page 3 of 15 Rev. 0 5.1 Inspection of Motors 5.1.1 Main Drive and Micro Drive Motors 5.1.1.1 Check brushes for excessive wear (40-60% of original).
5.1.1.2 Ensure brushes move freely in the holder and contact the slip ring properly.
5.1.1.3 Ensure the brush pigtail lugs are secure.
5.1.1.4 Check brush spring tension.
Proper tension is 3.5-4#
per square inch of contact area.
5.1.1.5 Clean out dust and dirt. A vacuum or compressed air up to 50 psi may be used. Wipe the slip rings.
5.1.1.6 Ensure terminals are tight and insulation is not worn.
5.1.2 Main Holst Position Indicator (Synchrotie Motor) 5 1.2.1 Remove end bell and clean o't dust and dirt.
u 5.1.2.2 Check brushes for excessive wear.
5.2 Inspection of Brakes 5.2.1 Magnetorque Brakes 5.2.1.1 Clean out dust and dirt. A vacuum or compressed air
[
up to 50 psi may be used.
Ensure ventilation openings I
are clear.
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. ~ _ _
OM9B:PMI-0015 Page 4 of 15 Rev. 0 gpe CD Brakes (See F(gg,e,jy 5.2.2 a0Je STING NUTS YOgg ADNSTING NUT LOCENUT (2) tCCKNUT0) g anart POT
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1 - Type CD Brake - Bridge & Tro$: ley Drive Figure 5.2.2.1 Ensure linkages are not bent or worn.
5.2.2.2 Check brake shoe linings for excessive wear. Replace when 1/16" or less of pad remains.
5.2.2.3
' Check brake wheel (drum) for evidence of overheating.
5.2.2.4 Check brake wheels for cracks or other abnormalities.
5.2.2.5 Ensure mounting bolts are tight.
5.2.2.6 Check torque spring length (L).
If less than 2-7/8",
adjust as follows:
1.
Loosen locknut (2).
I 2.
Turn the torque spring adjusting nut until the i
desired length is obtained.
l 3.
Retighten the locknut.
l l
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OM9B:PMI-0015 Page 5 of 15 Rev. 0 5.2.2.7 Measure the air gap (s).
If not within the range of 3/64" to 3/32" adjust as follows:
1.
Loosen locknut (1).
2.
Turn the two air gap adjusting nuts as required.
3.
Retighten the locknut.
5.2.2.8 Measure the clearance between each brake shoe and the drum at the point even with the shot pivot pin.
If the two measurements differ, adjust the shoe equaliza-tion as follows:
1.
Back off the air gap locknut (1) and tighten it against the yoke until the air gap is closed.
2.
Loosen the shoe equalization locknut (3) and turn the adjusting screw until equal clearance is obtained.
3.
Retighten the shoe equalization locknut (3) and air gap locknut (1).
4.
Recheck measurement to ensure it has not changed.
5.2.3 Type SBE Brakes (See Figure 2.)
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Figure 2 - Type SBE
I OM9B:PMI-0015 Pags 6 of 15 Rev. 0 5.2.3.1 Ensure linkages are not bent or worn.
5.2.3.2 Check brake shoe linings for excessive wear. Replace when 3/16" or less of pad remains.
5.2.3.3 Check brake wheel (drum) for indication of overheating.
5.2.3.4 Check brake wheel for cracks or other abnormalities.
5.2.3.5 Ensure mounting bolts are tight.
5.2.3.6 Each SBE brake is fully adjusted at the factory and requires no periodic adjustments during normal ser-vice.
Lining wear is automatically compensated for by spacer plates at the end of the brake rod.
5.2.4 Pull-a-Hoist Brake 5.2.4.1 This brake is set at the factory. No inspection is required. Adjust only if drift is excessive or if hoist stops too quickly.
5.2.5 Zip-Lift Hoist Brake (See Figure 3.)
h01f i 3 A0 mile 4E p a*Cle04 DISC 10Catui mut p
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OM9B:PMI-0015 Page 7 of 15 Rev. 0 5.2.5.1 Check the armature operating clearance between 1/32" to 1/8".
Adjust as necessary using the following method:
1.
Remove the brake cover.
2.
Loosen the locknuts. Turn the adjusting nuts to obtain 1/32" clearance.
3.
Retighten locknuts and verify clearance.
4.
Replace brake cover.
5.2.5.2 Inspect and clean disc plate and linings.
5.3 Inspection of Electrical Panels and Controls 5.3.1 All Panels 5.3.1.1 Clean out all dust and dirt.
5.3.1.2 Check for evidence of overheating.
5,.3.1.3 Ensure contacts operate freely.
5.3.1.4 Check for worn insulation.
5.4 Inspection of Electric Clutch Couplings 5.4.1 Warner Electric Clutches 5.4.1.1 Check cleanliness of clutch.
5.4.1.2 Ensure no oil or grease is on friction surfaces.
Small amounts may be removed by wiping with a rag dampened with trichloroethylene.
OM9B:PMI-0015 Pags 8 of 15 Rev. 0 5.5 Inspection of Gearcases and Gear Reducers 5.5.1 Micro-Drive Gear Reducers and Tachometer Boston Gear Reducers 5.5.1.1 Check oil level proper. Check oil for presence of foreign material.
If necessary, fill to proper level with Mobil DTE Extra Heavy.
5.5.2 Gear Cases 5.5.2.1 Check exterior of case for evidence of leakage at joints and for cracks or dents.
5.5.2.2 Check oil seals for leakage, chipping or other abnor-malities.
5.5.2.3 Check gears for exc~essive wear, chipping or cracking.
5.5.2.4 Check oil for evidence of water or foreign material.
5.5 2.5 Ensure oil level is proper. Add as necessary using the following lubricants:
Mobil Vactra Oil BB - Bridge drive, auxiliary hoist, main hoist and trolley drive.
1 5.6 Inspection of Couplings l
5.6.1 Flexible Couplings i
5.6.1.1 Check bolts for t'ghtness.
l 5.6.1.2 Check for hole elongation.
l I
I
OM9B:PMI-0015 Page 9 of 15 Rev. 0 5.7 Inspection of Hoisting !!echanisms and Rope NOTE:
Lower the respective hook so it rests about one foot above the floor at the 689'6" IcVel. The block must be in the same position to ensure that the same areas of rope are inspected each time.
5.7.1 Inspection of Sheaves 5.7.1.1 Ensure all sheave grooves are smooth.
5.7.1.2 Ensure sheaves rotate smoothly.
5.7.1.3 Ensure sheave pins are secure.
5.7.1.4 Ensure the sheave frame is free of rough areas or sharp edges.
5.7.2 Inspection of Hooks 5.7.2.1 Ensure the hook nut retaining bolt is in place and securely tightened.
5.7.2.2 Ensure the hook safety latch operates smoothly and properly.
5.7.2.3 Visually inspect the hook for cracks.
5.7.2.4 Measure the hook throat opening between the punched gauge points and compare with the stamped dimension.
The measurement must be within 1 to 1.15 times the stamp.
5.7.2.5 Check for twisting of the hook point from center.
If twisting is evident, it shall not exceed 10*.
OM9B:PMI-0015 Pags 10 of 15 Rev. 0 5.7.3 Inspection of Drums
- 5. 7. 3.1-Check condition of drum grooves.
5.7.3.2 Check condition of flanges at end of drums.
5.7.3.3' Ensure rope end attachments are intact and tight.
5.7.4 inspection of Rope 5.7.4.1 Perform inspection on accessible areas of the rope as it leaves the drum and as it exits each sheave on the block.
5.7.4.2 Measure the rope diameter across its widest point with calipers. Rotate the caliper to ensure the true diameter is measured.
Loss in diameter shall not exceed 10%.
5.7.4.3 Take lay measurements. The following method may be used.
(See Figure 4.):
1.
Firmly hold a piece of carbon paper and a piece of white paper against the rope.
Stroke with the side of a pencil, so the ropes imprint is made on the paper.
2.
Draw a line through a strand, and a second line where the strand reappears.
I i
l-m
OM9B :PMI-0015 '
Pags 11 of 15 Rev. 0 3.
Measure the distance between the lines (lay length) and compare to previous measurements. An abrupt change may indicate impending problems.
NN
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k D
t Figure 4 - Rope Lay Measurements 5.7.4.4 Check for flattened sections where the diameter is less than 5/6 of original.
5.7.4.5 Check for surface wear not to exceed 1/3 of the original diameter of the outside wires.'
5.7.4.6 Check for broken or torn wires. The number shall not exceed six randomly distributed broken wires in one lay or 3 broken wires in one strand in one 1ay.
5.7.4.7 Slowly raise the hook and inspect the rope for evidence of external damage or abuse.
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6.0 POST-MAINTENANCE REQUIREMENTS 6.1 Ensure all guards and covers are properly reinstalled.
6.2 Ensure all tools and equipment are removed from the crane.
6.3 All switches and breakers shall be returned to normal.
e r
b' 4.
OM9B:PMI-0015 d,
'r Pags 12 of 15 Rev. 0
.6.4 Warning or out of order signs shall be removed.
7.0 ACCEPTANCE CRITERIA 7.1 Requirements of this instruction shall be satisfied and/or exceptions noted.
7.2 Discrepancies must ha corrected or scheduled for repair.
8.0 REFERENCES
8.1 OSHA Chap. XVII, Part 1910.179, Overhead and Gantry Cranes.
8.2 ANSI B30.2.0-1976, Overhead and Gantry Cranes.
8.3 Harnischfeger Service Manual - Polar Crane 125/10 Ton.
9.0 LIST ^F ATTACleiENTS 9.1 - Monthly Preventive Maintenance Checklist - Electrical.
9.2 - Monthly Preventive Maintenance Checklist - Mechanical.
913 - Wire Rope Inspection Report.
233/L/12/ba s
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OM9B:PMI-0015 Rev. O
~Page 13 of 15 Draft 1 -
MONTHLY PREVENTIVE MAINTENANCE Polar Cranes 1L51E0001 & 2L51E0001 Electrical Motors See Section 5.1 Satis.
Unsat.
Comments
- 1. Bridge Drive Motor A*
- 2. Micro-Drive Bridge Motor A*
- 3. Bridge Drive Motor B
- 4. Micro-Drive Bridge Motor B 1
- 5. Auxiliary Hoist Motor
- 6. Main Hoist Motor
- 7. Main Holst Micro Drive Motor
- 8. Trolley Main Drive Motor l
- 9. Trolley Micro Drive Motor
- 10. Main Hoist Position Indicator
- 11. Zip-Lift Hoist Motor 4
j
- 12. Pull-a-Hoist Motor
!L Brakes See Section 5.2 Satis.
Unsat.
f
- 13. Bridge Drive A* (Type SCD40) l
- 14. Bridge Drive B (Type SCD40) i
- 15. Trolley Drive (Type SCD40)
- 16. Aux. Hoist Brake A (Type 10SBE)
- 17. Aux.~ Hoist Brake B (Type 10SBE)
- 18. Main Holst Brake A (Type 13SBE)
- 19. Main Hoist Brake B (Type 13SBE)
- 20. Zip-Lift Hoist Brake 2'. Aux. Hoist Magnetorque Brake
- 22. Main Hoist Magnetorque Brake l
Panels &
See Section 5.3 Satis.
Unsat.
Controls
- 23. Push Button Station i
- 24. Main Line Switch Panel l
- 25. Utility Circuit Breaker
- 26. Bridge Breaker Rectifier j
- 27. Bridge Breaker Equipment j
- 28. Motor Breakers
- 29. Line Cont./ Aux. Hoist Control
- 30. Bridge Control i
- 31. Trolley Cont./ Aux. Equip. 1&2
- 32. Main Hoist Control J
- 33. Aux. Hoist / Bridge Resistor
- 34. Trolley / Main Hoist Resistor l
j Completed by Date
.Raviewed by Date l
- Bridge Drive A refers to unit above operator's cab.
233/N/1/mm 4
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OM9 B:PMI-0015 Rav. O Pags 14 of 15 Draft 1 MONTHLY PREVENTIVE MAINTENANCE Polar Cranes 1L51E0001 & 2L51E0001 Mechanical Gearcases & Gear Reducers See Sec. 5.5 Satis.
Unsat.
Comments
- 1. Bridge Drive A*
- 2. Bridge Micro-Drive Reducer A*
- 3. Bridge Drive B
- 4. Bridge Micro-Drive Reducer B
- 5. Trolley Drive
- 6. Trolley Micro-Drive Reducer
- 7. Aux. Hoist
- 8. Main Holst
- 9. Main Hoist Micro-Drive Couplings See Sec. 5.4 & 5.6 Satis.
Unsat.
1
- 10. Bridge Drive A (2 flex, 1 electric)*
- 11. Bridge Drive B (2 flex, 1 electric)
- 12. Trolley Drive (4 flex, 1 electric)
- 13. Aux. Hoist (1 flex.)
- 14. Main Hois; (2 flex, 1 electric Sheaves See Sec. 5.7.1 Satis.
Unsat.
- 15. Main Hoist Upper Block
- 16. Main Hoist Bottom Block
_17. Aux. Hoist Bottom Block
- 18. Aux. Hoist Equalizer Hooks Satis.
Unsat.
- 19. Main Hoist
- 20. Aux. Hoist
- 21. Zip-Lift Hoist Drums Satis.
Unsat.
- 22. Main Hoist
- 23. Aux. Hoist Completed by Date Rsviewed by Date
- Bridge Drive A refers to unit above operator's cab.
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i THE CLEVELAND ELECTRIC ILLUMINATING COMPANY PERRY NUCLEAR POWER PLANT OPERATIONS MANUAL MAINTENANCE SECTION INSTRUCTION NUMBER OM9B: PMI-0016 REVISIONO EFFECTIVE DATE TITLE: REACTOR POLAR CRANE QUARTERLY AND SEMIANNUAL PREVENTIVE MAINTENANCE PREPARED:
0/
M NA%/ TITLE /DATE
. R EVIEa'ED :
MAINTENANCE SECTION - NAME/ TITLE /DATE REVIEWED:
NQAD - PROGRAM QUALITY SECTION - NAME/ TITLE /DATE APPROVED:
MAINTENANCE SECTION - NAME/ TITLE /DATE PPD:
ADMINISTRATIVE SECTION - NAME/ TITLE /DATE REV.
MAINT. SEC.
ADMIN. EFFECTIVE NO.
PREPARED PPD REVIEW QA REVIEW APPROJAL SEC.
DATE y._
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7 8
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OM9B: PMI-0016 Paga 1 of 8 Rev. O REACTOR POLAR CRANE QUARTERLY AND SEMIANNUAL PREVENTIVE MAINTENANCE l
1.0 PURPOSE To provide guidelines for conduct of quarterly and semiannual preventive maintenance on the Reactor Polar Cranes.
These items are primarily lubrication requirements and shall be done in conjunction with monthly preventive maintenance as outlined in OM9B:
PMI-0015.
2.0 SCOPE This instruction applies when performing quarterly and semiannual preventive maintenance on:
1L51E0001 Unit 1 Polar Crane 125/10 Ton 2L51E0001 Unit 2 Polar Crane 125/10 Ton The enclosed requirements shall be satisfied once every 3 months and once every, 6 montha respectively when the crane is in regular use (several times per month). They shall be satisfied prior to use when the crane has been idle for an extended period of time (greater than 6 months).
3.0 PRECAUTIONS AND LIMITATIONS 3.1 only qualified crane operators may operate.the crane and its associated equipment.
3.2 The crane shall be positioned such that the maintenance will minimally interfers with other operatioial activities.
No maintenance may be performed with the crane resting over critical equipment.
l
OM9B:
PMI-0016 Page 2 of 8 Rev. 0 3.3 During preventive maintenance power shall be isolated and the associated breaker safety tagged in accordance with PAP 1104, unless periodic checks are required. When power is not isolated, the operator shall remain in the cab to ensure that the controls are not operated without authorization.
3.4 Warning er out of order signs should be placed on the crane or on the floor directly below.
3.5 After inspections and adjustments, the crane shall not be released for operation until guards have been replaced, safety devices reacti-vated and tools removed.
3.6 If any unsafe or abnormal conditions are discovered, the person in charge shall be notified.
4.0 REQUIRED EQUIPMENT 4.1 Basic Hand Tools.
4.2 Grease Gun.,
4.3 Mobil Lux EP-2 grease.
4.4 Mobil Tac gear lube.
4.5 Mobil Delvac 1210 oil.
4.6 Shell Cyprina #3 grease.
4.7 Shell Darina #2 grease.
4.8 WITCO CHEM SACI 300.
OM9B:
PMI-0016 Pzga 3 of 8 Rev. 0 4.9 Universal Wire Products UWP-AECL wire rope lube.
4.10 Mobil Vactra BB.
5.0 INSTRUCTIONS 5.1 Lubrication of Motors 5.1.1 Main Drive and Micro Drive Motors 5.1.1.1 Clean area around plugs and remove.
5.1.1.2 Remove any hardened grease around openings with plastic or wood stick.
5.1.1.3 With motor running (if possible), pump in grease through upper hole until expelled through lower hole.
5.1.1.4 If possible, run motor with lower plug removed until no grease flows from lower hole.
5.2 Lubrication of Brakes 5.2.1 Type CD Brakes 5.2.1.1 Lube pivot pins and bushings.
5.1.2 Magnitorque Brakes 5.1.2.1 Follow instructions outlines in Section 5.1.1 for motors.
=-
OM9B: PMI-0016 Page 4 cf 8 Rev. 0 5.3 Lubrication of Hoist Drum Cears and Pinions 5.3.1 Main and Auxiliary Hoist 5.3.1.1 Closely inspect gears for wear, chipping, and cracking.
5.3.1.2 While slowly rotating drum, brush gears with required lubricant.
NOTE:
" Brush on" lubricant vice spray must be used as spray requires application at more frequent intervals.
5.4 Lubrication of Hoist Ropes 5.4.1 Main and Auxiliary Hoist Ropes 5.4.1.1 Rope lubricant should be applied to the rope at a position where the rope is flexed and accessible.
This will allow the lubricant to penetrate'and lubricate the center. Best locations are as the rope leaves the drum or exits a sheave.
g 5.4.1.2 Prior to lubricating rope it should be cleaned to remove dust, dirt and dried lubricant.
k 5.5 Lubrication of Zip-Lift Hoist Gearcase 5.5.1 Zip-Lift Hoist 5.5.1.1 Change the gearcase oil as follows:
1.
Remove drain plug and drain oil into suitable container. ENSURE NO OIL DROPS TO ELOOR BELOW.
OM9B:
PMI-0016 Page 5 of 8 Rev. 0 2.
Wipe and replace the drain plug.
3.
Refill with 1 pint of Mobil Vactra Oil BB.
5.6 0ther Equipment 5.6.1 All other equipment shall be lubricated as defined on the appropriate checklists.
6.0 POST MAINTENANCE REQUIREMENTS 6.1 Ensure all guards and covers are properly reinstalled.
6.2 Ensure all tools and equipment are removed from the crane.
6.3 All switches and breakers shall be returned to normal.
6.4 Warning or Out of Order signs shall be removed.
7.0 ACCEPTANCE CRITERIA 7.1 Requirements of this instruction shall be satisfied and/or exceptions noted.
7.2 Discrepancies must be corrected or scheduled for repair.
8.0 REFERENCES
8.1 OSHA Chapter XVII, Part 1910.179, " Overhead and Gantry Cranes."
8.2 ANSI B30.2.0-1976, " Overhead and Gantry Cranes."
8.3 Harnischfeger Service Manual - Polar Crane 125/10 Ton.
OM9B: FMI-0016 Page 6 of 8 Rev. 0 9.0 LIST OF ATTACHMENTS 9.1 -Atsachment 1 - Quarterly Preventive Maintenance Checksheet - Lubrication.
9.2 Attachment 2 - Semiannual Preventive Maintenance-Checksheet - Lubrication.
A 405/G/6/es
\\
OM9B:
PMI-0016 Pags 7 of 8 Rev. O QUARTERLY PREVENTIVE MAINTENANCE POLAR CRANES IL51E0001 & 2L51E0001 LUBRICATION BRAKES SEE SECTION 5.2 LUBRICANT TYPE FITTINGS AMOUNT DONE 1.
Bridge Drive A*
(Type SCD40)
DELVAC 1210 Oil Sparingly 2.
Bridge Drive B (Type SCD40)
DELVAC 1210 Oil Sparingly 3.
Trolley' Drive (Type SCD40)
DELVAC 1210 Oil Sparingly CEARS & PINIONS SEE SECTION 5.3 4.
Aux. Hoist Drum Gears
. MOBIL TAC Swab Liberally 5.
M:in Moist Drum Gears
, MOBIL TAC Swab Liberally OTHER 6.
Bridge Wheels A End* (4)
LUX EP-2 Grs.
2 Ea.
8 Strokes 7.
Bridge Wheels B End* (4)
LUX EP-2 Grs.
2 Ea.
8 Strokes 8.
Pendant Festoon Trolley Wheels (4 Per Set /4 Sets)
LUX EP-2 Grs.
4 Per Set 2 Strokes 9.
Trolley Drive Wheels (4)
LUX EP-2 Grs.
2 Ea.
5 Strokes
- 10. Trolley Festoon Wheels (4 Per Set /4 Sets)
LUX EP-2 Grs.
4 Per Set 2 Strokes
- 11. Main Hoist Drum Pedestal Bearings (2)
LUX EP-2 Grs.
3 Ea.
4 Strokes
- 12. Main Hoist Upper Block LUX EP-2 Ges.
2 10 Strokes
- 13. Aux. Hoist Drum Pedestal Bearing LUX EP-2 Ges.
1 5 Strokes
- 14. Aux. Hoist Equalizer Saddle LUX EP-2 Grs.
1 3 Strokes
- 15. Aux. Hoist Equalizer Sheave Pins.and Bushings DELVAC 1210 Oil Sparingly COMMENTS l
COMPLETED BY DATE REVIEWED BY DATE
- Bridge A end equipment refers to end at which operators cab is located.
405/R/1/es
=
o OM9B: PMI-0016 Page 8 of 8 s
Rev. O SEMIANNUAL. PREVENTIVE MAINTENANCE PDLAR CRANES IL51E0001 & 2L51E0001 LUBRICATION MOTORS SEE SECTION 5.1 LUBRICANT TYPE FITTINGS AMOUNT DONE 1.
Bridge Drive Motor A*
Shell Cyprina #3 Grs.
2 3 Strokes 2.
Micro-Drive Bridge Motor A*
Shell Cyprina #3 Ges.
2 3 Strokes 3.
Bridge Drive Motor B Shell Cyprina #3 Grs.
2 3 Strokes 4.
Micro-Drive Bridge Motor B Shell Cyprina #3 Grs.
2 3 Strokes 5.
Aux. Hoist Motor Shell Cyprina #3 Grs.
2 3 Strokes 6.
Main Hoist Motor Shell Cyprina #3 Ges.
2 3 Strokes 7.
Main Hoist Micro-Drive Motor Shell Cyprina #3 Grs.
2 3 Strokes 8.
Trolley Drive Motor Shell Cyprina #3 Grs.
2 3 Strokes 9.
Trolley Micro-Drive Motor Shell Cyprina #3 Grs.
2 3 Strokes BRAKES SEE SECTION 5.2
- 10. Aux. Hoist Magnetorque Shell Darina #2 Grs.
2 2 Strokes
- 11. Main Hoist Magnetorque Shell Darina #2 Grs.
2 2 Strokes ROPE SEE SECTION 5.4 Coat
- 12. Aux. Hoist Rope UWP-AECL Spray Coat
- 13. Main Hoist Rope UWP-AECL Spray Coat
- 14. Zip-Lift Hoist Rope UWP-AECL Spray ZIP-LIFT HOIST SEE SECTION 5.5 l 1 Pint l
- 15. Zip-Lift Gearcase l Mobil Vactra BB l Change l OTHER
- 16. Aux. Hoist Bottom Block Witco Chem SACI 300 Grs.
5 Strokes
- 17. Main Hoist Bottom Block '
Witco Chem SACI 300 Grs.
5 Strokes
- 18. Pull-A-Hoist Wheels Mobil Lux EP2 Grs.
Repack-i
- 19. Zip-Lif t Hoist Wheels Mobil Lux EP2 Grs.
2 2 Strokes l
- 20. Zip-Lift Hoist Block Mobil Lux EP2 Grs.
1 2 Strokes COMMENTS l
COMPLETED BY DATE REVIEWED BY DATE
- Bridge A end equipment refers to end at Which operators cab is located.
405/H/2/es
THE CLEVELAND ELECTRIC ILLUMINATING COMPANY PERRY NUCLEAR POWER PLANT OPERATIONS MANUAL MAINTENANCE SECTION INSTRUCTION NU>iBEROM9B:PMI-0017 REVISION O
EFFECTIVE DATE TITLE: REACTOR POLAR CRANE YEARLY PREVENTIVE M^INTENANCE PREPARED:
J /'-
h!/ 7![2-Np'4t/ TITLE / DATE REVIEWED:
MAINTENANCE SECTION - NAME/ TITLE /DATE REVIEWED:
NQAD - PROGRAM QUALITY SECTION - NAME/ TITLE /DATE APPROVED:
MAINTENANCE SECTION - NAME/ TITLE /DATE PPD:
ADMINISTRATIVE SECTION - NAME/ TITLE /DATE REV.
MAINT. SEC.
ADMIN. EFFECTIVE NO.
PREPARED PPD REVIEW QA REVIEW APPROVAL SEC.
DATE
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5 6
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0}!9B : PMI-0017 Paga: i Rev.: 0 LIST OF INCOMPLETE ITDiS At the time this procedure was written, information regarding the items listed belov vere incomplete. These items are designated as "(Later)" within the procedure.
As the information becomes available, the procedures will be revised.
No.
Page Section Item Completed 1
10 ATT. 2 Oil Capac. (Amount) 2 3
4 5
6 7
8 9
10 11 12 13 1/.
15 16 17 18 19 20
6 OM9B:PMI-0017 Pags 1 of 10 Rev. O REACTOR POLAR CRANE YEARLY PREVENTIVE MAINTENANCE 1.0 PURPOSE To provide guidelines for the conduct of yearly preventive maintenance on the Reactor Polar Cranes. Use of this instruction and attention to detail by crane operators and maintenance personnel will serve to main-tain these cranes in their desired high state of operability.
2.0 SCOPE This instruction applies when performing yearly preventive maintenance on:
1L51E0001 Unit 1 Polar Crane 125/10 Ton 2L51E0001 Unit 2 Polar Crane 125/10 Ton The enclosed requirements shall be satisfied every 12 months when the crane is regularly used (several times a month) and prior to use when the crane has been idle for greater than 12 months.
These items should be done in conjunction with the monthly, quarterly and semiannual preventive maintenance requirements of OMPB:PMI-0015 and 0016.
3.0 PRECAUTIONS AND LIMITATIONS l
j 3.1 Only qualified crane operators may operate the crane and its associated equipment.
3.2 The crane shall be positioned such that the maintenance will minimally interfere with other operational activities. No maintenance may be performed with the trolley resting over critical equipment.
l OM9B:PMI-0017 Paga 2 of 10 l
Rev. 0 3.3 During preventive maintenance, power shall be isolated and the associated breaker safety tagged in accordance with PAP-1104, unless periodic oper-ational checks are required. When power is not isolated, the operator shall remain in the cab to ensure that the controls are not operated l
without authorization.
3.4 Warning or out of order signs should be placed on the crane or on the floor directly below.
3.5 After inspections and adjustments, the crane shall not be operated until all guards-have been replaced, safety devices reactivated and tools removed.
1 3.6 If any unsafe or abnormal conditions are discovered, the person in charge shall be notified.
4.0 REQUIREDEQUIPMdNT 4.1 Basic Hand Tools.
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l 4.2 Megger.
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4.3 Outside Micrometer.
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l 4.4 Mobil Vectra Oil BB.
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t 4.5 Mobil Oil DTE Extra Heavy.
4.6 Mobil Lux EP No. 2.
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OM9B:PMI-0017 Pags 3 of 10 Rev. 0 5.0 INSTRUCTIONS 5.1 Inspection of Motors 5.1.1 All Motors.
5.1.1.1 Ensure the motor mounting bolts are tight.
5.1.1.2 Check the rotor and stator resistance to ground by meggering in accordance with OM9A:EMI-0001, Perform-ing Insulation Resistance Checks. File a copy of each Megger Test Data Sheet (Attachment 1 of EMI-0001) with the completed PM checklist.
5.2 Inspection of Electrical Panels and Controls 5.2.1 All Panels and Controls.
5.2.1.1 Check all contacts for wear and pitting.
5.2.1.2 Ensure all contacts operate freely.
5.2.1.3 Check that all the connections are tight.
5.3 Inspection of Conductors and Collectors 5.3.1 Bridge.
l 5.3.1.1 Ensure contact surfaces are clean and polished.
l 5.3.1.2 Check that all the supports are securely fastened.
5.3.1.3 Check that all the insulators are clean.
5.3.1.4 Ensure continuous contact of collectors to conductors.
OM9B:PMI-0017 Pags 4 of 10 Rev. 0 5.3.1.5 Check the collector shoes and wheels for excessive wear and for freedom of movement.
5.3.1.6 Check term'inal and shunt connections for good contact.
5.3.2 Trolley.
5.3.2.1 Check the condition of the festoons.
5.3.2.2 Ensure cable support chains are of adequate length and are not broken.
5.4 Servicing Gearcases and Gear Reducers 5.4.1 Microdrive Gear Reducers.
NOTE:
The oil need not be changed if the crane has been idle for 1 year or greater and the oil appears clean and uncontaminated.
)
5.4.1.1 Drain old oil.
ENSURE NO OIL DROPS TO FLOOR BELOW.
5.4.1.2 Refill to proper level with Mobil DTE Extra Heavy.
5.4.1.3 Wipe up any spillage on gearcase and surrounding walkway.
5.4.1.4 Check that the mounting bolts are tight.
i 5.4.2 Main Driva Cearcases.
l NOTE:
The oil need not be changed if the crane has been idle for 1 year or greater and the oil appears clean and uncontaminated.
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OM9B:PMI-0017 Pags 5 of 10 Rev. 0 5.4.2.1 Remove gearcase breather and clean in solvent.
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5.4.2.2 Drain the oil from the gearcase.
5.4.2.3 Refill rhe gearcase with Mobil Vactra Oil BB to the level indicated by the dipstick.
5.4.2.4 Reinstall the gearcase breather.
5.4.2.5 Check that the mounting bolts are tight.
5.4.3 Pull-a-Hoist Gearcase.
NOTE:
The oil need not be changed if the crane has been idle for 1 year or greater and the oil appears clean and uncontaminated.
5.4.3.1 Remove gearcase breather and clean in solvent.
5.4.3.2 Drain the oil, tilting the gearcase so all the old oil is removed.
5.4.3.3 Refill with 1/2 pint Mobil Vactra Oil BB.
Ensure the oil is up to the level of the plug.
5.4.3.4 Reinstall the breather.
5.5 Inspection of Rails 5.5.1 Bridge and Trolley Rails.
5.5.1.1 Carefully inspect the rails along their full circum-ference or span.
Be alert for cracked rail clamp welds (trolley), loose clamp bolts (bridge), loose rails and any abnormal wear.
OM9B:PMI-0017 Pags 6 of 10 Rev. 0 5.6 Inspection of Wheels 5.6.1 Bridge and Trolley Wheels.
I 5.6.1.1 Check each wheel for flanging, flat spots and ab-normal wear.
5.6.1.2 Measure the tread diameter with a micrometer. Each pair of wheels shall not deviate by more than 0.010".
5.7 Structural Inspection 5.7.1 Bridge and Trolley.
5.7.1.1 Check girders, webs and supports for cracks, peeling paint or other signs of overstressing.
5.7.1.2 Randomly check mounting bolts for tightness.
5.7.1.3 Check for evidence of corrosion.
5.7.1.4 Check bumpers intact, and that the mounting bolts are tight, 5.8 Inspection of Hooks i
5.8.1 Hook MPT.
5.8.1.1 Conduct Magnetic Particle Testing of the hooks to detect any cracks.
l 5.8.1.2 File a copy of the completed MPT data sheets with the PM checklist.
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OM9B:PMI-0017 Pags 7 of 10 Rev. O i
5.9 Lubrication 5.9.1 Lubrication of flexible couplings.
5.9.1.1 Remove one of the grease plugs.
5.9.1.2 Fill with grease until it appears at vent hole.
5.9.1.3 Reinstall the vent plug.
6.0 POST-MAINTENANCE REQUIREMENTS 6.1 Ensure all guards and covers are properly reinstalled.
6.2 Ensure all tools and equipment are removed from the crane.
6.3 All switches and breakers shall be returned to normal.
6.4 Warning or out or order signs shall be removed.
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7.0 ACCEPTANCE CRITERIA 4
l 7.1 Requirements of this instruction shall be satisfied and/or exceptions noted.
7.2 Discrepancies must be corrected or scheduled for repair.
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8.0 REFERENCES
I.
8.1 OSHA Chapter XVII, Part 1910.179, " Overhead and Gantry Cranes."
I.
OM9B:PMI-0017 Pagn 8 of 10 Rev. O.
8.2 ANSI B30.2.0-1976,." Overhead and Gantry Cranes."
8.3 Harnischfeger Service Manual - Polar Crane 125/10 Ton.
9.0 LIST OF ATTACHMENT _S 9.1 - Yearly Preventive Maintenance - Electrical.
9.2 Attachment 2 - Yearly Preventive Maintenance - Mechanical.
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a OM9B:PMI-0017 Page 9 of 10 Rev. O YEARLY PREVENTIVE MAINTENANCE Polar Cranes IL51E0001 & 2L51E0001 Electrical Motors See Section 5.1 Satis.
Unsat.
Comments 1.
Bridge Drive Motor' A*
2.
Micro-Drive Bridge Motor A*
3.
Bridge Drive Motor B 4.
Ndcro-Drive Bridge Motor B 5.
Auxiliary Hoist Motor 6.
Main Hoist Motor 7.
Main Hoist Micro-Drive Motor 8.
Trolley Main Drive Motor 9.
Trolley Micro-Drive Motor 10.
Zip-Lift Hoist Motor 11.
Pull-a-Hoist Motor Panels & Controls See Section 5.2 Satis.
Unsat.
12.
Push Button Station 13.
Main Line Switch Panel 14.
Utility Circuit Breaker 15.
Bridge Breaker Rectifier 16.
Bridge Breaker Equipment 17.
Motor Breakers 18.
Line Cont./ Aux. doist Control 19.
Bridge Control 20.
Trolley Cont./ Aux. Equip. 1&2 21.
Main Hoist Control 22.
Aux. Hoist / Bridge Resistor 23.
Trolley / Main Hoist Resistor Conductors & Collectors See Section 5.3 Satis.
Unsat.
24.
Bridge 25.
Trolley Completed by Date Reviewed by Date
- Bridge Drive A refers to unit above operators cab.
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o QM9B:PMI-0017 Page-10 of 10 Rev. O YEARLY PREVENTIVE MAINTENANCE Polar Cranes IL5LE0001 & 2L51E0001 Mechanical Raila See Sectibn 5.5' Satis.
'Unsat.
Comments
- 1. Bridge
- 2. Trolley Wheels See Section 5.6
- 3. Bridge
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- 4. Trolley S truc ture See Section 5.7
- 5. Bridge
- 6. Trolley Hooks See Section 5.8
- 7. Main Hook MFI
- 8. Aux. Hook MPT GEARCAS ES SEE SECTION 5.4 LUBRICANT TYPE FITTINGS AMOUNT DONE
- 1. Bridge Drive A*
Mobil Vactra Oil BB Oil
- 2. Bridge Micro-Drive
- ~ '
Reducer A* '
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Mobil DTE Extra Heavy Oil 3.
Bridge Drive B Moo 11 Vactra Oil BB 011
- 4. Bridge Mic'ro-Drive Reducer B
~
Mobil DTE Extra Heavy 011
- 5. Trolley Drive Mobil Vactra 011 BB 011
- 6. Trolley Micro-Drive Reducer Mobil Vactra Oil BB'
' Oil
- 7. Aux. Holst Mobil Vactra 011 BB Oil
- 8. Main Hoist Mobil Vactra Oil BB Oil
- 9. Main Hoist Micro-Drive Mobil Vactra Oil BB Oil
- 10. Pull-a-Hoist Mobil Vactra Oil BB Oil 4 pint OTHER SEE SECTION 5.9
- 11. Bridge Drive A Coupling (2)
Mobilux EP-2 Grs.
1
- 12. Bridge Drive B Coupling (2)
Mobilux EP-2 Grs.
1 L3. Trolley Drive Coupling (4)
Mobilux EP-2 Grs.
1
- 14. Aux. Hoist Coupling (1)
Mobilux EP-2 Grs.
1
- 15. Main Hoist Coupling'(2)
Mobilux EP-2 Grs.
1 Completed by Date -
Reviewed by Date
- Bridge Drive A refers to unit above operators cab.
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.o GUIDELINE RECOMMENDATION
- 7. Crane Design (Section 2.3.7)
Information pertaining to the crane model maximum load capacity, manufacturer name, and purchase data should be provided for review.
RESPONSE
The following information (crane model, load capacity, manufacturer name and purchase data) is provided for review.
1.
Each crane shall be designed to meet the requirements of the American National Standards Code fsr Overhead and Gantry Cranes -- ANSI B30.2.0-1976, the Crane Manufacturers Association of American Specification No. 70 (CMAA No. 70) for Class Al indoor service, and Part 1910,179 of the Department of Labor Occupational Safety and Health Standards (OSHA).
2.
Motors and Controls shall be manufactured in accordance with National Electrical Manufacturers Association NEMA MGI-1972-18.501 through 18.520 (except for the Service Water Pumphouse Crane: which shall be as interpreted by Harnschfeger's Engineering Department -- SP-332),
NEMA ICS-1970 as follows:
SP-318 -- Part ICS 3-442 through 3-444 SP-332 -- Shall be met in its intent but not necessarily in every detail.
SP-502 -- Part ICS 3-442 Also the National Electric Code (NEC) 1971 Article 610 for SP-318 and 502. For SP-332 follow P&H Bulletin 580.
- 3. Gears shall be in accordance with the American Gear Manufacturers Association (AGMA) as follows:
SP-318 -- as modified by Section 4.5.2 of CMAA No. 70 SP-332 -- AGMA standards SP-502 -- AGMA Handbook 390.03 CRANE DATA Crane Manufacturer Capacity Type Serial No.
Turbine Bldg (4)
Whiting Corp.
215/25 T OVHD 11100, 01, 02, 03 Circ Wtr PH(2)
Whiting Corp.
80/10 T OVHD 11104,05 Service Wtr(l)
Harnischfeger 15 Ton OVHD CN 26300 Polar Crane (2)
Harnischfeger 125/10 T OVHD CN 25588, 89 Emg Ser Wtr Ph Harnischfeger 15 Ton OVHD CN 25591 Fuel Hdig Area Harnischfeger 125/20 T OVHD CN 25590
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