ML20049H911
| ML20049H911 | |
| Person / Time | |
|---|---|
| Site: | Sequoyah  |
| Issue date: | 08/02/1980 |
| From: | TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML20049H905 | List: |
| References | |
| REF-GTECI-A-36, REF-GTECI-SF, RTR-NUREG-0612, RTR-NUREG-612, TASK-A-36, TASK-OR GL-81-07, GL-81-7, MSL-A37, NUDOCS 8203040573 | |
| Download: ML20049H911 (14) | |
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0-TENNESSEE VALLEY AUTHORITY Page 1 SEQUOYAH NUCLEAR PLANT MSL-A37 MAINTENANCE SECTION LETTER Revision 2 3/20/80 OPERATION MAINTENANCE, TESTING AND INSPECTION OF NUCLEAR PLANT CRANES AND
- E0ISTS, ANSI standard B30.2.0 - 19y0Nrhead4nIGant
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s" S on Refe)ences:
19J0'179,/"Overhea nery Crapes '- (OSHA Rej;ulati d
ppMNo.p*74Mfs, m" p Qualifications of Crane Operators The electrical maintenance supervisor shall be responsible for determining who is qualified to operate eath~ crane in the plant._
A crane operator eligibility list shall be maintained by tne electrical maint-enance supervisor for each overhead traveling bridge crane in the plant. Each operator shall be requalified medically at least every two years.
The turbine room cranes, polar cranes, reactor building cranes, and auxiliary building cranes, when used for important lifts such as fuel. casks, reactor heads, reactor internals, turbine disassembly, etc., shall be operated only by crart operators who have proved to the electrical maintenance supervisor that they meet the following qualifications.
1.
Have vision of at least 20/30 snellen in one eye and 20/50 in the other, with or without corrective lenses.
2.
Be able to distinguish colors regardless of position of the color and have normal depth perception and field of vision.
3.
Have* hearing adequate for a specific operation.
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4.
Have emotional stability add physical con'dition without evidence or history of seizures or loss of physical control, or other conditions that could result during operation of the crane in a hazard to himself, other people, or the equipment.
t 5.
Have sufficient strength, endurance, agility, coordination, and speed of reaction to meet the demands of equipment operation.
6.
Know standard hand signals, crane operation safety procedures, and any special material nandling rules and restrictions for the area in which the crane operates. This knowledge.is to be evaluated through either written or oral examinations.
Standard signals are listed in Appendix E.
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8203040573 820301 PDR ADOCK 05000327 P
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MSL-A37 Revision 2.
3/20/80 7
7.
Have demonstrated to the electrical maintenance supervisor satisfactory ability in the proper operation of the particular crane for which the operator is to be certified.
An operator must demonstrate his ability a
to operate satisfactorily each different type of crane (controls layout, hook arrangement, travel mode, limitations, etc.) to which the operator is to be certified.
Credentials attesting to the satisfactory operation of duplicate equipment may be accepted in lieu of an operational test.
Operation of these cranes at other times and all other plant cranes and hoists shall be limited to the following qualified personnel:
1.
Certified operators 2.
Trainees under the direct supervision of a certified operator 3.
Maintenance, operations and test personnel when operation is necessary in the performance of their duties 4.
Inspectors Eligible operators for each crane are listed in Appendix A.
9 Inspections and Tests Three different inspections shall be performed on all overhead traveling bridge cranes.
These inspections shall be performed as indicated.
Inspection records shall be reviewed by the electrical maintenance supervisor and records of all inspections shall be kept for' review by 'the Nuclear Maintenance Branch and other authorized organizations.
A.
Frequent Incpections--This. inspection, performed by the crane operator, consists of a daily visual and operational inspection of each crane prior
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to use.
Operators of the same crane on different shifts shall make their individual inspection. On days when the crane will not be used, no inspec-tion'is necessary.
.If only one hoist on multihoist cranes will be used, the inspection need only be performed for that hoist. A checklist form e
(Appendix B, C, or D) shall be made and the crane operator shall initial each applicable checkpoint prior to crane operation, attesting to the fact that each point has been checked and is satisfactory.
This form shall include the following checks.
- 1. -Visual inspection of hoist ropes, end attachments, Icad plates, load cells,
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hooks, safety latches, and crane capacity markings. No measuring devices are necessary since these observations are intended to determine proper operating condition and that no observable damage has occured.
2.
Visual inspection of lifting slings or chains expected to be used during the i
shift..
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Page 3 MSL-A37 Revision 2 3/20/80 3.
Visual inspection of the crane for leaks, cleanliness loose objects, open panels, and excessive wear of any functional mechanical component.
4.
An approved fire extinguisher, in proper working condition, is mounted in the cab or other designated locations.
5.
Proper operation of all controls. This should be checked without a load on the hoists.
6.
Proper operation of all brakes. The load brake should be checked at the first heavy lift by stopping the lift when the full weight is first.taken by the crane and verifying the brake holds the load without. drifting.
7.
Proper operation of all limit switches, except the hoist down limit switch which may be omitted from checking. The upper limit switch and other limit switches are to be checked by " inching" to the switch or moving at the slowest speed without a load on the hoist.
8.
Proper operation of load-indication devices on the first lift of the day.
9.
Verify operation of bridge movement warning devices and manually operated warning devices.
B.
Periodic Inspections--This inspection consists of a more detailed inspection than the frequent inspection.
If a crane has been in nearly continuous service for approximately one month as during a refueling and/or modification outage in addition to the frequent inspections performed, all wire ropes are to be inspected per item Bl.
If the regular use of the crane is expected to be discontinued within 15 additional days, the wire rope inspection may be postponed and incorporated with the post-outage or the next preoutage general inspection. Otherwise, wire rope inspections are to be made ca a aor F..ly sched.le when the crancs are in regular service.
Cranes which.have been idle for more than one month, but less than six months shall have performed on them prior to being placed in service an inspection consisting of the frequent inspection items plus the wire rope inspection detailed as item Bl.
Cranes which have been idle for more than six months shall have performed on
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them prict to being placed in service an inspection consisting of the frequent inspection items plus all the itens listed in this paragraph B.
Cranes which are in continued regular use shall undergo, at least at six-month intervals, an inspection consisting of all the items listed in this paragraph B.
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Pagc 4 MSL-A37 Revision 2 3/20/80 1.
Hoisting wire ropes shall be thoroughly inspected including those
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portions normally hidden from view, and measurements taken as necessary to establish the amount of wear on the wire ropes. Inspections shall
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be of such details as to establish the condition of the wire rope, and a determination shall be made as to whether to continue use of the rope (or to increase frequency of inspections) if any condition progresses to the following extent:
Reduction of rope diameter below nominal diameter due to loss of a.
core support, internal or external corrosion, or wear of outside wires, as follows:
Nominal Reduction Nominal Re' duction
~ Diameter Greater Than Diameter Greater Than Up to 5/16" incl.
1/64" 7/8" 1/8" 1/16" 3/8" - 1/2" 1/32" 1-1/4" 1/2" 3/32"
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b.
Wear of one-third the original diameter of outside individual wires.
4-c.
Individual wires broken,12 random in one rope or 4 broken in one strand in one rope lay.
5 d.
Corroded or broken wires at end connections.
e.
Corroded, tracked, bent, worn, or improperly applied end connections.
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f.
Kinking, crushing, cutting, unstranding, or any other damage resulting in distortion of the rope structure.
g.
Exposure to temperature sufficient to discolor the wire or cause deterioration of any portion of the wire vtpe structure.
2.
Bridge motor commutator and brushes i
3.
Trolley motor commutator and brushes 4.
Main hoist motor commutator and brushes J.
5.
Auxiliary hoist motor commutator and brushes 6.
All MG set commutators and brushes
.7.
Sight and sound inspection of all gear boxes.
8.
Sight and sound inspection of track wheels and bearings 9.
Sight and sound inspection of all motor bearings d
10.
All controllers (operation and identification tags)
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11.
Properseatingofall; brakes 12.
All limit switches. Verify that, when the down limit switch is activated
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from the greatest speed, the hoist drum stops with two wraps of wire rope remaining on the drum.
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Page 5 MSL-A37 Revision 2 3/20/80
- 13. Visual-inspection of all structural members of the crane for deformation, cracks, corrosion, and loose fasteners.
b-
- 14. Rails and rail clamps for breaks, flat spots, looseness, general alignment, e
etc.
- 15. All. sheaves and hoist drums for wear, using groove wear indication gauges.
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- 16. Visual inspections of cabinets for loose articles, loose wires, and any evidence of unusual arcing or burning.
s.
- 17. Check all. lubrication levels where necessary.
- 18. Check calibration and prove proper operation of load indication devices.
- 19. Check proper operation of emergency stop buttons.
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- 20. Check all' radio control functions.
Periodic inspections shall be imp'amrated by detailed maintenance instructions which
.shall include itemized data sheets for reporting results of the inspections. The inspections shall be performed by persons designated by the plant superintendent
- Q' or Chief, Power Plant Maintenance Branch.
.a C.
Major Safety Inspection--This inspection consists of checking the major safety-
.related devices and components on each overhead traveling bridge crane
.and sh:1' includ-the #milot'ing igans in addition to all the ' requirements of the periodic inspection, paragraph B, and shall be performed at least annually on cranes in regular service.
If a crane will not be us,ed for a period of more 3
than one year, this inspection need not be performed annually but must be
- s performed prior to reuse. 0ther inspections may be performed at other times to, establish ~ the need for maintenance allowing sufficient time for any required maintenance to be performed prior to reuse.
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1.
A load test equal to the expected maximum lift is to be performed unless the load lifting record shows a lift of approximately equal or greater weight. The construction acceptance or preoperational tests may be used for ~
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new cranes.
2.
An inspection of-the_ crane hook for cracks by the magnetic particle or 2:
. other suitable crack testing method. Other load-bearing portions of the c
-i load attachment ' system shall also be checked if impending failure may s-
-not be readily detected.by the frequent inspectiou methods. Hooks shall
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be measured as a*part of this inspection to establish that the hook has no more than 15 percent in excess of the new throat opening dimension and that the hook. is not bent more than 10 percent from the plane of the unbent hook.
Cracks or wear. or distortion in excess of the amount stated.is cause for replacement of the hook.
d 3.
Prove proper operation of the phase loss of reversal relay.
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4.
Prove' proper operation.of the IOC (instantaneous overcurrent) relay.
-5.
Prove proper operation of the emergency dynamic braking.
6.-
Prove' proper operation of hoist field loss relays.
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rage u MSL A37 Ravision 2 3/20/80
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7.
Verify operation of the upper limit switch at increasing speeds up to and including the maximum hoisting speed.
8.
Inspect mechanical hoist, drive, and brake components for defects such as worn and cracked drums and sheaves and worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers, sprockets, chains, linings, pawls, ratchets, and locking and damping devices.
D.
Load Test--A load test of 125 percent of rated load shall be performed on each crane at the initial construction acceptance test (or preoperational test) and af ter a major modification or maintenance to load bearing members of the crane.
(The crane may be rated at not more than 80 percent of the test load imposed.)
A lqsd test of 100 percent of rated load shall-be~, performed on each crano after b cement of the wire.. rope ( This test should be performed only after proper brea 2u
- 2he J1re rope,_as specified in Appendix F.
The u
in attaTnTng a sansf ory_ service break-in routine is'especially important s
life.of stainless steel wire rope. % mr tWef, 8b (
4 E.
Preoperational Tests--Before transfer of a crane or major hoist to the Division of Nuclear Power as a permanent plant feature, a preoperational test shall be performed to ensure that all operational and safety features are functional as required.
This test shall consist of a periodic inspection supplemented by the major safety inspection, and shall'aerve as a " base line" for hook and wire rope. measurements.
Maintenance Maintenance of the cranes shall be performed by designated personnel in accord-ance sit!. -he manufacturer's instructions supplemented by TVA instructions which should also incorporate the provisions of ANSI standard B30.2.0 and Section 1910.179 regarding maintenance safety.
Load Markings The rated load of the crane shall be marked on each side of the crane and, if the crane has more than one hoisting unit, each hoist shall'have its rated load marked on it or its load block. This marking shall be legible j
fror the ground or floor.
i Records 2
All mai~ntanance activities and inspections shall be documented and records
.kept current for overhead traveling bridge cranes. A record of major lifts shall be kept. A record of major lifts serves the same purpose as test loads and verifies that the crane is capable of handling the various loads.
Major lif ts are considered as lifts of 60-percent capacity or more.
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Page 7 MSL-A37 Revision 2 3/20/80 Special Operating Instructions When lifting a load, special care shall be taken to operate the hoist at minimum speed until the load is fully suspended and has cleared all possible obstructions. All crane operating safety procedures should be observed as
- listed in DPM N78S2,Section IV, procedure M17-Cranes and Hoists.
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Y Maintenance Supe'rvisor, Electrical Attachment General Revision
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Page 8 APPENDIX A MSL-A37 Up,
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Revision 4
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8/2/80
, The following employees n're eligible to operate the turbine room 200-ton crane,
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MEDICAL REVALUATION MEDICAL REVALUATION DUE DUE Malcolm D. Brumley 81-03-26 Warner B. Hunnicutt 81-03-25
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. Charles E. Dudley 81-03-25 Joe W. Overton 81-04-09 James A. Nash 81-03-25 Charles W. Sauvage 81-04-09 Jerry L. Phillips 81-04-08 Clifford W. Suddeth Calvin S. Steele 81-03-25 James R. Thurman 3,
Sidney M. Thacker Michael E. Cope 81-03-19 Johnny H. Beene 81-03-26 Hugh P. Irvin 81-06-21_
Jerry W. Carpenter 81-03-25 James G. Newman 81-03-26 i
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Thomas V. Crider 81-04-02 Kabah Raheem 81-03-25 James B. Hogue 81-04-01 John D. Roberts, Sr.
81-04-02 Charles E. Holder 81-03-25 Charles L. Rogers 81-03-25 a
Jerry A. Hunt 81-04,_01 Charles R. Brown 81-07-08 Joseph R. Hope' 81-07-08 John D. Marsh William E. Johnson Thomas C. Reeves 81-03-25 M.hard S. Foltz 81-07-03 Robert R.'Randolph 81-04-09
]
The following employees are eligible to operate the auxiliary building crane.
Malcolm D. Brumley 81-03-26 Warner B. Hunnicutt 81-03-25 Charles E. Dudley 81-03-25 Joe W. Overton 81-04-09 James A. Nash 81-03-25
-Charles W. Sauvage 81-04-09 Jerry L. Phillips 81-04-08 Clifford W. Suddeth Calvin S. Steele 81-03-25 James R. Thurman Sidney M. Thacker Michael E. Cope 81-03-19 James A. Goodlet Gregory A. Lawson 81-04-09 i
Richard S. Foltz 81-07-03 William O. Scalf 81-04-11 Robert R. Randolph 81-04-09 Hugh P. Irvin 81-06-21 Johnny H. Beene 81-03-26 James G. Newman 81-03-26 Jerry W. Caprenter 81-03-25 Kabah Raheem 81-03-25 Thomas W. Grider 81-04-02 John D. Roberts, Sr.
81-04-02 James B. Hogue 81-04-01 Charles L. Rogers 81-03-25 Charles E. Holder 81-03-25 Charles R.. Brown 81-07-08 Jerry A. Hunt 81-04-01 John D.* Marsh i_
- Jospeh R. Hope 81-07-08
-Thomas C. Reeves 81-03-25 William E. Johnson The following employees are eligible to operate the reactor building polar cranes.
Malcolm D. Brumley 81-03-26 Warner B. Hunnicutt 81-03-25 Charles E.~ Dudley 81-03-25 Jerry L. Phillips 81-04-08 James A..Nash 81-03-25 Clifford W. Suddeth
- 5 Calvin S. Steele 81-03-25 James R. Thurman Sidney M. Thacker 81-03-25 Michael E. Cope 81-03-19 Johnny H.'Beene 03-26 Hugh P. Irvin
__ 81-06-21 Jerry W. Carpenter 81-03-25 James G. Newman 81-03-26 Thomas W. Grider 81-04-02 Kabah Raheem 81-03-25
' James B.'Hogue 81-04-01 John D.-Roberts, Sr.
81-04-02 a
Charles E. Holder 81-03-25 Charles L. Rogers 81-03-19 Jerry A. Hunt 81-04-01 John D. Marsh-Jospeh'R. Hope 81-07-08 Thomas C. Reeves' 81-03-25 William E. Johnson
. Charles,W.,FoltzSauvage.81-04-09
' Robert R.:Randolph,,
81-04-09' 91 Richard S.
81-07-03
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Paga 8a MSL-A37
, Revision 4 8/2/80 APPENDIX A The following employees are considered crane operator trainees and may operate either the turbine building. auxiliary building or reactor build-ing cranes whenever one of the eligible operators for respective crane is present in the control cab.
Medical Revaluation Medical Revaluation Due Due Henry C. Burnette Fred E. Mills 81-07-08 Bruce L. Gargis 81-03-25 William T. Mitchell 81-04-08 Billy M. Mitchell 81-03-25 Bobby L. Price Sam F. Cauble 81-04-08 William A. Fairfax 81-07-09 Nat Crews 81-07-08
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Walter A. Watson Electrical Msintenance Supervisor ed.
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AppendLE B Revision 2 3/20/80 AUXILIARY BUILDING CRANE FREQUENT (DAILY) INSPECTION DATA SHEET
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Instructions: Esch dny before lifting P lood, function =lly test and verify proper operntion of the following except:
a.
Overtrrvel limit svitches on inrge enpecity hoist need not be checked unless its us? is intended.
b.
Dean lLnit switches on either hook need not be checked unless hooks use is intended on same floor elevntion rs thet where limit is functionel.
l Initialed test operetion indicates setisfnetory operation. Any operetirn found unsetisfsetory shell be reported to the operntor's supervisor prior to lifting sny lor.d.
INITIALS OPERATION DATr.,
Emergency Ston Button i
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l Bridge c.
Control (East & West) l l
b.
Jog Control (East & West) l I
l c.
Brnkes (Electric) i d.
Brnkes (Hydraulic) i e.
LLnits Prevent Hook Movement Over i
Suent Fuel Po_o1_(East & West)
Trolley
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L WEY. M M <
c.
Control (North & South) b.
Jog Control (Ucrth & South) c.
':Bre;kes-i i
I d.
Limits Prevent Hook Movement Over Scent Fuel Pool (North & South) l Main Hoist e.
Controls (Up & Down) b.
Brrkes l
l c.
Up TAmit d.
Down Limit l
-l Auxilirity Hoist j
a.
Controls (Up & Down) b.
Brrikes c.
Up Limit d.
Down Limit j __ _
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' Visual inspection of hoist ropes, hooks, latche slings, chains, load cells and crane capacity I
markinc.
Visual inspection of crane for cleanliness,
, leaks, loose objects and excessive componet i
. wear._;/ Approved Fire Extinguisher in Cab 3*
Bridce movement and manual warning devices Reviewed By:
Date:
Electrical Maintenance Supervisor or Assistant Electrical Maintenance Supervisor
rbgt 1 U MSL-A37 Appendix C Revision 2 4
3/20/80 REACTOR B'?ILDING POLAR CPXIE FREQUENT (DAILY) INSPECTION DATA SHEET Unit "I
Instructions: Eech dny before lifting e lond, functionally test nnd verify proper operation of the following except:
n.
Overtravel limit switches on lerge capacity hoist need not be checked unless its use is intended.
.7 Initicled test operation indientes sntisfactory operetion. Any operotion found unse.tisfactory shall be reported to the operator's supervisor prior to lifting any lop.d.
INITIAIS OPERATION DATE Emercency Ston Button t
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Bricge a.
Control (Right & Left) b.
Jog Control (Right & Left)
I t
c.
Brekes (Electric)
I t
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Brekes (Hydraulle) q i
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Trolley n.
Control (Forward & Reverse) b.
Jog Control (Righ+,& ', eft) t c.
Ernkes j
j j
l Main lioist n.
Controls (Up & Down) b.
Brekes
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I c.
Up Limit i
d.
Down Limit t
m Auxiliery Hoist Controls (Up & Down) e.
b.
Brekes l
c.
Up Limit d.
Down Limit Visual inspection of hoist ropes, hooks, 5
latches, slings, chains, load cells and crane capacity marking.
Visual inspection of crane for cleanlinass leaks, loose objects and excessisa componet j
wear.
1 Approved fire extinguisher in cab bridge movement and manual warnine devices I
Reviewed By:
Date:
3 Electrical Main?.enance Supervisor or Assistant Electrical Maintenance Supervisor m
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Page 11 IGL-A37 Appen & D Revision 2 3/20/80 l
TURBIITE BUIlDIIU 200-TOIT CRAIG FREQUEI!T (DAILY) IIISPECTIOIl DATA SIEET Unit
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l Instructions: Eech day before lifting r. lond, functionclly test end verify operetion j
of the folloving except:
1-e.
Overtrsvel limit switches on irrge e pecity hoist need not be checked unless its l
use is intended.
i b.
Down limit svitches on either hook need not be checked unless hooks use is intended l_
on same floor elevation as that where limit is functional.
l Initialed test operrtion indicates sctisfoctory operetion. Any operation found
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ur.cntisfectory shell be reported to the operetor's supervisor prior to lifting eny load.
IITITIALS j
OPERATICI?
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l Emergency Ston Button i
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Bridge j
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Control (Right end Left)
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b.
Jog Control (Right & Ieft) c.
Ernkes (Electric) i d.
Brokes (Hydrnulic) i i
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c m Trolley i
c.
Control (Forvard & Reverse) l]
b.
Jog Control (Right & left) i i
c.
BrPkes
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Mein lioist j.,
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Control (Up & Down) i, b.
Brakes j
c.
Up Limit i
l d.
Down Limit l
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l Auxiliery lioist a.
Control (Up & Down) j b.
Brakes l
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c.
Up Limit 9
d.
Down Limit i
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Visual inspection of hoist ropes, hooks, l
J latches, slings, chains, load ec11s and crane capacity marking.
Visual inspection of crane for cleanliness leaks, loose objects and excessive.componet
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wear.
Approved fire extinguisher in cab bridge movement and manual warning devices 4
l
- Reviewed By:
Date Electrical Maintenance Supervisor or Assistant Electrical Maintenance Supervisor
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MSL-A37
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W Pagm 13 APPENDIX F MSL-A37 Revision 2 j
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3; 3/20/50
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