ML20086B212
| ML20086B212 | |
| Person / Time | |
|---|---|
| Site: | Robinson  |
| Issue date: | 12/22/1970 |
| From: | Utley E CAROLINA POWER & LIGHT CO. |
| To: | Morris P US ATOMIC ENERGY COMMISSION (AEC) |
| Shared Package | |
| ML20086B204 | List: |
| References | |
| NUDOCS 8311170099 | |
| Download: ML20086B212 (18) | |
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- Carolina Power & Light Company Raleigh, North Carolina 27602 g ..,
December 22, 1970 Y
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Dr. Peter A. Morris .
Division of Reactor Licensing
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U. S. Atomic Energy Commission .
Washington, D. C. 20545 RE: FACILITY LICENSE NO. DPR-23 ,
DOCKET No. 50-261 ,
Dear Dr. Morris:
On November 27, 1970 the. control rod assembly located in position P-6 failed to insert following a reactor trip. The attached 4' report concerning this incident is submitted as an item of interest !
to the AEC. 2 It is concluded that the circumstances that caused a piece of foreign material to lodge between a rodlet and corresponding guide gh' tube assembly was a unique and random event. The complete boroscope inspection of all guide tube assemblies affords reasonable assurance .,
le 6-that additional foreign material is not present. Additional tests to verify the operation of the control rods will be conducted prior to the' , #
y 1a resumption of the planned start-up test program. 4.4 a-IS/g@M&H.u/71 Yours very truly,
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Manager
'A b-Generation & System Operations
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H. B. Robinson Steam Electric Plant Unit No. 2 S V nr n%,
REPORT: Stuck Rod Control Cluster Assembly Decem,ber 21, 1970 I. Summary "
A. Following a reactor trip on November 26, 1970, there was an immediate indication that Rod Control Cluster (RCC) assembly at location P-6 did not fully insert following the trip signal.
B. Following removal of the reactor vessel head and subsequent investiga-tions, it was determined that RCC assembly P-6 was stuck in its. guide-tube assembly in the fully withdrawn position. The ctuck condition was judged to have been caused by a small metallic particle, foreign to the reactor coolant system, becoming lodged between one rodlet on the RCC assembly and the adjacent guide tube assembly louer tube.
C. The following components were considered unusable and were replaced as a result of the subsequent review and inspections: Rod Control Cluster assembly No. 44 and Cuide Tube assembly No. 3-A. No other adverse effects to the plant were determined as a result of this stuch RCC assembly.
D. Following re-assembly of the core components and reactor internals, the reactor vessel head was replaced on the reactor vessel on December 11,
- 1970. Tensioning of studs was completed and system checkouts initiated.
in preparation for carly resumption of the start-up test program.
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- II. Backnround The completed primary coolant system, with all control rod drive mechanisms and reactor internals in place, successfully passed _a cold hydrostatic test on March 29, 1970 and completed the hot-functional test on April 28,~1970.
Core loading was started on August 4,.1970 with initial criticality occurrini-on September 20, 1970. Cold and' hot Control Rod drop tests _wcre also com-plcted within this period. Cleaning, flushing, and cicanliness inspection.
of primary coolant components and the reactor coolant system interior had -
previously been completed in accordance with Ucstinghouse criteria.
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During the period September 25 through November 26, 1970', ' th'c' H'. B.; Robinson-Unit No. 2 plant was. operated at various power levels up to 29-percent of
' licensed power rating with no adverse ' history ~or erratic operation ~ noted' for the RCC assembly or drive chain at reactor vessel. grid location'P-6.
-On November 26, 1970, the-reactor coolant: system was operating at approxi-mately 18~ percent power; system pressure and' temperature were normal for-4
. this mode of_ operation. Following a plant trip at 1716 on November. 26,1970, thc' position indication for RCC location P-6 showed- that insertion:had 'not
- taken place; i.e. .. the position was indicated at 228 steps, or full withdrr.wa: .
No other unusual conditions wcro noted for_the reactor coolant system at thc3 time of this. plant trip.
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III. Investirstien and EvalualIon Investigatio_ of the stuck RCC assembly condition was started immediately, first to cent irm the RCC assembly was actually not in the fully inserted scram position, and subsequently, to establish the extent of adversely effected components, determine cause, and restore the plant to an operabic condition. Each operation taken during the step-by-step evaluation was made in accordance with requirements in the Technical Specifications as well as radiation control measures established by Carolina Power & Light Company. Procedures were prepared by Westinghouse to augment the normal refueling' procedures and present a logical sequence of positive checks to assure that additional damage would not be sustained by the drive line and reactor components (Figure 1) during disassembly. Procedures are appended to this report.
Immediately following the plant trip, the Rod Position Indication (RP1) system indicated the RCC assembly at grid location P-6 was almost fully withdrawn and could not be inscrted, tripped or further withdrawn. Several aJtemntLucre made to insert, withdrnu pad trip-(in lba_t_ order). Oscillo-graph traces were made during mechanism operation and from these traces it was determined that the mechanism magnets were functioning, however,
' the rod did not insert, withdraw or trip. Oscillograph traces of a CRDM-known to be operating properly were made for comparison purposes.
(Oscillograph traces consist of current traces.of the lift coil and two gripper coils, and sound transducer traces of cach of the three magnet )
poles). This indicated that the rod was probably stuck below the. control rod' mechanism.
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A review of the drive line record data indicated that guide tube assembly number 3-A (installed after hot functional testing) and RCC assembly t
number 44 were installed at reactor vessel grid location P-6.
Plant cooldown to cold shutdown conditions were initiated and the Residual llent Removal System (RIIRS) was .placed in service. . When cold shutdown conditions werc~ reached, the reactor coolant-system was drained to 18 inches.
below the vessel flange, borated to 2117 ppm boron and maintained less than
- 140*F by the RHRS. The seal wcld on the CRDM middle joint (rod travel housing to latch mechanism housing seal weld) was cut to' permit direct accessto the drive line attached to'the RCC assembly to establish if a mechanism malfunc, tion was the cause of the stuck RCC assembly.. See Figure 2.
The rod travel housing'and then'the latch assembly were removed but in each instance the remaining drive line still remained stuck indicat-j ing the cause of the interference was located in the lower' parts.
1 Dimension checks.at this point. indicated.the RCC assembly was at-the full withdrawn position with the RCC spider within the uppermost guidc' plate in the upper guide tube assembly. A furtherscheck was made to assure
-there was no interference between the CRDM drive shaf t and the reactor.
vessel head penetration / thermal sleeve prior to raising of the reactor
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Investination and Evaluation (Continued) .
vessel head. Radiation levels at the top of the drive mechanism housing were 7-8 mr/hr and 10 mr/hr at the reactor vessel flange with the head.
raised slightly. With these radiation levels, the refueling cavity was not flooded for continuation of operations. The reactor vessel head and control rod drive shaft were then removed without. incident. Prior to reactor vessel head removal, a remote TV camera was positioned to record (for later viewing via magnetic tape) all significant operations during this event.
A visual examination of the RCC spider and guide tube guide plate interface-did not reveal the cause of the interference. The spider was observed to have nominal clearance within the guide plate. The spider was also observed to be intact with no cracked braze joints or broken vancs.
The upper guide tube assembly (Figure 3) was unbolted from the intermediate assembly and carefully lifted off its support surface. It passed freely over the RCC indicating that no interference existed in this arca and alternate procedure (A) appendix A-1 was then put into effect.
The lower and intermediate guide tube assembly was lif ted from the upper -
internals. At this time the RCC assembly was observed to move with tive intermediate guide tube indicating that the interference condition existed in this portion of the drive line system. The guide tube and RCC assembly vere removed from the upper ' internals assembly and placed in a thoroughly cleaned, specially fabricated storage tank filled with D.I. water and l having a white lint free catch cloth placed on the bottom of the tank.
I A visual observation of the uppermost plate of the intermediate guide tube assembly indicated that a cicarance condition existed at this evaluation and the cause of the interference was below this arca; the exact rod causing the interference could not yet be' determined.
To separate the RCC assembly, the intermediate guide tube was secured to the specially fabricated storage tank and the RCC assembly was raised-approximately 6 inches and then ' lowered _ into the guide tube. The RCC moved freely downward for approximately.1-1/2 inches and then stoppad.
This process was repeated several times suggesting that an obstruction existed that would permit free upward movement of the RCC but only limited downward movement.
The RCC assembly was then raised in small increments until the end of the rods cleared the lower guide tube assembly. At this point the RCC was '
observed to have. free movement within the guide tube-in both directions.
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III. Investigation and Evaluation (Continued)
The RCC was then loucred a distance of 36 inches into the guide tube to permit the end of the rods to extend belou the bottom of the guide tube assembly, thus verifying that the RCC assembly was free. Inspection of the RCC spider assembly at this time now revealed a crack on the doubic control rod vano at the joint that secures the vane to the spider hub. The vane in question was located on the corner in the 180 - 270 quadrant of the RCC.
The RCC assembly was then removed from the guide tube, placed in a polyethylene bag and suspended from the refueling cavity wall. The guide tube was removed from the storage tank and placed on the refueling cavity floor.
Inspection of the catch cloth in the bottom of the storage tank showed a small metallic particle ellipsoidal in shape with dimensions approximately-
.090 inch by .060 inch. No other foreign matter was found in the storage tank or catch cloth, i
4 Examination of the guide tube was then made using a boroscope. No foreign i particles were observed on any of the intermediate-guido plates. Ilowever, a gougo mark was observed on a tubular guide which is a part of the lower guide tube assembly. This mark waa located at the top of the lower assembly on the inside diameter of the tubular guide adjacent to the sheath assembly housing the cracked control rod vane ~and c'n the 180 side of the sheath. The approximate dimensions of this gouge were .060 inch wide by
.75 inch long by .030 .060 deep at the deepest point. The mark was flush with the tube diameter at the top and tapered downward with regard to depth.
The lower guide tube assembly was then removed from the intermediate assembly for.a close visual inspection. This examination revealed an additional score mark approximately 1.50 inches long and. located 180 opposite the previously mentioned mark.
A boroscopic examination of the bottom of the control rod element associated with the severely gouged tube revealed similar score marks that began approximately 50 inches above the end of the rod and continued down to the bottom end.
A close visual examination of the RCC spider assembly was made. One zgane braze joint _was found cracked but no severe score marks on tRe vanes _
or_ fingers =were-obscryed. The crack began at the top of the joint and extended downward a distance of 2 inches.
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Figure 4 has been prepared to show a means by which the particle could have wedged between the control rodlet and tube sufficiently to cause binding and the stuck condition,for the RCC assembly, llorizontal burnish marks were also found on the control rods. The marks were caused by Jateral displacement induced by the stuck rod. These marks occur at discrect elevations that begin at the spider and are located along this length of the rods at points that correspond to the locations of the intermediate guide plates. No particular significance is placed on these marks.
, A complete boroscopic examination of all guide tubes was performed and no evidence of additional foreign particles was found.
A boroscopic cxamination of the specific fuel assembly and adapter plate at location P-6 was made. No damage or foreign material was evident from this inspection.
The CRDM drive shaf t removed from Location P-6 was examined in dethiled and determined.to be acceptable for reinstallation.
Complete inspection of guide tube assembly 3-A and RCC assembly No. 44 indicated they were unsuitable for reuse. Replacement of these two components was made with new assemblics. Installation was made as per attac.hed Procedure for Guide Tube Installation, Appendix A-2.
i: Af ter the replacement guide tube and RCC assembly were installed and '
completion of guide tube inspection, a pull test was performed on all drive shafts and RCC assemblics to verify case of movement. See Appendix l A-3 for procedure used.
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Reassembly of the CRDM mechanism, welding and testing were performed in accordance with Westinghouse criteria and specifications. The latch asscubly was inspected to assure freedom of all moving parts and reassembled.
Latching of drive shafts to RCC assemblies was completed on December 11, 1970 and reactor vessel head was placed in position on the.rcactor vessel on December 11, 1970. As part of the' final verification of CRDM drive line operability, cold and hot control rod drop tests .will be performed on all.CRDM's prior to resumption of the Start-Up Test Program.
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The small foreign object removed from the guide tubc/RCC assembly was cubmitted for analysis at Westinghouse labs at Waltz Mills, Pa. The object j was a spheroid .075" x .090" with the surface appearing slightly dimpicd (several 30X photos were madeiprior. to any analytical work). Analysis by x-ray fluorescence provided the'following results, accurate.within 5 percent of cach value:
Fe 65.6%.
i Cr- 28.8%
Ni 8.41%
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- The material conforms to'the analysis of Type;312 stainless steel.
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In an effort te determine the source of the Type 312 material (i.c, whether a wire clippin;; or wc]d spatter) the specimen was prepared meta]Iographically in tbc Haltz Mill llot Cc]ls. The specimen structure was determined to be cast (i.e.; weld spatter) with same laps and evidence of pcening on the surface indicating that the object had been battered about. T g far, no. source of Type 312 uc1d material within the reactor coolant system has been identifled. ^
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IV. _ Conclusions From the preceding facts, investigations, and evaluations , the following conclusions can be made:
A. The control rod malfunction at reactor vessel grid location P-6 was caused by a picec of foreign material lodging in the annulus betwacn an RCC assembly rodlet and its adjacent guide tube assembly lower tube.
B. The foreign material was Type 312 stainless steel weld spatter.
C. No source of the Type 312 stainless steel wcld material can bc ;
identified within the reactor coolant system. ,,
1 D. The interior of the guide tube assemblics are clean and free of all such foreign material that could cause a reoccurence of drive line malfunction.
E. The cracked vano on the RCC spider resulted from attempts to free the RCC assembly Irom the guide tube af ter removal from the reactor vessel.
F. The RCC assembly and guide tube are not reusable.
G. The control rod drive shaft used at reactor vessel grid location P-6 is reusable.
- 11. Subject to satisfactory completion of rod drop tests noted under Paragraph III, all control rods are considered operable with no imparcnent in performance or function. ~
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. o "St uck" - 1:CC - Ret. oval Procedite November 30, 1970 .
- 1. Secure .e top of the drive shaf t to a conv mifat st.it ionary chject .
- 2. Station 2 reactor personnel and health physics personnel at reactor head, near c' ore location P-6.
- 3. 11egin to If f t RV bead. !!onitor radiation Icvols and observe the drive chaft during RV head moveraent .
Note: Stop crane immediately if the drive shaft is liftel with the reactor vessel head, or if radiation icvels are too high, then follow refueling procedure F-2 to step 39, only raise water Icyc1 an amount necessary to maintain shiciding. *
- 4. Reiaove sling at tached in step 1 and plaec C-clamp on dri.vc shaf t at top f of latch c.cchat. ism housing. ContinuetoraiseandattachC-cla$ipas i
head is be.ing Iffted. * '
- 5. L' hen the RV head bac[been raised dn amount that will permit access to the top of'the guide tube, install the special C-clamp to the drive stiaf t to prevent th rSdfromente'ingthecore. r -
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Install sliding rubber collar en drive shaft.- ' .
- 7. Continue raising RV head. .
- 8. Place two new RV c1,osurc gaskets n'round the. closure head storage 1 -
pad. .
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Remove the RV head out of the refueling cavity and place on storage.
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l - 10. Attach the drive shaf t uniatching . tool. to the drive shaf t. -
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( Note: Be sure that the tool weight is entirely supported by the~ crane.
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- 13. Matically disengage the " finger" that hold t he renoveable insert to
- the guide tube. .
- 12. Secure the RCC to the upper guide tube assembly using a suitabic piece of nylon rope small enough to pass around the BCC vancs.
- 13. ' Unlatch and raise the drive shaft to the point of cont act with the
! removable incert.
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- 14. Continue raising the drive shaft and removable insert until cicar '
- of the upper guide tube assembJy and store in the drive shaf t storage t
d rack on cavity wall.
1 15. Visually observe the spider and guide tube and t ry to determine the
- cause of interference.
- 16. If the cause of the interference cannot be determined then remove the i
.i ' ' four 1/2 inch bolts that hold the upper guide tube to the Intermediate -
' guide tube.' , . .
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- 17. Slowly raise the upper guide tube ~and visually obscrye if the RCC
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moves with the guide tube.'
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Note: Use double sling arrangement around the top of the guide tube to insure that the assembly does not rotate ur tipL during lift.
i 18. If the' RCC moves with the upper guide tube then it .is hcld f ast on this assenbly. Continue raising the upper g,uide tube assembly until
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- 20. Lowe r t he upper guide tube assembly bac$ on t o the int eruediat e guide .
tube flange. *
- 21. At t ach two long nylon slingt. to the RCC spider vanes and secure to crane book. Ren.ove the sling of 14. ~
- 22. Cently tap the spider body in a downward direct Ion in an area that is close to t he ja n point to minimi:e bending en the vanes.
- 23. Af ter spider is f ree, lower the spider to the support ' comb'.
- 24. Res.ove upper guide tube assembly and set it aside on the upper support plate.
- 25. Locat e cause of interference. .
- 26. At tach the drive shaf t to the RCC using the tool of Step 10. ,
- 27. Raise the RCC an amount that will pernit renoval $f t he support combs and cloth. ~
- 28. Visually observe the spider and control rodlets for damage.
. Note: The RCC may be raised as necessary until safe radiation levels are execeded. ,
Alternate Procedure f rom Step 18 If the RCC does not move with the upper guide tube, then the following procedure will app}y:
19-A Remove the upper guide tube assembly and place on cavity floor.
20-A Visually examine the inside of the intermediate guide tube and try to detenaine the cause of the int erfer'ence.
21-A Remove the four 3/4" bolts that hold the intermediate assembly to e .
the upper support plate. '
22-A Secure the RCC to a convenient place on the internals assembly. -
Leave slack in line.
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j then recieve the guide tube f ro:a t he st orade t ank J f radiat ien Icvels
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i 39-A 1:eriove the " cat ch cloth" f rera the bottom of the' tank and examine 1
f or f oreign ntaterial.
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A6pendh: A-2 C:iide Tube In.tallation \
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, Decceber 9,'1970 4
1.
Clean the bolt and fit surf aces o:$ t!ie Internediate and ut per .
uscemblics, and cican t he saating hole in the uti per support plate.
- 2. Apply neolube to all fit surfaces, i .e., t he bot t o;a flange on the upper assembly, the fit dianeter on the top of the Intermediate
, assembly flenge, and the fit diar.teter on the under side of 'the in-tt.rmediate assembly flange, and the split pin diameters.
3.
Attach the two 1/2 inch eyebolt s t o the int ermediate assembly and orient the asserably so that the 90* stamp on the flange of the intermediate asscmbly agrees with the 90* orientation of the upper support plat e. :
4.
Lower the intermediate assembly into the hole in the upper internals .
very slowly using a "come along" and spring scale attached to the crane hook, until the scaic indicates that the split pins have contacted "the upper core plate. . '.
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- 5. Remove lifting devices from the guide tube.
6.
. t Install,the boroscope on the auxiliary crane and lower into the center of the guide tube an amount that will pc.Mit the split pins at the
. bot. tora to be observed. .
.v 7.. Visually observe that the pins are engaged lato their idating holes in
-the. core plate.
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' Level asscmbly by setting a : torpedo Icvel on. the top _ flange. *
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9.
Install the 3/4-10 all thread rods g '.
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- ' / l 10 Force e.pli t nins inyto the(t r'
' O s capective hole L'7 t oiqu ing t he 3/4-10 all thd'. reds in a saanner that u.rintains t he .en:etblylevel, i.e.
Alternate 180' bet ween bol t u when t o rquinp,.
Turn not e.1/2 tuto each until a gap of 1/16" existe. hetreen t he flange and upper 2.uppot t pit.
10-- A. Inn t al l tube down until flange seats.the 3/4-10 helti previously removed from guide ,
11 To insure that flange han been seated on the upper support plate a
.002" feeler, gage should pcss but a .00T reeler gage should not pass in the gap between the flange and the upper support plate.
12..
Inst all the 3/4" bolt locking caps and torque and weld bolts and caps per 17est'ing6ouse Drawing 685J681.
33.
Attach the small RCC handling too} to the new RCC, and attach to "come along" and spring scale on manipulator crane.
- 14. Install the special "alignrr.ent combs" at the top of the intermediate asse n.b 3 y. I 15.
Slowly lower the RCC into the guide tube through the alignment combs, and seat the spider on. top of the " combs."
Note:
Any sudden decrease in the weight indicated on the spring scale
.means that
\ the RCC is hung up and the crane should be immediately stopped.
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16.
. Remove the RCC handling tool from the spider. -
- 17. Install the new drive shaft to the auxiliary crane using the drive, shaft coupling tool and spring . scale. '
- 18. - Couple the drive shaf t to the RCC. '
-Note: Do not decrease the weight on.the ass'embly nore:than 20 lbs.
- 19. Remove the,"allgnment combs." . .
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- 20. Carefully lower the RCC into the fuel core: . . .- . .
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Any so Men decrease in t otal veight --i ndiat ely st ep t he ciane.
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- 2) . - linceuple tiu ' drive shaf t fica the.itCC.
- 22. ,
Inst aU the upper guide tube asseubly t o t he int ermediat e assembly.
23.
Install the locking caps and bolty and t<irque and weld pei Westinghouse Draw 685J070.
- 24.
Inst all the new drive shaf t assembly using the drive shaf t coupling tool.
- 25. Install the guide tube removabic cover.
26 Submit guide tube serial number and RCC serial number to U PUR design engineer - D. Boyle.
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Aypendix A-3
_ Drive ShafL 6 RCC Pul1 Test procodure, -
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- 1. Install drive shaft in guide tube.
- 2. Install guide tube cover.
- 3. Install spring scale between crane hook and drive shaft unlatching tool.
- 4. Lower tool over drive shaft and connect to RCC using Fuel llandling Procedure F-7.1.
- 5. Carefully center the tool and drive shaft and slowly raise the RCC.
Note 1: Maintain clearance between the drive shaft and guide tube cover.
If drive shaft touches cover, stop ll f t and readjust to obtain cicarance.
Note 2: Establish a maximum lift of 10 feet and designate this point by placing a piccc of tape at a convenient point on the tool.
Note 3: Do not lift in excess of 100 pounds over the combined weight of the tool, drive shaft and RCC. -
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