ML20202F470
| ML20202F470 | |
| Person / Time | |
|---|---|
| Site: | Paducah Gaseous Diffusion Plant |
| Issue date: | 01/28/1999 |
| From: | Toelle S UNITED STATES ENRICHMENT CORP. (USEC) |
| To: | Paperiello C NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM), NRC OFFICE OF NUCLEAR MATERIAL SAFETY & SAFEGUARDS (NMSS) |
| References | |
| GDP-99-0022, GDP-99-22, TAC-L32066, NUDOCS 9902040069 | |
| Download: ML20202F470 (36) | |
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USEC A Global Energy Company January 28,1999 GDP 99-0022 Dr. Carl J. Paperiello Director, Office of Nuclear Material Safety and Safeguards Attention: Document Control Desk U.S. Nuclear Regulatory Commission Washington, D.C. 20555-0001 Paducah Gaseous Diffusion Plant (PGDP)
Docket No. 70-7001 Transmittal of Revision 36 to Paducah Certification Application
Dear Dr. Paperiello:
In accordance with 10 CFR 76, the United States Enrichment Corporation (USEC) hereby submits twenty (20) copies of Revision 36 (January 27,1999) to USEC-01, Application for United States Nuclear Regulatory Commission Certification, Paducah Gaseous Diffusion Plant.
Revision 36 incorporates changes to the Technical Safety Requirements that were previously submitted for your review in accordance with 10 CFR 76.45 and were approved as Amendment 21 to Certificate of Compliance GDP-1 in your letter dated December 28, '1998 (TAC NO. L32066).
Revision 36 also incorporates related changes to the Safety Analysis Repc rt that have been reviewed in accordance with 10 CFR 76 and have been determined not to require prior NRC approval.
Revision bars are provided in the right-hand margin to identify the changes. Revision 36 was implemented effective January 27,1999.
Should you have any questions regarding this matter, please contact Steve Routh at (301) 5 There are no new commitments contained in this submittal.
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Sincerely, A
.S. A.
I N y
Steven A. Toelle l
Nuclear Regulatory Assurance and Policy Manager ADOCK 07007001l{j 9902040069 990128 PDR C
PDR j pV 4 6903 Rockledge Drive, Bethesda MD 20817-1818 Telephone 301-564-3200 Fax 301-564-3201 http://www.usec. corn Offices in Livermore, CA Paducah, KY Portsmouth, OH Washington, DC
Dr. Carl J. Paperiello January 28,1999 L
GDP 99-0022, Page 2
Enclosures:
- 1. Affidavit
- 2. USEC-01, Application for United States Nuclear Regulatory Commission Certification, Paducah Gaseous Diffusion Plant, Revision 36, Copy Numbers 1 through 20 cc: NRC Region III Office USEC-01, Copy Nos. 442,664 NRC Resident Inspector - PGDP USEC-01, Copy No. 697 Mr. Joe W. Parks (DOE)
USEC-01, Copy Nos. 641 through 644 NRC Resident Inspector-PORTS USEC-01, Copy No. 665 i
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OATH AND AFFIRMATION I, Steven A. Toelle, swear and affirm that I am the Nuclear Regulatory Assurance and Policy Manager of the United States Enrichment Corporation (USEC), that I am authorized by USEC to sign and file with the Nuclear Regulatory Commission this Revision 36 (January 27, 1999) of the USEC Application for United States Nuclear Regulatory Commission Certification, Paducah Gaseous Diffusion Plant (USEC-01), that I am familiar with the contents thereof, and that the statements made and matters set forth therein are true and correct to the best of my knowledge, information, and belief.
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Steven A. Toelle On this 28th day of January,1999, the person signing above personally appeared before me, is known by me to be the person whose name is subscribed to within the instrument, and acknowledged that he executed the same for the purposes therein contained.
In witness hereof I hereunto set my hand and official seal.
F
&LLL N.
LL.<11etle V adrie M. Knisley, Notary Public L
State of Maryland, Montgomery County My commission expires March 1,2002 i
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APPLICATION FOR UNITED STATES NUCLEAR REGULATORY COMMISSION CERTIFICATION PADUCAH GASEOUS DIFFUSION PLANT REMOVAL / INSERTION INSTRUCTIONS REVISION 36 JANUARY 27,1999 Remove Page Insert Page Volume 1 List of Effective Pages List of Effective Pages LOEP-1/LOEP-2 throuch LOEP-9/LOEP-10 LOEP-1/LOEP-2 through LOEP-9/LOEP-10 Section 33 Section 33 3.3-9/3.3-10.3.3 11/3.3-12 3.3-9/3.3-10.3.3-11/3.3-12 Section 3.4 Section 3.4 3.4-7/3.4-8 3.4-7/3.4-8 Section 3.5 Section 3.5 3.5-8a/3.5-Sb 3.5-8a/3.5-8b U
Section 3.7 Section 3.7 3.7-3/3.7-4 through 3.7-7/3.7-8 3.7-3/3.7-4 through 3.7-7/3.7-8 Section 3.15 Section 3.15 3.15-19/3.15-20 3.15-19/3.15-20 Volume 2 Section 43 Section 43 4.3-37/4.3-38 4.3-37/4.3-38 Volume 4 List of Effective Pages List of Effective Pages ii iii ii, iii Section 2.1 Section 0.1 2.1-47 2.14 Section 23 Section 2.3 I
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3.3.2.3.1 Cell Floor The C-310 building has two floor levels which, are referred to as the cell floor and the ground or operating floor. The cell floor contains the cascade equipment, which includes compressors, converters, i
condensers, Normetex product withdrawal pumps, tops purge pumps, and "B" booster stations. The switchgear, control centers, instrument cubicles, building control room. chemical trapping systems, and most of the auxiliary equipment are located on the ground floor.
The cell floor layout consists of ten cells, each containing six in-line stages. The 60 converters are arranged side by side, with 30 converters along each side of the building from north to south. Twelve centrifugal pumps serve each cell, two pumps per converter. Six pumps are situated along each side of the cell wM three designated as "A" pumps for the enriched stream and three designated as "B" pumps for the depleted stream. One Normetex product withdrawal pump is installed at the north end of cell 10 and a second Normetex pump is at the north end of cell 9.
Bypass piping, feed, and evacuation piping pass overhead above the cell floor through the center of the building.
The tops purge system is located in the southwest corner of the cell floor. The tops purge system consists of essentially two main parts, the tops booster station h>cated on the cell floor and the purge equipment located directly beneath cell 2 on the ground floor. A booster station is located in the southeast corner of the building on the cell floor. This station is designated as the "B" booster station
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consisting of two centrifugal compressors. Both compressors are normally in standby. A motor test stand is also located next to the booster station.
3.3.2.3.2 Ground Floor Instrument cubicles and valve control centers are located on the ground floor in two rows running north and south. The row east of the building center line serves the odd-numbered cells and the west row serves the even-numbered cells. The booster controls are located at the south end of these cubicles.
A 2 in. F header runs the length of the building along the inside of the east wall. This header provides 2
F: from C-350 to C-331 and the sodium fluoride (NaF) trap systems in C-310 as needed. A computer room in the northwest corner of the building houses the cascade automated data processing (ADP) system mainframe. Another trap room on the north wall houses the heated NaF trap housings for the north NaF trap system, which is used to burp cylinders, and a NaF oven, which is used to prepare NaF. The south l
NaF trap system is located along the east wall of the ground floor. A product withdrawal room, which houses two withdrawal positions / scales for tilling product and/or side withdrawal cylinder (s), is located in the northeast corner. The NaF trap system and product withdrawal systems are discussed in Section 3.4.
The ground floor also contains the area control room which houses the assay spectrometer room, monitoring and control for the purge cascade, and showers and locker room for operating personnel. The lube oil synem drain tank and pumps, seal exhaust pumps, and withdrawal stations are also on the ground l
tloor.
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SAR-PGDP January 27,1999 Rev. 36 3.3.2.3.3 Product Withdrawal Building The product withdrawal condensation system is located in the C-310-A building. This building, located at the northeast corner of C-310, was constructed following the 1956 fire in the C-310 building.
C-310-A is a windowless two-story steel-framed structure similar to C-310.
The building is 2
approximately 3,775 ft in floor area.
The building contains three condensers and two accumulators for the condensation of UF product 6
gas to a liquid for draining into UF. product cylinders located in the C-310 withdrawal area (see Section 3.4).
3.3.2.3.4 Cranes Two 5-ton capacity overhead cranes, which traverse above cell housings, facilitate maintenance work on motors, pumps, valves, and other cell equipment located on the cell floor. Hatches in the cell floor at the extreme north end of the building open over a rail and truck alley to facilitate the movement of equipment to the cell floor.
Two 20-ton overhead cranes are maintained on the east side of the C-310 building to facilitate the l
movement of UF cylinders to and from the withdrawal stations.
3.3.2.4 C-315 Surge and Tails Withdrawal Building This building, located east of the C-331 building, has three functions which are directly associated with the principal process of the plant. These functions are the surge system, process tails withdrawal system, and a dry air plant (which is numbered C-620). These three facilities are located in one building because of the operating and construction economics involved.
The building is rectangular and divided into three sections with dimensions of 210 ft x 110 ft x up to 52 ft 3 in. high. The ground floor area is 20,240 ft: and the second floor area is 5,800 ft for a total of 26,040 ft. The central portion of the building is a two-story seedon. This section contains the tails 2
withdrawal system, the process gas stream, and the control room. The north section, which is the tallest one-story section, contains the surge drums (Horton spheres). The south section, which is one story, contains the dry air plant and the electrical switchgear for all three sections. An extension for switchgear and battery rooms is located on the west side.
The one-story sections are steel-framed with transite siding and a built-up roof. The central section consists of a reinforced concrete structure up to the second floor with steel framing for the upper section.
The roof over this area consists of a built-up roof on a steel deck.
Building access is by pedestrian and truck doors and hatches.
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3.3.2.4.1 Ground Floor The control room, located on the ground floor, contains instrumentation necessary to monitor and control the process equipment. The tails withdrawal stations are located on the east side of the center section of the building. The remainder of the ground floor contains the C-620 air plant, the surge drums (Hortonspheres), change house, lobe oil drain tank, lube oil pumps, and electrical switchgear.
3.3.2.4.2 Second Floor The second floor of the central portion of the building contains the four centrifugal pumps and three Normetex pumps, which are used to compress the UF. gases for the surge and waste section of the casc.ide and to compress the UF for liquefication for tails withdrawal. The centrifugal pumps, two UF.
accumulators, and associated piping are enclosed in a heated housing to prevent freeze-out of UF. The electrical motors that drive the pumps are not enclosed for temperature considerations.
3.3.2.4.3 Third Floor The third floor area contains the three UF condensers and a portion of the ventilation system.
3.3.2.4.4 Cranes r'S Two semi-gantry cranes are h>cated on the east side of the C-315 building. The 20-ton cranes are l
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used to move cylinders to and from the scale carts to the cylinder storage areas. One 5-ton overhead crane is located on the second floor to facilitate removal of the Normetex pumps. Local jib cranes are placed at each centrifugal compressor to aid in removal of these items. This equipment is subsequently lowered through a hatch to the tails withdrawal room and then outside through the withdrawal position roll-up door.
i 3.3.3 Cascade Arrangement A unit consists of ten cells. There are four units in the C-331 and C-335 "00" building and six units in the C-333 and C-337 "000' buildings. A cell contains eight stages in a -000" building and ten stages in a "00" building. Each stage contains a motor, compressor, converter, control valve, coolant system, and associated instrumentation.
A cell is the smallest group of stages that may be isolated and taken out of service at one time. The piping to a unit is arranged so that any unit or cell can be bypassed, evacuated, purged, and opened for maintenance work without shutting down any other cells. Piping between buildings is called tie lines and the cascade can be changed to provide more length by arranging flow to different sections of the cascade.
This is done by changing feed points and the top and bottom overlap points.
To provide a constant flow and pressure in the cascade, compressors called boosters are used to boost the pressures between buildings, and surge drums are used to maintain UF. inventory.
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SAR-PGDP January 19,1996 Rev.2 3.3.3.1 Booster Stations At those points in a diffusion cascade where there is a change in equipment size and/or a transition in pressure level, the gas pressure can be increased by passing it through a booster station consisting of one or more gas compressors and gas coolers. The gas compressors are axial or centrifugal, depending on the volumetric tiow rates and pressure ratios required for the particular booster station.
Booster stations are used in locations where the gas must tiow from a low pressure to a higher pressure within the same piping network. This condition general.y occurs in the flow between buildings where there is a transition from one equipment size to another. The booster stations allow the cells on each side of the transition to operate at pressures that are more efficient for overall cascade operation.
The booster stations consist of one or more compressors, gas coolers, recycle lines, control valves, block valves, and associated piping. Axial compressors are used where large volumetric flows and compression ratios on the order of 5:1 are required. Centrifugal pumps are used where the volumetric flow is relatively small and compression ratios of about 3:1 are needed.
The plant has two axial booster stations with one standard "00" compressor in each station. One station, located in C-331, boosts the pressure in the "A"-stream from the top stage in the building to "B"-stream pressure. This tiow is sent back to the top stage as "B"-flow with a small portion of the flow being routed to the assay match point in the upper cascade (C-335 and C-337) as bottom overlap flow.
This tiow is essentially product flow from the lower cascade that becomes a feed stream for the upper cascade. The second axial booster, located in C-335, also boosts the pressure in the "A"-stream from the top stage in C-335 to "B"-stream pressure. Most of the tiow is sent back to the top stage as "B"-flow, with a portion routed to C-310 as interstage "A"-stream flow.
The plant has a total of three "B"-booster stations. Two of these stations are currently operational j
with the third in standby. The operational "B"-booster stations both serve the same purpose, with one j
located in C-333 and the other in C-337. These stations boost the "B"-stream from the bottom of the "000" buildings, which are at low pressure, to the top of the next downstream "00" unit, which is at a l
higher pressure in the adjacent "00" buildings. The third (standby) "B"-booster station, located in C-310, can be used to boost the pressure in the "B"-stream leaving the building or the "A"-stream pressure when it arrives in C-310. Generally, these flow are between C-310 and C-335. The "B"-booster stations in C-333 and C-3.37 consist of three centrifugal pumps, usually with two pumps in operation and the third in standby. The station in C-310 has two centrifugal pumps.
Both of the "00" buildings have a surge and waste booster station. Each station has two centrifugal pumps, usually one pump is operating and the other is in standby. The station in C-335 maintains the pressure in the bottom surge drums with a small portion of the flow through the pumps routed to the assay match point in the lower cascade as top overlap tiow. This flow is essentially the tails flow from l
the upper cascade which becomes a feed stream to the lower cascade. The surge and waste booster station in C-331 boosts the bottom "B"-stream from C-331 to C-315.
l C-310 has two other booster stations, the tops booster station and the side withdrawal station. The l
l tops booster station consisting of two centrifugal pumps boosts the low pressure tops purge gases to a l
higher pressure where the flow is split. Part of the flow is recycled to the last intermediate cell in C-310 1
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Rev.24 UF. detectors are also provided near the Normetex pumps. This system's operation and capabilities are described in Section 3.4.2.
The UF detection systems described above are do, t in Figure 3.4-5.
Upon failure of UF. release detection capabi'ity in an area, a smoke watch is established in the area but outside any housings to watch for " smoke" escaping from any UF. system.
The cylinder valve closer is air operated with a nitrogen backup. On less of plant air or low plant air pressure, a pressure switch on the air supph line (set at or above 75 psig) actuates to open a solenoid valve which makes nitrogen available to the air supply line. The cylinder valve can be closed by the nitrogen in 30 seconds. The nitrogen connection to the air supply line is made downstream from a check valve in the line which prevents loss of nitrogen pressure. The nitrogen bottle which supplies the system with backup nitrogen is a 1.5. ft' tank and must have an indicated pressure of at least 1200 psig. The nitrogen is regulated to an indicated 80 psig.
Check valve operability is verified during quarterly testing by monitoring for detectable flow from tubing located upstream from the check valve that is open to atmosphere open to atmosphere (no detectable flow after nitrogen has been supplied to the supply header down stream from the check valve indicates the valve has seated properly). Another indication of proper check valve performance is closing a cylinder valve using the nitrogen backup (also part of the quarterly test). If the cylinder valve will close within the required 30 seconds using nitrogen, then the check valve is providing sufficient resistance
'o to backflow for the system to function properly if called upon to do so.
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3.4.8 Liquid Cylinder Handling The movement of liquid-filled cylinders is restricted to removal from the filling station to the cool-down yard. After being tilled, cylinders are moved to the cooldown yard, where they remain for a minimum of five days for 10- and 14-ton cylinders and for a mimmum of three days for 2%-ton cylinders. Limited movement of cylinders may be conducted within the cooldown yard before completion of the cooldown period if the precautions for handling liquid-tilled cylinders are followed (i.e., moving cylinders as low to the ground as practical, using the overhead crane for cylinder movements, etc.).
Upon completion of the cooldown period, cylinders are handled as described in Section 3.7.3.
3.4.8.1 Scales and Scale Carts Each empty cylinder is placed on an air-driven cart equipped with cradles to accommodate the cylinder being moved to a scale and positioned for tilling. An alarm on the scale will alert the operator l
when the cylinder is almost full and causes the cylinder position to automatically stop tilling. The cylinder scales are checked with a test cylinder after each cylinder change. The test weights must agree l
with the established weights within specified control limits which are established and updated as described in Section 5.5 of the FNMCP. Examples of control limits are provided in Table 4-2 of the FNMCP.
The scale cart air supply is equipped with a key-operated interkick switch which blocks the air supply to the scale cart without the interlock key. Administrative controls require the air supply interlock key ring to be placed on the pigtail when the pigtail is connected to a cylinder. Additionally, even with the g
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SAR-PGDP January 27,1999 r
Rev. 36 key in the lock, a system required to be included in the TSR consisting of a pressure sensor on the drain line prevents scale cart motion unless the pigtail is close to atmospheric pressure ( 3 psi). A pigtail pressure not close to atmospheric pressure would indicate that the pigtail was pressurized and therefore not disconnected. Thus the key interlock system helps prevent moving the scale cart while the pigtail is connected to the cylinder. The key is only removed from the pigtail after the cylinder has stopped filling and the pigtail is purged and disconnecu.
The scale cart and scalc. platform are designed to reduce the potential for drainage into the scale pit, which has a water sensor to alarm if a water level is detected. The scale platform and cart design and water pit sensor help minimize the potential for accumulation of uranium bearing solutions in the scale pit, which could constitute a nuclear criticality concern.
3.4.8.2 Crane The product wit' 2rawal area has two 20-ton overhead bridge cranes that are used to move liquid-filled cylinders from the scale cart to the storage area. The cranes can service the entire runway area except that portion blocked by the other crane at the end of the runway. Administrative controls are used to ensure that the two cranes are not loaded or operated at the same time. The cranes are double-block cranes, each equipped with a special lifting beam specifically designed for lifting liquid UF.
cylinders.
The overhead bridge cranes were designed with several safety features. The south crane's hoist has two d.c. rectified shoe brakes. The north crane's hoist has one d.c. rectified shoe brake and an electro-hydraulic mechanical caliper brake. One shoe brake is used as a holding brake and the other shoe brake or caliper brake is on a timer that acts within one second as an emergency brake should the holding brake fail. These brakes are spring actuated in the event of a power loss. Both cranes have a geared up/down limit switch that is connected to the cable drum for use while lowering or hoisting the load. When activated, it will stop the motor and activate the hoist brakes. This geared limit switch will reset automatically once the motor is reversed. Both cranes have two paddle-type limit switches that prevent a collision between the lifting beam and the upper crane structure. Each paddle switch has a weight thr.t hangs on a wire from the crane trolley. If the lifting beam comes in contact with one of these weights, the tension in the wire is released and the crane hoist motor is de-energized. Once activated, the paddle-type limit switches require a manual reset to resume crane operation.
Proximity sensors on the south crane. limit switches on the north crane, and mechanical rail stops l
are located at the end of the bridge and trolley rails to prevent the crane from running off the end of its tracks.
Cylinder movement from the scale cart to the cylinder cool-down area is minimized to the greatest practical extent and restricted to the lowest practicGle height above ground.
3,4.S.3 Short-Term Storage Cylinder storage facilities, located on the east side of C-310, are used for the cool-down of liquid UF, cylinders prior to the burping operation. Cylinder saddles are used to position cylinders for storage.
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3.5.8.2 Crane The tails withdrawal area is equipped with two 20-ton semi-gantry cranes, which are used to move l
empty cylinders to the scale cart and to move the full cylinders from the scale cart to the cylinder cool-down yard. The cranes can service the entire runway area except that portion blocked by the other l
crane at tM end of the runway. Administrative controls are used to ensure that the two cranes are not loaded or operated at the same time. The cranes are double-block cranes, each equipped with a special lifting beam that is specifically designed for lifting liquid UF. cylinders.
The overhead bridge cranes were designed with several safety features. The south crane's hoist has two d.c. rectified shoe brakes. The north crane's hoist has one d.c. rectified shoe brake and one electro-hydraulic mechanical caliper brake. One shoe brake is used as a holding brake and the other shoe brake or caliper brake is on a timer that acts as an emergency brake within one second should the holding brake fail. These brakes are spring actuated in the event of a power loss. Both cranes have a geared up/down limit switch that is connected to the cable drum to prevent exceeding the limits for lowering or hoisting the load. When activated, it will stop the motor and activate the hoist brakes. Thir geared limit switch will reset automatically once the motor is reversed. Both cranes have two paddle-type limit switches that prevent a collision between the lifting beam and the upper crane structure. Each paddle switch has a weight that hangs on a wire from the crane trolley. If the lifting beam comes in contact with one of these weights, the tension in the wire is released and the crane hoist motor is de-energized. Once activated, the paddle-type limit switches require a manual reset to resume crane operation. Also, proximity sensors on the south crane, limit switches on the north crane, and mechanical rail stops are l
located at the end of the bridge and trolley rails to prevent the crane from running off the end of its tracks.
Administrative controls are employed to ensure that only licensed crane operators operate the crane, that it is inspected routinely, and that maintenance is performed by qualified maintenance personnel.
3.5.8.3 Short-Term Storage C-315 has a cylinder storage facility on the east side, which is used for cool-down storage of full cylinders and for empty cylinder storage. Liquid cylinders are moved from scale carts to the cool-down area by overhead crane. Cylinders are allowed to cool for five days to solidify before they are moved to a storage yard.
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If it can be detennined with confidence that the material inside the cylinder is UF or other material 6
compatible with UF. (most likely UO F ), then the cylinder is considered acceptable for filling. If, on 2 2 the other hand, the cylinder's contents cannot be determined with confidence, then the cylinder is permanently rejected until the condition is resolved (i.e., washed).
The 2.5,10, and 14-ton cylinders are provided with a 1-in. UF cylinder valve. This is a special valve designed for UF. service and has become accepted throughout the nuclear industry. The valve has an aluminum-silicon bronze alloy body and a monel stem with virgin Teflon packing rings and cap gasket.
To minimize points of leakage, one valve and one plug are specified for each cylinder. If additional valves or plugs are necessary, they may be provided if they are installed and tested in the accordance with ANSI N14.1, 3.7.2 UF Cylinder Storage Yards UF cylinder storage yards are provided for interim and long-term storage. These storage yards, as identified in Table 3.7-1, provide storage for approximately 68,000 cylinders. In addition to these l
yards, space is provided at C-310, C-315, C-333-A, C-337-A, and C-360 to serve as a staging area for cylinders scheduled for feeding, for empty feed and withdrawal cylinders, and as a cool-down area for cylinders which have been filled with tails or product. There is also a cylinder staging area at C-400 for shipping and receiving product cylinders. Tails cylinders that are in long-term storage are double stacked. Aisles are provided for access to visually inspect the cylinders and valves. Because of their p
weight, the cylinders require the use of large specialized handling equipment and a firm foundation for d
both transport and storage. Design considerations for new and recently developed cylinder storage areas include concrete over a compacted, dense graded aggregate layer. The yard lighting is designed to provide l
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an illumination level of 0.5 footcandle. Storm drainage is accomplished by a sub-surface drainage system and by sloping the storage pad to existing drainage to minimize corrosive exposure of cylinders.
The cylinders are placed on supports to prevent them from rolling and allow them to be stacked.
The saddles also help in corrosion prevention by keeping the cylinders off the ground and as dry as possible. The creosote-treated oak saddles are 9 in. x 7 in. x 4% ft long with a radius cut to conform to the cylinder diameter. Two saddles are provided to support each cylinder. Steel reinforced concrete cylinder saddles are used in newer cylinder yards for cylinder support.
UF. cylinder storage yards are listed in Table 3.7-1.
3.7.3 UF Cylinder Handling Cylinders containing UF. arrive at PGDP by rail or truck. Normal assay feed material is received at the C-360 Toll Receiving and Transfer Facility. After sampling ard weighing, the cylinders are moved
. by specially designed cylinder handling equipment to a storage yard to await feeding at a vaporization facility. After the UF is fed into the process, the cylinder, with a small quantity of heel, must be moved back to the storage yard for a cooling period.- When cooled, the cylinder is returned to the C-360 facility for shipment back to the customer.
e 3.7-3
SAR-PGDP January 27,1999 Rev.36 When tails material from the Portsmouth or Oak Ridge facility arrives at PGDP by railcars or trailer truck, the cylinders are unloaded, inspected, and stored for later use at one of the vaporization facilities.
Enriched product material is withdrawn into 10-ton cylinders at C-310, which after cool-down are moved to the C-400 building where they are loaded into overpacks installed on railcars or flatbed truck trailers. The cylinders are then shipped to the Portsmouth facility. The emptied Paducah product cylinders, with a small amount of heel material, are returned to PGDP. The cylinders are received at C-400 where they are unloaded and moved back to the C-310 product withdrawal facility for refilling with Paducah product.
Tails material produced by PGDP is withdrawn into 14-ton cylinders at the C-315 tails withdrawal facility. The solid cylinders are moved to the long-term storage yards by specially designed equipment.
Standard cylinder handling precautions for handling liquid-filled cylinders include:
moving the cylinder as low to the ground as practical.
not moving cylinders over other liquid-filled cylinders, not loading or operating the two cranes located on the same runway at the C-310 or C-315 facilities at the same time, installation of cylinder valve protector prior to movement of liquid-filled cylinders (exceptions e
include minimal movement on scale carts to facilitate valve protector installation and/or cylinder weighing), and l
cylinder valve at the 12 o' clock position (also precluded by lifting lug and lifting fixture design).
3.7.3.1 In-Plant Cylinder IIandling Equipment l
The major components of the in-plant cylinder handling system include scale carts, cranes, lifting l
fixtures, cylinder handlers, and trailers. Scale carts, along with some cranes and lifting fixtures, have l
been identified as design features for safety since they are involved in the handling of cylinders filled with l
liquid UF..
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Repairs are made only by qualified personnel and the resulting repair is inspected by qualified i
inspectors before the equipment is placed in service. Equipment is inspected as required by Occupational j
Safety and Health Administration (OSHA) 1910.179, 1910.184, and 1926.251 as well as ANSI /ASME B30.2,9, and 10.
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3.7.3.1.1 Scale Carts Scale carts with a capacity of 20 tons are provided in C-310, C-315, C-333A, C-337A, and C-360.
The carts operate along a rail system for the movement of cylinders. The cart is driven by an air motor connected to a gear box which drives the cart axle. The wheels are flanged forged steel. An air line is connected to a reversible air control valve which controls direction of the cart along the track.
The cans in C-360 are equipped with safety legs under each corner of th: platform, which prevents the platform from falling in excess of 2 in. if a wheel or cart axle should fail. This would prevent a 3.7-4
SAR-PGDP January 27,1999 Rev.36 (v) cylinder from rolling off the cart and mitigates the possibility of cylinder damage during transport within the facility.
The carts in C-333A, C-337A, C-310, and C-315 are a new, low-profile design. The low-profile design will not allow a fall of greater than 2 in., so there is no need to rely on safety legs. The carts are made of stainless steel to reduce corrosion. Saddles are provided on the carts to prevent the cylinders from rolling. As in the older system, the carts are air operated and will brake upon the loss of air.
3.7.3.1.2 Cranes and Lifting Fixtures Eleven different cranes can be used to move UF filled cylinders. Of these eleven, eight cranes are 6
designed to move solid and liquid UF filled cylinders and three are designed to move only solid and 6
empty UF6 cylinders. The cranes designed to move solid and liquid UF cylinders are located in the 6
following facilities: two at the C-310 product withdrawal facility, two a: the C-315 tails withdrawal facility, two at the C-360 toll sampling and transfer facility, one at the C-333-A feed facility (west crane),
and one at the C-337-A feed facility (south crane). The cranes designed to move only solid and empty UF cylinders are located in the following facilities: one at the C-333-A feed facility (east crane), one at 6
the C-337-A feed facility (nonh crane), and one in the C-400 chemical operations facility. The chemical j
operations facility in C-400 uses a semi-gantry crane to move solid UF filled 10-ton product cylinders.
6 Although designed to move liquid UF cylinders, the C-333-A west crane and the C-337-A south crane 6
are currently approved to move only solid and empty UFs cylinders.
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nIj The product withdrawal facility has two 20-ton overhead bridge cranes which are used to move solid j
or liquid-filled cylinders from the scale cart to the storage area. The tails withdrawal facility has two j
similar 20-ton semi-gantry bridge cranes. Each facility's cranes can service the entire runway area except that portion blocked by the other crane at the end of the runway. At each facility, adninistrative controls are used to ensure that the two cranes are not loaded or operated at the same time. Each of these cranes is a double-block crane equipped with a special liftieg team, which is specifically designed for lifting liquid UF filled cylinders.
6 The C-310 and C-315 Product and Tails withdrawal facilities cylinder handling bridge cranes are designed with several safety features. Each facility's south crane's hoist has two direct current (de) shoe brakes. Each facility's north crane's hoist has one de shoe brake and one electro-hydraulic mechanical caliper brake. One shoe brake is used as a holding brake, and the other shoe brake or caliper brake is on a timer which acts within one second as an emergency brake should the holding brake fail. These brakes are spring actuated in the event of a power loss. All cranes have a geared up/down limit switch that is connected to the cable drum for use in lowering or hoisting the load. When activated, the limit switch circuit will stop the motor and activate the hoist brakes. This geared.Umit switch will reset automatically onw the motor is reversed. All cranes have two paddle-type limit switches that prevent a collision between the lifting beam and the upper crane structure. Each paddle switch has a weight that hangs on a wire from the crane trolley. If the lifting beam comes in contact with one of these weights, the tension in the wire is released. the crane hoist motor is de-energized and the hoist holding brake is activated. Once activated the paddle +pe limit switches require a manual reset to resume crane operation.
The C-310 and C-315 cranes are eqt ped with proximity sensors on the south cranes and limit switches l
O 3.7-5
SAR-PGDP January 27,1999 Rev. 36 on the north cranes, and mechanical rail stops located at the end of the bridge and trolley rails. These l
devices are designed to prevent the crane from running off the end of the track.
The Toll Transfer and Sampling Facility at C-360 has two functionally identical 20-ton overhead bridge cranes. One crane can serve the high-bay work area over the autoclaves; the other crane can serve the cylinder storage area on the east side of the building. By opening the building crane door, both cranes can en:er or exit the building. During normal operations the two cranes are not used together on a single load. Each bridge crane is equipped with one 20-ton capacity polar trolley, controlled by push-button pendant or radio transmitter. Crane control can be interchanged from push-button pendant or radio transmitter. Operation of the trolley and hoist individually or simultaneously are allowed as needed for lifting a liquid UF6 filled cylinder.
Each C-360 crane hoist has one de rectified shoe brake and one electro-hydraulic mechanical caliper brake. Both are spring actuated in the event of a power loss. The hoist shoe brake is used as a holding brake, and the electro-hydraulic mechanical caliper brake serves as an emergency brake should the holding brake fail, if brake slippage. mechanical discontinuity or overspeed is detected, the electro-hydraulic mechanical caliper brake will engage and act as an emergency brake. A geared up/down limit switch is connected to the cable drum to prevent lowering or hoisting the load too far. When activated, the limit switch circuit will stop the motor and activate the hoist holding shoe brake. Paddle-type limit switches prevent the lifting assembly from colliding with the upper crane structure. The limit switch assembly has a weight that hangs on a wire from the crane trolley. If the lifting block comes in contact with this weight, the tension in the wire is released and the crane hoist motor is de-energized.
Mechanical rail stops are located at the end of the bridge and trolley rails to prevent the crane from running off the end of its tracks.
The C-333-A east and C-3F-A north overhead bridge cranes handle only cylinders that are empty or contain solid UF,,.
These cranes are 20-ton single-hook, pendant-controlled cranes that utilize an H-frame-type shng to lift the cylinders with their single hook.
The C-333-A east crane hoist has a direct current (de) rectified shoe brake and an eddy current l
brake. Tla hoist shoe brake is spring actuated in the event of a power loss. The C-337-A north crane hoist utilizes a shoe brake with a ratchet and pawl backup in case of shoe brake failure.
l The C-337-A south and C-333-A west bridge cranes were designed with several safety features. The south crane at C-337-A and the west crane at C-333-A are double-block cranes equipped with a special lifting beam specifically designed for hfting liquid UF filled cylinders. While the cranes are not 6
currently approved for handling liquid UF,, filled cylinders, the structural design is similar to the liquid UF handling crane at C-310. The C-337-A south crane hoist has two de rectified shoe brakes that are 6
spring actuated in the event of a power loss.
The C 333-A west crane has a de rectified shoe brake as a holding brake and a electro-mechanical caliper brake as an emergency brake. The emergency caliper brake is on a timer which acts within one second should the holding brake fail.
Ol 3.7-6 1
SAR-PGDP January 27,1999 i)
Rev.3'6 v
All of the feed facility cranes have a geared up/down limit switch connected to the cable drum for l
use in lowering or hoisting the load. When activated, the limit switch circuit will stop the motor and activate the shoe brake. To prevent the lifting hook from colliding with the upper crane structure, each crane uses a swivel bar attached to a wire hanging from a paddle-type limit switch on the crane trolley.
When the lifting hook conies in contact with the swivel bar, the tension in the wire is released and the crane hoist motor is de-energized. This switch will reset automatically once the motor is reversed. Two paddle-type limit switches prevent a collision between the lifting beam and the upper crane structure.
Each limit switch assembly has a weight that hangs on a wire from the crane trolley. If the lifting beam comes into contact with one of these weights, the tersion in the wire is released and the crane hoist motor is de-energized. Also, proximity sensors and mechanical rail stops are located at the end of the bridge and trolley rails to prevent the cranes from running off the end of their tracks.
The C-337-A south crane has been installed with a programmable zone control, which can be used l
to restrict the travel path of the load.
The chemical operations facility at C-400 uses a 20-ton single hook semi-gantry crane for loading 10-ton Paducah product cylinders into Tiger overpacks for shipment to Portsmouth or customers. The crane hoist has a de rectified shoe brake that is spring actuated in the event of a power loss. To prevent the lifting hook from colliding with the upper crane structure, each crane uses a swivel bar attached to a wire hanging from a paddle-type limit switch on the crane trolley. Like the paddle-type limit switches 1
described above, when the lifting hook comes in contact with the swivel bar, the tension in the wire is A
released and the crane hoist motor is de-energized. Mechanical rail stops are located at the end of the
()
bridge and trolley rails to prevent the crane from running off the end of its tracks. This crane uses an H-frame-type sling to lift the 10-ton product cylinders.
The hoists and cranes used for UF. cylinder-handling are carefully inspected prior to the first use of each shift to ensure proper operation and the absence of visibly detectable damage to the cables, brakes, and other critical items. Limit switches are tested without a load on the hook. Cranes are inspected periodically and the inspections documented by qualified inspectors. Any overhead and mobile cranes that are new, altered, uprated or repaired after extensive damage are load-tested at up to 125%
of their rated capacity before being placed in service.
The lifting fixtures, or rigging, used for UF. cylinder handling consists of nearly two dozen types of special slings and fixtures that have been designed, type-accepted, and certified for the specific handling tasks at the various facilities. H-frame-type lifting fixtures are provided for single-and double-hook cranes when handling UF.. Each of these riggings is a combination spreader bar that has four shackles designed for attachment to the four lifting lugs on the 10- and 14-ton cylinders. This H-frame-type fixture facilitates the requirements for loading and unloading UF cylinders into and from 6
the autoclaves without the use of any freestyle or impromptu rigging practices. Another example of a specialized lifting fixture is a sling assembly used for loading 2%-ton cylinders into shipping overpacks.
The sling has small hooks used to lift the overpack lids as well as large hooks required to lift the 2%-ton product cylinder. Another specialized sling assembly is used to lift a loaded 2%-ton overpack from the floor onto a flatbed semitrailer.
tO 3.7-7
i SAR-PGDP January 27,1999 Rev. 36 Lifting fixtures are periodically inspected by qualified inspectors. Users perform visual inspections for kinks, knots, cracked or bent hooks, and other obvious damage each time the sling is used. The slings or fixtures used to handle UF are identified by the type-acceptance and load-test date. The sling's 6
usable life expires two years following the completion of a load test.
The use of mobile cranes and H-frame cylinder lifting fixtures permit the loading and unloading of rail shipments at any point along the rail siding where a loading dock is not provided. The only cylindera handled by these cranes are empty or those containing solid UF.
6 A preoperational visual inspection of UF cylinder handling cranes and equipment is performed once 6
each shift prior to use.
3.7.3.1.3 Cylinder IIandlers The cylinder handlers are specially designed for use in the double stacking of tails cylinders and normal assay feed cylinders.in the long-term storage yards. Only cylinders containing solid UF are 6
moved with this equipment.
3.7.3.1.4 Trailers Heavy-duty. Iow-bed trailers are designed for use in hauling UF cylinders over intraplant roadways 6
and cylinder storage yards. Only cylinders that are empty or contain solid UF are placed on these 6
trailers.
3.7.3.2 Cylinder Shipment UF cylinders are moved between plants and to toll customers by truck or rail car. Before shipping, 6
cylinders containing > 1.0 wt. % *U are placed in protective packages called "overpacks." These packages protect the cylinders from damage due to fire or accident. For more information, see the Transportation Safety Quality Assurance (QA) Plan.
3.7-8
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t SAR-PGDP January 27,1999
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.Rev. 36 j
1.
Gamma detector channel.
2.
' Cluster logic module 3.-
Cluster housing.
4.
Associated circuitry J
' 5.
Local electric horn 6.-
' Backup battery for the cluster and horn 7.
Connecting cable to connect to the building system 3.15.1.3.8 Text Deleted 1
i l
3.15.1.3.9 Product and Tails' Withdrawal Area 20-ton Overhead Bridge Cranes' s
O Function-The cranes (two each in C-310 and C-315) function to safely move liquid-filled cylinders from the l
scale cart to the storage area.
. See Section 3.4.8.2 and 3.5.8.2 for a description of this system.
't Boundary The system boundary includes:
1.
Crane structure and structural supports, the crane rails, the bridge. the mechanical rail stops at the end of the bridge, the trolley rails, the trolley, and the. reeving.
3.15-19 u.
SAR-PGDP January 2,7,1999 Rev.36 2.
Two hoist brakes l
3.
Relays for hoist brake control 4.
.Holst motor contacts 5.
Geared up/down limit swit:h 6.
Two paddle-type limit switches 7.
Emergency stop button 8.
Associated circuitry The crane brake fails safe on loss of power.
3.15.1.3.10 UF Cylinder Lifting Fixtures Q Ftmetion Liquid UF, cylinder lifting fixtures are built and maintained to prevent the dropping of a cylinder, resulting in a possible release.
See Sections 3.4.8.2 and 3.5.8.2 for a description of this system.
Boundary The system boundary includes:
1.
Wire rope legs 2.
Lifting fixture assernbly.
3.15.1.3.11 Scale Carts O Function The function is to safely move cylinders containing liquid UF..
See Sections 3.4.8.1 and 3.5.8.1 for a description of this system.
I Boundary The system boundary include 1.
Cradles and substructure system.
3.15-20
, AR-PGDP January 27,1999 S
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4.3.3.1.5 Cylinder Drop and Puncture Cylinders containing liquid UF must be moved by overhead crane from the cylinder scale cart to 6
storage in the outside cool <! awn area of the C-310 cylinder storage yard. Administrative controls require that liquid-filled cylinders be moved with the lift height as low as possible to clear obstacles and to be as short a distance as possible. Administrative controls are also used in the C-310 and C-315 facilities to assure that both cranes are not loaded or operated at the same time. Cranes and lifting fixtures are inspected daily prior to use by crane operators and monthly by trained inspectors. All cranes and lifting fixtures are design features for safety which must have design authority approval prior to any changes.
PGDP product is withdrawn in 10-ton or smaller cylinders. Due to the small number of liquid cylinders moved, two to three 10-ton cylinders per 24-hour period and the strict administrative controls applied, the drop of a cylinder by crane is considered to have a low probability. The worst-case source term for such an accident would be the complete failure of a full 10-ton cylinder resulting in the loss of approximately 20.000 lbs of UF outside the C-310 building. In the event that C-315 is not available and 6
tails withdrawal must be accomplished at C-310, there is the potential for rupture of a full 14-ton cylinder resulting in a UF release of up to 28,000 lb. However, the probability of this event occurring is no 6
greater than at C-315, and the event is bounded by the analysis for the same event at C-315.
4.3.3.2 Operator Error Operator error could result in significant UF outleakage rates if pigtails are not properly installed 6
and tested per the administrative controls listed in Section 4.8.1.3 or if a cylinder valve is broken during r
G}.
f loading operations.
In either case, gaseous UF could be released at a rate of 80 lb/ min until the release is terminated.
6 The 10-ton and 14-ton cylinders are essentially identical except for length and, therefore, capacity. This scenario involves a gaseous release through a broken cylinder valve with the valve in the 12 o' clock position. The release rate is primarily a function of the opening size and is essentially independent of the cylinder size (10-ton or 14-ton). If the release is from the pigtail, the UF release detection safety 6
system will isolate the release as described in Section 4.3.3.1.3. If the release is due to a broken cylinder valve, the UF detection system will isolate the accumulator, but hazardous material (HAZMAT) response 6
will be required to terminate the release from the cylinder. This has been determined to be a low probability event.
Administrative controls for withdrawal areas, operator training and quality assurance (QA) plans for valve procurem,mt are relied upon to reduce the occurrence of this type accident.
Operator error during a release from fatigue failure on an accumulator could cause a significant l
increase in the amount of UF, released due to an increase in the time required to evacuate the system to i
below atmospheric pressure.
4.3.3.3 Failure of Controls The valves used for containment in the withdrawal area are fail-safe and would fail in the closed position upon loss of air or power supply. Valves on the accumuhtors are not redundant. However, as stated earlier. diverse 'nea-is are available to isolate and evacuatt, the system.
(7)
- ' \\d 4.3-37
SAR-PGDP July 26,1996 Rev. 4 4.2.3.4 Loss of Support Systems The C-310 product withdrawal facility uses essentially the same utilities as the rest of the cascade buildings. In general, a loss of support systems would cause operational problems, but would not cause a release of UF.. The cylinder valve closers rely on plant air to close. Upon loss of plant air, this safety system component is supplied by bottled nitrogen.
4.3.3.5 Fire or Explosion A UF,,/ hydrocarbon oil reaction in a liquid UF. cylinder on the drain station is an extremely low probability event. However, it is considered for completeness. As mentioned in Section 4.3.1.5, administrative controls in effect for the purchase and subsequent use of cylinders are expected to prevent the occurrence of such an accident. The worst-case accident during normal operation from a hydrocarbon reaction in the UF, cylinder drain positions would be the loss of the contents of a full 10-ton cylinder.
In the event that C-315 is not available and tails withdrawal must be accomplished at C-310, there is the potential for loss of the contents of a full 14-ton cylinder. This accident is bounded by the liquid cylinder drop scenario described in Section 4.3.3.1.5.
l The Normetex pumps now used for product withdrawal are cooled and lubricated by oil which is pumped through the spacer column and the vanes. The oil is returned to the 80 gal, self-contained oil j
reservoir in the pump. Several features protect the pump from rubbing and a potential lube oil fire.
These include an oil /UF. differential temperature indication and trip and various other alarms and pump trips associated with oil system problems. These diverse systems, the limited amount of oil in the pumps, I
and the presence of sprinkler systems will prevent a lube oil fire of the magnitude experienced in 1956.
The principal problem encountered with the reaction of hydrocarbon oil with the gaseous UF. is the formation of a viscous gum which solidifies when the pump is shutdown and cooled. Reaction of hydrocarbon oil and gaseous UF in the Normetex pumps which result in a;. txplosion are not predicted.
)
i 4.3.4 UF. Tails Withdrawal Facilities UF. tails are withdrawn from the PGDP enrichment cascade at the C-315 building. Withdrawal rates vary with power loads and assays At typical power rates three to four 14-ton cylinders are withdrawn each 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />. Accident scenarios are similar to those described for the product withdrawal area and will be referenced where possible.
l 4.3-38 i
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January 27,1999 i Rev. 36 --
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.' TSR-PGDP January 27,1999 Rev.36 i
rm.
.SECTION 2.1 SPECIFIC TSRs FOR TOLL TRANSFER AND SAMPLING
(,) -
FACILITY (C-360) 2.1.5 GENERAL DESIGN FEATURES 2.1.5.2 CRANE DESIGN 4
DF 2.1.5.2: The following aspects of the C-360 cranes are credited for safety:
- 20-ton overhead bridge crane
- Two hoist brakes that meet the requirements of ANS1 B30.2,1990 Edition (including l
l Addendum A,1991) l
- Geared up/down limit switch on cable drum
- Paddle-type limit switch to prevent blocking
- Mechanical rail stops at the end of the bridge and trolley rails SURVEILLANCE REQUIREMENTS:
Surveillance Frequency SR 2.1.5.2-1 Visual inspection for defects Prior to first use of shift SR 2.1.5.2-2 Hands-on Inspection (no disassembly required)
Monthly I
[/)'
SR 2.1.5.2-3 Hands-on Inspection (some disassembly Annually L
required)
SR 2.1.5.2-4 Load test at a minimum of 100% of rated Biennially capacity.
BASIS:
Cranes used to handle liquid filled UF cylinders are credited for prevention of the liquid 6
cylinder drop.and ruriture n:cident scenario. Visual inspection will detect obvious defects which could cause the cylinder drop accident scenario. Surveillance requirements 1, 2, and 3 are performed to meet the requirements of OSHA 1910.179. [SAR Section 4.3.5.1.2]
L.)
i 2.1-47
[..
- . TSR-PGDP -
January 27, 1999 Rev.36
.SECTION 2.3 SPECIFIC TSRs FOR ' PRODUCT AND TAILS WITHDRAWAL
(,^)
FACILITIES 2.3.5 GENERAL DESIGN FEATURES 2.3.5.1 UF CYLINDER LIFTING FIXTURES 6
DF 2.3.5.1: UF cylinder slings and lifting fixtures are designed with a structural factor of 6
safety of 5 to 1 ba. sed upon the material's ultimate tensile strength.
SURVEILLANCE REQUIREMENTS:
Surveillance Frequency SR 2.3.5.1-1 Visual inspection for damage Prior to first use of shift SR 2.3.5.1-2 Hands-on Inspection (no disassembly required)
Monthly SR 2.3.5.1-3 Load test at a minimum of 100% of rated Biennially capacity.
BASIS:
- Slings, H-frames, etc used to handle liquid filled UF cylinders are credited for prevention of 4
6 Q
the liquid cylinder drop and rupture accident scenario. Visual inspection will detect obvious defects which could cause the cylinder drop accident scenario. Surveillance requirements 1, 2, and 3 are performed to meet the requirements of OSHA 1910.184 [SAR Section 4.3.3.1.5 i
and 4.3.4.1.5]
l 2.3.5.2 CRANE DESIGN i
L DF 2.3.5.2: The following aspects of the C-310 and C-315 cranes are credited for safety:
20-ton overhead crane l
Mechanical rail stops at the end of the bridge and trolley rails Two hoist brakes that meet the requirements of ANSI B30.2,1990 Edition (including l
l Addendum A,1991) l Geared up/down limit switch on cable drum l
Paddle-type limit switch to prevent blocking
,-f F~
2.3-47
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