ML20212P082
| ML20212P082 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 10/16/1986 |
| From: | Murgatroyd R FLORIDA POWER CORP. |
| To: | |
| Shared Package | |
| ML20212N983 | List:
|
| References | |
| MP-509, NUDOCS 8703130272 | |
| Download: ML20212P082 (118) | |
Text
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I MAINTE [ M .E EE L 1 _
MP-509 L I
TLORIDA POWER CORPORATION I
CRYSTAL RIVER UNIT 3 MAINTENANCE OF PHILADELPHIA CEAR DRIVES ON SWP-1A, 19 ANC ETP-t THIS PROCEDURE ADDRESSES SATETY RELATED COMPCNENTS APPROVED BY: Responsible Section i Superintendent / Supe:viscr b hv%cea du_ vd._ ;
Date /d!d , ,
INTERPRETATION CONTACT: Nuclear Maintenance Superintendent 0703130272 070305 l8DH ADOCK 05000300 l' PDH
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o 1.0 Pffm80SE 1.1 This procedure is to Provide instructions for the disassembly, inspection and reassembly of gear drives on SWP-1A, 18 and l EPP-1, and to Provide instructions for the leak testing of the oil coolers on SWP-1A and IB gear boxes.
Procedure Sectien Disassembly 7.1 Reassembly 7.2 i
Testing of oil Coolers 7.3 l
2.0 arrraruers j 2.1 IMPLEMENTING REFERENCES 2.1.1 CP-115, In-Plant Equipment Clearance and Switching orders 2.1.2 MP-122, Disassembly and Reassembly of Flanged Connections 2.1.3 'PM-133, Equipment Lubrication Procedure 2.1.4 SP-601, Inspection and Testing of Lifting Devices 2.1.5 SP-344, Nuclear Services cooling System operability 2.2 DEVELOPMENTAL RITERENCES 2.2.1 Nuclear Plant Library Instruction Manual 8397, Philadelphia Cear Corporation 2.2.2 Nuclear Plant Library Aperture Card M-1876 MP-509 Rev. ; Q 6 Page 1 m -w m a m- w . :_ .. . :~~' ' _ *
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2.2.3 Nuclear Plant Library Instruction Manual #100 Ingersoll-Rand E.mergency Feedwater Pump Turbine Driven 3.0 ENCLOSURES Enclosure 1 Equipment Alignment Record Enclosure 2 Vibration Data Sheet Enclosce 3 SWP-1A, 1B, or ETP-1 Mai:rtenance Data Sheet Enclosure 4 leak Testing Schematic for Tube Side i
Enclosure 5 Data Sheet for Leak Testing '5 4.0 LIMITS AND PRECitTTIONS 4.1 Reasonable care should be taken to avoid chipping, marring. :r other damage to the machined surfaces and gaskets.
4.2 Relief valve used for heat exchanger testing is to have set ;!
pressure verified prior to each use. ,
5.0 EQUIPMDIT_ AND PERSONNEL REQUIRDtmI; 5.1 Personnel assigned shall be knowledgeable, experienced and quahfied to perform the spec 1tled tasks as determined by t e appropriate supervisor.
5.2 Replacement Parts (as required, 5.3 Sealing Compound, Non-Hardening Permatex, Type 2 (or equal)
(Quality Permatex is not required) i NP-509 Rev. g. p 9* -
Page '
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5.4 hati-SeizeCompound(Fel-Pron-1000orequal) 5.5 Grafoil Gasket Material 5.6 Testing rig as shown on Enclosures 4 and 5
. 5.7 K Sottle Nitrogen (3
5.8 Leak Detection solution - Laak Tec/ equal l 6.0 nonentern tufyvar. cosmITIoss AlfD Ff AMT STATUS 6.1 The equipment to be worked on is to be isolated and re::ved I
from service using an approved Operating Procedure and Equip-ment Clearance Order per CP-115, In-Plant Equipment Clearance and Switching Orders.
6.2 Obtain a Radiation Work Per:1t (RWP).
6.3 If slings, shackles, and/or hooks are required for th;s pr:ce-dure, they shall be tested in accordance with SF-601, Inspec-tion and Testing of Lifting Devices.
7.0 PROCEDURE .
7.2 ' Ensure o Limits and Precautions of Section 4.0 have been reviewed.
o Equipment and personnel are available per Section 5 0 o Initial Conditions of Section 6.0 have been set.
Completed By Date 1
MP-509 Rev. . .0 8 ,,,, 3
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7.0.2 The man in charge of performing this activity shall notify the Nuclear Quality Control (NQC) Supervisor or his designee at commencement of this procedure and at each ' HOLD POINT *.
7.1 DISASSDIBLY NOTE: Disassemble gear unit only to the extent required to complete repairs to the unit.
i 7.1.1 Disconnect driver and driven end shaft couplings.
7.1.2 Drain oil frca gear case.
7.1.3 Remove oil piping, brackets, and other interference items as necessary.
7.1.4 Lightly match-mark nating surfaces on oil pump and end caps :r locate match-marks fres previous saintenance.
Completed By Date 7.1.5 Remove oil pump and end cap bolts and remove oil pump.
7.1.6 Remove or slide end caps at least 1/2-in. away fres :ase.
While taking care not to damage end cap gaskets.
7.1.7 Remove capscrews and dowel pins frca housing jcint.
7.1.8 Remove bolts from housing and lift housing clear of unit.
NOTE: It may be necessary to pry with pry bars at housing joint to separate.
Mp-$09 Rev. #9 -' page 4
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7.1.9 Set upper housing on wooden blocks or soft material to prevent marring the mating surfaces.
Completed By Date 7.1.10 Check internals for damage or abnormal wear 7.1.11 Check gear teeth for any signs of destructive pitting as evidenced by pits being fairly large and relatively deep.
o NOTE: This condition could be caused by excessive loading or improper lubrication.
Sat Unsat Completed By Date
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CAUTION: Cover all openings to prevent et.try of foreign material.
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7.1.12 Check the gear teeth for any signs of abrasion or scratching as evidenced by groups of scratches running from the bottom to the top of the tooth.
l NOTE: This condit. ion could be caused by inadequate lubrica-tion or from presence of foreign material in the lube oil.
Sat Unsat e
Completed By Date 7.1.13 Check the gear teeth for any signs of scoring as evidenced ry general roughing of the whole tooth surface.
Sat Unsat Completed By Date NOTE: The marks caused by scoring are deeper than those caused by scratching and cover an area of the tooth instead of randos scratching or abrasion. This condi-tion could be caused by inadequate lubrication.
7.1.14 Any rough gear teeth should be stoned smooth if damage was caused by foreign saterial in oil. Gear teeth should have an even wear pattern. This area sust not be honed or fAled MP-$09 nev.
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7.1.15 If replacement of internal parts is necessary, remove the shafts to one of the Machina Shops as a unit for further disassembly.
100TE: If damage or wear is evident, notify the Nuclear slechanical/ Building service Supervisor for resolution and identify condition on Enclosure 3.
Completed By Date i
7.1.16 To disassemble shafts or remove bearings, remove c:upling ha'f .
by heating and/or pressing as necessary and remove shaf t key.
Limit coupling temperature to 200'T maximum.
7.1.17 Tape over shaft keyways to prevent damage to oil seals.
7.1.18 ' HOLD POINT
- Check the Condition of all bearings, #
7 NOTE: Bearings that were identified as noisy during opera-tion, or are discolored from overheating, corroded, pitted, or rough operating should be replaced.
Identify conditions found on Enclosure 3. Notify the Nuclear fler alcal/ Building Service Supervisor for resolution.
Inspected By Date l-Completed By Date l'
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7.1.19 Remove bearings by applying heat to bearing inner race and pressing as necessary. Limit maximum shaft temperature to 200'T.
IIOTE: Inner race may have to be removed by cutting with torch or grinder when extreme bearing damage has occurred.
7.1.20 Carefully note arrangement of gear helix on shafts for refer-ence, s
Completed By Date 7.1,21 .' HOLD POINT
- Check oil seals for damaged rubber sealing e'11e
- and check flexibility of retainer spring if applicable.
NOTE: !! secessary to replace thee, gently remove with a hammer and chisel from end caps. If it is not neces-sary to replace oil seals, store end caps carefully so as to avoid damage to oil seals.
Inspected By Date Completed By Date Mp-509 Rey. ON page 6
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7.2 REassninLY MTE: General Reassembly Instructions: l7 o Easure all bearings are properly oriented and replaced in original positions.
o Do not reuse 'nyloc" screws. Replace with new fasteners.
o Screws originally secured with 'locktite' and staked must be replaced in the same manner.
o Ensure all lubrication passages are aligned with passages n
in nating parts.
7.2.1 Clean all parts thoroughly before assembly.
7.2.2 ' HOLD P0fMT* Remove nicks, burrs, scratches, etc., en sa ;.a.; '
surf aces by filing, stening, or enery paper, as required. Or determined by the Nuclear Mechanical / Building Se r*ti:e Supervisor and/or authorized factory representative. Replace worn parts as necessary. Occument repairs made en Enclosure 3.
Inspected By Date Completed By Date NOTE: Acceptance criteria for mating surfaces is found in Mp-122.
Mp-509 Rev. 03
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7.2.3 When reassembling gears on shaf ts, make certain gear hand of cut (helix) is arranged in same position as before disasse:n-bly.
NOTE: Gear should rest firmly against shaft shoulder and square with shaft journals.
7,2,4 Bearino fnntallation a
NOTE: Searing parts are act interchangeable. Install a complete new bearing.
7.2.4.1 Heat bearing with conventional oven, inf rared oven /lasp, Or oil bath to expand inner race.
NOTE: Searing should not be heated greater than 250*T.
Completed By Date 7.2.4.2 Slip bearing onto shaft.
7.2.4.3 Ensure bearing is flush against shaft shoulder, s
NP-$09 Rey, Page to e__1 _m-c .- n w _ - - - w - e- . . ~ . - -- - ..
7.2.4.4 Following cooling, carefully tap inner race of bearing against shoulder with a soft bar and a hammer.
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Completed By Date NOTE: Tollow the above procedure for all bearings installed and document on Enclosure 3.
s j 7.2.5
- HOLD POINT' Install new oil seal if removed in Step 7.1.l*
i by pressing or tapping in with sof t aallet until it seats i
i firmly against shoulder of end cap and install end cap On i
1 shaft. I NOTE: Keyways on shaft should be taped over to prevent damage 1
to oil seal. !
{ Inspected By Date
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, 7.2.6 Install end cap on shaft. Use a new gasket, t
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, 7.2.7 Install coupling half on shaft by heating and/or pressing as necessary.
NOTE: Coupling halves should not be heated greater than 200*F.
Completed By Date 7.2.8 Transport shaft assemblies to area of equipment and prepare o
area for installation.
7.2.9 Remove splash pan from lower gear case.
7.2.10 Check lower case for dirt and debris, and remove wita : lean rags and suitable solvent as necessary.
7.2.11 Reinstall the splash pan / bolts and lockwire, paying particular attention to the bolts on the top side of the splash pan f:r they are very close to the shaft / gear assembly.
NOTE: The lockwire is to be installed /trinsed so there is no interference with shaft / gear assembly.
7.2.12 Slowly and carefully lower shaft assemblies one at a time int:
their respective places in lower housing, NOTE: Care should be taken not to chip or damage gear teeth,
, end cap gaskets, etc.
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NP-509 Rev.
08 ' Page 12 l
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7.2.13 a. Parts visible are thoroughly clean prior to closure and devoid of any detrimental nicks, burrs, scratches, etc.
- b. All gears are properly installed on shafts.
- c. Bearings are installed.
- d. 011 seals are installed. .
- e. Coupling is installed.
- f. Lower gear case is f.ee of dirt and debris.
- g. Shaft assemblies are in place and gears in mesh.
- h. Lubrication passages are aligned with passages in sating i
parts.
Completed By Date 7.2.14 " H OI.D POINT
- Adjust the icw speed shaft tapered roller j' bearings by varying shim pack si:es to allow .002 to .CC4 inches axial float.
NOTE: Cear should be centered in the gear housing and end caps snugged up so bearings just start to bind.
Actual Axial Float Inspected By Date Completed By Date l'
Mp-$09 Rev. NO page 13 r--- Aowm.__x.,sw m._ % ~- w.- . . . .
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7.2.15 " MOLD POINT
- The high speed shaft ball bearings are not to be l7 adjusted as such. Caps must be shimmed to allow g least 1/32 inch axial float of this shaft. With the pinion and gear in place, slowly roll the low speed shaf t (gear) to center the high speed shaft (pinion), then restrict movement of the gear and verify that there is still n least 1/32 inch end ficat in the pinion. ,
Actual End Float i
Instrument ID Cal Due Date Inspected By Date l' Completed By Date 7.2.16 Coat the housing split surfaces with s2 permately. Ensu:e sealant is not in bearings or bearing bores.
Completed By Date 7.2.17 Install gear case cover.
Completed By Date MP-509 Rev. M0 Page 14 p . . . .- ~ ~~ 7.*.73' * ;M . A . e . .a- ;r m u.. %
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7.2.1b Install the oil pump thru the low speed shaft cap paying particular attention to the pump coupling and its engagement with the (2) tuo cap screws located on the end of the icw speed shaft.
NOTE: Prior to inserting the pump thru the end cap check to see that the roll pin is installed thru the coupling, the end of the pump shaft is resting against the roll pin, and that the set screw on the coupling is tight.
e 7.2.19 Install oil piping brackets and interference items, excep coupling quards.
Completed By Date 7.2.20 Add oil to gear case up to oil level mark, in accordance w;:n pM-133, Equipment Lubrication procedure.
NOTE: After gear is running, it will be necessary to add more oil as oil piping fills up.
Completed By Date Np-509 Rev. .0 2 ' page is
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7.2.21 " HOLD POINT
- Align couplings to within .003 TIR (total indi-cated runout) face-to-face and .003 ria-to-rim and record final alignment on Enclosure 1.
Inspected By Date Completed By Date 7.2.22 Turn unit over by hand with strap wrench applied :: input shaf t to insure freedom of rotation and check for noise, r;:s.
etc.
7.2.23 Install coupling guards.
Completed By Date 7.3 TESTING OF OIL COOLERS (INTERNAL tr_AKAGE) ;3 7.3.1 Remove one cooler from the gear box per MP-122, Disasse::ly and Reassembly of Flanged Connections.
i NOTE: QC inspectica of flanged connections is required per HP-122.
l 7.3.2 Install a replacement cooler that has been leak tested ;n 4
accordance with this section.
MP-509 Rev.
08 Page 16
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7.3.3 Restore the system to an operable status per Section 8.0.
Completed By Date 7.3.4 Assemble the testing device as shown on Enclosure 4. Record {3 test pressure gauge and relief valve serial numbers and ca'. .
dates on Enclosure 4.
IIOTE: QC verification required on Enclosure 4.
A Completed By Date i NOTE: See Enclosure 4 for references to valves and gauges in l$
Steps 7.3.5 through 7.3.11. [
- QC verification required on Enclosure 4.
7.3.5 Close isolation valve V-1 and vent valve V-2. !
. 7.3.6 Attach pneumatic source to the isolation valve, V-t (N; -'
bottle would be normal source.)
Completed By Date 2 7.3.7 Tape the open 'oll side
- connection with one layer of duct 5 i
tape. Puncture the tape with a pin or pointed object.
7.3.8 Position the taped fittine in the vertical position. i MP-509 Rev.
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7.3.9 Slowly open isolation valve V-1. Raise leak test pressure to {8
+10 [
225 -10 psig and shut isolation valve V-1. I 7.3.10 " HOLD POINT
- Apply leak detector solution at pin hule. 1, Monitor pin hole for a minimum of 10 minutes, record results i, on Enclosure 5. Note any pressure decay. !
'QC verification required on Enclosure 5. ;
Inspected By Date :'
Completed By Date i
7.3.11 If a leak is detected, identify the cooler and relieve any 5 pressure from within the cooler. Remove fr0: the tes:In; device. Notify the Nuclear ISI Specialist for resolu:10n per the requirements of CP-131 Procedure for Failure Mode Evalua-tion of ASME Section XI pressure Retaining Co:ponents.
Completed By Date
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8.0 POST-parwrmANCE TESTING AND SYSTDI RESTORAk' ION 8.1 Upon completion of the maintenance activity, the equip:en: 15 to be returned to service by use of an approved Operating Frr-cedure and/or release of the Equipment Clearance Order, per CP-115, In-Plant Equipment Clearance and Switching Orders MP-509 Rev. .0 8 page is c mc2.?* g%:ba ... . . . ..,..s. p c m g .... a .a .- . =n .(. , . . . . . . - . ~ v % ..- -
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8.2 A functional test of the equipment involved is to be run by operations per SP-344, Nuclear Services Cooling System {7 Operability. Concurrent and independent of SP-344, perfor: l vibration check at unit startup and at approximately one hour j increments until four sets are obtained. Record data on Enclosure 2.
NOTE: The Nuclear Mechanical / Building Service Supervisor may [
vary the frequency of readings as long as a total of j four readings are obta.tned.
Completed By Date MP-509 Rev. P Page 19
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ENCLOSURE 1 (Page 1 of 1)
HANDLING, SETTING, INSTALLATION AND ALIGNMENT OF EQUIPMENT FPC EQUIPMENT ALIGNMENT RECORD Equipment Tag No.
. Building Alignment Tolerance Thermal Rise Specified (if any)
Dial Indicator No. Due Date COUPLING ALIGNMENT RECORD
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Face to Face Coupling Alignment By QC Verification By Date MP-509 Rev. .08 ease 20
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MP-509 Rev.
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ENCI.OSURE 2 ItgICENCT TEEDWATER PUMP (ETP-1) (Page 2 of 2)
MAGINE SIITCH l I p ' A .
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[ IRD T.I. No. I iA #
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' f a RPM T.I. No.
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Due Date "A", "3", "C",' and "H" vibration measured in ,
the horizontal direction, gquipment .ag . No.
"C", "D", "E", and "7" vibration seasured in the vertical directice.
" Position "G" is the only A.S..M.E. Section n recuired measurement.
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i i i i i I 6 I I i E DlEi 7i 1 i i i i l i i t I i i kAi i o I ii i I i 6 t i I e A al i l i e i e t I i i i E E 7I I I i - l i 8 i i i i i ' 7 Ai a l i e I I 1 i i I 6 1 A
E1 I i i l I i i i i i f I ' E 7 76 i e i i i i l I I i i ! '
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AI i i i l I i A MP-509 Rev. Page 22
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D SWP-1A, 1B, OR EFP-1 MAINTENANCE DATA SHEET ENCLOSURE 3 (Page 1 of 1)
(Circle the appropriate number.)
Maintenance Performed i
RL%RKS:
i I
Work Performed By Initials /Date L
i MP-509 Rev. .00 Page 23 l
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LEAM TESTING SCllEMATIC FOR TU E9 E S I DE . j SECORD THE FOLLOWING: s RELIEF VALVE SERIAL 0 SET PHESSURE (REQ'D) 250 f0 psi
- 8 GAUGE A TEST GAGE SERIAL 8 __ CAI,DATE O- 400 ',
psi QC VERIFIED DATE ;
VENT VALVE V-2 RELIEF VALVE .
^" PI THREADED PIPE PLUG LIFT l TAPED FITTING 250 1 0 paiq ..
H 71 L s .
q ;
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L p FROM N2 SOUltCE OIL COOLER d
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ISOLATION VALVE V-1 FLANGE ADAPTOR
!g TelHEADED Pl.UG g33 -
/ THREADED PIPE PLUG WITN in. TAP SEALING GASM t;T ' f SEALING GASKET FI,ANG E AD Al* TOR '
i l
l DESIGN tulle PR ESSIIH E =
250 psig DESIGN SilEl.l. l'H ES Sill 4 E = 200 psig i
MP ',09 ite v . .j l'.n p . .! 4 i-: Net.oSuni: 4 8 i
- DATA EHEET FOR LEAK TESTING ENCLOSURE 5 (8 Relief Test Valve Set Pressure Pressure Elapsed Time Cauce ID No Tube' NOTE: Acceptance criteria for this leak test: no leakage is allowed - any evidence of leakage at the tape /shell side pin hole is evidence of internal leakage and is reason for rejection.
1 l
Cooler is for SW Pump: 3 Upper or Lower:
Test Performed By: Date QC Inspected By: Date
' Complete c.e data sheet for each heat exchanger tested.
1
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MP-509 Rev. y * "
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075917 SRT t IVOID, RfFfP 10 WR s i DLit h510N F ASTE NE RS F OR UP Pt r in LWR IURB CASING lh1LRFACE.WUIU- (25 CLOSED t F f 0-0001 (EF I Eftt kCt NCY F L t t;W A T E R 01/29/06 . MATL7 CLb HLI f DCT d 0 O tilu MARS 7 UNKNUhN 02/15/86 . REFUEL? kWPF Not i O O INU CHRG ACCil OMC > STAFF . . FPWPT 15If 0 o ,
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8000rICATION APPROVAL RECORp pRomCT MAa Es Errd./ enveekar me ara.w. e,4 m ,ee a,we eneum, .a-3 sVSTEunAC E F73 - 8 MODIFICATION NO. ,Zfg - 0I - /3 -O/ WORK REQUEST NO. i1.-? O w*se "[18515I REQUIRED 7 ( )YES h NO j , TYPE OP MOOlPICATSON: ( % PERIM( # )
- TEMPORARY EXP.DATE SAPETY.RELATED ( )NON-5APETY RELATED *W.R.NO. POR REMOVAL l GU MECHANICAL ( ) ELECTRICAL ( )I&C ( ) STRUCTURAL ( ) HANGER DESCRIPfl0N OP PROPOSED MODIFICATSON (Use A if .": - _ _ - y):
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WORK AUTHORIZ mit NUMBER *' b.f.$NLee& I!dkbr )Yd 2 1 th e/f6 usar aN Er="l= 'DATE VE3UFICATM4 El%INEEK VATE f De i ATE WUDFICATRNW APPROVAL 5 NGNATURE DATE.IN DATE-OUT 5".'n' L e. U tise - ci v7 % A .)/s/u, .aAA e Cf _ _- ^. McRC Revis. Reve( )YES(46
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i 1 1 System Returned to Operation, Setpoent Change / Procedure Re,sesen veruication and Pr ,enutive Maaneenance Update TIIIS WILL BE PERFORMED BY MOP-502. E18C145URE 18 f NSOD g 3.g-sw j Canceustion Nuclear Flant Mgr ,
, Temporary Me6ficassen itemoved Nuclear Planner ,,
installatsen and Test Comporte MM c- 2 /7/$ G ' and All Documentation Encleoed Nuclear sanner '/ i M OP-302 REY 3 DATE: 9/18)/85
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