ML17334A175

Reactor Vessel Head Removal & Replacement.

ML17334A175
Person / Time
Site:	Columbia
Issue date:	12/17/1981
From:	WASHINGTON PUBLIC POWER SUPPLY SYSTEM
To:
Shared Package
ML17276B653	List: ML17276B652 ML17276B654 ML17334A175
References
10.3.5, NUDOCS 8210190582
Download: ML17334A175 (22)

Text

Yerified 8y~-j'UI JQQI~e I I rUe4Ief/IIoII%fkLI Poet Verif'ed P"<<'f1.'.IW I"PR()(:El) t*R Date R SUPPLY SYSTEM:.~1Ii:II 3 (.':II I, NUMBER~~VQI UME NAME APP VEO PATE 12/17/81 10 MAINTENANCE PROGR S AND PROCEDURES SECTION 10.3 REACTOR VESSEL SERVICING TI TEE+10.3.5 REACTOR VESSEL HEAD REMOVAL AND REPl ACEMENT 10.3.5.1~Pur oee d Tne purpose of this procedure is to detail the steps in tensioning and untensioning the vessel head studs as well as the head removal and replacement in sequence with the tensioning procedure.

Incidental to tnis procedure is the installation and removal of the refueling cattle-chute.

10.3.5.2 A.References Safe Load Path-RPV Head, Exhibit 10.3.5A Q.GE, Vessel Flange Bolting Print 105D4615C.G.GE, Head Strongback Head Lifting Fixture Pr'nt 767E187 GE, Nuclear Boiler Equipment Operation and Maintenance Instruction, GEK71311, CV1-02-02-01, Sheet 8 Chicago Bridge and Iron Company Reactor Vessel Instruction Manual, CVI 2-02B13-06, Sheet 150 A.Reactor in shutdown mode.C.D.Reactor vessel pressure at atmospheric and temperature maintained below 200oF.I Check with the shift supervisor to make certain water in the reactor vessel is at the proper level.Reactor vessel cavity shield blocks removed.E.Drywell head removed.("DR ADOCg~8>>00+i 019pSB E'500039~I DR vvP SS P R I PROCEQURE NUMBER REVISION NUMBER 10.ENCLOSURE 3 PAGE NUMBER 1 1 f 0 0 J' I 1 IF.G.Reactor vessel head insulation package removed.Water tight seal covers installed on drywell ventilation duct openings.Reactor vessel cavity drained of water.Work Request approved by Shift'upervisor in accordance with PPM 1.3.7.K.Clearance Order approved in accordance with PPM 1.3.8.RWP in accordance with PPM 11.2.8.L.N.10.3.5.4 Reactor building crane checked out per PPM 10.4.1.Reactor vessel head lifting fixture EPN NSSE-EQ-15 and Cattle Chute Slings EPN d t df~p Stud tensioners and pumps given preoutage PM.Precautions A.C.Notification of the Control Room when tensioning operation commences and is completed to assure temperature requirements for this procedure.

The head temperature must be maintained above 70oF.Vessel stud elongation holes must be void of moisture and dirt;While tensioners.

are in operation, all personnel shall ke p clear of stud tensioner heads.F.G.While hoisting stud tensioners and/or threading tensioners onto vessel studs,, be careful of damage to stud threads.Stud thread protectors shall always be in place except during stud tensioning operation or while studs are being cleaned, lubricated or removed for inspection.

Prior to head removal and all the time the head is removed, all small tools and equipment shall be sufficiently secured to prevent-falling into the vessel per PPM 1.3.18.The flange protectors shall always be in place while the head is removed except when the in-vessel staging tracks are mount d.H.The reactor vessel head and cattle chute shall be moved per the path shown on Exhibit 10.3.5A.'o 7e.'~7', gg j/p(U+y~@Sr Pre>c rlCJ laud+><~~~~pcs~~~HA Joacf~t/4 HPr4~<~g C~w~~~<>~~7'+~//~p C~g C~c~f~rg~~~~t~wvc'A dg WC'+<M~~/c Q spy~~.Wd'w~g ct Pr'~~w~~l~~~~gy~

cger'p dA gWi~4CCP+~~~VIP 598 PROCEDURE NUMBER L0.3.5.REVISION NUMBER PRBE iNVMBER 10.3.5-2 of 16 10.3.5.5 Materials Tools and E ui ment l.At least one set of vessel'0'ings 2.Three vessel studs and nuts 3.Recommended spares for stud tensioners 4.Recommended spares for stud tensioners pumps'B.S ecial Tools and Fixtures l.2~3~4.5.6.7~8.9.10.Head stud and nut rack 4f Vessel nut handling tool Stud handling tool Complete set of thread protectors Stud running air motors Set of flange protectors 12" machinist level Complete set of stud elongation rods Dial depth indicator Head temperature measuring instrumentation C.Re ular Tools and Fixtures 1.Reactor building crane 2.Mead lifting fixture-EPN NSSE-EQ-15 3.Stud tensioning carousel 4.Set of 4 stud tensioners 5.Tensioning pump 6.Fexible hose for head evacuation to the off-gas system 7.Refueling"cattle-chute" 8.Mead stud guide pins 9.'anyards for small tools..0.Materials l.2.3~Supply of lint free rags WPPSS approved cleaning fluid-Isopropanol or Methonal Alcohol Six cans each of Fel-Pro C-5A, Never-Seez compound or equivalent 10.3.5.6 Procedure A.Vessel Head Stud Untensionin 2.Using reactor building crane auxiliary hook place stud tensioner carousel with tensioners and manifolds, onto vessel head.Connect and check out operation of tensioner hydraulic pumps.3.Remove stud protective covers and store along outer periphery of reactor cavity.'.Contact control room to monitor head flange temperature.

Must<<>><<>>ove 70oF while tensioning is being performed.

PROCEDURE NVM8FR 10.3.5 RKVISION NVM88R RAGK NVMGFR 10.3.5-3 of 16 0

=5.For four tensioners two cycle procedure, use the following pattern sequence: Tensioner Number 82,~0eration Stud Numbers1 2 3 4 5 6 7 8 9 10 ll 12 13 14 15 16 17 18 19 1 13.5 17 9 15 7 19 li 2 14 6 18 10 4 12 8 16 20 32 24 36 28 22 34 26 38 30 21 33 25 37 29 23 31 27 35 39 51 43 55 47 41, 53 45 57 49 40 52 44 56 48 42 50 46 54 58 70 62 74 66 60 72 64 76 68 59 71 63 75 67 61 69 65 73 NOTE: This sequence is shown pictorially on Exhibit 10.3.5B.B.Connecting the tensioners to studs:'.The tensioners should be lowered simultaneously,, or individually, each tensioner being guided by an operator.The tensioner should go down over the stud and nut until the base rests on the flange.2.Turn the drive handle on the side of the tensioner until the driving teeth of the drive plate match up with the slots of'he nuts, the drive plate will drop into place and be ready for turning the nut.3.Push down on the puller bar by pushing down on the hand wheel and feel for the thread engagement between the pluller bar socket and the stud.4.After the threads have engaged, screw on the puller bar until the tensioner holding nut bottoms on the tensioner spherical washers.5.Back off the'puller bar about 1/2 to 1 turn.6.Step back to signal that unit-is ready for tensioning.

PROCEDURE NUMBER REVISION NUMBER PAGE NUMBER VIP 598 10.3.5 10.3.5-4 of 16 7.8.When this operation has been performed on all of the tensioners, they are ready to be pressurized.

Close tensioner bypass valves.Position control valve to tensioning"Position to Start Tensioner Pump".Continue pumping until nuts at-each tensioner are free to rotate (maximum hyd.press.should be approximately 8000 PSIG for operations 11-10 and 8600 PSIG for operations 11-19.)Position control valve to"Neutral" and signal that pump is at pressure.Turn drive handle on side of tensioner 5 turns counter clockwise (1 turn of nut)and step back to signify operation is complete.10.12.13.14.Crack the pressure relief valve and lower hydraulic pressure to 4500 PSIG (operations 1-10)or 4730 PSIG (operations 11-19)and signal that pump is at pressure.Turn drive handle clockwise until stud nut is snug against vessel flange and step back to signify operation is completed.

Position the control valve to"release" position and allow hydraulic pressure to decrease to"0" PSIG.NOTE: Leave control vavle in release during positioning of tensioners to next position.Disengage tensioners from studs by turning handwheel counter clockwise.

Hoist tensioners free from studs and index to next position.Repeast steps 5 thru 13 until all nuts (operations 1 thru 19)have been released to the intermediate tension.15.16.17.Index back to position 1 and engage tensioners onto studs per step 5.Position control valve to"tensioning" and increase hydraulic pressure until all nuts are free.(Aproximately 6800 PSIG for operation 1-10 and 8800 PSIG for operations 11-19)position control valve to"Neutral." Loosen the stud nuts by turning the drive handle counter clockwise 10 full turns (2 nut turns).18.Open the pressure relief valve and lower pressure to"0" PSIG.Position control valve to"Release."'9.20.Disengage tensionsers from studs and index to next position and o.ngage tensioners onto studs per step 5.Repeat steps 16 thru 19 until all nuts have been loosened (operations 1-19).PROCEDURE NUMOER RE'/ISION I'IUMOER PAGE NUMOER KVP 598 10.3.5 0 10.3.5-5 of 16 I

21.22.23.24.25.26.27.Check to see that all nuts are free.Transfer carousel, tensioners and pumps to storage.Place nut and washer storage racks in vessel cavity.Proceed with nut removal by use of nut threading tool.Place nut and washer in the rack, making sure both pieces are kept in sets and in sequence.When ccmpleted, transfer racks to refueling floor for storage.Replace all stud protectors, except at positions 81, 825 and 850 for head/stud guide caps and selected studs to be removed for inspection.

Install the three head/stud guide caps.Remove three or four studs for refueling passageway, using stud handling fixture.Check to see'that studs are correctly identified for vessel position.Remove other selected studs as specified by engineering for periodic surveillance testing.Check to see that studs are correctly identified for respective vessel position.Transfer studs in stud rack to refuel floor for storage or testing.C.Vessel Head Removal 2.Transfer vessel head lifting fixture and attach to head.NOTE: Make certain crane hook is properly mated to strong back pins and locking pins are in place.Carefully hoist head approximately 1" until it is free of the flange.Continuously monitor the crane load cell for overloading, (RPV maximum weight is 186,7000).

Check for head level, clearance and uniform loading, adjust turn-buckles as needed.3.4.NOTE:-Check with operations to make certain the RPV head has been evacuated of noncondensable gases that could go airborne and contaminate the 606 level.Have Health Physics check when vessel head has been lifted approximately 1" to see if further evacuation is needed through the head vent.Chal'lund 4~du~r~@~A.$~p f>3~)4 Waive crrfprh r'r r j pier s 4//~tseC s Hhen the head is cleared for removal, remove filter (if installed) and hoist head free.Hoist and transfer head to its storage pedestalsvI'elease head lifting fixture from crane hook.v/0 7/f<>gAFc cdAA J4P~/J o~4 P/fN/1 Igs3t5+.Install vessel flange orotectors and vessel stud hole protectors in void areas.WP.598 PROCEDURE NUMBER REVISION NUMBER 10.3.5 PAGE NUMBER 10.3.5-6 of 16 O."Cattle-Chute" Installation 2~Af'ter the fuel pool shield blocks have been removed per PPM 10.3.2, in preparation for the refueling operation, rig the"Cattle-Chute" for hoisting.Hoist and move to vessel cavity.Guide and set cattle-chute so that one end is protruding into fuel pool canal and the other end overhanging the vessel flange.=Remove rigging.E."Cattle-Chute" Removal l.Attach hoisting rigging.Hoist and transfer chute to storage position on refueling floor.Release hoisting rigging.2.Upon comoletion, fuel pool shield blocks may be reinstalled.

F.Yessel Head Re lacement l.Remove old"0" rings and collect all clips and retaining rings.Clean head flange and"0" ring grooves with isopropyl or methyl alcohol to level"B" cleanliness.

CAUTION: Oo not touch"0" rings with bare hands, use cotton gloves.Support uniformly with at least 6 people.2.Install new set of"0""ings into head grooves and attach retaining clips.Inspector Da e 4, Clean and lubricate all vessel studs and nuts with Fel-Pro-C-5A,"Nickel Never-SeezR compound or equivalent.

NOTE: All one product should be used at one refueling.

Install vessel studs previously removed f'r inspection.

Tighten in place by use of stud wrench.Hake sure studs are returned to their specific location.Inspector Date 5.Remove vessel flange protectors.

Clean flange with isopropyl or methyl alcohol to level"B" cleanliness.

Do not use a metal cleaning device on flange surfaces.Inspector Date WP.598 6.7i 10.3.5-7 of 16/7 lf/id'/g 5 AC p~Attach vessel head lifting fixture to the vessel head.Hoist head free and check for level and uniform loading.<Ace/~<//>g+>gg<<gr+,lgI P/41, PiSA P ePrrf4'C Crag+,S PROCOVR8 NVMB+R REVISION NVMBBR PAGB NVh188R 10.3.5 0 g g4fc/oo J/'<H>~~/~'//A@3~/

j/p 7.Transfer head to vessel cavity~Check out head orienta-tion.Slowly lower head over guide pins and studs until it sits firmly on vessel flange.Release head lifting fixture and-transfer to storage location.Inspector Date 8.Remove stud protectors and store in cavity outer periphery.

Remove and store vessel head guide caps.9.Transfer nut and washer racks to cavity floor.Assemble washers and nuts to their respective studs.Washers shall have rounded side up.With nut turning device, run nuts down to within 1/4" of flange.Return nut and washer racks to storage.Inspector Date 10.Attach head and flange temperature instrumentation.

Vessel stud tensioning cannot start until the head is above 70oF.G.Vessel Head Stud Tensionin 1.Place stud tensioner lifting rig with tensioners and manifolds onto the auxiliary hook.2.Remove cap screws and thoroughly clean each stud elongation measuring hole.and install respective measuring pins in each stud.Allow sufficient time for measuring'pins to assume related stud temperature.

Should generally take about one hour..Connect and check out tensioner hydraulic pump/pumps.

4.Contact control room to monitor head and flange temperature.

Temperature must remain, above 70oF while tensioning is being performed.

5.Using a dial depth indicator, take and record on data sheet 10.3.5.C two complete initial sets of'tud measurements.

If there is more than 0.005" difference between the two readings, then suf'ficient time has not been allowed for temperature changes.Use the final set of readings for eventual computation.

Inspector Date 1VP 598 PROCEDURE NUMBER 10.3.5 REVISION NVM8ER PAGE NUMBER 10.3.5-8 of'6 6.For four tensioner 3 cycle procedure, use the following pattern of sequencing:

~eration Tensioner Number t2 83 Stud Numbers 1 2 3 4, 5 6 7 8 9 10 ll 12 13 14 15 16 17 18 19 1 13 5 17 9 3 15 7 19 11 2 14 6 18 10 4 12 8 16 20 32 24 36 28 22 34 26 38 30 21 33 25 37 29 23 31 27 35 39 51 43 55 47 41'3 45 57 49 40 52 44 56 48 42 50 46 54 58 70 62 74 66 60 72 64 76 68 59 71 63 75 67 61 69 65 73 7.Position the Stud Tensioner Over Studs 1, 20, 39 and 58 (Operation 1)a.The tensioners should be lowered simultaneously, or individually, each tensioner being guided by an operator.The tensioner should go down over the stud and nut until the base rests on the flange.b.Turn the drive handle on the side of the tension until the driving teeth of the drive plate match up with the slots of the nuts, the drive plate will drop into place and be ready for turning the nut.c.Push down on the puller bar by pushing down on the hand wheel and feel for the thread engagement between the puller bar socket and the stud.d.After the threads have engaged, screw on the puller bar until the tensioner holding nut bottoms on the tensioner spherical washers.e.8ack off~the puller bar about 1/2 to 1 full turns and step back to indicate completion of operation.

f.When this operationhas been performed on all of the tensioners, they are ready to be pressurized.

PROCEDVRf NVMBER RKV1SION NVMBER x0.3.5 PAGE NVh1BKR 10.3.5-9 of 16 8.9.10.Close tensioner bypass valves.Position control valve to"Tensioning" position to start tensioner pump.Continue pumping'until hydraulic pressure reaches 3600 PSIG.Position control valve to"Neutral".

Signal this step is complete.Turn drive handle on side of tensioner clockwise until nuts are seated against head flange and step back.Position control valve to"release" and allow pressure to decrease to zero.NOTE: Leave control valve in release during position of tensioners.

11.12.13.14.Oisengage tensioners from studs by turning handwhell counter clockwise and step back.Moist tensioners free from studs and index to next position in the sequence.Repeat steps 7 thru ll for operations 2 thru 19.Index the tensioners to positions for operation 1.Repeat steps 7 thru ll for operations 1 thru 19 using the following pressures in step 8 of this section.15.Operation 1 thzu 7 Operation 8 thru 13 Operation 14 thzu 19 Repeat steps 7 thru ll for operations following pressures in step 8 of this 7370 PSIG 7035 PSIG 6700 PSIG I 1 thru 10 using the section.16.17.Operation 1 thru 10 7775 PSIG Operation ll thzu 19 7400 PSIG Oisengage tensioners fzom studs and lift to prov'de access to studs for elongation measurements.

Take with a dial depth indicator and record on data sheet (Exhibit 10.3.5.C)a complete set of studs end to extensometer rod measurements.

Record the difference between the final measurement and the initial measurement (taken in step 5)on the Stud Tensioning Record (Exhibit 10.3.5.C)for each stud.18.19.NOTE: The required elongation is"0.052 to.062"-any studs with less elongation must be retensioned.

Retension all studs not meeting the elongation requirements using the same sequence as before and using the pressures of step 15.Measure the retensioned studs and record the readings on the data sheet.WP.598 PROCEOURE NUMBER REVISION NUMBER 10.3.5 PACE NUMOER 10.3.5-10 nf 16 NOTE: Any studs that do not meet the elongation requirements must be retensioned until they do., 20.When completed, remove stud measuring pins and cap stud h'oles.Store measuring pins.21.Remove, dismantle and store stud tensioning equipment.

10.3.5.7 Documentation A.Complete signatures of this procedure as specified in the body of this procedure.

B.Enter data in Stud Tensioning Record (Exhibit 10.3.5.C).

C.When work activity as specified on Work Request is completed, attach this signed praocedure and record sheet to the respective Work Request.D.Return Work Request to'he Shift Supervisor as per PPM 1.3.7.F.File completed work request in the equipment history folder.10.3.5.8 Attachments Exhibit 10.3.5.A through 10.3.5.C PROCEDURE NUMBER REVISION NUMBER PAGE NUMBER ViP 598 i0.3.5 0 10.3.5-11 of 16 1 J ocwau 4~~~" stlcic~PEA gV)Ca P~M~Rf~eb~~I9 U 7 Q a APV fi'PAD~g('pg q<~Zk 5J&74pe'EL Poach I o QOvQRED QoUHgp Zy ap+~3~t~g/MAIN gg TOILET'AFE LOAD PATH-RPV HEAD EXHIBIT 10.3.5A PROCKOVRE NVMBER REVISION NVMBER PAGE NUMBER VIP.598 10.3.5 0 10.3.5-12 of 16

STUD TENSIONING AND UNBOLTING SEQUENCE Ql I I 7 l3 Operation Number Stud Number 10 l7 l3 Tens ioner 44 Teneionen gl L7 Tensioner Tensionez"2 V~2I EXHIBIT 10.3.5B PROCEDURE NUMBER REVISION NUMBER PAGE NUMBER WP.Sg8 10.3.5 0 10.3.5-13 of 16 STUD TFMP.STUD TENSIONING RECORD CLOSURE FLG.TEMP.VERIFIED BY: Inspec or Date STUD NO.2 I 5 I NO-LOAD ELONG.READ.1 la I lb LOADED ELONG.READ.2 STUD TRIM ELONG.ELONG.I READ.2-1 I 3 STUD ELONG.3-1, I I I I I I I I I I I I 7-I 8 I I 9 l 1O I 11 I 14 I 15 I 16 I 18 I 2O I 21 I 22 I 23 25 I 26 I 27.I I I I I t I I I I I'I I I I I I I'I I I I I I I I I I I I I I l I I I I I I I EXHIBIT 10.3.5.C PROCEOURE NUhlBER REVISION NUhlBER 10.3.5 PAGE NUMBER STUD TENSIONING RECORD (cont'd)STUD NO.28 29 30 32 39 40 41 45 46 47 48 49 50 51 52 54 55 56 57 58 NO-LOAD ELONG, READ.1 la I lb LOADED ELONG.READ.2 STUD EI ONG.2-1 TRIM ELONG.READ.3 STUD ELONG.I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I EXHI8IT 10.3.5.C PROCEDURE NUMBER REV>SION NUMBER PABE NUMBER 1 I I I STUD TENSIONING RECORD (cont I d)'STUD NO.I 59 I I 6O I I 61 I I 62 I I 63 I I 6e I 65 I 66 I 67 I I 6S I I 69 I l 7O I 71 I I 72 l I 73 I I 7<I I 75 I I 76 I I I I I I I i I I I NO-LOAD ELONG.READ.1 la 11b LOADED ELONG.READ.2 I.I STUD ELONG.2-1 TRIM ELONG.READ.STUD ELONG.3-1 l I I I a I I I I I I I I I I I I I I I I I I Iwp see EXHIBIT 10.3.5.C PRQCEOURE NUMBER REVISION NUMBER 10.3.5 PAGE NUMBER 10.3.5-16 of 16