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HEAVY LOADS REPORT On January 12, 1981, an NRC letter dated December 22, 1980, from Mr. | HEAVY LOADS REPORT On January 12, 1981, an NRC {{letter dated|date=December 22, 1980|text=letter dated December 22, 1980}}, from Mr. | ||
Darrell G. Eisenhut was received. The purpose of that letter was to l request that CG&E review its controls for the handling of heavy I | Darrell G. Eisenhut was received. The purpose of that letter was to l request that CG&E review its controls for the handling of heavy I | ||
l loads to determine the extent to which the guidelines of Enclosure 1 to that letter are presently satisfied at the Zimmer Plant, and to identify the changes in modifications that would be required in order to fully satisfy those guidelines. | l loads to determine the extent to which the guidelines of Enclosure 1 to that letter are presently satisfied at the Zimmer Plant, and to identify the changes in modifications that would be required in order to fully satisfy those guidelines. | ||
Latest revision as of 00:28, 31 May 2023
| ML20071P714 | |
| Person / Time | |
|---|---|
| Site: | Zimmer |
| Issue date: | 06/01/1983 |
| From: | CINCINNATI GAS & ELECTRIC CO. |
| To: | |
| Shared Package | |
| ML20071P711 | List: |
| References | |
| REF-GTECI-A-36, REF-GTECI-SF, RTR-NUREG-0612, RTR-NUREG-612, TASK-A-36, TASK-OR NUDOCS 8306080140 | |
| Download: ML20071P714 (108) | |
Text
{{#Wiki_filter:- _ ._. . I Docket No. 50-358 l I I WM. H. ZIMMER NUCLEAR POWER STATION - UNIT 1 HEAVY LOADS REPORT I I I I I I I I I June 1, 1983 l , l I l 8306080140 830602 , PDR ADOCK 05000358 E PDR l \ .. _ --
L r' HEAVY LOADS REPORT On January 12, 1981, an NRC letter dated December 22, 1980, from Mr. Darrell G. Eisenhut was received. The purpose of that letter was to l request that CG&E review its controls for the handling of heavy I l loads to determine the extent to which the guidelines of Enclosure 1 to that letter are presently satisfied at the Zimmer Plant, and to identify the changes in modifications that would be required in order to fully satisfy those guidelines. In May, 1981, the Cincinnati Gas & Electric Company submitted a response concerning the implementation of the Interim Actions listed on Enclosure 2 to the December 22, 1980, Eisenhut letter. Since the Zimmer Nuclear Power Station was under construction at that time the May submittal committed to implementation of the Interim Actions by initial fuel loading of the plant. In June, 1981 additional information concerning " General Requirements For Overhead Handling Systems" was submitted in response to Item 2.1 of Enclosure 3 to the December 22, 1980, Eisenhut letter. In September, 1981 a third response was submitted covering the I information requirements of Sections 2.2 and 2.3 of Enclosure 3 to the December 22, 1980, Eisenhut letter. The following submittal provides the necessary descripton of plant hardware, administrative controls and general state of compliance with the requirements of NUREG 0612. This submittal is organized in IJ cccordance with the topical sections contained in the draft Technical Evaluation Report prepared by EG&G Idaho, Inc. dated January, 1982. 2.1 Overview a For the purpose of reviewing ,the applicability of NUREG g 0612 to various load handling systems, the weight of a single spent fuel assembly and its handling tool was taken to be 1,000 lbs. Consequently those loads exceeding 1,000 lbs. were classified as heavy loads. 2.2 Heavy Lcad Overheed Handling Systems As previously described, the June, 1981 submittal reported the results of our review of plant arrangements to identify all overhead handling systems from which a load drop may result in damage to any system required for plant shutdown or decay heat removal. The following information is a revision and update of the June 21, 1981, submittal. Attachment 1 is a listing of every permanently installed or planned crane or overhead handling system incorporated into the design of the Wm. H. Zimmer Nuclear Power Station. Each crane or load handling device can be located on the equipment removal diagrams as referenced in
i 4 ; l Attachment 1. Note the 100-Series cranes are those j located in the reactor building. Attachment 2 provides a listing of those load handling devices from which a load drop will not result in damage ] 4 to any system required for plant shutdown or decay . heat removal without taking credit for interlocks, technical specifications, operating procedures or detailed 4 structural analysis. These cranes were excluded by j verifying through visual observation that sufficient physical separation from any load-impact point to safety related equipment exists. The attached equipment removal drawings provide sufficient detail to establish a. s-l reasonable confidence level in this assessment. - Attachment 2 also lists those load handling devices which_ l were excluded from further consideration since they are
! incapable of handling heavy loads. The consequences of a load drop from these load handling devices are bonded by the dropped fuel bundle accident as analyzed in the Zimmer Station FSAR. '
i }' Attachment 3 is a listing of those permanently installed i overhead handling systems which because of their location make lifts in the vicinity of equipment required for safe ' shutdown or decay heat removal. s 4 l . Attachment 4 provides justification for removing some
- overhead handling systems from fulfilling the General i
Requirements of NUREG 0612 Section 5.1.1 under specified. conditions which would normally exist ~during its use.'*, While being used under the plant conditions specified in N t Attachment 4 the overhead handling systems cannot degr,ade
- the shutdown or decay heat removal capabilities3 cf the's plant. Administrative controls will be established to f
ensure that crane use is restricted'to the conditions ' i " s I specified in Attachment 4 or the General Requir~ements bf , } NUREG 0612 Section 5.1.1 will be satisfied during usi { under other conditions. For those cranesslisted in - ! Attachment 3, Load / Impact area matrices are \ included \in j Attachment 5. y N? N l . . m
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The overhead handling systems which are listed ini Attachment 3 and no justification is given,in Attachment 4 are those systems which shall meet the General - Requirements of Section 5.1.l of NUREG 0612., These cranes- " are listed in Attachment 6. ' ^ t . N 'e s e N ; ., 2.3 General Guidelines ' ' l' . ~ y u-
~s The General Guidelines as presented in NURhG-0612 'Section '
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5.1.1, shall be implemented at the time of fuel load or . I when required as discussed in the following sections' ,' __ _s . st ;'
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L section 2.3.1
" Safe load paths should be defined per the guidelines o{ NUREG 0612, Section 5.1.1 (1) " .
As.in accordance with Section 5.1.1 of NUREG 0612, those cranes defined to carry " heavy loads" with the potential ~of impacting equipment required and/or for safe shutdovn or decay heat removal (see Section 2.2 of 'this document) will have defined for each, " safe load paths". The safe load path will." follow to the extent practicable structural floor members, beams, etc...." These safe load paths will be included in procedures, on equipment layout drawings. On the plant refueling floor safe load paths will be clearly marked (via' paint or safety roping) where the load shall be handled.
'" As is the case with alf' procedures at the Wm. H.
?Zimmer Nuclear Power Station temporary changes to approved written procedures must be approved before implementing any work. action deviating from a written procedure. The procedures regarding move-ment of " heavy loads" aresno different. The normal. approval cycle of any' procedure includes y review by the Station Review Board.
- c. Section 2.3.2 l -" Procedures should be developed and implemented per
v,, the guidelines oflSection 5.1.1(2)". '
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, Also in accordance with Section 5.1.1 of NUREG 0612, for applicable chanes defined by.Section 2.2, detailed procedures shall be written-governing the load handling op'e' rations of heavy loads over spent fuel or safe shutdown equipment. Such procedures ~
( shall be written and approved prior to performing applicable load handling operations ~following initial 43;' , fuel loading. Procedures shall contain detailed
; rigging instructions including sling lengths, rope
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. diameters) shackle diameters and minimum ratings.
-- The procedure shall,contain an isometric pictorial
. diagram of the required rigging. Multi-use rope
. . slings used at ZPS-1 -are labeled with tags to
, ~ xindicate their rat'ed' capacity.
Some h g^Vy loads
. located on the plant refueling floor.are handled with dedicated slingfarrangements. These slings will be
-s labeled for theit pp.rticular use (s) . The following applicable before:use rigging inspections shall be contained in the procedure:
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a) Latches, fastenings and attachments fs* proper operation. b) Excessive wear and/or distortion or deformation, c) Chemical or heat damage to materials. d) Cracking, fraying or parting of equipment.
, e) All end connections for damage. m f) Slings and ropes for cuts, crushing, kinks, broken wires, unstranding or corrosion (no more than six randomly distributed broken wires in one rope lay, or' three broken wires in one strand in one yope. lay).
g) Hooks and U-bolts for deformation or cracks (shall not exceed more than 15% in excess of [ normal throat opening or more than 10 deg. twist). h) Chains for weapr tvists, broken, cracked or otherwise damaged links.
- 1) Examine sling or rope width or diameter for indications of wear or faulty core support. -
Theprocedureshallbo'ntainstep-by-stepload movement instructions and shall; define the equipment removal path as previously discussed. Section 2.3.3 '
" Crane operators should be trainsd, qualified and conduct ther.selves per the guidelines of Sectica 5.1.1 (3)".
All, personnel who operate cranes'or hoists at ZPS-1 shall be trained, qualified and c6nauct themselves perthe,guidelinesofChapter2-3ofANSIB30.}-1976. Section 2.3.4 ; .
'Special lifting devices should satisfy the guidelines of ANSI-N14.6-1978".
In the June, 1981 and September, 1981 responses concerning the state of compliance with the guidelines of NUREG 0612 at the Wm. H. Zimmer Nuclear Power Station, two special lifting devices were identified. These special lifting devices are , ider[tified as. the reactor vessel head strongback and
i the steam dryer / moisture separator strongback. At the time of previous NUREG 0612 submittals the Cincinnati Gas and Electric Co. was in the process of
, obtaining detailed design and fabrication documentation to establish the status of compliance with the requirements of ANSI 14.6 as required by item 4 of NUREG 0612 Section 5.1.1.
The subject special lifting devices were designed and supplied by the General Electric Co. The following information details the design, fabrication and acceptance testing methods and controls which were employed to ensure the load handling reliability of the special lifting devices. The subject special lifting devices were designed by the General Electric Co. The design of each device is presented on detailed engineering drawings. The drawings indicate the specified materials and any required heat treatment. Commercially procured items are specified by manufacturer and catalog numbers. The material is specified as per the referenced catalog. The design drawings require welders and procedures be qualified in accordance with ASME Boiler and Pressure Vessel Code Section IX. Other fabrication practices are specified on the design - drawings. Quality Assurance requirements, required documentation and control of fabrication records were specified by General Electric Company QC Plans and associated supplements which are available for review. No limiting conditions for use of either device were specified. The reactor head strongback will be operated and stored in an environment which is suited for human beings and such an environment has no detrimental effects on the equipment as designed. The steam dryer / moisture separator lifting device was designed for the existing environment during use. It can be immersed in water and will operate reliably and safely at temperatures that exist when the RPV head is removed. The reactor head strongback was designed by General Electric to lift the reactor vessel head. However, since the reactor vessel head and the drywell head were both manufactured by Chicago Bridge and Iron, allowance has been made to lift both items with the same strongback. The weight of the containment head _ is less than or equal to the reactor vessel head. The attachment points are also located in the same dimensional relationship. Consequencly, although not specifically designed for this purpose by General ___,__,__,__,,__,.,____-_n_ - - - - - - - - - -'
I t Electric, the reactor vessel head strongback may be used for both purposes. The design documents require the attachment of nameplates to each device. The nameplates indicate the design drawing number and the rated capacity of the device. The design documents for the special lifting devices do not contain a critical items list. As previously described the design drawings and other referenced documents indicate any required material traceability or special fabrication practices. In-process testing was specified on the component design drawings. The specified in process testing involved magnetic particle inspection, per GE specifications, of structural welds prior to and following the proof load test. The crane hook engagement pins were magnetic particle and ultrasonic tested, per GE specifications, following the performance of the proof load test. Final product testing was specified on the design drawings. This testing involved, for the reactor head strongback, a proof load test of 100 tons with 25 tons applied simultaneously to the four lift points and for the steam dryer / moisture separator strongback a proof load test of 104 tons with 26 tons applied simultaneously to each leg cn a 194.25 inch spacing. As discussed above, for both devices, magnetic particle inspection of structural welds was performed following the proof load test. Stress analyses which demonstrate margins of safety are contained in the GE Design Record File DRF #F13-00011. These files are open for audit at the General Electric Company offices. The designer has not specified permissible repair procedures. Under the GE QA program any deviation from design drawings or specifications during fabrication are reported to the design individual. The design engineer approves the disposition o# the equipment which includes repair procedures or retesting requirements as applicable. Documentation received from General Electric lists the safety factor of the head steongback with respect to yield as 4.1. Similarly the staam dryer / moisture separator strongback safety factor is stated to be greater than 3.33 with respect to yield. For both devices the safety factor with respect to ultimate material strength is stated to be greater than 5.0. All intervening hardware between the strongback proper and the lifted load are part of the strongback design. These loads are very small in relation to the design capacity. The reactor building bridge
crane 110 ton hook hoisting speed is 5.5 ft/ min. Based on this slow hook speed the-subject special lifting devices are adequate with respect to yield point when dynamic loads are considered. The load bearing pins, turnbuckles and cables are designed as part of the special lifting devices. The stated safety factors apply to all load bearing components. The steam dryer / moisture separator lifting device employs a four legged sling in its design. Each leg has a documented 40,000 lb. working load rating and was proof tested by the manufacturer to 80,000 lbs. The four legged sling arrangement exhibits an approximate 24 degrees to the vertical angle. Including a conservative estimate for the strongback weight of 20 tons the slings are determined to meet requireaents of ANSI B30.9 while lifting the 51 ton moisture separator. Hardness tests were performed only on parts which were heat treated for the required material condition. The particular requirements were specified on the parts drawing. This requirement applied to the crane hook adaptor pins. Lamellar tearing was considered in the design of the devices. No laminations were observed in ! manufacturing when cutting plates or during magnetic particle testing of the hook adaptor pins which are I of tubular configuration. I l The design of each lifting device includes turnbuckles at each of the four lift points to accomplish even load distributions. The load carrying components that may become inadvertantly disengaged are fitted with locking devices. The steam dryer / moisture separator strongback requires remote engagement with the load attachment points. The design provides for sufficient clearance to allow simple motion engagement. Remote indication is supplied to confirm engagement. As previously described, fabrication of the special lifting devices was accomplished under the requirements of the General Electric Quality Control Plan. Product Quality Certifications are on file from General Electric which supply evidence that the subject devices are in conformance with the requirements of GE design drawings, referenced l [ specifications and purchase order requirements. Deviations from original design documents were approved by design engineers. 1_ .
device, presently under fabrication, will be installed using a special lifting device. Prior to its initial use the shield strongback will be evaluated to ensure compli'ance with the design and fabrication requirements of ANSI 14.6 The owners responsibilities for acceptance testing, maintenance and assurance of continued compliance will be addressed as provided in this submittal. The reactor vessel stud tensioning strongback was not evaluated as a special lifting device. The stud tensioners are used to tension and detension the reactor head nuts and studs. The vessel head is installed during these operations. Consequently the stud tensioners and strongback cannot impact fuel in the reactor vessel. The strongback will not be moved in close proximity to the spent fuel pool. Section 2.3.5 " Lifting Devices not Specially Designed" The rigging used with all plant load handling systems meets the requirements of ANSI B30.9. For those load handling systems listed in Attachment 6 additional allowance for dynamic loading will be included as follows. The capacity of the rigging will be specified as the static load plus 1/2% of the static load for each foot / minute of hoist hook speed. Table 1 is a revision of previous submittals which details the load handling combinations employed on the plant refueling floor. These load handling combinations are composed of rigging rated by the = manufacturer at 200% of the static load. These ratings take into consideration sling construction, sling leg angles and other considerations. All load handling combinations, therefore, meet or exceed the requirements of ANSI B30.9. Section 2.3.6
" Cranes should be inspected, tested, and maintained in accordance with the guidelines of Section 5.1. l ( 6 ) . "
All cranes and hoists at ZPS-1 shall be subjected to frequent and periodic inspections as described in Chapter 2-2 of ANSI B30.2-1976. All plant cranes are designated as either regular or standby service based upon a tcice/ week usage criterion.
Periodic testing, maintenance and actions to ensure reliable and safe operation of the special lifting devices used at the Wm. H. Zimmer Nuclear Power Station shall be implemented as follows. In accordance with the requirements of NrJREG 0612 use of the special lifting devices will be controlled through detailed procedures. The special lifting devices will only be used for their intended functions as described by procedure. The procedure will contain required precise visual inspections. Subparts or assemblies will not be exchanged from one special lifting device to another. Each special lifting device is marked with its rated capacity on its nameplate. Historical records of the special lifting devices will be maintained as described in ANSI 14.6. Special lifting devices will be removed - from service as required by ANSI 14.6 Section 5.1.7 until special testing is completed to ensure continuing compliance as described'in ANSI 14.6 Section 5.3.3. The proof load test performed as required by General Electric design requirements satisfies the intent of an initial acceptance test. Periodic testing required by ANSI 14.6 Section 5.3.1 will be performed. It is our interpretation that "If the device has not been used for a period exceeding one year, this testing shall not be required. However, in this event, the test shall be applied before returning the device to service" applies to both testing options. The special load testing prescribed in ANSI 14.6 Section 5.2.1 shall be performed following major maintenance or overstressing events as described in ANSI 14.6 Sections 5.3.2 and 5.3.3. The reactor head strongback has no non-load-bearing functional parts. The remote engagement system and the engagement display system of the steam dryer / moisture separator strongback will be functionally tested by procedure as described in Sections 5.3 4 and 5.3.5 of ANSI 14.6. All special lifting devices will bc visually inspected by staff engineering personnel before use; for intervals less than 3 months between use, inspection is not required. In addition to the steam dryer / moisture separator strongback and the reactor head strongback, a fuel transfer canal shield has been purchased. This
All cranes undergo an undocumented before use inspection encompassing those items listed under Section 2-2.1.2 of ANSI B30,2. All regular use cranes, or standby use cranes being operated regularly for more then a month, undergo a documented monthly inspection of these same characteristics. All cranes undergo a documented yearly inspection encompassing those items listed under Section 2-2.1.3 of ANSI B30.2. All new, altered, extensively repaired, or modified cranes will be tested as required by Section 2-2.2.1 and rated load tests will be performed per Section 2-2.2.2 of ANSI B30.2 with the following exceptions. We believe that the requirement of Sections 2-2.2.2.b.2&3 requiring full length travel of the crane trolley and bridge while handling a 125% test load is inappropriate and unnecessary. The load test as described in ANSI B30.2 may necessarily be performed in the vicinity of safe shutdown or decay heat removal equipment, thus placing the plant in an unsafe situation. We feel that this exception should be taken and is justifiable in certain situations where an inadvertant drop of the test load could impact safe shutdown or decay heat removal equipment. Preventative maintenance, equipment safety tagging, adjustments and lubrication will be performed as described in Section 2-2.3 of ANSI B30.3.0. Wire rope inspection, replacement and maintenance will be conducted as described in Section 2-2.4 of ANSI B30.2. Section 2.3.7 "The crane should be designed to meet applicable criteria and guidelines of ANSI B30.2-1976, " overhead and Gantry Cranes", and of CMAA-70, " Specifications for Clectric Overhead Traveling Cranes". An alternative to a specification in ANSI B30.2 of CMAA-70 may be accepted in lieu of specific compliance if the intent of the specification is satisfied." The miscellaneous hoist and trolleys located in the general areas of the plant are designed and constructed in accordance with ANSI B30.16-1973. They are described by the architect engineer and manufacturer as " electric overhead hoists". The refueling floor cranes include three jib cranes and the Reactor Building Crane. The three jib cranes on the refueling floor were designed and constructed in accordance with ANSI B30.11. The Turbine Building
f3hl 3_? q ' ;. - c _ s +. .~ . J l._7 : , , ;,. N .. _ ' .i.,. Y .[ .'.l[ ' crane meets EOCI specifications. The Service Water Maintenance bridge Crane complies with ANSI B30.2. The Reactor building bridge crane design is described in detail in Section 9,1.4.2.2 of the Wm. H. Zimmer Nuclear Power Station FSAR trhich is included with this submittal (Attachment 7). In particular the FSAR states:
"The cask crane will be designed, fabricated, installed, and tested in accordance with ANSI B30.2.0, Overhead and Gantry Cran-7 CMAA Specification, AISC, AISE, and otner applicable manufacturers' association and engineering society codes."
The reactor building crane main hook is believed to have sufficient design features to make the likelihood of a load drop extremely small as described in the September, 1981 submittal. The lifting point safety factors for shield plugs & pool gates on the refueling floor are listed in Table
- 2. These lift points were designed to AISC codes requiring a safety factor of approximately 1.67.
Design modifications will be completed to upgrade the spent fuel pool plug attachment points. This modification provides for the use of rigging rated at twice the lifted static load. The state of compliance to NUREG 0612 requirements for other overhead load handlilig systems which may impact safe shutdown or decay heat removal cystems is as described in the September, 1981 submittal. 2.4 Interim Guidelines Enclosure 2 of the NRC letter lists a series of Incerim Actions to be applied for the control of heavy loads. In May 1981 the Cincinnati Gas & Electric Company submitted a response which described planned Interim Actions to be implemented before initial fuel loading. In October 1982 additional information was supplied to clarify and update our commitments with respect to the Interim Actions. The Interim Actions will be met at the time of initial core loading as follows: (1) Licenses for all operating reactors not having a single-failure-proof overhead crane in the fuel storage pool area should be revised to include a specificatica comparable to Standard Technical Specification 3.9.7, " Crane Travel - Spent Fuel Storage Pool Building" for PWR's and Standard
= Technical Specification 3.9.6.2, " Crane Travel," for BWR's, to prohibit handling o# heavy loads over fuel in the storage pool until implementation of measures which satisfy the guidelines of Section 5.1. The main reactor building crane is used for handling heavy lends in the fuel storage pool area at the Wm. H. Zimmer Nuclear Power Station. The 110 ton hook of the main reactor building crane is designed with the following single fail.ure proof features described in the FSAR: a) A redundant idler gear train, which is a duplicate of the driving side gear reduction system (without drive motor). Each gear reduction train has a 150% of rated torque braking system, b) Structural steel support upon which the drum barrel will rest following gross failure of drum bearings, shaft, or bearing support. c) Redundant full capacity wire rope system. d) Redundsat designed hook within a hook load handling system. In addition to the single failure proof design features of the reactor building crane, the Wm. H. Zimmer Nuclear Power Station Technical Specifications contain a LCO for movement of equipment over fuel assemblies in the spert fuel pool. The technical specifications also contain surveillance requirements to assure operability of the crane interlocks which prevent travel over the spent fuel pool. (2) Safe load paths should be defined per the guidelines of Section 5.1.1(1) . Per the requirements of Section 5.1.1(1) of NUREG-0612, equipment removal paths have been defined for all lead handling devices. Equipment removal paths traverse structural members as much as is practical. For those heavy loads which are determined to potentially impact irradiated fuel in the reactor vessel or spent fuel pool or safe shutdewn equipment, the following additional controls shall apply: a) Heavy load movements shall be accomplished through detailed implementing procedures. The procedures shall contain an equipment layout drawing which indicates the equipment removal path.
s b) The equipment removal path shall be physically . indicated by marks on the floor or a series of stands connected with safety ribbon. c) - Temporary changes and revisions to such implementing procedures shall be accomplished in accordance with existing administative controls which apply to all plant implementing procedures. (3) Procedures should be developed and implemented per the guidelines of Section 5.1.l(2). Per the requirements of Section 5.1.l(2) of NUREG-0612, procedures shall be develcped to detail load handling operations for hoists determined to be operating over or in proximity to irradiated fuel or safe shutdown equipment. Such procedures shall be written and approved prior to performing applicable load handling operations following initial fuel loading. Procedures shall contain detailed rigging instructions including sling lengths, rope diameters, shackle diameters and minimum ratings. The procedure shall contain an isometic pictorial diagram of the required rigging. Multi-use rope slings used at ZPS-1 are labeled with tags to indicate their rated capacity. Lame heavy loads located on the plant refueling floor are handled with dedicated sling arrangements. These slings will be labeled for their particular use(s). The following applicable before use rigging inspections shall be contained in the procedure: a) Latches, fastenings and attachments for proper operation. b) Excessive wear and/or distortion and deformation. A c) Chemical or heat damage to materials. d) Cracking, fraying or parting of equipment. e) All end connections for damage. f) Slings and ropes for cuts, crushing, kinks, broken wires, unstranding or corrosion (no more than six randomly distributed broken wires in one rope lay, or three broken wires in one strand in one rope lay). g) Hooks and U-bolts for deformation or cracks (shall not exceed more than 15% in excess of normal throat opening or more than 10 deg. twist). h) Chains for wear, twists, broken, cracked or otherwise damaged links.
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i l i) Examine sling or rope width or diameter for k indications of wear or faulty core support. The preocedure shall contain step-by-step load movement ~ instructions and shall define the equipment removal path as previously discussed. (4) Crane operators should be trained, qualified and conduct themselves per the guidelines of Section 5.1.1 (3 ) ; - All personnel who operate cranes or hoists at ZPS-1 shall be trained, qualified and conduct themselves per the . _ _ guidelines o'i Chapter 2-3 of ANSI B30.2-1976. (5) Cranes should be inspected, tested, and maintained in accordance with the guidelines of Section 5.1.1 (6) . , See Section 2.3.6 for response. (6) In addition to the above, special attention should be given to procedures, equipment,,and 4 personnel for the handling of heavy loads over the core, such as vessel internals or vessel - inspection tools. This special review should include the following for these loads: (1) review of procedures for installation of rigging -- or lifting devices and movement of the load to assure that sufficient detail is provided and j that instruction are clear and concise; (2) visual inspections of load bearing components of _ cranes, slings, and special lifting devices to o identify flaws or deficiencies that could lead _ to failure of the component; (3) appropriate ; repair and replacement of defective components; and (4) verify that the crane operators have been properly trained and are familiar with ,i specific procedures used in handling these ; loads, e.g., hand signals, conduct of y operations, and content of procedures. ? The special review described in Item (6) will i be performed. _ T: f _
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e ATTACHMENT 2 - OVERHEAD HANDLING DEVICES EXCLUDED FROM THE REQUIREMENTS OF NUREG 0612 pg. 1 of 5 102---incapable of handling a heavy load 103---incapable of handling a heavy load 104---incapable of handling a heavy load 106---incapable of handling a heavy load. In addition the load impact point only effects the drywell floor drain and equip-ment drain sumps and sump pumps. The device is used for control rod drive removal which is only performed in cold shutdown. 110---Item 110 is a 25-ton cart to be used for transporting a Re-actor Recirculation pump motor through the drywell hatch. Since the load is not lifted, this is not an overhead hand-ling system and is therefore removed from further review. 113---incapable of handling a heavy load 115---incapable of handling a heavy load i 117---Item 117 is an overhead handling system which is indicated on the equipment removal plans as an undervessel service
- crane. Purchase and installation of this crane has not taken place. When installed a detailed review will be per- -
formed at that time to ensure the requirements of NUREG 0612 are satisfied. 123---Item 123 is a two-ton overhead handling system which is __ used to manipulate standby gas treatment train components. - When in use the Standby Gas Treatment train is moperable and no other decay heat removal or Safe shutdown equipment can be impacted. j 124---Item 124 is a two-ton overhead handling system which is over the second standby gas treatment filter train. Again, the ._f impact area contains no safe shutdown or decay heat removal . equipment. g 125---Item 125 is a 1.5-ton capacity winch used for pulling the [ reactor recirculation pump motor cart through the drywell - equipment access hatch. This winch is not an overhead hand-ling system. Furthermore this device would only be used with , the drywell open, requiring the unit to be in cold shutdown. Therefore this system has been deleted from further review. 1 127---Item 127 is a two-ton wall mounted j ib crane which is used in the secondary containment equipment access building to _ off load equipment from trucks in the equipment access build-ing. The impact area contains no safe shutdown or decay heat removal equipment.
I ATTACHMENT 2 pg. 2 of 5 129---Item 129 is a cart mounted winch used for removing control rod drives from the primary containment. This device is not an overhead handling system and control rnd drives can only be removed with the unit in cold shutdown. Therefore this device has been remcved from further consideration. 201---Item 201 is a 65 ton overhead handling system which would be used to remove the high pressure feedwater heaters from their cubicles if tube bundle replacement was ever necessary. This lifting device is indicated on plant equip-ment removal drawings but has not been purchased at this time. The load impact point for this device, involves numerous prices of equipment required for safe shutdown or decay heat removal located in the plant auxiliary building. Purchase and installation of this device will not proceed until the need for removing the high pressure feedwater heaters exists. If this is ever necessary a detailed review will be per-formed at that time to ensure that the requirements of NUREG 0612 are satisfied. 205---Item 205 is a 7.5-ton overhead handling system used for transporting various pieces of equipment located n the plant auxiliary building. The load impact area contains no equipment required for safe shutdown or decay heat re-moval. 207---Item 207 is composed of two 2 ton overhead handling system which are used to remove the offgas system prefiltering guard bed covers and adsorption media. The load impact area for this device contains no safe shutdown or decay heat removal equipment. 208---Item 208 is a 2 ton overhead handling system used to trans-port plant ventilation fans and motors during maintenance. The load impact area contains no safe shutdown or decay heat removal equipment. 302---Item 302 consists of a 13-ton overhead load handling system used for removal of the mani condenser circulating water system water boxes. The load impact area contains no safe shutdown or decay heat removal equipment. 303---Item 303 consists of 4 overhead handling hoists w lich are used for removing the circulating water system water boxes from the main condenser. The load impact area contains no safe shutdown or decay heat removal systems. 304---Item 304 consists of two 10-ton overhead handling systems which handle the turbine driven reactor feed pumps when being serviced. There is a four-inch Main Steam line in each of the Feedwater pump rooms. However the main steam lines are isolated outside of the Feedwater pump rooms.
- - - - - - ___________________1________ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
l ATTACHMENT 2 pg. 3 of 5
.Furthermore the pumps are in separate rooms and a load drop in one room cannot impact the other. Therefore a load drop will not impact any safe shutdown or decay heat removal systems.
305---Item 305 consists of four 2-ton overhead cranes w Ech handle the reactor feed pump turbines and miscellaneous equipment. The same situation as item 304 exists. If the turbine and/ or pump for the feedwater pumps were being serviced the steam lines would be isolated external to the feedwater pump room. The load impact area contains no safe shutdown or decay removal systems. 306---Item 306 consists of two 5-ton overhead cranes which handle miscellaneous equipment when servicing the main turbine oil cooler. These cranes are presently nqt installed. However the load impact area contains no safe shutdown or decay heat removal systems. 307---This is a 6-ton overhead handling system for manipulating the condensate and condensate booster pumps during mainten-ance. The load impact area contains no safe shutdown or decay heat removal systems. 308---This crane is a 12-ton crane over the emergency heater drain pump for maintenance of that pump and/or motor. A load drop would impact no safe shutdown equipment or decay heat removal systems. 309---Item 309 consists of two 25-ton overhead handling systems of which only one trolley beam is installed. These cranes will handle the Low Pressure Feedwater. Heaters 1A SB Drain Coolers which are located horizontally in the west side of the condensor. There is a 6-inch main steam line approximately 5-feet below the east end of this crane. How-ever the Drain Coolers are approximately 20-feet below the trolley beam of this crane. The Drain Coolers will not be brought up to the same level as the crane because it is only a grating level (there is no laydown area for the coolers on the 527' level). Furthermore, in order to remove the Drain Coolers the unit must be in cold shutdown. Therefore this crane will not be used unless in cold shutdown and has a very low probability of impacting the main steam line. 401---This crane is a 7.5-ton bridge crane which is used to load solid radwaste drums onto a truck for transport off-site. The impact area contains no safe shutdown or decay heat removal systems. 402---Item 402 is a 7.5 ton overhead handling system which is used to manipulate solid radwaste drums in the radwaste storage area. The impact area contains no safe shutdown or decay
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403---Item 403 is a 7.5-ton overhead crane which is used to handle T
.4 ,,5 solid radwaste drums when moving them from the storage ] y7 area to the budge crane for truck loading. The impact area . s i.:
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contains no safe shutdown or decay heat removal systems. 1 e $? 404---This crane is a 10-ton bridge crane located in the machine f. [s - or maintenance shop for lifting miscellaneous equipment in ?b.v;- the maintenance shop. A load drop would not impact :. . ;; . any safe shutdown or decay heat removal systems. : ,J.;j , 405---Item 405 is a 5-ton overhead crane which is in a room next [..;" to the maintenance shop. This crane is used for lifting f.t h . miscellaneous equipment for decontamination. The load 0;r ! n n ' impact area contains no safe shutdown or decay heat removal Jufs; s systems.. f 407---Item 407 is a 27-ton overhead crane which is used to lift *L
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the circulating water pumps and/or motors. The impact area ~ 'O ' contains no safe shutdown equipment or decay heat removal s. e n systems. 7+., 2: '. - 408---This crane is a 1-ton overhead crane used to install the ..i r i .- circulating water pump stop logs when servicing a pump. ,E b .. The impact area contains no safe shutdown or decay heat wd; removal systems. : ~ \; ( .
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409---Item 409 is a 2-ton crane used to manipulated Chlorine i?r,q storage tanks at the circulating water structure. The > . impact area contains no safe shutdown or decay heat removal ;;} ... systems. a 3,;
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410---This crane consists of two one-ton overhead systems in b;.'i the circulating water structure for handling the diesel ^4 'T ;f driven and motor driven fire protection pumps and/or J/ ,14 motors. The load impact areas contain no safe shutdown ? ,; 2 ^- or decay heat removal systems. L. f' 1 413---Item 413 is a 5-ton overhead handling crane used to manipu- ; j ^ *f. late the service water strainers during maintenance. These .g ; . . . . : will be by passed during maintenance and a load drop will ,1;p[ r not impact safe shutdown or decay heat removal equipment, f.- ? - JC t e. . < ; 414---This is an 8-ton general service overhead crane used for 3:( ." ' -.
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miscellaneous equipment. The impact area contains no safe shutdown or decay heat removal systems. i'$GifL. O.: _ me, 415---Item 415 is a 5-ton overhead crane which is used to handle Tc1 shielding slabs and miscellaneous equipment. The impact x; f i - area contains no safe shutdown or decay heat removal if :7 systems. "~~a=P L.
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ATTACHMENT 2 pg. 5 of 5 416---Item 416 is a 1.5-ton overhead crane used for servicing the Radwaste building ventilation fan's. A load drop would not impact safe shutdown or decay heat removal systems. 419---Item 419 is a 3-ton overhead crane which is used to manipulate the circulating water make-up pumps and/or motors within the pump cubicle. The load impact area contains no safe shutdown or decay heat removal systems. e
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ATTACHMENT 4 JUSTIFICATION FOR EXCLUSION OF OVERHEAD HANDLING SYSTEMS (FROM TABLE 3) FROM REQUIREMENTS OF NUREG 0612 Item 107 RHR C R8CCW 1181_ Heat _ Exchanger Item 107, is a 20-ton monorail overhead hoist to be used for tube bundle removal and overhaul of the IB R"CCa Heat Exchanger and RHR Heat Exchanger LA and 18. Suffici,ent separation exists insuring that inadvertant drop of any components would not degrade safe shutdown or decay heat removal capacity. The 18 RBCCW Heat Exchanger is separated by 12 ft. from the north bank hydraulic control units and by two fl oors f rom the RHR Heat Exchangers. The RHR Heat Exchangers are l ocated in separate cubicles and are located 2 floors below the IB RBCCW Heat Exchanger. Therefore, this crane need not meet the general requirements of Section 5 1.1/NUREG 0612. Item 108 Main _ Steam _ Hatch _ Slabs and Isolation _ V al ves Item 108 is a 20-ton overhead handling system used to do maintenance on the outboard MSIV's, outboaro feedsater check valves, and lift the associated equipment access slabs. Administrative controls shall be applied to assure that the main steam hatch slabs are not removeo wher the MSIV's are open. Inadvertent dropping of the main steam hatch slabs after isol ation will not effect plant safety. Similarly, inadvertant dropping of any of tne main steam i solation valve components of feeowater valve components, after they have been released for maintenance, will not have any effect on plant safety or decay heat removal. Item 111 datch Slabs and_RCIC_ Maintenance Item 111 is a 15-ton overhead handling system which could impact panel H22-P022 and some Reactor Building closed cooling water piping. Panel H22-P022 contains one steam line fl ow switch for each main steam line and the recirculation loop flow transmitters feeding the B tlow unit for APRM flow biased scrams. Based upon single f ail u re proof cri teria empl oyed in the design of these systems their f ailure can neither cause nor prevent the completion of a safety function. Therefore, this crane need not meet the general guidel ines of Section 5.1.1 of NUREG 0612.
Item 112 RBCCW IB Heat Exchanger Item 112 is a 20-ton monorail overhead hoist to be used for tube bundle removal and overhaul of the 1A RECCW Heat Exchanger. Sufficient separation exists to ensure inadvertant drop of any component would not cause damage to any other system required for safe shutdown or decay heat removal. Item 120 High_ Pressure Core _S ray 2 _ Pump Item 120 is a 15-ton overhead handling system. Sufficient physical separation exists insuring that inadvertent drop of the high pressure core spray pump components woul d not cause damage to any other system required for safe shutdown or decay heat removal. Item 121 D_C IC _ Tu rb i ne Pump _and_ Condenser Item 121 is a 4-ton overhead handling system which could impact panel H22-P022 and some Reactor Building closed cooling water piping. Panel H22-P022 contains one steam l ine flow switch for each main steam line and rec ircul ation loop fl ow transmitters feeding the a flow unit for APRM fl ow biased scrams. Based upon single f ailure proof cri teria employed in the design of these systems their failure can neither cause nor prevent the completion of a safety function. Therefore this crane need not meet the general guidel ines of section 5.1.1 of NUREG 0612. Item.122 Su2gression Pool Service Item 122 is a 2-ton overhead handling system. The trolley and hoist is used for performance of any corrective or preventative maintenance required in the suporession pool. Any such activities performed with the unit is during cold shutdown and would not cause damage to any component for decay heat removal. Item 126 v ain Steam Isolation valve 10utboard1_Clearanco Pull Item 126 is a 1.5-ton hoist which is movable to one of 4 locations within the MSIV cubicle. This hoist is furnished to assist Item 108 for MSIV val ve actuator removal. Use of this hoist requires i sol ation of the steam lines.
Item 128 Main Steam I s ol at i on_Va l v e_LI nboa r di Item 128 consists of four S-ton overhead handling systems over the inboard MSIV's. Maintenance performed on inboarc main steam isolation valves or feedwater check valves can onl y be per formed in cold shutdown. Inadvertant dropping of any main steam isolation valve components or feedwater , val ve components , after they have been released for maintenance, will have no effect on plant decay heat remov al . , Item 202 M i s c el l aneou s _Eguinmen t_E _S l ab s ! Item 202 is a 7.5-ton overhead load handling system J designed for transport of various equipment lucated in the e plant Auxiliary Building. The load impact point has E potential for effecting the main steam lines in the main
- steam tunnel. Analysis by the architect engineer indicates the main steaml ines would not be effected by a l oad drop. Therefore this crane need not meet the yeneral requirements of section 5.1 1 of NUREG 0612.
Item 203 D i es el Generators E 204 Planned future hoists for use in the diesel generatcr g rooms. Each of the three diesels will be served by two 1-g ton and one 5-ton hoists. The accidental dropping of the diesel engine component will have no effect upon any other h system required for safe shutdown or decay heat renoval. Item 301 Turbine _ Building _ Crane : L Item 301 consists of two turbine building overhead
, traveling bridge cranes. Both cranes consists of a 110- -
g ton hook and a 25-ton hook. The impact area of these Cranes contains the main steam tunnel, turbine stoo valves, associated turbine trip reactor protection L instruments and low condenser vacuum MSIV closure instruments. Unl ess the main steen lines are i sol ated. the turbine building b, ridge cranes shall be administratively restricted to handling less than 24 tons in tne area defined by rows L and R and columns 16 and 24. This shall preclude a load drop on the main steam lines end turbine stop valves. Furthermore, a load drop impacting the Reactor Protection Instrumentation will not effect safe shutdown or decay heat removal capacity due to the s i ngl e- = failure-proof criterion design basis for those instruments. w = E s_ ? E
~ Item 406 T ravel i n2_ Sc reen E_ Service Water _Pum2_Structurg_Eriggg Crenes Item 406 is a 30-ton bridge crane for lifting the traveling screens from the service water structure antake area for maintenance. Since the entire travel ing screen assembly is about 85 feet htgh and the maximum heignt of the' crane is about 50 feet, the entire assembly cannot be lifted and moved in one piece. The assembl y will be removed in several pieces. Each piece weighing no more than approximatel y 15 tons. A block 0ge of the intake is not possibl e. A wall establishes two redundant flow paths to the service water pump suction area, as shown on equipment removal diagram M-19 sheet '. 6 . Therefore a load impact will not reduce the safe shutdown or decay heat removal capacity c' the system. This crane need not meet the general guidelines of section 5.1.1 of NUREG 06L2. Item 411 C2oling_ Tower _Make-up Water Pumps Item 411 consists of two 5-ton overhead WSMCC handling systems which are used to move the circulating water make-up pumos and/or motors in and out of the pump cubicle. This crane can impact Service Water Motor Control Center LA which contains service water pump 1A cooling fan breaker. However, due to physical separation, a f ail ure of tnis system cannot degrade the safe shutdown or decay neat removal capacity of the plant. 5 Item 412 ierv i ce 'ia ter Pum21 I I teni 412 consists of two 8-ton overnead handling systems. These hoists are shown on M-19 sheet 16 of the Equipment Removal Plan and are used for corrective maintenance activities on tne service water pumps. A failure of these cranes coul d impact Service Water Motor Control Center 13 and LC. The IB motor control center contains breakers for service water pump 19EC ventil at ion cooling f ans and the pump discharge isol ation val ves for those same pumps. The IC moto r control center contains a breaker for the service water camp 1D ventil ation cool ing f an. Physical separation from separate pairs of service water pumps and single f ailure proof criteria employed in tne design of thi s system precl ude degradation of pl ant safe shutcown or decay heat removal capacility. Item 417 Sgrvice_ water _Pum2 uotors Maintpnance E 419 Items 417 E 418 are each 3-ton overhead handl inn sys tems. These hoists are used for maintenance of the service water pumps. Saintenance work can only be performed on pumps of _ the same cuoicle. Sufficient separation occurs between the service water pumps and preclude effecting plant -- safety.
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Attachment 6 CRANES WHICH WILL MEET REQUIREMENTS OF NUREG 0612 101 - Main Reactor Building Crane 105 - Relief and Safety Valve Maintenance and VP Cocler Unit Crane 109 - Recirculating Pump Motors Crane 114 - Valve Maintenance Crane e 116 - Drywell Access Hatch Cover Crane 118 - Low Pressure Core Spray Crane 119 - RHR Pump Crane
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U Pg 1 of 2 LOAD IDENTIFICATION LOAD WGT (T0tlS) DESIGNATED LIFTING DEVICE CONTROLLING DOCUMENT Reactor Cavity Shield (3) legged bridle sling rated at 180 tons Plugs (6) 90 Hax angle from vertical plane 44 HE.RFP.402 Dryer Separator Pit (3) 40 (?) 2 1/2" shackles HE.RFP.402 Plugs (1) 44 2 legged bridle sling, 88 ton rating Max angle from vertical plane 25 Fuel Pool Shield Plugs (4) 12 ( ) 1 3/8" shackle, (1) 24 ton rated sling HE.RFP.402 l Vertical lift l l Drywell Head 65 RPV head strong back, (4) 2 75" turnbuckle, HE.RFP.401 l (4) 2.5" shackles l l I RPV ;tead Insulation 75 Required rigging rated for 15 tons HE.RFP.403 Hax angle from vertical plane 35 RX Head Stud Tensioner 4 Stud Tensioner Strongback HE.RFP.404 Reactor Head 65 RPV head strongback, (4) 2 75" turnbuckles, HE.RFP.404 (4) 2.5" shackles l Steam Dryer 38 Dryer / Separator Strongback, 1 1/2" !WRC legged bridle sling HE.RFP.303 (4) 2.5" turnbuckles Max angle from vertical plane 25 Steam Separator 51 Dryer / Separator Strongback,1 1/2" IWRC 4 legged bridle sling, (4) 2.5" trunbuckles HE.RFP.304 Hax angle from vertical plane 250 Fuel Pool Gates (1) 5.5 (2) 1 1/2" shackles, 11 ton rated 2 legged bridle (1) 3.5 s1Ing HE.RFP.405 Hax angle from vertical plane 100 Dryer / Separator Pool Gate 23.5 (2) 2" shackle 47 ton rated 2 legged bridle sling HE.RFP.406 Max angle from vertical plane 30
MAIN REACTOR BUILDING CRANE - 110 TON HOOK i Pg 2 of 2 LOAD IDENTIFICATION LOAD WGT (TONS) DESIGNATED LIFTING DEVICE CONTROLLING DOCUMENT Shipping Cask Storage 4.0 (2) 1.5" shackles 8 ton rated 2 legged bridle ME.RFP.407 sling Max angle from vertical 100 Reactor Service Platform 6.0 I" 3 legged bridic sling HE.RFP.408 Max angle from vertical 35 i l Removable 1/2 Ton Jib Crane 4.0 1 3/8" shackle, 1 3/8" sling HE.RFP.409 Vertical lift Channel Handling Boom 2.0 1 3/8" shackle, 1 3/8" sling HE.RFP.409 Vertical lift Equipment Hatch Cover () Rigging rated greater than double static load Refueling Canal Shield 30 Strongback, 60 ton rated rigging HE.RFP.410 NOTE: Shackles were selected assuming a minimum breaking strength of six times safe working loads to yield a safety factor of ten between minimum breaking strength and the selected usage. (does not apply to fuel pool shield plugs as previously described) l l 1
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4 _c. . ,: ' Attachment 7 ~.
- 7. . j FSAR Section 9.1.4.2.2 '
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'i 9.1.4.2.2 Reactor Building Crane j
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g 9.1.4.2.2.1 Description
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f The main purpose of the reactor building crane is td handle the. spent i k,5 S ' , y ?- fuel cask between thc cask transport vehicle, the cack pool, and the fir . . - cask decontamination pit in the reactor building. Secondary purposes ;.O ( g ',- i of the reactor building crane include handling loads related to main- * * . -t " i i tenance and replacement of equipment from the reactor building received ::' -[
,t or shipped through the railcar loading facility. " 2 , , , ,.
,' The reactor building crane is a single-trolley top-running electric a -*
overhead traveling crane with a 110-ton capacity main hoist, a 10-ton . . - ;' , capacity auxiliary hoist and a span of 126 feet 3 inches. The general 3
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'3 arrangement 1.2-15. of the crane in the reactor building is shown in Figure a.
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ZPS-1
-s -REVJf pN 14 JULY.1976 -
The operating environment was specified in the purchase specifie.ntipn for the reactor crane. These included the fc11owing as a minimum;
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' Ambient Temperature , , .3
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105* F maximum 65* F minimum , , s s ., s - * - Ambient Pressure (tornado)_ ,, - 1 S,s
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300 mph (tangential) .' 60 mph (translational) , 1 psi change in 3 seconds Box girder to be provided with vent and drain holes for above pressure change. Earthquake Floor response spectra furnished for the CBE and SSE. c: Corrosion immersion of cuxiliary and main hook and block into demineralized water. Impact Minimum temperature to be considered in selection of m*:erials and the
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14 s need for impact tests.
- 4 The humidity was not specified in the original specifications. The , ,
i humidity requirements were reviewed with the vendor and confirmed to be within the capability of the crane design. ,
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' Ti e 's The reactor crane is located indoors in a controlled environment.
low building temperature and the material selected for the crane pret clude the need for performing fracture toughness tests, Upon completion of erection of the crane, the crane will be proof tested to 125% of the Jesign rated load of 110 tons. The test will be pcrformed at the minimum tc.perature of 650 F or lower unless not practical, at which time the test will be duplicated prior to fuel load at the minimum ambient temperature. The critical areas will be visually examined for cracks following the miniram temperature test load lift. Postweld heat treatment was not required due to the material thickness used. Preheat temperatures for weldments ware specified in the weld procedures. All welding was performed in accordance with AWS D1.1. The cask crane will be designed, fabricated, installed, and tested in accordance with ANSI B30.2.0, Overhead and Cantry Cranes CMAA Specifi-cation, AISC, AISE, and other applicabic manuf acturers' association and engineering society codes. 9.1-12 ll
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4 4 i.d , . h .. ZPS-1 REVISION 14 fe[ ' - ~ JULY 1976 ', s' ' . 7. .
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Operation of the crane will be from the cab or floor by pendant control ^ C'.- for all motions. Control at any one time vill be from one point only.
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l' ' m The ;tructure of the crane bridge consists of welded box-type girders #s with truck saddle and truck frames of velded-steel construction. The "C'.' trolley side frames, sheave frames, and truck frames are of structural
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steel w21ded construction. High strength friction-type bolts are used
sA for major field connections for bridle and trolley assembly. Spring 3' ?
bumpers are provided at each end of crane travel to limit travel move- 3 0..* '$ ment. L y, ,
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The rated full-load cspacities, lifts, and full-load speeds are as '
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follows: N Main Hook '. [ . .. s 4 ' - Rated full-load capacity, tons (2000 lb) 110 k '.d
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Hoisting speed, ft/ min at full-load 5.5 l 14 $Q(m.,.
Mt ', - Auxiliary Hook %-...." # (
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Rated full-load capecity, cons (2000 lb) 10 l]..j i
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; Hook travel, ft 150 >f4 ::. -,
R... .a...F,- .,. Hoisting speed, ft/ min at full-load 21 .y ~ 4
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n . s Travel Speeds ? '%. . >
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Trolley travel speed, ft/ min at full load 33
;; ' k ;a ', Bridge travel speed, ft/ min at full load 75 14 j d-
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The reactor crane runway runs in the north-south direction. When the :,,._. reactor crane le not in use, it vill be parked on the south end of the ': /
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reactor building over the dryer-separator storage pool. This location 24 't
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<.l is as far as possibic from the spent fuel storage pool. Access into the C i crane cab is ,.rovided from the elevator machine room roof in the south- 14
[ ' ,, * ' ' east corner of the reactor building. Figure 1.2-15 shows the travel
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; limits of the crane and the stored position. Tornado and earthquake lugs are provided on the trolley and bridge to prevent the crane from [ .'i . 1 being dislodged from the bridge or crane rail. 1@. . <
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The structural portion of the crane and trolley are designed for: l3
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(1) dead load plus rated lift load plus impact load not to exceed code +" M. , . .. i allowable stress, (2) dead load plus 1/2 SSE not to exceed code allow- :. A w(. p' , ' a'le o stress, (3) dead load plus 275% main hoist motor stall torque load g'T "J
- not to exceed a factor of 1.6 times code allowable stress, and (4) dead --
y load plus SSE load not to exceed a factor of 1.6 times code allowable . .: ("
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ZPS-1 PEVISION 14 JULY 1976 The lateral loads on the crane runway in the normal operating condition were 20% of the sum of the weights of the lifted load and of the crane l 14 trolley only, and seismic load of the deed load of the crane in the event of earthquake, applied at the top of the rail, one-half on each side of the runway rail and shall be considered as acting in either direction normal to the runway rail. l3 9.1.4.2.2.2 Safety Features Single failure' protection will be designed into the cask crane compo-nents in order to assure safe handling of the spent fuel cask and other heavy plant equipment. This protection is provided by the following featurcs. 9.1.4.2.2.2.1 Mechanical Power from a single hoist motor is transmitted through a multireducticn gearing system to the drum gear mounted on the barrel of the hoisting drum. This' reduction is defined as the driving reduction. On the opposite end of the drum barrel is another drum g2ar, again coupled to an exact duplicate gear reduction system which has a spring-set elec-tric shoe brake mounted on the high sp ed low-torque pinion shaft extension (Figure 9,1-4.) This second gear train is termed the idler gear case, since in the normal function of the crane the only torque transmitted backwards through the gear train from the drum gear is that
- force required to accelerate the inertia of the gearing and brake wneel.
Each gear case is designed to handle 100% motor torque. On the driving side of the system, the spring set 150% torque motor brake is mounted on the motor pinion shaft extension. In order to give redundancy to the gears, chafting, keys, and couplings used, the idler gear case is applied and the spring-set shoe brake on the idler gear case is also rated at 150% torque. This brake will be used along with the other motor brake on the driving side to share the deceleration of the hoist machinery and to hold a suspended load. The idler gear case brake mounted on the high-speed low-torque pinion shaf t ext.ension is also the brake to set and hold the load if a failure were to occur in the driving gear case system. The brake would set through the use of an overspeed device actuated by the speed of the revolving drum. To prevent load drop due to drum bearing, shaft, or bearing support failure, the lower periphery of the drum barrel at each end is encompassed by a close-fitting (but not touching) structural support upen which the barrel will rest if any of the failures mentioned previously should occur. The length of the drum system and the amount of drop are such that the mismatching of the faces of the drum pinion and drum gear under such a condition is still within the allowable alignment tolerances of AGMA recommendations. Also, single failure impact will not exceed per-missible stresses in the crane. The redundant full-capacity wire rope system consists of two balanced reeving systems utilizing two individual wire ropes reeved side by side from the double-scored drum grooving through the upper and lower block sheaves and to the double sheave-type equalizer. (See Figure 9.1-5). 9.1-14
ZPS-1 REVISION 14 JULY 1976 The main hoist cable is a 1-inch diameter, 6 x 46 IWRC with a 7 x 7 IWRC cable center. The load is supported by 8 parts of rope (reeving) for each cable system (16 parts total). Pitch diameter of the lead 3 sheaves is 33 3/4-inchet. Pitch diameter of the running sheaves is 30 inches. Pitch diameter of the equalizer sheaves is 10.75 inches. The maximum fleet angle of the main hoist cable is l' 52'. Breakage 114 of one cable system will, of course, reduce the factor of safety in half but not.the capacity. The stress in the lead line in the hoisting system at maximum design speed with the design rated load does not exceed 20% of the published breaking strength of the cable. The static stress in the rope with 3 the design load stationary is 14% of the published rated strength. Lead line speed during hoisting or lowering with the design load is 19.2 fpm. Since each system is reeved to both sides of the bottom block and upper block systems, there will be no swinging or pendulum action of the b:--ck upon failure of one system. Since failure of one hoist cable system would transfer the load on the equalizer entirely to the other equalizer, there would tend to be a rapid displacenent during this transition. (See Figure 9.1-6.) Maximum vertical travel is 1/2 inch 14 should one rope of the dual reeving system fail. This could result in a high dynamic shock to the crane system and is prevented from doing so by providing a two shock absorber arrangement for aach of.the equal-izers. This permits readjustment to be made slowly and smoothly, thus preventing any appreciable load shock. Each of the-equalizers is hung from a main pivot mechanism, this support mechanism being redundant within itself. The support system consists of a through shaft which in turn is encompassed by a hollow shaft, each of which is capable of handling the equalizer load forces. The ends of the internal shaft are supported on a structural system which is part of the trolley frame. The hollow shaft itself is several inches shorter than the through shaft and this hollow shaft would be supported by safety lugs should be in-ternal shaft break at its ends or in any part of its length. Should the internal shaft break i.: the middle, the hollow shaf t will in turn take over and take full load responsibility. Vertical travel of the main hoist will be approximately 1/2 inch should one rope of the redun- 3 dant reeving system fail. In both the lower block and the upper block, the sheaves are mounted in a structural cage system havinF supporting plates on each side of each sheave. (See Figure 9.1-7.) Thus, the load being carried by the sheave pin is shared by each of these diaphragm plates, and should a pin fail on any particular one sheave, the sheave adjacent to it will still main-tain ite integrity allowing system 1 or system 2 of the reeving to take over the entire load. The bottom block hook suspension system con-sists of a double main hook arrangement fitted one inside the other. This arrangement provides redundancy without requiring special slinging or hook box designs in lifting devices. The hook system consists of what appears to be a conventional bottom block utilizing a " hook within a hook." In effect, there is a sister 9.1-15
REVISION 89 CPS-1 DECEMBER 1982 hosk suspended from a hollow hook shaft and within this outer sister hosk a section is milled out and an inner sister hook is inserted sup-ported from an internal shaft. (See Figure 9.1-8). Both inside and cutside sister hooks have the same contour and look to be one and the scme. In supporting the hook shank of the bottom block, each one of thtse shanks is supported'from its own crosshead and'antifriction bear-ing. Failure in any one porticn of the system will result in the other's taking over its full load duties. The design of the crane per-cits repair, adjustment, or replacement of failed active components or cubsystems. The crane will maintain a load in a safe temporary position should a f ailure occur with a lifted load to allow for crane repair 75 - cr. adjustment. Th2 ZPS-1 reactor building crane system is provided with spring bumpers en the bridge to limit trolley travel and on.the crane runway to limit 14 bridge travel in the event of failure.of the limit switches. Limit cwitches are provided to sense overtravel. The control system incor-porates an overspeed control which sats the idler gear brake upon over- . cpzeds. Speed is sensed from the main hoist drum shaft. Circuit brzakers and thermal overloads are provided for the crane motors to limit excess current and high temperature which may result due to maloperation or component failure. In addition to the manufacturer's normal quality control inspection for anguring high quality, the main hook was ultrasonically tested and 3 magnetic particle inspected before and after a load test of 200% of ths design rated load at the manufacturer's shop. Certified test ragults have been furnished to document the results. 9.1.4.2.2.2.2 Electrical l89 Tha reactor building crane is furnished by the Harnischfeger Corporation End utilizes and Electrotorque 300 control system for main and auxiliary hoist control and a static stepless a-c reverse plugging control for bridge and trolley motion. Electrotorque is the registered trade name of the hoist control system. _ It converts three-phase a-c power to d-c power by means of thyristor bridges. A shunt wound d-c motor serves as the electromechanical output element. The d-c motor on the ZPS-1 crane is controlled in either the constant torque mode oc the constant horsepower mode. The control provides infinite speed control within its operating range. A tachoneter is used to obtain a signal proport4-aal to speed when operating in the constant horse' power range. High speed at light loads (3 times rated speed at no load) is obtained by field weakening. The maximum developed torque of the hoist system is 140% of the required 75 torque rating of the d-c hoist motor and less than the load-carrying capability of the hoist system. Tha bridge and trolley control provides infinite variable speed control between the minimum and maximum travel speeds and has no floating point. The control portion of the crane instruction manual is provided by The Reference 1. Figure 9.1-9 shows the pendsnt control for the crane. came functions are provided in the crane cab for crane control. 9.1-16
ZPS-1 REVISION 75 JULY 1981 The hoist is furnished with a geared upper and lower limit switch. The lower limit has a two-contact system switch connecteo in series and , operated from a single mechanical drive. The purpose of this is to protect against a frozen set of contacts. The upper geared limit 75 switch operates a control circuit limit switch by opening'a reversing switch control circuit, stopping the hoist motion, and setting the brakes. A separate block-type limit switch is provided to operate a 14 power circuit limit switch to positively interrupt the motor-raising circuit and to set the brakes. The control syctem also incorporates the use of an overspeed switch driven from the idler gear train or the idler side of the drum. The purpose of this switch is to " defeat" certain brake circuits that can be established by the crane operator should a h' o isting motor or control system fail. This overspeed switch is adjusted to open the circuit l3 of both the spring-set motor brakes and the hoist control circuit so that a load would immediately be held in suspension should the drive motor overpseed 40% in the lowering direction.
.The control system also incorporates means of safely lowering a load should there by a failure either mechanically or electrically in the drive system.
The main and auxiliary hoists are each provided with a d-c variable voltage control system equipped with regenerative braking and two d-c magnetic holding brakes. The d-c hoists motors are shunt wound and rated for 230-Vdc service. The motors are rated at 40 hp and 15 hp respectively with a 1.20 service factor. The calculated maximum con- 3 tinuous bhp required is 40 hp and 15 hp respectively for the main and auxiliary hoists. A full-capacity load can be lowered in a controlled mode at approxi-mately 120% speed using the dynamic braking circuit in the system. Under the worst conditions, which would include loss of power, defec-tive gear train, defective metor, etc. , the load can still be icwered
'ay using the brake release lever to open the holding brakes and lower 75 the load to the floor in a series of controlled steps.
Electrical track limit switches are provided for the bridge and trolley to prevent travel of the crane over the spent fuel pool. The crane interlocked area is shown in Figure 1.2-15. Thus, the spent fuel shipping cask or any other heavy object is never moved into a position where an' accidental drop could damage the spent fuel in the spent feel storage pool. 9.1.4.2.2.3 Safety Evaluation The ambient temperature under which the crane is to oparate does not exceed 40' C. Stresses in all structural-and mechanical parts will be far below the endurance limits for infinite life of the various mate-rials for both the rated crane capacity and the test load of 125% capacity. 9.1-16a
ZPS-1 REVISION 14 JULY 1976 In addition to the regenerative braking system for the main and auxil-fary hoists, cwo d-c magnetic holding brakes are provided. The trolley 3 is provided with one d-c magnetic holding brake, and the bridge is pro-vided with two electric-hydraulic brakes. Loads on the structural parts will vary but will not reverse. The only critical parts with stress reversals will be the rotating parts, and these are provided with single failure protection. Since the crane is to operate under normal temperature conditions and since the stress levels are below the endurance limits for infinite life, testing of the crane to 125% of rated capacity provides reasonable assurance that the crane will not fail while handling a spent fuel cask. During an earthquake, the crane bridge and the trolley could be dis-placed but they will not leave the rails. The bridge rails are firmly attached to the supporting concrete and steel superstructure, and the trolley rails are firmly attached to the bridge girders. Locking pins are provided for the bridge and uplifts are provided for the trolley to prevent the crane from being disjodged during a tornado. The cask crane will be tested to 125% of rated capacity at the low build-ing temperature (137.5 tons for the main hoist and 12,5 tons for the auxiliary hoist). The ability of the crane to perform all its intended 14 functions will be demonstrated durim; these tests and critical areas visually examined. Operational tests and visual inspections are to be made at perio'dic iatervals during the life of the craae to demonstrate its ability to safely perform its functions. The crane hooks have been inspected by the magnetic particle method and UT examined after the manufacturer's 200% full load proof test. Bridge speed will be administratively controlled to limit the maximum speed to 40 fpm when lifting heavy loads with the main hoist. Full 14 rated bridge sp'eed will be permitted when using the auxiliary hoist.
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REVISION 14 JULY 1976 l BR LtGHTS BRIDGE TROLLEY f # 15 N NCH U INCH ON OFF 8 17 20 2 18 21 O O O START O 19 10 IT. I 22 GTY. DESCRIPTION PART NO. NO. 3 1 CASE 314E761-1 1 25 ., 1 NAMEPLATE 32Z345 2 23 STOP 4 1 COVER 314E762 3 26 2 GASKET 20H855 4 2 INSULATOR 20F12 5 5 14 1/4"- 20 x 1/2" R.H.M.S. 0860V109 6 27 14 1/4" HELICAL L.W. 3616V007 7 2 1 1/4" BUSHED NIPPLE 0948V007 8 O 'R ,%*- "NA's' R O 2 1 1/4" GALV. CC'iD. L'NU1 0944V004 9 5 SINGLE SPEED P.B. 979H164-1 10 4 IND. MASTER-TRAVERSE 979H165-1 13 2 CORD GRIP 79Z1560012 15 6 TY-RAP TIES 32Z890-D3 16 2 #14 - 22 CABLE 24 FT. LG. P&H 2009 18 A HOtsT M HOIST l 1 JUNCTION BOX 14F3901 19 l3 LOWER LOWER 2 SEL. SWITCH (RUN-INCH) 79Z1773D38 20 2 1 TOGGLE SWITCH 79Z894 21 1 T. SW. N. P. (ON-OFF) 79Z805 22 3 BLANK 979H166-3 23
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Table 2 I.if ting Point Saf ety Factors Quantity WT Safety Factor Location _ R rctor Shield Plug - 18 90 tons 2.1 8 44 tons 1.7 Pool Plug 4 8.1 tons 10 Rafueling Slot Plug 3.7 Equip. Hatch (el. 627 '-9" East) 16 9 14.4 t6ns tons 2.3 Equip. Hatch (el. 627 '-9" West) 8 4.4 tons 2.0 New FOel Storage Vault Plug 8 2.2 Pool Gate No. 1 2 5.5 tons 2 5 tons 2.5 Pool Gate No. 2A 7.5 tons 2.2 Pool Gate No. 2B 2 2 26 tons 2.3 Pool Gate No. 3 2.2 tons 10.1 Skimmer Surge Tank Cover 3 Note: Act.ual weights may dif fer from the rated weights used for laydown area purposes. l 1 L
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