Regulatory Guide 1.104

Overhead Crane Handling Systems for Nuclear Power Plants

ML13038A096
Person / Time
Issue date:	02/28/1976
From:	Office of Nuclear Regulatory Research, NRC/OSD
To:
References
RG-1.104
Download: ML13038A096 (11)

U.S. NUCLEAR REGULATORY COMMISSION February 1976 REGULATORY GUIDE

OFFICE OF STANDARDS DEVELOPMENT

REGULATORY GUIDE 1.104 OVERHEAD CRANE HANDLING SYSTEMS

FOR NUCLEAR POWER PLANTS

A. INTRODUCTION

General Design Criterion 1, "Quality Standards and certain specified systems or components be in accor- Records," of Appendix A, "General Design Criteria for dance with generally recognized codes and standards.

Nuclear Power Plants," to 10 CFR Part 50, "Licensing This guide describes methods acceptable to the NRC

of Production and Utilization Facilities," requires that staff for complying with the Commissiofis regulations structures, systems, and components important to safety with regard to the design, fabrication, and testing of

1 be designed, fabricated, erected, and tested to quality overhead crane systems used for react,6Te fueling and standards commensurate with the importance of the spent fuel handling operations. This guide aplies to all safety function to be performed. General Design Cri- nuclear power plants for whi te,applicants elect to terion 2, "Design Bases for Protection Against Natural provide a single-failure-proof oveiadi crane handling Phenomena," requires that structures, systems, and com- system.

ponents important to safety be designed to withstand the effects of natural phenomena such as earthquakes. B. DISCUSION

General Design Criterion 5, "Sharing of Structures, Systems, and Components," prohibits the sharing of The safe'haniling* of critical loads can be accom- structures, systems, and components important to safety plished by"addirngsaety features to the handling equip- among nuclear power units unless it can be shown that menti by adding special features to the structures and such sharing will not significantly impair their ability to areas over "which the critical load is carried, or a combin- perform their safety functions. In addition, General ation of the two, thus enabling these areas to withstand Design Criterion 61, "Fuel Storage and Handling and thue ;effcýts of a load drop in case the handling equipment Radioactivity Control," requires, in part, that be1l 1,fas. This guide covers critical load handling equipment storage and handling systems be designed to ensure for those plants where reliance for safe handling of cri- adequate safety under normal accident condition.n- tical loads will be placed on the overhead crane system

"by making it single failure proof.

Regulatory Guide 1.13, "Spent Fuel Sto:a-e Facility Design Basis," describes methods acceptable Overhead crane handling systems are often used for to the NRC staff for complying with the Comi-mssion's handling critical items at nuclear power plants. The regulations with regard to the construction of spent handling of critical loads such as a spent fuel cask raises fuel storage facilities and 1 handling systems. the possibility of damage to the safety-related systems, structures, and equipment under and adjacent to the path on which it is transported should the handling Appendix B, "Quality, Assurance Criteria for Nu- system suffer a breakdown or malfunction during this clear Power Plantsaind FueVlReprocessing Plants," to 10 handling period. Definitions of critical items or critical CFR Part 50 rCquITr*, in .part, that measures be estab- loads should be submitted in the PSAR.

lished to ensure oontrol-fdesign, materials, fabrication, special processes, installation, testing, and operation of Design Criteria structures, systems, and components important to safety, including crane handling systems. Section. 50.55a, To provide a consistent basis for selecting equip-

"Codes and Standards," of 10 CFR Part 50 requires that ment and components for the handling of critical loads, design, fabrication, installation, testing, or inspection of a list of codes, standards, and recommended practices USNRC REGULATORY GUIDES Comments should be sent to the Secretary of the Commission, U.S. Nuclear Regulatory Commission, Washington, D.C. 20565. Attention: Docketing and Regulatory Guides are issued to describe and make available to the public Service Section.

methods acceptable to the NRC staff of implementing specific parts of the Commissions regulations. to delineate techniques used by the staff in evalu. The guides are issued in the following ten broad divisions.

sting specific problems or postulated accidents, or to provide guidance to appli cants. Regulatory Guides are not substitutes for regulations. and compliance 1 Power Reactors 6. Products with them is not required. Methods and solutions different from those set out in 2. Research and Test Reactors 7. Transportation the guides will be acceptable if they provide a basis for the findings requisite to 3. Fuels and Materials Facilities 8. Occupational Health the issuance or continuance 1 a permit or license by the Commission. 4. Environmental and Siting 9. Antitrust Review Comments and suggestions for i,, povenrenr.s ,n these guides are encouraged 5 Materials and Plant Protection 10 General at all times, and guides will be revised as appropriate. to accommodate com- ments and to reflect new information or experience However comments on Copies of published guides may be obtained by written request indicating the this guide, if received within about two months after its issuance, will be par- divisions desired to the U.S Nuclear Regulatory Commission. Washington. D.C.

tIcularly useful ,n evaluating the need for an early revision 20555. Attention: Director. Office of Standards Development.

generally available to industry is appended to this guide. ensure the absence of lamellar tearing in the base metal The applicable requirements of these standards and re- and the soundness of the weld metal; Other problems commendations should be used to the maximum extent with welding of low-alloy steels can occur if the base practical to obtain quality construction. Where dif- metal temperature is not properly controlled during ferences or conflicts in interpretation exist between the welding and the postweld heat treatment. Regulatory codes, standards, or recommendations, use of the most Guide 1.50, "Control of Preheat Temperature for Weld- stringent requirement is recommended. However, special ing of Low-Alloy Steel," identifies this potential prob- features should be added to prevent and control or stop lem and indicates an acceptable procedure for obtaining inadvertent operation and malfunction of the load- sound welds in low-alloy steels.

supporting and -moving components of the handling system. Cranes are generally fabricated from structural shapes and plate rolled from mild steel or low-alloy steel.

When an overhead crane handling system will be Some of these steel parts exceed 1/2 inch in thickness and used during the plant construction phase prior to its may have brittle-fracture tendencies during some of the intended service in the operating plant, separate perfor- intended operating temperatures, so that testing of the mance specifications are needed to reflect the duty material toughness becomes necessary. Specifically, the cycles and loading requirements for each service. At the nil-ductility transition temperature (NDTT) should be end of the construction period, changes to the crane determined.

system may be required to reflect the specifications for the permanent operating plant condition. For example, Safety Features if the specifications for the size of the hoist drive motor differ sufficiently for the two applications, the motor General. Numerous applications have been reviewed and the affected control equipment would have to be by the staff, and the need for inclusion of certain safety replaced or changed for the operating plant phase. Fea- features and the magnitudes of specific operational tures and functions needed for the cranes during the limits to provide adequate safety have been determined.

plant construction period are not considered in this guide except where the use of the crane may influence It is. important to prevent the release of radio- its design and operation for the permanent plant opera- activity in case of failure, inadvertent operation, mal- tion. function, or loss of load, and it may be necessary to include special features and provisions to preclude Overhead cranes may be operating at the time when system incidents that would result in release of radio- an earthquake occurs. Therefore. the cranes should be activity.

designed to retain control of and hold the load, and the bridge and trolley should be designed to remain in place A crane that has been immobilized because of mal- on their respective runways with their wheels prevented function or failure of controls or components while from leaving the tracks during, a seismic event. If a holding a critical load should be able to set the load seismic event comparable to a safe shutdown earthquake down while repairs or adjustments are made. This can be (SSE) occurs, the bridge should remain immobile on the accomplished by inclusion of features that will permit runway, and the trolley with load should remain im- manual operation of the hoisting system and the bridge mobile on the crane girders. and trolley transfer mechanisms by means of ancillary, auxiliary, or emergency devices.

Since all the crane loading cycles will produce cyclic stress, it may be necessary to investigate the potential A crane handling system includes all the structural, for failure of the metal due to fatigue. When a crane will mechanical, and electrical components that are needed be used for the construction period, it will experience to lift and transfer a load from one location to another.

additional cyclic loading, and these loads should be Primary or principal load-bearing components, equip- added to the expected cyclic loading for the permanent ment, and subsystems such as the driving equipment, plant operation for the fatigue evaluation. drum, rope reeving system, control systems, and braking means should receive special attention.

Materials and Fabrication All auxiliary hoisting systems of the main crane Bridge and trolley structures are generally fabricated handling system that are employed to lift or assist in by welding structural shapes together. Problems have handling critical loads should be provided with the same been experienced with weld joints between rolled struc- safety features as the rest of the main crane handling tural members. Specifically, subsurface lamellar tearing system.

has occurred at the weld joints during fabrication and the load-bearing capacity of the joint has thus been re- Hoisting Machinery. Proper support of the rope duced. Radiography or ultrasonic inspection, as appro- drums is necessary to ensure that they would be retained priate, of all load-bearing weld joints would help to and prevented from falling or disengaging from their

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braking and control system in case of a shaft or bearing Selection of hoisting speed is influenced by such failure. Two mechanical holding brakes in the hoisting items as reaction time for corrective action for the hoist- system (raising and lowering) that are automatically ac- ing movement and the potential behavior of a failed tivated when electric power is off or when mechanically rope. To prevent or limit damaging effects that may re- tripped by overspeed devices or overload devices in the sult from dangerous rope spinoff in case of a rope break, hoisting system will help ensure that a critical load will the hoisting speed should be limited. A 5 fpm hoisting be safely held or controlled in case of failure in the speed limit is an acceptable limit. The rope traveling individual load-bearing parts of the hoisting machinery. speed at the drum is higher than at other points in the reeving system, and the potential for damage due to rope Each holding brake should have more than full-load flailing and interference with other parts of the system stopping capacity but should not have'excessive capacity should be considered. Conservative industry practice that could cause damage through sudden stopping of the limits the rope line speed to 50 fpm at the drum as a hoisting machinery. A brake capacity of 125% to 150% conservative approach.

of the breakdown torque developed by the motor at the point of brake application has been determined to be Power transmission gear trains are often supported acceptable. by fabricated weldments of structural parts. The proper alignment of shafts and gears depends on the adequacy Manual operation of the hoisting brakes may be of bearings and their supports to maintain correct align- necessary during an emergency condition, and provision ment of all components. The proper functioning .of the for this should be included in the design conditions. hoisting machinery during load handling can best be en- Adequate heat dissipation from the brake should be en- sured by providing adequate support strength and proper sured so that damage does not occur if the lowering alignment of the individual component parts and the velocity is permitted to increase excessively. Features welds or bolting that binds them together.

should be included in the manual control of the brake to limit the lowering speed. A limiting velocity of 3.5 fpm Bridge and Trolley. Failure of the bridge and trolley has been determined to be acceptable for trouble-free travel to stop when power is shut off could result in operation. uncontrolled incidents. This would be prevented if both bridge and trolley drives are provided with control and Component parts of the vertical hoisting mechanism holding braking systems which will be automatically are important. Specifically, the rope and reeving system applied when the power is shut off or if an overspeed or deserves special consideration during design of the sys- overload condition occurs because of malfunction or tem. The selection of the hoisting rope which is a "run- failure in the drive system. Sufficient braking capacity ning rope" should include consideration of size, con- would be needed to overcome torque developed by the struction, lay, and means of lubrication to provide for drive motor and the power necessary to decelerate the the efficient working of the strands and individual wires. bridge or trolley with the attached load to a complete The load-carrying rope will suffer'accelerated wear if it stop. A holding or control capacity of 100 percent of rubs excessively on the sides of the grooves in the drum the maximum torque developed at the point of brake and sheaves due to improper alignment or large fleet application would be an acceptable capacity for each angles between the grooves. The load-carrying rope will braking system. Drag-type brakes are subject to excessive furthermore suffer shock loading if it is partly held by wear, and the need for frequent service and repair tends friction on the groove wall and then suddenly released to to make this type of brake less reliable; they therefore enter the bottom of the groove. The rope can be should not be used to control movements of the bridge protected by the selection of conservative fleet angles. and trolley.

Ropes may also suffer damage due to excessive strain developed if the cable construction and the pitch The travel speed of the trolley and bridge will in- diameter of the sheaves are not properly selected. fluence the operation of the crane as well as the equip- Fatigue stress in ropes can be minimized when the pitch ment design and selection. Numerous crane applications diameter of the sheaves are selected large enough to have been studied and it has been concluded that the produce only nominal stress levels. The pitch diameter travel speed for nuclear power plant application should of the sheaves should be larger for ropes moving at the be conservatively selected. Trolley and bridge speed highest velocity near the drum and can be smaller for limits of 30 fpm and 40 fpm, respectively, have been sheaves used as equalizers where the rope is stationary. determined to be acceptable.

Equalizers for stretch and load on the rope reeving Drivers and Controls. Of the basic types of electric system may be of either beam or sheave type. A dual drive motors available for crane operation, the series- rope reeving system with individual attaching points and wound a.c. or d.c. motors or shunt-wound d.c. motors means bor balancing or distributing the load between the are readily adaptable to various control systems, and two operating rope reeving systems will permit either either of these types would be acceptable. Compound- rope system to hold the critical load and maintain bal- wound motors should not be used because of difficulty ance in case of failure of the other rope system. in control of the breakdown torqu

e. The horsepower

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rating of the driving motor should be matched with the

C. REGULATORY POSITION

calculated requirement that considers the design load and acceleration to the design hoisting speed. Over- When an applicant chooses to provide safe handling powering of the hoisting equipment would impose addi- of critical loads by making the overhead crane handling tional strain on the machinery and load-carrying devices system single-failure proof rather than by adding special by increasing the hoisting acceleration rate. A motor rat- features to the structures and areas over which the criti- ing limited to 110% of the design rating would provide cal load is carried, the system should be designed so that adequate power without loss of flexibility and would be a single failure will not result in loss of the capability of acceptable. the handling system to perform its safety functions.

Normally, a crane system is equipped with mechani- Overhead crane handling systems used for handling cal and electrical limiting devices to shut off power to critical loads (following construction) such as loads dur- driving motors when the crane hook, trolley, and bridge ing reactor refueling and spent fuel handling should be approach the end of travel or when other parts of the designed, fabricated, installed, inspected, tested, and crane system would be damaged if power was not shut operated in accordance with the following:

off. It is prudent to include safety devices in the control system for the crane, in addition to the limiting devices, 1. Performance Specification and Design Criteria for the purpose of ensuring that the controls will return to or maintain a safe holding position in case of malfunc- a. Separate performance specifications that tion, inadvertent operation or failure, or overspeed and are required to develop design criteria should be pre- overtorque conditions. Overpower and overspeed con- pared for a permanent crane that is to be used for con- ditions should be considered an operating hazard as they struction prior to use for plant operation. The allowable may increase the hazard of malfunction or inadvertent design stress limits should be identical for both cases, operation. It is essential that the controls be capable of and the sum total of simultaneously applied loads should stopping the hoisting movement within amounts of not result in stress levels causing permanent deformation movement that damage would not occur. A 3-inch maxi- other than localized strain concentration in any part of mum hoisting movement would be an acceptable stop- the handling system.

ping distance.

b. The operating environment, including max- Operational Tests imum and minimum pressure, temperature, humidity, and emergency corrosive or hazardous conditions, Operational tests of crane systems should be per- should be specified for the crane and lifting fixtures.

formed to verify the proper functioning of limit switches and safety devices and the ability to perform as de- (1) Closed box sections of the crane struc- signed. However, special arrangements may have to be ture should be vented to avoid collapse during contain- made to test overload and overspeed sensing devices. ment pressurization. Drainage should be provided to avoid standing water in the crane structure.

Existing Handling Systems

(2) Minimum operating temperatures It may be necessary to determine the extent to should be specified in order to reduce the possibility of which an existing handling system and the areas in which brittle fracture of the ferritic load-carrying members of the load is transported may require that the crane the crane. Materials for structural members essential to handling system be single failure proof. Therefore, a structural integrity should be impact tested unless ex- detailed inspection may be necessary to determine the empted by the provisions of paragraph AM-218 of the condition of each crane prior to its continued use and to ASME Code,Section VIII, Division 2. However, the define the portion of, the system that may need "minimum design temperature" as used therein should alteration, addition, or replacement in order to ensure its be defined as 60'F below the minimum operating tem- ability to perform acceptable handling of critical loads. perature. Either drop weight test per ASTM E-208 or Charpy tests per ASTM A-370 may be used for impact Quality Assurance testing. The minimum drop weight test requirement should be nil-ductility transition temperature (NDTT)

Although crane handling systems for critical loads not less than 60'F below the minimum operating tem- are not required for the direct operation of a nuclear perature. Minimum Charpy V-notch impact test require- power plant, the nature of their function makes it neces- ments should be those given in Table AM 211.1 of the sary to ensure that the desired quality level is attained. A ASME Code.Section VIII, Division 2, which should be quality assurance program should be established to the met at a temperature 60°F below the minimum operat- extent necessary to include the recommendations of this ing temperature. Alternative methods of fracture anal- guide for the design, fabrication, installation, testing, ysis that achieve an equivalent margin of safety against and operation of crane handling systems for safe fracture may be used if they include toughness measure- handling of critical loads. ments on each heat of steel used in structural members

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essential to structural integrity. In addition, tfle tracture b. Auxiliary systems, dual components, or an- analysis that provides the basis for setting minimum cillary systems should be provided so that. in case of operating temperatures should include consideration of subsystem or component failure, ,the load will be stress levels; quality control; the mechanical checking, retained and held in a stable or immobile safe position.

testing, and preventive maintenance program; and the temperatures at which the design rated load test is run c. Means should be provided for using the de- relative to operating temperature. vices required in repairing, adjusting, or replacing the failed component(s) or subsystem(s) when failure of an

(3) As an alternative to the recommenda- active component or subsystem has occurred and the tions of regulatory position C. 1.b.2, the crane and lifting load is supported and retained in the safe (temporary)

fixtures may be subjected to a cold proof test as des- position with the handling system immobile. As an alter- cribed in regulatory position C.4.d. native to repairing the crane in place, means may be provided for safely moving the immobilized handling

(4) Cranes and lifting fixtures made of system with load to a safe laydown area that has been low-alloy steel such as ASTM A514 should be subjected designed to accept the load while the repairs are being to the cold proof test described in regulatory position made.

C.4.d.

d. The design of the crane and its operating c. The crane should be classified as Seismic area should include provisions that will not impair the Category I and should be capable of retaining the max- safe operation of the reactor or release radioactivity imum design load during a safe shutdown earthquake when corrective repairs, replacements, and adjustments (SSE), although the crane may not be operable after the are being made to place the crane handling system back seismic event. The bridge and trolley should be provided into service after component failure(s).

with means for preventing them from leaving their run- ways with or without the design load during operation 3. Equipment Selection or under any seismic excursions. The design rated load plus operational and seismically induced pendulum and a. Dual load attaching points (redundant de- swinging load effects on the crane should be considered sign) should be provided as part of the load block assem- in the design of the trolley, andthey should be added to bly which is designed so that each attaching point will be the trolley weight for the design of the bridge. able to support a static load of 3W (W is weight of the design rated load) without permanent deformation of d. All weld joints for load-bearing structures any part of the load block assembly other than localized including those susceptible to lamellar tearing should be strain concentration in areas for which additional mate- inspected, including nondestructive examination for rial has been provided ror wear.

soundness of the base metal and weld metal.

b. Lifting devices that are attached to the e. A fatigue analysis should be considered for load block such as lifting beams, yokes, ladle or trunnion the critical load-bearing structures and components of type hooks, slings, toggles, and clevises should be of re- the crane handling system. The cumulative fatigue usage dundant design with dual or auxiliary device or combina- factors should reflect effects of the cyclic loading from tions thereof. Each device should be designed to support both the construction and operating periods. a static load of 3W without permanent deformation.

f. Preheat and postheat treat~nent (stress re- c. The vertical hoisting (raising and lowering)

lief) temperatures for all weldments should be specified mechanism which uses rope and consists of upper in the weld procedure. For low-alloy steel, the recom- sheaves (head block), lower sheaves (load block), and mendations of Regulatory Guide 1.50, "Control of Pre- rope reeving system, should provide for redundantly de- heat Temperature for Welding- of Low-Alloy Steels." signed dual hoisting means. Maximum hoisting speed should be applied. should be no greater than 5 fpm.

2. Safety Features d. The head and load blocks should be de- signed to maintain a vertical load balance about the cen- a. The automatic controls, and limiting de- ter of lift from load block through head block and have vices should be designed so that, when disorders due to a reeving system of dual design. The loadblock should inadvertent operation, component malfunction, or dis- maintain alignment and a position of stability with arrangement of subsystem control functions occur singly either system being able to support 3W within the break- or in combination during the load handling and failure ing strength of the rope and maintain load stability and has not occurred in either subsystems or components, vertical aligrnment from center of head block through all these disorders will not prevent the handling system hoisting components through the center of gravity of the from being maintained at a safe neutral holding position. load.

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e. Design of the rope reeving systei(s) should geometric configuration of the attaching points should be dual with each system providing separately the load be made before and after the test and should be fol- balance on the head and load blocks through configura- lowed by a nondestructive examination that should con- tion of ropes and rope equalizer(s). Selection of the sist of combinations of magnetic particle, ultrasonic, hoisting rope or running rope should include considera- radiograph, and dye penetrant examinations to verify tion of the size, construction, lay, and means or type of the soundness of fabrication and ensure the integrity of lubrication to maintain efficient working of the indivi- this portion of the hoisting system. The results of exami- dual wire strands when each section of rope passes over nations should be documented and recorded for the the individual sheaves during the hoisting operation. The hoisting system for each overhead crane.

effects of impact loadings, acceleration, and emergency stops should be included in selection of rope and reeving h. Means should be provided to sense such items as electric current, temperature, overspeed, over- systems. The wire rope should be 6 x 37 NWRC (iron wire rope core) or comparable classification. The lead loading, and overtravel. Controls should be provided to line stress to the drum during hoisting (dynamic) at the absorb the kinetic. energy of the rotating machinery and maximum design speed with the design rated load should ,stop the hoisting movement within a maximum of 3 not exceed 20% of the manufacturer's published rated inches of vertical travel through a combination of elec- strength- Line speed during hoisting (raising or lowering) trical power controls and mechanical braking systems should not exceed 50 fpm. and torque controls if one rope or one of the dual reev- ing system should fail or if overloading or an overspeed f. The maximum fleet angle from drum to condition should occur.

lead sheave in the load block should not exceed 3-% i. The control systems should be designed as degrees at any one point during hoisting and should have a combination of electrical and mechanical systems and only one 180-degree reverse bend for each rope leaving may include such items as contactors, relays, resistors, the drum and reversing on the first or lead sheave on the and thyristors in combination with mechanical, devices load block with no other reverse bends other than at the and mechanical braking systems. The electric controls equalizer if a sheave equalizer is used. The fleet angles should be selected to provide a maximum breakdown between individual sheaves for rope should not exceed torque limit of 175% of the required rating for a.c.

1-1/2 degrees. Equalizers may be of the beam or sheave motors or d.c. motors (series or shunt wound) used for type or combinations thereof. For the recommended 6 x the hoisting drive motor(s). Compound wound dcc.

37 IWRC classification wire rope,*the pitch diameter of motors should not be used. The control system(s) pro- the lead sheave should be 30-times the rope diameter foi vided should include consideration of the hoisting the 180-degree reverse bend, 26 times the rope diameter (raising and lowering) of all loads, including the maxi- for running sheaves and drum, with 13 times the rope mum design rated load, and the effects of the inertia of diameter for equalizers. The pitch diameter is measured the rotating hoisting machinery such as motor armature, from the center of the rope on the drum or sheave shafting and coupling, gear reducer, and drum.

groove through the center of the drum or sheave to the center of the rope on the opposite side. The dual reeving j. The mechanical and structural components system may be a single rope from each end of a drum of the complete hoisting system- should have the re- terminating at one of the blocks or equalizer with pro- quired strength to 1 resist failure if the hoisting

2 system visions for equalizing'beam type load and rope stretch, should "two block" I or if "load hangup" should occur with each rope designed for the total load, or a 2-rope during hoisting. The designer should provide means system may be used from each drum or separate drums within the reeving system located on the head or on the using a sheave equalizer or beam equalizer, or any other load block combinations to absorb or control the kinetic combination which provides two separate and complete energy of rotating machinery prior to the incident of reeving systems. two .blocking oruload hangup. The location of mnechan- ical holding brakes and their controls should provide g. The portions of the vertical hoisting system positive, reliable, and capable means to stop and hold components, which include the head block, rope reeving the hoisting drum(s) for the conditions described in the system, load block, and dual load-attaching device, design specification and regulatory positions 1 and 2.

should each be designed to sustain a test load of 200% of This should include the maximum torque of the driving the design rated load. Each reeving system and each one

-of the load-attaching devices should be assembled with approximately a 6-inch clearance between head and load 1 blocks and should support 200% of the design rated load "Two blocking" is the act of continued hoisting in which the without permanent deformation other than localized load block and head block assemblies are brought into physical strain concentration or localized degradation of the com- contact, thereby preventing further movement of the load block and creating shock loads to rope and reeving system.

ponents. A 200% static-type load test should be per- 2

"Load hangup" is the act in which the load block and/or load is formed for each reeving system and a load-attaching stopped during hoisting by entanglement with fixed objects, point at the manufacturer's plant. Measurements of the thereby overloading the hoisting system.

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motor cannot be shut off. motion of the overnead brsage crane shouui nut exceea

110% of the calculated horsepower requirement at maxi- k. The load hoisting drum on the trolley mum speed with design rated load attached. Incremental should be provided with structural and mechanical or fractional inch movements, when required, should be safety devices to prevent the drum from dropping, provided by such items as variable speed or inching disengaging from its holding brake system, or rotating, if motor drives. Control and holding brakes should each be the drum or any portion of its shaft or bearings should rated at 100% of maximum drive torque at the point of fail or fracture. application. If two mechanical brakes, one for control and one for holding, are provided, they should be ad-

1. To preclude ekcessive *breakdown torque, justed with one brake in each system for both the trolley the horsepower rating of the electric motor drive for and bridge leading the other and should be activated by hoisting should not exceed 110% of the calculated de- release or shutoff of power. The brakes should also be sign horsepower required to hoist the design rated load mechanically tripped to the "on" or "holding" position at the maximum design hoist speed. in the event of a malfunction in the power supply or an overspeed condition. Provisions should be made for m. The minimum hoisting braking system manual operation of the brakes. The holding brake should should include one power control braking system (not be designed so that it cannot be used as a foot-operated mechanical or drag brake type) and two mechanical slowdown brake. Drag brakes should not be used. Oppo- holding brakes. The holding brakes should be activated site wheels on bridge or trolley that support bridge or when power is off and should be automatically mechani- trolley on their runways should be matched and have cally tripped on overspeed to the full holding position if identical diameters. Trolley and bridge speed should be malfunction occurs in the electrical brake controls. Each limited. A maximum speed of 30 fpm for the trolley and holding brake should be designed to 125%-1150% of the 40 fpm for the bridge is recommended.

maximum developed torque at point of application (lo- cation of the brake in the mechanical drive). The mini- q. The complete operating control system and mum design requirements for braking systems that will provisions for emergency controls for the overhead crane be operable for emergency lowering after a single brake handling system should be located in the main cab on failure should be two holding brakes for stopping and the bridge. Additional cabs located on trolley or lifting controlling drum rotation. Provisions should be made for devices should have complete control systems similar to manual operation of the holding brakes. Emergency the bridge cab. Manual controls for hoisting and trolley brakes or holding brakes which are to be used for movement may be provided on the trolley. Manual con- manual lowering should be capable of operation with trols for the bridge may be located on the bridge. Re- full load and at full travel and provide adequate heat mote control or pendant control for any of these mo- dissipation. Design for manual brake operation during tions should be identical to those provided on the bridge emergency lowering should include features to limit the cab, control panel. Provisions and locations should be lowering speed to less than 3.5 fpmrL provided in the design of the control systems for devices for emergency control or operations. Limiting devices, n. The dynamic and static alignment of all mechanical and electrical, should be provided to indicate hoisting machinery components including gearing, shaft- and control or prevent overtravel and overspeed of ing, couplings, and bearings should be maintained hoist (raising or lowering) and for both trolley and throughout the range of loads to be lifted, with all com- bridge travel movements. Buffers for bridge and trolley ponents positioned and anchored on the trolley ma- travel should be included.

chinery platform.

o. Increment drives for hoisting may be pro- r. Safety devices such as limit type switches vided by stepless controls or inching motor drive. Plug- provided for malfunction, inadvertent operation, or fail- ging 3 should not be permitted. Controls to prevent plug- ure should be in addition to and separate from the limit- ging should be included in the electrical circuits and the ing means or devices provided for operation in the afore- control system. Floating point 4 in the electrical power mentioned. These would include buffers, bumpers, and system when required for bridge or trolley movement devices or means provided for control of malfunction(s).

should be provided only for the lowest operating speeds.

s. The operating requirements for all travel p. To avoid the possibility of overtorque movements (vertical and horizontal movements or rota- within the control system, the horsepower rating of the tion, singly or in combination) incorporated in the de- sign for permanent plant cranes should be clearly de-

3 Plugging is the momentary application of full line power to the frned in the operating manual for hoisting and for trolley drive motor for the purpose of promoting a limited movement. and bridge travel. The designer should establish the max-

4 imum working load (MWL). The MWL should not be less That point in the lowest range of movement control at which power is on, brakes are off, and motors are not energized. than 85% of the design rated load (DRL) capacity for

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-the n.w crane at time, of operation. The redundancy in program based on the approved test results and informa- design, design factors, selection of components, and tion obtained during the testing; it should include such balance of auxiliary-ancillary and dual items in the de- items as servicing, repair and replacement requirements.

sign and manufacture will provide or dictate the maxi- visual examinations, inspections, checking, measure- mum working load for the critical load handling crane ments, problem diagnosis, nondestructive examination, systems. The MWL should not exceed the DRL for the crane performance testing, and special instructions.

Overhead Crane Handling System.

Information concerning proof testing on t. When the permanent plant crane is to be components and subsystems as required and performed used for construction anid the operating requirements for at the manufacturer's plant to verify the ability of construction are not identical to those required for pre- components or subsystems to perform should be avail- manent plant service, the construction operating require- able for the checking and testing performed at the place ments should be completely defined separately. The of installation of the crane system.

crane should be designed structurally and mechanically for the construction loads, plant service loads, and their functional performance requirements. At the end of the b. The crane system should be prepared for construction period, the crane handling system should the static test of 125% of the design rated load. The tests be adjusted for the performance requirements of the should include all positions of hoisting, lowering, and nuclear power plant service. The design requ.-ments for trolley and bridge travel with the 125% rated load and conversion or adjustment may include the replacement other positions as recommended by the designer and of such items as motor drives, blocks, and reeving sys- manufacturer. After satisfactory completion of the tem. After construction use, the crane should be thor- 125% static test and adjustments required as a result of oughly inspected by nondestructive examination and the test, the crane handling system should be given full performance tested. If allowable design stress limits are performance tests with 100% of the design rated load for to be exceeded during the construction phase, added all speeds and motions for which the system is designed.

inspection supplementing that of regulatory position This should include verifying all limiting and safety con- C.l.d should be considered. If the load and performance trol devices. The crane handling system with the design requirements are different for construction and plant rated load should demonstrate its ability to lower and service periods, the crane should be tested for both move the load by manual operation and with the use of phases. Its integrity should be verified. by designer and emergency operating controls and devices that have been manufacturer with load testing to 125% of the design designed into the handling system.

rated load required for the operating pl~t before it is The complete hoisting machinery should used as permanent plant equipment. be allowed to "two block" during the hoisting test (load block limit and safety devices are bypassed). This test, conducted at slow speed without load, should provide u. Installation instructions should be provided by the manufacturer. These should include a full expla- assurance of the integrity of the design, the equipment, nation of the crane handling system, its controls, and the the controls, and the overload protection devices. The limitations for the system and should cover the require- test should demonstrate that the maximum torque that ments for installation, testing, and preparations for oper- can be developed by the driving system, including the ation. inertia of the rotating parts at the overtorque condition, will be absorbed or controlled prior to two-blocking.

4. Mechanical Check, Testing, and Preventive The complete hoisting machinery should be tested for Maintenance ability to sustain a load hangup condition by a test in which the load block attaching points are secured to a a. A complete mechanical check of all the crane systems as installed should be made to verify the fixed anchor or excessive load. The drum should be cap- method of installation and to prepare the crane for able of one full revolution before starting the hoisting testing. test.

c. The preventive maintenance program rec- During and after installation of the crane ommended by the designer and manufacturer-4hkuld the proper assembly of electrical and structural com- also prescribe and establish the MWL for which the crane ponents should be verified. The integrity of all control, will be used. The maximum working load should be operating, and safety systems should be verified as to plainly marked on each side of the crane for each hoist- satisfaction of installation and design requirements, ing unit. It is recommended that the critical load handling cranes should be continuously maintained at The crane designer and crane manufacturer DRL capacity.

should provide a manual of information and procedures for uise in checking, testing, and operating the crane. The d. The cold proof test provided for in regula- manual should also describe a preventive maintenance tory positions C.l b.3 and 4 should consist of a periodic

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dumm% load test as follows: Metal temperature of the I. Except in those cases in which the applicant structural members, essential to the structural integri,ý proposes an alternative method for complying with spec- of the crane handling system should be at or below the ified portions of the Commission's regulations, this guide minimum operating temperature. The corresponding will be used in the evaluation of design, fabrication, as- d*mmy load should be equal to 1.25 times the max-  :*ulirig, and use of crane systems for critical load imum working load (MWL). If it is not feasible to handling ordered after September 1, 1976.

ý,-.hive the minimum operating temperature during the test, the dummy load should be increased beyond the design rated load 1.5 percent per degree F temperature 2. For crane handling systems ordered prior to difference. ,Test frequency should be approximately 40 September 1, 1976:

months or less; however, crane handling systems that are used less frequently than once every 40 months may be given a cold proof test prior to each use. The cold proof a. Regulatory positions C.1, C.2. C.3, and C4 test should be followed by a nondestructive examination will be used in evaluating crane handling systems that of critical areas for cracks. have been ordered but are not yet assembled.

5. Quality Assurance b. All regulatory positions except C.I.f: C.3.c, f, and q will be used in evaluating crane handling systems a. To the extent necessary, applicable pro- that have been assembled or may have been used for curement documents should require the crane manufac- handling heavy loads during plant construction. Regula- turer to provide a quality assurance program consistent tory positions C.l.f; C.3.c, f, and q will be used by the with the pertinent provisions of Appendix B, "Quality NRC staff to determine the extent of changes or modifi- Assurance Criteria for Nuclear Power Plants and Fuel cations necessary.

Reprocessing Plants," to 10 CFR Part 50.

c. All regulatory positions except C. I.f; C.2.a, b. The program should also address each of b, c, and d; C.3.a, b, c, e, f, g. j. n, o, p, q, r. and t will be the recommendations in regulatory positions C.1, C.2, used in evaluating crane handling systems that will be or C.3, and C.4. are being used to handle heavy loads that are defined as

D. IMPLEMENTATION

critical. Regulatory positions C.l.f; C.2.a, b. c, and d;

C.3.a, b, c, e, f, g, j, n, o, p, q, r, and t will be used by The purpose of this section is to provide informa- the NRC staff to determine the extent of changes or tion to applicants and licensees regarding the NRC staff's modifications necessary to meet the intent of the regula- plans for using this regulatory guide. tory positions.

At

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APPENDIX

ENGINEERING, MANUFACTURING, AND OPERATING STANDARDS,

PRACTICES, AND REFERENCES

AISE Association of Iron and Steel Engineers (Std. SAE Society of Automotive Engineers, "Stan- No. 6) dards and Recommended Practices"

General items for overhead cranes and Recommendations and practices for wire specifically- for drums, reeving systems, rope, shafting, lubrication, fasteners, blocks, controls, and electrical, mechani- materials selection, and load stability.

cal, and structural components. Copies may be obtained from the Society Copies may be obtained from the Asso- at 400 Commonwealth Drive; Warrendale, ciation at 3 Gateway Center, Pittsburgh, Pennsylvania 15096.

Pennsylvania 15222.

CMAA Crane ManufacturersAssociation of America AISC American Institute of Steel Construction, (CM-AA 70)

Manual of Steel Construction. Guide for preparing functional and per- Runway bridge design loadings for impact formance specification and component and structural supports. selection.

Copies may be obtained from the Copies may be obtained from the Asso- Institute at 101 Park Avenue, New York, ciation at 1326 Freeport Road, Pitts- New York 10017. burgh, Pennsylvania 15238.

ASME American Society of Mechanical Engineers NEMA National Electrical Manufacturers Asso- References for testing, materials, and ciation mechanical components.

Electrical motor, control, and component Copies may be obtained from the Society selections.

at United Engineering Center, 345 East Copies may be obtained from the Asso-

47th Street, New York, New York ciation at 155 East 44th Street, New

10017.

York, New York 10017.

ASTM American Society for Testing and Materials WRTB Wire Rope Technical Board and their manu- Testing and selection of materials.

facturing members for selection of rope, Copies may be obtained from the Society reeving system, and reeving efficiencies.

at 1916 Race Street, Philadelphia, Penn- Copies may be obtained from the Board sylvania 19103.

at 1625 1st Street, NW., Washington, ANSI American National StandardsInstitute (A.10, D.C. 20006.

B3, B6, B15, B29, B30, and N45 series) Mill Materials HandlingInstitute and their mem- N series of ANSI standards for quality ber associations such as American Gear control. ANSI consensus standards for Manufacturing Association for gears and design, manufacturing, and safety. gear reducers, Antifriction Bearing Manu- Copies may be obtained from the Insti- facturers Association for bearing selec- tute at 1430 Broadway, New York, New tion, etc.

York 10018. Copies may be obtained from the Insti- IEEE Institute of Electrical and Electronics Engi- tute at 1326 Freeport Road, Pittsburgh, neers Pennsylvania 15238.

Electrical power and control systems.

WRC Welding Research Council, "Control of Steel Copies may be obtained from the Insti- tute at United Engineering Center, 345 Construction to Avoid Brittle Fracture."

East 47th Street, New .York, New York Copies may be obtained from the Council

10017. at United Engineering Center. 345 East

47th Street, New York, New York AWS American Welding Society (DI,1. 72- 73/74 10017.

revisions)

Fabrication requirements and standards WRC Welding Research Council, Bulletin #168, for crane structure and weldments. "Lamellar Tearing."

Copies may be obtained from the Society Copies may be obtained from the Council at 2501 NW 7th Street, Miami, Florida. at United Engineering Center, 345 East

33125. 47th Street, New York, New York EEl Edison ElectricalInstitute 10017.

Electrical Systems.

Copies may be obtained from the Insti- tute at 90 Park Avenue, New York, New Regulatory Guide 1.50, "Control of Preheat Tempera- York 10016. ture for Welding of Low-Alloy Steel."

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UNITED STATES

NUCLEAR REGULATORY COMMISSION

WASHINGTON, 0. C. 20555 POSTAGE AND FEES PAID

UNITED STATES NUCt EAR

OFFICIAL BUSINESS REGULATORY COMMISSION

PENALTY FOR PRIVATE USE, $300