ML17276B032
| ML17276B032 | |
| Person / Time | |
|---|---|
| Site: | Columbia  |
| Issue date: | 02/09/1981 |
| From: | WASHINGTON PUBLIC POWER SUPPLY SYSTEM |
| To: | |
| Shared Package | |
| ML17276B029 | List: |
| References | |
| REF-GTECI-A-36, REF-GTECI-SF, RTR-NUREG-0612, RTR-NUREG-612, TASK-A-36, TASK-OR 10.4.1, NUDOCS 8202020272 | |
| Download: ML17276B032 (34) | |
Text
WASHINGTON PUBLIC POWER SUPPLY SYSTEMS~
PLANT PROCES) V RES MANVAL IVNP. 2 PROCEDURE NUMBER APPR0 DATE 10.4.1 2/9/Sly VOLUME NAME 10 MAINTENANCE PRO AMS AND PROCEDURES SECTION 10.4 TOOL AND EQUIPMENT TESTING AND CALIBRATION TITLE 10.4.1 CRANE OPERATION, INSPECTION AND MAINTENANCE 10.4.1.1 ~Put ose This procedure provides instructions on crane operation, inspection, testing and maintenance. It is designed to guard and minimize in-jury to workers and plant equipment by prescribing minimum opera-tion, inspection and maintenance requirements.
10.4.1.2 Discussion This procedure is specifically intended for the reactor and turbine building overhead cranes and all other motor operated cranes and hoists.
The use of cranes, hoists and other rigging equipment is subject to certain hazards that cannot be eliminated by mechanical safeguards, but only by the exercise of intelligence, care and common sense. It is therefore essential to have competent and careful operators and riggers, thoroughly trained in the safe operation of equipment used in handling loads. Serious hazards of overloading, dropping and/or slippage of the load caused by improper attachment, obstructions and/or misuse of equipment from its intended purpose mandate the use of safe procedures.
10.4.1. 3 References A. ANSI B30 Series, B. NRC Regulatory Guide 1.104 C. Whiting Corporation, Crane Maintenance, CVI02-31A-02, sheet 32 D. Clayton Corporation, Crane Maintenace, CVI02-32CD-OO, sheet 81 E. Yale Corporation, Crane Maintenance, CVI02-32CD-00, sheet 78 F. WPPSS Industrial Safety and Fire Protection Manual BQ020gpQ7 oocu~ e~p>>3 OS000397 PDR PROCEDURE NUMBER REVISION NUMBER PAGE NUMBER 10.4.1 10.4.1- 1 Rl WP 597
~~CA GDM~< ~
10.4.1.4 Prere uisites A. Each assigned operator is responsible to confirm that all in-spection and preventative maintenance'requirements'-are current and signed-off before proceeding with the use of any specific crane or hoist.
" B.
5 All operators of the reactor and turbine building cranes shall be certified crane operators or trainees. Trainees shall work under the direct supervision of a certified supervisor or an assigned certified opei ator.
C. All operators of floor operated motor driven cranes and hoists shall attend the introductory training session on crane opera-tion.
D. Check lists for daily and shift change inspections shall be posted on or near each motor operated crane or hoist.
10.4.1.5 Precautions A. Immediately prior to any load testing, a thorough inspection of all functional parts will be made to minimize over stressing load carrying components.
B. Only the crane operator will normally be allowed on a crane while it is in operation. If required, additional personnel will receive permission from the operator and keep the operator informed of their activity.
C. Any activity in the vicinity of either the crane or trolley power lines will require deenerization of these exposed con-ductors.
D. Any work activity on a overhead crane or hoist will require safety roping off of areas directly below until the work is completed.
E. Access to cranes positioned away from their normal storage area will require safety approved catwalks, hand rails and/or ladders.
F.'.
No load shall be tr an s ferred over per sonne 1 .
Personnel shall not work under suspended loads except where the load is sufficiently blocked up with cribbing.
ROCEDURE NUMBER REVISION NUMBER PAGE NUMBER WPiSSB 10.4.1- 2
10.4.1.6 Limitations A. Discrepencies encountered during tests shall be noted and re-ported to the Shift Supervisor and your immediate supervisor.'.
Defective equipment 'discovered during tests shall be handled per PPM 1.3.11.
Materials Tools and Test
-'0.4.1.7 E ui ment No special tooling required.
10.4.1.8 Procedures A. Discussion This instruction provides guidelines to be used during main-tenance and inspection of motor operated cranes and hoists. It is not intended to be used in place of manufacturer's instruc-tion manuals, but will supplement them with general information.
A manufacturer's service representative will be required during the annual inspection of the Reactor and Turbine Building cranes until WNP-2 Maintenance personnel can be trained as com-petent inspectors of these units.
All inspection activities other than daily inspections will be documented, signed off and filed for future reference using the annual inspection checklist.
B. Gear Box Ins ection
- 1. There are many sizes and types of gear cases. Those pur-chased from other vendors will have brochures in the main-tenance manual covering care and maintenance procedures and parts catalog. These should be adhered to.'.
A normal inspection would include opening inspection cover where provided, and inspecting visually with a light to see that all parts are being lubricated, gears are not worn badly or cracked or chipped, bearings are intact, gears do not have excessive backlash and proper clear ance is maintained between gears so they are not rubbing to-gether. If an inspection shows that there is trouble in the gear case, it should be taken apart for a closer look.
- 3. Gears should be rotated slowly so that all teeth on all gears can be inspected. This can be accomplished by re-leasing brake manually and rotating the high speed coup-ling by hand slowly.
ROCEOURE NUMBER REVISION NUMBER PAGE NUMBER WP 598 10.4.1-3
- 4. Most cases are made in halves bolted together with a cen-ter seam sealed with Permatex. When vertically mounted gear cases are disassembled, precautionary measures should be taken to prevent intermediate gear and shaft from roll-ing out of case. These are held in by top half of gear case and could roll out. To prevent this, lock brake to prevent shaft from turning. Most high speed pinion gears are made as in integral part of shaft. Other gears are pressed onto shaft and keyed.
C. Drum/In sweet i on Check hoist drums for wear, such as grooves worn deeper or sides of grooves worn to a point. Wear will show up first at'enter of drums, so groove depth at rope anchor can be used as a reference. If groove root diameter is worn 1/4 rope diameter or more, drum should be replaced. See Figure 1.
- 2. Most cranes are designed with stub shafts pressed into drums and welded. These welds should be wiped clean and visually inspected carefully for cracks. Overloads, side pulls or other crane abuse may cause cracks in this area.
If detected, consult factory for recommended procedure for correction.
D. STR Actual Ins ection Visually check all steel fabricated members for cracks.
Put particular emphasis on inspecting for cracks, on bridge girders near end trucks, at end of shelf angles where trucks are fastened to girders. See Figure 2. If cracks are detected, consult manufacturer for correct pro-cedure for repairs.
- 2. If there is loss of camber in girders due primarily to overloading, trolley will tend to roll down toward center span. Loss of camber can be checked with a transit and rod or with taut piano wire on the top of the grider.
- 3. Make sure that all bumpers are intact and securely bolted to trucks, springs aren't broken and safety cables are intact. All spring bumpers should be equipped with a safety cable fastened to truck in case bumper bolts break.
4, ANSI B30.2, Section 2-1-7.1 states that stops shall be provided at the limits of travel of the trolley. These should be inspected to determine that they are in place, secured to the rail and/or girder and properly located and lined up.
OURK NUMBKR RKVISION NUMBKR PAQK NUMBKR 10.4.1 10.4. 1-4
E. Sheaves E 0
Blocks Ins ection
- 1. All sheaves, upper,and lower, should be checked for ex-cessive wear, (1/8 rope diameter or more) making sure that all cables are engaged in sheaves. Lift cables out of sheaves to,inspect contact surfaces for excessive wear and gouges.
- 2. Check,all bearing housings. Cast housings sometimes break due to side pulls or bad runway conditions.
- 3. Crane blocks should be inspected regularly for worn or broken sheaves, or bent housing. Pay particular attention to the hook. Check for'xcessive wear, gouging, or cracks in palm and hook opening, and make sure hook eye has not spread or shank has not stretched.
F. Hoist Brakes
- 1. These are customarily spring-set and either solenoid-(AC) or magnet-(DC) released. Brakes should be inspected for:
- a. , Lining wear (replace when worn to within 1/16" of rivet heads or within 1/16" of shoe on bonded lin-ings).
- b. Cracked or broken shoes or brake-wheel rims.
- c. Worn, bent or broken linkage; missing pins.
- d. Actuation springs (are they cracked or have they taken a set2)
- e. Rated torque when holding, measured with a torque wrench or with a pipe wrench and spring scale, or by load on hook for large brakes.
Tightness of brake wheel on shaft. No free play is allowed.
- g. Condition of key and keyway. Check for rounded cor-ners and sloppy fit.
- h. Release in raising or lowering when power is applied.
Adjustment for wear. Some solenoid brakes have the solenoid and plunger operating in an oil-filled en-closure and this should be checked for leaks and height of oil fill. If the brake has a self-adjust-ing mechanism, this should be backed out EDVRE NUMBER REVISION NUMBER PACE NUMBER WP.44! 10.4.1 10.4. 1- 5
O. 0 of adjustment, then the brake released repeatedly by hand to determine if the adjustment device is rat-cheting and if the solenoid stroke is within speci-fied limits when it stops ratcheting.
- 2. Brake linings are the most frequently replaced crane parts. Linings are attached to the shoes by rivets or cement. Shoes with cemented linings should be replaced when linings are worn to 1/16" thickness. Linings which are riveted on should be replaced before wearing down to tlIe rivet heads, or they will cut grooves in the brake wheel. Grooved brake wheels should be replaced.
- 3. Brakes are a safety device and should be kept in top-notch condition.
- 4. If the brake wheel is found to have visual surface cracks, it should be replaced immediately. This thermal fatigue ~
condition progresses rapidly to destroy the lining and to complete disintegration of the wheel.
G. Retardin Brakes on Brid e or Trolle These are low-capacity brakes, generally applied to a shaft running at motor speed. They may be either a foot-operated hydraulic brake; a simple, spring-set drag brake applying a permanent drag torque to the motor shaft; or, like the hoist brakes, automatically spring-set and electrically released. If electrically released, they should be checked by operating with power to determine that release occurs when power is applied to the bridge or trolley (rack) motor. Foot-operated brakes should be checked for'peration and sponginess and maintained ac-cording to manufacturer's instructions.
- 2. These brakes should also be checked for worn or bent link-age, worn linings, cracked shoes, and badly scored, cracked or overheated wheels (blue or purple glaze on br aking surfaces). Worn, damaged or cracked parts should be replaced immediately. On automatically-set bridge or trolley brakes, torque should be set at such a valve that the load does not swing excessively when the bridge or trolley controller is returned to neutral.
H. Control Brakin Oevices
- 1. Th'ese are mechanical load brakes and eddy current (elec-trical) load brakes. They are intended to control the rate at which the load is lowered. Mechanical load brakes, typically, are also designed to hold the load II DURE NUMBER REVISIDN NVMSER PAGE NUMSER WP bbb 10.4.1 10.4.1-.6
after hoisting.
0 In such a brake, the brake screw shaft is frictionally coupled to a ratchet which is restrained against turning by a pawl, sprag clutch, or a one-way spring clutch.
The ratchet wheel is gripped from 2 sides by friction washers. The friction washer on one side also bears against a friction collar and the friction washer on the other side bears against a flanged nut. The nut screws onto threads on the brake-screw shaft. Load on the hoist causes the nut to tighten on tne brake screw, squeezing the friction washers onto the ratchet on both sides. In raising, this entire assembly then ratchets. When the load is stationary, the load is held by the ratchet and pawl. When the load is lowered the nut is partially un-locked on the screw allowing the load to slip down at a speed controlled by the rotational speed on the nut. Any tendency of the load to get ahead of the nut causes the nut and screw to tighten on the stationary ratchet, re-tarding the load.
,2 ~ Lift a small (1/4 capacity) load approximately one foot off the floor. Release the hoist brake manually to dete-mine if the load brake holds the load. Let the motor brake set, then power the load down slowly. Observe the h kk ff when the load is h
owered slow k
.
f <<h h etermine whether the I
brake is operating smoothly or chattering, and whether clear ance adjustment is too large.
- 3. Maintenance a ~ Without Oisassembl Examine the back-off adjustment of the nut. The brake should release. against its adjustment nut only enough to release the load. Lock the adjustment nut in this position. Also examine the pawl and ratchet wheel for cracks, battered or broken pawls or ratchet teeth; inoperative pawl shifter and broken or worn springs.
- b. With Disassembl Examine the braking surfaces, the friction washers, the brake screw thread and the nut thread. The latter two should look polished, not galled, and any surface roughness on the load-bearing faces of the brake screw threads should be removed, so that the nut turns freely on the screw thread.
EOURE NUMBER REVISION NUMBER I aOE NUMBER WP 99$
Friction washers should be examined for warpage, cracks, excessive wear, and, if metallic, upsetting or shrinkage onto their pilot surfaces on the nut, ratchet, or friction collar. If any of the above conditions are found, the friction washers should be replaced immedi'ately.
I. Footwalks Handrails and Ladders These are for protection against falling and for access of Maintenance personnel to service certain mechanical and/or electrical components of the crane footwalks, ladders and hand-rails should be inspected to assure 'that they are in sound and safe'tructural condition,'re not bent, loose, broken or miss-ing and are kept clean and free of debris, grease, oil, oily rags and hand tools.
J. U er and Lower Limit Switches
- 1. The upper hoist limit switch, is a safety device to prevent hoisting motion to a point where the block and sheave-nest are two-blocked (jammed together) with the hazard of stretching and breaking the ropes and dropping both load .
and block.
- 2. The upper limit switch must not be used to stop hoisting motion in normal operation. Its operation should be checked at the beginning of each shift daily with no load and slew jogging motions to observe whether hoist power is cut off before the block is fully raised.
- 3. If in this test the block can be observed to pass the
'imit switch operating-point without causing power to be cut off, the crane should be shut down and the problem reported by the operator to his immediate superior for corrective action.
- 4. ANSI B30.2, Section 2-3, Section 2-3.2.3h states, "the load shall not be lowered below the point where less than two full wraps of rope remain on the hoisting drum."
Where the crane has been supplied with a lower limit switch, this limit switch should be checked weekly as to its adjustment, to assure that lowering motion cannot be continued beyond this point. Where cranes are not sup-plied with such a switch, operators must be trained and cautioned to stop lowering motion when the drum has two full wraps of rope left. Further lowering motion leads to reverse reeving of the rope on the drum which can pull the EDURE NUMSER REVISION NUMBER PAGE NUMBER
block back into the hoisted position, wi hazards of breaking the rope, dropping the block and damaging the upper sheave nest and trolley structure. The wire rope will, i'n this instance, also be kinked at the rope anchors and'must be replaced even if not broken.
- 5. Upper- limit switches may be connected in either the hoist control circuit on the main'lipe disconnect circuit. If connected in the hoist circuit, it will not prevent re-verse reeving into the upper limit since this is caused by lo:ering, not hoisting motion.
K. Runwa s and Rail Ins ection
'I Most problems with bridge drives, wheels, axles, trucks and truck-to-girder connections are caused by poor runway condition and alignment. Runway girders and columns should line up straight and parallel. Runway girders should be sized to deflect not more than 1/800 of their span under a loaded crane with the trolley at the near end.
- 2. Runways should have rails of adequate size for the highest capacity crane to be used, tightly spliced with close and staggered joints, and with rail heads neither cracked, spalled-out nor mashed over to a sharp cutting edge (which will quickly destroy wheel flanges).
- 3. Rails should be tightly clamped to the girders, not float-ing. Vertical waviness of the runway rail from a flat and level plane, due to column settling or. initial installa-tion, should not be more than + 1/8" in 20 ft., and col-umns or girders should be shimmed periodically as required to maintain this level condition.
- 4. In the horizontal direction, rails should not curve, wave or bend from a straight line by more than 1" in any 400 ft., and span between rails should be held to a specified dimension within + 1/8" as measured with a tape.
- 5. Columns should be plumb, well-seated on their foundations and rigidly attached to them by tight, sound anchor bolts. The rail should not breathe, sway, or lean toward the crane while the crane is traveling along the runway by any amount sufficient to pinch the bridge wheels. Runway structure should be checked periodically for tightness of bolts and/or rivets, soundness of all welds, tight brac-kets, seats or girder connections to columns, and absence of rust or sagging of girders between columns.
- 6. Bumper stops should be square with the rai l. A method for checking squareness is shown in Figure 1.
EDURE NUMBER REVISION NUMBER PACE NUMBER 10.4.1 10 4 1"9
L. Crane S uareness and Structural Dama e
- 1. Cranes when assembled at the factory have both the end trucks and girders aligned for parallelism, with the end trucks squared with the girders to a precision, such that diagonals between wheels are equal within 1/4".
'2 This parallelism and squareness is then locked into the crane on shop assembly by individual reaming of matching bolt holes in the shelf angles and end-truck to girder gusset plates. These reamed hol~s are filled with driven, body-bound turn bolts which dowel the structure to main-tain the assembly. geometry. Turn bolts and matching holes are marked so the crane may be reassembled square at the job site with no difficulty. The rigidity of these con-nections is such that, in normal service, the crane will remain square, especially in view of the fact that bridge drives are designed to apply equal motion to drive wheels on both ends of the crane; however, the following condi-tions or abuse can repeatedly overstress the connections to the point where the bolt holes are enlarged, leading to the crane taking a diamond shape and rapidly wearing out both wheel flanges and rail heads:
- a. Striking end stops at high speed.
- b. End stops not on a line square with runway rail.
- c. Rail span varies more than + 1/8" causing wheel flange on opposite corners at all times.
- d. Unequal wheel tread circumferences, causing crane to flange or loose anchor bolts.
- e. Breathing or swaying of columns due to spongy foot-ings or loose anchor bolts.
- f. Vertical waviness in runway rail, causing crane to wrap and twist.
'o
- 3. check a crane for squareness, drop blumb bob from identical points at four'orners of crane on end truck.
Most cranes have a machined surface on the bearing strap next to the axle. Drape the plumb line over the shaft at these points. Put center-punch mark under point of plumb bob, on runway grider top flange.* Check diagonals bet-ween punch marks with tape and scale. The two diagonals should not differ by more than 1/4" per 100 ft.
DURK NUMBKR REVISION NUMBER PAGE NUMBKR WP SS!
- 4. 'ffor the crane is suspected of being out of square, check the following structural and mechanical conditions:
- a. Check end trucks for damage, bending or cracks. See Figure 3.
- b. 'heck worn wheel flanges or runway rail worn on side of the rail head. If worn on inside flanges only, the'ail span is too short. If worn on outside flanges on two opposite corners, and on inside flanges on other corners, crane may be out of square or wheels are of unequal diameter, and running skewed.
C. Check bolts for tightness on truck ends, girder end connections and girder U
tie connections.
- d. If shifting of trucks is suspected, remove bolts and check for elongation of bolt holes or mashing of the shank on body-bound bolts. This will show whether truck has been moving relative to girders;
- 5. If crane is out of square, it will be necessary to realign crane with jigs. Jigs for realigning Whiting cranes can be rented on a per diem basis from Whiting. When the crane is realigned and before it is returned to service, it will be necessary to ream all accessible bolt holes and drive in larger turn-bolts.
- On some cranes, it may be perferable to drop plumb bob from center line of wheel tread to rail head and place center punch mark there.
M. ~Hk
- 1. Hooks shall be inspected for damage, corrosion, wear, cracks, twist and opening. Hook opening will be checked against the dimension of a new hook or by measuring bet-ween reference points if scribbed or center punched on the hook. Hooks with 15K more than original throat opening, 10 degree twist from original plane, 5X shank elongation or 10K wear in the throat section shall be replaced.
Later model hooks have center punch marks on them showing original hook throat opening. See Figure 4. At least once a year, regardless of external physical appearance and condition of hook, the hook should be checked for this dimension between punch marks and for cracks by magua-fluxing or some other accepted method.
DURE NUMBER REVISION NUMBER PAOE NUMBER I .4.1
- 2. Small nicks and scratches on the hook surface may be re-moved by filing or grinding.
- 3. Hooks shall be visually inspected daily at the start of each shift and shall receive a magna-flux/ultra-sonic in-spection annually.
- 4. Hook swivels shall be checked for freedom of movement and checked to ensure the swivel locking device is secure.
- 5. Make sure top nut on hook shank is secure and has not turned on shaft. Some are secured with a pin and others by a set screw. Make sure these are intact. Check hoof to see that it swivels easily and thrust bearing is in good condition.
- 6. The Reactor Building crane hook shall be inspected prior to each refueling outage.
N. h'ire Ro e Ins ection
- 1. All wire ropes will be inspected visually before each major use (50K rated load or greater). An inspection of all wire rope will be made during the annual crane inspec-tion and a dated report of the condition of the rope will be kept on file.
- 2. Sections of rope which are normally hidden during visual and maintenance inspection, such as parts passing over sheaves, should be given close inspection as these are points most likely to fail.
- 3. The following are items to be considered when inspecting wire rope:
a~ Reduction of rope diameter below nominal diameter due to loss of core support, internal or external cor-rosion, stretch, or wear of outside wires.
- b. A number of broken outside wires and the degree of distribution or concentration of such broken wires.
c~ Corroded or broken wires at end connections.
- d. Corroded, cracked, bent, worn or improperly applied end connections.
c~ Severe kinking, crushing, cutting or unstranding.
DURK NUMBKR RKVISION NUMBKR PAOE NUMBKR W$ 4 ddd 10.4. 1-12
- 4. The following items shall be cause for replacement of the wire rope being inspected:
- a. 3 broken wires in one strand of 6 x 7 wire rope.
6 broken wires in one strand of 6 x 19 wire rope.
9 broken wires in one strand of 6 x 37 wire rope.
- b. Wear of one fourth the original diameter of outside individual wires.
- c. Kinking,'rushing, bird caging, or any other damage resulting in distortion of -the rope structure.
- d. Evidence of heat damage from any cause.
- e. Reduction from nominal diameter of more than:
3/64" for diameters to and including 3/4"; 1/16" for diameters 7/8" to 1-1/8" inclusive; 3/22" for dia-meters l-l/4" to 1-1/2" inclusive.
- 5. Wire rope must be thoroughly cleaned before it is lubri-cated. All foreign material and old lubricant must be removed from the valleys between strands and the spaces between the outer wires. This can be accomplished with the use of wire brushes, scrapers and compressed air if necessary.
- 6. The reactor building crane (MT-CRA-2) shall use GE sili-cone grease 351N. All others shall use Texaco Crates "A",
C.W. Crown and heavy duty willrupe lube., and Shell Cor-dium EP Fluid F or approved equivalent.
- 0. Rated Load Test 1, Prior to initial use, all new, extensively repaired, and altered cranes should be tested and inspected by, or under the direction of, an appointed or authorized person and a written report be furnished by such person, confirming the load rating of the crane. The l.oad rating should, not be more than 80 percent of the maximum load sustained during the test. Test loads shall not be more than 125 percent
. of the rated load, unless otherwise recommended by the manufacturer. The test reports shall be placed on file where readily available to appointed personnel.
- 2. The rated load test, if made, shall consist of the follow-ing operations as a minimum requirement.
OURE NUMBER REVISION NUMBER PAOE NUMBER INP-II%!
- a. Hoist the test load a di'stance to assure that the load is supported by the crane, and held, by the hoist brake(s).
- b. Transport the test load by means of the trolley for the" full length of the bridge.
- c. Transport the test load by means of the bridge for the full length of the runway in one direction with the trolley as close to the extreme right-hand-end of the crane as practical and in the other direction with the trolley as close to the extreme left-hand end of the crane as practical.
- d. Lower the test load, and stop and hold the load with the brake(s).
- 3. Complete Rated Load Test Check Sheet P. 0 erational Load Test Reactor Buildin Crane MT-CRA-2
- 1. At the side of each refueling outage the reactor building crane shall be operationally tested by hoisting the top middle step plug (90 tons) and transporting it per steps 2a, b, c, and d.
- 2. The results of the test shall be recorded on the Opera-tional Load Test Check Sheet.
10.4.1. 7 Documentation "A; Inspection instructions and checklists will be maintained for each type and manufacturer of motor operated cranes and hoists.'nspection check lists will be used on all scheduled maintenance.
B. The completed checklist should be attached to its companion work request or PM Card. When both are complete, they shall be returned to the Shift Supervisor per PPM 1.3.7.
10.4.1.8 Attachments Motor Operated Crane and Hoist Inspection Instructions
/
A. Figure 1, Inspection for Drum Groove Wear B. Figure 2, Examination of Trucks PURE NUMBER REVISION NUMBER PAPE NUMBER 10.4.1 10.4.1-14
C. Figure 3, Squareness of Bumper Stops
- 0. Figure 4, Inspection of Crane Hooks E. Figure 5, Inspection for Wheel Wear F. Daily'or Pre/Use Inspection Checklist G.. Annual Inspection Checklist O RE NUMBER REVISION NUMBER PAGE NUMBER WMSl
FIGURE I INSPECTION FOR DRUM GROOVE WEAR
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METHOD I USING STRAIGHT EDGE OVER UNWORN ROPES NEAR ROPE ANCHORS MEASURE DEPTH (A) OF UNWORN GROOVE. THEN MEASURE DEPTH (B) OF ANY GROOVE WITH MAXIMUM WEAR.
WHEN (8) EXCEEDS (A) BY MORE THAN 25M OF ROPE DIA-REPLACE DRUM.
METHOD II USING LARGE CALIPERS TO DETERMINE (C) 8 (D) - WHEN THE DIFFERENCE BETWEEN (C) E (D) BECOMES MORE THAN 50% OF ROPE DIA', REPLACE DRUM.
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PROCEDURE NUMBER REVISION NVMBER PAGE. NUMBER 10.4.1 0 10.4.1-ZO
DAILY OR PRE/USE INSPECTION CHECKLIST Crane or Hoist Number Date I.TZM
- 1. Functionally test all controls, limit switches and stops.
- 2. Visually check for oil and hyraulic leaks.
- 3. Visually check hooks for cracks and deformation.
- 4. Inspect hook latches for proper operation.
- 5. Inspect crane for general cleanliness, guards installed on electrical components and warning devices operational.
NOTE 1 Check all limit switches without a load on the hook. Each motion shall be inched into its limit switch or run in at slow speed.
NOTE 2 The crane operator shall report any malfunction or problem in the above list to his supervisor immediately.
KDglK$4$MBKR REVISION (UMBER PAOE fgMgKf WP $ 90
ANNUAL INSPECTION CHECKLIST Crane or Hoist Number Date Inspector Item Remarks
- 1. Automatic hoist brakes.
- 2. Bridge and trolley brakes.
- 3. Nechanical load brakes.
4, Inspect gearcases for damaged or worn parts.
- 5. Check all bolts and rivets for tightness.
- 6. Check all couplings for loose bolts, elongation of bolt holes, and keys for tightness in keyways.
- 7. Check all wheel.s for flanging, flat spots and measure diameter.
- 8. Check all welds for cracks.
9 Check hoist drums and sheaves for wear.
- 10. Check runway columns for plumbness, being seated and being rigidly bolted to foundations.
Check that runway girders do not sag between columns.
.12 ~ Check girder connections to columns for tightness.
- 13. Check that runway does not sway or breathe as crane passes over.
- 14. Rails level within + 1/8" in 20 feet.
- 15. Rails straight within 1" in 400 feet.
- 16. Rail span + 1/8".
SDglKggMBKR REVISION )UMBER PAGEflUMgEf
Item Remarks
- 17. Rail joints closed and splice bars tightly, bolted.,
- 18. Rail heads not cracked, indented, spalled out, mashed down to a sharp edge or worn on a side.
- 19. R'il clips tightly bolted to runway girder.
- 20. Check that crane is square.
- 21. Check crane for structural damage.
- 22. Inspect end stops.
23+ Check for loss of camber in crane girders.
- 24. Inspect hooks, hook bearings and safety latches.
Inspect wire rope.
- 26. Check the following safety devices:
a ~ Footwalks, handrails and ladders.
- b. Fire extinguisher available.
c~ Warning device operable.
NOTE 1: If an item on this checklist is not applicable to the particular crane or hoist being inspected, mark the item NA in the Remarks column.
NOTE 2: The manufacturer's instruction manual and the inspection instruc-tions for motor operated cranes and hoists shall be used to perform this inspection.
Dlf(KgUfABKR RKVISION )UMBER PAOK WP SSI $ (M)K$
RATED/OPERATIONAL LOAD TEST CHECK SHEET CRANE EQUIPMENT PIECE NUMBER DATE OF TEST REASON FOR TEST (NEW CRANE, EXTENSIVELY REPAIRING, OPERATIONAL)
DESIGN RATING OF CRANE MAXIMUM CRITICAL LOAD FOR CRANE TEST LOAD USED HOISTED LOAD IS SUPPORTED AND HELD BY HOIST BRAKES TEST LOAD IS TRANSPORTED BY TRAILER FULL LENGTH OF BRIDGE TEST LOAD IS TRANSPORTED BY BRIDGE FULL LENGTH OF RAIL RIGHT HAND END TEST LOAD IS TRANSPORTED BY BRIDGE FULL LENGTH OF RAIL LEFT HAND END TEST LOAD IS LOWERED, STOPPED AND HELD BY BRAKES r
D RK NUhlBKR RKVlSION NUMBKR PAOK NUMBER 0 10.4.1-24
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INTEROFFICE MEMORANOU Distribution:
CI EDC WNP-1/4 WASHINGTON PUBLIC POWER SUPPLY SYSTEM NKI EDC WNP-2 C3 EDC WNP.3/5 0 Admin File EA Fredenburg - 906D KF November 2, 1981 BA Holmberg - 906D BAH/lb To: J. W. Hedges, Manager Maintenance, WNP-2 -- 907M EAF/lb
- c. 'sf 2 pf 1 From: B. A. Holmberg,. eputy Project Manager-Engineering, WNP-2
Subject:
SINGLE FAILURE PROOF REACTOR BUILDING CRANE
Reference:
(1) Whiting Corporation letter to Burns 8 Roe, dated September 19, 1975 (Transmittal No. 39)
(2) BRWC-31A-76-006, dated February 13, 1976 (3) Conference Notes No. 473, (BRWP-76-595)
(4), Whiting Corporation letter to Burns and Roe, September 1, 1976, including "Crane Characteristics List", Rev. 1 (5) Tech Memo 989, Rev. 1, (BRWP-77-1113)
Following is our response to your request for assistance in identi-fying references for design and characteristics of the reactor building crane, per NUREG 0612, Appendix C.- If Project Engineering can be of further assistance in developing a response to the December 22, 1980 NRC letter on "Control of Heavy Loads", please advise.
(1) Allowable Stress Limits:
o Ref. 3, pg. 12, item B.l.b: "Maximum allowable stress for, any member under tension or compression subject to repeated load is 17.6 psi, which is less than 1/2 the yield stress for this material (ASTM A36)."
o Ref. 3, pg. 14, item B.3.a: "Dual load attaching points, consisting of sister hook and eye block, can each safely support a static load of 3.9 times the design rated load."
o Ref. 3, pg. 15, item B.3.d: "Load block can support 4.83 times the design rated load."
o Ref. 3, pg. 16, item B.3.e: "Stress in lead line is 16%
of, rated, vs. 20% allowable. Static stress in rope is 10.4% vs. 12.5% allowable."
o Ref. 3, pg. 18, item B.3.g: RVertical hoisting system components are designed to sustain 265% of design load, vs 200% NRC requirement."
WP.102 R2
~A/'6 < ~ 5 MAo
F-81 11 JW Hedges Nove r 2, 1981 Pa'ge 2 (2) Minimum 0 eratin Tem erature:
o Drop weight tests, or Charpy impact tests have not been per-formed on the reacto~ building crane. Typical values for NDTT for A36 steel are 40 F. (Ref. 3, pg. 12, item B.l.b).
o NUREG-0554, Section 2.4, says that as an alternative to impact testing, to determine fracture toughness properties and minimum operating temperatures, the crane may be operated only at temperatures above whi ch it was cold-proof tested at 125!
of rated load, followed by periodic nondestructuve examination of welds whose failure could result in drop of a critical load. Temperatures measured in the reactor building refueling floor e)evatiIIn during the 156 ton (125Ã) static load test were 64 - 60 , between 10:05 AM until 3<05 PM. Therefore, as long as the crane isIoperated above 64 F, it need not be retested or fracture toughness tested. (Ref. Reactor Building Crane load test report)
(3i ~50 Crane is designed as Seismic Categoy l. (Ref. 3, item 1C). Also see Contract 31A vendor submittals including seismic calculations, approved by Burns and Roe, and Reference (3), item B.l.c.
(4) Controls and Limitin Devices Ref. 3, page 14, item B.2 and Ref. 4, item 2a: More than one
'device would have to fail simultaneously for crane to be unable to stop and hold load.
o Ref. 5, and WPBR-77-457: Redundant lower limit switch for main block travel, redundant equalizer bar travel limit switch, and upper limit mechanical paddle type limit switch to prevent two-blocking and load hangup have been added to the reactor building crane.
o Ref. 3, pg. 19, item B.3.i: "...electrical controls ensure hoist motor power will cease prior to reaching 175Ã of full-load-motor torque."
o Ref. 3, pg. 20, item B.3.m: The mechanical brake will auto-matically set and sustain the load under any failure of any component upstream from the brake, including motive power.
~ )
~
JW Hedges-Page 3 November 2, 1981 (5) Wire Ro e Reevin S stem:
o Ref. 4, item 3f: A dual reeving system is provided. See Whiting figures T-55301 and T-55302.
o Ref. 3, pg. 15-18, items B.3.c to B.3.f: Description of dual reeving system is provided.
t6l ~si D 0 Ref. 3, pg. 18, item B.3.h: "Means are provided to sense electric current, temperature, overspeed, overloading, and overtravel."
Ref. 5 and WPBR-77-457: Redundant lower limit switch, equalizer bar limit switch, upper, paddle type limit switch, and critical travel path, limit switches to prevent travel over the spent fuel pool have been provided.
(7) ~T-B1 ki o See item (5) above.
o Ref. 3, pg. 19, item B.3.j and Ref. 5: A redundant upper "paddle type" limit switch has been added to prevent two-blocking.
(8) Ho'istin Drum Failure:
o Ref. 3, pg. 20, item B.3.k: The main hoisting drum has physical retainers to maintain the drum and gear mesh in the event the drum, shaft, or bearings fail.
(9) Limit Switches:
o Ref. 4, item 2a, 3h, and 3r: Limit switches and backups for crane travel and load travel are provided. Redundant limit switches were added as indicated in item 4 and 6 above.
(10) Cold Proof Test See item 2 above, and Contract 207 Transmittal No. 256.
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PROPOSAL SPEC IF l CATlONS WASHZNGION PUBLIC POLKR SUPPLY %'BTBf HhHPORV. UNIT NO. 2 Richland Mashingtqp Proposal No, .C-.2444................ C learance Sketch No, -B- November 16, 2972 Iten B CAPACITY:
Main Hoist (Vertical Lift) ...'............... tons; Aux. Hoist (Vertical Lift),---
~ ~ ~ 15
-- tons SPAN: {Center to Center of runway rails)226... ft..;...1&..... in.
J IFT (Vertical travel of m'ain hook).............. ft..........0.......... in. A~ilia y>
ELECTRIC CURRENT. 3 phase, 60 cycle~460 voltsalternating current SPEEDS: Approximate speeds in feet per minute:
Main Auxiliary T rolley Bridge Hoist Hoist T raver se T ravel Full load 55 pm 20 Fm Speeds; No load 5~ re 20 Zm Motor horsepower 60 Motor speed RPM 1200 900 Motor Frame No.
Louis Allis, llcstinghouse, General Electric, or equal, selection by Whiting, enclosed, ball bearing, vound rotor, crane type motors, vith Class B insulation,
'ated 60 minute 75 C rise.for:hoists; 30 minute 75o C rise bridge and trolley-Squirxel cage gearhead inching drive motors rated continuous duty 75o C riie.
Hotors vill comply vith NBA standards.
Vhi.ting fu22 magnetic reversing variable speed type, in NBfA 3 en-CONTROLLERS,'losures, vith overload protection,'complete with Bless 262 resistors Sec page 8. Hoists arranged vith Whiting eddy current braking control vith Class 162 resistors to allov full motor toxque on 1st point hoisting SWITCHBOARD and 50K motor toxque on 1st point lovering. Plain reversing bridge and
'rolley, vith bridge control being quadruplex type with modified Selsyn resistor Tie. CLutch coupled single speed reversing inching drive con-txol. for hoists.
MAGNETIC BRAKES Hanual magnetic main line disconnect svitch, Two (2) Whiting 13" GESA, electric operated, oil immersed, self-ad)usting solenoid brakes per Bulletin'CE-2 plus AB-706 eddy current brake complete vith rectifier for main hoist.
Tvo (2) 13." SESA brakes plus AB-705 eddy current brake complete vith rc8~r for
%HnlXG Cna&am'law P.RO POSADA S P ECI F I CAT lONS November 16, 1972 P opo~i No,....'.-.'-.244.4............... Date.. Page.....,..."..8.".....
Item B WHITING MAGNETIC CONTROL'hiting magnetic controls provide variable speed for each crane motion by means of variance of motor secondary currents through resistors.
The number of steps of control in each direction will be as indicated; was ~
Main Hoist Steps
'uxiliary Hoist II
" plus Trolley Trave 1 'drift Bridge Travel 'lus drift point point Each control panel consists of a three pole reversing contactor for handling motor primary current and the pxoper number of accelerating contactors for
.handling of the motor secondary current through the resistors. All contactors to be solenoid operated type, Overload relay provided on reversing contactor to prevent damage to motor, control or wiring system in case of current overloads. Contactors are mounted on steel panels and neatly wired with control circuit wires ending at a terminal board to facilitate proper connections. A time delay relay is included between all control points, except 1st and 2nd points on 5 step control.
Controls are furnished in gasketed sheet metal enclosures with hinged doors.
NEMA class 152 resistors (unless specified elsewhere) are provided for each motion to give proper secondary currents for smooth acceleration.
.og. peg,.,conte~ed cxpqps,<<,.<4, . w~h-.gaz~gootgan~&H.~~gyeided (cog'gaijf byi~~illO~gi~for,
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hS hopis'hp.+,~;i~@~is:"- ei:,,, M 556eqjs,Appar, ,,u"4E eg"e'Q'a'h'ijugK-ijjiii+~r<which..ke;.Qacledadg-mha ~a~lk
- 5)gg.,jig. 'i'phjjpiratox.,ooap,ng-,&..contact>wk,th-,)4jh'vol~j~s;;;;.piwt~riswi~Qg
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For floor operated cranes - A pendant pushbutton station will be provided which operates the contactors on the control. panels by means of pilot currents only, obtained through a transformer which is included, thus eliminating danger of crane operator coming in contact with high voltages.
Crane is arranged for floor operation.
N-2836
PROPOSAL SPEC) F)CAT) ONS C-2444 Proposal No....,....--..----
SHclge Page ...
Itea. 3
':a'l Bridge End Trucks: 1'eldcd box section per Unit, 83 with ~ 16 whee 1 cqualiz ing bogia type construction, pin connected as shown on page with fixed saddles. I
%'heel Diameter 16 6 27" Materi,l Ro1led Steel , .,..... ', I Bridge Drive:
gator, double reduction pex'nit 58 plus an enclosed Abart speed ~ r~ .-
p r ~ reducer located between eotor and double reduction unit. at each corner of bridge. Floating shaft with half-flexible coupling con-necting gearcaso output direct to wheel axles. A total of four (4) wheels driven.
"Brldgc Brake:
Four (4) Kthfting 6" ."ESA, electric operated, oil imtsersedself-ad)usting solenoid brakes per Bulletin CE-2.
Girders v g ~
~
lfelded box sections por Vnit 31.
Cage: C'pen type csb located at end of span with apron, shelf at front for ctounting of pendant station fox cab oparation, seat, foot gong, g0 CO2 fire extinguisher, and laddex to walk.
Bridge Conductors:
Znsu1.-8 or equal.
Footwalk:
All steel Cootwalk closed to girder extending Cull length oC bridge on drive side all similar to Unit 60.
plus a drive support platforat at each cnd with crossrailinga'umpers:
Four xubber bumpers provided on end trucks.
Runway Collectors:
Inaul-8 Runway Conductors and Fiuings Copper clad consul-8 runway wixing complete with hardware for runway 146'0" long.
Lubrication:
All crane bearings Inside oC gear cases are splash lubricated.
Other bearings arc lubricated by High speed gearing ls splash lubrl~~f te grease fittings, N 2833
WEH1'MIH II" HHPDIRT1DM PROPOSAL SP ECI FI CATIGNS Proposal No.
c-2444 'II'mlles Page ...
t'w '
Trolley Type:
~ Three........ motor type similar ln general design to that shown on Unitgekmdnt ...................... with l.'t welded steel frame.
g~
Center to center of trolley raljrt.
26'0" Trolley Drive: Enclosed speed reducer type as on Unit 23. crept to be throe reduction type<
Wheels:
Djameter Material .30LLOd...8keQL.......
60" 8rl r t' h'lain Hoist dla. Aux. Hoist .......,.........>.................. dla.
Ropes: h'lain Hoist. 12...plots...L..3/8."....................... Aux. Hoist .4...paxt6...),gg.!............,.
S lice e lubricated a1loy steel - 04 S ainle s Steel vith Limit Swnch:
Gcxav typo plus vaight operated contxol cixcuit type fox upper and 1ovox hoist iimits.
Hoist biechanlsms:
Similar to that shown nn Unit Zg with mechanical load brake,
~ pO P J ~ gasr xeductions on stain hoist. pV( C4 Load Block:
Main - Rodundrtnt type with bxon"e bushed sheaves.
hux. - 4ith bronse bushed sheaves.
Trolley Brake:
Tvo (2) Vhiting SESA brakes pex Bulletin CE-2.
Collectors:
Xnsul-0 ox equal.
Stops:
pour rubber trolley bunpers.
N-2834
v \' ~
iv
/
PROPOSAl.
SP ECl F I CATlONS I C-2A44 November 16, 1972 - ll i proposal Na,...lt...-..3---- Pa c r ~
P' GENERAL DESI GN CRITERIA: All crane parts shall equal or exceed design criteria as I established by C.M.A..A. Specification 870.
This proposal covers equipment which comp1ies with the mandatory requirements of the William-Steiger Occupational Safety & Health Act of 1970 {OSHA) as ammended August 13, 1971:'.
ASSKHBLY: Crane will be assembled at our works, marked for reassembling, and taken apart sufficiently for proper handling and shipment.
PAINTING: The crane'ill be cleaned and painted using a rust inhibiting "'.,
primer, and a finish coat of Colonial Yellow enamel.
Special painting if Tri>>polax White Prhoer.
required to be as follows: 3 ail m, i%D40, lgr d%
Electrics'I -equipment and purchased components 'will be furnished with manufacturex' standard finish.
SPECIAL CRANE DESIGN FEATURES:
Seismic calculations included by Option C method and based on exception to seismic critexia as noted.
t.'4>"
'hfalk-in" type girders to meet seismic and access requirements. I Earthquake up-kick lugs and tornado lock bars an bridge and trolley trucks, I<v Toznado racks included for bridge tx'avel oa one girder.
/th runways and trolley travel along Controls and xasistozs on ~ralk. Pendant station on motor driven reel with manual travel slang acsscncr trscI: undor csh gtrdcr ulth pash button control of cll actions sad real motor in pendant station. Push butt:on unit far xeal motor also in cab.
Track typo bridge and txalley limit switches.
Tool box and standard maintenance tools on walk.
Six (6) 1000 watt incandcscsnt floadlights (exclusive of bulbs) mounted fn walk>>.
galk, cab and contxol anclosuxe lightings Service receptacles on walk and in cab.
Gixdcr end connectians limit hook approaches at both ands of crane due to hoxisantal seismic critexia.
Certified material taste and xeports provided foz hooks, hoist xopcs, and load carryKhg structural members an1y.
Lifting lugs on sub-assemblias. s Steel drums and live sheaves at 24 xope diameters minimum.
Hain hoist redundant reeved and provided with safety lugs and shock absorbing equaliser assembly to prevent loss of load due to rope, drum shaft, or sheave shaft failure.
-Hain hoist machinery redundant except single drum right and left grooved.
blocks with bronxa bearing sheaves, stainless steal hook thrust bearings, and I'oth special painting fox underwater aperation.
Auxiliary hook, emiliaxy chum, and auxiliary rope stainless steel.
N-21S3R1
'%HIVING II:GRPISEATIDN
'te.
y fV PROPOSAL S P EC I F I CATIONS November 16, 1972 Page.......... 12.....
Proposal No
~Secial .:rane Desi Features cont'd.......
Hooks 200/ load and magnetic particle tested.
Load sensing system for overload and slack line limit signals on each hoist vith limit ad)ustmcnts at trolley on1y.
Wo brakes on each hoist and on trolley drive.
Eddy current speed control on hoists.
Bridge Weight: 700,300 lbs. Trolley Height: 166,350 lbs.
DEVIATIONS PROH SPECIPICATIO?iS:
Crane design based on use of 2/ damping curve on both SSE and SSE/2,and increasing SSE stres* Limit in accord vith AISC seismic criteria>allowances.
- 2. Stepped magnetic controllers and continuous duty inching drives provided on: "i ~,;; ":
a11 hoist motions for maximum safety without time lhnitations in all and compatkbiligy with mechanical load braking on both hoists.
spotting'='perations Stepless controllers and load floating not included.'
N ~ 2110
page C-2444 Proposal Y '"""If:em "B "" PROPOSAL Sketch Date November 16J .1972 a
The clearance dimens.'ons of thc electric crane covered by accornpanJ.I:Ig p:oposat are given
~r on diagram below. The mcus rcmenls conform to our regular pracuce and vzfri govern unless changes (subject to extra chcrg.) cte '"pec:i!cally made in the order.
125 ...... ,......... ........... tons Capacity of main hoist........
Capacity of auxiliary hoist... ..15 .....tons x5 + Elev. 652'2>" minimum e
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(ALLOVI FOR S*GI
]5 I 9 3/41I 7 ] II l3'9-I I
~I rr 9
~AUX. HOIST View LoolJieE East cab on fear sade 16'9- 3/4ll Lo pt. ele ttl IJ 0J 632llpg" 0 z
Hi"pt ~
E I R Eye g I IvthlN FEED WIRES ON 10 l7l II I Elev. 634'P II RUN'sVAY ADJACENT TO V I
V I tl CAGEr KXTRA HARGK IF LOCATED ELS CW HKR E sr t .rr
~a If ~.JIAIN HOOK MAiN HOOK C Mt el 2 MIN.
126'1" 1/8"'PAN KXTREMC OF CRANC PLAN VIEI.fif NOD>>
29 '0 I 22 I 6lt
- ,
TRAVEL OF HOO ~ 26 I 0 "~~ExTREME OF cRAN wain 190'0" 26'6" C Ito CI irders Aux. 193'0" r I
(L I
4 I 0 II tPII 1416 l4 tP tPII 4 tPII Elevation Mnx. Lcno Pe'R Vi:asst 97,600
~ L $ 606 '0"" 2 A.S.C.E. S 'D RUNWAY Rn:I Los.
DO NOT It;-.= IOH EmCTION 161 '0"." e f fec t ive s
I Blue prints shov;insg a..cage. Knt of patas for use in both hoists erecting will lfe fatti>M a
LO'IVEST LF V"L BELOW FLOOR I wr LINE TO DE SERVED BY CRANE.
SISS ~ 'TEP I I V ' N 2st7I rss res