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ENCLOSURE 2 ATTACHMENT 2 "Steam Dryer Vibration Instrument Installation Procedure," GE Specification 26A6492-NP, Revision 2, Non-Proprietary, dated April 22, 2005
ENCLOSURE 2
ATTACHMENT 2
"Steam Dryer Vibration Instrument Installation Procedure," GESpecification 26A6492-NP, Revision 2, Non-Proprietary, dated April 22,
2005
0 GE Nuclear Energy 26A6492-NP SH NO. II REV. 2 OF 35 _REVISION STATUS S}IEET
DOCUMENT TITLE STEAM DRYER VIBRATION INSTRUMENT INSTALLATION PROCEDURE
LEGEND OR DESCRIPTION OF GROUPS TYPE: INSTL SPEC
FMF: QUAD CITIES 2 (PROCEDURE)
MPL NO: N/AI - DENOTES CHANGE
SAFETY-RELATED CLASSIFICATION CODEQ
REVISION CFEB 21 2005
0 RMCN05632MAR 29 2005 1
I RS TSUKIDA I RJARMCN05957ENGR: RS TSUKIDA
APR 22 20052 RS TSUKIDA RJA
RMCN06057
MADE BY APPROVALS GENERAL ELECTRIC COMPANY02/03/05 02/21/05 175 CURTNER AVENUE
R. TSUKIDA R. TSUKIDA SAN JOSE CALIFORNIA 95125CHKD BY: ISSUED 26A6492-NP
FEB 21 2005NA RJ AHMANN CONT ON SHEET 2
MS WVORD (2/98)
W GE Nuclear Energy
IMPORTANT NOTICE REGARDING
CONTENTS IN THIS DOCUMENT
Pertaining to Proprietary Nature of this Document
26A6492-NP SH1 NO. 2| REV. 2 OF 35 _
The only undertakings of the General Electric Company (GE) respecting information in this documentare contained in the contract between Exelon and GE, and nothing contained in this document shall beconstrued as changing the contract. The use of this information by anyone other than Exelon, or forany purpose other than that for which it is intended is not authorized; and with respect to anyunauthorized use, GE makes no representation or warranty, express or implied, and assumes noliability as to the completeness, accuracy, or usefulness of the information contained in this document,or that it use may not infringe upon privately owned rights.
This document contains information that is the property of GE and/or its suppliers and subcontractors.It is furnished to you in confidence and trust. Information contained herein shall not be reproduced,disclosed to others, or used for any purposes other than those designated by GE. However, this doesnot alter in any way the rights and obligations defined by applicable contracts.
This is a non-proprietary version of the document 26A6492-P, which has the proprietary informationremoved. Portions of the document that have been removed are indicated by an open and closedbracket as shown here [[ ]].
Relating to General Contents
Work step sequences in this procedure may be changed or altered at the discretion of the GE ProjectManager or responsible Site Engineer, provided they do not affect quality or violate any approvedspecifications and may need further review by station work planning and refueling personnel.
Unless a +/- tolerance is specified, gauges and measurement devices do not need to be calibrated.Gauges are for reference only. "Approximately" in this procedure is defined as roughly +/- 10% ofnecessary gauge reading. When instruments requiring calibration are needed, the instrumentidentification number and calibration due date will be documented on the appropriate work document,and may require review by site station work planning and refueling personnel.
* GE Nuclear Energy [
INSTRUMENTED STEAM DRYER INSTALLATION
1.0 SCOPE
Z6A6492-NP SH NO. 3REV. 2 OF 35
2.0
1.1 Purpose: The purpose of this document is to detail the procedure for completing theinstallation of the Flow Induced Vibration instrumentation during the installation of thenew steam dryer and reactor vessel head at the Quad Cities Unit 2 site. The vibrationinstrumentation, partially installed at the dryer fabrication shop, is then transported tothe site (not covered in this procedure). This document covers from the receivinginspection sensor checkout to post-installation checkout of all sensor prior to finalreactor head closure at the Quad Cities site. Reactor re-assembly procedures is coveredin other document. The dryer vibration instrumentation is associated with the steamdryer vibration and acoustic pressure measurement during reactor startup operation.The final installed configuration shall be documented and included in the DesignRecord File.
1.2 The scope shall include preparation of final installation of the new steam dryer'svibration instrumentation and final testing at the Quad Cities site.
1.3 The final site preparations shall include mast and vibration instrumentation installationand any modifications or testing up to and including the reactor instrument nozzleflange bolting, covered in this document.
APPLICABLE DOCUMENTS
2.1 Applicable Codes. Standards. The following documents form a part of this installationprocedure to the extent specified herein.
2.1.1 ASME Boiler and Pressure Vessel Code, Section 111, forNuclear Power Plantcomponents.
2.1.2 ASME Boiler and Pressure Vessel Code, Section IX, Welding Qualifications
2.1.3 National Electrical Manufacturer's Association (NEMA) Standards
2.1.4 Any Applicable Local Codes, Standards, Requirements, and Procedures required bythe Quad Cities site.
0 GE Nuclear Energy 26A6492-NP SH NO. 4REV. 2 OF 352.2 Reference Documents. The following documents may assist the user
2.2.1 23A6395, Reactor Internal Vibration Instrumentation Design Specification2.2.2 209A7243P004, Clip for Vibration Test Instrumentation2.2.3 1 12D4859, Test Brackets, Conduit Clamps with Bolted Latch2.2.4 352B2248 Mounting Pads (2"x3",I"x2"), Conduit Clamp/Accel Mounts2.2.5 143-104-000-D60 1, Pressure Transducer Type CP- 1042.2.6 143-211 -000-D072, Pressure Transducer Type CP-2 11 (Internal)2.2.7 809-104-000-DOI 1, Floating Clamp Nut Type MA- 104 (for CP-21 1)2.2.8 144-901 -000-D50 1, Accelerometer Type CA-9012.2.9 KHC-I0-120-G9, Kyowa Strain Gage (with 321SS Flange)2.2.10 Reuter-Stokes Outline RS-E8-1000-208 String Assembly A (A,B,C,D)2.2.11 Reuter-Stokes Outline RS-E8-1000-209 String Assembly B (E,F,G,H)2.2.12 Reuter-Stokes Outline RS-E8-1000-210 String Assembly C (J,K,L,M)2.2.13 234C6971, Mast Assembly with Welded Parts2.2.14 284X898, Mast Master Parts List2.2.15 234C7084, Mast Assembly with Parts List2.2.16 234C7001, Mast Base Arrangement on the Dryer (Dryer Weld)2.2.17 343A2292, Lock Washer for Mast Clamp (Matl Inconel X-750L)2.2.18 QC2 Penetration Bolt & FIV Sensor String Design Spec.2.2.19 QC2 FIV Instrument Flange Design Specification2.2.20 E8-1000-203-81, Reuter-Stokes Washer for Penetration Bolt2.2.21 E8-1000-208-74, Reuter-Stokes Nut for Penetration Bolt2.2.22 26A6159, Dyn Press & Vib Monitor Sys, RPV Penbolt Assy Design Spec2.2.23 P50YP102, Arc Welding, Austenitic Stainless Steel Process Specification2.2.24 21A8675, Resistance Spot Welding (RSW) of Strain Gages2.2.25 26A5975, Instrument Flange Design Specification2.2.26 P5OYP211, Cleaning and Cleanliness Control of Reactor Sys Components2.2.27 P5OYP215, Capacitor Discharge Resistance Spot Welding (RSW)2.2.28 E50YP38, Resistance Spot Weld, Peel Test2.2.29 234C7124, Pressure Sensor Mount Bracket (6" cover, I-slot, CP-104)2.2.30 234C7125, Pressure Sensor Mount Brkt (6" cover, 2-slots, CP- 1 04/CP-211)2.2.31 234C7126, Pressure Sensor Mounting Pad for Dryer Hood Covers (flat ring)2.2.32 234C7127, Presssure Sensor Mounting Pad for Dryer Skirt Covers (RI 19.5")2.2.33 234C7128 Sh 1, Pressure Sensor Mounting (CP104 inside cover)2.2.34 234C7128 Sh 2, Pressure Sensor P23 Skirt Mounting Pad for CP-1042.2.35 352B2245, Nut Lock CP-211 for Floating Clamp Nut at P13, P142.2.36 EEI-10-1010010, Flange Mockup Stand (Tripod type stand)2.2.37 E8-1000-208-81, Instrument Flange (with 3 holes on 3.00" B.C.)2.2.38 26A6484 Functional Test Procedure for Sensors in String Assembly2.2.39 26A6499 Data Acquisition System Installation and Test Procedure2.2.40 26A6274 Steam Dryer Fabrication Specification2.2.41 E8-1000-203-72, Reuter-Stokes Gasket for Penetration Bolt
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2.3 Supplemental Documents. The following documents may assist the user to understandthe installation and testing procedure to the extent specified herein.
2.3.12.3.22.3.32.3.42.3.52.3.62.3.72.3.82.3.92.3.102.3.112.3.122.3.132.3.142.3.152.3.162.3.17
GE-NE-0000-0030-1244-01, Steam Dryer Instrumentation Philosophy124D 15 18, New Steam Dryer, Top Assembly26A6380, Dryer Hammer Test Specification105E3902, Instrumentation and Data Acquisition Wiring Diagram26A6366, FIV Sensors, Signal Conditioner & Data Acq Sys for Dryer Test352B2191, Penetration Bolt A, Sensor String Drawing352B2192, Penetration Bolt B, Sensor String Drawing352B2193, Penetration Bolt C, Sensor String Drawing25A5900, Foreign Material Exclusion Design SpecificationWPS-8.43.3/PQR-27, Weld Austenitic SS and Inconel22A4202, Rx Assy, Welding, Cleaning, Exam, and Storage Specification26A5734, Reactor Internals Modifications, Fabrication SpecificationWelding of CP- 104 (P23) to Mounting Pad Attached to Skirt with Hole26A6443, New Steam Dryer Installation SpecificationReuter-Stokes E8-1000-208-l l OX Conduit Clamps (A=1, B=2V, C=2H)Steam Dryer with Vibration Instrumentation Modification Drawing (later)Kyowa Strain Gage - Construction, Features and Gage Installation
3.0 MATERIALS REQUIRED (AT QUAD CITIES SITE)3.1 The following Table I is a list of items required for installation of the steam dryer.
TABLE 1 - List of Required hardware and Equipment
ID ITEM DESCRIPTION Ref ID Dwg# Qty Supplier/Resp Notes1 New Dryer w/ Instruments+Mast 234C6821 f[ General Electric (Draft)2 Mast Assembly and Parts List 234C7084 General Electric3 Mast Mounting Fastener-Screw I 343A2289 General Electric4 Mast Mounting Fastener-Screw 2 343A2290 General Electric5 Special Hex Nut (Jam Nut) 343A2291 General Electric6 Mast Clamp, Star Washers, X-750L 343A2292 General Electric No tack weld
____ ___ ___ ___ ____ ___ ___ ___reg 'd
7 Mast Mounting Fastener-Screw 3 343A2293 General Electric8 Washer, I"ODx.53"lDx.09" 304L 343A2294 General Electric9 Penbolt (Nuts, Gaskets, Washers) E8-1000-208-98 Reuter-Stokes 2 of each per kit10 Instrument Flange Spec (new 3- 26A5975 Reuter-Stokes I spare as_ hole) backupI Mockup Flange Supt Std xv/ Clamps N.A. General Electric12 Penbolt Nut Crowfoot N.A. General Electric13 Flange Lifting Bail N.A. General Electric14 Instr Nozzle N6A Fig Fasteners N.A. Exelon Site Suppl. Re-use from
disassy15 RPV Hd/Gasket/Studs/lnsulation N.A. Exelon Site Suppl. Re-use from
I 11 disassy
0 GE Nuclear Energy 26A6492-NP SH NO. 61 REV. 2 OF 35 _3.2 Table 2 is a list of requested equipment/material, for use at site during installation.
TABLE 2 - List of Equipment and Materials at Site
ID ITEM DESCRIPTION REF ID/DWG No. QtO SUPPLIER/RESP NOTESI Torque Wrench, 3/4" Drive, 0-250 fl-lb. N.A. I Exelon Site Supplied With Calibrat'n Certs2 Tack Welder and Weld Rods, Cert A.R. N.A. AR Exelon Site Supplied Re-use from disassy3 O/H Crane, Rigging, Slings, N.A. AR Exelon Site Supplied Re-use from disassy
Shackles,etc4 RPV Head/GasketlStudsflnsulation N.A. AR Exelon Site Supplied Re-use from disassy5 Work Platform/Planks for Top of Dryer N.A. AR Exelon Site Supplied Re-use scaffold plank6 Ladder or Work Scaffold w/ Planks N.A. AR Exelon Site Supplied Top Mockup Access7 Personnal Protective Device, Rad Monit. N.A. AR Exelon Site Supplied Site/OSHA Re mts.
3.3 Table 3 is a list instruments and materials installed on the newv steam dryer at thevendor's shop. Quantities listed are total supplied at the vendor shop, not as-built.
TABLE 3 - List of Installed Vibration Hardware
ID ITEM DESCRIPTION REF ID / D'G NO. Qty SUPPLIER/RESP NOTES1 VIB Sensor String wI Certificate RS-E8-1000-208 [[ Reuter-Stokes Certs with QC2 VIB Sensor String w/ Certificate RS-E8-1000-209 Reuter-Stokes Certs with QC3 VIB Sensor String w/ Certificate RS-E8-1000-210 Reuter-Stokes Certs with QC4 5 Tube (Conduit) Bracket Assembly 112D4859G002 Reuter-Stokes Need as-built qty5 4 Tube (Conduit) Bracket Assembly 112D4859G003 _ Reuter-Stokes Need as-built qty
6 3 Tube (Conduit) Bracket Assembly 112D4859G005 Reuter-Stokes Need as-built qty
7 2 Tube (Conduit) Bracket Assembly 112D4859G004 Reuter-Stokes Need as-built qty
8 Conduit Clamp (Single Tube) E8-1000-208-1 10A Reuter-Stokes Need as-built qty9 Conduit Clamp (Double-Vertical) E8-1000-208-1I OB Reuter-Stokes Need as-built qty10 Conduit Clamp (Double-Horizontal) E8-1000-208-1 IOC Reuter-Stokes Need as-built qtyI Pad 3- Permanent 2"x3"x114" 304L 352B2248P003 General Electric Certs with QC12 Pad 4- Permanent l"x2"x114" 304L 352B2248P004 General Electric Certs with QC13 Clips - for RSWelding Ml Cable 209A7243P004 General Electric Certs with QC14 Mast Bracket for Press Assy (P26) 234C6976 General Electric
15 Mast Bracket Assy (Conduit Clamp) 234C6983 General Electric
16 Mast Gusset Bracket (5-Cond Clamp) 234C6987 General Electric X _ _ _ _
17 Mast Base (Main Base on Bank D) 234C6996 General Electric
18 Long Gusset Base (Base on Bank C) 234C6997 General Electric
19 Union Support Bracket (Block Hl) 234C6982 General Electric
20 Pad 2-Mast Mounting Bases 234C6994 General Electric _
21 Pad 1-Mast Gusset Mounting Base 234C6995 General Electric22 Mast Base Arrangement-Dryer Weld 234C7001 General Electric23 Cover Plate 6" Dome (single slot) 234C7124 General Electric Certs with QC
24 Cover Plate 6" Dome (dual slot) 234C7125 General Electric Certs with QC
25 Sensor Mounting Pad (flat ring) 234C7126 General Electric Certs with QC
26 Sensor Mounting Pad (skirt RI19.5") 244C7127 General Electric Certs with Qf;
27 Skirt Pad, Mounting (P23, CP104) 352B2246 General Electric Certs with QC28 Nut Lock CP21 I (Inside P13, P14) 352B2245 11 General Electric
0 GE Nuclear Energy
4.0 RESPONSIBILITIES
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5.0
4.1 The Installer shall accept responsibility for one's work. The Installer shall comply with therequirements of this document and the supporting documents listed herein.
4.2 The Installer shall take responsibility for coordination of one's work with others, includingthe coordination of work planning and radiation monitoring with the Plant Owner.
4.3 The Installer shall be responsible for providing any specialized handling, alignment,and installation equipment, as may be necessary to perform this work, except asotherwise agreed to by the Plant Owner.
4.4 The Installer shall supply qualified personnel for supervision and for performing therequired tasks to complete the installation of the new instrumented steam dryer.
REQUIREMENTS (PRE-INSTALLATION)
5.1 The new steam dryer work area for the final installing of the vibration instruments shallbe reviewed for safety and compliance with site practices and procedures.
5.2 The dryer shall have safe access for personnel (i.e. erecting scaffolding, handrails, orproviding ladders for access, etc). The top shall be reviewed for use of a work platform(perhaps same as used at vendor's shop or aluminum scaffolding planks if acceptable).Handrails and other personnel protective safety devices and items, including radiationmonitors, shall be provided as required.
5.3 Overhead crane(s) shall be operable and available for use during the vibrationinstallation, along with slings, shackles, chainfalls, rope and other rigging devices.
5.4 The top of the dryer shall be accessible for re-mounting vibration instrumentationrouted on top of the dryer and up along the mast and finally up through the nozzle tothe instrument flange of nozzle N6A. The top work platform requires some sections beremovable for any required work access or inspection.
5.5 The area shall be approved for potential welding and tack welding fasteners and for anyresistance spot welding (RSW) of clips for mineral insulated (Ml) cable or strain gagesif required. Tarps or other site approved material shall be used to control debrisgenerated from any required welding and final installation.
5.6 The dryer surface and installed vibration instrumentation should minimize contact wvthnon-reactor approved materials. This includes tooling, test equipment, hand tools,
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rigging, lifting devices, etc. Follow station FME system or procedure which mayinclude a specific area designated to control such items.
5.7 Immediately after vessel head removal, it is critical to check the blank instrumentflange seal of nozzle N6A. This is to verify the new supplied instrument flange has thecorrect small tongue groove for proper seal with supplied gasket when the reactorvessel head is re-installed later in the outage. Verify it with the correct suppliedinstrument flange or immediately send the spare blank unmachined flange to a machineshop to have it properly machined before vessel reassembly.
5.8 An aluminum mockup instrument flange (with the three penetration bolt slots) is usedwith the flange mockup support stand for proper positioning, orientation and elevation.The stand is a tripod, temporarily attached to brackets on top of the dryer using SS C-clamps. Note orientation is not critical, original design had penetration-B bolt holefacing -0 degree azimuth, penbolt-A facing the -120 deg azimuth and penbolt-C holefacing the -240 degree azimuth. The mockup is designed with a nozzle opening of
]]. See mockup flange support (tripod) and the new instrument flangefor N6A nozzle below.
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Dryer with Mockup Flange Support Stand Temporarily Attached
C0/
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[[
Nozzle N6A Instrument Flange
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5.9 Receiving the steam dryer from the fabricator with partially installed vibrationinstrumentation due to the height of the mast and sensor strings at the site will requirere-installing the sensor strings, mast, final torque and clamp conduit clamps. Oncereceived, all protective transport tiedown and support hardware must be removed andreceiving inspection performed. Use 3/8" or 1/2" double braided nylon rope and tackleor chainfall and dynamometer to slowly and carefully raise the string assembly onlyone time, without applying excessive tension or bending of any conduit, from thehorizontal to the vertical position.
5.10 A second crane is required to raise the mast assembly for installing into bracketswelded to the dryer, using screws for attachments. The mast has an estimated totalassembly weight including base and fittings of approximately 345 pounds.
5.11 An overhead lift system (approximately 1000 pound capacity) is required to raise themockup flange support stand (tripod) into position, clamped to brackets on top of thedryer.
5.12 Installation Staging. Tooling, tools, mast and parts, mockup flange support stand,instrument flange with three (3) penetration bolt holes and associated equipment shallbe staged for installation.
5.13 Receiving Inspection. Perform functional receiving inspection per Reference 2.2.39 forall sensors installed on the new steam dryer prior to final installation.
5.13.1 Perform receiving inspection of strain gages and record test results.
5.13.2 Perform receiving inspection of accelerometers and record test results.
5.13.3 Perform receiving inspection of pressure transducers and record results.
5.13.4 Receiving inspection report shall be given to QC for record keeping.
5.14 Preparation for Installation.
5.14.1 Prepare installation activity and review safety work plan, schedule.
5.14.2 Clean the dryer surface per specification of Cleaning and Cleanliness Control ofReactor Systems Component before installing and maintain cleanliness during andfollowing final installation, including any foreign material exclusion (FME)concerns, Reference 2.3.9.
5.14.3 Confirm safe working area ready with platform and scaffolding setup.
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5.14.4 Complete required training of conduit benders, welders, RSW personnel ifrequired, torquing, any electronic test equipment, and other required tasks.
5.14.5 Stage available materials with certification (i.e. mounting pads, cable clips for spotwelding, conduit clamps, pads, proper weld rods issued for stainless or Inconelwelding, torque wrench/crowfoot for penbolt nut, etc).
5.14.6 Review daily work plan, pre-job review, schedule, any specific site or projectsafety issues/procedures, any required personnel protective equipment, etc.
5.14.7 Quality - QA performed by QC Inspectors, note hold points for inspection andsignoffs/acceptance before proceeding to final inspection.
5.14.8 Check if any special work permits are required, such as firewatch or burn permitfor welding/RSW, etc.
5.14.9 Review top view of the dryer in Attachment A2, Figure A2-1 and note sensorlocations. Also note the dryer orientation and dryer bank identification from BankA through Bank F (from 90 to 270 deg side) and tie bar numbering from I to 5(from 0 deg to 180 deg side).
5.14.10 Attachment A2, Figure A2-2 is a top view showing the N6A instrument nozzleflange in relation to the mast on Bank C. Confirm nozzle N6A is [[ ]] fromcenter of vessel head on 0 deg azimuth. Location of the mockup flange center maybe checked using a plum bob. The nozzle center is [[ ]] to the mast center.Also see Detail B in Attachment Al, Figure 2. Attachment Al Figure 3 shows the[[ ]] N6A instrument nozzle elevation.
5.14.11 Complete welder qualification for Austenitic Stainless and Inconel welds only ifrequired.
5.14.12 RSW qualification peel test is required, only if any modification or more Ml cableclips are required, testing per Reference 2.2.28, peel tests per paragraph 4.1.4.
5.14.12.1 A minimum of 6 peel tests required to qualify procedures.
5.14.12.2 A minimum of 3 peel tests to qualify each RSW operator.
5.14.12.3 Peel tests performed and accepted per criteria per Reference 2.2.28.
5.14.12.4 Production clip RSW peel testing to be performed at every production startand stop.
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5.14.12.5 All peel test coupons shall be visually inspected and conform torequirements, Reference 2.2.28, paragraphs 4.1.3 and 4.1.4. QC shalldocument and put into records package.
AM Do 1
0 1 Fl:
4
SPOT WELDING SEQUENCE
5.14.13 [[]]
5.14.14 Prepare mockup stand for supporting nozzle and instrument flange. Note properorientation and attachment of the flange, penbolt-B facing -0 deg azimuth.
5.14.15 Check the dryer mast Master Parts List Reference 2.2.15 for required hardware.
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5.14.16 Do not use any temporary SS bolts used at the vendor's shop for fitup. Use onlythe new supplied SS bolts for one time use only, With wvashers and special hex nut(am nut), with no final tack weld required.
5.14.17 The RPV head and head gasket must be elevated or supported such that tag lines ofsteel cable or rope can pass through the nozzle out the bottom of the vessel andthrough the vessel gasket.
5.14.18 Hardware installation sequence and parallel work procedures may be changed withthe approval of the site responsible engineer or site project manager, provided thechange does not compromise quality or integrity in providing dryer vibration dataduring reactor startup operation.
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6.0 INSTALLATION PROCEDURE (Mast, Strings, Dryer, Flange, RP%7, Insulation)
Review mast assembly, parts list, instructions, bolt torque, location and orientation on top of dryerbank, vertical angular position and tolerances shall be specified on drawings or contact responsibleengineer. The mast installation shall be coordinated with slow and careful one time lifting of thesensor strings and installing the instrument flange on the mockup stand (tripod), used to supportthe three vibration strings for final string installation, performed with the new steam dryer. Thefinal reactor pressure vessel head is installed per a separate Reactor Re-assembly Procedure.
6.1 [[]]
6.2 [[
6.3 [[
6.4 [[
]]
6.5 [[
6.6 [[
6.6.1 [[
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I]Penetration Bolt with Gasket, Washer and Nut Installed
6.7 [[
Il
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6.8 [[ 11
6.9
6.10 [III
6.11 ff
MAST ON TOP OF DRYER
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6.12 [[
1]3-WAY PENBOLT MOCKUP FLANGE
6.13 [[
6.14 [[
I
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6.15 [[
6.16 f[11
6.17 ff
]]
6.18 ff
6.19 [[
]]
6.19.1 [[]]
116.19.3 [[
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6.19.4 The recommended and minimum bend radii for Ml cable are given below:
Sensors MI Cable OD Recommended Minimum IBendinch (mm) Bend Radius Radius inch (mm)
inch (mm)
Pressure Transducers _ [IAccelerometersStrain Gages I]I I]II
Note 1: Going below the minimum bend radius can lead to sensor failure. QCneeds to verify. GE and Exelon need to approve any deviations.
Note 2: Bending of Ml cable has to be made carefully and should not berepeated in the same area.
Note 3: Do not bend Ml cable within 0.2" (5 mm) from the enlarged connectionnear strain gages to prevent damage to the silver brazing.
Note 4: RS-E8-1000-2xx calls out min bend radius of 1.0" for MI cable.
Note 5: Use recommended cable bend radii as much as possible unless thereare circumstances that can not be overcome or there are compellingreasons.
6.20 [[
6.21 Final check shall be made to assure all sensors strings are firmly attached, all excessconduit and cables are securely attached. Spot check clamps are secured with boltslocked with bent tabs. Check the pressure transducer on the mast (P26) and its cableare firmly attached. QC to make final check to assure all items are secure.
6.22 Update the final inventory listing of installed vibration string mounted hardware, bycounting the number of cable clips, conduit clamps by type, pads by type, the mastmounting screws, "star tab locking" washers, flat washers and jam nuts used.
6.23 The dryer cleanup may require'general cleanup of any loose debris or materials.
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6.24 Photographs may be used to document the final installation configuration. Digital stillsare preferred over film for convenience by including them in the final report.Videotaping is not required.
6.25 Final installed sensors are to be functionally tested prior to reactor vessel head re-installation per Reference 2.2.39, with results recorded and given to QC.
6.26 QC to approve final instrumentation installation of the three sensor strings beforeproceeding.
6.27 Prepare each penetration bolt for installation of the instrumented dryer into the vessel.
6.28 Remove the mockup flange support stand from the dryer to install the dryer strongback.
6.29 Unspool the LEMO connector and approximately 50 feet of cable for each penbolt.
6.30 Remove the mockup flange requires removing the temporary nuts and washers. Usetwo wrenches to keep the penbolt from tuning, one on the upper penbolt flats and theother wrench or crowfoot wrench to untorque the penbolt nut. Penbolt rotation candamage the sensor strings with some components brazed. Remove the nut and bothwashers of each penbolt. Support the cables from above. Discard the temporary SSnut if used and the temporary flat SS washer but save the recessed SS washer for reuse.Continue for all 3 penbolts.
6.31 Remove each penbolt from the temporary aluminum flange. Some rotation of thepenbolt mockup flange assembly may be required to remove each penbolt. After allthree penbolts have been removed, discard the mockup flange, loosen and lift legs,remove the C-clamps and support cables along with the mockup support stand (tripod).The 3 penbolt string assemblies and spools of cables are supported from above.
6.32 All items cleared from the dryer. Final documentation for vibration installation shall becompleted. Final dryer cleaning performed, and dryer now prepared for installation.
6.33 Install the new instrumented steam dryer. Refer to the new Steam Dryer InstallationSpecification, Reference 2.3.14. This requires rigging for installation into the RPV,fitup, removal from the RPV, final field adjust the lifting lugs, torquing the captive nutand proceed with final installation of the instrumented steam dryer into the RPV, afterfinal documentation and cleaning. The installer must carefully monitor and control theproper slack to assure no hangup during installation or removal of the dryer and laterstrongback removal from the dryer.
6.33.1 Lifting the dryer with the mast and all instrumentation will have approximately 20"interference with the bridge of the overhead crane without bending the 3 string
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assemblies and spooled cable, perhaps requiring one or more mast conduit clampsto be released and later reinstalled, torqued and locking-star washer tabs bend tosecure the clamp from personnel basket and use of FME tarp to catch any potentialdropped lose part. The dryer installation to be completed before continuing.
6.34 Remove the steam dryer strongback per reactor re-assembly procedure. This requiressupporting the sensor strings and cables from above. Note: Do not let the LEMOcables get wet.
6.35 Install two zoom pan and tilt cameras to assist installer in monitoring the next sequenceof vessel head installation. Camera-I shall be determined by the installer for best viewfrom inside, near the bottom or below the N6A nozzle, to best monitor the movement ofthe RPV head until the head is near orjust onto the vessel studs. It can be removed andremounted or have camera-2 mounted above on the RPV head strongback, to monitorthe final lowering and pulling of the strings up through the nozzle. It will be critical toassist the installer in coordinating the lowering of the RPV head by the crane operator.
6.36 Re-install the RPV head for closure of the vessel. Refer to QC-2 reactor re-assemblyprocedure to install the strongback onto the RPV head.
6.37 Prepare sensor strings for vessel closure. Use three stainless steel wire ropes (-1/8" diaSS cables as tag lines for the final installation). Insert from top down through the N6Anozzle and routed to the penbolt, loop through the bottom of the penbolt between theconduits and back up through the nozzle and out, and attach both ends together. Eachtag line is looped for ease in later removal. Continue for the second wire/cable to 2ndpenbolt and finally a 3rd looping wire/cable to the final penbolt.
6.38 Unspool the LEMO connectors and approximately 50 feet of cable for each penbolt andloosely secure to the steel tag line, used as a strain relief when pulling up on the threepenbolt bundle. Care should be taken not to apply excessive tension to the cables.Complete for all three penbolt strings.
6.39 Bundle all three penetration bolts assemblies together, with smooth tapered clamshelldevice or add duct tape to minimize or eliminate any edge hangup during installationwithout damage, so all three can be safely inserted by pulling up and through the[[ ]] of the N6A nozzle opening. (Alternate: tie all 3 penbolts together withone tagline).
Special Note: Penbolt C, L-string, LEMO connectors AI and A2 must be taped to forcestagger one behind the other to clear the penbolt opening, [[ ]] in theinstrument flange. This is the only location as all other cables have sufficient connectorstagger.
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6.40 Install the RPV head aasket, referring to the separate outage procedure
6.41 The RPV head must be installed onto the correct 'essel stud with N6A facing 0 deg.The RPV head movement must be carefully coordinated with the installer in providingproper slack or tension in the bundled tag line(s) to the bundled three penbolt string.
6.42 The RPV head must not be rotated during installation without careful coordination withthe installer of the strings monitoring from the remote camera. Once the RPV head isover the head studs in the proper orientation, carefully and slowly lower over the vesselhead so the installer can take up slack in the tag lines. Note, RPV head rotation,exessive tagline slack or excessive tension can cause damage the penbolt strings ormast. Once the head is engaged in the short vessel stud, it will eliminate furtherrotation of the RPV head.
6.43 Maneuver and lower the RPV head carefully and slowly, coordinated with the installerusing the camera monitor to take up slack in pulling the three bundled sensor strings upthrough the instrument nozzle N6A.
6.44 Once the RPV head is set and instrument flange is installed, the RPV must not be liftedwithout potential damage to the instrument strings.
6.45 The cables must be "threaded" through the penetration hole in the instrument flange.
6.46 Install the instrument nozzle flange gasket.
6.47 Separate the three penetration bolts for instrument flange installation.
6.48 Carefully pull the LEMO connector and cables through the proper hole in theinstrument flange. Remove any tape or device attached to provide single smoothstagger of LEMO Al and A2 through the flange opening.
6.49 Attach the flange bail or use wire rope or cable to carefully lower the instrument flangeinto position while guiding each of the 3 penbolts through the proper hole and alsoaligning the 12 flange bolts. Minimize flange rotation to prevent damage to anyconduit attached to the penbolt. Flange installation orientation is not critical.
6.50 Install the 12 instrument flange bolts. Torque to required torque specified in a separatereactor re-assembly procedure. Clean area of any lubricant.
6.51 Next remove any tape or any smboth insertion device installed, cut and remove cable orwire while holding onto the top of the first penbolt.
0 GE Nuclear Energy 26A6492-NP SH NO. 24| REV. 2 OF 356.52 Then install the SS washer, Reference 2.2.21. Note orientation, with the recess
installed facing up towards the nut.
6.53 [[
6.54 Calibrate the torque wrench input to provide a crowfoot output of [[]] Use this value to torque the penbolt nut below, without use of any thread
lubricant.
6.55 Take care when tightening the nut such that the penetration bolt does not rotate byusing a wrench to hold the flats on the penbolt end while the certified and calibratedtorque wrench with crowfoot is used to tighten the penbolt nut (Reference 2.2.22) to afinal torque of 153 +/- 2 ft-lbs. QC to verify. Continue with all three penbolts. Recordthe three torque readings.
CROWFOOT FOR PENBOLT NUT
6.56 Continue with reactor re-assembly. Re-install the mirror insulation. Add appropriateinsulation of the bundled 42 cables exiting the N6A instrument flange to retain reactorheat.
6.57 The 42 cables should be untwisted and all run in parallel with acceptable cablebundling towards the jumper to Junction Box I, outside the manway. Periodic suitablebundled cable ties and support is acceptable. A cable tray is not required.
6.58 A final resistance measurement of each sensor shall be performed prior to startup. Theresults shall be recorded and given to QC.
6.59 A final check shall be made to locate all hardware and any anomalies noted and thearea cleared. Final test data shall be recorded and a copy given to QC for project file
S GE Nuclear Energy | 26A6492-NP SH NO. 25| REV. 2 OF 35record keeping. Red line changes shall capture the final procedure and locations,inventory list updated, to maintain as-built records, documented on the modificationdrawing.
6.60 QC to confirm all data and status approved to confirm continuing. This concludes theinstallation procedure of the new instrumented steam dryer. The next phase is systemcheckout, in preparing to record data during startup.
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7.0 QUALITY ASSURANCE
Quality Control Representatives shall provide surveillance and document the work performedfor this modification, as necessary, to assure that the requirements of these procedures havebeen met.
This modification shall be accomplished under an Exelon approved QA program.
The completed (as-built) modification shall be documented by sketches and photographs.Videotaping is not required for visual inspection. As-built documents (e.g. capturedinspection images, sketches or drawings) of the final modificatin configuration shall be filed inthe GENE design record file.
Any deviations, substitutions, modifications of materials, engineering procedures or designshall be submitted by the installer to GENE Engineering for concurrence.
7.1 Sensor Records: The following records should be prepared for each sensor.
7.1.1 As-installed sketch or drawing. The as-installed location and orientation of allsensors should be confirmed by a description, sketch, or updated drawing,documenting location and orientation, or a statement that they are in accordancewith issued drawings. Photographs shall be taken of all sensors, their mounts,locations and routings, showing mounting hardware (cable clips and conduitclamps) to document the final configuration.
7.1.2 Sensor data sheets and calibration information.
7.1.3 Sensor element and insulation resistance recorded at different times during theinstallation
7.2 QA shall provide a final report of all documents filed for record keeping.
7.3 The steam dryer with vibration instrumentation installed and transported and with finalinstrumentation installed on the new steam dryer at Quad Cities shall also beperformed per the GENE QA requirements, in addition to the requirements of theQuad Cities site.
7.4 The project QA report shall include documents of installation and any testing indocumenting the final dryer configuration, plus the reporting of any non-conformancedocumentation.
7.5 Final report shall be provided follIowing the completion of the project.
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STEAM DRYER ['IBRATIONASTRINGSAttachment A Figures (Computer Aodlel Layouts, Sketches)
These are listed for reference in viewing computer model showing string routing on the dryer:
Attachment Al
Figure I - Layout of instrument nozzle, mast and top of dryer, elevation of [[ ]] frombottom of instrument flange to top of tie bars on the new steam dryer.
Figure 2 - Top view layout with Detail B showing dimensions from mast to instrument flange,with [[ ]] offset to Instrument Nozzle N6A.
Figure 3 - Elevation view showing instrument nozzle flange mating surface to RPV opening, with[[ ]] opening and elevations of [[ ]] to flange top.
Attachment A2
Figure A2. 1 - Dryer Sensor Locations - Top View
Figure A2.2 - Vessel Dryer - Top View
Figure A2.3 - Dryer Sensor Locations - Elevation View of 90 Degree Face
Figure A2.4 - Dryer Sensor Locations - Elevation View of 180 Degree Face
Figure A2.5 - Dryer Sensor Locations - Elevation View of 270 Degree Face
Figure A2.6 - Dryer Sensor Locations - Elevation View of 0 Degree Face
4
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STEAMIl DR YER VIBRATIOA' STRINGSAttachmewt A, Figures (Computer AModel Layouts, Sketches)
These are listed for reference in viewing computer model showing string routing on the dryer:
Attachment Al
[[
Figure I - Layout of instrument nozzle, mast and top of dryer, elevation of [[bottom of instrument flange to top of tie bars on the new steam dryer.
]] from
4
GE Nuclear Energy26A6492-NP SH NO. 29REV. 2 OF 35
Attachment Al
[[
11Figure 2 - Top view layout with Detail B showing dimensions from mast to instrument flange,
with [[ ]] offset to Instrument Nozzle N6A.
l1]
Figure 3 - Elevation view showing instrument' nozzle flange mating surface to RPV opening, withR[ ]] opening and elevations of [[ ]] to flange top.
0 GE Nuclear Energy 26A6492-NP SH NO. 30REV. 2 OF 35ATTACHMENT A2
FIGURE A2-1: DRYER SENSOR LOCATIONS - TOP VIEW
1]I
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FIGURE A2-2: VESSEL DRYER - TOP VIEWNI
180- -o0
INSTRUMENT NOZZLE FLANGE NGA
90-
'OP VIEW
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FIGURE A2-3: DRYER SENSOR LOCATIONS - 900 FACE
[I
I]
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FIGURE A2-4: DRYER SENSOR LOCATIONS - 1800 FACE
0 GE Nuclear Energy 26A6492-NP SF1 NO. 34REV.2 OF 35FIGURE A2-5: DRYER SENSOR LOCATIONS - 2700 FACE
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FIGURE A2-6: DRYER SENSOR LOCATIONS - 0° FACE
