Americn Crane & Equipment Corp. ACECO
Suppliers of the Single-Failure-Proof Hoist System at Oyster Creek
Oyster Creek Modifications Included
0 New 125/10 SFP Main & Aux. Hoists Trolley 0 1,25% Load 'esting of Trolley at ACECO's Test Facility 0 Functional Testing at ACECO's Test Facility & OCNGS 0 Evaluation of the existing Whiting Bridge 0 Evaluation ol'the existing OCNGS steel superstructure * Installation compliant with NUREG-0612 "* Trolley end stop modification "* Special Lifting Devices to Complete Installation "* Complete Documentation in accordance with QA Plan
10 CFR 50 Appendix B
RECENT HISTORY OF ACECO'S SINGLE FAILURE-PROOF CRANE DEVELOPMENT
* 1994 * 1995
* 1995 0 1995 • 1995 * 1996
• 1996 * 1996
* 1996
• 1996
• 1996 * 1997
* 1997
* 1998
Completed "Wonder Hloist" ACECO's first nuclear SFP hoist flor re-racking pools Developed a 5 year plan to enter DOE•, aerospace & commercial nuclear markets Updated and implemented ACECO's nuclear QA program Completed upgrade to Reactor Building Crane at OCNGS Seismic specialist is hired ACECO's revised QA program audited by DOE custome: (Hanford) Received firsi DOE order for 60/10 ton gantry crane for Hanford Site ACEC() engineer joins ASME NOG crane committee Evaluated OCNGS reactor building crane for possible SFP upgrade Received Aerospace order tfor 25-ton crane lor Boeing De& I I I launch complex Received order for 20 ton SIP crane for handling uranium it US Enrichment Received order for 7 SEP cranes & 15 SFP grabs for dismiiitlinm nuclear weapons
in Mayak, Russia as part of the Salt II Treaty ASME NOG -1 type I cranes Added 17,000 space square feet to plant to handle additional business Received several orders f'rom I lanford for NQA- I hoists & cranes
RECENT HISTORY OF ACECO'S SINGLE FAILURE-PROOF CRANE DEVEVOPMENT
• 1998 Built S11 dry fuel transfer crane in association with NES for INEEL * 1998 Second ma*jor locing order lor S1FP 50-ton Delta IV launch gantry crane • 1999 Completed firs"t NRC type licensing review tor a utility SFP crane 0 1999 I fired licensin-g support specialist 0 1999 Received first 125/10 SEP NUREG 0554 replacement trolley * 2000 PI3ICO completed NUPIC audit placing ACECO on there ASI, - 2000 Received OCNGS 125/10 SIP NUREG 0554 replacement trolley - 2001 Received third NUREG 0554 SFP hoist for INEEL project * 2001 Received 4th, & 5th NUREG 0554 SIP cranes and hoist Imr utility - 2001 Received orders From Boeing for 5 th, 6 th, & 7 th SEP cranes for Vandenberg AFB
Since 1996 all Boeing launch support cranes have been built by ACECO
OYSTER CREEK SFP DESIGN BASIS
"• Crane compliant to NUREG-0554 "• Crane Design compliant with CMAA #70
"° Crane compliant to Reg. Guide 1.29 (Seismic)
• Use NUREG-0612 Appendix C when applicable
• ASME NOG- 1 supplements above criteria
HIGHLIGHTS OF THE OCNGS SFP DESIGN
* Hook designed with 10:1 safety factor (0612 Appendix C) * Redundant reeving with 10:1 system safety factor * Redundant Drum mounted Emergency Disc Caliper Brake a 15% wear factor included for wire rope, hooks, & brakes a Crush pad type equalizer/load transfer system • Electrical control via variable frequency drives 0 Redundant hoist upper travel limits provided ° Over speed, over travel & rope protection limits provided * Cab control with radio control back-up 0 Emergency Stop Buttons provided in cab & radio control a Testing & Inspection compliant with NOG-1 Section 7000
Mechanical Systems
* l~rovide Ihe caiergy to move and stop the load
* Mechanical components are active and subject to wear
* Design Basis is redundant - Except single load path hook per NUREG-0612 Appendix C
• Seismic design is a consideration
(normally not controlling)
Upper & Lower Load Blocks
0 Directly supLj; orts the load -Single fai wri proof (NUREG-0612 Appendix C)
0 Critical Components including testing requirements: - Hook ................. CMTR, UT, MT,& 200% Proof load test - Hook Nut ............ CMTR, UT, MT,& 200% Proof load test - Crosshead ............ CMTR, UT, MT - Load Block Steel .... CMTR, Impact test - Load Block Welds... MT or PT - Sheave Pin ............ CMTR, UT, MT - Sheave ................ C of C
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Wire rope
• Directly supp)orts the load
* Dual reeving provides a redundant load path • 5:1 individual rope safety factor
* 10:1 system safety factor
o Testing of the wire rope Breaking strength test from sample of the rope installed
• Testing of the wire rope end fittings - 200% Proof Test based on wire rope strength
Equalizer /Load Transfer System
"* Equalizes rope tension during normal operation "* Equalizer is s€ingle failure proof connecting the dual ropes "* Design basis is enhanced safety (10:1 Safety Factor) "• Absorbs energy during a broken rope event "* Energy is absorbed via a honeycomb crush pad "• Crush pad is contained in a double acting steel cylinder "* The piston cylinder was proof load tested at the maximum
load transfer value
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Braking Systems
S1Holding -rake systems are redundant Primary brake located on high speed shaft
-- Emergency brake located on drum providing redundant drive train "* Holding brakes rated min. 165% torque where acting "* Control brake is dynamic provided via the freq. drive "* All brakes were individually tested at 125% of DRL * Any of thie brakes can stop the DRL load in less than 3"
inches
Structural Systems
"* Support the mnechanical & electrical systems
"* Structure provides support during & after the SSE
"• Structural systems are passive & not prone to wear
Trolley Frame
"• Indirectly supports the load "• Is passive and therefore is not subject to wear "* Is seismically designed to support the load during & after
OBE & SSE "* Is a welded steel plate structure "• Critical Components testing requirements include:
- Load Girt ..... CMTR, C of C, & Impact test
- Welds .......... MT or PT
Drum Catching Device
"* Structural members located V2" below drums "* Support the drum in the event of shaft or support failure "* Drum shell f'ailure is not a credible event "* Critical Con- ponents testing requirements include:
- Device..........CMTR, C of C, & Impact test - Welds ....... MT or PT
Electrical System
"• Provides control of the mechanical energy to move load "* Operator at all times has 2 means of stopping system "* Power is removed from crane on sensing of vibration on
the floor "• Removal of power places crane in safe condition
* Electrical system is not required to function during a seismic event
Flux Vector Variable Frequency Drive
"* Drive is the basis of the electrical system "* Drive controls the motor & primary brake "* Provides control braking via dynamic braking "° Drive provides the following features
- Torque proving at start
- Brake checking
- Load Float (Zero speed) .- Ability to precisely limit input drive torque
Hoist Upper Travel Limits
Redundant limits of differing designs "* Primary i:,; gýcar type control limit "* Final is the block actuated (paddle) power !ype limit "• Final limit removes power from motor "* Limits are NUREG-0554 alternate design
Over Speed Limits
"* Senses hoist over speed independent of the flux vector drive
"* Limit is electrically isolated from drive "° Limit provides control redundancy "• Actuation of limit sets both holding brakes stopping load
Over Weight Limit
0 Limit senses over capacity lifts setting brakes 0 Limit senses load hang-up * Limit protects crane from over stress • Limit actuation only permits hoist lowering
Wire Rope Protection Limits
"• Drum mnis-spioling limit protects wire rope from misspooling onto drum
"* Unbalanced load limit protects wire rope & crane from off center lifts
"* Actuation of either limit stops hoisting motion
Emergency Stop Buttons
"• Remove power from the crane Sets holding brakes
- Placing crane in a safe condition
"* Button located in the cab "* Toggle switch located on each radio control
Tests completed to confirm Design
Compliant with Section 7000 of NOG-1 Tests at ACI'.tCO's test facility
Functioinal & Dimensional tests . Mechanical & Electrical Inspection
100% & 125% DRL load tests - 125% DRL independent brake tests (Stopped within 3")
* Tests at OCNGS - Functional test with load
- Dimensional inspection
- Mechanical & Electrical Inspection
• Completed QA documentation package provided
Compliance with NUREG-0554
"* Failure Modes & Effects Analysis (FMEA) was performed - No single failure points were identified
"* NtJREG-0554/0612 compliance matrix was prepared - No exceptions noted by licensee
"* Design compliance with - NUREG-0554 using 0612 Appendix C
Summary of SFP Crane
• New 125/10 ton SFP trolley • Crane comnpliant to NUREG-0554/0612 • 10:1 safety factor on rope reeving system • 15% wear factor included in key mechanical components * Crush pad type equalizer/load transfer system 0 Two-block protection via redundant limit switches • Redundant drum brake provides SFP hoisting design • Operator at all times has 2 means of stopping system 0 Complete functional and load testing • FMEA identitied no single failure points