CR3 Steam Generator Replacement Movement Steps for Removal and Installation

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CR3 Steam Generator Replacement Movement Steps for Removal and Installation. Information Derived from EC/ED 67484. Linda Pressley McCray Nuclear Designer Crystal River Nuclear Plant. Performance of Motion Analysis. - PowerPoint PPT Presentation

Transcript of CR3 Steam Generator Replacement Movement Steps for Removal and Installation

CR3 Steam Generator ReplacementMovement Steps for Removal and Installation

Information Derived from EC/ED 67484

Linda Pressley McCrayNuclear Designer

Crystal River Nuclear Plant

Performance of Motion AnalysisFirst, a 3D Model was created which includes all structures, systems and components located within the D-ring.

All input for the model was gathered from pertinent component information located on the associated CR3 Station drawing.

Performance of Motion Analysis

Next, an independent validation of the original 3D model geometry was performed by the SGR Project Design group.

Performance of Motion AnalysisAn additional layer of model validation was performed by AREVA who overlaid our CR3 3D model on top of AREVA’s 3D Laser Scanned model

AREVA compiled a list of all deltas found within a four foot radius surrounding each generator

Each delta has been resolved and the SGR 3D model is considered to be an accurate depiction of the CR3 as-built configuration

Performance of Motion Analysis

A motion analysis has been performed for each generator which identifies all potential interferences and specifies a removal and installation path that provides sufficient clearances to all identified plant structures, systems and components

Symbols Used

The light blue North Arrow is used as a stationary point for tracking purposes on each clearance drawing. Point originates from the center of the generator @ EL 95'.

The yellow and red North Arrow is embedded in the generator to show generator movement.

Symbols UsedDenotes clearance of 6 inches or less. Great care must be taken at caution points to prevent the generator from colliding with plant structures, systems and/or components

Generator “A” Removal

STEP #GENERATORMOVEMENT

MOVEMENTDESCRIPTION

CLEARANCES< 6 INCHES

NOTES

1 Raise generator 25 FeetPositions cold leg pieces for unobstructed rotation

4 3/8" between service water piping and generator nozzle on east side (CLEARANCE MUST BE REDUCED BY PIPING INSULATION THICKNESS)

Remaining clearances exceed 6 inches

Generator Base @ 120'-0" EL

2Rotate Clockwise 90 Degrees

Repositions cold leg pieces for unobstructed removal

None < 6 Inches Generator Base @ 120'-0" EL

3 Raise 60 Feet - 6 InchesRaises generator above remaining obstructions

None < 6 Inches Generator Base @ 180'-6" EL

Path assumes all service water piping remains in place during the removal phase. This will provide the option of removing appropriate sections of service water piping after the existing generators have been removed.

Generator “A” Removal

The auxiliary feedwater header and main feedwater header will be disassembled and removed from generator “A” prior to removal of generator

Auxiliary Feedwater Header

Main Feedwater Header

Generator “A” Removal

INITIAL STEPPLAN VIEW

Prior to manipulation

Auxiliary feedwater header and main feedwater header will be removed prior to removal of generator

INITIAL STEPELEVATION VIEW

Prior to manipulation

Generator base is at EL 95’-0”

Auxiliary feedwater header and main feedwater header will be removed prior to removal of generator

Generator “A” Removal

INITIAL STEPISOMETRIC VIEW

Prior to manipulation

Generator base is at EL 95’-0”

Generator “A” Removal

STEP #1ELEVATION VIEW

Raise Generator 25 Feet

Generator base is at EL 120’-0”

Positions cold leg pieces for unobstructed rotation

Generator “A” Removal

Generator “A” Removal

STEP #1PLAN VIEWCLEARANCES

Raise 25 Feet

Clearances shown between vertical steel and generator cylinder on west side and between RCP steel and generator cylinder on both east and west sides

STEP #1ISOMETRIC VIEW

Raise 25 Feet

Generator base is at EL 120’-0”

Generator “A” Removal

Generator “A” RemovalSTEP #2PLAN VIEWCLEARANCES

Rotate Clockwise 90 Degrees

Positions cold leg pieces for unobstructed removal path

Clearances shown between vertical steel and generator cylinder on west side, between service water piping and generator cylinder on east side, and between RCP steel and generator cylinder on both east and west sides.

STEP #3ELEVATION VIEW

Raise 60 FEET – 6 INCHES

Raises generator above remaining obstructions

Generator base is at EL 180’-6”

Generator “A” Removal

Prepare To Install Replacement Generator

Some of the insulation support assemblies shown on the replacement generator are placed in temporary locations for installation to eliminate interferences during rigging

These insulation support assemblies will be moved to their final destination after the replacement generator has been installed

Generator “A” InstallationInsulation Support Assemblies

Generator “A” InstallationPath assumes removal of interfering portions of the following as designated in the governing EC package: Service Water Piping 305-706, 305-707, 305-710, 305-711 and associated hangers; and One Inch Piping 3A-4153-SW-2, 3A-4154-SW-1 and associated hangers.

STEP #GENERATORMOVEMENT

MOVEMENTDESCRIPTION

CLEARANCES< 6 INCHES

NOTES

1 Drift North 21 InchesPositions generator for initial lowering movement

None < 6 Inches Generator Base @ 180'-6" EL

2 Drift West 4.5 InchesEqualizes distance between interferences prior to lowering

None < 6 Inches Generator Base @ 180'-6" EL

3 Lower 68 FeetPlaces main feedwater header below rcp support steel

None < 6 Inches Generator Base @ 112'-6" EL

4 Drift South 10 InchesMoves generator away from main steam hangers

None < 6 Inches Generator Base @ 112'-6" EL

Generator “A” Installation

5 Drift East 4.5 InchesMoves generator away from vertical steel @ 128'-0" EL

None < 6 InchesGenerator Base @ 112'-6" EL

6 Lower 11 Feet 6 InchesMoves generator to suitable point for final positioning

4 13/16" between main feedwater header ring and vertical steel (see Step 6 Elevation #1)

Generator Base @ 101'-0" EL

7 Drift South 11 InchesReturns generator to original coordinates prior to setting

3 5/8" between rcp steel and nearest aux. feedwater header riser (see Step 7 Elevation #2)

4 13/16" between main feedwater header ring and vertical steel (see Step 7 Elevation #1)

Generator Base @ 101'-0" EL

8 Lower 6 Feet Sets generator

4 13/16" between main feedwater header ring and vertical steel (see Step 8 Elevation #1)

Generator Base @ 95'-0" EL

STEP #GENERATORMOVEMENT

MOVEMENTDESCRIPTION

CLEARANCES< 6 INCHES

NOTES

Generator “A” Installation

INITIAL STEPPLAN VIEW

Prior to manipulation

Generator base is at EL 180’-6”

INITIAL STEPELEVATION

Prior to manipulation

Generator base is at EL 180’-6”

Generator “A” Coordinates:(From Reactor Building center to center of generator base)

X = 17’-9 31/32”Y = 30’-4 ½”Z = 180’-6”

Generator “A” Installation

INITIAL STEPISOMETRIC VIEW

Prior to manipulation

Generator base is at EL 180’-6”

Generator “A” Installation

Generator “A” Installation

STEP #1PLAN VIEW

Drift North 21 Inches

Generator base is at EL 180’-6”

Moves generator away from obstacles interfering with first downward movement

Generator “A” Installation

STEP #2PLAN VIEW

Drift West 4.5 Inches

Generator base is at EL 180’-6”

Equalizes distance between interferences prior to lowering

STEP #3ELEVATION VIEW

Lower 68 Feet

Generator base is at EL 112’-6”

Places main feedwater header below RCP support steel

Generator “A” Installation

STEP #3PLAN VIEWCLEARANCES

Lower 68 Feet

Generator base is at EL 112’-6”

Places main feedwater header below RCP support steel

Generator “A” Installation

Clearances shown occur DURING downward movement.

STEP #3ELEVATION VIEWCLEARANCES

Lower 68 Feet

Generator base is at EL 112’-6”

Clearance shown is between main feedwater header outlet and steel at EL 164’-1”

Generator “A” Installation

STEP #3PLAN VIEWCLEARANCES

Lower 68 Feet

Generator base is at EL 112’-6”

Clearances shown reflect dimensions AFTER generator is lowered to EL 112’-6”

Generator “A” Installation

STEP #3ISOMETRIC VIEW

Lower 68 Feet

Generator base is at EL 112’-6”

Places main feedwater header below RCP support steel

Generator “A” Installation

STEP #4PLAN VIEWCLEARANCES

Drift South 10 Inches

Generator base is at EL 112’-6”

Moves generator away from main steam hangers

Generator “A” Installation

STEP #4ROTATEDISOMETRIC VIEW

Drift South 10 Inches

Generator base is at EL 112’-6”

Moves generator away from main steam hangers

Generator “A” Installation

STEP #5 PLAN VIEWCLEARANCES

Drift East 4.5 Inches

Generator base is at EL 112’-6”

Moves generator away from vertical steel at EL 128’-0”

Generator “A” Installation

STEP #6ELEVATION VIEW

Lower 11 Feet 6 Inches

Generator base is at EL 101’-0”

Moves generator to suitable point for final positioning

Generator “A” Installation

STEP #6PLAN VIEWCLEARANCES

Lower 11 Feet 6 Inches

Generator base is at EL 101’-0”

Moves generator to suitable point for final positioning

Generator “A” Installation

STEP #6ELEVATION VIEWCLEARANCES

Lower 11 Feet 6 Inches

Generator base is at EL 101’-0”

Clearances shown are between the main feedwater header ring and the vertical steel located on the east and west

Generator “A” Installation

STEP #7PLAN VIEWCLEARANCES

Drift South 11 Inches

Generator base is at EL 101’-0”

Returns generator to original coordinates prior to setting

3 5/8” clearance is between the corner of the RCP steel and the nearest aux. feedwater header riser and is shown in elevation view on the next slide

Generator “A” Installation

STEP #7ROTATED VIEWCLEARANCE

Drift South 11 Inches

3 5/8” clearance is between the corner of the RCP steel and the nearest aux. feedwater header riser

Clearance is shown in PLAN VIEW view on previous slide

Generator “A” Installation

STEP #7ELEVATION VIEWCLEARANCES

Drift South 11 Inches

Generator base is at EL 101’-0”

Clearances shown are between the main feedwater header ring and the vertical steel located on the east and west

Generator “A” Installation

As generator is drifted south the clearances between the main feedwater header ring and the vertical steel remain the same as in Step #6

STEP #8ELEVATION VIEWCLEARANCE

Lower 6 Feet

Sets Generator – Base is at EL 95’-0”

Clearance shown is between the main feedwater header ring and the vertical steel located east of the generator

Generator “A” Installation

STEP #8PLAN VIEWCLEARANCES

Lower 6 Feet

Sets Generator

Generator Base is at EL 95’-0”

This final lowering movement places the aux. feedwater header risers below the RCP steel. 4 13/16” clearance is between the main feedwater header ring and the vertical steel (see previous slide)

Generator “A” Installation

STEP #8SIDE VIEWVERTICAL

CLEARANCE

Lower 6 Feet

Sets Generator

Generator Base is at EL 95’-0”

Vertical clearance shown is between the RCP steel and the nearest aux. feedwater header riser

Generator “A” Installation

STEP #8ELEVATIONGENERATOR IS SET

Final Destination

Generator Base is at EL 95’-0”

Generator “A” Installation

Prepare To Remove “B” Generator

Generator “B” RemovalPath assumes all service water piping remains in place during the removal phase. This will provide the option of removing appropriate sections of service water piping after the existing generators have been removed.

STEP #GENERATORMOVEMENT

MOVEMENTDESCRIPTION

CLEARANCES< 6 INCHES

NOTES

1 Raise generator 25 FeetPositions cold leg pieces for unobstructed rotation

None < 6 InchesGenerator Base @ 120'-0" EL

2Rotate Counter-Clockwise 90 Degrees

Repositions cold leg pieces for unobstructed removal

None < 6 InchesGenerator Base @ 120'-0" EL

3 Raise 60 Feet - 6 InchesRaises generator above remaining obstructions

None < 6 InchesGenerator Base @ 180'-6" EL

Generator “B” Removal

The auxiliary feedwater header and main feedwater header will be disassembled and removed from generator “B” prior to removal of generator

Auxiliary Feedwater Header

Main Feedwater Header

INITIAL STEPELEVATION VIEW

Prior to manipulation

Generator base is at EL 95’-0”

Auxiliary feedwater header and main feedwater header have been removed

Generator “B” Removal

INITIAL STEPISOMETRIC VIEW

Prior to manipulation

Generator base is at EL 95’-0”

Generator “B” Removal

STEP #1ELEVATION VIEW

Raise Generator 25 Feet

Generator base is at EL 120’-0”

Positions cold leg pieces for unobstructed rotation

Generator “B” Removal

Generator “B” Removal

STEP #1PLAN VIEWCLEARANCES

Raise Generator 25 Feet

Generator base is at EL 120’-0”

Positions cold leg pieces for unobstructed rotation

Generator “B” Removal

STEP #2PLAN VIEWCLEARANCES

Rotate Counter-Clockwise

90 Degrees

Generator base is at EL 120’-0”

Repositions cold leg pieces for unobstructed removal

Generator “B” Removal

STEP #2ELEVATION VIEW

Rotate Counter-Clockwise

90 Degrees

Generator base is at EL 120’-0”

Repositions cold leg pieces for unobstructed removal

Generator “B” Removal

STEP #3PLAN VIEWCLEARANCES

Raise Generator 60 Feet – 6 Inches

Generator base is at EL 180’-6”

Raises generator above remaining obstructions

Generator “B” Removal

STEP #3ELEVATION

Raise Generator 60 Feet – 6 Inches

Generator base is at EL 180’-6”

Raises generator above remaining obstructions

Prepare To Install Replacement Generator

SAFETY….PRIORITY #1

A Motion Analysis Contingency Plan was created in case the service water piping in “B” cubicle is left in place

The Contingency Plan steps are located here:

EC/ED 67484 R1Attachment Z10

Generator “B” Installation

NOTE:

Some of the insulation support assemblies shown on the replacement generator are placed in temporary locations for installation to eliminate interferences during rigging

These insulation support assemblies will be moved to their final destination after the replacement generator has been installed

Generator “B” InstallationInsulation Support Assemblies

Generator “B” InstallationPath assumes removal of interfering portions of the following as designated in the governing EC package: Service Water Piping 305-712, 305-713, 305-716, 305-717 and associated hangers

STEP #GENERATORMOVEMENT

MOVEMENTDESCRIPTION

CLEARANCES< 6 INCHES

NOTES

1Drift South 19 Inches

Provides clearance between main feedwater header and rcp steel

None < 6 Inches Generator Base @ 180'-6" EL

2 Lower 68 FeetPlaces main feedwater header and risers below rcp steel

5 25/32" between main feedwater header ring and rcp steel west of generator

Generator Base @ 112'-6" EL

3Drift North 10 Inches

Equalizes distances between interferences for next downward movement (step #4)

None < 6 Inches Generator Base @ 112'-6" EL

4 Lower 8 Feet

Places main feedwater header below vertical main feedwater rupture restraints and places aux. feedwater header above rcp steel

None < 6 Inches Generator Base @ 104'-6" EL

5Drift South 3 Inches

Provides clearance between rcp steel and aux. feedwater header ring on west side of generator

5 3/32" clearance between main feedwater header ring and main feedwater piping support

Generator Base @ 104'-6" EL

6 Drift East 3 Inches

Provides additional clearance between rcp steel and aux feedwater header ring on the west side of generator prior to next lowering step

5 3/32" clearance between main feedwater header ring and main feedwater piping support

Generator Base @ 104'-6" EL

Generator “B” Installation

STEP #GENERATORMOVEMENT

MOVEMENTDESCRIPTION

CLEARANCES< 6 INCHES

NOTES

7 Lower 4 Feet

Places main feedwater header and risers below vertical steel and moves aux. feedwater header ring below rcp steel

4 15/16" clearance occurs when aux feedwater header ring passes the rcp steel during this lowering movement

Generator Base @ 100'-6" EL

8 Drift West 3 InchesReturns generator to original western coordinates

None < 6 InchesGenerator Base @ 100'-6" EL

9 Lower 4 Feet 3 InchesMoves aux. feedwater header risers below rcp steel

None < 6 InchesGenerator Base @ 96'-3" EL

10 Drift North 12 InchesReturns generator to original coordinates prior to setting

1 7/8" vertical clearance between RCP steel and nearest aux feedwater header riser - should not impede movement because the diagonal clearance exceeds 6" (See Elevation #1)

Generator Base @ 96'-3" EL

11 Lower 1 Foot 3 Inches Sets generator None < 6 InchesGenerator Base @ 95'-0" EL

Generator “B” Installation

INITIAL STEPPLAN VIEW

Prior to manipulation

Generator base is at EL 180’-6”

INITIAL STEPELEVATION

Prior to manipulation

Generator base is at EL 180’-6”

Generator “B” Coordinates:(From Reactor Building center to center of generator base)

X = 11’-21/32”Y = 30’-4 ½”Z = 180’-6”

Generator “B” Installation

INITIAL STEPISOMETRIC VIEW

Prior to manipulation

Generator base is at EL 180’-6”

Generator “B” Installation

Generator “B” Installation

STEP #1PLAN VIEW

Drift South 19 Inches

Generator base is at EL 180’-6”

Provides clearance between main feedwater header ring and RCP steel for first downward movement

Generator “B” Installation

STEP #2ELEVATION VIEW

Lower 68 Feet

Generator base is at EL 112’-6”

Places main feedwater header and risers below RCP steel

Generator “B” InstallationSTEP #2PLAN VIEWCLEARANCES

Lower 68 Feet

Generator base is at EL 112’-6”

Places main feedwater header and risers below RCP steel

Clearances shown reflect dimensions between the main feedwater header ring and all potential interferences that occur during this lowering step

Generator “B” Installation

STEP #3PLAN VIEWCLEARANCES

Drift North 10 Inches

Generator base is at EL 112’-6”

Equalizes distances between interferences for next downward movement (Step #4)

Generator “B” Installation

STEP #3ELEVATION VIEWCLEARANCES

Drift North 10 Inches

Generator base is at EL 112’-6”

Clearances shown are between the main feedwater header outlets and the vertical steel on east and west sides

STEP #4ELEVATION VIEW

Lower 8 Feet

Generator base is at EL 104’-6”

Places main feedwater header below vertical main feedwater rupture restraints and places aux feedwater header above RCP steel

Generator “B” Installation

STEP #4PLAN VIEWCLEARANCES

Lower 8 Feet

Generator base is at EL 104’-6”

Places main feedwater header below vertical main feedwater rupture restraints and places aux feedwater header above RCP steel

Generator “B” Installation

STEP #4ELEVATION VIEWCLEARANCES

Lower 8 Feet

Generator base is at EL 104’-6”

Places main feedwater header below vertical main feedwater rupture restraints and places aux feedwater header above RCP steel

Clearances shown above are between the main feedwater header ring and the vertical steel on east and west sides

Generator “B” Installation

STEP #5PLAN VIEWCLEARANCES

Drift South 3 Inches

Generator base is at EL 104’-6”

Provides clearance betweenRCP steel and aux. feedwater header ring on west side

5 3/32” clearance between main feedwater header ring and main feedwater piping support

Generator “B” Installation

STEP #6PLAN VIEWCLEARANCES

Drift East 3 Inches

Generator base is at EL 104’-6”

Provides additional clearance between RCP steel and aux. feedwater header ring on west side

5 3/32” clearance between main feedwater header ring and main feedwater piping support

Generator “B” Installation

STEP #6ELEVATION VIEW LKG SOUTHCLEARANCES

Drift East 3 Inches

Generator base is at EL 104’-6”

Provides additional clearance between RCP steel and aux. feedwater header ring on west side

Clearances shown are between the main feedwater header ring and the vertical steel on east and west sides

Generator “B” Installation

STEP #7ELEVATION VIEW

Lower 4 Feet

Generator base is at EL 100’-6”

Places main feedwater header and risers below vertical steel and moves aux. feedwater header ring below RCP steel

Generator “B” Installation

STEP #7PLAN VIEWCLEARANCES

Lower 4 Feet

Generator base is at EL 100’-6”

Places main feedwater header andrisers below vertical steel and movesaux. feedwater header ring below RCP steel

4 15/16” clearance occurs when aux. feedwater header ring passes the RCP steel during this lowering movement

RCP steel clearance on east side is larger because the aux. feedwater header ring has a gap at that location

Generator “B” Installation

STEP #8PLAN VIEWCLEARANCES

Drift West 3 Inches

Generator base is at EL 100’-6”

Returns generator to originalwestern coordinates

11 15/32” clearance is between the RCP steel and the nearest aux. feedwater header riser. The aux. feedwater header ring is below the RCP steel at this point

Generator “B” Installation

STEP #9ELEVATION VIEW

Lower 4 Feet 3 Inches

Generator base is at EL 96’-3”

Moves aux. feedwater header risers below RCP steel

Generator “B” Installation

STEP #9PLAN VIEWCLEARANCES

Lower 4 Feet 3 Inches

Generator base is at EL 96’-3”

Moves aux. feedwater header risers below RCP steel

11 15/32” clearance is between the RCP steel and the nearest aux. feedwater header riser DURING this lowering movement

Generator “B” Installation

STEP #9ROTATED ELEVATION VIEWCLEARANCES

Lower 4 Feet 3 Inches

Generator base is at EL 96’-3”

Moves aux. feedwater header risers below RCP steel

Shows proximity of RCP steel to nearest aux. feedwater header riser (approximately 1 foot)

This clearance becomes critical during the next step (Drift North 12")

Generator “B” Installation

RCP STEEL

AUX. FW HEADER RISER

STEP #9ROTATED ELEVATION VIEWCLEARANCES

Lower 4 Feet 3 Inches

Generator base is at EL 96’-3”

Moves aux. feedwater header risers below RCP steel

Shows proximity of main steam hangers to aux. feedwater headerring and main feedwater header ring

Generator “B” Installation

STEP #9ELEVATION VIEWCLEARANCES

Lower 4 Feet 3 Inches

Generator base is at EL 96’-3”

Moves aux. feedwater header risers below RCP steel

Shows proximity of generator cylinder to blowdown hangers

Generator “B” Installation

STEP #10PLAN VIEWCLEARANCES

Drift North 12 Inches

Generator base is at EL 96’-3”

Returns generator to original coordinates prior to setting

10 29/32” clearance is between the aux. feedwater header ring and the vertical steel

Generator “B” Installation

STEP #10ELEVATION VIEWCLEARANCES

Drift North 12 Inches

Generator base is at EL 96’-3”

Generator “B” Installation

Elevation View Looking EastShows proximity of RCP steel on west side of generator to nearest aux. feedwater header riser after drifting north 12 inches

Elevation View Looking WestShows proximity of RCP steel on east side of generator to nearest aux. feedwater header riser after drifting north 12 inches

STEP #11ELEVATION VIEWFINAL STEP

Lower 1 Foot – 3 Inches

Generator base is at EL 95’-0”

Sets Generator

Generator “B” Installation

Successful Removal and InstallationTime to Celebrate!

Questions or Comments?

Call or Email Linda McCray x1533