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


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.


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


INITIAL STEPPLAN VIEW

Prior to manipulation

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

INITIAL STEPELEVATION VIEW


Generator base is at EL 95’-0”

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


INITIAL STEPISOMETRIC VIEW




STEP #1ELEVATION VIEW

Raise Generator 25 Feet


Positions cold leg pieces for unobstructed rotation



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 “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.


Raise 60 FEET – 6 INCHES

Raises generator above remaining obstructions



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.


MOVEMENTDESCRIPTION


NOTES

1 Drift North 21 InchesPositions generator for initial lowering movement


2 Drift West 4.5 InchesEqualizes distance between interferences prior to lowering


3 Lower 68 FeetPlaces main feedwater header below rcp support steel


4 Drift South 10 InchesMoves generator away from main steam hangers


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)


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)



8 Lower 6 Feet Sets generator




MOVEMENTDESCRIPTION


NOTES

INITIAL STEPELEVATION



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

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



STEP #1PLAN VIEW

Drift North 21 Inches


Moves generator away from obstacles interfering with first downward movement


STEP #2PLAN VIEW

Drift West 4.5 Inches


Equalizes distance between interferences prior to lowering


Lower 68 Feet


Places main feedwater header below RCP support steel



Lower 68 Feet




Clearances shown occur DURING downward movement.

STEP #3ELEVATION VIEWCLEARANCES

Lower 68 Feet


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



Lower 68 Feet


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


STEP #3ISOMETRIC VIEW

Lower 68 Feet





Drift South 10 Inches


Moves generator away from main steam hangers


STEP #4ROTATEDISOMETRIC VIEW



Moves generator away from main steam hangers


STEP #5 PLAN VIEWCLEARANCES

Drift East 4.5 Inches


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



Lower 11 Feet 6 Inches


Moves generator to suitable point for final positioning





Moves generator to suitable point for final positioning





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





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


STEP #7ROTATED VIEWCLEARANCE


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





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


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



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)


STEP #8SIDE VIEWVERTICAL

CLEARANCE

Lower 6 Feet

Sets Generator


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


STEP #8ELEVATIONGENERATOR IS SET

Final Destination



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.


MOVEMENTDESCRIPTION


NOTES

1 Raise generator 25 FeetPositions cold leg pieces for unobstructed rotation


2Rotate Counter-Clockwise 90 Degrees



3 Raise 60 Feet - 6 InchesRaises generator above remaining obstructions


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



Auxiliary feedwater header and main feedwater header have been removed




Rotate Counter-Clockwise

90 Degrees





Raise Generator 60 Feet – 6 Inches




STEP #3ELEVATION

Raise Generator 60 Feet – 6 Inches



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


MOVEMENTDESCRIPTION


NOTES

1Drift South 19 Inches

Provides clearance between main feedwater header and rcp steel


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


3Drift North 10 Inches

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


4 Lower 8 Feet

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


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


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




MOVEMENTDESCRIPTION


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


8 Drift West 3 InchesReturns generator to original western coordinates


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


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)


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

INITIAL STEPELEVATION



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

X = 11’-21/32”Y = 30’-4 ½”Z = 180’-6”



STEP #1PLAN VIEW



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



Lower 68 Feet


Places main feedwater header and risers below RCP steel

Generator “B” InstallationSTEP #2PLAN VIEWCLEARANCES

Lower 68 Feet


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





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





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


Lower 8 Feet


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



Lower 8 Feet





Lower 8 Feet



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





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



Drift East 3 Inches


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


STEP #6ELEVATION VIEW LKG SOUTHCLEARANCES

Drift East 3 Inches


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



Lower 4 Feet


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



Lower 4 Feet


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



Drift West 3 Inches


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





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


STEP #9ROTATED ELEVATION VIEWCLEARANCES




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")


RCP STEEL

AUX. FW HEADER RISER

STEP #9ROTATED ELEVATION VIEWCLEARANCES




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






Shows proximity of generator cylinder to blowdown hangers





Returns generator to original coordinates prior to setting

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






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


Sets Generator


Successful Removal and InstallationTime to Celebrate!

Questions or Comments?

Call or Email Linda McCray x1533

cr3 steam generator replacement movement steps for removal and installation

Documents

generator movement

inchesnotes1raise generator

inchesraises generator

generator nozzle

d model geometry

model areva

d laser

inchesgenerator base