Nuclear Power Corporation of India Limited

(A Government of India Enterprise)

Narora Atomic Power Station
Coolant Channel Replacement Group

PROCEDURE NO.NAPS-I/EMCCR/P#119/R-0

PROCEDURE FOR INSTALLATION

OF
SHOCK ABSORBER ASSEMBLY

Neet Agarwal (SO/D,CCRG)

Prepared by :

M.K.Sharma (SO/D,CCRG)

Checked by : (S.Patra)
SO/G, CCRG

Reviewed by : (R.D Bhatt)

M.S.

Approved by : (L.K.Jain)
Chief Superintendent

Doc Ref. No :- NAPS-I/EMCCR/P#119/R-0

Procedure for installation Revision No. 0 Page No. 1
Topic
of SA Assembly Issue No. 1 01-01-2009

NAPS-I/EMCCR/P#119/R-0 Page 1 of 10
 CONTENTS

Sl. No. Description Page No.

1.0 Scope 3

2.0 Reference Drawings 3

3.0 Pre-Requisites & Preparations 3

4.0 Radiation Field 4

5.0 Man Power Requirement & Estimated Man-rem 4

6.0 Man Power / Training 5

7.0 Tools/Tackles And Consumables 5

8.0 Working Procedure 6

9.0 Precautions 7

10.0 Format Of Checklist/Report 9

NAPS-I/EMCCR/P#119/R-0 Page 2 of 10
1.0 SCOPE:

This procedure describes the method of installation of Shock Absorber

Assembly of End Fitting after en-masse coolant channel replacement at
Narora Atomic Power Station Unit # 2. The assembly consists of split
yokes, fixing blocks (two sets), square head cap screws (four numbers),
washers, shock absorbing studs (two numbers), front nut (two numbers)
lock nut (two numbers) and back nut (two numbers).

2.0 REFERENCE DOCUMENTS

2.1 SPECIFICATIONS

PP-E- 2142 E/F Shock Absorber Stud details

PP-E- 2141 E/F Shock Absorber System Yoke Details
PP-P-2125 Technical specification for En-masse Coolant Channel
Reinstallation requirements for NAPS-2

2.2 DRAWINGS:
1. NAPS-1/31120/2417/GA Reactor Coolant Channel End Fitting
Assembly
2. NAPS-1/31120/2419/DD Shock Absorber Stud Details
3. NAPS-1/31120/2420/DD Shock absorber system Yoke details
4. NAPS-1/31120/2421/DD Coolant channel assembly shock
absorber fixing arrangement & details
5. NAPS-1/31120/2414/DD End fitting & Shock Absorber Units
Installation Diagram

3.0 PRE REQUISITES AND PREPARATIONS:

3.1 Communication system is available in both vaults.

3.2 Sufficient illumination is available in both Vaults and emergency lighting
check.
3.3 FM vault ventilation system is operating.
3.4 Ensure top shielding plates of SEP are closed and the front shielding
window is opened to the required extent only.
3.5 Required tools, tackles and consumables as specified in this procedure
are available in the working area. Only qualified tools shall be used for the
work.
3.6 Self-Elevating Platform is available to reach at different elevation and
should be locked at the required height. Extension put at the front side of
SEP for access during installation phase.

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3.7 Sequence of installation of assemblies shall from top row (i.e. A-row) to
bottom row (Trow) and from outward to inward progressively.
3.8 Radiological work permit is taken from HPU for each shift.
3.9 Recommendations as mentioned in RWP shall be followed.
3.10 The entire work shall be under the control of a Green qualified
departmental coordinator.
3.11 Ensure front & rear area gamma monitors are in working condition.
3.12 All the components of shock absorber assembly such as yokes, studs and
other hardware are degreased and cleaned thoroughly.
3.13 Stud holes of FSTS are checked for healthiness of threads and tapped if
required and cleaned.
3.14 DCR of End-fitting checked for assessing the requirements of special size
yoke if any. Check for use over size stud from construction document.
3.15 Bellow welding to bellow attachment ring is complete and cleared for
channels up to one row below the working row.

4.0 RADIATION FIELD:

The following radiation level is expected at the time of taking up this work:

i. Vault entrance field 10-15 mR/hr

ii. General radiation field Inside the 20-30mR/hr

Platform
iii. On contact at E-face 300mR/hr

The radiation fields shown above are for general guidance only. However,
actual fields are likely to vary. Refer RWP for latest radiation fields.
5.0 MANPOWER REQUIREMENT & ESTIMATED MAN REM:

5.1 Installation Crew

Supervisor 1
Technician 1
Rigger cum Helper 1
5.5 Number of crew operating per vault in a shift 1
5.6 General Radiation field anticipated (infront of open 80-100mR/Hr
window)
5.7 Working time required at the active area in each 40 minutes
Vault/SAA
5.8 Dose expected per vault 32 man-rem
5.9 Total man Rem for installation of 612 SAA 64 man Rem

NAPS-I/EMCCR/P#119/R-0 Page 4 of 10
6.0 MAN POWER TRAINING:

6.1 Adequate number of people from supervisory and tradesmen cadre will be
involved in this operation.

6.2 The personnel proposed to engage in fieldwork shall undergo proper

training using qualified tools at the mock up facility at CCR shop. Orange
qualification shall be done at Station Training center while practical skill
based training shall be carried out at CCR shop. A committee constituted
for this purpose shall qualify the personnel. Only qualified personnel will
be permitted to work on this module. These personnel shall be qualified
only after they perform the required operation successfully 3-5 five times
with the required tools on the mock up facility.

6.3 Personnel to be engaged in this work must have orange qualification and
industrial safety training.

7.0 TOOLS /TACKLES AND CONSUMABLES:

7.1 Long tool to hold the fixing block 4 nos.

7.2 Tool to hold yoke halves 4 nos.
7.3 Long tool to install the square head bolt. 4 nos.
7.4 Long tool to install the studs 4 nos.
7.5 Torque wrench 2 nos.
7.6 Long tool to install back nut One set
7.7 Long tool to install front side main nut One set
7.8 Long tool to install front side lock nut 1 No
7.9 Gap measuring tool for creep nut adjustment 1 No
7.10 GO/No-Go gauge to check flatness of spring 2 Nos
washer
7.11 Wire brush 4 Nos
7.12 Cotton cloth 4 Nos
7.13 Polythene sheet -
7.14 Collecting trays covered with polythene sheet 2 nos
7.15 Omega-99 Never-seize compound Adequate
quantity

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8.0 WORKING PROCEDURE:
In order to centralize the channel the total compression in the bellows
shall be equally divided by displacing the channel suitably and fixing it by
positioning front nut and back nut of fixed end of channel. Never-seize
compound shall be applied on threaded parts of shock absorber assembly
hardware prior to their installation.

Steps for North side ( Fixed End )

8.1 Measure & record distance from E face of end fitting to F/M side tube
sheet face.
8.2 Fix bellow protective cover with SAA stud by tightening screw provided on
bellow protective cover.
8.3 Keep back nut with lock washer & front nut with washer & lock nut in
approximate position on shock absorbing studs before tightening stud into
Fuelling machine side tube sheet. This activity should be carried out
outside FM vault to avoid radiation exposure.
8.4 Apply never-seize compound on threads of stud.
8.5 Install the studs on end shield and carry out tightening with torque wrench
with torque value of 8Kg-m. Note down stud Sr No in check lists.
8.6 Fix back side fixing block on rear side of upper yoke half by tightening M4
hexagonal socket head cap screws (2 Nos) with proper alignment of fixing
block holes with the yoke halves. This activity should be carried out
outside FM vault to avoid radiation exposure.
8.7 Hold the upper half yoke by fabricated tool/ hand and place it on the end
fitting at the step provided.
8.8 Place the lower yoke in position by fabricated yoke holding tool/hand and
hold the yoke in position. Note down yoke Sr No in check list.
8.9 Install upper front fixing block by square head screw along with spring
washer (4 nos) using fabricated tool.
8.10 Similarly install rear and front fixing blocks at the lower side with square
head screw and washers.
8.11 Tighten rear side nut of both the upper and lower studs against yoke
halves. Tighten front main nut by torque wrench with a torque of 4 kg-m to
flatten the spring washers. Measure the flatness of spring washer with the
help of No-Go gauge. Ensure locking of channel by proper tightening of
front and back nut against yoke.
8.12 Measure the E-face to FSTS distance. It should be with in 1150 + 1 mm.
8.13 Adjust the channel by tightening the main nuts (front or rear) such as to
achieve E-Face to FSTS distance 1150 mm +1 mm.

NAPS-I/EMCCR/P#119/R-0 Page 6 of 10
 For example: - Torque the front main nut to move the channel away from
the operator or vice-versa.
8.14 Apply torque of 8 Kg-m at the front lock nut by using torque wrench so that
it gets tighten over the main nut. Similarly repeat the process to torque
lower front nuts.
8.15 Measure FSTS to E-face distance. The distance should be 1050+1 (1149-
1151) mm. for both the sides.
Steps for south side (Floating End )

8.16 Fix bellow protective cover with SAA stud by tightening screw provided on
bellow protective cover.
8.17 Keep back nut and lock washer at the end of the unfinished threads of
stud towards F/M side tube sheet & front nut & lock nut at approximate
position 36 mm cold margin. This activity should be carried out outside FM
vault to avoid radiation exposure.
8.18 Apply never-seize compound on threads of stud.
8.19 Install the studs on end shield and carry out tightening with torque wrench
with torque value of 8Kg-m.
8.20 Fix back side fixing block on rear side of upper yoke half by tightening M4
hexagonal socket head cap screws (2 Nos) with proper alignment of fixing
block holes with the yoke halves. This activity should be carried out
outside FM vault to avoid radiation exposure.
8.21 Hold the upper half yoke by fabricated tool/hand and place it on the end
fitting at the step provided.
8.22 Place the lower yoke in position by fabricated yoke holding tool/hand and
hold the yoke in position.
8.23 Install upper front fixing block by square head screw along with spring
washer (4 nos) using fabricated tool.
8.24 Similarly install rear and front fixing blocks at the lower side with square
head screw and washers.
8.25 Adjust a gap of 39 mm between the yoke and the front main nut to achieve
a creep margin of 36 mm. Install & tighten the lock nut against the front
nut by applying a torque of 8 kg-m to prevent any movement.
8.26 Measure E-face to FSTS distance. It should be between (1149-1151) mm

9.0 PRECAUTIONS:

1. Before commencing the work, ensure top shielding plates of SEP are
closed and front small windows are open to the required extent only.
2. Ensure wearing of TLD and DRD and check the dose every 15 minutes.

NAPS-I/EMCCR/P#119/R-0 Page 7 of 10
3. Use Radiation and Industrial Safety protections as advised.
4. Use oro-nasal respirator / surgical nose-pad to avoid any particulate/dust
intakes whenever advised by HPU.
5. Care should be taken not to drop components and tools.
6. Move out from platform to 100 M El MAL lobby during any interval,
however short.
7. Inform supervisor in case of any difficulties.
8. Always ensure working platform is clean and free of any oil or slippery
surface.
9. Caution / Communications if any, to next shift to be conveyed.
10. All materials shall be deposited at the storage location in service building
at the end of each shift.
11. Radiation protective equipments (Respirator) shall be brought back to
service building after use.

NAPS-I/EMCCR/P#119/R-0 Page 8 of 10
 CL NO. NAPS-
Nuclear Power Corporation of India Limited
1/EMCCR/P#119/CL-1
(A Government of India Enterprise)
Narora Atomic Power Station
Coolant Channel Replacement Group

NAPS-2 EMCCR CHECK LIST- INSTALLATION OF SHOCK ABSORBER ASSEMBLY

(To be filled for every SA Assembly)

Prepared By Checked By Reviewed By Approved By

M.K.Sharma S.Patra R.D.Bhatt L.K.Jain

SO/D,CCRG SO/G,CCRG MS CS,NAPS

Date_________________ Shift_______________

1. LATTICE LOCATION:
NORTH END SOUTH END
(Fixed end) ( Floating end )
2. (a) Top Stud Sr No.
(b) Bottom Stud Sr No.
(c) Yoke Sr No.
3. Visual inspection of bellows.
4. Installation of stud:
(a) Nuclear grade never seize
compound on threaded part.
(b) Back nut along with spring washer Zero Moved to the
installed on stud at its position. gap from unthreaded
yoke end of stud.
face
(c)Install front main and lock nut along Zero 39 mm gap
with spring washer on stud at its gap from from yoke
approximate position. yoke face.
face
(d)Tighten the studs at proper
orientation (along with bellow
protective sleeve, front nut and
back nut in position) in end shield
hole (specified torque 8 kg-m).
5. Upper back fixing block assembled
with the yokes by tightening socket
head cap screws.

NAPS-I/EMCCR/P#119/R-0 Page 9 of 10
6. Place the yoke set in position on end
fitting and locate the front fixing blocks
by loosely screwing the square head
bolt.
(To be done from platform extension)

7. Tightening of square head bolts.

8. Ensure position of back nut. Zero gap from Moved to the
yoke face unthreaded end of
stud
9. Positioning of front nut zero gap from 39 mm gap from
yoke face yoke face
10. FSTS to E-face distance (E = 1149-
1151 mm)
12. Centralization of channel done if E-
face to FSTS distance is not in range.
13 Measure the distance between front NA
main nut and the yoke face
16 Tightening of front main nut (Torque 4 NA
Kg-m)
17 Gap between the front main nut & back NA
nut with the yoke face is checked by
GO/NO-GO gauge
18 Tightening of front lock nut (Torque 8
Kg-m)
19 Total length of coolant channel

Remarks: ________________________________________________________
___________________________________________________________________

CONTRACTOR NAPS
EXECUTION QA CCRG QA

Signature:
Name:
Date:

Reviewed by:

NAPS-I/EMCCR/P#119/R-0 Page 10 of 10