Attachment C TCT Replacement Tools.pptx

Steel Concrete Frame Graphite Liner Inlet / Outlet Elbows Tank Bolts Tank (TCT) Graphite and Boral Blocks Dam Plate Door V-Groove Fill

Thermal Column Cavity Tunnel Thermal Column Components

Tools (Laser Scanner) An preferred alternative to any physical tool is a laser scan of the entire graphite block area. When accurate enough (+/- 0.01”) this can be used to verify that the TCT will in fact come out. Data are taken with the V-groove covers removed (V-Grooves provide datum). The side, top and bottom shields (Graphite Liner) are also removed. Full front of TCT is exposed, all fasteners are left in place.

Removal of Bolts, Preparation of Tapped Holes; Keep track of final preparation of tapped holes (.5”-13 or .38”-16), see tooling description below.

A

B

C

D

E

E

A

B

C

D A: Thermal Column Door B: Graphite Blocks C: Bismuth D: Water Tank E: Concrete F: Reactor Fuel Element

C+D = TCT

F Elevation Cross Section showing south side of NBSR

Remove Door and Perform Thorough Cleanup debris

Replace Door and Pull Rods (Threaded Rods) Properly align V-grooves in Door and TCT track

Also check alignment for V-Grooves for Tool 25 at this point.

Withdraw TCT and attach to Door;

Cut off Studs and fasten

Roll out Door/Tank assembly to make room for Clam Shells

Install Set of Clamshells

Portal Crane (Tool 20) not shown

Roll Out Door/Tank/Clamshell Assembly

Install Front Face of Cask

Roll Out Cask by Small Amount

Move Cask, Place Temporary Barrier/Shield (Piecemeal)

Move Cask to Final Resting Place

Clean Mounting surface

Tools 23 and 24: no further detail available.

Fit Second Door with New TCT;

Approach Temporary Barrier/Shield

Remove First Part of Temporary Shield; Approach further

Remove Second Part of Temporary Shield; Approach further

Remove Last Part of Temporary Barrier Shield;

Clean out gasket debris (from the side)

Drive in Door/TCT Assembly

Drive in TCT

Insert and fasten all bolts

Tools: Replacement Door for Extraction Replacement TC Door made of pure steel. Door has bolt pattern same as TCT, with respect to datum provided by rolling wheels. These are 1.25 Inch THRU holes. On the outside surface shouldered bronze bushings are installed (ID 1.0”). These bushings provide gimble for tool application. Door to be slightly smaller than present door in width and height to provide for minor manipulation to have TCT disengage V-Grooves upon extraction (i.e. needs bit more clearance). Other difference with real door is an inside pocket so the TCT is shielded the moment it is captured by the door. Note there is also room for the TCT flanges. The bottom of the front ledge has V-grooves to receive the TCT. For this tool to work properly we need the dimensional relationship between the Reactor Room Rails and the V-Grooves and set this up properly before using the tool using alignment features. Gauging alignment with cylindrical rods from the back would be an option.

Tools: Replacement Door for Insertion Replacement TC Door made of pure steel. Door has bolt pattern same as TCT, with respect to datum provided by rolling wheels. These are 1.25 Inch THRU holes. On the outside surface shouldered bronze bushings are installed (ID 1.0”). These bushings provide gimble for tool application. Door to be slightly smaller than present door in width and height to provide for minor manipulation to have TCT engage V-Grooves upon insertion (i.e. needs bit more clearance). Unlike the Extraction Door, this one has vertical channels instead of pockets to allow for the Flanges to slide in from above. The bottom of the front ledge has V-grooves to Hold the TCT. For this tool to work properly we need the dimensional relationship between the Reactor Room Rails and the V-Grooves and set this up properly before using the tool using alignment features. Gauging alignment with cylindrical rods from the back would be an option.

Tools

.38” Allen Wrench to remove present bolts and insert new bolts. Allen wrench is attached to 1” rod (hex broached connection and Loctite). On drive side rod is machined .75” hexagon to receive impact wrench (or other driver). Tool is long enough to extend out of Tool 1, while engaged with TCT fasteners.

Bismuth side Frame Wall

Gasket

Mounting Surface .25” Jobber) .31” .38” .44” .59”

Tools Addressing Bolt Removal Contingencies

2.13” 1.5”

.31” Jobber .38”-16 Tap

Rounded out Hex: 0.43” DIA .50” -13 UNC Socket Cap Screw

.38”-16 UNC Socket Cap Screw Drill with .44” bit .38” deep (drill tip to bottom of head) (red outline) #5 center drill into bolt shank (green outline) Remove head with .31” drill (drill in only .50” ) (blue Outline) Drill and Tap for .38”-16-UNC LH 1.5” DP (purple outline) Install .38”-16-UNC LH 1 Head clears clearance hole in tank frame Torque that can be transferred to .50”-13 bolt shank (through thin-walled tube, .50” OD, .38” ID) exceeds snapping torque of minor diameter of .50”-13 bolt.

Fully seated .38”-16 bolt is more than capable of delivering this torque (because its shank is not torqued); See spreadsheet

#5

Rounded out Hex Procedure

.50”-13 UNC Socket Cap Screw (7075-T6)

#5

Coping with a rounded out hex

.38”-16 LH UNC

.31” Jobber .56” Jobber #5 Center Drill .44” Jobber

.31” Allen Wrench to place “bolt extractor” (.38” -16 LH-1” LG). Allen wrench is attached to 1.0” rod (hex broached connection and Loctite). On drive side rod is machined .75” hexagon to receive impact wrench (or other driver). Tool is long enough to extend out of Tool 1, while engaged with TCT fasteners.

0.66” jobber drill attached (Loctite) to 1” rod. Drive side is turned down to .50” DIA to fit driver. Function is to open up certain holes (4) in TCT to tap .75”-10 UNC threads for threaded rods that will be used in tank extraction. Drill protrudes 3” from drive shaft.

.75”-10 UNC tap with narrow shank (NTE 0.6”) attached (Loctite) to 1” rod, which is turned down to .75” over 1” to fit into countersink holes on TCT. Square connection to be preserved. Drive end is .75” square. Function: tap holes in existing TCT for threaded rods to perform extraction.

.75”-10 UNC threaded rod for old tank extraction. Extraction works with the nut acting against the bronze bearing in the temporary TC door.

Mirror image clamshells that come in from both sides of the TCT to provide shielding and provide the building blocks of a cask. Half-shells have a lip on top that allows them to rest on the shielding that is already there. Bolts secure the half shell and push them down. The interface with the floor is the same as the TCT door: a steel wheel. Thickness has to be small enough so that no major radiation field exists prior to installation.

The last clam shell is in fact the front cover of the cask.

Stack of Steel block of sufficient thickness that covers TC cavity after cask is driven away. This Assembly remains in place until the new tank is ready to be pushed in. Shield allows access for cleaning tools to remove gasket as well as access to CCTV.

Tube 1" OD .38” ID; .38” -16 UNC threaded rod through entire length +2 inches. One end is turned down to 0.59” (0.01” slip fit into TCT fastener holes). Length of tip is 4”. Inside thin end is opened up conically with very acute angle (less than 5 degrees). Three slots are machined lengthwise in the conical section (as in expanding collet). Truncated conical nut with same cone angle is supplied (large OD 0.59). Thread is .38” -16 UNC. Conical nut is attached to threaded rod /w Loctite. Threaded rod is secured with .38” -16 nut and jammed nut pair (one of which acorn). Other end of tube is chased 1”-8 UNC over length of couple of inches and receives 1”-8 UNC nut. Function of tool is to be a fastener of new TCT to TC door during insertion. Need at least 2.

.75” -10 UNC threaded rod for new tank insertion. Insertion works by installing second nut and jamming it onto the first one and installing a drawing plate with .75”-10 thread onto the surface of temporary TC door. A thrust bearing, installed with a stripper bolt prevents marring of the TCT counterbores. Potential buckling of the rod needs to be considered

Replacement Fasteners Bolt does not snap at all (and comes out clean).

Use modified steel fastener .50” -13. Length 10.63”; thread length 1.25” min.; thread .50”-13.

Bolt snaps or Hex is damaged and bolt is made to snap anyway: Use steel fastener, original .50” -13. Length 10.63”; thread length 1.25” min.; thread .38”-16.

In both case thread engagement is 1”. Compare to present 2” thread engagement (present bolts are 11.63 LG; 2.25” threaded length).

Bolts to be made of Alloy Steel.

Television (Snake, endoscope) camera that can peer through holes on either side of the action hole to check for proper tool engagement. Perhaps bury in .75” OD inch tube for ease of manipulation

I-beam crossing the thermal column to provide overhead rails to drive in clamshells. Clamshells can be loaded well outside of radiation field and “driven” into place. Need remote control crane on I-beam trolley to lift wheels from clamshells just off floor. Crane hooks can be taken off when fasteners are put into place. Can think of remote control fasteners (for the clamshells), which would imply remote control unhooking. There are safety questions that are going to be raised by that.

Installation (tapped holes, steel straps etc.) to connect all shields (temporary TC door and all clamshells and front door) and allow for solid structure to be formed for the cask.

image1.emf image2.jpeg image3.jpg image4.jpeg image5.jpeg image6.jpeg image7.png image8.jpeg image9.jpeg