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OWL-TM-3 041

Contract No. W-74-5-eng-26

Molten-Salt Reactor Program

MSRE OPERATOR TRAINING AND OPERATING TECHNIQUES R. H. Guymon

. AUGUST 1973 NOTICE This report was prepared as an account of work sponsored by the United States Government. Neither the United States nor the United States Atomic Energy Commission, nor any of their employees, nor any of their contractors, subcontractors, or their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness or usefulness of any information, apparatus, product or process disclosed, or represents that its use would not infringe privately owned rights.

OAK RTDGE NATIONAL LABORATORY Oak Ridge, Tennessee 37830 operated by UNION CARBIDE CORPORATION for the U. S. ATOMIC ENERGY COMMISSION

iii CONTENTS Chapter ABSTRACT

........................

ACKNOWLEDGEMENTS

1 2

. 4. 5. 3

....................

...................... DESCRIPTION OF THE MSRE . . . . . . . . . . . . . . . . CHRONOLOGY . . . . . . . . . . . . . . . . . . . . . . . OPERATING PERSONNEL . . . . . . . . . . . . . . . . . . TRAINING . . . . . . . . . . . . . . . . . . . . . . . . Initial Training . . . . . . . . . . . . . . . . . . Precritical Training and Certification . . . . . . . . Prepower Training . . . . . . . . . . . . . . . . . . Training of Chief Operators . . . . . . . . . . . . . Training Before 233U Startup . . . . . . . . . . . . Other Training . . . . . . . . . . . . . . . . . . . Training of Replacements . . . . . . . . . . . . . . . Equivalence to AEC Examination . . . . . . . . . . . OPERATION OF THE REACTOR . . . . . . . . . . . . . . . . Planning . . . . . . . . . . . . . . . . . . . . . . Instructions to and Communications with Operators . Data Taking and Record Keeping . . . . . . . . . . . . APPROVAL OF MAINTENANCE AND DESIGN CHANGES . . . . . . . INFORMATION AVAILABLE TO OPERATORS . . . . . . . . . . . Design and Operations Report . . . . . . . . . . . . . OtherReports . . . . . . . . . . . . . . . . . . . . Drawings . . . . . . . . . . . . . . . . . . . . . . Miscellaneous . . . . . . . . . . . . . . . . . . . . RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . REFERENCES . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION

. 8. 7

Appendices A Schedule for Initial Training B Instructions for Flowsheet Checkout C Schedule for Precritical Training D Precritical Examinations E Schedule for Pre-Power Training F Pre-Power Examinations G Chief Operator Training Schedule H Chief Operator Review Test I MSRE Operator's Examination - May, 1969 Examples of Instructions and Communications J K Examples of the Control-Room and Building Log L Forms Used in Making Changes M. Example of MSRE Daily Report

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OWL-TM-3041

MSRE OPERATOR TRAINING

AND OPERATING TECHNIQUES

R. H. Guymon

ABSTRACT The MSRE was a unique, fluid-fuel reactor that operated successfully at ORNL from 1965 through 1969. MSRE operators and supervisors, mostly, veteran ORNL employees, were trained and examined within the Molten-Salt Reactor Program. Formal training sessions were held at the beginning of prenuclear testing, just before initial criticality and before the approach to power. Training of replacements and retraining of operators was a continuing effort. This report describes the training, the information provided for use by the operators, operations planning and administration, and the use of procedures. Recommendations by the author (former MSRE operations chief) conclude the report. Keywords: *MSRE + *operation + *procedures -I- *training administration 3. communications + examinations $. operators 3. qualifications + reactors + startup + testing

ACKNOILEDGEMENTS

The a u t h o r wishes t o acknowledge t h e e f f o r t s of S . E. Beall and C. E. Wolfe i n supplying v e r y a b l e o p e r a t i n g personnel and express a p p r e c i a t i o n t o t h e e n t i r e crew f o r t h e i r c o n t r i b u t i o n s and f i n e t e a m s p i r i t d u r i n g t r a i n i n g and throughout t h e o p e r a t i o n of t h e MSRE.

S p e c i a l thanks i s due

t o P. N. Haubenreich f o r h i s l e a d e r s h i p of t h e p r o j e c t hnd h i s s u g g e s t i o n s on t h i s r e p o r t . J. R. Engel and B. H. Webster d e s e r v e much of the c r e d i t f o r the co-

o p e r a t i o n between o p e r a t i o n s , experimentation, and maintenance.

1 1.

INTRODUCTION

The o b j e c t i v e of t h e Molten-Salt Reactor Program was t h e development of a p r a c t i c a l b r e e d e r r e a c t o r i n which t h e f i s s i l e and f e r t i l e materials are i n c o r p o r a t e d i n a molten mixture of f l u o r i d e salts.'

A major s t e p i n

t h a t development w a s t h e Molten-Salt Reactor Experiment (MSRE), a 7.4-MW r e a c t o r t h a t operated a t ORNL from 1965 through 1969.

The main purpose

of t h e MSRE w a s t o demonstrate t h a t t h e d e s i r a b l e f e a t u r e s of t h e molten-

s a l t concept could be embodied i n a p r a c t i c a l r e a c t o r t h a t could be cons t r u c t e d and maintained without undue d i f f i c u l t y and one t h a t could b e operated s a f e l y and r e l i a b l y .

This purpose w a s accomplished, as t h e MSRe

operated f o r long i n t e r v a l s and w i t h a high o v e r a l l a v a i l a b i l i t y . 2 , 3 Among t h e f a c t o r s c o n t r i b u t i n g t o t h e s u c c e s s of t h e MSRE were t h e v e r y thorough p r e p a r a t i o n s f o r o p e r a t i o n , i n c l u d i n g c a r e f u l s e l e c t i o n and t r a i n i n g of o p e r a t i n g p e r s o n n e l , and t h e d i s c i p l i n e d manner i n which t h e o p e r a t i o n was planned and conducted.

It i s t h e purpose of t h i s r e p o r t t o

d e s c r i b e t h e s e a s p e c t s of t h e MSRE.

Only b r i e f d e s c r i p t i o n s of t h e physi-

c a l p l a n t and i t s h i s t o r y are i n c l u d e d , s i n c e t h e s e have been widely re8

ported.

DESCRTPTION OF THE MSRE:

The MSRE w a s a s i n g l e - r e g i o n ,

graphite-moderated,

which produced heat a t a r a t e of 7.4 MW(th).

thermal r e a c t o r

T h e fuel w a s UFL, ( o r i g i n a l l y

235U and l a t e r 233U) i n a carrier s a l t of LiF-BeFz-ZrFk.

A t the operating

temperature of 1200째F, t h i s s a l t w a s a l i q u i d w i t h good p h y s i c a l proper-

ties

-- v i s c o s i t y ,

8 c e n t i p o i s e (about l i k e kerosene); d e n s i t y , ~ 1 3 5

l b / f t 3 ; h e a t c a p a c i t y , 0.57 B t u / l b OF; and a v e r y low vapor p r e s s u r e of

cO.1 mm Hg.

The l i q u i d u s temperature of t h e f u e l s a l t w a s 813OF, s o t h e

equipment and procedures had t o b e designed t o p r e v e n t f r e e z i n g .

The s a l t

a l s o had t o be p r o t e c t e d from c o n t a c t w i t h a i r t o minimize c o r r o s i o n and accumulation of o x i d e s . The d e s i g n c o n d i t i o n s f o r full-power o p e r a t i o n are shown i n t h e f l o w diagram (Fig. 1). The g e n e r a l arrangement of t h e p l a n t i s shown i n Fig. 2.

TO ABSOCUTE FILTERS

Fig, 1. MSRE Flow Diagram.

ORNL-DWG

REACTOR RooM\___

63.1209R

CONTROL A

.~.

Fig.

General

1. 2. 3. 4. 5 6.

REACTOR VESSEL HEAT EXCHANGER FUEL PUMP FREEZE FLANGE Tt IERMAL SHIELD COOLANT PUMP

Arrangement

of MSRE.

7. 8. 9. 10. 11. 12. 13.

RADIATOR COOLANT DRAIN TANK FANS FUEL DRAIN TANKS FLUSH TANK CONTAINMENT VESSEL FREEZE VALVE

4 I n t h e r e a c t o r primary system, t h e f u e l s a l t w a s r e c i r c u l a t e d by a sumptype c e n t r i f u g a l pump through a shell-and-tube actor vessel.

h e a t exchanger and t h e re-

The h e a t generated i n t h e f u e l s a l t as i t passed through

t h e r e a c t o r w a s t r a n s f e r r e d i n t h e h e a t exchanger t o a molten LiF-BeF2 coolant salt.

The c o o l a n t s a l t was c i r c u l a t e d by means of a second sump-

type pump through t h e h e a t exchanger and through t h e r a d i a t o r where t h e h e a t w a s d i s s i p a t e d t o t h e atmosphere.

The r a t e of h e a t removal w a s con-

t r o l l e d by u s i n g e i t h e r one o r two blowers and by a d j u s t i n g doors i n t h e r a d i a t o r a i r stream and dampers i n a bypass stream.

Drain tanks w e r e pro-

vided f o r s t o r i n g t h e f u e l and c o o l a n t s a l t s a t h i g h temperature when t h e reactor was not operating.

Drain and t r a n s f e r l i n e s included f r e e z e v a l v e s ,

where s a l t could be f r o z e n o r thawed t o block o r permit flow.

The s a l t s

were d r a i n e d by g r a v i t y , and were t r a n s f e r r e d back t o t h e c i r c u l a t i n g syst e m s by p r e s s u r i z i n g t h e d r a i n t a n k s w i t h helium.

Electric heaters were

used t o keep t h e s a l t molten i n t h e t a n k s and t o p r e h e a t t h e p i p i n g system before f i l l i n g .

Diesel-powered

h e a t e r s and s a l t pumps.

g e n e r a t o r s provided emergency power f o r

The s a l t systems normally o p e r a t e d w i t h t h e cover

gas a t 5 p s i g . Most of t h e f i s s i o n products remained i n s o l u t i o n i n t h e f u e l s a l t . One c l a s s , known as â&#x20AC;&#x153;noble m e t a l s , I t d e p o s i t e d on g r a p h i t e and metal s u r f a c e s . The gaseous f i s s i o n product s , krypton and xenon, were removed cont i n u o u s l y from t h e c i r c u l a t i n g f u e l s a l t i n t h e f u e l pump t a n k .

There they

t r a n s f e r r e d from t h e l i q u i d t o t h e helium cover gas and were swept o u t of t h e t a n k by a s m a l l purge stream.

This stream passed through holdup p i p i n g ,

a f i l t e r , and long, water-cooled beds of a c t i v a t e d carbon.

The passage of

krypton and xenon through t h e s e beds r e q u i r e d days t o weeks, by which t i m e a l l the r a d i o i s o t o p e s b u t t h e 85Kr had decayed s o t h a t t h e stream could b e s a f e l y d i l u t e d w i t h a i r and discharged t o t h e atmosphere. The f u e l and c o o l a n t systems were provided w i t h equipment f o r t a k i n g samples of t h e molten s a l t w h i l e t h e r e a c t o r was o p e r a t i n g a t power.

The

f u e l sampler w a s a l s o used d u r i n g o p e r a t i o n f o r adding s m a l l amounts of uranium o r plutonium t o compensate f o r burnup.

An a r r a y of g r a p h i t e and

m e t a l specimens a t the center of t h e c o r e w a s removed and r e p l a c e d p e r i -

o d i c a l l y d u r i n g shutdowns.

5 W

The n e g a t i v e temperature c o e f f i c i e n t of r e a c t i v i t y of t h e f u e l and g r a p h i t e moderator made n u c l e a r c o n t r o l of t h e system v e r y simple.

How-

e v e r , t h r e e c o n t r o l rods were provided f o r a d j u s t i n g t e m p e r a t u r e , compens a t i n g f o r b u i l d u p of f i s s i o n p r o d u c t s , and f o r shutdown. I n s t r u m e n t a t i o n was i n s t a l l e d t o a d e q u a t e l y monitor a l l v a r i a b l e s and t o a u t o m a t i c a l l y handle any a n t i c i p a t e d m a l f u n c t i o n s .

This, together with

c o l l e c t i o n of much d a t a by an o n - l i n e computer, made i t p o s s i b l e t o o p e r a t e w i t h a minimum o p e r a t i n g crew. Because of t h e f i s s i o n - p r o d u c t a c t i v i t y , t h e f u e l - s a l t equipment w a s c o n t a i n e d i n h e a v i l y s h i e l d e d c e l l s t h a t were k e p t s e a l e d except when maintenance w a s b e i n g done w i t h long-handled t o o l s through openings i n t h e c e l l The f u e l off-gas system w a s a l s o s h i e l d e d and c o n t a i n e d .

roof.

Radiation

zones were e s t a b l i s h e d around t h e c o o l a n t s a l t system and a few o t h e r l o c a t i o n s , b u t normal o p e r a t i o n of t h e r e a c t o r d i d n o t r e q u i r e e n t r y i n t o t h e s e zones. Although n o t shown i n Fig. 2, t h e p l a n t i n c l u d e d a simple p r o c e s s i n g f a c i l i t y f o r t r e a t i n g f u l l 75-ft3 b a t c h e s of f u e l s a l t w i t h hydrogen f l u o -

r i d e or f l u o r i n e gases,

The hydrogen f l u o r i d e t r e a t m e n t w a s used f o r re-

moving o x i d e contamination from t h e s a l t as H 2 0 vapor; t h e f l u o r i n e t r e a t ment, f o r removing t h e uranium as gaseous UF6.

CHRONOLOGY

Design of t h e MSRE w a s s t a r t e d i n t h e summer of 1960.

Construction

of t h e primary system components and m o d i f i c a t i o n s of an e x i s t i n g b u i l d i n g t o house t h e MSRE began i n 1962 and by mid-1964,

i n s t a l l a t i o n of t h e

s a l t systems w a s completed. E a r l y i n t h e d e s i g n and development of t h e E R E , some of t h e e n g i n e e r s involved were a s s i g n e d t o become members of t h e o p e r a t i n g s t a f f .

As design

and c o n s t r u c t i o n p r o g r e s s e d , t h e s e e n g i n e e r s made p e r i o d i c reviews and i n s p e c t i o n s t o a s s u r e t h a t p r o p e r c o n s i d e r a t i o n w a s b e i n g given t o operability,

They a l s o began w r i t i n g procedures f o r checkout and o p e r a t i o n of

t h e systems and components, W

The e n g i n e e r who was t o head t h e o p e r a t i o n s

s t a f f w a s given t h e r e s p o n s l b l l i t y f o r d e t a i l e d p l a n n i n g of t h e t r a i n i n g

program, and he and t h e o t h e r e n g i n e e r s prepared t h e i n s t r u c t i o n a l material.

A s i n d i c a t e d on Fig. 3 , t h e i n i t i a l o p e r a t i n g s t a f f w a s assembled by J u l y ,

1964 and b a s i c o p e r a t o r t r a i n i n g w a s s t a r t e d on J u l y 6. ' I

A s c o n s t r u c t i o n w a s completed on more p a r t s of t h e p l a n t , t h e e f f o r t s p e n t on checking, c a l i b r a t i n g , and t e s t i n g i n c r e a s e d . o p e r a t i o n s were placed on a 24-hour, crews.

I n l a t e September,

7-day b a s i s w i t h f o u r r o t a t i n g - s h i f t

Flush s a l t w a s added t o t h e f u e l f l u s h t a n k , c o o l a n t s a l t was added

t o t h e c o o l a n t d r a i n tank, and a u x i l i a r y equipment w a s put i n t o o p e r a t i o n . The f u e l and c o o l a n t c i r c u l a t i n g systems w e r e f i l l e d w i t h s a l t and t h e p l a n t w a s operated d u r i n g most of January and February, 1965.

The loops

were t h e n d r a i n e d t o h y d r o f l u o r i n a t e t h e f l u s h s a l t , t o load f u e l c a r r i e r s a l t , and t o complete o t h e r p r e p a r a t i o n s f o r zero-power n u c l e a r o p e r a t i o n . During t h i s p r e c r i t i c a l shutdown, s e v e r a l weeks w e r e s p e n t i n advanced t r a i n i n g of t h e r e a c t o r o p e r a t o r s , w i t h emphasis on n u c l e a r a s p e c t s , and t h e a d m i n i s t r a t i o n of comprehensive c e r t i f y i n g examinations by Molten-Salt Reactor Program s u p e r v i s i o n . C r i t i c a l i t y w a s a t t a i n e d on June 1, 1965 and t h e zero-power n u c l e a r experiments w e r e completed d u r i n g t h a t month.

The r e a c t o r w a s t h e n d r a i n e d

f o r completion of s h i e l d i n g and containment p r o v i s i o n s and minor modifications.

During t h i s shutdown, t h e o p e r a t o r s underwent a d d i t i o n a l t r a i n i n g

and t e s t i n g w i t h emphasis on power o p e r a t i o n . sumed i n December, 1965.

Nuclear o p e r a t i o n w a s re-

A f t e r some d i f f i c u l t i e s w i t h t h e f u e l off-gas

system were overcome, f u l l power w a s a t t a i n e d i n May, 1966.

By December

of t h a t y e a r , t h e planned program of s t a r t u p t e s t i n g had been completed and s o l u t i o n s had been found t o t h e v a r i o u s problems t h a t had a r i s e n .

i n d i c a t e d i n Fig. 3 , t h e r e a c t o r w a s a t f u l l power a l a r g e p e r c e n t a g e of t h e t i m e f o r t h e remainder of t h e o p e r a t i o n w i t h 235U, which ended i n March, 1968.

During t h e 5-month shutdown i n 1968, c o r e specimens were

changed, v a r i o u s maintenance w a s done, t h e f l u s h and f u e l s a l t s were processed t o remove t h e uranium, and a charge of 233U f u e l w a s added t o t h e f u e l carrier s a l t .

During t h e s e months, t i m e w a s a v a i l a b l e f o r guided

s e l f - s t u d y by t h e o p e r a t o r s , and b e f o r e n u c l e a r o p e r a t i o n w a s resumed, they were reexamined.

C r i t i c a l i t y w a s a t t a i n e d on October 2 , 1968 and on October 8 , USAEC Chairman Seaborg took t h e r e a c t o r power t o 100 kW, markfng the f i r s t t i m e

ORNL-DWG 73-3081 FIRST EXAM

4 .

CHARGE CHARGE FLUSH COOLANT SALT SALT

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PRECRITICAL TRAINING

INITIAL TRAINING

lEPARE FOR OPERATION AND ASSEMBLE CREW v. ...

PRECRITICAL EXAM 235U CRITICALITY

PREPOWER TRAINING

............. ..........

....................

CHARGE

PREPOWER EXAM

TEST CONTAINMENT

A E E L

MODIFICATIONS AND COMPLETION OF CONSTRUCTIO''

PROCES' F L U S Z A L T

...................................................

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FLUSH J

1964

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INVESTIGATE OFF-GAS

1965

GOT0 FULL

MODIFICATIONS AND

REMOVE

CHIEF OPERATOR TRAINING

REPAl R MAINTENANCE

............

REPAIR IR LINES

CORE SPECIMENS

$ 8

u 6 g

a 2 FUEL 0 FLUSH COOLANT J

1966

CORE SPECIMENS El

1967

T E S T ~ & ~ ~ M O DFICATIONS I OF CHEM PROCESSING PLANT .:.::..:w ., >>:. ..-.= :.................,++.>

233U CRITICALITY OPERATORS EXAM

MAINTENANCE & INSPECTION

P R o ~ [ADD ~ 233U ~~ FUEL $!j~?-

GAMMA

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5 4

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3 2 2 0 {FU FLUSH EL COOLANT

1968

Fig. 3 .

1969

Chronology of Operator T r a i n i n g and Reactor Operation.

that any reactor had been operated with 233U fuel. After completion of rod-calibration and other tests, the reactor was taken to full power in January 1969. Investigations of the effects of gas circulating with the fuel involved revisions to permit operation of the fuel pump at reduced speed. Power operation continued until the first of June when the loops were drained to change the core specimen array and to make preparations for some special experiments. The remainder of the operation involved extensive sampling, gamma scanning, and varying of operating conditions to study the distribution of fission products and tritium. Consideration of the limited funds available to the Molten-Salt Reactor Program, the fact that the primary goals of the MSRE had been achieved, and the funding needs of other moltensalt breeder development led to a decision by program management to terminate the

operation. Accordingly the reactor was shut down on Dec. 12,

1969 and within 2 weeks the operating staff was disbanded.

OPERATING PERSONNEL c

The initial operating staff was comprised of four crews, each consisting of two engineers and three technicians, all under the supervision of an operations chief and assistant operations chief, and augmented by two day-shift technicians. Long-range planning, analysis of data, maintenance coordination, and design changes were handled mostly by other groups within the MSRE Operations Department, whose original organization is outlined in Fig. 4 .

In addition to those shown, personnel of other ORNL di-

visions such as chemical analysis groups, health physics, industrial hygiene, metallurgy, chemistry, instrumentation, computer programing, and maintenance forces contributed significantly to the MSRE. After the completion of the nuclear startup tests, the shift crews were each reduced to one engineer and three technicians.

Later, after the

operation became more routine, each crew was further reduced to 3 technicians.

On day shifts or when special experiments were being run this

3-man crew was augmented by an engineer and 1 or 2 technicians. V

OWL-DWG 67-6006 OPERATIONS DEPT. HEAD

DESIGN L I A I S O N ENGR.

ANALYSIS CHIEF

1 TECHNICIAN

Z TECHNICIANS

Fig. 4 .

SHIFT SUPERVISOR ASST. S H I F T SUR, 3 TECHNICIANS

SHIFT SUPERVISOR ASST. SHIFT SUP. 3 TECHNICIANS

SHIFT SUPERVISOR ASST. SHIFT S U P 3 TECHNICIANS

Original MSRE Operations Organization Chart.

Turnover in personnel was moderate; between July 1964 and December 1969

3 engineers and 5 technicians joined the operations group and 10 engineers and 4 technicians left the group. The duties of the original operating staff were as follows. The Operations Chief was responsible for organizing and training the operations staff. He participated in long-range planning, general policy decisions, and safety reviews of the reactor. He (or the Assistant Operations Chief) was responsible for the execution of the daily experimental program and decided on the course of action to be taken in case difficulties prevented carrying out the planned program. The Assistant Operations Chief, in addition to substituting for or assisting the Operations Chief in the above, investigated special operational problems encountered, reported on operational activities at planning meetings, and directly supervised the activities of the day-shift technicians. The Operations Chief and Assistant Operations Chief were on call at all times.

There were frequent communications between them and the evening

and midnight shifts and all shifts over the weekends. The day-shift technicians helped in special experiments, helped take routine samples, maintained records of chemical analyses, filed other data, maintained operating supplies including l o g forms, check lists, etc., and provided vacation relief for the regular operators. Each Shift Supervisor was responsible for coordinating and overseeing

It was his duty to carry out all shift instructions, to maintain an overview of the plant with special all operations and maintenance on his shift.

alertness for anomalous conditions, and to keep all members of his crew informed of changes in equipment, plans, or operating procedures.

He was re-

quired to be especially familiar with all equipment and operations so as to be able to react promptly and effectively to any emergency. The Assistant Shift Supervisor assisted in the foregoing duties and handled special tasks such as the numerous tests required during the startup phase of the MSRE. The three technicians on each shift rotated through three different assignments; building-log, control-room, and utility.

The building-log

11 W

t e c h n i c i a n w a s r e s p o n s i b l e f o r t a k i n g a l l r o u t i n e d a t a except t h e c o n t r o l room l o g .

During each 8-hour s h i f t , he made 2 complete rounds of t h e re-

a c t o r s i t e and w a s r e s p o n s i b l e f o r n o t i n g any a b n o r m a l i t i e s o r d e p a r t u r e s from t h e recommended maximum and minimum l i m i t s shown on h i s l o g s h e e t s . The control-room t e c h n i c i a n took t h e control-room l o g , c a l c u l a t e d and p l o t t e d important d a t a , and w a s r e s p o n s i b l e f o r t h e o p e r a t i o n of t h e r e a c t o r H e k e p t a w r i t t e n r e c o r d i n t h e c o n s o l e l o g of a l l

from t h e c o n t r o l room.

occurrences during h i s s h i f t .

The u t i l i t y t e c h n i c i a n w a s r e s p o n s i b l e f o r

sampling and m i s c e l l a n e o u s t e s t s and d u t i e s as r e q u e s t e d .

Because t h e

t h r e e assignments were r o t a t e d , each o p e r a t o r had a good u n d e r s t a n d i n g of t h e o v e r a l l o p e r a t i o n and a f a m i l i a r i t y w i t h each j o b . I n t h e f i n a l o r g a n i z a t i o n , one of t h e t h r e e t e c h n i c i a n s on each crew

w a s d e s i g n a t e d Chief Operator and assumed most of t h e d u t i e s of t h e p r e v i ous s h i f t s u p e r v i s o r .

Candidates f o r Chief Operator were given a d d i t i o n a l

t r a i n i n g and examination b e f o r e b e i n g given r e s p o n s i b i l i t y f o r t h e s h i f t . S i x t e c h n i c i a n s were c e r t i f i e d as Chief O p e r a t o r s s o t h a t v a c a t i o n r e l i e f

could b e handled,

An e n g i n e e r w a s a s s i g n e d as s h i f t s u p e r v i s o r on t h e day

s h i f t t o h a n d l e t h e e x t r a work a s s o c i a t e d w i t h c o o r d i n a t i n g s p e c i a l t e s t s and scheduled maintenance. The e d u c a t i o n a l background and p r e v i o u s e x p e r i e n c e of t h e o r i g i n a l s t a f f p l u s t h o s e who were l a t e r added are summarized i n F i g . 5. A l l of t h e s u p e r v i s o r s had BS d e g r e e s o r e q u i v a l e n t . school graduates,

Two were r e a c t o r

F i v e had majored i n chemical e n g i n e e r i n g , 2 i n n u c l e a r

e n g i n e e r i n g , 2 i n mechanical e n g i n e e r i n g , and one each i n e l e c t r i c a l engin e e r i n g , marine e n g i n e e r i n g , e l e c t r o n i c e n g i n e e r i n g , and c h e m i s t r y .

Two

of t h e s h i f t s u p e r v i s o r s came t o MSRE as new h i r e s , having j u s t r e c e i v e d BS d e g r e e s i n n u c l e a r e n g i n e e r i n g .

The o t h e r s had a minimum of 7 y e a r s of

p r i o r e x p e r i e n c e i n d e s i g n and/or development.

The a v e r a g e p e r i o d of p r i o r

employment by Union Carbide w a s 1 3 y e a r s ( i n c l u d i n g t h e new h i r e s ) . Most of t h e t e c h n i c i a n s had a t l e a s t 2 y e a r s of c o l l e g e ( a v e r a g e 2.6) and a minimum of 4 y e a r s d e s i g n o r o p e r a t i n g e x p e r i e n c e ( a v e r a g e , 12) bef o r e coming t o t h e MSRE. Carbide w a s 1 2 y e a r s .

The a v e r a g e p e r i o d of p r i o r employment by Union

ORNL-DWG

ENGINEERS 1

If!

COLLEGE

ETC.

REACTOR

SCHOOL

MOLTEN SALT CONSTRUCTION

F::p,:z;,‘;

:>,I

MOLTEN

fi:

‘. _

‘, _

‘~.;

DESIGN

DEVELOPMENT (OTHER THAN

Fz-1

SALT

SALT,

AND

AND OPERAT,“N MOLTEN SALT) DEVELOPMENT

1 OPERATION

REACTOR

OPERATION

OTHER

PREPARATION OR OPERATION

FOR

MSHF

L.OOPS RFAC‘IORS THAINING

9 8 7 6 5 4 3 2

3087

TECHNICIANS 7

DESIGN AND CONSTRUCTION (OTHER THAN MO1 TEN

Fig.

73.

Educational Background and Previous Experience of MSRE Operators. (as of date of hire by MSRE Operations Department)

TRAINING

Although most of t h e MSRE o p e r a t i n g s t a f f had had c o n s i d e r a b l e p r e v i ous experience and s e v e r a l had an i n t i m a t e f a m i l i a r i t y w i t h some p a r t s of t h e p l a n t , a l l were r e q u i r e d t o p a r t i c i p a t e i n a t r a i n i n g program l e a d i n g t o examination and c e r t i f i c a t i o n .

Because of t h e unique n a t u r e of t h e

MSRE, t h e c o n t e n t of t h e t r a i n i n g program and examinations w a s determined by Molten-Salt Reactor Program personnel.

The g o a l s of t h e t r a i n i n g program were t o i n s t i l l i n each o p e r a t o r and s u p e r v i s o r t h e proper a t t i t u d e s , a good b a s i c knowledge of t h e e n t i r e p l a n t , an adequate understanding of every phase of t h e o p e r a t i o n , and a f a m i l i a r i t y w i t h t h e procedures t h a t he would b e following.

The approach

used a t t h e MSRE, chosen on t h e b a s i s of p a s t e x p e r i e n c e , w a s a combinat i o n of formal t r a i n i n g , s e l f - s t u d y , and on-the-job

training.

Maximum ad-

vantage w a s t a k e n of t h e s p e c i a l knowledge of members of t h e s t a f f , by usi n g them as i n s t r u c t o r s f o r t h e s u b j e c t s i n which they were e x p e r t s .

Other

i n s t r u c t i o n w a s given by members of ORNL's H e a l t h , H e a l t h P h y s i c s , I n s t r u mentation and C o n t r o l , Reactor Chemistry, and Chemical Technology D i v i s i o n s . The i n i t i a l p e r i o d of formal t r a i n i n g began when t h e s t a f f w a s f i r s t assembled i n J u l y 1964.

The second formal t r a i n i n g p e r i o d ( c a l l e d pre-

c r i t i c a l t r a i n i n g ) followed t h e i n i t i a l f l u s h - s a l t o p e r a t i o n . zero-power

After the

experiments, t h e r e a c t o r w a s a g a i n s h u t down and i n t h e f a l l

of 1965 w e had t h e t h i r d formal t r a i n i n g p e r i o d ( c a l l e d prepower t r a i n i n g ) . I n 1967, b e f o r e t e c h n i c i a n s w e r e c e r t i f i e d as C h i e f O p e r a t o r s , t h e y w e r e given s p e c i a l t r a i n i n g .

P r i o r t o t h e beginning of o p e r a t i o n w i t h 2 3 3 U f u e l

i n 1968, extra t i m e w a s a l l o c a t e d t o a l l o p e r a t o r s f o r s e l f - s t u d y but t h e r e were no formal t r a i n i n g s e s s i o n s . A s i n d i c a t e d i n Table 1, a t o t a l of approximately 350 hours w a s s p e n t

i n formal t r a i n i n g on v a r i o u s t o p i c s .

*Although

I n addition, considerable t i m e w a s

t h e d e t a i l s of t r a i n i n g and examinations were n o t s u b j e c t t o o u t s i d e a p p r o v a l , t h e e n t i r e o p e r a t i o n of t h e MSRE, i n c l u d i n g o p e r a t o r t r a i n i n g , procedures, e t c . , w a s reviewed p e r i o d i c a l l y by t h e ORNL Reactor Operations Review Committee. There was a l s o an annual s a f e t y review by an AEC-OR0 committee and the Operating S a f e t y L i m i t s r e q u i r e d AEC approval,

Table 1.

Hours Spent i n Formal T r a i n i n g S e s s i o n s

I n i t i a l Training

Subject

Pre-Critical Training

---

Shift Supr.

A s s 't Shift Supr.

Tech.

S h i f t Supr. & A s s ' t S h i f t Supr.

Tech.

Pre-Power T r a i n i n g

All

Design and Operation

107

Instrumentation

Reactor P h y s i c s

Reactor Chemistry and M e t a l l u r g y

H e a l t h P h y s i c s and I n d . Hygiene

7 8

227

Other R e a c t o r s

On-Line Computer Flow Sheet Checkout

Total

61 233

227

15 allocated f o r self-study.

D e t a i l s of each t r a i n i n g p e r i o d and t h e t r a i n -

i n g of replacements a r e d e s c r i b e d i n t h e remainder of t h i s c h a p t e r .

I n i t i a l Training The i n i t i a l t r a i n i n g p e r i o d l a s t e d s e v e r a l months.

Most of t h e t i m e

d u r i n g t h e f i r s t f e w weeks w a s s p e n t i n classroom s e s s i o n s w i t h some s e l f s t u d y p e r i o d s and t o u r s .

Later, less t i m e w a s a l l o c a t e d t o classroom in-

s t r u c t i o n and more t i m e w a s s p e n t i n checking o u t f l o w s h e e t s , l a b e l i n g equipment, l i n e s , v a l v e s , and s w i t c h e s , shakedown of equipment, and s e l f study. Assignments had been made a t l e a s t a month i n advance and t i m e had been a l l o c a t e d f o r t h e i n s t r u c t o r s t o p r e p a r e f o r t h e t r a i n i n g s e s s i o n s .

A s t h i s w a s t h e f i r s t s t e p i n t h e development of t h e o p e r a t i n g crew, t h e t e a c h e r s were i n s t r u c t e d t o cover a l l i n f o r m a t i o n which might b e needed by a l l o p e r a t i n g p e r s o n n e l , b u t t o p r e s e n t i t s o t h a t i t could b e understood by newly-hired o p e r a t o r s who knew n o t h i n g about t h e r e a c t o r .

All

s e s s i o n s were h e l d i n a conference room a t t h e r e a c t o r s i t e where a blackboard, s l i d e p r o j e c t o r , and opaque p r o j e c t o r were a v a i l a b l e .

F u t u r e oper-

a t o r s and s u p e r v i s o r s a t t e n d e d a l l s e s s i o n s ; o t h e r p r o j e c t p e r s o n n e l a t tended t h o s e s e s s i o n s p e r t a i n i n g t o t h e i r f u t u r e r e s p o n s i b i l i t i e s a t t h e MSRE.

The s c h e d u l e followed f o r t h e f i r s t 4 weeks and t h e i n s t r u c t o r s f o r t h e l e c t u r e p e r i o d s a r e given i n Appendix A .

The f i r s t s e s s i o n w a s an i n -

f o r m a t i o n and o r i e n t a t i o n meeting c o v e r i n g such i t e m s as o r g a n i z a t i o n c h a r t s , s c h e d u l e s , and p l a n s .

T h i s w a s followed by a g e n e r a l d e s c r i p t i o n

of t h e r e a c t o r emphasizing t h e f u n c t i o n a l i n t e r r e l a t i o n s h i p s , and o m i t t i n g nonessential d e t a i l .

Drawings of t h e b u i l d i n g and g e n e r a l equipment l a y -

o u t were t h e n d i s c u s s e d , followed by guided t o u r s .

I n s t r u c t i o n then turned

t o t h e d e s i g n of t h e v a r i o u s systems and equipment, i n t e r s p e r s e d w i t h ses-

s i o n s on t h e b a s i c s u b j e c t s of m o l t e n - s a l t h e a l t h p h y s i c s , and i n d u s t r i a l hygiene.

chemistry, r e a c t o r physics,

Beginning on J u l y 1 5 , emphasis

was switched from d e t a i l s of d e s i g n t o methods of o p e r a t i o n .

The s t a r t u p ,

normal o p e r a t i o n , shutdown, and unusual o p e r a t i o n of each a u x i l i a r y system

16 w a s covered.

This w a s followed by i n s t r u c t i o n on t h e a c t u a l s t a r t u p of

t h e r e a c t o r , i n c l u d i n g heatup, a d d i t i o n of f u e l s a l t , f i l l i n g t h e r e a c t o r , and going t o power. During t h e period from J u l y 2 1 t o J u l y 28, classroom t r a i n i n g was held only i n t h e mornings w i t h s e l f - s t u d y and equipment checkout i n t h e a f t e r noons.

I n t h e morning s e s s i o n s , t r a i n i n g on c o n t r o l c i r c u i t s and i n s t r u -

mentation was s t a r t e d and s u b j e c t s n o t completed i n t h e f i r s t 2 weeks were covered.

I n t h e a f t e r n o o n s , t h e s t a f f was d i v i d e d i n t o f o u r groups and

each group w a s assigned c e r t a i n systems t o check o u t flowsheets.

Phase 1

of t h e flowsheet checkout involved a thorough check t o a s s u r e t h a t t h e flowsheets agreed e x a c t l y w i t h what had been i n s t a l l e d .

When a group had

f i n i s h e d checkout of a system, they were considered e x p e r t s and i n Phase 2 provided d e t a i l e d guided t o u r s of t h e i r systems t o a l l o t h e r o p e r a t o r s . ( I n s t r u c t i o n s given t o t h e o p e r a t o r s are reproduced i n Appendix B.) During t h e following 3 days, t h e a s s i s t a n t o p e r a t i o n s chief and t h e

4 s h i f t s u p e r v i s o r s s p e n t f u l l t i m e a t t h e Oak Ridge Research Regctor observing a startup.

The remaining crew had classroom d i s c u s s i o n , equipment

s t u d y i n t h e f i e l d , and v i s i t e d molten-salt

test loops.

On August 3 , 1964, a l l t r a i n e e s were given t h e i r f i r s t t e s t , c o n t a i n i n g

153 q u e s t i o n s w i t h 2-1/2 hours a l l o c a t e d t o complete i t .

This f i r s t test,

made up mainly from q u e s t i o n s noted d u r i n g t h e t r a i n i n g s e s s i o n s , w a s n o t intended as a q u a l i f y i n g examination but r a t h e r as a g u i d e t o each i n d i v i d u a l as t o h i s r e l a t i v e p r o g r e s s .

On t h i s , as w e l l as l a t e r tests, i t

w a s f e l t t h a t t h e r e should be d e f i n i t e answers t o a l l q u e s t i o n s .

Therefore,

m u l t i p l e c h o i c e , t r u e / f a l s e , matching, and f i l l i n g b l a n k s were used where possible.

A t e s t of t h i s type minimizes misunderstanding of t h e q u e s t i o n s

and allows coverage of a wide v a r i e t y of s u b j e c t s i n a r e a s o n a b l e t i m e . No i n t e n t i o n a l t r i c k o r c a t c h q u e s t i o n s were used.

Where c o n f l i c t i n g in-

formation w a s given i n d i f f e r e n t s o u r c e s o r where t h e exact answer w a s n o t important, a range of answers w a s accepted.

I n t h e assignment of c r e d i t

f o r each q u e s t i o n , an attempt w a s made t o weigh t h e d i f f i c u l t y and/or importance of t h e q u e s t i o n .

The t i m e a l l o c a t e d w a s considered t o be adequate

f o r most people t o f i n i s h .

The d i s t r i b u t i o n of grades on t h e t e s t f o r t h e

23 e n g i n e e r s and t e c h n i c i a n s who took i t are shown i n Fig. 6.

ORNL-DWG 73-3088 100

w K

s v)

I-

0 1

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PERSON NUMBER

Fig. 6 .

I n i t i a l T r a i n i n g Test Grades

The papers were graded promptly and were returned for self-evaluation by each individual and further study. Although this was the primary purpose, comparisons were made of average grades in various subject categories in an attempt to determine which areas needed the most additional training. The results, listed below, showed that the trainees had learned the physical layout rather well, and showed little difference in proficiency among the other subjects.

Subject

Average Grade, 2

Design

Physical Layout

Line and Valve Numbers

Operation (General)

Chemistry

Nuclear

Instrumentation

Engineering Conversions

General

From August 4 to August 1 8 , 1 9 6 4 , 2 to 4 hours each day were spent on training sessions emphasizing control circuits. The rest of the time was used for self-study and operational duties.

Self-study consisted of

studying available documentation as well as tracing out lines, studying equipment in the field, and becoming familiar with the area.

Operating

duties included such items as checkout, calibrating and operating equipment, making up log forms, procuring supplies, and labeling panel boards. All operating personnel attended all sessions of a special MSRP Information Meeting on August 18 and 1 9 , 1 9 6 4 .

The meeting recognized the

completion of MSRE construction as an important milepost and t ~ papers e presented there gave a comprehensive picture of the development of moltensalt reactor technology up that point. report, reference 9 . )

(The papers were issued as an ORNL

The p e r i o d between August 20 and l a t e September 1964, when r o t a t i n g s h i f t work s t a r t e d , w a s s p e n t l a r g e l y on o p e r a t i n g d u t i e s .

Formal t r a i n -

i n g c o n s i s t e d of some a d d i t i o n a l c o n t r o l c i r c u i t i n s t r u c t i o n and a thorough

review of t h e f u e l , c o o l a n t , and a l l a u x i l i a r y systems.

Each system w a s

a s s i g n e d t o an o p e r a t i o n s e n g i n e e r and s u f f i c i e n t classroom t i m e w a s a l l o c a t e d t o cover a l l i n f o r m a t i o n p e r t i n e n t t o o p e r a t i o n of t h e r e a c t o r .

Top-

i c s covered included normal s t a r t u p , normal o p e r a t i o n , unusual o r s p e c i a l o p e r a t i o n s , normal shutdown, o p e r a t i n g l i m i t s , a s s o c i a t e d i n s t r u m e n t a t i o n and o p e r a t i o n p r i o r t o c r i t i c a l i t y .

A s h o r t q u i z w a s g i v e n a f t e r each ses-

s i o n t o determine p r o g r e s s . During t h e p r e n u c l e a r o p e r a t i o n and t e s t i n g , n e a r l y a l l of t h e r e a c t o r equipment was o p e r a t e d except f o r t h e heat-removal equipment, containment, and c o n t r o l r o d s .

This v a l u a b l e on-the-job

t r a i n i n g w a s supplemented by

i n f o r m a l t r a i n i n g by s h i f t s u p e r v i s o r s and day p e r s o n n e l . self-study,

To s t i m u l a t e

each person w a s asked t o submit a l i s t of q u e s t i o n s and an-

swers which he f e l t were i m p o r t a n t .

These were reviewed t o e l i m i n a t e d u p l i -

c a t i o n , o t h e r q u e s t i o n s were added t o f i l l i n gaps and t h e f i n a l compilat i o n of 569 q u e s t i o n s and answers p l u s a s e p a r a t e group of 42 q u e s t i o n s and answers on n u c l e a r c h a r a c t e r i s t i c s were i s s u e d f o r s t u d y .

P r e c r i t i c a l T r a i n i n v and C e r t i f i c a t i o n I n March 1965, when t h e r e a c t o r w a s s h u t down f o r completion of prepa r a t i o n s f o r zero-power

n u c l e a r t e s t s , t h e o p e r a t i n g p e r s o n n e l were t a k e n

o f f s h i f t f o r i n t e n s i v e t r a i n i n g , examination, and c e r t i f i c a t i o n . A l l rec e i v e d two weeks of formal t r a i n i n g i n which r a d i a t i o n s a f e t y and n u c l e a r i n s t r u m e n t a t i o n and c o n t r o l were s t r e s s e d .

The e n g i n e e r s were g i v e n a n

a d d i t i o n a l week of formal t r a i n i n g , w i t h emphasis on n u c l e a r a s p e c t s of t h e MSRE and d i s c u s s i o n s of t h e zero-power p h y s i c s experiments.

The sched-

u l e f o r t h i s s e s s i o n i s given i n Appendix C. Two s t e p s were t a k e n t o develop some f a m i l i a r i t y w i t h and p r o f i c i e n c y i n n u c l e a r t e s t i n g and o p e r a t i o n .

F i r s t , each person p a r t i c i p a t e d i n a

c r i t i c a l i t y experiment a t t h e O W L Pool C r i t i c a l Assembly (PCA).

Second,

a r e a l i s t i c s i m u l a t i o n of t h e MSRE w a s s e t up and w a s used e x t e n s i v e l y .

The MSRE s i m u l a t i o n made u s e of a TR-10 a n a l o g computer s e t up i n t h e

MSRF: c o n t r o l room, w i t h i n p u t s i g n a l s from t h e c o n t r o l - r o d p o s i t i o n i n d i -

cators.

Outputs r e p r e s e n t i n g l o g count rates, l o g power, p e r i o d , and l i n s

ear power were s e n t through t h e a c t u a l i n s t r u m e n t and c o n t r o l channels, i n c l u d i n g d i s p l a y s i n t h e r e a c t o r c o n t r o l room.1째

Thus i t w a s p o s s i b l e

f o r each o p e r a t o r t o p r a c t i c e t a k i n g t h e r e a c t o r c r i t i c a l , u s i n g t h e same procedures and c o n t r o l s and r e a d i n g t h e same i n s t r u m e n t s t h a t would b e used l a t e r i n t h e a c t u a l experiments.

To f u r t h e r f a m i l i a r i z e p e r s o n n e l w i t h t h e

c o n t r o l s and response of t h e MSRE each crew w a s g i v e n a set of "experiments" o r problems r e l a t i n g t o p r e d i c t e d c r i t i c a l i t y , rod worth, e t c . , t h a t they w e r e r e q u i r e d t o c a r r y o u t on t h e s i m u l a t o r . On A p r i l 13, 1965, a l l o p e r a t o r s were g i v e n a q u a l i f y i n g examination c o n t a i n i n g 300 q u e s t i o n s and l a s t i n g 7 hours.

An a d d i t i o n a l t e s t , con-

t a i n i n g 57 q u e s t i o n s and l a s t i n g 1 h o u r , w a s given t o t h e s h i f t superv i s o r s and a s s i s t a n t s h i f t s u p e r v i s o r s . q u e s t i o n s are given i n Appendix D.

An o u t l i n e of t h e t e s t s and sample

Before t h e t e s t s were g r a d e d , p a s s i n g

grades f o r each s u b j e c t were e s t a b l i s h e d by t h e MSRE Department Head and t h e MSRE Operations C h i e f .

A breakdown of t h e v a r i o u s c a t e g o r i e s and t h e

number of persons f a i l i n g t o m e e t t h e s t a n d a r d i s g i v e n i n T a b l e 2.

The

o v e r a l l t e s t s grades are p l o t t e d i n F i g s . 7 and 8 a l o n g w i t h a weighted average p a s s i n g grade. A f t e r t h e tests had been graded, each p e r s o n w a s examined o r a l l y by t h e department head and t h e o p e r a t i o n s c h i e f t o v e r i f y t h a t h i s t e s t s c o r e s a c c u r a t e l y r e f l e c t e d h i s u n d e r s t a n d i n g of each s u b j e c t .

I n addition, vari-

ous s i t u a t i o n s were posed and q u e s t i o n s asked t o d e t e r m i n e how t h e o p e r a t o r would react under unusual circumstances.

During t h e o r a l examinations,

s u b j e c t s a p p a r e n t l y needing a d d i t i o n a l s t u d y were noted and were p o i n t e d o u t t o t h e i n d i v i d u a l s o t h a t self-improvement could be made.

I f t h e exam-

i n e r s judged t h e person t o be q u a l i f i e d , h e w a s f o r m a l l y c e r t i f i e d .

n o t , he was given f u r t h e r t i m e f o r s e l f - s t u d y and i n f o r m a l i n s t r u c t i o n . H e w a s then reexamined and i n most cases showed s u f f i c i e n t improvement t o

be c e r t i f i e d . Before s t a r t u p a t l e a s t one s h i f t e n g i n e e r and 2 t e c h n i c i a n s had been c e r t i f i e d on each s h i f t .

U n c e r t i f i e d persons were n o t p e r m i t t e d t o o p e r a t e

any of t h e c o n t r o l s r e l a t i n g t o n u c l e a r o p e r a t i o n except i n t h e p r e s e n c e and under t h e s u p e r v i s i o n of a c e r t i f i e d o p e r a t o r .

Table 2.

Evaluation of Precritical Test

Time allowed for test (minutes)

Engr.

Tech.

Instrumentation

100

Flow Sheets and Operating Parameters

100

Health Physics and Industrial Hygiene

Miscellaneous

Layout

Electrical

Emergencies

Processing or Sampling

Subject

Design

Calculations

Physics and Nuclear

Passing grade (W )

Number not passinga Engr. Tech.

ENGINEER'S EXAM General Computer Abnormal Operating Procedures

Physics and Nuclear

a13 engineers and 18 technicians took the test.

Of these, 1 engineer and 5 technicians had not been in the initial tfaining program.

ORN L-DWG

100

I lll!!~~N~~~ a.1 ( ,I PASSING

GRADE (ENGINEERS) I I I I I I I I I PASSING GRADE (TECHNICIANS) -mm-

0 o-o-. +I+ 00000 v0

-c&o-d

TECHNICIANS

ENGINEERS

0 1

-“-”

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 PERSON NUMBER

Fig.

Precritical

Training

Test

Grades

73-3089

ORNL-DWG 73-3090

100

-8w

% I-

40 1

0 ENGINEERS

0 1

9 10111213

PERSON NUMBER

F i g . 8.

Precritical Training Test Grades (Engineer's Exam)

24 C r i t i c a l i t y w a s a t t a i n e d on June 1, 1965.

During t h e zero-power runs

v e r y l i t t l e t i m e w a s a v a i l a b l e f o r any t r a i n i n g o t h e r t h a n t h a t gained from c a r r y i n g o u t t h e d e t a i l e d e x p e r i m e n t a l procedures.

,I 2 8

Prepower T r a i n i n g I n September and October 1965, d u r i n g t h e shutdown p r i o r t o approach t o power, each o p e r a t o r w a s given a week of formal i n s t r u c t i o n .

(Since i t

w a s n o t p o s s i b l e t o l e a v e t h e r e a c t o r u n a t t e n d e d , two t r a i n i n g s e s s i o n s

were provided, w i t h h a l f of t h e o p e r a t o r s i n each.) and t i m e s p e n t on each are given i n Appendix E.

The s u b j e c t s covered

The s e s s i o n i n c l u d e d some

review coupled w i t h d e t a i l e d i n s t r u c t i o n on t h e o p e r a t i o n of equipment and systems n o t i n u s e d u r i n g t h e p r e v i o u s o p e r a t i o n a l p e r i o d . P r o v i s i o n s were a l s o made t o a l l o w each o p e r a t o r t o p r a c t i c e s i m u l a t e d power o p e r a t i o n , u s i n g two TR-10 a n a l o g computers connected t o t h e r e a c t o r c o n t r o l s and i n s t r u m e n t a t i o n . l o I n p u t s t o t h e computers w e r e s i g n a l s i n d i c a t i n g t h e a c t u a l p o s i t i o n s of t h e r o d s and r a d i a t o r doors and t h e a c t u a l p r e s s u r e drop of t h e c o o l i n g a i r a c r o s s t h e r a d i a t o r .

The o u t p u t s i n d i -

c a t e d on t h e r e a c t o r i n s t r u m e n t a t i o n were l i n e a r power, l o g power, l o g count rate, p e r i o d , f i s s i o n chamber p o s i t i o n , r e a c t o r i n l e t t e m p e r a t u r e , r e a c t o r o u t l e t temperature, r a d i a t o r salt o u t l e t temperature, r a d i a t o r s a l t AT, and r a d i a t o r h e a t power (flow t i m e s AT).

The o p e r a t o r s p r a c t i c e d

t a k i n g t h e r e a c t o r c r i t i c a l and r a i s i n g and lowering t h e power u s i n g manual S i m u l a t o r problems were s o l v e d such as d e t e r -

or automatic load control.

mining t h e power level w i t h v a r i o u s l o a d system c o n f i g u r a t i o n s , d e t e r m i n i n g t h e h e a t c a p a c i t y of t h e l o o p , and d e t e r m i n i n g t h e t e m p e r a t u r e and power c o e f f i c i e n t s of r e a c t i v i t y . P r i o r t o s t a r t u p f o r power o p e r a t i o n , a 2-hour w r i t t e n examination

w a s given t o a l l o p e r a t o r s and an a d d i t i o n a l one-hour examination w a s g i v e n t o t h e engineers.

The d i s t r i b u t i o n s of g r a d e s f o r t h e s e examinations are

given i n F i g s . 9 and 10. Appendix F.

Sample p o r t i o n s of t h e examinations are g i v e n i n

A s was done on t h e p r e - c r i t i c a l c e r t i f y i n g tests, each p e r s o n

was examined o r a l l y b e f o r e he w a s c e r t i f i e d f o r o p e r a t i n g t h e r e a c t o r a t power.

(

ORNL-DWG I 0. 0. 80 1 0째1 O.1 $j

00 l tt 1 I I I PASSING GRADE (I I

\IEZERS)

I I I PASSING GRADE (TECHN IC

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PERSON NUMBER

Fig.

Prepower

Training

Test

Grades

----

0 ENGINEERS

73-3091

0.0

0 TECHNICIANS

(

ORNL-DWG 73-3092 1001

0 .

80 1

0 60

-e . *

2o 0

ENGINEERS

910111213

PERSON NUMBER

Fig. 10. Prepower T r a i n i n g T e s t Grades (Engineer's Exam)

27 T r a i n i n g of Chief O p e r a t o r s The r e d u c t i o n of t h e o p e r a t i n g crews t o t h r e e men each had been caref u l l y considered from t h e s t a n d p o i n t s of s a f e t y and e f f e c t i v e n e s s and w a s judged t o be f e a s i b l e .

(By mid-1967,

equipment d i f f i c u l t i e s encountered

d u r i n g e a r l y o p e r a t i o n had been overcome and t h e t e s t program w a s w e l l i n t o i t s s u s t a i n e d high-power o p e r a t i o n phase, s o t h a t unusual demands on t h e

o p e r a t i n g crews on o t h e r t h a n t h e day s h i f t had been minimized.)

It w a s

r e c o g n i z e d , however, t h a t t h e t e c h n i c i a n s who were t o t a k e o v e r t h e superv i s i o n of t h e crews would need some s p e c i a l t r a i n i n g f o r t h e i r new d u t i e s . S i x c a n d i d a t e s f o r Chief Operator were chosen on t h e b a s i s of t h e i r p a s t e x p e r i e n c e and t e s t g r a d e s , and t h e o p i n i o n s of t h e s h i f t s u p e r v i s o r s , ass i s t a n t o p e r a t i o n s c h i e f , o p e r a t i o n s c h i e f , and o p e r a t i o n s department head. These t e c h n i c i a n s were given t h e a d d i t i o n a l i n s t r u c t i o n o u t l i n e d i n Append i x G.

T r a i n i n g w a s on an i n d i v i d u a l b a s i s and t o some e x t e n t w a s t a i l o r e d

t o t h e i n d i v i d u a l ' s need.

Emphasis w a s p l a c e d on d u t i e s p r e v i o u s l y handled

by t h e s h i f t s u p e r v i s o r s , such as t r o u b l e - s h o o t i n g , c i r c u i t s , etc.

tracing out control

A f t e r i n s t r u c t i o n , each c a n d i d a t e w a s g i v e n c h a r g e of a

s h i f t f o r one o r two weeks w i t h an o r i g i n a l s h i f t s u p e r v i s o r on d u t y b u t a c t i n g o n l y as a d v i s e r .

They were t h e n g i v e n a 2-1/2-hour

w r i t t e n examination and a 1-1/2-hour

closed-book

open-book w r i t t e n examination.

p o r t i o n s of t h e s e examinations are given i n Appendix H.

Sample

A l l 6 candidates

passed and a f t e r o r a l examinations, a l l were c e r t i f i e d as q u a l i f i e d Chief Operators. It appeared t h a t c o n s i d e r a b l e b e n e f i t w a s gained from t h i s t r a i n i n g .

Therefore, i t w a s subsequently given t o a l l t h e o t h e r operators.

No exami-

n a t i o n was g i v e n t o t h e o t h e r s , however. T r a i n i n g Before

3U S t a r t u e

The 5-month shutdown t h a t followed t h e end of extended o p e r a t i o n w i t h

235U f u e l and preceded t h e 233U s t a r t u p experiments w a s recognized as an a p p r o p r i a t e t i m e f o r r e f r e s h e r t r a i n i n g of t h e o p e r a t o r s .

I n s t e a d of t r a i n -

i n g s e s s i o n s a t t e n d e d by t h e e n t i r e s t a f f , however, a program of s e l f - s t u d y f

and small-group s t u d y w a s i n i t i a t e d .

The s c h e d u l e w a s r a t h e r f l e x i b l e t o

permit o t h e r j o b s t o be c a r r i e d on, b u t a d a t e w a s announced on which a l l members of t h e o p e r a t i n g s t a f f were t o b e reexamined.

The n u c l e a r a s p e c t s

s e c t i o n of t h e Operating P r o c e d u r e s l l w a s r e v i s e d t o show t h e c a l c u l a t e d r e a c t i v i t y c o e f f i c i e n t s and o t h e r c h a r a c t e r i s t i c s w i t h 233U f u e l and a memorandum summarizing t h e changes w a s i s s u e d .

A s a n a i d i n review of a l l

systems, a 74-page programmed i n s t r u c t i o n manual w a s prepared.

Prior to

s t a r t u p w i t h 233U, a comprehensive review t e s t w a s g i v e n t o a l l o p e r a t o r s . The d i s t r i b u t i o n of grades on t h i s t e s t i s shown i n Fig. 11.

The r e s u l t s

of t h e tests were d i s c u s s e d w i t h each o p e r a t o r and each w a s r e q u i r e d t o do

more s t u d y i n g of s u b j e c t s i n which t h e y appeared weak.

Other T r a i n i n g From t h e s t a n d p o i n t of keeping i n p r a c t i c e , i t would have been benef i c i a l i f each o p e r a t o r could have f i l l e d and s t a r t e d up t h e r e a c t o r , shut

down and d r a i n e d t h e r e a c t o r , and done a l l o t h e r o p e r a t i o n s p e r i o d i c a l l y . However, w i t h t h e MSRE, which w a s on l i n e most of t h e t i m e , t h i s was n o t possible.

The v a r i o u s j o b c a t e g o r i e s were r o t a t e d among t h e o p e r a t o r s t o

h e l p d i s t r i b u t e t h e e x p e r i e n c e and, whenever t h e r e w a s o p p o r t u n i t y , each o p e r a t o r was r e q u i r e d t o t a k e t h e r e a c t o r c r i t i c a l and s u b c r i t i c a l and t o raise and lower t h e power as w e l l as most of t h e o t h e r r o u t i n e o p e r a t i o n s .

O c c a s i o n a l l y i n s l a c k p e r i o d s , problems were a s s i g n e d f o r each crew o r each individual t o solve.

T y p i c a l l y t h e s e involved r a d i a t i o n and h e a l t h p h y s i c s ,

r e a c t i v i t y changes and o t h e r t o p i c s t h a t were i m p o r t a n t b u t were seldom encountered i n r o u t i n e o p e r a t i o n .

I n f o r m a t i o n r e g a r d i n g changes i n p l a n s o r

equipment were u s u a l l y communicated t o o p e r a t i n g p e r s o n n e l by means of S h i f t I n s t r u c t i o n s and changes i n t h e O p e r a t i n g Procedures.

8.)

(See Chapter

Each S h i f t S u p e r v i s o r o r Chief Operator w a s r e s p o n s i b l e f o r a s s u r i n g

t h a t a l l persons on h i s s h i f t w e r e f a m i l i a r w i t h a l l changes and t h a t t h e y remained a d e q u a t e l y t r a i n e d t o run t h e r e a c t o r .

ORNL-DWG 73-3093 100

-E

w K

% I-

n "

6 7

9 10 1 1 12 13 14 15 16 17 18 19 20 21 22 23 PERSON NUMBER

Fig. 11. Pre-233 Training T e s t Grades

30 T r a i n i n g of Replacements During t h e f i v e y e a r s of r e a c t o r o p e r a t i o n , 3 e n g i n e e r s and 5 techn i c i a n s were a s s i g n e d t o t h e MSRE f o r t r a i n i n g and u s e as o p e r a t o r s . t r a i n i n g w a s on a person-to-person t h e MSRE s t a f f .

Their

b a s i s , w i t h i n s t r u c t i o n by members of

The program o u t l i n e s which were followed f o r group t r a i n ?

i n g w e r e used as g u i d e s .

Considerable t i m e w a s provided f o r s e l f - s t u d y of

t h e v a r i o u s s e c t i o n s of t h e MSRE Design and O p e r a t i o n s Report, semiannual r e p o r t s , flow s h e e t s , c o n t r o l c i r c u i t s , e t c .

When t r a i n i n g w a s complete,

each of t h e s e o p e r a t o r s w a s given t h e same s e r i e s of t e s t s and o r a l reviews t h a t had been used w i t h t h e main group.

The e l a p s e d t i m e between a r r i v a l

a t t h e MSRE and f i n a l t e s t i n g v a r i e d from 3 t o 8 months depending upon need

f o r replacement, a v a i l a b i l i t y of i n s t r u c t o r s , background of t h e individual., and t h e e x t e n t of h i s o t h e r d u t i e s . Equivalence t o A E C Examination I n t h e i r annual s a f e t y review of t h e MSRE i n September 1968, t h e USAEC-

OR0 committee suggested t h a t t h e MSRE o p e r a t o r examinations b e reviewed t o a s s u r e e q u i v a l e n c e w i t h t h e requirements f o r non-AEC r e a c t o r o p e r a t o r s ( r e f . 13).

A t t h e i r s u g g e s t i o n , a n OWL employee who a d m i n i s t e r s t e s t s f o r t h e

A E C ' s D i v i s i o n of Reactor L i c e n s i n g reviewed one of the t h r e e m a j o r t e s t s

t h a t had been used a t the MSRE.

T t was h l s o p i n l o n , Based on t h i s one t e s t ,

t h a t t h e MSRE o p e r a t o r t e s t i n g was adequate and e q u i v a l e n t .

However, h e

suggested t h a t i f o t h e r o p e r a t o r s were t o be c e r t i f i e d , new t e s t s should b e prepared conforming more d i r e c t l y t o t h e AEC g u i d e l i n e s . up u s i n g 10-CFR-55, examiner.

t h e AEC L i c e n s i n g Guide,"

A t e s t w a s made

and s u g g e s t i o n s from t h e

T h i s t e s t , d e s i g n a t e d %SRE O p e r a t o r ' s Examination

i s given i n Appendix I.

- May

1969,"

One e n g i n e e r , who w a s i n t r a i n i n g a t t h e time, w a s

given t h e MSRE P r e c r i t i c a l , Prepower , and Pre-23 3U e x a n i n a t i o n s , and t h e n took t h e May 1969 examination and an o r a l o p e r a t i o n a l t e s t b e f o r e c e r t i f i cation.

Twelve hours were a l l o c a t e d f o r t a k i n g t h e o p e r a t o r ' s s e c t i o n s

(A-G) of t h e May 1969 examination and 9-1/2 hours f o r t a k i n g t h e s h i f t s u p e r v i s o r ' s s e c t i o n (H-L).

H e passed a l l t e s t s , b u t c e r t i f i c a t i o n was

based, as w i t h p a s t o p e r a t o r s , on t h e more i n c l u s i v e MSRE t e s t s , i n f o r m a l

review, and o r a l q u e s t i o n i n g ,

OPERATION OF THE REACTOR

Although t h e g o a l of t h e t r a i n i n g program a t t..e MS E w a s t o make a l l o p e r a t o r s c a p a b l e of o p e r a t i n g t h e r e a c t o r w i t h o u t i n s t r u c t i o n s o r proced u r e s i f need b e , t h e p r a c t i c e w a s t o f o l l o w d e t a i l e d w r i t t e n i n s t r u c t i o n s t o t h e maximum p r a c t i c a b l e e x t e n t .

The i n t e l l i g e n c e , i n t e r e s t , and capa-

b i l i t y of t h e o p e r a t o r s w a s r e c o g n i z e d , however, and i n a l l i n s t r u c t i o n s an a t t e m p t w a s made t o g i v e t h e r e a s o n f o r as w e l l as t h e d e t a i l s of t h e I n r e t u r n , i t w a s each o p e r a t o r ' s d u t y t o p r o v i d e feed-

required actions. back.

For example, he w a s expected t o p r o v i d e an e x p l a n a t i o n , i f known,

f o r a l l l o g n o t a t i o n s which were n o t s e l f - e x p l a n a t o r y and f o r any deviat i o n s from normal o r expected e v e n t s .

S u g g e s t i o n s , i n c l u d i n g unproved b u t

c r e d i b l e t h e o r i e s t o e x p l a i n observed e v e n t s , were encouraged.

Planning O p e r a t i o n of t h e MSRE followed a p u b l i s h e d t e s t program,15,16 and t h e o b j e c t i v e s of each r u n were worked o u t i n advance among t h e e n g i n e e r s , chem-

i s t s , p h y s i c i s t s and d i r e c t o r s of t h e Molten-Salt Reactor Program.

d e t a i l e d p l a n n i n g w a s done i n p l a n n i n g m e e t i n g s h e l d a t t h e

t h e day-to-day, reactor site.

Most of

O r i g i n a l l y h e l d each day, t h e s e meetings l a t e r came t o b e

h e l d a t i n t e r v a l s of 1 t o 3 t i m e s p e r week, depending upon t h e need.

All

t e c h n i c a l p e r s o n n e l on d u t y a t t h e r e a c t o r p l u s r e p r e s e n t a t i v e s of supp o r t i n g groups a t t e n d e d t h e s e meetings. a l l y present also.)

(The MSR Program D i r e c t o r w a s usu-

A member of t h e o p e r a t i o n s group ( u s u a l l y t h e A s s i s t -

a n t O p e r a t i o n s C h i e f ) began t h e meeting by r e p o r t i n g on t h e p r e v i o u s p e r i od's activities.

Others added t o t h i s any o t h e r p e r t i n e n t e v e n t s , a n a l y s e s

made, maintenance s t a t u s , etc. discussed.

T e n t a t i v e p l a n s w e r e t h e n p r e s e n t e d and

Often a smaller group remained t o work o u t d e t a i l s o r t o d i s -

c u s s problem areas.

I n cases where t h e r e w a s u n c e r t a i n t y o r c o n f l i c t s (be-

tween e x p e r i m e n t e r s , o r between maintenance and o p e r a t i o n , f o r example) t h e MSRF, Department Head u s u a l l y made the

a t 1 1 : O O a.m.,

f i n a l decision.

T h e meetings s t a r t e d

which allowed ample t i m e b e f o r e t o d i g e s t most of t h e p r e v i -

ous p e r i o d ' s work and s u f f f c i e n t t i m e a f t e r w a r d t o p r e p a r e d e t a i l e d s h i f t

32 i n s t r u c t i o n s , o b t a i n materials needed and make t h e n e c e s s a r y p l a n s t o c a r r y o u t t h e program f o r t h e f o l l o w i n g p e r i o d b e f o r e t h e end of t h e day s h i f t .

I n s t r u c t i o n s t o and Communications w i t h O p e r a t o r s S h i f t I n s t r u c t i o n s were prepared each weekday by a member of t h e oper a t i n g group ( u s u a l l y t h e A s s i s t a n t Operations Chief o r t h e Operations Chief).

These were based mainly on d e c i s i o n s reached i n t h e p l a n n i n g m e e t -

A g e n e r a l i n f o r m a t i o n s e c t i o n o u t l i n e d t h e p l a n s and provided o t h e r

ings.

i n f o r m a t i o n of i n t e r e s t t o t h e s h i f t p e r s o n n e l .

The i n s t r u c t i o n s sometimes

were v e r y s p e c i f i c , such as a d e t a i l e d check l i s t ; a t o t h e r t i m e s they ref e r r e d t o a s e p a r a t e procedure such as a s e c t i o n of t h e Operating Proceduresâ&#x20AC;&#x2122;â&#x20AC;&#x2122;

o r a test memo.

I f t h e i n s t r u c t i o n s were t o b e followed f o r l o n g e r

p e r i o d s , i n s t e a d of b e i n g r e p e a t e d each day i n subsequent s h i f t i n s t r u c t i o n s , they w e r e u s u a l l y p u t i n t h e Permanent S h i f t I n s t r u c t i o n s .

The Permanent

S h i f t I n s t r u c t i o n s were reviewed p e r i o d i c a l l y and a p p r o p r i a t e s e c t i o n s w e r e i n c o r p o r a t e d i n t o t h e Operating Procedures,

The s h i f t i n s t r u c t i o n s could

o v e r r i d e t h e o p e r a t i n g procedures o r t e s t memos.

I f d i f f i c u l t i e s prevented

f o l l o w i n g t h e p r e s c r i b e d program, t h e Chief O p e r a t o r , S h i f t S u p e r v i s o r , Ass i s t a n t Operations C h i e f , Operations C h i e f , and/or Operations Department Head decided what a l t e r n a t i v e s t o f o l l o w .

T y p i c a l examples of S h i f t In-

s t r u c t i o n s , Operating Procedures, and Test Memos a r e given i n Appendix J, A master up-to-date

i n the operations office.

copy of t h e O p e r a t i n g Procedures w a s maintained To avoid c o n f u s i o n , changes i n t h i s master copy

were e n t e r e d o n l y by t h e Operations Chief o r A s s i s t a n t Operations Chief.

A l l personnel were r e q u i r e d t o be f a m i l i a r w i t h t h e s e changes and r e c o r d s were maintained i n d i c a t i n g t h i s .

The master copy o r a copy c o r r e c t e d t o

a g r e e w i t h t h e master w a s used f o r a l l o p e r a t i o n s .

Control-room

b u i l d i n g l o g forms were a p a r t of t h e Operating Procedures.

l o g and

Current limits

were i n d i c a t e d on t h e s e f o r each v a r i a b l e as w e l l as t h e frequency f o r recording v a r i a b l e s .

The f i r s t few pages of t h e control-room and b u i l d i n g

l o g forms are shown i n Appendix K.

Before s t a r t i n g a l o g ( o r check l i s t )

t h e o p e r a t o r w a s r e q u i r e d t o c o r r e c t h i s copy of t h e form t o a g r e e w i t h t h e master.

I f v a r i a b l e s were found o u t of l i m i t s , t h e y were c o r r e c t e d

o r r e p o r t e d t o t h e S h i f t S u p e r v i s o r o r Chief Operator.

H e decided on t h e

33 c o u r s e of a c t i o n t o be taken e i t h e r i n d e p e n d e n t l y o r a f t e r c o n t a c t i n g app r o p r i a t e day p e r s o n n e l .

During t r a n s i e n t c o n d i t i o n s , such as a t shutdown

o r s t a r t u p , when t h e a p p r o p r i a t e l o g l i m i t s were changing r a p i d l y , s h i f t p e r s o n n e l were expected t o d e c i d e on what l i m i t s w e r e p r o p e r and what equipment should b e o p e r a t i n g a t t h e t i m e . T e s t Memos were d e t a i l e d procedures which were w r i t t e n f o r more i n volved s p e c i a l tests.

These r e q u i r e d t h e a p p r o v a l of t h e MSRE O p e r a t i o n s

Department Head, t h e Operations C h i e f , and o t h e r s as d e s i g n a t e d by t h e Oper a t i o n s Department Head. There w a s , of c o u r s e , an o r a l exchange of i n f o r m a t i o n and i n s t r u c t i o n s

a t s h i f t change between t h e c r e w l e a v i n g and t h e one t a k i n g over.*

Every-

one w a s r e q u i r e d t o read t h e s h i f t i n s t r u c t i o n s and c o n s o l e l o g as soon as p o s s i b l e a f t e r r e p o r t i n g f o r duty.

Data Taking and Record Keeping One of t h e primary r e c o r d s of t h e MSRE o p e r a t i o n w a s t h e Console Log, which w a s e s s e n t i a l l y a c h r o n o l o g i c a l n a r r a t i v e of e v e n t s .

The t i m e w a s

recorded a t t h e s t a r t of each e n t r y and t h e i n i t i a l s of t h e p e r s o n making t h e e n t r y were p u t a t t h e end. end of each s h i f t .

A s t a t u s and summary e n t r y was made a t t h e

P r a c t i c a l l y a l l operat$ons e y e n t s were n o t e d , b u t o n l y

t h e most i m p o r t a n t maintenance items.

(Other maintenance was r e p o r t e d on

t h e completed work r e q u e s t s o r by memos.)

Copies were made of t h e c o n s o l e

l o g s h e e t s and d i s t r i b u t e d d a i l y t o i n t e r e s t e d p e r s o n n e l .

The originals

( i n bound books) were k e p t i n t h e o p e r a t i o n s f i l e s a t t h e s i t e . A s mentioned p r e v i o u s l y , almost a l l v a r i a b l e s were recorded on t h e b u i l d i n g l o g o r c o n t r o l room l o g forms. f a c i l i t a t e r e c o r d i n g of d a t a .

*C r e w members

These w e r e a r r a n g e d by areas t o

Completed c o p i e s of t h e s e were f i l e d i n t h e

were r e q u i r e d t o b e a t the c o n t r o l room, ready f o r d u t y , 6 minutes b e f o r e the nomlnal s h i f t change, (They r e c e i v e d 0 . 1 hour o v e r t i m e pay f o r t h i s , )

34 o p e r a t i o n s f i l e s along w i t h completed check l i s t s , o p e r a t i n g p r o c e d u r e s , and t e s t memos.

Recorder c h a r t s were marked a t l e a s t once each s h i f t and

w e r e removed and f i l e d d a i l y .

The bulk of t h e d a t a were logged by an o n - l i n e d i g i t a l computer (Bunker-Ramo Model 340) ,l 7 which monitored a l l of t h e i m p o r t a n t v a r i a b l e s and recorded t h e s e on magnetic t a p e every 5 minutes.

I n a d d i t i o n , i t typed

o u t an h o u r l y l o g , an 8-hour l o g , and a d a i l y r e p o r t .

I n case a v a r i a b l e

went out of l i m i t s , an a n n u n c i a t i o n o c c u r r e d and t h e v a l u e of t h e v a r i a b l e

w a s typed o u t by a t y p e w r i t e r l o c a t e d i n t h e main c o n t r o l room.

When any

of c e r t a i n important v a r i a b l e s went o u t of l i m i t s , i t i n i t i a t e d a f a s t s c a n which i n c r e a s e d t h e frequency of r e c o r d i n g of a s e l e c t e d group of v a r i a b l e s t o 4 t i m e s p e r second.

A f a s t s c a n could a l s o be i n i t i a t e d by t h e o p e r a t o r .

V a r i a b l e s could b e trend-logged o r p l o t t e d i f d e s i r e d . t h e computer w a s removed and f i l e d each day.

Data typed o u t by

Magnetic t a p e s were removed

d a i l y and then t r a n s f e r r e d t o r e c o r d t a p e s which h e l d several d a y s ' d a t a . These were f i l e d a t t h e r e a c t o r s i t e .

APPROVAL OF MAINTENANCE AND DESIGN CHANGES

The forms used i n connection w i t h maintenance and d e s i g n changes are included i n Appendix L.

Anyone knowing t h e need of maintenance could i n i t i -

a t e a c t i o n by f i l l i n g o u t a Punch L i s t form.

I f t h e job w a s s m a l l , the

work w a s completed w i t h o u t any a d d i t i o n a l paper work. w a s kept of work done i n t h i s manner.

Request w a s i s s u e d .

No formal r e c o r d

I f t h e j o b w a s more i n v o l v e d , a Work

T h i s had t o b e approved by t h e O p e r a t i o n s Chief o r

A s s i s t a n t Operations Chief.

I n e i t h e r case t h e S h i f t Supervisor's approval

was n e c e s s a r y b e f o r e work w a s s t a r t e d .

H e w a s r e s p o n s i b l e f o r making neces-

s a r y changes i n t h e system and t a g g i n g o u t n e c e s s a r y v a l v e s o r s w i t c h e s t o a s s u r e s a f e t y of t h e r e a c t o r and p e r s o n n e l .

A f t e r maintenance w a s complete,

he checked o u t t h e j o b b e f o r e removing t h e t a g s and p u t t i n g t h e equipment back i n s e r v i c e .

The completed work r e q u e s t s were r e t a i n e d as a r e c o r d of

what w a s done. Proposed m o d i f i c a t i o n s which could produce s i g n i f i c a n t l y d i f f e r e n t c h a r a c t e r i s t i c s o r f u n c t i o n s i n any component o r system (such as p i p i n g ,

35 W

i n s t r u m e n t a t i o n , s w i t c h s e t t i n g s , e t c . ) were i n i t i a t e d u s i n g a “Change Request” form.

The MSRE Operations Department head reviewed a l l change

r e q u e s t s and determined what o t h e r reviews w e r e n e c e s s a r y .

INFORMATION AVAILABLE TO OPERATORS

Documents are l i s t e d i n t h i s s e c t i o n which were u s e f u l i n t h e t r a i n i n g of o p e r a t o r s o r were used by them i n t h e o p e r a t i o n of t h e MSRE.

A brief

d e s c r i p t i o n of t h e i r c o n t e n t and how t h e y were used i s g i v e n where a p p l i cable.

The approximate d a t e of i s s u a n c e i s a l s o given when t h i s i s thought

t o have been p e r t i n e n t t o t h e t r a i n i n g program o r o p e r a t i o n of t h e r e a c t o r . c

Design and Operations Report The need f o r documentation of r e a c t o r d e s i g n and p r e p a r a t i o n s f o r oper a t i o n s , w a s recognized v e r y e a r l y by t h e MSR Program D i r e c t o r , who i s s u e d a memorandum i n J u l y , 1962 a s s i g n i n g r e s p o n s i b i l i t i e s f o r w r i t i n g p a r t s of a Design and Operations Report.

Table 3 l i s t s t h e s u b j e c t s and t h e d a t e s

when t h e v a r i o u s p a r t s w e r e e v e n t u a l l y p u b l i s h e d . Part I the reactor.

w e r e given.

- Design4

d e s c r i b e d t h e mechanical and e l e c t r i c a l p o r t i o n s of

Flowsheets, e l e c t r i c a l one-line drawings and equipment d e t a i l s Bases f o r d e s i g n o r d e s i g n c a l c u l a t i o n s were n o t i n c l u d e d .

rough d r a f t of P a r t I was a v a i l a b l e f o r t h e i n i t i a l o p e r a t o r t r a i n i n g and proved t o be very h e l p f u l .

The r e p o r t w a s i s s e d a t t h e t i m e of t h e zero-

power experiments and a l t h o u g h i t clias n o t k e p t up t o d a t e , i t w a s neverthe-

less r e f e r r e d t o f r e q u e n t l y d u r i n g subsequent o p e r a t i o n . P a r t s 11-A and 11-B

- Nuclear

and P r o c e s s I n s t r u r n e n t a t i o n l 8 , ”

de-

s c r i b e t h e i n s t r u m e n t a t i o n l a y o u t , i n d i v i d u a l i n s t r u m e n t s o r systems, cont r o l c i r c u i t r y and o t h e r d e t a i l s .

Unfortunately, these w e r e not available

f o r u s e i n t r a i n i n g and i t w a s n e c e s s a r y f o r t h e i n s t r u c t o r s t o s e a r c h through drawings and unpublished i n f o r m a t i o n t o p r e p a r e f o r t h e t r a i n i n g sessions.

The s t u d e n t s had t o t a k e v e r y good n o t e s and had t o s e a r c h f o r

i n f o r m a t i o n i f needed l a t e r . W

S e c t i o n 11-A w a s used f o r r e f e r e n c e a f t e r i t s

p u b l i c a t i o n n e a r t h e end of 235U o p e r a t i o n . u n t i l a f t e r t h e c o n c l u s i o n of MSRE o p e r a t i o n .

S e c t i o n 11-B w a s n o t p u b l i s h e d

Table 3.

Part

ERE Design and Operations Reports

Title

ORNL-TM

P u b l i c a ti o n Date

D e s c r i p t i o n of Reactor Design

728

6/65

IIA

Nuclear and Process I n s t r u m e n t a t i o n

729

2/68

IIB

Nuclear and Process I n s t r u m e n t a t i o n

729

9/72

I11

Nuclear Analysis

730

2/64

Chemistry and Materials

731

Reactor S a f e t y Analysis

732

8/64

V-A

S a f e t y Analysis of Operation w i t h 233U

2111

2/68

Operating S a f e t y L i m i t s

733

V II

Fuel Handling and P r o c e s s i n g P l a n t

907

VI11

Operating Procedures

980

12/65'

S a f e t y Procedures and Emergency P l a n s

909

6/65

Maintenance Equipment and Procedures

910

6/68

T e s t Program

911

12/66

X I -A

Test Program f o r 233U Operation

2304

9/68

X II

Lists

aThree r e v i s i o n s of ORNL-TM-733 w e r e i s s u e d i n 8/65, bA s u b s t a n t i a l l y r e v i s e d v e r s i o n of ORNL-"-907 C

4/65' 5/65b

9/66, and 7/69.

w a s i s s u e d i n 12/67.

Loose-leaf c o p i e s were i s s u e d t o members of t h e o p e r a t i n g s t a f f i n 12/65; r e v i s e d pages were i s s u e d as n e c e s s a r y a t l a t e r d a t e s .

P a r t 111

- Nuclear

Analysis20 d e s c r i b e d t h e p r e d i c t e d n u c l e a r charac-

t e r i s t i c s , rod worth, c o e f f i c i e n t s of r e a c t i v i t y , p o i s o n i n g e f f e c t s of f i s s i o n p r o d u c t s , k i n e t i c s of o p e r a t i o n and adequacy of b i o l o g i c a l s h i e l d i n g . It w a s t h e f i r s t p a r t p u b l i s h e d and w a s a v a i l a b l e f o r a l l of t h e t r a i n i n g

periods.

Although i t w a s n o t k e p t up t o d a t e , i t w a s used o c c a s i o n a l l y f o r

reference during operation. P a r t I V -Chemistry

and Materials w a s expected t o i n c l u d e i n a form

convenient f o r t h e o p e r a t o r s :

( a ) a summary of s a l t chemistry ( p h a s e d i a -

grams, e f f e c t s of m o i s t u r e , oxygen, e t c . ) , (b) a d e s c r i p t i o n of t h e chemist r y of w a t e r systems ( a c c e p t a b l e l i m i t s , s u g g e s t e d a n a l y s i s , and e f f e c t of a c t i v a t i o n ) , ( c ) a l i s t i n g of t h e p r o p e r t i e s of l u b r i c a t i n g o i l f o r t h e c i r c u l a t i n g pumps ( a n a l y s i s r e q u i r e d , a c c e p t a b l e l i m i t s , e t c . ) , (d) informat i o n on t h e m e t a l l u r g y of INOR-8 and s t a i n l e s s s t e e l , ( e ) a d i s c u s s i o n of g r a p h i t e , ( f ) e x p l a n a t i o n f o r keeping t h e oxygen and w a t e r c o n t e n t of helium cover gas low, and (g) a d i s c u s s i o n of f i s s i o n p r o d u c t s .

T h i s p a r t of t h e

Design and Operations Report w a s never prepared. Part V

- Safety

A n a l y s i s 2 I d e s c r i b e d some of t h e more i m p o r t a n t sys-

t e m s , c o n t r o l s , and i n s t r u m e n t a t i o n .

P l a n t l a y o u t , s i t e f e a t u r e s , con-

s t r u c t i o n , s t a r t u p and o p e r a t i n g p l a n s were covered.

Various p o s s i b l e ac-

c i d e n t s w e r e d i s c u s s e d and t h e consequences d e l i n e a t e d . f o r most of t h e t r a i n i n g and w a s extremely v a l u a b l e .

This w a s available

The o p e r a t i o n s copy

w a s updated p e r i o d i c a l l y and used r e g u l a r l y d u r i n g o p e r a t i o n .

Prior t o

o p e r a t i o n w i t h 233U f u e l , a n o t h e r s a f e t y a n a l y s i s r e p o r t 2 2 w a s p u b l i s h e d , which provided a b a s i s f o r o p e r a t o r t r a i n i n g and w a s a u s e f u l r e f e r e n c e . Part V I

- Operating

S a f e t y Limits2*26

w i t h i n which t h e r e a c t o r had t o b e o p e r a t e d . c r i t i c a l i t y and w a s used f o r i n s t r u c t i o n . P a r t VI1 - F u e l

tabulated the absolute l i m i t s This was available before Three r e v i s i o n s were i s s u e d ,

Handling and P r o c e s s i n g P l a n t covered a l l a s p e c t s of

t h e f u e l processfng p l a n t , (design, hazard a n a l y s i s , operating procedures, e t c . ) and w a s u s e f u l i n t r a i n i n g o p e r a t o r s and f o r running t h e chemical processing plant.

The o r i g i n a l v e r s i o n 2 7 w a s i s s u e d a t t h e t i m e of t h e

h y d r o f l u o r i n a t i o n of t h e f l u s h s a l t i n 1965 and a s u b s t a n t i a l l y r e v i s e d v e r s i o n 7 was i s s u e d i n p r e p a r a t i o n f o r t h e p r o c e s s i n g i n 1968.

Part V X C

- Operating P r o c e d u r e s l l

necessary f o r operation.

provided most of t h e i n f o r m a t i o n

A s i m p l i f i e d d e s c r i p t i o n of b a s i c n u c l e a r f a c t s

and n u c l e a r c h a r a c t e r i s t i c s of t h e MSRE w a s given.

Methods of s t a r t u p ,

o p e r a t i o n , and shutdown of a l l systems were covered w i t h d e t a i l e d check lists.

S p e c i a l and unusual o p e r a t i o n s were d e s c r i b e d and a t t e m p t s w e r e

made t o a n t i c i p a t e any t r o u b l e s which might have developed and s u g g e s t corrective action.

For i n s t a n c e , each a n n u n c i a t o r was l i s t e d .

Things which

could cause t h e a n n u n c i a t i o n , c o n t r o l a c t i o n s which would occur and sugg e s t e d o p e r a t o r a c t i o n s were t a b u l a t e d .

Data s h e e t s , l o g s , and check l i s t s

were included and t h e methods.of t a k i n g d a t a and i t s s t o r a g e w a s covered i n detail.

The methods used f o r g e t t i n g maintenance done s a f e l y and f o r making

m o d i f i c a t i o n s t o t h e system o r approved documents w a s d e s c r i b e d . d r a f t of t h i s w a s a v a i l a b l e f o r t h e i n i t i a l t r a i n i n g .

A rough

T h i s r e p o r t w a s is-

sued i n a bound e d i t i o n (two volumes) t o t h e r e c i p i e n t s who d i d n o t d e s i r e o r need t o b e n o t i f i e d of changes. i s s u e d loose-leaf

e d i t i o n s and they were s e n t c o p i e s of r e v i s e d s e c t i o n s

as they appeared, Part I X

O t h e r s , i n c l u d i n g a l l o p e r a t o r s , were

The master copy w a s updated as changes o c c u r r e d .

- Safety

Procedures and Emergency P l a n s 2 8 provided procedures

and background i n f o r m a t i o n t o a s s i s t p e r s o n n e l i n a n t i c i p a t i n g , p r e v e n t i n g , and h a n d l i n g emergencies such as f i r e s , release of b e r y l l i u m , o r i n c r e a s e s i n radioactivity.

T h i s procedure w a s a v a i l a b l e b e f o r e c r i t i c a l i t y and w a s

used f o r t r a i n i n g o p e r a t o r s .

O p e r a t o r s ' c o p i e s were updated p e r i o d i c a l l y

but a formal r e v i s i o n w a s n o t i s s u e d . P a r t X - Maintenance Equipment and Procedures29 gave g e n e r a l procedu r e s f o r doing remote maintenance.

The r e a c t o r o p e r a t o r s were n o t normally

involved i n maintenance except t o p r e p a r e t h e system and a s s u r e t h a t adeq u a t e s a f e t y p r e c a u t i o n s were followed. Part X I

- Test

Program15 d e s c r i b e d t h e program f o r t h e shakedown of

equipment, approach t o c r i t i c a l i t y , and power o p e r a t i o n . tests and experiments were d e s c r i b e d .

Various s p e c i a l

Details of experiments were n o t

given i n t h e r e p o r t i t s e l f , b u t t e s t memos, numbered t o correspond t o t h e s e c t i o n s i n t h e test r e p o r t , d i d g i v e d e t a i l s .

These were w r i t t e n and ap-

proved b e f o r e t h e experiment o r t e s t w a s s t a r t e d .

O p e r a t i o n w i t h 233U

f u e l w a s conceived and planned a f t e r t h e o r i g i n a l program w a s underway and a s e p a r a t e document16 w a s i s s u e d t o o u t l i n e t h i s phase of t h e program.

39 Part XI1 -Lists

w a s t o g i v e a ready r e f e r e n c e o r i n d e x t o a l l r e p o r t s ,

drawings, and o t h e r i n f o r m a t i o n . drawings were t o b e i n c l u d e d .

Such t h i n g s as a c r o s s r e f e r e n c e i n d e x t o

It would have been v e r y v a l u a b l e d u r i n g de-

s i g n , c o n s t r u c t i o n , and a l l s t a g e s of o p e r a t i o n , b u t i t was n e v e r prepared.

Other Reports P r o g r e s s r e p o r t s of t h e Molten S a l t Reactor Program were i s s u e d s e m i annually.

I n f o r m a l r e p o r t s c o v e r i n g p r o g r e s s i n most areas of t h e program

were a l s o i s s u e d monthly.

Copies of t h e s e , as w e l l as t o p i c a l r e p o r t s on

m o l t e n - s a l t work done a t t h e r e a c t o r o r elsewhere, were maintained a t t h e site.

Copies of o t h e r p e r t i n e n t r e p o r t s such as ORNL and Reactor D i v i s i o n

S a f e t y Procedures, H e a l t h P h y s i c s Procedures and ORNL S t a n d a r d P r a c t i c e Procedures were a l s o a v a i l a b l e .

A Daily Report w a s i s s u e d c o v e r i n g a l l

known e v e n t s of importance a t t h e MSRE and a t a b u l a t i o n of i m p o r t a n t i t e m s such as number of hours c r i t i c a l , t o t a l power produced, o p e r a t i n g conditions, etc.

(See Appendix M.) Drawings

A s t i c k f i l e was m a i n t a i n e d w i t h t h e l a t e s t r e v i s i o n s of f l o w s h e e t s , i n s t r u m e n t a p p l i c a t i o n drawings, b l o c k diagrams, c o n t r o l c i r c u i t schema-

t i c s , a n n u n c i a t o r s c h e m a t i c s , h e a t e r s c h e m a t i c s , h e a t e r and thermocouple l o c a t i o n drawings, e l e c t r i c a l o n - l i n e drawings, and a few l a y o u t drawings. These w e r e updated whenever a change w a s made i n t h e system.

The t r a n s -

p a r e n c i e s were r e v i s e d p e r i o d i c a l l y and new r e v i s i o n s p u t on t h e s t i c k file.

Microfilm n e g a t i v e s of t h e s e drawings and a l l o t h e r MSRE drawings

w e r e maintained a t t h e s i t e .

A r e a d e r - c o p i e r w a s a v a i l a b l e f o r q u i c k view-

i n g o r o b t a i n i n g c o p i e s of any drawing. Miscellaneous (1) C a l i b r a t i o n c u r v e s and o t h e r o p e r a t i o n a l i n f o r m a t i o n on equipment o r systems w a s maintained i n a l o o s e - l e a f notebook i n t h e o p e r a t i o n s o f f i c e . These were updated as new i n f o r m a t i o n was accumulated.

40 (2)

Copies of manufacturers' b u l l e t i n s and i n s t r u c t i o n s f o r a l l

equipment w e r e maintained i n t h e maintenance o f f i c e .

(3)

Switch t a b u l a t i o n s g i v i n g t h e s e t p o i n t s of a l l s w i t c h e s were k e p t

up t o d a t e .

(4)

Two thermocouple t a b u l a t i o n books were maintained which gave t h e

readout l o c a t i o n of each thermocouple.

One w a s indexed a c c o r d i n g t o thermo-

couple number and t h e o t h e r a c c o r d i n g t o r e a d o u t i n s t r u m e n t number.

Ac-

c u r a t e r e c o r d s on t h i s were n e c e s s a r y because t h e r e were approximately 1000 thermocouples which were routed through a p a t c h p a n e l t o t h e r e a d o u t d e v i c e s .

(5)

The l a t e s t c o p i e s of t h e i n s t r u m e n t t a b u l a t i o n s , i n s t r u m e n t s p e c i -

f i c a t i o n s , l i n e s c h e d u l e s , and d e s i g n d a t a s h e e t s were a v a i l a b l e . (6)

Up-to-date

i n f o r m a t i o n r e g a r d i n g t h e computer i n c l u d i n g t h e "Com-

p u t e r Manual f o r MSRE Operators"30 w a s k e p t i n t h e computer room l o c a t e d n e x t t o t h e main c o n t r o l room.

(7)

The main c o n t r o l board w a s a g r a p h i c p a n e l and w a s v e r y h e l p f u l Most of t h e c o n t r o l c i r c u i t s were d e p i c t e d g r a p h i c a l l y

t o the operators. on a jumper board.

I n d i c a t o r l i g h t s provided t h e o p e r a t o r w i t h i n f o r m a t i o n

on each c o n t a c t i n t h e c o n t r o l c i r c u i t s . t o bypass some of t h e i n t e r l o c k s . behind-the-board

Plug-type jumpers could b e used

The jumper board reduced t h e need f o r

A l l jumpers a t t h e MSRE were used o n l y under

jumpers.

strict administrative control.

RECOMMENDATIONS

The f o l l o w i n g recommendations are based on t h e a u t h o r ' s e x p e r i e n c e gained d u r i n g o p e r a t o r t r a i n i n g , s t a r t u p and o p e r a t i o n of t h e MSRE.

The

i n t e n t i s n o t simply t o c r i t i c i z e t h e way t h i n g s were done a t t h e MSRE b u t t o t r y t o s h a r e recommended t e c h n i q u e s w i t h o t h e r o p e r a t o r s and t o p o i n t out p o s s i b l e p i t f a l l s .

I n g e n e r a l , only t h o s e i t e m s which d i r e c t l y a f -

f e c t e d t r a i n i n g , p r e p a r a t i o n f o r o p e r a t i o n , o r a c t u a l o p e r a t i o n are i n cluded. A.

The MSRE Design and Operations Report was i n t e n d e d t o cover a l l

phases of t h e r e a c t o r and t o avoid d u p l i c a t i o n as much as p o s s i b l e .

There-

f o r e t h e Operating Procedures, P a r t V I I I , d i d n o t cover d e s c r i p t i o n s of t h e systems, equipment, o r i n s t r u m e n t a t i o n .

To l e a r n what w a s needed f o r ope-

r a t i o n , t h e o p e r a t o r s had t o r e a d through much i n f o r m a t i o n which w a s n o t

41 pertinent t o operation.

A l l o t h e r p a r t s of t h e Design and O p e r a t i o n s Re-

p o r t should have been a b s t r a c t e d and t h e i n f o r m a t i o n needed f o r o p e r a t i o n should have been r e p e a t e d i n t h e Operating Procedures o r i n a T r a i n i n g Manual. B.

A s p e c i a l s e t of drawings needs t o b e made f o r u s e by o p e r a t o r s .

S i n c e t h e s e would b e r e p e a t e d l y r e f e r r e d t o , more t h a n normal e f f o r t should be spent i n proper layout, cross-referencing,

etc.

Most of t h e s e need t o

b e reduced t o 11- x 17-in, s i z e as were t h e flow s h e e t s a t t h e MSRE.

Some

s p e c i f i c examples are given below. (1)

Flow s h e e t s should be s i m i l a r t o t h o s e i s s u e d f o r t h e MSRE. They should i n c l u d e l i n e numbers and names, equipment numb e r s and names, s i m p l i f i e d i n s t r u m e n t numbers, l o c a t i o n s of l i n e s and equipment, d i r e c t i o n of flow, normal flow rates, normal t e m p e r a t u r e s , normal p r e s s u r e s , r e l a t i v e e l e v a t i o n s when i m p o r t a n t , and normal and f a i l p o s i t i o n of v a l v e s . To avoid unnecessary c o n f u s i o n , most d a t a on components, cross-references,

and a p p r o v a l s i g n a t u r e s could be on a

s e p a r a t e s h e e t r a t h e r t h a n on t h e drawings.

Such t h i n g s

as l i n e s i z e s , t h e number of thermocouples o r h e a t e r s on a l i n e o r equipment, f l a n g e s and l e a k d e t e c t o r s , e t c . , would n o t need t o b e i n c l u d e d . Considerable e f f o r t should be taken t o include a l l i t e m s needed i n r o u t i n e o p e r a t i o n b u t t o make t h e s e as s i m p l e as possible. The MSRE f l o w s h e e t s w e r e made s o t h a t l i n e s e x t e n d i n g beyond t h e edge of one drawing matched t h e n e x t drawing.

o t h e r words i t w a s p o s s i b l e t o f a s t e n t h e f l o w s h e e t s t o g e t h e r and end up w i t h a l a r g e drawing of t h e e n t i r e p l a n t . T h i s is d e s i r a b l e as i t f a c i l i t a t e s t r a c i n g l i n e s . (2)

Although f l o w s h e e t s , as d e s c r i b e d above, s u p p l i e d most of t h e day-to-day

needs of t h e o p e r a t o r s , t h e r e was o f t e n a

need t o know more d e t a i l e d f l o w s h e e t t y p e i n f o r m a t i o n . Drawings showing t h i s s h o u l d b e made u s i n g t h e s i m p l i f i e d

f l o w s h e e t s as a s t a r t i n g p o i n t s o t h a t t h e o r i e n t a t i o n on t h e drawings is t h e same.

Details of i n s t r u m e n t a t i o n l o o p s ,

l i k e given on t h e i n s t r u m e n t a p p l i c a t i o n diagrams, should b e added along w i t h any i n s t r u m e n t v a l v i n g and v a l v e numbers. Control and a n n u n c i a t o r c i r c u i t numbers s h o u l d b e given from a l l s e n s i n g elements as w e l l as t o a l l v a l v e s and equipment

such as pumps.

Line s i z e s and f l a n g e s s h o u l d b e shown along

with the flange leak detector lines. of thermocouples should b e i n d i c a t e d .

Approximate l o c a t i o n These drawings would

be t h e s t a r t i n g p o i n t f o r most t r o u b l e - s h o o t i n g . (3)

Four t y p e s of c o n t r o l c i r c u i t drawings were provided f o r t h e MSRE.

Examples of t h e t h r e e used most by o p e r a t i n g p e r s o n n e l

are shown i n Fig. 1 2 .

No one t y p e was e n t i r e l y s a t i s f a c t o r y .

The block diagrams w e r e probably t h e easiest t o u s e when l e a r n i n g t h e c i r c u i t s b u t they were n o t s u f f i c i e n t f o r oper a t i n g t h e r e a c t o r s i n c e t h e y d i d n o t r e a d i l y show a l l t h e c o n t r o l actions t h a t occur, t h e switches t h a t i n i t i a t e t h e a c t i o n , r e l a y numbers, jumper board l i g h t s , e t c .

The engi-

n e e r i n g e l e m e n t a r i e s s u p p l i e d most of t h e i n f o r m a t i o n necess a r y b u t were d i f f i c u l t t o u s e .

The jumper board drawings

lacked d e t a i l and c r o s s - r e f e r e n c i n g .

These t h r e e i f com-

bined as shown i n Fig. 13 should b e much more u s e f u l t o t h e reactor operators.

Switch s e t p o i n t s should n o t b e shown

b u t should be t a b u l a t e d s i m i l a r t o t h e MSRE Switch Tabulat i o n 3 1 w i t h p r o v i s i o n s f o r keeping a master copy up t o d a t e .

(4)

S i m p l i f i e d e l e c t r i c a l d i s t r i b u t i o n drawings were needed showing a l l s w i t c h e s , b r e a k e r s , i n d i c a t o r s , r e c o r d e r s , e t c . Control power f o r t h e b r e a k e r s s h o u l d b e shown.

Control

c i r c u i t s and s w i t c h t a b u l a t i o n similar t o t h a t d e s c r i b e d above would b e h e l p f u l .

(5)

Combination h e a t e r and thermocouple drawings as used a t t h e MSRE were v e r y h e l p f u l .

These showed t h e approximate loca-

t i o n of t h e h e a t e r s and t h e thermocouples.

I s o m e t r i c draw-

i n g s could have been used t o advantage i n some p l a c e s .

ORNL-DWG 73-3094 181

Reactor Temp. TR > 1 3 W F 2 out o f 3 Channels

Fuel Pump Pressure >10 psig

NO EMERGENCY DUMP REQUIRED

Overflow Tank Level Not High

K144A

Emergency

OFT LEVEL NORMAL

Demand

? :

BLOCK DIAGRAM

K181A

EMERGENCY DUMP 181, 30, 127 137,1088 EMERGENCY DUMP WHEN DEENERGIZED

ENGl NE ER ING ELEMENTARY

Fig. 1 2 .

C o n t r o l C i r c u i t Drawings Used a t MSRE.

DUMP WHEN DEENERGIZED

JUMPER BOARD

c. w

ORNL-DWG 73-3095

EMER. DUMP SW. ON CONSOLE

PS 380A

OPEN WHEN FP PRESSURE IS HIGH

OPEN WHEN R TEMPATURE IS HIGH

K144A

== K33

OPEN WHEN OFT LEVEL IS LOW

. =JUMPER 30, 127 137, 1088 EMERGENCY DUMP

ECC -

1088

= SAFETY

JUMPER CONTACT

ACTION WHEN K181 IS DEENERGIZED FILL RESTRICTION THAWS FV 298 CLOSES HCV 355 ANNUNCIATES EMERGENCY DUMP MB8-1

Fig. 1 3 .

Suggested Type Drawings f o r C o n t r o l C i r c u i t s .

45 E a r l y i n c o n s t r u c t i o n c e r t a i n drawings and documents such as

f l o w s h e e t s and most s e c t i o n s of t h e Design and Operations Report should b e a s s i g n e d t o p e r s o n n e l who are r e s p o n s i b l e f o r keeping t h e s e up t o d a t e . Most of t h i s should probably be a s s i g n e d t o f u t u r e o p e r a t i n g p e r s o n n e l . During p r e p a r a t i o n f o r o p e r a t i o n s , a t a b l e was made l i s t i n g a l l

known v a r i a b l e s i n alpha-numerical o r d e r .

Columns were provided f o r i n d i -

c a t i n g t h e r e a d o u t i n s t r u m e n t number and l o c a t i o n , t h e f u n c t i o n of t h e v a r i a b l e , t h e normal v a l u e , t h e alarm and c o n t r o l s e t p o i n t s and proposed l o g g i n g frequency.

Members of t h e d e s i g n and development groups were con-

t a c t e d t o determine recommended i n i t i a l c o n d i t i o n s .

T h i s provided a v e r y

good s t a r t i n g p o i n t f o r making up t h e v a r i o u s l o g s and a i d e d i n w r i t i n g o p e r a t i n g procedures.

Design and development p e r s o n n e l should b e r e s p o n s i -

b l e f o r a d v i s i n g o p e r a t i o n s of any recommended a d d i t i o n s o r changes i n these. Flowsheets and c i r c u i t elementary drawings should always precede

p i p i n g and w i r i n g drawings. nel.

These s h o u l d b e approved by o p e r a t i o n s person-

Operations p e r s o n n e l should f o l l o w c o n s t r u c t i o n o r c o n s t r u c t i o n per-

s o n n e l s h o u l d b e thoroughly f a m i l i a r w i t h o p e r a t i n g c r i t e r i a .

All l i n e s ,

v a l v e s , wires, and equipment should b e l a b e l e d as t h e y are i n s t a l l e d . During d e s i g n of t h e E R E , i t was thought t h a t extreme f l e x i -

b i l i t y would b e needed f o r thermocouples and t h e i r r e a d o u t i n s t r u m e n t s . During o p e r a t i o n i t w a s obvious t h a t t h e f l e x i b i l i t y provided by t h e p a t c h p a n e l w a s n o t n e c e s s a r y f o r a good p a r t of t h e thermocouples.

To keep

t r a c k of t h e over 1000 thermocouples a t t h e MSRE p r e s e n t e d a d i f f i c u l t prob-

l e m b u t t h e system of two l o g books d e s c r i b e d earlier a d e q u a t e l y s o l v e d t h e problem

The o p e r a t i n g crew s h o u l d b e a t t h e s i t e l o n g b e f o r e t h e c e l l s

are c l o s e d s o t h a t t h e y can become f a m i l i a r w i t h t h e p h y s i c a l l a y o u t .

model of i n - c e l l equipment i s v a l u a b l e f o r o p e r a t i o n and maintenance.

The d e s i r e of non-operating p e r s o n n e l t o know t h e s t a t u s of t h e

r e a c t o r o f t e n l e d t o confusion i n t h e c o n t r o l room e s p e c i a l l y a t t h e s t a r t of t h e work day.

T h i s w a s a l l e v i a t e d by p o s t i n g a s h o r t r e p o r t on t h e

control-room window g i v i n g t h e major happenings f o r t h e l a s t 24 h o u r s , t h e i m p o r t a n t problems encountered and t h e p r e s e n t p l a n s .

Copies were a l s o

made of t h e c o n s o l e l o g s h e e t s each morning and p l a c e d i n convenient l o c a t i o n s .

46 V

useful.

The use of s i m u l a t o r s f o r o p e r a t o r t r a i n i n g w a s found t o b e v e r y The v a l u e of t h i s w a s enhanced by having t h e o p e r a t o r s i t a t t h e

r e a c t o r console, u s e t h e a c t u a l c o n t r o l s w i t c h e s , and r e f e r t o t h e r e g u l a r reactor instrumentation.

Perhaps a d d i t i o n a l t r a i n i n g could b e done by

s i m u l a t i n g f a i l u r e of some of t h e c o n t r o l and/or s a f e t y i n s t r u m e n t a t i o n . By running tests where t h e system i s maloperated, t h e s i m u l a t o r would v e r y d r a m a t i c a l l y i l l u s t r a t e t h e consequences. J.

Often i t i s d i f f i c u l t f o r t h e s h i f t s u p e r v i s o r t o f i n d t i m e t o

thoroughly review t h e b u i l d i n g l o g . vided.

The person t a k i n g t h e l o g l i s t e d i t e m s o u t of l i m i t s o r i t e m s re-

quiring attention.

To a i d i n t h i s , a cover s h e e t was pro-

(See Appendix K.)

Limiting t h e number of people who are a u t h o r i z e d t o change ope-

r a t i n g procedures i s recommended.

was cumbersome.

Keeping everyone informed of t h e changes

These were e n t e r e d i n an o p e r a t i n g procedures change book

and a t f i r s t i t was t h e r e s p o n s i b i l i t y of t h e s h i f t s u p e r v i s o r t o keep a l l o p e r a t o r s on h i s s h i f t informed.

Vacations and o t h e r l e a v e made i t d i f f i -

c u l t t o be s u r e t h a t a l l had been n o t i f i e d .

P l a c e s were t h e n provided i n

t h e Operating Procedures Change Book f o r each o p e r a t o r t o s i g n when h e had read and understood t h e change.

w a s t o o much l a g t i m e .

T h i s worked f i n e except t h a t o f t e n t h e r e

I n reviewing t h e d i f f i c u l t y , i t w a s decided t h a t

many of t h e changes w e r e on check l i s t s o r f o r some o t h e r r e a s o n d i d n o t need t o be known by everyone.

T h e r e f o r e , o n l y important changes were en-

t e r e d i n t h e Operating Procedure Change Book.

Reading of t h e s e w a s s t r i c t -

l y enforced. L.

Graphic p a n e l s showing important f l o w s h e e t s w i t h v a l v e p o s i t i o n

and equipment s t a t u s and jumper boards showing important c o n t r o l c i r c u i t s and t h e i r s t a t u s were v e r y h e l p f u l t o t h e o p e r a t o r s .

The tagging system used a t t h e MSRE worked v e r y w e l l .

All.valves

and s w i t c h e s , which i f i n a d v e r t e n t l y o p e r a t e d could cause harm t o p e r s o n n e l o r t o t h e r e a c t o r , were tagged.

The t a g s used are shown

in Fig. 14.

The

v a l v e s o r switches were n o t o p e r a t e d w i t h o u t removing t h e t a g which r e q u i r e d t h e approval of t h e s h i f t s u p e r v i s o r on duty. as s p e c i f i e d i n t h e s t a r t u p check l i s t s .

o r switches which were operated r e g u l a r l y .

Most of t h e s e w e r e a t t a c h e d

I n general, we did not tag valves

Green

Red Cardboard

Cardboard

KEEP VALVE CLOSED

KEEP VALVE CLOSED OR SWITCH OFF

OR SWITCH OFF

This is the normal position for this valve or switch during operation. It should not be operated without permission of the shift supervisor.

This is the normal position for this valve or switch It should not be operated during operation. without permission of the shift supervisor.

Item

liem

No.:

Day

No.:

Signed

UCN - 5923 7-64) (3

um-5924 0

Fig.

14.

Operations

7-w

Tags.

Da-

48 "DO Not Operate" t a g s were used f o r t a g g i n g o u t v a l v e s and s w i t c h e s

f o r maintenance and s p e c i a l procedures.

A s i n d i c a t e d i n Fig. 1 5 , s p a c e

w a s provided on t h e s e f o r a d d i t i o n a l i n f o r m a t i o n .

The w h i t e paper was re-

moved and a t t a c h e d t o t h e maintenance work o r d e r o r s p e c i a l procedure. This aided i n a s s u r i n g t h a t a l l t a g s were removed when t h e work w a s complete.

I n g e n e r a l , t h e requirement t o remove t h e t a g w a s t o have t h e s h i f t It w a s h i s r e s p o n s i b i l i t y t o see t h a t t h e work

s u p e r v i s o r ' s permission.

was complete and t h a t i t w a s s a f e t o o p e r a t e t h e s w i t c h o r v a l v e . N.

The system used i n s e l e c t i n g i n s t r u m e n t , h e a t e r , and v a l v e num-

b e r s a t t h e MSRE was an a i d t o t r a i n i n g and o p e r a t i o n . a s s i g n e d a series of numbers ( i . e . ,

Each system was

f u e l system i s 100 t o 200).

Any v a l v e s

i n t h e l i n e , i n s t r u m e n t s a t t a c h e d t o t h e l i n e o r h e a t e r s i n s t a l l e d on i t were numbered a c c o r d i n g l y .

(i.e.,

HV-522A w a s a hand v a l v e i n Line 522,

PS-575C w a s a p r e s s u r e s w i t c h a t t a c h e d t o l i n e 575, H-101-2

was a h e a t e r

on l i n e 101, and TE-103-1 w a s a thermocouple on l i n e 103.) 0.

The t r a i n i n g i n s t r u c t o r s were e n g i n e e r s and s c i e n t i s t s who, i n

most c a s e s , w e r e v e r y f a m i l i a r w i t h t h e i r s u b j e c t .

However, some d i d n o t

understand t h e needs and t h e l i m i t a t i o n s of t h e o p e r a t o r s and most had no e x p e r i e n c e as t e a c h e r s .

I t would be b e t t e r if a few s k i l l e d i n s t r u c t o r s

were used, with the experts p r e s e n t t o answer q u e s t i o n s t b t the f n s t r u c t o r could n o t h a n d l e ,

These i n s t r u c t o r s should b e g i v e n some p r i o r t r a i n i n g

on such t h i n g s as t h e o r y of l e a r n i n g , l e s s o n p l a n n i n g , and methods of presentation. P.

A t r a i n i n g manual should be w r i t t e n .

T h i s would have been help-

f u l i n t h e e a r l y t r a i n i n g and would have saved c o n s i d e r a b l e t i m e i n t r a i n i n g replacements.

T h i s manual should b e updated as changes are made.

S i n c e much of t h e n u c l e a r , h e a l t h p h y s i c s , and g e n e r a l e n g i n e e r i n g t r a i n i n g needed is common t o most r e a c t o r s , a v a i l a b l e i n f o r m a t i o n s u c h as t h e programmed i n s t r u c t i o n manuals p u b l i s h e d by t h e ORNL O p e r a t i o n s D i v i s i o n 3 2 , 3 3 , 3 4 , 3 5 , 3 6 should be p u t t o use.

However, t h i s s h o u l d be care-

f u l l y reviewed and t h e a p p r o p r i a t e s e c t i o n s made a p a r t of t h e t r a i n i n g manual f o r t h e p a r t i c u l a r r e a c t o r .

The r e a c t o r d e s i g n , i n s t r u m e n t s i n -

s t a l l e d , and methods of o p e r a t i o n should b e covered from t h e o p e r a t o r ' s viewpoint,

To a i d i n l e a r n i n g and i n h a n d l i n g emergencies and unusual oc-

c u r r e n c e s , t h e r e a s o n f o r the v a r i o u s f e a t u r e s s h o u l d b e s t r e s s e d .

5 REDCARDBOARD

UCN . 5925 I3

7-64

REDCARDBOARD

Fig. 15.

Maintenance Tags.

50 I n s t r u c t i o n s should be i n c l u d e d f o r m a n i p u l a t i v e t r a i n i n g and f o r a i d i n g t h e t r a i n e e i n becoming f a m i l i a r w i t h t h e p h y s i c a l l a y o u t .

Photo-

graphs of o p e r a t i n g areas would be h e l p f u l . D e t a i l e d o u t l i n e s of t o u r s and o r a l i n s t r u c t i o n should be provided. Operating t e c h n i q u e s such as changing c h a r t p a p e r , l o g - t a k i n g ,

etc.,

should be included. The manual should be designed f o r t h e l e a s t educated o p e r a t o r and should advance t h i s person t o t h e s t a g e needed t o o p e r a t e t h e r e a c t o r . A d d i t i o n a l s e c t i o n s should be provided f o r t h e s u p e r v i s o r s i n c l u d i n g t h e

a r t of s u p e r v i s i o n . This manual would probably be more v a l u a b l e i f p u t i n t o t h e form of programmed i n s t r u c t i o n . each s e c t i o n .

Review tests should be i n c l u d e d a t t h e end of

REFERENCES 1. M. W. Rosenthal e t a l , The Development Status of MoZten-Salt Breeder Reactors, OEWL-4812 (August 1972). 2.

P. N. Haubenreich and J . R. Engel, "Experience w i t h t h e MSRE,"

NucZ. AppZ. Tech. 8, - 118 (1970).

M. W. Rosenthal, P. N. Haubenreich, H. E. McCoy, and L. E. McNeese, "Current P r o g r e s s i n Molten-Salt Reactor Development," Atomic Energy Review, g,601 (1971).

R. C. Robertson, MSRE Design and Operations Report, Part I , Description of Reactor Design, ORNL-TM-728, (January 1965).

J. R. T a l l a c k s o n , MSRE Design and Operations Report, P a r t I I A , Nuclear and Process Instrumentation, ORNL-TM-729, P a r t I I A , (February 1968).

R. L. Moore, MSRE Design and Operations Report, P a r t I I B , Nuclear and Process Instrumentation, OWL-TM-729, P a r t I I B , (September 1972).

R. B . Lindauer , MSRE Design and Operations Report, P a r t V I I , Fuel Handling and Processing Plant, ORNL-TM-907 Revised, (December 1967).

B. H. Webster, Quality-Assurance Practices in Construction and Maintenance o f the MSRE, ORNL-TM-2999 ( A p r i l 1970).

MSR Progr. Semiannu. Progr. Rep., July 31, 1964, ORNL-3708.

10.

S . J. B a l l , Sirnulators for Training Molten-Salt Reactor Experiment Operators, ORNL-TM-1445, A p r i l 5, 1966.

11, R. H. Guymon, MSRE Design and Operations Report, Part VIII, Operating Procedures, VoZs. I and XI, ORNL-TM-908, (Dec. 1965) . 12.

B. E. P r i n c e , S. J. B a l l , J. R. Engel, P. N. Haubenreich, T . W. K e r l i n , Zero-Power Physics Experiments on the MSRE, ORNL-4233 (Feb. 1968)

13.

O p e r a t o r s ' L i c e n s e , Code of F e d e r a l R e g u l a t i o n s , T i t l e 1 0 , P a r t 55.

14.

"A Guide f o r t h e L i c e n s i n g AEC L i c e n s i n g Guide Operators' Licenses of F a c i l i t y O p e r a t o r s , I n c l u d i n g S e n i o r Operators" p u b l i s h e d by t h e D i v i s i o n of Reactor L i c e n s i n g , USAEC.

15.

R. H. Guymon, P. N. Haubenreich and J. R. Engel, MSRE Design and Operations Report P a r t X I , Test Program, OWL-TM-911, (Nov. 1966).

16.

J . R. Engel, MSRE Design and Operations Report, Part XI-A, Test Program f o r 2 3 3 U Operation, ORNL-TM-2304, (Sept. 1968).

i n Analysis

17.

J. R. Engel and P. N. Haubenreich, Use of &-Line Computer of MSRE Operation, OWL-CF-62-3-26, (March 1962).

18.

J. R. T a l l a c k s o n , MSRE Design and Operations Report - P a r t 11-A: Nuclear and Process Instrumentation, ORNL-TM-729, P a r t 11-A, (Feb. 1968).

19.

R. L. Moore, MSRE Design and Operations Report - P a r t 11-B: Nuclear and Process Instrumentation, ORNL-TM-729, P a r t 11-By (Sept. 1972).

20.

P. N . Haubenreich, e t a l . , MSRE Design and Operations Report, Part 111, (Feb. 1964).

Nuclear Analysis, ORNL-TM-730, 21.

S . E. Beall, e t a l . , MSRE

Design and Operations Report, Part V, Reactor

Safety Analysis Report, ORNL-TM-732 , (Aug

. 1964) .

22.

P. N. Haubenreich e t a l . , MSRE D e s i T and Operations Report, P a r t V-A, Safety Analysis of Operation with 3U, ORNL-TM-2111, (Feb. 1968).

23.

S . E. Beall and R. H. Guymon, MSRE Design and Operations Report: P a r t V I , Operating Safety L i m i t s f o r the Molten-Salt Experiment, OWL-TM-733,

( A p r i l 1965). 24.

S . E. Beall and R. H. Guymon, MSRE Design and Operations Report, P a r t V I , Rev., Operating Safety L i m i t s f o r t h e Molten-Salt Experiment,

OWL-TM-733, 25.

(Aug

1965) ,

S . E . Beall and R. H. Guymon, MSRE Design and Operations Report, P a r t V I , 2nd Rev,, Operating Safety L i m i t s f o r t h e Molten-Salt

Experiment, OWL-TM-733,

(Sept

. 1966) .

26.

R. H. Guymon and P. N. Haubenreich, MSRE Design and Operations Report, P a r t V I , 3rd Rev., Operating Safety L i m i t s f o r the Molten-Salt Experiment, ORNL-TM-733 , ( J u l y 1969).

27.

R. B . Lindauer, / E R E Design and Operations Report, Part V I I , Fuel Handling and Processing Plant, ORNL-TM-907 , (May 1965).

28.

A. N . Smith, MSRE Design and Operations Report, Part I X , Safety Procedures and Emergency Plans, ORNL-TM-909, (June 1965).

29.

R. Blumberg and E . C. H i s e , MSRE Design and Operations Report, P a r t X : Maintenance Equipment and Procedures, ORNL-TM-910, (June 1968).

30.

G. H . Burger, J . R. Engel, and C. D. M a r t i n , Computer Manual for MSRE (Jan. 1967).

Operators, ORNL-CF-67-1-28, 31.

R. L. Moore, Molten Salt Reactor Experiment Process Instrument Switch Tabulation, Om-CF-65-6-5.

53 APPENDIX A SCHEDULE FOR INITIAL TRAINING

( J u l y 1964)

Day Monday July 6

Tuesday July 7

Wednesday July 8

Thursday July 9

Time

Subject

Instructor

0800-1000

Information Meeting. Organization c h a r t , schedule, g e n e r a l comments, q u e s t i o n s , and answers)

Operations Dept. Head and Operations Chief

1015-1200 1300-1400

General D e s c r i p t i o n of a l l Systems

Operations Chief

1415-1500

D e s c r i p t i o n of Area

S h i f t Supervisor

1500-1630

Guided Tour

S h i f t Supervisor

0800-0930

Guided Tour

S h i f t Supervisor

0930-1015

Questions on Guided Tour

S h i f t Supervisor

1030-1 2 00

Reactor Chemistry

Reactor Chemistry D i v i s i o n D i r e c t o r and Chemist

1300-1500

Design of F u e l System

A s s t . O p e r a t i o n s Chief

1500-163 0

S e l f -S tudy

0800-093 0

Reactor P h y s i c s Problems and Group S o l v i n g

O p e r a t i o n s Dept. Head

0930-1130

Design of Coolant System

S h i f t Supervisor

1130-1200

S e l f -S tudy

1300-1400

Reactor Chemistry

Chemist

1415-1600

Design of Fuel and Coolant Drain Tank Systems

S h i f t Supervisor

1600-1630

Self-study

0800-1130

Reactor P h y s i c s

1130-1200

S e l f -S tudy

1300-1400

Design of Cover and Off-gas System

Cover and Off-gas System Design Engineer

1415-1630

Design of Fuel Pump and O i l System

Pump and O i l System Design Engineer

Operations Dept. Head

* Day Friday July 10

Monday July 13

Tuesday July 1 4

Time

Instructor

0800-0930

Reactor Physics

Operations Dept. Head

0930-1030

Design of LKD System

Leak Detector Design Engr.

1030-1200

Design of Cooling Water System

Shift Supervisor

1300-143 0

Design of Component Coolant System Shift Supervisor

1445-1630

Review

Operations Chief

0800-0900

Design and Operation of Instrument Air System

Asst. Shift Supervisor

0900-1000

Health Physics

Health Physicist

1015-1130

Beryllium Hazards

Head of ORNL Industrial Hygiene Dept. and Asst. Director of ORNL Medical Division

1130-1200 1300- 1500

S e l f -S

tudy Instrumentation

Instrumentation Engr.

1515-1630

Instruments -Explanation of each in the field

Instrumentation Engr.

Design and Operation of Shield and Containment Systems

Shift Supervisor

0945-1200

Explanation of Control Schematics

Operations Chief

1300-1400

Design and Operation of Electrical System

Shift Supervisor

Design and Operation of Ventilation System

Shift Supervisor

0800-0930

1415-1530

Wednesday July 15

Subject

1530-1630

Self-study

0800-0900

Electrical Systems

Shift Supervisor

0900-092 0

Instrument Air System

Asst. Shift Supervisor

092 0-0940

Water Systems

Shift Supervisor

0940-1020

Component Cooling Systems

Shift Supervisor

1030-1100

Shield and Containment Systems

Shift Supervisor

1100-1130

Ventilation Systems

Shift Supervisor

1130-1200

Leak Detector Systems

Shift Supervisor

1300-13 30

Cover and Off-gas Systems

Shift Supervisor

1330-1400

Oil Systems

Asst. Operations Chief

55 W

Day

Time

Subject

Instructor

Wednesday July 15 (continued)

Thursday July 16

Friday July 17

Monday July 20 W

1400-1500

Self-study

1500-1530

Auxiliary System Startup Check Lists

Operations Chief

1530-1600

Purging Systems

Asst. Operations Chief

1600-1630

Startup and Operation of Cover and Off-gas Systems

Shift Supervisor Shift Supervisor

0800-0820 0820-0850

Heatup of Drain Tanks Addition of Salt

Asst. Operations Chief

0850-0920

Startup and Operation of Lube Oil System

Asst. Operations Chief

0920-0940

Heatup of Fuel and Coolant Systems Shift Supervisor

1000-1030

Prepare for Reactor Startup, including Pressure Test

Shift Supervisor

1030-1130

Filling Fuel and Coolant Systems

Asst. Operations Chief

1130-1200

Self-S tudy

1300-1330 1330-1430

Starting Power Operation Normal Operating Conditions

1445-1615

Nuclear Instrumentation

1615-1630

Self-study

0800-0900 0900-1030 1045-1200

Unusual Operations Heat Balance

Analysis Chief

Control Rods

Control Rod Design Engr.

1300-1400

Remote Maintenance

Remote Maintenance Design Engineer

1400-1530

General Operating Practices, Plans, etc.

Operations Chief

Operations Chief Operations Chief Nuclear Instrumentation Design Engineer

Operations Chief

1530-1630

Self-study

0800-0900

Discuss Precritical Testing

0900-1200

Self-study, get clothing and lockers

Operations Chief

Day

Time

Monday July 20 (continued) 1300-1430 Tuesday July 2 1

Wednesday July 22

Thursday July 23

Friday July 24

Monday July 27

Tuesday July 28

Subject

Reactor Physics

1 430-1 630

Operational Checkout

0800-1000

Unusual Operating Conditions and Control Circuits

Instructor

Operations Dept Head

Operations Chief

1000-1100

Self-S tudy

1100-1200

Melton Valley Facilities

1300-163 0

Operational Checkout

0800-1000

Reactor Physics

1000-1100

Self-S tudy

1100-1200

Thermocouple Scanner

1300-1630

Operational Checkout

0800-1000

Samplers

1000-1100

Self-S tudy

1100-1200

Metallurgy

1300-163 0

Operational Checkout

0800-1000

Control Schematics

1000-1100

Self-study

1100-1 2 00

Discussion

1300-1630

Operational Checkout

0800-0930

Chemical Processing of the Fuel Salt

Chemical Processing Engr

0930-1030

Control Shematics

Operations Chief

1030- 1200

Fuel Salt Production

Salt Production Engr.

1300-163 0

Operational Checkout

0800-093 0

Electrical System

0930-1030

Self-study

1030-1 2 2 0

Waste System

1300-1630

Operational Checkout

Operations Chief

Operations Dept. Head Asst. Shift Supervisor

Sampler Design Engineer Metallurgist

Operations Chief Operations Chief

Shift Supervisor Shift Supervisor

APPENDIX B INSTRUCTIONS FOR FLOWSHEETS CHECKOUT First Phase Using a copy of all flowsheets and all instrument application drawings needed for the system being checked, proceed as follows:

Trace all lines and equipment including instrumentation at least to the primary sensing element.

Mark flowsheets and instrument application drawings with yellow pencil as lines are traced. Do not miss anything.

Change flowsheets and instrument application drawings to agree with the actual installation. Use green pencil for deletions and red pencil for additions.

Tag all lines, instruments and equipment at locations where permanent tags are needed. (Use round tags and green pencil. Tags should be exactly like desired permanent label. Line numbers should not be preceded by any symbol. Hand valves should be labeled V-501, V-944, etc. Control valves should be HCV-516, PCV-522, etc. Instruments should be PI-500, FI-933, etc.)

NOTE:

Some special things to look for are given below:

Location of tees, sample valves and capped lines. Double lines and containment extensions. Instrument valves not shown or numbered, hand valves and check valves. Leak detector lines. Areas where items are located. Be on the lookout for any faulty construction, or errors in design or construction which might cause mal-operation.

Second Phase Using a copy of t h e s m a l l s i z e f l o w s h e e t s : 1.

Trace o u t l i n e s under t h e d i r e c t i o n of t h e "dystem flowsheet experts. "

When completed, r e t u r n t o conference room f o r s e l f - s t u d y u n t i l t h e o t h e r group has r e t u r n e d . Then c o n t i n u e t o n e x t flowsheet checkout.

NOTE:

It w i l l n o t b e n e c e s s a r y t o t r a c e e v e r y l i n e t o check f o r tees, sample v a l v e s , e t c . , however, each p e r s o n should b e f a m i l i a r w i t h each system when t h e checkout i s f i n i s h e d .

59 V

APPENDIX C SCHEDULE FOR PRECRITICAL T R A I N I N G

(March 1965) A l l o p e r a t i n g personnel p a r t i c i p a t e d i n t h e s e s s i o n s from March 1 5 through March 26 u n l e s s o t h e r w i s e noted. Only t h e e n g i n e e r s p a r t i c i p a t e d i n t h e s e s s i o n s from March 29 through A p r i l 2 u n l e s s o t h e r w i s e noted.

Day

Time

Monday March 1 5

0830-1000

Discussion of S t a t u s and P l a n s

1030-1630

System Discussions (Brief Reviews)

Subject

Fuel System Coolant Sys t e m Fuel Drain Tank System Cover and Off-gas System O i l System Component Coolant System Water System Instrument A i r System S h i e l d and Containment System V e n t i l a t i o n System Waste System Tuesday March 16

Wednesday March 1 7

Instructor

Operations Dept. Head & Operations Chief Asst. Shift Shift Asst. Asst. Shift Shift Asst. Shift Asst. Shift

Operations Chief Supervisor Supervisor S h i f t Supervisor S h i f t Supervisor Supervisor Supervisor S h i f t Supervisor Supervisor S h i f t Supervisor Supervisor

0830-1000

Radiation S a f e t y Policy

Head of ORNL R a d i a t i o n Safety

1000-1130

Annunciators

Instrumentation Engineer

1230- 133 0

Process Monitors (and High Level Gamma)

P r o c e s s Monitor Design Engineer

1 330-1400

V e n t i l a t i o n System

A s s t . S h i f t Supervisor

1500-163 0

Instrument Tour (Group 1)

I n s t r u m e n t a t i o n Engineer

P o r t a b l e Radiation Instruments (Group 2)

Health P h y s i c i s t

0830-1000

Radiation Safety

Health Physicist

1030-1200

Personnel Monitors

Personnel Monitor Design Engineer

1300-1500

E l e c t r i c a l Systems

S h i f t Supervisor

60 Day

Time

Subject

Instructor

Instrument Tour (Group 2)

Instrumentation Engineer

Portable Radiation Instruments (Group 1)

Health Physicist

0815-1015

Control Circuits

Operations Chief

1030-122 0

Computer

Analysis Chief

1300-1430

Freeze Valves

Freeze Valve Design Engr.

1500-1630

Tours : Chemical Processing (Group 1) Instruments (Group 2)

Chem. Processing Engr. Instrumentation Engr.

0830-0930

Safety Circuit Testing (Process)

Safety Instrumentation Design Engineers

0930-1030

Discussion of Pool Criticality Assembly Experiment

Pool Criticality Assembly Engineer

1100-1200

Jumper Board

Asst. Operations Chief

1300-1400

Safety Circuit Testing (Nuclear)

Safety Instrumentation Design Engineers

1500-1630

Tours : Chemical Processing (Group 2) Instruments (Group 1)

Chem. Processing Engr. Instrumentation Engr.

PCA Experiment (Group A)

Pool Criticality Assembly Engineer

Chemical Processing (Group B)

Chem. Processing Engr.

0830-1200

PCA Experiment (Group F)

Pool Criticality Assembly Engineer

1230-1630

PCA Experiment (Group C)

Pool Criticality Assembly Engineer

Sampler (Group D)

Sampler Design Engineer

PCA Experiment (Group F)

Pool Criticality Assembly Engineer

Chemical Processing (Group B)

Chem. Processing Engr.

Wednesday March 17 (continued) 1500-1630

Thursday March 18

Friday March 19

Monday March 22

Tuesday March 23

NOTE:

0800-1200

1230-1630

Crews will spend spare time Monday and Tuesday on group or fndividual study.

Day

Time

Subject

Wednesday March 24

0830-0930

PCA Discussion

0930-1200

Start-up Check Lists (Brief Summaries)

4A Electrical 4B Instrument Air 4c Water 4D Component Cooling 4E Shield and Containment 4F Ventilation 4G Leak Detector 4H Instrumentation 41 Freeze Valves

Thursday March 25

Shift Asst. Shift Shift Shift Shift Asst. Asst. Asst.

Supervisor Shift Supervisor Supervisor Supervisor Supervisor Supervisor Shift Supervisor Shift Supervisor Shift Supervisor

5A Purging Systems

Asst. Shift Supervisor

1330-1400

Start up of Cover Gas

Asst. Shift Supervisor

1400-1445

5C Heatup of Drain Tanks

Asst. Operations Chief

1500-1630

Tours : Instrument System (Group 1) Electrical System (Group 2)

Instrumentation Engr. Shift Supervisor

0830-0845

Ass t

0845-0930

5F Heatup of Fuel and Coolant System

Asst. Operations Chief

0930-1000

5G Prepare DT's for Startup

Shift Supervisor

1030-1100

5H Routine Pressure Test

Asst. Shift Supervisor

1100-1200

51 Filling Fuel and Coolant System Asst. Operations Chief Operations Dept. Head Criticality and Power

Startup of Lube Oil System

. Shift Supervisor

Criticality and Power Tours : Instrument System (Group 2) Electrical System (Group 1)

Instrumentation Engr. Shift Supervisor

0830-1000

Normal Operation

Shift Supervisor

1030-1200

Shutdown and Transfers

Shift Supervisor

1300-1400

Sampling and Analysis

Asst. Shift Supervisor

1400-1500

Data Taking, Operating Techniques, etc. Asst. Operations Chief

1530-1630

Plans

1400-1500 1500-1630

Shift Supervisor

1300-1330

1300-1400

Friday March 26

Instructor

Shift Supervisor

Operations Chief

62 ~~

Day

Time

Monday March 29

0830-1030

Nuclear Aspects of MSRE

Operations Dept. Head

1100-1200

Control Rods

Control Rod Design Engineers

1300-1400

Computer

Analysis Chief

1530-1630

Reactor Chemistry Discussion

Chemist

0830-1030

Nuclear Aspects of MSRE

Operations Dept. Head

1100-1200

Core Specimen Arrays

Remote Maintenance Engrs.

1300-1500

Computer

Analysis Chief

1530-1630

Maintenance Discussion

Remote Maintenance Engr.

0830-1200

Nuclear Instrumentation

Nuclear Instrument Design Engineer

1300-1500

Nuc1ear S imulation

Instrument Engineer

1500-1630

Computer

Analysis Chief

0830-1030

Computer

Analysis Chief

1100-1200

Critical Experiments

Analysis Chief

1300-1400

Critical Experiments

Analysis Chief

1430-1630

Nuclear Instrumentation

Nuclear Instrument Design Engineer

0830-1030

Nuclear Aspects

Operations Dept. Head

1100-1200

Operating Limits

Operations Chief

1300-1400

Nuclear Aspects

Operations Dept Head

1400-1500

Emergency Plans

Operations Chief

1530-1630

Plans

Operations Chief

Tuesday March 30

Wednesday March 31

Thursday April 1

Friday April 2 .

Subject

Instructor

Appendix D PRECRITICAL EXAMINATIONS I n A p r i l , 1965, s i x weeks b e f o r e t h e beginning of n u c l e a r o p e r a t i o n , w r i t t e n examinations were a d m i n i s t e r e d t o a l l MSRE o p e r a t o r s .

T h i s ap-

pendix reproduces t h e i n s t r u c t i o n s and t h e s c h e d u l e i s s u e d j u s t p r i o r t o t h e examinations. included.

Some r e p r e s e n t a t i v e q u e s t i o n s and problems a r e a l s o

(The complete examination covered 4 3 pages.) Instructions

T h i s examination i s t o be g i v e n i n f i v e p e r i o d s p l u s one e x t r a p e r i o d f o r t h e engineers.

Various t y p e q u e s t i o n s a r e asked throughout.

True-

f a l s e q u e s t i o n s a r e worth one p o i n t (+1>i f r i g h t , z e r o (0) p o i n t s i f n o t answered and minus one (-1)

i f answered wrong.

A l l o t h e r t y p e s have d i f -

f e r e n t v a l u e s as noted t o t h e l e f t of each q u e s t i o n number.

A summary of

t h e exams and t i m e a l l o c a t e d f o r each p e r i o d i s g i v e n i n t h e a t t a c h e d table I t should be noted t h a t t h e v a l u e of t h e q u e s t i o n o r t h e number of b l a n k l i n e s l e f t f o r answers does n o t n e c e s s a r i l y i n d i c a t e how many c o r r e c t answers t h e r e are.

For i n s t a n c e i f t h e r e are 3 t h i n g s which t u r n o f f t h e

control-room a i r c o n d i t i o n e r and 5 l i n e s are l e f t , t h e q u e s t i o n may s t i l l be worth 1 o r 2 p o i n t s . There are some questions which are marked extra credit.

u n t i l a l l o t h e r q u e s t i o n s are answered. complete t h e s e .

Skip these

Then i f t i m e p e r m i t s go back and

It i s more d e s i r a b l e t o answer t h e r e q u i r e d q u e s t i o n s r i g h t

than t o answer t h e o p t i o n a l ones. B e s u r e t o r e a d a l l i n s t r u c t i o n s throughout t h e t e s t .

I n g e n e r a l , i t i s f e l t t h a t t h e meaning of e a c h q u e s t i o n i s c l e a r . down t h e b e s t answer t h a t you know, based on your u n d e r s t a n d i n g of i t . not ask f o r assistance. do so.

Put

I f you f e e l i t i s n e c e s s a r y t o e x p l a i n your answer,

C r e d i t w i l l b e g i v e n i f a q u e s t i o n i s n o t clear, however, no c r e d i t

w i l l b e g i v e n i f i t a p p e a r s t h a t t h e q u e s t i o n was c l e a r and t h e i n t e n t w a s changed by your e x p l a n a t i o n even though your answer t o your e x p l a n a t i o n i s c o r r e c t , i . e . , you cannot make up your own q u e s t i o n s .

When f i n i s h e d be s u r e your name and d a t e are on t h e f i r s t s h e e t and your i n i t i a l s are on t h e bottom of each s h e e t .

Do a l l c a l c u l a t i o n s , ex-

p l a n a t i o n s etc. i n t h e margin o r on t h e back of t h e examihation s h e e t s . Turn i n your p a p e r s promptly when r e q u e s t e d .

The n e x t test p e r i o d w i l l

s t a r t promptly a t t h e t i m e i n d i c a t e d i n t h e t a b l e s .

you w i l l n o t have as much t i m e f o r t h a t t e s t p e r i o d .

I f you are l a t e ,

65 Schedule (All operators take tests in periods 1-5.

Only engineers take tests

in period 6.)

Period

Duration (min)

Time

Subjects Covered

Required Questions No. Value

100

0815-0955 (1615-1755)

Instrumentation

165

100

1005-1145 (1805-1945)

Flow Sheets

176

1215-1305 (2015-2105)

Design 40 Health Physics & Industrial Hygiene 27

50 37

6 8 0 3 6 7 8 9 10

1315-1415 (2115-2215)

Nuclear Chemistry General Chemical Processing Lay Out Engineering Calculations Electrical Emergency Procedures Chemical Processing or Samplers

13 13

Nuclear Characteristics

Total of above

298

566*

1425-1450 (2225-2250)

1500-1600 (2300-2400)

Operating Parameters

General Computer Abnormal Operating Procedures Nuclear Characteristics Total of this part

*Either

14 0 3 27 12

14 9

20 10 7 20

49 10 10 28

Chemical Processing or Sampling Section of the test is to be taken.

Samples of Questions Instrumentation

1. High reactor outlet temperature (>1300째F) causes a rod scram.

True False

Reactor cell activity will cause a fuel drain.

True False

High reactor outlet temperature will cause a load scram.

True False

16.

Reactor cell air activity closes all air line block valves. True False

31.

All three fill valves (104, 105, and 106) must be thawed True False

to be in the operate mode. 39. 54.

If the power level is changing circuits will not permit going into the run mode. (Period <30 sec)

True False

Automatic load control will not raise the radiator doors above the lower intermediate limit unless the reactor is in the run mode.

62.

True False

When in servo the regulating rod limit switches can be raised but not inserted using the manual rod actuator switch (S-19) on the console.

78.

True False

Stack fan #2 will start automatically only if the start button has been pushed after starging #1 stack fan.

84.

There are a number of annunciators at the MSRE.

Check

which of the following will cause an annunciation.

(A list of 36 conditions followed. One point was scored for each correctly marked.)

85. Assuming that FV-103 is frozen on automatic, fuel drain is caused by: (Five blanks. 93.

Question worth 10 points.)

If the reactor is at full power the following may stop the fuel pump.

True False

67 Flow S h e e t s and Operating Parameters

The v a r i o u s systems have series of numbers a s s i g n e d t o various lines.

P l a c e t h e number 100, 200, 300, a f t e r

each of t h e following.

10.

(a)

Fuel System

(b)

Coolant System

(c)

Cover Gas

(d)

Containment V e n t i l a t i o n

(e)

O i l System

(f)

Fuel Processing

(g)

Waste

(h)

Leak D e t e c t o r

(i)

Water

---

The d r a i n t a n k condensers are cooled by c i r c u l a t i n g water through t h e tubes.

28.

---

P l a c e t h e proper l e t t e r i n t h e f o l l o w i n g b l a n k s .

Normal c o o l i n g water

(a)

Potable

Emergency c o o l i n g water

(b)

Process

(c)

Cooling Tower

(d)

Treated

(e)

Condensate

A t f u e l pump levels above approximately

% t h e r e i s entrainment

o r c a r r y o v e r t o t h e overflow tank. 41.

Check which of t h e f o l l o w i n g are monitored by p r o c e s s r a d i a t i o n monitors. (a)

Cell a i r on l i n e 565.

(b)

C e l l a i r i n t h e c e l l by h i g h l e v e l gamma meter.

(c)

Coolant pump off-gas.

(d)

Helium supply t o b u b b l e r s .

(e)

Of E-gas from c h a r c o a l beds.

(f)

Off-gas upstream of t h e c h a r c o a l beds.

(g)

F u e l o i l supply tank.

(h)

Coolant system o i l supply t a n k .

(i)

Cooling tower w a t e r .

(j)

Reactor and d r a i n t a n k sump j e t d i s c h a r g e .

46. There are two levels of annunciation on the monitron. normally set at 50.

mr/hr and

These are

mr/hr.

Assume that the reactor has been filled from FD-2 and is operating at a few watts after the criticality tests. which are considered to be normal.

Check the items below

(Watch out for units.)

(a)

Fuel salt temperature Q1200'F.

(b)

Coolant salt temperature ~1200'F.

(c)

Fuel salt flow 1200 gpm.

(d)

Fuel salt indicated by FT-201.

(e)

F. P. power -25 kW.

(f)

Both FP bubblers in operation.

(8) Flow indicators in supply to bubblers is 25 psig. (h) Main flow to FP (FIC-516) = 4.2 R/min.

(i)

Gas flow to OCT-1 would be %50% of MCB.

(j) Water flow to FP = 5 gpm. (k) FOP-1 in operation, FOP-2 in standby.

(1) Oil flow to lubricate FP bearings = 3-5 G/m. (m) CCP 1 or 2 on. (n)

One RC cooler on, other in standby.

(0)

Both drain tank cell coolers on.

(p)

Component coolant air on the CP shroud.

(4)

PdIC 960 set at 8 psi AP.

(r)

CP power reading approximately 38 W.

(s)

CP speed is approximately 1750 rpm.

(t)

Main purge to CP (FIC-512) reads 0.37 Rlmin.

(u)

FV-103 frozen.

(v)

FV-106 deep frozen.

(w) FV-105 thawed. (x)

FV-108 thawed.

(y)

FV-107 and 109 deep frozen.

(z)

FV-204 thawed.

(aa) FV-206 frozen. (bb)

FI-201 reads 40%.

(cc) (dd)

Equalizer 545 open between FD-2 and FP. Other equalizer valves closed.

69 W

FFT v e n t (577) open. A l l d r a i n tank helium supply v a l v e s open (572, 574, 576).

CDT e q u a l i z e r (527) open. Approximately 5000# of s a l t i n FFT.

FD-2 p r a c t i c a l l y empty. Feedwater t a n k s f u l l . Steam dome l e v e l i n d i c a t o r s a t g r e a t e r t h a n 70%.

FP v e n t open (533). AP a c r o s s main c h a r c o a l bed ~4 i n . of w a t e r . Valves i n l i n e 566 open. High bay a t a s l i g h t n e g a t i v e p r e s s u r e . S t a c k f a n No. 2 on. S t a c k f a n No. 1 i n standby. Helium being f e d from helium t r a i l e r whose p r e s s u r e i s above

500 p s i g . Helium d r y e r s a t 800'F. Oxygen removal u n i t s a t 1200째F.

FCV-500S i n d i c a t i n g less than 1 0 R/m. Water c o n t e n t of cover gas less t h a n 1 ppm, oxygen c o n t e n t

less than 6 ppm. Lube o i l system a t 5 p s i g . Lube o i l supply t a n k level (OT-1) s e t p o i n t s e t a t %l% above l e v e l i n d i c a t e d i n t h e tank. Reactor and d r a i n tank c e l l sumps empty. Three c o o l a n t c e l l c o o l e r s on. No. 1 o r No. 2 c o o l i n g tower pump on. N o . 1 o r No. 2 t r e a t e d water pumps on and t h e o t h e r s e t f o r

automatic s t a r t u p . Process water flowing through t h e d r a i n t a n k condensers. A l l "A" v a l v e s t o t h e f l a n g e s from t h e l e a k d e t e c t o r system open. All

"Bl'

valves t o t h e flanges closed.

LKD p r e s s u r e g r e a t e r t h a n 90 p s i g .

FD-1 may b e a t 1200'F W

o r may b e cooled i f d e s i r e d .

Fuel system o v e r p r e s s u r e w i l l b e maintained a t approximately

5 psig.

Coolant system will be at a slightly higher overpressure to

(iii)

assure that any leakage at the heat exchanger will be from the coolant system to the fuel system. (jjj) All three containment air filters will be on stream. (kkk) Oil level in the oil catch tank should be just above the

intersection between the smaller and larger sections. (111) Auxiliary air compressor will be in operation with CCP #3 in standby for cooling FV 204 and 206. (m) Either instrument air compressor can be in operation.

(nnn)

Vapor condensing system will be vented to the stack filters.

(000)

The bypass valve around the vapor condensing system rupture discs should be closed.

(ppp)

MG sets 1 and 4 will be in operation and either MG 2 or 3 .

(qqq)

DG-5 should be in operation.

(rrr)

The computer will be in operation at all times.

If trouble

develops with it, the reactor will be shut down. (sss)

All process and personnel radiation monitors will be in operation.

(ttt)

An engineer must be in the control room.

(uuu)

The waste tank blower will be on.

(wv)

HFIR feeder line will be in parallel with the normal TVA feeder.

(www)

Radiator heaters will be on.

(xxx)

Reactor cell will be at -2

(zzz)

Helium surge tank will be on stream.

in. of water.

Design 3.

Fuel pump flow is approximately (a) (b)

850 gpm 1200 gpm

(c)

1800 gpm

(d)

3000 gpm

6. Volume of reactor plus drain tank cells is

(a)

12000 cubic ft

(b)

18000 cubic ft.

(c)

24000 cubic ft

(d)

1200 cubic ft,

71 (e)

1800 c u b i c f t .

(f)

2400 c u b i c f t .

17.

Normal motor d r i v e n speed of t h e c o n t r o l r o d s i s

33.

What i s provided t o i n d i c a t e a plugged r a d i a t o r t u b e d u r i n g power

i n . /sec.

o p e r a ti o n ? 43.

A t 1 0 MW t h e l a r g e s t i t e m i n t h e r e a c t o r h e a t b a l a n c e i s determined by

(a)

Measuring t h e h e a t e r amperes and c o n v e r t i n g t o power.

(b)

Determining t h e AT a c r o s s t h e r e a c t o r and c o n v e r t i n g t h i s t o power u s i n g t h e f u e l s a l t flow rate. C a l c u l a t i n g t h e h e a t l o s s a t t h e r a d i a t o r based on s a l t AT and

(c)

and c o o l a n t s a l t flow. C a l c u l a t i n g t h e h e a t l o s s a t t h e r a d i a t o r based on t h e a i r AT

(d)

and t h e a i r flow up t h e c o o l a n t s t a c k . H e a l t h P h y s i c s and I n d u s t r i a l Hygiene

mrems

The maximum recommended weekly r a d i a t i o n dose i s

How much c o n c r e t e (TLV = 11 i n c h e s ) would b e r e q u i r e d t o reduce r a d i a t i o n from l r / h r t o 10 mr/hr?

16,

Readings are taken of a r a d i a t i o n f i e l d and w e f i n d t h a t i t i s 300 r a d s / h r f o r f a s t n e u t r o n s which have a RBE of 1 0 and 2 r a d s p e r hour f o r Gamma which have a RBE of 1.

I f w e s t a y i n t h i s f i e l d f o r 6 minutes, how much

dose would w e r e c e i v e ?

B e s u r e t o i n c l u d e p r o p e r u n i t s i n answer.

~~~~~

20.

Approximately 1 / 2 of t h e people who r e c e i v e a one-time dose of

w i l l die. 26.

The maximum p e r m i s s i b l e c o n c e n t r a t i o n f o r a c u t e exposures of b e r y l l i u m pg/mS.

(micrograms p e r c u b i c meter)

Chemistry

1. The f u e l s a l t t o b e used i n i t i a l l y i n t h e MSRE h a s t h e f o l l o w i n g composition.

F i l l i n proper l e t t e r .

BeFz

(a)

5 mole %

LiF

(b)

0.9 mole %

ZrF4

(c)

65 mole %

UF 4

(d)

29.1 mole %

re m

Z r O o starts t o p r e c i p i t a t e a t

(a>

100 ppm

(b)

200 ppm

(c)

300 ppm

(d)

400 P P ~

(e)

500 PPm

Fuel' s a l t l i q u i d u s t e m p e r a t u r e i s approximately (a)

650째F

(b)

750째F

(c)

850째F

Layout

F i l l i n t h e blanks with t h e proper letters.

Not a l l l e t t e r s need b e

used and any l e t t e r can b e used more t h a n once. OCT Level i n d i c a t o r s

CT Pumps S t a r t Button Lube o i l pumps Off-gas r a d i a t i o n monitor (RE-557) Scanner Switches F u e l P r o c e s s i n g Heater Controls Sampler E n r i c h e r FP p r e s s u r e t e s t s w i t c h Bubbler T e s t Switch HS 519

HS 523 Test l o helium s a f e t y switches

CCP No. 1

Vapor Condensing Rupture Disc

CCP No. 3

(a)

Main C o n t r o l Room

(b)

A u x i l i a r y C o n t r o l Room

(c)

T r a n s m i t t e r Room

(d)

North E l e c t r i c a l S e r v i c e Area

(e)

South E l e c t r i c a l S e r v i c e Area

(f)

High Bay S t a c k Area Vent house Water Room

S e r v i c e Room o r Tunnel Blower House

Heater P a n e l s Diesel House Switch House 840 l e v e l o t h e r t h a n t r a n s m i t t e r room and h e a t e r p a n e l s

S p e c i a l Equipment Room Coolant D r a i n Tank C e l l

CW r o t a m e t e r for l u b e o i l o i l system

Emergency A i r usage Rotameter

MG No. 1

MG No. 2

250v b a t t e r y bank PCV-5 28 PCV- 5 22

Reactor P h y s i c s and MSRE Nuclear C h a r a c t e r i s t i c s

I f t h e f l u x i s on a s t a b l e p e r i o d , i t v a r i e s as etâ&#x20AC;&#x2122;T. is

(3.14,

fi, 2.72,

The v a l u e of e

1.414)

I n t h e f o r e g o i n g s i t u a t i o n , i f t h e f l u x doubles every 21 seconds, what i s t h e v a l u e of T ?

13.

I f keff changes b6 0.01 and t h e s u b c r i t i c a l m u l t i p l i c a t i o n doubles, what was keff b e f o r e t h e change?

14.

When t h e f u e l pump i s s t a r t e d , k e f f d e c r e a s e s because of and

29.

The r e a s o n why t h e f u e l s a l t i s c r i t i c a l i n t h e c o r e , b u t s a f e l y subc r i t i c a l i n t h e d r a i n tank i s

APPENDIX E

SCHEDULE FOR PRE-POWER TRAINING

Day Mon

Tu.

Wed.

b Subject

Time

Fri.

SESSIONC~

0800-1200

OP2 (Nuclear Aspects of Operation)

1230-1630

OP3A-OP3J (Opeeration of Auxiliary Systems)

0800-1200

OP3K-OP5H (Operation and Startup of Auxiliary Systems, Reactor Startup)

1230-1630

OP5I-OP6 (Reactor Startup, Sampling and Additions)

0800-1000

OP7-OP9D (Heat Balance, Instrument Calibrations, Unusual Operating Conditions)

1015-1200

Instrumentation

1230-1630

Nuclear Power Operation

0800-1000

On-Line Computer and Data Logger

1000-1200

Self-Study

1230-1330

Reactor Simulator

1330-143 0

OP9D-OP9H (Unusual Operating Conditions)

1430-163 0

On-Line Computer

0800-1630

Shutdown Procedures, Plans for Power Ascension, Miscellaneous Questions on Procedures and Plans

â&#x20AC;&#x153;Attended by all MSRE operations personnel. Instruction by MSRE engineers. b OP refers to sections of Operating Procedures (ORNL-TM-908).

77 APPENDIX F PREPOWE R EXAMINAT I O N I n October 1965, p r i o r t o power o p e r a t i o n , a d d i t i o n a l w r i t t e n examin a t i o n s w e r e g i v e n t o a l l o p e r a t o r s . Some r e p r e s e n t a t i v e q u e s t i o n s are g i v e n below. A l l Operators

What v a r i a b l e s a f f e c t r e a c t i v i t y i n c o r e ?

I f you i n c r e a s e c o n c e n t r a t i o n of

2 35

(Name 4 . )

U by 1%,how much w i l l r e a c t i v i t y

increase? 16.

What stream does t h e B e monitor i n t h e v e n t house sample?

21.

S i n c e f i s s i o n chamber confidence w i l l n o t b e e s t a b l i s h e d b e f o r e f i l l i n g t h e r e a c t o r , i n t e r l o c k s are provided which p r e v e n t withdrawing t h e rods u n l e s s you have s a f e t y chamber confidence.

49.

True o r F a l s e

Automatic rod scram i s caused by:

(C> (dl 55.

According t o t h e o p e r a t i n g s a f e t y l i m i t s , u n d e r l i n e g r e a t e r t h a n o r t h a n and f i l l i n b l a n k s . Cover-gas p r e s s u r e must b e g r e a t e r t h a n o r less t h a n The maximum c e l l l e a k a g e should b e g r e a t e r t h a n o r less t h a n c a l c u l a t e d f o r c o n d i t i o n of maximum c r e d i b l e a c c i d e n t . The s t e a d y s t a t e power should be g r e a t e r t h a n o r less t h a n The s a f e t y t e m p e r a t u r e level rod scram s h o u l d b e g r e a t e r t h a n o r less t h a n

Engineers o n l y 2.

I f t h e r e g u l a t i n g rod i s n e a r i t s maximum s e n s i t i v i t y , how much d i f f e r e n c e would t h e r e b e between c r i t i c a l p o s i t i o n c i r c u l a t i n g and n o t c i r c u l a t i n g (assume shim r o d s do n o t move).

inches.

The

rod would be i n s e r t e d f u r t h e r when s a l t i s C i r c u l a t i n g o r n o t c i r c u lating?

The r e a c t o r i s o p e r a t i n g a t 2 MW w i t h t h e r e a c t o r i n l e t temperature of 1210'F.

C a l c u l a t e t h e r e a c t i v i t y change r e q u i r e d t o compensate

f o r t e m p e r a t u r e e f f e c t s i n going t o 8 MW and o u t l e t t e m p e r a t u r e of

1200'F.

(Use p r e d i c t e d v a l u e s of t e m p e r a t u r e c o e f f i c i e n t s . 6k/k.

How f a r w i l l t h e r e g u l a t i n g rod have t o b e moved and i n which d i r e c t i o n ? (Assume i t h a s maximum v a l u e . )

11. Describe t h e system of g e t t i n g r e p a i r s o r minor changes done a t t h e MSRE s t a r t i n g w i t h t h e punch l i s t and ending w i t h a completed and

checked-out j o b .

15.

According t o t h e IrOperating S a f e t y L i m i t s " how many s a f e t y channels must be i n s e r v i d e d u r i n g r e a c t o r o p e r a t i o n ?

APPENDIX G CHIEF OPERATOR TRAINING SCHEDULE (October and November, 1967)

Approximate Time Allocat ed

Subject and Items Covered

Instructor

1 hour

Discussion: Justification for removing engineers from shifts, training schedule, suggested general subjects for review.

Operations Chief

4 hours

Unusual Review ators. taken,

Shift Supervisor

3 hours

Information Available and Use of It: Cover stick file, switch tabulation, line schedule, calibration curves, etc. Give problems to be worked.

Asst Operations Chief

3 hours

Instruments and Controls: Cover important circuits and reasons for these. Include fill restrict, drain, rod scram, load scram, modes, FP, and CP circuits.

Asst Operations Chief

2 hours

Nuclear Instruments: Cover types installed, Operations Chief what each is used for and how trips are tested. Explain flux s e w 0 and temperature servo

Operating Conditions and Alarms: of Section 9 and important annunciCover power outage, action to be and consequences.

2 hours

Health Physics and Emergency Plans: Cover definition of terms, monitoring, use of instruments, permissible exposures, shielding, evacuation matrix, stack monitoring, and handling emergencies.

2 hours

Nuclear Aspects: Cover neutron balance, de- Operations Dept Head or Analysis Chief layed neutrons, reactivity, criticality sources and limits of deviation from calculated reactivity. Explain reason for and values of various coefficients of reactivity.

Operations Chief and Health Physicist

Approximate Time Allocated

S u b j e c t and I t e m s Covered

Instructor

2 hours

Computer: Cover s p e c i a l o p e r a t i o n and o p e r a t o r d u t i e s as w e l l as f a i l u r e s and what t o do.

A n a l y s i s Chief

2 hours

Normal Operating Conditio=: Review 5K and t h e l o g s . T i e i n a l l systems and emphasize the interrelationship.

Operations Chief

1 hour

Operating S a f e t y L i m i t s : answer q u e s t i o n s .

S h i f t Supervisor

1 hour

S h u t t i n g Down t h e Reactor: P o i n t o u t d i f f i c u l t i e s which might b e encountered. Suggest p l a c e s where each could u s e more s e l f -study.

A s s t Operations Chief

1 hour

Miscell_aneous: Review p r e v i o u s t e s t s and Answer s u g g e s t areas f o r s e l f - s t u d y . questions.

Operations Chief

Review t h e s e and

UPENDIX H CHIEF OPERATOR REVIEW TEST I n t h e f a l l of 1967 p r i o r t o c e r t i f y i n g s e l e c t e d t e c h n i c i a n s as c h i e f o p e r a t o r s , a 2-1/2 hour c l o s e d book and a 1-1/2 hour open book w r i t t e n examination w a s given t o each. Sample q u e s t i o n s from t h e s e are g i v e n below. Closed Book

1. Put t h e p r o p e r l e t t e r o r l e t t e r s i n t h e blanks. A

Compensated i o n chamber

BF3 chamber

F i s s i o n chamber

Uncompensated i o n chamber

S a f e t y channel L i n e a r channel Log P Used f o r f l u x s e r v o P r o v i d e s a g bypass Used f o r t e m p e r a t u r e s e r v o Used f o r i n v e r s e count r a t e p l a t

We have t h r e e of t h e s e Has automatic p o s i t i o n c o n t r o l

Connected w i t h range s e a l C a l l e d wide-range

c o u n t i n g channel

Gives a 5-sec rod r e v e r s e

Gives a 9-MW rod r e v e r s e

Confidence r e q u i r e d f o r e a r l y f i l l 500-kW r u n p e r m i t

An u n s h i e l d e d gamma s o u r c e i s p l a c e d a t t h e s o u t h e a s t c o r n e r of t h e d r a i n t a n k c e l l a t t h e 852' e l e v a t i o n and i t does n o t g i v e a h i g h

l e v e l alarm on t h e Chem P l a n t monitron.

What i s t h e approximate

maximum r a d i a t i o n r e a d i n g a t t h e n o r t h end of t h e d r a i n t a n k c e l l (852 f t e l e v a t i o n ) ?

Show assumptions and calculations.

82 10.

The following v e n t t o t h e (A) MCB

(B) ACB o r (C) d i r e c t t o t h e s t a c k .

Put proper l e t t e r following each. FP off-gas

(522)

F. Drain t a n k s

CP off-gas

(528)

FP o i l l e a k a g e (524)

C. Drain Tanks

17. 33.

CP o i l l e a k a g e (526)

9 mg/mR = PPm. What i s t h e f u l l - l o a d o p e r a t i n g l i f e of t h e 250-V b a t t e r y a f t e r t h e

-_---

l o s s of TVA power?

47.

N a m e f o u r v a r i a b l e s t h a t have important e f f e c t s on r e a c t i v i t y o r k. S t a t e b r i e f l y how each a f f e c t s n e u t r o n s and hence k .

-Open Book

Use any information a v a i l a b l e i n t h e Operations O f f i c e b u t do n o t c o n s u l t w i t h anyone. answer.

I n c l u d e i n f o r m a t i o n as t o how you a r r i v e d a t t h e

(That i s , remembering c i r c u i t s i s n o t s u f f i c i e n t . )

Include

drawing numbers, c i r c u i t numbers, e t c . 1. A requirement of t h e r u n mode c i r c u i t i s t h a t t h e FP b e running. I n t h i s c i r c u i t t h i s requirement i s m e t by which of t h e s e :

(a)

Both of two normal speed s i g n a l s .

(b)

E i t h e r of two pump motor c u r r e n t normal.

(c)

E i t h e r of two normal speed s i g n a l s .

(d)

Two of t h r e e normal speed s i g n a l s .

According t o t h e b u i l d i n g l o g , t h e normal l e v e l i n t h e feedwater t a n k s

(FWT) i s 46%. What q u a n t i t y of water i s t h i s i n g a l l o n s ? 9.

10.

XPR-201A r e c o r d s r a d i a t o r power. (a)

Where i s t h i s l o c a t e d ?

(b)

What i s t h e c h a r t speed?

(c)

What does i t read f u l l scale?

(d)

This r e c o r d e r should be how a c c u r a t e ?

Determine t h e f o l l o w i n g on Line 991. Size Schedule Mater ia1

M W

APPENDIX I MSRE OPERATOR EXAMINATION -May

1969

Point Value

A, (8)

P r i n c i p l e s of Reactor Operation

Define t h e f o l l o w i n g : Criticality Chain Reaction Subcritical CO d o Moderato r e, F i s s i o n p r o d u c t s f. Keff Reactivity Period a. bo

E x p l a i n t h e r e a c t i v i t y b a l a n c e c a l c u l a t e d by t h e computer. What i t e m s a r e used i n t h e c a l c u l a t i o n and what i s t h e meani n g of t h e f i n a l v a l u e ( i a e o 9 %ET) ,.

E x p l a i n why t h e count rates on t h e c o u n t i n g channels i n c r e a s e as t h e r e a c t o r i s f i l l e d . How can w e p r e d i c t t h a t w e w i l l n o t go c r i t i c a l b e f o r e t h e r e a c t o r i s completely f i l l e d ?

What i s t h e r e a c t i v i t y e f f e c t of each of t h e f o l l o w i n g (decrease o r i n c r e a s e ) , E x p l a i n each, a, bo

Fuel burnup Decrease i n t e m p e r a t u r e

Removal of bubbles from the core

d, e. f.

Buildup of f i s s i o n p r o d u c t s S t a r t i n g t h e f u e l pump I n s e r t i o n of c o n t r o l rod

E x p l a i n t h e importance of delayed n e u t r o n s t o t h e c o n t r o l of t h e r e a c t o r ,

What i s meant by " t h e r e a c t o r i s on a s t 3 b l e p e r i o d ? " Exp l a i n how v a l u e s f o r s t a b l e p e r i o d s can b e c a l c u l a t e d ,

84 Point Value B.

(3)

Operating C h a r a c t e r i s t i c s and F e a t u r e s of Design 1.

Two modes of s e r v o rod c o n t r o l were provided a t t h e MSRE.

Explain each, when used, and t h e need f o r t h e two t y p e s . (2)

Describe t h e r e a c t o r v e s s e l and r e a s o n f o r v a r i o u s f e a t u r e s .

( 2)

Describe t h e h e a t removal system of t h e MSRE and t h e funct i o n s of t h e components, ( S t a r t a t the coolant salt l i n e s outside the reactor cell.)

(5)

V e n t i l a t i o n and off-gas from v a r i o u s systems must b e p r o p e r l y handled t o avoid u n d e r s i r a b l e releases of a c t i v i t y . Connect up t h e l i n e s on F i g u r e B-4 a t t a c h e d and p u t arrows t o show d i r e c t i o n of flow. I n d i c a t e important l i n e numbers, v a l v e s , and i n t e r c o n n e c t i n g l i n e s .

+ t

+TI

Point Value C.

General Operating C h a r a c t e r i s t i c s

(3)

Assuming t h a t t h e system i s h e a t e d and c o o l a n t s a l t i s c i r c u l a t i n g , d e s c r i b e t h e s t e p s t a k e n t o f i l l t h e r e a c t o r and s t a r t f u e l s a l t c i r c u l a t i n g . A t each s t e p i n c l u d e normal r e s p o n s e of p e r t i n e n t v a r i a b l e s and p r e c a u t i o n s .

(3)

D e s c r i b e and e x p l a i n b r i e f l y t h e r e s p o n s e of t h e f o l l o w i n g t o a complete power o u t a g e ( i . e . , l o s s of TVA). Assume t h a t t h e r e a c t o r i s o p e r a t i n g a t f u l l power and t h e d i e s e l s cannot be s t a r t e d . a. b. c. d.

(3)

(2)

Load and n u c l e a r power Fuel syst e m temperatures Temperatures a t FV-103, 105, 2 0 4 , and 206 O i l flow t o FP s h i e l d and b e a r i n g s

D e s c r i b e what happens t o t h e r e a c t o r i n l e t and o u t l e t temperat u r e and t o t h e n u c l e a r power f o r each of t h e f o l l o w i n g (Assume no o p e r a t o r a c t i o n e x c e p t as noted.) changes. a.

I n s e r v o rod c o n t r o l w i t h one blower on, b o t h doors open and t h e bypass damper open, what happens when t h e o t h e r blower i s s t a r t e d ?

I n manual rod c o n t r o l w i t h b o t h blowers on, b o t h doors open, and bypass damper n e a r l y c l o s e d , what happens when one blower i s s t o p p e d ?

I n s e r v o rod c o n t r o l a t ~ 1 kW 0 w i t h b o t h blowers o f f , b o t h d o o r s c l o s e d , and bypass damper opne, what happens when b o t h doors are opened about 50%?

Assume t h a t t h e f u e l pump i s o f f , system i s f i l l e d w i t h f u e l s a l t and a t temperature. The o p e r a t o r a t t e m p t s t o t a k e t h e r e a c t o r c r i t i c a l and t o 100 kW. H e proceeds as f o l l o w s : a. b. c. do e. f.

I n s e r t s a l l rods S t a r t s FP Switches t o manual rod c o n t r o l Raises Rods 2 and 3 t o 4 0 i n . Raises Rod no. 1 slowly t o t a k e t h e r e a c t o r c r i t i c a l and t o a few watts Raises Rod No. 1 t o g e t on a 100-sec p e r i o d and l e v e l s t h e power a t 100 kW.

What i n t e r l o c k s p r e v e n t him from doing t h i s and what i s t h e purpose of t h i s i n t e r l o c k ?

Instrumentation and Control

Interlocks require that certain nuclear instruments are in service during a fill of the reactor with fuel salt, a, Explain which are required and why.

Does the fill section of the operating procedures (5-1) require any other chambers to be in service?

Interlocks require what nuclear instruments to be in service at 8 MM? Explain,

Why was the coincidence type safety system chosen â&#x201A;Źor use at MSRE?

What signals will automatically cause a rod scram? Explain the reason for each,

What provisions are made to remove afterheat. What instrumentation assures this will function.

Describe the emergency fuel drain circuit and explain the reason for each interlock and the matrix used (ioea92 out of 3 , 2 of 2, 1 of 2, 1 of 1, etc.).

Point Value

E. (3)

S a f e t y and Emergency System 1.

Double containment i s r e q u i r e d a t t h e MSRE. During normal power o p e r a t i o n (no sampling b e i n g done) d e s c r i b e t h e primary and secondary containment f o r t h e FP and a l l c o n n e c t i n g lines.

Describe t h e emergency e l e c t r i c a l systems.

Describe t h e normal and emergency i n s t r u m e n t a i r system.

B r i e f l y d e s c r i b e t h e b u i l d i n g e v a c u a t i o n procedure f o r t h e MSRE.

What p r o v i s i o n s are made t o a s s u r e t h a t w e always have a s t a c k f a n i n service? D e s c r i b e power s u p p l y , i n t e r l o c k s , dampers ( a t s t a c k f a n ) , etc.

Point Value

Standard and Emergency Operating Procedures Describe t h e procedure f o r burping t h e OFT and p r e c a u t i o n s i n case 522 i s plugged. During full-power o p e r a t i o n , you r e c e i v e a low r a d i a t o r o u t l e t t e m p e r a t u r e alarm. a.

What a c t i o n should you t a k e t o p r e v e n t i t c o n t i n u i n g t o t o decrease?

I f no o p e r a t o r a c t i o n i s t a k e n and t e m p e r a t u r e s c o n t i n u e t o d e c r e a s e , what c o n t r o l a c t i o n w i l l occur?

Describe waht w i l l happen as a r e s u l t of t h i s and what t h i n g s t h e o p e r a t o r should do,

What areas cannot be e n t e r e d due t o h i g h r a d i a t i o n when w e are a t f u l l power? What i s t h e main s o u r c e of t h e r a d i a t i o n i n each of t h e s e areas? While o p e r a t i n g a t f u l l power, a 5-min TVA power o u t a g e o c c u r s , Describe what must b e done i n t h e approximate sequence t h a t i t should b e done. D e s c r i b e sampling of t h e f u e l s a l t i n g e n e r a l terms, manpower r e q u i r e d , and p r e c a u t i o n s .

Point Value G.

R a d i a t i o n S a f e t y and C o n t r o l

(1)

E x p l a i n what i s meant by RBE ( R e l a t i v e B i o l o g i c a l E f f e c t i v e n e s s ) and how t h i s i s used i n d e t e r m i n i n g an exposure dose.

(6 )

Give your r e a c t i o n t o and t h e b a s i s f o r your r e a c t i o n t o each of t h e following:

(4)

Using a G-M survey meter t o measure t h e dose r a t e n e a r a y s o u r c e of unknown, b u t p o s s i b l e l a r g e , s t r e n g t h .

Using a G-M survey meter w i t h o u t u s i n g t h e earphones.

Making a contamination survey of p e r s o n n e l l e a v i n g a contamination zone i n a d i r e c t r a d i a t i o n f i e l d of 10 mr/hr.

Using a c u t i e p i e t o make a contamination survey.

Using a c u t i e p i e t o measure t h e dose r a t e i n a y f i e l d f o r t h e purpose of c a l c u l a t i n g working t i m e .

C a l c u l a t i n g t h e working t i m e f o r a j o b a t one of t h e beam h o l e s on t h e b a s i s of dose r a t e s determined u s i n g a c u t i e pie.

An o p e r a t o r i s s t a n d i n g 1 5 f e e t from a r a d i o a c t i v e p o i n t s o u r c e . H e r e a d s 1000 mrem/hr on a p o r t a b l e i n s t r u m e n t . I f h e must o p e r a t e a v a l v e l o c a t e d 5 f e e t from t h e s o u r c e , how long can h e l i n g e r a t t h e v a l v e b e f o r e o b t a i n i n g t h e O W L q u a r t e r l y whole body r a d i a t i o n exposure l i m i t ? Whose approval i s r e q u i r e d f o r t h e j o b ? Explain.

Point Value H.

(5)

Reactor Theory

A r e a c t o r h a s a count r a t e of 30 cps when i t has a K eff of 0.95, a.

Is 40 cps t h e p r o p e r count r a t e when K i s 0.975? eff Show how you a r r i v e d a t your answer,

I f t h e r e g u l a t i n g rod p o s i t i o n w a s 1 6 and 18 i n c h e s when Keff = 0.94 and 0.975, what p o s i t i o n would you estimate for criticality?

(5)

Show your c a l c u l a t i o n s ,

Discuss t h e f o l l o w i n g r e a c t i v i t y c o e f f i c i e n t s as t o ior as a p p l i e d t o ERE.

a. b. c. do e.

Reactor o u t l e t t e m p e r a t u r e Power Uranium Bubblers Xenon

(5)

DiaHTy t h e p r o c e s s e s and r e g i o n s involved i n t h e p r o d u c t i o n X e i n t h e MSRE, i t s t r a n s p o r t and i t s e v e n t u a l f a t e , of

(6)

What p e r c e n t a g e of t h e 2 3 3 U i n t h e f u e l loop i s consumed i n a full-power day? %. How much would t h e r e g u l a t i n g rod have t o b e withdrawn t o compensate f o r t h i s e f f e c t ? i n , (Use t h e f o l l o w i n g d a t a and show your c a l c u l a t i o n s .

1g mole 6.02 x loz3 atoms 1 f i s s i o n y i e l d s 197 Mev F u l l power = 8 MW

1 day 86,400 s e c , 1 j = l w a t t - s e c = 6 , 2 5 x 1GP2Mev = 0,11f o r 2 3 3 ~ ae/clf

94% of a l l f i s s i o n s i n MSRE are now i n 233U, There i s 29 kg of 233U i n t h e f u e l l o o p ,

U c o n c e n t r a t i o n c o e f f i c i e n t , (Ak/k)/(Ac/c) = 0 37 R e g u l a t i n g rod s e n s i t i v i t y = 0,07%'6k/k p e r i n c h . 233

Radioactive materials Handling, Disposal, and Hazards 1.

A reading is taken and found to be 2000 mr/hr; 6 hours later 300 mr/hr.

What is the half-life of the material?

What are the requirements for entry, work in, and exit from a contamination zone? Radiation zone?

What is the difference between radiation and contamination?

A small fission-product source reads 80 mr/hr at 3 ft through 1.5 in. of Pb shielding. If the source is taken out of the shield at what distance will the dose rate be 200 mr/hr? (Use a tenth layer value for Pb of 1.9 in. and show your work.)

Assume that you are Shift Supervisor and the CAM and monitor in the southeast corner of the highbay alarm. If you cannot wait for a health physicist and you feel that you must remain in the control room, what instructions and precautions would you give your operators in determining the source of the difficulty. (Assume that they are not familiar with handling of activity.) How can they tell whether it is airborne activity?

Point Value J,

Specific Operating Characteristics

(5)

Describe the modes and sub-modes of operation at the MSRE. What operations are done in each and what are some of the requirements to be in each?

(5)

Using the attached FP level curves (Fig, 5-2) show calculations for filling reactor if we wish to operate at 5 5 60% at 1210'F and 60 cycles. Assume that average temperature is 1180'F and the maximum operating level of salt is in the

OFT (3)

,After filling the reactor there is a 3-hour delay before starting the fuel pump, Explain the reason for this,

(5)

How can the nuclear power be changed without the control rods moving? In such a case which remains more nearly constant: the core outlet temperature or the average temperature of the fuel in the core?

(5)

What process parameters are used in causing an instrumented control rod scram (safety)? Explain the purpose of each of these.

95 Point Value K.

F u e l Handling and Core Parameters

(3)

D e s c r i b e t h e tests made and c o n d i t i o n s which should e x i s t p r i o r t o f i l l i n g t h e system w i t h f u e l s a l t .

(3)

What i s t h e v a l u e of t h e o v e r a l l t e m p e r a t u r e c o e f f i c i e n t of r e a c t i v i t y ? I f a n e n r i g h i n g c a p s u l e of '33U i s added and t h e c o n t r o l rods are n o t moved, how much w i l l t h e r e a c t o r temperatures s h i f t ?

Describe what happens t o t h e r e a c t i v i t y immediately a f t e r t h e f u e l pump i s s t a r t e d and e x p l a i n why,

Describe t h e v a r i o u s n e u t r o n s o u r c e s a t t h e MSRE ( e x t e r n a l and i n h e r e n t ) .

(3)

A d m i n i s t r a t i o n , Conditions, and L i m i t a t i o n s

Why are up-to-date procedures n e c e s s a r y t o t h e e f f i c i e n t o p e r a t i o n of t h e MSRE? Who i s r e s p o n s i b l e f o r t h e maintaini n g of up-to-date procedures? How i s t h i s accomplished?

Describe t h e procedure n e c e s s a r y t o make a major change i n the reactor. (For i n s t a n c e , bypassing t h e flow r e s t r i c t o r i n t h e supply l i n e t o t h e overflow t a n k . )

Describe t h e minimum p e r s o n n e l and c l a s s i f i c a t i o n of p e r s o n n e l r e q u i r e d d u r i n g v a r i o u s s t a g e s of o p e r a t i o n . a. b.

I n t h e c o n t r o l room A t the reactor site

Describe t h e consequences of complete loss of b o t h t r e a t e d water pumps w h i l e t h e r e a c t o r i s a t f u l l power. Assume t h a t flow of t r e a t e d water cannot b e r e s t a r t e d f o r an extended p e r i o d . What o p e r a t i o n a c t i o n should b e t a k e n and w h y ?

Rod scram i s caused by s a f e t y c i r c u i t s i n a 2-out-of-3 m a t r i x . T h e r e f o r e , l o s s of one s a f e t y channel w i l l n o t scram t h e r o d s . I f w e a r e making an extended full-power r u n and d u r i n g 8 D check l i s t i t i s found t h a t a h i g h f l u x s i g n a l w i l l n o t i n i t i a t e a scram, e x p l a i n what you would do and j u s t i f y your a c t i o n s .

What are t h e Operating S a f e t y L i m i t s ? I n what ways are t h e y t r e a t e d d i f f e r e n t l y from t h e O p e r a t i n g Procedures?

D e s c r i b e t h e r e a s o n f o r having jumpers a v a i l a b l e i n t h e jumper board? What are t h e two t y p e s ? What a p p r o v a l i s n e c e s s a r y t o u s e each t y p e ?

APPENDIX J

Examples of Instructions and Communication

99 S H I F T

I N S T R U C T I O N S

December 1 3 , 1968 GENERAL INFORMATION

It seems t h a t whatever i s c a u s i n g bubbles i n t h e f u e l system remains

Note t h a t WR-2947 h a s r a i s e d OFT l e v e l alarm and a c t i o n set-

w i t h us.

p o i n t s t o 30 and 35%. We w i l l o p e r a t e t h e FP between 50 and 59% l e v e l on t h e No. 1 b u b b l e r ( s w i t c h p o s i t i o n No. 2 ) . marked i n t h e c o n t r o l room l o g . reasons

- t h e most

gas connection.

These new l i m i t s are

The lowering of FP l e v e l i s f o r two

i m p o r t a n t b e i n g t o keep t h e foam away from t h e o f f -

The o t h e r being t o l e n g t h e n t h e t i m e i n t e r v a l between

OFT burps. The most important d i s a d v a n t a g e of t h e above changes comes when

w e have a FP stoppage f o r some reason.

The r e s u l t i n g FP l e v e l w i l l b e

much lower t h a n n e c e s s a r y t o restart t h e pump.

The OFT must t h e n b e

p a r t i a l l y emptied t o g e t t h e FP l e v e l t o ~ 6 4 % . With t h e FP on and

~ 8 worth % of bubbles c i r c u l a t i n g , t h e FP l e v e l i s o u t of l i m i t s ( i . e p , >59%). Care must b e t a k e n t o avoid r e h e a t i n g t h e system t o o r a p i d l y and c a u s i n g l e v e l t o i n c r e a s e even more.

several s h i f t s ,

The r e c o v e r y could t a k e

See i n s t r u c t i o n s i n Permanent S h i f t I n s t r u c t i o n s .

SHIFT INSTRUCTIONS I

Continue w i t h o p e r a t i o n a t 1 kW and 1210 k 2'F OAFOT u n t i l such t i m e the computer is repaired and w e can go to 1 MW.

Take t e m p e r a t u r e b i a s

d a t a p e r I t e m 111 of 12/12 i f n o t a l r e a d y done. I1

When computer i s r e p a i r e d (today o r Monday) w e s h o u l d b e ready t o go t o 1 MW heat-balance power on t e m p e r a t u r e s e r v o .

T h i s w i l l b e w i t h no

blower and a jumper i s approved f o r 139f t o g e t i n t o r u n mode. I t e m I11 f o r sample t o t a k e 1 hour a f t e r going t o 1 MW.

w i l l b e done w h i l e a t 1 MW.

See

Dynamics tests

100

Shift Instructions

I11

December 1 3 , 1968

I s o l a t e a FV s a l t sample one hour a f t e r going t o 1-MW power.

Isolate

p e r 6A3 except as follows: (1)

I n S t e p 3.3.2.1,

leave i n s a l t f o r 1 0 minutes.

Do n o t h e s i t a t e

on i n s e r t ion. (2)

Add between 3.2.3.1-

3.2.3.2.

Hold 5 minutes a t ~6 f t

- 5 in.

t o a l l o w f o r drippage.

Deliver t o l a b " s p e c i a l FV s a l t sample f o r K i r s l i s . "

Hang a 10-gm

c a p s u l e on t h e l a t c h .

To prevent t h e p o s s i b i l i t y of the FV c a p s u l e now on t h e l a t c h from

l o s i n g i t s vacuum, keep Area 1 C evacuated u n t i l ready t o use. V

P l e a s e review Daily Report S h e e t s from computer 8-hr l o g ( p r i n t e d at

0745) and t a b u l a t e thermal c y c l e s ( h e a t , f i l l , and power c y c l e ) on FP, CP, FF-102,

and FF-200.

Daily from 0745 11/11/68 t o 0800, 12/13/68.

Computer s h e e t s are e i t h e r i n Watt's o f f i c e o r are f i l e d downstairs.

J. L. Crowley

101

PERMANENT SHIFT INSTRUCTIONS December 1 3 , 1968 I n t h e e v e n t an FP stoppage (and scram i f a t power) r e q u i r e s t r a n s f e r of s a l t from t h e OFT t o r e s t a r t , f o l l o w t h e g e n e r a l p l a n below,

T r a n s f e r o n l y enough s a l t from t h e OFT t o r e s t a r t t h e FP p e r 91.

While a w a i t i n g t r a n s f e r , begin t u r n i n g up system h e a t e r s ( i f l o a d and rod scram h a s o c c u r r e d ) .

Bring up t o normal temperature.

Restart t h e FP and b r i n g t h e r e a c t o r c r i t i c a l t o 1 kW p e r 55.

Add n u c l e a r h e a t up t o 100 kW as n e c e s s a r y a l o n g w i t h e l e c t r i c a l h e a t t o m a i n t a i n FP l e v e l a t 65% u n t i l system t e m p e r a t u r e r e a c h e s 1210'F. T h i s may t a k e several s h i f t s .

A t t h i s t i m e you can r e t u r n t o power o r

whatever c o n d i t i o n c a l l e d f o r i n s h i f t i n s t r u c t i o n s .

102

55-1

Approved byk*,hT

9/14/65 2/2/68 7/2/69

55 C R I T I C A L I T Y AND POWER OPERATION

The f u e l and c o o l a n t s a l t w i l l b e c i r c u l a t e d s u b c r i t i c a l l y i n t h e l o o p s u n t i l power o p e r a t i o n i s d e s i r e d , a t which time t h e c o n t r o l r o d s

w i l l b e withdrawn t o o b t a i n c r i t i c a l i t y . During normal power o p e r a t i o n , manual l o a d c o n t r o l and s e r v o rod c o n t r o l w i l l b e used. sary.

However, manual rod c o n t r o l may b e used i f neces-

Automatic l o a d c o n t r o l w i l l b e used only f o r s p e c i a l t e s t s f o r

which d e t a i l e d i n s t r u c t i o n s w i l l b e s u p p l i e d , The f i r s t s e c t i o n i s w r i t t e n for u s e as a "Quickie" check l i s t f o r recovery of t e m p e r a t u r e s a f t e r a rod and l o a d scram.

After recovery i s

made, t h e r e a c t o r w i l l b e t a k e n s u b c r i t i c a l and t h e normal pre-power o p e r a t i o n checks of S e c t i o n 2 completed. Any time t h e power i s reduced below

200 kw,

the e n t i r e preparation

( S e c t i o n 2) check should b e completed. T h i s procedure i s organized as f o l l o w s .

Q u i c k recovery of t e m p e r a t u r e check l i s t .

P r e p a r a t i o n f o r power o p e r a t i o n .

S t a r t i n g power o p e r a t i o n u s i n g r o d s e r v o .

S t a r t i n g power o p e r a t i o n u s i n g manual rod c o n t r o l .

QUICK TEMPERATCTRE RECOVERY C E K LIST This check l i s t i s t o a i d i n r e c o v e r i n g system t e m p e r a t u r e u s i n g nu.clear power f o l l o w i n g a r o d and l o a d scram. Init.

Date/Time

1.1 If necessary, complete E l e c t r i c a l Power Outage Q u i c k Check L i s t 1.2

- 9Al.

S e t FT h e a t e r v a r i a c s t o

f o r low-power

operation.

1.3 1.4 1.5 1.6

C l e a r s a f e t y channels and u n g a l l o p s a f e t i e s . Check o r p u t f i s s i o n chambers i n a u t o m a t i c . Switch rod s e r v o o f f . S e t f l u x demard a t

40 - 60% of

1 . 5 x lo5 range (150 kw)

s c a l e and s e l e c t

103 W

9/1?6: 2/2/68 7/2/69 Init. Date/Time

1.7

Group withdraw t o

in.

Rod-3 l o w e r - l i m i t

l i g h t may n o t c l e a r .

1.8 Switch rod s e r v o on.

R e s e t t h e f l u x scram s e t -

p o i n t s t o Low S e n s i t i v i t y (Red) r a n g e .

1.9 I n s e r t No.

1 rod t o 20 i n .

1.10 Group withdraw rods u n t i l a 30-sec p e r i o d i s

o b t a i n e d o r u n t i l No. 2 and No. N

- in.

(See C o n t r o l Room Log.)

are at If 30-sec

p e r i o d o c c u r s , f i n i s h withdrawing No. 2 and No. 3 i n d i v i d u a l l y .

NOTE: R e a c t o r w i l l become c r i t i c a l below normal rod

PO-

s i t i o n s because of low-system t e m p e r a t u r e . 1.11Withdraw No. 1 rod u n t i l c r i t i c a l and s e r v o i s

c o n t r o l l i n g rod n e a r middle of r e g u l a t i n g rod l i m i t switches. 1.12 Note whether Rod No. 3 lower l i m i t c l e a r e d .

Yes

1.13 If Rod No. 3 l o w e r - l i m i t l i g h t d i d n o t c l e a r , r a i s e Rod No. 3 t o c l e a r l o w - l i m i t l i g h t and t h e n a d j u s t Rod N o . 3 t o Rod N o . 2 p o s i t i o n . Keep r e g u l a t i n g rod on s c a l e d u r i n g t h i s s t e p . NOTE:

If t e m p e r a t u r e i s n o t i n c r e a s i n g a t a r e a s o n a b l e r a t e , i n c r e a s e f l u x demand t o 40% of .5 x lo6 s c a l e .

1.14 When 1175'F t e m p e r a t u r e (OAFOT) is reached, reduce power t o 10 kw (66% of 1 . 5 x lo4 r a n g e ) . 1.15 R e s e t l o a d scram and u s e r a d i a t o r doors t o p r e v e n t o v e r h e a t i n g (above 1210'F) because of f i s s i o n p r o d u c t decay.

1.16 Review 53-2.

A s soon as convenient, t a k e r e a c t o r

s u b c r i t i c a l , r u n rod drop t e s t , f i d u c i a l z e r o of W

rods and any o t h e r t e s t s o r check l i s t s which have n o t been done w i t h i n s p e c i f i e d time l i m i t e s .

1.17 Then r e t u r n t o power o p e r a t i o n u s i n g 5J-3 o r 53-4 procedure.

104

55-3 9/14/65 2/2/68 7/2/69 2

PREPARATION F3R P O W E R OPERATIXI P r i o r t o t a k i n g t h e r e a c t o r c r i t i c a l , t h e system should b e checked t o a s s u r e t h a t a l l p e r t i n e n t equipment and i n s t r u m e n t a t i o n a r e functioning properly. l i s t e d below. conditions.

The more important items t o b e done are

A d d i t i o n a l t e s t s may be n e c e s s a r y depending upon

A t times, such as d u r i n g experiments, a f t e r s h o r t

p e r i o d s of s u b c r i t i c a l o p e r a t i o n , e t c . ,

all tests.

it may b e d e s i r a b l e t o omit

This i s a t t h e d i s c r e t i o n of t h e s h i f t s u p e r v i s o r . Init.

Date/The

2.1 Check rod drop time f o r each rod t o b e l e s s t h a n 1 second. T h i s can b e omitted i f it has been done w i t h i n approximately one month of t h i s d a t e .

2.1.1

Check t h a t 2 rods are between 1 and

3 inches. 2.1.2 R a i s e o t h e r rod t o 50 i n c h e s above t h e r o d p o s i t i o n where t h e f i r s t lower l i m i t i n d i c a t o r l i g h t l i g h t s up. 2.1.3

Plug i n t h e rod drop t i m e r and s e t t o

zero, 2.1.4

Actuate t h e rod scram s w i t c h and check

t h a t a l l t h r e e rods drop. 2.1.5

Repeat w i t 3 o t h e r two rods ar,d r e c o r d

r e s u l t s i n t a b l e below.

Rod

Starting Position

Rod Drop Time Should Not Exceed 1.0 Sec.

Note That A i l Three Rods Dropped

Initial

Date

1 2 I I

105 W

Approved by &&&u#+F*

55-4 9/14/65 2/2/68

Init. 2.2

7/2/69

Date/Time

Check f i d u c i a l zero of each rod i f rods have been scrammed s i n c e l a s t FIDO determination. Otherwise t h i s can be omitted i f it has been done within approximately one month of t h i s date. 2.2.1 Check t h a t c e l l - a i r a c t i v i t y i s not high: and m-565c Record RM-565B Also check r a d i a t i o n l e v e l i n TR: CAM , and Monitron

Record Do not

proceed i f c e l l - a i r a c t i v i t y i s >5 m r / h r . 2.2.2

S e t valves as follows:

HV-985-M open HV-987-A2 open

HV-987-A3 closed w-986A open 2.2.3 Open ~ v - 9 8 6 ~987A, , or 9 8 8 ~ . T h r o t t l e HV-985-Al and HV-989 u n t i l ZI-987A i n d i c a t e s approximately 50%.

2.2.4

E s t a b l i s h communications between TR

and Control Room. 2.2.5

I n s e r t c o n t r o l rod and determine c o n t r o l -

rod r e f e r e n c e p o s i t i o n . Record rod p o s i t i o n when maximum dp i s obtained.

Determine p o s i t i o n

i n d i c a t i o n s f o r each rod being i n s e r t e d and f o r each being withdrawn.

106

Init. 2.2.6

Open HV-987-A3.

2.2.7

Close iiV-985-A1, 989A, 9 8 6 4 987-A1,988A.

2.3 See 'J-gA. 2.1,

Check t h a t two o u t of t h r e e s a f e t y channels w i l l scram a l l t h r e e r o d s .

T h i s can b e o m i t t e d i f it

has been done w i t h i n approximately one week of t h i s date. 2.4.1

I n h i b i t f a s t scan.

2.4.2

With a l l rods above 1 inch, t r i p s a f e t y

channels 1 and 2 by pushing t e s t b u t t o n s on RSSNSClA4 and RSSNSC2Ab and n o t e t h a t rods scrax.

2.4.3

Reset S a f e t y Channels 1 and 2 .

2.4.4

Raise a l l r o d s t o 1 t o 3".

2.4.5

T r i p S a f e t y Channels 2 and 3 by pushing

t e s t b u t t o n s on RSSNSC2A4 and RSSNSC3A4 and n o t e t h a t a l l t h r e e rods scram. 2.4.6

Reset S a f e t y Channels 2 and 3.

2. L.7

R a i s e a l l t h r e e rods 1 t o 3 i n c h e s .

2.4.8

T r i p S a f e t y Channels 1 and 3 by pushing

t e s t b u t t o n s on RSSNSClA4 and RSSNSC3A4 afid m t e t h a t a l l t h r e e rods scram. 2. 4.9

R e s e t S a f e t y Channels 1 and 3 and r e -

e s t a b l i s h desired p o s i t i o n s . 2. 4.10 Cancel " I n h i b i t f a s t scan".

2.5

Check t h a t thermocouples on t h e r a d i a t o r o u t l e t t u b e s a r e plugged i n t o Scanner D and E and t h a t t h e g a i n on b o t h s c a n n e r s i s s e t a t 150 s o that, a n alarm w i l l occur a t 90C"Y o r 1300째F.

This

can be o m i t t e d i f no h e a t i s t o b e removed by the radiator.

Date/Time

107

55-6 9/14/65

Approved by,-

2/2/68 7/2/69 Ila t e /Time Init 2.6

Complete t h e Neutron I n s t r u m e n t s Check L i s t ,

(8A).

T h i s can be omitted i f it has been done

w i t h i n approximately one month of t h i s d a t e .

2.7 Complete t h e C a l i b r a t i o n Check of Process R a d i a t i o n Monitors ( 8 B ) . This can b e omitted i f it has been done w i t h i n approximately one

week of t h i s date. 2.8

Complete t h e e n t i r e S a f e t y C i r c u i t s Check L i s t

(8D).

T h i s can b e o m i t t e d i f it has been done

w i t h i n approximately one month of t h i s d a t e . 2 - 9 Take TE b i a s d a t a i f r e q u e s t e d by Gabbard.

2.10 Take zero-power h e a t b a l a n c e i f n o t done w i t h i n approximately 1 week. 2.11Check t h a t a n n u n c i a t o r s are c l e a r o r approved by t h e s h i f t s u p e r v i s o r .

S h i f t Supervisor's

approval 2 . 1 2 C h e c k t h a t e n t r a n c e t o a l l e x c l u s i o n a r e a s are p r o p e r l y r e s t r i c t e d and r a d i a t i o n s i g n s p o s t e d . 2.12.1

Door No. 1 t o r a d i a t o r n e a r n o r t h

annulus blower i s locked. 2.1-2.2

Door No. 2 a t f o o t of ramp t o CDT c e l l

i s locked. 2.12.3

Door No. 3 t o blowers i s locked.

2.12.4

Blocks are on r e a c t o r c e l l , d r a i n - t a n k

c e l l , coolant c e l l , south e l e c t r i c service a r e a , and s p e c i a l equipment room.

STARTIISG POWER OPERATION USING R3D SEXL'O The shim r o d s w i l l be withdrawn manually while t h e s e r v o con-

t r o l l e r m a n i p u l a t e s t h e r e g u l a t i n g r o d t o a t t a i n c r i t i c a l i t y and c o n t z o l s t h e power a t t h e s e t p o i n t . To i n c r e a s e t h e n u c l e a r power, t h e f l u x demand w i l l be i n c r e a s e d . T h i s may c a u s e t h e r e g u l a t i a g rod t o withdraw u a t , i l t h e r e g u l a t i n g - r o d

l i m i t i s reached.

The l i m i t can b e changed by o p e r a t i n g t h e r e g u l a t i n g - r o d

108 W

Approved by/.

5J-7 9/14/65 2/2/68

+ &

7/2/69

(continued)

d r i v e s w i t c h o r t h e shim r o d s can be manually withdrawn which w i l l c a u s e t h e r e g u l a t i n g rod t o i n s e r t . As t h e flux demand i s i n c r e a s e d , t h e n u c l e a r power may c a u s e t h e

system temperatures t o r i s e n e c e s s i t a t i n g removal of h e a t a t t h e radiator.

Xumber one blower w i l l be s t a r t e d and t h e r e s u l t a n t

a c r o s s t h e r a d i a t o r w i l l c a u s e t h e bypass damper t o open i f damper c o n t r o l i s on a u t o m a t i c . Before pushing t h e run b u t t o n , t h e power s h o u l d b e between 0.5 and 1 Mw; b o t h range s e l e c t o r s should b e i n t h e 1.5-Mw range, and t h e temperature demand s e t p o i n t should b e s l i g h t l y h i g h e r t h a n t h e o u t l e t temperature. p o r t i o n of i t s usef;ll

limit.

The r e g u l a t i n g r o d should b e i n t h e c e n t e r

range and not a t e i t h e r t h e i n s e r t or wir,hdraw

When t h e r e a c t o r i s switched t o t h e "run" mode, t h e r a n g e

s e l e c t o r w i l l be s e a l e d i n t h e l 5 - M ~range, and t h e r o d - c o n t r o l c i r c u i t r y w i l l be changed f r c i m flux s e r v o t o t e m p e r a t u r e s e r v o . Under t h e s e c o n d i t i o n s , t h e r e g u l a t i n g r o d w i l l b e a u t o m a t i c a l l y i n -

s e r t e d or withdrawn t o m a i n t a i n t h e r e a c t o r - o u t l e t t e m p e r a t u r e constant.

The t e m p e r a t u r e can b e changed by a d j u s t i n g t h e t e m p e r a t u r e -

demand s e t p o i n t . Operation a t f u l l power will be reached w i t h b o t h doors open, b o t h blowers i n o p e r a t i o n and t h e bypass damper c l o s e d .

If t h e rem-

l a t i n g r o d r e a c h e s t h e withdraw l i m i t , Bo. 2 and No. 3 roc3 w i l l have t o be manually withdrawn o r t h e l i m i t w i l l have t o be raised.

Vhen

c r i t i c a l , Rod 2 and 3 s h o z l d always b e withdrawn t h e same amount (within

i n c h of each o t h e r ) .

Rod 1 should k e k e p t a t l e a s t

inches

below Rod P and 3 and w i t h i n t h e range o f 8 i n c h e s and 39 i n c h e s withdrawn.

3.1 To t a k e t h e r e a c t o r c r i t i c a l on s e r v o rod c o n t r o l , prcceed as follows :

109 W

55-8 9/14/65

Approved by

2/2/68 7/2/69 Date /Tine Init.

3.1.1

Put rod c o n t r o l on servo u s i n g servo-mode

s e l e c t o r switch

(s-16).

Note t h a t l i g h t s

on console i n d i c a t e t h a t t h e f l u x servo cont r o l i s on.

3.1.2

S e t s e r v o f l u x channel s e l e c t o r s w i t c h

(S-17) t o No. 1 channel.

3.1.3

S e t f l u x demand on s e l e c t e d channel t o

10 kw u s i n g r a n g e - s e l e c t o r switch (Rm-ARC-A5)

and f lux-demand knob (RXNARC -A6)

3.1.4

S e t o t h e r channel r a n g e - s e l e c t o r switch

a t lowest p r a c t i c a l range.

3.1.5

Check t h a t r e g u l a t i n g rod i s a t t h e upper

regulating-rod l i m i t .

Regulating rod should

b e a t 1 2 inches o r l e s s .

3.1.6

S e t fission-chamber s e l e c t o r switch

(S-15)

as desired.

No. 2

3.1.7

Both

S e t fission-chamber No. l m o d e s e l e c t o r

s w i t c h (S-13)

3.1.8

No. 1

t o automatic (pushed i n ) .

Set fission-chamber No. 2 mode selector

s w i t c h (S-14) t o automatic (pushed i n ) .

3.1.9

Withdraw t h e shlm rod No. 2 t o

Then withdraw shim rod No. 3 t o

in. in.

3.1.10 Reset t h e f l u x scram s e t p o i n t s t o low s e n s i t i v i t y (RED) range.

3.1.11

Switch r e g u l a t i n g - r o d a c t u a t o r switch

( S - 1 9 ) t o withdraw.

This w i l l r a i s e t h e

r e g u l a t i n g - r o d l i m i t switch allowing t h e f l u x s e r v o t o withdraw t h e r e g u l a t i n g rod. Continue r e g u l a t i n g - r o d withdrawal u n t i l W

c r i t i c a l i t y i s a t t a i n e d and d e s i r e d f l u x i s reached.

When c r i t i c a l t h e r e g u l a t i n g rod

should b e w i t h i n t h e range of

8 t o 39 inches

and should b e a t l e a s t 4" below t h e shim r o d s .

110

Approved by

5rJ-9 9/14/65 2 12 I68

~12169 NOTE:

As f l u x i n c r e a s e s , change t h e range on t h e a l t e r n a t e picoammeter

as r e q u i r e d and observe t h e l i n e a r f l u x i n d i c a t o r ,

Also observe t h e

p e r i o d m e t e r s on t h e c o n s o l e . The withdrawal of t h e r e g u l a t i n g rod can b e made as f a s t as t h e 25-sec p e r i o d c o n t r o l r o d withdraw i n h i b i t w i l l p e r m i t . When withdrawing t h e rods, c r i t i c a l i t y f o r o p e r a t i n g purposes i s def i n e d as b e i n g a t t a i n e d when t h e c o u n t r a t e i s a t l e a s t 500 times t h e c o u n t r a t e p r i o r t o withdrawing t h e r o d s ( a l l r o d s f u l l i n s e r t e d ) and

RR-8100i n d i c a t e s 1 kw o r

greater.

When t a k i n g t h e r e a c t o r c r i t i c a l a f t e r a n u n i n t e n t i o n a l shutdown,

unless s p e c i a l i n s t r w t i o n s a r e given, a t t a i n c r i t i c a l i t y as d e s c r i b e d here except t h a t RR-8100 s h a l l i n d i c a t e a power l e v e l n o t l e s s t h a n 1.1 kw f o r t h e c r i t i c a l r o d p o s i t i o n s of S t e p 3.1.12.

Init. 3.1.12

When t h e f l u x r e a c h e s t h e f l u x demand

s e t p o i n t , t h e s e r v o w i l l l e v e l t h e power a t the setpoint.

The r e g u l a t i n g r o d a c t u a t o r

s w i t c h S-l9 should b e r e l e a s e d when t h e r e g u l a t i n g r o d i s n e a r t h e c e n t e r of t h e r e g u l a t i n g rod l i m i t switches.

3.1.13

! h i l e maintaining t h e r e a c t o r a t t h i s

power, r e c o r d r o d p o s i t i o n s (Rod Xo. 1 Rod No. 2 OAFOT

Rod Uo. 3

) and

Check t h e r e a c t i v i t y b a l a n c e

$ 6k/k.

Xet r e a c t i v i t y i s normally

less t h a n rl: 0.2%.

S h i f t Supervisor's per-

m i s s i o n t o i n c r e a s e power

3.2

To r a i s e t h e power i n r o d s e r v o and manual l o a d control

NOTE:

The t r a n s i t i o n frorn s t a r t mode t o pm mode ( i . e . from 10 kw t o 1 Mw) should b e rrade q u i c k l y t o a v o i d o v e r - h e a t i n g t h e system. Review t h e remaizder of t h i s p o r t i o n of t h e check l i s t s o t h a t t h e f o u r most i m p o r t a n t s t e p s can b e done w i t h minimum d e l a y . These are S t e p s 3.2.7, 3.2.8, 3.2.9, and 3.2.13 and

Date/Time

111 Approved by

5~-10

9/14/65 2/2/68 7/2/69 Init, 3.2.1

Check t h a t f i s s i o n chambers No. 1 and 2

are i n automatic. 3.2.2

S t a r t annulus blowers (MB-2 and MB-4)

3.2.3

Check t h a t t h e bypass damper i s s e t on

a u t o m a t i c and t h e bypass damper i s f u l l y open. 3.2.4

Using S-18, a d j u s t t h e teinperature demand

s e t p o i n t s l i g h t l y more t h a n t h e i n d i c a t e d o u t l e t temperature. 3.2.5

Adjust t h e r e g u l a t i n g r o d l i m l t ; ?.witch s o

t h a t t h e r e g u l a t i n g r o d i s about e e r t e r of

i t s range. 3.2.6

Check t h a t t h e blower damper switches,

on blowers which you expect t o o p e r a t e , a r e s e t t o " m n " p o s i t i o n (MB-5). 3.2.7

I n c r e a s e n u c l e a r power t o a b o u t 700 kw by

i n c r e a s i n g b o t h picoammeter range s e l e c t o r s w i t c h e s t o t h e i r maximum range p o s i t i o n and s e t t i n g f l u x demand knob t o a b o u t 45%. 3.2.8

S t a r t MB-1.

3.2.9

Push run b u t t o n (S-11). T h i s seals t h e

r e a c t o r i n r u n mode and you should b e i n t e m p e r a t u r e servo. Check t h e consoLe t,o confirm t h i s . 3.2.10

Raise r a d i a t o r doors.

BegiE by r a i s i c g

o u t l e t door h a l f way, i n l e t door t o i t s minimlam s e t t i n g , o u t l e t doGr to upper l i m i t , and t h e i n l e t door t o upper l i m i t . 3.2.11

R a i s e t h e h e a t e r s on coclazit system f l c w

t a r a m m i t t e m t o t h e i r power operatior_ setting.-

3.2.22 Adjust the t e m p e r a t u r e dernazd t o g i v e t h e d e s i r e d o u t i e t t.emperatsre (norma:!.ly

1210

2째F).

Date /Time

112

5~-11

9/14/65 2/2/68 7/2/69 Init. Date/Time 3.2.13

Close t h e bypass damper by r a i s i n g t h e

radiator

AP demand w i t h t h e damper on a u t o -

matic c o n t r o l .

NOTE:

So t h a t t h e bypass w i l l reopen upon s t a r t i n g of 2nd blower, r a i s e t h e AP demand o n l y enodgh t o c l o s e bypass damper 3.2.14

- no

more.

When t h e bypass damper i s c l o s e d , s t a r t

t h e second main blower (MB-3).

The damper

should open a u t o m a t i c a l l y . 3.2.15

Continue r a i s i n g t h e r a d i a t o r

AP demand

u n t i l t h e bypass fianper i s completely c l o s e d

o r u n t i l d e s i r e d power i s reached. 3.2.16 3.2.17

Take a r e a c t i v i t y b a l a c c e . k Wk*Vhen s t e a d y power i s a t t a i n e d , s e t t h e

l i n e a r power s w i t c h e s t o alarm i f power v a r i e s by i:

3.2.18

5$ of s c a l e .

Check t h a t t h e t r e a t e d water s u r g e t a n k

and degassing t a n k a r e b e i n g purged w i t h a i r .

STARTING POWER OPERATIOS USII'JG MANUAL ROD COiVTROL The r e a c t o r h e a t l c a d and f l u x cail b e a d j u s t e d manually i n a number of d i f f e r e n t ways.

The c o n t r o l rode carz b e manipulated

manually t o a t t a i n c r i t i c a l i t y and a d j u s t pijwer u s i n g t h e i n d l v i d c a i a c t u a t o r switches.

Tke r e g u l a t i n g - r o d lirr,its have no fiznctior! when

i?? mama1 c o n t r o l .

Group i n s e r t i o n i s p o s s l b l e a t a l l times and

group wi5kdrawal can b e done when i n t h e s t a r t mode.

'&en c r i t i c a l ,

Rods 2 acd 3 s h m l d a l v a y s b~ w i t h d r a m t h e same arnount ( w i t b l n

k in.

of eacb G t l T e r )

Rod 2 ac6 Eo?

Rod 1 s h c u l d 3e k e p t a? l e a s t

4 inches

below

2 and w i t k i n t h e rar-ge of 8 i n c h e s t o 39 i n c h e s w i t h -

drawn.

A t v e r y l c w powers, it may b e n e c e s s a r y t o a d j u s t power removal by a d j u c t i n g t h e e l e c t r i c a l h e a t e r s or i t may b e advantageous t o r a i s e one or b c t h r a d i a t o r doors w i t h tk,e blowers o f f .

A t higher

113 V

Approved by

55-12

9/14/65

2/2/68 7/2/69 power w i t h one o r b o t h of t h e blowers on, f i n e adjustment may b e made by s e t t i n g t h e doors a t a f i x e d p o s i t i o n and changing t h e

The damper c o n t r o l may b e set on a u t o m a t i c

bypass-damper p o s i t i o n .

which w i l l h o l d a c o n s t a n t r a d i a t o r

AP o r on manual which w i l l

m a i n t a i n a f i x e d damper p o s i t i o n . Init.

4.1

To t a k e t h e r e a c t o r c r i t i c a l manually, proceed

as f o l l o w s :

4.1.1

Put r o d c o n t r o l on manual u s i n g s e r v o -

mode s e l e c t o r s w i t c h

(s-16).

Note t h a t

l i g h t s on c o n s o l e i n d i c a t e t h a t t h e f l u x servo control i s o f f . 4.1.2

S e t s e r v o flux channel s e l e c t o r s w i t c h

(S-17) t o No. 1 c h a n n e l .

4.1.3

S e t b o t h l i n e a r channel r a n g e - s e l e c t o r

s w i t c h e s a t lowest p r a c t i c a l range.

4.1.4

Check t h a t r e g u l a t i n g rod i s a t 1 2 i n .

o r less.

4.1.5

S e t fission-chamber s e l e c t o r s w i t c h

(S-15) as d e s i r e d . No. 2

4.1.6

No. 1

, Both

S e t fission-chamber No. 1 mode s e l e c t o r

s w i t c h (S-13) t o a u t o m a t i c (pushed i n ) .

4.1.7

S e t f i s s i o n - c h a m b e r No. 2 mode s e l e c t o r

s w i t c h (S-14) t o automatic (pushed i n ) .

4.1.8

Withdrhw t h e shim rod No. 2 t o

Then withdraw shim rod No. 3 t o

4.1.9

in. in.

Check t h a t f l u x scram s e t p o i n t s a r e t o

low s e n s i t i v i t y (RED) range. 4.1.10

Switch r e g u l a t i n g - r o d a c t u a t o r s w i t c h

(S-19) t o withdraw. regulating-rod.

This w i l l r a i s e t h e

Continue r e g u l a t i n g - r o d

withdrawal u n t i l c r i t i c a l i t y i s a t t a i n e d and d e s i r e d f l L x i s reached.

When c r i t i c a l , t h e

Date /Tim e

114

55-13 9/14/65 2/2/68 7/2/69 Init.

4.1.10

(continued)

r e g u l a t i n g rod should b e w i t h i n t h e range of

8 t o 39 i n . and s h o u l d b e a t l e a s t 4 i n . below t h e shim r o d s .

NOTE:

A s f l u x i n c r e a s e s , change t h e range on b o t h t h e sel e c t e d and t h e a l t e r n a t e picoammeter as r e q u i r e d and observe t h e l i n e a r - f l u x i n d i c a t o r . Also o b s e r v e t h e p e r i o d meters on t h e c o n s o l e .

4.1.11 Level t h e power a t 10 kw u s i n g t h e r e g u l a t i n g rod. 4.1.12

While m a i n t a i n i n g t h e r e a c t o r a t t h i s

power, r e c o r d rod p o s i t i o n s (Rod N o . 1 -,

, arid

Rod ?io. 2 OAFOT

balance

Rod No. 3

) and

Check t h e r e a c t i v i t y 6k/k.

Net r e a c t i v i t y i s

normally l e s s t h a n 5 0.2%.

S h i f t super-

v i s o r ' s permission t o increase power

4.2

To r a i s e t h e power w i t h manual r o d c o n t r o l and manual l o a d c o n t r o l Check t h a t F i s s i o n Chambers No. 1 and

4.2.1

No. 2 are i n autornatic. k.2.2 S t a r t annulus blowers (MB-2 and MB-4).

4.2.3

Check t h a t t h e bypass damper i s s e t on

a u t o m a t i c and t h e bypass damper i s f u l l y

open.

4.2.4

Check t h a t t h e blower damper s w i t c h e s , on

blowers which you e x p e c t t o o p e r a t e , a r e s e t t o "run" p o s i t i o n

NOTE:

(m-5).

The t r a n s i t i o n from s t a r t t o run mode ( i . e . frorn 10 kw t o 1 Mw) should be done c a r e f u l l y t o a v o i d o v e r - h e a t i n g t h e system. Review t h e remainder of t h e check l i s t s o t h a t t h e n e c e s s a r y a c t i o n may be t a k e n w i t h a xinimum of d e l a y .

Dateprime

Approved b

115

mpl

55-14 9/14 /65 2/2/68

7/+9 Init. 4.2.5

S t a r t MB-1.

4.2.6

Adjust r e g u l a t i n g rod t o i n c r e a s e t h e

n u c l e a r power.

I n c r e a s e t h e range on b o t h

picoammeters as n e c e s s a r y t o keep l i n e a r power on s c a l e .

Continue t o i n c r e a s e n u c l e a r

power t o about 40 t o 50% of

1 . 5 Mw (maximum

range p o s i t i o n of picoammeter s e l e c t o r switches). 4.2.7

L i f t o u t l e t door t o minimum s e t t i n g i f

n e c e s s a r y a t t h i s time t o m a i n t a i n r e a c t o r o u t l e t temperature. 4.2.8

Push run mode b u t t o n .

Check t h a t run

mode s e a l s i n ( s e e jumper b o a r d ) . 4.2.9

Continue t o i n c r e a s e b o t h l o a d and

n u c l e a r power w h i l e m a i n t a i n i n g r e a c t o r o u t l e t temperature f a i r l y steady.

Raise o u t l e t

door h a l f way, i n l e t t o i t s m i n i m u m s e t t i n g , o u t l e t door t o upper l i m i t , and then t h e i n l e t door t o upper l i m i t . 4.2.10

Rajse t h e h e a t e r s on t h e c o o l a n t system

flow t r a n s m i t t e r s t c t h e i r power s e t t i n g . 4.2.11

Close t h e bypass damper by r a i s i n g t h e

r a d i a t o r AP demand w i t h t h e damper on a u t o matic c o n t r o l ,

NOTE: So t h a t t h e bypass w i l l re-open upon s t a r t i n g of t h e second blower, r a i s e t h e AP demand o n l y enough t o c l o s e bypass damper 4.2.12

- no

When t h e bypass damper i s c l o s e d , s t , a r t

t h e second blower (MB-3). open a u t o m a t i c a l l y . W

more. The damper should

I n c r e a s e n u c l e a r pcwer

as n e c e s s a r y t o m a i n t a i n r e a c t o r o u t l e t temperature.

I)ate/Time

116

55-15

9/14/65 2/2/68

7/2/69 Init.

NOTE:

Very l i t t l e adjustment of t h e r e g u l a t i n g rod should b e n e c e s s a r y s i n c e you w i l l g e t some i n c r e a s e i n n u c l e a r power due t o lowering of t h e a v e r a g e temperature ( n e g a t i v e temperature c o e f f i c i e n t ) when more l o a d i s b e i n g removed. 4.2.13

To r e a c h maximum power, c o n t i n u e t o

add l o a d t o t h e system by i n c r e a s i n g t h e radiator

demand u n t i l t h e bypass damper

i s closed. 4.2.14 4.2.15

$ Wk. Take a r e a c t i v i t y b a l a n c e When s t e a d y power i s a t t a i n e d , set t h e

, -

l i n e a r power s w i t c h e s t o alarm i f power v a r i e s by 4.2.16

5$ of s c a l e .

Check t h a t t h e t r e a t e d w a t e r s u r g e t a n k

and degassing t a n k are b e i n g purged w i t h a i r .

E a t e /Time

117 MSRE DYNAMIC TESTS MSRE T e s t Memo 3.2.4.1 T r a n s i e n t Flowrate Measurements

Approved f o r u s e

Introduction Measurements w i l l be made t o determine t h e f u e l and coolant s a l t flow r a t e s d u r i n g s t a r t u p and coastdown of t h e c i r c u l a t i n g pumps.

The t r a n s i e n t

behavior of t h e f u e l void f r a c t i o n s as i n d i c a t e d by t h e gamma-ray d e n s i t o meter w i l l a l s o be measured. Purpose I n f o r m a t i o n on t h e t r a n s i e n t s a l t flow rates and void f r a c t i o n s d u r i n g pump s t a r t u p and coastdown w i l l be used t o i n t e r p r e t r e s u l t s of t h e t e s t s

of flow on r e a c t i v i t y ( s e e MSRE T e s t Memo 3.2.4.5). Description These t e s t s w i l l be r u n w i t h t h e r e a c t o r s u b c r i t i c a l and e s s e n t i a l l y

at thermal equilibrium.

For t h e c o o l a n t l o o p t e s t s , salt flow rate and

pump speed w i l l be monitored, and f o r t h e primary loop t e s t s , pump speed and f u e l d e n s i t y (from t h e gamma-ray d e n s i t o m e t e r ) w i l l be monitored. S p e c i a l Equipment and F'reparat i o n s S i n c e t h e pump s t a r t u p time i s q u i t e s h o r t , a m u l t i c h a n n e l o s c i l l o g r a p h r e c o r d d r w i l l be used t o monitor t h e o u t p u t s of t h e coolant s a l t v e n t u r i d i f f e r e n t i a l p r e s s u r e c e l l s d i r e c t l y , and b o t h primary and c o o l a n t pump speed. The d a t a l o g g e r w i l l be used i n t h e continuous fast scan mode t o a l s o r e c o r d c o o l a n t flow r a t e , pump speeds, and f u e l d e n s i t y , as w e l l as c e r t a i n l o o p temperatures for reference. Procedures

1. S e t i n p u t power t o l o o p h e a t e r s so t h a t a c o n s t a n t temperature (nominally l200'F)

i s maintained w i t h b o t h c i r c u l a t i n g pumps

running.

2. Jumper t h e control i n t e r l o c k s o t h a t t h e f u e l pump may o p e r a t e w i t h t h e c o o l a n t pump o f f .

118 Put t h e l o g g e r i n t h e continuous fast scan mode, and monitor c o o l a n t flow and pump speed on t h e o s c i l l o g r a p h .

Shut o f f t h e c o o l a n t pump.

After t h e flow t r a n s i e n t has d i e d out, restart t h e c o o l a n t pump.

6 . Monitor primary pump speed on t h e o s c i l l o g r a p h ( a l s o d e n s i t o m e t e r signal if possible).

Put l o g g e r i n fast scan mode.

Shut o f f t h e f u e l pump.

8 . R e s t a r t f i e 1 pump after f l a w t r a n s i e n t ( i . e . pump speed and d e n s i t o m e t e r s i g n a l s ) has s e t t l e d o u t .

Repeat

7 and 8 a f t e r w a i t i n g v a r i o u s i n t e r v a l s between s t a r t s

t o s e e i f t h e r e i s any burping e f f e c t d e t e c t e d on t h e d e n s i t o m e t e r .

119

MSRE T e s t Memo 3.2.4.1 Appmdix I Check L i s t f o r T r a n s i e n t Flowrate Measurements

g8B.ac)63%

Submitted Submitteak).

Approved Approved

4/<16~'

./4

&b h & S

Approved f o r use T h i s check l i s t i s t o be used i n connection w i t h t h e t e s t procedures d e s c r i b e d i n E R E T e s t Memo

3.2.4.1. Initial

1. Provide a c o n t r o l i n t e r l o c k jumper t o permit o p e r a t i o n of t h e f u e l c i r c u l a t i n g pump w i t h t h e c o o l a n t c i r c u l a t i n g pump o f f .

147 from ~ 1 8 i~n 7c o n t r o l

(Connect jumper wire i n c i r c u i t t e r m i n a l R14E10 t o t e r m i n a l r e l a y cabinet

Permission t o i n s e r t jumper.

Connect t h e d e n s i t o m e t e r output ( 1 s e c .

T/C f i l t e r ) t o t h e d a t a logger fast scan sequence i n p u t

(replacing

LT-599( OFT)).

Connect o u t p u t s of t h e c o o l a n t salt v e n t u r i s ' d/p c e l l s and c o o l a n t c i r c u l a t e d pump speed t r a n s m i t t e r s t o a multi-channel oscillograph.

S e t i n p u t power t o loop h e a t e r s s o t h a t a c o n s t a n t t e m p e r a t u r e (nominally l200'F)

i s maintained w i t h b o t h c i r c u l a t i n g pumps running.

(reactor sub-critical)

Put t h e data logger i n t h e continuous fast scan mode and start o s c i l l o g r a p h .

6. Turn o f f t h e c o o l a n t pump. 7. After t h e flow t r a n s i e n t has

d i e d out,

r e s t a r t t h e c o o l a n t pump.

8. A f t e r flow t r a n s i e n t has d i e d out, take W

l o g g e r out of fast scan.

D a t e / t ime

120

I n i t i a l Date/time

Connect o u t p u t s of t h e f i e 1 c i r c u l a t i n g pump speed t r a n s m i t t e r and t h e f i e 1 s a l t densitometer t o t h e multi-channel oscillograph.

10. Put t h e data logger i n t h e continuous fast scan mode. 11, Turn o f f t h e f u e l pump. 12. Re-start t h e f u e l pump a f t e r t h e t r a n s i e n t has d i e d o u t .

13. After f l o w t r a n s i e n t has d i e d out, t a k e logger out of f a s t scan.

14. Repeat s t e p s 11 t o 13 s e v e r a l times at t h e d i s c r e t i o n of t h e experimenters.

15.

Remove jumper of s t e p 1.

121

APPENDIX K

Examples of the Control Room Log and the Building Log

123 W

1.0 / 3/66 2/15/67

5/23/67 8/22/67

12- 2A CONTROL ROOM I.QG (Computer i n Operation) COVER SHEET

I n t h e spaces provided, l i s t any v a r i a b l e n o t i n l i m i t s o r which you judge needs a t t e n t i o n .

Page No.

I Date S t a r t e d

I T E M S

8 - 4

4 - 12

- 8

-1

I Supplement Cover

124

1S-U

8/4/65 1/17/66 3/7/66 6/20/66 10/3/66 211 5/67 5 123/6?

1s-2A CONTROL ROOM UX;

(Coupter in Operation)

Log taken by:

8 - 4

-8

CONSOIE Record every 4 hours starting a t 0830 unless otherwise indicated.

*I f

temperature exceeds 75째F due t o I c i n g , t u r n normal u n i t up t o 80째F and standby u n i t down t o 70째F for several hours.

Date Started

-_ a-,

125 W

1%-2A

8/6/65 4/24 68 1/17/66 12/2 168 3 17 I66 6720166

Record e v e r y 4 hours s t a r t i n g a t 0830 u n l e s s otherwise I n d i c a t e d .

2/7/68

126 Approved by

12A-2A

8/6/65 4/24/68 1/17/66 12/26/61 3/7/66

6/20/66 10/3/& 2/15 167 5/23/67 Record every 4 hours s t a r t i n g a t 0830 u n l e s s o t h e r w i s e i n d i c a t e d . 8 22/67

bi'I68

Read c o a r s e p o s i t i o n i n d i c a t o r t o n e a r e s t p r i n t e d num3er below p o i n t e r . Add f i n e r e a d i n g t o t h i s and r e c o r d t h e sum. Keep a l l t h r e e a t 24 inches when sub-critical. *FF3 chamber w i l l be withdrawn while c i r c u l a t i n g f i e 1 s a l t . W n c e p e r day e x e r c i s e b o t h f i s s i o n chambers by s e l e c t i n g a l t e r n a t e , manua l l y withdrawing ( o r i n s e r t i n g ) s e v e r a l inches and r e t u r n i n g t o o r i g i n a l position. -At s t e a d y s t a t e and @AFW 1210째F. If n o t a t 1210째F o r if FP is off c a l c u l a t e new l i x i t s . Allow 1-114 i n . f o r every 10" of OAFQT and 1-1/4 i n . for FF Off-On.

Date Started

127

4/26/67 9/18/67

l a - 3 BUILDING LCG

I n t h e spaces provided, l i s t a n y v a r i a b l e n o t i n l i m i t s or which YOU j u d g e needs a t t e n t i o n .

t a c k Panel I

ER, Hi Bay 852 t

1 Date S t a r t e d

Supp-mei::

128

Approved by

f i 9{\7

12A-7

12A-3

BUILDING WC;

Taken by :

8 12 -

i i u n No *

I+

LO/5/65 1/18/46 2/24/66 5/9/66

;;/l:J/G;

4/7/69

8/25/46

SERVICE TUNNEL 2 /6/68 Record every 4 hours s t a r t i n e ; a t 0830 u n l e s s o t h e r w i s e i n d i c a t e d .

*Colcnr

it' process v a t e r is in use.

**Discharge p r e s s u r e from t h e pumps which are on s h o u l d be >55 p s i g . *w

l ' h r o t t l e ?-765 (0,--pa:s) only a s :.eqd:rec! o b t a i n d e s i r e d s h i e l d plug.f'low. This w i l l p e r z i t m a x i ~ mrecirculatia:

V-754 should be wide open.

rate. m t e Started

129

&HFP&

Approved by

12A-3 10/5/65

1/18/66

8/12/68 4/7/69

2/24/66

6/9/66 Record e v e r y

*M s c h a r g e .mc

hours o t a r t i n g a t

0830 unless

otherwiae indicated.

p r e s s u r e from t h e pumps which are on s h o u l d be

3 5 palg.

V-704 s h o u l d be wide open. T h r o t t l e V-715 (by-pass) o n l y as r e q u i r e d t o o b t a i n desired s h i e l d plug flow. This will p e r m i t maximum r e c i r c u l a t i o n

rate.

SERVICE AREA Record e v e r y

x 7%

hours s t a r t i n g a t 0830 u l e s s o t h e r w i e e i n d i c a t e d .

S e t c a l i b r a t i o n a t 0 . 2 5 t o 0.35 mr/hr b e f o r e r e a d i n g . Date S t a r t e d

131

APPENDIX L Forms Used i n Making Changes

133

Form H-1.

To Imation

MSRF: PUNCH LIST

Priority

Date Requested by :

Equipment, Line No., etc.

Description of Work t o be Done:

Precautions :

Estimated Cost: Approval t o proceed :

Describe work done i f d i f f e r e n t

Job Completed and Accepted by:

Date:

134

LJ 1

WORIOIOCINUUBCI

iawco

WORK a i o u c a r ~ ~ u o ~ m

LI10R1T"

COUIPYCNT.

011.

svarcw.

SIC.

DESCRIPTION O r W O I I

ACCROVCD U l l U l C N l N C C

A C C I O I C D OCCIA71ONS

CICCAUTIONS

STARTING DATE OR TIME

ENDING DATE OR TIME

1 CRACTSMAN

tc C - C . E SUPERVISOR

SIGNED

REACTOR OIVISION MAINTENANCE

REACTOR DIVISION OPERATIONS

WORK COMPLETED ~

WORK INSPECTED WORKAPPROVED mCU4"Ks

ucw-aea. 1s

*...I

D I T S COUPLETCO

135 U C N 8820 13 5881

M S R E C H A N G E REQUEST -

SUBJECT

___

TARGET DATES TYPECHANGE

APPROVAL T O P R O C E E D

0 PERMANENT

e c

DESIGN C O M P L E T E D

0 ELECTRICAL 0

0 TEMPORARY

MECHANICAL

PROCUREMENTCOMPLETEO

FROM DOCUMENTS A F F E C T E D

0 OTHER

REQUESTEDEY

REQUESTED COMPLETION D A T E

DATE REQUESTED I

PURPOSE AND D E S C R I P T I O N

INIT. MSRE D E P T

DATE

0 I e c DESIGN 0R D D E V E L O P M E N T

HEAD

0 MSRE O P E R A T I O N S

0REACTOR D I V

INlT

DATE

___

_ _

DIRECTOR

COMMENTS O F REVIEWERS

DATE

0 DESIGN C O M P L E T E D 0 PROCUREMENT COMPLETED 0 WORK R E Q ISSUED: NO

DATE

0 WORKCOMPLETEDANDTESTED .~-

ORIGINAL DOCUMENTS REVISED

0 CONTROL

ROOM D O C U M E N T S R E V I S E D

137

APPENDIX M

Example of MSm D a i l y Report

139

MSRE DAILY REPORT period

0800

3/22/68 to

0800

The power o p e r a t i o n of t h e r e a l t o r f o r Run No.

a t 0100, 3/25/68, by a r o d and l o a d scram as planned.

3/25/68

was d i s c o n t i n u e d

After 8 minutes of

s u b c r i t i c a l o p e r a t i o n , t h e r e a c t o r was r e t u r n e d t o reduced power o p e r a t i o n t o r e c o v e r t h e t e m p e r a t u r e l o s t d u r i n g t h e scram t r a n s i e n t .

The power was

t h e n reduced t o 10 kw and i s c o n t i n u i n g a t t h a t l e v e l and a t 1210"r'. Dynamics t e s t s were completed a t hll power and a t 2.5 Mw.

The t e s t s

a t 2 . 5 Mw were run because t h e t e r n a r y sequence used i n t h e p r e v i o u s t e s t s had n o t been c o r r e c t .

The power w a s reduced t o 2.5 Mw f o r a b o u t

hours f o r

t h e s e t e s t s ; o t h e r w i s e t h e r e a c t o r r a n a t full power u n t i l t h e scheduled power r e d u c t i o n t h i s morning. s e r v o a f t e r t h e dynamics tests. c o n t a c t s on Relay ICA-lTOB,

There was d i f f i c u l t y i n r e t u r n i n g t o t e m p e r a t u r e The t r o u b l e , w h i c h was found t o b e f a u l t y

was c o r r e c t e d .

T e s t i n g c o n t i n u e d on t h e o f f g a s sampler t h e r m a l c o n d u c t i v i t y c e l l s t o d e t e r m i n e the effect of t h e f l o w r a t e through t h e a b s o r b e r bed.

The r e s u l t s

were t o o e r r a t i c t o form any c o n c l u s i o n s .

MG-3 w a s reason.

found running b u t o f f - l i n e t h r e e t i m e s w i t h no a p p a r e n t

Noma1 o p e r a t i o n was r e s t o r e d each time w i t h o u t d i f f i c u l t y ,

There were two computer outages d u r i n g t h e weekend b u t t h e cork;ater was r e s t z r t e d a f t e r a b o u t 1/2 hour in both cases.

The equfpment t o b e u s e d i n gama scanning t h e h e a t exchanger a f t e r t h e shutdown was c a l i b r a t e d on a mockup of t h e heat exchanger and a 50-cr;i-ie i 9 2 1 r ~ ~ ~ r ~The e . gamma scan fs

t o be done w i t h

Ge(Li) d i o d e t o a e t e m i n e

t h e c o n c e n t r a t i o n s of t h e v a r i o u s f i s s i o n p r o d u c t s that are d e p o s i t e d or, -,he h e a t exchanger tubes.

140

Contents

.. ..... Pressure (Psig) . . .

Circulating

Maximum Temperature

(OF)

Minimum Temperature

(OF)

Samples Taken

Enrichments

Overflow ~ a n kLevel ($)-

REACTIVITY

- Calculated PW Nuclear Power &)eoMw Rod 15% 7in. Rod Control Mode flu% Rod 2 4 i n . Observed

srfo

Rod 3

k 235 in

loop6%#&

235 in

s a l t PWficg

in.

" I T REMOVAL Load-Control Mode &mu=?

Inlet mor

in.

in,

7/00

Blower 1

0 di-'

O u t l e t Door

Blowerg3

OFF

amper

ACCUMJLATED OPERATING DATA This Period

Tnis Run

Totsl

. . , . . . . . , . ( h r s ) 7/.87 9?#cLd7 //&#-27 I n t e g r a t e d Power . . . . . . . (Mw-hrs) 4 7 8 /73 ~ z#sz/ d-?zdz Fuel Loap Time Above 90G"F , . , . ,( h r s ) 72 447W.'C Z%$S' Fuel Pump Time C i r c u l a t i n g Helium , . ( h r s ) 0 / / # Z 5 _'37Y3+ Time C r i t i c a l

Fuel M p Time C i r c u l a t i n g S a l t , (hr s ) Coolant Loop Time above 9 0 째 F (hrs) Coolafit Pump Time C i r c u l a t i n g Helium . ( h r s )

.. .

Coolant Pump Time C i r c u l a t i n g Salt iicating, Cycles (Fuel/Coolant) e e ,

.(hrs)

. F i l l Cycles (Fuel/Coolant) . .. Power Cycles (Fuel/Coolant) . ., ,,

Equivalent fiXL-Parer Hours

7. 72 0

7& "10 %27

I//

4424 zrlqC'c'd /(L,A%-

44BSc e 3 8 g's /

447z7x % f

&%r337844

/hf/3 9/s

=w3

6g/64

pGJs3-9

141

O X G A S SYSTZN

Charcoal a d s in S e r v i c e

,I#

74% C f n

Conâ&#x20AC;?&iment Stack Flow

F i l t e r k d Pressure Drop (in.-&O)

(in -E~o) I)

Coolant C e l l

0.19

hieactor C e l l In-leakage

Roughing

Hiah B y Containment Vacuum

Pressbe Bop

J/min

/. 5-3

Chem C e i l

Absolute

gsi

/;27

Reactcr Z ? l l

-2.226

Va2or Cond. Sys. Pressure

psig

p i g

143

Internal Distribution 1. 2. 3.

4. 5. 6. 7-11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

S . E. Beall R. B. Briggs W . B. C o t t r e l l J . L. Crowley J. R. Engel A. P. F r a a s R. H. Guymon P. N. Haubenreich H . W. Hoffman T . L. Hudson P. R. Kasten A. I . Krakoviak (K-25) K e r m i t Laughon, AEC-OSR R. N. Lyon R. E . MacPherson H . C . McCurdy

21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33-34. 35. 36-38. 39.

A . J. Miller R. L. Moore A. M. P e r r y M. Richardson M. W . R o s e n t h a l Dunlap S c o t t M. R. Sheldon M. J. S k i n n e r I. Spiewak D. A. Sundberg D. B . Trauger G. D. Whitman C e n t r a l Research L i b r a r y Y-12 Document Reference S e c t i o n Laboratory Records Department Laboratory Records (RC)

External Distribution

40-42. 43-44. 45-46. 47. 48. 49-65. 66. 67-68.

D i r e c t o r , D i v i s i o n of Reactor L i c e n s i n g , USAEC, Washington, D.C. D i r e c t o r , D i v i s i o n of Reactor S t a n d a r d s , USAEC, Washington, D.C. N. Haberman, USAEC, Washington, D.C. 20545 D. F. Cope, AEC-OR0 T.A. Nemzak, IJSAEC, Washington, D.C. 20545 Manager, T e c h n i c a l l n f o r m a t i o n C e n t e r , AEC ( F o r ACRS Members) Research and T e c h n i c a l Support D i v i s i o n , AEC, OR0 T e c h n i c a l I n f o r m a t i o n C e n t e r , AEC

20545 20545