ML20136C706

QC Surveillance Rept 75-182 Re Testing & Reinstallation of Valve RC-RV-2 to Rcs.Work Request Procedure Form for 750913, 18 & 30 Work Request Approvals & 741217 Maint Procedure 1401-2.1 Re Pressurizer Relief Valve Encl

ML20136C706
Person / Time
Site:	Crane
Issue date:	10/08/1975
From:	Neidig R, Potts W METROPOLITAN EDISON CO.
To:
References
TM-0962, TM-962, NUDOCS 7910010535
Download: ML20136C706 (48)

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TMI DOCU!ENTS DOCUMENI NO:

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COPY HADE ON OF DOCUMENI PROflDED BY METROPOLITAN EDISON COMPANY.

Supervisor, Docu:nent Control, NRC e

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QC SURVEILLANCE REPORT

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[ rouse Mechanic

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Reactor Coolant 1.VCU C.. iUR7EILLED:

Testing and Reinstallation of RC-RV-2.

DATE(S) 0F SURVEILLANCE:9/29 to 10/2/75 RE?IP.I:::I.

(DWG. SPECIFICATION, PRO'CEDURE, VELD'!!AP, ETC. ) W/R 5625 and Addendums 1 & 2, C/M

1. 145.

CBSFJ.'.*ATI':::

(Continue en additional plain sheets if necessary indicating page and Surveillance Report Numbers)

Work proceeded to the point of having the inlet flange bolts and several outlet flange bolts loosened prior to the arrival of the QC inspector. Removal of the outlet flange bolts was witnessed and the valve was removed to the clean area located on the 346' ele-vation of the reactor building. The flanges of RC-V-2 (outlet flange being part of mechanical joint to RC-RV-2) and the discharge pipe were covered with graphited gasket material and taped in place to prevent damage to the flanges.

The Unit #1 valve SR # 8905 was bolted to the test stand and prepara'tions for testing were made. The Dresser Representative, T. Cassidy, prefixed the Crouse test procedure with an additional step which required raising pressure to 200 PSIG below the valve seat and causing the valve to lift and then reset. This was done to permit removal of any foreign material from between the seat and disc.

Upor. performing the 200 PSIG lift, the valve failed to reseat as expected; so pressure was raised to 400 PSIG at which time the valve reseated. Testing was satisfactorily completed per Crouse maintenance test procedure #145, at a pressure of 2300I150 PSIG.

RC-RV-2 was returned to the vicinity of the pressurizer upon completion _of testing.

Removal of the pipe stub from within the inlet socket of the leakoff line elbow was completed and the valve installed. The new lower flange studs procured were too short -

to obtain the required thread engagement. It was thus necessary to use the original DIST.

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8' M-GO-N QA SYSTEMS LIST NO

@ M-GE M-GO-F CONFORMINO c m 10/2/75 QC SPEC / ASST.

DATE MONCONFORMING

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QC SPEC / ASST.

DATE 3 CCONI2. DEPT. HEAD D.M. Shovlin NCR OR STOP WORI: NO.

@ CRIGINAL FILE APPROVED:

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RECCDIEND AUDIT

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l QC SURVEILLANCE REPORT NO. TMI 75-182 OBSERVATION:

studs which were in satisfactory condition. The valve and flexitallic gasket were installed upon removal of. the flange protection material and the inlet mechanical l

joint was made per section 7.4.10 of 1401-2.1 as referenced by Crouse.

The nipple for the leakoff line was installed, and the thread angagement was inspected and found satisfactory. Fit up of the socket joint (nipple to elbow) and tacking of the joint was found satisfactory visually by E. Gee.

The leakoff line was visually and liquid penetrant inspected satisfactorily upon completion of the welding. The valve inlet flange was torqued per section 7.4.10 and the joint history.

Initial inspection of the valve discharge flanges found them unacceptable for reasons of cleanliness. After some preparatian. the flanges were found cleaned to the satis-faction of the inspector. The flexitallic gasket was placed in position and the studs and nuts installed af ter proper lubrication.

The studs were later removed to facilitate performance of addendum 2 which required cold pulling of the discharge piping per the guidance.cf GAI Representatives. With cold pulling completed (see Figure $ the outlet flange studs were reinstalled; and torquing was commenced per section 7.4.10 of the Net-Ed procedure af ter verifying that the 160 f t. lb. value listed on the flange history was in error. The torquing was witnessed to 250 ft. Ib and found satisfactory. The electrical connection of the valve was completed, and operational testing of the valve will follow. The valve was electrically tested and found satisfactory by operations personnel.

In addition, a leak te.t for the Unit 11 electromatic relief was witnessed after it was rebuilt to verify the status of the valve upon turnover. The leak rate was observed as six (6) drops per minute.

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CHECKLIST FOR REMOVAL, OVERHAUL, TESTING AND REINSTALLATION OF ELECTROMATIC RELIEF VALVE RC-RV-2

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REMARKS I

Removal 1.

Rubber pipe plugs, securely tied to a fixed anchor, installed 1.n pipe openings to and from relief valve.

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Record serial number of valve being removed 7

S/N TW 42.33 L

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Setpoint Verification & Overhaul 1.

All valve replacement parts shall be QC accepted.

O 2.

Record serial number of valve to be tested S/N A965 Wd 3.

Leakage past seat at normal operating pressure.

NOTE: Vendor representative to supply acceptance criteria LEAX RATE o w '^*l - -

ACCEPTANCE CRITERIA

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Actuate solencid and " pop" valve at 2300 pSIG.

w' Q) n ACCEPTANCE CRITERIA

Clean' loud report.

LIFT TIME LIFT PRESSURE

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Allow valve to reseat after popping and perform a second leak test.

I NOTE: Vendor rep. to supply acceptance criteria LEAK RATE ACCEPTANCE CRITERIA W.

Reinstallation 1.

Record serial number of valve being installed S/N t.w c c c '.

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Gasket surfaces cleaned.

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pipe plugs removed.

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Flexitallic gaskets

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' Electr::= tic Relief Yalve RC-RV-2 i

Page 2 SAT.

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REMARKS 5.

Studs and nuts QC cleaned and lubricated.

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Torque wrenches and special tools calibrated.

0 Tool S/N Cate Cal. Date Due

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Inlet flange torqued to 355 ft.1bs. in 25 f t. Ibs.

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Outlet flange torqued to 250 f t. Ibs in 25 f t. lbs.

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Valve tested satisfactorily per " Electrical Control i

and Interlock Test Procedure".

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APPROVED:

COMPLETED:

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Date Supervisor - Quality Control Work Request #

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Unit No., /

Work Request No.j

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l Work Plequest Procedure f A.P.1016 Sect. 6.0)

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should be used as a guide in fiiling out this forrn.

W.O./Accc nt No.4....U,

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Comconet.t (nt:ne & nemh)

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Ce:triba rmtfunction or..cdificaticn and recommindcd corrective action.

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Orbin: tor's Sumtvicer's Shnitu e

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ltems 6 threa.h 12 corraletd by Sottrvisor of Maintenance or Dosinnee 6.

Does work repretent a chance or rnodif: cation to an existing sys*em or component? If yes, the Yes No );f work mu:t be approvad via tne ch.in;;c mocification crocccure before work can be performed.

flotify Technicai Services Cept. for a::istance. (See A.P.1016, Sect. 7.0) C/M No.

7.

Dees the work require : Radiation Work Permit? If yes. the work must be performed using a Yes V No PC'lC rtiviewed, Station Superintendent approved precedure.

8.

Is week on a QC component as defined in G.P.100S? If yss, then ans..?r questions 9 & 10; ei:o Yu No Gaalny Control Dept. must review the work request prior te commencement cf work.

9.

Doet the work have an affect cn nacitar safety? If yes the work must be performed using a Yes No V PORC l? viewed, Station Superintendent Appreved erocedure.

10. If the wo k dccs not have en effeet on nucieor safety or radiation exposure to personnel fi.e.,

require 2 ilediation Work Fermit), the work may bo performed without a PO RC reviewed, S:ation Superintendent approverl procedure.

10a, A;reement that a PO RO reviewed, S:stion Superintendent approved procedure is not required for this wcrk 'equ2:t bric3use the work has no eifact on nuclear :afety.

Unit /Statior Swe"encent Dat e

11. P! ant status or Pr: regisite conditions required for per!armance of work.

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Limits and Precautions:

4 a) Parscene!

4 O COMPLY TiITH THE PROVISIO. S l

SET TORTH IN.'21002, 1003 UlD ET ZD SA.FLTY LLA5UAL i

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Post aintenance Testing required and Acceptance Criteric.. ~,. cjsj. - G. $._

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15. Maintenance Foreman Asdgned:

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16., QC Dept, revien,il required in item No. 8 7

Date l

l'/... Supervisor of Maintenance approval to commente work:

I Date

18. Shi!c Foremen *2 approrJ to commer.ca work Raciation Work Permit No.

Taggir$ Appi. cation No.

19. Main:enance Fpreman's comments on work performed:

Date/ Time Work Completed - Maintenance Foreman's Signature

20. Work completed and :omponent aligned for testing.

Data Shitt Foreman's Signature

21. Testing completed and component released f or normd use.

Date Shif t Foreman's Sigrature i

Qaatity Control Ocpartment review of work and testing comp!sted (OC work only).

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Date i

QC Department j

Suppvisor cf Maintenancs: Work reauest end procedure are complete and signed off as req l

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has hen signed oil as required. Machinery histor$/ entry lies been made,if required.

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• j WORK REGUEST' PROCEDURE TMI Nuclear Station Maintenance Procedure Format and Approval Unit No.

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This form outlines the format and acts as a cover sheet for a maintenance procedure. Due to the limited size i

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UNIT il MAlliTEi!A CE PP.0CEDURE 1401-2.1 4

l PRESSURIZEP. RELIEF YALVE REf 0 VAL All0/GR REPLf,CEMEtti j

' Table of Elfective P2;;es

,m Date Revision Page Date Revis!cc Pag's Octo Revision P

1.0 12/17/74 1

20.0 51.0 2.0 12/17/74 1

27.0 52.0 3.0 12/17/74 1

28.0 53.0 4.0 12/17/74 1

29.0 54.0 5.0 12/17/74 1

30.0 55.0 S.C 31.0 50.0 7.0 32.0 57.0 8.0 33.0 58.0 3

9.0 34.0 59.0 10.0 35.0 00.0 11.0 36.0 61.0 12.0

' 37.0 62.0 13.0 38.0 63.0 14.0 30.0 G4.0 l

15.0 40.0 65.0 16.0 41.0 66.0 17.0 42.0 67.0 13.0 43.0 68.0 19.0 44.0 60.0 20.0 45.0 70.0 21.0 46.0 71.0 r

4 22.0 47.0 72.0 23.0 48.0 73.0 4

24.0 49.0 74.0 25.0 50.0 75.0 Unit 1 Staff' Recommends,Ap5roval Unit 2 Staff Recolnmends ANproval Approval

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Date Approval Date Ccanizint Dapt. Head Cc'jni:an: 01st. H eld I

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E Unit 1 PORC Recommends Approval Unit 2 PORC Recommends Approval I

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Chairman of PORC Ch!ir.i.an of P0ilC,

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i THREE MILE ISLAt:3 tiUCLEAR STATIO?!

UNIT !1 fMIflTENA?tCE PROCEDURE 1401-2.1 Pressurizer Relief Valve Removal and/or Replacement 1.0 PU?.FOSE 1.1 To establish and define conditions, preparations, and maintenance procedure for the removal and/or installation of Pressurizer Safety valves RC-RV-1 A and 1B_, Electromatic Relief valve RC-RV2, and Electromatic Isolation valve RC-V2.

2.0 DESCRIPTION

2.1 Closed bonnet maxiflow safety valves.

RC-RV-1A and RC-RV-1B i

Height 40" Width 13" j

Weight approx. 400 lbs.

Mfr. Dresser Industrial Valve & Instrument Div.

J 2.2 Electromatic Relief Valve RC-RV2.

I Hefoht 9" Width 1 "

Weight approx. 75 lbs.

Mfr. Dresser Industrial Valve & Instrument Div.

2.3 Electromatic Relief Valve Isolation Valve RC-V2 Heicht 18" Width 35" Weight approx. 100 lbs.

Mfr. Hancock Valve Co.

4 Mfr. Phila. Gear Corp.

(Limittorque) 3.0 REFEP.Et!CES

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3.1 Consolidated Closed Bonnet i%.dfim. Safety Valve t' ental No.

_ l 31700 - B &

',! Instruction boa ::o. 01-0034-00.

3.2 Consolidated Electronatic Relief Velve :Unual 31533'/X - B & W Instruction Book I!c. 01 -0029- : ';.

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Blanketing of R{., System.

Revision 1

,3. 3 0.P. 1103-11 braining and fl2 l

3.4 TMI f;uclear Station Radiation Protection !!anual AP #1003.

3.5 Rules for the Protection of Iten Working on Mechanical and I

Electrical Apparatus, AP #1002_.

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'a 3.6 P.espiratory Protective Device Manual, Chap.1.

4.0 PLA;lT STATUS AND/OR PREREQUISITE CONDITIO.!S 4.1 Insure plant conditions are satisfied per Ref. 3.3, Section ll.4.5-Procedure for Pressurizar Safety and/or Relief Valve Removal.

5.0 LIMITS AN0/0R PRECAUTIONS 5.1 Insure Radiation Work Permit is issued per 3.4 above.

5.2 Insure Pressurizer Heaters are de-enargized and tagged per i

I Ref. 3.5.

l 5.3 Quality of Materials and Workmanship shall be of QA level.

-l 6.0 SPECIAL TOOLS AND MATERIALS, Af!D/OR QUALIFICATI0ilS 6.1 Tools.

6.1.1 0-500 ft lb torque wrench 6.1.2 6 f t, 500 lb nylon sling 6.1.3 1/2 ton chain block 6.1.4 MSA 0 indicator, 0-25%

2 3

6.1.5 Flow meter suitable to read 1.5 ft /hr of f! '

2 6.1.6 1 ton chain block 6.1.7 2-5000 f 8' nylon siings 6.1.8 Special Urenches for RC-R7-1 A & 18 6.2 Mr.terial 6.2.1 For RC-RV-1A $ IB Flexi talic Gashat, 3 3/31.D. X 3 3/4 0.0.

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l Flexitalic Gasket, 6" X 600 lb 6.2.2 For RC-RV-2 l

Flexitalic Gasket, 41/2" X 600 lbs.

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Flexitalic Gasket, 2 1/2" X 2300 lbs.

i 6.2.3 For RC-V-2 Flexitalic Gasket, 3 3/8" I.D. X 3 3/4" 0.0.

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l Flexitalic Gasket, 21/2" X 2300 lbs.

7.0 PROCEDURE 7.1 Erect ladder and scaffolding as required around pressurizer i

head to allow access to valves. Remove necessary insulation.

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7.2 Establish clean, area around valve and/or valves to be installed

//11ip or removed.

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7.4.1 Switch off and red tag pressurizar electromatic relief valve RC-RV2 250 Vcit,0.C. supply located in I

125/250 V.D.C. Distribution Panel 1C switch #2.

7.4.2 Test for voltage across Terminal 1 and Terminal 2 in the pressurizer electromatic relief valve solenoid housing.

If no voltage present remove wire R froa Terminal 1 and wire U from Terminni 2.

Disconnect circuit E0-523A frc ;'rup.:ci:er electmmatic relief valve scicnoid housing.

L0ccen and rem:ve studs ar.d nuts.

Install 1/2 ton chain block above valve.

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' 1401-2.1

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Revision 1 CAUTI0ti: During loosening and removal of studs and nuts,1 nlJ.3.. ~

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i..o '.r t-J's c.a.... J ;,,,, a level is high enough check 0 % level to insure 02 2

for personnel safety due to :2 purging.

Safe 0 level 2

to be 16+5 (Respiratory Protective Device Manual.

Chapter 1.)

7.4.3 Connect 2 ton chain block and 5000! slings to discharge piping to restrain during removal of valve.

7.4.4 Install 6 ft. 500 lbs. nylon sling on relief valve and take up slack.

Loosen and remove studs and nuts from valve flanges. Slowly slip relief valve out between inlet and outlet flanges insuring weight of relief' valves is ' held by chain block and nylon sling. Remove compression ring, tag, 5 attach to PZR Flange.

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CAUTI0ti: Continue to take 0 levels as per 7.4.2.

2 7.4.5 Install open and closed rubber test pipe plugs in piping to re ief valve and frc.n. relief valve. 'T=" h"j" usa W

% c..ume.- 2 mch.

7.4.6 Clean gasket surfaces.

I 7.4.6.1 Clean compression ring.

7.4.7 To install valve recove plugs frora inlet and outlet piping.

7.4.8 Clean studs and nuts and lubricate threads.

N, 7.4.9 Install gaskets.

7.4.9.1 Instcil c=pression ring.

7.4.10 Lower valvo inplace and install studs. Torque inlet flange to 355 f t lbs, outlet flange to 250 f t Ib; in 4

25 lb. increments.

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7.4.11 Take tension off of discharge piping and off valve.

7'.Nressurizer safety valves RC-RV-1A,13 - Removal and Installation.

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7.5.b For removal complete 7.4.4 (lif t vajve-vbrtiically)

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is no.t-required on discharge to. 4, 6.

.N piping).

7.5.2 For ins.t ation complete 7.4.7 to 7.4.11.

Torque

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Inlet flange 245 ft. Ibs. outlet; 250 ft.

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lbs. in 25 lb. increments.

N 7.6 Electromagnet Isolation Valve RC-V2 P.emoval and/or Installati'an.

7.6.1 Open and Red tag electrical power supply to Motor Operation of RC-V2.

7.6.2 Rig 1/2 ton chain block and 500 lbs. nylon sling to Motor Operator, disconnect motor operator mechanically

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and tie back enough to clear valve for remo'ial.

-7.6.3 For' removal complete 7.4.4 to 7.4.6.

i 7.6.4 For installation complete 7.4.7 to 7.4.11.

Torque valves-all bolts 355 ft 1bs in 25 ft. Ibs. increments.

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7.6.5 Check and readjust if necusary motor operator.

limits and torque switches.

8.0 FOST REPAIR 8.1 Install or renew insulation as needed to original condition.

Remove all materials used to build clean area, scaffolding ladders and riggings.

8.2 Perform hot leak check as required.

8.3 Remove all tags installed.

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'I CROUSE COMPANf INC.

Lii' ield, Penouyttanta, sone f

7

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i C.u. # 145 l""

ell:CTROMATIC. RELIEF VALVE (RC-RV 2)

TEST PROCEDURE l

1

_I.

PRECAUTIO:iS:

A.

Proper ventilation should be used to keep testing area reasonably free of nitrogen build-up.

B.

Special effort should be made to keep valve as clean as' possible, in order to minimize chances of contamination-f to seating surfaces.

ken "poppi g" valve under pressure, all personnel to I

C.

remain clear of valve discharge area.

If necessary, temporary deflectors (wood, sheet metal, etc.) will be installed for personnel protection.

II.

SPECIAL EC.UIPMENT:

A.

Temporary power supply to valve, switchable, with. switch located near test stand, but well clear of valve discharge.

(110 or 220 depending upon Unit I nilot valve (110) or Unit 2's being tested.)

B.

Test stand.

O.

Adaptor ring for test ' stand.

D.

2500 lb. n2 source (compressed gas bottles).

E.

3000 lb. test gauge.

UOTE:

CHECK CALIBRATION DATE.

F.

" Snoop" type leak detector.

III.

TESTING:

A.

Install valve on test etend.

Toroue to 355 ft./lbs. in 25 ft./lb. increments.

Adactor rin! may have to be used if the test stand has a " ton ue and groove" type flange.

l 3.

At 0 oci, electrically actuate valve to insure pilot valve is operational.

C, Cradually increase pressure to 2300 nsi.; checking periodi-cally for loaks by enolying "snoon" directly to the seat area.

Record any lonks on data sheet (attac5:ed).

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I

W

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.Page 2 D.

At 2300 psig, electrically actuate RC-R7 2.

Valve I

should lift.- There should be a loud, clean report.

J'

. Lift time and pressure to be recorded on data sheet.

~.

E.

Re-pressurize to 2300 psig and check for leaks.

Record on data sheet.

j-F.

Reduce pressure to O psig.

G,

' Remove RC-R7 2 from test stand and seal ocenings in preparation for transporting to pressurizer vessel.

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• T.

EICTRICAL COUTROL AND IUTERLOCF.

TEST PROCEDURE

. 1 I

PRESSURIZER ELECTRO:"ATIC RELIEF VV RC-RV2 t

INTROD'*0TIOH :

The followin; test procedure is to determine if the control and inter-1.

satisfactory lock srstem perforss as indicated by dw;. SS-209-034 Rev.

Derformance of. he system is based upon successful comoletion of the folicw-l t

1.ng tests and is indicated by the tester's initicls in passing colu=n.

Ite. s uhtch do not meet test requirements will be indicated by initial in fail column and will be resolved by established procedure as outlined in

.i Testing and Checking of. Mechanical and Electrical Equip =ent Manual.

1 FRERE 2UISITE:

All s:srt-up. checks, as outlined in " Testing and Checking of Mechanical i

and Electrical Equipment".

must be completed prior to performing the follcw-ing tests.

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