ML20136C718

Ofc of QA Surveillance Rept 74-253 Re Removal & Replacement of Valve RC-RV-2.Nonconformance Rept for 741030,741026 NDT rept,741026 Checklist,Weld History Record of RC-RV-2 & Work Request Encl

ML20136C718
Person / Time
Site:	Crane
Issue date:	11/22/1974
From:	Potts W METROPOLITAN EDISON CO.
To:
References
TM-0963, TM-963, NUDOCS 7910010542
Download: ML20136C718 (24)

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b" ~L / '7/gp7 OQA SURVEILLANCE REPORT NO.74-253 hyl & ?%a. 97 DEPARTMENT:

Crouse SYS. TEM: RC-RV-2 l

EVOLUTI.ON SURVEILLE0:

Removal & Replacement of RC-RV-2

REFERENCE:

(DWG., SPECIFICATION, PROCEDURE, WELD MAP, ETC.)

OBSERVATION: RC-RV-2 was removed from the system according to the approved, procedure with the exception of the rubber test pipe plugs specified in step 7.4.5. (See NCR 502).

Re-placement RC-RV-2 from Unit #2 was hydroed and tested on a test stand in the mechanical maintenance shop. These tests proved satisfactory. This valve was then moved into.the Reactor Building and placed on the deck near the equipment access door.

Valve RC-RV-2 was moved to the pressurizer area and mounted on RC-V-2.

Bolts were then installed and torqued to 200 f t/lbs. in 25 f t/lbs increments. RC-RV-2 was' subsequently removed due to the improper installaticn of valve RC-V-2.

Upon proper installation of RC-V-2 on the day shif t of 24 Oct.1974, RC-RV-2 was once again mounted atop RC-V-2.

RC-RV-2 inlet flange bolts were then torqued to 355 f t/lbs. in accordance with the W/R procedure.

Torque wrench due for cal.' 4/16/75. Outlet flange bolts were then torqued to 250 f t/lbs.

Differential on inlet flange perimeters =.007" Differential on outlet flange perimeters =.015" Witnessed Bench Test and Set Points" verified" prior to Installation of RC-RV2:

e Ine following personnel were present at the test:

1.

Mr. Pruitt, Dresser (Consolidated Safety Valve) 2.

Mr. Walter A Japack, The Hartford Steam Boiler - Inspection and Insurance Co. -

Code Inspector.

3.

Mr. Gil Stambaugh, Met-Ed Maintenance Foreman 4.

Mr. R. Neidig, Met-Ed Quality Control Assistant.

Equipment Used for Test:

1.

Pressure Vessel for Setting Pressurizer Safety Valves, Max. working pressure of 0

2500 P.S.I.; tiin. working temp. of 50 F; Max. working temp. of 6000F; Hydrostatically 0

tested at 3750 P.S.I.110 F; July 18,1974; Wall Thickness by UT: Min. 830. (See Attached Sheet Dist: Oriainal-File D.M.Shovlin QA Systems List desD No L.L.Lawver File 18.10.1 Conforming QC Spec / Asst.

Da R. M. Kl i naama n Nonconforming r s' './,'. / Ef [(N

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502 GPF 4012.001 Approved: /E f6 pd//v 4/30/74 Supervisor - QC Date Rev. 0 QC Form #29 Page 1 of 2

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Pressure Source, Nitrogen ' Bottle to 2250 P.S.I.

3.

Used Solenoid with 125 Volt D.C. Capacity (Solenoid energized at 2300 P.S.I.)

4.

Auxiliary Pump (Pump was stopped at the time the valve was lif ted - Manufacturers name; Engersol-Rand,100# Operational Air Pressure, Max. 30, 520 P.S.I.G. Dis-charge Pressure, Displacement for Stroke.1074 gal., 58 x 6 0. A. HP, Serial No.

21515 - No. C0P 7.

Sequence of Test Events:

1.

Torqued Flange Bolts to 245 ft/lbs.

2.

Filled Pressure Tank Vessel 4 full with water.

3.

Turned Nitrogen supply on (leading into Pressure Vessel).

4.

With the use of the auxiliary pump and thepressure vessel, pressure was boosted at the seat of the valve to 2300 P.S.I.

Mr. Pruitt noted there was a leak at the seat (also indicated on the gauge as it dropped slowly).

5.

The pressure was built up to its " pop" pressure of 2300 P.S.I. for RC-RV-2, 6.

The Solenoid was energized for approximately 2 seconds, which activated the pilot valve which activated the opening of the main valve.

7.

Af ter de-energizing the Solenoid, the main valve closed with the pressure dropping to approximately 1500 P.S.I.

8.

With the aid of the auxiliary pump the pressure was built up to 2250 P.S.I. or approximately 97% of the manufacturer's specifications required 93% for testing after being popped. Water was on top of the seat once again and the leak appeared negative. The gauge also held at 2250 P.S.I.

NOTE:

Mr. R. Pruitt (Dresser - Consolidated Safety Valve) informed G. Kunder an'd J. Colitz of his recommendation to manually " pop" RC-RV2 after its installation and when the pressure is built-up to a range between 500 to 1000 P.S.I. (Manually) to provide for the expansion of the ring (much like that of a piston ring) under high tempera-ture giving the ring a chance to properly re-seat itself.

10/24/74 1000-1200; 1400-1630:

Noted that RC-RV-2 had been mounted on RC-V2 on the previous shif t; however, the mating flanges did not have their bolts torqued, at this point. NOTE: They were torqued according to procedure two days later.

10/26/74 1000-1200 1400-1630:

Noted that RC-RV2 had been completely installed and all bolts appeared to be torqued.

(Torquing confirmed by the night QC representative.) However, it was also noted by the QC representative, that the upper seat drain line was loosely screwed into the body of RC-RV2.

Mr. Ned Bulmer was immediately notified. The loose threaded drain pipe was later welded to the valve body and accepted by Mr. L. Laime, Q.C. Specialist. The welding initials ar.d date of the welding were etched onto the pipe on 10/27/74 with the joint numbers to be etched at a later date.

Witnessed the installation of leakoff lines to valve RC-RV-2.

Leakoff lines were welded into place as per procedure. No discrepancies noted.

Welds were visually inspected and dye-penetrant tested to ensure welds are satisfactory.

Page 2 of 2 l

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WCogniz. Dept. Haad Receipt Inspection jX I File Originated by:

X Surveillance Report No.74-234 Item Name Electromatic Relief Valve P.O. No.

n/J B/M n/A location Reactor Buildlina Vendor N/A Dsg/Part No. & Rev.

N/A Dep t. __.}jec h. / Ma i n t.

System RC-RV-2 Procedure No.

W.R. 4650 i

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Description:==

RC-RV-2 was removed from the Reactor Coolant System without the open and closed rubber test pipe plugs installed in piping to and from the relief valve as specified in step 7.4.5 of the approved W/R procedure.

The downstream pipe fla'nge from RC-RV-2 is covered with two small strips of green tape. This affords no protection to the gasket sealing surface and minimal protection for cleanliness of the pipe internal.

Since this problea was not discovered until reinstallation of the relief valve, and the integrity of the tape was maintained, no effort was made to stop the job, Prepared by 8A:~4ae 23 Oc/ 79' Date Resolu tion:

Supervisor of Maintenance to inform Crouse personnel of importance of cleanliness maintenance on Nuclear Safety Related Systems.

Cog. Dept. llead 8/n /)/twd._ /d 7Y Date Supervisor - QC M6 M ~3d-N Date Closed:

GPF 4012.002 QC Spec / Asst.

4/30/74 Date Rev 0

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f Work Request Torm - Page 1 of 2 f

TMI Nuclear Station l

Work Request Approval Work Request ' o.

62'(7 I Unit No.

/

Priority /

f l

Note: Work Request Procedure;( A.P.1016 Sect. 6.0) should be used as a guide in filling out this form.

~

N b

Items 1 thru 5 completed by Originater 1,

System: /d : < &:-

Cc rt. d.,vC~

2.

Component: // C - t, - /

3.

Describe malfunction or mcdification and reco-mended corrective action.

A -48 h C-L - /

7

/

u.

Originator:4A,J h 6 Date : /O. /J'. 7v 5.

Orig.'s Dept. Head's Signature /rf>7 AG A Items 5 thru 12 completed by Supervisor of Maintenance or Designec 6.

Does work represen a change or modification to an existing system or component? Yes no g If item 6, is yes, the work must be approved via the change / modification procedure before work can be performed. Notify Technical Services Department for assistance.

(Eee A.P. 1016, Sect. 7.0) l-7.

Does work require a Radiation Work Pemit?

Yes /No l

If Item 7, is yes, the work must be performed using a PORC reviewed, i

Station Superintendent approved procedure.

[

8.

Is work on a Q.C. ecmponent? (See S.P. 55 Quality Assurance Systems List) Yes )( No If item 8, is yes, the work must be performed using a PORC reviewed, I

Station Superintendent approved procedure and the Quality Control Department must review the Work Request.

Quality Control Dept. [Yh d'/dC[7 v r g,1,,eering 9.

List suppert required from Station Technical Services Department or' Generation n

Department.

f3D f Yi:'

10 Estimated manhours to perform job:

E.

IC.

M.

b 11.

Maintenance Foreman Ansigned:

12.

Supervisor of Mainten.ince approval to commence werk:

Date 12A. GPU Snift Test Engineer Approval (during S/U only) 13.

Shift Foreman's approval to cemence work Date Tagging Application No.

Radiation Work Permit No.

8 14 Maintenance Foreman's comments on work performed :

Work completed - Maintenance Foreman's Signature 15.

Work ccmpleted and component aligned for testing. Shift Foreman's signature Date

16. Testing completed and component released for normal use.

Shift Foreman's signature Date L

17.

Quality Control Department review of work and testing completed (Q.C. Work only)

Q.C. Dept.

Date 1

18.

Supervisor of Maintenance: Work Request and procedure are complete and signed off as required. Change / Modification form has been signed-off as required. Machinery history t

}

entry has been nade, if required.

l Actual Manhours to perform job:

Supervisor of Maintenance Signature Date i

j

.L

y. 9 4

i,

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q1 Work Request Perm - Pa!;e 2 of 2 i

THI Nuclear Station Maintenance Procedure Format and Approval Unit No.

/

This form outlines the fcrmat and acts as a cover sheet for a maintenance procedure. Due to the limited size of the form additional pages may be attached as required. Work Request procedure A.P. 1016 Sect. 6 should be used as a guide in preparing the maintenance procedure.

1.

Procedure Title E. No. :

/?,r i31./(

ys, L.i r 2.

Purpose:

f)

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g

(,,

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3.

Description of system or component to be worked on.

• A

/??/tc7ts:

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/? c,. - tt'- )

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References:

,,,,, fg,s y ggn

,,,,,,. yy; f.,.y ye a r,cw g,a n;u w a.,..A: ow c 4

O d' FL.:67: y hic,,e - /J AWM fvC.

p,

'l'A

/J J' /61.> 3 - /?/ hows is sa

/ */.'d,7c,~ s ir y.s

./ siiv.., g t.

i 5.

Plant Status or Prerequisite Conditions required for performance of work.

I (Of /)

S J/u It3esa d h5 b '@ 5 d

d c%-

6.

Limits and Precautions: '

(a) Personnel

6. /

ccryptp w

• Fy' & fil.Sc~.7 /si.Trf trJ f'. /

(b) Equipment

1. ~ d"

1. # '# A7

1. ?A'

4'# I# # I/

1. /

• D

, /.,'q (c) Environment (d) Nuclear p s.u f p ; e n ;,,

c.s, n,y y i 7s,-

7.

Special Tools, Materials ana Qualifications requ r ec.

w-Q s !>2 7 go o / %

,PA We'ssv6

/ ) ! L. l.r/~*a SW/ svt1 s4.0 in A. so M. gy s

f'n a. </ s.i <-

m si ra 8.

Detailed Procedure (attaen additional pages as required) e. f~

.4 /7 A /.fi,0 9.

Post Maintenance Testing required and Accept.nce Criteria;

/ tie J c'A,Y.c Jsv M sc 0 /%'/:'s2 Tied A A ' C % %

GPU Test Superintendent approval of tes,t,,.4ipping)/U only)

Supe, p'r of Maintendnce recommends approvaldbM

.21_7,&r.Date/d/,'.hC//'

'/?/ ?)agM2 so}r 7Y

/)

/

.C i g ( M.

y O,

[C/i

) Date,.,s/,j h 6

/C airman

• P ecommend f

Q.-.h (8dd

Date b

<<7 7(/

• Station Superintendent / g. Superintendent Approval l

• Note: These approvals required only on Q.C. or Radiation Work Ferdit jcb d

• • Note: These sections are not required to be filled in prior to use for generic procedurec 4

,,66 which are prepared before their need arises.

'*hese two sections may be approved

?

prior to use by telephone call to the PORC Chairman and Superintendent / Assistant Superintendent.

i j

j TMid9 2 74 l

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.COTROLLcD Curt.1 mL

'7 i on 0 f

Work Request Porm I

g;9,y 13 THI Macicar Station Maintenance Procedure format and Approval i

I en!t No.,,,

1 o:- outlines the "orinat and acts as a cover sheet for a maintenance procedure.

Due to t

g,,, s Work P.cquest g3, ilmi:cd si:c of the form additional pages may ", attached as required.

i 6 should be used'as a guide in preparing the maintenance procedure

';.co:edurc A.P.1016 Sect.

h ecedure Title f. No. :

lul0-V 1.3 APD, REPACK C'. ADJUST VAINE PACKD:G 1.

i 2.

h:rpose :

To add packing, to repack or tighten packing gland on QC/Nucicar Safety Related Syst.

to oe worke.d on.

3.

Description or syster. or component All valves havind removabic packing.

• • 3.1 4

References:

Vendor Tochtanusi for applicable valvo.

4.1 AP 1002 P.ules for Protection of Men Working on Electrical & Hechanical Apparatus.

4.2 u.1 AP 1003 Rt:19e Pnr W.diation Protection.

~

~

Plan-Status or-i crcquisite Conditions required for performance of work.

5.

• • 5.1 Valve to be isolated.

o.

(a) Personnc1 Insure line is depressurized.

'(b) Equipment Oc not tighten valve to bottoming position, insure gland is not cocked..

(c) Environrent N/A (d) Nucicar N/A 6.1 AP 1002. AP *.003 to be followed.'

7 Spacial Tools, Ms:criais and QuaWica*.; ions required.

7.1 Packing puller 7.4 QC approved packing 7.2 Wrenches of appropriate size 7.5 Pocket F.ule 7.3 Knife D.

Detailed Frecedure (attaca additional pages as required)

I

!'.EE ATTACi!E"i DP.C P. DUP.E.

9.

Post l'.aintenance Icsti:.g required and Acceptance Criteria:

0.1 Valve packin; rejuced to an acceptab],e icvel of Icakage.

.9.2 Valve operates and cycles properly after adjustment / repacking.

jy (.7k Orh.

g GPU Test Superintendent approval of test (during C/U only)

E,

~

Superviser of Maintenance recommends approva' // b /hi/ r A..s Da,te ['- / -

C

'p:hnc - oY W 7!?

sPORC rece mends approval - Chairman

.4-.o ( r. t.e E.

Date A,/.2-

• Station Superintendent / Asst. Superintendent Approva

.I.

e.

Date,,

/

• Note: These approvals required only on Q.C. or Radiation 'Jork perm' t jobs.

i W

• • Note: These sections are not required to be filled in prior to use for gener!'c procedure which are prepared before their need arises. Thene two sections may be approved prior to use by tplephonc call to the POP.C Chairman and Superintendent /Assictant s

Superintendent.

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Revision 0 1410-V-13

.8/2/74 T){REE MILE IGLAND !!UCLC/.R STATIO!!

Unit (J1 Corrective !!alnten. nce Procedure 1410-V-13 l

l

' ADD, P11'ACK OR ADJUOT VALVE PACKIllG 1i 8.0 PROCEDURE '

]

.S.1' Tighten gland nuts until packing leak is reduced or stopp'ed.

~j 1

v 9

I G

The gland should be taken up evenly to avoid having the gland 3

i i'

cocked. Thls is done by tightening gland nuts alternately, il

. apprcximately 1/2 turn at a timo.

E.2 'After the leak is reduced or stopped, measure the distance 6

i from the valve bonnet to the top of the gland to insure the gland is straight.

8.3 Insure that during gland tf.ghtening the top of. the gland does i

{

not contact the bonnet.

8.4 If repacking is required or rings are to be added proceed I

i below.

I l

8.5 If a ring or several rings are to be added loosen packing gland and remove gland nuts. Slid.c gland out of way, s.

o 8.6 Cut packing rings to fit system. If ribbon pack is desired, S'

F wrap ribbon pack around stem and tighten gland. Remove gicnd and add additional ribbon pack, if necessary. Place desired

~

s.

rings (if not using ribbon pack) in stuffing box and seat gland i

b(

a I

on top of ring to force top ring to contact next ring down.

8.7 Tighten gland evenly to got desired leakoff.

h]'

CAUTION: Alternately tighton gland nuts in small increments so that gland does not cock and packing does not e

bind stem.

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8.8 If repack is required, loosen gland and remove gland nuts,

^

t Slide packing out' of way.

8.9 Remove old packing using packing puller.

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8.10 Cut new packing rings to fit stem and stuffing box.

u

- t 8.11 If packing is to be ribbon pack, wrap stem as tight as possible I

L

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-to fit stuffing box. After each ring of ribbon pack draw I

down packing gland. Continue to' add packing until gland I's in position to be tightcr;cd periodically as leakoff develops.

8.12 If packing rings are to b. used, put new rings in stuffing box and put gland in hand tight for each ring to be added.

- i (Stagger butt ends 900) t l

8.13 Adjust gic.nd to obtain desired leakoff and free stem r

~

movement.

j 8.14 CAUTIO!I: insure gland is taken up evenly by adjusting each gland nut in alternately small increments to

. prevent binding of the packing on stem, and to prevent 4

gland cocking.

Heasure distance from bonnet to lip of gland to f

insure gland is in straight.

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4E' D copy, nety-en;===a=

>=== end ^27=o>et T"I Nu:ler G:ction R

l<U; This !:.--. outlines the fortat and acts u a cov er.@.ee t for a maint2nr.cc procedure. Due to che..i:11;W. site of th! forp additicna. pages. sy be attached as required, Nork ?.equ est

-n ro: :^..r 4 A.?. 1015 $ect. S should be used as a guid2 In prep.irinf, the naintenance procedeb

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.e:!ure Title 4. No. :

lul3 V-10 D IS A33I:13LS. IiiS? ECT. C LE.\\S, P.I?AI?.'~.\\.0 iYi".t3L6

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2.[ To provida for tk.e disassembly, inspection, :13aning.:nd reassembly of all :; ate 4

und globe valvss.

l l

3.

.;escriptier. of sys*;em or compone:n; to be werkad on.

• i' 3.1 Any valve.

,.. F.cfsessees:

I 4.1 Manufa::urers instruction canual.

1, 4

i. F.c. : 5:::.ts or Prerequisite Conditions requred for performance of won, 1.*

Operating or Ohut dom.

% uw;s anc trecaunona:

(c) ?srconnel Applicable portion of system is isolated and depressurl:ed and p operly (a) Iquipmen:

None %g-ed. Obtain ?adiation ',ierk ?cmi-if app *.icablo.

,, c ) Invu.o rr. ant Mone s

(d) Muclea.r ?;one 7.

3pe::.el Isous, da er als anc Qua.t.;.ficat:.ons requeec.

'/.1 Appropria e hand tools.

S.

L.e:cilec Procecurs (attach additional pages as required) 3.-.

1. 5. Am,.r.".) P.w~e,.r.s~uw.

S.

ios: Maintenance Testing required and Accep;ance Criteria:

9.1 '/alve holds system pressure, does not leak and operates properly.

G?U Test Superintendent approval of test (during S/U only)'

Supervisor of Maintenancyegds approval

./jdl d d.t M-Date.f: 2v

^ ^ =

.] f*g;./, i,w W '/ +{ W a.~

5-N c,---- -

Q. Q_ (Qf De:e

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^?C?.C recc:. mends approval - Chairman

, i,viu Station Superintendent / Asst. Superintendent Approval, '

Dat e -C- ?

4;o 2 : These appro/nis required only en Q.C. or Radiation ',lork Pemit jobs.

1. s:To : i : Tiene sec lons are not required to be filled in prior to use for generic precedure which are prepred before their need arices. Thesa :so sections may be approved prior to use by relephone call to the Po?0 Chairman ard Superintenden:/ Assist:nt M.perint:ndent.

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Th'9.SE HILO ISLAND NUCLEA2 STATICM Unit li 1 Corrective Maintenance Procedure 1410-V-10 DISASSEMS*.E, INSPECT, CLEAM, P.EPAIR AND ASSEM3LE CATE E GLOVE VAL'/ES t

?

a.0 PROCEDURE B.1 Tag out appropriate valves to isolate valve to be opened.

8.2 Depress'.c iza and drain isolated section of line.

CAUTION: Shift Supervisor should be consulted prior to draining isolated section of line. Liquid may be radioactive, cor.tain hi

~

boron concentration, etc.

8.3

'Loosan and remove bonnet fasteners.

8.'4 Remove bonnet.

8.5 Inspect the valve parto fer wear, gauling, cracks, pitting, etc.

e and repair as necessary.

8.6

' Clean all parts with an approved colvent.

Use prussian blue to verify that saat and disc are nating properly.

C.7 8.8 Lap saat and disc as necessary to get proper seating, verify as in 8.7 above.

8.9 Reassemble valve and torqua fasteners using the torque values l

for the size fastene-s tised. See pttached chcrt. [ 8 8 ((f 7k rf u/ in 23f1f/& L ~ A e 8.10 Operate valve through one full cycle (open/close,s to insure proper operation.

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8.11 Adjust packing gland as required.

8.12 Remove tags, ret'.trn cystem to nermal and verify valve tightness.

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Data (0s Use with Machine Colts 3nd Cold "tolleJ Steel Stud 00lts h,F

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Lo'ad in po f on Bolts and Stud Boitshhan Torrtue toerls Ary Led e

STid.,

NU. 3ER

• Of AMETER xHEA l

,.ilN AL Y

OF ATHOOT AT ROOT f 7.500 PSI i

15.000 PSI l

30.000 PSI THREADS lOF THREAD.0F THHE AC AAMETER Torque l Compres. ! Tor ova Cornpre e j Torque Corn pre e l 01 EOLT 5

l (Sq.Inchll! F f. Lbs. l sion. Lbs. I F t. Lbs.

sion. Lbs. I F t. LM.

., ion. Les.

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203 2

435 4

ata j.

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675 8

1350 3/3 16

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510 6

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698 10 1395 20 2700

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1/2 13 400 12S 8

945 15 1390

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3/4 10

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h 7/3 9

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8

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16530 11/3 7

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11/4 7

1.064

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137 6875 273 13350 545 257c0 13/3 6

1.153 1.054 183 7905 365 15310 730 31F20 11/2 6

1.233 1.294 219 9705 437 19410 875 33320 h

15!3 51/2 1.339 1.515 300 113G3 600 22725 1200 45453 1 3/4

.5 1.490 1.744 300

.13080 775 26160 1550 52320 1 713 5

1.S15 2.043 525 15353 1050 30735 2l00 61470 2

41/2 1.711 2.300 563 17250 1125

"'4500 2250 63000 i

~ Dat3 for Use with~ Alloy Stul Stud Bolts Land lre Pounds on Stud Bolts when Torque Loads Ars Applied STRESS NOMINAL l NUMSER ' OIAMETER AREA Olt.*.!ETIR OF AT ROOT AT ROOT 20.000 PSI I

45.000 PSI

\\

60.000 PSI l Comptes.. Torc;u.e Compew I.

OPSTUD THREAOS O F,THR EAD OF THREAC Torqua Compres. j Tornua.

l F t.1.bs.

sion. Lbs l tinem es)

(Par trich)

(Inches)

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sion. Lbs. I F t. l.bs.

e sion. Lbs. I l

1/4 20 135 027.-

4 210 6 [

1215 8

1620 l

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3/3 16

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1.088

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1000 55740 J;

13!3 3

1.213 1.155 630 3'650 1020 51975 1350 69300 1 1/2 8

1.333 1.405 800 42150 '

1200 6"l225 1600 84300 1 5/6 8

1.463 1.680 1100 50400 1650 75s00 2200 100300 1 3/4 8'

1.583 1.980 1500 594CO 2250 20100 3000.

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2.588 5.259 5920 157773 8880 235555 11640 '

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