ML20198K506

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Rev 1 to Startup Administrative Procedure CP-SAP-24, Sys Cleanliness Requirements & Control
ML20198K506
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 08/10/1983
From: Camp R
TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
To:
Shared Package
ML20197J316 List: ... further results
References
FOIA-85-59 CP-SAP-24, NUDOCS 8606040042
Download: ML20198K506 (18)
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A CPSES STARTUP ADMINISTRATIVE, PROCEDURE CP-SAP-24 SYSTEM CLEANLINESS REQUIREMENTS AND CONTROL Revision:

1 EOR INFO Prepared By:

R. E. Camp g

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i Reviewed by:

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  • tar up Engineer Reviewed By:

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TUGCO'Q4 Startup/ Turnover Surveillance Supervisor Reviewed By:

Title:

Reviewed By:

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Title:

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Approved By:

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Date::

Ma geF, CPSE Startu t

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Effective Date [' b-

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8606040042 860527 1 PDR FOIA GARDE 85-59 PDR g.3 47

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CP-SAP-24 Ravision 1 Page 2 of 18 C

TABLE OF CONTENTS SECTION TITLE PACE COVER SHEET 1

TABLE OF CONTENTS 2

1.0 PURPOSE 3

2.0 APPLICABILITY 3

3.0 DEFINITIONS 3

4.0 PROCEDURE 3

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5.0 REFERENCES

4 5

6.0 ATTACHMENTS 5

EOR INFO l ONLY i

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CP-SAP-24 Rsvisien 1 Page 3 of 18 SYSTEM CLEANLINESS REQUIREMENTS AND CONTROL

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1.0 PURPOSE The purpose of this procedure is to define cleanliness classifications, specify system cleanliness requirements, and to define responsibilities for maintaining the required cleanliness levels during maintenance, modification and/or rework activities.

2.0 APPLICABILITY l

The requirements of this procedure apply only to the interior surfaces The of piping systems and components that contact the process medium.

cleanliness classifications specified for plant systems contained herein shall be used as acceptance criteria for initial cleanliness verification and for establishing the required cleanliness level when s

work activities are performed after the required cleanliness level has been verified in accordance with Prerequisite Test Instruction XCP-ME-4.

' FOR INFu 3.0 DEFINITIONS ONLy A state of being clean in acc0 2__

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3.1 Cleanliness -

predetermined standards, usually implying freedom from dirt, scale, heavy rust, oil and other l

centaminating impurities.

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3.2 Cleanliness Control - The control of the internal environment of systems and equipment to maintain a l

predefined state of cleanliness.

3.3 Contaminates -

Any undesirable foreign material on the surface

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of a item, in the atmosphere, or held in process gases or liquids.

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3.4 Cleaning -

The removal of any contaminatas that might have a deleterious effect on plant safety and reliable i

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. operation.

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l 3.5 Flushing -

Flowing fluid through a component or system at adequate velocity to suspend and carry away l

anticipated contaminants.

i 4.0 PROCEDURE l.

4.1 Attachment A defines cleanliness classifications and associated acceptance criteria for visual and flushing methods of verifying acceptability.

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CP-SAP-24 Rsvision 1 Page 4 of 18 Attachment B specifies the applicable cleanliness classificatica

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4.2 for plant systems and the flushing medium to be used when flushing is selected as the method of cleaning or cleanliness verification.

4.3 Attachment C describes the requirements for media used for, flushing and cleaning activities.

4.4 Prior to authorizing work on components that have been verified to meet the cleanliness criteria of this procedure, the STE shall ensure that applicable work control procedures and/or documents specify methods required to be implemented to maintain and/or obtain final cleanliness levels specified by this procedure.

1 Notes (1)

Where appropriate, the STE should s

specify visual cleanliness exam-ination hold points on the work FORINFOl

' ^l documents.

(i.e., Travelers, SWA, ONI y SWP etc.).

(2)

Attachment D provides guidelines that should be followed and describes activities that should be performed

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prior to (prerequisite), during (in progress) and af ter (final) perf arn-ing the work activity in order tc, maintain the required cleanliness level.

4.5 The o ganization that performs the work shall be responsible for f

making provisions and performing inspections as required to ensure that a high degrea of cleanliness is maintained during the work activity.

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4.6 The STE is responsibile for verifying final cleanliness by visual examination and/or flushing as described in this procedure. This l

verification shall be documented on the applicable work control document (i.e., SWA, SWP, etc.).

A cleanliness plan (flush plan),

as described by XCP-ME-4, shall b.s used for flushing and/or j

solvent cleaning activities. A flush plan will not be required j

for hand wiping and/or visual examinations.

5.0 REFERENCES

5.1 CP-SAP-6, Control of Work On Station Components After Release From Construction to TUCCO 5.2 XCP-ME-4, System Cleanliness Verification k

5.3 ANSI N45.2.1-1973 s

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CP-SAP-24 Ravision 1 Page 5 of 18 5.4 TBX/TCX-SU-1.2.1

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5.5 Westinghouse Process Specification 292722 R7 5.6 2323-MS-100, Piping Erection Specification 5.7 Gibbs & Hill Inc., Letter GTN-33497 I

5.8 Fire Protection Code - 1979 5.9 ACPSI Turbine Generator Technical Manual 5.10 ACPSI Memo ACT-737 dated June 28, 1977;

Subject:

Lube Oil Flush Criteria 5.11 TNO-82682 3

5.12 TNO-82495

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6.0 ATTACHMENTS FOR gygg r

A - Cleanliness Classifications and Acceptance Criteriaj__ ONI.y B - System Cleanliness / Flushing Medium Requirements C. Flushing / Cleaning Medium Criteria D - Guidelines for Maintaining Required Cleanliness Level 1

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CP-SAP-24 R visicn 1 Page 6 of 18

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ATTACHMENT A Cleanliness Classifications and Acceptance Criteria A.

CLEANLINESS LEVEL A 1

A very high level of cleanliness in which there is no evidence of contamination of a surface either under visual examination, with or without magnification, or with the aid of sensitive detection methods.

Class A cleanliness applies to special items such as fuel elements, control rod drive mechanisms, delicate instruments, and other close j

tolerances or carefully controlled surfaces or assemblies. Such items should receive their required level of cleanliness at the point of manufacture. For these reasons, requirements of this level of cleanliness are considered to be outside of the scope of chia document.

FOR INFO B.

CLEANLINESS LEVEL B ONLY A high 1evel of cleanliness applicable to reactor coolant systems, E_

components and other items, such as the reactor coolant purification system, which have similar cleanliness requirements. Piping and components in systems which are designed as requiring Level B Cleanliness shall meet the following requirements:

B.1 Visual Examination a.

The surface should appear " metal clean" when examined without magnification under a lighting level (background plus supplementary lighting) of at least 100 foot candles.

(Equivalent l

to that of regular office lighting). Scattered areas of tightly t

adherent rust are permissible provided the aggregate area of the i

rust does not exceed two square inches in any one square foot area.

b.

The surface shall be free of particulate contaminants such as lj; sand, metal chips, weld slag, weld spatter, etc.

f c.

The surface shall be free of organic films and contaminants such as oils, paint and preservatives as determined by a visual examination or an organic solvent-dampened white cloth

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1 or an equivalent alternate method.

d.

When a visual examination is not posslble and the surfaces are accessible, a dry white-cloth wipe, followed by a solvent dampened white-cloth wipe, may be used to evaluate the cleanliness of the surface'.

If either cloth exhibits indications of contamination, the system shall either be recleaned or the specific contaminant shall be determined and evaluated as to its potential deleterious effect.

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CP-SAP-24 Ravision 1

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Page 7 of 18 1

ATTACHMENT A (Cont'd)

B.2 Flushing a.

If flushing is the only practical means for determining system cleanliness, the system shall be evaluated by examining a 20-mesh or finer screen, " Nainsook" sample cloth or equivalent, installed on the outlet of the cleaning i

circuit or at specified aample locations. The system shall be flushed at a flowrate that is equal to or greater than the design flowrate, not to. exceed equipment limitations, until the sample cloth / screen shows no more than slight particle speckling and no more than slight rust staining. There shall be no particles larger than 1/32 inch in any dimension, except fine hairline slivers of less than 1/32 inch thickness are permissible up to 1/16 inch long. There shall be no 3

evidence of organic contamination in the efflueuw -_;;r -- an the sample cloth / screen.

EOR INFO OffLY b."

Effluent flush water shall meet the chemistry a

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criteria as follows:

ChlorideIon,maximumppmasCl[

0.15 Flouride ion, maximum ppm as F1 0.15 Conductivity, maximum micromhos/cm 5.00 l

Silica, maximum ppm as SiO 0.10 2

pH range 6.0 - 8.0 Visual Clarity No visual turbidity oil or a

sediment.

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Note t.

Where water has been subjected to CO absorption, the effluent 2

flush water pH acceptance criteria 1

can be relaxed to fall between 5.8 and 8.0.

The PH. requirement may be lowered even.further to 5.5 provided the conductivity of the source of flush water (i.e. storage tank) does not exceed 1.0 micromho/cm.

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CF-SAP-24 Rsvision 1 Page 8 of 18 ATTACHMENT A (Cont'd)

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If.the' flush water has been chemically treated, the ef fluent c.

flush water shall meet the applicable Chemistry acceptance criteria as follows:

After After boric lithium addition acid addition i

Chloride Ion, maximum ppm as Cl 0.15 ppm 0.15 ppm i

Fluoride Ion, maximum ppm as FL 0.15 ppm 0.15 ppm

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Conductivity, maximum micromhos/cm Less than 15 Determined by umho/cm boric acid and alkli g

concentration Silica maximum ppm as SiO 0.2 ppm 0.2 ppm 2

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1.0 to 2.2 ppm 1.0 to 2.2 ppm r

Lithium 7.0 to 10.5 4.2 to 10.5 l

pH Range

-- Boric acid, ppm as B N/A Variable from O to 4000 ppm

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Suspended solids 1.0 ppm 1.^ ppm FOR INFO ONLY

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CLEANLINESS LEVEL C An intermediate level of cleanliness generally applicable to closed service water systems that cool components containing reactor coolant, engineered safety systems and other high integrity systems.

C.1 Visual Examination I

Surfaces shall meet the requirements for Level B cleanliness, t

except as follows:

Thin uniform rust films are acceptable on carbon steel a.

surfaces.

t Scattered areas of tightly adherent rust are permissible b.

provided that the area of rust does not exceed 15 square l

inches in any one square foot on corrosion resistant alloys.

For Diesel Oil systems designated for Cleanliness Level C.

c.

visual examination requirements specified by Cleanliness Level B paragraph c.

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CP-SAP-24 R2 vision 1 Page 9 of 18 ATTACHMENT A (Cont'd)

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C.2 Flushing - (for systems other than Turbine Generator Control Fluid, Lube Oil, Seal Oil and Lube Oil purification)

Flush samples shall meet the requirement for Level B cleanliness, except as follows:

1 Sample cloths / screens may exhibit considerable rust staining.

a.

b.

Effluent flush water shall meet the chemistry acceptance criteria as follows:

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Chloride ion, maximum ppm as C1_

1.00 Flouride ion, maximum ppm as F1 0.15 Conductivity, maximum micromhos/cm -

50.0 Silica, maximum ppm as SiO 0.10 2

pH range 6.0 - 8.0 Visual Clarity No visual turbidity, oil g,

or water b

'I Note Where water has been subjected FOR INFdi to CO absorption, the effluent ONLY

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flush water pH acceptance criteria 2

can be relaxed to fall between 5.8 and 8.0.

The pH requirement can be lowered further to 5.5. provided j'

the conductivity of the source of I'

flush water (i.e. storage tank) i does not exceed 1.0 micromho/cm.

c.

If the flush water has been chemically treated, the effluent flush water shall meet the chemistry acceptance criteria as' follows:

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Chloride Ion, maximum ppm as Cl 1.0 ppm

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Fluoride Ion, maximum ppm as Fl 0.15 ppm

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Conductivity, maximum micromhos/cm 50.0 Silica, maximum ppm as SiO 0*l0 2

pH 6.0 to 10.5 Hydrazine maximum 150.0 ppm Ammonia As pH requires L

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CP-SAP-24 Ravision 1 Page 10 of 18 ATTACHMENT A (Cont'd)

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d.

When impingement targets are used for steam blows, the target shall show no more than one particle per 2500 pounds of steam There shall be no sampled as a result of particulate impingement.

The pits due to particles larger than 1/32 by 1/16 inch long.

target surface shall be examined without magnification under a j

lighting level of at least 100 foot candles.

(Equivalent to the lighting level found in a normally lighted office). This examination will be assisted by back lighting the target area with i

a hand held flashlight to provide particle high-lighting per

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normal industry practice.

i C.3 Flushing - (Applicable to Turbine Control Fluid System)

Two 100 milliliter samples will be obtained at the supply s.

Both line and analyzed for the following micron ranges.

samples shall meet the SAE criteria and at least one sample shall meet the ACPSI criteria as follows:

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Paricle Size SAE-Acceptable ACPSI-Acceptable r

i (Micron)

Number of Particles Number of Particles 5 - 10 24,000 24,000 10 - 25 5,360 5,360

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FOR INFO i

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25 - 50 780 780 50 - 100 110 110 ONLY

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100 - 250 11 0

Drain line filter strainer must not catch any particle larger b.

than.004", tank screen must be clean.

C.4 Flushing _ - (Applicable to Turbine Generator Lube Oil, Lube Oil Purification and Seal Oil System)

Two 100 milliliter samples will be obtained at the supply a.

Both line and analyzed for the following micron ranges.

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samples shall meet the SAE criteria and at least one sample shall meet the ACPSI criteria as follows:

Paricle Size SAE-Acceptable ACPSI-Acceptable (Micron)

Number of Particles Number of Particles 5 - 10 32,000 32,000 10 - 25 10,700 10,700 25 - 50 1510 1510 50 - 100 225 225 100 - 250 21 0

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CP-SAP-24 Rsvision 1 t

Page 11-of 18 ATTACHMENT A (Cont'd)

D.

CLEANLINESS LEVEL D The level of cleanliness applicable to fire protection, open service I

f water and simiJar systems requiring only a nominal degree of The following are acceptable on items which meet Level D cleanliness.

l cleanliness.

D.1 Visual Examination Tightly adherent mill scale on carbon steel surfaces.

a.

Paint or preservative coatings on carbon steel surfaces that b.

will not peel or flake when exposed to cold water flushing.

I Rust films on carbon steel and stainless steel surfaces that~

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resist removal by scrubbing with a bristle brush' 3R INF0 ONLY

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D.2 Flushing l

Applicable for closed loop water flushes only (i.e., turbine l

plant cooling water) - if flushing is the only practical l

a.

j means of determining system cleanliness, the system shall be l

evaluated by examining a 14-mesh or finer screen, cloth, or installed on the outlet of the cleaning circuit equivalent, or at the specified sample locations. The system shall be flushed at a flowrate that is equal to or greater than the design flowrate, not to exceed equipment limitations, until the sample cloth / screen shows not more than occasional There shall be no particles larger than particle speckling.

1/16 inch in any dimension, except hairlike slivers of less chan 1/16 inch thickness are permissible up to 1/8 inch long.

i There shall be no evidence of organic contamination on sample screens or flush cloths. Considerable rust is acceptable.

  • i If flushing is the only practical means of determining system l

b.

.I cleanliness of open water systems, (fire protection, service water), the system shall be evaluated by examining effluent or sample water for visual clarity at a flowrate that is equal to or greater than the design flowrate, not to exceed equipment limitations.

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CP-SAP-24 R: vision 1 Page 12 of 18

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ATTACHMENT B SYSTEM CLEANLINESS REQUIREMENTS Cleanliness Flushing i

System Classification Medium l

Auxiliary Feedwater C

B j

Auxiliary Steam C

B/ Steam Boron Recycle B

A Chemical Feed FOR INFO C

B ONLY Chemical and Volume Control B

A d

Chilled Water C

B 1

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Circulating Water D (Note 2)

D E

Component Cooling Water C

B Condensate C

B Condensate Polishing C

B i

Condenser Vacuum and Water Box Priming Pump C

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Vacuum D (Note 2)

D Containment Spray B

A/ Gas Demineralized and Reactor Make-up Water B

A j

Diesel Generator Fuel Oil System C

011 Diesel Generator Starting Air C

Air (Note 3)

Diesel Generator Intake and Crankcase Air C

Air (Note 3)

Diesel Generator Jacket Water C

B Diesel Generator Lube Oil C

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Extraction Steam C

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i Fire Protection D (Note 2)

D i

i Gaseous Waste Processing C

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Caseous Gas Supply C

Cas Cenerator Primary Water Supply B

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I Cenerator Seal Oil Supply C

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CP-SAP-24 R2 vision 1 Page 13 of 18 l

1 ATTACHMENT B (Cont'd)

Cleanliness Flushing System Classification Medium FORincu i

Heater Drains C

B ONLY I.

Instrument Air B

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Liquid Waste Processing - Reactor Coolant Drain Tank B

A 1

j Liquid Waste Processing - Drain Channel A -

I to evaporator D

B I

Drain Channel A -

from evaporator C

B g

Liquid Waste Processing - Drain Channel B -

to evaporator D

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b Drain Channel B -

l from evaporator C

B Liquid Waste Processing - Drain Channel C -

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to evaporator D

B Drain Channel C -

4 from evaporator C

B t

f Liquid Waste Processing - Evaporator Bottom l

and Spent Resin Lines D

B Main Steam Hot & Cold Reheat C

N/A Main Steam Reheat & Steam Dump C

B

'i Process Sampling - CVCS VCT Sample B

Cas

- Steam Generator Blowdown Sample C

B

- Primary Samples B

A

- Spent Fuel Pool Cooling System Samples C

B i

- Equipment Drains D

B Plant Cas - CO C

Cas 2

Plant Cas - H B

Cas 2

Plant Cas - N B

Cas i

2 h-Plant Cas - 0 B

Gas 7

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CP-SAP-24 Revisica 1 Page 14 of 18 ATTACHMENT B (Cont'd)

Cleanliness Flushing System Classification Medium Reactor Coolant B

A 4

Residual Heat Removal B

A 1

f Safety Injection B

A FOR INFO Secondary Sampling C

ONLY B

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Service Air C

Air (Note 3)

j Spent Fuel Pool Cooling & Cleanup C

B i

Station Service Water D (Note 2)

D Steam Generator Blowdown Cleanup C

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Steam Generator Feedwater C

EOR INFO B

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Turbine / Generator Lube Oil C

L Oil Turbine Control Fluid C

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Turbine Gland Steam System C

B/ Steam Turbine Oil Purification C

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Turbine Plant Cooling Water C

B I

i Vents & Drains t

a.

Containment Safeguards Auxiliary & Fuel Building D (Note 2)

D' b.

Turbine Building Floor Drains D (Note 2)

D c.

All drains to Atmospheric Drain Tank and Main and Auxiliary Condenser C

B Water Treatment Systems (@ effluent to DWST)

B A

Equipment Oil Systems Note 1 Note i i

Notes:

(1) If cleaning is required, the cleanliness level shall be established based on

,i applicable guidelines provided by the vendor and oil used as the flushing medium.

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(2) Particulate sample not required j

(3) Air supplied by sys*em compressor t

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's CP-SAP-24 R vision 1 Page 15 of 18 ATTACHMENT C FLUSHING / CLEANING MEDIUM CRITERIA Water GRADE l

A B

C D

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j Chloride ion, maximum ppm as C1 0.15 1.0 Flouride maximum ppm as F1 0.15 0.15 Conductivity, maximum micromhos/cm 2.0 20.

Silica, maximum ppm as SiO

.05 0.10 2

Total solids ppm maximum 0.5 pH range 6.0-8.0 6.0-8.0 -

Visual clarity No turbidity, oil or sediment.

(For A, B & C water)

FOR INFO Notes ONLY a

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(1) Demineralized water normally meets the j

,l requirements for Grade A water. Where water has been subjected to possible CO 2

absorption, such as when retained in

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storage tanks, the pH requirement may be lowered to 5.8 to compensate for CO, pickup.

The pH requirement may be lowered even further to 5.5 with the following restriction:

a.

The water in the storage tank from which flush water is drawn shall not exceed a maximum conductivity of 1 micrombos/cm.

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-l (2) Power plant condensate meets the requirements for Grade B water.

1 (3) Crade C vater is fresh water as obtained from plant potable water system.

i (4) Grade D is Squaw Creek reservoir water.

(5) Where source water for flushing (i.e.,

refueling water storage tank, condensate storage tank) has been treated for Chemistry Control, the flush water criteria for pH and conductivity can be relaxed to that established by TUCCO Chemistry for the

' j particular tank (source water).

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CP-SAP-24 i

Rsvision 1 Page 16 of 18

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ATTACHMENT C (Cont't)

FLUSHING / CLEANING MEDIUM CRITERIA OIL l

Oil flushes will use the type of oil specified by vendor's instructions or a l

TUCCO approved equivalent.

i AIR /CAS t

j When gas is specified as the flushing fluid in Attachment B, it shall be clean, dry, filtered air or gas, free of oil vapor and droplets. Air or gas shall be filtered through filters rated at 10 micron removal capacity beforc i

use for flushing. Plant instrument air shall be generally used for this purpose. Air systems (i.e., service air) shall use air as supplied by the 3

system compressor for the flushing medium.

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-l When steam is specified as the flushing fluid, it shall be as obtained from E

3 the plant auxiliary boiler.

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APPROVED SOLVENTS

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Acetone - New or redistilled Technical grade FOR INFO ONLY Alcohol - Isopropyl, Technical grade Distilled Petroleum Spirits - Stoddards solvent, Varsol i'

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CP-SAP-24 Rsvision 1 Page 17 of 18

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ATTACHMENT D Guidelines for Maintaining Required Cleanliness Level

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Prerequisite Cleanliness j

1.

Housekeeping - Cleanup of the area surrounding the work activity will j

reduce the possibility of introducing foreign matter into an open system or component.

2.

Containments - Use of containments built about the system opening or the immediate work area will reduce the possibility of introducing foreign matter into an open system or components. Containments will also reduce the area surrounding the work activity to be cleanliness controlled.

-t 3.

Dams / Plugs - Plugs, caps, covers, dams or other suitable closure devices should be utilized to prevent the introduction of foreign matter into open pipes, vessels, tanks or duct during work activities.

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g This is'particularly important where foreign material entering an open j

system will be difficult to retrieve. Use of these devices will also r

reduce the area to be cleaned during in-progress or post-work clean-up.

When internal closure devices such as pipe plugs are used, they should be installed as soon as the system is opened and remain in place throughout the work activity. When external closure devices such as

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covers are used they should remain in place at all times except when i

access to internals is required.

4.

Special Requirements - Additional prerequisite cleanliness rgr$Qs may include:

ONLY Specification of cleaning materials to be available prior to the a.

initiation of work.

b.

Prohibition of certain materials, tools, solvents, etc., which may degrade system cleanliness, damage system materials or be exceptionally difficult to remove upon completion of work.

f c.

The removal or covering of certain materials (such as pipe insulation) within a selected distance of the system opening to

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reduce the possibility of introducing foreign matter into the system interior.

In-Progress Cleaning In-progress cleaning methods are similar to those utilized for final cleaning (e.g., vacuuming, wiping, brushing, solvent cleaning, etc.) except that final cleanliness requirements need not be met.

The work area should be kept c. lean and free of accumulations of foreign matter which could be

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introduced into the open system interior. Where the work location is such ll M

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CP-SAP-24 Rcvision 1 Pego 18 cf 18

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ATTACHMENT D (Cont'd) h that foreign matter will be extremely difficult to remove from system interiors, periodic cleaning of the exposed interior surfaces should be conducted. When in-progress cleaning is specified at critical points of a work activity, hold points or inspections should be specified prior to continuing the work.

I Final Cleaning Final cleaning methods include:

1.

Mechanical cleaning by grinding, brushing, vacuuming or similar methods I

to remove debris, foreign matter, loose soil, unacceptable rust, weld splatter or slag, etc. Material compatibility requirements (e.g.,

8 grinding and brushing tools used on nonstainless steel materials shall be used on stainless steel) shall be observed.

Exhaust from vacuum cleaners shall be directed away from the work area.

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2.

Hand ' cleaning by brushing or wiping. Stiff bristle, nonshredding brushes shall be used. Wiping shall be done after all loose surface contamination has been removed. Clean, lint-free cloths shall be used.

Wiping cloths should be changed frequently to avoid redeposit of contaminants. Cloths saturated with an approved solvent may be used lh for degreasing. Surfaces shall be thoroughly dried after sul.ma --

cleaning.

FOR INFO ONLY 3.

Flushing may be utilized for cleaning or for proof of clear----

work.

In general, however, flushing should be avoided as a cleaning method unless it can be restricted to the work area since flushing may sweep contaminants into undisturbed portions of the system. Use of flushing vill also result in having to verify that the entire flushed portion of the system has reached the desired final cleanliness level rather than just the portion of the system which was affected by the l;

work activity.

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