ML20136H237

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Rev 6 to Maint Procedure MP 1401.19, Hydrostatic Testing of ASME Section III Class 1,2,3 & ANSI B31.1 Sys & Components
ML20136H237
Person / Time
Site: Davis Besse Cleveland Electric icon.png
Issue date: 10/17/1984
From: Briden D, Daft C, Quennoz S
TOLEDO EDISON CO.
To:
Shared Package
ML20136H086 List:
References
MP-1401.19, NUDOCS 8601090318
Download: ML20136H237 (15)


Text

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MP 1401.19 0.*vic-0 sae Nucicar Pcwer Section Jnit No. 1 Maintenance Procedure MP 1401.19

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Hydrostatic Testing of ASME Section III Class 1, 2, 3 and ANSI B31.1 Systems & Components "I Q !

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1. PURPOSE 1.1 The purpose of this procedure is to establish the requirements for pneumatic and hydrostatic testing of piping and equipment per ASME (Section III) and ANSI Codes.

1.1.1 In-service hydrostatic testing (per ASME Section XI Codes) is covered under MP 1401.27 and will be used only when this procedure is not practical.

j 1.2 This procedure shall be followed for hydrostatic and pneumatic testing of. piping and equipment. The test pressures shall be 4 those given in " Piping Class Summary Sheets 12501-M-602".

l 1.2.1 The hydrostatic or penumatic tests also apply to welded attachments such as insulation saddles, hanger lugs, supports, etc. Welded attachments are attachments that are welded directly to the pipe. Hydro test

would be required if a pad is welded to the pipe but would not be required if welding a piece to a pad which had already been welded to the pipe.

1.3 Definitions 1.3.1 Hydrostatic Test - Pressurizing piping and equipment with water to demonstrate pressure boundary strength and integrity.

1.3.2 Penumatic Test - Pressurizing piping and equipment with air or inert gases to demonstrate strength and integrity of the system.

1.3.3 Leak Test - Pressurizing piping and equipment and water, air, inert gases, steam, etc. , to demonstrate leak tightness of pressure boundary.

i 4 2. REFERENCES 2.1 Administration Procedures

, 2.1.1 AD 1805.00 Procedure Preparation and Maintenance

, 4 2.1.2 AD 1803.00 Safety Tagging 2.1.3 AD 1835.00 Flushing and Cleaning 2.1.4 AD 1844.00 Maintenance 2.2 Maintenance Procedures i '

2.2.1 MP 1401.27 In-service Hydrostatic Testing 4l 2.3 Nuclear Construction Procedures i

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2 MP 1401.19.4 2.3.1 NCDP 6050.01 Preparation and Impl-mentation of an NWO Work Package 4

2.3.2 NCDP 6120.01 Control & Calibration of Measuring and 4

Test Equipment 2.3.3 NCDP 6170.01 MWO Work Package Completion, Sign-off and >

Turnover to Operations 2.3.4 NCDP 6070.04 Safety Tagging 2.4 Specifications 4l 2.4.1 12501-M-602 Piping Class Summary Sheets

'2.5 Other References 4l

, 2.5.1 ' I:P 8003.00 Plant Systems Cleanliness Inspection 2.5.2 TED Nuclear Quality Assurance Manual 2.5.3 ASME Boiler and Pressure Vessel code - Section'III -

1971 Nuclear Power Plant Components 2.5.4 American National Standards Institute, Power Piping Code ANSI B31.1 1980 4 2.5 5 Ohio Pressure Piping System Rules - July 1981 1 2.5.6 Ohio Building Code - 1980

3. SPECIAL EQUIPMENT REQUIRED NOTE: Equipment identification to be recorded on Data Sheet,
Attachment 1.

i 3.1 Oil-free hydro test pump with suitable valves and other equipment as required to conduct test.

3.2 Calibrated pressure gauges - These gauges shall be connected directly to the piping under test. -The gauges shall have dials graduated over a range of about double the intended maximum test pressure, but in no case shall the range be less than 1-1/2 times nor more than four times the test pressure.

.; 4. PRECAUTIONS AND LIMITATIONS 4.1 When a REP is. required, all requirements of the REP must be met.

4.2 Pressure gauges shall be identified by gauge number and shall be

, -calibrated against'a standard dead-weight teste'r or a calibrated

  1. - master gaLge by I&C prior to each test or series of tests.

Gauges shall be recalibrated by I&C at least every 6 months.

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3 MP 1401.19.6 These gauges shall be verified as to calibration and range prior to being used for testing. A calibration log shall be maintained by I&C on all gauges used for testing. A copy of this log for the applicable gauge shall be part of the test package.

4.3 If a pressure test is to be maintained for a period of time during which the test medium in the system is subject to thermal 6 expansion, a pressure relief device with the appropriate set pressure, shall be provided to protect system from overpressure.

4.4 The Maintenance Engineer / Piping Supervisor or his designee should inform the TED Code Inspection Supervisor and the TED QC Supervisor of hydrostatic or pneumatic tests at least 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> in advance of the test so arrangements can be made to have the authorized inspectors on hand prior to testing as outlined in paragraphs 4.4.1 and 4.4.2 below.

4.4.1 ASME Boiler and. Pressure Vessel Code - Section III; Systems - Authorized Inspector (Hartford) and TED Special Piping Inspector.

4.4.2 American National Standards Institute - ANSI B31.1; i Systems - TED Special Piping Inspector.

4.5 Pneumatic testing shall no't be used in lieu of other means of leak testing except a preliminary pneumatic test not to exceed 25 PSIG may be applied, prior to other methods of leak testing, as a means of locating major leaks or if one of the following conditions exist:

4.5.1 -When specification requires or permits the use of a pneumatic test.

4.5.2 When components, appurtenances or systems are so designed and/or supported that they cannot be safely i filled with water.

4.5.3 When components, appurtenances or systems which are NOT readily dried, are to be used in services where traces of the testing medium cannot be tolerated.

. NOTE: When pneumatic tests are used, they shall be in accordance with this procedure.

4.6 The hydrostatic or pneumatic test pressures shall NOT exceed the maximum allowable test pressure of any non-isolated component such as vessel, pumps or valves in the system.

(TS 3.7.2.1)

(TS NOTE: If doing a hydrostatic test,on the steam generators 3.4.9.2) and secondary pressure in the steam generator is >237

4 MP 1401.19.4 4l PSIG and TAVE is <200'F than the temperature of the secondary coolant in each steam generator shall be determined to be >110*F at least once per hour and noted in the Unit Log.

4.7 Test Medium 4.7.1 The test medium for hydrostatic tests shall be condensate water (unless noted otherwise on data sheet). The water quality shall be verified by C&HP and shall be part of the test package. The water quality shall be equivalent or better than normal system water quality.

4.7.2 The test medium for pneumatic tests shall be air or inert gases. If inert gases are used they shall be non-flammable and non-toxic. Since compressed gas may be hazardous when used as a test medium, it is recommended that special precautions for protection of personnel be observed when gas under pressure is used as the test medium.

4.8 Control valves and check valves shall NOT be used as a test boundary, without permission from the Maintenance Engineer.

4.9 The Maintenance Engineer or his designee shall coordinate the test with Operations as to when testing of system can be conducted so as NOT to disrupt station operations. He shall then notify 4 the TED Code Inspector Supervisor.

5. PREREQUISITES 4 5.1 All joints including welds h0T previously tested have been left -

uninsulated'and exposed for examination during the test.

5.2 Expansion joints are provided with temporary restraints if required for additional pressure load under. test or they are

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isolated during system test.

5.3 Permanent relief valves in the system are either gagged, blanked or isolated from the system during test.-

5.4 Equipment that is NOT to be subjected to the pressure test has been disconnected from the system or isolated by a blank or similar means.

.5.5 Vents are provided at the high points of the system or component under test.

5.6 The temperature of the test medium is that of the available i

5 MP 1401.19.5 source unless otherwise specified. The test shall be made at a temperature that will minimize the possibility of brittle fracture. The test shall not be applied until the system and the pressurizing medium are approximately at the same temperature.

5.7 All personnel not involved in the test are clear of system under test.

5.8 Flushing of lines has been completed prior to hydrostatic test or air blow of lines has been completed prior to pneumatic test.

5.9 All NDT has been completed prior to testing.

5.10 Do Not Operate Tags have been placed on all valves and their controls which form part of the test boundary. (Reference valve lineup for test). Valves within the test boundary can be operated as required by those performing the test.

5.11 The test equipment has been examined before pressure test is applied to ensure that it is tightly connected and suitable for the test. All low pressure fill lines and other items not subject to the pressure test have been disconnected or isolated by valves or .other suitable means.

5.12 The Maintenance Engineer or his designee has provided a scoped P&ID or prepared a sketch showing the test boundaries, along with a valve lineup for each test. These papers shall indicate any special conditions or abnormalities such as blanks, etc.,

required to conduct the test.

5.13 The Maintenance Foreman or his' designee has reviewed these papers and the procedure and physically inspected the system under test to familiarize himself with all its aspects. Any special conditions or abnormalities other than those shown on the test sheet have been brought to the attention of the Maintenance Engineer and so noted on the test sheet.

5l 5.14 Operations have performed the valve lineup as per Attachment 1.

5.15 The Piping Supervisor / Maintenance Foreman or his designee has independently verified the valve lineup.

6. PROCEDURE 6.1 The test pump and calibrated gauge has been connected to the system under test. The test medium (water quality) has been verified. If a hydrostatic test is being performed, it is not necessary to verify the test medium quality for pneumatic tests.

6.2 The system is filled and vented. The pressure in the system shall then be gradually increased to about one-half of the test

6 MP 1401.19.5 pressure. The system shall then be inspected for gross leaks; if satisfactory, the system shall gradually be increased to test pressure. Any leaks that are found such as flanged joints, valve bonnets, valve packing glands, etc., while at one-half test pressure, shall be repaired and the system repressurized to one-half test pressure, and reinspected before gradually going to test pressure.

6.3 The hydrostatic and/or pneumatic test pressure for ASME Section III Systems.shall be maintained for a minimum time of 10 minutes.

The examination presssure for leakage (except in the case of valves, which shall be examined while at test pressure) shall be made at a pressure equal to the greater of the design pressure or three-fourths of the test pressure. .The hydrostatic and/or pneumatic test pressure for ANSI B31.1 Systems shall be maintained for a minimum time of 10 minutes and for such additional time as may be necessary to conduct the examination for leakage. The authorized inspectors are to be present during the test.

6.4 For hydrostatic tests examination for leakage shall be made of all joints and connections and of all regions of high stress, such as regions around openings and thickness transition sections.

The piping system exclusive of possible localized instances at pump or valve packing shall show no visual evidence of weeping or leaking.

6.5 For pneumatic tests examination for leakage detected by use of Leak-Tec No. 277 NE shall be made of all joints and connections and of all regions of high stress such as regions around openings and thickness transition sections (such as reducer or tapered valve body, etc.). The piping system exclusive of possible localized instances at pump or valve packing shall show no evidence of leaking.

6.6 After test has been completed, vent system and notify Shift Supervisor that the test has been completed and the "as left" valve positions.

7. ACCEPTANCE CRITERIA 5 NOTE: Acceptance Criteria will be signed off on data sheet (ED 7204).

7.1 The systems tested under this procedure shall show no visual evidence of' weeping or leaking at welded joints and connections, except for localized instances at pump or valve packing.

7.2 All new or repaired joints and connections in addition to-visual examination for leakage have been examined for compliance with the acceptable code.

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7 MP M E~1401 #JLJ~~~~~ "PIdl HYDROSTATIC AND PNEUMATIC TEST DATA SHEET E G 7204 OF ASME CLASS g y g, MWO ST A TION 1 0, 3 0 8211

[ UNIT SVSTEM CLEANLINESS REQUIRED PER :P 8003 00 i

TEST PRESSURE TYPE TEST VALVE LINEUP SIGN A TUR E DATE VALVE LINEUP ON TEST V ALVE LINEUP SHEET MAS BEEN VERIFIED TEST GAUGE TEST GAUGE NO ~AANGE TEST GAUGE IS OF PAOPER RANCE PEA PARAGRAPH 3 2 OF MP 140119

= AND HAS BEEN CALIBR ATED IMMEDIATELY PAIOA TO THIS TEST / SERIES OF TEST AS AEQUt AED BY PARAGR APH 4 2 OF MP140119 ATTACH A COPY SIGN ATUR E 'DATE

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Q OF THE CAUBR ATION DATA SHEETS c.

TEST MEDIUM TEST MEOrVM IS IF TEST MEDIUM iS WATER. VERIFY THAT C & HP HAS CHECKED WATER C WATER O Aia Oi~ Eat GAS iSPECirv GAS, AND IT IS OF A QU ALtTY EQUAL TO OR BETTER THAN TN A T REQUIRED TO C & HP SaGNATURE DATE MAINTAIN THE SVSTEM OF CLEANLINESS SDECIFIED ABOVE PAEAEQUISITES THE FAEREQUISITES SPECIFIED IN PA AAGA APH S OF MO 141019 MAVE BEEN MET , ,

TEST M % AL T A IZED l CA DATE Tnt TEST VEETS THE ACCEPTANCE CAtTERf A OF SECTIO ' )

OF MP 140119 PECIAL%SPECTOR DATE

-f e.co'TIONAL CCMMENTS 3'

/b Yv NOTE PA AT 1 AND NE VALVE LINEUP SHEET IS CCYPLETED AT THE TIME THE APPLICABLE MWO IS INITI ATED PA AT 11IS COUPLETED ANC SIGNED WHEAE INCiCATED BY THE PE ASCN PEAFCAVING THE TESTS PA AT lli 15 CCYPLETED BY THE TED SPECI AL PIPING INSPECTGA AND AUTHC AIZED INSPECTC A AS APPLIC ABL E TEST VALVE LINEUP SHEET VALVE NO l OPEN l CLOSED VEAIFIED I I i

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4001TIONAL COMMENTS ATTACHMENT 1 gg 73 - . .

Rieur:ON D VIS BESSE NUCl. EAR POWER STATION UNIT 1 -- Oriolae'. Responsibi Section Head Action ,

TEMPORARY MODIFICATION REQUEST E D 6g261

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1 Shift Supervisor 1 Working Copy PROCEDUR AL COMMITMENT 1 Cent-of Room _ Control Room File 1 Operations Eng. _

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I SECTION 2 SAFETY REVIEW Yes O NSR change in the f acility es described in the USAR.

No[

Yes O NSR change in the procedures as described en the USAR.

No[

Yes O NSR test or experiment not described in the USAR.

NoK Yes O No S Change in the Technical Specifications.

NOTE: If any of the above Section 2 are "Yes.* a written safety evaluation shall be performed per AD 1845 01 (Safety Evolustion No ) and a Section 3 Safety Evaluation shall be performed, unless this is part of an FCR (FCR No. if apphcable).

Yes O Noh Decrease in the effectiveness of the fndustrial Security Plan. If this is *Yes,* the change cannot be made without N RC coecurrence.

Yes C No 2i Decrease in the effectiveness of the Davis-Besse Emergency Plan. If this is "Yes,* the change cannot be made without NRC concurrence.110CFR50.S4(q)

Yes O No T is an ALARA review requirgd:

NOTE: if "Yes* submit a copy of the modification to the Chemist & Health Physicist. The procedure may be approved prior to the review; the C&HP will submit the review to the SRB.

SECTION 3 SAFETY EVALUATION Yes O Not The probabihty of occurrence or the consequences of an accident or malfunction of equipment important to safety preveusly evaluated in the Safety Analysis Report may be increased.

Yes O No S A pess bihty for an accident or ma! function of a different type than any evaluated previously in the Safety Analysis Report may be created.

Yes O No 3 The margin of safety as defined m the bases for any Technical Spec.fication is reduced.

NOTE: If any of Section 3 is "Yes," an *Unreviewed Safety Question" is mvolved and the change cannot be made without NRC Concurrence.

(FCR No. if apphcable)

SECTION 4 FOR MODIFICATIONS TO SURVEILLANCE TEST (ST)WHICH AFFECT THE SCOPE OF THE PROCEDURE (SURVEILLANCE REQUIREMENTSI, A TEMPORARY MODIFICATION MUST BE SUBMITTED TO AD 1838.00 AND OR PP 1102.01,IF APPLICABLE.

TEMPORARY MODIFICATION SUBMITTED Yes O NAO AD 1838 00 Surveillance and Periodic Test Program (ST, Tech Spec cross reference)

Yes O NA O PP 1102 01 Pre-Startup Checkhst SECTION 5 FOR NSR MODIFICATIONS REQUIRING SAFETY EVALUATIONS, AND NSR NON NSR CHANGES.

SRB Comments:

SRB Recommendation: Date PLANT MANAGER APPROVAL DATE SECTION 6 For ST's ONLY; Review by STE for ST schedule, mode checkhst and A01838 00 changes.

REVIEW PERFORMED Yes O NAO COMMENTS I

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o*TL September 23, 1985 -)

INTRA. COMPANY MEMORANDUM File: 9365 M-215Q, 0294 l co stu 2 FCR 83-133, FCR 85-134 y su o

I Stephen Smith / Bill O'Connor roou A A R _ ~v7'

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n J. K. Wood [ g SUOJECT Differential Pressure Testing of Limitorque Actuated Valves and Dampers In order to resolve concerns about excessive dP testing and permitting systems to be placed in unsafe modes during the tests, NFE has reviewed and revised the August 27, 1985 (A85-0774D) memorandum attachments. To highlight the changes:

1. Twenty valve tests required in lieu of twenty-three.
2. Sixteen more safety related valves and dampers added to the list to be MOVATS set which brings the list to a total of one-hundred sixty-eight.

In order to emphasize the importance of completing this project of dP testing and MOVATS setting prior to plant startup, an NRC/TED agreement was made August 14, 1985 to provide dP sample tests representative of the corrective action taken to prevent reoccurrence of the AF 599 and 608 isolation valve problem.

For information and records the following are attached:

Attachment No. Description 1

MOV's to be dP Tested Revision 1 (9-20-85) 2 Limitorque M0V's to be MOVAT's Set Revision 1 A report is being developed and sent to file 9365 by NFE to document the evaluation process used during the review. Also, a report is to be submitted by Maintenance Engineering to NFE of the results, i.e., valves passing the test or requiring rework prior to passing the test.

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T. E. Hiss N. L. Bonner C. T. Daft E. C. Caba M. M. Bajestani A. K. Zarkesh T. A. Lang G. D. 14mmon l

fff)A ATTACHMEhT 1 MOTOR OPERATED VALVES TO BE dP TESTED dP TEST P&ID MOV NO. PSIG AF 3870 1050 AF 3869, 3871 and 3872 ,

1050 DH 9A or 9B 70 CS 1530 or 1531 240 RC 239A or 239B 2435 HP 2A 2155 HS 603 or 611 1050 AF 599 and 608 1050 DH 830* or 831* 420 DH 1A or IB 420 DH 2733 or 2734 300 W 601 or 612 1100 DH 7A or 73 35 CF 2 A or B or 700 CF SA or B .

DH 2735 420 HU 1A or B 2155 l HU 2A or B 2155-DH 2736 420

  • Testing difficulties may preclude this test attaining the desired dP.

l se d/32/2 l Rev. 1 (9-20-85) .

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/ fNI ATTACHMENT 2 SAFETY RILATED LIMITORQUE ACTUATED VALVES VALVE NUMBER AF 3872 CV 5010E DH 2735 MU 1A AF 360 . CV 5011A DH 2736 HU IB AF 3869 CV 5011B DR 2012A MU 2A AF 3870 CV 5011C DR 2012B MU 2B AF 3871 CV 5011D W 786 MU 12A AF 388 CV 5011E W 601 MU 12B AF 599 CV 5017 W 612 MU 59A AF 608 CV 5018 -

FW 779 MU 59B CC 1328 CV 5024 FW 780 MU 59C CC 1338 CV 5025 W 790 MU 59D CC 1407A CV 5037 HA 5261A RC 10 CC 1407B CV 5038 HA 5262A RC 11 CC 1409 CV 5056 HA 5305 RC 2 CC 1410 CV 5057 HA 5305A RC 200 CC 1411A CV 5065 HA 5305B RC 239A CC 1411B CV 5070 HA 5314 RO 239B CC 1567A CV 5071 HA 5314A .

RC 240A CC 1567B CV 5072 HA 5329 RC 240B CC 2645 CV 5073 HA 5329A SW 1366 CC 2649 CV 5074 HA 5329B SW 1367 CC 4100 CV 5075 BA 5329C SW 1368 CC 4200 CV 5076 HA 5336 SW 1379 CC 4300 - .x CV 5077 HA 5336A SW 1380 CC 4400 CV 5078 HA 5336B SW 1381 CC 5095 CV 5079 BA 5336C SW 1382 CC 5096 CV 5090 HA 5439 SW 1383 CC 5097 CV 624B HA 5440 SW 1395 CC 5098 CV 645B HA 5441 SW 1399 CF 1A DH 1A HA 5442 SW 2927 CF IB DH IB HA 5597 SW 2928 CF 2A DH 7A HA 5598 SW 2929 CF 2B , DH 7B HP 2A SW 2930 t

CF SA DH 9A HP 2B SW 2931 ,

CF 5B DH 9B HP 2C SW 2932 CS 1530 DH 63 HP 2D SW 5067 CS 1531 DH 64 HP 31 SW 5068 CV 2000B DH 0830 HP 32 SW 5421 CV 2001B DH 0831 MS 603 SW 5422 CV 20023 DH 11 MS 106 SW 5423 CV 20038 DH 12 MS 106A SW 5424 CV 5010A DH 1517 MS 107 SW 5425 CV 5010B~ DH 1518 MS 107A CV 5010C DH 2733 MS 611 CV 5010D DH 2734 MU 40

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