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BRUNSWICK NUCLEAR PLANT DATE COMPLETED UNIT _ % PWR GMWE SUPERVISOR REASON FOR TEST (check one or more): Routine surveillance W/O # Other (explain)

R Reference Use

FREQUENCY: Valves shall be tested per the frequency defined in the OM Code, if applicable.

PLANT OPERATING MANUAL VOLUME X PERIODIC TEST

UNIT 0

0PT-11.0 SAFETY/RELIEF VALVE SET PRESSURE AND SEAT LEAKAGE TEST REVISION 27

0PT-11.0

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Page 1 of 30

1.0

PURPOSE The purpose of this procedure is to provide the controls and instructions for verifying the operational readiness of relief valves. This procedure will satisfy the applicable requirements specified in the Inservice Testing (IST) program, 10 CFR 50.55a(f), and the OM Code, 2001 Edition with 2003 Addenda.

2.0

REFERENCES 2.1

Section 50.55a(f), Inservice Testing Requirements, of Title 10 of the Code of Federal Regulations (10 CFR 50.55a(f)).

2.2

Updated Final Safety Analysis Report (UFSAR)

2.3

Technical Specifications, Unit 1 and Unit 2

2.4

ASME OM Code, 2001 Edition with 2003 Addenda

2.5

NUREG-1482, Revision 1, Guidelines for Inservice Testing at Nuclear Power Plant

2.6

0ENP-17, Pump and Valve Inservice Testing (IST)

2.7

0ENP-16.5, Administration of Safety/Relief Valve Testing Program

2.8

0PLP-08, Repair/Replacement Program

2.9

NGGM-PM-007, Quality Assurance Program Manual

2.10

FP-85133, Crosby Valve and Gauge Company Instruction Manual, Crosby Test Bench

2.11

ESR 99-00008, Third Interval - Class 2 & 3 Relief Valves

2.12

ASME PTC - 25 1994 Edition, Pressure Relief Device Testing Code.

2.13

0ENP-62, Compliance with State Boiler and Pressure Vessel Regulations

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Page 2 of 30

3.0

DEFINITIONS 3.1

Chatter - abnormal rapid reciprocating motion of the movable parts of a pressure relief valve in which the disk contacts the seat.

3.2

Opening Pressure - the value of increasing inlet static pressure of a pressure relief valve at which the discharge become continuous as determined by seeing, feeling, or hearing.

3.3

Popping pressure - the value of increasing inlet static pressure at which the disk moves in the opening direction at a faster rate as compared with corresponding movement at higher or lower pressures. Popping pressure only applies to safety or safety relief valves on compressible fluid service (e.g., air, nitrogen).

3.4

Ramp Rate - the rate of change at which the test pressure is increased.

3.5

Simmer - the audible or visible escape of fluid between the seat and disk at an inlet static pressure below the popping pressure and at no measurable capacity. Simmer only applies to safety or safety relief valves on compressible fluid service (e.g., air, nitrogen).

3.6

Thermal Relief Valve – A relief valve whose only overpressure protection function is to protect isolated components, system, or portions of systems from fluid expansion caused by changes in fluid temperature.

4.0

RESPONSIBILITIES 4.1

Engineering Engineering is responsible for the following actions when performing testing in accordance with this procedure: 4.1.1

0PT-11.0

Ensuring personnel, who perform testing, are knowledgeable of relief valves and properly qualified in accordance with a plant approved process.

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Page 3 of 30

4.0

RESPONSIBILITIES 4.2

Maintenance Maintenance is responsible for the following actions when performing testing in accordance with this procedure: 4.2.1

Ensuring personnel, who perform testing, are knowledgeable of relief valves and properly qualified in accordance with a plant approved process (e.g., Qualification Card for Relief Valves).

4.2.2

Assigning an individual to perform the duties of the Test Supervisor.

4.3

Relief Valve Program Manager Program Manager is responsible for the following actions: 4.3.1

Administration and maintenance of this procedure.

4.3.2

Review and evaluate the test results for ASME Code Class 1, 2, and 3 valves.

4.3.3

Resolving conflicts that may develop as to the use, intent, or interpretation of this procedure.

4.4

Test Supervisor Test Supervisor is responsible for the following actions: 4.4.1

Ensuring that personnel who are involved in taking readings, making pressure and temperature adjustments, or performing any other function that will affect the accuracy of the test results are fully informed as to the correct method of performing such function.

4.4.2

Ensuring that instrument calibrations are current.

4.4.3

Ensuring compliance with the written test procedure.

4.4.4

Sign and date the test results, thereby stating they were accurate and that the test was conducted in accordance with this procedure.

4.5

Materials and Contract Services (M&CS) M&CS is responsible for the following actions: 4.5.1

0PT-11.0

Sending VR stamped valves to VR certified shops for repairs. Refer to MCP-NGGC-0401 for additional information. Rev. 27

Page 4 of 30

5.0

PREREQUISITES

NOTE:

If a group of valves are to be tested, Attachment 6 is only required to be completed once. If applicable, the test gauge can be changed as required.

5.1

The test bench operational start up checklist (Attachment 6) has been completed.

5.2

A test supervisor has been assigned for the performance of this procedure.

6.0

PRECAUTIONS AND LIMITATIONS 6.1

Avoid dropping and/or handling relief valves by their lifting lever.

6.2

When handling the relief valve, protect the component against damage and foreign material entry.

6.3

During testing, ensure the valve discharge is not pointed toward personnel and appropriate measures are taken to contain any liquid release.

6.4

Eye and/or ear protection should be worn during testing.

6.5

Safety requirements outlined in plant procedures will be followed during the performance of this procedure.

6.6

Plant radiation controls requirements and good ALARA practices will be followed during the performance of this procedure.

6.7

If observed during testing, record adverse mechanical characteristics (e.g., tightness before and after relieving, presence of chatter, sticking, and/or harmful vibration) on Attachment 5.

6.8

During repeated setpoint verification, the ramp rate should be maintained consistent to the extent practical.

6.9

If the test media is water, use ONLY demineralized water to minimize chlorides.

6.10

To prevent damage, do not over tighten test bench valves.

6.11

BNP has a limited volume test bench. This test bench cannot be used to verify blowdown ring settings.

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6.0

PRECAUTIONS AND LIMITATIONS 6.12

The test bench is designed to accept up to a nominal 10” flanged valve or 2” screwed valve.

6.13

The test bench SHALL not be operated above the maximum pressure specified in Table 1.

6.14

NO maintenance, adjustment, disassembly, or other activity which could affect the “as found” set pressure or seat tightness SHALL be performed prior to testing.

6.15

The pressure gauge SHALL have an overall accuracy within +/- 1 percent at the specified pressure.

6.16

When testing valves listed in Table 2, the ambient temperature at the test location SHALL be between 40°F and 115°F.

6.17

Valves E41-F050, E11-V51 and E11-V54 SHALL be tested in the horizontal position in a similar manner as in service.

6.18

North Carolina State Coded Vessels (VR) is subject to special rules for any repairs or set point adjustments. Repairs for VR stamped valves must be performed by a VR certified shop. BNP Maintenance does not hold this certification. Valves needing VR repairs will be turned in to stores and M&CS will be responsible for sending VR stamped valves to VR certified shops. To determine if a valve is subject to VR requirements, in PassPort the requirements section of EDB has a VR yes or no check off. Valves that are checked yes are subject to VR requirements.

7.0

SPECIAL TOOLS AND EQUIPMENT

NOTE:

The below tool list is recommended and may not be inclusive. Personnel performing the testing are responsible for ensuring the appropriate tools and/or equipment are available for the performance of this procedure.

7.1

Crosby Relief Valve Test Bench

7.2

Hand Tools (as required for setup)

7.3

Comparator Pump (if required)

7.4

Calibrated Test Gauge

7.5

Calibrated Thermometer

7.6

Calibrated Stopwatch (if required)

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Page 6 of 30

7.0

SPECIAL TOOLS AND EQUIPMENT 7.7

Nitrogen (if required) CAUTION

The minimum pressure rating of the pressure hose is to be equal or greater that the maximum gauge range. 7.8

Pressure Hose (as required)

7.9

Container (if required to collect and measure leakage)

7.10

Snoop (if performing a bellows integrity test)

8.0

ACCEPTANCE CRITERIA Testing of the relief valve is considered satisfactory when the following applicable criteria are met: 8.1

Visual Inspection 8.1.1

The inlet and outlet nozzles are free of foreign material or blockage.

8.1.2

No evidence of damage to the external pressure retaining surfaces that may prevent the valve from performing its function.

8.2

Opening or Popping Pressure 8.2.1

8.3

The opening or popping pressure (i.e., first and second test) is within the established set pressure range.

Seat Leakage 8.3.1

0PT-11.0

The leakage is less than or equal to the established seat leakage value. Or in the case of nitrogen/air operated valves, no audible leakage. Engineering may evaluate leakage greater than established values for acceptability. A copy of that evaluation shall be vaulted with the completed test package.

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Page 7 of 30

8.0

ACCEPTANCE CRITERIA 8.4

Re-seat 8.4.1

8.5

After relieving pressure, the valve’s disk re-seats. The reseat pressure will be recorded for information. This is not a verification of appropriate setting of blowdown rings.

Bellows Integrity Test 8.5.1

0PT-11.0

Apply snoop to the temporarily installed but loosened bonnet plug to verify the absence of air leakage through the bellows when the outlet flange is pressurized. Zero leakage is required.

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Page 8 of 30

9.0

INSTRUCTIONS

NOTE:

For valve disassembly and reassembly instructions, the applicable Corrective Maintenance procedure should be consulted.

NOTE:

VR stamped valves per NC State Code Vessels are subject to special rules for any repairs or set point adjustments. VR stamped valves needing repairs will be returned to stores and M&CS will be responsible for sending these valves to a VR certified shop.

NOTE:

Completion of the steps listed below will be documented upon the sign-off of the Test Supervisor on Attachment 5.

9.1

ENSURE the prerequisite(s) listed in Section 5.0 are met and PERFORM a pre-job briefing of the testing activity.

9.2

If the test medium is nitrogen, PERFORM the relief valve testing in accordance with the instructions provided in Attachment 1.

9.3

If the test medium is demineralized water, PERFORM the relief valve testing in accordance with the instructions provided in Attachment 2.

9.4

If the test medium is AAA tester oil, PERFORM the relief valve testing in accordance with the instructions provided in Attachment 3.

9.5

If a bellows integrity test is required, PERFORM the testing accordance with the instructions provided in Attachment 4.

9.6

If the testing results are SAT, the relief valve may be RETURNED to service or placed back in stores when valves are swapped out.

NOTE:

For valves listed in Table 2 or 3, CONTACT Engineering (IST Engineer) if results are UNSAT. Sample expansion may be required.

9.7

If the seat leakage, opening/popping pressure, and/or valve re-seat results are UNSAT, the valve SHALL be refurbished or replaced in accordance with an approved plant procedure.

9.8

For relief valves listed in Table 2 and 3, SUBMIT the original Attachment 5 to Engineering (IST Engineer) for review.

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FIGURE 1A(B) Page 1 of 1 Relief Valve Test Bench

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ATTACHMENT 1 Page 1 of 3 Instructions for Testing Relief Valves Using Nitrogen NOTE:

If relief valve test bench is unavailable, the test may be performed using a nitrogen bottle and pressure regulator with appropriate fittings.

NOTE:

Refer to Figure 1A and 1B for test bench equipment location.

NOTE:

Check-off each step when completed.

NOTE:

If the visual inspection results are UNSAT, do not continue with the test and CONTACT Engineering for disposition.

PEFORM a visual inspection of the valve and RECORD results on Attachment 5. PLACE the valve concentrically over the test plate and CLAMP the valve inlet flange to the test plate using the adjustable hold down clamps. TIGHTEN the clamps uniformly and firmly while maintaining the T-bolt in the center of the slotted clamp. VERIFY INSTALLATION of or INSTALL the applicable test gauge into the quick disconnect (35 & 36) on the test bench. RECORD ambient temperature on Attachment 5. CLOSE or VERIFY CLOSED the Drain Valve (7C) and Test Plate Supply Valve (7B). CRACK OPEN the Test Bench N2 Supply Valve (7A). Once the pressure stabilizes, OPEN the Test Bench N2 Supply Valve (7A). Gradually OPEN the Test Plate Supply Valve (7B) and increase pressure to 90% of set pressure or the seat leakage pressure for valves in Table 3 and listen for audible leakage. RECORD the presence or absence of audible leakage on Attachment 5. If there is audible leakage past the seat, contact Engineering to assess the impact prior to re-installing the valve.

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ATTACHMENT 1 Page 2 of 3 Instructions for Testing Relief Valves Using Nitrogen NOTE:

Contact Engineering prior to exceeding 110% of set pressure. Additional research should be performed on the pressure retaining capability of the valve in order to ensure personnel safety.

NOTE:

The next step may involve two people to complete.

While watching the test gauge, gradually OPEN the Test Plate Supply Valve (7B) and INCREASE the pressure at a rate equal to 2% of set pressure per second or at a rate which permits accurate pressure readings until the popping pressure is determined. RECORD the popping pressure value on Attachment 5 and DETERMINE if the relieving pressure is within the established set pressure range. DEPRESSURIZE the test volume by opening/closing the Drain Valve (7C) and WAIT at least 10 minutes to demonstrate repeatability. Following the 10 minute wait period, gradually OPEN the Test Plate Supply Valve (7B) and slowly INCREASE the pressure until the popping pressure is determined. RECORD the second popping pressure value on Attachment 5 and DETERMINE if the popping pressure is within the established set pressure range.

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ATTACHMENT 1 Page 3 of 3 Instructions for Testing Relief Valves Using Nitrogen

VERIFY the valve's disk re-seats after relieving by one of the following methods and RECORD the results on Attachment 5. 1 Valve De-pressurization a)

WAIT until the valve stops relieving.

b)

VERIFY the pressure remains steady for approximately 1 minute.

c)

RECORD the initial pressure on Attachment 5. OR

2 Valve Re-pressurization a)

DEPRESSURIZE the test volume by OPENING/CLOSING the Drain Valve (7C).

b)

Gradually OPEN the Test Plate Supply Valve (7B) to re-pressurize the valve to approximately half of the valve’s set pressure.

c)

CLOSE the Test Plate Supply Valve (7B) and VERIFY the pressure remains steady for approximately 1 minute.

TERMINATE the test by CLOSING the Test Bench N2 Supply Valve (7A). OPEN the Drain Valve (7C). Stroke OPEN and CLOSE the Test Plate Supply Valve (7B) until the test bench is depressurized. REMOVE the valve from the test bench plate.

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Page 13 of 30

ATTACHMENT 2 Page 1 of 5 Instructions for Testing Relief Valves Using Demineralized Water NOTE:

Refer to Figure 1A and 1B for test bench equipment location.

NOTE:

Check-off each step when completed.

VERIFY INSTALLATION of or INSTALL the applicable test gauge into the quick disconnect coupler (35 & 36). CLOSE or verify CLOSED the Drain Valve (7C). OPEN or VERIFY OPEN the Test Plate Supply Valve (7B). VERIFY the air regulator (34) is backed off fully. OPEN or VERIFY OPEN the Water Test Supply Valve (7D) and the Test Air Supply Valve (7E). ADJUST the air regulator (34) sufficiently to cause the pump to stroke uniformly. FILL the test bench with demineralized water, as required. BACK OFF the air regulator (34) and CLOSE the Test Plate Supply Valve (7B). NOTE:

The following step is ONLY applicable for valves listed in Table 2. If the ambient temperature is outside the specified range, do not continue with test and CONTACT engineering (IST Engineer). VERIFY the ambient temperature at the test location is between 40ºF and 115ºF and RECORD the temperature on Attachment 5.

PEFORM a visual inspection of the valve and RECORD results on Attachment 5. PLACE the valve concentrically over the test plate and CLAMP the valve inlet flange to the test plate using the adjustable hold down clamps.

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Page 14 of 30

ATTACHMENT 2 Page 2 of 5 Instructions for Testing Relief Valves Using Demineralized Water NOTE:

The following step is ONLY applicable for valves listed in Table 2. The purpose of this step is to ensure the outlet spool piece is not sloping upward. Potential seat leakage may be masked if the outlet spool piece is sloping upward. For valves with a spool piece welded to the outlet nozzle, VERIFY the outlet spool piece is level (to the extent practical) or sloping downward.

TIGHTEN the clamps uniformly and firmly while maintaining the T-bolt in the center of the slotted clamp. Test Block 1 NOTE:

The test pressure should be set higher than the valve's upper set pressure range.

NOTE:

The steps within this test block are ONLY applicable for valves listed in Table 2. The purpose of these steps is to measure any potential seat leakage. PLACE a container at the outlet port to collect any potential leakage. Gradually INCREASE the air regulator (34) as required to keep the pump stroking until the pressure required to verify seat leakage is reached on the system pressure gauge. Seat leakage testing should be performed at 90% of set pressure. While watching the test gauge, gradually OPEN the Test Plate Supply Valve (7B) and slowly INCREASE the pressure until the seat leakage test pressure (± 2 %) is obtained. While at seat leakage test pressure, START the stopwatch and COLLECT any leakage for 10 minutes.

NOTE:

0PT-11.0

If no leakage is observed or the collected volume is less than 10 mL, the seat leakage test is considered SAT and the next step is not applicable. Record no leakage or < 0.003 gpm on Attachment 5.

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Page 15 of 30

ATTACHMENT 2 Page 3 of 5 Instructions for Testing Relief Valves Using Demineralized Water Test Block 1 (continued) MEASURE the collected volume in a mL beaker and DETERMINE the leakage rate using the following formula: gpm = (Collected Volume (mL) ÷ 3780 mL) ÷ 10 minutes Example: Collected Volume = 50 mL over 10 minutes (50mL ÷ 3780 mL) ÷ 10 = 0.0013 gpm NOTE:

If the seat leakage is greater than 0.003 gpm, CONTACT Engineering prior to re-installing the valve. RECORD the seat leakage rate on Attachment 5 and DETERMINE if the seat leakage is below the established value.

INCREASE the pressure at a rate equal to 2% of set pressure per second or at a rate which permits accurate pressure readings until the pressure required to verify opening pressure is reached on the pressure gauge. NOTE:

Contact Engineering prior to exceeding 110% of set pressure. Additional research should be performed on the pressure retaining capability of the valve in order to ensure personnel safety.

NOTE:

The next step may involve two people to complete.

While watching the test gauge, gradually OPEN the Test Plate Supply Valve (7B) and slowly INCREASE the pressure until the opening pressure is determined. RECORD the opening pressure value (including time) on Attachment 5 and DETERMINE if the opening pressure is within the established set pressure range.

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Page 16 of 30

ATTACHMENT 2 Page 4 of 5 Instructions for Testing Relief Valves Using Demineralized Water DEPRESSURIZE the test volume by opening/closing the Drain Valve (7C) and WAIT at least five (5) minutes to demonstrate repeatability. Following a five (5) minute wait period, gradually OPEN the Test Plate Supply Valve (7B) and slowly INCREASE the pressure until the opening pressure is determined. RECORD the second opening pressure value (including time) on Attachment 5 and DETERMINE if the opening pressure is within the established set pressure range. VERIFY the valve's disk re-seats after relieving by one of the following methods and RECORD the results on Attachment 5. 1 Valve De-pressurization a)

WAIT until the valve stops relieving.

b)

VERIFY the pressure remains steady for approximately one (1) minute.

c)

RECORD the initial pressure on Attachment 5. OR

2 Valve Re-pressurization

0PT-11.0

a)

DEPRESSURIZE the test volume by OPENING/CLOSING the Drain Valve (7C).

b)

Gradually OPEN the Test Plate Supply Valve (7B) to re-pressurize the valve to approximately half of the valve’s set pressure.

c)

CLOSE the Test Plate Supply Valve (7B) and VERIFY the pressure remains steady for approximately one (1) minute.

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ATTACHMENT 2 Page 5 of 5 Instructions for Testing Relief Valves Using Demineralized Water TERMINATE the test by backing off the air regulator (34). OPEN the Drain Valve (7C). CLOSE the Water Test Supply Valve (7D) and the Test Air Supply Valve (7E). Stroke OPEN AND CLOSE the Test Plate Supply Valve (7B) until the test bench is depressurized. If a bellows integrity test is required (ie. C41-F029A/B) proceed to Attachment 5. REMOVE the valve from the test bench.

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Page 18 of 30

ATTACHMENT 3 Page 1 of 3 Instructions for Testing Relief Valves Using AAA Tester Oil NOTE:

Check-off each step when completed.

PEFORM a visual inspection of the valve and RECORD results on Attachment 5. MOUNT the valve in a vertical position using a vise or other similar device. INSTALL the applicable test gauge between the comparator pump and the test valve. CONNECT a test flange or other suitable connection to the relief valve’s inlet nozzle. RECORD ambient temperature on Attachment 5. OPERATE the comparator pump until the discharge hose is filled solid. CONNECT the comparator pump’s discharge hose to the relief valve’s inlet nozzle. INCREASE pressure to 90% of set pressure or the seat leakage pressure for valves in Table 3. PLACE a container at the outlet port to collect any potential leakage. While at seat leakage test pressure, (± 2 %), START the stopwatch and COLLECT any leakage for 10 minutes. If no leakage is observed or the collected volume is less than 10mL, the seat leakage test is considered SAT and the next step is not applicable. RECORD no leakage or