SEABROOK STATION RELIEF VALVE PROGRAM

SEABROOK STATION RELIEF VALVE PROGRAM

Roger Samson Bob Thomas

Plant Engineering Maintenance

PRDUG MEETING, ORLANDO, FLA.

JANUARY 24-26, 2001

Seabrook Relief Valve Team 2


• Testing Video R. Samson / R. Thomas

• Program overview R. Samson

• ORO-7 Code Revision R. Samson

• Determination of testing parameters R. Samson

• Test Equipment / Facility development R. Thomas

• Data Package Revision For Hot TestingR. Thomas

• ORO-7 testing results R. Thomas / R. Samson

• EPRI Test Model R. Samson / R. Thomas

• Questions and Answers R. Samson / R. Thomas


Program Overview

• Last plant using ASME XI, 1983 Edition, Summer Addenda

No thermal relief valves

TWO PARAGRAPHS - PTC 25.3

Bench test at ambient temperature

• First plant using ASME O&M Code 1995 Edition, 1996 Addenda in its entirety

Thermal relief valves now included

Significant changes - prescriptive test requirements

(Test media and ambient air temp requirements)












OR07 Code Revision

New prescriptive test requirements:

• Class 1 RV’s and MSSV’s – 5 years, 20% min. in 2 yrs.

• Class 2&3 RV’s – 10 years, 20% min. in 4 yrs.

• .Additional scope if failure occur

• .Replacement Valves – special testing requirements.

• .Rupture Disks – replace every 5 years.

• Instrumentation ‑ 1% of setpoint.


OR07 Code Revision

New prescriptive test requirements (con’t)

• Testing Sequence:Visual, Leak, Setpoint, Leak, Bellows

• Test Media same as operating, (e.g., steam, air, N2, water, oil, etc.).

• Test Media Temperature & Ambient Temperature

Operating vs. conditions when valve is expected to actuate

• Thermal Equilibrium Criteria, (10F change in 30 minutes)

• 10 Minutes between Lift Tests

• 2 Consecutive Lifts, (without adjustment)

• Alternate Test Media Correlation.


Significant Changes

Test Media Temperature & Ambient Temperature -

• Expected to perform its intended function

• These conditions also apply to Seat Tightness.

• Requires test equipment with “Hot” testing capabilities.


Significant Changes (con’t)

Alternate Test Media Correlation

• Permits testing using both cold ambient and media conditions provided that correlation test data exists to support cold testing.

• Some vendors had media correlation

• No vendors combined media and ambient temperature

• No vendors had ambient temperature correlation

• Some vendors refused to do alternate media testing












Determination of testing parameters

Temperature Requirements - two methods:

• Normal system operating

Versus

• Conditions when valve is expected to perform its function

upset system or emergency accident condition

what function each valve was performing

what conditions were associated with its function

Document search included Technical Specifications, UFSAR, System Calculations and technical (T/P) sheets


Test valve

TEST GROUP NO. 4

Valve No. P&ID No. Train Class FP Manual Size TypeTest

Medium Setpoint

AcceptanceCriteria

(+0, - 3%)Leak Test Pressure

AcceptanceCriteria

RC-V24 1-RC-D20841 A 2 50457 C710-1 3" JB-35-TD-WR Water 450 psig 436.5 to 450 psig 405 to 410 psig 30 cc/hr

RC-V89 1-RC-D20844 B

SPEC 248-43 MEDIA

TEMPERATURE

(+/-10F)

SERVICE

ENVIRONMENT

AMBIENT

TEMPERATURE

(+/-10F)

TESTPROCEDURE

REPAIRPROCEDURE

REMARKS

R-32 350F Containment -Heatup and

Cooldown

120F EX1804.044 MS0519.13 RHR Suction Relief Valves-Heatup

and Cooldown.












Test Equipment / Facility Development


Test Equipment / Facility developmentDesign Considerations

•SAFETY

•VOLUME CONTROL

•TEMPERATURE CONTROL

•ERGONOMIC OPERATOR CONTROLS


SAFETY

Due to the increased energy potential created by flashing fluids, special safety features were included in the equipment and facilities design.


SAFETY

RCA TEST STAND

Due to radiological release concerns, the RCA test stand discharge system includes an adjustable, sealed discharge pipe for each table and a vented discharge tank. The tank is equipped with a sparging system and has provisions for connection of a HEPA filter, if required.

COLD SIDE TEST STAND

The cold side test stand discharge system includes an adjustable, sealed discharge pipe and an exhaust pipe vented to atmosphere through the side of the building.


SAFETY

Quick Acting Valves

Quick acting air operated valves were added on the accumulator and table vent lines This allows for rapid venting if the pressure increases in the test stand due to internal flashing. Quick acting air operated valves were also added on the accumulator / table isolation valves in case of a stuck open valve.



•SAFETY

•VOLUME CONTROL




VOLUME CONTROL

Manual bypass valve on water side

Three rates of air feeds to the accumulator

Bypass line on the water circuit allows for low volume set pressure testing on smaller valves or when lifting larger valves is undesirable.

Three rates of air feed to accumulator lets the operator vary the fill rate and air volume from air storage to accumulator.


VOLUME CONTROL

Restricting Devices

Valves are often partially gagged to restrict lift and conserve heated water.



•SAFETY

•VOLUME CONTROL




TEMPERATURE CONTROL

Local Controllers

Each heat zone has a local controller to program final temperature settings, and ramp rates

Separate Heat Zones

Vessel, piping, and environmental chambers are divided into seperate heating zones for variable heat control.



•SAFETY

•VOLUME CONTROL




ERGONOMIC OPERATOR CONTROLS


Cold Side Test Stand Control Panel

Because of the extended testing duration's, sit down control panels were used on both hot and cold side testers. All controls are within easy reach of operator. Valves, pressure gauges, switches and heating controllers are all accurately positioned on the tester’s schematic “mimic”.



















Data Package Revision For Hot Testing


SETPOINT VERIFICATION / DATA ACQUISITION

SETPOINT VERIFICATION









Cold SideTester Piping Hot Side Tester Piping






















OR07 Test Results

• New Scope thermal relief valves - near 100%

• One LER - RH Suction Relief Valve lifted low

• Expanded scope for several groups

Containment

Component Cooling system

• 2 Rupture Disc replaced

• Oil tests - DG System


OR07 Test ResultsGroup Valve ID Set As Found Delta Ambient Media Size Manufacture Status

Pressure Pressure Pressure Temp Temppsig psig psig (F) (F)

01 1-cc-v-474 150 149 1 273 97 1.5x2 Lonergan

04 1-rc-v-24 450 415 35 120 350 3x4 Crosby Outside Tolerance

04 1-rc-v-89 450 452 2 120 350 3x4 Crosby EXPANSION

05 1-cbs-v-96 350 359 9 104 104 3/4x1 Lonergan

05 1-cbs-v-94 350 345 5 0 0 3/4x1 Lonergan

06 1-cbs-v-149 325 300 25 104 350 3/4x1 Crosby Outside Tolerance

06 1-cbs-v-150 325 340 -15 104 350 3/4x1 Crosby Outside Tolerance-EXPANSION

06 1-cbs-v-151 325 325 0 104 350 3/4x1 Crosby EXPANSION

06 1-cbs-v-152 325 320 5 104 350 3/4x1 Crosby EXPANSION

07 1-cs-v-227 220 198 22 220 180 .75 x 1 Crosby Outside Tolerance

07 1-cbs-v-62 220 204 16 180 189 3/4x1 Crosby Outside Tolerance-EXPANSION

08 1-wld-v-213 150 150 0 273 120 1.5 Lonergan

09 1-sf-v-183 150 148 2 104 75 .75 x 1 Lonergan

09 1-sf-v-45 150 148 2 104 75 .75 x 1 Lonergan

09 1-sf-v-74 150 160 10 104 75 .75 x 1 Lonergan Outside Tolerance

10 1-cs-v-250 150 147 3 198 130 2.0 Crosby

11 1-rc-v-337 2485 2412 73 273 120 .75 x 1 Lonergan

12 1-rc-v-312 2485 2165 320 273 120 .75 Lonergan Outside Tolerance

12 1-rc-v-314 2485 2290 195 273 120 .75 x 1 Lonergan Outside Tolerance-EXPANSION

12 1-si-v-247 2485 2483 2 273 120 .75 x 1 Lonergan EXPANSION




13 1-si-v-101 1750 1724 26 104 120 .75 x 1 Crosby

14 1-si-v-60 700 712 12 120 120 1.0 x 2 Crosby

15 1-rh-v-57 600 615 15 104 120 .75 x 1 Crosby

17 1-cc-v-407 150 148 2 104 260 1.5 Lonergan

17 1-cc-v-409 150 154 4 104 278 1.5 Lonergan

18 1-cc-v-343 150 152 2 104 350 2.0 x 3 Lonergan

20 1-cc-v-26 150 135 15 104 260 .75 Lonergan Outside Tolerance

20 1-cc-v-141 150 144 6 104 350 .75 Lonergan Outside Tolerance

20 1-cc-v-1277 150 154 -4 130 130 3/4 X 1 Lonergan EXPANSION

20 1-cc-v-1278 150 156 6 130 130 3/4 x 1 Lonergan Outside Tolerance-EXPANSION

20 1-cc-v-1279 150 161 11 158 150 .75 Lonergan Outside Tolerance-EXPANSION


20 1-cc-v-269 150 148 2 104 350 .75 Lonergan EXPANSION






21 1-dg-v-118 55 55 0 114 120 1.5 x 2 Lonergan

21 1-dg-v-124 55 54 1 114 120 1.5 x 2 Lonergan

22 1-dg-v-211a 70 68 2 113 135 .75 x 1 Circle Seal




22 1-dg-v-211b 70 74 4 113 135 .75 x 1 Circle Seal Outside Tolerance

23 1-sw-v-514a 145 171 26 113 135 .75 x 1 Circle Seal Outside Tolerance

23 1-sw-v-514b 145 170 25 113 135 .75 Circle Seal Outside Tolerance

24 1-cc-v-1105 150 146 4 273 175 .75 Lonergan

26 1-sw-v-32 150 152 2 104 175 2.0 x 3 Crosby

26 1-sw-v-73 150 205 55 104 175 2.0 Lonergan Outside Tolerance

27 1-cs-v-48 600 594 6 273 290 2 x 3 Lonergan

41 1-cs-v-834 300 330 30 104 104 .75 x 1 CON. 1975 Outside Tolerance

47 1-hd-v-232 170 176 6 80 350 .75 x 1 consolidated Outside Tolerance

53 1-co-v-430 150 151 1 80 100 .75 x 1 CON. 1975c












EPRI Test Model

The plan involved 60 lifts, 10 at each set of ambient and fluid temperatures. The first three tests will evaluate fluid temperature effects alone. The next two (when combined with the first) will evaluate the effects of ambient temperature alone. The final test when compared to the first will evaluate the combined effects of fluid and ambient temperature increases. By conducting 10 lifts at each test condition we will obtain excellent statistical confidence in the observed mean values from each data set.

EPRI will begin the development of the thermal model with the intention of predicting the set point changes resulting from the testing described above. Based on the results of this effort, EPRI will be able to develop a cost effective research plan for validating the model for the full range of class 2 and 3 relief valve designs in use in the industry. In addition, the data obtained will provide very significant insights into the effects of fluid and ambient temperatures on relief valve set points.

Fluid Temperature (F) Ambient Temperature (F) Number of lifts80 80 10

150 80 10350 80 1080 150 1080 350 10

350 350 10

Shortly after our facility was declared operational EPRI was invited for a facility tour and demonstration. After the visit EPRI requested that Seabrook run a series of tests at various combinations of fluid and ambient temperatures. Seabrook agreed to perform the testing which was completed in late November.

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SEABROOK STATION RELIEF VALVE PROGRAM

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