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

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Rev. 27

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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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

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Sending VR stamped valves to VR certified shops for repairs. Refer

to MCP-NGGC-0401 for additional information.
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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 40F and 115F.

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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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 valves 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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Page 9 of 30

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

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Page 10 of 30

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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Page 11 of 30

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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Page 12 of 30

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 valves 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 40F and
115F 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 valves 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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Page 17 of 30

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 valves inlet
nozzle.
RECORD ambient temperature on Attachment 5.
OPERATE the comparator pump until the discharge hose is filled solid.
CONNECT the comparator pumps discharge hose to the relief valves 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 <0.003 gpm on Attachment 5.
MEASURE the collected volume in a mL beaker and DETERMINE the leakage
rate using the following formula:
gpm = (Collected Volume (mL) 3780 mL/gal) 10 minutes
Example: Collected Volume = 50 mL over 10 minutes, (50mL 3780 mL/gal) 10 minutes
= 0.0013 gpm

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Page 19 of 30

ATTACHMENT 3
Page 2 of 3
Instructions for Testing Relief Valves Using AAA Tester Oil
RECORD the amount of leakage on Attachment 5. If there is leakage past the
seat, contact Engineering to assess the impact prior to re-installing the valve.
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, slowly INCREASE the pressure until the opening
pressure is determined.
RECORD the opening pressure value on Attachment 5 and DETERMINE if the
relieving pressure is within the established set pressure range.
DEPRESSURIZE the test volume. WAIT at least 5 minutes to demonstrate
repeatability.
Following the 5-minute wait period, slowly INCREASE the pressure until the
opening pressure is determined.
RECORD the second opening pressure value 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
a)

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DEPRESSURIZE the test volume by OPENING/CLOSING the Drain

Valve (7C).
Rev. 27

Page 20 of 30

ATTACHMENT 3
Page 3 of 3
Instructions for Testing Relief Valves Using AAA Tester Oil
b)

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

c)

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

DEPRESSURIZE and DISCONNECT the comparator pump for the relief valve.
DISCONNECT the test flange or other suitable connection from the relief valves
inlet nozzle.
REMOVE the relief valve.

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Page 21 of 30

Attachment 4
Page 1 of 1
Instructions For Performing a Bellows Integrity Test
REMOVE the relief valve from the test stand and REMOUNT outlet flange to test
stand flange.
TEMPORARILY INSTALL a pipe plug at the bonnet vent. Leave the temporary
pipe plug loose such that it will create a leak path upon a bellows integrity failure.
This plug should be loosened enough to allow any bellows air leakage through the
plug/bonnet thread interface.
PRESSURIZE the outlet flange to 30 psig for 1 minute.
APPLY snoop at the plug area to detect any air leakage. No leakage shall be
allowed.
RECORD the results on Attachment 5 in the comments section.
REMOVE the temporary pipe plug installed in the bonnet vent in the previous
steps.

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ATTACHMENT 5
Page 1 of 1
Relief Valve Test Data Sheet
WO No. _____________

Valve Serial No. ___________________

Valve No. ______________

Test Date ____________

Set Pressure ______ (psig)

Set Pressure Range ______ to ______ (psig)

Test Medium Used:

Demineralized Water

Reason for Testing:

As-Found Verification

As-Left Verification

Nitrogen

AAA Tester Oil

Post-Maintenance Testing

Other _________________________________________________

Thermometer ID

Calib. Due Date

Last Calib. Date

Stopwatch ID

Calib. Due Date

Last Calib. Date

Pressure Gauge ID.

Calib. Due Date

Last Calib. Date

Ambient Temperature
Visual Inspection Results:

SAT

UNSAT

Seat Leakage Value __________ gpm or audible sound

SAT

1st Opening/Popping Pressure ____ (psig) Clock Time ______

nd

Opening/Popping Pressure ____ (psig) Clock Time ______

Valve Re-seats: ______ (psig)

Initials

SAT

UNSAT
SAT

UNSAT

SAT

UNSAT

UNSAT (This is not a valid verification of blowdown setting)

Name (Print)

Initials

Name (Print)

Test Performed By:

Comments:

Reviewed By:

Date:
Test Supervisor

IST Review:

Date:
(For valves in Tables 2 and 3)

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ATTACHMENT 6
Page 1 of 2
Test Bench Operational Start-Up Checklist
To ensure the test bench is performing properly, COMPLETE the following preoperational actions.
NOTE:

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

NOTE:

Check-off each step when completed.

BLANK the test plate with an appropriate blind flange (i.e., rated at greater than or
equal to the test pressure and properly sized per Table 1) using the adjustable
hold down clamps provided for valve mounting.
CLOSE the following valves:
Test Bench N2 Supply Valve (7A)
Test Plate Supply Valve (7B)
Drain Valve (7C)
Test Water Supply Valve (7D)
Test Air Supply Valve (7E)
TURN the air regulator (34) counterclockwise to back off any pressure.
INSTALL the applicable test gauge into the quick disconnect on the test bench.
Gradually OPEN the Test Bench N2 Supply Valve (7A) until it is FULLY OPEN and
CHECK to see that the supply pressure is registered on system pressure gauge
mounted on the left hand side of the control panel.
While watching the test gauge, crack OPEN the Test Plate Supply Valve (7B)
allowing the pressure to build up UNTIL it reaches the mid-point of the gauge
scale.
NOTE:

After performing the following step, there should be no decay in pressure

on the test gauge. If the pressure drops, locate and repair the leak in the
system and re-perform the applicable steps.

CLOSE the Test Plate Supply Valve (7B) and OBSERVE that the system is
pressure tight for approximately one (1) minute.

0PT-11.0

Rev. 27

Page 24 of 30

ATTACHMENT 6
Page 2 of 2
Test Bench Operational Start-Up Checklist
If pressure tight, CLOSE the Test Bench N2 Supply Valve (7A) and OPEN the
Drain Valve (7C).
REMOVE the blind flange and CLOSE the Drain Valve (7C).
The test bench is now ready to be used for valve testing

0PT-11.0

Rev. 27

Page 25 of 30

TABLE 1
Page 1 of 1
Test Bench - Maximum Test Pressure
Groove Number

Outside Diameter (inches)

Maximum Test Pressure (psig)

1-45/64

3000

2-3/4

3000

3-3/4

3000

4-3/4

3000

6-7/8

2600

8-5/8

1650

10-7/8

1000

0PT-11.0

Rev. 27

Page 26 of 30

TABLE 2
Page 1 of 1
ASME Code Class 2 and 3 Relief Valves
Maximum
Seat
Leakage
(gpm)
0.5

Set
Pressure
(psig)

Set
Pressure
Range
(psig)

E11-F025A

Seat
Leakage
Pressure
(psig)
338

375

364-386

Demin.
Water

0-600

E11-F025B

338

0.5

375

364-386

Demin.
Water

0-600

E11-F029

167

0.5

185

180-190

Demin.
Water

0-400

E11-V51

405

0.5

450

437-463

Demin.
Water

0-900

Valve must be
tested in horizontal
position

E11-V54

405

0.5

450

437-463

Demin.
Water

0-900

Valve must be
tested in horizontal
position

E21-F012A

450

0.5

500

475-525

Demin.
Water

0-1000

E21-F012B

450

0.5

500

475-525

Demin.
Water

0-1000

E41-F020

90

0.5

100

97-103

Demin.
Water

0-200

E41-F050

94

0.5

110

100-120

Demin.
Water

0-200

E51-F017

90

0.5

100

95-105

Demin.
Water

0-200

E51-F018

90

0.5

100

95-105

Demin.
Water

0-200

C41-F029A

1350

025

1500

1455 1545

Demin.
Water

0 - 3000

Valve inlet must be

kept wet after
removal for testing

1350

025

1500

1455 1545

Demin.
Water

0 - 3000

Valve inlet must be

kept wet after
removal for testing

Valve No.

*note
C41-F029B
*note

Suggested

Test
Medium

Gauge
Range
(psig)

Remarks

Valve must be
tested in horizontal
position

* A bellows integrity test should be performed on the SLC relief valves as a matter of good practice.

This test is not

needed to satisfy code requirements as the bellows does not serve as a balancing device. Ref NCR 206391.

0PT-11.0

Rev. 27

Page 27 of 30

TABLE 3
Page 1 of 2
Non-ASME Code Class IST Relief Valves
Seat
Leakage
Pressure
(psig)

Set
Pressure
(psig)

Set
Pressure
Range
(psig)

Test
Medium

CAC-V59

50

56

54-58

Nitrogen

0-100

2-CAC-PSV-1

135

150

146-154

Nitrogen

0-300

2-CAC-PSV-2

135

150

146-154

Nitrogen

0-300

2-CAC-PSV-3

90

100

97-103

Nitrogen

0-200

2-CAC-PSV-4

135

150

146-154

Nitrogen

0-300

2-CAC-PSV-5

135

150

146-154

Nitrogen

0-300

RNA-PRV5256

110

125

121-129

Nitrogen

0-300

RNA-PRV5258

110

125

121-129

Nitrogen

0-300

RNA-PRV5259

2240

2490

2415-2565

Nitrogen

0-5000

RNA-PRV5260

2240

2490

2415-2565

Nitrogen

0-5000

2-DSA-RV2

349

360

353-370

Nitrogen

0-600

2-DSA-RV4

349

360

353-370

Nitrogen

0-600

2-DSA-RV5

95

110

107-113

Nitrogen

0-300

2-DSA-RV7

349

360

353-370

Nitrogen

0-600

2-DSA-RV9

349

360

353-370

Nitrogen

0-600

2-DSA-RV10

95

110

107-113

Nitrogen

0-300

2-DSA-RV12

349

360

353-370

Nitrogen

0-600

2-DSA-RV14

349

360

353-370

Nitrogen

0-600

2-DSA-RV15

95

110

107-113

Nitrogen

0-300

2-DSA-RV17

349

360

353-370

Nitrogen

0-600

2-DSA-RV19

349

360

353-370

Nitrogen

0-600

2-DSA-RV20

95

110

107-113

Nitrogen

0-300

Valve No.

0PT-11.0

Rev. 27

Recommended

Gauge Range
(psig)
Remarks

Page 28 of 30

TABLE 3
Page 2 of 2
Non-ASME Code Class IST Relief Valves
Seat
Leakage
Pressure
(psig)

Set
Pressure
(psig)

Set
Pressure
Range
(psig)

Test
Medium

2-FOD-RV-1A

40

50

48-52

Oil

0-100

2-FOD-RV-1B

40

50

48-52

Oil

0-100

2-FOD-RV-2A

40

50

48-52

Oil

0-100

2-FOD-RV-2B

40

50

48-52

Oil

0-100

2-FOD-RV-3A

40

50

48-52

Oil

0-100

2-FOD-RV-3B

40

50

48-52

Oil

0-100

2-FOD-RV-4A

40

50

48-52

Oil

0-100

2-FOD-RV-4B

40

50

48-52

Oil

0-100

Valve No.

0PT-11.0

Rev. 27

Recommended

Gauge Range
(psig)
Remarks

Page 29 of 30

REVISION SUMMARY

Revision 27: Incorporates reference to administrative procedure for the NC State

Coded Vessels program, 0ENP-62, responsibilities of Material and Contract Services
group in section 4 and additional guidance on management of repairs of VR stamped
relief valves in Section 6 and 9. This is corrective action per NCR 324862-17.
Revision 26: Changes the seat leakage pressure for the 2-DSA-RV12, 2-DSA-RV14, 2DSA-RV17, and 2-DSA-RV19 from 320 psig to 349 psig following replacement with new
valves per Master EC 62588 (Child ECs 67131 and 67132).
Revision 25: Changes the seat leakage pressure for the 2-DSA-RV2, 2-DSA-RV4, 2DSA-RV7, and 2-DSA-RV9 from 320 psig to 349 psig following replacement with new
valves per Master EC 62588 (Child ECs 67129 and 67130). Also, changed Unit 1 to
Unit 0 on cover page of this procedure.
Revision 24 incorporates IST Program update to the 2001 Edition of the ASME OM
Code through OMb 2003 addenda by updating Section 2.0 and adding definition 3.6.
Revision 23: Deletes reviews by the ANII based on a relief request granted on 2/23/06.
Adds steps for performing a bellows integrity test. Provides clarification on seat
leakage calculation. Changes time between lifts to 5 minutes from 10 minutes for liquid
media testing based on new code allowance. Adds steps to record ambient
temperature to the body of the procedure. Provides clarification to acceptance criteria
in step 8.2. Added 2001 Edition with 2003 Addenda of the OM Code to the references.
Revision 22: Adds discussion in acceptance criteria to allow for Engineering evaluation
of leakage. Adds the recording of pressure to the reseat check in the acceptance
criteria and body of the procedure. Corrects a deficiency in the leakrate calculations.
Adds guidance to procedure to contact Engineering for guidance prior to testing a valve
at >110% of setpoint. Adds recording of the valve serial number to the data sheet in
Attachment 4.
Revision 21: Changes the setpoints for the 1-C41-F029A/B following replacement with
new valves per EC 51017 and 51020. Deletes step 6.15 which directed heating the
1-C41-F029A/B since the SLC system on Unit 1 is no longer heat traced.

0PT-11.0

Rev. 27

Page 30 of 30