ICS 27.120.99
F 69
National Standard of the People’s Republic of China
GB/T 25739—2010
Technical Guideline of Valves Commissioning for Nuclear Power Plant
Issued on December 23, 2010 Implemented on May 1, 2011
Issued by General Administration of Quality Supervision, Inspection and Quarantine of the People's Republic of China and Standardization Administration of the People's Republic of China
GB/T 25739-2010
Foreword
This Standard is drafted according to the rules stated in GB/T 1.1-2009.
This Standard is proposed and archived by China Electricity Council.
Drafting Organizations: Suzhou Nuclear Power Research Institute, China Nuclear Power Engineering Co., Ltd, Zhejiang Electric Power Test and Research Institute, Electric Power Research Institute of Guangdong Power Grid Corporation
Drafters: Hou Cunliang, Liu Yong, Yu Yang, Ying Mingliang, Liu Zhigang, Chen Xiaowei, Sun Quanrong, Yang Yanzhu
GB/T 25739-2010
Technical Guideline of Valves Commissioning
for Nuclear Power Plant
1. Scope
This Standard stipulates the commissioning method, test requirements and acceptance criteria for the safety and non-safety electric isolation valves, pneumatic isolation valves, electric regulating valves, pneumatic regulating valves and manual isolation valves of the nuclear power plant.
This Standard applies to the onsite commissioning of the valves of nuclear power plant.
2. Terms and definitions
The following terms and definitions are applicable in this document.
2.1 Actuator
A driving device which operates the valve and connects the valve body; this device can adopt electric, pneumatic or combined mechanism. Its movement can be controlled via stroke, torque, thrust or their combinations.
2.2 Valve remote controls
A mechanical force transfer mechanism that transfers the force of the valve actuator or hand wheel to the remote valve stem to open or close the valve (also called valve remote transfer mechanism).
2.3 No-load test
The action test of the valve when there is no medium.
2.4 Load test
The action test of the valve under the medium pressure and system running conditions;
3. Commissioning
3.1 Commissioning of electric isolation valve
3.1.1 Commissioning preconditions
3.1.1.1 The commissioning personnel shall have received the electric isolation valve commissioning skill training and have the corresponding qualifications and authorizations.
3.1.1.2 The instruments and meters used for the commissioning shall pass the relevant inspections and tests and are still in their service life.
3.1.1.3 The design and manufacture documents of electric isolation valve are complete and valid.
3.1.1.4 The electric isolation valve and the relevant accessories have been installed in the operable and maintainable positions.
3.1.1.5 The electric, instrument and control circuits of the electric isolation valve have been connected and delivered for commissioning.
3.1.1.6 The power and control power for the electric isolation valve are available, and the relevant safe isolation conditions are provided.
3.1.1.7 The control system of the electric isolation valve has passed the commissioning and acceptance test.
3.1.1.8 The system containing the valve has passed the flush and sealing test. The vale cleanness and sealing performance meet the relevant requirements.
3.1.1.9 The system containing the electric isolation valve has the conditions for safe and reliable isolation.
3.1.1.10 The documents for electric isolation valve commissioning have taken effect, and the relevant commissioning work permit has been obtained.
3.1.2 Inspection before commissioning
3.1.2.1 Confirm that the power and control power of the electric isolation valve have been isolated, and the current protection value has been adjusted.
3.1.2.2 Confirm that the power and control circuits of the electric isolation valve are correctly connected, and the electric parts are properly grounded as per the drawings,
3.1.2.3 Check the components in the control cabinet and their rated values one by one by referring to the drawings.
3.1.2.4 Use the megohmmeter to measure the insulating resistance between the motor coil and enclosure of the electric isolation valve, which shall meet the design requirements.
3.1.2.5 Complete the visual inspection of the electric isolation valve, including the valve marking, nameplate, medium flow direction, valve switch indicators, etc.
3.1.2.6 Confirm that the lubricant of the electric isolation valve meets the technical requirements stated in the manufacturer’s maintenance manual.
3.1.2.7 Confirm that the manual/electric switching mechanism of the electric isolation valve is flexible and reliable, without any clamping stagnation, and the operating torque is proper.
3.1.2.8 Check the switch setting point of the electric isolation valve, which shall meet the design requirements, and check if the torque switches of electric isolation valve act properly and the switch contactors have good contact.
3.1.2.9 Fully close and open the electric isolation valve manually. The valve openness shall be consistent and synchronous with the valve indicator. The valve stroke shall meet the design requirements. Check if the valve stroke switch acts properly and the switch contactors have good contact.
3.1.2.10 Verify the control mode of the electric actuator.
3.1.3 No-load test
3.1.3.1 Place the electric isolation valve in the test bay, turn on control power, and check if the control circuit acts properly.
3.1.3.2 Manually adjust the electric isolation valve actuator to the middle position and power on.
3.1.3.3 Electrically operate the electric isolation valve on the spot and check the actuator running direction.
3.1.3.4 Electrically operate the electric isolation valve on the spot, and check the torque switch and stroke switch control functions, check if the interlinked torque switch and stroke switch act in correct order, if the valve runs smoothly, and if there is no abnormal noise, vibration, shaking or motor overheat.
3.1.3.5 When the actuator runs to the two limit positions, the limit switch shall act correctly and trigger relevant signal, and the actuator shall stop operation.
3.1.3.6 Check the electric isolation valve open and close time, which shall meet the design requirements and specifications.
3.1.3.7 Check the electric isolation valve open and close operating current, which shall meet the design requirements.
3.1.3.8 Check the electric isolation valve position indication and the actual openness difference, which shall meet the design requirements.
3.1.3.9 Place the electric isolation valve in the test bay, operate the electric isolation valve in the main control room, and check if the control circuit acts properly.
3.1.3.10 Place the electric isolation valve in the test bay, and operate the electric isolation valve in the main control room. The valve shall act reliably. Measure the valve open and close time, which shall meet the design requirements.
3.1.3.11 During the remote control operation of the electric isolation valve, the valve shall operate normally, and the valve position indication in the control system shall be consistent with the local actual indication.
3.1.3.12 There shall be no abnormal alarm during the action of the electric isolation valve.
3.1.3.13 For the electric isolation valve with valve remote control, the mechanical force transfer mechanism shall rotate flexibly, and the operation shall be stable and reliable.
3.1.3.14 If the emergency shutdown panel, backup panel and standby control room have the requirements for electric isolation valve control operation, the relevant functions shall be verified.
3.1.3.15 The full open/full close test of the valve shall be conducted for at least 3 times, which shall be recorded for verification.
3.1.3.16 If the electric isolation valve belongs to the containment isolation system, isolation valve leak tightness test shall also be conducted. The leakage value shall meet the design requirements.
3.1.4 Load function verification test
3.1.4.1 During the system function test, the electric isolation valve shall act properly and run smoothly. There shall be no abnormal vibration, noise or alarm.
3.1.4.2 Measure and record the operating current, openness, stroke, open and close time of the electric isolation valve during the system function test, and compare with the parameters of no-load test. The results shall meet the design requirements.
3.1.4.3 After the load test of the electric isolation valve is completed, check the valve and the actuator, including:
a) Confirm that the surface of mechanical component has no wear, scratching and deformation.
b) Confirm that the fasteners are not loose.
c) Confirm that the valve has no leakage.
3.2 Commissioning of electric regulating valve
3.2.1 Commissioning preconditions
3.2.1.1 The commissioning personnel shall have received the electric regulating valve commissioning skill training and have the corresponding qualifications and authorizations.
3.2.1.2 The instruments and meters used for the commissioning shall pass the relevant inspections and tests and are still in their service life.
3.2.1.3 The design and manufacture documents of electric regulating valve are complete and valid.
3.2.1.4 The electric regulating valve and the relevant accessories have been installed in the operable and maintainable positions.
3.2.1.5 The electric, instrument and control circuits of the electric regulating valve have been connected and delivered for commissioning.
3.2.1.6 The power and control power for the electric regulating valve are available, and the relevant safe isolation conditions are provided.
3.2.1.7 The control system of the electric regulating valve has passed the commissioning and acceptance test.
3.2.1.8 The system containing the valve has passed the flush and sealing test. The vale cleanness and sealing performance meet the relevant requirements.
3.2.1.9 The system containing the electric regulating valve has the conditions for safe and reliable isolation.
3.2.1.10 The documents for electric regulating valve commissioning have taken effect, and the relevant commissioning work permit has been obtained.
3.2.2 Inspection before commissioning
3.2.2.1 Confirm that the power and control power of the electric regulating valve have been isolated, and the current protection value has been adjusted.
3.2.2.2 Confirm that the power and control circuits of the electric regulating valve are correctly connected, and the electric parts are properly grounded as per the drawings.
3.2.2.3 Check the components in the control cabinet and their set values one by one by referring to the drawings.
3.2.2.4 Use the megohmmeter to measure the insulating resistance between the motor coil and enclosure of the electric regulating valve, which shall meet the design requirements.
3.2.2.5 Complete the visual inspection of the electric regulating valve, including the valve marking, nameplate, medium flow direction, valve switch indicators, etc.
3.2.2.6 Confirm that the lubricant of the electric regulating valve meets the technical requirements stated in the manufacturer’s maintenance manual.
3.2.2.7 Confirm that the manual/electric switching mechanism of the electric regulating valve is flexible and reliable, without any clamping stagnation, and the operating torque is proper.
3.2.2.8 Confirm that the manual/electric switching mechanism of the electric regulating valve is flexible and reliable, and that the manual operating hand wheel is flexible and reliable, without any clamping stagnation, and the operating torque is proper.
3.2.2.9 Operate the electric regulating valve at 0%, 25%, 50%, 75% and 100% output manually. The valve openness shall be consistent and synchronous with the valve indicator. The valve openness and stroke shall meet the design requirements. The valve stroke switch shall act properly and the switch contactors have good contact.
3.2.2.10 Verify the control mode of the electric actuator.
3.2.3 No-load test
3.2.3.1 Manually adjust the electric regulating valve to the middle position, and set the control signal at 50% position.
3.2.3.2 Turn on the power and control power of the electric regulating valve.
3.2.3.3 Input the control signal. The control actuator shall act properly from 0% to 100%, and provide correct feedback.
3.2.3.4 Input the control signal, calibrate the electric regulating valve, and check the valve linearity, dead zone, and return-stroke error of the valve, which shall meet the design requirements.
3.2.3.5 Input the step signal, and check the open and close time of the electric regulating valve, which shall meet the design requirements and specifications.
3.2.3.6 Operate the electric regulating valve in the main control room, and control the actuator to complete the action verification at the openness of 0%, 25%, 50%, 75%, 100%, 75%, 50%, 25% and 0%. Verify that the electric regulating valve has correct position feedback, the parameters meet the design requirements, and the main control display is consistent with the onsite actual openness.
3.2.4 Load function verification test
3.2.4.1 During the system function test, the electric regulating valve shall act properly and run smoothly. There shall be no abnormal vibration, noise or alarm.
3.2.4.2 During the full-stroke operation of the electric regulating valve, check the pressure drop change, openness and regulation control parameters at the two sides of the inlet and outlet of the electric regulating valve. Important regulating valve shall be subject to flow characteristic test. The steady state flow characteristic curve shall fall within the scope specified in the technical specifications and meet the system flow control function requirements.
3.2.4.3 Measure and record the operating current, openness, stroke, open and close time of the electric regulating valve during the system function test, and compare with the parameters of no-load test. The results shall meet the design requirements.
3.2.4.4 After the load test of the electric regulating valve is completed, check the valve and the actuator, including:
a) Confirm that the surface of mechanical component has no wear, scratching and deformation.
b) Confirm that the fasteners are not loose.
c) Confirm that the valve has no leakage.
3.3 Commissioning of pneumatic isolation valves
3.3.1 Commissioning preconditions
3.3.1.1 The commissioning personnel shall have received the pneumatic isolation valve commissioning skill training and have the corresponding qualifications and authorizations.
3.3.1.2 The instruments and meters used for the commissioning shall pass the relevant inspections and tests and are still in their service life.
3.3.1.3 The design and manufacture documents of pneumatic isolation valve are complete and valid.
3.3.1.4 The pneumatic isolation valve and the relevant accessories have been installed in the operable and maintainable positions.
3.3.1.5 The control circuits of the pneumatic isolation valve have been connected and delivered for commissioning.
3.3.1.6 The control system for the pneumatic isolation valve has passed the commissioning and acceptance test.
3.3.1.7 The system containing the valve has passed the flush and sealing test. The vale cleanness and sealing performance meet the relevant requirements.
3.3.1.8 The compressed air circuit for the instrument is available. The air source is clean, dry and free of corrosive gas, solvent, oil or other liquid.