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APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
LIST OF APPENDICES
STARTUP NETWORK
LIST OF MAJOR PREOPERATIONAL TESTS AND CHECKS
LIST OF MAJOR STARTUP TESTS AND CHECKS
PROCEDURE FOR CONDUCTING THE INTEGRATED STARTUP PROGRAM
7908160 355
50-28\ Ur 8-·13-=l-9
qqo81l,065+
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e
APPENDIX A
STARTUP NETWORK
-
•
Construction Test Phase
SEC. HYDRO
PRIMARY HYDRO·
e STARTUP NETWORK SURRY UNIT NO. 2 ,
"~' LEAK TEST
ECCS INTEGM D
TEST
FUEl-LDAD
HOT NCTION L START
HOT NCTIO
COMPLET
Preoperatlonal Test Phase Startup Test Phase
.. '
('IOTg - All Construction tests ara not required prior to tho
Preoperatlona/ test phase.
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•.
APPENDIX B
LIST OF MAJOR PREOPERATIONAL TESTS AND CHECKS
-
TITLE OF TEST OR CHECK
1. Nuclear Instrumentation
2. Process Instrumentation
1. Pressure Boundary Integrity Tests
a. Hydrostatic test
b. Baseline data for inservice inspection
2. Component Tests
a. Pressurizer Safety Valve
APPENDIX B Pagel of 5
LIST OF PREOPERATIONAL TESTS AND CHECKS
PLANT CONDITION/PREREQUISITE
I. PLANT INSTRUMENTATION
Prior to core loading
Ambient and/or at temperature
TEST OBJECTIVE
Nuclear instruments are aligned and source range detector
reponse to a neutron source checked as the primary source is
loaded.
Required equipment is aligned per station. procedure.a.
II. REACTOR COOLANT SYSTEM
Below 200°F (after verification of cleanliness and fill of
system)
During preoperational testing
Ambient pressure
Cold hydrostatic testing of each Reactor Coolant System loop
will be performed at test pressures as specified by ASME standards
for the system. Prior to pressuriza-tion, the effected portions of
the system will be heated above the minimum temperature for
pressurization. The pressure is then increased in increments, and
at each increment inspections are made for leakage. Leaky valves or
mechanical joints are not a basis for rejecting the test,
Overpressure protection is provided during testing.
Systems and components that require inspection in accor-dance
with Section XI of the ASME Code are examined for base line data.
Data from these inspections provide base line data for subsequent
inservice inspections,
The setpoints of the safety valves are verified using existing
station procedures,
•
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TITLE OF TEST OR CHECK
1. Automatic Reactor Power Control Test Systems
1. Reactor Protection System
2. Engineered Safety Features
1. Residual Heat Removal System Test
APPENDIX B Page 2 of 5
LIST OF PREOPERATIONAL TESTS AND CHECKS
PLANT CONDITION/PREREQUISITE TEST OBJECTIVE
III. REACTIVITY CONTROL SYSTEMS
Preoperational testing The system alignment is verified at
preoperational con-ditions to demonstrate the repsonse of the
system to simulated inputs. These tests are performed to verify
that the systems will operate satisfactorily at power.
IV. REACTOR PROTECTION SYSTEMS
Prior to .core loading
Prior to core loading
Prior to core loading the Reactor Protection is tested to
demonstrate operability, proper logic, redundancy, and coincidence.
The protection channels are verified through to tripping of the
reactor trip breakers.
Prior to core loading the Engineered Safey Features logic
systems are tested to demonstrate operability, proper logic,
redundancy, and coincidence.
V, POWER CONVERSION SYSTEM
Done under Startup Testing
VI. AUXILIARY SYSTEMS
Prior to core loading
I'
"I
Thia aystem i!j tested by verifying pressure and flow. 111 1·,
"• I 11•
•
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TITLE OF TEST OR CHECK
2. Containment Instrument Air System
3. Neutron Shield Tank Cooling System
4. Leak Detection System Tests
1. F.mergency Power Systems
1. Reactor Containment Tests
APPENDIX B Page 3 of 5
LIST OF PREOPERATIONAL TESTS AND CHECKS
PLANT CONDITION/PREREQUISITE
Prior to core loading
Prior to core loading
Prior to and during preoperational tests
VII. ELECTRICAL SYSTEM
Prior to core loading
VIII. CONTAINMENT SYSTEMS
Prior to core loading
TEST OBJECTIVE
characteristics of the pumps and operation of the iso-lation
valves.
The instrument air system. including air receivers and
compressors. is tested to verify proper operation.
The system is operationally checked out to verify heat exchange
operability.
Temperature detectors in the drain lines from pressurizer safety
valves and the reactor vessel head 'seal and their alarm functions
are checked. Pressurizer relief tank level and temperature sensors
are calibrated and associ-ated alarms checked.
The automatic starting and loading of the diesel genera-tors is
demonstrated under loss of emergency bus alter-nating current
power.
Containment Type A leakage tests will be performend in
accordance with USNRC approved topical report BN-TOP-1 Rev. 1,
which provides for a reduced duration test.
Containment Type B & C leakage tests will be performed in
accordance with Appendix J to lOCFRSO •
•
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TITLE OF TEST OR CHECK
2. Containment Isolation Tests
1. High pressure Safety Injection Tests
.\.:.::
2. Low Pressure Safety Injection Tests
e APPENDIX B Page 4 of 5
LIST OF PREOPERATIONAL TESTS AND CHECKS
PLANT CONDITION/PREREQUISITE
Prior to core loading
TEST OBJECTIVE
The operation of actuation systems and components used for
containment isolation is verified.
IX. GASEOUS RADIOACTIVITY REMOVAL SYSTEMS
Done under St:artup Testing
X. EMERGENCY CORE COOLING SYSTEM
Prior to core loading
Prior to core loading
This system is operationally tested to verify pressure/ flow
values. Tests are also conducted to check pump operating
characteristics. More specifically that:
a. Valves installed for redundant flow paths operate as
desigend,
b. Pump operating characteristics are verified.
c. Valves and pumps operate on operator and/or automatically on
initiation of injection signal.
initiation a safety
d. Level and pressure instruments are properly cali-brated.
The low head Safety Injection System is checked to verify design
flow, flow paths, and pump operating characteris-tics. More
specifically that:
a. Valves installed for redundant flow paths operate as
designed.
&
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TITJ.E OF TEST OR CHECK
1. Refueling Equipment (hand tools and power equipment,
including protective interlocks)
1. Criticality and area monitor tests
APPENDIX B Page 5 of 5·
LIST OF PREOPERATIONAL TESTS AND CHECKS
PLANT CONDITION/PREREQUISITE
b. Pump the
TEST OBJECTIVE
operating characteristics reactor coolant system at
are verified with ambient conditions.
c. Valves and motors operate on operator initiation and/or
automatically on initiation of a safety in-jection signal.
d. Level and pressure instruments are properly cali-brated.
In addition a 100 hr. endurance test witl be performed, the pump
disassembled and inspected.
XI. FUEL STORAGE AND HANDLING SYSTEM
Prior to core loading Tests are performed prior to core loading
to demonstrate · the fun~tioning of the fuel transfer system.
XII. REACTOR COMPONENTS HANDLING SYSTEM
Done during startup
XIII. RADIATION PROTECTION SYSTEM
Prior to core loading The radiation alarms aasociated with core
loading are checked out and the alarm setpoints verified.
&
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APPENDIX C
LIST OF MAJOR STARTUP TESTS AND CHECKS
-
TITLE OF TEST OR CHECK
I. Nuclear Instrumentation (excore)
2. Process Instrumentation (Temperature, pressure, level, and
flow instruments)
1. Vibration and amplitude
2. Expansion and Restraint
3. Integrated Hot Functional Tests
APPENDIX C Page 1 of 11
LIST OF STARTUP TESTS AND CHECKS
PLANT CONDITION/ PREREQUISITE
I. PLANT INSTRUMENTATION
Prior to criticality
Ambient and/or at temperature
TEST OBJECTIVE
Just before criticality all channels are checked to verify high
level trip functions, alarm set points, audible count rates where
applicable, and operation of strip chart re-corders, and any
auxiliary equipment.
Equipment is aligned per station procedures,
II. REACTOR COOLANT SYSTEM
After fuel load
During plant heat-up
Heat-up and at temperature Hydrostatic testing has been
satisfactorily com-completed and Reactor Coolant System instruments
aligned and operational. Associated auxiliary systems shall be
operational to the
Vibration sensors are placed on the main coolant pumps and main
cooling piping in order to check for excessive vibration while
starting and stopping the pumps. ·
During the heat-up to operating temperature, selected point on
components and piping of the Reactor Coolant System are checked at
various temperatures to verify unrestricted expansion. Points of
interference detected during the heat-up are corrected prior to
increasing the temperature.
The Reactor Coolant System is tested using pump heat to reverify
heat-up procedures and to demonstrate satis-factory performance of
components and systems exposed to reactor coolant system
temperature. Proper operation of instrumentation, controllers and
alarms, is checked against design operating conditions of auxiliary
systems and set points verified. Among the demonstrations
per-formed are:
•
I \·
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TITLE OF TEST OR CHECK
4. Component Tests
a. Pressurizer
APPENDIX C Page 2 of 11
LIST OF STARTUP TESTS AND CHECKS
PLANT CONDITION/PREREQUISITE
extent required to support hot functional testing,
At operating temperature,
TEST OBJECTIVE
a. To check that water can be charged by the Chemical and Volume
Control System at rated flow against normal reactor coolant
pressures,
b. To check letdown design flow rate for each operating
mode,
c. To check response of system to change in pressurizer
level,
d, To check operation of the excess letdown and seal water flow
paths.
e, To check steam generator level instrumentation re-sponse to
level changes.
f. To check thermal expansion of selected system com-ponents and
piping.
g, To perform temperature
isothermal detectors
calibration and incore
of resistance thermocouples,
h. To operationally check out the Residual Heat Removal
System,
During the hot functional testing the pressure controlling
capability of the pressurizer is demonstrated to be with-in the
controlling band, With reactor coolant pumps operating and with
full spray, the pressure-reducing capa-bility of the pressurizer is
verified. With the spray secured and all heaters energized, the
pressure-increasing
•
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TITLE OF TEST OR MEASUREMENT
b. Reactor Coolant Pumps and Motors
c. Steam Generators
5. Pressure Test of Reactor Coolant System
APPENDIK C . Page 3 of 11
LIST OF STARTUP TESTS AND CHECKS
PLANT CONDITION/PREREQUISITE
At ambient conditions and during heat-up and at temperature.
At ambient conditions and during heat-up and at temperature.
Prior to criticality
I
I ..
TEST OBJECTIVE
capability of the pressurizer is verified. Pressurizer Relief
valves are functionally checked.
As the pumps and motors are placed in operation they are checked
for:
1. Direction of rotation (initial start only)·
2. Vibration
3. Power requirements
4. Lubrication
5. Cooling
6. Megger and hi pot test (as applicable)
7. Overload protection
8. Correct power supply voltage
The proper operation of instrumentation and control systems of
steam generators are checked during heat-up and at temperature. The
heat transfer capability of the steam generators is demonstrated.
The functioning of the blowdown system will be checked.
Following core loading and installation of the Reactor Vessel
head and torquing of the reactor vessel heads studs, pressure
testing is performed in accordance to Tech. Spec.
•
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TITLE OF TEST OR CHECK
6. Chemical Tests (to establish water quality)
7. Reactor Coolant Flow Test
l. Chemical and Volume Control System Tests
2. Emergency Boration System Teats
APPENDIX C Page 4 of 11
LIST OF STARTUP TESTS AND CHECKS
PLANT CONDITION/PREREQUISITE
Prior to heat-up during startup testing
Prior to plant criticality
TEST OBJECTIVE
Water fr Reactor Coolant System fill and makeup is analyzed for
chloride content, conductivity, total sus-pended solids, pH,
clarity, and fluorides to requirements specified by the chemistry
manual for ~SSS. Following core loading and prior to exceeding 250
F, hydrazine is added to scavenge oxygen prior to critical
operation. Prior to, at criticality, and during power escalation,
chemical analysis is performed to verify requirements.
Following core loading, measurements are made of elbow tap
differential pressures to make relative comparison. At hot shutdown
conditions following core loading, measurements of loop elbow
differential pressure drops were made. Using these data with the
reactor coolant pump performance curve, the calculated flow is
verified to the design flow. Flow coastdown and transients
following reactor coolant pump stoppages are also determined at
shutdown conditions following core loading.
III. REACTIVITY CONTROL SYSTEMS
At ambient and/or at operating conditions. System components are
operationally checked out,
During hot functional testing.
Makeup and letdown operations are conducted with the Chemical
and Volume Control System to check out the dif-ferent modes of
dilution and boration and verify flows in the different modes. The
adequacy of heat tracing to main-tain the required Boric Acid
concentration in solution is verified. The ability to adequately
sample is demon-strated.
The pressure/flow characteristics of the emergency bora-tion
system are verified . by pumping into the Reactor Coolant
System.
•
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TITLE OF TEST OR CHECK
3. Incore Monitor System Test
a. Incore Thermocouples
b. Moveable Detector System
4. Control Rod Systems Tests
a. Rod Control System
b. Rod Drop Tests
c. Rod Position Indication
APPENDIX C Page 5 of 11
LIST OF STARTUP TESTS AND CHECKS
PLANT CONDITION/PREREQUISITE
During heat-up and at temperature.
At ambient conditions following core loading and critical
testing.
Ambient conditions following core loading and hot conditions
after core loading. '
Cold and hot plant conditions following core loading,
At ambient conditions and at temperature following core
loading.
TEST OBJECTIVE
During heat-up and at temperature the incore thermocouples are
calibrated to the average of the Reactor Coolant System resistance
temperature detectors. All readout and tempera-ture compensating
equipment is checked during the calibra-tion and isothermal
corrections for the operative thermo-couples are determined.
After core loading, the installation checkout of the move-able
detector system will be completed.
During the installation check of this system it is ener-gized
and operationally checked out with mechanisms connected to each
power supply. The ability of the system to step the mechanism is
verified, the alarm and inhibit functions checked out and the
correct values of system parameters adjusted to specified values.
After core load-ing the operation of each rod over its full range
of travel is demonstrated.
At cold and hot plant conditions following core loading the drop
times of the full length rods are measured, The drop time is
measured from the release of the rod until the rod enters the top
of the dashpot. This time was verified to be less than the maximum
value specified in the Technical Specifications.
During rod control system tests the position indication system
was aligned to provide rod movement indication. Rod bottom set
points will b!! adjusted during these tests. After plant heat-up
individual rod positions a["e cali-brated to within tolerances
specified by the test proce-dure,
Cl
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• TITLE OF TEST OR CHECK
1. System Tests
a. Vibration Frequency and Amplitude
'' ··-b. Expansion and Restraint ··:::• ·
2. Components and Individual System
a. Steam Generator Pressure Relief and Safety Valves
APPENDIX C Page 6 of 11
LIST OF STARTUP TESTS AND CHECKS
l PLANT CONDITION/PREREQUISITE TEST OBJECTIVE
IV. REACTOR PROTECTION SYSTEM
Done during Properational Testing
V. POWER CONVERSION SYSTEM
Hot Functional Testing and/or plant heat-up following
criticality
During heat-up, and at temperature.
Pressure Conditions
When the main turbine is rolled, vibration readings are
monitored. · (Turbine vibrations are also monitored throughout the
power escalation program.) Major equip-ment (e.g., feedwater pumps
and condensate pumps are operated as they become available and are
observed for indications of excessive vibration.
During heat-up to operating termperature, selected points on the
components and piping of -the systems are checked at various
temperatures to verify that they can expand un-restricted.
The set point of safety valves was verified by in-plant tests at
pressure and temperature conditions when the unit was shut down.
Setpoints were checked by using a pressure assist device which adds
to the force due to pressure. Once the valve leaves the seated
position the assist device was vented, allowing the valve to reseat
immediately. Steam relief valve set point checks were made during
instrument alignment •
•
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TITLE OF TEST OR CHECK
b. Emergency Feedwater (Auxiliary) System
c.
d.
e.
f.
T~rbine Control and Bypass Valves
Feedwater and Feedwater Co·· ,:-rol System
Condenser Circulating Water
Makeup Water and Chemical
• APPENDIX C Page 7 of 11 •• LIST OF STARTUP TESTS AND
CHECKS
PLANT CONDITION/PREREQUISITE
Prior to citicality
Hot Functional test:1.ng and/or power operat:l.on following
criticality
Hot functional testing and at Power
Prior to bot functional testing
During Steam generator fill, hot functional testing and
TEST OBJECTIVE
During bot functional testing prior to criticality the emergency
feedwater system is checked out to verify its ability to feed the
steam generators. Automatic starting is checked during checkout of
the safeguards logic system tests. The auxiliary feedwater piping
is checked for excessive vibration while starting and stopping the
auxi-liary -feedwater pump with normal operation of the associ-ated
motor operated discharge valves in the auxiliary feedwater
system,
During hot functional testing the turnbine control system will
be demonstrated in turbine operation up to and in-cluding a period
of operation at synchronous speed, The turbine bypass valves to the
condenser and their associat-ed control systems are operationally
checked out during hot functional testing.
The feedwater and condenstate pumps are operationally checked
out during hot functional testing. During· power escalation the
power is increased and the ability of the feedwater pumps and
control system to maintain level in the system generators are
aligned prior to filling the system and during fill, the system is
used to monitor level in the steam generator.
Prior to hot functional testing the main circulating water
system valves are tested to verify operability.
The makeup system to the system generators is checked out during
hot functional testing and at Power at power. The chemical
treatment system is checked out when chemicals are added to the
steam generators at heat-up to steaming conditions.
•
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TITLE OF TEST OR CHECK
1, Reactor Coolant System Makeup Test (CVCS)
2. Seal and Pump Cooling Water Test (CVCS)
3. Secondary Vent and Drain System Test
4. Component Cooling System Test
5. Residual Heat Removal System Test
6. Service Water System Test
7. Control Rod Drive Mechanism and Rod Position Indication Coil
Cooling System Test
8. Primary Sampli~g System
• APPENDIX C Page 8 of 11 •• LIST OF STARTUP TESTS AND
CHECKS
PLANT CONDITION/PREREQUISITE
VI. AUXILIARY SYSTEMS
Prior to heat-up and at temperature
During hot functional testing
Ambient and/or hot plant conditions
Prior to and during hot functional testing
Prior to hot functional
Prior to and/or during hot functional tesintg
Prior to and/or during hot functional testing
I
./ TEST OBJECTIVE
See III REACTIVITY CONTROL SYSTEM, Item 1.
Prior to reactor coolant pump operation and with the system
pressurized flow to the pump seals and cooling water is set, flow
is adjusted to specified values using installed instruments. During
hot functional testing when at operating temperature and pressure,
seal and cooling flows and temperatures are checked, ·
During hot functional testing following core loading the
secondary system is vented while pressurizing the second-ary
system, Secondary drains are tested for unrestricted flow in
accordance with operating procedures,
Component cooling flow to the various components in the affected
systems is adjusted, the system operationally checked out, and set
points verified,
Heat removal capability demonstrated,
The system is operationally checked out to verify pressure and
flow. Service water flow is verified to components in the
system.
The system is operationally checked out to verify air flow,
temperatures and motor current,
Operations are performed to:
-.;"r'
•
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TITLE OF TEST OR CHECK
9, Primary Pressure Relief System
1, Containment Ventilation System Test
2, Post Accident Heat Removal System Tests (Containment
Sprays)
• APPENDIX C Page 9 of 11 •• LIST OF STARTUP TESTS AND
CHECKS
PLANT CONDITION/PREREQUISITE
Prior to hot functional · testing and at pressure conditions
TEST OBJECTIVE
a. Demonstrate that liquid and gas samples can be obtain-ed from
sample points.
b. Demonstrate that valves, instruments, and controls funtion
properly.
c. Verify power functioning of the sample cooler.
The pressurizer relief tanks associated valves, and
in-strumentation are checked out to verify performance of design
functions, For testing of pressurizer relief and safety valves see
II REACTOR COOLANT SYSTEM. '
VII. ELECTRICAL SYSTEM TESTS
Done during Preoperational Testing
VIII. CONTAINMENT SYSTEMS
Prior to and/or during hot functional testing
Prior to criticality
The system is operated to balance air flows and to verify the
ability to maintain temperatures below maximum allow-able
limits,
Testa are performed to verify pump operating charcteris-tics,
and response to control signals, sequencing of the pumps, valves
and controller, (and to ensure that spray nozzles were
unobstructed,)
•
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TITLE OF TEST OR CHECK
1. Accumulator Tests
l. Spent Fuel Storage Radiation Monitoring Equipment
•..... ........
-
TITLE OF TEST OR CHECK
l, Initial Criticality
l. Power Ascension
• APPENDIX C Page 11 of 11 •• LIST OF STARTUP TESTS AND
CHECKS
PLANT CONDITION/PREREQUISITE TEST OBJECTIVE
XIV. INITIAL CRITICALITY AND LOW POWER TESTS
Plant at hot shutdown
XV. POWER ASCENSION
Criticality
,.
-The objective is to bring the reactor critical from the plant
conditions specified. Prior to start of rod with-drawal, the
nuclear instrumentation had been aligned, checked, and conservative
reactor trip set points made per procedures, At preselected points
in rod withdrawal, data is taken and inverse count rate plots made
to enable extrapolating to the expected critical rod position, In
addition, the following teats associated with modified system will
be performed: steam generator water hammer test, blowdown system
capability test and thermal expan-sion monitoring.
Normal poet refueling testing will apply for power ascen-sion,
In addition the following design tests associated with modified
systems will be performed.
steam generator carryover tests
steam generator recirculation ratio test
steam generator thermal and hydraulic perfomrance
verifi-cation
steam generator water level stability and control
demon-stration
condensate polishing performance testing
load rejection testing with condensate polisher
•
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APPENDIX D
PROCEDURE FOR CONDUCTING THE INTEGRATED STARTUP TEST PROGRAM
•
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I Issue Date: AUG 8 1979
PROCEDURE
FOR CONDUCTING THE
INTEGRATED STARTUP TEST PROGRAM
•
A,HA!P.'.,,1/\N- SUR~ PO\NER STATION .NlJCU.:1\R s.:1FET AND
OPERATING
. COM.MiHEE
FOR POST
STEAM GENERATOR REPLACEMENT
AND
P.O. & M. DESIGN CHANGES
SURRY POWER STATION
VIRGINIA ELECTRIC AND POWER COMPANY RICHMOND, VIRGINIA
Superintendent Operations:
Lead Advisory Engineer:
PO & M Resident Engineer:
DA TE
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•
•
INTEGRATED STARTUP TEST PROGRAM
TABLE OF CONTENTS
1. 0 Purpose and Scope
2 • 0 References
3 • 0 Definitions
4, 0 Participating Organizations
5. 0 Construction Test Phase
5, l General 5. 2 Responsibilities 5. 3 Release for
Preoperational Testing
6. 0 Preoperational Test Phase
6 .1 General 6. 2 Respons bili ties 6. 3 Release for Startup
Testing
7, 0 Startup Test Phase
7 .1 General 7, 2 Responsibilities 7. 3 Startup Release
Points
8. 0 Attachments
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1. 0
SURRY UNITS 1 AND 2 VIRGINIA ELECTRIC AND POWER COMPANY
RICHMOND, VIRGINIA
PURPOSE AND SCOPE
1.1 To provide a procedure for the accomplishment of the tests
and checks to be completed prior to plant operations.
1. 2 To define the phases of the Integrated Startup Test
program.
1. 3 To define the responsibilities of the organizations
participating in the Integrated Startup Test program.
1. 4 To provide the necessary administrative controls to ensure
all pre-requisites are complete prior to commencing the next phase
of test-ing.
1. 5 To define responsibilies for the preparation of test
procedures and test matrices.
2 .0 REFERENCES
2.1 ES-119, Equipment and System Tagging, Surry Power Station
Units Nos. 1 and 2
2. 2 VEPCO Nuclear Power Station Quality Assurance Manual
2. 3 Stone & Webster Logic Diagrams and System
Descriptions
2. 4 VEPCO Calibration Procedures
2. 5 Final Design Change Packages for each modification
3.0 DEFINITIONS
3 .1 Phases of the Integrated Startup Test Program
The Integrated Startup Test program is divided into three
phases: Construction Tests, Preoperational Tests and Startup Tests.
The objectives and responsibilities of each phase are defined
below.
The Construction tests are under the direction of the Release
Coordi-nator and are designed to assure proper construction of
modified or new systems. Construction deficiencies are resolved by
the Release Coordinator •
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The Preoperational Tests are under the direction of the Startup
Group and are designed to assure proper functioning of new,
modified and existing equipment, subsystems and systems.
The Startup Tests are under the direction of Station Operations
and are designed to assure the proper integrated operation of all
re-quired systems prior to the next sequence of power
operation.
3. 2 General Electrical, Instrument and Mechanical Test
Procedures
These procedures are referred to as TEP's TIP's and TMP's. These
generic procedures are approved by the Station Nuclear Safety and
Operating Committee and are used to verify proper installation and
initial operability of equipment. These procedures are used during
the Construction Test phase and Preoperation Test phase.
3. 3 Cleaning And Flushing
3. 3 .1 Cleaning Procedures
Cleaning will be performed in accordance with issued guides and
general procedures to ensure satisfactory cleanliness of systems
and components. Cleaning will include mechanical cleaning and hand
cleaning, The Station Nuclear Safety and Operating Committee shall
designate cleanliness grades for individual systems via approved
design change packages •
3. 3. 2 Flushing Procedures
A written procedure to ensure strict compliance with
cleanli-ness requirements for nuclear steam supply and safety
related systems. Station Nuclear Safety and Operating Com-mittee
approval is required for generic flushing procedures and design
change controlling procedures.
3 . 4 Electrical Checks
Checks performed as part of design change package to ensure that
an instrument or electrical control loop is complete and correctly
connected. These checks shall include, but not be limited to,
breaker tests, insulation tests, and motor control center tests to
ensure the integrity of the control circuit or equipment.
3. 5 Mechanical Checks
A set of checks performed for the purpose of verifying that a
piece of mechnical equipment (pump, compressor, blower, etc.) is
ready for initial startup. These checks shall include, but not be
limited to, alignment, coupling, manufacturers' recommended
lubri-cation, packing gland adjustment, etc., as applicable for the
equip:-ment being readied for startup •
3. 6 Hydrostatic Test
Pressure testing to meet the applicable erection code and to
ensure
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3.7
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system integrity. The Station Nuclear Safety and Operating
Com-mittee approval is required for these generic procedures.
Calibration
Quantitative adjustments of instruments and control devices,
includ-ing characterization of analog signals, quantitive setting
on all control and monitoring loop elements and verification of
response characteristics.
It also applies to those calibration checks which verify
quantitive accuracy and functional integrity of the devices or
instruments loop previously calibrateq. by others, or to verify
functional inte-grity of the devices or instruments which are not
adjustable by normal means, such as thermocouples, conductivity
cells, thermo-meters, etc.
3. 8 Calibrated Loop Check
A set of tests performed for the purpose of verifying that an
in-strument loop is acceptable in terms of quantitive agreements,
proper inter-relationship, and expected responsiveness of several
loop elements. This set of tests is performed with all loop
com-ponents in place, individually calibrated and documented, and
devices energized by applying simulated inputs and measuring or
observing loop performance .
3 • 9 Functional Loop Check
A set of tests performed for the purpose of verifing that a
control and/ or telemetering loop is acceptable in terms of
functional in-tegrity and interrelationship of the several loop
elements. This set of tests is performed with all loop components
in place, structurally complete, and engergized, by applying
simulated inputs and observ-ing loop performance. Loop elements
need not be individually calibrated.
3 .10 VEPCO Electrical Check-Out
VEPCO electricians, for 480 V circuit breakers, will perform
contact inspection, dashpot and mechanism inspection, set trip
valves with multi-amp tester, and megger insulation. For 4160V,
they will perform contact and mechanism inspection and check trip
and close times with analyzer. Additionally, dielectric checks will
be made on 4160V cables, doble tests and ratio 4160 / 480V
transformers and doble test 4160V circuit breakers.
3 .11 Preoperational Check-Out
Test of an individual item of equipment, subsystem or minor
system to verify readiness for operations •
3 .12 Operating Procedure (OP)
A station procedure developed by VEPCO and approved by the
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3 .13
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Station Nuclear Safety and Operating Committee for normal
opera-tion of equipment and systems.
Periodic Test Procedure (PT)
A station procedure developed by Vepco and approved by the
Station Nuclear Safety and Operating Committee to meet Tech. Spec.
or surveillance requirements for operability.
3.14 Special Test Procedure (ST)
A station procedure developed by Vepco and approved by the
Station Nuclear Safety and Operating Committee to obtain data,
associated equipment performance, or other technical data required
for engineering or operational evaluation.
3 .15 Functional System Operability Procedure ( FSOP)
3.16
A procedure developed by the Startup Group to verify and
docu-ment the functional operation of equipment and/or controls. It
will verify and document the functional operation of critical
controls. FSOP's are generally written to utilize existing logic
diagrams.
Electrical, Instrument and Mechanical Maintenance Procedures And
Maintenance Operability Procedure
These generic station procedures are referred to as EMP's,
IMP's, MMP's and MOP's. These procedures are used by station
person-nel to checkout previously installed equipment that has
undergone maintenance and to remove and replace safety related
equipment in service.
3 .17 Test Matrix
A matrix that indicates which TEP, TIP, TMP, and/or existing
station procedure (OP, PT, ST, IMP, EMP, MMP or MOP) will be
performed on an individual test loop, instrument, valve, device or
component.
4.0 PARTICIPATING ORGANIZATIONS AND RESPONSIBILITIES
4.1 Station Nuclear Safety and Operating Committee
4.2
Consisting of representatives from Surry Power Station as
desig-nated in the Vepco Nuclear Power Station Q. A. Manual. The
Station Nuclear Safety and Operating Committee reviews and approves
all test procedures. The committee reviews a summary of test
results and approves release of the next phase of Startup
Testing.
VEPCO Operating Staff
Consists of VEPCO employees engaged in the operation and
main-tenance of systems, subsystems, or portions of the station
under the supervision of the station manager.
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VEPCO Operating Staff may witness Construction tests as desired
for correct operation, testing and verification of design
performance during final construction testing. VEPCO Operating
Staff will per-form necessary and timely inspections and perform
evaluations as necessary to effect a smooth release of systems for
Preoperational testing.
VEPCO Operating Staff will conduct Preoperational and Startup
test-ing and is responsible for the operation of the plant and the
per-manently installed plant process equipment connected to an
ener-gized power source.
4. 3 Westinghouse Electric Corporation (W)
The term Westinghouse or W shall be limited to equipment and
services furnished as part of or under the contract for the nuclear
steam supply and turbine generator systems.
4.4 NUS Corporation (NUS)
The term NUS shall be limited to equipment and services
furnished as a part of or under the contract between Vepco and NUS
Corpora-tion. NUS shall furnish engineering services where required
by Vepco.
4. 5 Stone & Webster Engineering Cor oration - Engineerin
Department S&W-BOSTON
S&W shall furnish engineering services where required by
VEPCO.
4. 6 Daniel Construction Company ( Daniel)
Daniel shall furnish construction services as required by
Vepco.
4. 7 Vepco Project Engineers
This group of engineers is responsible to resolve component and
system deficiencies discovered during the Construction Test and
Preoperational Test phases.
4. 8 Quality Control
Consists of Quality Control related functions as defined in
approved design change packages and test procedures.
4.8.1 Vepco SGRP Q.C.
This group is responsible for quality control for all
con-struction work and construction testing as defined in the Vepco
Nuclear Power Station Quality Assurance Manual. Daniel Q. C.
supplements Vepco Construction Q. A, as directed by Vepco .
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4. 8. 2 Vepco Station Q. C.
This group is responsible for quality control during the
Preoperation Test phase and Startup Test phase. The level and
extent of Q. C. coverage is defined in the individual
procedure,
4. 9 Startup Group
The Startup Group is responsible for the development and
implemen-tation of the Integrated Startup Test program. It consists
of S & W Advisory Engineers under the direction of the S &
W Lead Advisory Engineer and designated VEPCO operators under the
direction of the designated VEPCO Shift Supervisor each responsible
to the Station Superintendent of Operations.
The S & W Lead Advisory Engineer is responsible for the
implemen-tation of the Integrated Startup Test program described
herein and as outlined in station directives and applicable
regulatory guides. In conjunction with the VEPCO Shift Supervisor,
he will provide the technical direction and expertise to ensure the
timely completion of the required testing. He will also be
responsible for the develop-ment and management of the necessary
documentation to support the Integrated Startup Test program.
The designated VEPCO Shift Supervisor is responsible for the
execution of the Integrated Startup Test program. He will provide
coordination with the operating staff for the safe operation and
the interfacing of existing plant systems to support the Integrated
Startup Test program. In conjunction with the Lead Advisory
En-gineer, he will direct the assigned personnel and provide
operational guidance to ensure the timely completion of the
required testing.
The Startup Group is responsible for conducting the test and
checks under their jurisdiction. The group will ensure that all
required test procedures and test matrices are developed and are
available for use. The Startup Group is responsible for assuring
all tests in the Integrated Startup Test program are performed in
accordance with approved test procedures and for reviewing and
approving all test data through the Preoperational Test Phase. The
group is responsible that all design change test procedures and
test matrices are written and approved to support Construction,
Preopera-tional and Startup testing. The group is responsible for
records management for the Preoperational and Startup Test
phases.
4 .10 VEPCO Construction Staff
The construction program is functioning under the direction of
two resident engineers, the Resident Engineer for the Steam
Generator Replacement Project (SGRP) and the Resident Engineer for
the Production Operation Modifications ( P. 0. M.) .
The Resident Engineer (SGRP) will be responsible for all rework
associated with the Stearn Generator Replacement Project.
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4.11
-- -- -- --~----- - -, - ----
--·----------------··------------~- --~----- ---~---
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All the rework associated with the other modfications and the
Construction Test phase will be the responsibility of the Resident
Engineer (P. 0 .M.) who is designated the Release Coordinator. The
Release Coordinator is responsible to the Superintendent of
Operations for the Construction Test phase.
VEPCO Construction Test Group ( CTG)
The Construction Test Group is composed of designated
individuals from each organization participating in the
construction program,-and is directed by the Release
Coordinator.
The CTG is responsible for timely completion of all segments of
the Construction Test phase. Also, the CTG will provide support, as
required, to the Startup Group during the Preoperational and
Startup Test phase.
4, 12 Superintendent of Operations
The overall responsibility for the direction and management of
the Integrated Startup Test program is under the control of the
Station Superintendent of Operations. The responsiblity for the
direction and management within the Construction Test and·
Pre-operational Test phases is assigned to the Release Coordinator
and Startup Group respectively .
4 .13 Startup Coordinator
The Startup Coordinator works directly for the Superintendent of
Operations. His sole responsibility is to ensure the smooth
day-to-da y operation of all phases of the Integrated Startup Test
program.
4.14 Superintendent of Technical Services
The Superintendent of Technical Services engineering review and
analysis of the Program. He will be responsible for analysis,
engineering review and analysis tional tests and the major Startup
tests.
will provide the required Integrated Startup Test
the development, safety of the selected Preopera-
5.0 CONSTRUCTION TEST PHASE
5.1 General
The Construction Test Phase for new and modified systems is the
responsibility of the Release Coordinator and will be accomplished
by construction personnel. The Construction Test Phase includes all
nondynamic tests and checks included in the design change package
to verify proper installation of equipment. A list of unre-solved
system deficiencies will be recorded during the test period and
transmitted to the Startup Test Group with the system release. All
systems will be released as soon as possible to support
pre-operational tests.
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All activities of the Construction Test Phase shall be performed
in accordance with specifications and design change packages and
other approved procedures, as applicable.
The tests associated with this phase include: insulation
resistance measurements, control circuitry checkout, low-voltage
switchgear inspection, MOV (static) checkout, Circuit breaker and
overload checkout (Vepco A & C), 480V MCC inspection, I & C
electrical checkout, I & C mechanical checkout, annunciatior
checkout, heat trace checkout and general hydrostatic tests.
5. 2 Responsibilities
5.2.1 Vepco Construction Staff
5. 2 .1.1 Construction Test Group
5.2.1.2
5.2.1.3
Works directly for the Release Coordinator and in conjunction
with the Startup Group and is responsi-ble for ensuring the timely
completion and testing of systems and components, The group is
addi-tionally responsible for correction of outstanding
construction deficiencies found as a result of accep-tance tests,
or Q, C. inspection during the next phase of testing .
All Category I deficiency corrections shall be docu-mented by a
Daniel or VEPCO generated noncon-formance report.
Release Coordinator
The responsibilities of the Release Coordinator are assigned to
the PO&M · Resident Engineer for new and modified .systems.
He is responsible for seeing that System Releases are promptly
processed and he will maintain a status of all outstanding design
change deficiencies. For operating systems that did not require
modifica-tions, the Startup Group will maintain the status.
Responsible System Engineer
As the Construction Test phase of the Design Change Package is
completed, the responsible construction System Engineer will
walkdown the release and ensure that all work has been completed
and the system is ready for initial operation and Preoperational
testing. Any items that are found to be incomplete shall be
documented on a Deficiency List. Those deficiencies that limit
Preoperational testing will be resolved prior to System
Release.
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5 , 2. 2 Startup Group
5.2.3
The Startup Group is responsible to provide technical advice in
the preparation of systems and components to support planned
Construction Tests.
The Startup Group is responsible for assuring that all
Elec-trical, Mechanical and Instrument Construction tests are
performed in accordance with established test procedures (TEP, TIP
and TMP's) and for reviewing and verifying com-pleteness of all
test data. It is also responsible for writing additional detailed
procedures as needed for implementation of general procedures. It
will be responsible for obtaining resolutions for all
deficiencies,
The Startup Group shall verify that a System released by the
Release Coordinator has reached a point of construction completion
to be accepted for Preoperational testing.
Vepco Construction Quality Control
Shall perform required inspections and audits to assure that the
Construction Test Program is conducted in accordance with the
design change packages.
5.2.4 Vepco Station Quality Control
VEPCO station QC shall ensure the requirements for system
documentation of the Station Nuclear Safety and Operating Cammi
ttee are met,
5, 3 Release For Preoperational Testing
When construction testing on a system or subsystem thereof is
complete, the responsible system engineer will perform a walkdown
of the system to ensure completion, markup II as-built" conditions
on DC package drawings and generate a 1 deficiency list based on
the test results and visual inspection.
The· system is presented to the Startup Group for Preoperational
Testing via a (Design Change-Construction) System Release form (
Attachment 8 .1) and a Deficiency Punch List ( Attachment 8,
2).
The Startup Group either "accepts" or "rejects" the system
release, A rejected system release is returned to the Release
Coordinator for completion of Preoperational Test limiting
deficiences,
6.0 PREOPERATIONAL TEST PHASE
6.1 General
When a system or subsystem is sufficiently complete and other
re-lated systems have progressed for enough so it can perform
its
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assigned function, the Startup Group, accepts the released
system for Preoperational Testing.
Prior to signing the system release form ( Attachment 8 .1), the
Startup Group will make a thorough review of all the attached
documents and a member of the Startup Group will walkdown the
system to insure that there is no outstanding item that will affect
safe operation of equipment or system. If any items are found to be
unsatisfactory the required acceptance signatures will then be
withheld by the Startup Group until these items are resolved.
The Preoperational Test Phase for modified, new and existing
systems is the responsibility of the Startup Group and will be
accomplished by Vepco operations staff supplemented by construction
personnel.
As the system releases for new and modified systems are accepted
by the Startup Group, the required Preoperational testing will
begin. During this phase, field changes will be generated to
resolve problems discovered during testing and operations, These
field changes will be forwarded to Release Coordinator for
resolution and implementation. Any rework that is needed will be
controlled by a "Rework Control Form" (Attachment 8.3) issued by
the Start-up Group listing the required retests.
System release forms will be generated by the Startup Group for
all remaining systems associated. with the Unit. The existing
systems not associated with design changes can be classified as
follows: remained in service, removed from service for maintenance
and re ... turned to service, did not remain in service and is in
the area of design change construction, and did not remain in the
service but is not in an area affected by design change
construction, The extent and level of testing assigned by the
Startup Group to testing of these systems will be based on this
classification.
Vepco I & C will calibrate instruments and controls as the
precali-bration tests are completed by the Startup Group.
Preoperational testing includes all designated tests procedures
(TIP, TEP and TMP) along with applicable station procedures (ST,
PT, OP, MOP, EMP, IMP, MMP).
The tests associated with this phase include: dynamic MOV
check-out, uncoupled and coupled motor runs, uncoupled and coupled
vibration tests, I & C functional checkout, AOV / AOD setup and
checkout, I & C hydrostatic test, AOV / AOD dynamic checkout,
air balancing, pump curve verification, flushing and FSOP 1S.
6. 2 Responsibilities
6.2.1 Construction Test Group
Responsible as noted on the Deficiency Punch List (Attach-ment
8. 2) for correction of construction deficiencies found as a result
of testing or Q • C, inspection.
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6, 2, 2 Startup Group
6.2.3
6.2.4
The Startup Group is responsible for: ensuring the timely
Preoperational testing of systems and components., documen-tation
of discrepancies determined during testing; maintain-ing a status
of all outstanding deficiencies for existing systems that did not
require modification, providing technical direction in the
preparation of systems and components to support planned
Preoperational tests, assuring that all Electrical, Mechancial and
Instrument tests are performed in accordance with established test
procedures, (TEP, TIP and TMP's), reviewing and approving of all
test data, writing additional detailed procedures as needed for
implmentation of general procedures and obtaining resolutions for
all defi-ciencies. The group will also be responsible for initial I
& C and electrical setup of new equipment.
The Startup Group shall be responsible for determining if a
system has reached a point where it can be presented to the Station
for approval for unrestricted operation.
Vepco Station Quality Control
This group shall perform required inspections and audits to
assure that the Preoperational Test phase is conducted in
accordance with the approved procedures •
Vepco Station Q , C, shall ensure the requirements for system
documentation of the Station Nuclear Safety and Operating Committee
are met.
Vepco I & C and Electrical
These groups shall perform calibration and maintenance on
equipment per system test matrices. All TIP and TEP data sheets
will be completed and returned to the Startup Group,
6, 3 Release For Startup Testing
Upon successful completion of all Preoperational tests, the
Startup Group will review all system documentation and test data as
re-quired to verify the functional operability of the system, The
Startup Group system engineer will walkdown the equipment to ensure
the system is· ready for unrestricted operations by the
station.
Any items found to be incomplete but not limiting for
unrestricted operation will be documented on the Deficiency Punch
List ( Attach-ment 8, 2). The Startup Group will then sign the
System Release form (Attachment 8.1), The System Release and the
required documentation will then be turned over to the Startup
Coordinator for review and acceptance .
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·- - - -- -- ---=--------···----_-_-_ -_ -
-12-
Prior to the Superintendent of Operations review of the system,
the Station Quality Control Department will review the
documentation to insure that all documents are complete. Any
deficient items will be turned back to the Startup Group for
resolution. Upon completion and acceptable audit, the Station
Quality Control Department will sign the required signature block
on the release. The Station Superintendent of Operations will then
review the deficiency list to approve the items to be carried on
the Master Deficiency List. Any items that are not acceptable will
be returned to the Startup Group for resolution. When all deficient
items are acceptable to the Station Superintendent of Operations,
he will then sign the transmittal accepting the Release for the
Station allowing Unrestricted Opera-tions of the system.
ST ART UP TEST PHASE
7 .1 General
When a system has completed Preoperational testing and is
accepted by the station for unrestricted operations it is ready for
Startup testing. Prior to initiation of the Startup Test phase the
Station Nuclear Safety and Operating Committee will review the
systems that are available for unrestricted operation to ensure
safe operation and testing conditions.
The first event is fuel loading. The sequence for subsequent
Startup testing is determined by the Integrated Startup Test
Sche-dule and the initial conditions and prerequisites of the
station startup procedures.
The Station Nuclear Safety and Operating Committee will review
the status of systems and test results at major milestones
throughout the Startup Test phase. At no time will the safety of
the plant be totally dependent on the performance of untested
structures, systems or components.
The comprehensive Startup Testing phase is to ensure that
equip-ment and systems perform in accordance with design criteria.
This phase includes tests, adjustments, calibrations, and system
opera-tions necessary to ensure that criticality and subsequent
power operation can be safely undertaken. These procedures will be
normal station startup procedures, PT's, OP's supplemented as
required by Special Tests.
Preoperational tests are performed to verify as near as
possible, the performance of the system under actual operating
conditions. Where required, simulated signals or inputs are used to
verify the full operating range of the system and to calibrate and
align the systems and instruments at these conditions. During
Startup testing, systems and instruments that are used for normal
opera-tions are verified and calibrated under actual operating
conditions. Systems that are not used during normal plant
operation, but must be in a state of readiness to perform safety
functions, are checked under test conditions prior to unit
startup.
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-----------
-13-
7. 2 Responsibilities
7. 2 .1 VEPCO Operating Staff
Virginia Electric and Power Company has the overall
respon-sibility for development, supervis10n, performance, and
documentation of all Startup Testing at the Surry Power Station.
Test preparation and all test performance during Startup Testing
are under control of VEPCO to ensure proper and effective emphasis
is maintained on personnel and plant safety by all individuals
participating in the testing program.
The Superintendent of Technical Services will be responsible for
providing the safety analysis for all major tests and will provide
engineering review and coverage to ensure the con-duct of the major
tests satisfies the necessary design and safety criteria.
7. 2. 2 Startup Test Group
The Startup Test Group will act as advisers and consultants to
the VEPCO staff in all areas of the Startup Testing.
7. 3 Startup Release Points
The following milestones in the Startup Test phase of the
Integrated Startup Test Program Schedule require Station Nuclear
Safety and Operating Committee review and approval prior to
implementation:
a. Fuel Loading b. Hot Functional Testing c. Criticality and Low
Power Physics Testing d. Power Range Testing e. Extended Full Power
Operation
The Startup Group and the Station Operations department will be
responsible to present evidence that all required testing is
success-fully complete and proper documentation available.
8.0 ATTACHMENTS
8 .1 Equipment Release for Checkout and Operation
8. 2 Deficiency Punch List
8. 3 Rework Control Form
8. 4 Overall System Test Matrix
8. 5 Test Program Flow Chart
8. 6 Organization Chart
8. 7 List of Construction and Preoperational Tests
-
. . ATTACHMENT 8.1
SURRY POWER STATION UNIT NO.
SYSTEM RELEASE FOR PRF~l'ERATIONAL TESTING AND UNRESTRICTED
OPERATI.ONS SYSTEM NO. ---
DESCRIPTION OF EQUIPMENT:
THE ATTACHMENTS WITH THIS RELEASE ARE INTENDED TO INDICATE THE
BOUNDARIES OF THIS RELEASE. FUTURE CHANGES THAT MAY BE MADE TO THIS
SYSTEM ARE INTENDED TO BE CON-SIDERED A PART OF THIS RELEASE IF
WITHIN THESE ESTABLISHED BOUNDARIES.
ATTACHMENTS DEFINING. BOUNDARIES:
RELEASED FOR PREOPERATIONAL TESTING:
Daniel's Proj. Mgr/Asst. Proj. Mgr. Date
e Vepco Q. C. Date The Following Items Are Attached:
Test Matrix ----Completed Construction Tests ----Construction
Deficiency List ----ACCEPTED FOR PREOPERATIONAL TESTING:
Vepco S/U Supervisor
All Documentation Received: (Initials)
RELEASED FOR UNRESTRICTED OPERATIONS:
Vepco S/U Supervisor
Vepco Q. C.
The Following Items Are Attached: Test Matrix ----Completed
Construction Tests
Date
Date
Date
----Completed Pre-Op Tests Master Deficiency List e
ACCEPTED FOR UNRESTRICTED OPERATIONS:
S/U Coordinator Date
SEO Project Engineer Date
Release Coordinator Date
Lead Advisory Engineer Date
Lead Advisory Engineer Date
Supt. of Operations Date
-
s~s. tio. .- ATTACHMENT 8. 2
,•, • • I
'JEPCO
DEF IC I rncv flU/iCH LI ST
• 0/\TE: -----------PAGE OF ---- ------==
--~!~-=-==.:====-=--=-== f DEFICIE!ICY ~ DESCRIPTIOU • NO. C
~ I
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, • ATTACHMENT 8. 3 R!:'N O~l< CO NT!< Oi. FORM RCF = . -·
----
1- DATE f--------------
------~-----·-·-·------.-·--------·---····· ..
I S'(c;.T, ;:M EQUl?,"EN·r1'CO'\PONEN-, ~ ~ V\ IV EQUIPMENT
S::R!AL.::: ystem Number
i------:---------i------------+-----------+--------------DRAWING/REVISION
SPECIFICATION/REV. LOCATION F.C. ATTACHED
YES D NO 0 REASON FOR REWORK:
WORK DESCRIPTION:
RETEST REQUIREMENTS:
ADVISORY ENGINEER DATE:
AUTHORIZATION FOR DISASSEMBLY ACKNOWLEGMENT
1------------~---=---------1,------------1-----------·· R!:SIDENT
ENGINEER
REASSEMBLY COMPLETE
Release Coordinator
DATE
' ADVISORY ENGINEER FIELD QUALITY CONTROL
REWORK COMPLETION STATUS
RETESTS COMPLETE REASSEMBLY INSPECTIONS COMPLETE
RETEST INSPECTIONS COMPLETE
----+------- ----ADVISORY ENGINE::R
DATE FQC
INSPECTION CHECKLIST ATTA.CHED
DATE
YES D NO 0
FQC DAT
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• SYSTEM NO.
2-2-2-1 2-2-2-2 2-2...:2-3
2-2-3-1 2-2-4-1
2-2-5-1 2-2-6-1 2-3-1-1 2-3-2-1 2-3-3-1 2-3-3-2 2-3-3-3 2-4-1-1
2-4-1-2
a-4-1-3 W-4-2-1
2-4-2-2 2-4-3 2-4-3-1 2-4-3-2 2-4-3-3 2-4-3-4 2-4-3-5
2-4-3-6 2-4-3-7 2-4-3-8
2-4-3-9 2-4-3-10 2-4-3-11 2-4-3-12
2-4-3-13
2-4-3-14
2-4-3-15 2-4-3-16 2-4-3-17
A-4-3-18 ·-4-3-19
2-4-3-20 2-4-3-21
SURRY POWER STATION UNIT NO. 2
SYSTEM MATRIX
QUALITY. SYSTEM GROUP
Gire. Water-Water Box Vac. Prim. Gire. Water & Serv. Wtr.
Rad. I Monitors Disch. Vac. Prim. Screen Wash Pps & Traveling
Screen Condenser Tube Cleaning H.P. Heater Drain Main Steam
Extraction Steam Aux. Steam Aux. Boiler & Controls Fuel Oil
Sys. Condensate Storage Tk Main Condenser Condensate Sys. L. P.
Htr. Drns. Secondary Misc. Drns. Condensate Polishing System
C.P.S. SWGR & MCC's Neutralization Sumps Low Conductivity
Sumps Instrument Air Hdr. C.P.S. Control Pnl (Interior) Condensate
By-Pass Condenser Connection #57 Connecting Piping Turb. Bldg.
Demineralizers Resin. In/Out Demins. 8 11 Piping Demin. to Cond. 4
11 Piping Demin to L. C. Sumps Regen. & Demin. Piping to Sumps
Sluice Water & Air to Demin. Air to Demin. Vessels Regen.
Vessels Acid to Cation Vessel Caustic to Anion Vessel Water Rec. to
Regen. Vessels Air Compressor Air Compressor Cooling
I
I
affected by affected by remained in
remained in affected by
affected by in the area affected by in the area in the area
remained in in the area affected by affected by affected by
affected by in the area affected by
-- --- ------ ---- ----------------
Attachment 8.4 Page 1 of 5
BASIS FOR TESTING
design change construction design change construction
service
service maintenance
design change construction of design change construction design
change construction of design change construction of design change
construction service of design change construction design change
construction design change construction design change construction
design change construction of design change construction design
change construction
-
-f ••
e SYSTEM NO.
2-4-3-22 2-4-3-23 2 4-3-24 2-4-3-25 2-4-3-26 2-4-3-27
2-4-3-28 2-4-3-29 2-4-3-30 2-4-3-31 2-4-3-32 2-4-3-33 2-4-3-34
2-4-3-35 2-4-3-36
2-4-3-37
2-4-3-38 2-4-3-39
•4-3-40 4-3-41
2-4-3-42 2-4-3-43
2-4-3-44 2-4-3-45 2-4-3-46 2-5-1-1 2-6-1-1 2-6-3-1 2-6-4-1
2-7-1-1 2-7-1-2 2-7-2-1
2-7-3-1 2-7-4-1 2-7-5-1
2-7-6-1
2-7-6-2
67-6-3 ·9-1-1
2-9-2-1 2-9-3-1
SYSTEM
Water Recovery Tank Spare Regen Vessels Air Blower Neut. Sumps
Pumps to PND Low Cond. Sump Pumps Filters & Piping to CW Tunnel
Caustic Recovery Tk Acid Rec. Tk Aux. Control Pand Fire Control
Sys. Floor Drainage Caustic Storage Acid Storage Ammonia Storage
Ammonia to Anion Vessel & Ammonia System Neut. Caustic &
Acid Feed Pumps Sampling System Heat Trace Sys. Building Release
URC Control RM A/C NUS Area Blowdown Fans Main Bldg. Vent. Storage
Area Vent. Misc. Fans
Cond. Air Removal Feedwater Stm. Gen. Blowdown Aux. Feedwater
Radiation Monitors Manipulator Rad. Monitors CRD-MG Sets, Full Rod
Controls Nuclear Instrumentation Incore Instrumentation Rod
Position Indication Racks & Controls, RPI Indicators Systems
& Controls Solid State Protection Aux. Relay Rack Input Logic
& Output Cabinets Safeguards Test Cabinets & Aux. Relay
Circuits Aux. Relay Cabinets & Panels Component Cooling Chilled
Comp. Cooling Chilled Water
QUALITY GROUP
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Attachment 8.4 Page 2 of 5
BASIS FOR TESTING
in the area of design change construction affected by design
change construction affected by design change construction in the
area of design change construction remained in service affected by
design change construction affected by design change
construction
remained in service in the area of design change construction
affected by design change construction
remained in service
remained in service
remained in service in the area of design change construction
affected by design change construction affected by design change
construction
-
e SYSTEM NO.
2-9-4-1 2-9-5-1 2-9-5-2 2-9-5-3 2-9-6-1 2-12-1-1 2-12-1-2
2-12-2-1 2-12-2-2 2-12-3-1 2 12-4-1 2-13-1-1 2-13-2-1 2-13-2-2
2-13-2-3 2-13-2-4 2-13-2-5 2-13-2-6 ~-13-3-1 ~-13-3-2 ~-13-3-3
~-13-3-4
•13-3-5 13-3-6
~-13-4-1
~-13-4-2 ~-13-4-3
~-13-4-4 ~-13-5-1
~-13-5-2 ~-13-5-3
~-13-5-4 ~-13-6-1 ~-13-6-2 2-13-7-2 2-13-7-3 2-14-1-1 2-14-1-2
~-15-1-1 2-15-1-2 2-15-1-3 2-15-3-1 2-15-3-2 2-15-3-3
.15-3-4 915-3-5
2-15-3-6
SYSTEM
Neutron Shield TK Cooling Service Water
QUALITY GROUP
I I
Service Water to R.S.Ht. Exch. I Service Water to CH Pumps
Coolers I Bearing Cooling Instrument Air Compressor Instrument Air
Sys. Service Air Compressor Service Air System Containment Instru.
Air. Air Start - Emerg. Diesels I Chemical Feed Flash Evap.
System
Unit #2 M/U Demin. Unit #2 Acid Supply Unit #2 Caustic Supply
M/U & Dilution Water #3 Demin. M/U & Filtered Water TK
Influent & Effluent Air Supply Surface Wash Backwash &
Backwash Sump Evaporator Makeup Caustic Supply - Waste Neut. Acid
Supply - Waste Neut. Waste Neut. Supply from Demin. Sump Waste
Neut. Sys. Distilate - Dilut. & Demin. Supply Distillate Truck
Loading Distillate - Cond. Pol. Regen. Distillate - Seal Water
Polyner Sys. Hypochlorite Sys. Unit 2 Blowdown Treat. Drain TK
& Stor. Area
Nitrogen Supply Hydrogen Supply Fire Protection Pumps &
Control Sprinkler & Deluge Hose Reel Stations Lo. Press. co
2 Cable Vault
Lo. Press. Co2
Emerg. Gen. Lo. Press. Co
2 Charc. Filters
Lo. Press. co2
- Turb. Gen. Lo. Press. Co
2 - Exciter
Lo. Press. co2
Cable Trays
I
Attachment 8.4 Page 3 of 5
BASIS FOR TESTING
affected by design change construction affected by design change
construction in the area of design change construction remained in
service remained in service remained in service in the area of
design change construction remained in service in the area of
design change construction affected by design change construction
remained in service affected by design change construction affected
by design change construction
affected by design change construction remained in service
remained in service remained in service remained in service
remained in service remained in service remained in service
affected by maintenace affected by maintenance remained in
service
-
e SYSTEM NO.
2-15-5-1 2-15-5-2 2-15-5-3 2-16-1-2 2-16-2-1 2-16-2-2 2-16-2-3
2-16-3-1 2-16-4-1 2-16-5-1 2-16-6-1 2-16-7-1 2-16-8-1 2-16-9-1
2-16-9-2 2-16-9-3 2-21-1-1 2-21-2-1 2-22-1-1 2-22-4-1 2-22-5-1
• 22-6-1 22-7-1
2-22-7-2 2-22-8-1 2-22-9-1 2-22-10-1 2-22-11-1 2-22-11-2
2-22-12-1 2-22-13-1 2-22-14-1 2-22-15-1 2-22-16-1 2-23-5-2
2-23-5-3 2-23-5-4 2-23-5-5 2-23-5-6 2-24-1-1 2-24-1-2 2-24-1-3
2-24-1-4 2-24-1-5 2-24-2-1 2-24-3-1
A-24-4-2 ~-24-6-1
2-24-6-2 2-24-7-1
QUALITY SYSTEM GROUP
Smoke Detector - Control Rm Smoke Detector - System Radiant Heat
Sensors Turb. Gen. Gland Stm & Seals Emgerg. Turb. Oil Pump
Bearing Oil Pump HP Seal Oil Backup Pump Turn. Lube Oil Sys.
Turning Gear & Bearing Lift EH Control Fluids Sys. Generator
Seal Oil Generator H
2 & co
2 Generator Leads Main Gen. & Exciter & Controls Turbine
Supervisory Main Turbine Turb. Plant Sampling Reactor Sampling
Station Transformers 4160V Busses & Controls Station Batteries
& DC I Dist rib • Emergency Diesels I 480V Mcc's & Controls
480V Emerg. Bus & Mcc's I Vital Busses I 120V AC Distribution
Station Lighting Heat Tracing (Borated Systems) I Heat Tracing
(NonBorated Systems) Computer & Controls Main Control Board
(Unit 2) I Secondary Plant Process Racks I Primary Plant Process
Racks I RC#2 Electrical Penetrations I Safeguards & Valve Pit
Sumps Containment Sumps Subsurface Sumps RC Floor Drainage Turbine
Sumps CRD Cooling Fans I RC Air Recirc Fans I RC Iodine Fans I
Sfgd. Supply & Exhaust I MCC Cable Vault Vent. Switchgear Vent.
Turbine Exhaust Turbine Supply Air Control & Relay Rm. A/C I
Control & Relay Rm. Vent. Turb. Bldg. Stm. Heat
Attachment 8.4 Page 4 of 5
BASIS FOR TESTING
remained in service remained in service remained in service
affected by maintenance remained in service remained in service
remained in service affected by maintenance affected by maintenance
affected by maintenance remained in service remained in service
remained in service affected by maintenance affected by maintenance
affected by maintenance remained in service affected by design
change construction remained in service affected by design change
construction remained in service
remained in service remained in service affected by design
change construction remained in service remained in service
remained in service remained in service remained in service
remained in service remained in service remained in service
remained in service remained in service remained in service
affected by design change construction remained in service affected
by design change construction remained in service affected by
design change construction affected by design change construction
in the area of design change construction remained in service
remained in service remained in service remained in service
remained in service remained in service remained in service in the
area of design change construction
-
e SYSTEM NO.
2-24-7-2 2-24-8-1 2-25-1-1 2-26-1-3 2-26-2-1
~-26-3-1 ~-26-3-2 2-26-3-3 2-27-1-1 2-27-1-2 2-27-2-1 2-27-3-1
2-27-4-2 2-27-4-3 2-27-4-4 2-27-4-5 2-27-6-1 2-27-6-2 2-27-6-3
~-30~1-l ~-30-2-1
·-30-1-2
~-30-3-1 ~-30-4-1 ~-30-4-2 !2-30-5-1 ~-30-5-2 ~-30-5-3 ~-30-6-1
!:z:-30-6-2 2-31-1-1 2-31-4-1 2-33-1-1 2-34-1-1 2-34-1-2 2-34-1-3
2-35-1-2 2-35-1-3 2-36-1-1 2-36-1-2 2-37-1-1 2-37-1-2 2-38-1-1
2-40-1-1 2-41-1-1 2-42-1-1
&-43-1-1 W-44-1-1
2-45-1-1 2-46-1-1 2-47-1-1 2-48-1-1
SYSTEM
Safeguard Bldg. Stm. Heat RC Purge Reactor Coolant Charging
Letdown Charging High Head SI & Seal Water Boric Acid Storage
& Controls Boric Acid Transfer Boric Acid Blender &
Controls Low Head S. I. S.I. Accumulators Residual Heat Removal
Containment Vacuum RWST Recirc. Pumps Containment Spray RWST Chem.
Add. TK Outside Recirc. Spray Inside Recirc. Spray Post DBA H
7 Recombiner
Liquid Waste Decontamination Sys. Liquid Waste Evaporation &
Controls Solid & Liquid Waste Drumming Gaseous Waste Gaseous
Waste Recombiners Boron Recovery Gas Strippers Boron Recovery Evaps
Boron Recovery Sys. & Controls Primary Grade Water PG Water to
RC #2 Primary Drains Process Vents Cont. L~akage Monitor Refueling
Purification Reactor Cavity Fuel Pit Cleanup & Cooling RC
Elevator Personnel and Equipment Hatch RC Polar Crane RC Jib Cranes
Fuel Transfer Sys. RC Cavity Manipulator Crane S.G. Recirc. &
Transfer Security Sys. Turb Bldg. Service Bldg. Aux. Bldg. Reactor
Containment Excore Detectors Fuel Bldg. Decon. Bldg. Fire Pump
House
QUALITY GROUP
I I I
I I I I I I I
I I I I I
I I I
I
I
I I
I I
I I I I I I I
~-----
Attachment 8.4 Page 5 of 5
BASIS FOR TESTING
remained in service affected by design change construction
affected by design change construction
-----·---
in the area of design change construction in the area of design
change construction
remained in service remained in service remained in service
affected by design change construction in the area of design change
construction affected by design change construction in the area of
design change construction remained in service affected by design
change construction affected by design change construction affected
by design change construction affected by design change
construction affected by design change construction in the area of
design change construction remained in service remained in service
remained in service
remained in service remained in service remained in service
remained in service remained in service remained in service
remained in service in the area of design change construction
affected by design change construction in the area of design change
construction remained in service affected by design change
construction affected by design change construction remained in
service affected by design change construction affected by design
change construction affected by design change construction affected
by design change construction in the area of design change
construction affected by design change construction affected by
design change construction affected by design change construction
affected by design change construction remained in service remained
in service affected by design change construction in the area of
design change construction remained in service remained in service
remained in service
-
...... __ ......
-
-
e
ATTACHMENT 8.5
b Conser. Forces
Perform Gonstr. Tests Field Chang~s initiated as required
(TEP's, TIP's, hydros).,.-~~~, as re uired SEO reviews, modifies,
as required,
approves Field Chan_ge rennests
"""',_. _ _._ __ -tSEO returns Field Change to Constr. Forces
for im lementation
SEO review & approval 1-----~-i
Const •. phase _of D.C. pkg on ·system compl,.
SEO walk-down of system-. to insure completion and to generate
deficiency·l-7-+-+-f'--r'-I~ list.
:..?:~-- : ,, ..
· >;{t;.t~.-~..;.:.';j sign-off Release Transmittal
Release to Start-up Grp. with deficiency list, for PRE-OP TES
ING
.... ----------------'Jlo,fStart-up Group reviews sys·tem· for·
ACCEPTANCE
S/U Grp "Accepts" Sys tell)
"Rejects" System returri to SEO for com-pletion of
DISCREPANCIES
S/U Grp. performs required,-...~~~~~~--~~--, ,---------iTEP1s,
TIP's, TMP's for
initial o eration
VEPCO I & C calibration as re uired.
$ystem returned to .. S/U Grp for completio of discrepancies
S/U Grp performs require~ flushing and pump verification
performing require TEP's TIP's TMP's
of syste!ll· -
Review
Field
S/U Grp to perform necessary tests to insure proper functional
opera- 1
1
bility of systems that may have been damaged during construction
activities.
Released with deficiency list SU Grp sign-off system OPERATIONS
for PLANT -~,......-~ transmittal.
START-UP
OPERATIONS rejects system
OPERATIONS accepts sy~tem
VEPCO Station & S/U Grp to perform re uired S/U Tests
POWER OPERATION
-
ATTACH~ 8.6
SUPT. MAINT.
e ORGANIZATIONA. L CHART
INTEGRATED STARTUP TEST PROGRAM
STATION MGR
-----
SUPT. TECH SER\i
SAFETY COMMITTEE
SUPT. OPERATION: :
/ STARTUP /· COORD.
/
e ·. ;-
SGRP MGR
RELEASE COORD.
' . . ,,
(MAINT. TEST) (I a C TESTS) _JPROJECTENf __ 1---1
MAINTENANO ~ INST. TECH
__ ___._ __ (S/u , STARTUP TESTS GROUP
CONST. CONST. ----------- TEST
GROUP ENG.
~CONST. TESTS) -__.ea.-. , (PREOP TESTS) OPERATIONS DANIEL
-
--·· -- ---- -- -- - ---- ---··-·----- -- ----- ----
CTG REQUIRED TESTS CONSTRUCTION TEST PHASE
TEP-1
TEP-2
TEP-3
TEP-4
TEP-5
TEP-9
TIP-1
TIP-2
TMP-1
TEP-10
TEP-12
Insulation Resistance Measurements
Control Circuitry Checkout
Low-Voltage Swgr Inspection
Motor Operated Valve Check-Out (Static)
(VEPCO A & C) Circuit Bkr & 0/L's Checkout
Computer Point Checkout
I & C Electrical Checkout
I & C Mechanical Checkout
General Hydrostatic Tests
Annunciator Checkout
Heat Trace Checkout
---- -- -- ··-- ------------·---
Attachment 8.7
S/U GROUP REQUIRED TESTS PRE-OP TEST PHASE
TEP-40 TEP-8 TEP-7
TEP-70
TEP-llU
TEP-llC
TIP-3
TIP-4
TIP-5
TIP-40
TMP-2
TMP-3
Flushing
FSOP's
Dynamic MOV Checkout D.C. Motors Uncoupled Motor Runs
Coupled Motor Runs
Uncoupled Vibes
Coupled Vibes
I & C Functional Checkout
AOV/AOD Setup and Checkout
I & C Hydro
AOV/AOD Dynamic Checkout
Air Balancing
Pump Curve Verification