Approved by

Resolution

of the Federal

Environmental,

Industrial

and Nuclear Supervision Service

dated December 30, 2005 No. 25

Effective

as of May 1, 2006

FEDERAL RULES AND REGULATIONS IN THE FIELD OF

NUCLEAR ENERGY USE

PIPELINE VALVES FOR NUCLEAR POWER PLANTS.

GENERAL TECHNICAL REQUIREMENTS

NP-068-05

The federal rules and regulations in the field of nuclear energy use "Pipeline Valves for Nuclear Power Plants. General technical requirements" are intended for legal entities exercising design, manufacture and operation of pipeline valves for nuclear power plants.

This document sets the requirements for design, manufacturing, transportation, storage, installation and operation of pipeline valves for nuclear power plants.

They are developed for the first time <*>.

They were developed on the basis of regulatory legal acts of the Russian Federation, federal rules and regulations in the field of nuclear energy use, as well as in compliance with industry standards.

The regulatory document has passed legal examination at the Ministry of Justice of Russia (Letter of the Ministry of Justice of dated February 28, 2006 No. 01/1496-ЕЗ).

--------------------------------

<*> The present edition of the regulatory document was developed by SUE SEC VNIIAES, with the participation of Musvik A.B., Malinin Yu.I. (SUE SEC VNIIAES), Melamed V.Ye. (Rosteсhnadzor), Nescheretov I.I. (FSU SEC NRS).

When developing the document, comments of specialists of FSUE "VNIIA", FSUE "VNIPIET", FSUE "NIKIET", FSUE "EDO Gidropress", FSUE "Concern Rosenergoatom" and its branches: Balakovo, Beloyarsk, Kalinin, Kola, Kursk, Leningrad, Novovoronezh and Smolensk nuclear power plants; CJSC "Research and Production Firm CKBA"; FSUE "TSNII KI Prometey", RF State Research Center "CNIITMASH", FSUE "AEP", FSUE "SPbAEP", Smolensk branch of FSUS "Atomtechenergo", CJSC "Solenoid VELV", JSC "Penztyazhpromarmatura", JSC "Chekhov Power Engineering Plant", JSC "Lepse Znamya Truda", structural and inter-territorial units of the Federal Environmental, Industrial and Nuclear Supervision Service were considered and taken into account.

ABBREVIATIONS

NPP         - Nuclear Power Plant

NPI         - Nuclear power installation

PFO         – Probability of failure-free operation

PV          - Pilot Valve

PORV        - Pilot-Operated Relief Valve

DD          - Design Documentation

SSE         - Safe Shutdown Earthquake

RD          - Regulatory Documentation

NO          - Normal Operation

AO          - Abnormal Operation

QCD         - Quality Control Department

DD          - Duty Duration

OBE         - Operating Basis Earthquake

RDSO        - Federal rules and regulations regulating requirements for design and operation of NPI equipment and pipelines

RF          – Reactor Facility

ECCS        – Emergency Core Cooling System

BU          - Bellows Unit

CPS         - Control and Protection System

ToR         - Terms of Reference, or a substitute document

TS          - Technical Specifications

EA          - Electrical Actuator

EMD         - electromagnetic drive

LIST OF CONVENTIONAL SIGNS

A₅    - relative elongation of a five-fold sample at static breakage during tension tests

DN    - nominal diameter (nominal size)

HRC   - Rockwell hardness

НВ    - Brinell hardness

IP    - ingress protection class

РE    - protective earth conductor

Р_d    - design pressure

R_a    - arithmetic mean surface roughness height

R_m    - minimum value of ultimate strength of material

R_p0.2  - minimum value of yield point of material

R_z    - average peak to valley height of surface for 10 points

T_KO    - critical brittle temperature

Т_d    - design temperature

Т_al    - full assigned service life

Z     - relative contraction of the sample cross-sectional area at static breakage during tension tests

TERMS AND DEFINITIONS

The following terms and definitions are used in this document.

Pipe valves is a class of devices installed on pipelines and branch pipes of vessels, and designed to control the flow (shutdown, distribution, regulation, discharge, mixing, phase separation) of working media (liquid, gaseous, gas-liquid, suspension, etc.) by changing the area of the flow section. Pipeline valves are classified by the following criteria: purpose, working conditions (pressure, temperature, type and composition of the working medium), the nature of the interaction of the locking or regulating body with the working media, nominal size. Valves are classified as follows:

- fast-acting valves – safety valves with actuation time of maximum 10 sec;

- shut-off-valves – valves designed to block the flow of the working medium with the degree of tightness determined in accordance with the requirements of regulatory documents;

- shut-off and control valves - control valves that can be used as shut-off valves;

- shut-off and throttle valves – valves designed to reduce the pressure of the working medium that can be used as shut-off valves;

- check valves – protective valves intended for automatic prevention of the working medium backflow;

- cutoff valves – automatically controlled safety shutoff valves;

- safety valves – protective valves intended for automatic protection of equipment and pipelines from unacceptable excess of pressure by discharging the working medium;

- control valves – designed to change the parameters of the working medium by changing its flow rate;

- bellows (valves with bellows seal) - valves in which bellows are used for sealing of moving parts (rod, spindle) relative to the outer medium.

High-speed reduction unit - a unit consisting of a valve and a throttling device and designed to reduce the steam parameters before it is discharged into the atmosphere, a condenser, a deaerator, etc.

Probability of failure-free operation is the probability that no article (facility) would fail within the assigned running hours.

Vibration resistance is the ability of an article to retain its strength, stability, air-tightness and operability during and after vibration impact.

Tightness (of lock, seal) - the ability of individual elements and connections of pipeline valves to limit the spreading of liquid, gaseous substances and aerosols, including steam.

Leak-tight valve is a flanged power-driven tight shutoff valve.

Operating pressure is the maximum excessive pressure of the working medium in pipeline valves under normal operation conditions defined with allowance for hydrostatic pressure.

Design pressure is the maximum excessive pressure of working medium in pipeline valves used when choosing the valves’ dimensions determining their strength, under which normal operation of the valves is allowed under the design temperature.

Main parts of valves are parts (except for gaskets and gland seals), the destruction of which can lead to a loss of tightness of the valve in relation to the outer environment and of the lock.

Nominal diameter (nominal size) - the inner diameter of the pipeline connected to the pipeline valves corresponding to the nearest value in a series of numbers accepted in adopted in accordance with the established procedure.

Gate - pipeline valve, in which the locking or regulating element moves perpendicular to the axis of the flow of the working medium passing through the flow part. The gate is mainly used as a shut-off valve, i.e. the locking element is usually in the extreme positions - "open" or "closed".

Shut-off body is a part of the lock, generally movable and associated with the driving device, allowing, at interaction with the seat, to control (shut, disconnect, distribute, mix, etc.) flows of working media by changing the area of the flow section.

Lock is a totality of movable (spool, disc, wedge, gate, plunger, etc.) and fixed parts of the locking or regulating component of the valve, changing the area of the flow section.

Valve version - design of a specific type of pipeline valves, stipulated for implementation based on the following data: purpose, nominal diameter, working pressure, materials of the main parts, methods of control and connection to the pipeline, etc.

Check valve (lifting valve) - valve intended for automatic prevention of the working medium backflow.

Proportional valve is a safety valve, in which the spool can be fixed in any intermediate position, depending on the pressure in the protected volume.

Two-position valve is a safety valve, in which the spool can only be fixed in extreme positions.

Pilot valve - a direct action or controlled safety valve, the opening of which leads to the opening of the main valve in pilot-operated relief valve.

Control valve - a valve designed to regulate the parameters of the working medium by changing the area of the flow section and controlled from an external energy source.

Availability factor - the probability of a product (facility) being operable at any given time, except for the planned periods during which its use for its intended purpose is not provided.

Cock is a pipeline valve, in which the shut-off or regulating body has the form of a body of rotation or a part thereof, which rotates around its axis arbitrarily located relative to the direction of the flow of the working medium.

Assigned service life - total operating time of valves stipulated by the project, on achievement of which its further operation can be continued only after a special decision made on the basis of the performed substantiation of safety of operation, for example, after examination of technical condition (diagnostics).

Assigned operation period - the calendar duration of operation of the valves established by the project, on achievement of which its further operation can be continued only after a special decision made on the basis of the performed substantiation of safety of operation, for example, after examination of technical condition (diagnostics).

Remaining service life - accumulated operational time of the valves from the moment of its technical condition control until transition to the limit state.

Pneumatic valves - valves driven by a pneumatic drive.

Pneumatic drive - a drive using the compressed air energy.

Pneumatic distributor - a device for controlling the operation of the pneumatic drive.

Drive - a device designed to move the locking or regulating component, as well as to create an effort to ensure the required tightness of the lock. A drive can be electric (with electric motor, solenoid), hydraulic, pneumatic depending on the type of energy consumed, and it can be built-in or remote, depending on the location relative to the valve.

Service life - accumulated operational time of the valves from the beginning of its operation until transition to the limit state.

Seismic strength is the ability of an article to retain its strength, and air-tightness during and after an earthquake.

Seismic resistance is the ability of an article to performed its assigned functions according to the project during and after an earthquake.

Flow section - the smallest of the areas formed by the shutoff (or regulating) element and the seat.

Bellows - thin-walled (single - or multi-layer) corrugated tube or chamber.

Bellows unit - bellows with welded end parts.

Operation period - calendar duration of operation from the beginning of operation of valves, or its resumption after repair until transition to the limit state.

Design temperature - the temperature of the wall of equipment or pipeline equal to the maximum arithmetic mean of temperatures on its outer and inner surfaces in one section at normal operation, at which the value of permissible stress is chosen at calculation of the basic dimensions of the valve.

Type of valves - classification unit characterizing the functional features and defining design features of pipeline valves, for example, wedge gate, regulating valve.

Typical series - a group of structurally similar products differing only in basic dimensions.

Upper seal - a seal that duplicates the gland or bellows seal formed by surfaces made on the spindle (rod) and in the lid, which provides sealing of the inner cavity of the valve in relation to the outer medium at the extreme upper position of the locking element.

Pilot-operated relief valve - a device that performs the function of safety valves and consisting of interacting main and pilot (built-in or remote) valves.

Equivalent voltage is the supply voltage of electric winding, which provides at a temperature of 20°C, the same current through the winding, which can take place at an increased (decreased) temperature and the minimum (maximum) operating voltage permissible at this temperature.

Solenoid valve - a valve, which includes a solenoid, including for support functions (latch, changing the actuation pressure, etc.) controlled by electric signal.

1. GENERAL

1.1. Purpose and scope

1.1.1. This document sets out the requirements for the design, manufacture, installation and operation of NPP valves with nominal diameters from 10 to 2000 mm, that are in contact with the media listed in Appendix 1, at temperatures of up to 550 °C and pressures up to 25 MPa.

1.1.2. The document applies to valves manufactured after the enactment of this document for all NPPs of various types and purposes (except floating ones) that are operating, under construction and being designed and are covered by the federal rules and regulations setting the requirements for the design and operation of equipment and pipelines of NPI.

The requirements of this document may be extended to valves used and operated at other nuclear power installations if the characteristics of the working medium match the data given in Appendix 1 and its pressure and temperature do not exceed the values specified in paragraph 1.1.1.

1.1.3. This document is mandatory for all organizations and enterprises that design, manufacture and operate NPP pipeline valves.

1.2. Quality assurance

The following must be prepared for newly developed valves:

- quality assurance program at development of the valve design - by the valve developer;

- quality assurance program at manufacture of the valves - by the valve manufacturer.

It is allowed not to develop the above programs, instead using model programs of quality assurance in the development or manufacture of valves, which are employed at the enterprise, if these model programs take into account the specifics of the newly developed valves. Quality assurance programs in place at the enterprise may be used for serial products, provided that these programs meet the requirements of the quality assurance program for the NPP or NPP units.

2. DESIGN

2.1. Classification of valves

The valves must be classified as per Table 1.

Table 1

CLASSIFICATION OF VALVES ACCORDING TO PURPOSE

AND OPERATING CONDITIONS

The safety class and the group of valve, according to the classification of federal rules and regulations setting the general NPP safety requirements as well as requirements for design and operation of equipment and pipelines of nuclear power installations, and the classification designation in accordance with this document must be issued by the NPI and/or RP project developer in the ToR and specified in the specifications and certificates on the valve. The safety class, the group of valves and the class of welded joints must be specified in working drawings.

2.2. Valve boundaries

The boundaries of the valve, if they are not specified in the ToR or TS, must pass through the following parts and devices:

- branch pipes with dressing for welding;

- terminals of switching box for power supply - for valves with a built-in drive;

- terminals for connection of external diagnostic tools;

- fittings for delivery of operating medium - for pneumatic and hydraulic drives;

- valve control input shaft with a hinge coupling - for remotely operated valves;

- edges for welding of mating flanges (nipples) - for valves with flanges (fittings).

2.3. Requirements for the design and main technical

characteristics of valves

2.3.1. The valves must be designed taking into account the working media from the following range of parameters:

 Design pressure Pd, MPa: 0.0035 (abs.); 0.1; 0.16; 1.0; 1.6; 2.5; 4.0; 6.0; 8.6; 11.0; 12.0; 14.0; 16.0; 18.0; 20.0; 25.0

 Design temperature Td, °C: 150, 200, 250, 275, 300, 350,400, 450, 500, 550.

 Specific values of Рd and Тd must be set in ToR and specified in technical specifications. In the course of preparation of ToR for development of a specific type of valve, one must be guided by Appendix 2.

 For gates, cocks, control valves, shut-off valves bellows, check valves, the values of Рd and Тd must be assigned with consideration of recommendations stated in Appendix 3.

2.3.2. The main technical data and characteristics of valves must be presented in the specifications for each product in the form of tables in Appendix 4. The list of regulatory documents used as the basis for design and manufacturing of NPP valves must be presented in TS.

ToR and TS for valves may contain requirements different from this document approved by the operating organization.

2.3.3. The valves must be suitable for operation when exposed to one or a number of working media stated in Appendix 1, and the ambient medium, whose parameters are specified in tables 3, 4, 5. Specific working media must be stated in ToR and TS.

2.3.4. ToR and TS must specify the modes of variation of working medium parameters. In the absence of specific instructions of parameters of the modes for valves of primary circuit of NPP with VVER and for valves of NPP with on armature of as with RBMK, one must be guided by Appendix 5.

Valves of NPP with EGP reactors, secondary circuit of NPP with VVER reactors and tertiary circuit of NPP with BN reactors must maintain their operability at rates of heating and cooling of the medium to 150 °C/h (not less than 2000 cycles of heating and cooling), unless otherwise indicated in the ToR and TS.

2.3.5. When developing the design of the flow part of the shut-off and check valves, decisions must be made to ensure the lowest flow loss coefficient and noise level (excluding drive noise) at fully-opened shut-off body. The flow loss coefficient must be assigned in the ToR, determined experimentally and specified in the TS. The flow loss coefficient at fully-opened valve gate must not exceed the values specified in table 2.

Table 2

ZETA VALUE

2.3.6. Unless otherwise specified in ToR and TS, the valves must be operable throughout the operation period at the following working medium flow rates in the pipeline at the inlet to the valve.

2.3.6.1. Water:

- up to 5 m/sec in the nominal mode;

- up to 7.5 m/sec over 1000 hrs during the operation period;

- up to 25 m/sec in the pipeline at the outlet of the valve for 10 h/year for ECCS valves and reactor emergency cooling systems, which is stipulated in ToR and TS.

2.3.6.2. Steam and gas:

- up to 60 m/sec in the nominal mode;

- up to 100 m/sec over 1000 hrs during the operation period.

The degree of opening of the control and throttle-control valves at increased flow rates of the working medium must be stipulated in TS for the specific type of valves.

2.3.7. The valves must be connected to the equipment and pipelines by welding, unless otherwise specified in the ToR and/or TS. Safety valves may be connected to equipment and pipelines with flanges and nipples, and sealed valves - with flanges. The sizes and shape of dressing of edges of pipelines welded to valves are established in Appendix 6.

2.3.8. Air-tightness

2.3.8.1. The tightness of the check valve valve lock must be determined by testing with water at the operating pressure at a temperature of 20 +/- 10 °C. Unless otherwise specified in the ToR, the leakage must not exceed:

- 3 cm3/min for DN <= 100;

- 7 cm3/min for 100 < DN <= 200;

- 12 cm3/min for 200 < DN <= 300;

- 25 cm3/min for 300 < DN <= 800;

These tightness standards must be confirmed by acceptance tests.

 The leakage amount must also be determined at the lowest of the above range of operating pressures and entered into the TS and the valve certificate. In case of uncertainty about the value of the minimum pressure, tests must be held at the pressure

   +0.1

0.5    MPa.

The need for air tests and the specific values of the test pressures and leaks must be specified in the ToR and/or TS.

2.3.8.2. Leaks in the safety valve lock must be specified in the ToR, TS and ascertained based on results of tests of prototypes.

2.3.8.3. The relative leakage of the medium in the lock of the control valve must be set according to the requirements of ND with the lock closed and the maximum pressure drop. The tightness class must be set by the NPP project developer.

2.3.8.4. For two or more seat valves, the leakage values must be determined by the prototype test results.

2.3.8.5. Tightness of the lock of shut-off, fast-acting shut-off and cutoff valves of groups A, B, C on RDSO must be established for DN < 300 respectively on classes A, B or C of the regulatory document "Shutoff pipeline valves. Norms of tightness of locks", and for DN > 300 - also for shutoff valves with an EMD irrespectively of DN - respectively, for classes В, С or D of the above document.

In case of any mismatch between the inlet and outlet nominal diameter, permissible leakages must be determined according to the outlet branch pipe.

2.3.8.6. For direct-flow hydraulic discharge valves, leaks in the lock up to 1 l/h are allowed.

2.3.8.7. Leaks through a gland seal into the environment are not allowed.

2.3.8.8. In the absence of requirements to airtightness in the ToR and/or the TS, in the course of operation, the amounts of leaks at acceptance tests after work-off of the service time as per paragraph 4.2.1 must not exceed those specified in paragraphs 2.3.8.1, 2.3.8.3, 2.3.8.5, 2.3.8.6 by a factor of more than ten.

2.3.9. The level of sound pressure during operation of the valve must not exceed the level given in the ToR. In the absence of such instructions, the sound pressure level during operation of the valve (excluding drive noise) must not exceed 80 dB at a distance of 2 m from its outer circuit. For shut-off valves, the sound pressure level must be measured in its open state; for control and check valves, the sound pressure level must be measured without taking into account the operation in its initial stage in the throttling mode (about 10% of the shut-off body stroke from the "closed" position). The sound pressure level is measured on test samples during acceptance tests and, if necessary, during the operation of operating valves. For safety valves (and PORV) the sound pressure level is not regulated.

2.3.10. The valves whose inner surfaces come into contact with radioactive media, must enable flushing of the inner and outer surfaces with decontamination solutions followed by evacuation of the volume of the valve. At external decontamination the maximum possible removal (runoff) of the applied solutions must be provided.

The materials of valves and components, as well as their protective coatings, must be corrosion-resistant to the decontaminating solutions specified in Appendix 7.

2.3.11. It is not allowed to have electrical equipment, sensors or pneumatic distributors submerged into baths with decontamination solutions. Modes of external decontamination of electrical equipment are established in TS for such equipment and in TS for the valves.

2.3.12. For manually driven valves the value of the effort applied to the handwheel must not exceed:

- 295 N - at movement of the shutoff body;

- 735 N - at the separation of the shutoff body and extra compression under the condition that opening and closing of the same must not be done more than once a day, with the exception of the valves closed to stop using the inertia of the flywheel.

2.3.13. For valves with a gland seal installed on equipment and pipelines with radioactive working medium, if required by the operating organization, removal of leaks from the inter-gland space into the system must be provided at a pressure within the range of 0.09-0.15 MPa. It is allowed to increase the pressure up to 0.6 MPa once a year for 1 hour. The diameter of the fitting to drain leaks DN = 10 (for the pipe 14 x 2). This requirement must not apply to C&I gland valves. The pressure outside the gland seal is stated in paragraphs 2.4.1 - 2.4.4.

2.3.14. If the power supply is lost, the shut-off body of a power-driven valve must not change its position. Valves with EMD must come to the initial state (open or closed). The version of valves with EMD must be specified in the ToR and TS. The valves intended for installation in safety systems must maintain their position in the event of a power failure for at least 24 hours.

2.3.15. The rotation of the flywheel clockwise must correspond to the closing of the valve.

2.3.16. For power-driven valves, the torque limiter must be adjusted to the value stated in the TS in the relevant table in the form of Appendix 4, to ensure the tightness of the lock.

2.3.17. Strength calculations of the valve body parts must be performed taking into account mechanical loads and temperature effects corresponding to the design modes of NO and AO. The loads transferred from pipelines must be determined according to the recommendations of Appendix 8 and specified in TS. Strength calculations must be performed in accordance with the requirements of federal rules and regulations regulating the strength calculations of equipment and pipelines of NPI.

2.3.18. The valve must not lose tightness in relation to the outer medium in case of failure of the disconnecting devices of the drive in any position of the shut-off body of the valve.

2.3.19. Valves must be serviceable without being cut from the pipelines. The requirement does not apply to non-detachable designs of check locks used in the repair of valves.

2.3.20. The required time of closing (opening) of valves must be specified in ToR, and, finally, in TS - based on results of tests. Unless otherwise specified in ToR, this must not exceed:

-  10 sec - for fast-operating valves with electric drive and pneumatic drive (except for fast-operating -speed shut-off and cutoff valves and valves, which make part of a fast-operating reduction unit);

- 60 sec - for valves with an electric drive;

- 5 sec - for valves with EMD DN < 100;

- 10 sec - for valves with EMD DN > 100;

- 1.5 min - for gates, cocks 50 <= DN <= 400;

- 3.0 min - for gates, cocks DN > 400;

- according to requirements of paragraph 2.3.33.1 - for safety valves.

2.3.21. The TS must contain assembly drawings (with specification) of the valves indicating overall dimensions (including mounting dimensions), connection dimensions, sketches of edge dressing, type of weld, places of attachment to construction structures and permissible loads on places of attachment. Overall dimensions of valves are given in Appendix 9. For valve types not specified in Annex 9, overall dimensions and connection dimensions must be agreed upon with the operating organization.

2.3.22. The newly developed valves and components must be vibration-resistant in the frequency range from 5 to 100 Hz under the action of vibration loads in two directions with acceleration up to 0.1 g and with vibration amplitude up to 50 µm, with one of the directions of impact coinciding with the axis of the pipeline. Acceptable minimal level of opening and acceptable max. pressure differential must be indicated in the specification for control and throttling valves, affected by vibration from working medium flow. Vibration resistance must be proved by calculation and (or) by experimental approach. Requirements for vibration resistance may be increased by the operating organization. Vibration level during operation must not exceed values indicated in this paragraph.

2.3.23. Application of coatings and/or any other design measures to protect the casing and the internals of valves as well as the adjacent pipeline sections against erosion wear must be provided for the valves contacting with two-phase and boiling media. Requirements for protection from erosion wear must be specified in the ToR and/or TS. TS for control valves and the operation manual must stipulate conditions providing the non-cavitation mode of operation.

2.3.24. Check valves must revert to their initial state upon stoppage of the direct medium flow and open in case of pressure differential of not more than 0.03 MPa (the actual pressure differential must be determined in the course of testing of prototypes).

2.3.25. Requirements for remote signaling of position of the valve working body.

2.3.25.1. Signaling on control boards of extreme positions of shut-off body of shut-off valves with an electric drive must be carried out by the position sensors (limit switches) making part of the electric drive. For other types of valves, the need to install sensors must be indicated in the ToR.

2.3.25.2. Valves with classification designation 1A, 2ВІІ, 2ВІІІ, in which unintended movement of the locking bodies can lead to consequences that affect the safety of the NPP, must have A device for forming a position signal of the valve for the computing system over the entire range of the valve travel, which must be specified at issue of the ToR or at approval of the TS.

2.3.26. Requirements for diagnostics

2.3.26.1. The newly developed valves must, at the request of the operating organization, have built-in and (or) be adapted for connection of external means of technical diagnostics for continuous or periodic monitoring of the technical condition (including the state of inner surfaces). The letter "D" must be added to the classification designation of the valve equipped with built-in means of technical diagnostics. The manufacturer must specify the limit values of the diagnostic parameters in the product certificate.

2.3.26.2. Potential failures on which it is recommended to focus the methods and means of diagnostics of the technical condition of the valve are listed in Appendix 10.

2.3.26.3. The TS, certificate and OR must specify the presence or absence of built-in means and/or the possibility to connect external means of technical diagnostics.

2.3.26.4. When using the technical means of diagnostics, the operating manual must contain a list of diagnostic parameters, methods and technical means, as well as the frequency of diagnostics of the valve.

2.3.27. The shut-off, regulating and fast-operating shut-off valve DN <= 50 must enable its installation on the pipeline in any position, DN > 50 - in any position in the upper half-sphere relative to the horizontal plane (including in horizontal position), with the vertical position recommended. Manually-driven valves must enable installation in any position.

Check valves must maintain operability at a deviation by +/- 3° from the position stipulated in the engineering documents. Requirements for orientation of safety valves must be approved by the oeprating organization.

2.3.28. Except for EMD valves and valves installed under a shell, the shut-off valves must have a local indicator of extreme positions of the shut-off body. The need to install a local indicator of extreme positions of the locking body for other types of valves, for valves with EMD and those installed under the shell, must be determined in the ToR and/or TS.

2.3.29. Shut-off valves, except for shut-off valves with EMD, must be designed for a full working pressure drop with a two-way medium supply. Shut-off valves with EMD must be designed for a full pressure drop with one-way medium supply. If ToR or TS have no indication on the preferred medium delivery,  shut-off valves with EMD are developed for a full pressure drop with medium delivered "onto the spool". The permissible pressure difference for valves with EMD with reverse medium delivery must be specified in the ToR and TS.

2.3.30. The gates must enable having their cavity filled with water in the closed position of the lock to provide tightness and to enable being protected from unacceptable rise of pressure in the cavity during heating with the lock closed. Requirements to tightness of the lock must be stipulated in ToR and TS. Gates and cocks intended for vacuum operation must be designed to ensure tightness with respect to the outer medium and the lock at a pressure of up to 0.0035 MPa (abs.).

2.3.31. The need to install locking devices that prevent unauthorized opening or closing of shutoff valves must be specified in the ToR.

2.3.32. For valves with a top seal, the actuator torque limiter must be able to be adjusted to the amount of torque ensuring the tightness of the top seal, which must be specified in the TS.

2.3.33. Requirements for safety valves

2.3.33.1. The design of safety valves must ensure:

- the possibility of its fine adjustment within +/- 7% of operating pressure;

- protection from unauthorized change of settings;

- time of opening (closin) of valves with a mechanized drive, unless otherwise specified in ToR, within: for opening - 2 sec, for closing - 5 sec from the issue of signal;

- stability of the characteristics of springs making part of the safety valve, such that their adjustment is not required more often than once in every two years;

- fastening of housings and inlet (outlet) branch pipes, which must be calculated taking into account both the requirements of paragraph 3.1.12 and dynamic efforts arising from actuation of safety valves.

The use of shaft seals of the stem for safety valves marked with classification designation 1A, 2ВІІа, 2ВІІв is not allowed.

2.3.33.2. Controlled safety valves using an external power supply must have at least two independent control circuits with separate measuring devices. The locations of the control signal sources must be spatially staggered so that, under an external impact, simultaneous damage of the two supply points would be excluded. For controlled valves, in which a failure of power supply from an external source does not cause their opening signal at least three independent control circuits with separate measuring devices and controls must be used. Any of the control circuits must be designed and constructed so that the valve operates correctly when one of the control circuits is damaged or disconnected and can be checked during operation without actuating the valve.

2.3.33.3. PORV must perform the function of protection without the supply of energy from the outside (passive principle). Pilot valves may also serve to perform the remote control functions of the main valve at trial runs, forced reduction of pressure inside the protected equipment (with the response time of the PORV and maximum achievable values of pressure reduction specified in the ToR and/or TS ). In the design of the PORV a device is to be provided for holding the PV lock in the closed state at hydraulic tests of the protected equipment or pipelines. This device must have a local or remote PV blocking indicator (signaling device). In cases where PV have a permanently operating additional winding for closing, the PV control circuits must be provided with redundancy of control circuits with separate measuring devices.

The design of the PORV must provide measures to prevent the opening of HV as a result of leaks in the PV.

The pulse lines and the control lines of the PORV must be as short as possible, and their internal diameter, including the internal diameter of the PV seat, must be not less than 15 mm and not less than the diameter of the corresponding PV fitting.

2.4. Environment parameters

2.4.1. Environmental parameters during normal operation of the valve in the rooms of tertiary circuit of NPP with BN reactors and in the attended premises with VVER reactors outside the containment must be as follows:

- temperature - from +5 to + 40 °C (up to 70 °C in the rooms of tertiary circuit of NPP with BN-600 reactors at AO);

- absolute pressure - 0.1 MPa;

- relative humidity - 75% at 40° C (up to 95% in the rooms of the tertiary circuit of NPP with BN-600 reactors at AO).

2.4.2. The environmental parameters in the accident localization zone (under the containment) of NPP with VVER reactors are shown in table 3.

Table 3

ENVIRONMENT PARAMETERS IN

CONTAINMENT OF NPP WITH VVER REACTORS

2.4.3. The environment parameters in premises of NPP with RBMK reactors are specified in table 4.

Table 4

ENVIRONMENT PARAMETERS IN PREMISES

WITH RBMK REACTORS

2.4.4. For RP of other types, the environment parameters must be specified in ToR or TS for the valves.

 2.4.5. Environment parameters for specific valves

must be presented in ToR for development of new valves and specified

in TS. At assessment of radiation resistance of materials used

for manufacture of valves and its components, the

maximum possible strength of absorbed dose must be taken equal to

 4

the value up to 1 Gy/h at NO and up to 5 х 10 Gy/h for 720 hrs

in the "major leak" mode <*>.

--------------------------------

<*> Specific parameters characterizing the modes of "minor" and "major" leak at design-basis accidents are specified in the ToR or TS for the valves.

2.4.6. The safety system valves intended for installation in a sealed enclosure or in a leak-tight box must remain operable during and after the emergency impacts specified in the tables 3 and 4. In this case, at least 10 cycles of valves must be performed: five - during emergency "major leak" modes, five - during the post-emergency mode.

It is allowed to confirm the operability of the valves by checking the operability of components with simulated workload.

After the "major leak" mode, the valves must be checked, maintained and (if necessary) repaired.

2.5. Resistance to seismic impact

2.5.1. The valves referred to seismic resistance class I according to the classification of "Standards of design of seismic-resistant nuclear power plants" must be seismic-resistant <*>. The rest of the valves must be seismically strong.

--------------------------------

<*> This requirement does not apply to control valves.

2.5.2. The seismic strength of valves must be confirmed by calculations, and seismic resistance - by calculations and/or experimental studies. Software tools used at calculation must be attested subject to an established procedure.

2.5.3. The levels of seismic loads are set in ToR in the form of floor-by-floor accelerograms or response spectra corresponding to the seismic conditions of the NPP arrangement, which are determined according to the requirements of the "Standards of design of seismic-resistant nuclear power plants".

2.5.4. Theoretical substantiation

2.5.4.1. For valves referred to seismic resistance class I, the load on the valve from the seismic impact must correspond to the impact of the SSE, for valves referred to seismic resistance class II, the load on the valve must correspond to the impact of the level of OBE. Design combinations of loads and allowable stresses in the materials of valve structures are adopted in accordance with the "Standards of design of seismic-resistant nuclear power plants".

2.5.4.2. When calculating the valves it is necessary to take into account that the seismic load acts simultaneously in three directions - a vertical direction and two horizontal directions. It is allowed to set one aggregate horizontal load instead of two horizontal loads.

2.5.4.3. At calculation of valves as part of a pipeline, the inertial load must be set for the pipeline points of attachment to the building structure in the form of floor-by-floor accelerograms or response spectra. Calculation of valves as part of a pipeline must be carried out by dynamic analysis or linear-spectral method. The theoretical model must take into account the availability of supports for valves and pipelines.

2.5.4.4. In the case of calculation of valves separately from the pipeline, the method of setting the inertial load depends on the presence of rigid fastening of the valves to the building structure. In case of rigid fastening to the building structure, the inertial load is set for the attachment points in the form of floor-by-floor accelerograms or response spectra. For valves that have no rigid fastening to the building structure, it is allowed to set the inertial load at the ends of the branch pipes in the form of accelerograms or response spectra obtained from the calculation of the pipeline.

2.5.4.5. In the absence of floor-by-floor accelerograms or response spectra at the design stage, unified inertial loads can be used as loads for calculation of valves. In this case, the calculation is performed by a static method, in which the load values are equivalent to the values of unified inertial loads, the accelerations of which depend on the natural frequency of the first form of vibration of the valve.

If the natural frequency of the first form of oscillations is higher than 33 Hz, the constant acceleration is set at all points of the theoretical model: 3g in the horizontal direction (with the most hazardous direction chosen) and 2g - in the vertical direction.

If the natural frequency of the first form of vibration of valves with remote mass is higher than 33 Hz, variable acceleration is set in the horizontal directions: 8g in the center of mass of the drive and 3g on the axis of the pipeline (with the most hazardous direction chosen); in the vertical direction the acceleration 2g is set.

If the natural frequency of the first form of oscillation is below 20 Hz, the calculation of the valve is performed by dynamic analysis taking into account the inertial load at the ends of the valve branch pipes - 3 g in the horizontal direction (with the most hazardous direction chosen) and 2 g - in the vertical direction.

2.5.5. Experimental substantiation

2.5.5.1. Valves with the natural frequency of the first form of oscillations in the range 1 - 33 Hz must be tested for dynamic impact. The lower limit of the amplitude-frequency response of the dynamic impact for testing must be taken at 5 Hz below than the natural frequency of the first form of oscillations of the valve. The parameters of accelerations must be taken on the basis of accelerograms for points of fixing valves on the pipeline or building structure. In case of absence of the above data it is allowed to use values of the unified inertial loads according to item 2.5.4.5.

2.5.5.2. Tests must be held in three mutually perpendicular directions simultaneously. It is allowed to carry out tests in each direction alternately, with the most hazardous directions chosen and total accelerations set. Valves with the natural frequency of the first form of oscillations above 33Hz must be tested for static load.

2.5.5.3. Applying the results of a valve to another valve of the same type must be justified.

2.6. Reliability targets

2.6.1. Valves, apart from integral designs of check locks are referred to products of rated reliability.

2.6.2. Reliability parameters for a particular product must be selected by the developer of the NPP project, quantitative values of the parameters must be assigned by the NPP project developer in the ToR with taking into account specifics of installation of valves in the system, operating parameters, operating procedures, the consequences of valve failures and other factors, and must be specified in the TS.

2.6.3. For valves or its individual parts, assemblies, components, the following parameters must be set:

by durability:

- assigned operation period (years, hrs);

- assigned service life (cycles, hrs);

by fail-safety:

- PFO at least... with operating hours...;

- time between failures at least... (cycles, hrs);

preservability:

- specified preservability period (years);

maintainability:

- average operating duration of scheduled repair (hrs);

- average operating labor-intensity of scheduled repair (man*hrs);

2.6.4. At the request of the operating organization, the values of the assigned operation period and service life to any specific regulatory action (maintenance, average repair, overhaul, etc.) can be additionally established.

The minimum value of the availability factor and (or) operational availability factor must be specified for valves periodically or continuously operating in the standby mode.

2.6.5. For valves with a pronounced cyclic operation mode (shutoff valves: gates, valves, locks, cocks; protective and safety valves: check locks and valves, safety valves, etc.) the service life must be measured in hours and cycles. For valves with no pronounced cyclic operation mode (e.g., control valves, the service life must be measured in hours.

2.6.6. The PFO set for the valve in the ED must be calculated based on a combination of critical and non-critical failures. At the request of the operating organization, the ED may specify the PFO calculated based on critical failures only.

2.6.7. The assigned operation period of valves for the NPP must correspond to the assigned operation period of the NPP power unit and be at least 40 years.

For newly developed valves a list of wear parts, assemblies, components must be presented in the TS and in the certificate for the valves. The TS for repair (or the operating manual) must specify methods of restorative repair or conditions of replacement (based on the operating time or criteria of limit states) of wear parts, assemblies, components.

2.6.8. Parameters of reliability of valves developed after enactment of this document must be not less than those specified in table 5.

Table 5

NUMERICAL VALUES OF PFO OF VALVES

--------------------------------

<*> For these valves the operating availability factor is 0.9999.

2.6.9. Reliability parameters must be calculated according to the requirements of RD at the design stage, and for safety system valves, at the request of the operating organization, further confirmed by the test results or operating results. The valves must be tested for reliability in accordance with the requirements of the relevant RD. For safety system valves, the confidence probability for the calculation of the lower confidence limit of the PFO must be taken to be 0.95. For valves installed in NO systems, the confidence probability for the calculation of the lower confidence limit of the PFO must be taken to be 0.9.

For valves not included in table 6, the PFO values are set in agreement with the operating organization.

Table 6

TYPES OF CONTROL AND TESTS OF MATERIAL OF MAIN PARTS

(EXCEPT FOR FASTENERS AND BELLOWS)

3. MANUFACTURE

3.1. General

3.1.1. Materials and parts whose quality meets the requirements of the RDSO and ED are admited to be used in manufacture of valves.

3.1.2. Parts and components to be assembled must be cleaned of scale, rust, dirt, oil, protective grease. Burrs or nicks are not allowed.

3.1.3. The roughness of surfaces of parts of stamped and forged and welded valves in contact with radioactive medium must not exceed Ra = 6.3 µm or must not exceed Rz = 40 µm. In hardly accessible places, it is allowed to have roughness Ra up to 12.5 µm or up to Rz = 80 µm. Roughness of outer surface of valves must not exceed Ra = 100 µm (Rz = 500 µm) or comply with requirements of non-destructive testing.

3.1.4. Roughness of inner surfaces of casting of box-like parts must comply with requirements of federal standards and rules regulating the rules of control of steel casting for NPI. Requirements to roughness of other surfaces of casting must be specified in ED.

3.1.5. Cylindrical portion of gland valve spindle passing through a gland seal must have roughness within Ra = 0.2 µm (Rz = 1.6 µm). For bellows valves with a doubling gland seal, it is allowed to have roughness of cylindrical part of spindle within Ra = 0.8 µm (Rz = 3.2 µm).

3.1.6. In machining of parts, no cutting of necks, sharp corners or edges are allowed, except for the cases stipulated in ED.

3.1.7. The valves attached by welding must be supplied with the ends of the branch pipes machined for welding. The wall thickness of the connecting end of the branch pipe must be determined from the condition of equal strength with the pipeline. The strength of the branch pipe may exceed the strength of the connecting pipe; in this case, a smooth transition must be designed from one element to another and the ability to control welded joints by all provided methods.

3.1.8. The packing material or gland rings must be installed in the gland chamber according to the technology, the observance of which guarantees the reliable operation of the seal.

3.1.9. The height of the packing gland after the final tightening of packing seal must be such that the seal gland bushing locked into the socket connector minimum by 3 mm and not more than by 30% of its height.

3.1.10. The difference between the hardness of workpieces for studs and nuts or threaded surfaces thereof must be not less than 12 N, while the hardness of the nut must be lower than the hardness of the stud.

3.1.11. Assemblies and parts of valves, made of carbon steel must be coated with protective coating according to the manufacturer’s process instruction. The grade of the coating must be specified in TS.

3.1.12. The valves with built-in electric and pneumatic drive and any valve with DN <=  50 must have arrangements for its rigid fixation to the building structures. The fastening must withstand the inertial loads of the valve and the actuator arising from the seismic effects and the loads of the pipelines to be connected, as determined in accordance with Appendix 8. The method of fastening and permissible loads must be specified in TS. It is allowed not to have an extra fastening subject to approval of the operating organization.

3.1.13. Valves with a built-in electric drive must allow their rotation relative to the spindle axis by an angle multiple of 30° or 45°.

3.1.14. The valve with an upper seal must enable control of its tightness.

3.1.15. The sealing of the housing-to-cover flange connections must be provided with grinding of surfaces or a gasket. In the design of valve flanges intended for operation with radioactive medium, elements (for example “whiskers”) must be provided, which enable additional sealing of the joint by welding at least three times during repairs. The necessity of additional sealing must be established by the operating organization. The operation manual must specify the technology of restoration of elements for welding in case of the need to provide sealing more than three times. The scope of inspection of this weld must be specified in the general drawing and in the operating manual.

3.1.16. In the housing-to-cover connection, the fasteners must be tightened by the design force or torque specified in the ED.

3.1.17. It is allowed to manufacture valves for Pd <= 10 MPa, not being in contact with radioactive media, without plugs for air removal if, at filling with water with parameters Td = 20 °C, Pd = 0.1 MPa, the air volume does not exceed 30% of the volume inner cavities of valves.

3.1.18. The valves (along with the drive) must meet the requirements of the relevant RD for fire and electrical safety.

3.2. Materials and semi-finished products

3.2.1. The materials specified in Appendices 11 and 12 and in RDSO are allowed for the manufacture of the main parts of the valve.

3.2.2. In the valves with corrosion-resistant steel in the material of parts (except bellows) with a surface area of over 10^-2 sq m in contact with the coolant of the NPP primary circuit, the content of cobalt must not exceed 0.2%. Using copper-based alloys or metals alloyed with copper for manufacture of parts in contact with coolant of the NPP primary circuit is not allowed.

3.2.3. Requirements to sealing semi-finished products and articles

The requirements of the paragraph apply to non-metallic materials, semi-finished products and sealing products included in the pressure-holding circuit (gasket flange connections, housing-to-cover connections, gland seals), as well as the combined gaskets (metal-graphite, spiral-wound ones, etc.).

3.2.3.1. For the manufacture of gaskets and gland seals, materials and semi-finished products must be used that are produced based on RD (the requirements of which relate to bellows) or TS approved by the developer of the valve and the operating organization.

3.2.3.2. The use of materials containing asbestos is prohibited in newly developed valves.

3.2.3.3. TS on sealing products must be approved by the developer of products, approved by the manufacturer of valves and the operating organization. TS needs to specify physico-mechanical characteristics of materials of which the products are made; conditions; permissible loads and the radiation levels over the operation period; service life at operation of gaskets and gland seals; storage life; possibility of re-use; resistance against decontamination solutions; the level of corrosion of construction materials of valves in contact with gaskets and gland seals.

Requirements of TS for sealing semi-finished products and articles must be confirmed by tests or calculations. It is allowed to confirm the conformity of gaskets and gland seals to meet TS requirement at acceptance tests of valves.

3.2.3.4. A change of the type of sealing products on valves already in operation, is made out by a decision (or a technical solution) approved in accordance with an established procedure.

When drawing up the decision (or technical solution), all the TS requirements must be confirmed for the applied semi-finished products and articles.

3.3. Welded joints and overlaying

3.3.1. Welded joints, welding materials and welded surfaces must meet the requirements of this document and the federal rules and regulations setting the requirements for welding and surfacing and for control of welding and surfacing of NPI.

3.3.2. Materials for surfacing of sealing and guiding surfaces must be selected by the developer from those listed in Appendix 13. The use of new surfacing materials must be agreed upon with the head material science organization. The technology of surfacing of sealing surfaces must be developed in accordance with the requirements of RD.

3.3.3. Welded joints of bellows assemblies, the scope and methods of their control, quality assessment must be carried out according to the documentation agreed with the head material science organization.

3.4. Monitoring

3.4.1. Materials

The requirements of this subparagraph apply tothe main parts of valves.

3.4.1.1. Materials intended for the manufacture of valves must be subjected to control and testing according to the requirements of table 6. For valves operating at temperatures above 450 °C, additional types of control and testing are determined by the head material science organization.

3.4.1.2. The quality and properties of semi-finished products must be confirmed by quality documents, which must include the designation of the material, the number of melt and batch, the nominal mode of heat treatment, the results of all tests (control), as well as data on the correction of defects.

3.4.1.3. Requirements for fasteners of valves must be determined according to the corresponding RD.

3.4.1.4. Requirements to multilayered and single-layer bellows, as well as to their components, must be determined based on the corresponding RD. Bellows must meet the following requirements:

- the outer layer of the bellows must be sealed (solid);

- SU must withstand at least 20 cycles of pressure testing during the assigned operation period;

- T_al and PFO of SU must ensure meeting the relevant requirements for valves in terms of reliability.

3.4.2. Welded joints, welded sealing and guide surfaces

3.4.2.1. Control of welded joints must be carried out in accordance with the requirements of federal rules and regulations setting the requirements for control during welding and surfacing of NPI. The class of welded joint is assigned by the developer of the valves.

3.4.2.2. Control of the deposited surfaces must be carried out according to the requirements agreed upon with the head material science organization.

3.4.2.3. The list of main parts must be specified in the TS for a specific valve. The type and scope of control of workpieces of the main parts can be supplemented.

3.4.2.4. The quality of welded joints and surfacing must be controlled by color flaw detection according to class II of sensitivity as per the regulatory document "Non-destructive testing. Liquid penetrant methods. General requirements". Scope of control - in accordance with the requirements of federal rules and regulations regulating the control of welding and surfacing of NPI.

3.4.2.5. Welds must be controlled for vacuum tightness according to class III of tightness of the federal rules and regulations setting the requirements for control during welding and surfacing of NPI.

3.4.3. Control of products

3.4.3.1. Quality control of individual parts, assemblies and products must be carried out in accordance with the requirements of the ED and the quality control program of the valve manufacturer.

3.5. Tests

3.5.1. Prototypes and serial products of valves must be subjected to the following types of tests:

- acceptance tests carried out on prototypes or samples from a pilot batch;

- standard tests carried out on serial products or on samples from a pilot batch;

- qualification tests carried out on serial products or products from a pilot batch;

- comparative tests carried out on prototypes or serial products;

- periodic tests carried out on individual serial products;

- commissioning tests carried out on all products.

3.5.2. Acceptance testing must be performed for confirmation of:

- compliance of technical characteristics of valves with requirements of ToR, TS and ED;

- rationality of technical solutions provided in the design;

- compliance of manufacturing technology with requirements to the quality of products;

- service life of the product (determination of actual service life and data substantiating the design reliability parameters);

- easy maintenance and repair;

- operating safety.

Development and coordination of programs and techniques of acceptance tests must conform to requirements of the RD determining the procedure of development of products and their putting in production.

The requirements for a standard program and the methods of acceptance tests intended for use in the development of the working program of tests are presented in Appendix 14. At putting in production of a standard series of valves, acceptance tests may be performed on individual samples (standard sizes) of the standard series only, with tests held on the products, whose DN differ by more than two times.

Prototypes of control valves must be tested to determine the coefficient of conditional throughput and throughput characteristics according to the procedure specified in the prototype testing program.

In case of necessity stipulated in ToR, cavitation characteristics must be determined.

The value of the conditional throughput factor and the throughput characteristic must be specified on the assembly drawing of the control valves.

3.5.3. Standard tests must be carried out when changing the design or manufacturing process of products, if these changes may affect the technical characteristics of the products.

The program of standard tests must be drawn up by the developer of the valves and coordinated with the operating organization; this program must determine the quantity of the samples which are subject to the tests.

3.5.4. Qualification tests must be carried out in the following cases:

- to assess the readiness of the enterprise to produce products of this type;

- to verify that all deficiencies identified by the acceptance committee are eliminated, and deviations of parameters related to the production technology do not go beyond the permissible limits in accordance with the requirements of the RD in effect. In this case, the program of qualification tests includes and takes into account all the requirements of the acceptance commission, as well as the necessary tests to confirm the acceptability of changes, additions to the design and requirements for the products specified in the TS, after their adjustment based on the results of acceptance tests;

- at the beginning of production of valves in case of transfer of production from one manufacturer to another;

- if there are new requirements for the operation of the valve, not previously confirmed by tests.

The qualification test program must be drawn up by the valve designer and agreed upon with the operating organization.

If there is no need for any other tests, qualification tests are carried out to the scope of acceptance tests, followed by operation for a service life with operating parameters, with a flow rate determined by the capacity of the stand. At testing of shutoff and control valves, the stand must ensure the implementation of a full cycle of opening and closing; at testing of safety valves the stand must ensure the actuation of valves at operating parameters; testing of check valves for service life is allowed to be held at a "cold" stand, where the stand needs to provide full opening of the check valve DN <= 500. After running for an assigned number of service hours, commissioning tests are repeated.

3.5.5. Comparative tests must be carried out to compare the technical characteristics and quality of valves from different manufacturers under adequate conditions. Comparative tests must be carried out at the request of the operating organization. The comparative test program must be developed by the testing organization and agreed upon with the operating organization.

3.5.6. Periodic testing of valves manufactured according to the same TS must be carried out with the notification of the valve developer and the operating organization at least once in every three years in order to confirm the stability of quality parameters. The duration and conditions, as well as the volume of products subjected to tests (checks) must be established in the TS and in the ED on the product.

It is allowed to confirm the stability of quality parameters, instead of carrying out periodic tests, based on results of acquisition of information on operational reliability of the valves.

3.5.7. Commissioning tests

3.5.7.1. The manufacturer of valves must subject each product (unit of valves) furnished with regular components and equipment to commissioning tests for compliance with requirements of TS:

- hydraulic (pneumatic) tests for strength and tightness of the material of the main parts and welded joints subject to the pressure of the working medium, in accordance with the RDSO;

- for tightness of welds and detachable joints;

- for operability and smoothness of travel;

- for tightness of the lock;

- for tightness in relation to the external medium for valves operating under vacuum, and bellows valves;

- for tightness of the gland seal on the spindle (rod), including the lower and upper stages of multi-chamber gland assemblies, as well as the upper seal;

- other types of tests provided in TS for the valves.

The test sequence is recommended and determined by the manufacturer.

Before testing, each product must undergo visual and measuring control. Hydraulic (pneumatic) tests must be carried out at a temperature determined by the RDSO.

3.5.7.2. Tests for strength and tightness of the material and welds must be carried out before painting of the valves.

3.5.7.3. Parts and assemblies of bellows valves must be tested for strength and tightness of the material before assembling the products according to the instructions of the ED. For avoidance of damage, the bellows must be guaranteed (protected) from compression or tension.

3.5.7.4. The valve assembly must be subjected to pressure testing for tightness of gland and gasket seals, housing-to-cover joints, for tightness of the upper seal (for valves with output of controlled leaks from the inter-gland space) and the lock of the product.

The value of the pressure value of the test fluid must meet the requirement of the ED for the product and TS for the valves, but be not below Рd.

During hydraulic testing of gland and gasket seals, housing-to-cover joints, no leak of the test fluid through the seals is allowed.

3.5.7.5. When testing the product, the lock must be closed (depending on the method of control - with a spring, actuator or manually) with a force (torque), the value of which is specified in the ED.

3.5.7.6. Tests of hydraulic drives must be carried out with water, those of pneumatic drives - with air.

3.5.7.7. At tests, it is not allowed to lubricate the sealing surfaces of the lock of the valves.

3.5.7.8. The installation position of the products in the tests - in accordance with the instructions of ED.

3.5.7.9. Valves designed to operate on gas and steam, when assembled, are subjected to additional air tests for tightness of parts, welds and joints at the working pressure. The duration of exposure of products to pressure must not be less than 2 minutes for valves with DN < 100, 3 min for DN = 100 - 300 and at least 5 min for DN > 300. When testing the housing-to-cover joint, the valve must be closed with the design force.

3.5.7.10. When testing with air, the tightness of joints must be checked according to the manufacturer's instructions by soap bubble method or by submerging the product in water. Water ingress into the bellows is not allowed. Products are considered to have passed the test, if no breach of tightness (appearance of bubbles) is detected. The presence of non-breaking bubbles during the control in the bath with water or non-bursting bubbles during the control by the soap bubble method is not considered a sign of defect.

3.5.7.11. For testing of the lock of valves operating on a gaseous medium (including steam) for tightness, air must be used, and for testing of other valves - water or air must be used:

a) for bellows valves, the tests must be carried out after the closure of the valve for three times. The medium must be delivered "onto" and "under" the spool, with the exception of the cases, where the one-way flow of medium is stipulated. Closure of the valve is to be carried out with the design force at the air flow through the valve seat and through the throttle at the outlet. It is not allowed to have the medium flow pass through the valve seat owing to incomplete opening of the valve lock from the closed position. Test parameters must be specified in TS.

When testing the valve with air, leaks must be determined either by immersion in water or by draining the leakage through a tube from the cavity under control. Exposure after shutoff must be at least 3 minutes. Permissible leaks - as per paragraph 2.3.8;

b) for gates and cocks, the lock tightness test must be performed with pressure in accordance with paragraph 3.5.7.4, for a check valve - with pressure according to paragraph 2.3.8.1.

The pressure supply in gates, cocks must be carried out alternately from each side or, for gates, into the inter-disk, in check valves - onto the lock. The duration of exposure - at least 5 minutes.

Tests of gates, cocks must be repeated after double opening and closing of the lock without a pressure drop on the shutoff body. Leakage of the test medium - in accordance with the requirements of paragraph 2.3.8. Tests must be carried out with standard drive units.

3.5.7.12. Each direct-acting safety valve, including the PV of PORV, must be subjected to tests for tightness of the lock, pressure of full opening and back seat.

The pressure of full opening and back seat of safety valves must comply with the requirements of the RDSO and be confirmed by the prototype test results.

Tests must be carried out on prototypes of safety valves to determine the throughput or the flow rate factor according to the procedure specified in the prototype test program.

According to the test results of the prototype of the safety valve, the opening pressure, the back seat pressure, the throughput (flow rate factor), the area of the smallest flow section of the seat with the valve fully open must be specified in the TS, in the general view drawings and in the certificates of the valves.

3.5.7.13. Tests for the operability of shut-off (except for check valves) and control valves must be carried out at operating pressure inside the product, and those of safety valves - at the valve inlet, in accordance with the program and procedure of testing agreed upon with the operating organization.

The test for the operation of valves with pneumatic and hydraulic drives must be carried out at the operating pressure of the medium inside the static valve with supply of the control medium into the drive. Simultaneously with the operability test, one must check the remote signaling for the product.

Operability of the valves with EMD must be checked with a pressure drop on the lock as stated in he TS, and without the pressure drop, at the operating pressure in the housing.

3.5.7.14. It is allowed to conduct operability tests under a special program agreed upon with the operating organization.

3.5.7.15. The vacuum tightness test of the joints and material relative to the external medium of the bellows and vacuum valves must be carried out with a helium leak detector, unless otherwise provided by the ED. Requirements to the tightness of valves in relation to external medium as well as the scope of the test must be specified in TS. Before the test, the internal cavities of the housing must be thoroughly washed and dried to ensure the sensitivity of class III as per federal rules and regulations setting the requirements to control at welding and surfacing of NPI.

3.5.7.16. Tests of the top seal (if available) of gates for tightness must be carried out after double opening of the lock from the drive or the flywheel with a torque specified in TS and issued in the form of Appendix 4. Leakage of the medium through the upper seal is not allowed.

3.5.8. All tests must be carried out by the manufacturer or a specialized organization. Results of all test types (except for acceptance and commissioning tests) must be documented with a certificate. The results of commissioning tests must be recorded on the certificates of products.

3.5.9. Bellows testing

3.5.9.1. At commissioning tests, SU of the manufactured batch must be subjected to the following tests:

- for control of the quality of surface, structure, dimensions, stiffness, strength and tightness - bellows making part of the SU, in accordance with the requirements of RD;

- for tightness of the outer layer - each product. The tests must be carried out with an outside air pressure equal to the maximum pressure of the hydraulic tests in the valve used, with the minimum duration of exposure to this pressure being 3 minutes.  After pressure relief, the SU must be immersed in a container of water. A sign of leakage of the outer layer must be systematic separation of air bubbles from the surface of the bellows;

 - for confirmation of Tal (service life test) - for each batch of bellows under control. Bellows must be selected by the "blind random" method according to RD in effect. Sample size - not less than two and not more than five of bellows. Tests must be held on BU after welding of end parts to bellows to operating time of at least 1.2 Тal. If at testing of a sample made up of more than two BU, a failure is detected in the range of 1.0 to 1.2 Тal, the testing of other BU of the sample should be held to a failure or fulfillment of assigned service hours of 3 Тal, with PFO calculation held in compliance with RD. If at testing of a sample made up of two BU, a failure is detected in the range of 1.0 to 1.2 Тal, additional testing to a failure of two BU selected from the batch under control, with calculation of PFO held.

 3.5.9.2. For determination (confirmation) of the possibility of application of a specific standard size of BU in the valves within acceptance (standard, qualification) tests of bellows, service life tests must be held. The tests must be held at parameters (pressure, temperature, travel) stipulated in TS for the bellows of the standard size in question, or at the maximum parameters of the valves, in which this standard size may be used for the bellows, if at least one of these parameters exceeds the values stipulated in RD. For each standard size of bellows from a manufactured batch that has passed commissioning tests, a sample must be taken of at least eight units.

Tests must be held on BU after welding to the bellows of end parts. It is allowed to include BU samples previously subjected to service life tests at commissioning tests of the batch under control. Service life tests must be held to a failure, but not exceeding 3.0 Tal. Calculation of PFO must be performed in accordance with RD. The results are considered positive if all the BU of the sample have run for at least Тal, and the BU PFO obtained as a result of the calculation ensures the PFO of the valves.

Pressure testing of BU with a test pressure equal to the maximum pressure of hydraulic tests in the valve used must be carried out before the service life tests for all types of tests (acceptance, standard, qualification, commissioning, periodic ones). The number of pressurizations - at least 20, with exposure of at least 3 minutes.

3.5.9.3. BU periodic testing procedure.

As scheduled, periodic tests must be carried out at least once in three years for each standard size of the bellows under the conditions established in TS.

From the manufactured batch of the bellows that has passed commissioning tests, a sample must be taken of at least eight units. Tests must be held on BU after welding of end parts thereto. It is allowed to include in the sample the BU previously subjected to service life tests during commissioning tests of the batch under control.

3.5.9.4. Service life tests must be held in compliance with a procedure established for acceptance tests of BU.

3.5.9.5. To ensure higher reliability of BU at the development of new designs of valves, it is recommended to use multilayer bellows instead of single-layer ones.

3.6. Complete scope of supply

The scope of supply must include valves with its components and cover technical documents.

3.6.1. Articles:

а) motor-driven valves DN <= 300 with a drive mounted on the valve. For motor driven valve, DN > 300 it is allowed to deliver the valve with dismantled motor drive (motor) in the single shipping container.

b) remote alarm electrical sensors of the extreme positions of shutoff device installed directly on the valve (see 2.3.25.1) or packed in conformity with TS for the sensors or valve;

c) a set of spare parts, tools and accessories, their specific list and quantity determined at approval of TS;

d) a set of control rings of each standard size with one dressed edge for welding of control samples in accordance with the requirements of federal rules and regulations setting the requirements for control during welding and surfacing of NPI. The need to supply the control rings, their quantity and dimensions must be specified when ordering the valve;

e) the quick-acting pneumatic valves must be supplied as complete set with an air control valve and terminal switches;

f) counter flanges (fittings) and fasteners to flange (nipple) valves (the need of delivery is determined by the operating organization at approval of TS);

g) valves with EMD must enable delivery complete with (or without) a rectifier device for solenoids operating at a constant (rectified) current;

h) counter flanges (nipples) supplied complete with valves must be butt-welded;

i) valves with classification designation 1А, 2ВIIа, 2IIа, ЗСIIIа, with a cover-housing opening available, must be supplied with devices assuring controlled torque of studs.

3.6.2. Cover technical documents:

a) certificate of the form of Appendix 15;

b) drawings of fast-wearing and box-shaped parts;

c) calculation of strength of box-shaped parts, or extract from strength calculation;

d) operation manual including a section on guidelines for repair;

e) certificate, operation manual and assembly drawings with specifications (if not available in the operation manual) for components;

f) packing list;

g) other documents (on request of the operating organization).

The following must be provided for each newly designed valves: repair documents (on request of the operating organization); repair fixtures, accessories. For the valves in operation, the need in development of the above documents, fixtures and accessories is determined by the operating organization.

The certificate must be delivered with each valve product with DN > 150 and with each safety valve (with each main and pilot valve for PORV) independent of DN. For valve DN < 150 it is allowed to document one certificate for a batch of products in the quantity up to 50 pcs.

The remaining documentation, in addition to the strength calculation and working drawings of box-shaped and wear parts, must be supplied based on one set for a batch of up to 50 pieces, inclusive, two sets for a batch of more than 50 pieces, with specification of serial numbers of all products included in the sets.

Calculation of strength and working drawings of box-shaped and wear parts of each standard size must be sent with the first product in one copy per batch of products.

The cover documentation must be handed over to the operating organization simultaneously with the delivery of the valves.

3.7. Marking, preservation and packing

3.7.1. The manufacturing plant shall apply the marking with the following data in a well-visible place on the valve housing: manufacturer’s name or trademark, serial number, year of manufacture, rated pressure (in the housing), rated temperature (in the housing), nominal inside diameter DN, flow arrow (during unidirectional medium feed), type of operating medium (liquid - "l", gas - "g", steam - "s"), valve class notation (according to table 1), valve safety class and group, product notation, steel grade and melt number (for housins made of castings).

In absence of restrictions as to the medium type its designation is not marked. An example of designation for ordering of the valves must be given in the Specifications.

3.7.2. During transportation and storage, the valves must be preserved in accordance with the instructions for preservation.

Fastening parts, rods and other surfaces without paint shall be mothballed with lubricant K-17 or other conserving agent by agreement with the operating organization.

3.7.3. Surfaces of valve parts made of pearlite class steel, machined for preweld during installation are not painted for a width 20 mm from the edge, but are conserved.

3.7.4. Packaging of valves, components and parts must ensure the safety of products during transportation and storage. The packaging method must be specified in TS. In this case it is recommended to take into account the following:

- valves, a set of spare parts, electric drive, tools, standard gland packing must be packed in a box lined inside with waterproof paper inside, and secured inside to prevent mutual displacements. Packaging must ensure the safety of valves and components from mechanical and climatic impacts;

- products with DN < = 50 must be pre-packed in polyethylene film, which must be welded; for packing of valves DN > 50 and electrically operated valves polyethylene film and other materials must be used; packaging must prevent contamination and moisture; inhibitors must be placed inside the packaging of the film for carbon steel valves;

- to prevent electrochemical corrosion of the surfaces interfaced with the gland packing, valves with gland packing on the rod, except for the C&I valves, must be supplied with a temporary gland packing of type AS impregnated with inhibitor G-2 under TS or water-glycerin solution of sodium nitrate, or other similar compositions. If the absence of electrochemical corrosion of the rod and the chamber is guaranteed, it is allowed to supply valves with regular packing. Before operating the valve, the temporary packing must be replaced with the regular one supplied with the product.

Other types of packaging may be permitted subject to approval of the operating organization.

The valves must be stored in places protected from atmospheric precipitation and direct sunlight.

3.7.5. Branch pipes must be closed with plugs preventing the cavity of the valve from dirt and moisture, protecting the edges from damage. Variant of internal packaging –  VU-9

3.7.6. Marking of bellows and bellows units must be carried out with electrographic or impact method. The method is determined by the manufacturer's technology.

3.7.7. The documentation supplied with the valve must be packed in a waterproof envelope, which is placed together with the first product in the package tare. One copy of packing list must be inserted in the box. The second copy shall be affixed to the outside of the box in a waterproof envelope.

3.7.8. The cover documentation for the preserved products must specify the date of preservation, the protection option, the internal packaging option, storage conditions and the period of protection without re-preservation.

3.8. Transportation and storage

3.8.1. The valves must allow being transported by any means of transport and to any distance. When transporting, the measures shall be taken to ensure that the valves and its packaging are not damaged.

3.8.2. Requirements to conditions of storage and transportation of valves and components must be specified in the ToR or TS.

The valves shall withstand storage in the undamaged factory packing for at least 36 months without repeated preservation. The condition of the container and storage conditions must be inspected upon expiry of the shelf life and every 12 months afterwards. In case of any breach of the container integrity and violation of storage conditions, integrity of preservation must be checked. In case of any violation of preservation, re-preservation must be made and a report drawn up.

If stored for more than 6 years, the assembling must be allowed in accordance with the instructions approved by the operating organization.

3.8.3. The date of preservation and packing, the period of preservation and storage in original packing shall be specified in the certificate on the valves.

3.9. Warranties

3.9.1. The manufacturer must ensure that the technical characteristics of the manufactured valves and components of its products meet the requirements of the TS subject to the consumer's adherence to assembling, repair, operation, transportation and storage conditions set in the TS and (or) the operation manual.

3.9.2. The warranty period shall constitute at least 36 months from the date of issue of the confirmation of delivery (or from the date of transportation through the border for import), including at least 24 months from the date of commissioning (subject to observation of the rules of transportation, storage, assembling and operation).

4. ASSEMBLING AND OPERATION

4.1. General

4.1.1. Instructions on keeping the valves ready for operation, on commissioning, on possible malfunctions, damage and ways of their elimination shall be given in the operation manual provided by the RDSO.

4.1.2. It is forbidden to operate the valve in the absence of a certificate and operating manual.

4.1.3. It is recommended to provide a straight section of the pipeline before and after the valves with a length of at least 5 outer diameters; conditions for assembling, inspection, maintenance and repair work should be specified in the TS.

4.1.4. Welding of valves with the pipeline must be carried out with the lock partially open, it should ensure the protection of the internal cavities of the valves and pipeline from ingression of welding flash and scale.

4.1.5. The valves must withstand multiple hydraulic tests as part of the process system carried out during commissioning and operation in accordance with the RDSO. The permissible number of hydraulic tests must be specified in the specifications.

4.1.6. It is not permitted to use shutoff valves as regulating devices.

4.1.7. Use of control valves as shut-off and regulating ones is only possible only if stipulated in the TS for the specific product.

4.1.8. Maintenance and repair of valves should be carried out in accordance with the program of maintenance and repair of valves adopted at each specific NPP, aimed at ensuring the safety, reliability and efficiency of the NPP operation.

4.1.9. The following requirements must be considered in the valve maintenance and repair program:

- inspection and maintenance (lubricant refilling, tightening or re-packing of gland seals, etc.) must be necessary not more often than each 15000 hours of the process system operation;

- the valves must be subjected to technical examination in accordance with the RDSO requirements;

 - the frequency of maintenance and time to overhaul and intermediate repair, their scope specified in TS must be determined for the most severe conditions of operation (the maximum values of service life, parameters Рd and Тd, pressure drop in the lock, etc.), as specified in TS.

For valves of the same type valves with the classification designation 3SIII, taking into account the actual conditions of its operation, the operating organization can set the frequency and scope of maintenance and repair different from those set out in the TS, ED and the manufacturer's cover documentation.

4.1.10. For valves with the classification designation 3CIII it is allowed to apply planning of maintenance and repair based on the actual condition, for valves adequately equipped with means of technical diagnostics. The possibility of planning maintenance and repair according to the actual condition for a particular valve should be established by the developer of the NPP project in the ToR, or by the operating organization subject to approval of the developer of the valve.

4.2. Periodicity of maintenance and repair

4.2.1. Unless otherwise specified in the ToR, TS for the valves, the overhaul of valves (except control valves) should be carried out upon expiration of the service life of the valves in the "open-closed" cycles:

500 - for gates, cocks;

1350 - for check valves and locks;

1500 - for shutoff valves;

100 - for safety valves;

250 - for shutoff and throttle valves;

250 - for fast-acting cutoff valves;

250 - for check valves and locks of safety systems;

5000 - for shutoff valves with EMD.

4.2.2. Unless otherwise specified in the TS, the overhaul of valves must be carried out at least once in 12 years.

If over the specified overhaul period the valves with the classification designation 2BII, 2BII operating at a temperature below 200 °C and water speed less than 3 m/s, or steam speed less than 30 m/s, and the valves with the classification designation 3SIII has not exhausted its assigned service life in cycles, their operation can be continued until full expiration of the service life if no defects or damage are detected during inspection at operation, outer inspection and hydraulic (pneumatic) tests as a part of the equipment or pipelines, and in the absence of unacceptable thinning of the walls of the box-shaped parts.

4.2.3. For the regulating and shut-off and control valves, the overhaul service life (in cycles) and the assigned time before overhaul must be assigned in the ToR, adjusted and entered on the TS based on results of acceptance tests. The operating mode of the control valves, the number of actuations per hour and the range of control must be assigned in the ToR and/or in the TS.

4.3. Technical safety

4.3.1. The assembling, maintenance, operation and repair of the valves must comply with the safety rules set out in the operating manuals and safety instructions applicable to the NPP.

4.3.2. The NPP employees may only be admitted to the assembling, maintenance, operation and repair of valves only after examination of the above documents, examination of knowledge, and appropriate briefing.

4.3.3. To ensure safe operation, it is forbidden:

- to use the valve for operation at parameters exceeding those specified in the operating manual;

- to perform works on elimination of defects, to fill gland seals with the pressure of the working medium in the housing, or with voltage in electric circuits (motors, sensors, etc.).;

- to use additional levers for manual control of the valve, or to use wrenches of a size not corresponding to the size of fasteners;

- to work with valves without personal protective equipment, or failing to comply with fire safety, electrical safety, radiation safety or industrial sanitation rules.

4.4. Extension of assigned operation period (service life)

4.4.1. Extension of operation period (service life) of valves with classification designation 1A, 2BII, 2BIII must be performed for each unit of valves in accordance with the requirements of the RD in effect.

4.4.2. Extension of operation period (service life) of valves with the classification designation 3CIII of the same type is allowed to be carried out based on positive results of inspection of one or two units of valves of this type for the specific NPP.

5. DRIVES AND ELECTRIC PART OF VALVES

5.1. General

5.1.1. The electrical part of the valves must meet the general requirements of safety and electromagnetic compatibility, and have a degree of protection according to the regulatory document "Ingress protection classes (IP Code)":

- not less than IP 55 - for valves installed under the shell and in the boxes;

- not less than IP 44 - for valves installed in attended premises.

Cables, wires and cords for non-propagation of combustion must meet the requirements of the relevant RD.

5.1.2. Power supply of electric drives, EMD and EIM must be exercised from alternate current of 50 (60) Hz and voltage:

- single-phase mains 220 (240) V;

- three-phase 380/220 (415/240) V.

The neutral is solid-earthed.

The need to supply valves with power supply of the drive with voltage 415, 240 V, 60 Hz must be specifically stated at placement of order. The frequency tolerance is +/-2%, permissible voltage deviation of + 10% to minus 15%, where the voltage and frequency deviations shall not be opposite.

Electric drives and EMD of safety systems must also be operable under the following conditions:

- voltage decrease to 80% from the rated value and simultaneous frequency fall by 6% from the rated value for 15 sec;

- voltage increase to 110% of reference value and simultaneous frequency growth by 3% of nominal value during 15 s.

In such case the drive shall not stop and the valve actuation shall be provided. It is possible to implement EMD valves powered by a DC voltage of 220 V (+22 V, -44 V), subject to its approval by the operating organization.

5.1.3. Each switch (limit or position switch) and each torque limiter switch must have one closing contact and one opening contact with separate outputs.

Switches shall work in the following conditions:

- in AC circuits of frequency 50 and 60 Hz, voltage up to 250 V, the current through the closed contacts is from 20 to 500 mA;

- in DC circuits from 15 to 60 V, the current through the closed contacts is from 5 mA to 1.0 A (or, subject to approval of the operating organization, from 1.0 to 400 mA), where the drop in voltage on the closed contacts should not exceed 0.25 V;

- the actuation time on closing and opening must not exceed 0.04 sec.

Specific values of voltage and current should be specified in the ToR, TS and the operating manual for the valve or electric drive.

5.1.4. For any valve other than the safety valve installed under the shell, the terminals of all electrical components must be connected without jumpers to one common series of clamps (or electrical connector), which must be supplied complete with the valve (for electrically driven valves - complete with a drive). A series of clamps (or an electrical connector) shall have a degree of protection not lower than that specified in 5.1.1 (for electrically driven valves - the same as the drive as a whole), and shall allow for the installation of the necessary signaling and control circuits.

Drives must have two or three inputs for connection of external cables: one - for the power supply circuits of the electric motor, the other -for control and signaling circuits, the third (if necessary) - for the position sensor circuits. With the length of the signaling (control) inside the housing of the electric drive more than 20 cm, these must be placed in a common screen or use a shielded cable. At the request of the operating organization, for electric drives located under the shell with power up to 7.5 kW inclusive, and for high-speed shut-off valves it is allowed to provide one input for the common cable of electric motor power supply circuits, and control and signaling circuits.

When two electrical connectors are used that have their own contact markings, the wiring arrangement of the electric drive must be specified in the drive operating manual. The conductor cross-section and the outer diameter of the cables must be specified in the drive operating manual and the driver certificate. For safety valves the outputs from all electrical components of the valves shall meet the requirements of paragraph 2.3.33.2.

5.1.5. On the inside of the cover of a number of clamps or the mating part of the electric connector, an electric diagram of internal connections of all the elements of the electric part of the valves must be located.

5.1.6. The impedance of insulation of electrical circuits in relation to the housing and between themselves at a temperature of (20 +/- 5) °C and humidity from 30 to 80% must be at least 20 MOhms. The impedance of insulation of electrical circuits in the most severe operating conditions, subject to the requirements of paragraph 2.3.11.and subsection 2.4., shall not be less than 0.3 MOhms (immediately after the test in the "major leak" mode for 10 hours). The impedance of insulation of of electrical circuits under the effect of environmental factors (temperature and humidity) shall be specified in TS.

5.1.7. The impedance of insulation of electrical circuits in relation to the housing and between themselves at a temperature of (20 +/- 5) °C and humidity from 30 to 80% must withstand the testing voltage of sinewave AC of 50 Hz for 1 minute. The effective values of the test voltages should be selected according to the rated circuit voltage according to table 7.

Table 7

SELECTION OF TEST VOLTAGE

Requirements for the electrical strength of the insulation circuits under the influence of environmental factors (temperature and humidity) must be specified in the TS for the product.

5.1.8. If additional special low-voltage equipment is required to ensure the operability of the valve (drive), the latter shall be placed in an appropriate low-voltage complete device and supplied complete with the valve (drive). The low-voltage complete device shall enable receiving power supply, electric commands of remote (from the board) and automatic control, valve signaling circuits. The TS for the valve (drive) must to specify single-line electric diagrams, wiring diagrams, as well as overall and installation dimensions of a low-voltage packaged device.

5.1.9. The electrical part of the valve must have grounding clamps fitted with a self-unscrewing device. Additional safety requirements must be established in the TS for the product.

5.1.10. The design of the manually operated valve shall allow for the installation of two limit switches to indicate the end positions of the shutoff body. The type of switches must be specified in the TS and in the certificate.

5.1.11. Requirements for cable entries and the form of presentation of the main technical data and characteristics of electric drives are given in Appendices 16 and 17, which do not apply to valves with EMD. The requirements of Appendices 16 and 17 may be ascertained in particular TS.

5.1.12. Electrical wiring diagrams and circuit breaker operation diagrams are given in Appendix 18 (not presented), which does not apply to valves with EMD.

5.1.13. Technical safety

Only specially trained personnel who have studied the technical description and the manual on operation of electric drives and have been properly briefed on safety measures shall be allowed to assembling and operation of electric drives.

The following requirements must be observed during electric drive operation:

a) maintenance of electric drives should be carried out according to "Rules of technical operation of electric installations of consumers" and the operation manual;

b) free space shall be provided between the electric drives and the building structures to ensure safe maintenance in accordance with the "Electrical Installation Code";

c) the electric drive must be safely grounded;

d) it is forbidden to use electric drives under the maximum load at DD exceeding the DD of the electric motor.

5.1.14. Components must meet the following requirements:

a) components and elements shall be stored by the manufacturer of electric drives in the closed premises in accordance with the TS for these products;

b) purchased products must comply with the drawings and TS of the supplier and be accompanied with appropriate documentation indicating the characteristics obtained during the tests, warranty periods and an opinion on suitability;

c) purchased parts, components and products shall be subject to selective incoming control to the following scope:

1) rubber and fluoroplastic - external examination for damage, measurement and verification of cover documentation;

2) electric motors, solenoids and miniature switches - visual examination, checking of cover documentation and operability tests. Test parameters must be specified in TS for the electric drive;

d) it is forbidden to put articles in production without incoming control.

5.1.15. The following requirements must be satisfied during manufacturing:

a) assembling of conductive parts must prevent insulation breakdown;

b) on bent surfaces of pipes with a diameter up to 25 mm, no corrugations higher more than 2 mm are allowed, on surfaces of pipes with a diameter over 25 mm - no currugations higher than 3 mm are allowed;

c) prior to solderin, the joints must be thoroughly cleaned of rust, paint, oxide film and other contaminations. The soldering areas must have no drips of solder, local dry joints, air holes or traces of flux;

d) it is not allowed to use flux for hot tinning. The joints subjected to hot tinning must have no convex or sharp overlaps. The thickness of a coating layer with hot tinning (if there are no instructions in the ED) - from 0.05 to 0.1 mm.

5.2. Electic drives of shutoff valves

The requirements of this subsection apply to built-in and remote electric drives with a two-way torque limiter designed as part of the complete scope of supply of shut-off valves.

5.2.1. The operating position of electric drives may be chosen at will, provided that the motor would not be located under the reducer.

Electric drives must ensure:

- movement of the shutoff body of the valve operated from the control panel;

- movement of the shutoff body of the valve with a manual backup control of the electric drive;

- shutdown of the shutoff body of the valve at any intermediate position by pressing the STOP button;

- automatic shutdown of the electric motor by limit switches when the shut-off valve reaches the end positions;

- automatic shutdown of the electric motor with torque limiter switches when the set torque value is reached on the output body of the drive at the closing and opening stroke (see also paragraph 2.3.32.);

- light signaling on the control panel of extreme positions of the shut-off body of the valve;

- light signaling on the control panel of actuation of torque limiters;

- issue of an alarm on the control panel when the shutoff body reaches a specified intermediate position;

- indication of extreme and intermediate positions of the shutoff body on the scale of a built-in indicator (for drives installed outside the shell);

- prevention of self-displacement of the shut-off body of the valve under the impact of the medium in the pipeline and external factors (temperature, vibration, seismic impacts, etc.).

5.2.2. Characteristics of products

Electric drives must be designed to operate in the intermittent duty mode with DD of at least 25%, with no more than six starting modes per hour allowed. A larger number of starting modes must be stated in the TS. Electric drives shall have two limit switches, two position switches and two moment limiting switches. Position and coupling switches must enable switching off of the electric motor and indication of the position "closed", "open", "torque".

Electric drives must be provided with a manual backup control. The manual backup control must be switched on manually and switched off at the start of the electric motor. The effort on the manual backup control must not exceed 735 N at the maximum torque of opening (closing) and 295 N at displacement of the shutoff body.

The sound pressure level during operation of the electric drive must not exceed 80 dB at a distance of 2 m from its outer circuit.

The electric drives must have two limit and position switches and torque limiter switches, which must ensure switching off the electric motor and indicate the position "closed", "open", "accident".

Adjustment of torque limiters, limit switches and position switches must be exercised separately both in the direction of "closing" and in the direction of "opening". Measures must be provided that would prevent spontaneous repeated start-up of the electric motor and ensuring the beginning of movement of the shutoff body with the maximum torque of the drive. The permissible torque deviation from the set value must not exceed +10% of the maximum adjustment range.

Electric drives must have local position indicators. Electric drives installed under the sealed enclosure are allowed not to have local indicators. The main technical data and characteristics of electric drives for shut-off valves shall be specified in TS in the form of table 1 of Appendix 17.

Windings of the elecric motor must have the insulation class in terms of heat resistance not worse than F.

Electric drives must perform their functions at the environmental parameters, at which the valve is operated.

5.2.3. Labeling

Every electric drive shall have a plate stating the following: name or trademark of the manufacturer; conventional designation of the electric drive; torque range, Nm; speed, RPM; speed limit, RPM; rated power, kW (on the motor plate); protection class; weight, kg; serial number; year of manufacture.

5.2.4. Preservation

Selection of a preservation grease should be based on the conditions of storage and transportation of electric drives. The quality of preservative greases must be confirmed by the manufacturer's certificates.

The chosen method of applying the grease should provide a solid layer of grease on the surface to be preserved, homogeneous in thickness, not containing air bubbles, lumps or foreign inclusions at an external inspection. The certificate for the electric drive must specify the date of preservation, the method of preservation and the duration of preservation.

5.2.5. Packaging

After preservation, the drives must be packed in boxes, the drawings of which are developed by the manufacturer. Before packing of electric drives, the opening of housings, fittings and other openings shall be closed with plugs.

5.2.6. Tests

5.2.6.1. The electric drives must be subjected to the tests specified in paragraph 3.5.1.: prototypes - in accordance with the requirements of ToR and/or TS and RD, pilot and serial samples - in accordance with TS.

5.2.6.2. Electric drive testing programs shall be developed and approved subject to a procedure established for development and approval of programs of tests of valves. Acceptance tests shall be carried out according to the programs approved with the developer of valves and the operating organization, other types of tests (except for commissioning tests) - according to the programs approved with the developer of valves. If, in the course of the tests, products will be found to fail to comply with the requirements of the TS, repeated tests must be held (repeated tests are held on the double number of samples).

5.2.6.3. The actual weight of the electric drive should be checked on prototypes and serially produced electric drives subjected to considerable structural modification, and when replacing materials with a large difference in specific weight.

5.2.6.4. The electric drive must be checked for compliance with the requirements of paragraph 5.2.2.

5.2.6.5. The insulation impedance (between electrical circuits and conductive parts and the housing) and electrical insulation strength of conductive parts should be checked in accordance with the requirements of the relevant regulations.

5.2.6.6. To check the electric drive for compliance with the requirements of paragraph 5.1.2., tests shall be carried out to confirm that the electric drive is operable under the specified conditions.

5.2.6.7. The class of protection of electric drives according to requirements of point 5.1.1 should be checked at the stage of acceptance, periodic and standard tests.

5.2.6.8. Based on the results of commissioning tests, it is necessary to make a graph for setting the torque limiters for each electric drive, which must be stated in the certificate for each electric drive.

5.2.7. Reliability

Electric drives are referred to the class of repairable restorable products of regulated reliability.

During operation, preventive inspections and, if necessary, maintenance should be required no earlier than once in 15,000 hours.

The operation period of electric drives (average or appointed) is at least 20 years.

Time between overhauls – at least 4 years. The scope of repair must be specified in the operating manual of the electric drive.

The assigned service life for the overhaul period is at least 1500 cycles. The cycle consists of a "closing-opening" stroke with breaks corresponding to DD.

The PFO of the actuator shall meet the requirements of subsection 2.6. The confidence probability for the calculation of the lower confidence limit of the PFO must be taken to be 0.95. Calculation and confirmation of values of reliability parameters should be carried out according to requirements of paragraphs 2.6.9 and 2.6.10.

5.2.8. Complete scope of supply

The scope of supply must include:

а) assembled electric drive;

b) certificate for electric drive;

c) operation manual;

d) set of spare parts (as per ED);

e) certificate and operation manual for electric motor (one copy per batch).

An operation manual is allowed to be supplied per batch of drives shipped to one address, but no less than one copy per 10 units.

5.3. Electric drives of control valves (EIM)

5.3.1. Type and key parameters

The types, key parameters and test methods of EIM shall be in accordance with RD. EIM must have modifications that allow them to be installed directly on the valve or outside the valve on a separate base.

It is preferable to install EIM directly on the valve.

5.3.2. Technical characteristics

EIM should be equipped with two limit switches and two position switches. EIM must be equipped with a manual backup control, which is switched on manually and switched off automatically at operation of the electric motor or must not prevent automatic control.

The force on the manual backup control must not exceed:

295 N at the rated torque - for control valves;

735 N in an extreme position - for shutoff and control valves.

EIM must have a local position indicator. The position indicator must be set to zero and 100%.

EIM installed under the enclosure is allowed not to have a local indicator.

 Mechanisms must be operable and maintain the technical

characteristics at external vibration impacts with a frequency of 5

 2

to 120 Hz, with vibration acceleration up to 10 m/sec (amplitude value).

The impedance of insulation of electrical circuits of EIM in relation to the housing and between themselves at an ambient temperature of (20 +/- 5) °C and relative humidity up to 80% must be at least 20 MOhms.

All the outputs from the electric motor, from contacts of switches and from the position indicator shall be connected without jumpers to one common row of clamps (or an electrical connector) in accordance with Appendix 18.

The possibility must be provided of installing jumpers between the terminals of the terminal box from the side of cable connection or between the contacts of the mating part of plug and socket terminal.

The starting torque (force) of EIM at the rated supply voltage must exceed the rated torque (force) by at least 1.7 times.

The amount of backlash and run-out of the output body of EIM should be taken according to the appropriate RD. For electric multi-turn mechanisms without self-braking elements, no requirements are imposed to the value of the backlash. The values of runout must be stated in TS.

EIM should be supplied with a built-in electric position sensor with a unified current signal of 4-20 mA and a device for its power supply from the 220 V AC mains. Delivery of EIM with current signals 0-5 mA and 0-20 mA must be specifically stated at placement of order.

It is allowed to have a sensor implemented with remote units. The distance from the EIM to the remote unit is up to 100 m (a distance of more than 100 m is specified in TS).

EIM shall be designed for operation in the repeated short-term reverse mode with the number of actuations not less than 320 1/h and DD no more than 25% at a load on the output body within the limits from the rated value of the counteracting load to 0.5 of the rated value of the attending load. At the same time, EIM must enable operation for 1 hour in a short-term reverse mode with the number of actuations up to 630 1/h and the duration of inclusions up to 25% with the next repetition no sooner than in 3 hours. The time interval between switch-off and switch-on in the reverse direction must be at least 50 msec.

It is possible to supply EIM with the number of actuations up to 320 1/h, which should be specified in the TS.

EIM should enable operation in the smooth regulation mode. The installation position of EIM may be chosen at will except for cases with the use of liquid lubricant. The possibility of installation of the valve with the electric drive orientated downwards must be additionally agreed upon with the manufacturer.

PFO of EIM over the period to overhaul must be at least:

0.98 - for EIM installed in safety systems;

0.97 - for EIM installed in NO safety-related systems;

0.92 - for EIM installed in other NO systems.

Average EIM operation period – at least 20 years.

EIM must function normally for 15,000 hours without maintenance or repair.

EIM must ensure the fixation of the position of the output body under load on termination of power voltage supply.

For electric multi-turn mechanisms, no requirements are imposed to fixation.

EIM for shut-off and control valves should be implemented so that braking of the output body with loading is enabled. In this case, the mechanisms should develop a torque (force) of not less than 1.7 of the rated value. The time of the mechanism remaining in the inhibited state is no more than 3 seconds, after which EIM must be disabled.

The allowable time for EIM to stay in the inhibited state and the magnitude of the displacement of the output body under load after the shutdown should be established in the TS for EIM of specific types.

EIM for shutoff and control valves shall be delivered with limiters of the largest torque (force) (see paragraphs 5.2.1 and 5.2.2).

No requirements are imposed to EIM in the emergency "major leak" mode or after the same.

The set of EIM must include a special assembly tool (if necessary); spare parts and accessories in the quantity satisfying the need of operation of EIM during the period to overhaul.

Each EIM should be accompanied with a certificate, an operation manual, a general view drawing (if absent from the operation manual), general view drawings and designations of wear parts.

5.3.3. Labeling

Each EIM must be equipped with a plate stating the name or trademark of the manufacturer; conventional designation; rated torque (force), Nm (N); rated power supply voltage, V; rated time of full stroke of the output body, sec; rated value of the full stroke of the output body, mm; rotation speed, RPM; class of protection; weight, kg; serial number; year of manufacture.

5.3.4. Preservation, packaging, acceptance rules for EIM shall be in accordance with the requirements of paragraphs 5.2.4, 5.2.5, 5.2.6.

5.4. Pneumatic drives with electromagnetic control

of fast-acting cutoff valves

5.4.1. Pneumatic drives designed for operation in conjunction with valves in the NPP safety systems must be resistant to the environment, decontaminating solutions and seismic effects to an extent at least as large as that of the valves they are supplied with, and meet the requirements of TS and ED.

5.4.2. Parameters of pneumatic drives:

a) control medium - air;

b) control air pressure - 4.5 +/- 0.5 MPa (it is allowed to increase the pressure up to 5.5 MPa when the safety valve is actuated);

c) control air temperature - -10 °С to +60 °С;

d) dew point - up to -10 °С;

e) the class of pollution - within 7 according to the current regulatory document "Industrial cleanliness. Compressed air. Pollution classes".

5.4.3. The TS for the valve with a pneumatic drive must specify the rated flow rate of compressed air per actuation, the amount of leakage in the drive and the minimum pressure at actuation.

5.4.4. Each pneumatic valve must be controlled from an individual distributor installed thereon. Isolating valves must enable forced (manual) closing on site.

5.4.5. The shut-off body of pneumatic drive valves must not change its position ("closed" or "open") in case of emergency termination of air supply for at least 10 hours. The time for the valve to stay in the position after actuation is not defined.

5.4.6. In case of emergency loss of pressure of the control air (for at least 10 h) the distributor shall provide is single actuation from the electromagnetic drive (opening or closing).

5.4.7. When developing the valves, it should be taken into account that when the ambient temperature rises to 90 °C, 150 °C (see table 3, 4 and 5) valve control systems are also heated to these temperatures, which consequently leads to an increase in the pressure in the pneumatic drive valve control systems.

5.4.8. The pneumatic drive and pneumatic distributor must be resistant to repeated pneumatic tests of the containment and the equipment accommodated therein in accordance with RDSO. The design of the pneumatic drive and pneumatic distributor must prevent ingression of water therein at operation.

5.4.9. The external and internal design of the pneumatic drive must ensure the maximum possible removal of sedimentation, corrosion products, dust and other contaminants.

5.4.10. Pneumatic distributors should be designed for the pipe 14 x 2 (material - steel 08Х18Н10Т).

5.4.11. Power supply of coils of pneumatic distributors is alternating current 220 (240) V, 50 (60) Hz, or direct current rectified (with a rectifier, which makes part of the distributor). Permissible deviations of voltage and frequency are in accordance with 5.1.2. The power consumption of the control solenoid (one way) should not exceed 60 VA.

5.4.12. Valves with a pneumatic drive must have limit switches to control the solenoid valves and signaling of extreme and intermediate positions of the valve.

Switches shall work in the following conditions:

a) two opposite contacts of switches closed in the end and in the intermediate position - in the circuits of the windings of the corresponding control solenoids to break their circuits after the completion of the opening or closing operation; their switching ability is determined by the parameters of the windings of solenoids;

b) the rest of the contacts of switches - as per 5.1.3.

5.4.13. Reliability

Pneumatic drives are referred to the class of repairable products. During operation, preventive inspections and, if necessary, maintenance should be required no earlier than once in 15,000 hours of continuous operation. The average oepration period of pneumatic drives – at least 20 years. Time between overhauls – at least 4 years. The assigned service life for the overhaul period is at least 1000 cycles. The PFO of the drive over 25 cycles or over the period to overhaul must be at least 0.998.

5.4.14. The remaining requirements for the manufacture, testing, completeness, labeling, preservation, packaging, acceptance - in accordance with the requirements for the valve, which is supplied with a complete pneumatic drive.

5.5. Electromagnetic drives

5.5.1. The requirements of this subsection apply to EMD (including built-in) regulating, shutoff valves, pilot and control valves making part of PORV.

5.5.2. Electromagnetic drives can be manufactured with a manual backup control, and without the same, which should be specified in the TS for EMD.

5.5.3. EMD must be equipped with devices for remote signaling of extreme positions of the output shaft (rod).

5.5.4. On a failure of power supply, the rod of the electromagnetic drive must take one of the starting positions depending on the version (at the closing or opening of valves). The electromagnetic drive intended for installation in safety systems must maintain its position in the event of a power failure for at least 24 hours.

5.5.5. EMD must have two or four position switches. The number of switches and their diagram must be specified in TS.

5.5.6. The design of EMD must provide replacement of coils of the electromagnet and position switches. Adjustment of position switches must be enabled.

5.5.7. All the outputs from all the electric elements must be connected without jumpers to one common row of clamps (or an electrical connector), which is specified in the ToR, or TS. The row of clamps (or the connector) must have the same class of protection as the EMD and must be designed to connect two cables: one - for power circuits, the other one - for control circuits. The power and control cable outlets within one terminal box shall be separated to avoid the effect of the power supply circuit on the control circuit. The row of clamps or the electrical connector should be designed to connect a power cable with a copper core section of 2.5 sq. mm, a control cable - 0.5-1.5 sq. mm.  The values of outer diameters of cables must be specified in the ToR and TS. The cables must be hermetically dressed. Cable entries must be included in the complete scope of supply of the drive. The power terminal box must be provided with an "earth" terminal. The control terminal box must be provided with an "earth" terminal for connection of a shield of the control cable.

5.5.8. Electromagnetic drives must exercise:

- opening and closing of valves remotely from a control panel;

- signaling on the control panel of extreme positions of the valve;

- preventing spontaneous movement of the valve plunger or spool under the effect of the working medium in the pipeline;

- ensuring the given position of the regulating valve plunger.

5.5.9. Electromagnetic drives must comply with the requirements of RD for electromagnetic compatibility and undergo appropriate tests.

5.5.10. EMD operation modes: continuous; intermittent; short-term. Requirements to EMD operation modes must be stipulated in ToR and TS.

5.5.11. The main EMD parameters that must be controlled and specified in the certificate:

- resistance of windings at 20 °C

- insulation resistance;

- insulation electric strength;

- rated armature stroke (for EMD delivered as a component);

- traction force and (or) pushing force (for EMD delivered as a component);

- holding force (for EMD delivered as a component);

- power supply voltage, current type;

- operation mode;

- operability at equivalent voltage (for DC EMD only);

- electromagnetic compatibility;

- power consumption;

- power consumption in the holding mode (if such mode is stipulated).

The values of these parameters are determined on the basis of EMD tests separately or as part of the valve.

5.5.12. The class of heating resistance of solenoids depending on operating conditions and ambient temperature should be chosen in accordance with the RD requirements. For solenoids designed for equipment of valves installed in the containment with classification designation 1A 2BII, 2ВІІІ, the insulation heat resistance class must be not lower than 200 °C.

5.5.13. EMD solenoids should be referred to non-restorable products. EMD should be referred to the class of repairable products. During operation, preventive inspections and, if necessary, maintenance should be required no earlier than once in 40,000 hours of continuous operation.

5.5.14. For assessment of reliability of EMD supplied as components, the following parameters must be established: PFO, average service life; time to failure.

The values of reliability parameters must be specified in ToR and TS for EMD.

5.5.15. The average operation period of EMD is 40 years.

5.5.16. The following types of tests must be established for EMD: acceptance, qualification, commissioning, periodic, typical tests.

Acceptance and qualification tests of EMD must be carried out according to the programs and techniques prepared by the EMD developer and agreed upon with the developer of the valves and the operating organization. During acceptance and qualification tests, heat resistance must be assessed. All types of tests must be carried out in accordance with the requirements of RD extending to the control solenoids.

5.5.17. Each EMF should be marked in accordance with the requirements of the detailed design documentation and TS. The marking must contain the name of the manufacturer or its trademark; designation of EMD; rated voltage and type of current of the power supply mains; rated traction force; frequency of the power supply mains (for AC EMD); operating mode (DD); weight; year of manufacture.

5.5.18. Each EMD must be supplied with a certificate, which shall specify the main technical characteristics and the results of commissioning tests.

5.5.19. EMD intended for delivery as component parts must be supplied with the following technical documentation: certificate; assembly drawing; manual; packing list.

It is allowed to supply one set of technical documentation per batch of articles of not more than 10 pcs.

Appendix 1

(for reference)

WORKING MEDIA

1. In the working media referred to in paragraphs 1, 3 (type I), 4 (type I and II), 5, 6 (type I), 9 to 14, individual non-abrasive particles up to 100 µm.

2. Using other media musts be approved by the valve developer.

Appendix 2

(recommended)

COMPOSITION AND CONTENTS OF TERMS OF REFERENCE FOR VALVES

The scope and contents of these requirements may be changed subject to the operating organization’s approval.

The pipeline valves must be equipped with a manual drive (except for the main and pilot valves of PORV and check valves) and a plate with marking and the trademark designation.

The valves may be furnished with the following equipment and devices to constitute the scope of supply:

- drives (electric, electromagnetic, pneumatic, hydraulic);

- local position indicators;

- units of limit switches;

- interlocking devices (for holding the valves in the open and (or) closed position);

- devices for checking the valves for operability (opening and closing of the lock);

- electrical (for cables), pneumatic and (or) hydraulic (for pipelines) connecting parts;

- built-in technical diagnostic tools with a contact connector;

- terminals for connection of external technical diagnostic tools;

- remote control devices (buttons, keys, electric cabinets, etc.);

- remote position indicators;

- if there are flanges (fittings) - mating flanges (nipples) with gaskets and fasteners of connection;

- controlled leak drain devices;

- lubrication fittings and grease boxes;

- equalizing, purging lines, equalizing apertures;

- terminal boxes;

- pneumatic distributors;

- spare assemblies and parts.

The ToR must contain the following data related to valves.

1. Type of valve ____________________________________________________

 (Shutoff, regulating, etc.)

2. Leading design organization ______________________________________

 (name and address)

3. Name and scope of application ____________________________________

4. Purpose __________________________________________________________

 (functions performed)

5. Systems to be installed in  ______________________________________

 (N - in the NO system,

_____________________________________________________________________

 L - localizing, P - protective, S - supporting,

_____________________________________________________________________

 C - control system)

5.1. Safety class and group of valves _______________________________

5.2. Classification designation under this document (Paragraph 2.1) _____________________________________________________________________

5.3. Nominal size  __________________________________________________

5.4. Working medium flow direction __________________________________

 (onto, under the spool, any)

5.5. Throughput characteristic ______________________________________

 (for control valves: L -

_____________________________________________________________________

linear, E - equal percentage, S - special strictly monotonous)

5.6. Using shutoff valves as regulating ones (paragraph 4.1.7) _____________________________________________________________________

5.7. Sealing on the rod _____________________________________________

 (Bellows,

_____________________________________________________________________

 gland, bellows with a doubling gland)

5.8. Requirements to reliability (paragraphs 2.6.3, 2.6.4, 2.6.8, 2.6.9,

2.6.10) _____________________________________________________________

 (durability, probability of failure-free operation,

_____________________________________________________________________

 confidential probability for calculation of lower

_____________________________________________________________________

 confidential limit)

6. Working media (paragraph 2.3.3) __________________________________

 (name,

_____________________________________________________________________

 as well as possible additional characteristics)

6.1. Design pressure, MPa (kg*f/sq cm)  _____________________________

6.2. Design temperature, °С  ________________________________________

6.3. Pressure drop on the lock (paragraphs 2.3.29, 2.3.24) __________

_____________________________________________________________________

 (permissible for shutoff and control valves,

_____________________________________________________________________

 minimum on opening - for check valves)

6.4. Availability, value of radiation _______________________________

6.5. Working media flow rate in pipelines (paragraph 2.3.6) ________________________

 (in nominal, emergency mode)

6.6. Requirements on change of working medium parameters

(paragraph 2.3.4) ___________________________________________________

 (to be specified according to Appendix 5 or other requirements)

6.7. Availability of abrasive particles and their size ______________

 (if necessary)

6.8. Necessity of protection from erosion wear and cavitation

(paragraphs 2.3.23, 3.1.11) _________________________________________

 (application of coatings, surfacing, etc.)

6.9. Environment (paragraph 2.4) ____________________________________

 (temperature, humidity, etc.

_____________________________________________________________________

 in working rooms)

6.10. Additional requirements for changing parameters of

environment _________________________________________________________

 (to be specified under this document, or other requirements)

7. Operation conditions _____________________________________________

 (periodicity and types of maintenance)

7.1. Range of adjustment, number of actuations per hour _____________

_____________________________________________________________________

 (for control valves)

7.2. Tightness of lock (paragraph 2.3.8) ____________________________

_____________________________________________________________________

 (permissible leaks in closed condition under RD <*>

__________________________________________________________________

 and, if necessary, at customer’s request, cubic cm/min)

 ----------------------------

 <*> Pipeline shutoff valves. Standards for tightness

of locks.

7.3. Tightness to environment      _____________________________

 (tightness class) <*>

 ----------------------------

 <*> According to federal rules and regulations regulating the rules of control for welding and surfacing of NPI.

7.4. Seismic strength (seismic resistance) (paragraph 2.5) _______________

7.5. Vibration resistance (paragraph 2.3.22) _____________________________

7.6. Opening or closing time (paragraph 2.3.20) __________________________

7.7. Place of installation _______________________________________________

 (P - in attended rooms, B - in boxes,

__________________________________________________________________________

 C - under containment (sealed zone))

7.8. Necessity of operation of valves to be installed inside the containment,

in case of beyond-design-accident ___________________________________________

7.9. Necessity of local indicator of extreme positions (paragraph 2.3.28) __________________________________________

7.10. Necessity of lock position holding device (paragraph 2.3.31) _______

__________________________________________________________________________

7.11. Necessity of remote signaling of extreme positions of shutoff body (paragraph 2.3.25.1) ________________________________

7.12. Necessity of generation of signal of position of lock for

information and computing system (paragraph 2.3.25.2) ______________________

__________________________________________________________________________

7.13. Availability of thermal insulation on valves after installation ______

__________________________________________________________________

 (no, yes, specify the type of thermal insulation)

7.14. Permissible loads on branch pipes __________________________________

 (specify table number

__________________________________________________________________________

 and lines therein from Appendix 8, or data for a specific system)

7.15. Electric equipment decontamination modes (paragraphs 2.3.10, 2.3.11) __________________________________________________________________________

8. Version _______________________________________________________________

 (export delivery, climatic version,

__________________________________________________________________________

 class and type of atmosphere as per RD <*>)

 ----------------------------

 <*> Machines, Instruments and Other Industrial Products. Versions for different climatic regions. Classes, conditions of operation, storage and transportation as regards climatic environmental factors.

8.1. (Hydraulic) flow loss coefficient (paragraph 2.3.5) __________________

__________________________________________________________________________

 (for shutoff valves, check valves and locks)

8.2. Conventional throughput factor, m3/hr ________________________________

 (for control valves)

8.3. Flow rate factor _____________________________________________________

 (for safety valves, including

___________________________________________________________________________

 pilot, valves)

8.4. Pressure of full opening under action of spring (MPa) ________________

__________________________________________________________________

 (for safety valves, including pilot, valves)

8.5. Back pressure at the valve outlet, max (MPa)

__________________________________________________________________

 (for safety valves, for main valves of PORV)

 with the lock closed _________________________________________

 with the lock fully open _______________________________

8.6. Back seat pressure _________________________________________________

(for safety valves

_____________________________________________________________________

 including for PORV)

8.7. Material of pipeline to be connected _______________________

8.8. Type of housing _________________________________________________

 (angle, though, three-way,

__________________________________________________________________

 direct flow, etc.)

8.9. Operation method __________________________________________

 (under a hinge coupling, pneumatic drive,

__________________________________________________________________

 electric drive, etc.)

8.10. Parameters of power and air supply of the drive _________________

 (current,

__________________________________________________________________

 voltage or air pressure, protection class as per RD <*>, etc.)

 ----------------------------

 <*> Protection degrees ensured by claddings (IP code).

8.11. Values of outer diameters of cables connected ___________

8.12. Method of connection to pipeline (paragraph 2.3.7) _________

__________________________________________________________________

 (type of dressing, diameter of bore for welding, flanged, etc.)

8.13. Connection dimensions of pipeline (paragraph 2.3.3) ________________

__________________________________________________________________

 (outer diameter x wall thickness)

8.14. Position on pipeline__________________________________

 (any, or specify)

8.15. Locations and method of attachment to building structures

(paragraph 2.3.21) __________________________________________

 (fastening sites, etc.)

8.16. Construction length _________________________________________

8.17. Permissible height of valve _________________________________

 (from upper pipeline axis)

8.18. Weight, max _________________________________

 (if limited)

8.19. Displacement of branch pipes (mm) ____________________________________

 (for z-shaped valves)

9. Tests

9.1. List of tests (paragraph 3.5) _________________________________

__________________________________________________________________

 (tests on customer’s suggestions, tests for confirmation of

__________________________________________________________________

 reliability, test at an increased medium flow speed as per

__________________________________________________________________

 paragraph 2.3.6; test for confirmation of throughput _______________________________________________________________

__________________________________________________________________

of safety valves on a medium with operating parameters, etc.)

9.2. Additional requirements for control of workpieces (paragraph 3.4.1.1,

note 2 to table 4) _______________________________________________

 (if required)

10. Complete scope of supply (paragraph 3.6) ________________________________

10.1. Packaging (paragraphs 3.7.4, 3.7.5) ____________________

__________________________________________________________________

 (version of internal packaging as per RD <*>)

10.2. Preservation (paragraphs 3.7.2, 3.7.3) ____________________

 (version of temporary

__________________________________________________________________

 corrosion protection as per RD <*> and grade of preservative)

 ----------------------------

 <*> Temporary corrosion protection of product. General requirements.

10.3. Storage and transportation (paragraph 3.8.2) __________________

 (conditions

__________________________________________________________________

 and temperature of storage/transportation as per RD,

__________________________________________________________________

 specified in item 8 of ToR)

11. Defects observed at operation of similar products _________

__________________________________________________________________

 (according to the operating organization)

12. Requirements to reparability _______________________________

13. Parameters and methods of diagnostics, design requirements

__________________________________________________________________

14. Other requirements _____________________________________________

15. Date of fulfillment of order ____________, approval ___________

 (under the contract)

Appendix 3

(recommended)

RECOMMENDED COMBINATIONS OF VALUES OF DESIGN PRESSURES AND TEMPERATURES FOR GATES, COCKS, CONTROL VALVES, BELLOWS SHUTOFF VALVES, CHECK VALVES

Appendix 4

(mandatory)

FORM OF PRESENTATION OF MAIN TECHNICAL PARAMETERS AND CHARACTERISTICS OF VALVES

Table 1

SHUTOFF VALVES

Continuation of table 1

--------------------------------

<*> RD “Pipeline shutoff valves. Standards for tightness of locks”.

Ending of table 1

Table 2

CHECK VALVES AND CHECK LOCKS  <1>

--------------------------------

<1> Type of valve.

Ending of table 2

Table 3

CONTROL VALVES

Continuation of table 3

Ending of table 3

Table 4

SAFETY VALVES AND PILOT-OPERATED RELIEF VALVES

Continuation of table 4

Ending of table 4

Table 5

VALVES WITH EMD

Continuation of table 5

Ending of Table 5

--------------------------------

<*> Permissible location of valves is specified: in attended premises - P, in boxes - B, under containment - C.

Appendix 5

(for reference)

CHANGE OF WORKING MEDIUM PARAMETERS

Table 1

FOR VALVES OF PRIMARY CIRCUIT OF NPP WITH VVER-1000

--------------------------------

<*> Analysis of operating conditions of emergency gas removal system, fast boron injection system and primary circuit overpressure protection system must also involve taking into account the modes presented for the pressure compensation system (section 1 of this table)

Table 2

 FOR VALVES OF NPP WITH RBMK REACTORS AT Рp = 8.6 - 11.0 MPa

--------------------------------

<*> Abrupt change suggests delivery of cold (hot) medium into pre-heated (cold) valve.

<**> Cycle 1 in emergency mode corresponds to a failure of pressure header, cycle 2 - to a failure of group distributing header.

Table 3

 FOR VALVES OF NPP WITH RBMK REACTORS AT Рp = 2.5 - 4.0 MPa

--------------------------------

<*> Abrupt change suggests delivery of cold (hot) medium into pre-heated (cold) valve.

Appendix 6

(mandatory)

DRESSING OF WEDGES OF PIPELINES FOR WELDING

When preparing pipelines for welding, it is allowed to round tolerances for the bore diameter to the nearest smaller value multiple of 0.1 mm. The type of dressing is taken in accordance with the requirements of federal rules and regulations regulating the control of welding and surfacing of equipment of NPP. For valves of tertiary circuit of NPP with BN reactors, the type of dressing is determined by the NPP project developer.

Table 1

VALVES OF STAINLESS STEEL

--------------------------------

<*> The type of dressing 1-23(С-23) is allowed.

Continuation of table 1

--------------------------------

<*> To be used at the temperature <= 55 °С.

<**> To be used at the temperature <= 170 °С.

<***> The type of dressing 1-23(С-23) is allowed.

Ending of table 1