Approved by the
Decree
 of the Federal
Environmental,
Industrial and
Nuclear Supervision
 Service dated December 20, 2005 No. 14

Effective
from 01 May 2006

FEDERAL RULES AND REGULATIONS
IN THE FIELD OF ATOMIC ENERGY USE.

RULES OF
DESIGN AND SAFE OPERATION
OF EQUIPMENT AND PRODUCTS OF REACTOR PLANTS
WITH WATER COOLANT OF FLOATING NUCLEAR PLANTS

NP-062-05

These rules and regulations "Rules of Design and Safe Operation of Equipment and Products of Reactor Plants with Water Coolant of Floating Nuclear Plants" establish requirements to arrangement, operation, repair and (or) replacement of equipment, products and pipelines of reactor plants with water coolant of floating nuclear plants

First issue <*>.

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

<*> This edition of the normative document was developed by SUE Engineering Centre of Strength and Material Science for Nuclear Engineering Elements, OKBM Afrikantov, FSUE Dollezhal NIKIET.

The preparation of the document involved using suggestions and taking into account remarks of Concern Rosenergoatom, the Russian Maritime Register of Shipping, FSUE "EDO Gidropress", Russian Research Center "Kurchatov Institute",  SSC RF-PPI, "TSNII KI Prometey", the Federal Industry Agency (Shipbuilding Administration).

These rules are developed based on the federal rules and regulations in the field of atomic energy use, as well as other normative documents regulating the rules of design and safe operation of equipment and products of reactor plants with water coolant, with consideration of the current state of science and technology.

The regulatory document has passed legal examination at the Ministry of Justice of Russia (Letter of the Ministry of Justice dated March 02, 2006). No. 01/1602-ЕЗ).

ABBREVIATIONS

 CPS AM - Control and Protection System Actuating Mechanism

 PORV - Pilot-Operated Relief Valve

 I&C - instrumentation and control device

 RD - Regulatory Document

 SAR - Safety Analysis Report

 FNP - Floating Nuclear Plant

 SPM - Scheduled Preventive Maintenance

 RP - Reactor Plant

 CPS - Control and Protection System

GENERAL TERMS AND DEFINITIONS

The following terms and definitions are used for the purposes of this document.

Operating pressure is the pressure in equipment or a pipeline, the value of which is set by the engineering (design) documents for the normal operation of the reactor plant at the maximum designed capacity.

Design pressure is the pressure in equipment or a pipeline, the value of which is set by the engineering (design) organization, and which is used at calculation for selection of the basic dimensions. At development of equipment or pipelines for a particular reactor plant, the adopted value of design pressure corresponds to operating pressure.

Shutoff valves are products (valve, gate, cock, etc.) or a combination thereof (including drains and breathers in-between) intended for isolation of systems, equipment and sections of pipeline systems (pipelines) from each other, including fast-acting pressure-reducing devices.

Component is a constituent part of a system or element of the reactor plant, confined by one or more non-detachable and (or) detachable connections.

Body is an assembly unit, or a totality of assembly units and parts (confined by bottoms, flanges, branch pipes) being the boundary of a vessel (equipment).

Surfacing is application of a layer of metal onto the surface of an article by means of welding.

Design temperature is the maximum value of average temperature across the wall (section) thickness of a component, or article at normal operation.

1. GENERAL

1.1. Purpose of the Rules

1.1.1. The rules of design and safe operation of equipment and products of reactor plants with water coolant of floating nuclear plants (hereinafter referred to as the Rules) establish requirements to design and safe operation of internal- and external- pressure-holding assembly units or parts of equipment, products and pipelines assembled thereof with water coolant of FNP.

1.1.2. These Rules are binding for organizations exercising design, engineering, manufacture, assembling, operation, repair and (or) replacement of equipment, products and pipelines of RP of FNP.

1.1.3. The requirements of these Rules shall apply to vessels (including reactor vessels), heat exchange components of steam generators and heat exchangers, pipelines and other pressure-holding elements of RP, classified as referred to groups A, B or C according to federal norms and standards establishing requirements to design and safe operation of equipment and pipelines of nuclear power installations. The FNP RP elements covered by these Rules shall be hereinafter referred to as equipment and pipelines.

1.1.4. The following FNP elements shall not be covered by these Rules:

- fuel elements and assemblies, control devices of CPS actuating mechanisms, other structures inside the reactor vessels, channels containing fissile, absorbing or retarding materials;

- pipes and devices built in the equipment, whose destruction does not lead to the working medium getting beyond the limits of this equipment, or to a leakage through the air-tight components separating different media (including media with different parameters sealed off from each other);

- mechanical and electrical devices located in the equipment (e.g. mechanisms of refueling devices);

- devices arranged in housings of equipment or in pipelines for control of their operability;

- turbine housings and rotors, cut-off valves, bypass pipelines within the turbine and steam extraction pipelines (with a shutoff device installed on the pipeline) from the turbine to the shut-off device;

- supports and hangers of equipment and pipelines;

- packing gaskets and non-metal components of sealing assemblies;

- metal components not loaded with coolant pressure.

1.1.5. The specific nomenclature of equipment, pipelines and components, with specification of their being referred to items of safety classes 1, 2 3 and groups A, B and C, must be stated in the FNP RP design and substantiated in the SAR.

1.1.6. The boundaries between the equipment and (or) pipelines referred as per 1.1.5 to different groups shall be set by the engineering (design) organization. A component, a welded or detachable connection adopted as a boundary must be referred to a group with higher requirements.

1.2. Documentation

1.2.1. All documentation (for design, engineering, process, installation, operation and repair) developed for equipment and pipelines falling within the scope of paragraph 1.1.1, shall meet the requirements of these Rules.

1.2.2. Reliability parameters (assigned operation period and assigned service life of equipment or pipelines) must be confirmed by strength calculations in accordance with the RD requirements FNP RP, the results of experimental studies (if necessary) and durability assessments. Here, the assigned operation period must be:

- at least 10 years for equipment and pipelines subject to replacement, unless otherwise stipulated in terms of reference for development;

- not less than the operation period assigned to the FNP - for non-replaceable elements of equipment and pipelines, unless otherwise stipulated terms of reference for development of the FNP RP.

The assigned service life and operation period may be extended during operation upon receipt of new scientific and technical data and taking into account the operation record.

1.2.3. The assigned operation period of the equipment and pipelines shall be specified in engineering documentation and data sheets (forms). At the stage of development of the technical design, the assigned operation period must be specified in the general view drawings of the equipment and pipelines.

1.2.4. At strength calculations to substantiate the assigned operation period, the characteristics of materials and welded joints are taken according to RD for the FNP RP.

1.2.5. The engineering (design) organization must confirm that there shall be no change of characteristics of materials or welded joints connections to the values below those adopted in calculations according to paragraph 1.2.2 over the assigned operation period of the equipment and pipelines.

1.2.6. All changes in the design and engineering documentation, the need for which would arise in the manufacture, installation, testing, operation, repair and (or) replacement of equipment and pipelines, shall be made by the organizations - developers of this documentation and shall be brought to the attention of the operating organization.

The introduced amendments shall be reflected in the relevant documentation and in the documentation handed over by the manufacturer and the construction organization of the operating organization, in particular in data sheets (forms) for the equipment and pipelines.

1.2.7. The equipment manufacturer must hand over to the construction organization a filled data sheet (form) along with the equipment supplied.

1.2.8. Accessory instruments, valves and protective devices must be supplied with installation, adjustment and operation instructions.

1.2.9. The following data shall be prominently displayed on the equipment housings:

- name or trademark of the manufacturing organization;

- serial number;

- date of manufacture;

- design pressure;

- design temperature;

- hydraulic test pressure;

- type of medium (liquid, gas);

- name and (or) designation of equipment as per the drawing.

1.2.10. The operating organization must organize and ensure proper storage of engineering documents and data sheets (forms) for the equipment and pipelines received from the manufacturing organization.

1.3. General requirements to personnel

1.3.1. All the personnel shall be regularly examined for knowledge of these Rules.

2. STRUCTURES

2.1. General requirements

2.1.1. The equipment and pipelines must be designed to ensure the performance of the established functions throughout the operation period specified in the data sheets (forms).

2.1.2. The design and layout of equipment and pipelines must enable their technical inspection and repair (replacement) during operation.

2.1.3. At design (development), one should provide for use of materials ensuring the operability of structures in the working media, including the media used in the cleaning, washing and decontamination, throughout the assigned operation period.

2.1.4. Equipment and pipelines must be equipped with devices for coolant drainage, decontamination and removal of decontaminating solutions.

The aforesaid structures must have no zones from which it is impossible to remove products of contamination along with the washing and deactivating solutions. If the supply and removal of washing and decontaminating solutions, as well as the drainage of the coolant from the circuit cannot be carried out through working pipelines, supplying and drain pipelines or other devices providing flushing and removal of solutions from the circuit and drainage of the coolant must be provided.

2.1.5. The equipment and pipelines must enable removing air when filled with the medium, as well as removal of the working medium and condensate formed during the heating or cooling of the circuit.

2.1.6. The FNP RP must be designed with systems or devices protecting the equipment and pipelines from excess of pressure or temperature by implementation of measures for mass and heat removal, change of physical and (or) chemical properties of the coolant. Instrumentation and control devices must also be provided to control the integrity of equipment and pipelines.

2.1.7. The FNP design must also provide for stationary or removable (demountable) platforms, ladders and other fixtures for convenience of service and examination of equipment.

The equipment design must enable its secure attachment to metal structures subject to dynamic overloads adopted in the design documentation.

2.1.8. During normal operation, all the elements of equipment and pipelines with the temperature of the outer surface above 45 °C located in attended premises, and 60 °C - in restricted access premises, must be thermally insulated. At the same time, the temperature of the outer surface of thermal insulation in the attended premises must not exceed 45 °C, in the restricted access premises - 60 °C. In maintenance-free premises thermal insulation may be installed on the walls of the premises. Pipelines and equipment in locations that are subject to control by nondestructive methods in the process of operation, must have removable thermal insulation.

Pulsed instrumentation piping conduits may be left free of thermal insulation.

2.1.9. In the presence of detachable connections, the equipment of group A in all cases and the equipment of group B in the cases determined by design documentation shall be provided with devices ensuring the controlled tightening of pins. These devices must be included in the scope of delivery of the equipment or in the relevant process equipment (refueling, repair equipment).

2.1.10. The assigned service life and (or) operation period of equipment specified in the data sheet (form) may be revised upon strength calculations as per paragraph 1.2.4.

2.2. Joints and overlays

2.2.1. Joining pipeline articles between themselves and their connection to equipment must be implemented by welding.

It is allowed to use thread-soldered connections, diffusion connections, as well as detachable flange connections, if these are required as is determined by the design of the FNP RP.

2.2.2. Categories of welded joints are assigned according to the RD for FNP RP in effect as of the time of design.

Welded joints on boundaries of elements (components) of RP of different groups are referred to the higher category.

Welded joints for welding supports, hangers, hoisting parts, backing boards, etc. to equipment must be classified according to requirements of RD for the FNP RP.

2.2.3. Surfacing of corrosion-resistant coatings must be performed in accordance with requirements of effective RD for the FNP RP.

It shall be allowed to perform surfacing based on production processes approved by the operating organization and coordinated with the engineering (design) organization, the manufacturing organization and the material science organization.

2.2.4. Butt weld joints of articles made of steel must be performed with full penetration.

Weld joints with remaining backings (including backing rings) shall be considered weld joints with full penetration.

2.2.5. Angle and T-shaped full-penetration weld joints are permitted for welding of flat bottoms, flat flanges, tube boards (sheets), nozzles, manholes and jackets.

2.2.6. Angular welded joints with a structural gap may be used in areas not exposed to external power bending loads (e.g., with pipes welded into piping boards (sheets), with service channels welded to standpipes, with protective service jackets and measuring devices welded to housings, etc.), as well as in the presence of special fasteners, supports, ties or other engineering solutions that reduce these loads on the welded joints.

2.2.7. T-shaped weld joints with a structural gap are permitted for welding of supports and auxiliary parts (hangers, brackets, stiffening ribs) to equipment and pipelines, as well as for welding ribs in valves with design pressure within 4.9 MPa (50 kg*f/sq cm).

2.2.8. Application of lap joints is permitted for welding of reinforcement overlays, support plates, backing boards, plates for platforms, stairs, brackets, membranes, etc. to equipment and pipelines. The rings welded from the inside of housings for strengthening of such components as hatches, fittings etc. must be made with signal ports for control of tightness of the welded joint.

2.2.9. Weld joints and overlays must be accessible for inspection in the course of manufacturing and installation of equipment and pipelines.

2.2.10. Smooth transition from one component to another shall be ensured in butt weld joints of components with different wall thickness. Specific forms of the transition must be established by the engineering (design) organization based on the requirements for strength calculation and the need to ensure control of welded joints by all methods provided.

2.2.11. The manufacture of welded shells, housings, pipes with nominal outside diameter up to 900 mm with longitudinal seams of three or more segments shall not be allowed. At the manufacture of two segments, the central angle of the smaller segment must be at least 90°.

2.2.12. Longitudinal seams of the parts of shells, connected by welding, and the seams of the bottoms must be displaced relative to each other by a distance measured along the surface and making at least three times the maximum value of the wall thickness of the parts, but anyway not less than 100 mm between the axes of the joints.

2.2.13. In welded of bottoms or lids consisting of several parts (sheets) with weld joints located chord-wise, the distance from the weld joint outer edge to the bottom or lid diameter parallel to the chord must not exceed 0.2 of the nominal inner diameter of the bottom, or lid.

In welded bottoms and lids (except for spherical and dished ones) and the center of the bottom, or lid must not exceed 0.25 of the nominal inner diameter of the bottom or lid.

2.2.14. The distance between the axes of neighboring transversal butt welds on cylindrical and conical pipelines must be at least three-fold nominal wall thickness of the welded parts (for greater thickness), but at least 100 mm for parts having the nominal outer diameter above 100 mm, and no less than the specified diameter with its value up to 100 mm, inclusive.

2.2.15. The distance from the edge of the weld of the fitting (pipe, nipple, nozzle) to the edge of the nearest transversal weld of equipment or pipeline, as well as the distance to the beginning of the pipeline bending must be at the same time not less than threefold wall thickness of the welded fitting (pipe, nipple, nozzle) and threefold design height of the fillet weld.

2.2.16. The distance  between the edges of the nearest fillet welds for welding nozzles (fittings) or pipes to equipment or pipeline must be equal to at least three-fold design height of the fillet weld, or three nominal thicknesses of walls of the nozzles or pipes welded. At different values of the specified heights or thicknesses, their greater value is to be taken. The requirements of this paragraph shall not apply to welding pipes into piping boards (sheets ) or headers.

2.2.17. When welding flat parts not loaded with pressure to the surfaces of equipment and pipelines, the distance  between the edge of the fillet weld for welding these parts and the edge of the nearest butt weld of equipment or pipeline, and the distance between the edges of the fillet welds of the nearest welded parts must be equal to at least three-fold design height of the fillet welds.

The distance between the welds is determined by the maximum design height of the fillet weld (at its different values).

When welding parts and devices inside (outside) the housing, it is allowed to have an intersection of butt welds of the equipment with the fillet welds with a design height up to 0.5 of nominal wall thickness of the housing, but not more than 10 mm.

2.2.18. The distance between the edge of the seam of the butt-welded connection of the pipeline with the nozzle (fitting) of the equipment and the edge of the seam of the nearest butt welded-connection on the pipeline must be not less than the nominal outer diameter for pipelines of the smaller diameter.

2.2.19. The distance from the edge of the butt weld to the beginning of the curvilinear section of the pipeline bend must not be closer than half the diameter of the pipe, but not less than 40 mm.

2.2.20. Longitudinal welded joints of housings of equipment intended for operation in horizontal position must not be located within the lower central angle equal to 140° except for cases where inspection and control of the specified joints at operation is provided.

2.2.21. Welds should generally be located outside the supports.

The arrangement of supports and hangers above (under) welded connections is allowed if at production or installation of equipment the implemented welded joint is exposed to total ultrasonic or radiographic control, and the site of the welded joint located under the support (hanger) is also exposed to magnetic-powder or capillary control.

In all cases, it is not allowed to overlap zones of intersection and conjugation of welded joints with supports (hangers).

2.2.22. It is not allowed to have welded joints on sections of pipes subject to bending.

2.2.23. In butt welded joints subject to local heat treatment of  cylindrical parts, the length of a free straight section in each direction from the axis of the seam (or from the axis of extreme seams with simultaneous thermal treatment of a group of welds) must be not less than the value found from the following equation:

 ________

 L = \/(D - S)S,

where:

L - length of free straight section;

D - nominal outer diameter of parts to be connected;

S - nominal thickness of parts to be connected.

The length of the specified sections must be not less than the nominal outer diameter of the welded parts at its values up to 100 mm inclusive, and not less than 100 mm at values of this diameter above 100 mm.

A free straight section is a section (with a gradient of not more than 15°) from the seam axis to the edge of the nearest welded part, or the beginning of a bend.

2.2.24. In butt welded joints subject to ultrasonic testing of pipelines, the length of the free straight section in each direction from the axis of the weld must not be less than specified in the table.

2.2.25. The distance from the edge of the seam welding the pipeline to a flanged nozzle to the nearest butt weld of equipment or pipeline must be at least three times the wall thickness of the welded part. The aforesaid distance is measured along the generatrix (arc).

3. MATERIALS

3.1. General requirements

3.1.1. Materials for the manufacture of equipment and pipelines of FNP RP must be selected with consideration of the required physical and mechanical characteristics, workability, weldability and operability in operation throughout the assigned operation period, as well as the requirements to structures stipulated in paragraph 2.1.3. The possibility of restoring the mechanical characteristics of materials during operation must be substantiated.

3.1.2. For production, installation and repair of the equipment and pipelines, the basic materials (semi-finished products and workpieces) stipulated in RD for the FNP RP should be used.

3.1.3. The quality and properties of the basic materials (semi-finished products and workpieces) must meet the requirements of the corresponding RD for the FNP RP and be confirmed by certificates.

3.1.4. The organization - manufacturer of equipment and pipelines must carry out incoming quality control of incoming basic materials. Quality assessment is carried out in accordance with the requirements of RD for the FNP RP to the delivered semi-finished products and workpieces.

3.1.5. Methods and scope of control of basic materials should be specified on the basis of RD for the FNP RP in the design documentation and agreed with the manufacturer (installation company). For the primary facility (the project of the first FNP with a reactor of the type in question), the methods and scope of control of the basic materials should also be coordinated with the material science organization.

3.1.6. Welding and surfacing materials specified in RD for the FNP RP should be used for welding and surfacing of equipment and pipelines. Incoming inspection of welding and surfacing materials should be carried out according to RD for the FNP RP requirements.

3.1.7. Materials and semi-finished products intended for the manufacture of equipment, products and pipelines of FNP RP must be protected from damage and spoilage during transportation and storage. Materials of different structural classes (perlite and austenite steel, non-ferrous metals) shall be transported and kept in conditions preventing contact between them. Methods of protection of materials and semi-finished products during transportation and storage shall be developed by the manufacturing organizations.

3.1.8. In some cases, non-metallic materials may be used for the manufacture of specific equipment or its parts. Non-metallic materials must be compatible with the working medium in the operating temperature range. The use of non-metallic materials is allowed subject to the conclusion of the material science organization.

3.2. New materials

3.2.1. New materials include:

- basic materials not stipulated in the RD for the FNP RP;

- basic materials stipulated in RD for the FNP RP, if used at temperatures exceeding the maximum permissible values as per the RD for the FNP RP;

- welding materials not stipulated by the RD for the FNP RP (coated electrodes, welding and surfacing wires and tapes, fluxes and shielding gases), as well as metals of welded joints and overlays performed by technological processes other than those specified in RD for the FNP RP.

3.2.2. Basic materials, whose marks are given in RD for the FNP RP, but smelted by methods not provided for by RD for the FNP RP (e.g., by vacuum arc or electroslag remelting), are not referred to new materials.

3.2.3. To apply new materials, organizations interested in their application must conduct research to the scope stipulated in the RD for the FNP RP.

3.2.4. For the manufacture of specific equipment or piping it is allowed to use new materials under a joint technical decision of the engineering (design) organization, the material science organization and the organization of the manufacturer (the construction organization) as agreed with the operating organization.

The aforesaid decision must be accompanied with RD for semi-finished products and (or) welding (surfacing) materials and data on physical and mechanical, technological and corrosion properties of the basic metal and (or) welded joints (the overlayed metal) determining the possibility of production of the equipment and pipelines with ensuring the required operability. Here, the scope and nomenclature of the submitted information should be determined by the organizations that have compiled and agreed on the technical decision, depending on the specific operating conditions for the equipment and pipelines.

4. MANUFACTURE AND INSTALLATION

4.1. General requirements

4.1.1. The manufacture, installation, testing, repair and (or) replacement of equipment and pipelines should be carried out in accordance with the process documentation (process instructions, process flow charts, etc.) regulating the content and procedure for performing all the process and control operations. The process documentation shall be developed by the manufacturing organization (installation or repair organization) and the construction organization, or a specialized organization employed thereby, with observance of requirements of these Rules and other RD applying the corresponding equipment and pipelines, as well as engineering documentation. The process documentation for the installation of prototypes of equipment and pipelines, as well as amendments introduced thereto (including for subsequent serial production samples) must be agreed upon with the engineering organization.

In the process of manufacture of pipelines, testing, acceptance and transportation of the FNP power unit, there must be ensured the cleanliness of the surfaces of the RP components and the absence of foreign objects in their internal cavities.

4.1.2. The process documentation for smelting and casting of metal, thermal cutting, pressure treatment, welding, surfacing and heat treatment should be agreed with the material science organization. For elimination of defects in metal of pipelines (including those in welded connections and surfacing) by means of welding, only the standard technological instructions regulating the process of elimination of the most common (standard) defects must be coordinated with the material science organization.

The above coordination is not obligatory if technological documentation is prepared in full compliance with the RD.

4.1.3. At manufacture, installation and repair, the manufacturing organization and the construction organization must carry out production technical control to the scope provided for by engineering and process documentation. The control results must meet the requirements of RD for the FNP RP and engineering documentation applicable to the equipment and pipelines under control.

The results of the manufacture, installation and testing shall be recorded in the data sheets (forms). Samples of data sheets passports (forms) for the vessel, pipelines and equipment are given in Appendices 1, 2 and 3.

4.1.4. Welding (surfacing), including all operations for preparation and assembly for welding, performance of welded joints (welding), their subsequent thermal treatment and quality control of welded joints and metal with cladding should be in accordance with the requirements of the RD for the FNP RP and engineering documentation.

4.1.5. Parts and assembly units must be marked to identify them during manufacture and assembling, as per the drawing.

The depth of imprints when marking is applied by the impact method must not exceed 0.3 mm. The edges of brands must have no sharp ribs.

Marking of parts and assembly units of austenitic steels and iron-nickel alloys by electrographic method is not allowed.

4.1.6. Before installation, products (assembly units, parts) shall be subjected to cleaning,  preservation and packaging (including plugging the holes) in accordance with the requirements of the RD for the FNP RP.

4.1.7. Transportation and storage of materials intended for the manufacture, installation and repair of equipment and pipelines, as well as finished equipment and assembly units of equipment and pipelines, shall be carried out in accordance with the requirements of RD for the FNP RP and specifications for particular materials, specifications for equipment and pipelines and relevant instructions.

4.1.8. The manufacturing organization and the construction must assure the integrity of technical documentation on semi-finished products, workpieces, parts and assembly units of the equipment and pipelines on magnetic and paper media for at least the assigned FNP operation period.

4.1.9. The operating organization shall install plates with the following data at the entrance to each non-attended room:

- name of equipment;

- serial number;

- operating pressure;

- periodic hydraulic test pressure;

- type and temperature of working medium;

- conventional designations as per installation diagram.

4.1.10. Manufacturing, installation, testing, repair and (or) replacement of equipment and pipelines should be carried out by organizations with qualified personnel, process and control services, technical facilities necessary to perform the relevant work.

4.2. Heat treatment

4.2.1. Heat treatment should be applied to workpieces, parts, assembly units and other products, if it is stipulated by RD for the FNP RP, engineering or design documentation.

The need for heat treatment of assembly units and parts in the course of manufacturing or installation, and the requirements to the procedure of the same must be specified in the engineering documentation.

4.2.2. Shells, half-shells, bottoms, covers and other parts made of carbon and silicon-manganese steels after cold rolling or stamping must be heat treated if the ratio of the nominal wall thickness to the nominal inner radius of the shell (half-shell) or to the smallest radius of curvature of the bottom or cover exceeds 0.05.

4.2.3. Bended pipes of carbon and silicon-manganese steel are to be heat-treated if the ratio of the mean bend radius to nominal outer diameter of the pipe is less than 3.5 and the ratio of pipe wall thickness to its outer diameter is exceeding 0.05.

4.2.4. Heat treatment of parts made of carbon and silicon-manganese steels after hot rolling, bending or stamping is allowed to be skipped, if at the end of the deformation the temperature of the metal was not below 700 °C.

4.2.5. In cases not specified in paragraph 4.2.3, the need for heat treatment of parts after deformation is established by the RD, the product drawings and process documentation depending on the properties of the material of the parts and on the maximum value of deformation.

4.2.6. The combination of heat treatment after deformation of parts (assembly units) with subsequent heat treatment of the product after two process operations (e.g., welding) must be provided by the process documentation.

4.2.7. In the process of heat treatment,  control must be provided over compliance with the modes of heating and aging specified in the process documentation,  with the registration of their parameters.

4.2.8. At quenching and normalizing the entire product must be placed in a thermal furnace.

4.2.9. In cases specified in engineering and (or) design documentation, at tempering and austenization of bent sections of pipes, local heat treatment is allowed of the bending section and the straight sections of pipes adjacent thereto on both sides, with a length not less than three times nominal wall thickness, but anyway not less than 100 mm.

4.2.10. The properties of metal products that have undergone heat treatment are checked by testing samples cut from allowances or from individual control samples taken from workpieces. Samples must be taken from the material of the same batch (melting) as the controlled product, and must be subjected to heat treatment to the same extent and under the same conditions (together with the controlled product or separately from it) as the product during manufacture or installation, taking into account tempering in cases of correction of metal defects.

4.2.11. At process tempering of control samples it is allowed to reduce the duration of exposure compared to exposure set for the products in the process documentation, but by no more than 20%.

4.2.12. If the controlled products are subject to multiple process tempering operations at the same temperature with identical total duration of exposure, the control sample is allowed to be subject to a single tempering operation at the same temperature with duration of exposure equal to 100% of the total duration of exposure of tempering operations.

4.2.13. If the controlled products are subject to multiple process tempering operations at different temperatures with the same (total) duration of exposure at the same temperature, the control sample may be subjected to a single tempering operation with a duration of exposure at each temperature at each temperature equal to 100% of the (total) duration of exposure of the corresponding tempering operation(-s). In this case, the exposure is first carried out at a lower temperature, and then at a higher temperature. The time of transition from one temperature to another is not counted in the duration of exposure.

If among the provided multiple process tempering operations at different temperatures there are tempering operations with the same temperature and the same total duration of exposure, at a single tempering operation of control sample the duration of exposure at each such temperature must make not less than 80% and no more than 100% of the total duration of the relevant tempering operations.

4.2.14. It is allowed to carry out control of characteristics of metal on one control sample with observance of requirements of paragraphs 4.2.13 and 4.2.14 of these Rules in cases where the duration provided at the same temperature (total duration) of exposure of tempering operations is different, but the difference between the maximum and minimum duration (total duration) of exposure does not exceed 20% of the maximum duration (total duration) of exposure. Here, during the tempering of a control sample the duration of exposure must be not less than 80% and not more than 100% of the maximum duration of exposure of the tempering operation (a maximum total duration of exposure of the respective tempering operations).

4.2.15. If the controlled products are to be tempered at different temperatures (except as specified in paragraph 4.2.14 hereof) and (or) with different exposure durations times (except as specified in this paragraph), the metal characteristics must be tested on two separate control samples.

The first control sample must be subjected (with consideration of directions given in paragraphs 4.2.13 and 4.2.14) to the same tempering as the product, for which the lowest tempering temperature and (or) the minimum duration of exposure (in case of a single tempering) are provided, or the lowest temperatures and (or) the shortest total duration of exposure at the highest tempering temperature are provided for the product (in case of multiple tempering operations).

If among the controlled products there are both those subject and not subject to process tempering, the first control sample shall not be subjected to tempering.

It is allowed to skip examination of characteristics of the metal in the first sample, if prior to construction (assembling) of products (pipelines) the characteristics of the metal of workpieces were tested and found to comply with the requirements;

The second control sample must be subjected (with consideration of directions of paragraphs 4.2.13 and 4.2.14) to the same tempering as the product, for which the highest tempering temperature and (or) the maximum duration of exposure (in case a single tempering) are provided, or the highest temperatures and (or) the longest total duration of exposure at the highest tempering temperature are provided for the product (in case of multiple tempering operations).

At determination of the maximum total duration of exposure, all tempering operations provided in process documentation, including tempering operations after correction of defects in the basic material and welded joints, must be considered.

4.2.16. If the controlled products made of carbon and silicon-manganese steels are subject to multiple normalization (hardening) or heating for deformation at temperatures of normalization (hardening), the control sample is allowed to be subjected only to normalization (hardening) under the latest regime used.

4.2.17. The necessity for heat treatment of weld joints of parts made of corrosion-resistant austenitic steel must be stipulated in the engineering documentation.

5. HYDRAULIC TESTS

5.1. General requirements

5.1.1. Hydraulic tests are carried out to check the strength and tightness of equipment, pipelines, their parts and assembly units loaded with pressure.

5.1.2. Hydraulic tests are held:

- after the manufacture of equipment or its components by the manufacturing organization;

- after installation of equipment and pipelines by the construction organization within pipelines (systems);

- after repair performed by the operating organization;

- regularly in the course of operation by the operating organization.

Hydraulic tests are carried out in accordance with the requirements of RD for the FNP RP. It is allowed to determine the parameters of hydraulic tests and their procedure in accordance with Appendix 4.

6. REQUIREMENTS TO FURNISHING EQUIPMENT AND PIPELINES
WITH VALVES AND INSTRUMENTATION AND CONTROL DEVICES

6.1. General requirements

6.1.1. The quantity, type, places of installation and other requirements to valves and instrumentation and control devices of the equipment and pipelines are determined by the engineering (design) organization, proceeding from specific operating conditions and requirements of these Rules.

6.1.2. Redundancy of valves and instrumentation and control devices must be implemented in accordance with the requirements of RD.

6.1.3. The installation of valves and instrumentation and control devices must enable the maintenance, control, repair and replacement of FNP RP components.

6.1.4. It shall not be allowed to use control valves as shut-off valves, or to use shut-off valves as control valves.

6.1.5. Equipment and pipelines that are subject to inspection and repair in the course of operation, as well as low pressure pipelines connected to lines with a pressure equal to or above 2.2 MPa must be disconnected by two consecutive shut-off valves with drainage arranged between them. Requirement of installation of drainage devices between shutoff valves on high and low pressure boundaries shall not apply to the I&C control lines.

The project must provide for technical and organizational measures that exclude the possibility of changing the state of the specified valves in case of erroneous actions of servicing personnel.

6.2. Protection devices

6.2.1. Safety devices shall be installed on equipment or pipelines where the pressure may exceed the operating pressure, both due to physical and chemical processes occurring in them and by external sources of pressure increase calculated taking into account the conditions specified in paragraph 2.1.6.

If the pressure in the equipment or pipelines cannot exceed the operating pressure, no installation of safety devices is required. This must be substantiated in the RP design.

6.2.2. The number of safety devices, their throughput, opening pressure and closing pressure must be specified in the design (engineering) documents based on the fact that the pressure in the protected equipment and pipelines must not exceed the operating pressure by more than 15% when these devices are activated 15% (with consideration of dynamics of transitional processes in the equipment and pipelines, as well as dynamics and time of actuation of safety valves), nor cause unacceptable dynamic impacts on the safety valves.

For systems with a possible short-term local increase in pressure, a local increase in pressure is allowed above the value at which the safety devices must be activated (taking into account the hydraulic resistance in the area from the pressure rise  location to the safety devices).

6.2.3. In the equipment and pipelines with operating pressures up to 0.3 MPa, pressure must not be exceeded by more than 0.05 MPa. The possibility of increasing the pressure to the specified value must be confirmed by the strength calculation of the relevant equipment and pipelines.

6.2.4. If a safety device protects several interconnected RP components, it must be selected and adjusted according to the lower operating pressure for each of these units of equipment.

6.2.5. The safety valves must be designed to close after actuation when the pressure reaches a value of not less than 0.9 of the operating pressure, for which the setpoint for actuation of the valve in question was assigned.

This requirement shall not apply to safety membranes and hydraulic locks.

6.2.6. The setpoint for the seat of PORV with an electromagnetic or other drive must be set by the design (engineering) organization based on the specific conditions of operation of the equipment and pipelines.

6.2.7. The number of safety valves and forced-rupture safety membranes protecting equipment and pipelines of groups A and B must be increased by at least one of the number specified in accordance with the requirements of paragraph 6.2.2.

This requirement shall not apply to direct rupture membranes and hydraulic locks.

6.2.8. The calculation of throughput of safety devices shall be performed in accordance with requirements of RD.

The throughput of safety devices shall be checked at the relevant tests of the prototype of this design carried out by the manufacturer of the safety valves.

6.2.9. At determination of the number and throughput of safety devices there must be taken into account the total capacity of all the potential pressure rise sources with consideration of design basis accidents that could lead to a rise in pressure.

6.2.10. On pressure pipelines, a safety valve preventing the rise of pressure in pipelines above 1.1 of the operating value must be installed between the piston pump, which has no safety valve, and the shut-off device.

6.2.11. It is not allowed to install shutoff valves between the safety device (membrane or another device as per 6.2.7) and the equipment or pipeline protected by it, or on discharge or drainage pipelines.

It is allowed to install shut-off valves upstream pulse-operated valves of pilot-operated relief valves (PORV), and downstream such valves, if PORV are provided with at least two pulse-operated valves, and protection from overpressure above the permissible value allows taking only one of these valves out of operation.

6.2.12. The use of lever-driven pulse-operated valves is not allowed.

6.2.13. In the safety valve, it shall not be possible to change the setting of the spring or other adjustment elements. The springs of safety valves and pulse-operated valves of PORV must be protected against direct impact of medium and overheating.

6.2.14. It is allowed to install switching devices upstream of the safety valves in the presence of a doubled number of PORV or safety valves, where  the equipment and pipelines are protected from exceeding the pressure at any position of switching devices.

6.2.15. The design of the safety valves shall provide for the possibility of checking its serviceability by opening manually or from the control panel. For PORV this requirement shall apply to the pulse-operated valve. The manual opening force must not exceed 196 N.

If it is not possible to check the operation of the safety valves on the operating equipment, switching devices installed upstream of the valves and allowing each of them to be checked with disconnection from the equipment must be used.

The switching devices must be such that, with them at any position, equipment or piping would be connected to so many units of valves as necessary to ensure compliance with the requirements of paragraph 6.2.2.

This requirement shall not apply to direct rupture membranes or hydraulic locks.

6.2.16. Safety valves (for PORV - pulsed channels) protecting the equipment and pipelines of groups A and B must have mechanized (electromagnetic or other) drives ensuring timely opening and closing of the specified valves according to requirements of paragraphs 6.2.2 or 6.2.3 and 6.2.5. These valves shall be so arranged and adjusted that, in the event of a failure of the actuator, they would operate as direct-acting valves and comply with the requirements of the above paragraphs. In the presence of several valves on a protected object, each of the mechanized drives of these valves shall have independent control and power supply channels. Mechanized drives can be used to check the correct operation and forced pressure reduction in the object under protection. For group C equipment, the need to install valves with such a drive must be determined by the design organization.

6.2.17. Safety devices shall be installed on branches or pipelines connected directly to the vessel. With multiple units of safety valves installed on a single header, the cross-section area of the header must be at least 1.25 times the calculated total cross-section area of the connecting branches of the safety valves installed thereon. The pressure pulse to open the safety valves must be taken from the protected equipment. It is allowed to select the pulse from the pipeline, on which the safety valves are installed, taking into account its hydraulic resistance.

6.2.18. Equipment and pipelines of group C are allowed to be equipped with safety membranes that are broken when the pressure in the protected equipment increases by 25% of the working pressure of the medium (if confirmed by calculation).

It is allowed to install safety membrane devices upstream of the safety valve, provided that a device is installed between them that enables to control the operability of the burst disc, as well as preventing parts of the destroyed burst disc from penetrating into the safety valve. The efficiency of such pairing of devices needs to be confirmed with tests.

The flow cross-sectional area of the device with a destroyed membrane must be not less than the cross-sectional area of the inlet pipe of the safety valve. The membrane marking should be visible after installation.

6.2.19. The equipment operating under a lower operating pressure than the pressure of its supply source must have an automatic reducing device (downstream pressure regulator) on the supply pipeline with a pressure gauge (pressure transducer) and safety valves placed on the side of the lower pressure.

A group of equipment operating from the same supply source and at the same pressure is allowed to be provided with a single automatic pressure-reducing device with a pressure gage and safety valves located on the same general line upstream the first branch. When maintaining a constant pressure downstream the pressure-reducing device is either not possible for technological reasons or not required, pipelines from the supply source can be equipped with uncontrolled reducing devices (plates, throttles, etc.).

6.2.20. If the pipeline on a section from the automatic reducing device to the equipment is designed for the maximum pressure of the supply source and the equipment is provided with a safety device, it is allowed not to install a safety device downstream the pressure-reducing device on the pipeline.

6.2.21. In case the design pressure in equipment is equal to the supply source pressure or exceeds it and the possibility of pressure increase due to external and internal sources is eliminated, installation of safety devices is not necessary.

6.2.22. Automatic control devices and safety valves are not required:

- on pump recirculation pipelines;

- on pipelines downstream level control devices;

- on purge, drain pipelines, and pipelines for air removal during medium dumping into the equipment provided with safety devices as per 6.2.9.

The need to install throttle plates on these pipelines shall be determined by the design documentation.

6.2.23. Safety devices of equipment and pipelines shall be installed in places accessible for maintenance and repair.

6.2.24. Drainage pipes, unless self-drainage is arranged, must be provided with a drainage device. Installation of shutoff valves on drainage pipes shall not be allowed.

The inner diameter of a discharge pipeline must be no less than the inner diameter of the outlet branch pipe of the safety valve and designed so that, at the maximum flow rate, the back pressure in the zone of the outlet pipe would not exceed the maximum back pressure limit for the valve in question. The working medium going out of the safety devices must be discharged to a place safe for the personnel.

6.2.25. The functional ability (operability) of action of safety valves, including control circuits, with release of the working medium, must be checked before the first start-up of the equipment with operating parameters and the subsequent planned starts, but at least once in 12 months. If such verification reveals defects or faults in switching the safety devices or control circuit, the equipment must be repaired and re-checked.

6.2.26. Checking the settings of the safety valves should be carried out after installation, repair of the valve or control circuit, but at least once every 12 months by raising the pressure on the equipment with the devices included in the scope of supply of the valves in question, or by testing on a stationary bench. After a safety valve is adjusted for actuation, the adjustment module shall be sealed.

The check of operability and settings of the systems protecting the equipment and pipelines from excess of temperature shall also be carried out at least once in 12 months. These settings must be recorded in the operation and repair log of the safety devices.

6.2.27. The check of operability and settings of the systems protecting the equipment and pipelines from excess of pressure or temperature (according to paragraph 2.1.6) must be carried out within the time limits established by paragraph 6.2.26.

6.2.28. The check of operability of hydraulic locks, replacement of safety membranes and check of devices for their forced rupture shall be carried out according to the approved schedule.

6.2.29. For protection against overpressure the closed sections of the second and third (high pressure) FNP RP circuits, single-acting safety devices must be used. The setpoint of actuation of the aforesaid devices shall be guaranteed to exclude false actuation of the devices at all modes of normal operation, providing the required strength of the circuit.

6.2.30. For automatic actuation of safety systems in the conditions of beyond design basis accidents associated with an unacceptable pressure increase in the primary circuit system, hydro-mechanical devices of the passive operating principle should be used actuating as a result of a direct impact of the pressure pulse of the primary circuit medium on the sensitive item of the device. These devices must be used in addition to traditional electrical control systems.

6.3. Furnishing with control and instrumentation

6.3.1. Equipment and pipelines to be furnished with instrumentation and control devices and subject to technical diagnostics must meet the requirements of RD on assurance of controllability (their adaptability to the provision with measuring instruments and performance of diagnostics).

6.3.2. Equipment and pipelines must be equipped with instrumentation for measuring pressure, temperature, flow rate, level of the working medium, leakage, etc. At the same time, the design of instrumentation devices must ensure their stable operation at the operating parameters of the FNP RP.

6.3.3. The design of the equipment, pipelines and installation of instrumentation and control devices shall provide for the possibility of periodic metrological verification at the place of installation or in the dismantled condition. The procedure and time limits of verification must be specified in the I&C operating instructions.

6.3.4. The nomenclature of the I&C, as well as the scope of control according to paragraphs 6.3.2. and 6.3.3., the locations of installation of sensors and taps, methods of control, accuracy class, measurement error, limits of safe operation must be set in design (engineering) documentation.

6.4. Requirements to diagnostics of technical condition
and load control

6.4.1. The creation of equipment, pipelines and their components should be accompanied by the development of diagnostic support, the need for which is established by the technical specification for the design of the FNP RP. The diagnostic support must include a diagnostic system (a list of parameters to be diagnosed, the conditions and frequency of measurement, methods and means of diagnostics, technological processes for diagnostics) and software systems for processing the results of monitoring of technical condition.

6.4.2. The list of equipment and pipelines subject to diagnostics shall be determined by the design (engineering) documentation. The list should contain equipment and pipelines that limit the service life of the FNP RP and the diagnostics of which can cut the operating costs or reduce forced shutdowns of the FNP.

For each type of equipment and pipeline as an object of diagnostics, the following activities must be performed:

- the analysis of loading characteristics, characteristics of materials and factors affecting their variations in the process of operation;

- identification of the most probable types of malfunctions (classification of failures), the list of controlled parameters, the locations of installation of sensors, the number of control points, diagnostic tools;

- determination of information processing algorithms;

- estimation of limit values of the parameters, which, when attained, disrupt the strength and (or) operability.

The systems of diagnostics of technical condition of the equipment and pipelines provided by design (engineering) documentation must provide for continuous control of process parameters of the current condition of the object of observation and creation of a data bank of these parameters.

Diagnostic systems must take into account the rate of development of faults (deviations), up to the limit state at which an alarm and (or) a protection system of the FNP RP protection must be actuated, if it is provided by the design. In the diagnostics systems, data must be acquired on damage, destruction or reaching the limit state occurring in the process of operation of similar equipment and pipelines.

6.4.3. Systems of diagnostics of technical condition of the equipment and pipelines must contain means for operational notification on the current parameters of technical condition and an emergency alarm system in case of reaching the limit condition.

6.4.4. Diagnostic systems should provide continuous and periodic monitoring of operational parameters.

6.4.5. The general requirements for diagnostic support of equipment and pipelines include:

- combining the information obtained in diagnostic combinations;

- automation of assessment of data obtained;

- providing control and diagnostic information to operational personnel in real time and forecasts in a form that is easy to understand.

6.4.6. The implementation of the diagnostic software adopted in the FNP RP designs must be carried out with support from individual software systems with the possibility of extending the same to standard equipment and pipelines.

6.4.7. Diagnostic systems should provide monitoring of loading and operating parameters affecting the strength of equipment and pipelines to the extent necessary for assessment of resource parameters of the FNP RP.

7. CONTROL OF CONDITION OF METAL OF EQUIPMENT
AND PIPELINES AT OPERATION

7.1. General

7.1.1. Equipment and pipelines referred to groups A and B must be subject to periodic control to the scope specified in the engineering documentation and technical inspection programmes.

The necessity and scope of control of metal of equipment and pipelines of group C are established in the engineering (design) documentation.

7.1.2. Control of the condition of metal of equipment and pipelines provides for periodic and ad hoc control.

7.1.3. Periodic control shall be routinely held by the operating organization in the process of operation of the FNP RP. The rules of control are established in the operational documentation.

7.1.4. Ad hoc control must be held:

- after shock impact (external effects);

- if water leaks or signs of its contact with equipment or pipelines are detected;

- after violation of normal operating conditions, which led to a change in the parameters of the equipment and pipelines to a level exceeding the limits of safe operation;

- on decision of the operating organization.

7.2. Objects, methods and scope of control

7.2.1. The objects of control are equipment and pipelines referred to groups A, B and C.

7.2.2. A specific list of equipment and pipelines to be controlled must be stipulated by standard control programs developed by the RP engineering organization. Standard programs must be agreed with the FNP design organization.

7.2.3. Methods of control, frequency of control of metal components of the RP during operation and special requirements to its implementation shall be established by the engineering organization for each type of RP and FNP as a whole in coordination with the material science organization.

7.2.4. On detection of a defect of metal, a report must be executed in the form given in Appendix 5.

8. REGISTRATION AND TECHNICAL EXAMINATION

8.1. Registration of equipment and pipelines

8.1.1. The safety-related equipment and pipelines must be registered in territorial bodies of the Federal Service for Environmental, Industrial and Nuclear Supervision.

8.1.2. The specific nomenclature of equipment and pipelines to be registered, the boundaries of their registration must be stated in the lists developed by the engineering and design organizations. The above lists must be prepared prior to the beginning of installation work.

8.1.3. In determining the boundaries of the registration of equipment and pipelines one must be guided by the following requirements:

- the boundaries of registration of a vessel shall be the inlet (outlet) branch pipes and fittings (the seam welding the pipeline to the vessel fitting is deemed belonging to the pipeline).

Only individual short sections of pipelines (e.g., those used for connection of safety valves) may be registered together with the vessel;

- it is allowed to register separately individual reactor units (reactor vessel, covers, cases and housings of CPS drives, etc.), tanks and heads of deaerators, etc. provided there are data sheets for these products;

- if at least one cavity of equipment is subject to registration according to the parameters of the medium or by virtue of belonging to certain groups, then such equipment shall be registered entirely according to the highest group;

- valves are to be registered as part of the pipeline (if the valve is installed on the branch pipe of a vessel, it shall be registered as part of the equipment);

- discharge pipelines from safety and pressure reducing devices shall not be registered if the medium is discharged into a tank under atmospheric pressure or vacuum;

- the boundaries of a pump are the inlet and outlet branch pipes;

- the main steam lines shall be registered up to the seam welding the same to the branch pipe of the turbine shut-off valve body;

- if there is no shut-off device on the steam extraction line from the turbine to the vessel, then the boundary of the non-isolable part of the pipeline shall be marked by a check valve, and in the absence of the latter - by the seam welding the pipeline to the vessel.

8.1.4. For registration of equipment, the following must be submitted:

- A written application from the operating organization or its authorized legal entity.

- Equipment data sheet of an established form.

- As-built connection diagram of equipment with indication of parameters of the working medium, sources of pressure and their parameters (the maximum created pressure and the flow rate), valves, safety and instrumentation & control devices, relief, purging and drainage devices.

- Report certifying that the equipment has been assembled and installed in accordance with the design and the requirements of these Rules, and that the equipment is operable. The report shall be approved by the chief engineer or the head of the construction organization, or the head of the operating organization. Drawings, in which actual data on installation of the equipment, supports, limit stops, shock absorbers are specified, shall be enclosed to the report.

8.1.5. For registration of pipelines, the following must be submitted:

- A written application from the operating organization or its authorized legal entity.

- Pipeline data sheet of an established form.

- As-built spatial diagram of the pipeline indicating the working medium parameters, diameters and thicknesses of pipe walls, locations of expansion joints, headers, valves, instrumentation and safety devices, supports, hangers, limit stops, shock absorbers, movement benchmarks, all welded joints with indication of their numbers, and actual slopes of pipelines.

- Report certifying that the assembling has been performed in accordance with the design, the requirements of these Rules, and that all the pipeline components are operable. The report shall be approved by the chief engineer or the head of the construction organization, or the head of the operating organization.

8.1.6. The registered data sheet for equipment or pipelines, with the documents attached thereto, must be returned to the applicant.

8.1.7. In case the documents submitted for registration are found to have deviations from these Rules and (or) design documentation, the territorial body of the Federal Service for Environmental, Industrial and Nuclear Supervision shall send a written refusal of registration with the corresponding substantiation to the applicant according to paragraph 8.1.4 or paragraph 8.1.5.

8.1.8. Deregistration of equipment and pipelines shall be performed by the territorial body of the Federal Service for Environmental, Industrial and Nuclear Supervision on a the written application of the operating organization or its authorized legal entity. The application must contain a substantiated reason for deregistration.

8.2. Technical examination

8.2.1. Technical examination shall be performed for equipment and pipelines, which are subject to these Rules, namely:

- equipment and pipelines of group A;

- equipment of group B;

- equipment of group C in case of any of the following conditions:

the destruction of the equipment leads to release of medium- or high-level radioactive media beyond the designed limits;

the coolant temperature exceeds 200 °C;

the temperature of the coolant does not exceed 200 °C, but the product of the capacity and the operating pressure exceeds 1 m3 x MPa;

- group B pipelines with an outer diameter of 57 mm or larger;

- group C pipelines:

pipelines with an outer diameter of 57 mm or larger, which contain the medium- or high-level active coolant;

other pipelines with an outer diameter of 108 mm or larger.

8.2.2. Equipment and pipelines must be subjected to:

- primary technical examination after the assembling prior to the beginning of the RP tests;

- after testing of the RP and the floating power unit of FNP in the construction organization;

- periodically during operation, but not less than 5 times during the assigned operation period, and ahead of schedule (if necessary).

8.2.3. The purpose of the primary technical inspection is to establish that the equipment and pipelines are manufactured and installed in accordance with the design, these Rules and the submitted reporting documents (for the primary examination), are in good condition and can be used at the stages of testing and operation at the specified medium parameters (pressure and temperature).

8.2.4. The purpose of the technical examination after the tests in the construction organization is to establish that the equipment and pipelines of the floating power unit of the FNP after tests are in good condition and can be used at the FNP operation stage.

8.2.5. The purpose of technical examination during operation is to establish that in the process of operation there has been no damage that would prevent operation at the assigned parameters, i.e., the equipment and pipelines are in good condition and can be used in the operation of the object at the set medium parameters (pressure, temperature).

8.2.6. The FNP design organization, together with the RP design organization, must prepare a comprehensive program of technical examination of equipment and pipelines according to paragraphs 8.2.1 - 8.2.5, comprising the programs of hydraulic (pneumatic) tests, control of the metal condition, including tests of surveillance specimen, diagnostics of equipment and pipelines during the periods between the technical examination, monitoring of modes, loads and water-chemical mode, methods of assessment of the technical condition of equipment and pipelines based on results of accomplishment of the listed programs considered by the Federal Service for Ecological, Industrial and Nuclear Supervision.

9. OPERATION OF EQUIPMENT AND PIPELINES

9.1. General

9.1.1. The operating organization must, based on these Rules, design and engineering documentation, prepare the FNP RP operating instructions (operating manuals).

Operating instructions must contain:

- the procedure for preparation for start-up, the procedure of start-up, shutdown and service during normal operation;

- a situation, where equipment and pipelines must be withdrawn from operation without fail:

upon detection of cracks or air holes in the base metal and welded joints;

at destruction of supports and hangers;

if there is an increase in pressure, temperature or activity in non-attended premises, where equipment and pipelines are located;

in case of abnormal noise, vibration, shock in equipment and pipelines;

at increase in pressure above the operating value specified in the design (engineering) documentation, and its further increase despite the fulfillment of all requirements specified in the instructions;

in other situations stipulated by the design;

- the cases, where measures must be taken to withdraw equipment and pipelines from operation as planned, in particular:

on detection of leaks in flanged connections;

on deterioration of the coolant quality relative to established norms;

- procedure of personnel's actions in case of equipment and systems malfunctions and failures;

- procedure for withdrawal of equipment and pipelines for repair.

9.1.2. In case of change of the technical condition or operating conditions of equipment and pipelines in the instructions as per 9.1.1, the operating organization must introduce relevant amendments to be brought to the notice of the personnel.

9.2. Special requirements

9.2.1. Changes in the operating conditions of equipment and pipelines (operating pressure, design temperature, maximum power, coolant flow rate, heating and cooling rate, maximum fluence on the reactor vessel) can only be allowed subject to the safety substantiation and amendments made to data sheets (forms) of equipment and pipelines in accordance with the terms of the license.

9.2.2. In the presence of safety or protective devices according to subsection 6.2, these must be kept operable as a part of systems (components) throughout the RP operation period, except for:

periods of hydraulic (pneumatic) testing of systems and equipment;

the periods when systems are taken out of operation, and the pressure of working media for devices of these systems to operate on are lower than the operating values.

9.3. General requirements to performance of repair

of equipment and pipelines

9.3.1. During the operation of equipment and pipelines, the requirements for performance of SPM approved by the operating organization must be observed.

Postponement of time limits for repair of individual systems of the RP, or reduction of the scope of work on technical examination of equipment and pipelines at the current SPM can be allowed by the operating organization only subject to approval from the RP design organization.

9.3.2. The timing of the SPM and overhaul of equipment and pipelines shall be set subject to the timeline of the technical examination of equipment and pipelines, the turnaround time according to the requirements of the comprehensive program of technical examinations as per paragraph 8.2.6.

9.3.3. No repair or other work with detachable connections of equipment and pipelines under pressure are allowed.

9.3.4. Welding on equipment or pipelines under pressure is prohibited.

9.3.5. When carrying out repair work on the equipment and pipelines, measures must be taken to prevent contamination of their internal cavities or ingress of foreign objects into them.

9.3.6. Repair work with the use of welding during operation shall be allowed to be performed according to the technology developed by the operating organization and agreed with the material science and design organizations. At the same time, the welding technology must meet the requirements of RD for the FNP RP.

Appendix 1

DATA SHEET (FORM) OF VESSEL

(specimen)

Vessel name and designation

Registration N ______________________

Contents

1. General instructions.

2. General information.

2.1. Purpose.

2.2. Name.

2.3. Designation.

2.4. Date of manufacture.

2.5. Serial number.

2.6. Name and address of engineering organization.

2.7. Name and address of the manufacturing organization;

3. Technical data and characteristics.

3.1. The key technical data and characteristics are presented in table 1.

Table 1

Technical characteristics and parameters

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

<*> Names of other workspaces (pipes, heating jacket, etc.).

<**> To be filled by the construction organization.

<***> To be specified in cases stipulated by engineering (design) documents.

3.2. Rated assembly units and parts.

3.2.1. The rated assembly units and parts are specified in table 2.

Table 2

List of assembly units and parts

3.3. Data on base metal of assembly units and parts.

3.3.1. Materials of main parts of the housing are presented in table 3.

Table 3

Materials of main parts of the housing

3.3.2. The data on thermal treatment is presented in table 4.

Table 4

Data on thermal treatment

3.3.3. The chemical composition of materials is presented in table 5.

Table 5

Chemical composition

3.3.4. The mechanical properties of materials are presented in table 6.

Table 6

Mechanical properties

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

<*> The temperature value T must be specified in the engineering documentation or in the delivery specification (manufacturer's standard).

3.3.5. The results of non-destructive testing of materials are shown in table 7.

Table 7

Non-destructive testing of materials

3.4. Data on welded joints and surfacing of certified assembly units.

3.4.1. The layout of the main welds and surfacing areas is shown in the appendix to this data sheet. (The appendix is a sketch (drawing) of the vessel (housing, block of housings), indicating the designations and locations of welded joints and surfacing areas, as well as other information on welded joints and surfacing areas, the need for which is established by the developer of the data sheet of the vessel).

3.4.2. The list of the main welded joints of the housing is presented in table 8.

Table 8

Main welded joints of the housing

3.4.3. The data on thermal treatment of welded joint is presented in table 9.

Table 9

Data on thermal treatment of welded joint

3.4.4. The chemical composition of the welding material is presented in table 10.

Table 10

Chemical composition of welding material

3.4.5. The mechanical properties of welded joints are presented in table 11.

Table 11

Mechanical properties of welded joints

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

<*> The temperature value T must be specified in the engineering documentation or in the delivery specification (manufacturer's standard).

3.4.6. The results of non-destructive testing of welded joints are shown in table 12.

Table 12

Testing of welded joints with methods

of non-destructive control

3.4.7. The list of surfacing areas is presented in table 13.

Table 13

Surfacing areas

3.4.8. The data on thermal treatment of metal with surfacing is presented in table 14.

Table 14

Data on thermal treatment of metal with surfacing

3.4.9. The chemical composition of surfacing metal is presented in table 15.

Table 15

Chemical composition of surfacing metal

3.4.10. The mechanical properties of surfacing metal are presented in table 16.

Table 16

Mechanical properties of surfacing metal

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

<*> The temperature value T must be specified in the engineering documentation or in the delivery specification (manufacturer's standard).

3.4.11. The results of non-destructive testing of surfacing areas are presented in table 17.

Table 17

Non-destructive testing of surfacing areas

3.5. Tests and inspections.

 3.5.1. (The name of the vessel, housing, block of housings) was tested for strength and tightness with hydraulic (pneumatic) pressure P = ______ h (name of testing medium) for ____ min., whereupon the pressure was reduced to P = ______ and maintained for _____________ h

(as required for inspection).

No leakage, sweating or visible residual deformations or pressure drops were found.

Temperature (of testing medium) at tests: _______ °C.

Signatures of persons in charge for the tests

3.5.2. The cleanliness of inner cavities is ensured in compliance with requirements of RD. No contaminations or foreign objects are found.

Signatures of persons in charge

3.5.3. Actual weight (without process or transportation plugs) ______________ kg.

Signatures of persons in charge

3.5.4. Results of measurements are presented in table 18.

Table 18

Results of measurements

3.5.5. The list of deviations from requirements of drawings is presented in table 19.

Table 19

List of deviations from requirements of drawings

The text of table 19 may be accompanied by a sketch made on this sheet (below the text). If it is impossible to fulfill these requirements, sketches shall be attached to the data sheet.

3.6. Data entered on tables 1 - 19 of the date sheet (form) must be signed by an authorized person of the organization - manufacturer of the vessel.

4. Complete scope of supply

4.1. The complete scope of supply must be specified in the data sheet in accordance with the specification stated in the engineering documentation.

5. Labeling

5.1. Labeling (in terms of its location and contents) shall be applied according to the drawing requirements.

6. Service life, operation period and warranties of manufacturer (supplier)

6.1. Assigned service life________ hr at energy yield within _______ MW x hr.

6.2. Assigned operation period of housing ________ years.

6.3. Storage life in manufacturer's (supplier's) package ________ years from the date of shipment by the manufacturer. In every ______________ years the customer must control the condition of preservation and (if necessary) carry out re-preservation.

6.4. Warranty operation period ___ years from the date of signature of the RP acceptance report.

6.5. The remaining requirements: as per RD ________________.

7. As based on the data of items 3 - 6, a conclusion must be prepared in the following form:

CONCLUSION

Based on checks and tests, the following is certified:

 1. ________________________________________ is manufactured in accordance with (name of vessel) requirements of the Rules of Design and Safe Operation of Equipment and Products of Reactor Plants with Water Coolant of Floating Nuclear Plants and RD ______________________________________________________________

for the product: _______________________________________________________________

 (name of RD)

___________________________________________________________________________

 2. ________________________________________ and its components were subjected (name of vessel)

to inspection and tests and found compliant with the above Rules and RD. 3. ________________________________________ and its components were subjected (name of vessel) to and withstood hydraulic (pneumatic) testing.

 4. ________________________________________ is found suitable for operation with (name of vessel) the parameters specified in the data sheet.

 5. This section of the data sheet filled by the manufacturer contains _____________ sheets.

Date _______________

8. Preservation

8.1.1. (Name of vessel), serial number ______________ was subjected to preservation at ______________________________ in accordance with requirements_______________________________.

8.1.2. Type of preservation ________________________________________________

8.1.3. Type of preserving agent________________________________________________

8.1.4. Protection period according to storage conditions _______________ years.

8.2. Information on subsequent works on depreservation and represervation is given in table 20.

Table 20

Information on depreservation and represervation

9. Packaging certificate

(Name of vessel), serial number ____________________, is packed in the organization _________________________________ in accordance with requirements _____________________.

10. Acceptance certificate.

(Name of vessel), serial number ___________________ is manufactured and accepted in accordance with requirements of drawing ____________________ and found suitable for operation.

11. The operating organization shall supplement the vessel data sheet with data presented in tables 21 - 27.

Table 21

Data on operating parameters and location of vessel

Table 22

Data on persons in charge of operable condition
and safe operation of vessel

Table 23

Data on valves installed at assembly of vessel

Table 24

Results of technical examination <*>

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

<*> Technical examination includes inspection and measurements in accessible places of the external and internal surface of the vessel and hydraulic (pneumatic) testing.

Table 25

Results of hydraulic (pneumatic) tests

Table 26

Results of metal condition control

in the course of operation

Table 27

Replacement or repair

12. Registration of vessel

Registration of the vessel within the RP shall be carried out at the request of the operating organization in the following form:

 REGISTRATION ___________________________________

 (name of vessel)

_______________________ is registered ___________________ with No. __________

at _________________________________________________________________________

 (registration body)

 The data sheet has _________________ pages numbered and, in total _________ sheets bound, including drawings (diagrams) on ___________ sheets.

 _________________________________________

 (position of registering officer, signature)

 Date ___________________

Recommendations on filling the data sheet (form):

- the vessel manufacturer shall fill two counterparts of the data sheet (form). One of the counterparts shall be handed over to the customer (construction organization), whereas the other counterpart shall be kept with the manufacturer. The signed data sheets (forms) shall be kept throughout the vessel operation period;

- the organization being the customer of the vessel may establish additional requirements to filling the data sheet (form) of the vessel by the manufacturer;

- it shall be allowed to attach duplicates of quality certificates to the data sheet (form) instead of tables.

Appendix 2

PIPELINE DATA SHEET (FORM)

(specimen)

___________________________________________________________________________

(name)

___________________________________________________________________________

 Registration No. ______________________

 The registration number shall be assigned by the territorial body of the Federal Service for Environmental, Industrial and Nuclear Supervision.

CONTENTS OF DATA SHEET

FOR PIPELINE ______________________________________________________________

(name)

 LIST OF DOCUMENTS ATTACHED TO PIPELINE DATA SHEET

___________________________________________________________________________

 (name)

 1. The general data is presented in table 1.

 Table 1

General data

 2. Technical characteristics of the pipeline are specified in table 2.

 Table 2

Technical characteristics of pipeline

 3. The data on pipelines is presented in table 3.

 Table 3

 Data on pipelines

 4. The data on valves installed as part of the pipeline is presented in table 4.

 Table 4

 Data on valves installed as part of the pipeline

 5. The data on safety valves is presented in table 5.

 Table 5

 Data on safety valves

 6. Based on data of items 9 - 13, there must be prepared

a conclusion according to the following form:

CONCLUSION

 Based on checks and tests, the following is certified:

 1. The pipeline is manufactured and assembled according to technical documentation_____________________________________________

 (name and designation of documents)

 2. The pipeline was subjected to and withstood hydraulic (pneumatic) testing.

 3. The pipeline is found suitable for operation with the parameters specified in the data sheet.

 4. The pipeline data sheet contains_____________________________ sheets.

 Person in charge of construction organization

 ________________________________________

 (signature, seal)

 Date ____________________________________

 7. The operating organization shall supplement the pipeline data sheet with data presented in tables 6 - 9.

 Table 6

Data on persons in charge of operable condition and safe operation of pipeline

 Table 7

 Results of inspections

 Table 8

 Results of hydraulic (pneumatic) tests

 Table 9

Results of control of condition of metal in the course of operation

 8. The data on repair and reconstruction of the pipeline are presented in table 10.

 Table 10

 Data on repair and reconstruction of the pipeline

 9. Registration of pipeline

 Registration of the pipeline within the RP shall be carried out at the request of the operating organization in the following form:

REGISTRATION OF PIPELINE

 The pipeline is registered with No. _____________________ at ______________

___________________________________________________________________________

(registration body)

 The data sheet has _________________ pages numbered and, in total _________ sheets bound, including drawings (diagrams) on ___________ sheets.

___________________________________________________________________________

(full name and position of registering officer, signature)

 Date____________________

Recommendations on filling the data sheet (form):

- the data sheet (form) of the pipeline prepared by the FNP RP construction organization shall be accompanied with the following documents:

a set of diagrams and drawings of the pipeline, which should make it possible to control the compliance of the pipeline with the requirements of the design, the provision of valves and instrumentation, the locations of welded joints and supports;

data of the manufacturer on the characteristics and quality of products and materials used in the installation of the pipeline, or copies of quality certificates;

certificate of installation of pipelines prepared by the construction organization;

data sheets of pipeline valves;

strength calculation or extract <*> therefrom, with specification of calculation designation;

tables of control of quality of welded joints and base materials;

documents on deviations from design (engineering) documents;

- it shall be allowed to change the size of tables and graphs, as well as replace the tables with copies of certificates containing the necessary data;

- data sheets (forms), along with appendices, must be kept by the construction organization and with the operating organization throughout the pipeline operation period.

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

<*> The extract from the strength calculation must contain: the list of calculated pipeline components and their loads and temperature effects, the list of test modes, operation (including violations of normal conditions) and external influences, for which the calculation was carried out; the number of loading cycles at each mode; strength assessment data for all criteria required by the current RD for the FNP RP.

Appendix 3

DATA SPECIFIED IN PUMP DATA SHEET

In addition to the contents of the vessel data sheet (a specimen of data sheet (form) of the vessel is given in Appendix1 of these Rules), the following data shall be entered on the data sheet of a pump:

1. Pump drawing number.

2. Pump grade.

3. Serial number.

4. Date of manufacture, name and address of manufacturer.

5. Pump characteristics:

pressure at pump outlet;

maximum and rated head of the pump;

inlet pressure;

design temperature;

working medium;

rated feed;

pressure of hydraulic testing of pump housing;

temperature of hydraulic testing of pump housing;

specified service life;

assigned service life;

quality compliance certificate.

6. The data on pull-out components of the pump are presented in table 1.

Table 1

Data on pump components

7. Information on valves and instrumentation is presented in table 2.

Table 2

Valves and instrumentation

8. Data on the results of periodic technical examination in the course of operation and repair activities fulfilled.

Recommendations on filling the data sheet:

- the pump manufacturer shall fill two counterparts of the data sheet. One of the counterparts shall be handed over to the customer, and the other counterpart shall be kept with the manufacturer. The signed data sheets (forms) shall be kept throughout the pump operation period;

- the organization being the customer of the pump may establish additional requirements to filling the data sheet (form) of the pump by the manufacturer;

- it shall be allowed to attach duplicates of quality certificates to the data sheet instead of tables.

Appendix 4

HYDRAULIC TESTS OF EQUIPMENT AND PIPELINES

1. GENERAL REQUIREMENTS

1.1. Equipment and pipelines shall, after manufacture, installation and repair, be subjected to hydraulic testing prior to the application of protective external anti-corrosion coatings or thermal insulation, unless otherwise provided in the engineering documentation.

1.2. Hydraulic tests of equipment and pipelines during operation shall be carried out after removal of thermal isolation in the places specified in engineering documentation.

1.3. Hydraulic tests after manufacture of equipment and products for the pipelines loaded in the course of operation by external pressure may be carried out at loading by internal pressure.

1.4. Requirements for the quality of the test medium must be specified in the engineering documentation.

1.5. During hydraulic testing of equipment and pipelines, the safety rules provided by the current instructions and regulations of the construction organization (at the FNP RP construction stage) and the operating organization (at the stages of commissioning and operation) must be observed.

1.6. For components and systems subjected to hydraulic tests, measures shall be taken to prevent the formation of gas bags during filling with liquid. Before starting the test, make sure that the air is removed from all parts of the system.

1.7. Hydraulic tests of the equipment in the construction organization are allowed to be skipped make if the equipment has passed hydraulic tests in the manufacturer of this equipment, whereupon the equipment was not subjected to operations or effects as a result of which the material of this product could be subjected to plastic deformations that shall be reflected in the accompanying documentation.

1.8. Hydraulic tests of individual parts and Assembly units of equipment and pipelines after their manufacture may be skipped if the manufacturer carries out their hydraulic tests as part of prefabricated assembly units or products.

2. DETERMINATION OF PRESSURE OF HYDRAULIC TESTS

OF COMPONENTS AND SYSTEMS

2.1. The value of the hydraulic test pressure for a structural member shall not be less than that determined from the following equation:

 T

 h

 [sigma]

 (P ) min = 1.25P ---------. (1)

 h T

 [sigma]

 The nominal allowable stresses at the design temperature T and the hydraulic test temperature T shall be determined from the following ratios:

 T T

 R R

 T m p0.2

 [sigma] = min {--; -----}, (2)

 n n

 m 0.2

 T T

 h h

 T R R

 h m p0.2

 [sigma] = min {---; -----}, (3)

 n n

 m 0.2

 where n and n are margin factors, their values stipulated in RD

 m 0.2

according to the FNP RP strength calculations.

 2.2. The value of the hydraulic test pressure for the element under consideration at the design pressure P of less than 0.49 MPa shall be more than 1.5 P, but not less than 0.2 MPa.

 At the design pressure P less than or equal to 0.49 MPa, the minimum pressure value of the hydraulic test P shall be determined from h of the condition of paragraph 2.1., but not less than P + 0.29 MPa.

 The minimum pressure value of hydraulic tests meeting the requirements of paragraphs 2.1 and 2.2 shall be referred to as the minimum test pressure (minimum pressure of hydraulic tests (P )min.).

 h

 For fasteners and gaskets, the minimum hydraulic test pressure shall not be determined.

 2.3. Stresses arising in vessels and pipelines during hydraulic tests shall be limited to the following values:

 T

 h

 (sigma) <= 1.35 [sigma] , (4)

 1

 T

 h

 (sigma) <= 1.7 [sigma] . (5)

 2

 Stresses in bolts and pins shall be determined by the following ratios:

 T

 h

 (sigma) <= 0.7R , (6)

 3W p0.2

 T

 h

 (sigma) <= 0.85R . (7)

 4W p0.2

 For the elements loaded by external pressure at hydraulic tests, the following condition shall be additionally met:

 P <= 1.35 [P], (8)

 h

 where [P] is the permissible value of the external pressure in hydraulic tests, determined in accordance with the RD based on the FNP RP strength calculations.

 The maximum hydraulic test pressure value that meets the requirements (4) - (8) shall be referred to as the maximum test pressure (maximum hydraulic test pressure (P ) max).

 h

 2.4. The hydraulic test value P shall be assigned in the range:

 h

 (P )min <= P <= (P )max. (9)

 h h h

 2.5. If a system consisting of equipment and pipelines operating at different operating pressures and/or design temperatures, or made of materials with different allowable stresses [sigma] and/or [sigma], is subjected to hydraulic testing, the pressure value of the hydraulic testing of this system (circuit) should be assigned to be not less than the maximum value of the total minimum hydraulic test pressures calculated for all the components of the system. At the same time, the test pressure shall not exceed the maximum test pressure for any part of the system as defined in paragraph 2.3.

It shall be allowed to assign the value of pressure of the hydraulic test of a system below the minimum pressure value of the hydraulic test of individual components of the system, provided that the components of the system having the minimum pressure value of the hydraulic test exceeding the pressure of the hydraulic test of the system shall be subjected to an additional hydraulic pressure test, the value of which shall be greater than or equal to the minimum pressure value of the hydraulic test defined in paragraphs 2.1.or 2.2.

2.6. Values of pressure of hydraulic tests of equipment, pipelines and systems as a whole shall be determined by the engineering (design) organization.

2.7. The minimum and maximum hydraulic test pressures for equipment and pipelines shall be specified in the vessel (equipment) or piping data sheet.

2.8. On agreement with the operating organization, the engineering (design) organization and the construction organization, the of hydraulic test of system after installation and during operation can be specified in the limits provided by paragraph 2.5 on the basis of the data contained in data sheets of the equipment and the pipelines completing the system.

2.9. In case of control of condition of metal by 100% ultrasonic and (or) radiographic methods in the course of manufacture of components making the system and installation of the system as a whole, it shall be allowed to adopt the value of the minimum pressure of hydraulic tests of this system equal to 1.25 P. The zones, methods and scope of control shall be determined by the engineering (design) organization and must be specified in the engineering documentation.

2.10. The rise and decrease of the hydraulic test pressure shall be held at a rate of no more than 0.98 MPa/minute. For tanks with a capacity of not more than 50 liters, the pressure change rate is not limited.

 2.11. The duration of exposure of equipment and pipelines (system being tested) under pressure P should not be less than 10 min.

 h

 After such exposure, the pressure shall be reduced to 0.8 P and maintained for the time required to inspect all the components of the system under testing, but anyway not less than 10 minutes. Should it be impossible to hold the inspection of all components of the system under testing, the time of exposure under pressure of 0.8 P must be not less than 24 hours.

2.12. In the course of hydraulic tests, variations in the pressure values within +/- 2% and the test temperature +/- 3 K (+3 °C) from the assigned values shall be allowed.

2.13. The dates of hydraulic testing of equipment and pipelines during operation shall be set by the operating organization in the working program of hydraulic tests.

3. DETERMINATION OF TEMPERATURE OF HYDRAULIC TESTS

3.1. Hydraulic tests of the equipment and pipelines shall be carried out at a temperature of the test medium, at which the temperature of the metal shall not be lower than the minimum permissible temperature determined according to the RD based on the strength calculation for the FNP RP. Permissible metal temperatures during hydraulic tests after manufacture, installation and operation of equipment, assembly units and systems, and the temperature of the test medium shall be determined by the engineering (design) organization, taking into account variations in the properties of the metal during operation and shall be specified in the engineering documentation.

3.2. The minimum permissible temperature of the metal during hydraulic tests carried out after manufacture shall be given in drawings, data sheets of equipment and pipelines.

3.3. The minimum permissible temperature of metal at hydraulic tests of equipment and pipelines as a part of the system after installation shall be not lower than the maximum value of the minimum temperatures of the hydraulic tests established by strength calculations for the equipment, products and components of pipelines of the system in question and (or) specified in data sheets of the equipment and pipelines of this system.

The minimum permissible temperature of the metal of the elements being tested and the medium at hydraulic tests shall not be less than 5 °C (278 K).

3.4. The temperature of hydraulic tests during operation (including those held after repair) may be specified by the operating organization in coordination with the engineering (design) organization on the basis of strength calculations taking into account the actual duration of the RP operation till the next hydraulic test, the number of loading cycles and neutron fluence with energy E >= 0.5 MeV.

4. REGULATIONS FOR PERFORMANCE OF HYDRAULIC TESTS

4.1. For hydraulic tests during the construction of a floating power unit of the FNP, at commissioning and in the course of operation of FNP, the design organization must prepare a comprehensive testing program (CTP).

4.2. Hydraulic tests of the equipment and pipelines in the course of the FNP construction, commissioning and in the course of operation shall be carried out by the construction organization and the operating organization, respectively, according to the working programs of tests made on the basis of the CTP as per 4.1.

4.3. The CTP must include the following data:

- name and boundaries of the system under testing;

- dates of hydraulic testing;

- operating pressure;

- hydraulic test pressure;

- hydraulic test temperature;

- test media and requirements to their quality;

- minimum ambient temperature value;

- permissible rates of pressure increase and decrease;

- permissible rates of temperature increase and decrease;

- pressure, at which inspection must be performed;

- methods of filling and drainage of test medium;

- source of pressure;

- method of heating of test medium;

- locations for installation of pressure control sensors (instruments);

- locations for installation of temperature control sensors (instruments);

- acceptable limits of variation of pressure and temperature during exposure period;

- design leaks;

- means for detection of leaks and monitoring of condition of equipment and pipelines.

4.4. The CTP must be approved by the design organization and agreed upon with the RP engineering organization.

4.5. On the basis of the CTP, the construction organization (for the construction stage) and the operating organization (for the stage of commissioning and operation of the FNP) must develop working CTPs. A working CTP shall, in addition to information listed in paragraph 4.3., contain the following data:

- specification of hydraulic test pressure and temperature values of the equipment and pipeline system according to the data sheets of components;

- location for connection of pressure source;

- list of sensors and devices used for monitoring of pressure and temperature, with specification of the accuracy class;

- the testing schedule (stages of hydraulic test pressure rise and relief, temperature increase and decrease, exposure duration);

- methods for control of the condition of the equipment and pipelines under testing during inspection and after completion of tests;

- measures for preparation and implementation of tests (with specification of the valves being shut and opened, which limit the system under testing, or a part thereof);

- the list of places for removal of thermal insulation (for the program of the operating organization);

- measures for protection from excess of pressure above the testing value;

- safety requirements;

- organizational measures (including the appointment of the person in charge of the tests);

- number of the comprehensive program, on the basis of which the working program is prepared.

5. REQUIREMENTS TO INSTRUMENTS MONITORING THE HYDRAULIC TEST
REGIMES

5.1. The pressure measurement at hydraulic tests shall be carried out on two independent pressure gauges or measuring channels.

The places for installation of independent instruments for measuring pressure on pipelines and equipment shall be specified by the designer in the CTP.

5.2. The accuracy class of the pressure measuring instrument shall not be less than 1.5.

5.3. The pressure measurement error of the measuring channels at hydraulic tests shall not exceed +/- 3% of the test pressure.

5.4. The temperature of the ambient and test media must be controlled with means of measurements with an error of less than +/- 1 K (+1 °C).

5.5. At tests lasting for more than 2 hours, it is recommended to use a recording device in addition to the indicating devices.

5.6. The analog pressure gauges used in the tests shall be selected so that the pressure values of the hydraulic tests would be kept within the second third of the scale.

5.7. The pressure measuring instruments used shall be verified before each single test or series of tests in accordance with RD.

6. ASSESSMENT OF RESULTS OF HYDRAULIC TESTS

6.1. Equipment and pipelines shall be deemed to have passed the hydraulic test if all of the following conditions are met:

- no leaks (except for design ones), sweating or tears of metal are found in the process of testing or inspection;

- in the course of exposure, the pressure drop would not go beyond the limits set by paragraph 2.12;

- no visible deformations or dimension variations are found after the test;

- after testing of parts having coupling dimensions, no residual deformations determined by measuring the geometric dimensions before and after the hydraulic tests are detected; coupling dimensions after the hydraulic tests must remain within tolerances, if specified in the engineering documentation;

- additional requirements stipulated by the CPT are met.

6.2. Leaks through process seals designed for testing shall not constitute grounds for conclusion about the negative results of the hydraulic tests (subject to compliance with the requirements of paragraph 2.12).

 6.3. Should it be impossible to inspect all items of equipment and pipelines, it shall be allowed to consider equipment, pipelines, and the system as a whole to have passed the hydraulic pressure test if the pressure P within 10 min. and the pressure of 0.8 P would remain constant within the limits established by paragraph 2.12 for 24 hrs. At the same time, inspection at accessible locations must be held

in accordance with requirements of this Appendix.

7. SAFETY REQUIREMENTS

7.1. During the hydraulic tests, the safety rules stipulated in the current instructions and regulations of the construction and operating organizations shall be observed.

7.2. If the test medium in the system is prone to thermal expansion, precautions should be taken against rise of pressure.

7.3. All low-pressure lines and other equipment unrelated to the tests shall be switched off.

8. DOCUMENTATION OF HYDRAULIC TESTS

8.1. Hydraulic tests shall be held in compliance with a comprehensive and (or) working programs.

8.2. Upon completion of the hydraulic tests, a report shall be drawn up to include the following data:

- name of organization that held the tests;

- name of tests of the system (part of system, equipment, pipelines, components);

- design pressure;

- design temperatures;

- testing pressure;

- testing temperature;

- ambient temperature;

- testing medium;

- duration of exposure at testing pressure;

- pressure, at which inspection is performed;

- working program number;

- signature of officer in charge, and date.

8.3. Should it be technologically impossible to meet any of requirements of this Appendix, it shall be allowed to prepare reasonable technical decisions made by the construction organization or the operating organization with deviations from this Appendix, which shall be agreed with the design and engineering organizations, approved by the operating organization and approved by Federal Service for Environmental, Industrial and Nuclear Supervision.

9. ADOPTED DESIGNATIONS AND ABBREVIATIONS

P is design pressure, MPa;

P is hydraulic test pressure, MPa;

 h

T is design temperature of metal of equipment or pipeline, K (°C);

T is temperature of hydraulic testing of metal

 h of equipment or pipeline, K (°C);

 T

[sigma] is rated permissible stress at design temperature T, MPa;

 T

 h

[sigma] is rated permissible stress at hydraulic test temperature T, MPa;

 h

(sigma) , (sigma) , are groups of categories 1, 2 of reduced stresses adopted in strength calculations, MPa;

(sigma) , (sigma)

 3W 4W

 T

R is the value m of ultimate resistance of metal at design temperature T, adopted in strength calculations, MPa;

 T

 h

R is the value m of ultimate resistance of metal at hydraulic test temperature T, adopted in strength calculations, MPa;

 h

 T

R is the value of yield limit p0.2 of metal at design temperature T, adopted in strength calculations, MPa;

 T

 h

R is the value of yield limit p0.2 of metal at hydraulic test temperature T, adopted in strength calculations, MPa;

 h

n is the margin factor for ultimate resistance m;

n is the safety factor for yield limit;

 0.2

[P] is permissible external pressure at hydraulic tests, MPa;

CTP is comprehensive testing program.

Appendix 5

(specimen)

DEFECTIVE UNIT EXAMINATION ACT

The defective unit examination act should contain the following information:

- date of accident or detection of defect;

- name of pipeline, assembly unit or part;

- designation of drawing of assembly unit or part;

- name of manufacturing organization (assembling organization);

- name of owner;

- grade of metal of the part at the place of defect;

- pipeline operation period before detection of defect;

- the symptoms which helped to identify the defect;

- operating conditions: medium, operating pressure, temperature, regime parameters, the number of cycles of each of the transient modes, the number of hydraulic tests, neutron fluence, the intensity and spectrum of the neutron flux (for pipelines affected by neutron flux), the nature of the stress state and its variation during operation (with specific parameters in all operating modes and tests), a list of violations of normal operating conditions and emergencies, the composition of the medium that affected the damaged surface, the time of contact between the medium and the surface at different temperatures;

- assessment of the general condition of the surface of damaged metal;

- location, nature, dimensions (extent, depth, opening) and configuration of defect;

- methods used at examination;

- photographs, cast or schematic image of defect;

- results of laboratory tests for determination of mechanical properties;

- results of metallographic studies;

- causes of damage of metal;

- previous cases of damage of this or similar assembly;

- measures for elimination of the defect and prevention of similar damage during further operation;

- numbers of reports and conclusions.

Signatures:

Date