Grp Teciotor @€skom Detaled Works infomation ‘Prosicton. iter a Te: Paorm Ont Testing Boller Unie Wert ns Seay anee Alternative Reference Number: NIA cea of Aoplcaity: Engineering Documeniston Type Works Information Revision 5 Tota Pages ° Nest Review Date Aprit20%4 Disclosure Claseicaton: CONTROLLED pectosure omy Palo Repetaty ore // a heer) CLE. SJ Soloana JL Bierman Do Bhima Valve Speciaet—Torbines Senior Manager Turbines Senior Manager PEIC Group Technology Group Tezmology Group Technology vate He f20/3... oae..2 MAME one: 2744/43, “TR pvelaned 2207 200Perform Onlin Testing of Boller Safety Valves Unique dente: 324 Rosson 5 Page 2ot8 CONTENTS Page ‘LINTRODUCTION. 2 SUPPORTING CLAUSES... 2:4 §COPE OF WORKS INFORMATION 21 Pupose 3 2 Aopatiy 22 NORATVEINFORMATIVE REFERENCES 22 Nomatie 29 EFINTIONS 231 Guseaioa 2aaeoremarions 23 Derauto Seore Gr Wr Zo RoLss AND RESPONSIEL TES 2 bnocess Por wonToRNG EA mELATebsuprontve DOCUiiENTS 3. REVISIONS... ‘4, DEVELOPMENT TEAM 41SJSELOANA — - VALVE SPECIALIST S2HCVNIEKERK _” SENIOR CONSULTANT. 23M AMIR = SENIOR CONSULTANT ‘44am xBA = COMPLIANCE SPECIALIST. APerform Online Testing of Bollar Safety Valves Unive isenter: 324 Revision 5 Pat Bots 4. INTRODUCTION ‘This Works Information is to highight and aderess potential major safety hazards or threats to the ‘commercial postion of Eskom plants which coulé result from the fale of operational plant, due to incorect safety pressure rele valves setings “This document highlights some ofthe important considecatons relating to the safe and efcient use of _sfely valves and rele safety forthe rele’ of excessive pressure, setting of iting pressure, and to provide a basis from which local siategies for the care of such devices in operational plant can be Saveloped Safely pressure relief Valves are primary safety devices. Inadequate system design, instalation andlor ‘operational care can result in sighifcant safely re or commercial penales to Eskom as business why. It is advisable to set an enabling contract with # competent service prouder, o perform an Onine Testing of safely pressure relief valves hnstaliad, ater repaire have boon conducted to such valves, anor te confirm the fing pressures, when deemed requires, NB: Online Testing” only apoicable to conventional spring loaded type or to-sion bar type of safely Valves, Main objectives of “On line Testing: ‘a To highight those issues that should be considered by plant engineers and maintenance team in evelosing local svategies for the care and maintenance of pressure relieving safely devices on ‘operational plan, , To support decision making inthe replacement strategy (age related or obsolesces) of pressure relieving systems with new technologies in the market wren the need deemed. & To calate data information relating o the use of pressure relieving safety devices to maintain and develop company history base in respect of pressure relieving safely systems 4. Toensure compliance to the OSH Act requirements Benefits of Online Testing: a. Minimise plant dowstime Has the ability to tet safety pressure rbef valves, and idetiy those in neee of adjustments wih no ‘operational interrupions. Has the capability to measure several ype phenomena during testing procedures In this works information, only six (6) coal fred power stations were identified to perform the Oniine ‘Tesing to al Boiler Safety Valves installed on the Drum and Supernears Systems,Perform Online Testing of Boller Safety Valvor Unique identi 924 Revision 5 02 ot 2. SUPPORTING CLAUSES 2.4 SCOPE OF WORKS INFORMATION Description of the works The scope of work includes the ‘Oh line Testing” ofthe conventional spring loaded type and torsion bar ‘ype of Safely Pressure Ree! Valves, afer sipping for maintenance purposes or the valves repars has been conducted curing the appertunty mainteranca or the planned plant outages on ESKOM plans “AS and When required basis” or When cases of overpressure is noticed and the Operation of the Safety Pressure Relief isin doubt ‘The goal Is to validate or confirm the safe working conditons of the Safely Valvee! functional performance; integrity and relabity during plant operations (very and set safety or relief vaves ing Set pressures). The “Online Testing” will ensure ecical components maintsin plant product, safety and proftabity by ‘onsuring every valve is operating at peak eficency and meeting al safety requirements. NB: Testing frequency — not to exceed 3 years (mearing the cartiieaion fo be valid for tae 3 years ater vave testing). ‘Work to be performed by Contractor forthe works: Presmaintenance or outage work > Conduct safety assessment ofthe works prior to commencing > Ensure equipment and tools in use are certifies Hoisting/TransportationLiting of materaslequipment to allocated stes Inform the maintenance department of ary scaffolding, platform or lagging requirements before time. > Do vigual inspection inthe veinty (workplace), ESKOM! CONTRACTOR AIA > Verily valve KKSIAKZ. serial or figure number, and ensure that the Contractor has these In the alabase of his Testing Equsment. Detalles Procedural Requirements Boller Off lose: = Request permit to work to remove valve + Stipvales fom pipetne + Transpo valve tothe workshop + Conduct pre-stipping test (workshop bench test) and log alltests resus When the valve is cismantied measure the actual port size and record the nozzle diameter and umberPerform Online Testing of Boller Safety aves Unique dente. 324 Revsien 5 Page ot Boiler On lad: To aclyrequest PTW pri io commence of any actives onthe specicplantisystem equipment, Inform the relevant operating department ofthe activities to perform Only sccrdited Service Providers wil be alowed to perform the Trevtesting of Safety Pressure Relef Valves, ‘To involve a Government accredited Inspection Authority (ALA) for witness and approvals ‘To carry out Trevitest where necessary (ensure the valves tag coding correspond with the valve identieaten on the PTW), Perform necessary tests as per the specific plant Safely Valves Setings specified in the URS. ‘+The Univeysiom to be onload — Baller firing ‘+ Connest the Tevtest equipment othe vaive tobe tested +The condition ofthe unilsystem tobe stable ‘+ Cheek communication with control room and test supervisor + Estabish communications, ence the contin ofthe univsystem is stable ‘+The set pressures tobe achioved within a tolerance of 356 Once the fina! test has been completed, ‘+ TheContracterte remove the eauiement +The supervisor to clear permit +The Contractor to hand over Tests Reports o AIA Inspectr for approval + Acaloration certincate with the valve's unique number, contractors name, set pressure value {ale of tests submitted to AIA for endorsemant ae well. This wl form the stator caloaton ‘certificate, tobe kept at station level as part of safety valve register. GMR 2, (or responsi Berson eppainied in wring by GM 2) should also endorse the cerficate +The Conteactr to report and confi vith Glent of any other adltonal scope of work + Allthe testing to satisfy the "User Requirement Specification’ submited by the Cent (include Safely valves vetings on station C-Schedul, In-House Safety Valves Procedures) General Safety Valves testing will be done in conjunction with operating and the Government Approved Inspect Authority on ste (AIA). AIALwil seal the adjusting device witha tamper proof seal, and AIA will ensure his unique marking is fited to tamper proof deve. (On completion, remove all equipment and replace the safely Valves cover cap and secure the valves by camping sstety lead (to prevent unlawful sting of Valves) ‘The Contractor, to submit certificates and other valuable documentations fr approvals ‘The Contractor to submit al safety fies end required contractual documentations prior te commence wit any work A orks procedures tobe issued for acceptance to the Employer and ALA.form Online Testing of Bollr Safety Valves Ungue enter: 24 Resision 5 Page. sors = Detailed data book Index to be submited, ths data book then to be comaleted as the actly progress. 2.44 Purpose ‘To vetly and record the “Set Pressure” of install safely pressure rele valves. Pressure rele valves are destaned to protect a plants astats, physical and human; fom over-pressurng that could resus in ‘apture and uncontrolled release of high pressure energy, with catastrophe failures. 2.41.2 Applicability ‘This document shall apply troughout Engineering, Maintenance and Operating Departments within the ‘8x (6) coal fred Power Plats identiieg 2.2 NORMATIVE/INFORMATIVE REFERENCES Parties using the document shall appy the most recent ediion of the documents listed inthe following paragraphs. 2.2: Normative I) 1809001 Qualty Management Systems. [2] OSA Act Cccupatonal Health and Safely Act (OHSA Act 85 of 1993), [3] NPSz45-223 High Pressure Pipework of Fossi Fred Power Staton |] RWE P0020100_V23_ Safety valves systems and busting dsc safety devices. 2. DEFINITIONS. 2.31 Classification 8. Controlled disclosure: controled disclosure to external parties (ether enforced by law, of ‘Sseationay) 2.4 ABBREVIATIONS Aibreviation Description xa ‘Government Apareved napecion Authority 180) invematonal Standard Organisation (ons Act ‘Occupatonsl Hesth ond Sally Act of Republic of Sou Area ot 1085, URS: ‘User Requrements Spenser Ww ‘Wer informationi i =a : i # 4 a Tee 5 ; z ~~ meg g 1 FIV BURSST BUH SEAR HBTS sr 5 wee ou 36a “uo j90) andr (ww) Sy10m 40 3008 aaTIv130 5% S2NeA Aoies 21109 0 BuNso) aUUO wHOHodi é NOUVS waMOu'IVaNSH TRI NRT wosnoy r2e soynuep nbn sanren Anes smog yo Suns2y auto uO}2.6 ROLES AND RESPONSIBILITIES “The vaive ests are a8 minimum tobe witnessed by: “The Bolor Maintenance ~ Bor Plant Maintenance Supervisor ‘The AIA ~alocated Government Approved Inspection Authority Engineering Department ~ Pressure Parts System Engineer + Commissioning Department - Senior Commissioning Engineer = The Contractor ~ Accredited Service Provider 2.7 PROCESS FOR MONITORING ‘The Power Station Engineering Deparment is responsible for the works of record keeping after the cuments have been signed bythe AIA and the appointed Site Senior Manager. 2.8 RELATED/SUPPORTING DOCUMENTS Na. 3. REVISIONS Date Compier Remarks February 2013, S7Sacana ‘Eiababmen of he Enabing Coniract~ nine Tesing of Sey & Relef Vavee, February 2076 7 | SiSeoana NA 4, DEVELOPMENT TEAM “The folowing people were involved in the development ofthis document AASJSELOANA —- VALVE SPECIALIST 42HCVNIEKERK —- SENIOR CONSULTANT 43M AMIR ~ SENIOR CONSULTANT 44 AM XABA = COMPLIANCE SPECIALIST