Section 505.2500  Repairs and Alterations

 

Repairs and alterations of non-ISI boilers and pressure vessels, and pressure relief valves associated with non-ISI boilers and pressure vessels, except boilers and pressure vessels and those pressure relief valves associated with boilers and pressure vessels that are exempt under Section 505.50(a) of this Part, shall be made in accordance with this Section.  Non-ISI boilers and pressure vessels, and pressure relief valves associated with non-ISI boilers and pressure vessels, that are repaired or altered after February 7, 1994 shall be repaired or altered in accordance with this Section or other codes and standards as reflected in the facility's Operating License, Final Safety Analysis Report, technical specifications or other licensing documents as required or approved by the NRC.  The requirements of this Section are subject to the limitations of Section 505.20(c) of this Part.

 

a)         The requirements of this subsection (a) are limited to welded repairs and welded and non-welded alterations of non-ISI boilers and pressure vessels.  Where requirements for a repair or alteration are not given, it is intended that, subject to approval of the Authorized Inspector, details of design and construction, insofar as practical, will be consistent with the ASME Code for boilers and pressure vessels constructed to the ASME Code, or the code to which the item was originally constructed for boilers and pressure vessels not constructed to the ASME Code or the repair rules of the National Board Inspection Code.

 

1)         All non-ISI boilers and pressure vessels covered by the Act that are repaired after February 7, 1994 shall be repaired by one of the following organizations:

 

A)        An owner and those organizations under contract to the owner, provided that:

 

i)          such repairs are made in accordance with a Quality Assurance Program that meets the requirements of 10 CFR 50 Appendix B and has been approved by the NRC;

 

ii)         all portions of the owner's 10 CFR 50 Appendix B Quality Assurance Program, described in subsection (a)(1)(A)(i) of this Section, that are applicable to a repair activity are applied to the repair; and

 

iii)         the owner notifies the Department of his intention to apply 10 CFR 50 Appendix B Quality Assurance Program, described in subsection (a)(1)(A)(i) of this Section, to the repair of boilers and pressure vessels.  This notification only needs to be given once for all repairs of boilers and pressure vessels performed under the owner's 10 CFR 50 Appendix B Quality Assurance Program at the nuclear facility.

 

            AGENCY NOTE:  The application of the owner's 10 CFR 50 Appendix B Quality Assurance Program, described in subsections (a)(1)(A)(i), (ii) and (iii) of this Section, is subject to review by the Authorized Inspector.

 

B)        An organization in possession of a valid "R" certificate of Authorization issued by the National Board.

 

C)        An organization authorized by the Division of Boiler and Pressure Vessel Safety, Office of the State Fire Marshal, to repair boilers and pressure vessels.

 

2)         Repairs shall be initiated only after they have been authorized by the Authorized Inspector who has reviewed and accepted the weld procedures, welders and welding operators' qualifications and repair methods.  The Authorized Inspector may give prior approval for repairs of a routine nature.  In every case the Authorized Inspector shall be advised of each repair under prior agreement.

 

3)         All non-ISI boilers and pressure vessels covered by the Act that are altered after February 7, 1994 shall be altered by one of the following organizations:

 

A)        An owner and those organizations under contract to the owner, provided that:

 

i)          such alterations are made in accordance with a Quality Assurance Program that meets the requirements of 10 CFR 50 Appendix B and has been approved by the NRC;

 

ii)         all portions of the owner's 10 CFR 50 Appendix B Quality Assurance Program, described in subsection (a)(3)(A)(i) of this Section, that are applicable to an alteration activity are applied to the alteration; and

 

iii)         the owner notifies the Department of his intention to apply 10 CFR 50 Appendix B Quality Assurance Program, described in subsection (a)(3)(A)(i) of this Section, to the alteration of boilers and pressure vessels.  This notification only needs to be given once for all alterations of boilers and pressure vessels performed under the owner's 10 CFR 50 Appendix B Quality Assurance Program at the nuclear facility.

 

            AGENCY NOTE:  The application of the owner's 10 CFR 50 Appendix B Quality Assurance Program, described in subsections (a)(3)(A)(i), (ii) and (iii) of this Section, is subject to review by the Authorized Inspector.

 

B)        An organization in possession of a valid "R" Certificate of Authorization issued by the National Board, provided the alterations are within the scope of such authorization.

 

4)         Alterations shall be initiated only after they have been authorized by the Authorized Inspector who has reviewed and accepted the alteration methods and calculations.  If considered necessary, the Authorized Inspector shall make an inspection of the object before granting such authorization.

 

5)         Reports documenting repairs and alterations shall be sent to the Department in addition to the distribution required by the National Board Inspection Code.

 

6)         Documentation of repairs and alterations shall be in accordance with the National Board Inspection Code, except that, in lieu of a form R-1, an alternative form containing equivalent information may be used. All alternative forms shall be signed by the Authorized Inspector.  All alterative forms shall be approved by the Department prior to use.  The Authorized Inspector shall determine whether the completion of the form R-1 or alternative form is required for routine repairs.

 

7)         Repairs and alterations shall be accepted by either an Authorized Inspector employed by the Authorized Inspection Agency responsible for the boiler or pressure vessel or by an Authorized Inspector employed by the Authorized Inspection Agency of record for the organization making the repair or alteration.  It shall be the responsibility of the organization making the repair or alteration to coordinate the acceptance inspection of the repair or alteration.

 

8)         For pressure parts, the rules of Section RC-1050 of the National Board Inspection Code shall apply.

 

9)         Pressure Testing

 

A)        The Authorized Inspector may require a pressure test after completing a repair to a boiler or pressure vessel when in the Authorized Inspector's judgment one should be conducted.

 

B)        A pressure test in accordance with the National Board Inspection Code shall be applied to the boiler or pressure vessel on the completion of an alteration.

 

10)          For repair methods, the rules of Parts RC and RD of the National Board Inspection Code shall apply.

 

11)          Alteration methods shall comply with the general requirements of this subsection (a), and with the appropriate ASME Code Section or Part RC of the National Board Inspection Code, as applicable, including any service restrictions.

 

12)          Major replacement of pressure parts, including drums and shells, which are fabricated by welding and for which a Manufacturers Data Report is required by the applicable ASME Code Section shall be fabricated by a manufacturer having an ASME Certificate of Authorization and the appropriate ASME Code Symbol Stamp.  The item shall be inspected, stamped with the applicable ASME Code Symbol and the word "PART", and reported on the appropriate Manufacturers Partial Data Report.

 

13)          When a repair or alteration requires removal of that part of a non-ISI boiler or pressure vessel containing the Code stamping, the Authorized Inspector shall, subject to the approval of the Department, witness the making of a facsimile of stamping, the obliteration of the old stamping and the transfer of the stamping to the new part.  When the stamping is on a nameplate, the Authorized Inspector is to witness the transfer of the nameplate to the new part. The ASME Code Symbol is not to be restamped.

 

14)          For rerating, the rules of this subsection (a) and Part RC-3000 of the National Board Inspection Code shall apply.  Additionally, the following shall apply:

 

A)        All requirements in Parts RC-3020, RC-3021, RC-3022 and RC 3030 of the National Board Inspection Code and this subsection (a) shall be met to the satisfaction of the Authorized Inspection Agency at the location of the installation.

 

B)        Revised calculations verifying the new service conditions shall be required from the original manufacturer or, when such calculations cannot be obtained from this source, they may be prepared by an Engineer in accordance with Part RC-3022(a) of the National Board Inspection Code.

 

C)        The boiler or pressure vessel shall be pressure tested for the rerated condition as required by subsection (a)(9)(B) of this Section.

 

b)         All ASME Code Section I "V" stamped, Section III "NV" stamped, and Section VIII "UV" stamped pressure relief valves associated with non-ISI boilers and pressure vessels shall be repaired in accordance with this subsection (b).

 

1)         All pressure relief valves covered by this subsection (b) that are repaired after February 7, 1994 shall be repaired by one of the following organizations:

 

A)        An owner and those organizations under contract to the owner, provided that:

 

i)          such repairs are made in accordance with a Quality Assurance Program that meets the requirements of 10 CFR 50 Appendix B and has been approved by the NRC;

 

ii)         all portions of the owner's 10 CFR 50 Appendix B Quality Assurance Program, described in subsection (b)(1)(A)(i) of this Section, that are applicable to a repair activity are applied to the repair; and

 

iii)         the owner notifies the Department of his intention to apply 10 CFR 50 Appendix B Quality Assurance Program, described in subsection (b)(1)(A)(i) of this Section, to the repair of these pressure relief valves.  This notification only needs to be given once for all repairs of pressure relief valves performed under the owner's 10 CFR 50 Appendix B Quality Assurance Program at the nuclear facility.

 

            AGENCY NOTE:  The application of the owner's 10 CFR 50 Appendix B Quality Assurance Program, described in subsections (b)(1)(A)(i), (ii) and (iii) of this Section, is subject to review by the Authorized Inspector.

 

B)        The manufacturer of the valve who is in possession of a valid ASME "V", "NV" or "UV" Certificate of Authorization, provided repairs are within the scope of the organization's Certificate of Authorization and are performed under the organization's Quality Control System or Quality Assurance System, as applicable.

 

C)        An organization in possession of a valid "VR" Certificate of Authorization issued by the National Board, provided repairs are within the scope of the organization's Certificate of Authorization and are performed under the organization's Quality Control System.

 

D)        An organization in possession of a valid Certificate of Authorization issued by the Division of Boiler and Pressure Vessel Safety, Office of the State Fire Marshal, to repair pressure relief valves provided repairs are within the scope of the organization's Certificate of Authorization and performed under the organizations's accepted Quality Control System.

 

2)         Repair of a pressure relief valve is considered to be the replacement or machining of any critical part, lapping of seat and disc or any other operation which may affect the flow passage, capacity, function or pressure retaining integrity.  Disassembly and reassembly or adjustments which affect the pressure relief valve function are not considered a repair, but a test confirming the valve's set pressure shall be performed.  The initial installation, testing and adjustments of a new pressure relief valve on a non-ISI boiler or pressure vessel are not considered a repair.

 

3)         Nameplates

 

A)        The rules of Part RA-2260 and Appendix 2 of the National Board Inspection Code shall apply.  The exceptions and clarifications of this subsection (b)(3) shall also apply.

 

B)        Individuals authorized by the Division of Boiler and Pressure Vessel Safety, Office of the State Fire Marshal, who are properly trained and qualified employees of the owner may make adjustments to the set pressure provided the adjusted settings and the date of the adjustment are recorded on a metal tag secured to the seal wire.  All external adjustments shall be resealed showing the identification of the organization making the adjustments.

 

C)        For owners that act as the valve repair organization under the provisions of subsection (b)(1)(A) of this Section who are not in possession of a valid "VR" Certificate of Authorization issued by the National Board, the requirements for stamping the ASME Code "V", "UV", "NV" or National Board "VR" mark in Parts RA-2262, RA-2264, RA-2265 and Appendix 2 of the National Board Inspection Code shall not apply.  All other requirements shall be met.

 

4)         Performance Testing

 

A)        The rules of Part RA-2280 of the National Board Inspection Code shall apply, regardless of whether the "VR" stamp will be or has been applied. The exceptions and clarifications of this subsection (b)(4) shall also apply.

 

B)        For owners that act as the valve repair organization under the provisions of subsection (b)(1)(A) of this Section who are not in possession of a valid "VR" Certificate of Authorization issued by the National Board, the requirements for stamping the "VR" mark in Part RA-2280 of the National Board Inspection Code are not required.  Also, performance testing equipment qualified by the owner under Part RA-2281 of the National Board Inspection Code shall be done by the owner.  The Authorized Inspector shall witness the qualification of test equipment and review the documentation of such qualification as required in Part RA-2281 of the National Board Inspection Code.

 

5)         Organizations that repair pressure relief valves under subsections (b)(1)(B) through (b)(1)(D) of this Section may perform field repairs in accordance with the following requirements.

 

A)        Qualified technicians in the employ of the repair organization perform such repairs.

 

B)        Procedures that address field repairs are contained in the Quality Control System or Quality Assurance System, as applicable, and are maintained.

 

C)        All functions affecting the quality of the repaired pressure relief valves are controlled from the location for which the appropriate authorization was issued.

 

D)        Periodic audits of work carried out in the field are made by quality control personnel of the repair organization to ensure that the requirements of the Quality Control System or Quality Assurance System, as applicable, are met.  This audit may include witnessing the test of the field repaired pressure relief valve.

 

(Source:  Amended at 23 Ill. Reg. 13089, effective October 6, 1999)