Post on 31-Dec-2015
description
Valve Manufacturers’ Association – Charlotte 2013
& Life Extension
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Neal Estep nestep@kalsi.comKalsi Engineering, Inc.745 Park Two DriveSugar Land, TX 77478
Valve Manufacturers’ Association – Charlotte 2013
OutlineOverview of requirementsNuclear design and construction
requirementsNuclear qualification requirementsNuclear market penetrationNuclear life extension considerations
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Valve Manufacturers’ Association – Charlotte 2013
KEI BackgroundKalsi Engineering, Inc.
Having worked with valves and actuators in a variety of industries for well over 35 years KEI can bring some unique perspective on this subject.
Served clients for over 35 years (founded 1978)Engineering services: Design, analysis, testing,
R&DIndustry wide recognized specialist in valves,
seals, & mechanical equipmentNuclear power industry Oilfield/petrochemical industries
Advanced models, software, hardware, test facilities & patented technologies
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Valve Manufacturers’ Association – Charlotte 2013
Overview of RequirementsValve Product
Line
ASME N,NPT-Stamp
Certification
NQA-1 Program
Authorized Nuclear
InspectorQME-1
Functional Qualification
Testing & Model
ValidationAnalysis
Market Penetration
New Entrant Barriers
Product Differentiation
Sales $$
Qualified Product
Sales & Support
Infrastructure4
Valve Manufacturers’ Association – Charlotte 2013
Challenges for New EntrantsExpense of implementing a nuclear programLack of experience with Nuclear Regulatory
Commission operating environment and related history – a fundamental shift in thinking and new learning is required
Lack of Nuclear Industry operating environment experience and knowledge history
Lack of in-plant and industry test data for product line
In-plant diagnostic test equipment and methods are mature for existing product lines
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction RequirementsClient procurement specifications identify the
design &construction code, qualification & testing, and other requirements (e.g. weak link analysis).
ASME Boiler & Pressure Vessel Code Section III is required for ASME Class 1, 2, and 3 nuclear safety-related applications.
ANSI B31.1/B16.34 is usually specified for balance-of-plant, non-nuclear safety-related applications.
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction Requirements: Nuclear Class 1Components within the reactor coolant system pressure boundary.
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction Requirements: Nuclear Class 2Components important for nuclear safety that typically interface with the reactor coolant system pressure boundary.
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction Requirements: Nuclear Class 3Components in cooling water and auxiliary feedwater systems that are important to nuclear safety.
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction Requirements
ASME Nuclear Class NRC Quality Class-Regulatory Guide 1.26
Code Design Criteria NRC Regulatory Guide 1.29 Seismic Category
1 A Class 1, ASME Sect. III, Class 1 I2 B Class 2, ASME Sect. III, Class 2 I3 C Class 3, ASME Sect. III, Class 3 I4 D ANSI B31.1 / B16.34 I5 D ANSI B31.1 / B16.34 II or NS
Relationship of Nuclear Class to Design Requirements:
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction RequirementsASME Code Service Level Design Requirements:Primary Stress Limits: Intended to prevent plastic deformation
and to provide a nominal factor of safety on the ductile Burst pressure.
Primary + Secondary stress limits: Intended to prevent excessive plastic deformation and to validate the application of elastic analysis when performing the fatigue evaluation.
Peak stress limit: Intended to prevent fatigue failure as a result of cyclic loading (crack initiation)
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction RequirementsASME Code Service Level Design Requirements:
• A: Normal Operation: Includes stresses due to normal installation, start-up, shut-down, power reduction, etc.
• Considers primary stresses, secondary stresses, and fatigue
• B: Upset Conditions (Moderate Frequency): Permits no damage that requires repair. Includes turbine trips, reactor trips, safety-relief valve actuation, operating base earthquakes, etc.
• Same as Level A but allows higher limits for primary stresses
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction RequirementsASME Code Service Level Design Requirements:Can go into a significant level of strain with C and D
service limits• C: Emergency Conditions (Infrequent)
• Permits large deformations in areas of structural discontinuity. Component is required to be removed from service for inspection and repair. Includes over-pressure events, pressure transients, safe shutdown earthquakes, etc. • Allows up to yield strength (Sy) for primary general membrane
stresses• Allows elastic limits for pressure loading with ferritic material up
to 90% of Sy• Secondary and peak stress evaluation is not required
• D: Faulted Conditions• Permits gross general deformations with damage that requires
repair. Includes safe-shutdown earthquakes, pipe rupture / loss of coolant accidents, and other low probability design-basis events.• Evaluated per rules in Appendix F of Section III.
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction Requirements
Manufacturer’s must hold an N-Stamp Certification for Class 1, 2, and 3 valves:
• N Certificate: Code Compliance for materials, design, fabrication, installation, examination, testing, inspection, certification, and stamping.
• NPT Certificate: Required for fabricating parts, piping subassemblies, or appurtenances.
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction RequirementsManufacturers must have a QA Program that
satisfies NCA-4000 requirements:• ASME NQA-1
• Design Control• Procurement Document Control• Control of Purchased Items and Services• Identification and Control of Items• Control of Processes• Inspection• Test Control• Control of M&TE• Etc.
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction Requirements: Nuclear InspectorManufacturer’s must have a relationship with
an Authorized Inspection Agency to utilize services of an Authorized Nuclear Inspector (ANI) who will:• Verify scope of work to be performed• Monitor QA program and subcontracted activities• Review qualification records• Verify materials• Witness fabrication, examinations, and tests.• Review and sign reports
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction RequirementsASME B&PV Code - Sections
Section I: Rules for Construction of Power Boilers
Section II: MaterialsSection III: Rules for Construction of Nuclear
Power Plant ComponentsSection IV: Power BoilersSection V: Nondestructive ExaminationSection VI: Recommended Rules for the Care
and Operation of Heating BoilersSection VII: Recommended Guidelines for the
Care of Power Boilers17
Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction RequirementsASME B&PV Code
Section VIII: Rules for Construction of Pressure Vessels
Section IX: Welding and Brazing QualificationsSection X: Fiber-Reinforced Plastic Pressure
VesselsSection XI: Rules for In-service Inspection of
Nuclear Power Plant ComponentsSection XII: Rules for the Construction &
Continued Service of Transport Tanks
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction RequirementsNuclear customers require that the design
consider the maximum and minimum ranges:Minimum and maximum friction coefficientsMinimum and maximum voltage conditionsMinimum and maximum supply pressure
conditionsEtc.
Required for stress analysis, seismic, weak-link, and sizing the actuator
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Design & Construction RequirementsThe resulting design often resembles an
elephant (actuator) riding a bicycle (valve)
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Actuator
Valve
Valve Manufacturers’ Association – Charlotte 2013
Nuclear Functional QualificationNuclear Plants must demonstrate on an on-going
basis that their POVs will function under worst case conditions that (hopefully) may never be seen during normal plant operations.
Evolution of Functional Qualification Standards:
ANSI N278.1-1975
Valve Specification Guidance
ANSI B16.41-1983
Functional Qualification
ASME QME-1Very
comprehensive, but costly to fully
implement
Old New
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Valve Manufacturers’ Association – Charlotte 2013
ASME QME-1QME-1 Requirements Overview
• Identify product line to be qualified• Develop qualification plan,
including analytical model development and qualification extension approach
• Develop test procedures• Perform testing• Validate analytical model and
qualification extension approach from test data
• Prepare functional qualification report
• Prepare application reports (as needed) for customers
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Valve Manufacturers’ Association – Charlotte 2013
ASME QME-1 (continued)Establish Qualified Valve AssemblyDevelop methodology to extrapolate
qualification of valve assemblyAssure Production Valve Assembly performs
as predicted by Qualified Valve AssemblyApplies for:
ValveActuator Valve and Actuator Interface
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Valve Manufacturers’ Association – Charlotte 2013
ASME QME-1 (continued)Documentation Requirements
Qualification Plan Translates the Qualification Specification into a
step-by-step qualification program.
Functional Qualification Report Documents compliance of the qualified valve
assembly and its production valve assemblies
Application Report Documents suitability of any qualified valve
assembly and its production valve assemblies for a specific nuclear plant application
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Valve Manufacturers’ Association – Charlotte 2013
Qualification IssuesAssessment of stresses, strains, loads, or
displacements against allowable capacity limits. Analysis should be sufficiently rigorous to
allow for scaling from small to large sizes. Deflections should not create
interference, impede function, cause galling, or a lack of functionality.
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Valve Manufacturers’ Association – Charlotte 2013
Qualification IssuesAging: Must consider aging effects on both
design (corrosion, erosion, etc.) and function (degraded seats, friction factors, etc.).
Differences in normal operation and accident conditions: Pipe break requirements can drastically increase flow-rate
requirements for the same DP, or greatly increase both DP and flow-rate requirements.
Accident conditions may require consideration of harsh environmental conditions: temperature, humidity, radiation, corrosive spray, etc.
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Valve Manufacturers’ Association – Charlotte 2013
Qualification Issues: Flow Rate Effect on Globe Valve Performance
The required thrust to operate a globe valve can increase significantly with higher flow rates due to increase in side load on the plug and the corresponding increase in friction due to side load
Side load friction for a globe valve depends upon– The key valve design/dimensional parameters– The flow rate, which depends upon valve resistance
relative to the system resistance– The friction coefficient of the material pair
Damage to the valve internals can occur if localized loads/stresses exceed threshold of galling
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Valve Manufacturers’ Association – Charlotte 2013
Qualification Issues: Flow Rate Effect on Globe Valve Performance
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Flow loop tests were performed to determine the effect of flow rate on globe valve performance
Valve Manufacturers’ Association – Charlotte 2013Qualification Issues: Flow Rate Effect on Globe Valve Performance
Increase in flow rate dramatically increased the valve operating thrust
Blowdown conditions resulted in galling damage to the internals
Detailed CFD/FEA model validated, provided bounding predictions
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Blowdown
Vmax = 50ft/s
Valve Manufacturers’ Association – Charlotte 2013
Qualification Issues: Flow Rate Effect on Butterfly Valve Performance – Incompressible flow
P0001636
Hydrodynamic Torque For Butterfly/ Other Quarter Turn Valves Increases Modestly with DP, but Increases Significantly with Flow Rate Increase
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
15 fps @ 90 Psi
15 fps @ 60 Psi
15 fps @ 30 Psi
27 fps @ 90 Psi
Hyd
rod
ynam
ic T
orqu
e
Angle
High Flow ( 2xNormal Flow)
Normal Flow ( 3 DPs)
Valve Manufacturers’ Association – Charlotte 2013
0 10 20 30 40 50 60 70 80 90
Disc Opening Angle, degrees
Ctc
, To
rqu
e C
oef
fici
ent
0
High Pressure Drop Ratios
Low Pressure Drop Ratios
Self Opening Regime
Self Closing Regime
+VE
- VE
.
• Butterfly Aerodynamic Torque depends strongly on Flow Rate (dictated by DP/P1 Ratio);
• Torque can even switch from self-closing to self-opening based on flow rates for certain designs
.
Torque Coefficients ( Compressible Flow) Depend on Pressure Drop Ratio
Valve Manufacturers’ Association – Charlotte 2013
• For high flow conditions, fluid forces can cause disc to tip (instead of remaining flat against guides or seat under low flow conditions) and result in damage to gate valve internals
• Manufacturer’s experience based on years of satisfactory performance under normal plant flow rates does not serve as an acceptable technical basis to justify performance under high flow/accident conditions in nuclear power plants
Valve Manufacturers’ Association – Charlotte 2013
Disc/Seat Face and Guide Damage After A Blowdown Closure Test by NRC/INEL
Valve Manufacturers’ Association – Charlotte 2013
Fluid Flow Around Disk
Internal Reaction ForcesForce & Moment Equilibrium Equations
Detailed First Principles Gate Valve Models to Predict Thrust Requirements Permit Qualification of the Entire Product line Based upon prototype testing and Model Validation
Valve Manufacturers’ Association – Charlotte 2013
Barriers to Entry Into NuclearHigh Switching Costs for Nuclear Utilities
ProceduresSpare PartsTraining & QualificationStandardization EffortsMature programs for existing equipmentBusiness relationships – comfort, history,
familiarityDiagnostic test equipment and practices
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Valve Manufacturers’ Association – Charlotte 2013
Items Required by Nuclear Decision MakersProduct conforms to specifications: ASME
Code, NQA-1, Size, ANSI Class, etc.Environmental effects on capability (e.g.
temperature)System effects on capability (e.g. voltage)System effects on requirements (e.g. P, DP, Q,
fluid type, fluid temperature, cleanliness, etc.)Degradation (Age- and Service-related)How to calculate required torque under
different operating conditionsHow to perform field diagnostic testing
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Valve Manufacturers’ Association – Charlotte 2013
Fundamental NeedRequired torque or thrust calculation
methodology must be test-based to meet regulatory requirements10CFR50.55a, GL 89-10, ASME OM
OMN-1/App IIIMethodology must account for various
system and environmental conditionsMethodology must account for age- and
service-related degradationGL 96-05
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Valve Manufacturers’ Association – Charlotte 2013
How to AddressASME Design & Construction Code (Section
III)ASME Functional Qualification (QME-1)Nuclear Qualified Actuators (IEEE-382)
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Valve Manufacturers’ Association – Charlotte 2013
Possible Nuclear Target Segment StrategiesBalance of Plant (BOP) only: Existing and New
BuildSafety-Related: Existing plants (utility personnel)Safety-Related: New build (NSSS, EPC, utility
personnel)Domestic NuclearInternational Nuclear
The target segment will greatly dictate the degree of qualification required
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Life ExtensionNuclear Plants were originally licensed for a
40-year life.Nuclear Plants are receiving a 20-year life
extension.There are “life after 60” programs currently
under way.
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Life ExtensionMajor issues for POVs:
Obsolescence: replacement partsConfirm original design considerations for
pressure boundary: fatigue, erosion, corrosion, and embrittlement
Increase the required valve torque or thrust requirement to operate under worst-case conditions
Decrease the actuator capability
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Life ExtensionNRC and Industry have implemented aging-
management programs:In-service inspection (ASME Section XI)In-service testing (ASME Operations &
Maintenance Code, Periodic Verification Programs)
Maintenance Rule (10CFR50.65, RG1-160)License Renewal Rule (10CFR54)
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Valve Manufacturers’ Association – Charlotte 2013
Nuclear Life Extension-OpportunitiesReplacement components or partsEvaluation of original Code Design reports
with respect to fatigue, corrosion, erosion, and embrittlement
Analysis and testing to qualify components for a longer life
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Valve Manufacturers’ Association – Charlotte 2013
ConclusionRequirements for the Nuclear Industry are
unique and require a significant commitmentUse of rigorous test-based validated methods are
required for Nuclear products. Experience-based methods are often suitable for other industries.
A judicious combination of validated first-principle analytical models and testing the is most effective approach for qualifying a product line.
Contact information: nestep@kalsi.com
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