Valve Manufacturers’ Association – Charlotte 2013 & Life Extension 1 Neal Estep...

Valve Manufacturers’ Association – Charlotte 2013

& Life Extension

1

Neal Estep [email protected] Engineering, Inc.745 Park Two DriveSugar Land, TX 77478


OutlineOverview of requirementsNuclear design and construction

requirementsNuclear qualification requirementsNuclear market penetrationNuclear life extension considerations

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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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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


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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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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Nuclear Design & Construction Requirements: Nuclear Class 1Components within the reactor coolant system pressure boundary.

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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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Nuclear Design & Construction Requirements: Nuclear Class 3Components in cooling water and auxiliary feedwater systems that are important to nuclear safety.

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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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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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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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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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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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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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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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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


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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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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Nuclear Design & Construction RequirementsThe resulting design often resembles an

elephant (actuator) riding a bicycle (valve)

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Actuator

Valve


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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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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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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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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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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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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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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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


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)


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


• 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


Disc/Seat Face and Guide Damage After A Blowdown Closure Test by NRC/INEL


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


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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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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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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How to AddressASME Design & Construction Code (Section

III)ASME Functional Qualification (QME-1)Nuclear Qualified Actuators (IEEE-382)

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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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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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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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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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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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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: [email protected]

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