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V-Rep 85-2
Edward Valves
ABSTRACT
During the 1970s, Rockwell devoted substantial resources to the development of the Equiwedge gate valve and a very special quick-closing actuator which permitted such valves to be used in critical applications in nuclear power plants. With the decline in construction of nuclear power plants in the United States, many would assume that such development work would have been curtailed. Instead, it has been carried forward to cover an extensive proof test of a size 30 (DN750) valve. Why? Global prospects for nuclear power production remain vital Nations with poor alternative energy resources forecast a continuing need for nuclear power. Technology cannot stand still, so development and qualification of improved valves for critical services had to continue. A major program was necessary to verify performance reliability of new valves built in Rockwells plant in France for French nuclear power facilities. This program enhances the qualification base of these valves, providing even greater assurance of their reliability for applications in other nations all over the world.
was the Main Steam Isolation Valve (MSIV). First boiling water reactor (BWR) and then pressurized water reactor (PWR) power plants were required to include large valves that could be closed quickly (typically within 3 to 5 seconds) in main steam lines to isolate the reactor system under conditions that ranged in severity to include an instantaneous main steam line break. The primary function of the MSIV is to prevent or minimize the escape of radioactive material from the reactor or the containment vessel to the steam lines to the turbines, even if a severe accident should occur within the nuclear part of a power plant. Depending on power plant size, MSIV sizes ranged typically from size 16 through size 32 (DN 400 through 800). Until the quick closing isolation requirement emerged, valves in this size range usually had operating speed specifications measured in minutes, not seconds. Previous Rockwell publications (see References at the end of this article) have documented the progressive development of improved valves and actuators dedicated to the assurance of safe and reliable closure of MSIVS. Over about fifteen years, major test and qualification programs were necessary to back up the extensive design and analytical work that had gone into each type of valve/actuator combination. While nuclear power plant construction has declined sharply in the United States over the last five years, nuclear power is still necessary in many other nations with fewer alternative energy resources. In particular, France has maintained an active
nuclear plant construction program, with emphasis on PWR plants, but also including work on the new Superphenix liquid metal fast breeder reactor (LMFBR). The Flow Control Division and its Rockwell Valves S.A. (RVSA) plant at Unieux, France, have participated actively in the continuing development of the nuclear power program in France, and, through this work, have maintained an active role in nuclear power activities in a number of other nations. As an illustration of the nature of ongoing work dedicated to global qualification of critical valves for nuclear power plants, this article will describe the extensive test program conducted in France on a size 30 (DN 750) Rockwell Equiwedge MSIV built at RVSA for Framatome-designed Electrocite de France (EDF) 1300 megawatt PWR stations. During the late 1960s and 1970s, nearly all MSIV development work was associated with specialized balanced disc globe valves. These valves had the advantage that pressure forces acting to assist or resist valve closure could be at least partially balanced. In early applications, this permitted fairly small actuators and control systems to be used to provide rapid but controlled closure of even very large valves. Controlled is a key word, because excessive closure speed of a large valve can be a hazard in itself. Uncontrolled valve closure speed may damage the valve or nearby pipe supports due to dynamic force reactions, and piping and other equipment 2
Background
Introduction
During the exciting decade of the 1970s, many technical papers and articles were published on a variety of subjects related to the rapid growth of nuclear power production in the United States. Rockwell contributed many articles on the development of special valves for critical services in nuclear power plants. One critical valve application that demanded great attention
The purpose of this test series was to demonstrate that the Equiwedge gate valve and Type A actuator meet performance requirements while subjected to line rupture and seismic forces. The test program 3
Fa
Fh1 Fh2
AXIAL FORCE HORIZONTAL BENDING MOMENT VERTICAL BENDING MOMENT TORSIONAL MOMENT UPPERSTRUCTURE FORCE PARALLEL TO FLOW UPPERSTRUCTURE FORCE PERPENDICULAR TO FLOW
Mh = Mv = T
Mv SECTION A-A
Fh1 = Fh2 =
Fa
Mh
The external loading applied to the valve was intended to simulate the effects of expected loads from both the attached piping and the valve upper structure. The five types of loading considered were: Axial pipe load Horizontal pipe bending moment Vertical pipe bending moment Torsional pipe moments Valve upperstructure loads The directions of the above loads are shown in Figure 1, and their magnitudes are listed in Table 1. Four different load combinations were applied (Cases 1 through 4); after each combination was applied, loads were adjusted to the values shown for Case 5, and the valve was closed. Case 5 represented the specified seismic loading on the valve. During each test, the valve was internally pressurized with nitrogen over demineralized water at 1220 psi (84 bar). The valve was fastclosed under pressure, and the following valve performance data were continuously recorded: Stem position Actuator gas pressure Actuator hydraulic pressure Closing force Valve body pressure In addition, readings from strain and deflection gages were monitored during these tests to provide a correlation with applied loads. After each valve closure, a
30-minute seat leakage test with water was performed. All of these tests were performed at the RVSA plant at Unieux, France. The valve was mounted in the test fixture, which was designed in the U.S. but built in France. Test instrumentation was provided by a French firm, CETIM; test performance was directed by a combination of U.S. and French Rockwell engineers. Results of these tests agreed very well with predictions based on prior analyses and test data. Recorded valve closing times were very consistent and almost independent of applied pipe and superstructure loadings. Measured valve seat leakages were always well within current requirements for nuclear isolation valves. In all cases, the valve closed without hesitation or binding. There were no significant deviations in performance between baseline tests and the tests with high pipe and superstructure loads.
1 2 3 4 5
Note: Fh1 shown for load case 5 is applied to the valve after application of load case 1, 2 and 3. Fh2 shown for load case 5 is applied to the valve after application of load case 4.
While the A-290 actuator had been qualified independently in a separate dynamic seismic test reported in Reference 2, and other static tests conducted in the U.S. and France left little doubt as to the dynamic integrity of the valve/actuator combination, an additional specific test program was planned and conducted in France to demonstrate the performance of the complete size 30 (DN 750) valve assembly built at RVSA. These tests were performed
Hot functional testing had previously been conducted on a size 16 (DN 400) Equiwedge gate valve, as reported in Reference 1. However, as part of the qualification of the MSIVs for the EDF 1300 megawatt PWR stations, a full scale hot functional test was conducted on a complete size 30 (DN 750) production valve with a Rockwell A-290 actuator. Since the function of the MSIV is to close quickly when required at any time during the life of a nuclear power plant, it was necessary to show that the Rockwell Equiwedge gate valve and Type A actuator can operate reliably and perform their required function under the normal service conditions in a PWR. A procedure was developed, and a test program was conducted at CETIM laboratories in Nantes, France. The valve used for this test was the same as had been used for the other tests described above. The test arrangement capped pipe extension were connected at each end of the valve, and the valve and pipes were partially filled with water. Heated oil in jackets outside the pipes generated saturated steam inside the test assembly. The test procedure required that the valve/actuator combination: Perform at least 400 full-stroke, fast closures using both actuator hydraulic 6
Post-Test Inspection
References
1 . E. A. Bake and R. L. Clapper, QUICKCLOSING ISOLATION VALVES THE EQUIWEDGE ALTERNATIVE, Rockwell Technical Article V-Rep. 78-4. 2. E. A. Bake, THE ROCKWELL TYPE A STORED ENERGY ACTUATORDEVELOPMENT AND QUALIFICATION, Rockwell Technical Article V-Rep. 80-3. 3. E. A. Bake and J. B. Gallagher, QUICK-CLOSING EQUIWEDGE- ISOLATION VALVES ONGOING QUALIFICATION, Rockwell Technical Article VRep. 82-2.
Acknowledgements
The authors wish to acknowledge the many contributions made by others to the planning and performance of the tests described in this article. In particular, recognition is due to J. B. Gallagher (Pittsburgh), Y. Portefaix (Unieux), and G. Rouchouze (Unieux) who devoted many long days, nights, and even weekends auditing, observing, and writing reports on the tests conducted at Unieux, Paris, and Nantes. In addition, we wish to acknowledge the contributions and suggestions of many people (too numerous to list here) from CETIM, SOPEMEA, Framatome, and EDF who were consulted during the plan8
Edward Valves
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