ML18047A353

EPRI Summary Rept:Westinghouse Gate Valve Closure Testing Program, Revision 1

ML18047A353
Person / Time
Site:	Palisades, Midland, 05000000
Issue date:	03/31/1982
From:	Collier D, James Drake, Leri M WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP.
To:
Shared Package
ML18047A350	List: ML18047A349 ML18047A351 ML18047A352 ML18047A353
References
RTR-NUREG-0737, RTR-NUREG-737, TASK-2.D.1, TASK-TM EM-5683, EM-5683-R01, EM-5683-R1, NUDOCS 8206100268
Download: ML18047A353 (81)

Text

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l.LJ c:: WESTINGHOUSE ELECTRIC CORPORATION 0  :..

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ELECTRO-MECHANICAL DIVISION.

. L.l.J co

i: l.O CHESWICK, PENNSYLVANIA in.

l.LJ EPRI

SUMMARY

REPORT:

WESTINGHOUSE GATE VALVE CLOSURE TESTING PROGRAM March 31, 1982 ENGINEERING MEMORANDUM 5683, REVISION 1

• APPROVED BY:

~-p,E.

WRITTEN BY: ~ A

~(\. ~'t?E.

D. R. Collier, PE James A. Drake, PE Manager, Corrmercial Nuclear Manager, Valve and CROM Eng.

Products SK/WANG 1322E .

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Michael A. Leri, Engineer Valve and CROM Engineering

• 8206100268 820601 PDR ADOCK 05000255 p

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RECORD' OF-:REVISIONS; -*,,*

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Rev. :O *Ori gi ha 1. ls sue ...*.*

Report was. r~vis-ed to. i ncorpora~e EPRI

- Rev. l

.*. c'onirnents' to .. i n'corporate steam; friction )is ting ' .

data, and to correct several tYP,ographical errors

• ABSTRACT This report discusses the r~sult.s of testing run* by Westinghouse on EMO gate valves to determine the cause of the valve closure problem uncovered during the EPRI/Marshall PORV and.Block Valve testing. Based on these results, conclusions are dtawn on how such problems can be avoided in the future.

This report was specially prepared to support the Utilities through EPRI Block Valve testing .

• II Page i

EM 5683, . Rev. 1 Page O-*

TABLE OF*CONTENTS 1-1 ABSTRACT i

1.0 INTRODUCTION

1 2.0 EXPECTED SERVICE: PORV BLOCK VALVE 2

2. 1 Philosophy of Use 2 2.2 Fluid Conditions 3 I

I I

I 3.0

SUMMARY

OF MARSHALL TEST DATA ON EMO GATE VALVES 4 I 4.0

SUMMARY

OF WESTINGHOUSE TEST RESULTS 6 I

4. 1 . Introduction to WEMD Valve Terainology 7 i 4.2 Flow Testing Results 12 i

! 4.3 Mechanical Fixture Testing 41 I

I 4.4 Friction Factor Testing 50 I

5.0 CONCLUSION

S -76 6.0 ACKNOWLEDGEMENTS 78 7.0 DISTRIBUTION 79

, . {. *.. ' .

. E.M 5683 ~: Rev.. 1

.. Page l - ,,'

1 .O. INTRODUCTION. -*- ,*

The EPRI Marshall Stearn test+n9. of: the Model 3GM88 in Ju1y. and Augus*t; 1980~

• 1 ** represented the first incident. where a* Westinghouse de.signed valve failed to *

.*. * , .

• c1ose aga i:ns t i tS sjlec 1f i ed fl ow and* di ffOrent1 al. pi-es sii re cond i t1 ons. The stern t~ru.st required to*close the valve was 1Jeasured using axial-type strain gages and the resulting forces were considerably higher than expected *.

• • These.results were discussed_ at 1ength in several *subsequent Westinghouse*.

meetings~- Although the EPRI results were co~sidered extreraely important,iit.

. . I was generally concluded that the problem waslirnit~d and*was assumed .to be*

• * ... related to the high temperature, high fl~w, ~nd high differentiaJ *pressures

.~WJ associated with the steam fl ow testing cbnditions present.

I. '*.

Il When .several more Model 3GM88, Westinghouse gate valves.-fai.led to close during I

I room temperaure, high flow and differential pressure water testing at the i

I Alrnarez Nuclear Station in Spain i.n early-October, it ~1as :concluded .that a i

I. generic p_robler.i existed. Based*on this conclusion, safety-review committee I. . . . . .

1 *.meetings* were held and the utility customers were.notified under the

• requirer.tents of 10CFR21 and 10CFRSO.SS(e) .*. Several internal .Westinghouse I! r.ieetings resulted in.a series of tests and analyses to detemine the cause of I

the higher than expected closing loads that were leading to the valve failure.

I l

i l

The purpose of this report is to review that work within the specific context i

1*'

of the PORV .block valve applica.tion and to draw some general conclusions applicable to the.Westinghouse. EMO gate valve. design and possibly to gate

~alves in general.

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• 1 EM 5683, Rev. 1 Page*2 I -*-~

2.0 EXPECTED SERVICE Ii I

I- 2.1 Philosophy of Use All Westinghouse pressurizer power-operated relief valves (PORVs) are provided with isolation valves (block valves). The-function of the block valves is to isolate the PORVs for maintenance purposes and to isolate

_the PORVs should.excessive leakage .occur during non;ial operation.

I Additionally, the block valves provide ~he operator a aeans to isolate a I failed open PORV following a pressurization transient in which the PORVs I opened to relieve pressure.

Proper operation of the PORVs and their associated block valves are not I

I II required to mitigate the consequence of any design basis accident.

/:.,.

! Failure of a block valve to isolate a failed open PORV would result* in a sraal 1 LOCA. Analyses of small LOCAs to incl ud~I failed- open PORVs have i'

been perfon;ied. 1 1 "Report on Small Break Accidents for Westinghouse NSSS System, 11 WCAP 9600, Volume III, Section ~.3, June, 1979

• EM 5683, Rev~** l * *

• *p~ge 3 .

• 2~2 Fluid Conditions

.The fluid conditions occur.ring at*thetir.1e a.blo~kvalve would be requfred to close will' vary .considerably, d,ependent upon the.

transient .

,. . anQ '.

the' .*tir.le into the.* transient at which .ttie. . operator< took . '

acti (in to. .

close the. valve~ Additionally, trans5etit response;* hence fluid conditions depend upon system parar.ieters that vary from plant~to.;.plant.

Due to the-wide range bf fluid conditioni pos~ible, yalve:specifications addres~ enveloping condi~ions~for valve perfor~a~ce~ The design pressure

. and temperature for the block valves a.re 24.as psig *an~ 650°F,

• . respectively.

The. i n:l et fluid c.ondi tions for the* PORVs are reported: i ~"an EPRI: P.eport 2.* Discussed are FSAR events.that.produce the greatest. challenge to the syster.i for steam* and water discharge through the valves *. Additionally~

extended* high pressure injection and cold overpressure events are included.

.\

2 Meliksetian, A. AndSklencar, A. M., "Valve Inlet Flufd.Conditions*for Pressurizer Safety and Relief Valves in Westin~house-Desi.gned Plants,"

EPRI Research Project V1Q2-19, Interir.i Report, Deceaber, 1981.

• ,* *;- t, '

EM5683,.Rev. 1 Page 4

• I .

i. 3.0

SUMMARY

OF MARSHALL TEST DATA ON EMO GATE VALVES

.I During late-june, July, and August, 1980, EPRI tested a WEMD Model 3GM88,

• • 1.I ..

3 ... -1500 class valVe in a stear.i flow system at Duke Power's Marshall Stear:t I

. Station. Later, in January, 1981, they also.tested a WEMD Model 3GM99, I 3 11 -1500 class. The results of this testing is described in the 11 EPRI/Marshall I

Electric Motor Operated Valve (Block Valve) Interir.i Data Report."

I I1 . Pretest check-out began on the 3GM88 in late-June with a Rotork 14-NAl II

• .i i I

• actuator supplied by Duke Power. Problems were encountered in closing the valve against flow so the 14-N.Al was replaced with a Rotork 16-NAl. When

-further probl er.is were encountered, the valve stern was strain gaged and valve I

I

! closing loads and actuator* output loads were r.ieasured. Based on lir:iited i

1

• strain gage results fror.i July 22 testing, a Lir:iitorque SB-00-15 actuator was j *selected for this application and in Au~ust the valve and actuator I successfully passed the EPRI testing sequence.

i I

i

• ! The 3GM99 valve was supplied to Duke in Decrneber.., 1980. As shipped it uti 1i zed an SMB-000-10 Ur.ii torque actuator. By January, 1, 1981, Westinghouse had cocpleted sufficient testing of its own to conclude that the SMB-000-10 actuator was not sufficient to close the valve against the pressures present in the EPRI tests. On January 12, EPRI tested the valve against stear.i flow

.[ and the valve failed to close fully. The valve was returned to WEMD and the SMB-000-10 was replaced with a properly size SB-00-15 actuator. In

• late-January,. this configuration passed the. EPRI test sequence.

.* . 1

.: EM 5683*~ Rev. 1

.- I

- I

• .Page. 5 . * *.*,.I Ster.i strain gage data was only collected :o:n* .the two Westinghouse valves because of a specj al request b./ Westi nghotise*. :. The* val~e stems* of 'the,c6ther,,

Si~ valves tested: by EPRI were not strain-gaged.*. Becau~e the strain 'gage data:

( .

... was a special request by Westinghouse and'not pa.rt of the. fon:iaf-EPRI prograr.i,:

the*records and data were not controlled in a rigorous -manner *. Recently.EPRI

• providedWEMD with strain gagedata*on both t'1e 3GM88 andJGM99 t~sts at:

Marshall. .However, the available calibration infomation was-sketchy and ~e, I I

could not convert th_e voltage output to strain or 1oad. EPRI and WEMD had .

• both hoped that this data could be used .. to. verify. the conclusion- that. th.e closing loads for_high temperature stear.i flow are slightly higher than those r.ieasured for cold water fl ow. -

The limited -load data *developed by Westinghouse from the_ July 22, 1981,

.testing at Marshall is-insufficient to confirm the.cont;lusions and tendencies

~GM88 - **

noted in.the var.ious Westinghouse tests that are-discussed.in.section 4.0 of

. this report.

. *1

• EM 5683, Rev. 1

• 4.0

SUMMARY

OF WESTINGHOUSE TEST RESULTS Page 6 .

~ . . .

To detennine the causes of the higher than expected stern thrust measured during the EPRI Marshall Steam Station tests and during the tests at the Almarez Nuclear Station in Spain, the Westin*ghoiJse Electro-MechaniCal DJvision undertook three testing programs. The first and most* important of these programs involved water flow testing. Approximately sq separate flow tests were run against 60 to 600 gpm flow and 1500 to 2600 psi differential pressure. These tests were perfotT.Jed using the safety injection and charging I pump manufactured by the Pacific Pumps Division of Dresser Industries and the I

I testing loop at Pacific Pumps that is used to production test this type of pur.ip *

. The second testing program, called the rnechanical fixture test, utilized a

• **hydraulic.cylinder to applY. sirnul ated fl ow 1oads to the valve disc. i The purpose of this test was tJ study load loss due to backseat frictio~ reactions I

or due to friction at other load points inside the valve. Since the valve was only partially filled with water, strain g*ages and dial indicatqrs could be er.1ployed to r.ieasure the internal strains*-and deflections. This type of instruaentation could not be utilized in the high pressure, high flow water

'I i testing.

In early technical reviews on the closure problem, a higher than anticipated seat face friction factor ~1as i den ti fi ed as a potenti a1 cause of the higher loads. Because it is difficul.t to accurately.extract seat face friction

' .. l .

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• *page* 7 .-

. EM* 5683(.Rev~ l- *.

factors. fror.i the available fl OW testing. data, Sp~Ci al. fri Cti on factor tests

• were cornr.iissiotied. This testing epiploys* small sar.ipl~s cut fror.i the faces of -_

• • .

• actual.discs (wedges} and seat rings *. The sar.iples were lapped to have' the sar.ie finish as production valve par~s *

' {' ' "

In.this ~ectio~ of the report each of these tests. an.d their results will -be.**

discussed in detail. A discussion of ten:ii_nology .is also provided to help.the reader *.

4.'l Introduction to Westinghouse El ectro;.:Mechani cal Di vision Valve *ren:ii nol ogy

4. 1. 1 . Load Terninol ogy--A rather standard ~equation has been used for a number of* years to-calculate the.ster.i thrust loads required to*close a Westinghouse designed .wedge gate valve~

Closing Valve *Di SC* .. Stem . Packing . '.

Stem = Factor *x* Differentfal* .+ Pressure*+* Drag Thrust Pressure Load End Load .Load

• For a wedge gate valve, the valve factor has normally been assur.ied. -~*

to be 0.3. This type of sir.iplif.ied equation appears in the *sizing

.1 iterature of aost actuator manufacturers.

• If. one considers nornal **

gate valve seat angles, the valve factor corresponds. to a seat

. friction factor of* about p = 0.3.

• ..... l "

EM 5683, Rev. l Page 8 Figure 4. l-1

.1*

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• PrOwoion to Mount S-lcMs on Yoke E*ltmal Limit --------!

--~~ .-i+-------Two-Piec9 Gland Design. Stainlen SI... Gr.nd Studs *nd Nu11

---3--..,.---uniom*Aiftc:i P>ek"'v Gland With LHkaH Pipe

.... EM 5683,* Rev: -.1

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• .>page 9

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• • To simplify this ten:iinolow for.:the *purpo*s~ of computerizing t~e:

• . cakul ation, the equation was writ~en in the form: *,.

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~~ ~0~3 F1 + F2:+ F3 Where F * = Required Closing Lo_ad

.* .*. 4.

. '.*' 2 p *.

. F = Disc Differential Pressure. Load Fl =1f'D2 1 2

. o2 = Seat. Face Inside Di arneter 4

. P2 =*Differential* Pressure

• F2 =Stern Pressure End.Load 1YD2 ** P I

F 2=1*4 .. l

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.*o4._ = Stern Di araeter J>

1 ._=.Bonnet Pres.sure or Maximum Design: Pressure

EM 5683, Rev. l Page 10 Some of these tems appear in the discussion or the figures that follow.

At sorae time during the flow testing program the tern "pure closing" load was coined. *This term refers to the load that is actually overcoming the friction and flow forces present within the valve.

In words, pure closing load eliminates the stern end load and the packing drag from consideration.

Therefore, Pure Valve Disc Closing = Factor x Differential Load Pressure Load Qr. in ten:ts of simplified variables, F = (VF) 7 Fl = F4 - F2 - F3 Where, F7 = Pure Closing Load, and VF = Valve Factor

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'* .; *.*.-. EM 5683~ Re*L l

• Page 11

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.. *, Model -Nui:1berTenninology~-Each valve.manufactured by WEMD has-~*

unique, 24..;digft .identification nurab'er

'that

.completely describes 1t~>.

The first* 12. digits of the: i 9entific~tion number.is nomal ly called* *.  ;

',. J

.. j the val.ve model number. An ex~raple of.*such.a rnod~l number is: , 1

. i 0 4 0 0 0 G M 8 .8 F N H IM~tor TSize Ins~lation Class .\

• Design-.-._...,.

• Gate* Pressure Operating**. DP .

I

.Variation Valve ... Class ... Speed

. *Motor*----- ----Body Materi a1 Operated &Code Class In words, this is a 4 11 -1500 class gate valve made from 316 sst to

\

ASME Class 1 *requirer.tents with' a fast . . operating*c1ass .. H r.iotor

• operator that can close against 2750 psi.

l i!

For a case where some of these details* are not necessary this nur.iber

• is* often* shortened to 4GM88. Ii

EM 5683, Rev. 1 -

• 4.2 Flow Testing Results

• Page 12 Over 50 sets of flow tests were run over a period.of 14 months to study the closing characteristics of the EMO gate valve design. Valve models tested during the program included: .*.

2 valves Model 3GM88 2 valves Model.3GM99 1 valve Model 4GM88 1 valve Model 8GM88 Li mi torque r.totor operators tested included. Models SMB-000-10, several SB-00-15, SB0-00-15, SB-0-25, and SB0-2-80. Other equiprnent tested I included several Limi torque operator torque switch spring packs and

• modified valve internal components.

I I

II iI 4.2.l Introduction to the Flow Testing*Prograrn--The EMO motor operated gate valves were tested in a closed* l~op hydraulic syster.i with flow .

provided by r.ieans of a 600 HP centrifugal pump identical to.those used in {4) loop, Westinghouse designed plant for charging/safety injection service. Pump characteristi!cs were approximately 60 GPM I .

at 6000 feet head and 660 GPM at 3000 ,feet head with flows and

• pressures adjustable within those units.

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• Des.ired flows and pressures were obtained by controlling. the.

• Page 13 i:iodul a ting valve in the pump -~ypass .1 i ne and the modul ati.lig valve ,

• dow~stream of the *EMO. gate v:a 1ve*.

• Flows of 600 G.PM to 100 GPM and

• differential. pressu.~e of 2550 psi to 1500 .psi: were imposed on the "-

I

• - va1ve. during testing. Power to the*charging/sa.fety injecti 9 n ~ump.~

was obtained .from a di esel-*generator ~

System and valve pressures were monitored via pressure transducers

• either mounted directly .in the hydraulic loop or the* valve *. Suction

-water te~perature was monitored by a thennocouple. Valve flow.was

• _ detennined using a venturi-type_ flow meter. Valve stem load and travel were detennined.

by means-of strai*n .gages and _a position transducer, respectively *. v*i bration or* noise characteri sties *of- the valve during the opening.and.closingcycle were monitored by ari *

. _acce 1erometer* attached to the val i/e body adjacent tcr the valve seat.

)

I

.The -test valves were equipped with flanges on the inlet and outlet and the .valve was installed *in a horizontal line with the bonnet vertically upward* with- ten (10} .d,iame~~rs of straight pipe upstream

. and downstream of-the test valve.

Figure 4. 2-1 shows .a typical head/fl ow curve for the type of pump used in the testing.and Figure 4.2-2 shows a photograph of the test loop. Figure 4.2-3 shows the details of the *instrumentation

. mounting*.

EM .5683 , Rev. 1 .

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PUMP FLOW *TEST* SCHEMATIC FIGURE 4. 2-2 I

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EM.5683~ .Rev~ *.1

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• The Effect .of Cycl in*g. on Required* Cl ~sing Load--In the EP.RI/M~rsha~J

• *.4.2.2 testing and. in the ::Alr.iarez* star*t-up testing. the valves h~d always * :'. ***

• .. '. . * * ** . * - ***. l ., * * .. - - ** .

. closed successfully for several cycles *before *the failure toclos.e *:

occ.ured. This: indicated* some kind of cyclic phenomenon was i nvo 1ved *

To. study ihi s *characteristic each valve was repeatedly cycled open .

and closed once every two cinutes against 6o'O gpr.L_full-open flo~ and.

2600 psi rnaxiraut:l differential pressure *. The stet:l**strains *were

.-monitored us.ing an oscillograph *. The result.ing sten .  :

t~rust requir~d to force the wedge to the closed'.position was.determined and plotted against cycle nuraber.

F_igures4.2-4, 5, and 6 are.typical examples of the results. They show. that the. required closing *load :or pure closing .load increases * *

. with repeated cycling for 25 to. 100 cycles and then.levels off'.or drops sligh~ly~ I

• It was* also detennined during the *testing that the r.iagnitude of the closing load is a -function of the. time* delay be.tween cycles.

Typically during a one-hour 1 unch break the re qui red closing l oa~ .

would drop 15 .Percent. However, within Sto 10 cyles*the load would return to its prepause level.

The results.of these -tests clearly demonstrated that.the steo thrusts that were original1y used to select the valve motor operator are

. significantly too low. To deterr.iine

. what.actuator. sizes

. valve.s actually require, a new closing load equation was/ requfred.

Such an equation was developed f:rom the data shown in Table 4.2-I.

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. EM 5683, Rev. 1 Page 22 Based on data shown in the tabl el which is the average of: nur.ierous tests, and ..

considering the effect of pause time, the exp,ected cyclic usage of the valve,

.* and the slightly hfgher 1oad re qui rer.ient expected at higher temperatures, WEMD has settled on the following equation:

• .' .... ~

In using this equation one ~ust give proper consideration to picking a conservative packing drag level, to adding any other load losses associated with the particular gate valve design in question, and to the operator

• dynar.iics issues discussed in Section 4.2.4 of this report. With the proper consideration of these issues, the equation provides a generalized, conservative.tool for sizing actuators for high pressure services

• EM *5683,. Rev. 1 Page 23 4.2.3 Effect of Flow and Differential Pressure on Closing Loads--Prior ta.

running these flow tests, closing load was judged to be related to

~pplied differential pressure~ as the required closing load equation indicates,.*but the effect of flowra:te was not clear. To determine

• the actual relationships between closing load and differential pressure and between closing load and flow, a series of tests were run where these parameters were varied.

Once the closing load had stabilized at the maximum flow and differential pressure, the loop control valves were manipulated to provide either lower flows or lower differential pressures. To reduce the final differential pressure, the pump miniflow control valve was opened increasing the bypass flow. Therefore, when the test valve is closed, a smaller differential pressure exists across.

the test valve because the system flow resistance is decreased and the pump is running farther out on its head/flo~1 curve. To reduce the flow through the test valve, the downstrear.i control valve is closed farther. This increases the flow resistance of the system when the test valve is full open driving the pump back on the head/flow*curve.

Figures 4.2-7 through 4.2-10 show the results of how varying differential pressure effects the pure closing load required to fully close several valve models *. From test-to-test the loads vary

.slightly but in any given series of tests the results clearly show the re qui red pure closing load is directly related to the full differential pressure present once the flow passage is sealed.

EM 5683, Rev. 1

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. EM 5683, Rev. l Page 29 Figure 4.2-11 through 4.2-14 show the results of how varying the ,

full open flow through the. valve, while holding the final differential pressure constant, effects the pure closing load required to fully close the valve. Th.ese curves indicate that flo\~

rate is not an important parar.ieter in whether a valve will clo~e and.

it can be ignored in any equation to predict required closing loads~

EM 5683, Rev. 1 Page 30

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• Page 34,'

4.2.4 Operator Oynar.tics--During the flow testing a number of different operator load output changes'were encountered and some special

. *testing was done to attempt to quantify these reductions in 1oad

~' .

output.

To begin each flow test sequence a so-called baseline"test was run against no flow and no pressure to determine the packing drag and the operator output. Then the pump was started and the cyclic tests against fl ow and differential pressure were begun. In each of those tests a drop,in final actuator output load was noticed from the baseline case to the first flow cycle. This drop is assur.ted to be due to the lower motor speed when the operator runs against pressure loads. The, lower motor speed results in less motor inertia once the*

torque switch trips and this results in less output. The amount of output drop varies from operator-to-operator and is probably rela~ed I I to the mechanical advantage of the power tr~i n function of torque!

switch.setting.

Special testing was perfonned to study this effect. Table 4,.2-11 and Figure 4.-2-15 show the results of such a test on an SB*00-15 actuator *

':'. . EM *5683; *Rev~ 1

• ** * , - i Page 35

.-*,1_.,,..:

The* *second output change that* was* notited cfu*r~ng the flow te~ti.ng .

w'as a drop in :operator output with. cy.cl es~

• Figure 4.2.'.i,6 sh9ws *how * . (

the final output or wedging'.load of an SB.;.Q0-l5*unjt was effected~by

. cycling *.. At first thiS drop*was. assumed.to* be .due to* changes :in motor inertia as the closing .load*i11creased ...*.However, 1:1easurement (

o.f the to.rque s\'li tch trip 1oad showed ft was a1so dropping. Next, it was assumed that the drop was *due* to heat.:.up of the r.iotor *.

I.

• Discussioh

. I. .

with Limftorque indicated. that their testing, which is.

concerned with .output torque, did not show such drops in output. At

-i this poin't rosette strain' gages were applied to.tlie.valve' ster.1 and.*

\

. .the'. output* torque .from the acme. power screw was 1:1easur:ed. The.*. **

'. A::"'

results of* a typical test are included on Figure 4.2-16 *.

_The increase in stern torque shown in the figure* indicated a change in the efficiency of the power s.crew. Calculations based on this data .shewed that ~he'*drop in output is due to an increase in friction*at the acme threads.* Figure 4.2-17displaysthese results *.

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TABLE 4.2-II OPERATOR OUTPUT DROP DUE TO MOTOR INERTIA Torque. Flow Differential Operator Output Operator Output Switch .. gpr.a Pressure Load-5000 series Load-5900 Series Setting psi Lbs. Lbs.

2.5 0 0 23,415 32,725 2.5 . 600 2550 21 ,665 29,400 2.25 0 0 21,665 28,875 2.25 600 . 2550 19 ;600 . 26,950 2.0 0 0 19,285 26,250 2.0 600 2550 17,500 1.75 0 0 17 ,360 22,575 1.75 600 255.0 16,380 20, 125 1.50 0 0 18,900 1.50 600 2550 .17 ,325 1.25 0 0 ------ 17 ,325 1.25 600 2550 ------ 15 ,400 1.0 1.0 600 0

2500 0 12,425 10 ,010

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• 4.3

• Mechanical Fixture Testing* *

• '4~3.1 . Test F1xture..:*-The -test fixture set-up *is shown in Figure. 4~3~1 and

. 2~ The WEMD. six- and eight-inch production valve **test: *stand was.

i:'aodi.fi ed on one .end. to support .af1 n..:.square-i nch bore hydrau*l ic * *

• cylinder* (Enerpace Model Rc.:.:so_6). The .hydra*iilic pressure control

.system.consisted.of a. nitrogen gas bottle (2200 psi) with 1l pressure * .. **

regul"atorand an acc1Jmulator.

The accumulator .. - ... -was connected to the

.*. hydraul.ic cylinder and also* to. a.hydraulic *ha~d. pump to* provide ~ *

. . :1 ',' . . .. ' .

initial charging of the accumulator. This* set-up I pemitted the.

• hydraulic cylinder plunger to travel i .n. and: out during valve opening

. I ** \ * .. and ciosing strokes while maintaining a*constant applied load.*

.\

Thehy,draulic load was applied to the valve*disc through arac bolted to the hydraulic cylinder plunger (Figure 4.3-3). '

The ram

• I was designed to hold.various size cac. follower bearings which*

-transmitted load to a flat machined in the valve disc. A nylon

• sleeve fitted with. O'."rings was designed.to seal on the.OD of the rar.1

• and.the.ID of the valve bore. This configuration *permitted the ram to travel back and forth in the bore, as required during-valve*.

stroking, while maintaining a low pressure wat*er tight seal.

. '. ~ ..

i

• *_ **.<'Page 4_2 .

• A. r.ecording oscill ogrp.ph was us~d to ~ec~r*d dynar.t.ic .data during* the_

test.* Motor voltage,' ram load*and stem .strains at t~ree :locations

'. * - . . . . * : '. . *, ' . '. ' ' * -. ' - .. r ~ *. * '. . . ', . . ' ' . ' ..

-- i w~re measured.* Stera strain *.wasj:1easured below the:torque: ar~".,./ith i

1.

two *120 ohm gages 180° apart and a'bri~*ge cfrcuit to measure axfa1:

load with .bending.. . .

cancel atfon." . Two. .-180°.

gage. .

.pairs were .

1ocated *

-on the st~m 11/2 inches above the back~eat 90° apart. The* pair

. in".'"1 i ne with the va1ve... bore centerline

. . . .was bri d,ged to measu.re bending~ whi"le'the pair perpendic!Jlar to* the bore was bridged to

- measure axial_. load with bending* cancel ation. Valve* stem i nterrial gage 1eads .were brought outside the valve ;through *a view window machined in the bonnet. -

. The** test *program procedure consisted of: fi 11 ing the valves wJ th

• water through the. ban.net access hole. and *applying the hydraulic *ram .

I .* .  : *. - . . .. - .*. -

.* lioad to the disc *.. The ram load wasr.iaintainedconstantly as the I . "' . . '

~alve was cycled, with closed dwell times of approximately two seconds and open dwe 11 tir.ies of approxir.iately two minutes.

Oscillograph traces were taken on every other cycle.

1.,,._*

. EM 5683 ' :Re*v. *.1

-* . .l Page 43 t!

MECHANICAL .TEST FIXTURE FIGURE 4.3-1

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.EM*568311 Rev.:.1*

. Page 44 MECHANICAL TEST FIXTURE FI.GURE 4. 3-2 *

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• SulTllilary of *Results-~The object .oLthe test *:program* was' to. deternine <

the backse~t/stelil i nterac1:i on and. the di sci seat face. fri 2tion. factor' . '

as a functio"n _of opening and clo~ing *cycles.

• In* ac:idition, th.e internal bending)train gages. pr<>v"ided .ins.ight to the stern side

'l' :* .*.-

• *... , ..-* * * " * ** ...*_ *>. - 1oads ***:

Figures 4.3-3, .. 4, and 5 *show the effect of valve.cycling on opening

• and closing *loads for the threetestvalves.*.. Both the*internal aiid external axial stem :loads are shown for each valveo All thtee valves exhibited sir.iilar load build-up characteristics with

• cycling.* The r.iagnitude of the opening aryd closing 1 oads increased

.with the number of cycles until *30 to 40 cycles were completed; The I '

.. ' . loads stabilized after this point, apparently due to "wearing in 11 of the surf aces. I

• • • .  ::~;- I I

I These figures also shJow the absence of any significant backseat/ster.i l 1

1 I

I load loss.* The difference in the* load values between the internal

• .*and.external* axial stem load is due to the:packing drag plus.any

• . backseat 1oad 1ass~ The dashed curve on Figures 4~3-4 and 5

• represent the external stem load minus *the'paCking drag. The distance between the dashed curve and the internal *stem-load curve represents the backseat to stem load loss *. Figure 4.3-3, the 3GM88.

valve,. do~s not show a dashed curve since there was no back.seat/ster.i load 1ass; i.e., the only difference. between the internal and external axial load is packing drag.

• ar.iount of stem load

. I The*3GM99 had the largest

' I loss:I at the. backseat of the .three vaJves*:tested.

• 1 I . **  !

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• 4.4 Friction *Factor Tests--As was discussed in the introduction, the friction**.

f.actor tests were cornmissio~ed *to provide* infon:iation about seat face.*

frii:tion factors. Friction fac.tors.can be calculated fro1:1 the fl ow

. testing data, but the assurapti ans that are* re qui red in the: cal cul ati on r.iake the r'esults somewhat questionable~* Also the* flow test ter.iperature and*bearing*stress range a~e.limited*and difficult to modify.* The direct measurer.tent provided by' the fri ctfon te.sti rig machine e 1imi nates those '

calculational uncertainties and makes the other variables.easier.to study.

• *The disc seating faces and the seat ring faces: in the Westinghouse gate.

• valve de.sign are hardfaced with.Stellite 156materiaL This hardfacing alloy is the powder form of Stell;.te 6 and is applied to a stainless steel forging using a plasma transferred ar~ welding process. Thesr.tall safolples required for this testing were cut from actual disc and seat

• fai::es*that had been hardfaced, machined; and lapped to a4..:.a microfinish, frosted surface.

I Figures 4.4-1 through 4.4-4 show the Westinghouse Research and Development Center testing devices that are used to perform the friction factor testing. The sliding stroke* length used to generate the data that*

follows was+ 0.375 inches for the water device and.+ .10 for the steam device with one cycle being run every minute.

At the time this report was written, this testing program was not completed. The data generated to-date*. is di splayed in Figures 4.4-5 through 4.4-22. The* remainder of .the testi'ng sequence will include further pause time and stroke length testing I

~o\. help quantify these I ,

variables more completely.

. EM 5683, Rev. 1 Page 51 Table 4.4-I sur.1r:1ari zes the tests perforned with the resultant friction and wear results.

The test data .generated to-date sho.ws: *

1. that at room ter.iperature the friction factor will increase from as low as-0~12 until a level of 0.4 to 0.75 is .reached at lOOuto 200 cycles and then level off or drop slightly (see Figure 4.4-6);

2 * . *that bearing stresses.in the 4,000 to.12,000 psi range have little or no effect on the .r.iaximum friction factor reached *(?ee Figures 4~4-6 and 4~4~7).

• 3~*. that'.at*l80°F*the shape of the curve is sir.Iilar but.the*magnitude.

• is hi,gher than at room teiriperature with *peak values,of: 0.64 to~;l .00

-(se~figures 4.4~8 through.4.4-12);

• 4. that at extended cyclic lives, the surfaces apparently degrade and

• - the friction factor increases again (see Figures 4.4-13 and 14 l; 5~

• that changing from borated .water to* deionized water, has* -1 ittle *or no effect on friction factor (see Figure 4.4-15);

6. *

• that applying lubricants such as colloidal graphite increases the number of cycles required to reach the maximum friction level (see Figures 4.4-16 and 4.4-17);

~ .* ..,

STELtiTE 1-56 veRSUS STELL.ITE l S6 '

TEST CotlDITIONS FRICTION - -- .AVERAGE ----

COEFFiCIENT WEAR.:..r.1qi:'ls PRESSURE TEt1P. . . NO *  ;

TEST NO.- TEST ENVIRONMENT PSI . - Of CYCLES INITIAL FINAL BLOCK PAD 1 Water~4,000 PPM Boric Acid -4,000 180 100 .55 ' ~ 75' _- ' -** 7 . LO 2 Water-4,ooo- PPM Boric Acid ----4,000 180 250 .50 .68. .5 .8 3 Water-4,000 PPM Boric Acid 4,000 180 500 .38

• 74 ' 1.3_ .6 4 Water-4,000 PP~t Boric Acid - 4,000 180 1,000 '.38 .92 L6:  :

2.0' 5 Water-4,000 PPM Boric Acid .4,000 180 2,000 .46 .84 4.8 3.3 6 Water-4,000 PPM Boric Acid 4,000 70 2,0QO .12 -_ -.34 3.5 *- 1. 7 7 Water-4,000 PPM Boric Acid 8,000 .70 2,000

• 16' .36 1.2 1.5 8 Water-4,QOO PPM Boric Acid -o,_ooo 180 5,000 .31 .86 25.5. 69-~0' 9 Water-4,000 PPM Boric Acid 10,000 70 5,000 .3.2 ' -

~74_. .4.5 4.5-10 Water-4 ,000 PPM Boric Acid ' 10,000_ 18_0 5,000 .31 -~4 ' 32."4 70.0 -

11 Water-4,000 PPM Boric Acid 12,000 70 5,000 .2_1 .48 9.0 2~5 12 Water-4,000 PPM Borit Acid 12,000 180 900 ' .49 -. .69 8.6 -- -

13.3  !

13 Dry 4,000 70 2,000 .27 .29 17.3. 46.3 14 Dry 4,00Q . 180 2,000 .29 .28 13. 7 56~'5 '

15 Steara 4,000 550 2,000' .51 ~31 +l .5 ._ 13.5 16 Stear.i 8,opo ,550 2,000 .58 *28 - 14~0 . -; 34.; 7 *' -

17 Water + Neolube on sample* 4,000 70 2,000. .09 ' .. .41 *. 7.2 .4

--18 Water

. - +. Neolube on sar.iple 4,000 180 -2,000 .27 .93' -_ 5.3 1.8

__l9 Water+ DGF'on saraple** - 4,000 70 2,000 .07 ' - .45 4.8 4.2 20 Water + DGF on sar.ipl e 4,000 1(30 2,000 .27 1.01- 1.7 ' '5.9 _-._

21 Deionized Water 4,000 180 2,000 '~34 1.03 '

• 9: 3.8 i

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• 21 .59 N/A .: N/A '11  ::=:

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• • raphite/Aerosol .< --

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. EM 5683, Rev. 1 7.

Page 53 that limited dry data indicates little change in friction factor occurs.with cycling, and that the friction.level is approximately 0.3, but that wear is significantly higher than in the water or steam cases {see Figures 4.4-1.8, 19, and 20};

8. that with 550°F steam, at *1 east.* at a + O. 1 stroke 1ength*~ the friction factor starts in.the 0.5 to.0.6.range and drops-rather quickly to approximately 0.35 {see Figure 4.4-21); and,

9. that pause time under load {simulating valve in closed position) increases the friction factor and pause time under no load

{sir.iulating valve in open position) decreases the friction factor.

Th.e tendencies visible in this data agree with those seen in the flow*

testing and the mechanical fixture testing *

~ . "'...-" ..

• EM 5683 , REV. 1 PAGE 54 *.

FRICTION fACTOR TESTING DEVICE FOR WATER AND DRY .TESTING FIGURE 4.4-1

. .. . . ' \.

EM .5683, REV. 1 PAGE 55 i .,,.

~ .* '

FRICTION FACTOR TESTING DEVICE FOR STEAM TESTING FIGURE 4.4-2

EM 5683, Rev. 1 Page *56

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Drive Kocor 1&11 Sc rev

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EM 5683, Rev. 1.

Page 58 .

Stainless.

Drive

• Drive Alignment Shaft

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i '

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SCHEMATIC. OF TEST SAMPLE HOLDING FIXTURE FOR STEAM TESTING FIGURE 4.4-5

EM 5683, - Rev. 1 Pag~ 59

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.. Page 76

.e 5 .O CONCLUSIONS

• Based on the data presented in this report, the following conclusions have been reached.

l. *The valve closure problems.encountered by.Westinghouse.valves-during the*

EPP.I/Marshall PORV blo~k**valve testing~ and ~t Alr.iarez Unit 1 during. cold.

water flow testing were the result of under-predicting the ster.i thrust required to close the valve against high differential pressures

• Since the required stern closing thrust is the key variable in sizing the valve actuator, the result of this error is an.actuator with insufficient force capability to close the.valve.

2. Tq correctly predict the required closing thrt.ist a valve factor of*n~55

• should be used in the;standard"clostng:.load.equation.

F4 = .55 F1 + F2 + F3 Other possible friction losses should be considered as appropriate to the.

particular valve design.

3.' All three. types* of'. test; ng 'done by we*sti nghouse-. cl early shows that;**the required closing load increases with repeated cycling and drops*.after delay periods, when the valve is held in the open position during the delay period.

4. The required closing thrust is .directly related to the differential pressure present during the closing stroke. Within the lir.iits of the tests considered in this report, the flow present during the closing has proven to be an insignificant variable.

EM 5683, Rev. l Page 77

. 5. In sizing a valve actuator to close against high differential pressures the dynamic characteristics of the actuator and power train, and valve must be considered. Some examples of the characteristics to* be weighed are the possible drop in load output due to motor inertia changes and t~

thread friction changes; proper selection of the control.equipment (i.e.,

torque switch spring pack); and reduced voltage stall output.

6. . The limited test data available at the time of- the wri.ting of this report indicates that required closing loads are slightly higher, under higher temperature conditions, than they are under cold conditions.

Several of the other valves in the EPRI program closed quite successfully ev~n though their actuators were most likely sized using the 0.3 valve factor. This can be explained by the difference in operator sizing philosophy between Westinghouse.and most other valve companies. Most other companies allow Limitorque to perform their operator sizing. The standard Limitorque technique .has sufficient margin built into it at other points of the-sizing calculation that the final operator size is adequate and most valves would close at the higher actual loads.

On fast operating valves these added margins can result in operator stall output loads that can damage a valve that is not designed to accept them. In early nuclear plant experience there was considerable evidence of such damage and in developing its valve design Westinghouse attempted to prevent such damage by minimizing and controlling operator margins .

The reduced margins make the Westinghouse design less tolerant of errors in estimating closing thrusts.

EM 5683, Rev. 1

• 6.0 ACKNOWLEDGEMENTS Page 78 The author would like to.express his thanks to E. M. Burns of the WNTD Huclear Safety Department, and Brian Newh~use for*his help in preparing this report; to Dave Boes of R&D for the~friction test data; and to Stephanie Kaskan for a fine typing job.

Messrs. T. E. A~ble of EPRI and J. P. Kozuch of Westinghouse deserve credit for their assistance in coordinating.the report and the transfer of data between the two organizations~

EM 5683, Rev. l Page .79 7 .O DISTRIBUTION EMO Engineering Files ' ( 2}

EPRI (3}

J. B~ Allen F. R. Bakos M. Bonfiglio E. M. Burns .

D. R. Collier r: T. K. Cori ale J. A* Drake (10}

• J. p. Kozuch*

M. A. Leri B. L. Newhouse, E. Petros~y A. F. Phillips E. J. Rusnica G. L. Schlemmer

.-~