ML20094N455
| ML20094N455 | |
| Person / Time | |
|---|---|
| Site: | Fort Calhoun  |
| Issue date: | 08/13/1991 |
| From: | Adamo P, Sibiga D ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY |
| To: | |
| Shared Package | |
| ML20094N438 | List: |
| References | |
| PROC-910813, NUDOCS 9204060365 | |
| Download: ML20094N455 (91) | |
Text
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I 1
TEST PROCEDURE GUIDELINE FOR
'OUT-OF-PLANT TESTING OF PORV BLOCK VALVES- '
AT THE FORT CALHOUN STATION OMAHA PUBLIC POWER-DISTRICT Prepared by ABB-COMBUSTION ENGINEERING NUCLEAR POWER 9204060365 DR 920401 ADOCK 05000285 PDR
TEST PROCEDURE GUIDELINE FOR OUT-OF-PLANT TESTING OF TIIE PORV BIcCK VALVES AT TIIE FORT CAlIlOUN STATION OMAIIA PUBLIC POWER DISTRICT e
Prepared . N /B d4(to Date: 8!/2 /
P. A. Adamo VERIFICATION STATUS: COMPLETE TWJefwfkil:d derJgn Wxntrst c::ri* w! b Ns exert hu tec<t vtrAnd bbecarrepa maarts cr-L WRMrstsrgChe:Mrds) a b_ c!QAM101
$0Yr $o YtR in Lu9UL,a/k U N 21-M -91 inweineneweriiumsonare/onw ErtNS /Vor Anustart 1 Chec4hr I: An duti.s fi S- 10,1 'l Approved by: bdA4 lhL DLb Date: 3' I3' kI D. Sibigh,0 Supervisor CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 1 of 49
RECORD OF REVISIONS Revision Effective Number Sections Date Prepared By Approvals 00 All (Original April 1991 T.P. Jaeger D. Sibiga Issue)
Total pages=74 01 Revised:
- Table of July 1991 P. A. Adamo D. Sibiga Contents
- Table 1
- Figure 1
- Paragraphs:
1.2.9; 3.2.1; 3.3; 3.3.1; 3.3.2; 3.4.3; 4.2.1; 4.2.2.1; 4.2.2.2; 4.2.2.5; 4.3.5; 4.4.1 (Entirely) 4.4.2.2; 4.4.2.3; 4.4.2.7; 4.4.2.9; 4.4.2.19; 4.4.2.22; 4.4.3.28; 4.4.3.29; 4.4.4.29; 4.4.5; 4.4.5.1; Added:
- Paragraphs:
4.4.2.23 through 4.4.2.36
- Appendix C
- Appendix D Deleted:
- Paragraphs:
3.5; 4.4.5.2 4.4.5.2.1 through 4.4.5.2.13 02 }Levised : August 13,1991 P.A. Adamo D. Sibiga
- Table 1
- Paragraphs:
3.3; 3.3.1; 3.4.4.1; 4.2.1 4.4.1.[8;11;13;14;19;21;24;27;28]
4.4.2.[2;3;6;7;9;24;25;31;32]
4.4.3.[2;8;28]
4.4.4.[2;9;29]
CE REPORT NO. 602977-MPB-5EFPR-002, REV. 02 Page 2 of 49
TABLE OF CONTENTS S,getion Title Paoe No.
1.0' PURPOSE 4 2.0 SCOPE 5 3.0 TECHNICAL BASES 5 3.1 Valve / Actuator Data 5 3.2 Functional Requirements 6 3.3 Design Basis Operating Conditions 8 3.4 Determination of Required Testing 14 4.0 TEST GUIDELINE 26 4.1 Premise 26 4.2 Test Equipment 26 4.3 Test Prerequisite 32 4.4 Test Procedural Guideline 32 4.5 Results Evaluation 46 Appendix A: Forms And Figures For Measuring Gate Al-A18 Valves Internal Dimensions And Internal Performing Inspections.
Appendix B: Gate Valves Internal Inspections. B1-B9 Gate Valves Visual Inspection Information Recording Sheet.
Appendix C: Letter 0-MPS-91-098 Rev. 1, dated Cl-C11 July 12, 1991 from A. A. Ostrov (ABB-CENP) to P.-A. Adamo (ABB-CENP) .
"OPPD Fort Calhoun Block Valves HCV-150 and -151 Operating Conditions."
Appendix D: Letter from OPPD stating the maximum D1-D3 amount of condensate upstream of a closed PORV Block Valve at Fort Calhoun Station.
CE REPORT NO. 602977-MPS-5EI- PR-002, REV. 02 Page 3 of 49
~~} 1.0 PURPOSE 1.1 This Test Guideline provides support to the Omaha Public Power District's (OPPD) Motor Operated Valve (MOV)
Program at the Fort Calhoun Station. The program is being implemented by OPPD in response to the Recommended ,
Actions of NRC issued Generic Letter 89-10, " Safety-Related Motor-operated Valve Testing and Surveillance" _
and its supplements.
1.2 The purpose of this document is to provide guidelines to OPPD for establishing the procedural, documentational, parametrical and correlational requirements for testing the Power Operated Relief Valves (PORV) Block Valves HCV-150 and HCV-151. The following listing details the provisions made for in this guideline:
1.2.1 Provide documentation of the functional requirements for the PORV Block Valves.
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1.2.2 Provide documentation of the maximum design basis conditions for which the PORV Block Valves are required to operate in Step 1.2.1, above.
1.2.3 Provide recommended tests and test conditions for which the PORV Block Valves are to be tested in situ.
1.2.4 Provide required tests and test conditions for which the PORV Block Valves are to be tested out-of-plant.
CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 4 of 49
l 1.2.5 Provide test justification and guidelines for correlation between maximum design basis conditions, out-of-plant testing and in situ testing.
1.2.6 Provide a test gu ialine'for out-of-plant testing which has sufficient detail on test method, test conditions and data acquisition requirements which will allow the out-of-plant test facility procedure writer to develop detailed test procedure (s).
1.2.7 Provide a guideline for correlating test results and expected results with justification and explanet. ion for significant variances.
1.2.8 Provide guidelines for establishing detailed test acceptance criteria.
1.2.9 These guidelines also apply to testing required to meet any OPPD commitments to the NRC concerning NUREG 0737.
2.0 BCOPE '
This Test Guideline specifically addresses the PORV Block Valves, HCV-150 and HCV-151, at OPPD's Fort Calhoun Station.
It's scope is to establish testing guidelines for OPPD to develop specific-testing procedures which will verify the valves' operability at the maximum design basis conditions.
The scope of this guideline is also to provide the basis for an in' situ periodic surveillance / trending testing program to ensure continued operability.
CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 5 of 49
3.0 TECHNICAL BASES 3.1 Valve / Actuator Data T
3.1.1 Tag Number: HCV-150 and HCV-151 3.1.2 Valve Type: 2500# ANSI Class Gate 3.1.3 Valve Size: 2 1/2 inch 3.1.4 V':lve Orientation: Installed in hori-Jntal line with stem upright 3.1.5 Valve Manufacturer: Crane 3.1.6 Valve Model: 797-U 3.1.7 Actuator Manufacturer: Limitorque 3.1.8 Actuator Model: SMB-00 3.2 Functional Recuirements The PORV Block Valves must be capable of providing the following functions:
l l 3.2.1 The PORV Block Valves are normally open during ,
most plant conditions when the reactor head is on the reactor vessel to allow the PORVs to provide for overpressure protection. However, in order to provide reactor coolant pressure boundary integrity, the block valves must be capable of being closed if required to isolate a PORV which has excessive leakage. The valve must then be capable of remaining closed to maintain the integrity of the reactor coolant pressure boundary.
3.2.2 In addition to isolating a PORV due to excessive leakage, a normally open PORV Block Valve must CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 6 of 49
also be capable of being closed to isolate a stuck open PORV during any postulated plant condition.
3.2.3 The PORV Block Valve (s) may be required to be closed during plant operation for limited periods as a result of excessive leakage (case described in Section 3.2.1) of one or both of the PORVs, or as a result of one or both of the PORVs being stuck open (case described in Section 3.2.2). If a PORV Block Valve is placed in the closed position for one of these reasons, the valve must be capable of being reopened and then closed as necessary, to provide for
- 1) overpressure protection.
- 2) depressurization for the mitigation of steam generator tube rupture and other design basis events.
- 3) once through cooling upon loss of all feedwater.
3.2.4 As a reactor coolant pressure boundary valve which is normally open, the Combustion Engineering Emergency Procedure Guidelines (prepared for the CEOG), CEN-152, requires the PORV Block Valves to be closed as part of the LOCA recovery procedure to isolate the PORV in order to maintain reactor coolant system inventory.
i 3.2.5 The PORV Block Valves must be capable of being repositioned to their correct open or closed position in the event of mispositioning by the CE REPORT NO. 602977-KPS-SEFPR-002, REY. 02 Page 7 of 49
control room operator. This would be required under any conceivable operating condition.
3.3 Desion Basis Oueratina Conditions Appendix C to tbis guideline provides a listing of the operating scenarios presently ascribed to the PORV Block Valves. The list identifies the event, tho valve stroke direction, maximum pressure, maximum AP, stximum flow rate, fluid states and the assumptions made for each ,
required operating condition of the valve.
Of the 19 cperating conditions identified in Appendix C, the PORV Block Valve need to ha tested only to the 6 enveloping conditions identified in Table 1 of this guideline.
3.3.1 Test "ases Selection criteria The 6 test case of Table 1 were selected from the list of tr. ORV Block Valve operationhl requirements 3 Appendix C following the criteria note 6 aelcw.
The valve performs two basic operations:
Opening and closing. However, the dynamic and static loads created by the internal fluid impact the valve's ability to perform those basic operations in a dramatic fashion.
Temperature, pressure, pressure differential, fluid state and flow rates all combine to create substantially complex flow conditions within the valve to render highly questionable any CE REPORT NO. 602977-MPS-SEFPR-002, REV. 02 Page 8 of 49 j
prediction of the local / internal valvo loading state, and thus its ability to operate, without testing the valve at the bounding conditions.
It cannot be stated without verification that if a valve strokes successfully in one direction under a given set of conditions it will stroke successfully in the alternate stroking direction at the same or even less severe set of conditions. The reason in that/ when first opening, tho valve must overcome the maximum AP Icad although the dynamic loada are initially O.
When closing, the AP may be negligible but the dynamic loads are at moximum. The dynamic loads may cause turbulence and valve a chatter",
deflect and misalign valve components and gor.erally tend to create conditions for mechanical damage and ultimately seizure of the valve. Therefore, the test cases selection process started with the grouping of all operating conditions that require the valve to open and again those conditions that require the valve to close.
The next criteria for selecting test cases was to identify the fluid ctates under which the valve is required to operate in opening and/or closing. The state of the fluid is an important selection criteria. The state of a fluid affects its dynamic behavior in a piping system and, accordingly, it also affects the dynamic loading conditions on a valve.
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CE REPORT No. 602977-KPS-5EPPR-002, REV. 02 Page 9 of 49 i
The last critoria for selecting test casos is to pick chose casos within each subgroup that represent the various fluid states, that have the greatest maximum pressure, greatest maximum AP and greatest maximum flow rates. This process is performed for events when the valve is required to open and then repeated for events when the valve is required to close.
The only exception to the above critoria is provided by case II-1 in Appendix c The flow rato in this case is so small that the fluid stato is not a significant critorion. Por Appendix D, the amount of condensate present in the loop seal is 66.4 lbs. (at most). The only test caso for which this condition may have any bearing is Test Case Number 6, where the valve would be opening at high pressure. However, tho amount of vntor is so small that it would be blown out of the valvo as soon as the valve is unseated, leaving the valve unfettered for the rest of the stroke. Therefore, duplication of the water plug during testing for the purpose of demonstrating valve operability is not deemed strictly necessary.
3.3.2 Maximum Conditions for Valvo Operability The test casos below envelope the PORV Block Valve functions in a progressively savoro order.
The corresponding conditions are provided in Table 1.
CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 10 of 49
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CASE 1 - Open Block Valve to enable the LTOP syslam. Hisposition is postulated.
(Appendix C, Case III-1, Liquid Flow.)
CASE 2 - Open Block Valve to allow the functional recovery of the Red pressure control using pORV as a success path.
Hisposition is postulated. (Appendix C, Case VI-3, Liquid Flow.)
4 CASE 3 - Close Block Valve due to a stuck-open PORV. (Appendix C, Case I-3, Liquid Flow.)
CASE 4 - Close Block Valve due to a stuck-open PORV. (Appendix C, Case I-3, Two Phase Flow.)
CASE 5 - Close Block Valve stuck-open PORV.
(Appendix C, Case I-1, Saturated Steam Flow.)-
CASE 6 - Open Block Valve to enable the LTOP.
Mispositioning is postulated. (Appendix C, Case III-3, Saturated Steam Flow.)
/--
CE REPORT NO. 602977-NP8-5EFPR-002, REY. 02 Page 11 of 49
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1 Table I wastaus Condition Casig kasteue Minleus Maulous Upstrean 00mstresse Differentist salaus imition Pressure Pressure Pressure flow temperature Process fluid Appendia C LAl[ 12 pen /Closel . iDe l e)._ h (Deld) fitsVhr) ('M tiete esse l
1 OPlu 485 15 470 (1) 225,000 82 WAtta 111 1 2 Cett 1203 15 1185 (1) 180,000 540 WAftt VI 3 l 3 CLost 1400 15 1585 (2) 368,480 (3) 540 (4) WAftt 1+3 i 4 CLost 1400 15 1385 (2) 160,000 58T TWO PMAst 13 ;
5 CLost 2376 15 2361 (2) 110,220 661 SAT. titAM 11 l
, 6 OPlu 2500 il 2485 (1) 130,000 668 $AT. $f tM ll].)
e01(8: I
- 1) the velve starte te stroke ocen from o tutty stooed pueltion. The differentist pressure acrose the ,
velve when fully closed is et its eastman. As the valve continues te open, the pressure dif f erential j scross the velve contiftJee to decrease mill it Locames essentistly tere when th9 volve reaches its fully open position. $leutteneously, the flow rete across the volve starte et 0 the/hr when the velve .;
la fully stooed ard increases en the velve strokes open, mtit it reaches its moulous value een the valve is fully open.
- 2) the volve starts to close from o fully open poettion the dif ferential pressure across the volve 6Aen i fully open la essentietty O. As the velve contirues to close, the pressure dif ferentist across the velve conttrues to increase mtit it reaches its mesteun value when the valve reaches its fully closed position. $leuttoneously, the flow rate across the volve starte et its stealous value when the vslve is fully open and decreases se the valve strokes towerti the closed position, mtil the flow completely stops teen the velve la fully stooed. .
- 3) The flow rate for this cose tsas computed using the foreule O = cv AP 62.4 -p frasi crene's ;
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l technicet Peper he. 410, 1916 Edition tocause no ptblished flow rete values teere fourd. Mealous flow rete is achieved when the PORY Stock velve is futty opened, in this condition, the flow choking is eenleved by the PORY tocause it hos e emeller flow eres et the seat (1.093 Irrh diameter).
Therefore, the samlaus flow rate, 0, is computed using the PORY's Cv, the maxims AP etW the density of the Llwid P, es is ecolicable.
4 This le en estimated maalutes temperature based on the assumption of coeatstence of tlwid with saturated steen et the specified pressures.
l CE REPORT NO. 602977-MP8-5EFER-002, REY. 02 Page 12 of 49
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3.4 Determination of Reauired Testina Section 3.3 identified the maximum cases for which the )
PORV Block Valves must be capable of operating. To l Verify the valves' capability to function and remain l operable under these conditions, it is desirable, and in I some cases necessary, to perform testing to demonstrate that the valve can in fact perform its safety functions.
There are two reasons for testing, one is to demonstrate capability and the other is to verify continued operability.
3.4.1 Demonstration of' capability Testing performed to demonstrate capability, for the most part, can be considered a one time test. This is true as long as the valve is maintained in a condition similar to that tested and/or has not undergone major maintenance which could have affected valve operability. This testing should, when possible, be perfo,rmed at or above the maximum conditions for which the valve is required to operate. Unfortunately, it is not always possible to perform this type of testing in situ. This is the case for the PORV.
Block Valves. Testing at these conditions would challenge the primary safety valves and reactor coolant pressure boundary as well as introduce significant transients which compromise the plant's safety. It is therefore recommended that this testing be performed in an out-of-i CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 13 of 49 l
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plant test loop. This testing will evaluate the valve's capability to perform repeated cycles at tho maximum conditions by monitoring valve degradation, if any, during the operability stroke tests. Also, this testing will develop a basis for correlation to in situ testing at
- reduced conditions. See Sections 3.4.3 and j 3.4.4 for specifics on out-of-plant and in situ testing.
3.4.2 Verification of Continued Operability i a
Testing which is performed to verify continued ;
operability is basically performed to demonstrate the valve has not degraded or deviated from that originally tested at the design basis conditions. This testing does not necessarily have to be performed at the maximum -
conditions but at some reduced conditions which would still provide 'an indication of continued cperability. The reduced conditions should be at some point (s) above zero static conditions which could provide suitable evidence that the valve's condition has not deviated from that= i tested at maximum design basis conditions. It
! -is standard practice to establish a baseline at a predetermined reduced condition which can be I
recreated in situ and for which the results can provide suitable evidence of the valve's continued operability (i.e., the valve has not degraded from the maximum design basis test condition) via correlation of the reduced condition test results to the maximum design l
CE REPORT NO. 602977-MPS-5EPPR-002, REV. 02 Page 14 of 49 l
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basis condition test. Thus, the guideline providos for testing at recommended reduced conditions to provide that correlation. The reduced conditions are based on testing during hot standby or hot shutdown modos as recommnnded by the NRC in Generic Letter 90-06. See Section 3.4.4 for specifics on in situ operability testing.
3.4.3 Out-of-Plant Testing -
Testing at the maximum design basis conditici, cases listed in Table 1 will provide the necessary verification that the valvo can perform all safety functions. Testing at those conditions is recommended for out-of-plant testing. The test guideline of section 4.0 provides for such testing.
In addition to testing at the maximum design basis condition cases above, the out-of-plant testing must also make provisions for testing at the reduced conditions which can be reproduced during in situ testing. This provision is incorporated into- the ont-of-plant test guideline of Section-4.0. The testing at conditions below the maximum design basis is necessary in order to provide the correlation between the recommended in situ test conditions and the design basis test conditions.
l CE REPORT No. 602977-MPS-5El#PR-002, REV. 02 Page 15 of 49
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3.4.4 In Situ Testing This tost proceduro guidelino does not provida .
guidelinos for in situ testing. However, it !
does provide recommended in situ tust conditions as a means to establish common test conditions betwoon the out-of-plant and in situ testing, ,
This will preclude any chance of not being able to provide the needed correlation between the two. It is noted that, as a result of review and evaluation of the out-of-plant test results, it may be desirable to change the recommended in situ test conditions in order to improve test correlation.
3.4.4.1 Recommended In Situ Test Conditions The NRC recommends stroke testing the PORV's during Hot Standby (Mode 3) or Hot Shutdown (Mode 4) prior to entering or establishing conditions where the PORV's are used for Low Temperaturo Overpressuro Protection (LTOP) .
Likewise, it - follows that the PORV Block valves should be tested prior to entering into the LTOP mode. This is particularly true because testing at this condition would represent a closer simulation of the pressure / differential pressure-seen by the valve at the maximum conditions than would testing which is performed at the some lower conditions, such as those present during CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 16 of 49
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Cold shutdown or Refueling.
Based on Figure Ib of the LTOP study Final Report (dated July 1990) for 20 CFPY, mide by CE (refer to letter of 0- j HPS-90-053 to Mr K. Holthaus dated July l 20,1990) and the Telecon of 8/12/91 i between P. Adamo (CE) and K. Holthaus (OPPD) , LTOP is assumed to start at 1600 psia and 385'F. Therefore, the reduced test conditions will be established ;
slightly above this point at 1600 psia and 400'F. This is the recommended pressure and temperature at which the PORV Block Valve should be tested in situ for establishing correlation point -
with the test of section 4.0 of this guideline.
A second correlation point will be initial.1y established at zero static conditions. These conditions are easily established during any refueling shutdown. However, this point may be more prone to change because testing at static conditions versus testing at_even a-small pressure such as 100 psia may prove not to' provide representative test results suitable for correlation.
3.4.4.2 Inservice Testing In addition to thu in situ MOV testing above where actuator signatures may CE REPORT.No. 602977-MPS-5EPPR-002, REV. 02 Page 17 of 49
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i provide for trending and advanced l indication of oncoming dngradation, inservice testing (IST) of these valves is also performod in accordance with the ASME Code Section X7. as required by 10CFR50.55a. This testing also performs a Go/Ho-Go type operability test but !
does not provide much indination for detecting oncoming degradation. The advantage here is that"this testing is performed frequently (quarterly) where as the MOV diagnostic testing is only performed every several years primarily due to the extent of setup tinn involved. Thus, operability testing on this smaller scale continues to provide some level of assurance that the valves will perform their intended functions in the time between the MOV in situ testing. The in-service testing shall be, per the ASME Code Section XI and the Generic Letter 89-04, performed to verify all safety functions of the valve. Therefore, the PORV Block Valve shall be tested in both the open and closed directions. Response #2 in OPPD Letter LIC-90-0982 to the NRC, Response to Generic Letter 90-06, " Power-Operated Relief Valve and Block Valve Reliability, Additional Low-Temperature overpressure Protection for Light-Water Reactors" dated December 19, 1990 indicates the Block Valve is only tested CE REPORT NO. 602977-MPS-5EPPR-002, REV. 02 Page 18 of 49
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in the closed direction. Both the l overpressure control (automatic or manual) and the once Through cooling scenarios require the PORV Block Valve to open if previously closed to isolate the PORV.
As ASME/ ANSI operation and Maintenance (OH) becomes applicable to OPPD (either-by reference in ASME C6de Section XI or by referenco in 10CFR50.55a), OPPD will be required to establish test reference value's for the PORV Block Valves obtained at'a time taken when the valve is known to be operating acceptably and performed at conditions which can be easily reproduced in situ, so that all future in-service test results can be compared to them. The testing recommended in Section 4.0 verifies the valves' acceptability and establishes the appropriate reference values. The reference values should be the same as the correlation points previously discussed so that when the !!OV in situ testing is performed, it will satisfy the inservice testing as well.
3.4.5 Test Approach The maximum pressure and differential pressure values listed in Table 1 represent the limiting pressure and differential pressure conditions.
CE REPORT NO. 602977-MPS-5EPPR-002, REV. 02 Page 19 of 49
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-v v-,-m- <wm---u~- -r~ n-= ,
l These values are associated with the no-flow condition. As a result of dynamic head losses and vena contracta offects, the actual conditions at the valve will vary under flow conditions; however, at the moment of closure the conditions will return to the limiting values. These values always bound the dynamic conditions. To address the difference between, no-flow and flow conditions, this guideline will setup tho initial and final conditions and use the dynamic conditions which actually result at the Block Valve. This is a valid approach because the test setup simulates the as-built piping resistances as those found in the plant.
Therefore, if the actual pressures and differential pressures at the Block Valve during the various flow test conditions are different than the listed maximum values, it's because they would actually be that way in situ. This is an acceptable condition and no correction of the input source pressure will be warranted to adjust the actual pressures at the valvo. In fact, actual pressures imrediately upstream and downstream of the Block Valve's disc may even be different than that seen by the pressure instrumentation which is located in the upstream and downstream piping. Placement of pressure measuring equipment inside the valve would significantly increase testing costs, require physical attachment to the valve and may alter the flow condition within the valve thus compromising the simulation. This effect is due to Vena Contracta effects. Although this effect CE REPORT NO. 602977-MPS-5EPPR-002, REV. 02 Page 20 of 49
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is probably occurring in our case but may not be directly noticed, it will be detected, if significant, via a change in the required thrust l and/or visual observation of accolorated wear / damage.
Although the effects upon the valve thrust requirements caused by the static internal pressure and pressure differential across the disc are fairly predictable and simulated, the dynamic effects of the fluid flow within the valve is less predictable and harder to simulate. The reasons for the latter are the complex phenomena of energy exchange and turbulent flow that occurs within the contorted flow paths within the valve. Flow can also impact the rate of loading of the actuator and the valve's ability to withstand the negative effects of high flow rates. Such effects may be accelerated wear and/or mechanical damage of sliding surfaces, cavitation and other damage which would cause increased valve factors. The reason for performing the tests under flow conditions in lieu of no flow are many 'and compelling. The goal is to determine whrc.' the threshold is for such flow induced conc, :1.e if 1
l it exists in the range of flows involved.
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CE REPORT NO. 602;77-MPS-5EFPR-002, REV. 02 Page 21 of 49 e
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l 4.0 Test Guideline 1 4.1 Purnose This guideline provides a method for verifying the functional capability of the valve and valve actuator as defined in Section 3.2. Also, titis guideline provides sufficient detail on required data collection and acquisition for the purpose of test data extrapolation and correlation to the recommended in situ test conditions.
4.2 Test Eauiement 4.2.1 A test loop facility and all required S
instrumentation necessary to ensure proper operation of the facility. The test loop (s) should be capable of providing 130,000 lb/hr of saturated steam at 668'F and 2$00 psia; 160,000
, lb/hr of two phase water media at 587'F and 1400 psia, and 368,480 lb/hr of water at 540 / and 1400 psia. The above conditions shall be I available continuously for a period of time sufficient to establish steady state conditions and to then perform the open-to-close and/or close-to-open stroke tests specified in this i
guideline. See Figure 1 for additional detail on arrangement.
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1 CE REPORT No. 602977-NPS-5EFPR-002, REY. 02 Page 22 of 49 I -- - _ _ .. . - _ _ - _ . .- - - - -
FIGURE 1 CONCEPTUAL TEST VALVE AIUtANGEMENT Piping between points I and 2 shall have an effective Resistance Coefficient of K = 4.6.
The pipe shall be 21/2 inch schedule 160 for at least 10 pipe diameters upstrearn of point 2.
Piping between points 3 and 4 shall be: 21/2 Inch size, Schedule 160, 2 feet long.
Piping down stream of point 5 shall be 4 inch size for a minimum length of 5 pipe diameters. Beyor.d that point, any larger pipe size may be used.
ATMOSPilERIC ATh10SPIIER' VINT VENT h h DOWN STREAM UPSTREAM g
<_._, y PRESSURE PRESSURE GAUGE y yW _
vg \/ GAUGE TV1 POWER OPERATED O Mk V2
'ITST VALVE Mk P P RELEFVALVE T'- (PORY DIX)CIO '
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hy4mm1!IlifilIlli ggg - FUEL -y TilRO1TLE VALVE CE REPORT NO. 6 0 2 9 7 7 -MPS-S EPPR*= 0 0 2, REY. 02 Page 23 of 49 l
d 4.2.2 A data acquisition system (s) capable of recording analog or digital time history input for each of the system process and motor operated valve parameters identified below. If multiple systems are used for data acquisition (i.e. a MOV performance and data acquisition and diagnostic test system such as MOVATS, VOTES, etc. is used to collect some or all of the MOV related data and another system is used to collect the remaining information), all inputs shall be referenceable to a common point in time. The data acquisition 6ystem(s) shall provide for data point collection, storage, manipulation and real time display of each measured pr.rameter at the sampling frequencies indicated below. The real time display outputs may be via LCD/cRT scrcen or multichannel chart recorder plots. The data acquisition system (s) shall also support data download to an IBM PC based systt , format.
4.2.2.1 Pressure shall be monitored for both the upstream and downstream conditions using pressure transducers connected at pressure taps as close to the test valve as practical. the pressure transducars shall have a response time of 50 mi?.liseconds or less. The acquisition system shall have a sampling rate consistent with or greater than the transducers' response time. The transducer accuracy shall be 0.5% or better. If the transducers are uced to CE REPORT No. 602977-MPS-5EFPR-002, REV. 02 Page 24 of 49
1 provide for pressure indication in lieu of gauges, the overall instrument loop accuracy shall be 14 or better.
4.2.2.2 The process fluid temperature shall be monitored upstream of the test valva l
-using a thermocouple or RTD with a -
responso time less than or equal to 100 milliseconds and accurate to within 2'F. The sampling rate shall be consistent with or greater than the measuring devices response time. If the RTD or thermocouple is used to provide temperature indication, the overall instrument loop accuracy shall be 2% or better.
4.2.2.3 The process fluid flow shall be monitored upstream of the test valve using an orifice, venturi.or clamp on ultrasonic flow meter with a response time less than or equal to 100 milliseconds and accurate to within 2%
of full scale. The sampling rate'shall be consistent with or greater than the measuring device's response time. If this flow meter is used to provide flow indication, the overall loop accuracy shall be within 3% of full scale.
4.2.2.4 The actuator motor voltage and current shall be monitored using appropriate voltage and current measuring devices P CE REPORT NO. 602977-KP8-5EFPR-002, REY. 02 Page 25 of 49 i
l
_ .._.._._._ _ _ _ , . _ _ _ . _ _ . . . . _ , _ . _ - _ _ _ _ . _ _ _ _ _ . . _ . . - . . _ - . ~ . . _ - - . - . . _ , _ . ,
l l
Which have response times of 1 l millisecond or less and are accurate to l within 1% of scale. The sampling rate shall be consistent with or greator than the measuring device's response time.
4.2.2.5 The test valve stem torque and thrust shall be monitored at the valve stem using standard strain gauge technology.
The total torque or thrust measurement system accuracy shall be 5% or better.
The strain gauge sampling rate shall be 1 millisecond or less.
4.2.2.6 The test valvo's actuator spring pack linear disp?acement shall be monitored using a LVDT installed on the spring pack assembly. Displacement shall be measured with respect to the proload position. The accuracy of measurement shall be within 0.5% of actual displacement. The sampling rate shall be 1 millisecond or less.
- 4. 2. . 7 The test valve's stem position shall be monitored using a,LVDT (or equivalent) installed on the valve's stem and yoke to obtain a 2% accuracy or better. The LVDT's response time shall be 100 milliseconds or less. The sampling rate shall be consistent with or greater than l
the response time.
l CE REPORT NO. 602977-KP8-5EFPR-002, REY. 02 Page 26 of 49
4.2.2.8 The motor control switch actuation contact, the torque switch contacts and any limit switch contacts which provide a control function shall be monitored for rtate or condition using any excepted method (such as monitoring voltage across contacts or condition of auxiliary contacts). The sampling rate shall be i millisecond or less.
4.2.3 Pressure gauges, upstream and downstream, shall i be installed at pressure taps as close as practical to the test valve. The pressure gauges' range shall be such that the test pressure value of concern is greater than 25% of scale but does not exceed 75% of range. The accuracy shall be 10.25%. If the pressure transducers used for data acquisition provide indication with total loop accuracy of 1% or better, then the pressure gauges are not required.
4.2.4 Temperature measuring thermocouple or RTD and indication installed upstream of the-test valve with a loop accuracy of 2'F or better. This may be the same measuring device as that used for input to the data acquisition system input temperature measurement.
CE REPORT NO. 602977-NPS-5EFPR-002, REY. 02 Page 27 of 49 J
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- - - . - - . - . - _ _ - _ - . - - - _ _ - - . - . - . _ . - - ~ - . . - - - . _ - _ - _ . -
4.2.5 Flow meter installed upstream of the test valve with an accuracy of 2% of full scale or better.
This pay be the same flow meter as that used for input to the data acquisition system input flow measurement.
4.2.6 Various dial indicators, measuring calipers, micrometers, etc. as needed to make dimensional measurements specified in this guideline are required. They shall be capable of providing measurements to the nearest 0.001 inch with an accuracy of 0.001 inch.
4.3 Lest Prerecuisites 4.3.1 The test valve has been completely inspected
- (internally and externally) and dimensioned per l
EPRI recommended practices. The results shall be recorded per Appendices A and B. l l
4.3.2 The test valve is properly assembled, l
maintained, lubricated, and setup as it would be for normal plant operation.
4.3.3 All instrumentation / equipment is calibrated.
4.3.4 The test instrumentation of Section 4.2 and the test loop monitoring equipment are installed on-the test valve and tant loop as necessary.
l.
CE REPORT No. 602977-KPS-SEPPR-003, REY. 02 Page 28 of 49
4.3.5 The test loop is operable at the desired pressure and temperature with the test valve installed.
4.4 Test Procedural Guidelines The PORV Block Valve will be initially tested at static conditions and than the internal pressure, differential pressure, process fluid flow and temperature parameters will be independently and incrementally increased to the maximum design basis conditions. All specified parameters shall be monitored throughout the testing.
The Test Engineer shall modify the tasting, inspections and dimensioning detailed herein as appropriate to address any observed trends in the test results. These observed trends may be, but are not limited to:
- 1) An increase in required stem thrust beyond that estimated with accepted industry equations or that extrapolated from earlier test results.
- 2) An increase in seat leakage.
- 3) A deviation from the expected motor current signature or RMS motor current during the valve's stroke.
- 4) A change in valve stroke time.
The test results from each test shall be reviewed and evaluated before proceeding to the next test. If any results deviate from that expected, the Test Engineer CE REPORT NO. 602977-KPS-5EFPR-002, REY. 02 Page 29 of 49 )
shall determine the cause and perform, as necessary, inspection and dimensional verifications as detailed in Appendices A and D.
Refer to Figure 1 for a schematic diagram of the test set-up and the identity and function of the various valves, pump and other equipment referred to throughout this test guideline. The following tests of 4.4.1, 4.4.2, 4.4.3, 4.4.4 and 4.4.5 shall be performed in order.
4.4.1 Static Test 4.4.1.1 Ensure that all the prerequisites are met.
4.4.1.2 Encure that upstream and dow1: stream pressure are at atmospheric conditions by checking closed the upstream isolation valve V3 and warmup bypass valve V4 and opening Vent Valves V1 and -
V2. Record the pressures.
4.4.1.3 Start the Dat,a Acquisition System.
4.4.1.4 Open TV1, allad TV1 to fully open, then close TV1.
4.4.1.5 Stop the Data Acquisition System.
4.4.1.6 Examine the data recordings to ensure that all desired readings have been g collected successfully and that the test CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 30 of 49 i
results have not deviated from thct predicted by the industry equationu. If required thrust is significantly different than that predicted, secure the testing and perform the inspection /dimensioning detailed in Appendices A and D. Document any conclusions / justifications for observed conditions.
4.4.1.7 Repeat Steps 4.4.1.3 through 4.4.1.6 for repeat test.
4.4.1.8 Close V1 & V2. Ensure V5 & V7 are closed.
4.4.1.9 Open V6 and V8.
4.4.1.10 Open TV1 valve.
4.4.1.11 Establish Pump P1 Water flow on recirculation through Throttle Valve V8 at 15 psia and room temperature. Record upstream pressure.
4.4.1.12 Close TV1 valve.
4.4.1.13 Establish Pump P1 flow on recirculating through throttle valve V8 at 485 psia and room temperature. Record upstream pressure, i
CM REPORT NO. 602977-KP8-5EFPR-002, REY. 02 Page 31 of 49
___ _ ~ - . . . _ - . _ _ _ . _ _. . _ _ _ _ _ , _ _ _ _ _ , , _
4.4.1.14 Ensure downstream pressure is still at 15 psia. Record the pressure.
4.4.1.15 Start ** data acquisition system.
4.4.1.16 Open TV1, .llow TV1 to fully open, then close TV1.
4.4.1.17 Stop the data acquisition system.
4.4.1.18 Examine the data recordings to ensure that all desired readings have been collected successfully and that the test results have not deviated from that predicted by the industry equations. If required thrust is significantly different than that predicted, secure the testing and perform the ,
inspection /dimensioning detailed in Appendices A and B. Document any conclusions /justifice,tions for taq observed conditions.
4.4.1.19 Vent off downstream pressure by' opening V2 until the pressure downstream of TV1 reaches 15 psia, then close V2.
4.4.1.20 Repeat Steps 4.4.1.14 through 4.4.1.19 for repeat test.
4.4.1.21 Repeat Steps 4.4.1.14 through 4.4.1.20 for 1200 paia and 1400 psia pressures upstream with is psia downstream pressures.
CE REPORT NO. 602977-KPS-5EFPR-002, REV. 02 Page 32 of 49 u - - , - _ _ _ - - _
I 4.4.1.22 Repeat Steps 4.4.1.10 through 4.4.1.21 at water temperature of 540'F. Document any observable effects as a result of elevated temperature. If there are any significant changes, repeat the testing j at room temperature to determine if the effect is reversible.
4.4.1.23 Stop Pump P1, close V6 and V8.
4.4.1.24 Adjust steam accumulator pressure to 500 psia. The accumulator should be at the saturation temperature for 500 psia.
4.4.1.25 Open warmup bypass valve V4. Record upstream pressure.
4.4.1.26 Repeat Steps 4.4.1.14 through 4.4.1.20. f 4.4.1.27 Repeat Steps 4.4.1.24 through 4.4.1.26 for 1000 psia, 1500 psia, 2000 psia, 2376 psia,-2500 psia upstream pressures and 15 paia (in all cases) downstream pressure.
4.4.1.28 Close V4. Open V1 and V2 to ensure atmospheric pressure upstream and downstream of the test valve. Close V1 and V2.
4.4.1.29 Repeat Steps 4.4.1.2 through 4.4.1.7 to confirm static conditien baseline.
CE REPORT NO. 602977-MP8-SEFPR-002, REY. 02 Page 33 of 49
I 4.4.1.30 The above testing completes the recommended static and no flow differential pressure testing portion of this guideline. To verify the extent of valve degradation, if any, visually inspect and dimension the Test valve per Appendices A and B. Compare the results from this round of inspection and dimensioning to the baseline inspection and dimensioning results performed prior to the start of the static testing.
! Provide documented justification and i evaluation of any observed differences and provide correlation to that predicted by the accepted industry equations. Specifically, an increase in required thrust beyond that predicted by industry equation or extrapolation of previous test data should have a corresponding degradation observed in the valve. Such degradation may be a change in metal-to-metal sliding contact surface areas and finish (resulting in increased coefficient of friction), a change in internal tolerances, a deformation or erosion of disc guides, flow induced tilting of the disc resulting in premature disc-to-seat contact or single point contact, etc.
The goal is to determine the operating condition threshold where any of these mechanisms begin to impact the valve's performance or operability.
l CE REPORT NO. 602977-MPS-5EFFR-002, REY. 02 Page 34 of 49
l 4.4.2 Water Flow Test 4.4.2.1 Ensure that all prerequisites are met.
4.4.2.2 For the flow test with water at ambient temperature, establish Pump P1 water flow on recirculation to stabilize water temperature at 82'P and a discharge pressure of 485 pain.
4.4.2.3 open Test Valve TV1, Valve V7 and slowly open valve V6 to establish flow through Test Valve TV1 at 50,000 lbm/hr, 82'P and upstream pressure of 485 pain.
Throttle Valve V7 and Vhive V8 as neces-sary to stabilize at these conditions.
4.4.2.4 Stop Pump Pl. A. low flow to decay to 0.
4.4.2.5 Close Test Valve TV1.
4.4.2.6 Open, then close vent valve V2 to vent downstream to atmospheric pressure.
Record the pressure.
4.4.2.7 Start Pump Pl. Record the upstream pressure. If pressure at this time is significantly above 485 psia, record the l position of V8 by counting the number of turns in the open direction which are required to obtain an upstream pressure of 485 psia. Record the number of turns.
CE REPOP.T NO. 602977-MPS-5EFPR-002, REV. 02 Page 35 of 49
1 4.4.2.8 Start the Data Acquisition System. i 4.4.2.9 Open Test Valve TV1. Imat.diately close V8 the nonbar of turns recorded in step ;
4.4.2.7 t.o maintain the upstream l pressure at 485 psia. 1 4.4.2.10 Stop the Data Acquisition System.
4.4.2.11 Review the test results to determine if
-actual thrust is consistent with that q predicted. If it is not, determine the ]
reason by performing inspection and ;
disensaioning per Appendices A and B.
Document the results.
4.4.2.12 Repeat Steps 4.4.2.4 through 4.4.2.11 for a repeat test. Evaluate test
)
results for repeatability and any I evidence of degradation.from repeated valve strokes at these conditions.
4.4.2.13 Start the Data Acquisition System.
4.4.2.14 Close Test Valve TV1 and then open V8 the :. amber of turns recorded in 4.4 2.7. !
I 4.4.2.15 -Stop the Data Acquisition System.
4.4.2.16 Review the test results to determine if actual thrust is consistent with that predicted. .If it is not, determine the CR REPORT No. 602977-NPS=5EFPR-002, REY. 02 Page 36 of 49
-. _ ., _ .. i . - - -- - - - - - - -. - ~'
k 5
reason by performing inspection and
~dimensioning per Appendices A and B.
Document the results.
4.4.2.17 Open Test Valve TV1.- Close V8 the number of turns race,rded in Step 4.4.2.7.
4.4.2.18 Repeat' Steps 4.4.2,13 through 4.4.2.16 for a repeat test. Evaluate test results for repeatability.and any evidence of degradation from repeated valve strokes at these conditions.
4.4.2.19 Repeat Steps 4.4.2.3 through'4.4.2.18
/ for flow at 100,000 lbm/hr, 160,000 lbm/hr and 225,000 lbm/hr.
4.4.2.20 Secure Pump Pl.
4.4.2.21 Close valves VG, V7, V8.
4.4.2.22 'rhis complates the water flow test at
.Abient temperature. To-verify'the
~
extent of valve' functional.-degradation, if any, compare the water flow test results with those of the static testing. Provide documented justification and evaluation of any observed differences and provide L correlation to that predicted by accepted iMustry equations.
Specifically, an increase in required l
l-1:
CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Pagn 37 of 49
thrust beyond that predicted by industry equation or extrapolation of previous test data should have a corresponding degradation observed in the valve. This shall determine if the operating condition threshold is being approaching or has been exceeded.
4.4.2.23 Ensure that all prerequisites are met.
4.4.2.24 For the flov teet with water at high ts 'ne ture, .icablish Pump P1 water flow on recirculation to stabilize water tdmpnrature at 540'F and a discharge preneure of 1200 psia.
4.4.2.25 Repeat Steps 4.4.2.3 through 4.4.2.18 for an initial flow rate of 50,000 lbs/hr at 540*F and upstream pressure of 1200 psia.
4.4.2.26 Repeat Steps 4.4.2.3 through 4.4.2.18 for flow rates of 100,000 lbs/hr, 150,000 lbs/hr, and 180,000 lbs/hr.
4.4.2.27 Secure Pump Pl.
4.4.2.28 Close valves V6, V7, V8.
4.4.2.29 This completes the first hot water flow test. To verify the extent of valve degradation, if any, compare the test results of this test with those of the h
CE REPORT NO. 602977-KPS-5EFPR-002, REY. 02 Page 38 of 49
static testing and whter flow test at ambient temperature. Provide documented justification and evaluation of any observed differences and provide correlation to that predicted by accepted industry equations.
Specifically, an increase in required thrust beyond that predicted by industry equation or extrapolation of previcus test data should have a corresponding degradation observed in the valve. This shall determine if the operating condition threshold is being approached or has been exceeded.
4.4.2.30 Ensure that all prerequisites are met.
4.4.2.31 For the flow test with water at high temperature, astablish Pump P1 water flow on recirculation to stabilize water temperature at 540*F and a discharge pressure of 1400 psia.
4.4.2.32 Repeat Steps 4.4.2.3 through 4.4.2.18 for an initial flow rate of 50,000 lbs/hr at 540*F and upstream pressure of 1400 psia.
4.4.2.33 Repeat Steps 4.4.2.3 through 4.4.2.18 for flow rates of 200,000 lbs/hr, 300,000 lbs/hr, and 368,480 lbs/hr.
4.4.2.34 Secure Pump Pl.
I CE REPORT NO. 602 977-MPS-5 EFPR-002, REV. 02 Page 39 of 49 l
4.4.2.35 Close velves V6, V7, V8.
4.4.2.36 This completes the last hot water flow test. To verify the extent of valve degradation, if any, campare the test results of this test with those of the static testing and water flow test at ambient temperature from the first hot water flow test. Visually inspect and dimension the tett valve per Appendices A and B. Compare the t'esults with those of the inspection and dimensioning performed following static testing.
Provide documented jnsitification and evaluation of any observed differences and provide correlation to that predicted by accepted industry equations. Specifically, an increase in reqaired thrust beyond that predicted by industry equation or extrapolation of previous test data should have a corresponding degradation observed in the valve. This shall determine if the operating condition threshold is being approached or has been exceeded.
4.4.3 Steam Flow Test 4.4.3.1 Ensure that all the prerequisites are met.
4.4.3.2 Establish the accumulator full of saturated steam at 500 psia.
CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 40 of 49
i 4.4.3.3 Open Test Valve TV1 and Valvo VS.
4.4.3.4 Slowly throttle open warmup bypass valvo V4 to warmup the downstream piping and test valve. Allow this small steam flow to flow until all piping appears to be warm, close Valve V4.
4.4.3.5 Close Test Valve TV1.
4.4.3.6 Slowly open Valve V4 to allow upstream pressure to stabilize at the accumulator pressure, then open Valve V3.
4.4.3.7 Close Valve V4.
4.4.3.,8 Record upstream pressure. The downstream pressure should be at atmospheric level. Record the downstream pressure.
4.4.3.9 Start the data acquisition system.
4.4.3.10 Open Test Valve TV1. The flow and temperature will stabilize as TV1 fully opens.
4.4.3.11 Record temperature, flow, upstream pressure and downstream pressure.
4.4.3.12 Stop the data acquisition system.
4.4.3.13 Close Valve V5.
CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 41 of 49
4.4.3.14 Examine the data recordings to ensure that all desired reading have been collected successfully and that the test results have not deviated from that predicted by the industry equations or extrapolation of test data. If required thrust is significantly different than that predicted, secure the testing and perform the inspection /dimensioning detailed in Appendices A and B.
Document any conclusions / justifications for the observed conditions.
4.4.3.15 Close Test Valve TV1.
4.4.3.16 Open Valve VS.
4.4.3.17 Repeat Steps 4.4.3.8 through 4.4.3.14 for a repeat test. Evaluate test results for repeatability and any evidence of degradation from repeated valve strokes at these conditions.
4.4.3.18 Open Valve VS, '
4.4.3.19 When flow and temperature stabilize, record flow, temperature, upstream pressure and downstream pressure.
i 4.4.3.20 Start the data acquisition system.
4.4.3.21 Close Test Valve TV1.
CE REPORT NO. 602977-MPB-5EYPR-002, REY. 02 Page 42 of 49
4.4.3.22 Stop the data acquisition system.
4.4.3.23 Close Valve V5.
4.4.3.24 Examine the data recordings to ensure that all desired readings have been collected successfully and that the test results have not deviated from that predicted by the industry equations or extrapolation of test data. If required thrust is significantly different than that predicted, secure the testing and perform the inspection /dimensioning detailed in Appendices A and B.
Document any conclusions / justifications for the observed conditions.
4.4.3.25 Open Test Valve TV1.
4.4.3.26 . Repeat Steps 4.4.3.18 through 4.4.3.24 for a repeat test. Evaluate test results for repeatability and any evidence of degradation from repeated valve strokes at these conditions.
l 4.4.3.27 Close Valve V3.
4.4.3.28 Repeat Steps 4.4.3.2 through 4.4.3.27 for steam accumulator pressures of 1000 psia, 1500 psia, 2000 psia, 2376 psia, 2500 psia.
4.4.3.29 This completes the saturated steam flow CE REPORT NO. 602977-MPS-5EFPR-002, REY. 02 Page 43 of 49 l
i test. To verify the extent of valve degradation, if any, visually inspect and dimension the test valve per Appendices A and B. Compare the results with those of the inspection and dimensioning performed following the static testing. Provide documented justification and evaluation of any observed differences and provide ccrrelation to that predicted by accepted industry equations.
Specifically, an incrcase in required thrust beyond that predicted by industry equation or extrapolation of previous test data should have a corresponding degradation observed in the valve. This shall determine if the operating condition threshold is being approached or has been exceeded.
4.4.4 Two Phase Flow Test 4.4.4.1 Ensure that the prerequisites are met.
4.4.4.2 Establish the steam accumulator full of saturated steam at 500 ::sia and place Pump P1 on recirc at, or slightly greater than, 500 psia by opening Valve V8 and starting Pump Pl.
4.4.4.3 Open Test valve TV1 and Valve V5.
4.4.4.4 Slowly throttle open warmup bypass valve CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 44 of 49
1 1
V4 to warmup *.he downstream piping and test valve. Allow this small steam flow to flow until all piping appears to be warm, close Valve V4.
4.4.4.5 Close Test Valve TV1.
4.4.4.6 Slowly open Valve V4 to allow upstream pressure to stabilize at the accumulator pressure, then open valve V3.
4.4.4.7 Close Valve V4.
4.4.4.8 Open Valve V6.
4.4.4.9 Record upstream pressure and downstream pressure. The downstream pressure should be at atmospheric level.
4.4.4.10 start the data acciuisition system.
4.4.4.11 Open Test Valve TV1. The flow and temperature will stabilize (to the extent possible under these conditions) as TV1 fully opens.
4.4.4.12 Record temperature, flow, upstream pressure and downstream pressure.
4.4.4.13 Stop the data acquisition system.
4.4.4.14 Close Valve VS.
CE REPORT NO. 602977-dPS-5EFPR-002, REV. 02 Page 45 of 49
4.4.4.15 Examine the data recording. Ensure that all test results have been collected successfully and have not deviated from that predicted by industry equation and previous test data. If required thrust is significantly different than that predicted, secure the testing and perform the inspection /dimensioning detailed in Appendices A and B.
Document any conclusions /justific.ations for the observed conditions.
4.4.4.16 Close Test Valve TV1.
4.4.4.17 Open Valve V5.
4.4.4.18 Repeat Steps 4.4.4.9 through 4.4.4.15 for a repeat test. Evaluate test results for repeatability and any evidence of degradation from repeated valve strokes at these conditions.
4.4.4.19 Open Valvo V5.
4.4.4.20 When flow and temperature stabilize, record flow temperature, upstream i pressure and downstream pressure.
i 4.4.4.21 Start the data acquisition system.
- 4. 4.4.22 Close Test Valve TV1.
4.4.4.23 Stop the data acquisition system.
CE REPORT NO. 602977-MPS-5EFPR-002, REV. 02 Page 46 of 49 l
4.4.4.24 Close Valvo VS.
4.4.4.25 Examine the data recordings to ensure that all desired recordings have been collected successfully and that the test results have not deviated from that predicted by the industry equations or extrapolation of test data. If the required thrust is significantly different than that predicted, secure the testing and perform the inspection /dimensioning detailed in Appendices A and B. Document any conclusions / justifications for the observed conditions.
4.4.4.26 Open Test Valve TV1.
4.4.4.27 Repeat Steps 4.4.4.19 through 4.4.4.25 for a repeat test. Evaluate test results for repeatability and any evidence of degradation from repeated valvo strokes at these conditions.
4.4.4.28 Close Valve V3 and Valve V6.
4.4.4.29 Repeat Steps 4.4.4.2 through 4.4.4.28 for two phase flow at 1000 psia, 1400 usia accumulator pressures with Pump P1 discharge pressure at 1000 psia, 1400 psia respectively.
4.4.4.30 Stop Pump Pl.
CE REPORT NO. 602977-MPS-5EFPR-002, REY. 02 Page 47 of 49 I l
e 4.4.4.31 Close or check close Valves V3, V4, VS, V6, V7, V8.
4.4.4.32 This completes the Two Phase Flow Test.
To verify the extent of valve degradation, if any, visually inupect and dimension the Test Valve per Appendices A and B. Compare the result from this round of inspection and dimensioning to the basoline, inspection .
and dimensioning performed following the static testing. Provide documented iustification and evaluation of any observed differences and provide correlation to that predicted by accepted industry equations.
Specifically,-an increase in required thrust beyond that predicted by industry equation or extrapolation of previous test data should have a corresponding degradation observed in the valve. This p shall determine if the operating condition threshold is being approached
~
or has been exceeded.
4.4.5 Results Evaluation 4.4.5.1 The Test Engineer shall evaluate all test results to determine if any of the tests must be repeated. If no test need to be repeated, prepare a summary report of all testing results, any conclusicns, justifications or failures. This shall CE REPORT NO. 602977-MPS-5EPPR-002, REV. 02 Page 48 of 49 l
J
=
include a discussion of extrapolation of data to the line break condition. This shall also include a discussion on correlation to in situ testing and any extrapolation of the in situ test results to verify operability at design basis conditions.
l l
l
)
l l
CE REPORT-NO. 602977-MPS-5EFPR-002, REY. 02 Page 49 of 49
APPENDIX A FORMS AND FIGURES FOR MEASURING GATE VALVE INTERNAL DIMENSIONS AND PERFORMING INTERNAL INSPECTIONS EXTRACTED FROM EPrd'S IN SITU TEST GUIDE FOR
.- MOTOR OPERATED VALVES '
' ~
APPENDIX L PAGES L1 THROUGH L17 RESEARCH PROJECT 3433-03 REV. 01, OCTOBER 1990 .
Page Al of A18 CE Report No. 602977-MPS-5EFPR-002, Rev.01.
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' Guide Slot ,
OA ,
1 gg .. G 2 ---
00 0 f \/ V / /V d i i i 1 t. f l
- 1/ 2* ~ ~
(Typ 4 PO MEASURED ONENSIONS 03 04 G2 G5 OA8 00 0 00 0 3 OlA DIA G1 f See Notes on Sheet 2 l
D-- r '
V j FLOW f gg o
{ j p, p ,
- l- G4 - -- G3 - l -( p U A' ' / A d T OC o -
V g 4 i 1
!e I
- s I ! 'd I
- 02 OIA E_
> a.
a.
]
k -- 0101#. -- 1 MEASURED ONENSIONS 01 \ 02 G3 G6 OC OE" OlA 1 OlA l
- G(
See Notes on ChJet 2 VALVE DISK MEASUREMENTS FIGURE 1 L-1 SHEET 1 CE Report No. 602977-MPS-5EFPrt.002, Rev. 01. Page A2 of A18 l
.- .~. .- . . . . .
m ... m .tes e.we .=
veoes .
. .e Etttit
- 1. If disk seats are solid circles (rather than rings as shawal, thse diaeestens 02 and 04 are inapplicable (eart NA).
- 2. Nasare dimenstems Gl. G2. G3. G4. 01. 02. 03 and 04 estag etal cattpers. Measure staaeters to edge of polished seat surf ace.
- 3. Nasere negles (A. 08. DC. 00 and DE by plactag dist on surface plate and estag a settersal bevel wrotracter (with~ optical magnifter).
If a bevel protracter of sufflctent accuracy (0.I') is met available er caanet be adapted to this measurenset. as alternative approach te esasertog the above magnes caa be used. One such approect is to seesere the ' rise' and 'run' dimenstens of the desired surface relative to the plate. For examele:
-a W f { h *
...w t___
IT I N Y //
are Q.3 -
t/ ////A Q L > L
\ \ M N N N N N N N N N N N s. NN N N. -
DA* = are en was
- 4. G5 and G6 anasareo per figure 4 VALVE DISK MEASUREMENTS FIGURE 1 l L-2 SHEET 2 CE Report No. 602977-MPS-5EFPR-002, Rev.01. Page A3 of A18
. . - - . . . _ . . . . - ~ . . . . . - . . . . . . - - - . ~ . . ~ . . - . - . .. .- - .
ene f. an.acoutts
..e entse
., Plant Name:
Valve LD. Numoort Prepar eti
~ 0 8 --
V 9 q i 0 6 ~- _
I- k - V/// / A l .T ' .
-l 4 /3 4 Wl l llA DS f f 9 ..
em .-
09
~ 07 P
MEASURED OIMENSIONS 05 06 07- 08 0 9 ..
NOTES:.
t D5 and 06 Measured Per Figure 3
- 2. 07 . 08 and 09 Measured Per Figure 4 h
l VALVE DISK SEAT-TO-GUIDE MEASUREMENTS l FIGURE 2 L-3 CE Report No. 602977-MPS-5EFPR-002, Rev.01, Page A4 of A18
,, .. - .. . _ ~ . ~ _ . . - - . . . . , .. - , _ . . - . - . _ . - = . . . . . - . - - ~ - - . - , - ~
h een AssocaAffs.
y ' rt.::."
ADJUSTA8LE PARALtIL 1-2-3 BLOCK 5 (46 gVALVCOtSK X4-PAAAu.tts (23 bi [ t __
i i/
OOO !
OOOOO Ji
)OOOO 0OOOO O OOOO K [,u -
'/ / //////\ //////////'///
SURFACE PLATE x 4- .
vALvu can
[PARAt/{'.S423 M- t _ j7 -
. i. 1 3 stocks to
) . ( t-a-Oc '
'- , O.
W O I -
O -
o y O. .
js
/ '/ /-/. / ////////////
AQJusTA8LE PARALLEL SURFACE PLATE
=
vmw x-x NOTE:FOR NEASURTMENT PROCEDURL SEE SHEET to w
APPROACH FOR MEASURING DISK DIMENSIONS OS AND D6 FIGURE 3 t. 4 SHEET 1 i
CE Report tio. 602977-MPS-5EFPR-002, Rev.01 Page A5 of A18 t- -
- - ~.- . .. - . . .. .-..- . . .-.. . - - - - .. .-.
tape assocsasce p.e.e.es.ee
.. ess4#ee Plant Name: ,,
Vaive 4.0, Numbert Preparer:
PreeMirre and Werteeet fer Mtaintna Ottk Otnenstant Ds and 06 (Fleure 3.
$heet 1 .
- 1. Werttog es surface plate, set me valve disk se tha' each guide surface rssts se a parallel supported by two 12 3 blects. Ensure that guide-surfaces restta9 en parallels am smeeth and free free easage. $btft disk en parallets as neeeed se ensure that the disk it supported on cleaa getde surfaces. 41se. ensam parallels de est tend more than 0.001' due te disk weight. - (Verify estag feeler gage). U e tatuar f arallels er sove 12 3 blocks closer te dist as seeeed te steletas bewiteg.
I 1. Record dimenstes A (eastaal castteed belght of 12 3 blect and parallel) below. It is met secassary to measure this diseasiest use the acetaal dientstens of 1 2 3 blect and parallel.
- 3. Set as adjsstable parallel at sech a disensten se that it just spans tae
- height free the table to the hettes edge si the disk saattag surface (as ,
shoun). Measure steensten E (height of aOssted parallet) uttag a etcre. .
meter to the nearest 0.001', and record below.
4 An accept &ble alternative te seasertog 4teenstes 8 is te ese a ns.chlaist's height gage te detefulne the metet of the.lemer edge of the disk seattog serface aeove the serf.co plate. , ,
- 5. The desired disonstes (05 or 06) is casosted on the wortsheet below as A staus 4.
- 6. Dimeestes 05 is ettateed when stees I through 5 are pcrformed with the downstreae face of the disk factag mensuam . Oteensten 06 is entained when Stoos I threega $ are perforund with the eeumstrene f ace of the elst factog epured.
- 7. Enter results for 05 and DE en Figers 2.
Worksheut Downstrene Face DowmraN Downstrens Face coward A = ta. A = in.
8 = la. S . In.
05 = A . 8 = la. 06 = A 8 * ' in.
a)
APPROACH FOR-MEASURING DISK DIMENSIONS DS AND D6 l
l FIGURE 3 '. - 5 SHEET 2 CE Report No. 602977-MPS-5EFPR-002, Rev.01 Page A6 of A18
)
1 WPA A450Gaf ES p.e.e.4e-er s esgues C2 E2 A2
/ y e2-3 SLDCE (48
)
AQJUSTASLE PAAALLEL
! . . ./_$ . -. j g/J -N V[ '
/ p- i I VALVE OtSK
/
STgu a
-- 11 Axis :
- t 8 PARAL 11L I/
4.
h ... _ _ _ _ _
j
__ / b
) , ! I '
N umE eurc Et At C1
=- WMUSTASLE PARAL 1ZL m vE cisx
/
A 7 eAnAust m '
y I
uma ruTu
,. =- __
Lwi - i / .
l I r J} O ' 0 00000 "N O O 00000 s 0 /\ 0 00000 \
///// /V////// / / / / / // ///
SURFACE PLATE - H2-3 SLOCX t4l MOTYlFOA WEASUREMENT PROCEDURE SEE SMEET 2.
APPROACH FOR MEASURING DISK DIMENSIONS D7, D8, D9, G5 AND G6 FIGURE 4 .g SHEET 1 CE Report ik 602977-MPS-5EFPR-002, Rev.01 Page A7 of A18
wen Assocmarts p.we=er -na essetes
) Plant Hama:
Vake t.D. Number:
Prep arer; PfttMure and Voet1heet fer Obt ainino Otsk Otswasiens DL 08 09. CS and t4 fFleure 4
$hett il
- 1. Worttog on surface plate, set op valvo disk se each getoe surf ace rests on a parallel supported by two 1 2 3 tiocas. The two parallels should t< parallel. with their f actag eoges a distance '815' apart, where 815 is measured from the valve body (Figure 9.
Sheet 1). Versfy the dimenstoe between parallels is equal to 815 at each end (using dial caltsers) withis
- 0.001'. Allgo stes axis of disk with parallels and center etst between parallels (by eye).
- 2. Set as angle plata sear valve disk so that vertical surface is perpendicular to parallels. If parallels are long e w ega, they can be eutted,scuarely agatast angle plata; otherwise, use aa 'L*.souare to set up. ,
- 3. 1st an adjestable parallel ai such a diseaston that it just spans the distance from the angle plate to the edge of the saattog surf ace tu shownl. Matsure dimenston 8 (span of adjusted parallel) ustag a alcrometer to the nearest 0.001' and recera below.
4 Obtate dimensions At and A2 using cattpers to ga9e the dimenston and dial caltpers to measure the gaged disenstoa (to the acarest 0.001') and record below.
- 5. Measure diseastems El and E2 using dial callpers (to the nearest 0.001'), and record
- etiow. .
- 6. Measare diosastens C1 and C2 by setting a parallel on the surface plate and aligning tt with the T. slot noper inside surf ace (by hand). Measure C1 and C2 using a machtatst's scale on the surfaca plata (to the starest 0.01'), and record below.
. 7. All dimensions abecid be obtataed with the downstream face up and with the downstreae face down. The desired dimensions are caloslated as shown on the wortsheet below.
- 8. Entar results for 07. 08 and 09 on Figure 2. Enter rossits for G5 and C6 on Figure 1 Sheet 1.
vertsheet 815 ta. (Fig. 9. Sheet 1)
') owns tre me F a ce Om Oewastrene Face tM
~
A1 = is. Al = la.
M = ta. AZ = la.
8 = la. 8 = te.
C1 = in. C1 = la.
C2 = la. C2 = in.
Eld = in. Ele = ta.
[2d = in. E.2m = in.
la. D7 = 1/2(Al + AZ) . 8 = in.
08 = 1/2(Al + A2) 8 =
in. 09e = 1/2(C1 + C2) - 1/2(Al + A2) = In.
09d = 1/2(C1 + C2) - 1/2(Al + A21 =
C5 = 1/2(EZd + Elu) = in.
C6 = 1/2(Eld + E2u) = in.
? 09 = 1/2(09d + 09e) = in.
AFPROACH FOR MEASURING DISK DIMENSIONS D7, D8, D9, G5 AND G6 FIGURE 4 L _i SHEET 2 CE Report No. 602977-MPS-5EFPR-002, Rev.01. Page A8 of A18
, . _. . ~ . , . ._ - .. . _. ._ - . ._.. 2 . _ _ _ _ - _.
l asmiassocusus roue-se-se Plant Name:
Vatve LO. Hum 0ef.
Propatetr DISK LOCATION 2 i
X X a a t .
LOCATION 1
____/
l Ot3C SEAT LOCATION 3 LOOWNSTEAM FACO
- 03 t- OS2 f/ LS*
I//,l' / O
/,'/ /
LD.
/ OD.
TYPCAL SECTION X-X COWNSTF.EAM SEAT MEA 5URED DIMENSIONS .
012 0S3 l
0 51 LOCATION 1 LOCATON 2 :
LOCATION 3 NOTES: t IF OtSK SEAT IS SCLC CIRCLE tRATHER THAN R8NG AS SHOW94 -
THEN DMENS40N OSt IS INAPPUCASLE LMARK HM
- 2. CNENSIONS CAN SE OgTAlNED SY OtRfCT MEASUREMENT ON TNG OtSK OR ON NPRES$40H mot.DS OF THE DISK SEAT. USE OLAL CAUPERS FOR OSL USE MACMaMcST SCALE FOR 032 ANO
' 053. CITRICON (MANUFACTURED BY F ERR)IS AN ACCEPTA8t.E MOLDNG COMPOUNO FOR USE P6 THIS PROCEDURE.
' DISK SEAT MEASUREMENTS FIGURE 5 L-6 CE Report No. 602977-MPS-5EFPR-002, Rev.01 Page A9 of A18
r.
4' -
'-g e. -.e-o
-^
eserse Plant Name:
' Vatve LD. Number:
Prepator:
- T1 ~ c T8 -
T2- ~ T3 e L_ #' f T4 / /
/
// --
TS
.l- s i
l T10 T5 / ,
f/ / "
l T7 - *-T6 + .
Flow Perpendicular OR
~
Flow Parallel to T-Stot to T-Slot
.~
MEASURED ONENSIONS MEASURED DMENSIONS T1 T2 T3 T4 T5 T8 T7 T8 T9 T10 .
NOTES ,
Fill in One Set of Bases Only. As Appropriate..
Use Olai Caupers to Measure Olmensions, s
h DISK T- SLOT MEASUREMENTS FIGURE 6 L-9
.CE Report No. 602977-HPS-5EFPR-002, Rev.01. Page A10 of A18
. _ . ~ . - . . - . . . . . - . _ . . , _ . . _ . . . _ - _ . . . . - . . _ - . ~ , ~ - . .
we associares e.see-se.ee seson Plant Name:
- )- Vatve LD. Number - ,
Propster *
. e A h Cb-^
e r m y (. . - y 83 - S8
.34 i.
e OW S10 S5 = *-St-h --.
.. S7 ~
-=- S4 + _g_
+--- $1 - - .
9 Flow Pete#ed Flow Perpendicular , 3 to T-Slot to T-Slot MEASURED ONENSIONS MEASURED DNENSIONS S3 i S4 i S5 I S6 l S7 S8, ! S9 l S10 l S1 ( S2 ,
! NOTES:
Fill in One Set of Boxes Only. As Appropriate.
Use Olal Caupots to Measure'Olmeno6cna, h -
STEM T-HEAD MEASUREMENTS FIGURE 7 L-10 CE Report-No. 602977-MPS-SEFPR-002, Rev.0'l. Page All of A18
__ . ~ . _ .. _
.. ,- . . - - . - ~ . . . ~ . . . . - -, ,. - .. . ~_~--.-
une AssoonAres F.ese e-n Plant Name:
van e 1,D. N urntet:
Pt opat et'.
~ 612 ~
- - - _ - _ - . /- N Valv. Body
/ R 3,
~ / /
ss% 3 g --a W s
, m l '
813 OtA FLOW
> 01 0 %
g g.
814 OtA 82 OIA
.l_ 1 i 84 87, } l-a
' ~ ll11 -
MEASURED DSAENSIONS 51 82 83 64 87 B4 8 11 - 8 12 8 13 SW Rt R2 R3 R4 OIA DIA og> OlA s.. woi.. on sn. 2 __ _
_ -?
i
- /
'SWI Q /
a
- I-as- . ..
( FLOW i VALVE BODY MEASUREMENTS FEURE 8 l lIl SHEET 1 CE Report flo. 602977-MPS-5EFPR-002 Rev.d. Page A12 of A18
weaa- aras e.ue .et -
. .e .
,y l
l f21 tit
- 1. If valve body has a single.ptece 'U*. type guide rail. 87 and 88 are not apellcable taart mal. Also, if quies rati extends past bottaa of seat ring. 87 and sa are not apolicable (nart MA). Otherwise esasure 87 and 88 per Figure 10.
Z. Measure seen dlaaeters 81 and 82 when a blue check is perfereed es the valve. Use caltpers to gage the mean diameters off tne disk estca has !
been blue checaed. Use dial caltpers to seasert the paged esaa j diameters. (
- 3. Nessere seat contact widths 83 and 44 den a blee e.hecx is performed ea the valve. Use a sacatetsts scale to esature t*# sest estact tieth. :
Taka esasernesets at least fear places artend f to disk face and record !
the average contact vidth. ;
,,/ 4. Measure diameters B13 and 814 estag caltpers er snap blocks to gage the diameter and dial callpers ta motsere the gaged diaasta . ,
- 5. Messert 44eensteet 811 and O!! esing teside calipers or snap blocks ,.
to gage the steessses and 4tal caltpers to messert the gated diseasten.
- 6. Measert diesestees 11.12. R3 and R4 estag estside caltpers te gage the dimensten and dial caltpers to nessert the geged dimensten. R1 and R3 should be tasan at a locattee approximately en pipe centerline (s1/2tocht. R2 and R4 theeld be taken at the top of the getde.
VALVE BODY MEASUREMENTS FIGURE 8 H2 SHEET 2 CE Report No. 602977-MPS-5EFPR-002,Rev.01 Page A13 of A18
- Plant Name:
-y Yatve ID. Numcor:
Pr eonter:
Plate Wedge Block (Woodl
, 2 \'
A il Q 1 11 I .
i u FLOW ) l1, O
pl B6 - U
- /
? , & c -
i 6f 3^ ,M 4-FLOW ) hig 'II
,, l
/ 1
-- l s _.
. c B9 MEASURED OtMENSIONS B5 B6 89 Bio 815 s.. not.. on sne.t 2 VALVE BODY SEAT-TO-GUIDE RAll MEASUREMENTS FIGURE 9 L,13 SHEET 1 CE Report No. 602977-MPS-5EFPR-002,Rev.01 Page A14 of A18
- A r-se s-s s-w
. .s. ,
I i
!!21111
- 1. lasta11 machined flat plate in valve body egatast gelde rati sliding surfaces. fis plata in position with toosee endte block. (De not deferin plata.) Diseastees 66 and 810 are obtateed eben flat plate
- ts testalled asalest downstream face of gutee rails. Otosastens 65 ac4 33 an obta;aed id.ee flat plata is tastalled agatast upstnaa face of gelde retts.
,) 2. Measure diseastees 65. BA. 89. 810 and 815 esteg adjustcle parallels or anas blects to g49e the diseas*ee and dial Caltpers to seasure the
./
gaged stamasten. 81$ is takaa at a locattee a;qmn:ioately en pipe centarltos (* 1/2 inch).
e VALVE BOO'/ SEAT-TO-GulDE RAll MEASUREMENTS FIGURE 9 i
" f SHEET 2 CE Report No. 602977-MPS-SEFPR-002, Rev.01. Page A15 of A18
4
- e-ee i ,
Body s' '#
Hota:
'/
e If bottom of guide railis not square.
/ f measure to m6dpoint
/
/ . Guide Rail
/
Valve Bouy Retotence Plate
.. _ m - - .
l
'll m
.f p Gulde Ralf (Ah (C)
$64,t Alng ,
~ ~
/ .
hwL E - '
V . -.
.L-I o' _L
?
h measuf ed on c4posite sad, if vaive from h For usasurement Proceoute see Sheet E 3
J APPROACH FOR MEASURING BODY DIMENSIONS B7 AND B0 FIGURE 10 SHEET 1 CE Report flo. 602977-f1PS-5EFPR-002, Rev 0'l. Page A16 of A18
I una mo.utrh L I
. . ..e e.
m, Plant Name:
) Valve LD, Humper'.
Prepaser:
i M.'-Jure fer PeaturiM 01eentient 97 iM 19
- 1. litte volve beer etes at tmt (Itage and stas and dist + moved.
astabilth a refeckace plane by retting a fitt plate 6 cross tM top of the flange. The plate should not completely cover the speetag.
- 1. Uslag a escatalats scale messere disonstems Al. M. 8. and f free LM too surface ef the elate te tbe approtrtate yeiets te LM
- r- set 1/64 ef as tact. If the battaa eeps of the guide rtils in tu ,,< Y are not seuare, use a niepetet of the end of LM telde rail
- tr e usuring Al and A2. Recor1B results below.
- 3. Cater resetta for 87 and te on flyers 8. Sheet 1.
. .=
Mat 12htti .
Al e ta. A2 = la.
Unsinaa Yalve tagI. ital Downtinam Valve Radv Sant I= la. C. to.
87 t .1/2(Al e A2) = la. 38 = C 1/2(Al + A2) e _ in.
4 APPROACH FOR MEASURING BODY DIMENSIONS 87 AND B8 FIGURE 10 SHEET 2 CE Report No. 602977-ItPS-5EFPR-002, Rev.01 Page A17 of A18
_ _ - - _ _ . . ~ . _ _ _ . . . . - _ . _ _ _ . _ . _ . _ , . . _ _ _ _
i
.eoomaves eeme.se.se l Plant Name:
J,,.-
Valve LD. Number:
Prepstert VALyt 900Y SEAT Anal (DOWNSTREAW)
.)
f
( x x k r .\
s LD CAft M t LfA:ATION 8 ,,
P
) Qr"' ,- gr"'
m -
est ,.
sat ,
on, ' oD.
p C0secA4 saAT TYPacAL fuT SEAT setmoM X-X secTeose X-X CowsestpeAte esAT Dowo857nsAad SEAT MEASURED DNENSIONS' _ _ _
' S$1 att LOCAficN t '
toCATom : l l LOCATO4 s l l
l woTc osaawesoses Aas ocTAosen ey WaAsuRawawT oN suPaetssON'
! MOLDS OF THE stat Apes. USS A MACHeati SCAW PCM Os4 Am Oss. CITRICON tWAheUPACTURED SY MEAfu en AN ACCEPTAaLE WoutatMG ('OMPounc stoM USE wt THis PROCEDURL
~
VALVE BODY SEAT RING MEASUREMENTS FK3URE 11' c=t 7 l
CE Report No. 602977-MPS-5EFPR-002, Rev.0'l. Pap 9 A18 of A18
- p. _. _ - . - . _ . _ _ , _ . _ _ _ .
APPENDIX B GATE VALVE INTERNAL INSPECTIONS GATE VALVE VISUAL INSPECTION INFORMATION RECORDING SIEET EXTRACTED FROM EPRI'S IN SITU TEST GUIDE FOR . .:.
v.'
MOTOR OPERATED VALVES APPENDIX M PAGES M1 THROUGH M8 I'
RESEARCH PROJECT 3433-03 REV. 01, OCTOBER 1990 CE Report No. 602977-MPS-5EFPR-002, Rev. 01 Page B1 of B9
3 l
h GATE VALVE INTERNS.L INSPECTIONS GATE VALVE VISUAL INSPECTION 1NFORMAT10N RECORDING SHEET Plant Name:
Valve I.D. Number: ,
- 1. OlskGuideSurfactsHardfaced(Yes/No):
- 2. Valve Body Guide Rati Surfaces Hard Faced (Yes/No): ,
- 3. Stuffing Box Inside Otameter: in I
- 4. Sten Surface Finish in Packing Region: ms
- 5. Stuffing Box inner Wall Finish: rus
- 6. Describe war or damage to disk guides. Focus on ends of guide slots.
Include extent and depth of wear areas if possible. Indicate wear or damage areas on Figure 12 of this data sheet: ,
I i
- 7. Describe wear or damage to valve body guide rails. Focus on upstream face of guide rails. Include extent and depth of wear areas if possible. Look for deformation of unsupported lengths of guide rails.
Indicate wear or damage areas on Figures 13 and 14 of this data sheet:
t Sheet of MOV No.
Preparer:
u-1 ,
CE Report No. 602977-MPS-5EFPR-002, Rev.6L Page 82 of 69
. . _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ . . . . _ _ _ . . . _ _ _ _ . _ _ _ _ . . . - - _ . _ . _ _ , , _ . _ _ _ _ _ . _ . . _ . _ . , ~
GATE VALVE INTERNAL INSPECTIONS GATE VALVE VISUAL INSPECTION INFORMATION RECORDlHG SHEET
- 8. Describe wear or damage to disk seat surfaces. Focus on lower half of downstream seat surface. Include extent and depth of wear areas if possible. Indicate wear or damage areas *on Figure 12 of this data sheet:
- 9. Describe wear or damage to valve body seat rings. Focus on lower half of downstream seat ring. Include extent and depth of wear areas if 3 possible. Indicate wear or damage areas on Figures 13 and 14 of this jf data sheet: .
- s
- 10. Describe valve body guide rail configuration. Select type of configuration from exuoles provided on Figure 15. If type of g Jide rail configuration is not shown, draw in configuration on sketch marked "Other Type Guide Rail Configuration'. Fill in answers to questions opposite appropriate rail configuration sketch.
l Sheet of MOV No.
- Preparer:
l CE Report No. 632977-MPS-5EFPR-002, Rev.01 Page B3 of 89
t GAfE VALVE INTERMAL INSPECTIONS
)
GATE VALVE VISUAL INSPECTION INFORMATION RECORD!HG SHEET
- 11. Other Rerarks:
8 t
I l
-l ..
l Sheet of _
MOV No.
Preparer:
P.- 3 CE Report No. 602977-MPS-5EFPR-002, Rev.01. Page 84 of B9
. . _ , . _ . _ - _ _ . - m.. __ - _.._ _______.- _ _ _ _ _ _ _ _ . . _ _ _ _ . _ _ . ,
1 Sheet of ___
MOV No, Preparer;
)
GATE VALVE INTERNAL INSPECTIONS GATE VALVE VISUAL. INSPECTIM INF4%T10N RECORDING SHEET
^
DOWNSTREAM FACE UPSTREAM FACE I
s x s w e
ll i
a,'
V 7 V T -'
7-T 7 .
N \
g \ .
> \
\
Q9 Flow now \ '
\ N \
\
1 1 1 i
A
- G
'L_ D
}
VALVE DISK WEARIDAMAGE LOCATIONS
'e- 4 FIGURE 12 CE Report No,- 602977-MPE-SEFPR-002,Rev.01 Page B5 of 89
.t
--~.~-_a_-.L-._____.., _ _ _ . . - - . _ _ . _ . _ , . . . . . . . . . - . . . _ _ . _ . . ~ . . _ . . _ . _ _ _ . _ _ _ _ _ _ . _ - _ . - . . . _ _ _ _ _ . - - _ . . . . . - - _ - - . , _ , . . . , . - . . _ _ , . - . . .
Sheet of MOV No.
) Prena.rer:
CATE YALVE INTERNAL. IMSPECTIOKS CATE VALVE VISUAL. IRSPECTION INFORMATION RECOPalHG DIEET
// l
/ /
/ /
fg . ! /
-( ,
FLOW
// ///\r 3
/ l/
-9 f/ 'rg
/ -
/l
/ a/ -
^*
) ..
[
mqw,,ygww a
VALVE BODY WEAR / DAMAGE LOCATIONS FIGU RE.13 n.c CE Report flo. 602977-MPS-5EFPR-002,Rev.01 Page B6 of 89
Sheet of Mov No.
Prepater-:
l 1
l I
l GATE VALVE INTERNAL INSPECTIONS GATE VALVE V!st!AL !KSPECTION INFORMATIOi4 RECORDING S!!EET l
i l
t i
r ,_
.) -
~
[ N A .Dh
~
x M -
1 e l
f l VALVE BODY WEAR / DAM. AGE LOCATIOt4S FIGURE 14 I
CE Report No. 602977-f tPS-5EFPR-002, Rev,01 Page 87 of 89 '
\
Sheet _. of MOV No.-
Prepnter:
. GATE VALVE INTERMAL INSTECTIOMS GATE VALVE VISt!AL INSPECTION INFORKATION RECORDING SNEEl' I
N// """
Guide rail faces machtned.
/ as-cast, or hand-ground?
l /
e g6 h j ._.
// p .
/ ,r Use This Figure For
. Valve Body cuide Rails Cast in Placo . .
. N/
/
_['T . Continuous or discontinuous
/ weld?
/ 'T / . Olstance between welds
. I' /
^
(dimensionA): in
. Frei length at top of rail
._. (dimensionB): in
. Free length at bottom of rail
q j'p (dirensionC): in Use This Figure for Valve Body Guide Rails Welded in Place 4
VALVE BODY GUIDE RAll CONFIGUriAT10N FIGURE 15 g SHEET 1 CE Report tio. 602977-tips-5EFPR-002, Rev.01 Page BC of B9
i MOV ilo, s Preparer:
GATE val.YE INTEPJ(AL INSPECTIONS GATE VA!.YE VI!11AL IRSPECTION INFORMATION RECORD 1MG SHEET n
/ . Note unsupported length of
! / guide rail (dimension 0):
/ /
-777 l y/
I k W /zf'r//N Use This Figstre For
. Capttrred (or Rennytble) Valve Body Guide Ratis . ..
i W// '/ l . Draw in guide rail configuration.
/ /
/ . Guide rail faces machined,
/ as-cast, or hand-ground?
. Note unsupported length of guide rail: in y,- .
. / /
Use This figure For Other Type Guido Rail Configuration
( t VALVE BODY GUIDE R All cot 4FIGURATIOt1 FIGURE 15 SHEET 2 CE .; port No. 602977-MPS-5EFPR-002,Rev.01 Page 89 of B9
APPENDIX C COPY OF LETTER 0-MPS-91-098, REV. 01 DATED JULY 12,1991 FROM A. A. OSTROV (ABB-CENP)
TO P. A. ADAMO (ABB-CENP)
OPPD FORT CALHOUN BLOCK VALVES HCV-150, HCV-151 -
OPERATING CONDITIONS l
l CE REPORT liO. 602977-MPS-5EFPR-002, REV. 03. Page C1 of C11
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ABB ASEA BnOWN BOVE Al Inter Office Correspondence July 12, 1991 0-MPS-91-098, Rev. 01 Supersedes the original memo dated July 3, 1991 Toi P. Adamo xct P. P. Ferraraccio R. F. Paakkonen D. L. Bibiga MPS Filo Quality Records From: A. A. Ostrov o C Subjects OPPD Fort Calhoun Block valves EcV-150 and -151 operating Conditions
References:
- 1. Fort Calhoun Design Basis Document SDDD-RC-128, Reactor Coolant, March 1990.
- 2. CE Report CDI-114-P, Review of Small Drea.k.
Transients in Combustion Engineering Nuclear steam Supply Systems, Amendment 1-P, July 1979.
- 3. Fort Calhoun Station Unit No. 1 Operating Instructions OI-RC-1, RCS Normal Operation, March 1984.
- 4. Fort Calhoun operating Licnnse DPR-40 and Technical Specifications, Amendment 109, May 1987.
- 5. Calculation 83888-MPS-5 CALC-012, Rev. 00, Low Temperature Overpressure Protection for 20 EFPY, issued May 18, 1990.
- 6. Memo PSA-85-042, Dresser PORV Capacity for Liquid Upstream Conditions, Feoruary 20, 1985. !
- 7. Suppler.ent 1 to Generic Letter 89-10:
Results of the Public Workshops, Issued June 13, 1990.
- 8. EPRI/Wyle Power operated Relief Valve Phase III Test Report, Volume 3: Summary of Phase III Testing of the Dresser Relief Valve, HP-2670-LD, Interim Report, October 1982. l
- 9. Fort Calhoun Updated Safety Analysis Report !
(USAR), Rev. July 1987. l Page 1 of 3 CE fuTORT tD. 602977-MPS-SITm-002, REY. 01 Page C2 of C11 L
I ..
Ref. (cont.) 10. Engineering Evaluation of Feed and Bleed for TI4FW Events at Fort Calhoun Stat 4.on, Report, December 1988. >
- 11. Fort Calhoun Station Unit No. 1 Emergency Operating Procedure EOP-20, " Functional Recover' Procedure", Rev. 07.
Enclosure FCS Block Valve Functions and Operating Conditions (for Various Events) - Tables I thru VII. .
! The Enclosure provides Fort Calhoun ftation (FCS) PORV block valve functions and expected operating conditionc for seven events during which block valve operations may be rTguired.
These data are generated in response to your request to support the effort to develop testing guidelincu fer the block valves.
Two of the events addressed, nariely, A Stuck-Open* PORV
, (Enclosure, Table I), and A Leaking PORV (Table II) are the original design basis events for these block valves. The remaining five events are included herein as a result of (1) New safety-related functions, beyond the original design basis, that PORVs are now required to perform, and/or (2) Generic Letter 89-10 recommendation to consider MOV mispositioning in addition to design basis events in determining limiting operating conditions during block valve opening and closing on demand.
These remaining five events are as follows:
Enabling the LTOP System (Table III),
FSAL Chapter 14 Events (Table IV),
.Once-Through-Cooling Following TIDFW (Table V),
Functional Recovery of RCS Pressure control Using PORVs as a Succesu Path (Table VI), and Long Term Cooling Following a Small Break LOCA The caseh in each table identify various scenarios for a particular event. These scenarios result from different initial conditions, operator actions and/or equipment availability.
The data in the tab'.es were derived from the references.
Although some of these references such as References 2,6, and 10,
, were not originally QA-verified, there is high confidance in the E
accuracy of the data contained therein, since in each case, the data were verified through independent engineering review.
Page 2 of 3 CE REPORT 10. 602977-MPS-5EFPR-002, REY.01. Page C3 of C11 I
I.._._,._,_,.._,__,~., , _ , _ , _ _ , , , . _ _ , _ . . , . _ . , _
The parameters provided in the encit., sed tables are as follows:
P., is the maximum bicek valve upstream (line) pressure in a particular case (scenario) at the and of the valve closing stroke or at the beginning of the opening stroke.
P% is the minimum block valve downstream pressure during valve operation. Generally, this parameter is not readily available; it depends on flow rate through the PORV, PORV discharge piping resistance and quench tank pressurs, and needs to be calculated. A conservative value of 15 psia is assumed for each case to mitximize AP., (see below) . This value represents the containment atmospheric pressuro assuming that the quench tank rupture diec is ruptured.
- AP., is the maximum differential pressure across the block valve in each case.
- Q is the maximum flow rate through the bicck valve in the fully open positien.
- Temperature and phnse refer to the conditions of the fluid flowing through the block valve.
The information contained in the enclosed tables provides a sufficient data base to approp. intely identify testing l conditions. It should be noted that both the block valves and i the PORVs at FCS are located in the loop ueal inlet piping I
configuration. Bas 6.d on information recently obtained from OPPD, this loop seal is normally filled with condensate. This condit!,on may need to be accounted for in testing of the block valves to the most limiting scenarios in Tabica I thru VII.
e e ramo has been QA-verified in accordance with the applicable requi);ements of QAM-101.
AAO: sit l AA0004.WP VERIFICATION STATUS: COMPLETE USDNA,Y3E9E E2' Eci U f#f 9 F89" 3 f3 CWh IQ1.
R.1%u - (2 d e 67XIW '
l b:upaxuntamew: tes.m Nyue.can l l
CS RSPORT to. 603977-MPS-5EFPR -002, REV. 01 Page C4 of C11
i Enclosure to Memo 0-hPS-91-098, Rev. 01 l Page 1 of 7 Table I f_(L PORY Block Valve Functions and Qperatino Conditions.
CASE VALVE P,
P b m AP, Q TEMPERATURE & NOTE FUNCTION ps T psia psi ibm /hr PHASE NO I-l CLOSE 2376 15 2361 110,220 sat. steam (2) (3) 1-2 CLOSE 2180 15 2165- 100,400 sat. steam (4) 1-3 CLOSE 1400 15 1385 (6) sat. steam, (5) 160,000 two-phase. (7)
(6) liquid I-4 CLOSE 1130 15 1115 (G) sat. steam, (8) 137,000 two-phase, (7)
(6) liquid I-5 CLOSE 1200 15 1185 (6) sat. steam (5)
NOTE: (1) This is one of the original design bases of the subject block valves.
(2) This is a hypothetical case (scenario) based on Reference 1 '
(Attachment 18) data.
(3) P,, is assumed to equal PORV blowdown pressure.
(4) This case is for LOFW event with two stuck-open PORVs, per Reference 2, Section 3.10.3.3.
(5) This case is for LOFW event, per Reference 2, Section-3,11.3.6.
The PORVs are assumed to stic(-open when RCS pressure' starts decreasing at t - 10,000 sec., per Fig. 3.11-19.
(6) Q is not cticulated.
(7) 0 is conservatively calculated based on a critical flow model for saturated we.ter.
(8) This case is for isolation of small breaks, per Reference 3, Section 4.2.
(9) This case is for inadvertent opening of a PORV, per Reference 2 Case 4.
l VN CE REPORT NO. 602977-MPS-5EFPR 002, REV. 02. Page C 5 of Cll
^
Enclosure to Home 0-MPS-91-098, Rev. 01 Page 2 of 7 Table 11 FCS PORV Block Valve Functions and Operatino Conditions.
Event: ALEAKINGPORV$
CASE VALVE Pb in AP , Q TEMPERATURE NOTE FUNCTION P,ps U, psfa ps7 lbm/hr &
NO PHASE _
11-1 CLOSE 2150 (3) (4) 3,050 53t. water (2) 9 NOTE: (1) This is one of the original design bases of the subject block valves.
(2) This case assumes that leaking occurs during plant normal operation at full power. P = normal operating pressure plur 50 psi tolerance, per M Terence 3; Q is assumed to equal the maxit,Lm allowable reactor coolant leakage ratn (10 gpm, Reference 4, LC0 2.1.4).
(3) This pressure is close to P since the flow rate through the closed PORY is low (Q = 305 P b /hr).
(4) In light of Note (3) above, this pressure differential is negligible.
4 9 q
Enclosure to H:mo 0-MPS-91-098, Rev. 01 Page 3 of 7 Table !!!
FCS POI 9 Block Valve F. unctions and Operatino Conditiam Event: Enablino the LTOP System " L CASE VALVE P3 m A P, Q TEMPERATURE ~ NOTE NO FUNCTION P, ps II psfa psi ibm /hr &
PHASE 111-1 OPEN 485 15 470 225,000 Water, 82*F (2) ,
Ill-2 OPEN 1743 15 1720 68,000 sat steam (3) (5)
III-3 OPEN 2500 15 2485 130,000 sat. steam (4) (5)
NOTE: (1) Block valve mispositioning is postulated for this event.
(2) This case igresents the lower pressure - temperature boundary of the LTOP region. P is equal to the maximum transient pressureinthatregio,nl,seeReference5);Qiscalculated using Equation (1) of Reference 6.
(3) This case represents the upper pressure - temperature boundary of the LTOP region for 20 EFPY. P is equal to the maximum transientpressureinthatregionIs,eeReferance5).
(4) This hypothetical case assumes both PORVs are unavailable for LTOP transient mitigation: one, due to a single failure, another, due to a closed block valve. This assumption is based upon interpretations of responses to Questions 7 and 8 of Reference 7. It is assumed that an attempt to open the mispositioned block valve is taken during an LTOP transient when pressure approaches the safety valve setpoint (P, ).
(5) Q is calculated based on actual Oresser PORY flow test data obtained from Reference 8 and a critical flow model.
l l
l CE REIORT fD. 602977-MPS-5EFPR-002, REY.-01 Page C7 of C11
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Enclosure to Memo 0-MPS-91-098, Rev. 01 Page 4 of 7 Table IV FCS PORV Block Valve Functions and Operatino Conditions.
Event: FSAR CHAPTER 14 EVENTS CASE VALVE P, , Pb in AP , Q TEMPERATURE NOTE NO 7 UNCTION psia psfa ps7 lbm/hr &
PHASE IV-1 OPEN l 2500 15 2485 130,000 sat. steam (2)
NOTE: (1) Block valve mispositioning is postulated for this event.
(2) This case is for a Loss of laad event (see Reference 9) during which pressure can reach the safety valve setpoint. Q is the same as in Case III-3.
4 p02 { -MS }E m @ 2, PEV. 01 Page C8 of 011 I .. , _ _
~
Enclosure to Hemo 0-HPS-91-098, Rev. 01 Pege 5 of 7 Table V FCS PORV Block Valve [sagtions and Operatina Conditions.
Eventt Once-lbroua kCoolina Fo110wina TLOFW'"
CASE VALVE P3 AP ,, Q TEMPERATURE NOTE NO FUNCTION PT ps psfa in psi ibm /hr &
PHASE V-1 OPEN 1700 !! 1685 72,000 sat. steam (2)
V-2 CLOSE 1200 15 1185 180,000 water 540*F V-3 OPEN 2500 15 2485 126,000 sat, steam NOTE: (1) Block valve mispositioning is postulated for this event.
(2) This and other cases in the table represent various scenarios addressed in Reference 10. P,,, and Q for each case are per Reference 10.
4 CE REPORT to. 602977-t4PS-5FEPR-002, REY. 01 Pa9e C9 of C11
- =
Enclosure to Hemo 0-HPS91-098, Rev. 01 Page 6 of 7 l
Table VI FCS PORV Block Valve Functions and Operatina Conditions.
Event: Functional Recovery of RCS Pressure Control Usina PORVs as a Success Path"#
CASE VALVE P, in AP, Q TEMPEPATURE NOTE NO FUNCTION ps IY P,ps fa psi lbm/hr &
PHASE VI-1 OPEN 2500 15 2485 130,000 sat. steam (2) (4) l l
VI-2 CLOSE 2300 15 2285 110,220 sat. steam (4) l VI-3 OPEN 1200 15 1185 180,000 water 540*F (3) (4) ,
NOTE: (1) Block valve mispositi aing is postulated for this event'.
l (2) This case has the same fluid conditions as Case III-3.
(3) This case is similar to Case V-2.
(4) This case is identified based upon Reference 11, pp. 183-184.
l CE REPORT !O. 60^977-t4PS-5EFPR-002, REV. 01 -
Page c10 of C11
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Enclosure to Hemo 0-HPS-91-098, Rev. 01 Page 7 of 7 l
Table Vl!
LCS PORV Block Valve functions and Goeratino Conditions.
Event: Lona Term Coolina followino A Small Break LOCA'"
CASE VALVE P, y, P b in A P,,, Q TEMPERATURE NOTE NO FUNCTION psia psfa psi lbm/hr &
PHASE (2)
NOTE: (1) Block valve mispositioning is postulated for this event.
(2) This event, described in Reference 9 Section 14.15.4, is similar to the Once-Through-Cooling Following TLOFW event addressed in Table V (page 5) in that during both events E0Ps instruct the operators to open PORVs for RCS heat removal. In the subject event however pressure generally tends to be lower than in the other event because of a break in the RCS pressure boundary.
As a result, it is concluded that block valve functions and operating conditions during the subject event are enveloped by those in Table V.
l.
i l
CE REPORT to. 602977-MPS-SEFPR-OO2, REV. 01 Page Cll of Cll
APPENDIX D LETTER FROM OPPD STATING THE MAXIMUM AMOUNT OF CONDENSATE UPSTREAM OF A CLOSED PORV BLOCK VALVE AT -
FORT CALHOUN STATION
- CE REPORT No. 602977-MPS-5EFPR-002, REV. 01 Page D1 of D3 2 - - - - - . . - _ __ -. .>
, .- ..,_-w--- : - -
\ . .- - -
Onuha PitbGc Power Distziet P.O.Dx 309 Hwy.75 Northof Ft.Calhoun FortCalhoun.NE 000230329 402/636c000 July 24, 1991 PED-91-NP-064E Mr. Peitro Adamo ABB Combustion Engineering Nuclear Power 1000 Prospect Hill Road P. O. Box 500 Windsor, Connecticut 06095-0500
SUBJECT:
Omaha Public Power District (OPPD) Octen61 nation of Water Weights in the PORY Relief Lines Ocar Mr. Adamo The purpose of this letter is to officially transmit the values of water weight in the pressurizer relief lines if the lines are completely filled with water.
These water weights are for the relief lines to the Power Operated Relief Valves (PORVs)only.
The attached sketch shows the piping configuration with corresponding pipe lengths and size. This sketch was developed using Fort Calhoun Station Isometric Drawing 10-158, Revision 2, GSE File 35712.
By using the piping size and lengths, the weight of water per unit length of pipe for the corresponding pipe size was obtained using the tables in " Mark's Standard Handbook for Mechanical Engineer's," Seventh Edition.
Using this methodology, the results from the attached sketch are as follows 1J.EE. WATER WEIGHT (LBS)
Press pizer to PCV-102-1 66.37 .
Pressurizer to PCV-102-2 64.51 If you have any questions regarding the above, please feel free to call me at 402-533-7303.
5 Sc5 Ralph K. Schwartzbe HOV Program Engineer RKS:cjf c: T. J. Melvor R. E. Lewis CE REPORT NO. 602977-MPS-5EFPR-002, REV. 01 Page D2 of D3 l
1
,csu s.o. ,
GENERATING STATION ENGINEERING l
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Leot,rn et (?.v.i LYEf.its. To b-fot-l = lb. 3 o 8
- ' 3
. Oeu.H r sr dyna. Ichte 1.53 S*/cr =. 2.5. O t* ,
"1 l 22 . .Pc A.: 15,o i Kr.s Q n Lua.w os PC2,4.NI2*a r or '.J ATa. T. Pc.0-ta: Ia ?,9e = 53 r 2 2.3.14"
,. <w. i
- l - . Wm Unry_Wmar 9 f.53
- v -
to [
29 30 31 t 22 33 EV-Ot.CO c e l 7 bNo MLD o Goo r k Ecker4st At, 0410 CC8-3 A Vene.t5 %~4, k ik A4. e , $ m w E D g T-l 0 4 Tomt P.03 i
CE REPORT No. 602977-MPS-5EFPR-002, REV. 01 Page D3 of D3
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