ML20094N602

Staff Exhibit S-54,consisting of Vendor Nuclear Qualification Rept Including Test Methods,Actual Aging Parameters,Environ Tests & Qualified & Design Life

ML20094N602
Person / Time
Site:	Farley
Issue date:	02/14/1992
From:	LIMITORQUE CORP.
To:
References
CIVP-S-054, CIVP-S-54, NUDOCS 9204070024
Download: ML20094N602 (38)

Text

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3-5Y Staff Exh. 54

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TABLE OF CONTENTS 1

1.0 GENEPAL '

l.1 Purpose Page 1 1.2 Method Pape 1 2.0 TEST hETH00 2.1 1EEE Test Guides Page 1 to 3 2.2 Aging Regsf rements Pag 1 3 to 6 2.2.1 Life Aging Prge 3 to 4 2.2.2 Dis:us:; ion - Aging Page 4 2.2.3 Mecanical Aging Page 4 to 5 2.2.4 Raciation Aging Page 5 2.2.5 Se smic Aging Page 6 2.3 . Accident 11vironmental Simulation Page 5 to 9 2.3.1 Gereral Page 6 to 7 2.3.2 Stam Line Break Page 7 to 8 2.3.3 Te t Parameters Page 8 2.3.4 Dit:ussion - Outside Contoiment Qualification ' Page 8 2.4 Environmertal Qualification Acceptanct Criteria Page 9 3.0 ACTUAL AGING PRAMETERS 3.1 General- ,

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• 3.2 Thernal Afing Page 9 to 16

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3.2.1.1' iiscussion Page 9 to 10

,~ 3.2.1.2 bntainment

• Page 10 to.ll 3.2.1.3 f.utside Containment hge 12 to 13 3.2.2 Sw tch Mai:erials Pege 13 to 1(

3.2.3 Se:Is Page 14 tc 15 3.2.4 Me:al Components Page 15 3.3 'Mechanica Aging Page 15 to 16 3.4 Radiation Aging Page 16 to 17 3.5 Seismic Page 17 to 20 3.1.1 Ealy Tests Page 17 to 18 3.5.2 Anlysis - Internal Resonance Page 18 3.5.3 Reonance Search Below 5 Hz Page 18 to 19 3.5.4 Di;cussion - Cross Coupling Page 19 3.5.5 Swtch Chatter Monitoring Page 19 to 20 3.5.6 Reonance Search Acceleration Levei Page 20 4.0 ENVIRONMENTAL *EST 4.1 General Page 20 to 24 4.1.1 Omlification Sumary Page 20 to 21 4.1.2 Deign Philosophy Page 21 4.1.3 1%nting Position -

Page 22 '

4.1.4 Ge)eric Qua'.ification Page 22 4.1.5 E.vironmental Parameters Page 22 to 23 4.1.6 Rduced Voltage Page 23 4.1.7 E:ectrical Measurements Page 23

(' 4.1.8 A:eptance Criteria Page 24 l

4.1.9 k:uator Loading During Qualification Page 24 i - .,

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. 4.2.2 Discussion - my Page 25 4.3 PWR Qualification Page 26 4.4 Superheat Temperature Test Page 26 to 27 4.5 Outside Contairrnent Page 27 to 28 4.6 0.C. Actuator Page 28 4.7 Seismic Qualification Envelope Page 28 to 29

5.0 CONCLUSION

Page 29 to 30 6.0 DE$1GN LIFE 6.1 Lubricant Page 30 to 31 6.2 Switches Page 31 7.0- QUALIFIED LIFE Page 31 8.0 INSTALLATION Page 32 9.0 LUBRICATION Page 32 10.0 MAINTENANCE 10.1 Operation Fage 32 10.2 Maintenance Procedure Page 32

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' APPENDIX G

1.ubrication Data - Form LC8 Maintenance -Procedure - Fonn LC9 Appendix A

.h BWR Containment Qualification - 60037GA V -Appendix B

' PWR Containment Qualification - 600456- Appendix C Outside Containment Qualification-Report B0003 Appendix 0 DC Actuator Qualification - Report B0009 Appendix E

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~ Seismic Qualification Envelope-Report B0037 Appendix F Superheat Temperature Test-Report B0027 Appendix G

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i 5114 hbodall Road . P. O. Box 11318 Te% hone--804 528-4400 Lynchburg. Virginia 24506 Telex--82 9448 I 070038 NUCLEAR QUALIFICATION 1.0 GENERAL 1.1 Purpose A qualification program was developed to demonstrate that the design '

of Limitorque's safety related actuators sre adequate to insure they will perform their safety related function during a DBE (Design Basis Event) condition in a nuclear power plant.

It is also the intent of. the qualifications to satisfy the requirement 3

,h ^ of NRC Reg. Guides 1.73 and'1.89.

1.2 Method The various methods of qualific'aticn used in this program include experience, analysis, and testing. In the testing phase of this program, IEEE 323-1971, IEEE 323-1974. IEEE 344-1971 IEEE 344-1975, and IEEE 3_82-1972_ were used as guides. The prime effort in qualification is directed toward type tests of complete actuators with experience and analysis being applied to establish the guidelines of the type test and extrapolate the results.

2.0 TEST METHOD 2.1 ~IEEE Test Guides _

IEEE 323 is the general standard for qualifying all Class IE electrical l

j Automated Valve Coeenter s and Jacks for incuatry

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t i J equipment. IEEE 382 is the specific test guide for valve actuators in Class IE service. IEEE 344, in turn, is the gui.ie for seismic l

qualification which supports both of the above documents. Both 0904 '}f) lEEE 323 and IEEE 344 were the f'rst documents released and were later revised to ericompass inre detail and to update them to more current practice.

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IEEE 323-1974 is a general qualification stancard that encompasses all )

electrical eqJipment in a nuclear plant, whereas IEEE 382-1972 is directed specifically to cover valve actuators. Both documents provide the same guidelines for qualification making them complementary to each other.

. The Limitorque environmental qualifications wete conducted per IEEE ,

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38,2-1972 and meet the requirements of IEEE'323-1974 as they. apply to valve actuators.

Both IEEE 382-1972 and IEEE 323-1974 address the requirements of pre-aging the equipment to simulate a 40 year life and then delineate LOCA

(, Loss of coolant accident) conditions that could be expected in a cantainment chamber for both BWR and FWR reactors. They also establish spray compositions and flows that would be expected to occur.

l Bota .dE 382-1972 and IEEE-323-1974 stipulate the same basic qualification parameters, except that in addition IEEE 323-1974 makes mention of vibration aging such as would be experienced by pipe mounted equipment and also suggests margins (criteria over and above expected conditions) i f a

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l that should be considered to establish a substantial 9evel of safety I

to the results of the test. 070M40 Vibrati(n although mentioned in IEEE 323-1974, is not defined in relation to either intensity or frequency. Genera'lly, in power plant applications, thit vibration would be of low intensity (low acceleration less than 1G) which exist whenever the plant is generating power The accelerations are not of sufficient intensity to cause actuator failure or malfunction. The only effect low intensity system vibration nas on Limitorque equipment is to produce a tendency for fasteners, which are not properly tig'htened, to become loose. Due to Limitorque's long power plant experience as weil as shipboard experience where the vibrations are much more severe, we can discount low intensity system

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y1bration as a potential problem a; ea and, thereforu, vibration is not

'- addrassed in environmental qui,ifications.

All of the Limitorque environmental qualificati.ons contain substential margin es shewn later in this qualifica: Ton.

The qualifications were conducted to er.compas.; the entire family of Limito*qu actuators - SMB, SB, SBD, and SMB/HBC in all available unit sizes (SMB-000 to SMB-5). This was accomplished by conducting the qualification testing on a mid size unit (SMB-0) subjecting the actuator j to simulated seating loads equivalent to tne actuators published unit rating during the test procedure.

2.2 Agina Requirements l (

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2.2.1 Life Aging The valve actuatcrs are aged wnere applicable, to place them in their 3

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07044.1 I end of life conditions. This means that the accumulated degradation of 40 years of service is incorporated in the equipment prior to subjecting it to an " accident or DBE" condition. It is the intent of this aging to establish a 40 year qualified life for Limitorque actuators without major maintenance or replacement of s. mmponent or lubricant.

This aging is broken into four major cater . - thermal, mechanical, radiation, and seismic.

2.2.2 Discussion - Aging In normal operation, themal aging, mechanical aging, ar.d radiation aging would occur simultaneously throughout the life of the plant.

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For purposes of this qualificatien, the themal aging is the first aging process .since it is intended to add conservatism and margin to the qualification. ,

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Thermal aging consists of subjecting the actuator to elevated tempera-tures for specific lengths cf time to simulate any degradation cauh1 to the unit in its installed ambient temperature plus any elevatM temperaturt: caused by operhtion during its 40 year life in a Nut..ar power Genen ting Plant.

Since metal parts are uneffected by moderate elevated temperatures, only organic parts are ccnsidered for themal aging.

2.2.3 Mechanical Aoing i

Mechanical aging is the second step of the aging procers. Mechanical aging simulates the mechanical wear the actuator would experience e

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070442 i{ during the 40 year plant life. This consists of stroking the actuator from . set "open" position to " closed" torque seated position and then back to the original open position for a minimum of 500 stroke cycles per the requirenents of IEEE 382. The actuator is required to develop its full output rating at the "torqr ;eated" position to simulate its mechanical life.

2.2.4 Radiation Aging Radiation aging consists of subjecting the entire actuator to garrrna radiation equivalent to that which would be experienced in a Nuclear Power Generating Plant during normal life (40 year) plus " Accident or DBE" condition. This is normally accomplished by exposing the unit to irradiation from a colbalt 60 source. Specific irradiation levels vary ,

depending on the location in the Nuclear plant in which the equipment is installed. Generall'y , containment actuators are exposed to a total irradiation of 204 megarads and outside contairvnent actuators to a total irradiation of 20 megarads.

Of the total irradiation dosage, four megarads simulates normal life radiation exposure and tne remainder is the " accident" condition exposure.

Since the accident conditier. is considered to have been co-incidental with a seismic event, the normal life irradiation can be applied prior to seismic aging with the remainder applied following seismic aging.

Limitorque test experience clearly demonstrates that for Limitorque actuators there is no difference on the equipment as a result of where irradiation occurs in the aging sequence.

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2.2.5 Seismic Agino Seismic aging is comprised of subjecting the test actuator to mechanical vibration to simulate an earthquake situation. In order to assure that the worst case condition has been used, it is necessary to deter-mine if any natural frequency resonance exists ir, the frequency range of interest. A resonant frequency search froin 1 to 33 f.a frequency range is conducted. If no resonance is evident, the seismic aging can be performed at the approprie.te "G" level at any frequoicy between 1 - 33 hz and equally simulate seismic conditic7s as far as the actuator is concerned.

During the seismic dwells, the unit is stroked to simulate operating a valve to the torque seated position (usually full closed) and back. ,

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to the e9posite unseated position (usually full open) to v'erify .th,at the actuator would perform satisfactorily duririg this event. Due to limitations of the available " shaker tables", the stroke of the actuator is normally limited to a shorter stroke time for the seismic aging.

The length of stroke of the actuator during a seismic dwell is not related to the :eismic aging and operation is meant to verif/ the operability of the actuator. The actuator is fixtured to develop its rated thrust and torque at the simulated valve seated position.

2.3 Accident Environmental Simelation 2.3.1 General The environmental accident condition is simulated by exposing the actuator to a steam-temperature-pressure condition with possible spray 4

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exposure. IEEE 382-1972, Table'l on page 12 outlines the environmental conditions for actuators located in the contaiment chamber of a PWR and Table 2 on the same page outlines the enviromental conditions for actuators ~ located in the containment chamber of a BWR. Limitorque, in pursuing its Nuc~ ear Qualification Program, used these tables in establishing both radia~ tion and environmental chamber test parameters.

In addition, the actuators were exposed to two pressure-temperature transients to include additional margin in the test results. Further.

the tests were conducted with saturated steam instead of superneated steam which subjects the actuators to pressures much in excess of those seen during an actual accident condition.

-- Due tc,the " unsealed actuator' design,'this over-pressure forces additional k .. . -

' moisture into insulating materials and in effect adds considerable ,

conservatism (margin) to the qualification test.

2.3.2 Steam Line Break

'In recent months, Nuclear Power G :nerating Plant derigners have been addressing the possibility of a main steam line break (MSLB) in the containment chamber of a PWR which does not significantly effect the

-qualification pressure as seen during a LOCA but does increase the temperature substantially. The temperatures indicated by the Nuclear Industry vary from plant to plant with the highest known to date of 4920 including margin. In all cases, this high superheated temperature 7

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containment chamber rapidly diminishes to levels r.tipulated for a .

i LOCA in IEEE 382-1972.

?. 3.3 Test Parameters -

In containment chamber environmental qualifications, as suggested by IEEE 382, the tests were conducted foe 30 days. The first four days of the test encompass the most severe concitions of the DBE. During the next 10 days, environmental conditions lessen and tend to be -

nominal for ialve actuator service. The remaining 16 days of excesure are intended to increase confidence level (See Note - Part' III, Section  ;

(4'), Pasa 12 of IEEE 282-1972).  !

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j P. 3. 4 Discussion - %tside Contginment Qualifiestion Outside Containment Yalve Actuater Qualificatioil parameters are not l

de=cribec by 7EEE 382 '.972. An sccident condition for an outside g

containment valve actuator would be caused by a steam line break which f

would allow steam to impiege on thf attua tor for a short duration. Due f to the location of the actuators (Outside CJntainment) substLCtial prersures could not be established thereby limiting the taperatures sasn by the actuators. Typically, this pure steam environment would neve ambient temperatures of 2200F (pressure of 2 ?sig) Siv:a the steam  ;

impingement is cf short duration. Limf *orque conducted a M day test inchding two trtnsienes which would ;rovide ample margin to qualify _y the Limitorque valve actuator for outside containment service.

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\ 2.4 Environmental Qualification Acceptance Criteria The basic function of a valve actuator during a nuclear accident condition is to provide the required torque and/or thrust to actuate a valve to either the opan ur closed position, as required. Also,

-it is recuired that limit switches ard torque switches function properly to provide control of the equipment without producing malfunction.

All qualifications conducted by Limitorque have been directed toward the actuator providing its rated thrust / torque and that both the limit switch and torque switch are providing the proper control . The remainder of information obtained during the qualification is considered

. informa tive.

3.0. ACTUAL AGING PAP)N GERS

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3.1 General .

A. IEEE 382-1972 stipulatas test requirements necessary to demonstrate the adequacy of a valve actuatcr to provide the rated mecnanical force during life cycling, seismic aging, and a Post-LOCA transient. The l

valve actuator is aged to the end of 40 year life by:

1. Thermal aging

2. tiechanical aging (cycling) l -3. Radiation aging (exposure to gamma irradiation) l 4 Seismic aging 3.2 Thermal Aginq

! 3.2.1.1 Discussion -

Thermal aging is incorporated in the overall test plan to place the

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equipment in its end of life condition so that the effect of the CBE test can best be evaluated.

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.FM 02q4D Each natorial of the actuator r2sponds differently to thermal aging P depending upon its chemical composition. Some materials, such as ,

metalic parts, do not respondit all, while other materials, such as ,

. motor insulation,- respond in proportion to the thermal rating of material vs. the thermal environment in which it is located.

I Life aging of organic materi !s used in motor insulation can be ,

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. accelerated by exposing the components to elevated te.nperatures for short periods of time. This is detemined from a thermal regression curve (Arrhenius Equation) which plots failure life against tuperatwe exposure by plotting a line parallel to the failure life curve from a point representing the average arabient temperature and desired life.

, . The thermal regression curve for Limitorque Class RH and typical Class B

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motors, established per IEEE 101-74 and 117-74 a*re discussed below.

3.2.1.2 Containmen c- .

THERFAL LIFE OF LIMITORQUE RH MOTOR INSULATION AT VARIOUS TEMPERATURES PER EQUATION LOG LIFE = 512,2. - 5.8930 1

Degrees ' Degrees-Life  % Life Centidrade  : Kelvin Hours increas_e, 180 ~ 453 259,324 100 373 69,008,000 239 90 363 164,889,000 251 80- .- 353 413,919,000 265 70 343 1,096,338,000 281 60 333 3,078,799,000 299 50 - 323 9,216.906.000 10

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070048 Referring to the life table established above, it is noted at 600C that average life failure would occur in 3,C78,799,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br />. Forty years of service at an ambient temperature of 600C (Typical of containment continuous ambient temperatures) is equal to .01% of the average failure life. Degradation to the insulation systen would be proportional to the percentage of failure life which as can be seen above is a very small figure with the expected degradation negligible.

This means that artificial life aging of Limitorque Class RH motors for purposes of environmental qualification would be unnecessary.

Although heat ging was theoretically unnecessary, no actual test data was available to support this position at the time so' heat aging was included in our test program.

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Heat aging was based on the average ambient containment temperature only without regard for the motor thermal rise. This was cone because the motor temperature rise would creata insignificant degradation. To illustrate this, a typical motor (5'#) with an average stroke time of _

30 seconds and a typically average motor run load of l'# would experience a motor temperature rise of approximately 2 0C, Considering the number of valve strokes normally required over the 40 year life of the power plant, the dditional motor aging incurred by valve operation would be extremely negligible and can be disregarded.

The RH insulated motor was heat aged at 1800C for 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> which per the above life table theoretically ages the motor fer 135 years based on 600 C average ambient temperature and proportioning to the thennal I liic figures above.

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J3;2.-1.31 Outside containment _

. THERMAL LIFE OF A TYPICAL LIMITORQUE CLASS B MOTOR

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INSdLATION AT-VARIOUS TEMPERATURES PER THE EQUATION LOG LIFE - 4675.475

- 7.045 r

~0egrees. Degrees Life  % Life Centigrade. Kelvin' Hours Increase  ;

-100- 373- 309,000 220

- 90 363 684,000 230 q 60- 353 1.584.790 '

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Tr 60 333 9,S96,030' y -

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,, 50 323 26,925,000 .

290 40 l313- 78,100.000 i'

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Referring to the life . table' established above,: 1t is noted at- 500 C that average life: failure would occur in 26,925,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br />. Forty years of 1 service atL500C (Typical-of outside containment continuous ambient

'a ' temperature)his equal to 1.3%'of the failuie life.

Degradation to the insulation system would be. proportional to the

percentage of; failure life which as can be seen above is a very sma'.l.

figure with' the expected degradation negligible. This means that iartificial life aging .of Limitorque Class B motors for- purposes of p , ,, ,--

environmental qualification.would be unnecessary The motor, henver,

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070750 t( did receive some accelerated aging by virtue of being installed on the actuator during the actuator thennal aging at 1650 F (73.90 C) for 200 hours0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> and an average 97.50 C for 144 hours0.00167 days <br />0.04 hours <br />2.380952e-4 weeks <br />5.4792e-5 months <br /> during the mechanical cycling.

At the time of our qualification testing program (November 1974) there were and still are no IEEE 382 standards te provide guidelines on test profiles and parameters for outside containment quaification. Concurrent with our test program, the IEEE 382 subcommittee working group was in process of writing a revised IEEE 382 standard which was intended to provide aging as well as transient profiles and parameters for "outside containtent" qualification testing.

. When we began our test progr&m, the IEEE subecomittee discussions hAd . .

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1 progressed to the point.of general agreement that a,cceptable pre-test '

environmental and mechanical aging was achieved by exposing an entire 0

actuator and motor to 165 F,100". Rli for 200 hours0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br /> in addition to applying a total of 2,000 simulated operating cycles, keeping the motor at a

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tee.perature of approximately 97/980C. Since the IEEE subcommittee was inYestigating actuator aging and was considered an authority on the subject, Limitorq'ie accepted 'he aging procedure.

3.2.2 Switch Materials Expanding on Section 3.2.1.1, thermal aging is a function of the thermal rating of the material in question. When considering the phenolic insulation material used for switches, U.L. was the only reference that could be found that addresses thermal rating / life of plastics.

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.I. - Underwriters Laboratory has conducted detailed studies into many

- phenolics deriving a published temperature index. This index is considered the maximum teaperature at which the material can be used continuously. An article titled "A New Temperature Indes.; Who Needs It" published in September 1970 in " Modern Plastics" discusses the iridex and indicates how it was established. The article indicates that the temperature index was established at the point where the property of impact strength, tensile strength, or dielectric strength reduced to one-half 6f its new value at the conclusion of 6 x 104 hours0.0012 days <br />0.0289 hours <br />1.719577e-4 weeks <br />3.9572e-5 months <br />.

The switch material we are using is a molded phenolic which has a

. tenperature index of 150 0C. Since a valve actuator is ar intermittent operating device and does not run continuously, it would be safe to assume the aging characteristic follows the 100 C rule.

j' Considering a 600C ambient as the base for an aging temperature, tne switch material would reach its 50% property (the same base as U.L. used) in 3.07 x_107 hours. Forcy year life would represent 1.2t of available L

.-life. Since degradation would be directly proportional to life, it becomes obvious.that degradation would be negligible and for purposes L - of _ qualification, artificial aging could be disregarded without effecting the results of the_ qualification.

- 3.2.3 Seals Limitorque actuators for Nuclear Plant application are designed to permit then to survive riormal and accident conditions withoat depending h .

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OSOO32 I. ~ -on absolute sealing. In fact, the ambient is not absolutely restricted from entering the actuator. The seals are of no importance for qualification and, therefore, require no consideration for the qualification.

3.2.4 Metal Components Metal components are unaffected by aging and would not respond to thennal aging. No effort was made to themally age the metal components.

3.3 Mechanical Acing -

Prior to subjecting the complete valve actuators to mechanical aging, the unit was mounted on a torque stand and the torque switch was calibrated to obtain the rated output torque. The test stem was chosen with acme threads to obtain the rated thrust or slightly above. This simulates seating of a valve exposing the test unit to Comparable Ivads,

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as would be expected during valve operation.

• IEEE 382-1972 requires a ' minimum of 500 cycles. During the period of conducting the various qualification tests, the industry considered increasing the number of aging cycles to 2,000. The IEEE 382 subcomittee during this same interim adopted 2,000 aging cycles for insertion in the new draft of the IEEE-382 document. As a result, aging for the BWR qualification (600376A), whic iad already been coupi sted before tne new mechanical aging considerations took place, consisted of subjecting the unit to 500 stroke cycles for mechanical aging. The PWR qualification (600456) consisted o'f subjecting the unit to 1,208 cycles prior to the temperature-pressure transients with the remainder of 2,002 cycles after

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, comoletion of the day; envirornnental exposure. The Outside containment-Qua1111 cation (80003) consisted of subjecting the unit to 2,000 cycles during the nonnal aging sequcmce. In all cases, the actuator was cycled- from an "open" position (controlled by a Itmit switch) to a -

torque seated "close" position and back to the "open" position. The

actuator was required to produce its full output rating at- the " torque seated" . potition.

' At the conclusion of the temperature-pressure environmental exposure in

all of_ the qud1fications, the actuators were disassembled and inspected.

In all. cases there were no' signs of wear, but did show the nonr,a1 polishing

-showing the' gearing had been "run in".

__ 3.4 - Radia cion ' Aging - -

e ,IEEE 3J2-1972. Part III, Page 11, suggests that 'all' irradiation be accomplished prior to seismic aging, or alternatively divide the irradia-tion into twe'er more parts;:ene conducted prior to seismic (4 M rads) and the o* Der _after seismic' aging (200'M raos).

"In our BWR Report (,600376A), the actuator was subjected to 4 megarads prior to_ seismic aging with the remaining 200 megarads applied af ter 1

set s.aic laging. . In the PWR Reoort:(600456), ali radiation aging was-applied following seismic aging.. In our outside-containment report

(.B0003)., the entire actuator was subjected to the full 20 megarads irrt. iation prior to saismic aging. In fact, during the 80003 test, two motors with~ Class B insulation, in addition- to the motors on the actuators, .

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Yc..  ! O'10A $4 m were also qualified and were subjected to 204 megarads prior to seismic 4,

aging. This high radiation level was-incorporated to detemine the affect of very high radiation on the Limitorque Class B insulation system.. In all cases, there was no noticeable detrimental effect of-radiation on any component in any of the test sequences or radiation level employed.

3.5 Seismic, During the environmental- qualifications, each of the actuators was seismically aged to insure that no physical weakness exists in the-actuator-that would affect the qualification.

in the several- environmental qualifications we have conducted, we have noted that preaging (themal, mechanical, or irradia< tion up to 204 '

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megarads) has no affect on the ability of the Limitorque valve actuator to. qualify to a seismic test.

Although all Limitorque actuators, type SMB/SB/SBD/SMC/HBC are a generic family, they do not--.all possess the same center of gravity. To insure that the actuator picked as " representative" of the actuator family truly represents the entire family,'a seismic envelope was constructed-(Report-l- 80037. " Seismic Qualification Envelope").

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3.5.1 Early Tests Since the seismic aging conducted for both the BWR and PWR were conducted prior to release of~IEEE 344-1975, the detail procedures we are currently e

l using were not followed. However, as shown below, it did not effect the

(' 4 validity of the results.

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'4 The. great number of sei'mic tests we have conducted have shown no resonances or cross couple effects exist below 33 Hz, pennitting single axis testing per the second paragraph of Section 6.6,6, Page 22 of IEEE 344-1975 (lack of resonances or cross coupling make the dwell frequency unimportant since it would be equivalent of repeated static loading). The only difference between the seismic aging conducted for both PWR and BWR qualifications and current day seismic testing is the search for cross couple effects, which does not add to the seismic aging of the actuator. The seismic aging conducted for the qualifications is equal to current day testing.

3.5.2 Analysis - Internal Resonance Considering the gssibility of resonance occurring in the internal i'

componen. . of the Limitorque val t actuator, an engineering evaluatien shows that the elenents used in the construction of Limitorque actuators are rigid members with clo;ely spaced supports with resonant frequencies much in excess-of 33 Hz. This same stipulation is true with cross coupling since resonance is required before cross coupling could exist.

3.5.3 Resonance Search Below 5 Hz Some of the earlier seismic tests did not include resonance or cross couple searches below 5 Hz. This was due to the fact our engineering avtluation concluded that resonances below 5 Hz would not occur in a Limitorque valve actuator. Also, the test equipment used for these earlier tests was unstable and would provide erroneous infortnation below 4 to 5 Hz, so no search below 5 Hz was included.

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More recent tests conducted on a hydraulic table with resonance and cross coupling search from 1 to 33 Hz have verified our previous evaluation that Limitorque valve actuators have no resonances or cross coupling below 5 Hz nor as proved by earlier tests up to 33 Hz.

3.5.4 Discussion - Cross coupling Several of the Aero Nav lab report data indicates the possibility of cross coupling existing in the Limitorque valve actuator. These tests were conducted on a mechanical table that was subject to " cross tar' An investigation conducted on the table alone showed that accelera x existed in other than the axis of excitation. In fact, the mapping of .

the table showed that it also had a rotary motion as well as a rocking motion.

(

Ouring the seismic test shown in Peport 5-6167-5, matching accelerometers were countee on +.he table and the Limitorque actuator in each of the three axis. Comparison cf the readings of the accelerometers on the tab,le to the matching accelerometers on the unit shows the Limitorque actuator following the table motion. This indicates there is no cross coupling ,

in the actuator and that the accelerations measured in axis other than the one excited are created by the table. Recent seismic tests on a hydraulic table verify that there is no cross coupling or resonance from 1 to 33 Hz.

3.5.5 Switch Chatter Monitoring The switches used in Limitorque actuators have been monitored on several seismic tests checking for switch chatter. Most of the tests were s

19

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/(- conducted using- an-8 millisecond " chatter" relay with recent tests

. I checking for " chatter" of. l- millisecond duration. No chatter has yet been detected.

l .5.6 - ' Resonance Search Acceleration Level Resonance searches.and cross coupling searches were conducted at a j i

fractional 9 level sufficient to excite any resonances that might exist. '

The Aero Nav seismic tests were conducted on-a mechanical table that.

is excited by counter-rotating adjustable weights. Adjustment of these H weights can be accomplished only when the table is not operating. As the frequency of excitation is increased, the acceleration level is also increased. During these seismic tests, resoncnce and enass coupling search scans ',were conducted at g levels .of -.1- to 1.0.g to minimize the number -

.b; of times'the weights are reset. In our recent seismic tes,ts with a -

hydraulic? table, the g level during the resonance-c.ross couple scan is - f retained at .2 g. ,

4.0 ENVIRONMENTAL TEST

. 4.1 Generni 4'.l .l_ , qualification Sup_ary.

To provide full qcalification of:the Limitorque valve actuator for the Nuclear' Industry, we chose to conduct four environmental qualifications and supporting seiscic data consisting of:

A.

Containment Chamoer af BWR (Report 60G376A)

B. Contaiment Charrber of PWR-(Report 600456)

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C. Outside Contaiment (either BWR or PWR) (Report 60003)

D. Limited Qualification DC Actuators (Report B0009)

E. Scismic Qualification Envelope (Report B0037)

Nh During recent months, a short-cent '.est (Report B0027) was conducted to establish information that would permit existing qualifications to

^

be used for the postulated accident of a steam line break.

m .f 4.,1,2 Desion Philosophy In all cases the philosophy of using an actuator that did not require j complete integrity of sealing was used. In fact, containment units f

include "T" drains to permit them to breathe.

Limitorque adopted this philosophy to minimize maintenance man-hours in a contaiament chamber which would be necessary to replace seals on ,

a periodic schedule and the extremely difficult chore of assuring the actuator doesn't leak when exposed to an external pressure which would actually be the responsibility of the utility once the actuator shipped from the manufacturer's plant.

The second reason for adopting this philosophy is to orovide additional confidence in Limitorque valve actuators by eliminating the concern that t any one of the several seals or gaskets might start leaking during plant operation which in all prooability would assure failure of a " sealed" actuator in event of a DBE.

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07063,9 4 '

4.1.3 Hounting position The mounting position of the actuatar was chosen with the limit switch compartment up and the motor horizontal. This is considered the worst possible position because it allows any condensate that collects in the unit to flow through the motor to provide the most damaging ef fect on its insulation system.

4.1.4 Generic Qualification, Ger:aric qualification means qualifying a group (family) of actuators by subjecting a valve actuator representative of the family to the aging and environmental criteria indicated in this report. The qualification of the Limitorque Size SMB-0, as reported in the documentation of each of t'he ' four tests, was used to generically qualify all siz'es of

[_ ^

Limitorque operators for the environmental ' test' conditions in accoroance 1,

with IEEE 382-1972. The Size SMB-0 actuators is an average mid-size unit, and all other sizes of the type SMB, SB, SBD, and SM3/HBC are also deemed qualified. Ali sizes are constructed of the same materials with componer.ts designed to equivalent stress levels, same clearances and tolerances with the only difference being in physical size which varies corresponding to the differences in unit rating.

4.1.5 Envircrrnental parameters In addition to the aging discussed in Section 3, the valve . actuator, during envirornnental testing, is exposed to two thermal-pressure transients instead of the one that would t,e actually experienced during

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Jl, lal Nuclear Accident: tc introduce additional conservatism in the test.

~0ur Reports 600376A and 600456 for inside contaim. ant and B0003 for

\ outside containment all :in luded in the attached appendices reflect the result _of. qualifications to the above parame+.crs.

x 4.l.6 L Reduced voltage =

-No effort wasmade to introduce reduced voltage' testing in the environmental' qualification because it would not have created the most severe coerating condition on the actuator. The test actuator is sized >

to obtain-the maximum' output torque and thrust as well as developing the maximum torque it would~ see in the heaviest' loaded normal application.

LDuring' normal sizing for a Lreduced voltage application, the motor 9- sizing -is increased-to provide- the requ' ired motor torque at the reduced' ,

A voltage. ; InLahtual' service, at 100 percent voltage, this motor' is

lightly. loaded: subjecting it to _a much less severe duty cycle than the

motor tested environmentally. . Since the environmental qualification subjected the test motor to a more rigorous condition than the motor- ,

iniactualiservice, the motor that possibly might be subjected to reduced voltage is covered by the qualification.

14.1.7 Electrical Measurements

-The current voltage and power measurements tabulated in each of the qualifications show some inconsistencies. Those inconsistencies have

- no effect on-qualification.since the purpose of the test was to demonstrate U operability throtighout the qualification, which was achieved. These

-g measurements have no meaning in relation to an actual unit installed in a Nuclear _ Power Generatin' g Plant since the power and current requirements

.would differ from enlication to application and could not be compared to the test unit.

23

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-" .4.1.8 - Acceptance Criteria-w IEEE :323-1974, -Section 3,1 Page 8.--stipulates:

' " Equipment' Qualification. The generation and maintenance of evidence toLassure the equipment can operate on demand to meet the system per-

formance requirements." i

, Increlation to valve actuators, this means that the actuator be capable of opening or clocing at valve or, demand.

4.1.9 - Actuator Loading Durino Qualification InLall~ Limitorque qualifications, prior to mechanical aging, the torque i

switch was set to'obtain the units nominal torque and thrust retings and left at this setting for the-entire qualification. - The thrust was measured prior.'to and following mechanical aging. Itwas,measuredij /

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the case of the PWR-qualification, immediately after installation fin .

.the : test chamber,i during the steam-chemical exposure, at conclusion of (sf '

O' the envirorusentalg test and finally 'at the conclusion of the-post load

cycling,. all by means;of. attest stem operating against a load cell mounted 6

external?to the test chamber.

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@ The thrust remained substantially~ constant, with minor diff:rences s

L< attributed .to change of friction between the stem nut and test stem.

4'.'2f BWR Qualification' Report 600376A

4. 2.1 Actuator Loadino 7 ,

lThe valve actuator tested included a self-contained thrust tube and was-

. . , arranged--to trip by torque switch to simulate seating of a valve. The m N; l.

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• actuator was Lycled during the'BWR environmental qualification at the

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times showW in' the report. being subjected to the simulated valve seat load each time.

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The-torque. switch was set at 1-7/8 prior to mechanical aging and retained at' this setting throughout the entire qualification. Thrust-was not ' measured.- however', it can readily be determined by referring to'the-PWR Report 600456 that.the torque switch does retain its

. calibration even when exposed to higher pressures and tenperatures. ,

-It.is logical to assume the actuator was subjected to its rated thrust and torque- throughout this qualification.  ;

i L4.2.2 0iscu:,sio' n - Spray .

Paragraph 4.5'.'l, Category III of IEEE 382-1972 indicates a prime

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. , , concern for-injection of chemicals into the environmental chamber with -

little regard for spraying: pure water. In the stiuplated . SWR LOCA conditions,-_ t the high tanperature levels, the steam is in a super-

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heated conditio'n,:which would mean that any water spray applied, whether

-in the environmental chamber or actual containment chamber, would immediately

. flash into steam. Saturated steam conditions necur only at the lower

' temperhtures ..

The BWR qualification conducted at Franklin Institute was accomplished with low quality steam throughout the entire test. . Daring the low temperature partions of the test, a heated pool of. water and daily injections of steam insured complete saturation of the chamber atmosphere.

g It becomes obvious the surfaces of the valve BCtuator were completely -

wetted by water with their being incapable of holding more fiuid.

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. k i~ 4.3 PWR Qualification Report 600456 .

_IEEE 382-1972, Part III, Page 11. suggests that all irradiation'be accomplished prior to seismic aging or alternately divide the irradf a-tion into two or more parts; one conducted prior to seismic (4 M reds)-

and the other after seismic aginn (200 M rads),

e In our ?WR Report (600456), we describe that the sequence was thermal aging, mechanical i.ging, seismic aging, radiation aging, and environmental I  ; qualification. This did not apply the life radiation prior to seismic ,

aging as it had already been established that the sequence used relative to radiation' aging was unimportarit in tems of actuator response. This

-aging sequence was further justified by our Report 80003. During the

- outside contairinent qualification (B0003) two motors with Class B f insulation were su')Jected to 204 megarads irradiation ' prior to seismic 7;ing and environmental qqslification. No problems were experienced with these motors during the qualification even though they were subjected to irradiation well in emess of the lav.el recommended for Class B

. insulation.

- 4.4lSuperheat Temperature Test.

Recently, 'in.the Nuclear Industry, parameters have been established to accommodate the possibility.of a Main Steam Line Break driving containment chamber temperatures up to 492 o- p for a short period of time (few minutes).

'f P Pressures remain substantially the same. Due to the heavy metal sections of the actuator, which act as a heat sink. Limitorque theorized that the

) .-

internal areas of the actuator would not exceed saturated steam temperature ,

during the few minutes it would be exposed to the high superheated 20

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D'?nnt;4

-i temperature. In interest of verifying this theory, Limitorque con-ducted a 6 hour6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br /> superheat test subjecting an actuator to superheated temperatures of up to 3850 F at a pressure of 66 psig. The actuator was not connected electrically to permit use of thermo couples on limit switches and in several locations in the limit switch compartment.

Report B0027 describes the test and proved the actuator acts as a heat sink, maintaining saturated steam temperatures corresponding to the test chamber pressure, even with elevated ambient temperatures for short durations of time. This test proves that the existing BWR

, (600376A) and PWR (600456) containment qualifications are applicable and qualify Limitorque valve actuators for a Main Steam Line Break DBE.

4.5 Outside Contairrnent Outside containment ambient conditions during a Nuclear Accident are'not defined in IEEE 382-1972 IEEE 323-1974, or for that matter, in any official standardization cocument currently known to Limitoroue. prior to conducting this test, Limitorque contacted reactor manufacturers and consultants to determine conditions that might be expected in this area.

It was determined that a steam line breal could create saturated steam temperatures at pressures only slightly exceeding atmospheric pressure for short duration. On basis of this information, Limitorque establisned the conservative 16-day qualification as shown in Report 80003.

The SMC-04 actuator, although of different housing material, would be qualified for outside containment service by the SMS outside containment l7 qualificatu n, Report 80C03.

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( The primary effect on qualification created by.the above mentioned

, variation in the SMC-04 would be in mechanical cycling, seismic s capabilities, and the effect of radiation. Mechanical cycling tests under, simulated- valve loads, irradiation exposure and seismic testing of the SMC-04 demonstrates the actuator reacts the same as the SMB to the aboveLparameters supporting the fact the SMC-04 is qualified by Report B0003. These additional test reports are available at

'Limitorque for audit purposes.

4.6 0.C.' Actuator

.In relatio'n; to- the Nuclear D.C. actuator. need arose for a qualification

}'

for a BWR Nuclear Generating Plant for specific environmental conditions, f This'L resulted 'in the qualification Report B0009 Test conditions consist of a. temperature-pressure transient to 340d F (120 psig) in a '

. pure steam ambient holding for one hour and slowly dropping temoerature to a flow of.212 F.at the end of seven hours and holding for the remainder of. the' test (25 hours2.893519e-4 days <br />0.00694 hours <br />4.133598e-5 weeks <br />9.5125e-6 months <br /> from start of test). The test irradiation level was 10 megarads.

lOn prot 'sion the radiation level .is suitable, due to the :everity of the pressure and temperature profiles, this would qualify the Nuclear.

0.C. actuator for outside containment service or li:nited inside containment Y use.

4. 7__ Seismic Qualification' Enveloce

_ After considering the generic line of Limitorque valve actuators and 28

3

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unit combinations, it was decided that to demonstrate a true generic qualification for actuators fr use in Nuclear Power Generating Power Plants, it was necessary to perform additional seismic tests enveloping the entire Limitorque actuator line. The Seismic Qualification Envelope B-0037 includts seismic tests of typical and the most severe actuator configurations and unit combinations that would be supplied for Nuclear Plant Service. Since these seismic tests are to demonstrate the validity of the ceneric family concept, they were not subjected to aging or any other environmentsl qualification requirements. It is intended that the Seismic Qualification envelope be used to support the above environmental qualifications and not be used as qualifications in and of itself. These tests, however, do qualify the equipment to IEEE 344-1975 because as previously mentioned, preaging has no effect on Limitcrque actuators.

It has to be recognized that the various physical combinations and cg relationships in the unit sizes constituting the generic Limitorque actuator line has an efft.t on seismic qualification that does not effect other areas of environmental qualification.

5.0 CONCLUSION

Mid-size Limitorque valve actuators were subjected to four comolete environmental qualifications consisting cf BWR, PWR, Outside Containment, and D.C. Qualifications. Each qualification exposed the actuator to thennal and mechanical aging, radiation aging, seismic aging, and environmental transient profile test. To investigate the effect of the recently conceived steam line break, an actuator was subjected to a very 29

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1

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c E90M7 0(-

i high.superheated temperature to demonstrate that the electrical components

of the actuator never exceeded che saturatad temperature correspondir,;

to the ambient pressure for. the short duration of the test. This shcrt i

tem test proves the existing qualifications envelope the steam line break 08E for superhected temperatures as high as 4920 F for a few minutes.

All the qualifications were conducted per IEEE 382-1972 and meet the requirements of IEEE 323-1974 and IEEE--344-1975 as they apply to valve

' actuators. Further, since the actuators performed satisfactorily without .

4 maintanance throughout the various qualifications, the Limitorque valve actuators'are fully qualified for use in Nuclear Power Generating Plants.

6.0! DESIGN LIFE The-inside containment and outside c' ontainment actuators are of the'same

' basic designjand construction with some differences in material to pemit .

- the- actuator to withstand' the more severe containment chamber DBE conditions.

These differences consist.of use of different phenolic insulating material for the switches, a. special motor. insulation system, Viton seals instead

~

of. Buna N, elimination of all external aluminum parts and the use of "T"-

E '

. drains and grease relief valve to-accomodate the extreme temperatures and pressures of containment 08E environments.

5. 6.1 -Lubricant Life expectancy of. the lubricants would be difficult to ' access due to 4

the.many variables that would differ from unit to unit located in the .

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$.me Nuclear Fiant. towever, on provision the lubricant is maintained per Limitorque Procedura LCB and not subjected to contamination, it would have a design life expectancy of 40 years.

6.2 Switches It has been noted that irradiatton of 204 M rads does effect the appearance of the gray switch insulating material provided for contain.

mer.t char.ber service. This slight change of apbearanca e,f the material has no measurable effect on its insulating proper ties. Short-term cavelopment tests conducted on non-irradiated switches show they respond

- identically to irradiated switches when subjected to the same environmental conditions. Since the* containnent switches in the units that were * *

-(- qualified were also exposed to the 204 megarads gamma irradiatign, th) .-

design life expectancy "of the containment switches :as well as outside contcinmers switchas is 40 years.

7.0 QUALIFIED LIFE Since the entire actuator, including matcr. lubricant, seals, and switch components were subjected to the same detrimenta, elements and actions it would be expected to see in its 40 years life, and furthei since at the conclusien, the unit was subjected to a simulated LOCA condition without failure with verification that a DBE condition of steam line Leeak is equal to the LOCA condition, the Limittrque valve actuator is considered qualified for 40 years.

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070497)

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4 8.0 INSTALLATIONg Limitorque Lorporation Release SMBI-17C, " Instruction and Maintenance Manual" provides installation information. Relating to containment chamber actuators in addition to the above, install the two motor drains as indicated on the tag on the actuator and after the equipment is powered, remost the Silica Gel fmn the limit switch compartment.

-9.0 LUBRICATION ,

The " Lubrication Oatt from LC8 included in the appendix describes recomended lubrication maintenance. Recognizjng the fact that access to containment .

chambers of Nuclear Plants are limited, the lubrication inspection '

frequncy can be paried to match the containment chamber maintenance

'4 (f period 'of 12 to'18 months.

10.0- MAINTENANCE .

10.1 It:is _recomended that Limitorque valve actuators be operateo periodically, not less than twice a year to maintain.a coating on operating parts and also to remix the grease to maintain it.in proper condition.

P-10.2 Maintenance Procedure luring maintenance periods, perform the routine maintenance functions  :

. indicated on Limitorque Maintenance Procedure, Fonn LC9, included in

• Appendix A l

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