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Effective March 21, 2008, this report has been made publicly available in accordance with Section
734.3(b)(3) and published in accordance with Section 734.7 of the U.S. Export Administration Regulations.
As a result of this publication, this report is subject to only copyright protection and does not require any
license agreement from EPRI. This notice supersedes the export control restrictions and any proprietary
licensed material notices embedded in the document prior to publication.
Volume I
Effective March 21, 2008, this report has been made publicly available in accordance with Section
734.3(b)(3) and published in accordance with Section 734.7 of the U.S. Export Administration Regulations.
As a result of this publication, this report is subject to only copyright protection and does not require any
license agreement from EPRI. This notice supersedes the export control restrictions and any proprietary
licensed material notices embedded in the document prior to publication.
EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com
ORDERING INFORMATION
Requests for copies of this package should be directed to the EPRI Distribution Center, 207 Coggins Drive, P.O.
Box 23205, Pleasant Hill, CA 94523, (925) 934-4212.
Electric Power Research Institute and EPRI are registered service marks of the Electric Power Research Institute, Inc.
EPRI. POWERING PROGRESS is a service mark of the Electric Power Research Institute, Inc.
Copyright 1999 EPRI, Inc. All rights reserved.
CITATION
This report was prepared by
Kalsi Engineering, Inc.
745 Park Two Dr.
Sugarland, TX 77478
Principal Investigators
Bahir H. Eldiwany
Daniel Alvarez
and
EPRI Nuclear Maintenance Applications Center (NMAC)
1300 W.T. Harris Blvd.
Charlotte, NC 28262
This report describes research sponsored by EPRI. The report is a corporate document
that should be cited in the literature in the following manner:
Valve Application, Maintenance, and Repair Guide, Volume 1, EPRI, Palo Alto, CA: 1998.
TR-105852-V1.
iii
REPORT SUMMARY
The Valve Application, Maintenance, and Repair Guide is a two-volume series that provides
a generic overview of valve application, selection, maintenance, and repair. Volume 1
of the series is a comprehensive reference on the application and use of valves that
provides guidance on the selection of specific types of valves on the basis of functional
and system requirements. This document is based on an earlier EPRI document (NP6516, Guide for the Application and Use of Valves in Power Plant Systems). Extensive
illustrations and sample calculations make the guide useful to a wide range of
personnel. This volume has been expanded to include general maintenance
requirements and diagnostics for different valve types.
Information on valves and valve operators, where other comprehensive NMAC
documents are available (such as Air Operated Valves, Solenoid Valves, Check Valves, Safety
and Relief Valves, and the Technical Repair Guide series on Limitorque operators), have
been referenced without duplicating the contents in this volume.
Background
The improper application, incorrect use, and ineffective maintenance of valves in
power plant systems cause significant losses in plant availability. Over the last several
years, EPRI, the U.S. NRC, and the electric utilities have conducted many valve and
actuator research projects to improve plant safety and availability by reducing valve
and actuator problems. These projects resulted in many proprietary and nonproprietary documents that deal with the various specialized areas of valve/actuator
sizing, performance characteristics, maintenance, repair, testing, and diagnostic
techniques. However, information to aid plant personnel in resolving these problems is
difficult to glean from scattered sources, and access may be restricted by proprietary
considerations.
Objective
To provide a comprehensive and authoritative guidebook on the application, use, and
maintenance of valves, in which information is readily accessible and understandable
by a wide range of plant personnel.
v
Approach
The project team was selected from a group of specialists who were heavily involved in
recent valve and actuator research projects. The project team determined the scope of
this project using the initial release of this guide (EPRI NP-6516) and all of the
significant reports from the recent research projects. This guide outline was revised to
eliminate topics that were either irrelevant or covered in greater depth elsewhere. The
scope of this guide was expanded to include maintenance, troubleshooting, and
diagnostic equipment. An overview of other key documents is provided to assist the
reader in quickly finding sources of additional information. Numerous illustrations
and examples of applications, valve sizing, and strategies for use and maintenance
were incorporated to make the guide easier to use.
Results
The guide contains a thorough treatment of the application of valves on the basis of
their functional requirements. It covers gate, globe, butterfly, ball, plug, and diaphragm
valves and manual, hydraulic, and electro-hydraulic actuators, including their
installation, operation, maintenance, and most common problems. For other types of
valves and actuators not covered in this guide, references to pertinent EPRI/NMAC
documents are given. The guide presents information in a clear and understandable
manner to those with little knowledge of the factors involved in successful valve
applications. For those who have extensive experience with valves and actuators, this
guide provides easy access to specific information that is pertinent to specific needs
with references.
EPRI Perspective
Although the information contained in the guide focuses on the application and
maintenance of valves in power plant systems, it is also directly applicable to
comparable system applications in the chemical, petroleum, marine, and similar
industries. The intended audience of the guide includes system designers; engineers
who establish specification requirements for valves; personnel who install, operate,
maintain, and repair valves; plant training instructors; and others for whom a more indepth knowledge of valves could lead to improved valve performance. The guide will
be helpful in evaluating valve/actuator applications in existing systems, selecting new
and replacement valves/actuators, and developing/updating valve maintenance
programs and procedures.
Interest Categories
Valves
Plant Support Engineering
vi
ACKNOWLEDGMENTS
The original Guide for the Application and Use of Valves in Nuclear Power Plant Systems
(NP-6516), published by EPRI in 1990, was developed by Stone & Webster Engineering
Corporation of Massachusetts and Kalsi Engineering, Inc., of Texas. They received wide
cooperation from experienced nuclear utility personnel and service industries. This
revision was created on the solid framework of the earlier publication.
We wish to extend our thanks to the individuals who spent many hours performing
detailed reviews of this revision, so necessary to produce a quality document. In
particular, we thank Kenneth Hart of Pennsylvania Power & Light for his extensive
comments and input on valve packing and maintenance program issues. Other
reviewers include Chris Hansen of Vermont Yankee, Greg Harttraft of GPU, John
Holstrom of Duke Engineering Services, Eric Cartwright of PECO, and Jim Wilson and
Eugene Phillips of Wisconsin Electric Co.
vii
CONTENTS
ix
xi
xii
xiii
xiv
xv
xvi
xvii
xviii
xix
xx
LIST OF FIGURES
Figure 2-1 Globe Valve Typical Valve Nomenclature.............................................................. 2-2
Figure 2-2 Gate Valve Typical Valve Nomenclature ............................................................... 2-3
Figure 2-3 Screwed Bonnet .................................................................................................. 2-20
Figure 2-4 Flanged (Bolted) Bonnet...................................................................................... 2-21
Figure 2-5 Welded Bonnet.................................................................................................... 2-22
Figure 2-6 Pressure-Sealed Bonnet ..................................................................................... 2-22
Figure 2-7 Seat Joint Mating Surfaces (Lay of Roughness Concentric) ............................... 2-23
Figure 2-8 Seat Plane Distortion under Vertical and Horizontal Bending Moments .............. 2-24
Figure 2-9 Typical Globe Valve Seating Configurations ....................................................... 2-27
Figure 2-10 Cross Ring Indentation ...................................................................................... 2-28
Figure 2-11 Soft Seat Retention Methods............................................................................. 2-29
Figure 2-12 Methods for Attaching Seat to Body .................................................................. 2-31
Figure 2-13 Flexible Seat...................................................................................................... 2-32
Figure 2-14 Floating Seat ..................................................................................................... 2-32
Figure 2-15 Spring-Loaded Packing Seals ........................................................................... 2-33
Figure 2-16 Stem Connections ............................................................................................. 2-34
Figure 2-17 Gate Valve Gate Guide ..................................................................................... 2-36
Figure 2-18 Manual Override Lever on Pressure-Relief Valve.............................................. 2-38
Figure 2-19 Manual Override Handwheel on Motor-Operated Valve .................................... 2-38
Figure 2-20 Steam Leak-Off Connection .............................................................................. 2-39
Figure 2-21 External Bypass................................................................................................. 2-41
Figure 2-22 Bonnet Extension .............................................................................................. 2-42
Figure 2-23 Trim Components .............................................................................................. 2-44
Figure 2-24 Bellows Seal ...................................................................................................... 2-56
Figure 2-25 Bellows on Butterfly Valve ................................................................................. 2-57
Figure 2-26 Metal Diaphragm Stem Seal.............................................................................. 2-58
Figure 2-27 Basic Types of Stem Seals................................................................................ 2-60
Figure 2-28 Packing Gland Details ....................................................................................... 2-62
Figure 2-29 Distribution of Stresses in the Packing and Location of Actual Sealing Point.... 2-63
Figure 2-30 Live Loading of Valve Packing Using Disc Springs ........................................... 2-73
xxi
xxii
xxiii
Figure 13-5 Hydraulic Actuator with Fail-Safe Operation Using a Gas Spring .................... 13-10
Figure 13-6 Solenoid Actuator ............................................................................................ 13-12
Figure 14-1 Manual Lever..................................................................................................... 14-1
Figure 14-2 Worm Gear Actuator.......................................................................................... 14-2
Figure 16-1 Butt Weld End Connection .............................................................................. 16-24
Figure 16-2 Socket Weld End Connection.......................................................................... 16-24
Figure 16-3 Butterfly Valve End Connections ..................................................................... 16-26
Figure 19-1 Test Valve Arrangement for Maintained Flowrate Test...................................... 19-9
Figure 19-2 Globe Valve Reverse Air Test (Test Pressure Under Seat)............................. 19-10
Figure 19-3 Globe Valve Reverse Air Test (Test Pressure Above Seat) ............................ 19-11
Figure 19-4 Gate Valve Reverse Air Test (With Body Vent Test Connection) .................... 19-12
Figure 19-5 Gate Valve Through Body Air Test (LOCA pushes disc toward outboard
seat. Through body pressurization measures leakage by both seats.) ....................... 19-12
Figure 19-6 Required Valve Maintenance Clearance for Typical Installation...................... 19-19
Figure 19-7 Required Maintenance Clearance for Chain-Operated Valve.......................... 19-20
Figure 19-8 Human Factors Clearance-General ................................................................. 19-21
Figure 21-1 Valve Selection Chart (This figure is located in a pouch inside the back
cover of this report.) ...................................................................................................... 21-1
Figure 23-1 Tilted Disc Contact Mode Resulting in Point Contact with the Downstream
Seat............................................................................................................................... 23-5
Figure 23-2 Limitorque Actuator Test Fixture...................................................................... 23-15
Figure 24-1 Pressure Profile of Fluid Passing through a Valve............................................. 24-3
Figure 24-2 Pressure Profile through Restriction .................................................................. 24-4
Figure 24-3 Effects of Vaporization....................................................................................... 24-5
Figure 24-4 Globe Valve FL Values..................................................................................... 24-11
Figure 24-5 High Performance Butterfly/Ball FL Values....................................................... 24-12
Figure 24-6 Liquid Critical Pressure Ratio Factor Curve ..................................................... 24-13
Figure 24-7 Globe Valve Liquid Incipient Cavitation Factor (Fi) Values .............................. 24-17
Figure 24-8 Reynolds Number Factor................................................................................. 24-18
Figure 24-9 Compressibility Factors for Gases with Reduced Pressures from 0 to 40 ....... 24-34
Figure 24-10 Compressibility Factors for Gases with Reduced Pressures from 0 to 6 ....... 24-35
Figure 24-11 Conventional Method of Recirculation Control: Control Valve (On-Off) in
Series with a Breakdown Orifice ................................................................................. 24-44
Figure 24-12 Method of Recirculation Control Using High Pressure, Modulating AntiCavitation Valve .......................................................................................................... 24-44
Figure 24-13 Globe Angle Control Valve with Anti-Cavitation Trim..................................... 24-45
Figure 24-14 Globe Control Valve with Low Noise Trim ..................................................... 24-48
Figure 24-15 Typical Condensate System .......................................................................... 24-53
Figure 24-16 Typical Condensate System Curve ............................................................... 24-54
xxiv
Figure 24-17 Globe Control Valve with Anti-Cavitation Variable Resistance Trim .............. 24-54
Figure 24-18 Main Feedwater System ................................................................................ 24-57
Figure 25-1 Suggested Manual Valve Data Sheet by Purchaser.......................................... 25-8
Figure 25-2 Suggested Manual Valve Data Sheet by Bidder/Seller ................................... 25-11
Figure 25-3 Suggested Motor-Operated Valve Data Sheet by Purchaser .......................... 25-13
Figure 25-4 Suggested Motor-Operated Valve Data Sheet by Bidder/Seller ...................... 25-17
Figure 25-5 Control Valve Data Sheet ................................................................................ 25-20
Figure 25-6 Relief Valve Data Sheet .................................................................................. 25-24
Figure 25-7 Rupture Disc Data Sheet................................................................................. 25-26
xxv
LIST OF TABLES
Table 2-1 Corrosion Ranking for Materials Selection............................................................ 2-46
Table 2-2 Critical Variables for Accelerated Erosion-Corrosion ............................................ 2-49
Table 2-3 Chart of Wear and Galling Resistance of Material Combinations ......................... 2-52
Table 2-4 Typical Properties of Plastics and Elastomers Used in Valves for Soft Seats,
Seals, and Gaskets ...................................................................................................... 2-68
Table 2-5 Typical Radiation Resistance of Plastics .............................................................. 2-70
Table 2-6 Gasket Materials and Contact Facings, Gasket Factors M for Operating
Conditions, and Minimum Design Seating Stress y...................................................... 2-79
Table 3-1 Control Valve Seat Leakage Classifications (In Accordance with ANSI/FCI
70-2-1976........................................................................................................................ 3-6
Table 3-2 Seat Leakage Criteria ............................................................................................. 3-7
Table 6-1 Valve Cv and Pressure as a Function of Flow Rate without Line Losses .............. 6-23
Table 6-2 Valve Cv and Pressure as a Function of Flow Rate with Line Losses ................... 6-26
Table 13-1 Normal Application of Power Actuators for Valves.............................................. 13-3
Table 14-1 Maximum Recommended Rim Pull as a Function of Handwheel Diameter ........ 14-3
Table 16-1 Valve Design Codes ........................................................................................... 16-2
Table 16-2 Typical Valve Standards ..................................................................................... 16-3
Table 16-3 Safety Classes and Applicable Standards .......................................................... 16-5
Table 16-4 Pressure/Temperature Ratings for Steel Valves. Source: ANSI B 16.34 1981 .............................................................................................................................. 16-6
Table 16-5 Cast Iron Gate Valve Ratings Source: MSS-SP-70 ............................................ 16-8
Table 16-6 Bronze Gate, Globe, and Check Valve Ratings Source: MSS-SP-80................. 16-9
Table 16-7 Commonly Used Pressure Boundary Materials ................................................ 16-13
Table 18-1 Inspection Checklist for Solid and Flexible Wedge Gate Valves....................... 18-17
Table 18-2 Inspection Checklist for Butterfly Valves........................................................... 18-25
Table 19-1 Valve Maintenance Clearance Data ................................................................. 19-16
Table 20-1 Comparison of Selected Diagnostic Methods ..................................................... 20-9
Table 21-1 Valve Selection Matrix ........................................................................................ 21-2
Table 24-1 Typical Valve Recovery Coefficients (FL) and Incipient Cavitation Factors (Fi) . 24-10
Table 24-2 Typical Critical Pressure Values ....................................................................... 24-14
Table 24-3 Typical Values of Cv: Globe Valve, Flow over the Seat..................................... 24-20
xxvii
Table 24-4 Typical Values of Cv: Globe Valve, Flow under the Seat .................................. 24-21
Table 24-5 Typical Piping Geometry Factors, Fp : Valve with both Reducer and
Expander..................................................................................................................... 24-22
Table 24-6 Typical Piping Geometry Factors, Fp: Valve with Outlet Expander Only ........... 24-23
Table 24-7 Terminal Pressure Drop Ratios (xT)................................................................... 24-31
Table 24-8 Gas Physical Data ............................................................................................ 24-32
xxviii
1
INTRODUCTION/SUMMARY HOW TO USE THE
GUIDEBOOK
1.1
Introduction
The latest advances in the application, use, and maintenance of valves and actuators
Over the last several years, EPRI, the U.S. NRC, and electric utilities have conducted
many research projects to improve plant safety and availability by reducing valve and
actuator problems. These projects resulted in many proprietary and nonproprietary
documents, which deal with various specialized areas of valve/actuator sizing,
performance characteristics, valve and actuator maintenance/repair as well as testing
and diagnostic technologies. However, information to aid plant personnel in resolving
these problems is difficult to glean from scattered sources, and access may be restricted
by proprietary consideration. Brief summaries along with a comprehensive listing of
key documents are included in this guide to assist the reader to quickly find additional
sources of information.
1-1
This is Volume 1 of a two-volume guide. In this volume, the focus is on the application,
use, maintenance, and troubleshooting of gate, globe, butterfly, plug, and diaphragm
valves in power plant applications. Volume 1 is a revision of NMAC NP-6516, issued in
August 1990. Apart from the technical update (which is very extensive), several topics
were eliminated from this revision because they are covered in great depth in other
recent EPRI/NMAC publications. For example, check valves are not discussed in this
revision because they are covered in two very detailed documents [1.20,1 1.21]. Airoperated valves and solenoid valves are also omitted because they are covered in
References 1.2 and 1.7 respectively. Only minimum discussions of motor operators are
included because detailed discussions are given in other EPRI documents [1.22, 1.23,
1.24, 1.25, and 1.26].
Volume 2 of this guide [1.1] provides detailed discussions about most current valve
repair techniques both in situ and off-line for gate, globe, and check valves. The
discussions in Volume 2 cover component repair, flaw removal techniques, material
selection, machining, welding, heat treatment guidelines, final inspection and testing
requirements, which are also applicable to other valve types.
This guide was developed for persons who prepare valve specifications, install and
operate valves in various applications, and perform required valve maintenance and
repairs. The guide will also be useful to system designers, plant management,
engineers, and others who need in-depth understanding of the capabilities and
limitations of valves that affect performance and system availability. For readers with
little valve background, the guide is intended to provide basic understanding of valve
technology. For readers with extensive valve experience, the guide is a reference book,
which provides easy access to specific valve information as well as guidance to other
sources of specialized areas.
1.2
1.2.1 General
This section provides the reader with a road map to the information presented in this
guide and to facilitate easy access to it. The Table of Contents provides a fairly
descriptive title for each section. Section 2 provides the nomenclature and glossary of
terms that are common in the industry and used throughout the text. Aspects of
component construction common to several different types of valves and actuators are
discussed in Section 2. Figures are used extensively to illustrate the different types of
valves and specific component details and features.
1-2
1-3
In this volume of the guide, the discussion of check valve application, use and
maintenance is kept to a minimum because these subjects are discussed in great detail
in References 1.20 and 1.21. Volume 2 of this guide provides detailed guidance for
check valve repair.
Pressure-Relief. Pressure-relief valves are used to protect piping systems and
components from overpressurization by dissipating excess system pressure to a
pressure suppression system or to the atmosphere. Pressure relief is performed in a
number of ways including:
The valve opens automatically to discharge system media when pressure at valve
inlet (acting directly on valve disc) exceeds a predetermined level. No external
power source is needed.
A pilot valve opens automatically when pressure at the inlet of the pilot valve
exceeds a predetermined level. The opening of the pilot valve subsequently opens
the main valve. Alternatively, the pilot valve may be opened at any inlet pressure
by the application of an external power source.
The valve opens when the actuator power source receives a signal that the valve
inlet pressure exceeds a predetermined level.
The valve opens when the actuators power source receives a signal that other
system conditions or events have occurred that will cause a pressure rise to occur
(for example, power failure to a pump or the sub-normal pressure preceding a
pressure surge or water hammer).
In this guide, the discussions of pressure relief valves are eliminated because these
valves are discussed in great detail in Reference 1.4.
for gate valves are relatively longer than for globe valves, which could adversely affect
the system performance. On the other hand, globe valves, while satisfying stroke time
requirements, introduce high flow resistances and pressure drops, which may be
unacceptable in some applications.
Design. Using a valve cross-sectional drawing, the design features of the specific valve
type are discussed.
The effect of different variants of the valve type (for example, solid wedge versus
flexible wedge gate valves) on valve performance is noted. The advantages and
disadvantages of the variants are discussed.
Installation Practices. The proximity of other components (pumps, piping connections,
etc.) may affect valve performance. Installation configuration, direction of flow, forces,
and moments applied to the valve by the connecting pipe, orientation to vertical, and
accumulation of debris/biological growth inside the valve are typical installation
considerations. These are discussed as they apply to each specific valve type and
function, and an assessment is provided where a particular sensitivity to any of these
exists. General guidelines for valve installation are given in Section 19.
Operation Practices and Precautions. Methods to improve the functional reliability of
valves through correct operational practices are discussed. Practices that may adversely
affect the performance of valves are presented. Such practices include applying
excessive actuator loading thrust to reduce seat leakage and using of valves for other
than the intended function (for example, long-term throttling with a gate valve).
Common Problems. For each valve type, a section is devoted to provide a concise list of
the common valve problems and malfunctions. Wherever possible, suggested corrective
and preventive actions are given. Detailed repair procedures are given in Volume 2
[1.1].
Maintenance. General discussions of maintenance methods and practices for specific
valves are provided. The focus is on areas that are considered critical to achieve
satisfactory valve performance. General discussions of other valve maintenance issues
including programmatic consideration, troubleshooting, corrective action, maintenance
requirements, and diagnostic equipment are given in Sections 17 through 20.
1-5
Corrosion allowance
1-7
1.2.13 Appendices
Appendices are provided to broaden the scope of knowledge presented in the text.
References in the text are made to specific appendices where additional information is
given on the subject being discussed.
Section 23 provides a brief discussion of recent advances in the valve and actuators
technology along with latest regulatory requirements. Section 23 also provides a brief
summary of some key EPRI/NMAC documents that are believed to be of particular
interest to the reader.
Section 24 provides a brief discussion of control valve sizing methods based on the
Instrument Society of America (ISA) approach. Several examples are provided to
further clarify the methods used and to understand their limitations. It should be noted
that several computer programs have been developed by valve manufacturers and
others to perform control valve sizing calculations. Evaluation and discussion of these
computer programs are outside the scope of this guide. It is recommended, however,
that the reader seek information about such software from the developing
organizations.
Section 25 provides valve procurement specifications. Suggested data sheets for use by
the purchaser and bidder/seller are included for convenience.
Finally, complete reading of the entire guide, including the appendices, should provide
the reader with an overall view of the current state of the art of valve and actuator
technology.
1-8
2
GENERAL VALVE DESIGN
2.1
Nomenclature/Glossary of Terms
2.1.1 Introduction
This section covers commonly used valve terminology and nomenclature. As an
example, Figures 2-1 and 2-2 show a globe and a gate valve along with typical
nomenclature used for these valve types. Reference is given, where appropriate, to
figures found in later sections which depict the term being defined. Many terms used in
this document are defined in the following standards and technical textbooks.
Glossary of Valves Terms, Grove Valve Regulator Company, Oakland, CA, 1980.
ISA Handbook of Control Valves, Second Edition, Instrument Society of America, 1976.
2-1
Figure 2-1
Globe Valve Typical Valve Nomenclature
2-2
Figure 2-2
Gate Valve Typical Valve Nomenclature
Backpressure
Pressure on the downstream side of the valve.
Backseat (Figure 2-1)
A shoulder on the stem disc of a valve that seals against a mating surface inside the
bonnet to act as a back-up seal to the packing to limit stem seal leakage.
2-3
Belleville Spring
A cone-shaped washer/disc spring used where small deflections and relatively high
loads are required.
Bellows Seal Bonnet (Figure 2-24)
A bonnet that uses metal bellows for sealing against leakage of controlled fluid around
the valve stem.
Block and Bleed
The capability of obtaining a pressure seal across the upstream and downstream seats
of a valve, usually a gate valve, when the body pressure is bled off to the atmosphere
through blowdown valves or vent plugs. This is useful in testing the integrity of seat
shut-off and in accomplishing minor repairs under line pressure. It is also useful in
keeping different process fluids separated. See Double Block and Bleed.
Body (Figures 2-1 and 2-2)
The principal pressure-containing part of a valve where the closure element and seats
are located.
Bonnet (Figures 2-1 and 2-2)
The separable portion of the valve pressure boundary that permits access to the
internals.
The major part of the bonnet assembly, excluding the sealing means.
The top pressure-containing part of a valve, attached to the body, that guides the
stem and adapts to extensions or operators.
Bonnet Assembly
An assembly that includes the part through which a valve plug stem moves and a
means for sealing against leakage around the stem. It usually provides a means for
mounting the actuator.
Bore (or Port)
The inside diameter, or other control configuration, of the flow passage through a valve
(for example, the diameter of the hole in the ball of a ball valve, the inside diameter of
2-4
seat rings). The bore is usually the minimum flow area when the disc is in the fully
open position.
Boss (Figure 2-1)
A localized projection on a valve surface provided for various purposes, such as
attachment of drain connections or other accessories.
Breaking Pin
See Shear Pin.
Breaking Pin Device
See Shear Pin Device.
Breaking Pressure
The value of inlet static pressure at which a breaking pin or shear pin device functions.
Terms such as breaking pressure, force, load, or torque are used to identify the
load for which the intentional section of weakness is designed to fail.
Bubble-Tight Shut-Off
A phrase used in describing the sealing ability of a valve. During air pressure testing of
a valve in the closed position, leakage past the seats is bubbled through water. To
qualify as bubble-tight, no bubbles should be observed in a prescribed time span.
Burst Pressure
The value of inlet static pressure at which a rupture disc functions.
Bypass (Figure 2-21)
A system of pipes and valves intended to permit the diversion of flow or pressure
around a line valve or to communicate the body cavity to either the upstream or
downstream side.
Cage. (Figure 6-9A)
A hollow cylindrical trim element that is a guide to align the movement of a valve disc
with a seat ring and also to retain the seat ring in the valve body. Often the walls of the
cage contain openings that determine the flow characteristics of a control valve.
2-5
Capacity
Rate of flow through a valve under stated conditions of pressure drop and fluid
density.
Chatter
Rapid reciprocating or vibrating motion of the valve disc during which the disc
contacts the seat. In mid-stroke, a valve may chatter on its guides or cage without
touching the seat.
Closing Pressure
The value of the decreasing inlet static pressure at which the valve disc of a safety valve
re-established contact with the seat or at which lift becomes zero.
Closure Element (Figures 2-1 and 2-2)
The moving part of a valve, positioned in the flow stream, that controls flow through
the valve. Ball, gate, plug, clapper, disc, etc., are specific names for closure elements.
Coefficient of Discharge
The ratio of the measured flow capacity to the theoretical flow capacity.
Control Valve
A power-operated device that modifies the fluid flow rate in a process control system.
It consists of a valve connected to an actuator mechanism that is capable of changing
the position of a flow-controlling element in the valve in response to a signal from the
controlling system.
Cv (Valve Flow Coefficient)
The number of gallons of water at 60F (15.6C) that will flow through a given valve
within 1 minute, with a pressure drop (loss) of 1 psi (6.9 kPa).
Dead Band (Diaphragm Actuator)
The amount that the actuating pressure on the diaphragm can be varied without
initiating valve disc motion.
2-6
Design Pressure
The pressure used in the design of a valve and other pressure-retaining components for
the purpose of determining the minimum permissible wall thickness. When applicable,
static head should be added to the design pressure to determine the thickness of the
pressure-retaining components. There are slight differences in the exact definition of
the design pressure used by different codes; therefore, the definition from the
applicable code, such as ASME, must be used.
Design Temperature
The temperature that is used to determine allowable stresses for the purpose of design
calculations. Generally, the design temperature is set at a value higher (or further from
ambient) than the operating temperature and includes allowances for upsets and
variation in operating conditions.
Diaphragm (Figure 2-1)
A flexible pressure responsive element that transmits force to the diaphragm plate.
Diaphragm Actuator (Figure 2-1)
An assembly utilizing fluid pressure acting on a diaphragm to develop a force to move
the actuator stem. It may or may not have a spring for positioning and return of the
actuator stem.
Diaphragm Pressure Span (or Range)
Difference between the high and low values of the diaphragm pressure range. This
may be stated as an inherent or installed characteristic.
Direct Acting Actuator (Figure 6-19)
A diaphragm actuator in which the actuator stem extends with increasing diaphragm
pressure.
Disc (Figure 2-1 and 2-2)
The closure element of a gate, globe, check, butterfly, safety, or relief valve. The disc in
different valve designs may be referred to as gate, wedge, poppet, or plug.
Discharge Area
See Actual Discharge Area.
2-7
2-8
Fail-As-Is1
A characteristic of a particular type of actuator that, upon loss of power supply, will
cause the valve plug, ball, or disc to remain in the position attained at the time of the
loss of external actuating power.
Fail-Closed
A condition wherein the valve disc will move to the closed position upon loss of
external actuating power.
Fail-Indeterminate
A characteristic of a particular type of actuator that, upon loss of power supply, can
move to any undefined position.
Fail-Open1
A condition wherein the valve disc will move to the open position upon loss of external
actuating power.
Fail-Safe1
The selection of fail-as-is, fail-closed, or fail-open action that avoids an undesirable
consequence in a fluid system.
Field Serviceable
A statement indicating that normal repair of the valve or replacement of operating
parts can be accomplished in the field without return to the manufacturer.
Fire Safe
A statement associated with a valve design that is capable of passing certain specified
leakage and operational tests during and after exposure to fire of specified conditions.
In addition to the loss of actuator power, a loss of actuator signal should be considered in determining the failure
position of the valve disc.
2-9
Flow Characteristic
Relationship between flow through the valve and percent rated travel as the latter is
varied from 0 to 100%. This is a special term. It should always be designated as either
inherent flow characteristic or installed flow characteristic.
Flow Coefficient
See Cv.
Flow Rating Pressure
The inlet static pressure at which the relieving capacity of a pressure relief device is
measured for rating purposes.
Flutter
Rapid reciprocating motions of the valve disc during which the disc does not contact
the seat or body.
Fusible Plug Device
A type of non-reclosing pressure relief device designed to function by yielding or
melting a plug of suitable melting temperature material.
Gate (Figure 2-2)
The closure element of a gate valve.
Globe Valve (Figure 2-1)
A basic control valve type that gets its name from the globular shape of its body. It
normally uses the basic valve disc as its valve closure member.
Hard Facing
A surface preparation in which an alloy is deposited on a critical valve surface (for
example, seat, guide, disc), usually by weld overlay or spray coating techniques, to
increase resistance to wear, galling, abrasion, and corrosion.
High-Recovery Valve
A valve design that dissipates relatively little flow stream energy due to streamlined
internal contours and minimal flow turbulence. Therefore, pressure downstream of the
2-10
valve vena contracta recovers to a high percentage of its inlet value. (Straight-through
flow valves, such as rotary-shaft ball valves, are typically high-recovery valves.)
Inherent Diaphragm Pressure Span (or Range)
The high and low values of pressure applied to the diaphragm to produce rated valve
plug travel with atmospheric pressure in the valve body. (This range is often referred to
as a bench set range since it is the range over which the valve will stroke when it is
set on the work bench.)
Inherent Flow Characteristic
Flow characteristic when constant pressure drop is maintained across the valve.
Inherent Rangeability
Ratio of maximum to minimum flow coefficient within which deviation from the
specified inherent characteristic does not exceed some stated limit.
Inlet Size
The nominal pipe size of the inlet of a valve, unless otherwise designated.
Installed Diaphragm Pressure Span (or Range)
The high and low values of pressure applied to the diaphragm to produce rated valve
plug travel with stated conditions in the valve body. (It is because of forces acting on
the valve plug that the installed diaphragm pressure range can differ from the inherent
diaphragm pressure range.)
Installed Flow Characteristic
Flow characteristic, when pressure drop across the valve varies, as dictated by flow and
related conditions in the system in which the valve is installed.
Lantern Ring (Figure 2-20)
A spacer installed between packing sets to permit injection of sealant or lubricant into
the packing area, or as a leak-off collection chamber from which leakage past the first
set is piped to a safe location.
2-11
2-12
2-13
Passive Valve
A valve that maintains obturator position and is not required to change obturator
position to accomplish its intended function(s).
Piston Actuator
A fluid pressure operated piston and cylinder assembly for positioning the actuator
stem in relation to the operating fluid pressure or pressures.
Pilot Valve
An auxiliary valve that, when actuated, causes the actuation of a main valve.
Plug
See Closure Element.
Port
The flow control orifice of a control valve. It is also used to refer to the inlet or outlet
openings of a valve.
Port Guided (Figures 5-1, 5-2)
A design in which the valve plug is aligned by the body port or ports only.
Pressure-Containing Member
A part of the component that is in actual contact with the pressure media.
Pressure-Retaining Member
A part of the component that is stressed due to its function in holding one or more
pressure-containing members in position.
Push-Down-to-Close Construction
A globe-style valve construction in which the valve plug is located between the
actuator and the seat ring, so that extension of the actuator stem moves the valve plug
toward the seat ring, finally closing the valve.
2-14
Push-Down-to-Open Construction
A globe-style valve construction in which the seat ring is located between the actuator
and the valve plug, so that extension of the actuator stem moves the valve plug away
from the seat ring, opening the valve.
Quick Opening Flow Characteristic
An inherent flow characteristic in which there is maximum change in flow coefficient
with minimum stem travel.
Rangeability
Ratio of maximum to minimum flow coefficient (Cv) within which the deviation from
the specified flow characteristics does not exceed stated limits.
Rated Cv
The value of Cv at the rated full-open position.
Rated Lift
The design lift at which a valve attains its rated flow capacity.
Rated Travel
Linear movement of the valve plug from the closed position to the rated full-open
position. (The rated full-open position is the maximum opening recommended by the
manufacturer.)
Reseating Pressure
The pressure at which the pressure relief valve reseats after discharge.
Reverse-Actuating Actuator
A diaphragm actuator in which the actuator stem retracts to the actuator with
increasing diaphragm pressure.
Rising Stem (Figure 4-1A)
A valve stem that rises as the valve is opened.
2-15
Shear Pin
The load-carrying element of a shear pin device. It is an intentional section of weakness
or minimum strength used to protect other valve or actuator components. It should be
easily identifiable and replaceable with minimum effort.
Shear Pin Device
A type of non-reclosing pressure relief device actuated by inlet static pressure and
designed to function by shearing a load-carrying pin that supports a pressurecontaining member.
Static Unbalance
The net force produced on the valve disc in its closed position by the fluid pressure
acting upon it.
Stem (Figures 2-1 and 2-2)
A rod or shaft transmitting force/torque from an operator to the closure element of a
valve to change its position.
Stem Connector (Figure 2-1)
A fitting to connect the actuator stem to the valve stem.
Stem Guided (Figure 2-1)
A special case of top guided construction in which the valve disc is aligned by a guide
acting on the valve stem.
Stem Unbalance, Stem Rejection Force, or Piston Effect
The net force produced on the valve disc stem in any position by the fluid pressure
acting upon it.
Stuffing Box (Figure 2-28)
The annular chamber provided around a valve stem in a sealing system into which
deformable packing is introduced.
2-17
Through Conduit
An expression characterizing valves that, in the open position, present a smooth
uninterrupted interior surface across the seat rings and through the valve port, thus
affording minimum pressure drop. There are no cavities or large gaps in the bore
between seat rings and body closures or between seat rings and ball/gate.
Top Guided (Figure 2-1)
A design in which the valve plug is aligned by a single guide in the body, adjacent to
the bonnet or in the bonnet.
Top and Bottom Guided (Figure 6-4)
A design in which the valve plug is aligned by guides in the body or in the bonnet, and
in the bottom flange. The plug is guided above and below the seat.
Top and Port Guided
A design in which the valve plug is aligned by a guide in the bonnet or body, and the
body port.
Trim
The internal parts of a valve that are in contact with line fluid other than the body and
bonnet (usually consisting of the seat ring, valve plug, stem, valve plug guide, guide
bushing, and cage.)
Trunnion
A trunnion is a reinforced area, similar to a boss, that houses opposing pivots, journals,
and other mechanical devices (for example, packing), generally cylindrical in shape
and projecting from the exterior of each side of the piece. In butterfly, ball, and plug
valve bodies, trunnions provide the support for the shaft journal bearings, thrust
bearings, packing, and actuator mounting. (The ball in a ball valve may have trunnions
that mate with the sleeve bearings).
Upper Valve Body
A half housing for a split-body type valve.
Valve Body Assembly
An assembly of a body, bonnet assembly, and bottom flange.
2-18
2.2
Details of construction common to most valves are related to the minimum required
components to achieve pressure and seating integrity and to actuate the valve.
Although some variance may be found between manufacturers, these common
construction feature serve the same basic functions of connecting the body and bonnet,
shutting off pressure, connecting the stem to the disc, and sealing around the movable
stem.
2-19
Figure 2-3
Screwed Bonnet
2-20
Flanged (Bolted) Bonnet: Flanged bonnet joints, such as those found in valves shown in
Figure 2-4, have an advantage over the screwed joint in that smaller tools and lower
torque are required to tighten the joint. Flanged joints can be used on any size valve,
under any operating pressure, but they become very bulky and heavy when used on
very large valves and under high operating pressures. At temperatures above 650F
(343C), creep relaxation can, in time, noticeably lower the bolt load and allow the joint
to leak. If the application is critical, the flanged joint can be seal welded.
Figure 2-4
Flanged (Bolted) Bonnet
Welded Bonnet: Welding the bonnet to the body effectively provides a very economical
and long-term seal regardless of size, operating pressure, and temperature. This
arrangement can be used to achieve both a sealing function and a load carrying
function, as shown in Figure 2-5. When coupled with screwed or flanged joints, the
weld joint is designed to seal only against pressure and requires minimal weld
material. Except for cast iron, welding can be performed on most materials.
This arrangement is used where the valve is expected to be maintenance-free for long
periods, where the valve is a throw-away design due to its relative cost to replace
versus repair, or where the required sealing reliability of the valve far outweighs the
difficulty of gaining access to valve internals, such as in bellows-sealed stem valves.
2-21
Figure 2-5
Welded Bonnet
Pressure Sealed Bonnet: The pressure sealed bonnet design, shown in Figure 2-6,
provides the advantage of reduced weight and size over flanged connections and
allows the internal bonnet pressure to increase the joint sealing contact stress instead of
unloading it as in bolted designs. This joint is most attractive in larger valves and high
pressure applications where the pressure forces are high enough to generate the
required contact stress to seal at the metal-to-metal joint. This type of bonnet seal is
usually available only on valves of pressure class 600 or higher. It is particularly suited
to high temperature applications (660F or 348.9C) where bolted bonnet joints can
loosen due to bolt creep. One of the disadvantages of this type of bonnet joint is that it
provides no positive mechanical location between the bonnet and body and often
allows misalignment to occur, which can cause stem binding. Binding can lead to stem
galling, leakage through stem packing, and potential valve inoperability. In large
valves, proper assembly of the bonnet usually requires the valve to be installed with
the stem vertical and pointing upward.
Figure 2-6
Pressure-Sealed Bonnet
2-22
Another drawback of the pressure seal bonnet joint is that it can start to leak in
applications where frequent pressure or temperature fluctuations are experienced;
therefore, the bonnet cannot be safely tightened under pressure when a leak occurs
because of the possibility of making the leakage more severe when attempting
corrective action. In addition, if a leak should occur, it is more difficult to repair and
reassemble the valve than with a bolted bonnet due to the required careful alignment
and tightening sequence procedures during assembly.
Graphite pressure seals have seen wide acceptance in the valve industry because they
can eliminate many of the problems associated with metal pressure seals. Most major
valve manufacturers offer graphite pressure seals for their product lines. Utilizing
graphite pressure seals requires special precautions to prevent extrusion and to ensure
adequate loads to effect a seal.
Figure 2-7
Seat Joint Mating Surfaces (Lay of Roughness Concentric)
2-23
In addition to the basic design of the seat itself, other factors that directly affect seating
and operability are distortions that can occur at the disc/seat interface due to pressure,
thermal gradients, and mechanical loads transmitted to the valve body by the adjacent
piping. As shown in Figure 2-8, applied bending moments on gate valve bodies cause
the seat plane to tilt and distort, which can result in leakage and gate pinching in
wedge-type valves. Gate pinching can also be caused by thermally induced deflections
(see Section 4.2.10). In globe valves, body distortions produce ovality in the seat, which
leads to mismatch with the circular seating area on the tapered seated plugs.
Distortions caused by line loads become more severe when venturi-type valves or
valves that are smaller than the pipeline size are installed with upstream and
downstream reducers.
Figure 2-8
Seat Plane Distortion under Vertical and Horizontal Bending Moments
To avoid leakage or binding problems caused by line loads, valves should not be
located at points of large line loads. Also, the section modulus of the valve body should
be significantly greater than the pipe to keep the stresses and distortions within
acceptable limits. Axisymmetric type valves, such as ball and butterfly, tend to be
stiffer and are less sensitive to line loads.
2-24
2-25
accomplish a seal is to lap the disc and seat during assembly; however, lapping the
surfaces should be limited so that a wide contact band does not develop.
Developing high compressive stress to achieve good seating should be weighed against
potential damage due to galling or gross surface yielding. Surfaces that slide under
load, such as the disc of a gate valve, should be sized so that contact stress is
maintained below the galling threshold for the material combination. Depending on the
mating materials and the details of the actual geometry, the calculated average contact
stress to gall can vary from as low as 2,000 psi (13.8 MPa) for some stainless steels to as
high as 47,000 psi (324 MPa) for cobalt-based materials such as Stellite 6 [5.39]. In
reality, the contact stress at the surface is not uniform due to the irregular and uneven
loading encountered in actual application; therefore, the average contact stress should
be limited to lower values. Typically, the contact stress for Stellite 6 is limited to 20,000
psi (137.9 MPa) to avoid galling in sliding applications.
In gate valves, the sliding surfaces may encounter one or more of the following contact
modes during an opening or a closing stroke: flat-on-flat, edge-on-flat, edge-on-edge
(nonscissoring), and edge-on-edge (scissoring) [2.1, 2.2, 2.9, 2.10]. The contact mode
depends primarily on the edge geometry of the seats and guides, and on the length and
location of the body guides with respect to the disc guides. The magnitude of contact
stress and associated wear/damage is proportional to the valve internal clearances (for
example, guide rail-to-guide slot clearance and stem head-to-gate clearance) and to the
valve operating conditions. Some contact modes may cause severe damage to the
seating surfaces and result in seat leakage.
Typical seating configurations employed in globe valves are shown in Figure 2-9. The
seat design shown in Figure 2-9A, used in low pressure globe applications, provides
the advantage of not requiring precise alignment between the disc and seat, and it
eliminates galling because the surfaces move normal to each other during loading. The
seat design shown in Figures 2-9B, 2-9C, and 2-9D allows higher contact stress to be
developed due to the narrower contact band between the mating surfaces; however, it
requires better control of alignment between the disc and seat. As shown in Figures 29C and 2-9D, taper angles (half-cone angle) between 15 and 45 are in use in various
disc designs. Even though small taper angles (as low as 15) have been used in some
valves, they should be avoided because it has been found that for reliable nonsticking
operation of the disc, magnitudes of 30 and higher should be used.
2-26
Figure 2-9
Typical Globe Valve Seating Configurations
When selecting the disc/seat contact geometry and materials, the potential for cross
ring indentation type damage should also be considered. Seat ring indentation, as
shown in Figure 2-10, is caused when a hard narrow surface and a soft wider surface
contact, and the softer material yields. Indentation left on the softer component can
create leakage during subsequent shut-off if the normal clearances present in the
assembly of the plug-to-seat components allow the new seating band to cross the
previous indentation. Cross ring indentation damage and its adverse effect on shutoff
can be prevented by making the narrower component of a softer material than the
wider component.
2-27
Figure 2-10
Cross Ring Indentation
Soft Seating: Soft seats are used to accomplish good seating with much lower contact
force than in metal-to-metal seats. It is easier to deform the softer materials and fill out
the valleys in the mating surfaces with considerably lower forces. In most designs, the
soft seat rings provide the primary seating with metal-to-metal closure acting as a
secondary seal in case of damage or failure of the soft seal material. This secondary
metal-to-metal contact also makes the seats fire safe and allows some degree of seat
tightness should the resilient seat ring fail. Whenever the temperature, radiation, and
pressure environment permit, soft seals should be strongly considered because of the
ease in accomplishing good seating with low contact force.
Since soft seat ring materials do not have the required strength and stiffness to resist
rupture against pressure and blowout against differential pressure, they must be
securely clamped in the seat. Several methods of restraining the seat ring in globe
valves are shown in Figure 2-11. Similar restraint methods are employed in some gate
and butterfly valves.
2-28
Figure 2-11
Soft Seat Retention Methods
3. Hardness
4. Permanent set and extrusion under load
5. Rate of recovery upon removal of the load
6. Tensile, compressive, and tear strength
7. Radiation resistance
8. Abrasion resistance
9. Wear resistance
10. Thermal resistance
The material properties of seals, soft seats, and gasket materials are discussed in detail
in Section 2.5.
Seat Attachment: The method of attachment and sealing of the leakage path between the
seat and the body is as important as the seat itself. Methods of attaching fixed seats to
the body (Figure 2-12) include screwing, welding, interference fitting the seat ring into
the body or seat pocket using press or shrink fits, bolting, clamping between two
pieces, and welding and machining the seat face into the body. Sealing at the body is
achieved using elastomers, gaskets, soft metals, metal-to-metal sealing by interference,
and seal welding.
2-30
Figure 2-12
Methods for Attaching Seat to Body
The seat-to-body restraint should be independent of the seat loading and should not
depend on the seat load to achieve a seal. Inherent in fixed seat designs is the problem
that body distortions, caused by pressure, thermal gradients, and line loads, are
transmitted directly to the seat. These distortions create leakage paths between the discto-seat mating surfaces in metal-to-metal seating unless some flexibility is designed into
the disc (as in flex disc gate valves) or globe valve seat, as shown in Figure 2-13. The
type of attachment to the body should also consider maintenance that may be required
on the seat.
2-31
Figure 2-13
Flexible Seat
When using gaskets, the seat should incorporate a metal-to-metal stop as shown in
Figure 2-11B to limit the amount of compression applied to the gasket since repeated
stress cycling of the gasket will lead to relaxation of the joint seal and eventual leakage.
Metal type gaskets should not be reused unless explicitly permitted by the gasket
vendor.
Floating seats, such as those used in trunnion-mounted ball valves, do not require
independent restraints but are held in place by the ball itself. Sealing of the floating
seat in the body is accomplished using elastomeric or packing seals, as shown in Figure
2-14.
Figure 2-14
Floating Seat
2-32
One ball valve design for high temperature service applications uses spring-loaded
packing seals as shown in Figure 2-15.
Figure 2-15
Spring-Loaded Packing Seals
2-33
Figure 2-16
Stem Connections
2-34
Fixed Joints: Typical fixed joint disc-to-stem connections commonly used are integral,
welded, and screwed. These connections are normally used in non-rotating stem
applications where the stem and seat maintain their axial alignment. When this joint is
used in a globe valve application, an external means to prevent stem rotation should be
provided. This is necessary to prevent galling at the disc-seat interface. When used in
wedging-type gate valves, precautions should be taken to ensure that excessive lateral
displacement of the stem would not cause binding of the stem in the bonnet stuffing
box area.
Free to Rotate Connections: Free to rotate connections should be used in rotating stem
applications or when disc-to-seat rotation is undesirable. These joints are frequently
found in globe valves and non-rising stem gate valves. In non-rising stem gate valves,
the disc-to-stem joint is threaded so that the rotation of the stem in the disc opens and
closes the valve (Figure 4-1). Most free to rotate connections provide some limited
lateral disc displacement to prevent stem binding and allow the disc to align itself with
respect to the seat face. Free to rotate connections should incorporate some means of
preventing the disc from spinning. Asymmetric flow created by multiple elbows
upstream can cause the disc to spin; in fact, this has occurred in some swing check
valve designs [1.20]. Spinning discs can damage the disc and seat upon contact, and can
cause premature failure of the connection due to excessive wear.
Laterally Floating Connections:. Floating connections are generally T-slot designs that
permit assembly of the joint by simply sliding the parts together in a lateral direction.
The T-slot is usually oriented in the direction of the flow (that is, in line with the
expected disc displacement) to permit sliding to occur without causing stem binding.
These joints are most commonly found in gate valve applications where the gate
receives its alignment from guides in the body during the complete open to close cycle.
These joints incorporate an anti-rotation type feature, such as a square head, to prevent
stem rotation.
As shown in Figure 2-16C, another type of design found in power plants uses a double
articulated link type stem-to-disc connection to allow the wedge to float freely in the
lateral direction.
2-35
Wedge Gate Guides: Gate guides (Figure 2-17) are provided specifically on wedge gate
valves to keep the gate away from the seat faces, except for a small distance very near
the fully-closed position, so as to minimize wear on the seating faces. The disc can slide
on the guide in either flat or tipped orientation, depending upon the details of the valve
internal geometry (for example, guide length and guide clearance), the severity of the
P load across the disc at mid-stroke positions, and the magnitude of the friction
coefficient at the sliding interfaces. Typically, the sliding surfaces on the gate and guide
are overlaid with hard-facing materials to prevent galling of the sliding interfaces, due
to the load generated by the differential pressure acting across the gate as the valve is
being closed or opened. Under certain conditions, the localized guide stresses can cause
plastic deformation as well as galling/gouging of the sliding surfaces. In some extreme
cases, the guide rail may break and cause the gate to stick in midstroke.
Figure 2-17
Gate Valve Gate Guide
2-36
Stem Guides: Stem guides (Figure 2-23) are most commonly found in globe valves. Stem
guides, which provide alignment for the plug, are typically manufactured from softer
materials to provide some lubricity and to prevent galling of the stem. Stem guides
should be provided where significant side loads on the plug are present. These forces
can be generated by side discharge such as in angle globe valves. Stem guides are also
provided when the stem is relatively long and flexible, such as in extended bonnet
globe valves.
Disc Guides: Disc guides (Figures 6-7, 6-8, and 6-9) are most commonly found in control
valves and relief and safety valves. These guides provide alignment between the disc
and seats and offer lateral support for uneven fluid discharge forces.
2.3
The selection of accessories and special features for a valve can be as important as the
valve itself and, in some cases, actually controls the type of valve selected. Control
valves have a larger selection of accessories and options available because they are
often placed in special service. Although some accessories can be used in any type of
valve, they are suitable only for certain applications.
Accessories common to valves of all types are discussed below.
2-37
Figure 2-18
Manual Override Lever on Pressure-Relief Valve
Figure 2-19
Manual Override Handwheel on Motor-Operated Valve
2-38
Figure 2-20
Steam Leak-Off Connection
2-39
As discussed in Section 2.5.2, recent advances in valve packing technology show that
the presence of lantern rings doubles the required number of packing rings and the
packing thrust/torque. Furthermore, leak-free packing with lower packing
thrust/torque can be achieved by eliminating the lantern ring (see Section 2.5.2 for
details).
2-40
Figure 2-21
External Bypass
2-41
Figure 2-22
Bonnet Extension
2-42
The valve is opened until a shoulder on the stem or disc bears firmly against a
prepared beveled surface below the packing, provided on the underside of the bonnet.
This provides a metal-to-metal seal against leakage through the stem. Stem backseating
is available on both rotating and nonrotating stem valves and is commonly found on
gate and globe valves. This feature is not found on 90 turn valves such as plug, ball,
and butterfly.
2.4
Valve Trim
2-43
Figure 2-23
Trim Components
Closure gaskets and seals are neither pressure boundary components nor trim
components but maintain leak-tightness integrity of the valve.
Stainless steels 316 SS, 410 SS, and 17-4 PH SS are the most commonly used materials
for valve stems and other valve trim materials. Although not as corrosion resistant as
316 SS, the higher strength and correspondingly higher allowable stresses make the 410
SS and 17-4 PH materials much more attractive for larger sizes and higher pressure
rated valves since smaller diameter stems can be used. Cobalt-free trim materials are
discussed in Section 2.4.5.
In general, trim material selection should consider all of the important factors discussed
below, in addition to mechanical strength considerations. Additional discussions are
provided in Section 15.
2-44
Carbon steel
Cast iron
Ni-resist
Type 440-C SS
17-4 PH SS
Type 316 SS
Nickel
Inconel
Copper Bronze
Monel
Platinum
2-45
Boric Acid
Chlorine Gas
Chlorine Liquid
Freon, Wet
Freon, Dry
Hydrogen
Oxygen
Sodium Chloride
Sodium Chromate
Sodium Hydroxide
Sodium Hypochloride
B-C
B-C
Water, Distilled
Water, Sea
Key:
In the above listing the electrolytic potential and the rate of galvanic corrosion between
trim and body material is proportional to their separation.
Area differences also affect galvanic corrosion. A larger anodic area, compared to the
cathodic area, is preferred because it reduces the amount of corrosion. As an example, a
stainless steel bolt in carbon steel body will usually cause the carbon steel to corrode at
only a slightly increased rate, whereas a carbon steel bolt in a stainless steel body will
corrode at a rapid rate because the stainless steel acts as a large cathode.
2-46
Abrasive particle
Cavitation
Erosive-corrosive
These types of erosion and specific guidance regarding how to improve the resistance
of the trim materials to their effects are discussed in the following paragraphs.
Abrasive Erosion: In abrasive erosion, small particles which are harder than the trim
surface are carried at high velocity in the fluid stream and impinge upon and scour
away the trim metal. Resistance of materials to impingement erosion varies with the
angle of impingement. At low impingement angles (<15 with respect to the surface),
hard-facing materials with large amounts of carbides, such as Stellite 1, are
recommended. At high impingement angles (>80), hard-facing alloys with large
amounts of relatively ductile matrix material, such as cobalt in Stellite 21, are
recommended.
Stellite 6, however, has been found to provide the best combination of erosion
resistance and wear resistance as a trim material for the widest range of valve
geometries that have large variations in impingement angles. However, Stellites with
their cobalt content will be activated if they are in fluids that are transported through
the reactor core region, thus creating a radiation concern in that the cobalt may plate
out on the interior walls of a piping system or be captured in crevices. Cobalt-face
alternatives are discussed in Section 2.4.5.
Cavitation Erosion: Cavitation occurs as the result of vapor bubbles forming when the
pressure of a liquid flowing in the restricted passages of a valve becomes less than the
vapor pressure of the liquid at that temperature. The bubbles then collapse as the flow
area enlarges and the pressure recovers. The implosion of bubbles produces shock
2-47
waves and very high localized stresses at the surface of the metal, causing the material
to fail and detach from the surface.
Since no known material can withstand continuous severe cavitation service without
failure, ease of trim replacement should be a strong consideration for service in
cavitating conditions. Cobalt-based hard-facing alloys, such as Stellite 6 and Stellite 21,
have found extensive use for resisting cavitation erosion. Other materials used are Type
440C, No. 6 Colmonoy, hardened tool-steel, Deloro 50, NOREM 02, NOREM B4, and
sintered tungsten carbide with a nickel binder.
Cavitation erosion may be reduced by system design or by selecting the hardest trim
material that will not crack from the impact of repeated valve closure and thermal
shock; using multiple valves to distribute the total pressure drop by providing back
pressure; and using valves that incorporate multiple pressure drop stages designed to
prevent cavitation through any one stage.
High Velocity Fluid Impingement Erosion: High velocity fluid impingement erosion occurs
when extremely high velocity fluid jets turn abruptly, bouncing off one surface to
impinge and erode the adjacent part. Impingement erosion may be a form of erosioncorrosion, whereby the high velocity fluid jet blasts away the protective surface coating
as rapidly as it forms.
Fluid impingement erosion can be prevented or reduced using the same techniques and
materials for improving resistance to abrasive erosion and cavitation erosion.
Combined Erosion and Corrosion: Both erosion and corrosion may occur in a piping
system, although not simultaneously. The erosion strips away the protective coating of
corrosion, thus allowing additional corrosion to occur by repeating the cycle.
Accelerated failures of carbon steel piping and fittings have occurred in feedwater
service due to a combined erosion-corrosion phenomenon. Valves and other
components installed in these systems are subjected to the same degradation mode. The
failures are attributed to a single phase erosion-corrosion phenomenon that occurs to
plain carbon steel when exposed to flowing water having a low dissolved oxygen
content (less than 10 ppb) in combination with a pH value less than about 9.3.
As reported in References 1.10 and 1.20, erosion-corrosion is essentially a flow-assisted
dissolution process of the magnetite corrosion film normally present under
deoxygenated feedwater conditions. This phenomenon results in much higher metal
corrosion rates than would normally be encountered. Loss rates can be greater than
0.040 inch (about 1 mm) per year in severe cases. The worst attack occurs in areas of the
feedwater system where temperatures are between 260F and 400F (125C and 200C).
The phenomenon is critically dependent on a number of variables, particularly flow
velocity, temperature, pH and oxygen content of the feedwater, and the elemental
2-48
Typical PWR
Feedwater Condition
Valve parts intended for PWR feedwater applications, particularly parts exposed to
highly turbulent flow, should not be constructed of plain carbon steel. The use of low
alloy steel, with at least 0.5% chrome, has been shown to significantly reduce erosioncorrosion attack and should be used as a replacement material whenever possible.
Typical replacement materials would be 1/2 Cr-1/2 Mo Plate (A-387, Type 2), 1/2 Cr1/2 Mo Plate (A-387, Type 12), 1/2 Cr-1/2 Mo Forging (A-182, Type F12 and A-336,
Class F12), 1-1/4 Cr-1/2 Mo Casting (A-217, Type WC6) and 1-1/4 Cr-1/2 Mo Bar (A739, Type Bll).
2-49
Factors affecting galling include the type of materials in contact, temperature, surface
finish, hardness, contact pressure, and the line fluid. Higher temperature will generally
anneal or soften the metals, increasing their galling potential.
Test data show that hardness is the most significant factor affecting wear; the harder
the material, the less the wear.
Galling, like wearing, can be prevented by:
Selecting pairs of material with low galling potential (Table 2-3). Using different
materials for components in contact rather than the same material.
Designing a reasonable loading. As a rule of thumb, 10,000 psi (70 MPa) average
contact stress provides adequate margin against galling when using Stellite material
pairs.
One of the most common methods used to prevent wear and galling is hard-facing.
Hard-facing is the process of applyingby welding, plasma spraying, or flame
sprayinga layer, edge, or point of wear-resistant metal onto another metal to increase
its resistance to abrasion, erosion, or galling. In a few cases hardfacing is applied to
impart some corrosion resistance to the base metal. It is used when external lubrication
is not feasible or is inadequate to give the desired service life, and is usually applied
only to the critical surfaces. As opposed to heat treatment to achieve high surface
hardness, hard-facing can be used effectively in very large components where the
contact area is small and heat treatment of the entire component would be impractical.
Also, because hard-facing is a welding technique, it can be used for in-line repair or to
refurbish large components without dismantling. No particular restrictions are
imposed when using a base metal of carbon steel, but there are some restrictions when
using other metals, including stainless steels. For most metals it is desirable to preheat
the base metal to prevent cracking of the hard-facing, as well as the base metal, as
cooling occurs.
2-50
Stellite, Colmonoy, and tungsten carbide are the principal materials used in hardfacing; however, tungsten carbide has limited corrosion resistance and is subject to
thermal shock failure. Hard-facing on valves is typically used on the plug or disc-toseat joint to maintain a tight seal. Other areas that are overlaid include the stem,
bushing, and disc or plug guides.
The most popular hard-face materials are Stellites, which are patented alloys of hard
tungsten and chromium particles in a softer cobalt matrix. Stellite 6 is used on valve
seats, while the slightly harder, but more brittle, Stellite 12 may be used on plugs. For
field repair of worn surfaces, Stellite 21 offers more ductility and lower cracking
tendencies, making its use more practical, even though its wear properties are not as
good as Stellite 6. The erosion resistance of Stellites is higher than indicated by their
surface hardness, which is a measure of the matrix rather than micro particle hardness.
For smaller valve parts, the disc or plug and seats may be made of solid Stellite
material.
In contrast to Stellite, Colmonoy and tungsten carbides are usually applied to all trim
shapes by the spray welding process and are then fused to give a non-porous surface.
Colmonoy has high hot-hardness and holds this hardness with thermal cycling. When
using tungsten carbide, service temperature and thermal shock must be given careful
consideration. Loading the valve seat must be uniform, and impact forces during
closure should be low to prevent cracking of tungsten carbide.
For wear resistance, hardness is required only on the surface of the metal. Additionally,
hard facing may be achieved by case hardening techniques such as carburizing and
nitriding. These superficial hardness treatments usually produce case depths of less
than 0.025 inch (0.635 mm) that are normally not detected by conventional hardness
measurement such as Brinell and Rockwell tests but require microhardness testing
methods.
Table 2-3 lists the wear and galling resistance of various combinations of materials. In
addition to these materials, plastic lined bushings have been found to be effective when
service conditions permit their usage. More quantitative information on wear and
galling can be found in References 5.15 and 5.40.
2-51
Table 2-3
Chart of Wear and Galling Resistance of Material Combinations (Reference 5.1)
304 ss
316 ss
Bronze
Inconel
Monel
Hastelloy B"
Hastelloy "C"
Titanium 75A
Nickel
Alloy 20
17-4 Ph
Alloy 6 (co-cr)
ENC*
Cr Plate
AL Bronze
Key:
S Satisfactory
F Fair
P Poor
* Electroless Nickel coating
Natural cobalt in these alloys is 100% cobalt-59, having a thermal neutron absorption of
34 barns and, if it is in a pathway to the reactor vessel, will pass through the core, be
exposed to thermal neutron flux, and be activated to cobalt-60, having a half life of 5.25
years and emitting 1.3 meV gamma rays. These small particles accumulate in the piping
system in crevices and cracks where the flow velocity is small and in stagnant pockets
or crud traps, which are inherent in the design of some valve bodies. The strength of
these radioactive sources thus grows with time and becomes a major hindrance to
access for maintenance work.
Several years ago, primarily because of high price and uncertain availability, there had
been some effort by manufacturers to develop hardsurfacing using cobalt-free alloys
such as ASTM A565, Gr616, Deloro-Cabot 40 and 50, and Colmonoy 5. Because these
alloys did not exhibit the same mechanical and corrosion-resistant attributes of
Stellite and because the price and source of cobalt stabilized, most of these efforts
were discontinued.
Recently, there have been renewed efforts to develop low-cobalt or cobalt-free alloys to
replace cobalt-base alloys to reduce the exposure of service personnel to radiation due
to cobalt-60. Several EPRI-sponsored efforts have been conducted to evaluate the
release of cobalt from PWR valves and from valve repair, evaluate low-cobalt alloy or
cobalt-free hardfacing, and to develop cobalt-free alloys as a valid alternative to cobalt
alloys for hardfacing.
A family of cobalt-free alloys named NOREM emerged as a good candidate for
further evaluation and testing. For nuclear power plant applications, cobalt-free alloys
should meet several requirements including:
1. Material should have high resistances to erosion, corrosion, wear, and galling under
typical plant conditions which may include high flow velocities,
cavitation/flashing, high contact stresses, and large temperature variations.
2. Material should have multi-layer hardfacing deposit capability for various base
materials typically used in power plant applications. The hardfacing should be
homogenous, not subject to cracking, and capable of being applied with little or no
preheat. The deposits should be economical to apply using existing
equipment/machinery and should be repairable on a localized basis.
3. Material should be available in different forms such that it can be used in spare
parts and other repairs.
Extensive testing and evaluation by EPRI [5.27] and some utilities showed that some of
the NOREM alloys meet the above requirements and in general are equivalent to or
better than those of the cobalt-base Stellite. Several utilities and manufacturers are
currently using NOREM in field repairs and as replacement of the Stellite hardfacing
2-53
material. EPRI's Welding Repair Guide [1.1] provides detailed discussion for the selection
and application of welding filler materials including NOREM alloys. Interested valve
users should consult the manufacturers for the latest technical information and test
results.
2.5
This section presents the different types of stem seal arrangements typically used in
nuclear power plants. It also presents the major factors that affect stem seal
performance.
The stem seal performance discussion is included here for the following reasons:
1. Stem leakage is a common problem in all valve designs discussed in the following
sections.
2. Stem leakage is one of the major factors that affect equipment reliability and plant
availability/productivity.
3. Recent advances in valve packing technology resulted in eliminating many valve
leakage problems. However, solving stem leakage problems requires a good
understanding of the stem sealing mechanism and correction of the misconceptions
carried over from the older and obsolete technology.
There are two basic ways of sealing the fluid around the stem: using flexible seals such
as diaphragms or bellows, or using packings. Flexible seals experience no sliding
between the stem and the seal and depend on flexure of the sealing member to
accommodate the stem movement. Packings allow the stem to slide through them and
depend on radial pressure between the packing and the stem to achieve a seal.
Flexible seals are available in either elastomers or metals, depending on the fluid media
and pressure to be sealed, and are either a diaphragm or bellows design. Flexible seals
provide better sealing and are used where external leakage or periodic maintenance is
not permissible. Flexible seals are available in either elastomers or plastic and metal,
but the pressure and temperature limitations of the elastomeric and plastic seals
prevent them from being used to any great extent in power plant applications. The
flexible elastomeric seals are found primarily in diaphragm valves (see Section 12).
Packings are found most commonly in valve applications because they can
economically seal against some of the harshest environments and can permit virtually
unlimited axial, as well as rotational, movement of the stem. Packings are typically
made of flexible materials, which can be compressed to generate the required radial
pressure to seal against the stem. Unlike metal bellows and diaphragms, packings
require periodic maintenance and replacement to maintain their effectiveness.
2-55
Figure 2-24
Bellows Seal
Bellows seals are of either internal pressurized or external pressurized design. In the
internal pressurized version, only the inner surface of the bellows is subjected to the
fluid pressure, thus permitting the use of non-corrosion resistance materials for the
outer extension bonnet. A well-designed bellows seal has an anti-rotation device
preventing torsion-induced damage during operation, assembly, or disassembly.
2-56
Single-ply bellows are limited to low internal pressure, and multilayer designs increase
the useable range to as high as 3,000 psi (20.7 MPa) differential pressure.
Bellows are ideal for service where the fluids are highly toxic, radioactive, volatile, or
extremely expensive and external leakage cannot be tolerated. Another example where
bellow applications are particularly suited is in borated water where even a minute
leakage of fluid past a seal can result in the formation of abrasive crystals. Conventional
packing rings are rapidly worn away in such applications. For high temperature
applications, bellows are seal welded onto the stem and bonnet, thus eliminating the
need for elastomeric or plastic seals at these joints.
Bellows seals are relatively expensive, require a long length, have limited fatigue life,
and have a shorter stroke, which restricts their use to services that cannot be served by
conventional seals. Since bellows do have a finite life, they should be inspected
frequently. A conventional packing is customarily used as backup to prevent external
valve leakage in case of bellows failure.
Bellows are normally used on valves having non-rotating rising stems, such as globe
valves, gate valves, and safety valves, where the stem travel is relatively short. Recently
bellows have been used in quarter-turn valves (Figure 2-25) in low pressure and
vacuum service.
Figure 2-25
Bellows on Butterfly Valve
2-57
Metal Diaphragm Seals: Metal diaphragm seals (Figure 2-26) are either single- or
multiple-ply thin flexible members installed between the stem and the valve plug to
seal the system fluid. The diaphragm is attached to the bonnet by either clamping or
seal welding. Movement of the plug in the closed direction is provided by the stem
force acting through the diaphragm, and the return stroke is provided by the system
pressure and/or springs.
Figure 2-26
Metal Diaphragm Stem Seal
Metal diaphragm seals are used for the same applications as bellows seals but have the
disadvantages of having a much shorter stroke and no physical connection between the
stem and plug. Lack of a physical connection between the stem and plug prevents
positive indication of the plug position and mechanical operation of the valve in the
opening direction. Valves using this type stem seal rely on the fluid pressure to open
2-58
the plug and, therefore, can be used only in the fluid flow to open orientation, and
preferably with the stem vertical. Since metal diaphragms have no physical connection
to the stem, they cannot be mechanically pulled open. Metal diaphragms should not be
used in throttling applications because they can flutter, due to fluid/structure
excitation, which can cause rapid fatigue failure.
Metal diaphragms have a finite life and should be inspected or replaced at regular
intervals. Conventional packing should be installed as backup in the event of
diaphragm failure.
2-59
Figure 2-27
Basic Types of Stem Seals
2-60
The most commonly used packing in valve stems is compression-type packing rings of
braided or precompressed flexible sealing material, usually of square or rectangular
cross section, which are placed into a packing box and compressed by a packing gland.
This type of packing relies on externally applied compressive force to achieve a seal.
Such packings require periodic adjustment or some other means (discussed later) to
continue to supply the necessary packing pressure to maintain a seal.
Lip-type packings, usually called V-packing or chevron type, rely on a relatively low
external force to effect an initial seal and a pressure energizing action due to their crosssectional shape. As the system pressure increases, the force at the sealing edge
increases, thus maintaining a positive seal. Such seals usually require little or no
adjustment during operation. In order to prevent binding and over-adjustment, a
compression stop ledge is often used to limit the minimum packing height.
The interference type of seal (for example, O-rings) relies on the radial cross-sectional
squeeze and system pressure to effect a seal and on the elasticity of the seal material to
maintain the sealing preload. This type of stem seal also requires no adjustments in
service.
Packing Gland Construction and Sealing Mechanism: Figure 2-28 shows a cross-sectional
view of a typical packing gland design. The assembly consists of a packing gland
flange, gland follower, and a number of packing rings. The packing flange transmits
the applied bolt force through a spherical contact surface to the follower, which, in
turn, axially compresses the packing rings. The spherical contact interface prevents side
loading of the follower against the stem under the unavoidable misalignment of the
gland flange during tightening the bolts.
2-61
Figure 2-28
Packing Gland Details
The axial compressive load transmitted to the packing rings tends to expand them in
the lateral, or radial, direction. This lateral expansion tendency of the packing crosssection is prevented by its confinement against the stem and the stuffing box inside
wall. This causes a radial contact pressure to be developed between the packing and
stem interface, as well as the packing and stuffing box wall. Friction losses in the upper
packing rings (due to friction with the stem and the stuffing box wall) reduce the axial
compression load on the lower rings, which in turn results in a decrease in the radial
contact pressure between the lower packing rings and the stem.
Fluid pressure can migrate between the packing rings and the stem up to a point where
its magnitude exceeds the radial pressure between the packing and the stem. Sealing is
achieved at a point where the radial packing pressure just exceeds the fluid pressure
trying to force its way across this interface. All the packing rings below the sealing
point are essentially ineffective in providing a seal around the stem. However, many
valve manufacturers have employed deep stuffing boxes in their designs in the past.
The first and most significant documented research towards understanding the sealing
mechanism of flexible packings was conducted by White and Denny under the
sponsorship of the British Ministry of Supply during the war and published in 1947
[5.41]. One of the important contributions from their work was a simple apparatus that
2-62
allowed the radial contact pressure distribution between the packing and the stem to be
determined. The apparatus used a small diameter radial hole in the stem, through
which an externally adjustable pressure could be introduced at the sealing surface. This
pressure was gradually increased until it reached the magnitude necessary to overcome
the contact packing pressure between the packing and the stem. By positioning the
stem with the balancing hole at various locations along the packing length, detailed
static pressure distributions were obtained for a number of packing configurations.
Two other notable fundamental research contributions that led to further
understanding of contact pressure distribution in packings under static as well as
dynamic conditions were made by Turnbull [5.42] and Denny and Turnbull [5.43] in
1958 and 1960, respectively. The major finding from these research studies was that the
packing ring closest to the gland follower has the highest radial pressure, and this
radial pressure decays exponentially as the distance from the gland increases (Figure 229). They also found that under dynamic conditions this radial pressure tends to
redistribute itself, tending to decrease in the packing rings farther away from the gland
follower and concentrating near the top rings.
Figure 2-29
Distribution of Stresses in the Packing and Location of Actual Sealing Point
2-63
For nuclear power applications, considerable research has been done by many different
organizations, including EPRI, valve manufacturers, packing manufacturers, material
suppliers, research institutes, and nuclear power utilities in the USA, Canada, U.K., and
France.
In recent years [5.44 through 5.50], the performance of valve stem packing has been
enhanced as a result of:
Improvements in gland loading arrangements that eliminate the need for packing
adjustments in service. Live loading has become an accepted term for such an
arrangement.
Testing to determine the optimum number of packing rings and range of gland
loads for different applications. Comparative testing of various shapes of packing
rings such as square, chevron, and wedge cross-section.
Collection of a vast amount of valve diagnostic data over a long period of time with
different valve designs and under different operating conditions.
Self-lubricating
Flexible, yet free of cold flow or high temperature flow problems (low creep
relaxation)
Corrosion resistant
Anisotropic, having high thermal conductivity along the plane of the sheet
Asbestos free
Nuclear grade with typical leachable chloride content of less than 50 ppm available
2-65
Available in high density (70 to 110 lb/ft ; 1,120 to 1,760 kg/m ) die-formed rings
(which have excellent flexibility) or ribbon form
Available with passivating corrosion inhibitors which prevent stem pitting without
loss of packing stress, as encountered with sacrificial inhibitors
The above factors, along with misconceptions carried over from the era of asbestosbased packings, resulted in many packing problems in the early stages of employing
flexible graphite packing. Reference 5.44 provides an excellent discussion of these
misconceptions and shows that proper application of graphite packing can eliminate
many of the packing problems. These misconceptions, along with recommendations for
proper application of flexible graphite packing, are summarized as follows:
1. Myth: Valves require periodic repacking.
Asbestos packing required periodic repacking (at some periodic frequency) because
of the loss of packing flexibility and elasticity that is caused by the depletion of the
various binders and fillers under pressure and temperature. Flexible graphite, on
the other hand, does not contain binders or fillers and tends to maintain its elasticity
throughout its life. However, flexible graphite packing must be contained with
upper and lower anti-extrusion rings to prevent extrusion outside the packing box.
In the absence of live loading, retorquing may be occasionally required to
compensate for packing consolidation.
2. Myth: Valve sealing is accomplished by pressure breakdown mechanisms.
With asbestos packing, it was assumed that sealing is accomplished by a series of
pressure breakdowns, similar to the labyrinth seal design. This assumption led to
deep stuffing box designs to accommodate a large number of packing rings,
especially for higher pressure systems. Testing has shown that only one die-formed
graphite ring is required to provide adequate sealing. However, to ensure backup
protection, the graphite packing set typically includes several die-formed rings in
addition to anti-extrusion rings on the top and bottom. Graphite bushings are also
used to fill the space previously occupied by excessive packing rings.
3. Myth: Valve packing will leak.
Because asbestos packing is harder to consolidate (due to higher friction and stiffer
Inconel reinforced rings), packing leakage at start-up was considered normal. With
proper installation and adequate consolidation of flexible graphite packing, valve
packing will not leak.
4. Myth: Lantern ring prevents packing leakage.
Lantern rings do not serve a good function in modern packing designs. They can
corrode to the stuffing box, damage the stem and at best require an additional set of
2-66
packing rings. With lantern rings, it is extremely difficult (if not impossible) to
adequately load and consolidate the lower rings. Utilization of lantern rings also
doubles the packing drag on the stem.
5. Myth: Every mechanic knows the right amount of torque to tighten a packing.
Packing loads depend on several factors including system pressure, friction
coefficient, stem diameter, packing height, and the ability of the packing material to
transfer axial load to radial pressure. The 1,000-pounds-per-inch of stem diameter
rule does not differentiate between different applications or operating conditions.
Packing loads should be predicted using analytical or empirical formulas that
account for all packing parameters as well as operating conditions.
6. Myth: Packing is not part of the valve pressure boundary.
Although the ASME Pressure Vessel Code views valve packing as outside the scope
of the valve pressure boundary, packing failure can have a significant impact on
personnel/plant safety and on the environment. Recent advances in packing
technology will eventually lead to leak-free packing designs. Additional research
will be needed if valve packing is to be considered part of the valve pressure
boundary.
Plastics and Elastomers. Several plastics and elastomers are used in valve stem
packings for temperatures lower than those requiring graphite. Teflon in virgin form or
as filler materials is used extensively in valves because of its low coefficient of friction
and excellent chemical resistance for temperatures up to 400F (200C). Teflons main
limitation is lower radiation resistance (maximum 104 rads) than other plastics and
elastomers used as packing, gasket, and soft seating insert materials. However, Teflon
is used in many applications in power plants where radiation levels and temperatures
are low.
An important development in elastomers came from the Department of Energys
funding to develop high temperature elastomers for geothermal applications. One
formulation of EPDM (ethylene propylene family) capable of withstanding 600F
(315C) water or steam environment has been developed and is in commercial use.
EPDMs main limitation is its inability to tolerate any exposure to petroleum-based
fluids, which cause excessive swelling, degeneration, and sticking to metal surfaces,
especially copper alloys. EPDM is particularly unsuited for solenoid-operated valves in
air systems, which invariably transmit some lubricant mist. In nuclear power
applications, some grades of EPDM are likely to make strong inroads and extend the
temperature limits of soft seating materials. EPDM is commercially supplied by several
seal manufacturers in O-ring, chevron, V-packing, or other special forms.
2-67
Tables 2-4 and 2-5 give a summary comparison of properties of various plastics and
elastomers used as gaskets and seals.
Table 2-4
Typical Properties of Plastics and Elastomers Used in Valves for Soft Seats, Seals,
and Gaskets
(Source: Reference 5.51)
TEFLON
(Halon, TFE, Fluon)
TEFLON
(Glass Filled)
NYLON
(Zytel, Nypel, Fosta)
KEL-F
(CTFE)
TEFZEL
POLYETHYLENE
2-68
Susceptible to abrasion
Susceptible to abrasion
VITON
ETHYLENE,
PROPYLENE,
TERPOLYMER
2-69
Table 2-5
Typical Radiation Resistance of Plastics
(Source: Reference 5.51)
GROUP 1
GROUP 2
GROUP 3
GROUP 4
GROUP 5
GROUP 6
Polyurethane
Plastics retaining satisfactory properties after exposure to 109 rads
Polyethylene
Silicone, unfilled
Polypropylene
Plastics retaining satisfactory properties after exposure to 107 rads
Phenolic, unfilled
Urea - formaldehyde
Polyester, unfilled
Tetrafluoroethylene* (Teflon)
* Tests have shown these materials to evolve halogenated gases due to radiation exposure, possibly at lower doses than
indicated here; their use should be restricted.
2-70
Guidelines for Stem Packings: One of the most significant activities in the United States in
this area was EPRI research project RP2233-3, Valve Stem Packing Improvements,
initiated in early 1984. The work performed under this project culminated in the
development of specific guidelines for improving the stem packing performance in
nuclear power plants. EPRI Report NP-5697 [1.15] provides a comprehensive
description of effort under this project. Subsequent testing and field experience by
several utilities [5.44] and packing companies [5.45] provided new insights into
understanding and predicting valve packing performance. These efforts resulted in the
development of effective valve packing programs and prediction models that
eliminated many packing problems [5.44, 5.45, 5.46]. This in turn resulted in:
Misalignment
Vibration
In the following sections, some of the important findings from recent developments are
summarized. However, the reader is encouraged to refer to the original references for
more detailed discussions.
Packing Assembly and Consolidation [5.46]: Proper packing assembly and consolidation is
a determinant factor in obtaining leak-free packing. Packing consolidation should be
performed by retorquing and stroking to ensure uniform radial loading of the entire
valve packing set. Better load transfer is obtained by reversing stem direction between
retorquing. Recommendations of packing manufacturers should be followed.
Break-Away vs. Running Packing Friction [5.50]: Field and laboratory testing show that
break-away packing friction can be as low as 5% higher than running friction and as
high as two times higher than running friction. In designing or modifying a valve
packing, the break-away packing friction should be kept as close as possible to the
running friction.
Higher break-away packing friction reduces operating margins in MOVs and causes
control problems, especially in air-operated valves. Packing material, stem finish, and
temperature are the main factors affecting the ratio of break-away packing friction to
running packing friction.
Maintaining Gland Load by Live Loading: Conventional packings progressively
consolidate and wear in service, thereby causing a loss of gland load which is initially
applied to achieve a good seal. Eventually, this leads to leakage when the radial
packing stress due to reduced gland load falls below the fluid pressure to be sealed.
Periodic adjustment of the packing gland has been an accepted practice in conventional
applications to maintain adequate gland loading and to prevent leakage. Some utilities
have found that periodic retorque every three to four years provides good packing
performance. However, this approach is not preferred in some nuclear power
applications due to higher reliability requirements and the additional radiation
exposure that complicates maintenance activities. The regulatory aspects of plant
operation may dictate plant shutdown or reduced power operation to correct leakage if
operating limits are exceeded.
2-72
Figure 2-30
Live Loading of Valve Packing Using Disc Springs
2-73
Figure 2-31
Packing Compressive Stress Versus Consolidation
Improved Packing Composition and Configuration: The improved packing gland design
utilizes a square cross-section, precompressed flexible graphite material packing rings
in the middle of the packing box, in combination with braided graphite or braided
carbon anti-extrusion rings at the top and bottom. It has been found that an
arrangement consisting of three or four flexible packing rings and one end ring at top
and bottom locations gives good performance. The anti-extrusion rings prevent
extrusion of the flexible graphite material into the relatively large radial clearance
usually present between the stem and gland follower. The anti-extrusion rings also act
as scraper rings, preventing the loss of graphite material, which has a tendency to
adhere to the stem, during cycling.
It may be possible to adjust packing configuration to improve performance. For
example, running load may be reduced by using two die-formed rings (instead of three
or four) or by using narrow rings instead of the square design. Another packing
configuration utilizing wedge rings that can convert axially applied gland load more
efficiently in the radial sealing direction has also been developed as a result of this
EPRI project. Instead of relying upon the gland load alone, this configuration also
utilizes the system pressure to increase the radial sealing load as pressure is increased.
Specific values of gland compression details for various types of packings should be
obtained from the valve/packing manufacturer.
Retrofit Considerations: To install the live-loading as a retrofit to existing valves requires
careful evaluation of several factors. The space needed to incorporate a spring stack
that provides sufficient force throughout the anticipated range of deflection is limited
2-74
in both the vertical and radial clearances in the valve stuffing box area. This can make
retrofitting particularly difficult in the smaller valves. New and longer gland studs are
usually needed to install the spring stack, and adequate guiding of the individual
Belleville spring must be provided to ensure proper performance. To get the proper
benefits from the live loading arrangement, the guidelines established in EPRI Report
NP-5697 [1.15] should be followed. Several manufacturers have utilized guidelines to
make recommendations for specific installations with proper consideration to the
maximum and minimum gland loads that can be achieved within the space constraints
and the expected in-service packing consolidation that can be tolerated without
leakage.
Stuffing Box Spacers: For many years, some valve designers have erroneously considered
deep stuffing boxes to be more effective in controlling stem leakage; stuffing boxes with
twelve packing rings were not uncommon. As discussed earlier, since the gland
pressure decays exponentially as a function of distance away from the follower, it has
been found that only three to four packing rings are essential to accomplish a good seal,
and the use of additional rings contributes to an unnecessary increase in stem friction.
One of the primary reasons for packing leakage is inadequate gland load. As packing
wears and consolidates with usage and time, the gland load decays, which eventually
results in leakage. Deeper stuffing boxes with a larger number of packing rings results
in more consolidation of packing and a greater loss of gland load. Deep stuffing boxes
are also more difficult to clean and repack.
To overcome these deficiencies, metal or carbon spacers can be installed in the bottom
of the stuffing box to reduce the number of packing rings. A set of five rings, consisting
of three die-formed graphite packing rings (which accomplish the sealing function) and
two braided graphite end rings (which confine the loose graphite particles within the
sealed gland), has been found to work well (5.44, 5.45, 5.46). Hardened carbon spacers
on the top and bottom of the packing set can also improve stem alignment and provide
additional radial support.
Lantern Ring/Stem Leak-Off Connection: Deep stuffing box designs were inherited from
other industries, and they usually employ lantern rings in the center. In petrochemical
and other non-nuclear power applications, lantern rings are used to allow injection of a
grease or sealant material through an external connection in the middle of the packing
ring stack to provide a secondary backup seal (Figure 2-32). Lantern rings can be used
to effectively seal off a leaking stem when additional gland load cannot successfully
overcome the leakage. Relatively high viscosity sealants, capable of performing at high
temperatures, are available. Since the pressure sealing capability using viscous sealant
is increased by an increase in the length of the resistance path, deep stuffing boxes do
provide an advantage when sealant injection is permissible. However, in most nuclear
power applications, this is not acceptable.
2-75
Figure 2-32
Lantern Ring / Stem Leakoff Connection
In some nuclear power plant applications, the lantern ring and associated leakoff
connection, in conjunction with double packing arrangement, is used to collect leakage
of contaminated water past the lower packing ring set and allow contaminated water to
be piped off to a remote location. It should be pointed out that in double-packing
arrangements, the gland load has to be high enough (typically higher than in a single
packing arrangement) to transmit sufficient compressive load to the lower packing set
to achieve a seal.
Stem Corrosion and Use of Inhibitors: Stem corrosion and pitting can cause quick failure of
the packing by abrading away the packing material. It has been found that low
chromium content stainless steel stem materials (400 series) are more prone to pitting
corrosion than high chromium materials (300 series steel) in the presence of moisture.
In general, properly heat-treated 17-4 PH material has been found to be very resistant
to pitting corrosion.
When the valve is hydrostatically tested with water and then stored without taking
precautions to avoid corrosion, stem packing failures are often encountered during the
2-76
first cycle of operation due to severe pitting of the stem during storage. Both asbestos
and graphite, the most commonly used packing materials, can cause corrosion of the
stem, even though graphite packing material has less corrosion-inducing impurities
and is, therefore, less aggressive than asbestos. One of the practices used to avoid stem
corrosion during storage is to specify that valves be shipped with packing removed.
Historically, most valve manufacturers use generous quantities of grease when
installing stem packings for many non-nuclear applications. The greases used provide
reasonable protection against pitting corrosion of the stem during storage by
preventing intrusion of water or moisture into the packing material during hydrostatic
testing, especially at the interface between the stem and packing. The level of protection
provided by this approach is not very reliable. In nuclear power plants, the use of
grease is unacceptable in most stem packing applications.
Corrosion inhibitors are employed in stem packings to provide a positive protection
against stem pitting. The most frequently used inhibitors have been sacrificial types
which undergo oxidation corrosion instead of allowing the stem material to be
attacked. This effectively prevents pitting corrosion of the stem, while the sacrificial
anode is consumed. Zinc and aluminum in various forms have been the most
commonly employed sacrificial corrosion inhibitors. Zinc has been found to be more
effective than aluminum. Both have been used in the form of washers in the packing
set, as well as in a powder form uniformly distributed in the packing material itself.
The protection obtained by using the powdered form, even with best attempts to
achieve uniform dispersion and the use of binding or tacking agents to keep the
powder particles in place, has been found inadequate. Solid zinc washers have been the
preferred sacrificial corrosion inhibitor by most users.
One recent development has been the use of passivating corrosion inhibitors that form
a protective film on the stem that inhibits corrosion. Some manufacturers offer flexible
graphite packings impregnated with barium molybdate; other manufacturers are
offering nonmetallic, inorganic inhibitors that are an integral part of the graphite sheet
itself. An advantage of the passivating type of inhibitor over the sacrificial type is that
there is no loss or increase of material in the packing box; therefore, there is no change
of packing compressive stress due to the inhibitor material being consumed.
2.6
Table 2-6, taken from ASME Section VIII, Division 1, Appendix 2, which also provides
design rules for bolted flange connections using gaskets. The differences between the
actual gasket width furnished and the effective width recommended should be taken
into account, as discussed in these standards, to avoid either over-stressing the gasket
or having insufficient stress, causing leakage.
Table 2-6 lists the types of gaskets in the order of increasing minimum design seating
stress required. The Code-suggested design values of the gasket factors (m) (m is the
multiple of pressure to develop sufficient compression load to ensure a tight joint) and
the minimum design seating stress (y) are not mandatory. Gasket manufacturers can
suggest lower values which still provide a satisfactory static seal at lower bolt loads.
There are other commercially available gasket materials that are not included in the
ASME Pressure Vessel Code Table 2-6. For gasket materials other than those given in
this table, the supplier should be contacted to obtain y and m values.
2-78
Table 2-6
Gasket Materials and Contact Facings, Gasket Factors M for Operating Conditions,
and Minimum Design Seating Stress y
(Extracted from the ASME Pressure Vessel Code, Section VIII Division 1)
2-79
2-80
2-81
3
FUNCTIONAL REQUIREMENTS OF VALVES
3.1
General
Many different types of valves are used in power plants to perform various functions.
Valves are used for on-off service, modulating/throttling service, to protect
components against overpressure, and to prevent backflow from occurring. Many
different types of valve designs and valve body styles can be used to perform these
functions. Some of the valve types in common use are:
Gate valves
Ball valves
Butterfly valves
Globe valves
Check valves
Plug valves
In general, valves may be categorized within the following four groups (Figure 3.1):
Isolation Valves: Used for on-off service (including throttled position) with local or
remote actuation. Depending on the particular application and operating conditions,
isolation valves can be either gate, globe, butterfly, ball, plug, or diaphragm valves.
Pressure Relief Valves: Used to provide protection against excessive pressure. The
valve opens automatically when pressure exceeds a preset level and closes after
pressure recedes below a preset level. Power-operated relief valves that open or
close in response to command signals are also utilized.
3-1
Check Valves: Used to allow flow in the normal flow direction and to prevent flow
in the opposite flow direction (reverse flow). Check valves are typically opened and
closed by the flow forces.
Figure 3-1
Valve Classification by Function
3.2
Isolation Valves
Valves are categorized as isolation valves when their function requires them to be
either closed or open (including partially open positions). Isolation valves, both manual
and power operated, are typically used to isolate a system component or a section of
the piping system for:
Maintenance
When an isolation valve is fully closed, it normally exhibits a very low leakage rate
across its closed port(s).
Isolation valves may be required to perform some safety functions such as shutting
down the plant and maintaining the plant in a safe shut-down condition under design
basis conditions. Containment isolation valves are a special subset of isolation valves
used in nuclear power plants. The selection of containment isolation valves must meet
the following requirements:
U.S. Code of Federal Regulations 10CFR50, General Design Criteria 54, 55, 56,
and 57
3-3
Selection of metal seated valves should consider the ease of seat repair. For example,
in situ repair of globe valve seats is easier than the repair of gate valve seats.
In valve selection, attention should be given to design features which provide better
leak-tightness. For example, some pressure-energized seat designs and triple-offset
disc butterfly valves can provide better leak-tightness as compared to conventional
disc butterfly valves.
The valve and actuator should have adequate access to facilitate maintenance and
repair activities.
Some valve designs (such as double disc gate valves) must be installed with stem
vertical.
Local drains should be a Y-pattern globe, gate, ball, plug, or straightway diaphragm
valve in the system pressure/temperature rating to make provision for cleaning out
the drain.
3-4
It is suggested that instrument root valves be 3/4-inch (19-mm) valves, except for
orifice flanges.
3.3
3-5
Table 3-1
Control Valve Seat Leakage Classifications
(In Accordance with ANSI/FCI 70-2-1976 [6.12]
Maximum
Class
Leakage
Allowable
Test
Medium
Test Pressures
3-6
Testing
Procedures
Required for
Establishing
Rating
No test required, provided
user and supplier so agree
II
0.5% of rated
capacity
Air or water
at 50125F
(1052C)
III
0.1% of rated
capacity
As above
As above
As above
IV
0.01% of rated
capacity
As above
As above
As above
0.0005 ml per
minute of water
per inch of port
diameter per psi
differential
Water at
50125F
(1052C)
Max. service
pressure drop across
valve plug, not to
exceed ANSI body
rating. (100 psi/690
kPa pressure drop
min.)
VI
Not to exceed
amounts shown in
Table 3-2 based
on port diameter
Air or nitrogen
at 50125F
(1052C)
Inches
ml per
Bubbles per
Minute
Minute*
25
0.15
38
1-1/2
0.30
51
0.45
64
2-1/2
0.60
76
0.90
102
1.70
11
152
4.00
27
203
6.75
45
A control valve assembly consists of a valve body subassembly and an actuator subassembly. Many different styles of control valve bodies are in common use, each having
certain advantages and limitations for a given service requirement.
Valve styles typically used in control valve service include globe valves, ball valves,
plug valves, butterfly valves, and diaphragm valves. Variations of these styles are used
to provide a higher degree of accuracy, as well as linear flow to valve position
indication. These variations are discussed in the section dealing with a particular valve
and function.
There has been a growing trend in recent years toward the use of rotary valves in
control applications. The major reasons for this are that rotary valves:
Can provide good throttling control, especially with special shaped or contoured
closure elements
Leading control valve manufacturers estimate that most existing control valve
application problems can be resolved and could have been averted if accurate
application data and operating conditions had been provided prior to the selection and
sizing of the valve. Recent studies [1.6, 5.38] show that an accurate prediction of valve
performance requires a detailed study of the entire hydraulic system including
pressure/flow sources (for example, pumps, upstream tanks/reservoirs, surge tanks,
accumulators); flow resistances in the hydraulic system (such as heat exchangers,
strainers, other valves, orifice plates, pipes, elbows, tees); piping layout (single-line
flow or parallel-line flows); fluid type (water, steam, air, nitrogen); and operating
conditions.
The reason is that, as the control valve disc position changes, the total system flow
resistance changes. In a pumped system for example, the pump operating point on the
pump curve will also change to a new equilibrium point where the total system
pressure drop at the new flow rate matches the head developed by the pump at the
new operating point. Thus, analyzing a control valve problem should involve
examination of the entire hydraulic system (see Reference 1.6 for additional discussion).
3.4
Pressure relief valves are discussed in great detail in Reference 1.4 and are only briefly
discussed here.
Valves provided to function as pressure relief devices are used to dissipate excessive
system pressure to a pressure suppression system or to the atmosphere, thus avoiding
overpressurization of the protected system. This pressure relief function can be
performed by:
Use of a pilot valve that opens automatically when pressure at the inlet of the valve
exceeds a predetermined level. The opening of the pilot valve subsequently causes
the main valve disc to open by action of the inlet pressure. The pilot valve may
alternately be provided with means to be opened at any inlet pressure by the
application of an external power source.
Installation of a power-operated valve where the main valve disc is opened by the
application of external power to the actuator.
The term pressure relief valve encompasses relief valves, safety valves, and safetyrelief valves.
3-8
Relief, safety, and safety-relief valves are used to provide protection for both system
components and operating personnel. These valves were originally designed using
weights mounted on the valve stem. The weights established the set point at which the
valve would automatically open to protect against overpressure. The valve would then
close automatically when pressure dropped below the set point. This design has the
disadvantage of being sensitive to system vibration, as well as lacking proper enclosure
to provide protection of valve components.
The disadvantages associated with the use of weights led to the use of springs for
controlling system pressure. Springs resulted in a more compact design, which is
highly desirable in large volume, high pressure applications. Although the use of
springs to control force on the valve disc is preferable to weights, springs are
susceptible to changes in force applied as system temperature is elevated. As an
alternative to the spring-type relief device, pressure may be controlled using pilotoperated valves.
Pilot-operated relief valves are a type of pressure relief valve that utilizes either the
process pressure or an external power source through a pilot mechanism to actuate the
valve. Since the valve operating mechanisms (pilots) have static and moving seals with
small clearances, the process fluid must be extremely clean. Some of these pilotoperated valves offer the advantage of allowing independent adjustment of both
accumulation and blowdown external to the valve.
A rupture disc is a unique type of overpressure protection device, consisting of a
membrane held between flanges, which is designed to burst at a predetermined
pressure. The major difference between rupture discs and pressure relief valves is that
the rupture disc does not re-close. It will remain tight until it bursts, at which time it
must be replaced. Since the rupture disc is operated by a pressure differential, it is
sensitive to back pressure; therefore, the burst pressure of a rupture disc will vary as
the back pressure or downstream pressure varies. Rupture discs can be used to
supplement relief valves. They can also be used at the inlet of a pressure relief valve to
protect the valve from the corrosive effects of the process fluid.
Power-operated relief valves (PORVs) are used in conjunction with spring-loaded relief
valves. PORVs are actuated at a system pressure well below the set point of springloaded valves to eliminate unnecessary operation of spring-loaded valves that often
leak after reseating.
Proper selection of pressure relief valves requires an understanding of the relieving
requirements of the system or component that is to be protected and the environmental
conditions associated with that installation. The system relieving requirements include
considerations such as response time and discharge capacity.
3-9
Typical process areas that must be protected are low-pressure storage tanks, pressure
vessels, heat exchangers, pumps or compressors, and piping systems.
Low-pressure storage tanks must be protected when liquid is pumped into or out of the
tank. This is required to prevent overpressurizing or collapsing the tank when liquid is
being moved from or to the tank.
Heat exchangers that have valves on both the inlet and outlet can be isolated if both
valves are shut. Safety/relief valves should be provided to protect the heat exchanger
from the effects of thermal expansion of the liquids that may be isolated within the heat
exchanger. Consideration should also be given to protection of equipment on the low
pressure side if a tube within the heat exchanger should rupture.
Positive displacement pumps and reciprocating compressors should have pressure
relief valves on their discharges to relieve the fluid if the discharge should be blocked.
3.5
Check Valves
This section provides an overview of check valves (also called non-return valves).
Detailed information on selection, installation, troubleshooting, and maintenance of
check valves is given in EPRIs Application Guide for Check Valves [1.20] and EPRIs Check
Valve Maintenance Guide [1.21].
Check valves are self-actuated valves whose functions include:
Check functions are generally satisfied by using lift, swing, tilting disc, double disc, or
silent (nozzle) check valves. These valves are best installed in a horizontal line and are
opened by the velocity head of the flowing fluid in the normal flow direction. In almost
all cases, the impetus to close the disc is initiated by the weight of the valve disc or by
springs with the primary seating force generated by the system differential pressure. In
some instances, auxiliary external weights, springs, dashpots, or other actuation means
3-10
are used to aid closing, decrease slamming action against the seats, or to prevent
closing when servicing.
Check valves are used to ensure that the process medium flows in one direction only.
Typical applications are at the discharge of multiple pumps that provide flow and
pressure head to a common manifold. In the event that one of the pumps ceases to
produce flow and pressure head, the check valve at its discharge prevents a flow
reversal through that pump caused by the pressure head produced by the other
pump(s). Other applications include feedwater lines to boilers and, in general, a means
to minimize the loss of process media in the event of a pipe line rupture.
Even though good shut-off can be provided by some check valves (especially when soft
seats are used), the main function of these valves should be to prevent flow reversal.
Check valves should not normally be considered as a suitable replacement for isolation
valves.
Check valves should not be oversized and should be located a safe distance from any
flow disturbance (such as pumps, elbows, tees, or other valves). Over-sizing and
turbulence caused by upstream flow disturbances create instability of the closure
member and may result in premature degradation or failure of the valve. Some designs
are available in right angle patterns. Almost all check valves are top entry designs and
allow servicing without removal from the line.
Various manufacturers, architect engineers, nuclear steam supply system suppliers, and
users have developed their own criteria for selecting the type of check valve to be used
in a particular service. In general, the selection criteria have been qualitative, and more
than one type of check valve can be chosen to successfully meet the requirements of a
given application, provided all the important technical factors are properly taken into
consideration during sizing and selection. Therefore, it is not uncommon to see swing,
tilting disc, or lift checks being used in similar applications and performing
successfully at different plants and sometimes even within the same plant. The
application and use of check valves in power plants has been the subject of a
comprehensive study, the results of which are documented in Reference 1.20. This
study was prompted by the unexpected failure of several check valves in nuclear
power plants, which resulted in significant loss of plant availability, as well as
equipment damage.
Recently, EPRI published the Check Valve Maintenance Guide [1.21] to provide nuclear
utilities with detailed discussions of check valve maintenance issues. Check valves are
not discussed further in this Guide, and the reader is referred to References 1.20 and
1.21.
3-11
4
GATE VALVES
4.1
Gate valves, the most commonly used valves in power plants, are primarily used for
on-off service. Gate valves are available in a variety of materials; therefore, they are
suitable for the toughest applications in high pressure and high temperature systems.
Gate valves, ranging in size from 1/4 inch (6 mm) to sizes exceeding 48 inches (1200
mm), offer the lowest pressure drop during fluid flow conditions, approaching that of
an equal length of straight pipe when fully open, but tend to have more operability
problems and a higher seat leakage rate than globe valves.
4.2
Design
This section provides general descriptions, advantages, and disadvantages of most gate
valve designs in nuclear power plants. Other gate value designs not commonly used in
nuclear power plants (such as knife gate valves) are not discussed here.
4.2.1 General
Gate valves can be either rising stem or non-rising stem design (Figure 4-1). Rising stem
designs, utilizing an outside screw and yoke (OS&Y) (Figure 4-2), provide the
advantage of having the power threads outside the fluid, thus minimizing thread
damage from exposure to the fluid. Rising stem action allows the incorporation of an
optional backseating feature to assist in isolating the packing from the process fluid by
pulling the stem up against the inside of the bonnet (see Section 2.3.8).
4-1
Figure 4-1
Inside Screw Stem Thread Configurations
Figure 4-2
Rising Stem Design, Outside Screw
Another rising stem option utilizes a power screw inside the valve body that exposes
the threads to the fluid. A non-rising stem configuration requires the power screw to be
inside the valve disc or wedge. Since the stem rotates in the packing without axial
motion, packing wear and damage resulting from abrasive contaminants and
undesirable materials being dragged across the packing is minimized. The
disadvantages of the non-rising stem are that the threads are exposed to the fluid, the
4-2
stem cannot be backseated, and the disc position cannot be judged by the stem position
from the outside. Additionally, inside screw and non-rising stem configurations are
usually limited to low pressure and low temperature applications. These designs are
generally used in fluids with good lubrication properties and without abrasive
components because the working fluid lubricates the stem threads.
Most gate valve designs are offered with metal-to-metal seating at the gate-to-seat
interface. Metal-to-metal seating allows valves to operate at a much higher temperature
than would be possible with elastomeric or polymeric-type seat materials. Metal-tometal seating also makes the valve fire safe for most applications. The types of gate
valves available include:
Solid wedge
Split wedge
Flexible wedge
Parallel expanding
Slab
Knife
Figure 4-3
Wedge Gate Valve
The solid wedge design is preferred in smaller sizes where the stiffness of valve body
and disc is much higher than that of the adjacent pipe. The increased stiffness
minimizes seat distortion which can increase seat leakage or gate pinching, due to pipe
loads transmitted to the valve ends. The solid wedge gate design is not suited for large
valves, especially in high temperature applications where differential expansion and
distortion of the gate, body, and seats, due to mechanical and thermal loads, can cause
loss of seat tightness and/or binding of the gate, which can either increase the
operating thrust required or, in some cases, cause complete inoperability.
4-4
The following list identifies some of the advantages and disadvantages of the solid
wedge gate.
Advantages:
Simple construction.
Disadvantages:
Sensitive to line loads: bending moment, torsion, and axial loads that are
transmitted by the adjacent pipe to the valve ends. The sensitivity increases with the
size of the valve.
Seating is sensitive to thermal distortions because the solid wedge gate does not
have the ability to easily conform to the seat face plane distortion.
Lack of disc flexibility makes solid wedge gate valves more susceptible to thermal
binding (see Section 4.2.10).
Depending on the clearance in the gate area, the gate could tilt under flow forces
and create galling or high wear at the disc/seat faces.
4-5
Advantages:
Better immunity to line loads than solid wedge design, minimizing sticking and
leakage.
Simultaneous seating of both discs can be used to check body seat integrity, without
line pressure, by pressurizing the body between the seats.
Easier to repair seat faces in line than the solid wedge since the flexible wedge
design can tolerate more angular mismatch.
Flexible wedge gate valves are less susceptible to thermal binding than solid wedge
gate valves.
Disadvantages:
Both wedge pieces can independently seat simultaneously, thus trapping pressure
in the body. This can cause inadvertent overpressure in the body during pressure or
thermal transients and an increase in thrust required to open the valve due to the
combined friction from the two wedge pieces, in some cases rendering the valve
inoperable. This condition is often referred to as pressure locking or double-disc
drag (see Section 4.2.9).
Depending on the clearance in the gate guide area, it is possible for the gate to tilt
under flow forces and create galling or high wear at the disc/seat faces.
The following list identifies the advantages and disadvantages of split wedge type gate
construction.
Advantages:
Better immunity to line loads than solid wedge design, minimizing sticking and
leakage.
Can provide simultaneous shut-off against pressure on both the upstream and the
downstream seats (block and bleed).
Simultaneous seating of both discs can be used to check body seat integrity without
line pressure by pressurizing the body between the seats.
Easier to repair seat faces in line than the solid wedge because the split wedge
design can tolerate more angular mismatch.
Disadvantages:
Both wedge pieces can independently seat simultaneously, thus trapping pressure
in the body. This can cause inadvertent overpressure in the body during pressure or
thermal transients and an increase in thrust required to open the valve due to the
combined friction from the two wedge pieces, in some cases rendering the valve
inoperable. This condition is often referred to as pressure locking or double-disc
drag.
The two-piece construction is more expensive and somewhat more complex than a
solid wedge. It also has the potential for allowing disengagement between the gate
pieces and the stem.
Depending on the clearance in the gate guide area, it is possible for the gate to tilt
under flow forces and create galling or high wear at the disc/seat faces.
Valve cannot be used for throttling, and disc assembly cannot be left in midstroke
position for any extended period of time.
4-7
Figure 4-4
Anchor/Darling Double-Disc Gate Valve
4-8
Figure 4-5
W-K-M Through-Conduit Double-Wedge Parallel Expanding Gate Valve
When going from open to closed position, the wedge pieces move down together, as an
assembly, without any relative motion between them until, at the very end of the
stroke, one of the pieces contacts the bottom stop. Continued motion of the stem after
this contact causes a climbing action of one wedge piece on the other at the inclined
plane interface between them, which in turn expands them laterally against their
respective seats. Parallel-expanding gate valve designs can provide simultaneous
seating against both the upstream and downstream pressures. This can be an advantage
because of the redundancy in seating available in such design. However, the double
seating feature can also be a disadvantage because the body can trap fluid, which can
cause inadvertent high pressure during thermal transients.
The W-K-M parallel-expanding gate valve designs employ special mechanisms that
kinematically prevent premature gate expansion when the gate assembly is in the midtravel position. Expansion of the gate before reaching the end of the stroke may prevent
the gate from closing completely. This design is also made in a through-conduit
double-wedge arrangement that permits expansion of the gate in the open position as
well as the closed position (Figure 4-5). The valve preferred flow direction is with gate
downstream (segment upstream).
4-9
Through-conduit double-wedge design can double block and bleed, that is, provide
block and bleed in closed position and also prevent the line pressure from entering
the body cavity through both seats simultaneously in the open position.
Disadvantages:
Depending on the actual construction and stiffness of the gate, the parallelexpanding gate design can be very intolerant of line loads and thermal transients.
Normally unidirectional or has a preferred flow direction for best performance. The
two wedge pieces are usually asymmetrical, and one of the two pieces has better
ability to self-align with respect to the seat face.
Both wedge pieces can independently seat simultaneously, thus trapping pressure
in the body. This can cause inadvertent overpressure in the body during pressure or
thermal transients and an increase in thrust required to open the valve due to the
combined friction from the two wedge pieces, in some cases rendering the valve
inoperable. This condition is often referred to as pressure locking or double-disc
drag.
4-10
Depending on the clearance in the gate guide area, it is possible for the nonthrough-conduit gate designs to tilt under flow forces and create galling or high
wear at the disc/seat faces. The through-conduit gate design, shown in Figure 4-5, is
not susceptible to this problem.
Valve cannot be used for throttling, and disc assembly cannot be left in midstroke
position for an extended period of time.
Figure 4-6
Parallel Slide Double-Disc Gate Valve
4-11
Figure 4-7
Through-Conduit Parallel Slide Double-Disc Gate Valve
The following list identifies some of the advantages and disadvantages of the parallel
slide double-disc gate valve.
Advantages:
Of all the gate valve designs discussed, parallel slide double-discs are most tolerant
of, and virtually immune to, line loads due to the ability of the spring between the
gate pieces to absorb large seat deflections with virtually no change in seat contact
force.
4-12
They are tolerant of temperature changes during operation. The gate will not bind
due to differential thermal expansion effects because of the resilient spring between
the discs.
They are tolerant of a lack of parallelism between the two seat faces because of the
ability of the two independent gate pieces to align themselves. This feature also
provides a good shut-off under bending moments transmitted to the valve ends by
the adjacent pipe, which causes tilting of the seat faces. The ability to absorb large
variations in dimensions between the seat faces, without any adverse effect on the
valve performance, allows more economical fabrication tolerances to be used than in
wedge gate valves.
Less tendency to galling due to smaller changes in seat loading under line loads and
thermal transients.
Double-disc seating can be used to check body seat integrity without line pressure
by pressurizing the body between the seats.
Disadvantages:
Downstream sealing only, upstream disc does not seal against line pressure.
Floating gate pieces can trap body pressure and effect double-disc seating, allowing
inadvertent overpressure in the body during pressure or thermal transients.
Gate has constant spring load over entire stroke creating nominally higher running
torque.
Depending on the clearance in the gate guide area, it is possible for the nonthrough-conduit gate designs to tilt under flow forces and create galling or high
wear at the disc/seat faces. The through-conduit gate design, shown in Figure 4-7, is
not susceptible to this problem.
clevis-type stem head to which the linkage system is connected. The double-pinned
linkage allows the disc to translate relative to the stem in a direction parallel to fluid
flow. The upper portion of the disc contains a keystone-shaped slot that retains the
bearing block of the stem-to-disc connection. The disc is a one-piece flexible wedge
with hardfaced sealing surfaces and guide slot surfaces.
Figure 4-8
Westinghouse Flexible Wedge Gate Valve
4-14
Two guide rails are installed in parallel slots in the body cavity to guide the disc during
opening and closing strokes. The upper portion of the guide rails is wider than the
lower portion with a tapered transition between the two portions. This design results in
a smaller disc-to-guide clearance in the vicinity of the fully open position that keeps the
disc from rattling under flow turbulence. The larger disc-to-guide clearance in the
vicinity of the fully closed position allows the disc to contact the downstream seat
earlier during the closing stroke than a valve with tighter clearance.
As part of EPRIs PPM, the required thrust prediction methodology was developed for
the Westinghouse flexible wedge gate valves [2.15]. Apart from the complexity of the
connection between the stem and the disc assembly, the advantages and disadvantages
of the typical flexible wedge gate valve design given in Section 4.2.3 also apply to the
Westinghouse design.
4-15
Figure 4-9
Slab Gate Valve
4-16
The following list identifies some of the advantages and disadvantages of slab-style
gate valves.
Advantages:
Can tolerate line loads better than wedging type gate valves without binding or seat
degradation. Virtually immune to line loads if sufficient clearances are present, due
to the spring-loaded seat design that can absorb large changes in dimensions of the
seat pocket area caused by line loads transmitted to the valve ends by the adjacent
pipe.
Will self-relieve body overpressure to the high pressure side by pushing the spring
energized seats away from the gate. This eliminates the high pressure build-up in
the body cavity associated with most of the other gate valves under temperature
increases.
Disadvantages:
Service conditions limited to 400F (200C) with conventional soft seating materials
made of elastomers and plastics. Some designs utilize higher temperature seat
materials, for example, carbon or graphite for higher temperature applications.
4-17
Thermally induced pressure locking occurs when the temperature of the liquid trapped
in the valve body increases above its initial value. Hydraulically induced pressure
locking occurs when the upstream and downstream pressures drop, leaving the
trapped body pressure at its initial level.
Hydraulically induced pressure locking can also be caused by system pressure
surges/transients that increase the body pressure. Pressure locking is not limited to
liquid flow and can occur in steam applications where valve configuration permits
condensate to collect and enter the bonnet.
Double seating or pressure locking is most common in double-disc gate and flexible
wedge gate valves, where each side of the gate can make contact with its respective
seat, as shown in Figure 4-10. Operating problems associated with this phenomenon
prompted the U.S. NRC to issue Generic Letter 95-07 [4.2], requesting nuclear utilities
to review safety-related, power-operated (including motor-, air-, and hydraulically
operated) gate valves for susceptibility to pressure locking and thermal binding.
Concerns about pressure locking and fluid entrapment in the valve bonnet have been
recognized for over 20 years [4.27].
Figure 4-10
Gate Valve Bonnet Overpressurization
4-18
Recent research identified the major factors that affect required opening thrust under
pressure locking conditions. Some limitations in the previous pressure locking
calculation methodologies developed by Commonwealth Edison [5.53] and Entergy
Operations [5.54] have been addressed in a later study [5.30]. It should be noted that a
calculation methodology to predict required opening thrust under pressure locking
conditions is needed to solve pressure locking problems when physical valve
modifications cannot be performed due to operational or time constraints. The main
factors that affect the required opening thrust under pressure locking conditions are
summarized as follows [5.30]:
Disc Flexibility: Disc flexibility is one of the major factors responsible for increased
thrust requirements under pressure locking conditions. In double-disc designs (such as
split wedge and parallel-expanding disc designs), the trapped bonnet pressure acts on
the entire upstream and downstream disc areas and results in increased seat contact
force and friction. In flexible wedge disc designs, the trapped bonnet pressure acts on
each disc less the disc hub area and results in pressure, bending, and shear deflections
that are resisted by the body seats.
Valve Body Flexibility: Valve body flexibility is another major factor that contributes to
pressure locking, especially for low pressure class valves. For a solid wedge gate valve
where the disc is relatively rigid, body flexibility is the main factor that causes the seat
load changes under varying pressure conditions.
Strain Energy in Stem and Valve Topworks: A self-locking stem and gear train can store a
significant amount of elastic strain energy in the stem and valve topworks during
wedging. Spring-loaded actuators (such as Limitorque models SB and SBD) can store
even more strain energy due to their higher flexibility. The stored strain energy can
drive the disc deeper into the seat when the valve body expands under pressure. A
subsequent pressure drop will cause disc pinching and an increase in unwedging
thrust.
Sequence of Pressure Changes: The actual sequence of pressure changes (including short
duration pressure surges) that occur in the bonnet, upstream pipes, or downstream
pipes when the valve is closed can result in hydraulically induced pressure locking,
which affects the opening thrust (see Reference 5.30).
Thermally Induced Pressure Locking: Idaho National Engineering and Environmental
Laboratory (INEEL) performed pressure locking tests to investigate the effect of
temperature on bonnet pressure and opening thrust [5.52]. INEEL found pressure to
increase rapidly with temperature in a water-solid bonnet. The tests show that
pressurization of the bonnet might not occur if seat leakage is high. However, such
leakage is not reliable in preventing pressurization. These tests also showed that the
opening thrust increases linearly with bonnet pressure.
4-19
Bonnet Entrapped Air: The INEEL testing mentioned above showed that pressurization
curves of 0.5, 1.0, and 2.0% of entrapped air by volume are similar to those with no
entrapped air, except that initial pressurization begins at higher temperatures.
Furthermore, the temperature at which initial pressurization begins increases with the
increase of percentage entrapped air (up to 2%). Subsequent pressurization following
depressurization occurs immediately, as in the case of tests with no entrapped air. The
fact that the presence of an air pocket delays first pressurization but not subsequent
pressurization suggests that the air pocket is either collapsed or forced into solution by
the first pressurization cycle.
Packing Leakage: Packing leakage can prevent pressure locking from occurring.
However, as the bonnet pressure increases, the packing pressure increases and sealing
capability tends to improve. Furthermore, an increase in bonnet pressure and packing
contact pressure will likely increase the packing force, which will further increase the
opening thrust.
Even though a lack of bubble-tight seating would reduce the amount of pressure
generated in the body, there are cases of catastrophic failure of the valve body or
bonnet due to pressure locking. Provisions must be made to eliminate the possibility of
this excessive pressure build-up in the body cavity to avoid structural damage to the
pressure boundary.
When a relief valve is used to prevent overpressure in the body cavity, the actual
pressure in the body may still be higher than in the upstream or downstream piping.
This condition should be considered when sizing actuators. The differential pressure
across each seat must be considered to arrive at the total frictional resistance.
The required operating thrust/torque can also increase under another scenario that
involves thermally induced pressurization in the piping between two valves with tight
seats [4.30]. The heating of water-filled piping between two closed block or isolation
valves can increase both the trapped pressure between the two valves and the required
opening thrust/torque for both valves. This phenomenon can occur inside or outside
the containment and is not limited to gate valves. In some applications, the installation
of a pressure relief valve in the piping between the two valves may be required to
prevent fluid pressurization.
4-20
Install external bypasses to connect the body cavity to the upstream or downstream
pipe or nozzle. These bypasses often incorporate manually operated valves that can
be used during valve or system testing.
Incorporate external bypass in the body to communicate the body cavity to the
upstream or downstream conduit.
Install a non-functioning upstream seat (for example, with a notch across the face).
Install a relief valve to vent excessive pressure from the body cavity.
Install an internal relief valve in the upstream disc to limit the amount of differential
pressure between the body and the upstream side.
The method selected will depend on the desired end result and on the particular
function of the valve. External or internal bypasses on the body make the valve body
unidirectional and, when connected to the downstream side, require that the valve be
capable of achieving upstream seating. Modifying the upstream disc makes the gate
unidirectional, and special attention needs to be given when initially installing the
valve and when reassembling after maintenance. Relief valves installed in the upstream
disc may corrode, leak, or get stuck open or closed with line debris, thus rendering
them ineffective. Block valves that isolate two fluid media are better served by using
administrative controls to energize power-operated relief valves to vent the pressure in
the body before actuation begins.
The coefficient of thermal expansion of the gate material (gate) is different from the
coefficient of thermal expansion of the valve body material (body). The opening
thrust tends to increase when:
The valve temperature during opening is lower than the valve temperature
during closing and gate < body.
The valve temperature during opening is higher than the valve temperature
during closing and gate > body.
Under either of these conditions, the change in temperature tends to increase the
disc-to-seat interference and opening thrust.
The average temperature of the gate is less than the average temperature of the
body. As the temperature of the gate increases after closing, the gate expands
causing additional gate-to-seat interference, which increases the opening thrust.
The stem temperature during closing is less than the stem temperature after closing.
As the stem temperature increases, the stem compressive force increases, and the
disc is forced deeper into the seat.
When hot fluid enters a cold valve, it immediately surrounds the valve trim. The trim
expands quickly, causing differential thermal expansion between the trim and body
due to the relatively lower mass of some of the trim components. For moving parts, this
expansion results in reduced working clearances causing accelerated wear, high
actuation forces, or binding and galling. For interference fit parts, such as seats and
bushings or guides, thermal cycling can cause loosening. These parts must be screwed,
welded, or brazed in place in applications where high thermal gradients and cycling
are present.
4-22
For existing valves, Attachment 2 of the NRC Generic Letter 95-07 [4.2] provides
potential resolutions for gate valves susceptible to thermal binding which include:
For new valves, the valve operating conditions should be considered in the material
selection of valve components and in disc shape design. Detailed finite element
analyses may be performed to ensure that thermal binding will not occur under any
plant operating conditions. Alternatively, parallel-disc gate valves may be used in
applications where thermal binding is a concern.
4.3
Installation Practices
General valve installation practices are discussed in Section 19. The ideal orientation for
any valve is to have the stem (or bonnet) vertically up in a horizontal run of piping to
obtain optimal wear characteristics and operability. This orientation cannot always be
accommodated when considering overall plant design and arrangements. There are
also precautions that should be taken with certain valves relative to proximity of other
equipment or pipe fittings. Valves should always be installed in an orientation in which
they are seismically qualified, when seismic qualification is required.
Regardless of the type of gate valve used, with the stem in other than the vertical
upright orientation, uneven, unpredictable wear can occur on guides, guiding surfaces,
stems, T-slots, and seats, and packing life can be shortened. In addition, testing,
disassembly, and maintenance become more difficult.
If the stem (and thereby the bonnet) is oriented at an angle below the horizontal, the
relatively large volume of the bonnet acts as an unflushable accumulator and traps any
insoluble material passing through the valve. The bonnet can also act as a cold trap
(that is, it can precipitate out material that is held in solution by the heat of the fluid).
This precipitate material can shorten valve life, packing life, and can hamper
disassembly. If the material is radioactive, the disassembly procedure becomes even
more difficult.
4-23
Valves that require manual operation or frequent maintenance and repair should be
readily accessible. Valves and actuators should have sufficient clearance for repair or
removal and reinstallation. Large and heavy valve/actuator assemblies may require
additional supports. Power supply equipment (such as power cables or air lines)
should be routed in such a way as to not interfere with maintenance activities.
Valve/actuator assemblies should be protected from corrosive drippings from other
equipment and should not be subjected to extreme temperatures and/or radiation
beyond design limits.
4.4
Because of the potential for seat erosion and/or damage to the gate, gate valves should
not be used for long term throttling unless specifically designed for that service.
Double-disc valves should never be used for throttling.
Never use anything other than the handwheel to operate a manual valve. For example,
the use of a cheater bar to open or close a valve may damage the operator or the valve
internals. On a motor-operated valve where the handwheel is used, care should be
taken to limit the amount of handwheel torque or force to avoid damage to the valve or
actuator.
Care must be used when backseating a valve to reduce packing leakage, especially in a
hot valve. If the line is hot, the portion of the stem that is withdrawn from the body will
cool to ambient temperature, causing the stem to shrink and possibly causing damage
to the stem and/or backseat. When backseating to reduce packing leakage, avoid
backseating a valve with motor operation, because damage to the backseat, stem, or
motor might occur. Instead, carefully use the handwheel. (See Section 2.3.8 for cautions
on backseating.)
4.5
Common Problems
In conventional wedge gate valves, fluid force during intermediate disc travel
imposes a moment on the disc that tends to cause disc tipping, which in turn is
responsible for high edge loading and damage to the disc and seat faces as well as
the lower guide surfaces as shown in Figure 4-11. The fluid-induced moment on the
disc for any given flow and P condition is zero in the fully open and fully closed
positions with a maxima at an intermediate disc travel position. The magnitude of
the fluid-induced moment on the disc and the potential for damage increases with
an increase in flow velocity. Under high energy blowdown conditions, damage to
the disc and seat faces and/or the guide surfaces has been observed with many
conventional wedge gate valve designs and parallel disc designs [5.55].
4-24
Figure 4-11
Typical Seat and Guide Damage Locations in Conventional Flexible Wedge Gate
Valves Under High Flow Conditions
Normally open valves with high turbulence flows (such as downstream of pumps,
control valves, orifices, strainers, and elbows) may be subject to high wear rates due
to the turbulence-induced motion between internal components. In solid and
flexible disc valves (with single-piece discs), wear typically occurs at two locations:
(1) stem head and disc T-slot and (2) body and disc guides.
In other gate valves with multiple-piece discs, additional wear can occur between
the disc components. Excessive wear can cause valve failure, including stem
separation from disc and disc sticking at an intermediate position.
Seat leakage is a common problem in gate valves and can be caused by several
factors:
Wire drawings or steam cuttings caused by high flow velocities between the disc
and seat
High pipe loads and moments, especially with low pressure class valves
4-25
Leakage through the bonnet flange is also a frequent problem. Body-to-bonnet joints
utilizing a spiral wound gasket may exhibit leakage if gasket surfaces are not
cleaned properly or have not been properly dressed. Occasionally, the dimensions
of the joints do not provide for proper gasket compression, or the bolts are not
torqued properly.
The increase in the required opening thrust under pressure locking and/or thermal
binding conditions can cause the valve to fail to open. The common modes of failure
to open under pressure locking and/or thermal binding conditions include
insufficient actuator output and failure of the weak link (in the valve or the
actuator).
Stem thrust may become smaller under higher disc friction loads due to increase in
stem factor or stem coefficient of friction. This phenomenon (called rate of loading
effect or load sensitive behavior) was observed during EPRIs testing, NRC-sponsored
testing at INEEL, and valve operations in nuclear plants. These tests show that
conversion of actuator output torque to stem thrust became less efficient at higher
thrust levels. For the same actuator torque switch setting, the stem output thrust
under high P condition can be lower by as much as 25% of its value under static
conditions. The rate of loading effect must be accounted for in evaluating required
stem thrust under load.
Static and fatigue failures in internal valve and actuator components can occur due
to excessive stem thrust values. In particular, during programs to verify MOV
design basis capability, the opening/closing thrust levels for many valves had to be
increased significantly to ensure MOV capability. During in situ testing and control
switch activities, some valves and actuators were inadvertently overloaded beyond
their thrust ratings. Failures include broken stems, stripped stem threads, broken or
severely deformed gate T-slots, and bent or broken guide rails. Such failures can be
prevented by appropriate stress/fatigue analyses of the weak link components.
In some service situations, isolation valves may stay in one position for long periods
of time. If left in the open position for a long time, deposits and particulates can
accumulate in the gate guides and recesses of the valve, preventing full closure and
possibly resulting in damage to the disc or seat if the valve is forced closed.
Threads often bind due to corrosion and foreign matter, especially in gate valves
with inside threads. Outside threads also become corroded and crusted with
4-26
deposits, but the deposits are easily seen and can be removed to make the valve
operable.
The use of gate valves in throttling service is a basic misapplication, and this
practice usually leads to damage of the valve or the valve seats.
Some valve vendors underpredicted thrust and torque requirements for some gate
valves by underestimating friction coefficients, flow effects, and metal-to-metal
interactions.
Weak link failure can be caused by under-predicting the actuator output thrust,
which can be caused by overpredicting stem friction coefficient (stem factor) or
ignoring inertia overshoot.
Many valve problems are caused by improper maintenance and/or repairs. For
example, elastomeric and non-metallic components can be damaged by improper
solvents and cleaners. The use of counterfeit and low-quality, commercial grade
spare parts can also cause valve failures.
4.6
Maintenance Methods
General good maintenance practices are discussed in Section 17. Always follow the
manufacturers maintenance instructions. Valves should be stroked at least once every
six months to ensure proper operation and to detect internal or external leakage such as
in the seat, packing, or bonnet-gasket.
Lapping or grinding of disc and seats are the most common corrective maintenance
actions taken (see Reference 1.1 for detailed discussion). When these operations are
done with a lapping machine or lapping plate, ensure that the original angle of the
sealing surface is maintained.
During disassembly of the valve, match mark the bolted joint or pressure seal pressure
boundary parts to assure proper orientation upon reassembly. Improper orientation of
pressure boundary parts will often result in joint leakage or malfunction due to
misalignment upon return to service.
In body-to-bonnet joints, ensure that gasket surfaces are cleaned properly and properly
dressed and that the bolts are torqued properly.
A procedure for valve assembly should include proper cleaning of the sealing surfaces,
a check of the dimensions and surface finish of joints, and require that bolts be torqued
4-27
4.7
The research activities conducted in response to the U.S. NRC GL 89-10 revealed
several problems with many flexible wedge gate valves from different valve
manufacturers. These problems relate to lack of reliable operation under design basis
conditions including higher than anticipated stem thrust requirements, unpredictable
valve behavior, damage to the valve seats and guides under blowdown/high flow
conditions, failure of some internal components (weak links) under high thrust
conditions, significant degradation of performance when cycled under P and flow,
thermal binding and pressure locking. With good understanding of these problems and
their causes, many valve manufacturers started implementing design changes in order
to minimize and hopefully eliminate these problems. For example, in a joint effort
between General Electric Company and Kalsi Engineering, Inc., an improved flexible
wedge gate valve design was developed [5.55]. The new design (called Sentinel
Valve) incorporates several features to address known problems such as pressure
locking, thermal binding, seat leakage, disc/guide gouging, structural strength
margins, and fatigue life.
4-28
5
GLOBE VALVESISOLATION FUNCTION
5.1
A globe valve can be used full open, full closed, or for throttling within limits of the
disc and seat configuration.
Globe valves are normally metal or hard-seated, but they can be furnished with
resilient disc inserts or seats that are suited for compressed air, compressed gas, or
fluids that contain small particles of foreign material.
Globe valves have fewer operability problems as compared to gate valves and normally
provide excellent seat leak tightness, but they do so at the penalty of a higher pressure
drop. Globe valves also require large actuators.
5.2
Design
Standard pattern (also called T-pattern), which is the most common shape
(Figure 5-1).
Y-pattern (Figure 5-3), in which the stem is inclined at an angle (for example, 45)
with respect to the pipe axis. The Y-pattern body is designed to reduce the flow
resistance of the globe valve. The flow resistance of the angle valve is between that
of the standard globe and Y-pattern.
5-1
Figure 5-1
T-Pattern Globe Valve
Figure 5-2
Angle-Pattern Globe Valve
5-2
Figure 5-3
Y-Pattern Globe Valve
pressure area. Testing has shown that, for common valve designs under incompressible
flow conditions, there are two possible areas that need to be considered: (1) the area
based on disc seating diameter (seat-based valves), and (2) the area based on disc guide
diameter (guide-based valves).
The required thrust prediction methodology for globe valves is given in Reference 2.3
along with a detailed criterion for determining whether a valve is seat-based or guidebased. Figures 5-1, 5-2, and 5-3 show typical seat-based designs. A guide-based design
is shown in Figure 5-4.
Figure 5-4
Velan 2" (5.1 cm), 1500# Globe Valve (Guide-Based)
Model: Figure No. 137132
5-4
5.3
Installation Practices
Installation practices noted for gate valves in Section 4.3 apply to globe valves as well.
Additionally, installation of globe valves with the stems vertically upright is even more
critical than for gate valves, as proper guidance of the disc into the seat is needed to
achieve tight closure. If the stem and valve body are other than vertical, the disc tends
to cock or go off center, and the disc seating surface, when going into the seat, will have
little tendency to compensate to effect the correct seating angle. Y-pattern globe valves
are normally provided with improved guidance to permit valve operation with the
stem at an angle to vertical.
Flow Direction
Globe valves are normally installed so that flow is from under the seat. In some
applications, however, it is more important that stem packing be isolated from pressure
or vacuum from the downstream side when the valve is closed. For example, a valve
used as a containment isolation valve in a line with normal flow into the containment,
but with containment accident flow out of the containment, should be installed with
normal flow over the seat. In addition, valves connected directly to a vacuum
condenser should be installed so that the packing is not exposed to vacuum when the
valve is shut.
5.4
The operation practices and precautions for gate valves indicated in Section 4.4 also
apply to globe valves.
Globe valves may be used for rough throttling. However, if the valve was not specified
for throttling, cavitation, chattering, and vibration may occur in the throttled position.
5.5
Common Problems
Most problems noted for gate valves in Section 4.6 also apply to globe valves.
Globe valves improperly applied for throttling will cause damage to the valve
and/or adjacent piping (for example, erosion, cavitation damage, flow-induced
vibration, and high wear).
Thrust requirements for some globe valves may be greater than predicted by valve
vendors. The required thrust for globe valves can be alternatively calculated using
EPRIs PPM [2.1, 2.3].
5-5
Some globe valve designs may experience stem guide or plug damage due to high
side loads caused by high midstroke differential pressures. This most often occurs
under high flow rates such as during blowdown events.
Similar to gate valves, globe valves operated by motor actuators are susceptible to
load-sensitive behavior (see Section 4.5).
Metal diaphragm sealed globe valves (Figure 2-25) do not have their stem connected
directly to their disc and rely on a spring to open the valve when the stem is
withdrawn. Therefore, these valves should not be used as throttle/control valves,
nor should they be used in dirty service.
5.6
Maintenance Methods
5-6
6
GLOBE VALVESMODULATING/THROTTLING
FUNCTION
6.1
6.1.1 General
Globe valves are the most extensively used valves for modulating service, due in part
to the adaptability of the basic design to accommodate difficult conditions such as high
pressure, temperature, and differential pressure applications. Compared to ball and
butterfly valves, globe valves present a higher flow resistance. The flow capacity of
globe valves is about one-third that of low-resistance valves such as ball and butterfly.
However, as flow capacity decreases, resistance to cavitation and noise increases.
This section presents a general discussion of globe valve designs used in modulating
and throttling applications along with their performance characteristics and limitations.
As will be shown, most control valve problems are caused by improper selection,
sizing, and/or installation. Leading control valve manufacturers estimate that most
existing control valve application problems can be resolved and could have been
avoided if accurate application data and operating conditions were established and
provided before selecting and sizing the valve.
Technical papers and standards have been published by control valve manufacturers,
individuals, and organizations such as the Instrument Society of America (ISA) to aid
the user in the sizing, specification, selection, and testing of control valves. ISA-S75.01
[6.37] provides flow equations for sizing control valves. Derivation of the various
factors that appear in the sizing formulas, as well as representative values of valve
capacity factors, are included in this standard. Alternatively, these factors can be
measured using the control valve test procedures given in ISA-S75.02 [6.38].
Additional information can be found in other EPRI documents (see Sections 22.1 and
22.2). The following information highlights areas that cause recurrent control valve
sizing problems.
6-1
Figure 6-1
Pressure Drop Through a Control Valve at Minimum, Design, and Maximum
System Flows
The control valve represents a variable flow resistance in the hydraulic system. A
control valve will change the total flow resistance of the entire hydraulic system until
the total system pressure drop is equal to the system head imparted by the pressure
source (for example, centrifugal pump) at a given flow rate.
6-2
Moore [5.57, 5.1] has developed guidelines for the allocation of pressure drop across the
control valve, acknowledging that the choice of pressure drop is a complex problem
which cannot be defined by a set of numerical rules. The guidelines should thus be
used more as benchmarks than design criteria. They are as follows:
1. In a pumped circuit, the pressure drop allocated to the control valve should be
equal to 33% of the dynamic loss in the system at the rated flow or 15 psi, whichever
is greater.
2. The pressure drop allocated to a control valve in the suction or discharge line of a
centrifugal compressor should be 5% of the suction absolute pressure or 50% of the
dynamic losses of the system, whichever is greater.
3. In a system where static pressure moves liquid from one pressure vessel to another,
the pressure drop allocated to the valve should be 10% of the lower terminal vessel
pressure, or 50% of the system dynamic losses, whichever is greater.
4. Valves in steam lines to turbines, reboilers, and process vessels should be allocated
10% of the design absolute pressure for the steam system or 5 psi, whichever is
greater.
Some confusion exists in differentiating between assigned P and actual P. There is a
tendency to assume that because a P is assigned to a valve, the valve creates that P;
however, this is not the case. The assigned pressure drop is the pressure that is added
to the system resistance to ensure that sufficient P is available to permit the control
valve to perform its function. This assigned P is a design number, necessary in
determining requirements for motive force, such as the pump in a liquid handling
system. Thus, assigned P has no significance under actual operating conditions.
Under actual operating conditions, the control valve is throttled to dissipate energy
developed in excess of system equipment losses (actual system P).
Most often, the size of the control valve is too large for the application, which results in
control problems including instability (Section 6.2.11). Furthermore, oversized control
valves may have to be throttled to small openings, which can result in cavitation,
flashing, and/or choking.
Control valves are, by design, capable of controlling over a wide range of conditions.
However, a sizing error usually results in higher energy consumption. Control
requirements, both minimum and maximum, are usually met.
Under some circumstances, however, the following factors may result in an installed or
actual P so high that control under minimum flow requirements may become
impossible:
6-3
Conservative (high) surface roughness used for determining friction losses in pipe.
Example: The use of high friction factors in the formula for determining line loss
in a piping system will indicate a friction head loss of as high as twice the loss
through clean new pipe. Losses through pipe and fitting, when the installation is
new, could be only half of that anticipated after a period of service (that is, actual
piping causes lower pressure loss at a given flow).
Result: Control valve pressure drop is higher than expected, and flow control at
low flow rates becomes difficult.
The design margin imposed on system head to compensate for anticipated piping or
equipment additions that never materialize will increase actual P across the control
valve.
Addition of safety factors to flow requirements will increase actual P to the system.
In summary, the control valve does not dictate the P in a fluid handling system, but it
provides a variable restriction to dissipate the difference between the system head (by a
pump or upstream tank) and the system head loss (other than the control valve) at a
given flow rate. Thus, for a given flow rate, the pressure drop across the control valve
should satisfy the following equation:
Pcontrol valve = Psource - Psystem
If the actual pressure drop across the control valve (at a given disc opening) is smaller
than the above value, the valve is oversized.
If the P assigned for the control valve during system design is less than the P
available in the actual installation, the valve could be oversized. Control valve
oversizing, which results in oversizing the pressure source (for example, pump), can
result in a considerable waste of energy over the life of the system.
In the illustration shown in Figure 6-2, there are two sets of conditions given: calculated
and actual. The calculated inlet and outlet pressures are the result of applying line
losses based on old pipe. Actual inlet and outlet pressures are based on conditions that
6-4
could exist in a new installation. That is, they exclude the increase in the friction losses
associated with old pipe, resulting in a higher P across the control valve.
CALCULATED
FLOW
ACTUAL
Max
Nor
Min
Pi psia
620
640
672
Pf psia
Lto in ft
Lfrom in ft
387
200
132
P1 psia
600
625
671
672
679
738
748
P2 psia
400
397
388
394
392
387
15
200
228
283
278
287
351
733
3000
350
0.89
200
2500
600
3000
2500
600
156
34
170
137
30
200
100
0.99
8
P psid
Q gpm
T F
Specific Gravity
Cv
Max
Nor
Min
683
687
739
Start-Up
748
15
111
70
Figure 6-2
Control Valve Sizing Example
6-5
The normal and maximum flow rates remain unchanged; however, minimum flow rate
for the actual condition is lowered to 200 gpm. This is not unusual, particularly in the
early stages of a project when production is low or under test or startup conditions.
Finally, should temperatures differ from those anticipated, serious complications could
result. In this case, cavitation would occur at the startup/test condition. This problem
may not be worth designing for if the conditions that result in cavitation are short term;
however, cavitation should be considered in the application. Valve styles other than
globe could and should be considered for this application, but for purposes of this
illustration, the discussion is limited to globe style valves.
The valve flow coefficient (Cv in gpm/ psi ) is defined as the flow rate in U.S. gallons
per minute of 60F water that flows through a valve with a pressure drop of one psi.
The valve flow coefficient for each flow rate is calculated as follows (see C v results in
the table of Figure 6-2):
Cv
= Q
(62.4 )
where
Q
Referring to the percent travel versus Cv curves, shown in Figure 6-2, for typical 4- and
6-inch valves, the Cv of 200 required for the maximum flow rate of 3000 gpm exceeds
the capacity of the 4-inch valve, indicating that the 6-inch valve will be required. This
would seem to satisfy the capacity requirements in that the 6-inch valve will be
throttled from between approximately 8% travel to 50% travel under the calculated
conditions.
If, however, the installed valve is to operate under the conditions marked startup, a
Cv requirement of 8 falls somewhat below the point of control in the 6-inch valve.
For the 6-inch valve, the Cv at 10% travel is 40, and the valve will have a Cv of 8 at a
travel of somewhere between 10 and 0%. This point is difficult to predict and will not
be repeatable below approximately 2% travel. Refer to Section 6.2.10 for a detailed
discussion on rangeability.
6-6
6-7
Feedwater recirculation
Examples of control valve sizing for these applications are shown in Section 24.
6.2
Design
6.2.1 General
In order to meet the ever changing requirements of fluid flow control, several styles of
globe valves have been developed. This section describes the available styles.
6-8
Figure 6-3
Single-Port Control Valve
6-9
Since the high pressure fluid acts across the entire area of the disc defined by the seat
port diameter, the resultant unbalanced force on the disc can be quite large and is the
dominant component in sizing the actuator. Because of relatively high actuator thrust
requirements, single-port globe valves are most commonly used in 3-inch (75-mm) and
smaller valves, even though they may also be used in 4-inch to 8-inch (100-mm to 200mm) sizes with high thrust actuators.
The flow direction in globe valves can be either over the plug or under the plug. These
different flow directions produce different plug force and actuating force requirements.
The plug force versus travel curve, as the plug is moved away from the fully closed
position, plays an important role in determining the stability of valve operation at any
given position. A flow over the plug control valve configuration exhibits the highest
degree of control instability when operating near the fully closed position, due to a
relatively steep negative plug force versus travel gradient in this type of construction.
See Section 6.2.11 for a discussion on valve stability.
6-10
Figure 6-4
Double-Seated Globe Valve
It should be pointed out that the double-seated valves use slightly different diameters
for the top and bottom seat to allow assembly and removal of the smaller disc through
the larger seat. This difference in seat areas contributes to some unbalanced force on the
disc. Additionally, complete cancellation of forces on the disc when it is off the seat is
not possible because of the difference in fluid dynamic forces for flow under the disc
versus flow over the disc in the two ports. The total imbalance forces can reach as high
as 40% of the equivalent single-port valve value in some designs.
6-11
6-12
Figure 6-5
Balanced Disc Cage Style Valve
The standard direction of flow is through the cage openings and down through the seat
ring. Standard shutoff performance meets ANSI/FCI-70-2 Class III requirements, and
Class IV or better shutoff is offered in some designs (see Table 3-1). Due to reduced disc
forces and smaller actuator requirements, these valves are used in sizes up to 16 inches
(400 mm) and pressure ratings up to ANSI Class 2500.
Figure 6-6
Y-Style Body Valve
Figure 6-7
Three-Way Valve for Flow Diverting Service Unbalanced Disc
6-14
Figure 6-8
Three-Way Valve, Balanced Plug
6-15
Another type of disc and seat design, which does not utilize a cage-type construction
but is also suitable for high pressure drop service, is shown in Figures 6-10 and 6-11.
This design consists of a series of expansion chambers along the length of the disc that
act as a labyrinth passage from the high pressure side to the low pressure side.
Figure 6-9
Low Noise, Anti-Cavitation Trim
6-16
Figure 6-10
High Pressure Drop Multiple Step Plug and Cage
6-17
Figure 6-11
High Pressure Drop Control Valve, Labyrinth Design
6-18
Figure 6-12
Inherent Flow Curves for Various Valve Plugs with Constant Delta P Across the
Valve
Linear. An inherently linear characteristic produces equal changes in flow per unit
of valve stroke, regardless of plug position. Linear plugs are used on those systems
where the valve pressure drop is a major portion of the total system drop.
Quick Open. Quick open plugs are used for on-off applications designed to produce
maximum flow quickly.
When placed into service in actual systems and the pump characteristics and piping
loss are accounted for, equal percentage, linear, and quick open inherent flow
characteristics change significantly to what is referred to as installed characteristics. The
deviation of the installed characteristics from the inherent characteristics depends on
the system flow resistance and system head source. In systems with very small flow
resistance and constant head (such as between constant pressure upstream and
downstream reservoirs), the difference between installed characteristics and inherent
characteristics is small.
A typical example is containment isolation valves where the containment represents an
infinite reservoir. In systems with high flow resistance and variable head source (such
as a centrifugal pump), the difference between installed characteristics and inherent
characteristics can be very significant (see Figure 6-13 for a typical example). In Figure
6-13, the inherent equal percentage trim exhibits a nearly linear installed characteristic,
while the inherent linear trim appears to be almost quick opening when installed.
Figure 6-13 contrasts inherent characteristics with installed characteristics. The curves
in Figure 6-13 show, from the standpoint of proportional band, that in the low flow
operating region, for a given flow change, a very small change in lift is required for the
linear trim, compared with the equal percentage trim. Thus, the flow rate is sensitive to
valve opening in the low flow rate region.
Figure 6-13
Comparison of Installed Characteristics versus Inherent Characteristics
6-20
Operating in the higher flow region, the opposite is true; that is, a larger change in lift
is required for the same change in flow for the equal percent trim, while the linear trim
requires an even higher change in lift. Consequently, overall sensitivity will be
decreased for both trims. The equal percentage trim would exhibit an almost constant
sensitivity over the entire operating range, thus requiring only one proportional band
setting in the controller. Because the linear trim does exhibit a nonlinear change in flow,
as a function of lift, it would require several proportional bands.
In deciding whether an inherent linear characteristic or an inherent equal percentage
characteristic should be chosen, the general rule is that if the valve is the primary
pressure loss mechanism and the inlet pressure is constant, the linear characteristic
should be chosen. However, such a system (having very little system pressure loss
and/or constant inlet pressure) is not typical. On the other hand, if pipe and fitting
resistance are major factors in the system, equal percentage would be the appropriate
choice (which is the case in the majority of applications).
In actual practice, control instruments can be adjusted to handle normally anticipated
flow changes without having to be readjusted. It is difficult to determine from control
performance whether the valve has linear or equal percentage trim, unless manual
control is required, then there will be a tremendous difference.
To illustrate the above flow characteristics, assume that a centrifugal pump supplies
water to a system in which a control valve is used to maintain the downstream pressure
at 80 psig. The pump characteristics and system flow schematic for this set of
conditions are given in Figures 6-14 and 6-15, respectively. Assuming a maximum flow
rate of 200 gpm with a pump discharge pressure (P1) of 100 psig and that pipe friction
losses are negligible, the flow coefficient (Cv) can be determined to be 45, using the ISA
liquid sizing formula (see Section 24). A 2-inch valve would provide this flow capacity.
6-21
Figure 6-14
Typical Pump Characteristics
Figure 6-15
Flow Schematic without Piping Losses
To determine the plug valve characteristics that should be specified, analyze the
installed flow characteristic of equal percentage and linear trim for this 2-inch valve.
Based on the typical pump characteristic in Figure 6-14, Table 6-1 shows several values
of flow, the required valve Cv and the percent of maximum Cv that the valve must have
to control flow.
6-22
The inherent percentage of total valve lift for equal percentage and linear plugs can be
determined using Figure 6-12. The installed characteristic, plotted as valve lift versus
flow in gpm, is shown in Figure 6-16. A study of Figure 6-16 shows that either installed
characteristic would provide good control for this situation.
Table 6-1
Valve Cv and Pressure as a Function of Flow Rate without Line Losses
Q Flow Rate
(gpm)
P1 Pump Discharge
Pressure (psig)
P Across
Valve (psid)
Cv
Required
Percent of Required
Maximum Valve Cv
200
100
20
45*
100
150
125
45
22
49
100
150
70
12
27
50
170
90
5.2
11
* Cv = 45 is assumed to be maximum Cv
6-23
Figure 6-16
Installed Characteristics without Piping Losses
In the previous idealized example, the downstream pressure was held constant and
pressure drop variations were due to the pump only. A more realistic installation exists
where the delivered pressure must be held constant after passing through the valve
with some line restriction (R) in series with the valve. This installation is shown
schematically in Figure 6-17.
6-24
Figure 6-17
Flow Schematic with Piping Losses
To find the installed characteristic of equal percentage and linear trim in a suitably
sized valve, a pressure drop distribution must be determined. The pressure drop across
the control valve, Pv, is given by:
v = 1 R 80
where
P1
PR
CR
CR
Let
CR
50 gpm
psi
psi
At maximum pump flow rate of 200 gpm, the control valve pressure drop is given by:
2
200
v = 100
80
50
= 4.0 psi
6-25
200
4
gpm
= 100
psi
The control valve can then be sized for the maximum required Cv of 100 gpm/ psi .
A 3-inch control valve would be chosen to handle these maximum flow conditions.
Since the pressure drop across the restriction will vary with flow in accordance with the
square root law Q = C R , the available pressure drop across the valve at various
flowing quantities can be determined, keeping in mind the pump characteristics. This is
shown in Table 6-2. As before, the percent of maximum C v that the valve must have to
control flow is calculated, and the installed characteristic is plotted, as shown in Figure
6-18.
Table 6-2
Valve Cv and Pressure as a Function of Flow Rate with Line Losses
Percent of
Required
Maximum
Valve Cv
Q
Flow Rate
(gpm)
P1
Pump
Discharge
Pressure
(psig)
PR
Across
Restriction
(psid)
Pv
Across Valve
(psid)
200
100
16
100*
100
150
125
36
25
25
100
150
66
12
12
50
170
89
6-26
Control Valve
Required Cv
gpm/ psi
gpm/ psi
Figure 6-18
Installed Characteristics with Piping Losses
6.2.10 Rangeability
The Instrument Society of America (ISA), in Standard S75.05, Control Valve
Terminology (6.39), defines inherent rangeability as the ratio of the largest flow
coefficient (Cv) to the smallest flow coefficient (Cv) within which the deviation from the
specified inherent flow characteristic does not exceed the stated limits.
Permissible deviation values between actual and manufacturer-specified inherent flow
characteristics for globe and butterfly valve specimens are published in ISA S85.11,
Inherent Flow Characteristics and Rangeability of Control Valves. These deviations
(or acceptable limits) vary from approximately 10% at 100% Cv to 18% at 10% Cv.
6-27
A quick opening plug has a fairly linear characteristic over the first 80% of its flow
range (Figure 6-12), and the linear characteristic is maintained down to a point close to
its seat. Rangeability is generally in excess of 100 to 1, with higher values observed on
the larger sizes with plugs having low seating angles.
Linear and equal percentage plugs follow their intended characteristic down to a plug
position, at which the flow is a function of the proximity of the seating surfaces rather
than of the plug contour. This point generally occurs at around 5% flow in the smaller
plugs and drops to about 1% in the larger sizes, giving rangeabilities from 20:1 to as
high as 100:1.
This inherent rangeability should not be confused with the range of loads over which it
will operate satisfactorily in service. If, for example, a linear plug is selected with a
rangeability of 100:1 for a liquid pressure control application, a narrow range of loads
would be available over which optimum control could be obtained within the
capability of the controller. An equal percentage plug, even with a lower rangeability
than the quick opening plug, would perform well over a wide range of loads. On the
other hand, a liquid level loop might operate satisfactorily over a wider range of loads
with a quick opening plug than a high rangeability equal percentage plug. Only where
the valve characteristic is well matched to the application will the valve rangeability
correspond to the range of loads (with constant relative stability) observed in service.
6.2.11 Stability
Valve stability must be given consideration while sizing a control valve actuator. When
stability criteria for actuator sizing (discussed in Appendix D1 in Reference 1.2) are not
fulfilled, certain valve/actuator combinations can lead to unstable operation. Unstable
operation is characterized by oscillations of the stem, sometimes at a very high
frequency, around the desired travel position. In addition to causing poor control (or
loss of control), rapid stem cycling can cause quick degradation of the stem packing,
actuator rubber diaphragm failure due to fatigue, or damage to the plug and seat areas.
Valve stability is achieved when the actuator rate of change of forces exceeds the rate of
change of forces acting on the valve plug. Figure 6-19 shows a typical control valve
force balance diagram.
6-28
Figure 6-19
Force Balance Diagram for Control Valves
Criteria for stability have been well established for different types of valve internal
designs and actuators. In general, increasing the actuator spring stiffness to well above
the force gradients, due to fluid forces across the plug, eliminates instability problems.
See Appendix D1 in Reference 1.2 for more detailed quantitative criteria specific to the
valve and actuator combination of interest.
6-29
6.3
Installation Practices
Valve sizing coefficients are usually determined by the manufacturer from tests with
the valve mounted in a straight run of pipe that is the same diameter as the valve body.
If the installed process piping configurations are different from the standard test
manifold, the valve capacity is changed.
Control valves are often smaller than the line size in which they are installed, and care
should be exercised to ensure proper alignment in the pipeline to avoid overstressing
the valve.
Care should be used when laying out piping adjacent to control valves to avoid
interference between the control valve operator and the piping.
The valve should be installed with the stem vertical and up. With the stem in other than
the vertical orientation, uneven and unpredictable wear can occur on the guides,
guiding surfaces, and seats. The stem packing life will also be shortened. In addition,
maintenance becomes more difficult with the stem shifted from the vertical.
Long air lines leading to the air-operated actuator may result in poor control and
response.
Changes from the installation design should not be made without first ascertaining that
the change will not have an adverse impact on valve operation or seismic integrity,
where applicable.
6.4
Unlike most isolation valve operations, control valve operation is automatic and
requires no special instructions to the operator. Theoretically, all of the operating
parameters are addressed at the outset and are incorporated into the selection and
specification so that the final installation will function in a satisfactory manner with no
additional operator intervention required.
Unfortunately, there are occasions when, due to improper or incomplete specification,
control valves cannot meet the actual system requirements and must be manually
operated until such time as replacement parts or a replacement valve can be
substituted. Under these conditions, concerns should be for proper system operation,
with the understanding that there is no automatic compensation for process deviations
in the control process parameter.
6-30
6.5
Common Problems
Common problems encountered with improperly sized and/or specified control valves
include:
Wire drawing caused by operating the plug close to the seat over extended periods.
This most often is the result of oversized trim in the valve.
Malfunctioning positioners.
Instability, which may result in poor control, high packing wear, and actuator
component wear. See Appendix D1 in Reference 1.2 for a detailed discussion of
valve stability.
All of the above problems can be the result of operation of the valve beyond the
conditions for which it was designed. This may be due to changes made to the system,
incomplete specification data, poor communication between designers and suppliers,
or a combination of the above.
6.6
Maintenance Methods
For a general discussion of good maintenance practices, see Sections 17, 18, and 19.
Most control valve manufacturers have highly skilled service engineers available for
maintenance and repair of their valves and actuators. Many recurring valve problems
are the result of improper maintenance and/or the use of substandard or counterfeit
parts. It is recommended that all service and maintenance work be performed by
qualified personnel, using authorized parts furnished by the control valve
manufacturer. Training programs are available through the manufacturer to train
personnel in the operation, maintenance, and service of the equipment. When ordering
replacement parts, always include the model and serial number of the valve being
repaired. Periodic inspections should be made to ensure that biasing springs have not
vibrated out of adjustment.
6-31
7
BUTTERFLY VALVESISOLATION FUNCTION
7.1
Butterfly valves are high pressure recovery valves (also called high capacity and high
area ratio valves) with relatively small overall pressure drop in the fully open position
as compared to globe valves. Butterfly valves are used for both isolation and throttling
service. This section provides general discussions of butterfly valves in typical nuclear
power plant applications. Special considerations related to butterfly valves in
modulating/throttling service are given in the next section. The Butterfly MOV
Application Guide [1.6] provides detailed discussions for the design, installation,
operation, and torque requirements for butterfly valves in nuclear power plants.
Reference 1.6 should be consulted for additional details not covered here.
Figure 7-1 shows an overall assembly of a motor-operated butterfly valve in which the
following principal components are identified:
Butterfly valve
Motor
Switch compartment
7-1
Figure 7-1
Typical Motor-Operated Butterfly Valve
Butterfly valves offer several advantages over other types of valves, especially in
applications where soft seats are acceptable. Their advantages include:
Reduced operating energy cost because of high flow capacity (Cv) and low pressure
drop in the full open position
7-2
Reduced maintenance cost even when handling dirty fluids and fluids with
suspended solids (for example, in service water applications)
Flow characteristics that make butterfly valves well suited for throttling service
7.2
Design
7.2.1 General
Butterfly valves are typically installed as line size valves where valves and inlet/outlet
pipes have the same nominal diameters. Alternatively, butterfly valves may be
installed in larger diameter pipes using inlet reducers and outlet increasers in order to
enhance the low-flow/throttling characteristics and to reduce the cost of the MOV and
its installation.
The overall population of butterfly valves in a U.S. nuclear power plant are divided
into two broad categories:
AWWA Design Butterfly Valves. A large population of ASME Class 2 and 3 nuclear
safety-related as well as nonsafety-related valves in U.S. nuclear power plants are
limited to maximum shutoff differential pressure of 200 psi or less (1,379 kPa), a
maximum normal service temperature of 300F (150C), and a one-time faulted
temperature capability of 350F (175C). Many valves for these service conditions are
basically designed in accordance with requirements of ANSI/AWWA Standard for
Rubber-Seated Butterfly Valves [6.36]. Henry Pratt, Fisher, Allis-Chalmers, and BIF are the
major suppliers of this type of design.
High Performance Butterfly Valves. In the 1960s, a new class of butterfly valves
emerged with a higher pressure/temperature envelope and shutoff capability
conforming to the full pressure ratings of ANSI B16.34 Class 150, 300, and 600 [6.24].
This class of valves is now commonly referred to as high performance butterfly
valves. Posi-Seal, Rockwell (McCanna), and Jamesbury are the major suppliers of high
performance butterfly valves to U.S. nuclear power plants.1
Butterfly valve bodies are generally very stiff in comparison to the adjacent piping,
making them virtually immune to line loads (axial, bending moment, or torsion). They
are also insensitive to thermal gradients through the body due to their symmetric axis
and stiff construction.
The torque required to fully seat the disc can be minimized by using pressureenergized seats (see Section 7.2.9). Butterfly valves have no body cavities that can trap
solids or contaminants. Servicing any of the major components of the valve requires
removal of the valve from the line. Because the shaft rotates without axial motion, the
butterfly valve shaft cannot be backseated. However, some designs can be furnished
It should be noted that some manufacturers provide both American Water Works Association
(AWWA) and high performance designs.
7-4
with secondary shaft seals inboard of the shaft bearing to protect the bearing from
contamination.
The most common butterfly valve disc shapes used in U.S. nuclear power plants are
shown in Figure 7-2, and can be divided into two basic disc designs: conventional
symmetric (concentric) disc and nonsymmetric disc designs (Figure 7-3).
Figure 7-2
Most Common Butterfly Valve Disc Shapes Used in Nuclear Power Plants
7-5
Figure 7-3
Typical Variations in Butterfly Disc Designs
7-6
Requires smaller dynamic torque in the closing direction than in the opening
direction because the hydrodynamic torque is typically self-closing [1.6]. This is
particularly beneficial in applications where the isolation valve is required to close.
Disadvantage:
Sliding action under interference between the seat and disc causes higher seat wear
than in nonsymmetric disc valves.
7-7
Figure 7-4
Typical Symmetric Disc Design with Elastomer Lined Body
7-8
7-9
Figure 7-5
Cross-Section of a Typical Nonsymmetric Butterfly Valve
7-10
Figure 7-6
Valve Disc Flow Orientation Terminology
7-11
Figure 7-7
Triple Offset Butterfly Valve
7-12
Figure 7-8
Fishtail Disc
Figure 7-9
Special Disc Design for Noise and Cavitation Reduction
As shown in Figure 7-5, the shaft is supported on both sides of the disc by sleeve
bearings and is connected to the disc by dowel pins, taper pins, or other means. The
other end of the shaft is connected to the actuator by a single key, double key, spline,
square head connection, or other special design.
Sealing of the shaft in butterfly valves (and quarter-turn valves in general) is relatively
easier than that for rising shaft valves such as gate and globe valves. This is due to the
fact that the rotary shaft motion does not have a tendency to transfer and create a loss
of the packing material to the environment outside the packing box area. The most
commonly used butterfly valve shaft seals are:
Pull-down packing gland (stuffing box). Both live loaded packing (for example, with
Belleville springs) and conventional bolt torque preloaded pull-down packing
glands (as shown in Figure 7-5) are used with butterfly valves. The stuffing box is
usually designed to accept a minimum of four packing rings. Flexible graphite
packing rings with composite carbon/graphite end rings are commonly used in this
type of design.
V-type (self-adjusting chevron type) packing. V-type packing is well suited for quarterturn valves in general. Line pressure acts on the inside surface of the V-rings to
effect a seal across the shaft; therefore, correct orientation of the V-rings in the
packing cavity is required. Ethylene propylene terepolymer (EPT), rubber, and
composite Teflon are the typical packing materials for this type of packing design.
The shaft seal design for butterfly valve applications should allow for easy packing
replacement and in-service adjustment. One of the less commonly used shaft seals is a
conventional O-ring, which is not suited for easy maintenance or replacement in
service.
less) may be obtained with Teflon and other self-lubricating reinforced plastic bearing
materials in clean fluid applications. The valve manufacturers should be consulted for
the bearing material coefficient of friction or the bearing friction factor applicable to
their specific valve designs.
In addition to the sleeve bearings, which carry the forces induced by differential
pressure across the disc, valves larger than 20 inches (500 mm) are typically equipped
with one or two thrust bearings to support the weight of the disc assembly and to keep
the disc centered with respect to the seat [6.36]. The torque contribution from these
thrust bearings to the total operating torque requirements is negligible.
7-15
Figure 7-10
Typical Seat Designs
7-16
Figure 7-11
Inflatable Seat Butterfly Valve
material) variation of the interference seat designs, respectively. The adjustable type
seat design requires a controlled magnitude of torque (specified by the valve
manufacturer) on the seat retainer ring adjustment screws. The amount of seat
adjustment varies with seal tightness and required seating torque. Over-adjustment
of the seat increases required seating/unseating torque and reduces seal life due to
increased wear rate. This seat design offers the advantage of being easily
replaceable in the field.
Inflatable type seat. In inflatable type seat designs, external pressure is applied to the
resilient seat member after seating and removed before unseating the disc. Figure 711 shows an inflatable type elastomer seat design for a symmetric disc valve.
Typical materials used for the seal ring in the elastomer type seal design are ethylene
propylene terepolymer (EPT) or nitrile. Maximum temperature for EPT material used
in the seats is 300F (149C) for normal conditions and 350F (177C) for faulted
conditions.
Rubber seats in butterfly valves are usually made of 40 to 80 durometer hardness
(based on shutoff pressure requirements); 65 to 70 durometer is the most typical range.
Continuous exposure to high temperature and/or certain fluid environments can cause
hardening of the rubber material with age, thus causing an increase in
seating/unseating torque. Valve manufacturers provide recommendations for the seat
replacement frequency to ensure satisfactory seal performance.
The valve seat design or the actuator torque requirements may dictate a preferred flow
direction for the valve. The shaft upstream (seat ring downstream) is the preferred
direction from a sealing standpoint because elastic deflections due to the differential
pressure across the disc tend to close up the clearances between the disc and seat
mating surfaces, thus providing a tighter seal. The shaft downstream direction exhibits
lower dynamic torque and is the preferred direction from an actuator size standpoint.
Another advantage for shaft downstream installation is that the shaft packing is on the
low pressure (downstream) side of the seat and the potential for packing leakage is
mostly eliminated. This feature can be particularly important for some applications (for
example, containment isolation) where the valve safety function is to isolate and remain
closed for an extended period of time such as in post-LOCA conditions.
7-18
Because of the large variation in seat designs and materials, the required seat torque
value or calculation procedures should be obtained from the valve manufacturer or
from in situ testing.
7.3
Installation Practices
This section presents the main factors to be considered during the selection and
installation of butterfly valves. (See Section 8 for additional discussion.)
7-19
Figure 7-12
Effect of Upstream Disturbance, Shaft Orientation, and Disc Opening Direction on
Hydrodynamic Torque
Configuration 3 (where the valve shaft and the elbow are in the same plane) is typically
recommended because it has the least effect on the valve performance in both the
closing and opening direction.
An upstream elbow model [1.6, 2.4] has been developed to bound torque requirements
with an upstream elbow in a given orientation and proximity from valve inlet. The
upstream elbow model can be used to estimate the effect of other upstream piping
components on butterfly valve torque requirements. The effect of an upstream
disturbance diminishes after 8 to 10 pipe diameters. Two out-of-plane elbows produce
a swirl that can persist for more than 20 pipe diameters.
Figure 7-13
Hydrostatic Torque Component in a Horizontal Shaft Installation
The hydrostatic torque becomes zero (or negligibly small) under any one of the
following conditions:
7-21
Valve shaft is vertical. This orientation results in a zero moment arm for symmetric
and single offset discs, and a negligible moment arm for a majority of the double
offset disc designs.
Liquid levels in both the upstream and downstream pipes are the same (either full,
empty, or partially full).
In some large valves, the magnitude of the hydrostatic torque component can be high
enough to overcome the total seating/unseating torque. In the absence of valve
operator resistance, the valve may open by itself under hydrostatic torque.
For double and triple offset disc designs (where the shaft is offset from the pipe
centerline), the pressure drop across the valve disc gives another hydrostatic torque
component, which is referred to as P-induced hydrostatic torque. This hydrostatic
torque component can be very significant, especially for large valves under high
pressure drop.
Caution: Both symmetric and nonsymmetric disc butterfly valves can experience very
high unseating torque requirements if an incompressible fluid is trapped between two
tight seal valves. Increase in the pressure of the trapped liquid or water (such as by
heating) can lead to a pressure locking scenario. In addition to the increase in the
bearing torque, double and triple offset disc valves will have a P-induced hydrostatic
torque component.
7.4
Butterfly valves, depending on the design and direction of flow, may open or close by
themselves under flow conditions. Therefore, care should be used when operating a
lever-operated manual butterfly valve to prevent personnel injury. Most worm gear
operators have self-locking gear trains to prevent the valve disc from drifting [1.6].
Although the use of standard design butterfly valves is usually restricted to isolation
service, throttling with these valves can be tolerated if the valve is no less than 20%
open, and the design limits are not exceeded [1.6].
7.5
Common Problems
Valve disc does not reach the fully open or fully closed position due to improperly
set limit switches.
7-22
Liner deterioration due to chemical attack on lined butterfly valves can occur if the
liner material is not selected properly. Liner deterioration can also occur due to high
fluid velocity or improper use as a throttling valve.
High flow turbulence may cause disc vibrations and high bearing and packing
wear.
Butterfly valves used for containment isolation valves frequently fail the annual leak
rate tests because the resilient seat material dries and/or hardens between tests.
Liner hardening can also increase the torque required to operate the valve.
For service water butterfly valve applications, the presence of solid particles and
biological growth can cause several valve problems, including:
Disc erosion may be a problem in normally open applications with high flow
velocities (for example, over 16 ft/sec or 5 m/sec) because the disc is always in the
flow stream. The presence of solid particles in the fluid will increase disc and body
erosion.
Many service water valve problems can be eliminated by proper material selection and
adequate maintenance.
7-23
7.6
Maintenance Methods
Removal of the valve is normally required to perform maintenance, except for packing
adjustment/replacement. However, some maintenance, such as seat replacement, can
be performed on a lugged or flanged butterfly valve with offset discs by removing the
piping on the seat side of the valve.
Always follow the manufacturers maintenance recommendations.
7-24
8
BUTTERFLY VALVESMODULATING/THROTTLING
FUNCTION
8.1
Butterfly valves have unique flow and torque characteristics that can cause valve
instability in some throttling applications. The Butterfly MOV Application Guide [1.6]
and the Butterfly Performance Prediction Methodology [2.4] provide detailed discussions of
these characteristics and their effect on valve performance. In this section, some of the
butterfly valves key characteristics are discussed, and the reader is referred to
References 1.6 and 2.4 for comprehensive discussions. Information given in Section 7
for isolation functions also applies (for the most part) to modulating/throttling
functions.
Butterfly valves have high pressure recovery factors [1.6, 5.1, and 6.37] and tend to
cavitate and choke at low disc opening angles. Thus, butterfly valves are not
recommended for throttling/modulating near the fully closed position. For example,
butterfly valves are not recommended for some service water systems where water has
large seasonal temperature variations. Although a service water butterfly valve may
provide acceptable performance during the hot weather season, it may cavitate during
the cold weather when the valve is throttled at low disc angles to satisfy system
requirements. It should be noted that some butterfly valves have special disc designs
that reduce flow cavitation and noise (see Section 7.2.6).
Under certain flow conditions, some butterfly valves with single offset disc designs
may experience dynamic torque reversal at midstroke positions when installed with the
shaft on the downstream side [1.6, 2.1, 2.4 and 2.11]. Dynamic torque reversal may
cause instability, vibrations, and high bearing wear. Thus, for throttling/modulating
service, single offset disc valves should not be installed with shaft downstream unless it
can be shown that the valve is not susceptible to dynamic torque reversal under
operating conditions.
8-1
8.2
Flow around a butterfly valve disc produces both lift and drag forces similar to the
forces acting on an airplane wing. The non-uniform pressure distributions on the
upstream and downstream faces of the disc have a resultant force that does not pass
through the shaft axis, as shown in Figure 8-1. The product of this resultant force on the
disc and its moment arm to the center of disc rotation is the hydrodynamic torque
component, Thyd. For a given disc shape, the hydrodynamic torque is proportional to the
valve pressure drop, Pv, and disc diameter, ddisc, raised to the third power. The
constant of proportionality, Ct, called hydrodynamic torque coefficient, varies as a function
of disc opening angle. For a given disc shape at a fixed disc angle, the hydrodynamic
torque, Thyd, is given by:
Thyd =
1
C t d 3disc v
12
Thyd = 10 6 C t d 3disc v
Figure 8-1
Flow Through a Symmetric Disc Butterfly Valve
Most manufacturers determine torque (and flow) coefficients by performing flow loop
tests on full-size valves of selected sizes and pressure ratings, or on precisely scaled
models of their valve product line. Tests are typically performed under fully turbulent,
non-choked flow conditions using water or with air at low pressure drop ratio
(maximum flow velocity is well below the speed of sound) to simulate nearly
incompressible flow.
8-2
8.3
The hydrodynamic torque coefficient, Ct, curve has a peak at around 70 to 80 disc
opening for most disc designs. In actual valve installations, the peak in the
hydrodynamic torque does not necessarily occur at the location where the
hydrodynamic coefficient, Ct, has a peak. This is due to the fact that the pressure drop
across the valve, Pv, typically changes with the disc opening. The amount of change in
Pv across the valve depends upon the valve flow characteristics and the characteristics
of the hydraulic system in which it is installed. Since both Ct and Pv depend upon the
disc opening angle, the actual peak in hydrodynamic torque occurs at a disc position
where the product of these two quantities reaches a maximum value. The following
two cases illustrate this effect.
Case 1: Nearly constant pressure drop across the valve
Figure 8-2a shows a hydraulic system in which the differential pressure between the
two reservoirs is constant and the total resistance of the piping is low. Pressure drop
across the valve, Pv, decreases only slightly near the full open position due to the
relatively small amount of pressure loss to overcome the piping resistance. Thus, the
valve has nearly a constant pressure drop regardless of the disc opening angle. This
means that the hydrodynamic torque will reach a maximum at nearly the same disc
opening where the hydrodynamic torque coefficient peaks.
Case 2: Variable pressure drop across the valve
In pumped systems and/or in systems having high piping resistance, the pressure drop
across the valve, Pv, can change significantly as a function of disc opening, in a
manner similar to that shown in Figure 8-2b. The large variation in Pv is caused by the
combined effect of pump characteristics (discharge pressure drops with increasing flow
rates), system resistance (pressure drop across the piping resistance increases as a
square function of the flow rate), and the valve flow characteristics (flow resistance
coefficient decreases with increasing disc angles).
The effect of decreasing Pv with increasing disc opening on the hydrodynamic torque
is shown in Figure 8-2b. The peak in the torque curve has shifted toward a lower disc
opening angle because the product of the torque coefficient, Ct, and Pv reaches a
maximum at this location. It should also be noted that the magnitude of the torque at
the peak location will be different because it depends on the actual Pv at that disc
opening angle.
8-3
Figure 8-2
Variation in Location of Peak Hydrodynamic Torque for Constant Head
and Pumped Systems
In closing, it should be noted that the discussion here focused on the hydrodynamic
torque component only. The total dynamic torque curve exhibits a similar, but not
exactly the same, behavior. The difference is due to the contribution of the bearing
8-4
torque component, T b , which is also dependent upon the differential pressure across
the valve. The relative contribution of each of these components determines the actual
location of peak total dynamic torque. The calculation procedures to determine the
magnitude and location of the peak dynamic torque are described in References 1.6 and
2.4.
8.4
The required actuator torque is the larger of these two torque requirements. Figure 8-3
shows a typical opening torque curve for a symmetric disc butterfly valve along with
various torque components in a high flow application. The actuator torque required to
open the valve in this example is determined by the total dynamic torque, TTD, rather
than the total seating/unseating torque, TTS. A good knowledge of the behavior of
various torque components is required to determine the total seating torque
requirements as well as the total dynamic torque requirements.
8-5
Figure 8-3
Typical Opening Torque Characteristics of a Symmetric Disc Butterfly Valve under
High Flow Conditions
Hydrodynamic torque can be very high in applications with high flow velocities. When
the hydrodynamic torque assists disc rotation and the sum of the frictional torques
(bearing, packing, and hub seal) is relatively small, the actuator will apply a restraining
torque to prevent the disc from slamming shut. Under these conditions, the concern
would be the structural strength of the shaft and its connections to the actuator and to
the disc rather than the actuator motive torque. To account for these conditions, the
maximum transmitted torque, TTR, is defined as the maximum motive or restraining
torque applied by the actuator to the valve shaft during a valve stroke under the
specified flow conditions and is equal to the largest of:
Seating/unseating torque
The maximum transmitted torque excludes any additional actuator torque caused by
disc obstruction before reaching a specified disc position as set by the actuator. The
maximum transmitted torque is used to evaluate the structural strength of the key
components within the torque train of a butterfly valve.
8-6
8.5
Common Problems
Butterfly valves may cause noise, cavitation, choking or/and flashing when
subjected to high pressure drops especially in applications where valve inlet
pressure and temperature are near saturation conditions. Extended operation under
these conditions may result in damage to the downstream piping as well as to the
valve. Thus, it is particularly important to carefully evaluate valve characteristics at
operating conditions.
The location of the peak total dynamic torque depends on the system resistances
and the pressure source (see Figure 8-2). Operating near the peak total dynamic
torque may result in unstable operation.
Nonsymmetric disc valves with shaft downstream orientation may have torque
reversal at midstroke. Operation near torque reversal may result in unstable
operation.
Butterfly valves are rather sensitive to upstream flow disturbances such as pumps,
elbows, and other valves. These flow disturbance sources cause velocity skews and
high turbulence that can affect the performance of butterfly valves and increase the
bearing and packing wear.
8.6
Maintenance Methods
Information given in Section 7 for isolation butterfly valves also applies to modulating
service.
8-7
9
BALL VALVESISOLATION FUNCTION
9.1
Ball valves are quarter-turn valves, occupy less vertical space than rising stem valves,
and can be installed in almost any orientation. Ball valves are bi-directional except for
some eccentric or wedged ball designs. With elastomeric or plastic seat designs, ball
valves are normally limited to 400F (200C) service. With metal seats and high
temperature packing materials, they can be used in higher temperature applications.
Due to their basic spherical-shaped sealing members and stiff body design, ball valves
can tolerate high pipe bending moments and thermal gradients without affecting their
seating or operating.
Ball valves (like butterfly valves) are high pressure recovery valves and are susceptible
to cavitation, choking, and flashing. The pressure drop across a full-bore ball valve in
the fully open position is nearly equal to the pressure drop across an equal length of
straight pipe. Reduced and venturi bore valves are used in low flow velocity
applications where some pressure drop is acceptable or desirable.
9.2
9.2.1 General
Ball valve bodies are available in two- or three-piece designs with either end-entry, or
top-entry (of the ball) construction. Body pieces are joined by welding, flange bolting,
or threading, and may incorporate multiple ports. Figures 9-1 and 9-2 show end-entry
designs with two- and three-piece construction respectively. Some designs, such as the
top-entry (Figure 9-3) and bolted three-piece swing out type body designs, allow the
valve to be serviced without completely removing it from the line. Ball valves do not
normally incorporate stem backseating since the valve stem only rotates without axial
movement.
The body cavity can trap crud and foreign materials because in the fully open position
the valve seats isolate the body cavity from the main flow. Body drains are usually
provided to flush the body. Special features available in some designs include rotating
9-1
seats to provide uniform seat wear, pressure energized seats to improve sealing, and
coatings to provide corrosion resistance. In addition to the typical solid spherical shape,
balls can use ribbed, tubular, or hollow construction to minimize weight, especially in
larger sizes.
Ball valves are grouped into two basic types: floating ball and trunnion-mounted ball.
A variation of the trunnion-mounted is the wedged ball design that allows mechanical
loading of the seat. The selection of a particular ball valve design depends on the size of
the valve and the application.
Economical.
Can easily be made fire safe by use of fire-safe seat materials and stem packing
materials.
Absence of bearings and nonfloating seats make floating ball valves more suitable
for dirty service than trunnion-mounted valves.
9-2
Disadvantages:
Even though 1-inch and smaller size floating ball valve designs are suitable for high
pressure service (up to ANSI Class 1500), the high torques associated with this
design limit use of larger sizes to lower pressures (up to ANSI Class 300). For sizes
larger than 12 inches, floating ball designs are typically not recommended or
available due to the fact that the force caused by differential pressure across the ball
acts on the downstream seat instead of the bearings in a trunnion-mounted ball
design. Torque created by the seat friction in a floating ball is much higher because
of its larger effective radius compared to the radius of the bearings used in
trunnion-mounted balls.
9-3
Figure 9-1
Floating Ball
9-4
Figure 9-2
Trunnion-Mounted Ball
Some of the advantages and disadvantages of the trunnion-mounted ball valve design
are identified below.
Advantages:
Relieves body over-pressure to low pressure side of the system by pushing the
floating seat away from the ball.
Suitable for higher pressure service than floating ball design, especially in larger
sizes.
9-5
Ball weight can be supported by the thrust bearings instead of the seats as in the
floating ball design, thus providing more uniform seating load and wear.
Disadvantages:
Bearings can experience high wear if abrasive solids are present in the fluid which
can cause the torque to increase, making it unsuitable for fluids contaminated with
solids.
Due to the non-floating action of the ball, fire safety is more difficult to achieve.
9-6
Figure 9-3
Wedged Ball Design
Some of the advantages and disadvantages of the wedged ball valve design are
identified below.
Advantages:
Torque is minimized since the ball does not drag on the seat during turning.
Fire safe.
Disadvantages:
Unidirectional.
Uses multiple turns of the handwheel or actuator to achieve 90 rotation of the ball.
9.3
Installation Practices
The performance and reliability of ball valves are relatively unaffected by orientation.
However, orientation that places the body shaft penetration at the low point of the
valve should be avoided to minimize the effect of debris on the packing system.
For other than flanged or screwed end valves, care must be taken to avoid overheating
or burning the seats and seals when welding or brazing into the line. Manufacturers
installation instructions must be followed. Some designs may require removal of the
seats and seals prior to installation.
9.4
Although the use of standard design ball valves is normally restricted to isolation
service, rough throttling with these valves can be tolerated if the valve is no less than
20% open and the manufacturers design limits are not exceeded.
The internal body/ball configuration of ball valves is such that there are inaccessible
areas behind the ball where suspended solids in the fluid can be trapped. If the solids
are not tightly adhering or do not coagulate, removal of the solids from inaccessible
areas can be accomplished by putting the valve in the partially open position. This
results in internal turbulence and eddies that tend to scour out the valve. This
procedure is especially critical in radioactive service. Depending on the design and
flow direction, ball valves may open or close by themselves under flowing conditions,
especially in larger sizes. Therefore, care should be used when operating a leveroperated manual ball valve to prevent personal injury.
The correct size valve wrench must be used to open or close a manual valve. Exercise
caution against the use of excessive leverage on the wrench. Do not use a pipe wrench.
9.5
Common Problems
The primary problems with ball valve seats are damage by debris and wear of the
elastomer or plastic.
If a ball valve has not been operated for an extended period of time, the initial
breakaway torque can be two to three times the normal operating torque (for some
seat designs). Accumulation of debris and foreign materials in the valve body cavity
may also interfere with valve operation.
In MOVs, the ball may not reach the fully open or fully closed position because the
limit switches are not properly set. When used, torque switches may also trip before
reaching the fully closed position.
9-8
Sometimes, the ball assembly in a large trunnion valve will shift during transit,
making the valve inoperable after installation.
9.6
Maintenance Methods
9-9
10
BALL VALVESMODULATING/THROTTLING
FUNCTION
10.2 Design
Conventional ball valves are used primarily for isolation service. Like butterfly valves,
conventional ball valves cannot provide fine control, and they also experience erosion,
cavitation, or noise when operated near the fully closed position. For modulating
service, special features are incorporated into the design, as shown in Figures 10-1, 102, and 10-3.
10-1
The special cam type (partial ball) rotary valve (Figure 10-1) is particularly useful in
situations where particulates are present and finer control is required. This rotary valve
offers good control and metal-to-metal seating. It uses a cam-shaped eccentrically
mounted disc connected to the shaft by arms that can flex slightly to provide a tight
shut-off without requiring high closing forces.
Figure 10-1
Eccentric Rotating Plug/Ball Control Valve
Figure 10-2 shows a U-shaped ball design that provides finer control near the fully
closed position. The tube bundle (immediately downstream of the ball) prevents
excessive pressure drop across the ball itself, thus limiting valve cavitation. This design,
however, is less cavitation resistant than the design shown in Figure 10-3.
10-2
Figure 10-2
Segmented Ball with Tubular Resistance Trim
The ball design shown in Figure 10-3 incorporates a multistage pressure drop path
when the ball is in the mid-travel position. The orifices in this ball design provide finer
control and limit the pressure drop across any one stage, which prevents cavitation.
This ball valve design is being successfully used in low pressure throttling applications
and is much better suited for dirty service than are globe-type control valves. Another
advantage to this design is its high rangeability with relatively low pressure drop when
in the fully opened position.
10-3
Figure 10-3
Multistage Anticavitation Ball Valve
10-4
10-5
11
PLUG VALVES
11.2 Design
Like the ball valve, the plug valve is a quarter-turn valve. The plug valve is compact
and simple in construction. It uses a cylindrical or conical-shaped closure member
instead of the spherical shape used in the ball valve. The plug valve is basically an onoff service valve, but can be used for throttling if precise control is not required.
The two basic designs of plug valves are the nonlubricated type (Figure 11-1) in which
a metal plug is either surrounded by a resilient sleeve or fits between resilient seats and
the lubricated plug (Figure 11-2) in which sealant or lubricant is injected between the
plug and body seating surface to achieve a tight seat. An all-metal construction
variation of the nonlubricated plug valve uses a lift-turn-reseat motion of the plug.
The lubricated design is available in both cylindrical plug (Figure 11-2) and tapered
plug (Figure 11-3) types. Tapered plug valves are more widely used than the
cylindrical designs because the plug can be adjusted within the body (by an external
adjustment screw) to compensate for wear, thus providing better shutoff during
service. However, conventional tapered plug valves are prone to being wedged into the
body due to hydraulic pressure imbalances that exist above and below the plug ends
during rapid hydraulic transients. This wedging problem is commonly referred to as
taper locking and results in a substantial increase in operating torque. Some
manufacturers have incorporated special patented design features to eliminate this
taper locking problem.
11-1
Nonlubricated plug valves require a higher torque to operate than ball valves because
plug valves have a larger area constantly in contact with the plug sleeve, which acts as
a seat.
Figure 11-1
Nonlubricated Plug Valve
Figure 11-2
Lubricated Plug Valve
11-2
Figure 11-3
Lubricated Tapered Plug Valve
Plug valves feature either a top- or bottom-entry design, both of which can be readily
serviced in line. Application of conventional lubricated plug valves is generally limited
to temperatures not exceeding 250F (120C) and where slight contamination of the
process fluid by the sealant is acceptable. At higher temperatures, the asymmetric
construction of the valve body leads to significant distortion of the body seating
surfaces which increases the seating gap, making it harder to seat. The nonlubricated
design is more tolerant of temperature, but is still limited to 400F (200C) by the
resilient material used. The all-metal variation is suitable for higher temperature
service.
11-3
11-4
11-5
12
DIAPHRAGM VALVESISOLATION FUNCTION
12.2 Design
The diaphragm valve is comprised of a bonnet, body, and flexible-sealing member. The
flexible sealing member is available in a variety of materials such as Buna-N, Viton,
TFE, polyethylene, or neoprene. This valve is particularly suited for corrosive fluid,
slurries, scale-forming service, and where zero stem leakage is mandatory. The body
may also be fully lined to accommodate these services.
Although diaphragm valves have been tested and operated satisfactorily for over
50,000 cycles, design life of the diaphragm should be limited to 20,000 cycles or 10
years, whichever occurs first. The valves are available in sizes from 1/2 inch to 16 inch
(12 mm to 400 mm); but, due to their large overall size, they are not generally
recommended larger than an 8-inch size. Because of their materials of construction,
flexible diaphragm valves are limited to temperatures less than 300F (150C).
Flexible diaphragm valves are available in three basic body configurations (Figures 121, 12-2, and 12-3):
Depending on the valve design and installation, there is a potential for trapping fluid in
the valve and upstream or downstream piping.
The Saunders pattern or conventional weir design (Figure 12-1) is the most commonly
used diaphragm valve. The valve is self-draining when installed in horizontal piping
with the stem axis oriented to approximately 20 above horizontal.
The straightway design (Figure 12-2) has no weir but incorporates a straight-through
flow path. However, the pressure-temperature rating for the diaphragm in this valve is
less than the rating for the diaphragm found in a Saunders pattern valve.
The full-bore type (Figure 12-3) provides a full rounded bore and streamlined flow.
This type also has a weir, but the weir height is considerably less than the weir height
in the Saunders pattern valve.
Figure 12-1
Saunders Pattern Flexible Diaphragm Valve
12-2
Figure 12-2
Straightway Flexible Diaphragm Valve
Figure 12-3
Full Bore Body Flexible Diaphragm Valve
12-3
Damage to the lining of a lined diaphragm will occur if the lining material is not
compatible with the fluid chemistry. In a corrosive service, body corrosion can occur
if the lining is damaged and the process fluid has leaked through the lining.
12-4
13
VALVE ACTUATORSGENERAL INFORMATION
13.1 General
Actuators are devices installed on valves to permit control of the closure member. The
actuator can be either locally or remotely controlled to open, close, change, or maintain
a position. The basic types of actuators are:
Manual
Electric motor
Solenoid
Pneumatic
Hydraulic
Electrohydraulic
Figure 13-1 provides a brief summary of the most typical actuator types, and Table 13-1
presents features, capabilities, and suitable areas of application for power actuators.
Other conditions which should be considered in actuator selection are stability
requirements for the application, temperature, and fail-safe operation.
Most valves can operate by means of a handwheel or lever supplied with the valve.
Various accessories can be adapted to fit most types of valves to permit valve operation
under the following conditions:
13-1
Figure 13-1
Types of Valve Actuators
13-2
Table 13-1
Normal Application of Power Actuators for Valves
Actuator Type
Feature
Pneumatic
Hydraulic
Output thrust
or torque
Up to 23,000 1b
(102 kN)*
Virtually unlimited
Stroke length
Unlimited
Unlimited
High
Low
High
All
All
Normal
speeds
Failure mode
Any required
position can be
accommodated
Source of energy to
operate
Station compressed
air, accumulators,
electric power,
springs, dedicated
pressurized hydraulic
system; one or
combination thereof
Yes
Best
Yes
* Special pneumatic actuators have been developed providing thrust up to 100,000 pounds (444.8 kN).
13-3
The Electric Power Research Institute (EPRI) has published several application guides
to address sizing, installation, operation, maintenance, and repair of the most
commonly used electric motor actuators in U.S. nuclear power plants (see References
1.5, 1.6, 1.22, 1.23, 1.24, 1.25, and 1.26). EPRI has also published several other
documents to address special types of valves, such as air-operated valves [1.2], safety
and relief valves [1.4], solenoid valves [1.7], and main steam isolation valves [1.27 and
1.28]. The actuators and devices used to operate these valves are discussed within each
document, and the reader is referred to these documents for detailed information. The
discussion in this document is limited to the actuator types and their selections for
nuclear power plant applications. Manual actuators are also discussed.
Figure 13-2
Limitorque SMB-0 Motor Operator Cutaway View
13-5
Figure 13-3
Simplified Motor Operator
To convert the higher speed, multiturn motion from the motor actuator to a slower
quarter-turn motion required for the operation of rotary valves (such as butterfly, ball
and plug valves), a gear reducer with position stops is utilized between the actuator
and the valve stem (Figure 7-1). The stroke time for quarter-turn valves varies from less
than 5 seconds to over 60 seconds.
Control devices (such as limit and torque switches in Figure 13-2) are used to sense the
position of the valve stem and/or the amount of applied torque and to shut off the
motor power supply once the required limit is reached. The reduction gears are usually
self-locking such that the valve stem position is maintained without the continued
application of an external power source. Thus, the actuator can be used to position the
valve at an intermediate position, as in throttling service.
Motor operators are available for modulating and throttling service. When motoroperated valves are ordered for infrequent (or non-modulating) throttling service, it is
essential that all the conditions are given to the manufacturer, including the number of
times the valve is going to be positioned per hour and the approximate range of
movement of the valve stem. This information is required to ensure that a continuous
duty motor (as opposed to the normally provided 15-minute duty motor) is supplied
and that the motor actuator sizing and selection is correct.
13-6
The motor operator has an automatic transfer mechanism to switch from the manual
mode to the electric power mode and visa versa. This mechanism uses a pawl-clutch
arrangement, which is subject to wear and possible failure when used frequently. A
motor-operated valve should not be specified when it is intended that the valve be
throttled manually.
Electric motor sizing calculations, installation, maintenance and repair procedures are
typically provided by the actuator manufacturer. EPRI has published several technical
repair guides for Limitorque and Rotork electric motor actuators, which are the most
common in U.S. nuclear power plants (see References 1.22, 1.23, 1.24, 1.25, and 1.26).
Motor actuator sizing calculations are provided in EPRIs MOV guides [1.5, 1.6]. These
documents provide detailed discussions and data, and can be reviewed for in-depth
information.
13-7
shooting, maintenance, and repair. Reference 1.2 should be reviewed for in-depth
discussions of air actuators.
13-8
Figure 13-4
Hydraulic Actuator with Fail-Safe Operation Using a Mechanical Spring
13-9
Figure 13-5
Hydraulic Actuator with Fail-Safe Operation Using a Gas Spring
Hydraulic operators are not widely used in the nuclear power industry. They have to
be provided with an integral hydraulic system, normally supplied by the valve
manufacturer. Control of leakage and particulate content in these systems is of primary
importance since small bleed orifices and clearances are often used.
13-10
The operating speeds of electrohydraulic actuators are sometimes lower than can be
obtained with a diaphragm actuator.
Their maximum stem thrust is somewhat lower than can be obtained with large
diaphragm actuators or high pressure cylinder actuators.
13-11
Figure 13-6
Solenoid Actuator
The valves can be direct acting, where the plunger is connected directly to the main
disc of the valve, or pilot operated, where the plunger opens a small pilot valve that
allows system pressure to act on components of the valve to open the main disc.
Actuation time of solenoid valves is very rapid. Solenoid valves can be obtained in twoway, three-way, or four-way design. A common application is in directing the flow of
compressed air or hydraulic fluid to larger actuators.
Solenoid actuators, like electric motor actuators, require an electric power source.
However, the use of solenoid actuators as a direct method of actuating valves is limited
because of their relatively low output force. Solenoid actuators are used extensively to
actuate small pilot valves in remote-controlled pneumatic and hydraulic systems.
Solenoids are used in actuating valves up to 8 inch, class 2500, when provided with a
pilot arrangement. Normally solenoid valves can only seal in the flow-to-close
direction. Solenoid valves without pilot operation are generally limited to 2-inch and
smaller sizes. Multiple solenoids can be supplied to provide more than one direction or
mode of operation, such as in three- and four-way valves.
Solenoid valves should not be used where foreign magnetic material can be attracted to
the operating mechanism. When solenoid actuators are specified, both the minimum
and maximum operating differential pressure should be specified. This allows the
manufacturer to determine the force required to actuate or prevent actuation of the
valve.
EPRIs Solenoid Valve Maintenance and Application Guide [1.7] provides a comprehensive
discussion of various aspects of solenoid valves including application, operation,
trouble shooting, maintenance and repair. Reference 1.7 should be reviewed for indepth discussions of solenoid actuators.
13-12
Valve type
Type of service
Temperature limitations
Ionizing radiation
On-off or modulating
Duty cycle
Stability
Fail-safe operation
13-13
Override requirements
Weight
Maintenance requirements
Cost
Availability
When selecting manual actuators, such as levers and handwheels, excessive protrusion
increases the risk of injury or accidental change of the valve setting. When using
handwheels or levers, consideration should be given to the selection of methods for
locking the position of the closure member.
Particularly important in power plants is the fail-safe operation of the actuator. The
valve may be required to fail-open, fail-closed, or fail-in-last-position. The fail-safe
mode may be provided by springs, weights, gas pressure, or gears. Mechanical springs,
weights, or gas springs can provide the fail-open and fail-closed modes. Gear actuators
are usually incapable of providing a fail-open or fail-closed action and are suitable only
for fail-in-last-position applications.
When procuring an isolation valve, it must be specified if the valve must operate
against a high differential pressure in an off-normal condition so that the operator
can be properly sized. This off-normal condition is often overlooked during valve
procurement.
13-14
14
MANUAL ACTUATORS
Figure 14-1
Manual Lever
14-1
Figure 14-2
Worm Gear Actuator
The use of the manual actuator for normal operation is limited by the amount of
force/torque required to actuate the valve and the stroke time. In larger valves, manual
actuators are coupled with gears (see Figure 14-2) to produce the required force.
Manual actuators on large valves are normally provided for manual override and
emergency operation. Manual actuators are most frequently used in small valves and
control equipment. These actuators should not require more than 60 pounds (0.27 kN)
of force during the majority of the travel, and 150 pounds (0.67 kN) of peak force to
fully operate the valve (see Table 14-1).
The effort that can be exerted by an average person depends upon the size of the
handwheel and the orientation of the handwheel relative to the person. Hammerblow
or impact handwheels are used to create higher starting torques than can be achieved
by a gradual application of effort, as discussed in Section 2.3.7.
14-2
Resulting Torque
ft-lb (N-m)
Below 4 (100)
50 (220)
8 or less (10.8)
4 to 6 (100 to 150)
60 (270)
10 to 15 (13.6 to 20.3)
7 to 9 (180 to 230)
100 (440)
29 to 38 (39.3 to 51.5)
10 to 14 (250 to 360)
125 (550)
52 to 72 (70.5 to 97.6)
15 to 23 (380 to 580)
145 (640)
150 (670)
14-4
The most common problem with remote operating systems is lack of proper
lubrication (including grease aging, hardening, and contamination), which can
make the system difficult to operate.
Solid shafting, gearing, and flexible shafting, if not sized properly, will result in
difficult operation and sometimes failure of a component.
Inadequate maintenance may result in loosening of nuts and bolts and may cause
personnel injury.
14-5
15
GENERAL DESIGN REQUIREMENTS FOR VALVES
AND ACTUATORS
15.1 Introduction
Many valves perform critical functions in a power plant. Besides effectively meeting the
requirements of normal system operating conditions, many valves, particularly those in
nuclear safety-related systems, must perform their functions, often under degraded
conditions and in a harsh environment. Sometimes the valves function is merely to failas-is and to retain its pressure boundary. At other times, it may be required to open,
close, or modulate while in a harsh environment, such as saturated steam, extreme heat,
high radiation, or full submergence, often concurrently with loss of power or loss of
instrument air.
In order to establish performance requirements and to properly specify a valve, it is
necessary to determine the fluid parameters being contained by the valve and to
consider other factors that could affect valve operation. Considerations include
Anticipated localized conditions, such as water trapped in the valve bonnet, thermal
overpressurization due to inadvertent line isolation, or inadvertent line
pressurization due to seat leakage of a pressure boundary valve
This determination is made by first identifying all the system operating conditions such
as normal, startup, shutdown, standby, abnormal/upset, emergency, faulted, and test.
It is also important to identify which plant operating conditions apply to each of the
above since the requirements imposed on the systems and their valves may vary by
plant operating and environmental conditions.
15-1
Once the system and plant operating conditions are identified, the required design flow
rate, differential pressure, system pressure, and temperature are determined. Other
requirements that do not apply to the particular application can be eliminated. This
approach will narrow down the types of valves and operators that may be acceptable.
The available space for installation, operation, and maintenance is also evaluated in
order to further narrow down the valve selection.
In addition to safety and environmental requirements imposed by the applicable codes,
all valves should undergo a commercial evaluation to determine the reliability and
redundancy requirements to adequately fulfill their functions. For example, a large
valve in a power production system that could cause loss of production should it fail or
have to be removed from service frequently for repair would have more stringent
design and maintenance requirements than a small valve in a system that would not
adversely affect power production should it be out of service.
15.2.3 Pressure/Temperature
System design pressure, temperature, and differential pressure across the valve are
based on the most severe pressure and temperature combination expected during
system operation or under design basis conditions. The design pressure and
temperature are used to determine the primary pressure rating of the valve. The
adjusted pressure/temperature rating tables given in ANSI B16.34, B16.5, and MSS
standards (for non-ferrous valves) list the maximum allowable working pressures for a
given temperature. The maximum operating temperature may be limited to a
temperature lower than that specified in the pressure/temperature rating table if
elastomers are used for valve seats and seals. This restriction is described in the
applicable code or is sometimes available in manufacturers catalogs in the form of
tables or charts, and is typical for diaphragm, butterfly, ball, or plug valves. Section
16.2 discusses pressure/temperature ratings in greater detail.
15.2.4 Velocity
Flow velocity is determined by flow rate and pipe size. Mean pipe velocity in the range
of 515 ft/sec (1.54.5 m/sec) for water and 100300 ft/sec (3090 m/sec) for saturated
or super heated steam is not generally a concern for on/off valve applications.
However, excessive flow velocities (such as during blowdown conditions) can cause
tipping of the valve disc in some gate valve designs and might result in galling or
gouging of the guides, guide slots, disc, and seating surfaces, which in turn can lead to
excessively high thrust/torque requirements.
In throttling and modulating applications, flow rate is used in the control valve sizing
calculation and will influence the choice of valve size and type. Control valve
cavitation, flashing, and choking are of particular concern especially in high flow
velocity applications (see Section 15.4.2). Accurate evaluation of valve cavitation and
choking is particularly important for throttling/modulating service where continuous
operation under cavitation causes severe damage to the valve and downstream piping
components. Such evaluation should include the entire hydraulic system including the
pressure source (for example, pump) and the upstream and downstream flow
resistances. Some valve manufacturers and engineering companies have computer
software to perform such evaluation throughout the valve stroke.
15-3
15.2.5 Viscosity
Most valve applications involve a turbulent flow where the valve resistance coefficient
(Kv) is independent of viscosity. The valve flow resistance coefficient (Kv) is used in
sizing valves for water flow and for flow of other liquids that behave like water. If the
liquid is extremely viscous and viscosity is ignored, significant sizing errors may occur.
It is important to note that because fluid viscosity depends on the operating
temperature, the valve performance can change with the operating temperature,
especially for very viscous fluids.
15.2.7 Radiation
Elastomers and synthetics are commonly used in valve construction as seats, seals,
liners, and sleeves. They have a lower radiation resistance than metals. Therefore, if
elastomers or synthetics are considered for handling of radioactive flow media or if
their location would expose them to radiation, the total radiation dose must be
specified, including the design basis accident dose, to establish the design basis for the
valve over its specified design life. This integrated total radiation dose, together with
temperature and flow media chemistry, will determine the type of elastomer to be used
in the valve and the frequency with which it must be replaced. Sections 2.5 and 2.6
provide more detail on elastomeric materials.
Seat leakage, by preventing the valve from being fully seated if dirt accumulates on
the seat
15-4
Damage to the valve seat or disc, through erosion or abrasion of the seat/disc
material
Upset conditions
15-5
Emergency conditions
Faulted conditions
Plant Test Conditions: Plant test conditions include hydrostatic, pneumatic, and leak
tests specified by plant requirements. Other types of tests are performance tests
classified as normal conditions.
15-7
15-8
Condensation collapse in steam pipe after initially injecting steam into subcooled
water (water cannon)
Steam and subcooled water interactions in horizontal and near horizontal pipes
Hot water entering lower pressure line with subsequent flashed steam bubble
collapse
15-9
Rapid valve operation (for example, < 1.0 second for every 200 feet (61 m) of
connecting pipe)
Normal water hammer conditions that should be accounted for in the design include:
Water entrainment in steam lines caused by factors such as steam line control valves
or relief valves opening with a loop seal or condensed steam in the line
Although not strictly a water hammer, improper selection and installation of a check
valve on the discharge of a reciprocating pump can chatter between pulsations and
damage the valve seat.
Cavitation: Cavitation is a phenomenon that usually occurs in systems where liquid
velocities are high and pressures are near the saturation pressures of the liquid in the
system. When the velocity of the liquid increases at sudden changes of pipe cross
section, at sharp bends, at throttle valves, or in other similar situations, the localized
liquid pressure drops below the vapor pressure of the liquid, and the liquid will flash.
The flowing stream now consists of liquid plus pockets of vapor. As the liquid flows
back to regions of higher pressure, the pockets of vapor collapse (cavitate). It is the
collapse of the vapor pockets that causes the damage. Although mild cavitation is of
little concern, severe cavitation can destroy valves and piping and must be considered.
If cavitation is long term rather than transient, valve design/sizing factors discussed in
Appendix B should be considered. For example, cavitation can occur in a control valve
under conditions where relatively cold water is reduced in pressure to just below the
vapor pressure. If this condition is common during normal operation of the valve, not a
transient condition, then cavitation should be a design consideration.
Flashing: Flashing occurs when a liquid is reduced in pressure below its vapor pressure.
Flashing may occur in a valve when the liquid passes through a restriction and then
expands again. When this condition exists, vapor bubbles form and the result is a twophase flow consisting of the liquid and its vapor.
15-10
Thermal Shock: Thermal shock results from the rapid heating or cooling of metals.
Thermal shock is usually the result of rapid realignment of systems or portions of
systems, disturbance of thermal stratification, or operation of pressure relief devices.
These conditions should be avoided to the extent possible while still maintaining the
system and valve function. However, for nuclear plants, it may not be possible to
eliminate thermal transients during some plant conditions because of operational
sequences that require safety systems to operate rapidly to mitigate or prevent more
serious conditions. In designing for these operating conditions, it is generally assumed
that only one thermal cycle is involved and that the system can be designed to perform
its safety function.
Severe thermal transients can affect valve operability by distorting the working parts,
causing binding and sometimes incomplete stroking. Full torque seating during a
thermal transient can render a valve, particularly a gate valve, inoperable following
equilibrium temperatures because differential expansion of the gate and body can
allow the gate to be too deeply seated and cause it to bind when it is cooled down. In
extreme cases of thermal shock, equipment may no longer be functional.
In order to minimize the effect of thermal shock on valves and equipment, the
operators should ensure that systems are slowly heated or cooled during manual plant
startup or shutdowns. Slow plant heatup using warming or bypass lines may be
required. Standby systems may be brought in to operation slowly to provide for mixing
of fluids having different temperatures.
Column Separation: Column separation occurs in piping when the vertical water column
cannot be supported by upward pressure of an idled system (approximately 30 feet
(9 m) for cold water). If a pump stops and a leaky check valve at the pump discharge
allows back-leakage, the water column will separate, forming a vacuum void. Upon
restart of the pump, water hammer will occur if the system logic does not provide for a
slow opening pump discharge valve to allow slow filling of the void. Another method
of solving the problem is to provide low leakage tilting disc check valves in the vertical
pipe run to reduce the column length to less than a separable length.
upstream of the relief valve, while the downstream forces vary depending on the
system parameters. For example, if the downstream piping is empty and the liquid
does not flash, downstream piping segments will experience relatively small forces (F,
in pounds) due to momentum change at each elbow equal to AV where is the
density of the liquid in slugs per cubic feet, A is the pipe area in square feet, and V is
the liquid velocity in feet per second. When the downstream piping is filled with liquid
or with liquid slugs, significant downstream forces may occur. A transient analysis
should be considered for all possible significant forces, upstream or downstream.
If the relief valve has superheated liquid upstream, a special two-phase flow analysis
should be considered for the affected portions of the piping, including the valve,
because these forces could become quite large.
Another special relief valve application exists when steam discharge is preceded by a
loop seal water slug. This example often occurs in pressurized water reactor plant
pressurizer safety valves where high pressure (2,500 psia or 17.24 MPa) steam drives a
subcooled slug of water through the valve and then into the discharge piping, creating
severe forces in the piping. Generally, this is still the AV case, but the velocity of the
slug may approach 400 feet/second (120 m/sec).
Steam safety valves usually create modest forces in closed piping systems after flow is
established, but will create significant discharge forces at the discharge pipe in an open
system. This discharge force is sustained and will build up if the upstream pressure
increases due to accumulation. An open pipe inside a drip pan assembly should also be
treated as an open discharge. The discharge force is the combined PA + AV, where P
is the pressure in the exit pipe and other variables are as noted above.
Check Valve Fluid Transients: The operating characteristics of check valves affect their
individual response to various fluid transient conditions. For example, swing check,
tilting-disc check, and double-disc check valves generally close very quickly after the
flow reverses in direction. Lift check valves have a controlled closure rate, which
usually means that closure follows the flow reversal by a predictable time.
There are two applications where check valves induce significant fluid transients. The
most common application is where two or more pumps, each of which has a discharge
check valve, combine into a common header. When one pump trips and one or more
pumps continue to operate, sudden closure of the check on the discharge side of the
tripped pump sends pressure waves throughout the piping system. When a check valve
is closed just before or very close to the start of flow reversal, water hammer will not
occur or will be negligible. Swing check valves cause the most severe transients because
of the relatively long distance and time to travel to the seat. Silent or lift check valves
cause the least severe transients because of their relatively short distance and time to
travel to the seat.
15-12
The second application is less common but may produce a more severe transient.
Typical of the second case is the use of a check valve to protect a system following a
postulated pipe rupture. Designing for transients of this type is common for nuclear
power plants. For example, a postulated rupture of the main feedwater piping,
upstream of a check valve in a line to the steam generator, will create severe loads on
the check valves, which close rapidly to contain the reactor or steam generator
inventory.
Other applications of single in-line check valves usually do not cause significant
transient loads when flows stop in the system. However, the system analyst should be
sensitive to possible transients if a particular check valve can be forced to close
suddenly due to system back pressure because the closure may create high pressure
flow reversals.
Power-Operated Valve Fluid Transients: Motor-operated, air-operated, and other standard
closing valves typically do not create significant fluid transients. However, there are
several cases that require consideration in a power plant. The main turbine trip
isolation valve, which closes in approximately 100 milliseconds following a turbine
trip, can create significant fluid transients. When the turbine trips, the governor valves
close as rapidly as possible, without dependence on any steam isolation valves. The
rapid closure of the governor valves leads to extremely large loads in the main steam
piping. The fast operating steam bypass valves to the condenser should be also
evaluated.
Most isolation or control valves 6 inches (150 mm) in diameter or less, with operating
times greater than 5.0 seconds, will not require analysis for transient loads. Valves that
close more quickly should be considered possible fluid transient producers.
Additionally, valves that open in less than 2.0 seconds should also be evaluated.
Isolation or control valves of sizes larger than 6 inches in diameter, in general, require
careful review to determine if transient analysis is required.
The following sections identify some of the environmental and natural phenomena that
should be considered in valve selection and system valve design.
Chemical fluid (for example, boric acid) from leakage of nearby piping.
Salt air
Dripping seawater
Caustic NaOH (Valves inside containment only) - containment spray after LOCA or
main steam line break.
Humidity: Valves in high humidity areas, particularly inside the containment, should
include humidity as a factor in material selection for both valves and power actuators.
Radiation Exposure: When valves are located in radiation areas, the radiation exposure
expected to be received by the valve over the life of the plant must be included when
considering the use of any nonmetallic parts that may deteriorate under high radiation.
These nonmetallic parts may include gaskets, O-rings, packing, linings, diagrams, seals,
15-14
and soft seats. The radiation exposure to be considered in selecting a specific part is a
function of several variables. The source, source strength, distance from the source,
length of exposure time, radiation type (generally only gamma and beta are of
concern), and radiation shielding provided are generally considered.
Regardless of the radiation source, radiation level, or the material being used, safetyrelated valves must be designed so that their safety function is not impaired by the
degradation of nonmetallic parts over the life of the valve. Therefore, the radiation
exposure used in the evaluation of the suitability of valve material must be the sum of
the normal service design life dose plus the accident dose. The total exposure should
consider, as a minimum, radiation exposure from the contained fluid, direct radiation
from adjacent radioactive lines or equipment, and external harsh environment,
primarily inside the containment following a plant emergency or faulted conditions.
In selecting nonmetallic parts, it is necessary to select materials preferred under normal
conditions without radiation (avoiding materials such as Teflon that have a very low
tolerance for radiation). The radiation tolerance of the properties (for example, tensile
strength, compressibility, etc.) of these materials is then compared to the total 40 year
normal dose plus full accident dose. If the tolerance exceeds the exposure, the material
is satisfactory, and no additional evaluation is involved. Most valves located outside
the containment will pass this evaluation if the internal fluid is not reactor coolant from
the containment sump or some other very radioactive source.
If the evaluation of the material choices is not satisfactory for the radiation conditions,
systematic evaluation of the factors that determine the actual dose to the specific valve
part will be required. It may be possible to qualify the valve for operation over the life
of the plant by:
Decreasing the time interval between replacement of the specific valve part
Invariably, a few valves (usually inside containment) will require detailed evaluation
of all effects, including possible modification of valve design, use of a different type of
valve, increased maintenance or replacement of nonmetallic parts, or relocation of the
valve to satisfy mechanical environmental qualification. An example of qualification by
functional evaluation is the soft seat of the accumulator relief valves, which must resist
harsh LOCA conditions for only a few minutes. Since the accumulators perform their
15-15
safety function (that is, they discharge) within minutes of a LOCA, the relief valve has
no further function. However, soft-seated containment isolation valves must remain
leak-tight for the design basis duration of the accident, plus a 10% margin.
Where it is cost effective, the radiation concerns identified above should be applied to
all valves in radiation areas.
Tornadoes, Hurricanes, and High Wind: Depending on the design of the plant, these
environmental hazards could affect valves in a number of ways. For example:
Structural integrity.
Motor operators could suffer from grease migration into limit switches.
The set point of safety/relief valves will be affected by the pressure difference.
Seismic (Earthquake): Valves that are required to withstand the effects of an earthquake
must be designed to accept those forces and moments when supported by inlet and
outlet connections only and to ensure the ability of the valve and system to maintain
pressure boundary and/or operability (for example, no binding). The weight of the
valve assembly, the size and configuration of the operator with respect to the valve,
and the orientation of the operator are of concern to the stress engineer. A small valve
with a large and heavy operator is of special concern due to amplification of seismic
loads. The use of socket-welded valves should be minimized in seismic systems due to
difficulty in qualifying these joints.
An active valve that must operate during or after a seismic event is required to be
tested for operability under simulated seismic conditions prior to delivery. The design
of the valve, yoke, and actuator assembly should exhibit a relatively high natural
frequency (greater than 33 hertz) to avoid amplification on the seismic acceleration.
Flooding: Flooding can be caused by natural external sources (dam failure; lake, river, or
coastal flooding; extreme rainfall, tidal wave) or by internal sources, generally due to
an operator error (most likely) or a line break (unlikely, but part of the design basis for
a nuclear plant). The effect on valves is the same from either source. Flooding
submergence is not likely to have an adverse short-term effect on a manual valve unless
15-16
it normally operates at a high temperature and the chill shock could damage it. If an
electric (motor- or solenoid-) or air-operated valve could be submerged, the electrical
device and power supply or the control air circuit must be watertight. This is the case
even if the valve is a passive valve that is required only to maintain position, rather
than change position (otherwise, a short circuit due to flooding could cause an
undesired change of position).
Regardless of the event or combination of events, a valve should be designed to
maintain its pressure boundary. Additionally, if required for reliable system operation
or plant shutdown, the valve should be designed for normal operation during the
design basis event.
Although the design requirement may not be as stringent in some cases for nonnuclear-related piping systems, the most severe operating cases expected during plant
operation should be considered in valve design and selection.
15-17
Relief, safety, and safety-relief valves are inherently fast acting valves. The speed of
operation must be compatible with system operating requirements.
Speed of operation for many valves depends on the valve load and actuator power (air,
hydraulic, or electric). The speed of operation under test conditions may not be the
same as under design basis conditions. Changes in the required actuation thrust/torque
(due to changes in the valve pressure drop, friction, or packing load) and changes in
actuator output (due to reduced voltage, air/hydraulic pressure or gear efficiency) can
significantly alter the stroke time.
15-18
Some valves, particularly those in steam service, cannot tolerate any significant amount
of seat leakage without possible damage to the seats due to steam cutting. Control
valves usually do not perform an isolation function, and seat leakage is not a concern.
16
PRESSURE CONTAINMENT AND STRUCTURAL
INTEGRITY REQUIREMENTS
16.1 Introduction
Valves must be constructed not only to provide pressure containment, but also to be
structurally secure under all loading conditions over and above internal fluid pressure
loads. Industry codes and standards provide extensive design rules and guidance for
valve design (see Section 22.6). These codes and standards provide the necessary rules
for establishing such design requirements as wall thicknesses for pressure boundary
parts, end connection configuration, and accepted materials, along with their allowable
stresses. Industry codes and standards do not provide design rules for non-pressure
boundary parts critical to valve operation such as valve yokes, gaskets, and packing.
American Society of Mechanical Engineers (ASME Boiler and Pressure Vessel Code)
For nuclear plants, the codes and standards most frequently used for valve design are
the ASME Boiler and Pressure Vessel Code, Section III, Nuclear Power Plant
Components; and ANSI B16.34. A chronology of the development of the major codes
and standards is presented below and summarized in Table 16-1.
Table 16-1
Valve Design Codes
Valve Type/Function
Code or Standard
Applicable Dates
MSS-SP-66
ASME III
ANSI B16.5*
ANSI B16.34*
*as invoked by ASME III
(Note 1)
(Note 2)
1971 on
up to 1977
1977 on
ASME I
ANSI B16.5*
ANSI B16.34*
*as invoked by
ASME I (Note 1)
1914 on
up to 1977
1977 on
ANSI B16.5
ANSI B16.34
Up to 1973
1973 on
Notes:
1.
ANSI B16.34 provides the pressure-temperature rating, as well as requirements for minimum wall thickness, materials,
marking, dimensions, and testing. ANSI B16.5 provides the pressure-temperature rating, minimum wall thickness, and outlines
the requirements for testing.
2.
ASME III applies to nuclear safety-related valves. The earlier editions of ASME III referred to ANSI B16.5 or MSS-SP-66
primarily for pressure-temperature ratings and wall thickness, but retained the rules for materials, design, examination, and
testing. The current ASME III refers to a large extent to ANSI B16.34 for valve requirements, but it still retains design rules,
special material requirements, and special nondestructive examination requirements.
16-2
The earlier editions of ASME III relied on ANSI B16.5 and/or MSS-SP-66 for
pressure/temperature ratings and wall thickness but retained the rules for materials,
design, examination, and testing. Currently, ASME III refers to ANSI B16.34 for most
valve requirements. ASME III still retains design rules, special material requirements,
and special nondestructive examination requirements.
In addition to providing rules for nuclear plant valve design, ANSI B16.34 applies to
nuclear balance-of-plant valves and to fossil plants. For these applications, other
standards also have been used for the design of valves. Table 16-2 identifies other
standards that might be applied to the design and/or selection of valves to be used in
non-nuclear valve applications.
Table 16-2
Typical Valve Standards
Standard No.
Title
AWWA-C504
API-602
MSS-SP-67
Butterfly Valves
MSS-SP-70
MSS-SP-72
Ball Valves
MSS-SP-80
MSS-SP-84
MSS-SP-66
MSS-SP-71
MSS-SP-85
Bronze Valves
For older plants, ANSI B16.5 provided primary guidelines, and MSS-SP-66 provided
alternative guidelines for the design of butt weld end valves. When ANSI B16.34 was
issued, the thrust of MSS-SP-66 was incorporated as special class valves (that is,
nondestructive examination such as radiography allowed a higher pressure for a given
temperature), and MSS-SP-66 was withdrawn.
Special consideration should be made if these or any other utilized standards are not
included in Table 126.1 of ANSI B31.1.
The above referenced standards provide many of the design rules for valves. However,
they do not address non-pressure containing functional components or internal parts
for non-nuclear valve applications. For nuclear valves, the requirements for internal
parts have been given only a limited formal design approach for class 1 valves by
ASME III, Subarticle 3500. In order to properly address ASME code class 2 and 3
16-3
valves, ASME code case N62-4 was issued providing rules for materials, design,
fabrication, inspection, and examination of internal and external valve parts. Prior to
use, the code case should be consulted for the full scope of items covered. Code cases
are optional. Code case rules become mandatory only if a purchaser invokes its
requirements on a manufacturer, and then the entire code case is mandatory. Code
cases are periodically reviewed, at which time they are reaffirmed or annulled. Code
cases are annulled when the requirements have been incorporated into the code (that is,
ASME III) or when the code case is no longer needed.
The categorization of nuclear safety-related equipment, including valves, is determined
by referring to ANSI/ANS-51.1 (formerly ANSI N18.2, Nuclear Safety Criteria for the
Design of Stationary Pressurized Water Reactor Plants), ANSI/ANS-52.1 (Formerly
ANSI N2.2, Nuclear Safety Criteria for the Design of Boiling Water Reactor Plants),
Code of Federal Register (10CFR50.55a), and U.S. NRC Regulatory Guide 1.26 (Quality
Group Classifications and Standards for Water, Steam, and Radioactive-WasteContaining Components of Nuclear Power Plants). It should be noted that ANSI/ANS51.1 and ANSI/ANS-52.1 are currently undergoing revision and will result in a new,
combined standard, ANSI/ANS-50.1.
The following safety classes and the basic standards that apply to them are given in
Table 16-3. Consult 10CFR50.55a, Regulatory Guide 1.26, and ANSI/ANS-51.2 and 52.1
for complete definitions.
Safety Class 2 is for components that form part of the reactor coolant pressure
boundary but may be excluded from Safety Class 1 by provisions of 10CFR50.55a,
or those that are necessary for safe shutdown of the reactor or to maintain the
reactor in a safe condition.
16-4
Table 16-3
Safety Classes and Applicable Standards
Safety Class
1
l0CFR50.55a
Reactor Coolant
Pressure Boundary
(referred to as
Quality Group A in
Reg. Guide 1.26)
Remarks
ASME III Cl 1
Quality Group B
ASME III Cl 2
Quality Group C
ASME III Cl 3
NNS*
Steel, Nickel Alloy, and Other Special Alloy Valves: ASME III, ANSI B16.34 (see
Table 16-4)
Bronze Gate, Globe, and Check Valves: MSS-SP-80 (see Table 16-6)
16-5
A155-KCF70 (e)
A350-LF2 (d)
A675-70
A 155-KC70 (e)
A216WCB (a)
A 515-70 (a)
NOTES:
(a) Permissible, but not recommended for prolonged usage above about 800F (425C).
(d) Not to be used over 650F (340C).
(e) Not to be used over 700F (370C).
(g) Not to be used over 850F (450C).
STANDARD CLASS VALVES-FLANGED AND BUTT WELDING END
Temp. F
300
400
600
900
1500
2500
4500
-20 to 100
285
740
990
1480
2220
3705
6170
11110
200
260
675
900
1350
2025
3375
5625
10120
300
230
655
875
1315
1970
3280
5470
9845
400
200
635
845
1270
1900
3170
5280
9505
500
170
600
800
1200
1795
2995
4990
8980
600
140
550
730
1095
1640
2735
4560
8210
650
125
535
715
1075
1610
2685
4475
8055
700
110
535
710
1065
1600
2665
4440
7990
750
95
505
670
1010
1510
2520
4200
7560
800
80
410
550
825
1235
2060
3430
6170
850
65
270
355
535
805
1340
2230
4010
900
50
170
230
345
515
860
1430
2570
950
35
105
140
205
310
515
860
1545
1000
20
50
70
105
155
260
430
770
16-6
300
400
600
900
1500
2500
4500
-20 to 100
290
750
1000
1500
2250
3750
6250
11250
200
290
750
1000
1500
2250
3750
6250
11250
300
290
750
1000
1500
2250
3750
6250
11250
400
290
750
1000
1500
2250
3750
6250
11250
500
290
750
1000
1500
2250
3750
6250
11250
600
275
715
950
1425
2140
3565
5940
10690
650
270
700
935
1400
2100
3495
5825
10485
700
265
695
925
1390
2080
3470
5780
10405
750
240
630
840
1260
1890
3150
5250
9450
800
200
515
685
1030
1545
2570
4285
7715
850
130
335
445
670
1005
1670
2785
5015
900
85
215
285
430
645
1070
1785
3215
950
50
130
170
260
385
645
1070
1930
1000
25
65
85
130
195
320
535
965
16-7
Table 16-5
Cast Iron Gate Valve Ratings
Source: MSS-SP-70.
(Used by Permission of Manufacturers Standardization Society)
Class
125
250
800 Hyd
Temp
Degrees F
NPS
2-12
NPS
14-24
NPS
30-48
NPS
2-12
NPS
14-24
NPS
2-12
-20 to 150
200
150
150
500
300
800
200
190
135
115
460
280
225
180
130
100
440
270
250
175
125
85
415
260
275
170
120
65
395
250
300
165
110
50
375
240
325
155
105
355
230
350
150
100
335
220
375
145
315
210
400
140
290
200
425
130
270
450
125
250
16-8
Table 16-6
Bronze Gate, Globe, and Check Valve Ratings
Source: MSS-SP-80.
(Used by Permission of Manufacturers Standardization Society)
Pressure Class
End Connection
Temp(1)
degrees F
-20 to 150
200
250
300
350
400
406
450
500
550
125
THD
200
185
170
155
140
-125
120(4)
---
150
THD
FLG(2)
ASTM B-62
300
270
240
210
180
-150
145(4)
---
225
210
195
180
165
-150
----
Pressure psi(3)
200
300
THD
THD(5)
MATERIAL
400
375
350
325
300
275
-250
225
200
1,000
920
830
740
650
560
-480
390
300
THD
FLG(2)
350
THD
ASTM B-61
600
560
525
490
450
410
-375
340
300
500
475
450
425
400
375
-350
325
300
1,000
920
830
750
670
590
-510
430
350
Notes:
1. For lower temperatures, see Paragraph 2.5 in MSS-SP-80.
2. P-T Ratings - ANSI B16.24
3. Refer to Paragraph 2.4 for safe P-T rating for solder-joint pipe systems.
4. Some codes (that is, ASME BPVC, Section I) limit the rating temperatures of the indicated material to 406F (208C).
5. Alternate ratings for valve size 1/8 - 2 inches (3 - 50 mm) having threaded ends and union ring body-bonnet joints.
Prior to determining the rating of a valve, a determination of the ANSI pressure class
must be made. The class is based on the design and operating conditions of the system
(that is, temperature and pressure). After the ANSI pressure class is determined, it
must be recognized that other conditions may limit the valves final rating. Valves with
elastomeric or plastic gaskets, packing, or seating elements may not meet the entire
range of pressure-temperature conditions for their designated pressure class.
ANSI B31.1 rules for non-nuclear valves provide no specific allowance for excursions of
operating pressure or temperature above design condition values. The maximum
design pressures and temperatures are established by the pressure/temperature tables
previously referenced.
The user of this document should refer to the codes or standards and addenda
applicable to the particular plant to determine the code provisions, if any, that permit
allowance for variations from design conditions.
16-9
Current editions of several codes and standards now permit the operating pressure to
exceed the design pressure by not more than 10% under conditions of relief or safety
valve operation. In addition, under certain conditions ASME III permits class 2 and 3
valves to operate at a higher pressure than that normally allowed for the attained
temperature. If the ASME criteria are allowed for these occasional transients, then other
sections of ASME III apply as appropriate. ANSI B16.34 also makes provisions for
departure from the standard pressure/temperature ratings.
The applicable code or standard should always be consulted when selecting a valve to
ensure that the system design pressure and temperature are enveloped by the pressure
temperature rating allowed by the applicable code or standard. When selecting the
pressure class of the valve, other considerations may apply such as pressure spikes due
to dynamic loads (for example, water hammer) or greater strength required to support
a heavy operator.
Special Class Valves: A special class valve is a standard class butt weld end valve for
which additional nondestructive examination (for example, radiography) is required,
thus permitting a higher pressure-temperature rating. Tables of acceptable pressure
and temperature are published in ANSI B16.34 for both standard class valves and
special class valves. For example, a class 600 carbon steel valve made from A216 WCB
may be used at 1,200 psig (8,274 kPa) at 500F (260C) as a standard class valve. The
same valve, when nondestructive examination is performed to merit the rating of class
600 special class, may be used at 1,500 psig (10,340 kPa) at 500F (260C).
This option can be valuable when the pressure and temperature allowed by B16.34
standard class do not meet the system requirements, but the special class does meet the
system requirements. A special class is sometimes cost effective and would not have the
higher fluid flow pressure drop associated with the higher pressure class valve.
Intermediate Rating Valves: ANSI B16.34 and ASME III specifies a minimum wall
thickness for each standard pressure class (that is, class 150, class 300) and inside
diameter of valve. When the actual wall thickness of valve exceeds the minimum wall
thickness specified for the standard pressure class and inside diameter but is less than
the specified minimum wall thickness for the next higher standard pressure class, ANSI
B16.34 and ASME III make provisions and provide formulae for determining an
intermediate pressure rating. This option requires higher hydrostatic test pressures
than the next lower standard pressure class and should be exercised by or through the
manufacturer.
Intermediate rating valves are used when system pressures and temperature exceed
those allowed for a standard pressure class and the wall thickness exceeds that
required for the standard pressure class. For example, a manufacturer may provide a
class 1878 valve for a PWR reactor coolant system where a standard class 1500 would
not suffice, but a standard class 2500 would far exceed the requirements.
16-10
This option is different from special class valves in that an additional wall thickness
above the minimum is required to allow a higher pressure-temperature rating for
intermediate rating versus additional nondestructive testing for special class.
16-11
16.3 Materials
16.3.1 Material Compatibility
Materials must be compatible with the fluid and with each other. Wetted materials
must be carefully considered. Bonnet bolting, for example, may be wetted by stem seal
leakage. It may be false economy to use a stainless steel body to resist boric acid
corrosion, yet specify carbon steel bonnet bolting.
It is important to avoid using materials of wide electrical potential difference.
However, it is not sufficient to consider only potential differences when evaluating the
corrosion rate of dissimilar metals in contact. The relative areas of dissimilar metals
must also be considered. If the surface area of the anode is large, the current density at
the anode will be small, and corrosion due to galvanic effects will be insignificant.
Thus, bronze trim in a steel valve is acceptable, in spite of the substantial potential
difference between bronze and steel. There is not enough area of the bronze trim to
accelerate the corrosion of the large area of the anodic valve body, but on the other
hand, it would be unwise to use a steel seat in a bronze valve (see Section 2.4 for
additional discussions).
Carbon steels
Low-alloy steels
16-12
Valve Part
Stainless
Steel Valves
Carbon
Steel Valves
Low Alloy
Steel Valves
Body/bonnet
ASTM A351,
Gr CF8 (304 SS)
ASTM A216-WCB
ASTM A217-WC6
(1-1/4 Cr, 1/2 Mo)
Disc/wedge
ASTM A351,
Gr CF8M (316 SS)
ASTM A216-WCC
ASTM A217-WC9
(2-1/4 Cr, 1 Mo)
Forgings
ASTM A105
ASTM A182-F304L,
F316L
ASTM A350-LF2
ASTM A515GR70
ASTM A516GR70
ASTM A193, Gr B7
ASTM A194, Gr 2H
ASTM A193, Gr B7
ASTM A194, Gr 2H
ASTM A193, Gr 16
ASTM A194, Gr 4
Plate
* Although sometimes provided, these materials are not appropriate for stainless steel valves due to their potential for
corrosion.
** Not recommended for threading into 304 or 316 bodies, as galling may occur.
16-13
16-14
Low cost
Disadvantages:
Low cost
Disadvantages:
Limited in temperature and pressure (The limits are normally 350 psig (2,413 kPa)
at 550F (288C), up to 1,000 psig (6,895 kPa) at 150F (66C), depending on the alloy
used, pressure rating of the valve, and the method of installation, that is, threaded,
flanged, soldered, or silver brazed.)
Moderately priced
16-15
Disadvantages:
Should never be used for any trim parts, except base material for the disc, which is
overlaid with corrosion-resistant material at the seat
Chrome-moly - ASTM A217, Gr WC6 and WC9, are low alloy steels and not stainless
steels.
Advantages:
Disadvantages:
Stainless steel - ASTM A351, Gr CF8 (304 SS), or ASTM A351, Gr CF8M (316 SS)
Advantages:
Disadvantages:
16-16
There are many more alloys available that are generally used because of their own
particular resistance to various fluid chemistries, such as aluminum bronze (ASTMB148), bronze (ASTM-B61), alloy 20 stainless steel (ASTM-A35a, CN7M), Monel
(ASTM-A494, M-35), and Inconel (ASTM-A494, CYAO).
16.3.4 Special Considerations for Material Selection for Valves in Raw Water,
Especially Seawater
This section provides an overview of material selection considerations for valves in raw
water service including candidate materials and a brief discussion of microbiologically
induced corrosion.
Material Selection: The service conditions that need to be identified prior to selection of
materials for raw water service are:
Fluid chemistry, including bacterial analysis; and flow velocity range, including
possible stagnant conditions
Chemical additives or treatment to control fouling and/or limit bacteria that may
result in microbiologically induced corrosion (MIC)
Candidate Materials: The selection of appropriate materials of construction for fluidwetted components of the valves depends upon the design basis service conditions and
the corrosion allowance. Some candidate materials and their technical limitations or
performance concerns are:
Carbon steel or cast iron - Corrosion rates must be determined for the site-specific
application and integrated into the valve design as a corrosion allowance for wetted
surfaces. Trim should be corrosion resistant or coated with appropriate material.
Carbon steel or cast iron is generally not suitable for seawater service.
Lined carbon steel or cast iron - Elastomeric (natural rubber, BUNA-N, EPDM)
materials or multifunctional epoxy resin (MFER) linings can be applied to allow
seawater service. High maintenance costs and downtime may result from holidays
and/or pinholes in the lining and separation of the lining from valve components.
16-17
Plastics or reinforced plastics - Jointing requires special care and attention to obtain
leak-tightness. Ultraviolet stabilizers are required for outdoor above-ground
applications of reinforced plastics to avoid embrittlement degradation.
300 series stainless steels - 300 series stainless steels are susceptible to severe
localized corrosive attack in slow moving or stagnant fluids. Sediment deposits or
bacterial colonies impede the supply of oxygen to the metal surface, which causes it
to lose passivity and resistance to pitting attack. Increases in velocity above 5 ft/sec
result in less fouling. Stainless steels and other nickel-bearing alloys maintain their
passive layers and corrosion resistance at higher velocities. Crevice corrosion can
also occur in the 300 series stainless steels.
High nickel alloys -Monels, Inconels, Incoloys, and Hastelloys are suitable for
seawater applications, although they can pit under certain conditions.
Titanium - Appropriate for seawater service but can foul without proper treatment,
and can pit at temperatures above 250F (120C). Fabrication by welding can be
difficult. Degradation of titanium due to MIC is unreported.
System Design Pressure (Pd), System Design Temperature (Td), and Valve
Pressure Class, Size (diameter), and Material
Find:
Corrosion Allowance CA
16-19
Step 1
Enter the appropriate pressure-temperature rating from Table 2 of ANSI B16.34 at the
design temperature (Td), and determine the pressure rating of the valve for the valve
pressure class and the next lower valve pressure class. Call these pressures P2 and P1,
respectively.
Step 2
Enter Table 3 of ANSI B16.34 at the valve diameter (d) and determine the valve body
minimum wall thickness for the valve pressure class and the next lower valve pressure
class. Call these thicknesses t1 and t2, respectively.
Step 3
The required valve body minimum wall thickness (tm) at the design pressure (Pd) and
design temperature (Td) may be found by interpolation from:
t m = t1 +
Pd P1
(t 1 t 2 )
P2 P1
Step 4
The corrosion allowance CA is then:
CA = t 2 t m =
P2 Pd
(t 2 t 1 )
P2 P1
Example. Consider a check valve at the discharge of the main feedwater pumps for a
PWR. Typical valve parameters are:
Design pressure Pd = 1650 psig
Design temperature Td = 460F
Size = 16 inch/class 900
Material = SA350-LF2
Determine the corrosion allowance CA.
16-20
Step 1
From Table 2-1.1 (ANSI B16.34)
Class 900 P2 = 1837 psig @ 460F
Class 600 P1 = 1228 psig @ 460F
Step 2
From Table 3 (ANSI B16.34)
Class 900 t2 = 1.77 inch @ 16 inch diam
Class 600 t1 = 1.18 inch @ 16 inch diam
Step 3
The valve body minimum wall thickness is
t m = t1 +
Pd P1
(t 1 t 2 )
P2 P1
t m = 1.18 +
1650 1228
(1.77 1.18)
1837 1228
t m = 1.59 inches
Step 4
The corrosion allowance is
C A = t 2 t m = 1.77 1.59
C A = 0.18 inch
The result in this example is that an installed valve could have a local or general loss of
wall material up to 0.180 inch and still meet code requirements. If we further postulate
a loss rate of 0.02 inch per year (a high rate), the valve body would last nine years in
that particular application before the allowed code minimum wall was reached. If this
rate were known one to two years in advance of the nine-year point, the valve body
could be replaced or repaired as a routine outage item. An alternative to this would be
to include a higher rated valve or use a different alloy to extend the life of the valve to
match the life of the plant.
16-21
Threads
Welding
Brazing
Soldering
These types of end connections are most commonly used on valves, although not all of
them are suitable for all piping materials or services.
Pipe threads
Malleable - Iron Thread Fittings, 150 and 300 lb
Cast Iron Threaded Fitting, 125 and 250 lb
Forged Steel Fittings, Socket Welding, and Threading
Cast Bronze Threaded Fittings, 125 and 250 lb
The joint is basically self-aligning as pipe end slips into pipe and the joint is
supported by the pipe.
A disadvantage to socket welds in dirty or contaminated systems is that they may trap
radioactive particles. In addition, they represent a high stress concentration and may
cause stress qualification problems in ASME III systems.
Figures 16-1 and 16-2 show butt weld and socket weld end configurations.
Applicable Standards:
ANSI B16.25 - Butt Welding Ends
ANSI B16.11 - Forged Steel Fittings, Socket Welding, and Threading
16-23
Figure 16-1
Butt Weld End Connection
Figure 16-2
Socket Weld End Connection
16-24
Wafer or flangeless. The valve is held in position between the inlet/outlet pipe
flanges, using through bolting.
16-25
Lug. The same as above except that there are lugs on the valve body.
Single flange. The same as lug type except inlet and outlet faces of body are
provided with tapped holes.
Figure 16-3
Butterfly Valve End Connections
Applicable Standards:
ANSI B16.1 -
ANSI B16.5 -
Steel Pipe Flanges and Flanged Fittings, 150, 300, 400, 600,
900, 1500, and 2500 lb, including reference to valves
ANSI B16.24 -
MSS SP-44
16-26
16-27
16.6.3 Leakage
System leakage should always be evaluated in consideration of whether the fluid is
hazardous or corrosive. Flammable fluid leaks could pose a fire hazard. Boric acid
leaks are of particular concern in a PWR plant because of the rapidity with which boric
acid can corrode carbon steel over which it may trickle from a stem leak of a stainless
steel valve. All reactor water in a PWR plant contains boric acid. Leakage that collects
or dribbles on a warm surface will become concentrated as the water evaporates.
Concentration may increase to the point at which the boric acid precipitates as crystals
on the warm surface. Corrosion will continue underneath the crystals so long as
moisture, even in the form of humid air, is present.
Leakage of radioactive fluids always presents a hazard that must be considered. If the
fluid is highly radioactive, packless valves are generally used.
16.6.4 Vibration
It is prudent to consider that all valves in the plant will be subject to vibration.
Vibration may be transmitted to the valve through piping connected to rotating
equipment, or it may result from hydrodynamic forces in the valve itself or in adjacent
piping. By itself, vibration of such small amplitudes is not a problem requiring
correction, but it could cause loosening of attachments and often complete separation.
Screwed connections of any kind require positive locking to prevent unscrewing or
complete separation of the mating pieces.
A positive locking device is one that does not depend (in any way) on friction to
perform its function. Thus, a split washer is not a positive locking device; a castellated
nut with a split pin is a positive locking device. Taper pins are not positive locking
devices. Small beads of weld metal intended to secure a pin can crack from vibration or
thermal cycling. Upset threads depend on friction.
Many examples exist of such failures leading to valve damage or worse. This is
especially the case when the loose fastener is not observable because the valve is
inaccessible (for example, inside the containment), or the fastener is inside the valve
body, or inside the housing of a valve operator.
Reference 1.20 gives a detailed discussion of check valve locking devices. Vibration
considerations must also include checking that the vibration frequency does not match
the resonant frequency of the piping. Vibration can also cause fatigue failures in
components with high stresses.
16-28
16-29
Seat leakage testing criteria and operability testing criteria should be specified by the
user. ASME Sections I and VIII (non-nuclear) require, on valves exceeding 1 inch (25
mm) or 300 psig (2,069 kPa) set pressure, an inlet hydrostatic test of at least 1.5 times
the design pressure and an outlet test for closed bonnet valves used on closed system
applications at a minimum of 30 psi air (207 kPa). These sections also specify set point
testing requirements and seat leakage testing requirements. ANSI Standard B147.1 (API
Standard RP-527) is a commonly used standard to clarify testing methods and tightness
standards.
Mechanical joining (and locking) of components (for example, disc to valve stem
joint, valve stem to actuator stem joint)
Structural members that support and join the valve actuator to the valve proper
Some of these areas have already been discussed in the text of this report as well as in
other publications. Reports of valve malfunctions in power plants, however, continue to
show problems with stem seal leakage, bonnet gasket leakage, separation of the valve
stem from the valve disc, broken yokes, and bent stems. Recent regulatory and industry
efforts significantly reduced such failures.
Valve stem seals are discussed in Section 2.5.2, and the reader is encouraged to examine
this information.
Gaskets for use in circular body to bonnet or similar connections of the valve should be
provided with a gasket width comparable to those used in pipeline flanges of
comparable size, type, and service rating. Gaskets of marginally adequate width may
successfully pass shop hydrostatic tests without leakage but may result in maintenance
problems during actual service.
16-30
Expansion of piping segments on both sides of a valve can cause binding of the valve
internals and increase the thrust/torque requirements to open/close the valve. Thus,
piping forces and moments should be taken into account in procurements of new
valves and evaluations of existing valves.
The load carrying capability of mechanical joints of valve components should exceed
the capability of the components being joined.
Valves provided with power actuators, particularly those actuators of large weight,
extended mass and high thrust/torque output should be evaluated to ensure the
adequacy of the valve yoke to support the actuator and the maximum force it can
impose on the valve and the adequacy of the valve stem to accept this loading,
particularly in a column buckling mode (for example, large gate valves). The design of
the valve yoke should be evaluated to ensure that its natural frequency, as assembled in
the valve, exceeds 33 hertz. This evaluation can be performed using a classical
spring/mass determination of its frequency. In achieving this requirement, the
proportions of the yoke should be adequate for the applied compression, tension, and
shear loads. The proportions of the valve stem and the location of guides should be
evaluated for column buckling.
16-31
17
VALVE MAINTENANCE AND INSPECTION PROGRAMS
17.1 Introduction
The U.S. electric power industry is under ever-increasing pressure to improve plant
efficiency, shorten plant outages, and cut costs, which means fewer people and
resources. In this environment, the burden is on plant maintenance personnel to
improve the efficiency of repair and maintenance activities. Valve maintenance groups,
in particular, will be under extreme pressure to keep the plant on-line.
With the recent activities to satisfy regulatory commitments such as GL 89-10, GL 95-06,
GL 96-07, etc., many valves were subjected to extensive testing, increased actuator
output thrust/torque, and various modifications in the valves as well in the actuators.
These activities will put even more pressure on the plant maintenance groups to
improve efficiency and productivity.
Furthermore, the changes in regulatory requirements, the evolution of design codes
and new technologies, combined with aging of some plants will increase the
responsibilities of the valve maintenance groups in nuclear power plants. For example,
in order to reduce the risk of plant personnel exposure to radiation, cobalt-free alloys
are being developed to replace cobalt-based alloys (such as Stellite 6). As this
technology matures and gets industry approval, utilities may decide to replace Stellite 6
seats in many valves with the new cobalt-free material, which will add to the
responsibilities of the valve maintenance group.
The objective of this section is to address the valve maintenance programs within
electric utilities in anticipation of the upcoming scenarios. This guide can provide only
general recommendations on programmatic considerations and minimum maintenance
requirements for valves (within the scope of the guide) because most power plants have
different management styles and spare-part inventory requirements. This section
provides some recommendations for plant management and engineering to consider in
upgrading or maintaining their valve maintenance and inspection programs.
References 5.20 through 5.24 provide recent experiences in nuclear power plant
maintenance programs.
17-1
17.2 Definitions
Some of the most commonly used definitions in the maintenance field and in this guide
are given below.
Maintenance. All activities performed on equipment in order to maintain or restore
their operational functions (corrective or preventive).
Corrective Maintenance (CM). Tasks performed to restore functional capabilities of
failed equipment - diagnosis and repair.
Preventive Maintenance (PM). All activities performed on equipment to avoid or
reduce the probability of failure.
Periodic Preventive Maintenance. Maintenance actions initiated as a function of time,
regardless of the actual condition, including life limit (discard) tasks (scheduled
replacements) and overhauls (scheduled rework).
Condition Directed Preventive Maintenance. Actions initiated as a result of equipment
condition assessment and comparison with defined acceptance criteria. This includes
surveillance tasks as in-service inspection (ISI), in-service testing (IST), and monitoring
and diagnostics (predictive maintenance).
Predictive Maintenance. Assesses the status of equipment or system degradation
through correlation with one or more parameters.
Conditional Overhaul. Restoration of equipment to a reliable condition, undertaken
when the acceptance criteria are no longer met.
Reliability Centered Maintenance. Based on identifying equipment/system functions,
functional failures, and dominant failure modes to develop or revise PM tasks.
17-2
Design type
17-4
Age
Industry
17.3.3 Scope
The scope of a good valve maintenance program should include both safety-related and
non-safety-related valves. Valves that are not essential to plant operation and safety are
typically given lower priority and eventually may require more resources to repair. A
good maintenance program must also address other elements such as spare parts
inventory, personnel training, and special tools, as discussed below. The following
discussions are equally applicable to valve actuators because they are essential for
valve operation.
17-5
Valve maintenance groups should frequently attend in-depth technical training and
short courses (such as those offered by NMAC and equipment manufacturers
including valves, actuators, and diagnostic equipment).
Scheduling and coordination engineer who interfaces with operations and other
groups in the plant
Outside contractors and temporary task force personnel should be under direct
supervision from the valve maintenance group.
17-6
Valve maintenance group personnel must have accountability, ownership, and longterm commitment to their duties.
The performance history of the valves or valve groups considering the application,
flow conditions, media, the manufacturer, the valve design, etc.
Valves can be categorized and prioritized for maintenance and repair using various
approaches. One approach is to divide the valve population into three groups, as
follows:
Group 1
Group 1 consists of the valves that require mandatory actions, regardless of other
activities. This group includes valves that have special requirements for maintenance
because of operating license, safety reasons, or government regulations, or occasionally
due to manufacturer warranty requirements (for example, turbine stop valves).
Preventive maintenance or inspections must be performed on these valves. The valves
within this group can be identified using:
FSARs
17-7
Technical specifications
NRC bulletins
Insurance requirements
Manufacturer warranties
Group 2
Group 2 consists of the valves that typically have experienced a high rate of failures,
caused a loss of plant availability, have high corrective maintenance costs, or have
safety problems including release of radiation. Plant maintenance history records are a
good source of information, as is experience gathered from other plants. Plant records
would help to identify the types of failures and frequencies being experienced by the
plant, and the consequences of each failure, including impact on plant power
production, out-of-service time, hours to repair, spare parts required, causes of failure,
and the failure mechanisms involved.
Group 3
Group 3 includes valves that do not have a history of failures; however, their failure
would impact safety or significantly increase the operating cost through the loss of
plant production. Valves to be included in this group should be identified by plant
engineers based on analysis of the plant piping and instrumentation diagrams or other
pertinent documents.
It is clear that a large number of valves, especially small bore manual valves, will not be
included in these groups. They will mainly consist of vents, drains, miscellaneous
valves, and valves in systems not important from a safety and operational point of
view. Their maintenance will be basically a corrective type (that is, repair or
replacement of the affected part or a whole valve).
Another method of prioritization in use in the industry is a powerful tool for
establishing the cost consequence of valve failures. Logic models, such as those built
17-8
with availability block diagrams and/or fault trees, enable the maintenance engineer to
properly relate the likelihood of plant availability losses to component failure, even to
the level of component failure mode. These logic models, using such available
computer codes as EPRIs UNIRAM, provide a ranked criticality list based on failure
rates, forced outage rate, or plant availability loss contribution. Industry typical failure
rates can be used to establish an initial criticality list, which is gradually revised and
supplemented as plant-specific data become available. (It has been found, for example,
that some nonsafety-related equipment is highly important to plant availability.) These
model-generated criticality lists are more accurate than a simple categorization because
they include the effects of failures on other equipment as well as their direct effect on
the unit.
Spare parts, materials, tools, and procedures should be made available prior to
valve disassembly.
An ideal maintenance schedule would result in a reasonable and uniform work load
for the available work force. However, this is not always possible because many
maintenance/repair activities have to be completed during plant outages.
Scheduling should be coordinated with other groups in order to implement the one
trip concept where all activities can be performed in one trip to the valve.
Scheduling valves with similar designs for maintenance within the same timeframe
may provide significant efficiency.
17-10
Scheduling must account for the sequence of activities. For example, VOTES testing
on the operator may require LLRT on the valve.
Many spare parts are long-lead items and are not readily available. The
responsibility of the spare parts specialist within the valve maintenance group
includes identifying these items and having a contingency plan in case of an
emergency need. Options include sharing parts with other plants (including
decommissioned units), using dedicated parts, and developing and sharing spare
part electronic databases via the Internet.
Upgrades and obsolescence do affect the spare part inventory and associated capital
investments.
The evolution of design codes and changes in regulatory requirements can render
some of the inventory obsolete (for example, asbestos packing and seals).
Spare part storage should consider the materials shelf life and required
environment.
Control and maintenance of spare part records are key concerns for safety-related
components.
17-11
18
TROUBLESHOOTING AND RECOMMENDED
CORRECTIVE ACTIONS
18.1 Introduction
This section provides guidance on troubleshooting and recommended corrective
actions for gate, globe, butterfly, ball, plug, and diaphragm valves. EPRI/NMAC has
also published several reports to address air-operated valves [1.2], safety and relief
valves [1.4], solenoid valves [1.7], and check valves [1.20 and 1.21]. EPRI/NMAC has
also published several other reports to address Limitorque actuators [1.22, 1.23, 1.24,
and 1.25] and Rotork actuators [1.26]. Troubleshooting a valve usually involves the
actuator. However, in the following, the focus will be on troubleshooting valve
problems assuming that actuator troubleshooting has been performed using the
applicable document.
Before repairing a valve, it is important to determine and eliminate the root cause of the
valve failure. For example, if a valve stem is bent (or twisted) due to accidental
overload during testing, then stem replacement with proper measures to prevent
further overload is sufficient. However, if the stem is bent (or twisted) during normal
operation, then it is necessary to evaluate the actuator output thrust (or torque) versus
required stem thrust (or torque) and stem strength before ordering a replacement stem.
If this evaluation shows that the stem stress exceeds the allowable stress, then it may be
necessary to redesign the stem with a stronger material.
A repeated valve problem indicates that the valve needs special attention. For example,
repeated packing leakage may be caused by stem corrosion, bent stem, large lateral
stem movement, or inadequate packing selection/design. If the packing leakage is
caused by stem corrosion, then the stem should be redesigned with a material that is
compatible with the process fluid. If the stem is bent, then the evaluation in the
preceding paragraph must be performed. If the stem has large lateral movement that
cannot be accommodated by the packing resilience, then it is necessary to determine the
root cause. For gate and globe valves, the lateral stem movement can be caused by a
small clearance between the stem head and the disc or due to misalignment between
the disc and seat. For butterfly and ball valves, the lateral stem movement can be
caused by excessive bearing wear. The point is that even simple problems should not
18-1
be ignored if they occur frequently because they may be symptoms of more serious
problems.
New valves and overhauled valves should be broken in at low loads for a few cycles.
Loads should be increased gradually until normal operating loads are reached.
Most valve problems require a walkdown and investigation at the valve, and in some
cases internal inspection would be required. Some actuator problems can be diagnosed
from the control room (such as instrument air pressure and control power availability).
In diagnosing a valve problem, the past history of the valve, similar valves, and other
valves in the same system should be reviewed. In all cases, simple things should be
checked first. It can be extremely embarrassing and wasteful to tear down a valve
searching for a problem when the real culprit is a cocked packing gland or loss of
power.
The cost and delivery schedule of new parts (or replacement valves) should be
considered before authorizing repairs. Alternative solutions should be also considered
while scheduling for valve repair or replacement. For example, on-line leak sealing (see
Reference 1.16) may be used to support continued operation until the valve is repaired
during the following outage.
It should be noted that some valve problems are caused by design/installation
deficiencies such as:
Power sources (for example, cables, air lines, and hydraulic lines) are not protected
from damage under design basis conditions.
Such problems may require valve/actuator replacement with major design evaluations.
These problems are outside the scope of this document. As part of troubleshooting and
root cause investigations, it may be necessary to calculate the required torque/thrust to
operate the valve under a given set of operating/design basis conditions. These
calculations typically require detailed internal dimensions, which may be obtained
from the valve manufacturer. Alternatively, these dimensions may be obtained during
valve disassembly for inspection or repair. For example, detailed internal dimensions
are needed to calculate the required thrust/torque using EPRIs Performance Prediction
Methodology (PPM). References 2.1 through 2.4 and 2.14 through 2.17 provide data
18-2
sheets and illustrations showing the dimensions needed for each valve design within
the scope of EPRIs PPM.
Packing leakage is one of the major problems for all types of valves. Reference 1.15
provides extensive discussions of packing designs, troubleshooting, and
recommendations for solving packing leakage problems. Additional information can be
found in References 5.44 through 5.50. Some of the more common packing problems are
summarized as follows:
Improper consolidation.
Bent stem as measured by the total indicated runout (TIR). The amount of allowable
TIR will vary depending on the valve size, type and manufacturers allowance
(typically < 0.007 inch).
18-3
Split ring packing improperly aligned (split-ring packing rings should be lined up
with their cuts or separations staggered).
Excessive stem lateral movements due to small clearance between stem and disc or
guide rail and guide slot. In this case, the stem lateral movement can be seen at any
disc position except in the wedged position.
Excessive stem lateral movements due to misalignment between the disc and seat.
In this case, the stem lateral movement is most pronounced as the gate wedges into
or unwedges from the seat.
Excessive stem lateral movements due to actuator side loads on the stem.
Visual inspection and stroking the valve under some pressure can be used to
investigate the source of the packing leakage. In many cases, it may be sufficient to
increase the packing compression to stop a packing leakage. However, it is important to
verify that the margin between the available actuator thrust and the required stem
thrust to operate the valve (including packing friction) under worst case flow
conditions is acceptable.
18.2.1.2
The first step is to determine whether the problem is actuator related or valve related.
For actuator-related problems, the following references should be consulted for root
cause and repair practices:
18-4
If the problem is related to the gate valve, then it may be caused by one of the following
reasons:
The valve/actuator assembly does not have adequate operating clearances. Direct
interference from scaffolding built too close to the valve/actuator assembly has
prevented some valves from stroking.
Packing resistance is extremely high and is locking the stem. If appropriate, loosen
the packing and check the valve operation (when there is no pressure in the system).
If the stem does not move in the opening direction, then the valve may be
experiencing a pressure locking, thermal binding, or disc pinching condition (see
Section 4). Verify that bonnet pressure is not higher than either the upstream or
downstream pressures. It can be dangerous to plant personnel to loosen packing to
relieve bonnet pressure from a valve. Permanent modification to eliminate pressure
locking and thermal binding may be required on valves that are susceptible to
pressure locking.
If the stem does not move and the disc is in the wedged position, then the
unwedging thrust is not sufficient to unwedge the gate. The required thrust and
actuator output thrust should be evaluated for inadequate sizing.
If the stem does not move and the disc is not in the wedged position, then the stem
may have lost engagement with the actuator. Dismounting the actuator may be
required for further investigation.
If the stem moves but the disc does not, then the stem has lost engagement with the
disc. Possible problems are stem head broken, excessive wear between the stem
head and the gate T-slot, or T-slot ears broken or severely deformed. Internal
inspection is required.
If the stem does not move from midstroke position, the guide slots may be stuck to
the guide rails. Possible causes include guide galling, guide rail deformation, stuck
anti-rotation arm, accumulation of foreign materials in the clearance between the
guide rail and guide slot, or the presence of an obstruction especially in raw water
systems such as service water systems.
If the valve initially fails to operate and then appears to operate normally, this may
mask a potential problem with the valve or the actuator. In such a case, the valve
and the actuator should be evaluated to determine the cause of the initial failure.
As mentioned above, simple things should be checked first. Some factors can be quickly
eliminated by visual inspection or by stroking the valve using the handwheel.
18-5
18.2.1.3
The first step is to determine whether the problem is actuator related or valve related.
Apart from the actuator, the valve problem may be caused by one or more of the
following reasons:
The valve does not have adequate operating clearances. Direct interference from
scaffolding built too close to the valve has prevented some valves from stroking.
The required thrust near the fully open position is only a small percentage of the
unwedging thrust. Valve failure to fully open suggests either a very simple problem
(such as improper limit switch setting in the actuator) or serious damage inside the
valve as mentioned above. This problem must be corrected even if the valve is not
required to open fully, because it may lead to additional damage and ultimately
prevent the valve from stroking.
18.2.1.4
In addition to the applicable problems in Section 18.2.1.3, the problem may be caused
by one of the following reasons:
Insufficient stem thrust to allow adequate wedging; verify the actuator output thrust
and required thrust to close and wedge the disc.
Damaged seat or disc (which generally requires internal inspection). This may be
caused by:
Galling or gouging between the disc and seat under tilted contact mode as
discussed in Section 4.5
18-6
Bent guide rails; this is most common with guide rails that do not have full length
welds
Expansion of the discs prior to reaching the fully closed position; this occurs in split
wedge valves and can occur in flex wedge valves having T-slots perpendicular to
the flow axis. Disc expansion is caused by the stem torque prying the T-slot and
discs apart; it can be eliminated by installing an external stem torque restraint.
Disc and seat angles do not match; this can occur during disc and seat lapping.
The disc seat face overlay is not large enough to accommodate the disc and seat
position variance; this may occur after the disc and seats have been resurfaced and
the disc travels too far.
After ruling out the simple causes, it may be necessary to perform internal valve
inspection. Reference 1.1 provides detailed discussions for damage assessment and
repair options for gate valves.
18.2.1.5
Flange leakage can occur between the mating flanges on the piping to the valve or
between the bonnet and valve body. These leaks can be caused by several problems,
but a typical cause is one of the following:
Gasket problems, including reuse of the old gasket, absence of the gasket, gasket of
the wrong material or size, or improper gasket crush (see EPRI/NMAC TR-104749,
Static Seals Maintenance Guide, [1.14]).
Bolting problems, including use of the old bolts that do not tighten properly,
insufficient torque for the service, or incorrect torque pattern (see EPRI/NMAC TR104213, Bolted Joint Maintenance and Application Guide, [1.17]).
18-7
The bonnet flange design is not adequate for internal and external (actuator) forces.
Corrosion and pitting of the pressure seal surfaces in the bonnet and body of a
pressure-sealed bonnet valve.
Changes in piping forces and moments due to changes in operating conditions were
not accounted for in flange design. For example, if changes in operating
temperature cause flange leaks, then it is possible that under thermal piping loads,
the flange or gasket stresses exceed the allowable stress.
Changes in piping forces and moments due to changes in operating conditions can
also cause fatigue failure to the gasket, bolts, or flanges.
Under pressure-locking conditions [4.2, 5.30], the large increase in bonnet pressure
can cause the bonnet gasket to leak. If both the packing and bonnet do not leak, then
the bonnet or bolt stresses can reach yield stress.
In addition to the problems listed in Section 18.2.1.2, the following problems apply to
double-disc gate valves:
18-8
The upper disc does not break free from the lower wedge, which can increase
required thrust significantly even when the valve is installed in the preferred flow
direction. EPRI testing shows that on one stroke the wedge did not break free [2.14].
This can be caused by many factors including galling/corrosion in the valve disc
components and accumulation of foreign materials between the moving parts in the
valve disc assembly.
18.2.2.3
In addition to the applicable problems in Section 18.2.1.3, the problem may be caused
by one of the following reasons:
Failure of the upper wedge to unwedge from the lower wedge (see Figure 4-4).
Excessive wear between the disc trunnions and the upper wedge. This wear may
happen in the absence of disc anti-rotation devices (which prevent the discs from
spinning inside the upper wedge holes).
After ruling out the obvious possible causes, it is generally necessary to perform an
internal valve inspection.
18.2.2.4
In addition to the applicable problems in Section 18.2.1.4, this problem may be caused
by one of the following reasons:
Premature wedging between the upper and lower disc wedges before reaching the
fully closed position.
18.2.2.5
Insufficient actuator thrust for the actual flow direction. For example, if the required
thrust is based on flow under the plug, the valve may not open under the same
pressure drop if the flow direction changes to flow over the seat (for example, due
to flow reversal). Thus, for globe valves, it is critical to verify that required thrust is
based on the worst possible combination of stroke direction, flow direction, and
pressure drop.
Insufficient actuator thrust for the applicable pressure drop area. The effective
pressure drop area in unbalanced plug globe valves can be based on either the plug
seating diameter or the plug guide diameter. The EPRI Globe Valve Model Report [2.3]
provides the criteria to determine whether a globe valve is seat based or guide
based. The use of the guide area will always result in conservative thrust prediction.
The operating temperature exceeds the trim design temperature, which includes
geometric characteristics (such as clearance and coefficients of thermal expansion).
18-10
Misalignment between the plug and the seat. Plug misalignment prevents proper
mating of seating surfaces.
Improper mating angles between the plug and the seat. This problem usually occurs
after plug and/or seat repair.
For rising and rotating stem globe valves, the following problems apply:
18-11
Packing resistance is extremely high and is locking the stem. If appropriate, loosen
the packing and check valve operation.
Interference of the disc or ball with the body due to excessive wear of the sleeve or
thrust bearing. Excessive sleeve bearing wear may also cause stem-to-body galling.
If the disc or ball does not unseat, then the opening torque is not sufficient to
overcome high unseating torque. The total unseating torque is the sum of the seat
torque, the bearing torque, the packing torque, and the hydrostatic torque for nonvertical stem installations. An increase in the total unseating torque can be caused
by:
Pressure locking between the subject valve and an adjacent tight-seal closed
valve (see Section 7.3.4 for details). In this case, the trapped pressure should be
relieved at the adjacent valve.
High hydrostatic torque in nonsymmetric disc butterfly valves (see Section 7.3.4
for details).
In either case, the required torque and actuator output torque should be evaluated
for inadequate sizing.
If the stem does not move and the disc or ball is not in the closed position, then the
stem may have lost engagement with the actuator. Dismounting the actuator may be
required for further investigation.
If the stem moves but the disc (or ball) does not, then the stem has lost engagement
with the disc (or ball). Possible causes include broken stem/key/pin due to high
maximum transmitted torque (see Section 8), wear, fatigue, or galvanic corrosion
especially in salt-water applications. Internal inspection would be required.
If the stem does not move from the midstroke position, then the valve may have an
obstruction or the hydrodynamic torque is too high. The hydrodynamic torque can
be ruled out if: a) the flow velocity is relatively low, or b) the direction of stem
rotation is in the same direction in which the hydrodynamic torque acts. For
18-12
example, if the stem would not rotate in the closing direction and the hydrodynamic
torque is self closing, then the valve has an internal obstruction.
As mentioned above, simple things should be checked first. Some factors can be quickly
eliminated by visual inspection or by stroking the valve using the handwheel.
High total dynamic torque. Check the valve torque requirements against the
available input torque.
Bent stem causing interference between the stem or disc/ball and valve internals.
Disc interference with the line due to inside diameter buildup in the line. This
problem is peculiar to butterfly valves where the disc extends outside the valve
body near the fully open position.
Under design basis conditions (which may include blowdown), the flow velocity can be
relatively high.
Caution:
For butterfly valves under relatively high flow velocity conditions (such
as under blowdown conditions), the required total dynamic torque near the fully open
position can be very high (see Reference 1.6). For these cases, some valves (such as
containment isolation valves) are limited in the open direction to about 50 open in
order to enable the valve to perform its safety function under design basis conditions.
The limit switch for these valves should not be altered without proper engineering
assessment.
18-13
Insufficient stem torque to allow adequate seating. Verify the actuator output torque
and required torque to close and seat the disc/ball.
Damaged seat or disc/ball (which generally requires internal inspection). This may
be caused by:
Improper seating position. Disc/ball may be stopping outside the seating zone.
After ruling out the simple causes, it may be necessary to perform internal valve
inspection.
18-14
The maintenance group should develop as many checklists as necessary to cover the
variety of valve/actuator types in their plant(s). Manufacturers instruction manuals
can be used as the starting point to develop checklists.
The checklist can be designed and revised to reflect the plant maintenance
experience for each valve/actuator type in a given application. For example, the
checklist may emphasize detailed inspection of the stem-to-disc connection for signs
of wear in applications with high fluid turbulence (such as in pump discharge
valves).
The checklist should provide enough questions and blank spaces to help in
documenting observations that may shed light on unusual performance.
The checklist should follow a logical sequence that ensures that important
information is captured. For example, external visual inspection should be
performed and documented before valve disassembly.
18-15
The checklist should include both the valve and actuator (see Section 17.6 for a
discussion of the one trip approach).
Table 18-1 is a sample checklist for performing a solid or flexible wedge gate valve
inspection. It can be easily expanded to cover other types of gate and globe valves.
Table 18-2 is a sample checklist for performing a butterfly valve inspection. Similar
checklists for ball, plug, and diaphragm valves can be developed.
18-16
Table 18-1
Inspection Checklist for Solid and Flexible Wedge Gate Valves
Unit
Size
WO No.
Manufacturer
Date
Actuator
Valve Function
INSPECTION AREA
(IF CHECKED)
Body External
General Condition
Anti-Rotation Arm/ Mechanism
External Bolting/Threads
Bonnet
Packing
Yoke
End Flanges/Welds
AS FOUND CONDITION(S)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
INSPECTION AREA
(IF CHECKED)
Disc
General Condition
Seating Surface:
General Condition
Upstream
Downstream
Guide Slots:
General Condition
Upstream side
Downstream Side
T-Slot/Stem Connection
AS FOUND CONDITION(S)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
INSPECTION AREA
(IF CHECKED)
Stem
General Condition
Orientation from Vertical
T-Head/Disc End
Packing Area
Actuator End
Thread Surface
Thread Lubricant
Backstop Area
Total Indicated Runout:
(Note 1)
Bent or Crooked
AS FOUND CONDITION(S)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
INSPECTION AREA
(IF CHECKED)
Curved or Bowed
Tapered
Eccentric
Body Internal
General Condition
Downstream Seat:
Seat Surface
Seat Weld/Retainer
Upstream Seat:
Seat Surface
Seat Weld/Retainer
AS FOUND CONDITION(S)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
INSPECTION AREA
(IF CHECKED)
Guide Rails:
Upper Part (disc near/at open
position)
Middle Part (disc at
midstroke)
Lower Part (disc near/ at
closed position)
Gasket Sealing Area
Pressure Seal Ring Area
Pressure Seal Retainer Groove
Gasket
Pressure Seal Ring
Threads/Bolt Holes
AS FOUND CONDITION(S)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
INSPECTION AREA
(IF CHECKED)
Bonnet Internal
General Condition
Gasket Sealing Area
Pressure Seal Ring Area
Threads or Bolt Holes
Stem Backstop Area
Packing Ring Set
Packing Box Area
Packing Follower
Packing Follower Bolts
Live Load Springs
AS FOUND CONDITION(S)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
AS FOUND CONDITION(S)
INSPECTION AREA
(IF CHECKED)
ACTION
REMARKS
Other Components:
Comments:
Check here if complete disassembly was NOT required.
Check here if continuation sheets are used. No. of sheets: ____
Inspection performed by:
Date:
Final Approval:
Date:
Note 1:
rd
See Machinerys Handbook, 23 edition (Dimensioning, Gaging And Measuring, Checking for Various Shaft Conditions; Figure 9 on page 696) for illustrations of possible
forms of runouts and methods for measuring TIRs.
Table 18-2
Inspection Checklist for Butterfly Valves
Unit
Size
WO No.
Body Style:
(Flanged, Wafer, Lugged or Welded)
Date
Disc Design:
(Symmetric, Single/Double/Triple Offset)
Actuator
Valve Function
Manufacturer
INSPECTION AREA
(IF CHECKED)
Body External
General Condition
External Bolting/Threads
Packing
Bonnet/Top Cover Plate
Upper Trunnion
Lower Trunnion
Bottom Cover
AS FOUND CONDITION(s)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
INSPECTION AREA
(IF CHECKED)
Upstream Flange/Weld
Downstream Flange/Weld
Disc Position Stop
Upper Bearings
General Condition
Lower Bearings
General Condition
Outboard Thrust Bearing
General Condition
Upper Thrust Bearing
General Condition
AS FOUND CONDITION(s)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
INSPECTION AREA
(IF CHECKED)
AS FOUND CONDITION(s)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
INSPECTION AREA
(IF CHECKED)
Shaft-to-Disc Connection
(1)
AS FOUND CONDITION(s)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
INSPECTION AREA
(IF CHECKED)
Body Internal
General Condition
Body Liner
Seat Area
Packing Ring Set
Packing Box Area
Packing Follower
Packing Follower Bolts
Live Load Springs
Upper Bearing Area
Lower Bearing Area
Upper Shaft Penetration
Lower Shaft Penetration
AS FOUND CONDITION(s)
ACTION
REMARKS
Unit
Size
WO No.
Manufacturer
Date
INSPECTION AREA
AS FOUND CONDITION(s)
ACTION
REMARKS
(IF CHECKED)
Comments:
Check here if complete disassembly was NOT required.
Check here if continuation sheets are used. No. of sheets: ______
Inspection performed by:
Date:
Final Approval:
Date:
Note 1:
rd
See Machinerys Handbook, 23 edition (Dimensioning, Gaging And Measuring, Checking for Various Shaft Conditions; Figure 9 on page 696) for illustrations of possible
forms of runouts and methods for measuring TIRs.
19
INSTALLATION, TESTING, AND MAINTENANCE
REQUIREMENTS
19.1 Introduction
A valve must be properly installed, tested, and maintained to function as it was
designed. This section discusses general installation, testing, and maintenance
requirements for valves. Suggested postmaintenance testing is given in Reference 1.13.
Cleanliness examination
Verification that end connections for mating to piping system are correct
19-1
Receipt inspection should be carried out in a clean area to prevent the introduction of
foreign matter into the valve. Following receipt inspection, the valve should be dried
out (if it has been wetted during inspection), sealed, and stored until installation.
The following preinstallation activities can be performed to ensure trouble-free
operation after installation:
For gate and globe valves, disassemble, inspect, and blue-check valve seats prior to
installation.
For check valves, disassemble and measure the dimensions of critical components
for future wear trending.
19.2.2 Bypasses
For intermittent operating systems, bypass lines for equipment and control valves are
not normally provided. Where bypass lines are provided, the bypass valve should be of
the same material as the main valve or the equipment isolation valve, and at least the
same pressure-temperature rating as the main valve or equipment isolation valve. The
bypass valve and associated piping should also be of the same safety class and quality
group as the main valve or equipment being bypassed.
The bypass valve operator (whether manual or remote) should primarily be
determined by a specifically defined system operational function and, secondarily, by
valve accessibility, either because of radiological considerations (ALARA) or physical
location. Consideration should be given to providing clearance and accessibility to the
bypass valve. Where ALARA radiation requirements are a concern, location of main
valves, in addition to the bypass valve, must be considered. Centerline elevation and
pitch (if any) of the bypass valve and piping should be the same as the main valve and
piping, except for steam lines where low point drainage of condensate is a
consideration.
For high energy systems, the bypass piping arrangement should be evaluated for
proper consideration of thermal and other loading conditions.
Control Valve Bypass: Control valves should be installed with isolation (maintenance)
valves and a bypass line (to provide an alternative flow path in the event of control
valve failure, malfunction, or maintenance) only when the system is required for
continuous plant operation and can perform its function without continuous
19-3
adjustment of the bypass valve. In general, the bypass valve and piping have the same
characteristics as the main flow loop. Existing instrumentation should be used to the
maximum to assess the effect when bypass control is used.
For safety-related applications, control valves should not be provided with manual
operators due to the possibility of manually changing the position or limiting the
position of the valve. A bypass line and valve should be used. For nonsafety-related
applications, control valves equipped with manual operators can be used in place of a
bypass line and bypass valve when control features of the control valve (high
performance trim) or actuator override provisions (valve pre-positioning) are desired
or required by service conditions.
Isolation Valve Bypass: An isolation valve may require a bypass for the following
reasons:
To gradually warm up a steam line downstream of a closed valve, to ensure that the
downstream piping is properly drained, to minimize thermal stress to piping
and/or equipment, and to avoid water hammer from condensate
19-4
The recommended equipment bypass line and valve sizes are as follows:
Steam:
3/4-inch bypass
Gas or liquid:
1-inch bypass
2-inch bypass
3-inch bypass
4-inch bypass
6-inch bypass
For 4-inch and larger valves, the bypass size is in general accordance
with MSS SP-45 [6.44].
19-5
tests, and ASME Section XI, article IWB, IWC, and IWD for required post-disassembly
and post-repair pressure tests for ASME III, Class 1, 2, and 3 (or equivalent),
respectively. There are regulatory test requirements in addition to these code
requirements, for instance, 10CFR50 Appendix J testing requirements for containment
isolation valves.
The owner must categorize valves per the definitions in ASME XI, Article IWV, and
then perform the required periodic operational tests, normally every 3 months, and
required periodic leak tests, normally every 2 years, for line (as opposed to safety and
relief) valves. For safety and relief valves, testing is in accordance with ANSI/ASME
OM-1 (Requirements for In-Service Performance Testing of Nuclear Power Plant
Pressure Relief Devices). ASME -Section XI and ANSI/ASME OM-10 [6.31] provide
information on test performance and acceptance. For example, acceptable leakage for a
line valve, if not specified by the owner, is 30 cc per hour per inch of nominal valve
size, or, when tested with air, 7.5 standard cubic feet per day per inch of nominal valve
size.
Because of the exemptions, exceptions, or permitted deferrals contained therein or
permitted by the NRC, the edition of ASME XI to which the plant is committed should
always be consulted for the required details and valves that need to be tested. OM-10
has now become ANSI/ASME OM (Part 10), and the current edition of ASME XI refers
to ANSI/ASME OM (Part 10) for in-service testing of valves.
Overall Responsibility for In-Service Testing: The plant owner or agent is responsible for:
Test Boundary and Connection Considerations: The following considerations are listed
regarding the test boundary leakage rate testing provisions:
Direction of Testing. The leakage test should be in the same direction as the
leakage that the limiting boundary would see when called upon to perform its
function. A reverse test (test from the opposite direction) or an alternative test (such
as a through-body test on a gate valve) may be used where proven to provide
equivalent or more conservative results. A further discussion of reverse testing is
given later in this section.
19-7
Main steam
Other large bore piping where additional valves create additional leakage paths
and costs
limiting barrier, but, due to their infrequent use and multiple barriers, they do not
require leakage testing as long as the barrier configuration is maintained using an
administrative control program.
Test Medium. The leakage limiting boundary should be tested with the fluids used
when performing its safety function. Some boundaries may require testing with
several media, based on their services, unless one can be shown to be bounding.
Test Methods: The maintained flow rate test (air, water, or nitrogen) is the most
conservative test method and is often called make-up test. In this test, the test volume
is pressurized to the required pressure (Figure 19-1). Makeup of fluid to the test volume
required to maintain test pressure is a direct measure of the entire boundary leakage.
However, leakage in any path on the test boundary is assigned to the isolation valve;
therefore, this measure is conservative for the valve. Other leakage sources (if any)
should be investigated during the test.
Block Value
Outside Containment
Inside Containment
Test
Vent
Isolation Valve
Test Boundary
Test Panel
Connection
Figure 19-1
Test Valve Arrangement for Maintained Flowrate Test
Seat leakage in an isolation valve can be determined by measuring the flow rate in a
vent/drain line located between the test valve and the nearest downstream leak-tight
valve. Either a physical walk-down of the test boundary or an evaluation of the
makeup flow is required to verify that the remaining test boundary leakage is
acceptable. Due to system and piping constraints, seat leakage tests can be difficult to
perform, and it is generally easier to perform the make-up test.
Alternative Testing of Globe Valves. If the leakage rate test pressure on a globe
valve is under the valve disc, tending to unseat it, and if containment pressure tends
to seat the valve disc, then the reverse direction test method can be overly
conservative and may result in a high leak rate (Figure 19-2).
19-9
LOCA
Flow
Figure 19-2
Globe Valve Reverse Air Test (Test Pressure Under Seat)
If test conditions put pressure over the disc, then the design requirements of the
valve and the sizing of the valve actuator should be evaluated to demonstrate that
reverse testing of the valve provides equivalent or conservative results. It is
recommended that sizing of the valve operator be such that the operator seating
force is at least three times the test pressure force when the valve is reverse tested
(Figure 19-3). Operator seating force is the total stem load, which is equal to the
seating thrust (including stem rejection thrust) plus the packing friction.
19-10
LOCA
Flow
Figure 19-3
Globe Valve Reverse Air Test (Test Pressure Above Seat)
The test pressure on a flow-to-close valve pushes the disc onto the seat with a finite
force, aiding in seat tightness. A seating force of three times the test pressure force
ensures that there is some margin over and above the test force, should the valve
have to operate to isolate the containment. This force margin has been found
acceptable by the NRC at certain sites. However, verification of acceptability by the
NRC should be made prior to the use of a flow-to-close valve.
Alternative Testing of Gate Valves. If a body vent test connection is provided on
the valve, then reverse testing can be considered conservative because test pressure
pushes the disc away from the seating surface used during a LOCA. The cavity
between the seating surfaces is vented and provides a direct measure of valve
leakage (Figure 19-4). Body test connections may be added in the field after the
valve has been installed.
19-11
LOCA
Flow
Downstream
Isolation
Valve
Body Vent
Test Connection
Apply Test
Pressure Here
LOCA Seat
Figure 19-4
Gate Valve Reverse Air Test (With Body Vent Test Connection)
LOCA
Flow
LOCA Seat
Figure 19-5
Gate Valve Through Body Air Test (LOCA pushes disc toward outboard seat.
Through body pressurization measures leakage by both seats.)
19-12
A letter of concurrence from the valve manufacturer that the proposed testing is
conservative since the operator seating force is at least three times the test pressure
force
Verification that the closing circuit uses a torque switch to close as opposed to a
limit switch
Effects of Periodic Testing on Valves Normally Out of Service: Exercising test schedules need
not be maintained for valves in systems declared inoperable or not required to be
operable per OM-10 [6.31], paragraph 5217, Valves in Systems Out of Service.
Continuing with the test schedule would require the following:
System filled and vented unless valve can be stroked dry (not normally
recommended practice)
Procedure deviations
19-13
Leakage tests are generally performed only when the system is out of service to permit
the necessary venting and draining. Leakage test frequency is generally 18 to 24
months, except for certain types of valves that may require leakage tests as often as
after every stroke, as has been required for containment purge and vent valves on a few
nuclear plants.
Effect on Plant or System of Periodic Valve Testing: For those valves that operate in the
course of plant operation at a frequency that would satisfy the code requirement,
additional tests are not required, if the observations otherwise required for testing are
made and analyzed during such operation and are recorded in the plant records at the
required intervals (see OM-10, paragraph 5215) [6.31].
For valves in standby systems, the following problems can develop:
Potential over-pressurization
Creation of transients
19-14
Radiography has been used to establish valve closure member position and to verify
the integrity of valve internals.
Access to and clearance for swing of clutch lever for motor operators
Access to pipe plugs on the gear case of the motor operator (to inspect for quality
and quantity of grease)
19-15
Table 19-1
Valve Maintenance Clearance Data
19-16
19-17
19-18
Figure 19-6
Required Valve Maintenance Clearance for Typical Installation
19-19
Figure 19-7
Required Maintenance Clearance for Chain-Operated Valve
19-20
Figure 19-8
Human Factors Clearance-General
19-21
Tests to verify that opening and/or closing times are within prescribed limits
Many valve problems can be detected during a walkdown, especially during plant
start-up and shut-down. Valve problems can be predicted by trending available data.
To augment an effective preventive maintenance program, it is desirable to maintain a
valve history file containing records of corrective and preventive maintenance work
performed on all valves, so that the performance of each valve can be evaluated. These
records also help to develop and identify proper intervals for certain preventive
maintenance operations.
19-23
When performing maintenance on a valve, the area around the valve should be as clean
as possible to prevent the entrance of foreign material from the surrounding
environment into the valve. The valve should be thoroughly inspected and cleaned just
prior to reassembly.
Since maintenance and plant operations may be carried out simultaneously, it is
important that adequate safeguards be established for protection of personnel. As
previously stated, all work on radioactive systems must be in compliance with
radiation control procedures. Administrative procedures should be developed to
specify the required degree of isolation from operating systems when maintenance is
performed.
The operations department should prepare specific instructions for each maintenance
operation. These instructions should reflect the pressure and temperature conditions in
the operating systems from which isolation is desired and identify the valves to be
shut, tagged, etc. The maintenance department should require a copy of this
instruction, certified as completed, before maintenance is started. When the
maintenance work has been completed, it should be carefully inspected and the
maintenance personnel should certify to the operating personnel that the work has been
completed, isolation of the sections can be secured, and the section re-pressurized.
19-24
20
DIAGNOSTIC EQUIPMENT AND METHODS
20.1 Introduction
Proper assessment of valve condition or malfunction is highly dependent on the tools
used for diagnosis. Based on the diagnostic methods used, the assessment can be either
qualitative or quantitative and either static or dynamic. Prior to the issuance of NRC
Bulletin 85-03 in 1985, not many tools were available that could easily quantify the
required thrust or torque to actuate a valve. Since then, several tools have been
developed and refined to the point where accurate quantification of required thrust or
torque is now easily achievable.
In addition to these quantitative tools, conventional tools such as boroscopes continue
to be used when internal valve inspection is required or when valve disassembly is not
practical. The tools covered in this section deal primarily with the valve types covered
in this guide. Diagnostic tools for air-operated valves, safety and relief valves, solenoid,
and check valves are covered respectively in EPRI documents identified in References
1.2, 1.4, 1.7, 1.20, and 1.21 respectively.
Diagnostic equipment in most cases is temporarily mounted or attached to the
valve/actuator but can also be permanently mounted for continuous monitoring.
Permanent monitoring is used on valves that:
Need to be trended
Are located in high radiation areas (ALARA concerns) or are difficult to access
20.2 Equipment
20.2.1 Boroscopes
The boroscope is probably one of the earliest tools used to inspect valves in line. The
boroscope can be inserted into the valve through drain penetrations in the valve body
or through line fittings located close to the valve. Depending on the type of boroscope
used, these examinations can range from qualitative to some limited level of
quantification. Boroscopes can be equipped with a graduated reticle that can measure
linear indications, but the range of measurement is quite limited. In most cases, the use
of a boroscope requires that the valve and system be depressurized and drained so that
body or line penetrations can be removed for insertion of the boroscope.
20.2.2 Radiography
Radiography inspection is possibly the oldest method of nonintrusive valve
examination. It is the easiest to perform because it does not require that the valve or
system be depressurized. Depending on valve location, radiography inspections can be
performed during plant operation. Images captured by radiography are not affected by
the fluid medium. Radiography examinations are usually qualitative in nature, but can
provide some reasonable accuracy in gross measurements. Radiography has the
advantage of covering a larger area than boroscope examinations, but it lacks the depth
perception of the boroscope. In many cases, this examination method is used to
determine the position of the closure element or to determine if the stem has
disengaged from the closure element.
Depending on valve size, this examination method can be used to determine the need
for a more detailed inspection via valve disassembly. Radiography is usually not used
on large valves because the combined wall thickness limits the clarity of images.
Conventional radiographic examination records are produced by passing x-rays or
gamma rays through the valve and making a permanent image on a single use film.
Newer methods of radiography permit reusable phosphor plate screens that capture
the image by an electron trapping method. The image on the screen can be optically
read by scanning the screen with a focused laser beam. This information can also be
digitized for further manipulation and viewing on a computer monitor. The phosphor
plate can then be erased and reused.
20.2.3 Acoustics
In the past, acoustic monitoring had limited use in power plant applications because of
the interference caused by high ambient noise. New methods of filtering ambient noise
20-2
have made its usage more popular. Acoustic monitoring utilizes an accelerometer
attached to the body to measure acoustic emissions that are generated when solids
contact each other or when liquids or gases flow through pipes and fittings. Acoustic
emissions can be used to make qualitative leakage assessments by comparing the
acoustic levels from the upstream side of the valve to the acoustics levels on the
downstream side of the valve.
Acoustic techniques are easy to set up and usually take only minutes since they require
no valve intrusion or adaptations. Acoustics have been used extensively in check valve
nonintrusive diagnosis for monitoring disk oscillations and impacts, and in safety relief
valves for measuring leakage and operation. Acoustic monitoring is discussed in more
detail in References 1.2, 1.20, and 1.21.
20.2.5 Ultrasonics
Ultrasonic sensors are used to determine the relative position of internal components.
This technique uses sound reflections of the internal components to characterize their
configuration but cannot provide accurate absolute positions. This technique is limited
to use on valves made from carbon steel or fine grain stainless steel and installed in
liquid service such as water (that is, cannot be used in air or steam systems). This
technique is primarily used in check valves to determine the disc fluctuations as a
function of flow velocity. More detailed information can be found in References 1.20
and 1.21.
20-3
Feasibility: Can the sensor or instrument be easily attached on either the valve or
actuator?
method also has the disadvantage of being unable to measure loads below the initial
spring pack assembly preload and can therefore not yield packing load levels in many
valves. The spring pack displacement method is also unable to measure loads above the
load required to compress the spring pack to its solid height, which in turn results in
the inability to capture maximum thrust developed. This method has several
advantages including:
capable only of measuring stem thrust. Strain gauges mounted directly on the stem can
yield individual measurements of thrust and torque.
Two methods are used to attach strain gauges on the stem. In the first method, the
strain gauges are premounted on a strip which is then bonded to the stem. This method
allows installation on the stem without removing the stem from the valve, but it yields
measurement accuracies of about +/- 5%.
In the second method, the strain gauges are bonded directly to the stem, which
typically requires that the stem be removed from the valve. Bonding the strain gauges
directly on the stem yields the highest accuracy in measurement, especially when the
stem is removed from the valve. Accuracies as high as +/- 0.5% are typically achievable
with directly mounted strain gauges.
The disadvantage of this method is that the strain gauges may interfere with valve
stroking if there is insufficient stem length between the bottom of the actuator and the
top of the packing follower. If complete stroking is required and the smooth portion of
the stem is not long enough, then some of the stem threads may have to be removed to
permit installation of the gauges at the thread root diameter. Depending on available
space, threads can be machined using special tools without removing the stem from the
valve.
20-6
Stem thrust
Stem torque
Motor current
20-7
Pressure
Flow rate
Stem position
Motor torque
Motor speed
Diaphragm/piston pressure
Acoustic level
Sound level
Temperature
Data acquisition is normally initiated manually by the test engineer but can also be
triggered automatically. Automatic triggering is accomplished by initiating data
acquisition when a threshold value is exceeded in the selected channels. However, false
indications can create problems with automatic triggering because data acquisition can
be initiated by spurious signal spikes. Most data acquisition systems can also export the
data for use with other data analysis software.
20.4 Summary
Significant technological advances have been made in diagnostic equipment for various
types of valves. These advances provide the user with more options and accuracy to
assess the condition and determine the performance of the valve/actuator. A summary
of selected diagnostic methods is presented in Table 20-1. The user is encouraged to
consult equipment vendors for detailed information on these tools and for new
technology being developed.
Permanent installation of diagnostic equipment permits continuous monitoring of
valve/actuator performance during plant operation to verify and trend valve
performance, minimize radiation exposure, and improve plant availability.
20-8
Table 20-1
Comparison of Selected Diagnostic Methods
Diagnostic
Method
Boroscope
Application
Accuracy
Internal visual
surface
inspection (for
ex., seats, guides,
discs, stem)
Depends on
lens power.
This device is
typically not
used for taking
measurement.
Qualitative.
Radiography
Internal
inspection
Acoustics
Audible signals
Qualitative.
Thermocouples
Leak detection
by measuring
temperature
gradient
Temperature
measurement
is accurate but
correlation to
leakage is
qualitative.
Ultrasonics
Identify location
of internal
components
Stem
thrust/torque
measurement
devices
Accurately
measure applied
stem
thrust/torque
Limitation
Advantages
Disadvantages
Cannot be used
with
valve/system
under pressure.
Internal
temperature
measurements
require pressure
boundary
penetration
during
installation.
Fluid in valve
must be liquid;
valve should be
of carbon steel or
fine grain
stainless steel.
Requires slight
modification to
the actuator,
stem, or yoke.
21
VALVE SELECTION GUIDELINE CHARTS
The valve selection chart (Figure 21-1 and Table 21-1) is intended to provide the user
with a simplified, logical way to select a valve. Before using the selection chart, it is
advantageous for the user to review the sections of this document that are pertinent to
the type of valve being selected. Selection of control and pressure relief valves is not
fully covered by the selection chart. For control and pressure relief valves, selection
depends on body type, pressure/temperature rating, and material; but since the
selection of other features is more complex and requires calculations, control and safety
valves cannot be fully covered by a logic decision chart.
Before starting the selection process, information on system, fluid, piping material,
system design conditions, pipe size, and environmental conditions should be available.
The selection process should start from the top of the selection chart marked Start and
continue to the end, using Table 21-1 as a source of information to answer questions
about valve function and performance and about availability in a particular size,
pressure and temperature rating, and material. Supporting charts are provided for
selection of valve body material and valve actuators. Table 21-1 contains current
information, but valve availability in certain designs, materials, and pressure ratings
may change with time. Cost information should be used with caution since cost
information does not take into consideration maintenance cost, which can significantly
change cost calculations.
As a result of the selection process, a ranking list can be developed that should contain
at least one, but most likely more than one, valve that can be successfully used. At this
point, a top ranking valve may be chosen or, at the purchasers decision, other aspects
may be considered (for example, delivery time, economic cost, etc.).
Figure 21-1
Valve Selection Chart
(This figure is located in a pouch inside the back cover of this report.)
21-1
Table 21-1
Valve Selection Matrix
21-2
21-3
21-4
Example 1
Selection of Service Water Main Pump Isolation Valve
Step 1 - Collect data in accordance with block one on the valve selection matrix (Table
21-1).
1. System: Service water
2. Fluid: Seawater
3. Pipe: Cu-Ni clad pipe
4. System design condition: 100 psig, 95F
5. Size: 30 inch
6. Environment: Salt water, no radiation
Step 2 - Determine the primary function of the valve.
The valve isolates the non-operational train; therefore, the primary function is
isolation.
From Table 21-1, valves suitable for isolation are gate, globe, butterfly,
diaphragm, plug, ball, sealed gate, and sealed globe.
Step 3 - Select the valve size.
The valve size will be equal to pipe nominal size (30 inches).
From Table 21-1, 30-inch size, globe, diaphragm, ball, plug, sealed gate, and
sealed globe valves are not available, leaving gate and butterfly valves available.
Step 4 - Determine the valve pressure class.
Based on the design conditions, 150-pound pressure class is sufficient.
From Table 21-1, both gate and butterfly valves are available in this pressure
class.
Step 5 - Select the valve material.
Based on the material selection chart, materials suitable for this application are
copper alloys, nickel alloys, and high molybdenum austenitic steel.
21-5
Aluminum bronze is selected for the valve body material, based on previous
experience with this material.
Step 6 - Select the performance required.
1. Pressure drop in open position: low
2. Seat tightness: good
3. Maintainability: good
Based on information from Table 21-1, three ranking lists are created:
Pressure Drop
Seat Tightness
Maintainability
1) Butterfly
1) Butterfly
1) Butterfly
1) Gate
2) Gate
2) Gate
(no difference)
Step 7 - Combine the ranking lists into one overall ranking list.
There is no significant difference between the valves for the first two
characteristics; however, butterfly valves are somewhat easier to maintain.
Therefore, the final ranking is:
1. Butterfly
2. Gate
Step 8 - Is the valve size/weight a concern?
Valve size/weight is a concern because of limited space in the pumphouse.
From Table 21-1, butterfly valves are more compact and lighter than gate valves,
and the ranking remains unchanged.
Step 9 - Secondary function.
There is a possibility that the valve may be required to throttle and, in this case, a
butterfly valve is better.
The ranking remains unchanged.
21-6
21-7
Example 2
Selection of an Isolation Valve at the Inlet to
Moisture Separator Reheater in the Main Steam System
Step 1 - Collect data in accordance with block one on the valve selection chart.
1. System: Main Steam
2. Fluid: Saturated steam
3. Pipe: Carbon steel
4. System design condition: 1185 psig, 600F
5. Size: 16 inch
6. Environment: Mild, no radiation
Step 2 - Determine the primary function of the valve.
The valve isolates the non-operational train; therefore, the primary function is
isolation.
From Table 21-1, valves suitable for isolation are gate, globe, butterfly, diaphragm,
plug, ball, sealed gate, and sealed globe.
Step 3 - Select the valve size.
The valve size will be equal to pipe nominal size (16 inches).
From Table 21-1, 16-inch size globe, diaphragm, plug, sealed gate, and sealed globe
valves are not available, leaving ball, gate, and butterfly valves available.
Step 4 - Determine the valve pressure class.
Based on the design conditions, 900-pound pressure class is sufficient.
From Table 21-1, both gate and ball valves are available in this valve pressure class.
Butterfly valve is deleted because it is available only as a special design.
Step 5 - Select the valve material.
Based on the material selection chart, a material suitable for this application is
carbon steel.
21-8
Seat Tightness
Maintainability
1) Ball
1) Ball
1) Ball
1) Gate
2) Gate
2) Gate
(no difference)
The ranking is based on gate valve superiority in size/weight ranking and its
availability on the market.
Step 11 - Follow gate valve-specific chart.
Step 12 - For sizes larger than 3 inches, a bolted bonnet design is selected because the
temperature is 600F, which is below the 700F required for a pressure seal bonnet.
Step 13 - Outside stem and yoke design is selected since it is the only one available.
Step 14 - Select the wedge/disc type.
In the closed position, the pressure differential is expected to be high and line loads
are expected to be significant; therefore, based on the chart, the following valves
may be used: split wedge, flexible wedge, or parallel slide double disc. The final
decision should be based on availability, price, and plant preference.
Step 15 - Select the seat material.
Because steam is not considered a corrosive fluid and no erosion and cavitation is
expected, any manufacturer-selected material for this application is acceptable.
Step 16 - Return to the main chart, and select an actuator using the actuator selection
chart. The valve is not required to fail open or closed, and fast speed is not required.
Motor operator is selected. The thrust calculated does not exceed 500,000 pounds.
Step 17 - Incorporate all the data into the valve data sheet (see Section 25).
21-10
Example 3
Selection of a Manually Operated 3-inch
Isolation Valve in Liquid Waste System
Step 1 - Collect data in accordance with block one on the valve selection chart.
1. System: Liquid waste
2. Fluid: Water
3. Pipe: Stainless Steel
4. System design condition: 150 psig, 200F
5. Size: 3 inch
6. Environment: Radiation 108 rads/over plant life
Step 2 - Determine the primary function of the valve.
The valve isolates the non-operational train; therefore, the primary function is
isolation.
From Table 21-1, valves suitable for isolation are gate, globe, butterfly, diaphragm,
plug, ball, sealed gate, and sealed globe.
Step 3 - Select the valve size.
The valve size will be equal to pipe nominal size (3 inches).
Step 4 - Determine the valve pressure class.
Based on the design conditions, 150-pound pressure class is sufficient.
From Table 21-1, all valves are available in this pressure class.
Step 5 - Select the valve material.
Based on the material selection chart, a material suitable for this application is
stainless steel.
Step 6 - Select the performance required.
1. Stem leakage - low
21-11
Stem Leakage
Seat Tightness
Maintainability
1. Diaphragm
1. Diaphragm
1. Ball
2. Ball
2. Diaphragm
3. Plug
3. Plug
4. Globe
4. Gate
5. Ball
5. Globe
6. Plug
7. Gate
7. Gate
8. Globe
Step 7 - Combine the ranking lists into one overall ranking list. After considering all
aspects of the valve characteristics, the following ranking is established:
1. Diaphragm
2. Ball
3. Plug
Other valves will not be considered for the following reasons:
Diaphragm sealed globe, bellows sealed gate, and bellows sealed globe are
expensive and difficult to maintain. This application does not require such a high
degree of leak tightness.
21-12
21-13
22
REFERENCES AND BIBLIOGRAPHY
In Situ State-of-the-Art Valve Welding Repair (Gate, Globe, & Check Valves), Volume 2.
EPRI, Palo Alto, CA: December 1996. Report TR-105852V2.
1.2
Air-Operated Valve Maintenance Guide. EPRI, Palo Alto, CA: November 1996.
Report NP-7412.
1.3
Maintenance Job Cards; Joint EPRI-CRIEPI Human Factor Studies. EPRI, Palo Alto,
CA: December 1994. Report TR-104602.
1.4
Safety and Relief Valve Testing and Maintenance Guide. EPRI, Palo Alto, CA: August
1996. Report TR-105872.
1.5
Application Guide for Motor-Operated Valves in Nuclear Power Plants. EPRI, Palo
Alto, CA. Report TR-106563-V1. Volume 1: Gate and Globe Valves, published in
1998. (This is Revision 1 of EPRI NP-6660, March 1990.)
1.6
Application Guide for Motor-Operated Valves in Nuclear Power Plants. EPRI, Palo
Alto, CA. Report TR-106563-V2. Volume 2: Butterfly Valves, October 1998. (This is
Revision 1 of EPRI NP-7501, January 1993.)
1.7
Solenoid Valve Maintenance and Application Guide. EPRI, Palo Alto, CA: April 1992.
Report NP-7414.
1.8
Predictive Maintenance Primer. EPRI, Palo Alto, CA: April 1991. Report NP-7205.
1.9
The Maintenance Engineer Fundamentals Handbook. EPRI, Palo Alto, CA: November
1996. Report TR-106853.
22-1
1.10 EPRI Workshop on Erosion-Corrosion of Carbon Steel Piping, April 1415, 1987,
Washington, DC.
1.11 Assessing Maintenance Effectiveness. EPRI, Palo Alto, CA: December 1996. Report
TR-107759.
1.12 Lubrication Guide, Revision 2. EPRI, Palo Alto, CA: February 1995. Report NP-4916.
1.13 Postmaintenance Testing, A Reference Guide. EPRI, Palo Alto, CA: April 1991. Report
NP-7213s.
1.14 Static Seals Maintenance Guide. EPRI, Palo Alto, CA: December 1994. Report TR104749.
1.15 Valve Stem Packing Improvements. EPRI, Palo Alto, CA: March 1988. Report NP5697.
1.16 On-Line Leak Sealing, A Guide for Nuclear Power Plant Maintenance Personnel. EPRI,
Palo Alto, CA: July 1989. Report NP-6523.
1.17 Bolted Joint Maintenance & Application Guide. EPRI, Palo Alto, CA: December 1995.
Report TR-104213.
1.18 How to Conduct Material Condition Inspections. EPRI, Palo Alto, CA: September
1994. Report TR-104514.
1.19 Development of a Honing Tool for Main Steam Isolation Valve Seats. EPRI, Palo Alto,
CA: November 1983. Report NP-3291.
1.20 Application Guide for Check Valves in Nuclear Power Plants. EPRI, Palo Alto, CA:
June 1993. Report NP-5479, Revision 1.
1.21 Check Valve Maintenance Guide. EPRI, Palo Alto, CA: August 1995. Report TR100857.
1.22 Technical Repair Guidelines for Limitorque Valve Operator Model SMB 000. EPRI, Palo
Alto, CA: December 1994. Report NP-6229R1, Revision 1.
1.23 Technical Repair Guidelines for Limitorque Valve Operator Model SMB 00. EPRI, Palo
Alto, CA: June 1995. Report NP-6231R1, Revision 1.
1.24 Technical Repair Guidelines for Limitorque Valve Operator Model SMB 0-4. EPRI, Palo
Alto, CA: May 1993. Report NP-7214.
22-2
1.25 Technical Repair Guidelines for Limitorque Valve Operator Model HBC 0-10. EPRI, Palo
Alto, CA: December 1993. Report TR-100539.
1.26 Technical Repair Guidelines for Rotork Valve Actuators. EPRI, Palo Alto, CA:
December 1995. Report TR-104884.
1.27 Anchor/Darling MSIV Guide. EPRI, Palo Alto, CA: May 1991. Report NP-7211.
1.28 Anchor/Darling MFIV Guide. EPRI, Palo Alto, CA: May 1991. Report NP-7212.
1.29
Infrared Thermography Guide. EPRI, Palo Alto, CA: December 1994. Report NP-6973,
Revision 2.
EPRI MOV Performance Prediction Program: Topical Report. EPRI, Palo Alto, CA:
April 1997. Report TR-103237-R2, Revision 2.
2.2
EPRI MOV Performance Prediction Program: Gate Valve Model Description Report.
EPRI, Palo Alto, CA: November 1994. Report TR-103229.
2.3
EPRI MOV Performance Prediction Program: Globe Valve Model Report. EPRI, Palo
Alto, CA: April 1994. Report TR-103227.
2.4
2.5
EPRI MOV Performance Prediction Program: System Flow Model Description Report.
EPRI, Palo Alto, CA: June 1994. Report TR-103225.
2.6
EPRI MOV Performance Prediction Program: Assessment Report. EPRI, Palo Alto,
CA: November 1994. Report TR-103231.
2.7
22-3
2.8
2.9
EPRI MOV Performance Prediction Program: Gate Valve Design Effects Testing
Results. EPRI, Palo Alto, CA: July 1994. Report TR-103255.
2.10
EPRI MOV Performance Prediction Program: Friction Separate Effects Test Report.
EPRI, Palo Alto, CA: November 1993. Report TR-103119.
2.11
EPRI MOV Performance Prediction Program: Butterfly Valve Design, Elbow, and
Scaling Effects Report. EPRI, Palo Alto, CA: April 1994. Report TR-103257.
2.12
Review of NRC/INEL Gate Valve Test Program. EPRI, Palo Alto, CA: January 1991.
Report NP-7065.
2.13
EPRI MOV Performance Prediction Program: Stem/Stem Nut Lubrication Test Report.
EPRI, Palo Alto, CA. Report TR-102135.
2.14
EPRI MOV Performance Prediction Program: Stem Thrust Prediction Method for
Anchor/Darling Double Disk Gate Valves. EPRI, Palo Alto, CA: November 1994.
Report TR-103232.
2.15
EPRI MOV Performance Prediction Program: Stem Thrust Prediction Method for
Westinghouse Flexible Wedge Gate Valves. EPRI, Palo Alto, CA: November 1995.
Report TR-103233.
2.16
EPRI MOV Performance Prediction Program: Stem Thrust Prediction Method for
Aloyco Split Wedge Valves. EPRI, Palo Alto, CA: August 1996. Report TR-103235.
2.17
EPRI MOV Performance Prediction Program: Stem Thrust Prediction Method for
W-K-M Parallel Expanding Gate Valves. EPRI, Palo Alto, CA: May 1995. Report TR103236.
2.18
Limitorque Actuators. For information concerning these documents, contact the project
manager, P. D. Alvarez of Kalsi Engineering, telephone: 281/240-6500; e-mail:
alvarez@kalsi.com.
3.1
3.2
3.3
3.4
3.5
P. Daniel Alvarez. Limitorque SMB-2 Actuator Overload Cycle Test Interim Report.
Kalsi Engineering, Inc. June 22, 1994. Document No. 1837C, Rev. 0.
3.6
P. Daniel Alvarez. Torque Cycle Test Report for Limitorque SMB-000 Electric Motor
Actuator. Kalsi Engineering, Inc. December 19, 1994. Document No. 1861C,
Rev. 0.
3.7
3.8
Desi Somogyi. LTAFLA User's Manual - Predicting Fatigue Life of Limitorque Type
SMB/SB/SBD Actuator Torsional Components. Kalsi Engineering, Inc. December 29,
1994. Document No. 1863C, Rev. 0.
3.9
Desi Somogyi. LTAFLA Validation and Verification Manual - Predicting Fatigue Life
of Limitorque Type SMB/SB/SBD Actuator Torsional Components. Kalsi Engineering,
Inc. December 29, 1994. Document No. 1866C, Rev. 0.
3.10
P. Daniel Alvarez. Limitorque H0BC Operator Overload Cycle Test Report. Kalsi
Engineering, Inc. December 8, 1995, January 1996. Document No. 1860C, Rev. 0.
22-5
U.S. NRC Generic Letter 89-10: Safety-Related Motor-Operated Valve Testing and
Surveillance, June 28, 1989, including the following supplements:
Supplement 1:
Supplement 2:
Supplement 3:
Supplement 4:
Supplement 5:
Supplement 6:
Supplement 7:
4.2
U.S. NRC Generic Letter 95-07: Pressure Locking and Thermal Binding of SafetyRelated Power-Operated Gate Valves, August 17, 1995.
4.3
4.4
4.5
U.S. NRC Generic Letter 89-08: Erosion/Corrosion Induced Pipe Wall Thinning, May
2, 1989.
4.6
4.7
U.S. NRC Information Notice 97-07: Problems Identified During Generic Letter 89-10
Closeout Inspection, March 6, 1997.
4.8
U.S. NRC Information Notice 97-18: Problems Identified During Maintenance Rule
Baseline Inspections, April 14, 1997.
22-6
4.9
4.10
U.S. NRC Information Notice 96-30: Inaccuracy of Diagnostic Equipment for MotorOperated Butterfly Valves, May 21, 1996.
4.11
4.12
U.S. NRC Information Notice 94-44: Main Steam Isolation Valve Failure to Close on
Demand Because of Inadequate Maintenance and Testing, June 16, 1994.
4.13
U.S. NRC Information Notice 94-67: Problem with Henry Pratt Motor-Operated
Butterfly Valves, September 26, 1994.
4.14
4.15
U.S. NRC Information Notice 94-61: Corrosion of William Powell Gate Valve Disc
Holders, August 25, 1994.
4.16
4.17
U.S. NRC Information Notice 92-60: Valve Stem Failure Caused by Embrittlement,
August 20, 1992.
4.18
4.19
U.S. NRC Information Notice 92-56: Counterfeit Valves in the Commercial Grade
Supply System, August 6, 1992.
4.20
U.S. NRC Information Notice 92-50: Cracking of Valves in the Condensate Return
Lines of a BWR Emergency Condenser System, July 2, 1992.
4.21
4.22
U.S. NRC Information Notice 91-58: Dependency of Offset Disc Butterfly Valve's
Operation on Orientation with Respect to Flow, September 20, 1991.
22-7
4.23
4.24
4.25
4.26
4.27
4.28
U.S. NRC IE Circular 77-05: Fluid Entrapment in Valve Bonnets, March 29, 1977.
4.29
U.S. NRC Information Notice 98-24: Stem Binding in Turbine Governor Valves in
Reactor Core Isolation Cooling (RCIC) and Auxiliary Feedwater (AFW) Systems, June
1998.
4.30
4.31
4.32
5.2
5.3
Flow of Fluids Through Valves, Fittings, and Pipe. Crane Company, 1988. Crane
Technical Paper No. 410.
5.4
J. L. Lyons. Lyons Valve Designers Handbook. Van Nostrand Reinhold Co., New
York, NY, 1982.
22-8
5.5
5.6
R. C. Merrick. Valve Selection and Specification Guide. Van Nostrand Reinhold Co.,
New York, NY, 1991.
5.7
5.8
Valves, Piping and Pipelines Handbook, 2nd Edition. Compiled and published by
the Trade and Technical Press Limited, Surrey, England, 1986.
5.9
W. Ulanski. Valve and Actuator Technology. McGraw-Hill, New York, NY, 1991.
5.10
5.11
A. J. Ward-Smith. Internal Fluid Flow: The Fluid Dynamics of Flow in Pipes and
Ducts. Clarendon Press, Oxford, 1980.
5.12
W. C. Young. Roarks Formulas for Stress & Strain, 6th Edition. McGraw-Hill, New
York, NY, 1989.
5.13
5.14
Fluid Meters, Part 1, 6th Edition. American Society of Mechanical Engineers, New
York, NY, 1951.
5.15
5.16
5.17
22-9
5.18
T. G. Scarbrough, NRC Regulatory Activities Regarding Performance of SafetyRelated Power-Operated Valves, presented at the Sixth EPRI Valve Technology
Symposium (July 1997).
5.19
5.20
5.21
K. A. Hart, Treating the Whole Valve to Develop Cost Effective Maintenance and
Innovative Solutions to Valve Problems, presented at the Sixth EPRI Valve
Technology Symposium (July 1997).
5.22
5.23
5.24
5.25
5.26
5.27
5.28
5.29
22-10
5.30
5.31
5.32
5.33
5.34
5.35
W. G. Knecht. Hardfacing Materials Used in Valves for Seating and Wear Surfaces,
NUREG/CP-0152, July 1996.
5.36
5.37
5.38
5.39
5.40
5.41
22-11
5.42
5.43
5.44
5.45
5.46
5.47
5.48
5.49
5.50
5.51
5.52
5.53
22-12
5.54
D. E. Smith. Calculations to Predict the Required Thrust to Open a Flexible Wedge Gate
Valve Subjected to Pressure Locking, U.S. NRC NUREG/CP-0146, February 1994.
5.55
5.56
5.57
Section 50.55a
Section 50.65
Section 50.70
Inspections
Section 50.71
Section 50.72
Appendix A
to Part 50
Appendix B
to Part 50
Appendix J
to Part 50
22-13
American National Standard Institute (ANSI) and the American Society of Mechanical
Engineers (ASME) publish many codes which apply to nuclear power plants,
including:
6.2
6.3
ASME Boiler and Pressure Vessel Code, Section III, Rules for the Construction
of Nuclear Power Plant Components, Division 1.
6.4
6.5
ASME Boiler and Pressure Vessel Code, Section VIII, Rules for Construction of
Pressure Vessels, Division 1.
6.6
ASME Boiler and Pressure Vessel Code, Section VIII, Rules for Construction of
Pressure Vessels, Alternative Rules; Division 2.
6.7
ASME Boiler and Pressure Vessel Code, Section IX, Welding and Brasing
Qualifications.
6.8
ASME Boiler and Pressure Vessel Code, Section XI, Rules for In-Service
Inspection of Nuclear Power Plant Components.
6.9
ASME III Code Case N62, Internal and External Valve Items, Division 1, Classes
1, 2, and 3.
6.10
6.11
6.12
6.13
6.14
6.15
6.16
22-14
6.17
6.18
6.19
ANSI B16.15, Cast Bronze Threaded Fittings, Classes 125 and 250.
6.20
6.21
ANSI B16.22, Wrought Copper and Copper Alloy Solder Joint Pressure
Fittings.
6.22
ANSI B16.24, Bronze Pipe Flanges and Flanged Fittings, Classes 150 and 300.
6.23
6.24
6.25
ANSI B16.41 Standards, Functional Qualification Requirements for PowerOperated Active Valve Assemblies for Nuclear Power Plants.
6.26
6.27
6.28
6.29
6.30
6.31
6.32
6.33
6.34
22-15
6.35
6.36
6.38
6.39
6.40
MSS SP6, Standard Finish for Contact Faces of Pipe Flanges and Connecting
End Flanges of Valves and Fittings.
6.41
MSS SP25, Standard Marking System for Valves, Fittings, Flanges and Unions.
6.42
MSS SP42, Class 150 Corrosion-Resistant Gate, Globe, Angle, and Check Valves
with Flanged and Butt Weld Ends.
6.43
MSS SP44, Steel Pipe Line Flanges (26 Inches and Larger).
6.44
6.45
MSS SP53, Quality Standard for Steel Castings and Forgings for Valves,
Flanges, and Fittings and Other Piping Components - Magnetic Particle
Examination Method.
6.46
MSS SP54, Quality Standard for Steel Castings for Valves, Flanges, and Fittings
and Other Piping Components - Radiographic Examination Method.
6.47
6.48
6.49
22-16
23
APPENDIX A: RECENT ADVANCES IN VALVE AND
ACTUATOR TECHNOLOGY
23.1 Introduction
In the last few years, many significant developments have taken place in valve and
actuator technology, especially for nuclear power plant applications. These
developments resulted from extensive research programs conducted by EPRI, the U.S.
Department of Energy/Nuclear Regulatory Commission (NRC), electric utilities,
valve/actuator manufacturers, and service and consulting organizations.
Several groups were organized to address different industry problems and to better
communicate the interim results of industry research, including the MOV Users Group
(MUG), EPRI MOV PPP Users Group, the Nuclear Industry Check Valve Group (NIC),
the Air-Operated Valve Group, etc. The U.S. NRC has been very active with these
groups to monitor their progress and assist them with regulatory issues.
The American Society of Mechanical Engineers (ASME) in coordination with the U.S.
NRC held several pump and valve symposiums and published the proceedings in
NUREGs. EPRI held several symposiums to address similar issues. The Nuclear
Maintenance Applications Center (NMAC) prepared several maintenance and repair
guides and conducted many workshops and training courses for nuclear power plant
engineers and maintenance personnel. In this section, highlights of current
developments and the factors that initiated them are presented. For the latest
developments in valve and actuator technology, the reader is referred to nuclear
industry publications such as the ASME/NRC symposiums, NUREGs, and valve users
group meetings.
23.2 Background
Operating experience at nuclear power plants in the 1970s and 1980s revealed
weaknesses in the performance of power-operated valves. The NRC sponsored valve
and actuator tests to evaluate valve performance and disseminated the test results
through public meetings and publications. On June 28, 1989, the U.S. NRC issued
23-1
Generic Letter 89-10 [4.1] requesting that nuclear power plant licensees verify the
design basis capabilities of MOVs in safety-related systems. On September 18, 1996, the
NRC issued Generic Letter 96-05 [4.3] requesting that nuclear power plant licensees
ensure that programs are in place to periodically verify the capability of their safetyrelated MOVs to perform their safety functions in accordance with the licensing bases.
On August 17, 1995, the NRC issued Generic Letter 95-07 [4.2] requesting that nuclear
power plant licensees ensure that safety-related power-operated gate valves susceptible
to pressure locking or thermal binding are capable of performing their safety functions
within the current licensing bases of the facility. The NRC issued many more Generic
Letters and Information Notices (see Section 22.4) to address other safety-related issues
concerning valves and actuators.
The nuclear industry responded to these safety concerns with comprehensive programs
to solve the problems. Highlights of these programs are summarized in the following
sections.
23-2
23-3
The mid-stroke valve pressure drops are very high such as under blowdown
conditions with little system flow resistance.
The gate pressure force does not transfer to the seats until the valve is nearly
closed and the valve pressure drop is almost equal to the shutoff pressure drop.
This in turn can be caused by a very tight clearance between the guide rail and
guide slot.
2. Figure 23-1 shows one of the important contact modes in which the disc is tilted,
theoretically making a point contact at two locations against the downstream seat.
Simultaneously, the upper edge of the disc guide slot makes a line contact against
the body guide. Stresses at the contact points and contact lines depend on the local
geometry and the magnitude of the valve pressure drop at a given disc position.
Under certain conditions, localized stresses can cause plastic deformation as well as
galling/gouging of the mating surfaces. In some extreme cases, the guide may break
and the gate get stuck in mid-position.
3. One of the major results from EPRIs PPM is the development of detailed friction
coefficient data tables for valve materials [2.1, 2.10]. The friction coefficient data
tables were obtained by extensive laboratory tests using test specimens of different
geometries and materials applicable to gate valves. The friction coefficient matrix
provides nominal and maximum (upper bounding) values and includes the
following:
Different contact modes, including flat-on-flat, edge-on-flat, edge-on-edge (nonscissoring), and edge-on-edge (scissoring)
Different contact stresses from less than 5 ksi to 50 ksi (34.5 MPa to 345.0 MPa)
Different fluids including water and steam at temperatures from less than 70F
to about 650F (20C to 340C)
4. In some gate valves, the clearance between the guide rail and guide slot is very
small. The accumulation of foreign materials in such tight clearance (from process
fluid or from the guide surface) may increase the friction force and, in some cases,
may lock the gate.
23-4
Figure 23-1
Tilted Disc Contact Mode Resulting in Point Contact with the Downstream Seat
23-5
23-6
23-7
Technical descriptions for gate, globe, and check valves. Individual sections on
design and application along with advantages and disadvantages are provided.
A section on each valve type, the typical repair issues, and the repair options. The
repair options direct the user to specific repair sections.
23-8
accident conditions. These evaluations are necessary to ensure safe plant operation and
to meet regulatory requirements and various industry code requirements. The
organization of the guide provides a framework around which a plant-specific MOV
evaluation program can be developed.
The guide is published in two volumes:
Volume 1 deals with the non-rotating, rising stem type gate and globe valves.
23-10
Trend analysis
Pattern recognition
Correlation
Reliability-centered maintenance
Problem-solving approaches
23-13
Valve stiffness
Actuator/motor size
Motor speed
The match between actuator output capabilities and valve thrust requirements
With the use of diagnostic devices in recent years, inertia thrust overshoots have been
quantified. It is not uncommon to see thrust overloads of 25 to 50% above rated
capacity of the actuators in some applications. Even higher thrusts are experienced in
some MOV assemblies. During in situ testing, some actuators were inadvertently
overloaded beyond their thrust/torque ratings.
Recognizing this as a generic problem, Duke Power Company initiated a test program
to systematically determine the capability of Limitorque actuators to withstand such
higher overloads and to qualify them for higher thrust levels on a technically sound
basis. Duke Power was joined by more than 35 U.S. utilities in sponsoring this project.
The objective of this project was to qualify the most widely used population of
Limitorque actuators (SMB-000 through SMB-2) for higher thrusts than the published
ratings. Under the overall project objective, the specific subobjectives were:
1. To test Limitorque actuators to 200% of the rated thrust, both in the opening and
closing directions for 4,000 cycles
2. To recommend an allowable number of cycles under various levels of thrust
overloads, based on appropriate justifiable margins applied to the test results
3. To seismically qualify these actuators while being cycled under 200% of the rated
thrust in the opening and closing directions
23-14
Figure 23-2
Limitorque Actuator Test Fixture
23-15
23-16
24
APPENDIX B: CONTROL VALVE SIZING METHODS
AND EXAMPLES
Examples: A 6-inch (150-mm) or larger valve is required for a l0-inch (250 mm) line.
A 16-inch (400-mm) or larger valve is required for a 20-inch (500 mm) line.
Another rule of thumb states that the valve should be sized to throttle the process fluid
from between 20 and 80% of valve capacity. Some specifications even make this a
requirement for the control valve vendor. While this limit may be a reasonable point
from which to start the sizing/selection process, the examples discussed in Sections 6.1
and 6.2.9 illustrate that any serious attempt to adhere to these limits could be, at best,
unnecessarily complicated and expensive, requiring the addition of a second valve or a
valve that could be oversized for the application. This section is designed to expose the
user to different aspects of valve sizing. The step-by-step procedures given in Sections
24.1.3 (for liquid flow) and 24.1.4 (for gas flow) are the most common methods for
sizing control valves and can be applied regardless of the type of valve being sized.
Several examples are provided to illustrate the use of these procedures.
24-1
24.1.2 Definitions
Capacity. Flow capacity is based on the industry standard ANSI/ISA S75.01 [6.37]. This
standard and the corresponding measuring standards contain equations used to predict
the flow of compressible and incompressible fluids in control valves. Different forms of
the basic equations are used for liquids and gases.
Flow Coefficient (Cv). Basic steps for sizing and selecting the correct valve include
calculating the required Cv. Equations for calculating the required Cv for both gases and
liquids are given in this section.
The valve flow coefficient most commonly used as a measure of the capacity of the
body and trim of a control valve is Cv. Cv is defined as the flow of water in U.S. gallons
per minute at 60F that will flow through a given valve producing a pressure drop of 1
psi. The general equation for Cv is as follows:
C v = Flow rate
Cv = q
Gf
P
(Equation 24-1)
Where:
Cv
Gf
psi
When selecting a control valve for an application, the calculated Cv is used to determine
the valve size and the trim sizes that will allow the valve to pass the desired flow rate
and provide stable control of the process fluid.
Pressure Profile. Fluid flowing through a control valve obeys the basic laws of
conservation of mass and energy and the continuity equation. The control valve acts as
a restriction in the flow stream. As the fluid stream approaches this restriction, its
velocity increases in order for the full flow to pass through the restriction. Energy for
this increase in velocity comes from a corresponding decrease in pressure.
24-2
Maximum velocity and minimum pressure occur immediately downstream from the
throttling point at the narrowest constriction of the fluid stream, known as the vena
contracta. Downstream from the vena contracta, the fluid slows and part of the energy
(in the form of velocity) is converted back to pressure. A simplified profile of the fluid
pressure is shown in Figures 24-1 and 24-2. The slight pressure losses in the inlet and
outlet passages are due to frictional effects. The major excursions of pressure are due to
the velocity changes in the region of the vena contracta. Detailed discussions can be
found in many references including 5.1, 5.3, 5.4, 6.36, 6.38, and 1.6.
Figure 24-1
Pressure Profile of Fluid Passing through a Valve
24-3
Figure 24-2
Pressure Profile through Restriction
Allowable Pressure Drop. From the definition of Cv, an increase in the pressure drop for a
given Cv should result in an increase in flow rate. This occurs up to a point after which
any further increase in the pressure drop does not yield an increase in flow rate. This
point, called choked flow, is illustrated in Figure 24-3.
24-4
Figure 24-3
Effects of Vaporization
In liquids, when the pressure at any point in the valve drops below the vapor pressure
of the fluid (as shown in Figure 24-1), vapor bubbles form. These bubbles occupy more
volume than the liquid from which they were formed. As further increases in pressure
drop occur across the control valve, the proportion of bubbles to liquid increases until
the volume of the flow is so great that the valve cannot pass additional flow. When
additional flow can not be passed, the pressure drop at this point is referred to as the
choked pressure drop point (see Section 8.2.3 for additional discussions).
In gases, as the downstream pressure decreases with a corresponding increase in
pressure drop, the velocity of the gas across the vena contracta increases due to the
increasing volume of the gas. When the velocity reaches sonic (Mach = 1.0), any further
increase in the pressure drop due to decreased downstream pressure will not result in
additional flow. Sonic velocity generally occurs when the total valve pressure drop is
greater than about one half of the absolute inlet pressure (psia) but should be calculated
for each unique situation. The pressure drop that corresponds to the sonic velocity
condition across the vena contracta is the choked (or critical flow) pressure drop (see
Appendix D in Reference 1.6 for additional discussions).
When sizing a control valve, the actual pressure drop should be compared to the
allowable pressure drop, and the smaller of the two must be used in the sizing
equation. This does not imply that the control valve cannot operate at the higher
24-5
pressure drop, but that only the lower pressure drop is effective in producing flow
under the stated conditions.
Cavitation. In liquids, when the pressure at the vena contracta drops below the vapor
pressure of the fluid, vapor bubbles begin to form in the fluid stream. Downstream
from the vena contracta, the fluid decelerates with a resultant increase in pressure. If
this pressure is higher than the vapor pressure, the bubbles collapse (or implode) as the
vapor returns to the liquid phase. This two-step mechanism, called cavitation, produces
noise and vibration and causes physical damage to the valve and downstream piping.
The onset of cavitation, known as incipient cavitation, is the point when the bubbles first
begin to form and collapse. It can be determined from Equation 24-6. The point at
which full or choked cavitation occurs (severe damage, vibration, and noise) can be
determined from Equation 24-4. Under choked conditions, allowable pressure drop
is the choked pressure drop. Continuous operation under cavitation or choking
conditions should be avoided.
Liquid Pressure Recovery Factor (FL). The liquid pressure recovery factor (FL) predicts the
amount of pressure recovery that will occur between the vena contracta and the valve
outlet. FL is an experimentally determined coefficient that accounts for the influence of
the valves internal geometry on the maximum capacity of the valve [6.37, 6.38].
FL also varies according to the valve type. High recovery valves, such as butterfly and
ball valves, have significantly lower pressures at the vena contracta and, therefore,
recover more for the same pressure drop than a globe valve. Thus, butterfly and ball
valves tend to choke (or cavitate) more easily than globe valves.
Liquid Critical Pressure Ratio Factor (FF). The liquid critical pressure ratio factor (FF),
multiplied by the vapor pressure, predicts the theoretical vena contracta pressure at the
maximum effective (choked) pressure drop across the valve.
Flashing. Flashing occurs when the downstream pressure is equal to or less than the
vapor pressure. Vapor bubbles formed at the vena contracta do not collapse, resulting
in a two-phase (liquid-vapor) mixture downstream of the valve. Velocity of this twophase flow is usually high and may erode the valve and piping components.
Choked Flow. Choked flow is a limiting, or maximum, flow rate. With fixed inlet
(upstream) conditions, it is manifested by the failure of decreasing downstream
pressure to increase the flow rate. With liquid flows, choking occurs as a result of
vaporization of the liquid when the pressure within the valve falls below the vapor
pressure of the liquid at operating temperature. Choked flow will be accompanied by
either cavitation or flashing. If the downstream pressure is greater than the vapor
pressure of the liquid, cavitation occurs. If the downstream pressure is equal to or less
than the vapor pressure of the liquid, flashing occurs.
24-6
Choked flow occurs when the fluid velocity approaches sonic values at any point in the
valve or line. This happens in liquids when the vapor, formed as the result of pressure
drop, increases the specific volume of the fluid to the point where sonic velocity is
reached. In gases, as the pressure in the downstream line is lowered, the specific
volume increases to the point where sonic velocity is reached. Lowering the
downstream pressure beyond this point in either case will not increase the flow rate.
The velocity at any point in the valve or downstream piping is limited to sonic (Mach =
1.0). As a result, the flow rate will be limited to an amount which yields a sonic velocity
under the specified pressure conditions.
Reynolds Number Factor (FR). Nonturbulent flow occurs at high fluid viscosities and/or
low velocities. In these circumstances, the flow rate through a valve is less than for
turbulent flow, and the Reynolds number factor FR must be introduced. FR is the ratio of
nonturbulent flow rate to the turbulent flow rate predicted using Equation 24-1 (see
also Equation 24-2).
Piping Geometry Factor (Fp). Valve sizing coefficients are determined from tests run with
the valve mounted in a straight run of pipe that is the same diameter as the valve body.
If the process piping configurations are different from the standard test manifold, the
valve capacity is changed. These differences can be approximated by the use of the
piping geometry factor (Fp). The effect of the piping geometry factor is significant only
at large disc openings (see Appendix D in Reference 1.6).
Velocity. As a general rule, valve outlet velocities should be limited to the following
maximum values:
Liquids
Gases
Mixed Gases
and Liquids
The above values are guidelines for typical applications. In general, smaller sized
valves can handle slightly higher velocities, and large valves can handle lower
velocities. Special applications have special velocity requirements, some of which are
described below.
In liquid applications where the fluid temperature is close to the saturation point, the
valve outlet velocity should be limited to 30 feet per second (9 m/sec) to avoid
reducing the fluid pressure below the vapor pressure. This limit is also appropriate for
applications designed to pass the full flow rate with a minimum pressure drop across
the valve.
24-7
The velocity in valves in cavitating service should also be limited to 30 feet per second
(9 m/sec) to minimize damage to downstream piping and to localize the pressure
recovery that causes cavitation immediately downstream from the vena contracta.
In flashing services, velocities become much higher due to the increased volume
resulting from vapor formation. For most applications, it is important to keep velocities
below 500 feet per second (152 m/sec). Expanded outlet style valves help to control
outlet velocities on such applications. Erosion damage resulting from flashing can be
limited by using chrome-moly body material and Stellite overlaid trim. On smaller
valve applications that remain closed most of the time, such as emergency heater drain
valves, velocities of up to 1500 feet per second (457 m/sec) may be acceptable.
In gas applications where special noise attenuation trim is used, the velocity
downstream of the valve should be limited to approximately 0.33 Mach. In addition,
pipe velocities downstream from the valve are critical to the overall noise level.
Experimentation has shown that velocities around 0.5 Mach can create substantial
noise, even in a straight pipe. The addition of a control valve to the line will increase
the turbulence downstream, resulting in even higher noise levels. Equations to calculate
Mach velocities are given later in this section.
A comparison of the velocities stated above with those listed as reasonable for pipe
[5.3] reveals a considerable disparity due to different considerations required for sizing
pipe and sizing control valves.
The most important consideration when sizing pipe is line loss. Pipe and installation
cost must be weighed against the cost of energy required to move fluid through the
piping system. Losses due to velocity in the valve body (not to be confused with total
drop across the valve) are inconsequential compared with the piping system and,
therefore, are not a factor in determining energy requirements for the system.
Expansion Factor (Y). The expansion factor (Y) accounts for the variation in specific
weight as the gas passes from the valve inlet to the vena contracta. Y also accounts for
the change in cross-sectional area of the vena contracta as the pressure drop is varied.
Ratio of Specific Heats Factor (FK). The ratio of specific heats factor (FK) adjusts the
equation to account for the different behavior of gases other than air.
Terminal Pressure Drop Ratio (xT). The terminal pressure drop ratio for gases (xT) is used
to predict the choking point where additional pressure drop (by lowering the
downstream pressure) will not produce additional flow due to the sonic velocity
limitation across the vena contracta. This factor is a function of the valve geometry and
varies similarly to FL, depending on the valve type.
24-8
Compressibility Factor (Z). The compressibility factor (Z) is a function of the reduced
temperature and the reduced pressure of a gas. Z is used to determine the density of a
gas at its actual temperature and pressure conditions.
q
F p FR
Gf
(Equation 24-2)
Pa
where
Cv
Fp
FR
Pa
Gf
psi
The following steps should be used to compute the required Cv, body size, and trim
size:
Step 1: Calculate actual pressure drop.
The actual pressure drop across the valve (P) may be found using the following
equation:
P = P1 P2
(Equation 24-3)
Where:
P1
P2
24-9
The allowable pressure drop may be less than the actual pressure drop if the flow is
choked.
Step 2: Check for choked flow, cavitation, and flashing.
P(choked) = FL2 (P1 FF Pv )
(Equation 24-4)
Where:
FL
FF
Pv
See Table 24-1 and Figures 24-4 and 24-5 for FL values, and Figure 24-6 for FF
values.
Table 24-1
Typical Valve Recovery Coefficients (FL) and Incipient Cavitation Factors (Fi)
NOTE: Values are given for full open valves unless otherwise stated.
Valve Type
Flow Direction
Trim Size
FL
Fi
Globe
Flow-to-close
Full Area
0.85
0.76
Flow-to-close
Reduced Area
0.80
0.72
Flow-to-open
Full Area
0.90
0.81
Flow-to-open
Reduced Area
0.90
0.81
60 Open
Full
0.74
0.64
90 Open
Full
0.56
0.49
Ball
90 Open
Full
0.60
0.54
Multi-Stage
Under Seat
All
1.0
1.0
Butterfly
24-10
Figure 24-4
Globe Valve FL Values
24-11
Figure 24-5
High Performance Butterfly/Ball FL Values
The liquid critical pressure ratio factor (FF) can be found from Figure 24-6 or estimated
using the following relationship:
FF = 0.96 0.28
Pv
Pc
(Equation 24-5)
Where:
24-12
FF
Pv
Pc
Critical pressure of the liquid, psia (see Table 24-2 for typical
critical pressures)
Figure 24-6
Liquid Critical Pressure Ratio Factor Curve
24-13
Table 24-2
Typical Critical Pressure Values
Liquid
Ammonia
Critical Pressure
(psia)
1,636.1
Liquid
Hydrogen Chloride
Critical Pressure
(psia)
1,205.4
Argon
707.0
Isobutane
529.2
Benzene
710.0
Isobutylene
529.2
Butane
551.2
Kerosene
350.0
1,070.2
Methane
667.3
507.1
Nitrogen
492.4
Carbon Dioxide
Carbon Monoxide
Chlorine
1,117.2
Nitrous Oxide
1,051.1
Dowtherm A
547.0
Oxygen
732.0
Ethane
708.5
Phosgene
823.2
Ethylene
730.5
Propane
615.9
Fuel Oil
330.0
Propylene
670.3
Fluorine
757.0
Refrigerant 11
639.4
Gasoline
410.0
Refrigerant 12
598.2
Helium
32.9
Refrigerant 22
749.7
Hydrogen
24-14
188.1
Sea Water
3,200.0
Water
3,198.7
If P(choked), as calculated from Equation 24-4, is less than the actual pressure drop from
Equation 24-3, use P(choked) in Equation 24-2.
It may also be useful to determine the point at which cavitation begins. If cavitation is
marginal, it may possibly be eliminated by simply turning the valve end-for-end in the
line, if permitted for this application. With the direction of flow thus reversed,
reconfirm the adequacy and stability of the actuator. The following equation defines the
pressure drop at which cavitation begins:
P(incipient ) = Fi2 (P1 Pv )
(Equation 24-6)
Where:
Fi
(Typical values for Fi are given in Table 24-1 and Figure 24-7.)
P1
Pv
Re v = 17,300
q Fd
Sv
FL C v Fp
(Equation 24-7)
Where:
24-16
Rev
Fd
Valve style factor (1.0 for globe valves, 0.71 for ball and butterfly
valves)
Fp
FL
Cv
Sv
Figure 24-7
Globe Valve Liquid Incipient Cavitation Factor (Fi) Values
24-17
Figure 24-8
Reynolds Number Factor
24-18
(Fp), which can be determined from Tables 24-5 and 24-6. If the pipe diameter is the
same as the valve size, Fp is 1.
Step 9: Calculate the final Cv from Cv Fp.
Step 10: Calculate the valve exit velocity.
The following equation is used to calculate entrance or exit velocities for liquids:
V = 0.321
q
A
(Equation 24-8)
Where:
q
Velocity, ft/sec
24-19
Table 24-3
Typical Values of Cv: Globe Valve, Flow over the Seat
Valve Type:
Body Rating:
Trim Characteristics:
Flow Direction:
Unbalanced
Class 150-600
Equal Percentage
Flow Over
For each valve size below, the full area values are shown on top for each size. Reduced
trim values follow, in descending order. All valve sizes in this table are in inches.
24-20
Table 24-4
Typical Values of Cv: Globe Valve, Flow under the Seat
Valve Type:
Body Rating:
Trim Characteristics:
Flow Direction:
Unbalanced
Class 150-600
Equal Percentage
Flow Under
For each valve size below, the full area values are shown on top for each size. Reduced
trim values follow, in descending order. All valve sizes in this table are in inches.
24-21
Table 24-5
Typical Piping Geometry Factors, Fp : Valve with both Reducer and Expander
Ratio d/D
Valve Size (in.)
0.50
0.60
Globe
0.70
0.80
0.90
Class 150-1500
1/2, 3/4
0.91
0.93
0.96
1-6
0.94
0.95
0.97
0.98
8-24
0.96
0.97
0.98
0.99
1.00
30-48
0.92
0.94
0.96
0.98
0.99
1.00
Class 2500
1/2-16
0.98
0.98
0.99
0.99
0.84
0.87
0.91
0.95
4, 6
0.80
0.84
0.88
0.94
0.98
8-12
0.77
0.82
0.87
0.93
0.98
14-24
0.70
0.75
0.82
0.90
0.97
Butterfly/Ball
Where:
d = Nominal valve size in inches
D = Internal diameter of the piping in inches
24-22
Table 24-6
Typical Piping Geometry Factors, Fp: Valve with Outlet Expander Only
Ratio d/D
Valve Size (in.)
0.50
0.60
Globe
0.70
0.80
0.90
Class 150-1500
1/2, 3/4
1.05
1.06
1.07
1-6
1.03
1.04
1.04
1.04
8-24
1.02
1.03
1.03
1.03
1.02
30-48
1.04
1.05
1.06
1.05
1.03
Class 2500
1/2-16
1.01
1.01
1.01
1.01
1.01
1.11
1.14
1.15
1.14
1.09
4, 6
1.16
1.21
1.24
1.21
1.12
8-12
1.20
1.27
1.31
1.27
1.16
14-24
1.36
1.52
1.62
1.52
1.28
Butterfly/Ball
Where:
d = Nominal valve size in inches
D = Internal diameter of the piping in inches
The maximum effective pressure drop (P(choked)) may be affected by the use of reducers
and expanders. This is especially true of ball and butterfly valves.
After calculating the exit velocity, compare the calculated number to the acceptable
velocity for that application. It may be necessary to go to a larger valve size.
Step 11: Recalculate Cv if the body size has changed.
Recalculate Cv if the Fp has been changed due to the selection of a larger body size.
24-23
Water
3198.7 psia
250F
314.7 psia
104.7 psia
0.94
Flow-to-open
4-inch (Class 600)
500 gpm
30 psia
0.14 centistokes
Equal Percentage
Solution:
Step 1: Calculate actual pressure drop using Equation 24-3:
P = 314.7 psia - 104.7 = 210 psid
Step 2: Check for choked flow. Find FL using Table 24-1. Looking under globe, flow-toopen, find FL as 0.90. Next, estimate FF using Equation 24-5:
FF = 0.960.28
30
= 0.93
3,198.7
24-24
Since the actual P is less than P(choked), the flow is not choked; therefore, use the actual
P to size the valve. At this point, also check for incipient cavitation using Equation 246 and Table 24-1:
P(incipient) = 0.812 (314.7 - 30) = 187 psid
Since P(actual) exceeds P(incipient), cavitation is occurring, but the flow is not choked.
Special attention should be paid to material selection.
Step 3: The specific gravity for water is given as 0.94.
Step 4: Calculate the approximate Cv FpFR using Equation 24-2, assuming FR and Fp are 1:
0.94
= 33.4
210
C v = 500
Step 5: Calculate the valve Reynolds number (Rev) using Equation 24-7:
Re v =
(0.90)(33.4)(1)
= 11.3x10 6
= 0.5
33.4
0.94
Step 10: Using Equation 24-8, the velocity for a 2-inch body is found to be nearly 51
ft/sec. Since this application is cavitating, this velocity may damage a 2-inch valve.
Therefore, calculate the velocity for a 3-inch body. This choice lowers the velocity to 22
24-25
ft/sec, which is acceptable. In this example, a 4-inch valve with 2-inch trim could also
be chosen. It may be less costly than a 3-inch valve, and the larger outlets will lower the
velocities. It may also be less costly to install a 4-inch valve in a 4-inch line.
Step 11: Since the body size has changed, recalculate the Cv by following Steps 8 and 9.
The Fp is now 0.97 and the final Cv is 34.4.
Step 12: Referring to the Cv tables, for a Cv of 34, a 3-inch valve would require at least a
trim size of 1.25. A trim size of 2.0 would also suffice.
Example Two (for Liquid Sizing):
Given:
Liquid
Critical Pressure (Pc)
Temperature
Upstream Pressure (P1)
Downstream Pressure (P2)
Specific Gravity
Valve Action
Line Size
Flow Rate
Vapor Pressure (Pv)
Kinematic Viscosity
Flow Characteristic
Ammonia
1636.1 psia
20F
149.7 psia
64.4 psia
0.65
Flow-to-close
3-inch (Class 600)
850 gpm
45.6 psia
0.02 centistokes
Linear
Solution:
Step 1: Calculate actual pressure drop using Equation 24-3.
P = 149.7 psia - 64.4 psia = 85.3 psid
Step 2: Check for choked flow. Find FL using Table 24-1. Looking under globe, flow-toclose, find FL as 0.85. Next, estimate FF using Equation 24-5:
FF = 0.96 0.28
24-26
45.6
= 0.91
1,636.1
0.65
78.2
= 77.5 gpm
psi
Step 5: Calculate the valve Reynolds number (Rev) using Equation 24-7:
Re v =
(0.85)(77.5)(1)
= 90.6x10 6
Flashing Liquid Velocity Calculations: When the valve outlet pressure is lower than or
equal to the saturation pressure for the fluid temperature, part or all of the fluid flashes
into vapor. When flashing exists, the following equation, applicable to any fluid, can be
used to determine flow velocity:
V=
0.040
A
Xp
Xp
Vf2 +
Vg2 W
1
100%
100%
(Equation 24-9)
Xp
Xp
20
Vf2 +
Vg2 q
1
A 100%
100%
(Equation 24-10)
Where:
V
Velocity, ft/sec.
Vf2
Vg2
Xp
Calculating Percentage Flash: The percent flash (Xp) can be calculated from
Equation 24-11:
Xp =
h f1 h f2
(100%)
h fg2
(Equation 24-11)
Where:
24-28
Xp
hf1
hf2
hfg2
When the fluid of concern is water, the enthalpies (hf1, hf2, and hfg2) and specific volumes
(Vf2 and Vg2) can be found in the saturation temperature and pressure tables and the
enthalpy (hf1) in the saturation temperature tables of a set of steam tables.
Flashing Liquid Example. Assume that the water temperature at the valve inlet is
350F, and the pressure at the valve outlet is 105 psia. Referring to a set of saturated
steam temperature tables, the saturation pressure of water at 350F is found to be 134.5
psia, which is greater than the outlet pressure of 105 psia. Therefore, the fluid is
flashing. Since a portion of the liquid is flashing, Equations 24-10 and 24-11 must be
used. Xp (percent flashed) can be determined using Equation 24-11 and the given
information:
hf1 = 321.8 Btu/lb at 350F
Xp =
321.8 302.3
886.5
(100%) = 2.2%
Therefore, the velocity can be determined from Equation 24-10 using the following
information:
Vf2 = 0.0178 ft3/lb at 105 psia (from saturation pressure tables)
Vg2 = 4.234 ft3/lb at 105 psia (from saturation pressure tables)
V=
(20)(500)
2.2%
2.2%
1
(0.0178) +
3.14
100%
100%
(Equation 24-12)
24-29
Q = 1,360 Fp C v P1 Y
x
G g T1 Z
(Equation 24-13)
W = 19.3 Fp C v P1 Y
x Mw
T1 Z
(Equation 24-14)
Q = 7,320 Fp C v P1 Y
x
M w T1 Z
(Equation 24-15)
Where:
W
Fp
Cv
Expansion factor
Gg
T1
Compressibility factor
Mw
Molecular weight
P1
psi
The numerical constants in the above equations are unit conversion factors.
The following steps should be used to compute the correct Cv, body size, and trim size:
Step 1: Select the appropriate equation.
24-30
Based on the information available, select one of the four equations: 24-12, 24-13,
24-14, or 24-15.
Step 2: Check for choked flow.
Determine the pressure drop ratio (xT) for the valve by referring to Table 24-7.
Next, determine the ratio of specific heats factor (Fk) using Equation 24-16:
Fk =
k
1.40
(Equation 24-16)
Where:
Fk
Ratio of specific heats (taken from Table 24-8, Gas Physical Data)
Table 24-7
Terminal Pressure Drop Ratios (xT)
Valve Type
Flow Direction
Trim Size
xT
Globe
Flow-to-close
Full Area
0.70
Flow-to-close
Reduced Area
0.70
Flow-to-open
Full Area
0.75
Flow-to-open
Reduced Area
0.75
Multi-Stage
Under Seat
All
1.00
High Performance
60 Open
Full
0.46
Butterfly
90 Open
Full
0.26
Ball
90 Open
Full
0.25
24-31
Table 24-8
Gas Physical Data
Critical
Pressure (psia)
492.4
Critical
Temperature (R)
227.1
Molecular
Weight (Mw)
28.9
Ratio of Specific
Heats (k)
1.4
1636.1
730.0
17.0
1.31
707.0
271.4
39.9
1.67
1070.2
547.5
44.0
1.29
Carbon Monoxide
507.1
239.2
28.0
1.4
Ethylene
730.5
508.3
28.0
1.40
Ethane
708.5
549.7
30.0
1.19
Helium
32.9
Gas
Air
Ammonia
Argon
Carbon Dioxide
9.34
4.00
1.66
Hydrogen
188.1
59.7
2.01
1.4
Methane
667.3
343.0
16.04
1.31
Natural Gas
667.3
343.0
16.04
1.31
Nitrogen
492.4
227.1
28.0
1.4
Oxygen
732.0
278.2
32.0
1.4
Propane
615.9
665.6
44.0
1.13
3198.7
1165.5
18.02
1.33
Steam
Calculate the ratio of actual pressure drop to absolute inlet pressure (x) using Equation
24-17.
x=
P
P1
(Equation 24-17)
Where:
24-32
P1
Choked flow occurs when x reaches the value of FkxT. Therefore, if x is less than Fk xT,
the flow is not choked. If x is greater than Fk xT, the flow is choked. If the flow is choked,
then FkxT should be used in place of x (whenever it applies) in the gas sizing equations.
Step 3: Calculate the expansion factor.
The expansion factor (Y) may be expressed as:
Y= 1
x
3 Fk x T
(Equation 24-18)
If the flow is choked, use F kxT instead of x (that is, Y = 2/3 at choked flow).
Step 4: Determine the compressibility factor.
To obtain the compressibility factor (Z), first calculate the reduced pressure (Pr) and the
reduced temperature (Tr):
Pr =
P1
Pc
(Equation 24-19)
Where:
Pr
P1
Pc
Tr =
T1
Tc
(Equation 24-20)
Where:
Tr
T1
Tc
24-33
Figure 24-9
Compressibility Factors for Gases with Reduced Pressures from 0 to 40
24-34
Figure 24-10
Compressibility Factors for Gases with Reduced Pressures from 0 to 6
24-35
If the pipe size is not given, use the approximate body size (from Step 6) to choose the
corresponding pipe size. The pipe size is used to calculate the piping geometry factor
(Fp), which can be determined from Table 24-5 or 24-6. If the pipe diameter is the same
as the valve size, then Fp = 1.
Step 8: Calculate the final Cv.
With the calculation of Fp, determine the final Cv.
Step 9: Calculate the valve exit velocity.
Equations 24-21, 24-22, 24-23, or 24-24 are used to calculate entrance or exit velocities
(in terms of the approximate Mach number). Use Equations 24-21 or 24-22 for gases,
Equation 24-23 for air, and Equation 24-24 for steam.
Q
M gas =
k T
Mw
5,574A
M gas =
k T
Sg
1,035A
Q
1,225A
M air =
M steam =
WS
1,515A
(gas flow)
(Equation 24-21)
(gas flow)
(Equation 24-22)
(air flow)
(Equation 24-23)
(steam flow)
(Equation 24-24)
Where:
24-36
Actual flow rate in cubic feet per hour (CFH, not SCFH)
Sv
Sg
Mw
Molecular weight
Ps Vs
Ts
(Equation 24-25)
Where:
Pa
Va
Ta
Ps
Vs
Ts
After calculating the exit velocity, compare the calculated velocity to the acceptable
velocity for that application. Select a larger size valve if necessary.
Step 10: Recalculate Cv if the body size has changed.
Recalculate Cv if Fp has been changed due to the selection of a larger body size.
Step 11: Select the trim size.
Identify if the valve will be used for on-off or throttling service. Using the Cv tables,
select the appropriate trim size for the Cv calculated and the body size selected. The trim
size and flow characteristic may be affected by how the valve is throttled.
24-37
Steam
Temperature (T1)
910R (450F)
139.7 psia
49.7 psia
10,000 lb/hr
Valve Action
Flow-to-open
3,198.7 psia
1165.5R (705.5F)
18.026
1.33
Flow Characteristic
Equal percentage
Line Size
1.079 ft3/lb
Solution:
Step 1: Given the above information, Equation 24-14 can be used to solve for Cv.
Step 2: Referring to Table 24-7, the pressure drop ratio (xT) is 0.75. Calculate Fk using
Equation 24-16 and x using Equation 24-17:
Fk =
24-38
1.33
1.40
= 0.95
x =
139.7 49.7
139.7
= 0.64
Therefore, Fk xT is 0.71 (= 0.95 x 0.75). Since x is less than Fk xT, the flow is not choked.
Use x in all equations.
Step 3: Determine Y using Equation 24-18:
Y = 1
0.64
(3)(0.71)
= 0.70
Step 4: Determine Z after calculating Pr and Tr using Equations 24-19 and 24-20:
Pr =
139.7
3,198.7
Tr =
450.0 + 460
705.5 + 460
= 0.04
= 0.78
10,000
(19.3)(139.7)(0.70)
(910)(1.0)
(0.64)(18.026)
= 47.1
Step 6: From Table 24-4 (flow-under, equal percentage, Class 600), select the smallest
body size for a FpCv of 47.1, which is a 2-inch body.
Steps 7 and 8: Because the pipe size is the same as the body, Fp is 1. The Cv remains 47.1.
Step 9: Since the gas is steam, calculate the velocity using Equation 24-24:
M steam =
(10,000)(1.079)
1,515 (3.14) 450 + 460
= 0.075
Step 10: The velocity is low and does not affect the current size selection.
Step 11: Referring to Table 24-4, a C v of 47.1 would require a 2-inch body with a trim
size of 1.62.
24-39
xl
Natural Gas
Temperature (T1)
525R (65F)
1314.7 psia
99.7 psia
Flow Rate
2,000,000 SCFH
Valve Action
Flow-to-open
672.92 psia
344.2R (-115.80F)
16.042
1.32
Flow Characteristic
Linear
Line Size
0.55
Solution:
Step 1: Given the above information, Equation 24-15 can be used to solve for Cv.
Step 2: Referring to Table 24-7, the pressure drop ratio (xT) is 0.75.
Calculate Fk using Equation 24-16 and x using Equation 24-17:
Fk =
24-40
1.32
1.40
= 0.94
x =
1,314.7 99.7
1,314.7
= 0.92
Therefore, Fk xT is (0.94) (0.75) or 0.71. Since x is greater than Fk xT, the flow is choked.
Use Fk xT in place of x in all equations.
Step 3: Determine Y using Equation 24-18:
Y = 1
0.71
3 (0.71)
= 0.67
1,314.7
672.92
Tr =
65 + 460
115.80 + 460
= 1.95
= 1.53
2,000,000
(7,320)(1,314.7)(0.67)
(16.04)(525)(0.85)
= 31.1 gpm/ psi
0.71
Step 6: From Table 24-4 (flow under, linear, Class 600), select the smallest body size for
a Cv of 31.1, which is a 1-1/2-inch body.
Steps 7 and 8: Since the pipe size is unknown, use 1 as the Fp factor. The Cv remains
31.1.
Step 9: Since the gas is natural gas, calculate the velocity using Equation 24-22:
M gas =
293,209 *
(1.32) (65+ 460)
(1,035)(1.23)
0.55
= 6.49
level. To properly size the valve, select a size to reduce the velocity to less than 1.0
Mach.
Step 11: Using Equation 24-22, solve for the minimum valve area (A) required for
subsonic velocity as follows:
293,209 CFH
M gas =
1,035 A
(1.33)(65+460)
0.55
= 1.0
A = 7.95 inch2
Solve for the valve diameter from the area by:
A =
d2
4
d =
4A
(4)(7.95)
= 3.18 inch
cavitation range, and the remaining drop is taken across the breakdown orifice. In
addition to the cavitation problem, tight shutoff is important since even the smallest
leakage across the seat will destroy the trim in a relatively short period of time under
high pressure drop conditions. By careful selection of orifice size and sufficient seat
loading, this approach has been marginally successful in the past.
In the control of high pressure reduction of liquids, conventional valves convert inlet
pressure to kinetic energy with corresponding excessive velocities. These high
velocities result in erosion, vibration, and usually cavitation. Control of high pressure
liquids, without the erosive effects that lead to premature failure of conventional
valves, is currently accomplished through the use of high pressure anticavitation valves
used as shown in Figure 24-12. In these valves, the fluid pressure is reduced through
multiple steps so that each step handles only a fraction of the total pressure drop. As a
result, there is neither cavitation nor the associated phenomena of noise and trim
erosion.
Use of this type of valve, shown in Figure 24-13, eliminates the need for breakdown
orifices. Smooth, vibration-free operation can be achieved with the multiple-step plug
and cage design and is applicable wherever there is a need for high pressure reduction
of liquids, especially those that tend to cavitate in conventional valves. The multiplestep design makes it ideal for modulating applications.
24-43
Figure 24-11
Conventional Method of Recirculation Control: Control Valve (On-Off) in Series
with a Breakdown Orifice
Figure 24-12
Method of Recirculation Control Using High Pressure, Modulating Anti-Cavitation
Valve
24-44
Figure 24-13
Globe Angle Control Valve with Anti-Cavitation Trim
24-45
Example:
Required:
505,000 lb/hr
Fluid Temperature
335F
Solution:
Use the inlet pressure as the sizing pressure drop since this design can handle the drop
without cavitation. No breakdown orifice is required.
Using Equation 24-5, the liquid critical pressure ratio is found to be:
FF = 0.96 0.28
110
3,198.7
= 0.91
The vapor pressure of water at 335F is 110 psia [5.3]. The choked differential pressure
is determined from Equation 24-4:
P(choked) = 1[3,515 (0.91)(110)] = 3,415 psi
Since the choked flow differential pressure is less than the actual differential pressure,
this smaller value is applied in Equation 24-2 to determine the required C v. The flow
rate is converted from lb/hr to gpm.
C v = 1,122
0.9
= 18 gpm/ psi
3,415
Thus, the required Cv = 18. From manufacturers data, select a 3-inch valve:
2500 lb ANSI rating
Carbon steel body
Balanced trim
440-C plug
Teflon soft seat (for tight shutoff)
24-46
24-47
Figure 24-14
Globe Control Valve with Low Noise Trim
24-48
Example:
Required:
Outlet pressure
Atmospheric
Flow
403,000 lb/hr
Temperature
547F
Class 2
1.33
1.40
= 0.95
1,025
1,040
= 0.9856
0.95
(3)(0.95)(1)
= 0.6667
24-49
403,000
(63.3) (0.6667)
Valve Selection:
Required Cv is 199 gpm/ psi
Use an 8-inch valve
Carbon steel body
600 lb ANSI
Lo-dB trim with diffuser and Lo-dB plates for SPL less than 90 dBA
Rated Cv is 275
Spring diaphragm actuator
Stroking speed - less than 3 seconds
Maximum allowable pressure drop 1,100 psi
Seat leakage - ANSI/FCI 70-2-1976 (R1982)
Meets requirements of ASME Section III, Class 2
24-50
One of the means available for controlling steam temperature in non-nuclear plants is
by attemperation. An attemperator is a device that reduces the temperature of a
superheated vapor or of a fluid passing through it.
Attemperators may be classified as of two types surface and direct contact. In the
surface type, the steam is isolated from the cooling medium by the heat exchanger
surface. In the direct contact type, the steam and the cooling medium are mixed. The
direct contact type spray attemperator has proved successful for regulating steam
temperature. Feedwater is introduced into the superheated steam line through a spray
nozzle at the throat of a venturi section within the line. Because of the spray action at
the nozzle, the water quickly vaporizes, mixes with, and cools the steam. The spray
attemperator is used to control the steam temperature in the superheater and the
reheater. This application is similar to the boiler feedwater pump recirculation control
valve application in that cavitation protection and tight shutoff is required. In the
primary superheater section, the full feedwater pump discharge pressure is used as the
inlet pressure to the spray valve. In the reheater section, lower steam pressures are
involved, and the customary practice is to tap an interstage section of the feedwater
pump.
In the control of high pressure reduction of liquids, conventional valves convert inlet
pressure to kinetic energy, which results in excessive velocities, causing erosion,
vibration, and usually cavitation. A valve such as that shown in Figure 24-13 can be
used to control high pressure liquids without the erosion effects that lead to premature
failure of conventional valves. The fluid pressure is reduced through multiple steps so
that each step handles only a fraction of the total pressure drop. As a result, there is
neither cavitation nor the associated phenomena of noise and trim erosion. The use of
this style valve results in smooth, vibration-free operation, due to the multiple-step
plug and cage design, and is applicable wherever there is a need for high pressure
reduction of liquids, especially those that tend to cavitate in conventional valves. The
multiple-step design makes it ideal for throttling applications.
Example:
Required:
Outlet pressure
Flow
180 gpm
Temperature
365F
24-51
Solution:
From Equation 24-5,
FF = 0.96 0.28
162.7
3,198.7
= 0.90
0.88
15
= 44 gpm/ psi
typical condensate system with secondary items, such as alarm switches and interlocks,
removed for clarity. The level in the deaerating feedwater heater storage tank is
maintained by the deaerator level control valve that throttles the condensate pump
discharge and regulates the flow of condensate to the deaerator. The requirements of
this valve are twofold: (1) During startup and minimum load conditions, the deaerator
level control valve must handle low flow at a high pressure drop. (2) While under
normal loads, it must pass a large flow with a relatively low pressure drop.
Figure 24-16 shows a typical condensate system curve and the pressure drop available
for the deaerator level valve at various load conditions. The high pressure drop at low
flow rate induces cavitation that, if not properly controlled, can destroy the valve.
Therefore, the valve trim must be specifically designed to minimize the effects of
cavitation at low flows with near pump shutoff head on the valve inlet with
atmospheric outlet pressure.
The valve shown in Figure 24-17, with a special cage to provide cavitation protection
for approximately the first 25% of stroke and ample flow area to provide the required
capacity for the remainder of the stroke, is well suited for this application.
Figure 24-15
Typical Condensate System
24-53
Figure 24-16
Typical Condensate System Curve
Figure 24-17
Globe Control Valve with Anti-Cavitation Variable Resistance Trim
24-54
Normal
Maximum
700
5,860
6,590
P1 (psig/psia)
475/490
359/374
344/359
P2 (psig/psia)
35/50
222/237
267/282
100
151
156
33
495
743
T (F)
Cv
At minimum conditions:
Using Equation 24-5,
FF = 0.96 0.28
0.95
3,198.7
= 0.96
0.94
440
= 33 gpm/ psi
At normal conditions:
FF = 0.96 0.28
3.75
= 0.95
3,198.7
24-55
0.98
137
At maximum conditions:
FF = 0.96 0.28
4.5
3,198.7
= 0.95
0.98
77
contained some form of anti-cavitation trim, is utilized to handle the low flow high
pressure drop conditions. Once beyond the cavitation range, the conventional control
valve is used to obtain the required capacity. This approach has been successful in the
past but necessitated the additional expense of a bypass system with its associated
piping and controls.
Figure 24-18
Main Feedwater System
24-57
The valve shown in Figure 24-17 represents another approach to the control of high
pressure liquids and can be used quite successfully in this application. Cavitation
protection is provided through the first 20% of the rated capacity by the variable
resistance trim concept. Pressure distribution reduces the fluid pressure through
multiple stages so that each stage handles only a fraction of the total pressure drop. As
a result, there is neither cavitation nor the associated phenomena of noise and trim
erosion. Above 20% of the rated capacity, the conventional cage trim provides ample
flow capacity. This concept, with features such as axial flow through segmented plates,
results in a feedwater control valve with high controllability, extended valve life, and
maximum cavitation protection.
Typical service conditions are:
Minimum
Maximum
900
3,300
P1 (psig/psia)
3,300/3,315
2,650/2,665
P2 (psig/psia)
105/120
2,550/2,565
290
350
15
311
Q (gpm)
T (F)
Cv
At minimum conditions:
From Equation 24-5,
FF = 0.96 0.28
57
3,198.7
= 0.92
24-58
0.92
3,195
= 15 gpm/ psi
At maximum conditions:
FF = 0.96 0.28
134
= 0.90
3,198.7
0.89
100
24-59
25
APPENDIX C: VALVE PROCUREMENT
SPECIFICATION
25.1 General
The applicable code or standard has to be established prior to procuring a valve. For
new construction, the code or standard is established by licensing documents/permits
for nuclear plants, by the issue of standards referenced in the governing edition of
ANSI B31.1, and by Appendix F of ANSI B31.1 for non-nuclear balance-of-plant and for
fossil plants.
Once a nuclear plant goes into operation, ASME XI governs for the nuclear plant
equipment. ASME XI requires that replacements meet the requirements of the edition of
the construction code to which the original component was constructed. ASME XI
permits replacements to meet the requirements of all, or a portion of, later editions of
the construction code or ASME III if the four requirements described in ASME XI, IWA7210 [6.8], are met. ANSI B31.1 has no similar rules or instructions for a plant in-service.
When ordering replacement nuclear valves, some utilities invoke the older codes, as
permitted by ASME XI. This can present some difficulties, particularly for older plants.
Manufacturers, for the most part, are geared up to present-day codes, and materials.
Manufacturers do not produce materials to older codes or standards. However,
regardless of the code specified in the valve order, the valves must be manufactured
under a Quality Assurance Program that complies with 10CFR50, Appendix B.
Discussions with manufacturers indicate ordering to older codes or standards is still
occurring, but the trend is to order using the latest code or standard. Replacement
valves for ANSI B31.1 applications should use the newer codes or standards.
When preparing specifications for valves for nuclear plants, it is recommended that the
following three documents be consulted for overall content:
1. Guidelines for Preparing Specifications for Nuclear Power Plant Applications (NCIG-04),
EPRI Report No. NP-5638, dated April 1988, prepared for the Nuclear Construction
Issues Group and the Electric Power Research Institute.
25-1
25-2
Packing material should be specified rather than determined by the vendor. When
ordering a line valve or a resilient seated valve, be specific as to what generic material
is desired (for example, natural rubber, Buna N, Teflon, etc.).
End-to-End Dimension. For replacement valves, specify the end-to-end dimension of the
original valve which may be in accordance with ANSI B16.10 [6.17]. If the replacement
valve is shorter than the original valve, then consideration should be given to weld the
necessary pipe length to the ends of the replacement valve, with appropriate weld
preps, in order to shorten replacement time at the plant.
For new systems, specify ANSI B16.10. ANSI B16.10 permits options on end-to-end
dimensions for types within the same generic grouping (for example, pressure seal
valves can be short pattern or long pattern). For control and relief valves, the
manufacturer should be consulted.
End Connection. Specify the end connection that is compatible with the installation
method and the piping into which it will be installed. For welding end valves, specify
ANSI B16.25 [6.23] and the schedule of the piping. If special welding details or
dimensions are required, a weld preparation drawing should be provided.
For socket weld valves, specify ANSI B16.11 [6.18]. Also specify the required hub
thickness against which face the fillet weld will be applied to ensure that the weld
dimension of ASME III or ANSI B31.1 can be maintained.
For flange end valves, specify ANSI B16.5 [6.15] and the pressure class.
Overpressure Protection for Gate Valves. Specify the method to be used if overpressure
protection is required, such as providing a bypass from the bonnet cavity to the
upstream nozzle or providing a relief valve or a connection for a relief valve to be
provided by others. Section 4.2.9 discusses overpressure protection options.
Internal Locking Device. Specify proven locking devices, and specify that internal locking
devices should be of corrosion-resistant material.
Handwheels/Gear Operators. Specify the limit of rim pull for manual valves and motoroperated valves. The differential pressure will have to be specified. See Section 14 for
recommended handwheel rim pull limits.
Nondestructive Examination (NDE). Specify only that NDE that is really required. NDE
specified by the applicable code or standard is normally adequate. NDE in excess of the
codes and standards is recommended for such things as:
Visual inspection to MSS-SP-55 [6.47] for all cast steel parts that act as structural
parts (vs. pressure-retaining parts) of the assembly, such as a valve yoke.
25-3
NDE of butt weld ends of cast valves, using the same method that will be used for
the weld that joins the valves to the piping in the plant. This NDE should detect
imperfections at the manufacturers shop that might otherwise be detected later in
the finished installation and would have to be evaluated.
Consumable Parts and Fasteners. Require that parts such as studs, bolts, nuts, gaskets,
packing, and O-rings be identified as to specific material and that the dimensions be
specified. This is to allow replacements to be ordered directly from the part
manufacturer, thereby reducing costs, improving delivery times, and permitting
consolidation of spare parts.
Hydrostatic or Air Testing. Specify a hydrostatic shell and disc or seat test for all valves.
Check the specified code or standard to see if an acceptance criterion for seat leakage is
defined. Some codes or standards give options for seat leakage or give no criteria at all.
Ensure that seat leakage criteria is specified precisely in some manner.
An additional air seat test should also be specified if the valve will be tested with air
after it is in service, such as a containment isolation valve. The air test pressure should
be the same pressure at which the valve will be tested in service.
Operational Tests. Specify operational tests for all power-operated valves and check
valves to ensure that valves operate freely with no binding.
Review the nuclear qualification requirements, and specify any further required tests
(for example, operational tests with differential pressure, operational tests with external
loads applied, etc.). Active valves may require additional testing, such as a static load
deflection test for operability.
Environmental Conditions. Environmental conditions should be specified for all ASME
III valves, or specify environmental conditions that envelope the group of valves being
ordered.
Seismic, Environmental, and Functional Qualifications. The extent and acceptable methods
of required seismic and environmental qualifications should be specified. The seismic
and environmental conditions for all power-operated valves and certain manual valves
have to be specified. See ASME III, paragraph NB-3524 [6.3], for guidance for ASME III,
class 1, 2, and 3 valves.
Evaluate the need to have active valves qualified in accordance with ANSI B16.41
[6.25], Functional Qualification Requirements for Power Operated Active Valve
Assemblies for Nuclear Power Plants.
Note that some fossil plants require seismic qualification for valves.
25-4
Drawings. Require drawings that show installation dimensions and provide information
as to the weight and center of gravity. For nuclear valves, the weight of the valve
assembly should be the actual weight, 10%.
In addition, require that detailed dimensional drawings of the valve internals be
provided if and at such time as the manufacturer is unable or unwilling to provide
replacement parts of the required quality level.
Instruction Manuals. Require that comprehensive instruction manuals be provided to
give details necessary for any required preventive or corrective maintenance.
Dimensions should be provided for such things as seat angles, gasket joints, and other
parts that are dimensionally critical.
Shipment. Require that all nuclear valves be weighed prior to shipment to ensure that
correct weights are available for any required piping stress analysis.
Motor Operators. The manufacturer or the user should demonstrate the MOV capability
to perform its functions under worst case conditions (including design basis conditions)
by testing and/or analysis. Furthermore, to help ensure that the motor operator is
properly paired with the valve, the following points should be considered:
Require that the valve and motor operator have the ability to withstand, without
damage, the stall torque/thrust at the maximum voltage. If this cannot be done, the
seller must make a recommendation and must reach agreement with the purchaser
on the course of action to be taken. The published nominal rating (the rating
without safety factor) must not be used without the purchasers concurrence.
Require that the valve assembly be furnished, complete and ready for operation
with all fasteners properly installed, including locking of the stem nut locknut.
Specify self-locking gearing to ensure that the operator will not be back driven by
the valve when the motor stops with attendant periodic operation of the torque
switch and motor. If this cannot be accommodated, the seller should receive
concurrence on another course of action that can be taken.
Ensure that there are a sufficient number of limit switches to perform all the
required functions of the valve.
Specify a handwheel to operate the assembly manually. This handwheel should not
rotate during electric operation, nor should a stalled motor prevent manual
25-5
operation. When the motor is energized, the motor operator should automatically
return to electric operation.
The motor operator should have a built-in lost motion device that permits the motor
to attain full speed before the load is encountered and that imparts a hammerblow
to start movement of the valve disc.
Power Operators. Require that power operators, including all accessories, be solidly
mounted to the valve.
Pneumatic Operators. The attached Instrument Society of America (ISA) data sheet
(Figure 25-5) shows the areas that must be considered in the specification of pneumatic
operators.
Take exception to the specification and include a variety of options that cover
various application contingencies.
When a quotation is strictly in accordance with the specification, the purchaser may not
be receiving the full advantage of the manufacturers experience with options that
could provide a better valve installation. The vendor is not likely to include options
that would improve the installation if the additional cost could jeopardize the chance of
receiving an order, since the order may be based on the lowest quoted cost. When the
request for a quotation includes words to the effect that no exceptions to the
specification will be accepted, the manufacturer will tend not to include items that
might improve the valve installation/application. With these additional items, the total
25-6
price of the quote may be more, hence less attractive than a competitors quote that was
in accordance with the specification and took no exceptions.
Two potential problem areas occur when the manufacturer interprets the specification.
First, the valve application may not be as the manufacturer assumed; consequently, the
wrong valve could be quoted. Second, the pricing of various quotes may not be
equivalent since various manufacturers could have made different assumptions;
therefore, it is difficult to compare quoted price and select the most economical quote.
When the quote contains a variety of options, the judicious acceptance of those options
may provide the best overall valve application/installation. However, the quotations
may be much more difficult to evaluate, due to the deviations from the base
specification by the various manufacturers who furnished quotations.
In summary, the selection of the proper valves for the intended applications requires
the careful evaluation of the manufacturers response to the specification and inclusion
of those deviations from the bid specification that are suitable and economically
justified. The addition of a little more cost during the engineering and construction
phase of the project (due to additional evaluation/review time or inclusion of options
that were not in the bid specification) can often be justified by the result that costly
repairs or loss of operating time is avoided during the life of the installation.
25-7
Note
Page
Spec. No.
P.O.
Date
Station:
Valve Identification No.
Type
Quantity
Size
Service/Fluid
End Connection
P&ID/Line No.
Design Pressure
10
Design Temperature
11
Materials
Body/Bonnet
12
Disc
Stem/Shaft
Ball/Plug
Body Lining
Packing
Seat Facing
Valve Location
13
Special Requirements
14
Figure 25-1
Suggested Manual Valve Data Sheet by Purchaser
3. Generic number assigned for a valve type and material together with other features
if used.
4. Brief description of valve usage (for example, main steam, feedwater, radioactive
liquid waste, resin slurry, etc.).
5. Identification of applicable code and standard (for example, ASME III CL2 CL150,
ANSI B16.34 CL600, ANSI B16.34 Special CL1500, etc.).
6. Flanged (for example, ANSI B16.5 CL150), butt weld (for example, ANSI B16.25 Sch
80), socket weld, threaded, etc.
7. P&ID and line number in which valve is installed.
8. Design pressure and temperature of the piping in which the valve is installed. See
Note 14.
9. The maximum differential pressure against which the valve must operate under all
normal or transient conditions.
10. The maximum differential pressure to which the disc/ball/plug must be designed,
if different from 9. If 9 and 10 are the same, combine 9 and 10. See Note 14e.
11. Both maximum and minimum flow rates for butterfly, ball, and check valves should
be given. The maximum flow rate should be given for other valves such as gate and
globe.
For check valves it is also recommended that normal flows be specified, together
with any change in process conditions (for example, steam pressure and
temperature for extraction non-return valves). For control valves, minimum,
normal, and maximum flows should be given.
12. Generic description of materials for parts (for example, carbon steel, stainless steel,
EPDM, etc.). Delete or add items as applicable. If items are addressed in the text of
the specification, refer to the text.
13. Location within the plant and environmental qualifications are required.
14. Specify any special requirements, such as:
a. Radiation, if not specified elsewhere.
b. Fluid chemistry for lined valves, or unique service.
25-9
c. For isolation valves used also for throttling, specify fluid, temperature, P
across valve, and flow rate under throttling conditions. This is particularly
important for globe, butterfly, and ball valves to ensure that the correct disc
characteristics are supplied.
d. Features and accessories not specified in data sheet or in text.
e. If the piping system can experience a transient condition when the design
temperature and pressure are exceeded, explain here. This is because piping
codes and standards have provisions for exceeding design conditions that do
not apply to valves.
25-10
Note
1
Station:
Valve Identification No.
Valve Description No.
Valve
Type
Quantity
Size
Pressure Class
Manufacturer Figure No./Model No.
End-to-End Dimension
Handwheel Diameter/Lever Length
Weight (including operator if required)
End Connection
Gear Operator
Manufacturers Fig. No.
Type
Handwheel Diameter
Materials
(include material specification or manufacturer
designation)
Body
Bonnet
Bonnet/Cover Bolting
Disc
Stem/Shaft
Ball/Plug
Body Lining
Seat Facing
Packing
Pipe Plugs
Performance Data
Cv
% Open for Throttling Condition
Maximum required shaft torque at maximum differential pressure
Normal Cycling
After prolonged idleness
Maximum handwheel input at maximum differential pressure
Page
Spec. No.
P.O.
Date
2
3
4
4
4
4
4
4
4
4
4
4
4
5
6
7
7
Figure 25-2
Suggested Manual Valve Data Sheet by Bidder/Seller
25-11
2.
3.
Generic number assigned for a valve type and material, together with other
features, if assigned.
4.
Material used in construction of the valves. Use items as applicable. Require that
the material designations be given or sufficient identifications provided so the
materials can be evaluated, such as:
Body - SA 351 CF8M
Stem/Shaft - ASTM A564 Gr 630
Lining - UHMP (Ultra High Molecular Weight Polyethylene)
Seat Facing - Stellite #6
5.
6.
7.
If sleeved plug valve or ball valve is ordered, the torque required under these
two conditions should be specified. The required torque can increase
significantly if the valve is not cycled frequently.
25-12
Note
Page:
Spec. No.
P.O.
Date:
Station:
Valve Identification No.
Valve:
Manufacturer
Model
Code (Include Class for ASME III)
Size
Service/Fluid
Design Pressure
10
8
11
Materials:
Body/Bonnet
12
Disc
12
Stem/Shaft
12
Packing
12
Seat Facing
12
Guide Facing
12
Detailed Dimensions
13
14
14
15
Valve Location
16
17
18
Actuator:
Manufacturer
Figure 25-3
Suggested Motor-Operated Valve Data Sheet by Purchaser
25-13
Size
Type
Gear Ratio
19
Electric Motor:
Manufacturer
Starting Torque
Running Torque
Enclosure
20
Power - Volts/Phase/Hz
21
Insulation Class
22
23
24
25
Open, max.
25
Close, +
%, -
25
Open, +
%, -
25
Special Requirements
26
5. Code or standard pressure class and valve type (for example, CL600 gate valve).
6. In reduced port designs, size reductions from nominal pipe size should be limited
to no more than two sizes.
7. Brief description of valve usage (for example, main steam, feedwater, radioactive
liquid waste, etc.).
8. Design pressure and temperature of the line in which the valve is installed.
9. The maximum differential pressure against which valve must operate under normal
or transient conditions.
10. The maximum differential pressure for which the disc/ball/plug must be designed
if different than 8. If 8 and 9 are the same, combine 8 and 9.
11. Specify the maximum flow rate because it can affect actuator sizing, particularly for
butterfly valves.
12. Generic description of materials (for example, carbon steel, 410 stainless steel, etc.).
Delete or add items as applicable. If items are addressed in the text of the
specification, refer to the text.
13. Specify or attach a description of detailed dimensions needed to perform detailed
analysis such as EPRIs PPM.
14. Specify the type of end connection on the inlet and outlet nozzles (for example,
ANSI B16.5 CL150 flange inlet, ANSI B16.5 CL300 flange outlet).
15. P&ID and line number in which the valve is installed.
16. Location within the power plant (for example, inside reactor containment, turbine
building). This is to correlate the valve location with the environmental conditions
given in the text of the specifications.
17. In the opening and/or closing direction using worst case operating conditions
including design basis conditions.
18. Such as EPRIs PPM, valve factor, seat and guide friction coefficients and packing
load.
19. Based on motor RPM and stroke time.
20. Type of enclosure desired (for example, totally enclosed, nonventilated [TENV]).
25-15
21. Available power supply (for example, 575 V/3 ph/60 Hz). Specify voltage range if
not given in the text.
22. Motor insulation class desired (for example, B, H).
23. Ambient temperature at valve location (for example, 50C).
24. Space heaters desired (that is, in limit switch compartment and/or motor, 120 V).
25. Specify the stroke time. Always provide a reasonable range or tolerance. The stroke
time should never be given as a finite time because it is virtually impossible to have
a motor operator operate in a specific time repeatedly.
26. Specify any special requirements, such as:
25-16
a.
b.
c.
d.
e.
If the piping system can experience a transient condition where the design
temperature and pressure are exceeded, explain here. This is because
piping codes and standards have provisions for exceeding design
conditions that do not apply to valves.
Note
1
S &W identification No.
Code & Class
Valve-Press. Class & Type
Quantity
Manufacturers Model No.
Size-in.
Flow Coefficient - Cv
Stem/Shaft-Diameter
Thread/Pitch/Lead
Port/Seat Area-in.
Materials-(ASTM/ASME or Manufacturers Designation)
Body
Bonnet
Stem/Shaft
Disc & Disc Facing
Seat & Seat Facing
Yoke
Bolting
Packing Type/Make
Dimensions
End -to-End
Valve to Operator Top
Internal Dimensions
Total Weight incl. Operator
Torque
Required to Open/Close
Limit For Valve
Limit For Operator
Operator Output-Max. Value
Operator Output-Min. Value
Torque Switch Setting & Torque-Normal
Torque Switch Setting & Torque-Max.
Operator - Make
Type
Overall Gear Ratio
Handwheel Diameter
Page:
Spec. No.
P.O.
Date:
2
3
4
5
5
5
6
8
8
9
10
Figure 25-4
Suggested Motor-Operated Valve Data Sheet by Bidder/Seller
25-17
Motor-Make
Type
Rated Torque
Rated Speed-rpm
Starting Current
Full Load Current
Max. Winding Temp
Insulation Class
Stalled Torque
Overload Heater
Rating-amps
Max. Locked Rotor
Time & Rated V-sec
Rated Horsepower
Time To Close, sec (min./max.)
Time To Open, sec (min./max.)
Valve Required Thrust/Torque Prediction
Method and Parameters
Actuator Output Thrust/Torque Prediction
Method and Parameters
Test Results
Hydrostatic and Seat Leakage Testing
Dynamic Flow Testing
Special Requirements
11
25-18
6. Materials used in construction of the valves. Require that the material designations
be given or sufficient identifications provided so the material (such as disc and disc
facing - SA216WCB W/Stellite #6) can be evaluated.
7. If requested, attach detailed dimensions (such as those specified in EPRIs PPM data
sheets).
8. The maximum torques the valve or operator can withstand without damage.
9. The setting of the torque switch that should operate the valve.
10. The maximum setting of the torque switch representing the limit of the valve or
operator.
11. List the purchasers special requirements and design features and/or data necessary
to meet these special requirements.
25-19
Figure 25-5
Control Valve Data Sheet
25-20
25-21
25-22
25-23
Figure 25-6
Relief Valve Data Sheet
25-24
25-25
Figure 25-7
Rupture Disc Data Sheet
25-26
25-27
26
APPENDIX D: TRANSLATED TABLE OF CONTENTS
26-1
26-5
26-6
26-7
26-9
26-10
26-12
26-13
1 ............................................................................... 1-1
1.1 20 ................................................................................1-13
1.2 ...........................................................1-16
1.3 ................................................................................1-20
2 ...................................................................................... 2-1
2.1 ..................................................................................... 2-1
2.2 ........................................................................................... 2-9
2.3 ...................................................................................2-12
3 ................................................................................ 3-1
3.1 ............................................................................... 3-1
4 ....................................................................................... 4-1
4.1 ............................................................................................ 4-1
4.2 ........................................................................................ 4-2
4.3 .................................................................................... 4-5
5 ................................................................................ 5-1
6 ................................................................................................ 6-1
6.1 1:6060 RPM5BFPLos Angeles............................................... 6-1
6.2 2:3570 RPMBFPHenderson ................................................ 6-1
6.2.1 .............................................................................................. 6-2
6.2.2 121976BFP
124BFP ........................................ 6-3
6.2.3 .................................................................................... 6-4
6.2.4 .............................................................................................. 6-4
6.3 3:8-WNC-95 (5) ...........................................6-10
6.3.1 .............................................................................................6-10
7 ....................... 7-1
7.1 B .................................................................................................... 7-5
7.2 A .................................................................................................... 7-8
7.3 AB...................................................... 7-8
7.4 .................................................................................... 7-8
26-14
26-15
10.3 .......................................................................................10-19
10.3.1 ......................................................10-19
10.3.2 .......................................10-19
10.3.3 ...........................................10-19
10.4 Lomakin....................................................................................10-23
11 ............................................................................................... 11-1
11.1 ...............................................................................11-1
11.1.1 ...................................................................................11-1
11.1.2 .................................................................................11-1
11.1.3 .................................................................................11-2
11.2 .....................................................................................11-8
12 ................................................................................... 12-1
12.1 ......................................................................................12-1
12.1.1 .....................................................................12-3
12.1.2 RCPPCPRRPMCP ....................................12-7
12.1.2.1 .........12-7
12.1.2.2
...........................................................................12-10
12.1.2.3 .....................................12-10
12.1.2.4 . 12-10
12.1.3 APKD ...........................................12-11
12.2 .......................................................12-14
12.2.1 :95-CHTA-5 .......................................12-16
12.2.2 ..................................................................12-16
12.3 .................................................................12-20
12.3.1 .......................................................12-20
12.3.2 ...........................................................................12-22
12.2.3 ...................................................................................12-22
12.3.4 ........................................................................................12-23
12.3.5 ..................................................................................12-24
12.3.6 ..................................................................12-24
26-16
12.4 ..........................................................................12-25
12.5 ........................................................................................12-27
12.5.1 ......................................................................12-27
12.5.2 .......................................................12-28
13 ........... 13-1
13.1 .....................................................................13-2
13.2 ERCO...........................................13-7
13.2.1 : .......13-8
13.2.2 ............................................................13-9
13.3 .....................................................13-14
14 ..................................................................................... 14-1
14.1 ...................................................................14-1
14.2 ..................................................................................14-7
14.3 ....................................................................14-17
15 ................................................. 15-1
15.1 ................................................15-1
15.1.1 ...................................15-2
15.1.2 .............................................15-6
15.1.3 ...........................................15-8
16 ............................................................................................ 16-1
TR-114612-V1
26-17
8-4 AAB
3 .......................................................... 8-8
8-5 A...........8-10
8-6 A............................................................8-11
8-7 A1976THC2BJ1993Comanche PeakSulzerBingham...........................8-13
8-8 BFP12 RHMB-5 ...............................................8-14
8-9 BFPB-J 12x12x14 HDB-6 .....................................................8-15
8-10 A ...........................................8-17
8-11 .......................................................................8-19
8-12 .....................8-19
8-13 OEMAA1.5%....8-22
8-14 A3
..........................................................8-23
8-15 A
...............................................................8-24
8-16 AB .................................................8-25
8-17
....................................................................8-26
8-18
A..................................................................8-27
9-1 ERCOAB................... 9-2
9-2 ...................................................................... 9-3
9-3 ......................................................................... 9-4
9-4
Ingersoll-RandRJR ....................... 9-5
10-1
...........................................................................10-4
10-2 ...............10-5
10-3
A .......................................................................10-6
10-4 65%BEP .............................10-8
10-5 8x20WDFRHR
.........................................................10-9
10-6 8x20WDFRHR
.................................................10-10
10-7 8x20WDFRHR
...........................................................10-11
10-8 .................................10-13
10-9 PP&L Montour#1BFP ..................10-14
26-20
10-10 Decordova
BFP ............................................................10-16
10-11 Eagle Mountain#3BFP...............10-17
10-12 Limerick
.................................................................10-18
10-13 ......................10-20
10-14 AB ........10-21
10-15 ...................................10-22
10-16 Lomakin ............................10-24
10-17 Lomakin
.......................................10-25
10-18 .............................10-26
11-1 ....................................................11-4
11-2 A.BC.............................11-5
11-3 ...................11-5
11-4 .....................11-6
11-5 .............................11-7
11-6 AB..........................11-9
12-1 ..................................................12-2
12-2 ......12-3
12-3 65-CHTA-4BFPCrystal River 2.......................12-5
12-4
.....................................................................12-6
12-5 Crystal River A1988
....................................................12-8
12-6 ................................12-9
12-7 34APKD .......................................................12-12
12-8 ......................................................12-12
12-9 ........................................................12-13
12-10 ........................12-15
12-11 ....12-16
12-12 BFPERCO ............................................12-18
12-13 Brayton Point 3595-CHTA-5 ....12-19
12-14
............................................................................12-21
12-15
.............................................................................12-26
12-16 BFP ..................................12-28
12-17 HPZurn-Ameriflex ..........12-29
13-1 1983Makay ....................................13-4
13-2 KSBPeter Hergt ..............................13-5
26-21
13-3 ERCO
Cooper ....................................13-6
13-4 5BFP..........................................................13-7
13-5 1990PSONE348x47S
....................................................................13-11
13-6 1992BWRAl-Ch114x78
WMCC.................................................13-12
13-7 .................................................................13-13
13-8 ..............13-15
13-9 NPSHNPSH3% ..............13-16
13-10 NPSHNPSH
.............................................13-17
14-1 ..............................................14-4
14-2 ...............................................................14-5
14-3 Byron Jackson and Pacific ...............................14-5
14-4 Ingersoll-Rand.........................14-6
14-5 Byron Jackon........................14-6
14-6 ..........................................................14-9
14-7 ...........................................................14-9
14-8 ...........................................14-10
14-9
..............................................................14-11
14-10
....................................................................14-12
14-11
ERCOPCP7 .............................14-13
14-12 ................................14-14
14-13 Vogtle..............................14-15
14-14 3...............................................14-19
14-15 3...............................................14-21
14-16
............................................................................14-22
15-1 SandowTU ....................15-2
15-2 .......................15-9
15-3 ............15-9
15-4 BEP .............15-10
15-5 ERCO..................................15-11
26-22
26-23
CONTENIDO
1 BOMBAS CENTRFUGAS DE GRAN ENERGA................................................1-1
1.1 Desarrollos durante los ltimos 20 aos ......................................................1-13
1.2 Definiciones de voluta/impulsor-difusor........................................................1-16
1.3 Determinacin de dnde pueden surgir problemas......................................1-20
DISEO DE LA BOMBA CENTRFUGA 2.............................................................2-1
2.1 Seleccin de las dimensiones bsicas...........................................................2-1
2.2 Clculos secundarios .....................................................................................2-9
2.3 Clculos del difusor......................................................................................2-12
3 FRECUENCIAS DE VIBRACIN TPICAS .........................................................3-1
3.1 Anlisis y recogida de datos de vibracin ......................................................3-1
4 FRECUENCIA DE VIBRACIN SNCRONA.......................................................4-1
4.1 Estndares de equilibrio.................................................................................4-1
4.2 Desequilibrio dinmico ...................................................................................4-2
4.3 Desequilibrio hidrulico ..................................................................................4-5
5 FRECUENCIA DE VIBRACIN SUBSNCRONA ...............................................5-1
6 EJEMPLOS DE COMBINACIN.........................................................................6-1
6.1 Caso 1:6060 RPM, cinco etapas BFP1, ciudad de Los ngeles ....................6-1
6.2 Caso 2:3570 RPM, nueve etapas BFP, ciudad de Henderson.......................6-1
6.2.1 Conclusiones .........................................................................................6-2
6.2.2 Resumen y seguimiento de las 1976 modificaciones de diseo
principales de las BFP en las unidades 1 y 2 (dos bombas por
unidad, total de cuatro BFPs motorizadas) ...........................................6-3
6.2.3 Resumen de las conclusiones ...............................................................6-4
6.2.4 Conclusiones .........................................................................................6-4
6.3 Caso 3: Tipo de bomba de alimentacin de la caldera: 8-WNC-95
(cinco STGS).................................................................................................6-10
6.3.1 Conclusin ...........................................................................................6-10
7 FRECUENCIA DE PASO DEL LABE Y SUS MLTIPLOS EN LAS BOMBAS
CENTRFUGAS DE ALTO CONSUMO ENERGTICO.......................................7-1
7.1 Huelgo B ........................................................................................................7-5
7.2 Huelgo A ........................................................................................................7-8
7.3 Interaccin entre los huelgos A y B y el solape..............................................7-8
7.4 Combinacin del nmero del labe................................................................7-8
1
26-24
26-27
LISTA DE FIGURAS
Figura 1-1 Aumento de caballos de potencia por labe del impulsor de la BFP
en cinco aos en centrales de los EE.UU. ..........................................................1-3
Figura 1-2 Eficacia esperada de la bomba centrfuga en funcin de la velocidad
especfica, caudal y geometra del impulsor .......................................................1-7
Figura 1-3 Caudal habitual, colector y rangos de velocidad especficos de
las BFPs en centrales fsiles de los EE.UU........................................................1-9
Figura 1-4 Historia de ERCO del huelgo A, huelgo B y de las modificaciones
del bloque anti-calado para las centrales ..........................................................1-10
Figura 1-5 Vista seccionada transversalmente de una etapa del difusor de la
BFP con su nomenclatura apropiada ................................................................1-17
Figura 1-6 Vista meridional de una etapa del difusor/impulsor de la BFP
antes y despus apropiada de la modificacin del huelgo A y del huelgo B .....1-18
Figura 1-7 Tienda de la bicicleta (generalmente el licitador ms bajo): con
carne barata se hace sopa barata" ..................................................................1-21
Figura 1-8 Difusor original de la primera etapa L/d3 = 3,6; Corte a 0,6, lo
que origin una perdida de eficacia significativa ..............................................1-22
Figura 1-9 Difusor original de la etapa normal L/d3 = 4,0; Corte a 1,5, lo que
origin una prdida de eficacia significativa .....................................................1-22
Figura 2-1 Tabla para seleccionar la velocidad rotatoria y la velocidad
especfica ............................................................................................................2-2
Figura 2-2 Comparacin entre la eficacia de la tabla y la velocidad especfica
en funcin de la capacidad..................................................................................2-4
Figura 2-3 Comparacin entre el coeficiente principal y la velocidad especfica
en funcin de la predotacin ...............................................................................2-5
Figura 2-4 Ratio del dimetro en funcin de la velocidad especfica ......................2-6
Figura 2-5 Comparacin entre la velocidad especfica y el ratio del dimetro/
anchura del impulsor ...........................................................................................2-8
Figura 2-6 Efectos del nmero del labe en la subida del colector en una
bomba con velocidad especfica NS= 1500 ........................................................2-8
Figura 2-7 Tringulos de velocidad de entrada y salida para una bomba,
con imgenes de las bombas incluidas para definir las dimensiones ...............2-11
Figura 2-8 Tabla para determinar el coeficiente de deslizamiento ........................2-12
Figura 2-9 Tabla ratio-rea....................................................................................2-15
Figura 2-10 Comparacin entre el ratio de rea normalizado y la velocidad
especfica normalizada......................................................................................2-16
Figura 2-11 Tabla general de diseo para el ratio de solape de la placa
lateral del impulsor al difusor.............................................................................2-18
Figura 3-1 Componentes tpicos de vibracin medidos en bombas
centrfugas grandes.............................................................................................3-3
Figura 3-2 Tabla de severidad de la vibracin ........................................................3-4
Figura 4-1 Incremento rpido de la vibracin sncrona que causa la destruccin
del rotor ...............................................................................................................4-6
Figura 4-2 Chavetas de acoplamiento carecen de 0,125 pulg. de material.............4-6
26-28
Figura 4-3 Geometra del anillo de desgaste existente modificada para incluir
las ranuras Lomakin ............................................................................................4-7
Figura 4-4 Chaveta inadecuada con falta de material .............................................4-7
Figura 4-5 Fuentes de cargas del cojinete y tensiones del eje las bombas de
refrigerante del primario ......................................................................................4-8
Figura 5-1 Desarrollo del chicoteo de aceite en BFPs de alta velocidad de
32000 caballos de potencia, 95 CHTA-5............................................................5-3
Figura 5-4 Componente de vibracin subsncrona destructiva ...............................5-2
Figura 5-3 Modificacin del huelgo A y B de la bomba de alimentacin de
la caldera.............................................................................................................5-7
Figura 5-4 Inestabilidad hidrulica a 62% de la BEP antes de introducir
el huelgo A y B apropiado ...................................................................................5-8
Figura 5-5 Las pruebas de vibracin de la bomba de alimentacin de la caldera
muestran el empuje axial estabilizado despus de la modificacin del
huelgo A y de B...................................................................................................5-9
Figura 5-6 Bomba de alimentacin de la caldera, tipo HPTX-40, 3 etapas ms
la etapa de arranque .........................................................................................5-10
Figura 5-7 Modificacin del anillo de desgaste (Lomakin) y del impulsor/
difusor ...............................................................................................................5-11
Figura 6-1 Modelo matemtico simple ....................................................................6-6
Figura 6-2 Cambio de velocidades crticas en funcin del desgaste del rotor.........6-7
Figura 6-3 Historia de la vibracin del eje de Ciudad de Henderson .......................6-8
Figura 6-4 Doble amplitud de vibracin a x N .....................................................6-8
Figura 6-5 Inestabilidad del cojinete: (a) Latigueo del cojinete, (b) latigueo
por friccin en seco .............................................................................................6-9
Figura 6-6 Arranque del rotor recientemente reparado .........................................6-11
Figura 6-7 Vibracin subsncrona (8 milipulgadas) ...............................................6-12
Figura 6-8 Amplitudes de vibracin antes de las modificaciones ERCO...............6-13
Figura 6-9 Modificacin de voluta/impulsor del arranque de la BFP .....................6-14
Figura 7-1 Tabla de combinacin de impulsor/difusor. Pulsacin de presin
dominante debida a las combinaciones del nmero del labe voluta/impulsor
a difusor ..............................................................................................................7-3
Figura 7-2 Tabla de combinacin de impulsor/difusor. Frecuencias de pulsacin
de la presin dominante calculada debido a las combinaciones
del impulsor a labe ............................................................................................7-4
Figura 7-3 Extremos rotos a la entrada de los labes de difusor - huelgo radial
B pequeo (1%), inestabilidad hidrulica con caudal bajo y parada en la
entrada del difusor ..............................................................................................7-7
Figura 7-4 Parada causada por el ngulo de incidencia del caudal, lo que
origina cavitacin y daos mecnicos en los extremos de entrada del
labe difusor........................................................................................................7-7
Figura 7-5 Diagrama Campbell de un impulsor de siete labes ............................7-10
Figura 7-6 Tabulacin para predecir frecuencias de paso del labe y
armnicos potencialmente dainas ...................................................................7-12
26-29
Figura 7-7 Espectros de vibracin de una bomba del tipo 3BB1I512 que
muestra cambios en la vibracin de frecuencia de paso del labe 3 y 4
veces mayor con la velocidad ...........................................................................7-15
Figura 7-8 Espectro de vibracin de la central de Havasu que muestra una
vibracin de frecuencia de paso del labe 2 veces superior .............................7-17
Figura 7-9 Reduccin de pulsaciones de presin 2 superior a la frecuencia
de paso del labe con modificaciones a la entrada del difusor .........................7-18
Figura 7-10 Modificaciones realizadas en la entrada del difusor que reducen
las pulsaciones de presin y estabilizan la curva de caudal del colector ..........7-19
Figura 7-11 Curva de caudal del colector que muestra el efecto de
estabilizacin conseguido gracias a la modificacin a la entrada del difusor ....7-20
Figura 7-12 Espectro de vibracin para DeLaval 1BSXI516 con un impulsor
de siete labes y un difusor de ocho labes .....................................................7-22
Figura 7-13 Comparacin de amplitudes de vibracin en la frecuencia de
paso del labe del impulsor antes y despus de la modificacin de diseo
del difusor..........................................................................................................7-23
Figura 7-14 Comparacin de amplitudes de vibracin en la frecuencia de paso
del labe antes y despus de la modificacin de diseo del difusor .............7-24
Figura 7-15 Amplitudes dainas 2 veces superiores a la frecuencia de paso
del labe, Palo Verde, 3 unidades de 1300 MW, PWR (RCP, cuatro por lazo,
12 bombas en total) ..........................................................................................7-27
Figura 7-16 Resonancias acsticas y mecnicas con impulsores de cinco
y siete labes: se observan la primera velocidad crtica del rotor, canal
intermedio y resonancia de la carcasa del cojinete para detectar problemas ...7-28
Figura 7-17 Longitud acstica de los canales intermedios para las etapas 2,
4, y 6 de los modelos HDB y HSB, con y sin etapa de arranque para
varios tamaos de impulsores tipo BFP ............................................................7-29
Figura 8-1 Primera modificacin del huelgo A en una bomba de tipo difusor .........8-2
Figura 8-2 Primera modificacin del huelgo A en una bomba de refuerzo de
agua de alimentacin de alta velocidad, tipo voluta, central Navajo ...................8-3
Figura 8-3 Curva del colector estabilizada en carga parcial mediante la
introduccin del huelgo A y B y solape apropiado...............................................8-5
Figura 8-4 Tres formas de estabilizar la curva del colector de una bomba
mediante distintas combinaciones del huelgo A, solape del huelgo
A y huelgo B........................................................................................................8-8
Figura 8-5 Tabla general de diseo para el huelgo A, su solape y otras
geometras asociadas del impulsor ...................................................................8-10
Figura 8-6 Tabla de la optimizacin para el huelgo A y su solape ........................8-11
Figura 8-7 Insercin de un anillo en el huelgo A de estilo cola de paloma
(B-J en THC2 en 1976 y Sulzer/Bingham en Comanche Peak propuesto
en 1993) ............................................................................................................8-13
Figura 8-8 Voluta doble de BFP: Pacific 12 pulg. RHMB-5 ...................................8-14
Figura 8-9 Voluta doble de BFP: B-J 12x12x14 HDB-6.........................................8-15
Figura 8-10 Bomba de alimentacin del reactor de alta velocidad antes y
despus de la modificacin del huelgo A ..........................................................8-17
Figura 8-11 Modificacin de la bomba de alimentacin del reactor nuclear..........8-19
26-30
26-34
LISTA DE TABLAS
Tabla 1-1 Tabulacin de las bombas de refrigerante principales en las
centrales nucleares BWR y PWR de los EE.UU. ................................................1-4
Tabla 1-2 Tabulacin de las bombas de alimentacin de la caldera de los
EE.UU.. por fabricante ......................................................................................1-12
Tabla 1-3 Varias dimensiones y parmetros probados y recogidos por
ERCO en centrales nucleares y fsiles .............................................................1-13
Tabla 2-1 Resumen de los clculos bsicos del impulsor .......................................2-7
Tabla 2-2 Resumen de los clculos del difusor e impulsor ...................................2-19
Tabla 4-1 Estndares de equilibrado usados para la maquinaria hidrulica ...........4-2
Tabla 6-1 Resumen de las conclusiones.................................................................6-4
Tabla 7-1 Comparacin entre la velocidad de operacin y la velocidad de
periodicidad y fase (combinacin de los labes 6 y 8) ......................................7-13
Tabla 7-2 Datos de vibracin de campo (medidos en velocidad)..........................7-13
Tabla 7-3 Comparacin entre la velocidad de operacin y la velocidad de
periodicidad y fase (combinacin de los labes 7 y 13) ....................................7-16
Tabla 7-4 Comparacin entre la velocidad de operacin y la velocidad de
periodicidad y fase (combinacin de los labes 7 y 8) ......................................7-21
Tabla 9-1 Varias dimensiones y parmetros probados y recogidos por ERCO
en una gran nmero de centrales nucleares y fsiles .........................................9-1
Tabla 14-1 Configuraciones del cojinete para impulsores de motores
elctricos de bombas de refrigerante primario del reactor nuclear..................14-16
Tabla 15-1 Recopilacin incrementos porcentuales en la capacidad de la
bomba para distintas modificaciones ................................................................15-4
Tabla 15-2 Incremento en la generacin de la central mediante el incremento
en la capacidad de la bomba en trminos de caudal porcentual de la BEP......15-5
26-35