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EPR Italia

Workshop on valves

Roma, 8/7/2010
D. Pinier (EDF/SEPTEN)
M. Mazouzi (EDF/CEIDRE)
P.M. Nahon (AREVA)
F. Bogaert (AREVA)
R. Rotella (ENEL EDF/CNEN)

Summary
1.

Valves technologies for EPR-FA3

2.

General requirements for EPR-FA3 valves

3.

Qualification requirements for EPR-FA3 valves

4.

EPR-FA3 valves qualification: who does what

EPR Italia
Workshop on valves
1. Technologies for EPR-FA3
Roma, 8/7/2010
F. Bogaert (AREVA)
R. Rotella (ENEL EDF/CNEN)

EPR areas
Generalities

BOP

IC
NSSS

BNI

44plant
plantareas:
areas:
Nuclear
NuclearSteam
SteamSupply
SupplySystem
System--NSSS
NSSS
Balance
Balanceof
ofNuclear
NuclearIsland
IslandBNI
BNI
Conventional
ConventionalIsland
Island--CI
CI
Balance
Balanceof
ofPlant
PlantBOP
BOP

8/07/2010

Workshop valves

EPR areas

Classified and not classified equipments

NSSS+BNI
Nuclear Steam Supply System (NSSS)
Balance of Nuclear Island (BNI)

Examples of classified systems


Safety Injection System
Chemical and Volume Control System
Containement Heat Removal System

Examples of not-classified
systems
Internal Containment Filtration
Hydrogen Distribution

8/07/2010

IC
Turbine Island (TI)
Balance of Conventional Island (BCI)
BOP

CLASSIFIED
EQUIPMENTS

CONVENTIONAL
EQUIPMENTS

Workshop valves

Examples of classified systems


Essential Service Water System
Ultimate Cooling System
Fire-Fighting Water Production

Examples of not-classified
systems
Main Turbine Steam and Blow-down
System
Main Steam By-pass
Demineralized Water Production

Valves classification
General requirements

Classified equipments have to perform essential functions for NPP safety.


Nuclear Codes and Technical Standards for design, manufacturing, erection,
commission and tests
Qualification to process and ambient conditions (seism, radiation, pressure,
temperature, humidity, etc.)
Qualification to normal conditions
Qualification to accidental conditions
Qualification to severe accident conditions
All players must abide by additional Quality Assurance requirements with regards to
ISO 9001, depending of safety class
Safety classification, mechanical classification and radiological classification =>
QUALITY CLASSES

8/07/2010

Q1

Workshop valves

Q2

Q3

QC

Valves for EPR-FA3


Generalities

Standard Valves
o Classified standard valves: mainly for NSSS and BNI (only few valves for CI and BOP)
o Not-Classified (NC or QC) standard valves: similar to conventional valves, taking into
account additional client requirements
Special valves: Pressurizer Safety Valve, Main Steam Isolation and Control Valves, Main
Feedwater Isolation and Control Valves, etc.

Carbon Steel

Stainless steel

Pneumatic actuator
(not used in Reactor Building - RB)

8/07/2010

Electric
actuator

Workshop valves

Solenoid
actuator

Manual
actuator

Standard valves of NSSS, BNI, BOP and CI


Generalities: examples of standard valves types (1/2)

H pressure and/or H temperature: > 40 bar and/or > 200 C


Gate valves for large valves
Globe valves for small valves and for some large valves
M pressure and/or M temperature: 20 40 bar and/or 100 200 C
Ball valves
Butterfly valves
L pressure and L temperature: < 20 bar and < 100 C
Diaphragm valves for limited dimension
Ball valves
Butterfly valves

Analysis not exhaustive: other parameters have to be


taken into account radioactive fluid, valves reactor
building isolation, qualification requirements, etc.

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Workshop valves

Standard valves of NSSS, BNI, BOP and CI

Butterfly valve

Gate valve

Globe valve

Diaphragm valve

Generalities: examples of standard valves types (2/2)

Swing check
valve

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Workshop valves

Standard valves of NSSS, BNI and BOP


Classified standard valves

CLASSIFIED VALVES

Gate valves
Globe valves (with or
without bellow)
Diaphragm valves
Plug valves
Butterfly valves
Containment isolation
specific valves
Safety valves
Control valves
Swing check valves
Lift check valves
TOTAL

Indicative
number of
equipment
< 150

Max
Max
Max
Min
diamet pressur temperat
diameter
er
e [bar] ure [C]
DN80
DN350
170
310

4600

DN8

DN350

250

360

2000
1250
350

DN8
DN8
DN80

DN100
DN200
DN900

20
20
35

100
250
170

DN500

DN1000

170

200
~ 250
300
400

DN15
DN80
DN8

DN600
DN350
DN50

170
250
250

310
210
350

~ 9500

Other valves are supplied in packages contract.

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Standard valves of NSSS, BNI and BOP and CI


Not-classified standard valves
NSSS+BNI+part of BOP

NOT-CLASSIFIED VALVES

Globe valves
Diaphragm valves
Plug valves
Butterfly valves
Safety valves
Control valves
Swing check valves
TOTAL
Lift check

valves

Indicative
number of
equipment
1100
1200
350
50
< 100
50
< 50

Max
Max
Max
Min
diamet pressur temperat
diameter
er
e [bar] ure [C]
DN8
DN350
250
360
DN8
DN100
20
100
DN8
DN200
20
250
DN80
DN900
35
170

~ 3000
100

Part of BOP and IC

~ 5000

TOTAL not-classified

~ 8000

DN15
DN80

DN600
DN350

170
250

310
210

DN8

DN50

250

350

Other valves are supplied in packages contract.


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Valves for NSSS


Special valves (1/2)

Steam Safety Valve

Main Steam Isolation Valve

Flowrate
Min

160 kg/s

Set
Pressure

105 bar a

8/07/2010
Diameter

8" x 14"

Workshop valves

Flowrate Max

640 kg/s

Max pressure drop

0.25 bar

Design
Pressure/Temperat
ure

100 bar a /
311 C

Closing time

<5
12

Valves for NSSS


Special valves (2/2)

Main Steam Relief Isolation Valve

Pressurizer Safety Valve

Flowrate Safety
Min/max

320 / 384 kg/s

Design p / T

100 bar a /
311 C

8/07/2010
Stroke
time Max

40 seconds

Workshop valves

Design Pressure

175 bar g

Set pressure

174/177/180
bar g

Reseat pressure min

149/152/155
bar g

Design / Normal
operating
Temperature

362 / 345 C
13

EPR Italia
Workshop on valves
2. General requirements for EPR-FA3
Roma, 8/7/2010
D. Pinier (EDF/SEPTEN)
M. Mazouzi (EDF/CEIDRE)
P.M. Nahon (AREVA)
R. Rotella (ENEL EDF/CNEN)

Summary
1.

Technical codes and standards

2.

Quality Assurance

3.

Design requirements

4.

Manufacturing

5.

Tests

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Summary
1.

Technical codes and standards

2.

Quality Assurance

3.

Design requirements

4.

Manufacturing

5.

Tests

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Technical Codes & Standards

General framework for classified equipments (1/2)

Q1

FA3

RCC-M

ITALY
(**)

RCC-M

Mechanical equipment
Q2
Q3
RCC-M
RCC-M
ASME III NC + EDF
ASME III NC + EDF
specification (*)
specification (*)
EN standard or
KTA class 2
equivalent + EDF
specification (*)
RCC-M
RCC-M
EN standard or
ASME III NC + Client
equivalent + Client
specification
specification

Electrical equipment
EE1
EE2

RCC-E

RCC-E or IEC
or equivalent

RCC-E

RCC-E or IEC
or equivalent

(*) EDF specification to take into account the RCC-M requirements


(**) Preliminary proposal to verify after Nuclear Safety Authority establishment

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Technical Codes & Standards

General framework for classified equipments (2/2)

Technical
Standard

Description

Standards
editor

Country

RCC-M

Code for design and manufacturing of mechanical


equipment for Pressurized Water Reactor

AFCEN

France

ASME

American Society of Mechanical Engineers

ASME

USA

KTA

Germany

CEN

Europe

AFCEN

France

KTA
EN 12516

RCC-E

8/07/2010

Kern Technischer Ausschuss


Calculation method for steel valve shells
Code for design and manufacturing of electric
equipment for Pressurized Water Reactor

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18

Technical Codes & Standards framework


General framework for not classified equipments

Design, manufacturing and erection requirements of non-classified equipments are


similar to conventional ones (quality management according to ISO9001,
conventional technical standards, equipment qualification not required, etc.).
However, some particular requirements can be demanded in technical specifications.

Technical standards: examples


European Standards
ASME-Code VIII
IEC-Standards for electric equipments and I&C
IEEE standards for electric equipments and I&C

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Summary
1.

Technical codes and standards

2.

Quality Assurance

3.

Design requirements

4.

Manufacturing

5.

Tests

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Quality Management Specification

Quality requirements are based upon importance with regard to safety, complexity and
availability: a graded approach

COMPONENT STATUS

QUALITY SYSTEM REQUIREMENTS


ISO 9001 complemented by specific
nuclear requirements based upon
Product and services safety related
IAEA GS-R-3 2006, local regulations
(mainly Class1 (Q1), Class2 (Q2) & Class3
& laws and Client added
(Q3))
requirements
Products and services non safety related

ISO 9001

(mainly QC)

For all: environmental ISO 14001 and health & safety OHSAS 18001 are
considered
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Quality Management prescription for Safety classified


activities
Addition to ISO 9001-2000 are precisely defined:
Activities important for the safety: refer to activities performed during purchase order performance and
which failure may lead to a nonconformance regarding requirements linked to safety notified by the Client.
Safety Culture: measures are required from the supplier management system to promote and support a
strong safety culture.
Grading the application of the quality management system: for the performance of the purchase order,
identification of the activities important for the safety.
Documentation: it is required a quality management plan from the supplier
Control of the design documentation: The Design/Engineering activities are verified by individuals
competent and other than those who carried them out.
Inspection: for the inspection is carried out by individuals competent and not involved in carrying out the
activity. The conditions of this inspection are described and justified
Purchasing: Anyone involved in the subcontractor chain will take the required measures in his purchasing
data to ensure that the requirements, adapted to purchasing, are taken into account by the subcontractors.
At every level of the subcontractor chain, each organization involved shall take the required
provisions to check that contractual requirements are being correctly met by subcontractors.

PAQP for the project


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Quality Surveillance requirements


EPR-FA3

Nuclear Specificities based upon French Practices and I.A.E.A. GS-R-3 (2006)
Definition of the Activities important for the safety (also called quality concerned activities)
which are the activities performed during purchase order performance and which failure
may lead to a nonconformance regarding requirements linked to notified safety
activities of the Quality Assurance Plan
activities of the Inspection Plan
Grading of the surveillance level:
according to the criticality of equipments design and manufacturing
according to the confidence level assigned to the supplier

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Manufacturing & Test Follow-up


Inspection Plan (Follow-up Document)

The follow-up document ensures the traceability and the control of the manufacturing
activities important for the safety.
The first best surveillance is the one done internally by the supplier itself
Two types of notifications for external surveillance (Customer/third party):
Witness points: it is not a mandatory inspection visits and it should not be a reason
slow down the manufacturing process
Hold points: The supplier shall not perform the activity without inspector approval,
except in case of a written authorization

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Some key points about the quality surveillance


Management of sub-contracts
Appropriate selection of the sub-contractors
Appropriate definition of the content of the sub-contracts
Close surveillance of the sub-contractors
Regular and up-to-date information of the customer about the progress of subcontracts
Management of non conformance
Truth and trust should prevail within the company at all level (the sooner a non
conformance is known to be corrected, the better)
Receiving inspection
EOMR (End Of Manufacturing Report)
OMM (Operating and Maintenance Manual)

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Experience feedback on QM evaluations of suppliers


(1/2)
Key points related to organisation, detail design and purchasing:
Documentation management (lack of records, incomplete Particular
Quality Assurance Programme - 5rev!)
Design monitoring and software qualification (independence of the
checker, checking consistency)
Identification and monitoring of Activities Important for Safety (from
design till manufacturing)
Cascading of requirements in the supply chain (Quality, specifications)
Subcontractors qualification (according to nuclear standards)

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Experience feedback on QM evaluations of suppliers


(2/2)
Key points for performance in the workshop:
Manufacturing activities (traceability, Equipment maintenance,
Inspection tests plan implementation, measurement process)
Internal Audits (independence, scheduling, audits follow-up and report
consistency)
Non Conformance handling (root cause analysis prior to corrective
action implementation)
People skills (auditors, translators, engineers)
Safety culture implementation (personnel endoctrination,
implementation in-situ)

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Experience feedback on Surveillance from Inspection


department (1/3)
Organization:
Lack of safety culture
Know How not matching with Project requirements
Absence of requirements cascading from Suppliers to Sub-suppliers
Lack of surveillance applied by Suppliers to their main Sub-suppliers
Welding:
Welding process qualification
Welder qualification
Filler material storage
Filler material in and out management
Portable oven
Welding parameters

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Experience feedback on Surveillance from Inspection


department (2/3)
Non Destructive Test
Operator qualification
Dye penetrant product out of date
Correctness of UT probes choice

Heat treatment
Thermocouple calibration
Furnace calibration
Respect of temperature slope
Quenching time
Recorder calibration

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Experience feedback on Surveillance from Inspection


department (3/3)
Metrology
Management of end of calibration process
Tool in and out management
Traceability and record
Management of reference for calibration
Machining/dimensional
Qualification of operator
Machine maintenance schedule
Management of machining parameters
Document
Document not approved
Wrong revision
Not taking into account Project specific requirements

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Key issues - Conclusion

Management commitment
Clear responsibilities of key players
Project Manager
Design Responsible
QA&QC strong internal surveillance
Trained & Qualified Personnel
Knowledge of the technical specifications
Employees safety culture sensitization
Personnel stability for the critical functions of a project

Anticipation is imperative in order to be ready when


projects are launched
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Summary
1.

Technical codes and standards

2.

Quality Assurance

3.

Design requirements

4.

Manufacturing

5.

Tests

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Design requirements

Origins of the technical requirements


Safety requirements
Unit availability requirements
Radiological protection requirements
Requirements for the operators security (pressure vessel)
On the basis of these requirements, equipments are subject to classification
(some of which are regulatory):
Safety classification (mechanical and functional)
Availability (consequences on plant availability)
Radiological protection: fluid transported radioactive or not
Operator security: subject to the PED or not, etc.
Different technical requirements should be applied or not applied,
in accordance with these classifications.

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Design requirements

General requirements (1/4)


To ensure the integrity of the equipment:
Mechanical strength of the body

External sealing (body-bonnet connection, stem seal, etc.)


Requirements:
Sizing of the pressure vessel: RCC-M code or EN 12516 standard (and, if necessary,
ASME, KTA)
Internal / external loading (earthquake, forces on end fittings, etc.)
Rules: pressure rating, minimal thickness, stresses limitation with criteria levels
(dependant on accidental conditions).
Requirements for the design of the packing seal (e.g.: spring washers), body-bonnet
connection (e.g.: metal-metal contact), welded connection (e.g.: design of end fittings)
Requirements concerning maximum concentrations of halogens and sulphur (seals,
packing, greases): specific products list mandatory
Requirements concerning materials (e.g.: chrome content of carbon steel, grade of
material for stems)

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Design requirements

General requirements (2/4)


To ensure the operability / the functional capacity of the
equipment under all conditions required:
Opening/closing
Internal sealing (in accordance with the criteria)
Mechanical strength of the mechanism

Requirements:
Equipment qualification (normal and accident operating conditions)
Respect of rules concerning the sizing of electric actuators/operating
forces of isolation valves
Mechanical sizing of the mechanism
Stability (safety valves, control valves, etc.)
Flow rate required (safety valves, control valves, etc.)

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Design requirements

General requirements (3/4)

To minimize radiation level for the operator:


Reduction of area without flow (hot spots)
Easy, quick maintenance
Use of appropriate materials
Requirements :
Reduction of dead ends (e.g.: socket welding forbidden for ND > 25)
Elimination of cobalt based deposits (e.g.: sealing surfaces free of Stellite)
Improved sealing of stems (e.g.: metal bellows, double packing gland with
leak return)
Equipment quick and easy to maintain (e.g.: valves fitted with
interchangeable internals)

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Design requirements

General requirements (4/4)

Life time conception : 60 years


o Operation in continuous service during at least 48 months without maintenance
o Few maintenance per 10 years period

Maintenance :
o
o
o
o

Simple and quick


Without specific tools other than tools supplied by the Manufacturer
Only replacement on wear parts
Facilitate conditional maintenance

Interchangeability of spare parts (use of spare parts on all valves of


the same type).
General layout drawings (list of information required)

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Design requirements

General Requirements specific to each technology (examples) 1/2


Globe valves:
Body-bonnet connection: bolted type (bolted-welded connection forbidden)
Metal diaphragm valve (without a stem-flap connection):
Risk of not opening: technology forbidden!
Solid wedge gate valve:
Risk of jamming during opening: technology forbidden!
Valves with double seals:
Risk of the boiler effect in the space between gates pressure locking
effect prevention required
Measurement of leaks by pressurisation of the space between gates
pressure tap on the bonnet

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Design requirements

General Requirements specific to each technology (examples) 2/2

Swing check valves:


In the open position, the top stop is on the lever and not on the clapper (in
order to reduce stress on the lever/clapper connection)
Instrumentation valves and fittings:
Risk of cracking of the instrumentation nozzle lightweight valves
Limit switches:
Installation as close as possible to the obturator (REX from Three Miles Island)
generally on the stem.
Etc...
Strong Organizational & Engineering capability required
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Summary
1.

Technical codes and standards

2.

Quality Assurance

3.

Design requirements

4.

Manufacturing

5.

Tests

8/07/2010

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Parts concerned by the Client requirements

The manufacturing requirements are applicable to at least the following


parts :
Body, bonnet, obturator
Seat, nozzle, cage,...
Flange and mating flange
Control stem, control pin, valve pin, disk arm,,
Valve spring
Closing fasteners and fasteners subject to pressure

Use to European standards for the other parts of the valve

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General requirements
Choice of materials according to the conclusions of the risk analysis (PED*) :
Resistance of corrosion and erosion,...
Low alloy steel or carbon steel are prohibited for the fasteners when the circuit
contains borated water (flange, body/bonnet connections, stuffing box, yoke,
etc.)
Nuts shall be made of X12Cr13 steel when the circuit contains borated water
Austenitic stainless steel grades may also be used if an appropriate treatment is
performed to prevent seizure problem
When the yoke is separated from the bonnet, it is made with a carbon steel or
with the same material as the bonnet
The stem nut is made from a non-ferrous copper based alloy
Cast irons are prohibited for all component parts of valves themselves in some
cases and copper aluminum alloys are not accepted for the principal parts of
pressure equipment
* European Pressure Equipment Directive 97/23/EC
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Specific requirements
Class Q1, Q2 and Q3 components (mainly in NSSS and BNI)
Manufacturing is done in accordance with the RCC-M or equivalent, according to
quality class
Class QC components (mainly in CI and BOP)
Class QC1 and QC2 components
European standards with additional Client requirements
Class QC3 components, said to have "no special requirements"
manufactured in accordance with the best state-of-art practice.

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are

RCC-M - Main requirements

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RCC-M Main requirements

Special parts Reference and Procurement specification

Procurement specification M140


For main parts of Q1 equipments (Q1 stamped or forged bodies with a nominal diameter 200
mm; Main Steam Isolation Valve bodies; Main Feedwater damped check valves; Main Steam
Relief Isolation Valves)
M140 qualification to check that a part, manufactured in accordance with a specified program,
will respond satisfactorily to manufacturing operations and service conditions. Its the time to
determinate the characteristics of the product and particularly singularities and
testability

Qualification content (not exhaustive list, to be completed after qualification)


Melting process / Chemical composition aimed / Weight and type of ingot / Discard percentage
Manufacturing operation in chronological order / Ratio of reduction / Drawing of part showing
profiles for heat treatment and as delivered / Intermediate and final heat treatments
Position in the part of the test sample / Position of test specimens within test samples

Check that characteristics are homogeneous in the whole volume

Check that acceptance operations and criteria are well selected for quality surveillance

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RCC-M Main requirements

Part and Product Reference and Procurement specification

Part and product procurement specification (e.g. bars, castings products)


Based on standards as much as possible
Possibility to procure small quantities according to foreign standard (with contractor
agreement and conformance to RCC-M criteria)
Complete set of rules gathered for the procurement
Scope / Melting process / Chemical requirements
Manufacture / Mechanical properties / Surface examination / Volumetric
examination / Dimensional check
Marking / Cleanliness Packaging transportation
Test reports

End Manufacturing Report mandatory

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RCC-M Main requirements


Materials in relation to standards

Examples of additional requirements


Limitation of carbon content, lower Chromium content, control of delta ferrite
content, intergranular properties,
Limitation of Sulfur, Phosphorus and Silicon content (Product toughness, ageing).
A minimum KV notch impact energy is required (low inclusion content) and others
tests parameters (e.g. temperature)
Tensile test at high temperature in some cases
Others coatings to replace Stellite hardfacing (e.g. NOREM)
Limitation of Boron content for Weldability

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RCC-M Main requirements


Welding and manufacturing
Welding
In general, the RCC-M refers to the European and French standards with additional requirements.
Example:
Limitation of range of qualification
Requirements about shapes of joints
Hardness test for carbon steels
Welder qualification
Hardfacings and coatings are presented entirely in the RCC-M (the paragraph is self
sufficient because of the specific hardfacings stellite, Norem 02,)

Manufacturing
The RCC-M presents some operations like :
Marking procedure
Repair without welding
Surface treatment
Heat treatment
Bolted assemblies
Cleanliness
All requirements for manufacturing are in the RCC-M; others processes can be used providing a
justification file approved by the Client
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RCC-M Main requirements


Non-destructive examinations
Main examination methods:
Visual test
Dye penetrant test
Magnetic particles test
Ultrasonic test
Radiographic test
All these examination methods are based on the standards with specific
options except for the radiographic test
The radiographic test is entirely presented in the RCC-M (self sufficient paragraph)
Surface examination criteria are listed in the RCC-M
For what concerns volume examination criteria, RCC-M refers to standards
EN12681, EN10228-3, ...
Non destructive examinations are performed at procurement and
manufacturing stages

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European standards with additional requirements


European standards can be used for class Q3, QC components with additional
requirements concerning Valves, Cleanliness, Welding, Non-Destructive Tests,
Quality of equipment manufacturing
These additional requirements concern for example:
Limitation of carbon content, lower Chromium content, control of delta ferrite
content, Intergranular properties,
Limitation of Boron content, range of qualification and requirements on shapes of
joints (welding)
Hardness test for carbon steels, qualification welders (welding)
Criteria for Non Destructive Examinations (Criteria are equivalent to RCC-M)
...
Client additional requirements are closed to RCC-M requirements

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50

Summary
1.

Technical codes and standards

2.

Quality Assurance

3.

Design requirements

4.

Manufacturing

5.

Tests

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Manufacturing tests
In accordance with EN standards :
EN
o
o
o

12266-1: mandatory tests (compliance with PED regulations)


Strength test of the pressure vessel (1.5 x maximum admissible pressure)
Sealing test of the pressure vessel (1.5 x maximum admissible pressure)
Sealing test on the seat (1.1 x maximum admissible differential pressure)

EN
o
o
o

12266-2: additional tests


Strength test of the obturator (1.1 x maximum admissible differential pressure)
Operating test

EN 1349 for control valves and fittings


EN ISO 4126 for safety devices (safety valves)

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Manufacturing tests
With several additional requirements:
Sealing test on the seat:
Leak criteria (metal sealing surfaces): 0.11 cm3/h/mm (rate C EN12266-1)
Leak criteria (non metal sealing surfaces ): 0.01 cm3/h/mm (between rate A and
rate B EN 12266-1)
Reactor Building isolation valves : Test with air at 5.5 bar g; 16Ncm3/h/mm
Leak criteria for control valves:
Butterfly valves: class II (EN 1349 standard )
Globe valves: class IV (EN 1349 standard )
Leak criteria for safety valves:
Test carried out at 92% of cold differential test pressure
Criteria in water: 100 cm3/h/mm
Criteria in air/steam/other gas: 10 bubbles/min (Kellog method)
Operating test (isolation valves):
Opening at maximum P

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53

EPR Italia
Workshop on valves
3. Qualification of EPR-FA3 equipments: definition and
valves concerned
Roma, 8/7/2010
D. Pinier (EDF/SEPTEN)

Definition and equipment concerned

Aim

Equipment
concerned

8/07/2010

To prove the equipment capability to perform its function in


specific conditions.
Examples for valves and fittings:
To prove that a globe valve fitted with an electric actuator will close
under degraded ambient conditions (pressure, temperature,
irradiation)
To prove that a check valve will close when operating in water
charged with debris
Equipment required for the operation of systems performing a safety
function.
Qualification required for equipment important for safety.
The families of equipment to be qualified are as follows:
Rotating machines
Valves and fittings (valves, check valves, safety valves, etc.)
Electrical equipment and automated systems (including valve
actuators)
Ventilation fire
Other equipment and materials
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Requirements for safety related equipments

Requirement 1

Equipment has to prove its capability to assure a specific function.


Equipment qualification

Requirement 2

Manufacturer deemed to be able of mass equipment producing in


accordance with the qualified model.
Manufacturer subject to the manufacturing assessment
procedure.

Requirement 3

Compliance with the model to be assured throughout mass production.


Manufacturing subject to the approved equipment monitoring
procedure.

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Qualification conditions

Normal
conditions

Accident
conditions

Severe Accident

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Ability of the equipment to perform its role under normal


operating conditions.

Ability of the equipment to perform its function under the


following accident conditions:
Degraded ambient conditions in terms of pressure,,
temperature, irradiation, etc.
During and/or after an earthquake
High Energy Piping Break (HEPB)
Charged and radioactive water
Note: all equipment qualified at accident conditions must be
qualified at normal conditions.
Ability of the equipment to perform its role in case of Severe
Accident conditions: irradiation, pressure and temperature
conditions resulting from hypothetical core meltdown.

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Qualification - normal conditions


Methods

Operation Feedback : Operation feedback of similar equipment operated in an


existing installation under similar operating conditions.
Test: Programme of tests to be carried out on one or more items of model
equipment.
Extension: Extension rules for qualification for other rated diameters, nominal
pressures, etc., on the basis of the test carried out on a model equipment

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Qualification - normal conditions


By test

Standard test program on a model equipment:

Equipment characterisation:
Operation at nominal conditions (e.g.: leaktighness, operating time, flow
resistant coefficient...);
Operation at limit conditions (e.g.: opening at reduced voltage, reduced air
pressure...)

Assessment of time behaviour (accelerated ageing tests):


Ageing irradiation. (e.g. : 35 kGy / 10 years inside the Reactor Building)
Cycling on test loop (e.g.: for isolation valves: 1000 opening/closing cycles).
Mechanical vibrations (endurance test by frequencies scanning, natural
frequencies)
Evaluate the life time of the valve (10, 20, 30 years).

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Mechanical vibrating test

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Qualification - accident conditions


Profiles 1/2

Accident conditions profiles: K1, K2, K3 (RCC-E designation)


Earthquake + groups of accident
conditions

Specific conditions

High Energy Piping Break (HEPB)

K1: equipment in the RB required during


and/or after a thermohydraulic accident +
earthquake

Charged, radioactive water

K2: equipment in the RB not required after


a thermohydraulic accident + earthquake
K3: equipment outside the RB required in
normal conditions + earthquake
K3ad: equipment outside the RB required
normal and accident conditions +
earthquake

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K1
K3

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K2

Conventional

K3
Conven
tional
61

K3

Qualification - accident conditions


Profiles 2/2

K1

K2

K3

Conventional

Resistance over time

YES

YES

YES

YES

Earthquake

YES

YES

YES

NO

Irradiation ageing

YES

YES

NO

NO

NO

YES for
K3ad

NO

NO

YES for
K3ad

NO

Accidental irradiation
Thermodynamic
conditions

YES
YES

+ specific conditions for some component (Hygh Energy Piping


Break, Charged Radioactive Water)

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Qualification - accident conditions


Methods 1/2

Qualification by test
Model equipment subject to loads representing operating conditions
Tests carried out on a model equipment equivalent to equipments to be qualified

Examples:
Valve and actuator test on vibrating table
Electric actuator test under degraded ambient conditions
Irradiation test of a butterfly valve with elastomer seals
.

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Qualification - accident conditions


Methods 2/2

Qualification by analysis
By calculation using calculation methods and/or codes: to demonstrate
operability capability under loading conditions; validation of the calculation / test
methods required
e.g.: calculation of natural frequencies for earthquake resistance.
By analogy: based on a model equipment test to qualify a family of similar
equipment.
e.g.: Qualification for irradiation of a valve NPS 200 /other valve NPS 100 qualified
by test.
Mixed method: combination of several methods (test, calculation, etc.)

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Qualification - accident conditions

Degraded ambient conditions and earthquake (1/3)

Earthquake :
Building spectrum (equipment fixed to the building structure): 4 g max
Component spectrum (equipment indirectly fixed to the building structure) : 20
g max
Bi-axial test of 1 Design Basis Earthquake (DBE) + 5 half-DBE
Accidental exposure : maximum values for K1
gamma radiation: 68 kGy
beta radiation: 84 kGy
+ ageing radiation (depending on the lifetime of the equipment)
Standard test values adopted: for example, 600 kGy for electrical equipment

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Qualification - accident conditions

Degraded ambient conditions and earthquake (2/3)

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Qualification - accident conditions

Degraded ambient conditions and earthquake (3/3)

Degraded ambient conditions inside the RB : K1 profile


1er choc

2e choc

Post accident

P r(ek sP aio) n T e m p( C r )a t u r e

156

100

50

560
200
100

24 h 12 min

naturelRre

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24 h

96 h

240 h

Refroidissement naturel

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Thermodynamic chamber (1/2)

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Thermodynamic chamber (2/2)

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Qualification - accident conditions


General procedure

Qualification tests sequence for a "model" equipment :


Ageing
vibration
thermal ageing
prolonged operation
Ageing by irradiation (factor 4 to be taken into account, in accordance with
3.7 of the Safety Report)
Earthquake
Irradiation
Thermodynamic accident

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Qualification - accident conditions


Specific conditions (1/2)

HEPB: High Energy Piping Break:


Concerns isolation valves or check valves operating on High Energy pipes: in the event of
a pipe break the equipment has to close in the following conditions:
maximum flow rate
maximum differential pressure
acceleration conditions due to the break

Complex phenomena (water hammer, tilting of the gate, etc.) Qualification on loop test
or by analogy to a model equipment (qualified by test).

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Qualification - accident conditions


Specific conditions (2/2)

Charged radioactive water:


Equipment transporting fluids charged with debris (fibres, particles, etc., diameter < 100
m) has to assure its function (closing, opening, regulation, etc.).
Phenomena that are difficult to understand, mainly for equipment of small dimensions (risk
of clogging) and check valves (risk of incomplete closing) Qualification generally by test.

Severe Accident:
Equipment required in case of hypothetical core meltdown event: specific degraded ambient
conditions and, in particular, very high irradiation Qualification of the degraded ambient
conditions.

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Qualification failure causes

Equipment weak points: examples of failure causes during qualification test:


Wrong choice of materials with respect to irradiation, pressure and
temperature conditions
Unexpected materials corrosion
Differential expansion between adjacent parts producing leakage or jamming
Screws not tightened to the right torque (sealing, earthquake), or loose
pneumatic connections between static and dynamic parts
Accessories failure
A surplus of grease which turns into soap under the effect of irradiation and
jams everything

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Qualification a few figures

~ 17000 valves in a NPP


400 valves to be qualified at earthquake conditions (~ 8000 seismic classified)
~ 10 tests
400 valves to be qualified at K1 profile
~ 10 tests
50 valves to be qualified at HELB
~ 5 tests
50 valves to be qualified at Charged and Activated Water
~ 5 tests

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EPR Italia
Workshop on valves
4. EPR-FA3 valves qualification: who does what
Roma, 8/7/2010
R. Rotella (ENEL EDF/CNEN)

Technical offer
Equipment qualification requirement

For the supply of classified equipment requiring qualification, the technical offer has
to include a credibility report in addition to typical documentation (financial and
economic information, quality organization, technical information, etc.).

Objectives of the technical offer analysis:


To evaluate if the equipment qualification is feasible
To evaluate the supplier capability to compile documentations required for qualification
To evaluate the supplier capability to manufacture equipments in line with those already
qualified

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Credibility reports

Bring necessary elements to justify the feasibility of equipment qualification


Give a description of qualification methods and standards to be used

The Client analyses the content of all credibility reports to evaluate the
technical acceptability of the offer.
A credibility report must be submitted for each family of valves.

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Reports required to attest qualification


Responsibilities

Qualification tests: realized by the supplier according to test procedures validated


by the Client
Qualification reports: issued by the supplier and agreed by the Client.

The supplier performs all qualification activities and the Client declares the
equipments qualification.
Qualification is cost and time consuming.

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Reports required to attest qualification


Example

Qualification
specification

Identification
Report

Guidelines for
qualification by test

Guidelines for
qualification by analysis

Particular specification for


qualification test

Report for qualification by


analysis

Test report

Reference
Report

Modification
Request Sheet

Qualification
Synthesis Report

Client reports
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Supplier reports
79

Grazie per lattenzione!


Roma, 8/7/2010
D. Pinier (EDF/SEPTEN)
M. Mazouzi (EDF/CEIDRE)
P.M. Nahon (AREVA)
F. Bogaert (AREVA)
R. Rotella (ENEL EDF/CNEN)

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