4.workshop valves 2010-07-08 final

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 valves1. Technologies for EPR-FA3

Roma, 8/7/2010

F. Bogaert (AREVA)


8/07/2010 4Workshop valves

BOP IC

BNINSSS

4 plant areas:• Nuclear Steam Supply System - NSSS• Balance of Nuclear Island – BNI• Conventional Island - CI• Balance of Plant – BOP

4 plant areas:• Nuclear Steam Supply System - NSSS• Balance of Nuclear Island – BNI• Conventional Island - CI• Balance of Plant – BOP

EPR areas Generalities


Examples of classified systemsSafety Injection SystemChemical and Volume Control SystemContainement Heat Removal System

CLASSIFIED EQUIPMENTS

CONVENTIONAL EQUIPMENTS

Examples of classified systemsEssential Service Water SystemUltimate Cooling SystemFire-Fighting Water Production

Examples of not-classified systems

Internal Containment Filtration Hydrogen Distribution

Examples of not-classified systems

Main Turbine Steam and Blow-down System

Main Steam By-passDemineralized Water Production

ICTurbine Island (TI)Balance of Conventional Island (BCI)

BOP

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

EPR areas Classified and not classified equipments


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 Q1 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.

Pneumatic actuator (not used in Reactor Building - RB)

Electric actuator

Solenoid actuator

Manual actuator

Stainless steel Carbon Steel


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

L pressure and L temperature: < 20 bar and < 100 °C Diaphragm valves for limited dimension Ball valves Butterfly valves

M pressure and/or M temperature: 20 ⇒ 40 bar and/or 100 ⇒ 200 °C Ball valves Butterfly valves

Analysis not exhaustive: other parameters have to be taken into account → radioactive fluid, valves reactor

building isolation, qualification requirements, etc.


Gate

valv

e

Glo

be v

alv

e

Dia

ph

rag

m v

alv

e

Swing check valve

Bu

tterfl

y v

alv

e

Standard valves of NSSS, BNI, BOP and CI Generalities: examples of standard valves types (2/2)


Indicative number of equipment

Min diameter

Max diamet

er

Max pressure [bar]

Max temperature [°C]

CLA

SS

IFIE

D V

ALV

ES

Gate valves < 150 DN80 DN350 170 310Globe valves (with or without bellow)

4600 DN8 DN350 250 360

Diaphragm valves 2000 DN8 DN100 20 100Plug valves 1250 DN8 DN200 20 250Butterfly valves 350 DN80 DN900 35 170Containment isolation specific valves

8 DN500 DN1000 6 170

Safety valves 200Control valves ~ 250 DN15 DN600 170 310Swing check valves 300 DN80 DN350 250 210Lift check valves 400 DN8 DN50 250 350

Standard valves of NSSS, BNI and BOPClassified standard valves

Other valves are supplied in packages contract.

TOTAL ~ 9500


Indicative number of equipment

Min diameter

Max diamet

er

Max pressure [bar]

Max temperature [°C]

NO

T-C

LA

SS

IFIE

D

VA

LV

ES

Globe valves 1100 DN8 DN350 250 360Diaphragm valves 1200 DN8 DN100 20 100Plug valves 350 DN8 DN200 20 250Butterfly valves 50 DN80 DN900 35 170Safety valves < 100Control valves 50 DN15 DN600 170 310Swing check valves < 50 DN80 DN350 250 210

Lift check valves 100 DN8 DN50 250 350

Standard valves of NSSS, BNI and BOP and CI Not-classified standard valves

Other valves are supplied in packages contract.

TOTAL ~ 3000

NSSS+BNI+part of BOP

Part of BOP and IC ~ 5000

TOTAL not-classified ~ 8000


Flowrate Min

160 kg/s

Set Pressure

105 bar a

Diameter 8" x 14"

Pressure 78 – 92 bar a

Steam Safety Valve

Flowrate Max 640 kg/s

Max pressure drop 0.25 bar

Design Pressure/Temperature

100 bar a / 311 °C

Closing time < 5 seconds

Diameter 32"

Main Steam Isolation Valve

Valves for NSSS Special valves (1/2)


Main Steam Relief Isolation Valve

Flowrate Safety Min/max

320 / 384 kg/s

Design p / T 100 bar a / 311 °C

Stroke time Max 40 seconds

Inlet/Outlet Diameter 14" / 16"

Pressurizer Safety Valve

Design Pressure 175 bar g

Set pressure174/177/180 bar g

Reseat pressure min149/152/155 bar g

Design / Normal operating Temperature

362 / 345 °C

Mass flow rate min (saturated steam / water)

300 000 / 450 000 kg/h

Valves for NSSS Special valves (2/2)

EPR Italia

Workshop on valves2. General requirements for EPR-FA3

Roma, 8/7/2010



P.M. Nahon (AREVA)



1. Technical codes and standards

2. Quality Assurance

3. Design requirements

4. Manufacturing

5. Tests

Summary





4. Manufacturing

5. Tests

Summary


Mechanical equipment Electrical equipment Q1 Q2 Q3 EE1 EE2

FA3 RCC-M

RCC-M RCC-M

RCC-ERCC-E or IEC or

equivalent

ASME III NC + EDF specification (*)

ASME III NC + EDF specification (*)

KTA class 2EN standard or

equivalent + EDF specification (*)

ITALY(**)

RCC-M

RCC-M RCC-M

RCC-ERCC-E or IEC or

equivalentASME III NC + Client specification

EN standard or equivalent + Client

specification

(*) EDF specification to take into account the RCC-M requirements(**) Preliminary proposal to verify after Nuclear Safety Authority establishment

Technical Codes & Standards General framework for classified equipments (1/2)


Technical Standard

DescriptionStandards

editorCountry

RCC-MCode for design and manufacturing of mechanical equipment for Pressurized Water Reactor

AFCEN France

ASME American Society of Mechanical Engineers ASME USA

KTA Kern Technischer Ausschuss KTA Germany

EN 12516 Calculation method for steel valve shells CEN Europe

RCC-ECode for design and manufacturing of electric equipment for Pressurized Water Reactor

AFCEN France

Technical Codes & Standards General framework for classified equipments (2/2)


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

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 Codes & Standards frameworkGeneral framework for not classified equipments





4. Manufacturing

5. Tests

Summary


For all: environmental ISO 14001 and health & safety OHSAS 18001 are considered

COMPONENT STATUS QUALITY SYSTEM REQUIREMENTS

Product and services safety related

(mainly Class1 (Q1), Class2 (Q2) & Class3 (Q3))

ISO 9001 complemented by specific nuclear requirements based upon IAEA GS-R-3 2006, local regulations

& laws and Client added requirements

Products and services non safety related

(mainly QC)

ISO 9001

Quality Management Specification

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


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.

PAQP for the project

Quality Management prescription for Safety classified activities

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.


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

Quality Surveillance requirements EPR-FA3


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

Manufacturing & Test Follow-upInspection Plan (Follow-up Document)


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 sub-contracts

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)

Some key points about the quality surveillance


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)

Experience feedback on QM evaluations of suppliers (1/2)


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)

Experience feedback on QM evaluations of suppliers (2/2)


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…

Experience feedback on Surveillance from Inspection department (1/3)


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…



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…



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





4. Manufacturing

5. Tests

Summary


Different technical requirements should be applied or not applied, in accordance with these classifications.

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.

Design requirements Origins of the technical requirements


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)

Design requirements General requirements (1/4)


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 valvesMechanical sizing of the mechanismStability (safety valves, control valves, etc.)Flow rate required (safety valves, control valves, etc.)



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)



Life time conception : 60 yearso Operation in continuous service during at least 48 months without maintenance

o Few maintenance per 10 years period

Maintenance : o Simple and quicko Without specific tools other than tools supplied by the Manufacturero Only replacement on « wear » partso 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)



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

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


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...

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

Strong Organizational & Engineering capability required





4. Manufacturing

5. Tests

Summary


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


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

General requirements

* European Pressure Equipment Directive 97/23/EC


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" are manufactured in accordance with the best state-of-art practice.


RCC-M - Main requirements


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. It’s the time to determinate the characteristics of the product and particularly singularities andtestability

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

RCC-M Main requirements Special parts – Reference and Procurement specification


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

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)

RCC-M Main requirements Part and Product – Reference and Procurement specification

End Manufacturing Report mandatory


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

…

RCC-M Main requirements Materials in relation to standards


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

RCC-M Main requirements Welding and manufacturing


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

RCC-M Main requirements Non-destructive examinations


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

European standards with additional requirements





4. Manufacturing

5. Tests

Summary


In accordance with EN standards :

EN 12266-1: mandatory tests (compliance with PED regulations)o Strength test of the pressure vessel (1.5 x maximum admissible pressure)o Sealing test of the pressure vessel (1.5 x maximum admissible pressure)o Sealing test on the seat (1.1 x maximum admissible differential pressure)

EN 12266-2: additional testso Strength test of the obturator (1.1 x maximum admissible differential pressure)o Operating test o …

EN 1349 for control valves and fittings

EN ISO 4126 for safety devices (safety valves)

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/mmLeak 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

Manufacturing tests

EPR Italia

Workshop on valves3. Qualification of EPR-FA3 equipments: definition and

valves concerned

Roma, 8/7/2010



Definition and equipment concerned

Aim

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 concerned

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


Requirements for safety related equipments

Requirement 1Equipment 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 3Compliance with the model to be assured throughout mass production.

Manufacturing subject to the approved equipment monitoring procedure.


Qualification conditions

Normal conditions

Ability of the equipment to perform its role under normal operating conditions.

Accident 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.

Severe AccidentAbility of the equipment to perform its role in case of Severe Accident conditions: irradiation, pressure and temperature conditions resulting from hypothetical core meltdown.


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

Qualification - normal conditionsMethods


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…).

Qualification - normal conditionsBy test


Mechanical vibrating test


Earthquake + groups of accident conditions

K1: equipment in the RB required during and/or after a thermohydraulic accident + earthquake

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

Specific conditions

• High Energy Piping Break (HEPB)

• Charged, radioactive water

+

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

Conventional

Conventional

K3K3

K3

K1

K2

Qualification - accident conditionsProfiles 1/2


K1 K2 K3Conven-tional

Resistance over time YES YES YES YES

Earthquake YES YES YES NO

Irradiation ageing YES YES NO NO

Accidental irradiation YES NOYES for K3ad NO

Thermodynamic conditions YES NO

YES for K3ad NO

+ specific conditions for some component (Hygh Energy Piping Break, Charged Radioactive Water)

Qualification - accident conditionsProfiles 2/2


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

• ….

Qualification - accident conditionsMethods 1/2


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.)

Qualification - accident conditionsMethods 2/2


• 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

Qualification - accident conditionsDegraded ambient conditions and earthquake (1/3)


• Degraded ambient conditions inside the RB : K1 profile

156

100

50

560

200

100

Te

mp

érat

ure

(°C

)P

res

sio

n(k

Pa)

24 h 12 min 24 h 96 h 240 h

naturelRre Refroidissement naturel

1er choc 2e choc Post accident



Thermodynamic chamber (1/2)


Thermodynamic chamber (2/2)


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

Qualification - accident conditionsGeneral procedure


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).

Qualification - accident conditionsSpecific conditions (1/2)


Charged radioactive water:

• Equipment transporting fluids charged with debris (fibres, particles, etc., diameter < 100 µm) 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”.

Qualification - accident conditionsSpecific conditions (2/2)


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

Qualification – failure causes


• ~ 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

Qualification – a few figures

EPR Italia

Workshop on valves4. EPR-FA3 valves qualification: who does what

Roma, 8/7/2010



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

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.).

Technical offerEquipment qualification requirement


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.


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.


Report for qualification by analysis

Qualification Synthesis Report

Guidelines for qualification by analysis

Particular specification for qualification test

Test report

Reference Report

Modification Request Sheet

Guidelines for qualification by test

Identification Report

Qualification specification

Reports required to attest qualification Example

Client reports Supplier reports

Grazie per l’attenzione!

Roma, 8/7/2010



P.M. Nahon (AREVA)

F. Bogaert (AREVA)


4.workshop valves 2010-07-08 final

Documents