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 valves
1. Technologies for EPR-FA3
Roma, 8/7/2010
F. Bogaert (AREVA)
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
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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)
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Electric
actuator
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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
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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
P.M. Nahon (AREVA)
Summary
1.
Technical codes and standards
2.
Quality Assurance
3.
Design requirements
4.
Manufacturing
5.
Tests
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Summary
1.
2.
Quality Assurance
3.
Design requirements
4.
Manufacturing
5.
Tests
8/07/2010
Workshop valves
16
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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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.
2.
Quality Assurance
3.
Design requirements
4.
Manufacturing
5.
Tests
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20
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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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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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.
2.
Quality Assurance
3.
Design requirements
4.
Manufacturing
5.
Tests
8/07/2010
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32
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

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
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
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
8/07/2010
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Summary
1.
2.
Quality Assurance
3.
Design requirements
4.
Manufacturing
5.
Tests
8/07/2010
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40
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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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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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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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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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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Summary
1.
2.
Quality Assurance
3.
Design requirements
4.
Manufacturing
5.
Tests
8/07/2010
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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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EPR Italia
Workshop on valves
3. Qualification of EPR-FA3 equipments: definition and
valves concerned
Roma, 8/7/2010
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

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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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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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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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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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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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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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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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
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
P.M. Nahon (AREVA)
F. Bogaert (AREVA)

4.workshop Valves 2010-07-08 Final

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EPR Italia

Valves technologies for EPR-FA3

General requirements for EPR-FA3 valves

Qualification requirements for EPR-FA3 valves

EPR-FA3 valves qualification: who does what

Classified and not classified equipments

Examples of classified systems

Examples of classified systems

Classified equipments have to perform essential functions for NPP safety.

Valves for EPR-FA3

Standard valves of NSSS, BNI, BOP and CI

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

Analysis not exhaustive: other parameters have to be

Standard valves of NSSS, BNI, BOP and CI

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

Standard valves of NSSS, BNI and BOP

Other valves are supplied in packages contract.

Standard valves of NSSS, BNI and BOP and CI

Part of BOP and IC

Other valves are supplied in packages contract.

Valves for NSSS

Steam Safety Valve

Main Steam Isolation Valve

Max pressure drop

Valves for NSSS

Main Steam Relief Isolation Valve

Pressurizer Safety Valve

320 / 384 kg/s

Reseat pressure min

Technical codes and standards

Technical codes and standards

Technical Codes & Standards

General framework for classified equipments (1/2)

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

Technical Codes & Standards

General framework for classified equipments (2/2)

Code for design and manufacturing of mechanical

American Society of Mechanical Engineers

Kern Technischer Ausschuss

Technical Codes & Standards framework

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

Technical standards: examples

Technical codes and standards

Quality Management Specification

QUALITY SYSTEM REQUIREMENTS

Quality Management prescription for Safety classified

PAQP for the project

Quality Surveillance requirements

Manufacturing & Test Follow-up

Some key points about the quality surveillance

Experience feedback on QM evaluations of suppliers

Experience feedback on QM evaluations of suppliers

Experience feedback on Surveillance from Inspection

Experience feedback on Surveillance from Inspection

Experience feedback on Surveillance from Inspection

Key issues - Conclusion

Anticipation is imperative in order to be ready when

Technical codes and standards

Origins of the technical requirements

General requirements (1/4)

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

General requirements (2/4)

General requirements (3/4)