Application Obsolescence and the Nuclear Promise - …fsrug.org/Presentations2017/18.pdf · Application Obsolescence and the Nuclear Promise 1/31/2017 ©2015 ValvTechnologies

January 16 - 19, 2017

Application Obsolescence

and the Nuclear Promise

©2015 ValvTechnologies. All rights reserved.1/31/2017 1

Bill Henwood Vice President & Director of Industry, Nuclear

Tim Howard National Sales Manager, Nuclear

Feedwater System Reliability Users Group

Austin Hilton Hotel

Content

• Introduction of ValvTechnologies

• Application Obsolescence

• Case Study: Application Obsolescence at Sizewell B

• Introduction :Background/History

• Effects on Operations and Maintenance

• Cycle Isolation Methodology via ValvPerformance™ Testing

• Additional Examples and Conclusion

1/31/2017 ©2015 ValvTechnologies. All rights reserved. 2

Our Company

ValvTechnologies Headquarters

Houston, Texas U.S.A

Our Company

Incorporated in 1987 – 30 Years

Over 450 Employees Worldwide

Corporate Headquarters

Factory and Engineering Locations:

United States - Houston TX (2)

United Kingdom – Stockton-On-Tees

China – Sales and Engineering

India – Chennai (Asia Market)

Sales Offices: Direct Personnel

Malaysia

Dubai

Korea

Spain

Poland

Central & South America

United Kingdom

The Global Leader in Absolute ZERO LEAKAGE Metal Seated Valve Technology

Bingle Road Facilities


Authorizations & Qualifications

• ASME III Class 1, 2 & 3

• 10CFR50 Appendix B

• Part 21 Acceptance

• ANSI N45.2

• NQA-1

• ISO 9001 - 2000

• PED Compliant (Europe)

• Lloyds EMEA Register

• SIL-3 (Europe)

• NUPIC Approved

• NIAC Member


Standard Nuclear Product Lines

V1-1

V1-2

V1-3

V1-4

V1-ERV

V1-Xactrol

Isotech® PSG

In-line Check Valves


Nuclear Promise & Obsolescence


The Nuclear Promise outlines three strategic areas of focus as

follows:

Maintain Operations Focus – “Safety is a top priority, safety as it pertains to

advancing reliability, which is fundamental to continued operations”.

Increase Value – “Generation of additional revenue, valuing unrecognized

attributes”: i.e. recuperating lost megawatts attributed to degradation of

critical systems due to valve performance.

Improve Efficiency –“Identifying focus areas, improving efficiency of industry

oversight, evaluating enablers for cost reduction, while contributing to the 30%

industry cost reductions.” i.e. improving and maintaining efficiencies

attributed to performance of critical systems due to equipment by

elimination of leakage caused by application obsolescence

Nuclear Promise & Obsolescence


Obsolescence – The Nuclear Utility Obsolescence Group Charter’s purpose is to

“create an environment where nuclear utilities can mutually identify obsolete items

and potential replacements”, with a focus on long term equipment reliability

solutions to reduce station risk and vulnerabilities.

ValvTechnologies is dedicated to providing the industry with products and services

which can strongly contribute toward these important industry goals. Our durable

Zero Leakage products, the latest designs in isolation, and control technology can

add to the operating fleet valuable areas for improvement through:

• The elimination of leaks causing system and equipment degradation,

• Recuperating lost megawatts,

• Drastic reductions in maintenance and reductions in costly spares inventory


http://www.ans.org/advertising/whitepapers/




• Generation I & II Plant designs utilized the best available technologies in

terms of Isolation, Vent and Drain Valves

• Gate Valves – Suitable for isolation when normally closed

• Globe Valves – Throttle valve in Isolation service

• Metal Seated Ball and Seat Protected Parallel Slide Gate Valves' were

not available during the design build wave using the Generation I & II

Design Technologies (operating fleet)

• Designed specifically for these applications, using the latest zero cobalt High

Velocity Oxygen Fuel hardcoating technologies which were perfected in the

mid 1980’s.

• Utilizing misapplied valves in high energy and temperature applications

directly impact efficiencies as well as contributing to increase O&M costs.




• SEAT RINGS UNPROTECTED IN DIRECT FLOW PATH = Increasing Leakage• HIGH TURBULANCE IN BODY BOWL AREA = Increased Seat Erosion

ABSOLUTE ZERO LEAKAGE

Isotech® Seat

Protected PSG

Globe Valve – Throttle Valve in

Isolation Applications

Flow Induced Damage/Flow Accelerated

Corrosion

• Torturous Flow Path

• Exposed Seats

• Impingement

• Steam Cutting / Wire Drawing

• Internal Erosion

• Flashing

• Cavitation

• Vibration

• Down Stream Degradation High Unseating Forces

MS Quarter Turn Isolation Valve


Delivering on the Nuclear Promise

The Sizewell B Story

Westinghouse 4 Loop Single Unit PWR

Output - 1195 MW

Turbine Supplier – Alstom

MS Vent Drain & Isolation Valves:

• Since 2008

• 500 Valves Identified in MSS

• 80 mm (3”) and Smaller

• ANSI- ASME 300# - 1500# Class

• Actuation: MOV/AOV/Gear and

Manual

• Carbon Steel and Stainless Steel

History –Sizewell B, Leiston UK


O & M Process Improvement

Implementation

Measured losses attributable to passing valves, as

measured by plant personnel were 11-13 megawatts prior

to program commencement.

In economic terms that is 12MW*8760HRS*$50/MWHR

or $5,000,000 PER YEAR!


O & M Process Improvement

Implementation

MSS Valve Replacement Program at Sizewell B

• Spearheaded by Steam and Rotating Plant Group with Management

Support.

• Over 500 Gate and Globe Valves Identified for Replacement.

• Quantify and Target the Valves with the Highest Efficiency Losses and

Downstream Component Damage Due to the Leakage

• Approximately 50% of the Total Replaced to Date.

• Measured Recovery of over 8 MWe

• Cost of Valve Replacement Including Actuation $780K

• “Overnight” Payback was as low as 8 Weeks

• The Program has Significantly Reduced Down Stream Damage to

Piping and Components Caused by Leaking Drain Valves.


ValvPerformance™ Test Results at Sizewell B


Ultrasonic Emission Testing

ValvTechnologies tests valves for Ultrasonic Emissions and correlates the test

results to a vast database of valves with known leakage rates to provide a

mass-flow rate of leakage for the subject valve.

The process was verified accurate

by an independent laboratory.

Additionally, using the mass-flow

rate of leakage, ValvTechnologies

calculates the impact of the leaking

valve on plant system efficiency in

terms of Mw output improvement


Overview:

• 136 Valves Tested

• The Balance of Valves were Recent Replacements, Inaccessible or were

Deemed Unsafe due to System Degradation.

• Total Losses Measured of 2.2 MWe

• Losses Valued at Close to £1.4MM

• 80% of the Losses (£1.1MM) From Just 30 Valves

• Follow up ValvPerformance™ Testing ongoing for outage planning

• Expanding the program fleet-wide (additional 6 operating

sites) and impacting the isolation valve technology for Hinkley

Point C (Areva EPR x 2)

Sizewell B Results


Sizewell B Results

Top 15 Worst Performers $1,156,1401/31/2017 ©2015 ValvTechnologies. All rights reserved. 25

Actual Wedge

2” 900# Wedge Gate Valve in

Condensate Drain Application

Down Stream Seat after six weeks in

Operation


Value Proposition $

MWe Recovered Vlv & Act Cost Cost MW Hr $78 % of the year Weeks Payback

8 $781,524 $4.99MM .156 8

8 $1,563,049 $4.99MM .312 16

8 $1,953,812 $4.99MM .391 20


8 $781,524 $3.9MM .200 10

8 $1,563,049 $3.9MM .400 21

8 $1,953,812 $3.9MM .500 26


8 $781,524 $3.4MM .227 12

8 $1,563,049 $3.4MM .454 24

8 $1,953,812 $3.4MM .568 30

2X

2.5X

2.5X

2X

2X

2.5X


Salem Nuclear Generating Station • Westinghouse Reactors 1,100 MW

-Installed over 200 valves in 1995 - 1996

- up to 22 years untouched.

•V1-1 2“ (51mm) and smaller \

•Startup Steam Drains and Steam Trap Isolation

-These valves see 500°F / 260C steam with

continuous pressure drops of 800 to 1000 PSI /

55 to 69 bar during the startup.

•Globe valves replaced by MSBV were source of

continuous leakage, replacement and

maintenance resulting in $125,000+ in annual

savings = $2,750,000 and counting.

•6” 900# 316 SS IsoTech® Seat Protected

PSGV in Aux Feedwater Suction Isolation

Service – 4 years

O&M Successes


OconeeB&W 850 MW,

McGuire/CatawbaWestinghouse Reactors 1,100 MW

•Installed approximately 250+ 19mm (.75”) -

51mm (2”) valves at each site since 2000

- No reported problems.

•Valves are used on the high pressure side of the

system (Design Conditions are 2485 psig /171 bar at

649°F /343C).

•Additional applications:

•Small bore replacement program

•High Pressure Injection Valves ASMEIII Class 2 • 12- 6” (152mm) V1-3 ASME/ANSI 300# Class 316SS

•Borated Water Storage Isolation Valves Safety Related• 6 – 3” (76mm) Full Port V1-2 ASME/ANSI 300# Class 316SS

O&M Successes


Qinshan Nuclear Power Company

Phase IIITwo AECL CANDU 6 Units

Zhejiang Province, PRC

Unit 1 – September 2002 – 15 years of service

Unit 2 – April 2003 – 14 years of service

• 42 VTI V1-2 Air Operated Steam Drain Control Valves per Plant

• 38mm (1.5”), 51mm (2”), and 102mm (4”) 600# ANSI Class with Air Actuators.

• LP Turbine Extraction Steam to LP Heater

• FW Heater Extraction Steam Header

• LP turbine Extraction Steam Deaerator

• HP Turbine Extraction Steam to HP Heater

• Main Steam Balancing Header

• Main Steam Drip Leg Drain

• HP Extraction Steam Drain

Reference


Conclusion

• It is very important to understand this is a long term solution to a

long term problem.

• Although the recovery and associated cost savings overview is

summarized as an “overnight” payback it doesn’t require wholesale

change-out of hundreds of valves all at once.

• Measurable savings are immediately realized

• Tools are available to identify leakage, quantify losses to assist

Operations and Maintenance to once and for all cease the practice

of forever fixing it versus fixing it forever.

• The first step is to identify and quantify those losses, and then plan

the next step in the road to megawatt recovery by addressing

Application Obsolescence and contributing to the Nuclear Promise!


ZERO LEAKAGE

=Zero Spare Parts, Zero Maintenance, Zero Service Calls

Our Nuclear Promise


Thank you!

www.valv.com

http://www.valv.com/

Documents

Application Obsolescence and the Nuclear Promise - …fsrug.org/Presentations2017/18.pdf · Application Obsolescence and the Nuclear Promise 1/31/2017 ©2015 ValvTechnologies