Retrofits and Actuator Upgrades - fsrug.org

Retrofits and Actuator Upgrades

Kurt Christianson, PE

Application Engineer, Americas

FSRUG

1-18-17

Operating Experience, Teflon Balance Seals

Manufacturer’s include Furon and Variseal.

The concern is FME when the seal fails.

Operating Experience, Teflon Balance Seal

‣ The balance seal

eliminates flow

through the balance

holes in the plug (or

disc).

‣ Teflon seals are low

friction.

‣ Reduce actuator

force required

‣ Reduce hysteresis

‣ Teflon seals provide

tight shutoff.


Balanced Plug vs. Unbalanced

Unbalanced Plug Balanced Plug (No Step)

Teflon Balance

Seal


“The picture of the orange finger indicating a wire caught in a disk stack was taken from River Bend. They had similar

FME issues as Grand Gulf. It did not look like a variseal failure, because they use a ribbon element inside the Teflon

balance seal. Today we use St. Gobain "Furon" balance seals, which is a competitor of Variseal. The Furon balance seal

has a ribbon spring element as well.

The Teflon balance seal manufactured by Furon which is similar to the Variseal design is the preferred option for plug

sealing when Teflon is allowed in nuclear applications. The Teflon balance seals used by IMI CCI have no record of

chronic failure. If other manufactures are seeing failures of similar balance seals in their valve designs (i.e. Copes

FWREG at Riverbend) it may be due to valve design.

There is no concern of failure with Teflon balance seals in DRAG® valve designs, and IMI CCI will continue to use these

seals when possible to take advantage of their superior sealing capabilities, long life, and low friction.”

Sincerely,

Kurt Christianson, PE

Application Engineer, Nuclear

IMI CCI

© 2002. CCI – Control Components Inc. All rights

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Trim measurements before retrofit

© 2002. CCI – Control Components Inc.

All rights reserved.

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FWR RETRIFITED WITH CCI DRAG TRIM


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REPLACEMENT OF THE ACTUATOR


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RECIRC RETROFITED WITH CCI DRAG TRIM


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ATMOSPHERIC VENT VALVE

We are an international leader in the engineering and manufacturing of critical service flow control valves for the Nuclear Industry.

We solve control valve problems.

Our global reach

IMI CCI (California) manufacturing

• 194,000 sq. ft. facility

• 300 employees

• DRAG® technology

• Full manufacturing

• Located in Rancho Santa Margarita, CA

• Primary supply location for North America

• Designed to maintain fast-response

capability for parts and maintenance

services

• Sales/customer service, engineering,

project management & quality

management resources

• Spare parts, repairs, and technical

service

• Full manufacturing/machining/welding/

assembly & test capability

• Assembly & test for complete valves

• Stellite machining

• Valve repair services

• Spare parts supply & distribution

• Technical services

• Project management

• Design engineering for DRAG®

• Upgrade design team

• Quality management services

CapabilitiesCredentials Products

• ASME N & NPT certification

• 10CFR50 Appendix B, Part 21

• HAF604 (China)

• NB National Board certified

• Dir. 97/23/CE (PED)

• API 6A

• RTN & GOST-R (Russia)

• CRN (Canada)

• NUPIC and NIAC audited/approved

• ISO 9001:2000 (2008)

• Residual heat removal applications

• ASDV/CSDV/TB

• Power operated relief valve

• Feedwater/level control

• Reactor water cleanup

• Recirculation valves

• Temperature/pressure control

• Chemical volume & control valves

• AUX steam control

• Pump test loop/sampling

• Heater drain valves

• Pneumatic actuation

Presentation Overview

25

Severe Service Applications

DRAG® Technology Overview

QuickTrak® Valve Positioning System

High Rangeability Valve Design

IMI Technologies for Nuclear

ButterflyBall

Globe

Severe service

Control Valve HierarchyPe

rfo

rman

ce

Severity

DRAG® Valve Applications in Nuclear (not all!)


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CCI APPLICATIONS IN PWR UNITS

ISA guide: velocity control limits

Service conditions

Gas / steam kinetic

energy criteria

Equivalent liquid /

water velocity

psia ft / s

Continuous service single

phase fluids70 100

Cavitating & multiphase fluid

outlet40 75

Vibration sensitive system 11 40

Intermittent duty 150 -

Trim outlet kinetic energy criteria

KE =V2

2gc

Velocity control principle

‣ Single stage pressure drop

DP = P1 - P2

Velocity control principle

‣ Multiple stages of pressure drop

Single Stage and Multi Stage Valve Trim

33

‣ DRAG® Eliminates Cavitation

Cavitation damage can not be predicted.

Cavitation Damage – Not Enough Stages

Determining valve trim loss coefficients

• The loss coefficients of control valves can be calculated using the

piping system methods from Crane 410.

• Loss coefficients can be summed in series. The summation must

include the effect of changes in area. This can be done using the area

expansion coefficient, Ec.

exitn

ci

ientryT K

E

KKK 2

2

1

A

AEc

Typical loss coefficients for control valves

• Single-stage cage has K = 1.5.

• Three-stage cage with Ec = 2 has K = 1.97

• A series of right angle turns with Ec = 1.072

have an average loss coefficient of K = 1.32

(determined experimentally).

• Four right angle turns with Ec = 1.072 have

K = 6.7.

• Discharge velocity can be found using

Darcy equation, pressure drop, density, and

loss coefficient.

K

PgV

net1442 D

Cv=29.9d^2/K^0.5

Key Critical Service Elements

Process Insight

• Understanding of the applications

Reliability

• Control of Fluid Velocity/ Kinetic

Energy

• Material of Construction

• Robust Design

• Multi Stage Pressure Reduction

• Discrete Flow Passages

Control Resolution

• Actuator/Positioner

• Trim Design

Multi Stage Pressure Reduction

Discrete Flow Passages

DRAG® velocity control flow path

Over the plug flowUnder the plug flow

DRAG® EDM Diskstacks

Inlet

Outlet

Inlet

Inlet Inlet

DRAG® Laser Cut Disk Stacks

Feedwater Regulator Valve

‣ Rangeability for low flow

conditions

‣ Rangeability achieved

through trim

characterization

Basic Design Parameters

42

Low pressure drop

High CvFull Load

High pressure drop

Low Cv

Startup

SPINDLE

BONNET

PLUG

BONNET FLANGE

DISK STACK &

TRIM ASSEMBLY

Disk Stack in Control Valve

Quick Change Trim

‣ No parts screwed or welded into the valve body.

‣ Lifting holes provided for all trim components.

‣ No special tools for disassembly.


45

Severe Service Applications Feedwater




Actuator Upgrades

DRAG® Boiler Feedpump Recirculation

1/23/2017

‣ Features

‣ Offers reliable pump protection -

28 Stages of pressure drop

‣ Pressurized seat provides long-

term, reliable shut-off – MSS-SP61

‣ Coins seat with 1500 PLI

‣ “Soft” 316 seat ring coins under

load & provides erosion / corrosion

protection

‣ Weir groove deflects clearance jet

‣ PER Groove provides equal

pressure boundary between plug

and disk stack

DRAG® 100D feedwater regulator

1/23/2017

‣ Features

‣ DRAG® disk stack control element

‣ Equal-percentage trim characteristic

‣ High rangeability

‣ Long valve stroke

‣ Angle & globe configuration

‣ Can combine start up and main into a

single control valve element

‣ Long service life

‣ Low cost of ownership

‣ Aux Feedwater Applications

‣ Smaller

‣ Safety Related

‣ Tight Cv control required

‣ Tight shutoff

Flashing Fluid Solutions

CCI has the best heater drain valve in the industry.

Heater Drain with through body leakage, addressed with seat diffuser.


49





Actuator Upgrades

50

QuickTrak™ transformationComplex system to simple system

5

QuickTrak™ improves plant performance

‣ Fast stroking & fast response for system

protection - NO OVERSHOOT

‣ Precise positioning for accurate process

control – Superior performance

‣ Reduces maintenance time, down time &

cost – Severe service rugged design

‣ Elimination of quick exhausts, boosters &

relays – Simple calibration

‣ Integral electronic position feedback

eliminates complex linkages susceptible

to wear, damage & poor resolution

52

Key components – QuickTrakTM Controller

‣ Digital microprocessor control with digital display

‣ Highly accurate tuning with high repeatiblity

‣ Simple calibration – no boosters or exhaust

‣ Magnetostrictive probe feedback

‣ Diagnostic program‣ Advanced I/O system

53

Key components – High Capactiy Pneumatic Control with no mechanical linkage

Encoder

Step Motor

Pressure Sensors

Spool Valve

High Capactiy

Cv 30 or

Cv 9

Probe

3 Way Valve -

for fail modes

Fully

rem

ote

dPa

rtia

llyre

mo

ted

Versions :•Standard Location ( CE or UL)•Hazardous Location ( ATEX/IECEX)

Options :•On Board•Remote ( fully or partially)

1

Note 1 : the remote mounting can affect the performances

Remote Installation Features

‣ Remote Mount

‣ Longest remote mount in the industry

‣ Unlimited feedback probe wire length

‣ High air capacity minimizes pneumatic lag

55


56





IMI Technologies for Nuclear

Level Control Valves

• Single control valve solution. High Rangeability.

• Characterized Disk Stack. Multi-stage for start up. Low restriction for full load.

• High resolution with CCI Piston Actuator.

Level Control Valves

58

Plug-in-plug design

• Can meet the highest

rangeability requirements.

• 200:1 or better

59

Plug in Plug, Cv vs. Stroke 100% range

Cv vs. Stroke

0.0000%

10.0000%

20.0000%

30.0000%

40.0000%

50.0000%

60.0000%

70.0000%

80.0000%

90.0000%

100.0000%

0.0000% 10.0000% 20.0000% 30.0000% 40.0000% 50.0000% 60.0000% 70.0000% 80.0000% 90.0000% 100.0000%

% stroke

% C

v

60


61





Actuator Upgrades

The Problem

• O-rings in the piston and stem bushing were rolled, broken and dry.

• Seals failed, leading to leakage and actuator going to fail position

• 12 to 15 cycles/minute

• High radiation, high temperature environment

Failure Mechanism

• Wear on only 1 side• High cyclic operation• Coil spring buckling

64

Improved Design

• Solution• Replace

Buna-N o-rings with Viton o-rings

• Two thrust rings

• Increased o-ringclearance

Testing

• 7,800,000 cycles• Grease was were it belonged

66

Testing (cont)

• O-ring NOT cracked and worn• Thrust rings in good condition

Improving on a sound designComparison

Legacy Actuator

‣ No piston guiding

‣ Minimal stem guiding

‣ No lubrication reservoirs

‣ Full actuator disassembly to change

stem o-ring

‣ No stem wiper

‣ Limited accessory mounting

67

HE Actuator

‣ Double piston guiding

‣ Double stem guiding

‣ Piston and stem lubrication

reservoirs

‣ Quick change bushing housing

‣ Stem wiper ring

‣ Larger diameter stem

‣ Greater accessory mounting

flexibility

‣ Improved performance in

horizontal orientation

Endurance Actuation features

‣ Double piston guiding

Two graphite filled PTFE guide bands on the

piston, one above and one below the O-ring

‣ Double stem guiding

Two graphite filled PTFE guide bands in the

bushing housing, one above and one below the

O-ring

‣ Piston and stem lubrication reservoirs

O-ring grease reservoirs machined into the

piston and bushing housing

‣ Quick change stem bushing housing with

integral wiper

‣ Wiper keeps debris off of actuator shaft,

resulting in longer service life and better

sealing

‣ Easily field-serviceable bushing housing3

Endurance Actuation features

‣ Increased quantity of cylinder tie rods

Increased actuator structural stiffness

‣ Increased quantity of pneumatic ports

Increased the number of pneumatic ports from

3 per end cap to 4 giving greater pneumatic

component mounting flexibility

‣ Increased accessory connection pads

Increased the number of accessory mounting

pads from two to eight for ease of installing

accessories

‣ Increased stem diameter

Stiffer stem to take full advantage of the better

piston and stem guiding

4

Hardware improvements

1. Double piston guiding

Legacy Actuator

‣ No specific guiding

‣ Relied on O-ring which wears in operation, reducing guiding

HE Actuator

‣ Graphite filled Teflon guide rings above and below the O-ring

‣ Significantly more guiding independent of the O-ring (performance supporting data)

5


2. Double stem guiding

Legacy Actuator

‣ Simple bronze bushing

‣ May gall the stem if in direct contact

HE Actuator

‣ Graphite filled Teflon guide rings above and below the O-ring

‣ Significantly more guiding independent of the O-ring

6


3. Piston and stem

lubrication reservoirs

‣ O-ring grease reservoirs machined into the piston and bushing housing

‣ Significantly longer O-ring service life

7


4. Quick change stem bushing

housing with integral wiper

Legacy Actuator

‣ Previous designs needed actuator disassembly to service stem O-ring or had a difficult screw-in assembly

HE Actuator

‣ Easily field serviceable bushing housing. Remove six ¼-20 screws and it slides out. Has an extraction groove to pry if needed.

8

Ready to support your needs

5. Complete life-cycle support

‣ Designed and supported by IMI-CCI’s engineering team in California

‣ Industry common accessories and controls

‣ Direct fit to existing Drag® valves - No machining required

‣ Spare parts availability from California

‣ (17) Trained field service technicians

Positioner, componentand accessory options

‣ Positioners

‣ FasTrak, DVC6200, Siemens PS2, Siemens 760, Westlock, Metso

‣ Pneumatic Components

‣ Norgren, YTC, Parker, Midland, Bifold, Versa, Fairchild, ControlAir

‣ Electrical Accessories

‣ ASCO, Norgren, Versa, Westlock, Namco, Topworx, Go switch, Hoffman

Contact Information:

Kurt Christianson, PEApplication [email protected]

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