ASCO Products for AP1000 Lessons Learned

Confidential - Property of ASCO Valve Inc.

Agenda

Solenoid Valve Basics

Evolution of ASCO Nuclear Solenoids

AP1000 Challenges & Solutions

Qualification Lessons

Next Step


Function of Solenoids in Air Operated Valve The solenoid valve is an electromechanical device that converts an

electric control signal to mechanical energy to actuate the AOV The solenoid valve is located between control instrumentation and

actuator The solenoid valve is a specific safety related device The solenoid valve initiates the safety function by venting air from the

actuator Failure of solenoid valve will prevent AOV from operating correctly

and will prevent valve from achieving safety related function


Typical Safety Related Valve Schematic


SOVs on Main AOV

AOV (air operated valve)

SOV (solenoid operated valve)


Operational Testing of Fisher Valve With Solenoid Valve

Solenoid Valve


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How we got to where we are A Brief History 1978 -1995 Nuclear products evolved from

commercial products already installed in plants

Selected by Nuclear Industry based on robust design and proven performance

ASCO modified design to meet NPP needs – All metal components – High Temp elastomers (Viton &

EPDM) – Radiation resistant components – Special coils and lead wires


How we got to where we are A Brief History 1978 -1995 Qualified line of valves based

on IEEE and NRC guidance in 1978 – AQR21678

Qualified to higher levels in 1982 based on Westinghouse requirements – AQR 67368


How we got to where we are A Brief History 1995 - 2007 ASCO responds to industry needs

for reducing maintenance costs by: – Increasing qualified life – Increased radiation resistance – Improved moisture resistance – Interchangeable with existing

products ASCO qualifies NS line of valves

input from the NUQEQ and NRC


How we got to where we are A Brief History 1995 - 2007 Features of NS product

– Gamma Plus Elast – Molded coils – PEEK Lead wires

Latest IEEE standards and reg guide requirement


Nuclear Valve Evolution

NP8316 NS8316 NT8316

Developed 1978 First SOV in Nuclear for Safety

Developed 1995 Harsh environment, long life

Developed 2011 Digital & more feature (AP1000)

• EPDM/FKM elastomers • Non-molded varnish • impregnated coils.

• Special elastomeric compound developed by ASCO

• Better radiation resistance, longer thermal life

• Increased resistance to high temperatures

• Red Hat II Coil with built in diode for digital applications.

• Quick Disconnect • Zero Minimum PSID • PEEK Leads


NP/8300 Series

IEEE Nuclear Qualified Products

NT/8316 Series

NU Series

329 Series

Solenoid Valves

AD/156/163 Series

MT/231-232

Series

MB/121 Series


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AP1000 Solenoid Valve Challenges

AP 1000 Requirements All solenoid valves

require suppression diode 200 C rated lead wire 30

ft lead wire Coil must be removable

Non 1E and 1E different

coating to distinguish Increased seismic loads

ASCO NT solution Integrate diode into one

piece molded coil PEEK lead wire from NS

qualification Red Hat II with molded in

QDC Red Hat II coils Black- 1E

Green non-1E Thicker mounting bracket


Lessons Learned Solenoid Valves Leverage existing knowledge base

– Red Hat II – Commercial line – Peek Lead Wire – NS – Gamma Plus Elastomers - NS – Don’t re-event the wheel – use standard materials

Prequalification Screening – Establish Thermal & Radiation limits

• diodes, elastomers, coils, lead wires – Verify designs prior to qual testing

• Try several variations of materials / processes


SOV – NT 8316 Safety Related AP1000

NT 8316 is used for safety related (1E) on AP 1000

Quick Disconnect (QDC) RHII Encapsulated Coil Internal Diode High Temp Radiation Resistant

Elastomers Zero Minimum Pressure


NT Qualification Levels Thermal Aging: Zone 1 12 years at 50°C Other zones 18 years at 50°C Wear Aging: 15,000 cycles Radiation Aging/DBE: 40 Mega-Rads


ASCO NT LOCA Critical Characteristics Inside Valve


NT Qualification Levels Vibration Aging: 0.75 G’s 90 min. in X,Y,Z axes Operating Basis Earthquake: 4.4 G’s 2hz -> 64hz -> 2hz,

X,Y,Z axes. Seismic DBE: Sine beat test 1/3 octave 2 to

32 Hz intervals up to 6.6 G’s 1/6 octave from 32 to 64 Hz for

HRHF


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AP1000 Qualification Challenges AP1000

Rapid LOCA curves

High HELB Temps Chemical Spray variation Mission Time w margin vs

actual time

Solutions

Labs can’t meet – Monitor component temps

for Thermal lag

Can materials function – Screening / Simulation

Verify with customer & Lab – every parameter

Understand safety function


Qualification Program – Environmental Dbe LOCA - 425°F, Zone 1 profile.


HELB: 485°F Zone 5 and zone10 profile

Qualification Program – Environmental Dbe


Other EQ Lessons Learned Back up test samples

– Run in parallel 2 phases behind – Separate options/variations

– Increases sample size but minimizes risk Separate zones – aging isn’t cumulative across zones

– Zone 1 equipment doesn’t have to work in Zone 5 Age in phases with sacrificial parts to establish limits Qual. levels are based on component life not plant life

– AP1000 – 60 year life – Component thermal life = 10 years


NT Qualification Levels LOCA: 450°F(232°C), Zone 1

profile. HELB: 500°F(260°C) Zone 5

and zone10 profile


Electromagnetic Compatibility (EMC) • EMC Testing: • Required for compatibility

with digital equipment • 33 tests, • 5 month process • Get approval for any

variations including those suggested by consultants.

• Follow spec. based on rev dates

Conductive Ground Plane

Ground Reference Plane (GRP); floor

Gas In (P)

Exhaust Gas out (Cyl )

Bond to Ground plane

SOV (EUT)

DC Voltage SupplyGas Supply

72-inch SOV QDCfield Leads

Table Top Ground Plane

+ DC - DC

Insulating support between Ground Plane and EUT; when required

Non-conducting table

Shield Room Wall; when required

Test Setup BoundaryAntenna; when required Outside Shield Room

Wall; when required

Anechoic Chamber Wall; when required


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NT Line Extension

Legacy NP Products 3 way Std Flow

– 8314 – 8320

3 way Mod. Flow – 8300

3 way High Flow – 8316 – 8321

NT Upgrade 3 way Std Flow

– NT 8320

3 way Hi Flow – NT8316

Simplification of Plant SOV (inventory), Longer Life


NT Line Extension Curves NT HELB NT LOCA

Products series Maximum temp (F) Max Environment Pressure (Psi) Qualified standards

NP 450 68 IEEE

NT 500 (for HELB) & 420 ( for LOCA) 113 AP1000 & IEEE

Comparison table:


NT line extension Leveraged lessons from NT AP1000 testing

– Molded coil – Internal diode – QDC – Reverse flow – NT 8316 ( ¾ & 1 inch) – Increased qualified thermal life


Questions

ASCO Products for AP1000 Lessons Learned

Documents

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