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Check Valve Condition Monitoring Workshop

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					        Check Valve Condition
        Monitoring Workshop

     ISTOG/NIC Summer Meeting 2005

               WORKSHOP TEAM MEMBERS

               Debbie Masters, FP&L – Team Lead
Shawn Comstock, WCNOC            Les Harris, SCE&G
Steve Hart, Duke Power           Brian Lindenlaub, APS
Tony Maanavi, EXELON              Mike Robinson, K&M Consulting
Vinod Sharma, Kalsi Engineering
           Workshop Rules

• Professional Etiquette
  – Only one speaker at a time
  – Hold major questions for panel discussion –
    pl. use index card
  – Stay on time - time keeper will be used
         Workshop Format
• Code broken down into sections
• Review the applicable sections of the code
  - these slides will be in ‘Italics’
• In simple terms, explain what it means -
  our interpretation
• Examples - from different plants using
  CM
• Implementation tips
• Discussions
                     AGENDA
8:00 – 8:25   Appendix II.1 Introduction - DM
8:25 – 8:50   Appendix II.2 Groupings - VS
                             BREAK
9:00 – 9:25 Appendix II.3 Analysis - LH
9:25 – 9:50 Appendix II.4 Condition Monitoring Activities - DM
                             BREAK
10:00 – 10:25 Appendix II.5 & II.6 Implementation - MR
10:25 – 10:50 CM Best Practices - VS
                             BREAK
11:00 – 11:30 Panel Discussion
  INTRODUCTION

Presented by: Debbie Masters
              What is CM?
Alternative to prescriptive testing of IST valves
Living Program
Continuous/periodic measurement of characteristics
using the proper mix of activities to validate the
condition of a check valve
A trending process and evaluation process that’s part
of a living check valve program in which predictions
are confirmed and adjusted - review after each
outage/test to validate the plan
 Test strategy is to identify and trend attributes
indicative of degradation that could lead to failure
                   CM Evolution...
• ASME/NRC agree on the need for improved rules for check valve
   – Testing not detecting all degradation
   – Need for trending
   – testing and need for disassembly
• Initial OM22 meeting
   – Standard vs. Code
   – Piece meal changes to Code - Shawn’s paper
• NIC proactively works to change testing requirements
   – NRC requests - NIC work with OM22 for better/improved
     testing related guidance and requirements
• NRC to ASME - need to revise the requirements to ensure the
  adequacy of certain pump and valves to perform their intended
  safety function
   – NUREG 1352 - NRC expressed concern about MOV’s & CV’s
   – Generic Letter 89-04 (NUREG-1482)
                ...CM Evolution
• NRC Activities
   – NUREG’s 1482 and 5944
   – Studies ORNL/NRC/LTR-96/11 and -96/13
   – Symposiums
   – Change 10CFR50.55A to include Condition
     Monitoring
• Approval (Sept 1999) of Rule Change which included
  Appendix II of the ASME OM Code with limits
  (discussed later)
• Approval (Nov 2004) of Rule Change which includes
  step wise interval extensions with outage time based
  maximum intervals.
         Workshop Objectives
• Review the code requirements to establish a
  Condition Monitoring Program
• Present actual information and data from
  utilities on how to establish a program
• Address issues related to Condition
  Monitoring
• Use as basis to develop “CM for Dummies”
      Appendix II.1 Purpose

• To establish and maintain a Check Valve
  Condition Monitoring Program in
  accordance with ISTC - 5222
    What valves can go into CM?
• IST (Inservice Test) Program Valves only
• Concept of CM Program may be applied to non-IST
  valves - may or may not be in the same program
• Begin with the ones that provide the most bang for
  the buck
              All Check Valves
                           IST
                         CM
                Traditional IST vs. CM

       TRADITIONAL IST                         CONDITION MONITORING

1.   Check valve tested as a part of     1.   Check valve treated as a component
     a system – all check valves are          with unique, design, application &
     treated and tested as if they            failure mechanisms
     are the same                        2.   Flexible program allows adopting
2.   Prescriptive test program is             most suitable test methods and
     set at the beginning of each             technologies as they become
     code update (change requires             available or continuing existing
     a relief request)                        maintenance and test practices
3.   Test is a snapshot of valve’s       3.   Use of methods (disassembly, NIT,
     ability to function in the safety        etc) that are already being used
     direction – at the time of the      4.   Test strategy concentrates on likely
     test                                     failure mechanisms and therefore
                                              addresses present and future
                                              reliability
                     Why go to CM?
TECHNICALLY: Value adding test activities - concentrate on developing
       useful intelligence on unique valve(/group) specific failure mechanisms
ECONOMICS:
Living program cuts costs through savings in
     -    valve maintenance/testing crew man-hours for scaffolding,
          insulation, temporary instrumentation,
          RP/OPS/MM/Engineering/RT
    -     ALARA mRem exposure avoided,
    -     Reduced disassemblies – with reduction in maintenance induced
          failures,
    -     aligning CM program with other programs e.g. by taking credit
          for Option B for leak testing, Appendix J LLRT program, PIV
Additional cost savings through
    -     Enables setting test frequency based on plant history
    -     Step wise interval extension
    -     Enables adopting latest and most suitable test methods &
          technologies
    -     Added flexibility - Scheduling tests and disassemblies off the
          critical path, bidirectional test not required in the same interval –
          on-line disassemblies, LCOs
            Why not go to CM?
TECHNICALLY: Not yet at 10-yr update - Will eventually have to go
   to bidirectional testing;

ECONOMICS:
-  implementation costs
-  Testing in safety direction only
-  If already gone to update and it is too late to implement CM
   immediately
    Invoking Condition Monitoring
• 10-yr Code Update
OR
• Letter to NRC – should include the following:
  – What valves are going into the program
  – Application of the latest code to all of the IST valves
  – Implementation time frame - rule of thumb - two
    years
  – Using a letter, utility must wait for NRC approval
    before implementing later editions of the code.
    Clarified in NRC Regulatory Issue Summary 2004-
    12 <PROVIDE SAMPLE>
                    Definitions
• Cherry Picking - If you have not had a code update,
  cherry picking is choosing to apply Appendix II to
  some of the your valves without bi-directionally
  testing all of them. Any application of Appendix II
  will require testing all IST check valves to the latest
  code (bi-directional testing).
• Bi-directional Testing - Valve opening and closing
  functions must be demonstrated when flow testing or
  examination methods (non-intrusive or disassembly)
  are used. Flow testing does not need to be at full
  flow.
     Terms Used in Workshop


• CM - Condition Monitoring Program
• PM - Preventative Maintenance
• CM-PI - Condition Monitoring Program
  - Performance Improvement
• CM-O - Condition Monitoring Program -
  Optimization
     GROUPING

Presented by: Vinod Sharma
      Appendix II.2 Grouping
Determined by Owner
Shall be technically justified based on:
• Intended Purpose: CM-PI or CM-O
• Assessment/performance analysis (Plant Specific)
   – Test results
   – Maintenance History
• Justification:
   – Design Characteristics: Types, sizes
   – Application/safety function
   – Services Conditions: frequency of usage
                        Interpretation…
• Why are the valves being added to the Condition Monitoring
  Program? Performance Improvement or Optimization
   – Background knowledge
   – Available plant specific tests
• Why are the valves being grouped together?
  – Design Characteristics – Type & Model – incl. suffixs
       •   Bonnet: Bolted, pressure seal, seal welded, screwed,
       •   Seat: soft, hard
       •   Hangar Arm: Bonnet Hung
       •   Materials: Body, seat
       •   Flange design
       •   Size
   – Application/safety function
   – Services Conditions : Fluid, duty, flow, pressure,
     temperature
           …Interpretation

•Justification factors to consider:
  –Manufacturing data
     –Manufacturer
     –Valve type
     –Size
     –Model Number
     –Vendor Drawing
     –Vendor Manual
Example - Plant A - Grouping
        Evaluation
Example - Plant A - Design
    Characteristics
Example - Plant B - Design
    Characteristics
                        Tips - Grouping
• Look at the IST population not as 100 valves but
  30 groups. Much easier to manage
• No benefit of very large groups – e.g. Hard to
  correlate performance data for stepwise interval
  extension (4 valves/ group optimal e.g. 8 as in 2 groups of 4 clumped
  together –cannot extend interval)

• Typical type groupings - same valve on different
  trains, accumulator dump valves, favored trains
    (but watch for exceptions - two pumps with elbow oriented differently)

• Difference between CM-O and CM-I
•   Groups across units vs. keep separate: + interval extension for all – Do common
    cause for all
 Application Experience/Quick
   Clarification – 5 Minutes
• Any utility experiences with groupings
    ANALYSIS

Presented by: Les Harris
          Appendix II.3 Analysis
Analyze test & history of valve or group to establish
a basis for specifying in-service testing,
examination, and preventive maintenance; shall:
   – Identify common failure or maintenance patterns
   – Analyze patterns to determine significance and identify
     potential failure mechanisms to determine (plant
     specific and industry)
      • If certain PM will mitigate failure or maintenance patterns
      • Feasibility & effectiveness of CM activities like NIT in
        monitoring for valve/group specific failure mechanisms
      • Effectiveness of periodic disassembly & examination in in
        monitoring for valve/group specific failure mechanisms
      • Need for changes in the valve grouping
           Interpretation...
• For each group (looking at history):
  – analyze all of the maintenance history
  – analyze all of the test history
• Need to review industry information
• Determine if there is any common failure
  or maintenance history patterns
• Evaluate potential effects
               ...Interpretation...
• If there is no common failure or maintenance pattern, then
  group can go into CM activity – optimization of good actors
• If there is a common failure or maintenance pattern, then
  the group needs to be analyzed for the significance and
  potential failure mechanisms.
• Determine:
       • If certain PM will mitigate failure or maintenance
         patterns
       • Feasibility & effectiveness of CM activities like NIT in
         monitoring for valve/group specific failure
         mechanisms
       • Effectiveness of periodic disassembly & examination
         in monitoring for valve/group specific failure
         mechanisms
       • Need for changes in the valve grouping
          ...Interpretation…
• If there is sufficient information to perform
  the analysis, then the group may be placed in
  the CM - optimization
• If there is not sufficient information to
  perform the analysis or if the analysis is not
  conclusive, then the group shall be placed in
  the CM - performance improvement
  activities (3 years or 2 cycles which ever is
  greater)
         ...Interpretation –
       Where to get information
• NRC – Generic Notices, Information Notices
• NIC templates and failure database
• LER/OE notices
• EPIX database review
• EPRI PM Templates
• Vendor Notifications
• Utility/Plant Records
• IOM Review
• Post 1984 – NIC database 95% completed
        Examples – Failure Modes
                       • Failure to Open
                       • Failure to Close
                      • Internal Leakage
                      • External Leakage
                       • Disk Separation
                       • Hinge Pin Wear
EG: PWR full dump of SI tank if failure to open is not a plausible failure then can
Go to partial stroke NIT test to avoid flow testing; also can use PIV tests.
      Examples – Failure Causes
• Abnormal Wear –               • Foreign Material
 flow velocity < Vmin or seat
 leakage                        • Procedure Error
• Design                        • Improper Installation
• Human Error                   • Stress Corrosion
• Maintenance Error               Cracking
• Manufacturing                 • Erosion/Corrosion
  Defect                        • Improper Installation
• Corrosion                     • Other
 Examples - Test & Inspection Effectiveness
      to Detect Failure/Degradation
• Full Open Stroke w/flow    • Temperature Monitoring
• Partial Open Stroke        • Thermography
  w/flow                     • Radiography
• Back Flow Test             • Ultrasonic Testing
• Manual Exercise            • Magnetics
• Leak Test/LLRT             • Acoustics
• Disassembly & Inspection   • Routine Operator
• PIV                          Rounds
• Other                      • System Monitoring
Example - Analysis - Plant A
Example - Analysis - Plant B
Example - Analysis - Plant C
Example - Analysis(continued) -
           Plant C
           Tips - Analysis


• Service Experience: NRC – NIC database
  (www.checkvalve.org), GNs & INs,
  LER/OE notices, EPIX, Vendor
  Notifications
• Get best information possible
Application Experience/Quick
  Clarification – 5 Minutes
• Utility experiences with analysis
 CONDITION MONITORING
      ACTIVITIES
Performance Improvement and Optimization


       Presented by: Debbie Masters
    Appendix II.4a Condition Monitoring
   Activities - Performance Improvement...
IF lacking sufficient information for II.3 Analysis or if
results are inconclusive then perform the following to
determine cause of the failure or maintenance patterns,
THEN identify
   – interim tests to assess performance
   – interim examination to evaluate potential degradation
     mechanisms
   – Other types of analyses to assess valve condition
   – Set of above performance improvement (CM-PI) activities
     for each valve in the group and interval for activity;
Document PI activities in CM Program test plan
…Appendix II.4a Performance Improvement


  Perform PI activities until,
    – Sufficient information to assess performance
      adequacy
    – End of 5 years or two fueling outages
  Review results of each PI to determine need
  for changes; if changes significant repeat
  Sections of II.2, II.3 & II.4 as applicable
        Interpretation - Performance
               Improvement
• If determined to be in Performance Improvement then:
  – Develop an interim strategy to gather data for the 2 refueling
    or 5 years (which ever is less)
  – Strategy should identify:
     • interim test to assess performance
     • interim examination to evaluate degradation
     • other types of analysis to assess condition
     • the interval of each activity
• Need to gather sufficient information to perform
  analysis
• If enough information is gathered, then CM-
  optimization
Tips - Performance Improvement

• Performance improvement plan is done
  until enough information is gathered to
  perform the analysis and determine if
  there are any common mode failures or
  maintenance patterns
    Appendix II.4b Condition Monitoring
         Activities - Optimization...
If sufficient information for II.3 Analysis to assess
performance adequacy, then identify
   – Applicable PM activities & intervals to maintain continued
     acceptable valve performance
   – Applicable examination activities & intervals to periodically
     assess the condition
   – Applicable test activities & intervals to periodically verify
     acceptable performance
   – Set of above CM-O activities to be performed on each valve in
     the group and interval for activity
Revise CM Program test plan to document CM-O
activities
  …Appendix II.4b Condition Monitoring
       Activities - Optimization
Perform CM-O activities

Review results of CM-O activities to determine
need for changes; if changes significant repeat
Sections of II.2, II.3 & II.4 as applicable
Interpretation- CM Optimization...

• If the group has been determined to be in
  CM-optimization then the following
  activities need to be considered:
  – preventative maintenance activities required
    to maintain performance
  – examination activities to assess condition
  – test activities to verify acceptable
    performance
...Interpretation - CM Optimization

• The activity plan identifies:
  – which activities will be performed on each
    valve in group
  and
  – the interval for each activity
• There are NRC limitations on these - will
  be discussed next
                 NRC Limitations
1.There are no limitations if evoking the code as accepted in the
   NRC Rulemaking dated Nov. 2004.
2. If invoking the NRC Rulemaking dated 1998, the NRC required
   following:
    – Valve opening and closing functions must be demonstrated -
       bi-directional testing
    – Initial interval for tests/associated examinations may not
       exceed 2 fuel cycles or 3 yrs, whichever is longer; any
       extension of this interval may not exceed 10 yrs (unless
       adopted 2003 in which case is 10, 12 or 16 years? depending
       on group size of 1, 2-3, or >=4, respectively)
    – If Appendix II Condition Monitoring Program is
       discontinued, then requirements of ISTC 4.5.1 through 4.5.4
       must be implemented.
Example - Condition Monitoring
     Activities - Plant A
Example - Condition Monitoring
      Activity - Plant B
Example - Condition Monitoring
 Activity (continued) - Plant B
Example - Condition Monitoring
 Activity (continued) - Plant B
Example - Condition Monitoring
      Activity - Plant C
Example - Condition Monitoring
 Activity (continued) - Plant C
Tips for Developing Condition
    Monitoring Activities
• Know what test are performed currently
  in the plant
• Need to think about the bi-directional test
• Take credit for testing whenever possible
  - pump starts, valve closure for opposite
  train pump starts
 Application Experience/Quick
   Clarification – 5 Minutes
• Utility experience with Condition
  Monitoring Activities
IMPLEMENTATION

Presented by: Mike Robinson
Appendix II.5 Corrective Maintenance

IF
  corrective maintenance is performed on valve
THEN
  Review analysis used to formulate basis of CM
  activities for the valve and the group to determine
  the need for changes; if changes significant
  repeat Sections of II.2, II.3 & II.4 as applicable
    Interpretation for Corrective
            Maintenance
• It is important to consider baseline data
  after the completion of corrective
  maintenance
• Need good baseline data for the
  application of any frequency extension
   Appendix II.6 Documentation
Shall include:
• List of valves in program
• List of valves in each group
• Dates and the reason that the valves were
  added/deleted to the program
• Analysis forming the basis for the program
• Identified failure or maintenance history pattern
  for each valve
• Program activities & interval
Interpretation for Documentation

• New procedures for CM
• Adding/removing valves
• Extension of due dates/missed test?
• Test Start dates – simultaneously for all
  groups?
• Importance of feedback
   Intervals - Frequency Extensions

• Ensure adequate baseline
• Two successful tests in a row on the group,
  then one interval extensions may be applied
• Should not exceed one extension at a time
• Do not exceed the code allowable limits
Stepwise Interval Extension Savings
      Traditional IST vs CM
                          TRADITIONAL IST
    Oc    0    1    2     3   4    5     6    7    8    9    10   11   12
    A    X     X    X     X   X    X    X    X     X    X    X    X    X
    B    X     X    X     X   X    X    X    X     X    X    X    X    X
    C    X     X    X     X   X    X    X    X     X    X    X    X    X
    D    X     X    X     X   X    X    X    X     X    X    X    X    X

                        CONDITION MONITORING

   Oc    0    1    2     3    4   5    6     7    8    9    10    11   12
   A     Xb   X                        X
   B     Xb        X                              X
   C     Xb              X
   D     Xb                   X                             X
                  9<    10   yrs ---- -->                             X
52 prescriptive tests reduced to 12 targeted CM Program tests over 18 years
Stepwise Interval Extension
 Frequency Extensions….
Stepwise Interval Extension
 ...Frequency Extensions...
Stepwise Interval Extension
  ...Frequency Extensions
         Self Assessments
      Some Things to Consider

• Defined program responsibilities
• Verify testing methodology demonstrates the
  required function of the valve
• Maintenance and failure reviews have been
  conducted and results documented
• Valve performance and failures are being
  documented and test plan re-evaluated
   Example - Interval
Extension/Implementation
     Implementation Tips -
Documentation, Interval Extension,
       Self-Assessments
• Responsibility for CM program can lie with the
  CV engineer, IST Coordinator, or system engineer
• Implementation can be done by in-house, vendor
  or combination of each of these
• Interval extensions may get confusing if train
  related outage are employed
Resources Requirements – Time &
            Expense
Start-up
Groupings
Analysis
Condition Monitoring – Performance Improvement
  Activities
Condition Monitoring – Optimization Activities
Documentation
  Program procedure
  Data Storage
 Application Experience/Quick
   Clarification – 5 Minutes
• Utility experiences with application,
  frequency extensions or implementation
  issues
 CM Best Practices – Vinod Sharma
• Goal: No unexpected/unanticipated failures
• Employ the use of an expert panel - optional
• Keep the program living through periodic reviews
  e.g grouping basis, power uprate, obsolesence
• Aggregate information about the valve from many
  different sources - NIT, pressure tests, flow tests,
  LLRT, etc + Ties in with other programs e.g.AP-913
• Tracking and Trending of trendable attributes
  - NIC Phase 4, NIC T&T Guide
• CVAP for quantitative analysis – forecasting vs.
  accounting
• Other examples?
Plants that have implemented CM

         PWR            BWR
•   Seabrook     • Vermont Yankee
•   Surry        • Pilgrim
•   Millstone
•   VC Summer
•   Byron
•   Wolf Creek
•   McGuire
•   Palo Verde
                     12/8/04 Feedback
•   Add to NIC database
     – Frequently asked questions with answers
     – References – white papers, presentations, latest OM code; letter (Using a letter,
        utility must wait for NRC approval before implementing later editions of the code.
        Clarified in NRC Regulatory Issue Summary 2004-12 ) in 10CFR50.55
     – Provide plant examples – Diablo Canyon
•   Procedure change one lines
     – Reverse closure of parallel pumps; other pump not rotating backwards
•   Introduction, Plant CM or not, Expectations

				
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