Nuclear Power Forged Valves
Nuclear Power Forged Valves
power, chemical, petrochemical, oil and Whether it is for valves to handle liquid
gas, pulp and paper, cryogenics, mining, Helium at -272°C (-458°F) in the
and marine industries. world’s largest particle accelerator at
CERN, Geneva, four-way switch coker
A Global Manufacturing Force ball valves to handle one of the refining
industry’s toughest services, or valves for
With 1,165,500 sq. ft. (108,300 m2)
main steam isolation service in an
of production space in thirteen
operating nuclear power plant, Velan has
specialized manufacturing plants,
been selected by most of the world’s
including six in Canada and U.S.A., four
leading engineering construction firms
in Europe and three in Asia, Velan is a
and industrial end users. A long-standing
truly global manufacturing force. Velan
commitment to quality has kept Velan at
uses the latest automation technology,
the forefront of industry standards.
including over 150 CNC machines and
many special purpose transfer machines, Velan holds all major industry
enhanced with proprietary production certifications, including ASME Section III,
techniques. A wide variety of equipment ISO 9001:2000, PED and API 6D. Many
provides the company with the ability to prominent companies have established
efficiently handle highly customized partnerships or global supply agreements
Founder & CEO A.K. Velan (top row, middle) overseas his dedicated sales, quotations, contracts, orders, as well as large production runs. with Velan.
engineering and service team focusing on nuclear power.
Velan employs over 1,400 people, 75%
Total Quality Commitment
Leading The Way… of which are located in North America.
International production centers are Velan has always remained totally
Velan is one of the world’s largest complemented by a global sales and committed to offering products and
manufacturers of industrial steel valves, distribution network, offering personal service that not only meet, but exceed
leading in quality and innovation. customer service and quick access to customer expectations. All Velan valves
Founded by A.K. Velan in 1950, the stock worldwide. are designed and manufactured with an
company leveraged advanced emphasis on low emissions, safety, simple
engineering capabilities and innovation- maintenance, ease of operation, and
Engineered Solutions
driven focus to continuously expand its above all, long and reliable service life.
offering of industrial valves. Today, Velan Velan’s Engineering Department has vast
gate, globe, check, ball, butterfly, knife experience and sophisticated software
gate and engineered severe service and testing tools, that enable the
valves are installed throughout the world, company to find solutions to any
Velan’s consolidated sales have reached handling diverse applications in the customer challenge.
over $300 million.
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Serving The Nuclear
& Fossil Power Generation Industries
2
Velan in Nuclear Power:
A Historical Perspective
3
The USS Dwight D.
Today Eisenhower, one of
several nuclear-
Velan remains committed to providing service functions, we are ready to powered Nimitz-class
new solutions for a changing industry. handle requirements of the most aircraft carriers
Our Triple-Offset Torqseal Butterfly Valve, demanding nuclear orders standardized on
introduced in 2001, is already earning Velan valves and
its keep in nuclear service. Velan’s new Our international sales organization, steam traps.
quick-acting double-disc main steam and our partnerships with key stocking
isolation valve is ready to handle the distributors, such as Framatome-ANP,
most critical nuclear plant applications. ensure that a considerable amount of
valves and parts are readily available.
Velan has also developed a range of Framatome-ANP stocks Velan ASME III
valves for sodium-cooled fast breeder Cl. 1 small forged gate, globe and
reactors, in which the fluid itself is used to check valves and are also embarking on
perform the seal. Liquid sodium is cooled a ball valve and bellow seal program.
in the upper part of the cover extension in
order to freeze along the upper part of the Velan’s North American and European
stem; the frozen sodium becomes like a service departments have vast
continuous packing ensuring a perfect experience in working with customers in
level of tightness. the nuclear industry, for on-site
maintenance, or many other services.
Today, Velan’s global reach make us the
ideal choice in supplying nuclear valves.
With four state of the art manufacturing
centers certified for nuclear valve
production, and over 100 people in
engineering, QA/QC and customer
Velan valves in a cooperative program – Qualification testing with Électricité de France at their
R & D facility in Renardière.
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Velan Quality Focus Assures
Performance and Safety
Quality Control
Velan has held ASME ‘N’ and ‘NPT’
certificates of authorization for our
North American production facilities
since 1971. Constantly working to
improve the quality of our products,
Velan adopted a Total Quality
Management Program, aimed at
improving production processes in
1990, and was awarded ISO 9001 An ASME ‘N’ certificate. Velan holds ASME
III certification for 3 North American plants.
status the following year.
Furthermore, Velan’s comprehensive frequency testing with design nozzle
Quality Assurance Program is fully loads applied, and cold cycling tests
compliant with NCA 4000, ASME NQA- performed during seismic simulation.
Flow testing on a 10” Class 1500 forged bolted cover swing check valve. 1 and 10 CFR 50 Appendix B. Velan’s Eighteen uniaxial strain gauges were
nuclear quality programs have been mounted on the stem, crotch and other
surveyed by ASME and audited by critical areas, and strain data was
NUPIC, Newport News Shipbuilding, recorded. It was demonstrated that the
DCMA, nuclear utilities, and other valve possessed sufficient functional and
organizations – such as Framatome- structural integrity to withstand a seismic
ANP and Black & Veatch – from around event of prescribed magnitude.
the world.
A further example of Velan nuclear
We have a history of meeting and valves’ superior reliability comes from
exceeding the exacting requirements of simulated line rupture tests. At the cost
our customers. All Velan valves undergo of about $500,000, a major North
the stringent, code-prescribed non- American utility carried out closure tests
destructive testing regimen before they on a Velan forged 8” ASME Class
are shipped to customers. In addition, 1500, fast-closing (20 seconds)
for nuclear applications, certain valves electrically actuated isolation valve to
also go through destructive testing in simulate a Loss of Coolant Accident
order to prove the performance of the (LOCA). The energy dissipated during
product line. each discharge of 2,129,570 lb/h was
dramatic. The accompanying vibrations
To meet a particular customer’s needs, a caused a local earth tremor, but the
20” Velan ANSI 1500 fast operating Velan valve shut off perfectly during
main steam gate valve was subjected to all sixteen closure tests, with little
seismic simulation test. The test program wear exhibited during subsequent
consisted of hot and cold cycling, biaxial examinations.
resonant searches, biaxial random multi-
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MOV Testing
Valve Factor
0.12 Preconditioning Valve Factor
qualification testing for valves to 900, 8" X 6" X 8" flex wedge gate (mean seat diameter)
0.6
address issues raised in the Nuclear valve with a Limitorque SMB-1-60 0.1 0.55
Regulatory Commission's Generic motor operator was submitted to a 0.5
Valve Factor
00.8 0.45
Letter 89-10. series of inspections and tests. 0 3 6 9 12
0.4
Number of Strokes 0.35
GL 89-10 required operating nuclear The loop isolation and blowdown test Two graphs from the Wyle test report
0.3
0.25
utilities to identify critical MOV's and (shown below) was designed to results show the preconditioning stem 0.2
1 2 3 4 5 6 7 8 9 10 11 12
re-analyze the actuator's ability to demonstrate the capability of the valve factor and valve factors based on the Test Number
close the valve in a "worst case" to isolate sections of the nuclear plant in mean seat diameter.
design/operation condition as in the unlikely event of a catastrophic loss
a LOCA. In addition, the utilities have of coolant accident.
called upon Velan to reavaluate the
ability of valves to withstand higher The flow interruption test with saturated
VALVE PERFORMANCE VALIDATION BY FULL DIFFERENTIAL
operating thrust end torque valves steam (shown right) is just one PRESSURE FLOW INTERRUPTION TESTING
dictated by the GL 89-10 consider- segment of a suite of tests designed to (BLOWDOWN TESTING) PROCEDURES:
ations. prove that the valve will close under
extreme accident conditions and to • A comprehensive pre-test inspection. • A thermal binding test.
One of the corollary actions initiated to demonstrate resistance of the valve to • Static pressure stroking of valve to (Close hot - open cold and
assure proper actuator and valve sizing pressure entrapment, thermal binding develop performance baseline close cold - open hot)
and integrity was a MOV Qualification and seismic loading. characteristics. • A hot static, seismic
Test Program that verified proper • Disk & Seat preconditioning. deflection test.
actuator/valve function at extreme The valve was designed and fabricated • Three Full Differential Steam Flow Tests • Comprehensive post-test
design limits. in accordance with Velan's ASME @1050 psig & 240,000 lbm/hr flow. inspection.
Nuclear Certificate of Authorization and
• A pressure locking test.
As a primary supplier to nuclear stamped per Section III, Class 2
power, Velan has participated requirements. Duke Energy procured Test results in all categories surpassed requirements.
heavily in this testing, qualifying a this valve to their newly developed
wide range of MOV's for a variety of MOV Specification that incorporated
applications in operating plants. requirements gleaned from operating
experience, the input of Velan design
Velan recently completed a engineering and EPRI-PPM data.
comprehensive test program for Duke
Energy at Wyle Laboratories, the results These valves are currently installed and
of which were presented at the 2002 providing excellent service at Duke
ASME/NRC Valve Symposium. Energy's Oconee Nuclear Power Plant.
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The Leading Choice
for Nuclear Service
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Velan Installed Base
In World’s Nuclear Power Plants
NET % OF ALL
COUNTRY UNITS IN MWE IN TOTAL TOTAL VELAN VALVES PLANTS WITH
OPERATION OPERATION UNITS MWE SUPPLIED TO VELAN VALVES
Argentina(1) 2 935 3 1,627 1 33%
Armenia 1 376 1 376 — 0%
Belgium 7 5,712 7 5,712 7 100%
Brazil 2 1,855 3 3,084 2 67%
Bulgaria 6 3,538 6 3,538 6 100%
Canada(1) 22 15,149 22 15,149 22 100%
China(1) 3 2,167 11 8,587 9 82%
China (Taiwan) 6 4,884 8 7,484 6 75%
Czech Republic 4 1,648 6 3,610 4 67%
Finland 4 2,656 4 2,656 2 50%
France 57 60,303 59 63,203 58 98%
Germany 20 22,360 20 22,360 — 0%
Hungary 4 1,755 4 1,755 2 50%
India(1) 14 2,548 18 5,320 3 33%
Iran 0 - 1 950 — 0%
Japan 52 43,255 58 48,893 5 9%
Lithuania 2 2,370 2 2,370 — 0%
Mexico 2 1,364 2 1,364 2 100%
Netherlands 1 452 1 452 — 0%
North Korea 0 - 2 2,000 — 0%
Pakistan(1) 2 425 2 425 1 50%
Romania(1) 1 655 5 3,135 2 40%
Russia 26 19,849 31 24,174 4 13%
Slovakia 6 2,512 8 3,392 4 50%
Slovenia 1 620 1 620 1 100%
South Africa 2 1,842 2 1,842 2 100%
South Korea(1) 16 12,970 20 16,770 13 65%
Spain 9 7,345 9 7,345 5 56%
Sweden 11 9,460 11 9,460 7 64%
Switzerland 5 3,170 5 3,170 3 60%
Ukraine 13 11,195 18 15,945 — 0%
United Kingdom 33 12,038 33 12,038 33 100%
United States 104 99,326 107 102,929 105 98%
Total 438 354,734 490 401,735 309 63%
(1) Includes heavy water reactors supplied by AECL, Canada
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Engineered Solutions
A. Acceleration A.
over disc
B. Deceleration
of flow at
stagnation point
B. D.
C. Vortex behind
the seat
D. Wake with
vortices C.
A Computer Simulation of flow through Velan Torqseal Triple-Offset Butterfly Valves destined for nuclear containment isolation service.
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Next Generation
Nuclear Valves
Field Service SPECIFIC FIELD SERVICE
CAPABILITIES INCLUDE:
To address the unique, critical
Capabilities
application requirements for Duke • Commissioning
Our 50 year history of supply to the
Energy’s Oconee Nuclear Power • Troubleshooting
nuclear industry has developed our
Station, Velan designed special 11/2” • Witness Start-Up
expertise in a complete range of valve
gate valves to accommodate actuators
maintenance and other field services. • Forensic Engineering
capable of withstanding 31,000 lbf
thrust in both directions. This design • Process, Start-Up
At Velan, we take aftermarket service
incorporates hardfaced guides (wedge Sequence Study
seriously, maintaining a high level
and body), rounded leading edges of • Valve Repair, Refurbishment
commitment to support our products in the
all seating and guiding surfaces (per and Upgrading
field. Our Manager of Field Engineering
the EPRI guidelines) and specially
Services supervises a staff of highly • Sales of Tooling and
designed backseat, seat rings, bore
trained technicians qualified to evaluate Lapping Equipment
profile and barrel style yoke.
reported issues and, working with the
owner's engineering/maintenance
Duke Energy’s Dave King wrote,
personnel, effect corrective action.
“overall, the entire main steam valve
replacement project has gone well and
Our technicians are industry professionals,
has been a model that we will follow in
with years of valve and customer service
future replacement motor operated
experience to draw from in solving
valve projects.”
application issues that may arise. Clear,
comprehensive reports are prepared
A next generation gate valve developed by
detailing activities and the scope of service
Velan to meet the requirements of a major
North American utility. calls made. Every service issue reported is
documented and maintained in a
database, which is periodically reviewed to
determine if trends are evident. Keeping
the owners/ users of Velan products
satisfied is part of the key to our success
over the years, and our service group
takes pride in continuing and supporting
In-line seat removal and seat welding and
that tradition of excellence. lapping, performed in association with
Global Field Services.
Velan used Computational Fluid Dynamics to improve the flow characteristics of this
4” (100 mm) globe valve.
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THE MOST COMPREHENSIVE LINE OF INDUSTRIAL FORGED AND CAST STEEL,
GATE, GLOBE, CHECK, BALL, BUTTERFLY AND ENGINEERED SEVERE SERVICE VALVES
ASME Pressure Classes 150– 4500 in Carbon, Alloy and Stainless Steel