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CITATIONS
This report was prepared by
Duke Engineering and Services, Inc.
215 Shuman Boulevard
Suite 172
Naperville, Illinois 60563
Principal Investigators
D. Caron
J. Holstrom
S. Korn
L. Lutz
M. Murphy
S. Swanigan
P. Young
iii
REPORT SUMMARY
Proper engineering evaluation and setup of air-operated valves is critical to the safe
operation of a nuclear power plant. This Guide provides an overview of air-operated
valves and how to complete an engineering evaluation of them. Also discussed are
methods for evaluating design basis system conditions, required thrust or torque, airactuator output thrust/torque capability, and operating margin. Guidelines also are
given for static and dynamic tests on air-operated valves and for interpreting test
results.
Background
In 1994, EPRI completed the EPRI Motor-Operated Valve (MOV) Performance
Prediction Program to develop and validate methods for predicting performance of
motor-operated valves in nuclear power plants. Nuclear utilities have applied these
methods extensively in response to Nuclear Regulatory Commission Generic Letter 8910. In 1996, EPRI initiated a pilot program at several nuclear plants to apply the lessons
learned and methods developed under the MOV Performance Prediction Program
toward the development and implementation of plant air-operated valve programs.
This Guide incorporates the lessons learned and methods developed in these pilot
programs.
Objectives
To provide comprehensive guidelines for engineering evaluations and testing of airoperated valves to demonstrate their capability to function under design basis flow and
differential pressure conditions.
Approach
EPRI teamed with four utilities to develop and implement technically sound and costeffective air-operated valve programs. The process included evaluation of design basis
system conditions (media, temperature, flow, and differential pressure), required
actuation thrusts and torques, air-operator output thrust/torque capability, and margin
for selected air-operated valves.
Where applicable, researchers used validated methods developed under EPRIs MOV
program to define required thrust/torque. In cases where such methods were not
applicable, new methods were developed. Specifically, the EPRI balanced globe valve
model includes a plug side loading term that is considered overly conservative for
v
many caged globe valve designs. Project researchers applied a refined balanced globe
valve modelwhich explicitly accounts for plug imbalance area and neglects plug side
loadingfor such valve designs. In addition, the EPRI unbalanced globe valve model is
currently applicable to water flow up to 150F (65.6C). For nominal flow cases where
fluid temperature was above 150F, researchers applied the EPRI unbalanced globe
valve model as the best available methodology. Plans call for validation of these
modeling approaches in 1999. First-principles-based methods also were developed and
applied for double-seated and three-way globes, as well as ball valve designs.
Project researchers developed first-principles methods for evaluation of air-actuator
output thrust/torque capability for air-actuator designs commonly applied in nuclear
service. They used these methods, as well as actuator vendor information, to determine
actuator output capability.
Results
The EPRI Performance Prediction Methodology (PPM) applied directly to most airoperated gate and butterfly valves and to unbalanced globe valves with operating
temperatures below 150F. The pilot programs defined a need for additional data to
define friction coefficients for butterfly valve non-metallic bearings and to refine and
extend the applicability of the EPRI globe valve methodology.
EPRI Perspective
This Guide provides an excellent basis for developing and implementing a technically
sound air-operated valve program. It incorporates lessons learned and tools developed
under the EPRI MOV Performance Prediction Research Program and several pilot airoperated valve programs.
TR-107322
Keywords
Valves
Air-operated valves
vi
ABSTRACT
This guide presents methods for conducting an engineering evaluation of the design
basis capability of air operated valves in nuclear power plants. The methods presented
incorporate lessons learned and tools developed as part of the EPRI Motor Operated
Valve Performance Prediction Research Program and during EPRI pilot AOV programs
implemented at several nuclear power plants.
The guide includes methods for determining design basis operating conditions,
required thrust/torque, actuator output capability, and thrust/torque margin for AOV
applications. Guidance is also provided for static and dynamic testing of AOVs.
The methods are applicable to most rising stem gate and globe valve designs and onequarter turn butterfly and ball valves. Actuator types covered include cylinder,
diaphragm, scotch yoke, and rack and pinion.
vii
ACKNOWLEDGMENTS
The following individuals and organizations are acknowledged for their support and
guidance in the preparation and review of this Guide:
Pilot AOV Program Utilities
Alliant /IES Utilities
Mr. Clifford McDonald
Consumers Energy Company
Mr. Robert Gambrill
Mr. Gary Foster
Detroit Edison Company
Mr. A. Nayakwadi
TU Electric Company
Mr. Ben Mays
Additional Technical Reviewers
Mr. Kenneth Beasley, Duke Energy Corporation
Mr. Daryl Bradford, Southern California Edison Company
Mr. Timothy Chan, Tennessee Valley Authority
Mr. Mark Colemen, Public Service Electric and Gas Company
Mr. Kevin Cortis, Northeast Utilities Company
Mr. James Hallenbeck, PECO Energy Company
Mr. Frank Pisarsky, American Electric Power Company
Mr. Robert Poole, Tennessee Valley Authority
Ms. Sonja Waters, Arizona Public Service Company
ix
CONTENTS
INTRODUCTION............................................................................................................. 1-1
1.1 Purpose and Objective ................................................................................................. 1-1
1.2 Scope of Evaluation Guide ........................................................................................... 1-2
1.3 Organization of the Evaluation Guide ........................................................................... 1-2
1.3.1 Overview of AOV Evaluation Methodology (Section 2) .......................................... 1-3
1.3.2 Functional Description and Introduction to Air-Operated Valves (Section 3) .......... 1-3
1.3.3 Definition of AOV Functional and Design Requirements (Section 4) ..................... 1-3
1.3.4 Determining Required Thrust or Torque (Section 5).............................................. 1-4
1.3.5 Evaluation of Valve / Actuator Rated and Survivable Thrust and Torque
(Section 6)....................................................................................................................... 1-5
1.3.6 Evaluation of Air Actuator Output Thrust / Torque Capability (Section 7) ............... 1-5
1.3.7 Calculating and Evaluating Margins (Section 8)..................................................... 1-5
1.3.8 AOV Testing (Section 9) ........................................................................................ 1-5
1.3.9 References (Section 10) ........................................................................................ 1-6
1.3.10 Appendices.......................................................................................................... 1-6
1.4 Basis for Guide.............................................................................................................. 1-6
Globe Valves (unbalanced, balanced, double seat, three-way, piloted) ............... 3-2
xi
3.1.5
xii
xiii
xiv
6
EVALUATION OF VALVE / ACTUATOR RATED AND SURVIVABLE THRUST
AND TORQUE........................................................................................................................ 6-1
6.1 Valve Limits.................................................................................................................. 6-1
6.2 Actuator Limits ............................................................................................................. 6-2
xv
xvi
10
REFERENCES.............................................................................................................. 10-1
ACTUATOR WORKSHEETS..........................................................................................B-1
Calculation worksheets............................................................................................C-2
xvii
LIST OF FIGURES
Figure 2-1 AOV Evaluation Methodology ................................................................................ 2-3
Figure 3-1 Principle Components of Air Operated Valve ......................................................... 3-1
Figure 3-2 Basic Flow Path of a Globe Valve .......................................................................... 3-3
Figure 3-3 Flow Passages in the Cage.................................................................................... 3-3
Figure 3-4 Top Guided Valve .................................................................................................. 3-4
Figure 3-5 Flow Curves with Constant Differential Pressure.................................................... 3-4
Figure 3-6 Flow Curves Corrected for Piping Losses .............................................................. 3-5
Figure 3-7 Equal Percentage Flow Characteristics.................................................................. 3-6
Figure 3-8 Three Types of Stem Packing ................................................................................ 3-7
Figure 3-9 Globe Valve ........................................................................................................... 3-8
Figure 3-10 Unbalanced Disc Globe Valve.............................................................................. 3-9
Figure 3-11 Balanced Disc Globe Valves .............................................................................. 3-10
Figure 3-12 Double Seat Globe Valve ................................................................................... 3-10
Figure 3-13 Converging Three-way Valve ............................................................................. 3-11
Figure 3-14 Diverging Three-way Valve ................................................................................ 3-12
Figure 3-15 Piloted Disc Valve .............................................................................................. 3-13
Figure 3-16 Gate Valve ......................................................................................................... 3-14
Figure 3-17 Butterfly Valve.................................................................................................... 3-15
Figure 3-18 Butterfly Valve Body Styles ................................................................................ 3-15
Figure 3-19 High Performance Butterfly Valve ...................................................................... 3-16
Figure 3-20 Floating Ball Valve ............................................................................................. 3-18
Figure 3-21 Trunnion Mounted Ball Valve ............................................................................. 3-18
Figure 3-22 V-Notch ball valve .............................................................................................. 3-19
Figure 3-23 Eccentric Rotating Plug Valve ............................................................................ 3-20
Figure 3-24 Direct Acting Spring and Diaphragm Actuator .................................................... 3-22
Figure 3-25 Reverse Acting Spring and Diaphragm Actuator ................................................ 3-23
Figure 3-26 Spring Return Direct Acting Rotary Diaphragm Actuator .................................... 3-24
Figure 3-27 Air Cylinder, Spring Return................................................................................. 3-25
Figure 3-28 Double Acting Rack and Pinion Actu.................................................................. 3-25
Figure 3-29 Scotch Yoke Actuator......................................................................................... 3-26
xix
xx
Figure 7-31 Percentage of Break Torque Plot for Scotch Yoke, Double Acting ..................... 7-37
Figure 7-32 Scotch Yoke, Single Acting Air Cylinder ............................................................. 7-39
Figure 7-33 Percentage of Ending Torque Plot for Scotch Yoke, Singlele Acting .................. 7-40
Figure 7-34 Rotary Diaphragm Actuator................................................................................ 7-42
Figure 7-35 Percentage of Ending Torque Plot for Rotary Diaphragm................................... 7-42
Figure 7-36 Double Acting Rack & Pinion, Rotary ................................................................. 7-46
Figure 7-37 Available Torque Plot for Double Acting Rack and Pinion .................................. 7-46
Figure 7-38 Single Acting Rack and Pinion, Rotary ............................................................... 7-47
Figure 7-39 Available Torque Plot for Single Acting Rack and Pinion.................................... 7-48
Figure 8-1 AOV Margins and Uncertainties ............................................................................. 8-6
Figure 9-1 Example AOV Static Test Diagnostic Data Traces ............................................... 9-17
Figure 9-2 Example Direct Acting AOV Static Test Diagnostic Data Plot............................... 9-18
Figure 9-3 Analysis of Example Direct Acting AOV Static Test Data ..................................... 9-19
Figure 9-4 Determination of Unwedging Load from Air Operated Gate Valve Static Test
Data .............................................................................................................................. 9-20
Figure 9-5 Analysis of Example Reverse Acting AOV Static Test Data ................................. 9-21
Figure 9-6 Analysis of Example Double Acting AOV Static Test Data ................................... 9-22
Figure 9-7 Example Air Operated Gate Valve Dynamic Test Data ........................................ 9-23
Figure 9-8 Example Air Operated Gate Valve Dynamic Test Data - Details........................... 9-24
xxi
LIST OF TABLES
Table 7-1 Parameter Definitions.............................................................................................. 7-3
Table 8-1 AOV Component Ratings ........................................................................................ 8-4
Table A-1 Required Thrust for Unbalanced Disc Globe Valves (Section 5.4.1) ....................... A-2
Table A-2 Required Thrust for Balanced Disc Globe Valves (Section 5.4.2) ........................... A-4
Table A-3 Required Thrust for Balanced Disc Globe Valves With Pilot Valve (Section
5.4.3) ............................................................................................................................... A-6
Table A-4 Required Thrust for Double Seat Globe Valves (Section 5.4.4)............................. A-10
Table A-5 Required Thrust for Three-Way Globe Valves (Section 5.4.5)............................... A-12
Table A-6 Sealing/Wedging Loads for Gate Valves (Section 5.5).......................................... A-16
Table A-7 Required Torque for Ball Valves (Section 5.7) ...................................................... A-18
Table B-1 Actuator Capability Calculation Worksheet (Double Acting Air Cylinder
Actuator).......................................................................................................................... B-6
Table B-2 Actuator Capability Calculation Worksheet (Single Acting Air Cylinder
Actuator)........................................................................................................................ B-19
Table B-3 Actuator Capability Calculation Worksheet (Diaphragm Actuator)......................... B-29
Table B-4 Actuator Capability Calculation Worksheet (Diaphragm Actuator)......................... B-36
Table B-5 Actuator Capability Calculation Worksheet (Diaphragm Actuator)......................... B-43
Table B-6 Actuator Capability Calculation Worksheet (Diaphragm Actuator)......................... B-51
Table B-7 Actuator Capability Calculation Worksheet (Scotch Yoke Actuator) ...................... B-59
Table B-8 Actuator Capability Calculation Worksheet (Scotch Yoke Actuator) ...................... B-66
Table B-9 Actuator Capability Calculation Worksheet (Rotary Diaphragm Actuator) ............. B-74
Table B-10 Actuator Capability Calculation Worksheet (Rotary Diaphragm Actuator) ........... B-81
Table B-11 Actuator Capability Calculation Worksheet (Rack & Pinion, Double Acting) ........ B-88
Table B-12 Actuator Capability Calculation Worksheet (Rack & Pinion, Single Acting) ......... B-91
xxiii
1
INTRODUCTION
Defining the functional and design requirements for an air-operated valve (AOV)
and its accessories including code requirements and design basis/normal operating
conditions.
Evaluating valve design features that can affect AOV operation and calculating
valve thrust/torque requirements.
Evaluating air actuator design features that can affect AOV operation, calculating
the actuator output thrust/torque, and evaluating the compatibility of the actuator
and the valve.
Evaluating the available margin between the actuator output thrust/torque and the
required stem thrust/torque (i.e. capability margin), and evaluating valve/actuator
survivable thrust and torque.
Performing and interpreting baseline static and dynamic testing to confirm actuator
output thrust/torque and margin.
In summary, the major objectives of the Evaluation Guide are to provide: (1) practical
methods for evaluating whether existing AOVs meet the design and functional
requirements for their applications in nuclear power plants, and (2) suggested
approaches for resolving AOV application problems. The guide does not address AOV
maintenance issues or requirements. Maintenance issues are covered in EPRI report
NP-7412, Revision 1, Maintenance Guide for Air Operated Valves, Pneumatic
Actuators, and Accessories (Reference 10.9).
1-1
Globe Valves (Balanced and Unbalanced, 2-way, 3-way, Piloted, Double seated)
Gate Valves (Solid wedge, Flexible wedge, Anchor/Darling double disk, Aloyco
split wedge)
While other types are found in nuclear power plants, the four types covered by the
Guide are the most widely used in AOV applications in United States nuclear power
plants.
The Evaluation Guide is applicable to the following air actuator types:
x
Diaphragm
Piston
Scotch Yoke
These actuators encompass the majority of air actuators found in the nuclear industry.
1-2
Other utilities and utility organizations (e.g., AOV Users Group, AOV Joint Owners
Group)
This Guide is organized into ten sections and three appendices, as follows:
Section 4 presents a suggested methodology for defining the functional and design
requirements for an AOV application. Specific subsections address definition of
requirements considering:
Calculation sheets for applying the methods presented in this section are provided in
Appendix A.
1-4
1.3.5 Evaluation of Valve / Actuator Rated and Survivable Thrust and Torque
(Section 6)
Section 6 presents considerations for determining the valve rated thrust and torque and
the valve survivable thrust and torque. In addition, considerations for the functional
and structural ratings/limits for the actuator and accessories are presented.
Static Testing to confirm actuator output capability and setup (Section 9.2)
1-5
Lessons learned and methods developed as part of the EPRI MOV Performance
Prediction Research Program (Reference 10.2).
Lessons learned and methods developed during implementation of EPRI Pilot AOV
programs at several plant sites.
Review of NRC and AEOD publications related to MOV and AOV performance.
Input from a Technical Advising Group made up of utility MOV and AOV
engineers.
1-6
Lessons learned from EPRI and utility Motor Operated Valve (MOV) programs and
pilot EPRI AOV programs show that AOV performance and reliability could be
enhanced via improvements in sizing, setup, testing, and maintenance practices. Some
of the specific observations include:
x
Thrust requirements for gate valves may have been under predicted during initial
sizing.
The appropriate area (seat vs. guide) needs to be chosen for differential pressure
applications for unbalanced globe valves.
The side loading algorithm in the EPRI balanced globe valves modeled may be
overly conservative for some valve designs.
Butterfly valve bearing coefficients may have degraded from those values used in
sizing.
Spring safe loads need to be considered if changes to vendor supplied preloads are
made.
This guide addresses these issues and provides guidance for evaluating AOV
applications in nuclear power plant service.
1-7
2
OVERVIEW OF AOV EVALUATION METHODOLOGY
2-2
Start
No
Yes
Determine worst case system requirements for the
valve's operation based on the functional review
(4.3.4)
No
Is the Actuator Capability Margin
sufficient including potential
degradations and uncertainties? (8.2)
Yes
No
No
Will the adjustments give
adequate Component and
Actuator margin?
Yes
Yes
Confirm AOV set up and design input assumptions
by testing or other engineering analysis as required.
(9.1, 9.2)
End
Figure 2-1
AOV Evaluation Methodology
2-3
3
FUNCTIONAL DESCRIPTION AND INTRODUCTION TO
AIR-OPERATED VALVES
3.1 Valves
This section describes rising stem gate and globe valves along with quarter turn valves
commonly used for AOV applications in nuclear power plants. Air operated valves are
used extensively in the power generation industry for process control and system
isolation functions. Proper operation of these valves is critical to running a safe,
dependable, and economic plant. This section is included to provide the user with an
understanding of the principle components of common air operated valves (see Figure
3-1).
Figure 3-1
Principle Components of Air Operated Valve
3-1
Valve
Air Actuator
Controls
Solenoid Valve
Positioner
Speed controls
Position transmitter
I/P converter
Supply System
Volume Boosters
3-2
Figure 3-2
Basic Flow Path of a Globe Valve
Note: Valves that are used as block valves to isolate a section of a piping system are generally
required to provide tight shutoff. Globe valves are typically designed to modulate flow and often
operate in mid-flow or at a throttled position. These valves are typically built to withstand
process pressures and high-cycle service but are not designed for tight shutoff.
Desired flow characteristics can be obtained by changing the shape of the flow passages
in the cage (Figure 3-3) and by replacing or modifying the valve disc and seat in top
guided valves (Figure 3-4).
Figure 3-3
Flow Passages in the Cage
3-3
Figure 3-4
Top Guided Valve
These changes in trim components affect the flow characteristics of the valve. The three
most common trim types are equal percentage, linear operation, and quick open.
Figure 3-5 shows typical flow curves for these trim types with a constant differential
pressure across the valve. Figure 3-6 shows the flow curves adjusted for typical piping
losses. The objective of trim selection is to obtain optimum process control. A general
rule of thumb is to select a linear flow characteristic if the pressure drop is constant with
increasing flow rate and an equal percent characteristic when the differential pressure
decreases with increasing flow rate.
Figure 3-5
Flow Curves with Constant Differential Pressure
3-4
Figure 3-6
Flow Curves Corrected for Piping Losses
3-5
Equal percentage trim is most commonly used because many systems use centrifugal
pumps. In these systems, an increase in flow rate results in decreased pressure drop at
the control valve based on the head/flow characteristic of the pump. The flow
characteristic for equal percentage resembles Figure 3-7.
Figure 3-7
Equal Percentage Flow Characteristics
Quick Open trim is used for On-Off applications and provides maximum flow quickly.
If a valve does not appear to fit the existing process conditions, check with a
manufacturer's technical representative or with a valve services vendor. Many times
the exchange of trim can be accomplished at the next outage at a reasonable cost.
Stem packing is used to seal the stem opening in the bonnet, and the gland is used to
pre-load the stem packing. The packing may be live loaded (e.g., by Belleville springs),
pressure energized or torque preloaded (e.g., by torquing the gland bolts). Live loaded
packing uses springs to maintain a nearly constant load on the packing even though the
packing may shrink. Shrinkage may be due to thermal expansion, aging, and
consolidation. Pressure energized packing is usually a TFE V-ring type lip seal. This
packing has some initial loading from the spring and system pressure is used to seal the
packing lip to the packing box wall and valve stem. Square compression packing relies
on the compressive force exerted on the packing by tightening the packing gland bolts.
All three types are shown in Figure 3-8.
3-6
Live Loaded
Pressure Energized
Torque Preloaded
Figure 3-8
Three Types of Stem Packing
The stem is a shaft that has a smooth portion that passes through the packing and a
threaded portion that engages the actuator coupling. The valve disc has a hardened
surface, which contacts the seat ring to provide sealing.
3-7
1.
2.
3.
4.
5.
6.
Plug Stem
Packing Box Studs
Packing Box Stud Nuts
Packing Flange
Packing Follower
Packing
7.
8.
9.
10.
11.
12.
Spacer
Bonnet
Valve Body Studs
Valve Body Stud Nuts
Valve Body Gaskets
Guide Bushing
13.
14.
15.
16.
17.
Seat Ring
Valve Plug
Plug Stem Pin
Body
Drive Nut
Figure 3-9
Globe Valve
Figure 3-10
Unbalanced Disc Globe Valve
3-9
Figure 3-11
Balanced Disc Globe Valves
Figure 3-12
Double Seat Globe Valve
3-10
Figure 3-13
Converging Three-way Valve
In diverging valves (Figure 3-14), the fluid flows from the common port to one or both
of the other two ports (diverting the flow). These valves are generally designed with
two discs, one on each side of the body seats so that flow is under the seat for both
discs. As in converging valves, V-ported discs may be used to provide more accurate
control of the flow. Diverging valves can only isolate flow to one inlet port at a time.
The other port will be open.
3-11
Figure 3-14
Diverging Three-way Valve
3-12
Figure 3-15
Piloted Disc Valve
Figure 3-16
Gate Valve
Stem packing is used to seal the stem opening in the bonnet, and the gland is used to
preload the stem packing. The packing may be live loaded (e.g., by Belleville springs)
or torque preloaded (e.g., by torquing the gland bolts) as shown in Figure 3-8. Live
loaded packing uses springs to maintain a nearly constant load on the packing even
though the packing may shrink. Shrinkage may be due to thermal expansion, aging, or
consolidation.
The stem is a shaft that has a smooth portion that passes through the packing and a
threaded portion that engages the actuator coupling. Typically the stem is attached to
the valve disc by a "T" slot connection. The valve disc has two hardened seating
surfaces, which engage with the seat rings. These surfaces are the sealing surfaces of
the valve.
Gate valves normally have a backseat, which can be used to seal the stem to the bonnet,
when the valve is in the fully open position. The backseat seal is provided for
maintenance purposes.
3.1.3 Butterfly Valves
Butterfly valves are high pressure recovery valves. They offer minimal friction losses
due to the location of the disc in the center of flow at the full open position. Butterfly
valves allow more flow with less pressure drop than globe valves. Figure 3-14 shows a
conventional symmetric disc butterfly valve. When the disc is rotated 90 degrees from
the closed position, the disc is in-line with the process flow and adds very little pressure
drop or turbulence.
3-14
Figure 3-17
Butterfly Valve
Butterfly valves are constructed into three different body styles; wafer style, lugged,
and flanged (Figure 3-18). The wafer style is lighter, requires very little additional
piping support, and is easy to install. The main benefit of the lugged style is the ease of
installation. They are typically used for end-of-line installations. Flanged butterfly
valves provide much greater support for the valve but require additional strength
piping for valve support.
Wafer
Lugged
Flanged
Figure 3-18
Butterfly Valve Body Styles
3-15
Figure 3-19
High Performance Butterfly Valve
Most high performance discs are double offset; that is, the shaft is offset from the plane
of the sealing surface and it is also offset from the center of the body bore. The double
offset swings the disc face away from the seal during the initial 10 to 15 degrees of
rotation and minimizes disc to seal contact throughout the remainder of rotation. This
minimizes the possibility of permanent depressions in the seal caused by prolonged
disc to seal contact. The disc must be rotated in the proper direction and should never
be permitted to overtravel. These two actions are the most frequent causes of
permanent seal damage. Proper sealing depends on the very fine finish between the
disc and the sealing edge.
Pressure assisted seals require a minimum pressure drop across a closed valve to
maintain the rated shutoff. To seal, process pressure is ported behind the seal, forcing
the seal against the sealing edge of the disc. As pressure is increased, shutoff becomes
tighter and tighter. Seals are available for various materials and configurations. PTFE
seals are used for tight shut off (ANSI/FCI 70-2 Class VI shut off) at temperatures up to
450 F. The seals are supported by stainless steel springs that compensate for wear and
distortion; stainless steel spring seals are used between 450 F and 1000 F with reduced
shutoff capabilities.
The shaft is a round bar that has a smooth portion that passes through the packing and
a keyed portion that engages the actuator coupling. Typically the shaft is attached to
the valve disc by a keyed, pinned or bolted connection. The valve disc has a seating
surface that contacts a seating surface in the valve body when in the closed position.
The seating surfaces may be of a corrosion resistant material (e.g. stainless steel, Monel,
inconel) or may be a combination of a corrosion resistant and an elastomer or plastic
material (e.g. rubbers or Teflon).
3-16
A butterfly valve is a pipeline flow control device that operates by rotating what is
essentially a thin circular disc within the pipe on a major diametrical axis of the disc.
The disc is supported in the valve body by a shaft and two sleeve bearings located in
two valve body trunnions. The shaft may be a single or two piece construction. Full
stroke (open to closed) disc rotation is essentially through a 90 arc. (Note: Not all valve
designs travel the full 90.) When the disc is parallel to the pipe axis, full pipeline flow
results. This position is referred to as the full open or 90 open position. When the disc
is perpendicular to the pipe axis, the valve is closed; there is no flow and the edge of the
disc comes into contact with a seal in the valve body. This position is referred to as the
fully closed or zero degree (0) position. The disc is rotated within the valve body by
the actuator shaft that extends through the valve body to its exterior where an actuating
device is mounted on the body trunnion to rotate and hold the valve disc in the full
open, full closed or intermediate positions. Larger valves have thrust bearings that
center and support the disc and shaft as well as the fluid pressure end loads on the
valve shaft.
Shaft packing is used to seal the shaft opening(s) in the valve body. The shaft will
penetrate the body at the actuator connection trunnion but may not penetrate to the
exterior of the body at the non-actuated body trunnion. Therefore there may be one or
two packing glands. In pull down or compression style packing, a gland is used to
preload the shaft packing. The packing may be either live loaded (e.g., by Belleville
springs) or torque preloaded (e.g., by torquing the gland bolts) as shown in Figure 3-5.
Live loaded packing glands use springs to maintain a nearly constant load on the
packing even though the packing may shrink. Shrinkage may be due to thermal
expansion, aging, or consolidation. Packing may also be of the chevron or o-ring style.
These packing types are generally compressed by the physical dimensions of the gland
or groove and are pressure activated or loaded to seal. This style of packing gland
does not generally have springs or mounting bolts that permit adjustment.
3-17
Figure 3-20
Floating Ball Valve
Trunnion mounted ball valves (Figure 3-21) support the ball with a bearing supported
trunnion instead of relying upon the valve seats, as in a floating ball valve. With the
trunnion carrying the differential pressure across the valve, lower actuation torque is
required and hence the trunnion mounted ball valves can be used for higher pressures
and larger sized valves.
Figure 3-21
Trunnion Mounted Ball Valve
Shaft seals prevent upstream pressure from leaving the shaft bores. These seals
perform the same job as packing does for other types of valves. Seats and/or flow rings
provide a seal between the ball and the valve ports.
Some ball valves have a single soft-seal design, which provides a pressure-assisted seal
when fluid flows toward the seal. A metal protector ring is commonly used to protect
the seal from damage. Shims between the valve body and the ball seal determine the fit
between the seals and ball.
3-18
Some ball valves have a double soft seal design, which provides tight shutoff in either
flow direction. This seal also provides a "block and bleed" feature, which allows the
body to be bled of any internal pressure as a means of checking seal integrity, or to be
purged between uses. A metal flow ring can be used when conditions dont allow the
use of soft seals; such as in high temperature or corrosive service. Because no seal is
used, the flow ring has some clearance with the ball and only moderate shutoff can be
obtained.
A V-Notch ball valve is a modification to a standard ball valve where a "V" shaped
notch is cut out of the ball face. The geometry of the V-Notch valve ball segment
(Figure 3-22) combines with the straight through flow path of a ball valve to provide
wide range ability or the ability to control both very low flow rates and very high flow
rates. Flow is controlled from when the notch just begins to expose the port to the full
open position. The V-Notch ball segment is supported and positioned by a drive shaft
and a guidepost. The drive shaft and ball are attached with a splined connection. The
ball's opposite side is supported by a guidepost. A gasket between the guidepost and
the body prevents leakage. Packing arrangements of different materials are available to
seal the shaft and prevent leakage of fluid to the atmosphere. The main shaft bushing
which supports the drive shaft is precisely located to keep the ball segment aligned in
the center of the body for proper contact with the seals. The seals are generally
shimmed to zero deflection, meaning the seal is just in contact with the ball.
Figure 3-22
V-Notch ball valve
Sealing can be accomplished with stainless steel seals to temperatures of 1000 F with
leakage less than ANSI/FCI 70-2 Class IV leak allowance. Stainless steel seals have
limited pressure drop ratings. Composition seals of PTFE and polymer binders provide
tight shutoff at temperatures below 450 F. Because of their ability to control a wide
range of flow rates, these valves work well in steam and drain service.
Shaft packing is used to seal the shaft opening(s) in the valve body. The shaft will
penetrate the body at the actuator connection trunnion but may not penetrate to the
exterior of the body at the non-actuated body trunnion. Therefore there may be one or
3-19
two packing glands. In pull down or compression style packing a gland is used to
preload the shaft packing. The packing may be either live loaded (e.g., by Belleville
springs) or torque preloaded (e.g., by torquing the gland bolts) as shown in Figure 3-8.
Live loaded packing glands use springs to maintain a nearly constant load on the
packing even though the packing may shrink. Shrinkage may be due to thermal
expansion, aging, or consolidation. Packing may also be of the chevron or o-ring style.
These packing types are generally compressed by the physical dimensions of the gland
or groove and are pressure activated or loaded to seal. This style of packing gland
does not generally have springs or mounting bolts that permit adjustment.
Figure 3-23
Eccentric Rotating Plug Valve
The shaft is a round bar that has a smooth portion that passes through the packing and
a keyed portion that engages the actuator coupling. Typically the shaft is attached to
3-20
the valve disc by a keyed, pinned or bolted connection. The valve disc has a seating
surface that contacts a seating surface in the valve body when in the closed position.
The seating surfaces may be of a corrosion resistant material (e.g. stainless steel, Monel,
inconel) or may be a combination of a corrosion resistant and an elastomer or plastic
material (e.g. rubbers or Teflon).
Shaft packing is used to seal the shaft opening(s) in the valve body. The shaft will
penetrate the body at the actuator connection trunnion but may not penetrate to the
exterior of the body at the non-actuated body trunnion. Therefore there may be one or
two packing glands. In pull down or compression style packing a gland is used to
preload the shaft packing. The packing may be either live loaded (e.g., by Belleville
springs) or torque preloaded (e.g., by torquing the gland bolts) as shown in Figure 3-8.
Live loaded packing glands use springs to maintain a nearly constant load on the
packing even though the packing may shrink. Shrinkage may be due to thermal
expansion, aging, or consolidation. Packing may also be of the chevron or o-ring style.
These packing types are generally compressed by the physical dimensions of the gland
or groove and are pressure activated or loaded to seal. This style of packing gland
does not generally have springs or mounting bolts that permit adjustment.
have only one chamber sealed and air pressure is used to move the valve stem in only
one direction. The return motion of a single acting actuator is provided by other means
such as gravity, springs or fluid dynamic forces. If a spring is installed in one of the
chambers, the spring force opposes the force generated by the air supply pressure
acting on the diaphragm.
DIAPHRAGM
CASE
DIAPHRAGM
PLATE
AIR INLET
DIAPHRAGM
ACTUATOR SPRING
ACTUATOR
STEM OR ROD
SPRING SEAT
YOKE
Figure 3-24
Direct Acting Spring and Diaphragm Actuator
3-22
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Figure 3-25
Reverse Acting Spring and Diaphragm Actuator
bearings in the actuator housing support either the lever assembly or the valve shaft. A
typical cross section of this actuator type is shown in Figure 3-26.
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Spring Return Direct Acting Rotary Diaphragm Actuator
3.2.3 Piston
A piston actuator is similar to a diaphragm actuator, except that air pressure is applied
to a piston, which moves to provide linear motion of the actuator stem. Piston actuators
provide some advantage over diaphragm actuators in that they can typically withstand
higher pressures. Therefore, they are capable of delivering more output force for the
same actuator size. Additionally, diaphragm operators are often limited to shorter
stroke lengths; cylinder stroke lengths may be longer. The total work available from
either a diaphragm or cylinder is the product of the force available times the distance
traveled. As the cylinder actuator can often withstand higher pressure and also
provides greater travel lengths, the total work capability of the cylinder actuator is
much greater than a diaphragm actuator. Piston actuators can either be double acting
or single acting (generally spring opposed). However, the typical application is the
positioning of control valves in conjunction with a positioner by use of balancing air
pressures alone (double acting). A typical cross section of this actuator type is shown in
Figure 3-27.
3-24
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Air Cylinder, Spring Return
D CYLINDER DIAMETER
SLIDING SEAL
GUIDE ROD
ACTUATOR STEM
"d" PISTON
ROD
DPG PINION
GEAR PITCH
DIAMETER
AIR
INLET
PISTON
RACK
PINION
Figure 3-28
Double Acting Rack and Pinion Actuator
3-25
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Scotch Yoke Actuator
3.3 Accessories
3.3.1 Boosters, Accumulators, Solenoid valves
3.3.1.1 Boosters
There are two types of boosters -- pressure boosters and volume boosters. A volume
booster takes an input signal, typically from a controller or positioner, and increases the
volume of air available to operate the actuator. Volume boosters are typically installed
to increase the speed of operation of the actuator. The signal received from the
controller requires approximately one cubic inch of air to reposition the pilot valve in
the booster; therefore, the volume of air in the connecting signal tubing is very small.
When the booster pilot valve shifts, it allows operating air from a separate source to
pass through the large capacity pilot in the booster to stroke the actuator. This action
3-26
allows the valve to stroke more quickly. The system designer needs to be aware that if
a pressure-reducing valve is used for the supply pressure side of the booster, it may
limit the output capacity of the booster. The system designer also needs to be aware
that if a pressure reducing valve is not used, the volume booster may apply a pressure
to the actuator that is greater than the actuator is rated for.
Pressure boosters increase the pressure from the input signal to a higher value. Typical
pressure boosters are piston type air pumps using the input signal for both the driving
force and the supply for booster output. The ratio for pressure increase is the ratio of
the piston area of the driving and driven pistons of the booster. Figure 3-30 is an
outline of a typical pressure booster.
Figure 3-30
Pressure Booster
3.3.1.2 Accumulators
Accumulators are pressure vessels used to store an additional volume of air. This
separate volume may be used as an "Emergency source" of air to stroke the actuator on
loss of normal actuating air. This volume may also be used to ensure a valve will
maintain position during loss of normal operating air.
3.3.1.3 Solenoid Valves
Solenoid valves are used to control the flow of air to an air actuator. Solenoid valves are
used most frequently in "On - Off applications," where the valve is either fully opened
or closed, but not throttled. When the AOV is required to move to its failure position,
3-27
the solenoid valve positions itself to isolate the air supply to the actuator and to vent air
from the actuator. When the AOV is required to stroke in the opposite direction, the
solenoid valve positions itself to allow air to the actuator. Typical installations are
shown in Figure 3-31. More complex configurations can use SOVs in conjunction with
positioners to achieve a fail safe position.
Figure 3-31
Solenoid Valve
3-28
3.3.1.5 Positioners
Positioners are used to control the flow of air to the air actuator. Positioners are used in
applications where continuous throttling (modulating) of the fluid system is needed. A
positioner generally works by comparing an input signal (pressure or current) to the
valve position and it increases or decreases the air pressure to the actuator until a
balance is reached. For a further explanation see Reference 10.9.
3-29
4
DEFINITION OF AOV FUNCTIONAL AND DESIGN
REQUIREMENTS
This section discusses the functional and design requirements which should be defined
as a first step in conducting an evaluation of the adequacy of an air-operated valve
application. Specifically, the following considerations are addressed:
x
AOV Orientation
AOV Accessibility
Acceptable maximum pressure drop across the open valve due to frictional losses in
the valve at system design flow rate (Note that for throttling valves, the pressure
drop as a function of position should be specified.)
4-1
Fluid medium and phase (Note that the phase can change from water to steam or a
two-phase mixture for AOVs whose applications include isolation of high energy
lines following a postulated pipe rupture.)
Fluid chemistry
Seismic classification
ANSI classification
All these requirements should be obtained from system design basis documentation.
New and replacement safety-related AOVs should be qualified in accordance with
ASME QME-1, Qualification of Active Mechanical Equipment Used in Nuclear Power
Plants, which is currently undergoing revision to reflect lessons learned from EPRI and
other industry research programs.
4-2
Effective diaphragm area as a function of stroke (or full area and efficiency as a
function of stroke)
This information should be obtained from the valve or actuator vendor or published
design documentation.
4.2.1.2 Piston
A piston actuator is a device in which the fluid pressure acts upon a moveable
cylindrical disc member, the piston, to provide a linear motion to the actuator stem
(a.k.a. cylinder rod or piston rod) as the disc or piston moves the cylinder barrel bore.
The structural and design requirement for the actuator should equal or exceed the
requirements of the piping in which it is installed. (Note: In many cases there may be a
design rating change just prior to the actuator at the location of pressure regulator with
relieving capability.) Design parameters that should be considered are provided below.
4.2.1.3 Double Acting
x
This information should be obtained from the valve or actuator vendor or published
design documentation.
Type of mechanism (i.e. link and lever, pivoting actuator, scotch yoke, rack &
pinion)
4-4
This information should be obtained from the valve or actuator vendor or published
design documentation.
4.2.3 Controls
4.2.3.1 Control Voltage Electric Power Supply
The electric power supply requirements are based on the AOV safety class. The most
frequent use of control voltage is for operation of solenoid valves (SOVs) associated
with the control of the AOV.
4.2.3.2 Non-safety-Related AOVs
If the AOV is non-safety-related, specifying the nominal AC or DC voltage is sufficient
(typically, single-phase power 24 VAC, 120 VAC, 125 VDC or 250 VDC). Normally, the
supply voltage range for non-safety-related AOVs is not specified because the nominal
line voltage is assumed to be maintained within the component design limits (10% of
nominal voltage).
4.2.3.3 Safety-Related AOVs
For safety-related AOVs, the minimum AC voltage is normally based on the emergency
diesel generator load carrying capability during sequencing. Sometimes it is based on
degraded grid conditions. Each plant has a specific reduced line voltage basis that is
typically in the range of 70% to 80% of nominal line voltage.
For those applications where the AOV must operate to maintain plant safety during loss
of all AC power (station blackout), the AOVs should be supplied with 125/250 VDC
power or other non-interruptible power source. The reduced DC line voltage at the
AOV is based on the specific plant design basis. Power (AC or DC) cables should be
sized to ensure that at least the specified minimum voltage is available at the AOV
component terminals when the component is drawing current at the in-rush (for SOVs).
Assurance of SOV performance at this reduced voltage is considered an important
design feature of the AOV assembly.
If the safety function of the valve is only related to a control voltage loss at the SOV and
no further operations are required, this review may not be required on the basis that the
failure will cause the safety function to be performed.
4-5
Modify the AOV electrical component to increase its operating capability with the
reduced voltage or redesign the power supply system to provide the required
voltage.
4-6
Valve Size
Each operating scenario for the AOV should be documented. This documentation
includes:
x
Valve stroke direction (open to close, close to open, unseating scenario (if
applicable)),
4-7
The following steps can be used to determine the limiting operating conditions:
1. Determine and document the direction of differential pressure and flow (e.g. over or
under disc for globe valves, shaft upstream or downstream for butterfly valves)
2. Determine and document the AOV elevation in feet. Note that upstream and
downstream pressures are corrected for elevation differences. These differences
may be insignificant for valves in systems where the process fluid is steam or gas.
3. Determine the type of fluid that flows through the valve (i.e. water, steam, gas, twophase flow). Additionally, the minimum and maximum fluid temperatures and
associated densities should be documented. (Note that the phase can change from
water to steam or a two-phase mixture for AOVs whose applications include
isolation of high energy lines following a postulated pipe rupture.)
4. Determine the maximum upstream pressure for the scenario, elevation, and source
(tank level drawings, pump curves, test data, relief valve set pressure, orifice data,
procedural trip/alarm set points, etc.).
5. Determine the minimum downstream pressure for the scenario, elevation, and
source (tank level drawings, sink elevations, tank pressures, procedural trip/alarm
set points)
6. Evaluate and document the potential for higher differential pressures as a result of
heat-up of the process media after closure of a valve.
7. Once the pressure inputs are determined for the specific scenario, the pressures
upstream and downstream of the valve can be determined. First the upstream and
downstream source pressures are corrected for elevation head to obtain the
pressures at the valve. The MEDP is then calculated by subtracting the downstream
pressure from the upstream pressure.
8. The maximum flow rate that the AOV can be subjected to should be documented by
reviewing the design requirements of the system, which may include reviewing
existing analyses. The maximum flow rate is needed to calculate hydrodynamic
torque for quarter turn valves and when implementing the Performance Prediction
Methodology (PPM) for gate valves. The system design flow rate can be used as the
design condition for non-safety-related AOVs and for safety-related AOVs that are
not required for isolating line breaks. For safety-related AOVs whose application
includes isolation of a line break, the design condition should be the flow rate
through the ruptured line.
The following should be considered when performing MEDP calculations:
4-9
This document uses the expression "worst case operating scenario" to describe the
set of operating parameters that yield the worst case calculated MEDP.
Upstream and downstream are defined by direction of flow during the scenario
under consideration.
Piping frictional losses are not normally considered in the calculation of MEDP. In
most cases the DP across the valve is a maximum at the moment when the valve is
either seating or unseating. At this time the flow in the line that contains the valve is
zero, which makes the line losses zero. Note that momentum effects are also not
considered in the calculation of MEDP. The momentum effect is a transient and
therefore does not need to be considered since the air actuator output is
continuously applied.
Tolerances and accumulation (if necessary) on relief valve setpoints and level
setpoints.
The documents and references to be used to determine the MEDP and system
conditions for a scenario include (as applicable) but are not limited to the following:
x
Isometric Drawings
Pump Curves
UFSAR/Technical Specifications
4-10
leakage paths depend on the test method. If the packing is not pressurized, the
measured leakage is through the seat or seats and pipe joints. Some system
configurations require pressurizing the packing in at least one valve being tested. In
these instances, the measured leakage includes leakage through the packing.
The allowable leakage rate should be specified for each of the important multiple
functions of an AOV. A typical allowable leakage rate for a nuclear quality,
safety-related valve is 2 cc/hr/in of nominal pipe size (Reference 10.11). This leakage
specification is applicable to newly manufactured valves and, if satisfied, should ensure
system leakage rate limitations will not be exceeded. Actual leakage will increase with
wear of the valve, and purchase specification leakage limits may be exceeded during
service. Periodic surveillance is performed to ensure that system leakage limitations are
maintained. Valve maintenance may be required to maintain maximum system leakage
limits.
Moisture content
Lubrication
Safety classification
4-12
Inside containment
Outside containment
Vibration (amplitude and frequency) of piping system due to fluid and mechanical
excitation during system operation.
External loads applied to the AOV as a result of the design basis event (e.g., pipe
reaction due to line breaks).
These parameters can be determined from a review of plant specific system drawings
and design documents.
For safety-related AOVs that are required to operate during a design basis event (DBE),
the ambient conditions may include high pressure, temperature, humidity, radiation,
and a harsh chemical environment.
Note: Regulators and diaphragm and cylinder actuators are often affected by the
exhaust or local environmental atmospheric pressure. The effect of a rising containment
pressure on actuator output thrust/torque and stroke time should be evaluated.
Temperature effects on elastomers should be addressed by each plants equipment
qualification program.
Active controls such as the SOV(s) and positioner may need to be environmentally
qualified (EQ) for these conditions in accordance with IEEE Std 382-1985 (Reference
10.12) or similar requirements. This qualification testing should include thermal aging,
ambient pressurization, radiation aging, vibration aging, seismic simulation, DBE
radiation exposure (high radiation), and DBE environmental (harsh environment) tests.
IEEE Std 382-1985 requirements for vibration aging are not intended to be
representative of actual plant operating conditions. The purpose of the vibration aging
testing is to accumulate operating time with a reasonable amount of vibration prior to
4-13
the DBE tests. If an AOV/SOV is installed in a system with high vibration, the expected
vibration should be compared to IEEE Std 382-1985 requirements. If they are
significantly different, steps should be taken to reduce the system vibration or to check
with the valve vendor to evaluate the suitability of the equipment for the application.
In summary, there is a wide range of potential operating environments. Examples
include:
I.
II.
A.
B.
C.
Non-safety-related
B.
C.
Non-safety-related
The extent of the environmental qualification for a given AOV should be consistent
with its application.
Horizontal pipe
Vertically upward valve stem (operator located above valve) - the stem of a Ypattern globe valve should be in the vertical plane
If the standard AOV/SOV and/or positioner orientation is not used, the reason for not
selecting this orientation (e.g., plant space limitation, orientation of piping) should be
documented and the valve vendor should be consulted about nonstandard valve
4-14
orientation. Any special precautions that need to be taken into account in the design,
operation, testing, and maintenance should be appropriately documented. Potential
problems with a nonstandard orientation include:
x
If an AOV was qualified in accordance with ANSI B16.41 (Reference 10.13) in the
standard orientation, this functional qualification may not be applicable in a
nonstandard orientation.
Special rigging and fixtures may be required to handle and position the AOV
components during installation and maintenance. For example, it is more difficult
to lap the valve seats if the valve stem is oriented in any position other than vertical.
Accelerated wear of the valve and actuator internals may occur. For example, if a
valve is oriented such that the stem movement is horizontal and the disc guide is not
designed to support the disc in the horizontal position, there may be greater than
expected friction between the disc and the guide. This can increase the stem thrust
requirements, increase the load on the actuator, accelerate operator and valve wear,
and complicate the setting of the AOV control and protection devices.
Seat leakage requirements may be more difficult to meet if the stem is not vertical.
The valve designer normally assumes a vertical stem with the disc not supported by
the disc guides.
If the valve is located upside down, radioactive materials may accumulate in the
valve bonnet and packing, thus increasing the potential radiation exposure to plant
personnel.
Stem packing leakage of borated water (or other process fluid), which can cause
corrosion of the actuator parts, may be higher for non-vertical installations.
The SOV may be more susceptible to mechanical binding (lock-up) if not vertical.
AOV installation/removal
Stem travel and operating clearances (e.g. some valve cylinder and diaphragm
casing move during actuation)
4-15
Installation of diagnostic (valve signature) equipment for AOV set-up and baseline
testing (including access to pressure sources, position indication, and limit switches)
Valve disassembly
The installation should be reviewed to ensure that items such as seismic supports or
cable trays do not interfere with operation of or access to an AOV.
rate and/or relaxation in the spring length, if not accounted for, can affect the available
force. If adjustments are made for these items, they can also impact the spring safe load
margin. Most OEMs, when asked about spring rate and length relaxation, had not
experienced these types of problems or had not had indications from field reports that
these issues were prevalent. The cause of relaxation could be excessive or improper
usage of the spring application. (i.e., number of cycles, percent of life at fully
compressed position, valve operation outside of normal design loading conditions).
There has been some work done by the spring manufacturers that indicates that springs
will relax under static loading and is dependent upon the stress, material, and duration
of loading.
Butterfly Valve Bearing Coefficient of Friction: The EPRI Performance Prediction
Methodology (Ref. 10.4) data is based upon normal metallic bearing coefficients of 0.25
for clean fluid and a dissimilar metal coupling and 0.6 for unclean water service or
similar metal couplings i.e. stainless steel against stainless steel. Many quarter turn
valves in nuclear service employ various types of bearing material combinations and
many use non-metallic materials which are known for low bearing coefficients of
friction and other good bearing properties. This friction (same is true for metallic
bearings) is generated by the rubbing of two cylindrical surfaces rotating relative to
each other which is a different load case than represented by linearly actuated rising
stem valves which have two flat surfaces rubbing along a plane and translating in a
linear motion. Additionally, the non-metallic materials have coefficients of friction
which are load dependent and often become more efficient at higher load levels and at
higher temperatures. The limited industry knowledge of this type of friction and the
effects of the different materials, operating temperatures and operating fluids, and the
potential for wear induced removal of the non-metallic coating on the metal base
material, forces the use of higher bounding valves for conservative results. The use of
higher required actuating force will likely increase the actuator size and can reduce the
control range and sensitivity of positioners and controllers. The correct selection of this
coefficient is important to quarter turn actuator sizing and design calculations as the
bearing friction torque is often the most influential torque requirement in many valve
applications. Additional data are needed to provide validated bearing friction
coefficients for non-metallic bearing materials.
Globe Valve Disc Guide-to-Body Friction (Side Loading): Side loading is an
additional thrust requirement that may be present with certain types of globe valves
caused by plug to body/cage friction. At this point, no validated prediction techniques
exist for evaluating the magnitude of this load. The EPRI PPM (Ref. 10.6) does contain a
correlation for predicting side loading based on one resource for non-caged balanced
globe valves and limited validation testing. However, this correlation may be overly
conservative for balanced caged valves. Most OEMs do not account for this type of
load in their actuator sizing methods. Lack of sufficient quality test data (dynamic
testing with thrust measurement by position and measurement of upstream and
downstream pressure) for balanced and pilot operated globe valves makes correlation
4-17
of a prediction method for side loading difficult at this point. EPRI is planning
evaluation of available industry data and additional testing to provide a basis for
refinement of the side loading assumptions in the PPM balanced globe valve model.
Mid-position loads may be greater than fully seated loads: Dynamic loads may peak
at stroke positions other than the fully seated position due to flow-induced effects or
bernoulli effects. In addition, for gate valves, there can be significant stem motion on
opening prior to flow establishment and resulting DP reduction. This can result in
reduced actuator capability at the flow initiation point relative to the fully seated
position. The exact stroke location and/or the magnitude of these effects may vary
based on design and/or system conditions. Because the actuator output changes over
the stroke for some air actuator designs, the actuator output thrust may actually be
lower during mid-position thereby reducing the available margin.
4-18
5
DETERMINING REQUIRED THRUST OR TORQUE
Present methods and equations for determining required thrust and torque for airoperated gate, globe, butterfly and ball valves, and
This section presents prediction techniques used to establish the thrust or torque
requirements for a particular valve. In some cases, the use of testing can remove
analytical conservatisms and validate an AOVs performance. Refer to Section 9 for
more information.
The results of this section will be used in conjunction with the actuator output
capability from Section 6 to evaluate margin in Section 8. Calculation worksheets for
the equations presented in this section are provided in Appendix A.
5-1
5.2 Variables
This section lists and describes the variables used for each valve type. The following
variables are used in this Guide for evaluating globe valves.
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5-3
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The following variables are used in this Guide for evaluating gate valves.
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The following variables are used in this Guide for evaluating butterfly valves.
8CTKCDNG
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The following variables are used in this Guide for evaluating ball valves.
8CTKCDNG
&GUETKRVKQP
&GPUKV[QHRTQEGUUHNWKFCVFGUKIPDCUKUEQPFKVKQPUNDUHV
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6
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5-6
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5.3 Definitions
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5-7
DP load (FDP),
Note that there is no torque reaction load for AOVs because the actuator does not
transmit torque to the valve disc.
Globe valve required thrusts are generally proportional to the DP across the valve. As a
result, the maximum required thrust for a globe valve will typically occur at the fully
seated position if the DP force opposes disc motion. If the DP force assists disc motion,
the maximum required thrust might occur at the fully open position. Since for many air
actuators, the available thrust from the actuator varies as the valve strokes (e.g., due to a
spring in the actuator), this guide provides equations for required thrust at the fully
open and fully closed positions.
5-8
The sections below discuss the thrust components as they apply to each of the globe
valve types. Note that positive thrusts values must be overcome by the actuator
(required thrusts), and negative thrust values assist disc motion.
(5.1a)
(5.1b)
See Figure 5-1 for a free body diagram of the closing stroke of an uncaged unbalanced
globe valve.
FC
FP
FSR
FDS
FSL
FSL
FDP
Figure 5-1
Free Body Diagram of an Unbalanced Globe Valve
(5.2)
FDS calculated from this equation can be positive or negative. The value calculated
should be multiplied by +1 or 1, as shown in the table below.
5-9
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
4GXGTUG #EVKPI
This equation is applicable at both the fully open and fully closed positions.
5.4.1.3 Packing Load
Packing load (FP) should be determined from static test data. If test data is not available,
values for packing load can be obtained from the valve or packing manufacturer.
Appendix C can also be used to determine packing load if none of the above are
available.
Since packing friction always opposes disc motion, FP is always positive. FP is
applicable at both the fully open and fully closed positions.
5.4.1.4 Upper Seal Friction Load
Upper seal friction load (FUS) is not applicable to unbalanced disc globe valves.
5.4.1.5 Stem Rejection Load
The stem thrust due to stem rejection load is calculated as follows.
FSR = (PB ) d S2
4
( )
(5.3)
At the fully closed position, the bonnet pressure, PB, is determined as follows.
(NQY &KTGEVKQP
7PFGTUGCV
1XGTUGCV
&KTGEV #EVKPI
272 K &2
272
4GXGTUG #EVKPI
272
272 &2
1RGPKPI
%NQUKPI
5-10
&KTGEV #EVKPI
272 K &2
272
4GXGTUG #EVKPI
272
272 K &2
The table above covers the conditions that apply the most resistance (or least assistance)
to the stem when the valve is fully open. If the specific system conditions at the valve
when it is fully open are known, a less conservative result may be obtained. For
example, if the bonnet pressure with the valve fully open is known, that pressure can be
used to calculate stem rejection load, rather than the value in the table above.
The sign for FSR is as shown in the table below.
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
4GXGTUG #EVKPI
This equation is applicable to globe valves that have a stem that penetrates the valve
pressure boundary. For other designs (e.g., valves with a diaphragm seal), the valve
manufacturer should be consulted to determine an appropriate method for determining
stem rejection load.
5.4.1.6 Disc-to-Body/Cage Friction Load
Disc-to-body/cage friction covers friction loads between the disc and the body guides,
stem bearing or cage, as applicable.
For unbalanced disc globe valves in incompressible flow applications (temperatures up
to 150F), disc-to-body friction load is considered negligible and is set to zero. Test data
from the EPRI MOV Program provided justification for this modeling approach.
For unbalanced disc globe valves in compressible flow applications or with
temperatures greater than 150F, disc-to-body friction load is also set to zero. However,
an additional factor is included in the DP load (see section below) for some globe valves
and flow conditions, to account for the potential for disc-to-body/cage friction load.
Data from the EPRI MOV Program indicated that thrust requirements for unbalanced
disc globe valves can be higher for compressible flow applications. Therefore, use of
this Guide to evaluate unbalanced disc globe valve applications with temperatures
greater than 150F should be considered best available information.
5.4.1.7 DP Load
For unbalanced disc globe valves, the stem thrust due to DP load is essentially zero at
the fully open position since there is negligible DP across the valve disc.
The stem thrust due to DP load at the fully closed position is calculated as follows.
5-11
FDP = (DP ) d 2DP
4
( )
(5.4)
Reference 10.2 provides guidance for selecting dDP, i.e., whether the seat area or guide
area should be used. Guide-based means that for a portion of the valve stroke (prior to
seating), the DP across the globe is acting over the projected guide area. Seat-based
means that the DP is acting over the seat area for the entire stroke. Determination of
whether a valve is seat-based or guide-based is the responsibility of the user. This
parameter is determined by analyzing the valve assembly drawing. Reference 10.2
(Appendix D) provides guidance for determining whether a particular globe valve is
guide-based or seat-based. If, after applying the guidance in Reference 10.2, there is any
doubt as to whether the globe valve under evaluation is guide-based or seat-based,
guide-based must be specified. The resulting prediction will be conservative, relative to
a seat-based prediction. When the seat area is used, the maximum seating surface
diameter (rather than the mean seat diameter) should be used.
The sign for FDP is as shown in the table below.
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
(NQY QXGT
(NQY WPFGT
(NQY QXGT
(NQY WPFGT
4GXGTUG #EVKPI
(NQY QXGT
(NQY WPFGT
(NQY QXGT
(NQY WPFGT
Equation 5.4 is applicable to single disc unbalanced disc globe valves in incompressible
flow applications. The NRC SE for the EPRI MOV Program (Reference 10.7) states that
the PPM is justified for use with globe valves with water at less than 150F. This
applicability range is based on testing of unbalanced disc globe valves in the EPRI MOV
Program. Only one globe valve was tested at elevated temperature. This valve was an
unbalanced disc, Y-pattern Rockwell-Edward globe valve tested under two-phase
flashing water conditions with flow underseat. The measured result for this test was
about 1.48 (Reference EPRI TR103674-V3P3). This component of thrust was 48% greater
than predicted (multiplied by 1.48). The most probable cause of the high thrust
requirement is that flashing of the fluid around the valve disc resulted in pressure
distributions that produced significant disc side loading. Disc-to-body friction then
caused the increased thrust requirements.
For globe valves with a design similar to the EPRI test valve and in applications similar
to the EPRI valve test conditions, applying the results of the EPRI test is considered to
be the best choice for determining thrust requirements. The following approach should
be used in applying this equation for unbalanced disc globe valve applications that
have a temperature of more than 150F or a fluid medium that is compressible (e.g., air,
steam or flashing water).
5-12
1. Use this equation multiplied by a factor of 1.5 based on the EPRI test result, for
valves that meet all of the following criteria.
- Valve is Y-pattern globe,
- disc is not guided within a cage,
- flow is opposing disc motion, and
- fluid is two-phase flashing water
This factor is applied for closing strokes with flow underseat and opening strokes
with flow overseat since the DP load resists disc motion. Because of the similarity to
the EPRI test valve and test conditions, this prediction is considered best available
information.
For strokes where the DP load assists disc motion (closing strokes with flow
overseat and opening strokes with flow underseat), the peak thrust occurs at the
fully open position, where the DP and DP load are essentially zero. For these strokes, the
DP load is not included in the required stem thrust, and these predictions are considered valid
(rather than best available information).
2. For other designs (e.g. T-Pattern globe valves), this equation should be used with no
factor applied (1.0). Based on engineering judgment, the disc side loading for other
designs is not as severe as for the EPRI test valve. Therefore, the EPRI test results
are not applied. Since the PPM methodology has not been formally approved by the
NRC above 150 F, this equation is considered best available information if the DP
load resists disc motion. As discussed above, if the DP load assists disc motion, the
DP load is not included in the required stem thrust, and the results are considered
valid.
5.4.1.8 Sealing Load (Closing Only)
Sealing load is only applicable for closing strokes, and the stem thrust due to sealing
load is zero at the fully open position. The stem thrust due to sealing load can be
calculated by the method listed below; however, there are alternate methods available.
FSL = (SSEAT * A SEAT )(sin + S cos )
(5.5)
2
2
A SEAT = OD SEAT
ID SEAT
4
(5.6)
Where:
Since sealing load always opposes disc motion, FSL is always positive. Typical values for
SSEAT are shown below (Reference 10.1).
5-13
2TGUUWTG VQ DG 5GCNGF
RUK
K
K
K
If the width of the valve seat is not known, a width of 1/16 inch should be assumed.
Values of S for Stellite seats are given in Section 5.5.2.
(5.7a)
(5.7b)
See Figure 5-2 for a free body diagram of the closing stroke of a balanced disc globe
valve.
FC
FP
F SR
FD F
FD F
FU S
FU S
FD S
FSL
FSL
FD P (Most Cases)
Figure 5-2
Free Body Diagram of a Balanced Globe Valve
5-14
(5.8)
FDS calculated from this equation can be positive or negative. The value calculated
should be multiplied by +1 or 1, as shown in the table below.
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
4GXGTUG #EVKPI
This equation is applicable at both the fully open and fully closed positions.
5.4.2.3 Packing Load
Packing load (FP) should be determined from static test data. If test data is not available,
values for packing load can be obtained from the valve or packing manufacturer.
Appendix C can also be used to determine packing load if none of the above are
available.
Since packing friction always opposes disc motion, FP is always positive. FP is
applicable at both the fully open and fully closed positions.
5.4.2.4 Upper Seal Friction Load
Upper seal friction load (FUS) should be determined from static test data. Note that static
test data typically yields information on the sum of the packing load and upper seal
friction load. If test data is not available, values for this load may be obtained from the
valve manufacturer.
Since upper seal friction load always opposes disc motion, FUS is always positive. FUS is
applicable at both the fully open and fully closed positions.
5.4.2.5 Stem Rejection Load
The stem thrust due to stem rejection load is calculated as follows.
FSR = (PB ) d S2
4
( )
(5.9)
5-15
At the fully closed position, the bonnet pressure, PB, is determined as follows.
(NQY &KTGEVKQP
7PFGTUGCV
1XGTUGCV
&KTGEV #EVKPI
72
72
&2
4GXGTUG #EVKPI
72
72
&2
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
72
&2
72
4GXGTUG #EVKPI
72
72
&2
The table above covers the conditions that apply the most resistance (or least assistance)
to the stem when the valve is fully open. If the specific system conditions at the valve
when it is fully open are known, a less conservative result may be obtained. For
example, if the bonnet pressure with the valve fully open is known, that pressure can be
used to calculate stem rejection load, rather than the value in the table above.
The sign for FSR is as shown in the table below.
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
4GXGTUG #EVKPI
This equation is applicable to globe valves that have a stem that penetrates the valve
pressure boundary. For other designs (e.g., valves with a diaphragm seal), the valve
manufacturer should be consulted to determine an appropriate method for determining
stem rejection load.
5.4.2.6 Disc-to-Body/Cage Friction Load
Disc-to-body/cage friction covers friction loads between the disc and the body guides,
stem bearing or cage, as applicable. Note that the sign of this term is always positive
since it always opposes disc motion.
For balanced disc globe valves, the stem thrust due to disc-to-body/cage friction load is
essentially zero at the fully open position since there is negligible DP across the valve
disc.
5-16
The stem thrust due to disc-to-body/cage friction load at the fully closed position is
calculated as follows (from Reference 10.6).
( )
Where,
G = 0.5039*(H2/dG) for flow overseat, and
G = 1.25*(H2/dG) for flow underseat
The side load factor, G, was developed from testing one Y-pattern balanced disc globe
valve with both overseat and underseat flow and is applicable for H2/dG ratios less
than or equal to 0.25. Accordingly, there is a technical basis tied to test data for
applying this correlation to both overseat and underseat flow. However, data from
testing of only one balanced disc globe valve was available for validation of the model
in the EPRI MOV Program. Since this valve was only tested with flow underseat, the
applicability of this equation is limited to valves with flow underseat. If the equation is
used for overseat flow, the results should be considered best available information.
As discussed above, data from the EPRI MOV Program has shown that thrust
requirements for unbalanced disc globe valves are higher for compressible flow. There
is no applicable data to determine if the disc guide/body friction load for balanced disc
globe valves is higher for compressible flow applications. If this equation is used for
compressible flow applications, the results should be considered best available
information.
This equation is based on testing of an un-caged Y-pattern globe valve. This equation is
judged to be bounding for other types of globe valves. However, some balanced disc
designs have features that are intended to minimize the disc side loading, for example,
a cage around the disc. As a result, this equation may provide an excessively
conservative prediction of disc-to-body/cage friction load. For some designs (e.g.,
valves that are cage-guided), users may choose to neglect disc-to-body/cage friction
loads until test data is available to more accurately predict this load. If the user chooses
to neglect side loading, the resulting prediction must be considered best available
rather than a design standard.
5.4.2.7 DP Load
For balanced disc globe valves, the stem thrust due to DP load is essentially zero at the
fully open position since there is negligible DP across the valve disc.
5-17
The stem thrust due to DP load at the fully closed position is calculated as follows:
FDP = (DP )(A I )
(5.11)
The imbalance area, AI, should be obtained from the valve manufacturer or from
vendor catalogues. For balanced disc valves, the pressure above the disc is the same as
the pressure below the disc. Therefore, imbalance DP loads result from differences in
the sealing areas at the top and bottom of the disc. The table below shows the direction
of the imbalance load for different flow configurations and relative sealing areas. Note
that in this Guide, the lower seal is the disc-to-body seat (normally Stellite), and the
upper seal is the sliding seal on the disc.
4GNCVKXG 5GCNKPI #TGCU
(NQY 7PFGTUGCV
CUUKUVU ENQUWTG
CUUKUVU QRGPKPI
(NQY 1XGTUGCV
CUUKUVU QRGPKPI
CUUKUVU ENQUWTG
For most balanced disc designs, the upper seal area is greater than the lower seal area
(seat area). In this case, the sign for FDP is as shown in the table below.
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
(NQY QXGT
(NQY WPFGT
(NQY QXGT
(NQY WPFGT
4GXGTUG #EVKPI
(NQY QXGT
(NQY WPFGT
(NQY QXGT
(NQY WPFGT
If the lower seal area is greater than the upper seal area, the sign for FDP is opposite of
that shown in the table above.
This equation is applicable to all balanced disc globe valves.
Use of the actual imbalance area represents a change from the approved PPM balanced
globe valve methodology. Accordingly, the results of the balanced globe valve
methodology described in this Guide must be considered best available information.
5.4.2.8 Sealing Load (Closing Only)
Sealing load is only applicable for closing strokes, and the stem thrust due to sealing
load is zero at the fully open position. The stem thrust due to sealing load is calculated
as follows.
5-18
(5.12)
2
2
A SEAT = OD SEAT
ID SEAT
4
(5.13)
Where:
Since sealing load always opposes disc motion, FSL is always positive. Typical values for
SSEAT are shown below (Reference 10.1).
2TGUUWTG VQ DG 5GCNGF
RUK
K
K
K
If the width of the valve seat is not known, a width of 1/16 inch should be assumed.
Values of S for Stellite seats are given in Section 5.5.2.
(5.14a)
(5.14b)
See Figure 5-3 for a free body diagram of the closing stroke of a balanced disc globe
valve with a pilot disc.
5-19
FSR
FDS
FP
FDF
FDF
FUS
FUS
FSL
FSF
FSL
Figure 5-3
Free Body Diagram of a Balanced Globe Valve with Pilot Disc
Two separate evaluations are required for these valves. The first evaluation covers the
main disc, which is a balanced disc valve because the pilot disc is in the open position
when the main disc strokes. The second evaluation covers the pilot disc, which is an
unbalanced disc because the main disc is in the closed position when the pilot disc
strokes. In general, these evaluations are performed as described in this Guide for
balanced and unbalanced disc valves. The sections below discuss any adjustments to
these approaches.
5.4.3.2 Disc and Stem Weight
For the main disc evaluation, the approach described in this Guide for balanced disc valves
should be used. For the pilot disc evaluation, the approach described in this Guide for
unbalanced disc valve should be used, except that the weight should not include the weight of
the main disc, i.e., WS should be used in place of WDS.
5.4.3.3 Packing Load
For the main disc evaluation, the approach described in this Guide for balanced disc
valves should be used. For the pilot disc evaluation, the approach described in this
Guide for unbalanced disc valve should be used.
5-20
(NQY &KTGEVKQP
7PFGTUGCV
1XGTUGCV
&KTGEV #EVKPI
72
72
&2
4GXGTUG #EVKPI
2
2 &2
72
72
*For valves with a port between the upstream area and the area above the
pilot disc, the larger of PUP and PUP-DP should be used.
This term is applicable for the pilot disc evaluation at the fully closed position and is set
to zero at fully open. These different pressures are used because the pilot disc strokes
after the main disc is closed, and there is typically no DP across the pilot disc.
5.4.3.6 Disc-to-Body/Cage Friction Load
For the main disc evaluation, the approach described in this Guide for balanced disc
valves should be used. For the pilot disc evaluation, the approach described in this
Guide for unbalanced disc valve should be used.
5.4.3.7 DP Load
For the main disc evaluation, the approach described in this Guide for balanced disc
valves should be used. For the pilot disc evaluation, the approach described in this
Guide for unbalanced disc valves should be used.
5.4.3.8 Sealing Load (Closing Only)
For the main disc evaluation, the approach described in this Guide for balanced disc
valves should be used. For the pilot disc evaluation, the approach described in this
Guide for unbalanced disc valve should be used.
5-21
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
4GXGTUG #EVKPI
The fully seated spring force can be obtained from the valve manufacturer or
determined from static test data.
(5.15a)
(5.15b)
See Figure 5-4 for a free body diagram of the closing stroke of a double seat globe valve.
5-22
FS R
FP
FSL
FSL
FD P
FD F
FD F
FSL
FSL
FD S
FD F
FD F
Figure 5-4
Free Body Diagram of a Double Seat Globe Valve
(5.16)
FDS calculated from this equation can be positive or negative. The value calculated
should be multiplied by +1 or 1, as shown in the table below.
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
4GXGTUG #EVKPI
This equation is applicable at both the fully open and fully closed positions.
5.4.4.3 Packing Load
Packing load (FP) should be determined from static test data. If test data is not available,
values for packing load can be obtained from the valve or packing manufacturer.
Since packing friction always opposes disc motion, FP is always positive. FP is
applicable at both the fully open and fully closed positions.
5-23
FSR = (PB ) d S2
4
( )
(5.17)
At the fully closed position, the bonnet pressure, PB, is determined as follows.
(NQY &KTGEVKQP
2CEMKPI FQYPUVTGCO
2CEMKPI WRUVTGCO
&KTGEV #EVKPI
72
&2
4GXGTUG #EVKPI
72
72
&2
72
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
72
&2
72
4GXGTUG #EVKPI
72
72
&2
The table above covers the conditions that apply the most resistance (or least assistance)
to the stem when the valve is fully open. If the specific system conditions at the valve
when it is fully open are known, a less conservative result may be obtained. For
example, if the bonnet pressure with the valve fully open is known, that pressure can be
used to calculate stem rejection load, rather than the value in the table above.
The sign for FSR is as shown in the table below.
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
4GXGTUG #EVKPI
This equation is applicable to globe valves that have a stem that penetrates the valve
pressure boundary. For other designs (e.g., valves with a diaphragm seal), the valve
manufacturer should be consulted to determine an appropriate method for determining
stem rejection load.
5-24
(5.18)
This equation is based on engineering judgment and adaptation on the side load
correlation for balanced disc globe valves. At this time, no test data is available to
validate this equation. The results should be considered best available information.
5.4.4.7 DP Load
For double seat globe valves, the stem thrust due to DP load is essentially zero at the
fully open position since there is negligible DP across the valve disc.
The stem thrust due to DP load at the fully closed position is calculated as follows.
FDP = (DP ) d 2FOD d 2P OD
4
(5.19)
The thrust obtained from this equation may be positive or negative, depending on the
relative size of dF-OD and dP-OD. This thrust should be multiplied by +1 or 1, as shown in
the table below.
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
&KTGEV #EVKPI
4GXGTUG #EVKPI
5-25
(5.20)
Where:
[(
A SEAT = d 2F OD d 2F ID + d 2P OD d 2P ID
4
) (
)]
Since sealing load always opposes disc motion, FSL is always positive. Typical values for
SSEAT are shown below (Reference 10.1).
2TGUUWTG VQ DG 5GCNGF
RUK
K
K
K
If the width of the valve seat is not known, a width of 1/16 inch should be assumed.
Values of S for Stellite seats are given in Section 5.5.2.
(5.22a)
5-26
(5.22b)
FS R
FP
FD S
FSL
FSL
FD P
FDF
FDF
Figure 5-5
Free Body Diagram of a Three Way Globe Valve
The equations presented in this Guide for three-way globe valves are applicable to
designs that have a common port that is in-line with one of the other ports. The port
that is in-line with the common port is designated port 1; the disc that seals port 1 is
designated disc 1. The port that is perpendicular to the common port is designated port
2; the disc that seals port 2 is designated disc 2. Flow through these valves may be
diverging (common port upstream) or converging (common port downstream).
Three-way valves do not have an opening or closing stroke because port 1 is
opened as port 2 is closed, and vice versa. In this Guide, the stroke direction is
considered opening if stem tension is required to stroke the valve and closing if
stem compression is required. The terms direct acting valve and reverse acting
valve are not applicable to three-way globe valves. For either stroke direction
(opening or closing), two evaluations of required thrust are needed one at each
extreme of disc travel. One extreme is designated flow straight through, indicating
that the discs are positioned such that flow is allowed between the common port and
port 1 but not between the common port and port 2. The other extreme is designated
angle flow, indicating that the discs are positioned such that flow is allowed between
the common port and port 2 but not between the common port and port 1.
5.4.5.2 Disc and Stem Weight
The stem thrust due to disc and stem weight is calculated as follows.
FDS = (WDS )(cos )
(5.23)
FDS calculated from this equation can be positive or negative. The value calculated
should be multiplied by +1 or 1, as shown in the table below.
5-27
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
(CEVQT
This equation is applicable at both the flow straight through and angle flow positions.
5.4.5.3 Packing Load
Packing load (FP) should be determined from static test data. If test data is not available,
values for packing load can be obtained from the valve or packing manufacturer.
Since packing friction always opposes disc motion, FP is always positive. FP is
applicable at both the flow straight through and angle flow positions.
5.4.5.4 Upper Seal Friction Load
Upper seal friction load (FUS) is not applicable to three-way globe valves.
5.4.5.5 Stem Rejection Load
The stem thrust due to stem rejection load is calculated as follows.
FSR = (PB ) d S2
4
( )
(5.24)
The bonnet pressure, PB, is always the pressure in port 1. At the flow straight through
position, PB should be set to P11; at the angle flow position, PB should be set to P12.
The sign for FSR is as shown in the table below.
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
5KIP
This equation is applicable only to globe valves that have a stem that penetrates the
valve pressure boundary. For other designs (e.g., valves with a diaphragm seal), the
valve manufacturer should be consulted to determine an appropriate method for
determining stem rejection load.
5-28
(5.25a)
(5.25b)
These equations are based on engineering judgment and adaptation on the side load
correlation for balanced disc globe valves. At this time, no test data is available to
validate these equations. The results should be considered best available
information.
5.4.5.7 DP Load
The stem thrust due to DP load is calculated as follows for three-way globe valves.
At the flow straight through position:
)]
(5.26a)
)]
(5.26b)
The thrusts obtained from these equations may be positive or negative, depending on
the relative size of the discs. These thrusts should be multiplied by +1 or 1, as shown
in the table below.
5-29
5VTQMG &KTGEVKQP
1RGPKPI
%NQUKPI
(CEVQT
(5.27)
Where:
At the flow straight through position:
A SEAT = d 22OD d 22 ID
4
(5.28a)
(5.28b)
Since sealing load always opposes disc motion, FSL is always positive. Typical values
for SSEAT are shown below (Reference 10.1).
2TGUUWTG VQ DG 5GCNGF
RUK
K
K
K
If the width of the valve seat is not known, a width of 1/16 inch should be assumed.
Values of S for Stellite seats are given in Section 5.5.2.
valves, and Westinghouse gate valves. The gate valve performance prediction
methodology has been validated against full scale flow loop and in situ value data and
has been approved as a design standard by the Nuclear Regulatory Commission. If the
PPM is used, adjustments to the inputs should be made to minimize the torque reaction
friction effect, which is applicable to MOVs but not AOVs. For solid and flexible wedge
gate valves for which the PPM software is used, the following adjustments should be
made.
For Anchor/Darling double disc, Aloyco split wedge, and Westinghouse gate valves,
PPM hand-calculation methods are implemented. For these calculations, the torque
reaction factor (TRF) should be set to 1.
Use of the PPM for evaluation of required stem thrust is recommended in cases where
insufficient test data is available to accurately define the seat friction coefficient (and
corresponding valve factor) for the valve and conditions (media, temperature) under
evaluation or in cases where high valve flowrates are to be evaluated. If such data is
available and nominal flowrates are to be evaluated, an alternative approach (Valve
Factor Method) can be applied (See Section 5.5.3).
( )
(5.29)
5-31
Where:
2
2
A SEAT = OD SEAT
ID SEAT
4
(5.30)
The value for S can be obtained from valve specifications or conservative estimations.
K
K
K
K
K
K
5VGCO (NQY
Since the sealing load always opposes disc motion, FSL is always positive. Note that if
FSL is calculated to be negative, it should be set to zero. Typical values for SSEAT are
shown below (Reference 10.1). However, adequate sealing can be obtained at lower
values of seating stress. Based on successful experience, other lower values can be used.
2TGUUWTG VQ DG 5GCNGF
RUK
K
K
K
Fo = Fp +
(5.31)
or
Fc = Fp
(5.32)
where
Fo =
Fc =
Fp =
ds =
Pup =
dms =
DP =
VF =
The valve factor (VF) for gate valves can be determined by first determining the disc-toseat friction coefficient (s) using methods described in Section 8 of the EPRI MOV
Performance Prediction Program Implementation Guide, Reference 10.2. Once the discto-seat friction coefficient has been determined, the corresponding valve factor can be
evaluated as follows:
VF =
s
cos + s sin
for opening
(5.33)
VF =
s
cos s sin
for closing
(5.34)
where
= wedge half angle, degrees
5-33
The stem thrust due to the unwedging load is calculated as follows (Reference 10.2) at
the fully closed position.
(5.35)
Since the unwedging load always opposes disc motion, FUW is always positive. B and C
are constants that depend on the half-wedge angle (), as shown below.
FGITGGU
The unwedging load calculated above should not be added to any other thrust
components. FUW should be compared directly to the available thrust from the actuator
to ensure the valve has margin for unwedging.
Note that this equation can be implemented several ways. The actual valve closure
thrust (maximum closing thrust achieved during the most recent static stroke) can be
used as FCT to obtain a predicted unwedging load based on current valve setup.
However, the recommended approach is to use the maximum allowable valve closure
thrust as FCT. The resulting predicted unwedging thrust then covers any valve setup, as
long as the maximum allowable valve closure thrust is not exceeded. If the predicted
unwedging load exceeds the actuator capability using this approach, then this equation
can be used to determine a new maximum allowable closing thrust to ensure positive
margin for unwedging.
Symmetric disc
5-34
The PPM butterfly valve methodology has been validated against flow loop and in situ
tests of butterfly valves and has been approved as a design standard by the Nuclear
Regulatory Commission. The PPM methodology covers the following torque
components.
Seat torque, TS
Bearing torque, TB
Hydrodynamic torque, TH
Butterfly valve required torque is proportional to the DP across the valve disc, except
for the seat torque. The approach used in the PPM is to calculate two torque
requirements one at seating and one away from seating. At seating, all torque
components are included except for hub seal and hydrodynamic torques. Away from
seating, only the packing, hub seal, bearing and hydrodynamic torques are included.
The torque at seating can only occur at the fully closed position; the torque away from
seating could occur within a range of possible stroke positions.
(5.36a)
TO = TP + TSS + TB + TH
(5.36b)
5-35
5.7.1.2 Closing
TC = TP + TSS + TDS
(5.37a)
TC = TP + TSS + TB
(5.37b)
Packing torque, TP
Bearing torque, TB
Hydrodynamic torque, TH
Ball valve required torques are proportional to the DP across the valve disc. The
approach used in this Guide for hydrodynamic torque is to combine the maximum
hydrodynamic torque for the entire stroke with the maximum values of the other torque
components. In this way, the maximum required torque is determined. This maximum
torque would only be expected to occur near the fully closed position. The maximum
torque that would be expected at the fully open position is the sum of the packing, static
seat, and hydrodynamic torques.
The sections below discuss the four torque components as they apply to the two ball
valve types. Note that all torques are positive, indicating that the actuator must provide
torque to overcome each component.
5-36
TDS =
d 2B d 2MS
* S *
d B + d 2B d 2MS
48
(5.38)
For trunnion ball valves, the stem torque due to dynamic friction from the seats is zero
since the DP load is reacted by the bearings.
TB = (DP ) d 2MS ( B ) S
4
24
( )
( )
1
HTF 3
TH = (DP )
dP
12
100
(5.40)
The method in this Guide is not applicable for compressible flow. For incompressible
flow, the hydrodynamic torque factor, HTF, is determined from Figure 5-6, using the
equivalent system resistance, KSYS, which is calculated using the following equation.
894.01 * d 4P * DP 62.4
K SYS =
2
MAX
(5.41)
5-37
6.00
5.00
HTF
4.00
3.00
2.00
1.00
0.00
0
100
200
300
400
500
600
700
Figure 5-6
Hydrodynamic Torque Factor vs Equivalent System Resistance
5-38
6
EVALUATION OF VALVE / ACTUATOR RATED AND
SURVIVABLE THRUST AND TORQUE
Stem
Stem Coupling
Disc
Seat
Stop Blocks
6-2
7
EVALUATION OF AIR ACTUATOR OUTPUT THRUST /
TORQUE CAPABILITY
The results of this section will be used to evaluate margins in Section 8. Calculation
worksheets for the equations presented in this section are provided in Appendix B.
7-1
7-2
Table 7.1 is a list of the Parameters used in the equations in the following sections and
the worksheets in Appendix B.
Table 7-1
Parameter Definitions
Symbol
Definition
Units
degrees
none
Aext
in2
none
Aret/tol
Atol
none
in
BSLower
psig
BStol
none
BSU/max
The minimum and maximum force stored in the actuator when the
spring is fully compressed (full compression based on valve stroke
length). This variable is used for calculating the actuator output.
lbf
Aret
Aext/tol
BSU/min
psig
Distance from the piston or diaphragm actuator center line to the center
line of the lever or gear pivot.
in
in
7-3
Symbol
Definition
Units
in
DPA
psid
DPA/max
DPA/min
DPG
in
FA/max
Maximum Actuator Output for rising stem valves. Used for the
structural margins.
lbf
FA/min
lbf
FD
lbf
Stroke Length used for actuator analysis. Either the smaller of the valve
rated travel, actuator rated travel, or the truncated stroke length if the
actuator stops are adjusted to limit valve stroke.
in
LBS
Actuator Length of travel for setting the benchset. This may or may not
be the same as L.
in
Npiston
none
PAdrift
none
PA
psig
PA/max
PA/min
7-4
Symbol
Definition
Units
PA/tol
none
PD
psig
SP
lbf
SP/max
SP/min
none
Note: The nominal value should include any spring degradation which
may occur.
SP/tol
SR
SR/max
SR/min
SR/deg
none
SR/tol
none
TA/max
Maximum Actuator Output for rising stem valves. Used for the
structural margins.
in-lbf
TA/min
in-lbf
lbf/in
7-5
ACTUATOR TYPE
(Rising Stem)
DIAPHRAGM
ACTUATOR
No Increased
Mechanical
Advantage
AIR CYLINDER
ACTUATOR
Increased
Mechanical
Advantage
Double
Acting
No
Spring
Direct
Acting
Reverse
Acting
Direct
Acting
Reverse
Acting
Single
Ended
See Sect.
7.2.1.2.1
& App. B
Table
B.3
See Sect.
7.2.1.2.2
& App. B
Table
B.4
See Sect.
7.2.1.2.3
& App. B
Table
B.5
See Sect.
7.2.1.2.4
& App. B
Table
B.6
See Sect.
7.2.1.1.1
& App. B
Table
B.1
Figure 7-1
Rising Stem Actuator Type Flowchart
7-6
Double
Ended
See Sect.
7.2.1.1.2
& App. B
Table
B.1
Single
Acting
Spring
Assisted
Direct
Acting
Reverse
Acting
Direct
Acting
Reverse
Acting
See Sect.
7.2.1.1.3
& App. B
Table
B.1
See Sect.
7.2.1.1.4
& App. B
Table
B.1
See Sect.
7.2.1.1.5
& App. B
Table
B.2
See Sect.
7.2.1.1.6
& App. B
Table
B.2
VALVE TYPE
(Rising Stem)
DIRECT ACTING
(push-down-to-close)
REVERSE ACTING
(push-down-to-open)
Fully Extended:
Fully Extended:
Fully Retracted:
Extend:
Note 1: Fully Extended is the actuator output as the actuator stem reaches the fully extended position (also refer to Figure 7.3).
Fully Retracted is the actuator output as the actuator stem reaches the fully retracted position.
Retract is the actuator output as the actuator stem just begins to retract.
Extend is the actuator output as the actuator stem just begins to extend.
Note 2: The actuator output to Fully Extended and Retract are both at the actuator fully extended position. However, the actuator
output is calculated differently since one may be a pressure stroke and the other one a spring stroke. Similarly, the actuator
output to Fully Retracted and Extend are both at the actuator fully retracted position but are calculated differently.
Figure 7-2
Rising Stem Valve and Actuator Position Correlation Flowchart
7-7
ACTUATOR POSITIONS
Fully
Retracted
Extend
Fully
Extended
Valve Fully Closed
Retract
Figure 7-3
Valve and Actuator Position Correlation Flowchart
7-8
Fully
Retracted
Extend
Fully
Extended
Valve Fully Open
Retract
ACTUATOR TYPE
(Quarter Turn)
SCOTCH
YOKE
DIAPHRAGM
ACTUATOR
Double
Acting
(No Spring)
Single
Acting
Direct
Acting
See Sect.
7.2.1.3.1
& App. B
Table
B.7
See Sect.
7.2.1.3.2
& App. B
Table
B.8
See Sect.
7.2.1.4
& App. B
Table
B.9
Reverse
Acting
See Sect.
7.2.1.4
& App. B
Table
B.10
Double
Acting
(No Spring)
Single
Acting
See Sect.
7.2.1.5.1
& App. B
Table
B.11
See Sect.
7.2.1.5.2
& App. B
Table
B.12
Figure 7-4
Quarter Turn Actuator Type Flowchart
7-9
AOV CONFIGURATION
(Quarter Turn)
Actuator Pressure
Closes Valve
For comparison
with Minimum
Required Torque
in the Opening
direction (evaluate
at each angle).
Actuator Pressure
Opens Valve
For comparison
with Minimum
Required Torque
in the Closing
direction (evaluate
at each angle).
Figure 7-5
Quarter Turn Valve and Actuator Position Correlation Flowchart
7-10
Actuator Pressure
Opens & Closes Valve
Double Acting Air Cylinder, Direct Acting (spring to retract actuator stem)
Double Acting Air Cylinder, Reverse Acting (spring to extend actuator stem)
Single Acting Air Cylinder, Direct Acting (spring to retract actuator stem)
Single Acting Air Cylinder, Reverse Acting (spring to extend actuator stem)
7.2.1.1.1 Double Acting Air Cylinder, Single Ended
Available output force of a double acting air cylinder actuator is essentially constant
and linear throughout its stroke (see Figure 7-6). When air pressure is acting on the top
(non-rod side) of the piston, available force is represented by the solid line (see Figures
7-6 and 7-7). This stroke direction is referred to as the rod extension stroke. When air
pressure is acting from the under side (rod side) of the piston, available force is
represented by the dashed line (see Figures 7-6 and 7-8). This stroke direction is
referred to as the rod retraction stroke. The only difference between the extending and
retracting strokes is the loss of the piston rod area when pressure is applied to the rod
side of the piston. Therefore, if air supply pressure is equal for both the rod extension
and rod retraction strokes, the actuator will have less output capability during the rod
retraction stroke due to the loss in piston rod area.
7-11
DA CYLINDER
AVAILABLE
FORCE
PUSH
PULL
100
% TRAVEL
Figure 7-6
Available Force Plot for Double Acting Air Cycinder
PA
PATM
PATM
PA
FA
FA
Figure 7-7
Double Acting Air Cylinder,Rod
Extension
Figure 7-8
Double Acting Air Cylinder, Rod
Retraction
Extend and Fully Extended Positions. The minimum and maximum1 force output to
extend and fully extend the actuator stem of a double acting air cylinder is:
FA/min =
(7.1)
The breakaway force is intended to account for the parasitic effect of the internal static friction of the cylinder
actuator. For conservatism, the piston breakaway force is not subtracted from the maximum output force (FA/max).
7-12
FA/max =
D 2 DPA/max (1 + PA drift )
4
(7.2)
Retract and Fully Retracted Positions. The minimum and maximum1 force output to
retract and fully retract the actuator stem of a double acting air cylinder is:
(7.3)
(7.4)
FA/min =
D 2 d2 DPA/min (1 PA drift ) FD
4
FA/max =
D2 PD
4
(7.5)
For the rod side of the piston, the piston breakaway force is:
FD =
D 2 d2 PD
4
(7.6)
Or, for simplicity and conservatism, Equation 7.5 can be used for both stroke directions.
The minimum and maximum supply differential air pressures are calculated as follows:
DPA /min = DPA (1 PA / tol )
(7.7)
(7.8)
The differential pressure may be the same or different for the extending and retracting
strokes. If different, the minimum and maximum differential pressures should be
calculated for each stroke position (fully extended, fully retracted, extended, and
retracted) and applied to the appropriate actuator output (actuator output to fully
extend, fully retract, extend, and retract).
7.2.1.1.2 Double Acting Air Cylinder, Double Ended
The double acting, double ended cylinder actuator (Figure 7-9) works the same way as
the single ended, double acting actuator (see previous section). The difference between
the double ended and single ended styles is the output capability for the rod extension
stroke. The actuator output for the rod extension stroke of the double ended actuator is
the same as the actuator output for the rod retraction stroke, assuming the actuator rod
is of the same diameter on both ends of the cylinder head. This is due to both ends of
7-13
the actuator stem being exposed to atmospheric pressure. The equations for the double
acting, double ended style actuator are provided below.
Figure 7-9
Double Acting Air Cylinder, Double Ended
All Positions. The minimum and maximum2 force output of a double acting, double
ended air cylinder at all positions of the actuator stem (to extend, retract, fully extend,
and fully retract) is:
(7.9)
(7.10)
FA/min =
D 2 d2 DPA/min (1 PA drift ) FD
4
FA/max =
The piston breakaway force and differential air pressure are calculated as follows:
FD :
DPA/min :
DPA/max :
The breakaway force is intended to account for the parasitic effect of the internal static friction of the cylinder
actuator. For conservatism, the piston breakaway force is not subtracted from the maximum output force (FA/max).
7-14
For a double acting, spring assisted air cylinder (spring to retract), pressure is used to
extend the actuator stem, whereas both pressure and spring force are used to retract the
actuator stem (Figure 7-10).
Figure 7-10
Double Acting Air Cylinder, Direct Acting
Fully Extended Position. The minimum and maximum3 force output to fully extend the
actuator stem of a double acting, spring assisted (spring to retract) air cylinder is:
(7.11)
(7.12)
Fully Retracted Position. The minimum and maximum3 force output to fully retract the
actuator stem of a double acting, spring assisted air cylinder (spring to retract) is:
(7.13)
(7.14)
Retract Position. The minimum and maximum3 force output to retract the actuator stem
of a double acting, spring assisted air cylinder (spring to retract) is:
The breakaway force is intended to account for the parasitic effect of the internal static friction of the cylinder
actuator. For conservatism, the piston breakaway force is not subtracted from the maximum output force (FA/max).
7-15
(7.15)
(7.16)
Extend Position. The minimum and maximum3 force output to extend the actuator
stem of a double acting, spring assisted air cylinder (spring to retract) is:
(7.17)
(7.18)
The piston breakaway force and differential air pressure are calculated as follows:
FD :
DPA/min :
DPA/max :
Two methods can be used to calculate the minimum and maximum spring preload.
These methods are:
1. Spring preload and tolerance (measured or vendor supplied)
2. Lower benchset (i.e., pressure at which the actuator begins its stroke while
uncoupled from the valve) and tolerance (measured or vendor supplied)
Option 1: Spring Preload and Tolerance
SP/min = SP (1 SP/ tol )
SP/max = SP (1 + SP/ tol )
(7.20)
(7.19)
(7.21)
(7.22)
Two methods can be used to calculate the minimum and maximum spring rate:
1. Spring rate and tolerance (measured or vendor supplied)
2. Upper and Lower benchset and tolerance (measured or vendor supplied)
Option 1: Spring Rate and Tolerance
SR/min = SR (1 SR/ tol )
(7.23)
(7.24)
(7.25)
SR/max =
(7.26)
Two methods can be used to calculate the minimum and maximum compressed spring
force. These methods are:
1. Spring preload and rate
2. Upper benchset (i.e., pressure at which the actuator is at full rated valve travel while
uncoupled from the valve) and tolerance (measured or vendor supplied)
Option 1: Spring Preload and Rate
) )
(7.27)
(7.28)
where
SP/min, SP/max, SR/min, SR/max are calculated in the above equations
7-17
D2
4
(7.29)
D2
4
(7.30)
Caution: In the majority of actuator designs in nuclear power plants, the benchset is set
when the valve and actuator are uncoupled. If the valve and actuator are coupled when
setting the benchset, Spring Preload, Spring Rate, and Upper Benchset, Option 2
(Equations 7.21, 7.22, 7.25, 7.26, 7.29, and 7.30) should not be used since the benchset
pressure will include valve loads as well as spring force. This could produce false
results. Option 2 can be used if using the vendor supplied benchset since this value
typically is for the uncoupled configuration.
7.2.1.1.4 Double Acting Air Cylinder, Reverse Acting (Spring to Extend)
For a double acting, spring assisted air cylinder (spring to extend), pressure is used to
retract the actuator stem and pressure and spring force are both used to extend the
actuator stem (Figure 7-11).
Figure 7-11
Double Acting Air Cylinder, Reverse Acting
7-18
Fully Extended Position. The minimum and maximum4 force output to fully extend the
actuator stem of a double acting, spring assisted air cylinder (spring to extend) is:
(7.31)
(7.32)
Fully Retracted Position. The minimum and maximum4 force output to fully retract the
actuator stem of a double acting, spring assisted air cylinder (spring to extend) is:
(7.33)
(7.34)
Retract Position. The minimum and maximum4 force output to retract the actuator stem
of a double acting, spring assisted air cylinder (spring to extend) is:
(7.35)
(7.36)
Extend Position. The minimum and maximum4 force output to extend the actuator stem
of a double acting, spring assisted air cylinder (spring to extend) is:
(7.37)
(7.38)
The piston breakaway force and differential air pressure are calculated as follows:
FD :
The breakaway force is intended to account for the parasitic effect of the internal static friction of the cylinder
actuator. For conservatism, the piston breakaway force is not subtracted from the maximum output force (FA/max).
7-19
DPA/max :
Two methods can be used to calculate the minimum and maximum spring preload.
These methods are:
1. Spring preload and tolerance (measured or vendor supplied)
2. Lower benchset and tolerance (measured or vendor supplied)
Option 1: Spring Preload and Tolerance
SP/min = SP (1 SP/tol )
(7.39)
(7.40)
(7.41)
(7.42)
Two methods can be used to calculate the minimum and maximum spring rate:
1. Spring rate and tolerance (measured or vendor supplied)
2. Upper and Lower benchset and tolerance (measured or vendor supplied)
Option 1: Spring Rate and Tolerance
SR/min = SR (1 SR/ tol )
(7.43)
(7.44)
7-20
) (
) (
SR/min =
SR/max =
(7.45)
(7.46)
Two methods can be used to calculate the minimum and maximum compressed spring
force:
1. Spring preload and rate
2. Upper benchset and tolerance (measured or vendor supplied)
Option 1: Spring Preload and Rate
) )
(7.47)
(7.48)
where,
SP/min, SP/max, SR/min, and SR/max are calculated from the above equations.
Option 2: Upper Benchset and Tolerance {see Caution below}
(7.49)
(7.50)
D 2 d2
4
D 2 d2
4
Caution: In the majority of actuator designs in nuclear power plants, the benchset is set
when the valve and actuator are uncoupled. If the valve and actuator are coupled when
setting the benchset, Spring Preload, Spring Rate and Upper Benchset Option 2
(Equations 7.41, 7.42, 7.45, 7.46, 7.49, and 7.50) should not be used since the benchset
pressure will include valve loads as well as spring force. This could produce false
results. Option 2 can be used if using the vendor supplied benchset since this value
typically is for the uncoupled configuration.
7.2.1.1.5 Single Acting Air Cylinder, Direct Acting (Spring to Retract)
The available force output of a direct acting cylinder actuator is essentially linear (but
not constant) throughout its stroke (Figure 7-12). For the direct acting type, the spring
is installed on the rod side of the piston. When air pressure is acting on top (non-rod
7-21
side) of the piston (Figure 7-13), the available force is represented by the solid line.
During the spring stroke (Figures 7-14 and 7-15), the available output force is
represented by the dashed line.
AVAILABLE
FORCE
SPRING
STROKE
PA
PRESSURE
STROKE
0
% RETRACT
100
Figure 7-12
Available Force Plot for Single
Acting Air Cylinder
PATM
FA
Figure 7-13
Single Acting Air Cylinder,
Direct Acting, Fully Extended
PATM
PATM
P ATM
PATM
FA
Figure 7-14
Single Acting Air Cylinder,
Direct Acting, Retracted
FA
Figure 7-15
Single Acting Air Cylinder,
Direct Acting, Fully Retracted
Fully Extended Position. The minimum and maximum5 force output to fully extend the
actuator stem of a direct acting air cylinder is:
The breakaway force is intended to account for the parasitic effect of the internal static friction of the cylinder
actuator. For conservatism, the piston breakaway force is not subtracted from the maximum output force (FA/max).
7-22
(7.51)
(7.52)
Fully Retracted Position. The minimum and maximum5 force output to fully retract the
actuator stem of a direct acting air cylinder is:
FA /min = SP/min FD
(7.53)
FA /max = SP/max
(7.54)
Retract Position. The minimum and maximum5 force output to retract the actuator stem
of a direct acting air cylinder is:
FA /min = BSU/min FD
(7.55)
FA /max = BSU/max
(7.56)
Extend Position. The minimum and maximum5 force output to extend the actuator
stem of a direct acting air cylinder is:
FA /min =
(7.57)
FA /max =
(7.58)
(7.59)
PA /max = PA (1 + PA / tol )
(7.60)
7-23
Two methods can be used to calculate the minimum and maximum spring preload, the
minimum and maximum spring rate, and the minimum and maximum compressed
spring load. These methods are:
SP/min (Option 1):
Available force of a spring return air cylinder actuator is essentially linear (but not
constant) throughout its stroke (Figure 7-16). For the reverse acting type, the spring is
installed on the non-rod side of the piston. During the spring stroke (Figure 7-17),
available force is represented by the dashed line. When air pressure is acting from
under the piston (Figures 7-18 and 7-19), available force is represented by the solid line.
AVAILABLE
FORCE
PRESSURE
STROKE
SPRING
STROKE
% RETRACTED
100
Figure 7-16
Available Force Plot for Single Acting Air Cylinder, Reverse Acting
7-24
ATM
P ATM
FA
Figure 7-17
Single Acting Air Cylinder, Reverse Acting, Fully Extended
FA
Figure 7-18
Single Acting Air Cylinder,
Reverse Acting Retractedt
PATM
PATM
PA
PA
FA
Figure 7-19
Single Acting Air Cylinder,
Reverse Acting, Fully Retracted
Fully Extended Position. The minimum and maximum6 force output to fully extend the
actuator stem of a reverse acting air cylinder is:
FA /min = SP/min FD
(7.61)
FA /max = SP/max
(7.62)
Fully Retracted Position. The minimum and maximum6 force output to fully retract the
actuator stem of a reverse acting air cylinder is:
The breakaway force is intended to account for the parasitic effect of the internal static friction of the cylinder
actuator. For conservatism, the piston breakaway force is not subtracted from the maximum output force (FA/max).
7-25
(7.63)
(7.64)
Retract Position. The minimum and maximum6 force output to retract the actuator stem
of a reverse acting air cylinder is:
FA /min =
FA /max =
(7.65)
(7.66)
Extend Position. The minimum and maximum6 force output to extend the actuator
stem of a reverse acting air cylinder is:
FA /min = BSU/min FD
(7.67)
FA /max = BSU/max
(7.68)
The piston breakaway force and actuator supply pressure are calculated as follows:
FD :
PA/min :
PA/max :
Two methods can be used to calculate the minimum and maximum spring preload, the
minimum and maximum spring rate, and the minimum and maximum compressed
spring load. These methods are:
7-26
Available force of a direct acting diaphragm actuator is linear throughout its stroke
(Figure 7-20). When air pressure is acting on top of the diaphragm (Figure 7-21),
available force is represented by the solid line. During the spring stroke (Figures 7-22
and 7-23), available force is represented by the dashed line.
AVAILABLE
FORCE
SPRING
STROKE
PRESSURE
STROKE
0
% RETRACTED
100
Figure 7-20
Available Force Plot for Diaphragm Actuator
7-27
PA
P A TM
FA
Figure 23
Figure 7-21
Diaphragm Actuator, Fully Extended
P A TM
P A TM
P A TM
P A TM
FA
Figure 24
Figure 7-22
Diaphragm Actuator , Retractedt
FA
F igure 25
Figure 7-23
Diaphragm Actuator, Fully
Retracted
Fully Extended Position. The minimum and maximum force output to fully extend the
actuator stem of a direct acting diaphragm actuator is:
[
]
FA /max = [PA /max (1+ PA drift ) A ext (1 + A ext / tol )] BSU/min
FA /min = PA /min (1 PA drift ) A ext (1 A ext / tol ) BSU/max
(7.69)
(7.70)
Fully Retracted Position. The minimum and maximum force output to fully retract the
actuator stem of a direct acting diaphragm actuator is:
7-28
(7.73)
FA /max = BSU/max
(7.74)
Extend Position. The minimum and maximum force output to extend the actuator stem
of a direct acting diaphragm actuator is:
FA /min = PA /min (1 PA drift ) A ret (1 A ret / tol ) SP/max
(7.75)
(7.76)
(7.77)
PA /max = PA (1 + PA / tol )
(7.78)
Two methods can be used to calculate the minimum and maximum spring preload.
These methods are:
1. Spring preload and tolerance (measured or vendor supplied)
2. Lower benchset and tolerance (measured or vendor supplied)
Option 1: Spring Preload and Tolerance
SP/min = SP (1 SP/tol )
(7.79)
(7.80)
(7.81)
(7.82)
Two methods can be used to calculate the minimum and maximum spring rate:
1. Spring rate and tolerance (measured or vendor supplied)
2. Upper and Lower benchset and tolerance (measured or vendor supplied)
7-29
(7.83)
(7.84)
SR/max =
( BS
Upper
)) (
(BSUpper Aext (1+ Aext / tol ) BSLower Aret (1 Aret / tol )) (1+ BStol )
LBS
(7.85)
(7.86)
Two methods can be used to calculate the minimum and maximum compressed spring
force:
1. Spring preload and rate
2. Upper benchset and tolerance (measured or vendor supplied)
Option 1: Spring Preload and Rate
) )
(7.87)
(7.88)
where
SP/min, SP/max, SR/min, and SR/max are calculated from the
above equations.
Option 2: Upper Benchset and Tolerance {see Caution below}
BSU/min = BSUpper (1 BS tol ) A ext (1 A ext / tol )
(7.89)
(7.90)
Caution: In the majority of actuator designs in nuclear power plants, the benchset is set
when the valve and actuator are uncoupled. If the valve and actuator are coupled when
setting the benchset, Spring Preload, Spring Rate, and Upper Benchset, Option 2
7-30
(Equations 7.81, 7.82, 7.85, 7.86, 7.89, and 7.80) should not be used since the benchset
pressure will include valve loads as well as spring force. This could produce false
results. Option 2 can be used if using the vendor supplied benchset since this value
typically is for the uncoupled configuration.
7.2.1.2.2 Reverse Acting Diaphragm (Spring to Extend)
Available force of a reverse acting diaphragm actuator is linear throughout its stroke
(Figure 7-24). During the spring stroke (Figure 7-25), available force is represented by
the dashed line. When air pressure is acting from under the diaphragm (Figures 7-26
and 7-27), available force is represented by the solid line.
AVAILABLE
FORCE
PRESSURE
STROKE
SPRING
STROKE
0
% RETRACTED
100
Figure 7-24
Available Force Plot for Reverse Acting Diaphragm
PATM
P ATM
FA
Figure 7-25
Reverse Acting Diaphragm, Fully Extended
7-31
PATM
FA
PA
Figure 7-26
Reverse Acting
Diaphragm, Retracted
P ATM
PA
FA
Figure 7-27
Reverse Acting
Diaphragm, Fully Retracted
Fully Extended Position. The minimum and maximum force output to fully extend the
actuator stem of a reverse acting diaphragm actuator is:
FA /min = SP/min
(7.91)
FA /max = SP/max
(7.92)
Fully Retracted Position. The minimum and maximum force output to fully retract the
actuator stem of a reverse acting diaphragm actuator is:
)]
(7.93)
)]
(7.94)
7-32
Retract Position. The minimum and maximum force output to retract the actuator stem
of a reverse acting diaphragm actuator is:
(7.95)
(7.96)
Extend Position. The minimum and maximum force output to extend the actuator stem
of a reverse acting diaphragm actuator is:
FA /min = BSU/min
(7.97)
FA /max = BSU/max
(7.98)
(7.99)
PA /max = PA (1 + PA / tol )
(7.100)
Two methods can be used to calculate the minimum and maximum spring preload:
1. Spring preload and tolerance (measured or vendor supplied)
2. Lower benchset and tolerance (measured or vendor supplied)
Option 1: Spring Preload and Tolerance
SP/min = SP (1 SP/tol )
(7.101)
(7.102)
(7.103)
7-33
(7.104)
Two methods can be used to calculate the minimum and maximum spring rate:
1. Spring rate and tolerance (measured or vendor supplied)
2. Upper and Lower benchset and tolerance (measured or vendor supplied)
Option 1: Spring Rate and Tolerance
SR/min = SR (1 SR/ tol )
(7.105)
(7.106)
SR/max =
( BS
Upper
)) (
)) (
(7.107)
LBS
(BS
Upper
(7.108)
Two methods can be used to calculate the minimum and maximum compressed spring
force:
1. Spring preload and rate
2. Upper benchset and tolerance (measured or vendor supplied)
Option 1: Spring Preload and Rate
) )
(7.109)
(7.110)
where
SP/min, SP/max, SR/min, and SR/max are calculated from the above equations.
Option 2: Upper Benchset and Tolerance {see Caution below}
7-34
(7.111)
(7.112)
Caution: In the majority of actuator designs in nuclear power plants, the benchset is set
when the valve and actuator are uncoupled. If the valve and actuator are coupled when
setting the benchset, Spring Preload, Spring Rate, and Upper Benchset, Option 2
(Equations 7.103, 7.104, 7.107, 7.108, 7.111, and 7.112) should not be used since the
benchset pressure will include valve loads as well as spring force. This could produce
false results. Option 2 can be used if using the vendor supplied benchset since this
value typically is for the uncoupled configuration.
7.2.1.2.3 Direct Acting Diaphragm (with Increased Mechanical Advantage)
Direct acting diaphragm actuators with a linkage arm (Figure 7-28) are used to increase
the actuator output for a given size actuator. The equations for this type of actuator are
the same as for the standard direct acting diaphragm actuator (Section 7.2.1.2.1) with
the exception of a multiplier (mechanical advantage). The actuator output equations
(FA/min and FA/max) are multiplied by the mechanical advantage. The mechanical
advantage varies throughout the stroke and is generally the greatest at the fully
extended position of the actuator rod. The equations for actuators with increased
mechanical advantage are provided as part of the worksheets in Appendix B.
Figure 7-28
Direct Acting Diaphragm with Link Arm
Reverse acting diaphragm actuators with a linkage arm (Figure 7-29) are used to
increase the actuator output for a given size actuator. The equations for this type of
7-35
actuator are the same as for the standard reverse acting diaphragm actuator (Section
7.2.1.2.2) with the exception of a multiplier (mechanical advantage). The actuator
output equations (FA/min and FA/max) are multiplied by the mechanical advantage. The
mechanical advantage varies throughout the stroke and is generally the greatest at the
fully extended position of the actuator rod. The equations for actuators with increased
mechanical advantage are provided as part of the worksheets in Appendix B.
Figure 7-29
Reverse Acting Diaphragm with Link Arm
The Scotch yoke actuator generates torque by converting the force produced by
pressurized air on a piston into rotary motion. It does this by means of a slotted lever
arm and sliding yoke as shown in Figure 7-30.
7-36
PRESSURIZED AIR
FORCE
OF
PISTON
YOKE
PISTON
PIVOT POINT
OF OUTPUT
Figure 7-30
Scotch Yoke, Double Acting Air Cylinder
Most scotch yoke actuators are of the type shown with the lever slot parallel to the lever
axis. There are variations of this mechanism referred to as slanted scotch yoke, where
the slot is at an angle relative to the lever axis. In this case the slot angle needs to be
included in the following analysis.
Torque characteristics of double acting scotch yoke type actuators resemble a U curve as
indicated in Figure 7-31. The torque at the base of the curve that occurs at mid stroke is
known as the run torque. This is also the minimum torque capability of the actuator.
The peak torque occurs at the beginning and end of the stroke and is known as the
break torque.
DOUBLE ACTING
PERCENTAGE OF
BREAK TORQUE
100
BREAK
TORQUE
RUN
TORQUE
50
0
- 45 o
0o
45 o
DEG. OF ROTATION
Figure 7-31
Percentage of Break Torque Plot for Scotch Yoke, Double Acting
7-37
The minimum and maximum output torque of a double acting scotch yoke actuator
(with pressure acting on the non-rod side of the piston) as a function of rotation angle is
defined by the following equations:
4
cos 2
(7.113)
cos 2
4
(7.114)
The minimum and maximum output torque of a double acting scotch yoke actuator
(with pressure acting on the rod side of the piston) as a function of rotation angle is
defined by the following equations:
(7.115)
(7.116)
2
T A /min = D P A /min (1 PA drift ) D 2 d FD
4
cos 2
C
2
T A /max = D P A /max (1 + PA drift ) D 2 d
cos 2
4
where:
Start Position
-45
Mid Position
End Position
45
Note 1: Starting and ending positions may be either the open or closed position.
Note 2: may vary over the stroke and must be obtained from the actuator vendor.
Note 3: Equations 7.113 and 7.114 should be used for one stroke direction and Equations 7.115
and 7.116 for the other stroke direction. Which equations to use for a particular stroke direction
is based on whether pressure is acting on the rod side or non-rod side of the piston for a
particular stroke direction.
The piston breakaway force and differential air pressure are calculated as follows:
FD :
7-38
DPA/min :
DPA/max :
Note: The differential pressure may be the same or different for the open and close
strokes. If different, the minimum and maximum differential pressures should be
calculated for each stroke position and applied to the appropriate actuator output.
7.2.1.3.2 Scotch Yoke, Single Acting Air Cylinder, Spring Return
Spring return actuators use the same mechanism but have the added complication of a
varying spring force. The force available to produce torque by the piston is reduced by
the force of the spring. See Figure 7-32.
+45o
0o
-45o
FORCE OF
PISTON
Figure 7-32
Scotch Yoke, Single Acting Air Cylinder
The torque output produced by spring return actuators is expressed as ending torque.
The ending torque is the torque produced by the spring when the spring is in the
extended position. Torque values indicated by the solid line in Figure 7-33 follow the
approximate torque produced by the Scotch yoke mechanism as the spring extends
from break position, providing continually changing force values. The torque values
indicated by the dashed line follow the approximate torque produced as pressure
provides the force required to rotate the Scotch yoke from the end position,
compressing the spring.
7-39
EN D IN G TO RQ U E
PERC EN TA G E O F
PRESSU R E
STRO K E
SPR IN G
STRO K E
150
SPRING RET U RN
100
50
EN D IN G
TO RQ U E
-45o
0o
D EG . O F R O TA TIO N
45 o
Figure 7-33
Percentage of Ending Torque Plot for Scotch Yoke, Singlele Acting
cos
cos2
(7.117)
(7.118)
Spring Stroke:
)]
C
cos 2
(7.119)
(7.120)
Depending on whether the valve is fail-open or fail-closed, the spring stroke shall
correspond to the failure mode direction. The efficiency () of the scotch yoke
mechanism must be obtained from the actuator vendor.
The piston breakaway force and actuator supply pressure are calculated as follows:
FD :
7-40
PA/min :
PA/max :
Two methods can be used to calculate the minimum and maximum spring preload and
the minimum and maximum spring rate:
SP/min (Option 1):
The equations for the direct and reverse acting actuators are similar and are combined
in the following section.
The rotary diaphragm actuator generates torque by converting the linear motion and
forces produced by pressurized air on a diaphragm into rotary motion. It does this by
means of a lever arm and a single (double pinned) linkage, as depicted in Figure 7-34.
7-41
PA
-45o
0o
TA
b
Figure 7-34
Rotary Diaphragm Actuator
This does not cover actuators where the diaphragm actuator is pivot mounted and
swivels during operation.
The torque output produced by spring return diaphragm actuators is expressed as
ending torque, which is the torque produced by the spring when the spring is in the
extended position. Torque values indicated by the solid line in Figure 7-35 follow the
torque produced by the lever arm as the spring extends from break position, providing
continually changing force values. The torque values indicated by the dashed line
follow the torque produced as pressure provides the force required to rotate the lever
arm, compressing the spring.
PERCENTAGE OF
ENDING TORQUE
PRESSURE
STROKE
SPRING
STROKE
150
ENDING
TORQUE
100
50
SPRING RETURN
-45o
0o
45 o
DEG. OF ROTATION
Figure 7-35
Percentage of Ending Torque Plot for Rotary Diaphragm
The curves in Figure 7-35 apply to both direct acting and reverse acting diaphragm
actuators. The diaphragm effective areas used in the equations below should include
the reduction of area due to the actuator rod diameter, where applicable. Therefore, the
7-42
equations are the same for both type actuators. The curves in Figure 7-35 are defined by
the following equations:
Pressure Stroke:
(7.121)
(7.122)
Spring Stroke:
(7.123)
(7.124)
Depending on whether the valve is fail-open or fail-closed, the spring stroke shall
correspond to the failure mode direction.
The actuator supply pressure is calculated as follows:
PA/min : Refer to Equation 7.59
PA/max : Refer to Equation 7.60
Two methods can be used to calculate the minimum and maximum spring preload:
1. Spring preload and tolerance (measured or vendor supplied)
2. Lower benchset and tolerance (measured or vendor supplied)
Option 1: Spring Preload and Tolerance
S P/min = S P (1 S P/tol )
(7.125)
S P/max = S P (1 + S P/tol )
(7.126)
(7.127)
7-43
(7.128)
(7.129)
S R/max = S R (1 + S R/tol )
(7.130)
SR/max =
( BS
Upper
)) (
)) (
)) (
(BS
Upper
(7.131)
(7.132)
7-44
( BS
Upper
(7.133)
SR/max =
(7.134)
Caution: In the majority of actuator designs in nuclear power plants, the benchset is set
when the valve and actuator are uncoupled. If the valve and actuator are coupled when
setting the benchset, Spring Preload, and Spring Rate, Option 2 (Equations 7.127, 7.128,
and 7.131 through 7.134) should not be used. This is due to inclusion of valve loads and
the loss in efficiency at the moment arm in the benchset when the valve and actuator are
coupled. This could produce false spring preload and spring rate results. Option 2 can
be used if using the vendor supplied benchset since this value typically is for the
uncoupled configuration.
7.2.1.5 Rack and Pinion Actuators
Rack and pinion actuator available forces during opening and closing are calculated for
the following configurations:
Rack & Pinion, Single Acting Air Cylinder, Spring Return, Rotary
7.2.1.5.1 Rack & Pinion, Double Acting Air Cylinder, Rotary
The double acting, rack and pinion actuator generates torque by converting the force
produced by pressurized air on one or two pistons into rotary motion. It does this by
means of one or more rack gears, each fixed to pistons, and a single pinion gear. (Figure
7-36)
7-45
Figure 7-36
Double Acting Rack & Pinion, Rotary
A V A IL A B L E
TORQUE
Torque output produced by the double acting rack and pinion actuator is constant and
linear throughout its stroke (Figure 7-37). Whether the air pressure is acting on the
outside of each piston (P2) or on the inside of each piston (P1), the torque output is
represented by the solid line in Figure 7-37.
D eg. of R otation
90
Figure 7-37
Available Torque Plot for Double Acting Rack and Pinion
Torque output, in either direction, is defined for the double acting rack and pinion
actuator by the following equations:
7-46
TA /min = Npiston
D PG
2
4
(7.135)
TA /max = Npiston
D PG
2
4
(7.136)
The piston breakaway force and actuator supply pressure are calculated as follows:
FD :
DPA/min :
DPA/max :
Note: The differential pressure may be the same or different for the open and close
strokes. If different, the minimum and maximum differential pressures should be
calculated for each stroke position and applied to the appropriate actuator output.
7.2.1.5.2 Rack & Pinion, Single Acting Air Cylinder, Spring Return, Rotary
The spring return, rack and pinion actuator generates torque by converting the force
produced by pressurized air and springs on two pistons into rotary motion. It does this
by means of two rack gears, each fixed to pistons, a single pinion gear and a set of
springs on the outside of each piston. See Figure 7-38.
0
TA
o
90 P 1
P2
Figure 7-38
Single Acting Rack and Pinion, Rotary
Torque output produced by the spring return rack and pinion actuator is linear
throughout its rotation (see Figure 7-39). When air pressure, P1, is acting on the inside
of each piston, available torque is represented by the solid line. During the spring
stroke, available torque is represented by the dashed line.
7-47
AVAILABLE
TORQUE
PRESSURE
STROKE
SPRING
STROKE
0
Deg. of Rotation
90
Figure 7-39
Available Torque Plot for Single Acting Rack and Pinion
TA/max =
Npiston
2
DPG
DPG PA /min 1 PAdrift D2 -FD SP/max SR/max
90 4
4
2
4
90 4
Npiston
(7.137)
(7.138)
Spring Stroke:
TA /min =
Npiston
TA /max =
2
Npiston
2
90 4
(7.139)
90
4
(7.140)
Depending on whether the valve is fail-open or fail-closed, the spring stroke shall
correspond to the failure mode direction. Conversely, the pressure stroke shall
correspond to the other mode.
The piston breakaway force and actuator supply pressure are calculated as follows:
FD :
PA/min :
7-48
PA/max :
Two methods can be used to calculate the minimum and maximum spring preload and
the minimum and maximum spring rate:
SP/min (Option 1):
since the calibration. The equations in the previous section account for this condition.
If the setting is not expected to drift, a value of zero is used for the air pressure drift
factor. There is not a lot of industry information for this phenomenon. Plant specific
trending of pressure setpoints may provide technical justification for values to be used
for pressure drifts.
7.2.2.4 Tolerances
Many of the actuator parameters used in the actuator capability evaluations have
associated tolerances. These parameters include the pressure, benchset, diaphragm
area, spring preload, and spring rate. Tolerances are provided by the vendor or are
based on the calibration equipment tolerances. The equations in the previous section
account for such tolerances.
Pressure Tolerance. Actuator supply pressure tolerance is the tolerance associated with
the air regulator between the actuator supply source and actuator. The tolerance used
in the equations is the equipment calibration tolerance used to calibrate the air
regulator. A pressure setting tolerance is included on the data sheets since the vendor
may provide a tolerance. The vendor tolerance would only be used if the actual
tolerance is unknown.
Benchset Tolerance. The benchset tolerance is the tolerance associated with the
equipment used for calibrating the benchset. A benchset tolerance is included on the
data sheets since the vendor may provide a tolerance. The vendor tolerance would only
be used if the actual tolerance is unknown.
Diaphragm Area Tolerance. The vendor typically provides a manufacturing tolerance
with the diaphragm area. This tolerance is included on the vendor data sheets provided
in Appendix B. If the diaphragm area is measured (using pressure and force
measurements to calculate the diaphragm area), the tolerance associated with the test
equipment would be used.
Spring Preload Tolerance. The vendor typically provides a manufacturing tolerance
with the spring preload. This tolerance is included on the vendor data sheets provided
in Appendix B.
Spring Rate Tolerance. The vendor typically provides a manufacturing tolerance with
the spring rate. This tolerance is included on the vendor data sheets provided in
Appendix B.
7-50
Travel Length/Rotation
Spring Preload
Spring Rate
Valve Load
Stroke times for a particular actuator can generally be found in vendor catalogues or
obtained directly from the vendor. Published stroke times are generally applicable to
tested conditions and valve and actuator configurations. Changing any one of these
parameters may change the stroke time.
Increase actuator supply pressure (may increase stroke speed of pressure stroke
only)
Install a heavier spring (increases stroke speed of spring stroke only; may decrease
stroke speed of pressure stroke).
7-52
8
CALCULATING AND EVALUATING MARGINS
This section discusses the calculation and evaluation of AOV Margins. Included in the
discussion is an overview of parameters affecting margin calculations as well as
techniques for addressing inadequate margin.
There are two types of margins applicable to AOV evaluations: actuator capability
margin and component allowable margin. Each is addressed in the following sections.
Regulator Drift
For elements of available or required thrust/torque that can be monitored via periodic
testing, margin needs to cover degradations during the interval between tests. For
elements not addressed by periodic testing, margin needs to cover degradations during
the remaining life of the AOV.
Adequate margin can cover degradation in two fundamental ways.
1. Adequate margin can be ensured by building in values of degradation in the
parameters used to calculate the margin value (required thrust/torque and actuator
capability). When this approach is used, the calculated margin is conservative
compared to the true margin for the desired interval.
2. Adequate margin can be ensured by demonstrating that the calculated residual
margin (i.e., without degradation factors built in) is sufficient to cover degradation
for the desired interval.
In addition, various hybrids of the above two approaches can be used.
8.1.2 Examples
EXAMPLE 1: Calculation of the fully closed margin for a direct acting globe valve
driven by a reverse acting diaphragm actuator.
Given: Minimum force to fully extend the actuator stem: FAmin = 2000 lbf.
Maximum expected total required thrust to close the valve: Fc = 1700 lbf.
Close Capability Margin = [(FAmin Fc)/ Fc] * 100% =
[(2000 1700)/1700] * 100% = 17.65%
EXAMPLE 2: Calculation of the closing margin at 15 degrees from full closed for a
butterfly valve coupled to a direct acting scotch yoke diaphragm actuator.
Given: Minimum torque available in the closing at 15 degrees from the seat:
TAmin/15 = 200 ft*lb.
Maximum expected total required torque to close the valve at 15 degrees:
Tc/15 = 225 ft*lb.
8-2
Table 8.1 lists the rating types for some standard AOV components along with the appropriate
operating parameter to be used in the margin comparison.
8-3
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Valve friction coefficients (not required if default and PPM values are used), and
Statistical uncertainty, which can result from engineering analysis of test data.
8-4
Where:
TotalE = The total combined error or uncertainty.
re = Random error or uncertainty (%)
be = Bias error or uncertainty (%)
Note that the equation makes a distinction between bias and random uncertainties.
Random uncertainties are errors that have an equal probability of increasing or
decreasing the value of a parameter. Bias uncertainties are errors that tend to either
increase or decrease the value of a parameter. There are a number of statistical texts
that outline tests that can be performed in order to determine whether a given
uncertainty should be treated as a random or bias error. Examples of such methods
include frequency distributions and probability plots.
Figure 8-1 shows a graphical representation of the AOV margins. The figure shows
only some types of uncertainties to consider in the margin calculations. The figure may
not cover every possible uncertainty. Moreover, some uncertainties may not apply
depending upon the valve and actuator configuration and the set up method in
question. For example, if actuator output is measured at the valve stem, uncertainties
associated with springs and effective areas are irrelevant.
8-5
Upper Scale
Diagnostic Inaccuracy
EDA Tolerance
Regulator Drift
Spring Uncertainty (Pre-Load, Rate)
Regulator Set Point Tolerance
Lower Scale
Figure 8-1
AOV Margins and Uncertainties
8-6
Spring Pre-load
Spring Rate
b) Valve
Disc Wedging/Unwedging
Bearing Coefficients
8-7
8-8
9
AOV TESTING
The main forces involved in the operation of an AOV include the diaphragm or piston
force (depending on the type of actuator), the spring force (for spring-return or
spring-biased actuators), the valve stem packing friction, the valve disc and stem
weight, the valve disc seating force, and the valve fluid force. An acceptable AOV setup
should ensure that the actuator output capability exceeds the required stem thrust or
torque determined from the main operating forces, and the maximum actuator output
capability is below the thrust or torque rating of the AOV assembly.
One of the fundamental purposes of testing an AOV is to confirm by measurement that
the AOV will perform its desired functions under its design basis conditions (i.e., that
the AOV setup is acceptable). Three main types of AOV testing are used: (1) bench set
testing, (2) static testing, and (3) dynamic testing. The tests have different objectives
and not all tests are typically performed on every AOV.
Bench set testing is typically performed following an AOV maintenance or repair
activity. It is a simple test which does not require extensive equipment or digital data
recording systems. It is intended to confirm that the actuator is set up in a manner to
deliver the desired stroke length and the desired thrust (or torque) range in both
stroking directions. The thrust (or torque) range is confirmed by measuring pressures.
There is typically no direct confirmation of the thrust (or torque) output capability of
the actuator. Bench set testing does not provide information about the actual thrust (or
torque) required to stroke the valve.
Static testing is the simplest type of test which can be done on an AOV using digital
data recording equipment. In a static test, the AOV is stroked while there is no flow or
differential pressure (DP) in the pipe. Measurements are recorded during the stroke.
The information which can be reduced and analyzed from the test depends on which
data measurements are recorded, but typically some information about the actuator
output thrust (or torque) as well as some aspects of the valve required thrust are
obtained. Also, indications of valve problems or degradation might be revealed by the
data. Static testing does not provide information about the thrust (or torque) required
to overcome loads caused by fluid flow in the pipe.
Dynamic testing is typically the more difficult AOV test to perform, because it requires
the most extensive set of instrumentation to be meaningful and it requires coordination
9-1
of system operation with the testing. In a dynamic test, the AOV is stroked while there
is flow and DP in the pipe. Stem thrust (torque) measurements are recorded which can
be interpreted to determine the thrust (or torque) required to overcome the loads
caused by fluid flow. Further, valve problems which are only revealed by flow-induced
loads (such as damage to load bearing surfaces) might be observed in the data. To be
most meaningful, data measurements should include fluid conditions in the pipe (e.g.,
pressure, DP and/or flow). Test conditions should be evaluated to ensure that
sufficient DP load can be generated to provide meaningful results.
An effective AOV program uses a combination of bench set testing, static testing and
dynamic testing. These types of testing, the measurements which can be made and the
information which can be obtained are discussed in the sections below.
pressure point. Only one of the bench set points is adjustable and the critical point
should be the one adjusted.
When conducting a bench set procedure, the configuration of the actuator and valve is
defined by the valve manufacturer. The most common configuration is to have the
actuator disconnected from the valve stem (an uncoupled bench set). Some
manufacturers require that the packing load be removed but the valve disc and stem
remain attached to the actuator (a coupled bench set). This method accounts for the
weight of the stem and valve disc. Because the valve forces are not typically present
during a bench set procedure, the bench set pressure range is not the same as the
pressure required to stroke the valve in actual service.
Double-acting actuators which do not include a return or bias spring do not require
selection and adjustment of bench set points. These actuators are set up (coupled to the
valve) to ensure that the actuator stem mechanical stops will not interfere with
movement of the valve over its full required stroke length.
The positioner output control air pressure to the actuator (both upper and lower control air
pressures for a double-acting actuator)
Stem displacement
The following additional recommended parameters may provide more insight for
assessing AOV condition and performance. These parameters are not necessarily
required to be measured to verify acceptable AOV setup. However, these data add
significantly to: (1) the ability to extrapolated data to other equipment, (2) the ability to
diagnose problems in AOV operation should they be encountered, and (3) the ability to
later review tracking and trending of maintenance issues and corrective actions.
9-3
Pressures in and out of accessories if not previously accounted for (i.e., volume
boosters)
The information provided by these parameters on the operating condition of the AOV
being tested is discussed later in this section.
Figure 9-1 provides an example of static test results (data traces) of a rising stem globe
valve (push down to close) equipped with a direct acting (air to extend, spring to
retract) diaphragm actuator. The air pressure to the diaphragm actuator is controlled
by an electro-pneumatic positioner. The AOV was instrumented as follows:
A current sensing transducer was used to measure the milliamp control signal
output from the AOV diagnostic system to the electro-pneumatic positioner (I/P
control signal).
A pressure transducer was used to measure the instrument control air pressure generated by
the electro-pneumatic positioner (control air pressure).
A pressure transducer was used to measure the regulated supply air pressure to the electropneumatic positioner (supply air pressure).
A pressure transducer was used to measure the electro-pneumatic positioner output control
air pressure to the actuator diaphragm (diaphragm pressure).
The data traces include both the closing and opening strokes of a properly operating
AOV under static conditions. Eleven different points, indicated by the letters A through
K, are noted on the example traces. The following discussion interprets the points:
Point A
9-4
Valve is full open. Milliamp control signal output from diagnostic system
to the valve positioner I/P transducer begins fixed-rate ramp increase to
close the valve.
I/P Control Signal:
Point B
Point C
Point D
Diaphragm Pressure:
Stem Displacement:
Stem Thrust:
Diaphragm Pressure:
Stem Displacement:
Stem Thrust:
Diaphragm Pressure:
Stem Displacement:
Stem Thrust:
Diaphragm Pressure:
Point E
Point F
Point G
9-6
Stem Displacement:
Stem Thrust:
Diaphragm Pressure:
Stem Displacement:
Stem Thrust:
Valve is fully closed. Milliamp control signal output from the AOV
diagnostic system to the valve positioner I/P transducer begins a fixed-rate
ramp decrease to open the valve.
I/P Control Signal:
Diaphragm Pressure:
Stem Displacement:
Stem Thrust:
Diaphragm Pressure:
Stem Displacement:
Stem Thrust:
Point H
Point I
Point J
Point K
Diaphragm Pressure:
Stem Displacement:
Stem Thrust:
Diaphragm Pressure:
Stem Displacement:
Stem Thrust:
Diaphragm Pressure:
Stem Displacement:
Stem Thrust:
Valve is full open. Milliamp control signal output from the AOV diagnostic
system to the valve positioner I/P transducer decreases to minimum value.
9-7
Diaphragm Pressure:
Stem Displacement:
Stem Thrust:
Figure 9-2 shows the plot of diaphragm pressure and stem thrust versus stem
displacement for the same valve test stroke from full open to full closed and back to full
open. From the data traces shown in Figures 9-1 and 9-2, the following AOV operating
parameters can be determined.
Note: The examples in the following sections are based on air diagnostics only. With
this method, stem thrust calculations should be adjusted for pressure measurement
errors and effective diaphragm uncertainty. Use of direct thrust measurements requires
consideration for diagnostic equipment error only.
The total friction calculated above was determined using the actuator effective
diaphragm area, which is typically specified by the vendor. Actuator effective
diaphragm area, and other as-built design information obtained from valve
specifications or vendor manuals, may serve only as nominal information. For
example, actuator effective area may prove to be variable over the valve stroke or as
actuator pressure changes. Such uncertainties in design information may unacceptably
reduce the calculated margin in an AOV application and may complicate proper
actuator setup.
Direct measurement of stem thrust (or torque) can be used to quantify variations in
valve design information such as actuator effective diaphragm area. The uncertainties
in the quantified values are dependent upon the stem thrust (or torque) measurement
methods and equipment used. However, these uncertainties may still be less than the
inherent uncertainty in the as-built design information, and subsequent setup
calculations using the quantified values may result in improved margin. Other
advantages of direct measurement of stem thrust or torque include the ability to
distinguish the valve from the actuator as a source of high thrust or torque
measurements, and identification of incorrect valve coupling resulting in an actuator
hitting mechanical stops prior to valve seating or backseating.
increase from seat contact to maximum diaphragm pressure is approximately 6 psi (15
psi to 21 psi). Given an effective diaphragm area of 69 square inches, the as-tested seat
load is:
Seat Load = (6 psig)(69 in2) = 414 lbs
Note that the final seat load for this valve may be different under dynamic (valve flow
and differential pressure) operating conditions. In particular, the stem ejection load will
reduce the final seat load achieved. For an unbalanced disk design, the differential
pressure load across the disc will increase the final seat load achieved if the valve is
flow over the seat, and will decrease the final seat load achieved if the valve is flow
under the seat. The effect is opposite for a balanced disk design. Also, as described
above, the use of actuator effective diaphragm area in calculating a valve operating
parameter (in this case, seat load) may introduce an uncertainty. If stem thrust (or
torque) is measured directly, the final seat load does not have to be calculated using
actuator effective diaphragm area. Direct measurement of stem thrust can also verify
that the actuator is not hitting its mechanical stops prior to valve seating.
Given an effective diaphragm area of 69 square inches, the as-tested spring rate is:
Spring Rate = (15.83 psi/in)(69 in2) = 1093 lbs/in
Again, the use of the actuator effective diaphragm area in calculating a valve operating
parameter (in this case, spring rate) may introduce an uncertainty.
As described above, the use of actuator effective piston area in calculating a valve
operating parameter (in this case, unwedging load), may introduce an uncertainty. If
stem thrust is measured directly, the unwedging load does not have to be calculated
using actuator effective piston area or the spring compression force.
9-12
Figure 9-6 provides an example of static test results (stem displacement versus net
piston pressure) of a rising stem globe valve (push down to close) equipped with a
double acting piston actuator with an effective area of 120 square inches. This actuator
does not include a return or biasing spring. Note that the stem plot for a globe valve
with a double acting actuator would have the same general shape as the pressure plot.
Analysis of the data trace gives the following AOV operating parameter values:
information on the magnitude of the torque or thrust developed by the actuator to fully
open or close the valve. In addition, when compared to the static test data, the dynamic
test data indicates the additional actuator torque or thrust required to overcome flow
and differential pressure induced forces such as stem ejection load, disc-to-guide or
disc-to-seat friction loads, dynamic valve stem packing load and butterfly valve
hydrodynamic load.
The recommended operating parameters to record during an AOV dynamic test include
the parameters listed in Section 9.2 for a static load test, as well as the following
additional parameters.
Fluid temperature
Figure 9-7 provides an example of dynamic test results (piston pressure and stem thrust
vs. stem displacement) of a rising stem gate valve equipped with a reverse acting (air to
retract, spring to extend) piston actuator. For comparison, the figure shows the static
test results for the valve traced over the dynamic test results. Enlargements of the
unseating and seating portions of the data traces are shown in Figure 9-8. For the
dynamic test, the valve was stroked from fully closed to full open, and back to fully
closed. The differential pressure across the valve at the start of the opening stroke was
approximately 30 psid (30 psig upstream and 0 psig downstream). The line pressure
quickly dropped to near 0 psig on valve opening, and recovered to 30 psig on valve reclosing. A discussion of the comparison of the dynamic test results to the static test
results follows.
resist closing of the valve through increased disc-to-guide and disc-to-seat friction
loads. The piston pressure equivalent of the increased friction loads is the remaining
piston pressure difference of 1.26 psig.
The net result of the lower piston pressure at wedging during the dynamic test is a
reduction in the final disc seat load. For the static test, the seat load is:
Static Test Seat Load = (17.0 psig)(55.5 in2) = 943.5 lbs
For the dynamic test, the seat load is:
Dynamic Test Seat Load = (15.5 psig)(55.5 in2) = 860.3 lbs
The reduction in seat load for the dynamic test is:
Reduced Seat Load = 943.5 lbs - 860.3 lbs = 83.2 lbs
9-16
Valve
Clos ing
Valve
Clos ed
DE
F
GH
Valve
Opening
Valve
Open
I J K
Diaphragm Pressure
(psig)
24
20
16
12
8
4
0
24
20
16
12
8
4
0
26
22
18
14
10
6
2
24
20
16
12
8
4
S tem T hrust
(lbs)
S tem Displacement
(Inches)
0
1.2
1.0
0.8
0.6
0.4
0.2
0.0
0.0
T ime
Figure 9-1.
Figure 9-1
Example AOV Static Test Diagnostic Data Traces
9-17
22
21
Pressure
20
T hrust
19
Valve Closed
18
17
16
S eat Contact
Point
15
13
11
10
9
8
7
6
5
4
3
2
Valve Open
1
0
-0.1
0.0
0.1
0.2
0.3
0.4
0.5
0.6
S tem Displacement (Inches)
Figure 9-2
Example Direct Acting AOV Static Test Diagnostic Data Plot
9-18
0.7
0.8
0.9
12
14
Figure 9-3
Analysis of Example Direct Acting AOV Static Test Data
9-19
60
55
Partially Open
Dis c
Unwedges
50
Unwedging
Pres s ure
45
40
35
S tem T hrus t
(lbs )
Opening
Pres s ure
30
25
Clos ing
Pres s ure
20
15
10
Clos ed
0
-0.5
0.0
0.5
1.0
S tem Dis placement (Inches )
1.5
Figure 9-4
Determination of Unwedging Load from Air Operated Gate Valve Static Test Data
9-20
2.0
Figure 9-5
Analysis of Example Reverse Acting AOV Static Test Data
9-21
Figure 9-6
Analysis of Example Double Acting AOV Static Test Data
9-22
70
S ee Figure 9-8,
Detail A
50
S tem T hrust
(lbs)
60
Open
40
30
20
10
S ee Figure 9-8,
Detail B
Closed
0
-0.5
0.0
0.5
1.0
1.5
S tem Displacement (Inches)
2.0
2.5
3.0
3.5
Figure 9-7
Example Air Operated Gate Valve Dynamic Test Data
9-23
50
S tem T hrust
Disc
Unwedges
45
Dynamic
T es t
S tatic
T es t
40
S tem T hrust
(lbs)
Dynamic
T es t
S tem
E jection
Load
35
T -S lot
Clearance
30
-0.1
0.0
0.1
0.2
S tem Dis placement (Inches)
0.3
0.4
0.5
Dynamic
T es t
Disc
Wedges
20
S tatic
T es t
S tem T hrust
(lbs)
25
Dynamic
T es t
15
S eat
Load
Difference
Closed
S tem T hrust
10
-0.1
0.0
0.1
0.2
S tem Dis placement (Inches)
0.3
Figure 9-8
Example Air Operated Gate Valve Dynamic Test Data - Details
9-24
0.4
0.5
10
REFERENCES
10.1
10.2
10.3
EPRI TR-103229, EPRI MOV Performance Prediction Program Gate Valve Model
Report, November 1994.
10.4
10.5
10.6
10.7
10.8
10.9
10-2
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Table A-1
Required Thrust for Unbalanced Disc Globe Valves (Section 5.4.1)
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Table A-2
Required Thrust for Balanced Disc Globe Valves (Section 5.4.2)
$291XPEHU
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Table A-3
Required Thrust for Balanced Disc Globe Valves With Pilot Valve (Section 5.4.3)
$291XPEHU
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Table A-4
Required Thrust for Double Seat Globe Valves (Section 5.4.4)
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Table A-5
Required Thrust for Three-Way Globe Valves (Section 5.4.5)
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Table A-6
Sealing/Wedging Loads for Gate Valves (Section 5.5)
$291XPEHU
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Table A-6
Sealing/Wedging Loads for Gate Valves (Section 5.5)
81:('*,1*/2$'23(1,1*21/<
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Table A-7
Required Torque for Ball Valves (Section 5.7)
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ACTUATOR WORKSHEETS
%
Serial No.
Actuator Manufacturer
Shop Order #
Model
Actuator Type
Diaphragm
Cylinder
Actuator Function
Spring Return
Double Acting
Actuator Spring
Direct Acting
(Spring-to-Open)
Reverse Acting
(Spring-to-Close)
N/A
Cylinder/Diaphragm Inputs
Actuator Size
Actuator Rated Travel
Actuator Travel for Benchset
(LBS)
in
in
(d)
(BSlower to BSupper)
in
psig
Tolerance:
(BStol)
Circle Unit
% or psig
Operating Pressure
(PA)
psig
Tolerance:
(PA/tol)
% or psig
(DPA)
Tolerance:
(PA/tol)
% or psid
(DPA)
Tolerance:
(PA/tol)
% or psid
(DPA)
Tolerance:
(PA/tol)
% or psid
(DPA)
Tolerance:
(PA/tol)
% or psid
psig
Spring
Spring Number
Spring Preload
(SP)
lbf
Tolerance:
(SP/tol)
% or lbf
Spring Rate
(SR)
lb/in
Tolerance:
(SR/tol)
% or lb/in
lbf
Tolerance:
in
Tolerance:
% or in
in
Tolerance:
% or in
% or lbf
(D)
(PD)
in
psig
(FD)
lbf
(Aext)
in
(Aret)
2
2
in
Tolerance:
(Aext/tol)
% or in
Tolerance:
(Aret/tol)
% or in
Does piston diameter include reduction of piston rod diameter when pressure acts on rod-side of piston?
Yes
No
Does diaphragm area include reduction of rod area when pressure acts on rod-side of diaphragm?
Yes
No
Yes
No
Date:
Checked By:
Date:
%
Serial No.
Actuator Manufacturer
Shop Order #
Model
Actuator Type
Diaphragm
Cylinder
Actuator Function
Spring Return
Double Acting
Actuator Spring
Direct Acting
(Spring-to-Open)
Reverse Acting
(Spring-to-Close)
N/A
Cylinder/Diaphragm Inputs
Actuator Size
Actuator Rated Travel
in
in
Circle Unit
in
Benchset
to
psig
Tolerance:
% or psig
psig
Tolerance:
% or psig
psig
Tolerance:
% or psid
Tolerance:
% or psid
Tolerance:
% or psid
Tolerance:
% or psid
Spring
Spring Number
Spring Preload
lbf
Tolerance:
% or lbf
Spring Rate
lb/in
Tolerance:
% or lb/in
lbf
Tolerance:
% or lbf
in
Tolerance:
% or in
in
Tolerance:
% or in
Tolerance:
% or in
Tolerance:
% or in
in
psig
lbf
in
in
2
2
Does piston diameter include reduction of piston rod diameter when pressure acts on rod-side of piston?
Yes
No
Does diaphragm area include reduction of rod area when pressure acts on rod-side of diaphragm?
Yes
No
Yes
No
Date:
Checked By:
Date:
%
Station
Actuator Manufacturer
Serial No.
Model
Shop Order #
Actuator Type
Diaphragm
Cylinder
Actuator Function
Spring Return
Double Acting
Actuator Spring
Direct Acting
(Spring-to-Open)
Reverse Acting
(Spring-to-Close)
N/A
Cylinder/Diaphragm Inputs
Actuator Size
Actuator Rated Travel
Actuator Travel for Benchset
(LBS)
in
in
Actuator Diameter
(d)
in
(b or C)
Actuator Efficiency
()
(BSlower to BSupper)
in
psig
Tolerance:
(BStol)
Circle Unit
% or psig
(PA)
psig
Tolerance:
(PA/tol)
% or psig
(DPA)
Tolerance:
(PA/tol)
% or psid
(DPA)
Tolerance:
(PA/tol)
% or psid
(DPA)
Tolerance:
(PA/tol)
% or psid
(DPA)
Tolerance:
(PA/tol)
% or psid
psig
Spring
Spring Number
Spring Preload
(SP)
lbf
Tolerance:
(SP/tol)
% or lbf
Spring Rate
(SR)
lb/in
Tolerance:
(SR/tol)
% or lb/in
lbf
Tolerance:
in
Tolerance:
% or in
in
Tolerance:
% or in
% or lbf
(D)
(PD)
in
psig
(FD)
lbf
Number of Pistons
(Npiston)
(Aext)
(Aret)
in
in
(Aext/tol)
% or in
Tolerance:
(Aret/tol)
% or in
Does piston diameter include reduction of piston rod diameter when pressure acts on rod-side of piston?
Yes
No
Does diaphragm area include reduction of rod area when pressure acts on rod-side of diaphragm?
Yes
No
Prepared By:
Date:
Checked By:
Date:
%
Tolerance:
Station
Actuator Manufacturer
Serial No.
Model
Shop Order #
Actuator Type
Diaphragm
Cylinder
Actuator Function
Spring Return
Double Acting
Actuator Spring
Direct Acting
(Spring-to-Open)
Reverse Acting
(Spring-to-Close)
N/A
Cylinder/Diaphragm Inputs
Actuator Size
Actuator Rated Travel
in
in
Actuator Diameter
in
Actuator Efficiency
Pinion Gear Pitch Diameter
Benchset
Circle Unit
in
to
psig
Tolerance:
% or psig
psig
Tolerance:
% or psig
psig
Tolerance:
% or psid
Tolerance:
% or psid
Tolerance:
% or psid
Tolerance:
% or psid
Spring
Spring Number
Spring Preload
lbf
Tolerance:
% or lbf
Spring Rate
lb/in
Tolerance:
% or lb/in
lbf
Tolerance:
% or lbf
in
Tolerance:
% or in
in
Tolerance:
% or in
Tolerance:
% or in
Tolerance:
% or in
in
psig
lbf
Number of Pistons
Diaphragm Actuator only
Diaphragm Extended Area
Diaphragm Retracted Area
in
in
2
2
Does piston diameter include reduction of piston rod diameter when pressure acts on rod-side of piston?
Yes
No
Does diaphragm area include reduction of rod area when pressure acts on rod-side of diaphragm?
Yes
No
Prepared By:
Date:
Checked By:
Date:
%
STEP
CALCULATION
1
Actuator Supply Pressure, Min and Max [DPA/min and DPA/max]
DPA/min = DPA (1 PA / tol )
DPA/max = DPA (1 + PA / tol )
To Fully Extend Actuator Rod:
Differential Actuator Supply Pressure (DPA) =
Supply Pressure Tolerance (PA/tol) =
psig
%/100
psig
%/100
psig
%/100
psig
%/100
CALCULATION RESULTS
Min/Max Actuator Supply Pressure (Fully Extended):
DPA/min =
psig
DPA/max =
psig
psig
DPA/max =
psig
psig
DPA/max =
psig
psig
DPA/max =
psig
CALCULATION
CALCULATION RESULTS
lbf
lbf
D2 PD
4
psig
inches
inches
*Set the piston rod diameter equal to zero for direct acting actuators
and double acting actuators- with no spring. The piston rod diameter
is included for reverse acting actuators and double acting, double
ended actuators. Setting the piston rod diameter to zero for all types
is conservative.
%
CALCULATION
CALCULATION RESULTS
SP/max =
psig
%/100
inches
inches
*Set the piston rod diameter equal to zero for direct acting actuators
Option 2: Using measured or vendor spring preload
SP/min = SP (1 SP/ tol )
SP/max = SP (1 + SP/ tol )
%
lbf
lbf
%/100
lbf
CALCULATION RESULTS
Min Spring Rate:
lbf/in
SR/max =
lbf/in
lbf/in
%/100
psig
psig
%/100
inches
inches
inches
*Set the piston rod diameter equal to zero for direct acting actuators
Option 3: No Spring Installed in Actuator
SR/min = 0
SR/max = 0
%
CALCULATION RESULTS
Min Spring Force:
4
BSU/min = BSUpper (1 BStol )
) )
630LQIURP6WHS
OEI
630D[IURP6WHS
OEI
650LQIURP6WHS=
lbf/in
650D[IURP6WHS=
lbf/in
Spring Rate Degradation (SR/deg) =
%/100
Stroke Length (L) =
inches
BSU/min =
lbf
lbf
CALCULATION RESULTS
Actuator Minimum Output - FULLY EXTENDED
Actuator Stem:
FA/min =
lbf
FA/max =
lbf
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
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$LU5HJXODWRU'ULIW3$GULIW
Option 2: Double Acting Air Cylinder, Double Ended (No Spring)
2
D d2 DPA/min (1 PA drift ) FD
4
4
FA/min =
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
3LVWRQ5RG'LDPHWHUG
LQFKHV
%
CALCULATION
$LU5HJXODWRU'ULIW3$GULIW
Option 3: Double Acting Air Cylinder, Direct Acting
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 4: Double Acting Air Cylinder, Reverse Acting
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
%
CALCULATION RESULTS
CALCULATION
Actuator Output - FULLY RETRACTED Actuator Stem (FA/min and
FA/max)
Note 1: The Minimum Actuator Output is the actuator capability and the
Maximum Actuator Output is used for the Structural Margins.
Note 2: The appropriate actuator supply pressure should be used from Step
1 (i.e., DPA/min for fully retracting should be used for the Fully Retracted
Actuator Output, etc.).
Option 1: Double Acting Air Cylinder, Single or Double Ended (No
Spring)
CALCULATION RESULTS
lbf
lbf
2
D d2 DPA/min (1 PA drift ) FD
4
4
FA/min =
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
3LVWRQ5RG'LDPHWHUG
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 2: Double Acting Air Cylinder, Direct Acting
%
CALCULATION
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
3LVWRQ5RG'LDPHWHUG
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 3: Double Acting Air Cylinder, Reverse Acting
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
3LVWRQ5RG'LDPHWHUG
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
%
CALCULATION RESULTS
CALCULATION RESULTS
Actuator Minimum Output - RETRACT Actuator
Stem:
FA/min =
Note 1: The Minimum Actuator Output is the actuator capability and the
Maximum Actuator Output is used for the Structural Margins.
Note 2: The appropriate actuator supply pressure should be used from Step
1 (i.e., DPA/min for retracting should be used for the Fully Retracted
Actuator Output, etc.).
lbf
lbf
4
FA/min =
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
3LVWRQ5RG'LDPHWHUG
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 2: Double Acting Air Cylinder, Direct Acting
%
CALCULATION
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
3LVWRQ5RG'LDPHWHUG
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 3: Double Acting Air Cylinder, Reverse Acting
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
3LVWRQ5RG'LDPHWHUG
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 4: N/A
$29LVDSXVKGRZQWRRSHQYDOYHW\SH
%
CALCULATION RESULTS
CALCULATION RESULTS
Actuator Minimum Output - EXTEND Actuator Stem:
FA/min =
Note 1: The Minimum Actuator Output is the actuator capability and the
Maximum Actuator Output is used for the Structural Margins.
Note 2: The appropriate actuator supply pressure should be used from Step
1 (i.e., DPA/min for extending should be used for the Extended Actuator
Output).
lbf
lbf
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 2: Double Acting Air Cylinder, Double Ended (No Spring)
4
FA/max =
2
D d2 DPA /max (1 + PA drift )
4
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
3LVWRQ5RG'LDPHWHUG
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
%
CALCULATION
Option 3: Double Acting Air Cylinder, Direct Acting
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 4: Double Acting Air Cylinder, Reverse Acting
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 5: N/A
$29LVDSXVKGRZQWRFORVHYDOYHW\SH
%
CALCULATION RESULTS
CALCULATION
Actuator Supply Pressure, Min and Max [PA/min and PA/max]
DPA/min = DPA (1 PA / tol )
DPA/max = DPA (1 + PA / tol )
Nominal Actuator Supply Pressure (PA) =
Supply Pressure Tolerance (PA/tol) =
psig
%/100
CALCULATION RESULTS
Min Actuator Supply Pressure:
PA/min =
Max Actuator Supply Pressure:
PA/max =
psig
psig
Breakaway Force:
FD =
lbf
2
D d2 PD
4
%
CALCULATION
CALCULATION RESULTS
SP/max =
%
lbf
lbf
%/100
lbf
CALCULATION
CALCULATION RESULTS
lbf/in
SR/max =
lbf/in
lbf/in
%/100
4
SR/min =
%
CALCULATION
CALCULATION RESULTS
4
BSU/max = BSUpper (1 + BStol )
2
D d2
4
) )
630LQIURP6WHS
OEI
630D[IURP6WHS
OEI
650LQIURP6WHS=
lbf/in
650D[IURP6WHS=
lbf/in
Spring Rate Degradation (SR/deg) =
%/100
Stroke Length (L) =
inches
%
lbf
lbf
CALCULATION
CALCULATION RESULTS
lbf
lbf
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 2: Single Acting Air Cylinder, Reverse Acting
FA/min = SP/min FD
FA/max = SP/max
CALCULATION
Actuator Output - FULLY RETRACTED Actuator Stem (FA/min
and FA/max)
The Minimum Actuator Output is the actuator capability and the
Maximum Actuator Output is used for the Structural Margins.
CALCULATION RESULTS
lbf
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
3LVWRQ5RG'LDPHWHUG
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
%
lbf
CALCULATION
Actuator Output - RETRACT Actuator Stem (FA/min and FA/max)
Note: This calculation is required when coupling with push-down-toclose valves only (not required for use with push-down-to-open
valves).
CALCULATION RESULTS
lbf
FA/min = BSU/min FD
FA/max = BSU/max
FA/max =
lbf
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
)' IURP6WHS
OEI
Option 2: Single Acting Air Cylinder, Reverse Acting
2
D d2 PA /max (1 + PA drift ) SP/min
4
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
3LVWRQ5RG'LDPHWHUG
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
%
CALCULATION
Option 3: N/A
$29LVDSXVKGRZQWRRSHQYDOYHW\SH
%
CALCULATION RESULTS
CALCULATION
Actuator Output - EXTEND Actuator Stem (FA/min and FA/max)
Note: This calculation is required when coupling with push-down-toopen valves only (not required for use with push-down-to-close
valves).
CALCULATION RESULTS
lbf
FA/min =
lbf
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
)' IURP6WHS
OEI
3LVWRQ'LDPHWHU'
LQFKHV
$LU5HJXODWRU'ULIW3$GULIW
Option 2: Single Acting Air Cylinder, Reverse Acting
FA/min = BSU/min FD
FA/max = BSU/max
%68PD[IURP6WHS
%68PLQIURP6WHS
OEI
OEI
%
CALCULATION
OEI
Option 3: N/A
$29LVDSXVKGRZQWRFORVHYDOYHW\SH
%
CALCULATION RESULTS
CALCULATION
CALCULATION RESULTS
PA /min = PA (1 PA / tol )
PA/min =
PA/max = PA (1 + PA / tol )
psig
PA/max =
psig
%
CALCULATION
CALCULATION RESULTS
SP/min =
SP/max =
lbf
%/100
%
lbf
psig
%/100
in2
%/100
lbf
CALCULATION
CALCULATION RESULTS
lbf/in
SR/max =
lbf/in
lbf/in
%/100
SR/min =
SR/max =
psig
psig
%/100
inches
in2
%/100
in2
%/100
%
CALCULATION
CALCULATION RESULTS
lbf
BSU/max =
psig
%/100
in2
%/100
) )
630LQIURP6WHS
OEI
630D[IURP6WHS
OEI
650LQIURP6WHS=
lbf/in
650D[IURP6WHS=
lbf/in
Spring Rate Degradation (SR/deg) =
%/100
Stroke Length (L) =
inches
%
lbf
CALCULATION
CALCULATION RESULTS
lbf
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
Diaphragm Extended Area (Aext)=
in2
Diaph Extend Area Tolerance (Aext/tol)=
%/100
$LU5HJXODWRU'ULIW3$GULIW
6
lbf
lbf
FA/min = SP/min ME
FA/max = SP/max ME
lbf
%
CALCULATION
CALCULATION RESULTS
lbf
%68PD[IURP6WHS
%68PLQIURP6WHS
Option 2: N/A
$29LVDSXVKGRZQWRRSHQYDOYHW\SH
%
OEI
OEI
lbf
CALCULATION
CALCULATION RESULTS
lbf
FA/max =
lbf
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
Diaphragm Retracted Area (Aret)=
in2
Diaph Retract Area Tolerance (Aret/tol)=
in2
$LU5HJXODWRU'ULIW3$GULIW
Option 2: N/A
$29LVDSXVKGRZQWRFORVHYDOYHW\SH
%
Table B-4
ACTUATOR CAPABILITY CALCULATION WORKSHEET
(Diaphragm Actuator)
CALCULATION
CALCULATION RESULTS
PA /min = PA (1 PA / tol )
PA/min =
PA/max = PA (1 + PA / tol )
%
psig
PA/max =
psig
CALCULATION
CALCULATION RESULTS
lbf
SP/max =
lbf
lbf
%/100
psig
%/100
in2
%/100
%
CALCULATION
CALCULATION RESULTS
lbf/in
SR/max =
lbf/in
%/100
SR/min =
SR/max =
psig
psig
%/100
inches
in2
%/100
in2
%/100
lbf/in
CALCULATION
CALCULATION RESULTS
lbf
BSU/max =
lbf
psig
%/100
in2
in2
) )
630LQIURP6WHS
OEI
630D[IURP6WHS
OEI
650LQIURP6WHS=
lbf/in
650D[IURP6WHS=
lbf/in
Spring Rate Degradation (SR/deg) =
%/100
Stroke Length (L) =
inches
%
CALCULATION
Actuator Output - FULLY EXTENDED Actuator Stem (FA/min and
FA/max)
The Minimum Actuator Output is the actuator capability and the
Maximum Actuator Output is used for the Structural Margins.
CALCULATION RESULTS
Actuator Minimum Output - FULLY
EXTENDED Actuator Stem:
FA/min =
lbf
FA/min = SP/min ME
FA/max = SP/max ME
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
Diaphragm Retracted Area (Aret)=
in2
Diaph Retract Area Tolerance (Aret/tol)=
%/100
$LU5HJXODWRU'ULIW3$GULIW
%
FA/max =
lbf
lbf
lbf
CALCULATION
CALCULATION RESULTS
lbf
lbf
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
Diaphragm Extended Area (A ext)=
in2
Diaph Extend Area Tolerance (Aext/tol)=
%/100
$LU5HJXODWRU'ULIW3$GULIW
Option 2: N/A
$29LVDSXVKGRZQWRRSHQYDOYHW\SH
%
CALCULATION
CALCULATION RESULTS
lbf
FA/max =
FA/min = BSU/min ME
FA/max = BSU/max ME
%68PD[IURP6WHS
%68PLQIURP6WHS
Option 2: N/A
$29LVDSXVKGRZQWRFORVHYDOYHW\SH
%
OEI
OEI
lbf
CALCULATION
CALCULATION RESULTS
PA /min = PA (1 PA / tol )
PA/min =
PA/max = PA (1 + PA / tol )
psig
PA/max =
psig
%
CALCULATION
CALCULATION RESULTS
lbf
SP/max =
lbf
%/100
%
psig
%/100
in2
%/100
lbf
CALCULATION
CALCULATION RESULTS
lbf/in
SR/max =
lbf/in
lbf/in
%/100
SR/min =
SR/max =
psig
psig
%/100
inches
in2
%/100
in2
%/100
%
CALCULATION
CALCULATION RESULTS
lbf
BSU/max =
psig
%/100
in2
%/100
) )
630LQIURP6WHS
OEI
630D[IURP6WHS
OEI
650LQIURP6WHS=
lbf/in
650D[IURP6WHS=
lbf/in
Spring Rate Degradation (SR/deg) =
%/100
Stroke Length (L) =
inches
%
lbf
CALCULATION
CALCULATION RESULTS
lbf
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
Diaphragm Extended Area (Aext) =
in2
Diaph Extend Area Tolerance (Aext/tol)=
%/100
$LU5HJXODWRU'ULIW3$GULIW
0HFKDQLFDO$GYDQWDJHDYDLODEOH
DWIXOO\H[WHQGHGSRVLWLRQ0(
lbf
%
CALCULATION
CALCULATION RESULTS
lbf
FA/min = SP/min ME
FA/max = SP/max ME
%
lbf
CALCULATION
CALCULATION RESULTS
lbf
FA/min = BSU/min ME
lbf
FA/max = BSU/max ME
%68PD[IURP6WHS
%68PLQIURP6WHS
0HFKDQLFDO$GYDQWDJHDYDLODEOH
DWUHWUDFWHGSRVLWLRQ0(
OEI
OEI
Option 2: N/A
$29LVDSXVKGRZQWRRSHQYDOYHW\SH
%
CALCULATION
Actuator Output - EXTEND Actuator Stem (FA/min and FA/max)
Note: This calculation is required when coupling with push-down-toopen valves only (not required for use with push-down-to-close valves).
CALCULATION RESULTS
Actuator Minimum Output - EXTEND Actuator
Stem:
FA/min =
lbf
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
Diaphragm Retracted Area (Aret) =
in2
Diaph Retract Area Tolerance (Aret/tol)=
in2
$LU5HJXODWRU'ULIW3$GULIW
0HFKDQLFDO$GYDQWDJHDYDLODEOH
DWH[WHQGHGSRVLWLRQ0(
Option 2: N/A
$29LVDSXVKGRZQWRFORVHYDOYHW\SH
%
lbf
CALCULATION
CALCULATION RESULTS
PA /min = PA (1 PA / tol )
PA/min =
PA/max = PA (1 + PA / tol )
psig
PA/max =
psig
%
CALCULATION
CALCULATION RESULTS
lbf
SP/max =
lbf
%/100
%
psig
%/100
in2
%/100
lbf
CALCULATION
CALCULATION RESULTS
lbf/in
SR/max =
lbf/in
lbf/in
%/100
SR/min =
SR/max =
psig
psig
%/100
inches
in2
%/100
in2
%/100
%
CALCULATION
CALCULATION RESULTS
) )
630LQIURP6WHS
OEI
630D[IURP6WHS
OEI
650LQIURP6WHS=
lbf/in
650D[IURP6WHS=
lbf/in
Spring Rate Degradation (SR/deg) =
%/100
Stroke Length (L) =
inches
%
BSU/max =
lbf
CALCULATION
Actuator Output - FULLY EXTENDED Actuator Stem (FA/min and
FA/max)
The Minimum Actuator Output is the actuator capability and the
Maximum Actuator Output is used for the Structural Margins.
CALCULATION RESULTS
lbf
FA/min = SP/min ME
FA/max = SP/max ME
lbf
%
CALCULATION
CALCULATION RESULTS
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
%68PD[IURP6WHS
OEI
%68PLQIURP6WHS
OEI
Diaphragm Retracted Area (Aret)=
in2
Diaph Retract Area Tolerance (Aret/tol)=
%/100
$LU5HJXODWRU'ULIW3$GULIW
0HFKDQLFDO$GYDQWDJHDYDLODEOH
DWIXOO\UHWUDFWHGSRVLWLRQ0(
%
lbf
lbf
CALCULATION
CALCULATION RESULTS
lbf
lbf
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
Diaphragm Extended Area (A ext)=
in2
Diaph Extend Area Tolerance (Aext/tol)=
%/100
$LU5HJXODWRU'ULIW3$GULIW
0HFKDQLFDO$GYDQWDJHDYDLODEOH
DWUHWUDFWHGSRVLWLRQ0(
Option 2: N/A
$29LVDSXVKGRZQWRRSHQYDOYHW\SH
%
CALCULATION
CALCULATION RESULTS
lbf
FA/max =
FA/min = BSU/min ME
FA/max = BSU/max ME
%68PD[IURP6WHS
%68PLQIURP6WHS
0HFKDQLFDO$GYDQWDJHDYDLODEOH
DWH[WHQGHGSRVLWLRQ0(
Option 2: N/A
$29LVDSXVKGRZQWRFORVHYDOYHW\SH
%
OEI
OEI
lbf
CALCULATION
CALCULATION RESULTS
%
CALCULATION
CALCULATION RESULTS
To Close Valve:
Differential Actuator Supply Pressure (DPA) =
Supply Pressure Tolerance (PA/tol) =
psig
%/100
To Open Valve:
Differential Actuator Supply Pressure (DPA) =
Supply Pressure Tolerance (PA/tol) =
psig
%/100
%
DPA/min =
psig
DPA/max =
psig
psig
psig
CALCULATION
CALCULATION RESULTS
lbf
lbf
Breakaway Force (Opening Direction):
lbf
3UHVVXUH$FWLQJRQ5RG6LGHRI3LVWRQ FD = D2 d2 PD
4
3UHVVXUH$FWLQJRQ1RQ5RG6LGHRI3LVWRQ FD =
D2 PD
psig
inches
inches
*Setting the rod diameter equal to zero is conservative and would give
an equal breakaway force for both stroke directions.
%
CALCULATION
CALCULATION RESULTS
The Minimum Actuator Output is the actuator capability and the Maximum
Actuator Output is used for the Structural Margins.
Angle ()
(in-lb)
cos2
cos2
4
2SWLRQVHH6WHS
-45
-40
-35
-30
-25
-20
-15
T A /min =
2 2
C
D P A /min (1 PA drift ) D d FD
4
cos 2
-10
-5
2 2
C
cos 2
4
-4
-3
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
)'IURP6WHS
OEI
(IILFLHQF\
'LVWDQFH&
LQ
3LVWRQ'LDPHWHU' LQ
3LVWRQ5RG'LDPHWHUG
LQ
$LU5HJXODWRU'ULIW3$GULIW
%
-2
-1
0
1
2
3
TA/min (in-lb)
TA/max
CALCULATION
CALCULATION RESULTS
4
5
10
15
20
TA/min (in-lb)
TA/max
25
30
35
40
45
%
CALCULATION
CALCULATION RESULTS
The Minimum Actuator Output is the actuator capability and the Maximum
Actuator Output is used for the Structural Margins.
Angle ()
(in-lb)
C
2
T A /min = D P A /min (1 PA drift ) D2 d FD
cos 2
2
T A /max = D P A /max (1 + PA drift ) D2 d
cos 2
4
45
40
35
30
25
20
15
4
cos2
10
5
cos2
4
4
3
'3$0LQIURP6WHS
SVLJ
'3$0D[IURP6WHS
SVLJ
)'IURP6WHS
OEI
(IILFLHQF\
'LVWDQFH&
LQ
3LVWRQ'LDPHWHU' LQ
3LVWRQ5RG'LDPHWHUG
LQ
$LU5HJXODWRU'ULIW3$GULIW
%
2
1
0
-1
-2
-3
TA/min (in-lb)
TA/max
CALCULATION
CALCULATION RESULTS
-4
-5
-10
-15
-20
TA/min (in-lb)
TA/max
-25
-30
-35
-40
-45
%
CALCULATION
CALCULATION RESULTS
PA /min = PA (1 PA / tol )
PA/min =
PA/max = PA (1 + PA / tol )
%
psig
PA/max =
psig
CALCULATION
CALCULATION RESULTS
lbf
lbf
Breakaway Force (Opening Direction):
lbf
FD = D2 PD
4
psig
inches
%
CALCULATION
CALCULATION RESULTS
lbf
SP/max =
lbf
%/100
D2
4
D2
4
%
psig
%/100
in
lbf
CALCULATION
CALCULATION RESULTS
lbf/in
SR/max =
lbf/in
lbf/in
%/100
D2 (1 BStol ) / LBS
4
D2 (1 + BStol ) / LBS
4
psig
psig
%/100
inches
inches
%
CALCULATION
CALCULATION RESULTS
Angle ()
(in-lb)
-45
-40
-35
cos 2
cos
-30
-25
-20
-15
3$0LQIURP6WHS
SVLJ
3$0D[IURP6WHS
SVLJ
)'IURP6WHS
OEI
63PD[IURP6WHS OEI
63PLQIURP6WHS OEI
65PD[IURP6WHS
OEILQ
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-10
-5
-4
-3
-2
-1
0
1
2
3
%
TA/min (in-lb)
TA/max
CALCULATION
CALCULATION RESULTS
4
5
10
15
20
TA/min (in-lb)
TA/max
25
30
35
40
45
%
CALCULATION
CALCULATION RESULTS
Angle ()
(in-lb)
45
C
TA /min = SP /min + SR /min 1 SR /deg C (1 + tan ) FD
cos2
)]
C
2
cos
40
35
30
25
20
15
10
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5
4
3
2
1
0
-1
-2
-3
%
TA/min (in-lb)
TA/max
CALCULATION
CALCULATION RESULTS
-4
-5
-10
-15
-20
TA/min (in-lb)
TA/max
-25
-30
-35
-40
-45
%
CALCULATION
CALCULATION RESULTS
PA /min = PA (1 PA / tol )
PA/min =
PA/max = PA (1 + PA / tol )
%
psig
PA/max =
psig
CALCULATION
CALCULATION RESULTS
lbf
SP/max =
lbf
lbf
%/100
psig
%/100
in2
in2
%
CALCULATION
CALCULATION RESULTS
lbf/in
SR/max =
lbf/in
%/100
SR/min =
SR/max =
psig
psig
%/100
inches
in2
in2
in2
in2
lbf/in
CALCULATION
Actuator Output to Extend Actuator Rod (TA/min and TA/max)
CALCULATION RESULTS
Force Output to Extend Actuator Rod:
Angle () A (in2)
(in-lb)
-45
-35
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%/100
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Spring Rate Degradation (SR/deg)=
%/100
Diaphragm (A)=
See results table and note below
in2
NOTE:
A at 45 is the fully extended diaphragm area
A at -45 is the fully retracted diaphragm area
A at intermediate positions is equal to values between the extended
and retracted area. If not provided by the vendor, areas at
intermediate positions can be interpolated from the extended and
retracted areas.
-40
-30
-25
-20
-15
-10
-5
-4
-3
-2
-1
0
1
2
3
4
%
CALCULATION
CALCULATION RESULTS
5
10
15
20
%
CALCULATION
CALCULATION RESULTS
Angle ()
(in-lb)
2
TA /min = SP /min +
SR /min 1 SR /deg b 1 + tan
2
) b cos
TA/min (in-lb)
TA/max
45
40
35
30
25
20
15
10
5
4
3
2
1
%
CALCULATION
CALCULATION RESULTS
Force Output to Retract Actuator Rod (Cont.):
Angle ()
(in-lb)
0
-1
-2
-3
-4
-5
-10
-15
-20
-25
-30
-35
-40
-45
%
TA/min (in-lb)
TA/max
CALCULATION
CALCULATION RESULTS
PA /min = PA (1 PA / tol )
PA/min =
PA/max = PA (1 + PA / tol )
psig
PA/max =
psig
%
CALCULATION
CALCULATION RESULTS
lbf
SP/max =
lbf
%/100
%
psig
%/100
in2
%/100
lbf
CALCULATION
CALCULATION RESULTS
lbf/in
SR/max =
lbf/in
lbf/in
%/100
SR/min =
SR/max =
psig
psig
%/100
inches
in2
%/100
in2
%/100
%
CALCULATION
Actuator Output to Retract Actuator Rod (TA/min and TA/max)
CALCULATION RESULTS
Force Output to Retract Actuator Rod:
Angle () A (in2)
(in-lb)
45
35
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Diaph Extend Area Tolerance (Atol)=
%/100
$LU5HJXODWRU'ULIW3$GULIW
Spring Rate Degradation (SR/deg) =
%/100
Diaphragm Area (A)= See results table and note below
in2
NOTE:
A at 45 is the fully extended diaphragm area
A at -45 is the fully retracted diaphragm area
A at intermediate positions is equal to values between the extended
and retracted area. If not provided by the vendor, areas at intermediate
positions can be interpolated from the extended and retracted areas.
%
40
30
25
20
15
10
5
4
3
2
1
0
-1
-2
-3
-4
CALCULATION
CALCULATION RESULTS
-5
-10
-15
-20
-25
-30
-35
-40
-45
CALCULATION
CALCULATION RESULTS
2
TA /min = SP /min +
SR /min 1 SR /deg b 1 + tan
2
) b cos
Angle ()
(in-lb)
TA/min (in-lb)
TA/max
-45
-40
-35
-30
-25
-20
-15
-10
-5
-4
-3
-2
-1
%
CALCULATION
CALCULATION RESULTS
Angle ()
TA/min (in-lb)
TA/max
(in-lb)
0
1
2
3
4
5
10
15
20
25
30
35
40
45
%
CALCULATION
Actuator Supply Pressure, Min and Max [DPA/min and DPA/max]
To Close Valve:
Differential Actuator Supply Pressure (DPA) =
Supply Pressure Tolerance (PA/tol) =
psig
%/100
To Open Valve:
Differential Actuator Supply Pressure (DPA) =
Supply Pressure Tolerance (PA/tol) =
psig
%/100
%
CALCULATION RESULTS
DPA/min =
psig
DPA/max =
psig
psig
DPA/max =
psig
CALCULATION
CALCULATION RESULTS
lbf
Breakaway Force:
FD =
lbf
D2 PD
4
psig
inches
in-lb
2
4
2
4
TA/max =
in-lb
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CALCULATION
Actuator Output for Opening Valve (TA/min and TA/max)
The Minimum Actuator Output is the actuator capability and the
Maximum Actuator Output is used for the Structural Margins.
CALCULATION RESULTS
in-lb
2
4
D
2
4
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in-lb
CALCULATION
CALCULATION RESULTS
N/A
PA /min = PA (1 PA / tol )
PA/min =
PA/max = PA (1 + PA / tol )
psig
PA/max =
psig
%
CALCULATION
CALCULATION RESULTS
Breakaway Force:
FD =
FD =
lbf
D2 PD
4
%
psig
inches
lbf
CALCULATION
Spring Preload, Min and Max [SP/min and SP/max]
CALCULATION RESULTS
SP/min =
lbf
SP/max =
lbf
psig
%/100
inches
%
CALCULATION
CALCULATION RESULTS
lbf/in
SR/max =
lbf/in
%/100
%
psig
psig
%/100
inches
inches
lbf/in
CALCULATION
Actuator Output for Pressure Stroke (TA/min and TA/max)
For simplicity, the actuator output is specified as the pressure stroke.
Which stroke direction this corresponds to (open or close) depends on
the configuration of a particular AOV.
The Minimum Actuator Output is the actuator capability and the
Maximum Actuator Output is used for the Structural Margins.
TA/min =
Npiston
TA/max =
Npiston
DPG
DPG PA/min (1 PAdrift ) D2 - FD SP/max SR/max
4
90 4
90 4
4
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Spring Rate Degradation (SR/deg)=
%/100
CALCULATION RESULTS
Force Output (Pressure Stroke):
Angle ()
TA/min (in-lb)
TA/max (inlb)
0
1
2
3
4
5
10
15
20
25
30
35
40
45
50
55
60
65
%
CALCULATION
CALCULATION RESULTS
70
75
80
85
90
%
CALCULATION
Actuator Output for Spring Stroke (TA/min and TA/max)
For simplicity, the actuator output is specified as the spring stroke.
Which stroke direction this corresponds to (open or close) depends on
the configuration of a particular AOV
The Minimum Actuator Output is the actuator capability and the
Maximum Actuator Output is used for the Structural Margins.
TA /min =
Npiston
TA /max =
Npiston
90
4
90 4
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CALCULATION RESULTS
Force Output (Spring Stroke):
Angle ()
TA/min (in-lb)
TA/max (inlb)
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
%
CALCULATION
CALCULATION RESULTS
4
3
2
1
0
%
C
PACKING LOAD METHODOLOGY
C.1
Nomenclature
AP
Dbolt
Ds
FPL
Gstress
HP
Klube
Nbolt
Pup
coefficient of friction between the packing and stem materials and = 0.1 based
on EPRI data.
Psys
Tbolt
TP
packing radial stress to axial stress transfer ratio and is assumed to = 0.5 and
remain constant. This assumption is based on industry experience.
WP
C-1
C.2
Methodology
>
Tbolt N bolt
S
2
2
and A P
D s 2WP Ds
4
D bolt K lube A P
Ds
2
Per "Application Guide for Motor-Operated Butterfly Valves in Nuclear Power Plants,"
(Reference 10.1), the gland stress for chevron packing is typically estimated by using 1.5
Psys, where Psys is the system design pressure (psi). For ring type packing the gland
stress is estimated the same way but with a minimum value of 1000 psi. The coefficient
of friction, Pup can range from 0.1 to 0.2 (Reference 10.1).
C.3
Calculation worksheets
C-2
Equation
Sign
Packing
FPL = GstressQSDsHpPup
Q = 0.5
Ds =
HP =
Pup = 0.1
Gstress = 2,000
Tbolt N bolt
G stress
D bolt K lube A P
Tbolt =
Nbolt =
Dbolt =
Klube = 0.15
AP =
AP
D 2W
4>
WP =
always positive
lbf
in.
in.
psi
in-lb.
in.
in2
Ds 2
in.
C-3
Equation
Sign
Packing
TP FPL
always positive
Ds
2
FPL = GstressQSDsHpPup
Q = 0.5
Ds =
in.
in.
HP =
Pup = 0.1 - 0.2
Gstress = 2,000 psi
Tbolt N bolt
G stress
or1.5Psys
D bolt K lube A P
Tbolt =
in lb.
Nbolt =
in.
Dbolt =
Klube = 0.15
AP =
in2
AP
or
C-4
D 2W
4>
WP =
Psys
Ds 2
in.
psi
in-lbf