Valve Maintenance Guide

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Air-Operated Valve Maintenance Guide LICENSED M AT E R I A L SINGLE USER LICENSE AGREEMENT THIS IS A LEGALLY BINDING AGREEMENT BETWEEN YOU AND THE ELECTRIC POWER RESEARCH INSTITUTE (EPRI). PLEASE READ IT CAREFULLY BEFORE REMOVING THE WRAPPING MATERIAL. THIS AGREEMENT CONTINUES ON THE BACK COVER. BY OPENING THIS SEALED REPORT YOU ARE AGREEING TO THE TERMS OF THIS AGREEMENT. IF YOU DO NOT AGREE TO THE TERMS OF THIS AGREEMENT, PROMPTLY RETURN THE UNOPENED REPORT TO EPRI AND THE PURCHASE PRICE WIL
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  SINGLE USER LICENSE AGREEMENT THIS IS A LEGALLY BINDING AGREEMENT BETWEEN YOU AND THE ELECTRIC POWER RESEARCH INSTITUTE(EPRI). PLEASE READ IT CAREFULLY BEFORE REMOVING THE WRAPPING MATERIAL. THIS AGREEMENTCONTINUES ON THE BACK COVER. BY OPENING THIS SEALED REPORT YOU ARE AGREEING TO THE TERMS OF THIS AGREEMENT. IF YOU DO NOTAGREE TO THE TERMS OF THIS AGREEMENT, PROMPTLY RETURN THE UNOPENED REPORT TO EPRI AND THEPURCHASE PRICE WILL BE REFUNDED. 1.GRANT OF LICENSE EPRI grants you the nonexclusive and nontransferable right during the term of this agreement to use thisreport only for your own benefit and the benefit of your organization. This means that the following may usethis report: (I) your company (at any site owned or operated by your company); (II) its subsidiaries or otherrelated entities; and (III) a consultant to your company or related entities, if the consultant has entered intoa contract agreeing not to disclose the report outside of its organization or to use the report for its ownbenefit or the benefit of any party other than your company.This shrink-wrap license agreement is subordinate to the terms of the Master Utility License Agreementbetween most U.S. EPRI member utilities and EPRI. Any EPRI member utility that does not have a MasterUtility License Agreement may get one on request. 2.COPYRIGHT This report, including the information contained in it, is owned by EPRI and is protected by United States andinternational copyright laws. You may not, without the prior written permission of EPRI, reproduce, translateor modify this report, in any form, in whole or in part, or prepare any derivative work based on this report. 3.RESTRICTIONS You may not rent, lease, license, disclose or give this report to any person or organization, or use theinformation contained in this report, for the benefit of any third party or for any purpose other than asspecified above unless such use is with the prior written permission of EPRI. You agree to take allreasonable steps to prevent unauthorized disclosure or use of this report. Except as specified above, thisagreement does not grant you any right to patents, copyrights, trade secrets, trade names, trademarks orany other intellectual property, rights or licenses in respect of this report. (continued on back cover) LICENSED MATERIAL Air-Operated ValveMaintenance Guide  EPRI NP-7412R1s Electric Power Research Institute November 1996 R E P O R T S U M M A R Y INTEREST CATEGORIES Nuclear plant operationsand maintenanceEngineering and technicalsupportMaintenance practicesNuclear componentreliability KEYWORDS ValvesControl equipmentMaintenancePredictive maintenancePreventive maintenance Air-Operated Valve Maintenance Guide Air-operated valves (AOVs) are used extensively in the power gen-eration industry for process-control and system-isolation functions.This guide provides methods for establishing predictive and preven-tive maintenance programs for AOVs. It suggests techniques forreducing failure rates and discusses proven repair methods that canhelp utilities reduce downtime and unplanned outages. BACKGROUND An increased awareness of AOV importance at nuclear powerplants has led to progressively more sophisticated maintenance practices withinthe nuclear industry. Non-nuclear plants are also heavily dependent on reliableAOV operation. The dynamic method used by fossil power plants to satisfytransient electrical demands places additional stress on plant components,including AOVs. Therefore, there is a growing need for standardized technicalguidance related to AOVs. OBJECTIVES To research degradation modes for AOVs and to provide guid-ance for a practical and cost-effective AOV maintenance program that willaddress these degradation modes. APPROACH EPRI’s Nuclear Maintenance Applications Center (NMAC) gath-ered information on maintenance techniques by visiting numerous power plantmaintenance department personnel. Failure data were gathered using theInstitute of Nuclear Power Operation’s Nuclear Plant Reliability Data Systemreports on AOV failures for all plants in the database. This research provideddata to support maintenance program recommendations. RESULTS This guide discusses air-operated valves (AOVs) and commonaccessories. Diagrams indicating the application and operation of various typesof actuators are presented as an aid for thorough investigation of malfunctioningequipment. Recent developments in diagnostic equipment for AOVs are cov-ered, and valve traces on valves with maintenance-related problems are usedto demonstrate how the diagnostic equipment can quickly solve complex valveproblems.The guide includes a troubleshooting section with tables that provide easilyaccessible information to minimize troubleshooting costs. A detailed discussionon diaphragms that provides guidance for selecting, installing, and maintainingAOV diaphragms is furnished. Appendixes augment the guide by providing aglossary of terms and various engineering schedules, including useful engineer-ing parameters for the proper maintenance of AOVs and accessories. EPRI Powering Progress   EPRI PERSPECTIVE Power plants rely on AOVs for the properoperation of many plant systems. AOVs are used extensively on bothlarge- and small-bore piping systems and heating, ventilating, and air-conditioning (HVAC) ducting to provide isolation and flow controlfunctions. Process applications include water, steam, N 2 , H 2 , and air.Predictive and preventive maintenance is one of the key ways toenhance AOV performance and subsequently reduce AOV failurerates. Through the proper implementation of key AOV maintenanceactivities, utilities can realize significant savings. This guide will helppower plant professionals take the most effective and appropriatemaintenance actions.Related EPRI research includes reports NP-7079, Instrument Air Guide  , and NP-7414, Solenoid Valve Maintenance and Application Guide  . PROJECT WO# 3814-17EPRI Project Manager: Kenneth F. BarryNuclear Maintenance Applications CenterNuclear Power GroupContractor: Marriott Valve ServicesAltran Materials Engineering, Inc.For further information on EPRI research programs, call EPRITechnical Information Specialists at 415/855-2411.  Air-Operated Valve Maintenance Guide Final ReportNovember 1996Prepared byRevision 0STANLEY E. PRECKWINKLERevision 1MARRIOTT VALVE SERVICESFran McDonaldWilliam MarriottALTRAN MATERIALS ENGINEERING, INC.Joseph GroegerLeslie ComptonPrepared for NUCLEAR MAINTENANCE APPLICATIONS CENTER 1300 W.T. Harris BoulevardCharlotte, NC 28262Operated by Electric Power Research Institute 3412 Hillview AvenuePalo Alto, California 94304EPRI Project ManagerKenneth F. BarryNuclear Power Group NP-7412R1Work Order 3814-17
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