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3.3 Design Basis Valve Stem Torque converted to linear motion of the stem.
Figure 3-22 illustrates this mechanical
For rotating-stem valves (ball, plug, process and shows details of the stem thread.
and butterfly), the torque needed to operate If both the stem thrust and the actuator
the valve is a summation of two loads: torque are measured in a test, the stem factor
can simply be calculated. (Measurement of
• Loads not dependent on pressure or stem torque, that is, the reaction torque in
flow such as bearing loads and the stem, can be substituted for
packing loads. measurement of actuator torque, since they
• Loads dependent on the flow or are equal.)
differential pressure acting on the
valve disc.
Once the required valve stem thrust For any valve, the relationship
is known, the required stem torque must be between actuator torque and stem thrust can
determined. This requires a determination of be evaluated in terms of the power thread
the stem factor for the valve. The stem equation for that particular stem/stem-nut
factor is a simple expression of the configuration. The only variable in that
relationship between the stem thrust and the equation is the stem friction, that is, the
actuator torque (the torque applied to the coefficient of friction at the interface
stem nut by the gearbox). Stem thrust between the stem and the stem nut. For our
divided by actuator torque equals stem example 6-in. gate valve, the following
factor. The stem factor mathematically Acme power thread equation is applicable:
represents the mechanical process by which
the rotational motion of the stem nut is
valve before torque switch trip. The torque switch setting was the same in all
literature sometimes refers to this four tests, the actuator torque at torque
phenomenon either as load-sensitive switch trip was presumably about the same
behavior or as the rate-of-loading effect. as well. Remember, though, that the torque
Figure 3-23 shows the stem thrust traces switch controls the torque output of the
from four tests of the same valve, with the actuator, not the thrust. A decrease in thrust
same torque switch setting, but with at a given torque indicates an increase in
different load histories preceding torque friction at the interface between the stem
switch trip. In this figure, the sudden and the stem nut. Such a decrease in thrust at
increase in stem thrust, as indicated by the torque switch trip is evident in the data
vertical portion of the trace, is caused when shown in Figure 3-23.
the disc wedges in the seats. The increase in
thrust after torque switch trip is caused The data trace on the left is from a
mostly by motor and gearbox momentum. low-load test, with a stem rejection load
Flow isolation occurs just before the disc created by the 1000 psig pressure in the
wedges in the seats. The margin is indicated valve and with a packing friction load, but
as the difference between the thrust needed with no flow load. The other three data
for flow isolation and the thrust delivered at traces are from tests with flow (and with
torque switch trip. One expects the margin differential pressure at flow isolation). In the
low-load test, the load increases suddenly
when wedging occurs, and the torque switch
trips during this sudden increase in the load.
This kind of load profile produces the lowest
possible stem friction and the highest
possible stem thrust at torque switch trip,
apparently because the abundance of grease
at the interface between the stem and the
stem-nut allows the stem-nut threads to
"float" on a layer of pressurized grease, with
little or no metal to metal contact. In
contrast, a load profile with a load that
steadily increases, as in the other three
traces, produces higher friction at torque
to decrease with higher loads, as more thrust switch trip, because more of the grease has
is needed for flow isolation. However, the been squeezed out of the interface by the
decrease in thrust at torque switch trip at high load before torque switch trip. Higher
higher loads was unexpected. Since the friction at torque switch trip corresponds
with lower stem thrust at torque switch trip. This is a rather broad range, but it is, in fact,
The thrust at torque switch trip in the first bounded by the 0.15 default value formerly
test shown in Figure 3-23 was 19,900 lbf; in used in the industry. The difference between
the fourth test, it was 16,500 lbf. the low end of the range and the high end of
the range can have a significant effect on the
One of the problems created by this analyst=s evaluation of valve operability.
phenomenon is the possibility that the valve
analyst might perform a low-load test to Diagnostic tests of valves in the
obtain data for a valve evaluation, then use plants have sometimes indicated stem
the stem factor, stem friction, or stem thrust friction values as high as 0.20. This
data from the low-load test (data measured corresponds with the high end of the default
at torque switch trip) to estimate the values formerly used in the U.S. nuclear
actuator's capability at design basis flow and industry. Today, a valve analyst at a U.S.
pressure conditions. This practice would utility would use plant data to justify use of
produce a nonconservative estimate, since a stem friction value in the range of 0.15. In
the stem friction in the design basis case is some cases, a higher default value of 0.20 is
almost certain to be significantly higher than necessary. When performing instrumented
the value determined from measurements in in-plant tests to determine the actual stem
the low-load test. friction for a valve, the analyst must take
special care to ensure that the values derived
When performing an evaluation of from the in-plant tests are used appropriately
valve operability, analysts in the U.S. and conservatively. To repeat: results from
typically use a stem friction value derived NRC/INEEL laboratory tests of valves and
from plant data, that is, data from in-plant actuators show that the stem friction can
testing of many valves in that particular vary significantly. The variability depends
plant. Formerly, analysts typically used on:
values recommended by the valve or
actuator manufacturer. Recommended • The particular stem and stem nut
industry default values ranged from 0.15 to configuration. Each stem and stem
0.20 in evaluations addressing valve nut have their own friction
operability at design basis loads. In the characteristics. Some stems show
NRC/INEEL tests of valves and actuators, higher friction than others, and some
we have seen design basis stem friction stems show higher friction at lower
values (friction near or at flow isolation in loads than at higher loads, while
tests with loads representing significant flow other stems show the opposite.
and pressure) generally ranging from about • The brand of lubricant used on the
0.08 to 0.14 with freshly lubricated stems. stem. NRC/INEEL testing of two
Equation (3-18)
maximum. For a known pressure drop designs with offset stems can experience
across the valve, the bearing torque can be significant hydrostatic torques.
calculated using the valve manufacturer=s
bearing torque coefficients, or by using
bearing geometry and the stem-to-bearing
coefficient of friction.
Where:
Ct = hydrodynamic torque coefficient Incompressible flow
(dimensionless)
Figure 3-31 shows typical
d = valve nominal diameter incompressible flow hydrodynamic torque
coefficients for symmetric disc butterfly
ΔP = differential pressure across the valves and both orientations of
valve. nonsymmetric disc butterfly valves. The
torque coefficient is given as a function of
To simplify sizing butterfly valves, disc opening angle, with 0 degrees being the
manufacturers use hydrodynamic torque closed position. Positive values of the
coefficients that are based on the valve hydrodynamic torque coefficient indicate a
nominal diameter instead of the disc self-closing torque, whereas negative values
diameter. Most manufacturers determine indicate self-opening torque. It should be
their torque (and flow) coefficients by stressed that even though the peak in the
performing flow loop test on valves of non-dimensional hydrodynamic torque
selected sizes and pressure ratings, or on
scaled models of their product line. The tests
are typically performed under fully
turbulent, non-choked flow conditions using
water, or with air using low pressure drop
ratio conditions (flow velocity well below
the speed of sound) to simulate nearly
incompressible flow. Due to test facility
limitations, valve sizes are typically small,
four to eight-inch diameter. Figure 3-31 Typical Incompressible
Flow Disc Butterfly Valves
Limited verification of extrapolation
techniques by flow loop testing has been coefficient occurs near 70 degrees, the
done by some manufacturers and actual peak in hydrodynamic torque will be
laboratories for valve sizes in the 18 to 24- at this location only if the differential
inch range. Extrapolation techniques are pressure across the valve is constant. In most
often justified by satisfactory performance applications, the differential pressure across
under normal operating conditions. the valve is not constant and the disc angle
However, test data at or near design basis associated with the peak hydrodynamic
conditions (i.e. high flow rates under torque will shift.
blowdown) are limited..