MOV/Gearbox Overtorque Protection (Ex: Limitorque Actuators) Power Generation Best Practice’s Meeting October 31, 2007 The topic of this presentation is overtorque protection of motor operated valves and gearboxes, such as Limitorque actuators. Presented By: Denise Lane Mech. Engineer Agua Fria Generating Station

Presentation Elements MOV/Gearbox Safety Concern Refresher Crystal River Common Causes of Failure Valve Wrench/Cheater Bar Usage Mechanical Overload Protection Device Operating Principle Information & Calculations Installation & Cost In the first segment of the presentation, I’ll remind you of the safety concerns by discussing the incident at Crystal River, the common causes of failure, and the use of valve wrenches and cheater bars. In the second part of the presentation, I’ll discuss a mechanical overload protection device to prevent failure. I’ll show a film clip on how the device works; touch on the information and calculations needed to buy the protectors; and briefly discuss the installation process and protector cost.

MOV/Gearbox Safety Concerns Crystal River - 01/2004 BFP Iso Valve Killed 20 Yr. Employee Valve Wrench To Close Gears Cranking to Open Cracked Actuator Housing Most of us are familiar with the Crystal River fatality that occurred in 2004. An employee that had worked at Progress Energy for 20 years was killed when part of an actuator housing ejected and flew through the air with line pressure momentum; hitting the employee. The root cause was determined to be from a feedwater pump requiring maintenance. An upstream valve was used to isolate the pump, but the actuator couldn’t completely shut it off so a valve wrench was used. Several days later, after the pump had been fixed, the operators attempted to open the valve with the actuator, but the attempt failed. While discussing alternative methods, the valve wrench’s seating force combined with the cranking torque of the gears that were still trying to open the valve. These forces cracked the metal casing and the projectile was set in motion.

MOV/Gearbox Safety Concerns Valve Failure Root Causes Using a Valve Wrench/Cheater Bar on the Handwheel Holding In the Motor Control Contactor Setting the Torque Switch Too High Beating on Valve Body to Unseat Valve Removing Stem Locknut Under Pressure Electrical Shock Because of this, a couple of years ago, AFGS hired Pinnacle Actuation to provide safety training for these types of equipment. In the training, we were instructed on the top (6) causes of failure. They are: Using a Valve Wrench &/or Cheater Bar on the Handwheel Holding in the Motor Control Contactor Setting the Torque Limit Switch Too High Beating on the Valve Body to Unseat the Valve Removing the Stem Locknut While the Line is Under Pressure And Electrical Shock The use of valve wrenches and/or cheater bars has been determined to be the #1 cause of the failures.

Safety – Handwheels & Valve Wrenches Handwheel Torque > Motor Torque Wheel Radius & Max. Hand Forces Limit Torque Designed for Max. Allowable Actuator Rating There are (2) facts that need to be considered in the use of valve wrenches and/or cheater bars. The first is that use of the actuator handwheel can achieve a greater torque than the motor. This is a specific safety measure incorporated by the actuator manufacturer to prevent normal operation stresses. The second fact is that the wheel radii and hand forces are the limiting factors in allowable actuator torques and should not be exceeded. Within these (2) facts lies the problem.

Safety – Handwheels & Valve Wrenches Valve Wrenches/Cheater Bars Benefit - Decreases Hand Force Needed to Seat or Unseat Valves Drawback - Uncontrolled Length Increases Induced Weak Link Stress Drawback – “Slipping” Safety Concern Because hand force is used as the limiting factor, a high average force of approx. 150 lbs is used in wheel radius determination. Quite often, an employee can not apply this force or the handwheel is not in the greatest location for force application. Therefore, a valve wrench is needed to fully close a valve. Because a wrench provides a longer force arm, less hand force is needed to seat the valve. On the other hand, if the wrench is too long, an over-stressed housing scenario can easily develop. There have also been instances noted where the valve wrench or cheater bar has dislodged and caused personnel injuries.

Safety Concerns Weak Links Can Stretch & Separate Yoke & Actuator Housing Cover Bolts Causes Actuator &/or Valve Housing Ejection “Missile” Safety Concern Not Just Limitorque More Often Now Over-stressed areas can cause bolts to stretch and then, ultimately, separate. This creates an immediate missile safety concern as evidenced by the Crystal River employee’s death. I spoke with Pinnacle Actuation recently and they reported that they are seeing this scenario a lot more in recent inspections and that it’s not just limited to Limitorque valves anymore.

Overtorque Protection Collar – How It Works Since we can’t easily control what length of valve wrench an employee uses, Aunspach Controls is one of a few companies that have created overload protection devices. They have graciously provided a film clip that details handwheel and valve stem overload protectors and how they work.

Protection Collar – Other Styles Top Mounted D82 Model D82TM-INT SMB-000 Aunspach Controls offers different styles of collars available to suit most needs. For instance, In the handwheel collar line, they offer a top-mounted model and an integrated model for the Limitorque specific model SMB-000. Integral part of Limitorque actuator

Protection Collar – Information Needed Valves Make & Model/Style Stem Diameter & Threads/Inch Actuators Shaft Diameter Keyways Width x Length x Depth Length Extended Through Handwheel Collar? Extruded or Inlaid? To order the collars, the following information is needed: For the Valves, you’ll need to know the make, model, stem diameter and threads/inch For the Actuators, you’ll also need to know the make, model, shaft diameter, and keyway information. The keyway information includes the width, length, and depth The length that the keyway extends through the handwheel collar. For instance does it extend all the way through or just part of the way through? And, lastly, is the keyway extruded or inlaid on the shaft?

Protection Collar – Calculations Needed - Formula Derivation – (4) Steps Parker/Winsmith Gear Speed Reducers Limitorque SMB-00 Actuator Supplier Pinnacle Actuation MOV/Gearbox Safety Training SRP Engineering The next several screens will show the required calculations. I’ll show the more important calculations on the screen and mention some important facts. If someone wants more in-depth details, they are more than welcome to access this presentation and an existing excel spreadsheet to aid in the calculations; just give me a call. There are (4) steps needed in handwheel collar sizing calculations. These formulas were derived by Parker/Winsmith, a manufacturer of gear speed reducers and a Limitorque supplier, Pinnacle Actuation, and SRP engineering.

Protection Collar – Calculations Needed Determine Actuator Parameters Limitorque SMB-00 = 260 ft*lbs Max. Input Aura Motor = 260 x 0.6 = 156 ft*lbs Max. rpm = hp x 5252/Torque Min. Angular Speed < Step 3 Ensures Max. Torque Not Exceeded The first step determines the minimum stem speed that can be supplied to open or close the valve.

Protection Collar – Step 1 Information Actuator Nameplate Service Factor Maximum Allowable Torque Input Motor Manufacturer Safety Factor Step 1 calculations require information regarding the actuator nameplate service factor, the maximum allowable actuator torque input, and the safety factor included by the actuator motor manufacturer.

Protection Collar – Calculations Needed Gear Output = Min. Torque to Open/Close Valve Wedge Diameter = Valve Diameter Seating Force = Line Pressure x Seating Area x Valve Turning Hardness Factor Required Output = Total Thrust x Stem Radius The second step calculates the minimum system torque required to open and close the valve.

Protection Collar – Step 2 Information System Line Pressure Valve Internal Diameter Valve Stem Diameter Valve Friction Coefficient: Gate = 0.3 Packing Friction Coefficient Graphite = 3,000 psig incl. S.F. Step 2 calculations require valve and system data. You will need to know the line pressure, the valve internal diameter, the valve stem diameter, and valve and packing friction coefficients.

Protection Collar – Calculations Needed Supplied Gear Output = Max. Actuator Torque Input = hp x 5252/rpm Stem Speed = rpm/Drive Sleeve Bevel Gear Ratio Must be > Step 1 Min. Calculated Speed Input Gear Torque = Output hp x 5252/Stem Speed The third step calculates the maximum stem speed and torque that the actuator motor can supply. The actuator’s maximum allowable torque value could also be used instead of this calculated value. But if the equipment is not new and you don’t know the current stressed state, using the maximum motor-based torque value will provide a good safety factor. The minimum and maximum torque parameters have now been established.

Protection Collar – Step 3 Information Motor hp Motor rpm Motor Efficiency Drive Sleeve Bevel Gear Ratio Step 3 calculations require motor and gear data. You will need to know motor hp, rpm, and efficiency along with the gear ratio.

Protection Collar – Calculations Needed Required Torque < Overload Protection Cutoff < Max. Actuator Torque Vector = Moment Arm Length About System C.G. Hand Force = Cutoff Torque x Vector Max. Bar Length Allowed = Cutoff Torque - Avail. Hand Torque_____ Hand Force Needed – Avail. Hand Torque The last step calculates a maximum valve wrench length so the collar does not disengage from the stem and cause operation frustration. In the example that I’ve been showing, the minimum torque was 88 ft lbs and the maximum was 106 ft lbs. I chose 95 ft lbs because other valves could use this same collar size. By using this value as the maximum, I could increase the torque value of the collar to accommodate more valves without having to worry about exceeding the maximum allowable torque. This also allowed the manufacturer to reduce the manufacturing time and provide a discount for using the same setup.

Protection Collar – Ease of Installation/Pricing Dependent on Qty. & Style Greg Bennett – “Relatively Easy” Kirk Mason – “Very Easy” “Piece of Cake” Successfully Tested In the last screen, we discussed minimizing the cost of the collars. So, what is the cost? We ordered a total of (17) handwheel collars in (4) sizes. Our total cost was approx. $16,000. We saved approx. $5,000 or 25% because we minimized the size changes and maximized the qty. At any rate, the collars are relatively inexpensive compared to the possible consequences. “How easy are they to install?” First, the keyed handwheel is removed. Second, the collar is slid along the keyway and tightened onto the shaft perimeter with bolts. Lastly, the handwheel is re-installed, but on the collar shaft instead. It’s that easy. Do they work? The collars are adequate for the job. We tested the collars and found that they allowed closing and opening of the valve; that they disengaged when they should; and that they automatically reset for another attempt if needed.

Collar Installed on FWH Extraction Valves Here, you can see a visual of before and after collar installation. The collar length is sufficiently small to avoid interference with close quarter equipment. No Collars Collars

Prevent Valve Questions? & Actuator Damage