Vinod Sharma, P.E.

Mr. Sharma has over 20 years of broad-based technical expertise in design analysis, testing, and management of the reliability, condition monitoring, and maintenance of mechanical equipment in flow systems. This includes performance evaluations and failure analyses in a variety of applications including industrial manufacturing facilities, domestic and international power plants, refineries, petrochemical plants, oil and gas onshore and offshore pipelines, marine vessels, and commercial and residential buildings. These assessments addressed questions relating to liability, product recall, economic and market due diligence, technology assessment, business process improvement, and intellectual property.

Mr. Sharma has hands-on experience with a range of flow-control hardware used in compressible and incompressible applications, including instrumentation, valves, pumps, and steam boilers. He has designed components for the drilling industry, and has performed structural and fatigue analysis of down-hole tools. He has used advanced analytical software and detailed computer-based analysis and testing tools, including non-intrusive diagnostics and flow measurements, experimental design and instrumentation, supervisory control and data acquisition (SCADA) and digital signal processing, computational fluid dynamic (CFD) analysis of valves, and finite-element analysis (FEA). His broad background and active industry involvement have provided him a well-rounded understanding of a range of related fields, such as 10CFR50 Appendix B and American Society of Mechanical Engineers (ASME) NQA requirements in the verification and validation of safety related analytical software, and the application of ASME Codes and Standards to evaluate operation and maintenance issues, fabrication, and design defects. He has taught several advanced technical courses on wear and fatigue failure analysis and prevention. He also received training in manufacturing processes at Sundaram Fasteners Ltd., Union Carbide, Ltd., Bharat Fritz Werner Ltd., and IAF Air Force #3 Base Repair Depot. His graduate research investigated the mechanics of birth injuries associated with shoulder dystocia and complications of clavicle fracture and brachial plexus nerve strain.

Sharma, V, Markowski D, Joss G. Evaluation of RHR pump vibration and solutions to detune the system to improve pump reliability and reduce uncertainty during in-service testing. NRC/ASME Symposium on Valve and Pump Testing, August 2011.

Sharma V, Huet R, Cruz D A, Burge R, Quan S.. Systematic evaluation of significant check valve application to improve reliability to enhance in-service test performance and plant availability. NRC/ASME Symposium on Valve and Pump Testing, August 2011.

Sharma V. Work Shop for Palo Verde Nuclear Station Check Valve Inspectors. Arizona Public Service Company, February 11–13, 2009.

Sharma V. Equipment replacement – how rigorous is your due diligence? Nuclear Industry Check Valve Group, June 2008.

Sharma V, Simon A, Stuhr D. Check valve program self assessment at Columbia and Cooper – benefits & critical success factors. Nuclear Industry Check Valve Group, January 2008.

Sharma V, Leutwyler Z, Sicking R. Case study – Analysis & testing of small size piston check valve w/ air flow. Nuclear Industry Check Valve Group, June 2005.

Sharma V, Kalsi MS, Wang JK. Advancements in valve technology and industry lessons lead to improved valve reliability. 13th International Conference on Nuclear Engineering, ICONE 13-50286, Beijing, China, May 2005.

Kalsi MS, Eldiwany B, Sharma V, Ritchie A. Effect of butterfly valve disc shape variations on torque requirements for power plant application. 8th NRC/ASME Symposium on Valve and Pump Testing, NUREG/CP-0152, Vol. 5, July 2004.

Masters D, Sharma V, Dixon, B, Maanavi T. Enhancing check valve programs by invoking Appendix II condition monitoring. Nuclear Industry Check Valve Group and Inservice Test Owners Group (ISTOG), June 2005 and December 2005.

Sharma V. Check valve condition monitoring & software for improved plant reliability. Annual Korea Institute of Nuclear Safety Workshop on AOVs/MOVs, KINS/PR-056, Vol. 1 July 2004.

Sharma V, Domingo Cruz et al. of the Non-Intrusive Examination Sub-committee of the Nuclear Industry Check Valve Group (NIC). Evaluation of nonintrusive diagnostic examination technologies for check valve trending. Presented to the Nuclear Industry Check Valve Group, December 2003.

Kalsi MS, Sharma V. Dynamic torque models for quarter-turn air-operated valves. Presented to the Annual Korea Institute of Nuclear Safety Workshop on AOVs/MOVs, KINS/PR-016 Vol. 3, May 2003.

Sharma V. Check valve wear quantification for improved cost effectiveness and plant reliability. Presented at the 9th EPRI Valve Technology Symposium, Portland, ME, August 2003.

Kalsi MS, Eldiwany B, Sharma V. Butterfly valve model improvements based on compressible flow testing benefit industry AOV programs. Presented at the 7th NRC/ASME Symposium on Valve and Pump Testing, July 2002.

Kalsi MS, Eldiwany B, Sharma V, Somogyi D. Dynamic torque models for quarter-turn air-operated-valves. Presented at the 6th NRC/ASME Symposium on Valve and Pump Testing, NUREG/CP-0152, Vol. 3, July 2000.

Sharma V, Somogyi D. Root cause analysis and elimination of check valve performance problems by computational fluid dynamics. Presented at the 5th NRC/ASME Symposium on Valve and Pump Testing, NUREG/CP-0152, July 1998.

Sharma V. CFD as a tool for check valve root cause analysis and performance improvement. Presented at the Electric Power Research Institute 6th Valve Technology Symposium, July 1997.

Sharma V, Ritchey A. Analysis and testing of small piston check valves with air flow. Nuclear Industry Check Valve Group, June 2005.

Sharma V. Role of quantitative analysis in check valve condition monitoring programs. Nuclear Industry Check Valve Group, Winter Meeting, December 2004.

Sharma V, Kalsi MS, Wang JK. Industry issues and lessons learned for improved valve reliability and competitiveness. Workshop on Valve Selection, Valve World, Maastricht, November 2004.

Kalsi MS, Eldiwany B, Sharma V. Effect of Butterfly valve disc shape variations on torque requirements for power plant applications. The 8th NRC/ASME Symposium on Valve and Pump Testing, NUREG/CP-0152, Vol. 5, July 2004.

Kalsi MS, Sharma V. AOV/MOV design basis evaluation and margin improvement methodologies. Annual Korea Institute of Nuclear Safety Workshop on AOVs/MOVs, KINS/PR-056 Vol. 1, July 2004.

Sharma V. Check valve condition monitoring and software for improved plant reliability. Annual Korea Institute of Nuclear Safety Workshop on AOVs/MOVs, KINS/PR-056 Vol. 1, July 2004.

Wang JK, Sharma V, Kalsi MS. Safety injection check valve evaluation to eliminate premature seat degradation problems. KHNP, Yeonggwang Nuclear Station, June 2004.

Kalsi, MS, Sharma V. Industry issues, initiatives and technology to improve valve and actuator reliability. British Energy – Sizewell Power Station, April 2004.

Sharma V, Kalsi MS. EPRI MOV performance prediction program—Butterfly valve design, elbow, and scaling effects test program. EPRI TR-103257, April 1994.

Kalsi MS, Horst CL, Wang JK, Sharma V. Prediction of check valve performance and degradation in nuclear power plant systems—Wear and impact tests. Prepared for the U.S. Nuclear Regulatory Commission, NUREG/CR-5583, April 1990.

• Senior Consultant and Director of Business Development, Kalsi Engineering, Inc., 1988–2005

Failure Analysis and Reliability Improvement
Performed several component design analyses to prepare independent evaluations and expert testimony related to flow control equipment used in a wide range of applications, including those installed in electric power plant turbine steam flow-control systems; fire safety, effluent, gas, hot water, and steam supply systems; marine engines; on an LNG pipeline; and at refineries and petrochemical plants. These evaluations provided an engineering basis to explain the observed or expected in-situ response. Such evaluations often require comprehensive examination of artifact and interfacing hardware, operating data and procedures, and maintenance records. Exemplar projects:

Oil & Gas – upstream
LNG Pipeline Network Design Assurance equipment reliability peer review
Monolithic Isolation Joint technology assessment for an LNG pipeline
Inspection of salvaged jack up drilling rig
Casing jump out at gas well

Oil & Gas - midstream
GOM South Marsh subsea ball valve inspection in matter involving an explosion and sinking of a dive support vessel
API650 Tank Corrosion at an oil terminal
Gas pipeline compressor discharge check valves failure
Oil terminal pressure regulating ball valve failure resulting in oil spilling into a bay
Gas pipeline compressor station compressor and turbine unit inspection
Fire at NGL process plant ascribed to leak at valve flange

Oil & Gas – downstream
Refinery explosion – role of failed drain valve
Refinery - inspection of failed gas turbine
Refinery fire attributed to wall thinning

Power Generation
Palo Verde nuclear station wide review of emergency core cooling system check valves
Exelon – Utility wide review of unreliable reactor recirculation pump seals
Ginna nuclear station residual heat removal pump vibration
Various failed gas compressor inspections
Coal power plant explosion related to steam trip and throttle/ valve and governor failure
Assessment of valve and pump programs at various nuclear power stations
Palo Verde Nuclear Station 3-day workshop to qualify engineering check valve inspectors

Industrial/Municipal
Chemical process plant manual butterfly valve failure
Contamination of building air system at a manufacturing plant
Fouling of steam system in paper mill from valve failure
Construction delay at municipal water plant attributed to insulating flange gaskets

Food/Pharmaceutical
Contamination of infant formula related to failure of a pneumatic butterfly valve
Self priming pump steam release on a hog farm
Grocery warehouse generator fire

Marine
Tug boat engine room fire resulting from diesel spray from a duplex filter
Role of hydraulic steering control valve failure in a vessel collision related injury

Public Buildings
Hospital mechanical room equipment damage caused by a safety relief valve
Fatality at assisted living center attributed to a faulty mixing valve
Noisy shower and tub valve in a newly constructed apartment complex
Role of dry sprinkler valves in flooding damage to a dormitory
Scalding injury in hospital hot oil heater thermowell failure
HVAC pump failure in a high rise hotel building

Residential
Role of gas appliance stop valves in explosions
Effluent contamination at multiple custom homes caused by septic system failures

Analysis/Design Component Capability Calculations

Served as the Project Manager for an independent evaluation of various internal apparent-cause and root-cause analyses for determining the source of unreliability in Reactor Recirculation Pump Seals installed at various boiling water reactors in the Exelon Corporation’s nuclear plant fleet. The results of this study, presented to senior corporate management, provided feedback on the root-cause analysis results and suggested process and equipment improvements.

Served on a design assurance team assigned to perform a peer review of design documents for a West African natural gas pipeline being developed by a consortium of major oil companies. The work included performing an independent third-party review of documents related to the Pre FEED/FEED trunkline design activities and nearshore and onshore sections—as requested by the team—on a range of topics, such as the fatigue demand report, the Gas Export Regulating Manifold, and geotechnical assessments. The final report provided comments based on an integrated look at a project’s underlying assumptions, decision logic, alternatives, and forward plans. This evaluation, performed on behalf of an entity representing the investors, provided assurance of the design and suggestions for improvement to the oil companies. For example, evaluated design contractor’s update of requirements to be placed on monolithic isolation joint manufacturers to fatigue test their joints to ensure physical integrity under the specified loading conditions expected in an LNG pipeline network. The effects considered included metal fatigue, corrosion, degradation of elastomeric seals, and the cumulative impact of pressure transients on the joint’s structural integrity over its 30-year design life. This study included a review of the Monolithic Isolation Joint Specification, Data Sheet, and Supplier Data Requirements List (SDRL) to assess the impact of aging-related loss of strength and loss of corrosion barriers.

Served as the project manager to determine the root cause of pump vibration at the Ginna Nuclear Station. This study provided the nuclear plant with the root cause, as well as with suggestions for design improvement and validation, prior to equipment replacement.

Supported the initial economic evaluation and due diligence of a proposed integrated PTA/PET complex for an overseas investment firm.

Contributed as a member of Failure Root Cause teams for several nuclear stations, including Ginna, H.B. Robinson, San Onofre, Grand Gulf, Millstone Unit 3, Catawba, Comanche Peak, Susquehanna, Nine Mile Point, Davis Besse, Pickering, Kori, Yeonggwang, Turkey Point, Shearon Harris, Laguna Verde, and Sizewell. These projects enhanced improved equipment reliability and plant availability.

Example: Applied Computational Fluid Dynamic (CFD) methods to determine the root cause of valve failure by simulating non-testable conditions for a 24-inch feedwater lift check valve that was experiencing excessive wear. Analysis validated the hypothesis that the internal flow geometry was creating an unfavorable pressure distribution within the valve. An optimal disc position was then determined to ensure disc stability and closure on reverse flow without introducing excessive pressure drop during forward flow.

Served as a project lead/projects specialist for check valve program development at San Onofre, Cooper, River Bend, Waterford 3, D.C. Cook, Callaway, and Wolf Creek. Contributor to INPO SOER 86-03 check valve application reviews for ANO 1, Clinton, Comanche Peak, South Texas, and Davis Besse. These projects generated technically rigorous and well-documented bases that facilitated the prioritization of the components for maintenance and condition monitoring programs.

Example: Detailed system- and component-level failure-modes-and-system-effects evaluation of over 3,700 valves to screen operating systems and valves based on their influence on personnel safety and plant reliability. Component- and system-level data collected included valve drawings; installation details; operating flow rate, pressure, and temperature data for all modes of plant operation; and valve maintenance histories. Comprehensive valve analyses were then performed on 1,100 check valves to quantify the rate of internal degradation, using the Check Valve and Analysis Prioritization (CVAP) methodology. Analysis results were used to prioritize valve maintenance, select condition monitoring methods, and schedule inspection intervals. Inspection recommendations included acceptance criteria for valve internals and use of non-intrusive diagnostic technologies.

Served as a project lead for GL 89-10 Analysis of MOV design-basis calculations for all non-testable gate valves at Millstone Power Station Units 1, 2, 3, and gate and globe valves for Palo Verde, to determine thrust requirements and fulfill the requirements of NRC Generic Letter 89 10. This included the procurement of valve internal dimensions from valve vendors; the integration of operating temperature, pressure, and flow data; and the analysis of MOVs using the EPRI GATM methodology to determine thrust requirements. For valves that fell outside the technical specification, justification was developed to support designating the valve either “operable, but out of design” or “unpredictable/inoperable.” These projects enabled plants to develop data required to fulfill the regulatory requirement of ensuring sufficient operating margin.

Performed Limitorque actuator fatigue life analyses for actuators loaded beyond their specified ratings, using the proprietary LTAFLA software for Carolina Power & Light. This evaluation enabled the utility to estimate the remaining fatigue life of motorized valve actuators.

Performed detailed thermal stress analysis on a high-temperature, high-pressure steam throttle valve for the Department of Defense. This effort contributed to the design of a valve for a proprietary naval system.

Contributed to the revision of EPRI/NMAC’s Application Guide for Check Valves in Nuclear Power Stations and provided sections on check valve hinge-pin wear and disc stud fatigue degradation. This document provided plant engineers with state-of-the-art guidance on the proper application of check valves.

Responsible for all aspects of data gathering, verification, and document control supporting the 86-03 check valve application review for Florida Power & Light Company’s St. Lucie Units 1 and 2 and Turkey Point Units 3 and 4. This project enabled the identification of potential bad actors from the valve population, and a basis to plan their maintenance.

Responsible for all aspects of compilation and analysis of MSSV operating history data used to study the dependence of MSSV degradation on duration of plant operation at diverse power levels for Toledo Edison’s Davis Besse Nuclear Power Station. This effort supported the evaluation of the root-cause analysis of in-service degradation.

Performed finite-element analyses of down-hole drilling mud motor sealed bearing assemblies of various sizes, and elastomeric hydrodynamically lubricated rotary shaft seals. Also performed structural and fatigue analyses of down-hole subs and bottom-hole assemblies. These projects supported the design of mechanical systems used in oil and gas exploration and production.

Laboratory and Flow Testing

Served as the Principal Investigator on the EPRI MOV PPM butterfly valve design, elbows, and scaling effect 10CFR50 Appendix B incompressible flow testing of butterfly valves, to quantify the effects of an upstream elbow on torque requirements, and to verify torque prediction and scaling equations used by the nuclear industry, published in EPRI TR-103257. This project culminated in the compilation of a comprehensive database on hydrodynamic torque coefficients of quarter-turn valves that is used by nuclear power plants to calculate the valve torque requirements.

Served as Project Lead for the EPRI MOV PPM Borg-Warner gate valves performance validation dynamic flow testing, to determine the root cause of high stem thrust requirements, published in EPRI TR-1032229V1. This project helped explain the cause of the gate valves’ anomalously high thrust requirements.

Served as Project Lead for the Kalsi Valve and Actuator Program (KVAP) model validation 10CFR50 Appendix B testing of quarter-turn valves to verify torque prediction and scaling equations, and to quantify the effects of upstream elbows on torque requirements. These incompressible and compressible flow tests were performed on a variety of valve types, including butterfly valves with symmetric, single-offset, and double-offset discs; ball valves of the full spherical and segmented type; and plug valves. This testing resulted in improved models to perform quarter-turn valve capability calculations for AOV JOG Program/RIS 2000-3 and GL 89-05 MOV JOG Periodic Verification programs.

Served as the Program Manager for the Nuclear Industry Check (NIC) valve trending program, to identify parameters that can be trended reliably to assess check valve internal wear and predict incipient failure. In consultation with the NEC Technical Advisory Group, developed a test plan, facilitated the flow-loop testing, and worked with TAG to prepare a final report for industry-wide distribution. This test program involved compressible and incompressible flow tests on swing, tilt, double disk, and piston check valves. This industry study helped nuclear power plant engineers develop plant condition monitoring programs.

Served on the project team responsible for Small Business Innovation Research/Nuclear Regulatory Commission’s (SBIR/NRC) Check Valve internal wear rate quantification Phase 2 test program. Performed tests and evaluated data gathered during the 18-month Phase 1 study of performance and prediction of degradation in swing check valves. The results formed the basis for the wear and fatigue methodologies provided in NUREG/CR-5583 and the NMAC Check Valve Application Guide, 5479 Rev. 1. This industry study resulted in the validation of first principal’s models and their use to prioritize the maintenance of check valves at several nuclear power stations.

Served on the project team for the EPRI Valve Design Separate Effects Test Program, with responsibility for the design and implementation of a closed-loop servo-hydraulic data acquisition and control system to simulate hydraulic loads on gate valve discs tested on the KEI gate valve design effects test fixture, described in EPRI TR-1032229V2. The test fixture developed under this study was used to evaluate key design features of gate valves in relation to their propensity to result in the unpredictable behavior of gate valves. The results of this study formed the basis of evaluation and modification of gate valves used in nuclear power stations.

Served as the Project Lead for several flow-loop tests that enabled clients to better quantify the performance of their valves and make better design choices, such as tests for Carolina Power & Light Company on 4- and 10-inch Westinghouse check valves to determine Vmin and disc stability. Designed special valve weld end adapters to mount 4- and 10-inch Westinghouse check valves on a KEI test flow loop. Additional tests to simulate the suitability of 18-inch Atwood & Morrill and Anchor Darling feed¬water swing check valves. Tests to evaluate performance of commercial-grade check valves, butterfly valves, nozzle checks, excess flow checks, and other items made by several manufacturers, including Velan, Stockham, Walworth, Crane, Powell, Bray, Noble Alloy, PGI, GariTech, GSI, and others.

Performed error analyses for various measurement systems in ANSI/ASME PTC 19.1-1985 Measurement Uncertainty supplement to the ASME Performance Test Code. This was a key requirement for safety-related testing performed in accordance with the requirements of 10CFR50 Appendix B.

Responsible for many laboratory and field tests, to support client research and development projects and enable the investigation of the root cause of component failure. For example, implemented data acquisition systems and processing systems for an industry-sponsored Limitorque actuator housing cover thrust overload increase test program; Department of Energy air motor performance characterization tests (progressive cavity); impact loading tests on proprietary threaded connection used in sub-sea piles; and product development testing for hydrodynamically lubricated rotary shaft seals used in oil and gas drilling applications. Performed many tests on mechanical equipment and structures, including studies of side loading induced by free-floating backup, and temperature effects on integrity of fiberglass piping. Evaluated the effect of component design on bursting during a freeze, unintentional operation/ fluid discharge, failure, etc.

Software Development

Contributed to the development, verification and validation, upgrades and implementation of advanced engineering analysis software packages used by US nuclear power plants to perform safety related calculations for improving equipment reliability. These software products were designed, developed, and maintained under the requirements of the 10CFR50 Appendix B Quality Assurance Criteria, ASME NQA-1 Requirements for Computer Software used in Nuclear Facilities, and 10CFR Part 21 for the reporting of defects and non compliance. Examples include:

• Check Valve Analysis and Prioritization (CVAP) Software (1990–2005) used to improve valve reliability at 22+ nuclear power plants. As Product Manager of the was responsible for quality assurance, training, technical support, sales, and marketing.
• Kalsi Valve and Actuator Program (KVAP) advanced engineering analysis software to calculate the design basis operability margin of safety-related valves in nuclear power generation stations.
• The KEIGATE software for analysis of MOV gate and globe valves installed in nuclear power generation stations.
• Marketed various other analytical software products: Limitorque Actuator Fatigue Life Analysis/Limitorque Life Evaluation (LTAFLA/LiFE) Software, Kalsi Pressure Locking and Thermal Binding (KPLTB) program.

Industry Involvement

Mr. Sharma has served as project manager for several plant-wide valve program development projects and was a key contributor in the development of industry-leading methodologies for performing component capability calculations and modeling wear degradation. These projects involved system and component-level evaluations, design basis calculations, detailed reviews of numerous valve applications, testing of a wide variety of nuclear and commercial valves, and leading self-assessment/audit teams and expert panels. Mr. Sharma has contributed to many R&D projects, including those sponsored by the Small Business Innovation Research/Nuclear Regulatory Commission (SBIR/NRC), Nuclear Industry Check Valve Group (NIC), Electric Power Research Institute (EPRI), U.S. Department of Defense (DOD), and U.S. Department of Energy (DOE). The following are examples of participation in industry forums and trade groups to stay current on ongoing and emergent industry issues related to the reliability of flow systems:

Active member of the Nuclear Industry Check Valve Group (NIC), 1990–2005; honored by the NIC group for contributions to the improvement of check valve reliability industry-wide.

Program Manager for the Non-intrusive Examination Committee of the Nuclear Industry Check Valve Group, and project lead for NIC-sponsored test program.

Lead Assessor on check valve program self-assessment teams at Wolf Creek, Waterford 3, Columbia, and Cooper. Example: served on expert panel that assessed the Wolf Creek check valve condition-monitoring program.

Developed course material for and presented the following courses: CVAP Software Training, Advanced Check Valve Failure Analysis course, Seminar on Computational Fluid Dynamics Applications to Valve Analysis and contributed to the NIC/ISTOG Check Valve Condition Monitoring Workshop: Courses provided at the EPRI Valve Symposium, NIC 2004 Winter Meeting, NIC /ISTOG 2005 Summer Meeting, and to the following plants and engineering companies: Davis Besse, Duke Power (Oconee, McGuire and Catawba), San Onofre, Cooper, Wolf Creek, Callaway, D.C. Cook, Nine Mile Point, Pilgrim, South Texas, Bruce Power, Korea Power Engineering Company (KOPEC), Korea Plant Services (KPS), Framatome ANP, UltraCheck Users Group.

Facilitated EPRI/NMAC Advanced Check Valve Non-Intrusive Diagnostic Technology Class and EPRI/NMAC Advanced AOV Non-Intrusive Diagnostic Technology Class at flow-loop facility.

• American Society of Mechanical Engineers (member)