ML19269E185
| ML19269E185 | |
| Person / Time | |
|---|---|
| Site: | North Anna  |
| Issue date: | 04/30/1979 |
| From: | Rauch B FRANKLIN INSTITUTE |
| To: | Novak T Office of Nuclear Reactor Regulation |
| References | |
| CON-FIN-B-6567 F-C5108-1, NUDOCS 7906260623 | |
| Download: ML19269E185 (35) | |
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.snk a REPORT Raport F-C5108-1 April 1979 RESULTS OF ACCEPTANCE TESTS OF OUTSIDE RECIRCULATING SPRAY PUMP AT NORTH ANNA NUCLEAR GENERATING STATION by B. Rauch Prepared for Uni +.ed States Nuclear Regulatory Commission Division of System Safety Reactor Systems Branch Washington, D.C. 20555 KlC Researci an6 Technical Assistance Report ~ '
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HEPORT Final Report F-C5108-1 April 1979 RESULTS OF ACCEPTANCE TESTS OF OUTSIDE RECIRCULATING SPRAY PUMP AT NORTH ANNA NUCLEAR GENERATING STATION e by B. Rauch Prepared for United States Nuclear Regulatory Ccmmission Division of System Safety Reactor Systems Branch Washington, D.C. 20555 b 2133 229
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. . . Franklin Research Center A Division of The Franklin Institute The Benjamin Frankhn Parkway, Phila., Pa. 19103 (215)448-1000
F-C5108-1 CONTENTS Section Title Page 1 INTRODUCTION. . . . . . . . . . . 1-1 2 RESULTS AND CONCLUSIONS . . . . . . . . 2-1 3 ACCEPTANCE CRITERIA . . . . . . . . . 3-1 3.1 Bearing Wear . . . . . . . . . 3-1 3.2 Pump Vibration . . . . . . . . . 3-2
- 3. 3 Test Criteria . . . . . . . . . 3-2 4 TEST PROGRAM AND SPECIFICATIONS . . . . . . 4-1 4.1 Test Program . . . . . . . . . 4-1 4.1.1 Phase I . . . . . . . . . 4-1 4.1.2 Phase II. . . . . . . . . 4-2 4.1.3 Phase III . . . . . . . . 4-2 4.2 Instrumentation. . . . . . . . . 4-2 4.2.1 Accelerometers . . . . . . . 4-2 4.2.2 Pressure Transducers. . . . . . 4-3 4.2.3 Tachome ter . . . . . . . . 4-4 4.2.4 Recording and Conditioning Equipment. . 4-4 4.2.5 Equipment and Instrumentation List . . 4-4 5 TEST RESULTS. . . . . . . . . . 5-1 5.1 Phase I Six Hour Test . . . . . . . 5-1 5.2 Phase II Six Day Test . . . . . . . 5-2
- 5. 3 Phase III 450 Hour Test . . . . . . 5-4 5.4 Bearing Wear Extrapolation . . . . . . 5-3 2133 230
F-C5108-1
- 1. INTRODUCTION The Franklin Research Center (FRC) was contracted by the U.S. Nuclear Regulatory Commission (NRC) to assist in the evaluation of the reliability of the Outside Recirculatir.g Spray Pumps (0RS) of the Emergency Core Cooling System (ECCS) at the North Anna Nuclear Generating Station operated by Virginia Electric Power Co. (VEPCO).
The areas where FRC provided assistance included: e Establish acceptance criteria. e Formulate test program and specifications to determine if pumps meet the acceptance criteria. e Evaluate test data and apply acceptance criteria. The purpose of this investigation was to assure the ability of tha ORS pumps to operate continuously for a six-month period without mainten-ance. Initial tests of the Low Head Safety Injection Pumps (LHSI) at the North Anna Facility indicated serious concerns regarding the ability of the LHSI pumps to operate for any significant period of time. Since the ORS pumps had not been subjected to the same scrutiny, and since these pumps are all similar in concept and arrangement, the ORS pumps' relia-bility was in doubt. o O 2t33 231 1-1
F-C5108-1
- 2. RESULTS AND CONCLUSIONS At the conclusion of each,of the three phases of the test program, the ORS pump was removed, disassembled, and inspected. The bearing and journal surfaces were inspected and measured. The data from the special instrumentation (see Section 3) was reviewed. The results of this pregram are:
o Pump vibration levels, which were monitored throughout the tests, indicated that the 1/2 rotating speed frequency had a bounded amplitude, o The vibrational amplitudes at the other frequencies were also bounded. e The measured f requencies agreed with those predicted by Stone & Webster modal analysis. e Continuous bearing contact was only present during the initial few minutes of the 6 day test. e Bearing and journal scoring was observed during tF e Phase I and II portions of the test. The Phase III test did r ot seem to add significantly to the observed scoring. e Pressure measurements did not indicate the presence of measureable hydraulic instabilities. e Bearing wear measurements indicated that the wear extrapolated to
- six months of continuous operation will be within the limits of the " acceptance criteria".
Figure 2-1 depicts the total cumulative bearing wear measured af ter each phase of testing. Also shown on this figure are the expected and maximum wear levels for six months continuous operation. Most of the data falls below the 8 mil acceptance criteria, except for the discharge bushing and the 1st stage upper bowl bearing. However, considering the many dis-assemblies and assemblies performed o'. this pump, the bearings were j udged to have met the acceptance criteria for wear. Based upon the results of these tests, it is FRC's opinion that these pumps meet the requirements for acceptance as defined by the NRC. 2-1
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. F-C5108-1
- 3. ACCEPTANCE CRITERIA The shaft of the subject vertical pumps (ORS) requires a multiplicity of journal bearings along their 50-foot axial length. These bearings can be classified as:
e Bowl bearings which provide radial support and define the spatial orientation of the pump impellers. e Shaft bearings which provide the radial guidance for the pumps very long shaf t. 3.1 BEARING WEAR The penalties and effects of bearing wear on pump service life and reliability are, in FRC's opinion: e most deleterious for the bowl bearings, followed by e the upper and lowermost shaf t bearings, and e least severe for the intermediate shaf t bearings This does not imply that any degree of wear of the discharge column intermediate shaft bearings is acceptable, but does imply that the wear of these bearings within broader limits would be " acceptable" compared to " acceptable" limits of the other, more critical bearings. Based upon FRC's experience with water lubricated journal bearings for a variety of similar applications, it is believed that reasonable limits of expected and " acceptable" bearing diametral wear for the ORS pump's journal bearings during the maxieum required service life (6 months) should: e not exceed 8 mils for the more critical bowl and upper and lower shaft bearings e not exceed 16 mils for the less critical intermediate shaft bearings Ideally and pref erably there should be essentially "zero" wear of the bearings. However, f rom a practical standpoint considering the very long 50-foot axial length of the shaf t, the multiplicity of bearings utilized,
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2133 234
non-lubricity and low viscosity characteristics of water, the relatively soft carbon bearing material, and the tolerances and inaccuracies accumu-lated during fabrication, assembly, and installation combined with ill-defined hydraulic loadings and system dynamic characteristics, one must art._ipate some significant degree of bearing wear. It is FRC's opinion that the above stated limits of acceptable wear of the bearings are a reasonable compromise between the competing criteria of maintaining a sufficient degree of bearing performance and of practical necessity. It is also believed that thp. . values of bearing wear within these limits can be achieved. 3.2 PUMP VIBRATION Another useful criteria is the radial vibration spectrum of the pump shaf ting at selected axial stations, particularly at the previously identified critical bearings. From a practical point of view it is not feasible to measure vibration at the bowl bearings, however it is feasible to obtain such measurements for the shaft bearings. Using radial vibra-tion of the shaf t bearings as a criteria the following can be evaluated: e Bearing contact e Rotor response to system dynamics
, Rotor-bearing system stability 3.3 TEST CRITERIA
;'.c evaluation of the bearing wear criteria of 3.1 was based upon a semi-logarithmic extrapolation of the cumulative wear taken from measure-ments performed af ter each phase of the pump test program. This data was then plotted on semi-logarithmic graph paper having a linear amplitude scale and a logarithmic time scale. A linear extrapolation was performed on this plot in order to predict the total bearing wear af ter six months of operation. The manner in which the test program was conducted, simu-lated extended operation af ter a simulation of pre-operational testing and fif teen months of required start /stop cycles. It was FRC's and NRC's concurrent opinion that this would be a realistic simulation.
2133 235
In evaluating the vibration criteria of 3.2 a trend was looked for in the vibration amplitude data at the one-half rotating speed frequency. This f requency is associated with bearing stability. In a vertical pump the bearings are in an unloaded condition (operating with an eccentricity near zero) and one would expect to see signs of bearing instability. This is a common occurrence in this type of pump. This does not mean that it is necessarily a destructive situation. In most vertical pumps the amplitude of the half rotational speed vibration frequency remains bonded. If it were to continue increasing, then the life of the pump woul.d be in doubt. The vibration information relating to bearing contact should indi-cate a " break-in" period where continuous contact occurs at the beginning of a test run and then disappears as the bearings are broken in. If the contact remains continuous throughout the test, this indicates that serious bearing wear is taking place. Vibration data is also evaluated for the running speed and twice running speed frequencies. These provide indications of the unbalance and alignment conditions of the pump. These frequencies should remain stable and fairly low in amplitude. w 3-3
F-C5108-1
- 4. TEST PROGRAM AND SPECIFICATIONS Based upon the criteria discussed in Section 3, it appears that a valid test program should consist of a series of instrumented tests of limited duration with periodic disassembly of the unit for physical measurement of bearing and journal wear.
4.1 TEST PROGRAM The following outline summarizes the test program formulated by FRC and approved by NRC. This program was designed to provide sufficient information so that a determination of " acceptance", and an extrapolation of bearing wear for six months operation was possible. 4.1.1 Phase I The ORS pump was assembled, aligned, and equipped with the required instrumentation. Section 4.2 describes the instrumentation requirements. The pump was run for six hours at the nominal flow rate of 4040 gpm to simulate the r e-operational test run. The test fluid was primary grade water with sodium hydroxide and was borated to simulate the post-LOCA sump conditions (boron concentration of approximately 1800 ppm + 100 ppa, sufficient sodium hydroxide tc urovide a pH of 8). Water temperature was approximately 110*F. This is the temperature normally encountered durine pre-operational testing. At the end of the 6-hour run, 15 start /stop cycles were performed with the pump in the wet condition. Upon completion of the start /stop cycles the pump was removed from the can and disassembled. Bearings and journals were mearured and recorded. 2133 237 4-1
4.1.2 Phase 1: The pump was reassembled with the original bearings, aligned and installed in the can. The pump was run for 6 days at the t. emal full flow rate of 4040 gpm. The water chemistry was the same as outlined in Phase I. The water temperature was maintained between 140' - 150*F to simulate the expected maximum post-LOC' sump temperature. Upon completion of the 6-day run the pump was removed and disassembled. Bearings and journals were measured and recorded. 4.1.3 Phase III The pump was reassembled with the same bearings, aligned, and installed in the can. The pump was then run for an additional 450 hours under the same conditions as the Phase II run. Upon conclusion of the Phase III run, the pump was removed and dis-assembled. All bearings and journals were measured and recorded. 4.2 INSTRUMENTATION The three phases of the test program were conducted using the follow-ing instrumentation types, locations, method of conditioning, and recording. 4.2.1 Accelerometers Ten accelerometers were installed as indicated in the following table: Accelerometer No. Flange No.* Axis 1 2 Y 2 2 X 3 3 Y 4 3 X 5 5 Y
, 6 5 X 7 7 Y 8 7 X 9 Top of Motor Y 10 Top of Motor X
*From bottom of pump
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4-2
The "X" axis is in the vertical plane containing the center line of the inlet pipe. The "Y" axis is 90* clockwise from the "X" axis as viewed from above. The accelerometers used were Clevite model 5A2H. These transducers have a frequency response from 3 Hz to a nominal 4 KHz. The natural frequency of these transducers is in excess of 30 KHz. The output signals from the accelerometers were transmitted into B&K Type 2635 charge ampli-fiers. These charge amplifiers have three operating modes: e an acceleration mode which is used for obtaining a vibration signal proportional to acceleration e a velocity mode in which the acceleration signal is integrated to obtain velocities e a displacement mode in which the acceleration signal is integrated twice The frequency range of the charge amplifiers is from 0.1 Hz to 200 KHz. When vibration signals were desired the charge amplifiers were placed in the velocity and the output signal was then recorded. If bearing contact information was desired the charge amplifier was placed in the accelera-tion mode. The output was high pass filtered, demodulated, and low pass f iltered. The resultant signal was recorded. 4.2.2 Pressure Transducers Pressure transducers were mounted at three locations in the flow path: e on the inlet pipe near the can e approximately one foot below the seismic ring on the column e on the discharge pipe These pressure transducers were manufactured by Data Sensor and have a pressure range of 0 to 200 psi, with a frequency range of DC to in excess of 1 KHz. They are 350 ohm, 4-arm bridge type transducers. The output of each transducer was transmitted into a channel of the Model 1800 Hawkeye strain gage amplifier. The output of the amplifier was r aorded. 2133 239 4-3
/
4.2.3 Tachoineter A proximity type pickup was used for measuring the speed of the pump. The probe used was a Type 3030-HTB manufactured by Electro. The output of this probe was directly recorded. 4.2.4 Recording and Conditioning Equipment A 14-channel FM tape recorder was used for the recording of all dynamic measurements. The tape recorder used was a Saber 6 manufactured by Sangamo Company. The speed of the tape recorder was 7-1/2 1ps. At this speed the frequency response of the tape recorder is DC to 5 KHz. The frequency content of the dynamic test data was analyzed with a Nicolet Model 440A Fast Fourier Transform real time analyzer. This unit digitizes the analog time signal in blocks of 1024 data points, and uses a fast fourier transform processor for computing a 400 line constant bandwidth spectrum. It has a built-in cathode ray tube for dispicying either the time signal or the spectrum in one of 14 ranges from an upper limit 10 Hz to 20 KHz full scale. Low f requency anti-aliasing filters are automatically selected with the frequency range. The dynamic range of this arc'_yzer exceeds 60 dB, relative to full scale. 4.2.5 Equipment and Instrumentation List The following is a list of all the equipment and instrumentation used in conjunction with ORS pump tests. Strain Gage Amplifier, Hawkeye Model 1800, 8-channel Charge Amplifier, Bruel & Kjaer Type 2635 Bruel & Kjaer Type 2511 Tape Recorder, Sangamo Sabre Six, 14-channel Bruel & Kjaer 7300, 4-channel Accelerometer, Clevite Model 5A2 Pressure Transducer, Data Sensor, Model PB509A-4
. Tachometer, Electro Type 30TJ-HTB 2133 240 4-4
Filters, Krohn-Hite, Model 335 Model 3100 Model 3202 Model 3342 Model 3550 Oscillographic Recorder, Midwestern Instruments, Model 621HT Spectrum Analyzer, Nicolet Model 440A Demodulator, WJE, 10-channel Voltmeter, Digital, Fluke, Model 8000A Meter, Ballantine, Model 300 X-Y Plotter, Hewlett Packard Camera, Oscilloscope, Polaroid 2133 241
~
4-5
- 5. TEST RESULTS 5.1 PHASE I - SIX HOUR TEST The following bearing wear was measured af ter the conclusion of the six hour, 15 start /stop cycles, test.
Average Average Average Bearing # Bearing Wear Journal Wear Total Wear Discharge He-4 1.1 mils 0.4 mils 1.5 mils 9 0 0.2 0.2 8 0 0 0 7 0 0.1 0.1 6 0.1 0. 3 0.4 5 0 0.1 0.1 4 0 0.1 0.1 3 0 0.2 0.2 2 0 0 0 2nd Stage Upper 0.8 0.7 1.5 2nd Stage Lower 0.6 0.6 1.2 1st Stage Upper 0.6 0.5 1.1 1st Stage Lower 0.9 0.4 1.3 To meet the bearing wear acceptance criteria the maximum total bearing wear allowable af ter the 6 hour test is 5 mils. The data indi-cares the maximum measured wear was 1.5 mils. Therefore all bearings met the initial wear criteria. A review of the vibration data taken during the Phase I test revealed the following: There are four predominant f requencies observed in the output of the bearing velocity data. These are 3. 5, 9. 5, 14.2 and 29. 75 Hz. 3_1 2133 242
Throughout the duration of the Phase I test the amplitudes of these frequencies, as measured on the four instrumented bearings, remained virtually constant. In particular, the amplitude of the 14.2 Hz vibration was unchanged throughout the 6 hour test 5.2 PHASE II SIX DAY TEST The following bearing wear was measured af ter the six day test. These values are average cumulative wear for each of the bearings. Average Average Average Bearing // Bearing Wear Journal Wear Total Wear Discharge Head 1.3 mils 1.9 mils 3.2 mils 9 0.4 0.5 0.9 8 0 0.6 0.6 7 0 0.7 0.7 6 0.1 0.4 0.5 5 0 1.2 1.2 4 0 0.5 0.5 3 0 0.4 0.4 2 0 1.0 1.0 2nd Stage Upper 0.8 1.2 2.0 2nd S tage Lower 0.6 1.1 1.7 1st Stage Upper 0.9 1.0 1.9 1st Stage Lower 0.9 1.0 1.9 The bearing wear acceptance criteria for allowable wear af ter the 6 day test is 8 mils. The table shows a maximum measured wear of 3.2 mils. Therefore all bearings met the wear criteria for Phase II. Vibration signatures taken throughout the test indicate the presence of a variety of frequencies. These frequencies agree with those calcu-lated by Stone & Webster. The following table summarizes the f requencies of interest and compares the measured values to those predicted by Stone & Webster. 5-2 2133 243
Predicted Frequency Observed Frequency Comments (Hz) (Hz)
- 3. 4 3.5 Column
- 6. 8 Not observed Can*
8.2 9.5 Column 15.3 14.2 Column 19.0 Not observed Can* 28.2 29.75 Column
*Since instruments were on column, can frequencies not observed Higher f requencies were present and correlated well with the analysis of Stone & Webster. No unexpected or anomalous frequencies were observed.
As previously stated, for vertical pumps with water lubricated journal bearings the frequencies of interest are approximately 1/2 the running speed and the running speed itself. For this pump they are 14.2 and 29.75 Hz respectively. The following table summarizes the vibration data for these two frequencies at 5 minutes after the start of the 6-day test and 1/2 hour before its conclusion. 14.2 Hz 29.75 Hz Location 5 mins 143-1/2 hr 5 mins 143-1/2 hr Brg 2 .19 mils .27 mils 1.40 mils 1.69 mils pk-pk pk-pk pk-pk pk-pk Brg 3 1.78 2.59 2.01 1.64 Brg 5 2.68 3.65 1.70 1.38 Brg 7 3.08 3.76 1.23 1.39 Top of .05 .15 1.24 1.39 Motor This data indicates a slightly increasing trend in the 1/2 running.
. speed frequency. Further testing was required to establish if the amplitude of the 1/2 running speed frequency was bounded.
2133 244 5-3
With respect to shaft-bearing contact, the data indicated that heavy rubbing occurred within the first few minutes of the 6-day test. This was break-in contact, which results from small assembly misalign-ments. The heavy rubbing disappeared very rapidly as was expected. During the remainder of the test, random single contacts were observed. It is felt that this was a result of debris entering the bearing clear-ance. The remainder of the data observed was stable. A visual inspection of the bearings and journals showed some scoring on both surfaces. Based upon the test data and wear measurements the pump appeared well behaved. Additional testing was recommended to deter-mine if the 1/2 running speed frequency amplitude becomes bounded and if the scoring and wear will remain within acceptable limits.
- 5. 3 PHASE III 450 HOUR TEST The following bearing wear was measured af ter the running of the 450 hour test.
Average Average Average Bearing # Bearing Wear Journal Wear Total Wear Discharge Head 3.1 mils 3.2 mils 6.3 mils 9 2.2 1.0 3.2 8 1.5 1.4 2.9 7 2.0 1.6 3. 6 6 2.1 1.0 3.1 5 2.2 1.5 3.7 4 1.5 0.7 3.2 3 1.3 1. 3 2.8 2 1.6 2.0 3.6 2nd Stage Upper 2. 3 1.8 4.1 2nd Stage Lower 1.0 1.7 2.7 1st Stage Upper 3.3 1.5 4.8 1st Stage Lower 2.7 1.5 4.2 2k f) 5-4
The acceptance criteria for bearing wear after the 450 hour test is 8 mils maximum. The measured data shows a maximum total wear of 6.3 mils. This value was considered acceptable. The vibration data recorded indicated that all vibration levels remained within a band of 4 to 6 Dd throughout the duration of the test. The conclusion drawn from this data was that the pump was operating in a stable manner and that any bearing instabilities present were not producing unbounded destructive vibrations. The pressure data taken throughout the test did not indicate any measureable hydraulic instabilities and further confirmed stable pump operation. Bearing contact data indicated only random contact through most of the test. This was due to debris passing through the bearings. At 382 hours into the test the transducer on the no. 5 flange showed a high activity for about an hour. This activity then diminished indicating that dirt had been in the bearing. In addition to the above information not sal pump vibration data was collected by Stone & Webster throughout the test. This data was taken at four points on the pump and motor: e Upper motor bearing cap e Lower motor bearing cap e Shaft in the vicinity of the pump /mt tor coupling e Top flange of the discharge head Figure 5-1 is a plot of the maximum readings taken at these locations. VEPC0 stated that the shaf t runout was 4.5 mils total indicated runout where the shaf t vibration readings were taken. If this value is sub-tracted from the shaft vibration level then shaf t vibrations were within 5 mils throughout the test.
~
5.4 BEARING WEAR EXTRAPOLATION
. Using a semi-logarithmic extrapolation, the expected wear af ter 6 months of continuous operation was predicted. Figures 3-2 through 5-14 5-5
are plots of the measured wear of each of the bearings af ter each phase of testing. These results were extrapolated to 6 months in the following two ways: e Using the 6 hour and 600 hour data to provide an expected 6 month wear e Using the 6 day and 600 hout data to provide a maximum 6 month wear It is expected that the wear one would actually see af ter six months would fall in-between these two extrapolated values. The following table summarizes these values. Bearing # Expected 6 Month Wear Maximum 6 Month Wear D.H. 8.3 mils 10.4 mils 9 4.4 6. 2 8 4.25 6.25 7 5.0 7.6 6 4.25 6.8 5 5.3 7.3 4 3.1 4.7 3 3. 9 6.2 2 5.1 7. 3 7nd Stage Upper 5.2 7.1
- 2nd Stage Lower 3.4 4.2 1st Stage Upper 6.4 8.8 1st Stage Lower 5.4 7.5 This extrapolation indicates that all the bearings will experience wear levels lower than the acceptance criteria of 8 mils af ter 6 months of operation. Two bearings, the discharge bushing and the 1st stage upper bowl bearing can exceed this level. However, since this test program had 3 disassemblies and 2 reassemblies with the same bearings this produced misalignments which resulted in additional wear that would not be present if the pump were not disassembled and reassembled.
5-6 2133 247
Therefore, based upon the test results and the acceptance criteria, the pump was judged to be suitable for its design function. 6 2133'248 5-7
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