ML20032E786
| ML20032E786 | |
| Person / Time | |
|---|---|
| Site: | Prairie Island  |
| Issue date: | 11/12/1981 |
| From: | Diianni D Office of Nuclear Reactor Regulation |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| NUDOCS 8111230150 | |
| Download: ML20032E786 (58) | |
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[g UNITED STATES e
g NUCLEAR REGULATORY COMMISSION ys
': p WASHING TON. D. C. 20555
\\,,,,j gg3. g3<34 ov u a Docket No. 50-306 LICENSEE: Northern States Power Company (NSP)
FACILITY: Prairie Island Unit 2 (PI-2)
SUBJECT:
SUMMARY
-0F MEETING ON OCTOBER 29, 1981 - REACTOR COOLANT PUMP SHAFT CRACK t
On October 29, 1981, the NRC staff met with NSP and Reactor Coolant Pump Manufacturer (Westinghouse Corp.) to discuss the failure of the Reactor Coolant Pump No. 21 (RCP No. 21) that was observed at PI-2 on June 11, 1981.
By letter dated August 24, 1981 we requested that the licensee and pump manufac-turer inform the staff of the nature of the failure in detail. This letter also transtr.itted a proposed agenda for a meeting to be held in Bethesda, Maryland covering areas of interest to the staff. The purpose of this meeting was to inform the NRC of the details of the failed RCP at PI-2.
A list of attendees and a copy of the viewgraphs presented during the meeting are enclosed (Enclosure 1&2).
The meeting opened with a presentation of a modified agenda similar to the one proposed by the staff on August 24, 1981. The modified agenda consisted of the following.
1.
Operating experience leading to the discovery of the pump failure at PI-2, 2.
Operating experience of other pumps of similar design including operating history as of June 1,1981.
Detailed description of the design, manufacturing history, pump sh, 3.
material selection, and mechanical loading.
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Fail ure Mode of PI-2:
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- Metallurgical Examination
- Fatigue and Fracture Mechanics Analysis
- Dynamic Analysis upgg 5.
Overview of the safety significance of the pump shaft failureTt'PI.
6.
Discussion of the pump failJre at PI as compared to Surry.
7.
Monitoring Methods and Criteria for Measuring Pump Vibrations:
- At PI
- Other Plants Description of Operating Experience Leading to the Discovery of RCP No. 21 Failure On June 11,1981 at 1530 hours0.0177 days <br />0.425 hours <br />0.00253 weeks <br />5.82165e-4 months <br /> the high vibration alarm was activated on RCP No. 21 indic ating a shaf t vicration cit.uiu incnes, nor ao. ci is a nes 6im;-
omesp. house-puep.Fodel- %.G3A for-whkhr.under.. normal.. 3peration,..the..vibrat. ion...i s..
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..003 to.005 inches. After the alarm sounded, the shaft vibration was monitored every 30 minutes and between 2000 and 2030 hours0.0235 days <br />0.564 hours <br />0.00336 weeks <br />7.72415e-4 months <br /> the vibration increased to.015 inches. Between 2100 and 2200 hours0.0255 days <br />0.611 hours <br />0.00364 weeks <br />8.371e-4 months <br /> the seal leakoff flow rate was observed to be 4.2 GPM (the normal flow rate is 3.0 to 3.5 GPM) and the measured shaft vibration was.020 inches. Between June 12 and 14, 1981 the lower motor bearing was disassembled and the support ring was repaired. On June 15, 1981 when the pump was restarted and an unacceptrole level of vibration was observed, the pump was shut down and disassembled. When the pump shaft was removed from the pump, a crack was found under the sleeve which measured 270-3000 around the circum-ference of the shaft. The pump shaft was sent to Westinghouse to have the failure analyzed.
Description of the Failure Westinghouse's detailed examination revealed the crack was initiated from a pin hole in the pump shaft. The metallographic examination of the fractured surface A review of indicates that the crack propagated due to high cycle fatigue.
the manufacturing history of the failed pump showed the pin that was inserted into the pin hole of the shaf t was twice welded to the sleeve that could possibly impose a high residual stress ir the vicinity of the pin hole of the This twice welding operation and the closeness of the welding operation shaft.
to the shaft pin hole is unique to the failed PI pump. Although this condition could reasonably explain the high residual stress that could result in the crack initiation localized in the vicinity of the pin hole, the propagation of the crack (i.e., 270*-300 around the shaft) cannot be explained by any identifiad dynamic loads used in the fatigue stress analysis. Using the most conservative load values, the fatigue stress analysis shows the Factor of hfety to be 1,61The (61% margin) indicating that tie observed failure should not have occurred.
licensee has engaged a third pan y consultant to review Westinghouse's effort regarding the cause of crack propagation.
Safety Significance of Reactor Coolant Pump (RCP) Shaft Failure The RCPs are designed and fabricated to the safety criteria of ANSI N18.2.
Although the RCPs are considered a non-nuclear safety component, the pressure retaining parts of the iamp are designed to the ASME Safety Class 1 and the The RCPs with their protection systems and rotating parts are Safecy Class 2.
associated supports are designed to withstand a sudden stopping of one RCP due to seizure or other similar causes without causing failure to the RCP pressure The shaft break transient resembles a locked rotor transient in which boundary.
a high pressure spike (peak pressure 2737 psia) occurs in a few seconds and then On this basis the licensee and Westinghouse do not consider the decays away.
event as being a safety significant issue.
Generic Considerations Four Seventeen utilities are currently using the Westinghouse Model 93A pump.
of the 17 utilities have pumps that have approximately the same or slightly The shaf t failure greater number of optrating hours as the failed pump at PI.
In the case of at Surry was different than the failure that occurred at PI.
Surry, the crack locotion was at the groove in the shaft. This groove is no The PI pump failure occurred at the pin hole.
In addition, the longer in use.
Sumj prp Mr a m"ch chnrtor nnerating history thal the PI pump (i.e., 9,697 vs 51 643 hour0.00744 days <br />0.179 hours <br />0.00106 weeks <br />2.446615e-4 months <br />). Westirghouse has ccncluded that the P1 pump failure snouhi Ee sTfisd"Ef"A"lewerir israe bared un a ti ngle-f ai4ure from..a.. total
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OFFICIAL RECORD COPY u m is m. ]
NRC FORM 318 (10-80) NROM 024a
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s Punn Ibnitoring Westinghouse recomends to its clients that vibration monitoring devices be installed
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on the prinarf coolant punps. According to !!astinghouse's records six plants operating with !bdal 93A RCPs and nine plants operatino with non 93A RCPs do not conttor pump vibration. Based on operating expc > cc Westinghouse recon-nends the following:
Shaft Vibration Action 003.005 'c.iches ilonni 015 inches Alam
.020 inches Recomcnd Shutdown The I:RC did not take a position on this matter uuring the necting since the infomation presented at the neeting still had to be reviated.
Or 'jnal signed by:
Dominic C. Dilanni, Pmject f'anager Operating Reactors Branch #3 Civision of Licensing
Enclosures:
1.
List of Attendees 2.
Vie.igraphs t' sed During Utg.
cc w/cnclosures:
See next page s
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oarn y OFFIClAL RECORD COPY usom ini-assa nne ronu sia omeo sncu oua
MEETING
SUMMARY
DISTRIBUTION-Licensee: Northern States Power Company
- Copies also sent to those people on service (cc) list for subject plant (s).
Docket File NRC_PDR L POR NSIC-TERA ORBf3 Rdg J01 shins'ki JHeltemes, AE00
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BGrimes RClark Project Manager Licensing Assistant ACRS (10)
Mtg Summary Dist.
All Participants e da e = e -e
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Northern ^ States Power Company l
cc:
i Bernard M. Cranum Gerald Charnoff, Esquire ~
B'ureau'of Indian Affairs, DOI Shaw, Pittman, Potts and Trowbridge
_ 15 South 5th Street 1800 M Street, N.W.
Washington, D. C.
20036 Minneapolis, Minnesota 55402 Mr. Louis J. Breimburst Mr. R.
L.' Tan'nner Executive Director County Auditor Minnesota Pollution Control Agency.
Red Wing,. Minnesota 55066. -
1935 W. County Road 32
_.._ __ l Roseville, Minnesota 55113 U. S. Envi.r_opmental Protectio.n, Agency Federak Activities Branch t'
The Environmental Conservation Library Region V Office Minneapolis Public Library ATTN:
Regional Radiations -
300 Nicollet Mall Representative Minneapolis, Minnesota 55401'-
230 South Dearborn Street -~
Chicago, Illinois 60604 Mr. F. P. Tierney, Plant Manager Prairie Island Nuclear Generating Plant
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Northern States Power Company - '
Route 2 Welch, Minnesota 55089 1
Jocelyn F. ~01 son, Esquire Special Assistant Attorney General "innestta Pollutien Control Agency 1935 W. County Rcad 52 Roseville, Minneosta 55112 i
I H.S. Nuclear Regulatory Ccemission I
Resident Inspecters Office Route =2, Box 500A Weich, Minnesota 55059 j
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ATTENDEES AT THE OCTOBER 29,1981 MEETIt1G REACTOR COOLANT PUMP CRACK: FKUBLjM NRC NSP Sm. J. Collins Gerald Nells Earl J. Brown Dean Hannam H. L. Brammer Ben Stephens Keith Wichman
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Warren S. Hazelton NUTECH
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C. D. Sellers Pete Riccardella D. C. DiIanni WESTINGHOUSE Andrew Madeyski Gary ' Elder Allan Hribar Ed Burns Alan Dietrick A
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3 PRAIRIE ISLAND N0. 2 RCP.21 OPEPATING HISTORY n
HOURS COLD YEAR
(<350*F)
HOT STARTS
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'75
- 73 8147 21 -
'76 210 7085 9
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8055 2-
'78 14 8242 24
'79 9
8694 20
'80 113 7617' 47
'81 - 6/11 109 3083 30 581 51,573 153
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(4.2 x 107 )
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l 21 HEAT-UPS 20 COOL-DOWNS l
Agenda Item 1 page 2 MAINTENANCE F.
1 RCP Date Description 11/27/74 Checked scals, fow J 0" Ring missing in #2 installed nev #3 seal.
11/1/76 Re'placed #1 scal, #2 seal, and #3 seal.
12/1/77 Inspected seals, replaced upper seal housing and #3 seal ring.
1/28/78 Replaced #1 seal insert, #1 seal r mner. #1 seal ring. -
- 2 seal ring. Seal had eratic lentoff.
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12/10/78 Removed 21 RCP Motor for cleaning and inspection.
1/19/80 Inspected sesis changed out #2 & 3 seals.
3/5/81 Inspected seals.
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Agenda Item 1 page 3 EVENTS LEADING TO 21 RCP SRAFT FAILURE JUNE 11 Time Event 1530 High Shaft Vibration Alarm received.
Alarm Set Point t15 mils Local Reading 10 mils-Starting checking local reading every half-hour.
2000-2030 RCS was diluted; number one seal leakoff increased; vibration 15 mils.
.2100-2200 Seal leakoff increased to about 4.2 gpm;
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Shaft vibration 20 mils.
2200 Shutdown begun.
2230 tait off line, 21 F.Ci ctopped; vibration 27 mils.
Seal leakoff returns to normal.
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Cooldown sammenced.
Inspection found 21 RCP motor lower radial bearing laose.
JUNE 12 JUNE 13 & 14 21 RCP motor lower radial bearing repaired.
JUNE 15 21 RCP restarted; initial vibration 7 mils.
After 20 minutes - 12 mils.
An attempt to balcnce was made, but vibration kept increasing.
Pump stop cooldown commenced.
JUNE 16 Determination nade to disassemble the pump -
Shaft would not rotate Shaft would not drop i
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Agenda Item 1 page 4 REACTOR COOLANT'PDtP VIBRATION MONITORING Type Location output 1.
Frame Vibration RCP Motor Cabinet Analog Reliance Computer 2.
Frame Vibration RCP Motor to Meter in Containment IRD Motor Stand 3.
Frame Vibration RCP Motor to Cabinet Bentley Nevada Motor Stand Control Board' Alarm 4.
RCP Shaft Vib RCP Shaft Just Cabinet Bentley Nevada Below Motor Lower Control Board Alats Radial Bearing 5.
RCP Shaft Thrust RCP Shaft at Cabinet Position Indication the Pump Coupling e
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. Page 1 93A~
REACTOR COOLANT PUMPS GROUP DESCRIPTIN NtreER 1
SME AS PRAIRIE ISLAND iX2 106 2
LOWERED IURNING VANES (LOWER HYIRAULIC LDADS)
.26 3
TACK WELDED PINS (LOWER RESIDtnt STRESS) 10 14 LN ERED IURNING VANES N O IACK WELDED PINS 30 (LNERlhDRAUUCLOADSANDRESIDuALSTRESS) i TOTAL 1 72 m.
Agenda Item 2 page 2 93A RCP
~0PERATIN'G HISTORY (AS OF JtnE 1,1981)
NO.OF OPERATING SHAFT RCP'S HOURS REWWTIONS Puwr 9
OCMEE 4
53,000 3.8x10 9
PRAIRIE ISUWD #1 2
53,000 3.8x10 KEWAUNEE 2
53,000 3.8xd 9
ZION #1 4
47,'200 3.4 x 10 9
SURRY#1 3
45,3(D 3.3x10 9
ZION #2 4
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45,000 3.'2xM SURRY#2 3
40,'000 2'.9 x 109 THREEMILEISLAND#1 4
33,000 23x109 9
TROJAN #1 4
27,000 1.9 x 10
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22,000 1.6 x 10 9
SALEM #1 4
20,500 1.5x10 tbRE ANNA #1 3
20,000 1.'4x109
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19,300 1.4 x 10 9
BEAVERVAU.EY#1
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9,000 6.5 x 10 IbRE ANNA #2 3
5,000 3.'6 x 108 9
FOREIGN PLANTS 18
>10 8
F0aEIm PuwrS 6
>10 TOTAL 8
10 REVOLUTIONS = L389 HOURS IN APPROXIt%TELY WO f(NES.
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Agenda Item 3 Page 4 SHAFT S/N516
~FABRI' CATION ROUGHIURNEDFORGINGMFG.BYSTANDARDSTEEL p
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ASSEMBLE BEARING JOURNAL SLEEVE AND THERMAL SLEEVE it.
2 SHAFr FINAL MACWINING l
ASSENLY COUPLING AND BALANCE.
v ASSEfELY SPOOL AND 3ALANCE l
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dgendaItem3Page6 SH' AFT
~ MATERIAL ASTM-A-182GRADEF-347 HEAT TREATED FOR DIfENSIONAL STABILITY 1500 - 1600*F FOR TWO HOURS PER INCH OF THICVNESS c0OLED To 300*F AT 200*F/HR. M X.
EXAMINEDBYU/TANDl.P MATERIALPROPERTIES:
YIELD STReism
- 37,000 PSI 85,000 PSI TENSILE STBENGm 9
ENDURANCE LIMIT G0 )
3L000 PSI
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Agenda Etem 3 Page 7 PRIPARY SHAFT LOADS _
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I g = Axial Thrust Load + Deadweight - Hydrostatic Load I
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genda Item 3 Page 8 HYDRAULIC LOADS-PRAIRIE ISLAND RCP'S CotnRtnour Cow OPERATION HoTOPERATIm 1 Ptw 2 Pt m 2 Ptws Fux (wM) 102,870 94,390 98,200 TORQlE (FT.-L3S.)
3L560 33,147 25,546 e
AXIAL IHRUST (LBS.)
64,670 68,789 50,726 NOMINAL FAXIMUM 7L140 75,670 55,800 RADIALTsRusT(LBs.)
tbMINAL 4,083 3,589 2,884 MAxIMtn 5,104 4,486 3,605
't fax.CYCLICIORQLE 180 118 89 l%x. CYCLIC AXIAL LDAD 297-194 147 RoTATINGRADIALLDAD 635 E
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\\
~
s i
/
\\
l
~
\\
\\
Crack Location f
\\
/
/
\\
/
e Lower T.B. Labyrinth L.,,,,..
t M/> <
i A l
(.020
.028 Dia.)
l
///*
--Upper Impeller Labyrinth
~~~~~~~
(.050
.060 Dia.)
I
/
E Y
-\\ l P
_l\\
l
\\
i s
i 9
?
l 7 Lower Impeller Labyrinth
(.050
.060 Dia.)
/
l i
_m SHAFT CLEARANCES l
9 dgendaItem3Page10 ISOTHERPAL DLOT STEADYSTATE-NORbLOPERATIONS si 88.,4'Pe t
?
IQ
~
?
m xs 1
M i
me ll M
n..
~
iL' a
il 2
l E
N
~
~
u.s g=
M ms 557'F Loop Temperature 1
100*F Bearing Water Temperature v.e a.s b.0 1
r M
:L a
i l= a ru m.c=
n.vi..mi acm i
=A Agenda Item 4 Page 1 SHAFT STRESSES Cc w RUNOUT HOTOP5 RATION 1%x, LOAD STRESS MX. LOAD STRESS LOADSOURCE (BS.)
(PSI)
' (BS.)
(PSI)
MOTORIORQUE 3L560 2880 2 5, 5l16 2330 AXIALTHRUST 7L110 1183 55,800 928 RADIALTHRUST 51110 ll25 3605 1999 180.
16
- 89
~
18 CYCUCIORQUE CYCLIC AXIAL BAD 297 15 ll47 2
ROTATINGRADIALLOAD 635 176 118 0 133 e
w 4
5 A
i
-Agenda Item 4 Page 2 FAT!GUE
' ANAL ~YSIS BASIC EcuATim I
F.S.
=
sf'a "f)3 } !
{[c /o )+(k o,/o )]2+3[(r./L 'y)+(k l
o u f
f s
1360 psi Normal Stress
=
=
o, Tensile Strength = 85,000 psi
=
ou 2.5(Q=.8)
Q(k - 1) + l k
=
=
f g
f o,
Alternating Bending Stress 1425 psi
=
=
l l
op Size Correctid Endurar:ce Strength 21,000 psi
=
=
2880 psi r
Steady Torsional Stress
=
=
g t
1.33 Limit Factor for Shear L
=
=
s i
3.2 k
=
sf l
l 3.20 (220% Margin)
F.S.
=
=
l 1
37,000 psi For A o
=o
=
n y
l h = 1.61 (61% Margin) i F.S.
=
I ee
-' +
,,g,,
,,g 9,7,,
.,9
,g
- we
.,w
gen a em 4 Page 3 RESIDUAL STRESS DUE TO WELDfNG l
1 EFF.
l' 2)
+~("2-#3)
+ (#3"1) o
"~
z
= 72 KSI (just below surface) o 36 GI
=
2 3
- EFF., KSI 40 32
'24 Second Weld 1325'F AT 16 8
-1.6
- 1. 2
.8
.4
.4
.8 Strain %
\\ First Weld 600'F AT
~
i,i.; I
';. fs i..
a i
ALTERNATINGSiRESSREQUIREDTOPROPAGATEASMALLCRACK 16 O
347SSNotched(K t
g 12 (Surry Shaft Material) i m
Size Correction g;
a:M
' Corrected for Micro Crack e
5 8--
l Q
/
I'.a' 4--
y, Required:o
>2.3 a
a.
~
- Required'.a = 1.4 a
g g.
~..
I m3
- 1 l
l a.
20 40 60 80 100 120 o,
i
.g A
I MEAN STRESS (KSI) 4
Agenda item 4 Page 5 FRACTURE MECHANITS MODEL P
t a
41 Bush's K-Solution for Edge Cracked Round Bar in 3-Foint Bending
\\
Y'AM AK y
=
D ASw(D)3 2
g 4
For AS = 2.6 KSI (+ 1.3) 171 Kip-In.
=
O e
k' I
i s,
+,
v~--
,y I
Agenda Item 4 Page 6 STRESS INTENSITY VERSUS' CRACK' DEPTH 14..
INITIAL SURFACE STRESS RANGE AS = 2.6 KSI
- 12..
~
10
(
12 N
8.
Constant Boment Range z
>.C E
s, f5
- 6..
aKth = 5.0
\\
i m
I J
I Constant Deflection Range 4
i I
l l
a-=-1.8-l la=2.4 l
l 2
i 1.
l l
l I
1 2
3 4
5 CRACK DEPTH, IN.
.-..e.
.3w
.,.---..-,,-,-,c.,,s-....,o..___.--..,-.,,,,.,,,...,.,~.-.,-.c
.,,,.__y-.,7--.
' Agenda Item 4 Pagn 7 STRESS VERSUS CRACK DEPTH l
l l
i l
[
l l
l 12-.
l l
=..
10.
_m V.
I m
m g
-m w
8-O u.
~ ~ ^
~.
~
AK = 17 KSI/iii.
E (From Striation Spacing) a<
l 6..
m 4..-
~
aKth = 5 KSI/Iii.
AS = 2.8 l
l 2
I i a = 1.6 l
I l
e.
i.
t.
.f e
i f
1
.2 3
4 5
6, i
CRACK DEPTH, IN.
1
Agenda Item 4 Page 8 CRACK FORMATION SCENARIO
-LOCALIZEDHIGHSTRESSDUETOWEGINGATPINHOLE-NOCRACK.
- PIN FRETTING PRODUCES ADDITIONAL _HIGH LOCAL STRESS.WHICH INITIATES AND PROPAGATES SMALL CRACK WITHIN HIGH CONTACT '
~
CRACK ARRESTS AS IT LEAVES HIGi CONTACT STRESS' FIEQ.
STRESS FIELD (0.1 IN.).
- NO KNOWN LOADS OF f%GilTUDE REQUIRED TO PROPAGATE CRACK TO
- - FAILlRE.
(NEED TWO TO THREE TIES KNOWN LOADS) 4 e
e t
l
'=^4f%
f Agenda Item'4.Page 9 1
DYNAMIC ANALYSIS REVIEW 0F i
NSP PUMP CHARACTERISTICS RESURRECTM0pE(_
^
UPDATE / REVISE MODEL (T0 REELECT CURRENT KNOWLEDGE')
4 CHECK MODEL VALIDITY CALCULATE AXIAL, TORSIONAL AND LATERAL RES0 NANCES' CALCULATE RELATIVE VIBRATION RESPONSE.
EXAMINE EFFECT OF THRUST BEARING STIFFNESS CHANGES
~
EVALUATE EFFECT OF LOOSE LOWER MOTOR BEARING EVALUATE POTENTIAL EXCITATION SOURCES EVALUATE.EFFECT' 0F LOCALIZED STIFFNESS CHANGES 9
i e
a 4
- l t
,n,
-, - - -~
,n.-
-n.
. ~, -.
n. -
A"genda Item 4 Page 10 RCP DYNAMIC MODEL PARAMETERS _
. WECAN, WESTINGHOUSE ELECTRIC COMPUTER ANALYSIS FINITE ELEMENT PROGRAM
. 108 UNIQUE N0 DES
.165 ACTIVE DYNAMIC DEGREES OF FREEDOM 193 ELEMENTS, 7'DIFFERENT TYPES AS FOLLOWS:
STIF 7 STRAIGHT PIPE AkISYMMETRIC STRUCTURAL MEMBERS SUCH AS THE ROTOR ASSEMBLY NON-SYMMERICSTRbCTURALMEMBERS STIF 4 STRAIGHT BEAM SUCH AS THE MOTOR FRAME
- --STIF 44 LUMPED'. MAS S__
.TO AOD MASS.T0J. RESERVE RIGID BODY MASS AND INERTIA DISTRIBUTION STIF 14 UNIAXIAL SPRING LINEAR REPRESENTATION OF BEARING FLUID FILM STIFFNESS STIF 38 FLUID ELEMENT HYDRODYNAMIC MASS INTERACTION 0F THE FLUID AND STRUCTURE STIF 29 CURVED PIPE PIPING ELB0WS IN THE MOTOR OIL COOLER PIPING SYSTEM STIF 27 GENERALIZED FOUNDATIO'N' SUPPORT AND PRIMARY SffhfESS PIPING INTERFACES WITH RCP, g
Agenda Item 4 Page 11 CA'LCULATED AXIAL MODE FREQUENCIES
~..
MODE FREQUE,NC,Y,HZ MODE DESCRIPTION
' RIGID ~B0DY DISPLACEMENT '0F 1
18.3 ENTIRE ROTOR 2
44.4 RIGID BODY DISPLACEMENT OF-i STATOR ON FOUNDATI0N 3
169.3 FLYWHEEL AND MOTOR ROTOR CORE MOVING OPPOSITE IMPELLER i
4 286.2 FLYWHEEL AND IMPELLER MOVING l
OPPOSITE DIRECTION OF MOTOR ROTOR CORE 0
4 t
I i
Agenda Item 4 Pige 12 i
"CAffULATs'D T0'RSIOSAL MODE FREQUENCIES :
i MODE FR5QUENCY,HZ MODE DESCRIPTION -
~'
1 30.4 FIRST TORSIONAL MODE OF ROTOR 2
43.2 S E_COND.
3 104.2 THIRD 4
309.5 FOURTH
- as g,.
e e
t
+
1 r
e
Agenda Item 4 Page 13 4
CALCULATED LATERAL MODE FREQUENCIES MODE FREQUENCY, HZ MODE DESCRIPTION j
l 1
- 7. 5 i BENDING.0F LOWER PORTION OF ROTOR 7.93 2
. 8.78_
-~,;_
ROCKING _0F ENTIRE RCP ON E,0UNDATION --
SLIGHT LO':lER ROTOR BENDING 3
23.1
~
BENDING OF MOTOR ROTOR NEAR FLYWHEEL -
24.4 SLIGHT BENDING NEAR IMPELLER 4
32.0 MID-ROTOR BENDING NEAR SHAFT SEALS AND COUPLING 5
32.5 "S" BENDING OF ENTIRE ROTOR 4
6 32.6 PUMP INTERNALS BENDING AND "S"
~
BENDING OF ENTIRE ROTOR f
1 F
l
Agenda Item 4 Phge 14 i
RELATIVE VIBRATION RESPONSE METHOD -
REPRESENTATIVE LOADINGS SELECTED APPLIED LOAD SWEPT THROUGH FREQUENCY PANGE.0F 200 OR 500 RPM TO 2500 RPM
~
i
. RELATIVE VIBRATION AMPLITUDE RESPONSE NEAR:
CRACK LOCATION OBSERVED i
ALTERNATING STRESSES ASSOCIATED WITH SPECIFIC POINTS OF THE RESPONSE CURVES CALCULATED SELECTED LOADS:
AXIAL - 1000 LB OSCILLATING VERTICAL FORCE AT IMPELLER TORSIONAL - 1000 IN-LB OSCILLATING TORQUE AT IMPELLER l
l LATERAL - l IN-LB UNBALANCE AT IMPELLER l
-~
f
\\
?
I L
i ev
- ~ < -
.~.--,-,-,,-------~,---,n
-nn---
,----,- +--
n-s.
Agenda Item 4 Page 15 l
t AX1AL RESPONSE RELATIVE DISPLACEMEr&TS IN VICINITY OF CRACK 16
_ g, g
,/,
14 18 x 10-6
~
12
_~
I C
5 10 j
RutGIftG
/ SPEED 18 adg g
C 5'k 4
o 2
~
0 I
I 500 1000 1500 2000 2500 FREQUENCY (RPH) g 1
x e
9
Agenda Item 4 Page 16 TORSIOilAL RESPONSE RELATIVE ROTAT10tl IN VICINITY OF CRACK 16 g
y 19 x 10~'
14 RUNNING p'
O SPEED \\
i
~
12 e
m E
5 10
=>
g i
8
,o s
y E6 3, 4 E
2 i
8 i
1 I
I l
500 1000 1500 2000 2500 FREQUENCY (RPM) i
('
g a
e
\\
6 e
e
~
Agenda Item 4 Page 17-
~
LATERAL RESP 0lSE RELATIVE BEND]NG ROTAT10ti IN VICIt41TY OF CPACK
~
12 g
i
=
r 10 n
!E a
RUilillflG 5
/ SPEED o
- C 6
e
[
4 I
s
~
3 2
k i
O I
I
-I"~~~---~
0 500 1000 1500 2000 FREQUEP4CY (RPM) g e
e
e.-..
a.
.. a -.
Agenda Item 4 Fage 18-
~
1 l
L
~
t EFFECT OF THRUST BEARING STIFFNESS CHANGES en Ax1AL MODE FREQUENCIES 300 i
g i
.I 7
L
' ~
20
~-
M DE 4. 286 HZ i
260 w
~~
pf 180 MDE 3, 169 HZ 8
E 160
.O 1
g b
y
=
W 60 1
NDE-2, 44 HZ S
40 g
~
MODE 1,18 HZ l
20 l
l 1
7 106 105 104 103 108 10 [6 NOM 2 x 10 EFFEC 11VC LihEAR STIFFNESS (LB/IN) l
\\
a4 U
~
~
Agenda Ztem 4 Page 19 EFFECT OF LOOSE LOWER MOTOR BEARItG 0.t LATERAL MODES 4
f 50 I
I
-l 1
9
~
8 40 MODE 4, 32 HZ MODE 3, 71 HZ g 30 p
MODE 2, 8.8 HZ u
i 5
t B,20
.~
MODE 1, 7.9 HZ m
.. ~
f f5.
/
/
10
/
I I
I I
6 103 102 O
106 105--
10 p
EFFECTIVE LINEAR STIFFNESS (LB/lH)
~ NOM 1.2 x.10s
~
t s
~
'....., '.. *,,.,. r.. i....'....
W
..c., :,..
s
.....s
~
i d
.=
v...
} -- -- - - -
~
m-we
Ag'enda item 4 Page 20 l
SUMMARY
OF RESULTS AXIAL AND TORSIONAL MODES DO NOT APPEAR TO BE POTENTIAL SOURCES OF THE PROBLEM l
. THE LATERAL MODE WHICH PRODUCES THE HIGHEST RELATIVE VIBRATION
^
.~
RESPONSE IS THE 7.9 HZ BENDING MODE T-.
/
- THE ALTERNATING STRESSES ASSOCIATED WITH THIS MODE ARE SMALL
,,, /
f THERE 15 ALSO NO EVIDENCE OF LARGE DEFLECTIONS ASSOCIATED WITH THIS MODE IN PUMPS WHICH ARE IN NORMAL CONDITION
.. m.,_
T OTHER A'CTION WORK IS. CONTINUING TO ACHIEVE A BETTER UNDERSTANDING OF
~.
THE FAILURE EVEN?.
r.
e e
,o.-
t 4
9
)
O s
e d
O b'
~~
, Agenda Item 5 Page 1 SAFEN SIG11FICAi4CE OF RCP SHAFF FAld!RE SAFEW CRITERIA (NISI [u8.2)
THE RCP IS IION-NUCLEAR SAFEN.
THEPRESStiRERETAININGPARTS(RCPB)ARESAFETYCLASS1.
~
~
~
THE ROTATING PARTS ARE SAFEW CLASS 2.
=. ~.
e THEnstSTANDARDSTATES:
~
~
~
}
"IHEREACTORC00t.ANTPRESSUREBOUNDARYTOGEEERWITHITSPROTECT
~
SYSTEMS SHALL BE DESIGNED SO W AT SUDDEN STOPPING OF ONE R COOLANT PUMP (CONDITION IV) DUE TO SEIZURE OR OTHER SIMILAR CAUSE WILL NOT RESULT IN FAILURE OF THE REACTOR COOLANT P BOUNr' /. "
G ANALYSES HAVE BEEN PERFORMED FOR:
Ft.0d C0ASTDWN.
LOCKEDROTOR.
SHAFTBREAK.
r Agenda Item 5 Page 2
~
REACTOR COOLANT FLOW STOPPAGE #MLYSES e
FLw COASTDOWN'VS.- INSTANTANEOUS STOPPAGE (LOCKED ROTOR)
FLW COASTDOWN ANALYSES FOR ONE AND TWO PUMPS HA'E BEEN PERFORMED (FSARCHAPTER14).
LOCKED ROTOR ANALYSES FOR ONE PUMP HAVE BEEN PERFORMED (FSAR 2
~
CHAPTER 14 AND, MORE RECENTLY, IN SUPPORT OF E RI S&RV TEST PROGRAM).
SHAFT BREAK AfMLYSES HAVE BEEN PERFORND.
SHAFTBREAKTRANSIENTSRESEMBLELOCKEDROTORTRANSIENTS.
A HIGH-PRESSURE " SPIKE" OCCURS IN A FEW SECONDS, TliEN DECAYS AWAY.
FORNORTHERNSTATESPCWER,THEPEAKRCSPRESSURECALCULATEDFORA LOCKEDROTORTRANSIENT'WAS2737 PSIA (FSAR).
INSUPPORTOFTHE PRI VALVE PROGRAM, liiE PEAK PRESSURE CALCULATED (2-LOOP REFERENCE PLANT)WAS2745 PSIA.
p y
e-x
i Agenda Item 5 Page 3 1
2800
. ~. i. _ -
=--.
4__
=2 __..... _ _._ _
_2_..A_
J.
.r._.,.. _...... _.....--
_. _ =
..:r...~,_
. _. t,.
t:_..
w._._
2700 _
I...
.2. _ ' _,.
....w
.....i...i _..,..
F._.
.,__t,._..-.
... t.. _ _, _
_. + _.... t...
_r_. -
_. 4_ ___..
.. :1.. _=
t _
- m..,
z._.2.....
. _. _. _....._--t....
...:1.. ~. _ _
__. h._
.4.._
1
.. _. _.,.1.._a.,
.....g..
.._.4.__.
_2 _t 2600 _.
,.4._...... _,..._._.
_.. r t.__._..
4
. _. _..t_:
.. -. =..
4........
r.
m
..t....
..........s. _ _.
t..,....
r...
.... p.
c.
.,...,. _._.y...
.. r _.
_.. 1..._......
w
- t. _...............
.. _.._._.._ :t... __.4_--
_n......
t
=>
... _ _e.t..t._.-...a_..
..-. v._
- r..._..._...
m w
_. :2.___
m
_...._._....e
.......... _.._. t _.._._._4 _
.. g.
r..
- t...
e m
r..... _. r......,
_. t_.
a
. _....... s.. r- -
t... -..
t..
t._....
n...t t_......
- a. t.
.. 4
.m
...t....r.
a
.-.a.
O
. _.. i...
_...L. <....a
- t.,
v O
........ r. ~
.t..
.... 1.
g.
.. _ a.. _
2400 _
.....a,
.t.
- t....t,.
- 3. t...
...... \\.... _..
... f _..
- n.,.... t....,
s
,m
_....... n _..._.... ;-
i.._..
. t_..
r
. e.
..._ t _._..
.......... _4 __
._. 4...
c.
t _......
.~
r_.,...s......._... _
... _.__. s.
... _..,. _..,1_.._..
.. t_...__..
.... r..
t _. _....
t......_.. _..
t,..,.
2300 __.
...n 7.
. n. 1....
-........u.. o.
.., u...
.... _. _.a...
..,._...r._..
i._.,
. v.,.
t........... _...
......... t t. __
..,.. i.
...., i..
_ t....
..n
. t.
.n.
c.
.....r.
=
.i..._..... _...i....
i,.
- i...,... i..
a..
.n.
... t. t.
...m
- n.._
....._- +,.... _ _
_.4
.r...
...t........... _... _. _ _.
- t. _.. m... t.at :
... : r.r..c a..
- n. 1.
.i..
.....r.
,..t
.a 2200 m-..
... 4.*..
i..... _.
.......u....,
, a...
, i. L. c _
,,n
..a. _..
._.-. a
_.i. i....,...
2..
t
. :. t t.
t
. _ _........,1._..
__. c,
m.
n,
.,i..
- t. t...
I, t.. -......
. r... u. o..t.
tr r.....
. a...
.. t.
. r,.
......t,n 4....., _. t......,...a.t....
L..... i. i
. i..
- i. ~..
- t. : n.....
n......
i......
i t..-..
I r...___
- n......
i....
t...,r..
i.i.,....
2100 I
.. r... i..
- n.. n..
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t.,.i..
m...
i...........
_.. u _
.r r_..._.
~..
..f t
1 10 5
0 TIME, SECONDS i
LOCKED ROTOR l
h
- -c
}
Agenda Item 6 Page 1 OPERATING HISTORY PRAIRIE ISLAND
. VERSUS SURRY Houas COLD TOTAf_
Puwr OPERATION 3, '-
E88 m
s PRAIRIE ISLAND 581 SL573 80 TEST SURRY 35I4 703 PRAIRIE ISLAND
= 35 70 i
)
O
(
IOTAL SURRY IM2
% 97 PRAIRIEISLAND 616 5L6/43 i
genda Item 6 Page 2
~
\\
/ n i
vg
- \\
/
p\\
i
- /J i l f
\\
/
\\
/
Apd's
/
/
/
f h
~~'
/
bec Surry Crack Location (Sleeve and Groove Not
/
i
't i
i Used on any Current
(
,s w
I
..I Shafts) j '
~
l~
\\
u p
N L6a
\\
\\
i
=
/ 'l
\\
l
/
\\
\\
/
4 Prairie Island Crack Location
/
k/),
i l
lll I
\\
l
\\ s Jd'\\
I
= __
i SURRY VERSUS PRAIRIE ISLAND CRACK LOCATION
Agenda ftem 6 Page 3 sH bb b
~>9 2 ~6 VIO 2'J2*6 00 HFw W
two-N 09f9 o mG
_O VIO 19fB e e w
- y e
- p-C-
5087 ddo SOV
$Ig \\/
fgg.
sm s ao 3-,e M
O Zed OOT*
~
. tr> m a.
=
=
N-
- 7) 7) Q..
. m._
.9F M.
\\
~
.7-9MO dl g
\\'N
\\x N
~
N \\
s o cr
'x-
/[/
.\\
k
\\
\\
x
- f.. o,
.sp.;
q_
\\
o.
s m
N m\\!
u a
l
. 3.x\\xx'.
\\~ >\\
op x
s
~
- e. c
/
'N
\\.
$g s
O-rq s
N,,.
r I / AG s ev
=.
o "wg p
r s
s s
5 j
.C o,
4 P
1
\\
m,,------
l 7r T
\\,A -
s La.
246'9 6
y,a ro
(
I
.y -.-
1 k, - -..-- J' I
l l
l Agenda Item 6 Page 4 RCP SHAFT FAILURE COMPARIS0NS SURRY PRAIRIE ISLAND Failure Location Upper Sleeve - Grooves Lower Sleeve - Pin Hole i
.: p.
Thermal Sleeve Shrink-Fit Yes No Expected in Service
~.3.
=
Type Failure High Stress Concentration, No Stress Concentration, Low Overstress, Rotating Low Overstress, Rotating Bending Bending Stress Concentration in 5.5 2.88 Bending, K t
Hydraulic Radial Thrust (lbs.)
5300 5104
' ^ '
Maximum Bending Stress (psi) 2850 l425 Pin Weld Residual Stress Yes Yes
.~
Number of Times Weld Applied 1
2 Shaft Material 347 SST 347 SST F
v 4
I
~
Agenda Item 6 Page 5 SURRY SHAFT FAILURE CLASSIFICATION HIGH CYCLE. LOW STRESS FATIGUE.
t 8
i CAUSEOFFAILIIRE SHARP GROOVE -- VERY HIGH STRESS CONCENTRATION MAXIMUM ROTATING BENDING STRESS AT SINGLE PUMP s
OPERATION AT COLD SYSTEM CONDITIONS JUST
=
SUFFICIENT TO PROPAGATE CRACK ONCE INITIATED
. HIGH LOCALIZED TENSILE RESID.UAL STRESS AT PIN WELDS PROVIDED SITES OF PRIMARY CRACK INITIATION
1
)
~
Agenda Item 6 Page' 6 i
1 SURRY
~ PATI'~GUE ANILYSIS
~
o, 2850 psi
=
1)+'l Q(K kf t
= 4.6
=
7 1
g=
.93 No Margin F.S.
=
j e
e em 0
I i
i e
}
L
~ -
l r
l' l
t
}
w
.,-e,,m,.m-on-.n.-
,,-,,-_-,_,,,,..,,,,.s
,n.,
,..-r.,.,,,
-.e.,.,.cn,
-4
~
' g'enda Item 6 Page 7 STRESS VERSUS CRACK DEPTH 1
~
12 - -
t 10 -
g
.e
+
"g 8 --
I' G
~
AK = 17 KSI S.
<b (From Striation Spacing) 5 6
a<
t-1 5
l
~~
l l
4 1
I AKth = 5 KSI M.
i 1
I I
2 i
l =0.4(Surry) I a=1.6(Prairie Island) a 1
I I
i l
I i
i i
e 1
2 3
4 5
6 CRACK DEPTH, INCHES
Agenda Item 6 Page 8 i
~
F A I L U R E - N O N - G' E N E R I C -
- SURRY FAILED SHAFT DESIGN DIFFERENT THAN /LL OTHER
~~ MODEL 93A REACTOR COOLANT Pires.
2
- .~,
s
- i;. -
- PRAIRIE'ISLdND SHAFT IS 10F $4 WITH SiSIFis(T OPERATING'
~
7 -- -
3
,3 -t;;
^
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SHAFT VIBRATION SYSTEM 6
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Agenda Item 7 Page 2 SHAFT VIBRATION MONITORING SYSTEM OPERATING 9 % RCP'S:
WI~il WESTINGOUSE SYSTEM
- 10 PLANTS 10 PLANTS WIm OmER SYSTEMS 7 PuwTS (6 IbESTIC)
NONE (PER WESTINGHOUSE RECORDS)
NON-OPERATING 9M RCP'S:
8PLAnrS WITHWESTINGHOUSESYSTEM 5 PLANTS Wim OmER SYSTEMS 10 PLArnS (9 DOMESTIC)
NONE(PERWF.STINGHOUSERECORDS)
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Agenda Item 7 Page 3 VIBRATION LEVEL CRITE'.IA FOR WESTINGHOUSE SYSTEM SHAFTVIBRATION:
15 MIts D.A. - AuRM 20 MILS D.A. - RECOMEND SHUHXM FRAW.VIBRTiON:
1; 3 MIts D.A. - AuRM 5 MIts D.A. - RECCMND SHUHXM 1
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