ML20045H797

Nonproprietary WCAP-13414, RCP Hydraulic Flow Test Prospectus.

ML20045H797
Person / Time
Site:	05200003
Issue date:	07/15/1993
From:	WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP.
To:
Shared Package
ML19303F731	List: ML20045H774 ML20045H792 ML20045H797 ML20045H800 ML20045H805
References
WCAP-13414, NUDOCS 9307210282
Download: ML20045H797 (8)

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WESTINGHOUSE CLASS 3 WCAP-13414

, WESTINGHOUSE PROPRIETARY CLASS 2 VERSION L EXISTS AS WCAP-13413 RCP HYDRAULIC FLOW TEST PROSPECTUS ED (C) WESTINGHOUSE ELECTRIC CORPORATION 19.3, 9 A leanse is reserved to the U.S. Govemment under contract DE4CO3-90SF18495.

O WEST:NGHOUSE PROPRIETARY CLASS 2 This *Joc* . n.ent cvitains eformabon propnetary to Westinghouse Electne Corporation; it is submitted in confidence arid is to be used solely for_the purpow for which it is fumished and retumed upon request. This document aM such information is not to be reproduced, transmitted, declosed or ..

used o"Mer wise m whole or in part without authorization of Westnghouse Electre Corporation, Energy Systems Busmess Unit, subject to the legends Conttir4 ~* hsroof.

GOVFRNMENT LIMITED RIGHTS:

(A) Thu ita are submitted with limited nghts under Gwomment Contract No. DE-ACO3-90SF18495. These data may be reproduced and used 3r the Govemment with the express lirnitabon that they will rot, without w%n permiseen of the Contractor, be used for purposes of manufacturor nor dselosed outside the Govemment; except that the Govamment may dsclose these data outside the Govemment for the Mowmg purposes,if any, pmvided that the Govemment makes such d cosure subject to prohibiton against further use and diadosure:

(1) TNs 'propnetary data' may be disdosed for evaluabon purposes under the restnchons above.

(PI) The ' prep:istary data' may be dsclosed to the Electne Power Research irshtute (EPRI), electric ubWty representanves and their drect cona#.snts, excludng droct commerdal competitoa, and the DOE National Laboratones under the prohibibons and restrictens above.

(B' ?Ns nunca shad be marked on any reproduebon of these data, in whole or in part.

G, WtiSTINGHOUSE CLASS 3 (NON PROPRIETArm)

EPRI CONFIDENTIAUOBLIGATION NOTICES:

NOTICE: 1@ 20 3 04 05 O CATEGORY: AOB DC DoOE OFO O DOE CONTRACT DELIVERABLES (DELIVERED DATA)

Subject to specified exceptons, disclosure of this data is restncted until September 30,1995 or Design Certifcaten under DOE contrwt DE AC03-90SF18495, whichever is later, Westinghouse Electric Corporation

' Energy Systems Business Unit-l1 Nuclear And Advanced Technology Division P.O. Box 'I55 Pittsburgn, Pennsylvania 15230 lc

@ 1993 Westinghouse Electric Corporation All Rights Reserved

WESTINGHOUSE CLASS 3 AP600 Water Test Prospectus Introduction Previous hydraulic development programs have successfully used model water testing as a means to verify pump perfomance characteristics when testing a full size pump was not practical. This type of program is considered as confirmatory testing of candidate hydraulic designs. The results of the testing are used to improve the operation and efficiency of the motor / pump system. This type of testing is done early in the design process prior to release for manufacture of full size pump parts.

Primarily, hydraulic performance parameters of total head, hydraulic brake horsepower, and hydraulic efficiency are detemined as a function of loop flowrate and are compared to specification requirements. Additional characteristics detemined during water testing are minimum Net Positive Suctien Head (NPSH) for non-cavitating impeller performance, and impeller thrust, which is used to calculate total bearing load for verification of the motor bearing design.

WEMD has available numerous test loops which are equipped with the required instrumentation to measure the above parameters. Special testing to detemine acoustic tones and measure vibration are also routinely done. The results of model testing used with the affinity laws of fluid dynamics provide an accurate database for calculation of the hydraulic performance of a full size canned motor. pump under actual operating conditions.

In the case of the AP600 system, to address the issue of pump / steam generator .

interface analysis, direct measurements of fluid pressure pulsations (frequency and magnitude) will be made at the suctic-n sie of the model pump impeller.

These measurements will be used to analyze the effect that these forcing functions have on pump / steam generator natural frequencies and the associated response spectra. To date, this will be the mov. concrete data available from actual testing which addresses the coupling effect of the steam generator and pump assemblies.

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Test Vehicle

[ An extremely important component to the test program is the drive vehicle used :

to operate the_ hydraulics. .Several systems could.be' utilized for testing'-

model hydraulics, but the selection of the:HLTV was det'ermitied toLprovidedhel l

- besttechnicalinformationatthelowestcost.?The-Hydraulic'LoadTestVNicle'

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(HLTV) recently became available to.WDGLfor the specific' purpose'ofJtestingh new hydraulic designs.; This test vehicle will' provide state' of thetart systest capability.- -- bj 6

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Previously, WEMD did not have accessibility to the HLTV and had planned to utilize the Hydraulic Test Facility (HTF) as the drive mechanism for the AP600 water test. The HTF was a capable system, but it was also a new design concept which was not yet in the fabrication stage and obviously had not been proof tested. The HLTV is a proven system and has more capabilities than the HTF.

In addition, since the HLTV has more capabilities available, an increased scope of technical information such as impeller and radial bearing loads can be measured. )

Proposed Test Procram The proposed test prograe for the AP600 is broken into two parts, the first l l consists of screening tests for two candidate hydraulic designs to determine the best design based upon hydraulic performance and required Net Positive SuctionHead(NPSH). The testing performed will determine the total head, hydraulic brake horsepower, efficiency, and NPSH characteristics over the entire prototypic flow range. A maximum flow point of 130% of design flow will be targeted for wide open loop flow. Based upon initial screening tests, the best design will be selected for final optimization to specification requirements. .

The first hydraulic design is based upon the Model 93D pump hydraulics operational at the Ringhals Power Plants in Sweden. This design was utilized for the recently completed air test program, and was the original choice for an AP600 hydraulic design since the specific speed and performance characteristics closely matched those needed for AP600.

l The second hydraulic design is a Model 100H design similar to that soon to be -

operational at the Sizewell Power Station in England. This hydraulic design was added to the test program due to potentially better NPSH and hydraulic l efficiency characteristics. Especially at high flows, the calculated NPSH values achievable with tin M100H hydraulics will provide direct benefit to the primary system by allowing single pump operation at startup instead of the present requirement for two pump operation. Having only one pump operational during startup will reduce reverse flow induced torques on the idle pumps; possibly eliminating the need for an anti-rotation device to be designed into the pump motor.

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Each candidate hydraulic design will consist of an impeller, a diffuser, and a t

suction adapter. The impeller will be a single stage centrifugal impeller with a mixed flow blade design. The diffuser and suction adapter will be designed around the impeller for optimal performance. Each candidate hydraulic system will be tested in the same casing, also specifically designed for the AP600 pump.

The second part of the test program will take the best hydraulic design and rigorously test it to determine its performance under all required conditions.

First, the impeller will be modified (diameter tria or vane underfiling) and a retest done to finetune the hydraulics to specification requirements. Over a prototypic flow range, the total head, hydraulic horsepower, efficiency, and axial thrust will be measured similar to the testing perfonned in Phase I.

Additional tests will also be performed, such as measurement of fluid inlet pulsations and determination of radial hydraulic loads. A final NPSH test will be performed to verify the impeller minimum suction pressure characteristic only at the design flow.

I. Initial Screenino Tests Hydraulic Performance (total head, hydraulic ' power and efficiency) will be measured on both candidate hydraulic systems as well as axial thrust.

Testing will cover a complete flow range representative of full size pump operation. In addition, an NPSH test will be performed over the full flow range. The best candidate design will be selected for Phase II testing.

II. Final Hydraulic Testina Only the best candidate design will be modified as required (impeller tris or underfile) to meet specification requirements and retested-for' hydraulic performance parameters (head, power, and efficiency) as well as' axial' thrust. In addition, fluid pulsations at the impeller inlet will be monitored and recorded (frequency and magnitude). Hydraulic load measurements will be recorded for evaluation of impeller and bearing radial loads. After completion of performance testing, a single point NPSH test will be done at the design flow to verify the results obtained in Phase I.

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Justification for Testino The justification for the testing as outlined in the preceding section is as follows. Performance parameters of hydraulic horsepower and efficiency can only be measured in water as opposed to total head which can be measured in water or air, as was demonstrated during the recently completed air tests.

Accurate determination of power, efficiency, and NPSH are important in order to select the best hydraulic design from several possible candidates and to provide accurate infonnation on motor horsepower requirements. The current motor size is based upon an estimated hydraulic efficiency of 83%. This value was obtained from the Model 930 SSP Instruction Book. In addition, hydraulic analysis of the new M93D based diffuser and AP600 casing indicated an additional increase in efficiency of 1 to 2%. However, these values must be confirmed through testing since experience with hydraulic programs has shown that expectations are not always the same as test results. Similarly, the Model 100H design must be tested to verify the calculated improvements in l performance and NPSH.

l If the actual hydraulic efficiency is different from the value used to design the motor, several problems can result. The motor will not operate at its design point, which can result in greater input power requirements. Larger input power increases the motor winding temperature and shortens operating  !

l life.

As was previously mentione.1, fluid pulsations at the inlet to the impeller will also be measured during the final phase of the performance testing. This infonnation could be used to further investigate the interface effects between the steam generator and the pump. Dynamic forcing functions from either component may influence the operation of the other.

Axial thrust measurements will also be performed on the final configuration impeller in order to numerically determine the impeller thrust characteristic over the anticipated flow range. This data improves confidence in the values used for sizing the thrust bearing; however, since no-load thrust results are not known, the total thrust bearing load will still be an estimated value.

Present impeller thrust estimates are based on H93D water model tests scaled to AP600 design conditions. The total thrust load must be accurately known in 5

order to verify the thrust bearing. for the motor. If loads are higher than estimated,alargerthrustbearingwouldberequired.[

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l HPSH testing will also be required to detemine minimum conditions for pump operation in the full size plant. NPSH information is available for both candidate designs based upon previous model water tests. However, this infomation is flow limited, and the AP600 operates at a different runout flow

{ (as a % of design) than the existing design data available. Accurate determination of required NPSH values is needed to prevent cavitation erosion at runout flows.

Both static and dynamic hydraulic load measurements (radial load and overturning moment) will also be made. These values are very important input parametersforaccurateanalysisoftheAP600 rotor /bearingsystem,which determines system stability and vibration magnitudes. Present radial hydraulic loads are based on air model tests and some EDF full size tests of a M930 hydraulics; however, casing and diffuser modifications will result in changes to these values. If the hydraulic loads are larger than anticipated, changes to the radial bearing design could be required, thereby impacting rotor dynamics, motor size, and overall efficiency. Accurate, measured values are preferable to the current estimated values.

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