ML20045H800
| ML20045H800 | |
| Person / Time | |
|---|---|
| Site: | 05200003 |
| Issue date: | 07/15/1993 |
| From: | WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP. |
| To: | |
| Shared Package | |
| ML19303F731 | List: |
| References | |
| WCAP-13420, NUDOCS 9307210286 | |
| Download: ML20045H800 (11) | |
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WESTINGHOUSE CLASS 3
-WCAP-13420 WESTINGHOUSE PROPRIETARY CLASS 2 VERSION EXISTS As WCAP-13419 HIGH INERTIA ROTOR TEST PHASE 3 TEST PLAN 2D (C) WESTINGHOUSE ELECTRIC CORPORATION 1913 A heense is reserved to the U.S. Govemment under contract DE4003-90SFtS495.
O WESTINGHOUSE PROPRIETARY CLASS 2 . This document contains informaton pmprietary to Washnghouse Electne Corporation; it is submitted in confidence and is to be used nonety for the purpose for which it is fumished and retumed upon request. This document and such information is not to be reproduced, transmitted, disclosed or used otherwise in whole or in part without authorization of Westinghoua Electne Corporation, Energy Systems Business Unit, subject to the legends contained hereof.
. GOVERNMENT LIMITED RIGHTS:
(A) These data are submitted with hmited nghts under Govemment Contract No. DE-AC03-90SF18495. These data may be reproduced and used ' by the Govemment with the express limrtatron that they will not, without wntion permission of the Contractor, be used for purposes of manufacturer nor declosed outside the Govemment except that the Govemment may dsclose these data outside the Govemment for the following purposes, if any, provided that the Govemment makes such dsclosure subject to prohibition against further use and disclosure: (t) This 'propnetary data' may be disdosed for evaluabon purposes under the restnetions above. (II) The ' proprietary data' may be dsclosed to the Electnc Power Research Insttute (EPRI), electric utility representatjves and their drect consultants, excludng droct commercial compettors, and the DOE National Laboratones under the ptohibitions and restriebons above. (B) This notice shall be marked on any reproduchon of these data, in whole or in part. DQ WESTINGHOUSE CLASS 3 (NON PROPRIETARY) EPRI CONFIDENTIAIJOBLIGATION NOTICES: NOTICE: 1E 20 3 04 O5 O CATEGORY: AEB DC ODDE OF 0 0 DOE CONTRACT DELIVERABLES (DELIVERED DATA) Subject to specified exceptons, disclosure of this data is restncted until September 30,1995 or Design Certification under DOE conuwe.t oE-Acos. 90SF18495, whichever is later. Westinghouse Electric ' Corporation Energy Systems Business Unit - Nuclear And Advanced Technology Division-P.O. Box 355 Pittsburgh, Pennsylvania 15230
@' 1993 Westinghouse Electric Corporation All Rights Reserved
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5 i ' -" t Y t!ESTINGHOUSE' CLASS' 3 -
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May 18, 1992 Test Plan for the DOE Phase- 111 1
- High inertia Rotor Test Program The Phase III testing will focus on measurement of the drag losses with the high-inertis rotor running in , water in an annular ' space,: ;
not as.a journal bearing.- The current test _ plan for Phase III is divided into six tasks. . The test plan will be reviewed periodically by~ EMD, NATD, and STO. The plan may be changed at such times'by mutual. d agreement, based on the available test results. TASE 1 - IALF-INCE GAP TEST t Objective - Measure the losses with the radial bearing-pads- l removed and a cylindrical shroud installed to'give an annular. space;with: o a radini gap of one halfJinch. . I Description-ThesevenradialbearingpadswillberemovedlfromL { the test l housing. A-cylindrical shroud, provided by NATD, will bei H L installed.in the radial housing to provide.m smooth annular ~ space with a-'
~
radial gap of one half inch. Several improvements in thel test rig:.will' be incorporated: two pressure transducers willibe replaced by models; H less sensitive to installation' method; an~ independent digital tachometer-will be used.to provide. accurate' speed' signals'to the dats' logging computer; the shaft will be leveled V ak- _-ing the support bearing pivot pias; thermocouples!will be installedLin the cyliidrical shroud'st: four =rimi locations; noncontacting displacement gauges willibe used toj monitor the relative position'of the rotor;and the housing during: .
,a 1
operation; and the computer program willLbe' modified to useithe-1- displacement'smuse information to~ calculate.the radial gap,during , d
. operation.
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<a Following assembly-of the cylindrical shroud into the radial housing,-tho' thrust bearing and the radial housing will be. reassembled .
on the test rotor. A mobile crane will be used'to renspeable the-housing and rotor onto the test rig. The drive. motor controller will be-tested and repaired by a factory technician to eliminate the
, oscillations noted at certain speeds during the-earlier. testing..
Following calibrat an of the torque measuring system, two sets.of test-runs will be made, covering the speed range from 600 to 1750 rps in'ench:
- direction of rotation. At or near tho' maximum speed, at least.three-different thrust' loads will be applied. These tests will enable as to'~ '
measure the losses associated with the-use of a half inch radial gap; instead of a radial bearing and to determine accurately the effect of thrust load on losses. By comparison with Phase II results we will be g able determine what portion of the losses found in Phase II<is-attributable to the radial bearing. . 0 As soon as results fron'the testing with half-inch radial' gap' 1 are available,--a review meeting will be held-involving EMD, NATD,Kand q STC personnel. Thepurposeofthemeetiniwillbe-todecideonthe:need for additional testing including the start /stop tests. Schedule for Task I' d n . Milestones Dates. Design of'8hroud and Fixtures 2-26 Rotor Dynamics Calculations- '4-21-92~ Test Specification 5-22-92, Assembly of Test Facility' 5-2C-92 Start-up' Testing- ^6-12-92 '
.Balf-inch Gap Testing- 7-10-92 Letter Report Issued .7-31-92
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Review Meeting. .. 8-14-92 - d
..,.. g A
4s I 5 4 n . .. n.. . g . ~ . 4 4
g g 4 L-0 F. f. E' TASK 2 - O n-INCE CAP.TBST'
, Objective - Measure the losses with an annular space having a radial' gap of one inch.
Description - The cylindrical shroud with a half-inch radial gap _- will be removed _ and replaced by a shroud (provided by NATD) with a'one-': ' inch radial gap. Following reassembly and'recalibration of the; torque nessuring system, two sets.of test runs will 'os made, covering the speed' range from 600 to 1750 rps in each direction of rotation. These> tests . will enable us to measure the losses associated with a second value of radial gap, allowing a determination to be made of the: significance of-the size of the gap on losses. Schedule for Task.2 - Milestones- -Dates Test Specification- .10-30-92 O Installation'of One-inch Gap Shroud
- One-inch Gap Testing 11-6-92:' 4 -
]
11-30 Letter' Report Issued ^ 12-31-92< q y. TASK 3 - QUARTR -INCE GAP TEST 1
' Obioetive - Measure the losses with'an annular space having a; radial gap of a quarter inch.-
Description - The cylindrical ~ shroud with a one-inch radial 1 gap
. V willLberemovedandreplacedby_mshroud-(providedbyNATD)'with'a quarter-inch radial gap. .Following~ reassembly and recalibration of the' I
torque measuring ~systaa,?two sets of test runs will be made, covering, h the speed' range from 600 to 1750 rpa'in each direction of rotation.: , , . 3. E n . ___._m_m__.___.__ _ . . _ - - - - - - -~->
These tests will enable us to determine the optimum value of radial gap by providing a third point on a curve of loss vs. radial gap. Schedule for Task 3 Milestones Dates Test Specification 1-22-93 Installation of Quarter-inch Cap Shroud 1-29-93 Quarter-inch Cap Testing 2-26-93 Letter Report 3-19-93 Final Report Issued 5-14-93 TASI 4 - START /STOP TEST Obiective - Verify the dimensional stability of the enclosed depleted uranium insert and the wear resistance of the thrust bearing by performint; 500 starts to 1750 rpm and complete stops. Description - The rotor and thrust bearing will be removed from the test rig for visual inspection before beginning the start /stop test, af ter 100 start /stop cycles, and af ter 500 cycles. Loss measurements will be made periodically at maximum speed to monitor any changes that might occur. The testing will be performed with the cylindrical shroud a,c L showing the lowest losses ~in the prior testing. Full _ _ thrust loading will be maintained on the thrust bearing at each start.
Schedule for Task 4 Milestones Dates Test Specification 3-26-93 Inspection 3-26-93 Perform 100 Starts and Full Stops 4-30-93 Inspection 5-14-93 Perform 400 Additional Starts and Full Stops 8-6-93 Inspection 8-20-93 Final Report Issued 10-22-93 TASK 5 - SLOT SPEED TEAR TEST Objective - Measure the wear of the thrust bearing shoes due to-operation at speeds below the film-generation speed. Description - The drive motor used in the crior testins will be a,c disconnectedandreplacedbyaslow-speed] system. Measurements'will be made with surface profilometry and/or-
] drive optical flats before, daring, and after testing to determine wear of the ,
a,c thrust shoes. Slow-speed testing will be conducted with full ~ ~ loading on the thrust bearing. The speed will be selected to be below the speed at which a lubricating film of water will form on the thrust shoes. Following the wear testing an option would be to perform some testing at full speed to show the'effect of the wear on full speed performance. After all testing is completed, the high inertis rotor and thrust bearing will be removed from the test rig for dismantling and inspection. The bearing and rotor / shaft assembly will be sent to EliD for Task 6. If no further testing is anticipated, the test rig will be decommissioned and prepared for storage. L l.
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9 Schedule for Task 5 Milestones Dates Test Specification 9-24-93 Install Slow Speed Drive 10-1-93 Testing 10-29-93 Final Report Issued 12-31-93 TASI 6 - FINAL RnMINATION OF TEST BEARING Objective - Verify that no damage has occurred to the thrust bearing or the enclosed depleted uranium rotor. Description - The thrust bearing and high inertis rotor will be further disassembled by EMD and visually and dimensionally inspected. The enclosed depleted uranium rotor will be shipped to Martin-Marietta at Oak Ridge for destructive examination of the depleted uranium alloy insert and its stainless steel enclosure. Task 6 will be performed entirely by others and is not included in the STO funding or schedule. It is included here for information only. GENERAL PROVISIONS Deliverables - For each task the deliverables will be: Test Specification, Monthly Progress and Financial Reports, and either a Letter Report or a Final Task Report. The Monthly Progress Reports will be furnished by the 1st of each month and the' Monthly Financial Reports by the 15th. The other deliverables will be furnished by the dates , shown in the task schedules. The dates for Tasks 2.through 5 assume that further funding will be received at STO at least a month in advance of.the due date for each Test Specification. At the conclusion of Task 5 all the task reports (including Phases I and 71) will be incorporated 6
.yx , . - - - -
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- 1 into.a single.overall project final report. This report will be~ issued
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by 3-31-94.- Enrineerina Testinz Practices at STC -An-important milestone in each Task is-the submission of a Test Specification. Any changes _in:the: Test Specification must be approved by-EMD and AP600 Project Test-Engineering.- Instrument calibratior., data reduction, and recording are described in tho'following paragraphs.
-Temperature measurements will be made by the use of thermocouples, connected either to an automatic data logger or to-m-manually operated readout device. The choice:of readout' device depends-on the need for continuous versus occasional monitoring.~ .In-Phase I--
each thermocouple was tested for correct output in ambient mir'and in boiling water;before installation in the thrust bearing or' support bearings. All agreed-to within l'F.with the appropriate temperature.; These same thermocouples will be used in Phase III.; Because-they are: . mounted in al==ina insulating tubes epoxied.into~1ocating. holes'in the bearing pads, they cannot be removed for recalibration.- These thermocouples will not be used for design verification measurements.. q They are used only for monitoring proper operation'of;the test facility..
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d similar thermocouples will be mounted in each cylindrical shroud, after-
~
calibration'in ice water and boiling water. The thermocouple prhbes,; n used for measuring water and oil tempreatures, will be removed from the: 0 y test rig and recalibrated together with their readout equipment;using; , j ice water and boiling' water. ! All the pressure transducers,.their signal conditioners, Land-the-data logger will be recalibrated on_a rotating-piston dead-weight. ; pressure-calibration fixture. The weights used-in this fixture will be. verified on a balance certified by the STC Standards Laboratory.-
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Electrical shunt calibration ~will be used before'ench day's testing to-verify that the instrument calibration'has.not changed.. g In Phases'I and II radial' load measurements wereLande.by; , caiibrated. strain sages applied to the thin piste-sections of the' upper alignment flexiplate fixtures.1 Each flex piste fixture was calibrated 0 p
, M 7L H
j
. . . = __ ____- - -
a,c overafullrangeofloadsupto[ lb in compression, using a testing machine which itself had been calibrated by certified load-proving rings. Electrical shunt calibrations were made on the strain sage signal conditioning equipment daily before use to ensure that the calibration of the gages had not changed. The same fixtures and shunt calibrations will be used in Phase III. The torque measuring system will be calibrated by dead weight loading on a temporarily attached lever. The weights will be calibrated by comparison with weights traceable to values certified by the STC Standards Laboratory. Calibration will be performed at 600 and 1200 rpm . rotation in both directions every time the test bearing housing is removed from the test rig. Between disassemblies electrical shunt calibration checks will be performed daily before use. The automatic data logger will be connected directly to a certified high-precision optical tachometer. The flowmeters will be-calibrated in place in the water system by the use of an electronic timer and calibrated containers. The timer will be certified by the STC Standards Laboratory. The volume of the containers will be verified by weighing water at room temperature on a certified balance. The displacement transducers, their signal conditioning equipment, and the automatic data logger will be calibrated by use of precision micrometer calibration equipment. A Hewlett-Packard Model 3497A data logger will be used to read the thermocouples and to take readings from the pressure transducers, the two radial loaders, the torque load cell, the tachometer, the flowmeters, and the displacement transducers. A Hewlett-Packard Model 85 computer will be used to read all the inputs from the data logger, calculate values in engineering units, continually display the most important results on the video monitor (updated every 20 s), print and store all results on demand, and plot selected results during the testing. Readings from other instrumentation will be logged manually at int'ervals during the testing. 1 8
p n - --- Documentation of Test Procedures and Results.- Check lists for all operating procedures will be used before and during each day's operation. Only properly trained personnel-will'he allowed to operate the test equipment. The check lists will be signed and dated by-the designated equipment operators. A check list of test conditions will be used.by the designated test. engineer.for each day's operation. Lists of instrumentation and data recorders will be maintained'along with calibration records.- Two such lists will be used, one for equipment' used to make essential measurements related to the test purposes, and the other for non-essential equipment. Dated test los sheets containing all the manually-obtained- l instrument readings will be maintained and initialled by the person: designated to make the readings. All computer-generated test data' 0 sheets will contain the time and date and will be maintainad as part of. the test log. For each task the principal investigator will sign m- ' statement indicating that all relevant test documentation has been l reviewed, that all test procedures have been followed, and that all: test' requirements have been met. Any deviations will be noted along with-the q corrective action to be taken. '
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