ML20106B969

Provides Info Re Company QA Field Tests & Insps of Nuclear Code Pumps,In Response to NRC 820325 Request for Info.Encl Re QA Program Allegations Sent to Nuclear Code Customers

ML20106B969
Person / Time
Site:	Palo Verde, Hope Creek, Braidwood, Limerick, River Bend, 05000000
Issue date:	04/14/1982
From:	Lyons B HAYWARD TYLER PUMP CO.
To:	Deyoung R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
Shared Package
ML20106B748	List: ML20106B969
References
FOIA-83-439 NUDOCS 8502120100
Download: ML20106B969 (2)

Text

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' fd 80 Industrial Parkway Burlington, Vt. 05402 (802) 863-2351 April 14, 1982 Mr. Richard C. DeYoung Director, Office of Inspection and Enforcement U.S. Nuclear Regulatory Comission 4350 East-West Highway Bethesda, Maryland 20555

Dear Mr. DeYoung:

Re* Hayward Tyler Pump Company --

Field Tests and Inspections I have received your letter of March 25. In the third paragraph of that letter, you request that the Hayward Tyler Pump Company (IRPC) confirm certain NRC assumptions about the Company's business activities.

Q I will address your requests for confimation in the order presented.

(1) The " List of Domestic Customers of Hayward Tyler Nuclear Code Pumps" on page 2 of your letter appears to depart in certain respects from the list of Code pump utilization given to Mr. Potapovs of the Region IV staff in January, 1982. In this regard, I call your partic-ular attention to the following: (a) the list provided to Mr. Potapovs shows :xmtps to be utilized at Hope Creek 1 as well as Hope C eek 2; (b) tw Hartsville plants am designated by TVA as A-1, A-2, B-1, and B-2, rather than as 1 or 2; and (c) as shown in the list given Mr.

Potapovs, we have sold nuclear Code pumps for use only in unit 1 at the Forked River site, not any other unit at that site. Based on IRPC's most recent review of the Company's contract documents,irrPC believes that its nuclear Code pumps are to be utilized at River Bend 1 but not River Bend 2, at Braidwood but not Byron, and at Yellow Creek Units 1 and 2. The available contract documents also indicate that the use of firPC nuclear Code pumps at Palo Verde may not be limited to Unit 2.

I should point out, however, that ifrPC is wholly dependent upon its customers for information concerning the intended application of nucicar Code punps manufactured by the Company. Accordingly, while ifrPC can, and has, provided NRC with the most accurate infomation regarding pump destination available to it, the Company cannot control the use its customers may decide to make of any particular pump sold to them by ifrPC.

As demonstrated by the foregoing paragraph, this feature is particularly

] likely to manifest itself at power station sites where more than one j generating unit is located.

8502120100 040003 Conti*****

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Mr. Richard C. DeYoung April 14, 1982 Page Two (2) Some of the pug s supplied for use at the Hope Creek Station were manufactured to ASME Class 2 requirements. Those puups so manufac-tured are designated by "CL-2" in the column labeled " National Board No."

on the list given to Mr. Potapovs in January. In addition, 4 pumps for Philadelphia Electric, Limerick 1 and 2, National Board Numbers 220, 222, 224, and 226 are ASME Class 2 ptmps. All remaining nuclear Code ptaps on that list supplied were manufactured to ASME Class 3 requirements.

(3) Your understanding that HTPC has supplied spare parts for use in nuclear Code pumps is correct. On March 12, I sent you a . list of all Code (our Quality Level 1) parts manufactured by HTPC for use in nuclear Code ptaps, including ptmps not manufactured by HrPC. Please refer to that list.

The Company has taken note of the statement in your letter that NRC is unable to evaluate the adequacy of the actions proposed by HIPC on March 10 until your investigation of the allegations concerning the Company's manufacture of nuclear grade pumps is completed. HIPC believes Q that, in light of what it hopes will be the early completion of NRC's investigation, innediately advising the Coupany's customers of recommen-dations of additional tests and inspections would be a premature and pointless exercise, except in the case of those two operating facilities (Oconee and Salem 1) using HTPC nuclear Code ptmps. HIPC has already connunicated with all its Code pump customers concerning the allegations.

A copy is attached.

Sincere ,

' l HAW PLNP C mPANY P. Lyons Chief Executive BPL/ gem Attach. '

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N P. O. Box 492 h- 80 Industrial Parkway Burlington. Vt. 05402 (802) 863-2351

. April 13, 1982 Le m 2 brwCw bd C N efr.

As you are most probably aware, the Hayward Tyler Pump Company (HTPC) is currently the subject of an inquiry by the NRC. This inquiry stemmed from allegations made by five of the Company's ex-employees, all of whom lef t HTPC mora than a year ago, concerning purported failures to adhere to the company's Quality Assurance program. These allegations were made to Congressman Edward J.

Markey (D-Mass.) and to the press. Congressman Markey asked the NRC to conduct o comprehensive investigation. HTPC also asked the NRC for a full and complete

.Qcudit. ,

In keeping with our desire that you be accurately informed on the facts, I am enclosing a copy 'of a letter to Congressman Markey from Marcus A. Rowden, c unsel for HTPC in this matter. The enclosed letter summarizes the conclusions re:ched by Mr. Rowden's law firm and the technical experts working with it in the separate inquiry into these allegations conducted on behalf of the NRC. This 10tter was included in the record of the hearing held by Congressman Markey on April 6 concerning the NRC's investigation of the allegations.

Mr. Rowden, as you may know, was formerly Chairman of the Nuclear Regulatory Commission. HTPC asked Mr. Rowden and his law firm to conduct a separate inquiry into the merits of the allegations to assure that the relevant evidence was developed and that it was fairly and competently evaluated. To provide technical assictance, Mr. Rowden's firm retained the services of Systems Research Applications Corp; ration and its President, Dr. Ernst Volgenau, former NRC Director of Inspection and Enforcement. .

The separate inquiry focused on the merits of the issues to which NRC attached primary importance. As set forth in the enclosed letter, the conclusions are that tha cx-employees' allegations regarding the safety and reliability of HTPC pumps are n:t cubstantiated and that the Company did not withhold any records from thu NRC nor fcicify any records, as alleged.

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O Page 2 April 13, 1982 The NRC inquiry is continuing and its report has yet to be issued. The April 6 hearing was not intended to address the merits of the allegations.

However, according to reports in the public press, various NRC representatives have previously stated that NRC's investigation failed to uncover any indication that any pumps were unacceptable and that the deficiencies in paperwork "were not very significant and dida't really have any bearing on the quality of work-manship that went into the pumps themselves."

We believe that we make products to the highest quality standards and ~ that cur pumps are among the safest and most reliable in the industry. Many of the pre:s reports on this matter have been fragmentary and incomplete. The enclosure, in cur view, is a straightforward summary of relevant facts and responsible con-clusions. ,As such, we hope it will be helpful. If you wish any additional inf;rmation, please do not hesitate to contact me.

Sincerely, [

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Davi . Woodhock Vic President, Manager of Engineering and Customer Service

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Hand Deliver Mr. Roger Fortuna U.S. Nuclear Regulatory Commission 4350 East-West Highway East-West West Building 5th Floor -- Room 568 Bethesda, Maryland Re Hayward Tyler Pump Company

Dear Roger:

Enclosed are materials which were prepared by Hayward Tyler Pump Company ("HTPC") relating to the inspection and inves-tigation of.HTPC. As we have stated to you previously, these-documents were generated by HTPC, and we consider them HTPC docu-ments and not in any way Nuclear Regulatory Commission documents.

We expect that these documents will be returned to us immediately after your review of them.

ry truly yours, r -

ohn T. doese JTBadig Enclosures 8

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G_ l PUhF COMPANY P. O. Box 492 80 Industrial Parkway Burlington, Vt. 05402 (802) 863-2351 July 28, 1982 Mr. Roger Fortuna Acting Chief of Inver.tigations Office of Inspection & Enforcement U.S. Nuclear Regulatory Commission Washington, D.C. 20555 Re: Hayward Tyler Pump Company (HTPC)

Dear Mr. Fortuna:

During their visit to HTPC's Burlington plant the week of July 12, Messrs. Dromerick and Peranich of your staff asked for HTPC's analysis of certain matters. The subject matters involved certain F-3 pumps manufactured for use at the Pilgrim 2 nuclear generating facility and the anti-rotation pin in the casing wear ring in pumps produced under Shop orders 8105/06. The requested analyses are enclosed.

HTPC calls your attention to the fact that these analyses consist of proprietary engineering and 'esign information. HTPC incurred significant expenses in obtaintag and (in some cases) creating this infor-mation, and it would be of significant value to HTPC'c competitors.

Accordingly, HTPC expects that NRC will not release this information to the public under any circumstances. Should NRC receive a request to release the enclosed analyses, HTPC expects that the agency will notify the Company immediately, and at least ten working days before the agency makes any decision with respect to such request.

Sincerely, i

B.P. Lyons Chief Execut ve BPL/ gem

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rune = cowww 7/28/82 l Plant: Boston Edison Pilgrim Unit #2 Service: Equipment Drain Pumps Pump Type: Hayward Tyler Type N3, Size 1-1/2 x 2 x 7 (BH1)

ABSTRACT During 1977 Hayward Tyler developed a pump product line for nuclear auxiliary and radwaste system applications. This range of pumps, which comprises fourteen (14) sizes, was named "N3". The N3 range of pumps is an end suction, vertically split configuration with a cantilever shaft / bearing arrangement designed for low stress / deflection and high bearing life. The range of 14 pumps is subdivided into 3 groups, i.e., BH1, BH2 and BH3, according to the bearing housing associated with each pump unit. See Figure 1.0 for a sectional view of the BH1 group.

The first HTPC pumps of this range became available for testing during the second quarter of 1978. These pumps were of sizes 1-1/2 x 2 x 7 N3 (BH1) and 2 x 3 x 10 N3 (BH2), two of each size, and were to be shipped to the Boston Edison, Pil, grim 2 generating facility. ' (This analysis is limited to the BH1 size.) The pumps were all hydrostatically and performance tested, during which vibration and bearing temperature readings were taken and recorded.

The initial BH1 bearing design was comprised of a cylindrical roller radial bearing (NU208) and a single row deep groove split inner race thrust bearing (QJ308). During assembly of the Boston Edison BH1 pumps, a considerable amount of radial displacement was observed at the impeller. HTPC determined that this excessive displacemcat was due to internal clearances at the anti-friction bearing. In an effort to remedy this problem, a number of different bearing configurations were tested. (See Hayward Tyler Report dated June 28, 1978, attached). As a direct result of these tests, the bearing design in the Boston Edison BH1 pumps was changed to incorporate a single row deep groove ball radial bearing (SKF 6208). The thrust bearing (QJ308) remained unchanged from the original bearing design.

It was recognized that, although this new bearing combination was acceptable for the comparatively lightly loaded Boston Edison BH1 pumps (1-1/2 x 2 x 7, which has the Icast load of all the BH1 sizes), it was unlikely that such combi-nation was acceptable for the full range of BH1 pumps, especially not for such pump sizes with higher loads as the 1-1/2 x 3 x 8 or the 2 x 3 x 8 sizes.

Accordingly, the Boston Edison pumps were shipped on August 1, 1978, but the bearing investigation regarding the BH1 pump range continued thereafter.

After the Boston Edison pumps had been shipped, additional pumps of the initial BH1 bearing configuration (including some of the 1-1/2 x 3 x 8 size) were manu-factured for other contracts and became available for testing. The 1-1/2 x 3 x 8 pump size exhibits the second highest load conditions of the BH1 group. During performance tests of these larger size pumps, contact of the rotating impeller and the stationary case ring was observed. As a result of tha ongoing bearing investigation program, HTPC concluded that the initial design of a single row

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deep groove split inner race ball bearing (QJ308) for the thrust bearing did not provide the rotating element sufficient stiffness during the maximum design operating conditions. To overcome this insufficiency of stiffness,.

the BH1 design was changed to incorporate a double row angular contact bearing as the thrust bearing, the same bearing configuration originally incorporated into the BH2 and BH3 designs. Again, based upon the relatively light hydraulic load of the Boston Edison BH1 pumps, HTP.C concluded that these pumps would operate satisfactorily with the bearing configuration as shipped.

This paper provides information concerning the Boston Edison 1-1/2 x 2 x 7 pumps in the form of additional technical detail to that generated at the time the redesign of those pumps' bearing configuration took place. The paper reconfirms HTPC's earlier determination that the bearing configuration as supplied in the Boston Edison BH1 pumps (SKF 6208 for the radial bearing and SKF QJ308 for the thrust bearing) is satisfactory for those pumps.

Boston Edison BH1 Pumps Service: Equipment Drain Pump Size: 1-1/2 x 2 x 7 (BH1)

Rating: 50 GPM at 185 FT S Speed: 3500 RPM Seismic OBE condition and DBE condition The following analysis provides further justification for retaining the bearing configuration fitted in the 1-1/2 x 2 x 7 Boston Edison pumps. The factors considered in this analysis are those both necessary and sufficient for reaching such conclusion:

1

! 1. Shaft Displacement

2. Bearing Life and Temperature

3. Shaft Strese 4 Materials l

5. Performance Test

! 1. Shaft Displacement l ,

Shaft displacement is a result of the combination of deflection due to hydraulic and dead weight loads plus the displacement due to anti-friction l bearint, clearance. No shaft loads are transmitted from the motor to the

pump, or vice versa, because a flexible coupling installed between these j components precludes such transmission.

Hydraulic (i.e., dynamic) loads encountered within a centrifugal pump are both axial and radial. Axial loads, however, do not increase shaft dis-

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i placement. In f.act, axial 1oads add some degree of stiffness to ,the, thrust I bearing, thereby tending to reduce shaft displacement; but for purposes '

o'f thei^ evaluation in this paper the beneficial effects from axial loads j will not be taken into account. Hydraulic radial loads result from pressure distribution around the periphery of the impeller within the volute section

, of the casing. When a pump's* flow differs from its best efficiency point (BEP), this pressure distribution becomes unsymmetrical and shaft deflection is increased.' Dead weight (static) loads are simply the result of the weight of the impeller and the shaf,e overhang.

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1,( ' Z g :.a As-noted above, hydraulic and dead weight loads are combined and the total becomes one element in computing total potential shaft deflection.

Figure 2.0 sets forth the loads and deflections, at various percentages of BIP, of the Boston Edison BH1 pumps compared to the more heavily loaded BR1 unit in which contact between the wearing surfaces was observed. '

To compute total potential shaft displacement, this deflection (computed based on loads) is added to shaft displacement due to the bearing clearances.

The HTPC report of June 28,1978 (copy attached) states that, in Configuration ')

No. 4 (used in the Boston Edison BH1 pumps), there was a radial, deflection ,

of .005 .010 inches. This range of measurement was sufficiently accurate -

for that testing program and, viewed as stating total deflection in the radial plane, ' allowed shipment of the Boston Edison pumps with the Config-uration No. 4 bearing design following unit performance tests. HTPC inter conducted more definitive and exacting testing on shaft displacement due to bearing clearance. These tests, undertaken in August 1978 (copy of report ,

attached), used b' earings identical */ to those used 'in Configuration No. 4 , '

and showed radial de'flection of .004 inch up and .006 inch down. This result is reconfirmed by reference to the bearing manufacturer's own published data on the radial internal clearances of its bearings. Combining that data j with the shaft length of the 1-1/2 x 2 x 7 pumps, HTPC has computed a maxi-num radial displacement of .0054 inch (this computation appears in Figure 5.0, attached). The August 1978 testing and the computations using the bearing manufacturer's data make clear that the actual reading within the - ,

range obtained in the June 1978 testing must have been much closer to .005  !

inch than .010 inch.  !

,. .ce 2 Figure 3.0 (attached). plots on curves both total deflection based on loads i and total shaft displacement at the impeller (i.e., from all loads plus l displacement due to bearing clearances), using the .0054 inch figure derived from the bearing manufacturer's data. ' Figure 3.0 sFoWihat the Boston Edison BH1 pumps should not exhibit contact of the rotating and stationary i surfaces during operation. Furthermore, no such contact was observed in HTPC's in-house performance tests of those pumps. ,

2. Bearina Life and Bearina Temperature i The N3 range was designed for 50,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br /> L bearing life as determined bytheAnti-FrictionBearingManufacturers'khoociation(AFBMA)'*S't'ndard. a i As the hydraulic loads for the Boston Edison BR1 pumps are low, the corres-ponding bearing life is high. As can be seen from Figure 4.0, bearing life for both radial and thrust bearings far exceeds this design criteria and will exceed all applicable indestry requirements. Bearing temperature checks wereperformedontheBostonEdisonBH1pumpsatneartoshutvalveconditfon  !

(bearingsathighestloadedpofnt). Maximum bearing temperatures were 125 F  :

for the radial bearing and 139 F for the thrust bearing (see June 28, 1978 '

test report), which are well within acceptance standards.

• / See column 2 of the test report. That configuration vises the same thrust  !

bearing QJ308 as in the Boston Edison BH1 pumps and a PRW 2085 radial bearing.

In accordance with AFBMA (Anti-Friciton Bearing Manufacturers' socia

• ion) l standards, the PRW 2085 bearing type is identical dimensional 1 n tolerances I to the SKF 6208 bearing used as the radial bearing in the Boston Edision BH1 pumps. <

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3. Shaf t S*rus No additional shaft stress results from the displacement due to bearing clearances. Design shaft stress levels, therefore, remain valid.

4. Materials

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As a design precaution to minimize the effect of wear ring rubbing, all pumps are supplied with opposing rings made of materials with a high differential in hardness so t' to resist galling.

5. Performance Test Full performance tests were conducted on the Boston Edison pumps in accordance with the Hydraulic Institute Standards and customer approved procedures.

Performance tests were customer witnessed and included Head, Capacity, Horsepower, NPSH, Vibration and Temperature Checks. No unusual effects were encountered during these tests with the exception that, at one speed, one of the BH1 pumps did not meet the applicable standard of accept-ability for the vibration test. The customer's representative, who witnessed the testing and was given the results, accepted the pump. Since the Test Engineer recorded a note "no unusual noise or vibration", the problem most probably lay in the testing loop connection rather than in the pump. In any event, HTPC will recommend that both the BH1 pumps be vibration tested again during commissioning, once they are installed and well prior to power-plant operations. Should commissioning tests confirm the validity of the high vibration reading obtained during performance testing, HTPC and its customer will take appropriate action to rectify the problem.

Conclusion It is the opinion of HTPC that the Boston Edison BH1 pumps will perform as required by the Design Specification when operated and maintained in accordance with Hayward Tyler's Operating and Maintenance Manual.

M

. Derek Clare Norm Schreib Chief Engineer Design Engineer DC/ga-

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