ML20141F682
| ML20141F682 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 04/08/1997 |
| From: | Dozier M, Koch R, Manan Patel FLORIDA POWER CORP. |
| To: | |
| Shared Package | |
| ML19355F179 | List: |
| References | |
| TR-9640, TR-9640-R, TR-9640-R00, NUDOCS 9705210416 | |
| Download: ML20141F682 (100) | |
Text
{{#Wiki_filter:-. . ._ \ O TR-9640 REV. 00 HYDRAULIC EVALUATION BYINGERSOLL-DRESSER PUMP COMPANY FOR FLORIDA POWER CORPORATION CRYSTAL RIVER 3 PLANT IDP ORDER NO: 050-61994 FPC PO#F772618D 4 Q b Decay Heat Pumps IDP Model 8HN194 PREPARED BY: RICK KOCH-ENGINEERING MANAGER MIKE DOZIER-PROJECT MANAGER MANISH PATEL-PRODUCT ENGINEER pu)RfDA POWER CORPORATION NUC1 EAR ENGNEERNG DEPARTMENT March 12,1997 CRYSTAL RIVER - UNf7 3 REYlEWED AND ACCEPTED BYt kvan- nets _ au.g w a 4h7 O w a-nr2m age P A
[} REVISIONS l l Rev/Date Remarks Action By/Date Prepared
. 00/ Original issue SEg COVER J
12-Mar-97 1%N r I
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e ABSTRACT Ingersoll-Dresser Pump Company (Phillipsburg, NJ) conducted low flow testing and a flow rangeability study of a model 8HN-194 pump for Florida Power Corp. The pump was an identical spare provided for testing by Three Mile Island. The testing program included pre and post dismantle and inspect sequences, baseline performance testing, a 30 day endurance test at 100 gpm, 8 hours of flow rangeability testing and a final report. Based on the results of the testing and IDP engineering judgment, new pump guidelines for operability were issued for the model 8HN-194 to indicate r that the pump can be operated for up to one year between 100-1200 gpm and that the minimum continuous stable flow can be established at 1200 gpm. During the course of the test program the pump operated satisfactorily over its entire range of flow while also having vibration levels at all flows remain . satisfactory as defined by the CR3 ASME Pump Monitoring Program. The post-run dismantle inspection revealed no abnormal wear of any parts. Therefore, the pump performed to IDP's satisfaction and provided test data to support modified operating guidelines. Previous guidelines were very conservative due to a lack of actual test data. l w
l I TABLE OF CONTENTS 7 , C 1.0 PURPOSE
2.0 BACKGROUND
3.0 WORKSCOPE a I 4.0 PTl/ TEST LOOP l 1
- 5.0 BASELINE PERFORMANCE TEST DATA 6.0 ENDURANCE RUN DATA l 4 I
7.0 POST ENDURANCE RUN PERFORMANCE TEST DATA : . 8.0 VlBRATION DATA l
9.0 CONCLUSION
10.0 REFERENCES
1 O e i l l O _ _ . . . ~ . . - _ . . . . _ . _.
1.0 PURPOSE l
' The purpose of this report is to detail the results of low flow endurance -
testing and flow rangeability testing performed by Ingersoll-Dresser Pump - i - Phillipsburg, N.J. for Florida Power Corporation Crystal River 3 on their model 8HN-194 Decay Heat Pumps. IDP has no prior low flow test data on this design pump. This report will analyze the results of the testing and realistic low flow operating guidelines will be provided to FPC CR3. Flow, differential pressure, : vibration and bearing temperature data as well as physical inspection results will i all be used to support the final recommendations for low flow operation of the ;
. pump, and a Minimum Continuous Stable Flow (MCSF) value. l
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2.0 BACKGROUND
The 8HN-194 model pump is designed to provide cooling water to the Reactor Coolant System (RCS), for Decay Heat (DH) Removal during plant shutdown and Low Pressure Safety injection (LPI) during potential accident conditions. The DH/LPI pumps are end suction,~ single stage overhung (cantilevered from radial bearing) pumps, designed with a high Suction Specific Speed (Nss)(>13,622) impeller inlet to provide the characteristic of reliable operation at low suction pressures (Net Positive Suction Pressure-NPSH). The pump was initially designed to achieve these specific flow requirements at the "Best Efficiency Point" (BEP). Refer to the 10/7/96 Performance curve (Section 5.0). The pumps, in actual operation, must operate at various flow points. The
' i Os present design was thought to experience equipment deterioration during low
. flow operation, when subject to hydraulic instability, vibration, shaft deflection, abnormal bearing loads and abnormal internal wear. The 1988 IDP and NRC 4 guidelines defined that the pump rotor must be clocked and monitored for low 1-flow operation. Extended operation at flow values less than 400 gpm and in the 1500 to 1600 gpm range, dictated disassembly and rotor refurbishment. Operation at approximately EEP is the preferred flow regime. Pump operation at lower or higher flows will subject the pump to increased static and dynamic axial and radial loads. These loads will induce rotor vibration, shaft stress, shaft deflection and abnormal bearing loading. Vibration and shaft
}
deflection will affect mechanical seal operation integrity and bearing life. f
I Plant installed pump testing was conducted in 1989 in an attempt to pO provide quantitative data to predict extended pump operating capability at low flow. 'The analysis was conducted by a third party (MPR). The consultant was _ I contracted to extrapolate the test data to define expected pump reliability at low j flow. To further define the pump reliability , based on actual extended testing l data, FPC recently determined that additional test analysis and more conclusive data was desired. The decision was made to conduct this test at the IDP
~ Phillipsburg, NJ facility in controlled laboratory conditions so as to precisely l control flows, NPSH and fluid temperatures. f
. The purpose of this endurance test program was to have IDP conduct a l t low flow analysis at critical flow points. The operating " vital signs" of the pump l
; t during the test and post test inspection findings would provide the objective evidence, based on sound engineering judgement and experience, to ;
extrapolate the expected service life of the pump at the low flow conditions. This is standard practice within the pump hydraulic design industry for qualifying . pumps for special conditions. Additional mid-range flow testing was also conducted to assure that there were no regions of hydraulic instability, and to determine if the 2350 gpm MCSF(minimum continuous stable flow) point could i be reduced. This is also standard practice for determining the recommended ; MCSF for a given pump design. O
)
1 9 f , 3.0 WORK SCOPE - (C Florida Power issued a contract to IDP to conduct low flow testing using a GPU/TMI (Three Mile Island) spare 8HN-194 pump which, other than minor differences described within this report, is a mechanical duplicate of the Crystal River pumps. The contract required IDP to perform the following:
- Initial teardown, inspection, and document condition
- Run baseline performance test to confirm pump performance
- Run constant 30-day low flow test (100 GPM)
- Run another performance test to confirm pump performance
]
- 8-hour flow rangeability study with focus on mid-range flow
- Post test teardown, inspection, and document condition
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- Refurbish pump as necessary to like new condition
- Issue findings report An initial inspection was performed and all critical dimensions were checked by IDP against the drawings. A copy of the inspection plan and summary is included in the Reference Section of this report. All parts conformed to the drawings except both wear ring bores measured .005" undersized, and the l stuffing box pilot fit to the casing measured .005" undersize. Per the discussion in Section 9.0 neither of these items would affect the low-flow test analysis therefore IDP decided to affect repairs to these parts during the post-test refurbishment.
y-) b
Testing was performed at IDP's Phillipsburg facility per the specified (K]
\
' . Performance Test instructions (PTI). Per the request of Florida Power, IDP also performed NPSH testing for information purposes. During low flow testing noise o due to pump recirculation was pronounced and steady. The mechanical seal
. exhibited no leaks, and the bearing housing (which was water cooled) remained cool to the touch (~70 F).
The results of testing are shown in Sections 4.0/5.0/6.0 of this report. During testing, Florida Power took vibration data which is shown in Section 7.0. Florida Power also took several oil samples during the test, each of which produced normal results. Copies of these analyses are located in the Reference Section. - After testing was completed, IDP dismantled and inspected the components. No visible signs of distress were found in the pump including wear surfaces, mechanical seal, or bearings. A dimensional check of the ring surfaces, f impeller and shaft showed no discemible wear. A copy of these results is located in the Reference Section. The 8HN-194 pump was refurbished at IDP Phillipsburg under the source inspection of GPU and will be returned to Three Mile Island. Workscope included restoration of the stuffing box / ring dimensions as previously identified and replacement of_ gaskets and bearings. All other components, including the mechanical seal, required no repair. A final performance test was run prior to shipment, which is included in the reference section.
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; 4.0 PTl/ TEST LOOP ; A. PTl dated 10/3/96 and revised 11/6/96 B. Description of Test Loop C. Test Loop Photos i
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, . PERFORMANCE TEST / CURVE INSTRUCTIONS
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n Uh ym ORDER t. ITEM NO: 050-61994 -00 - DATE: 10/3/96 E: 8mT-194 CUSTOMER: Florida Power Corp QUANTITY: 1 __, h M ORDER DESIGN WATER CORRECTION TEST TOL. CONDITIONS CONDITIONS CONDITIONS FACTORS
+ -
w f SPEED (rpm) 1780 1780 1.000 0 4
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FLOW (gpm) 3000 3000 1.000 N e m TDH (ft) 350 350 1.000 - EFF. (t) 79.0 79.0 1.000 l H NPSHR (ft) 14.0 14.0 1.000 lj O NPSHA (ft) 0.0 0.0 1.000 h m 0.000 1.000 N VIBRATION (mils) A 2 O OTHER 1.000 . REQUIRED TEST # OF # TESTS CERTIFIED CERTIFIED CURVE
- STING PROCEDURE PUMPS WITNESSED CURVES DATA APPROVALS Yes y p ERFORMANCE 1
l1 1 1 og - NPSH NONE TEST STANDARD (CHECK) HI API ASME IDP OTHER C m 1 Y VIBRATION (CHECK) TEST STANDARD SPECIAL (SEE BELOW) O SPECIAL TEST INSTRUCTIONS: MCSF = 1000 (gpm) i
-FLOW. HEAD. EFFICTYNCY, SPEED l l
S HJ T.T. BE MTASURED AT 125 GPM. 925 GF1 1900 GPM. 2800 GPM. 3250 GPM AND 3500 GPM. CUSTOMER WILL COLLEC"" VIBRATICN DATA AT EACH OF *MESE POIN'"S . 'e
~ BEARING HOUSING TEMPERATURE READINGS TO BE MONITORED PERIODICALLY. y$
, pl (PYROMETER READINGS ARE ACCEPTA3LE). #
-PREFERRED COUPLING ALIGNMENT TO BE OFFSET <3 MILS AND AMGULARITY WI* MIN 1 l
0.4 MILS / INCH OF COUPLING DIAMETER. Flow to seal s hit 11 be approx ~m i _-CLEAN WATER TO BE USED TO FLUSH SEAL. 20 PSI above suction eressure. Coolina water to bearinos to be ~N ! 7 GPM (+/- 2GPM),. )E N C l CONTACT FOR WITNESS: CUSTCMER ORDER NO: F772551B e p2 Mike Dozier o e, TAG NO.: :: REQUIRED NOTIFICATION: 2 DAYS sg N
?E ONTRACT PRODUCT ,,,
ADMINIS 7ATOR: Mike Dozier ENGINEER: MANISH PATEL O r;rm cricoo 4s. Rev. 2. 01s n3 l
Ing:rs lleDrcss:r.P;mps
- PERFORMANCE TEST / CURVE ADDITIONAL INSTRUCTIONS Y
P; R L ITEM No: 050-61994-00 DATE: 10/3/96 $ l g - }:- g PE: 8HN en CUSTOMER: Florida Power Corp QUANTITY: 1 $hm Tcat #1 Standard performance test per instructions. e Customer to instrument pump for vibration. ~$ After performance test is done pump shall be shut down and RM cllowed to cool to ambient temp. Curve approval required. w N c cn Tcst #2 Rastart pump for (30) day endurance test at 100 GPM and g cmbient temp (+/ 0 degress F). S.eal flush and bearing oo cooling to be malatained per instructions. NPSHA to be 19 -34 Ft Vibration data to be recorded by customer. during endurance test. o"h
~m Saal leakge and bearing temps to be monitored and recorded. $[
"6
- Contract administrator to be notified immediately if any negative trends occur in performance, vibration, bearing temp, or seal leakage.
V ' Customer to vitaess last (2) days of test. Pump to be shut
'( j own upon completion and allowed to cool to ambient temp. ,
E Test #3 $ Rspeat test # 1. Curve approval required T_ o_ _ s _t _ #_4_ p Instrument pump bearing housing to record bearing housing temp , y bearing housing vibration, and shaft vibration. H Run pump at flows and times per attached chart and record data . 8 Run complete test with approximately 19-20 feet NPSHA to pump. - Rscord differential head and DHP to evaluate performance (0,HD ,EF) , After completing runout flow point at 19-20 feet NPSHA re-run runout point with 33-34 feet NPSHA. New runout point should be 9 alightly higher than runout with 19-20 feet NPSHA. yh Shut down pump and allow to cool to ambient. o Note: After all testing is completed return pump to the assembly floor for disassembly and inspection. (gg k$ eM i OC 1
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[ Vic:c=F m l - l [ The pump will be operated for approximately 2 hours at design flow to stabilize bearing temperature. N]J Flow-com l Time-min TDH BH Temp BH Vib l Shaft Vib design 120 500 30 1 1000 30 1400 60 1500 60 1600 60 2000 30 2350 20 : 1 3500 20 4500 20 ' 30 5500(or max) 8 hrs I l i i O
FLORIDA POWER CORP - CRYSTAL RIVER
- 8HN-194 DECAY HEAT PUMP TEST O -
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i INGERSOLL-RAND' COMPANY:-.EHGINEERED' PUMP DIVISION STEPPED PERFORMANCE-TEST RECORD PAGE 1
-- DATE 10 /7 /96 11 320 jjoo********************************************************************************: -
A_/s 6 7 t POINT H l' 2 3 ,4 5 , a DISCHG (FT)' 444.3 444.6 -436.5 409.5 352.4 315.4 294.3 SUCTION (FT) 22.3 22.7 21.9 -19.8- '16.2 14.0 12.5 DIFF. VEL.HD. 0.0- 0.0' O.4 1.4 3. 0 - 4.1 4.7 l T.D.H.(FT) 421.9 421.9 415.0 391.1' 339.2 305.5 286.5 FLOW (GPM) 0.0 124,9 961.1 1902.6 2804.8 3262.3 3496.9 W.H.P. 0.0 13.3 100.6 187.7 240.0 251.4 252.8 i R.P.M.- 1792. .1792. 1792. 1792. 1792. 1792. 1792. l
' WATTS 111.0 113.1 146.0 196.5 237.5 256.6 264.6 ;
^
B.H.P. 138.7 141.4 184.4 250.0 302.7 327.0 337.2 { EFFICIENCY 0.0 9.4 54.6 75.1' 79.3 76.9 74.9 { t
~
s 4mDATA STEPPED TO SPEED OF 1780 RPM.
)
BTEP TDH 416.3 416.3 409.4 '385.9 334.7 301.4 282.7 STEP FLOW 0.0 124.1 954.6 1889.9 2786.0 3240.4 3473.5 i i STEP RPM 1780. 1780. 1780. 1780. 1780. 1780. 1780. l
-STEP BHP 135.9 138.6 180.7 245.0 296.6 320.5 330.5 :
l STEP-EFF 0.0 9.4. 54.6 75.1 79.3 76.9 74.9 1
==================================================================================== l ORDER #-ITEM CUSTOMER CUST. ORDER CUST. TAG /ITn ]
050-61994.00 . FLORIDA POWER CORP. PUMP TYPE SERIAL HO. IMPELLER IMPELLER DIA CUST. RPM 8HH-194 1624922 0.00 1780. i
====================================================================================
AmGUARANTEED CONDITIDHS: GUAR."GPM GUAR.-TDH. -GUAR. EFF. GUAR. NPSHR GUAR. MCSF 3000.0. 350.0 79.0 14.0 1000. a===================================================================================
'4mCUSTOMER CONDITIONS:
.( .CUST. SERVICE CUST. TEMP. C.VISC. (SSU) CUST. SP.GR. CUST. NPSHA f-ws. 0.0 0.00 0.0 1 j2================================================================================= APPROVALS: O TEST ENGR. K dOWscLuet- ENGR'G. DEPT.
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(
. WITNESSED BY' 0F conc 4******************************************************************************* ;
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.........===========================================================================
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==============================s=================================u===============r===
ORDER H-ITEN CUSTOMER CUST. ORDER CUST. TAG /ITM
-050-61994.00 FLORIDA POWER CORP.
PUMP TYPE GERIAL NO. IMPELLER IMPELLER DIA CUST. RPM
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================================================================u===================
4mGUARANTEED CONDITIONS: GUAR. GPM. GUAR. TDH GUAR. EFF. GUAR. NP5HR GUAR. MCSF
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====================================================================================
ORDER N-ITEM CUSTOMER CUST. ORDER CUST. TAG /ITM 050-61994.00 FLORIDA POWER CORP.
......__---------....... ...-_- __--_.---_-_----.---__._--------_-----__.--_-------- r PUMP TYPE SERIAL NO. IMPELLER IMPELLER DIA CUST. RPM ,
8HH-194 '1624922 0.00 1780. i
====================================================================================
4mGUARANTEED CONDITIONS: ! GUAR. GPM GUAR. TDH GUAR. EFF. GUAR. NPSHR GUAR. MCSF 3000.0 350.0 79.0 14.0 1000. l
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'4mCUSTOMER CONDITIONS: ,
CUST. SERVICE CUST. TEMP. C.VISC. (SSU) CUST. SP.GR. CUST. HPSHA l 0.0 0.00 0.0
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' STEPPED HPSH TEST RECORD - BREAK N1 AT 2015 GPM PAGE 2 l s , . DATE;J10 /7 /96 12 :2 hN2e********************************************************************************* a
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~ POINT H .9 DISCHG"(FT) 324.9 ;
i SUCTION;(FT) -26.9 ! IDIFF. VEL.HD. '1. 4 [ 1 T.D.H. (FT) 353.3 , RPM 1792. B ARD, (FT. ): ~33.9 H2O TEMP.(F) 75;B s i
'V.P./iFT;) 1.0 HPSH.(FT)- 6.8 AmDATA~ STEPPED TO SPEED OF 1780 RPM. STEPPED FLOW OF 2002 GPM. [
. a 7~' EP TDH 348.6 s
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4mGUARANTEED CONDITIONS: GUAR. GPM GUP.R. TDH ' GUAR. EFF. GUAR. HPSHR GUAR. MCSF 3000.0 350.0 79.0 14.0 1000.
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STEPPED NPSH TEST RECORD - BREAK H2 .AT 1007 GPM PAGE 1 l c#' 10 /7 /96 12 :2
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POINT H 11 2 3- 4 5 6 7 ) 1 DISCHG-(FT)' 430.0 412.1- 399.2J 388.9 300.0 372.0 360.3-SUCTION-(FT) 16.7 -0.2 -10.5 -18.4 -22.7 -24.4 -25.4 -j DIFF. VEL.HD. ' 0. 4 0.4 0. 4, 0.4 0.4 0.4 0.4 T.D.H.(FT) 413.7 412.8 410.2 407.7 403.2 396.8 386.1 j I RPn' 1792. 1792. 1792. 1792. 1792. 1792. 1792. , i BARO. (FT. ) 33.9 33.9 33.9 33.9 33.9 33.9 33.9 , H2O TEMP.(F) 75.0 75.0 75.0 75.0 75.0 75.0 75.0 1 HV. P. - (FT. ) 1.0 1.0 1.0 1. 0 1. 0 1.0 1~. 0 NPSH (FT) 49.8 32.8 22.6 14.7 10.3 8.6~ 7.7 4mDATA STEPPED TO SPEED OF 1780 RPM. STEPPED FLOW OF 1001 GPM. l 1 408.2 407.3 404.7 402.3 397.8 391.6 381.0 U'TEPTDH 1780. 1780. STEP RPM 1780. 1780. 1780. 1780. 1780.
' STEP NPSH 49.2 32.4 22.3 14.5 10.2 8.5 7.6
====================================================================================
ORDER N-ITEM CUSTOMER CUST. ORDER CUST. TAG /ITM j 050-61994.00 FLORIDA POWER CORP.
' PUMP TYPE SERIAL NO. IMPELLER IMPELLER DIA CUST. RPM 8HN-194 1624922 0.00 1780.
~==================================================================================== 4 j
4mGUARANTEED CONDITIONS: GUAR. GPM GUAR. TDH GUAR. EFF. GUAR. NP5NR GUAR. MCSF l 3000.0 350.0 79.0 14.0 1000. l
..==================================================================================
4mCUSTOMER CONDITIONS: CUST. SERVICE CUST. TEMP. C.VISC. (SSU) CUST. SP.GR. CUST. NPSHA 0.0 0.00 0.0 n=================================================================================== APPROVALS: O O # TEST ENGR. N Ouw EK3R'G. DEPT.
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LINGERS 0LL-RAND COMPANY - ENGINEERED PUMP DIVISION i
- STEPPED NPSH. TEST RECORD - BREAK M3 AT 522 GPM PAGE 1 C/ -
DATE 10-/7 /96 12 32 . . (' peo*****************************************************************************.**** , POINT H~ -1 2 3 4 5 6- '7 8 DISCHG (FT) 431.4 417.1 400.9 391.'9 388.2 379.5 366.8 360.3 l SUCTION (FT) 13.1 0.6 -8.9 -14.6 -18.3 -21.5 --24.7 -25.4 DIFF. VEL.HD. ~0.1 0.1 0.1 0.1 0.1 ' O.1 0.1 0.1 ; T.D.H.(FT) 418.4 -416.6 410.0- 406.7 406.7 401.2 391.7 385.9
' RPM 1792. 1792. 1792. 1792. 1792. 1792. 1792. 1792..
4
' BARD. (FT. )' 33.9' 33.9 33.9 ~33.9 53.9 33.9 33.9 33.9 '3
- H2O TEMP.(F) 75.0 75.0 75.0 75.0 75.0 75.0 75.0 75.0 V.P. - (F T. )~ 1.0 1. 0 1.0 1.0 1. 0 1. 0 1. 0 1. 0 ;
f ~ 1 HPSH (FT) 46.1 33.5 24.0- 18.3 14.5 11.3 8.2 7.5 , 4mDATA STEPPED TO SPEED OF 1780 RPM. STEPPED FLOW OF 518 GPM. , 4
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STEP RPM STEP NPSH 45.4 33.1 23.7 18.0 14.4 11.2 8.0 7.4 *
============================a=======================================================
ORDER W-ITEM CUSTOMER CUST. ORDER CUST. TAG /ITM 050-61994.00 FLORIDA POWER CORP. d PUMP TYPE SERIAL HO. IMPELLER IMPELLER DIA CUST RPM 8HH-194 1624922 0.00 1780.
...==================================================================================
4mGUARANTEED CONDITIONS: GUAR. GPM GUAR. TDH GUAR. EFF. GUAR. NPSHR GUAR. MCSF i 3000.0 350.0 79.0 14.0 1000.
==============u========================= ===========================================
4mCUSTOMER CONDITIONS: CUST. SERVICE CUST. TEMP. C.VISC. (SSU) CUST. SP.GR. CUST. NPSHA 0.0 0.00 0.0 :
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1 6.0 ENDURANCE RUN DATA l A. Data sheets dated 10/7 through 11/7/96 l 1 2 O ; 1 1
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ingerseN4resser Pump Company smices sattne2. tia 962 Wawrial Parkwmy Nilipsburp N OWM5 gpg 3 %, i 1 TV) a' March 12,1997 Mr. Philip Saltsman Florida Power Corp 15760 Power Line St
. Crystal River, FL 34428 ,
RE:FPC P.O. # F772618D 8HN-194 Decay Heat Pump Test
Dear Mr. Saltsman:
Please be advised that the following low flow test data was collected by various qualified IDP personnel during the course of this test: [' N Rick Oravec (,_-) Rick head Jim Smith Mike Dozier i >i I have reviewed the following data and found it satisfactory for the purposes of this report. If you have any questions regarding this issue please let us know. (' A Paul Kasztejna Design Engineer t1 - 1 cc:M Dozier l i i j rw LJ lagermlbReed Peelfic Worthington Pleoger hiento Jewment khmeider Pomps
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visaATioN TATA "TAV Ec u iTH I2.0 l'530 6MAa.T Mtrm- F S mA6MiC. 'BA51 Yoa. Hoos.or, p.cacihJ 06t eM AccELERoMctsA mooE' N A cce Lea.eM CTL/t v siti SAAFT' STILT < ATTACN ACMT FofL 6AWT' 12 EMid6S T*f 5"O tt (tet..a.ot.O est4 o MENA 4 so A4T gutNprog,. viag a nceeggy ^ $l5A& A)d/u ( 3 u we( n/?h? FPc i,pnalg J uv,ses. 9 e d
. _ _ _ _ _ _ _ _ . -_ -_. - .= . _ . . -. .
l i 8.0 VlBRATlON DATA
- William J. Brewer Report A
A i 0 l l l l 1 O i
DHP LOW FLOW TESTING VIBRATION
SUMMARY
BACKGROUND:- ' p: The Decay Heat Pump was tested utilizing a coIIection of vibration instruments. Bently i Nevada's Adre for Windows was setup to scan critical points every few minutes. In ' addition readings were taken utilizing a IRD 1330 digital vibration analyzer and a standard 100 mv/G accelerometer. ! Data for the 30 day,100 gpm. test was recorded at three locations. They were the inboard pump bearing in the horizontal and vertical directions. An axial reading was .i also recorded on the stuffing box near the mechanical seal. The locations were i selected based on sampling of many locations on the pump. These locations were found to represent the higher vibration areas on the pump and are the same locations used to monitor the pump in the field. i A review of the data recorded using the Bently Nevada system revealed a random source of electric noise which appears to saturate the data during different times of a frequency of exactly 60 hz. While the bulk of the data is very good, the trend displays are difficult to read with the noise present. In addition, the vibration levels for the pump remained very good and relatively stable for the duration of the test. For these reasons, the IRD data will be used as the source of the attached information. PLOT SYMBOL LEGEND 4
, l. in/sec Peak - This is standard velocity units in in/sec Peak
- 2. OveroII- This represent the unfiltered vibration level
- 3. A04 - This is the axiallocation on the pump stuffing box flange.
i
- 4. H03 - This is the horizontallocation at the pump inboard bearing >
- 5. V03 - This is the vertical location at the pump inboard bearing
)
- 6. FOI - This is a rnanual point to log the pump flow in (gpm) }
- 7. Ix vibs - This is the filtered vibration at the pump rotating speed
- 8. blade pass - This is the filtered vibration at the pump impeller blade pass frequency (5X). ,
i
- 9. S03 - This is the pump shaft vibration recorded in mils peak to peak.
- 10. . CPM- This is the freauency of the vibration in counts per minute or RPM.
1 I 1. ' COA- This is the vibration on the pump casing in the axial direction. l V 12. COH- This is the vibration on the pump casing in the horizontal direction. I3. 'COV-This is the vibration on the pump casing in the vertical direction. 1 e- -
DHP LOW FLOW TESTING VIBRATION
SUMMARY
(continued)
-f% PLOT DESCRIPTIONS O
I. Overall vibration trends for 30 day test.
- 2. Ix vibration trends for 30 day test.
- 3. Blade pass vibration trends for 30 day test.
- 4. Horizontal spectrums for 30 day test.
S. Vertical spectrums for 30 day test.
- 6. Axial spectrums for 30 day test.
Overall pump bearing vibration trends for performance test. 7.
' 8. ' Overall casing vibration trends for performance test.
- 9. Overall shaft vibration trends for performance test.
- 10. Pump vibration spectrums at 3000 gpm.
. (*3 11. Pump vibration spectrums at 500 gpm. .
U l2. Pump vibration spectrums at 1000 gpm. I3. Pump vibration spectrums at 1400 gpm. I4. Pump vibration spectrums at 1500 gpm. j
- 1 S. Pump vibration spectrums at 1600 gpm.
I6. Pump vibration spectrums at 2000 gpm. I 7. Pump vibration spectrums at 2350 gpm. I8. Pump vibration spectrums at 3500 gpm. I 9. Pump vibration spectrums at 4500 gpm.
- 20. Pump vit.ratior. spectrums at 4680 gpm.
- 21. Shoft vibration spectrums at 3000, 500,1000,1400-1600 gpm.
( Shaft vibration spectrums at 2000 thru 4680 gpm.
^} ' 2.2.
- 23. Casing vibration spectrums at 500 gpm.
- - DHP LOW FLOW TESTING VCRATION
SUMMARY
(continued) [~] PLOT DESCRIPTIONS (continued) U
- 24. Casing vibration spectrums at 3000 gpm.
- 25. Casing vibration spectrums at 1400 gpm.
' 26. Casing vibration spectrums at 1500 gpm.
- 27. Casing vibration spectrums at 1600 gpm.
- 28. Casing vibration spectrums at 4680 gpm. .
- 29. Pump stand bedplate holddown bolt test (tight and loose)
Olt ANALYSIS RESULTS
SUMMARY
- 1. Lubricon summary sheet. (TEST /l = DHP low flow tests)
O Data taken and compiled by: William J. Brewer, Supervisor Nuclear Plant Technical Support Florida Power Corporation - Crystal River Unit 3
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9.0 CONCLUSION
O The subject pump was tested to evaluate two critical flow points and to l revise any previous recommendations on how the unit could be operated, . i
- including applicable low flow and time period restrictions. The first critical flow j point was at 100 gpm. Previous field testing had been performed and disputed due to issues over test control. The testing conducted at that flow by IDP was in .
s a controlled and continuously monitored state, thereby making any conclusions reached reasonable. ! , The second aspect of importance for Florida Power Corp. was to ! l determine a new recommendation for minimum continuous stable flow, the J
.1 previous recommendation was 2350 gpm with a BEP occurring at 2900. This I figure was quite conservative and was based on a lack of good test data. The new recommendation is 1200 gpm or 41% of the BEP. The 8 hours of flow rangeability testing used to arrive at this recommendation is standard practice within the pump hydraulic design industry.
l As stated previously, the test pump had wear ring clearances that were ; tighter than the design drawings indicate. The actual clearance was .025," l whereas, the design drawings show that the clearance should be .030." The i stuffing box pilot fit to the casing also measured 0.005" undersized. These ; i attributes will be corrected during pump refurbishment and the pump will be
]
rerun to quantify whether opening up the clearance will have any significant , effect on the pumps performance and horsepower. However, the endurance test ;
- O
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w results and the MCSF determination are not effected by the difference in l 4 clearances. Running the pump with tighter ring clearance and looser pilot fit at l i such a low flow is actually a more rigid test. The pump would have contacted at ;
' the wear rings more easily with these conditions. Since the rings did not contact, j t
the pumps mechanical robustness was proven. The additional .005" of clearance and the additiornal pilot fit clearance will not impact on the 30 day test results, however, the retesting will be to reconfirm the performance characteristic I curve, prior to being returned to TMI. It is noted that the endurance test was conducted with a slightly smaller impeller diameter of 18.50" versus Crystal River's diameter of 18.75". This minor difference in diameter does not affect the impeller's low flow characteristics, 1 1- which are determined by the impeller eye [ inlet] configuration. The report data defines some minor variations in water temperature, suction pressure and flow rate. The variance is insignificant and does not affect the integrity of test evaluation program. (See reference section). The flow, temperature and vibration data (provided by Florida Power Corp.) helped in supporting the conclusions made about operation at 100 gpm and reestablishing the minimum continuous stable flow. The vibration data did not indicate any degrading conditions during the test. The 1X did increase during y a period of time; this was found to be due to loosening of the pump base (test stand base). Retorquing of the test stand foot fastener reduced levels to start-up i magnitudes. The following is a summary table of the recommendations. l
/ OPERATING GUIDELINES (D
( PUMP FLOW CONDITION RECOMMENDATION BASIS ENDURANCE RUN 100-1200 gpm Operation for 1 year is acceptable See guideline summary 1200 gpm Minimum Continuous Stable Flow l , The following is the guideline summary
- 1) The pump is expected to perform its intended hydraulic function with consideration of the following potential modes of degradation :
a) Mechanical seal leakage. Refer to inspection results/ conclusions (S. Lemberger letter to IDP). 4 b) Elevated bearing temperatures. c) Increased bearing loads and wear. d) Insignificant contact between the impeller ring wear surface and the casing wear ring bore or stuffing box extension wear ring bore. e) The pump rotor is to be dismantled, refurbished and replaced after operation at these flows.
e
10.0 REFERENCES
( A. FPC Memo, P.E. Saltsman to J.H. Terry, NPTS96-0506, and attachments, dated September 30, 1996 B. IDP 8HN Pump Drawing RX130855 - C. IDP Manufacturing and Quality Control Plan CQCM 11-470 D. IDP letter to FPC, Pre-Test Inspection Results, dated September 30, 1996 E. IDP Inspection Photographs F. Oil Analysis G. IDP QCM 655, Post-Test Inspection Results, dated December 10, 1996 H. IDP letter to GPU Nuclear, Undersized Wear Rings, dated December 4, 1996 I. John Crane Inc. letter to IDP, Evaluation of T-18 Seal, dated March 12, 1997 J. IDP Post Refurbishment Test Curve / Data, dated February 4, 1997 () K. IDP letter to FPC, Scenario #1, dated September 25, 1996 IDP letter to FPC, Performance Test Instructions, dated October 3,1996 L. M. IDP letter to FPC, Revised NPSHA, dated March 12, 1997 N. IDP letter to FPC, Post-Test Information, dated May 7, 1997 4
4 [' Flitrida- INTEROFFICE CORRESPONDENCE l Power Nuclear Nineerine Design _. NA1E - 244 3566 i ComponATIoM OFFICE MAC TELEPHONE , I ~ sunJECT: Design Requimments for Decay Heat Pump ; Law Flow Test ]:
~ REF: PR96-311 .
To: P. E. Kakaman DATE: September 30,1996 : NED96-0550 l l
References:
.1. Ingersoll-Dresser Letter, Patel to Saltsman, dated 9/25/96 (attached - 1 sheet) j
- 2. ' DHP-1B pump curve, Shop test from 1/11/71 (attached - 1 sheet) l
- 3. WR326422 and WR329749, dated 7/17/95 and 11/29/95 i
- 4. Uniflow Portable Dual-Path Clamp-on Transit Time Flowmeter, FPC Instruction Manual i 1817. :
l 5. Instrument Data sheet DH-10-TTS, Rev. 2. :
- 6. Evaluation of CR3 Decay Heat Pumps at Low Flow Operation, MPR-1134, June 1989.
- 7. MU System EDBD, Rev. 5.
- 8. SP-412 - ECCS and Containment Spray I2ak Rate Test, Rev.17.
9.' DC System EDBD, Rev. 3. ;
- 10. PT-136B, DC System Flow Balance and EDDG KW Loading, 10/19/95
- 11. PT-136B, DC System Flow Balance and EDDG KW Loading, 12/14/95
- 12. Crane Packing Co., Packing Seals, Shaft Seal (CR3 I.M. 430, Rev. 6).
i
Purpose:
i t i The purpose of this document is to specify conditions which must be met during the low flow Decay Heat Pump test at Ingersoll-Dresser, j
Background:
FPC's disposition of the issues identified in NRC Bulletin 88-04 resulted in a ten (10) hour low-flow (400 gpm) test of DHP-1B in 1989. Evaluation of the mechanical condition of the pump
- following testing resulted in an extrapolation of the predicted lifetime of the pump to 72 hours at the low flow condition. This extrapolation of pump condition was not accepted by the Regulator, and the time the DHPs could be considered to survive at low flow conditions was limited to 10 hours.' Recently, questions associated with low flow operation during SBLOCA mitigation and the
, ability to open the drop-line to increase DH flow resulted in a determination that the previous 10
- hour low-flow test may have been inadequate for certain SBLOCAs. FPCs compliance with the
' NRC Bulletin 88-04 concern was augmented by referring to the 9 day operation of a DHP prior to
- failure during plant hot-functional testing. The documentation of plant conditions which resulted in
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NED96-0550 - Page 2 of 6 r L
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this DHP failure'as~well as the failure evaluation itself, were not performed to today's standards.
- This lack of reliable information has resulted in the need to test the pump at very low flow for an extended period of time, in an effort to demonstrate the ability of a properly aligned DHP. _
he purpose of the low flow test at Ingersoll-Dresser is to demonstrate ability of the Decay Heat Pump to operate at a flow rate equivalent to minimum DH recirculation for an extended period of time. To date, the most appropriate demonstration of DH pump operation at low flow conditions has been an event which resulted in a DH pump failure during plant hot-functional testing. During
- that event, the A-train DHP was left operating with no injection flow to the RCS for a period of l nine (9) days. His condition resulted in the pump only providing minimum recirculation flow. ;
- Review of the cause of the pump failure resulted in a determination that the pump failed due to shaft misalignment, rather than a condition associated with the low flow operation of the pump.
1 nis condition has given FPC reasonable assurance of the Decay Heat pump's ability to endure low flow conditions. FPC testing of the DHP in 1989 as well as MPR's evaluation of the pump data (Ref. 6), in conjunction with TMI-l's extensive experience with operation of the same model DHP 1 in low-flow conditions has served to augment CR3's position. l Design Conditions for the Test This test will attempt to reprodcce worst case post-LOCA conditions for LPI pump operation. i nere were two scenarios identified by FPC engineering r.s being most challenging to LPI pump operation. Scenario 1 is the DHP operating at minir.um flow with approximately 100 gpm and 50*F fluid and abundant NPSH. This scenario is represcatative of DHP recirculation flow while taking suction from the BWST and no flow to the RCs. The second rcenario is representative of
- operation of the DHP during piggy-back from the RB sump. Minimum flow would be 200 gpm 4
(100 gpm for LPI recirculation and approximately 100 gpm of HPI recirculation (Ref. 7)). The emperature of the fluid would approach 212*F, with limited, but adequate, NPSH. According to IDP, Scenario I would be the worst-case scenario for DH pump long term operation (Ref.1). i l De parameters specified include pump flow, NPSHa, fluid suction temperature, cooling water requirements and test duration. De initial portion of the test should provide a baseline of pump j performance followed by the low flow test, then a second performance test, in order to quantify j degradation, if any, followed by disassembly and inspection of the pump. Flow Rate: The test shall be performed at 100 gpm minus the appropriate flow loop instrument error, as determined by the vendor and confirmed by FPC. Basis - Test flow should be limited to the minimum flow for the DHPs at CR3. nis flow occurs immediately following ES actuation when RCS pressure is still well above the
, maximum discharge head of the DH pumps. At this time, only recircuhdon flow will flow through the pump. De flow orifices, DH-27 and 28-FO are sized for 100 gpm, per the Instrument Data Sheets (DH-27 and 28-FO). The minimum flow was determined in the plant during 1995 via WR326422 and WR329749. De data from this test is as follows:
- O v - e r- ~m--r,we e+m-wp- -- -.ry--- *r m -'en-
NED96-0550 Page 3 of 6 m -
"O -
DHP-1A DHP-1B dP 147.5 psid dP 142 psid Recire flow 104 gpm Recire Flow 99 gpm Total flow 3104 Total Flow 3099 These recirculation flow rates were not at the pump minimum flow rate condition since DH was being recirculated to supply 3000 gpm to the BWST. The flow rate at minimum recirculation conditions would be: (b)- 02 {dP~ The dp for the minimum flow condition from Reference 2, is 425 feet or approximately 184 psi. The resulting flow in the recirculation line will therefore be: ( 99 gpm) _ /1TJ psid 02 /1TE psid ^ O Therefore the flow in minimum recirculation for DHP-1B should be approximately 112 gpm, with slighny more flow for DHP-1A. 1 i This additional flow will be more than adequate to account for the instrument error i associated with this test. The flow instrument was a Controlatron Model 990 ultrasome l flow meter (Ref. 3). Review of the vendor manual identifled a 1-3% flow error for the instrument (Ref. 4). The accuracy of the dP gauges used in the test is unknown. For I conservatism, the flow rate in the test shall not exceed 100 gpm. During SBLOCA mitigation, LPI flow will be in excess of recirculation flow since piggy-back operation will be used, and HPI flow will add to total LPI pump flow. Fluid Temperature: The test fluid shall be maintained at between 50'F and 60'F (minus instrument error) Basis - The low temperature alarm for the BWST is 60'F (Ref. 5). Automatic temperature control is normally used to maintain the minimum temperature in the tank greater than the alarm point. Long term operation of the DHP at a minimum flow condition will result in i DH flow approaching the temperature of the UHS (Gulf of Mexico). This occurs since the flow through the DH pump is cooled, in the DHHE by DC flow. There will be no other significant heat loads on the DC system during DH low flow conditions. DC is cooled by the UHS and will be approximately equal to the UHS temperature. There is no plant
7__
. y NED96-0550 Page 4 of 6 pn limitation on operation at a low UHS temperature, but based upon plant operating history, the UHS rarely gets below 50*F, and thermal increases between the UHS, DC and finally 1 DH, post-LOCA should not result in the DH system being below 50*F. l
, The 10*F " window" for the test will provide for the worst case temperature condition as l well as limit the maximum temperature. Ten (10) degrees is considered reasonable based I upon discussions with IDP test personnel. J These fluid temperatures are consistent with the more limiting operational condition i identified in Ref.1.
NPSHa: The NPSHa should be maintained near NPSHr at the test flow (+5 ft to +20 ft minus ) instrument error). t Basis - With minimum water level in the BWST, adequate NPSH exists for the operation of a DHP at design flow conditions. Design analyses demonstrate adequate NPSH exists for the DH pumps during all modes of operation. Limiting the NPSHa during the test to the specified " window" will provide adequate, but not excessive NPSH for the pump. ! These NPSHa values are consistent with the more limiting operational condition identified .l in Ref.1.
\ Cooling Water: 1. 7 gpm (+/- 2 gpm) of cooling water shall be provided to the bearing oil cooler. l
- 2. Cooling water flow to the pump seal shall be maintained approximately 20 psi l above the pump suction pressure. j Basis - The minimum bearing oil cooler flow rate is 5 gpm (Ref. 9). Currently, per j Reference 10 and 11, the actual flow is 10 gpm. l The pump seal cooling water flow is assured by providing a minimum of 20 psi across the !
seal (Ref.12). , i Duration: The test should be run for a minimum of fourteen (14) days. Basis 'Ihe test duration of 14 days is chosen since it would allow adequate time to repair - or otherwise restore a failed LPI pump to operable status while the redundant LPI pump is in service. l Additional Test Requienents: A review has been performed of the MPR Associates document " Requirements for Minimum Flow Testing of the Decay Heat Pumps at Crystal River Unit 3', Enclosure 1 to MPR letter dated March 21,1989. Use of this document for identification of Test Sequence, Parameters to
. ._-.c.. .__ _ . , _ , _ _ _ . . . , _ . . _ . . . ~ . . . _ , . _ . _ _ , , _ - . . . _ . - _ . . . . . . . , ,
t, NED96-0550
- Pag 5 of 6 i
(D Monitor, Acceptance Criteria, and Disassembly Inspection Acceptance Criteria is acceptable, with the following changes. Test Sequence
- After determining the initial performance characteristics of the pump, the NPSHr for the pump at minimum tecirculation flow rate condition should be determined. NPSHr is not ,
casily predicted at extremely low flow rates. In order to prevent damage to the pump, as well as assuring an excessive amount of NPSH is not available for the pump during the low ficw test, the NPSHr must be determined.
- Add an item after the second paragraph in step #2, to ensure appropriate time delay to allow the DH pump to cool-down following the initial performance test. Appropriate time delay should be ensured by the FPC representative.
- Delete the first bullet item in step #2. Running the pump for I hour at 300 gpm is not representative of r.ctual pump performance required following ES actuation. The pump should experience a minimum flow condition immediately following pump start.
- Add an item #4 to essentially reperform item #2 after the low-flow test. Monitoring key j pararr.eters following the test at a full flow condition is not adequate to predict the effect of
(] the test en putnp performance at all flow conditions. The post-test pump performance V should exceed the attached CR3/TMI Composite Minimum Performance Curve (1 sheet ). ; Failure to meet the curve may not constitute unsatisfactory performance, but further l evaluation will be required. j Parameters to Monitor
- Add an item to monitor DHP seal leakage. Seal leakage is critical to adequate performance of the DHP since leakage is directly proportional to Offsite and Control Room dose. Total ECCS and Building Spray system leakage is currently limited to 1.19 GPH, (Ref. 8) but raay be larger if additional analysis is performed. The acceptability of acal leakage will be evaluated, if significant, following the low-flow test.
Test Procedure - Acceptance Criteria
- SP-340-B and E are the appropriate references for surveillance testing.
Test Instrumentation
- It is imperative that appropriately scaled instrumentation, with calibrated loop error less l than 2% of the minimum test flow, be used for the low-flow test.
A O
>4 9 ye 6
NED96-0550 Page 6 of 6 ([ Test Prerequisites
- No changes If you have any questions or require any further information', please don't hesitate to call me at
- (352) 795-6486 ext. 3566.
Prepared By: Verified by: K.R.C pbell E. M. Morea Sr. Nuclear Mechanical Engineer Principal Mechanical Engineer b O F. X. Sullivan . Manager, Nuclear Engineering Design Attachments cc: C. L. Miller M J. H. Terry Records Management (EQUIP 4-15) 4 e O er. -m-=y. -
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