ML20246K368
| ML20246K368 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 06/30/1989 |
| From: | FLORIDA POWER CORP. |
| To: | |
| Shared Package | |
| ML20246K329 | List: |
| References | |
| MPR-1134, NUDOCS 8907180152 | |
| Download: ML20246K368 (245) | |
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b ,e MPR ASSOCIATES. INC. 4
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EVALUATION OF CRYSTAL RIVER UNIT 3 'T DECAY-HEAT PUMPS AT LOW-FLOW OPERATION MPR-1134
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.g E. j L.I' Prepared for
[. D kh500 02 PNU - florida Power Corporation St. Petersburg, FL
' June 1989
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..w 1050 CONNECTICUT AVENUE. N.W. WASHINGTON. D.C. 20036 202 659-2320 1
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T.ABLE OF CONTENTS
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1.0 INTRODUCTION
2.0-SUMM(RYOFRESULTSANDCONCLUSIONS
,' A. SUPMARY.0F RESULTS B. CONCLUSIONS
. 3.0 -DISCUSSIGN l
A. EXPECTED OPERATION DURING A SBLOCA
, B. DECAY-HEAT PUMP 3B LOW-FLOW TEST Test Description
! Test Instrumentation Test Acceptance Criteria Test Results C. DECAY-HEAT PUMP 3B POST-TEST INSPECTION Inspection Requirements
.( Inspection Results D. PUMP OPERATING HISTORY E. TECHNICAL EVALUATIONS
, Available Net Positive Suction Head (NPSHA)
Pump Shaft Evaluation Pump Bearing Life j_
4.0 REFERENCES
5.0 APPENDICES l a,eg
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MPR AOOOCIATED. (NC. a Lo Section 1 INTRODUCTION The purpose of this report is to summarize an evaluation of the operability l of the Crystal River Unit 3 (CR-3) decay-heat pumps at the low-flow L conditions ~ expected during a small-break loss-of-coolant accident (SBLOCA). This evaluation is based on a low-flow test of a decay-heat pump at CR-3, a i post-test inspection of the pump, a review of the operating history of the I CR-3 decay heat pumps, and technical evaluations of net positive suction head (NPSH), pump shaft loads, and bearing life at low flows. The concern for pump low-flow operation was raised by USNRC IE Bulletin 88-04. This bulletin requested utilities to verify that multiple safety-related pumps sharing a minimum recirculation line would receive adequate recirculation flow and that the minimum-flow lines for all safety-related pumps are adequately sized to prevent pump damage.
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Florida Power Corporation (FPC) evaluated the safety-related pumps at CR-3
- j. and found a postulatM low-flow condition for the decay-heat pumps F (Worthington Model iM-194, horizontal, single-stage pumps) that exceeds the pump vendor's limits for low-flow operation. This postulated low-flow
, condition could occur during a SBLOCA when one of the pumps would have to
- 1. operate at a flow as low as 400 gpm (design flow is 3000 gpm) for as long as three days while taking suction from the containment sump.
The vendor, Dresser (formerly Worthington), has specified the following operating times and low-flow limits assuming the available net positive ; suction head (NPSHA) is above the required net positive suction head
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f (NPSHR): 2350 to 3000 gpm - continuous operation j 3 1200 gpm - 100 hours per year 80 gpm - 2 hours total lifetime (per rotating assembly) O 1-1 I 1
. j
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-a.l zh These limits are very conservative; continuous operation is not recommended below about 80% of rated flow. Dresser recognizes that:these limits'.may well be conservative. However, they indicate that they'have no low-flow operating data on this pump design and consider that they must set L'
conservative limits in the absence of specific test data. Because the pump vendor's operating limits are restrictive with respect to the expected SBLOCA operati~g n requirements, FPC has undertaken a program to demonstrate the operability of the pumps at low flow. The program includes e a low-flow test, a post-test disassembly and inspection, a review of the I' pump operating history, and technical evaluations of NPSH, shaft loads,'and bearing life. l' i i This report has five sections. Following this introduction, Section 2 summarizes the results and conclusions from the low-flow test and post-test
- inspection, a review of the pump operating history, and the technical evaluations of NPSH, shaft loads and bearing life at low-flow operation.
Section 3 discusses these items in detail. Section 4 lists the References, and Section 5 provides the appendices, b 1 D . l-2
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' MPR ASSOCIATE 3.' INC.
n - Section 2 1 L , _.
SUMMARY
OF RESULTS AND CONCLUSIONS-i l r A.
SUMMARY
bFRESULTS The low-flow test performed on Decay-Heat Pump 3B' was designed to simulate
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l[ the expected SBLOCA operating conditions as closely as was practical. A l- comparison of the expected SBLOCA conditions and the test conditions is i c provided below. L't
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, Parameter Expected SBLOCA Condition Test Condition l! Flow 400 gpm 3 days 400 gpm 10 hours l Time Available Net l' Positive Suction 14 feet 115 feet Head. r
- I (The three-day operating time was not identified until after the ten-hour test had been completed)
The results of this low-flow test, the post-test inspection, a review of l ii_ operating history, and the evaluations of NPSH, shaft loads and bearing life have been provided to FPC in several letter reports. These results
?' are summarized below:
L
;- o Test Results - the test results indicate that the pump operates 1~
satisfactorily at low flows. The head-flow performance, bearing vibration, and process temperature data all remained within
, acceptable limits at all times. Operation of the pump at rated flow after the low-flow operation demonstrated no change to the
{~ pump performance as a result of the tast, p l l 1 1t
- The FPC tag number for this pump is DHP-1B.
Le la L________________________________________ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
r -- r p m o Post-Test Insoection - the pump was disassembled and inspected
) after the inw-flow test. The wear rings, volute tongues, N' impeller, shaft, and bearings were inspected for wear, cavitation damage, and cracking. The post-test pump inspection showed that the low-flow test did not cause any significant wear or
. degradation.
o Review of Operatina History - a review of the operating history of the decay heat pumps at CR-3 was performed to determine
- whether any connection between low-flow operation and pump
! degradation is evident. The review identified one shaft failure which occurred during hot-functionai testing after nine days of i pump operation at minimum recirculat. ion flow (80-100 gpm). The failure was initially attributed to extended low-flow operation, but after a second shaft failure occurred with extended operation near design flow, the pump was inspected and the casing was found I to be severely mismachined such that contact between the impeller i and the casing could occur. No shaft failures have occurred in this pump since the casing was replaced. Additionally, the i
failure location in both shafts was not consistent with the type l of loading expected during low-flow operation, and was consistent with the type of loading expected from the mismachined casing. Other instances of pump degradation were reviewed and are not
- related to low-flow operation. Accordingly, no connections I between low-flow operation and pump degradation are evident in g the CR-3 operating history.
o Results of NPSH Evaluation - the difference in available net positive suction head (NPSHA) during the test and the NPSHA t expected during a SBLOCA (the SBLOCA NPSHA is a factor of eight 4 lower than the test NPSHA) should not be significant. The SBLOCA NPSHA is greater than the required net positive suction head (NPSHR) for the pumps. The potential for loss of prime during the SBLOCA was evaluated and the conditions required to cause i i loss of prime do not exist. Hence, loss of prime should not be a concern. The difference in NPSHA between the test and a SBLOCA
' should not affect pump vibration or radial and axial loads based L on tests reported in technical literature. Cavitation damage as a result of lower NPSHA is not considered to be a concern for the c SBLOCA because the pumps must operate only for a short duration at low flows; cavitation. damage sufficient to compromise pump l" function would be expected only after long-term operation at '
these conditions. C o Results of Evaluation of Shaft Loads - the pump shaft was evaluated for the radial loads and moments on the impeller r necessary to fatigue the shaft and to deflect the shaft to cause I the light rubbing at the stuffing-box wear ring observed in the post-test inspection. The range of expected radial loads based g' on empirical correlations in technical literature, and the load l necessary to cause the rubbing at the stuffing box wear ring N j,f 2-2
ii are consistent. The expected shaft stresses are at least a
/ T factor of four lower than that which would cause the shaft stress V to be at the endurance limit. Hence, shaft fatigue is not ,
expected to be a concern. o Results of Bearino Life Calculation - bearing life was evaluated for the increased radial thrust loads due to low flow. The expected bearing lifetime is about 1600 hours. Hence, bearing life is not a concern. k B. CONCLUSIONS Based on the CR-3 pump testing performed, the available CR-3 operating experience, and the additional technical evaluations performed, there is a reasonable basis to expect the decay-heat pumps have the capability to
).
; operate for at least three days under the postulated SBLOCA conditions.
The principal factors supporting this conclusion are: r~ o During the in-plant tests performed, the CR-3 decay-heat pump. tested operated stably over the range of flows from minimum recirculation flow to rated flow without degradation in head-flow I performance or vibration levels which would have prohibited continuous operation of the pump. o The post-test inspection showed no indication of pump degradation as a result of the 10-hour test, indicating that low-flow operation in excess of 10 hours is permissible. o During hot-functional testing, DHP-1A operated for nine days at minimum recirculation flow, with a mismachined casing, before failure occurred. The failure is considered to be a consequence
- of the mismachined casing and not due to low-flow operation.
o An evaluation of low-flow conditions expected during the SBLOCA f
..l. indicates that the NPSHA is above the NPSHR, would rot cause a loss of prime, or have any significant effect on pump shaft
;- loads. Impeller cavitation damage is not a concern because of the short duration of operation (up to three days) at low flow l conditions.
[ o An evaluation of shaft fatigue due to the forces and moments u expected to be present during low-flow operation predicts that the shaft stresses are at least a factor of four below the j' fatigue endurance limit. o An evaluation of the pump-bearing life under the loading expected i
, for low-flow operation predicts bearing lifetime well in excess l L of three days (about 1600 hours).
I L 2-3 V______-____________________ . _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ . _ _ ___
MPR ASSOCIATES. INC. , e g Y) . Section 3 1 DISCUSSION 1 l A. EXPECTED OPERATION DURING A SBLOCA During FPC's review of CR-3 safety-related pumps to answer IE Bulletin l :. 88-04, it was determined that the decay-heat pumps may operate at a flow of l 13Y, of design flow during a SBLOCA, for as long as threa days'. The l specific conditions identified by Florida Power are: I I i Parameter Exoected SB_LOCA Condition
! Flow 400 gpm Time 3 days Available Net
- f Positive Suction 14 feet Head L D. DECAY-HEAT PUMP 3B LOW-FLOW TEST Test Description A low-flow test was designed to simulate actual conditions as closely as was practical within the limits of plant operation. The test requirements, including procedural requirements, instrumentation requirements, and initial acceptance c'riteria, are provided in Appendix A. However, l
b subsequent to the letter in Appendix A, and prior to the test, the SBLOCA conditions were determined to be: flow as low as 500 gpm for five hours and f an NPSHA of 14 feet. Accordingly, test conditions of 400 gpm for 10 hours were selected to conservatively bound the flow and time requirements. (The
,[ three-day requirement was not identified until after the test was
! completed.) The test sequence was as follows: I
- During the SBLOCA, the pumps may be required to operate at minimum recirculation flow for a short time (less than 2 hours). This l
operating condition is within the low-flow limits specified by Dresser I (Reference 11). b 3-1 1 I
q l t i 1 o Operate the pump at design flow (3000 gpm) to provide baseline . , head, vibration, power, and temperature data. l i o Slowly throttle pump flow to 400 gpm, stopping at intermediate flow rates to trend the data with flow and ensure the acceptance criteria are not exceeded teefore reaching very low flows. Lr l Operate the pump at 400 gpm total flow for ten hours. Trend pump
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o
, head, vibration, power, and temperature.
l- o Reduce flow to minimum recirculation flow (about 130 gpm indicated). Monitor pump vibration. o Operate the pump at design flow to verify pump performance (head, vibration, power, and temperature) has not degraded in the test. k The NPSHA during the pu p test was about 115 feet. This is significantly
- - higher than that expected in the SBLOCA (14 ft). During a SBLOCA, the pump
! would be drawing hot water from the containment sump; during the test, the pump must draw ambient-temperature water from the borated-water storage i tank (BWST). A discussion of the effect of the NPSHA difference is provided later in this report.
Test Instrumentation l; Instrumentation was installed to monitor pump head, flow, and power characteristics, process and bearing cooling water temperatures, and pump bearing vibrations. The requirements for this instrumentation are provided in Appendix A. Briefly, these requirements are: l' o Pump head, flow, and power were measured using plant-installed l
- instrumentation. The flow in the pump's minimum recirculation flow line was measured using an ultrasonic flowmeter. The P purpose of measuring these parameters was to track the overall
'I i hydraulic performance of the pump. r o The pump suction and discharge temperatures were measured using strap-on thermocouple with the output displayed on a strip chart {. recorder. The purpose of measuring these parameters was to monitor the fluid temperature rise in the pump. o The pump bearing enoling water inlet and outlet temperatures were measured using strap on thermocouple with the output displayed g; on a strip chart recorder. The purpose of measuring these
- parameters was to monitor the heat generated in the bearings which may overload the bearings.
l.' 3-2 L
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) o Pump bearing vibrations were measured using velocity transducers Lrs' mounted on the bearing caps of both pump bearings in the radial (horizontal and vertical) and axial directions. Unfiltered l
overall peak velocity vibrations and filtered spectra of vibration velocity were recorded. The purpose of measuring the vibration was to monitor the excitation at the pump bearings as pump flow varied and to provide an indication of overall pump condition throughout the test. i f o Bearing oil samples were taken before and af ter the test and analyzed as another measure of bearing condition. Test Acceotance Criteria L i Pump bearing vibration, pump suction-to-discharge temperature rise, and I pump bearing cooling water inlet-to-outlet temperature rise were measured for comparison to acceptance criteria. The bases for the acceptance I criteria are provided in Appendix B and are summarized below. j o Pump bearing vibration should not exceed 0.7 inches per second (ips) unfiltered overall at any of the monitor points. This l ' criteria is the required action limit specified in CR-3's decay l heat pump surveillance test which is based on the ASt4E Code Section XI criteria. o The pump suction-to-discharge temperature rise should be maintained to 15'F or less. The 15'F criteria is considered 3 appropriate based on experience, information in the technical i litercture, and provision for margin above the expected temperature rise at minimum recirculation flow (about 9'F). I o The pump bearing cooling water inlet-to-outlet temperature rise is monitored for significant deviations from the baseline value (i.e., at design flow) to ensure that the bearinos are not overheating. An absolute criterion was not established; however,
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changes in cooling water temperature across the bearings are a qualitative indication of bearing heatup. (The actual bearing condition was checked by oil analysis before and after the test and inspection of the bearings during the pump post-test disassembly.) p [. Test Results 7- The test was performed on April 13-14, 1989. Data from the test is b provided in Reference 1. The spectral plots of the bearing vibrations are presented in Reference 2. An evaluation of the test results is provided in Appendix C and is summarized below. 3-3 L E
P 1 y l l* 7 L
'l The pump developed head data was within 5% of the vendor's curve l
f T o over the range of flows in the test. Pump developed head data taken at design flow at the end of the test was unchanged from the baseline head data taken at the start of the test. Thus, the i- pump was functioning as expected and no performance degradation l ! occurred as a result of the test. j~ o The motor power calculated from the motor current data was within l (' 6% of the pump vendor's pump brake horsepower curve. Motor-current data taken at design flow at the end of the test was i . unchanged from the baseline current data taken at the start of the test. Thus, the pump was drawing power from the motor as expected.- ! o 'The suction and discharge temperature data indicated that the ! b' temperature rise across the pump was about the same at 400 gpm as it was at design flow. Thus, pump overheating is not a concern for flows as low as 400 gpm. I r o The bearing cooling water inlet and outlet temperature data did not indicate a temperature rise across the pump bearings at any I flow down to minimum recirculation flow (about 3% of design 1 flow) . Thus, bearing overheating is not a concern. A o The pump bearing overall vibration data at all monitoring points V did not exceed 0.55 ips at any flow during the test. In addition, the vibrations measured .at design flow at the end of ) : the test were about the same as the baseline vibration data taken l at the start of the test. Thus, the vibrations were within the range of values that would allow centinued oper;Ilon per the ASME Code Section XI criteria (and the CR-3 surveillance procedure), and no significant degradation with regard to vibration occurred i o as a result of the test. i- Spectral analysis of the vibrations indicate that the vane {~ passing frequency (five times the pump r'nning u speed) is the dominant vibration frequency at all monitored points on the pump. j
,. High vibrations at the vane passing frequency were expected because it is the frequency of hydraulic excitation typically observed during operation of centrifugal pumps kt low flow. l f' o Analysis of bearing oil samples taken before and after the test ,
indicated that the oil was in good condition. A comparison of i the two samples indicated that no bearing degradation occurred r during the test. l. i L 3-4 n 3 n l C L - - --- - -- - - - - - - - _ .
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t n n
-6 C. DECAY-HEAT PUMP 3B POST-TEST INSPECTION
~ An inspection of the pump internals and the rotating element was performed I after the low-flow test to verify that the pump did not significantly degrade during the test. A pre-test inspection to obtain baseline pump r
( condition data was not performed because the rotating element had been replaced about 16 months prior to the test, and the pump had seen limited f~ service since the replacement. Accordingly, all degradation detected was assumed to be due to the low-flow test. Insoection Requirements i The requirements for the inspectica, including the acceptance criteria, are provided in Appendix B and are summarized below. I Pumo Casin_q - The casing wear ring should be visually inspected for i rubbing and excessive wear. The diametral clearance between the wear ring and the impeller wear surface should be between 0.015 and 0.064 inches. The volute tongues, or cetwaters, should be visually [ ( inspected for cavitation damage. Any cavitation-induced damage observed should not be severe enough to compromise the structural integrity of the tongue. Stuffino-Box Head - The stuffing-box wear ring should be visually inspected for rubbing and excessive wear. The diametral clearance
' between the wear ring and the impeller wear surface should be between
! I. 0.015 and 0.054 inches. The stuffing-box bushing should be visually l inspected for rubbing and excessive wear. The diametral clearance l between the bushing and the shaft sleeve should be between 0.026 and l l 0.036 inches according to the vendor, Shaft - The shaft should be verified to be straight, with Total { Indicated Runout (TIR) not exceeding 0.002 inches. The shaft should L- be inspected for cracks using liquid-penetrant examination. The shaft should be free of cracks. The shaft sleeve should be visually {' inspected for rubbing and excessive wear. 1. JIppellgr - Both surfaces of the impeller vanes should be visually e . inspected at the impeller suction and discharge for cavitation damage. Any cavitation-induced damage should not be severe enough to
}* compromise the structural integrity of the impeller. The wear surfaces should be inspected for rubbing and excessive wear due to
; contact with the casing and stuffing-box wear rings. The impeller
' shroud si. auld be inspected for cracks near the impeller discharge using liquid penetrant examination. The shroud should be free of cracks. The tightness of the impeller on the shaft should be
'I- . verified. The impeller should not move relative to the shaft when
'O i
3-5 i. l.
l shaken and the impeller nut should be torqued to approximately ! i t 400 ft-lbs. pJ l
! Pumo Bearinos - The inner raceways of the line and thrust bearings i should be firmly held on the shaft. The bearing bore to shaft !
diametral clearance should be -0.0001 to -0.0012 inches (the negative 7 l sign indicates an interference fit) for both bearings. The inner raceways should be verified to be pressed firmly against the shaft shoulder. The outer raceways of the line and thrust bearings should J' r be firmly held in the bearing housing. The bearing to housing
! diametral clearance should be +0.0018 to -0.0006 inches for both .
bearings. The inner races of the duplex-mounted thrust bearings should be in contact, and the thrust bearing lock nut should be tight. The balls and raceways for both bearings should be visually inspected
}- for damage including cracking, scoring, and overheating. The bearings should be free of substantial degradation.
I
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- Inspection Results I'
The post-test inspection was performed during the week of May 8-12, 1989 at ( CR-3. A preliminary evaluation of the inspection results is provided in f Appendix D and the results are discussed in more detail below. Pumo Casino - The casing wear ring had no significant rubbing and was (x in good condition. The diametral clearance of the wear ring with the ld impeller wear surface was 0.047 inches. This clearance is within the allowable range. The volute tongues had no evidence of cavitation
,. damage and were in good condition. The east tongue had a sharp edge i on the inside 11 . but this is not considered significant. No damage I- was noted on any Uservable part of the casing. Thus, the test did not result in significant damage to the pump casing.
i S_tuffino-Box Head - The stuffing-box wear ring showed signs of rubbing. However, the depth of the wear was not excessive, estimated 1 to be abcut 0.001 inches deep. This wear was insufficient to warrant [' replacement of the ring. The diametral clearance of this wear ring with the impeller wear surface was 0.025 inches. T.,b& clearance is
,, within the allowable range. The stuffing box bushing had no significant rubbing and was in good condition. The diametral b tlearance of the bushing with the shaft sleeve was 0.029 inches. This clearance is within the vendor's allowable range. Thus, the test did not result in significant damage to the stuffing box head.
Shaft - The maximum runout measured on the shaft was 0.0015 inches. p This runout is within the allowable range. Liquid-penetrant j-examination of the shaft from the line bearing shoulder to the impeller nut threads revealed no crack indications in the shaft, including in the keyway. The shaft sleeve had no significant rubbing
} at the stuffing-box bushing. Thus, the test did not result in y ~s significant damage to the shaft.
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I<m ( ).- Imoeller - The impeller vanes showed no evidence of cavitation damage on either side of the vanes at both the suction and discharge of the impeller. The wear surface that mates with the pump-casing wear ring
-had no significant wear. The wear surface that mates with the
.- stuffing-box wear ring showed some signs of rubbing but the wear was !
l not excessive. The wear was estiinated to be about 0.001 inches deep. l Liquid-penetrant examination of the shrouds revealed no crack j indications. The loosening torque for the impeller nut was 150 ft-lbs j i' which implies an assembly torque of about 165-185 ft-lbs, assuming the j
- f. nut did not loosen in service. In discussions with maintenance 1 personnel, this torque value is consistent with past practice. This j
> torque is significantly less than the vendor-recommended torque value. <
L However, impeller-tightness on the shaft was verified by other methods. First, mechanical assistance (i.e., wedging).was necessary
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to remove the impeller from the shaft. Second, the diametral 1 clearance between the hub bore and the shaft indicated an interference i fit of 0.0005 inches. It is considered that the impeller was sufficiently tight on the shaft. Thus, the test did not result in j significant damage to the impeller. Pumo Bearinas - Both bearings were snug on the shaft as the bearings
, had to be pressed off the shaft. The bearings were verified to be ;
; firmly pressed against the shaft shoulders. Both bearings were also a snug in the housing as force was required to remove the bearings from the housing. The diameters gf the inner and outer surfaces of the V
O bearings, the shaft, and the housing were measured to determine the clearance / interference of the mating surfaces. However, only micrometers that measure in the 0.001 inch range, with a measurement t tolerance of 0.001 inches, were available, and the design values for i the diametral clearances were spacified to the 0.0001 inch range. Because two diameter measurements are necessary to determine the clearance, the clearance measurement tolerance is 0.002 inches.
! Thus, the measurements were not precise enough to compare against the design values, but they are presented below to show that the clearances / interferences are within the range of the design values.
Clearance Measured Value* Desian Value n Line Bearing +0.0025 to -0.0015 in. -0.0001 to -0.0012 in. to Shaft [ Thrust Bearing +0.0025 to -0.0015 in. -0.0001 to -0.0012 in. to Shaft t Line Bearing +0.004 to 0.0 in. +0.0018 to -0.0006 in. F to Housing l~ Thrust Bearing +0.0025 to -0.0015 in. +0.0018 to -0.0006 in. to Housing
)-
- Includes a measurement tolerance of 0.002 inches.
I 3-7 L i (J il - _ _ = _ _ _ _ . _:
.{
The measured clearances and the observed tightness of the bearings during
.- disassembly indicate the bearing fits were acceptable.
- '- The' inner races of the tandem-mounted thrust bearings were verified .to be in contact, .and the thrust-bearing. locknut was verified to be tight. The J' thrust-bearing balls and raceways had no indications of galling, scoring, or overheating. The line-bearing bal_1s and raceways also had. no indications of galling, scoring,- or overheating. Thus, the test did not.
*: . result in significant damage'to the bearings.
'[
D. PUMP 0PERATING HISTORY The operating history of the.CR-3 decay-heat pumps.was reviewed to determine whether low-flow operation caused or contributed to any failures. ^ r
! This review is provided in Appendix E, and its results are summarized below.
i If Plant records note twelve. instances where pump damage has occurred: two [ bearing failures, six instances of excessive shaft seal leakage, three shaft failures and one cracked shaft. The bearing failures were attributed to improper installation. The cu es of excessive seal leakage are spread N over time. Some early cases were attributed to pFoblems with the seal
. bellows. No specific causes for others were found._ Experience in the
! . industry with pump shaft seals in many types of pumps has been that they require periodic overhaul. Hence, no connection with low-flow operation is indicateo.
[ One of the shaft failures occurred early in the plant operating life
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(during hot-functional testing) after extended operation at minimum f: recirculation flow. The shaft failed at the impeller keyway after a period
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- of nine days operation at minimum recirculation flow. The initial
,. determination was that the failure occurred as a result of extended low-u ficw operation. However, a second failure subsequently occurred in the same pump at the same shaft location (impeller keyway) after about 60 days of near design flow operation. The pump casing was found to have been mismar.hined-such that it was skewed to the extent that the periphery of the
-j eye-side shroud on the impeller could contact the casing. No additional 3-8 L.
ya
6 e I i~ shaft failures have occurred in this pump since the skewed casing was { '< ~f]' ' repl aced. Also, the location of the failure in these 'wo events is consistent with application of an end moment on the impeller, as would be i expected from a skewed casing, and is not consistent with the radial force and moment loading expected in low-flow operation. Considering these two 7 1 failures together, and the location of the failures on the shaft, the skewed casing is considered to be the primary cause for these failures. However, it is important to note that, even with the skewed casing, the f pump operated at minimum recirculation flow (80-100 gpm) for nine days. The last shaft failure occurred in 1986 when air was entrained in the i suction during operation. This failure was r: lated to reactor coolant I- level and not to the operating flow. t l A cfacked shaft was discovered in 1980 during a teardown to replace a seal in the pump with the skewed casing. This occurred after the two shaft [ . failures discussed above and before the casing was replaced (a temporary repair was made before replacement). The casing was replaced at this time.
'fl Cracks were found in the impeller keyway and were attributed to a loose key fit and the hydraulic forces associated with the distorted casing.
I In summary, the available operating history of the decay heat pumps does not indicate a connection between low-flow operation and pump degradation. i It does show that the pump could be run for nine days on the minimum recirculation flow line, even with a skewed casing. i-E. TECHNICAL EVALUATIONS ,
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Additional technical evaluations have been performed to evaluate the pump
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performance because: o The NPSHA in the test was higher than that expected in a SBLOCA, owing to test limitations in the plant. o Subsequent to the 10-hour low-flow (400 gpm) test, it was determined that the pumps may be required to operate for as long
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as three days at low flow in a SBLOCA. l These evaluations are discussed below. L , 3-9 c m
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l L T~
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Available Net Positive Suction Head (NPSHA) The NPSHA during the 10-hour low-flow t.est was approximately 115 feet, g which is much higher than the 14 feet predicted for a SBLOCA. Three potential- concerns have been raised. I o Would the pump lose its prime when operated at the SBLOCA NPSHA 1 i y and low flow? o Would the pump vibrations be more severe at the SBLOCA NPSHA than observed at the test NPSHA? o .Would cavitation damage to the impeller be a concern for three j days of operation at the SBLOCA NPSHA and low flow? t
] Each of these topics is discussed below.
i
.j m i Pump Prime-l A necessary condition for assuring pump prime is to maintain NPSHA above NPSHR for the flow rate of interest. The NPSHA expected during a SBLOCA (14 ft.) is greater than the pump vendor's NPSHR (12.5 ft.) at design flow.
,[]
N At flows below design, the NPSHR generally decreases with decreasing flow; this is widely documented in vendor performance test data for centrifugal j pumps having low design-flow NPSHR values, at least to flow values of 30-40% of design. However, for the CR-3 pumps, the low-flow operating point is 10-15% of design flow' a question has been raised whether the -
~
.NPSHR remains lower than the de tign-point NPSHR at these very low flows.
D Experience in this flow range is very limited, but some doee exist. Work u by a pump vendor (KSB) documented in Reference (3) considered NPSHR down to I y values of about 10% of design flow for a pump having a design-flow NPSHR of about 11.5 ft and a design flow of about 2300 gpm; NPSHR was found to decrease with decreasing flow to 10% of design flow. b
.The possibility of losing prime in the CR-3 pumps at flow rates of 10-15%
l~ -of design was discussed with the vendor (Reference 4). He indicates that loss-of-prime occurs when noncondensible gasses accumulate at the pump i impeller eye and block flow. His general experience is that loss-of-prime )
/0 -
3-10 p m
1 should not be a concern if the fluid does not contain large amounts of lc ' noncondensibles or if the pump suction configuration is favorable (e.g., r .
; sump located above the pump suction and simple piping runs). During a SBLOCA, the water is expected to be at or near the saturation temperature and thus, free of r.oncondensibles. Also, the elevation of the sump water level is above the elevation of the pump by about 18 feet.
L Based on the limited data in the technical literature, and the vendor's experience, it is reasonaule to expect that the CR-3 decay heat pumps will not lose prime at the low flows, expected in a SBLOCA when the NPSHA is 14 ft. Pump Vibrations h Pump vibrations are primarily due to pump rotor motion in response to applied forces. Hydraulically induced forces are of primary concern, l especially at low flows. At the high NPSHA of the CR-3 low-flow test, N little cavitation is expected to occur. A question has been raised whether the pump vibration may be different at lower NPSHA.
!w Some industry research has been performed to determine the effect of NPSHA l
; on the magnitudes of steady and unsteady impeller forces. Reference (5) reports experiments done on a pump similar to the CR-3 pumps. The test pump was single-stage, overhung, with a specific speed of about 1900. The CR-3 pumps are of the same configuration with a specific speed of about i 1200. Hence, both pumps are of a radial-flow design. The results indicate "4 that the steady and fluctuating comp +1ents of the axial and radial impeller forces do not change significantly until pump head breakdown occurs (NPSHA
{- l
< NPSHR). Reference (6) comes to a similar conclusion and states "It is concluded that cavitation up to 3% head drop will not cause an increase in i- steady or unsteady radial thrust -- neither in volute nor in diffuser tj pumps."
3-11 m b_ {.
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$m Based on these investigations, there is a reasonable basis to expect that
' ' f,b . . vibration,'and more importantly, pump shaft loading will not be 1
; significantly different at the expected SBLOCA NPSHA conditions than at the NPSHA conditions of the low-flow test.
7 Impeller Cavitation Damage
'f Impeller cavitation damage is typically a concern Or long-term operation
-- many thousands of hours of operation. It becomes evident when damage i
degrades the impeller to the point where structural integrity or pump capacity is affected. For the SBLOCA, cavitation damage wculd only be a concern to the extent that the damage interferes with puma function. For V the short operating time expected, three days (72 hours),. cavitation damage
.. of such an extent would not occur. Hence, cavitation <tamage is not f.. considered to be a concern for SBLOCA.
fj Pumo Shaft Evaluation Provided the loads on the shaft result in stresses which are below the
.h fatigue endurance limit of the shaft, no fatigue damage to the shaft will occur as a result of low-flow operation. In order to determine if the
[ loads on the shaft during low-flow operation could result in fatigue damage to the shaft, a number of calculations have been performed. The types of j calculations performed, and the results of the calculations are described below. ( fl The radial thrust load necessary for the alteri ating stresses in the shaft to reach the endurance limit was calculated. The magnitude of the radial thrust load required to cause the alternating stresses to reach the endurance limit is about 2700 lb. The limiting stress occurs at the { shoulder fillet inboard of the line bearing, which corresponds approximately to the location of the highest bending moment in the shaft. J As stated previously, the post-test disassembly and inspection indicated
,, that a light rub occurred between the impeller and the stuffing box wear ring. The combined radial thrust 1oad and moment required to cause the 3-12 Ll' l:
u
p - p 4 , L i r~~} observed contadt between the impeller and the stuffing box wear ring was calculated. The radial force required is about 620 lb and there is a h. _ corresponding applied moment of about 220 in-lb. The limiting stress
,. occurs at the line bearing and the maximum alternating stress is about a ,
f factor of four less than the endurance limit. [ The radial thrust loads and moments acting on the impeller result from a non-uniform distribution of pressure around the impeller which occurs in
. centrifugal pumps, particularly at low flows. The expected radial thrust loads and moments based on the hydraulic characteristics of the CR-3 decay heat pump were calculated using correlations in technical literature which are based on vendor pump tests. References (6) and (7) are papers describing these tests and correlations. Briefly, the . tests covered centrifugal pumps with specific speeds ranging fica 400 to 3500, and flows from shut off to about 150 percent of design flow. The CR-3 decay heat f', pemps are within the range of specific speeds and flows covered by these tests.
/
The range of expected radial thrust loads for the CR-3 decay heat pumps is from 550 lb to 1300 lb. The expected lower bound radial thrust load is
! consistent with the. independent estimate of the radial thrust load of 620 lbs required to deflect the shaft such that the impeller contacts the l wear ring. Even if the radial thrust load was as high as 1300 lbs (which is not likely since a hard rub would have occurred at the stuffing-box wear f ring) the maximum shaft alternating stress would still be more than a 1
factor of two less than the endurance limit. f
'r It should be noted that the forces needed to reach the endurance limit y (2700 lb) and to cause contact at the stuffing-box wear ring (620 lb)
Lt reported here are slightly less than those previously reported in Reference (8). As noted in Reference (9), MPR was concerned that the distance between the impeller centerline and the line bearing centerline was probably longer than shown on the Impe11 drawing (from ~ Reference 10) used as the basis for the calculations. Since that time we have confirmed 3 13 L f
c r-- with the pump vendor that the longer dimension is correct (all other i rr) dimensions used in the calculations have been confirmed to be correct by rA>
' thevendor). Accordingly, the calculations have been revised. As noted in Reference (9), the original results were conservative. The revised l' calculations are included in this report in Appendix F. Also, the l calculations have also been expanded in scope to include the effect of a hydraulically induced moment.
f' In summary, the expected loading of the pump shaft s' hould result in alternating stresses well below the endurance limit of the shaft' material ) (17-4 PH). v Pumo Bearino Life y
} .
The pump bearings were evaluated to determine their life assuming the expected radial loads at 400 gpm were applied to the impeller (Appendix F). [ The bearing life at these loads is about 1600 hours, well in excess of the expected three-days operation. Also, as discussed earlier in the report, lf A the bearing performance in the low-flow test showed no sign of degradation. Hence, bearing life is not a concern for three days of pump operation at l
'l low flow. l i
i l' l 'l i 1 . l p. l + 1 r^ B OC. L 3-14 j .y G 4
= MPR A%:OCIATED. INC.
w .
- Section 4 REFERENCES I
- 1. Performance Test Procedure PT-321, " Florida Power Corporation, Crystal River Unit 3, ' Decay-Heat Pump 3B Minimum-Flow Test," Completed.by WR 112134.
- 2. PMA letter (Baker) (and associated vibration data) to FPC (Clemens)-
dated 4/18/89.
! 3. Dernedde, R., and Stech, P., " Design of Feed Pump Hydraulic
- Components," EPRI CS-3158, Power Plant Feed Pumps - the State of the Art.
t '
- 4. Telecons between MPR (Grant) and Dresser (Doolin) 6/22-23/89.
- 5. Turton, R. and Goss, M., "A study of the Fluctuating and Steady Forces on a Conventional Centrifugal Pump," British Rump Manufacturers' Assoc. Technical Conference Papers,1983 pp 235-248.
j ' 6. Guelich, J. et al, " Review of Parameters Influencing Hydraulic Forces
!k on Centrifugal Impellers," Institute of Mech. Engr. Proc. Part A 201:A3 (1987) pp 163-174.
4 7. Agostinelli, A. et al, "An Experimental Investigation of Radial Thrust in Centrifugal Pumps," Journal of Engineering for Power, Transactions of t:12 ASME, Vol. 82, Series A, No. 2 (April 1960) pp 120-166. j
- l. 8. MPR Letter (Russell) to FPC (Porter), dated 6/12/89.
- 9. MPR Letter (Russell) to FPC (Porter), dated 6/13/89.
l
- 10. Impell Report No. 03-0920-1146, " Evaluation of Alternatives for Improving Decay Heat Pump Reliability", dated 3/16/88.
- 11. Dresser Pump Division Facsimile (W. C. Smith) to Florida Power Corporation (E. Morea), dated 9/6/88.
~
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l MPR A"_SOCIATEJ. INC. G Section 5 APPENDICES A. Requirements for Minimum-Flow Testing of the Decay-Heat Pumps at Crystal River Unit 3, transmitted by MPR letter (Mazzola) to FPC (Simpson) dated 3/21/89. B. Technical Basis for the Acceptance Criteria for the Crystal River Unit 3 Decay-Heat Pump Low-Flow Operability Test, transmitted by MPR letter (Russell) to FPC (Porter) dated 4/12/89. C. Evaluation of Results from Crystal River Unit 3 Test PT-321, Decay-Heat Pump 3B Minimum-Flow Test, transmitted by MPR letter (Russell) to FPC (Porter) dated 5/2/89. D. Preliminary Evaluation of the Post-Low-Flow Test Decay Heat Pump Inspection, transmitted by MPR letter (Russell) to FPC (Porter) dated 5/19/89. E. Review of the Operating History of the Crystal River Unit 3 Decay-Heat Pumps, Transmitted by MPR Letter (Russell) to FPC (Porter) dated [] C 6/27/89. F. MPR Calculations
- No.102-72/1 Rev.1, " Impeller Radial Loads at the Fatigue Endurance Limit"
- No. 102-79/1 Rev. O, " Estimate of Radial Thrust on Pump Impeller Based on Design Formulas"
- No. 102-79/3 Rev. 1, " Axial Load on Impeller Required to Cause Fatigue Failure at Keyway"
- No. 102-79/4 Rev. O, " Relationship Between Hydraulically Induced Moment and Radial Force on Centrifugal Pump Impeller" r
- No. 102-79/5 Rev. O, " Radial Load and Moment Required to Deflect 1 Pump Shaft Through Wear Ring Clearance" i
- No. 102-79/6 Rev. O, " Estimated Rating Life of a Bearing as a Function of. Applied Load" n l V 5-1 j
1 l 1 i
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. MPR ASSOCIATES. INC. .
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, et APPENDIX A ljl- .
=;;b-Requirements for Minimum-Flow Testing of the Decay-Heat. Pumps
, at Crystal River Unit 3 3.g
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y . ~:y a l m MPR ASSOCIATES. INC. 11-March 21, 1989 7
'l
# Mr. E. C. Simpson
! Director, Nuclear Operations Engineering and Projects Florida Power Corporation 3201 Thirty-Fourth Street South
- i.: P.O. Box 14042 St. Petersburg, Florida 33733 i
Subject:
Crystal- River Unit 3 - Decay Heat Pump Minimum Flow Tests
Reference:
(a): Florida Power Corporation Letter Serial
. [_. No. NEA89-0414, dated March 17, 1989 L
Dear Mr. Simpson:
,y As you. requested in your letter of March 17, 1989, Reference (a), we have developed the requirements for minimum flow testing of the decay
& heat removal pumps at Crystal River Unit 3. The test requirements are
,b ' included as Enclosure (1). We have also prepared a checklist which summarizes specific actions which should be taken to prepare for the minimum flow testing. The checklist is included as Enclosure (2). The purpose of the tests is to determine whether minimum flow operating limits less restrictive than those specified by the pump vendor can be
-justified.
]
The pump vendor has specified the following operating time and low flow limitations assuming the available net positive suction head (NPSHA)
,. is equal to the required net positive suction head (NPSHR) of 121/2 ft l for the pumps:
1.' 2350 to 3000 gpm - continuous operation [ 1200 gpm - 100 hours per year
!, 80 gpm -
2 hours total lifetime y These criteria are restrictive (the design flow is 3000 gpm). The vendor indicates they do not have test data for this pump design which they can use to define less restrictive criteria, f The pumps are normally used for decay heat removal and the flow is L. in the continuous operation range specified by the pump vendor. However, the pumps would also be required to operate in the event of a loss of ji coolant accident, providing low pressure sa,fety injection or acting as boosters for the make-up pumps. Based on discussions with Florida Power W( Corporation (FPC) engineers on March 17 and 20, 1989, we understand that y b i
- l. }. ..
202-699 2320 t010 Co%_nf meu+ A vf uur N w_ . wasmucmu o c 20o36
l< t L i' [~ MPR ASSOCIATES. INC. A . {c Mr. Simpson - March 21, 1989 f during a small break loss of coolant accident (SBLOCA) these pumps could l
'! be required to operate in the following low flow modes in the worst case:
o 80 gpm for up to 5 hours
,l. o 300 gpm indefinitely We propose a test to justify operation in the minimum flow mode at 80 gpm for 5 hours and at.300 gpm indefinitely. The test outlined in Enclosure (1) is to operate the pump at design conditions to establish baseline data for monitored parameters, gradually reduce the flow to 300 l gpm for about I hour, reduce flow to 80 gpm for 5 hours, and then return
- 1. - to design conditions to verify no degradation in the performance of the pump. If the performance of the pump at 300 gpm is not significantly
, different than the performance at design conditions, then we consider the -i>- test provides sufficient justification for indefinite operation at 300 gpm. Additional assurance.that the pump is capable of operating at the's .
low flows would be provided by a disassembly and inspection of the pump following the test. t According to FPC engineers, the NPSHA during a SBLOCA would be as low as 13 ft if the pump supply is from the reactor building sump. This l is a more restrictive operating condition than can be'obtained during the test, because the pump supply will be from the borated water storage tank during the test, and the NPSHA will be about 50 ft. There appears to be no practical way to lower the NPSHA to 13 ft during the test. However, we consider that the proposed test should be sufficient to demonstrate the pumps can operate acceptably at minimum flow. 1 .
, There is limited experience operating these pumps at minimum flow, and there is the possibility that the ' pumps could be damaged by these l
<- tests. The test as outlined in Enclosure (1) provides for- careful I control and monitoring of pump conditions which should minimize the l
possibility of significant degradation. However, as a precaution, we i- recommend that FPC assure a set of spare bearings ar,d a spare rotating f assembly are on hand before running these tests. In parallel with FPCs effort to prepare for these tests, we [ recommend the fqllowing actions be accomplished by MPR: L' l o Perform scoping calculations to determine the approximate design margin of the pump shaft against fatigue failure l q;t due to radial loads on the impeller. o Review the circumstances of earlier failures of decay heat l t pump shafts at Crystal River Unit 3. O r O Lpa f 4
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k W MPR ASSOCIATES. INC . f'l V Mr. Simpson March 21, 1989 In. order to perform the shaft calculations, we will require the F snaft and impeller dimensions. Also, we will need whatever information l. I. is available concerning the earlier decay heat pump shaft failures. 1c We look forward to working with FPC to resolve the decay heat pump i.' minimum flow operation. concerns. Please do not hesitate to call us if you have any questions concerning this letter or the enclosures. Sincerely, 1
?
Domenic E. Nazzola d'i ' cc: E. Morea C, 8. Doyel I N' 4 l' L. - t [ N iwd L + f. U p I u-m__________ _ _ _ _ _ . - _ - - .
l Enclosure (1) to MPR Letter Dated MPR ASSOCIATES, INC. March 21, 1989
.. (
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i , a REQUIREMEllTS FOR MINIMUM FLOW TESTING OF TiiE DECAY HEAT PUMPS AT CRYSTAL RIVER UNIT 3 i t
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9I',]'. PilRPOSE 0F TESTS
;. _ The purpose of the tests.is to demonstrate whether operation of the decay
' heat pumps;in.the minimum flow mode for an extended period of- time is
'f .possible without damage which would cause degradation in the performance of the pumps. SCOPE OF~ TESTS The minimum flow testingL should be performed for both decay. heat pumps. i- Test Seouence. .
}. 1. Operate.at design flow conditions to establish base ~1ine values for all pump operating parameters to be monitored.
T J.
.2. Reduce flow in increments to the minimum flow by throttling the pump discharge valve, monitoring key pump operating parameters at each 1
flow level. The suggested flow increments in gallons per minute (gpm) are: 3000, 2000, 1500, 1250, 1000, 800, 600, 500, 400, 300, 200,
] 100, 80 (or actual minimum flow in the recirculation line)
! Satisfactory operation of the pump at each flow level will be verified by ensuring each monitored parameter is within specified 7 limits before further reduction of the flow. The flow should be i- maintained at each specified level long'enough to obtain steady p state value,s for all monitored variables, except. at 300 gpm and 80 g gpm .where the flow will be held longer:
o Maintain the pump at 300 gpm for 1 hour. Continually L monitor the pump performance and record and evaluate the f . monitored parameters every ?,5 minutes. O
.L:
L.
'fi(1 - _. ._ -- . _ _ _ _ . __- _ _ - _ - _ _ _ _ _ - - - _ . _ - - . _ _ _ - - _
f
- q. o Maintain the pump at 80 gpm for 5 hours. Continually i '
monitor the pump performance and record and evaluate the monitored parameters every half. hour. l 3. Return the pump to the design flow condition (3000 gpm). Record monitored parameters and compare to baseline values. l Parameters to Monitor l The parameters-which should be monitored, and the technical basis for monitoring each parameter selected are summarized below. f Monitored Technical
. Parameter Basis
( Pump suction and discharge Track Net Positive Suction Head' l l pressures (NPSH) and total developed head.
! Indicates overall hydraulic per-formance of pump.
\
V Pump flow to borated water storage tank Primary test control parameter and factor in the total developed head. Indicates overall pump hydraulic
; performance.
Flow in recirculation line Determine actual minimum flow for
; compr ' ,on with expected (80 gpm)
; minimt.. flow.
[" Suction and discharge: Measure fluid temperature rise in temperatures pump. l" Motor current Indicates overall motor performance. t. Pump bearing cooling water Indication of heat generated in [- inlet and out temperatures bearings. I~ Overall and filtered horizontal Best indicator of overall motor and and vertical vibration at all pump condition throughout test. f.v four bearings Overall and filtered axial vi- Compare the magnitude and frequency
- l. bration at inboard end of pump of any axial vibration with those of in (if feasible) lateral (vertical and horizontal)
(j vibrations. Indicates a change in p axial hydraulic excitation as pump jj flow is varied.
; U
e 1 7 (,
- ,w Test Procedure
__Q . A detailed step-by-step procedure for performance of the test should be developed, including data sheets for recording monitored parameter i . values and computing performance characteristics (pump NPSHA, pump head, motor power, hydraulic power, and pump temperature rise). The normal j: decay heat pump quarterly surveillance test can be used as a basis for developing the test procedure. ACCEPTANCE CRITERIA
- 1. At flows from 3000 - 300 gpm, the overall (unfiltered) vibration level should be less than 0.3* in/sec at all four bearings in both
-[ the vertical and horizontal directions, and in the axial direction at the inboard end of the pump.
r l; If this criteria is not met at the initial 3000 gpm operating condition, then the test should be stopped, and the follering inspections and checks should be performed: l o Check pump to motor alignment o Check tightness of pump and motor hold-down bolts, and F foundation bolts
- j. o Check coupling condition and integrity o Remove, inspect, and replace pump bearings if necessary.
- 2. At flows less than 300 gpm, the overall unfiltered vibration level y should not exceed 0.7* in/sec at any of the four bearings in both L. the vertical and horizontal directions, and at the inboard end of the pump in the axial direction. .
f ,. . . 1 U ' I
- 3. If the vibration exceeds 0.7* in/sec at any point in the test, the
)g flow ~should be increased to 3000 gpm, the final monitored parameter values recorded, and the test should be terminated. ;
q {1 i
- Vibration levels of 0.3 in/sec and 0.7 in/sec correspond to the x alert and action levels respectively for the FPC decay heat pumps,
[] as specified in FPC surveillance procedure SP-340A. These levels
- t. are consistent with industry practice.
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- 4. At minimum flow, the overall unfiltered vibration level should remain' essentially constant through the entire 5 hour run at each i bearing location and at the inboard end of the pump.
I 5. At minimum flow, the temperature rise across the pump should not exceed 15'F. l
- 6. At flows less than 3000 gpm, the pump bearing cooling water temperature rise should approximately equal the baseline value determined at 3000 gpm.
- 7. The pump hydraulic characteristics (head vs flow and power vs flow) should show approximate agreement with the Worthington head vs flow i curve throughout the test.
j.
- 8. When returned to 3000 gpm, the pump hydraulic characteristics and vibration levels should return to the levels observed at the beginning of the test.
I PUMP DISASSEMBLY INSPECTION CRITERIA j' 1. The most definite indication of the effects of minimum flow operation of the pump would be obtained by disassembling the pump and inspecting the rotating assembly. The specific items to be checked would include: o Impeller and case ring condition. Check for indications of l- severe rubbing wear between the impeller and either case ring. l' i= (Note: some rubbing between the impeller and use rings does L occur on many centrifugal pumps). o Impell Ensure the impeller is tight on theer shaft. - shaft joint integrity. o Impeller condition. Check for indications of cavitation damage. o Shaft condition. Inspect shaft for cracking and straightness. D ' 4: in
p. l O o Bearings. Inspect balls and raceways.for fatigue damage. Check for proper fit between shaft and inner bearing ring and
"* between pump housing and outer bearing ring.
j TEST INSTRUMENTATION 7 [ This test would utilize both installed instrumentation and temporary instrumentation. The installed instrumentation needed for this test is used for the quarterly pump surveillance tests and includes: o Flow Indicators DH-1-FIl and DH-1-FI2. These indicators display the return flow to the Borated Water Storage Tank for each decay heat pump. f o Pressure Indicators DH-4-PIl and DH-5-PII. These indicators display the suction pressure and discharges pressure,- respectively, for decay heat pump DHP-3A. i o Pressure Indicators DH-4-PI2 and DH-5-PI2. These indicators display the suction pressure and discharge icT LJ pressure, respectively, for decay heat pump DHP-38.
, The temporary instrumentation includes:
o Thermocouple attached to the suction and discharge piping [ 1. of both decay heat pumps. These thermocouple would monitor the temperature rise across the pump to ensure pump overheating does not occur. These thermocouple should be located as near the pump casing as practical.
~
o A datalogger or other instrument to display the thermocouple readings. o Proximity temperature probe to measure the bearing cooling water inlet and outlet temperature. This probe would monitor the temperature rise across the bearings to ensure J the bearings do not overheat. Thermocouple may be used in place of this proximity probe. o Clamp-on flowmeter to measure flow in 'the pump recircu-
~'
lation line (3 inch schedule 40 piping). An ultrasonic
, flowmeter that operates using the " transit-time" principle i is recommended for this application. This flowmeter Y should be installed in the middle of the longest straight 4
run of pipe (horizontal or vertical upward flow) upstream JU of the flow orifice in that section, if possible. f; - - _ - _ _ - _ _ _ - _ _ _ - _ - - _ _ _ - _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ . - _ _ _ - _ _ - _ _ - - _ _ _ ___ _______-___________________i
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/~ o Clamp-on ammeter to measure pump motor current, provided
}Q~T' pump motor current is not. indicated presently. This data '
determines the pump motor load. { 1' o Vibration monitor wit avelocitytransducertomonJtor vibration at each pum bearing, motor and at inbohd end 3 ... of pump. This monitor should be capable of filtering the
. signal and displaying / recording a spectrum analysis of the vibration readings. A spectrum of the vibration readings fj' is necessary to understand the nature of the vibration.
For. example, the dominant vibration is expected to occur at the vane-passing frequency (number of vanes x pump r running speed)'at low flow. TEST PREREQUISITES { . Before the test begins, all test instrumentation should be cali-F brated. The installed instrumentation should be verified to be in t' calibration. In addition,'the clamp-on flowmeter should be flow ( calibrated to ensure accurate results. It has been our experience - b that an electronic'"blackbox" calibration is not as accurate as manufacturers claim, being as much as 30% in error, h - A bearing oil sample should be taken and analyzed or the oil changed to provide baseline' data on the bearing condition. An oil sample f should be taken after the test as well to compare to the pre-test
- } sample. This will indicate if bearing damage occurred during.the T' test. .
I l b This test will operate the pumps at conditions that are beyond their 1 7 experience. Although we continually monitor the pumps for damaging t conditions, some damage to the pumps may result. For this reason, a spare rotating assembly, radial bearing assembly, and thrust bearing L(j assembly should be on hand to minimize plant down-time. p: 1 b, () L/ 3; L.
1 I 3 MPR ASSOCIATES. INC. Enclosure (2) to - t .'[O ' MPR Letter Dated March 21, 1989 a i l q? t l l~ i I i e
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i CRYSTAL RIVER-3 DECAY HEAT PUMP MTNIMUM FLOW TEST CHECKLIST r
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c . ., s > l , CRYSTAL RIVER-3 DECAY. HEAT PUMP MINIMUM FLOW TEST CHECKLIST ,
,(.
g 1. Write test procedure and data sheets.
- 2. Obtain necessary reviews and approvals for the test procedure and I
data sheets. .
}. ;q 3. Procure temporary test instrumentation (if none in-house).
f
., a.. Thermocouple -
- b. C1 amp-on' flowmeter
- c. Clamp-on ammeter r -
y\
, d. Proximity temperature probe
- e. Vibration monitor with velocity transducer.
- 4. Verify calibration of installed instrumentation.
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- a. Flow-Indicators DH-1-FI2 and DH-1-FI2 b.- Pump DHP-3A Pressure Indicators DH-4-PI2 and DH-5-PII
- c. Pump DHP-38 Pressure Indicators DH4-PI2 and DH-5-PI2.
- 5. Calibrate Temporary Test Instrumentation h
f a. Thermocouple
- b. Clamp-on flowmeter (flow calibration) y c. Clamp-on ammeters
'l3 d. Proximity temperature probe
- e. Vibration monitor with velocity transducers j.
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- 6. Determine sha.4 strength. (MPR) i i
. 7. Collect data on decay heat pump shaft failures.
- 8. Review data on shaft failures. (MPR)
.l"
- 9. Install temporary instrumentation.
b - 10. Sample and analyze bearing oil,'or change-out bearing oil, for 77 both pumps. (
- 11. Verify 'a spare rotating assembly, radial bearing assembly, and
._-\ thrust bearing assembly are on hand.
/ 12. Perform test on pump DHP-3A.
l ( 13. Perform test on pump DHP-3B.
, 14. Return system to normal.
- 15. Sample and analyze bearing oil for both pumps and compare to pre-test' sample.
f
- 16. Analyze test data.
L, i 17. Disassemble and inspect pump.
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- 18. Prepare test report.
k..
- 19. Submit test report.
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M MPR ASSOCIATES, INC.
, APPENDIX B Technical Basis for the Acceptance Criteria for the Crystal River Unit 3 Decay-Heat Pump f~ , tow-Flow Operability Test f
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p i[ Lh . ;. MPR ASSOCIATES. INC. l l ,, April 12, 1989 LI z., l p ,1 1' i Mr. D. E. Porter ! Florida Power, Corporation l 3201 34th' Street, South P.O. Box 140442 (( St. Petersburg, FL 33733 1. Attn: E. Mores ['
Subject:
Crystal River Unit 3 Decay Heat Pump Low Flow Operability Test - Technical Basis for Test Acceptance Criteria and Pump Inspection Requirements i
Dear Mr. Porter:
>~ The purpose of this letter is to forward the Technical Basis for
( the Acceptance Criteria for the Crystal River Unit 3 Decay Heat Pump tow Flow Operability Test-(Enclosure 1) and the Pump Internals Inspection
, Requirements (Enclosure 2). These enclosures include the resolutions to
! comments Mr. Morea provided to Tom Greene (MPR) in an April 5, 1989 telephone conversation. These enclosures are to support the upcoming low flow operability test for the decay heat pumps.
t' The planned test of the decay heat pump simulates as closely as possible the operating conditions which would be expected during a small 7
. break loss of coolant accident (SBLOCA)' including low flow operation
'j" (which are the main operating conditions of concern). Specifically, the pump will be run at a low flow rate of 400 gpm for about 10 hours. This is conservative because expected low flow conditions are 500 gpm for S hours. This test is consistent with the approach being taken at three
- i. other nuclear plants to address the NRC concerns presented in NRC Bulletin 88-04, based,on information from these other three plants, i However, the available net positive suction head (NPSHA) during an SBLOCA D~
at Crystal River Unit 3 will be lower than the minimum NPSHA during the test. Specifically, the NPSHA during testing is expected to be about 50 ft. while the NPSHA during the SBLOCA is expected to be just above the '
}.-
required net positive suction head (NPSHR) cf 12.5 ft. During the test.
'(' the pump supply will be from the borated water. storage tank (BWST).
During an SBLOCA, for part of the time, the pump supply will be from the i reactor building-sump which is at a lower elevation in the plant than the L; BWST. Also, the water temperature would be higher during part of a )
/ SBLOCA. It is not practical in the plant test to duplicate the lower
.- water level or the higher temperature experienced during an SBLOCA. ,
(I t .. h 1- 1050 CONNECTICUT AvtNut. N W Wa&*HNGTCN D.C. 2003 6 202-6S9 2320 1
P I g w MPR ASSOCIATES. (NC. Mr. D. E. Porter April 12, 1989 i Since the test' conditions and SBLOCA conditions with regard to NPSHA j" are different we consider that a firm technical basis is required to
' ensure the test results at a higher NPSHA can be used to demonstrate that the decay heat pump and system design are satisfactory for operation with the lower NPSHA during SBLOCA conditions.
- Our recommended approach to resolse the NPSHA question is as follows:
I o Review available test c:ata for the pumps at CR-3 (e.g., data l that may have been taken during initial plant startup in the l late 1970's) and for similar pumps to determine if low NPSH is l likely to <iamage the pump during low flow operations. l. o Obtain an assessment from the purnp manufacturer of the effect
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on pump performance of the lower NPSHA. ( i. o Based on results from the above, determine if further action is y needed. If you have any questions or comments regarding the enclosures, please do not hesitate to call me. l Sincerely, A /8. M Alan B. Russell Enclosures
)
cc: W. W. Nisula
'~
J. R. Maseda E. E. Welch E. C. Simpson
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iv ( 9 - L. 4 we
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.MPR ASSOCIATES. INC.
MPR Letter Dated
<m April 12,.1989 .l: . .
1 l TECHNICAL BASIS FOR THE ACCEPTANCE CRITERIA-FOR THE CRYSTAL RIVER UNIT 3 DECAY HEAT l-[ Ptw LOW FLOW OPER7'AILITY TEST l' 1 s Three distinct physical phenomena are a concern for centrifugal pump operation 'at low flows:' temperature rise, radial thrust loads, and impeller internal recirculation. These phenomena can cause short-term or ']' long-term pump damage to the point that the pump cannot satisfy its
;- functional requirements. The type of damage expected due to these 1: phenomena are described belos.
r o Temocrature Rise (Reference 1) - Pump efficiency decreases as .) flow decreases. This results in an increase in energy dissipated in the pump as heat which is absorbed by the pumped
.. flow'and the pump internals. This is a problem inherent to
,e centrifugal pumps and is the historical reason that minimum
' flow lines are provided. The temperature rise of the pump internals may cause reduced running clearances or loosened interference fits if the pump internals have different ,
[ coefficients of thermal. expansion. An increase in water temperature also causes an increase in vapor pressure which may lead to cavitation. damage if the available Net Positive Suction Head (NPSH) is near the required NPSH. Thus, a ttaperature 1' ' rise may cause rubbing between rotating and stationary parts, joined elements to loosen, and cavitation damage to the
- 1. impeller inlet.
t. o Radial Thrust (References 1. 2. 3. 4. and 5) - Radial thrust results when the pressure distribution around the circumference
/' of the impeller becomes non-uniform. This radial thrust load may be fixed in orientation with respect to the pump casing and it may fluctuate in magnitude. This results in an alternating bending stress in the shaft at once per revolution and may a result in large loads on the bearings. This may lead to two problems: fatigue failure of the shaft and bearing overload.
o Recirculation (References 1. 5. and 6) - Recirculation is a flow reversal in the impeller. This may occur at the impeller
; eye (suction recirculation) or at the discharge tips of the f b
'1 L
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impeller (discharge recirculation). Recirculatic Cavelops at f((]y some flow-less than design flow. Large dynamic loads in the radial and axial direction can result from recirculation.
)
'a Suction recirculation may also cause cavitation damags to the impeller vanes at the inlet or to the stationary vanes, surging in the suction, or pressure pulsations in the suction.
-Discharge recirculation may cause cavitation damage to the discharge tips of the impeller or to the volute tongue,
, lr , , overload of the thrust bearing, fatigue damage to the bearings, I cracking of.the impeller shrouds at the discharge, fatigue p failure of the shaft,'or pressure pulsations in the discharge. p However, pressure pulsations and surging are typically not a
" major concern for pumps with less than 1000 feet per. stage of total developed head which describes the decay heat pumps.
Thus, the damage that is likely to occur in these pumps from recirculation are cavitatbn to the impeller and volute
- tongues, bearing overload, fatigue damage of the bearings and shaft, and cracking of the shrouds.
l The Crystal River-3 decay heat pumps may require operation at low flow
' conditions for a short time period (on the order of hours) before flow is
.p returned to norma'. Because the expected low flow operation is for a
! short time period, only those concerns which lead to shrt-term damage need to be considered to verify this damage will not disable the pump.
Some of the above problems typically do not constitute a concern for short-term operation. For example, cavitation may damage the pumps in two ways that can result in a loss of pump operability. The first type of damage is metal wastage which affects pump operability only over a V long time period. This type of damage is not expected to be a concern
" for short-term operation. The other type of damage is shaft or bearing j damage from excessive cavitation-induced radial and axial loads. This b type of damage is a concern for short-term operation.
The concerns for this test are reduced running clearances or loosened interference fits due to pump temperature rise, shaft f.ilure by fatigue, and bearing overload or fatigue damage. o s [3
.b
^
l l 1 r The purpose of the Decay Heat Pump 3B Minimum Flow Operability Test is to j l .J verify that the pumps can operate at a low flow for at least the length f l_ of time they would be needed to operate at this flow during a small break i loss of coolant accident. The variables that.need to be monitored l include: Pump suction temperature and discharge temperature to determine ! o the pump temperature rise. 1. o Bearing housing vibration in the radial and axial directions
.- (unfiltered overall and filtered spectrum at each bearing), to indicate whether the dynamic loads (i.e., the radial and axial thrust loads caused by hydraulic instabilities, running interference, or loosened parts) will result in bearing or shaft failure. There is a direct relationship between i vibration magnitude and the magnitude of dynamic loads on the pump.
i l o Bearing cooling water inlet and outlet temperature to indicate ; if a bearing is failing due to overload (the bearing may heat up excessively). 1s For the test, the pump suction / discharge temperature rise acceptance criteria is 15*F or less to ensure against problems due to temperature [] rise. Calculations (Reference 7) indicate that the minimum flow line is I sized to maintain the temperature rise below 9'F. Based on our experience and on information in the literature (Reference 1), and to
; provide scne margin for practical considerations,15'F is an appropriate
{ limit. l i i The vibration criteria summarized above for continuous operation is 0.3 I [ inches per second (ips) overall, unfiltered. This value is the alert lbit for the decay heat pumps surveillance test (e.g., Reference 8). f# This is the vibration level above which increased monitoring is required per Reference 8. The ' action level currently established for these pumps 3 is 0.7 ips overall (Reference 8), above which imediate corrective action is required per Reference 8. Based on our experience and on others' experiences (Reference 9), these values are reasonable. The final j l acceptance of these vibration criteria is based on the successful
.t l completion of the test ud the after-test pump internals inspection (see !
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- c.
W.
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I b 'below). For vibration levels above the 0.7 ips l'imit, flow should be , I increased'and the test terminated. A' vibration spectrum is taken to Y provide important information on.the nature and cause of the vibration.
.No acceptance criteria is provided for the spectrum.
4 ,^'}, t Bearing cooling water temperature rise indicates the heatup of.the bearing. An absolute criterion for the temperature rise is not' desired ( as a limit to this test. Instead of an absolute criterion, the baseline
'e temperature shall be noted, and the temperatures monitored at each test 1 flow. However, if the cooling water temperature rise is sufficient to cause boiling, or the bearings start to. smoke, shut off the pump.
The test can be terminated if any significant deviations are noted (e.g., in vibration or bearing cooling water temperature) which could potentially lead to a loss of pump function. The test should be t i terminated, recording all data, and shutting down the pumps.
.The above criteria establish limits defining . indications.of unacceptable
- ( pump performance. . However, to ensure that the components would not be-damaged by the test, scoping calculations (References 10 and 11) were
/ performed to determine the expected radial thrust loads and the shaft's fatigue life under these loads. Because of the substantial margins indicated (to cover dynamic and other effects)'between endurance limit allowable loads (about 3000 lbs) and expected steady loads on impeller-(about 500 lbs). These calculations indicate that shaft failure by 1- fatigue is not anticipated (for the radial forces expected due to less-than-design flow rates).
In addition, to check the pump condition, bearing oil samples and pump
- k. internals inspections are recommended before and after the test. The v-pump internals and the rotating element should be inspected for running
'jI" interference at the wear rings and other critical locations, htigue cracking of the shaft,' bearing condition, cavitation damage to the impeller vanes (suction and discharge) and volute tongues, and cracking of the impeller shrouds. Replacement of the rotating element with the
. 4
'I f a.
6 1 '. l.
.D spare element is. recommended after the test because the tested shaft's fatigue life may have been reduced even if a crack is not observed on the
{ 'd shaft. The pump inspection requirements are provided separately. I-REFERENCES [- 1. Karrasik, I.J., et. al.; ed., Pumn Handbook, Second Edition,1986. l
- 2. Agostinelli, A., et al, "An Experimental Investigation of Radtal Thrust in Centrifugal Pumps," Trans. ASME Journal of Encineerina for E ntr, April 1960.
t
- 3. Turton, R. K.; Goss, M., "The Fluctuating Radial and Axial Thrusts l Experienced By a Centrifugal Pump," Operatina Problems of Pumn l Stations and Power Plants Proc. Symoosium.11th,1982.
!i
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- 4. Guelich, J.; et al, " Review of Parameters Influencing Hydraulic forces on Centrifugal Impellers," Institute of Mechanical Enaineers.
l[ Proceedings. Part A, 201:A3, 1987. I; 5. EPRI Report No. CS-1445, Centrifugal Pumo Hydraulic Instability, June 1980. J i l' 6. Fraser, W. H., " Recirculation in Centrifugal Pumps," ASME,1981. i
- 7. MPR Calculation " Temperature Rise Across the Decay Heat Pumps at Minimum Flow," Revision 0 dated April 7, 1989.
- 8. Florida Power Corporation Crystal ?iver Unit 3 Surveillance f Procedure SP-340A~, "A Train ECCS Pump and Valve Quarterly b Operability Test," Revision 14 dated January 12, 1989.
- 9. Maxwell, H., " Absolute Vibration Velocity Limit Needed for Pump Test Standard," Power Enaineerina, June 1986.
3 l b
];
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- 10.- MPR Calculation " Radial Loads on the Impeller at low Flow,"
~
[t Revision 0 dated 3/25/89.
- l
- 11. ' MPR. Calculation " Pump Shaft Loads and Deflections at the Fatigue Endurance. Limit," Revision 0 dated 3/23/89.
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1 1 1 4 l k, 4 I. . lfD g w 6 'l h M
l MPR ASSOCIATES. INC. MPR Letter Dated April 12, 1989 I f CRYSTAL RIVER UNIT 3 DECAY HEAT PUNPS ; PLMP INTERNALS INSPECTION REQUIREMENTS L s
.i
)
Inspections of the pump internals ard the rotating element of the decay ] heat pumps at Crystal River Unit 3 are recommended before* and after the proposed low flow operability test. The purpose of these inspections is 3 to document the initial condition of the pumps prior to the test, and to 4 l-i verify that the pumps were not significantly degraded during the test
,- (i.e., the pump's function is not compromised). The inspection )
ij requirements for before and after the test are as.follows:
- 1. Stationary Components I
il A. Casing Rings and Stuffing Box Rings,- These rings shall be 1 visually inspected for rubbed areas and excessive wear { r) from contact with the impeller caused by thermal expansion i 1 or deflections from hydraulically-induced loads. The i
" clearance between the casing ring and the impeller wear j y surface should be between 0.015 and 0.064 inches. The i clearance between the stuffing box ring and the impeller wear surface should be between 0.015 and 0.054 inches.
(See Refere"ce I for both sets of acceptance criteria). t If the clearances exceed these values, then the pump [ should be repaired per Reference 1. B. Volute Tongues - The volute tongues shall be visually inspected for cavitation damage resulting from discharge recirculation. The volute tongues should be free of severe cavitation-induced damage that would prevent the
! pump from functioning, e.g., when the structural integrity of the tongue may be compromised. This will be evaluated and repaired on a case basis.
Pump IB is to be tested. The rotating element for this pump was replaced in January 1988. The pump has seen limited service since then, but none at low flows; therefore, this pump
- should be in good condition. A pre-test inspection is not considered essential but is desirable to obtain baseline conditions. This will identify damage that accumulated during l) the test only. -
u
. l i- 1 L
f. y t . . 1 C. Areas of Tight J earances with Rotating Parts - Areas with
+ tight clearances .with . rotating parts (e.g., the stuffing -
t box bushing and the gland plate)'shall- be visually F ,
. inspected for _ wear caused by thermal. expansion or .
deflections from hydraulically induced loads.-- These areas
& should be examined.for evidence of severe rubbing damage .i. ,.
which might interfere with pump operation. The clearance A between the stuffing box-bushing and shaft should be between 0.001 and 0.004 inches. A clearance greater than 0.004 inches should be evaluated further by Site Nuclear Engineering for acceptability (Reference 1)'and need for repair.- p.. y 2. Rotating Components
-A. Shaft - The shaft shall be inspected for straightness, a fatigue cracking, and sleeve wear at areas of tight b clearances with stationary parts.
f i.. Straightness shall be verified by measuring its - 1.' runout at 0* , 90* , .180* , 270* , and 0* , along the entire len th of the shaft. Total Indicated Runout ' (TIR) shal not exceed 0.002 inches (Reference 1). A shaft that is-not straight should be repaired or
] '. replaced. ,
L 11. Liquid penetrant examination of the entire shaft shall be performed, with particular emphasis on the keyways and fillets. The shaft shall be free of cracks. A cracked shaft shall be replaced. Any crack indications should be evaluated on a case basis. 'A crack that is attributed to the test and 1 would have led to shaft failure shall indicate that the machine is unacceptable for the expected low flow ! v service. Corrective action shall be developed. W iii. The shaft sleeve shall be visually inspected for
~i- wear. Tais wear should be verified at the corresponding location on the stationary part. The acceptance criteria in 1.C applies, v B. Impeller - The impeller shall be visually inspected for cavitation damage, wear on impeller. surfaces, cracking of the shroud, and impeller-shaft joint integrity.
I 1. The pressure side of the impeller vanes shall be
,- visually inspected for cavitation pitting caused by ir.ternal recirculation at the s.uction (the underside
~
- of the vane) and at the discharge (the visible ' side of the vane). The impeller should be free of ingrJt
- (y . cavitation-induced damage which would comproadse the m structural integrity of the impeller. This will be e
1 s
l L
'h evaluated on a case by case basis. Evaluation should V ,
include need for repair or replacement. ii. The wear surfaces on the impeller shall be visually-inspected for rubbed areas and excessive wear. The l ,. acceptance criteria in 1.A. spplies. iii. The shroud at the discharge of the impeller shall be ~ l . inspected by liquid penetrant examination for cracks on the inner and outer .drfaces. The shroud should be free of cracks. All crack indications shall be evaluated on a case basis. Any damage shall be repaired or the impeller shall be replaced, iv. The tightness of the im>eller on the shaft thall be r verified. This joint s tall be considered acceptablo if no relative movement of the impeller vith respect l' to the shaft occurs when shaken by hand and the impeller nut is properly torqued. The pump manual nor the pump maintenance procedure provides any ; guidance on proper tightness. The pump vendor should supply the proper torque value. This ensures that no impact loads due to relative movement of the impeller and shaft becur during pump operation. C. Bearings - The bearings shall be in'spected for proper fit
,/s) onto the shaft and into the housing, scoring, overheating, b and fatigue damage.
.l i. The inner raceway shall be verified to be firmly held on the shaft, i.e., the raceway cannot turn on the shaft. A clearance of +0.0003/-0.0002 inches shall be verified for the line bearing and +0.0003/-0.0004 inches for the thrust bearing (Reference 3). Also, l the raceway shall be verified with a feeler gauge to be pressed firmly against the shaft shoulder. These conditions indicate that the bearing has been installed cprrectly (Reference 2).
- 11. The outer raceway shall be verified to be firmly held in the housing, i.e., the raceway cannot turn in the housing (Reference 2). A clearance of +0.001/-
0J006 inches shall be verified for the line bearing and +0.0024/-0.0001 inches for the thrust bearing a (Reference 3). t 9.__ 0- ' fle
o l 7, 111. The innqr races of the duplex mounted thrust bearings ! I shall be verified to be in contact and that the C) ( thrust bearing lock nut is tight. The pump manual (Reference 2) ptovides only this guidance. Because overtightne.ss may_ damage the bearings, the bearing vendor should supply the proper torque value. These conditions indicate that the thrust bearing has been installed correctly (Reference 2), iv. The balls and the raceways shall be visually inspected for cracking, scoring, and signs of overheating. .The balls and raceways shall be. free of cracks, substantial score marks, and signs of overheating. Any damage shall be evaluated on a case basis. This will indicate that the bearings were not damaged. I; To record the results of the inspections, data sheets should be developed. These data sheets should include space for recording clearances at the casing ring-impeller, stuffing box ring-impeller, and the stuffing box-shaft;. shaft TIR values; bearing-shaft clearances for the line bearing and thrust bearing; and bearing-housing clearances for the line bearing and thrust bearing. Sketches of damaged areas and i ) remarks on component conditions should be accommodated on these sheets. It is also recommended that this inspection be documented by photographs l of the components. REFERENCE
- 1. Florida Power Corporation, Crystal River Unit 3 Maintenance Procedure MP-131, " Maintenance of Building Spray and Decay Heat
~
Pumps," Revision 23 dated 01/27/89. L 2. Florida Power Corporation Instruction Manual Number 7, "'Worthington Centrifugal vumps Types HN, HNT, and HND Instructions," Revision 3.
..J
- 3. SKF Product Catalog Number 450B,1974. 4 i .
n
2 + t
. iii. The inner races of the duplex mounted thrust bearings
[ A shall be verified to be in. contact and that the .
~
. thrust bearing lock nut is tight. The pump manual (Reference 2) provides only this guidance. Because overtightness may damage the bearings, the bearing
[;; vendor should supply the proper torque value.. These conditicns indicate that the thrust bearing has been installed correctly (Reference 2). n iv. The balls and the raceways shall be visually inspected for cracking,. scoring, and signs of overheating. The balls and raceways shall be free of cracks, substantial score marks,.and signs of overheating. Any damage shall be evaluated on a case. basis. This will indicate that the bearings were not lj damaged. [ l '. To record the'results'of the inspections,' data sheets should be , .i developed. These data sheets should include space for recording clearances at the casing ring-impeller, stuffing box ring-impeller, and. the stuffing box-shaft; shaft TIR values; bearing-shaft clearances for the line bearing and thrust bearing; and bearing-hpusing clearances for the line. bearing and thrust bearing. Sketches of damaged areas 'and remarks on component conditions should be accommodated on these sheets. It is also recommended that this inspection be documented by photographs [' of the components. REFERENCE
- 1. Florida Power Corporation, Crystal River Unit 3 Maintenance Procedure MP-131, " Maintenance of Building Spray and Decay Heat Pumps," Revision 23 dated 01/27/8g.
j
- 2. Florida Power Corporation Instruction Manual Number 7, "Worthington l Centrifugal Pumps-Types HN, HNT, and HND instructions," Revision 3.
rn - 3. SKF Product Catalog Number 450B, 1974. L .
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LMPR ASSOCIATES, INC/ , u.; -o e _}r Y k-cr h e. APPENDIX C "hjf.
,L e, .,
J Evaluation of Results from' Crystal River Unit 3
.. Test PT-321, Decay-Heat Pump 3B Minimum-Flow Test s.
J
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' L.:
i r ie -- a f (1 s l'~ t:! r 4
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- pt.
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- - - = _ . _ _ _ - - - _ _ _ _ _ - _ . - . . . - _ _ . . _ _ . _ _ , _ _ . _ . _ _ _ _ _ _ , _ _ _ _ ___ _
MPR . ASSOCIATES. INC. 4 V( , May 2, 1989
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Mr.'D. E. Porter {. Florida Power Corporation 3201 34th Street, South P.O. Box 14042 t- St. Petersburg, FI 33733 Attn: E. Morea
Subject:
Crystal River Unit 3 Decay Heat Pump Low Flow Operability Test - Evaluation of Test Results
.[
j'
Dear Mr. Porter:
L The purpose of this letter is to forward our evaluation of the Decay Heat Pump Low Flow Operability Test results (Enclosure 1). These tests are to demonstrate the adequacy of the pump for low flow operations during a small break loss-of-coolant accident (SBLOCA). Specifically, daring an SBLOCA, the following are required: o The rimp must be capable of operating for at least 5 hours at . flow as low as 500 gpm.
,7
! o The pump must be capable of operation at an available net positive suction head (NPSHA) as low as 14 ft (while taking r
suction from the containment sump).
\
- By comparison, the CR-3 pump was tested and gave satisfactory performance (indicated no permanent degradation) under the follo # g
-f conditions:
o Operation at full rated flow of 3000 gpm. o Operation for 10 hours at an indicated nominal flow of 400 gpm. u Operation for 1/4 hour at the miniene flow (approximately 130 [_ ,
- gpm indicated flow).
L o Subsequent operation at full rated flow of 3000 gpm. j i- o Operation with an NPSHA of about 115 feet, with suction and discharge from the borated water storage tank (BWST).- I Since these tests conservatively cover t.he required low flow operating conditions of 5 hours at 500 gpm, the pump is considered satisfactory for 7-(} L low flow operations. 1050 CONNECTICUT AVENUE. N W. WAsHINGTDN D. C. 20036 202 659 2320
.. ._ _ _ _ _ _ _ _ _ = _ _ _ _ _ _ - _ - _
W" MPR ASSOCIATES. INC. Mr. D. E. Porter May 2, 1989
- The difference in the NPSHA between the test and the SBLOCA occurs P because the pump. takes suction from the BWST during the test (which is required from practical considerations) but takes suction from the containment sump during an SBLOCA. This difference is not considered '
significant regarding low flow operations, because the pump would still meet the vendor's required NPSH (estimated to be about 7 feet at flows less than 1000 gpm) during an SBLOCA. I' Pump vibration could.be different as NPSHA is reduced; however, the
- i. vibration levels measured during the test indicate substantial margin is available for vibration increases. No substantial change in vibration would be expected due to reduced NPSHA as long as NPSHA is above required NPSH, based on test data for another pump. In addition, only a few psi in containment pressure (which would in all likelihood actually exist) would substantially increase the NPSHA during an SBLOCA. Finally, the a tested pump will be disassembled. and inspected to confirm no significant I degradation during tha test. Accordingly, the tests performed are considered sufficient to demonstrate pump adequacy for the required low flow operations.
t If you have any questions or comments regarding this letter or its enclosure, please do not hesitate to call me. Sincerely, ,/7 i a swM Alan B. Russell Enclosure ce; J. R. Maseda i E. C. Simpson L C. B. Doyel u u
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U d. [ ', C.
.___ _ . _ .__ _ __ __ _ __ -___-_ _ _ _ _ _ _ _ _ _ a
- ._ _~__ _ - _ - t
;MPR ASSOCIATES, INC,
[ - to Mr. D.'E. Porter dated May 2, 1989
- ( m) .
I EVALUATION OF RESULTS FROM CRYSTAL RIVER UNIT 3 TEST PT-321, DECAY HEAT PUMP 3B MINIMUM FLOW TEST 4 PURPOSE L ,. The purpose of this test is.to obtain performance data from decay heat
- l. pump 3B at low flow rates to assess the acceptability of decay heat pump operation at the low flow rates expected during a small-break loss-of-coolant accident.
[ INTRODUCTION i NRC Bulletin 88-04 identifies two concerns for safety-related centrifugal pumps: interaction of parallel operating pumps that share a minimum flow line, and insufficient minimum flow line capacity to prevent damage from hydraulic instability. Florida Power Corporation (FPC) has determined that the Crystal River Unit 3 decay heat pumps could potentially be impacted by the latter concern. A possible low-flow operating condition [ (piggyback mode) during a small-break loss-of-coolant accident (SBLOCA) could result in pump operation that exceeds the pump vendor's (Dresser) conservative operating limits for low flows. The piggy-back mode of operation would result in a decay heat pump flow of approximately 500 gpm l' for 5 hours with an available net positive suction head (NPSHA) of 14 L feet (suction would be aligned from the reactor building sump). Dresser provided the following operating limits for these pumps to ensure against ,
. hydraulically-induced damage (References I and 2): continuous operation at flow rates above 2350 gpm,100 hours per year at 1200 gpm, and two hours for the life of the pump at 80 gpm. Dresser does not have a
[ specific operating limit for 500 gpm.
- \ '
Dresser's operating limits at low flows appeared to be very conse'rvative based on pump operating experience, and Dresser acknowledged that they
- had no test data for this pump design, requiring them to adopt '
h - se
E f, %
'/ 7 conservative operating limits in the absence of hard data. .Accordingly, LU a test at' Crystal River Unit 3 was developed to measure the pump's .
operating characteristics at low flow and ensure that operation in the
, piggy-back mode would _not result in damage that would prevent the pump I from functioning. This. test, completed on April 14, 1989, is to be confirmed by a pump teardown inspection that assesses the conditions of L the impeller, wear rings, shaft, and bearings.-
TEST DESCRIPTION [ s The test was designed to simulate operating conditions expected during the piggy-back mode as closely as was practical. The test consisted of n operating Decay Heat Pump 3B with pump suction and discharge' lined up v from and to the Borated Water Storage Tank (BWST). Total indicated pump i.
. l. flow was throttled from the design flow (3000 gpm) down to about 400 gpm and performance data was taken at several intermediate flow rates during i this throttling. The total indicated flow rate was held at approximately 400 gpm for 10 hours to provide sufficient operating -
history at this low flow, enveloping the expected operation during the
- ff..
piggyback mode. After this 10-hour hold, flow was throttled to minimum i flow, i.e., the flow path to the BWST was isolated so that the pump's I- minimum recirculation line was the only flow path (indicated capacity about 130 gpm). Then, the flow was increased to design flow, where performance data was taken to show no performance degradation occurred as a result of the test. NPSHA for the test (about 115 feet) was substantially higher than expected during piggy-back operation, and it [ was not practical to reduce the NPSHA to the expected value. Procedure r PT-321, ' Decay Heat Pump 3B Minimum Flow Test" Revision 0 was developed and used for this test. I L The following parameters were monitored during the test: o Pump suction and discharge pressure to monitor the head characteristic of the pump; o Pump flow to the BWST and flow through the minimum flow line r to monitor total pump flow; m.
.' h .l
- E
i 8 l. l f4 o Pump motor current to monitor the power draw of the pump; l 'o - .' Process suction and discharge temperatures to monitor temperature rise across the pump; ir o Pump bearing cooling water iniet and outlet' temperatures to ' -i monitor changes in bearing temperature rise; and' o Pump bearing vibration .verti' cal and horizontal velocities at the line and thrust bearings and axial velocity at the thrust bearing to monitor bearing condition and dynamic loading of the bearings. p i In addition, bearing oil samples were taken before and after the test and analyzed to verify bearing condition was not affected by the test. t TEST RESULT 3 o Head-Flow - Pung developed head at various flows measured during the test was compared against the pump vendor's curve in Figure 1. The test data was generally above, but within 5%, of the vendor's turve. Further, the head at design flow measured before and after the low flow test was unchanged, indicating no degradation of pump function from the test. Based on this, the pump was functioning as expected.
, o . Motor Power - The motor current data indicates that the motor power is within 6% cf the vendor's curve, as shown on Figure 1.
Cased on this, the pump was drawing power as expected. l' o Temperatures
- Process - The temperature rise across the pump was measured to determine if flow is adequate to prevent y
excessive pump heatup. ~Throughout the 10 hour hold at about 400 gps, the temperature rise across the pump was about the same as for rated flow and was insignificant as 1 shown in Figure 2. i .. I - Bearina Coolina W41Ar - The temperature rise across the y bearing cooling water jacket was monitored to ensure the bearing was not being overloaded or degraded (overheating
- would be an indication of these conditions). No temperature rise across the bearings was ceasured at any flow, indicating that the bearing , did not produce an apprinciable amount of heat. Thus, bearing overload does F not appear to be a concern.
L y . U
T. ,
, s ~
p
;]) ;
h . Lk Jg' o lPu=n'Bearina Vibration - The vibration;at'each be'aring was measured to indicate whether dynamic loads' from low-flow g operation would resultnin bearing.or shaft failure. At the
. indicated' flow rate of about 400 gpm, ghrust bearing vibration E in the vertical direction was 0.46 ips - (all other measured ,.r" vibrations were less than this as'shown on Figure 3). During d the 10 hour'run period at this flow, all vibrations were fairly; steady,without an upward trend of vibration. magnitude.- When.
v flow was throttled.to minimum'. flow, the thrust bearing vertical 1 vibration' increased to 0.54 ips. In addition, the vibration levels 'at the' pump flow rate of 3000 gpm at the end-of the test were not significantly different than the vibration levels j' measured at the same flow rate at the start of the test. This , i; result indicates that lo significant degradation regarding vibration occurred as a result of the test. Operating experience of the decay heat- pumps at Crystal' River Unit 3 includes a shaft failure after nine days of operation at minimum flow (Reference 3). Based on the April 1989 test data, c: the vibration levels measured at minimum flow were about 17%
~
4 higher than the vibration levels measured at the indicated flow of 400 gpm. Therefore .the vibration experienced.during this previous failure should have been about 17% higher than if the i flow rate was at 400 gpm, indicating that the pump could have operated at 400 gpm for longer than nine days. Accordingly.
~
in comparison, the requirement for operation at 500 gpm for-P only five hours (versus nine days) indicates substantial margin regarding vibration. The effects of NPSHA on vibration were not evaluated during this test because NPSHA could not be reduced to the expected _ SBLOCA NPSHA value of 14 feet in a practical manner. However,
' experiments done on a similar style of pump (Reference 4)'
suggest-that fluctuating radial and axial loads do not change significantly for an NPSHA above the required net positive suction head (NPSHR). The NPSHA during the decay heat pump I:, test was about 115 feet, and the NPSHA_during an SBLOCA is I- about 14 feet. Both of these values are above the vendor's estimated NPSHR value of 7' feet (this value is from the
.P estimated performance curves for these pumps - Referenco 5 - at the lowest indicated flow,1000 gpe). Accordingly, the u difference in NPSHA between the test and SBLOCA operating conditions are insignificant with regard to vibration.
This is the average value.for this bearing and direction over the 10 hours at this flow rate. The peak value during this 10 dlP a hours was 0.55 ips at the half hour mark when minor flow . adjustments were in process. These flow adjustments are
.m believed to be the cause of this h,igh~ reading, because vibratiuns returned to a steady reading of around 0.46 ips after the adjustments were made. ;
b- m m , A
.. .y. ~~_- +
c W ,? 7 r "- In addition, the' vibration levels at indicated flows above 1000-1250 gpm were as low as the vibration levels at.the design
' Q fl ow. .
i p o Bearino 011' Analysis - Oil samples taken before and after the 4' . test were analyzed and compared to each other to assess bearing degradation during the test. This oil analysis indicates that no bearing degradation. occurred during the test. h x I o. Pa=a Teardown Inspection - This' inspection will be performed to confirm that no physical damage to the pump occurred.
'l' TEST CONCLUSIONS-Y' This test verified that the decay heat pumps will operate acceptably 1
during an SBLOCA,' because the decay heat pump operated acceptably for 10 hours at an indicated flow rate of approximately 400 gpm which is a
'- lower flow and longer. time than expected during piggy-back operation (approximately 500 gpm for 5 hours). The process-temperature data did 'h not indicate a concern for pump overheating. ' Bearing cooling. water 4nlet and outlet temperatures did not diverge to indicate bearing overheating,
- and.the before and after oil samples indicated no degradation of the bearings. There are substantial margins for the vibration magnitudes
~
{- expected during' piggy-back operation. Also, the effect of NPSHA on vibration levels are considered insignificant. 1 The test data also indicates that pump operating characteristics (i.e., p vibration and process temperatures) at 1000-1250 gpm indicated flow are L no different than at the design flow (3000 gpm). This indicates that indefinite pump operation at flows down to 1000-1250 gpm is as acceptable as operation at 3000 gps. REFERENCES b Dresser tetter to Gilbert Associates, " Crystal River Unit #3 DHP 1.
- 1A,B,BSP 1A,B, Pump Minimum Flow Evaluation" Dated June 22, 1988.
- 2. Facsimile. Submittal from W.C. Smith (Dresser) to E. Morea (FPC) p Dated 9/6/88.
L. 5-U
~ . - _ ... , 4 . ,. .
1: j :s 7- < 3. Letter from B. L. Griffin (FPC) to R.W. Reid'(U.S. NRC) Dated *
'j' l... 1 July 7, 1978.-
- 4. . Turton, R.K., Goss, M.;-"A Study of the' Fluctuating and Steady '
Forces on a Conventional Centrifugal Pump," from the Eighth tr, Technical Conference of the British Pump Manufacturer's Association,. .
>J' Dated March 29-31,'1983, _I
.1 s
5.. -Worthington Drawing;E 185234, "8HN194", Dated May 9, 1967.
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- . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ l
MPR ACCOCIATES, INC.
, APPENDIX D Preliminary Evaluation of the Post Low-Flow Test Decay-Heat Pump Inspection P
i 4 o ( 1
-Il l
l l. l l
p,< < L. p m. E . MPR ASSOCIATES. INC. (}l May 19, 1989 1' 3 , Mr. D. E. Porter-T i,
- Florida' Power Corporation
. 3201 34th Street, South P.O. Box 14042 Ly St. Petersburg, FL 33733
' At'.n: Mr. E. M. Morea c ,
i Sibject: Crystal River Unit 3 Decay Heat Pump Low Flow Operability r/h' Test - Preliminary Evaluation of Pump Inspection Results i
Dear Mr. Porter:
The purpose:of' this. letter is to forward our preliminary evaluation of the inspection results for Decay Heat Pump 3B. This inspection was-
;Jt. performed after the Decay Heat Pump 3B Low Flow Operability. Test to verify that the test did not cause significant degradation of the pump, i.e.,-the pump's function was.not compromised. Overall,.the results of. 'A' the inspection: indicate that no significant degradation of the pump L/ - occurred during the test.
r hi As' planned, a final test and inspection report will be provided four weeks after the inspection. This final report will provide more detail- on the inspection results. j"' If you have any questions or comments concerning this letter or its enclosure, please do not hesitate to call me. Sincerely,. f i,.. OA~ B& Alan B. Russell r0 Enclosure
- 1
",6 cc: J. R. Maseda E. C. Simpson l.h, C. B. Doyal r
j
--f a
1050 CoNNecTecWT AVCNug. N.W. WASMSNCTON. D.C. 20036 202 659 2320
. . MPR ASSOCIATES. INC. M to
"~ MPR Letter Dated May 19, 1989 PRELIMINARY EVALUATION OF THE POST LOW-Flod TEST DECAY HEAT PUMP INSPECTION f
.[
PURP,0SE 7' The purpose of this inspection is to verify that the low-flow operability test of Decay Heat Pump 3B, performed on April 13-14, 1989 at Crystal River Unit 3, did not result in significant degradation of the pump y (i.e., the pump's function was not compromised).
't.
CONCLUSIONS , Overall, the pump inspection revealed no significant degradation of the pump due to the low-flow test. The only damage indicated was minor wear 4. of the stuffing box ring / impeller, but this damage did not result in an increased diametral clearance outside the allowed clearance. These inspection results verify the conclusions of the low-flow test evaluation that the pump can operate satisfactorily for the required low flow [ operating conditions of 500 gpm for 5 hours (see Reference 1). t SCOPE OF INSPECTION The inspection, requirements are detai, led in Reference 2. Briefly, the L scope of these inspections are as follows: L o Pump Casing - Inspect wear ring for excessive wear and check
.; wear ring diametral clearance with the impeller. Also, inspect the volute tongues for severe cavitation-induced damage.
~
o Stuffing Box Head - Inspect wear ring and stuffing box bushirg a for excessive wear and check wear ring diametral clearance with the impeller and bushing diametral clearance with the shaft sleeve. t' h i .
-11
e l T~ .o Shaft - Check the straightness of the' shaft. Examine the shaft for cracks using' liquid penetrant examination. Also, inspect
- l & the shaft sleeve.for wear.
U Impeller - Inspect the pressure side of the impeller vanes at
- . o
;" .the suction-and discharge for severe cavitation damage.
Inspect the impeller wear surfaces for. excessive wear. Examine s I ,_ - the shrouds at the impeller discharge for cracking using liquid I ' penetrant examination. Verify that the impeller is tight on
-the shaft.- -
l p, - Lh ~ o Bearings'- Verify raceway clearances / interferences with the shaft.and the bearing housing are within the bearing
- .- specifications. Verify the thrust bearings were installed l ;{!
- orrectly. Inspect the balls and raceways of both bearings for y cracking, scoring, and overheating.
1a 11 INSPECTION RESULTS
- A summary of the inspection results is provided below.
L '[: . i- 3 . Pumo Casino - The wear. ring was in good condition:. no significant rubbing was identified. The diametral clearance of the wear ring with the impeller wear surface was 0.047 inches which is in the allowable range (0.015-0.064 inches). Volute tongues did not have any evidence of cavitation induced damage. There was no damage noted on any i ' 'I observable part of the casing. Thus, the low-flow test did not result in significant I ( degradation of the pump casing. Li 1 . Stuffing The stuffing box wear ring showed signs of rubbing, l-f' Box Head - however, the wear was not excessive, estimated to be about l O.001 inches deep (the wear ring was reused). The .
- diametral clearance of the wear ring with the impeller r- - wear 5Jrface was 0.025 inches which is in the allowable
! range (0.015-0.054 inches). The diametral l~
1 -jl ' i n o 2 , i b
?"Y ,
clearance of the stuffing box bushing and shaft sleeve was c 0.029 in. This clearance is.within the vendors allowable
-) clearance (0.026-0.036 inches).
Sh3 ff1 - The maximum runout of the shaft was 0.001 ir.ches which is in the allowable rar.3e (<0.002 inches). The liquid penetrant examination of the shaft revealed no crack j indications, even in the impeller keyway or in the fillets. The shaft sleeve did not have any significant wear at the stuffing box bushing position.
;. Thus, the low-flow test did not result in significant I degradation of the shaft.
\,
Imoeller - The pressura _ side of the impeller vanes at the suction did not have any evidence of cavitation-induced damage. Likewise, the discharge end of the impeller vanes did not have any evidence of cavitation-induced damage. Rubbing O was evident on the impeller wear surface with the stuffing box ring. Consistent with the wear.on the stuffing box
~
. ring, the wear on the impeller was not excessive, also
~
estimated to be about 0.001 inches deep (the impeller was q reused). The impeller wear surface with the casing ring did not hhve any significant wear. Liquid penetrant exami.1ation of the shrouds revealed no crack indications. lJ. The loosening torque for the impeller nut was 150 ft-lbs which implies- an assembly' torque of about 165-185 ft-lbs (assuming no icosening occurred in service). In discussions .with maintenance personnel, this torque value is consistent with past practice. This' torque is significantly less than the vendor-recommended assembly j
" torque of 408 ft-lbs. However, the icseller required i mechanical assistance (i.e., wedges) to be removed from
'i - the shaft, and diametral measurements revealed a
~~
l l 0.0005 inch interference fit, indicating that the impeller (~^ was sufficiently tight on the shaft. )
'L] ~
1 Thus, tha low-flow test did not result in significant degradation of the impeller. 1
; Bearinas - Both bearings were snug in the housing and on the shaft
!. based on the effort required to remove the bearings. The ' ]
bearing inner and outer diameters, the shaft outer I diameter, and the bearing housing inner diameter were f measured for the line bearing and the thrust bearing to J determine the clearances / interferences of the mating f~ surfaces. However, the design fit values have v.agnitudes in the 1/10,000th of an inch range, and the micrometers used to measure the diameters measured in the 1/1,000th of i
; an inch range (with a measurement tolerance of 10.001 I inches). Thus, the measurements were not precise enough to compare against the design values but are presented
'f ) below to verify that the clearances / interferences are in the range of the design values.
I i Clearance Measured Desian Value 1 Line Berring to +0.0005 in. -0.0001 to -0.0012 in. Shaft 10.002 in.
. Thrust Bearing to +0.0005 in. -0.0001 to -0.0012 in.
3 Shaft 10.002 in. L ; Line Bearing to +0.002 in. +0.0018 to -0.0006 in. 1 Housing ~ 10.002 in. Thrust Bearing to +0.0005 in, to.0018 to -0.0006 in. } Housing 10.002 ir.. l c The measured clearances are considorod to be acceptabic bzsed on the limitations of the micrometers and the observed l tightness during the disassembly. ] I l l - r . I __m______ __._
'f , The inner races of the tandrm-mounted thrust bearings were [ verified to be in contact with each other and the thrust
~j
"['[d -
~
bearing lock nut was verified to be tight. These indicate that the thrust bearings were mounted correctly.
. The. thrust bearing balls.and raceways were in good condition:
no indications of galling, scoring or' overheating were found. 1 The line bearing balls and raceways also* had no indications of galling, scoring, or overheating. j Thus, the low-flow test did not result in significant i; -degradation of the bearings, a REFERENCES
- 1. MPR Letter from A. B. Russell to D. E. Porter (FPC), " Crystal River Unit 3 Decay Heat Pump Low Flow Operability Test - Evaluation of Test JL Results," Dated May 2,1989.
- 2. MPR Letter from A. B. Russell to D. E. Porter (FPC), " Crystal River Unit 3 Decay Heat Purp Low Flow Operability Test - Technical Basis for
[ Test Acceptance Criteria and Pump Inspection Requirements" Dated April 12, 1989. I
,7 Y
I . L O 1 i t >
MPR ' ACCOCIATES. INC. APPENDIX E Review of th,. Operating History of the Crystal River Unit 3 Decay-Heat Pumps 1 r I' 4 l I Ov l l f I l l. l L I l
= _ ._ .__ _. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ -
7 l l V l l
,; 3 .
V, MPR ASSOCIATES. INC. June 27, 1989 1 Mr. D. E.- Porter I' Florida Power Corporation ,
!. 320134th Street, South L P.O. Box 14042 St. Petersburg, FL 33733 Attn: E. N.orea
[
Subject:
Crystal River Unit 3 Decay-Heat Pumps t Re. view of Decay-Heat Pump Operating History
Dear Mr. Porter:
Enclosed please find a report of our review of the operating history 7 of the decay-ht.at pumps at Crystal River Unit 3. This review was made at
. the request of Florida Power Corporation to assess whether a connection is t evident between low-flow operation and pump degradation experienced. Our review included available records from the time period December 1976 to December 1987. We understand that no problems requiring repairs have
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1 cccurred since December 1987. The instances of pump degradation identified in our review were of three general types: excessive seal leakage, bearing failures, and shaft degradation. In only one instance was there a suggestion of a connection with low-flow operation, and after evaluation we conclude that it was i related to operation with a mismachined pump casing (which was replaced in L 1980) and not related to low-flow operation. .Accordingly, the results of our review indicate that no connection between low-flow operation arid pump
!. degradation is evident in the operating histcry. j I
The operating history and a more detailed discussion of our review are provided in the enclosed report. Please call if you have any questions or comments. i SincerpAy, ~ l
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A an B. Russell / /L Enclosure cc: J. R. Maseda
- E. C. Simpson C. B. Doyel t _
_; 1050 CONNtcT: CUT AvtNut, N W. WASHINGTON D.C. 20036 202-659 2320
[: 3 L I
- MPR ASSOCIATES. INC.
- l. - . . Enclosure to
.' MPR Letter dated June 27, 1989 l
'h-REVIEW 0F THE OPERATING HISTORY 0F THE CRYSTAL RIVER UNIT 3 L( DECAY-HEAT PUMPS i.
PURPOSE The purpose of this report is to provide the results of a review of the
-j' - operating history of. the Crystal River Unit 3 decay-heat pumps to determine
!' - whether low-flow operation caused or contributed to any failures.
CONCLUSIONS There have been twelve instances between December 1976 (hot functional testing) and December 1987 where damage to the two Crystal River Unit 3 decay-heat pumps has occurred. The damage includes three broken shafts, i one cracked shaft, two bearing failures, and six instances of excessive seal leakage.. No failures have occurred since December 1987. Only one of the twelve occurrences had any suggestion of a connection with j low-flow operation, and after evaluation, the failure is considered not to be connected to low-flow operation. Accordingly, the operating history of
, the decay-heat p.anps does not demonstrate a connectics Letween low-flow i
L operationandhumpdagradation. 4 DISCUSSION OF OPERATING HISTORY a ..
. The identified occurresce. of decay-heat pump degradation can be grouped
,; into three general typas: excessive seal leakes, bearing failures, and shaft degradation. Each of these general typo is discussed below. This
( is followed by a chronological list of the twelve identified instances of pump degradation. I y .
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--_m--_____._-___-._________m_ _ _ _ _ _
L-,: 4 Excessive Seal Leakaae Excessive seal-leakage has occurred in six different instances spread out over time and in both pumps. Two of the occurrences of excessive seal leakage early in life were attributed by B&W.to a materials ' [' problem with the seal bellows. The later occurrences of seal leakage-s occur at intervals of several years. No probable cause was identified for the-later occurrences of seal leakage. Industry experience in r many types of' pumps has been that shaft seals require periodic u j' overhaul. Hence, the seal repairs do not. appear to be unusual or l unexpected. No connection to low flow is evident in the shaft seal experience. Bearino Failures J' The two bearing failures that have occurred have been attributed, at
.{' the time of failure by B&W, and at a later time by Impe11 Corporation, to improper installation. There was limited if any low-flow operation of the pumps and limits against low-flow operation had been imposed.
Hence, no connection between low-flow operation and the bearing failures is indicated. l' Shaft Degradation Two of the three shaft failures and the one confirmed instance of i shaft cracking occurred in dip-1A early in life when the pump was equipped with a significant,y mismachined casing. The first shaft
~( failed at the impeller keyway during hot-functional testing after nine days of operation at minimum recirculation flow (80-100 gpm). The failure was initially attributed to the extended low-flow operation.
i However, the second shaft also failed at the impeller keyway after operation at near-design flow. The post-failure inspection showed that the eye-side impeller shroud had contacted the casing; it was L found that the casing had been mismachined during manufacture such ! that it was skewed to the rotor centerline, allowing contact with the i
,- impeller A replacement shaft also cracked at the impeller keyway
-i"- after temporary repairs were inade to the casing. The cracks were attributed to a loose key fit and the hydraulic forces associated with the distorted casing. The casing was replaced and no additional
' cracking failures have occurred. The shaft failure location in these <
instances is consistent with application of an end moment to the rotor, which would be expected with the skewed casing, and is not consistent with ,the large radial loading ex>ected at Iow-flow
,~ , operation. Accordingly, it is considered t1at the skewed casing, and not low-flow operation, is the primary cause of these failures.
However, it is important to note that, even with the skewed casing, the pump operated for nine days at minimum recirculation flow. ! The one remaining shaft failure occurred in DHP-1B in 1986 from air entrainment as a result of insufficient reactor coolant system level and was not related to the operating flow. a
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l . Chronological List of Failuret Each failure from December 1976 to December 1987 is described below in chronological order. The references for each event are identified. I
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Qgig Description of Event References
! December, 1976 The shaft of Pump DHP-1A failed 1, 2, 3, 25 after operating for about nine days ... at minimum recirculation flow. The fracture occurred transversely across the shaft at the impeller keyway. Pump DHP-1B's shaft was J inspected, and indications were i found in the keyway area. However, the indications were never , confirmed to be cracks. Babcock and Wilcox (B&W) reported that the DHP-1B shaft could be reused until the replacement shaft arrived, as long as the indications were ground out. The operating history of DHP-1B before this inspection is not known.
The failure of the DHP-1A shaft and the potential problem with the DHP-1B shaft were attributed by B&W to fatigue'due to operation at minimum recirculation flev based on
; a visual inspection of the CFPelA i Sha n . The replacer,ent shafts were reported by EAW and FPC to have -,- been manufactured with more 4 L generously radiused keywan to i reduce stress concentrations :nd to have been more thoroughly examit,'d with non-destructive examination methods than the original shafts.
In addition, miniu m recirculation ! c flow operation was limited to a 80 hours over the lifa of the pump. t 1 l ____ _ _ _ - _ _ _ _ _ _ _ _ - _ _ .l
l , f. l c. s;. . Descriot Dn of Event References
] QA1.1 ,
,- April, 1978 The shaft of pump DHP-1A failed at 3,4,5,6, the same location as in 1976 21, 22, 23, L ,- (impeller keyway) despite the 24, 25 improved impeller keyway geometry and limited if any operation at minimum recirculation flow.
.F Inspections of the pump showed that i .i . the pump casing was skewed. B&W reported the probable cause of the E failure was bending fatigue caused by interference between the impeller and the skewed casing.
The interference area on the casing
- was machined out, and the impeller
- i. was modified to sit farther back on the shaft These two fixes 1 ir. creased the clearance between the t impeller and the casing to prevent further interference.
i I August, 1978 A bearing on pump DHP-1A failed. 7 Inspections revealed that the oil rings and set screws were loose. The probable cause of the failure (qj i, was attributed by Impell Corporation (in 1980).to be the result of improper installation. No corrective action was identified. March, 1979 Pump DHP-1A experienced excessive 8, 9, 10 seal leakage, requiring replacement of the seal. The cause of this.
leakage was not' identified, but B&W L indicated that the bellows showed evidence of embrittlement. The i
seal was replaced. Pump DHP-18 experienced excessive seal leakage, requiring seal replacement. This leakage was attributed by B&W and Crane (seal manufacturer) to a a failure of the bellows. The seal was replaced. f f*: 1 L O 4 l- -. - -.-.----
l L. QAlt Description of Event Referenegg X/ . March,'1979: Both March 1979 instances of ( Continued) excessive seal leakage were similar and were believed by B&W and by . ,: Crane to be the result of the bellows and "0"-ring material not
- [ being nuclear grade due to a procurement error.
April, 1980 Pump DHP-1A experienced excessive 11, 12, 13, seal leakage. No probable cause 14, 15 was identified. During the pump teardown to replace the seal, shaft cracks were found in the impeller. y keyway. The failure was attributed
! by B&W to motion between the shaft I.' -
and impeller key. The motion was caused by increased key to keyway clearance (problems with assembly were suspected) and by dynamic loads related to the distorted pump
; casing. At this time che pump was
[ replaced with one (sa e model pump) obtained from Three Mile Island to eliminate the skewed casing as a lp potential cause of bearing and shaft failures. August, 1981 A bearing on pump DHP-1A failed. 16 This failure was attributed by BtW in 1982 to improper installation. May, 1983 Pump DHF-1B experienced excessive i -17
' seal leakage. No probable cause .
was identified. The seel was replaced. 1- Fe'aruary, 1986 The shaft of pt:r DHP-1B failed 18, 19 during decay heat removal operation L. when the reacter coolant level was below the minimum level. The r failure was att'ributed by B&W and FPC to air entrainipent- caused by [". vortexing and r.ubsequent torsional fatigue of the shaft. The failure occurred in the impeller keyway
'i corner. Stricter controls on reactor coolant level were put in place.
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L a s I QLt1 Description of Event References February,,1986 Pump DHP-1A experienced excessive 20, 26 seal leakage. No probable cause was identified. The seal was replaced. December, 1987 Pump DHP-1B experienced excessive 26 i' , seal leakage. No probable cause was identified. The seal was replaced. a.
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'O LQ REFERENCES
- 1. B&W Letter from E.L. Logan to J. Alberdi (FPC), " Decay Heat Pump DHP-1B", dated December 21, 1976, Document No. T1.2-620/0007-SOM324.
B&W Letter from E.L. Logan to J. Alberdi (FPC), " Decay Heat Pumps 2. DH-PIA and DH-PIB Shaft Replacements", dated March 1, 1977, Document No. T1.2-620/0007-SOM 367. ,I* 3. B&W Letter from G.T. Fairburn to R.S. Burns (FPC) " Decay Heat Pump / Shaft", dated September 8, 1977.-
- 4. B&W Letter from G.T. Fairburn to R.S. Burns (FPC) " Decay Heat Pump Operation", dated October 13, 1977.
[ 5. B&W Site Problem Report, " Decay Heat Pump Shaft Failure", dated 3 May 3, 1978, Document No. 13-620-0007-472.
- 6. FPC Inter-Office Correspondence from J. Cooper Jr. to 3.P. Beatty i Jr., "CR-3 Decay Heat Pump 1-A (Fig #5), Worthington Serial
#1624920, Model # HN-194 GPM 3000 Head 350" dated July 13, 1978, Document No. CS-78-155/3-0-6-a-1.
- 7. Impell Report No. 03-0920-1146, " Evaluation of Alternatives for Improving Decay Heat Pump Reliability", dated March 16, 1988.
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- 8. FPC Inter-0ffice Correspondence, from J. Cooper Jr. to G.P. Beatty Jr., " Activity Review #7, Decay Heat Removal Pump (DHP-1B) Repair",
dated March 20, 1979, Document No. 3-0-6-a-1/CS-79-82.
- 9. B&W Maorandum from R.V. Green to File, " Trip Report to Florida -
March 16 through March 18", dated March 20, 1979, Document No. NSS-7/T3.36.
- 10. B&W Memorandum from R.V. Green to J.T. Janis, " Failure of hechanict!
;- Seals on DH Prmps"., dated March 23, 1979, Document No. NSS-7/3.36,
- 11. B&W Site Problem Report, " Crack Shaft on "A" DH Pump", datd April 21, 1980, Document No. 13-07-0587-00.
h, 12. B&W Letter from R.L. Pittman to DJ. Fuole (FPC), " Crystal River 11. Nuclear Station, Failed Shaft Ceanclusion on IA DHP", dated July 21, r" 1930, Document No. CR-80-295. y~ ~
- 13. B&W Letter from R.L. Pittman to D.C. Poole (FPC), " Report on the Crystal River 3 Decay Heat Pumps", dated August 18, 1980, Document No. CR-80-308.
i-
- 14. B&W Report " Report on the Crystal River Unit #3 Decay Heat Pumps" dated August 1980 (Enclosure to Reference 13).
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- 15. rPC Nonconforming Operation Report, "DHP-1A Cracked Shaft", dated April 19, 1980, Document No. 80-90. !
- 16. B&W Report " Decay Heat Pump Design and Performance Comparisons and Options.for' Performance Improvement", dated January 1982.
- 17. B&W Trip Report by R.V. Green, " Provide A&C to .FPC for Repair of Decay Heat Pump DH-PIB", dated June 6, 1983, Document No. 432.
t' i 18. FPC Letter from R.C. Widell to NRC, " Crystal River Unit 3, Docket No. 50-302, Operating License No. DPR-72, Licensee Event Report
. No. 86-003-02", dated September 3, 1986, Document No. 3F0986-06.
- 19. FPC Licensee Event Report No. 86-003-02, " Loss of Decay Heat Removal Capacity", dated September 3, 1986.
1 3, 20. FPC CR-3 Work Request Form No. 77015,
Subject:
DHP-1A Seal Leakage, dated February' 17, 1986.
- 21. B&W Letter from G.T. Fairburn'to Q.B. DuBois (FPC), "(Response to) letter, R.W. Reid, NRC, to W.P. Stewaic, FPC, dated 6/7/78", dated June 29, 1978.
- 22. FPC Letter from W.P. Stewart to J.P. O'Reilly (NRC), (forwards LER No. 78-020/01T-0) dated May 8, 1978.
- 23. FPC Licensee Event Report No. 78-020/01T-0 (Low Flow on DHP-1A),
dated April 27, 1978.
, 24. FPC Nonconforming Operation Report, " Low Flow on DHP-1A", dated April 25, 1978.
i 25. FPC Letter from B.L. Griffin to R.W. Reid (NRC), " Crystal River Unit .i
, No. 3, Docket No. 50-302, Operating Licensee No. DPR-72", dated July {
7, 1978. f {' 26. FPC data printout, " Machine History by Date and Tag #", pp. 810-817, dated February 17, 1989. j
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MPR . ASSOCIATED INC. I i .. 1
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,id j APPENDIX F
'MPR Calculations I 1. No./102-72/1 Rev. _, " Impeller Radial Loads at .the Fatigue Endurance l
Limit"
'l
- 2.- No.102-79/1 Rev. O, ' Estimate of Radial Thrust on Pump Impeller Based
'on Design Formulas"
- 3. No. 102-79/3.Rev. 1, " Axial Load on Impeller Required to cause Fatigue Failure at Keyway" c
[.
- 4. No. 102-79/4 Rev. O, " Relationship Between Hydraulically Induced I
. ;- Moment and Radial Force on Centrifugal Pump Impelle ' ].,
- r. .
- 5. No.102-79/5 Rev. > 0, " Radial Load and Moment Required' to Deflect Pump i , ,
Shaft Through Wear Ring Clearance" I No. 102-79/6 Rev. O, " Estimated Rating' Life of a Bearing as a Function
- G- 6.
of Applied Load" , I e5
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1050 Connecticut Ave., NW-Washington, DC 20036 CALCULATION NO. PREPARED BY CHECKED BY fM 8 A p r. G il
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9 MPR ASSOCIATES, INC. 1050 Connecticut Ave., NW-Washington, DC 20036 l ,q CALCULATION NO. PREPARED BY CHECKED BY
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MPR ASSOCIATES, INC. 1050 Connecticut AvD., NW-Washington, DC 20036 CALCULATON NO. PREPARED BY CHECKED BY lo2-7E// d" M ._ -Js/#/ M PAGE /g tu<deh Se>>srE vilv EfvA f%m 12ch 3, p. 9 , Ac - (uheye no!zh heJac, I; Kf , < s. : Kp = g (Ne -i ) * / wk g is he. ook h semo Av, A,i wula q ua /
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!. )' CALCULATK)N NO. PREPARED BY CHECKED BY a[^ n o2-72 / u c"~ M g g;,, , 4- '^** t .')
ga u - /,n,J- (c) r S Fita, M. 4, p. m -
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$g = (0.G9)(08){l.0)ll.0)Se'=- 0 55 Se '
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90 30 40 50 60 70 80 10 20
.V = Ms Maximum steady radial thrust coefficient for single volutes: curve I according to reference (1): curve 2 for large clearances tJoTE : C uizv6. 1 A P PLI E S Fo lt.
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r865 17 M 2- 77/ j DHP-1B OVERALL VIBRATION READINGS
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TI APRIL 13, 1989 htC> ' ['~
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' . [dE AH AV AA BH BV BA CH CV CA DH DV DA FLOW 2145 .04 .03 .05 .06 .09 .10 .18 .32 .12 .13 .09 .11 3000 GPM 2230 .04 .02 .05 .06 .08 .07 .15 .29 .10 .09 .21 .06 3000 2250 .05 .04 .06 .06 .07 .07 .11 .24 .09 .06 .16 .07 2000 ' 2305 .06 .04 .07 .07 .08 .12 .27 .10 .06 .18 .08 1500 2315 .07 .04 .07 .08 .08 .15 .29 .11 .09 .19 .08 1250 2330 .07 .05 .08 .09 .08 .20 .31 .13 .13 .23 .10 1000 2345 .07 .05 .08 .09 .08 .20 .34 .14 .17 .22 .11 800 e
2400 .08 .06 .08 .09 .10 .21 .35 .14 .15 .23 .11 600 0015 .08 .06 .09 .10 .11 .25 .37 .15 .14 .25 .12 500 e-0045 .08 .06 .10 .09 .12 .12 .25 .42 .16 .16 .31 .13 400 0115 .08 .05 .10 .11 .13 .15 .25 .55 .17 .18 .39 .13 400 0145 .10 .06 .12 .10 .12 .13 .24 .45 .16 .14 .31 .13 400
.09 .06 .12 .10 .11 .13 .24 .44 .16 .16 .32 .12 400 h5
- c. 45 .09 .06 .11 .10 .11 .13 .25 .46 .16 .15 .33 .13 400 3315. .10 .06 .12 .10 .11 .14 .26 .45 .17 .17 .31 .14 400 0345 .09 .05 .13 .10 .12 .14 .25 .47 .17 .19 .32 .13 400 0415 .09 .06 .12 .10 .11 .14 .25 .47 .17 .16 .30 .12 400 0445 .10 .06 .13 .10 .12 .14 .26 .46 .16 .16 .31 .12 400 3515 .10 .06 .12 .10 .12 .13 .26 .46 .16 .17 .31 .14 400 0545 .09 .06 .12 .11 .12 .14 .25 .46 .16 .18 .32 .12 400 3615 .09 .06 .12 .10 .12 .13 .25 .43 .16 .14 .31 .13 400 3645 .09 .06 .12 .10 .12 .13 .25 .46 .16 .17 .32 .12 400 0715 .09 .06 .12 .10 .12 .13 .23 .48 .17 .17 .29 .14 400
}3745 .08 .06 .12 .10 .11 .14 .27 .44 .18 .16 .31 .14 400 0815 .09 .06 .12 .09 .11 .13 .24 .45 .17 .17 .32 .12 400 L?45 .09 .06 .12 .10 .11 .14 .24 .45 .17 .16 .30 .12 400 5 .09 .06 .12 .10 .12 .13 .24 '. 4 6 .16 .14 .30 .13 400 i
l ! .. _ - - _ _ - - __-- l
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AA BH BV BA CH CV CA DH DV DA FLOW TIME AH AV 0945 .09 .06 .12 .10 .11 .14 .24 .46 .16 .16- .31 . 13 400
.11 .14 .24 .45 .17 .17 .31 .12 400 1015 .09 .06 .12 .10
.18 .29 .14 400 f 1045 .09 .06 .12 .10 .12 .14 .26 .44 .16
.i
.11 .10 .10 .13 .26 .45 .16 .18 .31 .11. 300 (
1105 .11 .06 , f
.12 .10 .12 .15 .24 .44 .17 .17 .30 .13 200 1120 .09 .05
.12 .12 .15 .28 .54 .18 .17 .35 .18' MIN FLOW 1125 .10 .06 .13
.08 .09 .18 .28 .09 .10 .22 .07 3000 1150 .04 .06 .05 .07 l
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by CALCULATION NO. PREPARED BY CHECK
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4 MPR ASSOCIATES, INC.~ 1050 Connecticut Ave., NW-Washington, DC 20036
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'CR3 Decay Heat Pump Shaft Deflection Model !
y1=(R1*x^3/6+C1*x+C21/(E*11) y2=(R1*x^3/6+-R2e(x-a)^3/6+C3+x+C4)/(E*12) ) y3=(R1*x^3/6+-R2+( -a)^3/6+C5+ +C6)/(E*I3) y4=(R1*(a+b+c)^3/6+-R2*(b+c)^3/6+C5*(a+b+c)+C6)/(E*13)+43e( -a-b-c) i3= (R16 (a+b+c) ^2/2-R2+ (b+c) ^2/2+C5) / (E*! 3) C1=-21ea^2/6 C2=0 C3=R1*(12/11*a^2/3-a^2/2) C4=R1*a^3/3e(1-12/11) C5= ( 1-! 3/12 ) + ( R2+)*2/2-R1 * ( a+bl *2/2) +Rl
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Parameter Variables: T,Se,Su
].- Argu ent Variables: D Result Variables stresseau S Rule-st resseax=See (1-sort (3) #16+T/ (si () *D^3*Sul) ' l _.
I' RLAPFUICTI(N stress - Comments parameter V riables: [] (/ Argument Variables: Result Variables: N, D, Kf stress S Rul:
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i VARIABLE 9ET St Input- Name- - Output- Unit Comment CR3 Decay Heat Pumps Shaft Stresses - Case A Fr 65.69478 M 246.26054
.375 Ruf
.0125 y.
yease .01900422 ' 22.8955 x R1 1075.5115 R2 1732.2063 y1 .01353734 y2 .01137592 y3 .0125 l I y4 .0125 ' C1 -15605.02 28300000 E 4.681 11 2.807 12 2.115 13 C2 0 9.3304 a C3 -28099.71 C4 116580.4 C5 -40558.63 C6 246297.6 3,59375 b 9.9685 e 43 .0013693 2.09375 d L yplot .0125 1 2.6563 e L Mx L 1 up L Se L1 0 6373 T 49500 Se !'i
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.I, VARIA8LE!HEET St Input- nese- Output- Unit coment CR3 Decay Heat Pumps Shaft Stnesses - Case B l' Fr 615.90617
-230.9648 L M
.375 Ruf g- _.0125 y yease .01911644 22.89265 :
R1 1056.2174 l R2 1674.1236 i yi .01331966 y2 .01135121
'q y3 .0125
.g' y4 C1
.0125
-15354.09
, 28300000 E i 4.681 11 2.807 12 2.115 13 C2 0 9.3304 a C3 -27647.86
,- C4 114705.8 C5 -39954.57 l- C6 242901.46 3.59375 b 9.9685 e 43 .00139292 2.09375 d T L yliiot .0125
( 2.6563 m L Rn
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VARIRBl 9EET St Input- Name- Output- Unit Consent- , CR3 Decay Heat Pumps Shaft Stresses - Case C Fr -656.6948 M -246.2605
.375 Ref.
.0125 y yease .0190042 22.09265 :
R1 -1075.512 - R2 -1732.206 - y1 .0135373 y2 .0113759 y3 .0125 y4 .0125 l C1 15605.021 28300000 E 4.681 11 2.807 12 2.115 13 C2 0 9.3304 a C3 28099.705 C4 -116580.4 C5 40556.617 C6 -246297.5 3.59375 b 9.9685 e 43 .0013693 2.09375 d L yplot .0125 2.6553 e L k L1 up L Sa , l L1 D 6373 T 49500 Se 135000 Su I i L Sasa L0 Kf { l I l s
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St Input- Name- - Output- Unit comment CR3 Decay Heat Pumps Shaft Stresses - Case D Fr -615.9062 M 230.96481
- .375 Ref
,. .0125 y yease .0191164 22.89265 x R1 -1058.217 R2 -1674.124
[ y1 .0133197 y2 .0113512 y3 .0125 s y4 .0125 C1 15354.093 28300000 E 4.681 11 2.807 12
- 2. 11 5 13
- 2 0 9.3304 a C3 27647.864
, C4 -114705.8 C5 39954.57 b C6 -242901.5 3.5375 b 9.9685 e
' J' 43 .0013929 2.09375 d L yplot .0125 j; 2.6563 e L Mu L1
- f, L Sa
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. VARIABLE SEET St input- Nase- Outpat- Unit Cament ;
CR3 != cay that Pumps i Shaft Stresses - Case E
'e Fr 635.64681 M' 0 0 Ruf
.0125 y yease .01906213 22.89205 R1 1066.5873 R2 1702.2341 ,
y1 .01342501 y2 .01136317 y3 .0125 y4 .0125 q g C1 -15475.54 26300000 E 4.681 11 2.807 12 2.115 13 C2 0 9.3304 a C3 -27866.54 C4 115613.06 C5 -40246.92 C6 244545.11 l 3.5375 b 9.9685 e 43 .00138149 2.09375 d , L yplot .0125 2.6563 e , L Mn L1 up L Sa L1 D 6373 T 49500 Se 135000 Su
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- 1050 Connecticut Ave. NW-Washington, DC 20036 CALCULATION NO. PREPARED BY CHECKED BY
./67 - 79/ 5 )2 M W Ef2 s WARIABLE 9EET , St Input- Name- Output- Unit Comment CR3 Decay Heat Pusos l' Verification Probles 1 3 1000 Fr 0 M 0 Ref y .35555556 yease .39097289 80 n R1 .1000 R2 2000 _, y1 2.133E-10 y2 .3555556 -- y3 .3555256 y4 .35555556 q ),;' C1 -266666.7 3E7 E 1E10 11 2 12 2 13 C2 0 40 a C3 -600000 C4 21333333 C5 -800000 C6 21333333 20 b 20 c 43 .01333333 0 d , L yplot .3555556 2.6563 e L Mn L1 xp L Sa L1 D 6373 T 49500 Se 135000 Su L Seau L0 Kf I k
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t MPR ASSOCIATES, lNC. 1050 Connecticut Ave., NW-Washington,' DC 20036
) CALCULATION NO. PREPARED BY- CHECKED BY
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._. y =-0.133 sq t a,m u n u- _a Lt'o
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i i MPR ASSOCIATES, INC. , I 1050 Connecticut Ave., NW-Washington, DC 20036 _ CAI.CULATON NO. PREPARED BY CHECKED BY ' WW7&m PhuG f f
/O *L ~ ~) y lf* b[g v Fe = 0 o-y ) g = toom ,w lk 2-- / ///f
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) PREPARED BY CHECKED BY
'.( CALCULATION NO.
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N$'80 f-i. VARIABLE SHET j~ St Input- Nam-- Output- Unit Comment l, CR3 Decay Heat Pusos 1 Verification Probism 2 0- Fr 10000 M _h 0 M
- y .1333333 yease .151042 80 m j R1 -250 R2 -250 ,
y1 -5.33E-11 1 y2 .1333333
y3 .1333333 y4 - .1333333
't C1 EGE.M7 E E 1E10 11 t' 2 12 L 2 13 2 0 40 a I- C3 200030 C4 -5333333 C5 200000
C6 -5333333 b 20 b 20 e 43 .00E667
, O d L yptot .13333333 2.6563 e L k '
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VARIABLE SHEET St Input- Name- Output- Unit Comment CR3 Decay Heat Punes Verification Probles 3 , 1000 Fr 10000 N 0 Ruf y .??/P???? yease .23993089 80 x R1 750 R2 1750 ' y1 1.6E-10 y2 .22222222 . y3 .22222?.22 y4 .???????2 C1 -200000 { } I7 E 1E10 11 2 12 2 13 C2 0 40 a C3 -600000 C4 16000000 C5 -600000
. C6 16000000 ,
20 b 20 c
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)- y) I CALCULATION NO. PREPARED BY. CHECKED BY
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'1050 Connecticut Ave., NW-Washington, DC 20036 7-)3k. CALCULATION NO.
PREPARED BY CHECKED BY
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- - VARIAllLE 9tEET
>! 9t Input- Name- Output- Unit Comment
CR3 Decay Heat Pumps Verification probism 4
?.
1000 Fr
0 M 0 W y .08888889 yease .10364611 40 m R1 1000 R2 2000 ..
;[ y1 .13333333
; y2 .08888889 y3 .08888869
, y4 .hAAAAAA9 i C1 -66666.67 A E7 E 2 11 2 12 2 13 C2 0 20 a
' C3 66666.67 C4 0- *
, C5 -66666.67 3 5 0 b 10 b i
10 e I 43 .00555556
) 0 -d L yptot .0888889 2.6563 e
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'1050 Connecticut Ave., NW-Washington, DC 20036 CALCULATION TITLE PAGE CLIENT -
d FLORIDA' PowG R. PAGE 1 OF ] MOJEM TASK NO.
- D HP Low F low 102 -77 CALCULATION TITLE CALCULATION NO ECTIMATCO R A T i si G L I F E O' h S E A ft i N(y A'~, A tOPTlONAL)
' F U N C ~~ f D M 6F A P PL I E b LD A b ; g g _ q c) / (g PREPARER (S)/DATE CHECKER (S)/DATE REVIEWER (S)/DATE REV.NO. . \~ Wpof/h r w> h - lh.;.D g);h' "
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~' S toz-19ll9 W hS .
hZla (6g?d;xd ' e i
,i Porgn er :
To e,s4irna4 e Jhe r'a+ing life ( L d as o. f unc4(o n of i 4he applied load for 4hc bah bear',rg in 4hc Crys +a.I 1
%er Un. + 3 deca >j hea4 purop . Each parn e has a.
do uble - rovu , d eep q couve ro.clio l bcdl b earina ok l fhe in boctrcl (o Cco con and,two doubt e - rcw , argu.(cf l conktce bct_il bect. ring rnounb ecl bctck - t o -bc4cK ch l I lhe ovibca rd l eco* ion . < l' nn e l u e'n n : ll Th e calc u lo+ ed roaing l#c (in houc of opera 4,bn) voltses !' 4'o r Jhe Ii n C (inboa.cd ) on cl ihrusKovF6oa<d) beor in cp 4 e , r Actio n bearing loo.ds from 500 lb % 100oo Ib 0.rc provicled {, in Table i cend Z ctnct Tables 3 +hrowj h 9 , re 5 p ec+ivel y. T qures I and 2 c3raphically clepich 4he ces vils er i ) 4 he , Anrus.+ ancl l in e ocar;ng raFng IiSc. .
c [is; 'em . MPR ASSOCIATES,' INC. ' g- 1050 Connecticut Ave., NW-Washington, DC 20036
' (/ CALCULATION NO. PREPARED BY CHECKED BY- ;ij 1 o 2. - 3 9 llo WW1.$x .hf),Q.'c;;PAGE. 3 ]; ~
i f- Assurnptions : 1 Y 'l . The en+ ire 1oo.cl oA 4he anrus4 ecarrn 9 .to c.<>u on -{ J is cctrried by only one of 4he +wo rowi op
.. ta. tic. . 4
- z. The ecure. t oac\ a+ 4He \in e. bearing locct+ ion ;
; is co.rrtect by one row of +he deep c3 roove o
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I MPR ASSOCIATES, INC. , I l 1050 Connecticut Ave., NW-Washington, DC 20038' -( PREPARED BY C H E C K E D ,B Y CALCULATON NO. 4 102 - 79 /(0 WWAP , b (>;,2 6 w PAGE l_ Calco la4 ions : Bearing Dn4c The following bearing data is frorn Re4erence 1. Li o e Thrus+ J./ Model SKF 5214 SkF 7313 BYG Con +ac+ Angfe (Degl 24 (rad,aD 4o Ball Dictrnef er (in) O. (oB 75 O.9374 ( ) Nurnber of Balls 10 /per row ( 2. (2 rows) Pi4ch Circle Diarne+er6n) 3. 8 4 o z. 4. Os 3 3./ Diarne4ral Clearancelinl .000 7 .OOl7 .0009 .0022 I l Notes : {i I. Model Numbers are 4'roen Crystal her - UnR 3 InskucAion Manual No. ~7. l l
- 2. Refer 40 Feference 2.
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MPR ASSOCIATES, lNC. I ? ! ,q ' 1060 Connecticut Ave., NW -Washington, DC 20036 > s CHECKED BY -
. v'( I CALCULATION NO. PREPARED BY 102 -7 9 /(v WW76 [&g/f4,y )_
PAGE '$ f l ~ ( .. eastc Loocl' Ra+;na From Reterence 3:
.{ o z/3 .. s
_ = & li cos cd .7 f D D 6 1.o io. (Eq.U.
]
Ii where:
! C -* basic load ra4ing E.1b /106 cycles]
i O D5 ba.11 diarn e+er {. in) (( : i = nurober of rove of balls 3 M ' Conictc4 angle [. decy ] i
}
2* Dumber of balls Per row . Ce = loact 4cLc40r from Table i of ReAerence B, a l 3 func4 ion of paronie+e.r DcoS 4 /dm 3 where L dm = pitch circle. diarnc+er Oc) J 46 li The basic load ra4ings for each bearing are 4abolaked Y] s
% beloW.
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MPR ASSOCIATES, INC. 1050 Connecticut Ave., NW-Washington, DC 20036 CALCULATION NO. PREPARED BY CHECKED BY l 0 2 ~ ~19 h W Wlh / ),_ yhQ,:d , Dcosd Bearinct d rn fc. L C (lb / lob cydes) Li ne 0.1635 4564 i 10,l00 ( Eq. l) l* Th rus+ 0. 17 8l 4546 17,600 (Eq. 0
' pe r Assurnp4 ion 1 Ro + cnc. Life freic Reference 3, 4he un co r rected Fa+ing lifC [Lio) in r0illions ol revolv4 ions is c - ,3 L io =
1 90/. relio bi li+ y (Eq. al _ P_ P= X Fr + 'r Fa (Eq. 33 wherc ! P= equ'ivalent radial load Lib 3 Fr = opplied radial load Libi Fa
=
oppiced axici road Elb] X* radial load facAor frorn Table 2 of Ref erence 3 q g l Y= axiot lood fat 4cr frorn Table 2 of Peterence 3 L \ - L - - - _ - - - - _ -
1s 1.. MPR ASSOCIATES, INC. Jl - 1050 Connecticut Avs., NW-Washington, DC 20036 -
, ' ~)L CALCULATION. NO.. ~ PREPARED BY CHECKED BY .
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,j Th e. ra+ing life con be adjus+ed by fac4 ors which correc4- for
~
relia bili 4y >- applica4 ion condi4 ions, ma+ e rial , :peech bectring. l' clearance , and 04her f ac+or.s. This calcula4(on will co rre c + for bearing clearon ce only, t-Lin e 12 goring i i Lo' i
=
1c L io J Eq. M (Reference 4, p.388) f) where Xc is a 4adigue life reclucAlon facac e, bcsed on diarnc4ral (%J clectrance .,. from Figure G. lto of Reference 4. In orcter +o 4 cle4 errnine A c > ct pctrarne+er for -lhe evien& of rolling clement
\occiing (nuc+ be dekerrnineci.
I_
.. Frorn Refe rence 4 , p.146 -
I" l 6= _L l Pa (q . ri) 2 (Re.fecence 4 > p.148)
] -
2Jrnax a where: 6= load dis +ribu4 ion fa_c4o r v. j Pd = diame4 rat bearing cieorctnce lin] ! r , (' - L., l
MPR ASSOCIATES, INC. ~' 1050 Connecticut Ave., NW-Washington, DC 20036 CALCULATION NO. PREPARED BY CHECKED BY i o 2. - 7 9 /(a wxr/E, , glo(54m2 PAGE 8 i rnaxin1pm bearing displctcernen+ lin3 Jmax
- sm a, = Jr + Pf (Eq.lo) {fTetereocc 4, p.14N 2 ,
\
where ; dr = radia.1 bearing deflec+ ion lin3 in general, ihe probiern of becying de&lec4(ons 0s & Su nC4 (on M 100 clir,g is hig hly non lin e_ar. ond 4he equo3/ orc arc compler.{ } flowever, fer relO4ively Slov/ Speed bearingt , icsad ed rcid ia_H y, FreJeren ce 4 provicic 4e approxirnarc detie c4 ton - load rela 4 ien ship - 1
-5 Ph Jr = 4 62 x to Ee ( Ref 4 > P. 24(,)
Z'# D"co/# A For +he case of onh/ One row of 4he +hrus+ bear; rigs l 1 crAr r vin g lo ut , 4he rctdial de4( c_c+io n ic . I
~
fr = 4. to ? X 10
- l~ 'I l >.
10*' (.bST5Y CosEi 3r *
- l. 31 X 10 ' Fr" ( Eg. -0 ,
;,' p 5. -
.J l
1::. MPR ASSOCIATES,:INC. p, . 1050 Connecticut Ave., NW-Washin0 ton, DC 20036 l 9 ,_,, 1 3
'N k) ~ CALCULATION NO.
l O 2 --99-lU PREPARED BY CHECKED BY
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,1 f The adjusted rate'nq life.: can be cycpressed in opera + lng g.: hours. by dividirg bylhe cha(4 speed :
L,g .
=
le Lio x to" cvcies I he_ cu rev 40 mio
.p mio
.r. .
j.L L ,o = 16 /o G7 Ac L,o /t.o Lhours 1 (Eq. 8 ) i
'I where 6) = sha/4 . speed in rprn hO lV a, = ..l78 0 -rpm ( Res e rence N
' ; ~ ' Ta bles I and E- preseo+ 4he acijus4ed raHog life for- radioJ - loads i voutying krn 500 lb +t> lO000lb he bearing clectrances of b O. 0 0i~1 a.ricI O. 000 ~l in. V especkivel'j. These YET.,ules show 4 hah r
.L t.\ Earance has a. (e.tcewely S rncdl CMCCJ on lne rct+i09 We.
.1
[u The resuI&S Por the trc Ref B)
- . 5 0,0022 1.5 (o 0.0009 I.5
..l l ~l o,0022 5
- .. a r
g. S o.cozz to 9 00022 20 n..< L- ____ _ .
i MPR ASSOCIATES, INC. 1 1050 Connecticut Ave., NW-Washirgton, DC 20036 l CALCULATION NO. PREPARED BY A CHECKED BY PAGE 12. I O2 -79 /lO Y< >77 W ,V/gkki[l[.,, j
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Cimilo.r 4o Jhe lin o bectring , -lhe resul4s shovv 4 hot the bearing clea ran ce has a fairly s mall e##cc4- On 4hc rct4ing life The a x ial Ioad affec4s 4he rQ+ing life i bu+ only when the rcdio of uio 1 loctd 40 radiaJ lead becomes Iarg e (i. e. To/F,. > 1.14 ) . THe resul+s for 4he maXirnum Cl eo.ron ce condifion are de pic+ea graphically i n Figure 2. o_
i,. MPR ASSOCIATES INC.
'1050 Connecticut Ave., NW-Washington, DC 20036.
f CALCULATON NO.- PREPARED BY: - CHECKED BY O IO 2 :19 /(p ' Wrnh gggg.y ,.j PAGE 13'
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.i For ' Table' s: I and 2 .
o b enbols EauoMons Used
,f . .
Je T 6 5 3 O 1" Leo 2. It 3-a LgI l.
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t " i E, L i o, Li o , A same as for Tastes 1 A z efe IO
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--.-______.__.._._._.g__
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.1050 Connecticut Ave., NW-V.'ashington, DC 20036 k CALCULATION NO. PREPARED BY CHECKED BY PAGE 25 .
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- 1. Mernorands of Telephone Con versa #on be4 Ween kasey M . Lee ( VlPR ) and ken Feg el y '(5 KF) on 20-89.
2 Mernorandurn at TeJephone ConversoFon be+ ween Dorn y.. M azzcela . C MF R) and Bob Fra.ntoso (SKF) on 1 &9; 3 ANsl / AFBM A 5+Gn d ard 9 - m g , ." Loa.d PaM n gs o.ncl ' Fraig u e Zo r Ba.t i B earings
- 4. Ha.r ris , T. A. Pol lin g B o ri ,,g Analyris , Tohn wifey &
Son s Inc. > Ne.w 'fo r k > 1966.
- 5. Claude , E , &c. Io2-J?/ * > "Irn yet ter Ra&oJ Loads a+
Ahe Ga.Hg ue End urance L\ rvi + , " cigure .1, p. B l . 4 4 o wese
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