FSRUG Feedwater Systems Reliability Users Group (Jan 2015) San Antonio, TX Performance Testing &...

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Feedwater Systems Reliability Users Group (Jan 2015)

San Antonio, TX

Performance Testing & Commissioning

Presenter:

Art Washburn, P.E.

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DISCUSSION POINTS• Two Rules to Get You Home and Plant Priorities

• Feedwater Pump Performance Testing Protocol

• Commissioning Keys to Success

• Commissioning Remarks (Scars)

• Feedwater: Pumpage (Temperature vs. Specific Gravity)

• Source References

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Two Rules:

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Two Rules:

Rule #1 – Make Conservative Decisions

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Two Rules:


Rule #2 – Maintain Design Control

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Two Rules:



Plant Priorities:

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Two Rules:



Plant Priorities:

1. Nuclear Safety

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Two Rules:



Plant Priorities:

1. Nuclear Safety

2. Legal Requirements

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Two Rules:



Plant Priorities:

1. Nuclear Safety

2. Legal Requirements

3. Efficiency

Feedwater Pump Performance Testing

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General Test Loop Configuration with Closed Loop and Suppression Tank (Horizontal Pump)

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General Test Loop Configuration with Closed Loop and Suppression Tank (Vertical Pump)

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Thermal Transient Test Loop Configuration

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- Feedwater Pump with separate Lube Oil System and a Seal Injection System

- Job Driver (Electric Motor) – Sufficient for Pump Testing including NPSHR and Special Tests

- Separate Temporary Systems for Seal Injection and Force Feed Lubrication Oil

- Job Systems for Seal Injection and Force Feed Lubrication Oil

Feedwater Pump Performance Testing Protocol

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Standard Performance Test per Hydraulic Institute Standards and ASME PTC 8.2:

- WITNESSED

- 8 Test Points (Flow Points +/-10%): Shutoff, Minimum Flow, Duty Point, Accident Analysis Critical Condition, Runout Flow, Others

- Curve to reflect adjusted condition at Rated Speed using Affinity Laws.

- Curve to include Head, Efficiency, BHP and NPSHR against Capacity, Impeller Size, Stable Operating Range

- Data to include raw data and Affinity Law corrected data


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Standard Performance Test per Hydraulic Institute

Standards and ASME PTC 8.2: cont’d

- Pump Bearing Housing Vibration (Horz, Vert, Axial)- Pump Shaft Vibration (Two Positions, 90o Apart)- Record Bearing, Pump Casing, Motor Bearing & Winding

Temperatures- Lube Oil Flow and Pressure- Seal Injection Flow to Bushings- Seal Leakage Flow to Atmosphere


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Standard Performance Test Acceptance Criteria per

Hydraulic Institute

- At Rated Capacity, % of Rated Head- Rated Head, % of Rated Flow- Efficiency at Rated Capacity, -X%- NPSHR at Rated Flow (and Runout), Not more than X FT abs.- Vibration, based on agreement with Customer- Bearing Temperatures, Not to exceed XoF


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NPSHR Test:

- WITNESSED- Each Pump will be NPSHR Tested- NPSHR Test based upon 3% Head Drop- Pumpage Temperature, Less Than 150oF- Multiple Flow Test Points (+/-10%): Minimum Flow, Duty Point,

Runout Flow- Plot Curve based upon 3% Head Drop- Plot individual Knee Curves for each test Point

NPSHR(3%) Typical: Plot Point at 3% Head Degradation

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NPSHR, Customer Spec Requirement: NPSHR Minimum at Duty Point (Typical)

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NPSHR: NPSHR Minimum at Duty Point

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NPSHR: NPSHR Minimum at Runout

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NPSH Transient Test:

- WITNESSED- Test only one Pump - Pumpage Temperature, Rated (e.g., 375oF) but not controlled

throughout event- Pump will be set at Rated Flow and Speed- Reduce Suction Pressure Until Pump Head Falls Off to 50% of

Design Head- Continue Operation for 3 Minutes Minimum- Suddenly Restore Suction Pressure- Rerun Performance Test at 3 Flow Rates: Minimum, Rated and

Runout


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NPSH Transient Test: cont’d

- Verify no performance degradation- Disassemble Pump for Post Test Inspection


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Thermal Transient Test:

- WITNESSED- Test only one Pump at conclusion of performance and NPSHR

Testing- Pump will be set at Rated Flow and Speed- Temperature of Pumpage to be reduced from Rated Temperature

(e.g., 375oF) to Less Than 200oF in less than 3 minutes- Rerun Performance Test at 3 Flow Rates: Minimum, Rated and

Runout- Verify no performance degradation- Disassemble Pump for Post Test Inspection

Pump Performance Testing Protocol

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Hot Box Train Test:

- WITNESSED- Operate at Faulted System and Atmospheric Conditions- Test at Duty Point- Accident Atmospheric (e.g., 150oF)- Pumpage Temperature (e.g., 130oF)- Pump & Motor Mounted on Job Base Plate- Monitor Temperature of Atmosphere, Bearings, Motor Winding- Monitor Vibration- Operate pump long enough to allow bearing temperatures to

stabilize- Test Duration, 30 Minutes

Commissioning Keys to Success

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- Planning for each Commissioning Activity

- Contingencies (Implement Ahead of Time)

- Utilize Experience Field Service Support (protects warranty)

- Guard Schedule for each Commissioning Activity

- Don’t Cut Corners

Commissioning Remarks (Scars)

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- Foundation Preparation- Surprises (Field Condition does not meet original

construction drawing Details)

- Leveling Base- Pedestals can be found to not be level (stress relief,

field machining to correct condition)- Machinist’s Level (0.0005” Graduations), 0.002”/FT

- Anchor Bolt Hardware- Physical condition of existing hardware, corrosion

- Hardware does not meet original construction drawing details

- Location of Anchor Bolts differs from original construction drawing details


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- Grouting / Grout Repairs- Plan using API 686 Recommended Practices

- Plan using YouTube videos (several available)

- Utilize Experienced personnel

- Plan on Grout Repairs (purchase repair equipment to drill/metric tap base deck plate, injection equipment typically comes with metric fitting)

- Plan repair strategy (deck plate construction, drilling spacing rules for venting)

Pump/Motor Base: Grouting & Grout Repairs per API-RP686

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Pump/Motor Base: Grout Repair Map

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- Getting Equipment in to Compartment

- Access may require disassembly of components based on size of door (opening), limitation of Crane lifting capacity

- Disassembly may require components never intended to come apart (e.g., Motor joint with gasket). Gasket could have EQ requirements, purchase spare material ahead of time, confirm torque values


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- Setting Equipment- Motor Driven: Set Pump, Shim Motor to Align

- Turbine Driven: Set Turbine, Shim Pump to Align

- Lube Oil System may be mounted on skid or separate skid

- Pump Feet Torque Values could differ to accommodate thermal growth

- Devices installed to keep pump straight during thermal growth


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- Setting Equipment

Suction/Discharge Drain

Lines installed in field

(Connected and

Cross-Tied)


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- Setting Equipment (Thermal Growth Device helps pump grow straight thermally)


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- Nozzle Loads / Piping Strain

- Design Specs typically require pump/base to be designed to withstand 10X API-610 Nozzle Loads

- Installation of Piping required to be installed complete with permanent supports prior to attaching to pump nozzles. Do not allow attaching to pump nozzle with temporary pipe supports


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- Inspection Sheets (by Field Service)- Startup Checksheet (by Field Service)- Daily/Shift Logs (by Field Service)

- System Flushing- Pre-Approved procedure prior to implementation

- Pump (with rotating element removed – preferred)

- Seal Injection System in operation

- Lube Oil System in operation


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- Setting Axial Thrust Proximity Probes

- Change – Indicates a condition of Wear

- Site I&C Techs to understand Acceptance Criteria and direction of axial thrust

- Operating Procedures- Plan, Plan, Plan / Pre-Approve

- Training: Maintenance Workers, Operators- Plan, Plan, Plan / Pre-Approve


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- Ancilliary Systems…

- Lube Oil System (Pre-Ship Functional Test)- WITNESSED

- Lube Oil System (Flush, Operation)- Operating Procedures Pre-Approved

- Training: Maintenance Workers, Operators

- Seal Injection System (Flush, Operation)- Operating Procedures Pre-Approved

- Training: Maintenance Workers, Operators

Feedwater: Pumpage (Temperature, Specific Gravity)

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Specific Gravity (S.G.) Meters


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- Given Temperature (F): Determine Specific Gravity, S.G.

- Temperature (365oF) Specific Volume (Vf) = 0.01817

- 1 / Vf = 1 / 0.01817 = 55.03 lbm/ft3 = (ρ365oF, density)

- 1 / Vf = 1 / 0.016033 = 62.37 lbm/ft3 = (ρ60oF, density)

- S.G. = ρ365oF / ρ60oF = 55.03 / 62.37 = 0.883


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- Given Specific Gravity, S.G.: Determine Temperature (F)

- Specific Gravity (S.G. 0883)

- S.G. = ρ365oF / ρ60oF ρ365oF = (S.G.)(ρ60oF)

- ρ365oF = (0.883)(62.37) = 55.07 lbm/ft3

- Vf = 1 / ρ365oF = 0.01816 Temperature = 364oF


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- Determine Brakehorse Power (BHP) at Duty Point with Pumpage Temperature at 60oF.

BHP = (Flow, GPM)(Head, FT)(S.G.)

(3960)(pump eff.)

BHP at 365oF = 5,600 BHP

BHP at 60oF = (BHP) x (S.G.,60oF)

(S.G., 365oF)

= (5,600)(1.0)/(0.883)

= 6,342 BHP

SOURCE REFERENCES:• Centrifugal Pumps: Design & Application, Lobanoff and Ross

(practical application)• Centrifugal and Axial Flow Pumps, Stepanoff (theory)• Centrifugal Pumps, Gülich

• Vertical Turbine, Mixed Flow & Propeller Pumps, Dicmus• Centrifugal Pump Handbook, Sulzer• Pump Handbook, Karassik• Centrifugal Pump Clinic, Karassik• Centrifugal Pumps Selection & Operation, Karassik• Centrifugal Pumps, Karassik

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SOURCE REFERENCES: cont’d• API 686 - Recommended Practices for Machinery Installation

& Design (Chapter 5 - Mounting Plate Grouting)• API 614 - Lubrication, Shaft Sealing and Oil Control Systems

and Auxiliaries• Hydraulic Institute Standards• ASME PTC Code 8.2

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What Do We Know About The Movie: Titanic?

THE (HAPPY) END

QUESTIONS ?

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