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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 #1 – Make Conservative Decisions
Rule #2 – Maintain Design Control
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Two Rules:
Rule #1 – Make Conservative Decisions
Rule #2 – Maintain Design Control
Plant Priorities:
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Two Rules:
Rule #1 – Make Conservative Decisions
Rule #2 – Maintain Design Control
Plant Priorities:
1. Nuclear Safety
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Two Rules:
Rule #1 – Make Conservative Decisions
Rule #2 – Maintain Design Control
Plant Priorities:
1. Nuclear Safety
2. Legal Requirements
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Two Rules:
Rule #1 – Make Conservative Decisions
Rule #2 – Maintain Design Control
Plant Priorities:
1. Nuclear Safety
2. Legal Requirements
3. Efficiency
Feedwater Pump Performance Testing
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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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General Test Loop Configuration with Closed Loop and Suppression Tank (Vertical Pump)
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General Test Loop Configuration with Closed Loop and Suppression Tank (Vertical Pump)
Thermal Transient Test Loop Configuration
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Feedwater Pump Performance Testing
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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
Feedwater Pump Performance Testing Protocol
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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
Feedwater Pump Performance Testing Protocol
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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
Feedwater Pump Performance Testing Protocol
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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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Feedwater Pump Performance Testing Protocol
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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
Feedwater Pump Performance Testing Protocol
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NPSH Transient Test: cont’d
- Verify no performance degradation- Disassemble Pump for Post Test Inspection
Feedwater Pump Performance Testing Protocol
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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
Commissioning Remarks (Scars)
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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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Commissioning Remarks (Scars)
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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
Commissioning Remarks (Scars)
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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
Commissioning Remarks (Scars)
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- Setting Equipment
Suction/Discharge Drain
Lines installed in field
(Connected and
Cross-Tied)
Commissioning Remarks (Scars)
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- Setting Equipment (Thermal Growth Device helps pump grow straight thermally)
Commissioning Remarks (Scars)
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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
Commissioning Remarks (Scars)
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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
Commissioning Remarks (Scars)
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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
Commissioning Remarks (Scars)
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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
Feedwater: Pumpage (Temperature, Specific Gravity)
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Feedwater: Pumpage (Temperature, Specific Gravity)
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Feedwater: Pumpage (Temperature, Specific Gravity)
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Feedwater: Pumpage (Temperature, Specific Gravity)
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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
Feedwater: Pumpage (Temperature, Specific Gravity)
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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
Feedwater: Pumpage (Temperature, Specific Gravity)
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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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