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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
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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)
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Thermal Transient Test Loop Configuration
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Feedwater Pump Performance Testing
- 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
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Feedwater Pump Performance Testing Protocol
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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Feedwater Pump Performance Testing Protocol
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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Feedwater Pump Performance Testing Protocol
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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Feedwater Pump Performance Testing Protocol
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
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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
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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Feedwater Pump Performance Testing Protocol
NPSH Transient Test: cont’d
- Verify no performance degradation
- Disassemble Pump for Post Test Inspection
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Feedwater Pump Performance Testing Protocol
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
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Pump Performance Testing Protocol
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
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Commissioning Keys to Success
- 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
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Commissioning Remarks (Scars)
- 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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Commissioning Remarks (Scars)
- 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)
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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)
- 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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Commissioning Remarks (Scars)
- 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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Commissioning Remarks (Scars)
- Setting Equipment
Suction/Discharge Drain
Lines installed in field
(Connected and
Cross-Tied)
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Commissioning Remarks (Scars)
- Setting Equipment (Thermal Growth Device helps
pump grow straight thermally)
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Commissioning Remarks (Scars)
- 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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Commissioning Remarks (Scars)
- 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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Commissioning Remarks (Scars)
- 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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Commissioning Remarks (Scars)
- 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
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Feedwater: Pumpage (Temperature, Specific Gravity)
Specific Gravity (S.G.) Meters
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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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Feedwater: Pumpage (Temperature, Specific Gravity)
- 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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Feedwater: Pumpage (Temperature, Specific Gravity)
- 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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Feedwater: Pumpage (Temperature, Specific Gravity)
- 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
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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?
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THE (HAPPY) END
QUESTIONS ?