FSRUG Feedwater Systems Reliability Users Group (Jan 2015) San Antonio, TX Performance Testing & Commissioning Presenter: Art Washburn, P.E.

FSRUG

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

FSRUG Two Rules:

FSRUG Two Rules: Rule #1 – Make Conservative Decisions

FSRUG Two Rules: Rule #1 – Make Conservative Decisions Rule #2 – Maintain Design Control

FSRUG Two Rules: Rule #1 – Make Conservative Decisions Rule #2 – Maintain Design Control Plant Priorities:

FSRUG Two Rules: Rule #1 – Make Conservative Decisions Rule #2 – Maintain Design Control Plant Priorities: 1.Nuclear Safety

FSRUG Two Rules: Rule #1 – Make Conservative Decisions Rule #2 – Maintain Design Control Plant Priorities: 1.Nuclear Safety 2.Legal Requirements

FSRUG 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 FSRUG

Feedwater Pump Performance Testing FSRUG

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

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

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

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

Thermal Transient Test Loop Configuration FSRUG

Feedwater Pump Performance Testing FSRUG -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 FSRUG 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 FSRUG 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, 90 o 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 FSRUG 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 X o F

Feedwater Pump Performance Testing Protocol FSRUG NPSHR Test: -WITNESSED -Each Pump will be NPSHR Tested -NPSHR Test based upon 3% Head Drop -Pumpage Temperature, Less Than 150 o F -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 FSRUG

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

NPSHR: NPSHR Minimum at Duty Point FSRUG

NPSHR: NPSHR Minimum at Runout FSRUG

Feedwater Pump Performance Testing Protocol FSRUG NPSH Transient Test: -WITNESSED -Test only one Pump -Pumpage Temperature, Rated (e.g., 375 o F) 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 FSRUG NPSH Transient Test: cont’d -Verify no performance degradation -Disassemble Pump for Post Test Inspection

Feedwater Pump Performance Testing Protocol FSRUG 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., 375 o F) to Less Than 200 o F 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 FSRUG Hot Box Train Test: -WITNESSED -Operate at Faulted System and Atmospheric Conditions -Test at Duty Point -Accident Atmospheric (e.g., 150 o F) -Pumpage Temperature (e.g., 130 o F) -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 FSRUG -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) FSRUG -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) FSRUG -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 FSRUG

Pump/Motor Base: Grout Repair Map FSRUG

Commissioning Remarks (Scars) FSRUG -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) FSRUG -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) FSRUG -Setting Equipment Suction/Discharge Drain Lines installed in field (Connected and Cross-Tied)

Commissioning Remarks (Scars) FSRUG -Setting Equipment (Thermal Growth Device helps pump grow straight thermally)

Commissioning Remarks (Scars) FSRUG -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) FSRUG -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) FSRUG -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) FSRUG -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) FSRUG Specific Gravity (S.G.) Meters

Feedwater: Pumpage (Temperature, Specific Gravity) FSRUG

Feedwater: Pumpage (Temperature, Specific Gravity) FSRUG

Feedwater: Pumpage (Temperature, Specific Gravity) FSRUG

Feedwater: Pumpage (Temperature, Specific Gravity) FSRUG -Given Temperature (F): Determine Specific Gravity, S.G. -Temperature (365 o F) Specific Volume (Vf) = / Vf = 1 / = lbm/ft3 = ( ρ 365 o F, density) -1 / Vf = 1 / = lbm/ft3 = ( ρ 60 o F, density) -S.G. = ρ 365 o F / ρ 60 o F = / = 0.883

Feedwater: Pumpage (Temperature, Specific Gravity) FSRUG -Given Specific Gravity, S.G.: Determine Temperature (F) -Specific Gravity (S.G. 0883) -S.G. = ρ 365 o F / ρ 60 o F ρ 365 o F = (S.G.)( ρ 60 o F) -ρ 365 o F = (0.883)( ) = lbm/ft 3 -Vf = 1 / ρ 365 o F = Temperature = 364 o F

Feedwater: Pumpage (Temperature, Specific Gravity) FSRUG -Determine Brakehorse Power (BHP) at Duty Point with Pumpage Temperature at 60 o F. BHP = (Flow, GPM)(Head, FT)(S.G.) (3960)(pump eff.) BHP at 365 o F = 5,600 BHP BHP at 60 o F = (BHP) x (S.G.,60 o F) (S.G., 365 o F) = (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 FSRUG

SOURCE REFERENCES: cont’d API Recommended Practices for Machinery Installation & Design (Chapter 5 - Mounting Plate Grouting) API Lubrication, Shaft Sealing and Oil Control Systems and Auxiliaries Hydraulic Institute Standards ASME PTC Code 8.2 FSRUG

What Do We Know About The Movie: Titanic?

THE (HAPPY) END QUESTIONS ? FSRUG