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Case Study: “Improving
and Sustaining the
Reliability of Reactor
Feed Water Pumps”
Joseph A. Silvaggio, Jr.
Fellow Engineer
Pump Projects and
Engineering
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Page 2 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
PUMP PRESENTATION OUTLINE
1. Description of the Siemens Demag Delaval
Feed Water Pump
2. Design Fundamentals of This Type of Pump
3. Mechanical Improvements
4. Instrumentation Improvements For Diagnostic Purposes
5. Operation Modifications To Improve Reliability
6. Conclusions
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Page 3 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
1. DESCRIPTION of the SIEMENS DEMAG
DELAVAL FEED WATER PUMP
1. Description of the Siemens Demag Delaval Feed Water Pump
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Page 4 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
SINGLE STAGE NUCLEAR FEED WATER PUMP
Maine Yankee Atomic Power
Company
Largest Nuclear Feed Pump Ever
Built
24” Nozzles
28,000 GPM
14,763 HP
700 PSI SUCTION
1,800 PSI DISCHARGE
Driven By A Delaval Steam
Turbine
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Page 5 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
NUCLEAR FEED PUMPS IN THE SHOP
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Page 6 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
Turbine Driven Reactor Feed Pump
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Page 7 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
2. DESIGN FUNDAMENTALS of THIS TYPE of PUMP
2. Design Fundamentals of This Type of Pump
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Page 8 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
SIEMENS DEMAG DELAVAL NUCLEAR FEED
WATER PUMP
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Page 9 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
Assembly Drawing of a Reactor Feed-Pump
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Page 10 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
DOUBLE SUCTION
NORMALLY REFERS TO THE
DESIGN OF IMPELLER INLET
THE IMPELLER HAS TWO
(DOUBLE) INLET EYE AREAS
½ OF THE TOTAL PUMP
INLET FLOW ENTERS EACH
SIDE OF THE IMPELLER
PRIMARILY USED ON
SINGLE STAGE PUMPS
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Page 11 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
A Nuclear Feed Pump Rotor Assembly
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Page 12 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
3. Mechanical Improvements
3. Mechanical Improvements
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Page 13 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
Assembly Drawing of a Reactor Feed-Pump
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Page 14 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
HISTORY OF “A” GAPS
“A” Gap
First used in nuclear feed water pumps.
Single stage, double suction impeller design.
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Page 15 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
HISTORY OF “A” GAPS
Seals main flow from open space
between impeller sideplates and
stationary walls.
Filters unstable hydraulic
pressure pulsation.
Reduces onset of axial shaft
shuttling to lower flows on single
stage, double suction impeller
type pumps.
Delaval received an patent for
the "A" Gap.
“A” Gap
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Page 16 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
SUPERBOLTS ARE BEING USED MORE FREQUENTLY TO
BOLT THE END HEAD TO THE PUMP CASE
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Page 17 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
Monolithic Checknut
DEVELOPED AS A RESULT OF VIBRATION
PROBLEMS
GUARD (270) MIGHT BECOME LOOSE ON THE
SLEEVE NUT (402) IF SET SCREWS ARE
INSUFFICIENTLY TIGHTENED AND CAUSE
VIBRATION PROBLEMS
NEW DESIGN COMBINES THE GUARD AND
CHECKNUT INTO ONE PIECE
INSTALLS WITHOUT MACHINING OF THE
MATING PARTS
GUARD (270)
SLEEVE NUT (402)
MONOLITHIC SLEEVE NUT (402)
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Page 18 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
Carbon Steel Overlays at Journal Bearing Areas
416 & 410 STAINLESS STEEL SHAFT MATERIAL
OVERLAY IS A CABON MOLY FILLER
WHY?
TO PREVENT “WIRE WOOLING”
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Page 19 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
SHAFT PRE-MACHINED FOR WELD OVER-LAY
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Page 20 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
What is Wire Wooling?
ABRASIVE-WEAR FAILURE
SHAFT MATERIAL REMOVAL BY
MACHINING
WIRE SHAVINGS RESEMBLE STEEL
WOOL
OCCURS ON 410 AND 416
STAINLESS STEELS IN THE
PRESENCE OF CERTAIN CHLORIDE
CONTAINING OILS
HARD PARTICLES FORM &
DEPOSIT IN BEARING BABBIT
THESE PARTICLES CUT & SPIN
SLIVERS OF SHAFT MATERIAL
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Page 21 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
4. Instrumentation Improvements For Diagnostic
Purposes
4. Instrumentation Improvements For Diagnostic Purposes
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Page 22 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
RADIAL VIBRATION MONITORING
Radial proximity probes
Two probes (90 degrees apart) near
each radial bearing
Probes used in conjunction with a key
phaser
Configuration provides
Magnitude of shaft radial
displacement
Information to determine
shaft orbit shapes
Magnitude and frequency of vibration
are both important
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Page 23 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
AXIAL POSITION MONITORING
Used to determine stable operating
Particularly important for pumps with a
hydraulic balance device having a
radial variable orifice
“On-line” monitoring of axial position
Monitor if axial wear occurs
Determine and prevent
– “Operating events” that
affect wear
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Page 24 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
5. Operation Modifications To Improve Reliability
5. Operation Modifications To Improve Reliability
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Page 25 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
AN EXAMPLE of a REACTOR FEED WATER PUMP
PERFORMNCE CURVE
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Page 26 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
PUMP HEAD PRESSURE VS. NYC SKYLINE
A. Pump Head Pressure
~7570 ft (2307.3 m)
B. One World Trade Center
~1775.9 ft (541.3 m)
C. 432 Park Avenue
~1378.9 ft (420.3 m)
D. Two World Trade Center
~1350.4 ft (411.6 m)
E. Hudson Yards North Office Tower
~1292 ft (393.8 m)
F. Empire State Building
~1454.1 ft (443.2 m)
G. One Manhattan West
~1215.9 ft (370.6 m)
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Page 27 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
SUCTION AND DISCHARGE RECIRCULATION
AFFECTS THE HEAD CAPACITY CURVE
Pump Handbook 4th Ed.
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Page 28 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
ARTIST REPRESENTATION OF SUCTION
AND DISCHARGE RECIRCULATION.
Gopalakrishnan, S., “A New Method for Computing Minimum Flow”, presented at 5th International Pump Users Symposium, (1988)
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Page 29 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
WHERE IS MINIMUM FLOW?
Gopalakrishnan, S., “A New Method for Computing Minimum Flow”, presented at 5th International Pump Users Symposium, (1988)
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Page 30 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
PERFORMANCE CURVE AREAS TO AVOID
Minimum flow that may cause potential issues.
Suction and discharge recirculation.
Resulting pump operation effects from recirculation flows, (pressure
pulsations and vibration).
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Page 31 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
DEVELOPING THE “SWEET” ZONE
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Page 32 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
6. Conclusions
6. Conclusions
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Page 33 1/25/2016 Copyright © Siemens Demag Delaval Turbomachinery, Inc. 2016. All rights reserved.Joe Silvaggio
IMPROVING AND SUSTAINING RELIABILITY BY:
Applying Mechanical Improvements
Utilizing Instrumentation Improvements For
Diagnostic Purposes
Applying Operation Modifications To Operate In a
“Sweet Zone”.
6. CONCLUSIONS: