8 ORBIT Machinery Messages Case History December 1990 Reactor recirculation pump shaft crack by Leff 8. Bohaniek Stems and Performance Ergincer Grand Gulf Nuclear Station Shatems Energy Resources, Ine. ‘and Rickard Tiomas, PE. Senior Machinery Diagnose Senices Engineer ‘Bently Nexada Corporation IS case history documents a significant save of a nuclear reactor recirculation pump and motor. A crack propagited through the pump shaft in the ge eral area of the hyrestatic hearing between and 11 May, 1989. Driven by a 7,40 horsepower motor, euch reactor rocie- ‘ulation pump can pump approximately 45,000 gallons per rinute (170,325 litervmin) of water to the reactor care. The reactor recirculation pumps are permanent)y monitored for ‘ibration using proximity probes to measure shalt relative displacement, axial visration and shaft rotative speed. These ‘purnps are also monitored for flow rate beating temperature and motor winding temperatures, On 11 May, a Vibration Engineer at Grand Gulf Nuclear Station performed! routine monitoring and sibration checks ‘on all the continuously monitored eritical rotating machinery. Unfiltered and fitered Orbit displays and overall ampliaudes {rom the vibration monitors were used for this routine mon= itoring and vibration check. AII amplitudes were nearly iden ‘eal fo data observed (wo weeks previously under similar ‘operating conditions ‘A hall hour later, however, the Orbit pattesn on the B reactor recirculation pump changed. Amplitudes measured with proximity probes, located at the pump coupling, ‘ncreasod from 13 mils 331 pen) peaksto-peak to 16 ils (406 um) peak-to-peak. Thitty minutes later, the vibration at the pump coupling had reached 18 mils (457 wim) peak-to-peak Proximity teansdvcers located at the motor inboard bearing, ‘motor outboard bearing znd motor axial vibration locations a exhibited an increase in vibration levels as well. At this time, ‘the Vioration Enginoor was actively collecting vibration fre- ‘quency spectrum data and corelating process and vibration data to determine if process changes were eesponsible forthe ‘nerease in vibrtion. ‘Vibration spectra, coupled with the process Cats, verified that process conditions were not responsible fr the increase in vibration. The Vibration Engincer, convinced that an imme nent problem requiring machinery shutcown was in progress, started recording the vibravion signals on both reetculation| amps with an instrumentgrade tape rceorder and notified ‘the control room operates ofthe high vibration abserved on the B recirealation pump. ‘Vibration yeetor data revealed that she increases in vibration, were atthe IX and 2X frequencies with corresponding sig ceant [X end 2X phase shifts. half hour les, the vibration levels had increased above the Danger setpoint of 20 mils (508 Jum) peak-to-peak. Operations personne! adjsted the Tow ‘conto vahe Lo try 0 reduce the sibraton tend. These efforts ‘were futile and the vibration increzsed 1 30) mils (762 am) peak-to-peak. Three hours after the inital change inthe shaft (Orbits was abwerved, the pump was secured at slow speed and the overall pum coupling vibration amplitcie decreased 1911 mils (279 um) peak-to-peak. The recirculation loop operated at slow speed with continuous vibration monitoring and loose paris monitoring inorder to provide time for the data to be teviawed and o allow for further data collection. After looking at data te nest day, it was apparent that the pump had beer dmsged and that any further operation of the ‘pum, even at slow speed, sould note prudent. The pump ‘was shut down and the vibration, loose parts “noise” and process data were carefully eeviewed. Vibration data indicated ‘thatthe excossive vibration was cue toa purnp shat erack al oralent shat ‘Visual inspection revealed several things. Fist, ha the shaft hada visible erack approximately 320 degreesin cirevmference in the tapered shaft section immediately above the impeller attachment weld, Secondly thatthe wpper part of the hydrostae tic bearing had a 360 degree rub mark anc that the bearing journal had a 130 degree year mark. And lasly, that the shaft ‘was bent relative to the shaft centerineDecember 1990 Recirculation pump arrangomont ‘The general arrangement of the A and B reactor reciecula- tion pumps is depicted in Figute {, This figure also defines the angular locations af the wation transducers forthe 840 eto" systems with respect to an arbitrary G deyree reference, ‘On each ofthe two rotor systems there are three sets of XY rosimity probes atthe following oeations: 1) Upper Motor Bearing (UMB Y und UMB X) 2) Lower Motor Bearing (LMB Y und MBX) 3) Pomp Coupling Hub (PCH Y and PCH X) Adkitionally, exch pump is equipped with a single axial position transducer, observing a balance ring near the upper motor hearing and a Keyphasor® transducer located near the lower motor bearing (Figure 2), The Keyphesor® tansducer signal as usec as the referenec for al phase data presented in tisartele, Diagnostic approach ‘An analysis of the Grand Gulf taped data wes conducted 19 evaluate whether or not indications of a shaft eraek were apparent prior to reducing the pump to low speed operation, “The amalssiswas based on the following basic interpretation of shaft erack phenomena ORBIT Figure Reactor recirculation pump showing probe location ‘A shaftwith a. crack experiences. degredation of stifnessin the plane of the erick. Therefore, when subjected toa ridial fore, the shaft with 2 crack will bow more thar the shaft Without acraek. In addition, the shat with the crack wil] exhibit a different dynamie response both during steady sia: and during transiont(startupfoonstdewn) operating eoncitions In the ease of horizontal machine, te most common source of & steady sate force gravity In a reactor recireulation or a reactor coolant pump, racial Side load andlor seveze misalignment ofthe motor and pump shafts provide the necessary radial force. The erack ereates a ‘bowed condition, indicated by a change inthe 1X response and ‘an asymmetric rotor stifines creating ¢ 2X response, The IX. and 2X vibration response vectors thus became the key indiese torof porential cracks, ‘The data for the recirculation pump was acquired during theotted operation with the flow control valve opened frat 69% to 12%, In this condition, a net radia side load exists a the impeller periphery, ating any fom the throat of the pump, i.e toward the east. Steady stato deter Figures 3 through 10 show that the unfiltered, 1X ftered and 2X filtered shafe Orbits ha not changed in either magni- tude or phase through 2 May. However, the data for 11 May clearly shows that significant amplitude-snd phase changes hac ‘occurred in all oxbital presentations. >10 Case History 1 May 1 May ORBIT December 1880 ‘The relative changes in amplitudes from I May to LI May are as follows: Location Unfiltered. 1X Filtered 2X Filtered mils pp (um) mils pp Gum) mils pp (usm) ‘UMB Y 5.69 (44 jm) 2.48 (63 ym) at 259° (0.36 (9 pin) at 238° UMBY 13.41 G41 um) 3.52 (89 pm) at 125° 2.19 (56 pm) at 273° MB X 9.59 (246 jm) 3.05 (77 im) at 67° 2.10(53 pm) at 175° PCH Y 17.52 (445 pm) 14.07 (357 pm) at 323° (0.62 (16 jm) at 157° PCH X 16.92 (430 pm) 1.75 (298 im) at 199° 0.51 (13 ym) at 16° Location Unfiltered 1X Filtered 2X Filtered snils pp (um) ails pp (um) mils pp Gum) UMB Y 7.77 (197 um) 5.04 (128 jam) at 244° 0.36 (9 um)at 238° MB Y 21.21 (539 im) 47.91 (455 pm) at 130° 4.31 (109 am}at 246° MB X 24.06 (611 pm) 19.64 (499 um) at 74° 5.20/(132 pm)at 198° PCH ¥ 31.50 (800 jam) 29.00 (737 um) at 49° 6.10 (155 jam}at 209° PCH X 30.60 (777 um) 28.20 (716 um) at 284° 5.10 (130 pom) at 4 Refer to Figures 9 through 14 for the Orbit/timebase representations of this data.ORBIT December 1990 (SS) a 9] o A Sd ‘ Oo he og SG “oer12 ORBIT ‘The shaft Orbits areal oriented as if one were stonding on top of the motor, facing northeast andlooking down toward the ‘pump. With this consideration in mind, northeast is 20°, north is a 45° and east is et 318°. (Figures 1 and 2.) The expected radial preload on the impeller forthe flow conditions thatthe BB pump was experiencing would be @ force vector pointing toward 45°, i.e. ea. “The shaft Oxbitsof the B pump indicate that a preload docs ‘exis in the easowest plane, Although the Orbit does not indi ‘cate the direction of the preload, the elliptical shape of the (Orbit does indicate the presence of a preload. However, by viewing the IL Mey unfiltered Obits at the pomp coupling. one can conclude thatthe radial side load acts aL 45°, Initially, che unliered Orbits elliptial (Figures 3&4), (Over the following two hours, the elliptical shape of the Orbit Dogan to truncate on is eastside, indleating the shaft was preloaded in that direction Figures 15 through 18 are Amplitude and Phase versus Time (APHT) plots for both the 1X and the 2X vectors At all Jocabions, the amplitude and phase information was constant during the 26 hour period spenning I and 2 May. However, significant and continuous changes in both the 1X and 2X ‘octors were noted during 8 two hour period on 1 Mey In the presence of steady state radial fore, the crack will fect the rotor in two ways. Fist, it causes the rotor to bow which s reflected as a change in the 1X cesponse. Secondly, introduces.an asyenmetric rotor stifiness which isreflected asa ange in the 2X response. December 1990 ‘The 2X component is gncrated caring shaft eotation when ‘there are 1wo significant changes of rotor stihess inthe ditec- sion of the steady state radial foree duving each shalt sewolo= sion. Th shaft doflee loss when the stiffness eros section is oriented towatd she radial force ane! deflects more when the ‘weakest eross section isoricated toward the radia force, Ics therefore necessary 1 monitor the IX and 2X steady ate vectors on a continuons sis to establish the normal ‘Acceptance Region on the APHT plo:. Additionally, alarms lane nceossary in ore o alert the user to amplitude snc phase ‘ovations outside of the normal Accaptance Region. Whes either the IX or 2X weewr moses outside che established Acceptance Region, further diagnosis becomes necessary, Continuous changes in the IX and 2X vectors (Figures 15 through 18) are key indicators ofthe presence of a shafterack, Startup date. ‘Startup data acquired! on 3 May indiested that the r6xor systems first balance resonance occurred at 1360 epm with ‘additional resonance responses observed at 2540 pm, 3350 pm and 6530 com, The resonances were documented by observing the 1X, 2X and 5X vibration response during the startup period, Figure lis the 2X response, Figure isthe SX. response atthe pump coupling. The resonance responses are allsignieant as they not only indicate at what frequency the rotor resonances were observed, but also that the 2X and SX resonance responses ars in excess of 20 mils (SI ue) peat: peak snd in some instances ae in excess of A mis (102 jas) peak-to-peak, Bone gees rt Orb Timabae dota porto final exec propagation Figure 10 Orb Timebase data during incl crack propagationDecember 1990 ORBIT 13 Cuse History igure Figure 12 (Orbit Timebare deta pric to final sash propagation (OrbitTimeheae data during final crack propagation Figuro1s Figure lt OcbivTimebave date prior to final ercek propagation OrbivTimebace data during final crack propegetion14 ORBIT December 1990 FigurolS Pigue18 Amplitude and Phase veratus Tine Plot for IX vector Amplitude ond Phase veceus Tine Plot for 2X vector Figure 17 Figure 1 Amplitude and Phae vores Timo Pot for LX voetor Rempitude and Phase voreus Timo Pot ior 2X voctorDecember 1990 ORBIT Figure 18 Conclusions ‘Thettensiontresponseofthe oor shouldbe dacunentedto determine the balance resonance frequencies Destenses n'a Bel balance resonance frequency indicat that the syst sifncss tas deceased, an indieation of a posible shaft crack, “The actu dat forthe B pip shows significant 2X and 5X resonance actly The transient 2X and 5X setivity observed onthe & pomp is the diet rst of reduced stk Stffiess due to the exitence ofthe crack during startup on Ma To properly monitor @ rotor system for 8 shalt erack, ts neces to cortinuo.sl monk end tend the exeral am toce, the BX emp, te 1X phase the 2X amplitude and the 2X pace and to beable to slam on ay one OF ary sombination ofthese varcbts Ifthe vribies had been ttended at Grand Gulf, ll five vatiabls, 5 Observed by Doh ray cols prvi probe, would have been in ela on Ti Moy. ‘Charges inthe steady sat response from 2theough 1 May 1989 clear indicate the presence ofa tamer cack in the rotor sytem. On {1 My the 1X amplitades a tbe pump Ceuping ha inerase by 35% ore their val ueson May ith fn codiated phase shit of aporoxitely 76°. Sigficot changes were aso note in the 2X response wher the amp= tesa the pump coupling had increased by between 300 and 400%, with associated phase shifts of 52° and 37° respectively ‘onthe Vand X probes Asthe pur wesoperated at 1792 pm on it May the 2X mpltidos creased y an ations S12 andthe 2X amples increase ty 200. Two hous, the overall ampltage at the pump coupling was apprevmately ils (S13 pm) peak-o-peak 15 Figure 20 sAnowledgements 1. Aen Somes Wand aban Soy, "Cask Shel ingore fd Detection om Keasor Kesicuntion Pans st Grand Gall Sic Sein feng 89 Grn Pape, kW 2 2 Deny Doral, “Forced Reson! 2X Action: The Gv Ct cal? Bony Reade Corontion Aplications Not, DS ‘Benth, Donald, “Vibeation Anas Teshniquce for Deteting nd agnosia Sat Cech Or, ans 1985, V7, NAL 4 Beni Dora F “Detecting Sal Cred ates Ned On, daly 12, Vol 3, Na? 5 Benth, Dore Ed Bosman RE. "Shaft Cok Flare ase Ustory? EPRI Monitoring ane Diognotes Confeonce, San Franca, Califor, Mase 989 6 eat, Domes E, Marts, Agnes ape Thomson, AS. "Wibion Mowtoving Teewyes and Shalt Crack Deter ‘Techniques on Resto Colon Pape on Recicihion Pang” React Colt Pang Rectektion Pump Motering Worse, Toronto, Cann, Mar 98, 1. Bently Dons B. and Mussa, Ames, "arly tection of ‘Shit Crate on Eiesanding Machines” ASME Insert ‘Syrpocin om Ftd Machinery Tube Sein, Toh Winer Atal Meeting, Anaheim, Clio, 2 Deceber (86. 4 Den thiog, LP, Mechanics! Vato th Eon, Diner Pb Tate tng, Nev York Now Yor, 1985, pp 247-203, (Onna (Copjint MeGra 8 Boak Company, New York, New Yor 1ss0) 9 ass Igor Feta Pump Hane Me ai Book Com any, New Vouk New Von, 19% pp 2 592-30, 10, Lobast, Val a Ron obec Cental amps: Den & ‘Appleton, Gulf Publshag Company: House, Tees DSS, pa Stings 8140 185 8