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Feedwater Systems Reliability Users Group (Jan 2016)

San Antonio, TX

Diablo Canyon: Replacement Base & Installation

Presenter: Art Washburn, P.E.

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DISCUSSION POINTS• Two Rules to Get You Home and Plant Priorities

• Problem Statement: Condensate Booster Pump (CBP) & Motor Concrete Pad to Foundation Delamination

• Mechanical Performance

• Replacement Base

• Installation of Base, Pump and Motor

• 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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Problem Statement: CBP & Motor Base

Concrete Pad to Foundation Delamination

• Original Construction - early 1970s (Age > 40 years)

• CBP (Unit 1, Pump 3) developed significant increase in

vibration from 0.1 ips to 0.48 ips

• Primary frequency of vibration increase, 120 Hz or 2X

• Base vibration (0.15 ips), Foundation (<0.03 ips)

• Base had broken bond with the Concrete Pad and Floor

• Personnel could feel the difference in the area: Nibbling

Pump/Motor Base Delamination from Foundation

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Trend of Motor Vibration – Overall Amplitudes

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Trend of Pump Vibration – Overall Amplitude

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Spectral Waterfall – Motor Outboard Vertical

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Pre-Mainte Spectral Data – Motor Outboard Vertical

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Post-Mainte Spectral Data – Motor Outboard Vertical

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CBP 1-3 Pump,

Motor and Base

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CBP 1-3 Pump, Motor and Base

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CBP 1-3 Pump,

Motor and Base

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CBP 1-3 Pump,

Motor and Base

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CBP 1-3 Motor

Alignment

Bracket

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CBP 1-3 Motor Alignment Bracket

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CBP 1-3 Lube Oil

System Drain Line

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Overhead

Clearance and

Rigging

Limitations

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Original Base Required Removal

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- Work Commenced 2 Weeks Prior to Plant Shutdown

- Risk Management Reviews Performed in Support of

Activities

- Tent Installed Around Pump Skid to Contain Dust

- Personnel Donned Mechanical Respirators

Original Construction Details

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Original Base Required Removal

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- Remove components from Base

- Weight: Base (2,400 lbs), Pump (6,000 lbs), Motor (23,000 lbs)

- Motor required Disassembly due to Rigging Limitations

- Wire Saw Cut Base from Foundation

- Base plus Concrete Weight: 9,000 lbs

- Removal of Base Presented Floor Loading Issue

- Base was Saw Cut into 2 Foot Wide Strips and Removed

Original Base Required Removal

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- Anchor Bolt (Studs) were Cut Off During Saw Cutting

- Original Studs Welded to Foundation Steel Inserts; Removed

- Foundation chipped below level and rough to achieve

required anchor profile

Original Base Drawing – Typical Details for Vintage

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API-686 Recommended Practice for Machinery

Installation and Installation Design

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- Replacement Base: Maintain Design Control

- Unless FEA Modeled and Analyzed, Minimize Changes

- If Changes are Desired, Then Evaluate Potential Impact

Design Changes Implemented

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- Original Base is Non-API 610 Design

- Original Base Exhibited Continuous Welds on Exposed

Welds, and Stitch Welds underneath.

- Updated Base Included Continuous Welds. Increased

Stiffness Increased Margin of Separation from Critical

Operating Frequencies.

Design Changes Implemented - Continued

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- Original Base Drawing Fabrication, Machining and

Geometrical Tolerancing Details were lacking.

- Generated new Base Drawing to include Common Sense

Updates, Weld Details and Geometric Tolerances per Latest

Standards

- Grout Holes and Vents: Number and Location was Not

Optimum; Increased Number and Locations to Assure a Well

Grouted Base with Minimum Air Pockets

- Added Leveling Nuts Attached Adjacent to Each Bolt Hole

Design Changes Implemented - Continued

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- Added Lifting Lugs (Quantity, 4).

- Added Driver Alignment Brackets; Site Added in the Field in

the Past; Improved on Design based on Site Requests from

Lessons Learned

- Geometric Tolerancing: Base Flatness in Free State, Pump

Pedestal Feet Profile, Motor Pedestal Feet Profile, Parallelism

Between Pump and Motor Pedestal Feet

Design Changes Implemented - Continued

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- NDT, 100% Welds Visually Inspected per ASW D1.1, Table 6.1

- NDT, Lifting Lug Welds, NDE (MT) Examined. Methodology

per ASME Section V, Article 7; Acceptance Criteria per ASME

Section VIII, Division 1, Appendix 6. Qualification of NDE

Personnel per ASNT Recommended Practice SNT-TC-1A.

- Coating Requirements including Blast Preparation and

Coating Differ Between Topside and Underside of Base. A

unique Underside Coating System Assures Long Term

Reliability of Bond Between Base and Epoxy Grout.

Updated Base Drawing – Critical Dimensions only

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Replacement Base

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Replacement Base

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Replacement Base

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Installation Details – Civil Engineer’s Perspective

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Replacement Base Installation

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- Studs Mounted in New Base Anchor Bolt Holes, Base

Leveled with Pump Bolted to Piping, Studs Welded to Inserts

- Replacement Studs Re-Attached by Welding

Anchor Stud – Locating and Welding to Steel Floor Inserts

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Retrofit Installation – Not New Construction (Shims Under Pump Feet)

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Installation Details – Civil Engineer’s Perspective

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Base Installation

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Base Set, Grout Forms Installed and Anchored Into Floor

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Pouring Grout

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Grout – Initial Pour Filled to Bottom of Base Rails Plus 1/2 Inch

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Grout Pours Completed, Cured, and Forms Removed

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Vent Holes used for Gout Pour

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Grout Repairs as a Result of Voids Identified

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Grout Repair (Hardener & Resin Less Aggregate) – Injection to Fill Void

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Examples of Grout Pours Requirements

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- Ambient Temperature (70 +/- 10 degrees F)

- Critical Pour Time

- Critical Cure Time

- Plus many more requirements (see API-686)

- Grout Pours can be viewed on Youtube

Pump/Motor Base: Grouting & Grout Repairs

per API-RP686

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Pump/Motor Base: Grout Repair Map

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Mockup Grout Pour – Vertical Pump Soleplate

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Mockup Grout Pour – Plexiglas Soleplate

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Mockup Grout Pour – Plexiglas Soleplate, Grout Flows

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Lessons Learned:• Important Guidance: API 686 - Recommended Practices for

Machinery Installation & Design (Chapters 4 & 5 - Mounting

Plate Installation)

• Plan Required Rigging Needs

• Work Out Union Labor Requirements

• Terms & Conditions

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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

• API 686 - Recommended Practices for Machinery Installation

& Design (Chapters 4 & 5 - Mounting Plate Installation)

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What is this?

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Hint

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Hint

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EBR-1

THE (HAPPY) END

QUESTIONS ?

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