16 '@ei$ 2 - unt digital library/67531/metadc... · the equipment subjected to testing during...

c 1 6 '@ei$ ENGINEERING DATA TRANSMllTAL ,b. 2

8. Originator Remarks:

Test Report Approval and I n i t i a l Release.

11. Receiver Remarks:

I

4. Related EDT No.:

N/A

N/A

W-320 Pump/Winch Assemblies

7. Purchase Order No.:

9. Equip./Conponent No.:

10. SystRn/Eldg./Facility:

241-C-106, 241-AY-102 12. Major Assm. Dug. No.:

W-320-Pl7, W-320-P24 13. PermitlPermit Application No.:

N/A

N I A 14. Required Response Date:

IBI DocurnsntlOrawing No.

C t r l . NO. [I Approved [I Approved u l c m n t s [I Disapproved u l c m e n t s

80-7400-172-2 (04/94) GEFO97

WHC-SD-W320-TRP-003, Rev. 0

PROJECT W-320, COMBINED PUMP WINCH ASSEMBLY TEST - TEST REPORT

J . R. Bellomy Westinghouse Hanford Company, Richland, WA 99352 U.S. Department o f Energy Con t rac t DE-AC06-87RL10930

EDT/ECN: 606554 UC: 510 Org Code: 73532 Charge Code: D2MP6 B&R Code: EW3130010 T o t a l Pages: 19

Key Words: 241-C-106, P r o j e c t W-320, S l u i c i n g , Pump/Winch Tes t

Abs t rac t : Pump/Winch Tes t performed a t Lawrence Pumps.

Tes t Report documenting r e s u l t s o f t h e P r o j e c t W-320 Combined

TRADEMARK DISCLAIMER. t rade name. trademark, manufacturer, or otheruise, does not necessar i ly cons t i tu te OP imply i t s endorsement, recarmendation, or favor ing by the United States Goverrment OP any agency thereof o r i t s contractors or subcontractors.

Pr in ted in the United States of America. To ob ta in copies of t h i s docunent, contact: YHC/BCS D o c m n t Control Services, P.O. Box 1970, Mailstop H6-08, Fax ( 5 0 9 ) 376-4989.

Reference here in t o any spec i f i c comnercial product, proiess, o r serv ice by

Release Stamp

Approved for Public Release

I A-6400-073 ( 1 0 / 9 5 ) GEF321

WHC-SD-W320-TRP-003 Rev is ion 0

Project W-320. Combined Pump Winch Assembly - Test Report

1.0 INTRODUCTION

T h i s t e s t r e p o r t i s p repared t o document t h e r e s u l t s o f t h e i n t e g r a t e d t e s t i n g o f t h e P r o j e c t W-320 winch and immers ib le pump assembly. conducted a t t h e Lawrence Pumps f a c i l i t y l o c a t e d i n Lawrence, Massachusetts A p r i l 18, 1996 th rough A p r i l 20, 1996. P r o j e c t r e p r e s e n t a t i v e s w i t n e s s i n g t e s t i n g i n c l u d e d J. R. Bel lomy (WHC) and D. L . Evans (ICF-KH).

A summary o f t h e combined pump/winch t e s t i s p rov ided i n t h e f o l l o w i n g . I nc luded a re background in fo rma t ion , t e s t goa ls and o b j e c t i v e s , a b r i e f d i s c u s s i o n on t h e immers ib le pump 24 hour run - in , a d e t a i l e d d i s c u s s i o n o f t h e combined pump/winch t e s t , and conc lus ions and recommendations.

T e s t i n g was

2.0 BACKGROUND

P r o j e c t W-320 has been e s t a b l i s h e d t o remove and t r a n s p o r t r a d i o a c t i v e and chemical s ludge f rom s i n g l e - s h e l l t a n k 241-C-106 t o doub le -she l l t a n k 241-AY- 102. Waste r e t r i e v a l w i l l be accompl ished us ing pas t p r a c t i c e s l u i c i n g techn iques s u c c e s s f u l l y employed i n p rev ious t a n k waste r e t r i e v a l campaigns.

A l l equipment, components, and i n f r a s t r u c t u r e necessary t o conduct s l u i c i n g opera t i ons a re p rov ided as p a r t o f t h e p r o j e c t (designed, p r o c u r e d / f a b r i c a t e d , i n s t a l l e d , and t e s t e d ) . Th i s i nc ludes immers ib le and i n - l i n e s l u r r y and s l u i c e pumps, winch assembl ies, waste t r a n s f e r l i n e s , a waste s l u i c e r , a new a i r p rocess ing system a t t a n k 241-C-106, a i r , water , and f i r e p r o t e c t i o n systems a t C-Farm, and e l e c t r i c a l upgrades a t bo th C- and AY-Farm. Two ma jo r components o f t h e s l u i c i n g system i n c l u d e t h e immers ib le pumps and t h e winch assembl ies . An immers ib le pump/winch combina t ion w i l l be i n s t a l l e d a t bo th t a n k 241-C-106 and t a n k 241-AY-102. The pump/winch combina t ions a r e v i r t u a l l y i d e n t i c a l w i t h t h e excep t ion o f minor v a r i a t i o n s i n l i n k a g e l e n g t h s t o accommodate t h e d i f f e r e n c e s i n t h e t a n k p i t depths .

The immers ib le pump w i l l be suspended w i t h i n t h e waste t a n k by t h e w inch assembly and w i l l pump waste f rom w i t h i n t h e t a n k t o t h e i n - l i n e boos te r pump l o c a t e d i n t h e pump p i t o f each r e s p e c t i v e tank . The w inch assembly w i l l suppor t t h e immers ib le pump w i t h i n t h e t a n k and p r o v i d e t h e f l u i d connec t ion ( p i p i n g ) f rom t h e immers ib le pump t o t h e i n - l i n e boos te r pump. The w inch assembly w i l l a l s o p r o v i d e t h e mechanical means f o r remote v e r t i c a l p o s i t i o n i n g o f t h e immers ib le pump w h i l e suspended w i t h i n t h e tank .

The immers ib le pumps and t h e winch assembl ies a re be ing f a b r i c a t e d and t e s t e d by o f f s i t e vendors under separa te procurement c o n t r a c t s . a re b e i n g f a b r i c a t e d i n Lawrence, Ma. by Lawrence Pumps i n accordance w i t h Procurement S p e c i f i c a t i o n W-320-P17 under Purchase Order 78259. The w inch

The immers ib le pumps

1


assembl ies a re be ing f a b r i c a t e d i n Washougal, Wa. by O r b i t I n d u s t r i e s i n accordance w i t h procurement s p e c i f i c a t i o n W-32O-PZ4 under Purchase Order 82199.

Procurement s p e c i f i c a t i o n s f o r t h e immers ib le pumps and t h e winch assembl ies r e q u i r e f a c t o r y acceptance t e s t i n g o f t h e f a b r i c a t e d equipment t o demonstrate compl iance w i t h t h e equipment s p e c i f i c a t i o n s and v e r i f y adequacy o f des ign . Procurement s p e c i f i c a t i o n W-320-P17, i n a d d i t i o n t o r e q u i r i n g pump performance t e s t i n g , was m o d i f i e d by ECN-W-320-187 t o i n c l u d e requ i rements f o r pe r fo rm ing a comprehensive t e s t o f t h e combined pump/winch assembly.

Lawrence Pumps was se lec ted as t h e l o c a t i o n f o r performance o f t h e combined pump/winch t e s t , p r i m a r i l y because o f t h e i r pump t e s t f a c i l i t y . f a c i l i t y i n c l u d e s a 27 f o o t t a l l s t r u c t u r e w i t h work p l a t f o r m s a t 9 f o o t i n t e r v a l s , above a 15 by 15 f o o t square, 31 f o o t deep p i t . i d e a l l o c a t i o n t o accommodate i n t e g r a t e d t e s t i n g o f t h e pump and w inch assembl i e s .

To suppor t t h e combined pump/winch t e s t , O r b i t I n d u s t r i e s sh ipped one o f t h e two w inch assembl ies (Winch W-1361) t o Lawrence Pumps. f u n c t i o n a l t e s t i n g o f t h e winch assembly was per fo rmed by O r b i t Manu fac tu r ing u s i n g seve ra l temporary winch components and a pump mockup.

Temporary components i nc luded n y l o n s t r a p i n p l a c e o f t h e s t e e l f l a t cab le , carbon s t e e l sw ive l j o i n t s w i t h o u t r o t a t i o n s tops i n p l a c e o f s t a i n l e s s s t e e l sw ive l j o i n t s w i t h r o t a t i o n s tops , a temporary l i f t i n g f i x t u r e , and a t e s t c o n t r o l pane l . t o accommodate p r o j e c t schedules and was j u s t i f i a b l e i n t h a t temporary components were r e p r e s e n t a t i v e o f wors t case o p e r a t i n g c o n d i t i o n s .

The w inch assembly was shipped t o Lawrence Pumps seve ra l days p r i o r t o t h e scheduled combined pump\winch t e s t i n a p a r t i a l l y d isassembled c o n d i t i o n . Temporary w inch components used i n winch t e s t i n g a t O r b i t I n d u s t r i e s ( n y l o n s t r a p , carbon s t e e l sw ive l s , temporary l i f t i n g f i x t u r e and t e s t pane l ) had n o t been rep laced (as a n t i c i p a t e d ) and were reused f o r t h e t e s t i n g a t Lawrence Pumps. The winch p o s i t i o n i n d i c a t o r a l s o was n o t i n s t a l l e d as t h e CPU had n o t been r e c e i v e d by O r b i t I n d u s t r i e s p r i o r t o shipment.

The w inch p o s i t i o n i n d i c a t i o n system had o r i g i n a l l y been p lanned t o be checked as p a r t o f t h e combined/pump winch t e s t and a p p r o p r i a t e s teps had been i n c o r p o r a t e d i n t h e pump s p e c i f i c a t i o n f o r p o s i t i o n system v e r i f i c a t i o n s by ECN-W-320-187. However, because t h e CPU was n o t i nc luded w i t h t h e w inch shipment, ECN-W-320-263 was genera ted d e l e t i n g t h e requ i rements f o r v e r i f i c a t i o n o f t h e p o s i t i o n i n d i c a t o r . T h i s d i d n o t compromise t e s t i n g o f t h e w inch assembly as c a l i b r a t i o n and t e s t i n g o f t h e winch p o s i t i o n i n d i c a t i o n system was subsequent ly p lanned a t O r b i t I n d u s t r i e s f o l l o w i n g i n s t a l l a t i o n of t h e permanent s t e e l cab le .

The t e s t

T h i s p r o v i d e d t h e

P r i o r t o shipment,

The use o f temporary winch components i n t e s t i n g was necessary

2

WHC-SD-W320-TRP-003 Revision 0

Upon unpacking of the winch assembly at Lawrence Pumps, some damage to the equipment was noted. A nail had been driven through one of the conductors during packaging and the 4 inch stainless steel pipe at the winch support plate was not resting on the support bracket (temporary pipe attachment bracket at the winch plate had been bent). prior to initiation of testing activities, following consultation with ICF-KH Engineering.

Lawrence Pumps repaired the damage

3 .0 TEST GOALS AND OBJECTIVES

The primary objectives of the combined pump\winch test were to: 1) Verify that the immersible pump interfaced properly with the winch assembly during assembly and installation; and 2 ) Demonstrate that both components were capable of operating as designed under simulated operating conditions.

Specific test goals were as follows:

Verify assembly and proper interface of the immersible pump with the winch

Establish means of routing and attachment of pump power and instrumentation cables

Verify installation and performance swivel joint shrouds

Demonstrate proper balance and vertical alignment of the pump\winch assembly while suspended from the crane

Verify the remote installation of combined pump/winch assembly in a 34 inch diameter riser mockup while in the fully retracted position

Demonstrate the free movement of the winch components throughout the full range of motion

Demonstrate the capability of the winch assembly to maintain (hold) vertical pump position at various elevations (proper brake action)

Verify operability of the immersible pump soft start

Resolve concerns regarding wind up resulting from torque generated during startup of the immersible pump

Establish minimum pump suction head (submergence) during operation and startup to prevent vortexing

Demonstrate proper operation of the combined pump/winch assembly while pumping fluid at design parameters

3


V e r i f y t h a t t h e immers ib le pump d r a i n s f o l l o w i n g shutdown.

Demonstrate t h e c a p a b i l i t y o f t h e pump/winch assembly t o be remote l y removed f rom t h e mockup r i s e r i n t h e r e t r a c t e d p o s i t i o n

Re f ine equipment i n s t a l l a t i o n and removal sequence/procedures

Develop v ideo tapes t o suppor t personne l t r a i n i n g and t h e o p e r a t i o n a l read iness r e v i e w process .

4.0 IMMERSIBLE PUMP 24 HOUR RUN-IN TEST

Immers ib le Pump P-1361 was i n t h e f i n a l hour o f i t s 24 hour r u n - i n t e s t upon a r r i v a l o f t h e p r o j e c t r e p r e s e n t a t i v e s a t t h e Lawrence Pump Tes t F a c i l i t y . Water had been p iped d i r e c t l y i n t o t h e pump s u c t i o n i n t a k e such t h a t t h e pump and motor were o p e r a t i n g t o t a l l y i n a i r . no no ted d e v i a t i o n f rom t h e performance requ i rements e s t a b l i s h e d i n t h e procurement s p e c i f i c a t i o n .

A t t h e conc lus ion o f t h e 24 hour r u n - i n pe r iod , upper and lower b e a r i n g tempera tures and motor w ind ing tempera tures were ob ta ined f rom t h e i n t e r n a l RTDs u s i n g a V o l t Ohm Meter . A l l tempera tures ob ta ined were i n t h e d e s i r e d range and w e l l under a la rm s e t p o i n t s p rov ided by t h e motor manufac turer . Temperature read ings recorded were as f o l l o w s :

The pump opera ted ve ry smoothly w i t h

Manufac turer Ohms Corresponding Recommended

- RTD Res is tance TemDerature Alarm S e t p o i n t

Lower Bear ing 129 165 F 225 F

Upper b e a r i n g 135 195 F 225 F

Phase A Winding 141 225 F 330 F

Phase B Winding 141 225 F 330 F

5.0 COMBINED PUMP WINCH TESTING

A t t h e conc lus ion o f t h e immers ib le pump 24 Hour run - in , t h e immers ib le pump was removed f rom t h e t e s t bench and t h e combined pump winch assembly t e s t was i n i t i a t e d . Document Number 91231-1, Combined Pump/Winch Assembly Tes t (a t tached) . summary o f t e s t i n g a c t i v i t i e s i s p resented i n t h e f o l l o w i n g .

T e s t i n g was conducted f o l l o w i n g Lawrence Pump Tes t Procedure A

4


5.1 Equipment Description and Assembly

The equipment subjected to testing during the combined pump/winch test included the 241-C-106 Winch Assembly (W-1361), the temporary (prototype) winch lifting fixture, the winch test control panel, the 241-C-106 Immersible Pump (P-1361), and an immersible pump soft starter procured from H&N Electric to support testing (serial number not obtained). A 34” diameter by 9 foot 6 inch long riser mock-up, representative of the worst case riser configuration to be encountered during equipment installation also was provided to Lawrence Pumps in support of testing.

Prior to the initiation of equipment assembly, all winch components and the immersible pump were staged in the bay area of the test facility. riser had been previously installed at the 9 foot work platform elevation, and the soft starter and winch controller had been mounted on a rack adjacent to the test pit and connected to power.

The winch components were assembled following instructions supplied by Orbit Industries. winch swivel joints and fittings had not been modified following winch testing at Orbit Industries. This proved to be a bad assumption, as later on it was discovered that the 45 degree elbow at the intermediate swivel joint had been rotated 180 degrees out of position.

The mockup

During assembly it was assumed that the configuration o f the

Overall, the assembly of the winch went fairly smoothly; however; a few problems were experienced. lifting extensions which proved to be very difficult to install and for the most part inadequate. motor lifting lugs and had to be hammered into position. Also, because the fit was so tight the attachments were not free to pivot once pinned which caused the winch sheave to be slightly offset.

Another problem which was apparent during the assembly process was the routing of the immersible pump power and control cables. planned to route the cables along the winch piping and through a 2 inch diameter hole provided in the winch plate. was the consensus of the test team that the cables would be less likely to interfere with the operation of the winch if they were routed with the safety cable. Accordingly, the power and control cables were taped to the safety cab1 e .

The hole provided in the winch plate for cable penetration was also not large enough to pass all of the pump cables. cable was routed through the cable penetration and the instrumentation cables were routed through the winch plate drain hole.

The immersible pump motor had been supplied with

The lifting extensions had an interference fit with the

It had originally been

After studying the geometry, it

To accommodate testing, the main power

5


Examinat ion o f t h e immers ib le pump and d i scuss ions w i t h t h e Lawrence Pump r e p r e s e n t a t i v e s revea led some a d d i t i o n a l des ign problems w i t h t h e immers ib le pump. s u c t i o n screen.

Upon i n i t i a l obse rva t i on o f t h e l e v e l d e t e c t o r assembl ies, numerous problems were apparent . i n t e r f e r e d w i t h t h e movement o f t h e sw ive l j o i n t s . Second, t h e l e v e l d e t e c t o r s were mounted i n a h o r i z o n t a l p o s i t i o n such t h a t s ludge c o u l d e a s i l y be t rapped i n t h e e l e c t r o d e cas ing (vendor d a t a recommended mount ing i n a v e r t i c a l p o s i t i o n t o a l l o w d ra inage) . T h i r d , t h e w i r e s e x i t i n g t h e l e v e l d e t e c t o r s were unpro tec ted and exposed. F i n a l l y , t h e l ower l e v e l d e t e c t o r had been p o s i t i o n e d approx ima te l y 14 inches above t h e pump i n t a k e (no more than 6 inches was d e s i r a b l e ) .

The Lawrence Pump r e p r e s e n t a t i v e s i n d i c a t e d t h a t t h e l ower l e v e l i n d i c a t o r was p o s i t i o n e d a t l owes t l e v e l p o s s i b l e and were r e l u c t a n t t o l ower i t s p o s i t i o n because of concerns r e g a r d i n g v o r t e x i n g . However, a f t e r f u r t h e r c o n s i d e r a t i o n i t was agreed t o pe r fo rm a pump draw down t e s t as p a r t o f t h e combined pump/winch t e s t and r e l o c a t e t h e l o w l e v e l d e t e c t o r based on t h e a c t u a l p o i n t a t which v o r t e x i n g occur red .

Because o f t h e problems assoc ia ted w i t h t h e l e v e l d e t e c t o r assembly, t h e assembly was removed p r i o r t o i n s t a l l a t i o n o f t h e winch/pump assembly i n t h e t e s t r i s e r . t h e assembly pend ing t h e outcome o f t h e pump drawdown t e s t .

The f i n a l problem which was no ted a t assembly, p e r t a i n e d t o t h e pump s u c t i o n screen l o c a t e d a t t h e ve ry bo t tom o f t h e immers ib le pump. Dur ing assembly o f t h e pump and winch, t h e Lawrence Pumps p r o j e c t manager no ted t h a t t h e pump s u c t i o n screen would n o t c a r r y t h e l o a d o f t h e pump and suggested t h a t t h e screen be welded i n p o s i t i o n f o l l o w i n g r e c e i p t a t Hanford (sc reens were n o t i n p l a c e d u r i n g t e s t i n g ) . T h i s p resented a problem as t h e p lanned o p e r a t i o n o f t h e pump c o u l d p o t e n t i a l l y r e s u l t i n t h e most, i f n o t a l l o f t h e we igh t o f t h e immers ib le pump, be ing t r a n s m i t t e d t o t h e s u c t i o n screen. Lawrence Pumps agreed t o redes ign t h e screen such t h a t i t cou ld c a r r y t h e l o a d o f t h e pumps and reques ted t h e s p e c i f i c a t i o n be a p p r o p r i a t e l y m o d i f i e d t o i n c l u d e such a requ i remen t .

5 . 2

F o l l o w i n g assembly, t h e pump/winch combina t ion was r a i s e d w i t h t h e overhead c rane and p o s i t i o n e d above t h e mockup r i s e r a t t h e work p l a t f o r m . immers ib le pump was o u t o f p o s i t i o n and r e q u i r e d l o w e r i n g a few inches t o b r i n g i t i n t o t h e p roper r e t r a c t e d p o s i t i o n . by p l a c i n g an a i r wrench on t h e winch d r i v e nu t , depress ing t h e l o c k i n g p l a t e , and r o t a t i n g t h e n u t . tendency t o r u n away (pay ing o u t more cab le than des i red ) d u r i n g t h e t i m e

The problems cen te red around t h e l e v e l d e t e c t o r assembl ies and t h e pump

F i r s t , t h e l e v e l d e t e c t o r s were mounted i n a l o c a t i o n wh ich

Lawrence Pumps acknowledge t h e problems and agreed t o redes ign

I n s t a l l a t i o n o f t h e Winch Assembly i n t h e Tes t R i s e r and System S t a r t u p

The

T h i s was accompl ished manua l ly

T h i s p rocedure proved d i f f i c u l t as t h e w inch had

6


required to raise the air wrench off the drive nut such that the locking plate could engage.

About the time the immersible pump retracted position adjustment was completed, Lawrence Pumps received shipment of the swivel shrouds from Orbit Industries. The swivel shrouds were unboxed and installed at each of the swivel joint hose connections. The installation of the swivel shrouds was difficult as insufficient clearance was available for the shroud to clear the pipe and hose at the upper and lower clamping points. Adequate clearance was also not available at the bolt tabs to allow placement of a socket or wrench on the nut/bolt heads. None of the problems encountered with the shrouds were of a nature which precluded installation; however; it was apparent that the design was in need of refinement. shrouds also appeared to have a high potential to collect and trap tank waste. This was thought to be a minor problem which could be solved simply by providing drain holes or slots in the shrouds.

Following installation of the shrouds the overall pump/winch assembly was inspected for plumb while suspended from the crane. The immersible pump was not hanging as plump as desired and the winch sheave appeared to be skewed which resulted in a slight twist in the winch cables. The intermediate swivel joint was also hanging in a skewed position such that the swivel joint plane of rotation and was not parallel or in alignment with that of the other swivel joints. problems without modification of hardware and none of the problems noted would have any significant influence on component operation, the decision was made to proceed with testing.

Additionally, it was noted that the winch lifting fixture had not been correctly installed. During assembly it was assumed that the radial spacing of three hook arms on the lifting fixture was symmetrical (positioned at 120 degrees). However, upon studying the configuration and winch assembly drawings closely, it was determined that the hook arm positions were not radially symmetrical and the lifting fixture had been incorrectly positioned. It should be noted, that it was very difficult to visually determine the proper orientation of the lifting fixture as the difference in spacing was very slight (not obvious) and no markings were present. This condition, although undesirable, also did not create a condition which warranted abandonment of testing.

The pump/winch assembly was then lowered into the mockup riser. operation went very smoothly and without incident. Considerable operator attention did have to be provided to the winch control cables and the pump cables during the installation. It should be noted that this was not much of an issue and was overcome in a subsequent installation by wrapping the cables around winch assembly above the winch plate.

In addition to clearance problems, the

As it appeared that nothing could be done to correct the alignment

This

7

WHC-SD-W320-TRP-003 R e v i s i o n 0

Cables were then Once t h e pump winch assembly was i n p o s i t i o n w i t h i n t h e mockup r i s e r , t h e w inch motor d r i v e assembly was connected t o t h e winch. connected t o t h e r e s p e c t i v e equipment c o n t r o l l e r s and s t a r t u p checks were per fo rmed. and t h e o p e r a t i o n o f t h e upper l i m i t sw i tches were v e r i f i e d .

An a t tempt was then made t o bump t h e immers ib le pump such t h a t p roper phase r o t a t i o n c o u l d be es tab l i shed . s o f t s t a r t e r c o u l d n o t be made t o ene rg i ze t h e pump. t h e s o f t s t a r t vendor (H&N E l e c t r i c ) , i t was de termined t h a t t h e s o f t s t a r t e r i n c l u d e d p r o v i s i o n s f o r an emergency s top which had t o be presen t for t h e s t a r t e r t o opera te . A jumper was i n s t a l l e d a t t h e t e r m i n a l b l o c k f o r t h e emergency s t o p wh ich so l ved t h e problem and a l l owed t h e s t a r t e r t o opera te . The motor was then bumped, checked f o r p roper phase r o t a t i o n ( though t t o be c lockw ise when viewed f rom above, l a t e r found t o be coun te r c l o c k w ise when viewed f rom above) and a l l owed t o opera te momentar i l y i n a i r .

5 .3 Combined Pump Winch Test

F o l l o w i n g s t a r t u p checks t h e immers ib le pump was lowered i n t o t h e p i t . pump was lowered t h e i n t e r m e d i a t e sw ive l r o t a t e d i n t h e wrong d i r e c t i o n . pump was r a i s e d and re lowered w h i l e app ly ing a manual f o r c e t o r o t a t e t h e sw ive l i n t h e p roper d i r e c t i o n . extended p o s i t i o n .

Dur ing t h e l o w e r i n g o f t h e pump cons ide rab le n o i s e f rom t h e winch was observed. Upon f u r t h e r o p e r a t i o n and e v a l u a t i o n o f t h e n o i s e i t was no ted t h a t even though t h e i n t e r f a c e had been l u b r i c a t e d , t h e socket on t h e w inch d r i v e n u t was wear ing i n t o t h e l o c k i n g p l a t e . T h i s was de termined t o be an unacceptab le c o n d i t i o n , as l o n g te rm o p e r a t i o n would e v e n t u a l l y r e s u l t i n t h e socket wear ing th rough t h e l o c k i n g p l a t e , e l i m i n a t i n g t h e l o c k .

A lso , as t h e pump was lowered, t h e l ower hose k inked r a d i c a l l y and d i d n o t d i s p l a y t h e same a c t i o n as observed i n p rev ious t e s t i n g conducted a t O r b i t I n d u s t r i e s . The w inch drawings and t h e v ideo tapes o f t h e t e s t i n g a t O r b i t I n d u s t r i e s were c a r e f u l l y rev iewed and i t was de termined t h a t t h e 45 degree elbow a t t h e i n t e r m e d i a t e sw ive l j o i n t was 180 degrees o u t o f p o s i t i o n . No e x p l a n a t i o n c o u l d be o f f e r e d as t o how o r why t h e 45 degree elbow was i n t h e improper p o s i t i o n , a l t hough a minor d isc repancy w i t h t h e drawing was d i scove red wh ich c o u l d have c o n t r i b u t e d t o t h e m i s o r i e n t a t i o n .

Because t h e 45 degree elbow was i n t h e wrong p o s i t i o n , t h e d e c i s i o n was made t o d i s c o n t i n u e t e s t i n g , remove t h e pump winch assembly f rom t h e mockup r i s e r , p r o p e r l y p o s i t i o n t h e 45 degree elbow, and resume t e s t i n g f rom t h e s t a r t . However, s i n c e t h e d i scha rge p i p i n g f rom t h e winch had a l r e a d y been connected i t was dec ided t o f i r s t a t tempt i n i t i a l o p e r a t i o n o f t h e immers ib le pump w h i l e suspended f rom t h e winch.

The w inch was powered up, p roper phase r o t a t i o n was e s t a b l i s h e d ,

T h i s p roved f r u s t r a t i n g as t h e immers ib le pump A f t e r seve ra l c a l l s t o

As t h e The

The pump was then lowered t o t h e f u l l y

8


With the pump in the fully extended position, the pit was filled with water to a point where the pump motor was completely submerged. started with the soft starter set at 5 seconds. seconds of operation no liquid pumping was observed. evaluation of the circumstances, it was determined that the motor rotation was in the wrong direction. the soft starter and the motor was restarted with the proper rotation (visible motor rotation in the counter clockwise direction when viewed from above). The startup torque of the motor resulted in an approximate 90 degree rotation of the pump which was about what had been anticipated. The pump operation was very smooth and no problems were noted.

The pump was then After approximately 30

Following a short

Two of the motor power conductors were switched at

Following operation of the pump, the pump was raised to the retracted position using the winch assembly. During raising of the pump, the power/control cable assembly swung between the swivel shroud and the motor casing. This condition did not impair operation of the winch assembly but was a concern as it appeared to have potential to cause damage to the cables.

Once the pump/winch assembly was in the retracted position, power and control cables were disconnected and the winch drive assembly was removed. Power and control cables were wrapped around and tied to the winch gear box. The winch/pump assembly was then removed from the mockup riser using the overhead crane without incident. solved all problems experienced at Orbit Industries during removal. No problems were noted during the removal process.

The pump/winch assembly was positioned on the floor of the test facility and several adjustments were made. the proper position and the safety cable was disconnected at the winch plate and twisted approximately three revolutions in a counter clock wise direction such that the cable bundle looped away from the winch piping and swivels. Additionally, the motor 1 ifting brackets were removed and rotated 180 degrees slightly shifting the center of gravity of the pump due to the eccentric design of the motor lifting extensions and the winch lifting fixture was properly positioned on the winch plate.

The swivel shrouds proved to be very effective and

The 45 degree elbow was rotated 180 degrees to

While the winch assembly was removed for the adjustments, the pump/winch combination was inspected to verify that the assembly was free draining. signs of trapped water were observed,during the disassembly required to perform the adjustments.

Following the adjustments, the pump winch assembly was positioned above the mockup riser and lowered into position. Wrapping the control cables around the gear box completely eliminated problems encountered in the previous installation. improved by the adjustments. Overall, the installation went very smoothly and was accomplished with virtually no operator assistance. was maintained at all times and no problems were noted.

No

The balance and plumb of the pump/winch assembly was also

Adequate clearance

9

WHC-SD-W320-TRP-003 R e v i s i o n 0

The winch motor d r i v e mechanism was then connected t o t h e winch and t h e winch and pump power and c o n t r o l cab les were connected. t h e immers ib le pump was lowered i n t o t h e f u l l y extended p o s i t i o n u s i n g t h e winch assembly. The r o t a t i o n o f t h e 45 degree elbow i n t o t h e proper o r i e n t a t i o n r e s u l t e d i n t h e s w i v e l s r o t a t i n g i n t h e proper d i r e c t i o n , as expected. The i n t e r m e d i a t e swive l was s t i l l was o r i e n t e d i n a skewed p o s i t i o n approx imate ly 30 degrees o u t o f t h e d e s i r e d p l a n e o f a c t i o n . T h i s had a tendency t o r e s t r i c t t h e mot ion o f t h e i n t e r m e d i a t e s w i v e l and t h e s w i v e l a t t h e pump f l a n g e due t o t h e u n d e s i r a b l e f o r c e s a c t i n g on t h e s w i v e l face . d i d n o t r e s u l t i n a s e r i o u s problem, however i t d i d c o n t r i b u t e t o some minor k i n k i n g o f t h e hose i n t h e lower pump p o s i t i o n s . p o s i t i o n i n g o f t h e immers ib le pump b o t h p r i o r t o , d u r i n g , and f o l l o w i n g s t a r t u p .

With t h e pump i n t h e f u l l y extended p o s i t i o n t h e p i t was f i l l e d w i t h water u n t i l t h e motor was t o t a l l y submerged. t o evacuate t h e water f rom t h e t e s t p i t , l o w e r i n g t h e l i q u i d l e v e l u n t i l a i r was observed e n t e r i n g t h e i n t a k e (as i n d i c a t e d by a r e d u c t i o n i n d ischarge pressure and change i n pump sound). a n t i c i p a t e d and stopped pumping l i q u i d when t h e water l e v e l reach a p o i n t a t which t h e pump base p l a t e ( s u c t i o n i n t a k e ) was submerged approx imate ly one- h a l f inch . No s i g n s o f v o r t e x i n g were observed.

The l i q u i d l e v e l was then r a i s e d t o a p o i n t a t which t h e bottom o f t h e pump was submerged approx imate ly 4 i nches . i n t o t h e t e s t p i t and f u l l f l o w c o n d i t i o n s e s t a b l i s h e d , t h e pump was s t a r t e d , a l lowed t o r u n a few minutes , and stopped severa l t imes. was v e r y impress ive and n o t a f f e c t e d by t h e wave a c t i o n c r e a t e d by t h e r e t u r n l i n e d i s c h a r g e i n t o t h e t e s t p i t .

The water l e v e l o f t h e p i t was r a i s e d two f e e t and t e s t i n g cont inued i n accordance w i t h t h e t e s t procedure. and submerged 2 f e e t t h e pump was s t a r t e d and r a i s e d w i t h t h e winch ( w h i l e pumping) t o a p o i n t where t h e bottom, o f t h e pump was submerged approx imate ly 2 inches (gasket between t h e pump bottom base p l a t e and t h e bottom o f t h e i m p e l l e r c a s i n g used as r e f e r e n c e ) . Once t h e pump was a t t h i s l e v e l t h e winch was stopped, t h e pump was shut down, a l lowed t o d r a i n , r e s t a r t e d , and opera ted f o r a few minutes. The water l e v e l i n t h e p i t was then r a i s e d two f e e t and t h e procedure repeated u n t i l t h e pump had been r a i s e d a minimum o f 12 f e e t .

I n t h i s phase o f t e s t i n g , no problems were no ted w i t h t h e o p e r a t i o n o f t h e pump. a coup le o f problems beyond those p r e v i o u s l y no ted were observed. These problems were assoc ia ted w i t h t h e winch gear d r i v e / m o t o r assembly, t h e winch assembly i n t e r n a l d r i v e s h a f t , and t h e winch sheave.

Two problems were exper ienced w i t h t h e winch gear d r i v e / m o t o r assembly. F i r s t , toward t h e l a t t e r p a r t o f t e s t i n g a n o i s e i n t h e i n s t r u m e n t c a b i n e t above t h e motor gearbox was overheard.

F o l l o w i n g s t a r t u p checks

Th is

It a l s o e f f e c t e d r a d i a l

The pump was then s t a r t e d and a l lowed

The pump performed much b e t t e r than

With t h e pump d ischarge r o u t e d back

The pump per formance

Beginning w i t h t h e pump f u l l y extended

The winch a l s o performed i t s des ign f u n c t i o n s w i t h o u t f a i l u r e ; however;

I n t r a c i n g a n o i s e i t was d iscovered

10


that the set screws on the belt drive wheel had loosened and/or fell out. This allowed the drive wheel to move up the drive shaft such that it was not in proper alignment with the drive wheels on the resolver and the limit switch mechanism. In addition to being the source of an undesirable noise, it also caused some minor damage to the drive belt.

The second problem noted at the winch gear drive/motor assembly, was a noise emitted from the motor braking mechanism. Trouble shooting of the noise was not pursued as the noise was not discovered until late in testing. friction type noise sounded as though something had become loose within the brake mechanism. The noise was not thought to be a serious problem but will require further evaluation (to be resolved at Orbit Industries).

During operation, the winch assembly internal drive shaft was also noted to have a fairly significant wobble. and was determined to contribute to heat detected on the exterior of the winch gear box. observed while operating under load. operation of the winch assembly, if uncorrected the long term effects could potentially result in detrimental effects to the winch drive mechanism. It was the consensus of the group that the problem could be resolved simply by installing a bearing near the shaft seal.

The final problem noted with the winch assembly, was associated with the sheave assembly. During operation of the winch (primarily while lifting), the sheave assembly emitted a high pitched resonance. This did not affect operation of the sheave however, it was a very annoying undesirable noise. The noise had not been present during winch testing conducted at Orbit Industries and was attributed to the skewed orientation of the sheave assembly.

The

This was thought to be the source a noise

The side plate of the winch assembly was removed and the winch was Although this problem did not impair

Testing was concluded by raising the winch to the fully retracted position and shutting down system power. As a final step in testing, accessible components o f the pump/winch assembly were inspected for signs of damage. signs of damage or problem areas were noted.

The entire test sequence was video tapped by Lawrence Pumps as well as by the members o f the project team witnessing testing. available for review and will be retained as part of project files.

No further

Video tapes of testing are

6.0 CONCLUSIONS AND RECOMMENDATIONS

As a result of testing, it can be concluded that the pump/winch assembly in its present configuration is capable of performing its intended design function. Although several problems were identified, no major problems were discovered which could be considered significant.

11


Several items were noted during testing which will require further evaluation and/or correction. installation of the pump/winch assemblies in the waste tanks.

The following actions are recommended prior to

. .

Redesign immersible pump level detector assembly to orient detector electrodes in a vertical position, protect wires from damage and eliminate interference with the swivel joints.

Redesign and/or modify immersible pump motor lifting extensions to provide improved interface with the motor and the winch sheave assembly.

Revise winch drawings to show routing of winch power and control cables with the safety cables.

Revise winch drawings or ensure assembly instructions require the winch safety cable be rotated a minimum of three revolutions in the counter clock wise direction prior to attachment to the winch plate.

Increase the size of the cable penetration hole in the winch plate to accommodate all of the immersible pump cables or revise drawings to reflect routing of control cables through the winch plate drain hole.

Modify the immersible pump suction screen as required to ensure the screen does not collapse under all anticipated load conditions.

Modify swivel shrouds to provide adequate clearance at the pipe/hose clamping points and at bolt tabs.

Modify swivel shrouds to allow drainage of collected liquids

Install bearings at sheave assembly to eliminate resonance.

Install bearing at the socket interface on the winch drive nut locking plate.

Request Orbit Industries trouble shoot and repair winch motor brake mechanism.

Install bearing near the shaft seal on the winch assembly drive shaft.

Perform testing at Orbit Industries using steel pipe in place of upper hose to determine if swivel action and winch operation is improved.

Evaluate winch sheave/cable orientation to determine if adjustments are possible or feasible to improve orientation.

Mark or color code winch lifting arms such that proper orientation on the winch plate is easily discernable.

12

. WHC-SD-W320-TRP-003 R e v i s i o n 0

I n c l u d e requ i rements i n assembly i n s t r u c t i o n s t o check t o r q u e on t h e b e l t d r i v e wheel s e t screws i n t h e ins t rument c a b i n e t .

F o l l o w i n g a l l m o d i f i c a t i o n s t o t h e winch assemblies, p e r f o r m f i n a l winch

ECN-W320-295 has been generated t o mod i fy t h e winch assembly i n accordance w i t h t h e recommendations no ted above. t o proceed w i t h t h e recommended m o d i f i c a t i o n s t o t h e immers ib le pump.

F o l l o w i n g comple t ion o f t h e m o d i f i c a t i o n s , t h e winch assembly w i l l be s u b j e c t e d t o a comprehensive per formance t e s t a t O r b i t I n d u s t r i e s . t h i s t e s t i n g an immers ib le pump w i l l be shipped from Lawrence Pumps t o O r b i t I n d u s t r i e s . T h i s t e s t i n g w i l l serve as a f i n a l des ign v e r i f i c a t i o n p r i o r t o i n s t a l l a t i o n o f t h e pump/winch combina t ion i n t h e waste tank .

f a c t o r y acceptance t e s t i n g u s i n g an immers ib le pump.

Lawrence Pumps has a l s o been d i r e c t e d

To suppor t

13

WHC-SD-W320-TRP-003 Revis ion 0

JOB SPECIFICATION locument Xumocr: 91131-1 .evision: 0

Cunomer: Wcstin$touse W o r d Company LPI Shop O r d e r EK3 1-03-9123 1

age 1 of2 WHC P.O. NO.: W4-XW-78259

R e f m c c s : (a) Wesanghoure W o r d E a # W-i20-187. dated 1/19/96. Appendix C @ a g u 10. 11 9 12).

Wmch Innall-C Tank 9 Drawng Lis). (b) IC: Kaiser M o r d Co. Drawing it H-2.518494, rev. 0. (piping Pump &

1.0 PURPOSE

This procedure establishes the combined pump I winch assembly test requirements in accordancs With Rcfermc: (a) and 13).

2.0 SCOPE

2.1 Testing should be broken up into three sw.ions and should be Witnessed and approved by a WHC repraentaave.

2.1.1 Combined ?urnpiwinch ysembly tat. page 10 o f r e i (a). 2.1.2 Winch lowerins raising and bmk: tests, pages 10 m d I 1 ofrec (a). 2.1.; Pump opemion tw pager I 1 and 12 of re i (a).

j.0 TESTCOhDITXONS .

3.1 See reference (a) for cur conditions.

4.0 PROCEDURE

4.1 The testing should be performed per reference (a).

a;dd 4& Engineering d a t e

14

BEST AVAILABLE COPY

WHC-SD-W320-TRP-003 Revis ion 0

Document Number: 9123 1-1 Revision: 0 Paqe 2 of 2

Customer: Westinghouse Hanford Company LPI Shop Order: EK3 1-03-9123 1 WHC P 0. No. MZ4-XW-78259

5.0 ACCEPTAVCE CRITERIA

5.1 WHC representativewill witness and approve all testing and any modifications to the assembly.

15


ENGINEERING CHANGE NOTICE CONTINUATION SHEET P89. 10 d

~ C N U-320-187 3.t. 1/13/96

:OMBINED PU?APWINCH ASSEMBLY TEST The buyer will provide a field rcpresentuive to witness and ipprove all at' the below PumpNinch .Assembly testing and any modifications to rhis assembly. The Seller shall jrovide at least one week notice to Buyer before chis resting beg&. The Buyer's tic!rl representative in mmlwion with the vendor will determine what corrective adonr. 2 any. shall be implcmcnled based on the ' ~ 1 s of uch of be below mu.

I. Assemble FumpiWmch uxmbly in accord- with the winch manufdcrurer's inrrmcfionc. Balance and !erd~y.alipn~the=assembly.(th~ pump.musr h g me vemcd

l. Insnll and r c ~ o v c the Immmenible h m p N i n c h Assembly in the test riser with the CMC operator or signal aan viewing only i o m above. ic.. simulate the h i r e d visibility of acrud Reid i d l a t i o n opentiom. The .mullaiodrcmonl operation shall be repeated once to show rc;rcnabiliry. PumpAVimch Assembly shall be in rhe hlly rcuacted position during insullarion and removal through the test riser.

1. Monitor and document any inrerferencesiproblems identitied duriny this tesf.

$. Provide m u i v c md/or dawin: m u h p rceommendauonc for soditicltions of the assembly to c o m t m y iroblemr-idencilidduring the rest: ..:. .

5. The buyer's rqraentarive rhdl be rapomi'ik for m y Held moditicxion resulting fnrm this testing.

5. If mcdiicationc u e n u t s a y . rcpeu the test to verify that the problem have b r a coneued.

Video - The video taping of rhit ponion ofthe test should show rhe following. as a minimum:

I in. when fully ra id). . .

.

a. Raising the PumpAViih Assembly into the venial position b. Centering rhc Pump/Winch Assembly Over the riser c. The boaom end of the pump enuring the riser viewed from above d. The pump coming through dK boaom of the Cut riser viewed from below e. The nuung of the winch assembly t h e e with the test riser flange f. The inurvjon of the RmpiWnch .ksembly with chc rest riser wembly during the inculluion ad removal p-

WNCk cOV%rUNG. RAISING AND BRAKE TE5TS

I . Alter cnmpletion of rhc Jbove testing. insull [he winch drive asembly. e l ~ i n l p w e r and canuob. and initialize the pump position irulicator. The wt will be condund with the pump uff. Opcrafe the winch to bl ly


ecr U-320-187 ENGINEERING CHANGE NOTICE CONTINUATION SiiEET

P W O 11 Of ’- Da<* 1/19/96 lower and raise the pump. During the lowering and raising operation. che winch will be stopped DCY the upper and lower limirs of uavel and at approximately the mid point. to verify that the winch brake funnioru properly. .At each of these locations. the winch position wiU be nevurcd and recorded and the indication system will be dated for m r a c y . Thc cat shall be repeated at lust once IO verify repeatability.

2. Monitor and document any interferences/problem idenuied during chis :est.

3. provide ynarive and/or drawing m u h p recommendations for ncdificadons of dy assembly :o correct any problems idendfled during the test.

4. . .. The .- __ buyer’s -_-. r c p ~ ~ e ~ c ? i i v c .

5. Wmdiications drc ;~ctusary. repeat the test to verify lhat ;he problems have been corrected.

Video - The video uping of chis pardon of the t a r should show ;he following. 1 a minimum:

shaIl be mpoasible for any field mcdifiwtion raulting from this rating. . .

a. The movement of the bore and pump during the lowering and raisins process b. The stoppinp of the pump motion when the winch motor is stopped

&%iEOCER&TION TEST - - . . . .

1. After the rhove :at, cnmplere the irrttalluion uf rhe pump clccuical (pvwer & controls) and piping s y r t m (Hmiord disc.iu:c bed adapter. load rimuldtinp vdvc, rlow monitoring equipment. and ysociated piping).

2. Fully extend the Pump Winch Assembly and fill chc pit to achieve approximately 1 foot depth of submergmce o v a the pump intake. With the pump in thir configuration. start and stop the pump, observe and dccummt rhe rouldDp d o r u V w i n d u p c f f a s .

3. Test the pump/winch urcrnbly at 2 .%a i n t e r 4 dyouph the range from fully extended to a point w k e thc pump is raised I? fm above chii level. concurrently maintaining the water level to a I foot deprh aver thc pump intake. Sm .and r q rhc pump. o b w m and dacument the resulting windup effecu at each of IheK Ievelr. Ako record flow d i u at cuh of that Icveb. The winch position will be mcaurcd and recorded and thc i n d i d o n system will be checked for xcuncy at each of these stop positions.

4. With the pump running. operate the winch utembly through the above nnge o f height adjuxmcnc. recording daw data*&ions.

5. Monitor and document any interfercnca/prnblcms identitied during this rest.

I

ENGINEERING CHANGE NOTICE CONTINUATION SHEET ?15. l e Dt

7. T k buyer’s :cprcreatauve shall be raponsible for any field zodificauon resulting from this radnp.

8 . If mcdiiiudonr are necessary. rcput .he test to verify dut thc problem hlvc been correc:cd.

SW ‘J-320-187 3.1. 1/19/?6

3. Document that the pump h free draining.

Video - The video raping of this porrion oi the test should show the Following. as a minimum:

a. The movement of thc hose and pump during all the r d r t o p s of the pump 9. The movement oi the winch hose dnd pump during fhe :en@ adjustments

e. The final h l l retraction a i pomp and hose. d. The r e m 4 of PumprWinch Assembly from the riser

.. .

. .. ..

To

SST R e t r i e v a l P r o j e c t s From Page 1 of 1 SST R e t r i e v a l P r o j e c t s Date June 15, 1996

W . Abdual J. W . B a i l e y J. R. Bel lomy R. R . Bevins D. E . Bowers D. A . Bragg M. R . Custer D. L. Evans W . M. Ha r t y J. J. Huston C . D. Jones K . W . L e l i e f e l d R . P. Marsha l l T. H. May C . E. Nor ton W . J. Powell C . G . S t i t e s D. L. Stone C . D. West

P r o j e c t W-320 F i l e s Cen t ra l F i l e s

Project Tit lelWork Order

Test - Test Report / D2MP6 WHC-SD-W320-TRP-003, P r o j e c t W-320 Combined Pump Winch Assembly

s7-53 S2-48 S2-48 S2-48 S6-01 R1-43 S2-47 S2-47 S5-13 S2-48 s2-47 S2-48 H5-61 S2-48 S2-48 H5-49 S2-48 S2-48 SJ-53

s2-48 A3-88

EDT No. 606554 ECN No. N/A

X X X (2 Copies) X X X X X X X X X X X X X X X X

X X (2 Copies)

Name

A-6000.135 (01/93) VEF067

Text Text Only Attach./ EDT/ECN MSlN With All Appendix Only

Attach. Only

16 '@ei$ 2 - unt digital library/67531/metadc... · the equipment subjected to testing during...

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