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PetroChem & PowerThis information is proprietary and confidential to Greene, Tweed. Redistribution is forbidden without consent of Greene, Tweed.
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Salem and Hope Creek Nuclear Generating Stations
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Presenters …..
Presented August 2013 by:– Gene Delp – PSEG– Matthew Palucci – Greene, Tweed & Company
Updated Presentation – January 28, 2015– Greg Gedney, Greene Tweed – Pump Segment Manager– Jenna Fitz – Greene Tweed – Field Applications Engineer
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PSEG Nuclear – Salem and Hope Creek
Second largest site in country– Approximately 3,575 MWe– Enough electricity for ~3 million homes
Each unit licensed for 60 years (license renewal completed)– Salem Unit 1 (PWR, 1180* MW) – August 2036– Salem Unit 2 (PWR, 1175* MW) – April 2040– Hope Creek (BWR, 1219* MW) – April 2046
Each unit on an 18 month refueling cycle– Spent fuel dry cask storage facility on property– Enough space for 200 casks – all 3 units, 60 years
*Mean Annual Net Rating
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WGID Function
Salem – PWR Steam Generator Feed Pump (4) Model 24 WGID – 171 Pumps put in service –
– Salem Unit 1: 1976– Salem Unit 2: 1980
Hope Creek – BWR Reactor Feed Pump (3) Model 17 WGID – 171 Hope Creek – 1988
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WGID #11 Steam Generator Feed Pump
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WGID #11 Steam Generator Feed Pump
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Pump Cross-Section
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Pump BOM
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Breakdown Bushing Cross-Section
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Bushing – Sleeve Detail
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Detail Drawing w/ Greene Tweed Insert
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Breakdown Bushing Carrier
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Problem
Inherent start-up characteristic Temperature Gradient
Sealing System was Seizing & Galling
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Effect
2 pumps for 100% power
With 1 pump; 55% power
Loss of revenue >$500K /Day
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Breakdown Bushing Assembly
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Solution
Replaced ‘old style hardened steel (410 SS ) breakdown bushing with WR®525
Companion sleeve (old style) was 410 SS, now Chrome Oxide Ceramic (plasma applied coating)
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WR525 Spec Sheet
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WR®525 Characteristics
Composite made of continuous carbon fiber and poly-ether-ether-ketone, or PEEK (70 percent carbon fiber by weight)
Made using fiber-placement technology Physical properties approaching that of steel in the direction of fiber
windings Radial coefficient of thermal expansion is less than 1/2 that of
carbon steel Recommended for temperatures up to 525°F (274°C) Utilized for both press-in and press-on applications (impeller rings,
case rings, bushings, floating and split components) Size ranges available up to 48" diameter by 48" long
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WR®525 Manufacturing Process
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Typical WR525 Applications
Bushings (throat, throttle, diffuser, stuffing box, etc.) Bearings (line-shaft, etc.) Sleeves and liners (shaft over-sleeves, thick CX part liners) Case and impeller wear rings (floating, press-in, press-on) Split parts (concentric, steady-rest bushings, stuffing box) Virtually any wear component found in a pump (horizontal and
vertical) can be upgraded to a composite material or metallic/composite assembly for increased pump performance.
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Advantages of WR525 - Compared to Metallic Components
Nongall/nonseize—enables closer clearances Improved wear resistance in low specific gravity media Lower heat generation in momentary upsets (lower coefficient of
dynamic friction) Ductile nature of the thermoplastic composite materials assist in
dampening shock/vibration displacements Enhanced corrosion resistance through greater chemical
compatibility Sacrificial when severe upset conditions are unavoidable
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WR525 versus carbon or Graphalloy
Impact resistance Lower wear under heavy load Greater abrasion and erosion resistance Increased thermal shock resistance Will not fracture during installation Can be used under tension as well as compression
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Independent ASTM G105 Test
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Mass Loss Comparison of All Samples
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Teamwork
Teamwork– PSEG requested the pump upgrades– Flowserve (OEM) provided full cooperation
Worked with Flowserve team at Phillipsburg, NJ
Greene Tweed, Flowserve, & PSEG jointly redesigned breakdown bushing, eliminating multiple groove labyrinth
Maintained original running clearance (.010” -.012”)
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Performance
Physically performing – constant leak-off (has been reduced) the mixed leak-off is controlled at 140°F
The more leak-off there is; one must inject more water to maintain the 140°F
The first 18 month cycle – the controlling temp. never got above 125°F
Injection valves - injecting miscellaneous condensate water into the breakdown bushings
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WGID #11 – Control Temp Gauges
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WGID #11 – Control Temp Gauges
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Results
Results– No seizing and galling episodes
– Significantly less injection water and no leak-off drain system challenges
Runtime– 36 months to date with no incidents
– #11 pump was pulled at 18 months to inspect with no increase in running clearance
– Full cycle run time target – 6 Refuel Cycles (9 years) (NEIL)
– Runtime - #21 & #22 pumps 24 months run time without incident or increased leakage
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Summary
Other equipment upgrades –
CWP – Circulating Water Pumps
SWP - Service Water Pumps– - Salem (12) & Hope Creek (4)– . In the process of upgrading bearings & wear rings to AR-HT from cutlass rubber (two complete)
Screen Wash Pumps- all 11 have been upgraded to AR-1 from rubber cutlass
Heater Drain Pumps- have upgraded 2 of 6 pumps to WR525. None running yet
Condensate Pumps- have upgraded 1 of 6 pumps to AR-HT. None running yet.
CWTWS(FLABA) – Travelling Screens
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Pump References
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Quick Response Capability (QRC)
28,000 sq ft – 2.600 m² Composite Centre Of Excellence
7,000 sq ft – 650 m² dedicated to quickly responding to WR / AR composite needs