Nuclear Maintenance Applications Center:

Condenser Air Removal Equipment Maintenance Guide

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10427360
10427360
Nuclear Maintenance Applications
Center: Condenser Air Removal
Equipment Maintenance Guide

1015058

Final Report, December 2007

EPRI Project Manager

M. Bridges

ELECTRIC POWER RESEARCH INSTITUTE

3420 Hillview Avenue, Palo Alto, California 94304-1338 • PO Box 10412, Palo Alto, California 94303-0813 • USA
800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com

10427360
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES
THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN
ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH
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PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT.

ORGANIZATION(S) THAT PREPARED THIS DOCUMENT

Sargent & Lundy, LLC

NOTE
For further information about EPRI, call the EPRI Customer Assistance Center at 800.313.3774 or
e-mail askepri@epri.com.

Electric Power Research Institute, EPRI, and TOGETHER…SHAPING THE FUTURE OF ELECTRICITY
are registered service marks of the Electric Power Research Institute, Inc.

Copyright © 2007 Electric Power Research Institute, Inc. All rights reserved.

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CITATIONS

This report was prepared by

Sargent & Lundy, LLC

55 East Monroe Street
Chicago, IL 60603

Principal Investigators
R. Robey
B. Gogineni

This report describes research sponsored by the Electric Power Research Institute (EPRI).

The report is a corporate document that should be cited in the literature in the following manner:

Nuclear Maintenance Applications Center: Condenser Air Removal Equipment Maintenance

Guide. EPRI, Palo Alto, CA: 2007. 1015058.

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10427360
REPORT SUMMARY

The Condenser Air Removal Equipment Maintenance Guide provides power plant maintenance
personnel with current maintenance information on this system. This guide will assist the plant
maintenance personnel in improving reliability and reducing maintenance costs for the condenser
air removal (CAR) equipment.

Background
Most NMAC member plants use either steam jet air ejectors (SJAEs) or vacuum pumps to
remove air and noncondensible gases from the condenser. This equipment is vital for good plant
performance because if noncondensible gases are allowed to build up in the condenser, vacuum
will decrease and the saturation temperature of the condensate will increase, reducing overall
plant efficiency. These undesirable gases can also blanket the tubes of the condenser, which
effectively reduces the heat transfer capability of the condenser. For most plants, air-removal
equipment also serves to establish an initial condenser vacuum during plant startup.

Objectives
• To describe typical CAR equipment
• To provide guidance on preventive maintenance (PM), repair and replacement, and
troubleshooting recommendations for CAR equipment

Approach
The intent of the Condenser Air Removal Equipment Maintenance Guide is to address various
engineering, maintenance, and operations issues regarding equipment maintenance. Key
suppliers of air-removal equipment were solicited for assistance to ensure that the guidance
reflected the latest technologies available in the industry. A technical advisory group was formed
that consisted of EPRI NMAC utility members and equipment suppliers. Input was solicited
regarding current maintenance issues for the equipment. Experience-proven practices and
techniques were identified during this effort and are compiled in this report.

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Results
This technical report provides an overview of system design parameters and familiarizes
maintenance and engineering personnel at power plants with the components used for removing
air from condensers and for maintaining vacuum. The focus of the report is to provide guidance
for performing PM on the equipment. The report also provides guidance regarding the repair
and/or replacement of components and which components are typically repaired or refurbished
on site. Troubleshooting guidance is also provided for those components for which it is
applicable.

EPRI Perspective
The information contained in this guideline represents a significant collection of technical and
human performance information, including techniques and good practices related to CAR
equipment that is present at most power plants. This information provides a single point of
reference for plant engineering and maintenance personnel, both in the present and in the future.
Through the use of these guidelines, EPRI members should be able to significantly improve and
consistently implement the processes associated with the reliable operation of their CAR
equipment.

Keywords
Vacuum pumps
Air ejectors
Condensers
Maintenance
Preventive maintenance
Troubleshooting

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ACKNOWLEDGMENTS

Nuclear Maintenance Applications Center (NMAC) would like to acknowledge the following
individuals for their contributions during the development of this report.

Technical Advisory Group Members:

Name Utility/Location

William Black Luminant/Comanche Peak

Franc Brili Krsko

Jerry Dorn PPL/Susquehanna

Cuong Duong Exelon/TMI

Javier González Vandellos II

Edward Kramer Amergen Energy

Sarah McDaniel Progress Energy/CR3

Tom Meyers Exelon/Quad Cities

Mitchell Olinger Progress Energy/Robinson

Jair Orichio Angra

Rick Pepin Progress Energy

Don Statham Bruce Power/Bruce

Michael Welker Progress Energy/Harris

In addition to the individuals noted previously, the following companies provided technical
material, the use of figures, and review of the guide. Their support and willingness to provide the
majority of the technical guidance contained in this report is greatly appreciated.
Name Company Name

Paul Benard Gardner Denver Nash

Mark J. Forster Dresser Rand

Ron Speziale Dresser-Rand

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10427360
CONTENTS

1 INTRODUCTION ....................................................................................................................1-1
1.1 Purpose .......................................................................................................................1-1
1.2 Organization ................................................................................................................1-1
1.3 Key Points....................................................................................................................1-2

2 GLOSSARY OF TERMS ........................................................................................................2-1

2.1 Acronyms .....................................................................................................................2-1
2.1 Definitions ....................................................................................................................2-2
2.2.1 Air Binding...........................................................................................................2-2
2.2.2 Condition Monitoring ...........................................................................................2-2
2.2.3 Hydrogen Water Chemistry.................................................................................2-2
2.2.4 Partial Pressure...................................................................................................2-2
2.2.5 Standard Cubic Feet (Meter) per Minute.............................................................2-3
2.2.6 Vacuum ...............................................................................................................2-3

3 TECHNICAL DESCRIPTION/TUTORIAL ..............................................................................3-1

3.1 Introduction ..................................................................................................................3-1
3.2 BWR Off-Gas System ..................................................................................................3-4
3.2.1 BWR CAR System ..............................................................................................3-5
3.2.1.1 BWR Initial System Air Removal (Hogging) Mode........................................3-7
3.2.1.2 BWR CAR (Holding) Mode ...........................................................................3-7
3.2.1.2.1 BWR CAR System with the Booster SJAE............................................3-7
3.2.1.2.2 BWR CAR System Without the Booster SJAE......................................3-8
3.2.2 BWR Off-Gas Treatment System........................................................................3-8
3.3 PWR Off-Gas System ..................................................................................................3-9
3.3.1 PWR CAR System ............................................................................................3-10
3.3.1.1 Combination 1: MVP (Hogging Mode) – SJAE (Holding Mode)..................3-10
3.3.1.2 Combination 2: SJAE (Hogging Mode) – SJAE (Holding Mode) ................3-11

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 3.3.1.3 Combination 3: MVP (Hogging Mode) – MVP (Holding Mode)...................3-12
3.3.2 PWR Off-Gas Filter System ..............................................................................3-12

4 APPLICATIONS .....................................................................................................................4-1
4.1 SJAEs ..........................................................................................................................4-1
4.1.1 SJAE Fundamentals ...........................................................................................4-1
4.1.2 SJAE System Types ...........................................................................................4-2
4.1.2.2 Single-Stage, Multiple-Element SJAEs (see Figure 4-2[b]) ..........................4-2
4.1.2.3 Multi-Stage, Single-Element SJAEs (see Figure 4-2[c], [d], [f], [g], and
[h]) 4-3
4.1.2.4 Multi-Stage, Multiple-Element SJAEs (see Figure 4-2[e]).............................4-3
4.1.2.5 Condensing and Noncondensing Types .......................................................4-3
4.1.2.6 Inter-Condensers ..........................................................................................4-3
4.1.2.7 After-Condensers..........................................................................................4-3
4.1.2.8 Surface Inter-Condensers and After-Condensers.........................................4-4
4.1.3 SJAE Applications...............................................................................................4-5
4.1.3.1 Boiling Water Reactors .................................................................................4-5
4.1.3.2 Pressurized Water Reactors .........................................................................4-5
4.2 Rotary Screw MVP ......................................................................................................4-5
4.2.1 Spiral Rotor MVP ................................................................................................4-6
4.2.1.1 Theory of Operation ......................................................................................4-6
4.2.1.2 Application ....................................................................................................4-8
4.2.2 Helical Rotor MVP...............................................................................................4-9
4.2.2.1 Theory of Operation ......................................................................................4-9
4.2.2.2 Application ..................................................................................................4-16
4.3 Liquid Ring MVP ........................................................................................................4-17
4.3.1 Liquid Ring MVP Fundamentals ....................................................................4-17
4.3.2 Single-Stage Liquid Ring MVP..........................................................................4-19
4.3.2.1 Theory of Operation ....................................................................................4-19
4.3.2.2 Hogging Mode Application ..........................................................................4-20
4.3.2.3 Holding Mode Application ...........................................................................4-20
4.3.2.3.1 CEU Fundamentals .............................................................................4-21
4.3.2.3.2 Theory of Operation ............................................................................4-21
4.3.3 CEU with Two-Stage Liquid Ring MVP .............................................................4-27
4.3.3.1 Two Stage Liquid Ring MVP Operation ......................................................4-27

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 4.3.3.2 CEU Operation............................................................................................4-30
4.3.3.2.1 Overall CEU Operation .......................................................................4-30
4.3.3.2.2 CEU Control ........................................................................................4-31
4.4 Hybrid CEU ................................................................................................................4-34
4.4.1 Principle of Operation........................................................................................4-34
4.4.2 Part Load Operation..........................................................................................4-34
4.4.3 Retrofitting Hybrid Systems to Existing Plants ..................................................4-35

5 FAILURE DATA AND FAILURE MODES ..............................................................................5-1

5.1 SJAE System Failure Modes and Mechanisms ...........................................................5-1
5.1.1 SJAE Loss of Vacuum ........................................................................................5-2
5.1.2 SJAE Suction or Steam Supply Valve Failure to Close or Stuck Closed ............5-3
5.1.3 SJAE Steam Supply Valve Failure to Open or to Control Pressure....................5-3
5.2 MVP System Failure Modes and Mechanisms ............................................................5-3
5.2.1 MVP Trips ...........................................................................................................5-4
5.2.2 MVP Failures to Start ..........................................................................................5-5
5.2.3 MVP Degraded Performance ..............................................................................5-5
5.2.4 MVP Suction Valve Failure to Open or Close .....................................................5-5
5.2.5 SOV Failures.......................................................................................................5-6
5.2.6 Other Considerations ..........................................................................................5-6

6 TROUBLESHOOTING ...........................................................................................................6-1
6.1 SJAE Troubleshooting (Based on Heat Exchange Institute Tech Sheet # 102) .........6-1
6.1.1 SJAE Troubleshooting Difficulties .......................................................................6-1
6.1.2 SJAE Troubleshooting Techniques.....................................................................6-2
6.1.3 SJAE Troubleshooting Procedure.......................................................................6-2
6.1.4 SJAE Troubleshooting Matrix..............................................................................6-3
6.2 Liquid Ring Vacuum Pump Troubleshooting................................................................6-5
6.3 Rotary Screw Vacuum Pump Troubleshooting ............................................................6-7
6.3.1 Troubleshooting Rotary Screw Vacuum Pump Performance Problems .............6-7
6.3.2 Troubleshooting Rotary Screw Vacuum Pump Mechanical Problems................6-7
6.3.2.1 Rotary Screw Vacuum Pump Vibration.........................................................6-7
6.3.2.2 Rotor Thermal Growth ..................................................................................6-8
6.3.2.3 Rotary Screw Vacuum Pump Inspections.....................................................6-8
6.4 Non-Equipment-Specific Troubleshooting Guidance ...................................................6-9

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7 CONDITION MONITORING ...................................................................................................7-1
7.1 Operator Rounds and External Visual Inspections ......................................................7-2
7.1.1 Operator Rounds.................................................................................................7-2
7.1.2 External Visual Inspection...................................................................................7-2
7.2 Vibration Monitoring .....................................................................................................7-3
7.2.1 Parameters..........................................................................................................7-3
7.2.1.1 Amplitude ......................................................................................................7-3
7.2.1.2 Frequency .....................................................................................................7-3
7.2.1.3 Phase Angle..................................................................................................7-4
7.2.1.4 Vibration Form ..............................................................................................7-4
7.2.1.5 Vibration Mode Shape ..................................................................................7-4
7.2.2 Vibration Analysis................................................................................................7-4
7.2.2.1 Amplitude-Versus-Frequency Analysis .........................................................7-5
7.2.2.2 Real-Time Spectrum Analysis.......................................................................7-5
7.2.2.3 Time Waveform Analysis ..............................................................................7-6
7.2.3 Proximity Probes .................................................................................................7-6
7.2.4 Velocity Probes ...................................................................................................7-7
7.2.5 Accelerometer Probes.........................................................................................7-9
7.2.6 Data Acquisition ................................................................................................7-10
7.3 Oil Analysis ................................................................................................................7-11
7.4 Infrared Thermography ..............................................................................................7-11
7.5 Motor Current Analysis ..............................................................................................7-12

8 PREVENTIVE MAINTENANCE..............................................................................................8-1
8.1 Developing a PM Program...........................................................................................8-1
8.2 Basic Rules for Conducting Maintenance ....................................................................8-2
8.3 SJAE Maintenance Recommendations .......................................................................8-3
8.3.1 EPRI PM Basis Database—SJAE.......................................................................8-3
8.3.2 Ejector Internal Inspections.................................................................................8-3
8.3.3 Ejector Spare Parts .............................................................................................8-4
8.4 Liquid Ring MVP Maintenance Recommendations......................................................8-4
8.4.1 EPRI PM Basis Database Data Table—Liquid Ring Rotary Compressor
and Pump .........................................................................................................................8-4
8.4.2 Liquid Ring Vacuum Pump Manufacturer’s Recommendations..........................8-5
8.4.3 Case Study for Optimizing Liquid Ring Vacuum Pump PM Activities .................8-6

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 8.5 Rotary Screw MVP Maintenance Recommendations ..................................................8-7
8.5.1 EPRI PM Basis Database Data Table—Rotary Screw Air Compressor .............8-7
8.5.2 Rotary Screw Vacuum Pump Manufacturer’s Recommendations ......................8-8
8.6 Component Maintenance.............................................................................................8-9
8.6.1 Bearings ..............................................................................................................8-9
8.6.1.1 Routine Maintenance Recommendations ...................................................8-10
8.6.1.2 Bearing Overhaul ........................................................................................8-11
8.6.2 Lubrication System............................................................................................8-13
8.6.2.1 Routine Maintenance ..................................................................................8-13
8.6.2.2 Circulating Lube Oil System Overhaul ........................................................8-13
8.6.3 Couplings ..........................................................................................................8-14
8.6.3.1 Routine Maintenance Recommendations ...................................................8-15
8.6.3.2 Coupling Overhaul ......................................................................................8-16
8.6.3.3 Coupling Alignment.....................................................................................8-17
8.6.4 Structural Support System ................................................................................8-17
8.6.4.1 Concrete Foundation ..................................................................................8-17
8.6.4.2 Repairing Concrete Foundations ................................................................8-18
8.6.4.3 Surface Cleaning ........................................................................................8-18
8.6.4.4 Crack Repair ...............................................................................................8-18
8.6.4.5 Anchor Bolts................................................................................................8-19
8.6.4.5.1 Forces Affecting Anchor Bolts .............................................................8-19
8.6.4.5.2 Proper Installation ...............................................................................8-20
8.6.5 Electric Motors ..................................................................................................8-21
8.6.5.1 Dirt ..............................................................................................................8-21
.6.5.2 Moisture ........................................................................................................8-22
8.6.5.3 Friction ........................................................................................................8-22
8.6.5.4 Vibration......................................................................................................8-22
8.6.5.5 Rotor Shaft End Play ..................................................................................8-22
8.6.6 Solenoid Operated Valves ................................................................................8-23
8.6.6.1 Coils ............................................................................................................8-24
8.6.6.2 Elastomers ..................................................................................................8-24
8.6.6.3 Periodic Valve Cycling ................................................................................8-25

9 REFERENCES .......................................................................................................................9-1

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A FAILURE HISTORY OF INDUSTRY CAR EQUIPMENT ..................................................... A-1

B KEY POINTS......................................................................................................................... B-1

C SJAE TERMINOLOGY ......................................................................................................... C-1

D TRAINING SLIDES ............................................................................................................... D-1

E TRANSLATED TABLE OF CONTENTS .............................................................................. E-1

繁體中文 (Chinese – Traditional).......................................................................................... E-2

简体中文 (Chinese – Simplified) .......................................................................................... E-13

Français (French) ............................................................................................................... E-24

日本語 (Japanese).............................................................................................................. E-33

Español (Spanish) .............................................................................................................. E-44

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LIST OF FIGURES

Figure 2-1 Vacuum/Absolute Pressure/Gauge Pressure Relationships ....................................2-4

Figure 3-1 Typical Steam Surface Condenser...........................................................................3-2
Figure 3-2 Removal of Noncondensible Gas .............................................................................3-3
Figure 3-3 Typical BWR Off-Gas System ..................................................................................3-5
Figure 3-4 BWR CAR System with Booster SJAE .....................................................................3-6
Figure 3-5 BWR CAR Systems Without Booster SJAE .............................................................3-6
Figure 4-1 Typical SJAE Stage..................................................................................................4-2
Figure 4-2 Common Types of Ejector Units...............................................................................4-4
Figure 4-3 Spiral Rotor MVP......................................................................................................4-7
Figure 4-4 Cross-Section Spiral Rotor MVP ..............................................................................4-8
Figure 4-5 Helical Rotor MVP ..................................................................................................4-10
Figure 4-6 Cross-Section Helical Rotor MVP...........................................................................4-11
Figure 4-7 Inter-Stage Partition and Relief Valve ....................................................................4-12
Figure 4-8 Schematic Diagram for Air and Water Flow ...........................................................4-13
Figure 4-9 Schematic of Base and Reservoir ..........................................................................4-15
Figure 4-10 Flat Port Plate Liquid Ring Vacuum Pump Gas Compression Cycle....................4-18
Figure 4-11 Conical Port Liquid Ring Vacuum Pump Gas Compression Cycle.......................4-18
Figure 4-12 Types of Liquid Ring Vacuum Pumps ..................................................................4-19
Figure 4-13 Single-Stage Liquid Ring CEU .............................................................................4-23
Figure 4-14 Nash Atmospheric Jet Air Ejector.........................................................................4-24
Figure 4-15 Nash CEU (Before Start) ......................................................................................4-25
Figure 4-16 Nash CEU (Hogging)............................................................................................4-26
Figure 4-17 Nash CEU (Holding) .............................................................................................4-27
Figure 4-18 Major Components of a Two-Stage Vacuum Pump .............................................4-28
Figure 4-19 Vacuum Pump Low and High Vacuum Operation ................................................4-29
Figure 4-20 CEU Functional Operation....................................................................................4-33
Figure 4-21 Hybrid Condenser Exhaust...................................................................................4-36
Figure C-1 Designations for Ejector Assemblies ...................................................................... C-2

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10427360
LIST OF TABLES

Table 5-1 Failures in SJAE-Related Systems ............................................................................5-2

Table 5-2 Failure Modes in SJAE-Related Systems ..................................................................5-2
Table 5-3 Failures in MVP-Related Systems .............................................................................5-4
Table 5-4 Failure Modes in MVP-Related Systems ...................................................................5-4
Table 6-1 Multi-Stage SJAE No-Load Suction Pressure ...........................................................6-2
Table 6-2 SJAE Troubleshooting Matrix ....................................................................................6-4
Table 6-3 Liquid Ring Vacuum Pump Troubleshooting Matrix...................................................6-5
Table 6-4 Bearing Troubleshooting Matrix.................................................................................6-9
Table 6-5 Lubrication System Troubleshooting Matrix.............................................................6-10
Table 6-6 Noise Level Troubleshooting Matrix ........................................................................6-11
Table 8-1 SJAE PM Activities Based on EPRI PM Basis Database Data Table .......................8-3
Table 8-2 Liquid Ring PM Activities Based on EPRI PM Basis Database Data Table...............8-5
Table 8-3 Liquid Ring PM Activities Based on Vendor’s Recommendations .............................8-5
Table A-1 CAR Equipment Failure History ............................................................................... A-2

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10427360
1
INTRODUCTION

Most Nuclear Maintenance Applications Center (NMAC) member plants use either steam jet air
ejectors (SJAEs) or mechanical vacuum pumps (MVPs) to remove air and noncondensible gases
from the condenser. This equipment is vital for good plant performance because if
noncondensible gases are allowed to build up in the condenser, condenser vacuum will decrease,
causing turbine backpressure to increase and reducing overall plant efficiency. If turbine
backpressure increases significantly, the plants cannot be operated. The noncondensible gases
also blanket the condenser tubes, effectively reducing the heat transfer capability of the
condenser. For most plants, air removal equipment is used to establish condenser vacuum during
plant startup.

1.1 Purpose

This guide provides information on condenser air removal (CAR) system equipment for boiling
water reactor (BWR) and pressurized water reactor (PWR) nuclear power plants. System
description and theory of operation on a system level is provided for both BWRs and PWRs,
highlighting some of the different CAR equipment configurations. Specific information on the
functional description and application at a component level is provided for the SJAEs and MVPs
to assist nuclear power plant maintenance personnel in troubleshooting and maintaining SJAEs
and MVPs. A discussion of SJAE and MVP characteristics and components that serves as a
reference for understanding the basics of their performance and mechanical construction is also
provided. Preventive maintenance (PM) guidance is provided to assist in improving the
component reliability. Component failure data and failure modes are also included to assist in
improving reliability and troubleshooting. A troubleshooting guide is provided to assist in
diagnosing problems. Data for this guide were obtained from experience in nuclear plants,
review of industry surveys and industry failure reports, and vendor input.

1.2 Organization

The organization of this guide is as follows:

• Section 1 provides an introduction and discussion of the guide’s purpose and organization.
• Section 2 provides a glossary of acronyms and definitions used in the guide.

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Introduction

• Section 3 provides a system description and the theory of operation on a system level for the
CAR systems of BWRs and PWRs, highlighting the different possible configurations. To
provide a more complete understanding of the process for removing and treating
noncondensible gases in BWR condensers, a brief description of the effect of the BWR off-
gas treatment system on condenser vacuum is also provided.
• Section 4 provides specific information on the functional description and application at a
component level for the SJAEs and MVPs.
• Section 5 provides failure data and failure modes. All available sources, such as Institute of
Nuclear Power Operations (INPO), Equipment Performance and Information Exchange
(EPIX), NRC, vendor notices, and member records were used to identify failure modes of
concern to power plants.
• Section 6 provides guidance for troubleshooting and corrective actions.
• Section 7 provides a discussion of condition monitoring.
• Section 8 provides guidance for PM.
• Section 9 provides a list of references.
• Appendix A provides an industry CAR equipment failure history.
• Appendix B provides a list of all the key points indicated in the guide.
• Appendix C provides an explanation of SJAE terminology.
• Appendix D provides a training overview of this guide and its contents.

1.3 Key Points

Throughout this guide, key information is summarized in “key points.” Key points are bold
lettered boxes that succinctly restate information covered in detail in the surrounding text,
making the key points easier to locate.

The primary intent of a key point is to emphasize information that will allow individuals to take
action for the benefit of their plant. NMAC personnel, the consultants, and the utility personnel
that prepared this guide selected the information included in these key points.

The key points are organized according to three categories: operation and maintenance (O&M)
cost, technical, and human performance. Each category has an identifying icon, shown as
follows, to draw attention to it quickly when reviewing this guide.

Key O&M Cost Point

Emphasizes information that will result in reduced purchase, operating, or
maintenance costs.

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 Introduction

Key Technical Point

Targets information that will lead to improved equipment reliability.

Key Human Performance Point

Denotes information that requires personnel action or consideration in order
to prevent injury or damage or ease completion of the task.

Appendix B contains a listing of all of the key points in each category. The listing restates each
key point and provides reference to its location in the body of the report. By reviewing this
listing, users of this guide can determine whether they have taken advantage of key information
that the writers of the guide believe would benefit their plants.

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2
GLOSSARY OF TERMS

2.1 Acronyms

ASTM American Society for Testing and Materials

BWR boiling water reactor power plant

cfm cubic feet per minute

cmm cubic meters per minute

CAR condenser air removal

EPRI Electric Power Research Institute

fpm feet per minute

Hg chemical symbol for the element mercury, used as a unit of pressure

HP horsepower

HEI Heat Exchange Institute

kPa kilopascal, a unit of pressure equivalent to one thousand newtons per square meter

MK speed of sound

MVP mechanical vacuum pump

NMAC Nuclear Maintenance Applications Center

O&M operations and maintenance

PCV pressure control valve

PM preventive maintenance

psi pound(s) per square inch

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Glossary of Terms

psig pound(s) per square inch, gauge

psia pound(s) per square inch, absolute

PWR pressurized water reactor power plant

SOV solenoid-operated valve, or solenoid valve

2.1 Definitions

2.2.1 Air Binding

Air binding is the displacement of steam in the condenser with excess air that hinders the heat-
transfer process.

2.2.2 Condition Monitoring

Condition monitoring is used to describe any task that allows collection of data (periodically or
continuously) on the condition of equipment. The purpose of condition monitoring is to discover
whether the condition of the equipment has changed and how it has changed. Although the term
predictive maintenance is commonly used as synonymous with condition monitoring, it is
viewed as a subset of condition-monitoring activities for which the task/technology has the
capability to support decisions about how long equipment can continue to provide its function
before corrective action is needed.

2.2.3 Hydrogen Water Chemistry

The hydrogen water chemistry injection system injects hydrogen into the reactor feed pump
suctions. Its purpose is to suppress the dissolved oxygen in the reactor water to a sufficient level
so that susceptibility of the reactor internals to intergranular stress corrosion cracking (IGSCC) is
reduced. Because of radiolytic decomposition of water that occurs in the core, the level of
dissolved oxygen in the reactor coolant rises to 100 to 300 ppb. Dissolved oxygen concentrations
at these levels increase the potential for IGSCC of highly stressed, sensitized stainless steel.
Testing has shown that the injected hydrogen combines with the oxygen and decreases the
potential for IGSCC.

2.2.4 Partial Pressure

In a mixture of ideal gases, each gas has a partial pressure. Partial pressure is the pressure that
the gas would have exerted if it alone occupied the entire volume. Actual real-world gases come
very close to this ideal. The total pressure of a gas mixture is the sum of the partial pressures of
each individual gas in the mixture. The partial pressure of a gas is a measure of the
thermodynamic activity of the gas’s molecules. Gases will always flow from a region of higher
partial pressure to one of lower pressure, and the larger this difference, the faster the flow.

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2.2.5 Standard Cubic Feet (Meter) per Minute

Standard cubic feet (meter) per minute (SCFM or SCMM) is a volumetric flow rate that has been
corrected to a standardized pressure, temperature, and relative humidity. The standard ambient
conditions are defined by 14.7 psia (101.35 kPa) atmospheric pressure, some temperature (for
example, 68°F or 20°C) depending on the standard used, and some relative humidity (for
example, 36%, 0%) depending on the standard used.

2.2.6 Vacuum

Vacuum can be viewed as the relative emptiness of a given volume. It is impossible to obtain a
perfect vacuum, but it is possible to obtain some level of vacuum, which is defined as a pressure
in a system that is below barometric pressure. For convenience, in vacuum engineering design,
the term absolute pressure is used. Absolute pressure is a pressure above absolute zero pressure
(a perfect vacuum). Condenser absolute pressure is also referred to as backpressure because it is
a pressure exerted onto the turbine exhaust. Another convenient term is gauge pressure, which
is a pressure measured above barometric pressure. The relationship between the various pressure
and vacuum parameters is shown in Figure 2-1.

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Figure 2-1
Vacuum/Absolute Pressure/Gauge Pressure Relationships
Source: Heat Exchange Institute

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TECHNICAL DESCRIPTION/TUTORIAL

3.1 Introduction

The CAR system is designed to remove and process noncondensible gases from the main
condenser during startup and normal operation. For PWRs, noncondensible gases include in-
leakage of air and injected gases, such as nitrogen. For BWRs, noncondensible gases include in-
leakage of air and reactor gases, such as hydrogen, oxygen, fission product gases, and nitrogen-
16. A condenser is a large heat exchanger of the shell and tube type. A typical steam surface
condenser is shown in Figure 3-1. Cooling water enters through the waterbox and then travels
through the tube sheet and into the tubes. The shell side of the condenser receives steam from the
low-pressure turbine exhaust. The steam is cooled to a liquid as it passes over the tubes where
the cooling water is circulated and heat is transferred from the steam to the cooling water. For a
complete discussion of the condenser components and their functions, refer to EPRI 1003088,
Condenser Application and Maintenance Guide.

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Figure 3-1
Typical Steam Surface Condenser
Source: Senior Engineering Company

Vacuum is produced in the condenser by the condensation of steam to liquid, which causes its
specific volume to change. The higher the condenser vacuum, the lower the turbine
backpressure. The total work done by the steam flowing through the turbine increases as the
difference between the pressure of steam entering the turbine and the backpressure increases.
Therefore, the lower the condenser pressure, the more energy that is converted to power in the
turbine. The more power produced in the turbine, the greater the output of the turbine and the
greater the thermal efficiency. The backpressure is typically between 1 and 3.5 inches Hg (2.5
and 9 cm Hg) absolute.

Key Technical Point

It is the steam condensation process and the specific volume change from
steam to liquid that produces the condenser vacuum. The lower the
backpressure, the more work that is done by the steam in the turbine.

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In addition, a buildup of noncondensible gases around the tubes prevents heat transfer from the
steam to the cooling water and, therefore, prevents complete condensation of the steam.
Condensers must continually vent noncondensible gases to prevent air binding and the loss of
heat-transfer capability. Figure 3-2 shows how noncondensible gas flows within and out of a
condenser.

Figure 3-2
Removal of Noncondensible Gas
Source: EPRI TR-107422-V2

Noncondensible gases tend to flow toward the coldest area of the condenser, which is typically
the circulating water inlet region of the condenser. This occurs because the partial pressure of the
condensing steam is lowest in the cold region. However, having the air outlet at the circulating
water inlet might not be possible with all condenser bundle designs.

SJAEs and/or vacuum pumps are used to establish a vacuum in the condenser before startup, and
to pull noncondensible gases from the condenser during operation. Along with the
noncondensible gases, some water vapor or steam is also removed during operation.

Air-removal equipment must operate in two modes: hogging and holding. Prior to admitting
exhaust steam to a condenser, the noncondensible gases must be vented from the condenser. In
the hogging mode, large volumes of air are quickly removed from the condenser in order to
reduce the condenser pressure from atmospheric pressure to a predetermined level. Once the
desired pressure is achieved, the air removal system can be operated in the holding mode to
maintain condenser vacuum.

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3.2 BWR Off-Gas System

In BWRs, the steam is produced directly in the reactor. As a result, the noncondensible gases that
enter a BWR condenser include gases generated in the reactor. The volume of the reactor-
generated gases is dependent on power levels in the reactor but is typically an order of magnitude
larger than the volume of condenser in-leakage. As an example, in a 1000 MWe BWR power
plant condenser, air in-leakage may be on the order of 20 scfm (0.57 scmm), and the gases
generated in the reactor may be on the order of 200 scfm (5.66 scmm). Therefore, the equipment
used in the holding mode of a BWR is usually an order of magnitude larger in capacity than that
used in the holding mode for a PWR.

Reactor-generated gases entering the condenser include:

• Hydrogen and oxygen produced from the radiolysis of water
• Radioactive nitrogen-16 (with a half-life of 7 seconds), nitrogen-13 (with a half-life of 10
minutes), and oxygen-19 (with a half-life of 27 seconds), all produced from the neutron
activation of oxygen isotopes
• Fission product gases (primarily radioactive isotopes of xenon and krypton) released as a
result of fuel cladding leaks

The BWR off-gas system consists of the CAR system and the off-gas treatment system. Figure
3-3 is a typical schematic of a BWR off-gas system. Typically, two 100% capacity trains are
provided. At most BWR facilities, the off-gas treatment system was added later to reduce off-site
radiation exposures.

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Figure 3-3
Typical BWR Off-Gas System
Source: Sargent & Lundy, LLC

3.2.1 BWR CAR System

The BWR CAR system is designed to remove and process noncondensible gases from the main
condenser during startup and normal operation. Typically, the BWR CAR system consists of a
first stage SJAE, an inter-condenser, a second stage SJAE, an after-condenser, and a third stage
(booster) SJAE. At some BWRs, off-gas pre-coolers, cooled by station service water, are
provided upstream of the suction to each first stage SJAE.

As a result of problems with the operation of the BWR off-gas system, many plants have
modified the configuration of the second stage SJAE and removed the third stage SJAE
altogether. Figure 3-3 shows a BWR plant in which the third stage SJAE was removed in only
one of the two 100% trains. Figures 3-4 and 3-5 show expanded views of the CAR portion of the
off-gas system for the same plant, for the train with and without the third SJAE. A discussion of
each configuration is provided in Section 3.2.1.2.

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Figure 3-4
BWR CAR System with Booster SJAE
Source: Sargent & Lundy, LLC

Figure 3-5
BWR CAR Systems Without Booster SJAE
Source: Sargent & Lundy, LLC

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3.2.1.1 BWR Initial System Air Removal (Hogging) Mode

As shown in Figure 3-3, an MVP is provided for each condenser to evacuate air from the turbine
and the main condenser volumes and to establish a sufficient vacuum during plant startup. One
vacuum pump suction line services each main condenser shell.

The MVP takes suction on the common suction line to the SJAEs between the SJAEs and the
SJAE suction valves. It is used to draw an initial vacuum in the main condenser, as a result of its
much larger capacity than the SJAEs. The MVP discharges to the base of the main chimney.

The BWR MVP is typically a single stage, spiral rotor pump and is designed for a flow rate of
about 2300 scfm (65.13 scmm) at 15 inches Hg (38.1 cm) vacuum. Above 15 inches Hg (38.1
cm) vacuum, the MVP flow decreases, and the discharge temperature increases. The MVP will
increase the main condenser vacuum to 23–24 inches (58.42–60.96 cm) Hg before it stalls. If left
operating, the flow will drop to near zero, and the discharge temperature will rise rapidly to the
trip point. The operator should stop the MVP before this trip occurs. The SJAEs should be
started and already be drawing off-gas flow before the vacuum pump is tripped.

3.2.1.2 BWR CAR (Holding) Mode

3.2.1.2.1 BWR CAR System with the Booster SJAE

Main condenser suction lines to the first stage SJAEs are connected together into a common
suction line. The driving steam flow for the first and second stage SJAEs is a result of the main
turbine throttle equalizing header through a pressure control valve (PCV) that maintains steam
inlet pressure at ≈125 psig (861.84 kPa).

The first stage SJAEs discharge to the SJAE inter-condenser shell side where the steam is
condensed. The inter-condenser is a heat exchanger that uses the main condensate on the tube
side as the cooling medium. By condensing the steam out of the off-gas flow, the second stage
SJAEs do not have to be as large because they have only noncondensible gases to exhaust from
the inter-condenser. The condensate created in the inter-condenser shell side as a result of
condensing steam drains to the main condenser via a loop seal.

If enough cooling water is not circulated through the SJAE inter-condenser, the cooling water
will not be able to condense the steam content of the gas-vapor mixture entering the inter-
condenser. The second stage SJAEs then become overloaded because, instead of handling only
air, they must also handle the steam that was not condensed. A loss of vacuum will result.

The second stage SJAEs takes suction on the inter-condenser shell side and discharges to the
after-condenser shell side, where steam is again condensed and drains back to the main
condenser through a level-sensing loop and a level-control valve. Main condensate provides
tube-side cooling water for the SJAE after-condenser.

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The third stage SJAE (the booster SJAE) takes suction on the after-condenser and discharges to
the off-gas pre-heater in the off-gas treatment system. The steam supply for the third stage is the
same as for the first and second stages—via two additional stop valves and a different PCV to
maintain steam inlet pressure at ≈125 psig (861.84 kPa). This steam is supplied to both the inlet
of the SJAE as the driving steam, and to the off-gas line via an orifice as dilution steam to reduce
the hydrogen concentration to less than 4% by volume.

Hydrogen is injected into the feedwater as part of the hydrogen water chemistry control process,
and some of this excess hydrogen remains in the off-gas. Therefore, oxygen is injected upstream
of the catalytic recombiner to ensure that sufficient oxygen is available to completely combine
with the excess hydrogen in the off-gas system.

3.2.1.2.2 BWR CAR System Without the Booster SJAE

Off-gas fires upstream of the catalytic recombiners have continued to plague the industry.
Dislocated fines of the recombiner catalyst cause these fires. The catalyst fines, in a combustible
mixture of hydrogen and oxygen, heat up to the point of gas ignition. The hydrogen and oxygen
then burn back to the point where a combustible mixture begins to exist after the second stage
SJAE, which is in the after-condenser. The fire then continues to burn there until extinguished.

To resolve this issue, modifications have been installed to eliminate the booster SJAE and to use
larger second stage SJAEs. These modifications eliminated the recurring off-gas fires by keeping
the gas stream diluted with steam.

As a result of this modification, the discharge of the second stage SJAE releases directly to the
off-gas preheater in the off-gas treatment system. A steam trap has been installed on the second
stage discharge to return moisture to the main condenser because the after-condenser is
bypassed.

3.2.2 BWR Off-Gas Treatment System

The BWR off-gas treatment system is a non-safety-related system that is designed to reduce the
off-site exposures at the nearest site boundary to less than the established maximum limit in an
effort to minimize the release of radioactive gases by suitable short-term decay and to minimize
the release of radioactive particles to the atmosphere. This is achieved by a controlled
recombination of the hydrogen and oxygen in the catalytic recombiners and a holdup and
filtering process that allows radioactive gases to decay. Figure 3-3 shows the schematic for a
typical BWR off-gas system.

Catalytic recombination of hydrogen and oxygen requires that gases be heated above 240°F
(115.56°C). Therefore, steam from the line supplying the booster SJAE PCV is injected into the
preheaters to heat the steam/gas mixture.

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The catalytic recombiner recombines (burns) the hydrogen and oxygen gases into a water vapor.
The off-gas condensers cool and condense the superheated steam to water on the shell side. The
condenser is a U-tube-type heat exchanger with the off-gas process stream passing through the
shell side while main condensate as the cooling water flows through the tube side.

The water separator coalesces entrained water into droplets that drain back to the off-gas
condenser. The water separator contains a basket with shredded metal strips, through which all
the gas flows. The coalescing takes place on the metal strips.

A physical volume that requires a specific amount of time to transit accomplishes the holdup
phase. This volume was sized so that off-gas, with the design flow rates prior to the installation
of the off-gas treatment system, would take 30 minutes to traverse the volume. The
recombination of the hydrogen and oxygen reduces the off-gas flow rates and transforms the
same hold-up volume from 30 minutes without recombination to about 4–6 hours with
recombination.

In order for the charcoal adsorbers to operate, the gas must be dry. If too much moisture reaches
the charcoal, it will overheat and catch fire. Therefore, the off-gas stream is cooled to
approximately 45°F (7.22°C) in the glycol-cooled cooler/condensers, and the condensate is
removed by the moisture separator. Then, the gases are reheated by the reheaters to reduce the
relative humidity to an extremely low value.

The off-gas leaving the reheater passes through the prefilter for the removal of particulate
daughter products in the off-gas stream. Each of the two 100% capacity prefilters consists of a
filter assembly holding a removable, high efficiency, water resistant filter element. The filter
element is designed to remove 99.97% of the particles that are 0.3 microns or larger in size.

Charcoal adsorbers delay the noble gases (xenon and krypton) by adsorption, allowing greater
decay time for longer-lived radionuclides. Particulate daughters of these noble gases are retained
in the charcoal beds, and the effluent gases from the absorber beds are discharged to the after-
filters. The expected holdup time for xenon is > 30 days, while for krypton it is > 40 hours.

The after-filters receive flow from the charcoal adsorbers and filter out any carbon fines that
contain radioactive material and/or particulate daughter products of the off-gas prior to release
through the off-gas chimney. Typically, there are two 100% capacity filters installed.

3.3 PWR Off-Gas System

The PWR off-gas system consists of the CAR system and the off-gas filter system. The CAR
system is designed to remove air and to establish a condenser vacuum during unit startup and to
remove noncondensible gases during normal operation to maintain the condenser vacuum within
established limits over the range of condenser circulating water inlet temperatures.

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Air and noncondensible gases discharged from the CAR system are sent to the unit vent stack via
the off-gas exhaust header. Exhaust gases from the CAR system are monitored by the process
radiation monitoring system prior to discharge. A high radiation condition might exist in the
event of a primary to secondary leak in the steam generator, along with a high degree of fuel
cladding failure. Some PWRs provide only an alarm to alert the operator that a high radiation
condition exists. This allows the operator to take manual action to place the off-gas filter in
service. Other PWRs are designed with an off-gas filter system that is automatically put into
service upon a high radiation signal.

3.3.1 PWR CAR System

The PWR CAR system may be operated in either the hogging mode or the holding mode.
Different equipment is used for each mode, but the flow path is similar in either mode. The air-
removal equipment takes suction from the main condenser and discharges the air and the
noncondensible gases that are removed from the condenser to the plant ventilation stack. In the
hogging mode, high capacity air-removal equipment is required. Hogging mode equipment is
normally used during start up when the condenser and turbine volumes need to be evacuated.
However, the hogging equipment is sometimes put into service during off-normal plant operating
conditions when condenser vacuum is rapidly deteriorating as a result of condenser air in-
leakage rates beyond the capacity of the holding mode equipment.

In PWRs, MVPs are often used for hogging mode equipment and SJAEs are often used for
holding mode equipment. In some PWRs, MVPs are used for both the hogging and holding
modes, and in some other PWRs, SJAEs are used for both the hogging and holding modes. The
following sections describe the existing combinations of equipment used in the CAR hogging
modes and holding modes of PWRs.

3.3.1.1 Combination 1: MVP (Hogging Mode) – SJAE (Holding Mode)

The CAR system removes noncondensible gases from the main condenser during startup,
shutdown, and normal operation. MVPs and SJAEs are used to draw noncondensible gases from
the condenser and discharge them to the unit vent stack via the off-gas exhaust header. SJAE
exhaust gases are monitored by the process radiation monitoring system prior to their release.

Vacuum is drawn by the MVP during startup (hogging mode). For dual-unit plants, there is
typically one MVP for each unit and one shared MVP. The MVP takes suction from the
condenser through a pneumatically operated suction valve that would fail open on a loss of
instrument air and discharges to an air separator tank. A compressant heat exchanger uses non-
essential service water to cool the compressant water that is recirculated back to the MVP. The
makeup compressant water is supplied from the demineralized water system. The MVP
discharges to the off-gas exhaust header and from there to the unit vent stack.

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During normal operation (holding mode), one of the two sets of holding SJAEs is operating, and
one set is on standby. Air and noncondensible gases are drawn from the condenser by the first
stage SJAE via a pneumatically operated suction valve that would also fail open on a loss of
instrument air.

In a typical arrangement, the SJAEs are twin element, two stage units with separate inter-
condensers and after-condensers. Two first-stage elements are mounted on each side of the inter-
condenser, and two second-stage elements are mounted slightly above and on each side of the
after-condenser. High velocity steam is used to entrain noncondensible gases to remove them
from the condenser. The motive steam is supplied from the main steam crossover header.

The first stage takes suction on the main condenser and discharges to the inter-condenser. The
second stage takes suction on the inter-condenser and discharges to the after-condenser.
Noncondensible gases leave the after-condenser and go to the off-gas exhaust header.

Cooling for the inter-condenser and after-condenser is supplied by the condensate system. Using
condensate as the cooling medium results in increasing plant efficiency by regaining heat which
would otherwise be lost. The air ejector inter-condenser drains to its sump, and the air-ejector
after-condenser drains to the inter-condenser sump, which drains to the main condenser via a
loop seal. When steam pressure is insufficient for air ejector operation, such as during unit
startup or shutdown, the MVPs are used to remove noncondensible gases from the condenser.
SJAE exhaust gas from the condenser is monitored by the process radiation monitoring system
prior to discharge.

3.3.1.2 Combination 2: SJAE (Hogging Mode) – SJAE (Holding Mode)

The PWR CAR process for this combination of equipment functions the same as for combination
1 except that, in place of an MVP for use during startup (hogging mode), a high capacity, single
stage hogging SJAE is provided to evacuate the condenser and turbine volumes. The hogging
SJAE uses the same suction piping as the first stage SJAEs but discharges directly to the
atmosphere through a separate turbine building roof vent. After-condensers are not used with this
type of SJAE.

The typical hogging SJAE has a steam consumption of 7,000 lb/hr (3175 kg/hr) and has an air
removal capacity of 4,300 lb/hr (1940 kg/hr) at a suction pressure of 10 inches (25.4 cm) Hg
absolute. This is in comparison to the typical two-stage holding SJAE, which has a steam
consumption of 2,600 lb/hr (1179 kg/hr) and an air-removal capacity of 180 lb/hr or 40 scfm
(81.67 kg/hr or 1.13 scmm) at a suction pressure of one inch (2.54 cm) Hg absolute.

The holding SJAEs function is as described in Section 3.3.1.1.

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3.3.1.3 Combination 3: MVP (Hogging Mode) – MVP (Holding Mode)

For those plants that use strictly MVPs for both startup (hogging mode) and normal operation
(holding mode), there is no differentiation between the equipment used for the hogging mode
and that used for the holding mode. In a typical arrangement utilizing only MVPs to remove air
and noncondensible gases from the condenser, three, two-stage, motor-driven pumps are
provided. The pump suctions and discharges are connected to headers so that one, two, or three
pumps can be run as required.

The typical system design is to remove air and establish a condenser vacuum of 25 inches (63.5
cm) Hg during startup and to remove noncondensible gases and water vapor during normal
operation to maintain a condenser vacuum between 26.5 and 29 inches (67.3 and 73.7 cm) Hg
over the range of circulating water inlet temperatures.

The typical system design capacity is 75 scfm (2.12 scmm), divided equally between the three
MVPs. During startup, all three MVPs may be operated to initially evacuate the condenser and
turbine volumes. During normal operation, one or two MVPs are operated, depending upon the
level of air in-leakage, and the remaining one or two MVPs are placed in standby operation. In
the event of excessive in-leakage into the condenser, the MVPs selected for standby operation
start automatically when condenser vacuum falls below the MVP starting setpoint.

MVP exhaust gas from the condenser is monitored by the process radiation monitoring system
prior to discharge.

3.3.2 PWR Off-Gas Filter System

PWR condenser exhaust gases are normally free of radioactive particles or iodine but could
potentially contain these materials in the event of primary-to-secondary steam generator tube
leakage. Therefore, these gases are monitored by the process radiation monitoring system. In
some cases, there are radiation monitors dedicated to monitoring the condenser exhaust prior to
its discharge at the plant vent stack, and, in other cases, the exhaust is routed to the plant vent
stack via the controlled access exhaust units, which contain radiation monitors.

There is an off-gas filter system, either one that is dedicated to the condenser exhaust or one that
is part of the controlled access exhaust units. This filter system typically consists of a moisture
separator, prefilters, an electrical heating coil, HEPA filters, charcoal adsorbers, and centrifugal
fans. In dual-unit plants, the off-gas filter system is typically a system common to both units and
is capable of filtering the exhaust gases from either unit. During normal operation, the off-gas
filter system is typically bypassed, although, at some plants, only the charcoal adsorbers are
bypassed.

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For those plants with dedicated filter systems for the condenser exhaust gases, the system is
typically designed to operate only if high radiation in the exhaust gases is detected by the process
radiation monitoring system. The system is designed to operate following the event of a primary-
to-secondary steam generator tube leakage in order to filter the potential radioactive particulates
and iodine from the exhaust gases.

A water deluge system is provided for the charcoal adsorbers for fire protection purposes. A
deluge valve is locally mounted to permit an operator to deluge after performing a visual
inspection. The charcoal adsorbers are provided with a temperature switch that senses
temperature of air leaving the charcoal adsorbers. When the air temperature exceeds the switch
setpoint, it is annunciated in the main control room and at the local panel. Upon manual
operation of the deluge valve, the fan is tripped, and the outlet valves are closed. A flow sensor is
provided at the fan exhaust to monitor the air flow.

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APPLICATIONS

Specific information on the functional description and application at a component level for the
SJAEs and MVPs is provided in this section to assist nuclear power plant system engineers and
maintenance personnel by providing a deeper understanding the equipment and how it functions.
A discussion of SJAE and MVP fundamentals of operation that serves as a reference for
understanding the basics of their performance and mechanical construction is also included.

Manufacturers provide CAR units or condenser exhaust units (CEUs), which are comprised of
SJAEs, atmospheric jet air ejectors (ejectors using air rather than steam as the motive fluid), or
MVPs packaged together or separately, along with the necessary supporting components, such as
moisture separators, level control valves, steam supply valves, and associated instrumentation.
Several of these packaged units, along with the latest hybrid design, are also discussed.

4.1 SJAEs

4.1.1 SJAE Fundamentals

Figures 4-1 and 4-2 show typical SJAEs. Appendix D provides a discussion on SJAE
terminology. There are two separate fluid flows involved in the operation of an SJAE. The first
fluid is the high-pressure motive steam (other motive fluids, such as air, are sometimes used),
which is introduced into the nozzle (Item 3 of Figure 4-1). By expansion in the diverging part of
the nozzle, steam pressure is converted into velocity in the supersonic range (3000–4000 ft/sec)
(914–1219 m/sec). The second fluid involved is the load (from a vessel or process) and is
introduced into the suction of the SJAE (Item 6). The load can be from the main condenser
directly or from a preceding SJAE stage or inter-condenser.

In the suction chamber (Item 2), the high-velocity steam exiting from the nozzle continually
entrains the load, resulting in reduced pressure at the suction. The resulting mixture, at the
resulting velocity, enters the diffuser section where this velocity energy is converted to pressure
energy. As a result, the pressure of the mixture at the SJAE discharge is substantially higher than
the pressure in the suction chamber.

An SJAE stage has operating limitations on the attainable compression and will operate
efficiently only up to a limited ratio of compression. The ratio of compression is the absolute
discharge pressure divided by the absolute suction pressure. If greater ratios of compression are
required than can be attained in a single ejector stage, two or more stages can be arranged in
series. This assembly constitutes a multi-stage ejector.

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An SJAE stage is a constant-capacity device. The physical proportions of the diffuser determine
the capacity. To obtain increases in capacity, two or more SJAEs, either single or multi-stage, are
arranged to operate in parallel, with each series constituting an element of a multiple-element
ejector. This arrangement permits the operation of the number of elements needed for the
required capacity, as each element is capable of completely compressing a portion of the total
capacity.

Figure 4-1
Typical SJAE Stage
Source: Heat Exchange Institute

4.1.2 SJAE System Types

Some of the various types of SJAE systems commonly used are illustrated in Figure 4-2a
through 4-2h.

4.1.2.1 Single-Stage, Single-Element SJAEs (see Figure 4-2[a])

These consist of one basic assembly that is designed to operate at a suction pressure below
atmospheric pressure and to discharge at atmospheric pressure or higher.

4.1.2.2 Single-Stage, Multiple-Element SJAEs (see Figure 4-2[b])

These consist of two or more basic assemblies that are designed to operate at a suction pressure
below atmospheric pressure and to discharge at atmospheric pressure or higher. In these
combinations, each basic assembly is termed an element. The complete unit is termed a single-
stage, twin-element SJAE, a single-stage, triple-element SJAE, and so on, depending on the
number of elements provided.

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4.1.2.3 Multi-Stage, Single-Element SJAEs (see Figure 4-2[c], [d], [f], [g], and [h])

These are two or more basic assemblies arranged in series. The first and any intermediate
assemblies of the series are designed to operate at suction and discharge pressures below
atmospheric pressure. The final assembly of the series is designed to discharge at atmospheric
pressure or higher.

The discharge pressure of the first stage and the suction and discharge pressures of the
intermediate stages are selected to best subdivide the total compression among the several stages,
according to the particular operating conditions.

A complete series of stages, composed of one basic assembly per stage, is termed a two-stage,
single-element ejector, a three-stage, single-element ejector, and so on,, depending upon the
number of basic assemblies arranged in series.

4.1.2.4 Multi-Stage, Multiple-Element SJAEs (see Figure 4-2[e])

These consist of two or more multi-stage, single element SJAEs assembled in parallel and
arranged to permit the operation of any multi-stage element independently or in combination
with others. These SJAEs use common condensers with isolating inter-stage valves or
subdivided surface condensers.

4.1.2.5 Condensing and Noncondensing Types

Condensing multi-stage SJAEs have inter-condensers between some or all of the various stages
(see Figure 4-2[d] through [h]) for the purpose of condensing as much of the vapor discharged
from the preceding stage or stages as possible, in order to reduce the weight of gas to be
compressed by the next succeeding stage or stages. Noncondensing multi-stage ejectors have no
inter-condensers between stages (see Figure 4-2[c]).

4.1.2.6 Inter-Condensers

Inter-condensers can be of the surface (see Figures 4-2[e] and [g]) or direct contact (Figure
4-2[d], [f], and [h]) type. Surface condensers are typically shell-and-tube type.

Multistage SJAE systems can have more than one inter-condenser. The inter-condenser operating
at the lowest absolute pressure is the first inter-condenser and that following the next stage, the
second inter-condenser, and so on.

4.1.2.7 After-Condensers

Condensers arranged to condense the vapors discharged from one or more single-stage SJAEs or
from the final stage or stages of a combination of' SJAEs at approximately atmospheric pressure
are termed after-condensers. These may be of the surface or direct-contact type.

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4.1.2.8 Surface Inter-Condensers and After-Condensers

Surface inter-condensers and alter-condensers can be arranged in separate shells (as in Figure
4-2[g]) or can be combined in a common shell suitably subdivided (as in Figure 4-2[e]).

Figure 4-2
Common Types of Ejector Units
Source: Heat Exchange Institute

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4.1.3 SJAE Applications

4.1.3.1 Boiling Water Reactors

Figure 3-4 shows typical BWR CAR system configurations. BWRs use SJAE systems for the
holding mode of CAR because the large volumes of gases generated in the reactor (see Section
3.2) make the use of MPVs impractical. For those plants that have maintained the booster SJAE,
there are typically two trains of equipment. Each train is comprised of a two-element, two-stage
SJAE with an inter-condenser and an after-condenser. The booster SJAE is downstream of the
main SJAE and is a single-stage, single-element, noncondensing SJAE. The discharge of the
booster SJAE is not condensed because, as discussed in Section 3.2.1.2, dilution steam is needed
to reduce the off-gas hydrogen concentration to < 4% by volume.

For those plants that have removed the booster SJAE, there are typically two trains of equipment.
Each train is comprised of a two-element, two-stage SJAE with an inter-condenser but no after-
condenser. The discharge of the second-stage SJAE is not condensed because dilution steam is
needed to reduce the off-gas hydrogen concentration to < 4% by volume.

4.1.3.2 Pressurized Water Reactors

For those PWRs that use an SJAE in the hogging mode, there is typically one high capacity,
single-element, and single-stage noncondensing SJAE that takes suction from the main
condenser and discharges directly to the atmosphere.

For those PWRs that use SJAEs in the holding mode, there are typically either two or three
elements of a two-stage SJAE with both an inter-condenser and after-condenser. The first stage
takes suction from the main condenser, and the after-condenser discharges to the atmosphere.
The SJAE condensers drain back to the main condenser via a loop seal and SJAE condenser
hotwell level control arrangement.

Also, as will be discussed in more detail later, there are some PWRs that have CAR units that are
designed with a single-stage, noncondensing atmospheric jet air ejector that takes suction from
the main condenser and discharges into the suction of a single-stage, liquid ring vacuum pump.

4.2 Rotary Screw MVP

The rotary screw MVP is comprised of spiral rotor MVPs and helical rotor MVPs. The theories
of compression between the two are similar except that the spiral rotor is a single-stage, low-
pressure pump, and the helical rotor is a two-stage, high-pressure pump. Rotors for these two
designs are different. For the spiral rotor MVP, the main rotor has two lobes, and the gate rotor
has four matching grooves. For the helical rotor MVP, the main rotor has four lobes, and the gate
rotor has six matching grooves.

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4.2.1 Spiral Rotor MVP

4.2.1.1 Theory of Operation

As shown in Figures 4-3 and 4-4, the spiral rotor MVP consists essentially of just two moving
parts: a four-grooved gate rotor (at the top) and a mating two-lobed main rotor mounted directly
below it.

The shaft of the main rotor extends outside of the housing and is driven at high speed by an
external driver. The gate rotor is driven from the main rotor shaft by helical timing gears. The
gate rotor operates at half the speed of the driving main rotor.

The intake connection is located on one side of the housing at the timing-gear end, and the
discharge opening is located on the opposite side, at the drive-shaft end. Therefore, the flow of
air through the compressor is both rotary and axial.

During rotation and throughout the meshing cycle, the rotors do not come into contact, as timing
gears preserve the 2 to 1 rotor speed ratio and the predetermined rotor clearance relationship.
Each rotor shaft is supported and held by means of anti-friction bearings.

The compression cycle starts as the rotors unmesh at the inlet port. As rotation proceeds, the
fluid to be compressed is drawn into the cavity between the main rotor lobes and into the grooves
of the gate rotor, such as the suction stroke of a reciprocating compressor. The fluid is trapped in
these pockets and follows the rotational direction of each rotor. As soon as the inlet port is
closed, the compression cycle begins as the fluid is directed to the opposite, or discharge, side of
the compressor. The rotors mesh, reducing the normal free volume, thus increasing the pressure.
The reduction in volume continues, resulting in an increase in pressure until the closing pocket
reaches the discharge port.

Leakage loss of compressed fluid is held to a minimum by maintaining safe minimum clearances
between the meshing rotors, housing, and end walls. These clearances restrict fluid flow from the
discharge to the inlet. Because there is no contact between the rotor lobes, housing, or end walls,
no internal lubrication is required.

Each rotor shaft is equipped with anti-friction bearings. Self-aligning spherical roller bearings
are used at the discharge end of the compressor, while single-row ball bearings are used at the
inlet end of the compressor. All bearings are mounted in bearing cartridges fitted in bearing
carriers, thus permanently locating the rotors within the housing. Thermal expansion of the
rotors causes axial movement of the rotor shafts. The ball bearings allow this axial movement on
the inlet end of the rotor shafts, while the spherical roller bearings restrain the axial movement
on the discharge end of the rotor shafts.

The MVP is equipped with standard labyrinth seals with water slingers. The addition of a water
slinger prevents any water from entering the bearing cavity and mixing with the lubricating oil.
The standard labyrinth seal with water slinger consists of a stationary, Babbitt-lined seal bushing
and a rotating grooved seal sleeve. The seal sleeve is held in position on the rotor shaft by the

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stack-up of water slinger, oil slinger, and bearing. The heat of compression causes the rotor shaft
and seal sleeve to expand, thereby displacing the seal bushing Babbitt lining and creating an
effective seal.
The MVP is equipped with an internal, self-contained, forced-feed lubrication system. An oil
reservoir is provided in the inlet end-bearing carrier to supply oil to the gear-driven oil pump. Oil
from the pump is filtered and distributed to each bearing and the timing gears. The MVP is
provided with pump trip switches for high discharge temperature and low oil pressure.

Figure 4-3
Spiral Rotor MVP
Source: Dresser-Rand Company

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Figure 4-4
Cross-Section Spiral Rotor MVP
Source: Dresser-Rand Company

4.2.1.2 Application

Single-stage spiral rotor MVPs are used in the hogging mode by some BWRs, while SJAEs are
used for the holding mode. In this capacity, the pumps take suction on the common suction line
to the SJAEs between the SJAEs and the SJAE suction valves and discharge to the base of the
main chimney.

The condenser off-gas enters the vacuum pump saturated with water vapor. Water is also
injected into the inlet port to keep the inlet stream of gas saturated. This partly seals the clearance
between the rotors as well as the clearance between the rotors and the housing, and also prevents
excess discharge temperature. The additional amount of water that is added after the gas
becomes saturated seals the clearance and, thus, increases the delivery and the efficiency of the
vacuum pump. An injection of approximately one gallon (3.8 liters) of water per one thousand
cubic feet (28 cubic meters) per minute of inlet capacity is normally required to effect a slip
reduction, saturate the inlet, and control the discharge temperature.

A sufficient amount of water should be injected to maintain a discharge temperature of

approximately 130°F (54.4°C). When the injected water enters the compression area of the
vacuum pump and, as a result of the vacuum flashes into vapor, the heat of compression is
removed. As the water flashes, dissolved minerals in the water tend to form deposits on the
rotors. The amount of deposit is a function of discharge temperature, injection rate, and the

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percent of dissolved minerals in the water. By maintaining a discharge temperature of

approximately 130°F (54.4°C), the deposits on the rotors will normally remain soft and be
washed away. An adjustable water inlet valve with a fixed, maximum flow control valve and
water flow indicator is used to control the rate of water injection.

Drain piping is installed in the pump suction, along with a check valve that opens only when the
unit is shut down, to allow water that collects in the housing to drain out. At one plant, the drain-
flow check valve was initially installed in an improper geometric orientation, and the drain
piping was not properly sloped down and away from the machine to keep the water seal from
overflowing and filling up the compressor. This resulted in the intrusion of water into the oil.

Key Technical Point

Ensure that the drain-flow check valve is in the right geometric orientation
and that the drain piping is sloped down and away from the machine to keep
the water seal from overflowing and filling up the compressor such that the
water intrudes into the oil.

4.2.2 Helical Rotor MVP

4.2.2.1 Theory of Operation

Figures 4-5 through 4-9 show a typical helical rotor MVP. The helical rotor MVP is a two-stage,
rotary, positive-displacement compressor. In the helical rotor MVP, the displacement is obtained
through the meshing of two helical rotors on parallel shafts encased in a vertically split housing.
Inlet and discharge ports are at opposite ends of the rotor housing with the inlet port being at the
drive end.

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Figure 4-5
Helical Rotor MVP
Source: Dresser-Rand Company

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Figure 4-6
Cross-Section Helical Rotor MVP
Source: Dresser-Rand Company

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Figure 4-7
Inter-Stage Partition and Relief Valve
Source: Dresser-Rand Company

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Figure 4-8
Schematic Diagram for Air and Water Flow
Source: Dresser-Rand Company

The circular profile rotors in the MVP are known as male and female rotors. The male rotor has
four helical lobes, while the female rotor has six helical grooves that mesh with the male rotor
lobes. The power input is to the female rotor shaft. The power is transmitted to the male rotor
through the timing gears. The male and female rotors have the same outside diameter. The male
rotors and the male rotor shafts for both stages are made from a single piece of stock. This is also
the case for the female rotors and shafts.

The theory of compression for the helical rotor MVP is the same as that previously presented for
the spiral rotor MVP.

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The timing gears maintain a close clearance between the rotors and prevent the rotors from
contacting each other, and they also serve as speed-up gears.

The shafts are supported with anti-friction ball bearings at each end of each shaft. Thrust loads
are taken up by angular-contact, duplex-mounted ball bearings, located on the discharge end of
each shaft. The inlet end radial bearings are ball bearings.

The MVP is equipped with mechanical seals for sealing the rotor chamber from the seal vent
area and the lubrication system. Labyrinth seals regulate seal cooling water flow from the seal
chamber to the rotor chamber.

Lubrication is comprised of a splash system, utilizing an oil reservoir at each end of the vacuum
pump housing. These reservoirs are interconnected, and both are vented to the atmosphere. The
lubricating oil is picked up from these reservoirs by lubricating discs located on each end of the
female rotor shafts and is thrown from these discs in such a manner that it is distributed to the
timing gears and all bearing locations. The lubricating oil is kept from entering the seal cooling
water vent area by an oil slinger.

The inter-stage partition contains an inter-stage relief valve (refer to Figure 4-7). On pump down
(hogging mode), prior to the first stage reaching its balance ratio, the first stage discharges more
gas than the second stage can handle and causes a build-up of inter-stage pressure to a point
where it exceeds the discharge pressure. This unbalanced pressure causes the inter-stage relief
valve to open, and some of the first stage discharge gas bypasses the second stage. This saves on
horsepower by limiting the first stage discharge pressure and allows the second stage to operate
unloaded until the first stage reaches its balance ratio. After the first stage reaches its balance
ratio, the second stage starts to load, causing the discharge pressure to exceed the inter-stage
pressure, thereby closing the inter-stage relief valve. The inter stage relief valve stays closed
during the rest of pump down and during the normal operational period (holding mode).

The base is cast iron and is ribbed to provide a rigid mounting for the vacuum pump and all its
associated equipment. The cavity within the base provides a condensate reservoir and serves as a
receiver-separator for the air and vapor mixture that is discharged from the condenser vacuum
pump.

Figure 4-9 shows a cross-section of the base. An air and vapor mixture from the MVP discharge
enters the base at “A” where condensation of the vapor occurs. This water leg also acts as a
silencer. Additional condensation occurs as the air-vapor mixture moves from left into the cooler
area of the base cavity.

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Figure 4-9
Schematic of Base and Reservoir
Source: Dresser-Rand Company

During condenser pump-down (hogging mode), the airflow rate is greater than the airflow
indicator can handle, and large volumes of air are forced out through a second water leg “C,”
connected to the base discharge. As the condenser pressure approaches design values, airflow
through the water leg “C” falls off to where the water leg reseals. All of the air then flows
through the flow indicator “D” and on out the discharge.

A condensate makeup float valve “E” keeps the reservoir filled to the proper level, and an
overflow “F” is provided in case the condensate level rises.

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The MVP is equipped with a low-seal water pressure trip switch that will shut the MVP down on
loss of water pressure.

A centrifugal seal water circulating pump is flange mounted on the discharge end cover, directly
connected to the female rotor shaft. This pump provides demineralized water from the reservoir
in the base to the mechanical type shaft seals, located in the vacuum pump.

A seal water cooler is mounted on the side of the base to maintain the seal water temperature at
7.5°F (4.17°C) above the cooling water inlet temperature. Normally, the cooling water will be
condenser circulating water. The use of circulating water in the seal water cooler provides the
vacuum pump with seal water that is always cooler than the condenser at its operating pressure.
This difference between seal water temperature and saturation temperature provides the most
efficient air removal at any condenser vacuum level. The vacuum pump will automatically track
the condenser, thereby providing maximum air removal under any condenser load during the
whole year.

Key Technical Point

Maintaining the seal water at a temperature cooler than the condenser at its
operating pressure provides the most efficient air removal at any condenser
vacuum level. The vacuum pump will automatically track the condenser,
thereby providing maximum air removal under any condenser load during
the whole year.

Inside the intake separator is a vertical baffle that is arranged to separate the liquid from the
noncondensible gases. The gas flows over the top of the baffle. The liquid remains behind the
baffle and is metered into the gas stream through an orifice. This prevents large slugs of liquid
from entering the MVP and allows a uniformly controlled liquid flow that the MVP is capable of
handling. A spray nozzle is provided on the gas side of the baffle to facilitate the addition of a
cooling spray when required to control the MVP discharge temperatures.

4.2.2.2 Application

Two-stage, helical-rotor MVPs are used as CAR equipment at some PWRs. In this capacity, the
pumps function in both the hogging and holding modes. No additional equipment is needed. The
full capacity of the MVP is directly used during all levels of condenser vacuum operation
without any valve changes or switching of air flow.

The condenser air take-off is piped to the intake separator (Figure 4-5). Internal baffles in the
separator allow any water carried over from the system to collect and drain at a controlled rate
into the vacuum pump inlet. The air-vapor mixture from the condenser is drawn through the
intake separator and enters the first-stage rotor chamber where it is compressed to inter-stage
pressure. The air-vapor mixture then enters the second-stage where it is compressed to
atmospheric pressure.

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As stated earlier, the inter-stage partition is equipped with an inter-stage relief valve. In the
hogging mode, the inter-stage relief valve opens, and some of the first-stage discharge gas
bypasses the second stage, allowing the second stage to operate unloaded until the first stage
reaches its balance ratio. After the first stage reaches its balance ratio, the inter-stage relief valve
closes during the rest of pump down and during the normal holding mode operation.

4.3 Liquid Ring MVP

4.3.1 Liquid Ring MVP Fundamentals

The liquid ring MVP is a specific form of rotary positive displacement pump utilizing liquid as
the principle element in gas compression. The compression is performed by the liquid ring, as a
result of the relative eccentricity between the casing and a rotating multi-bladed impeller.

The eccentricity results in nearly complete filling then partial emptying of each rotor chamber
during each revolution. This partial filling and emptying creates a piston action within each set of
rotor or impeller blades. Parts are positioned in such a manner as to admit gas when the rotor
chamber is emptying of liquid and allow the gas to discharge once compression is completed.
Sealing areas between the inlet and discharge ports are provided to close the rotor areas,
separating the inlet and discharge flows.

A portion of the liquid in the casing is continuously discharged with the gas, and the cooler
service liquid is introduced to remove the heat generated during operation. Figures 4-10 and 4-11
provide typical examples of liquid ring MVPs and describe the gas compression cycle for each.
Figure 4-12(a) through (d) shows the four common types of liquid ring MVPs. The four types
are:
• Figure 4-12(a) - Single stage, flat port plates
• Figure 4-12(b) - Single stage, conical ports
• Figure 4-12(c) - Two stage, flat port plates
• Figure 4-12(d) - Two stage, conical ports

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Figure 4-10
Flat Port Plate Liquid Ring Vacuum Pump Gas Compression Cycle
Source: Heat Exchange Institute

Figure 4-11
Conical Port Liquid Ring Vacuum Pump Gas Compression Cycle
Source: Heat Exchange Institute

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Figure 4-12
Types of Liquid Ring Vacuum Pumps
Source: Heat Exchange Institute

4.3.2 Single-Stage Liquid Ring MVP

Individual single stage liquid ring MVPs are installed in some BWRs and PWRs as hogging
mode CAR equipment. Additionally, at some other PWRs the holding mode CAR equipment
consists of a combination of an atmospheric jet air ejector and a single stage liquid ring MVP
packaged by a vendor into a CEU.

4.3.2.1 Theory of Operation

In addition to being the compressing medium, the liquid ring absorbs the heat generated by
compression and friction, absorbs any liquid slugs or vapor entering with the gas stream, and
condenses water vapor entering with the gas. Therefore, for CAR service, a closed loop (or
total recirculation) seal system is typically used. The seal water temperature will be 3–5°F
(1.7–2.8°C) warmer than the cooling water to the MVP heat exchanger, which is normally taken
from the same source as the condenser cooling water.

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The vacuum attainable by a liquid ring MVP is limited by the vapor pressure of the seal fluid. As
the operating vacuum approaches the vapor pressure of the seal, more and more of the seal fluid
will “flash” into vapor. The capacity of the liquid ring MVP is reduced as more of the impeller
space is occupied by vapor from the seal fluid, leaving less space available to accept the
incoming load. If allowed to continue, cavitation will occur inside the pump, resulting in
damage to internal surfaces, and preventing the pump from achieving greater vacuum levels.

To prevent cavitation, the operating vacuum of the liquid ring MVP must be limited to
approximately 0.25 inch (0.64 cm) Hg above the vapor pressure of the seal liquid. This
differential varies somewhat according to pump model and the amount of heat added to the seal
water by condensible load, however the importance of vacuum limitations set by seal water
temperature should be emphasized. Even if the pump is oversized, it cannot obtain lower
pressure levels than those permitted by the vapor pressure of the seal water. This limitation is a
disadvantage when the condenser is operated under part load conditions. (See the discussion
under hybrid systems.)

Key Technical Point

Even if a liquid ring vacuum pump is oversized, it cannot obtain lower
vacuum levels than those permitted by the vapor pressure of the seal water.
To prevent cavitation, the operating vacuum of the liquid ring MVP must be
limited to approximately 0.25 inch (0.64 cm) Hg above the vapor pressure of
the seal liquid.

Liquid ring MVPs are normally supplied completely packaged with controls for fully automatic
operation. No separate hogging device for initial evacuation is required, as the pump gains
capacity rapidly at higher suction pressures.

4.3.2.2 Hogging Mode Application

Single-stage liquid ring MVPs are used in the hogging mode by some BWRs and PWRs with
SJAEs being used for the holding mode. In this capacity, a standard single-stage liquid ring MVP
takes suction on the main condenser and discharges to the atmosphere, with the BWRs
discharging to the atmosphere via the gland seal holdup volume.

4.3.2.3 Holding Mode Application

The holding mode CAR equipment consists of a combination of a first-stage atmospheric jet air
ejector and a second-stage, single-stage liquid ring MVP packaged into a CEU. (See Figure 4-13
and the following discussion.)

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4.3.2.3.1 CEU Fundamentals

The atmospheric jet air ejector (Figure 4-14), which constitutes the first stage of the CEU,
operates through the use of atmospheric air as the motivating medium. Steam and compressed
gas are not used. Instead, air at atmospheric pressure passes through a specially designed
acoustical nozzle into the suction chamber or ejector body.

This motive air, because of the pressure differential between inlet and outlet of the air jet,
accelerates to a velocity several times that of sound (MK 2.0). This high-velocity air entrains
gases entering the ejector body from the main condenser, effectively compressing the gas and the
motivating air.

A standard single-stage liquid ring MVP takes suction at the discharge of the atmospheric jet air
ejector, completing the evacuation.

Compressant liquid in the MVP is part of a closed loop consisting of heat exchanger, separator,
and circulating pump. At the time of initial start-up, the system is filled with condensate. During
subsequent operation, vapor is continuously drawn over from the main condenser and condensed
by the liquid ring in the MVP. Thus, there is a small amount of makeup being added to the
system constantly with a corresponding overflow from the separator.

Cooling water to the heat exchanger should be condenser circulating water whenever possible.
Because of the vapor pressure existing within the MVP, the pump will tend to track the main
condenser whenever both are fed the same temperature of coolant.

Key Technical Point

Cooling water to the liquid ring MVP heat exchanger should be condenser
circulating water whenever possible. Because of the vapor pressure existing
within the MVP, the pump will tend to track the main condenser whenever
both are fed the same temperature of coolant.

4.3.2.3.2 Theory of Operation

CEU Shut-Down (Figure 4-15). When the exhauster is not operating, the SOVs are de-
energized. Atmospheric pressure is on the system diaphragm valve, which causes the valve to be
in the closed position. Controlled air is on the inner side of the piston of the bypass valve,
causing it to be in the open position. The motive air valve and the balanced check valve are
closed.

Hogging Operation (Figure 4-16). Energizing the liquid ring MVP (exhauster) starter also
starts the seal water centrifugal pump. Energizing the exhauster starter also energizes the three-
way SOV, which forces controlled air to the bottom of the system diaphragm valve, causing it to
open. The bypass valve is also open, and, therefore, the flow of the air from the condenser
evacuation goes directly from the condenser to the exhauster inlet, bypassing the air jet.

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Holding Operation (Figure 4-17). When the pressure in the condenser reaches approximately
25 inches (63.5 cm) Hg. vacuum, or 5 inches (12.7 cm) Hg absolute, the jet vacuum switch
makes contact and energizes the four-way SOV, causing the vent to open and bleed the control
air from the inner side of the piston of the bypass valve. Control air is supplied to the outer side
of the piston through the four-way SOV, causing the bypass valve to close. Control air also goes
to the inner side of the piston of the motive air valve, causing the valve to change position and
allowing motive air to flow from the atmosphere to the air jet nozzle.

All system air in-leakage must now flow through the air jet, bringing both the jet and exhauster
into full operation to evacuate the condenser.

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(a) View 1

(b) View 2

(c) Liquid Ring

Rotor

Figure 4-13
Single-Stage Liquid Ring CEU
Source: Robinson Nuclear Plant

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Figure 4-14
Nash Atmospheric Jet Air Ejector
Source: Nash Gardner Denver

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Figure 4-15
Nash CEU (Before Start)
Source: Nash Gardner Denver

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Figure 4-16
Nash CEU (Hogging)
Source: Nash Gardner Denver

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Figure 4-17
Nash CEU (Holding)
Source: Nash Gardner Denver

4.3.3 CEU with Two-Stage Liquid Ring MVP

The main assemblies of the two-stage liquid ring (MVP) are shown in Figure 4-18. An electric
drive motor is directly coupled to the pump drive shaft that is common to both stages of the
MVP. Rotors in each stage are rigidly mounted on the shaft and rotate at the same speed as the
shaft.

4.3.3.1 Two Stage Liquid Ring MVP Operation

The operating principle of this MVP is the same as was described in Section 4.3.1 for the single
stage. Evacuated gas and water are discharged by the first stage of the MVP into the second stage
discharge manifold. During low-vacuum operation, a check valve in the second-stage manifold is
open, allowing the first-stage discharge to flow directly to an externally located atmospheric
discharge separator. Thus, at low vacuum, only the first stage of the vacuum pump performs an
evacuation function. During high-vacuum operation, the check valve is automatically closed. The
first stage discharge is then routed to the inlet of the second stage and through the second stage
before being discharged through the second stage manifold to the separator. Operation under
low- and high-vacuum conditions is shown in Figure 4-19.

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Liquid compressant (seal water) is applied to the vacuum pump to provide the makeup for the
liquid in the pump and to seal the clearances between the cone and rotor. The liquid compressant
enters the vacuum pump at the first-stage heads, where it then flows through a passage in the
heads to the cones and through the clearance between the cones and rotor into the rotor chamber.
Liquid compressant is discharged with the evacuated gas into the second-stage manifold. From
the second-stage manifold, it passes directly into the atmospheric discharge separator (low
vacuum operation) or flows into the second-stage inlet (high vacuum operation) before being
discharged with the evacuated gas into the separator.

Stuffing boxes on the vacuum pump contain packing rings and, in the first stage stuffing boxes
only, lantern gland seals. These stuffing boxes are lubricated by the liquid compressant. Liquid
compressant is applied to the lantern glands under a pressure of 2–5 psig (13.8 to 34.5 kPa) from
the second stage shroud, preventing atmospheric air from entering the vacuum pump through the
stuffing boxes.

Figure 4-18
Major Components of a Two-Stage Vacuum Pump
Source: Nash Gardner Denver

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Figure 4-19
Vacuum Pump Low and High Vacuum Operation
Source: Nash Gardner Denver

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4.3.3.2 CEU Operation

4.3.3.2.1 Overall CEU Operation

Liquid compressant (seal water) in the CEU is circulated through a closed loop that consists of a
two-stage vacuum pump, a separator, a centrifugal pump, and a heat exchanger. Seal water is
pumped by the centrifugal pump from the separator through the heat exchanger to the vacuum
pump. As the seal water flows through the heat exchanger, it is cooled to a temperature
approximately 2 to 4°F (1.1 to 2.2°C) above the inlet temperature of the cooling water that flows
through the heat exchanger. Seal water from the heat exchanger outlet flows to the vacuum pump
where it is fed to the inlet manifold and the first-stage heads of the vacuum pump.

Seal water entering the inlet manifold directly is applied through two spray nozzles that are
threaded into the inlet manifold. Horsepower requirements are kept to a minimum during low
vacuum operation by means of a spray water vacuum switch in the control panel, a water pilot
SOV, and a spray water control pneumatic valve which shuts off the supply of liquid sealant to
the spray nozzles at a vacuum of 23 inch (58.4 cm) Hg and below. The supply of liquid sealant to
the spray nozzles opens at a rising vacuum of 25 inch (63.5 cm) Hg. The spray nozzles form the
seal water into a spray pattern through which the system air-water vapor mixture must pass. As
the system air-water vapor mixture contacts the seal water spray, most of the water vapor in the
mixture is condensed. The condensed water vapor, the balance of the air-water vapor mixture
and seal water spray flow through inlet passages in the first-stage heads into the vacuum pump.

At the same time, the seal water fed directly to the vacuum pump from the heat exchanger flows
through the passages in the first-stage heads into the first stage pump to seal clearances in the
vacuum pump. Within the pump, the seal water contacts the mixture flowing from the inlet
manifold. Water vapor in this mixture is thereby condensed, reducing the volume of air that has
to be removed by the two-stage vacuum pump.

The inlet air is partially compressed in the first stage of the vacuum pump and is discharged with
the seal water to the inlet of the second stage of the pump. The second stage compresses the air
to atmospheric pressure and discharges all of the seal water and compressed air into the
separator. Within the separator, the seal water drops from the air stream to the bottom. The
discharge air passes through the separator outlet and through the air leakage test valve to the
atmosphere.

An automatic float switch senses the level of water in the separator. If the level is too low, the
float switch opens the makeup SOV, permitting makeup water to flow into the separator and then
to the vacuum pump. When the water level in the separator is high enough to provide the proper
reservoir of seal water for the vacuum pump, the float switch closes the makeup SOV. An
overflow loop with a check valve to prevent flow back into the separator automatically controls
the maximum water level in the separator. This prevents the loss of vacuum-pump capacity as a
result of insufficient seal water reservoir and prevents condensed vapor from accumulating in the
separator and entering the discharge vent piping.

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4.3.3.2.2 CEU Control

Figure 4-20 provides CEU component identification and a schematic of its functional operation.
When the CEU is shut down, an SOV in the control panel is de-energized. With the SOV de-
energized, air pressure in the diaphragm of the system inlet valve (not shown) is vented through
the SOV to the atmosphere, allowing the system inlet valve to remain closed

A differential vacuum switch is connected to the system piping upstream from the system inlet
valve and to the vacuum pump inlet manifold. The differential vacuum switch is closed when the
vacuum pump inlet pressure is within one inch of mercury of the system pressure. With the
differential vacuum switch in the closed position, an SOV in the control panel can be energized
to direct control air to the system inlet valve diaphragm.

At initial start-up when the system is at atmospheric pressure, the differential vacuum switch is
in a closed position. (The system and vacuum pump inlet manifold are also at atmospheric
pressure.) When the vacuum pump motor is energized, the SOV is energized, and control air
flows to the system inlet valve diaphragm, opening the inlet valve.

If the system is at a pressure less than atmospheric pressure and the vacuum pump is shut down,
the differential vacuum switch is in an open position. (The pressure in the pump inlet manifold is
greater than the system pressure.) When the vacuum pump motor is energized, the system inlet
valve remains closed while the pump is running until the pressure in the inlet manifold is within
one inch of mercury of the system pressure. At this pump inlet pressure, the differential vacuum
switch closes, energizing the SOV. Control air then flows to the system inlet valve diaphragm,
opening the valve.

With the system valve open, air from the condenser system can flow through the inlet manifold
to the first stage of the vacuum pump. During hogging mode operation, the discharge from the
first stage pump flows through the first-stage discharge manifold and the second-stage inlet
elbow to the second-stage inlet and discharge manifold. An inter-stage check valve, located
inside the second-stage inlet and discharge manifold, is open at this time, permitting the air and
water to be discharged into the separator. The water in this discharge is separated out, and the air
flows through the air leakage test valve to the atmosphere.

When the inlet vacuum increases to approximately 25 inches Hg vacuum, a vacuum switch
actuates, which energizes an SOV to send water to spray nozzles for full seal flow. When the
inlet vacuum decreases to approximately 23 inches Hg vacuum, a vacuum switch activates,
which shuts off water flow to the spray nozzles.

Holding mode operation begins automatically when the second stage inlet capacity is equal to the
volume of gas discharged from the first stage. (See the discussion in Section 4.3.3.1.) The
discharge of the first stage flows through the inter-stage piping to the second-stage inlet. The
second stage compresses the mixture to atmospheric pressure and discharges the air and water
into the separator. The air flows through the air leakage test valve to the atmosphere.

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The proper level of seal water is automatically maintained in the separator as previously
described.

The seal water circulating (centrifugal) pump is used to ensure sufficient flow of seal water to the
vacuum pump in order to maintain full pump capacity during hogging operation. During high-
vacuum operation, the vacuum pump inlet vacuum is sufficient to maintain proper flow of seal
water to the pump. Therefore, should the centrifugal pump fail when the vacuum pump unit is
holding condenser back pressure, the vacuum pump automatically maintains proper flow of seal
water and full holding capacity.

The centrifugal pump also provides a nominal pressure in the seal piping and heat exchanger.
Should a failure in the heat exchanger occur, the seal pressure prevents the entry of relatively
impure cooling water into the sealing water system.

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Figure 4-20
CEU Functional Operation
Source: Nash Gardner Denver

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4.4 Hybrid CEU

Refer to Figure 4-21. In the hybrid CEU, an SJAE is used as the first stage of the unit. The SJAE
discharges into an inter-condenser that is followed by a one or two stage liquid ring MVP. There
are presently no known nuclear plants that have installed hybrid CEUs.

4.4.1 Principle of Operation

The first-stage SJAE boosts the inter-stage pressure to the vacuum pump. Thus, a smaller pump
is required than if the entire compression was to be done by an MVP.

Condensate from the inter-condenser can be discharged directly into the liquid ring MVP. Thus,
no barometric leg or special pumping device is needed for condensate discharge.

Cavitation can be a maintenance problem for standalone liquid ring MVP systems that must
operate at pressures close to the vapor pressure of the pump service liquid. This problem is
minimized when a hybrid system is used, as the MVP operates at a higher inter-stage pressure.
Note that cavitation may still occur if air leakage is near zero.

The first-stage SJAE boosts the pressure, and the inter-condenser condenses the majority of the
motive steam and water vapor load, greatly reducing the load to the MVP. Thus, a smaller MVP
can be used. Hybrid units may be more energy efficient, can be optimized to account for low-
cost steam or electric utilities, and can be optimized to achieve the best balance between steam
and power usage.

Cooling is by condensate and/or closed cycle cooling water.

4.4.2 Part Load Operation

Improved Steam Condenser Gas Removal System authored by the American Society of
Mechanical Engineers describes the disadvantage of liquid ring pump during operation at part
load conditions. Liquid ring vacuum pumps are sized based on the assumption that the initial
temperature difference (ITD) for a given condenser is a fixed number. ITD is the difference
between the saturation temperature at the condenser pressure and the inlet cooling water
temperature. As the ITD increases, vacuum pump capacity increases. Conversely, as the ITD
decreases, vacuum pump capacity decreases. Once the ITD is calculated, the vacuum pump is
chosen from the pump performance curve. A large ITD allows use of a small vacuum pump,
while a small ITD requires a larger model.

Liquid ring vacuum pump selection is based on the condenser ITD, which is assumed constant.
This assumption of a fixed ITD is acceptable when the condenser is operated under full steam
load conditions. But what happens when this same condenser is operated under part load? The
condenser ITD decreases rapidly under part load conditions. The reduced ITD causes a severe
reduction in the vacuum pump capacity, especially when the condenser is operated at 50% load
or below.

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In the example given in the reference, the condenser was capable of operation at 1.97 inches
(5.00 cm) Hg Absolute under full load conditions, and 1.33 inches (3.38 cm) Hg Absolute at
50% load. However, at this reduced load and reduced ITD, the vacuum pump capacity fell off to
75% of design, and it would operate at 1.75 inches (4.45 cm) Hg Absolute. Therefore, the
vacuum pump would limit the condenser operating pressure, and the condenser would operate at
the elevated pressure.

Hybrid systems are designed for the maximum anticipated cooling water temperature and are not
dependent on the ITD. Capacity would be 100% for either condition given previously.

Many power plant operators are not aware that their CAR equipment may be limiting the
condenser under part load conditions. Only reference to the condenser performance curve will
reveal the fact that the operating pressure is above the pressure the condenser is capable of,
robbing the plant of available energy.

Key O&M Cost Point

Plant CAR equipment may be limiting the condenser under part load
conditions. Only reference to the condenser performance curve will reveal
the fact that the operating pressure may be above the pressure the condenser
is capable of, robbing the plant of available energy.

4.4.3 Retrofitting Hybrid Systems to Existing Plants

The operating advantages of the hybrid can be achieved by retrofitting existing SJAE or liquid
ring vacuum pump systems. In existing SJAE systems, the second-stage SJAE and after-
condenser can be replaced by a liquid ring pump. This results in the more efficient hybrid
arrangement.

Existing liquid ring vacuum pumps can be combined with a new first-stage SJAE and inter-
condenser to provide added capacity if the present system is not adequate. This inadequacy
might be as a result of increased air leakage, decreased pump performance, or operation of the
main condenser at off-design conditions. Also, with the advantages explained in Section 4.4.1,
the retrofit will allow the system to achieve greater vacuum levels with an improved ability to
maintain optimum condenser performance as well as reduce oxygen levels in the condensate.

System design should include all possible countermeasures to prevent leakage of live steam into
the vacuum pump. The pump will be damaged if live steam enters the unit without cooling water
supply to the inter-condenser and/or no seal water supply during vacuum pump shutdown.

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Under no circumstances should steam flow be permitted to enter the pump during vacuum pump
shutdown. Each of the following should be considered in the system design:
• A positive sealing valve should be used to isolate live steam from the pump during any time
that cooling water to the system is shut off.
• If possible, the interlock system should be designed so that cooling water is continuously
supplied to the inter-condenser/pump when steam is on.

Figure 4-21
Hybrid Condenser Exhaust
Source: Heat Exchange Institute

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FAILURE DATA AND FAILURE MODES

Failure modes and their causes are discussed in this section. The data presented here were
obtained from searches of industry databases and other sources for CAR system equipment
failures. The NRC Event Notification System and Inspection Report databases and the INPO OE
database were searched. The INPO OE database includes NRC Licensee Event Reports. The
individual results of the searches are tabulated in Appendix A.

The failure data presented here were supplemented with information obtained in a survey on
CAR equipment sent to select nuclear plants and with information obtained in follow-up
interviews from those surveys. Some technical advisory group members also provided additional
failure information as part of their review of the draft document.

Thirty-eight percent of the CAR system failures occurred on SJAE-related systems, while 62%
occurred on MVP-related systems. For failures occurring on the MVPs themselves and not to
supporting equipment, helical rotor MVPs accounted for 55% of the failures, while liquid ring
MVPs accounted for 45%.

Helical rotor MVPs are a subset of the rotary screw group of MVPs, along with the subset of
spiral rotor MVPs. There were no failures reported in the searched databases for spiral rotor
MVPs. This is not to say there have been no failures, but that the application of the screening
criteria for including the failures in the databases always eliminates them. The reason for this is
that spiral rotor MVPs, when used, are installed in the hogging mode for BWRs. In this mode,
the MVPs are typically operated to evacuate the condenser and turbine volume in parallel with
reactor startup. The pumps are low-pressure pumps and are not typically intended to be able to
establish sufficient vacuum by themselves to place the turbine online. At some point in the
startup, the SJAEs are placed online, and the MVP is secured to continue the condenser
evacuation. Therefore, MVP malfunctions that would require placing the SJAEs online earlier
than desired would be corrected but would not typically be reported unless startup was
significantly delayed.

5.1 SJAE System Failure Modes and Mechanisms

SJAE systems are fundamentally reliable because the SJAEs themselves have no moving parts. If
the steam supply is dry, the cooling water is clean, and the materials of construction are matched
properly to the corrosive nature of the process fluids, SJAE systems can, and do, last indefinitely.
If the SJAEs are operated within their design parameters for steam pressure, condensate
temperature, and SJAE backpressure, failures seldom occur, although failures of the supporting
equipment do sometimes occur. The most common problem areas for SJAE systems based on the

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review of failure history are SJAE loss of vacuum and malfunctions of the SJAE steam supply
and suction valves. The most common causes of SJAE loss of vacuum are operating the SJAE
with a condensate temperature or SJAE backpressure outside of the design limits. The relative
failures of the SJAE-related systems are further broken down in Table 5-1.

Table 5-1
Failures in SJAE-Related Systems

SJAE System Component Percent of Failures

SJAE 44%

Suction valves 25%

Steam supply valves 31%

The failure modes of the SJAE-related system components are given in Table 5-2.
Table 5-2
Failure Modes in SJAE-Related Systems

SJAE System Component Failure Modes

SJAE Loss of vacuum

Suction valves Failed to close

Failed to close
Failed to open
Steam supply valves
Stuck closed
Failed to control pressure

5.1.1 SJAE Loss of Vacuum

Because SJAE failures seldom occur, there is limited failure history for this failure mode with
which to provide associated failure mechanisms. However, additional failure mechanisms are
provided in the Heat Exchange Institute’s Tech Sheet # 102, “HEI Steam Jet Vacuum Systems
Troubleshooting Guide.” The failure mechanisms identified from the failure history are:
• Increased condensate temperature above system design as a result of changes in plant
operation
• Increased SJAE backpressure above system design as a result of malfunctions or operational
changes in the off-gas system (BWR only), downstream of the CAR system
• Flooded inter-condenser as a result of system design weaknesses that inhibited proper inter-
condenser hotwell draining
• Lost inter-condenser loop seal as a result of failed SOV

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Additional failure mechanisms from HEI Tech Sheet # 102 are:

• Plugged steam nozzles as a result of foreign material in steam supply
• Wear of internal working surfaces of nozzles and diffuser as a result of wet steam
• Too much friction in ejectors as a result of fouling of internal working surfaces

5.1.2 SJAE Suction or Steam Supply Valve Failure to Close or Stuck Closed

Most failure mechanisms for this failure mode are related to failures of SOVs to operate. SOV
failures occurred throughout the failure history for other failure modes on other equipment as
well, and are discussed in more detail later. The failure mechanisms identified from the failure
history are:
• Interference with SOV operation by SOV mounting bracket as a result of less than adequate
installation. Because new SOVs were physically different, new mounting brackets were
fabricated out of angle iron. The angle iron interfered with the magnetic flux generated by the
SOV coil, resulting in multiple failures of the valves to operate.
• Air leakage at bonnet-to-body flange that prevented SOV operation.
• Hardening of o-rings that prevented SOV operation as a result of the lack of PM.

5.1.3 SJAE Steam Supply Valve Failure to Open or to Control Pressure

The failure mechanisms identified from the failure history are:

• Disengagement of packing nut that caused a loss of valve packing as a result of less than
adequate previous maintenance
• Blocked pressure controller sensing lines as a result of corrosion product buildup
• Inaccurate pressure indicator, used for manually setting supply pressure, as a result of
instrument drift
• Failed auxiliary steam supply pressure controller as a result of untimely corrective
maintenance

5.2 MVP System Failure Modes and Mechanisms

Liquid ring (single-stage and two-stage), helical rotor (two-stage), and spiral rotor (single-stage)
MVPs are in use in nuclear power plants for CAR purposes. Spiral rotor MVPs are in limited use
at some BWRs for hogging mode operation. MVPs used for holding mode operation consist of
two-stage liquid ring MVPs, single-stage liquid ring MVPs coupled to an air jet air ejector, or
helical rotor MVPs. The relative failures of the MVP-related systems are further broken down in
Table 5-3.

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Table 5-3
Failures in MVP-Related Systems

MVP System Component Percent of Failures

Helical rotor MVP 43%

Liquid ring MVP 38%

Suction valves 19%

Based on the review of failure history, the most common problem areas identified for MVP
systems are MVP trips, MVP failures to start, MVP degraded performances, and MVP suction
valve failures. The failure modes of the MVP-related system components are given in Table 5-4.

Table 5-4
Failure Modes in MVP-Related Systems

MVP System Component Failure Modes

Tripped
Helical rotor MVP Failed to start
Degraded performance

Tripped
Liquid ring MVP Failed to start
Degraded performance

Failed to close
Suction valves
Failed to open

5.2.1 MVP Trips

The failure mechanisms identified from the failure history are:

• Elevated discharge temperature (helical rotor) as a result of design limitations or fouled seal
water cooler
• Failed seal water pump (liquid ring) as a result of a faulted motor or seized impeller
• Tripped motor thermal overloads (helical rotor) as a result of a failed inter-stage relief valve,
caused by a lack of PM
• Tripped oil pressure switch as a result of improper calibration during previous maintenance
• Tripped seal water flow switch as a result of improper adjustment during previous
maintenance

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5.2.2 MVP Failures to Start

The failure mechanisms identified from the failure history are:

• Tripped vacuum (pressure) switch (liquid ring) as a result of instrument drift
• Tripped motor thermal overloads for unknown reasons

5.2.3 MVP Degraded Performance

The failure mechanisms identified from the failure history are:

• Increased suction pressure (cyclically) (helical rotor) as a result of excessive motivating air
being introduced into the pump suction to reduce the discharge temperature.
• Lifted inter-stage relief valve (helical rotor) as a result of motivating air being injected at too
low an ambient temperature.
• Overheated outboard motor bearing as a result of insufficient quantity of grease applied to
the bearing by a motor repair shop.
• Inability to hold condenser vacuum at 1.8 inches (4.57 cm) Hg absolute (liquid ring) as a
result of the spray valve not opening. The spray valve was improperly installed during recent
modification and was not detected during testing because the vendor’s note that the spray
valve would be closed during low vacuum operation was misinterpreted by test engineer to
mean low absolute vacuum.
• Flooded separator tank as a result of a stuck makeup water valve.

5.2.4 MVP Suction Valve Failure to Open or Close

The failure mechanisms identified from the failure history are:

• Isolated valve controller sensing lines as a result of root valves not being opened after
maintenance.
• Failed SOV as a result of internal valve leakage.
• Failed differential pressure switch (liquid ring) as a result of initial incorrect calibration of a
new switch, with the differential pressure applied in the reverse direction. Unclear vendor
drawings were misinterpreted to establish calibration requirements.
• Failed differential pressure switch as a result of instrument drift.
• Failed SOV as a result of the repair kit diaphragm being installed in reverse orientation.

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5.2.5 SOV Failures

Twenty-four percent of the CAR equipment failures were related to SOV failures. In EPRI
publication NP-7414, Solenoid Valve (SOV) Maintenance and Application Guide, a failure
modes and effects analysis was performed on a data source consisting of thousands of SOV
failures across all nuclear plants and all systems. Five failure modes were identified. These are:
Failure to shift to the fully energized position
Failure to shift to the fully de-energized position
Excessive internal leakage
Excessive external leakage
Position indication failure

The major failure mechanisms associated with these failure modes are:
• Inadequate coil magnetic force
• Excessive residual magnetism
• Internal binding
• Seat wear or damage
• Valve body damage as a result of porosity, corrosion, or erosion
• Closure leakage

5.2.6 Other Considerations

Inappropriate human performance was involved in 45% of the failures. Some of the
inappropriate performance was related to a less than adequate understanding of how the CAR
equipment functions. Examples include the effects of iron brackets on SOV performance, proper
cooling water spray valve operation, and the effects of induced motivating air on helical rotor
vacuum pump performance. Training programs for system engineers and maintenance personnel
should be reviewed and strengthened as appropriate to address these weaknesses.

Key Human Performance Point

Training programs for system engineers and maintenance personnel should
be reviewed and strengthened as appropriate to address weaknesses in the
understanding of how the CAR equipment functions.

Condition monitoring or PM activities were not being performed on 13% of the equipment prior
to its failure. Examples include SOVs, the seal water cooler, the seal water pump, and the inter-
stage relief valve. Condition monitoring and PM practices on CAR equipment should be
reviewed as discussed in Sections 7 and 8.

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TROUBLESHOOTING

Troubleshooting and industry experience help identify probable causes and provide suitable
corrective actions. The following sections and tables provide potential problems, possible causes,
and possible solutions. Troubleshooting guidance in some instances is provided for specific types
of equipment, such as SJAEs, liquid ring vacuum pumps, and rotary screw vacuum pumps. In
other instances, it is provided for areas common to more than one type of equipment, such as
bearing problems, lubrication system problems, and noise level problems. For guidance on
troubleshooting coupling problems, refer to EPRI 1007910, Flexible Shaft Couplings
Maintenance Guide, and for guidance on troubleshooting speed reducer problems, refer to EPRI
1009831, Gearbox and Gear Drive Maintenance Guide.

6.1 SJAE Troubleshooting (Based on Heat Exchange Institute Tech

Sheet # 102)

As vacuum systems age, problems may arise. A gradual loss of vacuum usually suggests an
internal problem, such as erosion or corrosion, which should be addressed at the next routine
inspection. A sudden loss of vacuum, on the other hand, suggests external factors, such as a
change in quality of steam supply or quantity or temperature of water supply to the condensers.
Because most unexpected issues arise from easier-to-investigate external causes, most
troubleshooting begins on the outside. Issues arising from external and internal causes are
included in the troubleshooting matrix of Table 6-2. Internal SJAE issues are more difficult to
troubleshoot.

6.1.1 SJAE Troubleshooting Difficulties

The primary difficulties in troubleshooting an SJAE system result from the following factors:
• Not understanding how ejector systems work
• Not being able to easily observe the operation (fluids flowing inside)
• Becoming confused by the interaction of components
• Working in a high radiation field (for BWRs)

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6.1.2 SJAE Troubleshooting Techniques

Three methods to use in overcoming troubleshooting difficulties and simplifying the
troubleshooting process are:
1. Study the appropriate parts of the HEI Standard for Steam Jet Vacuum Systems and any
available manufacturer’s literature on how systems work and how ejectors behave.
2. Use the appropriate pressure and temperature gauges to determine fluid conditions and flow
meters to determine their rates.
3. Isolate and check the system and its components by performing the following
troubleshooting procedure.

6.1.3 SJAE Troubleshooting Procedure

The following procedure provides one method to isolate system components and check them for
proper operation. Refer to Appendix C for SJAE terminology used in the procedure.
1. Check the operational history of the overall system (vacuum user and vacuum producer).
Check for feed rate changes, trends, or abnormalities in the suction pressure being produced,
operation of valves, gages, and meters.
2. Isolate the vacuum producer (steam jet vacuum system) from the vacuum user by closing off
the suction valve or installing a blind flange on the jet system suction connection. (Ensure
that no liquid is trapped in the isolated section.) If the load suction pressure (for a system
designed to be stable at no load) is approximately as listed in Table 6-1, the steam jet system
is most likely working.

Table 6-1
Multi-Stage SJAE No-Load Suction Pressure

Number of Operating Stages No-Load Suction Pressure

1 35–50 mm Hg Abs

2 5 mm Hg Abs

3 1 mm Hg Abs

4 50–100 microns Hg Abs

5 5–10 microns Hg Abs

If the typical no load suction pressure is not obtained, keep the system isolated, install a blank on
the last stage (z) ejector, and turn on its steam only. (Leave the water on to all condensers.)
Check the z stage no-load suction pressure per Table 6-1 (one stage operating). If it works, put
the blank on the next stage up (y), and turn steam on to the z stage first (to check for inter-stage
leaks) and then to y and z stages. Check two-stage no-load suction pressure per Table 6-1.
Continue until unsatisfactory results occur.

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As you discover unsatisfactory operation, realize that an SJAE requires that only the following
four basic mechanical conditions be satisfied:
1. No plugs (stoppage or fouling) in the nozzle or diffuser exist.
2. No leaks from the atmosphere or steam at the steam nozzle connection (inside the
suctions head) exist.
3. The internal working surfaces of the nozzle and diffuser are reasonably smooth.
4. The correct parts are in place.

Similarly (inter-) and (after-) condensers (shell and tube type) require these four mechanical
conditions be satisfied:
1. Reasonable clean tube surfaces exist (inside and out).
2. No blockage to fluid flow exists.
3. No leaks from the atmosphere (including condensate drains) or from the water side to the
condensing side exist.
4. No flooding (of the condensing side) exists.
Call the manufacturer with the information you’ve obtained from (all or part of) this procedure.
They will be able to lead you to the problem cause most effectively. Ninety-nine percent of all
troubleshooting issues can be handled over the phone.

6.1.4 SJAE Troubleshooting Matrix

SJAE systems are fundamentally reliable vacuum producers, as they have no moving parts. If the
steam supply is dry, the cooling water is clean, and the materials of construction are matched
properly to the corrosive nature of the process fluids, SJAE systems can, and do, last indefinitely.
However, the reality of some operating environments creates potential problems (both short term
as well as long term). These are listed in Table 6-2, from the most common to the least common.

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Table 6-2
SJAE Troubleshooting Matrix (Based on Heat Exchange Institute Tech Sheet #102)

Problem Possible Causes Possible Solutions

Plugged (completely or partially) Foreign material in the steam Disassemble, inspect, and clean
steam nozzles. supply (particularly from pipe the nozzles.
fabrication at installation).

Wear of internal working surfaces Wet steam. Install a separator and trap at
of nozzles and diffuser. ejector system.
Insulate lines.
Trap low spots.
Set line sizes for 150 ft/sec (45.7
m/sec).
Superheat steam -50°F (27.8°C)
max.

Insufficient energy supply. Steam pressure lower than the Raise steam pressure (at the
design minimum pressure. ejector) above the design
minimum (or ask manufacturer to
redesign).

Suction flow overload and Excessive air leaks and Find and correct leaks and
increased suction pressure. unexpected process loads. overloads.

Insufficient condensing and Cooling water temperature higher Correct supply temperature.
cooling or high condensing than the design maximum. Increase water flow.
pressure.
Cooling water flow lower than the
design value

Too much friction in ejectors Fouling of internal working Clean parts.

and/or too little heat transfer rate surfaces (process fluids or
in condensers and/or blockage of cooling water).
the condensate drain.

Too much compression required System discharge pressure Decrease discharge pressure
given the design energy higher then the design maximum. drop or redesign (z) stage.
provided.

Too much pressure drop Suction pipe conditions: Correct suction pipe condition.
between vacuum user and
vacuum producer. • Smaller size than connection

• Partially closed block valves

• Fouling

• Liquid traps

• Undersized in-line equipment

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Table 6-2 (continued)

SJAE Troubleshooting Matrix (Based on Heat Exchange Institute Tech Sheet #102)

Problem Possible Causes Possible Solutions

Flooding of condensers. Insufficient condensate removal Clean tail pipe and check for air
provisions. leaks. Ensure operation of
installed mechanical equipment.

Too much or too little steam flow. Excessive steam pressure and/or Limit overpressure to
temperature. approximately 125%.
Limit superheat to approximately
50°F (10°C).

6.2 Liquid Ring Vacuum Pump Troubleshooting

Table 6-3 provides a list of liquid ring vacuum pump potential problems, along with possible
causes and possible solutions. Unless specifically identified as only applying to a two-stage
pump, the problems apply equally to both single- and two-stage pumps.

Table 6-3
Liquid Ring Vacuum Pump Troubleshooting Matrix

Problem Possible Causes Possible Solutions

Condenser back pressure high or High cooling water temperature. Resolve off-normal operating
increasing. conditions.

Low cooling water flow rate.

In-leakage greater than 15 scfm High air in-leakage. Investigate and repair leaks.
(0.42 scmm) at 1 inch (2.54 cm)
of Hg absolute.

Inlet pressure and horsepower Back pressure in excess of five Correct the separator back
increased. inches of water in the discharge pressure issue.
separator.

Substantially higher vacuum at Restriction in suction line. Correct restriction in the suction
inlet horn of the vacuum pump line.
than at the condenser.

Speed not according to Motor or power supply voltage Correct motor or power supply
nameplate. problem. voltage problem.

Temperature difference of seal Blockage in strainer, orifice Inspect strainer, orifice unions,
water into and out of the heat unions, or inlet spray nozzles. and inlet spray nozzles for
exchanger greater than 15°F blockage.
(8.33°C).

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Table 6-3 (continued)

Liquid Ring Vacuum Pump Troubleshooting Matrix

Problem Possible Causes Possible Solutions

Temperature difference between Blockage in heat exchanger Inspect and clean heat
the cooling water into the heat tubes. exchanger tubes.
exchanger and the seal water
into the pump greater than 2°F
(1.11°C).

Separator seal water level below Makeup SOV. Check operation of low-level
minimum level. makeup SOV and level float
switch.
Level float switch. Inspect the check valve for
proper operation and the strainer
and orifice union for blockage.

Hogging capacity of the two- Excessive system leakage. Investigate system leakage.
stage vacuum pump is
satisfactory, but the vacuum
pump does not evacuate the Inter-stage check valve. Inspect inter-stage check valve
system to the proper operating inside the second stage
pressure. discharge.

Two-stage vacuum pump shows Low or no instrument air Check all valves between the
no capacity either as indicated by pressure. pressure gauge at the control
checking leakage with the panel and the instrument air
rotameter or by observing that source to be sure they are open.
turning the unit on has no effect
on the system.
Control panel SOV. Check the solenoid coil to see if it
is energized. Check the exhaust
port for leakage of instrument air
inside the SOV from the supply
connection to the exhaust
opening.

Differential vacuum switch. Check the differential vacuum

switch located inside the control
panel to see if it is closed.

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6.3 Rotary Screw Vacuum Pump Troubleshooting

Troubleshooting the rotary screw vacuum pump can be divided into two areas based on whether
the problem is a performance problem or a mechanical problem.

6.3.1 Troubleshooting Rotary Screw Vacuum Pump Performance Problems

If the pump is not maintaining desired vacuum, check the following items before dismantling:
• Check for a restriction in the pump suction line. A substantially higher vacuum at the pump
inlet than at the condenser will indicate a restriction.
• Check for excessive backpressure in the pump discharge line. Pressure measured at the
vacuum pump discharge should be less than 2 psig.
• Check all valves for proper operation, and ensure that they are installed properly.
• Check all air and water lines to the pump to ensure that no valves are closed and no other
restrictions exist.
• Check the seal water pressure at the seal water manifold. It should be 6 to 15 psig.
• Check the rotation of the vacuum pump by referring to the rotation arrow.
• If the unit has been disassembled, there is a possibility that some of the parts have been
omitted or improperly installed.
• Make certain that the seal water cooler is clean and provided with sufficient water at a
temperature at least 7.5°F (4.17°C) below the vacuum pump inlet temperature.
• Make certain that the inter-stage check valve seats properly.

6.3.2 Troubleshooting Rotary Screw Vacuum Pump Mechanical Problems

6.3.2.1 Rotary Screw Vacuum Pump Vibration

Vibration is always a sign of trouble and is often the only indication of trouble. It is always
advisable to shut down the vacuum pump as quickly as possible if excess vibration is
experienced, and not to restart the vacuum pump until the cause of the vibration has been
determined and corrected. The most common causes of vibration are:
• Coupling misalignment.
• Rubbing or contact between rotating and stationary parts caused by loss of timing. If contact
is indicated, check the timing.

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6.3.2.2 Rotor Thermal Growth

Two-stage helical rotor vacuum pumps have tight internal clearances and, in some cases, were
designed for lower inlet temperatures then actually experienced in the field. This sometimes
caused rotors to thermally grow into the partition plate between the two stages and into the
casing. Plants that have experienced this excessive thermal growth have developed several
solutions.
• One plant trimmed the rotors to allow for increased thermal growth. This de-rated the pump
capacity 3–5%, but it did change the designed pump discharge temperature from 190°F
(87.8°C) to 201°F (93.9°C).
• Another solution implemented at several plants is to open vent valves to the turbine building
on the pump suction line to introduce “motivating air” into the pump, thus reducing the inlet
and outlet temperatures. Up to three vent valves are opened as condenser and ambient
temperatures increase above a predetermined value. Caution must be exercised to monitor
temperatures closely when large changes in day-to-night temperatures occur. With full
motivating air still applied, the decreased nighttime temperatures can result in exceeding the
pump capacity, and condenser vacuum may be reduced.

Key Technical Point

When vent valves on rotary screw pump suction lines are opened to
introduce “motivating air” into the pump, caution must be exercised to
monitor temperatures closely when large changes in day-to-night
temperatures occur. With full motivating air still applied, the decreased
nighttime temperatures can result in exceeding the pump capacity, and
condenser vacuum may be reduced.

6.3.2.3 Rotary Screw Vacuum Pump Inspections

If a rotary screw vacuum pump is shut down as a result of unsatisfactory operation, the following
inspection should be made:
• Check the operating conditions prior to shutdown to determine if the pump was operating
within both normal temperature range and normal pressure range.
• Eliminate the possibility that the pump driver may be the source of the trouble.
• Secure all details that indicate abnormal operation. If the pump is operating and can continue
to operate for a short period, attempt to determine the exact source of the trouble. Check for
noise, heat, vibration, a leakage condition, and so on.
• If the pump has been shut down, review the operating characteristics before and at the time
of shut down.

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• If the trouble has not been determined, remove the inlet and discharge piping. Check the
interior of the pump for foreign material or any indication of rotor contact.
• Check rotation. The rotation should be free, with no tight spots or excessive drag, and there
should be no metallic sounds during the rotation.
• Check the internal clearances, the gear backlash, and the bearing adjustment.

6.4 Non-Equipment-Specific Troubleshooting Guidance

Tables 6-4 through 6-6 provide guidance for the generic problem areas of bearing problems,
lubrication system problems, and noise level problems.

Table 6-4
Bearing Troubleshooting Matrix

Problem Possible Cause Possible Solution

High bearing Inadequate cooling Verify water flow and temperature

temperature (self contained bearing cooling).

Verify oil flow and temperature

(circulating lube oil system). Verify
pumps are operating and filters are
not blocked.

Erroneous data Verify that thermocouple/RTD is

operating correctly. A portable
thermometer is often used to check
bearing operating temperature
against a fixed sensor.

Lube oil contaminated Verify that the correct amount of

clean lube oil exists.

Oil ring damage Verify that the oil ring is operating

correctly.

Bearing alignment Check bearing alignment.

Bearing damage Open and inspect bearing:

• Check for excessive clearance or

insufficient clearances.

• Check for wiped bearing surfaces.

External heat source Verify that no externally applied heat

source is present, including high
ambient temperature.

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Table 6-5
Lubrication System Troubleshooting Matrix

Problem Possible Cause Possible Solution

No lube oil flow Low oil level Add oil.

Pumps not operating Repair pumps.

Dirty filter Clean or replace the filter.

Incorrect system lineup Review the valve lineup.

Heat exchanger plugged Inspect the heat exchanger.

Low oil pressure Dirty filter Clean or replace the filter.

Pump capacity Examine pumps.

Incorrect valve lineup Verify proper valve positions.

Oil viscosity Check oil temperature and type.

Pressure switches Verify set points and operation.

Relief valve Verify set points and position.

Flow orifice Verify size.

Noise/vibration Pump operation Check pump alignment for damage.

Relief valve Verify position of relief valve.

Oil viscosity Check temperature and oil type.

Oil contamination Cooling water leaks Examine and test heat exchangers.

Filter Verify the integrity of filters.

Storage tank Verify that the oil source is clean.

High oil temperature Heat exchanger fouled Inspect heat exchangers.

Cooling water Check the temperature and flow rate

of cooling water.

High bearing temperature Inspect bearing and bearing

clearance to identify heat generation.

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Table 6-6
Noise Level Troubleshooting Matrix

Problem Possible Cause Possible Solution

Noise Insufficient bearing clearance Adjust or replace bearing.

Damaged bearing surface Replace bearing or liner.

Inadequate lubrication Add oil or check lube oil system.

Worn or damage coupling Replace coupling.

Coupling alignment Realign coupling.

Motor noise Reference motor guide.

Loose motor bolts Tighten bolts.

Defective bearings Replace bearings.

Rotor or timing gear Check rotor clearances and gear

backlash.

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10427360
7
CONDITION MONITORING

EPRI 1000621, Equipment Condition Monitoring Templates—Addendum to Preventive

Maintenance Basis (TR-106857 Volumes 1–38), defines condition monitoring as any task that
allows collection of data (periodically or continuously) on the operating condition of equipment,
the purpose of which is to discover whether the condition of the equipment has changed and by
how much. The scope of the condition monitoring task must be such that the equipment cannot
be disassembled, opened, or changed in any way that materially compromises operation, or it
would induce the risk of equipment failure or degradation as a result of maintenance-related
errors, such as personnel errors, installation errors, or parts defects.

This broad definition includes tasks such as operator rounds, external visual inspections, general
visual-off-line and online, and nondestructive examination (NDE) inspection. Broadening the
definition to include these activities as condition monitoring allows a more comprehensive
analysis of all data on equipment condition. External visual inspections do not include activities
that require use of portals or removal of inspection covers, plates, or guards.

Predictive maintenance, which includes oil analysis, vibration analysis, and thermography, is
viewed as a subset of condition monitoring activities. Refer to EPRI 1000621 for discussions of
applicable condition monitoring templates. Condition monitoring uses advanced technologies to
determine equipment condition and, potentially, predict failure. It includes, but is not limited to,
technologies such as the following:
• Vibration measurement and analysis
• Oil analysis
• NDE
• Infrared thermography
• Motor current analysis

One goal of condition monitoring is to identify changes in the condition of the pump, motor, or
auxiliary that could indicate some potential failure. Physical characteristics are measured,
recorded, and analyzed so that trends can be identified.

Key Technical Point

One goal of condition monitoring is to identify changes in the condition of
the pump, motor, or auxiliary that could indicate some potential failure.

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7.1 Operator Rounds and External Visual Inspections

Operator rounds take place once per shift, while external visual inspections occur at longer
intervals, typically once per month.

7.1.1 Operator Rounds

Operator rounds are predictive maintenance tasks that take place once per shift and involve
observing and in some cases recording items such as:
• Bearing oil levels and temperatures
• Condition of condensate traps
• Discolored water that could indicate leaking cooler tubes
• Oil pressure
• Cooler pressures and temperatures
• Pressure drops across filters
• Fluid leaks

7.1.2 External Visual Inspection

External visual inspections include inspections for:

• Air, oil, and water leaks.
• Clogged or excessively dirty inlet air filters and motor intake screens.
• Indications of high operating temperatures, such as discolored paint.
• Unusual noises and odors.
• Visual indications of vibration.
• Unusual color of the condensate water in the traps.
• Normal oil levels and pressures.
• Loose, missing, or damaged parts, wiring, or tubing.
• Normal differential pressure and temperatures across filters and coolers. Record values for
trending.
• Proper light indications on control panels.

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7.2 Vibration Monitoring

Vibration monitoring consists of acquiring and analyzing specific machine operating parameters.

7.2.1 Parameters

The following parameters can be used to form a database for CAR equipment:
• Amplitude
• Frequency
• Phase angle
• Vibration form
• Vibration mode shape

7.2.1.1 Amplitude

Amplitude can be expressed in terms of displacement, velocity, or acceleration. Amplitude

provides an indication of severity by measuring how smoothly or roughly the equipment is
operating. Equipment that is operating within the manufacturer’s recommended limits will have
a stable amplitude reading. A change in this reading indicates a change in the condition of the
machine. This change signals a need for further investigation.

7.2.1.2 Frequency

The frequency of vibration is expressed in either cycles-per-second, cycles-per-minute, or as

multiples of the rpm. Examples of these multiples include the following:
• 1 x rpm: Vibration frequency is the same as the machine’s rpm.
• 1/2 x rpm: Vibration frequency is one-half the machine’s rpm.
• 0.43 x rpm: Vibration frequency is 43% of the machine’s rpm.

Vibrations occurring at frequencies that are direct multiples (for example, lx, 2x, 4x) of the
machine’s rpm are termed synchronous or harmonic. Vibrations occurring at frequencies that are
an integer fraction (for example, l/2x, 1/3) of the machine’s rpm are termed sub-synchronous.
Non-synchronous vibrations occur at frequencies other than direct multiples of the machine’s
speed.

Machine problems most often occur at low vibration frequencies, typically less than four times
(4x) the running speed. Frequency should not be used as a measure of the problem’s severity
unless roller and ball bearings are involved. In certain cases, specific frequencies can be linked
to specific problems such as unbalance and misalignment. However, this does not mean that
there is a direct correlation between problems and vibration frequencies.

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7.2.1.3 Phase Angle

The phase angle provides a reference measure of movement of a specific point on the shaft or
rotor. This point can be a high spot located on a shaft or a concentration of uneven weight that
may have collected on the pump rotor. The measurement is taken relative to either another
moving point or to a fixed point, such as a transducer. The phase measurement or angle is
expressed in degrees. Accurate phase-angle measurement plays an important role in balancing
vacuum pump rotors and in analyzing the mode shape of the vibration.

7.2.1.4 Vibration Form

Vibration form is the actual vibration displayed as a wave pattern. The wave pattern generated
represents shaft motion. Short-lived, transient types of vibrations are best analyzed through
observing their wave form characteristics (shape, amplitude, and pattern) on an oscilloscope.
This provides the ability to “see” what the equipment is doing at a particular instant of time.

Vibration form can be displayed as a time-based presentation or as an orbital presentation. Time-

based presentation uses inputs from a displacement transducer displayed on an oscilloscope in
the time-based mode. An orbital presentation uses the input from two probes spaced 90° apart
from each other in the X-Y mode of an oscilloscope. This latter method allows operating
engineers to observe the centerline motion of the shaft. As an example, if the probes were
mounted on a bearing housing, the display would show the movement of the shaft centerline
relative to the bearing.

7.2.1.5 Vibration Mode Shape

Vibration mode shape is obtained by recording vibration amplitude and phase values at many
points on the structure of the entire machine, including pump bearings, driver, and foundation.
The vibration mode of a piece of equipment provides a means of confirming resonance
conditions, locating nodal points (points of minimum amplitude), and identifying points of
structural weakness. By conducting casing measurements along a drive train, problems such as
pipe resonance, structural resonance, or loose/cracked foundations can be determined.

7.2.2 Vibration Analysis

Vibration analysis can be accomplished through a variety of available techniques. The following
techniques offer methods to obtain and display vibration data:
• Amplitude versus frequency
• Real-time spectrum analysis
• Time wave form

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7.2.2.1 Amplitude-Versus-Frequency Analysis

The vibration amplitude-versus-frequency analysis method is considered to be the most useful.

Over 85% of mechanical problems occurring on rotating equipment can be identified using this
method. This technique has applications for both continuous monitoring/machinery protection
and for diagnostic equipment checks.

Key Technical Point

The vibration amplitude-versus-frequency analysis method is considered to
be the most useful. Over 85% of mechanical problems occurring on rotating
equipment can be identified using this method.

The primary equipment needed to conduct this test includes a vibration-pickup (probe) and
vibration analyzer. Use of an X-Y recorder provides the added feature of automatically
producing a plot of frequency-versus-vibration amplitude. An additional option available on
some vibration analyzers is an automatic frequency tuner. This feature eliminates the need for
operators to manually tune through the frequency spectrum. Using an automatic frequency tuner
provides extended troubleshooting capability. It reduces the element of human error by
eliminating the chance of missing significant vibration frequencies, and it reduces the actual
analysis time by eliminating time spent on fine-tuning to each significant frequency.

The following are additional recommendations to follow when using the amplitude-versus-
frequency technique:
• Take vibration readings along the horizontal, vertical, and axial directions at each bearing.
• Select an amplitude range setting on the vibration analyzer sufficient for the maximum
vibration signature in order to obtain data that are plotted on the same range.
• Select a single amplitude range setting sufficient for the entire analysis.
• Obtain an overall “filter out” reading (in each of the three positions) at each bearing.

7.2.2.2 Real-Time Spectrum Analysis

This method is most effective when the vibration is not steady-state or the vibration is transient.
Use of a real-time spectrum analyzer allows O&M personnel to capture and analyze vibration
signatures. Two features available with real-time analyzers are Hold and Peak Hold. The Hold
control is operator-initiated when the transient frequency reaches its maximum amplitude. This
action stores the transient signal into the analyzer’s memory for future analysis. The Hold
feature provides a means to manually capture the transient signal. This method will work if the
following conditions are met:
• The operator is fully aware of when the transient signal will occur.
• The transient signal occurs slowly enough for the operator to depress the Hold button.

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The Peak Hold feature provides a method to capture and store a transient signal in situations that
do not meet the previous two conditions. If this feature is used, the operator must set the trigger
level, which specifies the percentage of the signal’s amplitude used to begin the process. For
example, if the operator chooses 50%, detection circuits will look for an amplitude level
exceeding this value from incoming signals. Once this 50% criterion is met, the circuit will
trigger and automatically capture an incoming transient signal.

7.2.2.3 Time Waveform Analysis

Time waveform analysis uses an oscilloscope to provide a time display of vibration amplitude.
The oscilloscope can be set up to receive an input vibration signal either directly from the
transducer or from a real-time spectrum analyzer. Either method allows operators to analyze
vibration quickly and easily. Data obtained are not filtered, thereby providing a true measure of
the maximum amplitude present. Using an oscilloscope can also provide an excellent means for
observing and evaluating transient vibration signals that may be present because of pump
pulsations or control problems.

Essential to any online monitoring system is the choice of sensors (transducers) to be used. For
vibration measurement, there are three types of transducers available. These transducers are
referred to as proximity (non-contact), velocity, and accelerometer probes.

7.2.3 Proximity Probes

A proximity probe is a transducer used for vibration and position measurement. Physical contact
with the object such as a shaft being measured for vibration or position is not required. Proximity
probes are used to measure the relative movement between the shaft and the bearing or bearing
housing. Principal components include the probe, pickup, connecting cable, and driver. Inside
the probe is a coil that receives high-frequency current from the driver. As this current passes
through the coil, a magnetic field is established. Conductive material, such as a steel shaft,
brought in proximity to the coil as a result of vibration or axial motion will “cut” the lines of the
magnetic flux, thereby setting up eddy currents on the conductive material’s surface. Stronger
eddy currents are established as the shaft gets closer to the probe and weakens the magnetic field
around it.

The strength of the magnetic field is directly related to the level of equipment vibration. In
practice, the field strength is monitored by detection circuitry located in the driver. Output from
the driver is either in the form of a dc signal or a combination of a dc and ac signal. When no
vibration is present, a dc voltage directly proportional to the distance (gap) between the shaft and
probe is transmitted from the driver. As vibration levels develop, a dc signal proportional to the
average gap and an ac signal proportional to vibration amplitude are generated.

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 Condition Monitoring

Applications

There are three applications for systems using proximity probes:

1. Radial vibration
2. Axial position, phase reference
3. Rotating speed reference

Advantages

A proximity probe offers the following advantages:

• It measures the motion of the shaft (primary source of machine vibrations) in terms of
displacement.
• It makes no contact with the shaft.
• It has no moving parts and is small.
• It has an excellent frequency response.
• It is easily calibrated.
• It provides accurate low-frequency amplitude and phase angle information.

Disadvantages

A proximity probe has the following disadvantages:

• It requires an external power source.
• It is sensitive to certain shaft materials.
• It is sensitive to shaft mechanical and electrical run out.
• It may not detect looseness in support components.

7.2.4 Velocity Probes

Operation of a velocity probe is based on the movement of a conductor (in this case, the coil)
through a magnetic field. The amount of voltage that is induced in the coil will be proportional to
the relative velocity between it and the magnetic field. Unlike a displacement probe, a velocity
probe requires no external power source to operate.

A velocity pickup consists of six principal parts: pickup case, wire coil, damper, mass, springs,
and permanent magnet.

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Condition Monitoring

The pickup case provides a structure to house the remaining components. The wire coil is
wrapped around the mass that, in turn, is suspended between the permanent magnet by the
springs and damper. The permanent magnet is attached to the pickup case and provides a
magnetic field around the suspended coil.

In certain applications, velocity probes and their cables can be susceptible to magnetic
interference. This magnetic interference may be caused by the alternating magnetic field that is
generated around large ac motors. Without proper shielding, these fields can induce a voltage in
the pickup or cable. Consequently, an erroneous vibration signal may be generated.

If this condition is suspected, the magnetic field’s intensity and presence can be determined. To
perform this test, personnel will need a vibration analyzer connected to a portable velocity probe.
The probe should be held steady by its cable near the permanently installed velocity probe, and
the suspended probe should not come in contact with the operating equipment. During vacuum
pump operation, a reading on the analyzer indicates that a strong magnetic field is causing
interference. To alleviate this problem, a magnetic shield should be installed around the fixed
velocity probe.

Advantages

A velocity probe offers the following advantages:

• The probe is mounted on the external housing of the machine component and it gives a
strong signal in mid-frequency ranges.
• No external power supply is required.
• The signal can be electronically integrated to provide a displacement signal.

Disadvantages

A velocity probe has the following disadvantages:

• The probe is relatively large and heavy.
• The probe is difficult to calibrate and requires a shaker table.
• The probe has mechanical moving parts that can be expected to wear out.
• The probe may pick up outside magnetic interference.
• The probe only measures dynamic motion.
• The probe has a narrow frequency response and amplitude and phase errors can be generated
at low frequencies.
• Because the probe is manufactured as a unit, a fault in any of the components will require
replacement of the entire unit.
• The probe is susceptible to cross-axis sensitivity at high vibration amplitudes.

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7.2.5 Accelerometer Probes

The internals of an accelerometer probe are made up of four components: mounting stud, frame,
piezoelectric disks, and mass.

The mounting stud provides a means to attach the probe assembly to the equipment being
monitored. The frame assembly houses the mass and the piezoelectric disks. The last two
components form the heart of an accelerometer probe.

Piezoelectric material can generate an electric charge when it undergoes mechanical stress. This
stress can be compressive or tensile. Disks of piezoelectric material are rigidly sandwiched
between the frame and the mass. In the event of vibration, these disks undergo a series of
compressive and tensile reactions. These, in turn, produce an electric signal proportional to the
magnitude of the force imparted to the mass. Because the amount of mass is known, the signal
generated represents the acceleration of the mass.

Accelerometers are small, lightweight, and rugged. A principal advantage of this type of probe is
its ability to operate over a wide frequency range. This capability makes an accelerometer well
suited for monitoring high-frequency vibrations that can develop in anti-friction bearings or
gears.

Accelerometers are unaffected by magnetic fields that may originate from nearby electric
machinery. They require no special shielding or other provisions.

Advantages

Accelerometer probes offer the following advantages:

• They are easy to install.
• They are useful for high frequency measurements above 2 kHz, highly reliable, relatively
lightweight, and have no moving parts.
• They are available for high-temperature applications.

Disadvantages

Accelerometer probes have the following disadvantages:

• They can be influenced by vibration transmitted to the vacuum pump housing by the
surrounding environment.
• Transducer fault will require replacement of the entire unit.
• They are difficult to calibrate and feature a poor signal/noise ratio.
• Double integration to displacement is susceptible to noise problems.
• They require and external power source and usually require filtering in the monitor.

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7.2.6 Data Acquisition

Accurate data acquisition is the basis for a successful vibration-monitoring program. It is

essential to adopt a systematic approach to obtaining and recording data for use in the analysis
process.

For machines equipped with installed vibration sensors, obtaining data means monitoring and
recording vibration levels displayed on the gauges or output devices provided. Monitoring
programs using portable equipment either to supplement existing installed vibration sensors or to
check equipment not outfitted with an installed monitoring system will require personnel to
identify specific locations on which to place the probes. These locations should be identified
both on the equipment or component and on the forms used to record the data. This procedure
will help ensure that consistent and reliable information is obtained. Use of color-coded marks
such as red dots provides operators with an easily seen reference point from which to take
vibration readings. The avoidance of confusion should be a prime consideration, because
introducing incorrect data into trending and equipment history files will produce erroneous
results.

Machine Diagram

An important part of the data acquisition process is the machine diagram. A diagram of this type
forms a link between the actual physical location on the equipment or component and the record
used to log the results. To be effective, the diagram should show all the essential elements. For a
vacuum pump, these elements should include the driver (motor), driven unit (pump), bearings,
coupling, speed changer (if applicable), and installed vibration sensors. Additional information,
such as motor rpm, type of bearings (sleeve or antifriction), pickup points, date, name of persons
performing the check, and space to enter vibration amplitudes and frequencies, should also be
incorporated onto the form.

Tri-Axial Readings

Recommended practice indicates that readings should be taken in the horizontal, vertical, and
axial directions at each bearing housing. This three-axis approach can assist the maintenance
organization in distinguishing between various mechanical problems, such as imbalance and
misalignment. For example, both of these problems are manifested as an increase in vibration.
The frequency of this vibration level is typically lx rpm for both misalignment and imbalance. A
pump out-of-balance will have high vibration levels in the radial directions (horizontal and
vertical); vibration levels observed in the axial direction would be significantly less.
Misalignment, however, typically produces high vibration levels in all three directions.

Analyzing horizontal and vertical readings can also provide insight into the condition of the
equipment. For vacuum pumps with a floating outboard bearing, the vibration levels in the
horizontal direction will be higher than those in the vertical direction. This difference is
considered normal for rigidly mounted pumps where the vertical stiffness is greater than the
horizontal stiffness. A deviation from this condition may indicate loose equipment hold-down
bolts, damaged grout layers and/or foundation, wiped bearings, or excessive bearing clearance.

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7.3 Oil Analysis

Oil samples taken for purposes of oil analysis are also appropriate for out-of-service checks. A
basic spectro-chemical analysis can provide maintenance personnel with the following
information:
• Particle count
• Viscosity
• Total acid/base measure
• Condition of oil additives

This information can be used to determine whether it is necessary to open and inspect a bearing
for wear and damage as well as provide a snapshot picture of the lube oil’s quality. However,
there are not any recognized industry standards for what is acceptable in lubricating oil. The oil
analysis should, therefore, be used to identify changes and trends. Oil analysis tests are often
offered free or for a nominal charge by the lubricant supplier as part of the overall service
provided. If the physical design of the equipment prevents ready access to the bearings, the pre-
startup checks should be accomplished during the out-of-service maintenance period before
closing up the pump for operation.

Key O&M Cost Point

Oil analysis tests are often offered free or for a nominal charge by the
lubricant supplier as part of the overall service provided.

7.4 Infrared Thermography

Infrared thermography is typically used to identify problems with electric motors and electrical
terminations. Other than on motors and electrical terminations, thermography has not been
typically used on CAR equipment. However, thermography can be effectively used wherever
temperature differentials or temperature changes signify degraded conditions. One nuclear
station routinely uses thermography to successfully identify sources of condenser air in-leakage
that challenges the performance of the CAR system by monitoring temperature differentials and
temperature changes on condenser attached piping, flanges, and so on. This station has also used
it to identify leaks and blockages in CAR equipment process lines and drains containing hot
fluids.

Key Technical Point

Thermography can be effectively used to identify sources of condenser air
in-leakage that challenges the performance of the CAR system and to
identify leaks and blockages in process lines and drains containing hot fluids.

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7.5 Motor Current Analysis

Condition monitoring of the electric motors is addressed in EPRI NP-7502, Electric Motor
Predictive and Preventive Maintenance Guide.

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8
PREVENTIVE MAINTENANCE

This section identifies recommended maintenance tasks and their frequencies. As each
application could be different, the experience at a given plant should be reviewed, and any
recommended frequencies should be adjusted. MVPs require periodic inspection and
maintenance to ensure their reliable operation. SJAEs typically do not. Internal SJAE problems
usually result from erosion or corrosion and usually reveal themselves by a gradual loss of
performance that affords the plant staff adequate time to schedule an overhaul. The discussion in
this section relating to SJAEs applies also to the atmospheric jet air ejectors previously described
as used in conjunction with a single-stage liquid ring vacuum pump in one type of packaged
CEU.

In order to support the utilities in their need to assess both the effectiveness and underlying bases
of their PM programs, EPRI developed and published between 1997 and 1999, TR-106857,
Volumes 1–38, Preventive Maintenance Basis Documents (PM Basis). These volumes are now
considered historical, as PM basis are now included and updated in the EPRI PM Basis Database
Component Data Tables.

8.1 Developing a PM Program

The evolution from a fix-when-fail philosophy to a PM philosophy begins with developing a list
of maintenance checks for each vacuum pump and its supportive auxiliary systems. This list of
checks is based on manufacturer’s recommendations, operational experience, and EPRI
component-level maintenance guides and PM templates. Knowing the capabilities of the
maintenance department helps determine which maintenance checks in-house staff can
accomplish and which must be contracted out. Use of recommendations from the manufacturer,
along with industry and plant operational experience, can provide valuable insight in determining
not only what checks should be done, but also how often they should be done. Conversely, for
maintenance checks that show no signs of wear, inspection intervals should be increased. Section
8.4.3 presents a methodology that one plant used to optimize the PM activities on their CAR
equipment.

Key O&M Cost Point

Use of recommendations from the manufacturer, along with industry and
plant operational experience, can provide valuable insight in determining not
only what checks should be done, but also how often they should be done.

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Warning signs, such as excessive equipment failure after maintenance has been completed, could
be indications of inadequately trained personnel and/or poor quality control standards. The
philosophy of “if it works, don’t fix it” should be considered in any maintenance program.
Opening and inspecting components, such as bearings or actuators, can lead to additional
problems and equipment down time. A balance must be attained by doing PM but avoiding
opening and inspecting equipment if no problems (such as high temperature or pressure) are
present. This balance is achieved by carefully determining an adequate time period (frequency)
between checks. Note that this does not in any way suggest that basic sound operating
engineering practices—such as ensuring adequate lubrication, clean lubrication, daily visual
inspection of the equipment, and cleaning equipment—should be ignored.

Key O&M Cost Point

A balance must be attained by doing PM but avoiding opening and
inspecting equipment if no problems (such as high temperature or pressure)
are present.

Once this list of checks is finalized, the next step is to develop written formatted PM tasks. Each
PM task should provide an itemized listing of what is required to accomplish the specific
maintenance action. Actual procedures to conduct a specific maintenance action may also be
incorporated on this PM task sheet. For example, a well-thought-out PM task should include
information such as the trades involved in the check, related additional checks that could be
accomplished simultaneously, special tools required to accomplish the job, man-hours required,
technical manuals and drawings required, and data readings to be taken. A database incorporated
into a PM task can provide a ready reference for personnel to use during equipment maintenance
periods. In certain cases, a “pictorial map” could also be attached to a task sheet to provide
standard locations to take measurements.

8.2 Basic Rules for Conducting Maintenance

To avoid unnecessary injury to personnel or damage to the equipment, sound basic maintenance
rules should be practiced at all times:
• Keep the area around the disassembled equipment clean.
• Take inventory of the tools brought in and out of a job.
• Use the correct tool for the specified job.
• Do not take shortcuts when safety is involved.
• Follow proper tag-out and valve-out procedures.
• Keep the shop supervisor informed of the progress and any problems encountered.
• For PM actions, verify that the required parts are available before starting the job.

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8.3 SJAE Maintenance Recommendations

The review of the maintenance history did not reveal any CAR system failures as a result of
internal SJAE problems. Responses to an industry survey conducted in support of the preparation
of this guide identified that plants that use SJAEs for CAR equipment typically do not perform
PM activities on their SJAEs unless indications of problems exist. An EPRI PM Basis Database
Data Table for SJAEs was developed as part of the preparation of this guide and is discussed in
Section 8.3.1.

8.3.1 EPRI PM Basis Database—SJAE

The following PM activity listed in Table 8-1 is based on the newly developed EPRI PM Basis
Database–Steam Jet Air Ejectors. (Refer to the EPRI PM Basis Database Data Table—Steam Jet
Air Ejectors for additional condition monitoring activities.)

Table 8-1
SJAE PM Activities Based on EPRI PM Basis Database Data Table

Duration Activity Basis

10 years Perform nozzle and condenser inspection. Expected life is 20 years with continuous
operation. Nozzle degradation as a result of
erosion would be expected after 10 years
with poor steam quality.

8.3.2 Ejector Internal Inspections

Erosion or corrosion that is obvious to the eye and touch will affect performance. There are
several things to look for when performing internal inspections of an ejector:
• Wet steam will cause “wiredrawing” lines etched up and down the inside of the steam nozzle.
• Wet steam will also cause gouging at the point along the diameter where the steam contacts
the venture.
• Steam leaking around the nozzle puts an additional load on that stage, resulting in poor
vacuum. This will be noticeable as a discoloration where the nozzle seats on the steam chest
or as erosion of the nozzle threads.
• Corrosion or buildup of material on the ejector internals will also affect the performance of
that unit.
• Compare critical dimensions, such as nozzle orifice or venture bore diameter, against the
manufacturer’s drawings to determine extent of wear.

Part numbers of the various ejector components should be checked to ensure that they are in the
right unit. Many ejector parts, and sometimes complete stages, are physically interchangeable
and care must be taken not to mix them up.

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Key Human Performance Point

Care must be taken to ensure that the various ejector components are in the
right unit. Many ejector parts, and sometimes complete stages, are physically
interchangeable.

8.3.3 Ejector Spare Parts

As a minimum, keep at least the following components in stock:

• One steam nozzle for every single-nozzle ejector stage
• One diffuser for every stage

Because most nozzles are relatively inexpensive, they should be considered sacrificial. If wear is
evident, they may be discarded and easily replaced. A complete (z) stage should be kept in stock.

8.4 Liquid Ring MVP Maintenance Recommendations

Two sources of PM recommendations were used for the development of this guide:
1. EPRI PM Basis Database Data Table—Liquid Ring Rotary Compressor and Pump: In the
course of the preparation of this guide, this data table was revised to recommend a 10-year
overhaul of the vacuum pump and to increase the frequency of the pressure switch calibration
to once every six months.
2. Liquid Ring Vacuum Pump Equipment Vendor Manual.

8.4.1 EPRI PM Basis Database Data Table—Liquid Ring Rotary Compressor

and Pump

EPRI categorizes a liquid-ring type CAR pump as a critical, high—duty cycle piece of
equipment that is exposed to severe service conditions.
• It is categorized as critical because it is required for power production or other regulatory
requirements.
• It is categorized as high-duty cycle because it is frequently cycled or partially loaded for the
greater part of its operational time.
• It is exposed to severe service conditions, such as high or excessive humidity, excessive
temperatures, or excessive environmental conditions.

Based on this categorization, the EPRI PM Basis Database Data Table—Liquid Ring Rotary
Compressor and Pump recommendations include the following PM activities listed in Table 8-2.
(Refer to the EPRI PM Basis Database Data Table—Liquid Ring Rotary Compressor and Pump
for additional condition monitoring activities.)

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Table 8-2
Liquid Ring PM Activities Based on EPRI PM Basis Database Data Table

Duration Activity Basis

10 years Overhaul MVP. Based on expected life of 10 years.

5 years Replace mechanical seals. Expected life is five years with continuous
operation.

2 years Replace SOVs. Could be relaxed for those SOVs with low
duty cycles. Refer to EPRI TR-106857-V7,
“Solenoid Valves.”

Coupling inspection. Based on coupling life of at least 10 years.

Instrument calibration. Collective significance of device failure

mechanisms supports this interval.

1 year Check valve, strainer, and trap inspection: Check valves are affected by debris,
strainers can become clogged in as little as
• Inspect and clean check valves, a few months, and traps can become
looking for internal seat leakage, clogged in as little as six months to a year.
binding, and broken or weak springs.

• Inspect and clean strainers and traps.

• Inspect flow control orifice for

evidence of wear.

As required Boroscope inspections of pump internals Done in conjunction with condition

(rotor, cone, lobe, internal casing, inlet and monitoring activities, such as vibration
outlet flanges) for erosion or corrosion. analysis or performance monitoring, which
would indicate a problem.

Moisture separator/seal water tank Interval based on water quality.

inspection for rust, corrosion, sediment, or
clogging of float valve.

8.4.2 Liquid Ring Vacuum Pump Manufacturer’s Recommendations

The liquid ring vacuum pump vendor recommends the PM activities as shown in Table 8-3. The
schedule can be modified based on plant-specific operating conditions and maintenance history.
Table 8-3
Liquid Ring PM Activities Based on Vendor’s Recommendations

Duration Activity

12 months Inspect and clean heat exchanger tubes.

Inspect soft seating surface of system inlet valve.

Check and lubricate vacuum pump bearings.

12 months Check low-level float switch for proper operation.

Clean and lubricate SOVs.

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Table 8-3 (continued)

Liquid Ring PM Activities Based on Vendor’s Recommendations

Duration Activity

12 months Replace packing in stuffing box in each head and bracket.

Check inter-stage check valve to ensure free movement of linkage.

6 months If coupling is of the lubricated type, re-lubricate it.

After initial 6 months of service, check and lubricate vacuum pump bearings.

As required Check packing in stuffing box to ensure that there is a constant drip. (Vendor
has informed some plants that this constant packing leakoff is not necessary.)

If the unit is shut down for two to three weeks, the manufacturer recommends that pump be
rotated by hand at least once every week to prevent rust buildup between cast iron parts. If the
unit must be taken out of service for more than three weeks, the manufacturer provides a detailed
lay-up procedure in the vendor manual to prevent seizing of the pump as a result of rust
formation during storage.

Key O&M Cost Point

To prevent pump damage as a result of the built up rust between cast iron
parts, follow the manufacturer’s recommendations for short- and long-term
lay up.

8.4.3 Case Study for Optimizing Liquid Ring Vacuum Pump PM Activities

One plant that uses liquid ring vacuum pumps as part of its CAR equipment had not previously
determined PM activities and intervals for the equipment. This plant is part of a utility that
owned a fleet of nuclear plants and was able to draw on the collective maintenance experience of
personnel from throughout the fleet. The flowing steps were followed by the utility to establish
PM activities and intervals:
1. A basic CAR equipment PM template containing activities and intervals was established
using the historical EPRI TR-106857-V27, Liquid Ring Rotary Compressor and Pump as a
guide.
2. This template was reviewed by a peer group comprised of members from all the plants in the
fleet. A standard template was issued for the fleet.
3. Each plant reviewed the standard template against their operating and maintenance history
and created site-specific requirements.

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The outcome of this process for the plant in question includes the following:
• Although EPRI TR-106857-V27 categorizes liquid ring rotary pumps in CAR applications as
critical, high duty cycle, and severe service condition, the process resulted in a categorization
of mild service condition.
• The main pumps and their motors are rebuilt every 10 years. Boroscope inspections between
these overhauls are not required.
• Soft-seated valves and valve operators are rebuilt every five years.
• Couplings are inspected and re-greased every 36 months.
• SOVs are rebuilt every 24 months.
• Vacuum pump heat exchanger tubes are cleaned every 12 months.
• Thermography is performed every 12 months.
• Vacuum switches are calibrated every six months.
• Oil analysis is performed every three months.
• Vibration analysis is performed every 45 days.

8.5 Rotary Screw MVP Maintenance Recommendations

Two sources of PM recommendations were used for the preparation of this guide:
1. EPRI PM Basis Database Data Table—Rotary Screw Air Compressor
2. Rotary Screw Vacuum Pump Equipment Vendor Manual

8.5.1 EPRI PM Basis Database Data Table—Rotary Screw Air Compressor

EPRI PM Basis Database Data Table—Rotary Screw Air Compressor was developed for rotary
screw machines used in an air compressor application, not in a CAR application. However, it can
be used as a guide for a vacuum pump application. For the same reasons the liquid ring type
CAR pump was categorized as a critical, high duty cycle, severe service condition piece of
equipment, the rotary screw CAR pump would be categorized also in the same way. Based on
these categories, EPRI PM Basis Database Data Table—Rotary Screw Air Compressor
recommendations include the PM activities in Table 8-4. (Refer to PM Basis Database Data
Table—Rotary Screw Air Compressor for additional condition monitoring activities.)

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Table 8-4
Rotary Screw PM Activities Based on PM Basis Database Data Table—Rotary Screw
Air Compressor

Duration Activity Basis

6 months Internal inspection: Need to ensure that components that may

be replaced during annual overhaul avoid
• Inspect motor bearing and coupling for failure during intervals between overhauls.
indications of loss of grease or oil.

• Ensure that motor air intake is not

clogged or dirty.

12 months Overhaul: 12-month period could be extended based

on plant experience.
• Clean the float valve.

• Inspect check valves.

• Test relief valves.

• Calibrate pressure and temperature

sensors.

• Pressure-test coolers.

• Inspect and lubricate coupling.

• Inspect condition of pump elements.

8.5.2 Rotary Screw Vacuum Pump Manufacturer’s Recommendations

The rotary screw condenser vacuum pump vendor recommends the PM activities as shown in
Table 8-5. The vendor does not provide a recommended interval but states that the schedule
should be based on specific operating conditions and maintenance history. Also, the vendor only
provides recommendations for inspection of the vacuum pump and not for the supporting
equipment, such as motors, check valves, and instrumentation.

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Table 8-5
Rotary Screw PM Activities Based on Vendor’s Recommendations

Duration Activity

General inspection, Remove inlet and discharge piping and accessories, and check
with interval based on condition of rotors. If rotors show signs of contacting each other or
plant-specific the housing, then check rotor timing.
operating conditions
Disconnect coupling and rotate pump by hand. Pump should rotate
freely with no indication of drag and no metallic sound

Check timing gear backlash to determine wear.

Replace bearings and mechanical seals.

Drain lube oil reservoir, clean reservoir, and refill with clean oil.

Remove oil lines and end covers and inspect all oil spitters. Clean
spitters if required.

8.6 Component Maintenance

The following subsections describe the maintenance tasks for the components and support
equipment of SJAEs and MVPs.

8.6.1 Bearings

Ensuring that the lubricant is at the correct level, clean, and of good quality is essential to
prolonging the operational life of a bearing. An inadequate amount of oil being supplied to a
bearing will result in its operating at higher-than-normal temperatures. High temperature
conditions can cause the oil to break down and the bearing to be damaged by excessive friction
levels. Similarly, excessive amounts of oil or grease can cause the bearing to overheat as well.
Levels recommended by the manufacturer should be adhered to.

Static lubricating oil systems offer a particular challenge to a maintenance department. If a low-
level condition is discovered during operation, personnel should proceed with caution when
adding oil to the affected bearing while the pump is in operation. Relatively colder oil that is
added while the shaft is rotating can disrupt the oil film that has been formed. If this condition
occurs, metal-to-metal contact can be expected with resulting damage to the bearing.

Key Technical Point

If oil in a self-contained sump is below normal level, adding relatively cold
oil may disrupt the oil film. Shut the vacuum pump down before adding oil.

The quality of the oil being used is best determined by taking an oil sample. Visual inspections
taken before pump startup can provide operators with assurance that the oil quality is
satisfactory. Periodic oil samples taken while the pump is in operation are recommended for

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bearings lubricated by a circulating oil system. Taking an oil sample on a static system during
pump operation is not recommended. Use of a drain valve installed in place of a drain plug can
provide some measure of control if personnel consider it necessary to sample oil during vacuum
pump operation. If a drain valve is used, it is good practice to install a cup or plug to seal the
discharge line from dirt and to act as a safeguard to prevent draining of the system if the valve is
accidentally opened. Two primary concerns are that the oil film may be disrupted as the oil is
being replenished with colder oil and that the sump may run dry while the vacuum pump is in
operation.

Do not mix oils in the lubrication system or bearing housing. Chemical additives in different oils
can cause a breakdown in the viscosity, cooling, or bearing lubrication.

Key Technical Point

Do not mix oils in the lubrication system or bearing housing. Chemical
additives in different oils can cause a breakdown in the viscosity, cooling, or
bearing lubrication.

There are four general indicators of impending bearing failure: vibration, excessive noise, steady
increase in bearing operating temperature over time, and/or a lube oil sample contaminated with
babbitt or water.

8.6.1.1 Routine Maintenance Recommendations

Routine maintenance should include the following:

• Verifying that oil is at the proper level
• Visually inspecting the seals for leakage
• Checking the bearing temperature and ensuring that heaters (if installed) are placed in
operation; adjusting the cooling water flow to maintain correct temperature

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The recommended minimum temperature varies for each manufacturer. For bearings cooled by a
circulating oil system, the following tasks should be performed:
• For bearings fitted with inspection covers, verify lube oil flow through the bearings, check
for proper operation of oil rings, and visually observe oil circulation.
• Wipe the inspection cover thoroughly before opening to prevent any dirt/debris from entering
the bearing system. Bleed any air pockets from the system by cracking open a vent valve.
• Inspect the bearing cooling systems:
– Verify alignment and start system.
– Inspect for leaks.
– Verify flow has been established.
– For a closed system, bleed any air pockets from the system by cracking open a system
vent valve.
• Draw an oil sample and conduct a visual inspection for the following:
– Water contamination
– Particulate contamination (dirt, metallic)
Note: When drawing an oil sample, ensure that the sample bottle is clean and dry; if not,
it should be wiped with a lint-free rag.
• Ensure that the area around the sample petcock/sample plug is clean before opening.
• For systems having sample lines, adequately flush the line to remove any dirt or
condensation that may have collected inside the line.

8.6.1.2 Bearing Overhaul

Worn components should be replaced as required. The replacement criteria are directly related to
physical damage caused by cuts, heat, corrosion, or other factors.

The following provides a list of components most susceptible to wear:

• Gaskets
• Packing rings
• Seals (including any auxiliary seals)
• Seal springs
• Laminated shims
• Garter springs
• Wave springs

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For sleeve bearings, an inspection should be made of the babbitt surface for surface scoring or
wiping. (Axial scoring is unacceptable; circumferential scoring is not to exceed manufacturer’s
recommendations.) The following should be noted during the inspection:
• Fatigue cracking
• Corrosion
• “Black scab” or “wire wool” damage
• Pitting as a result of electrical discharge
• Overheating
• Uneven wear
• Fretting
• Inadequate lubrication

An inspection should be made of the shaft journal for ridges, grooves, and/or sharp edges. If they
are present, they should be removed with an approved abrasive cloth. The shaft journal should
have a finish range specified by the manufacturer.

Thrust collars should be inspected for axial runout and radial runout. On a thrust bearing, the
face-to-face dimension is critical. A check should be made to ensure that the passes are
perpendicular to the face.

Clearance checks should be made to verify the following:

• Total indicated runout clearance between the sleeve thrust face and the thrust collar
• Distance from shaft to the bearing housing seal groove/recess
• Clearance between outer diameter of seal and inner diameter of bearing housing
• Clearance between inner face of oil conveyor disc and orifice partition
• Clearance between scoop and guide assembly

Some bearings require a specific housing-to-bearing clearance, which must be set.

The following alignment checks should be done:

• Inspect shaft journal, sleeves, thrust collars, and interior of bearing housings for corrosion
and dirt. Clean surfaces with an approved cleaning solvent, such as mineral spirits or
kerosene.
• Inspect water cavities and oil cavities for dirt and corrosion; clean as required.
• Inspect oil rings and oil conveyor for damage or looseness.
• Inspect threads of various bolts, pipe nipples, and so on, for burrs or corrosion.

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• Inspect sensor cavities for dirt and corrosion.

• Replenish oil to bearing sump.
• Enter accomplished maintenance actions on equipment PM records.

Maintenance will vary with the complexity of this system. Specific components requiring
various degrees of maintenance include the following:
• Pumps and motors
• Gauges/pressure relief valves/pressure switches/temperature switches/motor controllers
• Piping/valves
• Heat exchanger
• Cooling fan
• Sump

8.6.2 Lubrication System

8.6.2.1 Routine Maintenance

Some routine maintenance tasks should be completed to verify that the lube oil is at the proper
level in the sump and at the required temperature. To control the temperature through the heaters
or cooling system (air/water), it should be verified that the cooling fans are running (if installed).
The cooling water flow should be checked, and correct heater operation should be verified.

Discharge filters and pump suction strainers should be cleaned and inspected. In addition, all
electrical connections (cables for pumps, sensors, and so on) should be checked for cracks or
looseness, and all control panel access doors should be checked to verify that they are closed and
properly secured.

Any unusual noise or vibration should be noted. The differential pressure across filter elements
should be checked (shift, inspect, and clean as required).

8.6.2.2 Circulating Lube Oil System Overhaul

The calibration and inspection of all system instrumentation and sensors should include the
following:
• Pressure switches
• Thermostats
• Relief valves
• Liquid-level switches

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Pump operation and alarms at given system test pressures should be verified.

The inspection of a water-cooled heat exchanger should include the following:

• Open and inspect heat exchanger interior; remove sludge and scale deposits.
• If suspected, check for tube leakage (cracked tubes, damaged tube joints).

In the event of low-discharge pressure, the pump should be opened and the impeller surfaces and
wear ring as well as the foot valve should be inspected.

When poor oil quality is suspected, the sump should be drained and cleaned. All door gaskets
should be inspected and replaced as necessary. Before re-closing the sump, it is important to
ensure that all rags have been removed.

In the maintenance of all electrical components, the following tasks should be performed:
• Conduct continuity checks on electric motors and heater coils.
• Inspect all cables for cracking or other damage.
• Open, inspect, and clean all control and relay boxes.
• Verify that all electric motors have been connected properly by checking component rotation.

All exterior surfaces should be inspected and cleaned. All corrosion should be removed. Priming
and painting should be performed as required.

An inspection and cleaning of cooling fan blades and air-cooled heat exchanger surfaces should
also be performed.

All filters and strainers should be inspected and cleaned. The location of filters is very important.
Filters installed only at the suction side of the oil pump do well in protecting the pump.
However, pump wear or damage can pass to the bearings if oil is not final-filtered before is
enters the bearing. The optimum system has both suction filters and final filters. These final
filters should be installed as close to the bearings as possible.

All system components and lines should be primed and vented.

8.6.3 Couplings

Couplings provide a means of connecting the prime mover (electric motor or steam turbine) to
the designated load (the vacuum pump rotor). There are two types of couplings: flexible and
rigid. Flexible couplings are used extensively in vacuum pump service.

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Depending on the design and service requirements, flexible couplings can provide the following
benefits:
• They can provide protection for slight misalignment caused by thermal expansion and
contraction between the prime mover and its load.
• They can lessen vibrational torque to reduce noise and absorb any torsional oscillation that
may be generated during a transient condition (startup, shutdown, and speed changes
associated with a variable-speed motor).

There are four types of flexible couplings that could be used with vacuum pumps: grid, gear,
elastomeric sleeve and elements, and disc. These couplings can be divided into two broad
categories:
• Sealed lubricated (grid and gear types)
• Non-lubricated (rubber sleeve, rubber elements, and disc)

Gear and grid type couplings are designed with limited end float to prevent motor rotor axial
movement that can cause damage to the motor.

Coupling maintenance is discussed in more detail in EPRI report 1007910, Flexible Shaft
Couplings Maintenance Guide.

8.6.3.1 Routine Maintenance Recommendations

Some routine maintenance recommendations include the following:

• Verify that the coupling has correct type and amount of grease (grease lubricated couplings
only).
• Ensure that the fasteners and grease fittings are properly tightened.
• Visually inspect the area around the coupling for:
– Leaks
– Rags or other obstructions
• Ensure the coupling guard is installed.

These checks are performed on vacuum pumps having couplings that are readily accessible for a
pre-start inspection:
• Inspect for cracked discs (disc-type coupling).
• Visually inspect for unusual noise or vibration.
• Visually check for collection of rubber-like dust directly below coupling (elastomeric
sleeve/element type only).

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8.6.3.2 Coupling Overhaul

For a gear-type coupling, an overhaul would include the following tasks:

• Disassemble and inspect the coupling in accordance with manufacturer’s guidelines.
• Thoroughly remove and clean old grease from the coupling and inspect the following areas
for signs of wear or fatigue cracks:
– Teeth
– Grid
– Fasteners
– O-rings, gaskets, grease seals
• Obtain a sample of the grease for testing.
• Reassemble the unit.

Key Technical Point

Verify that components used to restrict motor shaft movement are installed.

• Replenish grease.
• Perform the following alignment checks:
– Parallel alignment
– Angular alignment
• Note that the gap spacer is in place and correctly installed (limited end float coupling
designs).

For a disk-type coupling, an overhaul would include the following tasks:

• Conduct a visual inspection for cracks developing in the disc(s).
• Disassemble the coupling, checking the extent of the disc cracks and replacing any damaged
disc.
Note: The order or number of the shims in a disc pack coupling must not be changed.
• Replace the fasteners if the locking feature is in doubt.
Note: The locking feature of these fasteners becomes compromised when they are removed
and reinstalled a certain number of times. As an example, Rexnord recommends replacing
the fasteners after they have been removed/reinstalled between 7 to 10 times.

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Key Human Performance Point

The locking feature of disc-type coupling fasteners becomes compromised
when they are removed and reinstalled a certain number of times.

• Perform the following alignment checks:

– Parallel alignment
– Angular alignment

8.6.3.3 Coupling Alignment

Misalignment can result in high vacuum pump vibrations. For vacuum pump installations that
have high vibration sensitivity, the coupling can be aligned to a tighter tolerance, which reduces
vibration. A tighter tolerance on coupling alignment can be achieved by using a computerized
alignment device.

It is important to verify that the thrust load of the vacuum pump is not imposed on the motor
thrust bearing. This requires knowledge of the magnetic center of the motor.

For more detailed information on alignment, refer to EPRI TR-112449, Shaft Alignment Guide.

Key Human Performance Point

It is important to verify that the thrust load of the vacuum pump is not
imposed on the motor thrust bearing. This requires knowledge of the
magnetic center of the motor.

8.6.4 Structural Support System

The structural support system (SSS) is a five-component system comprised of a concrete

foundation, a grout layer, anchor bolts, pedestal, and soleplate/baseplate. Maintenance of these
components is often nonexistent. The SSS is no different from any other supportive auxiliary
system and, therefore, should be incorporated into a PM program.

8.6.4.1 Concrete Foundation

An annual visual inspection of foundation is recommended.

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8.6.4.2 Repairing Concrete Foundations

Assuming that the soil base has been properly stabilized, the repair of concrete foundations
encompasses two areas:
1. Surface cleaning
2. Crack repair

To obtain maximum effectiveness, each of these maintenance actions should include both
prevention and detection. Prevention is a two-tier process. Early detection through regular
inspections will provide a decisive step toward prevention of major problems and the major
repairs that follow. Investigating and determining the cause of the casualty is the second part of a
PM action. Maintenance personnel should avoid hasty repairs without first addressing the
question, “What caused this problem?” This is especially true in the case of concrete foundation
repair. If the foundation continues to crack, hidden problems, such as voids in a concrete
foundation or an unstable soil base, should be considered for investigation.

The correction or repair of a concrete foundation involves the choice between a permanent fix
(which may require the erection of a new foundation) and a semi-permanent fix used as a stop-
gap measure to keep the vacuum pump online until a scheduled outage or until the needed
logistics are brought together to affect more permanent repairs.

8.6.4.3 Surface Cleaning

Over time, oil may degrade the structural integrity of concrete by causing a physical breakdown
in the matrix structure of the concrete. This breakdown process is not immediate and may take
years to develop into a serious problem. However, it is one problem that can certainly be
prevented and corrected.

Steam cleaning provides one possible solution for concrete surfaces that have been subjected to
oil spillage over a period of years.

8.6.4.4 Crack Repair

Curing cracks do not have any appreciable depth or pattern; structural cracks, however, are large
and deep. If structural cracks are not addressed, they may continue to develop in severity. As the
foundation continues to degrade, operators and maintenance personnel can expect equipment
misalignment, bearing problems, and an increase in vibration amplitude. Early detection is
critical to limiting damage to both the foundation and the vacuum pump.

Because anchor bolts are stress risers, structural cracks will appear most often in the immediate
vicinity of these bolts. Proper installation of these anchor bolts and correction of equipment
vibration offer the best courses of action to take in avoiding this problem.

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Before actual repairs can begin, the following several factors should be considered:
• Choice of the correct grout
• Severity of the damage
• Urgency to bring the vacuum pump back on line
• Access to the damaged area

The effectiveness of a grout is based on its ability to act as an adhesive and to bond the damaged
area into a structurally sound joint. Determining which grout resin system to use is an important
factor in the repair process. Variables such as pot life (curing time), non-shrink capability, ability
to bond through oil films, viscosity, and wetability all factor into the effectiveness of the grout to
penetrate the crack and bond the two cracked segments into a cohesive unit.

The extent of damage is the final determining factor in deciding whether a foundation can be
repaired. Experienced personnel in the field of concrete foundation repair should be consulted to
assist in the decision process. Once it has been determined that the foundation can be repaired,
the need for the vacuum pump provides an important input into the decision to conduct
temporary repairs or defer the maintenance action until a scheduled outage.

8.6.4.5 Anchor Bolts

An anchor bolt functions as a clamp to provide a secure means for holding the baseplate to
concrete foundation. This clamping effect is accomplished through a spring-type action between
the anchor bolts and the concrete foundation/grout layer system. As the bolt nuts are tightened,
the bolt itself begins to stretch. This stretching phenomenon plays an important part in the
successful application and performance of the anchor bolt. As each anchor bolt is tightened, the
bolts become a system of springs that will collectively apply a clamping or compressive effect
around the entire baseplate. The net effect achieved is a secure base for the vacuum pump to
operate on.

8.6.4.5.1 Forces Affecting Anchor Bolts

During the operational life of the vacuum pump, anchor bolts will be subjected to three loading
conditions:
• Initial preload: The load that develops when the anchor bolt is first tightened
• Residual preload: The load remaining after all anchor bolts have been properly tightened
• Working load: The load the anchor bolt is subjected to while the vacuum pump is in
operation

If properly installed and tightened, the residual pre-load on the bolts should be less than any load
caused by operation.

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Preventive Maintenance

8.6.4.5.2 Proper Installation

Critical to achieving a good installation is the need to properly isolate the anchor bolt. There are
two areas that require special attention to ensure anchor bolt isolation. Use of foam insulation in
the area around the grout where the bolt penetrates can provide adequate isolation. Failure to
accomplish this allows the grout to bond the bolt. Should this occur, the bolt would be limited to
stretch in a short section. Two consequences of this condition are the following:
• Loose bolts after vacuum pump startup with subsequent cracking of the grout around the bolt
• Inability of the anchor bolt to flex in case the baseplate moves laterally

The area between the sleeve and the anchor bolt is the second area requiring isolation. It is
suggested to fill the sleeve with a pliable material, such as silicone rubber. If the sleeve is filled
with grout or other rigid material, extremely high stresses can develop in the foundation by
preventing the anchor bolts from developing the spring action. As a direct consequence, cracking
can occur in the foundation in the area around the affected anchor bolt(s).

There are three principal checks associated with these components. Maintenance is based on
good housekeeping practices and consists of surface cleaning, corrosion prevention, and
inspecting hold-down bolts for proper tightness.

An oil-soaked surface can easily mask small leaks and provides a slip hazard to personnel
required to work in the affected area. It also provides a mechanism for oil to migrate down to the
grout and concrete foundation, encourages an attitude that accepts leaks or standing oil as normal
station procedure, and presents a potential fire hazard. Conversely, a clean surface provides a
visual baseline for personnel to quickly detect leaks, prevents oil from reaching the grout and
concrete, and allows inspections of bearing housings or hold-down bolts to be accomplished
without danger to personnel.

Corrosion prevention begins with the initial installation. Surfaces that will be in contact with the
grout layer should be coated with a primer that is compatible with the grout being used. Base
metal, blisters, rusted surfaces, and oil- or grease-soaked surfaces are all unacceptable. Failure to
take this precaution will prevent adequate bonding between the baseplate/soleplate and the layer
of grout. This condition will lead to the grout cracking over time.

Inadequate corrosion prevention and unchecked corrosion can have serious consequences to
machinery using cementatious grout with metallic filings. If corrosion develops at the metal-
grout interface, it will continue and spread to the metallic filings. The pressure caused by the
corrosive forces can be of such magnitude as to cause misalignment of the machinery and
cracking of the concrete foundation.

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 Preventive Maintenance

8.6.5 Electric Motors

Problems with motors can be identified early and corrected through a maintenance program that
is structured around motor cleanliness, lubrication, and routine inspections. These three
elements will form the necessary foundation for an effective electric motor maintenance program
that will lead to dependable and economical operation.

8.6.5.1 Dirt

Dirt is a common element to any generating station. Controlling this problem is a 24-hour-a-day
job. Electric motor ventilating spaces will be restricted over time if dirt is allowed to build up.
This problem will have a direct impact on the ability of the motor to cool itself. Consequences of
this problem (if it is allowed to go unchecked) include the following:
• Breakdown of motor insulation
• Increase in auxiliary power consumption
• Potential for abrasion and wear of motor internal components

An effective cleaning program requires regularly cleaning the exterior of the electric motor,
regularly cleaning the motor’s filter assemblies, and cleaning the motor internals. Components
such as access panels and covers also play an important role in keeping dirt outside. Verifying
that gasket material and dust seals are in good condition, together with properly installing the
access panels, will pay valuable maintenance dividends in the battle to keep dirt out. Use of a
pre-filter assembly has the added advantage of allowing personnel to clean the filters without
requiring the motor to be shut down. Cleaning should be performed during every scheduled
boiler shutdown.

Use of clean, dry, compressed air is effective in removing dry, loose dust and particles. Air
pressure at 30 psig (207 kPa) can be effective in blowing out a motor. Considerations when using
compressed air include the following:
• Blow out any accumulation of water in the air line and hose before using it.
• Consult the manufacturer on recommended air pressure. Pressure exceeding the
recommended value can cause abrasive particles to be driven into the insulation and puncture
it.
• Use recommended safety equipment when blowing out the motor. Safety goggles,
respirators, and hearing protection are highly recommended.
• Install a suction blower or similar device at the opposite end to remove dirt-laden air.

Additional options for removing dirt include the use of clean lint-free rags and vacuum cleaners.
Lint will adhere to the insulation, resulting in an increase in dirt collection. Lint is also
particularly damaging on high-voltage insulation, because it causes corona discharge to
concentrate in one area.

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Preventive Maintenance

8.6.5.2 Moisture

In all of the previous cases, simple anti-moisture precautions such as the following can be taken
to avoid motor damage:
• Protect motors opened for maintenance against moisture by using space heaters, coverings,
and, when feasible, reinstalling access panels.
• Identify and remove sources of moisture in and around the motor:
– Verify that all piping is properly insulated.
– Correct all leaks.
– Install protective coverings over motors when required, ensuring that these coverings do
not restrict air movement.

8.6.5.3 Friction

To avoid damage caused by friction, the motor manufacturer’s lubricating instructions should be
followed, and the proper type of lubricant in the proper quantities and intervals suggested should
be used. Verifying the proper quantity of lubricant is vital. Excess amounts of lubricant can be
just as damaging as insufficient lubricant. Too much grease can promote friction and heat and
can leak onto stationary windings and rotating elements. This, in turn, can cause overheating and
deterioration of insulation, resulting in eventual grounds and shorts.

8.6.5.4 Vibration

Excessive vibration can damage electrical connections, loosen fasteners, promote frictional wear,
and cause portions of the metallic structure to develop cracks. Checks to avoid vibration damage
include the following:
• Verify correct alignment between the motor and vacuum pump.
• Inspect the foundation for cracks.
• Open and inspect bearings when heavy wear or damage is suspected.
• Verify that machinery hold-down bolts are installed and properly torqued.
• Inspect the motor bearings at regular intervals during operation. Personnel should check for
signs of rapid heating and unusual noise.

8.6.5.5 Rotor Shaft End Play

The rotor shaft assembly of induction motors will have a certain amount of end play designed
into it. End play refers to the axial distance through which the motor’s shaft is free to move when
it is uncoupled from the load. This freedom of movement occurs because of tolerances that

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 Preventive Maintenance

inevitably occur in the design and manufacturing process. These tolerances include machining
variations, bearing design requirements to prevent binding, and allowances for any thermal
growth of the rotor shaft assembly during motor operation.

Induction motors designed with sleeve bearings have a larger end play than those that use roller
bearings. Typical values given for large motors with sleeve bearings are 1/4- to 1/2- inch. Motors
outfitted with roller bearings may have an end play range from 1/32- to 1/8- inch. If a bearing
locking arrangement is used, this range will be even smaller. Because induction motors with
sleeve bearings do not have any locking arrangement, the rotor shaft assembly is free to float.
This does not become a problem while the motor is in operation and is not subjected to any
external forces. Under these conditions, the rotor shaft assembly will align itself to the magnetic
center of the applied field.

Endwise restraint that limits the movement of the rotor shaft is achieved through one of the thrust
bearings. The forces of these bearings are designed to withstand the momentary thrust that may
develop during the starting or stopping of the motor. Damage from continuous thrust occurs
when external forces are applied that prevent the rotor shaft from seeking its magnetic center.
External forces can result from coupling misalignment or locking. When a coupling is
misaligned, asymmetrical forces between the hubs develop. This imbalance may cause the load
and motor coupling halves to move apart. This separation is limited by the thrust bearings on the
load and motor. Continuous thrust resulting in damage to the motor bearing thrust faces is likely
to occur. Limited end float couplings will prevent motor damage to the motor journal bearings by
excessive axial movement of the motor rotor.

External forces may also develop from a coupling locking. If a coupling is worn or poorly
lubricated, torque transmission through the coupling gear teeth sets up high friction, which
resists endwise movement (in-and-out or side-to-side movement of the coupling gear teeth or
grids). This condition could prevent the motor shaft from seeking its magnetic center and could
subject the thrust faces of the motor bearings to continuous thrust.

8.6.6 Solenoid Operated Valves

In addition to parts replacement during corrective maintenance, periodic replacement of age-

sensitive parts and rebuilding of selective SOVs are often performed to maintain long-term SOV
performance. The two major SOV component classes that may benefit from periodic
replacement are the SOV coil and the elastomeric components (for example, seats, diaphragms,
and seals).

Minimum periodic SOV or part replacement intervals may be required by special technical or
licensing commitments. Environmental qualification, per 10CFR50.49, is the best example of a
program requiring such replacements. The periodic rebuilding of BWR scram SOVs is another
example of an established SOV refurbishment frequency. When SOVs are not controlled by
these programs, periodic replacement intervals can be determined using manufacturer

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Preventive Maintenance

recommendations, rules of thumb, and operating experience. Because general recommendations

are, by their very nature, imprecise, the best method of establishing refurbishment/replacement
intervals is operating experience with the same or similar applications.

Key Technical Point

One of the most important factors for selecting periodic replacement
frequencies is operating experience.

The importance of operating experience is related to the lack of proven SOV condition
monitoring or diagnostic techniques. Without condition monitoring methods, SOV periodic
maintenance is generally based on calendar time. Unfortunately, because application conditions
vary widely, the uncertainty about the actual SOV condition can be significant. Under these
circumstances, the best method of determining the level and extent of in-service deterioration is
prior operating and maintenance experience in similar applications.

8.6.6.1 Coils

When SOV coils are properly protected from humidity damage and are not continuously
energized, they can have an indefinite life. When subjected to continuous energizing, particularly
at high ambient temperatures, their life is reduced considerably. As a rough rule of thumb, coil
insulating systems can be expected to remain functional at their insulation class rated
temperature for times ranging from four to 10 years. Conservatively, their thermal life should
double for every 15°F to 20°F (8.3°C to 11.1°C) decrease in temperature. Coils should not be
used continuously above their rated temperature because of rapid deterioration and failure.

If SOVs or materials are controlled by the EQ program, then the EQ qualified life for the
material in that application can be considered a very conservative estimate of the coil's life in
similar applications not controlled by the EQ program. In a recent test, air-pilot SOV coils were
successfully tested for time intervals six times longer than the previous established service
interval based on the SOV’s environmental qualification test.

8.6.6.2 Elastomers

The service time limits for elastomers are more difficult to establish because they vary with the
material, the part design, and its function. In general, manufacturer recommendations should be
followed when establishing initial intervals. The effects of contaminants and debris are
application specific and cannot be predicted. Assuming an otherwise ideal application,
temperature does have a significant effect on elastomer life.

If similar SOVs are controlled by the EQ program, then the EQ qualified life for the material in
that application can be considered a very conservative estimate of the elastomer's life. For
elastomers wetted by the process fluid and in SOVs that are normally open with fluid flow, the
elastomer temperature should be similar to the process temperature. When air-pilot SOVs are

8-24
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 Preventive Maintenance

energized for prolonged periods, the seat and seal temperatures can increase roughly 45°F–90°F
(25°C to 50°C) above ambient temperatures.

When operated near their upper service temperature limits, elastomers should be usable for a few
years. Long-term performance (for example, 5–10 years and longer) is achieved when the
elastomers are operated at temperatures well below these service limits.

When SOVs are periodically removed from service for repair or replacement, the elastomers
should be examined and their condition documented. Generally, an elastomer will continue to be
serviceable if it remains flexible and shows little evidence of swelling, cracking, compression
set, or shrinkage. Because elastomers are supplied in a wide range of hardness values,
comparisons should be made with new parts to gauge the amount of deterioration that has
occurred. This information can then be used to modify part replacement and valve refurbishment
intervals.

Key Technical Point

Examine the condition of elastomers when valves are disassembled.
Compare the condition to that of new components. Adjust service intervals to
keep the elastomers in a flexible condition.

8.6.6.3 Periodic Valve Cycling

With the possible exception of high pressure, high temperature applications, manufacturers
collectively agree that periodically cycling SOVs is one of the best SOV PM techniques. One air-
pilot SOV manufacturer’s instruction manual for commercial SOVs recommends monthly
cycling.

The potential for SOV sticking varies widely among valve styles. For example, SOVs with
elastomer sliding seals appear more susceptible to sticking than direct-acting SOVs with globe-
type seats. Application factors, such as process medium, contamination, debris, temperature, and
coil voltage, can all affect a valve’s susceptibility to sticking. In many commercial/industria1
applications (for example, pneumatic control SOVs on metal stamping machines) sticking often
occurs when the SOVs are idle for only a few days. In power plant applications, it appears that
SOVs on air systems are more prone to sticking than in other plant applications.

As a result of the variety of factors affecting SOVs, there cannot be one recommended cycling
frequency. The most relevant factor for selecting a cycle frequency is operating experience.
Other important factors include operating temperatures, valve design, and the level and types of
process contamination. As a general rule of thumb, air system SOVs should be cycled quarterly.
Longer intervals are readily justified when operating experience indicates no prior operating or
sticking problems. If SOV sticking is observed and the root cause cannot be readily determined,
the test interval should be shortened.

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Preventive Maintenance

Key Technical Point

One of the best SOV PM techniques is periodic valve cycling. No one cycle
frequency can be recommended. The most important factor for selecting a
cycle frequency is operating experience.

Refer to EPRI NP-7414, Solenoid Valve Maintenance and Application Guide, for a complete
discussion on SOV maintenance practices.

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9
REFERENCES

“Component Data Tables.” EPRI Preventive Maintenance Database. EPRI, Palo Alto, CA.
Condenser Application and Maintenance Guide. EPRI, Palo Alto, CA: 2001. 1003088.
Electric Motor Predictive and Preventive Maintenance Guide. EPRI, Palo Alto, CA: 1992. NP-
7502.
Equipment Condition Monitoring Templates—Addendum to Preventive Maintenance Basis (TR-
106857 Volumes 1–38). EPRI, Palo Alto, CA: 2000. 1000621.
Flexible Shaft Couplings Maintenance Guide. EPRI, Palo Alto, CA: 2003. 1007910.
Gearbox and Gear Drive Maintenance Guide. EPRI, Palo Alto, CA: 2004. 1009831.
“Installation and Operation Nash Vacuum Pumps CL Series.” Nash Bulletin 406-I, 1966.
“Installation, Operation, and Maintenance of Nash Condenser Exhaust Unit Size AT-3004E.”
Nash Bulletin 829-B.
“Instructions for Axi-Vac Type “H” AXI Packaged Two-Stage Vacuum Pump.” Dresser-Rand
Form 11169A, 1967.
“Instructions for Type “L” AXI Compressor Series 787L165.” Ingersoll-Rand Form 110121966.
Performance Standard for Liquid Ring Vacuum Pumps. Heat Exchange Institute, 2005.
Preventive Maintenance Basis, Volume 15: Rotary Screw Air Compressors. EPRI, Palo Alto,
CA: 1997. TR-106857-V15.
Preventive Maintenance Basis, Volume 27: Liquid-Ring Rotary Compressor and Pump. EPRI,
Palo Alto, CA: 1997. TR-106857-V27.
Shaft Alignment Guide. EPRI, Palo Alto, CA: 1999. TR-112449.
Solenoid Valve Maintenance and Application Guide. EPRI, Palo Alto, CA: 1992. NP-7414.
Standards for Steam Jet Vacuum Systems. Heat Exchange Institute, 2000.
Tech Sheet #102. Steam Jet Vacuum Systems Troubleshooting Guide. Heat Exchange Institute,
2004.
Thermal Performance Engineering Handbook, Volume II: Advanced Concepts in Thermal
Performance. EPRI, Palo Alto, CA: 1998. TR-107422-V2.
W. J. Kubik and E. Spencer. Improved Steam Condenser Gas Removal System. The American
Society of Mechanical Engineers.

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10427360
A
FAILURE HISTORY OF INDUSTRY CAR EQUIPMENT

Table A-1 contains the results of searches of industry databases for CAR equipment failures.
CAR system failures caused by failures of power supply equipment were not included in the
search. As a result, while motor failures are included in the tabulation, failures of circuit breakers
that supply the motors are not. In several cases, the same failure was reported in multiple
databases. In these cases, the same failure number was assigned to each line item.

The NRC Event Notification System (ENS) and Inspection Report (IR) databases and the INPO
OE database were searched. The INPO OE database includes NRC Licensee Event Reports
(LER). Search criteria included the following:
• CAR system
• Condenser vacuum
• SJAE
• Vacuum pump

Additionally, the INPO EPIX database was searched for:

• CAR system
• All manufacturers for component types of accumulators, tanks, receivers, blowers,
compressors, vacuum pumps
• Specific manufacturers: Ingersoll Rand, Nash, and Foster Wheeler

A-1
10427360
Failure History of Industry CAR Equipment

Table A-1
CAR Equipment Failure History

Failure Number Source Event Corrective Failed

Plant Power Change Event Description Cause
and Report Number Date Action Equipment

Failure 1 PWR 4/17/2000 Manual scram Steam pressure was Failure of air diaphragm The valve was SJAE steam
#1 as a result of lost to auxiliary steam packing in auxiliary repaired, tested, and supply valve.
LER 2000-005-00 low condenser header, resulting in a steam supply PCV as a returned to service.
vacuum. loss of condenser result of disengagement
vacuum. of packing nut. Packing
nut became disengaged
as a result of inadequate
previous maintenance.

Failure 1 PWR 4/17/2000 Manual scram There was Actuator packing nut The valve was SJAE steam
#1 as a result of inadequate steam disengaged as a result of repaired, tested, and supply valve.
IR 05000334 / 2000-004 low condenser supply to SJAEs as a inadequate previous returned to service.
vacuum. result of steam maintenance, resulting in
supply PCV failing to PCV going closed.
close.

Failure 2 PWR 2/24/1998 Output Pump suction valve Pump suction valve Valves were MVP liquid
#2 decreased by went fully open when controller sensing line opened. ring-suction
EPIX 119 15 Mwe, pump was started. isolation valves were not valve.
vacuum opened following
decreased by previous maintenance.
1.1" Hg.

Failure 3 PWR 10/1/2003 No change. Unit SJAEs stall on Inner-condensers did not SJAE inter-
#3 occasion as a result drain properly because condenser.
System Health Report– of improper inner- the condenser drip
Condensate condenser draining. receiver was under a
vacuum.

Failure 4 BWR 12/29/2001 No generation Pump suction valve Solenoid pilot valve was SOV was replaced. SOV-MVP
#1 lost. failed to open when blowing air and failed to liquid ring-
EPIX 284 MVP was being transfer. suction valve.
started for plant
startup.

A-2
10427360
 Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Event Failed

Plant Power Change Event Description Cause Corrective Action
and Report Number Date Equipment

Failure 5 BWR 4/17/2005 No generation SJAE isolation valve New brackets were Bracket was SOV-SJAE
#1 lost. SOV failed to operate made from angle iron. shortened, and all suction valve.
EPIX 553 after replacement. One was slightly longer brackets will be
New brackets had than the other three and replaced in the
been fabricated to came close enough to future with ones
mount the solenoids the coil to absorb or made of aluminum.
during the previous redirect enough
modification magnetic energy so that
installation. the SOV would not
actuate.

Failure 6 BWR 2/26/2006 No generation SJAE isolation valve The SOV coils were not The SOV coil did SOV-SJAE
#1 lost. failed to close after a aligned properly when actuate the valve suction valve.
EPIX 551 scram. All four SJAE they were initially when it was
inlet valve pilot installed. adjusted upward on
solenoids were the sub-base.
replaced under a
modification with a
different type during
RE22.

Failure 7 BWR 5/22/2006 No generation SJAE inlet valve SOV failed to cycle. SOV-SJAE
#1 lost. failed to close when suction valve.
EPIX 562 demanded by control
room as part of
scram recovery. This
is a repeat of events
in 4/2005 and 2/2006.

A-3
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Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 8 PWR 10/30/2001 No generation New two-stage Spray valve was not Spray valve MVP-liquid
#4 lost. vacuum pump opening because it was malfunction was not ring-seal water
EPIX 426 cannot maintain improperly installed detected during spray valve.
condenser vacuum during recent mod test because
at 1.8" Hg absolute. modification. test engineer
incorrectly
interpreted vendor
note that spray
valve would be
closed during low
vacuum operation to
mean low absolute
vacuum. Problem
was not corrected
on 10/30/2001
because another
problem masked it.

Failure 9 PWR 11/29/2001 No generation New two-stage Spray valve was not The spray valve MVP-liquid
#4 lost. vacuum pump opening because it was configuration was ring-seal water
EPIX 427 cannot maintain improperly installed corrected. The mod spray valve.
condenser vacuum during recent package for the
at 1.8" Hg absolute. modification. other MVP was
corrected.

Failure 10 PWR 12/12/2002 No generation Suction valve did not Inlet header-to-pump PS was recalibrated MVP-liquid
#4 lost. open when pump suction differential PS to proper dp in ring-PS-inlet
EPIX 478 started. did not actuate because proper direction. header-to-
it had been set in Other PS setpoints pump suction
reverse direction when will be reviewed. differential PS.
recently replaced. The
vender drawing used to
determine setting was
not clear.

A-4
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 Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 11 PWR 12/8/2003 No generation Suction valve did not Inlet header-to-pump PS was MVP-liquid
#4 lost. open when pump suction differential PS recalibrated. ring-PS-inlet
EPIX 523 started. did not actuate because header-to-
it was out of calibration. pump suction
differential PS.

Failure 12 BWR 4/1/2000 Automatic Recombiner bypass BPV SOV failed as a SOV had not been SOV-
#2 scram as a valve went closed result of seat material overhauled in 26 recombiner
IR 05000333 / 2000-003 result of low while taking embrittlement, resulting years. SOV was bypass valve.
condenser recombiner OOS, in bypass valve going overhauled.
vacuum. isolating the main closed.
condenser,

Failure 13 PWR 7/2/2000 No generation MVP (Train B) failed Vacuum (pressure) Switch was MVP-liquid
#5 lost. to start. switch failed to actuate recalibrated. ring-PS-inlet
EPIX 266 as a result of setpoint vacuum
drift, preventing CB switch.
from closing.

Failure 14 PWR 7/11/2000 No generation MVP (Train A) failed Vacuum (pressure) Switch was MVP liquid
#5 lost. to start. switch failed to actuate recalibrated. ring-PS-inlet
EPIX 267 as a result of setpoint vacuum
drift, preventing CB switch.
from closing.

Failure 15 BWR 9/16/1997 183984 MWHr "A" SJAE steam O-rings in positioner Positioner was SJAE steam
#3 generation lost. PCV stuck closed were hard. The overhauled. supply valve.
EPIX 9 until operator tapped positioner had been in
on valve with service since
pocketknife. 6/16/1981.

A-5
10427360
Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 16 PWR 12/20/2000 Power cycled Backpressure Air being injected into MVP-helical
#6 30–50 MWe as transients on the MVP suction to rotor.
OE12086 a result of 12/20/2000, lower the discharge
cycling of 12/21/2000, and temperature overloaded
condenser 1/22/2001, which the pump and caused
vacuum. were caused by the suction pressure to
increases in MVP increase.
suction pressure and
caused electrical
output transients.

Failure 17 PWR 10/23/1995 No generation This EPIX was to Inter-stage relief valve The rotors, timing MVP-helical
#6 lost. document a failed, resulting in gears, and inter- rotor.
EPIX 104 historical review of internal pump damage. stage relief valve
the CAR system were replaced.
WRs for
Maintenance Rule
applicability. One
failure applied to this
review.

Helical rotor pump

tripped on high
temperature.

Failure 18 PWR 8/15/1999 88 MWHr lost I-R pump tripped Pressure switch was Switch was MVP-helical
#6 generation. when started. incorrectly calibrated recalibrated. rotor-PS-oil.
EPIX 610 during previous
maintenance.

A-6
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 Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 19 PWR 5/20/2002 20 MW lost for Megawatts were lost The pump inter-stage Procedural MVP-helical
#6 about 50 as a result of a relief valve lifted as a compliance was rotor.
EPIX 847 minutes. reduction in helical result of cold ambient enforced to remove
rotor vacuum pump temperature with motivating air when
efficiency. motivating air still discharge
aligned. temperature in
145ºF.

Failure 20 BWR 7/23/2002 Manual scram CAR system failed Plant staff changed Procedures were SJAE.
#5 as a result of to function when procedure from 135ºF revised to reflect
IR 50-352/02-05 low condenser condensate to 150ºF in support of operating
vacuum. temperature in SJAE main turbine limitations.
condenser exceeded replacement.
147ºF.

Failure 20 BWR 7/23/2002 Manual scram Outside air Impact of elevated Procedures were SJAE.
#5 as a result of temperature temperature was not revised to reflect
LER 2-02-001 low condenser increased to 95ºF addressed during operating
vacuum. caused increase in turbine retrofit. limitations.
condensate
temperature.
Elevated
temperature caused
insufficient cooling in
SJAE inter-
condenser, stalling
first stage SJAE.

Failure 20 BWR 7/23/2002 125,038 MWHr All four first-stage Vender information Administrative SJAE.
#5 of generation SJAEs stalled as a indicated SJAE would controls were
EPIX 290 lost as a result result of high fail at a SJAE applied.
of manual condensate condenser temperature
scram because temperature. of 147ºF. Station
of degraded procedures allowed
condenser continued operation up
vacuum. to 150ºF.

A-7
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Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 21 BWR 7/10/2005 No generation MPV tripped. MPV seal water pump MVP seal water MVP-liquid
#6 lost. thermals initially tripped. pump motor was ring-seal water
EPIX 288 After resetting the replaced. pump-motor.
thermals, seal water
pump ran for two hours
before magnetics
tripped.

Failure 22 BWR 9/11/2005 No generation MVP failed to start. Motor tripped thermal Thermal overloads MVP-liquid
#6 lost. overloads. were reset. ring.
EPIX 293

Failure 23 BWR 10/2/2001 No generation MVP did not have Seal water pump Pump was repaired MVP-liquid
#7 lost. adequate seal water impeller seized. and placed in the ring-seal water
EPIX 178 to maintain PM program. pump-motor.
operation and pump
tripped.

Failure 24 BWR 10/14/2005 No generation While attempting to Low seal water flow Seal water switch MVP-liquid
#7 lost. start MVP, it tripped switch was not adjusted was adjusted. ring-seal water
EPIX 301 on low seal water properly. flow switch.
flow.

Failure 25 BWR 9/16/1988 Shutdown from Condenser vacuum Local temperature SJAE inter-
#8 100% to 0% began decreasing, measurements on condenser.
OE2900 power as a along with SJAE second-stage
result of loss of decreasing off-gas nozzles indicated
condenser flow. A second SJAE degraded SJAE
vacuum. was started with no performance as a result
improvement in of either flooded inner-
vacuum. condenser or loss of
inner-condenser loop
seal.

A-8
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 Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 26 BWR 2/28/2007 Manual scram Reduction in SJAE Corrosion products SJAE steam
#9 as a result of efficiency was accumulated in PCV supply valve.
LER 5000265-2007-00 low condenser caused by SJAE sensing line, causing
vacuum, supply pressure at valve to open, causing
caused by 120 psig, instead of RV to lift, and resulting
reduction in 127 psig. in loss steam pressure.
SJAE
efficiency.

Failure 27 BWR 8/21/2000 Manual scram Too much off-gas Operator fully opened The solenoid drain SOV-off-gas.
#10 as a result of purge air created service air valve used to valves for the off-
IR 50-458/00-13 low condenser backpressure on add purge air instead of gas cooler
vacuum. SJAEs, and they throttling it, resulting in condensers were
stalled. too much purge air. replaced.

Failure 27 BWR 8/21/2000 Manual scram Too much off-gas Operator fully opened The solenoid drain SOV-off-gas.
#10 as a result of purge air created service air valve used to valves for the off-
OE12187 low condenser backpressure on add purge air instead of gas cooler
vacuum. SJAEs, and they throttling it, resulting in condensers were
stalled. too much purge air. replaced.

Operations and
Engineering personnel
did not communicate to
task performer to only
throttle valve.

Failure 28 BWR 9/23/2003 No generation SJAE Off-gas SOV had body-to- Solenoid was SOV-SJAE
#10 lost; unit in hot suction valve would bonnet joint air leak. replaced and loop suction valve.
EPIX 216 S/D. not close. Valve setpoint was re-
failed to open on established at 16
loss of air. psig air.

A-9
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Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 29 PWR 3/10/1984 Automatic Main condenser Clogged piping drain The drain lines were SJAE-piping
#7 scram on low vacuum started lines caused water to cleaned. drain lines.
LER 84-008-00 condenser decreasing as a back up into the air-
vacuum. result of air removal removal piping.
piping restriction
when circulating
water pump was
stopped.

Failure 30 PWR 4/1/2003 Manual scram Low condenser Out-of-calibration PI The loop seal piping SJAE inter-
#8 as a result of vacuum was caused resulted in establishing was replaced. condenser
IR 05000335/2003006 low condenser by through-wall hole inadequate steam piping.
vacuum. in SJAE inter- pressure (115 psig The pressure gage
IR 05000389/20004008 condenser loop seal instead of 200 psig) to was replaced. Pressure
piping return to hogging SJAE. SJAE Indicator.
condenser. acted as a vacuum The hogging SJAEs
breaker. were inspected.
Operators attempted
to place hogging
SJAE into service to
help degrading
backpressure, and
backpressure rapidly
went from 3.0" to
5.6".

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 Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 31 PWR 11/4/1993 Power Two of the three Vacuum was lost The vendor manual SOV-MVP
#9 decreased to MVPs are normally because Pump A was changed to helical rotor-
OE6382 prevent turbine in operation. Pump suction valve did not identify need for suction valve.
trip on low A was taken OOS, close when pump was proper orientation of
condenser while B and C were stopped. Pump rotated SOV components.
vacuum. running. Vacuum in reverse, causing low
immediately began vacuum. Attempt to A training session
to drop. Pump A start Pump A while was held to provide
tripped when a spinning backwards instructions on
restart was damaged pump. proper assembly of
attempted. valve, emphasizing
Valve did not close subtle differences
because SOV failed. between proper and
SOV failed because improper assembly.
repair kit was installed
wrong during previous
maintenance.

Failure 32 PWR 6/2/2000 No generation Pump tripped on Modification to eliminate A temporary change MVP-helical
#9 lost. high discharge noise and vibration was initiated to rotor.
EPIX 226 temperature during during normal operation allow operation of
hot ambient isolated inlet seal vent the isolation valve
conditions. line that feeds second so operations could
stage of compressor. maintain balance
As a result, discharge between pump
air temperature noise and vibration
increased. and discharge air
temperature.

Failure 33 PWR 1/3/2001 No generation Pump failed to start Problem could not be A work request was MVP-helical
#9 lost. after maintenance identified. Breaker written to replace rotor.
EPIX 243 on cooler. worked in test position "X" relay and direct
and MVP started trip actuator, which
normally. are original to the
breaker.

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Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 34 PWR 6/20/2001 No generation Pump tripped as Vacuum discharge high The cooler was MVP-helical
#9 lost. designed when temperature was cleaned. rotor-seal
EPIX 278 discharge caused by seal water water cooler.
temperature high temperature. Seal
exceeded 200ºF. water high temperature
Standby MVP was caused by a fouled
started as designed. seal water cooler. The
fouled seal water cooler
was caused by an
inadequate
maintenance activity
that did not include
cleaning the cooler.

Failure 35 PWR 11/19/2001 No generation Pump tripped on The inter-stage relief The relief valve was MVP-helical
#9 lost. high motor current valve was found replaced and the rotor inter-
EPIX 292 during plant startup damaged and did not MVP ran without stage relief
at point where the allow the MVP to any problems. valve.
inter-stage relief transition from hogging
valve should have to holding modes.
actuated to place the
second stage into
service.

Failure 36 PWR 7/28/2003 No generation AXI-VAC-15 pump No abnormal equipment Steps were MVP-helical
#9 lost. tripped on high conditions were found. previously added to rotor.
EPIX 438 discharge High discharge the operating
temperature. temperature is a procedure to add
common occurrence in supplemental
the summer when cooling through the
ambient temperatures use of fans when
are high. discharge air
temperature
reaches 195ºF.

A-12
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 Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 37 PWR 6/6/2004 No generation Pump removed from The motor bearing The motor was MVP-helical
#9 lost. service as a result of failed as a result of repaired. rotor- motor.
EPIX 437 smoke coming from insufficient quantity of
the outboard motor grease applied to
bearing. bearing by motor repair
shop.

Failure 38 PWR 11/21/2005 No generation Pump tripped on The MVP was later MVP-helical
#9 lost. overload. The MVP started and ran rotor.
EPIX 485 was in hogging normally without any
mode at the time. unusual parameters
exhibited by the MVP.

Failure 39 PWR 10/2/1999 No generation Event 1: Started Event 1: SOV failed, Event 1: SOV was SJAE LCV
#10 lost, but SJAE # 1 on resulting in blown loop replaced; loop seal SOV.
EPIX 130 Event 1 vacuum below auxiliary steam. seal. was refilled.
minimum to Loop seal was lost,
operate steam resulting in air
dump valves. leakage.

Failure 40 PWR 10/2/1999 No generation Event 2: Started Event 2: Auxiliary steam Event 2: SJAE #2 SJAE steam
#10 lost, but SJAE #2 on auxiliary to SJAE # 2 PCV had was switched to supply PCV.
EPIX 130 Event 2 vacuum below steam, but SJAE did outstanding main steam.
minimum to not work. maintenance issue, but
operate steam no caution tag was
dump valves. placed on control board.

Failure 41 PWR 1995 No generation MVP tripped soon Tapered bearings failed Bearings were MVP bearings.
#11 lost. after periodic catastrophically after 25 replaced and a
System Engineer review of vibration test was years in service. nine-year MVP
draft guide performed. overhaul frequency
Vibration readings was established.
were within normal
range.

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Failure History of Industry CAR Equipment

Table A-1 (continued)

CAR Equipment Failure History

Failure Number Source Failed

Plant Event Date Power Change Event Description Cause Corrective Action
and Report Number Equipment

Failure 42 PWR 12/31/2006 No generation MVP tripped as a Jet air ejector nozzle Heating element MVP flow path.
#11 lost. result of flow froze as a result of was repaired.
System Engineer review of blockage when jet nozzle heating element
draft guide air ejector lost flow burning out.

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B
KEY POINTS

Key O&M Cost Point

Emphasizes information that will result in reduced purchase, operating, or
maintenance costs.

Section Page Key O&M Cost Point

Plant CAR equipment may be limiting the condenser under

part load conditions. Only reference to the condenser
4 4-35 performance curve will reveal the fact that the operating
pressure may be above the pressure the condenser is
capable of, robbing the plant of available energy.

Oil analysis tests are often offered free or for a nominal

7 7-11 charge by the lubricant supplier as part of the overall
service provided.

Use of recommendations from the manufacturer, along with

industry and plant operational experience, can provide
8 8-1
valuable insight in determining not only what checks should
be done, but also how often they should be done.

A balance must be attained by doing PM but avoiding

8 8-2 opening and inspecting equipment if no problems (such as
high temperature or pressure) are present.

To prevent pump damage as a result of the buildup of rust

8 8-6 between cast iron parts, follow the manufacturer’s
recommendations for short- and long-term lay up.

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Key Points

Key Technical Point

Targets information that will lead to improved equipment reliability.

Section Page Key Technical Point

It is the steam condensation process and the specific

volume change from steam to liquid that produces the
3 3-2
condenser vacuum. The lower the backpressure, the more
work that is done by the steam in the turbine.

Ensure that the drain flow check valve is in the right

geometric orientation and the drain piping is sloped down
4 4-9 and away from the machine to keep the water seal from
over flowing and filling up the compressor such that the
water intrudes into the oil.

Maintaining the seal water to always be cooler than the

condenser at its operating pressure provides the most
efficient air removal at any condenser vacuum level. The
4 4-16
vacuum pump will automatically track the condenser,
thereby providing maximum air removal under any
condenser load during the whole year.

Even if a liquid ring vacuum pump is oversized, it cannot

obtain lower vacuum levels than those permitted by the
vapor pressure of the seal water. To prevent cavitation, the
4 4-20
operating vacuum of the liquid ring MVP must be limited to
approximately 0.25 inch (0.64 cm) Hg above the vapor
pressure of the seal liquid.

Cooling water to the liquid ring MVP heat exchanger should

be condenser circulating water whenever possible.
4 4-21 Because of the vapor pressure existing within the MVP, the
pump will tend to track the main condenser whenever both
are fed the same temperature of coolant.

When vent valves on rotary screw pump suction lines are

opened to introduce “motivating air” into the pump, caution
must be exercised to monitor temperatures closely when
6 6-8 large changes in day to night temperatures occur. With full
motivating air still applied, the decreased nighttime
temperatures can result in exceeding the pump capacity,
and condenser vacuum will be reduced.

One goal of condition monitoring is to identify changes in

7 7-1 the condition of the pump, motor, or auxiliary that could
indicate some potential failure.

The vibration amplitude-versus-frequency analysis method

is considered to be the most useful. Over 85% of
7 7-5
mechanical problems occurring on rotating equipment can
be identified using this method.

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 Key Points

Thermography can be effectively used to identify sources of

condenser air in-leakage that challenges the performance
7 7-11
of the CAR system and to identify leaks and blockages in
process lines and drains containing hot fluids.

If oil in a self-contained sump is below normal level, adding

8 8-9 relatively cold oil may disrupt the oil film. Shut the vacuum
pump down before adding oil.

Do not mix oils in the lubrication system or bearing housing.

8 8-10 Chemical additives in different oils can cause a breakdown
in the viscosity, cooling, or bearing lubrication.

Verify that components used to restrict motor shaft

8 8-16
movement are installed.

One of the most important factors for selecting periodic

8 8-24
replacement frequencies is operating experience.

Examine the condition of elastomers when valves are

disassembled. Compare the condition to that of new
8 8-25 components. Adjust service intervals to keep the
elastomers in a flexible condition.

One of the best SOV PM techniques is periodic valve

cycling. No one cycle frequency can be recommended. The
8 8-26
most important factor for selecting a cycle frequency is
operating experience

Key Human Performance Point

Denotes information that requires personnel action or consideration in order
to prevent injury or damage or ease completion of the task.

Section Page Key Human Performance Point

Training programs for system engineers and maintenance

personnel should be reviewed and strengthened as
5 5-6
appropriate to address weaknesses in the understanding of
how the CAR equipment functions.

Care must be taken to ensure that the various ejector

components are in the right unit. Many ejector parts, and
8 8-4
sometimes complete stages, are physically
interchangeable.

The locking feature of disc-type coupling fasteners

8 8-17 becomes compromised when they are removed and
reinstalled a certain number of times.

It is important to verify that the thrust load of the vacuum

8 8-17 pump is not imposed on the motor thrust bearing. This
requires knowledge of the magnetic center of the motor.

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10427360
C
SJAE TERMINOLOGY

The first stage of a multi-stage SJAE system is the stage into which the vapor or gas being
compressed first enters, the second stage is that which it enters second, and so on. Figure C-1
shows the standard method of referring to each stage’s components based on their position in the
system. The last stage always has the letter Z assigned to it. The remaining stages are assigned
letters in reverse order from Z. For example, in a two-stage system, the first stage would be
labeled Y, while in a four stage, the first stage would be W. An inter-condenser is assigned the
two letters of the stages it is between. An after-condenser is assigned the combination ZA. A pre-
condenser is assigned the letter P followed by the letter for the stage following it.

C-1
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SJAE Terminology

Figure C-1
Designations for Ejector Assemblies
Source: HEI Standards for Steam Jet Vacuum Systems

C-2
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D
TRAINING SLIDES

D-1
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Training Slides

D-2
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 Training Slides

D-3
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Training Slides

D-4
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 Training Slides

D-5
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Training Slides

D-6
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 Training Slides

D-7
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10427360
E
TRANSLATED TABLE OF CONTENTS

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF

WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI).
NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY
PERSON ACTING ON BEHALF OF ANY OF THEM:

(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH
RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM
DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED
RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS
SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE, (IV) THAT ANY TRANSLATION FROM THE
ENGLISH-LANGUAGE ORIGINAL OF THIS DOCUMENT IS WITHOUT ERROR; OR

(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING
ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE HAS BEEN ADVISED OF
THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS
DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN
THIS DOCUMENT.

THE TRANSLATION OF THIS DOCUMENT FROM THE ENGLISH-LANGUAGE ORIGINAL HAS BEEN PREPARED WITH
LIMITED BUDGETARY RESOURCES BY OR ON BEHALF OF EPRI. IT IS PROVIDED FOR REFERENCE PURPOSES ONLY
AND EPRI DISCLAIMS ALL RESPONSIBILITY FOR ITS ACCURACY. THE ENGLISH-LANGUAGE ORIGINAL SHOULD BE
CONSULTED TO CROSS-CHECK TERMS AND STATEMENTS IN THE TRANSLATION.

ORGANIZATION(S) THAT PREPARED THIS DOCUMENT

Sargent & Lundy, LLC

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Translated Table of Contents

報告概要

宗旨
• 描述典型的CAR設備

• 為CAR設備的預防性維護(PM)，修理和替換以及故障檢修建議提供指導

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 Translated Table of Contents

內容

1介紹 ......................................................................................................................... 1-1

1.1目的 ....................................................................................................................... 1-1

1.2組織 ....................................................................................................................... 1-1

1.3關鍵點.................................................................................................................... 1-2

2術語表...................................................................................................................... 2-1

2.1首字母縮略詞.......................................................................................................... 2-1

2.1定義 ....................................................................................................................... 2-2

2.2.1氣結................................................................................................................ 2-2

2.2.2狀態監測 ......................................................................................................... 2-2

2.2.3氫水化學 ......................................................................................................... 2-2

2.2.4局部壓力 ......................................................................................................... 2-2

2.2.5標準立方英尺(米)每分鐘................................................................................... 2-3

2.2.6真空................................................................................................................ 2-3

3技術說明/講解 .......................................................................................................... 3-1

3.1介紹 ....................................................................................................................... 3-1

3.2 BWR廢氣系統 ........................................................................................................ 3-4

3.2.1 BWR CAR系統................................................................................................. 3-5

3.2.1.1 BWR初始的系統空氣除去(中拱)模式 ......................................................... 3-7

3.2.1.2 BWR CAR (保持)模式 ............................................................................... 3-7

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Translated Table of Contents

3.2.1.2.1帶有抽氣器SJAE的 BWR CAR系統 ....................................................... 3-7

3.2.1.2.2沒有抽氣器SJAE的 BWR CAR系統 ....................................................... 3-8

3.2.2 BWR廢氣處理系統 .......................................................................................... 3-8

3.3 PWR廢氣系統 ........................................................................................................ 3-9

3.3.1 PWR CAR系統............................................................................................... 3-10

3.3.1.1組合1 ：MVP (中拱模式) – SJAE (保持模式) ............................................ 3-10

3.3.1.2組合2 ：SJAE (中拱模式) – SJAE (保持模式) ........................................... 3-11

3.3.1.3組合3 ：MVP (中拱模式) – MVP (保持模式) ............................................. 3-12

3.3.2 PWR廢氣過濾系統......................................................................................... 3-12

4應用 ......................................................................................................................... 4-1

4.1 SJAE...................................................................................................................... 4-1

4.1.1 SJAE原理........................................................................................................ 4-1

4.1.2 SJAE系統類型 ................................................................................................. 4-2

4.1.2.2單級，多元SJAE (參見圖4-2 [b]) ............................................................... 4-2

4.1.2.3多級，單元SJAE (參見圖4-2 [c]、[d]、[f]、[g]和[h])................................… 4-3

4.1.2.4多級，多元SJAE (參見圖4-2 [e]) ............................................................... 4-3

4.1.2.5冷凝和非冷凝的類型 ................................................................................. 4-3

4.1.2.6中間冷凝器............................................................................................... 4-3

4.1.2.7二次冷疑器............................................................................................... 4-3

4.1.2.8表面中間冷凝器和二次冷疑器 .................................................................... 4-4

4.1.3 SJAE應用........................................................................................................ 4-5

4.1.3.1沸水反應堆............................................................................................... 4-5

4.1.3.2壓水堆 ..................................................................................................... 4-5

4.2旋轉螺旋MVP .......................................................................................................... 4-5

4.2.1螺旋轉子MVP................................................................................................... 4-6

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 Translated Table of Contents

4.2.1.1運行原理 .................................................................................................. 4-6

4.2.1.2應用......................................................................................................... 4-8

4.2.2單螺旋轉子MVP ............................................................................................... 4-9

4.2.2.1運行原理 .................................................................................................. 4-9

4.2.2.2應用....................................................................................................... 4-16

4.3液體環式MVP ........................................................................................................ 4-17

4.3.1液體環式MVP原理...................................................................................... 4-17

4.3.2單級液體環式MVP .......................................................................................... 4-19

4.3.2.1運行原理 ................................................................................................ 4-19

4.3.2.2中拱模式應用 ......................................................................................... 4-20

4.3.2.3保持模式應用 ......................................................................................... 4-20

4.3.2.3.1 CEU原理 ........................................................................................ 4-21

4.3.2.3.2運行原理......................................................................................... 4-21

4.3.3帶有兩級液體環式MVP的CEU .......................................................................... 4-27

4.3.3.1兩級液體環式MVP的操作 ......................................................................... 4-27

4.3.3.2 CEU運行................................................................................................ 4-30

4.3.3.2.1整體CEU運行................................................................................... 4-30

4.3.3.2.2 CEU控制 ........................................................................................ 4-31

4.4混合式CEU ........................................................................................................... 4-34

4.4.1運行原理 ....................................................................................................... 4-34

4.4.2部分負載運行 ................................................................................................ 4-34

4.4.3現有的電站中改裝過的混合系統...................................................................... 4-35

5故障資料和故障模式 .................................................................................................. 5-1

5.1 SJAE系統故障模式和機理........................................................................................ 5-1

5.1.1 SJAE真空喪失 ................................................................................................. 5-2

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5.1.2 SJAE抽氣或蒸汽供應閥門故障導致無法關閉或卡在關閉狀態 .............................. 5-3

5.1.3 SJAE蒸汽供應閥門故障導致無法打開或控制壓力 ............................................... 5-3

5.2MVP系統故障模式和機理 ......................................................................................... 5-3

5.2.1 MVP跳閘 ........................................................................................................ 5-4

5.2.2 MVP故障導致無法啟動 .................................................................................... 5-5

5.2.3 MVP性能退化.................................................................................................. 5-5

5.2.4 MVP抽氣閥門故障導致無法關閉或打開 ............................................................. 5-5

5.2.5 SOV故障......................................................................................................... 5-6

5.2.6其他考慮 ......................................................................................................... 5-6

6故障檢修................................................................................................................... 6-1

6.1 SJAE故障檢修(基於熱交換學會102號技術資料單) .................................................... 6-1

6.1.1 SJAE故障檢修難點 .......................................................................................... 6-1

6.1.2 SJAE故障檢修技術 .......................................................................................... 6-2

6.1.3 SJAE故障檢修步驟 .......................................................................................... 6-2

6.1.4 SJAE故障檢修範本 .......................................................................................... 6-3

6.2液體環式真空泵故障檢修 ......................................................................................... 6-5

6.3旋轉螺旋真空泵故障檢修 ......................................................................................... 6-7

6.3.1旋轉螺旋真空泵性能問題的故障檢修 ................................................................. 6-7

6.3.2旋轉螺旋真空泵機械問題的故障檢修 ................................................................. 6-7

6.3.2.1旋轉螺旋真空泵的振動 .............................................................................. 6-7

6.3.2.2轉子熱生長............................................................................................... 6-8

6.3.2.3旋轉螺旋真空泵檢查 ................................................................................. 6-8

6.4非針對具體設備的故障檢修指南 ............................................................................... 6-9

7狀態監測................................................................................................................... 7-1

7.1操作員輪班和外觀檢查 ............................................................................................ 7-2

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 Translated Table of Contents

7.1.1操作員輪班...................................................................................................... 7-2

7.1.2外觀檢查 ......................................................................................................... 7-2

7.2振動監測 ................................................................................................................ 7-3

7.2.1參量................................................................................................................ 7-3

7.2.1.1振幅......................................................................................................... 7-3

7.2.1.2頻率......................................................................................................... 7-3

7.2.1.3相角......................................................................................................... 7-4

7.2.1.4振動形式 .................................................................................................. 7-4

7.2.1.5振動模態和振形 ........................................................................................ 7-4

7.2.2振動分析 ......................................................................................................... 7-4

7.2.2.1振幅對頻率的分析..................................................................................... 7-5

7.2.2.2即時頻譜分析 ........................................................................................... 7-5

7.2.2.3時間波形分析 ........................................................................................... 7-6

7.2.3位移感測器...................................................................................................... 7-6

7.2.4速度感測器...................................................................................................... 7-7

7.2.5加速度感測器 .................................................................................................. 7-9

7.2.6資料獲取 ....................................................................................................... 7-10

7.3油的分析 .............................................................................................................. 7-11

7.4紅外熱像圖法........................................................................................................ 7-11

7.5電機電流分析........................................................................................................ 7-12

8預防性維護 ............................................................................................................... 8-1

8.1制定PM計畫 ............................................................................................................ 8-1

8.2進行維護的基本準則................................................................................................ 8-2

8.3 SJAE的維護建議 ..................................................................................................... 8-3

8.3.1 EPRI PM基本資料庫—SJAE ............................................................................. 8-3

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8.3.2抽氣器內部檢查 ............................................................................................... 8-3

8.3.3抽氣器備件...................................................................................................... 8-4

8.4液體環式MVP的維護建議 ......................................................................................... 8-4

8.4.1 EPRI PM基本資料庫資料表—液體環式旋轉式壓縮機和泵 .................................... 8-4

8.4.2液體環式真空泵的廠商建議 .............................................................................. 8-5

8.4.3液體環式真空泵PM行動最優化的實例研究 ......................................................... 8-6

8.5旋轉螺旋MVP的維護建議 ......................................................................................... 8-7

8.5.1 EPRI PM基本資料庫資料表—旋轉螺旋空氣壓縮機 ............................................. 8-7

8.5.2 旋轉螺旋真空泵的廠商建議 ............................................................................. 8-8

8.6部件維護 ................................................................................................................ 8-9

8.6.1軸承................................................................................................................ 8-9

8.6.1.1例行維護建議 ......................................................................................... 8-10

8.6.1.2軸承檢修 ................................................................................................ 8-11

8.6.2潤滑系統 ....................................................................................................... 8-13

8.6.2.1例行維護 ................................................................................................ 8-13

8.6.2.2迴圈潤滑油系統檢修 ............................................................................... 8-13

8.6.3接頭.............................................................................................................. 8-14

8.6.3.1例行維護建議 ......................................................................................... 8-15

8.6.3.2接頭檢修 ................................................................................................ 8-16

8.6.3.3接頭對準 ................................................................................................ 8-17

8.6.4結構性支援系統 ............................................................................................. 8-17

8.6.4.1混凝土地基............................................................................................. 8-17

8.6.4.2修理混凝土地基 ...................................................................................... 8-18

8.6.4.3表面清潔 ................................................................................................ 8-18

8.6.4.4裂縫修補 ................................................................................................ 8-18

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8.6.4.5地腳螺栓 ................................................................................................ 8-19

8.6.4.5.1影響地腳螺栓的力 ........................................................................... 8-19

8.6.4.5.2正確的安裝 ..................................................................................... 8-20

8.6.5電動機 .......................................................................................................... 8-21

8.6.5.1塵土....................................................................................................... 8-21

8.6.5.2濕氣....................................................................................................... 8-22

8.6.5.3摩擦....................................................................................................... 8-22

8.6.5.4振動....................................................................................................... 8-22

8.6.5.5轉子軸端間隙 ......................................................................................... 8-22

8.6.6電磁操縱閥門 ................................................................................................ 8-23

8.6.6.1線圈....................................................................................................... 8-24

8.6.6.2彈性體 ................................................................................................... 8-24

8.6.6.3週期性閥門迴圈 ...................................................................................... 8-25

9參考書目................................................................................................................... 9-1

A工業CAR設備的故障歷史............................................................................................ A-1

B關鍵點...................................................................................................................... B-1

C SJAE術語 ................................................................................................................ C-1

D培訓幻燈片 ............................................................................................................... D-1

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圖片目錄

圖2 1真空/絕對壓力/表壓力的關係.................................................................................. 2-4

圖3 1典型的蒸汽表面冷凝器 ........................................................................................... 3-2

圖3 2 不可凝縮氣體的除去 ............................................................................................. 3-3

圖3 3典型的BWR廢氣系統 .............................................................................................. 3-5

圖3 4帶有抽氣器SJAE的BWR CAR系統 ............................................................................ 3-6

圖3 5沒有抽氣器SJAE的BWR CAR系統 ............................................................................ 3-6

圖4 1典型的SJAE級 ........................................................................................................ 4-2

圖4 2抽氣器的普通類型.................................................................................................. 4-4

圖4 3螺旋轉子MVP......................................................................................................... 4-7

圖4 4螺旋轉子MVP的橫截面 ........................................................................................... 4-8

圖4 5單螺旋轉子MVP ................................................................................................... 4-10

圖4 6單螺旋轉子MVP的橫截面 ...................................................................................... 4-11

圖4 7級間隔板和安全閥................................................................................................ 4-12

圖4 8空流和水流示意圖................................................................................................ 4-13

圖4 9基地和儲水池示意圖 ............................................................................................ 4-15

圖4 10平面配流盤液體環式真空泵氣體壓縮迴圈............................................................. 4-18

圖4 11圓錐形配流盤液體環式真空泵氣體壓縮迴圈 ......................................................... 4-18

圖4 12液體環式真空泵的類型 ....................................................................................... 4-19

圖4 13單級液體環式CEU ............................................................................................. 4-23

圖4 14 Nash大氣噴射式空氣抽除器 ............................................................................... 4-24

圖4 15 Nash CEU (在啟動之前) .................................................................................... 4-25

圖4 16 Nash CEU (中拱) .............................................................................................. 4-26

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圖4 17 Nash CEU (保持) .............................................................................................. 4-27

圖4 18一個兩級真空泵的主要部件................................................................................. 4-28

圖4 19真空泵的高低真空操作 ....................................................................................... 4-29

圖4 20 CEU的功能運行................................................................................................. 4-33

圖4 21混合冷凝器排出的廢氣 ....................................................................................... 4-36

圖C 1抽氣器裝置的標識.................................................................................................. C-2

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表格目錄

表5 1 SJAE相關系統內的故障.......................................................................................... 5-2

表5 2 SJAE相關系統內的故障模式 ................................................................................... 5-2

表5 3 MVP相關系統內的故障 .......................................................................................... 5-4

表5 4 MVP相關系統內的故障模式.................................................................................... 5-4

表6 1多級SJAE無載吸引壓力........................................................................................... 6-2

表6 2 SJAE故障檢修矩陣 ................................................................................................ 6-4

表6 3液體環式真空泵故障檢修矩陣 ................................................................................. 6-5

表6 4軸承故障檢修矩陣.................................................................................................. 6-9

表6 5潤滑系統故障檢修矩陣 ......................................................................................... 6-10

表6 6雜訊級故障檢修矩陣 ............................................................................................ 6-11

表8 1基於EPRI PM基本資料庫資料表的SJAE PM行動 ........................................................ 8-3

表8 2基於EPRI PM基本資料庫資料表的液體環式PM活動 ................................................... 8-5

表8 3基於供應商建議的液體環式PM活動 ......................................................................... 8-5

表A 1 CAR設備故障歷史 ................................................................................................. A-2

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报告概要

宗旨
• 描述典型的CAR设备

• 为CAR设备的预防性维护(PM)，修理和替换以及故障检修建议提供指导

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内容

1介绍 ......................................................................................................................... 1-1

1.1目的 ....................................................................................................................... 1-1

1.2组织 ....................................................................................................................... 1-1

1.3关键点.................................................................................................................... 1-2

2术语表...................................................................................................................... 2-1

2.1首字母缩略词.......................................................................................................... 2-1

2.1定义 ....................................................................................................................... 2-2

2.2.1气结................................................................................................................ 2-2

2.2.2状态监测 ......................................................................................................... 2-2

2.2.3氢水化学 ......................................................................................................... 2-2

2.2.4局部压力 ......................................................................................................... 2-2

2.2.5标准立方英尺(米)每分钟................................................................................... 2-3

2.2.6真空................................................................................................................ 2-3

3技术说明/讲解 .......................................................................................................... 3-1

3.1介绍 ....................................................................................................................... 3-1

3.2 BWR废气系统 ........................................................................................................ 3-4

3.2.1 BWR CAR系统................................................................................................. 3-5

3.2.1.1 BWR初始的系统空气除去(中拱)模式 ......................................................... 3-7

3.2.1.2 BWR CAR (保持)模式 ............................................................................... 3-7

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3.2.1.2.1带有抽气器SJAE的 BWR CAR系统 ....................................................... 3-7

3.2.1.2.2没有抽气器SJAE的 BWR CAR系统 ....................................................... 3-8

3.2.2 BWR废气处理系统 .......................................................................................... 3-8

3.3 PWR废气系统 ........................................................................................................ 3-9

3.3.1 PWR CAR系统............................................................................................... 3-10

3.3.1.1组合1 ：MVP (中拱模式) – SJAE (保持模式) ............................................ 3-10

3.3.1.2组合2 ：SJAE (中拱模式) – SJAE (保持模式) ........................................... 3-11

3.3.1.3组合3 ：MVP (中拱模式) – MVP (保持模式) ............................................. 3-12

3.3.2 PWR废气过滤系统......................................................................................... 3-12

4应用 ......................................................................................................................... 4-1

4.1 SJAE...................................................................................................................... 4-1

4.1.1 SJAE原理........................................................................................................ 4-1

4.1.2 SJAE系统类型 ................................................................................................. 4-2

4.1.2.2单级，多元SJAE (参见图4-2 [b]) ............................................................... 4-2

4.1.2.3多级，单元SJAE (参见图4-2 [c]、[d]、[f]、[g]和[h])................................… 4-3

4.1.2.4多级，多元SJAE (参见图4-2 [e]) ............................................................... 4-3

4.1.2.5冷凝和非冷凝的类型 ................................................................................. 4-3

4.1.2.6中间冷凝器............................................................................................... 4-3

4.1.2.7二次冷疑器............................................................................................... 4-3

4.1.2.8表面中间冷凝器和二次冷疑器 .................................................................... 4-4

4.1.3 SJAE应用........................................................................................................ 4-5

4.1.3.1沸水反应堆............................................................................................... 4-5

4.1.3.2压水堆 ..................................................................................................... 4-5

4.2旋转螺旋MVP .......................................................................................................... 4-5

4.2.1螺旋转子MVP................................................................................................... 4-6

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4.2.1.1运行原理 .................................................................................................. 4-6

4.2.1.2应用......................................................................................................... 4-8

4.2.2单螺旋转子MVP ............................................................................................... 4-9

4.2.2.1运行原理 .................................................................................................. 4-9

4.2.2.2应用....................................................................................................... 4-16

4.3液体环式MVP ........................................................................................................ 4-17

4.3.1液体环式MVP原理...................................................................................... 4-17

4.3.2单级液体环式MVP .......................................................................................... 4-19

4.3.2.1运行原理 ................................................................................................ 4-19

4.3.2.2中拱模式应用 ......................................................................................... 4-20

4.3.2.3保持模式应用 ......................................................................................... 4-20

4.3.2.3.1 CEU原理 ........................................................................................ 4-21

4.3.2.3.2运行原理......................................................................................... 4-21

4.3.3带有两级液体环式MVP的CEU .......................................................................... 4-27

4.3.3.1两级液体环式MVP的操作 ......................................................................... 4-27

4.3.3.2 CEU运行................................................................................................ 4-30

4.3.3.2.1整体CEU运行................................................................................... 4-30

4.3.3.2.2 CEU控制 ........................................................................................ 4-31

4.4混合式CEU ........................................................................................................... 4-34

4.4.1运行原理 ....................................................................................................... 4-34

4.4.2部分负载运行 ................................................................................................ 4-34

4.4.3现有的电站中改装过的混合系统...................................................................... 4-35

5故障数据和故障模式 .................................................................................................. 5-1

5.1 SJAE系统故障模式和机理........................................................................................ 5-1

5.1.1 SJAE真空丧失 ................................................................................................. 5-2

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5.1.2 SJAE抽气或蒸汽供应阀门故障导致无法关闭或卡在关闭状态 .............................. 5-3

5.1.3 SJAE蒸汽供应阀门故障导致无法打开或控制压力 ............................................... 5-3

5.2MVP系统故障模式和机理 ......................................................................................... 5-3

5.2.1 MVP跳闸 ........................................................................................................ 5-4

5.2.2 MVP故障导致无法启动 .................................................................................... 5-5

5.2.3 MVP性能退化.................................................................................................. 5-5

5.2.4 MVP抽气阀门故障导致无法关闭或打开 ............................................................. 5-5

5.2.5 SOV故障......................................................................................................... 5-6

5.2.6其他考虑 ......................................................................................................... 5-6

6故障检修................................................................................................................... 6-1

6.1 SJAE故障检修(基于热交换学会102号技术资料单) .................................................... 6-1

6.1.1 SJAE故障检修难点 .......................................................................................... 6-1

6.1.2 SJAE故障检修技术 .......................................................................................... 6-2

6.1.3 SJAE故障检修步骤 .......................................................................................... 6-2

6.1.4 SJAE故障检修模板 .......................................................................................... 6-3

6.2液体环式真空泵故障检修 ......................................................................................... 6-5

6.3旋转螺旋真空泵故障检修 ......................................................................................... 6-7

6.3.1旋转螺旋真空泵性能问题的故障检修 ................................................................. 6-7

6.3.2旋转螺旋真空泵机械问题的故障检修 ................................................................. 6-7

6.3.2.1旋转螺旋真空泵的振动 .............................................................................. 6-7

6.3.2.2转子热生长............................................................................................... 6-8

6.3.2.3旋转螺旋真空泵检查 ................................................................................. 6-8

6.4非针对具体设备的故障检修指南 ............................................................................... 6-9

7状态监测................................................................................................................... 7-1

7.1操作员轮班和外观检查 ............................................................................................ 7-2

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7.1.1操作员轮班...................................................................................................... 7-2

7.1.2外观检查 ......................................................................................................... 7-2

7.2振动监测 ................................................................................................................ 7-3

7.2.1参量................................................................................................................ 7-3

7.2.1.1振幅......................................................................................................... 7-3

7.2.1.2频率......................................................................................................... 7-3

7.2.1.3相角......................................................................................................... 7-4

7.2.1.4振动形式 .................................................................................................. 7-4

7.2.1.5振动模态和振形 ........................................................................................ 7-4

7.2.2振动分析 ......................................................................................................... 7-4

7.2.2.1振幅对频率的分析..................................................................................... 7-5

7.2.2.2实时频谱分析 ........................................................................................... 7-5

7.2.2.3时间波形分析 ........................................................................................... 7-6

7.2.3位移传感器...................................................................................................... 7-6

7.2.4速度传感器...................................................................................................... 7-7

7.2.5加速度传感器 .................................................................................................. 7-9

7.2.6数据采集 ....................................................................................................... 7-10

7.3油的分析 .............................................................................................................. 7-11

7.4红外热像图法........................................................................................................ 7-11

7.5电机电流分析........................................................................................................ 7-12

8预防性维护 ............................................................................................................... 8-1

8.1制定PM计划 ............................................................................................................ 8-1

8.2进行维护的基本准则................................................................................................ 8-2

8.3 SJAE的维护建议 ..................................................................................................... 8-3

8.3.1 EPRI PM基本数据库—SJAE ............................................................................. 8-3

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8.3.2抽气器内部检查 ............................................................................................... 8-3

8.3.3抽气器备件...................................................................................................... 8-4

8.4液体环式MVP的维护建议 ......................................................................................... 8-4

8.4.1 EPRI PM基本数据库数据表—液体环式旋转式压缩机和泵 .................................... 8-4

8.4.2液体环式真空泵的厂商建议 .............................................................................. 8-5

8.4.3液体环式真空泵PM行动最优化的实例研究 ......................................................... 8-6

8.5旋转螺旋MVP的维护建议 ......................................................................................... 8-7

8.5.1 EPRI PM基本数据库数据表—旋转螺旋空气压缩机 ............................................. 8-7

8.5.2 旋转螺旋真空泵的厂商建议 ............................................................................. 8-8

8.6部件维护 ................................................................................................................ 8-9

8.6.1轴承................................................................................................................ 8-9

8.6.1.1例行维护建议 ......................................................................................... 8-10

8.6.1.2轴承检修 ................................................................................................ 8-11

8.6.2润滑系统 ....................................................................................................... 8-13

8.6.2.1例行维护 ................................................................................................ 8-13

8.6.2.2循环润滑油系统检修 ............................................................................... 8-13

8.6.3接头.............................................................................................................. 8-14

8.6.3.1例行维护建议 ......................................................................................... 8-15

8.6.3.2接头检修 ................................................................................................ 8-16

8.6.3.3接头对准 ................................................................................................ 8-17

8.6.4结构性支持系统 ............................................................................................. 8-17

8.6.4.1混凝土地基............................................................................................. 8-17

8.6.4.2修理混凝土地基 ...................................................................................... 8-18

8.6.4.3表面清洁 ................................................................................................ 8-18

8.6.4.4裂缝修补 ................................................................................................ 8-18

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8.6.4.5地脚螺栓 ................................................................................................ 8-19

8.6.4.5.1影响地脚螺栓的力 ........................................................................... 8-19

8.6.4.5.2正确的安装 ..................................................................................... 8-20

8.6.5电动机 .......................................................................................................... 8-21

8.6.5.1尘土....................................................................................................... 8-21

8.6.5.2湿气....................................................................................................... 8-22

8.6.5.3摩擦....................................................................................................... 8-22

8.6.5.4振动....................................................................................................... 8-22

8.6.5.5转子轴端间隙 ......................................................................................... 8-22

8.6.6电磁操纵阀门 ................................................................................................ 8-23

8.6.6.1线圈....................................................................................................... 8-24

8.6.6.2弹性体 ................................................................................................... 8-24

8.6.6.3周期性阀门循环 ...................................................................................... 8-25

9参考书目................................................................................................................... 9-1

A工业CAR设备的故障历史............................................................................................ A-1

B关键点...................................................................................................................... B-1

C SJAE术语 ................................................................................................................ C-1

D培训幻灯片 ............................................................................................................... D-1

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图片目录

图2-1真空/绝对压力/表压力的关系 .................................................................................... 2-4

图3-1典型的蒸汽表面冷凝器 ............................................................................................. 3-2

图3-2 不可凝缩气体的除去 ............................................................................................... 3-3

图3-3典型的BWR废气系统 ................................................................................................ 3-5

图3-4带有抽气器SJAE的BWR CAR系统............................................................................... 3-6

图3-5没有抽气器SJAE的BWR CAR系统............................................................................... 3-6

图4-1典型的SJAE级 .......................................................................................................... 4-2

图4-2抽气器的普通类型 .................................................................................................... 4-4

图4-3螺旋转子MVP........................................................................................................... 4-7

图4-4螺旋转子MVP的横截面 ............................................................................................. 4-8

图4-5单螺旋转子MVP ..................................................................................................... 4-10

图4-6单螺旋转子MVP的横截面 ........................................................................................ 4-11

图4-7级间隔板和安全阀 .................................................................................................. 4-12

图4-8空流和水流示意图 .................................................................................................. 4-13

图4-9基地和储水池示意图............................................................................................... 4-15

图4-10平面配流盘液体环式真空泵气体压缩循环............................................................... 4-18

图4-11圆锥形配流盘液体环式真空泵气体压缩循环 ........................................................... 4-18

图4-12液体环式真空泵的类型 ......................................................................................... 4-19

图4-13单级液体环式CEU ................................................................................................ 4-23

图4-14 Nash大气喷射式空气抽除器 ................................................................................. 4-24

图4-15 Nash CEU (在启动之前) ...................................................................................... 4-25

图4-16 Nash CEU (中拱) ................................................................................................ 4-26

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图4-17 Nash CEU (保持) ................................................................................................ 4-27

图4-18一个两级真空泵的主要部件................................................................................... 4-28

图4-19真空泵的高低真空操作 ......................................................................................... 4-29

图4-20 CEU的功能运行 ................................................................................................... 4-33

图4-21混合冷凝器排出的废气 ......................................................................................... 4-36

图C-1抽气器装置的标识.................................................................................................... C-2

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表格目录

表5-1 SJAE相关系统内的故障............................................................................................ 5-2

表5-2 SJAE相关系统内的故障模式 ..................................................................................... 5-2

表5-3 MVP相关系统内的故障 ............................................................................................ 5-4

表5-4 MVP相关系统内的故障模式...................................................................................... 5-4

表6-1多级SJAE无载吸引压力............................................................................................. 6-2

表6-2 SJAE故障检修矩阵 .................................................................................................. 6-4

表6-3液体环式真空泵故障检修矩阵 ................................................................................... 6-5

表6-4轴承故障检修矩阵 .................................................................................................... 6-9

表6-5润滑系统故障检修矩阵 ........................................................................................... 6-10

表6-6噪声级故障检修矩阵............................................................................................... 6-11

表8-1基于EPRI PM基本数据库数据表的SJAE PM行动 .......................................................... 8-3

表8-2基于EPRI PM基本数据库数据表的液体环式PM活动 ..................................................... 8-5

表8-3基于供应商建议的液体环式PM活动 ........................................................................... 8-5

表A-1 CAR设备故障历史 ................................................................................................... A-2

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RESUME DU RAPPORT

Objectifs
• Décrire les équipements typiques CAR
• Fournir un guide sur la maintenance préventive (PM), la réparation et le remplacement et des
recommandations sur le dépannage des équipements CAR

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TABLE DES MATIERES

1 INTRODUCTION ....................................................................................................................1-1
1.1 Objectif.........................................................................................................................1-1
1.2 Organisation ................................................................................................................1-1
1.3 Points clé .....................................................................................................................1-2

2 GLOSSAIRE DES TERMES ..................................................................................................2-1

2.1 Acronymes ...................................................................................................................2-1
2.1 Définitions ....................................................................................................................2-2
2.2.1 Colmatage par l'air .............................................................................................2-2
2.2.2 Contrôle des conditions.......................................................................................2-2
2.2.3 Chimie de l’eau hydrogénée ...............................................................................2-2
2.2.4 Pression partielle.................................................................................................2-2
2.2.5 Pieds cubes (mètres) par minute ........................................................................2-3
2.2.6 Vide .....................................................................................................................2-3

3 DESCRIPTION TECHNIQUE/DIDACTICIEL .........................................................................3-1

3.1 Introduction ..................................................................................................................3-1
3.2 Système des dégagements gazeux des réacteurs à eau bouillante ...........................3-4
3.2.1 Système CAR des réacteurs à eau bouillante ....................................................3-5
3.2.1.1 Mode d’élimination initiale de l'air des systèmes (arc) des réacteurs à
eau bouillante ..............................................................................................................3-7
3.2.1.2 Mode CAR (maintien) des réacteurs à eau bouillante ..................................3-7
3.2.1.2.1 Système CAR des réacteurs à eau bouillante avec amplificateur
SJAE 3-7
3.2.1.2.2 Système CAR des réacteurs à eau bouillante sans amplificateur
SJAE 3-8
3.2.2 Système de traitement des dégagements gazeux des réacteurs à eau
bouillante .........................................................................................................................3-8
3.3 Système des dégagements gazeux des REP .............................................................3-9

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3.3.1 Système CAR des REP ....................................................................................3-10

3.3.1.1 Combinaison 1 : MVP (mode d’arc) – SJAE (mode de maintien) ...............3-10
3.3.1.2 Combinaison 2 : SJAE (mode d’arc) – SJAE (mode de maintien)..............3-11
3.3.1.3 Combinaison 3 : MVP (mode d’arc) – MVP (mode de maintien) ................3-12
3.3.2 Système de filtrage des dégagements gazeux des REP .................................3-12

4 APPLICATIONS .....................................................................................................................4-1
4.1 SJAE ............................................................................................................................4-1
4.1.1 Principes fondamentaux de SJAE.......................................................................4-1
4.1.2 Types de systèmes SJAE ...................................................................................4-2
4.1.2.2 SJAE à un seul étage, à plusieurs éléments (voir Figure 4-2[b])..................4-2
4.1.2.3 SJAE à plusieurs étages, à un seul élément (voir Figure 4-2[c], [d], [f],
[g] et [h]) 4-3
4.1.2.4 SJAE à plusieurs étages, à plusieurs éléments (voir Figure 4-2[e]) .............4-3
4.1.2.5 Types avec et sans condensation.................................................................4-3
4.1.2.6 Inter-condensateurs ......................................................................................4-3
4.1.2.7 Après condensateurs ....................................................................................4-3
4.1.2.8 Surface inter-condensateurs et après condensateurs ..................................4-4
4.1.3 Applications SJAE ..............................................................................................4-5
4.1.3.1 Réacteurs à eau bouillante ...........................................................................4-5
4.1.3.2 Réacteurs à eau pressurisée ........................................................................4-5
4.2 MVP à vis rotative ........................................................................................................4-5
4.2.1 MVP à rotor en spirale ........................................................................................4-6
4.2.1.1 Principe de fonctionnement ..........................................................................4-6
4.2.1.2 Application ....................................................................................................4-8
4.2.2 MVP à rotor hélicoïdal.........................................................................................4-9
4.2.2.1 Principe de fonctionnement ..........................................................................4-9
4.2.2.2 Application ..................................................................................................4-16
4.3 MVP à anneau liquide................................................................................................4-17
4.3.1 Principes fondamentaux des MVP à anneau liquide .....................................4-17
4.3.2 MVP à un seul étage et à anneau liquide ........................................................4-19
4.3.2.1 Principe de fonctionnement ........................................................................4-19
4.3.2.2 Application du mode d’arc...........................................................................4-20
4.3.2.3 Application du mode de maintien................................................................4-20
4.3.2.3.1 Principes fondamentaux de CEU ........................................................4-21

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4.3.2.3.2 Principe de fonctionnement.................................................................4-21

4.3.3 CEU avec MVP à deux étages et à anneau liquide ..........................................4-27
4.3.3.1 Fonctionnement de la MVP à deux étages et à anneau liquide..................4-27
4.3.3.2 Fonctionnement du CEU ............................................................................4-30
4.3.3.2.1 Fonctionnement général du CEU ........................................................4-30
4.3.3.2.2 Contrôle du CEU .................................................................................4-31
4.4 CEU hybride ..............................................................................................................4-34
4.4.1 Principe de fonctionnement...............................................................................4-34
4.4.2 Fonctionnement avec charge partielle ..............................................................4-34
4.4.3 Adaptation des systèmes hybrides sur les réacteurs existants.........................4-35

5 DONNEES ET MODES DE DEFAILLANCE .........................................................................5-1

5.1 Modes et mécanismes des défaillances des systèmes SJAE ....................................5-1
5.1.1 Perte de vide de SJAE .......................................................................................5-2
5.1.2 Défaillance de la vanne SJAE d’aspiration ou d'alimentation en vapeur
fermée ou coincée en position fermée .............................................................................5-3
5.1.3 Défaillance d'ouverture ou de contrôle de la pression de la vanne SJAE
d'alimentation en vapeur...................................................................................................5-3
5.2 Modes et mécanismes des défaillances des systèmes MVP .....................................5-3
5.2.1 Déclenchements MVP ........................................................................................5-4
5.2.2 Défaillances du démarrage de MVP ..................................................................5-5
5.2.3 Détérioration du rendement de MVP ..................................................................5-5
5.2.4 Défaillance d’ouverture ou de fermeture de la vanne MVP d’aspiration .............5-5
5.2.5 Défaillances des vannes motorisées...................................................................5-6
5.2.6 Autres considérations..........................................................................................5-6

6 DEPANNAGE .........................................................................................................................6-1
6.1 Dépannage de SJAE (basé sur la fiche technique n° 102 du Heat Exchange
Institute) ................................................................................................................................6-1
6.1.1 Difficultés du dépannage de SJAE .....................................................................6-1
6.1.2 Techniques de dépannage de SJAE ..................................................................6-2
6.1.3 Procédure de dépannage SJAE .........................................................................6-2
6.1.4 Matrice de dépannage de SJAE ........................................................................6-3
6.2 Dépannage de la pompe à vide à anneau liquide........................................................6-5
6.3 Dépannage de la pompe à vide à vis rotative.............................................................6-7

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6.3.1 Dépannage des problèmes de rendement de la pompe à vide à vis

rotative 6-7
6.3.2 Dépannage des problèmes mécaniques de la pompe à vide à vis rotative ........6-7
6.3.2.1 Vibrations de la pompe à vide à vis rotative ................................................6-7
6.3.2.2 Croissance thermique du rotor......................................................................6-8
6.3.2.3 Inspections de la pompe à vide à vis rotative ..............................................6-8
6.4 Guide de dépannage non spécifique aux équipements...............................................6-9

7 CONTROLE DES CONDITIONS ............................................................................................7-1

7.1 Rondes des opérateurs et inspections visuelles externes ...........................................7-2
7.1.1 Rondes des opérateurs.......................................................................................7-2
7.1.2 Inspection visuelle externe..................................................................................7-2
7.2 Contrôle des vibrations ................................................................................................7-3
7.2.1 Paramètres..........................................................................................................7-3
7.2.1.1 Amplitude ......................................................................................................7-3
7.2.1.2 Fréquence.....................................................................................................7-3
7.2.1.3 Angle de phase .............................................................................................7-4
7.2.1.4 Forme des vibrations ...................................................................................7-4
7.2.1.5 Forme du mode de vibration ........................................................................7-4
7.2.2 Analyse des vibrations ........................................................................................7-4
7.2.2.1 Analyse de l’amplitude par rapport à la fréquence........................................7-5
7.2.2.2 Analyse du spectre en temps réel ................................................................7-5
7.2.2.3 Analyse de l’oscillogramme dans le temps ...................................................7-6
7.2.3 Sondes de proximité ...........................................................................................7-6
7.2.4 Sondes de vitesse...............................................................................................7-7
7.2.5 Sondes d’accéléromètre .....................................................................................7-9
7.2.6 Acquisition des données ...................................................................................7-10
7.3 Analyse de l’huile.......................................................................................................7-11
7.4 Thermographie infrarouge .........................................................................................7-11
7.5 Analyse du courant du moteur ...................................................................................7-12

8 MAINTENANCE PREVENTIVE .............................................................................................8-1

8.1 Développement d'un programme de maintenance préventive ....................................8-1
8.2 Règles de base de réalisation de la maintenance .......................................................8-2
8.3 Recommandations de maintenance de SJAE .............................................................8-3

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8.3.1 Base des données essentielles de maintenance préventive EPRI—SJAE ........8-3

8.3.2 Inspections internes des éjecteurs......................................................................8-3
8.3.3 Pièces de rechange des éjecteurs ......................................................................8-4
8.4 Recommandations de maintenance de MVP à anneau liquide ...................................8-4
8.4.1 Tableau des données EPRI de base de maintenance préventive—pompe
et compresseur rotatif à anneau liquide ...........................................................................8-4
8.4.2 Recommandations du fabricant de la pompe à vide à anneau liquide................8-5
8.4.3 Étude de cas pour optimiser les activités de maintenance préventive de la
pompe à vide à anneau liquide.........................................................................................8-6
8.5 Recommandations de maintenance de MVP à vis rotative .........................................8-7
8.5.1 Tableau de données EPRI de base de maintenance préventive—
Compresseur pneumatique à vis rotative .........................................................................8-7
8.5.2 Recommandations du fabricant de la pompe à vide à vis rotative......................8-8
8.6 Maintenance des composants .....................................................................................8-9
8.6.1 Roulements .........................................................................................................8-9
8.6.1.1 Recommandations des maintenances de routine.......................................8-10
8.6.1.2 Remise en état des roulements ..................................................................8-11
8.6.2 Système de lubrification ....................................................................................8-13
8.6.2.1 Maintenance de routine .............................................................................8-13
8.6.2.2 Remise en état du système d’huile de lubrification circulante ....................8-13
8.6.3 Coupleurs..........................................................................................................8-14
8.6.3.1 Recommandations des maintenance de routine.........................................8-15
8.6.3.2 Remise en état des coupleurs ....................................................................8-16
8.6.3.3 Alignement des coupleurs...........................................................................8-17
8.6.4 Système de support de la structure ..................................................................8-17
8.6.4.1 Fondations en béton ...................................................................................8-17
8.6.4.2 Préparation des fondations en béton ..........................................................8-18
8.6.4.3 Nettoyage de la surface ..............................................................................8-18
8.6.4.4 Réparation des fissures ..............................................................................8-18
8.6.4.5 Vis d'ancrage ..............................................................................................8-19
8.6.4.5.1 Forces affectant les vis d'ancrage.......................................................8-19
8.6.4.5.2 Installation correcte .............................................................................8-20
8.6.5 Moteurs électriques...........................................................................................8-21
8.6.5.1 Poussière ...................................................................................................8-21
.6.5.2 Humidité........................................................................................................8-22

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8.6.5.3 Frottement...................................................................................................8-22
8.6.5.4 Vibrations ....................................................................................................8-22
8.6.5.5 Jeu axial de l'arbre du rotor.........................................................................8-22
8.6.6 Vannes motorisées ...........................................................................................8-23
8.6.6.1 Bobines .......................................................................................................8-24
8.6.6.2 Élastomères ................................................................................................8-24
8.6.6.3 Cyclage flashes périodique des vannes .....................................................8-25

9 REFERENCES .......................................................................................................................9-1

A ANTECEDENTS DES DEFAILLANCES DES EQUIPEMENTS « CAR » DE

L'INDUSTRIE............................................................................................................................ A-1

B POINTS CLES ...................................................................................................................... B-1

C TERMINOLOGIE SJAE ....................................................................................................... C-1

D DIAPORAMA DE FORMATION ........................................................................................... D-1

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LISTE DES FIGURES

Figure 2-1 Relations Vide/Pression absolue/Pression relative ..................................................2-4

Figure 3-1 Condenseur typique de surface de vapeur...............................................................3-2
Figure 3-2 Éliminations des gaz non condensables ..................................................................3-3
Figure 3-3 Système typique des dégagements gazeux d’un réacteur à eau bouillante ............3-5
Figure 3-4 Système CAR de réacteur à eau bouillante avec amplificateur SJAE......................3-6
Figure 3-5 Système CAR de réacteur à eau bouillante sans amplificateur SJAE......................3-6
Figure 4-1 Étage SJAE typique..................................................................................................4-2
Figure 4-2 Types courants d'unités d'éjecteurs .........................................................................4-4
Figure 4-3 MVP à rotor en spirale..............................................................................................4-7
Figure 4-4 Coupe transversale de MVP à rotor en spirale.........................................................4-8
Figure 4-5 MVP à rotor hélicoïdal ............................................................................................4-10
Figure 4-6 Coupe transversale de MVP à rotor hélicoïdal .......................................................4-11
Figure 4-7 Partition inter-étages et soupape de surpression ...................................................4-12
Figure 4-8 Schéma de l'écoulement de l’air et de l'eau ...........................................................4-13
Figure 4-9 Schéma de la base et du réservoir.........................................................................4-15
Figure 4-10 Cycle de compression des gaz de la pompe à vide à anneau liquide sur la
plaque à orifices plats ......................................................................................................4-18
Figure 4-11 Cycle de compression des gaz de la pompe à vide à anneau liquide à
orifices coniques ..............................................................................................................4-18
Figure 4-12 Types de pompes à vide à anneau liquide ...........................................................4-19
Figure 4-13 CEU à anneau liquide et à un seul étage .............................................................4-23
Figure 4-14 Éjecteurs pneumatiques à jet atmosphérique Nash .............................................4-24
Figure 4-15 CEU Nash (avant démarrage) ..............................................................................4-25
Figure 4-16 CEU Nash (arc) ....................................................................................................4-26
Figure 4-17 CEU Nash (maintien)............................................................................................4-27
Figure 4-18 Principaux composants d’une pompe à vide à deux étages ................................4-28
Figure 4-19 Fonctionnement à vide bas et élevé d'une pompe à vide.....................................4-29
Figure 4-20 Exploitation fonctionnelle du CEU .......................................................................4-33
Figure 4-21 Échappement d’un condenseur hybride ...............................................................4-36
Figure C-1 Désignations des assemblages d'éjecteurs ............................................................ C-2

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LISTE DES TABLEAUX

Tableau 5-1 Défaillances dans les systèmes relatifs à SJAE ....................................................5-2

Tableau 5-2 Défaillances dans les systèmes relatifs à SJAE ....................................................5-2
Tableau 5-3 Défaillances dans les systèmes relatifs à MVP .....................................................5-4
Tableau 5-4 Modes des défaillances dans les systèmes relatifs à MVP ...................................5-4
Tableau 6-1 Pression d’aspiration sans charge de SJAE à plusieurs étages............................6-2
Tableau 6-2 Matrice de dépannage de SJAE ...........................................................................6-4
Tableau 6-3 Matrice de dépannage de la pompe à vide à anneau liquide ................................6-5
Tableau 6-4 Matrice de dépannage des roulements ................................................................6-9
Tableau 6-5 Matrice de dépannage du système de graissage ...............................................6-10
Tableau 6-6 Matrice de dépannage du niveau sonore ...........................................................6-11
Tableau 8-1 Activités de maintenance préventive de SJAE en se fondant sur le tableau
des données de la base de maintenance préventive d’EPRI.............................................8-3
Tableau 8-2 Activités de maintenance préventive des anneaux liquides fondée sur le
tableau des données de la base de maintenance préventive d’EPRI ................................8-5
Tableau 8-3 Activités de maintenance préventive des anneaux liquides fondée sur les
recommandations du fournisseur.......................................................................................8-5
Tableau A-1 Antécédentss de défaillances sur les équipements CAR .................................... A-2

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復水器空気除去機器保全ガイド

報告書の要約

目的
• 典型的な復水器空気除去機器を説明すること

• 復水器空気除去設備の予防保全（PM）、修理および交換、およびトラブルシューテ
ィングの推奨事項についてのガイドを提供すること

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目次

1 はじめに ................................................................................................................ 1-1

1.1 目的 .................................................................................................................... 1-1

1.2 構成 .................................................................................................................... 1-1

1.3 キーポイント ..................................................................................................... 1-2

2 用語集.................................................................................................................... 2-1

2.1 頭字語................................................................................................................. 2-1

2.1 定義 .................................................................................................................... 2-2

2.2.1 エアバインディング .................................................................................... 2-2

2.2.2 状態監視 ..................................................................................................... 2-2

2.2.3 水素水化学.................................................................................................. 2-2

2.2.4 分圧............................................................................................................ 2-2

2.2.5 標準流量(scfm).. (ft3/min) ........................................................................... 2-3

2.2.6 真空度 ........................................................................................................ 2-3

3 技術的説明／チュートリアル...................................................................................... 3-1

3.1 はじめに ............................................................................................................. 3-1

3.2 BWRオフガスシステム ......................................................................................... 3-4

3.2.1 BWR 復水器空気除去システム...................................................................... 3-5

3.2.1.1 BWRの初期システムエア除去（空気除去）モード ................................... 3-7

3.2.1.2 BWR 復水器空気除去（保持）モード ...................................................... 3-7

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3.2.1.2.1 ブースターSJAEを搭載したBWR 復水器空気除去システム ................ 3-7

3.2.1.2.2 ブースターSJAEを搭載しないBWR 復水器空気除去システム ............. 3-8

3.2.2 BWRオフガス処理システム .......................................................................... 3-8

3.3 PWRオフガスシステム ......................................................................................... 3-9

3.3.1 PWR 復水器空気除去システム .................................................................... 3-10

3.3.1.1 組合せ1：MVP（空気除去モード）―SJAE（保持モード）...................... 3-10

3.3.1.2 組合せ2：SJAE（空気除去モード）―SJAE（保持モード） ..................... 3-11

3.3.1.3 組合せ3：MVP（空気除去モード）―MVP（保持モード） ...................... 3-12

3.3.2 PWRオフガスフィルタシステム.................................................................. 3-12

4 適用 ......................................................................................................................... 4-1

4.1 SJAE ................................................................................................................... 4-1

4.1.1 SJAEの基本 ................................................................................................. 4-1

4.1.2 SJAEシステムの種類 .................................................................................... 4-2

4.1.2.2 一段、複数要素SJAE（図4-2[b]参照） .................................................... 4-2

4.1.2.3 複数段、単一要素SJAE（図4-2[c], [d], [f], [g], [h]参照） ........................ 4-3

4.1.2.4 複数段、複数要素SJAE（図4-2[e]参照） ................................................. 4-3

4.1.2.5 凝縮および非凝縮タイプ ........................................................................ 4-3

4.1.2.6 インターコンデンサ ............................................................................ 4-3

4.1.2.7 アフターコンデンサ ............................................................................ 4-3

4.1.2.8 表面接触型インターコンデンサ及びアフターコンデンサ ..................... 4-4

4.1.3 SJAEの適用 ................................................................................................. 4-5

4.1.3.1 BWR...................................................................................................... 4-5

4.1.3.2 PWR ...................................................................................................... 4-5

4.2 ロータリースクリューMVP (機械式真空ポンプ)..................................................... 4-5

4.2.1 スパイラルローターMVP .............................................................................. 4-6

4.2.1.1 動作理論 ............................................................................................... 4-6

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4.2.1.2 適用 ...................................................................................................... 4-8

4.2.2 ヘリカルローターMVP ................................................................................. 4-9

4.2.2.1 動作理論 ............................................................................................... 4-9

4.2.2.2 適用 .................................................................................................... 4-16

4.3 液封式MVP ........................................................................................................ 4-17

4.3.1 液封式MVPの基本 ................................................................................... 4-17

4.3.2 一段液封式MVP ......................................................................................... 4-19

4.3.2.1 動作理論 ............................................................................................. 4-19

4.3.2.2 空気除去モードの適用 ......................................................................... 4-20

4.3.2.3 保持モードの適用 ............................................................................... 4-20

4.3.2.3.1 CEU(復水器排気ユニット)の基本 ................................................... 4-21

4.3.2.3.2 動作理論 ...................................................................................... 4-21

4.3.3 二段液封式MVPを搭載したCEU................................................................... 4-27

4.3.3.1 二段液封式MVPの動作.......................................................................... 4-27

4.3.3.2 CEUの運転........................................................................................... 4-30

4.3.3.2.1 CEUの運転概要 ............................................................................. 4-30

4.3.3.2.2 CEUの制御.................................................................................... 4-31

4.4 ハイブリッドCEU............................................................................................... 4-34

4.4.1 動作原理 ................................................................................................... 4-34

4.4.2 部分負荷での運転...................................................................................... 4-34

4.4.3 ハイブリッドシステムの既存プラント適用への変更.................................... 4-35

5 故障データおよび故障モード ................................................................................... 5-1

5.1 SJAEシステムの故障モードとメカニズム .............................................................. 5-1

5.1.1 SJAEの真空破壊........................................................................................... 5-2

5.1.2 SJAE吸込又は蒸気供給弁の閉動作失敗または閉固着 ..................................... 5-3

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5.1.3 SJAE蒸気供給弁の開動作失敗または圧力制御失敗......................................... 5-3

5.2 MVPシステムの故障モードとメカニズム ............................................................... 5-3

5.2.1 MVPのトリップ ........................................................................................... 5-4

5.2.2 MVPの始動失敗 ........................................................................................... 5-5

5.2.3 MVPの性能劣化 ........................................................................................... 5-5

5.2.4 MVP吸込弁の開失敗又は閉失敗 .................................................................... 5-5

5.2.5 SOV故障...................................................................................................... 5-6

5.2.6 その他の考慮事項........................................................................................ 5-6

6 トラブルシューティング.......................................................................................... 6-1

6.1 SJAEのトラブルシューティング（熱交換器のテクニカルシート#102による）........ 6-1

6.1.1 SJAEのトラブルシューティングの難しさ ...................................................... 6-1

6.1.2 SJAEのトラブルシューティング技術............................................................. 6-2

6.1.3 SJAEのトラブルシューティング手順............................................................. 6-2

6.1.4 SJAEのトラブルシューティングマトリクス................................................... 6-3

6.2 液封真空ポンプのトラブルシューティング ........................................................... 6-5

6.3 ロータリースクリュー真空ポンプのトラブルシューティング................................. 6-7

6.3.1 ロータリースクリュー真空ポンプの性能面のトラブルシューティング ........... 6-7

6.3.2 ロータリースクリュー真空ポンプの機械部分のトラブルシューティング........ 6-7

6.3.2.1 ロータリースクリュー真空ポンプの振動................................................. 6-7

6.3.2.2 ローターの熱膨張 .................................................................................. 6-8

6.3.2.3 ロータリースクリュー真空ポンプの点検................................................. 6-8

6.4 設備を特定せずに適用可能なトラブルシューティングのガイド ............................. 6-9

7 状態監視 ................................................................................................................ 7-1

7.1 オペレータによるパトロールおよび外部の目視点検 .............................................. 7-2

7.1.1 オペレータによるパトロール ....................................................................... 7-2

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7.1.2 外部の目視点検 ........................................................................................... 7-2

7.2 振動の監視 .......................................................................................................... 7-3

7.2.1 パラメータ.................................................................................................. 7-3

7.2.1.1 振幅 ...................................................................................................... 7-3

7.2.1.2 周波数................................................................................................... 7-3

7.2.1.3 位相角................................................................................................... 7-4

7.2.1.4 振動波形 ............................................................................................... 7-4

7.2.1.5 振動モード形状 ..................................................................................... 7-4

7.2.2 振動解析 ..................................................................................................... 7-4

7.2.2.1 振幅対周波数解析 .................................................................................. 7-5

7.2.2.2 リアルタイムスペクトル解析 ................................................................. 7-5

7.2.2.3 時刻暦波形解析..................................................................................... 7-6

7.2.3 近接プローブ .............................................................................................. 7-6

7.2.4 速度プローブ .............................................................................................. 7-7

7.2.5 加速度プローブ ........................................................................................... 7-9

7.2.6 データ取得................................................................................................ 7-10

7.3 オイル解析 ........................................................................................................ 7-11

7.4 赤外線サーモグラフィ ....................................................................................... 7-11

7.5 電動機の電流解析 .............................................................................................. 7-12

8 予防保全 ................................................................................................................ 8-1

8.1 予防保全プログラムの立案................................................................................... 8-1

8.2 保全実施の基本規則............................................................................................. 8-2

8.3 SJAEの保全に関する勧告 ..................................................................................... 8-3

8.3.1 EPRIのPMデータベース―SJAE...................................................................... 8-3

8.3.2 イジェクタ内部検査 .................................................................................... 8-3

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8.3.3 イジェクタ予備部品 .................................................................................... 8-4

8.4 液封式MVPの保全に関する推奨 ............................................................................ 8-4

8.4.1 EPRIのPMデータベース表―液封ロータリーコンプレッサおよびポンプ .......... 8-4

8.4.2 液封真空ポンプメーカーの推奨.................................................................... 8-5

8.4.3 液封真空ポンプの予防保全活動の事例研究 ................................................... 8-6

8.5 ロータリースクリューMVPの保全に関する推奨 ..................................................... 8-7

8.5.1 EPRIのPMデータベース表―ロータリースクリュー式エアコンプレッサ .......... 8-7

8.5.2 ロータリースクリュー式真空ポンプメーカーの推奨...................................... 8-8

8.6 構成部品の保全 ................................................................................................... 8-9

8.6.1 軸受............................................................................................................ 8-9

8.6.1.1 日常の保全に関する推奨 ...................................................................... 8-10

8.6.1.2 軸受のオーバーホール ......................................................................... 8-11

8.6.2 潤滑系 ...................................................................................................... 8-13

8.6.2.1 日常の保全 .......................................................................................... 8-13

8.6.2.2 潤滑油循環系のオーバーホール ............................................................ 8-13

8.6.3 カプリング................................................................................................ 8-14

8.6.3.1 日常の保全に関する推奨 ...................................................................... 8-15

8.6.3.2 カプリングのオーバーホール ............................................................... 8-16

8.6.3.3 カプリングの配列 ................................................................................ 8-17

8.6.4 構造サポート ............................................................................................ 8-17

8.6.4.1 コンクリートの基礎............................................................................. 8-17

8.6.4.2 コンクリートの基礎の修理................................................................... 8-18

8.6.4.3 表面の洗浄 .......................................................................................... 8-18

8.6.4.4 クラックの修理 ................................................................................... 8-18

8.6.4.5 アンカーボルト ................................................................................... 8-19

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8.6.4.5.1 アンカーボルトに影響する応力 ..................................................... 8-19

8.6.4.5.2 正しい据付 ................................................................................... 8-20

8.6.5 電気モーター ............................................................................................ 8-21

8.6.5.1 ほこり................................................................................................. 8-21

.6.5.2 湿気 ...................................................................................................... 8-22

8.6.5.3 摩擦 .................................................................................................... 8-22

8.6.5.4 振動 .................................................................................................... 8-22

8.6.5.5 ローターシャフト端のあそび ............................................................... 8-22

8.6.6 ソレノイド作動弁...................................................................................... 8-23

8.6.6.1 コイル................................................................................................. 8-24

8.6.6.2 エラストマー ...................................................................................... 8-24

8.6.6.3 定期的な弁作動サイクル ...................................................................... 8-25

9 参考文書................................................................................................................... 9-1

A 産業界の復水器空気除去設備の故障履歴 ...................................................................A-1

B キーポイント..........................................................................................................B-1

C SJAE用語 ...............................................................................................................C-1

D トレーニングのスライド .........................................................................................D-1

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図のリスト

図2-1 真空／絶対圧／ゲージ圧力の関係 .......................................................................... 2-4

図3-1 典型的な蒸気表面復水器........................................................................................ 3-2

図3-2 非凝縮ガスの除去.................................................................................................. 3-3

図3-3 典型的なBWRオフガス系 ....................................................................................... 3-5

図3-4 ブースターSJAEを搭載したBWR 復水器空気除去システム ....................................... 3-6

図3-5 ブースターSJAEを搭載しないBWR 復水器空気除去システム.................................... 3-6

図4-1 典型的なSJAEの1段 ............................................................................................... 4-2

図4-2 一般的なイジェクタユニットの種類 ......................................................................... 4-4

図4-3 スパイラルローターMVP........................................................................................ 4-7

図4-4 スパイラルローターMVPの断面図 .......................................................................... 4-8

図4-5 ヘリカルローターMVP ......................................................................................... 4-10

図4-6 ヘリカルローターMVPの断面図............................................................................ 4-11

図4-7 各段間の仕切りおよび逃し弁 ............................................................................... 4-12

図4-8 空気および水のフロー概略図 ............................................................................... 4-13

図4-9 基礎および貯蔵タンクの概略図 ........................................................................... 4-15

図4-10 フラットポートプレート型液封真空ポンプのガス圧縮サイクル ........................... 4-18

図4-11 円錐ポート型液封真空ポンプのガス圧縮サイクル ............................................... 4-18

図4-12 液封真空ポンプの種類 ....................................................................................... 4-19

図4-13 単段液封CEU ..................................................................................................... 4-23

図4-14 Nash大気エアジェットイジェクタ...................................................................... 4-24

図4-15 Nash CEU（始動前） ......................................................................................... 4-25

図4-16 Nash CEU（空気除去） ...................................................................................... 4-26

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図4-17 Nash CEU（保持）............................................................................................. 4-27

図4-18 二段真空ポンプの主要構成部品.......................................................................... 4-28

図4-19 真空ポンプの低／高真空動作 ............................................................................. 4-29

図4-20 CEU機能操作 ..................................................................................................... 4-33

図4-21 ハイブリッド凝縮器の排気 ................................................................................ 4-36

図C-1 イジェクタアセンブリの名称................................................................................. C-2

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表のリスト

表5-1 SJAE関連系統の故障.............................................................................................. 5-2

表5-1 SJAE関連系統の故障モード.................................................................................... 5-2

表5-3 MVP関連系統の故障 .............................................................................................. 5-4

表5-4 MVP関連系統の故障モード .................................................................................... 5-4

表6-1 複数段SJAEの無負荷時吸込圧................................................................................... 6-2

表6-2 SJAEのトラブルシューティングマトリックス ......................................................... 6-4

表6-3 液封式真空ポンプのトラブルシューティングマトリックス ..................................... 6-5

表6-4 軸受のトラブルシューティングマトリックス ......................................................... 6-9

表6-5 潤滑系のトラブルシューティングマトリックス .................................................... 6-10

表6-6 騒音レベルのトラブルシューティングマトリックス ............................................. 6-11

表8-1 EPRIPMデータベースデータ表に基づくSJAEの予防保全活動.................................... 8-3

表8-2 EPRIPMデータベースデータ表に基づく液封箇所の予防保全活動 ............................. 8-5

表8-3 メーカの推奨に基づく液封箇所の予防保全活動 ...................................................... 8-5

表A-1 復水器空気除去設備の故障履歴 ............................................................................. A-2

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RESUMEN DEL INFORME

Objetivos
• Describir los equipos de extracción de aire del condensador típicos (siglas en inglés: CAR)
• Ofrecer directrices para el mantenimiento preventivo (MP), reparación y sustitución, así
como recomendaciones para la identificación y resolución de problemas en los equipos CAR

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CONTENIDO

1 INTRODUCCIÓN ....................................................................................................................1-1
1.1 Propósito......................................................................................................................1-1
1.2 Organización................................................................................................................1-1
1.3 Puntos principales .......................................................................................................1-2

2 GLOSARIO DE TÉRMINOS...................................................................................................2-1
2.1 Siglas ...........................................................................................................................2-1
2.1 Definiciones .................................................................................................................2-2
2.2.1 Arrastre de aire ...................................................................................................2-2
2.2.2 Monitorización del la condición ...........................................................................2-2
2.2.3 Química del agua hidrógeno ...............................................................................2-2
2.2.4 Presión parcial ....................................................................................................2-2
2.2.5 Pie (metro) cúbico por minuto estándar ..............................................................2-3
2.2.6 Vacío ...................................................................................................................2-3

3 TUTORIAL/DESCRIPCIÓN TÉCNICA ...................................................................................3-1

3.1 Introducción .................................................................................................................3-1
3.2 Sistema de gas de descarga en centrales BWR .........................................................3-4
3.2.1 Sistema CAR en centrales BWR.........................................................................3-5
3.2.1.1 Modo de extracción de aire (operación forzada) del sistema inicial en
centrales BWR .............................................................................................................3-7
3.2.1.2 Modo CAR (mantenimiento del vacío) en centrales BWR ............................3-7
3.2.1.2.1 Sistema CAR en centrales BWR con elevador de presión para
los eyectores de aire por chorro de vapor (siglas en inglés: SJAE)........................3-7
3.2.1.2.2 Sistema CAR en centrales BWR sin elevador de presión SJAE...........3-8
3.2.2 Sistema de tratamiento de gas de descarga en centrales BWR.........................3-8
3.3 Sistema de gas de descarga en centrales PWR .........................................................3-9
3.3.1 Sistema CAR en centrales PWR.......................................................................3-10

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3.3.1.1 Combinación 1: Bomba de vacío mecánica –siglas en inglés: MVP -

(modo de operación forzada) – SJAE (modo de mantenimiento del vacío) ..............3-10
3.3.1.2 Combinación 2: SJAE (modo de operación forzada) – SJAE (modo de
mantenimiento del vacío)...........................................................................................3-11
3.3.1.3 Combinación 3: MVP (modo de operación forzada) – MVP (modo de
mantenimiento del vacío)...........................................................................................3-12
3.3.2 Sistema de filtros de gas de descarga en centrales PWR ................................3-12

4 APLICACIONES.....................................................................................................................4-1
4.1 SJAEs ..........................................................................................................................4-1
4.1.1 Aspectos fundamentales de los SJAE ................................................................4-1
4.1.2 Tipos de sistema de SJAE ..................................................................................4-2
4.1.2.2 SJAEs de elementos múltiples, mono fase (ver figura 4-2[b]) ......................4-2
4.1.2.3 SJAEs de elemento único, multifase (ver figura 4-2[c], [d], [f], [g], y [h]) ......4-3
4.1.2.4 SJAEs de elementos múltiples, multifase (ver figura 4-2[e]) ........................4-3
4.1.2.5 Tipos con y sin condensado .........................................................................4-3
4.1.2.6 Condensadores internos (inter-condensers).................................................4-3
4.1.2.7 Condensadores posteriores (after-condensers) ...........................................4-3
4.1.2.8 Condensadores internos y posteriores de superficie....................................4-4
4.1.3 Aplicaciones de los SJAE ...................................................................................4-5
4.1.3.1 Reactores de agua en ebullición...................................................................4-5
4.1.3.2 Reactores de agua a presión........................................................................4-5
4.2 MVP de tornillo giratorio...............................................................................................4-5
4.2.1 MVP del rotor con estructura en espiral..............................................................4-6
4.2.1.1 Teoría de operación .....................................................................................4-6
4.2.1.2 Aplicación......................................................................................................4-8
4.2.2 MVP de rotor con estructura helicoidal ...............................................................4-9
4.2.2.1 Teoría de operación .....................................................................................4-9
4.2.2.2 Aplicación....................................................................................................4-16
4.3 MVP de anillo líquido .................................................................................................4-17
4.3.1 Aspectos fundamentales del MVP de anillo líquido .......................................4-17
4.3.2 MVP de anillo líquido de fase única ..................................................................4-19
4.3.2.1 Teoría de operación ...................................................................................4-19
4.3.2.2 Aplicación del modo de operación forzada .................................................4-20
4.3.2.3 Aplicación del modo de mantenimiento del vacío.......................................4-20

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4.3.2.3.1 Aspectos fundamentales de la unidad de descarga del

condensador (siglas en inglés: CEU)....................................................................4-21
4.3.2.3.2 Teoría de operación ...........................................................................4-21
4.3.3 CEU con MVP de anillo líquido de fase doble ..................................................4-27
4.3.3.1 Operación del MVP de anillo líquido de fase doble ....................................4-27
4.3.3.2 Operación del CEU .....................................................................................4-30
4.3.3.2.1 Operación general del CEU ................................................................4-30
4.3.3.2.2 Control de CEU ...................................................................................4-31
4.4 CEU híbrido ...............................................................................................................4-34
4.4.1 Principio de operación ......................................................................................4-34
4.4.2 Operación de carga parcial ...............................................................................4-34
4.4.3 Sistema híbrido de retroajuste para las centrales actuales ..............................4-35

5 DATOS SOBRE FALLOS Y MODOS DE FALLO .................................................................5-1

5.1 Mecanismos y modos de fallo del sistema SJAE ........................................................5-1
5.1.1 Pérdida de vacío del SJAE .................................................................................5-2
5.1.2 Fallo al cierre u obturación en la posición de cierre de la válvula de
alimentación de vapor o aspiración de los SJAE .............................................................5-3
5.1.3 Fallo al abrir o controlar la presión de la válvula de alimentación de vapor
o aspiración de los SJAE..................................................................................................5-3
5.2 Mecanismos y modos de fallo del sistema MVP..........................................................5-3
5.2.1 Disparos de la MVP ............................................................................................5-4
5.2.2 Fallos de arranque de la MVP.............................................................................5-5
5.2.3 Degradación en el funcionamiento de la MVP ....................................................5-5
5.2.4 Fallo al abrir o cerrar de la válvula de aspiración de la MVP ..............................5-5
5.2.5 Fallos de la válvulas de solenoide (siglas en inglés: SOV).................................5-6
5.2.6 Otras consideraciones ........................................................................................5-6

6 IDENTIFICACIÓN Y RESOLUCIÓN DE PROBLEMAS.........................................................6-1

6.1 Identificación y resolución de problemas de los SJAE (basado en la hoja 102
del Heat Exchange Institute Tech) ........................................................................................6-1
6.1.1 Dificultades en la identificación y resolución de problemas de los SJAE ...........6-1
6.1.2 Técnicas de identificación y resolución de problemas de los SJAE ...................6-2
6.1.3 Procedimiento para la identificación y resolución de problemas de los
SJAE 6-2
6.1.4 Matriz de identificación y resolución de problemas de los SJAE ........................6-3
6.2 Identificación y resolución de problemas de la bomba de vacío de anillo líquido........6-5

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6.3 Identificación y resolución de problemas de la bomba de vacío de tornillo

giratorio .................................................................................................................................6-7
6.3.1 Identificación y resolución de los problemas de funcionamiento de la
bomba de vacío de tornillo giratorio .................................................................................6-7
6.3.2 Identificación y resolución de los problemas mecánicos de la bomba de
vacío de tornillo giratorio ..................................................................................................6-7
6.3.2.1 Vibración de la bomba de vacío de tornillo giratorio .....................................6-7
6.3.2.2 Incremento térmico del rotor .........................................................................6-8
6.3.2.3 Inspecciones de la bomba de vacío de tornillo giratorio ...............................6-8
6.4 Guía de identificación y resolución de problemas no específicos de los equipos .......6-9

7 MONITORIZACIÓN DE LA CONDICIÓN ...............................................................................7-1

7.1 Inspecciones visuales externas y rondas por planta ...................................................7-2
7.1.1 Rondas por planta...............................................................................................7-2
7.1.2 Inspección visual externa....................................................................................7-2
7.2 Monitorización de la vibración......................................................................................7-3
7.2.1 Parámetros..........................................................................................................7-3
7.2.1.1 Amplitud ........................................................................................................7-3
7.2.1.2 Frecuencia ....................................................................................................7-3
7.2.1.3 Ángulo de fase ..............................................................................................7-4
7.2.1.4 Forma de vibración .......................................................................................7-4
7.2.1.5 Forma del modo de vibración .......................................................................7-4
7.2.2 Análisis de la vibración........................................................................................7-4
7.2.2.1 Comparación entre el análisis de frecuencia y amplitud...............................7-5
7.2.2.2 Análisis del espectro a tiempo real ...............................................................7-5
7.2.2.3 Análisis de la forma de la onda de tiempo ....................................................7-6
7.2.3 Sondas de proximidad ........................................................................................7-6
7.2.4 Sondas de velocidad...........................................................................................7-7
7.2.5 Sondas del acelerómetro ....................................................................................7-9
7.2.6 Adquisición de datos .........................................................................................7-10
7.3 Análisis del aceite ......................................................................................................7-11
7.4 Termografía de infrarrojos .........................................................................................7-11
7.5 Análisis de la corriente del motor...............................................................................7-12

8 MANTENIMIENTO PREVENTIVO .........................................................................................8-1

8.1 Desarrollo de un programa de MP...............................................................................8-1

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8.2 Reglas básicas para el desarrollo del mantenimiento .................................................8-2

8.3 Recomendaciones de mantenimiento de los SJAE .....................................................8-3
8.3.1 Base de datos de MP de EPRI - SJAE ...............................................................8-3
8.3.2 Inspecciones internas de los eyectores ..............................................................8-3
8.3.3 Repuestos de los eyectores................................................................................8-4
8.4 Recomendaciones de mantenimiento de la MVP de anillo líquido ..............................8-4
8.4.1 Tabla de datos de la base de datos de MP de EPRI – bomba y compresor
rotatorios de anillo líquido.................................................................................................8-4
8.4.2 Recomendaciones del fabricante de la bomba de vacío de anillo líquido ..........8-5
8.4.3 Estudio de un caso de optimización de las actividades de MP en la bomba
de vacío de anillo líquido ..................................................................................................8-6
8.5 Recomendaciones de mantenimiento de la MVP de tornillo giratorio .........................8-7
8.5.1 Tabla de datos de la base de datos de MP de EPRI – compresor de aire
de tornillo giratorio ............................................................................................................8-7
8.5.2 Recomendaciones del fabricante de la bomba de vacío de tornillo giratorio......8-8
8.6 Mantenimiento de componentes..................................................................................8-9
8.6.1 Cojinetes .............................................................................................................8-9
8.6.1.1 Recomendaciones de mantenimiento rutinario...........................................8-10
8.6.1.2 Puesta a punto de los cojinetes ..................................................................8-11
8.6.2 Sistema de lubricación ......................................................................................8-13
8.6.2.1 Mantenimiento rutinario ..............................................................................8-13
8.6.2.2 Puesta a punto del sistema de aceite de lubricación de circulación...........8-13
8.6.3 Acoplamientos...................................................................................................8-14
8.6.3.1 Recomendaciones de mantenimiento rutinario...........................................8-15
8.6.3.2 Puesta a punto de los acoplamientos .........................................................8-16
8.6.3.3 Alineación de los acoplamientos.................................................................8-17
8.6.4 Sistema de soporte estructural .........................................................................8-17
8.6.4.1 Cimientos de hormigón ...............................................................................8-17
8.6.4.2 Reparación de los cimientos de hormigón..................................................8-18
8.6.4.3 Limpieza de la superficie ............................................................................8-18
8.6.4.4 Reparación de grietas.................................................................................8-18
8.6.4.5 Pernos de anclaje .......................................................................................8-19
8.6.4.5.1 Fuerzas que afectan a los pernos de anclaje......................................8-19
8.6.4.5.2 Instalación adecuada ..........................................................................8-20
8.6.5 Motores eléctricos .............................................................................................8-21

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8.6.5.1 Suciedad .....................................................................................................8-21

.6.5.2 Humedad ......................................................................................................8-22
8.6.5.3 Fricción .......................................................................................................8-22
8.6.5.4 Vibración .....................................................................................................8-22
8.6.5.5 Juego axial del eje del rotor ........................................................................8-22
8.6.6 Válvulas de solenoide .......................................................................................8-23
8.6.6.1 Bobinas .......................................................................................................8-24
8.6.6.2 Elastómeros ................................................................................................8-24
8.6.6.3 Ciclo periódico de la válvula .......................................................................8-25

9 REFERENCIAS ......................................................................................................................9-1

A HISTÓRICO DE FALLOS EN LOS EQUIPOS CAR DE LA INDUSTRIA ............................ A-1

B PUNTOS PRINCIPALES ...................................................................................................... B-1

C TERMINOLOGÍA DE LOS SJAE.......................................................................................... C-1

D DIAPOSITIVAS DE FORMACIÓN ........................................................................................ D-1

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LISTA DE FIGURAS

Figura 2-1 Relaciones de presión de la manométrica/presión absoluta/de vacío......................2-4

Figura 3-1 Típico condensador de superficie.............................................................................3-2
Figura 3-2 Extracción del gas no condensable..........................................................................3-3
Figura 3-3 Típico sistema de gas de descarga en centrales BWR ............................................3-5
Figura 3-4 Sistema CAR en centrales BWR con elevador de presión de SJAE........................3-6
Figura 3-5 Sistemas CAR en centrales BWR sin elevador de presión de SJAE .......................3-6
Figura 4-1 Etapa típica de los SJAE ..........................................................................................4-2
Figura 4-2 Tipos comunes de unidades de eyección ................................................................4-4
Figura 4-3 MVP del rotor con estructura en espiral ...................................................................4-7
Figura 4-4 Sección transversal de la MVP del rotor con estructura en espiral .........................4-8
Figura 4-5 MVP del rotor helicoidal..........................................................................................4-10
Figura 4-6 Sección transversal de la MVP del rotor helicoidal ................................................4-11
Figura 4-7 Válvula de alivio y partición intermedia ..................................................................4-12
Figura 4-8 Diagrama esquemático del caudal de agua y aire .................................................4-13
Figura 4-9 Diagrama esquemático de la base y el depósito....................................................4-15
Figura 4-10 Ciclo de compresión del gas de la bomba de vacío de anillo líquido de la
placa de puerto plano.......................................................................................................4-18
Figura 4-11 Ciclo de compresión del gas de la bomba de vacío de anillo líquido de la
placa de puerto cónico .....................................................................................................4-18
Figura 4-12 Tipos de bombas de vacío de anillo líquido .........................................................4-19
Figura 4-13 CEU de anillo líquido de fase única......................................................................4-23
Figura 4-14 Eyector de aire atmosférico Nash ........................................................................4-24
Figura 4-15 CEU Nash (antes de arrancar) .............................................................................4-25
Figura 4-16 CEU Nash (operación forzada) ............................................................................4-26
Figura 4-17 CEU Nash (mantenimiento del vacío) ..................................................................4-27
Figura 4-18 Componentes principales de una bomba de vacío de dos etapas .......................4-28
Figura 4-19 Operación de vacío alta y baja de la bomba de vacío..........................................4-29
Figura 4-20 Operación funcional de la CEU ............................................................................4-33
Figura 4-21 Descarga del condensador híbrido.......................................................................4-36
Figura C-1 Denominaciones de los conjuntos de eyectores..................................................... C-2

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LISTA DE TABLAS

Tabla 5-1 Fallos de los sistemas relacionados con el SJAE .....................................................5-2

Tabla 5-2 Modos de fallo de los sistemas relacionados con el SJAE........................................5-2
Tabla 5-3 Fallos de los sistemas relacionados con la MVP.......................................................5-4
Tabla 5-4 Modos de fallo de los sistemas relacionados con la MVP .........................................5-4
Tabla 6-1 Presión de aspiración sin carga de los SJAE multifase.............................................6-2
Tabla 6-2 Matriz de identificación y resolución de problemas de los SJAE...............................6-4
Tabla 6-3 Matriz de identificación y resolución de problemas de la bomba de vacío de
anillo líquido .......................................................................................................................6-5
Tabla 6-4 Matriz de identificación y resolución de problemas de los cojinetes..........................6-9
Tabla 6-5 Matriz de identificación y resolución de problemas del sistema de lubricación .......6-10
Tabla 6-6 Matriz de identificación y resolución de problemas de nivel de ruido ......................6-11
Tabla 8-1 Actividades de MP en los SJAE basadas en la tabla de datos de la base de
datos de MP de EPRI.........................................................................................................8-3
Tabla 8-2 Actividades de MP en los anillos líquidos basadas en la tabla de datos de la
base de datos de MP de EPRI ...........................................................................................8-5
Tabla 8-3 Actividades de MP en los anillos líquidos basadas en las recomendaciones
del suministrador................................................................................................................8-5
Tabla A-1 Histórico de fallos de los equipos CAR .................................................................... A-2

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