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In a nuclear power plant, one of the most important systems for both safety and performance is the reactor cooling system. The cooling system is generally driven by one or more very large centrifugal pumps. Most reactor coolant pumps utilize a multi-stage mechanical face seal system for fluid containment. As a result, these seal systems are critical to safe, continued operation of a nuclear reactor. Without adequate sealing, loss of coolant volume can occur, and a reactor may be forced to shut down, costing the operating utility significantly until it can be brought online again. The main advantage of mechanical face seals is their self-adjusting properties. These seals are tuned so that they automatically adjust to varying fluid conditions to provide adequate leakage control. Because of the enormous pressures, complicated water chemistry, and possible large temperature transients, the mechanical seals inside a reactor coolant pump must be some of the most robust seals available. In addition, their long service life and continuous operation demand durability and the capability to adjust to a wide range of conditions. However, over time, wear, chemical deposition, or changing operating conditions can alter the face gap, which is the critical geometry between the sealing faces of a seal. An altered face gap can lead to undesirable conditions of too much or not enough leakage, which must be maintained within a certain range to provide lubrication and cooling to the seal faces without resulting in uncontrolled coolant volume loss. Nuclear power plants operate within strict leakage ranges, and long-term effects causing undesirable leakage can eventually necessitate a reactor shutdown if the seal cannot self-adjust to control the leakage. This document will examine possible causes of undesirable leakage rates in a commonly-used reactor coolant pump assembly. These causes will be examined to determine the conditions which promote them, the physical explanation for their effect on the operation of a mechanical seal, and possible methods of mitigation of both the cause and its effect. These findings are based on previous publications by utilities and technical and incident reports from reactor stations which detail actual incidents of abnormal seal performance and their root causes as determined by the utilities. Next, a method of increasing the ability of a mechanical seal to adapt to a wider range of conditions will be proposed. This method involves modifying an existing seal face to include a method of active control. This active control focuses on deliberately deforming one face of the mechanical sealing face pair. This deformation alters the face gap in order to make the fluid conditions inside the face gap more preferable, generating more or less leakage as desired. Two methods of actuation, hydraulic pressure and piezoelectric deformation, will be proposed. Finally, a model of the actively controlled seal faces will be introduced. This model includes a method of numerically solving the Reynolds equation to determine the fluid mechanics that drive the lubrication problem in the seal face and coupling the solution with a deformation analysis in a finite element model of a seal face. The model solves iteratively until a converged solution of a sealed pressure distribution, a resulting face deformation, and a calculated leakage rate is reached. The model includes a study of the effects of induced deformation in the seal via both hydraulic and piezoelectric actuation and the ability of this deformation to control the leakage rate.
Reactor Coolant Pumps (RCPs) of various types are used to circulate the primary coolant through the reactor in most reactor designs. RCPs generally contain mechanical seals to limit the leakage of pressurized reactor coolant along the pump drive shaft into the containment. The relatively large number of RCP seal and seal auxiliary system failures experienced at US operating plants during the 1970's and early 1980's raised concerns from the US Nuclear Regulatory Commission (NRC) that gross failures may lead to reactor core uncovery and subsequent core damage. Some seal failure events resulted in a loss of primary coolant to the containment at flow rates greater than the normal makeup capacity of Pressurized Water Reactor (PWR) plants. This is an example of RCP seal failures resulting in a small Loss of Coolant Accident (LOCA). This paper discusses observed and potential causes of RCP seal failure and the recommendations for limiting the likelihood of a seal induced small LOCA. Issues arising out of the research supporting these recommendations and subsequent public comments by the utility industry on them, serve as lessons learned, which are applicable to the design of new reactor plants.
Mechanical Seals, Third Edition is a source of practical information on the design and use of mechanical seals. Topics range from design fundamentals and test rigs to leakage, wear, friction and power, reliability, and special designs. This text is comprised of nine chapters; the first of which gives a general overview of seals, including various types of seals and their applications. Attention then turns to the fundamentals of seal design, with emphasis on six requirements that must be considered: sealing effectiveness, length of life, reliability, power consumption, space requirements, and cost effectiveness. The next chapter is devoted to test rigs used to establish the effect of the various seal parameters on the behavior of face seals. Special test rigs used to establish leakage, wear, friction losses, and temperature distributions for various material combinations, rubbing speeds, pressures, fluid media, and temperatures are highlighted. The following chapters explain primary leakage through the seal gap between the faces of the seals; factors that contribute to seal wear; friction and power of a mechanical seal; relationship of leakage to wear and friction of a balanced face seal; and importance of seal reliability and operating safety. The final chapter explores particularly interesting sealing problems together with the use of special accessories such as heat exchangers; magnetic and cyclone separators; and techniques such as cooling and auxiliary circulation. This book will be useful to mechanical engineers as well as seal designers and seal users.
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