Pump & Motor Services

Playbook

When it comes to the heart of your motor, you need reliability. This utility called on AREVA to do a fleetwide replacement of its stators. Why? The utility had already lost approximately $20M in reactor coolant pump (RCP) motor failures. Our stators reduce power consumption and are built for the life of the plant. And none of our 220+ RCP motors have ever experienced an electrical failure. The amount of revenue the utility has lost due to RCP motor failures since our stators were installed? Zero.

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Challenge: Stator aging Solution: Replacement stator Benefits: Improved reliability; reduced electrical losses

How important is it for a rotor shaft and flywheel to fit? Critical. During site-performed disassembly, this rotor shaft was damaged — affecting the critical fit between the rotor shaft and flywheel. An unstable fit creates the risk of pump vibration — which could lead to a plant shutdown. The solution? Manual welding, machining, nickel plating, and grinding. The fit was restored without the cost of replacing the rotor — or shutting down the plant.

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Challenge: Shaft damage Solution: GTAW weld buildup, nickel plate Benefits: Save cost and time over rotor replacement; restores critical fit

Two housings destroyed in service. No replacements available. Only 10 days left in the outage. Panic? No. The housings were expedited to the Pump & Motor Service Center (P&MSC) and precision machined and welded to the original specs (.001” tolerance) — and the outage was not even extended one day.

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Challenge: Housings damaged Solution: Weld and machine Benefits: Reduced cost; quick response; no outage extension

Everything old can be new again. Putting in a brand new stator costs more money — and produces more contaminated waste — than remanufacturing your current stator. Our remanufacturing process reduces the operating temperatures of your stator — increasing insulation life and saving money on power consumption. And we increase the longevity of your stator over a standard industry-supplied rewind.

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Challenge: Stator wear & tear Solution: Stator rewind Benefits: Reduces operating temperature; reduces cost vs. new stator

How low can we go? With our AREVA-designed shielded foreign material exclusion (FME) plug, we can provide a low-dose environment for our machinists while maintaining triple-seal protection against foreign material incursion into the primary system. When this plant had a leak through the pump to the casing joint in the primary system, we were able to fix it using our low-dose environment for in-situ machining. The result? No leakage. Original specs restored to the pump. And low dose.

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Challenge: Primary system leakage Solution: In-situ machining Benefits: Restores to original specifications; eliminates leakage

When you need to replace a shaft, it often means you need to replace the impeller, right? Not necessarily. You don’t want to replace the impeller when you already know how the old one will perform. With our match machining capabilities, we can match a new shaft to the old impeller — so when you start up your pump there are no surprises.

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Challenge: Shaft wear Solution: Replacement shaft Benefits: Reuse impeller; economical repair; less risk of RCP vibration

A plant is down with RCP seal failures. With no time to waste, an expert team of 14 AREVA technicians is mobilized and in containment within 24 hours of notification. And within merely four shifts, the seals were replaced — saving the customer from a lengthy forced outage and minimizing loss of revenue.

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Challenge: RCP seal failure Solution: Mobilized field technicians Benefits: Rapid deployment; rapid repair; saves money

Would you turn back time if you could? How about for your plant rotors? We can restore your rotor to its original operating condition without the addition of materials used as fillers. A “good as new” rotor saves money and man-hours by avoiding costly and time-consuming manual tack-weld repair.

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Challenge: Loose laminations Solution: Custom tool compresses core Benefit: Avoids new rotor expense; restores rotor to original condition

From the moment of start-up, this plant was plagued by an oil leak issue. Thirty-three years later, one new stator, a redesigned oil lift system and a brand new oil enclosure — designed, fabricated and installed by AREVA — and the leak was fixed. Top that off with a level one coating of safety-related paint performed at the P&MSC, and concerns about meeting Appendix R Fire Protection requirements — gone.

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Challenge: Wear and tear Solution: Re-engineering and refurbishment Benefits: Support all OEMs; designed, fabricated, and installed by AREVA

Pump vibration threatens to shut down the plant. Plant decides to replace RCP internals to solve the issue. Within eight hours, AREVA has a vibration specialist and pump advisor on site. The result? Inspection and vibration modeling pinpointed a problem with the RCP motor bearing. No pump internals replacements were needed and 15 days of forced outage time were saved.

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Challenge: RCP vibration Solution: Vibration specialist deployment Benefits: Direct on-station inspection; avoid unnecessary outage time

Even though this plant had RCP internal spare parts, they were unusable because of high contamination levels. After decontamination, an inspection revealed that only the shaft, radial bearing, bolting, impeller and coupling needed to be replaced. The RCP was repaired and reassembled, built to original design specs and ready for installation before the next outage. The rest of the spare parts were refurbished and re-used — a solution that was approximately 40% of the cost of a new pump.

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Challenge: Unusable spare parts Solution: Decon and repair Benefits: Refurbish to original specs; extensive cost savings

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The data contained herein are solely for your information and are not to be construed as a warranty or other contractual obligation. ©2010 AREVA Inc. All rights reserved. ANP:U-330-V1-10-ENG

AREVA in North America (AREVA Inc.) combines U.S. and Canadian leadership to supply high addedvalue products and services to support the operation of the nuclear fleet. Globally, AREVA is present throughout the entire nuclear cycle, from uranium mining to used fuel recycling, including nuclear reactor design and operating services. AREVA is recognized by utilities around the world for its expertise, its skills in cutting-edge technologies, and its dedication to the highest level of safety. Through partnerships, the company is active in the renewable energy sector. AREVA’s 4,300 employees in North America are helping build tomorrow’s energy model: supplying ever safer, cleaner and more economical energy to the greatest number of people.

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For more information, contact your VP, Key Accounts: 3315 Old Forest Road, Lynchburg, VA 24501 Tel: 434 832 2723 – Fax: 434 832 3840 – [email protected] – www.us.areva.com