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ADVANCED MATERIALS for PUMP SEALS COMPANY WIDE CW-127520-CONF-001 Revision 0 Conference Paper CONFERENCE PAPER - ADVANCED MATERIALS FOR PUMP SEALS COMPANY WIDE CW-127520-CONF-001 Revision 0 Prepared by Rédigé par Reviewed by Vérifié par Approved by Approuvé par 2013/02/13 2013/02/13 UNRESTRICTED ILLIMITÉ Atomic Energy of Énergie Atomique du Canada Limited Canada Limitée Chalk River, Ontario Chalk River (Ontario) Canada K0J 1J0 Canada K0J 1J0 CW-127520-CONF-001 Proceedings of the 2012 20th International Conference on Nuclear Engineering collocated with the ASME 2012 Power Conference ICONE20-POWER2012 July 30-August 3, 2012, Anaheim, California, USA ICONE20POWER2012-54685 ADVANCED MATERIALS FOR PUMP SEALS Timothy Sykes Marc Pinault Atomic Energy of Canada Limited Atomic Energy of Canada Limited Chalk River, Ontario, Canada Chalk River, Ontario, Canada Austin Jackson Nick Potvin Robby Baidwan Atomic Energy of Canada Atomic Energy of Canada Atomic Energy of Canada Limited Limited Limited Chalk River, Ontario, Canada Chalk River, Ontario, Canada Chalk River, Ontario, Canada next outage or, in the worst case, causing a forced outage of Abstract the reactor [1]. The effectiveness and durability of high performance pump Work is underway within the Fluid Sealing Technology seals in the broad range of conditions in which they operate is Branch at AECL’s Chalk River Laboratories to both better often limited by the behaviour of the materials from which understand the mechanism causing failures such as seal components have been designed and manufactured. degradation of nickel-bound cemented tungsten-carbide seal Aging management of active components, such as pumps and faces and to assess the performance of alternative seal face valves, requires a better understanding of the behaviours of materials for these applications. these materials in dynamic conditions in order to extend component life and to reduce losses associated with A suite of erosion and wear tests have been performed on a sub-component failures, such as those associated with seals. diverse range of carbon-graphite composites and ceramic seal Pump seal designs employ several types of materials, two of face material combinations, which includes the following: which have behaviours that are not well understood at their Steady-state wear tests at aggressive limits: carbon-graphite composites and wear-resistant pressure-velocity conditions, ceramics. An ongoing research program is underway at Accelerated wear-rate tests at low hydraulic pressure, AECL’s Chalk River Laboratories to both better understand Erosion tests at typical hot standby conditions, and the behaviour and assess the performance of new seal face Highly accelerated wear tests at dry-running materials, which have been developed using advanced conditions. technologies. This paper presents the results of this work. Introduction Seal Face Materials Mechanical seals are used in the pumps of a broad range of nuclear power plants systems. The mechanical pump seal This phase of the advanced materials test program required industry has been challenged to extend the service life and that AECL consider commercially-available seal face reliability of these seals such that they are replaced less materials—both the commonly used materials and the latest frequently and only at planned outages. A material commonly materials that have been produced using advanced used for rotors in mechanical seals is nickel-bound cemented technologies. Criteria such as mechanical properties and tungsten carbide. Although this material has performed well corrosion resistance were then used to select a subset of under some of the conditions in which it operates, it has also materials for comparative testing. caused repeated failures in other conditions. Failure Stator Materials investigations have shown that selective dissolution of the nickel binder weakens the tungsten carbide matrix leading to Several factors were considered when selecting the stator erosive wear of the rotor and ensuing high leak rates, materials for the test program - mechanical properties such as ultimately requiring replacement of the mechanical seal at the elastic modulus, thermal conductivity, and flexural strength as 1 Copyright © 2012 by ASME well as other characteristics such as dimensional stability, wear resistance, porosity and chemical composition. Carbon Graphite Potential stator materials were selected based upon a comparison of their properties to a specific grade of Raw Material carbon-graphite, which is referred to here as the reference Petroleum coke, pitch coke, carbon stator material. The strengths and weaknesses of this material, black, or graphite are mixed in based upon its performance in nuclear power plant pump seals specific quantities. over the last two decades and results of laboratory testing, Powder Formation were analyzed and documented, and collectively they provide The materials are crushed, milled a baseline of what constitutes an excellent stator material. and sieved until the grain structure is as required. Relative to this reference material, an excellent candidate material should have equal or higher elastic modulus, flexural Binder Addition strength, compressive strength and thermal conductivity, and Petroleum based pitch is added at an equal or lower thermal expansion coefficient. It would also elevated temperatures. have an equal or greater amount of graphite, to provide good wear resistance due to the high lubricity provided by graphite. Milling Four candidate stator materials were selected for comparative The mixture is milled into the testing against the reference material by applying these criteria desired grain size. to a list of commercially-available stator materials. The actual names of these materials have not been used in this paper Homogenizing because their test results, which are reported later, are The powder with binder is processed to ensure the mixture is protected intellectual property. However, code names have homogenous throughout. been assigned to each of the materials to allow the results of the test program to be reported here. These code names are summarized below: Compaction The powder is then pressed by one Stator-Ref: This is the reference stator material of the following techniques. against which the four candidate materials are compared. Isostatic Molding Die Molding This method presses the material in This method presses the material Material-S1 to Material-S4: These are the four all directions and is used for from two directions and is used for candidate stator materials. complex shapes in lower quantities. simple parts in large quanitities. The exact processes used to produce the carbon graphite stator materials that were tested are proprietary. Baking However, Figure 1 shows a typical set of processes for Heated in furnace at 1000°C to 1200°C. Pyrolysis converts binder these materials [2]. into carbon, which binds material. Impregnation Optional Carbonization Synthetic resin enters the porous Slowly Heated in furnace; 800°C to structure created by pyrolysis of the 1300°C. Pyrolysis converts binder. impregnant into carbon. Final Machining The components are machined to their final dimensions using conventional techniques. Special Treatments Some components are top coated with specific polymers to decrease water absorption. Figure 1: Production Process for Carbon-Graphite 2 Copyright © 2012 by ASME Rotor Materials After the sintering process, the component is final machined to Candidate rotor materials were selected for their mechanical its required dimensions [3]. and physical properties—strength, modulus of elasticity, Silicon Carbides thermal properties (conductivity and expansion coefficient) The silicon carbide family can be further divided into two and corrosion resistance. Chemical composition and forming sub-families—reaction-bonded silicon carbides and techniques were also investigated to better understand the pressure-less sintered silicon carbides. influence of these factors on physical properties and corrosion resistance. Reaction Bonded Silicon Carbides The properties of the candidate materials were compared to a The production process for reaction bonded silicon carbide specific grade of tungsten carbide, which is referred to here as starts with the creation of a single-phase silicon carbide the reference material. Similar to the reference stator material, powder (α-SiC). There are several known methods to create the strengths and weaknesses of this material provide a this powder. The simplest method is known as the Acheson baseline of what constitutes an excellent rotor material. process, whereby high-purity quartz sand, plus graphite or coal However, as discussed earlier, the susceptibility of the are electrically-heated in a resistance furnace between 1600°C reference rotor material—a specific grade of tungsten and 2400°C for about 36 hours. After cooling, the high-purity silicon carbide is separated and further processed into the carbide—to nickel leaching excluded it as a candidate for a required size fraction by crushing, milling, and sieving. The new rotor material. α-SiC is then milled to the sub-micron size and graphite flakes Ten candidate rotor materials from four material and polymer binders are then added to the silicon carbide families - tungsten carbide, silicon carbide, silicon nitride and powder. By heating this mixture under a vacuum, pyrolysis aluminum oxide—were selected for comparative testing converts the polymer binder into additional carbon. The against the reference material by applying these criteria to a mixture is then sintered
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