CASE HISTORY

Shaft Crack
Detection Methodology for Reactor
Coolant & Recirculation Pumps
D uring the normal operation of Reactor Recirculation Pumps (RRPs) and Reactor Coolant Pumps (RCPs),
the rotors are subjected to stresses. Depending upon the magnitude of the summation of forces and
the accompanying induced stresses, the fatigue limit of the material may be exceeded. Failures may occur
due to high- or low-cycle fatigue. Material failures will result in the initiation of a shaft crack, with a crack
potentially propagating sufficiently to cause total failure of the rotor. This article discusses the vibration
symptoms that indicate the presence of a cracked rotor and the required monitoring system for early detec-
tion. It includes a brief case history with field-acquired vibration data from an RRP operating under shaft
crack conditions, where the unit was successfully removed from service prior to a total shaft failure.

Typical Sources of Operating Forces F = (K * H * D2 * B2) / 2.31

F is the radial thrust force, in pounds
Unbalance forces
H is the pump head, in feet
Hydraulic forcesradial sideloads
D2 is the impeller diameter, in inches
Torsional forces
B2 is the impeller overall width, in inches
Longitudinal bending
K is a constant, which varies with pump specific speed
Misalignment
and flow rate
Temperature gradients* K varies from 0.01 to 0.12 at Best Efficiency Point (BEP)
*Significant alternating thermal gradients occur in RRPs where
the cooled stuffing box fluid mixes with the hot Reactor Coolant When the pump is operated significantly above or
System (RCS) fluid.
below the design flow (BEP), as occurs at startup in BWR
One of the key contributing forces acting on the impeller plants, the radial thrust force can become a large side
and rotor is the hydraulic side load force or radial thrust load force, K 0.4. This typically causes fully alternat-
force. The magnitude and direction of this force is ing bending stress in the rotor as shown in Figure 1.
dependent upon the design of the volute casing and the The radial thrust force, in combination with impeller
current flow rate versus the design flow. Radial thrust vane interaction forces, may introduce sufficient stress
force is described as follows: levels to facilitate propagation of thermally initiated
cracks and lead to fatigue failure of the rotor.

Ronald Bosmans
Global Machinery Diagnostics Services Manager
Optimization and Control Services
GE Energy

38 O R B IT Vo l.26 N o.3 2006

 CASE HISTORY

Figure 1 Radial sideload causes cyclical Stress Equations

bending stress in pump shaft.

T he governing stress equations for mechanical loads,

resulting from operating forces, are as follows:
Nominal stress equations (solid shaft)

Bending stress
b = (4 * M) / ( * r3)

Axial Stress
a = F / ( * r2)

Torsional stress
= (2 * T) / ( * r3)

Combined stress intensity

= [(a+b)2 + 4 * 2 ]0.5 * Stress Concentration Factors

Figure 2 Types of cracks leading to shaft failure and their frequency.

Transverse Frequent

Tensile Less Frequent

Less Frequent
Torsional except in final stage
of transverse break

Longitudinal - Rareusually arrested

unless mechanical loads
Thermally Induced
turn longitundinal cracks
circumferentially

Symmetric Rare

Vo l . 26 N o. 3 2006 ORBI T 39
CASE HISTORY
Shaft Crack Symptoms
S haft cracks introduce a reduction in the cross-sec-
tional area of the rotor and a subsequent reduction
in the stiffness of the rotor. This also causes an asym-
metry of the stiffness properties of the rotor in the radial
direction. The rotors deflection (bending), in response to
operational forces (unbalance, hydraulic, misalignment,
etc.), will begin to increase as the crack continues to
propagate. This will increase the synchronous (1X) vibra-
tion component. In addition, the stiffness asymmetry
will also manifest in an increase in the 2X vibration
component. The propagation of a crack around the
shaft circumference and radially inward is a very
non-linear mechanism. Therefore, vibration changes
may be gradual over time, but also may indicate erratic
changes over time.
Shaft Crack Indicators
1X vibration behavior
An increase in the synchronous (1X) vibration levels
1X increases may be gradual over time, but are often
step changes as the crack grows
Continuous 1X phase changes that may be gradual over
time, but also may be very erratic with step changes
Note 1: 1X vector data must be compensated for measurement
run out errors.
Typical Vibration Plots
Figure 3 Full Spectrum plot.
40 O R B IT Vo l.26 N o.3 2006
2X vibration behavior
An increase in the 2X vibration over time
2X vibration is caused by the asymmetry of the rotor
as the crack propagates.
Radial side load or radial thrust increases the amount
of observed 2X vibration.
Based upon acquired field data and experimental lab
studies, the 2X vibration is typically detectable after
the crack has penetrated to 2030% of the cross-sec-
tional area of the rotor. 2X phase changes will occur
over time. They may be gradual or step changes.
Note 2: 2X may indicate rapid changes of amplitude and phase
if the pump speed is the frequency of any resonance.
Vibration Plots for Shaft Crack Detection
Steady state data
Trend plots of 1X and 2X amplitude and phase angle
Full Spectrum plots Waterfall
Orbits and Timebase plots
Polar plots versus time with Acceptance Region
alarming
Transient data startup or shutdown
Bode and Polar plots
Orbits and Timebase plots 1X, 2X, Direct
Full Spectrum Cascade plots
 CASE HISTORY

Figure 4 Full Spectrum Cascade plot.

Figure 5 Bode plot of the 1X vibration.

Figure 6 Bode plot of the 2X vibration.

Vo l . 26 N o. 3 2006 ORBI T 41
CASE HISTORY

The transient data is one of the key indicators of the presence of a crack and its severity. As the pump shaft weakens
due to a propagating crack, the frequency of the balance resonance (critical speed) also decreases. The amount of
change (decrease) can be used to estimate the severity of the propagation of the crack. The natural resonance of a
rotor system is determined by the following equation:
res= (K/M) 0.5

K = dynamic stiffness matrix

M = modal mass matrix

Since the mass properties of the pump are not increasing, any decrease in the resonant frequency must be associated
with a loss of stiffness. The change in frequency can be determined from the Bode (Figure 7) and Polar plots obtained
during startup or shutdown.

Figure 7 Bode plot reduced resonance frequency.

Normal Frequency

Frequency Reduced

The Polar plot format is extremely useful to observe the vector changes (1X and 2X) that may occur during normal
(crack-free) operation versus operating with a cracked rotor. The domain of vectors during normal operation can be
quantified, and limits of amplitude and phase deviation or change can be identified. This domain is referred to as an
Acceptance Region. Vector movement outside the Acceptance Region can initiate an alarm notification (Figure 8).

42 O R B IT Vo l.26 N o.3 2006

 CASE HISTORY

Figure 8 Acceptance Region Polar plot showing

Monitoring Systems
rapid changes during shaft crack event.

POINT: Vertical / 0
MACHINE: Recirc Pump
1X UNCOMP
A typical monitoring system is shown in Figure 9.
The monitoring system consists of measurement
transducers, vibration protection monitors, and a
From 23NOV2005 14:58:46.1 To 23NOV2005 14:58:50.1 Start

0
computer-based data acquisition system. The monitors
perform the dual function of providing the Alert and
Danger setpoints that can activate relay functions to
alert operators to problems. The relay functions can
also be integrated into a shutdown logic control system.
Acceptance Region
In addition, the monitors convert the analog vibration
270
signals into digital signals for post-processing in the
90
data acquisition system.

Transducers

Proximity transducers observing the pump and motor

rotors must be utilized to provide the necessary data
to detect the presence of a shaft crack. Due to design
180
and the RCPs and RRPs radiation environment, instal-
lation of proximity transducers at the internal bearing

Figure 9 Typical monitoring system.

Vibration Protection
Monitors

Computer-based Data
Acquisition System

X, Y Proximity
Transducer Signals
RRP or RCP

Vo l . 26 N o. 3 2006 ORBI T 43
CASE HISTORY

area of the pump is not possible. Two transducers are

transient data
required, mounted orthogonal (XY) at each plane of
measurement. The measurement plane for the pump
rotor should observe the lower coupling hub or the
exposed pump shaft. Proximity probes should also be
located at the upper and lower motor radial bearings.
is one of the key
indicators of
Two proximity transducers observing the thrust collar
should also be utilized for axial position and dynamic
vibrations in both the pump and the motor. Seismic
(velocity) transducers mounted on the upper and lower
the presense of
motor bearing housings can also be used for additional
data. A Keyphasor transducer must also be installed at a crack and its
the coupling area to provide speed and phase data.

severity.
Vibration Protection Monitors

The monitors should be rack-mounted and provide con-

tinuous (24/7) monitoring and protection of the motor
and pump. They can be simple radial vibration monitors
or monitors that also include programmable setpoint

and alarming criteria (e.g., monitors able to provide
hardware alarms if the 1X or 2X vectors [amplitude or
phase] violate Acceptance Regions for normal opera-
tion). Since cracked shaft behavior invariably produces
changes in the 1X and 2X behavior, monitors that can
recognize aberrant behavior and provide alarming are
highly desirable.

Computer-based Data Acquisition System

In order to observe changes of the pump behavior

over time, a computer-based data acquisition system
is necessary. The system can present plots indicating
trend value changes, Orbit changes, vibration frequency
changes, and 1X and 2X vector changes. The system
must be capable of capturing the dynamic data during
startups and shutdowns. This data capture supports
the use of Bode and Polar plots as well as Full Spectrum
Cascade plots.

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 CASE HISTORY

Figure 10 Trend les.

Case History Reactor Recirculation

Pump with a Shaft Crack

Figure 11 Polar plot historical trend. T he following data was acquired from an RRP
operating with a cracked rotor. Figure 10 is
a trend file that indicates an increase in the 1X
3

amplitude over time. Unfortunately, phase data

2
was not shown on this display. Figure 11 is a Polar
plot that displays the erratic behavior of the 1X
amplitude and phase. 2X amplitude and phase
1 data was not measured during this time period.
However, dynamic vibration data was captured
0 and is displayed in Orbit form in Figure 12. The
-3 -2 -1 1 2 3

0
presence of the internal loop in the Orbit path is
the result of a 2X vibration component. Over time,
-1
the 1X and 2X amplitude increased and the phase
angle was also changing. Of particular interest was
-2
the 180 change of the 2X phase angle. In Figure
12, the location of the 2X vibration loop begins
-3
at the six oclock position and ultimately shifts to
3 mils pp Full Scale the 12 oclock position. This is a 180 phase shift
over time. The amplitude of the 2X vibration also
increased and decreased during the 180 phase
shift. This is a classic resonance type response. A
resonance frequency, initially greater than twice
the operating speed of the pump, decreased in fre-
quency due to the decrease in dynamic stiffness
of the rotor. This resonance was excited by the 2X
rotor vibration.
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 CASE HISTORY

Figure 12 Shaft Orbits.

time

Although the compensated vibration amplitudes were at low levels, the vibration symptoms indicated the strong
possibility of a rotor crack. The decision was made to remove the pump from service and perform an inspection.
Disassembly of the pump and inspection of the rotor did reveal the presence of a crack. The crack initially was propa-
gating longitudinally along the rotor, but then turned into a transverse crack. The transverse crack was propagating
around the circumference and radially inward (Figures 13 and 14).

Shaft cracks, if left unabated, can

lead to total pump shaft failureand
significant lost revenue can result
from production downtime.

46 O R B IT Vo l.26 N o.3 2006
 CASE HISTORY

Summary

S haft cracks, if left unabated, can lead to total pump

shaft failure. In addition to the expense of the
rotor replacement, significant collateral damage to the
pump assembly and internals may occur. The resulting
unplanned outage time can significantly impact
reliability and availability metrics, and significant lost
revenue can result from production downtime. Whereas
an effective monitoring system does not prevent a
shaft crack event, early detection can mitigate the
consequences of a total shaft failure. Computer-based
Longitudinal Crack systems can provide the necessary information, and,
in conjunction with a diagnostic methodology focused
Figure 13 Crack initiation location. on early detection of shaft crack behavior, catastrophic
consequences can be avoided.
Editors Note: Ronald Bosmans retired from GE Energy in
October 2006. This article was originally prepared for, and
presented at, the EPRI Predictive Maintenance Users Group,
Transverse Crack Vibration Forum in Annapolis, Maryland, July 2006.

Longitudinal Crack

Figure 14 Longitudinal and transverse cracks.

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