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'* I- e Inter-Office Memorandum*.

.

Date. September 14, 1979 F -

2M Serv 5ce-Subject TMI #2 Waste Gas System Comp . .aor '

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w 0 L - f> - / /.3 -

/ %9rd M /W7.To D. B. JENKINS Locahon Rea ng

On August 24, 1979. three failed parts from a waste gas system atTMI #2 were received for analysis and assigned lab number 56735. The.

parts consisted of the lobe (head), rotor (impeller), and cone (Figures1, 2 and 3). Two possible reasons for their failure which was advancedat that time were (1) the existence of possible casting defects in thelobe which acted as sites for erosion and created unbalanced hydraulicforces, and (2) pressure perturbations that may have resulted when theinlet pressure control valve was closed to ensure a vacuum on the wastegas header. Material specifications were Mil Spec B16576 for the lobeand rotor and Mil Spec B16444A for the cone. The first is an 88Cu'-8Sn-4Zncasting alloy while the second is an 85Cu-SSn-5Pb-5Zn casting alloy.

Visual Examination

The lobe had metal loss in areas on its inside surface near the .

unloader slots. This metal loss appeared to be the result of erosion andhad thinned the labe wall to a point where continued erosion and fluidflow had deformed two areas outward (Figure 4). No evidence of cavitationexisted on the lobe.

The rotor had suffered heavy mechanical damage as well as cavitation.Several blades were completely missing (Figure 5) while almost all bladeswere cracked at their juncture to the upper and lower plates, with thecracks emanating from the inner radius (Figure 16). Heavy mechanicaldeftreation was present on the leading edges of all blades and also on afew trailing edges. Cavitation damage was present along the leading edge.

The cone had what appdared to be cavitation damage at the two outletports near the apex of the coue ( igure 7). No damage was observed onthe larger inlet ports.

.

Lab Investigation fh}h 233*

The rotor was examip d 'irst. A wedge shaped section was cut fromthe rotor and f rom this section, a blade tha was cracked for three-quartersof its length was cut so that the crack surface was available for scanningelectron microscopy. The fracture surface was found to be rubbed slightlybut what appeared to be fatigue striations were observed on the fracturesurface (Figure 8). No evidence of intergranular cracking was found. Thecavitation region at the inner radius showed the porous topography typicalof cavitation (Figure 9). Energy dispersive X-ray qualysis of the fracturesurface revealed no foreign contaminants but it. should be noted .that allparts had been cleaned during decontamination. A metallographic sectionthrough one blade was then prepared for optical microscopy. Heavy mechanicaldamage was present on the leading edge as evidenced by deformation of grainsand slip lines observed (Figure 10).

GPU Servce Corporation is a subsidary of General Pubhc Ut:1. ties Corporaton-

e

-. ..y , ,

D. B. JE:: KINS -2- *

September 14, 1979-.

.

Lab Investination (continued)

The cone was examined next. A metallographic section containing acavitated reg.on showed a surface that was typical of that resulting from3

cavitation.

A cross section of the lobe through the small perforation and anadjacent eroded are sas prepared for optical microscopy (Figure 11). Heavydeformation typic of solid particle erosion was present on the I.D. surfacesof the regions exomined (Figure 12). No evidence of pre-existing castingdefects were found.

Energy dispersive x-ray analysis of the bulk metal of the lobe, rotor,and cone revealed energy spectrums consistent with the specifications. Thelobe and rotor were found to consist of copper, tin and zinc. The coneconsisted of copper, tin, lead and zinc.

Microhardness readings were found to be inaccurate on these samples;therefore, Brinell hardness values using a 500 Kg load were used. Theaverage hardness for the cone, lobe, and rotor were 57.0, 59.5 and 64.0respectively. Typical hardness values for 85Cu-SSn-SPb-5Zn castings are54-67 while those for 88Cu-8Sn-4Zn are 68-72. The hardness values recordedfor the rotor and lobe are below typical but it should be noted that hardnessmeasurements are not required in the specifications.

Discussion.

railure of the compressor resulted from cavitation, most likely occurringfrom pressure, perturbations due to the inlet pressure control valve beingclosed. The resulting pressure variations created regions of low pressure inthi ch gas bubbles formed and regions of high pressure in which they collapsed,

. casuing cavitation. It was not possible to determine whether cavitationoccurred first in the rotor or cone. The damage to the lobe resulted fromcrosion by cavitated particles and fragments of the rotor blades. The fatiguecracking of the blades was probably caused by impingement of cavitated part'iclesand flow imbalances.

Conclusions1]1Q }}4

1. Failure of the compressor resulted from cavitation. The cavitac!onoccurred because pressure perturbations resulted when the inlet pressure,y

control valve was closed to maintain a vacuum on the waste gas header.

2. Impingement of cavitated particles and flow imbalances producedfatigue cracking of the rotor blades.

3. Erosion of the lobe occurred by cavitated particles entrained inthe fluid flow.

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