Exe k nSMNuclear

Steam Dryer DesignTechnical Meeting

April 25 - 27, 2005

1

Agenda Exe kn MNuclear

* Introduction* Flow-Induced Vibration (FIV)* New Dryer 50.59 Evaluation* New Dryer Analyses

- Design Process Overview- Steam Dryer Load Definition- Benchmarking Update- Finite Element and Stress Analyses- Dryer Load Analysis - Load Cases- Hammer Test Results

* Dryer Instrumentation* Startup Test Plan* Operational Plans for Quad Cities Unit 2 (QC2) and Basis* Operational Plans for QC1 and Basis* Revised Commitments for Extended Power Uprate (EPU) Operation

2

Exe In..N ucl ear

Introduction

Jim MeisterVice President - Nuclear Services

3

Exektbn..Nuclear

FIV

Chuck AlguireEngineering Supervisor

Quad Cities Nuclear Power Station

4

Exelon Actions Exe lI¢n,.Nuclear

* Exelon established a comprehensive action planwhich included three teams to identify actions toprevent future EPU failures- Steam Dryer Team- EPU Vulnerability Team- Vibration Team

5

ResultsVibration General Assessment Exekrn.

N ucl ear* Evaluations concluded that all components are acceptable

as originally designed for full-cycle operation at full EPUthermal power with the following exceptions:- ERV susceptibility to vibration at QC required upgrades of

vulnerable parts- Target Rock Safety/Relief Valves (S/RVs) showed vibration wear

degradation at both Dresden (DR) and QC

* The team identified additional recommendations forenhancements in testing, monitoring, and refueling outageinspections- An example is confirmatory vibration testing of Limitorque and

Namco limit switches (completed successfully)

6

QC EPU Vibration AssessmentVibration Summary - October 2004 xe tn..

Nuclear* Validate preventive maintenance (PM) scope and

frequency for all evaluated components- Electromatic Relief Valve (ERV) PM changes already implemented

* Replace ERV actuator parts for both DR and QC duringfuture rebuilds

* Inspect ERV actuator internals each refueling outage untilperformance is validated

* Perform focused walkdowns during each refueling outage* Inspect minimum of one Main Steam Isolation Valve (MSIV)

internally each refueling outage until satisfactoryperformance is demonstrated

* Install upgraded Target Rock S/RVs

7

QC EPU Vibration AssessmentOpen Items from October 2004 xe tbnlm

Nuclear

* Perform detailed walkdowns* Install upgrades on ERV actuators* Finalize and install upgrade on Target Rock S/RV

pilot valve* Install new steam dryers

8

QC EPU Vibration AssessmentActions Completed Since October 2004 xe (5n..

N ucl ear

Actuator components upgraded on all ERVs(Inconel X750 bushings/guide rods and chamferedsprings)- QC2 upgraded in Spring 2004 refueling outage- QC1 upgraded in Spring 2005 refueling outage- Will inspect QC2 actuators during the planned

outage scheduled to begin on May 9, 2005

9

QC EPU Vibration AssessmentActions Completed Since October 2004 (cont.) LXe unfm

NuclearTarget Rock S/RV bellows cap/setpoint spring upgrade- Electrolyzed bellows cap, 0.001 5" minimum- Setpoint spring straightness within 0.02"- Coil perpendicularity within 0.03" top/bottom- No measurable cap wear after 24 hour shaker table test

(simulates one operating cycle at EPU)- Installed on QC1 during Spring 2005 refueling outage- Install on QC2 during planned outage scheduled to

begin on May 9, 2005

10

QC EPU Vibration AssessmentActions Completed Since October 2004 (cont.) Exe kn .

Nuclear

* QC1 Spring 2005 walkdown results

* New steam dryersQC2 during planned outage scheduled to beginMay 9, 2005

-QC1 during planned outage scheduled for May2005

1 1

Exe ksnSMNuclear

New Dryer 50.59 Evaluation

Roger HeynDesign Engineer

Quad Cities Nuclear Power Station

12

New Dryer 50.59 Evaluation Exek(n,.Nuclear

* Significant changes evaluated in 50.59- Dryer design loads- Increased dryer weight- Reduced pressure drop across dryer- Displacement of steam/water mass by metal mass

* Dryer design loads- Impact on structural integrity of dryer

* Increased dryer weight- Negligible impact on reactor internals seismic analyses- Impacts support bracket loading (meets Code requirements)

13

New Dryer 50.59 Evaluation (cont.) Exek6n.Nuclear

* Reduced pressure drop- Impacts transient and accident pressure distribution- Negligible impact on reactor level measurement- No change in main steam line (MSL) maximum break flow

* Displacement of steam/water mass by metal mass- Impacts transient thermal limits (0.01 Operating Limit Minimum

Critical Power Ratio increase)

* Safety Evaluation Report in support of the new steam dryer- Report will summarize cycle-independent analyses and evaluations

14

New Dryer 50.59 Evaluation (cont.) Exek6n.mNuclear

Analyses and evaluations contained in Replacement SteamDryer Analysis Report for QC1 and QC2- Reactor Internal Pressure Differences (RIPD)

* Steam dryer normal conditions* Steam dryer upset conditions* Other internal components normal and upset conditions* Steam dryer faulted conditions* Other internal components faulted conditions

- Seismic evaluation- Structural assessment- Anticipated Operational Occurrence evaluations- Stability evaluation- Appendix R evaluation- Anticipated Transients Without Scram

15

New Dryer 50.59 Evaluation (cont.) Exek6n..Nuclear

* Loss of Coolant Accident evaluation* MSL Break Accident evaluation* Water level instrumentation evaluation

- Setpoint analytical bases- Channel A / Channel B mismatch

* Other system evaluations- Reactor heat balance- Reactor Recirculation System- Three bundle average quality limit- Other systems and evaluations not adversely affected

16

New Dryer 50.59 Evaluation (cont.) Exe kn.SNuclear

* Conclusions based upon analyses that have beencompleted or are final draft- no significant impacts identified (i.e., more than minimal

increase)

17

QC2 New Dryer Load Definition* New Dryer Loads for QC2 Plant Data (0 - 200 Hz)

- QC2 Full Scale Pressure Data at EPU (11.24 Mlbs/Hr)* 4 Venturi Pressure Gauges

* 2 Water Reference Legs

* 1 Strain Gauge ("B" MSL)

- Analytically Inserted the New Dryer Shape into the HemholtzSolver

- New Dryer In-Plant Loads* 0 - 100 Hz - Venturi and Water Ref. Leg Pressure Transducer

* 100 - 200 Hz "B" MSL Strain Gauge (Phased to Maximize)

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ExekOnsmNuclear

Benchmarking Update

Keith MoserAsset Management Engineer

1

Benchmarking ACMLoad Definition Methodology Exe krnSM

Nuclear

XGEN FEA Benchmark Against Dryer DamageOriginal Dryer Pre-EPU - Borderline

2003 Repaired Dryer EPU - Damage Predicted

SMTQC1 ACM

2

XGEN FEA Benchmark ExekI on.Nuclear

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2003 Modified Dryer QC2 EPUCDI Acoustic Circuit

3

Exelon Steam Dome Benchmark Exek n SM

Comparison of Results for Data Point 21:

First Benchmark (No Annular Seal in CDI Model) - Data Point M21:

Nuclear

Raw Data M21 CD

mean(zf) = 3.70093x 10 n mea

Stdev(zf) = 22.06467 StdW

ma(zf) = 71.23197 maA

mitizf) = -86.15166 min

Plot of Filter SMT data (Red) compared to CDI predicted data (Blue) -First Benchmark Data Point M21

I Predicted Data M21

n(zfl) = 1.46813x 10 1

,v(zfl) = 20.146

(zfl) = 70.63575

(zfl) = -81.85192

Plot of Filter SMT data (Red) compared to CDI predicted data (Blue) -First Benchmark Data Point M21

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5

Exelon Benchmark with MSL Exekr)ns.Nuclear

* Exelon requested additionalSMT runs during the VYbenchmarking effort- Flow rate 144 CFM Approx

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- 8 pressures measured on MSL* Down stream of RPV nozzle* Up stream of S/RVs

- SMT of original dryerconfiguration

* Only 8 microphone data on MSLprovided to CDI

* CDI used AC to predictpressures measured on steamdryer at 21 locations

* Locations analyzed to date- M1, M12, and M21

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Exelon Benchmark with MSL Exe k n,.Nuclear

* Preliminary results- Two predictions provided

* First prediction incorporated transition cone into the Hemholtz Solution forthe steam dome

* Second prediction truncated transition cone at steam dome to water interfaceand increased dampening

TransducersMlM12M21

Prediction 127.841.725.3

Measured17.419.115.9

Prediction 215.826.412.4

RMS (pa)

7

Exelon Benchmark with MSL Exe kn 5.Nuclear

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8

Exelon Benchmark with MSL Exek(5ns,Nuclear

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9

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Exelon Benchmark with MSL Exe kn M

Nuclear11 10,.1.826904xlO,

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10

Benchmarking ACMLoad Definition Methodology (cont.) Exe kn..

Nuclearki ,.,. t.,.iS.

Bench mark'-kof ACM with' MSL

Strain Gauges

; Benchmarkof ACM with In-Vessel

Dryer Pressure-Transducers

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11

Exek(5n.mNuclear

Startup Test Plan

Brian StrubDesign Engineer

Quad Cities Nuclear Power Station

12

QC2 Startup Test Strategy Exe ItjnSM,-qudlea-r

/ Validate, \/ Loads and \

Design withIn-vessel

\ ~Data /

Strain GaugesNormalized to highest

Stress location & ASMEFatigue Curve B

Pressure TraFrequeiAmplit

of Design Lo

nsducersncyidead Cases

k_��

Startup Test PlanApproach

Nuclear* Power will be raised to OLTP level over a 3.5-day period

- Data will be taken at 33 Test Conditions (TCs) to this point- Three levels of Acceptance Criteria evaluated at each power level:

* Plant Equipment Acceptance Limits: Normal alarm points orestablished equipment operating limitations based upon historicalperformance data

* Level 2 Criteria: Not necessarily alter plant operation or test plan butwill initiate an Issue Report (IR)

* Level 1 Criteria: Initiate an IR and seek immediate resolution; repeattest portion to verify Level 1 can be satisfied; documented resolutionwithin the test procedure (Examples: dryer strain gauges and moisturecarryover)

- Will have Acceptance Criteria for dryer measurements (Go/No-Godecision)

* Will then raise to EPU power level over 29-hour period(TCs 34-41)

14

Startup Test PlanApproach (cont.) Exe k n .

NuclearQC2 MAY 2005 PLANNED OUTAGE STARTUP POWER ASCENSION

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15

Startup Test PlanApproach (cont.) Exek(5n.

NuclearPlanned data measurements- 42 dryer sensors recorded on GE data acquisition system (DAS)- 3 reactor steam dome pressure sensors and 4 pressure

measurements at the MSL flow venturis recorded on high speedrecorders

- 4 control valve positions recorded on high speed recorder- 56 strain gauges on MSLs in drywell/heater bay recorded on DAS- 33 accelerometers on MSLs in drywell recorded on tape drives- System equipment parameters recorded by computer points and by

Operator rounds (approximately 1 000 data points)- Hand held measurements for vibration levels and local temperatures

16

Startup Test Plan E loDryer Acceptance

NuclearThe dryer will have four Acceptance Criteria:

- Criterion A - Dryer strain gauges indicate that the peak dryer stresslevels have reached ASME Fatigue Curve "B" (16,500 psi)

- Criterion B - Dryer strain gauges indicate that the peak dryer stresslevels have reached 10,800 psi for outside dryer components, or13,600 psi for inside dryer components

- Criterion C - Six pressure gauges on the steam dryer (actual plantpressure data) will be compared to two load case frequencies andamplitudes; load cases are the SMT and QC2 data from poweraccession to EPU power levels in August 2004

- Criterion D - If less than the minimum number of strain gauges arefunctioning, then accelerometer criteria will be used as a backup

17

Startup Test PlanDryer Acceptance (cont.) Exek(5ns.

Nuclear* Criterion C will be implemented above 2511 MWt and whe

the strain gauges reach 50% of Criterion A* In addition, strain gauge and accelerometer results will be

trended during power ascension based on direct readingsand FFT analysis

* Moisture carryover will be sampled and trended during theapproach to full power; the dryer design criterion of 0.1%will be a Level 1 Criterion

n

18

Exe kbn.MNuclear

Startup Test Plan Update

Keith MoserAsset Management Engineer

19

Startup Test Plan Update Exek(nnmNuclear

Incorporated comments from NRC meeting April 11 - 13,2005, into startup plan- Trending strain gauge from previous power levels

* Direct reading* FFT

- Trending accelerometers* Direct reading* FFT

- Added Level D acceptance criteria for accelerometers in the eventthat strain gauges fail

20

Applying Acceptance Criteria Exe In..Nuclear

Yes/ Pressure \> + 30% Amplitude> + 20 Frequency

No T

No Yes

I Yes

YespP

.I.

6 No

Continue Test 21

Exe k nSMNuclear

Operational Plans for QC2and Basis

Roman GesiorDirector - Asset Management

22

QC2 Operational Plan Exekrn.Nuclear

Shutdown for QC2 dryer replacement outage on May 9,2005- Outage duration expected to be 10 days- Upgrade Target Rock S/RVs- Replace dryer- Install dryer instrumentation, cabling, and data acquisition system

(DAS)- Install steam line strain gauges- Confirm instrumentation operation prior to restart

23

QC2 Operational Plan (cont.) Exe InMNuclear

* Execute Startup Test Plan- Expect to be at full pre-EPU power (2511 MWt) - May 21- Expect to reach full EPU power (2957 MWt or 930 MWe) - May 23

* Operate at this level 5 - 8 hours to collect data- Return to 912 MWe - May 24- Confirm acoustic circuit analysis results demonstrate reasonable

loads- Confirm dryer qualification through FEA of instrumented dryer

pressure gauge information* Operate remainder of cycle at 912 MWe

* Within any limitations identified during startup test- Continue to monitor strain gauge data throughout the cycle as

thermal power increases due to environmental factors to confirmdryer stress is bound by predictions

24

QC2 Operational Plan Basis Exe kbni.Nuclear

Rigorous steam dryer qualification provides confidence inintegrity at EPU operation- Design philosophy that minimizes FIV susceptibility- Diverse loads applied to conservatively bound uncertainty

* QC1 SMT* QC2 In-plant loads

- Diverse and comprehensive FEMs conservatively bound analysisuncertainty

* Solid models* Weld evaluations

- Load frequency sensitivity analysis to address model uncertainties* Each model run with nominal and +/- 10% shift in time step

- Hammer test reduces uncertainty in as-built dryer frequency anddamping

25

QC2 Operational Plan Basis (cont.) Exekrns.Nuclear

Startup test plan- Instrumented dryer data to confirm analysis load inputs

(e.g., frequency and amplitude)- Dryer strain gauge data to confirm stress levels remain

bounded by predictions- MSL strain gauges will be used to confirm acoustic

circuit loads are reasonable- Dryer data will be trended to address unexpected

change in key monitored parameters (e.g., pressure andstrain)

- If Criteria A are exceeded, power will be reduced

26

QC2 Operational Plan Basis (cont.) Exek6n.Nuclear

* Startup test plan (cont.)- Monitoring of reactor parameters for timely identification

of issues- Other plant equipment will also be monitored to identify

adverse conditions (e.g., ERVs, Target Rock S/RV, BMSL, B MSIV, High Pressure Coolant Injection (HPCI)valve actuator)

- Moisture carryover

27

QC2 Operational Plan Basis (cont.) Exek6n..Nuclear

* Conclusions- Conservative design- Extensive evaluations- Detailed startup test plan

* Exelon has taken the necessary steps for safeEPU operation of QC2

28

Exe kn .Nuclear

Operational Plans for QC1and Bases

Roman GesiorDirector - Asset Management

29

QC1 Operational Plan ExeOns.Nuclear

* Outage to replace steam dryer expected last week of May2005- Outage duration expect to be -6 days

* Expect to execute a startup test plan similar to QC2 withoutdryer instrumentation- Power ascension to 912 MWe- No dryer instrumentation installed- MSL strain gauges will be installed to confirm, using acoustic circuit

analysis, that dryer loads remain reasonable

* Power operation for remainder of cycle at 912 MWe if nolimitations identified during startup test or from QC2instrumented dryer results

30

QC1 Operational Plan Basis Exe InSMNuclear

dryer qualification is equally as robust as QC2* QC1* Same design as QC2* No evidence that QC1 loads are greater than QC2* SMT loads obtained with QC1 configuration* MSL strain gauge data will be acquired

- Acoustic circuit analysis will be performed to confirmdryer loads are consistent with those used in FEA

- Acoustic circuit analysis method will be evaluated duringstartup testing of QC2

31

Exe k5n..Nuclear

Summary of Commitmentsfor EPU Operation

Patrick SimpsonManager - Licensing

32

Regulatory Commitments - QC2 ExeI6n.mNuclear

After dryer replacement, operation at EPU power levels will continuewhile detailed evaluations of the instrumented data are performed, if theStartup Test Plan acceptance criteria (i.e., go/no-go decision) are met- If the detailed evaluations are not completed within 60 days of data

collection at 930 MWe, power will be reduced to OLTP until the evaluationsare completed

* EGC will obtain NRC approval for long-term EPU operation of QC2* EGC will conduct daily monitoring of MCO and other key reactor and

plant parameters while operating at full power- If indications of dryer damage or structural integrity concerns are identified,

power will be reduced to OLTP and the issue will be evaluated inaccordance with the corrective action process

* During the Spring 2006 refueling outage for QC2:- EGC will perform a general visual inspection of the RPV internals, steam,

and feedwater systems, including inspection and disassembly if needed ofthe most susceptible components, which include ERVs

- EGC will conduct an inspection of the QC2 dryer using BWRVIP inspectionguidance

33

Regulatory Commitments - QC1 ExekOn.mNuclear

* After dryer replacement, operation at EPU power levels will continuewhile detailed evaluations of the QC2 instrumented data are performed- If the QC2 detailed evaluations are not completed within 60 days of data

collection at 930 MWe, QC1 power will be reduced to OLTP until theevaluations are completed

* EGC will obtain NRC approval for long-term EPU operation of QC1* EGC will conduct daily monitoring of MCO and other key reactor and

plant parameters while operating at full power- If indications of dryer damage or structural integrity concerns are identified,

power will be reduced to OLTP and the issue will be evaluated inaccordance with the corrective action process

* During the Spring 2007 refueling outage for QC1, EGC will conduct aninspection of the QC1 dryer using BWRVIP inspection guidance

34

Regulatory Commitments - DNPS Exekrn.Nuclear

* EGC will conduct daily monitoring of MCO and other key reactor andplant parameters while operating at full power- If indications of dryer damage or structural integrity concerns are identified,

power will be reduced to OLTP and the issue will be evaluated inaccordance with the corrective action process

* During the Fall 2005 refueling outage for D2:- EGC will perform a general visual inspection of the RPV internals, steam,

and feedwater systems, including inspection and disassembly if needed ofthe most susceptible components, which include ERVs

- EGC will conduct an inspection of the D2 dryer using BWRVIP inspectionguidance

* Results will be evaluated, considering the analytical work done to date, todetermine appropriate action for D3

* Evaluation results and plans for D3 (e.g., potential need for mid-cycle outage)will be shared with the NRC within one month of completion of the Fall 2005refueling outage for D2

- EGC will attempt to locate and retrieve the lost D2 feedwater sample probe

35

Regulatory Commitments Exek(nNuclear

EGC will evaluate the AC model using the MSL strain gauge datawithout bias from the QC2 instrumented dryer test data, and takeappropriate action in response to the application of the test results tothe DNPS dryers. EGC will share the predicted QC2 dryer loads basedon the AC model using the MSL strain gauge data with the NRC forcomparison to the actual QC2 loads obtained from the instrumenteddryer. EGC will meet with the NRC technical staff in late June 2005 todiscuss:- Results of the collected QC2 instrumented dryer data evaluations,- Results of SMT of the QC1 steam dryer, and- The decision and its basis regarding SMT of the D2 and D3 dryers.

* EGC will meet with NRC management in mid-July 2005 to present andsummarize the information above as it applies to operation of D2 andD3 at EPU conditions

36