Agenda One Day Course Focused on Plant Testing June 28...

053 2011 P2EP Agenda

Agenda

One Day Course Focused on Plant Testing June 28, 2011

Denver, Colorado

Tuesday, June 28 7:15 a.m. Breakfast (provided by EPRI) East Entrance (Lower Level)

8:00 a.m. – 5:00 p.m.

One Day Course Focused on Plant Testing

Thermal Performance Data Validation and Uncertainty Thermal Plant Testing Overview-1: Turbine Testing Thermal Plant Testing Overview-2: Turbine Testing

Procedure Thermal Plant Testing Overview: Exercise – Calculate

Turbine Test Results Cooling Tower Testing /Monitoring Cooling Tower Test Exercise

Frank Todd and Greg Alder, True North Consulting, LLC

Spruce Room


Agenda EPRI PE / P2EP Annual Meeting

June 29-30, 2011 Denver, Colorado

Purpose of Meeting:

Facilitator:

Informal meeting of thermal performance engineers to focus on the issues of nuclear power plant thermal performance.

EPRI-Plant Engineering

Agenda Topics - Day 1: June 29 (Wednesday) EPRI PE / P2EP Annual Meeting (Closed Door Session)

7:15 a.m. Breakfast (Provided by EPRI) East Entrance (Lower Level)

8:15 a.m. Welcome

A brief review of P2EP and meeting format

Jerry Kernaghan, EPRI-P2EP Project Manager

8:30 a.m. P2EP Web Navigation & Cvent Program Discussion

A brief overview of the PE Web Site/P2EP Web page and Cvent Program.

Beth McRimmon, EPRI-PE

9:00 a.m. Introductions

Each participant provides a brief introduction (Name, Company, Location, Years as TPE)

All

9:20 a.m. 2010 Plant Heat Rates

2010 Heat Rates of the US (and some foreign) nuclear plants are presented with respect to NSSS type, turbine type, and other parameters of interest to the TPE.

John Walden, Constellation Energy, R.E. Ginna Nuclear Power Plant

10:00 a.m. Break

10:20 a.m. P2EP Roundtable Discussion All, Moderated by Tim Robbins, P2EP Utility Chair

12:00 p.m. Lunch – (provided by EPRI) Lobby Court & Terrace

1:00 p.m. Predicting Nuclear Plant Output From Performance Losses and Gains

Gary Loeb, Exelon

1:40 p.m. Break

2:00 p.m. P2EP Roundtable Discussion (continued) All, Moderated by Tim Robbins, P2EP Utility Chair

3:00 p.m. Proposed Revision to ASME PTC 6 Steam Turbine Test Code for Nuclear Steam Turbine Testing

Cary Campbell, Vice Chair ASME PTC 6 Committee, Southern Company Services, Inc.

3:40 p.m. Break

4:00 p.m. P2EP Roundtable Discussion (continued) All, Moderated by Tim Robbins, P2EP Utility Chair

5:00 p.m. Adjourn


Agenda EPRI PE / P2EP Annual Meeting

June 29-30, 2011 Denver, Colorado

Purpose of Meeting:

Facilitator:

Informal meeting of thermal performance engineers to focus on the issues of nuclear power plant thermal performance

EPRI-Plant Engineering

Agenda Topics - Day 2: June 30 (Thursday) EPRI PE / P2EP Annual Meeting (Closed Door Session)

7:15 a.m. Breakfast – (provided by EPRI) East Entrance (Lower Level)

8:15 a.m. Welcome

A brief overview of the agenda for today.

Tim Robbins, P2EP Utility Chair

8:20 a.m. LEFM + C: Commissioning Lessons Learned Eric Sorg, DTE Energy

9:00 a.m. P2EP Roundtable Discussion (continued) All, Moderated by Tim Robbins, P2EP Utility Chair

10:00 a.m. Break

10:20 a.m. Comanche Peak Low Pressure Feedwater Heater Issues Tim Robbins, Luminant

11:00 a.m. P2EP Roundtable Discussion (continued) All, Moderated by Tim Robbins, P2EP Utility Chair

12:00 p.m. Lunch – (provided by EPRI) Lobby Court & Terrace

1:00 p.m. Condenser Air Removal Issues Richard Harris, AEP

1:40 p.m. P2EP Roundtable Discussion (concluded) All, Moderated by Tim Robbins, P2EP Utility Chair

2:40 p.m. Break

3:00 p.m. Future P2EP Research Project Discussion EPRI Project Manager

3:30 p.m. Meeting Critique/Closing Remarks All, Moderated by Tim Robbins, P2EP Utility Chair

4:00 p.m. Adjourn

EPRI 2011 Plant Performance Enhancement Program Annual Meeting

Jerry KernaghanP2EP Project ManagerOMNI InterlockenDenver, ColoradoJune 29-30, 2011

2© 2011 Electric Power Research Institute, Inc. All rights reserved.

Plant Performance Enhancement Program

Welcome to Denver!


Meeting Facility Safety Notes and Logistics

• In the event of an Emergency while in the meeting room: be aware of your surroundings and know where the nearest Exit is case an evacuation is required

• Please be alert for tripping and other safety hazards that may be present in the meeting room

• Bathrooms Location


P2EP Committee Chairperson Change

• Thanks to Gregg Sessler for his capable leadership as P2EP Utility Chairman during the past several years

• Welcome Tim Robbins as next P2EP Utility Chairman


Program Mission Statement

Enable Thermal Performance Engineers to optimize the heat rate of nuclear power plants through information exchange and technology transfer


Program Goal

• The goal of EPRI’s Thermal Performance Enhancement Program is to provide research results to help nuclear plant Thermal Performance Engineers (TPEs) optimize nuclear power plant heat rates through:

– Research in areas identified as important by nuclear plant TPEs or the industry

– Annual Plant Thermal Performance Enhancement Program coordinator’s meeting

– EPRI website access to reference and training materials/courses

– Thermal Performance Program Peer Assessment Assistance


Program Description

• Twenty three years of EPRI research focused on nuclear plant heat rate improvement

• Plant Performance Enhancement Program (P2EP) website provides site coordinators access to technical library that contains:

– results from over 150 member surveys

– past research project reports

– technical library containing literature related to plant heat rate improvement topics

– list of program meetings and training sessions

• Annual P2EP Coordinators Meeting provides forum for open discussions of thermal performance issues

– Provides best forum for TPEs to engage in plant thermal efficiency and power plant operation discussions


Current Research

• Current project funded for 2011: Predicting Nuclear Plant Output from Performance Losses and Gains

– Provides guidance for establishing an appropriate as-built best performance point or design efficiency

• Basis for deriving predicted performance

– Derives a thorough set of efficiency losses (and gains) to compare actual performance to unit design

– Helps Thermal Performance Engineers understand the corrections and adjustments being performed in commercially available performance monitoring software tools used to calculate plant losses


Proposed Research Projects

• Research needs identified by P.E. Integration Committee and P2EP Site Coordinators in order of priority:

1. Study/report on heat cycle isolation valve leakage: determination & quantification methods

2. Update of Thermal Performance Engineering Handbook, TR-107422 - Volume 2

3. Revise Main Turbine Performance Upgrade Guideline, TR-106230

4. Update MSR Sourcebook, TR-106345

5. Study/report on Main Condenser effects/limitations encountered as a result of plant upgrades/uprates to-date

• Project list and priorities can be adjusted based on your input


Meeting Format

• Member Roundtable Discussions

– Each participant provides thermal performance program highlights from their plant from past year-approximately 15 minutes each

• Presentations from site P2EP Coordinators on various topics of interest to the TPE community

– Each presentation is approximately 40 minutes including time for Q&A

• Roundtable discussions interspersed with presentations

• Scheduled breaks throughout the agenda

• Breakfast and Lunch provided both days


Plant EngineeringP2EP Program Staff

• Bo Clark: PE Program Manager

– 704-595-2684

– [email protected]

• Jerry Kernaghan: PE P2EP Project Manager

– 717-278-0328


• Beth McRimmon: PE Training & Technical Assistance Programs Coordinator

– 704-595-2536


• Jill Lucas: PE Staff Assistant

– 704-595-2574



QUESTIONS?


P2EP Webpage and EPRI Cvent System

• P2EP Webpage navigation and EPRI Cvent meeting planning system presentation by Beth McRimmon, EPRI Training & Technical Assistance Programs Coordinator


Introductions

• Each participant please state your name, company, job location and position title with years on the job, and ...

• Share something interesting about yourself; hobby, favorite vacation spot, ...

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Web Based P2EP Plant Performance Enhancement Program

Features of EPRI’s P2EP Program available through EPRI-WEB

Navigating to P2EP Home Page 2

P2EP Home Page 3

P2EP Technical Library 4

P2EP Technical Library – Option One – Key Words 5

P2EP Surveys 6

P2EP Surveys – Total Listing 7-8

EPRI Technical Reports on Thermal Performance Issues 9

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To navigate to the PSE website, and to access the P2EP section within the PSE website:

Go to www.epri.com Log-in with username and password, if you do not have a username and password, select “New User Registration”. Once you have logged-on to the EPRI website, click on “Members” (located within the thick line along the top of the page), then select "Subscriber Websites" From the “Subscriber Websites” page, select “PSE - Plant Support Engineering” (located under Nuclear in the center of the page) Within the PSE website, select “P2EP” on the left side of the page under Technical Assistance Programs. Plant Performance Enhancement Program (P2EP) The Plant Performance Enhancement Program (P2EP) is a forum of member nuclear utility representatives formed to facilitate information exchange and provide technical support to assist PSE member utilities to improve nuclear plant thermal efficiency and electrical output. To locate the P2EP Technical Library website: From the P2EP section within the PSE website, select “P2EP Technical Library” This will direct you to the P2EP Technical Library website. There are two search options provided on this site:

“Search by Predefined Keywords” 1. Select a subject from the dropdown list. 2. Search database.

Or

“Search Database Fields for Text” 1. Enter text to search for. 2. Select a field to search. 3. Search database.

To download EPRI reports and documents from the EPRI website: Log-in to www.epri.com Go to the Search Box located in the upper right corner of the home page, input the Product ID (referenced on each report/document) or type the Title of the product you are interested in.

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P2EP Home Page

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P2EP Technical Library

Option One – Papers are coded into the Tech Library based on “key words”. Option Two – User can search for specific text is a variety of different database fields

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P2EP Technical Library – Option One – Key Words 0000.4 Acoustic Emission 0001.0 Air Ejectors 0002.0 Air Inleakage 0003.0 ASME 0003.5 Assessment 0004.0 Balance of Plant 0005.0 Baseline 0005.5 Bellows 0006.0 Blade Failures 0006.5 Blowdown 0007.0 BOP Database 0008.0 BOPPMG 0009.0 BOPPMG Proceedings 0010.0 Calculations 0011.0 Calibration 0012.0 Calorimetrics 0012.5 Cathodic Protection 0012.7 Chemistry, General 0013.0 Chevrons 0014.0 Chlorination 0015.0 Circ Water Pumps 0016.0 Circulating Water 0017.0 Cleaning - Chemical 0018.0 Cleaning - General 0019.0 Cleaning - Mechanical 0020.0 Coatings 0020.3 Computer Modeling 0020.5 Computer, PC 0020.7 Computer, Plant 0021.0 Condensate 0022.0 Condensate Pump Motors 0023.0 Condensate Pumps 0024.0 Condensers 0025.0 Conference Proceedings 0026.0 Control Intercept Valves 0027.0 Cooling Towers 0028.0 Cooling Water 0029.0 Corrosion 0030.0 Cycle Isolation 0031.0 Cycle Modifications 0031.2 Data Collection 0031.5 Design 0032.0 Displays 0033.0 Drain Coolers 0034.0 Drain Tanks 0034.4 Economic Analysis 0034.6 Efficiency 0035.0 Electro-Hydraulic Control 0035.5 Environmental 0036.0 EPRI 0037.0 Erosion/Corrosion 0038.0 Expert Systems 0039.0 Extraction Steam 0040.0 Failure Analysis 0040.5 Fan 0041.0 Feedwater 0042.0 Feedwater Flow Venturi 0043.0 Feedwater Heaters 0044.0 Feedwater Pump Motors 0045.0 Feedwater Pumps 0046.0 Feedwater Turbines 0047.0 Filtration

0048.0 Flash Tanks 0049.0 Flow 0050.0 Flow Balance 0051.0 Flow Meters - General 0052.0 Flow Meters - Leading Edge 0053.0 Fouling 0054.0 Fouling Monitor 0055.0 General Electric 0056.0 Goals 0057.0 Good Practices Document 0058.0 Guidelines 0059.0 Handbooks 0060.0 Heat Rate 0060.5 Heat Exchangers 0061.0 Heat Transfer 0062.0 Heater Drain Pumps 0063.0 HEI 0064.0 Hotwell 0065.0 Hydrogen Cooling 0066.0 Innovative Technology 0067.0 INPO 0068.0 Inputs 0069.0 Inspection 0070.0 Instrumentation 0070.4 Insulation 0071.0 Intake Structures 0072.0 Lay-up 0073.0 Leak Detection 0074.0 Level 0075.0 Licensed Operation 0075.5 Life Extension 0076.0 Linings 0076.4 Lube Oil 0077.0 Macrofouling 0078.0 Main Generator 0079.0 Main Steam 0080.0 Main Turbine 0081.0 Maintenance 0082.0 Maintenance Rule 0083.0 Manufacturers 0084.0 Materials - General 0085.0 Materials - Specification 0086.0 Materials - Testing 0087.0 Megawatt Meters 0088.0 Metals 0089.0 MIC 0090.0 MSRs 0091.0 Motors 0092.0 MWe Improvement 0093.0 NEI (NUMARC) 0094.0 Non-Destructive Exam 0095.0 NPPI Seminar 0096.0 NRC 0097.0 On-Line 0098.0 Operations and Maintenance 0098.5 Outages 0098.7 P2EP Annual Meeting 0099.0 P2EP Surveys 0100.0 Performance, General 0101.0 Performance Monitoring 0102.0 Performance Test Codes 0103.0 Pipes & Piping

0104.0 Power-Generation 0105.0 Pressure 0106.0 Procedures 0107.0 Process Computer 0108.0 Programs 0109.0 Pumps 0110.0 Reactor Thermal Power 0111.0 Reference Material 0112.0 Reheat Steam 0113.0 Reheaters 0114.0 Reliability 0115.0 Reports 0116.0 Retrofits 0117.0 Safety Analysis 0118.0 Screens 0119.0 Sealing Steam 0120.0 Secondary Side Chemistry 0121.0 Sensing 0122.0 Sourcebooks 0123.0 Specifications 0124.0 Standards 0125.0 Stator Water Cooling 0126.0 Steam Generators 0127.0 Steam Packing Exhausters 0128.0 Steam, Main 0129.0 Steam, Auxiliary 0130.0 Steam Tables 0131.0 Structural Integrity 0131.2 Stress Corrosion Cracking 0131.4 Steam Trap 0132.0 Table of Contents 0133.0 TAG (P2EP) 0134.0 Temperature 0134.5 Testing 0135.0 Textbooks 0135.5 Thermal Kit 0136.0 Thermal Perf Indicator (TPI) 0137.0 Thermocouples 0138.0 Thermography 0139.0 Training 0140.0 Transformers 0141.0 Traveling Screens 0141.5 Trending 0142.0 Tube Plugging 0142.3 Tubes 0143.0 Turbine Auxiliaries 0144.0 Turbines - High Press 0145.0 Turbines - Low Press 0146.0 Ultrasonic 0146.2 Uncertainty Analysis 0146.5 Upgrade 0147.0 Upratings 0148.0 Valve Leakage Monitoring 0149.0 Valves, General 0150.0 Valves, Turbine 0150.2 Venting 0150.5 Vibration 0151.0 Water Treatment 0152.0 Welding 0153.0 Westinghouse 0154.0 Workstation, Computer 0155.0 Zeta Potential

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P2EP Surveys

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P2EP Surveys – Total Listing 1992 Surveys #1992-001 FW Heater Replacement #1992-002 FW Flow Venturis and Nozzles #1992-003 Turbine Generator Output/Bleeder Lines #1992-004 FW Flow Venturis #1992-005 Erosion/Corrosion #1992-006 Condenser Performance #1992-007 Second Stage Reheaters #1992-008 Condenser Hot Well Condensate 1993 Surveys #1993-001 MSR Drains Pumped Forward #1993-002 ASME Steam Turbine Testing #1993-003 HP Turbine Efficiency #1993-004 Unaccounted-For MWe Loss and Turbine Degradation #1993-005 Reheat Steam Valve Pneumatic Controllers #1993-006 Single Stage MSRs #1993-007 TAG Meeting Input #1993-008 Thermal Performance Indicator Revision #1993-009 Reactor Thot Reduction

#1993-010 Use of the UNIX Operating System for NTPA #1993-011 Reheater Tube Leaks #1993-012 Radiation Hardening of Key Press Xmitters #1993-013 Voltage Drop from Generator to MWe Meter #1993-014 Performance Training #1993-015 Flow Measurement Technologies #1993-016 Turbine Valve Leakage & Partial Arc Conversion #1993-017 Final FW Temperature Measurement #1993-018 Performance Trending #1993-019 Steam Quality Measurement #1993-020 MSR Impingement Baffles #1993-021 Turbine Performance Related to S/G Plugging #1993-022 FW Flow #1993-023 Megawatt Hour Meter Replacement #1993-024 ASME Flow Nozzle #1993-025 Thermal Performance Models #1993-026 In-House Loads #1993-027 MSR Shell Drains #1993-028 FW System #1993-029 Lost Megawatts within Turbine Cycle #1993-030 RCS Temperature Streaming 1994 Surveys #1994-001 S/G Degradation Model #1994-002 MSR Reheat Valves #1994-003 Pilot Training Course Module #1994-004 Feed Flow Element Fouling #1994-005 Precision Shaft Torque Meter for Large Utility Turbines #1994-006 MRES TAG Subgroup MSR #1994-007 MSR Drain Tank Level Oscillations #1994-008 Cycling of FW Heater Vents #1994-009 Estimating Loss Through Steam Dumps #1994-010 Steam Trap Monitoring #1994-011 Moisture Separator Effectiveness/Testing #1994-012 Revised Thermal Kit #1994-013 Proposed Guideline on Operation at Licensed Power #1994-015 Main Steam Header Pressure Loss #1994-016 Inlet FW Temperature #1994-017 Inputs to Secondary Calorimetric #1994-018 Condensers, Cooling Towers, and Circ Water Data #1994-019 Diagnosing FW Flow Nozzle Degradation

1995 Surveys #1995-001 FW Temperature Indication #1995-002 On-Line FW Flow Measurement #1995-003 Maximizing Reactor Thermal Power #1995-004 Heat Rate Degradation #1995-005 Outage Inspections #1995-006 Forced Draft Cooling Towers #1995-007 High Pressure FW Heater Bypass #1995-008 Stainless Steel Expansion Bellows #1995-009 Utility Organizational Structure for Testing #1995-010 Main Condenser Tube Cleaning #1995-011 Flow Loss in Moisture Separator Drain Tank Line #1995-012 Moisture Separator Reheater Drain Tank Orientation #1995-013 Limits on Turbine Cycle on Air In-Leakage #1995-014 Vibration/Fatigue Failures #1995-015 MSR Sourcebook Input #1995-016 Steam Generator Pressure Loss #1995-017 MSR Steam Blanketing System #1995-018 Variances in Condenser Pressure 1996 Surveys #1996-001 Eddy Current Testing of BOP Heat Exchangers #1996-002 Accounting for Blowdown on CalorimetricCalculations #1996-003 MSR Performance Survey #1996-004 Thermal Performance Program #1996-005 Nuclear Turbine Upgrade Activities #1996-006 House Loads Reduction #1996-007 Feedwater Pump Requirements #1996-008 Cycle Isolation Determination #1996-009 Detection of Feedwater Heater Tube Leaks #1996-010 Secondary Calorimetric Divergence #1996-011 Using Stm Flow to Correct for FW Venturi Fouling 1997 Surveys #1997-001 Steam Line Flow Imbalance #1997-002 Heat Rate Improvements vs. Power Uprates #1997-003 Steam Drain Moisture Removal Orifices #1997-004 Main Feedwater Pump Couplings #1997-005 Desktop Instruction for TPEs #1997-006 Extraction Non-Return Valves #1997-007 Condenser Microfouling and Circ Water Inleakage #1997-008 PWR Hot Leg Streaming 1998 Surveys #1998-001 Moisture Carryover Testing #1998-002 Sticky Electro-Hydraulic Valves #1998-003 Turbine Overhaul Procedure #1998-004 Turbine Blade Failure #1998-005 1st Stage Turbine Pressure Changes #1998-006 Feedwater Flow Measurement Techniques #1998-007 Reactor Coolant Monitoring Assessment #1998-008 Condenser Waterbox Vacuum Priming System #1998-009 Calibration of Feedwater Flow Transmitters 1999 Surveys #1999-001 Tubesheet Coating as a Means to Reduce Tube Leaks #1999-002 Anomaly in steam flow & feedwater flow Calorimetrics #1999-003 On-Line Chemical Condenser Cleaning #1999-004 Cooling Tower Software #1999-005 Layup of Condenser Tubes #1999-006 Condenser In-Leakage Guideline Data #1999-007 Turbine Cycle Isolation Valve Leakage Diagnostics #1999-008 Turbine Lube Oil in Bearing Cooling System

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P2EP Surveys – Total Listing (cont’) #1999-009 Feedwater Flow Testing #1999-010 Thermal Performance Engineering Program #1999-011 Condenser Tube Sleeving #1999-012 Condenser Performance and Cleanliness Factor 2000 Surveys #2000-001 Cooling Tower Safety Hazards #2000-002 Moisture Separator Drain Valve #2000-003 Steam Traps #2000-004 Control of MSR Two Stage Reheat #2000-005 High Differential Temperature #2000-006 ASME Steam Tables #2000-007 Implementing Final Feedwater Temp Red #2000-008 Plant Enhancements #2000-009 Inspection - Replacement of MSR Internals #2000-010 Feed Pump Suction Pressure Swings #2000-011 Turbine Bypass Valves #2000-012 Turbine Blading Protection #2000-013 Frequency of BOP Instrument Calibration #2000-014 Topics for 2000 P2EP Annual Meeting #2000-015 Lost MWth Situation #2000-016 Chain Filters at Water Intake Station #2000-017 Feed Pump Suction Pressure Swings #2000-018 Isolation of Drip Pot Drain Lines at Full Power #2000-019 Unexplained Change in Condenser Perf 2001 Surveys #2001-001 Throttling Steam to MSR Tube Bundles #2001-002 MSR Failures #2001-003 Finding Water In-Leakage with SF6 #2001-004 High Pressure Turbine Upgrades #2001-005 Replacing Steam Generators #2001-006 Acoustic Monitoring for FW Heater Tube Leaks #2001-007 Long Term Data Historian Systems #2001-008 LP Rotors #2001-009 Calorimetric Constants 2002 Surveys #2002-001 Feedwater Flow Indication #2002-002 Prediction of Circ Water Cycle Temperatures #2002-003 Feedwater Flow Variation #2002-004 Thermal Performance Monitoring #2002-005 Final FW Temperature Reduction for PWRs #2002-006 Study Orifice Plates for FW Flow Measurement #2002-007 Lagging on Extraction Steam Pipe #2002-008 Appendix K Uprate #2002-009 Iron fouling on Titanium Condenser Tubes #2002-010 Forced Loss Rate Calculation #2002-011 MSR Drain Valves #2002-012 Condenser Expansion Joint Replacements 2003 Surveys #2003-001 Moisture Separator Reheater Inspections #2003-002 Feedwater Control System #2003-003 Multi-pressure Main Condenser Equalization in Hot

Weather 2004 Surveys #2004-001 Steam Trap –Check Valve #2004-002 Non-conservative Venturi Fouling #2004-003 Feedwater Heater Level Control #2004-004 FW Heater Alarm and Isolation Testing

2005 Surveys #2005-001 Appendix K Uprate #2005-002 Info System for Thermal Performance Monitoring #2005-003 Main Turbine Control Valve Position Trend #2005-004 Condenser water inleakage questionnaire 2006 Surveys #2006-001 Experience Sharing of Reactor Power Drift Monitoring

Methods #2006-002 Primary Recirculation Loop Elbow Element Uncertainty 2007 Surveys #2007-001 Salt Water Corrosion Factors in Plant Models #2007-002 Measurement Uncertainty Recapture Uprate #2007-003 Operating Units Close to Licensed Limit 2008 Surveys #2008-001 Potential Moisture Carry-over #2008-002 Water Piping Velocity Criteria for Power Uprate #2008-003 Intercomparison of Methods for RX Drift Monitoring #2008-004 Capacity Factor Improvement and Forced Loss

Reduction #2008-005 Frequency and Reasons for Reactor Coolant System

T-ave Changes at Pressurized Water Reactors #2008-006 Modification to Condenser Tube Sizes 2009 Surveys #2009-001 Power Reduction For Major Cycle Bypass Conditions #2009-002 Circulating Water Pump Start up with Reverse

Rotation #2009-003 SG Moisture Carry-Over (MCO) Values in Calorimetric #2009-004 FW Flow Measurement Upgrade Impact on Existing

Device 2010 Surveys #2010-001 Qualify Valves Leakage With Acoustic Emission #2010-002 Steam Generator Blowdown System Design 2011 Surveys #2011-001 Rx Power Control at 100% Rated License Power Limit

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EPRI Technical Reports on Thermal Performance Issues

Product # Report Title

TR-106230 Main Turbine Performance Upgrade Guideline, January 1997

TR-106345 Moisture Separator Reheater Source Book, November 1997

TR-107422-V1 Thermal Performance Engineer's Handbook, Vol. 1, Introduction to Thermal Performance, March 1998

TR-107422-V2 Thermal Performance Engineer's Handbook, Vol.2, Advanced Concepts in Thermal Performance, August 1998

TR-112819 Condenser In-Leakage Guideline, January 2000

1000607 Small Power Uprates Under Appendix K

1003040 Application of Orifice Plates for Measurement of Feedwater Flow (EdF Plant Experience)

1006995 Tenth Nuclear Plant Performance Improvement Seminar Proceedings, August 2002

1009741 Eleventh NPPI Seminar (September 2004) (Austin)

1014875 Methodologies for Monitoring and Adjustment of Reactor Power Measurement Drift, September 2007

1019155 Methodologies for Monitoring and Adjusting Reactor Power Measurement Drift - Phase 2, September, 2009

1021068 Evaluating Equipment Performance Guarantees, December 2010

2010 US Nuclear Gross Heat RatesRank Unit Name Unit No Heat Rate Rank Unit Name Unit No Heat Rate Rank Unit Name Unit No Heat Rate

1 FARLEY 2 9,347 36 LIMERICK 2 9,945 71 CALVERT CLIFFS 1 10,233 2 SOUTH TEXAS 2 9,384 37 WOLF CREEK 0 9,946 72 FERMI 2 10,2663 SOUTH TEXAS 1 9,407 38 FITZPATRICK 0 9,969 73 PEACH BOTTOM 3 10,2694 CALLAWAY 0 9,525 39 PRAIRIE ISLAND 1 9,982 74 NORTH ANNA 1 10,2745 CATAWBA 2 9,540 40 BRAIDWOOD 2 9,989 75 PEACH BOTTOM 2 10,2926 CATAWBA 1 9,553 41 SEQUOYAH 1 10,003 76 HATCH 2 10,2987 SEABROOK 0 9,601 42 PRAIRIE ISLAND 2 10,004 77 BEAVER VALLEY 1 10,2998 OCONEE 3 9,661 43 DAVIS-BESSE 0 10,011 78 SUSQUEHANNA 2 10,3059 SUMMER 0 9,696 44 SAN ONOFRE 3 10,023 79 CLINTON 0 10,310

10 OCONEE 2 9,697 45 NINE MILE POINT 1 10,024 80 ROBINSON 2 10,33311 PALO VERDE 2 9,701 46 BYRON 2 10,026 81 BRUNSWICK 2 10,33512 DIABLO CANYON 1 9,719 47 THREE MILE ISLAND 1 10,032 82 WATERFORD 3 10,37513 COMANCHE PEAK 1 9,724 48 NORTH ANNA 2 10,035 83 COLUMBIA 2 10,37814 SALEM 2 9,728 49 HARRIS 0 10,038 84 PALISADES 0 10,38015 MILLSTONE 3 9,734 50 GINNA 0 10,045 85 QUAD CITIES 2 10,40416 PALO VERDE 3 9,738 51 SEQUOYAH 2 10,049 86 HATCH 1 10,41817 SALEM 1 9,742 52 VOGTLE 2 10,053 87 BEAVER VALLEY 2 10,42518 POINT BEACH 2 9,744 53 VOGTLE 1 10,059 88 CALVERT CLIFFS 2 10,43019 PALO VERDE 1 9,748 54 LIMERICK 1 10,067 89 INDIAN POINT 2 10,45220 PERRY 0 9,766 55 RIVER BEND 0 10,079 90 BROWNS FERRY 3 10,49521 WATTS BAR 1 9,767 56 KEWAUNEE 0 10,096 91 FARLEY 1 10,50922 OCONEE 1 9,769 57 OYSTER CREEK 0 10,102 92 BROWNS FERRY 2 10,52023 MCGUIRE 1 9,771 58 INDIAN POINT 3 10,106 93 DRESDEN 2 10,84524 COMANCHE PEAK 2 9,791 59 VERMONT YANKEE 0 10,110 94 QUAD CITIES 1 10,88825 BYRON 1 9,792 60 LASALLE 2 10,121 95 BROWNS FERRY 1 10,93526 MCGUIRE 2 9,795 61 MILLSTONE 2 10,127 XXX DRESDEN 3 11,07827 DIABLO CANYON 2 9,796 62 LASALLE 1 10,131 XXX COOK 1 No Data28 BRAIDWOOD 1 9,804 63 DUANE ARNOLD 0 10,140 XXX COOK 2 No Data29 NINE MILE POINT 2 9,809 64 COOPER STATION 0 10,156 XXX HOPE CREEK 0 No Data30 POINT BEACH 1 9,824 65 BRUNSWICK 1 10,159 XXX ST. LUCIE 1 No Data31 PILGRIM 0 9,829 66 SURRY 1 10,165 XXX ST. LUCIE 2 No Data32 FORT CALHOUN 0 9,842 67 SUSQUEHANNA 1 10,178 XXX TURKEY POINT 3 No Data33 SAN ONOFRE 2 9,892 68 MONTICELLO 0 10,184 XXX TURKEY POINT 4 No Data34 ARKANSAS 2 9,894 69 GRAND GULF 1 10,190 XXX CRYSTAL RIVER 3 Off Line35 ARKANSAS 1 9,907 70 SURRY 2 10,228

2010 Heat Rate Distribution by Reactor Type

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2010 Heat Rate Distribution by LP Turbine

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Heat Rate (BTU/KWHR)GEC/Alstom ABB GE 38" GE43" SPC 48" SPC 44" WE 40" WE44" WE 47" SPC 46" WE 45" SPC 52"

02-2010 US HEAT RATE DATA with Efficiency.xlsx

B&W Heat Rate W 3 Loop Heat RateOCONEE 3 9,661 FARLEY 2 9,347 OCONEE 2 9,697 NORTH ANNA 2 10,035 OCONEE 1 9,769 SURRY 1 10,165 ARKANSAS 1 9,907 SURRY 2 10,228 DAVIS-BESSE 0 10,011 NORTH ANNA 1 10,274 THREE MILE ISLAND 1 10,032 BEAVER VALLEY 1 10,299 CRYSTAL RIVER 3 Off Line ROBINSON 2 10,333

FARLEY 1 10,509 CE with CPC Heat Rate TURKEY POINT 3 No DataPALO VERDE 2 9,701 TURKEY POINT 4 No DataPALO VERDE 3 9,738 PALO VERDE 1 9,748 W Newer 3 Loop Heat RateSAN ONOFRE 2 9,892 SUMMER 0 9,696 ARKANSAS 2 9,894 HARRIS 0 10,038 SAN ONOFRE 3 10,023 BEAVER VALLEY 2 10,425 WATERFORD 3 10,375

CE without CPC Heat Rate W Newer 4 Loop Heat RateFORT CALHOUN 0 9,842 SOUTH TEXAS 2 9,384 MILLSTONE 2 10,127 SOUTH TEXAS 1 9,407 CALVERT CLIFFS 1 10,233 CALLAWAY 0 9,525 PALISADES 0 10,380 CATAWBA 2 9,540 CALVERT CLIFFS 2 10,430 CATAWBA 1 9,553 ST. LUCIE 1 No Data SEABROOK 0 9,601 ST. LUCIE 2 No Data DIABLO CANYON 1 9,719

COMANCHE PEAK 1 9,724 Newer GE Heat Rate MILLSTONE 3 9,734 PERRY 0 9,766 WATTS BAR 1 9,767 NINE MILE POINT 2 9,809 MCGUIRE 1 9,771 LIMERICK 2 9,945 COMANCHE PEAK 2 9,791 LIMERICK 1 10,067 BYRON 1 9,792 RIVER BEND 0 10,079 MCGUIRE 2 9,795 LASALLE 2 10,121 DIABLO CANYON 2 9,796 LASALLE 1 10,131 BRAIDWOOD 1 9,804 SUSQUEHANNA 1 10,178 WOLF CREEK 0 9,946 GRAND GULF 1 10,190 BRAIDWOOD 2 9,989 FERMI 2 10,266 SEQUOYAH 1 10,003 SUSQUEHANNA 2 10,305 BYRON 2 10,026 CLINTON 0 10,310 SEQUOYAH 2 10,049 COLUMBIA 2 10,378 VOGTLE 2 10,053 HOPE CREEK 0 No Data VOGTLE 1 10,059

Older GE Heat Rate W Older 4 Loop Heat RatePILGRIM 0 9,829 SALEM 2 9,728 FITZPATRICK 0 9,969 SALEM 1 9,742 NINE MILE POINT 1 10,024 INDIAN POINT 3 10,106 OYSTER CREEK 0 10,102 INDIAN POINT 2 10,452 VERMONT YANKEE 0 10,110 COOK 1 No DataDUANE ARNOLD 0 10,140 COOK 2 No DataCOOPER STATION 0 10,156 BRUNSWICK 1 10,159 W Small Heat RateMONTICELLO 0 10,184 POINT BEACH 2 9,744 PEACH BOTTOM 3 10,269 POINT BEACH 1 9,824 PEACH BOTTOM 2 10,292 PRAIRIE ISLAND 1 9,982 HATCH 2 10,298 PRAIRIE ISLAND 2 10,004 BRUNSWICK 2 10,335 GINNA 0 10,045 QUAD CITIES 2 10,404 KEWAUNEE 0 10,096 HATCH 1 10,418

EPRI Project:Predicting Nuclear Plant Output from

Performance Losses and Gains

EPRI P2EP MeetingJune 29, 2011

Gary Loeb, Exelon Nuclear

EPRI Project Planning

2010 P2EP Presentation on “Accounting for All of Your Megawatts – What’s in a Balance Sheet?” got positive feedback from Coordinators.

Attending P2EP Coordinators asked for more details.

EPRI P2EP Project Manager Submitted Project Concept and Budget for Consideration

EPRI PSE Integration Committee approved funding for research project and development of a report on this subject area.

EPRI Project Team

EPRI Project ManagerJerry Kernaghan

Subject Matter Experts Gary Loeb, PE - Principle Author

Senior Staff Engineer, Exelon Nuclear Corporate, Kennett Square, PA

Thermal Performance Program Manager

Deborah Cioffi, PE – Technical Reviewer Consulting Engineer, Mechanical Dynamics & Analysis, Ltd.,

Latham, NY

Technical Advisory Group P2EP Steering Committee – Perform Technical Reviews

EPRI Report Contents

Overview – Predicting Performance

Determining Design Output Reactor Heat Balances

Using ASME PTC-6 Type Tests

Turbine Heat Balances

Reconciling the Turbine Heat Balance to the Reactor

Considerations for EPU Units


Adjustments to Design Output (Losses and Gains)

Unrecoverable Adjustments Turbine Design vs. Licensed Reactor Power

Uncompensated Feedwater Flow Measurement Inaccuracy

Reactor Power Not at 100% But In Nominal Range

Nominal Reactor Water Clean-up (RWCU) Flow (BWRs Only)

Control Rod Drive (CRD) Flow (BWRs Only)


Unrecoverable Adjustments (continued) Nominal Steam Generator Blow-down (PWRs Only)

Main Steam Moisture Content

Main Steam Superheat

Throttle Pressure

Governor (Control) Valve Throttling

Nominal Moisture Separator (MS) Effectiveness

Feedwater Heater Nominal Differences

Feedwater Heater Vent Losses

Condenser Sub-Cooling


Unrecoverable Adjustments (continued) Generator Electrical Losses

Auxiliary Steam Usage

Condenser Performance and Turbine Exhaust Pressure Overall Affect of Turbine Exhaust Pressure

Seasonal Circulating Water Temperature

Estimation of Condenser Performance Loss


Recoverable Adjustments Reactor Power Below Nominal Range

Abnormal Steam Generator Blow-down (PWRs Only)

Moisture Separator (MS) Effectiveness Degradation

Reheater Performance Degradation

Turbine Efficiency

Feedwater Heater Performance Degradation

Feedwater Pump Combinations

FW Pump Turbine Steam Use difference

Unidentified Cycle Leakages


Recoverable Adjustments (continued) Circulating Water Flow Degradation Cooling Tower Performance Cycle-Isolation Leakages Abnormal Operation or Line-Up Megawatt Metering Errors

Expected Output Calculation Unknown Losses or Gains Data Sources and Measurement Discussion of Measurement Error


Calculation Methods Spreadsheets (i.e. Microsoft Excel)

Consultant and Vendor Services and Software

Reporting the Results

References and Suggested “Library”

EPRI Report Publication Schedule

7/31/2011 – First Draft Complete – Send to P2EP Steering Committee for Review

8/31/2011 – P2EP Steering Committee Review Complete

9/30/2011 – Final Draft Complete

November 2011 – Final Draft to EPRI Publications for Technical Editing and Layout

December 2011 – Report Published

Questions?

Proposed Nuclear Revisions to ASME PTC 6 – Steam Turbines

W. Cary Campbell, P.E.Vice-Chair PTC 6 Committee

EPRI P2EP MeetingDenver, CO

June 29, 2011

MEMBERS OF PTC 6 COMMITTEEP. G. Albert, Chair, General Electric Co. W. C. Campbell, Vice Chair, Southern Company Services J. H. Karian, Secretary, ASME K. C. Chan, Ontario Power Generation E. A. Giermak, Sargent & Lundy J. Gonzalez, Iberdrola Ingeniería y Construcción, S.A.U. Dong-Young Kim, ENESCO Energy Systems T. K. Kirkpatrick, McHale and Associates J. A. Meyer, Siemens Power Generation J. A. Panek, alternate, Siemens Power Generation R. W. Moll, Dresser Rand J. B. Nystrom, alternate Alden Research Laboratory P. S. Stacy, Alden Research R. A. Ransom, General Electric L. M. Svensen, Santee Cooper L. P. Thornton, Alstom Power D. J. Ugolini, Bechtel Power Corp. R. I. Wakeland, Fluidic Techniques J. C. Westcott, Mustan Corp. D. E. Wheeler, Clean Air Engineering J. A. Zoller, Black & Veatch

OBJECTIVES OF THIS REVISION

Update the 2004 Edition Correct typographical and obvious errors Remove references to obsolete equipment Allow use of modern instrumentation Clarify uncertainty analysis procedures Revise nuclear procedures to better match current

industry practice Insure that nuclear procedures are ready for the

next generation of nuclear plants

Evaluates Steam Turbine performance in terms of:

Turbine Cycle Heat Rate

Maximum Output at Valves Wide Open (VWO)

Draws a control volume around the steam turbine Corrects for deviation in steam turbine inputs and outputs from

design conditions

Primary flow is based on condensate or feedwater flow using special PTC 6 throat tap nozzle design

Full scale or Alternative Procedure (Formerly PTC 6.1)

No direct correction for throttle flow (uses throttle pressure)

Heat Rate determined at Valve Points

CURRENT PTC 6 PROCEDURE

TYPICAL TURBINE CYCLE CONTROL VOLUMES

Turbine Cycle Control Volume

Steam Turbine Control Volume

PTC 6 FW FLOW NOZZLE

EXISTING CORRECTIONS TO HEAT RATE AND LOAD (ABBREVIATED PROCEDURE) AT VALVE POINTS:

GENERATOR LOSSES1. H2 Pressure2. Power Factor

GROUP 1 CORRECTIONS (BALANCE OF PLANT EFFECTS):1. Top Heater TTD2. Top Heater Extraction Line Pressure Drop (ELDP)3. Auxiliary Steam Extractions (LP Steam to FP Turbine)4. Condensate Subcooling5. Condenser Makeup Flow6. MSR Performance (Optional) - If the MSR is not supplied by the turbine manufacturer or

is not part of retrofit.

Group 2 Corrections (Operating Conditions):

1. Throttle Pressure

2. Throttle Temperature (or Moisture if Saturated)

3. LP Turbine Exhaust Pressure (Condenser Backpressure)

CALCULATION OF HEAT RATE FROM TESTS AT VALVE POINTS

WHAT MAKES NUCLEAR UNIQUE?

Saturated steam

Operation at constant reactor power heat input, rather than VWO

MW output is of more interest than heat rate

Flow capacity is very important since it can limit reactor power capability

No IP turbine

Turbine moisture removal stages

MSR’s

Use of radioactive tracers (full scale test)

WHAT MAKES NUCLEAR UNIQUE? (Continued)

Heater drain pumps

Usually no deaerator

Steam Jet Air Ejectors (SJAE’s)

Blowdown heat recovery

Most units originally used FW flow nozzles for reactor power calorimetric and performance testing

Many units now use ultrasonic feedwater flow meters (for nozzle correction factors or direct control)

Few opportunities to install test instruments off-line

Industry perception that any PTC 6 test is impractical

SPECIAL CYCLE ISOLATION CONCERNS

Main steam bypass valves

Lot’s of drain tanks

Turbine and piping drains

FP recirc. to condenser rather than a deaerator

Long cycle cleanup

Some triple train feedwater heaters

Some valves are inaccessible during unit operation

Extreme reluctance to isolate cycle during performance tests

UNIQUE INSTRUMENT CONCERNS

Two phase flow calculations

Flashing liquid flow meters

Can measure pressure rather than temperature (when saturated)

Control Rod Drive (CRD) flows (BWR)

Radioactive environment (BWR)

Remote sensors & purge apparatus

Access to root valves

Measuring water legs

Instrumentation Requirements (Alternative Test)

OTHER NUCLEAR CONSIDERATIONS Governor valve throttling losses:

Significance varies based on Full/Partial arc admission mode

Actual heat rate and output worst than predicted by locus or valve best points heat balances

Steam Generator cleaning/fouling effects throttle pressures (Can go up or down)

T-avg reduction reduces throttle losses but lowers available energy

MSR HP heating steam flows effect flow into HP turbine

Non-reheat MSR’s (Saturated steam to LP Turbine)

Different NSSS designs (some HP superheat)

Next generation NSSS and turbine cycle designs

PROPOSED NUCLEAR RELATED CHANGES to PTC 6

1. Change the test objective to determine Corrected Output at 100% turbine cycle input power

2. Add a throttle flow margin test objective

3. Allow use of ultrasonic flow meters

4. Revise correction factors to a constant thermal power basis

5. Calculate corrected heat rate from corrected load (No need for heat rate correction factors)

6. Evaluate coordination of corrections?

7. Allow simultaneous computer based corrections?

PROPOSED NUCLEAR RELATED CHANGES (Continued)

8. Evaluate appropriate independent parameters (absolute or percent?)

FP Turbine % of Throttle Flow?

Blowdown/Makeup correction methodology (% of Feedwater Flow?)

9. Allow creation of condenser pressure correction curves by test (nuclear and fossil)

Theoretical curves may require a FP turbine available energy correction if not included in condenser pressure correction curve

Test curves include both the effect on the LP turbine and feedpump turbines

PROPOSED NUCLEAR RELATED CHANGES (Continued)

10. Revise assumed distribution of lost water volume

Can’t assume all leaks are in the boiler (tube leaks)

Distribute based on likely source or evidence of leak

11. Enhanced cycle isolation checking procedures

Pipe wall temperatures (upstream or downstream?)

Acoustic monitoring

Infrared temperature

Pressure/flow relationships

PROGRESS TO DATE?

NEW CONSTANT POWER CORRECTION

5-8 OUTPUT AT SPECIFIED THERMAL ENERGY INPUT

For turbines operating with limitations on thermal power, especially nuclear units, performance may be expressed in terms of capability corrected to a specified thermal energy input.

OTHER NEW NUCLEAR CORRECTION FACTORS

1. Throttle pressure correction for thermodynamic effects only (Not flow - since it is included in the thermal power factor)

2. Correct for throttle moisture correction rather than throttle temperature (unless superheated)

3. MSR corrections when not part of turbine scope of supply MSR TTD’s

Shell Pressure Drops

Moisture Separator Outlet Quality

4. Blowdown effects on thermal power calculation

5. Hydrogen Purity

NEW FLOW MARGIN SECTION5-4.3 Throttle Flow Margin

Throttle flow margin (TFM) is the percentage difference between the corrected test turbine throttle flow with the control valves wide open, and the rated throttle flow value stated in the VWO heat balance at specified steam conditions. A calculation of TFM requires that the test throttle flow be determined (see section 5-4.1) at the VWO condition. However, some units cannot be tested with the valves wide open. In this case the VWO flow must be predicted. For full-arc admission machines, the VWO flow can be predicted using techniques given in section 3-13.4. Partial-arc admission machine VWO flow can be predicted using a combination of manufacturer’s valve curves, 1st stage shell pressure, and the corrected test flow rates at other valve points. All parties must agree to the prediction methodology used.

The throttle flow margin can be used to determine the turbine excess flow capability.

NEW FLOW METERS CONSIDERED:

1. Coriolis Meters - Micro-Motion (Emerson)

2. Ultrasonic (Time of Transit) Meters – Caldon (LEFM)

3. Ultrasonic (Cross Correlation) Meters – AMAG (Crossflow)

CORIOLIS FLOW METERS Based on the effect of gravity on dual vibrating tubes

Determines Mass Flow Rate Directly (Not Volume)

Independent of Flow Profile

Uncertainty = Approx. 0.1%

Application Limits 5 million Lb/Hr

1400 PSIG

200 Deg. C (392 Deg. F) – Not quite high enough for Nuclear Feedwater

Cost for 12” Meter (Max. size available) = Approx. $80,000

Working on larger 4 tube model (less pressure drop)

Acceptable for small Fossil and Combined Cycle Performance Testing (Condensate Flow)

CORIOLIS FLOW METERS

ULTRASONIC TIME OF TRANSIT METERS (LEFM)

Based on time for sound waves to cross moving fluid

Permanent fixed transducer locations

8 beam paths (four in each direction)

Somewhat effected by flow profile Calibrated with piping system mock-up


Commonly used for Nuclear feedwater flow measurement

Direct Control of Reactor Power

Creation of Correction Factor for Nozzles

Acceptable for Performance Testing

ULTRASONIC CROSS CORRELATION METERS (AMAG - CROSSFLOW)

Based on time for recognizable turbulent flow patterns to move down the pipe

Strap-on transducers

Sensitive to flow profile and noise


Used in several BWR’s for Feedwater flow measurement

Compares Crossflow vs. Nozzle flows

Creates Correction Factor for Nozzles

Requires long statistical analysis periods (3 – 8 Hrs.)

Not acceptable for Absolute Performance Testing

Acceptable for Relative Pre/Post Modification Tests

CHANGES NEEDED FOR NEXT GENERATION OF NUCLEAR UNITS?

Most changes in next generation units are in NSSS systems

AP1000 steam turbine is by Toshiba (Basic GE Design)

SBWR steam turbine by GE

New turn-key units guarantee total plant performance only Use ASME PTC 46 for net unit performance

Initial startup steam turbine and BOP tests are still recommended for baseline purposes

Probably will come with LEFM’s, not sure about nozzles

Proposed revisions to PTC 6 should cover all nuclear units, existing and next generation

SCHEDULE

August 2011 – Subcommittees complete all draft sections and submit to entire committee for review

Oct 2011 - Meeting to review draft & develop actions to complete draft (Chicago?)

Feb 2012 - Issue draft for final review & comment by ASME PTC 6 committee.

March 2012 - Meeting to finalize draft

May 2012 - Issue Draft for Industry Review

October 2012 - Finalize Revised PTC document.

CONCLUSION

PTC 6-2004 is being revised to better cover existing nuclear steam turbine test techniques

Adding procedure to correct to constant thermal power

Adding use of ultrasonic flow meters

New revision should cover next generation of nuclear units

If you know of any other needed changes, please let me know!

Questions?

CONTACT:

W. Cary Campbell, P.E.Southern Company Services42 Inverness Center Parkway

Birmingham, AL 35242

(205) 992-7930

[email protected]

LEFM + C Commissioning

Lessons Learned

Eric T. Sorg – DTE Energy

EDP 36238: “Install Cameron Leading Edge Flow Meters”

The project was initiated by Performance Engineering in response to feedwater venturi fouling issues that had plagued the plant since 2007

Benefit was the recovery of fouling losses and potential MUR uprate

2

Historical Performance

3

Permutit Flow Elements

4

Flow Element Detail

5

Project Ownership

Project presented to, reviewed and approved by the Plant Health Committee and Project Review Group

Corporate Major Enterprise Projects and site Projects group provided oversight

Washington Group/URS prepared the design change package and implemented the change

6

Key Commissioning Personnel

Cameron Field Service Engineers

Fermi I&C Personnel

Fermi Engineering Personnel

True North Personnel

7

Diagram

8

Installation-Metering Sections

9

Installation-Flow Transmitters

10

Steam Tunnel Map

11

Installation-CPU

12

TB2 Location

13

Design Phase-Good Practices

Core Team concept worked well based on members’ participation

Schedule for issuance of design package was met

14

Design Phase-Lessons Learned

Change to CPU rack location required due to area temperature calculation

Spool design changes resulted in new snubbers being required

Fermi schedule was not in alignment with Cameron schedule which resulted in challenges for Cameron to meet documentation dates

Delays were introduced when CPU hardware and software and meter software was updated after FAT testing performed

Benchmarking of other plants early in design development phase HIGHLY recommended

15

Installation-Good Practices

Built mock up of entire distributed system in Nuclear Training Center using craft This allowed for identification of design problems early

enough to revise the EDP

Performed bench testing of distributed system with Integrated Plant computer and with itself

Much pre-outage prep work helped reduce job critical path in outage Conduit in accessible areas

Rack fabrication/installation

16

Installation-Lessons Learned

Schedule did not allow time for draining trapped water due to cant of piping

Scaffolding issues at spool site (side load on lifting beam caused twist)

Radiation Protection coordination issues for breach and installation

Welding issues at job site (air flow)

Mounting of transmitters took longer than planned

17

Commissioning-Good Practices

Cameron support of commissioning schedule

IPTE process used to control commissioning was a good practice for proper oversight

Independent means of verifying LEFM indication (True North statistical flow estimator based on River Bend Method) Needed because we could not count on our venturis for

flow indication

Cameron staff (Dave Markowski) very knowledgeable about process

18

Flow Validation Method

19

Unit 2 Thermal Power Estimator 5/23/2011

Description Tag Name Units Today Target EstimatedEstimated -

TodayEstimated -

Target UncertaintyPower Health

Rated Core Thermal Power B21CJ6204 MWt 3425.4 3428.8 3421.4 -4.0 -7.4 0.84% -0.12%

Feedwater Flow Rate C32CF6002,3KLB/HR 14987.8 14767.2 14720.2 -267.5 -47.0

.

Description Tag Name Units TodayBenchmark

DataEstimated

CTPInstrument Uncertainty

Adjusted Systematic Uncertainty

Random Uncertainty

Total Uncertainty

Sensitivity (Manual Input)

1/Uncertainty Squared

Weighting Factor

Weighted Contribution

to CTP

0MAIN TURBINE 1ST STAGE PRESSURE N30DP1652 PSIA 840.33 840.73 3424.3 1.20% 1.50% 0.2365% 1.5728% 1.000 4042 0.3007 1029.7381

0HEATER 6 EXTRACTION STEAM PRESSURE N30DP1716 PSIA 348.31 349.10 3418.2 1.00% 1.50% 0.1407% 1.5262% 1.000 4293 0.3194 1091.6518

1HEATER 6 NORTH SHELL PRESSURE N22DP1627 PSIA 349.38 358.40 3339.8 1.32% 3.00% 0.2957% 3.0577% 1.000 0 0.0000 0.0000

1HEATER 6 SOUTH SHELL PRESSURE N22DP1628 PSIA 329.67 329.58 3426.9 1.32% 3.00% 0.1486% 3.0147% 1.000 0 0.0000 0.0000

0HEATER 5 NORTH SHELL PRESSURE N22DP1621 PSIA 230.00 230.19 3423.1 1.10% 3.00% 0.1356% 3.0122% 1.000 1102 0.0820 280.6387

0HEATER 5 SOUTH SHELL PRESSURE N22DP1626 PSIA 226.77 226.84 3425.0 1.10% 3.00% 0.1603% 3.0171% 1.000 1099 0.0817 279.8922

1HEATER 5 NORTH DRAINS PRESSURE N22DP1711 PSIA 230.54 230.62 3424.8 1.30% 6.00% 0.1239% 6.0051% 1.000 0 0.0000 0.0000

1HEATER 5 SOUTH DRAIN PRESSURE N22DP1718 PSIA 227.30 226.99 3430.7 1.30% 6.00% 0.1291% 6.0055% 1.000 0 0.0000 0.0000

1RHTR/SEP WEST STEAM TO RFPT NORTH PRESSURE N11DP1606 PSIA 223.07 223.34 3421.7 0.64% 5.00% 0.1405% 5.0079% 1.000 0 0.0000 0.0000

1RHTR/SEP EAST STEAM TO RFPT SOUTH PRESSURE N11DP1607 PSIA 223.80 223.95 3423.7 0.64% 5.00% 0.1028% 5.0042% 1.000 0 0.0000 0.0000

1RHTR/SEP WEST DRAIN TO HTR 5 NORTH PRES N22DP1645 PSIA 233.64 234.02 3420.5 0.64% 5.00% 0.1292% 5.0067% 1.000 0 0.0000 0.0000

1RHTR/SEP EAST DRAIN TO HTR 5 SOUTH PRES N22DP1648 PSIA 227.34 226.86 3433.2 0.64% 5.00% 0.0953% 5.0036% 1.000 0 0.0000 0.0000

0RHTR/SEP EAST STM TO LPT CENTER PRESSURE N30DP1657 PSIA 224.62 225.20 3417.3 1.20% 4.00% 0.1388% 4.0096% 1.000 622 0.0463 158.1143

0RHTR/SEP WEST STM TO LPT CENTER PRESSURE N30DP1660 PSIA 223.88 224.43 3417.7 1.20% 4.00% 0.1270% 4.0081% 1.000 622 0.0463 158.2568

0REACTOR TOTAL STEAM FLOW C32DF1061 KLB/HR 14542.50 14558.77 3422.1 2.60% 3.00% 0.2715% 3.0487% 1.000 1076 0.0800 273.8786

0FEEDWATER LOOP A1 TEMPERATURE B21DT2504 DEGF 423.56 423.64 3423.1 1.41% 1.41% 0.0263% 1.4110% 34.260 147 0.0109 37.3327

0FEEDWATER LOOP A2 TEMPERATURE B21DT2506 DEGF 422.38 422.28 3429.4 1.41% 1.41% 0.0264% 1.4110% 34.260 147 0.0109 37.4007

0FEEDWATER LOOP B1 TEMPERATURE B21DT2507 DEGF 422.00 422.24 3417.7 1.41% 1.41% 0.0365% 1.4119% 34.260 146 0.0109 37.2265

0FEEDWATER LOOP B2 TEMPERATURE B21DT2508 DEGF 421.73 421.98 3417.4 1.41% 1.41% 0.0232% 1.4108% 34.260 147 0.0109 37.2827

Sum Sum Sum

13443 1.000000 3421.4131

Power Calculation Independent

Unit 2PWR Est Trend Sheet MW Accounting

Trend

Trend

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

On/Off

Commissioning-Lessons Learned

Fermi’s IPTE process may have not been most efficient means of controlling process

Commissioning process not well understood by plant staff

More tuning iterations were required than expected by plant personnel and communicated by Cameron

One sensor had IGSS firing issue

Level of Detail differences between Cameron and site procedures

20

Commissioning-Lessons Learned

Benchmarking of commissioning process is crucial

CPU temperature alarm needs to be adjusted to allow for location

Delays due to unrelated equipment issues presented scheduling challenges

21

Key Condition Reports

Transducer cover insulation change

Nuisance alarms in IPCS (due to tuning not performed yet) Following completion of the RFO in early December

2010, Fermi operated at ~75% power due to an unrelated issue so final commissioning was not performed until March 2011.

22

Key Condition Reports

1 Failed transducer (provided to Cameron for analysis which later turned out to be an IGSS issue, not really failed)

PARAMETER file issues (due to tuning)

Feedwater temperature lag between LEFM and #6 Feedwater Heater (expected response at low power)

CPU Temperature alarms (temperature limit to be increased following testing/manufacturer approval)

23

End Result

Shifting to LEFM from the venturis resulted in ~1.5% (15-18 MWe) immediate generation increase due to the fouling Fermi had been experiencing.

Plans for MUR continue and it is currently scheduled for 2013. Gain is projected to be another 15-18 MWe.

24

Questions?

25

DC Cook Unit 2 Loses 35 MWs Due to Degraded Feedwater Pump Turbine Condenser Performance

Summary

• In June 2010, Feedwater Pump Turbine Condenser performance lowered to a point where Low Pressure Turbine Condensers were impacted.

• 35 MWs were lost.• Lessons in Condenser Air Removal

System and Steam Jet Air Ejector (SJAE) Operation impacting Generation

Symptoms

• Feedpump Turbine (FPT) Condenser vacuum decreasing (bio-fouling)

• Data:

OEM versus Legacy Operations

• Original Equipment Manufacturer (OEM)• Condenser Air Crosstie Valves – CLOSED• Philosophy: Air removal not impacted by varying

condenser shell pressures, but limited to single air ejector capacity (15 scfm)

• Legacy Operations• Condenser Air Crosstie Valves – OPEN• Philosophy: Any condenser shell can handle up to

60 scfm air leak without losing vacuum• Feedpump & Main Condensers shell pressures

were historically (20+ years) within 0.5 inches Hg

Air Removal System Overview

Solution

1. Throttle Circ Water to Main Condensers to improve Feedpump Turbine Condenser Vacuum (equalized pressure between Main & FPT Condensers)

2. Close Condenser Air-Offtake Crosstie Valve between Main & FPT Condensers

2011 P2EP Conference

Questions and

Answers

Agenda One Day Course Focused on Plant Testing June 28...

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