Text

06Q4568-DR-005, Rev 1, Quad Cities ERC Pilot Valve Actuator Vibration Test Report.
	ML061450143
Person / Time
Site:	Quad Cities
Issue date:	04/11/2006
From:	Anagnostis S, Djordjevic W; Stevenson & Associates
To:	; Office of Nuclear Reactor Regulation
References
	FOIA/PA-2010-0209 06Q4568-DR-005, Rev 1
	Download: ML061450143 (72)
	v • d • e

{{#Wiki_filter:Document Type: Criteria Interface WI Report Specification Other Drawing Project Name: Quad Cities ERVs Job No.: 06Q4568 Client: Exelon This document has been prepared in accordance with the S&A Quality Assurance Program Manual, Revision 15 and project requirements: Initial Issue: Rev. 0 Prepared by: Date: Am3/8/06 Steve Anagnostis Reviewed by: Date:

                                   - y4                                    3/8/06 Walter Djordjevic Approved by:                                                                Date:

6Walter DjordJevic 3/8/06 Revision Record: Revision Prepared by/ Reviewed by/ Approved by/ Description of Revision No. Date Date Date 1 Gor4 / See Section 1 4/11/06 4/11//06 4/11//06 SA DOCUMENT APPROVAL SHEET Figure 2.8 CONTRACT NO. 06Q4568 Stevenson & Associates

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 2 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMPBY SA C'K'I ) BY WD TABLE OF CONTENTS 1 Introduction ................................... 6 2 Background ................................... 9 2.1 Degradation Issues ................................... 9 2.2 In situ Vibration Measurements .................................. 10 3 Shake Table Testing - Test Series #1.................................. . 11 3.1 Test Specimens ................................... 11 3.2 Axis Conventions ................................... 11 3.3 Swept Sine Tests .................................. 12 3.4 Aging Tests .................................. 13 3.4.1 Input and Response Levels .................................. 13 3.4.2 Inspection Results .................................. 15 4 Shake Table Testing - Test Series #2 .................................. . 19 4.1 Test Specimens ................................... 19 4.2 Axis Conventions .................................. 20 4.3 Actuator Modifications Made During Testing ............... ................... 20 4.3.1 Pivot Plate Pin Shims .................................. 20 4.3.2 #4 Guidepost Bushings .................................. 20 4.3.3 #4 Solenoid Frame Bolts .................................. 21 4.4 Swept Sine Tests .................................. 21 4.5' Aging Tests .21 4.5.1 Input, Instrumentation, Test Sequence .21 4.5.2 Inspection Results .24 5 Summary and Conclusions .................. 28 5.1 Test Series #1.................. 28 5.2 Test Series #2 .................. 30 6 References .................. 33 7 Tables .................... 34 8 Figures .................. 38 Attachment Al. Test Plan #1 .... ... 30 pages Attachment A2. Test Plan #1 Change Notice 1................... 9 pages Attachment A3. Test Plan #1 Change Notice 2................... 6 pages Attachment A4. Test Plan #2 ................... 25 pages Attachment A5. Test Plan #2 Change Notice 1................... 9 pages Attachment B1. Daily Test Report ACT-1 ................... 27 pages Attachment B2. Daily Test Report ACT-2 ................... 21 pages Attachment B3. Daily Test Report ACT-3 ................... 24 pages Attachment B4. Daily Test Report ACT-4 ................... 29 pages

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 3 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Attachment B5. Daily Test Report ACT-5 .................................................. 20 pages Attachment B6. Daily Test Report ACT-6 .................................................. 17 pages Attachment B7. Daily Test Report ACT-7 .................................................. 13 pages Attachment B8. Daily Test Report ACT-8 .................................................. 15 pages Attachment B9. Daily Test Report ACT-9 .................................................. 17 pages Attachment B10. Daily Test Report ACT-10 .................................................. 9 pages Attachment B1 1. Daily Test Report ACT-11 .................................................. 61 pages Attachment B12. Daily Test Report ACT-12 .................................................. 15 pages Attachment B13. Daily Test Report ACT-13 .................................................. 10 pages Attachment B14. Daily Test Report ACT-14 .................................................. 10 pages Attachment B15. Daily Test Report ACT-15 .................................................. 12 pages Attachment B16. Daily Test Report ACT-16 .................................................. 14 pages Attachment B17. Daily Test Report ACT-17 .................................................. 10 pages Attachment B18. Daily Test Report ACT-18 .................................................. 10 pages Attachment C Sine Sweep Test Data .................................................. 154 pages Attachment D Test Data provided by Quanta Laboratories .................................................. (digital) (Provided in digital format in a ZIP folder named 06Q4568-DR-005 Rev1 Attachment C)

Stevenson & Associates - s . j DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 4 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMPBY SA C'K'D BY WD TABLE OF TABLES Table 1. In-Situ Vibration Measurements .......................................................................... 34 Table 2. In-Situ Vibration Measurements - Banded Power Levels at EPU ............................................ 35 Table 3. Log of Actuator Shake Table Aging Tests - Test Series #1..................................................... 36 Table 4. Log of Actuator Shake Table Aging Tests - Test Series #2 ..................................................... 37 TABLE OF FIGURES Figure 1. ERV Pilot Valve Actuator, as installed in the plant prior to Jan 2006 .................................. 38 Figure 2. 2005 in-situ measurement data, EPU power level, U2 3D ERV and Pilot ........................... 38 Figure 3. Unit 2 ERV 3D actuator guide post after operating at EPU power levels for about 200 days. Measured acceleration levels were 1.5g rms to 2g rms ....................................................................... 39 Figure 4. Unit 2 ERV 3B actuator guide post after operating at EPU power levels for about 200 days. Measured acceleration levels were about 0.4g rms to 1g rms ................................................................ 39 Figure 5. Dresser #1 prepared for testing .......................................................................... 40 Figure 6. Dresser #2 prepared for testing (note washer between spring and bushing) ...................... 40 Figure 7. Dresser #3 prepared for testing ........................................................................... 41 Figure 8. All four actuators mounted on the shake table, prior to installing the covers (Target Rock actuator at left) ........................................................................... 41 Figure 9. All four actuators mounted on the shake table, after installing the covers .42 Figure 10. Y-Axis Swept Sine Plots, Dresser #2 Actuator, Y Response on Left Guidepost . 43 Figure 11. X-Axis Swept Sine Plots, Dresser #3 Actuator, X Response on Left Guidepost. 44 Figure 12. Y-Axis Swept Sine Plots, Target Rock Actuator, Y Response on Switch Bracket . 45 Figure 13. X-Axis Input Swept Sine Plots, Dresser #4 Actuator .46 Figure 14. Y-Axis Input Swept Sine Plots, Dresser #4 Actuator .47 Figure 15. Z-Axis Swept Sine Plots, Dresser #4 Actuator .48 Figure 16. Aging Test Time Histories, Dresser Base Plates, ACT-1 to ACT-5 .49 Figure 17. Aging Test Time Histories, Dresser Base Plates, ACT-6 to ACT-10.50 Figure 18. Aging Test Time Histories, Dresser Plungers, ACT-1 to ACT-5 .51 Figure 19. Aging Test Time Histories, Dresser Plungers, ACT-6 to ACT-10.52 Figure 20. Aging Test Time Histories, Target Rock, ACT-1 to ACT-4 .53 Figure 21. Aging Test Time Histories, Dresser Base Plates, ACT-11 to ACT-14 .54 Figure 22. Aging Test Time Histories, Dresser Base Plates, ACT-15 to ACT-18 .55 Figure 23. Aging Test Time Histories, Dresser Plungers, ACT-11 to ACT-14 .56 Figure 24. Aging Test Time Histories, Dresser Plungers, ACT-15 to ACT-18 .57 Figure 25. Response PSDs, Test ACT-9, Horizontal Direction .58 Figure 26. Response PSDs, Test ACT-9, Vertical Direction .59 Figure 27. Response PSDs, Test ACT-10, Vertical Direction .60 Figure 28. Response PSDs, Test ACT-1 0, Horizontal Direction .61 Figure 29. Response PSDs, Test ACT-1 3, Horizontal Direction .62 Figure 30. Response PSDs, Test ACT-14, Vertical Direction .63 Figure 31. Dresser #1 guide posts after the 9th day of aging tests .64 Figure 32. Dresser #2 guide posts after the 9th day of aging tests .64 Figure 33. Dresser #3 guide posts after the 9th day of aging tests .65 Figure 34. Cracks in solenoid frame of Dresser #3 after ACT-4.......................................................66

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. I PROJECT Quad Cities ERVs SHEET NO. 5 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Figure 35. Cracks repaired and gussets added to the solenoid frame of Dresser #3 after ACT-4 ...66 Figure 36. Damaged bolt holes in Dresser #2 cover after ACT-4 (typical for all actuators) .............. 67 Figure 37. Reinforced bolt holes in Dresser #2 cover after ACT-4 (typical for all actuators) ............ 67 Figure 38. Target Rock - Broken electrical leads after ACT-3 .......................................................... 68 Figure 39. Target Rock - Broken support cylinder after ACT-4 ........................................................ 68 Figure 40. Dresser #4 Broken bolt head - after ACT-16 .............................................................. 69 Figure 41. Dresser #4 - Disengaged contact switch after ACT-16 ................................................... 69 Figure 42. Dresser #1A - Guideposts after ACT-18 .............................................................. 70 Figure 43. Dresser #4 - Guideposts after ACT-18 .............................................................. 71 Figure 44. Dresser #4 (left) and Dresser #1A (right) pivot pins after ACT-17 ................................... 72 Figure 45. Dresser #1A pivot plate after ACT-17 .............................................................. 72

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 6 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'KD BY WD 1 Introduction This report documents a test program to evaluate the effect of operational vibrations on the Electromatic Relief Valve (ERV) pilot valve actuators at the Quad Cities Nuclear Plant. Several components of the pilot valve actuator have degraded with operation, apparently due to high vibrations caused by flow induced acoustical resonances in the Main Steam lines. To address this, several modifications were considered:

1. Modification of the pilot valve actuator internals to produce a more robust design,

2. Relocating the pilot valve and actuator to a location remote from the ERV to reduce the vibrations on the pilot actuator,

3. Replacing the actuator with a more robust product from another vendor.

The purpose of the testing is to develop the data required to determine the acceptable vibration levels for both the unmodified and modified actuator. These levels will be used to:

1. Determine whether the actuators are to be modified, relocated, replaced or some combination of these options,

2. Determine an acceptable level of vibration at the actuator location during plant operation.

The testing included the following actuator designs: Dresser #1: The design used at the Quad Cities Nuclear Plant prior to January 2006 (Inconel posts and bushings). The test actuator was provided by Quad Cities in accordance with Reference 5. The actuator weighed 60 lbs. Dresser #2: The design currently installed at the Quad Cities Nuclear Plant (same as Actuator #1 plus a tight tolerance hardened steel washer placed on the guidepost between the spring and the bushing). The test actuator was provided by Quad Cities in accordance with Reference 6. The actuator weighed 60 lbs. Dresser #3: A modification of the Dresser design developed by GE. The actuator was provided by GE. The actuator weighed 66 lbs. Target Rock: A potential replacement actuator from Target Rock. Section 2 provides background information on the actuators. Section 3 summarizes the testing. Conclusions are provided in Section 4. The testing procedure, daily test reports, and test data are provided in the attachments. Revision I The first series of tests described above were conducted in the period from February 10 - 20, 2006 (see daily test reports ACT-1 through ACT-10.) A second series of tests were conducted from March 21 -

Stevenson & Associates DOCUMENT SHEET NO. 0604568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 7 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD 31, 2006 (see daily test reports ACT-11 through ACT-1 8.) Revision 1 incorporates the second series of tests in this report. The second series of tests included the following actuators: Dresser #1A: A refurbished actuator of the same design as Dresser #1. This actuator functioned as the control - the damage sustained by this actuator provided the basis for comparing this aging test to the previous aging test, and to the operational vibrations. The actuator cover used for the second test series of tests was the same cover used for Dresser #1 in the first test series. Due to bolt problems during the first test series, stiffeners were welded over the bolt holes, and four additional bolt holds per side were drilled (for a total of seven bolt holes per side.) Only three bolt holes per side were used in the second test series - the same three bolt holes used for the original actuators. In the second test series, care was taken to always hand thread the cover bolts - to ensure that the threads were not stripped - and then torque each bolt to 14 ft-lbs using a calibrated torque wrench (The bolts were not torqued during the first test series.) Dresser #3A: A refurbished Dresser #3. This actuator was dismantled and reassembled as the testing proceeded in order to measure the rate of pivot pin wear. This allowed the Dresser #4 actuator to remain undisturbed. By the end of the first test series, the pivot plate pins had worn to the point were the pivot pin no longer lifted the contact when the plunger was actuated. New pivot pins and pivot pin bushings were installed in #3A which are fabricated using a hardened steel (Nitronic 50.) During the first test series, cracks developed in the angles that connect the solenoid frame to the base plate. These cracks were weld repaired and gussets were added. The same solenoid frame (with the gussets) was used in the second test series. The actuator cover used for the second test series of tests was the same cover used for Dresser #3 in the first test series. Due to bolt problems during the first test series, stiffeners were welded over the bolt holes, and four additional bolt holds per side were drilled (for a total of seven bolt holes per side.) Only three bolt holes per side were used in the second test series - the same three bolt holes used for the original actuators. In the second test series, care was taken to always hand thread the cover bolts (to ensure that the threads were not stripped) and then torque each bolt to 14 ft-lbs using a calibrated torque wrench. Dresser #4: The production version of the new GE design. The major changes from the original Dresser #3 design are (1) pivot plate pins and bushings fabricated from hardened steel (Nitronic 50), (2) gusset plates stiffening the solenoid base angles, and (3) stiffeners on the cover to reinforce the bolt holes. The cover had three bolt holes per side in the same locations as the original actuators (a total of three bolts per side.) In the second test series, care was taken to always hand thread the cover bolts (to ensure that the threads were not stripped) and then torque each bolt to 14 ft-lbs using a calibrated torque wrench. The objective of the second test series was to demonstrate the adequacy of the production actuator (#4). The #1A actuator acted as the control - the degree of guidepost wear and pivot pin wear provided

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 8 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMPBY SA C'KD BY WD the basis for comparing the second test series to the first test series and to the operational vibrations. The #3A was essentially identical to the #4 actuator. Its function was to be disassembled between - particularly to measure pivot pin wear - so that the #4 actuator could remain undisturbed until the end of the test series.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 9 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD 2 Background In situ accelerometer measurements show that main steam lines in the drywells at Quad Cities are vibrating at several distinct frequencies in the 140 Hz to 160 Hz range. Analysis indicates that these frequencies are the acoustic resonances of the standpipes branching off the main steam lines to the safety valves and relief valves. The increase in main steam flow rates due to Extended Power Uprate (EPU) has caused these vibrations to increase, resulting in problems with the RPV steam dryer and the pilot actuators on the Electromatic Relief Valves (ERVs). The Quad Cities ERVs are controlled by a solenoid actuated pilot valve. The solenoid actuator, as installed in the plant prior to January 2006, is shown in Figure 1. Energizing the solenoid causes the plunger to move down, traveling along two guideposts and compressing the guidepost springs which hold the plunger up when the solenoid is de-energized. 2.1 Degradation Issues Several components of the pilot valve actuator have degraded with operation. Observed degradations include:

Excessive wear on the bushings that bear on the top of the guidepost springs.

Originally, the bushing material was brass. Due to significant vibrations, the springs wore the brass bushings. The Unit 1 bushings and guideposts were replaced with Inconel (Alloy 750) in April 2005 (Q1 R1 8). Unit 1 operated at pre-EPU power levels (-800 MWe) for about 90 days, then EPU power levels (-920 MWe) for about 160 days. In Unit 2, the original ERVs were replaced with Target Rock PORVs in 1995. The PORVs were removed and ERVs reinstalled in March 2004. Inconel (Alloy 750) bushings and guideposts were installed in the ERVs at that time. Unit 2 then operated for about 400 days at pre-EPU power levels. The actuators were visually inspected and no significant damage was observed. Unit 2 then operated at EPU power levels for about 200 days. Both units were shut down around 1/1/06 and the ERVs were inspected. On some of the valves, the springs had jammed between the bushing and the guideposts, resulting in damage to the springs, scoring of the guideposts, and possibly preventing the actuator from moving. The Unit 2 ERV 3D actuator, which experienced the highest vibrations (see Section 2.2), had the most significant damage. Other actuators experienced lower vibration levels and had lower levels of damage (see Figure 2 and Figure 3) supporting the conclusion that high vibration is the cause of the degradation. All valves in both Units had tight tolerance hardened steel washers installed on the guideposts between the top of the springs and the bushings, and the Units were restarted on 1/19/06.

Loosened / fallen out screws that attach the limit switches.
Worn pivot plate pins.
Wearing indications on the brass sides of the plunger at the pivot plate and at the bottom slots.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 10 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD

Wearing of the lever arm adjusting screw.

Other identified issues that may not be related to vibration induced degradation include:

Binding of the plunger due to an improper spacer size at the roller.
Broken or cracked rivets that attached the support brackets for the guideposts to the actuator body.

2.2 In situ Vibration Measurements The RPV dryers were redesigned and replaced in 2004 / 2005 due to the effect of the acoustic resonances. Vibration levels on the ERV inlet flanges and on the ERV pilot valves were measured at various power levels (References 1, 2). Results at pre-EPU power levels and EPU power levels are summarized in Table 1. These measurements are typically dominated by one or more distinct spikes in the 140 Hz to 160 Hz range, with the highest measurements dominated by a spike at 151 Hz. Figure 2 shows typical measurements. Structures often respond to vibrations well below the dominant frequency range of these measurements. References 2 and 3 provide the 2005 in situ response levels for 0 - 200 Hz and 135 Hz - 165 Hz. The response level for 0 - 200 Hz excluding 135 Hz - 165 Hz is obtained by squaring the two known values, subtracting, and then taking the square root of the result. Results are summarized in Table 2 for EPU power levels. The following conclusions are drawn from the measurement data:

1. EPU levels are generally higher than pre-EPU levels, typically by about a factor of 2.

2. The maximum accelerations are at the U2 3D ERV. The power spectra for the U2 3D measurements are shown in Figure 2. XYZ measurements are available for the ERV, but only the Y measurement is available for the pilot due to instrumentation problems. The XYZ ERV spectra are essentially identical. All are dominated by a single frequency at 151 Hz. The Y Pilot spectrum has a comparable amplitude peak at 151 Hz, and some additional energy at lower frequencies (probably due to the structural modes of the pilot valve assembly).

3. From Table 1, 2.Og rms is a reasonable upper bound estimate of the narrow band motion induced by the acoustic resonances. It was observed at a frequency of 151 Hz for the U2 3D ERV. For this testing effort it will be assumed it has the potential to occur anywhere in the 20 Hz - 200 Hz frequency range, with an amplitude of 2.Og rms in the 100 Hz - 200 Hz, and at decreasing amplitudes in the frequency range from 20 Hz to 100 Hz.

From Table 2, 0.3g rms is a reasonable upper bound estimate of the broad motion from 0 to 200 Hz, excluding the effect of the acoustic resonances.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. I PROJECT Quad Cities ERVs SHEET NO. 11 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD 3 Shake Table Testing - Test Series #1 A test plan was developed. The test plan is included as Attachment Al. The testing was performed at Quanta Labs in Santa Clara, CA from February 6 - 20, 2006. Details are provided below. 3.1 Test Specimens The testing included the following actuator designs: Dresser #1: The design used at the Quad Cities Nuclear Plant prior to January 2006 (Inconel posts and bushings). The test actuator was provided by Quad Cities in accordance with Reference 5. The actuator weighed 60 lbs. Dresser #2: The design currently installed at the Quad Cities Nuclear Plant (same as Actuator #1 plus a tight tolerance hardened steel washer placed on the guidepost between the spring and the bushing). The test actuator was provided by Quad Cities in accordance with Reference 6. The actuator weighed 60 lbs. Dresser #3: A modification of the Dresser design developed by GE. The actuator was provided by GE. The actuator weighed 66 lbs. Target Rock: A potential replacement actuator from Target Rock. The test actuators are shown in Figure 5 through Figure 8. 3.2 Axis Conventions The following axis conventions were used in the testing: For the Dresser actuators: Front Y T Right Left Xo Base plate mounting holes Plan View of Actuator Base Plate

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 12 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA CK'D BY WD For the Target Rock actuators: X Plan View 3.3 Swept Sine Tests Horizontal swept sine tests from were performed over a frequency band from 20 Hz to 200 Hz. An input level of 0.2g was first used. An additional test using 0.5g was then performed to determine if the frequency shifted significantly with amplitude. The complete results are documented in Attachment C. The test plan specified that, based on the swept sine results, the shake table input motion was to be established as a broad band input with several sine waves. However, the swept sine sweep tests showed that the actuator frequencies shift significantly with amplitude. Figure 10 shows that the primary frequency at the top of the guidepost on the Dresser #2 actuator shifts from 93 Hz to 84 Hz when the input is increased from 0.2g to 0.5g. Figure 11 shows a similar drop of about 10 Hz for the Dresser #3 actuator. Even the Target Rock actuator (Figure 12) - which is a more tightly constructed device than the Dresser actuators and exhibited a more linear response - decreased in frequency by about 2 Hz. As a result, it was concluded that the original strategy of aging at specific frequencies identified by low frequency sine sweeps would not work. Instead, to ensure that all resonances would be excited, the nominal (scale factor = 1) table motion for the aging test was set as a broad band white noise of 0.3 g rms from 20 Hz to 200 Hz superimposed on the following set of sine sweeps: From To Sweep Time Amplitude 20 Hz 50 Hz 5 min 0.25 grms 40 Hz 80 Hz 5 min 0.72 grms 60 Hz 100 Hz 5 min 1.3 grms 95 Hz 125 Hz 5 min 2.0 grms 120 Hz 150 Hz 5 min 2.0 grms 145 Hz 175 Hz 5 min 2.0 grms 170 Hz 200 Hz 5 min 2.0 grms The objective of this input is to, at a scale factor of 1, excite any modes in the 100-200 Hz range at the upper bound level of 2g rms measured in the plant at EPU levels. Frequencies below 100 Hz are excited at a displacement level equivalent to 2g rms at 100 Hz. Note, however, that the sine sweeps were applied simultaneously (along with the 0.3g broad band input), each sweeping across its band

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 13 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'KD BY WD over a five minute interval. The total table motion can be computed by summing the squares of the individual components. The total motion, at a scale factor of 1, is 4.28g rms. 3.4 Aging Tests A series of aging tests were run over ten days. After each 24 hour test period, the actuators were removed from the shake table and detailed inspections were performed. The complete test reports for each day are provided in Attachment B. Each day's testing is referred to as ACT-1 through ACT-10. 3.4.1 Input and Response Levels Per Section 3.6.2 of the test plan (Attachment A), each 24 hour test period was to consist of a 10 hour horizontal and a 10 hour vertical test, and followed by a four hour inspection period. The table input was to be the input discussed above, multiplied by a scale factor. Due to practical issues that arose as the testing proceeded, the testing sequence did not precisely follow the plan. The log of tests run is listed in Table 3. For the aging tests, the Dresser actuators were oriented at 45 degrees to the horizontal table motion, and the Target Rock was oriented so that the valve was parallel to the horizontal table motion. See Figure 8 and Figure 9. For the aging tests, the actuators were instrumented as follows: Accelerometer Location Orientation Dresser #1 (same for all Base plate, between the electrical Vertical (Z) Dresser actuators) penetrations. See Figure 6, lower right corner. Dresser #2 (same for all Top of plunger. See Figure 7, upper At 45 degrees to all three Dresser actuators) center. axes. Target Rock #1 Top of cover. See Figure 9, top center. Horizontal (Y) for the horizontal tests, Vertical (Z) for the vertical tests. The accelerometer response time histories are shown in Figure 16 to Figure 20. The response value in the time histories is the root mean square (rms) acceleration, in g's, calculated over a 6.4 second or 12.8 second time period. A brief discussion for each test period follows (a more detailed discussion of the inspection results is in the next section). ACT-1 A horizontal test was run at SF=0.125 for 10 hours as a "shake down". The actuators were then inspected. A horizontal test was run at SF=0.25 for 10 hours each. The Target Rock valve was supposed to be pressurized with 100 - 120 psi of air to keep the seat from vibrating. The valve was inadvertently left unpressurized for the first 2.5 hours of this test. A vertical test was run at SF=0.25 for 10 hours, and the actuators were inspected. ACT-2 A vertical test was run at SF=0.50 for 7:57 hours, followed by a horizontal test for 10:00 hours, then the actuators were inspected.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 14 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD ACT-3 A horizontal test was run at SF=1.00 for 10:00 hours, followed by a vertical test for 8:33 hours, then the actuators were inspected. Based on the response level of the actuators, the decision was made to run the next test series at SF=1.50, rather than at SF=2.00. ACT-4 A vertical test was run at SF=1.5 for 8:00 hours. A horizontal test was run at SF=1.5 for a total of 9:00 hours. After about 2:30 hours, the Target Rock actuator began wobbling. The test was stopped briefly, no action was taken and the test was continued. The inspections were then performed. The Target Rock valve was disassembled and it was found that the cylinder that connects the actuator to the valve base had fractured. Accelerations of about 90g rms at the top of the actuator had been measured prior to the cylinder breaking. No further testing was performed on this equipment. After the test, the steel angles connecting the solenoid frame to the base plate in the Dresser #3 actuator were found to have cracked. The cracks were weld repaired and gussets were welded to the angles. ACT-5 The inspections and repairs described above delayed the start of test #5 into the late afternoon, so it was decided to run a horizontal test through the night. A horizontal test was run at SF=2.0 for 13:11 hours, then the actuators were inspected. The boxes enclosing the Dresser actuators had fractured at a number of locations around the bolt holes where they connect to the actuator base plate. 1/4" x 1-3/8" x 12" steel plates were welded on each side of all three covers to reinforce the bolt holes. ACT-6 A horizontal test was started at SF=2.5. After 1 hour, a total of five (5) bolts securing the covers on Dresser #1 and Dresser #2 had sheared and the test was stopped. None of the bolts on the Dresser #3 actuator had sheared. Response levels on the Dresser #3 actuator were about 1/2 those on Dresser #1 and #2 (see Figure 17). The actuators were removed from the table, all broken bolts were removed and all the threaded bolt holes were dressed with a tap. Given the level of response on the actuators, it was decided that it was not practical to continue testing at these levels with the multi-sine sweep input profile being used. The horizontal test was restarted using an input consisting of a 0.6g rms broad band plus a 4g rms sine at 151 Hz. This input is approximately 2x the maximum plant vibration level as measured at the U2 3D ERV (see Section 2.2). The test was run for 12 hours, and then the actuators were inspected. ACT-7 Prior to this test, four additional bolt holes were tapped into each side of the base plate on all three actuators. A vertical test was run for 14:07 hours using the same input as ACT-6. ACT-8 A horizontal test was run for 19:33 hours using the same input as ACT-6. The input motions for the final two tests sequences were a 0.6g rms broad band input plus a sine dwell at a frequency at or near a resonance for the Dresser #3 actuator. See Figure 25 to Figure 28.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 15 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test ReDort COMP BY SA C'K'D BY WD ACT-9 A horizontal test was run for 8:46 hours: 0.6g broad band + 2g rms @ 63 Hz A vertical test was run for 9:20 hours: 0.6g broad band + 2g @ 70 Hz The actuators were then inspected. ACT-10 A vertical test was run for 10:00 hours: 0.6g broad band + 4g @ 118 Hz A horizontal test was run for 9:45 hours: 0.6g broad band + 4g rms @ 80 Hz The actuators were then inspected. 3.4.2 Inspection Results After each test period, the actuators were removed from the table and inspected. Details are provided in the daily test reports in Attachments BI through B10. The major results of the inspections are summarized below.

Dresser Actuators: Guideposts, Springs and Bushings The guideposts, after the aging tests, are shown in Figure 31 to Figure 33. Wear measurements are summarized below:

Measurement (mils) Original Final Wear Dresser #1 Guidepost O.D. 501 420 81 Bushing l.D. 570 632 62 Dresser #2 Guidepost O.D. - under washer 501 433 68 Guidepost O.D. - under bushing 501 469 32 Bushing l.D. 569 603 34 Washer l.D. 518 532 14 Dresser #3 Guidepost O.D. 505 502 3 Upper Bushing l.D. 508 512 4 Lower Bushing l.D. 506 508 2 Upper Bushing O.D. 802 792 10 Upper Bushing Mating Hole I. D. 805 824 19 The Dresser #1 guidepost shows significant wear, primarily grooves caused by the spring being trapped between the bushing and guidepost. The bushing also showed general wear and grooves cut by the spring. In addition, the top two coils of one spring broke off during ACT-6, and the same spring had worn through the bushing and popped out the other side during ACT-9. By the end of the testing, the other spring had jammed into the bushing, rendering the actuator inoperable. The guidepost wear, caused by 10 days of testing, is not as severe as that shown in Figure 3 for the U2 3D ERV actuator after 5 months at EPU power levels, but it is clearly on the path to that condition. The wear on the test actuator is more severe than that shown in Figure 4 for the U2 3B ERV actuator after 5 months at EPU power levels.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 16 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMPBY SA CK'D BY WD The Dresser #2 guidepost also shows wear, but the wear is smoother. The springs did not jam into the washer, and were not significantly damaged. At the end of the testing, the plunger still moved up and down the guideposts smoothly. The washer is clearly an improvement, but the wear is significant. The original diameter difference between the washer I.D. and the guidepost O.D. was 518 - 501 = 17 mils; by the end of the test this had increased to 532 - 433 = 99 mils. Over a longer period of time, enough wear may occur to allow the spring to intrude between the washer and guidepost, eventually leading to the same sort of damage seen in the Dresser #1 actuator. The Dresser #3 guidepost showed only a small amount of wear on the guide post and the inside of the bushings. There was somewhat more wear on the outside of the upper bushing and the inside of the mating hole of the upper bushing. However, as the spring is captured on the outside of the bushings, none of this wear would lead to jamming of the actuator. The original diameter was 0.505". The minimum diameter at the end of testing was 0.502". At the end of the testing, the plunger still moved up and down the guideposts smoothly.

Pivot Plate, Contact Switch, Actuation After every test, contact switch performance was checked by first manually depressing the pivot plate and then electrically actuating three times by applying a 125V DC current.

Dresser #1 After ACT-3, the pivot plate had loosened (due to pivot pin wear) to the point where the spring had no tension when the pivot plate was in the start position. However, the contact switch could be operated successfully by manually depressing the pivot plate through ACT-9. After ACT-1 0, the plunger was stuck in the down position due to guidepost problems, so the pivot plate was not operable. The plunger would not actuate after ACT-6 because the guidepost spring had jammed in the bushing. The plunger was dislodged and actuated properly after ACT-7 and ACT-8. The plunger was inoperable after ACT-9 because one of the guidepost springs had worn completely through the bushing and popped put the other side. Dresser #2 After ACT-4, the pivot plate had loosened (due to pivot pin wear) to the point where the spring had no tension when the pivot plate was in the start position. However, the contact switch could be operated successfully by manually depressing the pivot plate through ACT-6. After ACT-6, the terminal attached to the solenoid coil broke off, so the plunger could not be electrically actuated (The terminal broke while the actuator was being handled. It is not clear if it broke due to mishandling or if had been fatigued by the testing.) However, the plunger could still be moved smoothly on the guideposts by hand. After ACT-7, manually operating the pivot plate would not lift the contact switch; it would lift if the plunger was manually slammed down onto the pivot plate.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 17 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibraton Test Report COMP BY SA C'K'D BY WD After ACT-1 0, a lead was welded to the coil and the plunger was successfully actuated three times, but the pivot plate did not lift the contact switch. Dresser #3 After ACT-5, the contact switch could not be lifted by manually operating the pivot plate, but electrically actuating the plunger did lift the contact switch through ACT-9. After ACT-10, the contact switch performance was marginal to unacceptable even under electrical actuation. The plunger operated smoothly under electrical actuation after all tests. The design of the pivot plate and contact switch is the same for all three actuators. The pivot plate remains a problem because the pivot pin wears under vibration, resulting in the pivot loosing its fulcrum, after which it cannot lift the contact switch.

Limit Switch Condition & Operation Limit switch functionality was established by a continuity check, and the switches were visually inspected after each test period. Results are summarized below.

Switch SI Switch S2 Dresser #1 Non-functional after ACT-4. Non-functional after ACT-2 Cover came off during ACT-4 Cover came off during ACT-5 Dresser #2 Entire switch fell off during ACT-5 Non-functional after ACT-8 Dresser #3 S1 switch slightly loose in case OK through all tests. after ACT-4; continued to function properly through all tests. Loctite was not applied to the Dresser #1 mounting screws (see Ref. 5). This may have caused the switches to loosen slightly and vibrate more; both switches became non-functional relatively early in the testing. Loctite was applied to the Dresser #2 mounting screws (see Ref. 6). Switch SI remained functional until it fell off during ACT-5 when one of the mounting screws broke. Switch S2 remained functional until ACT-8. Loctite was applied to the Dresser #3 mounting screws, and the mounting plate is thicker and stiffer than the Dresser #1 and #2 plates. The switches remained functional and in good condition through all of the tests.

Solenoid Frame During ACT-4, Dresser #3 developed longitudinal cracks in the crotch of the steel angles connecting the solenoid frame to the base plate (see Figure 34.) The cracks went completely through the thickness of the angle. The cracks were weld repaired and gussets were added (see Figure 35.) The cracking did not re-occur, even though the actuator was subsequently subjected to higher vibration levels.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. I PROJECT Quad Cities ERVs SHEET NO. 18 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD This cracking did not occur on Dresser #1 or #2. It is attributed to two factors: (1) Dresser #3 has a significantly heavier guide post support structure, and (2) Dresser #3 has a rubber isolation pad between the bottom of the frame and the base plate. Both factors increased the bending stress on the angles. The gusset plates reduce these stresses.

Cover The bolt holes in the actuator covers starting elongating and fracturing during ACT-3 and ACT-4 (see Figure 36.) Reinforcement was added after ACT-4 (see Figure 37). The reinforcement stopped the holes from fracturing, but several bolts sheared in subsequent tests.
Target Rock Actuator The electrical leads in the Target Rock actuator broke during ACT-3 (see Figure 38.) The support cylinder connecting the actuator to the valve body fractured during ACT-4 (Figure 39.)

The Target Rock actuator was more lightly damped than the Dresser actuator, resulting in higher accelerations on the actuator. Accelerations approaching 100g rms were measured on the cover prior to the support cylinder breaking.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 19 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD 4 Shake Table Testing - Test Series #2 A test plan was developed. The test plan is included as Attachment A4. The testing was performed at Quanta Labs in Santa Clara, CA from March 21 - 31, 2006. Details are provided below. 4.1 Test Specimens The testing included the following actuator designs: Dresser #1A: A refurbished actuator of the same design as Dresser #1. This actuator functioned as the control - the damage sustained by this actuator provided the basis for comparing this aging test to the previous aging test, and to the operational vibrations. The actuator cover used for the second test series of tests was the same cover used for Dresser #1 in the first test series. Due to bolt problems during the first test series, stiffeners were welded over the bolt holes, and four additional bolt holds per side were drilled (for a total of seven bolt holes per side.) Only three bolt holes per side were used in the second test series - the same three bolt holes used for the original actuators. In the second test series, care was taken to always hand thread the cover bolts - to ensure that the threads were not stripped - and then torque each bolt to 14 ft-lbs using a calibrated torque wrench (The bolts were not torqued during the first test series.) Dresser #3A: A refurbished Dresser #3. This actuator was dismantled and reassembled as the testing proceeded in order to measure the rate of pivot pin wear. This allowed the Dresser #4 actuator to remain undisturbed. By the end of the first test series, the pivot plate pins had worn to the point were the pivot pin no longer lifted the contact when the plunger was actuated. New pivot pins and pivot pin bushings were installed in #3A which are fabricated using a hardened steel (Nitronic 50.) During the first test series, cracks developed in the angles that connect the solenoid frame to the base plate. These cracks were weld repaired and gussets were added. The same solenoid frame (with the gussets) was used in the second test series. The actuator cover used for the second test series of tests was the same cover used for Dresser #3 in the first test series. Due to bolt problems during the first test series, stiffeners were welded over the bolt holes, and four additional bolt holds per side were drilled (for a total of seven bolt holes per side.) Only three bolt holes per side were used in the second test series - the same three bolt holes used for the original actuators. In the second test series, care was taken to always hand thread the cover bolts (to ensure that the threads were not stripped) and then torque each bolt to 14 ft-lbs using a calibrated torque wrench. Dresser #4: The production version of the new GE design. The major changes from the original Dresser #3 design are (1) pivot plate pins and bushings fabricated from hardened steel (Nitronic 50), (2) gusset plates stiffening the solenoid base angles, and (3) stiffeners on the cover to reinforce the bolt holes. The cover had three bolt holes per side in the same locations as the original actuators. In the second test series, care

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 20 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD was taken to always hand thread the cover bolts (to ensure that the threads were not stripped) and then torque each bolt to 14 ft-lbs using a calibrated torque wrench. 4.2 Axis Conventions The following axis convention was used in the testing: Front Y T Right Left I X Base plate mounting holes o 0 o 0 Plan View of Actuator Base Plate 4.3 ActuatorModifications Made During Testing (This section is out of sequence relative to the rest of the report, but it presented here as it clarifies some of the following discussion.) 4.3.1 Pivot Plate Pin Shims Prior to any testing, an initial inspection of the actuators was performed on 3/20/06. It was observed that the #3A and #4 pivot plate had about 25 mils of side-to-side play. #1A appeared to be tighter, but on closer inspection it was determined that this was due to binding due to a slight pin misalignment, and actual play was similar to the others. It was decided that reducing this play would help reduce the pivot pin wear. #3A and #4 were returned to Terminal Manufacturing, shims were installed (304 stainless steel washers placed on one of the pins). This reduced the play to essentially zero. Note that, to maintain consistency with the field condition, #1A was not modified. The actuators were returned to Quanta Labs on 3/21 at about 7 PM, #3A and #4 were visually and functionally inspected, and testing began. 4.3.2 #4 Guidepost Bushings After the first horizontal aging test in this series (ACT-1 1), the plungers on all three actuators failed to actuate when current was applied to the solenoid. Dresser #1A failed because one of the guidepost springs was caught in the bushing and jammed the plunger. Once the spring was freed, the plunger actuated. Dresser #3A and #4 failed because the upper guidepost bushings were bound. Once the bushings were freed, the plungers on both #3A and #4 actuated. The #3A and #4 guidepost bushings had tight tolerances - the bushing IDs were 0.002" to 0.004" larger than the guidepost ODs. The #4 actuator was returned to Terminal Manufacturing and the upper guidepost bushings IDs were increased to 0.014" larger than the guidepost ODs. In addition, the bottom of the upper bushings was chamfered to 0.020" clearance both the upper and lower bushing lips were

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR4005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 21 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD rounded to a radius of 0.020". For comparison purposes, the #3A guidepost bushings were left in the original condition. The #3A bushings bound one more time after ACT-13. The #4 bushings never bound again. In addition, in order to manually depress the plunger, a force of about 10 lb was required to initiate movement on #3, while a force of less than 1 lb was required to initiate movement on #4. 4.3.3 #4 Solenoid Frame Bolts I The bolt heads on three of the four bolts that attach the solenoid frame to the base plate on #4, broke during vertical aging test ACT-16. The bolt heads broke along the red line shown in the following sketch (see also Figure 40.) Due to the fact that the lower leg of the angle thickens towards corner, the bolt head did not rest flush on the washer, resulting in an eccentric point load on the bolt head. #4 was shipped back to Terminal Manufacturing, where the lower leg of the angle was machined (about 0.020" of material was removed) so that the washer lays flat and the bolt head makes full contact with the washer. This change was incorporated in all of the production actuators. Table 4 contains the test log. Figure 22 contains the response time histories for tests ACT-15 through ACT-18. From the response time history for the #4 Base Plate, it can be seen that the bolts began to break about 10 hours into ACT-16 (at about 0:00 hours on 3/29). #4 was repaired prior to starting ACT-

17. ACT-18 was an identical test to ACT-16; #4 withstood the entire 20 hour run without any problems.

4.4 Swept Sine Tests Swept sine tests of the Dresser #4 actuator were performed over a frequency band from 4 Hz to 200 Hz. An input level of 0.2g was used. The tests were first performed on 3/21 with the new pivot plate shims installed. The tests were repeated on 3/23 with the new guidepost bushings installed. The complete results are documented in Attachment C. Select results with the new guidepost bushings are shown in Figure 13 to Figure 15. 4.5 Aging Tests A series of aging tests were run in the period from 3/21/06 to 3/31/06. After each run (nominally 20 hours), the actuators were removed from the shake table and detailed inspections were performed. The log of test runs is listed in Table 4. Each day's testing is referred to as ACT-11 through ACT-1 8. The complete test reports for each day are provided in Attachments B1 1 to B1 8. 4.5.1 Input, Instrumentation, Test Sequence Per the test plan (Attachment A4), the test series was to consist of three pairs of 20 hour tests selected to produce approximately the same amount of damage on #1A as was produced on #1 in the first test series. Each pair was to consist of a 20 hour horizontal test and a 20 hour vertical test using the following three inputs:

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 22 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA CK'D BY WD

1. 0.8g rms broadband from 20 Hz to 200 Hz + 4g rms @ 151 Hz (similar to ACT-7,8) in the first test series,

2. The Scale Factor = 2 swept sine input used in ACT-5 in the first series.

3. 0.8g rms broadband from 20 Hz to 200 Hz + up to three sine dwells based on the resonant frequencies of the actuators.

Due to practical issues that arose as the testing proceeded, the testing sequence did not precisely follow the plan (see Table 4.) A series of four tests (ACT-11 through ACT-1 4) were run using the first input. The second input was not used, as the test team decided that the total input of about 8.5g rms generated by the seven swept sines in this input was unrealistically severe, and risked damaging the actuators in a manner that could not occur in the plant. Instead, a series of four tests (ACT-15 through ACT-18) using the third input. The sine dwell frequencies for this test series were established by considering the acceleration PSDs generated using the first input. These PSDs are shown in Figure 29 and Figure 30. They show the following: In the horizontal direction:

        * #4 has a significant mode at 120 Hz on the top bracket in the plane of the guideposts.

The base plate and top bracket out-of-plane response both drop off after about 80 Hz. The plunger response drops off after about 45 Hz. This shows that the higher clearance bushings are effective at decoupling the plunger from the rest of the actuator.

        * #3A has a significant mode at 60 Hz that involves the plunger. This shows that the tight clearance bushings couple the plunger response to the rest of the actuator.
        *   #1A has a significant mode that shows up on the base plate at about 85 Hz. The plunger is not involved - like #4, the plunger is somewhat decoupled from the rest of the actuator (although there is still enough interaction to cause the springs to wear the guideposts).

In the vertical direction:

For #4, 85 Hz is at or near the peak of the response functions for the top bracket out-of-plane, the base plate, and the plunger. 120 Hz is at the peak of the response function for the top bracket in-plane.
For #1A, 85 Hz is near the peak of the base plate response function and the plunger response function (except for the rising ramp in the low frequencies).
For #3A, 120 Hz is near the peak of the plunger response. Both the plunger and the base plate have their major peaks at 60 Hz, but as this frequency is relatively low and #3A is of lesser interest, there is no real point to exciting this response.

Based on the above, the input for the second set of runs (ACT-14 through ACT-1 8) was set as: Broad Band: 0.8g rms from 20 Hz to 200 Hz

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 23 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Sine Dwells: 3g rms @ 85 Hz + 3g rms @ 120 Hz For the aging tests, the Dresser actuators were oriented at 45 degrees to the horizontal table motion (same as the first test series - see Figure 8), and each actuator was instrumented with two accelerometers: Location Orientation Base plate, between the electrical penetrations. See Vertical (Z) Figure 6, lower right corner. Top of plunger. See Figure 7, upper center. At 45 degrees to all three axes. The accelerometer response time histories are shown in Figure 21 to Figure 24. The response value in the time histories is the root mean square (rms) acceleration, in g's, calculated over a 6.4 second or 12.8 second time period. A brief discussion for each test period follows (a more detailed discussion of the inspection results is in the next section). ACT-I 1 Due to the work involved in making the pivot pin modifications (see Section 4.3.1), the aging tests did not start until 23:00 on 3/21. A horizontal test was run using the broadband + 151 Hz sine dwell for 12 hours as a "shakedown" and to synchronize the testing schedule so that the inspections could be performed in the morning. The intent was to actuate the plungers on the shake table to confirm that they were operating properly and then proceed with a full 20 hour run. However, at the end of the initial 12 hour run, all three plungers failed to actuate. The actuators were removed from the table, disassembled and inspected. #1A failed to actuate because one of the guidepost springs was caught in the bushing and jammed the plunger. Once the spring was freed, the plunger actuated. Dresser #3A and #4 failed because the guidepost bushings were bound. Once the bushings were freed, the plungers on both #3A and #4 actuated. The #3A and #4 guidepost bushings had tight tolerances - the bushing IDs were 0.002" to 0.004" larger than the guidepost ODs. The #4 actuator was returned to Terminal Manufacturing and guidepost bushings IDs were increased to 0.015" larger than the guidepost ODs. For comparison purposes, the #3A guidepost bushings were left in the original condition. ACT-12 Once the #3A and #4 actuators were refurbished, the 12 hour horizontal test was repeated (#1A was left off the table for this run as it was not refurbished after the first 12 hour test). The actuators were the inspected, 19.5 hour vertical run was performed, and the actuators were inspected again. ACT-13 A 20 hour horizontal test was run and the actuators inspected. ACT-14 A 20 hour vertical test was run and the actuators were inspected. ACT-15 The input was changed to the broadband + sine dwells at 85 Hz and 120 Hz, a 20 hour horizontal test was run and the actuators were inspected.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 24 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD ACT-16 A 19.5 hour vertical test was run. On #4, three of the four bolts that secure the solenoid frame to the base plate had broken (see Section 4.3.3 for details.) The actuator was returned to Terminal Manufacturing for repair and modification. ACT-17 A 20 hour horizontal test was run and the actuators were inspected. ACT-18 A 20 hour vertical test was run and the actuators were inspected. 4.5.2 Inspection Results After each test period, the actuators were removed from the table and inspected. Details are provided in the daily test reports in Attachments BI 1 through B18. The major results of the inspections are summarized below.

Guideposts, Springs and Bushings, Actuation The guideposts, after the aging tests, are shown in Figure 31 to Figure 33. Wear measurements are summarized below:

Measurement (mils) l Original Final Wear Dresser #1A Guidepost O.D. 500 408 92 Bushing l.D. 570 594 24 Dresser #3 Guidepost O.D. 500 498 2 Upper Bushing l.D. 503 505 2 Lower Bushing l.D. 503 505 2 Upper Bushing O.D. 800 793 7 Upper Bushing Mating Hole I. D. 806 817 11 Dresser #4 Guidepost O.D. 500 500 0 Upper Bushing l.D. 514 516 2 Lower Bushing l.D. 503* 505 2 Upper Bushing O.D. 800* 792 8 Upper Bushing Mating Hole I. D. 806* 820 14

Not measured - assumed to be the same as #3A The Dresser #1A guidepost shows significant wear (Figure 42), primarily grooves caused by the spring being trapped between the bushing and guidepost. The bushing also showed general wear and grooves cut by the spring. In addition, the top two coils of one spring broke off during the testing. The plunger jammed after ACT-11, was freed and actuated properly after ACT-12 and ACT-13, jammed on I (of 3) actuations after ACT-1 4, 2 (of 3) actuations after ACT-15, and jammed on all actuations after ACT-16, 17, and 18. By the end of the testing, the springs were well jammed into the bushing, rendering the actuator inoperable. The guidepost wear is similar to that from the first test series (Figure 31) - not as severe as that shown in Figure 3 for the U2 3D ERV actuator after 5 months at EPU power levels, but it is clearly on the path to that condition. The wear on the

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 25 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD test actuator is more severe than that shown in Figure 4 for the U2 3B ERV actuator after 5 months at EPU power levels. The Dresser #3A guidepost showed only a small amount of wear on the guide post and the inside of the bushings. There was somewhat more wear on the outside of the upper bushing and the inside of the mating hole of the upper bushing. However, as the spring is captured on the outside of the bushings, none of this wear would lead to jamming of the actuator. #3A jammed after ACT-11 and again after ACT-13 due to binding of the low clearance guidepost bushings, however, once the guidepost and bushings wore in slightly, #3A actuated properly after the rest of the tests. The plunger was always "sticky" - when manually depressing the plunger, a force of about 10 lbs was required to initiate movement. The Dresser #4 guidepost showed no measurable wear, only some burnishing (Figure 43). The bushing showed a slight amount of wear. As with #3A, there was more wear on the outside of the upper bushing and the inside of the corresponding mating hole, but this is not a wear mechanism that would lead to jamming of the actuator. As discussed in Section 4.3.2, the actuator jammed after ACT-11 due to binding of the low clearance bushings, but after the bushing clearances were increased from 0.003" to 0.014", #4 actuated properly after all of tests ACT-12 through ACT-18. In addition, when manually depressing the plunger, little force (20g were recorded. These were most likely due to the contact switch coming loose and striking the accelerometer.

Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 38 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Viibration Test Report COMP BY SA C'K'D BY WD 8 Figures Figure 1. ERV Pilot Valve Actuator, as installed in the plant prior to Jan 2006 2005 Measurement Data, Unit 2, Valve 3D 10

-U2 3D ERVX U2 3D ERV Y a -U2 3DERV Z - U2 3DPilot Y 0 31.25 62.5 9375 125 156.25 187.5 Frequency Hz)
Figure 2. 2005 in-situ measurement data, EPU power level, U2 3D ERV and Pilot
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 39 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Figure 3. Unit 2 ERV 3D actuator guide post after operating at EPU power levels for about 200 days. Measured acceleration levels were 1.5g rms to 2g rms. Figure 4. Unit 2 ERV 3B actuator guide post after operating at EPU power levels for about 200 days. Measured acceleration levels were about 0.4g rms to Ig rms.
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 40 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Figure 5. Dresser #1 prepared for testing. Figure 6. Dresser #2 prepared for testing (note washer between spring and bushing).
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 41 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vi bration Test Report COMP BY SA C'K'D BY WD Figure 7. Dresser #3 prepared for testing. Note: The horizontal table motion is parallel to the table edge visible in the foreground. Figure 8. All four actuators mounted on the shake table, prior to installing the covers (Target Rock actuator at left).
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 42 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Viibration Test Report COMP BY SA CKD BY WD Note: The horizontal table motion is parallel to the table edge visible on the left side of the photograph. Figure 9. All four actuators mounted on the shake table, after installing the covers.
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 43 OF 72 DATE 4/11/06 SUBJECT . Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA CK'D BY WD gn RESPONSE ON GUIDEPOST LEFT Y - AXIS 7.9433 input6(fl: Peak =0.285 low-abort(f) high-abort(f) 1.0000 0.1000 0.0251 .1 20.00 100.00 200O0 Frequency (Hz) gn RESPONSE ON GUIDEPOST LEFT Y - AXIS 2.2909 - - 1.0000 0W 0.1000 - 0.0355 _ 20.00 100.00 200.00 Frequency (Hz) Figure 10. Y-Axis Swept Sine Plots, Dresser #2 Actuator, Y Response on Left Guidepost Upper Plot: 0.5G Input Lower Plot: 0.2G Input
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 44 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vi bration Test Report COMP BY SA C'K'D BY WD gn RESPONSE ON GuidePost Left X - AXIS 7.4989 input7(f):
-_ Peak =0.30 input7(f) high-abort(f) x Y 1 5 7. 7352 4.10183 low-abort(f) 1.0000 "I
I -I-,- -.;;, i, 1-1 ---- - I
- I i i
0.1334 _ 20.C10 100.00 200.00 Frequency (Hz) gn RESPONSE ON GuidePost Left X - AXIS 2.6303 1.0000 0.1000 0.0562 1 - I I -- -:-- -- I'l: A :.:
.-- - -:t=- 1 ----- " I 20.00 100.00 200.00 Frequencly (Hi)
Figure 11. X-Axis Swept Sine Plots, Dresser #3 Actuator, X Response on Left Guidepost Upper Plot: 0.5G Input Lower Plot: 0.2G Input
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 45 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Viibration Test Report COMP BY SA C'K'D BY WD gn RESPONSE ON SWITCH BRACKET Y - AXIS 89.1251
- Input3(f):
I - =0.682
\
IPeak input3(f) V I If high-abort(f) 1 90.5616 39.8131 10.0000 2 132.478 21. 7353 I \1 \
/ \low-abort(f) 1.0000
__ _ _ _ _ __ _ __ _ _ _ _ __ _ __ _ _ _ _ _ _ _ _ _ 1 __ _ __ _ __ _ __ _ _ __ _ __ _ __ _ __ _ _ __ _ __ _ _ _ _ __ _ _
-I , - ' I : I 4 0.1122 L.
20.00 100.00 200.00 r...que-y Ins-gn ESPONSE Et ONSWITCHBRACKET Y-AXIS 39.8107 - input3(ft Peak =0.321 high-abort(f) 10.0000 - A - 1 2 low-abort(f) 1.0000 0.1000 i-= n -- F U.2C31
°00 100.00 200.00 Frequency (Hz)
Figure 12. Y-Axis Swept Sine Plots, Target Rock Actuator, Y Response on Switch Bracket Upper Plot: 0.5G Input Lower Plot: 0.2G Input
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 46 OF 72 DATE 4/11/06 SUBJECT _ Quad Cities ERV Pilot Valve Actuator Vi bration Test Report r COMP BY SA C'K'D BY WD gn RESPONSEON GUIDEPOSTBRACKET X - AXIS 2 8040 , 1 0000 0 1000 0.0178 4.00 10 00 10000 200 00
- Fr.eq-ncy (Hz) gn 1.9387 1 0000 01000 0 0100 00020 1 1 1 1 . I 400 10.00 20000 Fnequency(Hz) gn RESPONSEON THE BASEPLATE Z -AXIS 2.5704 inputS(
1 0000 np (f) H Peek =0 26
-- I 73 1.1712: __=:== _ high-abort(f) 0 = = _ = = = t : c= .... = =1=
0 : . .
. II.' I :
0 0002 400 I ! i I 1000
= ' ~I '::::-=
10000 200.00 Frequnrcy (Hz) Figure 13. X-Axis Input Swept Sine Plots, Dresser #4 Actuator (0.015" Guidepost Bushing Clearance)
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 47 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD gn RESPONSE ON SOLENOIDFRAME Y - AXIS 2,3442 - - impuQ(f): Peak =0.22'
,npat2(f) 1 113 129 1.60966 high-aboOr(o 1.0000 o"Wtbol(f) .. ..--- r 0.1000 I. - I 01'0 II:
0.0316 4.10 10.00 00.00 200.00 Freqency (H.) Figure 14. Y-Axis Input Swept Sine Plots, Dresser #4 Actuator (0.015" Guidepost Bushing Clearance)
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 48 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD gn RESPONSEON GUIDEPOSTBRACKET X - AXIS 5.6234, K~ II input3(i): K inpt3(f) P.4k =0.86 1 103.604 2.26991 hig0-obrrt(f) 1.0000 i t 1 I 0 1' . _ 1;.__ _I I!q!!!l 7t _ _ _ _ _ _ _ _ _ _ 0 - 0.1000 0 0100 ----t- 17~ i/_- X t-------
- V ~_
t_____ : 0.0013 - 4.00 1000 100.00 200 00 Freque..y &Hz gn RESPONSEON SOLENOID FRAME X - AXIS 1 28B2____ ,.inpnt3(f)
-1 91.3212 0.628834 1 _ ,. - a0rltf) high 01000 - -- : - - Iswl- - ____i__ =09C V
I o0100 5W-i / II I
'I A . I I I 1i F-.
0.0010 7 0.0002 - 4.00 10.00 100 00 200.00 Freq.-ncy (Hz) Figure 15. Z-Axis Swept Sine Plots, Dresser #4 Actuator (0.015" Guidepost Bushing Clearance)
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 49 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator V ibration Test Report COMP BY SA C'K'D BY WD Dresser# I Base Plate 25.00 20.00
,, 15.00 m 10.00 5.00 0.00 2/10 2/11 2/12 2/13 2/14 2/15 2/16 Dresser# 2 Base Plate 25.00 20.00 0 15.00 E
0 10.00 5.00 0.00 2/10 2/11 2/12 2/13 2/14 2/15 2/16 Dresser #3 Base Plate 25.00 20.00 (, 15.00 E_ m 10.00 5.00 0.00 2/10 2/11 2/12 2/13 2/14 2/15 2/16 Figure 16. Aging Test Time Histories, Dresser Base Plates, ACT-1 to ACT-5
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 50 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Dresser # I Base Plate 25.00 20.00 a, 15.00
,E 010.00 5.00 0.00 2/15 2/16 2/17 2/18 2/19 2/20 2/21 Dresser # 2 Base Plate 25.00 20.00 , 15.00 0 10.00 5.00 0.00 2/15 2/16 2/17 2/18 2/19 2/20 2/21 Dresser #3 Base Plate 25.00 20.00 an 15.00 0 10.00 5.00 0.00 2/15 2/16 2/17 2/18 2/19 2/20 2/21 Figure 17. Aging Test Time Histories, Dresser Base Plates, ACT-6 to ACT-1 0
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev 1 PROJECT Quad Cities ERVs SHEET NO. 51 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Dresser#1 Plunger 18.00 16.00 14.00 12.00 E 10.00 0 8.00 6.00 4.00 2.00 0.00 2110 2/11 2112 2/13 2/14 2/15 2/16 Dresser #2 Plunger 18.00 16.00 14.00 12.00 - EA10.00 a, 8.00a 6.00 a 4.00 2.00 0.00 2/10 2/11 2/12 2/13 2/14 2/15 2/16 Dresser #3 Plunger 18.00 16.00 14.00 12.00
' 10.00 ," 8.00 6.00 4.00 2.00 0.00 2/10 2/11 2/12 2/13 2/14 2/15 2/16 Figure 18. Aging Test Time Histories, Dresser Plungers, ACT-1 to ACT-5
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 52 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Dresser #1 Plunger 18.00 16.00 14.00 12.00 0 10.00 t, 8.00 6.00 4.00 2.00 0.00 2115 2/16 2/17 2/18 2/19 2/20 2/21 Dresser #2 Plunger 18.00 16.00 14.00 12.00 E 10.00 a, 8.00a 6.00 4.00 2.00 0.00 2/15 2/16 2/17 2/18 2/19 2/20 2/21 Dresser #3 Plunger 18.00 16.00 14.00 12.00 0 10.00 E
, 8.00 6 00 4.00_
2.00 0.00 2/15 2/16 2/17 2/18 2/19 2/20 2/21 Figure 19. Aging Test Time Histories, Dresser Plungers, ACT-6 to ACT-10
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 53 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vi bration Test Renort COMP BY SA C'K'D BY WD Target Rock Cover 120.00 100.00 80.00 E 60.00 40.00 20.00 0.00 2/10 2/11 2/12 2/13 2/14 2/15 2/16 Figure 20. Ai ging Test Time Histories, Target Rock, ACT-1 to ACT-4
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 54 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD DR #1A Base Plate 4.00 3.50 3.00 2.50 w
, 2.00 0)w1.50 1.00 0.50 0.00 3/21 3/22 3/23 3/24 3/25 3/26 3/27 3/28 DR #3A Base Plate 4.50 4.00 3.50 3.00 ` 2 50 E '
i 2.00 _ I 1.50 i 1.00 0.50 0.00 3/21 3/22 3/23 3/24 3/25 3/26 3/27 3/28 DR #4 Base Plate 3.50 3.00 2.50 X 2 00 m 1.50 1.00 0.50 0.00 3/21 33/22 3/23 3/24 3/25 3/26 3/27 3/28 Figure 21. AginggTest Time Histories, Dresser Base Plates, ACT-1 1 to ACT-14
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 55 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Viibration Test Report COMP BY SA C'K'D BY WD DR #1A Base Plate 12.00 10.00 8.00 E 6.00 4.00 2.00 0.00 3/27 3/28 3/29 3/30 3/31 4/1 DR #3A Base Plate 5.00 4.50 4.00 3.50 3.00 g 2.50 2'00I 150 1.00 0.50 0.00 _ i 3/27 3/28 3/29 3/3C DR #4 Base Plate 35.00 30.00 25.00 w 20.00 E
' 15.000 10.00 5.00 0.00 3/27 3/28 3/29 3/3 0 3/31 4/1 Figure 22. Aging Test Time Histories, Dresser Elase Plates, ACT-1 5 to ACT-1 8
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 56 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vi/bration Test Report COMP BY SA C'K'D BY WD DR #1A Plunger 4.00 3.50 3.00 2.50 E 2.00 1.500 1.00-0.50 0.00 3/21 3/22 3/23 3/24 3/25 3/26 3/27 3/28 DR #3A Plunger 7.00 6.00 5.00 u) 4.00 o 3.00 2.00 *_ 1.00 0.00 I 3/21 3/22 3/23 3/24 3/25 3/26 3/27 3/28 DR #4 Plunger 2.50 2.00 0 1.50 0 1.00 0.50 0.00 I 3/21 3/22 3/23 3/24 3/25 3/26 3/27 3/28 Figure 23. Aging Test Time Histories, Dresser Plungers, ACT-11 to ACT-14
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 57 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration TesitReport COMP BY SA C'K'D BY WD DR #IA Plunger 12.00 10.00 8.00 E 6.00 0) 4.00 2.00 0.00 3/27 3/28 3/29 3/30 3/31 4/1 DR #3A Plunger 9.00 8.00 7.00 6.00 u 5.00
0) 4.00 3.00 2.00 1.00 0.00 3/27 3/28 3/29 3/30 3/31 4/1 DR #4 Plunger 9.00 8.00 7.00 6.00 5 00 3.00I 2.00 1.00 0.00 3/27 3/28 3/29 3/30 3/31 4/1 Figure 24. Aging Test Time Histories, Dresser Plungers, ACT-15 to ACT-18
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 58 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD (gn)2/Hz RESPONSEON THEPLUNGEROF DRESSER#3 Z - AXIS 630.96 10000 -- inputS(f): PSD Ms=9 549 . 10.00 - __-T 1 .00 0~01 0.100 0.00 ff';__ f -= Si f FrequencS(Hz) (gn)2/Hz RESPONSEON THEPLATEOF DRESSER#2 Z -AXIS 794533 mput2(f)t 100 00 __ iptX) S ~~~70== _ PSDR-0=0 10,00
-= l h0l-(flR 1.001 = 7-- r= -
0.10 _._ - 0.01. . V - --
- I- ----- -- I- -
UUUI 0.00 _I_ .-_-
...... I- -- ; I :11 -4 i 398E.-06 I 100 30 -re.ur-nco(Hz)
(g)21Hz RESPONSEON THEPLATEOF DRESSER#1 Z - AXIS 794.33
. t _ . ; . : : iput4(1):
100.00 _ - _____ .. _______ PSDRms=0
- ipe4f:= =h0getrrd(.3 10.00 : : := ------ - 9-I) 1.000 :. :: . --
100 =: :___ ___==:=__ :.:L .. _ ~~:::::- 0.10 _ _ ____- __ _ _ :== 001 --- _ _ _ _ _ _ __ _ 0.00 10ooo-05 .. -- - i - 1 26E-06 20 100 200 Frequency(Hz) Note: 2g rms sine dwell imposed at 63 Hz, near Dresser #3 resonance. Figure 25. Response PSDs, Test ACT-9, Horizontal Direction
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 59 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vi bration Test Report COMP BY SA C'K'D BY WD (gn)2/Hz 630.36 _ RESPONSEON THEPLATE OFDRESSERa3 Z- AXIS 10000 = _nput3(D) V 115=2.t60 - 1000_ : 105L .. .=.... . LL 0 10 0.00 0000_ =________ _ _. 20 10 200 Fn~q-ey (Hz) (g)21-Hz RESPONSEONTHE PLATEOF DRESSER#2 Z- AXIS 100.00
, i ,..-.- e inpZ521): Ps0 ms1=1.952 - I - ]inpz2(0).
PSDRfl-0 I I- [7) WiTZT-i z ><-~ 10.00 hi2-1"tl( IOS-abolflI
. . ~.--..-{ - -4Jfl77t ..
1.00 0.10 I -- 0.01 0.00 0.00 20 Fn Irn 100 100 200
. I........... .. . I .
(g0)2/Hz RESPONSEON THE PLATEOF DRESSER#1 Z AXIS 1584.89 PSiDRn160 ji npzt4(f): PSD RMS-8._5 __5_ 100.00 - - . -- - ----- :__ g a b hi o l(1 ___ = r-abort5f o.- 10.00 1.00 - 3 0 .00 6. 6.31E$5 20 100 200 Freq (Hz) Note: 2g rms sine dwell imposed at 70 Hz, near Dresser #3 resonance. Figure 26. Response PSDs, Test ACT-9, Vertical Direction
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 60 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'KD BY WD (gn)2/Hz RESPONSEON THEPLATEOF DRESSER#3 Z - AXIS 2511.'89 : } - 4 A: 1000 00I I m.put3(12:
# t -- - =L __ ___ -= PSDR-=0
_. RMS=4.b4I 100.00 hijh-aboq0(f f f== :? '; e = = f r=E:=f:j:: 0CS.. :'.._ . .f:=<? fc:;;_, I-vW-tbo0(1
= L fL = -TE 0 - =V=C ' _ ..._._ _ _ X :0E L = = V '
10.00 g 0g00-= X.=._ G i .._ =gg- =Xt: 1.00 C== ::= _ = E _ __ _ 7 = _ L== _ = ': _ _
...._ _ _ < .XtA X l __._.. __
0.10 0.01
, , _ W3 0.00 -V -- ~-_i '-If 0.00 20 100 200 I-peov(z (gn)21Hz RESPONSEON THE PLATEOF DRESSER;2 Z -AXIS 2511. 89 __-::::---
_ L _ 1000.00 _ -__ I -t-- - - iopSR2(f): PSDRmR=0O
- - ;nputiP.(f): DD R4.857 100.00 10.00 I vvt Io-aboIlp, TIv-botf 1.00 0.10 0.01 .
I 1I _=:z77_ SOS0 F7= 0.00 8____ 3.16E.05 20 100 200
---- uen04IHz)
(gn)2/Hz RESPONSEON THE PLATEOF DRESSER#1 Z- AXIS 316228 -- - __ __ 1. I . -1 . ...- 100.00
-inp4X4ff): P50 085=3463 j ___ - n --
_ inp ot4(f) _ i ___i __1___________ 10.00 - ._ ________ _ 107i 69 40.69791
' . M_ .2 97.1875 0.427078 --
1.00 - 0.10 0.01 5.00 Wf - - 0.00 - 1.2E-05 20-uF 100 200 FrNqsOicy(HZ) Note: 4g rms sine dwell imposed at 118 Hz, near Dresser #3 resonance. Figure 27. Response PSDs, Test ACT-10, Vertical Direction
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT _ Quad Cities ERVs SHEET NO. 61 OF 72 DATE 4/11/06 SUBJECT . Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD (gn)2/Hz RESPONSEON THEPLATE OFDRESSERh3 Z -AXIS 562341 . MOM.0 W= . i-t3ff): I I 516RM6..674 _:.: I-- 14-- - I I1 Ij -L inpt3(0): D - I1
-t:::- - m -~~~ - - -- ' - 1I 10.00 0.10 ~ -_ - - _ - _
A 0.01 r
- I I sx \ Jli=1 A A=
XT---qrl k I-/ I 0 1...E 00: 1.00&0S 3.16E-07 20 100 200 Fnqup.ey (Hz) (gn)21Hz RESPONSEON THE PLATEOF DRESSER#2 Z - AXIS 3162.28 -. __ _____
= .. _ . _ _
flp.Off)i PSOR-0=S 100000 .365 h2 t _l( 10.00 1.00 - 0.10 0 _01 _ ___- 20 I00 200 (HZ)
-reguency (gn)2-Hz RESPONSEON THEPLATEC F DRESSER#1 Z - AXIS 2511.89 1000 00 -
input4tf):, 100.00 1,000 I ..00....... ..- 0 20 100 200 e sFreqimncy (Hz) Note: 49 rms sine dwell imposed at 80 Hz, near Dresser #3 resonance. Figure 28. Response PSDs, Test ACT-1 0, Horizontal Direction
I Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 62 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Dresser #4, Horizontal Aging, O.8g rms BroadBand + 4g rms @ 151 Hz 1 .OOE02 1 .OOE-01 1 .OOEoOO0 1.00E-01
' .OOE-02 1 .OOE-02 1 .OOE-03 1 .OOE-04 20 40 60 80 100 120 140 160 180 200 Freq-encyl(HZ Top Bracket, In Plane, 5.3g mms - Top Bracket, Out of Plane, 1 .3g rs -Base Plate. Vertical, 2.6g tos --- Pl-ngerOut of Plane & Vertical. 0.8g ros Dresser #3A, Horizontal Aging, 0.8g rms BroadBand + 4g rms @151 Hz 1.006E02 1 .OEl01 1.OOE+OO 1.00E-01 1 0E-02 1 OOE-03 1.00E-04 4U do 1UU 120 140 160 180 200 Freq.ncy l(Hz) -Baca Plate,Vertical. ZOgrots -- PlangetOcI of Plane& Vertical,2.08cots Dresser #1 A, Horizontal Aging, O.8g rms BroadBand + 4g rms @ 151 Hz 1 .OOE002 1 .OOEg01 1 .OOE 000 i 1.OE-O1 1 .OOE-02 1OOE-03 1 .OOE-04 20 40 60 80 100 120 140 160 180 200 Frqency (H.) - Base Plat., Vertical. 3 20 rs- PlongetrOt of Plane & Vertical, 0 8g mms Figure 29. Response PSDs, Test ACT-13, Horizontal Direction
Stevenson &Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 63 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Dresser #4, Vertical Aging, 0.8g rms BroadBand + 49 rms @ 151 Hz 1.00E00; 3 1.O0E+O0 2 1 3 1 .OOE'-O' 1 1 .00E&02 1; 1.OOE-0'I 20 40 60 80 100 120 140 160 180 200 Frq.eocy (H.) Top Bracket, In Plane., 0.8g ros -Top Bracket. Out ofPlane, 6.6g tos Base Plate. Vertical.2.Og ros PlangarOot ofPlan & Vertial., 1 fig ts Dresser #1A, Vertical Aging, 0.8g rms BroadBand +4g rms @151 Hz 1 .00E-c01I 1l.0OE00( I1,OOE-01 I 1.00E-0' I 1.00E-01I 1 .00E-0NI 20 40 60 80 100 120 140 160 180 200 Feq...ncy (Hz)
- Base Plate. Vnti-c, 1 .8g rtt -PlungerOut of Plane & Vertical, 1 .7g ros Dresser #3A, Vertical Aging, 0.8g rms BroadBand + 4g rms @ 151 Hz 1 .OOE.02 1.00E001 1.00E00 I 1.00E-01 1 .OOE.02 1.00E-03 1.O0E-04 20 40 60 80 100 120 140 160 180 200 F"n-fcnry (Hz) = BasePlate. VertIcal 1 8grts-- PlungerOut of Plane & Vertical. 3.6g ros l Figure 30. Response PSDs, Test ACT-14, Vertical Direction
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 64 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vi bration Test Report COMP BY SA C'KD BY WD Figure 31. Dresser #1 guide posts after the 9th day of aging tests Figure 32. Dresser #2 guide posts after the 9th day of aging tests
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 65 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vi bration Test Report COMP BY SA CK'D BY WD Figure 33. Dresser #3 guide posts after the 9th day of aging tests
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 66 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Viibration Test Report COMP BY SA C'K'D BY WD Figure 34. Cracks in solenoid frame of Dresser #3 after ACT-4 Figure 35. Cracks repaired and gussets added to the solenoid frame of Dresser #3 after ACT4
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 67 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vi bration Test Report COMP BY SA C'K'D BY WD Figure 36. Damaged bolt holes in Dresser #2 cover after ACT-4 (typical for all actuators) Figure 37. Reinforced bolt holes in Dresser #2 cover after ACT-4 (typical for all actuators)
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 68 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Viibration Test Report COMP BY SA C'K'D BY WD Figure 38. Target Rock - Broken electrical leads after ACT-3 Figure 39. Target Rock - Broken support cylinder after ACT-4
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 69 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA C'K'D BY WD Figure 40. Dresser #4 - Broken bolt head after ACT-16 Figure 41. Dresser #4 - Disengaged contact switch after ACT-1 6
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 70 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vibration Test Report COMP BY SA CK'D BY WD Figure 42. Dresser #1A - Guideposts after ACT-18
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 71 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Vi bration Test Report COMP BY SA C'K'D BY WD Figure 43. Dresser #4 - Guideposts after ACT-1 8
Stevenson & Associates DOCUMENT SHEET NO. 06Q4568-DR-005 Rev. 1 PROJECT Quad Cities ERVs SHEET NO. 72 OF 72 DATE 4/11/06 SUBJECT Quad Cities ERV Pilot Valve Actuator Viibration Test Report COMP BY SA C'K'D BY WD Figure 44. Dresser #4 (left) and Dresser #1A (right) pivot pins after ACT-17 Figure 45. Dresser #1A pivot plate after ACT-1 7}}

ML061450143

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