Text

Meeting Slides, Measurement Uncertainty Recapture Fple/Caldon - NRC Meeting December 16, 2005
	ML060130031
Person / Time
Site:	Seabrook ; (NPF-086)
Issue date:	12/16/2005
From:	Estrada H, Hale S, Hauser E; Caldon, Florida Power & Light Energy Seabrook
To:	; Office of Nuclear Reactor Regulation
References
	PR542, TAC MC8434
	Download: ML060130031 (76)
	v • d • e

FPL Energy Seabrook Station 2 0 C

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MEASUREMENT UNCERTAINTY RECAPTURE FPLE/CALDON - NRC MEETING December 16, 2005 Steve Hale Herb Estrada Ernie Hauser II PR542 1

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All nghts reserved.

FPL Energy' o

Seabrook Station Proposed Agenda Introductory Remarks - NRC, FPL Energy, Caldon

Principles of Operation; the LEFM CheckPlusTm System

Discussion, Topical Areas of Concern (will follow the outline of the attachment to the meeting notice)

Laboratory Testing - Caldon*

Plant Installation - Caldon, FPL Energy UFM Operation - FPL Energy, Caldon X0 Conclusions; Action Items PR542

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FPL Energi Seabrook Station

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LEFM Principles I_1 Xi The volumetric flow in a pipe is given by the integral of the axial velocity over the cross sectional area of the pipe I

1 Y

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pipearea QI=

V (x,y)dx dy axial PR542 3

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Eneqrgy Seabrook Station aL A

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I LEFM Principles

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What the elapsed times of transiting pulses measure 9 1.......................................I................................................ _ h......... *M

'101 V

1 C = sound velocity of fluid at rest tdov = Lpath/(C + V) tup = Lpath/(C - V)

At = tup - tdowl = 2 Lpath V/(C2 -V2) tuptdo

= Lpath 2/(C 2 - V 2)

V = (1/42) At (Lpath/ tuptdowI)

Lpath V = (72) At (Lpatii 2/ tuptdown)

C = L/[tup/2 + tdo./

2 ]

For further study, TP-44 (Reference Tab 4 of INFO-19)

PR542 4

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FPL Energy

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[=12 S;eabrook Station LEFM Principles 2

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The UFM measures the transit times of ultrasonic pulses traveling in each direction along each acoustic path and uses these data to determine the average fluid velocity and the average sound velocity along each chord.

But the time measured includes more than the transit time through the fluid.

tmeasured telec + ttransducers + tcable + tfluid + tdetection Wrnj tter Cable PR542 5

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IleFPL Energy Seabrook Station LEFM Principles

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An 8-path chordal LEFM-the LEFM CheckPlus used for MUR uprates In the 8 path configuration, transverse velocity components exactly cancel The 4 path LEFM Check can be affected by transverse velocity but its sensitivity is low (- 0.2%)

in most hydraulic locations PR542 6

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

A FPL Energy Seabrook Station LEFM Principles o~

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,,sWeSsg f,,§2) li Ultrasonic pulses are generated and detected in an electronics unit, which also processes the transit time measurements and performs the mass flow and temperature calculations Seabrook Electronics Unit shown PR542 7

I FPLEnergy

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iS;eabrook Station LEFM Principles Chordal LEFMs determine volumetric flow by numerically integrating the axial velocity at 4 pre-selected chordal locations The LEFM measures the integral of W2 ID W3 ID Vaxial (x) dx at each location.

The volumetric flow is determined by summing the flow contribution of the four segments. Each l

contribution is calculated as the product of the width of the segment, (wi

ID), and the Vdx integral for that segment.

The low sensitivity of the result to axial velocity YY profile has been determined by analysis and by 1 OOs of hydraulic tests in a wide range of configurations.

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ID PR542

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8

FPL Energy Seabrook Station

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w LEFM Principles The chordal LEFM Mass Flow Algorithm:

4 1

IJ T

Wf = p

PF*Fa3 (T) *(ID/2) i=1 tan(qi)(ti

-f ffi(Ati)

+ Ati / 2 -ri)2 p = f (T. p)

T=fT(Cmean, P) 4 C

=Fai (T)Z[w1 Lffi]/[ti + (Ati/2) -ri]

Cmean a

T i=l Uncertainties Property functions and pressure measurement, Dimensions, Hydraulics (axial profile), Time Measurements PR542 9

Caklon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Energy Seabrook Station LEFM Principles Representative Mass Flow Uncertainties for LEFM CheckPlus

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TOTAL POWER UNCER7 'AINTY DETERMINATION Parameter(1 )

ER-1 57P Seabrook Station Uncertainty Uncertainty

1.

Hydraulics: Profile factor 0.25%

0.20%

2.

Geometry: Spool dimensions, alignment, thermal 0.09%

0.10%

expansion

3.

Time Measurements: Transit times and non fluid 0.045%

0.07%(6) time delay

4.

Feedwater Density: (2) LEFM temperature 0.07%

0.07%

determination, pressure input, and correlation(5)

5.

Subtotal: Mass flow uncertainty 0.28%

0.24%

(Root sum square of items 1, 2, 3, and 4 above)

6.

Feedwater Enthalpy:(3) LEFM temperature 0.08%

0.08%

determination, pressure input, and correlation(5)

7.

Steam Enthalpy: Pressure input and moisture 0.07%

0.08%

uncertainty

8.

Other Gains and Losses 0.07%

0.03%

9.

Total Power Determination Uncertainty 0.33%(4) 0.30%

Notes for Table are included in handout PR542 10

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FPL Energy Seabrook Station

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-1 LEFM Principles i

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In an 8 path meter, transverse velocity vectors projections are essentially equal and opposite on paired acoustic paths In a 4 path meter transverse projections due to swirl cancel if the swirl is centered. Projections of "Goertler" vortices (from a single bend) also tend to cancel when summed.

1up VT 5dn ldn 5up PR542 11

Caldon, LEFJ. LEFM Check, and CheckPlus are registered trademarks of Caklon, Inc. All tights reserved.

FPL Energy Seabrook Station Ace DEEc 0 LEFM Principles

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o Chordal LEFMs measure the axial velocity profile, characterizing it by its Flatness, the ratio of the outer path average velocity to the inner path average velocity For a 4 Path LEFM F =(V1 + V4)

(V2 + V3)

For an 8 path LEFM F = (V1+V4+V5+V8)

(V2+V3+V6+V7)

PR542 12

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FPL Energy 0

MO SeabrookStation LEFM Principles A

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-@;,,i s Axial profiles in nuclear feedwater systems can vary widely

Inertial effects dominate Wall roughness can be an RANGE OF MEASURED NUCLEAR FEEDWATER PROFILES important factor COMO Reynolds Number is a relatively oooc 1

small and inconclusive factor s90oo If CholdGauss f 0.980OO BUT

_097000_l When the chordal paths are located 098000 0.9500I in accordance with the rules of 0.94000 Gaussian quadrature numerical 0M93000 I

1 10 7

integration, the calibration of a 4 0.92000 IX 106 3x 10 7 0SMOOTHPIPE path chordal meter is not very 0.91000 ROUG H PIPE, e/D = 0.00 15 sensitive to axial profile. The graph 0.76000 0.80000 0.86500 0.0000 1.00000 plots the Profile Factor against ok 7_

6 FPL Energy Seabrook Station

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LEFM Principles a '

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Sensitivity to swirl and other factors Because transverse velocities cancel in an 8 path chordal LEFM, swirl and other vortices do not affect calibration significantly, except as they affect axial profile Experience has shown that the 4 path system integrates moderately asymmetric axial profiles within -0.1%

PR542 e A Caldon, LEFM, LEFM Check, and CheckPlus are registered I &

FPL Energy Seabrook Station LEFI\\

In contrast, an external UFM is constrained to measure a velocity along a diametral path An externally mounted transit time meter measures the diametral average axial velocity The relationship between diametral average axial velocity and cross-sectional average axial velocity is sensitive to profile shape

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4Principles D

I X___ffiS Effect of Velocity Profile on an External UFM 1.4 1.2 F

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9 0.8 0

2 0.0

.2 0.4-0.2-

-0n-repreaative of rounder nuclear profiles reptesentative of flatter nuclear profiles l

-Oiamelral average velocitry for rounder profile I

ametrel verae vselocity fo flatter profile 0000

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-0.8

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- 0 02 Radial distance from centerfin, 04 0.8 0.8 1

PR542 15

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FPL Energy Seabrook Station

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LEFM Principles R..

0 The relative sensitivities of chordal and external UFMs to axial velocity profile are shown in the graph on the right 4pjthdwudan d unmaiu bmsftIN~ffm~AIt8nS 1.003 4 AhG~

0.94 owRN=3x10' R'Ul=31 fant N

,.a.

PR542 16

FPLEnergy Seabrook Station a

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1. Laboratory Testing 1-4,a4"",ASEAN 1:'

041 11

, 0 141 1,

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&'11 Xl The tests calibrate the flow element for they establish the Profile Factor, PF, as form the basis for the uncertainty in the a spectrum of hydraulic conditions; a function of Flatness and also Profile Factor

Test Plan ALD-108 1 Rev. 1 (Reference Tab 5 of INFO 18)

Purpose, ARL and Caldon Responsibilities, Prerequisites, Tests, and Documentation

& Scheduled for January 16-20, 2006 PR542

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FPL Energy Seabrook Station c:7L2 0

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1. Laboratory Testing The Alden Research Lab Facility FIGURE 1 r

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L U-o L________

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IL..J L --

Om" 77'Ma BUILDING El FLO IEASUWE FACILITIES

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All fights reserved.

PR542 18

FPL Energy Seabrook Station E

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1. Laboratory Testing I

41

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44 Full scale model testing of the Beaver Valley 2 flow element PR542 19

Caldon. LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Energy

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===El ISeabrook Station 1.1 Laboratory Testing The Main Feedwater system at Seabrook (PID-1-FW-B20687)

X Feedwater pumps to the four feeds to the steam generators 0 P&ID and Isometric Drawings are included in the handout I.W_

mm PR542 20

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Energy Seabrook Station 11 Laboratory Testing BILE A description of the test configurations 48?~~~~~

s

.i i.ttH'.1 ia Test B-1 Reference configuration i 50-50 Flow split 6 25 weigh tank runs; 5 flow rates over a -4:1 range of flows LEFM SPOOL METERING SECTION 36 x 24" REDUCER SKEJM-30-1l.DWG KRB 12-12-05 PLANT MODEL TEST B-1 FLOW SPLIT -

50/50 PR542 21 PR542 21

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Energy Seabrook Station Laboratory Testing A description of the test configurations 4==Z:1 0=

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v Test B-2 Minimum branch flow 4 25-75 Flow split i 15 weigh tank runs; 3 flow rates over a -2.5:1 range of flows MITSUBISHI LEFM SPOOL METERING SECTION 36" x 24" REDUCER PLANT MODEL TEST B-2 FLOW SPLIT -

25/75 SKEJM-30-2.DWG KRB 12-12-05 PR542 22

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FPL Energy Seabrook Station

1. 1 Laboratory Testing A description of the test configurations

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Test B-3 Maximum branch flow X 75-25 Flow split w 15 weigh tank runs; 3 flows over a -2.5:1 range of flows MITSUBISHI FLOW LEFM SPOOL METERING SECTION 36" x 24" REDUCER PLANT MODEL TEST B-3 FLOW SPLIT -

75/25 SKEJM-30-3.DWG KRB 12-12 PR542 23

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FPL Energy Seabrook Station

1. 1 Laboratory Testing QE[

l A description of the test configurations A'IM e

si6 A

Test B-4, Upstream Profile Sensitivity Remove Flow Conditioner upstream of Branch 50-50 Flow split 25 weigh tank runs over a -4:1 range of flows LEFM SPOOL METERING SECTION 36" x 24" REDUCER SKEJM-30-4.DWG KRB 12-12-05:

PLANT MODEL TEST B-4 FLOW SPLIT -

50/50 PR542 24

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ed9 FPLrEnergy Seabrook Station 1.1 Laboratory Testing A description of the test configurations

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Test B-5 Maximum Swirl Test Half moon plate upstream of 45 degree bend in branch 50-50 Flow split 25 weigh tank runs over a -4:1 range of flows PR542 25

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Energy Seabrook Station 1.1 Laboratory Testing E =QG A description of the test configurations -

evAn" 4: Test A-I Straight pipe-4 A benchmark and low flatness datum 4

25 weigh tank runs over a -4:1 range of flows LEFM SPOOL METERING PLANT MODEL STRAIGHT PIPE TEST SK EJM-30-O.DWG KRB l12-12-05 PR542 26

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Energy 1.2 Laboratory Testing a

=

o Seabrook Station Description of supporting analyses The Preliminary Uncertainty Analysis for Seabrook, ER-482, Rev 1 (Reference Tab 6 of INFO 18)

EFP-6 1, Commissioning Procedure for the LEFM electronics used in the calibration tests (Reference Tab 7 of INFO 18)

A test procedure that establishes the signal quality, coherent noise level, nonfluid time delays, etc. for the lab equipment, thereby establishing the time measurement uncertainties for the calibration test.

PR542 27

Caldon. LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Energy Seabrook Station 1.2 Laboratory Testing

= 9A Description of supporting analyses I". m.~~

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m9 A profile factor calculation and uncertainty assessment will be issued for the Seabrook flow element following the calibration tests. Examples of previous reports are referenced below.

ER -287 Rev. 1, the PF Calculation and Accuracy Assessment for D C Cook 1 (Reference Tab 9 of INFO 18)

FCDP-118, Field Commissioning Data Package which includes the data for EFP-61 for the Cook 1 flow element (Reference Tab 8 of INFO 18)

PR542 n

I FPL Energy Seabrook Station 1.2 Laboratory Testing Description of supporting analyses ip-.'

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A new revision to the Seabrook Uncertainty analysis, incorporating the results of the calibration tests will be issued after these tests are complete.

An example is referenced below.

ER-275 Rev 2 (Reference Tab 1 of INFO 18) The final uncertainty analysis for D. C. Cook 1, incorporating the results of the calibration tests and the plant commissioning PR542

Caldon, LEFM, LEFM Check, and CheckPlus are registered 29 trademarks of Caldon, Inc. All rights reserved.

I OFPL Energy Seabrook Station 1.3 Laboratory Testing C£Q El G

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Summary of data from each lab test The calibration reports and dates for all calibration tests performed for LEFM Check and CheckPlus flow elements (Reference Tab 1 of INFO 19)- (Q-1.3.1)

No data are excluded from any calibration test (Q-1.3.2)

ER 486 Rev. 1 (Reference Tab 2 of INFO 18) is a compilation of calibration data for 44 LEFM Check and CheckPlus flow elements PR542 Caldon. LEFM. LEFM Check, and CheckPlus are registered MU trademarks of Caldon, Inc. All rights reserved.

CA ILPL Energy 1.3 Laboratory Testing C,\\ 0 C=

Seabrook Station Summary of data from each lab test A sample of the data in ER-486: D.C. Cook Unit 2 E Extrapolation to plant conditions based on Flatness is shown DC Cook Unit 2 H-as 1.050 -

1.040 -

1.030 -

1.020 1.010 1.000 -

0.990-0.980 0.970 0.960 0.950 0.7

Alden A Plant

-Unear (Theoretical slope)

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'50 0.800 0.850 0.900 Flatness Ratio 31 0.950 1.000 1.050 PR542

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do FPL EnergV Seabrook Station 1.3 Laboratory Testing A summary of data from each lab test 0

An ISO from ER-486: D.C. Cook Unit 2

I31 DETAIL v IMICATES LMT10N SkwMT AW stem MA"R ETAIL V PR542 32

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FPL Energy 1.4 Laboratory Testing Z El I

Seabrook Station Noise Issues r~.Gd 4v

-,$eim 4

CIB 110 (Reference Tab 4 of INFO 18), was issued on September 2003 analyzing the effects of hydraulic noise and vibrations on chordal LEFMs

LEFM Receiver pass band (700 kHz to 3 MHz) is above mechanical vibration frequencies of piping systems

Pressure pulsations can cause sound velocity variations but effects on LEFM less than 0.05%, bounded by uncertainty allowance for turbulent velocity variations Coherent and random noise from acoustic or electronic sources can cause errors in the measurement of transit time differences-At's Q Measurement errors due to random noise can be reduced to negligible magnitudes by multiple samples Measurement errors due to coherent noise can be significant and must be controlled if the instrument is to remain within its design basis PR542

'2 '

Caldon, LEFM, LEFM Check, and CheckPlus are registered 00) trademarks of Caldon, Inc. AR rights reserved.

di 14 FPL Energy 1.4 Laboratory Testing

_7 0

Seabrook Station Noise Issues LEFMs measure time from the initiation of pulse transmission to the zero crossing of the first positive half cycle of the received signal-the transit time including non fluid delays The graphs show the effect of coherent noise-a 2'

shift in the time at which the first zero crossing of the received signal occurs SNRC = the ratio of the received signal to the SNRC -6.1.6 coherent noise that is present Max At error = (1/SNRC)x(Transducer Period)/Tr The amplitude of the received signal must be monitored to ensure that SNRC remains within acceptable limits The signal to aggregate noise ratio is also monitored PR542 A

Caldon, LEFM, LEFM Check, and CheckPlus are reg 2,mo EXAM istered

FPL Energy 1.4 Laboratory Testing

==E0 Seabrook Station Noise Issues Coherent noise as well as other potential sources of time measurement errors must be monitored in the lab tests as well as in the plant to ensure that a')

This source of uncertainty in the Profile Factor determination is appropriately bounded b)

Time measurement errors in the plant flow determination remain within their budget Temperature changes, either spatially or temporarily, do not introduce errors in a transit time UFM They can degrade the statistics of the transit time measurements thereby requiring larger measurement samples to achieve desired accuracy PR542

Caldon. LEFM. LEFM Check, and CheckPlus are registered SO trademarks of Caldon, Inc. All rights reserved.

FPL Energy Seabrook Station 1.5.1 Laboratory Testing Application of Lab Test Results to Plant; Swirl

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~~i gm On one occasion, the calibration of an LEFM CheckPlus was questioned after 1004 installation. The calibration tests had

'°°A failed to model non planar upstream

-.99 features. Consequently the swirl in the Aon A,

plant was greater than that in the model.

A new calibration test was performed using a 16 inch prototype CheckPlus flow element ("Sputnik"). Model geometry 0.B4-.

was varied extensively, producing the data at the right.

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ti

Ai i

0.8Ao0 0.8800 0.000 0.9200 0.9400 Fftl4.8.

0.9860 Q The sensitivity of the chordal meter to increasing swirl (the lower curve) is entirely due to the increased flatness produced by the swirl.

An adjustment of 0.06% to the plant LEFM Profile factor.

r ER-293, (Reference Tab 3 of INFO 18)

PR542 36 1.0040.

.. 0020.

1.0000-04 AA A

'A A

08800' 09840.._L.A.

0%

8%

I0%

IF%

20%

25%

30%

35%

40%

8whi.

tf 88181 l' bIty 46%

I FPL Energy Seabrook Station 1.5.2 Laboratory Testing Application of Lab Test Results to Plant vt 'A B

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Interpolation/extrapolation of lab test results to plant conditions is performed on the basis of Flatness (see ER-486)

Flatness captures plant-lab differences due to inertial effects, wall roughness AND Reynolds Number In the examples shown (Loop B LEFM at Millstone 3) flatness and RN yield identical results In-plant commissioning tests are covered later in the presentation 1.0150 -

1.0100 1.0050 gL 1.0000 0.9950 0.9900 V------------11 W

0.9850 -II 0.800 0.820 0.840 0.860 0.880 0.900 0.920 0.940 0.

Flatness 960 straight pipe 33-0-67 0-0-100 X

100-0-0 Theoretical Sensitivity ilmplemented PF 1.015 r

T -

III 1

1111 1

1 1 1 11111 1

1 1

1.010 I

I I

-111 I

I I

1.005 1_1 I 1 11 I

I I

I Ifill I

0..9 4

--I-111111 I.

w I

1 1 1 wI Ill-li I

I 111 I

I II 0.990 I

1 I

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I 111111 1

1 11 11 11 0.985

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0.1 t.0-10.0 100.0

- Reynolds-Number/1.000.000 25-25-50

__=_-_

U 33-0-67 0-0-100 Theoretical Sensitivity

_t lamented PF 100-0-0 PR542 37

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F 1.6 Data Analysis Summary

PL Energy Uncertainty Analysis r

0

eabrook Station of the Calibration Data

The 130 weigh tank runs for the 6 hydraulic configurations in which the Seabrook flow element will be tested will be analyzed to determine its profile factor vs. flatness characteristic. These data, along with the signal noise and non fluid transit delay data of EFP-61 will also be used to establish the uncertainty in the profile factor

The elements of the uncertainty in profile factor include:

Facility uncertainty Observational (turbulence, etc.) uncertainty i Time measurement uncertainty Modeling and (Flatness) curve fit uncertainty (extrapolation/interpolation to plant conditions)

The results of the analysis of the Seabrook data will be published in a flow element specific report A typical analysis of calibration data has been cited on an earlier slide (1.6.1)

ER -287, the PF Calculation and Accuracy Assessmentfor D C Cook I PR542 38

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I 4

1.6 Data Analysis Summary Uncertainty Analysis Weabrook Station of the Calibration Data 4

-i

-4d 4

m m

ER-287 Rev. 1 also describes the application of the calibration data to the plant installation (Q-1.6.2)

,sa 4 The final revision of the uncertainty analysis for D.C. Cook 1, (ER-275 Rev 2, cited previously) is an example of the analysis of overall flow, feedwater temperature, and thermal power determination uncertainties, incorporating the results of the calibration tests, as well as the commissioning data of the LEFM in the plant The methodology for establishing instrument uncertainties follows ASME PTCL9.1 and is described in detail on Caldon Topical Reports ER-80P and ER-157P PR542 39

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

I FPL Energy Seabrook Station 1.6.3 Traceability of Laboratory Testing and Plant Installation to NIST a Au_

4=

"

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'- 11 11 -g'q

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.--- F.UOV 6 The Traceability of LEFM Check and CheckPlus measurements has been the subject of an ANS technical paper Traceability of Thermal Power Measurements, Part 1, Chordal Ultrasonic Flow Measurements D. Augenstein, et al.,

- (Reference Tab 7 of INFO 19) 4th International Topical Meeting on Nuclear Plant Instrumentation, Control and Human Machine Interface Technology. September, 2004 PR542 A n

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FPL Energy Seabrook Station 1.6.3 Traceability of Laboratory Testing and Plant Installation to NIST r\\0 z:=:cMc 0

-~=lo 31 w

-a PF-PF,+ dPF.F dF F - flatness - f (RN, Roughness, upstream hydraulic configuration)

F - (L (outside chord velocities)y a (inside chord velocities))

Facility Teast Flow iement calibration atcfiguratio a certiiiehyd rauline wcight, time, To and Pl configuration traceable per to NIST PF) n Wiht"PT u)

U&FM time mea-enem, %6to Tests in varying hydraulic configurations at certified hydraulic traceable to NIST per facility to establish sensitivity of calibration PF to flatness F Figure 1. Length at measurements nlinear -fit (PF - PF) required for flatness 4

(F, - Fe) calculation) also traceable l

The diagram opposite, extracted from the paper, illustrates the traceability of the calibration data (profile factor) as applied in the plant - TP76 (Reference Tab 7 of INFO 19)

UFM time and length measurements, required for field measurement of flatness, traceable.

Confirmation that change in flatness remains within threshold confirms that shape of axial profile remains within allowance for profile change in meter uncertainty analysis

'4 Determine flatness Ff in the field; establish PF for field installation Fro - ("

(outside chord velocities)y (sk (inside chord velocities))

PF -PFP + dPF x Fr(

dF Set threshold for change in flatness, AFT AFT= I/dPF x PF (F)

Where WPF (F) is the allowance for profile shape uncertainty is the meter uncertainty analysis For subsequent flow measurements in the field, confirm flatness is within threshold:

F.,- (

(outside chord velocities)y (L (inside chord velocities))

(FP,- Fro) < AFT ? If so, measurement is valid.

If not, measurement is rejected.

4.-

'4 PR542 41

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Energi Seabrook Station

2. Plant Installation 2.1 Specification for the UFM

4.

1 c10

=I=r-0 2 =

& The FPL Energy purchase specification is the governing document (Reference Tab 10 of INFO 18) 0 The preliminary uncertainty analysis for Seabrook, ER-482, previously cited, forms the performance specification for the LEFM FPL nry i

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2.18 Wut.

1 2.59 5bAPODLOADl 2.20 BOCJNDALYDELVdM. -

Y_

6 221 a25 AND mm 2.22 DnIOa -

Pe I of 39 PR542 42

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

6 FPL Entergy Seabrook Station

2. Plant Installation 0

2.1 Specification for the UFM a

LEFM Uncertainties versus Flow Rate Nozle and LEFM Mass Flow Errors as a function of food flow and temperature, LEFM properties fixed at 170 F below 250 F Volumetric Flow:

Most error contributors affect the measurement as a % of reading.

Exception: At errors which affect the measurement as a

% of rated flow

Mass flow:

Follows volumetric flow, density error due to temperature is a small % of reading 20.D0%

15.00%

10.00%

-0 a

I.

I.-

.4

%5.0%

10.0%

15.0%

200 20 A

_l 0.00%

0.

Fonze, psiiv7ero Pi.(Flow nozzle, poitve dp mui

-Pyiflow nozzle negalive dp efror on nnfi 1]U.WUb I

\\ /

-15.00%

-20.00%

Mms flow %raled PR542 43

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All fights reserved.

FPL Energy Seabrook Station

2. Plant Installation 2.1 Specification for the IJM

£~7i o c

=z1c o

a

=

1H=~

px' Ot

11 I LEFM Uncertainties versus Flow Rate Temperature derived from sound velocity can only be used above temperatures

- 2500 F.

Between this temperature and 150TF the RTD provides the mass flow computation and temperature output Temperature errors range from +1.5 degrees at 200 F to

+0.6 degrees at 430 primarily because of the changing slope of the temperature-sound velocity curve Sound Velocity vs. Temperature In pure water at 1000 psla 62000 60000

° 58000 a.

X 5M000 5ao

- 52000 0 000 400 0

50 100 150 200 -

-250 300 Tem wroxs. dagrms F 350 400 450 500 PR542 44

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Energy

2. Plant Installation 0 =

M0 Seabrook Station 2.2 Flow conditioners

-w As discussed in the calibration test slides, flow conditioners are used in calibration testing to "homogenize" upstream hydraulic effects

LEFM Check or CheckPlus flow elements are typically not installed downstream of flow conditioners in nuclear feedwater systems 4* Tests of chordal LEFMs in petroleum applications show that flow conditioners should be installed about 15 diameters upstream of the flow element if a lab calibration is to be transferred to the field X6 Experience in petroleum applications shows that tube type flow straighteners preserve distortions in axial profile that would otherwise dissipate PR542 45

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

FPL Energy Seabrook Station

2. Plant Installation 2.3 Description of Feedwater System a

a-1---

-=

2.3.1 P&ID and Isometric Drawings are included in the handout PR542 46

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. All rights reserved.

di f4 FPL Energy

2. Plant Installation a

==^

Seabrook Station 2.3 Description of Feedwater System 2.3.2 Hardware that can affect the profile The model includes The lateral Baao

C _

4 Bend upstream of the lateral branch

Reducer upstream of lateral straight The model does not include The long straights, planar bends and non planar bends from the outlet water boxes of the HP feedwater heaters 4 These effects are bounded by the test with the flow straightener upstream of the branch elbow removed and by the test with the "half moon" plate installed upstream of the branch PR542 47

FPL Energy

2. Plant Installation D

==[_O Seabrook Station 2.3 Description of Feedwater System 2.3.2 Hardware that will not affect the profile 1 1/2 inch vent and drain connections are located - 5 diameters upstream of the LEFM. The interfaces between the connections and the ID of the upstream pipe are flush. The lines are capped. Experience with similar connections show that they will not affect the axial profile seen by the LEFM X The tubes of the feedwater heaters act to eliminate the impact, on the profile, of hydraulic features upstream of the heaters

The 25-75 and 75-25 flow split tests bound the effects of operations with a heater bypassed PR542 48

FPL Energy

2. Plant Installation Ad MO Seabrook Station 2.3 Description of Feedwater System 2.3.3 Potential bypass flow paths 0 A sample connection immediately downstream of the LEFM is used intermittently to sample the chemistry of the feedwater. It is a 1/4/ inch connection and, if in service, would result in a negligible but conservative flow error.

1 inch chemistry injection connections in each of the individual steam generator feeds (4 total) are used only to inject chemicals during steam generator wet lay-up 4 inch emergency feedwater connections to each steam generator (4 total) can inject feed only if the emergency feedwater pumps are in operation, not a normal full power condition

==

Conclusion:==

No plausible bypass paths PR542

Caldon, LEFM, LEFM Check, and CheckPlus are registered 49 trademarks of Caldon, Inc. All tights reserved.

FPL Energy Seabrook Station

2. Plant Installation 2.4 Rationale for LEFM Location

£Z

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=

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'g

=-==.

11 - -"'

'. I

'

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-44

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'

X' '"M

', "

-v'r

^;s.

m e,

SNm AE nWW~'t O FPL Energy Criteria X Located inside (OE with existing system)

Facilitate maintenance X& Caldon Criteria Capability to model 6 Access for installation and maintenance 0 Consistent with the guidelines PR542 50

FPL Energy

2. Plant Installation Q 0 gyro SeabrookStation 2.5 Pre-operational Test Configurations

The parametric approach to calibration tests for LEFM CheckPlus flow elements obviates the need for varying feedwater system configuration A change in configuration may change the axial profile Axial profile is monitored to ensure that it remains within allowable variation (+/-0.05 change in Flatness) established at Commissioning Experience shows that changes in flatness exceeding +/-0.05 are extremely unusual Data supporting these conclusions can be found in Caldon Engineering Report ER-262 (Reference Tab 5 of INFO 19)

Spatial and temporal variations in feedwater temperature do not affect LEFM performance.

PR542 51

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caklon, Inc. All nghts-tested

2. Plant Installation FPL Energy 2.6 Comparison and Evaluation of Lab

==

O Seabrook Station Test Configurations with Plant Installations e~

A-n*

m 4

ts 2.6.1 Assessment of changes in profile between the laboratory test and the plant installation ER-486 provides calibration data for a comprehensive sample of installations, showing the Flatness measured in plant for each. For several of the installations variations in Flatness in plant are also shown ER-262 contains a comprehensive listing of measured variations in Flatness for 16 installations. Appendices describe the circumstances of two significant variations (Flatness changes of 0.04 to 0.05)

Caldon certifies the LEFM performance for all practical upstream hydraulic configurations including variations in lineup, wall roughness, and feedwater temperature/viscosity PR542

2. Plant Installation FPL Energy 2.6 Comparison and Evaluation of Lab 0

==o Seabrook Station Test Configurations with Plant Installations 2.6.2 Changes in profile are detected by changes in Flatness which is automatically measured and alarmed if a change exceeds +/-0.05.

There are no restrictions on the LEFM in terms of total flow rate or the flow rate in either branch of the lateral upstream of the LEFM

PR542

2. Plant Installation FPL Energy 2.6 Comparison and Evaluation of Lab Seabrook Station Test Configurations with Plant Installations 11-M--

Dee

- ----11--'1-7'

'Z-

2.6.3 This question has been addressed in previous slides.

Comment: While Caldon has used computationalfluid dynamics for parametric analyses offlow effects (e.g., the distortion of the flow field produced by the transducer apertures in smallflow elements) we have found that the CFD methodology is generally not accurate or traceable enough to use to establish profile factors.

PR542 54

FPL Energy Seabrook Station

2. Plant Installation 2.6 Comparison and Evaluation of Lab <

Test Configurations with Plant Installations§~

X H:

1 P

o m

A El 0 czScz1c o

-=

LI '--

I I "-own 2.6.4 The calibration process establishes the sensitivity of the profile factor to profile flatness. The uncertainty in applying this relationship to the plant conditions, as established by the flatness measured during commissioning is typically in the order of +/-0. 1%

PR542 55

Caldon, LEFM, LEFM Check, and CheckPlus are registered trademarks of Caldon, Inc. AU rights reserved.

I

2. Plant Installation "Nw,FPL Energy 2.6 Comparison and Evaluation of Lab 1_

MO Seabrook Station Test Configurations with Plant Installations 2.6.5 The effect of noise in the plant Coherent acoustic and electronic noise can cause errors in the measurement of At's To ensure that the errors due to noise remain within the bounds budgeted in the site specific uncertainty analysis:

During commissioning, the magnitudes of the received signals, coherent noise, and random noise are measured in each direction for each acoustic path, to ensure that potential errors from these sources are within the uncertainty budget

The magnitude of the received signals is continuously monitored during subsequent operation of the LEFM. If the signal strength on any acoustic path falls below the level at which the signal/coherent noise ratio is acceptable (from the standpoint of the budgeted uncertainty) that signal is rejected. Continuous rejections cause a path to be declared "out of service" and the meter will enter the

",maintenance mode" with increased uncertainty (and therefore a lower allowable thermal power).

In addition, a diverse back up, the ratio of signal strength to the aggregate noise (coherent plus random) is also used as a measure of signal acceptability PR542 56

2. Plant Installation FPL Energy 2.6 Comparison and Evaluation of Lab Seabrook Station Test Configurations with Plant Installations'

! - i..xA5 I~Z7L2 0C=

0 i

H C=ssai

-=

wood 4

2.6.6 Effect of pipe roughness changes An increase in pipe roughness will tend to decrease the flatness of the axial profile (because it makes the profile more rounded). The change in profile factor should be characterized by the parametric calibration tests. Typically, an increase in roughness will change the calibration by less than 0. I%, within the uncertainty budget for such effects.

PR542

2. Plant Installation FPL Energy 2.6 Comparison and Evaluation of Lab c D Gino Seabrook Station Test Configurations with Plant Installation a

R,

T W

-n?,

2.6.7 An examination of the evaluation results ER-262 and ER-486 provide a comprehensive database comparison between profiles encountered in lab calibration and encountered in the plant Important observations are:

Plant profiles cannot be precisely predicted in the laboratory

Profiles are subject to change over time and in fact, change in 100% of the cases

Therefore, an allowance must be maintained to account for meter factor change commensurate with profile changes observed. The

+0. 1% accounted for modeling uncertainty covers this effect for LEFM CheckPlus Systems PR542 58

FPL Energy

2. Plant Installation Seabrook Station 2.7 Duration of Data Collection During Lab Calibration For each run, filling the weigh tank takes between 40 seconds and 3 minutes to complete depending on flow rate The LEFM performs flow calculations with a frequency of about 50 Hz Thus the number of flow samples N per weigh tank run ranges between 2000 and 9000.

The standard deviation of each flow sample due to turbulence is - 2%.

The standard deviation of the average flow reading for a weigh tank run is reduced by the large number of flow samples. However the reduction is not as great as 1/(N)112 because the periods of some of the turbulent frequencies are only 1 order shorter than the weigh tank fill time The uncertainties due to these statistics are accounted as the observational uncertainty contributor to the profile factor uncertainty PR542

FPL Energy

2. Plant Installation

-\\ 0 =

Seabrook Station 2.7 Duration of Data Collection In the plant A sample period greater than 2 minutes will generally reduce uncertainties due to turbulence to - 0.1 %

However, a longer averaging period may be necessary to reduce observational uncertainties due to limit cycling of the feedwater regulating valves A longer averaging period-in the 5 minute range-may also be required to ensure that the measurement is representative of thermal equilibrium between the reactor/steam generators and the power conversion system Seabrook will use an LEFM rolling average of 30 seconds to be consistent with the 4 minute, 1 hour1.157407e-5 days 2.777778e-4 hours 1.653439e-6 weeks 3.805e-7 months , and 8 hour9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months rolling averages currently used at the plant PR542

FPL Energy Seabrook Station

2. Plant Installation 2.8 Evaluation of UFM c ve Operational Characteristics o

A.;),.

-1 EFP-61 is performed to commission the LEFM in-plant Signal Quality is confirmed (e.g., coherent and random signal noise ratios, reciprocity of upstream and downstream received signals)

Non fluid time delay inputs are confirmed by in-plant measurements for each acoustic path Settings for individual path alarms are established Upstream and downstream gains (signal magnitude)

Upstream and downstream signal/(aggregate) noise ratios (diverse backup to the gain alarms)

Individual path reciprocity requirements are established Allowable variations in transit times and At's are established, for use in signal processing filters PR542 61

At

.2. Plant Installation FPL Energy 2.8 Evaluation of UFM Seabrook Station Operational Characteristics t

Flatness is measured for each 4 path acoustic plane and for thi as a whole

The appropriate profile factor for operation in the 8 path (

mode is established

The range of acceptable changes to Flatness is established settings for the high and low flatness (profile change) alar The profile factors for each acoustic plane are established for plane is out of service (with reduced system accuracy in the "maintenance mode")

Settings for other system level alarms are established Allowable variation in individual path sound velocity ver:

sound velocity from all paths cjiZQ El EZ=ZDEa 0 an g

-men 1

==-a__

J5 i_-=

-~-

e 8 path system CheckPlus)

I to obtain the ms use when one sus average PR542 62

FPL Energy Seabrook Station

2. Plant Installation I

=

E2'1 ~

2.9 Vendor Validation and Certification S^ i

~

~P'S..

The final revision of the uncertainty analysis engineering report incorporates the results of the commissioning process ER-275 (for D.C.Cook) has been provided as an example (Reference Tab 1 of INFO-1 8)

The Caldon letter forwarding the final revision of the uncertainty analysis also forwards a certificate of compliance for the UFM installation 1k An example is shown (Reference Tab 9 of INFO-i9)

PR542 Caldon. LEFM. LEFM Check, and CheckPlus are registersd SO trademarks of Caldon, Inc. All rights Taserved.

FPL Energy Seabrook Station

3. UIFM Operation 3.1 Description of the UFM's

=A error analysis methodology

1i-4"^"

Am

=

ZDME2]

Table 6-1 of ER-80P lists the bounding, validation, and verification procedures for each elemental uncertainty of the uncertainty analysis of Appendix E of that document. The table also applies to the uncertainty analysis of Appendix A of ER-157P (for CheckPlus Systems). Table 6-1 demonstrates that all error contributors that can plausibly change in the short term in the field are alarmed.

Note: The table indicates that item 5c, signal to coherent noise ratio, is not alarmed. The LEFM does provide alarm protection for this variable in the form of a high gain (low signal strength) alarm.

PR542 64

Ile

3. UFM Operation FPL Energy 3.1 Description of the UFM's

=

Seabrook Station error analysis methodology r

IeD, r.-r*

-e --

3.1.1, 3.1.2 Changes in profile are recognized by changes in the measured flatness. An allowance for changes in flatness is included in the error budget. The allowance takes the form of a profile factor uncertainty - +/-01%. If a measured change in flatness exceeds that which would cause a change in calibration exceeding 0.1%

(flatness change -0.05), the condition is alarmed, the meter is considered "failed", and its output is not used.

The discussion in 3.1.2 appears to imply that errors in the LEFM are detected by comparing its indication with other plant indications. The LEFM does not rely on other plant indications for the detection of errors. Nevertheless, licensees are encouraged to perform calculations to determine a "best estimate" of the feedwater flow, as a diverse check. Caldon Information Bulletin CIB-121, Appendix A, (Reference Tab 11 of INFO-1 8), describes a rigorous process for forming a best estimate.

PR542 65

FPL Energy Seabrook Station

3. UFM Operation 3.1 Description of the UFM's error analysis methodology

/--\\

C2 p

3.1.3 Operational limits on the use of the UFM There are no operational limits on the use of the LEFM 3.1.4, 3.1.5 Effect of operating at operational limits, Cross Checking These topics are not applicable to LEFM Check and CheckPlus Systems PR542 66

3. UFM Operation FPLEnergy 3.1 Description of the UFM's

=,

==

Seabrook Station error analysis methodology 3.1.6 Effect of differing temperatures in the two feeds to the main feed header Temperatures of the two feeds may differ by 10 or 20F during normal operation and may differ by as much as 300 or 40"F if one of the two heaters is out of service, isolated and bypassed. Experience with similar situations in other installations shows the following:

Whether the lateral mixes the fluid or not, the LEFM will measure the bulk average feedwater temperature within its design basis accuracy

(-+0.6 degrees) because the sound velocity is numerically integrated over the pipe cross section (unlike RTDs which are point measurements).

v If significant streaming (varying spatial temperature gradients) is present, it may be necessary to increase the set point for the system alarm on path sound velocity differences.

Streaming can also increase variations in transit time, which may require broadening the statistical filter setting on this variable. (This measure was necessary to obtain an accurate reactor outlet temperature measurement in the presence of a coolant temperature gradient of about 200).

PR542

FPL Energy

3. UFM Operation Seabrook Station 3.2 Control Room Procedures

Operations personnel reviewed LAR and procedures to is required changes

Procedures revised to reflect MUR power level Maintenance Department - I&C notified of system alarm Allowed Outage Time (AOT), and Action Statement reqi provided in LAR 05-04 Attachment 1, Section 2.4 (page Will be incorporated as a Limiting Condition for Operatiox Technical Requirements Manual Although Caldon Topical Report provides an uncertainty one plane of LEFM CheckplusTm, power will be reduced pre-MUR levels when required by TRM Action Statemej PR542

Caldon, LEFM, LEFM' r-\\7 U EZ E MO rz f3-=

FPLEnergy

3. UFM Operation r-\\

_c= \\

Seabrook Station 3.3 Personnel Training X One of significant lessons learned with industry over power events was over reliance on vendor expertise

Took an aggressive approach to training General description of training provided in LAR 05-04, Attachment 1, Section 2.4 (Page 2-8)

Training courses at Caldon to train the trainers

- Engineering and Maintenance personnel Specific training for operators as part of the licensed operator training classes prior to the refueling outage PR542

3. UFM Operation FPL Energy 3.4 Operational Experience with Seabrook Station Currently Installed UFM' s W3

Flow rates in the individual steam generator leads are currently measured by two path chordal ultrasonic flow elements designed and built by another vendor X When the vendor no longer supported these nuclear installations, Seabrook contracted with Caldon to provide signal processing electronics (an LEFM 8300) so that the instruments could be used as a check on the venturis FPL Energy Experience No operational experience with the Caldon LEFM CheckPlusTm Older devices installed since original plant startup

- Maintenance, Engineering, and Operations personnel very familiar with maintenance and operation of the system

- Primary maintenance issues have been weather exposure and obsolescence PR542 71

FPL Energy Seabrook Station

3. UFM Operation

, 3.5 Time dependent plant conditions

- F that might affect UFM performance a

1

.14 "5- '

I==c-o iig

ER-262, previously cited, describes changes in velocity profiles that have been measured in nuclear feedwater systems. One case, documented in Appendix A of that report, describes a significant change in axial profile and swirl brought about by a marked decrease in wall roughness as evidenced by a flattening of the axial profile and increased swirl. The change in roughness is believed to have occurred as a result of several days of operation in the "cold recirculation" mode, at high pH. As described in the reference, the effect of the change in flatness on the LEFM calibration was less than 0. 1%.

The error was conservative Corrosion products do not preferentially deposit on the ID of the LEFM flow element (as they do in the throat of a flow nozzle). The interior diameter of the flow element is monitored by periodic measurement of the wall thickness, under the ISI program. A conservative allowance for wall thickness change (+/-15 mils) is included in the ER-157P uncertainty analysis PR542 72

FPL Energm Seabrook Station

3. UFM Operation x

3.6 Available comparisons of I

r UFM indications with other parameters

....q ",I X

I......

- = a lcn 0

Topic does not appear to apply to Seabrook since UFM is not yet installed.

As noted previously, comparisons with other plant parameters are not necessary to validate LEFM operation.

Nevertheless Caldon encourages users to form a "best estimate" of feedwater flow using diverse other indications. The best estimate methodology is described in Appendix A of CIB-121 Rev. 0, referenced earlier.

FPL Energy Monitoring primary and secondary parameters Existing UIFMs and venturies provide additional feedwater flow indication Evaluating additional "best-estimate" methods, including River Bend method PR542 73

FPL Energy Seabrook Station

3. UFM Operation 3.7 Participation in Caldon Nuclear Users' Group (CNUG)

?1L2 o &21= c:

Or Agendas and attendees for the annual meetings of CN`UG are provided (Reference Tab 8 of INFO 19)

FPL Energy decision to purchase in 2005 Obtained previous CNUG meeting minutes Reviewed and applied applicable information for previous CNUG meeting minutes into design change

Registered in the VIP Room on Caldon Website Will attend Users Group meeting in 2006 PR542 74

3. UFM Operation FPL Energy 3.8 Responding to information cHo712 0

=ZrE\\ 0 Seabrook Station obtained from Users' Group and from CIBs

.~~~~~~~~~~~~1

,Vf; -i>9.i9 i'gX_)Be ii

Users Group meetings are typically documented under self-assessments 0 Condition Report System used to evaluate

- Issues identified

- Applicable Technical Bulletins

- Applicable operating experience 6 Future applicable Caldon Customer Information Bulletins (CIBs) will be processed through the Condition Reporting System PR542 75

FPL Energy Seabrook Station

3. UFM Operation 3.9 Past instances M.1-4" ezJi o

Id.

%,gi ?

~4" 4"I

Past instances where UFM flow rate indications would have resulted in plant operation above the licensed power limit There has never been an instance where the use of an LEFM Check or Check Plus system has led to operation above a plant's licensed power level PR542 7f

Caldon, LEFM, LEFM Check, and CheckPlus are regis-stared 1D trademarks of Caldon, Inc. AM rights reserved.

FPL Energy Seabrook Station t2:7E-\\ 0 fZ==L 0

a Aw Conclusions; Action Items

"'j"" I I

'All I

X Open Discussion PR542 77

v t e Letter Sequence Meeting
TAC:MC8434, (Approved, Closed)
Initiation Request, Request Acceptance... Administration Withholding Request Acceptance Meeting, Meeting, Meeting, Meeting Questions 24 January 2006 1 February 2006 Answers 28 April 2006 Results Approval, Approval, Approval Other: ML053330007, ML060400418, ML061440259, ML061910324
MONTHYEAR2006-01-11 [Table View]

Person / Time
ML060130031
Site:	Seabrook (NPF-086)
Issue date:	12/16/2005
From:	Estrada H, Hale S, Hauser E Caldon, Florida Power & Light Energy Seabrook
To:	Office of Nuclear Reactor Regulation
References
PR542, TAC MC8434
Download: ML060130031 (76)
v • d • e

ML060130031

Text

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C _

==

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