NOC-AE-14003161, Engineering Report 1060, Rev. 1, Meter Factor Calculation & Accuracy Assessment for South Texas Project Units 1 & 2.

Engineering Report 1060, Rev. 1, Meter Factor Calculation & Accuracy Assessment for South Texas Project Units 1 & 2.

ML14260A439
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Site:	South Texas
Issue date:	08/31/2014
From:	Augenstein D Cameron Measurement Systems
To:	Office of Nuclear Reactor Regulation
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ML14260A432	List: ML14260A437 ML14260A438 NOC-AE-14003161, Engineering Report 1060, Rev. 1, Meter Factor Calculation & Accuracy Assessment for South Texas Project Units 1 & 2.
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NOC-AE-14003161 ER-1060, Rev 1
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NOC-AE- 14003161 ATTACHMENT 2 Cameron Measurement Systems/Caldon Ultrasonics Engineering Report No. 1060 Rev 1, "Meter Factor Calculation and Accuracy Assessment for South Texas Project Units 1 and 2." (Non-Proprietary)

Measurement Systems CCAMERON Caldon Ultrasonics ER-1060 REVISION 1 AUGUST 2014 Engineering Report No. 1060, Rev 1 Meter Factor Calculation and Accuracy Assessment for South Texas Project Units I and 2 Prepared By: Don Augenstein Reviewed By: David Markowski Reviewed for Proprietary Information By: Ernie HauserO,"-(

ER- 1060 Rev 1

1. rCAMERON Measurement Systems Engineering Report No. ER-1060, Rev 1 August 2014 ER-1060 Rev 1

Preparer: DRA Reviewer: OAPW Table of Contents

1.0 INTRODUCTION

................................................................................................ 3 1.1 S COPE ................................................................................................................ 3.......

3

1.2 BACKGROUND

.................................................................................................. 3 1.2.1 CALIBRATION METHOD ................................................................................... 3 1.3 REPORT

SUMMARY

............................................................................................. 4 2.0 DEFINITIONS ................................................................................................. 5 2.1 METER FACTOR DEFINITION .......................................................................... 5 2.2 FLATNESS RATIO DEFINITION ........................................................................ 5 2.3 SWIRL RATE DEFINITION ................................................................................. 5 3.0 INSTALLATION SITE MODEL ...................................................................... 7 3.1 LOOP A INFORMATION ...................................................................................... 7 3.2 LOOP B INFORMATION...................................................................................... 8 3.3 LOOP C INFORMATION ...................................................................................... 8 3.4 LOOP D INFORMATION ..................................................................................... 9 Trade Secret 4.0 [ 1... 10 j & Confidentiz Commercial 4.1 CALIBRATION DATA USED FOR ANALYSIS .................................................... 10 Information 4.1.1 DATA SET SELECTION ...................................................................................... 10 4.1.2 DATA SET EVALUATION ................................................................................ 10 4.1.3 CALIBRATION DATA ........................................................................................ 10 4.2 PARAMETRIC TESTING ................................................................................... 11 4.3 HYDRAULIC SENSITIVITY COMPUTED FROM CALIBRATION DATA ....... 14 4.4 USING METRICS TO CALIBRATION DATA POPULATION ......................... 15 4.4.1 POPULATION ............................................................................... 15 Trade Secret

& ConfidentiE 4.4.2 POPULATION [ ]...................................................................... 16 Commercial 4.5 METER FACTOR RELATIONSHIP [ ] ...... 17 Information 4.6 HYDRAULIC MODEL SENSITIVITY ............................................................... 19 Trade Secret 4.7 HYDRAULIC SENSITIVITY WHEN IN [ ]................... 19 & ConfidentiU 4.8 QUALITATIVE EXAMPLE [ Commercial I ............................................................................ 20 Inform ation 5.0 METER FACTOR ACCURACY ASSESSMENT ........................................ 23 5.1 FACILITY UNCERTAINTY ............................................................................... 24 5.2 MEASUREMENT UNCERTAINTY ................................................................... 25 5.3 EXTRAPOLATION ALLOWANCE ................................................................... 25 5.4 DATA SCATTER - MEAN METER FACTOR UNCERTAINTY ..................... 27

6.0 REFERENCES

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Preparer: DRA Reviewer: A ER-1060 Rev 1, Meter Factor Calculation and Accuracy Assessment for South Texas Project Units 1 and 2

1.0 INTRODUCTION

1.1 Scope This report documents the meter factor bounding uncertainty analysis for South Texas Project (STP) Units 1 and 2. Once the actual flow elements STP are made and calibrated, the actual calibration data and parametric tests will be used to compute meter factor uncertainty for each unit.

This report's approach is to use the body of calibration and parametric testing that Cameron has performed on 195 nuclear power plant flow meters.

Cameron will use the most conservative approach to compute a bounding uncertainty in the meter factor as applied to STP. Further, additional conservatisms are used such that the uncertainty can be considered to be bounding.

1.2 Background The LEFM flow meter uses measurements of the fluid velocity projected onto acoustic paths to determine the volumetric and mass flow. The LEFM makes the transit time measurements of ultrasonic energy pulses that travel between transducers and combines these with the distance separating the transducers to calculate the velocity. The flow meter uses eight acoustic paths that are arranged as two crossing planes, each plane containing four chords (essentially two four path meters). The LEFM calculates volumetric flow by numerically integrating the fluid-velocity chord length product along the chords.

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Confidential Commercial Information 1.2.1 CalibrationMethod The calibration tests are performed at Alden Research Laboratories (Alden), an independent hydraulic laboratory. Alden provides flow rates up to -4500 m 3/hr (-20,000 gpm). For most hydraulic models, the piping pressure losses and cavitation does limit the calibration flow rates to -3,400 m 3/hr (-15,000 gpm) - depending on the pipe size and flow model components (e.g.,

headers, nozzles etc.).

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During the calibration, reference flow rates are determined by Alden using a weigh tank, fill times, fluid temperature and barometric pressure measurements. All elements of the lab measurements including weigh tank scale, time measurements, thermometers and pressure gages, are traceable to NIST standards. In order to determine the meter factor, the flow meter outputs aire compared against the reference flow rates. Trade Secret &

An actual calibration for South Texas Project uses [ Confidential Commercial Information 1.3 Report Summary Table 1 provides the South Texas Project meter factor uncertainties. Refer to Section 5 for a detailed summary.

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Confidential Commercial Information 1- t Table 1: Uncertainty Summary Trade Secret &

[I Confidential Commercial Caldn Utraonic Pae 4ER-160 ev Information Caldon Ultrasonics Page 4 ER- 1060 Rev I

Preparer: DRA Reviewer: X"ik 2.0 DEFINITIONS 2.1 Meter Factor Definition The meter factor accounts for (typically small) biases in the numerical integration due to the hydraulics, dimension measurements and acoustics of the application. The flow meter software multiplies the result of the multi-path numerical integration by the product of the meter factor to obtain the flow rate.

The meter factor is calculated by the following equation:

MF - QAlden Qmeter Where:

Q meter = Volumetric flow rate from meter (with meter factor set to 1.000)

QAIden = Volumetric flow rate based on Alden weigh tank 2.2 Flatness Ratio Definition Cameron uses the flatness ratio (FR) to quantify the flatness of the velocity profile. FR is defined as:

FR= [V +V 4 + V+V8 V2 + V3 + V6 + V7 Where:

V 1 , V4 , V5 , V8 = velocities measured along the outside chords (or short paths)

V2 , V3, V6. V7 = velocities measured along the inside chords (or long paths)

When a velocity profile is perfectly flat, then FR equals 1.0. When a velocity profile is laminar, then the FR equals approximately 0.38. The limits of 0.38 and 1.0 represent extremes. The FR is a function of Reynolds number but also is strongly influenced by the hydraulics upstream of the flow meter.

Typical feedwater applications have FR in the range of 0.78 to 0.95. Downstream of flow conditioners or long pipe runs > 30 diameters, the velocity profile tends to be pointier and the FR value is lower, 0.78 to 0.80. Downstream of elbows and tees the velocity profile tends to be flatter and the FR value is higher, 0.85 to 0.95. The actual range at a given plant is dependent upon site upstream conditions (for example the hydraulic fittings such as tees, elbows, etc.).

Swirl typically flattens (increases FR) the velocity profile.

2.3 Swirl Rate Definition Swirl can be measured by the LEFM. Cameron quantifies swirl rate with a swirl rate calculation, as follows:

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Preparer: DRA Reviewer: A~ftW Swirl Rate = Average 5I-VV V4 V 2 -V 6 V7 -V 3]

Swirl Rat Avrge - s '.2"-ys 2.

2YL 2.

2"L Where:

V 1, V4 , V5 , V 8 = Normalized velocities measured along outside chords V 2, V 3, V 6, V 7 = Normalized velocities measured along inside chords Ys, YL = Normalized chord location for short and long paths Swirl rates less than 3% are low and are typically observed in models with only planar connections. Swirl rates greater than 3% are considered "swirling". Swirl rates greater than 10% are considered to have strong swirl.

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Preparer: DRA Reviewer: -A4 H 3.0 INSTALLATION SITE MODEL The STP installation sites will eventually be modelled during the calibration. The information regarding location has been provided by STP engineers to Cameron.

The piping arrangements are shown in Figures 1 through 4 (Loops A, B, C and D). In the following figures, the LEFM meter "section" is shown to be 12 feet long. Of that length, 72 inches is upstream pipe (upstream of the flow meter itself). The nominal ID of feedwater piping is 15.25 inches (OD is 18 inches).

3.1 Figure 1: Loop A Installation Site - Total distance is approximately 31 feet 7 1/8 inches (24.9 diameters) downstream of the UVT section (includes 6 feet inlet to meter)

Reference STP drawing 7G362PFW833 Sheet 7 Rev 0 Page 7 ER-1060 Rev 1 Caldon Ultrasonics Page 7 ER- 1060 Rev I

Preparer: DRA Reviewer: L,#1 ff 3.2 Loop B Information Figure 2: Loop B Installation Site - Total distance is approximately 12 feet (9.4 diameters) downstream of the UVT section (includes 6 feet inlet to meter)

Reference drawing 7G369PFW833 Sheet 8 Rev 6 3.3 Loop C Information 12' LEFM 2C Window Figure 3: Loop C Installation Site - Total distance is approximately 9 feet (7.1 diameters) downstream Non-Planar Elbows (includes 6 feet inlet to meter)

Reference drawing 7G369PFW833 Sheet 3 Rev 6 Caldon Ultrasonics Page 8 ER- 1060 Rev I

Preparer: DRA Reviewer: 421-It 3.4 Loop D Information Figure 4: Loop D Installation Site - Total distance is approximately 30 feet 7 1/8 inches (24.1 diameters) downstream of the UVT section (includes 6 feet inlet to meter)

Reference drawing 7G362PFW833 Sheet 4 Rev I Page 9 ER-1060 Rev 1 Ultrasonics Caldon Ultrasonics Page 9 ER-1060 Rev I

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[ Confidential Commercial Information 4.1 Calibration Data Used for Analysis 4.1.1 Data Set Selection The data presented in this section include only ISO17025 traceable calibration data for 195 flow elements. The calibration data in this report were obtained in full scale models of nuclear power plant feed water installations at Alden Research Laboratory. Each meter factor is obtained by Trade comparing the Alden Labs flow to the LEFM measured flow. [ Secret &

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Confidential Commercial Information 4.1.2 Data Set Evaluation

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4.1.3 CalibrationData Figure 5 summarizes the nuclear feedwater UFM calibrations. The figure's vertical axis is the ratio of ARL laboratory flow/volume to the UFM flow/volume, commonly known as the meter factor. Note that the lab tested data is in the range of 0.99 to 1.01 or +/- 1%.

These data in Figure 5 include not only the effects of hydraulic installation but also the effects of manufacturing and dimensional measurements (for example the path lengths and angle measurements). Therefore Figure 5 is the combination of both measurement/manufacture variations and hydraulics.

Meters are typically installed downstream of elbows or other piping disturbances that distort the Trade velocity profile. [ Secret &

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ConfidentiE CommerciE I Informatior 1.025 1.020 1015 1.010 1.005 0

LL 1.000 0.995 0990 0.985 0.980 0.975 Model Calibration Number 4

Figure 5- Population of Nuclear Meter Calibrations Inside diameters range from 12 inches to 32 inches. Each meter's MF has contributions due to dimensional and angle measurement errors and machining differences.

4.2 Parametric Testing Trade

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Model Component Parametric Tests I

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Inlet Conditions Parametric Tests I

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Model Velocity Profile Parametric Tests I

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Figures 6 shows a diagram of the typical parametric tests, and Figures 7, 8 and 9 shows photographs of some complex models of nuclear installations that have been built.

fQ MF= 1.0074 MF= 1.0070 MF= 1.0072 MF= 1.0072 Figure 6 - Example of Different parametrics for an Installation (Clockwise starting at top left - Test 1: Baseline, Test 2: Mitsubishi plate downstream of Tee, Test 3: Mitsubishi plate at inlet downstream of incoming elbow, Test 4: Rotate meter body 90 degrees)

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Preparer: DRA Reviewer: 0"1 Figure 7 - Example of Calibration with Multiple (Non-Planar) Flow Inlets (Flow balance changed from the 3 inlets - over full flow range)

Figure 8 - Example of Calibration with Non-Planar Model Components with Meter in Proximity to Upstream Elbow (Two meters shown)

(Tests performed with model, flow conditioner between last two elbows and in straight pipe)

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Preparer: DRA Reviewer: AiL Figure 9 - Example of Calibration with Meter in Proximity to Non-Planar Coupled Upstream Elbows 4.3 Hydraulic Sensitivity Computed from Calibration Data Trade Secret &

Confidential Commercial Information Calon ltasoic Pae1 R 16 e Caldon Ultrasonics Page 14 ER- 1060 Rev I

Preparer: DRA Reviewer: &W Summary of Nuclear Meter Calibrations 0.020 0.1 IL 0.010 11 0.005 0

0.000 9 *90 0

-0.005* 7oosi

-0.010 T

-0.015

-0.020 L

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Figure 10 - Population of Net Meter Factor for all Calibrations 6 (Net Meter Factor = Difference between parametric MF and the flowmeter's average MF) 4.4 Using Metrics with Calibration Data Population 4.4.1 Population[ I Trade Secret &

[ Confidential Commercial Information 6 Note: the x-axis represents the net meter factor for each meter/configurations performed.

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Confidential Commercial Information Figure 11 - Swirl Rates Observed in Model Testing Trade 4.4.2 Population[ 1 Secret &

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Confidential Commercial Information Figure 12 - FR Values Observed in Model Testing Page 16 ER-1060 Rev 1 Ultrasonics Caldon Ultrasonics Page 16 ER- 1060 Rev 1

Preparer: DRA Reviewer: A#iL 4.5 Meter Factor Relationship to [ I Figure 13 plots meter factor variation as a function of swirl. Trade Secret &

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Confidential Commercial Information Figure 13 - Net Meter Factor vs. Swirl Trade Figure 14 plots meter factor variation as a function of FR. [ Secret &

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Confidential Commercial Information Figure 14 - Net Meter Factor vs. FR Page 18 ER-1060 Rev 1 Ultrasonics Caldon Ultrasonics Page 18 ER- 1060 Rev I

Preparer: DRA Reviewer: _nW 4.6 Hydraulic Model Sensitivity Trade In Section 4.3, the variation in MF due to hydraulics (812 tests) had a standard deviation of Secret &

[ Confidential A 95% confidence value for hydraulic sensitivity is computed to be [ ] It is Commercial noted that of the 812 configurations used in the population, many may not be relevant to the Information hydraulics at STP. The population can be broken down into subsets by "key" characteristics.

The following table shows different population breakdown with 95% confidence uncertainties .

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.0 4.7 Hydraulic Sensitivity when in [ I Normally, the LEFM CheckPlus operates with two planes of velocity measurements each with four acoustic paths. These two planes cross each other and provide natural cancellation of cross velocities and making the meter nearly insensitive to upstream hydraulics. The efficacy of this method has been discussed in this report and more importantly in the Topical report and referenced papers (see Section 6).

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4.8 Qualitative Example [Confidential Commercia The meter installation model shown in Figure 15 is a case that demonstrates the robustness of the Information 8 path UFM to extreme changes in the upstream hydraulics. Clearly the hydraulics presented in this section are much more extreme that those of the STP application (Section 3) and fail to have the recommended 5 L/D between the meter and the upstream elbow.

Figure 15 - Meter Installation Model (Flow Right to Left)

(Arrow at Note 1 sight is where a Mitsubishi flow conditioner was installed)

Not only is it a complex installation, but it has the opportunity for both a planar flow and strong swirling flow, depending on the flow paths and fittings. Figure 16 shows an analysis of different swirls generated through tests (absolute values of swirl).

1o Clearly, individual planes can be calibrated to the two plane average - and this is done by procedure and software.

But, if in maintenance mode, the LEFM cannot calibrate the individual planes when hydraulic changes occur.

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Confidential Commercial Information Figure 16 - Analysis of the Swirl Conditions for Different Tests The profile with a long straight pipe is shown in Figure 17. It is marginally asymmetric.

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Confidential Commercial Information Figure 17 - Velocity Profile with a Straight Pipe Upstream The profile, however, with a Mitsubishi conditioner immediately upstream of the final bend, Figure I9 shows an extreme profile, one plane of which shows clearly an inverse effect.

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Confidential Commercial Information Figure 18 Flow Profile with Mitsubishi Plate Upstream of Last Bend The effects of the different conditions on both MF and FR are shown in Figure 19. Withstanding all these effects, a +/-+0.15% bound covers all the data.

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Confidential Commercial Information Figure 19 MF and FR - Highly Distorted Flow Caldon Ultrasonics Page 22 ER- 1060 Rev I

Preparer: DRA Reviewer: AAV!5to 5.0 METER FACTOR ACCURACY ASSESSMENT This section documents the methodology for calculating the uncertainty or accuracy of the meter factor. This report was produced using a process and quality assurance consistent with the requirements of ASME PTC 19.1 and ANSI/NCSL Z540-2-1997 (see References 11, 16 and 17).

The approach to determination of the set points is to combine the random (Type A) and systematic (Type B) terms by the means of the RSS approach given that all the terms are independent, zero-centered and normally distributed.

First, the sensitivity of the calculated flow to each independent variable or input is determined.

Once the sensitivities to the independent variables have been calculated, then the independent variables' uncertainties are calculated and multiplied with their sensitivity coefficient, such as calibration facility, timing errors, etc. The 95% confidence level uncertainty bounds are calculated for each element (uncertainty coverage for each term is 95%).

The evaluation of the sensitivity coefficients is performed by determining the independent variables in the mass flow (and volumetric flow) calculation. For example, if volume flow is a function of independent variables X1, X2 , ..., X,, as follows:

Q = f(Xl,X2,..., Xn)

The uncertainty effect of specific independent variables on the flow measurement is calculated by partial differentiation of the above equation. Expressing the result as a per unit sensitivity:

dQ Axl)[AX 2 . ...... +)

Q LQ3X,J6k1 x, ) LQ;R3X2J 2) Qd*J x.)

Where the terms in the brackets are the sensitivity coefficients for X1 , X2, ..., X". The magnitudes and signs of each uncertainty for a given flow measurement are then bounded by 95% confidence intervals.

ASME PTC 19.1 demonstrates that by combining the independent uncertainty contributions as the root sum square, the overall uncertainty in volumetric flow is bounded by a 95% confidence level.

The allocation of uncertainties for meter factor for the flow meter (consistent with the Cameron Topical report) is shown in Table 5 below. Using the data in Table 5 and the root mean square summation technique indicated for combining independent uncertainties of relatively the same magnitude, the total uncertainty due to MF is computed.

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Confidential Commercial Information Table 2: Uncertainty Summary for Meter Factor RMS values rounded to closest 0.001 %

(All terms are treated as normal distributions with k = 2, e.g., 95% coverage) 5.1 Facility Uncertainty Trade A facility uncertainty of [ ] is typically budgeted based on the ISO 17025 traceable Secret &

uncertainties of Alden Research Laboratories. The figure is increased conservatively to of Confidentla Commercia in the table above. Information This uncertainty term is considered to be systematic over all pipes.

See Reference 14.

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5.2 Measurement Uncertainty For each calibration, an analysis is done to compute the uncertainties in the volumetric flow Trade Secret &

measurement (excluding meter factor) of the flow meters used. The dominant calibration Confidential uncertainty is that due to the sensitivity of transducer installation [ I. Commercial Information Trade Secret &

Confidential Commercia Information Table 3: Uncertainties in Volumetric Flow Measurements (All Figures rounded to three decimal points)

(All terms are treated as normal distributions with k = 2, e.g., 95% coverage)

In order to be conservative, a combined uncertainty in any of the STP meters is considered to be Trade

[ ] This uncertainty term is random between meters - since the meters construction Secret &

Confidential (differences in assembly and manufacturer) will drive this uncertainty. Commercial Information 5.3 Extrapolation Allowance At the plant, it is likely that the hydraulic conditions will not equal those tested during the calibration. In particular, the plant's Reynolds numbers are higher than that achievable at the laboratory (approximately 20 million vs. -2 million). Further, the plant may have a lower wall roughness than the test pipes used at the laboratory.

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Confidential I Commercial Information 12 For this report, a typical average flow of 8,600 gpm (1953 CMH) is use. This is an expected average flow for computing the delta T value.

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Confidential Commercial Information Where:

u = axial velocity (ft/s) u = shear velocity (ft/s)

y. = Dimensionless distance from the pipe wall The numerical calculation of meter factor is illustrated below.

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Confidential Commercial Information Figure 20: MF vs. Reynolds Number (Reichardt Profile)

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Confidential Commercial Information Figure 21: FR vs. Reynolds Number (Reichardt Profile)

Trade Using this analysis, a meter factor extrapolation of [ ] is predicted from the average Secret &

Confidential calibration Reynolds number (-2e6) to the plant application (-20e6). The flatness ratio Commercial extrapolation is approximately [ I for the same range. Information Nevertheless, in order to address potential uncertainties in using this methodology, the meter Trade Secret &

factor extrapolation uncertainty budget is conservatively increased to [ I (e.g., doubled). Confidential Commercial Information This uncertainty term is considered to be systematic over all pipes.

5.4 Data Scatter - Mean Meter Factor Uncertainty Each meter factor is computed as the average (mean) of the meter factor measurements made for that flow element. The uncertainty in mean meter factor must address the 95% confidence limits on the uncertainty in that mean.

Trade A review of previous calibrations has shown that the typical uncertainty due to data scatter is Secret &

[ ] In order to be conservative, an uncertainty of [ ] is used to allow for additional Confidential Commercial scatter in the data. Information This uncertainty term is random between meters.

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6.0 REFERENCES

1. 2006 South East Asia Flow Workshop Paper, "The Relative Merits of Ultrasonic Meters Employing Between Two and Eight Paths", Gregor Brown, Don Augenstein, Terry Cousins, Herb Estrada

2. Moody, L. F., "Friction Factors for Pipe Flow," ASME Transactions, V. 66, 1944, pp.

671-694

3. National Bureau of Standards and Technology, "Experimental Statistics Handbook 1991"

4. Murakamni, M., Shimizu, Y., and Shiragami, H., "Studies on Fluid Flow in Three-Dimensional Bend Conduits," Japan Society of Mechanical Engineering (JSME),

Bulletin V. 12, No. 54, Dec. 1969, pp. 1369-1379.

8. Cameron Topical Report ER-80P Rev 0, "Improving Thermal Power Accuracy and Plant Safety While Increasing Operating Power Level Using the LEFM Check System"

9. ER-55 1, Transducer Replacement Sensitivity

11. ASME PTC 19.1-2005, Measurement Uncertainty

12. Cameron Engineering Report ER-160P Rev 0, "Supplement to Topical Report ER 80P:

Basis for a Power Uprate with the LEFM System"

13. Cameron Engineering Report ER-157(P-A) Rev. 8 and Rev. 8 Errata, "Supplement to Caldon Topical Report ER-80P: Basis for Power Uprates with an LEFM Check or an LEFM CheckPlus"

14. Cameron Engineering Report ER 262 Rev 0, "Effects of Velocity Profile Changes Measured In-Plant on LEFM Feedwater Flow Measurement Systems", January 2002

15. ANSIINCSL Z540.3-2006, "U.S. Guide to the Expression of Uncertainty in Measurement"

16. ISO "Guide to the Expression of Uncertainty in Measurement"

17. IGHEM Flow Paper 2008 Milan, Italy, "Accuracy Validation of Multiple Path Transit Time Flowmeters"

18. Westinghouse Research Laboratories Nov 3, 1972, "Integration Errors for Turbulent Profiles in Pipe Flow" Page 28 ER-1060 Rev 1 Ultrasonics Caldon Ultrasonics Page 28 ER- 1060 Rev I