ML080280315

Section 5 - a Description of the Crossflow System to Support 1.4% Power Uprate at San Onofre Nuclear Generating Station (SONGS)

ML080280315
Person / Time
Site:	San Onofre
Issue date:	01/23/2008
From:	Askari V, Phoenix W, Schwaebe M AMAG, Southern California Edison Co
To:	Office of Nuclear Regulatory Research
References
FOIA/PA-2008-0046
Download: ML080280315 (32)

Text

.n, S-e 5

A DESCRIPTION OF THE CROSSFLOW SYSTEM TO SUPPORT 1.4% POWER UPRATE AT SONGS Dr. Vahid Askarl AMAG, Inc.

William C. Phoenix Michael J. Schwaebe SONGS/SCE Foul

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-.Sesslop determine if the process signals are rapidly changing, for instance due to fouling or defouling of the main feedwater or main steam venturies. The installation and commissioning were reasonably trouble-free and the system has been operating successfully for approximately one year.

INTRODUCTION CROSSFLOW (UFM) & CORRTEMP (UTM) SYSTEMS SETUP CROSSFLOW (UFM) SYSTEM General Description CROSSFLOW system consists of four ultrasonic transducers mounted on a metal support frame that attaches, externally, to the pipe (see Figure 1). Transmitter (a transducer, that propagates an ultrasonic signal), placed at cross-section A, propagates ultrasonic signal in a perpendicular direction to the pipe axis. Receiver (a transducer, that receives an ultrasonic signal) is placed in the same cross-section on the opposite side, of the pipe. Similar pair of transducers (transmitter and receiver) is placed in a pipe's cross-section B with a certain distance L downstream of the cross-section A'. Turbulent flow in the pipe forms a spatial random pattern of eddies moving with the flow. In cross-section A the ultrasonic signal are affected by the eddies, causing modulation of ultrasonic signal, respectively [Ref. 1]. Demodulation of the ultrasonic signal results in a random signal X, (t). An ultrasonic beam in the cross-section B, a distance L downstream of the first beam, produces another random signal Xb (t). Turbulent pattern of eddies moving along the pipe, remains almost the same over a certain distance L,. If the distance L between cross-sections A and B is smaller then L,, the. signal Xb (t) is similar to signal X,, (t) with a certain time delay, X. (t) =Xb (t +)

()

Figure 1: CROSSFLOW system (ultrasonic cross-correlation flow meter) 5-3

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U Ituyv3 a Ly'I Ct a

LVaJ3 Cross-correlation funpion cuuIu-Je use' to cl~lhUtI--L.

t a

t htC correlation result. Function R(r) has well defined maximum at t-T

.T R(r) = f Xa (t)Xb (t + -r)dt (2) 0

'I Figure2:.Typical cross.correlatin function.

Measured flow velocity, which is a transport velocity of the turbulent pattern along the pipe, is calculated as follows:

V.=L'm=*

(3)

This velocity, V., is not the average velocity, V0, of the fluid. Hence, the measured velocity Vm must be multiplied by a velocity profile correction factor, Co, to obtain the average velocity of.

the fluid in the pipe.

V. =CO V (4) and the flow rate in the pipe is calculated by the following equation by substituting Equations 3 and 4:

W = A24Va=C~PA L (5)

Where: A4 is the cross-sectional flow area p is the density of the fluid.

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essio CORRTEMP (UTM)S 4YSTEM General Description The UTM system uses clamp-on ultrasonic transducers by definition. Figure 3 is a schematic representation of the ultrasonic arrangement using a transducer pair. The two transducers are installed perpendicular to the pipe surface on diametrically opposing positions. These are used to measure the speed of sound in water. Once the pressure is known, the water temperature is calculated from NIST water and steam properties table.

Transducer #I iTransducer

1. 2 Water Steel Figure 3: Schematic ultrasonic arrangements One of the transducers generates an ultrasonic pulse that reverberates in the pipe wall thickness at least two times and is received by the same transducer on each reverberation. The time difference between the two received back wall echoes, in combination With the speed of sound in steel, is used to calculate the pipe wall thickness. This is repeated with the second transducer in order to determine the pipe wall thickness at the second position. The inside diameter ID is calculated by subtracting the two thickness values from the pipe outside diameter OD. The pipe outside diameter is measured accurately once during system installation. In general, the system could be operated in two modes: 1) Through Transmission (TT mode); In the TT mode the opposing transducer receives the ultrasonic pulse that has passed through pipe walls and pipe diameter once. This waveform is processed to determine the time of flight of sound wave along one pipe inside diameter. 2) Pulse Echo (PE mode); In the PE mode the ultrasonic pulse is reflected from the opposing point on the inside diameter of pipe with respect to transmitter. The transmitter is used as a receiver after sending the ultrasonic pulse and receives the pulse after it has traveled one round trip along the pipe diameter. The round trip transit time of the reflected ultrasonic signal from the opposing pipe wall's inner surface is divided by two to determine the time of flight of sound wave along one pipe inside diameter. Details of this cancellation process are proprietary and are out of the scope of this document [Ref. 2].

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-y CROSSFLOW SYS TM i PLANTI MIPUTER INT A serial communication (RS232/RS485) was used to implement an on-line flow and temperature correction software layer to interface the AMLAG CROSSFLOW ultrasonic flow measurement system and AMAG CROSSTEMP ultrasonic temperature measurement system with the South California Edison SONGS.Piant Process Computers (Plant Monitoring System "PMS" & Colss Backup Computer System "CBCS"). The software ACL (Algorithm and Communication Layer) is composed of three different modules. These modules are OVCC.DLL (Online Venturi Correction Coefficient) and COMPRO residing on UFM unit, and OTCC.DLL (Online Temperature Correction Coefficient) residing on the UTM unit (Figure 4).

I CROSSFLOW

-SERIAL (LIFM)

EXPANDER r

i L-------------------

.r,,,.

RS232 RS485 SIackbax BBC Connector RS2321RS485 CBCS L_

Figure 4: CROSSFLOW / Plant Computer Interface Algorithm & Communication Layer "ACLU Configuration The CROSSFLOW & CORRTEMP systems are supplied as digital measurement devices that uses the outputs from Plant Process Computers (PMS and CBCS) to calculate the required Venturi flow correction, to calculate the required temperature compensation and sends the results back to the Plant Process Computers for flow and temperature corrections.

As a result, the ACL software layer is required to act as an interface between the CROSSFLOW (UFM) and the CORRTEMP (UTM) systems on one side and the Plant Process Computers on the other side. The ACL software layer acquires field input data from the Plant Process Computer, CROSSFLOW and CROSSTEMP systems, calculate the Venturi calibration correction factors and temperature correction factor in accordance with the SCE requirements, and provide output data to the Plant Process Computers. The ACL inputs/outputs provided/required by Plant Process Computers is transmitted through serial port communication.

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4 I

Figure 5: Product Prospective In summary, the ACL software layer will perform the following functions:

• Acquire field input data for the CROSSFLOW flow calculation and Venturi and temperature correction calculations

• Calculate flow adjustment correction factors

• Calculate temperature adjustment correction factors Detect and hiandle rapid efolin events

• Detect and handle communication error events

• Send output data to the Plant Process Computers through serial port communication By starting the CROSSFLOW the ACL reads database constants listed in the table below from "startup.ini" file. These values are user configurable and are read once at the start of each of CROSSFLOW and CORRTEMP. Each of the two systems will have its exclusive "startup.ini" file ("otcc.ini","movcc.ini", respectively).

Table 1: Some of the ACL Database Constant Input Data Variable Name Description 100%FF 100% power loop feedwater (100%FF*kFvmin)0/100 gives the kFv_min.

minimal feed-water power used in calculations CfFWUpperLinitConst The upper limit value for FW Cf CfFWLowLimitConst The lower limit value for FW Cf CfBDUpperLimitConst The upper limit value for BD Cf CfBDLowLimitConst The lower limit value for BD Cf 5-7

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Variable Name Description

_CfMSUpperLimitConst The upper limit value for MS Cf CfMSLowLimitConst The lower limit value for MS Cf DF Detection limit for rapid defouling Nf Size of Cf long buffer

_Kf Size of Cf short buffer CfPercentGoodFW Minimum Buffer Limit for Good Cf, FW CfPercentGoodMS Minimum Buffer Limit for Good Cf, MS CfPercentGoodBD Minimum Buffer Limit for Good Cf, BD CfBDUncertaintyLongConst Uncertainty limit for BD Cf long buffer CfFWUncertaintyLongConst Uncertainty limit for FW Cf long buffer CfMSUncertaintyLongConst Uncertainty limit for MS Cf long buffer Uncertainty limit, Cf short buffer, FW, CfUncertaintyShortConst' MS Plant's name determines Online ObjectFactory Operation, "Stand Alone" sets offline In general, CROSSFLOW UFM and CORRTEMP configuration parameters are divided into different categories. There are a few key parameters, which are important to the quality and performance of the system. These parameters are the values that will be used in on line calculation mode for verifying the quality assured uncertainty calculation for the transmitted data to plant computers. For example feedwater maximum allowable uncertainty "UncertaintyLongFw" is the value based on the quality assured calculation. The same type parameter limits the uncertainty verification for blow down and steam flow calculation. However, there are parameters that could be set and modified by utility Licensee (trained utility personnel). Those parameters are plant specific parameters such as correction factor upper and lower limits, the short and long buffer size, etc. Finally, the system is designed in a format that could, be used as an offline mode "Stand Alone". This feature gives flexibility to the user in case of experiencing any problem to use the system in the offline mode for calculating the flow and temperature correction factors.

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The CROSSFLOW system is supplied as a digital measurement device that uses the outputs from Plant Process Computers (PMS and CBCS) to calculate the required Venturi flow correction and sends the results back to the Plant Process Computers for flow correction. The CROSSTEMP system is supplied as a digital measurement device that uses the Plant Process Computers outputs to calculate the required temperature compensation and sends the results back to the Plant Process Computers for temperature correction. As a result, the ACL software layer is required to act as an interface between the CROSSFLOW (UFM) and the CROSSTEMP (UTM) systems on one side and the Plant Process Computers on the other side. The ACL software layer acquires field input data from the Plant Process Computer, CROSSFLOW and CROSSTEMP systems, calculate the Venturi calibration correction factors and temperature correction factor in accordance with the SCE requirements, and provide output data to the Plant Process Computers.

The ACL inputs/outputs provided/required by Plant Process Computers be transmitted through serial port communication (RS232 / RS485) (Figure 6). In summary, the ACL software layer will perform the following functions:

• Acquire field input data for the CROSSFLOW flow calculation and )Venturi and temperature correction calculations

" Calculate flow adjustment correction factors

" Calculate temperature adjustment correction factors

" Detect and handle rapid defouling events

• Detect and handle communication error events

• Send outnut data to the Plant Process Comnuters through serial nort communication CORRTEMP (UTM)

-"OT.C ACL Plant Process AMAG Computers

._Computers Figure 6: System Architecture In general, ACL consists of OVCC, OTCC, and COMPRO. COMPRO is the communication module between UTM!UFM system and Plant Process Computers (PPC) [Ref. 31. It collects the 5-9

HO'.M SSessioris Session I input data from PPC (pressure, temperature, and venturi flow data) and makes it available to OVCC and OTCC. Also, collecting output data and delivering it to PMS and CBCS. The OVCC is the correction factor algorithm (Cf) module. It delivers pressure and temperature to CROSSFLOW and collects F, (CROSSFLOW measured flow) for buffering and generating Cf and other outputs/alarms/errors for the system. Also the OTCC performing the same type of calculation as OVCC module. It delivers pressure to CORRTEMP and collects T(CORRTEMP measured temperature) for buffering and generating Ct and other outputs/alarms/errors for the system. Figure 7 and Figure 8 show the input/output/alarms/errors screens for both UFM and UTMI systems.

Figure 7: OVCC Maintenance Screen

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13...., Not ucough good datm in Ct bAUM GV823d0 OW0 PM Un~able to VabIdoPt COW4 CiVU Mm 00 PM Un.h to,datopatC0M2I BO.102)otaoddaam~tkdl OW 8/30100 PM Unabl atoe fbtdwpmt M012 2082, 060 PM Unabetovb to fpdt pat COM2 r @

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RVt' Figure 8: OTCC Maintenance Screen CROSSFLOW (UFM) & CORRTEMP (UTM) FIELD INSTALLATIONS The combined CROSSFLOW-(UFM) / CORRTEMP (UTM) systems is shown.in Figure9.JThe..

following describes the hardware for one unit and each unit is identical. In general in each unit, main feedwater flow rate & temperature for each of two main feed lines are measured by permanently installed ultrasonic detector assemblies consisting of brackets (IFM & UTM brackets) and permanently installed sensors that are strapped on the main feedwater lines (20 inches line). Also, blowdown flow rate & temperature for each of two blowdown lines are measured by permanently installed ultrasonic detector assemblies consisting of brackets (UFM

& UTM brackets) and permanently installed sensors that are strapped on the blowdown lines (4 inches line). Figure 10 to Figure 15 show the installed bracket for main feedwater and blowdown lines. A total length of 600 feet of cables was used for connecting the installed hardware transmitter and receiver probes to the electronics that was setup in demineralization control room.

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BDIM UZM.

LTM MW111 FW1121 BD1I21 LTM T

Figure 9: CROSSFLOW & CORRTEMP combined hardware for SONGS Unit 2 and 3.

Figure 10: UFM & UTM installation on blowdown lines 5-12

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& UTM installation on* man fec

'ater lines Figure 12: Insulated UFM & UTM brackets on blowdown lines 5-13

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Figure 13: Insulated UFM- & UTM -Tirackets on main feedWater lines Figure 14: SONGS typical feedwater line UFM and UTM installation plan view 5-14

C Se ios AS'i Figure 15: CROSSFLOW/CORRTEMP electronics system cabinet-.--.-----

CALCULATION OF REACTOR POWER Reactor power is based on a secondary calorimetric which uses steam flow rates, can be calculated using raw plant SYSTEM COMMISSIONING AND OPERATING EXPERIENCES The system commissioning and operating experiences are discussed in Reference 4.:

References

1. Westinghouse-CE Topical Report CENPD-397-P-A, Revision 01, "Improved Flow Measurement Accuracy Using Crossflow Ultrasonic Flow Measurement Technology," May 2000.

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2.

Advanced Measurtment-&-Analysis Group (AmAG), "AMAG-MAN EN -006-00 Users Manual for CORRTEMP 1.0.x UTM System," Revision 0, August 2001.

3.

Advanced Measurement & Analysis Group (AMAG), "Software Requirements Specifications SRS-7137-06-RevO2," January 2002.

4.

"A Description of the CROSSFLOW System to Support 1.4% Power Uprate at SONGS,"

Vahid Askari, AMAG, Inc, Joseph G. Murray, SONGS/SCE, and Michael J. Schwaebe, SONGS/SCE, presented to EPRI NPPI Conference July 2002.

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Session I eedwater UF M and UTM

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ACL Da, at.aba,&se i 'H ] i e s s a

n s Variable Name Description 100%FF 100% power loop feedwater (1000/oFF*kFv nm )/O0 gives the mnirr kFv-min feed water power used in calculations CfFWUpperLizitCorst The upper lint value for FW Cf CfFWLowinitConst The lowr finit value for FW Cf CfBDUperLinitConst The uper liit value for BD Cf CfBDLo'4nitCoist The lomer lirnit value for BD Cf CtMSU LerLjntCont The upr liit value for MS Cf CfMSLowLimitConst The lower linit value for MS Cf DF Detection Unit for rapid defouling Nf Size of Cf long buffer Kf Size of Cf short buffer CfPemitGoodFW Minum Buffer Uniit for Good Cf, FW CfPercerGooMS Minmm Buffer LiUnit for Good Cf, MS CfPercernoodBD rMininm-Buffer Linit for Good Cf, BD CfBDUncerdinq4ongCorst Uncertainty limit for BD Cf long buffer CfFWU*ertiaintyongComt Unertainty limit for FW Cf long buffer CfMSUncmbftt4"nConst Uncerhii limnit for MS Cf long buffer CflJxernittyShrCon Unct&-ty limnit, Cf short buffer, FW, MS Plant's nane demim OClim Opertion, "Stand Alone" sets offline n-oie.

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M Sbssions 4

FvFwl FvFw2 FvBdl FvBd2 FvMsl FvMs2 T!tFwl TtFw2 PFwl PFw2 TtBdl TtBd2 7.5UUU0e+U03' 7.50000e+003 1.00000et002 1=.0O00e4002 7.40000e+003 7.40000e+003 4.40000e+002 4.40000e+002 8.60000e+002 8.6OOOOe+002 5.=0000e+002 c; fl'nIfl2no,,?

GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD r*nnn CIFwl CfFw2 CfBdl CfBd2 CtMsl CIMs?

FuFwl FuFw2 FuBdl FuBd2 FuMsI FuM2 9.94747e-001 9.84535e.001 9.82237e.001 9.942o6e-001 9.94923e-OO 7.46838e+003 7.45847e+003 9.84927e+001 0.O000O+Oe+0 7.36988e+003 7.45847e+003 BAD BAD BAD BAD BAD GOOD GOOD GOOD BAD GOOD

.11 12 12 6

13 13 13 7

1 U. I r 0.13 0.16 0.59 0.17 0.18 0.16 0.13 0.16 0.57 Feedwater2Channel Blowdownl Channel Blowdown2Channel LongBufferSize 10O0PercentPower CoefFvMin CfLowUmitFw CfLowLinitBd cfLowLimitMs CQJppedrmiFw CfJpperwLmitBd 3

2 4

120 7.50000e+003 8.00000e+001 9.60000e-001 9.G0000e-001 9.600OOe-001 1.04000e+000 1.04000e+000 JIW,. SW J]Not enough good data in U buffer.

fFW., SG2) Not enough good data in Cf buffer.

(BD, SG1) Not enough good data in Cf buffer.

(BD, SG2) Not enough good data in Cf buffer.

tim berii cormrmunation tinout, berial-MS (MS. SG1) Not enough good data in Cf buffer.

I" (MS, SG2) Not enough good data in Cf buffer.

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Sessions-.

Lý,_7Sessiqn I ý,

IlFw2 PFwl PFw2 TtBdl Tt~d2 PB dl PBd2 4.40000e+002 8.60000e+002 8.60000e+0.02 5.00000e+002 5.OOOO0e+Q02 9.00000e+002 9.00000e+002, GOOD GOOD GOOD GOOD GOOD GOOD GOOD CtFw2 CtBdi CtBd2 TuF~

TuFw TuBdr TuBd 9.90909eO01 9.90000eO0 I

a900006-0Q 1

4.36M00+002 2

4.36000e+002 4.95000e+O02 2

4.95000e+002 BAD I...

62

.001 BAD 62 0.00 BAD 62 0.00 BAD 63 0.00 GOOD GOOD GOOD GOOD Feedwater2Channel Blowdownl Channel Blowdown2Channel-LongBufferSize CtLowLiritFw CtLowLimitBd CtUpperLimitFw CtUpperLinitBd UncertaintyTempera.

UncertaintyTempera.

CtPeroentGoodFw 3

2 4.

120 9.60000e-001 9.79000e-001 1I.05000e+000I 1.021 00e+00(1, 1.00000e+000I 1.00000e+00(1 7.50000o+001 [

I UFM is off-line (FW, SG1) Not enough good data in Ct buffer.

(FW, SG2) Not enough good data in Ct buffer.

[B5D, SG1) Not enough good data in Ct buffe.

(BD, SG2) Not enough good data in Ct buffer.

05/23/01 05/23/01 05/23/01 05/23/01 05M/230 05/23/01 05/23/01 05/23/01 W.01 PM 08.01 PM 08:01 PM 08:01 PM 08:01 PM 08:01 PM 08:01 PM 0801 PM Unable to open the port COM2 Unable to write to the port COM2 Unable to open the port COM2 Unable to open the port COM2 Unable to write to the port COM2 Unable to open the port: COM2 Unable to open the port COM2 Unable to write to the port COM2 Unable to open the port COM2 Unabla to ooen the anrt !M2 11 5-32

.4

I NGS Power uprate Configuration

• AMAG UFM and UTM on feedwater and blowdown

• CROSSFLOW ACL software calculates FW, BD and steam flow CFs and FW temperature CFs, determines quality, and provides alarms.

OCROSSFLOW ACL interface-between both the primary and backup process computers, with independent calculation of CFs.

STwo reactor power calorimetrics, FW and main steam Main.steam calorimetric reactor power is preferred. The steam venturis are not. subject to. rapid fouling and de-fouling like the FW.

tPlant process computer de-fouling alarm based upon FVV and main steam calorimetrics.

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