Application of Orifice Plates for Measurement of Feedwater Flow

EdF Plant Experience

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Technical Report

PLANT SUPPORT ENGINEERING

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

Final Report, December 2001

EPRI Project Manager R. Shankar T. Eckert

EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA 800.313.3774 650.855.2121 askepri@epri.com www.epri.com

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM: (A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE; OR (B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT. ORGANIZATION(S) THAT PREPARED THIS DOCUMENT EdF R&D

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CITATIONS
This report was prepared by EdF R&D 6 quai Watier Chatou, France Principal Investigator H. Jeanneau This report describes research sponsored by EPRI. The report is a corporate document that should be cited in the literature in the following manner: Application of Orifice Plates for Measurement of Feedwater Flow: EdF Plant Experience, EPRI, Palo Alto, CA: 2001. 1003040.

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REPORT SUMMARY

Background Accurate measurement of feedwater flow may allow nuclear plant operators to increase thermal power without affecting plant reliability and safety. The U.S. NRC has approved small thermal power uprates of commercial nuclear plants if the licensee implements certain feedwater flow measurement instrumentation with accuracy to within 2%. The uprates to the current rated power can vary from 0% to as high as 1.5%. The amount of the power increase is equal to the difference between the original 2% margin established by the NRC in 1973 and the demonstrable accuracy of the instrumentation being used. For example, if the instrumentation can be demonstrated to measure thermal power to within 0.6%, then a 1.4% power increase could be obtained. Consequently, commercial nuclear plants have the capability to increase both generated electrical power and revenue. Successful use of this technology requires that the plant ensure that the nuclear steam supply system (NSSS) safety requirements are met and that balance-of-plant considerations accommodate the allowable uprate. The new instrumentation so far approved by the NRC uses ultrasonic technology to measure flow rates and sometimes requires an expensive piping retrofit. According to EPRI report 1000607, Small Power Uprates Under Appendix K: Benefits and Considerations, the cost of such a retrofit varied widely although the return on investment in all cases was attractive. U.S. nuclear plants may have an opportunity to use orifice plates for accurate feedwater flow measurement. Orifice plates have been used at EdF nuclear plants and have achieved accuracies to within 0.8%. Objectives To document the use and performance of orifice plates for the measurement of feedwater flow at plants operated by EdF To develop a project plan that evaluates the accuracy of orifice plates for piping configurations that are typical of some U.S. nuclear plants

Approach EdF has operating experience using orifice plates for the measurement of feedwater flow for calorimetric calculations at certain plants. The accuracies are high enough to consider these instruments as alternatives to justify power uprates for U.S. nuclear plants.

This report describes EdF plant experience with orifice plates. Based on feedback from this report, EdF will assess their actual performance in typical installation conditions (reproducing the lack of upstream straight lengths) at the EdF EVEREST flow test loop. Results Feedwater flow measurement by orifice plate is reviewed, and the EdF plant experience is described. The review covers operating principles, installation requirements, and maintenance requirements. EPRI Perspective In most plants, it is more cost effective to increase plant productivity than to add new plant capacity. Consequently, nuclear utilities are striving to maximize economic production from existing assets. The availability of more accurate feedwater flow measurement instrumentation with the simultaneous relaxation of margins and focus on reduced costs have motivated many nuclear utilities to consider increasing thermal power. This report provides an assessment of the use of orifice plates for accurate flow measurement; however, its applicability to U.S. nuclear plants will have to be evaluated and demonstrated. Keywords Thermal performance Orifice plate Flow measurement Feedwater flow EdF plant experience

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CONTENTS

1 SYMBOLS ........................................................................................................................... 1-1 2 OVERVIEW OF FEEDWATER FLOW ................................................................................. 2-1 Overview of the Feedwater Flow at EdF Nuclear Plants ..................................................... 2-1 Measurement of the Nominal Thermal Power of a PWR ................................................ 2-1 Feedwater Flow Measurement in BIL100....................................................................... 2-2 Orifice Plates Used for Calorimetrics .................................................................................. 2-2 3 ORIFICE PLATE DESCRIPTION......................................................................................... 3-1 Measurement Principle....................................................................................................... 3-1 Types of Orifice Plates ....................................................................................................... 3-2 Orifice Plate Thickness and Beveling ................................................................................. 3-2 Beta Ratio and Measured Pressure Drop ........................................................................... 3-4 Total Pressure Drop from the Plate .................................................................................... 3-4 4 ORIFICE PLATE ACCURACY............................................................................................. 4-1 Calibration Requirements at EdF........................................................................................ 4-1 Installation Requirements at EdF........................................................................................ 4-1 Upstream and Downstream Lengths of Piping (L/Ds)..................................................... 4-2 Cost Benefits ................................................................................................................. 4-4 Special Orifice Plate Alignments .................................................................................... 4-4 Pressure Differential Instrument Accuracy Requirements .............................................. 4-4 Pipe Roughness and Circularity Requirements .............................................................. 4-4 5 EDF EXPERIENCE WITH ORIFICE PLATE MAINTENANCE ............................................. 5-1 Plate Inspection.................................................................................................................. 5-1 Upstream Pipe Inspection .................................................................................................. 5-1 Routine Diameter Measurements ....................................................................................... 5-1 Differential Pressure Transmitter Maintenance ................................................................... 5-1

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6 LICENSE EVENT REPORTS RELATED TO EDF FEEDWATER FLOW ............................ 6-1 7 IMPLEMENTATION REQUIREMENTS AT U.S. NUCLEAR PLANTS................................. 7-1 8 COST BENEFIT ANALYSIS FOR NUCLEAR PLANTS ...................................................... 8-1 Cost of Installing a Differential Pressure Device ................................................................. 8-1 Manufacturing Cost........................................................................................................ 8-1 Installation Cost ............................................................................................................. 8-2 Operating Cost............................................................................................................... 8-2 Summary of Costs ......................................................................................................... 8-4 9 REFERENCES .................................................................................................................... 9-1

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LIST OF FIGURES
Figure 2-1 Installation Diagram Showing the Measurement Points Needed for BIL100 ........... 2-2 Figure 3-1 Orifice Plate ........................................................................................................... 3-1 Figure 3-2 Orifice Plate, Rear View ......................................................................................... 3-3 Figure 3-3 Orifice Plate Location ............................................................................................. 3-4 Figure 4-1 Evaluation of Orifice Plate Installation Conditions on the EVEREST Loop: Pipework Configuration ................................................................................................... 4-3 Figure 4-2 Evaluation of Orifice Plate Installation Conditions on the EVEREST Loop: Bias Versus Flow-Rate .................................................................................................... 4-3

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LIST OF TABLES
Table 7-1 Required Straight Lengths Between Orifice Plates and Fittings Without Flow Conditioners (Values Expressed as Multiples of Internal Pipe Diameter D) ..................... 7-2 Table 8-1 Estimate for Supplying a Venturi Tube and Orifice Plate ......................................... 8-1 Table 8-2 Cost for Installing a Sensor in the Bugey (900 MW) Nuclear Power Plant ............... 8-2 Table 8-3 Comparative Pressure Losses - Orifice Plate/Venturi .............................................. 8-3 Table 8-4 Comparative Costs of Measurement Systems......................................................... 8-4

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SYMBOLS
Symbol C d D e E ec Definition Coefficient of discharge Dimension dimensionless SI unit m m m m m

Diameter of the orifice (or throat) of the primary device L at working conditions Upstream internal pipe diameter at working conditions L Thickness of the orifice of the primary device at working conditions Thickness of the plate of the primary device at working conditions Distance between the centerline of the orifice and the centerlines of the pipes on the upstream and downstream sides ec component in the direction perpendicular to the pressure tap ec component in the direction parallel to the pressure tap Angle of the bevel Feedwater enthalpy at the steam generator inlet Feedwater enthalpy at the steam generator outlet Blowdown enthalpy at the steam generator outlet Number of loops Absolute static pressure of the fluid Feedwater flow Blowdown flow Mass rate of the flow Diameter ratio (d/D) Differential pressure Pressure loss Density of the fluid L L L

eCn ecl F He Hv Hp n p QARE Qp qm p

L L dimensionless ML T mol ML T mol ML T mol

-1 -2 2 -2 2 -2 2 -2 -1

m m J/mol J/mol J/mol Pa kg/s kg/s kg/s Pa Pa kg/m

3

-1

-1

dimensionless ML T MT MT MT
-1

-1

-1

dimensionless ML T ML T ML3 -1 -1 -2

-2

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OVERVIEW OF FEEDWATER FLOW
Overview of the Feedwater Flow at EdF Nuclear Plants
Measurement of the Nominal Thermal Power of a PWR The nominal thermal power of a given pressurized water reactor (PWR) unit is periodically measured (at least once a month) by plant testing teams. On French PWRs, the procedure followed is known as BIL100 (thermal balance at 100% licensed thermal power). The procedure serves as a reference for calibrating nuclear measuring channels and for measuring the thermal balance established by control sensors (the BIL KIT procedure for 900-MW units and BIL SPIN for 1300-MW units). BIL100 is performed on the secondary circuit, at the inlet and outlet of each of the steam generators. With the BIL100 procedure, thermal power is defined by: Qp n Wr = Q i ( H i H i ) ( H i H ip) Wk ARE v e v n i = 1 where: Wr n QARE Hv He Qp Hp Wk = = = = = = = = thermal power number of loops feedwater flow feedwater enthalpy at the steam generator outlet feedwater enthalpy at the steam generator inlet blowdown flow blowdown enthalpy at the steam generator outlet primary power not coming from the core (heaters, primary pumps)
Eq. 2-1

Since EdFs PWRs are based on the original Westinghouse design (through a license to Framatome), this BIL100 procedure is identical to the procedure performed by Westinghouse PWRs (see Figure 2-1).

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EPRI Licensed Material Overview of Feedwater Flow

Figure 2-1 Installation Diagram Showing the Measurement Points Needed for BIL100

Feedwater Flow Measurement in BIL100 The predominant term in the calculation of uncertainty for BIL100 is the uncertainty related to feedwater flow, which accounts for 80% of the uncertainty related to thermal power. The uncertainty of BIL100 for a 1400-MW unit (known as the N4 unit) is 0.4 %, and the real uncertainty of the feedwater flow is 0.8 %. This feedwater flow measurement in BIL100 is extremely important for determining the primary flow by means of the primary/secondary enthalpic balance method, which is performed by all PWRs in the world today. This determination of primary flow rate is periodically required by safety authorities to guarantee that the rate of cooling of the core remains between the lower limit (to ensure sufficient cooling of the reactor vessel) and the higher limit (to ensure stability of the vessel internals).

Orifice Plates Used for Calorimetrics

The most common measurement tool for industrial flow measurement is a pressure differential device (venturi tube, orifice plate, or nozzle). This is governed by international standards described under ASME, ISO, and others.

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EPRI Licensed Material Overview of Feedwater Flow

In all French PWRs, each feedwater line is fitted with two flow measurement devices: A control flowmeter (always a venturi), whose reading serves to regulate power in the I&C system. A test flowmeter, whose reading is used in the BIL100 procedure for a more accurate determination of the feedwater flow rate. The test flowmeter is an ISO standard orifice plate.

The control flowmeter does not require extreme precision because it is regularly recalibrated by comparison with the test flowmeter measurement, which must have maximum precision. Depending on whether the plant design is PWR or BWR, these two feedwater flow measurements are performed either by identical devices (two venturi tubes, for example) or by different devices (a venturi and an orifice plate, as is the case in France). It is therefore clear that the risk of systematic error due to the measurement method varies from one PWR to another. Considering the importance of feedwater flow measurement in PWR calorimetrics, EdFs design engineers for the PWR fleet decided to have two different flowmeters in series on each feedwater line.

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ORIFICE PLATE DESCRIPTION
Measurement Principle
The measurement principle consists of inserting a primary device (see Figure 3-1) in a fluid flowing under pressure in a pipe, creating a differential pressure (S EHWZHHQ WKH XSVWUHDP length and the throat of this element (downstream). According to the Bernoulli principle, this differential pressure is proportional to the square of the velocity of the fluid.

Figure 3-1 Orifice Plate (Drawing from ISO Standard 5167)

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EPRI Licensed Material Orifice Plate Description

The equation for calculating the mass flow of the circulating fluid is: qm = where: qm = C = Af = 0 = S =  =  = d = D = mass flow discharge coefficient 1/4) = velocity of approach factor expansion factor (= 1 for incompressible fluids) differential pressure fluid density d/D = beta ratio diameter of orifice diameter of pipe

CA f d 2 2( p) 4

Eq. 3-1

This measurement method is described in ISO Standard 5167 and EPRI report TR-101388.

Types of Orifice Plates

In French PWRs, two types of orifice plates (made of stainless steel) are used. These plates are characterized by their pressure taps. The vena contracta plates are characterized by an upstream tap at distance D from the plate and a downstream tap dependent on the diameter ratio . This orifice plate is used on all 900-MW units. The other type of orifice plate has pressure taps at distance D upstream of the plate and D/2 downstream and has replaced the vena contracta design.

Orifice Plate Thickness and Beveling

The requirements in ISO Standard 5167 concerning the thickness and angle of the bevel are the following: The thickness (e) of the orifice bore shall be between 0.005D and 0.02D. The variance in the measured values of e at any point on the orifice should be less than 0.001D. The thickness (E) of the plate shall be between e and 0.005D. The angle of the bevel (F) shall be 45 15.

In French PWRs, the thickness of the plate is 10 mm (3/8 inch) and the bevel angle is 45.

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EPRI Licensed Material Orifice Plate Description

Figure 3-2 shows a rear view of an orifice plate, and Figure 3-3 shows the flange fitting where the orifice plate is placed.

Figure 3-2 Orifice Plate, Rear View

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EPRI Licensed Material Orifice Plate Description

Figure 3-3 Orifice Plate Location

Beta Ratio and Measured Pressure Drop

The diameter ratio (=d/D) is always less than or equal to 0.75. Within the limits described in the ISO 5167 standard, the value of  may be chosen by the user. An orifice plate generates a pressure loss of around 60% in the differential pressure measured. This value is high compared to other pressure differential devices; the drawback is a loss of energy in thermal power. To minimize this loss, the orifice plates used in French PWRs have high opening ratios ( 0.64). This ratio makes it possible to decrease the differential pressure and have a minimal resulting loss in production costs (see below). For feedwater flow measurement in all French 3:5V WKH YDOXH RI  VKRXOG UDQJH EHWZHHQ  and 0.75, the maximum limit allowed under ISO. The measured pressure drop is around 1 bar (16 psi or 105 Pa).

Total Pressure Drop from the Plate

The pressure loss ( ) is related to the differential pressure (p) by the equation: = 1 4 (1 C 2 ) C 2 1 (1 C ) + C
4 2 2

Eq. 3-2

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EPRI Licensed Material Orifice Plate Description

where: = pressure loss  = diameter ratio (d/D) C = discharge coefficient S = differential pressure This pressure loss is the difference in static pressure between the pressure measured at the wall on the upstream side of the orifice plate (approximately 1D upstream of the orifice plate) and that measured on the downstream side of the orifice plate (approximately 6D downstream of the orifice plate). An approximation value of Equation 3-2 is: = 1 1.9 p where: = pressure loss = differential pressure  = diameter ratio (d/D)
Eq. 3-3

For example, for = 0.65, the total pressure drop is around 56%; for  = 0.71, it is 47%. Typically, for the French PWR plants, the total pressure drop is approximately 13 psi (9E1 kPa) IRU  

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ORIFICE PLATE ACCURACY
Calibration Requirements at EdF
In Equation 3-1, the term C (discharge coefficient) was introduced to take into account the pressure losses at the orifice plate. This coefficient was determined on the basis of numerous tests performed in laboratories around the world to empirically determine the discharge coefficient. This significant amount of testing makes it possible to estimate a global uncertainty for C: C = 0.5% when  ^0.6 C = (1.667 x  - 0.5)% when  is between 0.6 and 0.8 No calibration laboratory is used because the requirements of ISO Standard 5167 are met. Nevertheless, EdF R&D has carried out various tests in their laboratory facility in Chatou to check the principal installation configurations (see Upstream and Downstream Lengths of Piping later in this section).

Installation Requirements at EdF

The installation requirements at EdF are described in ISO Standard 5167. The main requirements are the following : The pipe must be full of fluid at the section being measured. The primary device shall be fitted between two straight sections of cylindrical pipe of constant diameter and of specified minimum lengths in which there is no obstruction or branch connection other than those specified in Upstream and Downstream Lengths of Piping later in this section. The pipe bore shall be circular over the entire minimum length of straight pipe required (see Upstream Pipe Inspection in Section 5). The interior of the pipe shall be clean at all times. Dirt that can readily detach from the pipe shall be removed. Any metallic pipe defects, such as metallic peeling, must be removed. The pipe may be provided with drain holes and/or vent holes to permit the removal of solid deposits and entrained fluids; however, there shall be no flow through either drain holes or vent holes during the flow measurement process. Drain and vent holes should not be located near the primary device. 4-1

EPRI Licensed Material Orifice Plate Accuracy

Upstream and Downstream Lengths of Piping (L/Ds) To ensure the uncertainty of the discharge coefficient, ISO Standard 5167 imposes procedures that allow very little deviation for manufacturing and mounting the orifice plates. The primary device must be installed in the pipeline at a position such that the conditions immediately upstream approximate those of swirl-free, fully developed fluid flow. The required length upstream between the orifice plate and the first non-straight pipe section (bends, valves, or tees) must be greater than 46D (see Section 7 for more details). If these length requirements are not met, the potential error must be increased (typically by 0.5%). The required length downstream between the orifice plate and the first non-straight pipe section must be greater than 7D (see Table 7-1). The values of the required lengths are given in a table in ISO Standard 5167. They depend on the kind of non-straight section in the pipeline (single bend, double bend, angle of the bend, reducer, expander, etc.). The values also depend on the diameter ratio . The values given in ISO Standard 5167 (see Table 7-1) were determined experimentally with a very long straight length of pipe upstream of the fitting in question so that the flow immediately upstream of the fitting was considered as fully developed and swirl-free. It is strongly recommended that a flow conditioner be installed downstream of the header (for example, a conditioner whose cross-sectional area is approximately equal to 1.5 times the cross-sectional area of the operating flow meter tubes) because there will always be distortion of the flow profile and a high probability of swirl. Those requirements are met for most of the French PWRs; but for some of EdF 1300-MW units, this is not the case. The orifice plate is positioned 26D downstream from a combination of a venturi tube and a 90 elbow, although ISO Standard 5167 requires 28D for a guaranteed accuracy of 0.7%. Although the difference appears to be small, it does not allow strict application of ISO accuracy values. The 0.5% increase required by the ISO standard has to be applied for those 1300-MW units because the feedwater flow orifice plate installation conditions do not meet the ISO requirements. An experimental study relating to orifice plate installation conditions was carried out on the EVEREST experimental loop at EdF Chatou. The feedwater pipework was simulated, and the influence of the orifice plate installation conditions was evaluated. Figure 4-1 depicts the pipe configuration that was mounted in the EVEREST testing section.

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EPRI Licensed Material Orifice Plate Accuracy

Figure 4-1 Evaluation of Orifice Plate Installation Conditions on the EVEREST Loop: Pipework Configuration

Figure 4-2 represents the bias between the reference and the measured flow rate for two series of tests done with the orifice plate positioned at 28 and 26 pipe diameters from the elbow.

Figure 4-2 Evaluation of Orifice Plate Installation Conditions on the EVEREST Loop: Bias Versus Flow-Rate

Figure 4-2 seems to show a difference between the two flow rates of about 0.4%, but since the figures of bias versus flow rate are within the accuracy limits of the ISO standard, the accuracy of the orifice plate measurements is considered not to be affected by the installation conditions.

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EPRI Licensed Material Orifice Plate Accuracy

Cost Benefits An increase of 0.5% on the accuracy in each of four feedwater sections will yield an increase of 0.25% in thermal power accuracy (0.5%/ 4 = 0.25%). This increase represents a difference of 9 MWth because the estimate of the thermal power uncertainty is reduced from 24 MW to 15 MW (3867 nominal reactor thermal power). In terms of electrical power, it leads roughly to an annual gain of 3 MWe, which is a gain of $300,000 per unit. For the total number of 1300-MW units (12), this 0.5% uncertainty decrease has resulted in $3.6 million a year additional revenues. Special Orifice Plate Alignments The orifice plate should be perpendicular to the centerline of the pipe to within 1. The orifice plate should be centered in the pipe. The distance (ec) between the centerline of the orifice and the centerlines of the pipes on the upstream and downstream sides should be measured. For each pressure tap, the components of the distance between the centerline of the orifice and the centerline of the pipe in the directions parallel to and perpendicular to the axis of the pressure tap should be measured. The component in the direction parallel to the pressure tap Ecl and the component in the direction perpendicular to the pressure tap ecn should meet the requirements of ISO Standard 5167. It is necessary when holding the orifice plate between flanges to allow for its free thermal expansion and to avoid buckling and distortion. Pressure Differential Instrument Accuracy Requirements The pressure differential instrument accuracy must be 0.15% of the measured value (MV). The global uncertainty must be bounded to 0.2% of the MV during the 20-minute measurement (the duration of data acquisition for sampling and averaging). Pipe Roughness and Circularity Requirements The requirements for EdF are governed by ISO Standard 5167. EdF R&D has carried out various evaluations on the effects of the roughness and the circularity of the pipe and found the requirements under the standard to be adequate.

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EDF EXPERIENCE WITH ORIFICE PLATE MAINTENANCE

Plate Inspection
Plant operators make periodic inspections (one in three or four orifice plates is inspected at the time of each unit outage), and no problems have been detected. The uncertainties allowed are within the limits in ISO Standard 5167.

Upstream Pipe Inspection

The pipe bore should be circular over the entire length of straight pipe required. The cross section may be assumed to be circular if it appears so by visual inspection. The circularity of the outside of the pipe can be taken as a guide, except in the immediate vicinity (2D) of the primary device where special requirements apply.

Routine Diameter Measurements

The internal diameter is measured at the installation of the orifice plate. It is measured on three different sections and on four diameters on each section (12 measurements).

Differential Pressure Transmitter Maintenance

The EdF procedure specifies that the differential pressure transmitter must be calibrated every nine months. A number of statistical studies have been done by EdF R&D on this subject. In particular, in 2000 a study on drift indicated that no differential pressure transmitter showed any drift after being installed for nine months. The calibration interval may change to once a year instead of once every nine months.

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LICENSE EVENT REPORTS RELATED TO EDF FEEDWATER FLOW
No license event was ever reported that was caused by using orifice plates for feedwater flow measurement. Most of the problems were related to the reinstallation of the orifice plates after an outage and were due to human error: An orifice plate was remounted with a bad tightening torque. EdF has written a new procedure to help the technicians. In another plant, technicians had reinstalled the orifice plate in the wrong direction (facing upstream instead of downstream). A new procedure specifies that two people must be present to reinstall an orifice plate: one to do the job and another one to double check the work.

No fouling has been seen in any EdF plant since the orifice plates were installed; some of the plates were installed 20 years ago. The upstream length-to-diameter ratios (L/Ds) required by ISO Standard 5167 are not met in all French PWRs. The plant operators who identified the problem called EdF R&D to determine whether to increase the uncertainty as required by the ISO standard. As detailed in Section 4 (see Figure 4-2), there was no need to increase the uncertainty because it was within the ISO limits.

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IMPLEMENTATION REQUIREMENTS AT U.S. NUCLEAR PLANTS
The implementation requirements for U.S. nuclear plants are those described in ISO Standard 5167 (see Upstream and Downstream Lengths of Piping (L/Ds) in Section 4). Table 7-1 gives the required straight lengths for several fittings. The values are the same as in the ISO standard. The ISO standard also gives the values in case a flow conditioner is used. A study specifically for U.S. nuclear plants is necessary to precisely determine the following points: The best diameter ratio  The total lost pressure drop (depends on the diameter ratio) The accuracy of the feedwater flow measurement by an orifice plate in the various U.S. plant configurations

If the required straight lengths cannot be found in the U.S. plants, there are two options: Option 1: The uncertainty has to be increased as described in the ISO standard. Option 2: Some tests on the EVEREST loop can be carried out to determine if there is a need to increase the uncertainty given by ISO Standard 5167. This amounts to a specific calibration of the orifice plate.

Such tests have been done for some EdF PWRs. It was experimentally demonstrated that the uncertainty overestimation of 0.5% was unjustified, and this allowed EdF to save U.S. $3.6 million a year (see Section 4 for the required straight lengths).

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EPRI Licensed Material Implementation Requirements at U.S. Nuclear Plants Table 7-1 Required Straight Lengths Between Orifice Plates and Fittings Without Flow Conditioners (Values Expressed as Multiples of Internal Pipe Diameter D) Diameter Ratio Single 90 bend Two 90 bends in any plane (S>30D)* 0.40 0.60 0.67 0.75 16 42 44 44 Two 90 bends in the same plane (30D>S>10D)* Upstream (Inlet) Side of the Orifice Plate Downstream (Outlet) Side Reducer 2D to D over a length of 1.5D to 3D Full bore ball valve or gate valve fully open Any fittings (columns 2 to 8)

Two 90 bends in perpendicular planes (S<5D)* 50 65 60 75

Single Single 45 bend 90 tee Two 45 bends in the same plane (S>22D)*

10 30 44 44

9 29 36 44

30 30 44 44

5 9 12 22

12 14 18 24

6 7 7 7

* S is the separation between the two bends measured from the downstream end of the curved portion of the upstream bend to the upstream end of the curved portion of the downstream bend.

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COST BENEFIT ANALYSIS FOR NUCLEAR PLANTS
Cost of Installing a Differential Pressure Device1
Manufacturing Cost Differential pressure devices listed in decreasing order of manufacturing cost are: Orifice plates Nozzles Traditional venturi tubes

The orifice plates and nozzles, however, must be used with measurement tubes. The ISO standard requires straight lengths of 10D upstream and 4D downstream with a very low roughness coefficient that can be guaranteed only by proper surface machining. The EdF facility in Chatou asked for an estimate for supplying a venturi tube and an orifice plate to measure feedwater flow in an N4 design plant (These are 1400-MWe generating units; at present there are four such units in France). The cost estimate from a European manufacturer is shown in Table 8-1.
Table 8-1 Estimate for Supplying a Venturi Tube and Orifice Plate Pressure Differential Device Orifice plate Proposal Price

The plate is of stainless steel and centered on the flanges. The mounting has an upstream length of 10D and a downstream length of 4D, fully machined. The machining meets the criteria imposed by the ISO standard.

$10,326

Venturi tube

With a so-called cast convergent (or as-cast), in keeping with ISO Standard 5167:

$9,449

Pressure taps using welded vortex chambers Inlet cylinder length = 3D Divergent angle = 8

All costs are based on typical cost schedules and labor rates in France.

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EPRI Licensed Material Cost Benefit Analysis for Nuclear Plants

The manufacturer offered to calibrate the venturi tube prior to mounting. The calibration tests increase the price by some $1,369. In conclusion, the manufacturing costs are roughly identical for the two devices if all criteria of manufacturing and mounting stipulated in the ISO standard are met. To this cost for the pressure differential device, the cost of the differential pressure sensor must be added. Table 8-2 details the items and cost involved.
Table 8-2 Cost for Installing a Sensor in the Bugey (900 MW) Nuclear Power Plant Description Pressure sensor Manifolds Bosses 10 m impulse line preparation insulation valves and mounting Cabling and plan (from an existing network) Study (plan and launch of works on a nuclear site) Cost for one calibration Total Cost $1,096 $ 411 $1,917 $2,396 $1,369 $ 342 $7,532

Installation Cost The venturi can be mounted on shorter pipe lengths than an orifice plate; therefore, additional supports can be eliminated. The conditions under which a venturi must be installed are also less restrictive (less constraint with respect to relative roughness). The cost has been estimated by an EdF Engineering Support Team. The figures come from an estimate for replacing a feedwater flow orifice plate in the Bugey plant. The cost of the service is $10,956. This includes cutting, welding, inspecting the weld, hydrotests, and studies. For the purposes of this report, consider that the installation costs are the same for the three devices. Operating Cost On EdFs PWR fleet, sensors are calibrated every year at a cost estimated at $480 each; this includes not only calibration but also mounting and demounting the sensor, as well as verification of the mounting. Every three or four years, the plate is removed and inspected; the cost is around $2,464 or $820 per year. On the U.S. fleet of PWRs, dimensional inspection of the venturis has been performed regularly since the problem of fouling was first detected. Because it takes longer to inspect a venturi than a

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EPRI Licensed Material Cost Benefit Analysis for Nuclear Plants

plate, the cost is estimated at $1,369. This presupposes that the venturi is mounted between flanges and is easy to demount (access platform). The essential difference between the operating cost of a venturi and that of an orifice plate is due to the pressure loss with the orifice plate, which is greater than with the venturi. To estimate the advantage with the venturi, the N4 plant series was chosen as an example. The calculation data are shown in Table 8-3.
Table 8-3 Comparative Pressure Losses - Orifice Plate/Venturi System Differential Pressure (Measured) 820 mbars 1040 mbars Pressure Loss (Residual) 380 mbars 75 mbars

Orifice plate with pressure taps at D and D/2 now in operation at Chooz As-cast venturi

Difference in pressure loss

305 mbars

Maintaining the water level in each steam generator (SG) is extremely important to plant safety. Feedwater flow is directed to the SGs by a series of feedpumps (for the units at Bugey and Fessenheim, for example, three pump systems are used). Continuing to meet the stipulated value is ensured by a level-control channel that acts on each SG. Its role is to distribute flow among the SGs. Overall control of the flow is ensured by varying the speed of the main feedwater pumps. For the N4 plant, the delivery head for the main feedwater pumps is 1250 psig (86 bars). The gain in pump power output due to the difference in pressure loss (4.5 psid or 0.305 bars) between the two devices is negligible in comparison with this pressure. This small difference is offset by the control channel. For greater pressure losses (> 1 bar), however, a complete calculation must be made to estimate the impact on the SG level-control channel. In conclusion, it is estimated that the economic gain attributable to a venturi in comparison with an orifice plate is nil. Furthermore, U.S. plants with venturis have encountered problems of fouling. The percentage power loss due to fouling ranges from 0.8% to 2.2%. Assuming 80% availability and at $0.02/kwH, the annual loss at some operating units can be as high as $2.0 million. The budget for R&D and experience feedback studies is unknown, but the cost of the loss of operation and power de-rate is significant.

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EPRI Licensed Material Cost Benefit Analysis for Nuclear Plants

Summary of Costs Table 8-4 presents a summary of the costs of the two measurement devices.
Table 8-4 Comparative Costs of Measurement Systems Orifice Plate Investment (I) Manufacturing Cost of installation and inspection Purchase of the sensor and installation Operation (O) Cost of annual inspection and verification (calibration, dimensional inspection) Maintenance contract Yearly cost price (I/10 + O) $4,243 $10,268 $10,950 $8,213 $1,300 Venturi $9,445 $12,319 $8,213 $1,848

$0 $4,846

The costs are not very different. The advantage of the orifice plate is that no fouling was found in French PWRs, thus saving the cost of fouling studies and the loss of revenue through lost MW. Consequently, orifice plates can be considered for accurate and reliable feedwater flow measurement.

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EPRI Licensed Material

9
REFERENCES
1. 10CFR50 Appendix K, paragraph (I)(A), prior to July 2000 rulemaking revision. 2. ACRS letter dated June 22, 1999, from ACRS Chairman D. Powers to Dr. William D. Travers, Executive Director of Operations at NRC, Revision of Appendix K, ECCS Evaluation Models, to 10CFR Part 50. 3. ECCS Models, Federal Register, Vol. 65, No. 106, Thursday June 1, 2000. 4. Feedwater Flow Measurement in U.S. Nuclear Power Generation Stations, EPRI, Palo Alto, CA: 1992. TR-101388. 5. Improving Power Plant Efficiency and Safety Through Better Knowledge of Flow-Rates: The EdF Approach, M. Piguet, POWER-GEN EUROPE, 1998. 6. Measurement of Fluid Flow by Means of Pressure Differential Devices Inserted in Circular Cross-Section Conduits Running Full, Part 1: General, International Standard ISO 5167-2, 1999.

7. Measurement of Fluid Flow by Means of Pressure Differential Devices Inserted in Circular Cross-Section Conduits Running Full, Part 2: Orifice Plates, International Standard ISO 5167-2, 1999. 8. NRC Reg. Guide 1.49, Power Levels of Nuclear Power Plants, Revision 1, December 1973. 9. Nuclear Plant Performance Benefits From Flowmetering Improvements : EdFs Experience Feedback With Various Industrial Flowmetering Techniques, H. Jeanneau, J. M. Favennec, M. Piguet, EPRI/PSE/NPPI Seminar, Chicago, IL, August 78, 2000. 10. Pipe Flow Modeling for Ultrasonic Flow Measurement, H. Jeanneau, M. Piguet, FLOMEKO 2000, Salvador, June 2000. 11. Small Power Uprates Under Appendix K : Benefits And Considerations, EPRI, Palo Alto, CA: 2000. 1000607.

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Target: Nuclear Power

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