TR 107422 V2

Thermal Performance Engineers
Handbook, Volume II
Advanced Concepts in Thermal Performance
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Thermal Performance Engineering
Handbook, Volume II
Advanced Concepts in Thermal Performance
TR-107422-V2
Final Report
October 1998
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EPRI
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CITATIONS
This report was prepared by
Mollerus Engineering Corporation

455 Los Gatos Blvd., Suite 208
Los Gatos, CA 95032
Principal Investigators
Fred J. Mollerus
William B. Reuland
This report describes research sponsored by EPRI. The report is a corporate document
that should be cited in the literature in the following manner:
Thermal Performance Engineering Handbook, Volume II, EPRI, Palo Alto, CA, 1998.
TR-107422-V2.
iii
REPORT SUMMARY
The two-volume Thermal Performance Engineer Handbook will assist thermal

performance engineers in identifying and investigating the cause of megawatt (MWe)
losses as well as in proposing new ways to increase MWe output.
Volume I contains a thermal performance primer to provide a brief review of

thermodynamic principles involved in the steam power plant thermal cycle. The primer
also contains brief descriptions of the equipment and systems in the cycle that can be
sources of thermal losses. Also in Volume I is a section on the elements of a thermal
performance program and a guideline for developing a desktop instruction for the
thermal performance engineer.
Volume II contains detailed discussions of the components of the nuclear steam turbine
cycle as well as corrective actions and modifications that can be taken to maintain and
enhance plant electrical equipment.
Background
Thermal performance is the term used in this handbook to describe how well a nuclear
plant is converting thermal energy to electrical energy. The elements of a thermal
performance program and the duties of a thermal performance engineer (TPE) include:
x Monitoring and trending plant thermal performance
x Identifying and investigating the causes of loss of electrical production in

megawatts
x Developing potential remedial actions to correct conditions that cause MWe losses
x Developing potential changes and modifications to recover and enhance MWe

production
x Developing potential actions to ensure efficient MWe production during the life of
the plant
v
Utilities frequently rotate personnel through the plant performance engineer position,
and the transition of personnel into this position can be costly (training, lessons learned,
etc.). A group of utility thermal performance engineers (Plant Performance
Enhancement Program (P2EP) coordinators) recommended that EPRI capture both the
science and the art of thermal performance engineering and present them in
handbook form.
Objectives
To provide guidance to assist utility thermal performance engineers in identifying and

investigating the cause of MWe losses as well as in proposing new ways to increase
MWe output.
Approach
The EPRI Plant Support Engineering Program established the TPE Handbook Task
Group, which met five times in 1997. The Task Group reviewed various utility thermal
performance programs and identified the major elements in the most successful of
those programs. The Task Group used the actual utility best practices to develop the
guidance in this document.
Key Points
x A thermal performance primer provides a brief review of thermodynamic principles

involved in the steam power plant thermal cycle.
x The basic elements of a good thermal performance program are identified.
x The balance of plant components that can adversely affect electrical output are
discussed.
x Specific ways to improve heat rate and megawatt electrical output are covered.
x Industry consensus was achieved.
TR-107422, V2
Interest Categories
Plant support engineering

Thermal performance
vi
EPRI Licensed Material
ACKNOWLEDGMENTS
The following individuals were ongoing members of Plant Support Engineering's

Thermal Performance Engineers Handbook Task Group. As such, they have made
significant contributions to the development of this guide by attending the majority of
the task group meetings, reviewing/commenting on various drafts, and writing
portions of the document.
Mark Metzger, Utility Chairman Nebraska Public Power District
Barry Blair Centerior Energy
Eugene Matranga Centerior Energy
David Eder ComEd
Joe Wooten ComEd
Chad Main Consumers Energy
Mark Smith Duke Energy Corp.
Tom Bilger Duke Engineering & Services
Chaz McFeaters Duquesne Light Co.
Deborah Cioffi Encotech Engineering
Duke Dow Energy Management Services
Lawrence Bergeron Entergy Operations, Inc.
Bill Reuland Mollerus Engineering Corp.
Fred Mollerus Mollerus Engineering Corp.
John Lyons New York Power Authority
Robin Frederickson Northern States Power Co.
V. Ray Foster Pacific Gas & Electric
Amy ElChaar PECO Nuclear Company
Jim Klucar PECO Nuclear Company
Patricia A. Hinchey PECO Nuclear Company
John Walden Rochester Gas and Electric Co.
Ray Morris Southern Nuclear Operating Co.
Richard Mooney Tennessee Valley Authority
William Eberly Tennessee Valley Authority
Al Saunders TU Electric
vii
CONTENTS
1 INTRODUCTION ................................................................................................................. 1-1
2 COMPONENT FOCUS AREAS........................................................................................... 2-1

2.1 Condenser and Auxiliaries ............................................................................................ 2-1
2.1.1 General Description ............................................................................................... 2-1
2.1.2 Performance Calculations ...................................................................................... 2-4
Condenser Duty (Q) .................................................................................................... 2-4
Cleanliness Factor (CF)............................................................................................... 2-6
2.1.3 Impact on Thermal Performance............................................................................ 2-7
2.1.4 Typical Problems, Degradation Mechanisms, and Corrective Actions ................... 2-9
Microfouling................................................................................................................. 2-9
Macrofouling................................................................................................................ 2-9
Non-condensable Gases........................................................................................... 2-10
Condensate Depression............................................................................................ 2-12
2.1.5 References........................................................................................................... 2-13
P2EP Technical Library.............................................................................................. 2-13
Formal EPRI Reports/Software ................................................................................. 2-15
Non-EPRI References............................................................................................... 2-17
TPE Handbook References....................................................................................... 2-17
2.2 Cooling Towers ........................................................................................................... 2-18
2.2.1 General Description ............................................................................................. 2-18
2.2.2 Performance Calculations .................................................................................... 2-19
2.2.3 Impact on Thermal Performance.......................................................................... 2-22
2.2.4 Typical Problems, Degradation Mechanisms, and Corrective Actions ................. 2-22
2.2.5 References........................................................................................................... 2-26
ix

2.3 Feedwater Heaters ..................................................................................................... 2-28
2.3.2 Basic Calculations................................................................................................ 2-30
Terminal Temperature Difference (TTD) ................................................................... 2-30
Drain Cooler Approach (DCA) ................................................................................... 2-31
Plugged Tubes .......................................................................................................... 2-32
High Heater Level ..................................................................................................... 2-32
Low Heater Level ...................................................................................................... 2-33
Shell-side Erosion ..................................................................................................... 2-33
2.3.5 References........................................................................................................... 2-34
2.4 Steam Generators ...................................................................................................... 2-39
2.4.5 References........................................................................................................... 2-49
2.5 Steam Turbine ............................................................................................................ 2-53
2.5.5 References........................................................................................................... 2-65
x

2.6 Moisture Separator Reheaters.................................................................................... 2-70
2.6.2 Basic Calculations................................................................................................ 2-74
Heater Terminal Temperature Difference (TTD)........................................................ 2-74
Reheater Log Mean Temperature Difference (LMTD)............................................... 2-75
2.6.5 References........................................................................................................... 2-77
2.7 Reactor Power (Calorimetrics) .................................................................................... 2-81
2.7.5 References........................................................................................................... 2-85
3 CYCLE ISOLATION ............................................................................................................ 3-1

3.1 Unavoidable Flow Paths ............................................................................................... 3-2
3.2 Avoidable Flow Paths ................................................................................................... 3-3
3.3 Steam Traps ................................................................................................................. 3-3
3.4 Isolation Valves............................................................................................................. 3-4
3.5 Air-operated Valves (AOVs).......................................................................................... 3-5
3.6 Instrumentation ............................................................................................................. 3-6
xi
3.7 Loss Quantification ....................................................................................................... 3-7

3.8 References ................................................................................................................... 3-8
4 DATA VALIDATION ............................................................................................................ 4-1

4.1 Introduction ................................................................................................................... 4-1
4.2 Data Requirements ....................................................................................................... 4-1
4.3 Validation ...................................................................................................................... 4-3
4.4 Practical Applications.................................................................................................... 4-7
4.4.1 Main Steam Pressure............................................................................................. 4-7
4.4.2 Feedwater Flow Rate ............................................................................................. 4-7
4.4.3 Calculated or Measured Heater Drain Flow ........................................................... 4-8
4.4.4 Final Feedwater Temperature ................................................................................ 4-8
4.4.5 Condenser Performance ........................................................................................ 4-8
4.4.6 Feedwater Heater Performance ............................................................................. 4-9
4.4.7 Comparison with Heat Balance Program ............................................................... 4-9
4.5 References ................................................................................................................... 4-9
5 MOISTURE MEASUREMENTS........................................................................................... 5-1

5.1 Main Steam Line Moisture Carryover............................................................................ 5-2
5.2 MS/MSR Outlet ............................................................................................................. 5-2
5.3 LP Turbine .................................................................................................................... 5-3
5.4 References ................................................................................................................... 5-4
6 MEGAWATT ENHANCEMENTS ......................................................................................... 6-1

6.1 Improved Feedwater Flow Instrumentation................................................................... 6-2
6.1.1 Causes of Fouling .................................................................................................. 6-4
6.1.2 Compensation for Fouling ...................................................................................... 6-5
6.1.3 Differential Pressure Flow Measurement Devices.................................................. 6-6
Flow Nozzles ............................................................................................................... 6-6
Venturis ....................................................................................................................... 6-6
6.1.4 Ultrasonic Flow Measurement Devices .................................................................. 6-7
Transit Time ................................................................................................................ 6-7
6.1.5 Feedwater Flow References .................................................................................. 6-8
6.2 Reactor Primary Coolant Flow Measurement ............................................................. 6-10
6.3 Exhaust Hood Modifications ....................................................................................... 6-11
xii
6.4 MSR Modifications ...................................................................................................... 6-12

6.4.1 Moisture Separator Modifications......................................................................... 6-12
6.4.2 Excess Steam Modifications ................................................................................ 6-15
6.4.3 Tube Bundle Replacement................................................................................... 6-18
6.5 Heater Retubing.......................................................................................................... 6-20
6.6 Throttling (Governor) Valve Modifications (Throttling Loss Modifications) .................. 6-21
6.7 Full Arc and Partial Arc Operation............................................................................... 6-22
6.8 HP Turbine Nozzle Block Upgrade ............................................................................. 6-23
6.9 Reactor Uprate ........................................................................................................... 6-24
6.10 Turbine Upgrades ..................................................................................................... 6-27
6.11 House Load Reduction ............................................................................................. 6-30
6.12 References ............................................................................................................... 6-30
7 OPTIMIZING GENERATION FOR OFF-NORMAL PLANT CONDITIONS .......................... 7-1

7.1 End of Cycle Coastdown............................................................................................... 7-1
7.2 Reduced Feedwater Temperature ................................................................................ 7-1
7.3 Reduced Tave ................................................................................................................. 7-2
8 GLOSSARY......................................................................................................................... 8-1
8.1 Definitions ..................................................................................................................... 8-1
8.2 Acronyms...................................................................................................................... 8-3
8.3 Nomenclature ............................................................................................................... 8-5
xiii
LIST OF FIGURES
Figure 2-1 Basic Arrangement of a Condenser (Schematic)................................................... 2-2

Figure 2-2 Condenser Tube Arrangement and Installation ..................................................... 2-2
Figure 2-3 Removal of Non-condensable Gas........................................................................ 2-4
Figure 2-4 Typical Condenser Performance ........................................................................... 2-8
Figure 2-5 Typical Curve of Air-bound Condenser................................................................ 2-11
Figure 2-6 Condenser Pressure Response to Air-inleakage Test......................................... 2-12
Figure 2-7 Cooling Tower Performance ................................................................................ 2-20
Figure 2-8 Basic Feedwater Heater Arrangement ................................................................ 2-28
Figure 2-9 Typical Feedwater Heater Configuration ............................................................. 2-29
Figure 2-10 Westinghouse Model F Feedring Type Steam Generator ................................. 2-41
Figure 2-11 Effect of Fouling Factor on Steam Generator Pressure..................................... 2-45
Figure 2-12 Effect of Plugged Tubes on Steam Generator Pressure ................................... 2-45
Figure 2-13 SG Pressure vs. Plant Thermal Power .............................................................. 2-46
Figure 2-14 Turbine First Stage Pressure vs. Steam or Feedwater Flow ............................. 2-55
Figure 2-15 Heat Balance Diagram for HP Turbine Exhaust Enthalpy ................................. 2-57
Figure 2-16 Steam Path Audits as Part of Heat Rate Improvement Program ....................... 2-63
Figure 2-17 Typical Two-stage MSR..................................................................................... 2-71
Figure 2-18 Chevron Moisture Separator.............................................................................. 2-73
Figure 3-1 Cycle Isolation Valve Leakage Effects................................................................... 3-5
Figure 4-1 Example Application of Chauvenets Criteria......................................................... 4-6
Figure 6-1 MWe and Heat Rate Improvement Process .......................................................... 6-2
Figure 6-2 Schematic of Ultrasonic Metering Section ........................................................... 6-11
Figure 6-3 MSR Chevrons .................................................................................................... 6-13
Figure 6-4 Typical Moisture Removal Effectiveness of Chevron Separators ........................ 6-14
Figure 6-5 General Arrangement of G Type MSR Reconstruction........................................ 6-15
Figure 6-6 Original Drain Venting System............................................................................. 6-16
Figure 6-7 Two- and Four-pass Temperatures ..................................................................... 6-17
Figure 6-8 Function of By-pass Restrictor............................................................................. 6-19
xv
1
INTRODUCTION
Volume II of the Thermal Performance Engineers Handbook provides guidance for the
application of the elements of a thermal performance program that are described in
Volume I. Monitoring and trending of key parameters are aided by a knowledge of the
components monitored. Volume II contains a component focus section with the
following format:
x General description
x Performance calculations
x Impact on thermal performance
x Typical problems, degradation mechanisms and corrective actions
x References
The scope of this handbook is limited to the detail necessary to understand the basic
approach to monitoring components with a significant effect on thermal performance.
An extensive list of references is included where specific details of measurements and
their function are required.
Cycle steam losses account for the most lost megawatts. Therefore, Volume II contains a
section on cycle isolation and covers some specific ways to improve heat rate.
Specific measurements are included that are prone to significant uncertainties. Finally,
Volume II presents some fundamentals on data validation and the effects on
performance measurement caused by measurement uncertainty.
1-1
2
COMPONENT FOCUS AREAS
2.1 Condenser and Auxiliaries
2.1.1 General Description
The purpose of the condenser is to condense large amounts of turbine exhaust steam at
low (subatmospheric) pressure using cooling water, usually referred to as circulating
water. The condenser is located below the LP turbines and usually fits within an
envelope set by the turbine foundation.
Figure 2-1 shows a schematic of a condenser. In this case, a two tube pass arrangement
with circulating water inlet and outlet on the same side of the condenser shell.
Condensers come in several configurations and can be classified in several ways:
(1) orientation of the condenser tubes, transverse or parallel to the axis of the turbine;
(2) the number of condenser shells, usually one condenser shell for each set of turbine
two-flow exhausts; (3) the number of tube passes, one or two; and (4) whether the
circulating water flows in parallel through each condenser shell or whether it flows in
series through each shell. If the latter, each condenser shell has a correspondingly
higher inlet and outlet circulating water temperature and condensing pressure.
2-1
Component Focus Areas
To Air
Ejector
Circ. Water
Inlet
Circ. Water
Outlet
Figure 2-1
Basic Arrangement of a Condenser (Schematic)
Because condensers handle large quantities of steam at low, subatmospheric pressure,

the volumetric flow is high. As a result, the condenser tube arrangement must be
opened rather than compact in order to allow steam flow into the inner region of the
tube bundle. A typical tube arrangement is shown in Figure 2-2. The tube pattern and
shell volume are designed to minimize steam-side pressure drop. A cruciform region in
the middle of the bundle is void of tubes and forms a passageway to the circulating
water end of the condenser to vent non-condensable gases that can accumulate during
condensation of the steam.
Figure 2-2
Condenser Tube Arrangement and Installation
2-2
Condensers must continually vent non-condensable gases to prevent becoming air-

bound and losing heat transfer capability. Sources of non-condensable gases are air
inleakage and ammonia from oxygen scavenging chemical additions in PWRs and, in
the case of BWRs, oxygen and hydrogen that is generated in the reactor vessel and
mixes with main steam.
Figure 2-3 shows how non-condensable gas flows within and out of a condenser. The
key to removing non-condensable gas is the tendency of the non-condensable gas to
flow to the coldest or circulating water inlet region of the condenser by virtue of the
partial pressure of the condensing steam being lowest in the cold region. Steam jet air
ejectors (or vacuum pumps) are used to draw a vacuum and pull non-condensable gas
(with some steam) from the condenser.
Table 2-1 lists condenser instrumentation. A key condenser operating parameter is

condenser pressure, which is usually measured in the condenser neck (just above the
condenser tubes and below the turbine exhaust) using pressure taps enclosed in
baskets. These baskets prevent high steam velocities from affecting measured pressure.
Other parameters shown in Table 2-1 are used to calculate log mean temperature
difference (LMTD) and condenser heat load. Most plants do not directly measure
circulating water flow using devices such as orifices or venturis. Rather, it can be
determined by calculating circulating water flow using pump performance curves with
measured pump discharge pressure while accounting for suction elevation and the
number of operating pumps.
Table 2-1
Instrumentation for Condensers and Auxiliaries
Parameter Purpose
Condenser pressure Performance
Circulating water inlet temperature Calculated LMTD, heat load
Circulating water outlet temperature Calculated LMTD, heat load
Circulating water flow Calculate heat load
Circulating water pump discharge pressure Flow indicator
Circulating water box delta p Trending fouling
Circulating water box levels Flow
2-3
Figure 2-3
Removal of Non-condensable Gas
2.1.2 Performance Calculations
The following calculation methodology is provided as a means to measure the overall

performance of condensers. The methodology is applicable to hand calculations or PC
spreadsheets.
Condenser Duty (Q)
The condensing duty is the total heat transferred to the condenser cooling water
(circulating water). The condenser duty can be calculated by subtracting steam cycle
side non-condenser heat flows from the energy delivered to the steam cycle, QT (See
Volume I, Section 2.3). Typically, the non-condenser heat flows are generator electrical
output, generator losses, auxiliary steam, and steam driven feedwater pumps. PWR
steam generator blowdown should also be considered. The accuracy of this calculation
depends very much on the accuracy of the instrumentation used to measure the
parameters involved.
4 = 47 4HOHFW 4 JHQ 4DX[ 4 IZS 4EG
Where
2-4
QT = heat load to steam cycle

Qelect = generator gross output
Qgen = generator losses
Qaux = auxiliary steam loads
Qfwp = steam turbine driven pump load
Qbd = steam generator blowdown load
All heat loads need to be converted to a common set of dimensions, such as Btu/hr.
Condensing duty can be calculated based on circulating water flow and temperature
flow:
4 = :& (W W )
S R L
Where
Q = condensing duty, Btu/hr

W = circulating water flow rate, lbm/hr
Cp = circulation water specific heat = 1.0 Btu/lbm- qF
to = circulating water outlet temperature, qF
ti = circulating water inlet temperature, qF
An example calculation using circulating water flow and temperature change is shown
below:
Input Data W = 600,000 gpm

= 3 x 108 lbm/hr
ti = 65qF
to = 85qF
Calculation Q = 3 x 108 x (85-65)

= 6 x 109 Btu/hr
Condensing duty can also be calculated using turbine exhaust flow and enthalpy into
the condenser
4 = :H[ (KH[ KF )
Where
Wex = turbine exhaust steam flow, lb/hr

hex = turbine exhaust steam enthalpy, Btu/lb
2-5
hc = condensate enthalpy (enthalpy of water at the

condensing pressure), Btu/lb
Turbine exhaust flow and enthalpy are not measured. Instead, this method requires
that these parameters be estimated using turbine electrical output and the turbine heat
balance or thermal kit. This method is inherently inaccurate.
An example calculation using turbine exhaust flow and enthalpy is shown below:
Input Data Wex = 6.6 x 106 lb/hr

hex = 975 Btu/lb
hc = 80 Btu/lb @ Pc = 2 inch Hga
Calculation Q = 6.6 x 106 x (975-80)

= 5.9 x 109 Btu/hr
Cleanliness Factor (CF)
Cleanliness factor is the ratio of actual or operating overall heat transfer coefficient to
clean overall heat transfer coefficient.
8R
&) =
8F
Where
Uo = the operating or as-found heat transfer coefficient, Btu/hr-qF-ft2
Uc = the clean overall heat transfer coefficient, Btu/hr-qF-ft2
Operating overall heat transfer coefficient can be calculated from the equation
4R
8R =
$F 7P
Where
Ac = the surface area of the condenser, ft2
(7V W L ) (7V W R )
7P =
7V W L
OQ
7V W R
2-6
The condensing temperature, Ts, is the saturation temperature at condenser pressure, Ps,
and can be obtained from steam tables. The operating temperatures used to calculate
'Tm are actual measured data, while Q is obtained using the previous calculation. The
condenser heat transfer area is not easily calculated unless the total number of
unplugged tubes and their lengths are known. The clean overall heat transfer
coefficient, Uc, can usually be obtained from the manufacturers data specifications for
the condenser. The calculation shown below assumes the values are known. The clean
overall heat transfer coefficient (Uc) will increase with circulating water temperature.
The temperature affects the fluid properties, which affect the temperature profile in the
boundary layer at the tube wall. The clean heat transfer coefficient can increase about
1% per qF increase in circulating water temperature.
Input Data Uc = 500 Btu/hr-qF-ft2

Ps = 2 inch Hg
Ts = 101.1qF
ti = 65qF
to = 85qF
Nt = 70,000 tubes
Lt = 45 ft
dot = 0.75 inches
Calculation G RW /W 1 W
$F =

[ [ [
= = IW

7P = = )

OQ

8R = [ )
= %WX KU ) IW
&I =
=
2.1.3 Impact on Thermal Performance
Condenser performance has a large impact on plant thermal performance. As con-

denser pressure increases, there is less available energy and more heat rejection, re-
sulting in increased heat rate and less electric power production. Figure 2-4 shows a
typical change in heat rate due to change in condenser pressure. This curve is often
2-7
provided in the manufacturers thermal kit. The reason that the curve is relatively flat
below the design backpressure shown, 1.5 inches Hga, is that volumetric steam flow
increases as condenser pressure decreases. The last stage of the LP turbine experiences
increased windage or mechanical losses as volumetric flow increases. Plant cycle-
specific calculations using a heat balance program are needed if more exact, plant-
specific values are desired. Expected backpressure, based on inlet circulating water
temperature, can be compared to the measured backpressure to separate poor
condenser performance from the effect of change in ambient conditions. An electrical
megawatt deviation can then be assigned to each for accurate accounting.
Figure 2-4 also shows that last stage bucket (LSB) loading has a significant effect on
change in heat rate due to changes in condenser pressure. If LSB loading, defined as
design generator output in kW/sq.ft of last stage bucket annulus, is high, then last
stage bucket losses are high. High last stage bucket losses decrease with increasing
turbine backpressure and offset the loss in thermodynamic efficiency that occurs with
increasing turbine backpressure. Most nuclear turbines have fairly high LSB loadings
since turbine configurations are limited to six or fewer LP turbine ends and it has not
been economical to use more that three LP turbine casings at nuclear power plants.
Figure 2-4
Typical Condenser Performance
2-8
2.1.4 Typical Problems, Degradation Mechanisms, and Corrective Actions
There are several problems associated with condensers that can cause a heat rate
increase. Most also result in degraded heat transfer and increased condensing
pressure.
Microfouling
Microfouling is the formation of deposits on the inside of the condenser tubes and can
be of chemical or biological, or both.
Chemical fouling is the formation of a chemical deposit with poor heat transfer
properties on the inside of the condenser tubes. The most common such deposit is
calcium carbonate. The solubility limit for this compound decreases with increasing
water temperature causing deposition as inlet circulating water, with calcium carbonate
at its solubility limit, heats up in the condenser. One method of removal is by
mechanically cleaning the tubes. See EPRI Design and Operating Guidelines for
Nuclear Power Plant Condensers, NP-7382, for more details on condenser cleaning.
Biological fouling is the formation of a biological layer or slime on the inside of the tubes
that impedes heat transfer and, if of sufficient quantity, can impede circulating water
flow. Mitigation is usually by mechanical cleaning; on-line cleaning systems are
available. Prevention is usually by treating the water with chemicals.
Macrofouling
Macrofouling results in the blockage of tubes, usually at the tubesheet, with debris such
as seaweed or organisms such as Asiatic clams or zebra mussels. Severe macrofouling
in the condenser may be noticeable by increased condenser pressure and/or reduced
circulating water flow. An increase in 'P across the waterbox is also an indication of
fouling. (Circulating water flow is not usually measured. However, there may be an
increase in circulating water pump discharge pressure indicating a flow reduction.)
Macrofouling is almost always removed by mechanical means.
Prevention of macrofouling depends on site-specific conditions causing macrofouling.

If the source is debris such as seaweed or fresh water vegetation, then traveling screens
at the circulating water intake to prevent the debris from flowing into the condenser
become an important means of prevention. If the source is an organism such as clams,
then a biocide is needed. Many plants have the capabiltiy to backwash the condenser to
remove macrofouling. Strategies for backwashing depend on circulating water
conditions and trends in condenser performance.
2-9
Non-condensable Gases
Condensers are designed to remove air and additional oxygen and hydrogen in BWR
plants using vacuum equipment such as pumps or steam jet air ejectors (SJAEs). Non-
condensable gases retard efficient heat transfer. Accumulation of non-condensable gas,
referred to as air-binding, results in degraded heat transfer, high condenser pressure,
and increased heat rate. The result is similar to microfouling. In fact, it can be difficult
to distinguish between the two causes of high condenser pressure. If a rather sudden
increase in condenser pressure occurs, the likely cause can be either an increase in non-
condensable gas inleakage or a malfunction of the non-condensable gas removal
system. Inspections of equipment such as subatmospheric valve packing and
connections to the condenser and the vacuum equipment, as well as appropriate
corrective action, may be needed to reduce inleakage. If condenser pressure increases
gradually, then microfouling or macrofouling is a likely cause.
Although it may be difficult to differentiate air binding from fouling, there are several
methods that may be used to determine if the condenser is air-bound:
x System Operational Changes Baseline data can be taken with normal vacuum
pumps in operation. Then an additional vacuum or SJAE can be placed in service
while continuing to monitor condenser pressure, load, and circulating water
temperature. If the additional vacuum pump results in a decrease in condenser
pressure while the other factors remain constant, then the condenser is likely air-
bound.
x Load Versus Pressure Condenser pressure, circulating water inlet temperature, and
load can be monitored over a period of time when load reductions are planned or
can be scheduled. Condenser pressure should drop with decreasing load. It drops
less rapidly if the condenser is air-bound. A curve demonstrating how an air-bound
condenser behaves at low load is shown in Figure 2-5.
2-10
Figure 2-5
Typical Curve of Air-bound Condenser
x Air In-Leakage Rate Versus Pressure While holding constant load with air-
removal equipment in service, a measured rate of air, increased in steps, can be
added to the condenser. If the initial step of introducing air does not cause
condenser pressure to rise, then the condenser is not air-bound. Figure 2-6 shows
typical condenser pressure responses to controlled air-inleakage when the
condenser is air-bound and when it is not. Caution should be taken when using this
method since recovery can be difficult and there is the potential to lose control of
inleakage.
x Outlet Temperature Stratification A grid of temperature detectors can be installed

at the outlet of the condenser to identify regions of low heat transfer. Because air-
binding prevents the entrance of steam into the regions of the tube bundle where
air-binding is occurring, the circulating water temperature rise in the air bound
regions is reduced. This method can be costly to install and maintain.
2-11
Figure 2-6
Condenser Pressure Response to Air-inleakage Test
Condensate Depression
Condensate accumulates in the hotwell below the condenser tubes. Normally, the water
level in the hotwell is maintained below the condenser tubes. However, either by
intention or by malfunction of level control, the hotwell level can rise and flood the
lower tubes. This causes the condensate to subcool below saturation temperature
corresponding to condenser pressure. The subcooling is referred to as both condensate
depression and condensate subcooling. It can cause increased levels of dissolved oxygen
and corrosion of the bottom condenser tubes. It results in increased heat rate because
the condensate requires additional heating. As a rule of thumb, each 5F of condensate
depression results in a 0.05% increase in heat rate.
2-12
Some plants prefer to operate with condensate depression because subcooling reduces
cavitation in the condensate pumps. The need for this practice is questionable because
many condensate pumps are located well below the hotwell to minimize cavitation or
are designed to operate in a cavitating mode.
2.1.5 References
The following is a compilation of documents on the subject of Condenser and

Auxiliaries. They are not necessarily referenced by the preceding text.
P2EP Technical Library

2
The Plant Performance Enhancement Program (P EP) has a technical library that
provides an effective way to share information on plant thermal performance. Listed
below are the documents from the P2EP Technical Library that relate to the subjects
Condenser, Air Ejectors, Air Inleakage, Chlorination, Circulating Water. These
documents are available to eligible EPRI members by calling the P 2EP Administrator at
704/547-6024, or via the World Wide Web at
http://www.epriweb.com/npg/pse/ptp/index.html.
File # Document Title
0001.0-489 WPPSS Plant Efficiency and Reliability Monitoring Programs: Steam Jet Air Ejector
(SJAE) Performance Monitoring. Procedure No. 8.4.45. Rev 0. April 1988.
0002.0-101 Development And Implementation Of A Feedwater Heater Testing Program
0002.0-447 Air Binding and Condenser Optimization
0002.0-58 Condenser Leak-Detection Guidelines Using Sulfur Hexafluoride as a Tracer Gas
0002.0-91 An Air Ingress Monitor for Turbine Condensers - Its Development and Validation
0010.0-883 Surface Condensers
0012.5-80 Current Cathodic Protection Practice in Steam Surface Condensers
0016.0-440 On-Line Circulating Water Flow Measurement
0016.0-491 WPPSS Plant Efficiency and Reliability Programs: Circulating Water System
Performance Monitoring, Procedure No. 8.4.24. Rev. 1, 1988
0024.0-226 Niagara Mohawk Power Corp. Nine Mile Point 2. Plant Performance Monitoring
Instruction. Steam Surface Condenser Performance, N2-PPMI-3.1, Rev. 00
0024.0-227 Nine Mile Point 2 Condenser Performance Curves
0024.0-254 Nuclear Plant Component Basic Series-Condensers Workbook
0024.0-292 Pilgrim Nuclear Power Station Instruction PG.1090: Condenser Performance
Monitoring, Rev. 0, 1988
0024.0-461 Waterford III Standing Test Procedure: Condenser Performance, Proc. No. N8-008
0024.0-482 WPPSS Plant Efficiency and Reliability Monitoring Programs: Condenser
Performance Monitoring. Procedure No. 8.4.40. Rev 0. April 1988.
2-13
0024.0-52 Comprehensive Condenser Performance Testing at Indian Point 3 Nuclear Power

Plant
0024.0-55 Con Edison Technical Analysis Procedures: Performance Testing of Condensers,
TAP 7-4-1. 1986
0024.0-60 Condenser Performance
0024.0-622 An Improved Method of Estimating the Performance of Condensers with Both
Single and Multiple Compartments
0024.0-628 Investigation of Condenser Deficiencies Utilizing State of the Art Test
Instrumentation and Modeling Techniques
0024.0-66 Condenser Test (Watts Bar Nuclear Plant)
0024.0-854 Cost Effective Corrosion Control in Electric Power Plants
0024.0-894 Performance Monitoring of Three Compartment Condensers in Nuclear Plants
0034.6-519 Oyster Creek Thermal Performance and Availability Report
0053.0-619 Improved Condenser Performance can Recover up to 25 MW Capacity in a Nuclear
Plant
0053.0-752 Biofouling Control in Power Station Circuits: Overview of Electricite de France's
Experience
0054.0-645 On-Line Condenser Fouling Monitor Development
0060.0-263 Nuclear-Plant Performance, Reliability, Heat Rate Improvement & Life Extension
Basic Series-Heat Balances Workbook
0060.5-275 Performance Monitoring and Replacement of Heat Exchanger Components and
Materials
0060.5-309 Practical Aspects and Performance of Heat Exchanger Components and Materials
0067.0-757 INPO Significant Event Notification: Salt Water Intrusion Caused by Main
Condenser Tube Rupture
0073.0-460 Water Leakage to the Condenser
0073.0-719 Demonstrations of Condenser On-Line Leak Detection Using SF6 Tracer Gas
0088.0-867 Number of High Performance Stainless Steel Condenser Installations
0088.0-869 Application Experience with UNS N08366, UNS N08367 and UNS S44735 Alloy
Condenser Tubing
0088.0-870 Experience with High Performance UNS S44660 Ferritic Stainless Steel Tubing in
Power Plant Condensers
0088.0-871 Survey of High Performance Stainless Condenser Tubing Experience in Electric
Power Plants
0088.0-872 Application of UNS S31254 (Avesta Sheffield 254 SMO) Austenitic Stainless Steel in
Power Plants
0099.0-529 P2EP Survey 92-006, Condenser Performance
0099.0-531 P2EP Survey 92-008, Condenser Hot Well Condensate
0099.0-578 P2EP Survey 94-018, Condensers, Cooling Towers, and Circulating Water Data
0099.0-589 P2EP Survey 95-010, Main Condenser Tube Cleaning
0099.0-592 P2EP Survey 95-013, Limits on Turbine Cycle on Air In-Leakage
0099.0-597 P2EP Survey 95-018, Variances in Condenser Pressure
0100.0-521 Nine Mile Point 2 Lost Electrical Generation Summary
2-14
0101.0-205 Condenser Performance Monitoring

0101.0-280 Finding Lost MegaWatts
0101.0-301 Plant Thermal Performance and Availability Monitoring Report (GPU Nuclear -
Oyster Creek)
0101.0-421 The Performance Software Users Group Meeting Proceedings
0101.0-778 Clinton Power Station Condenser Performance Evaluation and Improvement
Program
0105.0-466 Waterford Unit 3 Standing Test Procedure: Condenser Basket Tip Pressure
Measurements, Procedure N8-009, Rev. 0
0106.0-735 Point Beach Thermal Performance Procedure TP3.0, Rev. 0, Condenser Fouling -
Data Collection and Analysis
0106.0-786 Callaway Plant Engineering Test Procedure: ETP-AD-01100, Condenser
Performance Monitoring
0124.0-388 Standards for Steam Jet Vacuum Systems (Fourth Edition)
0142.3-111 Effect of Tube Material on Steam Condensation
0142.3-162 Selecting Condenser Replacement Tubes
0142.3-407 Surface Condenser Tube Sample Heat Transfer Testing
0142.3-827 FitzPatrick 1995 Condenser retube and a Recent Operational Finding
0145.0-19 Aero-Thermodynamics of Low Pressure Steam Turbines and Condensers
0145.0-199 Latest Advances in Steam Turbine Design, Blading, Repairs, Condition Assessment,
and Condenser Interaction
Formal EPRI Reports/Software
EPRI has created formal reports and/or software on the subjects of Condenser,
Chlorination, or Circulating Water. These are available to eligible EPRI members by
calling:
x EPRI Document Distribution Center 925/934-4212

x EPRI Software Distribution Center 800/763-3772
Report # Report Title
AP-3651 Thermo-Economic Analysis of Power Plants
CS-1554 Biofilm Development and Destruction
CS-2251 Recommended Guidelines for the Admission of High-Energy Fluids to Steam
Surface Condensers
CS-2276 Design and Operating Guidelines Manual for Cooling-Water Treatment
CS-2961 Current Cathodic Protection in Steam Surface Condensers
CS-3200 High-Reliability Condenser Design Study
CS-3527 Augmented Heat Transfer Rates in Utility Condensers
CS-3550 Condenser Macrofouling Control Technologies
CS-3844 Condenser Procurement Guidelines
2-15
CS-4014 Proceedings: 1983 Fossil Plant Heat Rate Improvement Workshop

CS-4076 Laboratory Studies Supporting Cooling-Water Treatment Tests at a Power Plant
with Calcium-limited Water
CS-4279 Condenser Targeted Chlorination Design
CS-4329-SR Seminar Proceedings: Prevention of Condenser Failures--The State of the Art
CS-4339 Proceedings: Condenser Biofouling Control--State of-the Art Symposium
CS-4562 Effects of Sulfide, Sand, and Cathodic Protection on Corrosion of Condensers
CS-4736 Proceedings: 1985 Heat-Rate Improvement Workshop
CS-5032 Performance of Mechanical Systems for Condenser Cleaning
CS-5180 Commercial Assessment of Condenser-Targeted Chlorination
CS-5235 Recommended Practices for Operating and Maintaining Steam Surface Condensers
CS-5271 Guidelines on Macrofouling Control Technology
CS-5486 Non-radioactive Tracer for Steam Turbine Thermal Performance Tests
CS-5589 Effects of Selected Water Treatments and Cathodic Protection on Corrosion and
Embrittlement of Condenser Tubes
CS-5601 Engineering Assessment of Condenser Deaeration Retrofits for Cycling Fossil Plants
CS-5662 Condenser Performance Test and Replacement Tubing Material Evaluation
CS-5729 Condenser Performance Test and Back-Pressure Improvement
CS-5942-SR Proceedings: Condenser Technology Symposium (1988)
CS-6024 Condenser Condition Assessment and Retrofit Analysis: Ravenswood Unit 10
CS-6077 Effects of Targeted Chlorination on AL-6X Condenser Tube Corrosion in Seawater
CS-6080 Proceedings: 1987 Conference on Expert-System Applications In Power Plants
GS/EL-5648 MARK I Performance Monitoring Products
GS-6253 The TVA Moving-Manifold Targeted-Chlorination System: Second Field
Demonstration,
GS-6566 Non-toxic Foul-Release Coatings
GS-6576 Targeted Chlorination Schedules
GS-6635 1988 EPRI Heat-Rate Improvement Conference
GS-7003 Improvement of the Exhaust Flow of a Low-Pressure Turbine
GS-7009 Retrofits for Improved Heat Rate and Availability: Circulating Water Heat
Recovery Retrofits
GS-7181 Condenser Targeted Chlorination Demonstration at Brayton Point Station-Unit 2
GS-7349 Proceedings: Condenser Technology Conference
GS-7350 Condenser On-Line Leak Detection System Development
NP-1467 Assessment of Condenser Leakage Problems
NP-2294 Guide to the Design of Secondary Systems and their Components to Minimize
Oxygen-Induced Corrosion
NP-2597 Condenser Inleakage Monitoring System Development
NP-3395 Calculation of Leak Rates Through Cracks in Pipes and Tubes
NP-4564 High-Sensitivity Dissolved-Gas Monitoring System with Applications for PWR
Secondary-Side Chemistry
2-16
NP-7382 Design and Operating Guidelines for Nuclear Power Plant Condensers
TR-101096 Design Guidelines for Targeted Chlorination with Fixed Nozzles
TR-101772 R1 Electromagnetic NDE Guide for Balance-of-Plant Heat Exchangers, Rev. 1
TR-101846 Second EPRI BOP Heat Exchanger NDE Workshop
TR-101942 Condensate Polishing Guidelines for PWR and BWR Plants
TR-102922 High-Reliability Condenser Application Study
TR-103474 Review of Flow Problems at Water Intake Pump Sumps
TR-103475 Proceedings: Condenser Technology Conference, October 1993
TR-106741 Heat Exchangers: An Overview of Maintenance and Operations (NMAC Tech
Notes)
Non-EPRI References
Organizations and publishers other than EPRI have material pertaining to this subject.
Some of this other reference information is listed below to enable the reader to obtain
this material if desired.
American Society of Mechanical Engineers. Code on Steam Condensing Apparatus.

ASME Performance Test Code 12.2-1983. August 31, 1983.
American Society of Mechanical Engineers. Part 11 - Water and Steam in the Power
Cycle (Purity and Quality, Leak Detection and Measurement), Instruments and
Apparatus. ASME Performance Test Code 19.11-1970. August 8, 1972.
Heat Exchange Institute, Incorporated, Standards for Steam Surface Condensers,

Eighth Edition. Cleveland, Ohio: January, 1984.
Heat Exchange Institute, Incorporated, ADDENDUM 1, Standards for Steam Surface

Condensers, Eighth Edition. Cleveland, Ohio: January, 1989.
Heat Exchange Institute, Incorporated, Standards for Direct Contact Barometric and
Low Level Condensers, Fifth Edition. New York, New York: 1970.
TPE Handbook References
The following documents contain additional information on condensers:
Prevention of Condenser Failures- The State of the Art. Electric Power Research Institute,
Palo Alto, California: March 1982. RD-2282-SR (Special Report).
John V. Walden, Condenser Performance Monitoring and Cleaning, Thirteenth Annual

2
Plant Performance Enhancement Program (P EP) Annual Meeting Proceedings, San Antonio,
Texas (August 1997).
2-17
Corrosion Related Failures in Power Plant Condensers. Electric Power Research Institute,
Palo Alto, California: August 1980. Report NP-1468.
B. K. Long, Air Binding and Condenser Optimization. Alabama Power Company
Design and Operating Guidelines for Nuclear Power Plant Condensers. Electric Power
Research Institute, Palo Alto, California: September 1991. Report NP-7382.
2.2 Cooling Towers
Cooling towers are used to cool circulating water, which provides the condenser with
water at a low enough temperature to maintain the design vacuum. Cooling tower
designs are natural draft or forced draft, depending on climatic conditions and
economics. Natural draft cooling towers may be designed for crossflow or counterflow
of the air with the water in the cooling region. Counterflow towers are usually more
efficient than crossflow towers and are not as susceptible to ice damage, although ice
damage can still occur. Natural draft towers use the buoyancy of the air being warmed
and wetted to move the air through the tower.
Cooling towers are not always necessary where circulating water can be taken directly
from a river or body of water. However, cooling towers are sometimes used only to
satisfy ecological requirements or to isolate the condenser from some types of
biofouling. Forced draft cooling towers that use fans to move the air are used typically
in dry climates because fan power costs are low and the smaller towers have a lower
capital cost. Also, natural draft towers, which are the choice in most climates, will
sometimes stratify in low humidity.
The cooling tower cools water by evaporation caused by the air moving through the
tower. The coolest theoretical temperature that can be attained is the adiabatic
saturation temperature. This property of general gas mixtures can be measured for air-
water vapor mixtures by a wet-bulb thermometer because the wet-bulb temperature is
within one degree of the adiabatic saturation temperature for air-water vapor mixtures.
It may also be calculated from the dew point and dry-bulb temperatures. Because wet-
bulb temperatures are high in the summer, cooling tower design performance is not
always attainable.
The cooling region of the tower consists of the distribution system and is filled with
packing (or fill) that increases the water surface for evaporation and helps in attaining
the optimum water to airflow ratio. Cooling tower packing can be a splash or a film
type. The splash type fill packing disperses the water as droplets through horizontal or
vertical air flow. The film type is more efficient than the splash type because it forms
2-18
sheets of water which increases the evaporative surface. However, this increased
surface is more apt to become biofouled. The film type fill may be sheet or cellular in
design.
Table 2-2
Instrumentation for Cooling Towers
Parameter Purpose
Circulating water flow Duty and capability
Condenser hot well temperature Range and approach
Circulating water return temperature Range and approach
Make up flow Capability
Ambient wet-bulb temperature Approach
Ambient dry-bulb temperature Capability (redundant)
Ambient dew point Adiabatic saturation temperature
Cooling tower performance is defined by the following parameters illustrated in Figure

2-7.
x Range, qF: The temperature change in the water effected by the cooling tower.
There is a design range and an actual range measured during operation.
x Approach, qF: The temperature difference between the wet-bulb temperature, TWB,
and the circulating water temperature, TCW, typically 5qF or greater.
x Capability, %: The ratio of the heat removed from the water to the design amount.
Range:
Input THW = 109.6qF

TCW = 89.6qF
Calculation Range = 109.6qF - 89.6qF = 20qF
2-19
Approach:
Input TWB = 70qF
Calculation Approach = 89.6qF -70qF= 19.7qF
Capability:
Input THW = 109.6qF

TCW = 91qF
TWB = 70qF
THW (design) = 109.6qF
TCW (design) = 89.6qF
TWB (design) = 70qF
Calculation Capability (%) = 109.6 - 91__

109.6 - 89.6
= 93%
(assumes no adjustments for flow
rate, which may change due to
macroscopic condenser fouling)
Figure 2-7
Cooling Tower Performance
2-20
Some plants do not monitor circulating water flow rate. For purposes of trending
cooling tower performance, circulating water flow can be determined from the
condenser heat load as follows:
Input Qcp = Core Power = 6.45 x 109 Btu/hr

Qqe = Gross Generator Output = 630 x
103 kW
THW = 109.6 qF
TCW = 89.6 qF
Cp = 1 Btu/lbm qF
Calculation 4FRQG = 4FS 4TH

= [ [ [
%WX
= [
KU
%WX
[
0 IORZ = KU
%WX
[ )
KU )
OEP
= [
KU
Cooling tower performance can be measured using the temperature change of the
water multiplied by the circulating water flow rate. Cooling tower design performance
is typically based on a 5qF approach for the expected wet-bulb temperature that is not
expected to be exceeded for a given number of days per year. The capability is the
percent design capacity that the cooling tower can achieve. Another measure of
performance is the actual approach temperature compared to the design. This
comparison must account for ambient conditions. As a rule of thumb, a 2q degree
reduction in temperature of the cooling water leaving the tower can reduce the turbine
backpressure by 1 inch Hg.
Cooling tower models are complex, iterative, multidimensional models requiring a

computer to solve. Heat and mass transfer, momentum, and energy must be coupled in
a complex flow geometry. A major cause of poor cooling tower performance is
maldistribution of the water. Computational fluid dynamic (CFD) modeling has been
demonstrated to show the effects of maldistribution of the water on cooling tower
performance. Diagnostic testing of cooling towers by mapping air temperature and
velocities can aid in identifying distribution deficiencies.
2-21
Cooling tower performance impacts circulating water temperature which, in turn,

impacts the condenser vacuum. The cooling tower capital and operating costs are a
trade-off with cycle efficiency obtained by maintaining condenser pressure at an
optimum level for given ambient wet- and dry-bulb temperatures.
An EPRI survey indicates that the mean value estimated for cooling tower performance
is 85%. This is equivalent to a 22.5qF increase in circulating water temperature.
Cooling tower performance is the percent of rated flow that can be cooled to design
temperature.
Typical cooling tower problems include the following:
x Water maldistribution
x Fan design
x Fill type and fouling
As mentioned above, water maldistribution is often the cause of a cooling tower not
achieving full capability. The causes of maldistribution may be damage to the spray
system or a spray system design that does not provide a flow distribution over the fill
correct for the airflow pattern. There is a compound effect from a region not receiving
proper flow. First, the water goes to another fill region. Because the hot region is
overloaded, the water is not cooled to the design temperature. Second, the air flow
tends to follow the drier path through the fill.
The solutions to the maldistribution problems are changing (or fixing) the spray
nozzles, redesigning the distribution system, and adding to or redistributing the fill.
The nozzle size can be varied to compensate for flow maldistribution.
Table 2-3 shows the impact on power output of high wet-bulb temperatures at Watts
Bar Nuclear Plant (1160 MW PWR). BP-3 in the table is the backpressure in the third
zone of the condenser. The table has two calculations. One is based on maximum MWe
output, and the other is based on power reduction required to maintain a BP-3 less than
5.5 in. Hga for the turbine. The effect of degraded cooling tower performance in the
latter case is 22.3 MWe for each degree of wet-bulb temperature.
Fouling of the fill degrades performance. Changing the fill may be a solution to fill
fouling, and it may also be cost beneficial to upgrade the fill performance from the
original design. Chemical treatment can also help control fouling.
2-22
One utility reports that their biggest cooling tower problems have been macroscopic
condenser fouling caused by loose fill parts produced when freezing damages the fill.
These loose fill parts can also clog cooling tower spray nozzles.
Table 2-3
Impact of 5.5 In. Hga BP Limit on MWe (from EPRI survey)
No BP Limit BP Limited to 5.5 In. Hga.
WBT CWT BP3 MWe CWT BP3 MWe
40 70.3 3.08 1212.3 70.3 3.08 1212.3

50 75.5 3.55 1204.2 75.5 3.55 1204.2
60 80.9 4.14 1193.6 80.9 4.14 1193.6
70 86.8 4.88 1180.2 86.8 4.88 1180.2
75 89.8 5.32 1172.3 89.8 5.32 1172.3
80 92.9 5.81 1163.6 92.9 5.50 1111.6
85 96.1 6.35 1154.1 96.1 5.50 1010.1
90 99.3 6.97 1143.7 99.3 5.50 898.8
Prior to startup, TVA evaluated the expected performance of the Watts Bar cooling
towers. It had been some years since the towers were constructed, and a review of
cooling tower performance of peer plants indicated a potential problem. As a result of
computer modeling and thermal mapping of the exit air, it was estimated that 15% of
)
the air was passing through poorly wetted areas. A subsequent ASME PTC-23 test
confirmed that the tower would only perform at 88% capacity. This shortfall was
calculated to cause a 2 to 3q higher temperature, which would be equivalent to 34,000
lost MWe hours annually.
An extensive project was undertaken to evaluate alternatives and correct this problem.
The approach included modifications to the fill and water distribution system. The cost
was $1.5M, and the results provided an increase in performance from 88 to 106%
capacity for this natural draft tower.
A common problem with forced draft cooling towers is fan design and performance.
Proper fan performance can improve cooling, reduce fan power requirements, reduce
noise, and extend fan life. Fan performance improvements include optimizing fan
speed, pitch, number of blades, and plenum design. These fan performance
improvements are not additive. For example, if optimizing fan speed increased flow by
2% and optimizing the number of blades increased flow by 2%, then doing both may
not increase flow by 4%.
Identification of fan problems is complex. EPRI Report TR-108483, Proceedings: Cooling

Tower Technology Conference, contains a discussion of the causes of fan problems and the
2-23
parameters to adjust for improving performance. A frequent cause of reduced air flow
is dirty fan blades. Replacing a fan is expensive. Justification of a fan improvement
would probably include the need to replace a fan that was malfunctioning. A
performance improvement potential of 20% in airflow exists for some towers.
The type, placement, and condition of fill has a significant potential to affect
performance for all types of cooling towers. Depending on the suspended solids and
chemistry of the circulating water, the fill can become degraded.
Fill configurations vary for counterflow vs. crossflow and natural vs. forced draft
cooling towers. Traditional designs were of a splash type fill that breaks the water into
small droplets. Recent fill improvements include film type fill that increases the
evaporative surface. Film fill thicknesses on the order of one tenth the thickness of
equivalent performing splash fill is efficient, but splash fill is less susceptible to fouling.
The condition of fill can be tracked by trending circulating water approach

temperature. Visual inspections from the edge of the tower during operation have also
been shown to have benefit. Also, the weight of film fill increases significantly with
fouling as it picks up deposits. Typical film fill deposits are shown in Table 2-4. The
samples are from six plants with different circulating water conditions.
Table 2-4
Typical Film Fill Deposits - Analysis Characterization (%)
Samples
Ingredients #1 #2 #3 #4 #5 #6
Biological 30 10 80 60 45 20
Mud/silt 45 80 10 10 55 15
Calcium scales 10 5 0 0 0 60
Corrosion products 15 5 10 5 0 5
Oil material 0 0 0 25 0 0
TOTAL 100 100 100 100 100 100
The reference for Table 2-4 recommends the following requirements on circulating
water for the application of film type fill.
2-24
Table 2-5
Operating Guidelines for High Efficiency Film Fill
Parameter Circulating Water Limits
Total suspended solids, ppm <100

Bacteria, CFU/ml <10,000
Oxidant residual, ppm FAO 0.1 - 0.2
Polymer residual, ppm active 4-6
Table 2-6
Nuclear Plants with Mechanical Draft Cooling Towers
Unit Name Cooling Water Type Cooling System Type
Browns Ferry 2, 3 Fresh Mixed mode, once-thru/cool tower

Catawba 1, 2 Fresh Closed cycle
Crystal River 3 Saline Combination, once-thru/helper tower
Duane Arnold 1 Fresh Closed cycle
Farley 1, 2 Fresh Closed cycle
Hatch 1, 2 Fresh Closed cycle
Monticello 1 Fresh Mixed mode, once-thru/cool tower
Palisades 1 Fresh Combination, once-thru/helper tower
Palo Verde 1, 2, 3 Sewage effluent Closed cycle
Peach Bottom 2, 3 Fresh Combination, once-thru/helper tower
Prairie Island 1, 2 Fresh Mixed mode, once-thru/cool tower
River Bend Fresh Closed cycle
Vermont Yankee 1 Fresh Mixed mode, once-thru/cool tower
WNP 2 Fresh Closed cycle
Table 2-7
Nuclear Plants with Natural Draft Cooling Towers
Arkansas One 2 Fresh Closed cycle

Beaver Valley 1, 2 Fresh Closed cycle
Byron 1, 2 Fresh Closed cycle
Callaway 1 Fresh Closed cycle
Davis Besse 1 Fresh Closed cycle
Fermi 2 Fresh Closed cycle
Grand Gulf 1 Fresh Closed cycle
Harris 1 Fresh Closed cycle
2-25
Hope Creek 1 Brackish Closed cycle

Limerick 1, 2 Fresh Closed cycle
Nine Mile Point 2 Fresh Closed cycle
Perry 1 Fresh Closed cycle
Sequoyah 1, 2 Fresh Combination, once-thru/helper tower
Susquehanna 1, 2 Fresh Closed cycle
Three Mile Island 1 Fresh Closed cycle
Vogtle 1, 2 Fresh Closed cycle
Watts Bar 1 Fresh Closed cycle
2.2.5 References
The following is a compilation of documents on the subject of Cooling Towers. They

are not necessarily referenced by the preceding text.
The Plant Performance Enhancement Program (P2EP) has a technical library that
below are the documents from the P2EP Technical Library that relate to the subject
Cooling Towers. These documents are available to eligible EPRI members by calling
the P2EP Administrator at 704/547-6024, or via the World Wide Web at
0003.5-298 River Bend Station Thermal Performance Assessment
0027.0-110 Cooling Tower Performance
0027.0-473 WPPSS Plant Efficiency and Reliability Monitoring Program: Cooling Tower
Performance Monitoring. Procedure No. 8.4.22. Rev 0. June 1988.
0027.0-613 Cooling Tower Performance
0027.0-75 Cooling Towers - The Neglected Bonanza
0099.0-578 P2EP Survey 94-018, Condensers, Cooling Towers, and Circulating Water Data
0099.0-585 P2EP Survey 95-006, Forced Draft Cooling Towers
0101.0-481 WPPSS Plant Efficiency and Reliability Monitoring Program: Tower Makeup Water
System Performance Monitoring, Procedure 8.4.28., Rev. 0, 1988.
0136.0-509 WPPSS Operating and Engineering Test Procedure 8.4.53, Plant Thermal
Performance
0142.3-111 Effect of Tube Material on Steam Condensation
0147.0-826 Power Uprate Cooling Tower Projects
2-26
The Electric Power Research Institute (EPRI) has created formal reports and/or
software on the subject of Cooling Towers. These are available to eligible EPRI
members by calling:

CS-2276 Design and Operating Guidelines Manual for Cooling-Water Treatment
CS-3144-SR On the Hypotheses of Calculation of the Water Flow Rate Evaporated in a Wet
Cooling Tower
GS-6317 Proceedings: International Cooling Tower Conference
GS-6370, V-1 Cooling Tower Performance Prediction and Improvement, Vol. 1, Applications
Guide
GS-6370, V-2 Cooling Tower Performance Prediction and Improvement, Vol. 2, Knowledge Base
GS-6574 Model Validation: Cooling-Tower Performance
GS-6976 Proceedings: International Cooling-Tower and Spray Pond Symposium
The following documents contain additional information on cooling towers.
Proceedings: Cooling Tower Technology Conference. Electric Power Research Institute, Palo
Alto, California: July 1997. ReportTR-108483.
C. F. Bowman, Chuck Bowman Associates, and D. J. Benton, Environmental Consulting

Engineers, Cooling Tower Performance.
American Society of Mechanical Engineers. Atmospheric Water Cooling Equipment

Systems. ASME Performance Test Code 23-1983 (R1988).
Cooling Tower Fundamentals. The Marley Cooling Company, 1985.
Robert Burger. Cooling Tower Technology. Third Edition, 1995.
Proceedings: Cooling Tower and Advanced Cooling Systems Conference. Electric Power
Research Institute, Palo Alto, California: February 1995. Report TR-104867.
2-27
2.3 Feedwater Heaters
Figure 2-8 shows the basic arrangement of a train of feedwater heaters used to heat
feedwater from its temperature leaving the condenser to final feedwater temperature
(FFT) using steam extracted from various stages of the turbines. Some plants extract
steam from both the high- and low-pressure turbines; others extract steam only from
the low-pressure turbine. Most plants have more than one train of heaters, usually one
for each low-pressure (LP) tandem turbine, for example, three trains of feedwater
heaters if there are three LP turbines. Most BWRs are arranged to cascade all heater
drains back to the condenser. This allows all the condensate to be demineralized before
being returned to the reactor vessel as condensate. On the other hand, most PWRs
pump part of the higher stage heater drains forward to the next higher stage heater.
Figure 2-8
Basic Feedwater Heater Arrangement
Nearly all Light Water Reactor feedwater heaters are of the shell and U-tube,
horizontal, two zone configuration. A typical configuration is shown in Figure 2-9.
Feedwater flows on the inside of the U-tubes, which traverse both the condensing and
drain cooler zones. The condensing zone consists of a part of the inlet legs of the U-
2-28
tubes and is located in the bottom of the heater. Feedwater flows into the drain cooler
zone of the heater where it is heated by subcooling the condensate formed in the
condensing section of the heater. The feedwater then flows into the condensing zone,
comprising the remainder of the U-tubes. Feedwater is heated in the condensing section
by condensing turbine extraction steam, and steam is formed by the flashing of
condensate flowing in from the drain coolers of upstream heaters. Most of the
feedwater heating and heat transfer in a heater occurs in the condensing zone.
Figure 2-9
Typical Feedwater Heater Configuration
As previously noted, most feedwater heaters use U-tubes and are arranged to both
condense extraction steam and to subcool the condensate. Some plants use separate
drain coolers in the first stage of feedwater heating. In either case, it is necessary to
maintain water level to submerge all the tubing in the drain cooler section. This is done
by providing instrumentation to measure water level in the drain coolers section and
control valves to control the condensate flow rate out of the heater.
Table 2-8 lists instrumentation that can be used to monitor performance of feedwater
heaters. Temperature, pressure, and level instrumentation is commonly used with each
heater. However, there are very few plants that have instrumentation to routinely
measure feedwater and drain flows of the individual heaters. Instead, the flow is
estimated from measured feedwater flow and the design split between parallel
feedwater heater trains.
2-29
Table 2-8
Instrumentation for Feedwater Heaters
Parameter Purpose
Shell-side pressure Obtain extraction steam temperature, TTD

Feedwater inlet temperature DCA, LMTD
Feedwater outlet temperature TTD, LMTD
Extraction steam temperature DCA, LMTD
Feedwater flow Heat balance, tube-side film coefficient
Drain cooler flow Heat balance, drain cooler shell-side film
coefficient
2.3.2 Basic Calculations
Terminal Temperature Difference (TTD)
The TTD of a feedwater heater is the difference between the temperature of the
extraction steam being condensed on the shell-side of the heater and the temperature of
the feedwater leaving the heater. The design TTD for most plants varies from 5 to 8qF.
A high TTD indicates that the feedwater heat transfer performance is deficient. It is a
direct measure of the heat transfer capability of the heater and can be trended as a
means to predict future performance.
TTD = Ts - Tfwo
Where
Ts = shell-side extraction steam temperature, qF

Tfwo = feedwater outlet temperature, qF
Ps = condensing section steam pressure, psia
Ts = condensing section steam temperature (from steam tables)
Input Data Ps = 100 psia

Ts = 400.1qF @ Ps = 100 psia
Tfwo = 396qF
Calculation TTD = Ts - Tfwo

TTD = 400.1 -396 = 14.1 qF
2-30
Drain Cooler Approach (DCA)
The DCA of a feedwater heater is the difference between the subcooled condensate
leaving the heater and the feedwater entering the heater. It can be a direct measure of
the heat transfer capability of the drain cooler section of the heater.
DCA = Td - Tfwi
Where
Td = drain cooler outlet temperature, qF

Tfwi = feedwater inlet temperature, qF
Input Data Td = 360.3qF

Tfwi = 340.2qF
Calculation DCA = Td - Tfwi

DCA = 360.3 - 340.2 = 20.1 qF
Because the purpose of feedwater heaters is to increase cycle efficiency by heating the
feedwater, any reduction in heat transfer capability of a heater reduces cycle efficiency
and increases heat rate. In the case of a nuclear power plant that usually operates at or
near licensed thermal power, an increase in heat rate results in a reduction in electrical
output.
Heat transfer deficiencies are usually manifested by high TTDs and DCAs. Most plants
have been designed with TTDs of 5qF and DCAs of 15qF. Increasing TTDs and DCAs
cause increased heat rate and reduced electrical output. Usually, the TTD of the top
heater stage has the largest impact on thermal performance with the lower pressure
heaters having correspondingly less impact. The impact of a 3qF increase in final
feedwater temperature or TTD of the top heater is approximately a 0.05% increase in
heat rate. For the next highest heater, a 3qF increase in TTD increases heat rate
approximately 0.04%. Changes in the lower stages of feedwater heating have
correspondingly less impact. Changes in heater DCAs have significantly less impact
than changes in TTDs (approximately a 0.05% increase in heat rate if all DCAs increase
10qF). Impacts can also be less at part power.
Table 2-9 lists typical impacts of increases in TTDs and DCAs on heat rate. Plant cycle-
specific calculations using a heat balance program are needed if more exact, plant-
specific values are desired.
2-31
Table 2-9
Feedwater Heater Impact on Thermal Performance
1qF increase in top heater TTD (FFT) 0.016% increase in heat rate
1qF increase in other stage heater TTD 0.013% increase in heat rate
1qF increase in DCA 0.005% increase in heat rate
Feedwater heaters are subject to numerous problems. Of primary interest to this

handbook are those that result in reduction in feedwater heating that usually manifest
themselves in high TTD, high DCA, increased heat rate, and reduced power
generation. The following are the more significant of these problems and some of the
applicable diagnostics and corrective actions.
Plugged Tubes
Plugged heater tubes remove heat transfer surface from both the condensing and drain
cooling zones of the heater. The effect can be to increase both the TTD and the DCA.
Also, plugged tubes can increase the tube-side 'P. If 'P gets too high, the heater pass
partition plate can buckle. This can lead to leakage across the pass partition plate
instead of through the tubes and further deterioration of heater performance. Tubes are
plugged because of observed leakage or non-destructive evaluation (NDE) indicating
tube deterioration with a high potential to become a leaker. There can be several
reasons for tube deterioration including tube vibration and corrosion. These
maintenance and design related issues are discussed in some of the references at the
end of this section.
The need to plug tubes based on NDE that indicates potential leakage rather than an
actual leak is questionable, especially if the plugging criterion is very conservative (for
example, 50% through-wall indication). In most cases, a tube leak developed during
operation does not result in a forced plant outage. Tube plugging based on
conservative NDE practices can lead to premature loss of thermal performance and
high 'P.
High Heater Level
This condition can cause submergence of some condensing zone tube surface and heat
transfer capability. If the condition occurs, there should be a corresponding increase in
drain cooler heat transfer surface and a decrease in DCA. One cause can be a
malfunctioning drain cooler level control system. If the level is high, depending on the
design of the heater, a portion of the condensing zone heat transfer surface may be
submerged in condensate and not capable of condensing extraction steam and
2-32
completely heating the feedwater. At the same time, there could be additional drain
cooling capacity due to the high condensate level resulting in a small DCA.
Low Heater Level
A low heater level can have the opposite effect than a high level: low TTD and high
DCA. In some cases, this can improve thermal performance. However, low drain cooler
level should be avoided because it can subject the baffles and tubes supports in the
drain cooler zone to two-phase erosion.
Shell-side Erosion
Most heaters use carbon steel tube support plates and flow baffles. Carbon steel is
susceptible to flow-induced corrosion (FIC) especially if the flow is a two-phase
mixture of steam and condensate as in a feedwater heater. Some long term erosion in
the condensing zone is unavoidable. However, the heat transfer mode in the
condensing zone is by condensation and the plates in the condensing zone are
primarily for tube support, not to create high flow across the tubes and enhance heat
transfer. As a result, FIC does not necessarily have a direct impact on condensing zone
thermal performance and TTD. It can cause erosion of the tube supports, which can
increase susceptibility to tube vibration damage. FIC in the condensing zone is
primarily a life cycle problem.
On the other hand, the drain cooler is normally subject to single-phase condensate flow
where FIC is not of major concern. However, if the drain cooler is continually operated
with a low water level, the transverse flow baffle/tube supports can be subject to
steam/two-phase FIC. The result can be increased tube vibration and a reduction in
flow across the tubes, a reduction in drain cooler thermal performance, and an increase
in DCA.
If FIC is suspected in either the condensing or drain cooler zones, then a shell-side
visual inspection may be necessary to evaluate the extent of the problem.
Section 6 of EPRI NP-4057 contains a Problem Solving Guide. This guide is reproduced
as Table 2-10 in this handbook. EPRI NP-4057, a three-volume report, provides a
primer and design, procurement, operations, and maintenance guidelines for nuclear
plant feedwater heaters.
2-33
Table 2-10
Problem Solving Guide
Problem Experienced Areas to Investigate Possible Solutions
Temperature rise of feedwater Fouled heat transfer surfaces. Clean tubes. Prevent oil or other
gradually decreases. Pressure Deposits of scale or corrosion on contamination from getting into
drop across heater gradually interior surfaces of tubes. system.
increases.
Temperature rise of feedwater Air binding non-condensable Check for proper venting of
is less than specified. gases accumulating in steam heater. On heaters operating at
Temperature in shell side space of heater. Gland seals at vacuum, check for air leaks at
condensate is lower than L.P. end of turbine may be heater and pipe joints. Check
specified. Vent lines are cold. defective. turbine gland seals.
Temperature rise of feedwater By-passing. Leak at partition plate Check gaskets and gasket
is less than specified. Pressure in water channel allows water to contact surfaces for wire-drawn
drop across heater decreases. by-pass from one pass to the or eroded areas. Repair surfaces
next without passing through the and replace gasket.
tubes.
Shell flooding with condensate Ruptured tube or leak between Shut down heater as quickly as
when outlet control valve is feedwater side an steam space. possible to prevent damage to
fully open. other tubes or finished surfaces.
Repair leak.
Unstable condensate level Control devices not working Repair control devices or reduce
erratic surging of level. properly or backpressure in drain backpressure in drain line.
line too high.
Water hammer and vibration. Overloading, above normal Check flow rates, temperatures
temperatures or flow rates and pressure conditions of
causing pulsations in connecting entering steam and drains against
pipes. design operating specifications.
Check tube side flow rate.
2.3.5 References
The following is a compilation of documents on the subject of Feedwater Heaters.

They are not necessarily referenced by the preceding text.
Feedwater Heaters. These documents are available to eligible EPRI members by
calling the P2EP Administrator DW RU YLD WKH :RUOG :LGH :HE DW
KWWSZZZHSULZHEFRPQSJSVHSWSLQGH[KWPO
2-34

0006.0-212 Minimizing Turbine Blade Erosion With An Innovative Low-Pressure Heater Design
Modification
0010.0-141 Feedwater Heater Performance Prediction Calculation Procedure
0024.0-854 Cost Effective Corrosion Control in Electric Power Plants
0031.0-138 Feedwater Heater Cycle Configuration
0033.0-677 Miller Generating Station Drain Cooler Problems
0034.4-674 The Life Cycle Economics of Feedwater Heater Replacement
0040.0-364 Reliable Specification Criteria Confirmed Through Forensic Analysis Of A High
Pressure Feedwater Heater
0040.0-679 A Case Study of Tube Failure in Subcooling Zone of Low Pressure Feedwater
Heaters
0040.0-697 Manual for Investigation and Correction of Feedwater Heater Failures
0042.0-378 Sequoyah Nuclear Plant--Feedwater Venturi Fouling Investigation
0043.0-114 Effects of Geometry and Temperature Ramps on Feedwater Heaters
0043.0-123 Evaluation Of A Feedwater Heater Acoustic Leak Detection System: Phase II
0043.0-129 Feedwater Heater Testing Program at Alabama Power
0043.0-137 Feedwater Heater Replacement At Indian Point 3
0043.0-139 Feedwater Heater Life Extension Via Programs For Shell Liquid Level, Venting and
Allied Systems
0043.0-143 Feedwater Heater Replacements in Ontario Hydro's Thermal Generating Stations
0043.0-145 Feedwater Heater Tubesheet System Design Features For Cyclic Operation
0043.0-178 High Pressure Feedwater Heater Channel Head Cracking Update
0043.0-201 Level Control of Feedwater Heaters Using Resistivity Probe Sensors
0043.0-230 Nine Mile Point 2, Feedwater Heater Performance, N2-PPMI-6.2, Rev. 00, 1991
0043.0-251 Nuclear Plant Component Basic Series Feedwater Heaters Workbook
0043.0-295 Pilgrim Nuclear Station Instruction: Feedwater Heater Performance. PNPS SI-
PG.1021, Rev. 1
0043.0-366 Replacement Feedwater Heater Project Overview: Belews Creek Steam Station, Unit
2
0043.0-368 Restoring Heat Transfer Surface To Feedwater Heaters Using Explosively Welded
Sleeves At LA Cygne Generating Station
0043.0-377 Sequoyah Feedwater Heater Performance Test, Technical Instruction TI-106., Rev. 0.
0043.0-379 Single String Operation Of High Pressure Feedwater Heaters: A Systematic Design
Approach
0043.0-404 Study of Feedwater Heaters For Improved Coal-Fired Power Plants
0043.0-467 Waterford Unit 3 Standing Test Procedure: Feedwater Heater Performance,
Procedure No. N8-006, Rev. 0
0043.0-471 La Cygne Station Unit 2 Partial Retubing of High Pressure Feedwater Heater No. 21
0043.0-483 WPPSS Plant Efficiency and Reliability Monitoring Programs: Feedwater Heater
Performance Monitoring. Procedure No. 8.4.25. Rev 1, September 1988.
2-35
0043.0-53 Con Ed Feedwater Heaters, TAP 7-2-2, 3/86.

0043.0-621 Measurement of Sludge Deposits on Pickering NGS and Bruce NGS Retired Copper
Alloy Feedwater Heaters
0043.0-670 Application of a New High Strength FNi-Cr-MN Austenitic Tube Alloy for High
Pressure Feedwater Heaters
0043.0-671 Cracking in High Pressure Heater Heads
0043.0-672 High-Reliability Feedwater Heater Design and Construction
0043.0-673 An Evaluation of Tube Failure Rates of Original and Replacement Feedwater
Heaters in the Southern Electric System
0043.0-675 Gibson Feedwater Heater Shell Crack Repairs and Modifications
0043.0-676 Results Derived from Levels I to III Inspections of Two Stainless Steel Tubed High
Pressure Feedwater Heaters
0043.0-678 H.P. Feedwater Heater Level Control Modification
0043.0-681 Energy Analysis for Sensitivity to Turbine Induction
0043.0-684 Remote Visual Testing (RVT) for the Diagnostic Inspection of Feedwater Heaters
0043.0-685 Recent Improvements in RFEC Inspection Technology
0043.0-686 Experience with Remote Field Electromagnetic Technique (RFET) in the NDT of
Carbon Steel and High Ferritic Alloy Tubes
0043.0-688 Comparison of Electromagnetic NDE Procedures Using Realistic Feedwater Heater
Mock-ups
0043.0-689 Investigation of Hemi-Heat Cracking in the High Pressure Feedwater Heaters at
Homer City
0043.0-690 Feedwater Heater Tube Material Study
0043.0-691 Feedwater Heater Materials in the SCE System Historical and Current Practices
0043.0-692 Application of AL-6XN Tube Material in Feedwater Heaters
0043.0-695 Symposium Breakout Session 6A: Maintenance Technologies for Performing
Damage Assessments and Repair Evaluations
0043.0-696 Symposium Breakout Session 6B: Operation Technologies for Achieving Design
Enhancements and Performance
0043.0-698 Heat Exchanger Workstation: A Comprehensive Software Tool for Feedwater
Heater Operation and Maintenance
0043.0-699 Feedwater Heater Tube to Tubesheet Connections
0043.0-7 A Case History Of Feedwater Heater Condition Assessment and Life Extension
0043.0-700 First Header-Type Feedwater Heater Technology in the United States
0043.0-701 Reliability of Header Type Feedwater Heater Tube Joints
0043.0-717 Turbine Capability with Feedwater Heaters Out of Service
0043.0-723 Feedwater Heater Program Development
0043.0-824 Feedwater Heater Testing & Level Optimization Experience Within the Southern
Company
0057.0-360 Recommended Practices for the Prevention of Water Damage to Steam Turbines
Used for Electric Power Generation
2-36
0060.5-275 Performance Monitoring and Replacement of Heat Exchanger Components and

Materials
0060.5-309 Practical Aspects and Performance of Heat Exchanger Components and Materials
0060.5-328 Proceedings: Heat Exchanger Workshop
0070.0-773 Seabrook Station Feedwater Heater Digital Level Controllers
0072.0-781 Flash Drying Protects Standby Plants
0073.0-204 Magnetic Flux Leakage Examination of Feedwater Heater Tubing
0073.0-460 Water Leakage to the Condenser
0073.0-680 Acoustic Feedwater Heater Leak Detection Industry Application of Low & High
Frequency Detection Increases Response and Reliability
0073.0-683 Early Detection of Feedwater-Heater Leaks
0074.0-296 Pilgrim Nuclear Station Instruction: Feedwater Heater Controls. SI-PG.1022, Rev 1.
0074.0-353 Quantifying The Costs Associated With Feedwater Heater Drain Flow Bypass To
Condenser
0074.0-759 Ft. Calhoun Station Repetitive Special Services Procedure: Feedwater Heater
Optimum Level Test
0074.0-88 Performance Driven Level Control of Feedwater Heaters Utilizing Independent
Microprocessors and Host Distributed Digital Control Systems
0084.0-693 The Application of an Advanced FNI-CR-MN Austenitic Alloy for Feedwater
Heaters
0084.0-694 Alloy 400 (UNSNO4400) for Use in High Pressure Feedwater Heaters
0092.0-643 Feedwater Heating Performance Gains Developed Through AOV Maintenance
0092.0-831 FW Bypass of High Pressure Heaters
0094.0-248 Non-Destructive Examination Method For Carbon Steel High Pressure Feedwater
Heaters
0094.0-35 Available Non-Destructive Examination Techniques For Closed Feedwater Heaters
0099.0-524 P2EP Survey 92-001, Feedwater Heater Replacement
0099.0-576 P2EP Survey 94-016, Inlet Feedwater Temperature
0099.0-586 P2EP Survey 95-007, High Pressure Feedwater Heater Bypass
0099.0-669 P2EP Survey 96-009, Detection of Feedwater Heater Tube Leaks
0101.0-21 Feedwater Heater Performance Monitoring
0101.0-421 The Performance Software Users Group Meeting Proceedings
0102.0-682 Interim Status Report on the Revision of ASME PTC 12.1 - Closed Feedwater
Heaters
0106.0-787 Callaway Plant Engineering Test Procedure: ETP-A01102, HP Feedwater Heaters
0142.3-185 Improved Ferritic Stainless Feedwater Heater Tubing - Crevice Corrosion Resistance
In Chloride Faulted Feedwaters
0146.2-862 Testing, Instrumentation and Analysis Proposed for Revision of ASME PTC 12.1--
Closed Feedwater Heaters
0152.0-130 Explosively Welded Tube Joints in Critical Service Applications
2-37
software on the subject of Feedwater Heaters. These are available to eligible EPRI
members by calling:

CS-3239 Recommended Guidelines for the Operation and Maintenance of Feedwater Heaters
CS/NP-3743 Symposium on State of the Art Feedwater Heater Technology
CS-4155 Feedwater Heater Procurement Guidelines
CS-4285 Detection of Water Induction in Steam Turbines, Phase 3: Field Demonstration
CS-5856 High-Reliability Feedwater Heater Study
CS-6080 Proceedings: 1987 Conference on Expert-System Applications In Power Plants
GS-6635 Proceedings: 1988 EPRI Heat-Rate Improvement Conference
GS-6913 Feedwater Heaters: Replacement Specification Guidelines
GS-6935 Feedwater Heaters Maintenance and Repair Technology: Reducing Outage Cost
GS-7290 Proceedings: Feedwater Heater Technology Conference
GS-7417 Feedwater Heater Survey
NP-4057, V-1 Nuclear Plant Feed Water Heater Handbook, Vol. 1, Primer
NP-4057, V-2 Nuclear Plant Feed Water Heater Handbook, Vol. 2,
NP-4057, V-3 Nuclear Plant Feed Water Heater Handbook, Vol. 3, O&M Guidelines
TR-102923 Proceedings: 1992 Feedwater Heater Technology Symposium
Notes)
Non-EPRI References
2-38
American Society of Mechanical Engineers. Code on Steam Condensing Apparatus,

(Reaffirmed 1988). ASME Performance Test Code 12.2-1983. August 31, 1983.
American Society of Mechanical Engineers. Closed Feedwater Heaters, (Reaffirmed

1987). ASME Performance Test Code 12.1-1978. 1978.
Standards for Steam Surface Condensers, Eighth Edition. Heat Exchange Institute,
Incorporated, Cleveland, Ohio: January, 1984.
Standards for Closed Feedwater Heaters, Fifth Edition. Heat Exchange Institute,
Incorporated, Cleveland, Ohio: January, 1992.
The following document contains additional information on feedwater heaters.
Nuclear Plant Feedwater Heater Handbook, Volumes 1 - 3. Electric Power Research Institute,
Palo Alto, California: June 1985. Report NP-4057.
2.4 Steam Generators
Steam generators (SG) in PWR plants are heat exchangers with reactor primary cooling
water on the tube side entering at Thot and exiting at Tcold.
In a feedring steam generator, feedwater enters a downcomer region and flows up past
the tubes. Over most of the tubes, the secondary flow is saturated. Nearly dry saturated
steam exits from the top of the steam generator after passing through a moisture
separator section in the steam dome. The moisture that is separated from the saturated
steam recirculates with the feedwater. The moisture return path is via the downcomer
region between the tube wrapper and the outer steam generator shell. Figure 2-10
shows a typical feedring steam generator.
Preheating SGs have feedwater entering in a lower baffled section of the T cold region of
the tubes, which uses the primary coolant at Tcold to preheat the feedwater.
2-39
Table 2-11
Instrumentation for Steam Generators
Parameter Purpose
Main steam flow Check on FW flow

Feedwater flow Calculate heat transfer and Q
Mainsteam P, T Calculate tsat, Hs
Thot Calculate ' Tm
Tcold Calculate Tm
Feedwater temperature Calculate heat transferred Q
In a once-through steam generator (OTSG), feedwater enters a downcomer region and

then flows up past the tubes. Saturated steam is produced in the bottom third of the
tube region and is superheated 50qF in the top two-thirds of the region. Fouling in
OTSGs causes the water level to rise and decrease superheat.
2-40
Figure 2-10
Westinghouse Model F Feedring Type Steam Generator
2-41
Plant thermal performance can be affected by the capability of PWR steam generators
to transfer heat from the reactor coolant to the secondary system. This thermal
capability can be reduced by several degradation mechanisms, the three most
important being the quantity of plugged tubes, accumulation of deposits on the inside
and outside tube surfaces, and fouling of the moisture separators. Fouling of the
moisture separators increases pressure drop and allows more moisture carryover. The
number of plugged tubes should be accounted for and trended. The effect of deposit
accumulation is determined by calculation.
The resistance to heat transfer of a SG tube is the sum of the conductive resistance of the
tube wall, the boundary layer resistance of the primary and secondary fluids, and the
resistances resulting from the accumulation of any deposit layers on the inside and
outside tube surfaces. The effect of increased resistance is to require an increase in
reactor coolant temperature or a decrease in secondary side temperature, that is, steam
pressure to continue transferring the same amount of heat from the reactor.
The thermal resistance of SG tubes varies locally throughout the tube bundle,
depending on local coolant conditions and local deposit accumulation. It can be shown
that a global or mean overall thermal resistance can adequately account for local
variation and be used to evaluate and trend the performance of steam generators. The
global thermal conductance, U, is the inverse of the global thermal resistance and can
be calculated by:
U = Q/(A'Tm)
where
4 = 0 IZ (KV K IZ ) + 0 EG (KV KD )
7KRW 7FROG
7P =
7KRW 7VDW
OQ
7FROG 7VDW
and
A = the active heat transfer area of the steam generator, ft 2

Mfw = feedwater into steam generator, lb/hr
hs = steam enthalpy at SG pressure (Ps), Btu/lb
hfw = saturated water enthalpy at feedwater temperature, Btu/lb
Mbd = SG blowdown rate at the time data is taken, lb/hr
ha = makeup water enthalpy, Btu/lb
'Tm = log mean temperature difference, qF
2-42
Thot = primary coolant hot leg (SG inlet) temperature, qF

Tcold = primary coolant cold leg (SG outlet) temperature, qF
Tsat = saturation temperature at SG pressure, Btu/lb
After the global thermal conductance has been calculated, the global film resistance, Rf,
can be calculated from:
Rf = 1/U - 1/Uo
where Uo is the design global thermal conductance of the SG and can be calculated
using the above equations and design data.
The values of Ps, Rf, and U are all candidates for trending because they are measures of
steam generator heat transfer degradation. Another important indicator is the quantity
UA because it includes the impact of plugged SG tubes.
Sample calculations:
Input Data Mfw = 3.79 x 106 lbm/hr

hs = 1191.3 Btu/lbm
hfw = 419 Btu/lbm
mbd = 0 lbm/hr
Tsat = 541qF
Thot = 618qF
Tcold = 557qF
A = 48,300 ft2
Calculation 4 = [ [( )

= [ %WX KU

7P =

OQ

= $ )
[

8=
[
=
%WX
KU IW ) $
Input Data Uo = 1563 Btu/hr ft2 qF

U = 1500 Btu/hr ft2 qF
2-43
Calculation
5R =

KU IW )
$
= [
%WX

5=

KU IW ) $
= [
%WX
KU IW ) $
5 I = [
%WX
Uncertainties in the measurement of moisture in the steam and feedwater flow reduce
the accuracy of these calculations. An approach for trending steam generator heat
transfer performance has been used that reduces the effect of measurement
uncertainties. This approach requires adjusting the primary temperature slightly to
reproduce the steam pressure from the previous data point. A comparison can then be
made of the effects of steam enthalpy changes on the throttle position, power, and
feedflow that would indicate SG fouling.
Steam generator performance directly impacts thermal performance. The steam

generator removes heat from the primary coolant. Therefore, it must return coolant at a
value of Tcold that provides adequate heat transfer from the primary system. At its
maximum performance, it must remove heat equal to the reactor power while
providing steam flow and pressure to obtain 100% of plant MWe.
Figure 2-11 shows the reduction in steam pressure due to an increase in fouling factor
for a typical steam generator. Figure 2-12 shows the effect of steam generator tube
plugging on steam generator pressure, and is shown to emphasize that the heat transfer
area in fouling factor calculations must be corrected for plugged tubes.
2-44
Figure 2-11
Effect of Fouling Factor on Steam Generator Pressure
Figure 2-12
Effect of Plugged Tubes on Steam Generator Pressure
2-45
Figure 2-13 shows the effects of steam generator degradation on the ability to produce
full rated electrical power.
Figure 2-13
SG Pressure vs. Plant Thermal Power
Line A-B represents the power versus pressure that can be attained at the current or
baseline fouling factor. Line A-B assumes that the turbine throttle valves can be
adjusted to increase steam flow, which lowers the steam dome pressure and transfers
more heat, thereby increasing the power back to 100%. Line C-D represents increased
fouling, which requires a still higher flow and lower Tsat, Psat.
As the throttle valves are opened to compensate for fouling (or tube plugging, etc.), the
valves-wide-open (VWO) condition occurs. When it does, the power is limited by line
E-F. Hence, the plant is limited in power to the intersection points shown in the figure.
Also, as the throttle valves open to provide more steam flow to compensate for lower
enthalpy, there is more moisture carryover, which also affects power.
Changes in secondary cycle performance can offset some of the SG heat transfer
performance, which is primarily affected by fouling of the secondary surfaces of the
tubes.
2-46
Steam generator parameters that should be baselined and monitored include:
x Steam generator pressure (the primary indicator of steam generator performance)
x Reactor coolant system Tavg (which controls the steam generator pressure to some
extent and provides a subset for losses associated with steam generator pressure)
x Blowdown flow
x Moisture carryover (not normally monitored, but must be considered if determined

to deviate from design)
Each of these parameters affects not only the calorimetric calculations of core power,
but also has an independent effect on the turbine cycle efficiency. The baseline values
and further deviations must be considered for accurate electrical megawatt accounting.
The principle steam generator problems affecting thermal performance are:
x Secondary side deposits (including moisture separators)
x Plugged tubes - some plants have margin or excess tubes, others do not
x Primary side deposits - appear not to be significant
The first two are most significant, and primary side deposits do not appear to be
significant. All have the effect of decreasing the steam generator heat transfer capacity
(UA). In order to maintain the same reactor power and steam generation rate with
reduced UA, the steam generator mean temperature difference between the primary
and secondary coolants has to increase. This increase leads to decreasing secondary
side steam pressure (Psat) and temperature (Tsat). Figure 2-13 illustrates this relationship.
Most plants initially had excess turbine steam flow capacity (VWO) and steam
generator heat transfer capacity (UA). As SG tubes are plugged and the remainder
become fouled, Tave has to be increased or Psat has to be reduced to maintain reactor
power and turbine output. There may be some reduction in turbine output depending
on the change in heat rate with changes in Psat and turbine control valve throttling. At
some point, depending on available margins, T ave runs up against Tech Spec limits (and
is not usually an option) and Psat reduction results in turbine VWO conditions. Further
reduction in UA requires reduction in both reactor power and turbine output. The
point at which this occurs is plant unique and depends on steam generator and turbine
capacity margins.
2-47
The subject of corrective action for both secondary side fouling and tube degradation
are complex and beyond the scope of this handbook. However, there are several
caveats that can be brought to the attention of the user of this handbook:
x There is a great deal of uncertainty as to the effect of fouling deposits due to the
measurement process and other factors that may be reducing SG thermal
performance.
x Several plants have performed chemical cleaning to remove the secondary side
fouling deposits. Results have been mixed. In many cases, chemical cleaning has
not had beneficial results.
x Mechanical cleaning of moisture removal sections has increased steam pressure and
the performance of SGs.
x Prevention of tube degradation that results in the need for tube plugging is
dependent on many factors including the history of secondary side water treatment
and primary coolant Thot. Several plants have or are in the process of replacing steam
generators because of current and predicted steam generator plugged tube
conditions.
The references at the end of this section deal with the prevention and remediation of
tube fouling and tube degradation and with SG replacement. These are subjects and
responsibilities that are usually beyond the scope of just the thermal performance
engineer. As a minimum, personnel involved in secondary side water chemistry and
reactor power have responsibilities in these areas. The duties of the thermal
performance engineer can include informing others of the thermal performance of the
steam generators by determining and trending the number of plugged tubes, the U, the
UA, and the rf of the steam generators, as well as the impact of the condition of the
steam generators on heat rate and plant output.
Corrective actions for SG fouling should be based on a program that includes the
following steps:
x Compute the global fouling factor from available early data to develop a baseline of
initial performance. The initial performance should be compared with design
values.
x Track the global fouling factor and record all potential causes for changes such as
tube plugging. These items facilitate determining the root cause for trends.
x Determine actual measurement uncertainties for evaluation of data. These

uncertainties might suggest upgrading instrumentation to obtain usable accuracy.
2-48
x Consider adding instruments to obtain additional parameters. These include

pressure drop between the tube bundle and the steam pressure measurement
location to determine if there are flow changes in the internals, also, recirculation
ratio and preheater flow distribution (for preheater SGs) to detect tube support or
baffle clogging.
x Characterize and track tube scale properties.
x Track secondary side impurity ingress as an additional check on scale build-up.
x When scale build-up indicates potential corrective action, an economic evaluation

would include chemical cleaning, mechanical cleaning, cycle modifications and Thot
increases.
A power uprate reduces the steam generator performance margin. Therefore, degraded
SGs may prevent obtaining the full power uprate. In order to keep primary
temperatures constant, more heat must be removed, which requires a lower
temperature, hence a lower pressure. Primary side deposits are also a potential for
degraded SG performance. Estimating from industry data on primary side scale
deposits, primary deposits are probably not responsible for a significant portion of
steam generator pressure losses.
2.4.5 References
The following is a compilation of documents on the subject of Steam Generators.

They are not necessarily referenced by the preceding text.
2
below are the documents from the P EP Technical Library that relate to the subject
Steam Generators. These documents are available to eligible EPRI members by
calling the P2EP Administrator at 704/547-6024, or via the World Wide Web at
0017.0-833 Dimethylamine Technology to Remove Deposits and Reduce Fouling of Nuclear
Steam Generators
0031.5-648 Steam Generator Mass Calculation: The Cure for the "Shrink-and-Swell"
Phenomenon
0051.0-626 Steam Generator Performance Monitoring Using Non-Intrusive Downcomer Flow
Measurements
0053.0-608 Fouling of Heat Transfer Equipment
2-49
0053.0-642 Alternate Amine Improves Plant Performance at Comanche Peak Steam Electric
Station
0053.0-834 Steam Generator Pressure Reduction: Historical Perspective, Current EPRI Work,
Monitoring Tools, and Role of Deposits
0060.0-716 Heat Rate Performance of Nuclear Steam Turbine-Generators
0060.5-328 Proceedings: Heat Exchanger Workshop
0061.0-884 1996 Activity Report Heat Transfer and Aerodynamics Branch--Electricite de France
0069.0-707 The Role of Visual Inspection in Managing Steam Generator Sludge
0080.0-253 Nuclear Plant Component Basic Series--Turbine-Generators Workbook
0099.0-552 P2EP Survey 93-021, Turbine Performance Related to S/G Plugging
0099.0-556 P2EP Survey 93-025, Thermal Performance Models
0099.0-562 P2EP Survey 94-001, Steam Generator Degradation Modeling
0099.0-575 P2EP Survey 94-015, Main Steam Header Pressure Loss
0099.0-576 P2EP Survey 94-016, Inlet Feedwater Temperature
0099.0-595 P2EP Survey 95-016, Steam Generator Pressure Loss
0100.0-714 Predicting the Performance of 1800-RPM Large Steam Turbine-Generators
Operating with Light Water-Cooled Reactors
0101.0-355 Recent Innovations and Experience with Plant Monitoring and Utility Operations
0106.0-788 Callaway Plant Engineering Test Procedure: ETP-BB-01100, Steam Generator
0106.0-789 Callaway Plant Engineering Test Procedure: ETP-BM-01100, Steam Generator
Blowdown Performance Monitoring
0120.0-880 A Boiling Perspective of Tube Fouling, Water Chemistry and Steam Pressure
0126.0-109 Effect of Corrosion Product Fouling on Ginna Steam Generator Tube Heat Transfer
0126.0-354 R.E. Ginna Nuclear Station Steam Generator Performance
0126.0-394 Steam Generator Performance Degradation
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2-50
software on the subject of Steam Generators. These are available to eligible EPRI
members by calling:

NP-2987 Chemical Cleaning Process Evaluation - Westinghouse Steam Generators
NP-2990 Steam Generator Chemical Cleaning: Demonstration Test in a Model Boiler
NP-2997 Ultrasonic Enhancement of Chemical Cleaning of Steam Generators
NP-3009 Steam Generator Chemical Cleaning Process Development
NP-3302 Data Acquisition Reduction System for Chemical Cleaning Processes for Nuclear
Steam Generators
NP-3477, V-2 PWR Steam Generator Chemical-Cleaning Data Base
NP-4597 Chemical Cleaning of Millstone Unit 2,
NP-4600 Effect of Venting on Crevice Cleaning for PWR Steam Generators
NP-4604, V-3 ATHOS3: A Computer Program for Thermal-Hydraulic Analysis of Steam
Generators
NP-4708 Chemical Cleaning of PWR Steam Generator Sludge Piles
NP-4990, V-1 Thermal Performance Diagnostic Manual for Nuclear Power Plants, Vol. 1,
Development of Thermal Performance Diagnostic Manual
NP-4990, V-2 Thermal Performance Diagnostic Manual for Nuclear Power Plants, Vol. 2, Plant-
Specific Conversion Guidelines and Users Manual
NP-7524 Steam Generator Performance Degradation
TR-102952 R1 Advanced Amine Application Guidelines
TR-105003 ([SHULHQFH :LWK ,QKLELWRU ,QMHFWLRQ WR &RPEDW ,*6&& LQ 3:5 6WHDP *HQHUDWRUV
75 &KDUDFWHUL]DWLRQ RI 3:5 6WHDP *HQHUDWRU 'HSRVLWV
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TR-107262 Effect of Inhibitors on the Electric Resistance of Alloy 600 Surface Films
Non-EPRI References
2-51
American Society of Mechanical Engineers. Steam Generator Apparatus. ASME

Performance Test Code 4.1, 1964.
The following document contains additional information on steam generators.
White, et al., Causes of PWR Steam Generator Thermal Performance Degradation,

Presented at EPRI Nuclear Plant Performance Improvement Seminar, Asheville, North
Carolina (September 1996).
2-52
2.5 Steam Turbine
Nuclear plant turbines are composed of a high-pressure turbine and one or more low-
pressure turbines connected to the generator by a common shaft. Each turbine stage
consists of a stationary set of blades that act as nozzles that develop high velocity steam
and a set of rotating blades that convert the kinetic energy of the steam to torque on the
turbine shaft. A portion of the steam flowing through a stage may be extracted for
feedwater heating.
Turbine stages typically are categorized as impulse or reaction designs. An impulse

stage produces all of the stage pressure drop in the stationary blades (sometimes called
nozzles), and there is little relative velocity change across the rotating blades
(sometimes called buckets). In a reaction stage, approximately half of the stage pressure
drop is in the rotating blades. From the point of view of the thermal performance
engineer, there is negligible difference between the two types.
Turbines consist of a number of stages. A typical nuclear plant HP turbine has six
stages and the LP has eight stages. The pressure ratios are approximately the same for
all stages of a turbine over the entire load range, except for the first stage which has a
variable inlet area due to the turbine throttle valves, and the last stage, which has a
relatively constant exhaust pressure.
As load changes, the upstream pressure and flow on each stage changes, which causes
all of the stage pressure drops to change proportionally except the last stage of the LP
turbine, which always sees the condenser pressure on the downstream side. The other
pressure ratios in the LP turbine are constant across the load range. Therefore, the last
LP stage has a pressure ratio that varies with load and condenser pressure. As load
decreases or condenser pressure increases, the last stage pressure ratio decreases. Most
of the opportunity for turbine performance improvements is in the first HP stage
design and the last LP stage design. An important component of the flow path is the
exhaust hood, which can affect the last stage efficiency.
A key indicator of turbine performance is overall gross turbine heat rate. A sample
calculation of this parameter is contained in Table 2-2 Volume 1 of this handbook.
However, gross turbine heat rate is also affected by the cycle leaks and performance of
other cycle components such as condensers and MSRs. Nevertheless, gross turbine heat
rate is the most important parameter that can be monitored and trended.
2-53
Calculation of performance parameters that directly indicate turbine performance is

handicapped by lack of cost effective technology to routinely measure moisture and
enthalpy of wet steam. There are, however, several performance parameters that can be
calculated that do not require moisture measurement. Two that are discussed below are
turbine first stage pressure and HP turbine enthalpy drop efficiency.
The following describes how turbine first stage pressure can serve as a turbine
performance parameter. The flow-passing ability of a steam turbine is given by the
relationship:
0 =N S (2.1)
Y
Where
M = steam flow lb/hr

k = the flow coefficient
p = the stage inlet pressure, psia
v = the stage inlet specific volume, ft3/lb
This relationship holds at all turbine stages. Also, it can be shown that the relationship
between p and v is approximately:
Y (2.2)
S
Substituting Equation 2.1 into Equation 2.2 results in:
S
0 N
The above relationships are good approximations except when turbine stage pressure
ratios are substantially off-design, and the turbine is at low load.
Figure 2-14 shows the general relationship between stage inlet pressure and steam flow
or feedwater flow, and lists the causes of high and low first stage pressure. A single
relationship is shown because feedwater flow and steam flow are nearly identical.
(Nozzles refers to nozzles downstream of control or first stage.)
2-54
Figure 2-14
Turbine First Stage Pressure vs. Steam or Feedwater Flow
Depending on availability of pressure measurement points, this method of measuring

turbine performance can be used at all steam path points downstream of the HP inlet
steam, including feedwater heating steam extraction points. Note from Figure 2-14 that
the method can be used to indicate feedwater flow nozzle fouling.
Turbine enthalpy drop efficiency is defined as the actual enthalpy drop from turbine
inlet to turbine outlet divided by the ideal or isentropic enthalpy drop, or:
K
KSL KKSR
=
K
KSL KKSR

Where
hhpi = specific enthalpy of the HP turbine inlet (throttle) steam, Btu/lb

hhpo = specific enthalpy of the HP turbine exhaust steam, Btu/lb
hhpo = ideal specific enthalpy of the HP turbine exhaust steam, Btu/lb
Calculation of enthalpy drop efficiency across the HP turbine is possible in (and only
in) plants that have MSRs and the outlet temperature of the MSRs is measured and
used to calculated HP turbine outlet enthalpy (routine direct measurement of HP
turbine moisture to determine turbine outlet enthalpy is not practical). Also, cycle
steam flow and certain flows and enthalpy must be measured or estimated from cycle
2-55
heat balances and thermal kits. For this reason, absolute accuracy of an enthalpy drop
efficiency calculation is not high. However, the repeatability of the calculation, if
trended at nearly the same turbine load, can indicate turbine degradation due to
erosion, foreign deposits, or feedwater nozzle fouling.
The first step in this methodology is to calculate actual HP turbine exhaust enthalpy
using a heat balance and MSR data.
K (:W :H[W :PV (:U + :U )) + KPV :PV (KUL KUR ) :U (KUL KUR ) :U
K =
PVUR
KSR
: :
W H[W (:U + :U )
Where
hmsro = calculated MSR outlet enthalpy, Btu/lb

Wt = derived HP turbine throttle steam flow, lb/hr
Wext = derived total extraction flow from HP turbine to FW heaters, lb/hr
Wms = derived moisture separator drain flow, lb/hr
Wr1 = derived first- or single-stage reheat steam flow from HP turbine, lb/hr
Wr2 = derived second-stage reheat steam flow from HP turbine, lb/hr
hms = derived enthalpy of moisture separator drain flow, Btu/lb
hri1 = derived enthalpy of first- or single-stage inlet reheat steam, Btu/lb
hro1 = derived enthalpy of first- or single- stage reheat drain, Btu/lb
hri2 = derived enthalpy of second-stage inlet reheat steam, Btu/lb
hro2 = derived enthalpy of second stage reheat drain, Btu/lb
Except for MSR outlet reheat temperature and pressure, it is not practical to routinely
measure the MSR data and the turbine throttle extraction and reheat steam flows
needed in the above equation. The above data has to be derived from design heat
balances and thermal kits for the turbine load existing at the time the MSR outlet
temperature and pressure are measured.
MSR outlet enthalpy is determined from steam tables or the Mollier diagram using the
measured MSR outlet superheat temperature and pressure, Tmsro and Pmsro, respectively.
Figure 2-15 shows an example heat balance for a nuclear plant steam cycle with a two-
stage reheater. The calculations for the HP turbine exit enthalpy and the enthalpy drop
efficiency are shown in the sample calculation below.
2-56
Figure 2-15
Heat Balance Diagram for HP Turbine Exhaust Enthalpy
Extraction flows to the feedwater heaters can be taken from the guarantee heat balance
if the measured temperature rise in the heaters is about the same as the values given in
the heat balance. Reheat steam enthalpy can be obtained from the measured pressure
and the design expansion line for the turbine on a Mollier diagram. Determining the
enthalpy of the throttle steam requires the moisture content value. Using the Mollier
diagram and assuming that the steam leaving the steam generator is dry and saturated,
a constant enthalpy process from the steam generator dry saturated conditions to the
pressure just ahead of the throttle valve can be used to obtain the throttle steam
moisture.
In the example, the throttle steam is slightly superheated, which would be the case for a
once-through SG.
2-57
Input Data Pmsro = 88.0 psia

Tmsro = 530F
Wt = 7,181,148 lb/hr
Wext = 324,490 lb/hr
Wms = 685,420 lb/hr
Wr1 = 187,740 lb/hr
Wr2 = 624,371 lb/hr
hext = 1170 Btu/lb
hms = 564.7 Btu/lb
hri1 = 1170 Btu/lb
hro1 = 357.5 Btu/lb
hri2 = 1244.5 Btu/lb
hro2 = 540.2 Btu/lb
hhpo = 1102.0 Btu/lb
Calculations Determine MSR outlet enthalpy at a measured MSR outlet

temperature and pressure of 530F and 88 psia, respectively,
using Mollier diagram. Note that these should be the average
values for all MSRs receiving steam flow from the HP turbine.
hmsro = 1295.9 Btu/lb
Calculate HP turbine outlet enthalpy
( )

+ ( )
( )
K =
KSR
[ ]
= 1115 Btu/lb
Calculate HP turbine enthalpy drop efficiency

KS =

= 0.909
= 90.9%
2-58
K.C. Cottons Evaluating and Improving Steam Turbine Performance contains a

systematic approach to diagnosing potential turbine problems. Nuclear plant turbines
have controlled water conditions and also run at 1800 rpm to reduce moisture-caused
erosion. Therefore, they seldom have increased or decreased flow area caused by solid
particle erosion or buildup of deposits. However, there are instances of turbine
problems, and part of diagnosing trends in the monitored parameters should include
checking for HP and LP turbine degradation.
A complete tutorial for interpreting the data from turbine monitoring and testing is
beyond the scope of this handbook and can be found in Cottons book. However, the
following approach is a good starting point for the TPE:
1. Trend the parameters listed in Table 2-12. Also trend thermal efficiency, the stage
pressure ratio P1st/PEXH for the HP turbine, the first stage pressure ratio for the LP
turbine, the reheater TTD, and the pressure drop across the MSR.
2. Verify the data by looking for
x Changes in MSR 'P
x Suspicious changes in thermal efficiency
x Unexplainable changes in P1st/PEXH for the HP turbine
x Variations in duplicate measurements
x Inconsistencies in measurements
3. Reconcile data. This is done through redundant calculations of the heat and mass
balances for available flows.
4. Check for cycle isolation. This is usually indicated by a decrease in thermal

efficiency at licensed maximum MW thermal. Methods for detection include:
x Isolate the cycle one step at a time.
x Measure leakage flows to the condenser using pressures downstream from

leakage points.
x Check the temperature of lines entering the condenser.
5. Check power output versus valve positions to check for whether the problem is in
the valve or turbine.
2-59
6. Check the HP turbine efficiency versus percent load to check for HP turbine solid
particle erosion.
Table 2-12
Instrumentation for Steam Turbines
Parameter Purpose
Feedwater flow Throttle flow

Final feedwater temperature Thermal efficiency
Throttle pressure Throttle enthalpy and steam flow
Electric load Thermal efficiency
First stage pressure (P1st) Flow characteristics
Reheater exit pressure (Px-0) RH exit enthalpy
HP turbine exit pressure HP pressure drop and flow
HP turbine extraction temperature Check on heat balance
MSR drain flows Enthalpy drop
MSR drain temperatures Enthalpy drop
Reheater inlet pressure Extraction flow
LP turbine extraction temperatures Heat balance
Condenser pressure Enthalpy and turbine backpressure
LP turbine extraction pressure LP stage 'Ps
The turbine efficiency has a one-to-one effect on thermal efficiency or heat rate.
Although usually there is little deterioration in turbine performance, the turbine
performance should be trended. The turbine can degrade to a point where it is cost
effective to repair or upgrade it. HP turbine enthalpy drop efficiency can be an
indicator of SG moisture separator effectiveness. The LP turbine produces
approximately 65% of the total kilowatts in a non-reheat cycle and 69% in a reheat
cycle.
The opportunities for heat rate improvement in the steam path include 0.25% for last
stage LP turbine blade improvements and 0.5% for exhaust hood improvements.
Improved heat rate alone has not justified major turbine design modifications.
However, blade replacement due to stress corrosion cracking of the hubs has presented
the opportunity to justify upgrading blade design in the process of repairing the
turbine.
2-60
Since the development of the turbines used in the nuclear plants, two advancements in
turbine design and test capability have helped identify inefficiencies in the turbine
design and how to improve the designs. These advancements have been in three-
dimensional computational fluid dynamics (CFD) and interstage sample traverses to
measure pressure, velocity, flow angles, and moisture.
Turbines are designed to optimize as well as possible the mechanical forces that are
imparted to the blades by the steam. The maximum available work that the steam can
do is equal to the reversible isentropic process change in enthalpy from the turbine inlet
pressure to the turbine back pressure. Any less work than the reversible isentropic
work represents lost efficiency and shows up as increased entropy and enthalpy at the
condenser. Inefficiencies are caused by the following:
x Moisture droplets impinging on blades
x Leakage of steam through seals on the stationary blading, the blade tips, and at the
ends of the casings
x Aerodynamic drag on tie wires
x Profile losses from flow separation on portions of the blades
x Secondary losses or endwall losses in the low aspect ratio (length y chord) HP
stages
x Secondary losses due to high tip speeds and radial flow on LP blades (especially the
last stage)
x Exhaust losses due to high kinetic energy in the steam which is not converted to
work
Moisture is a problem in nuclear turbines because first stage inlet steam is saturated or
only slightly superheated in plants with once-through SGs. As the initial micron-sized
droplets impinge on surfaces, they coalesce into droplets that impact blades at various
angles. The net effect is a loss of aerodynamic efficiency.
Profile losses are the result of aerodynamic problems with blade designs. The relative
velocities of the blades and steam flow vary over the length of the blade. This variation
changes the angle of attack, which can be in a range causing stall or flow separation.
The energy is lost to friction that would otherwise produce lift on the blades.
2-61
Endwall losses are caused by radial crossflow. Vortices are formed at the blade tips.
Energy that would otherwise provide rotating forces on the blades is dissipated in
these vortices.
The exhaust hood forms the region of the flow path following the last stage of the
turbine. Optimum flow in the exhaust hood directs flow evenly to the condenser
tubing. Also, it should be designed so that steam leaving the last stage does not leave
with an excess of kinetic energy that could have been converted to work by the turbine.
Most of the turbine pressure drop should be in the turbine rather than the path to the
condenser.
A tool for measuring the turbine performance during overhaul is a steam path audit,
which quantifies performance improvements from both routine maintenance and parts
replacement. The purpose of the steam path audit is to quantify steam path
deterioration on a stage-by-stage and casing-by-casing basis. One engineer typically
takes from three to six days to collect the data, generate the loss reports, and present the
preliminary results before making any repair decisions. The timing of the steam path
audit is concurrent with turbine disassembly, and does not interfere with the outage
schedule. A steam path audit is part of a five-step heat rate improvement program
shown in Figure 2-16.
2-62
Figure 2-16
Steam Path Audits as Part of Heat Rate Improvement Program
1. Pre-Outage Test - A heat rate test before an overhaul establishes the condition of the
unit before routine maintenance and installation of any new parts. The heat rate test
results may indicate that, for example, the heat rate is up 4%, but it does not indicate
the cause of the poor performance.
2. Opening Steam Path Audit - An inspection of the steam path immediately upon
opening the steam turbine helps to quantify the damage and degradation found in
each stage in terms of efficiency, power, and heat rate. For example, a steam path
audit quantifies water erosion, rubbed packing seals, and foreign object damage in
the HP and LP casings that account for the measured 4% increase in heat rate. The
audit engineer measures material losses in the following categories:
x Interstage packings (diaphragm packings or shaft packings)
x Tip spill strips (shroud seals)
2-63
x End packings (shaft packings, dummy packings, n-1, n-2, and other packings)
x Miscellaneous leakages (snout ring, bell seal, manhole cover gasket, horizontal
joint, etc.)
x Solid particle erosion
x Deposits
x Mechanical damage (broken blading, foreign object damage, etc.)
x Surface roughness (deposits, machining, etc.)
x Deposits under rotating blade covers (deposits under shroud bands)
x Trailing edge thickness (from previous weld repairs)
x Hand calculations (anything that does not fit into the above categories)
3. Upgrade and Maintenance - The results of the steam path audit are used to
determine the most cost-effective routine repairs to the steam path. The cost-
effectiveness, or benefit-to-cost ratio, of individual maintenance actions is calculated
using the heat rate penalty assigned to the damage identified in the steam path
audit results and the corresponding repair costs. The benefit-to-cost ratio for each
possible maintenance action item is then ranked. A minimum benefit-to-cost ratio is
then established and the maintenance is completed.
4. Closing Steam Path Audit - After any new parts are installed and the remaining
maintenance has been performed, the closing steam path audit predicts the return-
to-service condition of the unit. Like the opening steam path audit, the closing audit
identifies stage-by-stage losses and quantifies the performance penalty associated
with each. For example, after repairing foreign object damage, suppose the nozzle
trailing edges were left at 40 mils rather than at their design thickness of 30 mils.
Additionally, some grinding marks were left on the suction side of the nozzle
exhaust. The closing steam path audit would quantify the trailing edge thickness
and grinding losses as, say, 10 BTU/kWh. The difference between the opening
results and the closing results is the performance gain due to routine maintenance.
The purpose of a closing steam path audit is twofold: 1) to estimate the return-to-
service condition of the unit and 2) to serve as a quality control check on
maintenance conducted during the outage.
5. Post-Outage Test - Shortly after the unit is back on line, a post-outage heat rate test
measures the actual return-to-service condition. The difference between the pre- and
post-outage tests is the performance improvement due to upgrades and routine
maintenance.
2-64
The steam path audits provide a calculated change in heat rate based on conditions of
packings, glands, blade surfaces, spill strips, etc., found when the turbine casings are
open. The five steps in Figure 2-16 yield the following heat rate values:
x Pre-test heat rate
x Opening steam path audit heat rate
x Closing steam path audit heat rate
x Post-test heat rate
The total improvement in heat rate due to maintenance and any turbine upgrades is
equal to the pre-test heat rate minus the post-test heat rate. The heat rate improvement
due to outage maintenance is the opening steam path audit heat rate minus the closing
steam path audit heat rate. Heat rate degradation due to startup is the post-test heat
rate minus the closing steam path audit heat rate.
2.5.5 References
The following is a compilation of documents on the subject of Steam Turbine. They

are not necessarily referenced by the preceding text.
Steam Turbine. These documents are available to eligible EPRI members by calling
2
the P EP Administrator at 704/547-6024, or via the World Wide Web at
0006.0-212 Minimizing Turbine Blade Erosion With An Innovative Low-Pressure Heater Design
Modification
0006.0-334 Proceedings: Steam Turbine Blade Reliability Seminar and Workshop
0020.0-79 Corrosion-Resistant Coatings for Low-Pressure Steam Turbines
0020.3-103 Development Of More Accurate Correction Factors Through Heat Balance Modeling
0031.5-223 Thermal Performance Data (Thermal Kit) for ComEd Braidwood Station
0034.6-160 Ginna Station Stationary Blading Design Optimization
0034.6-453 Upgrades To Turbine - MSR Hardware For Performance Improvement
0043.0-681 Energy Analysis for Sensitivity to Turbine Induction
2-65
0055.0-876 Heat Kit for Peach Bottom

0057.0-360 Recommended Practices for the Prevention of Water Damage to Steam Turbines
Used for Electric Power Generation
0060.0-523 1992 Heat rate Improvement Conference: Sessions 5A, 5B, 6A, 6B, 7A, and 7B
0080.0-104 Westinghouse Turbine Performance
0080.0-11 A Manufacturer's Experiences Of Improving The Heat Rate Of Large Steam
Turbines
0080.0-13 A Practical Guide To N2 Packing Testing On GE Combined HP-LP Turbines
0080.0-253 Nuclear Plant Component Basic Series--Turbine-Generators Workbook
0080.0-308 PP&L Heat Rate Improvement of Three Large Super Critical Turbines
0080.0-382 Some Thoughts On Plant Performance Evaluation
0080.0-398 Steam Turbine Performance Survey As Compiled From Steam Path Audits
0080.0-418 Comparison of Steam Turbine Path Audit Results to Performance Test Results
0080.0-485 WPPSS Plant Efficiency and Reliability Monitoring Programs: Main Turbine
Performance Monitoring. Procedure No. 8.4.41. April 1988.
0080.0-498 Design and Efficiency Increase of LMZ Turbines
0080.0-641 Turbine Steam Path Audits at San Onofre Nuclear Generating Station
0080.0-760 Fort Calhoun Station Repetitive Special Services Procedure: Steam Cycle
Performance Test
0085.0-516 Duct Retrofits Cut Leakage and Boost Heating-System Efficiency
0090.0-124 Evaluation of a Moisture Removal Device for Turbine Steam Piping
0090.0-18 MSR Performance Monitoring
0090.0-224 Optical Probe Measurements of Low Pressure Steam Turbine Wetness and
Efficiency at Morgantown Unit 2
0090.0-25 Interim Report #2 on Moisture Separator-Reheater Drain Systems
0090.0-269 General Description--Two-Stage Moisture Separator Reheater (Internal Header,
Vertical U-Bend Design)
0090.0-390 The MSR Evolution
0090.0-732 MSR Optimization Test Report
0099.0-528 P2EP Survey 92-005, Erosion/Corrosion
0099.0-533 P2EP Survey 93-002, ASME Steam Turbine Testing
0099.0-534 P2EP Survey 93-003, HP Turbine Efficiency
0099.0-535 P2EP Survey 93-004, Unaccounted-For MWe Loss and Turbine Degradation
0099.0-552 P2EP Survey 93-021, Turbine Performance Related to S/G Plugging
0099.0-566 P2EP Survey 94-005, Precision Shaft Torque Meter for Large Utility Turbines
0099.0-602 P2EP Survey 96-005, Nuclear Turbine Upgrade Activities
0100.0-257 Nuclear Plant Performance, Reliability, Heat Rate Improvement and Life Extension
Basic Series-Thermal Kits Workbook
2-66
0101.0-301 Plant Thermal Performance and Availability Monitoring Report (GPU Nuclear -
Oyster Creek)
0101.0-802 Use of Reconciled Process Data in Performance Tests of Low-Pressure Turbines at a
1000 MW Power Plant
0102.0-273 Performance Improvements of Fossil Unit Retrofit Designs
0102.0-439 Adaptation of the Alternative Test Code in Evaluating a Low Pressure Steam Path
Replacement
0106.0-784 Callaway Plant Engineering Test Procedure: ETP-AC-01100, Main Turbine
Generator Performance Monitoring
0113.0-252 Nuclear Plant Component Basic Series Moisture-Separators/Reheaters Workbook
0116.0-457 Variable Pressure Operation: An Assessment
0116.0-725 Rotor Retrofit at WNP-2
0134.5-897 Optical Probe for Measurement of Steam Wetness Fraction in LP Turbines
0139.0-518 P2EP Pilot Training: Thermal Kits Course Module
0144.0-12 A Method To Monitor High-Pressure Turbine Efficiency and Moisture-Separator
Effectiveness In LWR Power Plants Without Tracer Techniques
0145.0-102 Development of Low-Pressure Turbine Coatings Resistant to Steam-Borne
Corrodents, Vol. 2: Detailed Studies
0145.0-131 Steam Turbine Efficiency Improvement
0145.0-19 Aero-Thermodynamics of Low Pressure Steam Turbines and Condensers
0145.0-199 Latest Advances in Steam Turbine Design, Blading, Repairs, Condition Assessment,
and Condenser Interaction
0145.0-202 Low Pressure Turbine Exhaust Flow Improvement Study
0145.0-217 Model Testing Of Low Pressure Turbine Exhaust Ends
0145.0-288 Pilgrim Nuclear Power Station Instruction PG-1070: Main Turbine Performance,
Rev. 0, 1987.
0145.0-436 Direct Measurement of LP Cylinder and Final Stage Efficiencies Using Probe
Traverses
0145.0-448 TVA Technical Instruction TI-119: Turbine Cycle Performance Test, Rev. 0, 1989
0145.0-620 Low Pressure Steam Turbine Thermal Performance Improvements
0146.5-797 Survey of Performance Upgrade Experiences on U.S. Nuclear Turbines
0146.5-891 Turbine Upgrades at Grand Gulf
software on the subject of Steam Turbine. These are available to eligible EPRI
members by calling:
2-67

AF-903 Turbine Cycle Performance Improvement Through Titanium LP Blades
CS-1604 Detection of Water Induction in Steam Turbines
CS-2124 Review of Corrosion-Resistant Coatings for Steam Turbine Components
CS-2932 Corrosion Fatigue of Steam Turbine-Blading Alloys in Operational Environments
CS-3135 Detection of Water Induction in Steam Turbines, Phase II: Field Evaluation
CS-3251 Steam Turbine Condensation--Shock Wave Interaction
CS-3891 Survey of Steam Turbine Blade Failures
CS-4285 Detection of Water Induction in Steam Turbines
Phase 3: Field Demonstration
CS-4410 Demonstration of an Alternative ASME Steam Turbine Generator Acceptance Test
CS-4515 Titanium L-1 Steam Turbine Blade Retrofit
CS-4545-SR Proceedings: 1984 Power Plant Performance Monitoring Workshop
CS-4683 Solid-Particle Erosion of Utility Steam Turbines: 1985 Workshop
CS-5085 Steam Turbine Blade Reliability Seminar and Workshop, 1986
CS-5415 Erosion Resistant Coatings for Steam Turbines
GS-6535 Solid Particle Erosion of Steam Turbine Components: 1989 Workshop
GS-6725 Proceedings: Fossil Plant Retrofits for Improved Heat Rate Availability
GS-7003 Improvement of the Exhaust Flow of a Low-Pressure Turbine
GS-7295 Demonstration of EPRI Heat-Rate Improvement Guidelines
TR-100215 Field Measurement of Solid Particle Erosion in Utility Steam Turbines
TR-100603 Procedure for Economic Evaluation. of Steam Turbine Drives vs. Electric Drives
TR-104885 Introduction to Nuclear Plant Steam Turbine Control Systems
TR-106230 Main Turbine Performance Upgrade Guideline (final draft)
TR-106345 MSR Source Book (final draft)
Non-EPRI References
this material if appropriate.
American Society of Mechanical Engineers. PTC 6 on Steam Turbines Interpretations

1977-1983. ASME Performance Test Code 6. June 30, 1984.
2-68
American Society of Mechanical Engineers. Guidance for Evaluation of Measurement

Uncertainty in Performance Test of Steam Turbines. ASME Performance Test Code 6
Report-1985. August 31, 1988.
American Society of Mechanical Engineers. Steam Turbines (Reaffirmed 1991).

ASME Performance Test Code 6-1976. 1976.
American Society of Mechanical Engineers. Interim Test Code for an Alternative

Procedure for Testing Steam Turbines. ASME Performance Test Codes 6.1-1984. June
30, 1984.
American Society of Mechanical Engineers. Appendix A to Test Code for Steam

Turbines (Numerical Examples of Various Turbine Calculations) - Reaffirmed 1988.
ASME Performance Test Code 6A-1982. June 30, 1983.
American Society of Mechanical Engineers. Procedures for Routine Performance Tests

of Steam Turbines. ASME Performance Test Code 6S Report-1988. December 15, 1989.
Edwin R. Church. Steam Turbines. McGraw-Hill, New York 1950.
Kenneth J. Salisbury. Steam Turbines and Their Cycle. John Wiley & Sons, New York
1950.
The following documents contain additional information on steam turbines.
F. G. Bailey, K. C. Cotton, and R. C. Spenser, Predicting the Performance of Large

Steam Turbine-Generators Operating with Saturated and Low Superheat Steam
Conditions, GER 2454A, presented at the 29th Annual Meeting of the American Power
Conference, Chicago, Illinois (April 1967).
K. C. Cotton. Evaluating and Improving Steam Turbine Performance. Cotton Fact, Inc.,
Rexford, New York 1993.
Deborah H. Cioffi, P.E., Using Steam Path Audits in a Performance Guarantee

Program, presented at the 1997 Performance Software Users Group Meeting
sponsored by Scientech, Inc. and American Electric Power Service Corporation,
Columbus, Ohio (June, 1997).
2-69
2.6 Moisture Separator Reheaters
During expansion through the HP section, the moisture content in the steam increases
to approximately 12% at the HP turbine exhaust. Moisture in the cycle steam reduces
the mechanical efficiency in the LP turbines and causes erosion of LP turbine
components in the steam path. The function of MS/Rs, located between the HP and LP
sections, is to remove moisture from the steam in the HP turbine exhaust and, in the
case of MSRs, to reheat the dried steam before it flows into the LP turbine sections.
Moisture separation and reheat, however, do not improve the thermodynamic
efficiency of the LP turbines because moisture removal and reheat, using main and
extraction steam, do not increase the overall availability of energy in the steam cycle. In
fact, they cause small reductions in thermodynamic efficiency. If it were not for the fact
that reduced moisture improves mechanical efficiency, moisture separation and reheat
would not improve turbine heat rate. This benefit was not well recognized during the
period when many of the operating plants were designed. Since startup, several plants
have had to replace LP rotors and stationary internals. A major reason was erosion and
corrosion damage caused by moisture.
Although all MSR designs are based on the concepts of moisture separation and reheat,
the designs may vary in the details. The description below is also applicable to MSs to
the extent that they use the same principles of moisture separation and use large
vessels.
Figure 2-17 shows a simplified cutaway schematic of a two-stage MSR. The shell is
approximately 6 in diameter and 50 long, and usually is designed to be located in a
horizontal position. The vessel is designed to contain moisture separation equipment
and tube bundles used to reheat the cycle steam. The vessel is larger than the tube
bundles in order to produce low cycle steam velocities needed for efficient moisture
separation. Figure 2-17 shows two tube bundles. In the case of single reheat, there is
one tube bundle per shell, and no tube bundles in the case of MS only. However, even
if the vessel is MS only, it is large due to the need to have low cycle steam velocity in
order to achieve high moisture separation effectiveness.
When this report is referring to moisture separators with reheat capability, the abbreviation MSR is
used. When referring to moisture separators without reheat capability or the moisture separator section
of an MSR, the abbreviation MS is used. When referring to both types, MS/R is used. MS/Rs are used
only in light water reactor nuclear power plants; they are not used in fossil power plants.
2-70
Figure 2-17
Typical Two-stage MSR
The vessel has several large piping connections, usually one inlet connection at the end
or one or more inlet connections at the bottom of the vessel for inlet cycle steam, and
several cycle outlet steam connections on the top of the cylindrical part of the vessel.
2-71
The reason for multiple outlet nozzles is to aid in distributing cycle steam flow
uniformly across the moisture separators and reheat tube bundles and to provide
multiple feeds to the LP turbines.
The vessel usually has one or more drain connections at the bottom of the shell to drain
water removed from the inlet cycle steam by the separators. The water, at saturation
temperature corresponding to inlet cycle steam pressure, is directed to a drain tank and
then to a feedwater heater stage, operating at less than cycle steam pressure in the
MS/R.
MSR vessels also have nozzles and channels that supply reheat steam to the tube side of
the reheat tube bundles, along with channels and nozzles that drain condensed reheat
steam from the outlet of the tube bundles. The condensate, usually at saturation
temperature, normally drains to a feedwater heater.
The most common form of moisture separator is the chevron vane type shown in Figure
2-18. The chevrons are arranged to provide large steam passageways that achieve low
steam velocity and make changes in flow direction, which helps to separate the
moisture from the steam by the change in momentum. They also provide a large
amount of contact surface to collect moisture in the low velocity steam.
Cycle steam is reheated using heating steam and tube bundles located in the MSR
vessel. There are two sources of heating steam depending on the number of reheat
stages:
x Single-Stage Reheat This form of reheat usually uses one tube bundle per MSR
vessel with the main steam header as the source of higher temperature heating
steam. Some large MSRs have two tube bundles.
x Two-Stage Reheat This form of reheat usually uses two tube bundles per MSR
vessel with an HP turbine extraction point as the source of heating steam for the
first or LP stage and the main steam header as the source of the second or HP
stage heating steam. Some large MSRs use two sets of tube bundles for each stage.
2-72
: '
( 5
7 <
6 6
7 7
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Figure 2-18
Chevron Moisture Separator
Both single-stage and two-stage MSRs use U-tubes with most having the plane of the
U-tube oriented vertically. The heating steam is on the inside of the tubes and cycle
steam is on the outside. Heating steam flows into the top leg of the U-tube and
condenses along the length of the tube. The condensate and some steam flows out of
the bottom leg of the U-tube. Cycle steam is heated by flowing across the outside of the
tubes. The outside heat transfer coefficient for heating steam is not high. For this
reason, the outside of the tubes is usually finned with integral, low profile fins. The U-
tube bundles are enclosed in shrouds that provide a structure for tube support and
direct cycle steam flow up between the tubes. The tube sheets are generally located at
the end of the vessel opposite the end that may contain the cycle steam inlet nozzle. The
tube bundles extend the length of the MSR vessel. Usually, several cycle steam outlet
nozzles are provided along the length of the vessel to enhance uniform distribution of
steam flow up through the reheater.
There is usually little instrumentation provided by the original equipment

manufacturer (OEM) to monitor the performance of MSRs. This makes diagnostics and
isolation of problem areas difficult. Most MSRs have thermocouples or resistance
temperature detectors that measure reheater exit cycle steam temperature. These
temperatures are often the only direct indication of MSR performance. If temperature is
low, the reheater tube bundle heat transfer capability may be low, or the moisture
separation efficiency may be low and part of the reheater surface is being used to
evaporate carryover moisture.
2-73
Table 2-13 lists instrumentation that can be provided on a MSR and the reasons to
provide the instrumentation. The instrumentation is discussed in more detail in PTC
12.4. Moisture is not routinely measured. It is possible to set up special tests using
tracer techniques, but there is no technology available that can be used to routinely
measure moisture content in wet steam.
Table 2-13
Instrumentation for MSRs
Parameter Purpose
HP heater cycle steam outlet temperature HP heater TTD and heat balance
HP heater heating steam flow HP heater heat balance
HP heater steam inlet pressure and temperature Inlet enthalpy and HP heater TTD and
(temperature required only if steam is heat balance
superheated)
HP heater outlet flow pressure and temperature Subcooling, enthalpy, HP heater TTD,
and heat balance
HP heater excess steam flow Adequacy of flow, HP heat balance
LP heater cycle steam outlet temperature LP heater TTD and heat balance
LP heater heating steam flow LP heater heat balance
LP heater steam inlet pressure and temperature Inlet enthalpy, LP heater TTD, and
(temperature required only if steam is heat balance
superheated)
LP heater outlet flow pressure and temperature Subcooling, enthalpy and LP heater
TTD and heat balance
LP heater excess steam flow Adequacy of flow, LP heat balance
Moisture separator drain flow Moisture carryover, MSR heat balance
LP turbine inlet pressure Cycle steam flow
Feedpump turbine steam flow Cycle steam flow
2.6.2 Basic Calculations
The following calculation methodology is provided as a simple way to measure the

overall performance of an MSR. It is applicable to hand calculations or PC spreadsheets.
Heater Terminal Temperature Difference (TTD)
The TTD is a measure of the ability of the reheater to achieve a high heat transfer rate
indicative of high heat transfer coefficients, low fouling, and good heat transfer surface
properties. It can be compared with design and previous operating TTDs. An
increasing trend indicates degradation in heat transfer coefficient and area, or a
decrease in moisture separator effectiveness, or a combination of these factors.
2-74
TTD = ths - tcso
Where
ths = temperature of the heating steam, qF

tcso = reheater outlet cycle steam temperature, qF
Note that it may not be practical to determine TTDs for the first or LP stage of a two-
stage reheater since MSRs are normally not instrumented to measure tcso for the LP
heater.
An example calculation is shown below:
Input Data ths = 535qF

tcso = 520qF
Calculation TTD = 535 - 520 = 15qF
Reheater Log Mean Temperature Difference (LMTD)
The LMTD is the effective temperature difference that is heating the cycle steam in the
reheater.
/07' = (W KV W FVL ) (W KV W FVR )

W KV W FVL
OQ
W KV W FVR
Where
tcsi = temperature of the cycle steam flowing into the reheater
Single-stage HP reheaters and LP reheaters, ths and tcsi are saturation temperatures. In
two-stage HP reheaters, tcsi needs to be directly measured. In all cases, tcso is directly
measured.
An increasing trend indicates degradation in heat transfer coefficient and area, or a

decrease in moisture separator effectiveness, or a combination of these factors.
An example calculation of LMTD is shown below:
2-75
Input Data In addition to the data from TTD, the following

additional data is needed to calculate LMTD:
tcsi = 350qF
Calculation
/07' = (
) ( ) = )

OQ

Table 2-14 shows that the most gain in cycle efficiency is made by moisture separation;
incremental, but important, gains are made with single- and two-stage reheat. Results
may vary with individual plant design.
Table 2-14
Typical Moisture and Efficiency Gains
Condition LP Turbine Inlet LP Turbine Gain in Cycle

Condition Outlet Condition Efficiency
Moisture, % or Moisture, % %
Superheat, qF
No MS or reheat 12-15% 24- 30% -

MS without reheat 0-3% 12- 18% 4- 5%
MS and single stage reheat 140- 160qF 10- 12% 5- 6%
MS and two stage reheat 140- 160qF 10- 12% 6- 7%
Plant operating experience has shown that MS/Rs are susceptible to problems that have
required significant modifications. The cause of most of the problems involves moisture
entrained in the cycle steam and the potential for it to cause erosion, and large
temperature differences and rates of temperature change in MSRs that can cause
significant thermal distortion and high thermal stresses.
The original design intent was to achieve a high percentage removal of cycle steam
moisture in the moisture separators. There have been several problems related to
moisture separation: (1) use of wire mesh for moisture separation; (2) use of carbon
steel chevrons; (3) low moisture removal efficiency; (4) poor inlet steam flow
distribution; and (5) moisture re-entrainment. Wire mesh and carbon steel chevrons
have been largely eliminated. Low moisture removal efficiency, poor inlet steam flow
distribution, and re-entrainment remain problems at some plants. Others have
2-76
remedied these problems by modifying the inlet flow path and changing to more
efficient stainless steel chevrons. See the references for more detail.
2.6.5 References
The following is a compilation of documents on the subject of Moisture Separator

Reheaters. They are not necessarily referenced by the preceding text.
MSRs. These documents are available to eligible EPRI members by calling the P 2EP
Administrator at 704/547-6024, or via the World Wide Web at
0034.0-306 MSCDT Level Control Issue
0034.6-453 Upgrades To Turbine - MSR Hardware For Performance Improvement
0034.6-666 Determination of MSR Moisture Separation Efficiency at the Washington Nuclear
Power Station - Unit 2
0090.0-119 MSR Design
0090.0-124 Evaluation of a Moisture Removal Device for Turbine Steam Piping
0090.0-127 Moisture Separator Reheater Performance
0090.0-175 Improved Moisture Separator Reheaters for Nuclear Steam Supply Systems
0090.0-176 Tube Failures in Moisture Separator-Reheater Tube Bundles due to Restrain
Thermal Expansion
0090.0-18 MSR Performance Monitoring
0090.0-187 A Few Design Considerations for Moisture Separator Reheaters
0090.0-190 MSR Redesign and Reconstruction at Indiana Michigan Power Company's Donald
C. Cook Nuclear Power Plant, Unit 1
0090.0-191 MSR Performance Enhancements and Modifications at St. Lucie Power Plant
0090.0-20 In-Situ Reconstruction of the MSRs at the Beaver Valley Nuclear Power Station
0090.0-203 Moisture Separator-Reheaters: Entering the Second Decade
0090.0-219 Moisture Separator Reheaters
0090.0-224 Optical Probe Measurements of Low Pressure Steam Turbine Wetness and
Efficiency at Morgantown Unit 2
0090.0-23 Maintenance and Fuel with Ellison's Steam Calorimeter
0090.0-237 Testing to Detect Changes in Performance of a Steam Turbine Cycle
0090.0-24 Moisture Separator Reheater Design Technology
0090.0-247 Drainage and Venting in a Swirl Vane Moisture Separator Application
2-77
0090.0-25 Interim Report #2 on Moisture Separator-Reheater Drain Systems

0090.0-255 Design of Short Manifolds for Lateral Flow Distribution
0090.0-258 Moisture Separator Reheater Replacement Tube Bundle
0090.0-259 MSR Reheater Technology: Improved 4-Pass Vent Chamber and Excess Steam Flow
Regulation
0090.0-26 Redesign and Replacement of Connecticut Yankee Moisture Separator/Reheater
(MSR) Tube Bundles
0090.0-260 Report on Operational Problems and Modifications of Trojan Moisture Separator
Reheaters
0090.0-264 Improvement in Performance and Availability of Currently Operating MSRs
0090.0-267 Progress in Moisture Separator-Reheaters for Nuclear Power Plants
0090.0-269 General Description--Two-Stage Moisture Separator Reheater (Internal Header,
Vertical U-Bend Design)
0090.0-27 Moisture Separator Reheater (MSR) Performance Improvement Project
0090.0-350 MSR Testing and Evaluation; PTC-12.4--The ASME Performance Test Code for
MSRs
0090.0-373 Equipment Upgrades Increase MW Output at Prairie Island
0090.0-376 Sensitivity of Moisture Separator Reheater Performance To the Nuclear Steam
Turbine Generator Cycle
0090.0-38 Beaver Valley MSR Rebuild
0090.0-390 The MSR Evolution
0090.0-4 Reconstruction of the MSRs In-Situ at Beaver Valley
0090.0-402 Moisture Separator Source Book Compendium
0090.0-41 Moisture Separator-Reheaters (MSRs)
0090.0-463 Waterford III Standing Test Procedure: Moisture Separator Reheater (MSR)
Performance, Procedure No. NE-8-007
0090.0-470 WNP-2 MSR Program
0090.0-486 WPPSS Plant Efficiency and Reliability Monitoring Programs: Moisture Separator
Reheater Performance Monitoring, Procedure No. 8.4.27, Rev. 0
0090.0-610 MSR Literature
0090.0-611 MSR Performance Monitoring Presentation
0090.0-617 Thermo-Hydraulic Simulation Used to Rectify MSR Performance Deficiency
0090.0-618 MSR Flow-Induced Vibration and Fretting-Wear: A Case History
0090.0-647 Turbine Moisture Removal and Reheater Alternatives - Experiences in Performance
Improvement
0090.0-649 Excess steam Flow Optimization in Operating MSRs
0090.0-667 MSR Performance Improvement at Prairie Island Nuclear Station
0090.0-732 MSR Optimization Test Report
0090.0-810 PA Preview of the EPRI MSR Source Book
0090.0-843 MSR Installation List
0090.0-844 Experience with the Moisture Preseparator (MOPS) and with the Special Cross-
Under Pipe Separator (SCRUPS) in the Leibstadt Nuclear Plant
2-78
0090.0-845 Thermo-Flow Induced Tube Damage in Moisture Separator Reheaters

0090.0-846 Startup of Second Stage Reheat for the MSRs
0090.0-847 Moisture Separator Reheaters - Entering the Third Decade
0090.0-848 Feedwater Heater and MSR Performance Monitoring
0090.0-850 Performance Simulation Pinpoints MSR Problem
0090.0-893 PMSR Reconstruction Challenges at KEPCO's 900-MW KORI Units
0098.5-821 Outage Maintenance & Inspections
0099.0-532 P2EP Survey 93-001, MSR Drains Pumped Forward (B&W Plants Only)
0099.0-537 P2EP Survey 93-006, Single Stage MSRs
0099.0-542 P2EP Survey 93-011, Reheater Tube Leaks
0099.0-551 P2EP Survey 93-020, MSR Impingement Baffles
0099.0-558 P2EP Survey 93-027, MSR Shell Drains
0099.0-563 P2EP Survey 94-002, MSR Reheat Valves
0099.0-567 P2EP Survey 94-006, MRES TAG Subgroup MSR Survey
0099.0-568 P2EP Survey 94-007, Moisture Separator Reheater Drain Tank Level Oscillations
0099.0-572 P2EP Survey 94-011, Moisture Separator Effectiveness/Testing
0099.0-590 P2EP Survey 95-011, Flow Loss in Moisture Separator Drain Tank Line
0099.0-591 P2EP Survey 95-012, Moisture Separator Reheater Drain Tank Orientation
0099.0-594 P2EP Survey 95-015, MSR Sourcebook Input
0099.0-596 P2EP Survey 95-017, Moisture Separator Reheater Steam Blanketing System
0099.0-600 P2EP Survey 96-003, MSR Performance
0101.0-209 Moisture Separator/Reheaters Performance Monitoring
0102.0-31 ASME Performance Test Code 12.4 on Moisture Separator Reheaters: An Update
0105.0-849 Some Data for Crossflow Pressure Drop in Tube Banks that Contain 3/4 inch (0.0191
m) Integral Low-Finned Tubes with 27 Fins per inch (1063 FINS/m)
0106.0-361 Moisture Separator/Reheater Corrective Maintenance Procedure for Duke Power
0106.0-756 Reheat and Moisture Separator Procedure, No. OP 3317, Rev. 11
0106.0-785 Callaway Plant Engineering Technical Procedure: ETP-AC-01101, Moisture
Separator/Reheater Performance Monitoring
0144.0-12 A Method To Monitor High-Pressure Turbine Efficiency and Moisture-Separator
Effectiveness In LWR Power Plants Without Tracer Techniques
software on the subject of MSRs. These are available to eligible EPRI members by
calling:
2-79

NP-3692 Procurement and Operations Considerations for MSRs
NP-5911M Acceptance Criteria for Structural Evaluation of Erosion-Corrosion Thinning in
Carbon Steel Piping.
TR-103833 Testing and Evaluation of a Moisture Separator Drain Demineralizer at Davis-Besse
Nuclear Station
TR-106345 MSR Source Book
Notes)
Non-EPRI References
Organizations and publishers other than EPRI have material pertaining to the subject of
MSRs. Some of this other reference information has been provided below to enable
the reader to obtain this material if appropriate.
American Society of Mechanical Engineers. Moisture Separator Reheaters. ASME

Performance Test Code 12.4-1992. May 24, 1993.
Predicting Corrosion Damage with the CHECWorks Software Package, Nuclear

Engineering International (December 1992).
A. L. Yarden and C. W. Tam, Excess Steam Flow Optimization in Operating MSRs,

presented at the EPRI Nuclear Plant Performance Improvement Seminar (August 1994).
A. L. Yarden and C. W. Tam, The MSR Evolution, Nuclear Engineering (December

1994).
A. L. Yarden, and M. W. Thomas, MSR Performance Improvement at Prairie Island

Nuclear Station, presented at the EPRI Nuclear Plant Performance Improvement
Seminar (May 1993).
B. Chexal, R. Jones, J. Lang, D. Munson, C. Wood, R. Wang, J. Horowitz, CHECWorks

Integrated Software for Corrosion Control, presented at the ANS/ASME Nuclear
Energy Conference (August 1992).
Tubular Exchanger Manufacturers Association, Inc. Standards of the Tubular Exchanger

Manufacturers Association, Seventh Edition. 1988.
2-80
Two Stage Moisture Separator Reheater, General Electric General Description, (Internal
Header, Vertical U-Bend Design), January 1982, Revision A. Report GEK-72221A.
The following documents contain additional information on moisture separator

reheaters.
Procurement and Operation Considerations for Moisture Separator Reheaters. Electric Power
Research Institute, Palo Alto, California: January 1982. Report NP-3682.
Moisture Separator Reheater Source Book. Electric Power Research Institute, Plant Support
Engineering, Charlotte, North Carolina: November 1997. Report TR-106345.
2.7 Reactor Power (Calorimetrics)
7KH FDORULPHWULFV UHIHU WR WKH F\FOH KHDW EDODQFH FDOFXODWLRQV WKDW DUH XVHG WR FRQWURO UHDFWRU
SRZHU 7\SLFDO WKHUPDO SRZHU FDOFXODWLRQV IRU D 3:5 ZLWK ORRSV $ DQG % DUH DV IROORZV
Primary Power = WRCS-A (HOUT-A - HIN-A) + WRCS-B (HOUT-B - HIN-B) + QPLVS + QPAMB
Secondary Power = WFW-A (HSTM-A - HFW-A) + WFW-B (HSTM-B - HFW-B) + QSAMB + QBLOWDOWN
Where
QPLVS = Net miscellaneous losses from letdown, makeup, seal

injection and coolant pumps
QPAMB & QSAMB = Primary and Secondary Ambient losses
WRCS-A = reactor coolant flow in loop A

HOUT-A = enthalpy of reactor coolant leaving reactor, loop A
HIN-A = enthalpy of reactor coolant entering the reactor, loop A
FFW-A = feedwater flow, loop A
HSTM-A = steam enthalpy, loop A
HFW-A = feedwater enthalpy, loop A
WRCS-B = reactor coolant flow in loop B
HOUT-B = enthalpy of reactor coolant leaving reactor, loop B
HIN-B = enthalpy of reactor coolant entering the reactor, loop B
FFW-B = feedwater flow, loop B
2-81
HSTM-B = steam enthalpy, loop B

HFW-B = feedwater enthalpy, loop B
The above calculation of primary power is the total main coolant or reactor system
power. To calculate the core thermal power, the reactor coolant pump and pressurizer
heat inputs would be subtracted.
The reactor power is controlled on secondary power. Uncertainties in secondary power

propagate to the reactor power control with a one-to-one ratio. Therefore, if the
secondary power is less than feed flow and temperature measurements say it is, the
reactor is operating at a lower power than indicated. Therefore, if feedwater flow reads
1% high, the plant thermal power is 1% low. This decrease in reactor power produces a
proportional decrease in MWe output. Uncertainty of the core power is limited by
technical specifications.
Table 2-15
Instrumentation for PWR Reactor Power
Parameter Purpose
Feedwater flow Secondary power

SG pressure Main steam enthalpy
SG exit temperature Main steam enthalpy
Feedwater flow Secondary power
Feedwater temperature Feedwater enthalpy
SG blowdown flow Power correction
SG blowdown temperature Blowdown enthalpy
A BWR is controlled by controlling reactor pressure with the turbine electro-hydraulic

control system (EHC) which positions the turbine throttle valves. The core thermal
power is calculated by a heat balance performed on the reactor. An alternate
computation of core thermal power is provided by the averaging power range monitors
(APRM). Calibration of the APRMs is kept updated by the core thermal power heat
balance.
The energy balance for the reactor (in consistent units) is:
Core Power = WSTM HSTM - WFWAHFWA - WFWBHFWB) + QRAD + QRWCU - QCP
WSTM = WFWA + WFWB + WCRD
Where
2-82
WSTM = steam (STM) flow rate

HSTM = steam enthalpy, steam quality assumed for calculation
WFWA, WFWB = mass flow of trains A and B feedwater (FW) pumps
HFWA, HFWB = enthalpy of trains A and B feedwater
QRAD = core power loss to radiation (RAD)
QRWCU = power loss due to reactor water cleanup (RWCU)
QCP = power added by circulating pumps (CP)
Table 2-16
Instrumentation for BWR Reactor Power
Parameter Purpose
Feedwater flow Reactor flow

Feedwater temperature Inlet enthalpy
Steam pressure Steam enthalpy
Recirc pump current Recirc pump power
CRD feedwater temperature CRD feedwater enthalpy
CRD flow CRD energy
RWCU temperature RWCU enthalpy
RWCU flow RWCU energy
A sample heat rate calculation may also be found in Volume 1, Table 2-2.
PWR secondary power calculation using the equations in Section 2.7.1 is shown below
as an example.
Input Data WFW = 7,212,360 lbm/hr

HSTM = 1244.5 Btu/lbm
HFW = 350.1 Btu/lbm
QSABM = 0
WBD = 35,000 lbm/hr
HBD = 540 Btu/lbm
Calculation Secondary Power =

WFW (HSTM - HFW) + QSABM + WBD (HBD - HFW)
[ [
= 6.457 x 109 Btu/hr
= 1,891 MW
2-83
The impact on thermal performance is due to errors introduced into the measurement
of feedwater flow. The venturis used to measure feedwater flow become fouled, which
produces an increased pressure drop across the venturi for a given flow velocity. The
indication is that the feedwater flow is constant when it is actually less. Reactor power
reduces to match the actual feedwater flow (calculated secondary power). Fouling of
feedwater flow venturis has been widely documented in the industry.
The cause of the fouling is not fully understood. The foulant is a buildup of magnetite
and copper. Causes for the buildup have been hypothesized and investigated. Certain
changes in plant operation may cause defouling. Defouling causes the feedwater flow
measurement to decrease and the reactor power to increase. Therefore, care in
compensating for fouling is necessary to preclude exceeding maximum core power
including uncertainties. Defouling has been observed following scrams, power
reductions, and possibly water chemistry changes (zinc addition).
Fouling is noticeable soon after startup if the venturis have been cleaned, and it
continues at a fairly constant rate. Fouling can affect the feed flow measurement by 2%
or more during a fuel cycle.
Ideally, there would be a way to prevent the buildup of foulant on the feedwater flow
venturis. However, the only way to correct for fouling at present is to compensate for
the scale buildup throughout the cycle. Several redundant measurements of feedwater
flow are available, and ratios such as condensate flow divided by feedwater flow can
be calibrated and trended to indicate degradation of the feed flow measurements.
Some plants have ASME PTC 6 flow sections with ASME nozzles installed. These can
be used to calibrate the final feedwater flow venturis at the beginning of a cycle. The
ASME nozzles may also foul during the cycle. Therefore, a method of providing
continuous compensation throughout the cycle is desired. Ultrasonic flow meters
(UFMs) are not subject to fouling and may be used throughout the cycle. However,
UFMs have other problems that must be accounted for. UFMs are sensitive to high
temperatures and to the method used to attach their transducers to the pipe. They can
be used to improve the accuracy of feedwater flow, but further improvements could be
obtained with a more accurate and reliable method of measuring flow.
The process used to account for venturi fouling varies in detail depending on the
existing equipment and the investment that a plant can justify for additional feedwater
flow measurement. The generic approach begins with a baseline calibration of the
beginning of a fuel cycle. The calibration basis can be a measurement with clean
2-84
venturis and/or calibration with clean ASME PTC 6 flow sections. As the cycle
progresses, various indicators of fouling can be tracked, which can provide a correction
factor for the feedwater flow.
Different approaches are applied to determining a correction factor. If a UFM is

installed and calibrated, it can be used to calculate the correction factor. However, the
UFM should be validated with calorimetrics and other measurable parameters.
It is possible to use a set of trended parameters as a diagnostic of feedwater flow. One

BWR utility baselines and trends the following data:
x Main steam line (MSL) flow (measured)

x Feedwater (FW) flow (measured)
x Condensate flow (measured)
x First stage main turbine pressure
x RMSL = MSL flow y FW flow
x R1st = First stage main turbine flow y FW flow
x Rcond = Condensate flow y FW flow
The three ratios will decrease as actual feedwater flow decreases, while indicated flow
remains constant. They should increase after one of the conditions that cause defouling.
If economically feasible, flanged ASME PTC 6 flow sections can be cleaned and used to
calibrate the flow meters during a cycle.
2.7.5 References
The following is a compilation of documents on the subject of Reactor Power or

Calorimetric. They are not necessarily referenced by the preceding text.
below are the documents from the P2EP Technical Library that relate to the subjects
Reactor Thermal Power or Calorimetric. These documents are available to eligible
2-85
EPRI members by calling the P2EP Administrator at 704/547-6024, or via the World
Wide Web at http://www.epriweb.com/npg/pse/ptp/index.html.
0003.5-172 Final Report, Peer Assessment of NSP's Prairie Island Thermal Performance
Program
0003.5-337 Final Report for the Peer Assessment of NSP's Monticello Thermal Performance
Program
0003.5-338 Final Report for the Peer Assessment of Union Electric's Callaway Plant Thermal
Performance Program
0009.0-609 Meeting Minutes for the 1995 BOPPMG Meeting, Albuquerque, NM
0011.0-454 Use of ASME Nozzles to Provide Feedwater Venturi Adjustment Factor
0012.0-612 Plant Perspective of Steam Flow Calorimetric Implementation
0012.0-730 Prairie Island Modification 95L510 - Plant Calorimetric Improvement Program
0020.3-863 A Mathematical Model for Assessing the Uncertainties of Instrumentation
Measurements for Power and Flow of PWR Reactors (NUREG/CR-3659)
0042.0-459 Venturi/Flow Calorimetric Panel Discussion Transcript
0051.0-125 Evaluation of Available Technology in Flow Measurements
0053.0-772 Correcting for Feedwater Nozzle Fouling at Diablo Canyon Nuclear Power Plant
0060.0-408 Surveillance of Calorimetric and Heat Rate Results (Waterford Unit 3). Procedure
No. NE-8-004. 10/12/87.
0070.0-773 Seabrook Station Feedwater Heater Digital Level Controllers
0090.0-23 Maintenance and Fuel with Ellison's Steam Calorimeter
0092.0-704 Recovered Lost MegaWatts from Feedwater Nozzle Calibration Project (One
Percent Core Thermal Power)
0099.0-540 P2EP Survey 93-009, Reactor T-hot Reduction
0099.0-550 P2EP Survey 93-019, Thermal Performance Models
0099.0-553 P2EP Survey 93-022, Feedwater Flow
0099.0-561 P2EP Survey 93-030, RCS Temperature Streaming
0099.0-574 P2EP Survey 94-013, Proposed P2EP Guideline on Operation at Licensed Power
0099.0-577 P2EP Survey 94-017, Inputs to Secondary Calorimetric
0099.0-579 P2EP Survey 94-019, Diagnosing Feedwater Flow Nozzle Degradation
0099.0-582 P2EP Survey 95-003, Maximizing Reactor Thermal Power
0099.0-582 P2EP Survey 95-003, Maximizing Reactor Thermal Power
0099.0-599 P2EP Survey 96-002, Accounting for Blowdown on Calorimetric Calculation
0099.0-794 P2EP Survey 96-010, Secondary Calorimetric Divergence
0099.0-858 P2EP Survey 97-002, Heat Rate Improvements vs. Power Uprates
0100.0-771 Attaining 99.5% Thermal Performance at Sequoyah Nuclear Plant
0110.0-281 Discussion of "Licensed Power Level"
0110.0-474 WPPSS Plant Efficiency and Reliability Monitoring Program: CRD Hydraulic
System Performance Monitoring, Procedure No. 8.4.48. Rev. 0, 1988
2-86
0110.0-615 Increasing MW Output in Units with Reduced Main Steam Pressure can be
Performed Without Efficiency Gains
0126.0-808 Causes of PWR Steam Generator Thermal Performance Degradation
software on the subject of Reactor Thermal Power or Calorimetric. These are
available to eligible EPRI members by calling:

CS-5486 Non-Radioactive Tracer for Steam Turbine Thermal Performance Tests
GS-7295 Demonstration of EPRI Heat Rate Improvement Guidelines
NP-3915, V-1 Guidelines for Nuclear Plant Performance Data Acquisition, Vol. 1, Data Item
Matrix Identification
TR-100514, Survey and Characterization of Feedwater Venturi Fouling at Nuclear Power Plants:
V-1 Vol. 1, Feedwater Venturi Fouling
TR-101256 Identifying Prospective Anti-Fouling Coatings for Venturis (Zeta Potential
Measurements of Oxides at Elevated Temperatures)
TR-101388 Feedwater Flow Measurement in US Nuclear Power Generation Stations
TR-101867 MegaWatt Improvement Casebook and Guidelines (Vol. 1)
Non-EPRI References
Some of this other reference information has been provided below to enable the reader
to obtain this material if appropriate.
Memorandum SSINS #0200 from E.L. Jordan, Assistant Director for Technical
Programs, Division of Reactor Operations Inspection, IE. Discussion of Licensed
Power Level, August 22, 1980.
Memorandum to Richard W. Cooper, Division of Reactor Projects - Region I, from

Phillip F. McKee, Director of Reactor Projects - I/II. Subject: Response to Region I
Request for Technical Assistance Regarding the Adequacy of the Oyster Creek
2-87
Methodology for Determining the Reportability of Plant Operation Above the Licensed
Core Thermal Power Limit (TAC No. M87769), July 5, 1995.
The following documents contain additional information on Reactor Power

(calorimetrics.)
John Helton, Southern California Edison Company, Effects of Electrical Isolation of the
Feedwater Venturi.
C. S. Sullivan, Duane Arnold Energy Center, Feedwater Flow Venturi Fouling Study.
T. A. Nelson and G. L. Starnes, PG&E Company, Correcting for Feedwater Nozzle

Fouling at Diablo Canyon Nuclear Power Plant.
2-88
3
CYCLE ISOLATION
Cycle isolation is minimization of steam and heated water flow paths that bypass all or
part of the turbine cycle. Cycle losses of high enthalpy steam to the condenser can be
large. In addition to reducing cycle losses, there are other benefits to a cycle isolation
monitoring program. In many cases of leaking valves or poor level control, a
maintenance problem can be identified and planning done for corrective action. There
are also indirect benefits from having the plant working as designed. Plant personnel
are motivated by success in having the plant perform at its best. INPO reports thermal
performance index (TPI) as an industry performance parameter and encourages plants
to meet industry goals.
Cycle isolation improvement programs typically involve the following:
x Steam trap testing
x Isolation valve testing
x Heat rate monitoring
x Control valve monitoring and maintenance
The major focus is on high enthalpy leaks to the condenser, for example, any valves
isolating main steam from the condenser. One of the first places cycle isolation
problems may show up is in unaccounted losses in heat rate. Heat rate measurements
should be made before and after valve leakage correction to observe if there is
improvement to validate the corrective action.
There are several actual and potential steam and heated water flow paths that bypass
all or part of the turbine cycle and result in increased heat rate. The flow paths can be
divided into two categories: (1) unavoidable flow paths necessary for operation of
components in the turbine cycle, but which should be minimized, and (2) avoidable
flow paths which should be eliminated.
3-1
Cycle Isolation
3.1 Unavoidable Flow Paths
The unavoidable flow paths include leakage through the inner and outer turbine
control valve stem packing, leakage across the turbine shaft seals, MSR scavenging
steam, and feedwater heater vent valve losses:
x Turbine Control Valve Stem Leakage. Turbine control valves usually have an
inner and an outer stem packing. Normal valve stem leakage is approximately 0.1%
of rated turbine inlet steam flow. Most of this is vented to a heater where it
contributes to feedwater heating. The valve outer packing leakage is usually
directed through the steam seal regulator to the condenser or the first stage
feedwater heater. Deterioration of the outer packing increases this leakage and
reduces the inner packing leakoff rate. In the limiting case, the effect on heat rate is
approximately the valve stem leakage flow divided by turbine throttle flow
discounted by the fact that most of the leakage contributes to feedwater heating. The
effect is estimated to be approximately a +0.1% increase in heat rate if valve stem
leakage doubles.
x Turbine Shaft Seal Leakage. Turbines are usually arranged as double flow having
two half-capacity elements with the inlet at the center and the steam expanding
toward both ends. As a result, only the low pressure ends require shaft seals. Shaft
seals usually consist of inner and outer labyrinth glands. The design shaft seal flow
is approximately 17,000 lb/hr, with approximately 70% of the inner packing leakage
vented to a feedwater heater and the remainder leaking across the outer seal and
vented to the condenser or a low pressure heater via the steam seal regulator (SSR).
In the limiting case, the effect on heat rate is approximately the shaft seal leakage
flow divided by turbine throttle flow discounted by the fact that most of the leakage
contributes to feedwater heating. The effect is estimated to be approximately a
+0.1% increase in heat rate if shaft seal leakage doubles.
x MSR Scavenging Steam. Many single- and two-stage MSRs are now provided with
the capability to continuously vent heating steam from the outlet of the MSR U-
tubes. In many cases, this provision was added as a field modification to prevent
harmful temperature oscillation of the condensate produced inside the U-tubes. The
amount of scavenging steam varies from 2-10% of heating steam flowing to the MSR
tube bundle. This steam is either vented back into the cycle steam flowing into the
MSRs or is vented to a stage of feedwater heating. One plant estimates that the
penalty for scavenging steam is 1.6 MWe or 0.14% increase in heat rate. This loss is
set by plant configuration and should not change appreciably during operation.
x Feedwater Heater Vent Valve Losses. Feedwater heaters have vent lines to the
condenser that are used to remove non-condensable gases. These vent lines are
usually small and may be continuously or intermittently opened during operation
to vent non-condensable gases to the condenser. These losses are essentially
3-2
Cycle Isolation
unavoidable. However, restricting orifices in the lines could be oversized or worn

from erosion resulting in excess vent flow.
Feedwater heaters are provided with larger vent lines and valves to remove non-
condensable gases during startup. Leakage through the vent line shutoff valves or
leakage if the valves are left open during operation can have an effect on heat rate
similar to dump valve leakage.
3.2 Avoidable Flow Paths
There are many potential paths for steam or heated water to dump directly to the
condenser, including leakage through the turbine bypass valves, MSR drain tank dump
valves, and heater dump valves. If any of these paths leaks, cycle isolation is not
completely effective.
x Turbine Bypass Valves. Turbine bypass valves are provided for plant startup and
shutdown. In some cases, 80-100% bypass is provided to prevent a scram when a
turbine trip occurs. Bypass valve leakage during normal operation is a total loss of
steam energy because the leakage flows directly to the condenser. The change in
heat rate is +1% for each 1% increase in bypass valve leakage expressed as a
percentage of initial turbine steam flow.
x Feedwater Heater Dump Valve Leakage. The impact of valve leakage depends on
the stage of feedwater heating where the leakage is occurring. The higher the
feedwater heater pressure and temperature, the greater the impact.
x Other Flow Paths. There are other flow paths that can affect cycle isolation and
heat rate. These include feedwater pump, main turbine drain valves, recirculation
valves, steam traps, and pipe low point drain valves.
3.3 Steam Traps
Steam traps are normally checked for leakage by walkdowns using thermal and
acoustic devices. Steam traps must open to vent non-condensable gasses. Therefore,
some flow is to be expected. A normal temperature profile from upstream of the trap to
downstream can be used as a baseline to detect changes. The simplest approach is to
use a touch thermometer. For difficult to reach traps, it may be cost effective to install
one or more thermocouples on the trap.
Acoustic testing of steam traps can be done with a mechanics stethoscope or ultrasonic
listening device. A steam trap is isolated for a few minutes for condensation to build up
upstream of the trap. If no flow is detected or if the flow does not stop shortly after the
trap is un-isolated, it can be scheduled for repair. Traps that cannot be isolated for
3-3
Cycle Isolation
repair can be rebuilt during each refueling outage to reduce the potential for failure
during the fuel cycle.
Several different steam trap designs are available, and it is not uncommon to encounter
misapplication of steam traps in a plant. If a steam trap is not installed properly, is the
wrong size, or is not the correct type for the application, unnecessary loss of steam is
likely. Some plant thermal performance engineers keep a collection of steam trap
catalogs against which they review problem check valves for proper application,
installation, adjustment, and maintenance.
3.4 Isolation Valves
A typical BWR might have 60 isolation valves included in the cycle isolation program.
One utility has divided their BWR isolation valves into three categories:
x Valves isolating main steam from the condenser
x All valves larger than 4 isolating pressure sources 100 psi to 1000 psi
x All other cycle isolation valves
A cost-benefit analysis indicated the first two categories to be worth instrumenting.

Thermocouples were installed downstream of the valves during an outage. The
thermocouple wire was run outside the condenser to a connection board where
temperatures can be read using a thermocouple reader.
Isolation valves to be tested can be any of the following:
x Steam dump valves
x Level control dump valves
x Relief valves
x Startup vents
x Recirculation valves
x Bypass valves
Some valves can be visually inspected if they have visible leakage paths such as weep
holes or drains to the atmosphere. In general, the process is to measure upstream and
downstream temperature. Figure 3-1 demonstrates the effect of leaks on the
temperature profile upstream and downstream of a valve. Downstream temperature
3-4
Cycle Isolation
may be lower than saturation if condensate builds up behind the valve and can be
subcooled by conduction through or along the pipe. The temperature profiles may be
different than shown in Figure 3-1 due to flashing just downstream of the valve and
condensation at some point beyond.
Figure 3-1
Cycle Isolation Valve Leakage Effects
3.5 Air-operated Valves (AOVs)
AOVs are used for level and flow control. Many are in potential cycle isolation leakage
paths. AOVs can leak or pass more steam than necessary from any of the following
causes:
x Valve seat leakage
x Bad adjustment of a control system
x Mechanical failure
x Steam erosion
3-5
Cycle Isolation
x Bypassing
x Valve design misapplication
Problems with control valves can be identified by several methods. The temperature
profile can be obtained with a pyrometer. Measurement and trending of downstream
pressure can sometimes reveal a problem with control. Monitoring stem position to
observe a flow trend can show valve degradation or isolation leakage. For valves in
parallel, average stem position is an important parameter because the total flow is
proportional to the average. Isolation of a valve can be used to detect problems.
When leakage is suspected in control valves, the following maintenance or replacement

may be required:
x Calibration of positioners
x Spring replacement
x Travel adjustment
x Replacement or tightening of packing
x Adjustment or tightening of stem connections
x Adjustment of air supply pressure
x Replacement of eroded seats
x Replacement of bent stems
x Replacement of leaking diaphragms
Testing should be repeated before and after valve repairs.
3.6 Instrumentation
Instrumentation for monitoring and controlling cycle isolation falls into the following
categories:
x RTDs and thermocouples installed for continuous monitoring of valves
x Pyrometers for thermography
x Stethoscopes for acoustic monitoring
3-6
Cycle Isolation
x AOV diagnostic
x Periodic inspection (orifices)
The applications of these devices have been discussed above. However, some
additional discussion is provided in the following paragraphs.
Infrared thermography produces a temperature picture of a valve, piping, or other

cycle component. The best application of thermography is using its ability to make
comparisons. It can be used to pinpoint a problem that shows up in a heat balance. For
routine cycle isolation checks, a touch pyrometer or installed sensor is adequate.
Thermography may be cost beneficial for its ability to communicate pictorially a cycle
isolation problem.
Acoustic monitoring can be used to assess relative magnitudes of leakage flow through
valves. Its use before and after valve overhauls can enhance cost-effective maintenance.
In some cases, costly repairs can be avoided. The flow turbulence downstream of the
seat is detected to frequencies in the 200 kHz range. One such system determines a
measure of leakage by subtracting the measured valve background noise level from the
measured leakage noise pattern. It may also be used to differentiate between acoustic
signatures from two probes at different locations upstream and downstream of a valve.
An increase downstream indicates leakage. The effectiveness of determining leakage
versus isolation is dependent on proper location of the probe and the analysis of the
acoustic signature patterns versus frequency.
Another device measures valve stem travel and actuator air pressure to identify
actuator operating characteristics. The signals are downloaded to a floppy disk for
analysis. From these measurements, the device can diagnose most of the control valve
adjustments. Using these results allows the control valves to be adjusted to maintain
design conditions for the valve. Proper adjustment increases valve life and reduces
cycle losses.
3.7 Loss Quantification
Quantifying losses from faulty cycle isolation depends on the parameters that can be
measured or calculated. For example, the leak rate past a valve or steam trap may be
difficult to determine. Leaks of high enthalpy steam to the condenser have the largest
effect on heat rate. The effect on heat rate becomes less as the enthalpy decreases or the
leak is to a location in the cycle where some of the energy is recovered.
3-7
Cycle Isolation
Cotton provides the following tables for leakage to the condenser.
Table 3-1
Effect of 1% Leakage to the Condenser on Heat Rate
Origin of 1% Leakage Fossil Nuclear Nuclear Reheat

Flow Reheat Non-Reheat
Throttle 0.83% 0.91-1.09% 0.81-0.96%

HP TB exhaust 0.53% 0.56% 0.56%
Ahead of intercept valve 0.69% 0.56% 0.60%
X-over 0.44% 0.56% 0.60%
Table 3-2
Effect of 1% Leakage to the Condenser on the Load
Origin of 1% Leakage Fossil Nuclear Nuclear

Flow Reheat Non-Reheat Reheat
Throttle 0.94% 0.91-1.09% 0.81-0.96%

HP TB Exhaust 0.69% 0.56% 0.56%
Ahead of intercept valve 0.69% 0.56% 0.60%
X-over 0.44% 0.56% 0.60%
3.8 References
Bailey, K. C. Cotton, and R. C. Spencer, Predicting the Performance of Large Steam

Turbine-Generators Operating with Saturated and Low Superheat Steam Conditions,
GER 2454A, presented at the 29th Annual Meeting of the American Power Conference,
Chicago, Illinois (April 1967).
Trojan Thermal Performance Program. PSEP 30-1.
K. C. Cotton. Evaluating and Improving Steam Turbine Performance. Cotton Fact, Inc.,
Rexford, New York 1993.
The following is an additional compilation of documents on the subject of Cycle

Isolation. They are not necessarily referenced by the preceding text.
The Plant Performance Enhancement Program (P2EP) has a technical library as an

effective way to share information on plant thermal performance. The list below is
from the P2EP Technical Library, specifically those documents with the keywords of
3-8
Cycle Isolation
Cycle Isolation. These are available to eligible EPRI members by calling the P 2EP
Administrator at 704/547-6024, or via the World Wide Web at
0003.5-172 Final Report, Peer Assessment of NSP's Prairie Island Thermal Performance
Program
0003.5-299 Final Report for the Peer Assessment of TU Electric's Comanche Peak Thermal
Performance Program
0003.5-337 Final Report for the Peer Assessment of NSP's Monticello Thermal Performance
Program
0003.5-338 Final Report for the Peer Assessment of Union Electric's Callaway Plant Thermal
Performance Program
0030.0-721 Oyster Creek's Cycle Isolation Program
0030.0-776 Indian Point 2 Cycle Isolation Monitoring
0030.0-777 Cycle Isolation Techniques
0030.0-879 Waterford 3 Technical Procedure NE-008-012, Rev. 1, Turbine Cycle Isolation
0030.0-906 The Other Side of Turbine Cycle Isolation - Continuous Flow Orifices
0060.0-128 Heat Rate Recovery by Cycle Isolation and Control Diagnosis and Correction
0060.0-174 Heat-Rate Demonstration Project, Salem Harbor Station Unit 4, EPRI Report GS-
7329
0099.0-570 P2EP Survey 94-009, Estimating Loss Through Steam Dumps
0102.0-349 PTC 6S Report-1988: Procedures for Routine Performance Tests of Steam Turbines
0106.0-737 Point Beach Thermal Performance Procedure TP 5.0, Rev. 0, Cycle Isolation
0131.4-468 Waterford Unit 3 Technical Procedure: Steam Trap Leakage, Procedure No. NE-008-
010, Rev. 1
0138.0-192 Infrared Thermography As A Thermal Performance Tool: Myth Or Magic?
software on the subjects of Cycle Isolation. These are available to eligible EPRI
members by calling:

CS-1554 Biofilm Development and Destruction
CS-4410 Demonstration of an Alternative ASME Steam Turbine Generator Acceptance Test
3-9
Cycle Isolation
CS-4545-SR Proceedings: 1984 Power Plant Performance Monitoring Workshop

GS-6635 Proceedings: 1988 EPRI Heat-Rate Improvement Conference
IN-106658 Innovator, Using CHECWORKS to Enhance Valve Seat Leakage Monitoring
Programs
TR-101867 MegaWatt Improvement Casebook and Guidelines (Vol. 1)
TR-105416 Qualified Life of Main Steam Isolation Valves
3-10
4
DATA VALIDATION
4.1 Introduction
The foundation of thermal performance monitoring is data. Each performance

parameter for each system in the plant thermal cycle has data requirements that must
be satisfied if valid system performance is to be measured. Data requirements include
the following:
x Proper parameters for the performance measurement
x Required accuracy
x Sampling frequency
Measuring the proper parameter includes the measurement location as well as the
requirement for the measurement in the performance calculation. Developing accuracy
requirements includes uncertainty based on the sensitivity of the performance
calculations to errors in the parameter being measured. Sampling frequency
requirements are based on the rate at which thermal performance is expected to
undergo a significant change.
4.2 Data Requirements
The cost of obtaining measurements and tracking a measurement must be compared to

the potential benefit for performance improvement. The data needed to calculate a
parameter that has a significant effect on performance have a high monetary value.
However, data are not very useful if the uncertainty of measurement is greater than
accuracy required to indicate a performance change.
The uncertainty of a data point is usually stated as a range and a probability. One
component of the range of uncertainty is the precision that includes repeatability and
resolution, and the second part of the accuracy range is measurement bias. Bias is a
constant error that can be accounted for by calibration. Both precision and bias must be
accounted for in accuracy. For example, main steam pressure might be given as
1000 psia r10 psia (P=.95). This example means that considering both precision and
4-1
Data Validation
bias, 95% of the pressure measurements would be expected to fall with r10 psia of the
actual pressure. The percent accuracy of a measurement is dependent on the input
value. In this case, at 1000 psia the accuracy is r1%. In general, one must be careful that
the measurement accuracy is suitable for the value of the input parameter.
Calibration of a measurement device is done to reduce measurement bias.

Measurement calibration is done to a known value or standard. The accuracy of the
standard must be greater than the accuracy of the measurement device being
calibrated.
A general figure of merit for plant performance is a 1% deviation in the measured heat
rate. Table 4-1 gives the approximate change in heat rate for a given deviation of a
measured parameter value in the cycle. This table does not account for the effect of
deviations of more than one parameter.
Table 4-1
Effect of Instrument Accuracy
Parameter Estimated Change in

Heat Rate
Exhaust pressure 1.25-2% per inch Hg

Main condensate flow 1% per % flow
Power 1% per % power
Throttle flow 1% per % flow
Extraction line 'P 0.66% per % 'P
Miscellaneous 0.15%
o
Final feed temperature 0.12% per F
Hot reheat pressure 0.08% per % psi
o
Throttle temperature 0.07-0.12% per F
Cold reheat pressure 0.08-0.05% per % psi
Turbine extraction pressure 0.05% per psi
o
Cold reheat temperature 0.04% per F
Throttle pressure 0.084-0.02% per % psi
o
Hot reheat temperature 0.05-0.13% per F
Feedwater pump enthalpy rise 0.006% per % enthalpy rise
o
Increase in feedwater heater temperature 0.006% per F
o
Increase in heater approach temperature 0.0008% per F
Increase in feedwater pump seal flow 0.0007% per % seal flow
Table 4-2 demonstrates the combined uncertainties in an ASME PTC 6 alternative test.
Group 1 correction calculations are defined in ASME PTC 6 for six parameters.
4-2
Data Validation
Table 4-2
Alternative Test Uncertainty
Nuclear Feedwater Primary Flow Measurement
Parameter Effect of Measurement Uncertainty HR2

Errors on Uncertainty HR
Heat Rate
Temperatures
Feedwater flow 0.12% per qF 1qF 0.12 0.0144
Throttle quality 1% per 1% 0.1% 0.1 0.0100
Flows
Primary 1% per 1% 0.15% 0.15 0.0225
Feed pump turbine 0.02% 2% 0.04 0.0016
LP exhaust pressure *0.2%/in. Hg 0.1 in. Hg 0.02 0.0004
Power 1% per 1% 0.1% 0.1 0.0100
Isolation 1% per 1% 0.05 0.05 0.0025
Group 1 corrections 1% per 1% 0.1% 0.1 0.0100
6 H.R. 2
0.0714
OVERALL TEST
UNCERTAINTY 6HR2 0.27%
*NOTE: Based on the ASME PTC 6 permissible LP exhaust pressure deviation from design of
0.05 psi or 2.5% of absolute pressure, whichever is larger.
In Table 4-2, the total test uncertainty has been propagated using the square root of the
sum of the squares of the individual uncertainties. For the objectives of a typical
thermal performance program, a PTC 6 test with an overall test uncertainty of r0.27%
(P=.95) is probably not cost effective. However, an overall heat rate uncertainty goal in
the range of 1% is achievable with the instrumentation installed in most plants. ASME
PTC 19-1 contains a detailed discussion of measurement uncertainty.
The final major data requirement of concern to the thermal performance engineer is
sampling frequency. Sampling frequency depends on the trend being measured as part
of the thermal performance program. Other requirements for the data at the plant may
dictate a higher sampling frequency. Volume I, Section 3.4.4 shows some trending
examples that demonstrate the value of, and an approach for, selecting an effective
sampling frequency.
4.3 Validation
The first step in data validation is to detect gross instrument or sensor failures. Criteria
for identifying these failures are out-of-range indications, large inconsistencies with
4-3
Data Validation
other system parameters, and excessive rates of change in measured values for the
processes involved.
Analytical redundancy calculations can be performed using data that have survived the
initial check of the above criteria. This technique is often referred to as reconciliation.
These calculations can be done using basic mass and energy balance equations. A
computer-generated heat balance model or a dynamic simulation can also be used.
Data filtering techniques are also available that can smooth data and fill in data missing
from a faulty source. The choice of the data validation method used should be based on
the characteristics of the parameter, the number of data samples, and the characteristics
of the instrumentation.
Analytical redundancy does not provide new information, but takes advantage of
existing data. For example, feedwater mass flow rate equals condensate pump mass
flow rate plus heater drain mass flow rates not returned to the condenser hot well.
Therefore, indication of a change in one of these flows would be expected to show up
as a change in one of the others.
Limit checking can detect gross failures in a single instrument channel. If the signal is
either outside the measurement span of the instrument or outside the expected limits of
the signal, a gross failure is indicated.
A like-sensor comparison can also be used to detect gross failure of a sensor. If three
sensors are measuring the same parameter and more than half of the measurements fall
within the expected band, a sensor with a large deviation from the other two can be
assumed to be failed.
Instrument loop integrity checking tests the entire instrument circuit. The specific items
checked depend on the loop design. Loop resistance and insulation resistance are
commonly checked. Digital I&C systems are able to check for failures continuously and
reboot, shift to an alternate processor, or reload software automatically.
Calibration is part of signal validation. Calibration can be performed manually or

automatically if the instrumentation loop is digital. Calibration is the comparison of a
measurement to a standard and removes measurement bias from the data. The bias is
usually due to instrument loop drift. Digital systems are typically drift free except for
sensor drift. However, safety-related loops are calibrated periodically per the technical
specifications.
Statistical methods can be applied to test a few data points that lie outside the expected
range. These data may be due to a few faulty readings which, for example, are not
uncommon for thermocouples.
4-4
Data Validation
One statistical method, Chauvenets Criterion, specifies that a reading may be rejected
if the probability of obtaining the deviation of that sample from the mean is 1/2n,
where n is the number of samples. Table 4-3 can be used to test a sample for rejection.
Table 4-3
Chauvenets Criterion for Rejecting a Reading
Number of Ratio of Maximum Acceptable Deviation to

Readings Sample Standard Deviation
n S
10 1.96
15 2.13
25 2.33
50 2.57
100 2.81
300 3.14
500 3.29
1000 3.48
The standard deviation is calculated by:

([ [ )
Q
6=
Q = L
L
Where [ is the mean of the samples,
[ L
[= L =
An example application of Chauvenets Criteria is provided by Figure 4-1.
4-5
Data Validation
Sample Number Sample Reading Deviation from Ratio of Rejected

the Mean Standard Samples Based
Deviation to on Maximum of
Deviation r1.96 n=10
1.00 988 -1.70 -0.22

2.00 987 -2.70 -0.34
3.00 987 -2.70 -0.34
4.00 990 0.30 0.04
5.00 995 5.30 0.67
6.00 997 7.30 0.93
7.00 993 3.30 0.42
8.00 996 6.30 0.80
9.00 970 -19.70 -2.51 Rejected
10.00 994 4.30 0.55
Mean 989.70
Standard 7.86
Deviation
Figure 4-1
Example Application of Chauvenets Criteria
Chauvenets Criteria may be used for manually recorded data or programmed into
digitally obtained data. Combustion Engineering (CE) Qualified Safety Parameter
4-6
Data Validation
Display Systems use this technique [1]. Other data validation schemes are being
applied to digital instrumentation, control, and monitoring systems. The thermal
performance engineer should be aware that data from these systems may have been
filtered to remove potentially false data.
4.4 Practical Applications
Perhaps the most important use of data validation is to determine if observed problems
are real or are the effect of drifting or inaccurate instrumentation. As discussed above,
this type of validation is performed by comparing redundant instrumentation (either
installed or temporary), trending of calculated parameters, comparing the current
indication with expected effects on other parameters, or using a heat balance program
to validate the instrument readings observed in the plant. Some practical data
validation examples are provided in the following subsections.
4.4.1 Main Steam Pressure
Main steam pressure indication is very important to all power plants. Due to the
importance of this parameter, there are usually several instruments measuring this
parameter. For our example, lets assume there are 3 pressure indications on each of 4
main steam lines for a total of 12 pressure indications. Let us also assume the accuracy
of these instruments is 2% of full span (instruments range 0-1500 psig) with normal
operating pressures of 1000 psig. One could use the example in Figure 4-1 to provide a
statistical review of the data. An alternative trending method is to track the difference
between the average of the 12 pressure indications and each individual pressure
indication. For a 1000 psig normal reading it has been observed by one plant engineer
that this difference should track within 3 psi, which is much better than the 2%
accuracy of the instrument which would be 30 psi. For example, if one pressure
transmitter is indicating 1003 psig and the average of the 12 instruments is 998 psig, the
trended parameter should be -5 (998 psig - 1003 psig) and should remain between -2
and -8 (-5 -3 = -8, -5 + 3 = -2). This trending is easier than computing the standard
deviation of a group of instruments and remains consistent over a wide range of
pressure readings.
4.4.2 Feedwater Flow Rate
Most plants have precision flow measurement devices installed to accurately determine
cycle heat input. In addition to these precision instruments there are usually other flow
measurement devices used to determine the performance of individual pumps, for
example condensate heater drain and main feedwater pumps. Although these
instruments do not have the accuracy of the precision instruments, they generally trend
consistently. A good group to trend would be the sum of condensate flows, the sum of
4-7
Data Validation
heater drain flows, the sum of feedwater pump flows, the sum of condensate flows plus
heater drain flows, and the total feedwater flow as measured with the precision
instruments. An additional parameter to monitor would be the difference between total
feedwater flow and the sum of condensate and heater drain flows. By trending this
difference, flow changes will be easier to spot. With a total flow indication of about
15,000,000 lbs/hr, it has been observed that this difference should track within 40,000
lbs/hr. By trending total condensate flows and heater drain flows, one can detect a shift
in mass flow from the high pressure portion of the plant to the low pressure portion of
the plant (heater drain flow will decrease and condensate flow will increase by the
same amount if a high pressure heater emergency drain opens). If there is a change in
either condensate or heater drain flow without a change in total feedwater flow, then
look for an invalid indication of flow rate or the possibility of a feedwater heater tube
leak or other ways of short circuiting flow. A drifting transmitter could be identified by
swapping pumps. If the apparent bad pump is not shut down, the total flow rate will
not change. If the pump that is shut down is bad, the total flow rate will change. If
there is an actual change in total feedwater flow rate, either condensate flow, heater
drain flow, or both will need to increase.
4.4.3 Calculated or Measured Heater Drain Flow
When instrumentation allows, a calculated heater drain flow should be compared with
heater drain pump flows (what comes in must go out). This calculated flow could be
determined from a heat balance on a drain cooler just up stream of the heater drain
tank, from heat balances from upstream feedwater heaters, or estimated from heater
drain control valve position and differential pressure.
4.4.4 Final Feedwater Temperature
A consistency check between final feedwater temperature and last stage feedwater
heater outlet temperature can be useful. This check could be performed locally if
necessary. Because this is the same water, less than 1qF deviation should be expected if
the measurements are valid.
4.4.5 Condenser Performance
Because the main condenser is saturated, there should be a good correlation between its
pressure and temperature. Compare calculated temperatures from pressure with
measured temperatures or hotwell temperature where applicable. This may be difficult
in some instances due to inaccurate condenser pressure readings. The presence of non-
condensable gasses will also affect the saturation temperature comparison.
4-8
Data Validation
4.4.6 Feedwater Heater Performance
Redundant instrumentation checks, whether temporary or installed, can be used to

validate data. If a feedwater heater outlet temperature decreases by 3qF, the heater
drain temperature from the next higher pressure heater should also decrease (this is
assuming the higher pressure heater has an integral drain cooling section). If there is no
drain cooling section, the colder water entering the higher pressure heater affects the
performance of the drain cooling section, thus reducing the drain outlet temperature.
One TPE looks for the heater drain temperature of the higher pressure heater to
decrease about 2qF if the heater outlet temperature decreases by 3qF. If this does not
happen, the decrease in heater temperature could be a false indication.
4.4.7 Comparison with Heat Balance Program
Heat balance computer programs can help validate data when redundant
instrumentation is not available. One example of this was when a plant observed a
sudden decrease in extraction pressure from a low pressure feedwater heater along
with a decrease in generator output. The heat balance program was used to simulate a
failed extraction bellows inside the main condenser. The analysis indicated that the loss
of mass from the extraction line required to decrease feedwater heater pressure would
also decrease generator output by the amount observed. In another instance, there was
a brief plant transient (total of 5 minutes) that resulted in changing feedwater heater
inlet temperatures. In this case, there was no chance of validating in-plant data with
local readings. The heat balance program was used to simulate a failing open of one of
two heater drain pump flow control valves. This analysis mimicked the actual data
from the plant instruments and validated the observed event.
4.5 References
1. Guidelines for Nuclear Plant Performance Data Acquisition, Volume 2: Data Item
Requirements. Electric Power Research Institute, Palo Alto, California: October 1985.
Report NP-3915.
2. American Society of Mechanical Engineers. Steam Turbines. ASME Performance

Test Code 6-1996.
3. K. C. Cotton. Evaluating and Improving Steam Turbine Performance. Cotton Fact, Inc.,
Rexford, New York, 1993.
4. American Society of Mechanical Engineers. Measurement Uncertainty. ASME

Performance Test Code 19.1-1985.
4-9
5
MOISTURE MEASUREMENTS
A large part of the steam path in typical nuclear steam cycles is in the moisture region.
Moisture makes it impossible to directly measure enthalpy in the HP and LP exhaust,
turbine extraction lines, and the moisture separators. Also, moisture affects turbine
efficiency and the effectiveness of MSR reheat.
Determination of steam quality and enthalpy is possible using several techniques:
x Radioactive-tracer technique
x Heater-drain-flow measurement and heat balance
x Throttling calorimeter methods
The first two methods and some of their limitations are discussed in ASME PTC 6. The
third method is discussed in PTC 19.11. None of the methods are considered on-line
and suitable for routine monitoring. They are in the nature of special measurements
suitable for a PTC 6 acceptance test. Moisture measurement is not required for a PTC
6.1 test and should not be used for diagnostic component testing unless justified.
Tracer and throttling calorimeter methods are applicable to measurement of carryover

from both steam generators and moisture separators. The samples should be taken
from locations near the point of interest. Locations such as elbows should be avoided
because elbows tend to introduce swirl and separation of the moisture to the outside of
the pipe. On the other hand, moisture tends to flow closer to pipe walls and the bottom
of long pipe runs. Steam samples should be taken in accordance with ASTM D 1066 or
as described in ASME PTC 19.11-1970:
Throttling calorimeters operate on the principle that the initial and final enthalpies are
equal when steam passes through an orifice from a higher to a lower pressure,
providing there is no heat loss and the initial and final kinetic energies are negligible.
Throttling calorimeters have a limited range of use which varies with pressure (see
ASME PTC 19.11).
5-1
Moisture Measurements
5.1 Main Steam Line Moisture Carryover
Table 2-1 of Volume I of this handbook shows that a 0.1% increase in main steam line or
HP turbine inlet moisture content increases heat rate by about 0.03%. On the other
hand, the design moisture content for most nuclear power plants is approximately
0.2%. A 50% increase in main steam line moisture or +0.1% moisture increases heat rate
by approximately 0.03% and can decrease plant output 0.3 MWe on a 1000 MWe plant.
The changes described are the actual effects. A 0.1% error or uncertainty in the
measurement of main steam line moisture can have a two to three times higher effect
on calculated HR and plant output.
A change in the magnitude described above is not normally expected unless there have
been significant modifications to the PWR steam generator or BWR reactor vessel
dryers or visual inspections reveal substantial degradation of the dryer equipment. As
a result, main steam line moisture measurement is not done frequently. In the event
that main steam line moisture needs to be measured, then the tracer method is the only
practical approach to the problem. This method is described in Paragraphs 4.5.3 and
4.6.5 of ASME PTC 12.4-1992.
5.2 MS/MSR Outlet
Moisture carryover in the cycle steam leaving an MS can reduce mechanical efficiency
in the LP turbine; in an MSR, it can reduce reheat temperature and increase heating
steam consumption since the moisture is evaporated using some of the heat transfer
surface of the reheater tube bundle provided to superheat dry steam. Measurement of
moisture separation effectiveness can be used to determine if the moisture separator is
not meeting design expectations or if the major cause of off-performance is associated
with the reheater. At this time, there is no simple, inexpensive method to measure
steam quality as cycle steam exits the moisture separators. Several methods discussed
in PTC 12.4 are outlined below along with their limitations:
x Reheater Energy Balance Method This method uses an energy balance conducted
around each reheater stage to determine the specific enthalpy (moisture content) of
the cycle steam entering each reheater stage. This method requires that all flows
entering or exiting each reheater stage, as well as interstage temperature (enthalpy)
in a two-stage MSR, be accounted for and used in the determination of specific
enthalpy (moisture) leaving the moisture separator and entering the reheaters. This
method is not applicable to units that have only MSs. Furthermore, most MSRs are
Moisture separation effectiveness is defined in PTC 12.4 as the ratio of the mass flow rate of moisture
removed from the entering cycle steam to the mass flow rate of moisture entering the separator. A
moisture separation effectiveness of 100% means total removal of moisture from the incoming steam.
5-2
not provided with the extensive amount of instrumentation required by this

method. Most of the instrumentation required for the energy balance method is
needed for a full MSR test described in PTC 12.4.
x Throttling Calorimeter Method This method uses throttling calorimeters and

steam sample probes installed at the outlet of the moisture separators to obtain
representative samples. The probes need to be designed so they do not
preferentially sample either steam or moisture, but sample in proportion to the
steam and water content of the cycle steam exiting the moisture separator. Also,
there needs to be sufficient sample points to account for variations in exit quality
over the large exit area of the moisture separator. In addition to PTC 12.4, see PTC
19.1 for guidance on this method.
x Differential Tracer Method This method uses a two-step process. The first step
uses the tracer method to measure the moisture separator shell drain flow by
injecting a tracer into the shell drain flow downstream of the drain tank and
sampling the drain flow further downstream after thorough mixing takes place. The
second step moves the tracer injection point to a point in the cycle steam upstream
of the moisture separator. The moisture carryover is then calculated by accounting
for differences between drain flow tracer concentrations and tracer injection rates
observed during the two steps.
x Shell Drain Flow Method This method is applicable if there is flow measurement
of moisture separator shell drain flow. This method does not rely on measured cycle
steam flow and moisture content. Rather, it uses the turbine vendors thermal kit
data for information describing moisture in the cycle steam leaving the HP turbine
and entering the moisture separator. As a result, the calculated moisture carryover
is only as accurate as measured drain flow and how well the thermal kit represents
actual cycle steam conditions when the method is being used.
All four methods are discussed in Sections 4.5 and 5.4 of PTC 12.4. The differential
tracer method is the most accurate method. This method and the calorimeter method,
however, should be considered special tests that are not practical for continuous use.
On the other hand, energy balance and drain flow methods can be used for continuous
monitoring but are inherently inaccurate due to the amount of data required and
assumptions concerning the applicability of the thermal kit data. They can be used for
trending where accuracy is less important.
5.3 LP Turbine
Steam enters the LP turbine in nearly a dry state or slightly superheated if the steam
cycle includes an MSR. The moisture content of the steam increases as it expands in the
LP turbine, leaving the last stage with approximately 12-16% moisture. Because
5-3
moisture in the LP turbine reduces mechanical efficiency and causes erosion-corrosion

type damage, it would be desirable to measure the amount of moisture in the various
stages of the LP turbine.
Routine measurement of LP turbine moisture content is not currently practical or

economic. In general, the moisture content in the steam can be reasonably predicted at
each stage of expansion through the turbine by assuming an isentropic expansion
process and using the vendor-predicted stage mechanical efficiencies (usually on the
order of 80%). However, the local distribution of the moisture in each stage remains
uncertain and somewhat academic unless modifications to the turbine to improve
mechanical efficiency and repair or replace moisture damaged components are at issue.
This is discussed further in Section 2.5, Steam Turbine.
5.4 References
1. American Society for Mechanical Engineers. Steam Turbines. ASME Performance

Test Code 6.
2. American Society for Mechanical Engineers. Water and Steam in the Power Cycle
(Purity and Quality, Leak Detection and Measurement. ASME Performance Test
Code 19.11-1970.
3. American Society for Mechanical Engineers. Moisture Separator Reheaters. ASME

Performance Test Code 12.4-1992.
5-4
6
MEGAWATT ENHANCEMENTS
The objective of a thermal performance program is to maintain excellent thermal

performance and improve thermal performance when it is cost effective to do so.
To be effective in meeting this objective, a structured heat rate performance

improvement program is needed. The basic process, depicted in Figure 6-1, includes:
x An evaluation process to determine current performance, estimate achievable

performance, and establish performance goals based on cost benefit analyses.
x A process to implement the cost effective, corrective, and preventive options.

Operations, Maintenance and Engineering are all involved in good thermal
performance.
x A tracking and reporting system to inform management and to obtain support and
resources. Keeping everyone informed about thermal performance is important to
the bottom line.
x An effective method to obtain and maximize use of existing technology and to

promote R&D projects that fill technology needs.
x Methods to receive from and feed back to industry thermal performance

information and technology research and development needs. EPRI has established
P2EP to interface directly with utility performance engineers (designated as P 2EP
coordinators) expressly for this purpose.
6-1
Megawatt Enhancements
Figure 6-1
MWe and Heat Rate Improvement Process
6.1 Improved Feedwater Flow Instrumentation
In operation of nuclear power plants, it is essential that the total power in the reactor
core be determined accurately in order to control plant output. Inaccurate core thermal
power calculations may result in sacrificing valuable power generation capability [1].
6-2
In all nuclear power plants, a calculation is performed by the plant process computer
(PPC) to determine the mass and energy balance across the reactor core. For a boiling
water reactor (BWR), the mass and energy balance is
core
= Qst + Qcu + Qrd - Qfw - Qp - Qcd
Where
Qst = heat loss, primary steam flow

Primary steam flow = (mass flowrate, feedwater) + (mass flowrate, reactor
water cleanup)
Qcu = heat loss, reactor water cleanup
Qrd = radiative heat loss
Qfw = heat gain, feedwater
Qp = heat gain, recirculating pumps
Qcd = heat gain, control rod drive
For a Pressurized Water Reactor (PWR), which generally uses a steam generator mass
and energy balance (secondary calorimetric) to calculate the mass and energy balance
across the reactor core, the mass and energy balance is
core
= Qst + Qbd + Qlo - Qfw
Where
Qst = heat loss, steam generator steam flow

Steam generator steam flow = (mass flowrate, feedwater) - (mass flowrate,
blowdown)
Qbd = heat loss, steam generator blowdown
Qlo = other system heat losses
Qfw = heat gain, feedwater
As noted in both equations, accurately measuring feedwater flow is extremely

important to accurately measuring the reactor core power. Feedwater flow rates are
generally measured using differential pressure devices with a venturi or flow nozzle
installed in the feedwater pipe. Plant experience has shown that these flow devices
have fouled at some plants over time increasing the measured pressure drop across the
device. This produces erroneously high flow rate indications, which result in
erroneously high reactor power calculations and unwarranted plant power derating.
nwarranted plant deratings of 1-3% have been experienced by many nuclear plants due
to feedwater venturi or nozzle fouling.
It should be noted that a reduction in power output in a typical 800 MWe nuclear plant
reduces the revenues from that plant considerably. As an example, Palisades Nuclear
6-3
Plant (811 MWe gross) in western Michigan has determined that fouling of their
feedwater venturis has caused the plant to derate 2.2% as determined through
measurements using an ultrasonic flow meter. With a cost of producing power at
$0.025/kWh and the residential utility rate of $0.09/kWh, Consumer Energy can realize
an increase in revenue of $27,800/day or approximately $9 million/year (assuming
90% capacity factor). Since the incremental cost of producing the additional 2.2% power
is almost negligible, the Palisades cost center should benefit by approximately $3.5
million/year from this performance improvement [Section 6.1.5, Ref. 26].
6.1.1 Causes of Fouling
Fouling of feedwater venturis and nozzles is caused by deposits of corrosion products

that plate out on certain areas of the flow measurement devices. EPRI research has
shown that flow measurement devices become fouled by one or more of the following
mechanisms:
x Copper Deposits Plants with large amounts of copper-bearing alloys in their flow
systems that are not directed through full flow polishers experience deposits that
are 50-60% copper. Removal of the copper from the systems has reduced the amount
of fouling.
x Iron Oxide Deposits Plants with no copper-bearing alloys experience iron oxide
deposits that foul feedwater flow measurement devices throughout the feedwater
system.
x Exposure to Corrosion Products Plants that expose the flow measurement devices
to higher than normal concentrations of corrosion products during the pre-
operational cleanup cycle experience fouling of these devices.
x Surface Erosion Surface erosion has also been observed and has a tendency to
cause non-conservative feedwater flow measurement.
These fouling mechanisms appear to be accelerated by the following:
x Plants that have been in a wet or dry layup condition for a extended period of time
experience a much greater thickness of fouling deposits. Normal deposits are 10-15
microns, but plants with extended layups may have fouling deposits as thick as 150-
400 microns.
x Plants that have high mass flow rates through feedwater piping (5.5-6.5 million
pounds per hour) tend to have more fouling. This may be attributed to increased
corrosion products in the feedwater from increased flow-accelerated corrosion
(FAC) or increased deposition rates on the flow devices at increased velocities.
6-4
x Plants with high pressure drops across the flow devices experience greater fouling.
Plants with <15 psid across their flow devices see very little fouling, but plants with
pressure drops > 24 psid experience high levels of fouling.
x Deposits tend to accumulate along machining or polishing marks in the flow

measurement devices. Electropolishing, precision surface grinding, and mirror
finishing significantly reduce the amount of fouling.
x Non-uniform deposits have been found in regions of flow transitions. Sharper

transitions cause thicker deposits.
x Deposits have a tendency to be greatest within the pipe taps where stagnant flow
conditions exist.
6.1.2 Compensation for Fouling
Fouling can be successfully removed by mechanical or chemical cleaning of the flow

devices. Water jet and hand cleaning are the mechanical cleaning methods that
normally have been used. Chemical cleaning has been used successfully to remove the
fouling, but it must be matched to the chemical composition of the deposits and the
material being cleaned [Section 6.1.5, Ref. 1, 2, 3].
Cleaning can be performed only with the unit off-line and on plants with access ports
or removable flow devices. In most older plants, flow devices are welded in place with
no access to the device. For these plants, cleaning would be a major undertaking.
Another problem that has been noted [Section 6.1.5, Ref. 5] is that fouling, when
removed, reappears during each operating cycle. Methods have been devised by
utilities to correct for the fouling to allow the plant to operate at rated reactor power.
These methods include:
x Use of plant on-line and historical data to determine a feedwater flow device
fouling correction factor [Section 6.1.5, Ref. 6, 7].
x Use of steam flow devices to measure flow or to determine a feedwater flow device
x Installation of a secondary or bypass differential pressure flow device to measure

flow or determine a feedwater flow device fouling correction factor [Section 6.1.5,
Ref. 10, 11, 12, 13].
6-5
x Use of an ultrasonic flow measurement device to measure feedwater flow or

determine a feedwater flow device fouling correction factor [Section 6.1.5, Ref. 11,
12, 13, 14, 25, 26].
x Tracer testing to measure feedwater flow to determine a feedwater flow device

6.1.3 Differential Pressure Flow Measurement Devices
Flow Nozzles
An ASME flow nozzle with throat taps is the accepted standard for testing steam
turbine performance [Section 6.1.5, Ref. 1, 16, 17, 19]. The flow nozzle is a differential
pressure device installed in the flow stream. The flow through the nozzle contracts
gradually, creating a pressure drop across the nozzle which can be measured using a
differential pressure instrument. A diffusing cone can be installed downstream to
reduce the pressure drop across the nozzle by about 60%. Procedures for the design,
fabrication, and installation of the flow nozzle have been discussed by ASME [Section
6.1.5, Ref. 16, 18].
Accuracies of 0.25% of actual flow are possible if the manufacturers specified flow
range and piping configuration are met. Flow nozzles are used for feedwater,
condensate, and pump-ahead drain flows [Section 6.1.5, Ref. 10, 13] but they must be
calibrated before use. Proper calibration includes the flow nozzle, the entire flow
section including the diffusing cone (if used), flow straightener, and upstream and
downstream piping sections as a unit. Flow nozzles need to remain extremely clean to
ensure accurate readings. A deposit of 0.0002 x (throat diameter) is acceptable if it is
uniformly deposited. However, the nozzle must be cleaned and retested if the deposits
exceed this thickness. Maintenance requirements include regular visual inspections of
surfaces for deposits and pressure taps for blockage.
Venturis
A venturi is a differential pressure device installed in the flow stream. The flow enters
a tapered inlet section and exits through a tapered diffuser section [Section 6.1.5, Ref. 1,
17, 18, 19, 27]. The pressure drop is measured through taps at the inlet and throat. The
diffuser section allows the fluid pressure to recover smoothly and results in excellent
pressure recovery when compared to other differential pressure devices. Procedures for
the design, fabrication, and installation of venturis have been discussed by ASME
[Section 6.1.5, Ref. 17, 18].
6-6
Accuracies of 0.25% of actual flow are possible if the manufacturers specified flow
range and piping configuration are met. Venturis are widely used for nuclear plant
feedwater flow measurement. Maintenance requirements include regular visual
inspections of surfaces for deposits and pressure taps for blockage.
6.1.4 Ultrasonic Flow Measurement Devices
An ultrasonic flowmeter utilizes a pair of transmitting/receiving piezo-ceramic crystal

transducers. These transducers can be mounted through the pipe walls to form a
wetted interface with the liquid being metered, or they can be attached to the
external walls of the pipe to form a dry contact [Section 6.1.5, Ref. 1, 20]. Figure 6-2
shows an ultrasonic metering section.
Transit Time
Various systems that measure the effect on sonic transit time produced by the flow
velocity are used to measure the flow [Section 6.1.5, Ref. 1, 20.
Accuracies of 0.5 to 1% are possible if the manufacturers specified installation

requirements are followed.
The Chordal ultrasonic flowmeters use transducers that penetrate the pipe wall and are
referred to built-in or wetted systems. Wetted systems are highly accurate to 0.5%
and provide a high reliability and repeatability [Section 6.1.5, Ref. 5, 21]. However, the
wetted systems can experience fouling and need to be cleaned at regular intervals
[Section 6.1.5, Ref. 1].
Strap-on devices measure feedwater flow with an alternate instrument that is non-
intrusive. The strap-on transit time ultrasonic flowmeter has been used at many plants
[Section 6.1.5, Ref. 1, 11, 12, 13, 14,17, 20, 25]. This meter requires transmitters/receivers
to be mounted on the outside of the pipe to transmit/receive ultrasonic signals
projected diagonally across the pipe. These systems are accurate to 1% with good
repeatability. From discussions with plant engineers that have installed these systems,
coupling between the pipe and the crystal and alignment of the crystals are critical to
obtain accurate and reliable results.
To measure feedwater flow with a second instrument that is non-intrusive, the strap-on
cross-correlation ultrasonic flowmeter is available [Section 6.1.5, Ref. 1, 19, 20, 22, 23,
24, 26]. The meter has four crystals. Two are upstream (one transmit/one receive) and
two are downstream (one transmit/one receive). The upstream and downstream
transmitters send continuous-wave ultrasonic beams across the feedwater flow
perpendicular to the pipe centerline. The signals are modulated by the turbulence
signature of the flow and are received by the crystals on the opposite side of the pipe.
6-7
With a computer, the modulated waveforms are compared to identify turbulence

signatures that are identical at the upstream and downstream crystals. When identical
signatures are identified, the computer measures the elapsed time required to go from
the upstream to the downstream crystals, thus giving the feedwater flow velocity
which is used to calculate feedwater flow. These systems are accurate to less than 0.5%
with good repeatability and reliability. From discussions with plant engineers that have
installed these systems and strap-on transit time flowmeters, the cross-correlation
flowmeter is much easier to install, and time-consuming crystal alignments are not
required.
6.1.5 Feedwater Flow References
1. Feedwater Flow Measurement in U.S. Nuclear Power Generation Stations. Electric Power
Research Institute, Palo Alto, CA: November 1992. Report TR-101388.
2. Survey and Characterization of Feedwater Venturi Fouling at Nuclear Power Plants -- Vol.
1: Feedwater Venturi Fouling. Electric Power Research Institute, Palo Alto, CA: May
1992. Report TR-100514, Volume 1.
3. Survey and Characterization of Feedwater Venturi Fouling at Nuclear Power Plants -- Vol.
2: Photomicrograph and Chemical Analysis. Electric Power Research Institute, Palo
Alto, CA: May 1992. Report TR-100514, Volume 2.
4. EPRI P2EP Survey #94-017. Inputs to Secondary Calorimetric. November 29, 1994.
2
5. EPRI P EP Survey #94-004. Feed Flow Element Fouling. May 17, 1994.
6. C. S. Sullivan. Feedwater Flow Venturi Fouling Study. EPRI P2EP Paper
7. PO-0042.0-806.
8. Preston Gillespie and Leland Hawthorne. Development of the Feedwater Venturi

Fouling Coefficient at the Oconee Nuclear Station. EPRI P2EP Paper PE-0042.0-105.
9. EPRI P2EP Survey #96-010. Secondary Calorimetric Divergence. October 15, 1996.
10. EPRI P2EP Survey #96-011. Using Steam Flow to Correct for Feedwater Venturi
Fouling. January 1, 1997.
11. N. R. Deming, M. A. Moradian, G. I. Arnold, K. T. Hurt. ASME Performance Test

On TVA Sequoyah Unit 1. EPRI P2EP Paper PO-0005.0-32.
12. C. C. Mason and T. F. Siegler. Sequoyah Nuclear Plant -- Feedwater Venturi Fouling
Investigation. EPRI P2EP Paper PE-0042.0-378.
6-8
13. Allen L. Williams. Installation and Use of a Full Flow Feedwater Bypass Line
Venturi to Calibrate Feedwater Flow Ultrasonic Flowmeters at the Kewaunee
Nuclear Plant. EPRI P2EP Paper PO-0042.0-659.
14. T. A. Nelson and G. L. Starnes. Monitoring Feedwater Nozzle Fouling at Diablo

Canyon Nuclear Power Plant. EPRI P2EP Paper PO-0053.0-220.
15. T. Lestina and C. Contard. Using a Flow Correction Factor to Compensate for
2
Feedwater Venturi Bias and Increase Plant Generation. EPRI P EP Paper
PO-0049.0-805.
16. Keith A. Young. Recovered Lost Megawatts From Feedwater Nozzle Calibration
Project (1% Core Thermal Power). EPRI P2EP Paper PO-0092.0-704.
17. American Society of Mechanical Engineers.Steam Turbines. ANSI/ASME

Performance Test Code 6-1976 (Interpretations 1977-1983).
18. Richard W. Miller. Flow Measurement Engineering Handbook. McGraw-Hill Co.,

Inc., New York 1996.
19. American Society of Mechanical Engineers. Measurement of Fluid Flow in Pipes

Using Orifice, Nozzle, and Venturi. ASME MFC-3M-1989, 1989.
20. Robert P. Benedict. Fundamentals of Pipe Flow. John Wiley & Sons, Inc., New York
1980.
21. Lawrence C. Lynnworth. Ultrasonic Measurements for Process Control. Academic

Press, Inc., Boston 1989.
22. Bradley Devendorf, Donald Augenstein, and Steve Johnson. The Installation of the
Leading Edge Flowmeter (LEFM) at Texas Utilities Comanche Peak for
Measurement of Feedwater Flow. EPRI P2EP Paper PO-0052.0-660.
23. R. S. Flemons. A New Non-Intrusive Flowmeter. National Bureau of Standards

Special Publication 484, Proceedings of the Symposium on Flow in Open Channels
and Close Conduits, February, 1977.
24. J. R. Sherin and D. Zorbin. Feedwater Flow Measurements Using Ultrasonic Cross-
Correlation Flow Meter. EPRI P2EP Paper PO-0146.0-136.
25. D. Zorbin and J. R. Sherin. Recent Developments in Flow Measurement Using

Ultrasonic Cross-Correlation Flow Meter. EPRI P2EP Paper PO-0051.0-624.
6-9
26. D. Augenstein, S. Corey, and S. Egli. Correction of Dynamic Venturi Fouling at Watts
2
Bar Nuclear Plant Using an External Leading Edge Flow Meter (LEFM). EPRI P EP Paper
PO-0053.0-892.
27. Chad Main. Ultrasonic Flow Measurement at Palisades Nuclear Plant. EPRI P2EP Paper
PE-0146.0-901.
28. K. Thomas and R. W. James. Feedwater Flow Measurement Experience at Harris

2
Nuclear Plant. EPRI P EP Paper PE-0041.0-900.
6.2 Reactor Primary Coolant Flow Measurement
Primary flow measurement in a PWR is calculated from secondary calorimetrics and

primary coolant temperature and density. Direct measurement of primary flow can be
used to reduce the effects of feedwater flow biases caused by venturi fouling. These
biases, which typically trend toward indicating increased flow, cause the turbine to be
operated at reduced power. Therefore, a redundant calorimetric on the primary loop
has the potential to reduce unnecessary power reductions that mean lost megawatts.
Redundant flow measurements on the secondary side combined with careful baselining
of flow measurements following venturi cleaning can be used to provide some
correction for subsequent fouling. However, many plants have the concern that Tech
Spec limits on reactor power might be exceeded by removing the bias from venturi
flow calculations.
One approach to reducing the uncertainty of primary calorimetrics is to measure

primary flow directly. EdF has developed a tool that infers flow by measuring the time
difference between spatially separated sensors on the reactor coolant piping. EPRI
developed a tool that detects the N16 isotope signature using ultrasonic flow
measurement as described in Section 6.1. Figure 6-2 shows a primary flow
measurement system that has been tested at Ginna. The flow measurement accuracy in
the field was unsatisfactory but it was reasoned that with improved electronics and
using proper flow profile correction factor, the uncertainty could be reduced. However,
the reduction was not significant enough to warrant as a substitute for using secondary
calorimetrics. However, its value in reducing the uncertainty in trending venturi
fouling plus providing a redundant measurement for controlling reactor power may be
cost effective. The value would depend on the amount of venturi fouling experienced
and other factors discussed in the references.
6-10
Figure 6-2
Schematic of Ultrasonic Metering Section
6.3 Exhaust Hood Modifications
Potential gains in low-pressure turbine performance are available through exhaust

hood modifications. The exhaust hood forms the region of the flow path following the
last stage of the turbine. Optimum flow in the exhaust hood directs steam flow evenly
to the condenser tubing. Also, it should be designed so that steam leaving the last stage
does not leave with an excess of kinetic energy that could have been converted to work
by the turbine.
Modifications of exhaust hoods are generally a part of an overall LP section

replacement. Flow measurements and computer modeling have shown that the exhaust
hood flow is complex. Small changes in design can cause large effects in overall
pressure loss. The flow conditions in the exhaust hood depend on inlet conditions that
require that the design of the exhaust hood geometry and the last stage blade design
must be integrated.
The thermal performance engineer may be involved in planning LP turbine

replacement. Recognizing the relationship between the exhaust hood and last stage
6-11
blade designs helps with cost-benefit analysis and design decisions. Following any
turbine upgrade, the new baseline performance will need to be established. This new
baseline will provide a basis for trending and will provide a check that guaranteed
improvements in heat rate have been achieved.
6.4 MSR Modifications
Plant experience has shown that MS/Rs are susceptible to problems that require
significant modifications. These problems are discussed in Section 2.6.2 of this
handbook and in EPRIs Moisture Separator Reheater Source Book and Procurement and
Operation Considerations for Moisture Separator Reheaters. This section summarizes several
modification packages that have been used to improve MS/R performance and enhance
megawatt output. There can be several reasons to modify MS/Rs including economic
reasons, the need to prevent further degradation of the MS/Rs, and reduction of
moisture content and moisture damage in the LP turbines. Modifications are described
in much more detail in the references listed above.
6.4.1 Moisture Separator Modifications
Deficiencies in moisture separation have been caused by use of wire mesh separators;
carbon steel separator vanes, which can rapidly erode in the wet steam environment;
single vane or pocket vanes, which can have low separation efficiency especially when
there is high inlet velocity and flow maldistribution into the separators; maldistribution
of steam flow into the separators; and re-entrainment of separated moisture in the dry
steam exiting the separators.
Typical modifications include:
x Double-pocket, stainless steel chevron replacements for single-pocket chevrons.

Figure 6-3 shows both types. Moisture removal effectiveness depends on the
moisture and dynamic head, U V2, of the inlet steam. Figure 6-4 illustrates the effect
of these parameters on moisture removal effectiveness.
x Chevrons slanted outward as shown in Figure 6-5. This arrangement allows stray
separated moisture to drain back toward the incoming cycle steam rather than into
the path of the dry steam leaving the separator where it can re-entrain.
x Improved inlet steam manifolds and perforated plates at the inlet to the chevrons to
improve flow distribution into the moisture separators.
These modifications are applicable to both MSRs and MS-only units.
6-12
Figure 6-3
MSR Chevrons
(Courtesy of Senior Engineering)
6-13
Figure 6-4
Typical Moisture Removal Effectiveness of Chevron Separators
6-14
Figure 6-5
General Arrangement of G Type MSR Reconstruction
6.4.2 Excess Steam Modifications
Section 2.6.2 and References 1 and 2 discuss the problem of condensate subcooling and
oscillation. The problem is mitigated by venting steam through the reheater tubes to a
feedwater heater. The vented steam is referred to as excess steam. This excess steam in
the outlet leg of the reheater U-tubes prevents excessive subcooling of condensate in the
tubes. The amount of excess steam can be as high as 10% of total heating steam flow.
The energy in the excess steam flow contributes to feedwater heating but is not
available for expansion in the turbine. For this reason, an excess steam modification
results in an increase in heat rate and reduction in electrical output.
There have been several solutions to the problem of providing excess steam. The
simplest is to vent steam from the second pass tubes by installing a line, isolation valve,
6-15
and flow restrictor from the reheater outlet channel to the top stage of FW heaters. The
arrangement is shown in Figure 6-6. Since all tubes in the reheater tube bundle do not
have the same heat load, some modifications use tube inlet orifices to control the
amount of excess steam in the individual reheater tubes.
Figure 6-6
Original Drain Venting System
Despite the benefits of excess steam in a two-pass reheater bundle, there can be
inadequate excess steam flow to tubes with the higher heat loads. Increasing the
amount of orificing for lightly loaded tubes and increasing the total amount of excess
steam flow can be inefficient and wasteful. An alternate design is the four-pass vent
chamber design. This alternative requires modification to the inlet and outlet headers of
the reheater to make the existing U-tubes a four-pass configuration. Figure 6-7
compares the flow paths and Figure 6-8 compares typical temperature distributions in
the reheater for the two- and four-pass configurations.
6-16
Figure 6-7
Two- and Four-pass Temperatures
This modification, using the existing tubes and tubesheet, lacks the smooth tubesheet
surface needed for the first-third pass partition and fourth-pass vent and drain header
gaskets and bolting. Correcting this requires that some tube locations be converted to
threaded studs and requires careful, intricate design to the internal gasketing. If not,
leakage between passes can readily occur. As a result, the four-pass modification is
usually made in conjunction with replacement of the entire tube bundle so that the
tubesheet can be redesigned for pass partitions, bolting, and gasketing.
6-17
6.4.3 Tube Bundle Replacement
Reasons to replace an MSR tube bundle include the following:
x There is a need to remove sources of copper from the turbine cycle.
x The tube bundle heat transfer capacity has or is predicted to deteriorate to the point
where it is economically justified to replace the tube bundle.
x The improved replacement adds MWe and is cost effective.
The problems discussed in Section 6.1 of the MSR Source Book suggest that it is seldom
prudent to replace the tube bundle in kind. There are modification features that are
now considered necessary for good performance and long tube life that were not in the
design being modified:
x Operating experience has shown that tubes made of Type 439 stainless steel has
provided the best performance and durability. Stainless steel is susceptible to stress
corrosion cracking. Precautions need to be taken to specify material with low
residual carbon content and to specify adequate process for rolling fins and for
bending, welding, and heat treating the tubes.
x Section 12 of the TEMA standards provides guidance on providing adequate tube

support to prevent tube damage by vibration. As a rule of thumb, a tube span of 24
or less prevents harmful vibration.
x Even if the tube bundle shroud is not replaced, it should be modified to prevent
buckling and to minimize bypass of cycle steam around the tube bundle. Figure 6-8
shows a method to restrict bypass flow. The restrictor bars also strengthen the
shroud against buckling. A unique buckling analysis, based on the conditions of the
MSR under modification, should be made to ensure that there is adequate shroud
structural rigidity.
x The U-tubes and tubesheet should be designed to provide smooth surfaces and bolt
locations for pass partition and fourth pass header bolting and gaskets. The tube
arrangement shown in Figure 6-5 provides these features.
The above features should be incorporated in both HP and LP reheater tube bundles if
either or both are candidates for replacement. In no case should the tube bundle
exposed to cycle steam flow from the moisture separators be replaced unless there is
assurance that there is not significant moisture carryover. If this assurance does not
exist, first conduct moisture carryover tests and/or modify the moisture separators to
reduce carryover.
6-18
Figure 6-8
Function of By-pass Restrictor
If a decision is made to replace a tube bundle, there are other modification features that
should be considered as enhancements; their relative cost may be low compared to that
of the basic modification:
x Add more tubes by taking advantage of the original tubesheet diameter. Figure 6-5
shows a pattern that does this. Most OEM tube bundles had a rectangular pattern
that did not use the 3 and 9 oclock space in the tubesheet circle. The wider, pancake
tube pattern also reduces cycle steam 'P and the tendency for high 'P to lift the
tube bundle.
x Add thermocouples in the outlet of select second and fourth pass tubes to determine
if condensate oscillation is occurring and to adjust excess steam to prevent
condensate oscillation over the MSR operating range.
x Add features to reduce the problem of unequal thermal expansion of U-tube legs.
These are discussed in EPRIs MSR Source Book.
x Reduce tube diameter to increase the tube-side heat transfer coefficient. Reduced
tube diameter also increases cycle steam pressure drop. The tradeoff should be
evaluated if this method of tube bundle enhancement is considered.
6-19
6.5 Heater Retubing
Because heater tubes are usually welded into the tube sheet and are U-tubes,
replacement of individual tubes in a tube bundle is, as a rule, never undertaken.
Instead, leaking and otherwise suspect tubes are plugged and the increase in heat rate
is accepted. The decision to replace a heater tube bundle is generally made when there
are a significant number of plugged tubes or when NDE indicates gross loss of tube
wall thickness. In any case, a cost-benefit analysis should be made to determine if the
cost of replacement is justified by the increase in heat rate and plant output.
When assessing the option of replacing one or more heater tube bundles, it is important
that the history of the present heaters be considered:
x Age It is important to consider the age of the installed heater, the age of the plant,
and the expected remaining life of each. If an older plant is going to remain in
service for a long period of time and the heater is degrading slowly but
performance has been satisfactory to date, it may be economical to replace the
bundle and reap the benefit of increased plant output over a longer period of time.
x Tube Material Presently, Type 304 stainless steel appears to be the material of
choice for heater tube bundles. However, ferretic stainless steels such as Type 439
are becoming increasingly popular due to better thermal conductivity and lower
thermal expansion properties than the austenetic stainless steels. Heater bundles
using other than these materials should be considered as candidates for
replacement, especially if the present tubes are copper alloy. Copper deposits on
steam generator tubes and supports result in a type of steam generator damage
known as tube denting.
x Material Condition and Root Cause Analysis Detailed knowledge of the total
condition of the feedwater heater is important before tube bundle replacement.
First, it is important to know which tubes have failed and have been plugged, and if
possible, the axial location of the failure. The root cause of the failures should be
identified. The cause may be tube vibration and tube or support wastage. Although
the replacement bundle will have to fit into the same envelope and have nearly the
same overall dimensions as the present bundle, it is possible to change tube
supports and tube materials to address such causes. Also, it is possible to change
tube diameter to address a tube vibration if tube-side pressure drop remains
acceptable and the replacement strategy includes tubesheet replacement.
The EPRI Nuclear Plant Feedwater Heater Handbook contains a more detailed discussion of
heater replacement, material condition, and root cause. Generally, the most economical
approach to tube replacement is one that minimizes or has no impact on reactor outage
critical path time and minimizes field craft labor. A way to satisfy these conditions is to
6-20
have the tube bundle with new tubesheet shop fabricated and delivered to the plant
and installed in the existing heater shell. Most nuclear plant feedwater heaters have a
welded tube-to-shell and shell-to-connecting piping joints. This avoids removing the
shell and having to cut and reweld the attached piping, but does require that the
tubesheet-shell joint be cut and rewelded in the field. An alternative is to shop fabricate
an entire new heater, including the shell, and install it in the field by cutting and
rewelding the attached piping and removing the old heater. It is not possible to avoid
cutting and rewelding a thick-walled joint in the field when replacing a feedwater tube
bundle. Also, removal of the shell requires more plant work space than replacing only
the tube bundle.
The subject of tube bundle replacement is complex and extensive and is only
summarized in this handbook. The reader is referred to the references at the end of this
section for further information. The Nuclear Plant Feedwater Heater Handbook has
guidelines on failure cause and prevention and tube replacement.
6.6 Throttling (Governor) Valve Modifications (Throttling Loss

Modifications)
The function of a governor valve is to control the flow of steam to the HP turbine.
Control of flow is accomplished by throttling. That is, as the valve is closed, the
pressure drop across the valve increases. At full load, there is some pressure drop
across the governor valve.
Governor valve throttling is basically a constant enthalpy process. The governor valve
throttling process and subsequent expansion through the turbine is illustrated in Figure
6-9 where the dashed line A-C is the throttling process and C-D is the expansion
process after throttling. This figure shows that, while enthalpy is constant and is
conserved during governor valve throttling, the entropy increases. The result is that
there is less available energy during subsequent steam expansion in the turbine and the
thermal efficiency is reduced. This is illustrated by comparing the enthalpy drop
difference in expansion lines A-B and C-D in Figure 6-9.
6-21
Figure 6-9
Effects of Governor Valve Throttling
6.7 Full Arc and Partial Arc Operation
Almost all nuclear turbines use more than one throttle valve. A four valve design is
common. Most turbines are designed to open the valves sequentially with load and to
operate with the first three valves fully open and the fourth valve partially closed and
throttling at full reactor power. Some throttling at full load is needed for control.
There are two basic methods of admitting steam to the HP turbine first stage nozzles,
full arc and partial arc. Full arc admits steam from all the throttle valves to a common
plenum. Steam then flows from the plenum into all first stage nozzles located in a full
arc in front of the first stage HP rotor blades. Partial arc admits steam into separate
plenums, usually one for each throttle valve. Steam then flows from the plenums to a
part of the first stage nozzle, each set of nozzles occupying a part of the full arc
delivering steam to the first stage blades.
Whether at part load or full load regulation, full arc admission results in parallel steam
flow through all of the first stage nozzles while partial arc admission results in steam
flow through some, but not all, of the nozzles. As a result, more governor throttling is
required with full arc than partial arc. This difference results in more throttling loss for
6-22
full arc admission and higher heat rate. However, at valves wide open (VWO), full
admission can give better HP turbine performance because partial arcs have inactive
portions.
Most plants have full arc admission for several reasons:
x The intent has been to operate the plants at or near full load where thermal
performance differences between full and partial arc admission can be small.
Differences tend to be small whenever main steam pressure is reduced to offset
problems such as steam generator fouling and tube plugging and Thot reduction.
x Partial arc increases the cyclic loading of the HP turbine first stage blades since the
blades see a more intermittent loading. Some turbine vendors discourage the use of
partial arc admission.
In summary, there are thermal performance gains to be achieved by using partial arc
admission. A nominal value is 3 MWe for a 1000 MWe plant. The amount varies
depending on factors such as present governor valve type and design and future plant
operating strategy for parameters such as main steam pressure and reactor power.
Turbine reliability can be less with partial arc. The turbine vendor needs to be
consulted when considering a change in the governor valve system. The cost of the
change, parts plus field labor, including outage time chargeable to the modification
costs versus MWe gain needs to be considered when making a decision about the
modification.
6.8 HP Turbine Nozzle Block Upgrade
Another potential improvement to thermal performance is modification of the HP

turbine nozzle block. A modification may be appropriate to complement a modification
to incorporate partial or full arc admission. A modification may also improve first stage
turbine mechanical efficiency by reducing nozzle profile losses, which can be
approximately 15% of total stage mechanical losses.
Figure 6-10 illustrates the basic change from a conventional straight control or first
stage nozzle to a contoured nozzle. Because the control stage has a small aspect ratio
and the flow can vary from subsonic at full arc to transonic at partial arc, the low aspect
ratio can lead to high flow losses. Modifying the original endwall of the nozzles to
converging nozzles causes local flow to accelerate and reduces the boundary layer
along the endwalls. Increases of 1% in control stage efficiency have been reported.
6-23
Figure 6-10
Effect of Contoured Endwall Control Nozzles
6.9 Reactor Uprate
Increasing the reactor core power is a low cost approach to gaining megawatts for some
plants. Approximately 30% of the plants in the U.S. have uprated to gain electric output
by using available margin in plant design.
6-24
Uprates have been done for both BWR and PWR plants. Most plants can be uprated 5-
7% percent with few modifications to existing facilities. However, the added core
power has an effect on nearly every system in the plant. Also, the plant license will
require updated analysis leading to technical specification and FSAR changes. The
NRC will require a review of the Tech Spec changes for significant hazards and review
and approval of any unreviewed safety questions involved in the uprate. The NRC
places uprates into four categories as follows:
1. Requiring changes to FSAR/SER documentation
2. Requiring uprate design verification within existing equipment design
3. Exceeding existing plant equipment capacities but not exceeding ECCS capability
4. Requiring upgrade of current ECCS capability
Most of the existing uprates are in the first two categories and none are in the last.
The uprate process involves a feasibility study, technical evaluation for all systems
affected, preparation of licensing revisions and submittals, and the engineering and
implementation of plant modifications.
The scope of uprating programs for Westinghouse and GE plants is outlined in the
following documents:
x WCAP-01263, A Review Plan for Uprating the Licensed Power of a Pressurized

Water Reactor Power Plant.
x Licensing Topical Report NEDC-31897P-1, Generic Guidelines for General Electric

Boiling Water Reactor Power Uprate.
The following list gives an idea of some of the plant parameters that were affected by a
typical BWR power uprate:
x Total core flow
x Reactor recirculation pump speed
x Neutron flux
x Condensate flow
x Condensate demineralizer flow
x Final feedwater temperature
6-25
x Reactor feed pump suction pressure
x Feedwater flow
x Reactor feed pump turbine RPM
x Reactor feed pump discharge pressure
x Reactor steam dome pressure
x Main steam line flow
x Main steam line pressure
x Turbine inlet pressure
x Condenser pressure
x Offgas flow
x Circulating water temperature 'T
x HPCI/RCIC steam supply pressure
x HPCI/RCIC discharge pressure
x Control rod drive pump discharge pressure
x Feedwater heater extraction steam flow (all five heaters)
x Moisture separator drain tank flow
x Feedwater heater drain cooler flow (all six heaters)
x Feedwater heater pressure
x Reactor Building cooling water heat load
x Reactor Building closed cooling water heat load
x Turbine Building cooling water heat load
x Turbine Building closed cooling water heat load
x HVAC heat load
6-26
x Service water heat load
x Cooling tower evaporation rate
x Reactor water makeup flow
x Isophase bus duct heat load
x Generator stator cooling and hydrogen
x Main transformer heat load
x Liquid/solid radwaste quantity
x Plant radiation levels
There are some additional benefits of a power uprate that can be considered in the cost-
benefit analysis. One benefit is the review and updating of the licensing basis and
design information. Also, degraded BOP components can be identified and their
replacement or repair included in the megawatts gained and the cost of the uprate,
especially if more capacity is needed for the uprate.
The thermal performance program can be a major help in determining the feasibility
and cost benefit of a power uprate. For example, the thermal performance program
may have already determined performance margins for the steam generators, the
condenser, cooling tower, MSR, HP and LP turbines, FW heaters, FW pump, and so on.
Therefore, the major effects of an uprate can be anticipated.
6.10 Turbine Upgrades
EPRI has prepared a Main Turbine Performance Upgrade Guidelines, which addresses in
some detail the potential for various turbine steam path improvements. The following
conclusions concerning turbine upgrade options were developed in the EPRI guideline:
1. A majority of turbine section replacements are being implemented based on benefits

related to the perceived elimination of stress corrosion cracking in the disk bore,
keyways, and blade attachments. During LP turbine section replacement, utilities
have implemented other modifications to improve performance in order to offset
the substantial capital costs of the repairs.
2. A variety of upgrade strategies are presently available for consideration by the

industry. In general, the improvements offered can be characterized as further
adjustments or refinements to the original steam flow path. These refinements can
achieve between 1-5% improvement in unit output by:
6-27
x Reducing profile losses
x Reducing secondary losses
x Reducing leakage through seals
x Adding stages to the LP section
x Lengthening the L-0 blades and increasing the annulus area
3. Several available retrofit packages of advanced blades, stages, and sections have
utilized CFDs to improve turbine stage designs. Dramatic improvements in section
efficiencies cannot be expected from the application of CFD to existing designs.
Current upgrade efforts represent the process of fine-tuning.
4. Because of its disproportionate contribution to the overall turbine output, the L-0
stage constitutes a unique area of potential improvement for the turbine. In lieu of a
complete section replacement, there is an opportunity to progressively increase
output by 1% or more by installing an improved L-0 stage. The replacement of
eroded or worn diaphragms with stationary airfoils that are more precisely oriented
to their original rotating counterparts also offers an opportunity for achieving
nominal improvements as part of a planned, long-term upgrade strategy.
5. To date, the U.S. nuclear industry has done little to advance and apply the optical
wetness probe, which was originally introduced in the 1980s as a technique to
directly determine the power developed in an LP turbine. A probe currently being
developed by the Electric Power Research Institute should advance this new
technology. It will, however, require the support of the industry through field
applications to eventually establish the validity of this technology as a cost-effective
technique for establishing the LP used energy end point (UEEP) enthalpy. This new
technique will be available as an alternative to using ASME PTC 6 measurements.
6. The reason for HP section replacement is different from that reported for most LP
section replacements. HP section replacements can be economically justified by the
increase in efficiency. Output improvements of 20-40 MWe were reportedly
associated with HP section upgrades for units of 100-1200 MWe (2-3%). Because
there is a ratio of 1:2 or 1:3 in the number of HP turbines when compared with LP
turbines, the addition of an improved HP turbine may become more economically
palatable for those utilities that have embarked on a replacement strategy of LP
sections.
7. As previously mentioned, the upper limit of a current section replacement is likely

to provide an additional 5-6% output depending upon the vintage of the unit and
the extent of the upgrade. Tobtain additional improvements, U.S. utilities should
6-28
monitor the success of more advanced designs that have been instituted by some of
the European and Asian plants. For example, the application of L-0 blades up to 72
long are planned for the 1500 MWe Arabelle unit operated by the Electricite de
France.
Based on the previous conclusions, the EPRI Task Group responsible for the Main
Turbine Performance Upgrade Guidelines has developed the following lessons learned
related to upgrading turbines:
1. Extending maintenance and inspection intervals by installing new rotor

replacements remains the principal factor that justifies this costly investment.
2. Owners of new generation LP rotors have a long-term vested interest in the

development of a superior SCC-management technology. This will ensure that
further reliability issues do not compromise projected efficiency gains.
3. A variety of similar performance upgrade options are currently available for the
original Westinghouse and General Electric turbines.
4. Advanced measurement techniques that support in-situ testing of turbines to define

the inlet/outlet flow conditions of selected LP stages (including the L-0 stage) have
been available since the 1980s. The CFD analytical predictions are only as reliable as
the input used to characterize the boundaries of the portion of the turbine being
modeled. Field testing, therefore, remains a vital part of successful design
optimization with CFD, particularly where the goal is to achieve or qualify LP
section replacement enthalpy gains.
5. Utility experience indicates that significant MWe increases can be achieved by

upgrading the turbine flow path. Increases have been achieved by replacing all of
the four major LP turbine sections originally designed by Westinghouse and
General Electric. The margin for improvement, however, is limited. Potential
increases can also be limited by the degradation of other components within the
steam plant cycle, such as the steam generator.
6. The primary reason for performing an L-0 blade or diaphragm retrofit is to resolve
blade degradation concerns. The increased number of MWes alone does not justify
the cost of replacing the large number of blades in this stage.
7. It is important for utilities to accurately measure LP power output before and after
turbine upgrades. Accurate measurements are required to ensure that MWe
improvement promised by vendors was actually achieved.
8. Utilities should distinguish between HP output improvements attributable to the

use of an advanced steam path versus also increasing the mass flow into the HP
6-29
inlet within a vendors offer. The latter constitutes an uprate rather than an upgrade
of the original design.
9. Development of longer blades designed from lighter materials, such as titanium,

may provide nuclear plant operators with their next opportunity to effectively
upgrade the performance of their LP sections.
Modifications of exhaust hoods are generally part of an overall LP section replacement.

Diffuser testing and CFD analysis has shown that the flow is extremely complex. Small
changes can produce large effects on overall pressure loss. The flow in the exhaust
hood depends upon inlet conditions. This dependence indicates the need to optimize
the integrated design of hood geometry and last stage blade design.
6.11 House Load Reduction
Most of the discussion in this document addresses issues related to turbine output and
heat rate. However, the bottom line in terms of revenue and O&M costs is net unit
output, defined as generator output less the unit electrical loads. Many of the unit's
electrical loads are required to operate the plant. Included are reactor coolant pumps,
circulating water pumps, condensate pumps, and motor-driven feedwater pumps. It is
difficult to reduce these loads, except possibly at reduced reactor power. Therefore,
only a fraction of the total unit electrical load can be a potential for consideration in
improving net unit output. Despite this admonition, the performance engineer should
have a clear list of the unit's electrical loads and considerations for reduction of power
consumption and power factor improvement. Methods of power reduction include
using more efficient motors, securing some pumps during extended part power
operation, and using variable speed motors. The effects on operating limits and
component performance, such as the condenser pressure with reduced cooling flow,
must be evaluated. Appendix C.4 of EPRIs Megawatt Improvement Casebook and
Guidelines discusses a typical program including an extensive list of potential
improvement candidates.
6.12 References
1. C. S. Sullivan, Feedwater Flow Venturi Fouling Study. EPRI Nuclear Plant

Performance Seminar, Asheville, North Carolina (September 1996).
2. Development of an Ultrasonic PWR Primary Coolant Temperature/Flow Measurement

System (RCSM). Electric Power Research Institute, Palo Alto, California: December
1996. Report TR-106821-V1.
6-30
3. T. McCloskey et al, Low Pressure Steam Turbine Thermal Performance

Improvements, Thirteenth Annual Plant Performance Enhancement Program (P2EP)
Annual Meeting Proceedings, August 1997.
4. Main Turbine Performance Upgrade Guideline. Electric Power Research Institute, Palo
Alto, California: January 1997. Report TR-106230.
5. Moisture Separator Reheater Source Book. Electric Power Research Institute, Palo Alto,
California. Report TR-106345.
6. Procurement and Operation Considerations for Moisture Separator Reheaters. Electric

Power Research Institute, Palo Alto, California: September 1984. Report NP-3692.
7. TEMA Standards.
8. Nuclear Plant Feedwater Heater Handbook, Volumes 1 - 3. Electric Power Research

Institute, Palo Alto, California: June 1985. Report NP-4057.
9. Jim Nicholson, Nuclear Power Plant Core Power Capacity Uprating, Stone and
Webster Engineering Corporation.
10. Megawatt Improvement Casebook and Guidelines. Electric Power Research Institute,
Palo Alto, California: December 1992. Report TR-101867.
6-31
7
OPTIMIZING GENERATION FOR OFF-NORMAL PLANT
CONDITIONS
Sometimes nuclear power plants need to change the strategy of operating the steam
cycle in order to achieve other objectives. Usually, the change results in degraded
thermal performance conditions and an increase in plant heat rate, but an overall
improvement in other conditions that meet the plant operating strategy. The most
common examples are end of cycle coastdown, reduced Tave, and reduced feedwater
temperature.
7.1 End of Cycle Coastdown
Nuclear plants usually replace part of the nuclear fuel at fixed intervals, for example, 18
or 24 month intervals. The amount of enrichment in the fuel is set to allow full power
operation for the full interval between refueling. It is possible to extend fuel burnup
and the interval between refuelings by gradually reducing power toward the end of the
fuel cycle. Power reduction reduces the amount of core reactivity tied up in power
coefficients that becomes available for additional fuel burnup and electrical production
before refueling.
End of cycle coastdown has the disadvantage of decreasing plant electrical output and
increasing heat rate, resulting in additional loss of electrical output. However, it may
make economic sense to coastdown considering the added fuel burnup and deduction
in spent fuel storage over the remaining life of the plant.
7.2 Reduced Feedwater Temperature
There can be situations when the capacity of the HP turbine and control valves exceeds
the capability of the reactor system to deliver full steam flow without reducing main
steam pressure. A case in point is when the heat transfer capability of the steam
generators is reduced by tube plugging or fouling. One way to compensate for this
condition is to reduce the feedwater temperature by reducing or stopping extraction
steam to the top feedwater heaters. This has the effect of (1) increasing the steam flow
through the turbine because less steam is extracted and (2) improving heat transfer
7-1
Optimizing Generation for Off-Normal Plant Conditions
conditions including steam pressure because colder feedwater results in an increased

mean effective temperature difference between the reactor coolant and the steam.
7.3 Reduced Tave
In recent years, it has become evident that a high PWR hot leg temperature, Thot, can
have detrimental effects on the life of steam generators. Some plants have or are
considering a reduction in Thot. If Thot is reduced, then the cold leg temperature, Tcold,
must also be reduced by the same amount in order to maintain the same reactor power.
If Tcold is reduced, then steam side temperature and pressure in the steam generators
must be reduced in order to maintain the same heat transfer rate. This will result in
reduced steam cycle efficiency and generator output. Because turbine capacity depends
on maintaining high steam pressure, the reactor power level may have to be reduced as
a result of reduced steam pressure, further reducing plant output.
One way to compensate for a reduction in Tave is to reduce the feedwater temperature as
discussed previously.
In summary, the workarounds discussed above can be somewhat interactive. For

example, it maybe advantageous to reduce FW temperature when Tave reduction is
implemented. Solutions as described above and their mix are plant-unique.
7-2
8
GLOSSARY
8.1 Definitions
adjusted actual gross heat rate. The gross heat rate attained in the normal equipment
lineup during one 24-hour period each month, corrected to design condenser
backpressure, expressed in BTUs per kilowatt-hour (electric).
average adjusted actual gross heat rate. The heat rates attained in the normal
equipment lineup during each week of the month and adjusted to 100 % power (used
in calculating the INPO thermal performance indicator).
best achievable heat rate (BAHR). The heat rate at which the unit is capable of
operating, that, the design heat rate corrected for ambient conditions and other
conditions not chargeable to the cycle. The INPO thermal performance Indicator uses a
best achievable gross heat rate that has been attained by the plant referenced to 100 %
power. It may be obtained from performance monitoring, calculations, or a thermal
performance test. INPO documents specify standard adjustments to the BAHR to
account for unavoidable conditions.
cold reheat. Steam from high pressure turbine exhaust to the moisture separator
reheater. Also known as high pressure turbine exhaust.
design heat rate. The heat rate predicted during design.
design information. Information concerning the turbine cycle that was used during
plant design.
duty. Work done by a condenser, expressed in Btu/hr. (Also referred to as heat

rejected.)
gross turbine heat rate. The heat rate based on heat delivered to the turbine and the
generator output (for cycles with motor-driven feedwater pumps).
gross unit heat rate. The heat rate based on the heat generated by the reactor core and
the generator output.
8-1
Glossary
heat rate. The heat consumption rate per unit of output, that is, Btu/kW-hr.
Generically, heat rate is defined as the heat delivered to the turbine minus the heat
returned to the steam generator, divided by the electrical generator output.
moisture removal effectiveness. The amount of moisture removed by the moisture

separator divided by the amount of moisture entering the moisture separator times 100.
net electrical power. Electrical generation sent out from a station, expressed in MWe,
net.
net turbine heat rate. The heat rate based on heat delivered to the turbine and the
generator output (for cycles with steam-turbine-driven feedwater pumps).
net unit heat rate: The heat rate based on the heat generated by the reactor core and the
plant net output (generator output less power used by the unit).
performance engineer. The person, persons, or organization responsible for monitoring

and analyzing thermal performance and providing related information to management
and other organizations.
realistic achievable heat rate. The best achievable heat rate corrected for cycle
conditions and component degradations that, at the time of evaluation, are not
economical or practical to correct.
temperature rise. Increase of circulating water temperature from inlet to outlet of

condenser water boxes.
terminal temperature difference (FW). The feed water heater (FWH) shell-side
temperature minus the temperature of the exiting feedwater.
terminal temperature difference (MSR). The outlet temperature of the superheated

reheat system minus the temperature of the exiting steam/liquid in the MSR tube
bundles.
thermal kit. A set of heat balances and graphs that describes the design performance of
the unit.
thermal performance. The effectiveness or efficiency of the turbine cycle and its
components in converting thermal into electrical energy measured by generator
electrical output and heat rate. Heat rate is inversely proportional to efficiency.
thermal performance index. An INPO performance indicator. The ratio of the design
gross heat rate (corrected) to the average adjusted actual gross heat rate.
8-2
Glossary
8.2 Acronyms
A/D Analog to digital
ANSI American National Standards Institute
AOV Air operated valve
ASME American Society of Mechanical Engineers
BOPPMG Balance of Plant Performance Monitoring Group
BWR Boiling Water Reactor
CFD Computational Fluid Dynamics
CRD Control rod drive
DCA Drain Cooler Approach
ECCS Emergency Core Cooling System
ESFAS Engineered Safety Feature Actuation System
FFT Final Feedwater Temperature
FIC Flow induced corrosion
FW Feedwater
FWH Feedwater Heater
HP High Pressure
INPO Institute for Nuclear Power Operations
LP Low Pressure
LWR Light Water Reactor
MS Moisture Separator
MSL Main steam line
8-3
Glossary
MSR Moisture Separator Reheater
MWe Electrical Megawatts
MWt Thermal Megawatts
NDE Nondestructive Examination or Evaluation
NSSS Nuclear Steam Supply System
O&M Operations and Maintenance
OEM Original Equipment Manufacturer
OTSG Once through steam generator

2
P EP Plant Performance Enhancement Program
PC Personal Computer
PEPSE Performance Evaluation of Power System Efficiencies
PLEX Plant Life Extension
PTC Performance Test Code
PWR Pressurized Water Reactor
R&D Research and Development
RCS Reactor Coolant System
RH Reheater
RPS Reactor Protection System
RTD Resistance Temperature Detector
RWCU BWR Reactor Water Cleanup
SCC Stress Corrosion Cracking
SG Steam Generator
8-4
Glossary
SJAE Steam Jet Air Ejector
SSR Steam seal regulator
T/C Thermocouple
TPE Thermal Performance Engineer
TPI Thermal Performance Index
TR Temperature Rise, deg F
TTD Terminal Temperature Difference
UEEP Used Energy End Point
UFM Ultrasonic Flow Meter
VWO Valves wide open
8.3 Nomenclature
G Total error of a measurement
P Bias error
V Random precision error
h Enthalpy, Btu/lb
ID Inside diameter, inches
k Flow coefficient
m Flow, lb/hr
P kW or hp
p Pressure, psia
Q Heat transfer or generation rate, Btu/hr
t Temperature, degF
8-5
Glossary
TR Temperature rise, degF
U Overall heat transfer coefficient, Btu/hr-ft^2-degF
v Specific volume
X Quality of steam, percent of dryness
Subscripts
a Addition flow
c Clean
eg Gross electrical output
en Net electrical output
f Saturated water
fg Evaporation
fw Feedwater
fwe Feedwater extraction
h Heater
id Incoming heater drips
o Overall
od Outgoing heater drain
out Primary system heat losses
p Reactor pump energy
r Reactor or steam generator
s Steam
sat Saturated
8-6
Glossary
sg Steam generator
t Heat delivered to steam cycle
8-7
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What is the purpose of the Thermal Performance Engineering Handbook?

What is the purpose of the Thermal Performance Engineering Handbook?

What organization sponsored the research for this report?

What organization sponsored the research for this report?

Thermal Performance Engineers

Advanced Concepts in Thermal Performance

and License Agreement on the

back cover before removing the

EPRI Project Manager

ORGANIZATION(S) THAT PREPARED THIS REPORT

Mollerus Engineering Corporation

This report was prepared by

Mollerus Engineering Corporation

The two-volume Thermal Performance Engineer Handbook will assist thermal

Volume I contains a thermal performance primer to provide a brief review of

x Monitoring and trending plant thermal performance

x Identifying and investigating the causes of loss of electrical production in

x Developing potential changes and modifications to recover and enhance MWe

To provide guidance to assist utility thermal performance engineers in identifying and

x A thermal performance primer provides a brief review of thermodynamic principles

Plant support engineering

The following individuals were ongoing members of Plant Support Engineering's

1 INTRODUCTION ................................................................................................................. 1-1

2 COMPONENT FOCUS AREAS........................................................................................... 2-1

Formal EPRI Reports/Software ................................................................................. 2-27

P2EP Technical Library.............................................................................................. 2-65

3 CYCLE ISOLATION ............................................................................................................ 3-1

3.7 Loss Quantification ....................................................................................................... 3-7

4 DATA VALIDATION ............................................................................................................ 4-1

5 MOISTURE MEASUREMENTS........................................................................................... 5-1

6 MEGAWATT ENHANCEMENTS ......................................................................................... 6-1

6.4 MSR Modifications ...................................................................................................... 6-12

7 OPTIMIZING GENERATION FOR OFF-NORMAL PLANT CONDITIONS .......................... 7-1

Figure 2-1 Basic Arrangement of a Condenser (Schematic)................................................... 2-2

x Impact on thermal performance

x Typical problems, degradation mechanisms and corrective actions

2.1 Condenser and Auxiliaries

2.1.1 General Description

Because condensers handle large quantities of steam at low, subatmospheric pressure,

Condensers must continually vent non-condensable gases to prevent becoming air-

Table 2-1 lists condenser instrumentation. A key condenser operating parameter is

Condenser pressure Performance

Circulating water inlet temperature Calculated LMTD, heat load

Circulating water outlet temperature Calculated LMTD, heat load

Circulating water flow Calculate heat load

Circulating water pump discharge pressure Flow indicator

Circulating water box delta p Trending fouling

Circulating water box levels Flow

2.1.2 Performance Calculations

The following calculation methodology is provided as a means to measure the overall

Condenser Duty (Q)

4 = 47 4HOHFW 4 JHQ 4DX[ 4 IZS 4EG

QT = heat load to steam cycle

Q = condensing duty, Btu/hr

Input Data W = 600,000 gpm

Calculation Q = 3 x 108 x (85-65)

Wex = turbine exhaust steam flow, lb/hr

hc = condensate enthalpy (enthalpy of water at the

Input Data Wex = 6.6 x 106 lb/hr