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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
NON INTRUSIVE ULTRASONICFLOW AND TEMPERATURE MEASUREMENTS
Presented by: Yuri Gurevich
Material Prepared by: Leonid ChudnovskyDr. Armando Lopez (AMAG)Dr. Yuri Gurevich (Daystar Technologies) Brendan Sharp (AMAG)David Walker (AMAG)
References: • Metering of feed-water flow, temperature and thermal power with focus on applications in nuclear power plants, SP Workshop, Tokyo 2007, Washington 2009, Paris 2011, Shanghai 2013• NRC SER• AMAG @ Daystar Presentations and Reports
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
• TRACEABILITY AND UNCERTAINTY
IN FLOW MEASUREMENTS
USING CLAMP-ON ULTRASONIC METERS
• RECENT EXPERIENCE OF CROSSFLOW APPLICATION IN NPP
Feedwater and Reactor Coolant Flow Measurements
• AMAG’s ULTRASONIC NON INTRUSIVE CLAMP-ON
CROSSCORRELATION METER - CROSSFLOW
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….The assumption that laboratory calibration results are transferable to an in-plant configuration without additional in-plant calibration, without a complete uncertainty evaluation, and without traceability to a national standard.
Alternatively, if in-plant calibration is used to eliminate this assumption, the weaknesses of in-plant calibration without a complete uncertainty evaluation and without traceability to a national standard may remain.
Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
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TRACEABILITY AND UNCERTAINTY
Challenges of achieving Traceability in FLOW MEASUREMENTS
Challenges of achieving Traceability in FLOW MEASUREMENTS USING CLAMP-ON ULTRASONIC METERS
Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
Metering of feed-water flow, temperature and thermal power with focus on applications in nuclear power plants,, Tokyo 2007, Washington 2009, Paris 2011, Shanghai 2013
SP Workshop
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
Measurement – is Comparison of Unknown quantity with Known (Reference) Quantity
This comparison is achieved by comparing Meter's responses generated by
Reference and Unknown Inputs
Measurement – is a process of obtaining Meter’s response generated by Unknown Input
Calibration – is a process of obtaining Meter’s response generated by Reference Input
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
Calibration and Measurement
M
X
X Meter Response
Reference Mass Input
Laboratory and Real Calibration Curve
Error
R
X
X Meter Response
Reference Mass Input
Laboratory Calibration Curve
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
Traceability – FAIR comparison of the measured quantity to an accepted standard (Based on International Bureau of Weights and Measures or other equivalent agency)
Components of TRACEABILITY
Reference Quantity
Calibration of the Measurement instrument (Meter)
Measured Object
Measurement Conditions
Measurement Process
Maintaining Traceability During Long Term Operation
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Reference Flow Meter Weight
National Standard Flow Meter
Reference Flow Meter
???
Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
Flow is very sensitive to small disturbances
No Laboratory is Available to Produce Feedwater Flow Conditions
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
• Instrument calibration alone does not guaranteetraceability of measurement.
• In Power Plants other factors are present whichinfluence the measurement in various ways.
• Different instruments are affected by different factors because of the differences in measurement principles.
• Flow Characterization in terms of the Meter at the Meter Location – Key Factor in Providing Traceability
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Instruments measuring key process values have to meet a high standard of:• Traceability to Standards
Characterization of fluid dynamic conditions at the point of measurement
Design of the calibration testing to ensure traceability
Continuous self-checking to detect any changes affecting the measurement caused by changes in fluid dynamic conditions.
• Reconciliation with other plant instrumentation
Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
Flow Conditionings by the Meter
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
High Re Calibration Facility in Japan
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
Only empirical data do not provide solid basis for extrapolation.
Re Effect has to be extrapolated based on physics.
International Cooperation for Research is necessary
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
AMAG’s ULTRASONIC NON INTRUSIVE CLAMP-ON CROSSCORRELATION
METER
CROSSFLOW
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Turbulence StructureTurbulence Structure
Real Turbulence Average Model
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Turbulence StructureTurbulence Structure
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PhysicsPhysics
Approaching Eddy
Flow
Eddy Increased Ultrasound Velocity
Receiver
Transmitter
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PhysicsPhysics
•FLOW
Demodulation
A B
Cross-Correlation t
t = t0
t = t0 +t
Turbulence Patterns
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CROSS CORRELATION / TRANSIT TIMECROSS CORRELATION / TRANSIT TIME
Vm = L/ * Vm = TC2/(2Lcos )
Vm = L(T1-T2)/(2T1T2cos )
* 60ms T 1s
L
L
Alternative Technology
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Overview Overview ProductsProducts
• CROSSFLOW – Ultrasonic non-intrusive flow meter
• CORRTEMP – Ultrasonic non-intrusive temperature meter
• Algorithm and Communication Layer (ACL) – Software package for on-line monitoring and correction of Power Plant Feedwater flow and temperature instrumentation
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OverviewOverviewServicesServices
• Commissioning and operating support for CANDU power plants- Measurement of Neutron Flux distribution in CANDU
Reactor during start-up- Measuring reactor coolant flow distribution during start-
up- Measuring reactor coolant flow pump discharge and
Inner and Outer Zone flow distribution during start-up - On-line monitoring of reactor coolant flow on safety
shutdown channels during plant operation
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Correction Factor C for Straight Pipe
1
1.02
1.04
1.06
1.08
1.1
1.12
1.14
1.16
0.025 0.02
7 0.029 0.03
1 0.033 0.03
5 0.037 0.03
9 0.041 0.04
3 V*/V
1/C
Alden 96. Plastic Alden 97. Carbon Steel NIST Stainless Steel EDF 16in Sch 100 ASME Venturi Plant OH High Temperature Theory
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NIST/EPRI TEST PROGRAM NIST/EPRI TEST PROGRAM 19971997
-15
-10
-5
0
5
A B C D E F Participants
% E
rro
r
0.4 1.6 2.9Re/E6 =
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Chatou Flow Laboratory, Chatou Flow Laboratory, EDF 1998EDF 1998
Test # CROSSFLOW CHATOU Diff (%)1 1076.82 1079.46 -0.242 1077.75 1079.49 -0.163 1078.61 1079.59 -0.094 1076.73 1079.59 -0.265 1078.57 1079.56 -0.096 1080.57 1079.70 0.087 1078.99 1079.58 -0.058 1080.78 1079.59 0.119 1080.86 1079.58 0.1210 1082.73 1084.54 -0.1711 901.19 902.7 -0.1712 701.21 699.73 0.2113 589.43 590.53 -0.19
-0.070.15282
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Time Response data. NIST/EPRI Test Program 1997
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Example of Power Recovery and Power Up-rate
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OPEX: On-Line monitoring
Venturi fouling
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Ratio of ASME Nozzles Readings to Cross-Correlation Ratio of ASME Nozzles Readings to Cross-Correlation Readings for Each Pipe. OPG MaterialReadings for Each Pipe. OPG Material
F Vent uri / FUFM Rat i o
1
1. 004
1. 008
1. 012
1. 016
1. 02
1. 024
1. 028
A B C D
Ultrasonic flow meter readings are not corrected for the piping geometry
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
Characterization of fluid dynamic conditions at the point of measurement
Axial velocity profile downstream of out-of-plane elbows
22.1D 25.9D 29.1D 36.3D
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Example of Flow Characterization
14D
82
82.2
82.4
82.6
82.8
83
83.2
83.4
83.6
0 10 20 30 40 50
27D
Flow characterization maps at two locations downstream of a 90-degree bend
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Feedwater Systems Reliability Improvement MeetingSt Antonio, January 21-24, 2013
RECENT EXPERIENCE OF CROSSFLOW APPLICATION IN NPP
Reactor Coolant Flow Measurements
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CANDU RCS
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CANDU RCS
Outer Reactor Zone Header
Inner Reactor Zone Header
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RCS Flow Parameters
Pump Discharge Flow Rate – 3.2 m3/s
Pump Discharge Flow Temperature – 250
Pressure 10.2 Mpa
Pump Discharge Pipe Diameter – 22 in ID
Outer Zone Header Pipe Diameter – 18in ID
V = 13m/s
Re> 54 Mln (Common Header)
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Objective of the Project
Measurement of total Primary Heat
Transport System flow rate, and Outer and
Inner Reactor Zone flow distribution under
the following conditions:• Cold• 0% Power Hot
• Pump Trip, 3-Pumps Combination
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Approach• Objective is achieved by multiple installations of the clamp-on ultrasonic cross-correlation flowmeter CROSSFLOW (Total 4 flow transmitters are installed)
• Installations Location: – Common header pipe downstream of the PHT Pump #2 and Pump #4 – Outer Reactor Zone Loop downstream of the PHT Pump # 2 and Pump # 4
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Approach
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Methodology – Major Steps• Measurement of pipe dimensions prior to
transducers installation to obtain pipe cross-section area
• Modeling of PHT Pump Discharge flow in controlled laboratory environment with accurate and traceable reference instrumentation
• Deriving Hydraulic Factors for each transducer location for 4 pumps and 3 pumps combinations
• Verification of Plant flow traceability to laboratory testing
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Modeling of PHT Pump Discharge Flow
• Flow modeling is necessary to account for the possible effect of the pump and the Y on flow readings
• Review of possible flow test facilities and
selection of Utah University Flow Laboratory
• Scaling of PHT flow to the laboratory conditions
• Scaling Factors and modeling
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Selection of Test FacilityAlden Flow laboratory
Capable to represent real flow rate and real pipe dimensions.
Not capable to model Common Header Installation downstream of the pump
Utah State University Flow Laboratory
Scale Model of Common Header and Outer Zone Loop
Scale modeling of flow parameters
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Modeling of Pump Effect
• Pump design
• Piping configuration downstream of the pump
• Pump effect on turbulence spectrum for 4- pumps combination
• Modeling of 3-pump combination
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Test Model
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Modeling of Pump Effect
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Scaling Parameters
• Piping Geometry normalized to pipe diameter
• Pump Design – centrifugal 5 blades pump
• Flow scaling frequency Ff =U/D
• Pump Frequency Fp
• Filters Frequency F1 and F2
• Frequency Scaling Factors:
Ff/Fp; F1/Ff; F2/Ff
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Y- Modeling
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Y Model
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Modeling of 3-pump combination
Flow Driving Pump
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Benchmark Model. Modeling of Re Effect
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Testing Process and Results
Important Results
– Significant effect of the ratio of Pump Frequency with Turbulence Frequency
– Significant effect of pump mode operation– Re effect correlates with literature data for
long straight pipes – Outer Zone Loop Y effect agrees with
expectations
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Data Processing and Analysis
• Angular dependence
• AMAG Loop Testing
• Effect of Fp/Ff parameter
• Effect of pump mode operation
• Y – Effect and flow re-distribution between Inner and Outer Reactor Zones. Necessity of additional testing due to Y modeling
• Effect of Roughness on the benchmark model
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Pump RPM Effect on Calibration Factor for Outer Zone Loop
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Pump RPM Effect on Calibration Factor for Common Header
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4 Pumps OperationResults
0% Hot P2(CH) P2(OZL) P2(CH)-P2(OZL)=IZL IZL/OZL3290.17 1435.38 1854.80 1.29
0% Hot P4(CH) P4(OZL) P4(CH)-P4(OZL)=IZL IZL/OZL3339.97 1374.57 1965.40 1.43
0.985090802 1.044236862COLD P2(CH) P2(OZL) P2(CH)-P2(OZL)=IZL IZL/OZL
3954.3227 1601.822716 2352.50 1.47
COLD P4(CH) P4(OZL) P4(CH)-P4(OZL)=IZL IZL/OZL4025.464271 1732.944306 2292.52 1.320.982327105 0.924335947
IZL/OZL P2+P4
1.360
1.39
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Common Header Installation
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Outer Reactor Zone Header Installation
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0.99
0.995
1
1.005
1.01
1.015
1.02
0 1 2 3 4 5 6
Utah Lab
Bruce Pump Discharge
Alden 90-Degree
Feedwater 90-degree
• Utah Lab Pump Discharge Model
• Bruce Pump Discharge
• Alden Lab 57D Downstream of a 90-Degree Elbow
• Chernovoda Feedwater Flow 74D Downstream of 90-Degree Elbow
Flow Characterization
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Outer Reactor Zone Header
Inner Reactor Zone Header
Pump A Flow
Pump B Flow
Pump A Flow
Inner Reactor Zone Header
Outer Reactor Zone Header
Normal 4-Pumps Flow Pattern
Flow Pattern at 3-Pump Operation (Pump Trip Test)
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Smooth (Plastic) and Rough (Metal) Pipes. Lab Test
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Feedwater Lab Test and Plant
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ConclusionEstablishing traceability in flow measurement in
general, and in Feedwater particularly is a challenging problem
Determining and monitoring flow conditions at the flow sensors location is an important tool in establishing traceability/uncertainty
Clamp-on CROSSFLOW Enhanced System flow characterization capability is a powerful tool in establishing traceability/uncertainty