Feedwater Systems Reliability Improvement Meeting St Antonio, January 21-24, 2013

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


• 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

….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.


TRACEABILITY AND UNCERTAINTY

Challenges of achieving Traceability in FLOW MEASUREMENTS

Challenges of achieving Traceability in FLOW MEASUREMENTS USING CLAMP-ON ULTRASONIC METERS


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


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


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


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

Reference Flow Meter Weight

National Standard Flow Meter

Reference Flow Meter

???


Flow is very sensitive to small disturbances

No Laboratory is Available to Produce Feedwater Flow Conditions


• 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

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



Flow Conditionings by the Meter


High Re Calibration Facility in Japan


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


AMAG’s ULTRASONIC NON INTRUSIVE CLAMP-ON CROSSCORRELATION

METER

CROSSFLOW

Turbulence StructureTurbulence Structure

Real Turbulence Average Model

Turbulence StructureTurbulence Structure

PhysicsPhysics

Approaching Eddy

Flow

Eddy Increased Ultrasound Velocity

Receiver

Transmitter

PhysicsPhysics

•FLOW

Demodulation

A B

Cross-Correlation t

t = t0

t = t0 +t

Turbulence Patterns

CROSS CORRELATION / TRANSIT TIMECROSS CORRELATION / TRANSIT TIME

Vm = L/ * Vm = TC2/(2Lcos )

Vm = L(T1-T2)/(2T1T2cos )

* 60ms T 1s

L

L

Alternative Technology

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

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

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

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 =

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

Time Response data. NIST/EPRI Test Program 1997

Example of Power Recovery and Power Up-rate

OPEX: On-Line monitoring

Venturi fouling

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


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

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


RECENT EXPERIENCE OF CROSSFLOW APPLICATION IN NPP

Reactor Coolant Flow Measurements

CANDU RCS

CANDU RCS

Outer Reactor Zone Header

Inner Reactor Zone Header

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)

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

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

Approach

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

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

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

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

Test Model

Modeling of Pump Effect

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

Y- Modeling

Y Model

Modeling of 3-pump combination

Flow Driving Pump

Benchmark Model. Modeling of Re Effect

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

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

Pump RPM Effect on Calibration Factor for Outer Zone Loop

Pump RPM Effect on Calibration Factor for Common Header

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

Common Header Installation

Outer Reactor Zone Header Installation

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



Pump A Flow

Pump B Flow

Pump A Flow



Normal 4-Pumps Flow Pattern

Flow Pattern at 3-Pump Operation (Pump Trip Test)

Smooth (Plastic) and Rough (Metal) Pipes. Lab Test

Feedwater Lab Test and Plant

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

Feedwater Systems Reliability Improvement Meeting St Antonio, January 21-24, 2013

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Transcript of Feedwater Systems Reliability Improvement Meeting St Antonio, January 21-24, 2013