ML17188A267
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LR-N17-0044 LAR H17-03 2
Cameron Document ER-1132NP, Meter Factor Calculation and Accuracy Assessment for Hope Creek Nuclear Generating Station, Revision 2, (Non-Proprietary Version)
Measurement Systems Caldon Ultrasonics ER-1132NP Revision 2 March 2017 Engineering Report No. 1132NP, Rev 2 Meter Factor Calculation and Accuracy Assessment for Hope Creek Nuclear Generating Station ER-1132NP Rev 2 Prepared By: Joanna Phillips Reviewed By: Bobbie Griffith
CAMERON A Schlumbargar Company Measurement Systems
© 2016 Cameron Measurement Systems.
Any reproduction or use of these instructions, drawings, or photographs without the express written permission of an officer of Cameron is forbidden.
ER-1132NP Rev 2 All Rights Reserved.
Printed in the United States of America Engineering Report No. ER-1132NP, 2 March 2017
Preparer: JP Reviewer:
Table of Contents
1.0 INTRODUCTION
................................................................................................... 1 1.1 Scope................................................................................................................. 1 1.2 Background........................................................................................................ 1 1.3 Report Summary................................................................................................ 2 2.0 CALIBRATION TESTS.......................................................................................... 3 2.1 Meter Seup......................................................................................................... 3 2.1.1 Setup........................................................................................................... 3 2.2 Installation Site Model........................................................................................ 3 2.3 Calibration Data and Parametric Tests.............................................................. 4 2.3.1 Test Collection Procedure........................................................................... 5 3.0 METER FACTOR CALCULATION........................................................................ 5 3.1 Meter Factor Definition....................................................................................... 5 3.2 Test Results....................................................................................................... 6 3.3 Measured Velocity Profiles................................................................................. 7 3.3.1 Swirl Rate Definition.................................................................................... 8 3.3.1.1 Swirl Rate Results.................................................................................... 9 3.3.2 Flatness Ratio Definition.............................................................................. 9 3.4 Relationship between Flatness Ratio and Meter Factor................................... 10 4.0 METER FACTOR ACCURACY ASSESSMENT.................................................. 12 4.1 Facility Uncertainty........................................................................................... 14 4.2 Measurement Uncertainty................................................................................ 14 4.3 Extrapolation-Profile Variation Allowance...................................................... 14 4.4 Modeling Sensitivity Uncertainty...................................................................... 16 4.5 Data Scatter-Mean Meter Factor Uncertainty................................................ 17
5.0 REFERENCES
.................................................................................................... 18 Appendix A-Calibration Data........................................................................................
Appendix B - Meter Uncertainty......................................................................................
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ER-1132NP Rev 2, Meter Factor Calculation and Accuracy Assessment for Hope Creek Nuclear Generating Station
1.0 INTRODUCTION
1.1 Scope This report documents calibration and uncertainty analysis of the Hope Creek Nuclear Generating Station flow element S/N 4511180010-001.
This report includes:
Meter factor(s) and meter factor uncertainty Description of the hydraulic models Description of the tests conducted
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1.2 Background
Information The flow meter uses measurements of the fluid velocity projected onto acoustic paths to determine the volumetric and mass flow.
The meter makes the transit time measurements of ultrasonic energy pulses that travel between transducers and combines these with the distance separating the transducers to calculate the velocity.
The flow meter uses eight acoustic paths that are arranged as two crossing planes, each plane containing four chords (essentially two four path meters).
The meter calculates volumetric flow by numerically integrating the fluid-velocity chord length product along the chords.
It is Cameron's practice to perform a calibration test in order to determine the meter calibration constant, or meter factor. The meter factor provides a small correction to the numerical integration to account for the specifics of the fluid velocity profile as well as any dimensional measurement effects. Further, for this calibration, parametric tests were performed to determine the sensitivity of the meter factor to upstream hydraulics.
The parametric tests vary the model inlet conditions and/or piping components to vary the hydraulics.
The calibration test was performed at Alden Research Laboratories (Alden), an independent hydraulic laboratory. Alden can provide flow rates up to -4500 m3/hr
(-20,000 gpm). For these hydraulic models, the piping pressure losses and cavitation limited the calibration flow rate to -4,200 m3/hr (-18,500 gpm).
During the calibration, reference flow rates were determined by Alden using a weigh tank, fill times, fluid temperature and barometric pressure measurements. All elements of the lab measurements including weigh tank scale, time measurements, thermometers Page 1 ER-1132NP Rev 2
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and pressure gages, are traceable to NIST standards. In order to determine the meter factor, the flow meter outputs are compared against the reference flow rates.
The Hope Creek Nuclear Generating Station calibration test procedure was ALD-1164 Rev 2, which provided overall guidance for the test setup and test scope.
1.3 Report Summary
- a. Table 1.1 provides the Hope Creek Nuclear Generating Station meter factors and uncertainties when calibrated in the installation model. Refer to Section 4.0 for a detailed summary.
Table 1.1 Calibration Summary
+------
- b. [
- c. [
Table 1.2 [
1 This value is the weighted average of test data based on number of data points for each configuration.
This number is slightly different than averaging the average of the tests, since the number of data points is not equal in all tests.
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2.0 CALIBRATION TESTS The objectives for the calibration tests were to:
Determine the meter factor in a piping configuration that models the installation
- site, Determine the sensitivity of the meter factor to variations in the hydraulic model,
. [
]
2.1 Meter Seup 2.1.1 Setup The meter was installed in accordance with portions of Cameron Engineering Field Procedure EFP-68. Specifically, the portions of EFP-68 accomplished:
. [
2.2 Installation Site Model The hydraulic model configuration was designed as a hydraulic duplicate of the principle hydraulic features of the installation site (see Reference 1 for plant details). The model piping arrangement is shown in Figure 2.1 below. A photograph of the Alden Laboratories model is provided as Figure 2.2.
Charlie Alpha Figure 2.1 Hydraulic Model Page 3 ER-1132NP Rev 2 Trade I
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Figure 2.2 Header (Typical of all tests)- Hydraulic Model 2.3 Calibration Data and Parametric Tests Reference 1 outlines the model tests and parametric tests performed. These parametric tests included variations in the flow distribution [
]. With these parametric tests, installation uncertainty is addressed.
The Hope Creek Nuclear Generating Station parametric tests and calibration numbers are described below in Table 2.1. The Hope Creek Nuclear Generating Station test data is shown in Appendix A-Calibration Data. All the tests are used to determine the average meter factor to be used at the plant.
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Table 2.1 Test Summary Used in Comments Loop Test Test No.
Average MF Model test consisted of 25 we1ght tank runs over a range of different flow rates.
2.3.1 Test Collection Procedure Weigh tank testing at a specific flow rate began by setting the proper flow in the flow loop using a remotely operated butterfly valve located downstream of the model. The flow meter data is collected using a serial connection to a laptop PC. The flow data is polled by the PC from the electronics at approximately 5-second intervals. The ported information contains a time stamp and volumetric flows, as well as signal data quality, and path velocity data. Velocity data for Individual acoustic paths are recorded in order to evaluate the fluid velocity profile.
The test procedure at any given flow rate was as follows:
Set the flow rate and allow flow to stabilize Alden personnel operate weigh tank run by moving the diverter valve.
Cameron personnel separately record a start time and a stop time, as well as a complete data log from the flow transmitter for each test run. This information is used to synchronize the ported data with the weigh tank data.
3.0 METER FACTOR CALCULATION 3.1 Meter Factor Definition The meter factor accounts for (typically small) biases in the numerical integration due to the hydraulics, dimension measurements and acoustics of the application. The flow meter software multiplies the result of the multi-path numerical integration by the meter factor to obtain the flow rate. For the Alden tests, the meter factor was set at 1.000.
The meter factor is calculated by the following equation:
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Preparer: JP Where:
MF = QA!den Qmeter Reviewer:
Ometer 0Aiden
= Volumetric flow rate from meter (with meter factor set to 1.000)
= Volumetric flow rate based on Alden weight tank 3.2 Test Results Appendix A tabulates the results of the individual calibration runs. Each tab/subsection of Appendix A documents the different hydraulic configurations. All tables contain for each weigh tank run:
Alden certified flow rate Table 3.1 below summarizes the data (including velocity profile data).
Figure 3.1 plots the meter factors vs Alden recorded flows for all the tests (note: for clarity only, the average meter factor at each flow rate is plotted).
Loop Table 3.1 Meter Factors, Flatness Ratios (FR), and Swirl for Each Hydraulic Configurationz Used in Test No.
Average MF FR Swirl MF 2 Note- [
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3.3 Measured Velocity Profiles Using the flow meter it is possible to measure and understand the actual hydraulic velocity profile. Appendix A has the velocity profiles observed during each model test.
Figure 3.2 provides the velocity profile for the model test at each chord ("nominal" model only shown). The figures in Appendix A plot the velocity ratios (and differences between plans) for all the different model cases.
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Figure 3.2 Test A-1 (Model) Velocity Profile
- 3. 3. 1 Swirl Rate Definition Swirl can be measured by the flow meter. Cameron quantifies swirl rate with a swirl rate calculation, as follows:
[V1 - V5 V8 - V4 V2 - V6 Vy -V3]
Swirl Rate= Average
, 2
, 2
, 2
. 2
- Ys
- Ys
- YL
- Y1 Where:
V1, V4, Vs, Va= Normalized velocities measured along outside chords V2, V3, Ve, V? = Normalized velocities measured along inside chords ys, YL
= Normalized chord location for short and long paths Swirl rates less than 3% are low and are typically observed in models with only planar connections. Swirl rates greater than 3% are considered "swirling". Swirl rates greater than 1 0% are considered to have strong swirl.
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3.3. 1. 1 Swirl Rate Results Figure 3.3 shown below summarizes the absolute value of swirl rate observed during the calibrations.
Figure 3.3 Summary Swirl Rate for Tests 3.3.2 Flatness Ratio Definition Cameron uses the flatness ratio (FR) to quantify how flat the velocity profile is. FR is defined as:
Where:
V1, V4, Vs, Va = velocities measured along outside chords (or short paths)
Vz, V3, V6, V? =velocities measured along inside chords (or long paths)
When a velocity profile is perfectly flat, then FR equals 1.0. When a velocity profile is laminar, then the FR equals approximately 0.38. The limits of 0.38 and 1.0 represent Page 9 ER-1132NP Rev 2 Trade Secret &
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extremes. The FR is a function of Reynolds number but also is strongly influenced by the hydraulics upstream of the flow meter.
Typical feedwater applications have FR in the range of 0.78 to 0.95. Downstream of flow conditioners, the velocity profile tends to be pointier and the FR value is lower, 0. 78 to 0.82. Downstream of elbows and tees, the velocity profile tends to be flatter and the FR value is higher, 0.85 to 0.95. The actual range at a given plant is dependent upon site upstream conditions (for example, hydraulic fittings such as tees, elbows, etc). The tests are summarized in Figure 3.4 below. For the Hope Creek Nuclear Generating Station the range of FR values is [
].
Figure 3.4 Summary of Flatness Ratios for Tests 3.4 Relationship between Flatness Ratio and Meter Factor In 2002, Cameron published an analysis of velocity profiles observed in the field. In this analysis, an analytical relationship between the meter factor (MF) and the observed flatness ratio (FR) was computed. This relationship is based on integration of velocity profiles that were constructed using a power law representation. The power law velocity profile is described as follows:
u = (1 *- r)1fn Page 10 ER-1132NP Rev 2 Trade Secret &
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u r
n
=
=
=
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Velocity at any point in the pipe normalized with respect to the maximum velocity Distance from the center of the pipe as a fraction of the pipe radius Exponent term that changes the shape of the profile as a function of Reynolds number and pipe roughness This approach has been applied in a fairly large number of studies due to its simple form and good match to actual velocity profiles.
The analysis calculated profiles with values of n of between 4 and 20. This range of n covers a very wide range of Reynolds Numbers, as it has been shown that n = 6 ton=
15 covers a Reynolds number range of 4,000 to 3,200,000 (Reference 13). The analysis has shown that MF for a 4-path Gaussian integration will have a linear relationship with FR. According to Reference 2, the relationship between MF and FR should be approximately as shown below in Figure 3.5.
MF vs. Flatness Ratio* For Smooth Axi-symmetric Velocity Profiles 1.010 -.--
1.005 -
---l
'"'I' 11!111 IIII
.IIII' IIII
.Ill llill
9
- E 1.000 -------1-------+--------+-------=---"----1 0.995 ----+-------+-------+-----l
!l.99(} +----*--+---...t......-+--*----l------4 0.80 0,85 0.90 FR
().95 1.00 Figure 3.5 MF vs. FR for a 4-path Gaussian Integration of the Velocity Profile The importance of this relationship is that the minor changes in the MF observed in the different hydraulics configurations are not merely unaccountable error terms due to hydraulics, but are predictable changes that can be confirmed analytically. For Page 11 ER-1132NP Rev 2
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comparison, the average MFs for the loops are plotted in Figure 3.6 shown below (note that each meter has been offset such that the average MF lies on the "predict curve").
Figure 3.6 MF vs. FR for Calibrations 4.0METER FACTOR ACCURACY ASSESSMENT This section documents the methodology for calculating the uncertainty or accuracy of the meter factor. This report was produced using a process and quality assurance consistent with the requirements of ASME PTC 19.1 and ANSI/NCSL Z540-2-1997 (see References 6, 10, 14, and 15). The approach to determining the uncertainty is to combine the random (Type A) and systematic (Type B) terms by the means of the RSS approach given that all the terms are independent, zero-centered and normally distributed.
First, the sensitivity of the calculated flow to each independent variable or input is determined. Once the sensitivities to the independent variables have been calculated, then the independent variables' uncertainties are calculated and multiplied with their sensitivity coefficient, such as calibration facility, timing errors, etc. The 95% confidence Page 12 ER-1132NP Rev 2 Trade Secret &
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level uncertainty bounds are calculated for each element (uncertainty coverage for each term is 95% ).
The evaluation of the sensitivity coefficients is performed by determining the independent variables in the mass flow (and volumetric flow) calculation. For example, if volume flow is a function of independent variables Xi, X2,..., Xn, as follows:
The uncertainty effect of specific independent variables on the flow measurement is calculated by partial differentiation of the above equation. Expressing the result as a per unit sensitivity:
Where the terms in the brackets are the sensitivity coefficients for Xi, X2,..., Xn. The magnitudes and signs of each uncertainty for a given flow measurement are then bounded by 95% confidence intervals.
ASME PTC 19.1 demonstrates that by combining the independent uncertainty contributions as the root sum square, the overall uncertainty in volumetric flow is bounded by a 95% confidence level.
The allocation of uncertainties for meter factor for the flow meter (consistent with the Cameron Topical report) is shown in Table 4.1 below. Using the data in Table 4.1 and the root mean square summation technique indicated for combining independent uncertainties of relatively the same magnitude, the total uncertainty due to MF is computed.
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4.1 Facility Uncertainty A facility uncertainty of
] has been budgeted and this figure appears in Table 4.1 above.
4.2 Measurement Uncertainty Appendix B calculates the uncertainties in the volumetric flow measurement (excluding meter factor) of the flow meters used for this test. The results are summarized below in Table 4.2. [
For this report, a typical flow of 18,500 gpm was used.
Table 4.2 Uncertainties in Volumetric Flow Measurements 4.3 Extrapolation - Profile Variation Allowance At the plant, it is likely that the hydraulic conditions will not equal those tested during the calibration. In particular, the plant's Reynolds numbers are higher than that achievable at the laboratory (approximately 20 million vs. -2 million). Further, the plant may have a lower wall roughness than the test pipes used at the laboratory.
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The numerical calculation of meter factor is illustrated below.
Figure 4.1 MF vs Reynolds Number (Reichardt Profile)
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Figurl 4.2 FR vs. Reynolds Number (Reichardt Profile)
Using this analysis, a meter factor extrapolation of [
].
4.4 Modeling Sensitivity Uncertainty For the Hope Creek Nuclear Generating Station test, 4 different models were tested.
Using this population, the population statistics are calculated. This computation removes the mean meter factor from each meter factor test. Then these "normalized meter factors for all the tests are combined. For Hope Creek Nuclear Generating Station, a 95% confidence bound on the distribution was computed to be [
].
Alternatively, Cameron has elected to use its complete database of calibrations and hydraulic models to estimate the hydraulic variability. This approach is identical to that described in reference 17, except that today the database has a larger population of calibrated meters ([
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4.5 Data Scatter - Mean Meter Factor Uncertainty Each meter factor is computed as the average (mean) of the meter factor measurements made for that flow element. The uncertainty in mean meter factor addresses the 95% confidence limits on the uncertainty in that mean. Each set of data at a given flow rate is treated as a separate datum, since in fact the profile varies with flow rate (i.e., Reynolds Number) as shown in Section 3.2. Section 4.4 shows that meter factor is essentially independent of hydraulic configuration. Hence the precision with which the meter factor for a specific flow element is determined is enhanced by including all calibration data for that flow element. Accordingly the meter factor is determined as follows:
The calculation of the uncertainty of the mean proceeds as follows:
- a.
- b.
- c.
Using the above methodology, the uncertainty in the mean meter factor is computed to be as follows:
0
[
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5.0 REFERENCES
- 1. ALD-1164 Rev 2, Hydraulic Calibration Plan for Hope Creek Nuclear Generating Station
- 2. 2006 South East Asia Flow Workshop Paper, "The Relative Merits of Ultrasonic Meters Employing Between Two and Eight Paths", Gregor Brown, Don Augenstein, Terry Cousins, Herb Estrada
- 3. EFP-68, Commissioning Procedure for LEFMCheck Chordal Systems
- 4. EFP-55, Profile Factor Determination at a Flow Measurement Facility
- 5. Moody, L. F., "Friction Factors for Pipe Flow," ASME Transactions, V. 66, 1944, pp. 671-694
- 6. National Bureau of Standards and Technology, "Experimental Statistics Handbook 1991"
- 7. Murakami, M., Shimizu, Y., and Shiragami, H., "Studies on Fluid Flow in Three Dimensional Bend Conduits," Japan Society of Mechanical Engineering (JSME),
Bulletin V. 12, No. 54, Dec. 1969, pp. 1369-1379.
- 8. Cameron Topical Report ER-80P Rev 1, "Improving Thermal Power Accuracy and Plant Safety While Increasing Operating Power Level Using the LEFM.
Check System", March 1997.
- 11. Cameron Engineering Report ER-160P Rev 1, "Supplement to Topical Report ER 80P: Basis for a Power Uprate with the LEFM System", May 2000 *
- 12. Cameron Engineering Report ER-157(P-A) Rev. 8 and Rev. 8 Errata, "Supplement to Caldon Topical Report ER-80P: Basis for Power Uprates with an LEFM Check or an LEFM CheckPius", May 2008
- 13. Cameron Engineering Report ER 262 Rev 1, "Effects of Velocity Profile Changes Measured In-Plant on LEFM Feedwater Flow Measurement Systems", January 2002
- 14. NIST TN-1297, "Guidelines for Evaluating and Expressing the Uncertainty of NIST Measurement Results"
- 15. ANSI/NCSL 2540-2-1997, "U.S. Guide to the Expression of Uncertainty in Measurement" 16.1SO "Guide to the Expression of Uncertainty in Measurement" 17.1GHEM Flow Paper 2008 Milan, Italy, "Accuracy Validation of Multiple Path Transit Time Flowmeters"
- 18. Westinghouse Research Laboratories Nov 3, 1972, "Integration Errors for Turbulent Profiles in Pipe Flow" Page 18 ER-1132NP Rev 2
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Appendix A-Calibration Data This Appendix contains the raw data for each test. The data includes the Alden calibration period flow, the average flow during the calibration, and the computed meter factor at each flow.
No attachment to follow as Appendix is Proprietary in its Entirety ER-1132NP Rev 2
Preparer: JP Appendix B-Meter Uncertainty 8.1 -Inputs and Scaling 8.2-Flow Uncertainty 8.3-[
8.4- [
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