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Measuring Feedwater Flow with Ultrasonic Flow Meters
1004582
Ramesh Shankar
EPRI • 3412 Hillview Avenue, Palo Alto, California 94304 • PO Box 10412, Palo Alto, California 94303 • USA
800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com
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CITATIONS
This document was prepared by
EPRI I&C Center
714 Swan Pond Road
Harriman, TN 37748-8327
Principal Investigator or Author
R. Johnson
Additional Authors
P. Wolff
C. Taft
This document describes research sponsored by EPRI.
The publication is a corporate document that should be cited in the literature in the following
manner:
Measuring Feedwater Flow with Ultrasonic Flow Meters, EPRI, Charlotte, NC: 2001. 1004582.
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ABSTRACT
Accurate measurement of feedwater flow in fossil plants is necessary to quantify the turbine
cycle heat rate of the plant, which is a major component of the overall plant efficiency.
Traditional methods for flow measurement are being replaced by low-cost and potentially more
accurate methods that rely on ultrasonic technology—high frequency sound waves. This report
discusses ultrasonic flowmeter measurement methods and their potential for application at fossil
power plants.
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CONTENTS
1 INTRODUCTION..................................................................................... 1-1
2 ULTRASONIC FLOW METERS............................................................. 2-1
2.1 Transit Time Ultrasonic Flowmeter .................................................................. 2-1
2.2 Doppler Effect Ultrasonic Flowmeter ............................................................... 2-2
2.3 Cross-Correlation Ultrasonic Flowmeter .......................................................... 2-2
2.4 Suitability for Feedwater Flow Measurement................................................... 2-3
2.5 Advantages of Ultrasonic Flowmeters ............................................................. 2-5
2.6 Use of Ultrasonic Flowmeters in the Fossil Power Industry............................. 2-8
2.7 NIST/EPRI Study of Ultrasonic Flowmeters..................................................... 2-9
2.8 EPRI Efforts for Continued Improvement with Feedwater Flow
Measurement ......................................................................................................... 2-9
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LIST OF FIGURES
Figure 2-1: Principle of Transit Time Ultrasonic Flowmeter .................................................... 2-3
Figure 2-2: Arrangement of Multi-Path Ultrasonic Flowmeter................................................. 2-4
Figure 2-3: Principle of Cross-Correlation Ultrasonic Flow Meter ........................................... 2-5
Figure 2-4: Commercial Available Transit Time Meters (Courtesy: Controlotron,
Corporation)............................................................................................................................ 2-7
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1 INTRODUCTION
Accurate feedwater flow measurement is important for evaluating the performance of both
nuclear and fossil units. Ultrasonic methods to measure process flow [1,2] have been used widely
in other industries and are being utilized today in the nuclear industry to improve performance
and justify increases in reactor power [8,9]. A one percent error in feedwater flow measurement
produces a corresponding one percent error in the measured heat rate, which in turn has
important operating and maintenance implications. For example, if the maximum power output
of a unit decreases, and the feedwater flow measurement of the unit is inaccurate, it is extremely
difficult to determine whether the power output has decreased due to reduced feedwater flow, or
the power reduction is a result of unit deterioration. The importance of understanding causes of
reduced power output is especially timely, since every additional megawatt-hour a unit generates
may now be sold at prices that were unheard of a few years ago.
The standard approach for measuring feedwater flow is with a differential pressure flow meter.
Two commonly used configurations are nozzles and venturis. An obvious advantage of these
devices is that they are very accurate and widely used. When the test protocol outlined by ASME
PTC 6.0 [4] is followed, a flow nozzle has a stated uncertainty of 0.15 % of the reading.
Although, the initial accuracy of these devices can be very good, maintaining such high accuracy
over a longer term is difficult and expensive. Most feedwater flow nozzles are welded into the
piping system and do not contain inspection ports to examine and if necessary clean the nozzle.
This is important since contaminants in the feedwater can form deposits on the nozzle and
significantly reduce its accuracy. If performance engineers want to recalibrate a nozzle, it may
require asbestos removal. If the flow nozzle is located after the boiler feedpumps, removal and
reinstallation require modification to high-pressure piping. As a result of these difficulties, very
few fossil units have feedwater flow measurements with reliable calibration.
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A major disadvantage of the transit time ultrasonic flowmeter is that it only measures the mean
fluid velocity along a single straight line path and this is not equal to the average fluid velocity
across the whole pipe area. One way to overcome this is by using multiple chordal paths as
shown in Figure 2-2. A “weighting” technique can then be used to ensure that the area integral of
the velocity distribution over the pipe cross-sectional area is represented realistically by the finite
number of ultrasonic sampling paths used. The optimum number of paths and their spacings,
however, have to be chosen carefully.
where ft is the frequency of the incident beam, V is the mean fluid velocity, θ is the beam angle
and C is the speed of sound.
The Doppler effect utrasonic flowmeter therefore works by measuring the velocity of scattered
particles, such as air bubbles in the liquid. The accuracy depends upon various factors such as
flow profile and the nature, number, size and spatial distribution of the scattering particles.
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developed. This reduces the need to have extremely long straight runs of pipe which are required
for differential pressure devices.
The nuclear industry has benefited a great deal from the use of ultrasonic flow meters. In nuclear
plants the power produced in the reactor core must be accurately determined and tightly
controlled to ensure safe plant operation. Feedwater flow measurement is one of the key
measurements required to compute reactor power output. Originally, venturi flow meters were
commonly used. However, in some cases contaminants in the feedwater flow produced deposits
on the venturi meters which caused the flow meter to be biased to measure too high. This in turn
required that the power output of the unit was reduced to maintain the computed reactor power at
the required limit. These unnecessary power reductions ranged from 1-2 percent. Ultrasonic flow
meters are much less sensitive to fouling and have been used to recover lost megawatts.
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Figure 2-4: Commercial Available Transit Time Meters (Courtesy: Controlotron, Corporation)
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In any type of ultrasonic flowmeter, a key step in computing flow rate is in the assumption of a
flow profile. If the flow profile were precisely known, then the total flow could be accurately
computed by measuring the velocity over a single path. However, in many cases the flow profile
is not precisely known and must also be determined. Herein lies a key advantage of ultrasonic
flowmeters over differential pressure devices. Multi-path ultrasonic flowmeters can be
configured to measure velocities over several different paths. This in turn provides information
concerning the flow profile, which can be used to improve the accuracy of flow measurement
when the flow profile is not known a priori.
Measuring the flow over several paths is essential for determining the flow profile when it is not
well known. It may also be important for measuring flow in nuclear and fossil plants. There are
currently no laboratories with flow calibration facilities capable of producing flow rates that
match feedwater flow Reynold’s numbers typically found in fossil and nuclear units. The nozzles
are therefore calibrated at lower Reynold’s numbers and results are extrapolated to match actual
flow conditions. Again, one of the key assumptions is that the flow profile for the laboratory
calibration matches the actual flow profile exactly. It is difficult to verify this since flow
calibration facilities cannot reproduce the actual flow conditions. Multi-path ultrasonic
flowmeters may provide enhanced accuracy since the measurements can be used to evaluate the
flow profile.
A feature of ultrasonic flowmeters that has benefited the nuclear industry a great deal is that they
are not affected by fouling. In nuclear plants the power produced in the reactor core must be
accurately determined and tightly controlled to ensure safe plant operation. Feedwater flow rate
is one of the key measurements required to compute reactor power output. Originally, venturi
flowmeters were commonly used. However, in some cases, contaminants in the feedwater flow
produced deposits on the venturi meters, which caused the flowmeter to read too high. This in
turn required that the power output of the unit be reduced to maintain the computed reactor
power at the required limit. These unnecessary power reductions ranged from 1-2 percent.
Ultrasonic flowmeters are much less sensitive to fouling and have been used to recover lost
megawatts.
An additional advantage of ultrasonic flowmeters is that they are easily configured to be non-
intrusive. Flow nozzles and venturis must create a differential pressure to measure flow, which
creates energy losses across the flow measuring section. Non-intrusive ultrasonic flowmeters do
not create energy losses.
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Although the benefits for fossil power plants may not be as clear, there is little doubt that
improved feedwater flow measurement would improve operation and maintenance of fossil
plants. If the cost of this technology were reduced, it is likely that it would be widely used in
fossil units.
This study shows that clamp-on ultrasonics may provide a reliable flow measurement technique.
Subsequent phases of this study were not completed due to insufficient utility interest. One of the
planned phases was to evaluate ultrasonic flow meters, against a standard, in a feedwater flow
measurement on a fossil unit.
2.8 EPRI Efforts for Continued Improvement with Feedwater Flow Measurement
Ultrasonic flow measurement technology offers potential for power generators to improve
productivity with improved flow measurement. Although the technology is well developed, more
research and testing is required to evaluate their applicability to feedwater flow measurement in
fossil plants.
An EPRI host solicitation was published in 2000 announcing plans for establishing an interest
group for demonstrating and testing ultrasonic flow measurement technology. Interested persons
can obtain a copy of the solicitation from their EPRI Customer Services Representative.
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