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Measuring Feedwater Flow with Ultrasonic Flow


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Measuring Feedwater Flow with Ultrasonic Flow Meters

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Technical Review, December 2001

EPRI Project Manager

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
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Principal Investigator or Author
R. Johnson
Additional Authors
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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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2 ULTRASONIC FLOW METERS


Ultrasonic flow meters could provide a cost effective way to improve the accuracy of feedwater
flow measurement. The basic elements of an ultrasonic flowmeter are a pair of
transmitting/receiving piezo-ceramic crystal transducers which can be mounted through the pipe
walls to form a wet interface with the liquid being metered, or attached to the external walls of
the pipe to form a dry contact. There are several different configurations of ultrasonic flow
meters that use different operating principles.

2.1 Transit Time Ultrasonic Flowmeter


In this mode of operation, ultrasonic pulses are transmitted simultaneously in the upstream and
downstream direction as shown in Figure 2-1. The upstream moving pulses from the upstream
transmitter are retarded by the flow and take longer to reach the downstream receiving
transducer, while the downstream moving pulses from the downstream transmitter are sped up by
the flow and take a shorter time to reach the upstream receiving transducer. From these elapsed
time values, the mean fluid velocity (Vp) in the path of the ultrasonic pulses can be obtained,
independent of the sonic velocity. Mathematically, this is shown as follows:
Transit time of upstream pulse
tu = λ / (C - Vp cos θ) (equation 1)
Transit time of downstream pulse
td = λ / (C + V p cos θ) (equation 2)
Re-arranging the above equations by taking the difference in transient times and eliminating C,
the result is
Vp = (    tu td cos2 θ) (equation 3)
where
λ = ultrasonic signal path length between the up- and downstream transducers
t = Difference in transit times, tu – td
L = distance along pipe surface between up- and downstream transducers,
equals λcos θ
C = apparent velocity of sound
θ = angle between the direction of flow and the ultrasonic main beam
The accuracy of the instrument depends on the precision with which the transit times can be
measured. To obtain approximately ±1% accuracy, time must be measured to within
nanoseconds (10-9 seconds) for typical feedwater pipe sizes. Transit time measurements can be
affected by electrical or acoustic noise and by variations in the received signal level.

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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.

2.2 Doppler Effect Ultrasonic Flowmeter


In this mode of operation the Doppler principle is applied. When sound waves are reflected off a
moving object, the frequency of the reflected wave is different from that of the incident wave.
The shift in frequency is proportional to the velocity component of the object parallel to the
acoustic beam.
f = 2 ft (V / C) cos θ (equation 4)

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.

2.3 Cross-Correlation Ultrasonic Flowmeter


The cross-correlation technique makes use of the natural or induced disturbances existing in the
flow (e.g. turbulent eddies, density variations, or particulates). Two transverse, parallel beams of
ultrasound a known distance apart on the pipe, are directed diametrically across the flowing
medium Figure 2-3. As the disturbances pass through these beams, the signals as received by the
receivers will be modulated. By using suitable instrumentation, the modulations in the two
beams can be cross-correlated to track the passage of the disturbances and thus determine the
mean fluid velocity.
The cross-correlation flowmeter requires a substantial amount of averaging to get repeatable and
accurate readings due to the statistical nature of the signal modulating phenomena. It is a
relatively new method and is still under development.
Ultrasonic flowmeters should be installed in straight section of pipe and more than 10 diameters
away from any upstream bends so that the velocity profile is fully developed. They have been
used to measure liquid flow rates of up to 86,000 US gal/min and are able to operate under high
pressure and temperatures. Typical accuracies claimed for the transit time flowmeter are between
0.25% and 2% of actual flow, depending on whether the probe is in intimate contact with the
                     
correlation meter is similar.

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2.4 Suitability for Feedwater Flow Measurement


Both the transit time and the cross-correlation ultrasonic methods have been used for feedwater
flow measurement. Several U.S. utilities have used the transit time method to check the
calibration of their venturi meters. Dry type (or clamp on) ultrasonic transmitters do not require
any maintenance. Wetted type ultrasonic transmitters are susceptible to fouling and need to be
cleaned at regular intervals.

Figure 2-1: Principle of Transit Time Ultrasonic Flowmeter

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Figure 2-2: Arrangement of Multi-Path Ultrasonic Flowmeter

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Figure 2-3: Principle of Cross-Correlation Ultrasonic Flow Meter

2.5 Advantages of Ultrasonic Flowmeters


There are several advantages that ultrasonic flow meters provide over differential pressure
devices. Clamp-on assemblies do not require any penetrations into the pipe. Several transducers
can be combined to create a multi-path flow-meter that can determine the shape of the flow
profile. A significant advantage of a multi-path arrangement is that since the flow profile can be
determined, the flow meter can be installed in locations where the flow profile is not fully

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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.

2.6 Use of Ultrasonic Flowmeters in the Fossil Power Industry


Although there can be significant advantages of ultrasonic flow meters over differential pressure
devices, they are still not used for feedwater flow measurement in the fossil industry. The
commercially available flowmeters used in the nuclear industry are high cost systems. In the
nuclear industry, the use of these meters has resulted in an easily quantifiable benefit, increased
power output from the unit. However, for fossil plants, the benefits of a more accurate feedwater
flow measurement are not as easily quantified. Heat rate is usually not an emphasis in fossil plant
since in many cases fuel costs are passed through to the customer. This reduces the value of
accurately measuring the efficiency of a unit. In addition, strict legal requirements to maintain
feedwater flow under a given level do not exist as in the nuclear power industry. Therefore,
simply installing a new flowmeter will not help a fossil unit increase its power output.

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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.

2.7 NIST/EPRI Study of Ultrasonic Flowmeters


EPRI was an industrial partner in a consortium with the U.S. Commerce Department’s National
Institute of Standards and Technologies (NIST) [10] to study the accuracy of single-path, clamp-
on ultrasonic flowmeters. The intent of the study was to evaluate the accuracy of clamp-on
ultrasonic flowmeters with the ultimate goal of improving feedwater flow accuracy at a reduced
cost. One way this goal could be achieved is to develop a transfer standard that could be
transported from unit to unit to maintain the calibration of existing feedwater flow nozzles.
Phase 1 of the NIST study evaluated single pairs of clamp-on ultrasonic flowmeters from six
different vendors in a laboratory flow facility. The results of the study were promising, some of
which include:
1. The participant meters produced averaged accuracies in the range from 0 to +3%
2. Repeatabilities were mostly in the range from 0.1% to 0.2%
3. Reproducibilities ranged up to 3%, but three units were bounded by 1%.

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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Bibliography & References


1. L.C. Lynnworth, Ultrasonic Measurement for Process Control, Academic Press, San Diego,
CA. 1989.
2. Richard W. Miller, Flow Measurement Engineering Handbook, Third Edition. 1996.
3. Measurement of Fluid Flow in Pipes Using Orifice Plates, Nozzle and Venturi, ASME MFC-
3M-1989, ASME, New York, NY. 1989.
4. Power Test Code 6 on Steam Turbines, PTC 6-1996, ASME, New York, NY. 1996.
5. Measurement Uncertainty, ANSI/ASME PTC 19.1-1985, ASME, New York, NY. 1985.
6. Measurement of Fluid Flow by Means of Pressure Differential Devices—Part 1: Orifice
Plates, Nozzles and Venturi Tubes Inserted in Cross-Section Conduits Running Full, ISO
5167. 1991.
7. Survey and Characterization of Feedwater Venturi Fouling at Nuclear Power Plants, Volume
1: Feedwater Venturi Fouling, EPRI, Palo Alto, CA: May 1992. TR-100514.
8. Feedwater Flow Measurement in U.S. Nuclear Power Generation Stations, EPRI, Palo Alto,
CA: November 1992. TR-101388.
9. Nuclear Feedwater Flow Measurement Application Guide, EPRI, Palo Alto, CA: July 1999.
TR-112118.
10. NIST Ultrasonic Technology Assessment Program to Improve Flow Measurement, EPRI,
Palo Alto, CA: October 1998. TR-111311.

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