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IGORR 2014
Development of Equipment for Simulating
Coolant Flow in a Test Rig
18 Nov. 2014
J.T. Hong, J.B. Kim, S.H. Heo, C.Y. Joung, S.H. Ahn
Dept. of HANARO Utilization & Research, KAERI
Contents
Introduction of FTL in HANARO
Design of flow meter in the test rig
Development of coolant flow simulator
Calibrate the flow rate of coolant
Concluding remarks
Reactor structure & Characteristics of HANARO
3 /21
Features
Type
Open-tank-in-pool
Power
30 MWth
Coolant
Light Water
Reflector
Heavy water
Fuel Materials enriched
U3Si, 19.75%
Absorber
Hafnium
Reactor Building
Confinement
Max Thermal Flux
5x1014 n/cm2s
Typical flux at port nose
2x1014 n/cm2s
7 horizontal ports & 36 vertical holes
Vertical hole for cold neutron source
Operation Cycle
24 days@5 weeks
Necessity of Test Loop
4 /21
Capsule irradiation test without instrumentation
Not same condition with general nuclear power plants (15.5MPa, 300℃)
Limited data, difficult to analyze the performance of the test fuel
Reactor Pool
No history
Fresh
fuel rod
Irradiated
fuel rod
Establish a FTL(Fuel Test Loop) facility at HANARO in 2007
Fuel Test Loop Facility (1/2)
Schematics of FTL in HANARO
5 /21
Fuel Test Loop Facility (2/2)
6 /21
Fuel & material irradiation test under the same condition with
NPP’s steady state operating condition
Applications
Integral Fuel Irradiation Tests
Fuel Qualification Tests
High Burn-up Fuel Tests
Water Chemistry and Corrosion Tests
In-Pile test Section
Out-of-Pile System(Room#1)
Out-of-Pile System(Room#2)
3D modeling of FTL
In-Pile Section
► Design Pressure : 17.5 MPa
► Design Temperature : 350 ℃
Core technology for fabricating test rig
Fuel pellet drilling machine
Automatic TIG welding system
Automatic laser welding system
Brazing & Graphite sealing technique
7 /21
Difficulty in Coolant Flow Measurement
8 /21
Need to measure the heat generation rate of nuclear fuels
Outlet
Nozzle
Heat generation rate of nuclear fuels ( 𝑸𝒇𝒖𝒆𝒍 )
: Heat flux that coolant absorbs while passing though
the fuel rod.
Inlet
Nozzle
𝑸𝒇𝒖𝒆𝒍 = 𝝆𝒄𝒐𝒐𝒍𝒂𝒏𝒕 ∙ 𝑪𝒑 ∙ 𝒗𝒄𝒐𝒐𝒍𝒂𝒏𝒕 ∙ 𝑨 ∙ (𝑻𝟐 − 𝑻𝟏 )
𝑣𝑐𝑜𝑜𝑙𝑎𝑛𝑡
flow velocity of coolant
Test
Fuels
𝑇2
Q
Flow
divider
𝑇1
temp. deviation
Temperature deviation
: Measure with K-type TCs in the test rig
Flow velocity
: Difficult to measure in the test rig
: Measuring at the pipeline of the test loop is not accurate
(ex: head loss, internal leakage)
Spatial limit of the test loop in HANARO
9 /21
Decided to implement turbine FM and noise analysis technique
HANARO is an open-pool-type reactor
Test rig is assembled to PV assy in IR-1 hole
Hard to install general flow meters in the IPS
Measure flow rate in the test rig
using turbine FM, Noise analysis
Put the test rig into the irradition hole
Fix the test rig to the pressure vessel installed in the IR-1 irradiation hole
Modification of IPV design to install turbine FM
10 /21
Add turbine flow meter at the inlet of coolant to the fuel rod
Tachometer
① inner pressure vessel
② turbine flow meter
Assembly drawing of IPV and turbine FM
Flow measurement using noise analysis
Calculate flow rate using the phase difference of signals
Process signals of TCs using filters and amplifiers
Obtain time deviation between two TCs by cross correlation method
TC1
Channel
TC2
•
•
x1
x2
TC1
Amp
High pass
Filter
Low Pass
Filter
𝑉𝑓𝑙𝑜𝑤
𝑉𝑓𝑙𝑜𝑤
𝜋𝐷2
=
×𝑣
4
𝑥2 − 𝑥1
𝑣=
𝑡
Data
Acquisition
Cross Correlation
TC2
Amp
High Pass
Filter
Low Pass
Filter
Data
Acquisition
∅𝑠1 𝑠2 𝜏 = 𝐸 𝑠1 𝑡 − 𝜏 𝑠2 (𝑡)
※ Flow property should not be changed by obstacles  uniform cross section
11 /21
Fabrication process of test rig mockup
12 /21
Fabricate a test rig mockup with TCs for noise analysis
Position of k-type thermocouples
Mock up of the dual cooled fuel test rig
Distance between TCs : 380 mm
Sequence of assemble the IPS mockup
13 /21
Inner pressure vessel (IPV)
Turbine flow meter
Outer pressure vessel (OPV)
IPV assy
Assemble turbine flow meter
Assemble IPV assy with OPV
DCF test rig
IPS
head
Assemble IPS head with OPV
Install DCF test rig
Assembly of test rig mockup which includes turbine flow meter
P&I diagram for coolant flow simulator
14 /21
Need a simplified simulator with a laboratory scale
 Instrument 3 TCs, 2 manometers, 2 FMs in the pipeline
 Apply the impeller type pump (max 2.0 kg/sec) to minimize pulsation of coolant
 Bypass line to survey flow rate in calibrating flow meters
Bypass line
IPS
mockup
P-120
Impeller type pump
Development of the coolant flow simulator
15 /21
Coolant flow simulator to control and calibrate flow rate
 3-way valve turns the flow path
 Calibrate float type FM and digital FM by comparing bypassed amount of coolant
3-way valve
manometer
bypass line
Coolant tank
Control
panel
IPS
mockup
Circulation
Bypass
Float type
flow meter
Digital
flow meter
Data Acquisition
Board Panel
Pump (impeller type)
Setup of coolant flow simulator
Circulation of coolant
Calibration process of flow meters
16 /21
Bypass and store the coolant in the subsidiary tank (60 sec)
 Float type flow meter: Poor accuracy at low flow rate
 Digital flow meter: Constant error rate (Ave. 2.5%)
bypass valve
Set
90
110
130
Bypassed
Float type
coolant,bypass lineflow meter,
LPM
LPM
Data
Error
77.0
87
12.99%
78.0
87
11.54%
78.0
87
11.54%
105.3
108
2.56%
105.0
107.5
2.38%
106.5
108
1.41%
Subsidiary
129.5
130
0.39%
tank
123.5
128
3.64%
125.0
128
2.40%
Digital
flow meter,
LPM
Data
Error
79.3
2.90%
79.15
1.45%
80.51
3.12%
107.80
2.32%
107.34
2.18%
109.87
3.07%
132.30
2.12%
127.07
2.81%
128.62
2.81%
Calibration of digital FM and turbine FM
17 /21
Difference between digital and turbine FM : 17.5%
Steady flow at 80, 100, 120 liter/min
Set
80 liter/min
100 liter/min
120 liter/min
Digital flow meter (calibrated)
76.68
77.07
77.47
96.45
96.75
97.82
115.93
115.45
115.84
Turbine flow meter
Error (%)
63.64
64.27
65.21
78.64
79.27
80.1
96.04
94.79
94.9
17.01%
16.61%
15.83%
18.47%
18.07%
18.11%
17.16%
17.90%
18.08%
Unsteady flow from 0 ~ 120 liter/min.
Before calibration
Digital FM
Turbine FM
Flow rate (Liter/min.)
Flow rate (Liter/min.)
17.5%
error
Digital FM
Turbine FM
After calibration
Development of DAS for Noise Analysis
18 /21
Develop hardware for data acquisition and transformation
 Process temperature signals at the control board
Eliminate DC component
Extract fluctuation signals
Temperature signal  Amplify  HPF  Amplify  LPF
Data Acquisition
Control board
AD conversion
[Data Acquisition system]
[Control board]
 After AD conversion, save fluctuation signals for 15 min. (with 100 Hz)
Calculate phase shift between fluctuation signals
19 /21
Program cross correlation using Labview 2013
 After cross correlation, obtain phase shift of two fluctuation signals
𝑝ℎ𝑎𝑠𝑒 𝑠ℎ𝑖𝑓𝑡
 𝑠ℎ𝑖𝑓𝑡 𝑡𝑖𝑚𝑒 𝑡 =
𝑟𝑒𝑔𝑖𝑠𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦
Labview 2013
Flow rate obtained by noise analysis
20 /21
Compare theoretical elapsed time and noise analysis
D=48
d=30
𝑉𝑐𝑜𝑜𝑙𝑎𝑛𝑡
•
L=380
TC1
Flow rate of coolant (𝑉𝑐𝑜𝑜𝑙𝑎𝑛𝑡 )
TC2
•
𝐴𝐿 𝜋(𝐷2 − 𝑑 2 ) ∙ 𝐿
=
=
∆𝑡
4 × ∆𝑡
When, 𝑉𝑐𝑜𝑜𝑙𝑎𝑛𝑡 is Q liter/min.
𝑄 × 106
𝑉𝑐𝑜𝑜𝑙𝑎𝑛𝑡 =
[𝑚𝑚3 /𝑠𝑒𝑐 ]
60
𝜋 × (482 − 302 ) × 380 × 60
∆𝑡 =
4 × 𝑄 × 106
[𝑠𝑒𝑐]
Digital FM
Theoretical elapsed time
Noise analysis
Error
80 liter/min.
0.314 sec
0.62 sec (40.55 liter/min.)
49.3%
120 liter/min.
0.210 sec
0.38 sec (66.16 liter/min.)
44.9%
 Proportional relation
0.314 0.62
Theoretical elapsed time: Noise analysis =
:
= 1.495:1.631 = 91.7%
0.21
0.38
Concluding Remarks
21 /21
Introduce FTL in HANARO and development of core technologies
Design turbine flow meter and noise analysis to measure flow rate
D Development of coolant flow simulator and calibrate FMs
D Implement the noise analysis technique using the signals from TCs
Need to improve measurement accuracy of noise analysis
and prepare in-pile test
THANK YOU FOR YOUR
ATTENTION