In-Situ Level Sensor Calibration Chamber for Nuclear Reactors

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Solution Overview

Problem

In industrial plants, particularly nuclear power plants and small modular reactors, level sensors face challenges in in-situ calibration and response time testing due to harsh environments and impracticality of removing sensors for laboratory testing, leading to potential performance degradation.

Innovation Solution

A chamber system with upper and lower penetrations allows for in-situ calibration and response time testing of level sensors by connecting reference sensors and noise generators, enabling continuous measurement and dynamic performance analysis without removing the sensor assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If level sensor guide rod or thermal dispersion probe is removed from installation for periodic calibration and response time testing in a laboratory, then calibration and response time verification can be performed, but it is time-consuming and impractical especially in SMRs

Engineering Contradiction:

Improvelevel sensor calibration and response time verificationVSAvoidtime required for sensor removal and laboratory testing

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

A test chamber is introduced as an intermediary device that can be connected to the level sensor assembly in-situ. The chamber allows calibration and response time testing to be performed without removing the sensor from its installation, thereby resolving the contradiction between verification reliability and time loss.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If level sensor assembly is removed from installation for testing, then calibration and response time testing can be performed, but it is difficult based on probe length, surrounding plant architecture, shipping and handling constraints

Engineering Contradiction:

Improvelevel sensor calibration and response time verificationVSAvoidease of sensor removal and handling

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The test chamber serves as an intermediary that remains at the installation location, eliminating the need to remove and transport the sensor assembly. This resolves the contradiction by performing testing in-situ, avoiding shipping and handling constraints.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The testing function is extracted from the sensor assembly itself and placed into a separate, portable test chamber. This allows the chamber to be moved to the sensor location without moving the sensor, resolving the handling difficulties.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If level sensors are installed in harsh industrial plant process environments, then they can measure fluid level in process, but they are vulnerable to calibration and/or response time degradation over time

Engineering Contradiction:

Improvecontinuous level measurement capabilityVSAvoidsensor calibration and response time stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The test chamber enables periodic calibration and response time testing to be performed in-situ without shutting down the plant. This resolves the contradiction by allowing continuous productivity while maintaining reliability through regular testing cycles.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The sensor continues to perform its useful function of level measurement continuously while the test chamber allows periodic verification of its performance. This maintains both productivity and reliability simultaneously.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates efficient and continuous verification of level sensor calibration and response time, reducing downtime and handling challenges, applicable to various level sensor technologies in harsh industrial environments.

Implementation Method 1

GWR systems use time domain reflectometry (TDR) technology to measure fluid level by transmitting a high-frequency electromagnetic traveling wave down the length of a guide probe inserted into a process

Methodology Applied

Scientific EffectTime domain reflectometry (TDR):

Implementation Method 2

Thermal dispersion based level sensors operate on the principle of heat transfer between an electrically heated sensor probe and the surrounding process

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

One or more of these RTDs or resistive electrical wires may be Joule-heated, and the resulting heat generated within the probe is dissipated to the surrounding process

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11346702B2Methods and apparatus for calibration and response time testing of level sensors

Publication Date: 2022.05.31 ANALYSIS & MEASUREMENT SERVICES CORP

AI summary

Systems and methods of diagnosing performance of a level sensor of a fluid test chamber, including a data acquisition and processing unit configured to receive output signals of one or more level sensors that are installed to a fluid chamber, the data acquisition and processing unit being configured to connect to the one or more level sensors to record and process the output signals to test operation of the one or more level sensors.