ENGINEERING RESEARCH INSTITUTE UNIVERSITY OF MICHIGAN ANN ARBOR Final Report CALIBRATION OF ORIFICE-ASSEMBLY CONDENSER-PUMP DISCHARGE HEADER AS SHOWN BY DETROIT EDISON COMPANY DRAWING 5P515-254 FOR RIVER ROUGE POWER PLANT UNIT No. 1 by R. C. Porter Project 2339 THE DETROIT EDISON COMPANY DETROIT, MICHIGAN July 1955

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN ABSTRACT This report includes graphic and tabular results from the calibration of the subject orifice assembly, relating the A.S.M.E. flow coefficient K to Reynolds' number at the orifice diameter. These results are reported separately for the two diametrically opposite sets of pressure taps provided in the assembly. Also included are orifice and pipe line diameters and pressure tap locations as measured, and a description of the apparatus and procedures. OBJECTIVE The objective of this project was to determine the A.S.M.E. flow coefficient K in relation to Reynolds' number for the condenserpump discharge orifice for Unit No. 1 of the River Rouge power plant of the Detroit Edison Company. -_ _ _ _ _ _ _ _ _ _ _ __.ii

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ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN TABLE OF CALIBRATION RESULJTS Reynolds' Number A.S.M.E. Flow Meters Coefficient K at Orifice Diam For Taps For Taps 4* 100,2000 1B55 and. 1B56 1B57 and. 1B58 5.50 0.6187 o.6184 4.51 0.6190 0.6193 5.o8 0.6184 o.6185 5.10 0.6188 0.6188 6.025 0.6194 0.6201 7.45 0.6169 0.6167 7.76 0.6176 0.6179 8.13 0.6200 0.6202 8.84 0,.6172 0.6162 9.54 0.6177 0.6201 10.72 0.6192 0.6176 10.79 0..6174 0.6163 12.26 0.6170 0.6175 12.65 0.6189 0.6182 12.68 0.6207 0.6212 15.14 0.6188 0.6185 13.63 0.6169 0.6176 15.94 0..6185 o.6185 14.55 0.6175 0.6169 14.80 0.6206 0.6198 15.06 0.6200 0.6191 15.65 0.6189 0.6178 16.15 0.6225 0.6255 16.57 0.6187 0.6192 17.05 0.6208 0.6190

ENGINEERING RESEARCH INSTITUTE* UNIVERSITY OF MICHIGAN / ~~~~~Df G.0745 caznioz D?.00Y45 De4. *.0745 Dgm 12*015 ~~~~Dir 12.003 Dr 110969 De~~~P3 11.,80 120017 Dl~~~~~~~~w 12.*033 -4- X n 1 WV1 _ _ _ - -o~~~~~~~~~Q

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN EQUIPMENT The equipment is diagrammatically illustrated on page 6. A variablespeed motor-driven centrifugal pump rated at 5000 gpm against 50 feet head of water served as the water circulator. A laboratory pit was used as a sump for the pump intake and weigh-tank discharge. Flow rate was controlled by means of the variable-speed pump and the 12-inch gate valve located immediately downstream from the orifice assembly line. The 39,000-lb-capacity weigh tank was mounted on Fairbanks-Morse scales with a beam rating of 50,000 lb. The dump valve at the bottom of the weigh tank was compressed air operated through long, flexible hose connections. Effective dump-valve leakage was reduced to zero by means of a drip return gutter and return pump mounted on the scales integrally with the weigh tank. Pot-type mercury manometers of 60-inch range, as manufactured by King Engineering Corporation, were located entirely below the level of the orifice assembly line for measuring the pressure differentials across the orifice. The gage lines were liberally provided with risers and vent valves for assurance against air collection in the lines. Conventional stop watches were used for timing the water collection in the weigh tanks. PROCEDURE PRELIMINARY WORK During the first calibration attempt, an accumulation of rust scale inside the laboratory's permanent piping flaked off and damaged the original orifice to the extent that it became necessary to recondition the orifice before calibrating it. The Detroit Edison Company did the necessary reconditioning, slightly increasing the orifice diameter to provide a new sharp edge. All pipe lines and the associated hydraulic system were thoroughly cleaned before the orifice was remeasured and replaced for calibration. A large screen was placed around the intake of the pump to guard against further damage from external sources of foreign matter. CALIBRATION OF EQUIPMENT The weigh-tank scales were calibrated by the State of Michigan's Division of Weights and Measures and- sealed accordingly on May 24, 1955. With 5

d 11 m I through 12 ar air vents.... B Coo'l Orifioe Assembly Z D Dog1 31 1 7' oxt~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~~2 Gato Valve I r; -- 1~ r I as~/ I r l l l~O~rificeEl -l ml 6 Weigh Tank, _. l" I359,1000-1b o0~ ]\ w ith air- / m Variable- Opoo;A b,000 an at W- t No" *. OroGrte Pit._ __L 1- la 0 Sq ft, 1/8 l.s trais r. DIAz WIYMtIT 01 MrtOIMN - UGI ASRZ ES3 1R0 IN3TI!U!3 - PROJ o. 2s39. J9,me 19556. I

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN 39,000 lb of water in the tank, the scale balance was sensitive to the addition of a 10-lb weight. The mercury manometers were calibrated by connecting them in parallel with a.mercury U-tube and subjecting the group simultaneously to air pressure held essentially constant by means of a Moor pressure regulator. The range of the instruments was traversed and no perceptible error was observed in either of the manometers. The three stop watches used in the work were calibrated by comparison with United States Government radio time signals. No error was observed. MEASUREMENTS The inside diameter of the orifice was measured with a Lufkin inside micrometer at four different positions, as illustrated on page 4. The inside diameter of the pipe line was likewise measured at four different positions opposite the upstream and downstream pressure taps as illustrated on page 4. Pressure-tap location or K values were measured with a conventional steel scale. ORIFICE CALIBRATION After placing the orifice in the assembly line with the vent hole at the top position (orifice handle pointing up), water was circulated through the system to displace air from the pipe lines. With the supply pump operating, the 12-inch gate valve was closed, thus pressurizing the orifice assembly line. All air-vent valves were opened and reclosed one at a time until there was no sign of air bubbles in the manometers or in the connecting lines. The manometer scales were adjusted to read zero. The 12-inch valve was then gradually opened and set to obtain an arbitrary and essentially constant rate of flow. Water was collected in the weigh tank for a timed period limited by tank capacity, and the manometers were alternately read as rapidly as possible to obtain a large number of readings during this same timed period. The weight of water collected, the length of the collection period, the manometer readings, and the temperature of the circulated water and of the room constituted the test data. The 12-inch valve was then adjusted to other arbitrary settings and the previously described run repeated until a total of 25 runs up to and including the maximum possible output of the pump was obtained. The maximum rate of flow was 1,634,285 lb per hour and the maximum average manometer reading was 50~73 inches of mercury under water at 69~F. The water weighing and timing procedure actually involved three distinctly independent weights and their corresponding independent time intervals 7.

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN for each run, thus affording an average of three rate measurements for greater accuracy. The procedure consisted of selecting three tare weights separated by small weight increments and starting one of the three stop watches as each of these tare weights balanced the scale beam after the tank's dump valve was closed. Each watch was stopped after the selected net collection weight for the run had been added to the particular watch's starting tare weight. Thus the three weighing and time operations were for the most part simultaneous, yet they were distinctly independent of each other. The selected net collection weight was made as large as possible, with due consideration for time needed for operations, 20,000-lb and 25,000-lb being used. The shortest time interval used was 0.77 minute, during which seven readings of each manometer were obtained. CALCULATIONS ORIFICE DIAMETER The effective orifice diameter was calculated as that diameter of a single orifice having an area equal to the combined area of the major orifice and the 1/8-inch-diameter vent hole. EFFECTIVE DIFFERENTIAL PRESSURE The effective differential pressure for any one run was determined by converting the arithmetic average of the manometer readings for that run to inches of water of 680F, with due consideration for room temperature, in accordance with the A.S.M.E. Fluid Meters bulletin. ACTUAL FLOW RATE The actual flow rate for any one run was determined by correcting the net collection weight for that run for the effect of air buoyancy (thus increasing the observed weight by 1/10 of one percent), and then dividing by the average of the three stop-watch readings for that run. FLOW COEFFICIENT "K" The flow coefficient K was calculated by substituting the data obtained in the various runs into equation (99) on page 49 of the AoSoM.E. Flow Meters bulletin, Fourth Edition, 1937. All viscosities and densities used in the calculations were taken from this same A.S.M.E, publication.

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN REYNOLDS' NUMBER All Reynolds' numbers were calculated in accordance with equation (132), page 57 of the above-mentioned A.SoM.E. publication. EXAMPLE OF DATA AND CALCULATIONS (Run No. 8) DATA Orifice dif- Time in minutes for Pounds of water Temperature, ferential, water collection collected simul- OF Delta P (in. of simultaneous with taneous with time Hg under water) Delta P measurement measurement 34.4 Watch No. 1, 20,000 Flowing 34.1 0.898 water, 69.0 34.0 Watch No. 2, 20,000 34.1 0.900 34.0 Watch No. 3, 20,000 Room, 76.0 3355.8 0.900 33.9 33.5 8)271.8(335.975 Avg. Time, 0.899 Avg. Wt. 20,000 Orifice diameter, 6.0745" Vent hole diameter, 0.125" CALCULATIONS (according to A.S.M.E. Fluid Meters Bulletin, Fourth Edition,1937) W = pounds of water per hour 20,000 x 60 0.899 = 1,334,816 uncorrected for air buoyancy. Pounds of water per hour corrected for air buoyancy = W x 0.075 + W 62.32 = 1.001 W = 1,336,150. 9

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN Effective orifice D2 including vent hole = (620745)2 + (0125)2 = 36.8995 + 0.015625 = 36.9151. Effective orifice D2 = 607578 in. Reynolds' number (see page 57 of A.SoMoE Fluid Meters Bulletin) Rd = 48w _ 48 x 1,336,150 x 1000 1,393,000 ~IcDa~ 3.1416 x 6.076 x 3600 x.67 hw = inches of 680F water equivalent to orifice differential. Thus, for the particular conditions of Run No. 8, rorifice differential in density of Hg at 76~F-density of H0O at 76~F] =w inches of Hg at 680F density of H20 at 68~F hw = (33.975) [844.964 - 62. 253] = 426.731. 4Jh = 20.657. p1 = density of test flowing water, or 690F water in case of Run No. 8 = 62o310 from A.SoM.E. Fluid Meters Bulletin Chart. /P~ =- 7.8937. Referring to equation (99), page- 49, A.S.M.E. Fluid Meters Bulletin, w' = pounds per hour = 358.9 K D2 W Thus, K pounds per hour 1, 336,150 358.9 D2NF Xh w 358.9 x 36.9151 x 7o8937 x 20.657 - o6185 10