The nuclear industry is interested in automating the calibration of process instrumentation channels; this report provides key results of one of the sponsored projects to determine the validity of automated calibrations. Conclusion is that the normal outputs of instrument channels in nuclear plants can be monitored over a fuel cycle while the plant is operating to determine calibration drift in the field sensors and associated signal conversion and signal conditioning equipment. The procedure for on-line calibration tests involving calculating the deviation of each instrument channel from the best estimate of the process parameter that the instrument is measuring. Methods were evaluated for determining the best estimate. Deviation of each signal from the best estimate is updated frequently while the plant is operating and plotted vs time for entire fuel cycle, thereby providing time history plots that can reveal channel drift and other anomalies. Any instrument channel that exceeds allowable drift or channel accuracy band is then scheduled for calibration during a refueling outage or sooner. This provides calibration test results at the process operating point, one of the most critical points of the channel operation. This should suffice for most narrow-range instruments, although the calibration of some instruments can be verified at other points throughout their range. It should be pointed out that the calibration of some process signals such as the high pressure coolant injection flow in BWRs, which are normally off- scale during plant operation, can not be tested on-line.

This report provides key results of a three-year experimental and theoretical research and development effort performed under the auspices of the U.S. Nuclear Regulatory Commission. The goal of the R&D was to establish the validity of online calibration monitoring of process instrumentation channels in nuclear power plants. The author concludes that the normal outputs of instrument channels in nuclear plants can be monitored over a fuel cycle while the plant is operating and during startup and shutdown periods to verify the calibration of the instruments, thereby improving plant efficiency and safety, eliminating unnecessary calibrations, and reducing operations and maintenance costs.

An on-line instrumentation monitoring system was developed and validated for use in nuclear power plants. This system continuously monitors the calibration status of instrument channels and determines whether or not they require manual calibrations. This is accomplished by comparing the output of each instrument channel to an estimate of the process it is monitoring. If the deviation of the instrument channel from the process estimate is greater than an allowable limit, then the instrument is said to be {open_quotes}out of calibration{close_quotes} and manual adjustments are made to correct the calibration. The success of the on-line monitoring system depends on the accuracy of the process estimation. The system described in this paper incorporates both simple intercomparison techniques as well as analytical approaches in the form of data-driven empirical modeling to estimate the process. On-line testing of the calibration of process instrumentation channels will reduce the number of manual calibrations currently performed, thereby reducing both costs to utilities and radiation exposure to plant personnel.

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This report presents the preliminary results of a research and development project on the validation of new techniques for on-line testing of calibration drift of process instrumentation channels in nuclear power plants. These techniques generally involve a computer-based data acquisition and data analysis system to trend the output of a large number of instrument channels and identify the channels that have drifted out of tolerance. This helps limit the calibration effort to those channels which need the calibration, as opposed to the current nuclear industry practice of calibrating essentially all the safety-related instrument channels at every refueling outage.