v

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Name:

Date:

Joint GT-IMOG/TFG Meeting,

Automated Field Calibration

Moisture Standard

Russell L. Hallman, Jr. PhD

Consolidated Nuclear Security, LLC

russell.hallmanjr@cns.doe.gov

Senior Technical Staff II (Engineer)

9203-F-0009

Background

• Definition of calibration – “To check, adjust, or standardize a measuring

instrument, usually by comparing it with an accepted model.”1

• Moisture monitors throughout Y-12 must be calibrated, often quarterly, requiring

a source of process gas containing a precise amount of moisture spanning the

desired range of concentrations. Gas suppliers CAN NOT provide gases with a

precise amount of moisture because moisture is not a gas but a vapor that

interacts with the surfaces of pipes and containers causing unpredictable swings

in concentrations.

• Low concentrations of moisture in gases must be made when and where they

are going to be used, thus the need for a moisture blending system.

1) The American Heritage® Science Dictionary

Background

• Y-12 currently uses field calibration moisture standards we developed and

patented 2001 which are now inefficient and quickly becoming obsolete.

• Manually operated with moisture set points inferred from a temperature profile (not user

friendly)

• Each instrument has unique moisture-to-temperature correlation

• Limited number of calibration set points

• Embedded controllers are obsolete with vendor support for repairs only

• No data logging capability of the moisture monitor’s performance during testing

• Requires craftsmen presence throughout the workday to manually record the data

• For some sensors changes in moisture level require hours to equilibrate

• Operating pressure and flow ranges are 0-10 psig and100 cc/min which is insufficient

for some new monitors

• Original moisture range 0-10 PPMv

• 2nd modification raised moisture levels to 0-30 PPMv

• 3rd modification 0-100 PPMv

• 4th modification 0-300 PPMv

• Additional configurations for unique instrument calibrations

Objective

• To build an automated moisture blending system for field calibration of

hygrometers with the following attributes:

• Compact and portable

• Operable in a manual or programmatic mode

• Moisture bypass for quick dry down

• Multiple ranges (e.g. 0-10, 0-500, 0-2000 PPMv)

• Increased maximum operating pressure (e.g. 20 psi)

• Higher flow rate of blended gas (e.g. 1500 cc/min)

• Graphical user interface allowing the craftsmen to select

• Moisture content in units of choice (e.g. dew point, frost point, R.H., PPMv, ...)

• Moisture content testing profile (e.g. single setpoint, stair step, ramp and soak, …)

• Data acquisition from instrument being calibrated (e.g. USB, serial port, 1-10v, 4-20ma, …)

• Real-time data analysis of moisture monitor being calibrated (pass/fail, response time, accuracy,

stability, repeatability, …)

• Storage of test results

• Graphical display of testing parameters and moisture monitor performance

Accomplishments

• Accomplishments this FY

• Compact and portable

• To date we have constructed sub-systems of the overall system for development, testing, and

evaluation. The goal is to minimize the footprint while increasing performance. Final assembly

remains.

• Multiple operational modes have been devised with significant improvements to

performance.

• Mode 1) Moisture content controlled by temperature of permeation cell – Pros and Cons,

conservation of dry gas but slower system equilibration to set point change (30 minutes – 1 hour)

• Mode 2) Moisture content controlled by gas blending – Pros and Cons, very fast response rate to

set point change (seconds to minutes) but higher gas usage

• System operations

• Currently control is by PLC and manual flow control – ultimately all control will be by

touchscreen

• System operating pressure raised to 20 psi – no significant effect on moisture content

• System routinely operated higher flow rates of 1500 cc/min – promotes quicker equilibration of

detectors being evaluated

• Single-film permeation cell replaced by multi-film permeation cell for expanded moisture ranges –

films may be changed to meet performance expectations

Accomplishments

• Accomplishments this FY - continued

• Modifications discovered during development

• Polymer film chosen over polymer tube due to morphology of film effecting permeation

• Modified balance pressure manifold for more precise dry gas flow control

• Graphical user interface features

• Unit selection still under development

• Test profiles fully functional (single set point, stair step, and ramp and soak)

• Data acquisition and storage completed for RH Systems LX373, Edgetech DewMaster, Spectra

Sensor TDL

• Plans for the future• Integration of all system control for PLC and touch screen operation

• Test profile development based in other units (ppm, RH, absolute humidity)

• Data acquisition and storage remaining for Ametek 303B and 3050AM

• Statistical analysis for test unit pass/fail determination

• System evaluation and testing by Y-12 Metrology personnel

Permeation cell

Touchscreen User Interface

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Moisture profile

Moisture profile

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Moisture content as a function of flow and temperature

Testing of Ametek 3050AM and Edgetech DewMaster

Demonstration of Control Over Expanded Range

Low Moisture Range Control

Rapid Step Change with Quick Settling

Questions