FE Simulation of Welding Residual Stresses in Reactor Vessel Head Penetrations

2009 ◽  
Author(s):  
Anne Teughels ◽  
Christian Malekian
Keyword(s):  
Residual Stresses ◽  
Nuclear Power ◽  
Power Plants ◽  
Element Model ◽  
Mechanical Analysis ◽  
Alloy 600 ◽  
Finite Elements Analysis ◽  
Pressurized Water ◽  
Water Reactors ◽  
Set Up

The penetrations in the early Pressurized Water Reactors Vessels are characterized by Alloy 600 tubes, welded by Alloy 182/82. The Alloy 600 tubes have been shown to be susceptible to PWSCC (Primary Water Stress Corrosion Cracking) which may lead to crack forming. The cracking mechanism is driven mainly by the welding residual stresses and, in a second place, by the operational stresses in the weld region. It is therefore of big interest to quantify the weld residual stresses correctly. In order to determine the welding residual stresses, the weld procedure is simulated numerically by finite elements analysis. In the article, central as well as eccentric sidehill nozzles on the vessel head are analyzed. For the former a 2-dimensional axisymmetrical finite element model is used, whereas for the latter a 3-dimensional model is set up. A nonlinear transient thermo-mechanical analysis is performed, which is preceded by a transient thermal analysis simulating the heating during the multipass welding. Weld beads are deposited “all-at-once”. Different positions on the vessel head are compared and the influence of the sidehill effect is illustrated. The methodology is applied to the reactor vessels of the Belgian nuclear power plants by Tractebel Engineering (Belgium). The results are compared with literature. The global approach in both cases is very similar but is applied to different configurations, specific for each plant.

Weld Residual Stress Predictions in Reactor Vessel Head Penetrations: FE Simulation

2009 ◽  
Author(s):  
Anne Teughels ◽  
Rodolfo L. M. Suanno ◽  
Christian Malekian ◽  
Lucio D. B. Ferrari
Keyword(s):  
Residual Stress ◽  
Stress Field ◽  
Element Model ◽  
Mechanical Analysis ◽  
Welding Residual Stress ◽  
Alloy 600 ◽  
Residual Stress Field ◽  
Pressurized Water ◽  
Weld Residual Stress ◽  
Water Reactors

The penetrations in the early Pressurized Water Reactors Vessels are characterized by Alloy 600 tubes, welded by Alloy 182/82. The Alloy 600 tubes have been shown to be susceptible to PWSCC (Primary Water Stress Corrosion Cracking) which may lead to crack forming. The cracking mechanism is driven mainly by the welding residual stress and, in a second place, by the operational stress in the weld region. It is therefore of big interest to quantify the weld residual stress field correctly. In this paper the weld residual stress field is calculated by finite elements, using a common approach well known in nuclear domain. It includes a transient thermal analysis simulating the heating during the multipass welding, followed by a transient thermo-mechanical analysis for the determination of the stresses involved with it. The welding consists of a sequence of weld beads, each of which is deposited in its entirety, at once, instead of gradually. Central as well as eccentric sidehill nozzles on the vessel head are analyzed in the paper. For the former a 2-dimensional axisymmetrical finite element model is used, whereas for the latter a 3-dimensional model is set up. Different positions on the vessel head are compared and the influence of the sidehill effect is illustrated. In the framework of a common project for Angra 1, Tractebel Engineering (Belgium) and Eletronuclear (Nuclear Utility, Brazil) had the opportunity to compare their analysis method, which they applied to the Belgian and the Brazilian nuclear reactors, respectively. The global approach in both cases is very similar but is applied to different configurations, specific for each NPP. In the article the results of both cases are compared.

Finite Element Analyses of Residual Stresses in Typical Welded Joints Used in Nuclear Power Plants and Comparisons With Experiments

2010 ◽  
Author(s):  
Dean Deng ◽  
Kazuo Ogawa ◽  
Nobuyoshi Yanagida ◽  
Koichi Saito
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Residual Stresses ◽  
Welded Joints ◽  
Nuclear Power ◽  
Power Plants ◽  
Butt Joint ◽  
Welding Residual Stress ◽  
Dissimilar Metal ◽  
Water Reactors

Recent discoveries of stress corrosion cracking (SCC) at nickel-based metals in pressurized water reactors (PWRs) and boiling water reactors (BWRs) have raised concerns about safety and integrity of plant components. It has been recognized that welding residual stress is an important factor causing the issue of SCC in a weldment. In this study, both numerical simulation technology and experimental method were employed to investigate the characteristics of welding residual stress distribution in several typical welded joints, which are used in nuclear power plants. These joints include a thick plate butt-welded Alloy 600 joint, a dissimilar metal J-groove set-in joint and a dissimilar metal girth-butt joint. First of all, numerical simulation technology was used to predict welding residual stresses in these three joints, and the influence of heat source model on welding residual stress was examined. Meanwhile, the influence of other thermal processes such as cladding, buttering and heat treatment on the final residual stresses in the dissimilar metal girth-butt joint was also clarified. Secondly, we also measured the residual stresses in three corresponding mock-ups. Finally, the comparisons of the simulation results and the measured data have shed light on how to effectively simulate welding residual stress in these typical joints.

scholarly journals Reactor Vessel Internals Segmentation Experience using Mechanical Cutting Tools

2013 ◽  
Vol 10 (2) ◽  
pp. 6-10 ◽  
Author(s):  
Petr Pospíšil
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Cutting Tools ◽  
Reactor Vessel ◽  
Boiling Water Reactors ◽  
Abrasive Waterjet ◽  
Pressurized Water ◽  
Water Reactors ◽  
Mechanical Cutting ◽  
Reactor Internals

Abstract Some commercial nuclear power plants have been permanently shut down to date and decommissioned using dismantling methods. Other operating plants have decided to undergo an upgrade process that includes replacement of reactor internals. In both cases, there is a need to perform a segmentation of the reactor vessel internals with proven methods for long term waste disposal. Westinghouse has developed several concepts to dismantle reactor internals based on safe and reliable techniques, including plasma arc cutting (PAC), abrasive waterjet cutting (AWJC), metal disintegration machining (MDM), or mechanical cutting. Mechanical cutting has been used by Westinghouse since 1999 for both Pressurized Water Reactors (PWR’s) and Boiling Water Reactors (BWR’s) and its process has been continuously improved over the years. The complexity of the work requires well designed and reliable tools. Different band saws, disc saws, tube cutters and shearing tools have been developed to cut the reactor internals. All of those equipments are hydraulically driven which is very suitable for submerged applications. Westinghouse experience in mechanical cutting has demonstrated that it is an excellent technique for segmentation of internals. In summary, the purpose of this paper will be to provide an overview of the Westinghouse mechanical segmentation process, based on actual experience from the work that has been completed to date.

scholarly journals Plant Performance History of an Innovative Gate Valve in Critical Service Applications

2017 ◽  
Author(s):  
M. S. Kalsi ◽  
Patricio Alvarez ◽  
Thomas White ◽  
Micheal Green
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Gate Valve ◽  
Plant Performance ◽  
Flow Loop ◽  
Performance History ◽  
Pressurized Water ◽  
Maintenance Costs ◽  
History Of ◽  
Water Reactors

A previous paper [1] describes the key features of an innovative gate valve design that was developed to overcome seat leakage problems, high maintenance costs as well as issues identified in the Nuclear Regulatory Commission (NRC) Generic Letters 89-10, 95-07 and 96-05 with conventional gate valves [2,3,4]. The earlier paper was published within a year after the new design valves were installed at the Pilgrim Nuclear Plant — the plant that took the initiative to form a teaming arrangement as described in [1] which facilitated this innovative development. The current paper documents the successful performance history of 22 years at the Pilgrim plant, as well as performance history at several other nuclear power plants where these valves have been installed for many years in containment isolation service that requires operation under pipe rupture conditions and require tight shut-off in both Pressurized Water Reactors (PWRs) and Boiling Water Reactors (BWRs). The performance history of the new valve has shown to provide significant performance advantage by eliminating the chronic leakage problems and high maintenance costs in these critical service applications. This paper includes a summary of the design, analysis and separate effects testing described in detail in the earlier paper. Flow loop testing was performed on these valves under normal plant operation, various thermal binding and pressure locking scenarios, and accident/pipe rupture conditions. The valve was designed, analyzed and tested to satisfy the requirements of ANSI B16.41 [9]; it also satisfies the requirements of ASME QME 1-2012 [10]. The results of the long-term performance history including any degradation observed and its root cause are summarized in the paper. Paper published with permission.

Power Maximization of Fully Passive Lead-Bismuth Eutectic Cooled Small Modular Reactor

2014 ◽  
Author(s):  
Jaehyun Cho ◽  
Yong-Hoon Shin ◽  
Il Soon Hwang
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Natural Circulation ◽  
Reactor Core ◽  
Design Stage ◽  
Pressurized Water ◽  
Small Modular Reactor ◽  
Power Maximization ◽  
Lead Bismuth Eutectic ◽  
Water Reactors

Although the current Pressurized Water Reactors (PWRs) have significantly contributed to the global energy supply, PWRs have not been considered as a trustworthy energy solution owing to its several problems; spent nuclear fuels (SNFs), nuclear safety, and nuclear economy. In order to overcome these problems, lead-bismuth eutectic (LBE) fully passive cooling Small Modular Reactor (SMR) system is suggested. It is possible to not only provide the solution of the problem of SNFs through the transmutation feature of LBE coolant, but also increase the safety and economy through the concepts of the natural circulation cooling SMRs. It is necessary to maximize the advantages (safety and economy) of this type of Nuclear Power Plants for several applications in future. Accordingly, objective of the study is to maximize the reactor core power while the limitations of shipping size, materials endurance, long-burning criticality as well as safety under Beyond Design Basis Events must be satisfied. Design limitations of natural circulating LBE-cooling SMRs are researched and power maximization method is developed based on obtained design limitations. It is expected that the results are contributed to reactor design stage with providing several insights to designers as well as the methods for design optimization of other type of SMRs.

Background on Low Temperature Overpressure Protection System Setpoints for Pressure-Temperature Curves

2020 ◽  
Author(s):  
Jeffrey C. Poehler ◽  
Gary L. Stevens ◽  
Anees A. Udyawar ◽  
Amy Freed
Keyword(s):  
Low Temperature ◽  
Nuclear Power ◽  
Power Plants ◽  
Nuclear Power Plants ◽  
Pressure Vessels ◽  
Pressurized Water Reactors ◽  
Documentation System ◽  
Pressurized Water ◽  
System Pressure ◽  
Water Reactors

Abstract ASME Code, Section XI, Nonmandatory Appendix G (ASME-G) provides a methodology for determining pressure and temperature (P-T) limits to prevent non-ductile failure of nuclear reactor pressure vessels (RPVs). Low-Temperature Overpressure Protection (LTOP) refers to systems in nuclear power plants that are designed to prevent inadvertent challenges to the established P-T limits due to operational events such as unexpected mass or temperature additions to the reactor coolant system (RCS). These systems were generally added to commercial nuclear power plants in the 1970s and 1980s to address regulatory concerns related to LTOP events. LTOP systems typically limit the allowable system pressure to below a certain value during plant operation below the LTOP system enabling temperature. Major overpressurization of the RCS, if combined with a critical size crack, could result in a brittle failure of the RPV. Failure of the RPV could make it impossible to provide adequate coolant to the reactor core and result in a major core damage or core melt accident. This issue affected the design and operation of all pressurized water reactors (PWRs). This paper provides a description of an investigation and technical evaluation regarding LTOP setpoints that was performed to review the basis of ASME-G, Paragraph G-2215, “Allowable Pressure,” which includes provisions to address pressure and temperature limitations in the development of P-T curves that incorporate LTOP limits. First, high-level summaries of the LTOP issue and its resolution are provided. LTOP was a significant issue for pressurized water reactors (PWRs) starting in the 1970s, and there are many reports available within the U.S. Nuclear Regulatory Commission’s (NRC’s) documentation system for this topic, including Information Notices, Generic Letters, and NUREGs. Second, a particular aspect of LTOP as related to ASME-G requirements for LTOP is discussed. Lastly, a basis is provided to update Appendix G-2215 to state that LTOP setpoints are based on isothermal (steady-state) conditions. This paper was developed as part of a larger effort to document the technical bases behind ASME-G.

Coordinated Research Projects at IAEA Concerning RPV and Structural Integrity

2006 ◽  
Author(s):  
William Server ◽  
Timothy Hardin ◽  
Milan Brumovsky´
Keyword(s):  
Ferritic Steel ◽  
Nuclear Power ◽  
Power Plants ◽  
Structural Integrity ◽  
Current Status ◽  
Research Projects ◽  
Energy Agency ◽  
Pressurized Water ◽  
Toughness Testing ◽  
Water Reactors

The International Atomic Energy Agency (IAEA) has had a series of reactor pressure vessel (RPV) structural integrity programs that started back in the 1970s. These Coordinated Research Projects most recently have focused on use of the Master Curve fracture toughness testing approach for RPV and other ferritic steel components and on the issue of pressurized thermal shock (PTS) in operating pressurized water reactors. This paper will provide the current status for these projects and discuss the implications for improved safety of key ferritic steel components in nuclear power plants (NPPs).

Comparison of Nuclear Fitness for Service Codes: ASME Section XI and RSE-M AFCEN Codes

2014 ◽  
Author(s):  
Claude Faidy
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Nuclear Power Plants ◽  
Light Water Reactors ◽  
Pressurized Water ◽  
Term Operation ◽  
Mechanical Components ◽  
Water Reactors ◽  
Test Requirements ◽  
Service Inspection

Two major Codes are used for Fitness for Service of Nuclear Power Plants: one is the ASME B&PV Code Section XI and the other one is the French RSE-M Code. Both of them are largely used in many countries, partially or totally. The last 2013 RSE-M covers “Mechanical Components of Pressurized Water Reactors (PWRs): - Pre-service and In-service inspection - Surveillance in operation or during shutdown - Flaw evaluation - Repairs-Replacements parts for plant in operation - Pressure tests The last 2013 ASME Section XI covers “Mechanical components and containment of Light Water Reactors (LWRs)” and has a larger scope with similar topics: more types of plants (PWR and Boiling Water Reactor-BWR), other components like metallic and concrete containments… The paper is a first comparison covering the scope, the jurisdiction, the general organization of each section, the major principles to develop In Service Inspection, Repair-Replacement activities, the flaw evaluation rules, the pressure test requirements, the surveillance procedures (monitoring…) and the connections with Design Codes… These Codes are extremely important for In-service inspection programs in particular and essential tools to justify long term operation of Nuclear Power Plants.

The Next EDF Tracking System

2009 ◽  
Author(s):  
Emmanuelle Julli ◽  
Bertrand Lantes
Keyword(s):  
Radioactive Waste ◽  
Nuclear Power ◽  
Power Plants ◽  
Tracking System ◽  
Treatment Plant ◽  
Computer Application ◽  
Pressurized Water ◽  
Waste Package ◽  
Additional Processing ◽  
Water Reactors

EDF’s network of nuclear power plants (NPP) comprises 58 pressurized water reactors. Solid waste arising during plant operation (mainly VLLW, LLW and ILW) are conditioned and sent either to interim storage, an off site treatment plant for additional processing (e.g. the Centraco incinerator or the melting facilities of SOCODEI) or directly to one of the two final repositories operated by ANDRA, the French national radioactive waste management agency. The tracking system allows: - the checking of waste package characteristics against acceptance criteria of the final disposal facilities or off site treatment facilities; and - the transmission of the waste package data to ANDRA and SOCODEI. Since 1992, the EDF computer application DRA has been run on networked computers at EDF and ANDRA, and more recently at SOCODEI. DRA is also a key element in the management of radioactive waste. It allows a large range of inter comparisons to be made between the NPPs in operation and is thus the principal tool used optimize technical and economic performance. After 15 years of use, DRA was technically obsolete and could no longer be successfully developed to meet evolving regulatory requirements. It was therefore decided to completely replace the DRA system and in so doing to introduce new functionality.

Application of Mixed Equivalent Solid and Explicit Hole Models to Analysis of Thick Perforated Plates

2008 ◽  
Author(s):  
E. Josserand ◽  
F. Billon
Keyword(s):  
Thermal Gradient ◽  
Nuclear Power ◽  
Power Plants ◽  
Side Surface ◽  
Element Model ◽  
Fatigue Analysis ◽  
Pressurized Water Reactor ◽  
Pressurized Water ◽  
Geometrical Effects ◽  
Load Types

Confronted with the problem of how to conduct a complete fatigue analysis of the Tube Plate (TP) of Tubular and Shell Heat Exchangers and particularly of the Steam Generators equipping nuclear power plants of the Pressurized Water Reactor type (PWR), analysts have developed a method to analyse stress in perforated flat and thick Tube Plates with square penetration (crate) patterns, and in particular to analyse several specific zones such as the Interface Zones and various Effects, such as the Secondary (or Shell) Thermal Gradient Effect (STG Effect), the Thermal Gradient in the No-Tube Lane Effect (TGL Effect) and their interactions. The benefit of the approach is that it enables to analyze mechanical and thermal stress calculated using a full 3D Finite Element model incorporating an equivalent solid and the different Interface Zones, and allowing simulating the specific Thermo-Mechanical Effects. The Interface Zones (IZs) are those between the perforated and non-perforated area, the STG Effect is due to the strong gradient near the Secondary (or Shell) Side surface, the TGL Effect is produced by a temperature gradient across the No-Tube Lane. The method used for the fatigue analysis is based on a “Partitioning Stress Method” by means of which the stress induced by the various load types — mechanical loads, global thermal loads, local thermal effects (STG and TGL Effects), and local geometrical effects (IZs) — are first treated separately and then recombined with their appropriate Stress Multiplier Functions.

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