Development and Experimental Validation for Quantifying the Moisture Carryover in a Moisture Separator Using an Air/Water Test Facility

The moisture carryover (MCO) of the primary separator in a steam generator is the most important design parameter to ensure high efficiency in a steam generator. There is an inherent limitation to experimentally evaluate the MCO under the prototype conditions. In this study, the air/water test facility was constructed based on the similarity law, and a new isokinetic system was developed to quantify the MCO. Several experiments were performed for the mass quality ranging from 0.315 to 0.382. The accuracy and versatility of the experimental method was verified experimentally using a full and half scale of separators. The test results were compared with the prototype results. It was proved to be a reliable experimental method for evaluating the MCO of the moisture separator.

Development of Empirical Correlation of Two-Phase Pressure Drop in Moisture Separator Based on Separated Flow Model

Pressure drop across the moisture separator installed in the steam generator of a nuclear power plant affects the power generation efficiency, and so accurate pressure drop prediction is important in generator design. In this study, an empirical correlation is proposed for predicting the two-phase pressure drop through a moisture separator. To ensure the applicability of the correlation, a series of two-phase air-water experiments were performed, and the results of the present test and of the benchmark test of high-pressure steam-water were used in developing the correlation. Based on the experimental results, quality, dimensionless superficial velocity, density ratio of the working fluid, and the geometrical factor were considered to be important parameters. The two-phase pressure drop multiplier was expressed in terms of these parameters. The empirical correlation was found to predict the experimental results within a reasonable range.

Design of an Innovative Moisture Separator Technology for Use in Nuclear Power Plants: Numerical Approach — Part 1

The Moisture Separator Re-heater (MSR) is a key component of Nuclear Power Plants (NPP) both in terms of performance and avoiding erosion and erosion/corrosion damage. Wet steam is usually dried in a MSR by inertial separation using separator elements. Depending on the design of a MSR, the technology of separator elements contributes significantly to its size and performance, hence is seen as a subject for in-depth investigation, improvement and innovation. Computational Fluid Dynamics (CFD) has been used to understand the working principles of moisture separating devices, in particular the OpenFOAM platform has been utilized for this scope. Eulerian/Lagrangian models, wall-droplet interaction and water film formation models have been adopted to determine the physical phenomena occurring during the moisture separation process. Additional sub-models have been implemented to make a more robust solver and to solve in a comprehensive way all the possible physical processes: in particular a two-layers turbulence model and a film breakup model have been implemented. An out-of-the-box thinking approach was adopted to devise a new proposed chevron vane. Aerodynamic principles were used to design an innovative concept of separator panel, which can entrap the moisture droplets and water rivulets through a subsequent formation of recirculating steam representing artificial slots (hidden pockets) within the separator channel. The control of the steam separation on precise regions of the separator panel wall, helps the drainage of the water film without the utilization of physical obstacles (pockets or drainage channels). To validate the results achieved from the numerical simulation and to characterize separation performance of a new kind of separator technology, a bespoke test rig has been designed, built and put into operation at typical MSR operating conditions [1]. Throttling calorimeter methodology has been adopted to measure, with very good accuracy, the residual moisture content after the separator. The design developed has shown excellent separation performance. Particularly, this solution will allow improved MSR performance and significantly reduced MSR size. This represents an innovative technology which is a major advance on current technology available within the industry. The novel design features have been patented by General Electric. The first operation of a MSR with this technology is eagerly awaited.

Design of an Innovative Moisture Separator Technology for Use in Nuclear Power Plants: Experimental Validation — Part 2

The Moisture Separator Reheater (MSR) is a key component of Nuclear Power Plants (NPP), both in terms of performance and prevention of erosion/corrosion. Wet steam is usually dried in a MSR by inertial separation of the liquid water using separator elements. Depending on the design of the MSR, the technology of the separator elements contributes significantly to its size and performance. An innovative concept of separator panels was conceived by means of aerodynamic principles as outlined in part 1 of this paper [1]. Computational Fluid Dynamics (CFD) has been used to understand the working principles of various moisture separating devices. The investigated separator panels are designed to capture the water droplets in a region of flow separation (invisible pockets) within the separator channels. To characterize the separation performance of these separator panels, a test rig has been developed and built at the University of Applied Sciences Northwestern Switzerland (FHNW). This test rig was then operated at typical MSR operating conditions. To meet the required moisture content and flow conditions, preheated water was injected into the saturated steam flow. In order to measure the residual moisture content after the separation the throttling calorimeter methodology has been adopted. The newly designed panels have shown very good separation performance. According to the measurements carried out, a residual moisture content of less than 0.1 % can be guaranteed. The innovative technology, which clearly differentiates the OEM, for who this research was carried out, from its competitors, will allow considerable size and cost reduction as well as opportunities to retrofit existing MSRs.