Design of Oil Injection Quills for Hypercompressors Cylinders

Fatigue impacts the life of all components subject to alternating loads, including lube oil injection quills. These occurrences are more frequent if a defect (initial flaw) nucleates in the component due to corrosion, high stress, machining imperfections, etc. The design of components undergoing high fluctuating pressures needs advanced technologies, like autofrettage, and design methods, like FEM or fracture mechanics. This component can be identified as a cylinder with different outside diameters and notches deriving from the geometry variation and threaded connection. The inner diameter is the most stressed area and will require an adequate stress analysis. A sensitivity analysis of the autofrettage pressure can be performed to identify the most appropriate residual stresses on the inner diameter and to obtain a threshold defect larger than the minimum detectable. Fracture mechanics allows the analysis the propagation of an initial defect with materials having different properties and considering different autofrettage pressures. Finite Element Analysis is used to validate the residual stresses predicted by calculation for each autofrettage pressure. An optimized solution of the hypercompressor injection quill can be designed.

Thermo-Fluid-Dynamic Design of Reciprocating Compressor Cylinders by Fluid Structure Interaction (FSI)

Pressure losses at the cylinder valves of reciprocating compressors are generally calculated by the classical equation of the flow through an orifice, with flow coefficient determined in steady conditions. Rotational speed has increased in the last decade to reduce compressor physical dimensions, weight and cost. Cylinder valves and associated gas passages became then more and more critical, as they determine specific consumption and throughput. An advanced approach, based on the new Fluid Structure Interaction (FSI) software, which allows to deal simultaneously with thermodynamic, motion and deformation phenomena, was utilized to simulate the complex situation that occurs in a reciprocating compressor cylinder during the motion of the piston. In particular, the pressure loss through valves, ducts and manifolds was investigated. A 3D CFD Model, simulating a cylinder with suction and discharge valves, was developed and experimentally validated. The analysis was performed in transient and turbulent condition, with compressible fluid, utilizing a deformable mesh. The 3D domain simulating the compression chamber was considered variable with the law of motion of the piston and the valve rings mobile according to the fluid dynamic forces acting on them. This procedure is particularly useful for an accurate valve loss evaluation in case of high speed compressors and heavy gases. Also very high pressure cylinders, including LDPE applications, where the ducts are very small and MW close to the water one, can benefit from the new method.

Ultrasound and Nonlinear Resonant Testing of Nuclear Reactor Internals Bolts

As many nuclear plants approach the end of their initial 40 year license period, inspection or replacement of their reactor internals bolts must be considered. This is consistent with the Materials Reliability Program (MRP 227/228) guideline for plant life extension [1,2]. Assurance of the internals structural integrity is essential for continued safe operation of these plants. If there is no suspicion or indication of bolt failure, simple inspection is normally more cost-effective than replacement. Inspection vendors have inspected thousands of internals bolts with conventional and Phased Array UT but different head configurations and bolt capture mechanisms mandate specific qualifications for each bolt type. In some cases, complex bolt and head geometries coupled with counter-bore and locking bar interferences render classical UT inspections difficult or impossible. A range of solutions to inspect reactor internals including these difficult-to-inspect-by-conventional-UT baffle bolts has been developed by several vendors [3]. This presentation references developments to make bolt inspection a relatively quick and easy task through adaptations to the SUSI submarine inspection platform, the extensive UT qualification work suitable for conventional UT plus more recent advanced nonlinear resonant techniques to distinguish between flawed or loose, vs. acceptable bolts where conventional UT cannot be applied. Initial evaluations show that these advanced techniques may have the ability to reliably detect smaller flaws than previously possible with conventional techniques as well as provide information on bolt tightness.

The Best-Estimate Plus Uncertainty (BEPU) Challenge in the Licensing of Current Generation of Reactors

Within the licensing process of the Atucha II PHWR (Pressurized Heavy Water Reactor) the BEPU (Best Estimate Plus Uncertainty) approach has been selected for issuing of the Chapter 15 on FSAR (Final Safety Analysis Report). The key steps of the entire process are basically two: a) the selection of PIE (Postulated Initiating Events) and, b) the analysis by best estimate models supported by uncertainty evaluation. Otherwise, key elements of the approach are: 1) availability of qualified computational tools including suitable uncertainty method; 2) demonstration of quality; 3) acceptability and endorsement by the licensing authority. The effort of issuing Chapter 15 is terminated at the time of issuing of the present paper and the safety margins available for the operation of the concerned NPP (Nuclear Power Plant) have been quantified.

Ultrasonic Phased Array Evaluation of Control Rod Drive Mechanism (CRDM) Nozzle Interference Fit and Weld Region

Ultrasonic phased array data were collected on a removed-from-service CRDM nozzle specimen to assess a previously reported leak path. First a mock-up CRDM specimen was evaluated that contained two 0.076-mm (3.0-mil) interference fit regions formed from an actual Inconel CRDM tube and two 152.4-mm (6.0-in.) thick carbon steel blocks [1,2]. One interference fit region has a series of precision crafted electric discharge machining (EDM) notches at various lengths, widths, depths, and spatial separations for establishing probe sensitivity, resolution and calibration. The other interference fit has zones of boric acid (crystal form) spaced periodically between the tube and block to represent an actively leaking CRDM nozzle assembly in the field. Ultrasonic phased-array evaluations were conducted using an immersion 8-element annular 5.0-MHz probe from the tube inner diameter (ID). A variety of focal laws were employed to evaluate the interference fit regions and J-grove weld, where applicable. Responses from the mock-up specimen were evaluated to determine detection limits and characterization ability as well as contrast the ultrasonic response differences with the presence of boric acid in the fit region. Nozzle 63, from the North Anna Unit-2 nuclear power plant, was evaluated to assess leakage path(s) and was destructively dismantled to allow a visual verification of the leak path(s).

Numerical Evaluation of Corrosion Condition for Pressurized Water Reactor Secondary Cooling System

Flow-accelerated corrosion (FAC) in a pressurized water reactor (PWR) feedwater piping system is considered the leading degradation process that has been blamed for a number of accidents and incidents. One of the challenging issues in estimating FAC in piping is the hydrazine (N2H4) oxygen (O2) reaction rate and its subsequent impact on the wall mass transfer. N2H4 is injected in the system to maintain a stable pH in the water and also to act as an O2 scavenger. Previous research results indicate a varying degree of FAC rate dependence on the presence of N2H4 in the system. The N2H4-O2 reaction is also a complex function of temperature and pipe material. The present paper presents a two-part analysis that uses computational fluid dynamics (CFD) tools to investigate the N2H4-O2 reaction and its subsequent impact on mass transfer. In the first part of the analysis, chemistry and flow of water with dissolved O2 and N2H4 is simulated to assess different reaction mechanisms available in the literature. Results obtained from this study are compared with available experimental data for benchmarking. The numerical results were able to capture the general pattern of reaction rate as a function of temperature. Numerical simulations were also carried out to accommodate the surface effects on the reaction, but results indicate that such accommodations will yield useful results only if the geometrical extent of the near-wall-zone, where surface effects are prevalent, is well known. In the second part of the analysis, numerical simulations were carried out for a U-bend pipe. A number of restrictive assumptions were made to assess the dependence of O2 mass-transfer rate on N2H4-O2 reaction. Hydrodynamic results show the secondary flow pattern within the bend section. Results are also presented for the Sherwood number ratio at the pipe wall with and without reaction. Results indicate that the N2H4-O2 reaction decreases the O2 flow rate toward the wall. This calculation also shows that secondary flow in the bend affects the wall mass transfer pattern.

Dynamic Analysis of Intercoolers and Tubular Reactors of LDPE Plants

Large-scale LDPE plants involving ultra-high pressure piping and potentially high-pressure pulsations need a detailed dynamic analysis. Special attention must be paid to the vibration of intercoolers and tubular reactors that represent the most critical part of the system, being mounted on tall steel structures. The long delivery of such components requires a proper selection at an early stage of the project. This implies the assessment of plant pulsation-induced forces, the subsequent definition of layout adjustments, of piping supports locations, type and supporting structures. The study must consider the actual jacketed tube configuration to avoid internal piping vibrations, which are difficult to be monitored and able to produce unexpected failures. The final review of the plant design should bring just minor adjustments.

Large Impulsive Loading of Open Ended Rings

A series of tests have been carried out on cast high strength ferritic steel rings 1090 mm internal diameter, with a central 20kg PE4 spherical charge, equivalent to 25 kg TNT. The rings have circular regions in them which have been thinned, some 16 mm wall thickness and some 26 mm thickness. The bulk of the ring undergoes limited cyclic plastic straining as the rings vibrate following the blast impact. The locally thinned regions undergo cyclic plastic strains of up to +/− 4%. The paper describes the experimental arrangements and results. Methods have been developed to measure high strains in the rings and the final plastic displacements of the windows have also been measured. It has proved remarkably difficult to obtain good finite element calculations of the strains measured. After the first blast, the thinned regions had some cracking and the extent of the cracking increased on further blast loads. Within the limits of measured/calculated strains, an assessment has been carried out to the new local tearing rules in ASME VIII Div 2 and 3 and compared to the observed damage.

Operation and Maintenance of Hyper Compressor in LDPE Plant

Petlin (Malaysia) Sdn Bhd was incorporated in March 1999 and has a Low Density Polyethylene plant that was commissioned in February 2002. The plant has a capacity of 255,000 tons per annum. The aim of the plant is to generate a reasonable return by manufacturing top quality products. To realize this aim, it’s important for the operators of the plant to operate the machines in accordance to the parameters set by the original equipment manufacturer. This will also ensure the availability and reliability of the plant. It is also important to regularly monitor the performance of the plant in relation to the operation and maintenance activities in order to prepare a better plan for continuous improvement. The Hyper-Compressors are the most fragile component in the system as they’re running under fatigue conditions and high operating pressures. It is essential to have the right processes and procedures in place to ensure that safety is not compromise in meeting the production target.

Helical Steam Generator Tubes Containing Crack Under External Pressure: A Review of Applicability for Existing Integrity Evaluation Method

For integrity assessment of structure containing crack, evaluation method based on fracture mechanics such as linear-elastic and elastic-plastic fracture mechanics has been relatively common method and becoming more widespread. However, it can be used only if the crack opening or tearing is occurred. If the crack exists on the piping components subjected to internal pressure, net-section stress is occurred in the direction on crack opening no matter where crack locate. On the contrary to this, if the external pressure is applied to piping components, net-section stress is occurred opposite direction and it is expected crack opening not to be occur. The subject of this study is SMART steam generator tube which is designed as helical geometrical feature and to be pressurized outside. Three dimensional finite element analyses are carried out to investigate crack behavior under external pressure considered various crack geometries and locations. Furthermore, the possibility of failure of SMART steam generator tube under design pressure is investigated.