Professional Documents
Culture Documents
Mixture
Hot water in main pipe : 280oC
Cold water : 140oC
Case
347 stainless steel moderator circuit branch
piping in a pressurized hot water reactor
Hot spotExpand
under compression
D
D
-The mixing of process streams
with large differences in
temperature, typically on the order
of 150oC or greater, can result in
cracking due to thermal fatigue
Stress as a function of initial mix point
- Location of pipe at 1D-3D
distance from is the highest stress
area
MOC case
Distance from crack to spray : 415 mm
(300+115)
ID : 230 mm
Ratio : 1.8 from midpoint
(in high stress zone)
Desuperheater crack
Cl Cyclic stress
Pipe stress
O2 analysis Longitudinal thermal expansion (temperature fluctuation)
Longitudinal crack
COMPUTATIONAL FLUID DYNAMICS (CFD) SIMULATION
Pre-Analysis: Key Parameters
23
COMPUTATIONAL FLUID DYNAMICS (CFD) SIMULATION
Pre-Analysis: Key Parameters
Pipe Diameter
C B C Boiler Feed Water (BFW) BFW Droplet
Levap
DX D DX Lup Ldown
α
G F G
Superheated Desuperheated
Steam (SS) Steam (DSH)
24
COMPUTATIONAL FLUID DYNAMICS (CFD) SIMULATION
Pre-Analysis: Key Parameters
25
COMPUTATIONAL FLUID DYNAMICS (CFD) SIMULATION
Results Interpretation and Analysis: Atomization Effects
26
COMPUTATIONAL FLUID DYNAMICS (CFD) SIMULATION
Results Interpretation and Analysis: Atomization Effects
Operating Condition BFW = 3,814 kg/hr SS = 35,048 kg/hr Rws = 0.11
Lup (m/DDSL) 0.840 m/3.7DDSL
Nozzle Design/# Holes MOC/3 Holes MOC/6 Holes
Internal Cracks
Root Cause:
COMPUTATIONAL FLUID DYNAMICS (CFD) SIMULATION
↑ Number
of Open
Holes ↑ Impact of BFW
↓ Impact of BFW
↓ Homogeneous Mixing
↑ Homogeneous Mixing
↑ Number
of Nozzles
↑ Rws
Flow
Characteristics
Low
injection ↑ Lup
angle
No Impact of BFW = Impact of BFW
↓ Homogeneous Mixing = Homogeneous Mixing
29
Desuperheater crack
Cl Cyclic stress
Pipe stress
O2 analysis Longitudinal thermal expansion (temperature fluctuation)
Longitudinal crack
Further investigation of crack
morphology
1st crack fracture surface
Outer wall
Inner wall
Inner wall
Crack origin
Crack is originated from scratch
Another crack
Inner wall
Desuperheater crack
Cl Cyclic stress
Pipe stress
O2 analysis Longitudinal thermal expansion (temperature fluctuation)
Longitudinal crack
Lifetime extension by material Nov 10th,2015
Average life is about 6 years (through crack)
exiting
Option 0 1 2 3 4
Based material 347H 347H 347H 625 625
Polished x0.55 X 1.3 X 1.3
(scratch)
Crack initiation 1 1 1 X2 X2
(Thermal shock
resistance)
Crack 1 1 1 1.27 1.27
propagation
(after crack
initiation)
Life 0.55 1 1.3 2.52 3.3
Cost 200K 200K 230K 1000K 1030K
Cost / life 400K 200K 177K 397K 312K
0.00007
0.00006
x 1.96
0.00005
0.00004
Fracture 347H
toughness 0.00003 625
base x 2.15
0.00002
0.00001
0
0 100 200 300 400
Tensile stress
base