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Modal Characteristic Analysis of The Apr1400
Modal Characteristic Analysis of The Apr1400
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Reactor internals are sensitive to dynamic loads such as earthquakes and flow induced vibration. Thus, it is essential
to identify the dynamic characteristics to evaluate the seismic integrity of the structures. However, a full-sized system is
too large to perform modal experiments, making it difficult to extract data on its modal characteristics. In this research,
we constructed a finite element model of the APR1400 reactor internals to identify their modal characteristics. The
commercial reactor was selected to reflect the actual boundary conditions. Our FE model was constructed based on
scale-similarity analysis and fluid–structure interaction investigations using a fabricated scaled-down model.
KEYWORDS : Reactor Internals, Scaled-down Model, Fluid–structure Interaction, Finite Element Method, Commercial Reactor
important parts of the scale-similarity analysis. However, in structures has a low-frequency bending mode, since they
our previous research, it was difficult to clearly express each have a high slenderness ratio. When the structures
the boundary conditions in a scale-similarity analysis be- interact with the reactor coolant, a fluid–structure interac-
cause SMART was not a commercial reactor. For example, tion (FSI) effect occurs, reducing the natural frequencies
we could not consider the supporting conditions of the of the structures. Since earthquake inputs are generally
RV, so we fixed the entire lower surface of the RV to the of low frequency, the bending frequencies of these two
base surface plate. However, we were able to manufacture structures are of paramount importance in the prevention
support fixtures in this research because we knew the exact of seismic hazards.
supporting condition of the RV. The resulting differences
in the boundary conditions lead to considerably different 2.2 Modal Analysis using a Scaled-down Model
dynamic characteristics. Thus, this research has the great It is essential to obtain valid dynamic characteristics of
advantage of analyzing dynamic characteristics based on a system in order to construct a useful FE model. However,
exact boundary conditions. it is difficult to identify the dynamic characteristics of a
The main purpose of this study is to construct an FE full-sized model including FSI, because dynamic tests
model that can be used for seismic analysis based on modal cannot be performed on a full-sized model in a laboratory.
tests and FE analysis and which exploits the emerging Accordingly, a scaled-down model was constructed for
features of next-generation nuclear power plants. In order this study.
to use the FE model for seismic analysis, it is essential An advantage of a scaled-down model is that it enables
to reflect the characteristics of the real model. Thus, by exact determination of the added-mass effect by comparing
manufacturing a scaled-down model of the commercial the results of modal tests in air and in water. Another ad-
reactor internals and carrying out modal experiments on it, vantage is that it allows experiments to be performed by
we determined the dynamic characteristics of the scaled- using light materials and small structures. Also, it allows
down model. We then constructed the FE model with the dynamic characteristics of the actual system to be cal-
these characteristics in mind. Then, by applying scale- culated via scale-similarity analysis.
similarity relations, we constructed an FE model that re- We constructed a 1/10-scale model of the reactor in-
flected the characteristics of the full-scale model. ternals (Fig. 2). In general, the 1/10 scale ratio for reactor
internals is recommended by the Comprehensive Vibration
Assessment Program (CVAP). Also, the scale ratio was
2. IDENTIFICATION OF REACTOR INTERNALS’ selected by considering interferences among the reactor
DYNAMIC CHARACTERISTICS internals. By performing a pre-test, we found that 1mm
was the minimum gap that did not lead to collisions be-
2.1 Description of the APR1400 Internals tween the structures; that is to say, collisions could still
The RV assembly in the APR1400 consists of a verti- occur if the gap was smaller than 1mm. Therefore, taking all
cal cylindrical shell, a hemispherical lower head, and a conditions into consideration, we constructed the scaled-
hemispherical upper head (Fig. 1). The reactor internals down model to be as similar as possible to the actual model.
comprise the core support barrel (CSB) assembly and The scaled-down model had different dynamic char-
the upper guide structure (UGS) assembly. Each of these acteristics to a full-scale model due to three causes. As
mentioned above, the scaled-down model was designed so
as to have uniformly scaled-down geometry. Thus, firstly, this
geometry made the structures have high natural frequen-
cies. Secondly, the difference in material properties affected
Fig. 1. Schematic of the APR1400 Reactor Internals Fig. 2. Scaled-down Fabricated Model
the dynamic characteristics of the system. Finally, dif- sis was performed. By comparing the results of FE analysis
ferences in the added-mass effect arise from the differ- and a modal test in air, it was possible to construct valid
ences in FSI at the two scales. In this research, therefore, FE models of each component. In addition, this allowed
we focused on preparing a FE model that was based on an observation of the added-mass effect, thereby allowing
accurate scaling of the fabricated model’s dynamic charac- comparison with modal data in water. Secondly, a modal
teristics. analysis of the partially assembled models was carried out.
The differences in dimensions and material properties In general, connections between the structures reduced the
between the scaled-down model and the full-scale model natural frequency. Thus, in this process, it was important to
can be corrected for by means of scale-similarity analysis. exactly represent the boundary conditions of the scaled-
The characteristics of the structures in air vary according to down model when applying them to the FE model. Similar to
their differences in scale, Young’s modulus, and density. the modal analysis of single components, modal analysis
Considering these factors, we modified the characteristics of the partially assembled model was carried out in water
of the scaled-down model to accurately reflect the char- to observe the added-mass effect. Finally, the dynamic
acteristics of the full-scale model. characteristics of the completely assembled model were
To facilitate FE analysis and modal testing, our design analyzed in air and in water, and the dynamic character-
of the scaled-down model excluded structures for which istics of the full-scale model were predicted by means of
the natural frequency was outside the frequency range scale-similarity analysis.
relevant to seismic analysis. The major components for
modal analysis were selected based on a preliminary FE 2.3 Experimental Setup
analysis. Each single component was tested under free–free con-
Actual reactor vessels are made of low-alloy steel, and ditions to exclude natural frequency reductions due to fixed
reactor internals are made of 304 stainless steel, owing to boundary conditions (Figs. 4a, 4b). In order to create
its corrosion resistance. However, the scaled-down model free–free conditions, we used string to suspend the struc-
was made of aluminum alloy 6061 to facilitate experimental tures. Heavy components and the assembled model were
control. too heavy to be suspended in this way, and were instead
Hydroelastic vibration analysis of a scaled-down model placed on cushioning material. The structures were excit-
should be focused on extracting modal data such as natural ed by an impact hammer. The responses were measured
frequencies, modal damping values, and boundary condi- with accelerometers, and the modal characteristics were
tions. Thus, we performed modal experiments in various extracted by using LMS Test LAB software. An exciter
conditions: on each single component, partially assembled
models, and the completely assembled model; and testing
each component and assembly both in air and in water. Test-
ing all these conditions was important to extract the exact
dynamic characteristics. By performing these experiments,
we could reflect the exact boundary conditions and added-
mass effects.
The procedure of experiments followed the procedure
summarized in Fig. 3. First, a component-level modal analy-
Fig. 3. Hydroelastic Vibration Analysis Procedure Fig. 4. Experimental Setup for Modal Tests
(2)
4. SCALE-SIMILARITY ANALYSIS Assuming that the mode shapes in water are equivalent
to the mode shapes in air, the NAVMI factor can then be
As discussed above, it is difficult to perform modal expressed as follows.
experiments on an actual nuclear reactor, and accordingly,
we constructed a 1/10-scale model suited to laboratory
conditions. The natural frequencies, material properties,
and added-mass effect of the scaled-down model are dy- (12)
namic characteristics that differ from those of the actual
nuclear reactor. The differences in these characteristics
arise from the different densities and elastic moduli of their
different materials. Thus, to properly identify the charac- Here, Γs, Γr, ρLs, and ρLr denote the respective NAVMI
teristics of the full-sized model, these three factors should factors and fluid densities in the scale-similarity model
be corrected by means of scale-similarity analysis. and in the full-scale model. Combining these equations, the
natural frequencies of the full-scale model with different
4.1 NAVMI Factor material properties can be obtained as follows:
The added-mass effect varies considerably according
to the mode shapes and natural frequencies. Hence, it is (13)
necessary to add a NAVMI factor to quantify the added-
mass effect with respect to the vibratory mode. The NAVMI
factor (Г) can be represented as follows [10]–[14]: As indicated by the form of Equation (20), the natural fre-
quencies of a full-scale model that has different material
properties than the model can be calculated from the scale
(7) factor, material property correction factors, and a NAVMI
factor derived from FE analysis or a modal experiment.
where ζf, fO, and fL respectively denote the density ratio of
water to air, the natural frequencies of the structures in air,
and the corresponding natural frequencies of the struc- 5. RESULTS AND DISCUSSION
tures in water.
The results of the modal test were compared with
4.2 Scale Factor and Material Property Correction those of the FE analysis. Tables 1–4 give the results for the
Factor single-component models and the partially assembled
The material properties of the scaled-down model can models in air. Tables 5 and 6 give the corresponding results
be corrected using the elastic modulus correction factor (ε) and in water, and Table 7 gives the results for the completely
the density correction factor (ζp). Equations (15)–(20) below assembled model in water. Figure 8 gives the frequency
are taken from previous research [6]. response function of the completely assembled model in
water. As can be seen in Table 7, the constructed FE model
(8) reflects the dynamic characteristics of the scaled-down
model within a valid margin of error.
(9) In general, the vibratory mode (n, m) of a cylindrical shell
is distinguished by the number of nodal lines in the axial direc-
Here, Es, Er, ρs, and ρr are the respective elastic moduli tion (m) and the wave number in the circumferential direction
and densities of the materials used in the similarity model
and in the actual structure. The natural frequency (fOm) of
the similarity model with corrected material properties in Table 1. N
atural Frequencies of the RV in Air
air can then be written as Natural Frequencies
Mode Shape [Hz] Error
(10) (n, m) [%]
FEM Modal Test
where fOs denotes the natural frequency of the similarity Rigid body 66 71 7.0
model with uncorrected material properties in air. Also,
Rigid body 227 214 -6.1
(11)
(2,1) 355 360 1.4
where fOr denotes the natural frequency of the full-scale (3,1) 604 600 -0.7
model with correct material properties in air, and κ is a
(4,1) 1010 961 -5.1
geometric scale factor.
Table 2. N
atural Frequencies of the RV + UGS Assembly in Air (n). Because the mode shapes of the CSB were not dif-
ferent when tested in air and in water, these shapes were
Natural Frequencies compared by simply revolving them. These comparisons
Mode Shape [Hz] Error
(n, m) [%] were confirmed by comparing the vibratory mode number
Modal Test FEM of each of the mode shapes.
(1,1) 149 150 0.7 The out-of-plane (OOP) and in-plane (IP) modes
(3,1) 413 420 1.7
noted in Tables 7 and 9 indicate the phase differences
between the CSB assembly and the UGS assembly. The
(4,1) 688 665 -3.5 first bending frequency is about 50 Hz, according to the
(3,2) 792 736 -7.6 experimental and FE analysis results given in Table 1.
(4,2) 880 833 -5.6 Figure 9a shows the first bending mode shape of the CSB
Table 3. N
atural Frequencies of the CSB Assembly in Air
Natural Frequencies
Mode Shape [Hz] Error
(n, m) [%]
FEM Modal Test
(2, 1) 151 154 1.9
(2, 2) 217 217 0.0
(3, 1) 397 374 -6.1
Free–Free Condition
(3, 2) 511 533 4.1
(2, 3) 659 641 -2.8
(3, 3) 708 709 0.1
(1, 1) 149 150 0.7
(3, 1) 413 420 1.7
RV + CSB Assembly (4, 1) 688 665 -3.5
(3, 2) 792 736 -7.6
(4, 2) 880 833 -5.6
Table 4. N
atural Frequencies of the UGS Assembly in Air
Natural Frequencies
Mode Shape [Hz] Error
(n, m) [%]
FEM Modal Test
(2, 1) 375 354 -5.9
(3, 1) 866 824 -5.1
UGS (4, 1) 1108 1082 -2.4
in Free–Free condition (5, 1) 1429 1407 -1.6
(3, 2) 1586 1616 1.9
(6, 1) 1911 1885 -1.4
(2, 1) 72 74 2.7
(3, 1) 181 181 0.0
IBA Assembly
(4, 1) 328 326 -0.6
in Free–Free condition
(5, 1) 511 508 -0.6
(6, 1) 737 735 -0.3
(1, 1) UGS 362 - -
(4, 1) IBA 399 388 -2.8
RV + UGS Assembly (3, 1) IBA 406 - -
(5, 1) IBA 538 523 -2.9
(2, 1) IBA 606 - -
Table 5. N
atural Frequencies of the RV + CSB Assembly in Water obtained from the experiment. Figure 9b was obtained
from the FE analysis. Figure 9c shows the in-phase mode
Natural Frequencies shape of the overall model.
Mode Shape [Hz] Error
(n, m) [%] Using scale-similarity analysis, we derived the dy-
FEM Modal Test namic characteristics of the full-sized model, which are given
in Table 9. The scale-similarity analysis was carried out
(1, 1) 51 55 7.3
to the fifth mode in order to validate the FE analysis. The
(2, 1) 93 73 -27.4 correction factors listed in Table 8 were used to perform
(3, 1) 101 105 3.8
(4, 1) 214 213 -0.5
Table 6. N
atural Frequencies of the RV + UGS Assembly in Air
Natural Frequencies
Mode Shape [Hz] Error
(n, m) [%]
FEM Modal Test
(4, 1) 464 485 4.3
(2, 1) 566 525 -7.8
(5, 1) 613 631 2.9
Table 7. C
omparison of the Modal Tests and Finite Element Fig. 8. Frequency Response Function of the Completely
Analysis for the Completely Assembled CSB in Water Assembled CSB in Water
Natural Frequencies
Mode Shape [Hz] Error
(n, m) [%]
Modal Test FEM
(1,1) OOP 53 50 5.7
(1,1) IP 70 67 4.3
(2,1) 81 71 12.3
(3,1) 108 102 5.6
(4,1) 237 225 5.1
Fig. 9. Bending Mode Shapes of the APR1400 Reactor
(4,2) 247 252 -2.0
Internals: Amplitude of Vibration (Acceleration)
Table 8. C
orrection of Material Properties for the Scale-similarity Analysis
Structure Fluid
Scaled-down Scaled-down
Material Actual Model Correction Actual Model
Model Model
Property Factor
304 Stainless
Low Alloy Steel Aluminum 6061 Reactor Coolant Water
Steel
Density
8000 7850 2700 2.96 744.6 1000
[kg/m3]
Elastic Modulus
200 200 68.9 2.90 - -
[GPa]
Sound Velocity
in Fluid - - - 1019.5 1483
[m/s]
Table 9. R
esults of the Scale-similarity Analysis
Mode Shape Natural Frequencies
Factor
(n, m) [Hz]
Scaled-down Model Actual Model
Reactor Coolant
CSB AVMI NAVMI
Air Water Air Discrepancy
FEM Calculation
[%]
(1, 1) OOP 160.1 53 15.8 8.7 8.7 0.0 9.3 25.0
(1, 1) IP 160.1 70 15.8 11.3 10.7 5.3 7.2 19.4
(2, 1) 450.1 81 44.6 13.5 13.5 0.0 16.4 44.2
(3, 1) 457.0 108 45.2 15.6 16.2 -3.8 30.1 81.2
(4, 1) 744.8 237 73.7 38.6 39.4 -2.1 10.0 26.9
the similarity analysis. The materials used in the real model 5% between the first frequencies obtained by the FE
were low-alloy steel for the RV and 304 stainless steel for model and by the calculation based on scale-similarity
the other internals. Thus, we considered each material in analysis, validating our model. Thus, we can conclude that
the FEM. However, in scale-similarity calculation, it is our model is suitable for use in future seismic analysis.
impossible to calculate the NAVMI factor by using three
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