Heat Transfer, Thermal-Stress and Pipe-whip Analysis in Steel Pipes of a Nuclear Power Plants by ABAQUS/Standard

G. Snchez Sarmiento1,2, M.J. Mizdrahi2, P. Bastias3, and M. Pizzi2

1) Facultad de Ingeniera, Universidad de Buenos Aires, Av. Paseo Coln 850, Buenos Aires, Argentina. 2) KB Engineering S.R.L., Florida 274, Of. 35. Buenos Aires. 3) DANA Corporation, Plumley, TN, USA.

1. INTRODUCTION
The Second Heat Sink System (SHS) of the Nuclear Power Plant Atucha I (Buenos Aires Province, Argentina), is an auxiliary security system recently constructed into the existing Plant. This system has the purpose of extending the useful life of the Plant (put in operation in 1974) by an additional eight years. SHS is composed by two subsystems: a) a source of desmineralized water for the Steam Generators in emergency situations (Piping System RX); and b), an increase of the redundancy in the Venting Station of Life Steam (Piping System RA). The installation of this piping system had been accomplished by CONUAR S.A., a company who subcontracted to several local companies for the Detail Mechanical Engineering. Between them, KB Engineering S.R.L. performed the stress and thermal analyses of several mechanical components of SHS, employing sophisticated calculation techniques compatible with the several quality standards required for nuclear constructions. A brief review of several finite element models for the determination of mechanical and thermal stresses in the SHS System, is presented in this paper. The models were developed by ABAQUS/CAE [1], solving with ABAQUS/Standard the problems of temperature distribution and of thermo-elastic-plastic stress and strain distribution of several components, subjected to complex loads of normal operation as well as postulated accidents. As examples of the applications performed, the three following analyses are reviewed in this paper: a. Design and stress analysis of T-connections of the SHS System with an already installed Feed-water System RL. The design was based on internal pressure load, and further analysis take into account thermal shock, thermal stratification and pipe forces. Stress analysis of the penetrations of the piping circuits througth the steel containment.

b.

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c.

Calculations of pipe-whip displacements and stresses of the piping circuits caused by double-guillotine faults, and design of protection devices against impact on adyacent pipes, components or instruments.

Details of the analyses were previously described in several technical reports [2-7], and are briefly summarized in this paper. ABAQUS proved to be an efficient tool for modeling such complexes structural components, under the special mechanical and thermal efforts that appear in nuclear power plants.

2. DESIGN OF T-CONNECTIONS AND ANALYSIS OF ITS THERMAL SHOCK.

2.1. Methodology of design and analysis. The pipe subsystem RX, whose purpose is the resource of water to the steam generators in emergency situations, is composed by two independent circuits, named RX01 and RX02. They are connected to the formerly installed Feed Water Systems through two respective steel Tconnections. One of these T-connections is indicated in figure 1. The proposed methodology of design and analysis of the T-connections is as follows: Part 1: Design based on calculation standards [8-10] and finite element analysis applying only design internal pressure over the component. Part 2: Verification of the structural integrity by finite element analysis taking into account all other thermal and mechanical loads: Piping forces, thermal stratification and thermal shock. Between them, the thermal shock condition is by far the most important one in the case under consideration. For this consideration, the analysis consists of the following successive steps: Step a) Calculation of the transients flow and pressure of water within the pipes, by means of numerical techniques that are based on finite-difference schemes and on the characteristics method. Step b) Evaluation of the time-dependent heat transfer coefficient of the pipe internal surfaces, based on the results of step a). Step c) Finite element calculation of the transient temperature distribution in the component, using the heat transfer coefficient obtained in step b). Step d) Finite element calculation of the transient thermal stresses distribution, caused by the temperature gradients calculated in step c).

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Figure 1. Circuit RX01 and its T-connection with the System RL01. 2.2. Design of the T-connections Both T-connections have the function of connect a pipe with a nominal diameter of 300 mm and a thickness of 10 mm with a derivation of a diameter of 120 mm and of the same thickness. Following the calculation standards of refs. 8-10, taking into account only a design internal pressure of 60 bar and a design temperature of 60C, a geometrical design of the Tconnection has been proposed. With this geometry proposed, the finite element model shown in figure 2 has been developed using ABAQUS/CAE. Applying to the model only an internal pressure of 60 bar and the corresponding close forces on the three extremes of the pipes, the stress distribution in all the component was obtained. The von Mises equivalent stress distribution is shown in figure 3.

Figure 2.- General view of the finite element model developed for the T-connection, showing its finite element discretization

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Figure 3. Distribution of the von Mises equivalent stress on the internal surface of the T-connection and on the plane of symmetry, only by the design internal pressure (60 bar).

2.3. Calculation of the transients flow and pressure of water within the pipes
A thermal shock in the T-connection is produced immediately after a start-up of a valve, that produce a water flooding with a temperature of 20C into the pipes and the T-connection that were initially at a temperature of 170C. The time dependent flow and pressure of the water at the output of the valve was calculated by means of a finite-difference-characteristics scheme of the Navier-Stoeks equations. The main results for both circuits RX01 and RX02 is plotted in figure 4. One can there observes that at the beginning is generated an increase of the pressure, reaching 80 bar at the outlet of the pump, while at the valve section the pressure is of the order of 90 bar.

2.4. Calculation of the time-dependent heat transfer coefficient.

Using correlations formulae from the literature [11] between the Biot number and the Reynolds and Prandt numbers, estimation of the time-dependent heat transfer coefficient of the pipe internal surfaces are obtained. Details of the calculations are described in the internal report of ref. 4.

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Figure 4. Time variation of the flow and pressure through the pumps of the circuits RX01 and RX02 during their start-up.

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2.5. Calculation of the transient temperature distribution.

Using the finite element model of figure 2, the transient temperature distribution at all the extension of the T-connection since the valve opening, has been calculated by ABAQUS/Standard under the following initial and boundary conditions: An initial temperature of 220C, corresponding to the condition of normal operation. A convective boundary condition on the internal surface of the entire connection, with a heat transfer coefficient calculated in the former step, and a constant temperature of the fluid equal to 20C. An adiabatic boundary condition at all the external surface, assumed for the complete time of the simulation.

A total simulation time of 40 seconds has been considered. The temperature distribution at 28 seconds after the start-up of the valve opening is shown in figure 5 left.

2.6. Calculation of the transient stress distribution.

The transient stress state in the T-connection after the start-up of the valve is the result of the following simultaneous actions:

Figure 5.- Temperature distribution at the surface (left) and the corresponding equivalent von Mises stress on a simmetry plane at 28 sec after valve opening. Variable internal pressure, given by figure 4 down. Transient temperature distribution, previously calculated in Section 2.5. Forces and moments acting on the three extremes of the pipes, resultant from a former piping stress analysis.

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The transient stress distribution corresponding to the superposition of these three loads are obtained by means of ABAQUS/Standard, for the period of 40 seconds after the start-up of the valve opening. It was observed that the maximum stresses are reached at t = 28 seconds. As an example of the obtained results, the distribution of the normal stress in the plane of symmetry of the connection and on the internal surface is shown in figure 5 right.

3. CALCULATION OF THE STRESS AND STRAIN DISTRIBUTIONS IN PENETRATIONS OF THE PIPES UIT THE STEEL CONTAINMENT
Both piping systems RX01 and RX02 penetrate the steel containment through two identical nozzles. A drawing of the nozzle through a vertical plane of symmetry is shown in figure 6. The mechanical and thermal loads that act over the nozzles are complex combinations of internal pressure, temperature gradients and piping forces and torques. The main loads correspond to postulated loss of coolant accident (LOCA), in which case the containment and its penetrations are subjected to an internal pressure, gradient temperatures and piping forces. A finite element model shown in figure 7 was developed for the verification of the structural integrity of the nozzles to such postulated loads.

Figure 6.- Penetration of the pipes RX01 and RX02 through the steel containment. 2004 ABAQUS Users Conference 637

The design pressure of the present containment is of 2.8 bar, that cover the postulated LOCA for this plant. For this load, the stress distribution was calculated by ABAQUS/Standard. A deformation diagram as well as the corresponding von Mises equivalent stress distribution are shown in figures 8 and 9 respectively.

Figure 7. Detail of the finite element model developed for the penetration of the pipes RX01 and RX02 through the steel containment, viewed from the inside of the containment.

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Figure 8. Deformation diagram obtained for design internal pressure of the steel containment (Magnification factor: 50).

Figure 9. Von Mises equivalent stress distribution for design internal pressure.

4. CALCULATIONS OF PIPE-WHIP TRANSIENT DISPLACEMENTS AND STRESSES OF THE PIPE SYSTEM CAUSE BY DOUBLE GUILLOTINE FAULTS.
In stationary conditions, the pipes of the SHS System are completely full of water at room temperature and at a mean design pressure (43.3 bar in our case). But in an extreme unlikely event of a double-guillotine fault in some weld of a pipe, the internal pressure of water, unbalanced at both parts into the pipe is divided, produces dynamic reaction forces. These forces produce instantaneous displacements of both parts of the pipe, which can produce dangerous impacts into other adjacent pipes, components or instruments. This phenomenon is known as pipe-whip. It is necessary to provide adequate protection devices for this kind of event. Different kinds of energy absorber protection devices for pipe-whip phenomena are reviewed in refs. 12-13. Very complete reviews of calculation methodologies employed for this kind of dynamic analysis, with different types of protection devices, had been presented in the reports of refs. 15 and 23. Adequate computational systems are described in refs. 16, 17 and 18. Location of protection devices basically conformed by steel cables of U-shape are proposed for the SHS System in the report of Ref. 6. An example of them is indicated in figure 10. The technical characteristics of the U-shape devices are described in refs. 12 and 13. Following a methodology similar to the employed by the PIPERUP program [17], calculations of the dynamic stress and strain following double-guillotine faults had been performed using ABAQUS/Standard for a lot of postulated welds of the pipe system under consideration. For this purpose, models of both piping systems were been developed, constituted by PIPE and ELBOW elements. 2004 ABAQUS Users Conference 639

The isometric diagram of the circuit RX01 is shown in figure 12. The boundary conditions are indicated in figure 13 (superior view of the model).

Figure 10. Example of U-shape device installed for protection against pipe-whip force.

Figure 11. Postulated time variation of the pipe-whip force.

The reaction force FR is basically dynamic, and its maximum value is generally reached in a very short time (between 5 and 15 milliseconds). Following a usual practice [15, 21], we assume a time variation of the force as indicated in figure 11, where FR-max is given by:

FR max = s s P0 Ai + Ps ( Ae Ai )
where Ae is the external section of the pipe; Ai is its internal section; Po is the operation internal is a named thrust factor that pressure; Ps is the saturation pressure of the fluid; and ss depends on pressure and temperature of the fluid and on its friction with the wall pipe. For the present case a value of ss = 1.0 must be applied. As an example of the results obtained for the System SHS, that are detailed described in the report of ref. 6, some results concerning a part of the circuit RX01 is reviewed at follows. A vertical view of a part of the circuit RX01 is shown in figure 13- above. An U-shape protection device as in figure 10 was installed at the right-bottom elbow. Assuming a complete failure of a weld located in the right-top boundary, the maximum deformation calculated of the pipe part is shown in figure 13-below. The enlargement of the protection device is appreciated in this figure. The time-dependent displacement (modulus and cartessian components) of the elbow is plotted in figure 14-left. Also, in figure 14-right is shown the modulus and components of the reaction force at the U-shape device.

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5. CONCLUSIONS
Several applications of ABAQUS/Standard for a nuclear piping system were reviewed in this paper, showing the adequacy of this software in solving the most complex situations that appear in this kind of analysis. It was also presented a bibliographic review of the analysis described.

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REFERENCES
[1] [2] Hibbitt, Karlsson and Sorensen, Inc: ABAQUS/Standard, Versin 6.3. 2002. G. Snchez Sarmiento, P.C. Bastas, M. Mizdrahi and M. Pizzi: Second Heat Sink of CNA I. Design and stress analysis of T-connections of the SHS system with the Feed-water System RL (In Spanish). Technical Reports of CONUAR CNAI-MC-21, Rev. 1, 8-2-2002 and CONUAR CNAI-MC-25, Rev. 0, 8-5-2002. G. Snchez Sarmiento: Second Heat Sink of CNA I. Dynamic analysis of water hammer transients. Determination of the axial forces (In Spanish). Technical Report of CONUAR CNAI-MC-20. Rev. 0. 7-2-2002. G. Snchez Sarmiento, P.C. Bastas, M. Mizdrahi, M. Pizzi: Second Heat Sink of CNA I. Stress analysis of T connections between the Systems SHS and RL by thermal shock, pipe forces and thermal stratification (In Spanish). Technical Report of CONUAR CNAIMC-23, Rev. 0, 13-3-2002. Hibbitt, Karlsson and Sorensen, Inc: ABAQUS/Standard, Versin 6.3. 2002. G. Snchez Sarmiento, P.C. Bastas, M. Mizdrahi and M. Pizzi: Second Heat Sink of CNA I. Design and stress analysis of T-connections of the SHS system with the Feed-water System RL (In Spanish). Technical Reports of CONUAR CNAI-MC-21, Rev. 1, 8-2-2002 and CONUAR CNAI-MC-25, Rev. 0, 8-5-2002. G. Snchez Sarmiento: Second Heat Sink of CNA I. Dynamic analysis of water hammer transients. Determination of the axial forces (In Spanish). Technical Report of CONUAR CNAI-MC-20. Rev. 0. 7-2-2002. G. Snchez Sarmiento, P.C. Bastas, M. Mizdrahi, M. Pizzi: Second Heat Sink of CNA I. Stress analysis of T connections between the Systems SHS and RL by thermal shock, pipe forces and thermal stratification (In Spanish). Technical Report of CONUAR CNAIMC-23, Rev. 0, 13-3-2002. G. Snchez Sarmiento, P.C. Bastas, M. Mizdrahi, M. Pizzi: Second Heat Sink of CNA I. Stress analysis of the penetrations of the piping circuits RX01 and RX02 throught the steel containment (In Spanish). Technical Report of CONUAR CNAI-MC-23, Rev. 0, 13-32002. G. Snchez Sarmiento, M. Mizdrahi, M. Pizzi: Second Heat Sink of CNA I. Calculations of pipe-whip displacements and stresses of the piping circuits RX01 and RX02 (In Spanish). Technical Report of CONUAR CNAI-MC-24, Rev. 0, 8-4-2002.

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Figure 12. Isometric scheme of the circuit RX01.

Figure 13. Above: Vertical view of a part of the circuit RX01. Below: Displaced pipe in the case of a double-guillotine fault in the right-superior limit.

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[11]

G. Snchez Sarmiento, P.C. Bastas, M. Mizdrahi, M. Pizzi: Second Heat Sink of CNA I. Stress analysis of the penetrations of the piping circuits RX01 and RX02 throught the steel containment (In Spanish). Technical Report of CONUAR CNAI-MC-23, Rev. 0, 13-32002. G. Snchez Sarmiento, M. Mizdrahi, M. Pizzi: Second Heat Sink of CNA I. Calculations of pipe-whip displacements and stresses of the piping circuits RX01 and RX02 (In Spanish). Technical Report of CONUAR CNAI-MC-24, Rev. 0, 8-4-2002.

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Figure 14. Left: Displacement components of the below located at the right-bottom corner of figure 12 after a pipe-whip scenario. Right: Reaction forces at the corresponding U-shape device. [13] G. Snchez Sarmiento, P.C. Bastas, M. Mizdrahi, M. Pizzi: Second Heat Sink of CNA I. Stress analysis of the penetrations of the piping circuits RX01 and RX02 throught the steel containment (In Spanish). Technical Report of CONUAR CNAI-MC-23, Rev. 0, 13-32002. G. Snchez Sarmiento, M. Mizdrahi, M. Pizzi: Second Heat Sink of CNA I. Calculations of pipe-whip displacements and stresses of the piping circuits RX01 and RX02 (In Spanish). Technical Report of CONUAR CNAI-MC-24, Rev. 0, 8-4-2002. CONUAR MATERIAL SPECIFICATION SHEET: Heat resistant Steel forgings Tees with straight or angle sockets fir use at full service pressure (p = 100 bar; T= 300 C). MSS A(2) 01Rev.0 (R. Lpez y M. Solari). 01-07-01. DIN 2615 part 2: Deutsche Normen UDC 621.643.414.063 Butt Welding Steel Fittings.

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TRD 301: Technical Rules for Steam Boilers Calculation for cyclic loading due to pulsating internal pressure or combined changes of internal pressure and temperature. UDC 621.181.02.001.2:539.431. Ed. April 1975. RE-L 1515E: Specification Piping Quality Class 1, 2, and 3. KWU Rev. 29-8-90. A.J. Chapman: Heat Transfer. MacMillan Publishing Co. Fourth Edition, 1984. M.A.G. Silva: Project of energy absorber piping supports (In Portugues). RevBrCMec V.1, Sept. 1979, 1-10. P. Hernalsteen y L.C. Leblois: The use of energy absorbers to protect structures against loading. Nuclear Engineering and Design, 37 (1979) 373-406. Jedlicka, Bianchi y Jessikowsky: Calculation of pipe whip restraints. Technical Report of ENACE TM-IT 159 (1985). B.R. Strong, Jr y R.J. Baschiere: Pipe rupture and steam/water hammer design loads for dynamic analysis of piping systems. Nuclear Engineering and Design, 45 (1978) 419-428. S. Chen: PIPERUP Computer Program. Verification Manual. Quadrex Co. Report QUAD-7-81-048. Rev. 5. 17-8-84. G.H. Powell, D.G. Row, J.G. Hollings, D.T. Mondkar, M. Mahasuverachai, S. Nour-Omid, C. Oughourlian y A. Riahi: Computer Code Development for Pipe Whip and Impact Analysis. Progress Report for Year I. NUREG/CR-1721. UCRL-15273. R5. 1982. Schneberg: Data sheets for determining transients and steady state discharge rates and thrust factors in case of broken steam and water lines. Technical Report of KWU N R 142/3652 e. Stahl: Strahl -und Reaktionskrfte aus postulierten Rohrleitungsversagen inHilfs und Nebensystemen. Technical Report of KWU N R 612/84/001. Stahl: Strahlkraftebelastungen aus postulierten Rohrleitungsversagen auf den Hhenkoten 4.40 m und 8.5 m. Technical Report of KWU N R 612/84/0037a. Serrano: Jet and Reaction forces caused by pipe breaks. Calculation Catalog. Revised Version. Technical Report of ENACE TS2 394 (1993).

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