AREVA Fatigue Concept - Atoms for Peace and Development · PDF fileAREVA Fatigue Concept IAEA...

AREVA Fatigue Concept IAEA TM Lab Tour, JULY 8, 2016

Steffen Bergholz / Dr. Jürgen Rudolph PEEP-G AREVA GmbH [email protected] +49 9131 900 96170

All rights are reserved, see liability notice.

Introduction Regulatory Requirements AFC (AREVA Fatigue Concept) Fatigue Monitoring & assessment FAMOSi hardware & software

IAEA Technical Meeting on Fatigue Assessment in Light Water Reactors for Long Term Operation AREVA Fatigue Concept (AFC) – Steffen Bergholz / Dr. Jürgen Rudolph - p.3


1. Introduction



Introduction

Detail



The Civaux „case“ Le Duff et. al.: PVP2011-57951

Lessons learned: Thermal loads Operation modes Design Manufacturing improvements:

• Removal of weld roots • Fine polishing of internal surfaces

Forging of EPRTM RHRS mixing zones (forged 316L)

Low residual stresses


Introduction


Solution approach: AREVA FATIGUE CONCEPT To compute and monitor fatigue usage of NPP components To reduce conservatisms in fatigue evaluations due to the acquisition and evaluation of CUF based on real power plant transients

Current context: Longer lifetime of new NPP’s (e.g. EPRTM 60 years) Lifetime extension of existing plants 60 years or even 80 years Tightening of nuclear codes (EAF, Fen, more severe fatigue curves) Evolution of operating modes (load following operation)


Introduction

All rights are reserved, see liability notice. IAEA Technical Meeting on Fatigue Assessment in Light Water Reactors for Long Term Operation AREVA Fatigue Concept (AFC) – Steffen Bergholz / Dr. Jürgen Rudolph - p.8

Introduction


2. Regulatory requirements



Regulatory Requirements

Published on: http://www.kta-gs.de/common/regel_prog1.htm IAEA Technical Meeting on Fatigue Assessment in Light Water Reactors for Long Term Operation AREVA Fatigue Concept (AFC) – Steffen Bergholz / Dr. Jürgen Rudolph - p.10


Regulatory Requirements


EAF according to NUREG/CR-6909

Fen - factors for austenitic stainless steels

Strain rate in [%/s]

Temperature in [°C]

Fen

Fen - Factors for partial usage factors:

Fen = (NRT,air / NMedium)

Fen,SS = Fen( ; T, O2)

Fen,CS = Fen( ; T; O2; S)

Usage factor with EAF:

ε

∑=

⋅=n

kken

airrtk

k FNnU

1,

,,

Maximum value: 14,513! Typical values: 3 - 5

Design practice: individual determination requires strain rate dependance

ε



EPRI working Group developed methods for Fen determination

Stra

in

Time

“Simplified Peak-Valley modified” m

j jen,i i

jen,i m

ji

j

FF

⋅ ∆ε=

∆ε

∑

∑

∆ε ji

= 1j

∆ jiT

jen,iF

j m=

Local Maximum

Local Minimum

“Simplified Min-Max”

1 1, withen,i en,i iF F= ∆ε

∆ 1iT

1∆εi1

en,iF2i∆ε

1 1 2 2

1 2en,i i en,i i

en,ii i

F FF

⋅ ∆ε + ⋅ ∆ε=

∆ε + ∆ε

Local Maximum

Local Minimum

∆ 1iT ∆ 2

iT

“Simplified Peak-Valley”

2en,iF

1∆εi1

en,iF

All available in AREVA Fatigue Concept



3. AREVA Fatigue Concept (AFC)



Fatigue Monitoring methods



AREVA’s Philosophy

DESIGN TRANSIENTS

MONITOR THE LOCAL LOADS!

DESIGN PHASE

REAL OCCURED

TRANSIENTS

OPERATION PHASE



SBF different loading types different thermal stresses



Load Evaluation

Analyses

OPE

RAT

ION

ER

ECTI

ON

Analyses

FAMOSi Local Measurements

FAMOSi Software

Licensed status

Ageing & Lifetime Management

For

Long Term Operation

Optimization

Availability

Detection of failures

Design transients Approval

Thermal loads specification

Simplified fatigue estimation

Fast fatigue evaluation

Detailed fatigue calculation

Operational Measurements

Transfer Function (Virtual Measurements)

CONTARE + CBF

AREVA Fatigue Concept - AFC



AFC / FAMOSi Hardware



FAMOSi Locations on EPRTM Measurement section

Measurement sections are located at fatigue relevant points in the systems of the NPP (e.g. Taishan 1&2):

Primary loops Surge line Spray lines Chemical and volume control system Safety injection system lines Feedwater system and

emergency feedwater system of steam generator

170 thermocouples spread at 37 measurement sections are complementing the operating signals given by the standard plant instrumentation



FAMOSi Local Measurement Section

Temperature

Stress

Fatigue relevant location



History of FAMOS Measurement sections



Fatigue Monitoring Hardware FAMOSi (i = integrated) based on special analog/digital-converter supported by AREVA TXS I&C Hardware Bus structure reduces the cable routes AREVA standard hardware secures supply of spare parts FAMOSi Information Module IM for digitizing of thermocouple signals (inside containment) FAMOSi Processing Unit PU for data analyzing and storage (inside containment) FAMOSi Server Unit SU as long term database (outside containment)

EPR: 170 thermocouples spread at 37 measurement sections



AFC / FAMOSi software



AFC / FAMOSi software

-

INNER WALL THERMAL FIELD

STRESS FIELD

CUMULATIVE USAGE FACTOR

FFE

Rai

nflo

w

Rai

nflo

w

Wöh

ler d

ata

Uni

t tra

nsie

nts

Uni

t tra

nsie

nts

Inne

r wal

l tem

pera

ture

Stre

ss ra

nges

SELECTION OF

COMPONENT

DATA IMPORTER

Live display

Impo

rt to

dat

abas

e

FAMOSi VIEWER

SQL DATABASE

Dat

a fo

r vie

win

g

Rai

nflo

w

PLAUSIBILITY CHECK

Ran

ges

fluct

uatio

ns

CLASSIFICATION MATRIX

Ope

ratin

g si

gnal

s

Logi

c sc

ripts

SFE

Open platform for analysing measurement data further functions can be added to the database



SFE – Simplified Fatigue Estimation



Simplified Fatigue Estimation - SFE



Stresses due to the thermal shock: fa reduction factor for consideration of the final heat transfer coefficient fsn stress concentration factor for weld seams fkr stress concentration factor for consideration of the bent geometry ET Elastic modulus

Alternating Stress Intensity:

TEfff TT

KRSNav ∆⋅⋅−

⋅⋅⋅⋅=∆ αν

σ1

2

vT

KTAaE

ES σ∆⋅⋅= 5,0

Simplified Fatigue Estimation - SFE



FFE – Fast Fatigue Evaluation



SleeveTinnen (SINTOC)

Beispiele für ermüdungsrelevante Positionen

Tübertragen

Taussen (FAMOS)

Tin (FFE)

Tout (FAMOS)

Tin_transfer

FFE principle

Inner wall temperature at the measured section

FE- Model of the analyzed structure Elementary transient Stress reference responses DATABASE

Stress calculation at the fatigue relevant locations

Time dependant stress tensor

Stress [N/mm²]

Fatigue relevant positions



∆Tref

Elementary Transient


The elementary transients function is calculated based on an FE model Example for a stress calculation

The stress references are saved in a database

Stress [N/mm²]

-400

-300

-200

-100

00 10 20 30 40 50 60

Time [s]

Str

ess [

N/m

m²]

Stress [N/mm²]

Stress_reference

Time [s]

Stre

ss [N

/mm

²] FEM

UT Temperature slope

020406080

100120140

0 1 2 3

Time [s]

Te

mp

era

ture

[°C

]

Inner_wall tempPre

para

tion,

FE

- Cal

cula

tion

Tem

pera

ture

[°C

]

Time [s]

Tref

Elementary Transient




After initialization of the Green’s functions calculation can be done with FAMOSi

Scaling process is performed Stress is calculated Rainflow algorithm is implemented for fatigue calculation

FAMOSi Software






DFC – Detailed Fatigue Calculation



Generation of detailedcomponent model

Optional coupling withadjacent piping system

(piping loads)

T1.INP

T2.INP

T3.INP

TN.INP

TI.DBTI.RTHTI.OUT

Impl

emen

tatio

nof

tem

pera

ture

trans

ient

sIm

plem

enta

tion

of te

mpe

ratu

retra

nsie

nts

T1S.INP

T2S.INP

T3S.INP

TNS.INP

TIS.DBTIS.RTHTIS.OUT

Thermal transientFE-analyses

Thermo mechanicalFE-analyses

Fatigue Postprocessing (U = …)

I = 1

…N

Time

Tem

pera

ture

Load Data

I = 1

…N

ThermalDatabase

MechanicalDatabase




FAM (FAtigue Module) is a Post-Processing-Tool for ANSYS® for the detailed fatigue calculation according to established design codes including actual EAF demands




Detailed Fatigue Calculation: Loading data as essential input

• Data of operational period (catalogue of model transients) • Anticipated loads of future operation (updated design transients)

Fatigue analysis according to design codes (RCCM; ASME; KTA …) • Simplified elasto-plastic elastic FEA + plasticity correction by Ke

- Standard Ke-procedure - Advanced Ke-procedures (see PVP2012-78042 paper)

• Direct methods - Twice Yield Method - Simplified theory of plastic zones (see PVP2013-97137 paper)

• Elasto-plastic non-linear FEA - Standard plasticity models - Advanced plasticity models in connection with ratcheting check (see PVP2011-57229 paper)

SBF plus associated Fen-factors consideration of environmentally assisted fatigue = EAF

Analyses Model transients

catalogue Detailed fatigue

calculation C

ON

SERVATISM




Simplified elastic-plastic analysis by application of Ke-factors

Simplified elastic-plastic analysis by application

of direct methods

General elastic-plastic

analysis

CO

NSER

VATISM

EFFOR

T




0,00

50,00

100,00

150,00

200,00

250,00

300,00

350,00

01:00 01:30 02:00 02:30 03:00 03:30 04:00 04:30 05:00 05:30 06:00Time

Tem

pera

ture

in [°

C]

Tloc,eTloc,iTmclTprTsl

Tloc,eTloc,iTmclTprTsl

Pressurizer spray line

POI operational / local




FE model of spray line and pressurizer (shell type elements)

Pressurizer (PRZ)

Reactor coolant line (RCL)

Spray line

Auxiliary spray line

Analysis example: spray line




Model of spray line and pressurizer

(shell type elements)

Detail model of T-section (brick type elements)

Detail model of spool (brick type elements)

Detail model of spray line nozzle

(brick type elements)




[°C]

Exemplary temperature stratification modeling for transient thermal analysis

Cold water injection




[N/mm2]

Highly stressed regions

Conclusion: Thick walled transition regions and thermosleeve connections are particularly prone to fatigue damage

Pipeline connection (shell model)

Von Mises exemplary stress distribution in T-section due to thermal loading




LIVE presentation of AFC / FAMOSi



LIVE presentation of AFC / FAMOSi

7 Thermocouples

Lamp:

Periodically on/off

Amplifier and embedded computer

Live monitoring



Load Evaluation

Analyses

OPE

RAT

ION

ER

ECTI

ON

Analyses

FAMOSi Local Measurements

FAMOSi Software

Licensed status

Ageing & Lifetime Management

For

Long Term Operation

Optimization

Availability

Detection of failures

Design transients Approval

Thermal loads specification



Detailed fatigue calculation

Operational Measurements

Transfer Function (Virtual Measurements)

CONTARE + CBF

AREVA Fatigue Concept - AFC


END OF PRESENTATION AREVA Fatigue Concept IAEA TM Lab Tour, JULY 8, 2016

Steffen Bergholz / Dr. Jürgen Rudolph PEEP-G AREVA GmbH [email protected] +49 9131 900 96170


Editor and Copyright 2015: AREVA GmbH – Paul-Gossen-Straße 100 – 91052 Erlangen, Germany. It is forbidden to reproduce the present publication in its entirety or partially in whatever form without prior consent. Legal action may be taken against any infringer and/or any person breaching the aforementioned prohibitions.

Subject to change and error without notice. Illustrations could be similar. The statements and information in this brochure are for advertising purpose only and do not constitute an offer of contract. They shall neither be construed as a guarantee of quality or durability, nor as warranties of merchantability and fitness for a particular purpose. These statements are based on information that was available to us at the date of publication. Only the content of the individual contracts shall be authoritative for type, quantity and properties of goods and services.

AREVA Fatigue Concept / FAMOSi - Introduction for SNPI Steffen Bergholz - 2015 - AREVA GmbH Proprietary RESTRICTED AREVA - © AREVA - AL: N - ECCN: N - p.60

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