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e n e r g y

realistic Simulations for effective Decision Making

The safe design of nuclear reactor components is assured through a set of strict procedures from appropriate materials selection, detailed realistic modeling and analyses, high quality manufacturing processes, to non-destructive examinations and repair planning. Applying upfront design rules helps verify the acceptability of the calculated stresses for service and accidental scenarios.

To meet these stringent requirements, ESI offers scalable realistic simulation solutions where preliminary calibrations of the models are performed on elementary and generic coupons and the calibrated models applied to design assessments. This approach relies on increasingly realistic physics to deliver ‘as-built’ models under ‘as-operated’ loading conditions, allowing customers to make key decisions, providing significant gains in reliability, productivity and innovation through reduced conservatism whilst ensuring the respect of safety levels.

With the support of ESI‘s solutions, nuclear engineers simulate efficiently the behavior of specific nuclear components such as nozzles, primary circuit pumps, the reactor, the steam generator…. from their design through to manufacturing, maintenance, lifetime and decommissioning. This results in reduced complexity and risks, better decision making and a successful validation of physical prototypes.

eSI has unmatched expertise in realistic simulation for nuclear power, developed for many years with Framatome and validated by AreVA, along with other leaders worldwide in nuclear energy. As a result of this strong heritage, eSI complies with strict nuclear standards and brings a unique product-process approach for nuclear simulations. Today’s field of numerical modeling for nuclear engineering is broad and aims at guaranteeing conformity with nuclear standards and regulations for safety, performance, and lifetime of nuclear Power Plants (nPP).

Courtesy: Jeumont AREVA NP

engineering Modeling for nuclear Power

Design Optimization and Predictability for Lifecycle Certification using realistic computer simulation

✓ reliability: Step by step validation of the performance of the complete digital model

✓ Improved performance: Simulation of the Product Lifecycle

✓ Safety: Simulation of external hazards and associated safety measures.

✓ Lifetime: Assessment of the durability and integrity of components.

✓ Management: Spanning multiple domains and processes and integrating best practices

Mechanical Analysis

Realistic Modeling

Crack Analysis

3D mesh of a steam generator's bottom part

Courtesy: COMEX NUCLEAIRE

3D SYSTUS/SYSWELD simulation of a reactor vessel

Courtesy: AREVA

• Design and engineer

• Maintain

• extend Lifetime

• Decommission

Build it right

Test it right

Casting

Welding & Heat Treatment

Deliver it right

r e g U L ATO ry A S S e S S M e n T ST U D I e S

3-year Collaborative Project with COMeX nUCLeAIre: Stress report for replacement Steam generator

In collaboration with ESI, COMEX NUCLEAIRE (CxN) completed a Stress Report for Replacement Steam Generators (RSG) provided by Mitsubishi Heavy Industries Ltd. (MHI) in Japan. The project was undertaken for Electricité De France (EDF), the French utility company, under the control of the French Nuclear Safety Authority (ASN). The steam generator’s behavior was simulated in its environment taking into account 40 years of operating conditions and pre-defined accidental situations with help from an innovative realistic methodology complying with the RCC-M and RSE-M codes.

The approach consisted of evaluating large 3D structural models, coupling thermo-hydraulics and thermo-mechanics, assessing dynamics, elastic-plastic behavior and fast fracture along with fatigue and advanced analysis of the tube plate of the steam generator.

ESI experts in nuclear simulation played a major role by developing innovative modeling solutions for:

• Thermo-hydraulic analysis of the steam generator using the innovative meshless Finite Pointset Method (FPM) coupled with SYSTUS, ESI’s multiphysics software, and based on PAM-FLOW, ESI’s Computational Fluid Dynamics (CFD) code;

• Thermo-mechanical, Fracture Mechanics Analysis and regulatory checking using SYSTUS and SYSWELD, ESI’s welding and heat treatment simulation solution;

• Shock simulation using PAM-CRASH, ESI’s renown impact and crash simulation software.

ESI’s offering for nuclear

engineering is based on over

30 years of experience and is

highly recognized as meeting

the needs of the Nuclear Power

industry for thermohydraulics,

fluid dynamics, heat transfer,

metallurgy, structural

dynamics, mechanics and

electromagnetism, among

others.

ESI brings a comprehensive

and effective solution to the

nuclear sector, addressing the

need for design optimization,

time reduction, and high

quality results to meet safety

regulations.

NPP maintenance with ESI’s simulation solutions

Courtesy: COMEX NUCLEAIRE

Innovative analysis of the maintenance holes for the steam generator

Emergency cold water injection

Fluid flow during feedwater injection

3D lower assembly with primary manway and primary nozzle for in-shop hydrotest

eSI’s Proven Solutions Addressing nuclear Power Issues and Trends

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VIrTUAL PerFOrMAnCe

"as-built" conditions

"as-operated" conditions

VIrTUAL MAnUFACTUrIng

VIrTUAL enVIrOnMenT

Courtesy: AREVA, COMEX NUCLEAIRE, DCNS, EMIGE, IRSN,

Jeumont AREVA NP

P I O n e e r I n g A LT e r n AT I V e e n e rgy S O U rC e S

Prediction of Weld Assembly Distortions for ITer Vacuum Vessel

ITER (International Thermonuclear Experimental Reactor), currently under construction in the South of France, aims to demonstrate that fusion is a future energy source. AREVA has selected ESI and other partners to predict with simulation the advanced assembly of the ITER vacuum vessel during manufacturing. ESI’s electron beam welding study has been validated for the prediction of distortions in large welded assemblies.

Ag e I n g M A n Ag e M e n T

Mechanical Analyses for Lifetime Assessment

Advanced studies performed for AREVA over the years cover fuel assembly computations and detailed behavior analyses of nuclear components subject to heavy loads (pressure, vibration, corrosion, …).The analysis of the upper internals of ATMEA® – AREVA/MHI reactor vessel – confirms the ability of SYSTUS multiphysics software to quickly handle complex simulations and large models. Here the model comprised of 1 600 000 nodes and 590 000 quadratic elements was processed in 20 minutes on a Linux workstation (4 processors). ESI also used SYSTUS to carry out an elasto-plastic study of steam generator tube support plates, including large FE models with one million degrees of freedom.

S A F e T y M A rg I n A S S e S S M e n T

Improving Maintenance of nPP Components

ESI’s in-depth experience in fracture mechanics, built and validated in partnership with AREVA over the last twenty years, is continuously growing. ESI offers a recognized software solution based on SYSTUS and SYSWELD for accurate crack analysis in structures including crack propagation in bimetallic weldment. Ductile crack growth simulation is carried out with automatic mesh generation, automatic computation and post-processing for bends and cracks, enabling the accurate prediction of degradation mechanisms on components and structures accounting for the residual stresses from manufacturing.

ACC I D e n TA L S I T U AT I O n S

IMPACTDrop Test Simulation Including Internal Parts

ESI simulated a fuel cask regulatory drop test for AREVA: 9 m fall over a blunt target. The perforation analysis of the external skin was carried out with PAM-CRASH Multi-Model Coupling to handle large models and complex physics.ESI’s expertise also encompasses seismic loads, explosions in or around buildings and vehicles or aircrafts impact on structures.

eArTHQUAKeSSeismic requalification of nuclear Buildings

ESI has carried out the seismic requalification of nuclear buildings. The objective was to take into account an increased seismic load for a renewed usage of the building, new mass distributions and openings in the walls, and new regulations.3D static, dynamic simulations and stability evaluations were performed using SYSTUS, such as soil structure interaction, reinforcement steel calculation and detailed behavior of specific equipment included in the building model.

Courtesy: AREVA NP / Bernard Gaucherand

Accidental explosion. © Copyright 2002-2009 IRSN

Courtesy: AREVA, DCNS

Crack propagation and stability in bimetallic welded joint Courtesy: AREVA

eSI’s Proven Solutions Addressing nuclear Power Issues and Trends

Model of Reactor Vessel

Displacements

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Courtesy: AREVA

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C e rT I F I C AT I O nESI’s quality assurance program is established to meet the stringent needs of the nuclear sector. Indeed, in addition to our ISO 9001 certification, ESI complies with standards for nuclear applications such as 10CFR50, ASME-NQA1, Q-N-100 and Q-N-300 (for AREVA), and SGAQ (for EDF). In Japan, Nihon ESI is a certified supplier to MHI.

I n T e r n AT I O n A L r e F e r e n C e SeSI’s expertise is recognized by leaders in nuclear power worldwide including AreVA, B&W, BArC, COMeX nUCLeAIre, DHI, Dong Fang, eDF, general-electric, gnPH, IgCAr, JAeA, JSW, MHI, nPCIL, Skoda Power, Suez-Tractebel, Toshiba, Vitkovice, …

ESI’s expertise in the nuclear field dates back to the 1970s when ESI was involved in a series of safety related assessments for nuclear buildings under extreme loading conditions. It was extended in 1997 with the acquisition of Framasoft®, a subsidiary of Framatome (now AREVA). ESI's customers today benefit from its in-depth knowledge, developed in numerous Research and Development activities conducted jointly with AREVA.

K e y PA rT n e r S H I P SESI has strengthened its long lasting partnerships with AREVA, COMEX NUCLEAIRE, EDF and Mitsubishi Heavy Industries (MHI) and other industrial companies in a number of countries as well as with safety authorities such as the French Institute for Radiological Protection and Nuclear Safety (IRSN), French Atomic Energy Commission (CEA), and Japan Atomic Energy Agency (JAEA).

eSI’s Trusted Partners for nuclear engineering

Joint Services Offering

eSI’s partnership with COMeX nUCLeAIre aims at developing a universal services offering to help industry leaders improve the performance of their nuclear facilities by performing projects and tests virtually. Both companies collaborate on nuclear and industrial maintenance projects.ESI offers dedicated services in partnership with COMEX NUCLEAIRE:• Crack repair engineering: Methodology for optimal crack repair strategy and planning• Steam generator Operation engineering: Simulation-Based Management of steam generator ageing to optimize equipment performance

Courtesy: AREVA

Long Lasting Partnership

“ AREVA, world leader in the electro-nuclear engineering field, and ESI Group have established a strongtechnical cooperation over the years. This partnership includes detailed analyses of components behaviors, studies on fracture mechanics and the development of numerical simulation tools. ”Philippe gilles, International expert in structures and materials, AreVA

eSI has signed a Corporate Agreement with eDF-Septen - basic design and engineering department of EDF French utility - for nuclear power plants. The contract deals with mechanical studies for the design and maintenance of components in Pressurized Water Reactors such as fast fracture analysis, feasibility and validation studies.

A successful first experience with MHI in Japan allows eSI to offer advanced competencies to support the development of nuclear Power activities worldwide.

“ This agreement attests to the synergy of our fields of expertise and to the demonstrated effectiveness of our joint teams on several projects. ”Dr. François Billon, Technical Director and Director of the MHI-Cxn Partnership Courtesy: COMEX NUCLEAIRE

ESI Group Headquarters100-102 Avenue de Suffren75015 ParisFrAnCeT. +33 (0)1 53 65 14 14F. +33 (0)1 53 65 14 12