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DOE OSTI2016

Numerical investigation of the flow inside the helical coil steam generator test section - 18589

A Helical Coil Steam Generator (HCSG) is one type of heat exchangers used for the purpose of increasing the efficiency of heat transfer with low pressure drop in recent design of high temperature reactors (HTRs). To investigate the fluid phenomena around the coil bundle of HCSG, the experimental facility had been designed and computational fluid dynamics (CFD) simulations had been conducted to compare the results of experimental ones. In this study, various types of turbulent models in the commercial CFD code (STAR-CCM+) were tested with various grid sizes on the target Reynolds number, Re{sub D} = 163,000, to enhance the validity of the simulation result. The computational domain used to run the CFD simulation had the same geometry of the experimental test section which had the half-coil shaped ribs on each curved channel wall. The working fluid properties employed in the simulation was scaled to the target Reynolds number at room temperature. The averaged static pressure drop induced by coil bundle inside the test section was obtained between the inlet and outlet of the test section. In addition, flow structures inside the flow channel were examined going through the velocity field distribution around the coil and the effect of vortical structures in the flow channel. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Coupled Calculations in Helical Steam Generator: Validation on Legacy Data

The NEAMS program aims to develop an integrated multi-physics simulation capability “pellet-to-plant” for the design and analysis of future generations of nuclear power plants. In particular, the Reactor Product Line code suite's multi-resolution hierarchy is being designed to ultimately span the full range of length and time scales present in relevant reactor design and safety analyses, as well as scale from desktop to petaflop computing platforms. Flow-induced vibration (FIV) is widespread problem in energy systems because they rely on fluid movement for energy conversion. Vibrating structures may be damaged as fatigue or wear occurs. Given the importance of reliable components in the nuclear industry, flow-induced vibration has long been a major concern in safety and operation of nuclear reactors. In particular, nuclear fuel rods and steam generators have been known to suffer from flow-induced vibration and related failures. Advanced reactors, such as integral Pressurized Water Reactors (PWRs) considered for Small Modular Reactors (SMR), often rely on innovative component designs to meet cost and safety targets. One component that is the subject of advanced designs is the steam generator, some designs of which forego the usual shell-and-tube architecture in order to fit within the primary vessel. In addition to being more cost- and space-efficient, such steam generators need to be more reliable, since failure of the primary vessel represents a potential loss of coolant and a safety concern. A significant amount of data exists on flow-induced vibration in shell-and-tube heat exchangers, and heuristic methods are available to predict their occurrence based on a set of given assumptions. In contrast, advanced designs have far less data available. Advanced modeling and simulation based on coupled structural and fluid simulations have the potential to predict flow-induced vibration in a variety of designs, reducing the need for expensive experimental programs, especially at the design stage. Over the past five years, the Reactor Product Line has developed the integrated multi-physics code suite SHARP. The goal of developing such a tool is to perform multi-physics neutronics, thermal/fluid, and structural mechanics modeling of the components inside the full reactor core or portions of it with a user-specified fidelity. In particular SHARP contains high-fidelity single-physics codes Diablo for structural mechanics and Nek5000 for fluid mechanics calculations. Both codes are state-of-the-art, highly scalable tools that have been extensively validated. These tools form a strong basis on which to build a flow-induced vibration modeling capability. In this report we discuss one-way coupled calculations performed with Nek5000 and Diablo aimed at simulating available FIV experiments in helical steam generators in the turbulent buffeting regime. In this regime one-way coupling is judged sufficient because the pressure loads do not cause substantial displacements. It is also the most common source of vibration in helical steam generators at the low flows expected in integral PWRs. The legacy data is obtained from two datasets developed at Argonne and B&W.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2018

Demonstration of Fully Coupled Calculations in Helical Steam Generator: Toward Predictions of Fluid Elastic Instability

The NEAMS program aims to develop an integrated multi-physics simulation capability “pellet-to-plant” for the design and analysis of future generations of nuclear power plants. In particular, the Reactor Product Line code suite's multi-resolution hierarchy is being designed to ultimately span the full range of length and time scales present in relevant reactor design and safety analyses, as well as scale from desktop to petaflop computing platforms. Flow-induced vibration (FIV) is widespread problem in energy systems because they rely on fluid movement for energy conversion. Vibrating structures may be damaged as fatigue or wear occurs. Given the importance of reliable components in the nuclear industry, flow-induced vibration has long been a major concern in safety and operation of nuclear reactors. In particular, nuclear fuel rods and steam generators have been known to suffer from flow-induced vibration and related failures. Advanced reactors, such as integral Pressurized Water Reactors (PWRs) considered for Small Modular Reactors (SMR), often rely on innovative component designs to meet cost and safety targets. One component that is the subject of advanced designs is the steam generator, some designs of which forego the usual shell-and-tube architecture in order to fit within the primary vessel. In addition to being more cost- and space-efficient, such steam generators need to be more reliable, since failure of the primary vessel represents a potential loss of coolant and a safety concern. A significant amount of data exists on flow-induced vibration in shell-and-tube heat exchangers, and heuristic methods are available to predict their occurrence based on a set of given assumptions. In contrast, advanced designs have far less data available. Advanced modeling and simulation based on coupled structural and fluid simulations have the potential to predict flow-induced vibration in a variety of designs, reducing the need for expensive experimental programs, especially at the design stage. Over the past seven years, the Reactor Product Line has developed the integrated multi-physics code suite SHARP. The goal of developing such a tool is to perform multi-physics neutronics, thermal/fluid, and structural mechanics modeling of the components inside the full reactor core or portions of it with a user-specified fidelity. In particular SHARP contains high-fidelity single-physics codes Diablo for structural mechanics and Nek5000 for fluid mechanics calculations. Both codes are state-of-the-art, highly scalable tools that have been extensively validated. These tools form a strong basis on which to build a flow-induced vibration modeling capability. In the last two years a significant effort was devoted to 1) develop and validate a fully coupled capability in SHARP for Fluid-Structure calculations (FSI) and 2) validate the use of SHARP for one-way coupled calculations in helical steam generators on legacy data available as well as novel experiments. In this report we discuss an extension of previous one-way coupled calculations performed with Nek5000 and Diablo aimed at simulating available FIV experiments in helical steam generators in the turbulent buffeting regime. It was demonstrated that in the buffeting regime one-way coupling was judged sufficient because the pressure loads do not cause substantial displacements. However, higher speeds led to a reduction in accuracy and the need for a fully coupled capability for velocity or approaching the critical velocity and fluid elastic instability. In this report we demonstrate such fully coupled capability on the Argonne test case discussed in previous reports.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2013

Evaluation of the Effectiveness of a New Technology for Extraction of Insoluble Impurities from Nuclear Power Plant Steam Generators with Purge Water

An experimental technology for the removal of insoluble impurities from a horizontal steam generator with purge water during planned shutdowns of the power generating unit is improved through a more representative determination of the concentration of impurities in the purge water ahead of the water cleanup facility and a more precise effective time for the duration of the purge process. Tests with the improved technique at power generating unit No. 1 of the Rostov Nuclear Power Plant show that the efficiency with which insoluble impurities are removed from the steam generator volume was more than two orders of magnitude greater than under the standard regulations.

42 ENGINEERING↗

DOE OSTI2024

Supports with integrated sensors for nuclear reactor steam generators, and associated systems and methods

Supports with integrated sensors for nuclear reactor steam generators, and associated systems and methods, are disclosed. A representative method for forming a nuclear-powered steam generator includes forming an instrumented support, the instrumented support including a carrier portion and a retainer portion, with at least one of the carrier portion or the retainer portion being integrally formed with a sensor via an additive manufacturing process. The method can further include coupling the sensor to a communication link, supporting a helical steam conduit on the instrumented support, and installing the helical steam conduit and the instrumented support in a nuclear reactor. The helical steam conduit is positioned along a primary flow path, which is in turn positioned to circulate a heated primary flow in thermal communication with the helical steam conduit.

Welter, Kent↗

DOE OSTI2017

Numerical Analysis of Flow Instability in Once-through Steam Generator

Two-phase flow instability is a critical area to consider in the design of steam generators. Oscillation of the flow rate and the system pressure caused by heating may cause several problems and is unfavorable in an extreme case because it causes a burnout of the heat transfer surface. A large amplitude variation in the heat transfer tube wall temperature generally occurs under density wave oscillation (DWO) conditions, and a continuous cycling tube wall temperature may lead to damage to the tube, causing thermal fatigue problems. Therefore, instability of the flow should be avoided, and a two-phase flow system should be designed to have a sufficient margin to avoid this. A computer program was developed for predicting a two-phase flow instability in a steam generator heated by liquid sodium, and the results of numerical studies for several parameters are presented in this paper.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

Large Eddy Simulations for a Helical Coil Steam Generator

The desire for scalable power plants in remote locations and specialized applications has brought forth the small modular reactor (SMR). Now, smaller light water reactors are seen as viable means for meeting global energy requirements. Generally, straight or U-shape tubes are used to exchange heat from the primary to secondary coolant; however this is not ideal when size is a criterion. Helical coil steam generators (HCSGs) are advantageous for SMRs due to their enhanced heat transfer in compact spaces. Still, there is the concern of safety as steam generator tubes could rupture due to vibrations and fatigue on the material. Understanding flow characteristics and quantifying pressures for these tubes are important components for the design of safety and efficiency in these steam generators. The current study uses the spectral element computational fluid dynamic (CFD) code, Nek5000, to develop large eddy simulations (LES) for validation against experiments that will be conducted at Texas A and M University. Time-averaged pressure data will be compared with pressure tap readings, and velocity profile with particle image velocimetry (PIV) measurements. The presented preliminary results investigate the differences between 5.-, 7.-, and 9.-order polynomial simulations. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

Comparing Velocity Profiles Along the Rod Length of a Helical Coil Steam Generator Model

A model of a specific type of tube and shell heat exchanger, the helical coil steam generator (HCSG), was designed and constructed to study multiple fluidic properties that attribute to the efficiency of the heat transfer it provides. Tube and shell heat exchangers are currently used throughout industry in chemical, power and petroleum engineering. Most commonly, a primary flow is circulated through a shell, while the secondary flow is run through several small tubes that are bundled together. Methods to increase the heat transfer between the two flows include adding baffles to force shell side flow over more tubes, fins added in-between layers of tubes and passing tubes multiple times through the shell to increase heat exchanger effectiveness. The HCSG incorporates many of the proposed methods but also relies on a complex geometry to increase the heat transfer between tube and shell side flow. In an area where cost effectiveness is favorable, such as inside a nuclear reactor, helically banked steam generators makes extensive use of the room with no sharp tube bends. This increases the pressure loss on the secondary flow and can solve potential temperature manufacturing issues at the welds of junctions. Additionally, they have exhibited pure cross flow behaviors with high heat transfer coefficients and axial temperature profiles that correspond to pure counter-flow with high mean temperature differences. Early work showed that helical banks can have a significant increase of 16 to 43% higher heat transfer coefficient than straight pipe heat exchangers. While many previous studies have looked at the heat transfer, pressure drop and flow fields of a tube and shell heat exchanger, they all focus on tube bundles that are either in-line or staggered. The early flow visualization studies on these types of bundle arrangements reported that attached eddies were formed alternatively behind each of the rods and were occasionally dragged into the main stream of shell side flow. Later studies suggested that observable periodic vortex shedding was dependent on geometry. Experimental data taken using techniques such as laser Doppler anemometry (LDV) by Simonin and Barcouda (1986) as mentioned in Hassan (2002), hot-wire anemometry with Tsuchida (1982) and particle image velocimetry (PIV) conducted by researchers as late as 2007 have been used to characterize turbulent flow and distinguish flow field structures within in-line and staggered tube bundles. By studying these flow field structures, their contribution to fluidic properties such as heat transfer efficiency and pressure drop can be characterized effectively. Literature review lead to a design that incorporated five layers of coils wrapped around one another. The outermost and middle layers of tubes coiled at a specific pitch in a clockwise direction while the other two layers coiled counterclockwise. The proposed design incorporates a constantly changing lateral pitch ratio, a, between adjacent rods. The constructed test section isolates a single interface between two adjacent coiling rod bundles of twelve rods. Three distinct cross sectional planes along the rod bundles were looked at to study the effect of the local geometry to flow fields, Section A, B and C. Particle Image Velocimetry (PIV) frames of 896 x 848 pixels were captured at each section across a specific height. Profiles of mean velocity fields for each section are compared and discussed as possible features of the changing lateral pitch ratio.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2015

Study of treatment as an alternative WM pathway: examples of I-graphite and metallic components such as steam generators - 15212

EDF is working continuously to optimize and secure its waste management pathways, leading in some case to develop appropriate treatment solutions that could be implemented parallel to reference solutions, complementary or as alternative solutions to already existing paths. This approach is illustrated by the examples of steam generators replaced during the operation of French PWR power plants, and of irradiated graphite (stacks and sleeves), coming from the decommissioning of UNGG reactors, which have been shut down. Concerning graphite wastes, the near surface disposal facility intended for this waste does not exist yet, and is currently giving rise to the research of a suitable site, and an evaluation of its performances. While accompanying ANDRA (French national agency for nuclear waste management), in charge of the development of the facility, and while waiting for more data to be available, EDF is continuing the consolidation of graphite wastes radiological inventory, and is working on the development of an alternative management solution, based on a thermal treatment process. Depending on the nature of the treatment, and on the choice of operating parameters, this treatment may contribute to reduce graphite wastes volume and/or promote its acceptance in a disposal facility. Reducing the radiological inventory by decontamination is one of the means to achieve these objectives. Concerning replaced steam generators, nearly 200 of them will have been removed by 2030, and stored on site waiting for their treatment, which represents about 65 000 tons of metal. Initially intended to be cut and packed on NPPs' sites during their dismantling, EDF is studying the economic value of having the steam generators treated in a centralized facility, which allows reducing the volume of final wastes by optimizing cutting operations, while considering recycling after melting. However, this studied pathway implies a number of difficulties to be overcome. In particular, the shipment of such large components to a centralized facility may be complex. Moreover, French regulatory framework does not allow recycling outside nuclear industry, therefore limiting recycling opportunities to storage containers for radioactive wastes. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2012

Effect of steam generator configuration in a loss of the RHR during mid-loop operation at PKL facility

The loss of the residual heat removal system in mid-loop conditions may occur with a non-negligible contribution to the plant risk, so the analysis of the accidental sequences and the actions to mitigate the accident are of great interest in shutdown conditions. In order to plan the appropriate measures to mitigate the accident is necessary to understand the thermal-hydraulic processes following the loss of the residual heat removal system during shutdown. Thus, transients of this kind have been simulated using best-estimate codes in different integral test facilities and compared with experimental data obtained in different facilities. In PKL (Primaerkreislauf-Versuchsanlage, primary coolant loop test facility) test facility different series of experiments have been undertaken to analyze the plant response in shutdown. In this context, the E3 and F2 series consist of analyzing the loss of the residual heat removal system with a reduced inventory in the primary system. In particular, the experiments were developed to investigate the influence of the steam generators secondary side configuration on the plant response, what involves the consideration of different number of steam generators filled with water and ready for activation, on the heat transfer mechanisms inside the steam generators U-tubes. This work presents the results of such experiments calculated using, RELAP5/Mod 3.3. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

A dynamic model of once-through steam generator (OTSG) for prototypical advanced reactor - 374

new design of Small Modular Reactor, the Prototypical Advanced Reactor (PAR), features two sodium primary systems each connected to dedicated steam generators (SGs) and sharing a balance of plant (BOP) system. PAR adopts once-through steam generators (OTSG) for its compact structure. The existence of superheated steam in a OTSG improves turbine design by eliminating the need of bulky moisture separator in SG. The two cores and SGs' design enable PAR to adjust power flexibly, as a result, introduce more challenges to the control. Therefore, a fast simulation model with high accuracy OTSG model is needed. In this paper, a dynamic model is built for OTSG of PAR based on the conservation of mass, momentum, and energy. The OTSG is simulated as lumped pipe and divided into subcooled, evaporating, and superheated regions by moving boundaries. SIMULINK is adopted to this OTSG simulation to be merged into existing PAR system models easily. The steady state results show that key parameters are rational. The 5% step increase of feedwater enthalpy transient demonstrates that the model is capable to respond to the perturbations. Since the basic laws and algebraic method used in this paper are suitable for other fluids, the model can be easily applied to any other OTSG. Future work will also focus on model optimization, merging and improved control. The final aim is to perform full scope realtime simulations for PAR under normal operational transients. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Steam Generator Model Design Parameter Sensitivity Study Using Advanced Optimization Tools

This study focuses on design parameter sensitivity studies pertaining to a steam generator (SG) model, using both Python and machine-learning tools. The SG model is a mathematical representation (including fluid flow and heat transfer equations/models/correlations) of a steam-generating unit in a pressurized water reactor (PWR)-type small modular reactor (SMR) system. Design studies involve changing the model’s input design parameters (e.g., temperature, pressure, mass flow rate) to observe the resulting effects on the output of the system (e.g., heat transfer coefficient [HTC], Nusselt number, heat transfer performance). Sensitivity studies analyze the degree to which system output and/or desired parameters (e.g., HTC or heat transfer performance) are sensitive to changes in input parameters. By using machine-learning tools such as the Risk Analysis Virtual Environment (RAVEN) developed at Idaho National Laboratory (INL), detailed design parametric sensitivity studies and model optimization were performed. Six input parameters—namely, the pressure, temperature, and mass flow rate for the inlet of the primary-side (hot fluid) and secondary-side (cold fluid) of the SG—were randomly perturbed via RAVEN’s Monte Carlo Sampler module, using uniform distributions (±1% relative changes). The analysis results give valuable insights into SG system performance and optimization, and provide justification for researching optimized sensor placement to effectively monitor and obtain experimental data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Steam Generator Model Design Parameter Sensitivity Study Using Advanced Optimization Tools

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2012

Simulation of a main steam line break with steam generator tube rupture using trace

A simulation of the OECD/NEA ROSA-2 Project Test 5 was made with the thermal-hydraulic code TRACE5. Test 5 performed in the Large Scale Test Facility (LSTF) reproduced a Main Steam Line Break (MSLB) with a Steam Generator Tube Rupture (SGTR) in a Pressurized Water Reactor (PWR). The result of these simultaneous breaks is a depressurization in the secondary and primary system in loop B because both systems are connected through the SGTR. Good approximation was obtained between TRACE5 results and experimental data. TRACE5 reproduces qualitatively the phenomena that occur in this transient: primary pressure falls after the break, stagnation of the pressure after the opening of the relief valve of the intact steam generator, the pressure falls after the two openings of the PORV and the recovery of the liquid level in the pressurizer after each closure of the PORV. Furthermore, a sensitivity analysis has been performed to know the effect of varying the High Pressure Injection (HPI) flow rate in both loops on the system pressures evolution. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

A Semi-Empirical Correlation for the Onset of Density Wave Oscillations in a Helical Coil Steam Generator

NuScale Power has completed full length helical coil steam generator (HCSG) tests at SIET Laboratories in Piacenza, Italy. The test program included an investigation of the onset and evolution of density wave oscillations (DWO). This paper describes the mechanisms leading to the onset of DWO as inferred from tests performed in the full-height TF-2 counter-flow test facility. This research supports the concept that the onset of DWO is caused by liquid bridging inside the boiling length of the tubes. Using a separate cylinders approximation, a DWO onset correlation is obtained by performing a steady-state momentum balance on the density front created by liquid bridging. This yields a momentum balance equation in terms of a set of dimensionless superficial velocities, a corresponding dimensionless pressure drop term and an average void fraction. Envelope theory is then used to obtain a critical void fraction which is substituted into the dimensionless momentum balance to obtain a DWO onset correlation similar to the Wallis counter-current flooding correlation. A comparison of the DWO onset correlation to the TF-2 DWO experimental data is presented and shows excellent agreement when the average equilibrium vapor quality is greater than 0.2.

Density Wave Oscillations, Helical Coil Steam Gene↗

DOE OSTI2017

Eulerian Two-Fluid RANS-based CFD Simulations of a Helical Coil Steam Generator Boiling Tube

As part of a larger effort to demonstrate a simulation-based capability for the evaluation and optimization of helical coil steam generators, the performance of a helical coil steam generator tube is being considered using a Eulerian two-fluid multiphase flow capability implemented within the commercial computational fluid dynamics (CFD) code STAR-CCM+. The objective of these evaluations is to characterize boiling and the resultant two-phase flow structures within the helical coil heat exchanger tube so that structural analyses can more accurately account for vibration sources and damping. These studies have shown that CFD predictions using the two-fluid model are consistent with published measurements of pressure drop and heat transfer characteristics. The sensitivity of model predictions to both flow conditions and modeling parameters associated with bubble dynamics closure models has been investigated.

Pointer, Dave↗

NASA NTRS2009

Design and Activation of a LOX/GH Chemical Steam Generator

The purpose of this paper is to give a detailed description of the design and activation of the LOX/GH fueled chemical steam generator installed in Cell 2 of the E3 test facility at Stennis Space Center, MS (SSC). The steam generator uses a liquid oxygen oxidizer with gaseous hydrogen fuel. The combustion products are then quenched with water to create steam at pressures from 150 to 450 psig at temperatures from 350 to 750 deg F (from saturation to piping temperature limits).

Saunders, G. P.↗

DOE OSTI2020

Versatile coating with multifunctional performance for solar steam generation

In this work, a new kind of material, composite complex coating (CCC), with multifunctional performance has been developed for solar steam generation. The CCC has many advantages: (a) Scalability. The fabrication process is facile and mild; it can be realized in aqueous solution at room temperature, without high pressure, toxic organic solvents, or complex equipment. (b) Cost-effectiveness. The reagents used for preparation of CCC are low-cost and readily available. (c) Universality and stability. CCC firmly adheres on surfaces of various substrates with diverse shapes (cotton, filter paper, wood, polyurethane sponge, and even chemically inert and highly hydrophobic polyvinylidene fluoride membranes), and can withstand rinsing treatment (3000 r/min for 96 h), cyclic frost-thaw test (-18 °C ⇌ 30 °C, 90 times), and both high and low pH environments. In addition, many other reported coatings, such as carbon black, fail under similar process strain. (d) Anti-crude oil-fouling property. The CCC possesses stable superhydrophilicity and underwater superoleophobicity, which collectively endow substrates with the ability to resist fouling by oils. (e) Broad and strong light absorption. CCC can transform various substrates with diverse shapes into black materials with broadband light absorption due to its d-d transitions and rough surface. Together, these properties of CCC enable substrates with nearly any structural design to be easily transformed into photothermal materials for efficient solar steam generation. Furthermore, as a proof of concept, poplar wood is treated with CCC, achieving a water evaporation rate of ~1.8 kg m-2 h-1 (one sun), which is a record among wood-based photothermal materials.

14 SOLAR ENERGY↗