Thermal Hydraulic Design of Components for Steam Generation Plants

Maurizio Cumo

• Publisher: CRC Press
• Year: 2018
• Print ISBN: 9781315898155
• eBook ISBN: 9781351094153
• Topic: Tecnologia e ingegneria
• Subtopic: Ingegneria elettronica e telecomunicazioni

This book presents discussions regarding the design of the main components for steam generation plants, such as evaporators, steam generators for fossil-fuelled and nuclear power plants, waste heat boilers for chemical and related field plants, and auxiliary components in steam cycle plants. Information regarding the manufacturing and operational phases of the plants, as well as quality control procedures and environmental requirements, is included. The book features the most advanced technology, in addition to special skills and tricks based on the field experience of some of the leading scientific and technical people in the field. Plant manufacturing and operation engineers, engineering companies, and instructors teaching advanced courses in mechanical and chemical engineering will find this text essential reading.

Chapter 1

STEAM GENERATORS FOR NUCLEAR POWER PLANTS

R. De Santis and M. Sala

TABLE OF CONTENTS

I.	Introduction
	A.	The SG in the Nuclear Plant
	B.	Types Of SGs related in the NSSS Design
		1.	Steam Generators for PWRs
		2.	FBR Steam Generators
	C.	Design and Manufacturer’s Review
II.	Design
	A.	Functional Design
		1.	Aims
		2.	System Analysis
		3.	Interface of the SG with the System
	B.	Thermal and Fluid Dynamic Design
		1.	Aims
		2.	Steady State Analysis Principles
		3.	Mathematical Tools for Thermal Hydraulic Modeling
		4.	Steady State Calculation Procedure
			a.	One Dimensional Performance Analysis of the SGs
			b.	Three Dimensional Performance Analysis of the SGs
		5.	Transient Analysis
			a.	Operational Transients
			b.	Upset Conditions
			c.	Disturbance Conditions
		6.	Vibration Analysis
			a.	Basic Mechanisms of Flow-Induced Vibration Phenomenon
				i.	Fluid-Elastic Excitation
				ii.	Vortex Shedding
				iii.	Turbulent Excitation
			b.	Effects of the Vibrations on the Tubes and Their Dependence on the Boundary Conditions
			c.	Application of the Procedure to the Tube Bundle of a SG
	C.	Mechanical Design
		1.	Generalities
		2.	Analysis of Pressure Retaining Parts
		3.	Analysis of the Internals
III.	Manufacturing
	A.	Materials
		1.	Primary Side
		2.	Secondary Side
	B.	Manufacturing Technologies
		1.	Manufacturing Sequences
			a.	Manufacturing of the Pressure Boundary and Shells
				i.	Assembly of the Tube Bundle
				ii.	Final Assembly and Controls
	C.	Quality Assurance and Quality Control
IV.	Operating Experience
	A.	Life History
		1.	Corrosion Problems
			a.	Wastage
				i.	Denting
				ii.	Pitting
				iii.	Stress Corrosion Cracking
		2.	Mechanical Problems
			a.	Water Hammer
				i.	Fretting and Wear
		3.	Functional Problems
V.	R & D and Future Trends
	A.	Counteracting Service Problems
		1.	Tube Material
		2.	Thermal Hydraulic Design
		3.	Manufacturing Technologies
	B.	Developing a New Design
	C.	Conclusions
References

I. INTRODUCTION

A. THE SG IN THE NUCLEAR PLANT

Steam Generators (SGs) are boilers where the heat source is a hot fluid stream rather than the flue gases produced by a combustion process. Basically, they are shell and tube heat exchangers transferring heat from a primary system to the steam cycle. Boiling takes place in the shell side while the primary reactor coolant flows inside the tubes. Commercial power plants have a variable number of SGs, generally from two to four, depending on the Nuclear Steam Supply System (NSSS) design and power plant size. Characteristics of the SGs markedly depend upon the type of primary fluid. In the SG, the tubes represent the boundary between the primary and secondary side characterized by a very large and thin surface. Therefore, SGs represent the focal point of the plant.

B. TYPES OF SGS RELATED IN THE NSSS DESIGN

NSSS requiring SGs can be divided in two main categories:

1. Pressurized Water Reactors (PWR)

2. Liquid Metal cooled reactors (FBR)

The PWR plants can be further subdivided into light water (LWR) and heavy water (HWR) reactors.

Each of the above categories requires a specific SG design. The present chapter relates only to applications today and therefore, no reference is made to the large previous history of different SG types like the SGs for gas cooled reactors, BWR dual cycle, etc. The liquid metal cooled reactors are still in the development phase and a great number of SG designs have been proposed. As the unique, large industrial application of these SGs is the Super Phenix project, reference will be made only to the SGs used in this plant.

1. Steam Generators for PWRs

Two types of PWR SGs are in use today:

1. Recirculating SGs (RSG) for producing saturated steam

2. Once-through SGs (OTSG) for producing slightly superheated steam

In the RSGs the secondary fluid is driven by natural circulation arising from a density difference between a downflow stream and an upflow stream. Two designs have found industrial applications:

1. Vertical design, which is the most commonly used (tube plate SGs)

2. Horizontal design (tube header SGs)

Figure 1 shows a typical inverted U-tube whose main features are

• A channel head with two regions separated by a partition plate, where inlet and outlet of the primary fluid takes place

• A tube plate which supports the tube bundle, made of U-tubes

• A tube support system made by multiple plates located at...

Table of contents

• Cover
• Title Page
• Copyright Page
• Dedication
• Table of Contents
• Evaporators
• Chapter 1 Steam Generators for Nuclear Power Plants
• Chapter 2 Fossil Fuel Fired Large-Size Steam Generators
• Chapter 3 Fossil Fuel Fired Medium-Size Steam Generators
• Chapter 4 Chemical Plants and Allied Field Waste Heat Boilers for Plants
• Chapter 5 Steam Generations Sodium-Water Heat Exchangers
• Chapter 6 Thermal Hydraulic Design of Main Auxiliary Components in Steam Cycle Plants
• Index