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

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2 AREVA Fatigue Concept IAEA TM Lab Tour, JULY 8, 2016 Steffen Bergholz / Dr. Jürgen Rudolph PEEP-G AREVA GmbH steffen.bergholz@areva.com

3 Introduction Regulatory Requirements AFC (AREVA Fatigue Concept) Fatigue Monitoring & assessment FAMOSi hardware & software AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.3

4 1. Introduction AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.4

5 Introduction Detail AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.5

6 Introduction Lessons learned: Thermal loads Operation modes Design Manufacturing improvements: Removal of weld roots Fine polishing of internal surfaces Forging of EPR TM RHRS mixing zones (forged 316L) Low residual stresses The Civaux case Le Duff et. al.: PVP AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.6

7 Introduction Current context: Longer lifetime of new NPP s (e.g. EPR TM 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) 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 AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.7

8 Introduction AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.8

9 2. Regulatory requirements AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.9

10 Regulatory Requirements Published on: AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.10

11 Regulatory Requirements AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.11

12 EAF according to NUREG/CR-6909 F en - Factors for partial usage factors: F en = (N RT,air / N Medium ) F en - factors for austenitic stainless steels F en,ss = F en ( ε ; T, O 2 ) F en,cs = F en ( ε ; T; O 2 ; S) Usage factor with EAF: U = n k = 1 n N k k, rt, air F en, k F en Maximum value: 14,513! Typical values: 3-5 Temperature in [ C] Strain rate in [%/s] Design practice: individual determination requires strain rate dependance AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.13

13 EPRI working Group developed methods for F en determination Strain Simplified Min-Max F 1 1 en,i en,i i 1 F en,i = F, with ε 1 ε i Simplified Peak-Valley F en,i F = en,i i en,i i 1 2 ε i + εi Local Maximum ε + F 2 ε i ε 2 F en,i Simplified Peak-Valley modified F en,i = m j F Local Maximum j en,i m j ε ε j i j i Local Minimum j F en,i ε j i Local Minimum 1 F en,i 1 ε i j = 1 j = m T 1 i T 1 i T 2 i T j i Time All available in AREVA Fatigue Concept AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.14

14 3. AREVA Fatigue Concept (AFC) AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.15

15 Fatigue Monitoring methods AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.16

16 AREVA s Philosophy DESIGN PHASE OPERATION PHASE REAL DESIGN TRANSIENTS OCCURED TRANSIENTS MONITOR THE LOCAL LOADS! AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.17

17 SBF different loading types different thermal stresses AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.18

18 AREVA Fatigue Concept - AFC OPERATION ERECTION Design transients Load Evaluation Analyses Operational Measurements FAMOSi Local Measurements CONTARE + CBF Transfer Function (Virtual Measurements) Approval FAMOSi Software Simplified fatigue estimation Fast fatigue evaluation Licensed status Ageing & Lifetime Management For Long Term Operation Optimization Availability Thermal loads specification Analyses Detailed fatigue calculation Detection of failures AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.19

19 AFC / FAMOSi Hardware AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.20

20 Measurement section FAMOSi Locations on EPR TM 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 AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.21

21 FAMOSi Local Measurement Section Temperature Stress Fatigue relevant location AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.22

22 History of FAMOS Measurement sections AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.23

23 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 AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.24

24 AFC / FAMOSi software AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.26

25 AFC / FAMOSi software FAMOSi VIEWER Live display SFE FFE - SELECTION OF COMPONENT DATA IMPORTER PLAUSIBILITY CHECK CLASSIFICATION MATRIX INNER WALL THERMAL FIELD STRESS FIELD CUMULATIVE USAGE FACTOR Import to database Data for viewing Logic scripts Operating signals Rainflow Ranges fluctuations Unit transients Inner wall temperature Rainflow Unit transients Stress ranges Rainflow Wöhler data SQL DATABASE Open platform for analysing measurement data further functions can be added to the database AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.27

26 SFE Simplified Fatigue Estimation AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.28

27 Simplified Fatigue Estimation - SFE AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.29

28 Simplified Fatigue Estimation - SFE Stresses due to the thermal shock: f a f sn f kr E T σ v = f a f SN f KR ET 2 αt T 1 ν reduction factor for consideration of the final heat transfer coefficient stress concentration factor for weld seams stress concentration factor for consideration of the bent geometry Elastic modulus Alternating Stress Intensity: S a = 0, 5 E E KTA T σ v AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.30

29 FFE Fast Fatigue Evaluation AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.31

30 FFE Fast Fatigue Evaluation FFE principle Stress [N/mm²] Fatigue Beispiele für ermüdungsrelevante relevant positions Positionen T ref T out aussen (FAMOS) Elementary Transient T innen (FFE) (SINTOC) T in_transfer übertragen Sleeve Inner wall temperature at the measured section Elementary transient FE- Model of the analyzed structure Stress calculation at the fatigue relevant locations Stress reference responses DATABASE Time dependant stress tensor AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.32

31 The elementary transients function is calculated based on an FE model Example for a stress calculation FFE Fast Fatigue Evaluation Preparation, FE- Calculation Temperature [ C] Temperature [ C] Temperature slope Elementary Transient T ref Time Time [s] Inner_wall temp UT FEM Stress [N/mm²] Stress [N/mm²] Stress [N/mm²] Stress_ reference Time [s] [s] Stress [N/mm²] The stress references are saved in a database AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.34

32 FFE Fast Fatigue Evaluation After initialization of the Green s functions calculation can be done with FAMOSi FAMOSi Software Simplified fatigue estimation Fast fatigue evaluation Scaling process is performed Stress is calculated Rainflow algorithm is implemented for fatigue calculation AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.35

33 DFC Detailed Fatigue Calculation AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.42

34 DFC Detailed Fatigue Calculation Generation of detailed component model Temperature Load Data Optional coupling with adjacent piping system (piping loads) Time Mechanical Database TIS.DB TIS.RTH TIS.OUT T1S.INP T2S.INP T3S.INP I = 1 N Thermal Database TI.DB TI.RTH TI.OUT I = 1 N T1.INP T2.INP T3.INP Implementation of temperature transients Implementation of temperature transients TNS.INP TN.INP Thermo mechanical FE-analyses Thermal transient FE-analyses Fatigue Postprocessing (U = ) AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.43

35 DFC Detailed Fatigue Calculation FAM (FAtigue Module) is a Post-Processing-Tool for ANSYS for the detailed fatigue calculation according to established design codes including actual EAF demands AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.44

36 DFC Detailed Fatigue Calculation Detailed Fatigue Calculation: Model transients catalogue Analyses 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 K e - Standard K e -procedure - Advanced K e -procedures (see PVP paper) Direct methods - Twice Yield Method - Simplified theory of plastic zones (see PVP paper) Elasto-plastic non-linear FEA - Standard plasticity models - Advanced plasticity models in connection with ratcheting check (see PVP paper) SBF plus associated F en -factors consideration of environmentally assisted fatigue = EAF CONSERVATISM AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.45

37 DFC Detailed Fatigue Calculation Simplified elastic-plastic analysis by application of K e -factors EFFORT Simplified elastic-plastic analysis by application of direct methods General elastic-plastic analysis CONSERVATISM AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.46

38 Pressurizer 350,00 spray line DFC Detailed Fatigue Calculation 300,00 POI operational / local Temperature in [ C] 250,00 200,00 150,00 100,00 50,00 T loc,e T loc,i T mcl T pr T sl 0,00 01:00 01:30 02:00 02:30 03:00 03:30 04:00 04:30 05:00 05:30 06:00 Time AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.47

39 DFC Detailed Fatigue Calculation AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.48

40 DFC Detailed Fatigue Calculation Analysis example: spray line Auxiliary spray line Spray line Reactor coolant line (RCL) Pressurizer (PRZ) FE model of spray line and pressurizer (shell type elements) AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.49

41 DFC Detailed Fatigue Calculation Detail model of spool (brick type elements) Detail model of T-section (brick type elements) Model of spray line and pressurizer (shell type elements) Detail model of spray line nozzle (brick type elements) AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.50

42 DFC Detailed Fatigue Calculation Cold water injection [ C] Exemplary temperature stratification modeling for transient thermal analysis AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.51

43 DFC Detailed Fatigue Calculation Highly stressed regions Von Mises exemplary stress distribution in T-section due to thermal loading Pipeline connection (shell model) [N/mm 2 ] Conclusion: Thick walled transition regions and thermosleeve connections are particularly prone to fatigue damage AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.52

44 LIVE presentation of AFC / FAMOSi AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.53

45 LIVE presentation of AFC / FAMOSi Live monitoring 7 Thermocouples Amplifier and embedded computer Lamp: Periodically on/off AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.54

46 AREVA Fatigue Concept - AFC OPERATION ERECTION Design transients Load Evaluation Analyses Operational Measurements FAMOSi Local Measurements CONTARE + CBF Transfer Function (Virtual Measurements) Approval FAMOSi Software Simplified fatigue estimation Fast fatigue evaluation Licensed status Ageing & Lifetime Management For Long Term Operation Optimization Availability Thermal loads specification Analyses Detailed fatigue calculation Detection of failures AREVA Fatigue Concept (AFC) Steffen Bergholz / Dr. Jürgen Rudolph - p.58

47 END OF PRESENTATION AREVA Fatigue Concept IAEA TM Lab Tour, JULY 8, 2016 Steffen Bergholz / Dr. Jürgen Rudolph PEEP-G AREVA GmbH steffen.bergholz@areva.com

48 Editor and Copyright 2015: AREVA GmbH Paul-Gossen-Straße 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 RESTRICTED AREVA - AREVA - AL: N - ECCN: N - p.60 Steffen Bergholz AREVA GmbH Proprietary