Experimental study of the characteristics of the flow in the first rows of tube banks

This paper presents the experimental study of the flow instabilities in the first rows of tube banks. The study is performed using hot wire anemometry technique in an aerodynamic channel as well as flow visualizations in a water channel. In the wind channel three tube banks with square arrangement and pitch to diameter ratios P/D = 1.26, 1.4 and 1.6 were studied. The Reynolds number range for the velocities measurements, computed with the tube diameter and the flow velocity in the narrow gap between tubes was 7 × 10⁴–8 × 10⁴. Continuous and discrete wavelets were applied to decompose the velocity results, thus allowing the analysis of phenomena in time–frequency domain. Visualizations in a water channel complemented the analysis of the hot wire results. For this purpose, dye was injected in the flow in the water channel with a tube bank with P/D = 1.26. The range of the Reynolds number of the experiments was 3 × 10⁴–4 × 10⁴. The main results show the presence of instabilities, generated after the second row of the tube bank, which propagates to the interior of the bank. In the resulting flow, the three orthogonal components are equally significant. The three-dimensional behavior of the flow is responsible for a mass redistribution inside the bank that leads to velocity values not expected for the studied geometry, according to the known literature. The resulting flow process can be interpreted as a secondary flow which is characteristic of tube banks.     

Wavelet time–frequency analysis of accelerating and decelerating flows in a tube bank

In the present work, the steady approximation for accelerating and decelerating flows through tube banks is discussed. With this purpose, the experimental study of velocity and pressure fluctuations of transient turbulent cross-flow in a tube bank with square arrangement and a pitch-to-diameter ratio of 1.26 is performed. The Reynolds number at steady-state flow, computed with the tube diameter and the flow velocity in the narrow gap between the tubes, is 8 × 10⁴. Air is the working fluid. The accelerating and decelerating transients are obtained by means of start and stop of the centrifugal blower. Wavelet and wavelet packet multiresolution analysis were applied to decompose the signal in frequency intervals, using Daubechies 20 wavelet and scale functions, thus allowing the analysis of phenomena in a time–frequency domain. The continuous wavelet transform was also applied, using the Morlet function. The signals in the steady state, which presented a bistable behavior, were separated in two modes and analyzed with usual statistic tools. The results were compared with the steady-state assumption, demonstrating the ability of wavelets for analyzing time varying signals.     

Wall temperature measurement and heat transfer correlation of turbulent supercritical carbon dioxide flow in vertical circular/non-circular tubes

Experimental data are presented which describe heat transfer characteristics of turbulent supercritical carbon dioxide flow in vertical tubes with circular, triangular, and square cross-sections. Experiments are conducted at a constant pressure of 8 MPa under various conditions such as inlet bulk temperatures ranging from 15 to 32 °C, imposed heat fluxes from 3 to 180 kW/m², and mass velocities from 209 to 1230 kg/m² s. The corresponding Reynolds and Grashof numbers are in the range of 3 × 10⁴ to 1.4 × 10⁵, and 5 × 10⁹ to 4 × 10¹¹, respectively. The test section is composed of an entrance region of 0.6 m long and a heating region of 1.2 m long. Wall temperatures are measured by thermocouples installed at the outer surface of the heating region. In order to identify the effect of the cross-sectional shape on the supercritical heat transfer, wall temperature distributions in the streamwise direction are compared at the same heat flux and mass velocity conditions. Based on the wall temperature data, an improved heat transfer correlation, which can be applicable to both forced convection and mixed convection regimes, is proposed, and compared with previous ones.     

Critical heat flux under flow oscillation of water at low-pressure, low-flow conditions

In this work, the effect of flow oscillations on critical heat flux (CHF) is investigated for water flow in vertical round tubes at low-pressure, low-flow (LPLF) conditions. An experimental study has been conducted to investigate the difference in CHF between forced and natural circulations, and between stable and oscillating flow conditions with three vertical round tube test sections (5.0 mm ID×0.6 m in length, 6.6 mm ID×0.5 m in length, and 9.8 mm ID×0.6 m in length) for mass fluxes below 400 kg m⁻² s⁻¹ under near atmospheric pressure. It is found that flow oscillations can drastically reduce the CHF, in particular for natural-circulation conditions. In addition to the experiments, CHF correction factors for flow oscillation effects are developed for forced and natural circulations, respectively, based on the experimental data of the present work and others.     

Analysis of flow distribution a PWR fuel rod bundle model containng A 90% blockage

An experimental investigation, covering a Reynolds number range from 2 × 10³ to 3.5 × 10⁴, was conducted to study the velocity and turbulence intensity distributions due to the presence of a blockage in an unheated 7 × 7 rod bundle. The blockage configuration, consisting of a 4 × 4 rod array, created a maximum flow area reduction of 90% in the central nine subchannels. The blockage sleeve length was 38.3 × rod diameter and the 90% blockage zone length extended for 16.4 × rod diameter. The results showed that upstream of the blockage, the flow was not influenced by the blockage until it reached the location where the inlet taper section of the swelling started. At the downstream end, the flow disturbance was extensive and persisted over a distance of about 83 rod diameters. Compared to the downstream velocity profiles, the turbulence intensity measurements however showed a faster recovery from the blockage influence. At the higher Reynolds number, velocity profiles calculated using the COBRA subchannel computer code compared consistently with the experimental data. The general flow behaviour of the various subchannels was reasonably well predicted. However, at low Reynolds number, due mainly to the frictional form loss calculation scheme in COBRA and uncertainty in the flow transition, the flow diversion due to the blockage to the surrounding unblocked subchannels was overestimated. The influence of the degree of recovery from the rod swelling on the flow was also studied using COBRA.     

Assessment of aging of Zr---2.5Nb pressure tubes in CANDU reactors

In modern CANDU^™ nuclear generating stations, pressure tubes of cold-worked Zr---2.5Nb material are used in the reactor core to contain the fuel bundles and the heavy water (D₂O) coolant. The pressure tubes operate at an internal pressure of about 10 MPa and temperatures ranging from about 250°C at the inlet to about 310°C at the outlet. Over the expected 30 year lifetime of these tubes they will be subjected to a total fluence of approximately 3 × 10²⁶ n m⁻². In addition, these tubes gradually pick up deuterium as a result of a slow corrosion process. When the hydrogen plus deuterium concentration in the tubes exceeds the hydrogen-deuterium solvus, the tubes are susceptible to a crack initiation and propagation process called delayed hydride cracking (DHC). If undetected, such a cracking mechanism could lead to unstable rupture of the pressure tube. A fitness-for-service methodology has been developed which assures that this will not happen. A key element in this methodology is the acquisition of data and understanding—from surveillance and accelerated aging testing—to assess and predict changes in the DHC initiation threshold, the DHC velocity and the fracture toughness (critical crack length) as a function of service time. The most recent results of the DHC and fracture toughness properties of CANDU pressure tubes as a function of time in service are presented and used to suggest procedures for mitigation and life extension of the pressure tubes.     

A probabilistic method for leak-before-break analysis of CANDU reactor pressure tubes

In modern CANDU nuclear generating stations, pressure tubes of cold-worked Zr-2.5Nb material are used in the reactor core to contain the fuel bundles and the heavy water (D₂O) coolant. The pressure tubes operate at an internal pressure of 10 MPa and temperatures ranging from 250°C at the inlet to 310°C at the outlet. Over the expected 30 year lifetime of these tubes, they would be subjected to a total fluence of 3×10²⁶ n m⁻². In addition, these tubes gradually pick up deuterium as a result of a slow corrosion process. When the hydrogen plus deuterium concentration in the tubes exceeds the hydrogen/deuterium solvus, the tubes are susceptible to a crack initiation and propagation process called delayed hydride cracking (DHC). If undetected, such a cracking mechanism could lead to unstable rupture of the pressure tube. The service life of the pressure tubes is determined, in part, by changes in the probability for the rupture of a tube. This probability is made up of the probability for crack initiation by DHC multiplied by the sum of the probabilities of break-before-leak and leak-before-break (LBB). A probabilistic model, BLOOM, is described which makes it possible to estimate the cumulative probabilities of break-before-leak and LBB. The probability of break-before-leak depends on the crack length at first leak detection and the critical crack length. The probability of a LBB depends on the shut-down scenario used. The probabilistic approach is described in relation to an example of a possible shut-down scenario. Key physical input parameters into this analysis are pressure tube mechanical properties, such as the crack length at first coolant leakage, the DHC velocity and the critical crack length. Since none of these parameters are known precisely, either because they depend on material properties, which vary within and between pressure tubes, and/or because of measurement errors, they are given in terms of their means and standard deviations at the different temperatures and pressures defined by the shut-down scenario.     

Turbulent momentum transport in rod bundles

An experimental investigation was performed with air to obtain detailed information on the velocity and turbulence distribution for parallel turbulent flows through subchannels of rod bundles. Experimental results were obtained for wall and corner subchannels of rod bundles of four parallel rods. The pitch-to-diameter ratios were varied between 1.07 and 1.4. The Reynolds numbers ranged from 6 × 10⁴ to 2 × 10⁵, depending on the rod bundle arrangement.On the basis of the data measured, the eddy viscosities in the directions normal and parallel to the wall were calculated. The experimental results of the velocity and wall shear stress distributions are compared with the predictions by the VELASCO code. There are considerable differences between computed and experimental results especially for low pitch-to-diameter ratios. The reasons for the discrepancies are discussed together with the results of attempts to adjust the VELASCO code against the experimental data.     

Experimental studies on rewetting of hot vertical annular channel

Studies on the rewetting behaviour of hot vertical annular channels are of interest in the context of emergency core cooling in nuclear reactors following LOCA. Experimental studies were carried out to study the rewetting behaviour of a hot vertical annular channel, with hot inner tube, for bottom flooding and top flow rewetting conditions. The length of the inner tube of the test section was 3030 mm for bottom flooding rewetting experiments and 2630 mm for top flow rewetting experiments. The tube was made of stainless steel. Experiments were conducted for water flow rates in the annulus upto 7 lpm (11.7×10⁻⁵ m³ s⁻¹). The initial surface temperature of the inner tube was varied from 200 to 500°C. The experimental studies show that for a given initial surface temperature of the tube, the rewetting velocity increases with an increase in flow rate of water and it decreases with an increase in the initial surface temperature for a given water flow rate. For a given water flow rate and initial surface temperature, the rewetting velocity is higher in the case of rewetting under bottom flooding conditions as compared to that in the case of rewetting under top flow conditions. These conclusions agree with the conclusions reported in the earlier literature. Using the experimental data of the present work, correlations for bottom flooding and top flow rewetting velocities are developed.     

Experimental study on the Reynolds number dependence of turbulent mixing in a rod bundle

An experimental study for Reynolds number dependence of the turbulent mixing between fuel-bundle subchannels, was performed. The measurements were done on a triangular array bundle with a 1.20 pitch to diameter relation and 10 mm rod diameter, in a low-pressure water loop, at Reynolds numbers between 1.4 × 10³ and 1.3 × 10⁵.The high accuracy of the results was obtained by improving a thermal tracing technique recently developed. The Reynolds exponent on the mixing rate correlation was obtained with two-digit accuracy for Reynolds numbers greater than 3 × 10³. It was also found a marked increase in the mixing rate for lower Reynolds numbers.The weak theoretical base of the accepted Reynolds dependence was pointed out in light of the later findings, as well as its ambiguous supporting experimental data.The present results also provide indirect information about dominant large scale flow pulsations at different flow regimes.     

An experimental study of turbulent flow through a square-array rod bundle

Using laser-Doppler anemometry and calibrated Preston tubes, experiments were performed in water (80°C, 0.6 MPa) to obtain information on the distributions of wall shear stresses, mean axial velocities and turbulence intensities for fully developed adiabatic flow through a six-rod bundle at a Reynolds number of 5 × 10⁵. The rods were arranged in a square array with a pitch to a diameter ratio of 1.15 and a wall-distance to diameter ratio of 0.62. The core flow in the central subchannel appears to be similar to pipe flow, but in the gap regions much higher turbulence intensities are encountered. The skewed wall shear stress profiles together with the deformed constant-velocity lines suggest the presence of secondary flows in the corner subchannels.     

Structure of air–water two-phase flow in helically coiled tubes

Air–water two-phase flow in helically coiled tubes is investigated experimentally to elucidate the effects of centrifugal acceleration on the flow regime map and the spatial and the temporal flow structure distribution. Three kinds of test tubes with 20 mm inner diameters including a straight tube are used to compare the turbulent flow structure. Superficial velocities up to 6 m/s are tested so that the centrifugal Froude number covers a range from 0 to 3. The interfacial structure is photographed from two directions by a high-speed video system with synchronized measurement of local pressure fluctuations. The results reveal that the flow transition line alters due to centrifugal force acting on the liquid phase in the tube. In particular, the bubbly flow regime is narrowed significantly. The pressure fluctuation amplitude gets large relatively to the average pressure loss as void fraction increases. The frequency spectra of the pressure fluctuation have plural peaks in the case of strong curvature, implying that the periodicity of slugging two-phase flow is collapsed by an internal secondary flow activated inside the liquid phase. Moreover, under large Froude number conditions, the substantial velocity of the gas phase that biases to the inner side of the helical coil is slower than the total superficial velocity because the liquid flow is allowed to pass through the outer side and so resembles a radial stratified flow.     

Assessment of irradiation response of WWER-440 welds using samples taken from Novovoronezh unit 3 and 4 reactor pressure vessels

The results of the study on Novovoronezh unit 3 and 4 (NV NPP-3 and 4) reactor pressure vessel (RPV) radiation embrittlement measured using subsize impact specimens (5×5×27.5 mm³) fabricated from samples taken from the corresponding RPV walls are presented. The post-irradiation annealing effectiveness and the embrittlement kinetics of Novovoronezh unit 3 and 4 RPV welds under re-irradiation are discussed. Ductile-to-brittle transition temperatures (DBTT) obtained using standard Charpy (TT^10×10) and subsize impact (TT^5×5) specimens of trepans cut out from Novovoronezh unit 2 RPV are compared. A new relation between TT^10×10 and TT^5×5 has been developed.     

Vapour void fraction in subcooled flow boiling

Experimental data on steam void fraction and axial temperature distribution in an annular boiling channel for low mass-flux forced and natural circulation flow of water with inlet subcooling have been obtained. The ranges of variables covered are: mass flux = 1.4 × 10⁴−1.0 × 10⁵ kg/hr m²; heat flux = 4.5 × 10³−7.5 × 10⁴ kcal/hr m²; and inlet subcooling = 10–70°C. The present and literature data match well with the theoretical void predictions using a four-step method similar to that suggested by Zuber and co-workers.     

An experimental investigation of a passive cooling unit for nuclear plant containment

A set of condensation experiments in the presence of noncondensables (e.g. air, helium) was conducted to evaluate the heat removal capacity of a passive cooling unit in a post-accident containment. Condensation heat transfer coefficients on a vertically mounted smooth tube have been obtained for total pressure ranging from 2.48×10⁵ Pa(abs) to 4.55×10⁵ Pa(abs) and air mass fraction ranging from 0.30 to 0.65. An empirical correlation for heat transfer coefficient (h), has been developed in terms of a parameter group made up of steam mole fraction (Xs), total pressure (P_t), temperature difference between bulk gas and wall surface (dT). This correlation covers all data points within 20%. All data points are also in good agreement with the prediction of the diffusion layer model (DLM) with suction and are approximately 2.2 times the Uchida heat transfer correlation. Experiments with an axial shroud around the test tube to model the restriction on radial flow experienced within a tube bundle demonstrated a reduction of the heat transfer coefficient by a factor of about 0.6. The effect of helium (simulating hydrogen) on the heat transfer coefficient was investigated for helium mole fraction in noncondensable gases (X_He/X_nc) at 15, 30 and 60%. It was found that the condensation heat transfer coefficients are generally lower when introducing helium into noncondensable gas. The difference is within 20% of air-only cases when X_He/X_nc is less than 30% and total pressure is less than 4.55×10⁵ Pa(abs). A gas stratification phenomenon was clearly observed for helium mole fraction in excess of 60%.     

Effects of rolling on laminar frictional resistance in tubes

The laminar velocity distribution in tubes in rolling motion is obtained by properly simplifying the laminar flow equations. The method of 7 and 8 for analyzing the effect of periodic pressure on laminar flow is partly adopted. The influence of initial velocity on the velocity in rolling motion fades away quickly, while the periodic pressure due to rolling motion controls the velocity variation gradually. The effects of several parameters on the velocity profile in the cross-section are investigated. The rolling radius and amplitude only affect the velocity in a specified proportion, and the velocity profile shape remains unchanged. The tube radius, rolling period and fluid viscosity not only affect the velocity peak, but also the profile shape. The tube radius and fluid viscosity could limit the effect of rolling motion on the flow. The laminar friction coefficient in rolling motion is also obtained. The laminar friction resistance and factor for two special cases are investigated.     

T91 cladding tubes with and without modified FeCrAlY coatings exposed in LBE at different flow, stress and temperature conditions

Corrosion tests of 2000 h duration are conducted on tubes consisting of the steel T91 in liquid metal loops containing eutectic lead-bismuth melt with 10⁻⁶ wt% oxygen in solution. The experiments include tests at temperatures of 480-600° C, at liquid metal flow velocities of 1, 2 and 3 m/s and under mechanical stress due to an internal pressure of 15 MPa. The surface of tubes exposed to 600 °C and to different flow velocities are coated with a FeCrAlY alloy to examine its suitability as a protective coating for high loaded parts like cladding tubes. The coating was remelted by an electron pulse of GESA to homogenize the coating and improve its bonding to the bulk material. In all of the tests no liquid metal attack was observed. As received steel specimens developed multilayer oxide scales of a thickness increasing with temperature and internal pressure, while coated tubes had a thin protective alumina scale. Flow velocities above 2 m/s permanently removed formed magnetite at 550 °C. No influence of the flow velocity was observed for the coated surfaces which keep their stable thin alumina scale. The internal pressure of 15 MPa caused a strain of 0.7% in the tube wall, which obviously increases iron diffusion and enhances magnetite formation.     

Experimental investigation of turbulent transport of momentum and energy in a heated rod bundle

Turbulent air flow in a central channel of heated 37-rod bundles with triangular array at two different pitch-to-diameter ratios (P/D=1.12 and P/D=1.06) was investigated. Measurements were performed with a hot-wire probe with x-wires and an additional temperature wire. Time mean velocities, time mean fluid temperatures, wall shear stresses and wall temperatures, turbulent quantities such as the turbulent kinetic energy, all Reynolds stresses and all turbulent heat fluxes were measured at two different pitch-to-diameter ratios in a central channel of the bundle. It is shown that with decreasing gap width the turbulence field in rod bundles deviates significantly from that in a circular tube. Also, data on the power spectral density functions of the velocity and temperature fluctuations are presented. These data show the existence of large-scale periodic fluctuations of velocity and temperature in the gap region of two adjacent rods. These fluctuations are responsible for the high intersubchannel heat and momentum exchange. Spectral measurements with two hot wire probes imply a distinct similarity of motion of vortices in adjacent subchannels of the bundle.     

Power up-grading study for the first Egyptian research reactor

In the present work, power up-grading study is performed, for the first Egyptian Research Reactor (ET-RR-1), using the present fuel basket with 4×4 fuel rods, (17.5 mm pitch), and a proposed fuel basket with 5×5 fuel rods, (14.0 mm pitch), without violating the thermal hydraulic safety criteria. These safety criteria are; fuel centerline temperature (fuel melting), clad surface temperature (surface boiling), outlet coolant temperature, and maximum heat flux (critical heat flux ratio). Different thermal reactor powers (2–10 MW) and different core coolant flow rates (450, 900, 1350 m³ h⁻¹) are considered. The thermal hydraulic analysis was performed using the subchannel code COBRA-IIIC for the estimation of temperatures, coolant velocities and critical heat flux. The neutronic calculations were performed using WIMS-D4 code with 5 — group neutron cross section library. These cross sections were adapted to use in the two-dimensional (2-D) diffusion code DIXY for core calculations. The study concluded that ET-RR-1 power can be upgraded safely up to 4 MW with the present 4×4-fuel basket and with the proposed 5×5-fuel basket up to 5 MW with the present coolant flow rate (900 m³ h⁻¹). With the two fuel arrays, the reactor power can be upgraded to 6 MW with coolant flow rate of 1350 m³ h⁻¹ without violating the safety criterion. It is also concluded that, loading the ET-RR-1 core with the proposed fuel basket (5×5) increases the excess reactivity of the reactor core than the present 4×4 fuel matrix with equal U-235 mass load and gave better fuel economy of fuel utilization.     

Thermal mixing between subchannels: measurement method and applications

A new thermal tracing technique is presented for the measurement of enthalpy interchange between connected subchannels in one-phase axial flow. The method is simple and versatile, being capable of implementation on compact and non-homogeneous bundles using water as fluid. To present the technique, measurements of turbulent mixing were performed on a triangular array bundle with a relation of pitch to diameter of 1.33, at Reynolds numbers between 10⁴ and 6.8×10⁴. For this simple arrangement the precision of the method is discussed showing that accuracies better than 10% can be readily achieved. Measurements are also performed in presence of a mixing vane showing another field were the method can be advantageously applied.