Presentation made at NPCIL, Anushaktinagar Mumbai showcasing case studies of past seismic qualification projects successfully completed by ProSIM.

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SIMULATED DESIGNED DELIVERED
info@pro-sim.com
SEISMIC QUALIFICATION OF
EQUIPMENTS FOR
NUCLEAR POWER PLANT APPLICATIONS
Date : 10 September 2015
Venue : NPCIL (NUB), Anushaktinagar - Mumbai
Attendees : Engineering & Procurement teams of NPCIL
(Mechanical & Electrical)

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 ISO 9001:2008
 Core Group of Automotive Research (CAR – TIFAC)
 DSIR (Govt of India) recognized R&D House
Recognitions
Certifications
 2JSTP Japan Award
 EPMA 2003 ( Spain ) – Poster Award
 Best Paper Award in PM India Conference
Awards
 22 Publications in International Conferences & Journals
 26 + Invited Lecturers in technical forums in India, Germany, UK, USA and
Japan
Publications

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Domestic Customers (Partial list)
150 + Customers
9 Verticals

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Global Customers (Partial list)
Unisca Jecs

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ProSIM has an interdisciplinary team of :
Mechanical Engineers, Materials, Design, Manufacturing, Electrical Electronics, FEM experts,
Optimization experts, Pressure vessel designers, consultants and so on
4 PhDs with 15-35 years of exp
14 M Tech / MS
~38 Engineers
~40 Trainees
ProSIM Team
ProSIM adds significant value to its customer in various stages of product life cycle.
* Design stage
* Value engineering
* Failure analysis
* Maintenance stage (remaining life assessment)

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ABOUT ProSIM
• ProSIM is an NPCIL approved consultant for stress analysis for 3 years.
• Successfully executed more than 40 projects in qualification for seismic conditions.
• Mechanical & Electrical Equipments (Passive & Active equipments).
• Expertise in qualification of Class-1, 2, 3 & NINS equipments.
• Worked with DAE entities like IGCAR/BARC/BHAVINI and their vendors
• Worked for international agencies – ITER/AMEC
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• ProSIM has proven expertise of using commercial FEA codes Ansys/Abaqus.
• Develop macros for using qualification codes within the environment of Ansys / Abaqus
or CAD software such as Catia/NX or general platforms such as MathCAD and so on.
• Implementation of macros in Ansys for load combination for seismic qualification for
different service levels.
• Macros embedded XL sheets for weld, bolt and support qualifications.
Post processing and calculating various types of damages as per RCCM-R standards.
• Customized platform using ABAQUS to generate the design, verify design by FEM
analysis and generate qualification report for pressure vessels.
ProSIM STRENGTHS

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As a seismic consultant, ProSIM takes complete responsibility by engaging at various stages:
• Developing the seismic methodology
• Identify the loads applicable to the specific equipment
•Spectra based analysis (or) codal calculations
• Qualification as per ASME code
• Suggest design modifications to enable seismic qualification (with consultation with vendor &
NPCIL)
• Detailed documentation in NPCIL formats.
• Provide necessary technical support for discussions with certifying agencies (even after project
closure)
ProSIM as Seismic Qualification Consultant
EQUIPMENT LIST (Qualified)
•Vessels/Tanks (>40)
•Cylindrical
•Annular
•Vertical
•Horizontal
•Leg support
•Saddle support
•Overhanging
•Valves
•Pneumatic control valve
•Butterfly valve
•Dual check plate valve
•Ball valves
•Lattice tower supported chimney

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•4.2 MW DG set with alternator (and auxiliaries)
•HSD day tank
•LT water buffer tank
•Thermowells
•Duplex Filters
•Pre-heating module
•Plate-type heat exchangers
•Electrical Equipments
•Control Panels
•Cable tray support structures
•Bus ducts
•Chopper for FBTR fuel
•Dissolver for FBTR fuel
•Centrifuge for FBTR fuel
•Electrolyser for FBTR dissolver
•Evaporator off gas scrubber
•Vessel off gas scrubber
•Compressors & Pumps
•Triplex plunger pump
•ECCS compressor
•Hydraulic Power Units
EQUIPMENT LIST (contd...)
•Special Equipments
•Glove boxes
•Thermosyphon evaporator
•Shielding door
•Dissolver
•Automated Direct Fuel Transfer System
•Filters & Strainers
•Fuelling machine & pump room coolers
•Spent Fuel Chopper (39-pin)
•Steel structure (Sodium testing)
•Fuel Cell piping
•Emergency water system
•Air conditioning & ventilation system
including AC ducting & fans
•Centrifugal Extractor
•Chiller condenser (EOG, DOG, WVOG
•Spray column
•Evaporator - Pot type
•Evaporator - Thermosyphon type
•Sump Pump
•Liquid ring vacuum pumps

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PAST PROJECT CASES
(PARTIAL LIST)

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TANKS (partial list)
Electrolyser Scrubber Pot type Evaporator Thermo-Syphon Evaporator
Horizontal – saddle supports Vertical - leg supports Cylindrical - Lug supports Annular - Lug supports

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VERTICAL TANK (details)
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•Eigen value analysis with missing mass
correction
•Dynamic analysis carried out for sloshing effects
•Housner model used to adequately represent
the behavior
•Shell qualified as per ASME Sec III, ND
•Supports qualified as per ASME Sec III, NF
•Embedded plate size checks
•Weld adequacy checks
•impulsive mass, mi
•convective mass, mc
•mass of water, mw
•height of mi from bottom, hi
•height of mc from bottom, hc
•maximum height of fluid, h
•spring stiffness, Kc
Sloshing effect modeling

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SADDLE SUPPORTED TANKS
•Overall length of tank: 6202mm
•Outer diameter: 2324mm
•Nozzle sizes : 8NB, 15NB, 20NB, 25NB, 50NB

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GLOVE BOX
•Internal parts lumped
•Negative internal pressure
•Dead weight
•OBE & SSE (seismic loads)
•Contains Nitric Acid
•High temperature gradient load
•Titanium grade material
DISSOLVER

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CAD & FE-MODEL
•Transient heat transfer analysis.
•The region connecting the
internal pipes within the hot leg
to the base plate is critical.
HEAT-EXCHANGER TUBES &
BAFFLE PLATES MODELLED
USING SHELL ELEMENTS
THERMO-SYPHON EVAPORATOR

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FUEL CYCLE : VESSELS & SUPPORT
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25m
40m
10m

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4.2 MW DG SET
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Parts considered for
qualification:
- Base frame (skid)
- Engine crank case
- Alternator assembly
- Crank shaft
- Turbocharger support
- Turbocharger
- Fly wheel
- Flexible coupling
- Oil sump
•Checked for allowable
stress limits of the material
as per manufacturer’s
standard engineering
practice.
•Functional operability
checked

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ECCS COMPRESSOR
DAMPENERS AND PURGE BOTTLES QUALIFIED BASE FRAME
FE model with
lumped mass
connections

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•Weight = 5069 kg
•Peak spectral acceleration = 6g
•Modifications suggested after high stress observed in legs, cooler
coils & body
Initial Design
High stress in HE
AIR COOLER
Modified Design
Reduced stress after modification

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•Visited site (RAPP) to check availability of usable EPs and
area around the building
•Designed the tower from scratch
•Strength design of columns.
•Strength design of bracings.
•Strength design of stacks.
•Strength design of structure foundation bolts.
•Strength design of structure base plate and gussets.
•Pull out shear failure mode of foundation.
LATTICE TOWER SUPPORTED CHIMNEY
3 exhaust pipes entering the tower Silencer arrangement on the roof Complete lattice tower

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#4, 1st B Main, 1st N Block
Rajajinagar, Bengaluru - 560 010
Phone: +91 80 2332 3020
info@pro-sim.com
www.pro-sim.com