Structural Integrity

1. INDIAN STRUCTURAL INTEGRITY SOCIETY
WORKSHOP
Structural Integrity Assessment of Nuclear Energy Assets
9th – 10th May 2018
AERB Auditorium,Niyamak Bhavan-B Mumbai .

2. SIMULATED DESIGNED DELIVERED

3. WORK FLOW IN SIMULATION
CLASS OF
EQUIPMENT
Identify the loads on the
equipment
Loads from data
sheets, PID
Create FE model
Perform FE stress analysis
for all individual load cases
Modal analysis (determine
first natural frequency)
First natural
frequency < cut-
off frequency
Response spectrum
analysis
Equivalent static
analysis
Perform load
combination as per the
service levels
Determine stress for
different service levels
Compare stress with ASME
stress limits (as per class
and equipment)
Stress from
analysis is less
than ASME
stress limits
Redesign after
consulting approving
authority
Fail – Not
qualified
Pass–
Qualified
Yes
No
Yes
No

4. Typical load combinations

5. 4.2 MW DG SET (KAPP & RAPP – NPCIL)
5
•Checked for allowable stress limits of the material as per
manufacturer’s standard engineering practice.
•Functional operability requirement.
Parts considered for qualification:
- Base frame (skid)
- Engine crank case
- Alternator assembly
- Crank shaft
- Turbocharger support
- Turbocharger
- Fly wheel
- Flexible coupling
- Oil sump
• Approximate mass = 80 tons.

6. 4.2 MW DG SET (contd…)
Transverse forces on bearings
Lateral forces on cylinder
Piston force - Axial
Alternator Load Application
Engine Running Forces

7. CAD model FE model Stress plot
Preheating Module (DG set auxiliary)
Node diagram Rendered pipe
model in Caepipe

8. Control valves
CLASS 1 equipment

9. Gate Valves
CAD Mesh model
Temperature
distribution
from steady
state analysis
Stress contour
due to
temperature
loading
Class 2 equipment

10. Globe Valves
CAD Mesh model
Hydrotest
pressure
applied on
valve
Stress
contour for
Hydrotest
pressure
Class 3 equipment

11. Dual plate check valve
CAD Mesh model in the open position
of valve
Displacement
contour for
seismic load
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
ACCELERATION(g)
FREQUENCY (Hz)
Class 2 equipment

12. Design Condition qualification
Sl.
No.
Location
Membrane
Stress (MPa)
Allowable
Membrane
Stress (MPa)
Membrane +
Bending Stress
(MPa)
Allowable
Membrane +
Bending Stress
(MPa)
Design Criteria
Verification
1 Body -27.08 138 -55.82 207 PASS
2 Plate - 1 0.1604 138 3.249 207 PASS
3 Plate - 2 -3.596 138 -4.939 207 PASS
4 Clamping ring -38.35 215 -125.2 322.5 PASS
5 Stop pin 4.319 215 5.813 322.5 PASS
Qualification of Dual plate check valve

13. Pump-Room cooler
Fuel-Machine Cooler
Custom Coolers (PRC & FMC)

14. Hydraulic Power Pack
Code : ASME Sec III Div 1 ND
Qualified for operating loads , Seismic loads
(OBE & SSE) & also for the load combination

15. Control panel
Seismic category – NINS
Qualification code – IS1893
Spectra used for seismic case = IS1893
Overall size of structure :
1m x 1m x 2m (W x D x H)

16. Support structures
Cable tray support
structure
DG room HEPA
filter frame
Qualification code – ASME Sec III NF

17. Tensioning
Unit
Trolley Assembly
17
ADFTS – Automated Direct Fuel Transfer System (NRB-BARC)
Single pusher
assembly
Five - pusher
assembly

18. FUEL SHEARING
SYSTEM
FUEL DISTRIBUTI0N
SYSTEM
FUEL FEEDING SYSTEM
Design Validation of 37-pin Spent Fuel Chopper for NRB-BARC

19. Piping of STC structure (FRTG - IGCAR)
Iso metric view
Piping model
Stress contour

20. Macros for seismic qualification

21. Macros embedded spreadsheets for qualification
 Component evaluation as per NB, NC and ND of ASME code
 Bolt evaluation method as per ASME & IS code
 Weld Evaluation method as per ASME code
 Support Evaluation method as per ASME code
 Fatigue Evaluation method as per ASME code
 Qualification as per AERB code
 Sloshing Calculations

22. Macros embedded spreadsheet

23. Pressure Vessel- Customization

24. Objective
ASME Boiler and Pressure Vessel codes are used to qualify and certify pressure vessels
used in various applications
To generate a post processing tool to qualify the pressure vessels using ASME codes.
We used Abaqus capability of customization to develop this post processing tool.

25. 3D cad modelling : 2 - 7 days
Meshing : 2 - 7 days
Pre – processing : 2 - 3 days
Analysis : 3 - 7 days
Post-processing : 2 - 3 days
Code Qualification : 3 - 5 days
Report : 2 - 5 days
3D cad modelling : 2 - 7 days
Meshing : 2 - 7 days
Pre – processing : 2 - 3 days
Analysis : 3 – 7 days
Post-processing : 2 - 3 days
Code Qualification : 3 - 5 days
Report : 2 – 5 days
Objective
Design validation by FEM – Work flow

26. Animation

28. ProSIM R And D Pvt Ltd
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INDIAN STRUCTURAL INTEGREITY SOCIETY (InSIS)
Website: www.instint.in
Contact us: insisblr@gmail.com