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Test Facilities in Germany
Dr. Gerd Brinkmann / Dieter Vanvor
BriVaTech Consulting
Wien, 10.06. – 13.06.2014
BriVaTech Consulting, Hemhofen, GERMANY ALL RIGHTS RESERVED Page 1 Date 12-15.01.2015
Test Facilities in Germany
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Test Facilities and Projects in Germany
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HTR-MODULE with SG
HTR-MODULE with Steam Generator
Hot Gas Temperature 750°C
Cold Gas Temperature 250 °C
Core Barrel Alloy 800
Pressure Boundary 20MnMoNi55
Steam Generator
- inner shrouds Alloy 800
- tubing Alloy 800
- type helical tubing,
steam inside tubes
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HTR-MODULE with SR HTR-MODULE with Steam Reformer
Hot Gas Temperature for SR 950°C
Hot Gas Temperature for SG 750 °C
Cold Gas Temperature 350 °C
Core Barrel Alloy 800H
Pressure Boundary X20CrMoV121
Steam Reformer (SR)
- inner shrouds Alloy 800H/Alloy 617
- tubing Alloy 800H/Alloy 617
- type straight tube bundle for catalysator Steam Generator (SG) - inner shrouds Alloy 800H/Alloy 617
- tubing Alloy 800H/Alloy 617
- type helical tubing integrated, steam inside tubes
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HTR-MODULE with IHX HTR-MODULE with Helium-Helium-Heat-Exchanger
Hot Gas Temperature Primary 950°C
Cold Gas Temperature Primary 350 °C
Hot Gas Temperature Secondary 900 °C
Cold Gas Temperature Secondary 300 °C
Core Barrel Alloy 800H
Pressure Boundary X 20 CrMoV 121
Helium-Helium-Heat-Exchanger
- inner shrouds Alloy 800H/Alloy 617
- tubing Alloy 800H/Alloy 617
- type helical tubing
- max. pressure differenze Primary/Secondary under normal conditions 2 bar
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Vessel Steel for Pressure Boundary HTR-MODULE with Steam Generator is designed based on regulations for Light Water Reactors(KTA 3201). Therefore the best known pressure vessel material 20MnMoNi55 is used for the pressure boundary.
For all other HTR-MODULE types the pressure boundary material has to withstand higher temperatures during accident conditions.
HTR-MODULE with IHX or SR
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Vessel Steel for Pressure Boundary
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Vessel Steel for Pressure Boundary
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Steel for Metallic Internals
Draft safety standard KTA 3221 (parts 1 to 3) specifies the following materials for temperatures
up to 1000 °C:
Material Component
X 20 CrMoV 12 (1.4922) support pipe hot gas duct
up to 600 °C as pressure vessel material
X 5 NiCrAlTi 31 20 DE (1.4958 special), Alloy 800 DE liner for hot gas duct
up to 700 °C as pressure vessel material vee shape for hot gas duct
core barrel
support sytems inside pressure
boundary
rods
X 6 NiCrAlTi 32 21 H, Alloy 800 H liner for hot gas duct
up to 700 °C as structural component vee shape for hot gas duct
special areas for steam reformer
and intermediate heat exchanger
rods
Ni Cr 23 Co 12 Mo, Alloy 617 special areas for steam reformer
above 500 °C as pressure vessel material and intermediate heat exchanger
(e.g. nozzel and header)
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Graphite Internals
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Materials for Components
IHX
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Materials for Components
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Materials for Components
Hot Gas Duct (metallic version)
Material Specifications:
Liner, hot side of vee 1.4876 (X10NiCrAlTi32-21 / X10NiCrAlTi32-20)
and depressurization gap tube
Support pipe and cold side of vee 1.4571 (X6CRNIMOTI17-12-2) with specified cobalt content of maximum 300 ppm
Packed fibre insulation pads made of long fibre mats with 95% al2o3 + 5% sio2
Wrapped fibre insulation fibre-mats made of long fibre with 95% Al2O3 + 5% SiO2
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Materials for Components Hot Gas Duct (ceramic version)
Material Specifications:
Liner Graphite type ASR-1RG, carbon fibre composite (CFC)
Radial and axial ceramic spacers Al2O3 ceramic, under pressure from all sides
Packed fibre insulation pads made of long fibre mats with 95% Al2O3 + 5% SiO2
Wrapped fibre insulation fibre-mats made of long fibre with 95% Al2O3 + 5% SiO2
Support pipe 1.4571 (X6CrNiMoTi17-12-2) with specified cobalt content
of maximum 300 ppm
CFC-Tube Graphite-Tube
Fibre Insulation
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Materials for Components Isolation Valves (secondary side)
Design Features of RCS Isolation Valves In the course of the above-mentioned development project the following main design data and operating data were established for the secondary-side hot gas valves. Most of these specifications can be applied unchanged to new projects:
Operating pressure 41.9 bar
Hot gas temperature 900 ±18°C
Body design temperature (pressure boundary) 400°C
Helium mass flow 47.3 kg / s
Temperature transient (startup and shutdown) ± 2 K / min
Total closing time 5 s
Max. p across seat 42 bar
Max. p during opening and closing 3.5 bar (max: backpressure to be overcome)
Leakage rate from both seats 1 mbarl / s (cf. Section 3.5)
Design lifetime 140,000 h
Prototype dimensions:
Pressure-retaining pipe Dia. 1,120 mm, t = 30 mm
Free flow cross section Dia. 700 mm
Total length 2,400 mm
Isolation Valve (secondary side)
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Materials for Components
Isolation Valves (secondary side)
Direction of
movement on
closure
Double seal
system
Valve
seat
Valve
seat
Direction of
movement on
closure
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Materials for Components
Draft safety standard KTA 3221 (parts 1 to 3) specifies the following materials for
temperatures up to 1000 °C:
X 20 CrMoV 12 (1.4922) Support plate and support structure
up to 600°C tubes for SG, SR and IHX
pressure tube for secondary hot and
cold gas duct
X 5 NiCrAlTi 31 20 DE (1.4958 special), Alloy 800 DE tubes for SG, SR and IHX
up to 700°C liner, sealing structure, support system
X8 NiCrAlTi 32 21 H, Alloy 800 H tubes for SG, SR and IHX
up to 700°C liner, sealing structure, support system
Ni Cr 23 Co 12 Mo, Alloy 617 special areas of SR, IHX (nozzle and
above 500°C header) and special components
inside secondary separation valves
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Test Facility KVK
KVK Testing hall with operational and testing components
Thermal power 10 MW
(in one and two cycle test loop)
Helium Temperature 950 °C/900°C
Operating Pressure 40 bar/40 bar
Helium Flow 3 kg/s / 2,9 kg/s
Helium Velocity 60 m/s / 60 m/s
Temperature Transients ± 200 K/min
(only in primary loop)
Pressure Transient - 5 bar/s
(only in primary loop)
Operation time:
> 900 °C ~ 7.000 h
> 700 °C ~ 12.000 h
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Test Components inside KVK
KVK Hot Gas Duct
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Test Components inside KVK Hot Gas Duct (metallic version)
pictures from manufacturing
Horizontal test tube
outer diameter 1220 mm
wall thickness 30 mm
flow diameter 700 mm
90° elbow test tube
outer diameter 1320 mm
wall thickness 50 mm
flow diameter 700 mm
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Test Components inside KVK
Hot Gas Duct (ceramic design)
pictures from manufacturing
Horizontal test tube
outer diameter 1020 mm
wall thickness 20 mm
flow diameter 700 mm Core Connection
System test tube
flow diameter 700 mm
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Test Components inside KVK
IHX (U-Tube-Type), demension for 170 MW but
tubing only for 10 MW
Picture during assembling
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Test Components inside KVK
Picture during assembling
in back: IHX-Helical-Type
in front: SG for KVK
IHX (Helical-Tube-Type), dimension for 170 MW
but tubing only for 10 MW
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Test Components inside KVK
IHX (Helical-Tube-Type), dimension for 170 MW
but tubing only for 10 MW
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Test Components inside KVK
Picture during assembling
in back: IHX-Helical-Type
in front: SG for KVK
10 MW decay heat cooler for KVK (steam
generator)
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Test Components inside KVK
Isolation Valves (secondary
side)
axial valve type,
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