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nuclear science and technology

STRESS ANALYSIS OF
BWR PRESSURE VESSEL NOZZLES
by
J. BLANCKENBURG, J. PUTZEYS, J. REYNEN and P. DE WINDT

EUR 5374 e

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COMMISSION

OF THE EUROPEAN

COMMUNITIES

nuclear science and technology

STRESS ANALYSIS OF
BWR PRESSURE VESSEL NOZZLES
by
J.

BLANCKENBURG, J. PUTZEYS, J. REYNEN and P. DE WINDT

Joint Nuclear Research Centre

lepra Establishment Italy
E.S.M.I.S.

1975

EUR 5374 e

ABSTRACT
The report summarizes comparative analyses of B W R pressure vessel nozzles
by means of finite elements. The study covers loadings b y internal pressure
and by thermal transients.

3 -

L.

Introduction

-?

[.

D e s c r i p t i o n of the employed c o m p u t e r codes

[.

Mechanical Analysis

III. 1 Dodewaard N5 nozzle

III. 2 Philippsburg feedwater nozzle

V.

T h e r m a l Analysis

12

IV. 1 Philippsburg feed

12

A . Steady s t a t e Conditions

12

B . T r a n s i e n t Conditions

14

IV. 2 Dodewaard N5 nozzle

A . Steady state Conditions
V.

15
-jc

Conclusions

16

V . l Mechanical Analysis

15

V . 2 T h e r m a l Analysis

16

- 5

1. I NTRODUCTION

The p a p e r s u m m e r i z e s the r e s u l t s of n u m e r i c a l calculations to d e t e r m i n e

the s t r e s s d i s t r i b u t i o n in B . W . R . p r e s s u r e v e s s e l n o z z l e s . The a n a l y s e s
have been p e r f o r m e d by the finite e l e m e n t method, using different idealisation s c h e m e s .
The study c o v e r s both a m e c h a n i c a l a n a l y s i s i . e . the s t r u c t u r e under a
uniform i n t e r n a l p r e s s u r e and a t h e r m a l a n a l y s i s of the nozzle v e s s e l
junction during a t h e r m a l u p s e t condition.
In p a r t i c u l a r , c o m p a r i s o n s have b e e n made between t h r e e - d i m e n s i o n a l
a n a l y s e s and t w o - d i m e n s i o n a l a p p r o a c h e s , e . g . noz z i e - o n - p l a t e and
noz z i e - o n - s p h e r e m o d e l s .
The feedwater nozzles of the P h i l i p p s b u r g B . W . R . and of the Dode waard
B . W . R . have b e e n c o n s i d e r e d as r e f e r e n c e .
F o r the l a t t e r n o z z l e , e x p e r i m e n t a l and n u m e r i c a l r e s u l t s have been
published by the U n i v e r s i t y of Delft (The Netherlands) and a r e included
in the p r e s e n t work for c o m p a r i s o n .

II. DESCRIPTION OF THE EMPLOYED COMPUTER CODES

Both the m e c h a n i c a l and t h e r m a l a n a l y s e s have b e e n p e r f o r m e d by the

finite e l e m e n t c o m p u t e r codes BERSAFE

, for which
h
(3)
the m e s h e s have been p r e p a r e d by the computer p r o g r a m s EURCYL

and MESHGEN/MESHREF

and F L H E

^ .

BERSAFE (BFRkeley S t r e s s Analysis by F i n i t e E l e m e n t s ) is a s y s t e m

of i n t e g r a t e d c o m p u t e r p r o g r a m s designed to p e r f o r m the g e n e r a l s t r e s s
a n a l y s i s of a r b i t r a r y two and t h r e e d i m e n s i o n a l s t r u c t u r e s . The phase I
v e r s i o n of BERSAFE is c o n c e r n e d with e l a s t i c a n a l y s e s using the
d i s p l a c e m e n t m e t h o d . The p r o g r a m c a l c u l a t e s d i s p l a c e m e n t s and s t r e s s e s
at the n o d e s , a s well as p r i n c i p a l s t r e s s e s and the Von Mises equivalent
stress .
F L H E (Flow of HEat) is a c o m p u t e r p r o g r a m which c a l c u l a t e s steady
state or t r a n s i e n t t e m p e r a t u r e s throughout g e n e r a l s t r u c t u r e s .
The calculated nodal t e m p e r a t u r e s m a y be put onto tape for the p u r p o s e
of calculating t h e r m a l s t r e s s e s in the s t r u c t u r e using the BERSAFE
system.
Both p r o g r a m s use the front solution technique

(5)

to g e n e r a t e and to

solve simultaneously the m a i n m a t r i x e q u a t i o n . In the front solution

the s e m i - b a n d w i d t h value of the stiffness m a t r i x governs the n e c e s s a r y
c o m p u t e r fast c o r e and the computation t i m e . The c u r r e n t limit in
BERSAFE is 300 d . o . f . and in F L H E it is 100 d . o . f . The m a x i m u m
n u m b e r of nodes and e l e m e n t s ( E P 6 o r EX6) allowed is 2000 .tu.l
1500 r e s p e c t i v e l y , although the l a t t e r d e c r e a s e s as m o r e complex
e l e m e n t s a r e u s e d . A l a r g e n u m b e r of e l e m e n t t y p e s , i . e . s t r a i g h t side and i s o p a r a m e t r i c e l e m e n t s , is available in BERSAFE phase I
and a l s o in F L H E . Both computer p r o g r a m s a c c e p t automatically
g e n e r a t e d m e s h e s , usually s t o r e d on t a p e , and w r i t e the r e s u l t s on

- 7

tape so that, using an a u x i l i a r y p r o g r a m , s t r e s s and t e m p e r a t u r e plots

may be obtained.
The EURCYL c o m p u t e r p r o g r a m g e n e r a t e s a u t o m a t i c a l l y the t h r e e d i m e n s i o n a l m e s h of a p e r p e n d i c u l a r c y l i n d e r - c y l i n d e r i n t e r s e c t i o n and
is p a r t i c u l a r l y suited for the idealization of thick-walled v e s s e l - n o z z l e
junctions with curved t r a n s i t i o n s . The p r o g r a m subdivides the s t r u c t u r e
in l i n e a r , p a r a b o l i c or cubic 3-D e l e m e n t s and defines the c o r r e s p o n d ing nodal points with t h e i r c o o r d i n a t e s . The input is r e d u c e d to a
m i n i m u m i . e . only the d i m e n s i o n s of the s t r u c t u r e and a few options,
defining the r e q u i r e d m e s h d i s t r i b u t i o n , a r e r e q u e s t e d .
The MESHGEN and MESHREF c o m p u t e r codes allow to g e n e r a t e two
d i m e n s i o n a l m e s h e s , made up of t r i a n g u l a r e l e m e n t s . The MESHGEN
code defines for e a c h simply shaped block of the s t r u c t u r e the m e s h
d i s t r i b u t i o n , while the MESHREF p r o g r a m a s s e m b l e s the v a r i o u s blocks
in the c o r r e c t o r d e r , e l i m i n a t e s the thus obtained common nodal points
and then r e n u m b e r s the e l e m e n t s and n o d e s .
Both m e s h g e n e r a t i o n p r o g r a m s p r i n t out the e l e m e n t topology and nodal
point g e o m e t r y of the s t r u c t u r e and p r e p a r e c a r d s or a tape., in the
r e q u i r e d f o r m a t s , for BERSAFE a n d / o r F L H E . A c o m p u t e r controlled
drawing of the m e s h may be r e q u e s t e d .
All p r o g r a m s a r e run on an IBM 370/165 c o m p u t e r .

III. MECHANICAL ANALYSIS

T h r e e - d i m e n s i o n a l a n a l y s e s have been p e r f o r m e d for the Dodewaard

BWR nozzle N5 ( F i g . l) and for the P h i l i p p s b u r g BWR f e e d - w a t e r
nozzle ( F i g . 2) under i n t e r n a l p r e s s u r e .
The m a i n p u r p o s e s of the a n a l y s e s a r e :
- firstly to d e t e r m i n e the a c c u r a c y of the r e s u l t s obtained f r o m finite
e l e m e n t 3-D c a l c u l a t i o n s , using a fairly refined m e s h , by c o m p a r i n g
t h e m with published e x p e r i m e n t a l r e s u l t s and with a n u m e r i c a l a n a l y s i s
using F o u r i e r type finite e l e m e n t s
- secondly to investigate the influence of the m e s h size and of the used
finite e l e m e n t type on the a c c u r a c y of the c a l c u l a t i o n s .
The c o n s i d e r e d s e c t o r s for the a n a l y s e s a r e r e p r e s e n t e d on F i g s . 5 and
1 0 . In both c a s e s the n o z z l e - t o - v e s s e l d i a m e t e r r a t i o s a r e s m a l l so
that for each nozzle a n a l y s i s only a portion of the v e s s e l has b e e n
c o n s i d e r e d and since the effect of the pipe on the t h i c k e r section of the
nozzle is negligible, it has not b e e n i n c l u d e d .
The idealization of the solid c o n t i m u m is done by dividing it into an
a s s e m b l a g e of h e x a h e d r o n s , i . e . i s o p a r a m e t r i c 3-D finite e l e m e n t s .
A s p e c i a l p u r p o s e c o m p u t e r p r o g r a m EURCYL, applicable for n o z z l e s
of this configuration, a u t o m a t i c a l l y g e n e r a t e s the t h r e e d i m e n s i o n a l
m e s h , i . e . the h e x a h e d r a l e l e m e n t s with c o r r e s p o n d i n g nodal points
a r e defined and the nodal points c o o r d i n a t e s a r e c a l c u l a t e d .
The s t r e s s a n a l y s e s have been p e r f o r m e d for a v e s s e l under a uniform
i n t e r n a l p r e s s u r e and in o r d e r to obtain e a s i l y r e a d a b l e r e s u l t s , the
value of the p r e s s u r e was chosen such as to produce a nominal hoop
2
s t r e s s of 1 k g / m m in the continuous v e s s e l w a l l . At the "cut" ends
of the v e s s e l , a uniform s t r e s s is applied at a value of 0 . 5 k g // m m
and 1 k g / m m

in axial and tangential d i r e c t i o n r e s p e c t i v e l y , to

e q u i l i b r a t e the i n t e r n a l p r e s s u r e . The boundary conditions a r e the

c o n s t r a i n t s imposed by s y m m e t r y .

III.I

Dodewaard N5-nozzle

Computations have b e e n p e r f o r m e d for the nozzle N5 of the 1 to 4

s c a l e Dodewaard BWR v e s s e l model under i n t e r n a l p r e s s u r e . An
o v e r a l l view of the v e s s e l and the d i m e n s i o n s of the nozzle a r e shown
in F i g . 1 .
The idealization of the s t r u c t u r e was c a r r i e d out using the 3-D p a r a b o l i c
i s o p a r a m e t r i c e l e m e n t s EZ 60 ( F i g . 3) having 20 nodal points and giving
l i n e a r s t r e s s and quadratic d i s p l a c e m e n t s along the e d g e s . In angular
d i r e c t i o n the nozzle is subdivided into 6 equal s e g m e n t s , and along
n o z z l e , t r a n s i t i o n and v e s s e l 15 divisions a r e taken ( F i g . 4 ) .
Two s e r i e s of calculations have b e e n p e r f o r m e d , using a m e s h w i t h
2 l a y e r s and 3 l a y e r s of e l e m e n t s through the wall thickness r e s p e c t i v e l y ,
F o r r e a s o n s of s y m m e t r y and accounting for the Saint V e n a n t ' s p r i n c i p l e
a one fourth and a one sixteenth s y m m e t r y s e c t o r have b e e n analyzed
having both a half v e s s e l length of 300 m m . F i g . 5 shows the c o n s i d e r e d
s e c t o r s and gives the load-and boundary conditions that a p p l y .
The r e p r e s e n t a t i o n of the r e s u l t s has b e e n r e s t r i c t e d to the c i r c u m f e r e n tial and a x i a l s t r e s s e s , in the longitudinal and t r a n s v e r s e planes
r e s p e c t i v e l y , w h e r e they a r e h i g h e s t . The r e s u l t s computed using the
idealization s c h e m e s with two or t h r e e l a y e r s of e l e m e n t s a r e in good
a g r e e m e n t , as m a y b e s e e n on F i g . 6.

The Dodewaard N5 nozzle has a l s o been analyzed at the Delft U n i v e r s i t y

(7)
of Technology (The Netherlands)
. A q u a s i 2-D calculation has been
p e r f o r m e d using F o u r i e r type finite e l e m e n t s and the s t r a i n s have been
m e a s u r e d on a 1 to 4 scale m o d e l of the v e s s e l . The calculated and
m e a s u r e d s t r a i n d i s t r i b u t i o n in the longitudinal section of the N5 n o z z l e ,
under and i n t e r n a l p r e s s u r e of 90 k g f / c m , is shown in F i g . 7 .
Both the n u m e r i c a l and e x p e r i m e n t a l r e s u l t s a g r e e fairly well with
the 3-D computations p e r f o r m e d with BERSAFE (see F i g . 8).

10

The c o m p a r i s o n of the different r e s u l t s for the N5 nozzle shows that

a 3-D finite e l e m e n t a n a l y s i s , using a r a t h e r c o a r s e m e s h and
consequently a r e a s o n a b l y low computing t i m e , allows to obtain a c c u r a t e
design evaluations at a m o d e r a t e c o s t .
III. 2 Philippsburg F e e d w a t e r Nozzle
The Philippsburg feedwater nozzle ( F i g . 2) has been analyzed and some
n u m e r i c a l e x p e r i m e n t s have been p e r f o r m e d to d e t e r m i n e

the influence

of the m e s h r e f i n e m e n t on the a c c u r a c y of the r e s u l t s . S e v e r a l i d e a l i z a tion s c h e m e s , using EZ60 or E Z 9 6 i s o p a r a m e t r i c e l e m e n t s ( F i g . 3 ) ,

have b e e n utilized for the c o m p u t a t i o n s . The a n a l y s e s have b e e n done
for the v e s s e l under an i n t e r n a l p r e s s u r e of 5 b a r , producing a hoop
s t r e s s of 1 k g / m m

in the continious w a l l .

Calculations have b e e n p e r f o r m e d using an idealization s c h e m e in which

the wall t h i c k n e s s is divided into 2 or 3 s l i c e s . F o r both c a s e s the nozzle
is divided into 6 equal s e g m e n t s in angular d i r e c t i o n , while 15 divisions
a r e taken along the n o z z l e - t r a n s i t i o n - v e s s e l (see F i g . 9). F i r s t a o n e fourth s y m m e t r y s e c t o r was c o n s i d e r e d having a half v e s s e l length of
600 c m and 2 l a y e r s of p a r a b o l i c i s o p a r a m e t r i c e l e m e n t s ( i . e . EZ 60)
through the wall t h i c k n e s s . The r e s u l t s of this a n a l y s i s , with the load
and boundary conditions as shown in F i g . 10, have then been c o m p a r e d
with those obtained for a 400 c m long, o n e - s i x t e e n t h s y m m e t r y s e c t o r
for which the wall thickness is r e p r e s e n t e d by 3 l a y e r s of EZ 60 finite
e l e m e n t s . The c o m p a r i s o n shows a good a g r e e m e n t between the s t r e s s e s
calculated with the fairly c o a r s e and the m o r e refined m e s h (see
F i g s . 11 and 12). It m a y t h e r e f o r e be concluded that convergence is
obtained, r e s u l t s a r e t h u s r e l i a b l e , and that the calculations p e r f o r m e d
with the 2 l a y e r s s c h e m e a r e s t i l l a c c u r a t e .

In o r d e r to reduce the c o m p u t e r time of the a n a l y s i s , one should d e c r e a s e

the n u m b e r of nodal points and m i n i m i z e the s e m i - b a n d w i d t h of the
stiffness m a t r i x . S e v e r a l d i s c r e t i z a t i o n s c h e m e s have b e e n used and

11

the a c c u r a c y of the r e s u l t s was defined by c o m p a r i s o n with the r e s u l t s

obtained using the s c h e m e with 3 l a y e r s of EZ 60 e l e m e n t s through the
wall t h i c k n e s s .
A f i r s t a n a l y s i s was p e r f o r m e d having only one l a y e r of cubic i s o p a r a m e t r i c
e l e m e n t s EZ 96 ( F i g . 3) through the t h i c k n e s s . The s t r e s s e s p e r p e n d i c u l a r
to the longitudinal plane (see F i g . 13) may be c o n s i d e r e d as a fair e s t i m a t e ,
while those p e r p e n d i c u l a r to the t r a n s v e r s e p l a n e , cannot be calculated by
the 1 l a y e r s c h e m e as shown on F i g . 14. B e s i d e s that the calculated r e s u l t s
a r e not r e l i a b l e , the total c o m p u t e r time is even somewhat higher than
that for the 2 l a y e r s EZ 60 s c h e m e , as s e e n in Table 1.
A second s e r i e s of calculations has b e e n p e r f o r m e d using two l a y e r s of
EZ 60 e l e m e n t s through the wall thickness but with l e s s divisions in the
nozzle angular d i r e c t i o n , i . e . f r o m five to two instead of the six used
i n i t i a l l y . The different idealization s c h e m e s , even the one using only two
divisions in the nozzle angular d i r e c t i o n , give r e a s o n a b l y a c c u r a t e r e s u l t s ,
as shown in F i g s . 15 and 16. The c a l c u l a t i o n s p e r f o r m e d with c o a r s e
m e s h e s overe s titra te the s t r e s s e s in the t r a n s v e r s e plane and u n d e r r a t e
the s t r e s s e s in the longitudinal p l a n e , but in both c a s e s the d i s c r e p a n c y
is l e s s than 10% with r e s p e c t to the r e f e r e n c e v a l u e s , taken as those
obtained by the idealization s c h e m e with 6 angular d i v i s i o n s .
On F i g s . 17 and 1 8 it is seen that the r e s u l t s of the different a p p r o a c h e s
i m p r o v e monotonously by i n c r e a s i n g n u m b e r of angular subdivisions thus
with i n c r e a s i n g n u m b e r of e l e m e n t s in the idealization s c h e m e , which is
an indication that convergence is r e a c h e d and that the computed s t r e s s
values a r e r e l i a b l e .

One may conclude that 3-D finite e l e m e n t a n a l y s e s using r a t h e r c o a r s e

m e s h e s allow to obtain a c c u r a t e design evaluations without r e q u i r i n g e x c e s s i v e
computer time which m a k e s them economically competitive with other
numerical methods.
Table 1 s u m m a r i z e s some g e n e r a l informations on the different m e s h e s
and gives an e s t i m a t e of the c o m p u t e r costs for the v a r i o u s 3D a n a l y s e s .

- 12

IV. THERMAL ANALYSIS

The feedwater nozzle of the Philippsburg BWR and the N5 nozzle of the
Dodewaard BWR have been analyzed for a t h e r m a l u p s e t condition i . e .
under c e r t a i n accident conditions cold w a t e r is injected during s e v e r a l
hours through the feedwater n o z z l e s into the r e a c t o r v e s s e l , which
r e m a i n s for a long period at nominal operating t e m p e r a t u r e ( F i g s . 19
and 20).
This e m e r g e n c y situation m a y be divided into a t r a n s i e n t p a r t , i n the
beginning, and in a steady state conditions s e t up after s o m e h o u r s .
P r e l i m i n a r y calculations did show that the w o r s t conditions in the
v e s s e l - n o z z l e junction will occur during the steady state p a r t .

Therefore

firstly steady state calculations have been p e r f o r m e d for a t h r e e d i m e n s i o n a l model and for t w o - d i m e n s i o n a l a p p r o x i m a t i o n s . The t e m p e r a t u r e d i s t r i b u t i o n s computed for the 2-D a p p r o a c h e s have been found
to a g r e e well with the 3-D r e s u l t s , but the c o r r e s p o n d i n g t h e r m a l s t r e s s e s
show d i s c r e p a n c i e s . Next a t r a n s i e n t calculation has been p e r f o r m e d ,
using a 2-D a p p r o a c h , which gives fair r e s u l t s and is economically feasible
These r e s u l t s confirm the p r e l i m i n a r y calculations showing that during
the t r a n s i e n t p a r t only the cladding and the tube-nozzle junctions will be
subjected to higher s t r e s s e s than during the steady state c o n d i t i o n s .
r V . l . Philippsburg F e e d w a t e r Nozzle
A. Steady State Conditions
T h r e e - d i m e n s i o n a l a n a l y s e s have b e e n p e r f o r m e d using m e s h e s with
once t h r e e and one t w o l a y e r s of i s o p a r a m e t r i c e l e m e n t s (EZ 60)
through the wall t h i c k n e s s .
The r e p r e s e n t a t i o n of the v e s s e l cladding and of the t h e r m a l s l e e v e s
inside the nozzle would have involved the use of quite d i s t o r t e d
e l e m e n t s and i n c r e a s e d the n u m b e r of e l e m e n t s beyond feasible
l i m i t s . The i n t e r n a l s t r u c t u r e s , i . e . cladding and t h e r m a l s l e e v e s ,

13

have t h e r e f o r e not been r e p r e s e n t e d by the 3-D idealization s c h e m e s ,

but effective heat t r a n s f e r coefficients have b e e n used for the t h e r m a l
calculations .
F i r s t , the t e m p e r a t u r e d i s t r i b u t i o n in the s t r u c t u r e has been computed
applying the b o u n d a r y conditions as indicated in F i g . 2 1 . The r e s u l t s
obtained by using two or t h r e e l a y e r s through the wall thickness a g r e e
within a few p e r c e n t .

The t e m p e r a t u r e d i s t r i b u t i o n in the different

angular planes around the nozzle a r e v e r y s i m i l a r , thus indicating

that the t e m p e r a t u r e field is quasi a x i s y m m e t r i c (Cfr. F i g . 2 2 ) .
Then, the t h e r m a l s t r e s s e s , r e s u l t i n g f r o m the p r e v i o u s l y calculated
t e m p e r a t u r e distribution have been computed with the BERSAFE
p r o g r a m , using the s a m e m e s h grid as for the t e m p e r a t u r e c a l c u l a t i o n s . The input for the s t r e s s a n a l y s i s is thus r e d u c e d v e r y m u c h ,
b e c a u s e the t e m p e r a t u r e s

have a l r e a d y b e e n e s t i m a t e d in the nodal

points r e q u e s t e d by the s t r e s s calculating p r o g r a m . The highest

s t r e s s components a r e

hoop s t r e s s e s along the inner surface of the

n o z z l e . The t h e r m a l s t r e s s e s n o r m a l to the longitudinal and the

t r a n s v e r s e plane a r e shown in F i g . 2 3 . The hoop s t r e s s e s along the.
inner face of the nozzle a r e lowest in the longitudinal plane and inc r e a s e c o n s i d e r a b l y along the angular d i r e c t i o n reaching t h e i r
m a x i m u m values i . e . 30 to 40% h i g h e r , in the t r a n s v e r s e p l a n e , as
shown by F i g . 24 for some p a r t i c u l a r p o i n t s .

After this 3 d i m e n s i o n a l study, two a x i s y m m e t r i c a p p r o a c h e s have

b e e n p e r f o r m e d , using the boundary conditions as given in F i g . 2 1 .
An option of the EURCYL 3-D m e s h - g e n e r a t o r p r o g r a m allows the
preparation

of 2-D m e s h e s for the longitudinal and t r a n s v e r s e

planes of a n o z z l e - v e s s e l i n t e r s e c t i o n ( F i g . 2 5 ) . These m e s h e s ,
used in an a x y s y m m e t r i c c a l c u l a t i o n , r e p r e s e n t a noz z i e - o n - p l a t e
and n o z z l e - o n - s p h e r e (R
c

=R
sphere

.. , ) a p p r o a c h r e s p e c t i v e l y .
cylinder'

The r e s u l t s of the t e m p e r a t u r e d i s t r i b u t i o n s obtained for both

a p p r o x i m a t i o n s have been c o m p a r e d with the previously calculated
values of the 3-D a n a l y s i s , and show a quite good a g r e e m e n t ( F i g . 26),

14

thus confirming that the t e m p e r a t u r e d i s t r i b u t i o n in a n o z z l e - v e s s e l

junction, p r o t e c t e d by t h e r m a l s l e e v e s , is a l m o s t a x i s y m m e t r i c and
may be e s t i m a t e d quite a c c u r a t e l y by an a x i s y m m e t r i c a p p r o a c h .
The c o r r e s p o n d i n g t h e r m a l s t r e s s e s have been computed for both 2-D
m o d e l s . The highest s t r e s s components a r e hoop s t r e s s e s along the
inner surface of the n o z z l e . The c o m p a r i s o n of the r e s u l t s with the
3-D c a l c u l a t i o n s shows ( F i g . 27) that the s t r e s s d i s t r i b u t i o n along
the inner side of the nozzle has the s a m e s h a p e , but that the n u m e r i c a l
values do not ageee that w e l l .
It m a y be concluded t h a t the 2-D a p p r o a c h e s allow to obtain a c c u r a t e
t e m p e r a t u r e d i s t r i b u t i o n s and rough e s t i m a t e s of the t h e r m a l s t r e s s e s
in the 3-D s t r u c t u r e , but that they have the advantage to need v e r y little
c o m p u t e r t i m e , in p a r t i c u l a r when EX 16 e l e m e n t s a r e u s e d .
A computation using an a x i s y m m e t r i c m o d e l , t h e r e f o r e , p e r m i t s to
utilize m e s h e s with a l a r g e n u m b e r of ring e l e m e n t s thus allowing
for a m o r e detailed idealization than p o s s i b l e for a 3-D a n a l y s i s . A
fine m e s h , using i s o p a r a m e t r i c e l e m e n t s EX 12, has been g e n e r a t e d
a u t o m a t i c a l l y by the MESHGEN c o m p u t e r p r o g r a m , r e p r e s e n t i n g a
n o z z l e - o n - s p h e r e a p p r o a c h , including the cladding, the t h e r m a l s l e e v e s
and the upper junction between the nozzle and the piping ( F i g . 2 8 ) .
Both the t e m p e r a t u r e d i s t r i b u t i o n and the c o r r e s p o n d i n g t h e r m a l s t r e s s e s
in the n o z z l e - v e s s e l junction, computed by this idealization s c h e m e ,
a g r e e with the r e s u l t s obtained f r o m the c o r r e s p o n d i n g 2-D a p p r o a c h
using a quite rough m e s h of EX 16 e l e m e n t s (Cfr. F i g . 2 5 ) .
B e s i d e s the t e m p e r a t u r e s and the s t r e s s e s in the s t r u c t u r e one can
now a l s o calculate t h e m in the cladding and in the t h e r m a l s l e e v e s .
High c o m p r e s s i v e hoop s t r e s s e s a r e built up in the cladding along the
upper p a r t of nozzle and a t the beginning of the v e s s e l , as shown in
Fig. 29.
B . T r a n s i e n t Conditions
All the p r e v i o u s t h e r m a l a n a l y s e s have b e e n p e r f o r m e d for the steady
state condition,

occuring a few hours after the beginning of the a c c i d e n t ,

15

b e c a u s e p r e l i m i n a r y calculations indicated that the highest s t r e s s e s

in the n o z z l e - v e s s e l junction would then o c c u r .
Since it has been shown that t h e r m a l s t r e s s e s can be e s t i m a t e d by
a x i s y m m e t r i c a p p r o a c h e s , meaningful t r a n s i e n t c a l c u l a t i o n s , using
2D m e s h e s , may be p e r f o r m e d without prohibitive c o s t s .
A t r a n s i e n t a n a l y s i s has been done for a n o z z l e - o n - s p h e r e a p p r o a c h ,
using a c o a r s e d i s c r e t i z a t i o n with EX 16 e l e m e n t s (see F i g . 2 5 ) . The
obtained r e s u l t s confirm the p r e l i m i n a r y c a l c u l a t i o n s . F o r the n o z z l e v e s s e l junction the highest t h e r m a l s t r e s s e s occur at the q u a s i steady
state condition, i . e . about 3 h o u r s after the upset condition b e g u n .
Thus for the evaluation of the t h e r m a l s t r e s s e s in that r e g i o n , a steady
state calculation is sufficient. F o r the n o z z l e - p i p e junction the m a x i m u m
t h e r m a l s t r e s s e s o c c u r at the v e r y beginning, i . e . during the f i r s t
few m i n u t e s . The highest hoop s t r e s s e s t h e r e a r e up to t w i c e the value
obtained f r o m a steady state c a l c u l a t i o n . This m e a n s that a t r a n s i e n t
calculation is needed for the n o z z l e - p i p e junction and in p a r t i c u l a r for
the cladding and for the t h e r m a l s l e e v e s .
It may be concluded t h a t for the t h e r m a l a n a l y s i s of the n o z z l e - v e s s e l
junction a steady s t a t e calculation is the m o s t a d e q u a t e , and b e c a u s e
the a x i s y m m e t r i c a p p r o a c h e s do not give as good r e s u l t s as had been
expected, it s e e m s that one 3-D computation, using a c o a r s e m e s h ,
is to be r e c o m m e n d e d .
rV.2 Dodewaard N5 Nozzle
Steady State Conditions
A c o m p a r i s o n has been p e r f o r m e d , for the Dodewaard N5 nozzle ( F i g . 4),
between the t h e r m a l a n a l y s e s , computed by a t h r e e - d i m e n s i o n a l s c h e m e
and by both a x i s y m m e t r i c a p p r o a c h e s , i . e . n o z z l e - o n - p l a t e or n o z z l e - o n s p h e r e . The t e m p e r a t u r e d i s t r i b u t i o n in the n o z z l e - v e s s e l junction is
a l m o s t a x i s y m m e t r i c . The c o r r e s p o n d i n g t h e r m a l s t r e s s e s , obtained by
a 3-D a n a l y s i s , r e p r e s e n t the s a m e d i s t r i b u t i o n as those calculated for
the Philippsburg n o z z l e , i . e . they show an i m p o r t a n t v a r i a t i o n in the

16 -

a n g u l a r d i r e c t i o n . The t h e r m a l s t r e s s e s , calculated by the axisy m m e t r i e

a p p r o a c h e s , r e p r e s e n t a d i s c r e p a n c y in the highest s t r e s s e d zones with
the 3-D r e s u l t s .
Although the Dodewaard N5 nozzle is of a different design that the
Philippsburg feedwater nozzle and in p a r t i c u l a r has a different n o z z l e t o - v e s s e l d i a m e t e r r a t i o , the t h e r m a l s t r e s s a n a l y s e s show a fairly
s i m i l a r behaviour of both nozzle t y p e s .

V . CONCLUSIONS

V . l . Mechanical Analysis
One m a y conclude that although the m e c h a n i c a l s t r e s s e s due to i n t e r n a l
p r e s s u r e in BWR p r e s s u r e v e s s e l n o z z l e s , with d / D r a t i o s < l / 4 ,
can be successfully analyzed by a x i s y m m e t r i c 2-D F o u r i e r type finite
(7)
elements
, the 3-D calcula tions have shown to be f e a s i b l e , provided
that i s o p a r a m e t r i c e l e m e n t s a r e used and that the input is p r e p a r e d by
an automatic 3-D m e s h g e n e r a t o r p r o g r a m such as for instance
"EURCYL".
With only 60 p a r a b o l i c EZ 60 e l e m e n t s a quite a c c u r a t e s t r e s s d i s t r i b u tion can be c a l c u l a t e d , r e q u e s t i n g little c o m p u t e r time (Table 1). The
use of cubic EZ 96 e l e m e n t s is not advisable for a n o z z l e - v e s s e l
i n t e r s e c t i o n of this t y p e .
V . 2 . T h e r m a l Analysis
T h e r m a l ups.et conditions induce in a BWR v e s s e l - n o z z l e junction,
p r o t e c t e d by t h e r m a l s l e e v e s fairly a x i s y m m e t r i c t e m p e r a t u r e
d i s t r i b u t i o n s , which can be e s t i m a t e d with good a c c u r a c y by an axi s y m m e t r i c m o d e l . These 2-D a p p r o a c h e s need only little computer
t i m e , thus allowing to p e r f o r m computations using a v e r y detailed
idealization s c h e m e and to c a l c u l a t e , if n e c e s s a r y , t r a n s i e n t t e m p e r a t u r e
fields without prohibitive computer c o s t s .

17 -

F o r the t h e r m a l s t r e s s c a l c u l a t i o n s , one may divide the s t r u c t u r e

into two p a r t s , i . e . the n o z z l e - p i p e and the n o z z l e - v e s s e l junction.
In che n o z z l e - p i p e junction and in p a r t i c u l a r in the t h e r m a l s l e e v e s or
the cladding, the t h e r m a l s t r e s s e s a r e highest during the beginning
of the t h e r m a l t r a n s i e n t . The 2-D a p p r o a c h e s give r a t h e r a c c u r a t e
r e s u l t s in that r e g i o n , thus an a x i s y m m e t r i c c a l c u l a t i o n , allowing for
an economically feasible t r a n s i e n t a n a l y s i s , is an a c c e p t a b l e a p p r o a c h .
Concerning the n o z z l e - v e s s e l junction one o b s e r v e s that the highest
t h e r m a l s t r e s s e s occur after the t h e r m a l t r a n s i e n t , thus r e q u e s t i n g
only a steady state c a l c u l a t i o n . Both a x i s y m m e t r i c a p p r o a c h e s show
quite i m p o r t a n t d i s c r e p a n c i e s c o m p a r e d to the 3-D r e s u l t s and m o r e o v e r ,
the n o z z l e - o n - p l a t e a p p r o a c h , giving the highest values between the
two 2-D a p p r o a c h e s , does not always give a safe e s t i m a t e (Cfr. F i g . 30
and 32) for the 3-D

s t r e s s s i t u a t i o n . F o r an a c c u r a t e a n a l y s i s a

3 - dimensional computation is thus needed, but as only one steady'

state c a l c u l a t i o n is n e c e s s a r y and b e c a u s e a quite c o a r s e m e s h

gives

r e a s o n a b l y a c c u r a t e r e s u l t s , a 3-D calculation is economically f e a s i b l e ,

e s p e c i a l l y if an automatic m e s h g e n e r a t i o n p r o g r a m is u s e d .

The conclusions for the m e c h a n i c a l and thermaal a n a l y s e s apply for both

n o z z l e s , although the design of the P h i l i p p s b u r g and the Dodewaard
nozzles is quite different. It is t h e r e f o r e felt t h a t the above c o n s i d e r a tions a r e quite g e n e r a l and apply to a r a t h e r b r o a d c l a s s of BWR
feedwater n o z z l e s .

Table I - G e n e r a l i t i e s and Cost E s t i m a t e s for V a r i o u s Mes h Refinements (IBM 3 7 0 / l 6 5 )

L a y e r s through wall thickness
Divisions in angular d i r e c t i o n
' of the nozzle

1 of EZ 96

3 of EZ 60

2 l a y e r s of E Z 60 e l e m e n t s

N r . of e l e m e n t s in idealization

90

270

180

150

120

90

60

N r . of nodal points in i d e a l i z a tion

1252

1588

1163

990

817

644

471

Semibandwidth of stiffness
matrix
C . P . U . time for BERSAFE
3-D calculation
C . P . U . time for I / O Management
Costs at a r a t e of US $ 1 , 5 0 0 /
hr

21 6 d . o . f .

273 d . o . f .

204 d . o . f . 180 d . o . f .

156 d. o . f .

132 d . o . f . 108 d . o . f .

1 9 min

35 min

17 min

13 m i n

9 min

6 min

4 min

5 min

7 min

4 min

3 . 5 min

3 min

3 min

2 min

600

1000 $

500

400 S"

300 >

225

150

- 19

ACKNOWLEDGEMENT

P a r t of the r e s u l t s of the Philippsburg nozzle has b e e n obtained

during a collaboration between TUEV Baden and JRC EURATOM,
I s p r a . The a u t h o r i z a t i o n of KWU, G e r m a n y to publish these r e s u l t s
is acknowledged.
The p a r t i c i p a t i o n of M r . J . A . B e r b e e of Delft U n i v e r s i t y in the
calculations for the Dodewaard BWR nozzle during a s c h o l a r s h i p
period at the JRC is a l s o acknowledged.

20

REFERENCES

(1)

T.K. HELLEN,
" B E R S A F E : A Computer S y s t e m for S t r e s s A n a l y s i s "
C . E . G . B . R e p o r t R D / B / N 1761

(2)

K. F U L L R D ,
"FLHE: A Finite Element

P r o g r a m m e for the Calculation of

T e m p e r a t u r e s in A r b i t r a r y S t r u c t u r e s "
C.E.G.B.Report
(3)

RD/B/N1849

P . DE WINDT and J . REYNEN

"EURCYL: A Computer

P r o g r a m m e to G e n e r a t e F i n i t e E l e m e n t

M e s h e s for C y l i n d e r - C y l i n d e r I n t e r s e c t i o n s "
EUR-5030 e
(4)

J . REYNEN, J . BLANCKENBURG, P . DE WINDT, J . PUTZEYS

" M E S H G E N / M E S H R E F : Computer Codes for the Automatic
Generation of T r i a n g u l a r F i n i t e E l e m e n t

Meshes"

Working P a p e r JRC EURATOM, I s p r a (italy)(Not a v a i l a b l e . )

(5)

T.K. HELLEN,
"A F r o n t Solution for F i n i t e E l e m e n t T e c h n i q u e s "
C . E . G . B . R e p o r t R D / B / N 1459, October 1969

(6)

J . A . BERBEE
"The Calculation of S t r e s s e s in the Nozzle N5 of the l / 4 Scale
Model of the 50 MWe Dodewaard BWR V e s s e l "
Work p e r f o r m e d during a s c h o l a r s h i p period at the JRC
EURATOM, I s p r a (Italy) 1972.

(7)

D . H . VAN CAMPEN and H . A . C . M . SPAAS

"On the S t r e s s Distribution in Noz z i e - t o - C y l i n d e r Connections for
Small D i a m e t e r R a t i o s " , N u c l . E n g . Design, Vol.21(1972) N o . 3 .

Fig.1 : 1:4 SCALE MODEL OF THE 50 MWe DODEWAARD

BWR

VESSEL

NOZZLE 5 OF THE 50 MW e DODEWAARD

BWR VESSEL MODEL

ii Feedwater
orz It*
N5
CO

Inner diameter
585.5 cm
Wall thickness
1A.6 cm
Overalt height
2100 cm

Fig. 2 : SKETCH OF PHILIPPSBURG B.W.R. VESSEL

TRANSVERSE CROSS SECTION OF NOZZLE-VESSEL J UNCTION

- 23

EX 16

EX

EX12

li

EZ 60
19

20

18

9 i

i1

EZ 96

17
\l6

13

21

-A 5

V.

,10

13 j

/ "

Fig.3 SOME ELEMENT TYPES AVAILABLE IN THE BERSAFE AND

FLHE SYSTEM

24

MESH DISTRIBUTION IN TRANSVERSE AND LONGITUDINAL PLANES ( 3 LAYERS )

Fig. A : DODEWAARD NOZZLE N5 : 3D

MESHES

- 25 -

one-fourth symmetry
sector ( 3 layers )

0.5 K g / m m '

one-sixteenth s y m m e t r y
sector! 2 layers )

0.5 K g / m m 2
45"

1 Kg/mm'

Load

condition - uniform internal pressure of 0.057 K g / m m

- uniform axial stress of 0.5 Kg / m m 2
- uniform tangential stress of 1 K g / m m 2
Boundary conditions-plane A B C D 6y = 0
-plane E F G H Sx = 0
_ plane A B F E 6 i = 0

Fig. 5-SYMMETRY SECTORS OF DODEWAARD VESSEL

NOZZLE JUNCTION CHOSEN FOR ANALYSIS

26

^.

mesh 2

mesh 1
mesh 2

ce stress i Z-X piane

tfh nominai hoop stress

Fig. 6: DODEWAARD N5 NOZZLE .COMPARISON BETW EEN 3D

RESULTS IN THE LONGITUDINAL PLANE COMPUTEDUSING MESH 1 AND MESH 2

27

measured strain
calculated strain

2800
C
' 2400
l_

3.2000
1600
1200

800
men
400

ex
men
0
-400
-800

face 2

>\

K^4-

Fig. 7 : COMPARISON BETWEEN CALCULATED AND MEASURED

STRAIN DISTRIBUTION FOR TH E DODEWAARD BWR N5
NOZZLE ( VAN CAMPEN ; REF 7 )

- 28

30

25

20

15

1.0

x_JL.

experimental results
numerical results > Ref. 7

3D results BERSAFE

05
face 2
0.0

Fig.8 : DODEWAARD NOZZLE 5.: COMPARISON BETWEEN 3D

COMPUTATIONS AND RESULTS PUBLISH ED BY D.H . VAN
CAMPEN (Ref.7)

29

MESH DISTRIBUTION IN TRANSVERSE AND LONGITUDINAL

Fig.9

PHILIPPSBURG

PLANES

FEEDWATER NOZZLE : 3 D MESHES ( 2 layers )

30

136
one-fourth symmetry
sector(2 layers )

0.5 Kg/mm

CT)
CN

ro
CSI

(O

one-sixteenth symmetry
sector (3 layers)

0.5 Kg/mm*""*^
Kg /mm

Load condition - uniform interal pressure of 0.0498 Kg /mm'

uniform axial stress of 05 Kg/.mm
uniform tangential stress of 1 K g / m m 2
Boundary condition-plane A B C D i y r O
plane E F G H & x = 0
plane A B F F 4 z = 0

Fig. 10 : SYMMETRY SECTORS OF PHILIPPSBURG VESSEL - NOZZLE

JUNCTION CHOSEN FOR ANALYSIS

31 -

Fig.11; COMPARISON BETWEEN 3D RESULTS IN LONGITUDINAL

PLANE COMPUTED USING MESH 1 AND MESH 2
(PHILIPSBURG FEEDWATER NOZZLE)

32 -

&*

ff stressi -Y plane
adnominal hoop stress

Rg.12 : COMPARISON BETWEEN 3D RESULTS IN TRANSVERSE PLANE

COMPUTED USING MESH 1 AND MESH 2 (PH ILIPPSBURG
FEEDWAJER NOZZLE )

33 -

Oh nominal hoop stress

O stress 1 Z - X plane

Fig. 13 : STRESSES PERPENDICULAR TO LONGITUDINAL PLANE

CALCULATED USING 1 LAYER OF EZ 96 ELEMENTS
(PHILIPPSBURG FEEDWATER NOZZLE)

- 34

h nominal hoop stress

o" stress 1 Z-Y plane

O
O

Fig. 14 : STRESSES PERPENDICULAR TO TRANSVERSE PLANE

CALCULATED USING 1 LAYER OF EZ 96 ELEMENTS
(PHILIPPSBURG FEEDWATER NOZZLE)

35 -

Oh nominal hoop stress

o* stress i Z-X plane

la

*
2a

' a = 6 divisions in angular direction

b = 2 divisions in angular direction

Fig. 15 : COMPARISON BETWEEN STRESSES CALCULATED USING

6 OR 2 DIVISIONS IN ANGULAR DIRECTION ( PHILIPPSBURG
FEEDWATER NOZZLE )

36

Oh nominal hoop stress

0 stress 1 Z-Y plant

Fig. 16 : COMPARISON BETWEEN STRESSES CALCULATED USING

6 OR 2 DIVISIONS IN ANGULAR DIRECTION ( PHILIPPSBURG
FEEDWATER NOZZLE )

'%?+ -4260

0.90

D
fe

t>

2.50

0.80

2.40

0.70

2.30

0.60

220

0.50

2.T0 -

0.40

GO

--
2

Nela

--
2

Nela

Fig. 17 : STRESSES CALCULATED IN SOME POINTS USING MESHES WITH A DIFFERENT NUMBER
OF DIVISIONS IN THE ANGULAR DIRECTION ( NELA)

1.00

300

t)

b
090

to 0.90

0.80

0.80

0.70

0.70

0.50

0.60

0.50

0.50

CO

co

*>

Nela

Nela

Fig. 18 : STRESSES CALCULATED IN SOME POINTS USING MESHES WITH A DIFFERENT NUMBER
OF DIVISION IN THE ANGULAR DIRECTION ( NELA )

350

1
1
1

Q.

300
I

1
1

250

200

t50

= feed water temperature

= temperature of water in the vessel

U--

~~

'

i
I

CA5

CD

j
I
1

100

50

300

600

900

1200

1500

1800

2100

2400

2700

Time (sec)
Fig. 19 - THERMAL TRANSIENT : FEEDING COLD WATER
REACTOR VESSEL

INTO THE

3000

Fig. 20 : PHILIPPSBURG B.W.R. FEEDWATER NOZZLE : THERMAL BOUNDARY CONDITIONS

41

| Z -direction

T=30*C
=0.01 W/cm2'C

T=250*CV
0^0.24 W/cm2 eC
T-286C . r O W W i t m ^ C
T=270'C
o\=02^W/cm2'C

X - direction
longitudinal plane

i Z -direction

T=30*C
<*=0.01W/cm2,C

c<= 024 W/cm

T=270'C
*=024W/cm2eC
Y-direction
transverse plane

Fig. 21 : TH ERMAL BOUNDARY CONDITIONS FOR 3-D

AND COARSE 2-D CALCULATIONS

J60'C

160'C
3D ANALYSIS
TEMPERATURE DISTRIBUTION

tito

280'C

TRANSVERSE

LONGITUDINAL PLANE

Fig. 22: PHILIPPSBURG

NOZZLE : 3D TEMPERATURE

DISTRIBUTION

PLANE

43

115

189

263

337

11 85 559

638

707

781

855

Nodal point number

20

/
E

E
en

CM

/
/

10

53 rv

15

\
\

/
/

349

\
\

711

!
1

*^

/
/
53

127 201

275

349

423 571
497

645

719

793

867

Nodal point number

Fig. 23 : PHILIPPSBURG NOZZLE : THERMAL STRESS NORMAL
TO THE LONGITUDINAL AND TRANSVERSE PLANES

- 44 -

Fig 24 : THERMAL HOOP STRESSES VERSUS ANGULAR

DIRECTION

45

O) '

ti
T)
M

R - dire ction
NOZZLE-ON-PLATE

APPROACH

NOZZLE-ON-SPHERE APPROACH
R - direction

Fig. 25 .MESH DISTRIBUTION FOR

NOZZLE-ON-PLATE

AND NOZZLE-ON-SPHERE APPROACH

k irc

2D APPROACH
ANALYSIS

2D APPROACH
3D ANALYSIS

CT)

Fig. 26 : TEMPERATURE DISTRIBUTION IN A NOZZLE VESSEL JUNCTION

47

nodal point
41

115 189

263

337

411485 559 638

707

nodal point

53

127 201

18 29

275 349

423

571

numbe r
781

855

number

nodal point number

645
719
793
867

CT
IC

40

51 73 95

117
128
nodal point number

Fig. 27 : PHILIPPSBURG NOZZLE : Comparison between

2-D and 3-D results of thermal stresses

48

Fig. 28 : 2 D mesh of philippsburg feedwater nozzle

representing also thermal sleeve, gap, cladding.

co

-25

, 463 . 621. 706

420

544

671

795
749

847

903

1014

958

1098
1070

1184 1248
1216
1280

j _ _ i

1150

Nodal point number

Fig.29: AVERAGE THERMAL HOOP STRESSES IN CLADDING COMPUTED WITH A 2 - D
NOZZLE-ON-SPHERE APPROACH

21

(M

nozzle - o n - plate

E
E
CT
XL

approach

20

JZ

19

18

/
c
o
Q.

17

i2

c h nozzle -on-sphe re

a>
c
o

Q.

a>
</)

>
(fl
c

3-D calculation

approach

f-Z
o

'

16

15

14
0

15

30

A5

60

75

90

angle ( )
Fig. 30 : PHILIPPSBURG NOZZLE : Highest thermal hoop stress versus angular
direction

en

23

a h n ozzle - o n - plate

approach

CM

22

21

20

c
o

a*

c
o
X

c
5
CT

3-D

c a l c u l a t i on

IA

>

C
O

19

en

^ n o z z l e - o n - s p h e r e
approach

18

17

16 15

30

45

60

75

90

angleC)
Fig. 31 : DODEWAARD NOZZLE Highest thermal hoop stress versus
angular direction.

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