Development and application of an efficient method for performing modal analysis of steam generator tubes in nuclear power plants

A typical pressurized water reactor (PWR) steam generator has approximately 10,000 tubes. These tubes have different geometries, supporting conditions, and different material properties due to the non-uniform temperature distribution throughout the steam generator. Even though some tubes may have the same geometry and boundary conditions, the non-uniform distribution of coolant densities adjacent to the tubes causes them to have different added mass effects and dynamic characteristics. Therefore, for a reliable design of the steam generator, a separate modal analysis for each tube is necessary to perform the FIV (flow-induced vibration) analysis. However, the modal analysis of a tube including the finite element modeling is cumbersome and takes lots of time. And when a commercial finite element code is used, interfacing the modal analysis result, such as natural frequencies and mode shapes, with the FIV analysis procedure requires an additional significant amount of time and can possibly incur inadvertent error due to the complexity of data processing. It is therefore impossible to perform the complete FIV analysis for ten thousands of tubes when designing or maintaining a steam generator although it is necessary. Rather, to verify the safe design against the Fly, only a couple of tubes are chosen based on engineering judgment or past experience. In this paper, a computer program. PIAT-MODE, was developed which is able to perform modal analysis of all tubes of a PWR steam generator in a very efficient way. The geometries and boundary conditions of every tube were incorporated into PIAT-MODE using appropriate mathematical formulae. Material property data including the added mass effect was also included in the program. Once a specific tube is selected, the program automatically constructs the finite element model and generates the modal data very quickly. Therefore, modal analysis can be performed for every single tube in a straight way. When PIAT-MODE is coupled with the FIV analysis program, it gives an amazing benefit, which makes the FIV analysis of all tubes possible within a limited time during the design or maintenance period. Using the developed program, the stability ratio regarding the fluid-elastic instability and the amplitude of vibration resulting from the turbulence flow excitation can be calculated for all tubes according the standard ASME Code, therefore, much more reliable design of the steam generator against the FIV related failures can be achieved. For an operating plant, there is a requirement that every single tube must be quantitatively checked whether wear would be more than 40% in thickness during the next operation period. If yes, the tube must be plugged to prevent severe failure including the tube wall penetration. In order to decide the tube plugging, which leads the plant performance degradation, the wear prediction is required. The wear prediction analysis needs wear data by ultrasonic testing and modal property data of tubes. FIAT-MODE will be a power tool enabling the wear prediction in a limited maintenance period by supplying modal data for all tubes. (C) 2010 Elsevier B.V. All rights reserved.