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AREVA´s accredited testing facility
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AREVA’s Thermo-Hydraulic Platform qualified as test and inspection bodyIngo Ganzman, Wolfgang Herr, Holger Schmidt, Willi Stecher, Dirk Walter, Klaus Umminger, Achim Beisiegel, Michael Wich, Phillipe Dolleans and Thierry Muller
Kurzfassung
AREVAS´s Thermo-Hydraulik-Plattform als Prüf- und
Inspektionsstelle akkreditiert
AREVA betreibt eine weltweit einmalige Test- und Qualifizierungsinfrastruktur für Komponen-ten der Kraftwerkstechnik. Die dazugehörige Thermo-Hydraulik-Plattform wurde als Prüf- und Inspektionsstelle nach DIN ISO 17025 und DIN ISO 17020 akkreditiert. Diese Akkreditie-rung bescheinigt AREVA und ihren Kunden den hohen Standard der Untersuchungen, die in den zahlreichen Versuchseinrichtungen durch-geführt werden.
Die AREVA Thermo-Hydraulik-Plattform um-fasst zum einen Integralversuchsstände, in de-nen für Druckwasser- und Siedewasserreak- toren Störfallszenarien im Wechselspiel aller relevanten Systeme untersucht werden. Zum anderen werden Qualifizierungsversuchsstände betrieben, in denen nahezu alle Komponenten von Kernkraftwerken – von kleinen Steckern bis
Introduction
AREVA NP GmbH has been operating a worldwide unique testing and qualification infrastructure for more than 30 years, which is mainly delegated to systems and components of light water reactors. With the upcoming renaissance of nuclear energy, the require-ments regarding highly-qualified test capa-bilities have increased in such a way that it is not possible for all stakeholders to run their qualification programs at plant conditions within their own facilities. In addition, many facilities have been closed in the past decades for reasons of economic viability. Investments in new facilities or costs for a restart of old and closed facilities are far from reasonable financing. Therefore, AREVA has decided to open its Thermo-Hydraulic Platform for part-ners within the power plant industries, among which are authorities, research centres, com-ponent suppliers, utilities and/or engineering companies. To ensure our partners a high quality of test and qualification standards, AREVA has successfully applied for accre- ditation by the DAkkS GmbH (German ac-creditation body) as flexible test laboratory according to ISO/IEC 17025 and as independ-ent inspection body according to ISO/IEC 17020. The International Laboratory Accredi-tation Cooperation (ILAC) has settled an al-most worldwide cooperation agreement ac-cording to which the associated countries ac-cept each others` accreditations. According to this agreement, the accreditation of AREVA’s
Thermo-Hydraulic Platform is valid not only in Germany but also in almost all countries of the world, e.g. USA, Canada, India, China, Japan, Korea, Emirates, Russia and the EU. This article gives an overview of the general testing and inspection capabilities of AREVA in the field of thermal hydraulics and compo-nents testing.
Test and qualification range
The testing and qualification infrastructure is focused on flexible task solutions for power plant applications. Therefore, it is common practice to modify the existing testing infra-structure to fulfil the requirements of a quali-fication or an inspection task. To avoid new individual accreditations for each task, ARE-VA has successfully applied for a flexible ac-creditation based on which the general meth-ods and applicable range of measurement have been certified ( Ta b l e 1 ).
The methods are linked to the Thermo-Hy-draulic Platform, which is the basis for tests and qualifications. This means the facilities will be used or the methods that have been proven at the facilities themselves. The ap-plied methods can be concept inspections based on experiences supported by numerical analysis. In addition, the accreditation range covers on-site inspections and qualifications at power plant or component supplier sites. Some examples described in the following paragraphs indicate the range of the certifica-tion.
AREVA’s Thermo-Hydraulic Platform
At sites in Karlstein and Erlangen (both in Germany), AREVA operates the Thermo-Hy-draulic Platform with about 100 engineers and technicians. Therefore, AREVA is in the position to test all relevant components and systems of power plants.
“Primärkreislauf” (PKL) – primary system loop
The most impressive example for a system test facility is the PKL loop, which represents
Authors
Dr. rer. nat Ingo Ganzman Department manager thermohydraulic experiments Dipl.-Ing. Wolfgang HerrSection manager laboratory operationDr.-Ing. Holger SchmidtWorldwide manager thermal hydraulics and components testingDipl.-Ing. Willi StecherDepartment manager components qualificationDipl.-Ing Dirk WalterSection manager fluid dynamicsDipl.-Ing. Klaus UmmingerDepartment manager PKL project AREVA NP GmbH, Erlangen/Germany
Dipl.-Ing. Achim BeisiegelSection manager test technologyDipl.-Ing. Michael WichDepartment manager components qualification Karlstein AREVA NP GmbH Karlstein/Germany
Grad. Ing. Phillipe DolleansFrench technology line manager thermal hydraulics and components testing, department manager fluids and structural mechanics Dr. Ing. Thierry MullerSection manager hydraulics and heat transfer AREVA NP S.A.S. Le Creusot/France
hin zu Pumpen, Ventilen oder Brennelementen – unter Betriebsbedingen bezüglich ihres Ein-satzes qualifiziert werden.
Die maximalen Betriebsparameter der Ver-suchsanlagen der Thermo-Hydraulik-Plattform betragen bei Heizleistungen bis zu 22 MW, elektrischen Strömen bis zu 80 kA, Drücken bis zu 300 bar und Temperaturen bis zu 600 °C. Die Akkreditierung umfasst dabei Versuche und Bewertungen sowie sachkundige Kon-zeptbeurteilungen mit entsprechenden Unter-stützungsprogrammen. AREVA bietet auch die dazugehörigen Vor-Ort-Untersuchungen im Kraftwerk beziehungsweise bei Herstellern an – zum Beispiel die Funktionsnachweise von Ventilen. Der vorliegende Beitrag gibt einen Überblick über das Arbeitsgebiet der Prüf- und Inspektionsstelle.
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AREVA´s accredited testing facility
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the system of a four loop pressurised water reactor (PWR) plant. Based on a reference plant, the German nuclear power plant Philippsburg 2, the facility was built in a 1:1 scale regarding height and 1:145 with respect to power and volumes. F i g u r e 1 shows the scheme and the main components of the facil-ity, which include the reactor pressure vessel (RPV), steam generators (SG), reactor cool-ant pumps (RCP), accumulators and pressu-riser. The facility is also equipped with all relevant secondary-side components and other operational and safety systems, which are rel-evant for modelling of the total response of the entire system during accident situations – the main purpose of the PKL experiments. Based on tests performed for more than 30 years, safety margins of operating and future nuclear plants have been demonstrated. The thermal hydraulic experiments encompass de-sign basis accidents with and without loss of coolant (LOCA), as well as beyond-design-events. With more than 1,000 measuring sen-sors (much more than in the corresponding components of the PWR plants), the facility
provides detailed information on the system behaviour of PWRs under accident situations. Nowadays, it is also used by utilities to train their staff.
Apart from the PKL facility – delegated to PWR activities – an additional facility is in operation dealing with boiling water reactor (BWR) tasks. It is called INKA and is de-scribed in [1 and 2]. The main component – the reactor pressure vessel mock-up – of INKA is also the core of the world’s biggest valve testing facility GAP.
“Großarmaturen-Prüfstand” (GAP) – valve test facility
The flow scheme of the GAP is shown in F i g u r e 2 . A very big steam accumulator with a volume of 125 m3 is connected to a BENSON boiler with a total power of 22 MW. It supplies steam with a pressure of up to 165 bar and a temperature of up to 360 °C. Depending on the test requirements, a test
valve will be supplied with different condi-tions of water and steam – in case of a steam test, the valve will be connected to the top of the accumulator and for water tests to the bot-tom. In total, valves of diameters of up to 28" have been tested and qualif ied with blow rate flows of up to 2,000 kg/s steam and 4,000 kg/s steam/water mixture. The loop will be operated in an open mode where fluid flows through the test specimen, which is typ-ically a valve, into a quencher pool, where the steam will be condensed. Due to the high flexibility of the test set-up, different other objects have been tested up to now, for exam-ple vent pipes, through which steam enters the quencher of a boiling water reactor, or insula-tion cassettes destroyed by a jet. In this case, the fragmentation has been analysed to obtain representative data for the qualification of sump sieves in front of injection pumps.
SUSI – sump sieve test set-up
For the qualification of sump sieves in consid-eration of the related transport phenomena, an own test set-up exists which has an open rec-tangular vessel of about 21 m3 as basic com-ponent. This vessel represents a section of the sump which is filled up with water in the case of a LOCA. Pre-tests have indicated that the overlay on a sieve formed of debris and insu-lation material destroyed by a hypothetical jet depends on the transport along the sump. Therefore, this facility is designed in such a way that the total flow path from the leakage through the sump sieve via a reactor pressure vessel section is covered as shown in F i g - u r e 3. The aim of the tests is to demonstrate the performance of the filtering systems and to show that an increased pressure drop due to deposition of debris will have no negative im-pact on the cooling of the fuel assemblies. Optional tests with a flow through a fuel as-sembly dummy can be performed to demon-
Table 1. Accredited measurement range of AREVA’s Thermo-Hydraulic Platform.
Parameter Range Uncertainty
Temperature 0 °C to 600 °C ± 0.3 K
Pressure 10 Pa to 40 MPa ± 0.5 %
Volume flow rate 0.1 𝓵/h to 100,000 m3/h ± 0.5 %
Mass flow rate Up to 4000 t/h ± 5 %
Force Up to 10,000 kN ± 1 %
Momentum Up to 50,000 Nm ± 1 %
Length 1 µm to 10 m ± 0.5 %
Velocity 1 mm/s to 100 m/s ± 0.5 %
Acceleration 0,5 to 1000 g ± 1 % Linearity
Electrical power Up to 20 MW ± 0.5 %
Active power 50 KW ± 1 %
Current 85,000 A ± 0,5 %
Voltage 420 V ± 0,5 %
SG
SG
Main steam line
Feedwater line
Pressuriser
SG
SG
RCP
RCP
RCP
RPV
RCP
Figure 1. Flow scheme of the PKL facility (left), top view on PKL steam generators (right).
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strate the low impact on the downstream com-ponents in the case of an optimised filtering system.
„Komponentenprüfanlage“ (KOPRA) – component test facility
For the qualification of RPV internals and valves, AREVA operates the multi-functional test facility KOPRA. The focus of this facility is on full-scale functional tests respecting nominal temperature, pressure and mass flow. Beyond that, for endurance testing to investi-gate long-term behaviour and wear effects, it is also possible to adapt the water chemistry. In general, the facility consists of four test loops with three recirculation pumps and pressurisers as shown in F i g u r e 4. Main
qualification tasks are focused on valves, safety valves with its pilots, pumps, RPV core internals as fuel assemblies and control rod drive mechanisms (CRDM).
In the “Armaturenprüfstand” (APS) – valve test section – (shown on the left side of Fig- ure 4), different test objects (mainly valves) can be placed within different test sections of nominal diameters from 15 to 150 mm to measure pressure drops or determine the func-tional behaviour. Via the discharge line of the “Versuchsdruckhalter” (VDH) – test pressu-riser – qualification tests for prototypes or functional and setting tests for safety valves have been performed. The in-service hot ad-justment of a set of pilots of safety valves for PWR primary and secondary circuits with sat-urated steam is performed with the valve test array on top of the APS pressuriser. The advan-
tage of these in-service hot adjustments in comparison to functional testing during the start-up, beside a shorter start-up phase, is an immediate maintenance and hot adjustment in the case of leakage. The “Regelstabprüfanlage” (RPA) – control rod drive mechanism (CRDM) test section – (shown on the right side of Fig- ure 4) is designed to test CRDMs. Before in-stallation, it is required to run factory accept-ance tests over several hours under operational conditions to generate a magnetite layer on the sliding surfaces for serviceability and to ensure the functionality. The “Kernkomponentenver-suchsanlage” (KVA) – core component test section – simulates the complete geometry of the central core position with a 1:1 scale. The fuel assembly is inserted in a fuel assembly channel in-between the lower support plate and the upper core plate. The control rod guide as-sembly is fixed by the upper support plate. The vessel head of the test channel corresponds to the RPV head with the CRDM adaptor and flange. Within this test set-up, functional tests to verify the adequate performance and endur-ance tests to demonstrate the proper function-ing over the specified lifetime of the CRDM, mobile set and drop channel were performed. In addition, pressure drop characteristics over the fuel assembly were measured.
Test set-ups to qualify the functioning of fuel assemblies
To analyse the general thermal hydraulic be-haviour of fuel assemblies, AREVA operates
FromBenson boiler
Main stop valve
Steamaccumlator
Main steam line
DN
700
Test specimen:
A
1900 mm for 10"...18" valves2300 mm for > 20" valves
DN
350
Main water line
M?
Demineralisedwater supply
Quick-opening valvesfor pipe break simulation
Quench pool
DN 800
Quencher
DN 800
Discharge line
Preheating line
M
Noozle for spring loaded safety valve testing
M
Figure 2. Flow scheme of the GAP – the world’s largest valve testing facility.
Building structure Fuel assembly test rig
Test poolincludes strainerdevices andsimulates the sump Water storage tank
Debris preparation pool
Main pumpSuction line tothe pump
Suction boxconnection to the strainer device
Figure 3. Flow scheme SUSI for qualification of sump sieve designs.
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special unique facilities for this purpose called Karlstein Thermal Hydraulic Test Loop (KATHY). With respect to the determination of critical heat flux as the basis for correla-tion developments the KATHY loop is in op-eration. Fuel assemblies are simulated by electrically-heated rods. The critical heat flux is identified based on a significant tem-perature increase at a certain power level. Two different test vessels are installed – one for BWR and one for PWR fuel assemblies. Apart from critical heat flux tests, this facil-ity has also been used to analyse the flow stability in a BWR core including fuel as-semblies under forced and natural circulation conditions [3]. The operational conditions are similar to those of the licensing process
of fuel assemblies. The total electrical power is 20 MW.
Another set-up is focused on fluid-induced forces and possible vibrations. With advanced velocity measurement techniques like Laser Doppler Anemometry (LDA) and Particle Image Velocimetry (PIV) it is possible to an-alyse the flow pattern in the fuel assembly and potential consequences on the structure. For the measurement of the response of the structure itself laser triangulation sensors and laser vibrometers are installed in these facili-ties [4].
Loss of coolant (LOCA) qualification tests
All safety-related electrical components have to withstand LOCA conditions, even if they are in operation until they have reached their end of operation lifetime. For qualification over the entire lifetime spectrum, the test specimens will be artificially aged by consid-ering the main degradation mechanisms which are radiation, thermal and mechanical aging. Therefore, the test specimens will be installed in front of a radiation source in such a way that the irradiation over a couple of days/weeks is representative to the degradation
M
M
DN 150
DN 100
DN 50 DN 80
DN 25
DN 15
M M
Pum
p
Cooler
Test sections
Valve test array
APSValve test facility
RPACRDM test facilitySilencer 150 t/h
M
Pres-suriser1 m3
KVA
Test pressuriserVDH
4,5 m3
DN
100
Blo
w d
own
line
Test
sec
tion
for
FA, C
RG
A a
nd C
RD
M
DN 200 M
Coo
ler
Hea
ter
KVACore component
test facility
Pres-suriser1 m3
Pum
p
Pum
p
APS
Coo
ler
Hea
ter
DN 50
Figure 4. Flow scheme KOPRA.
Figure 5. LOCA test, preparation of a motor drive. Figure 6. Juliette test arrangement for the investigation of the lower plenum flow conditions in an EPRTM reactor.
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during operation of the plant. Thermal aging will be performed in climate ovens in which the temperature is significantly higher than the operational temperature. The thermal aging time will be determined based on the Arrhenius law. Mechanical aging is also per-formed e.g. in the case of active components by simulating movements over the entire life-time.
The artificially-aged specimens will be in-stalled in a vessel where they have to with-stand the loads of a LOCA. Depending on the defined conservative spectrum of the LOCA, a pressure and temperature time depending steam atmosphere will be injected in the ves-sel. After LOCA tests, further tests simulating post LOCA conditions have to be performed. Therefore, the specimens will be installed in a third vessel where they have to withstand low-er pressures and temperatures than in LOCA conditions, but in addition to that, water chemistry and regular wetting are main degra-dation effects in this phase.
AREVA operates several vessels ( F i g - u r e 5 ) to run the different stages of these qualification steps for test specimens of dif-ferent sizes.
Flow model and separate effect tests
The Thermo-Hydraulic Platform is organised in such a way that test set-ups are standard-ised as much as possible but it also has to be as flexible as possible. In a lot of cases the tests will be run only once for one application. Therefore, in addition to the above-mentioned, AREVA´s facility park also has the infrastruc-ture to run separate effect tests for water/steam applications and related flow model tests. Together with related flow modelling, they will be used to evaluate complex condi-tions. For example, the heat removing capa-bilities of an ex-vessel core-melt cooling sce-nario of a boiling water reactor was demon-strated in a multiple step approach [5]. In a first step, the flow behaviour around the RPV in the core melt experiment was investigated based on scaled water/air experiments. In a second step, the shape of a section was identi-fied in such a way that it represented the flow conditions. In the third qualifying step, a 1:1 section model was installed in a high-pressure separate effect test facility of a power up to 2 MW and maximal operational conditions of 300 bar/600 °C. It is part of the competence of the expert staff to imagine all relevant scal-ing aspects. In addition the expert staff are qualified to understand and to interpret ther-mal-hydraulics or fluid induced vibration (FIV) phenomena.
The AREVA thermal-hydraulic testing and qualification tasks are completed with an in-
frastructure installed in Le Creusot (France). Examples for advanced flow model tests per-formed in France are tests regarding the flow distribution and the temperature distribution at the core inlet of AREVA’s EPRTM reactor. For this purpose, a transparent mock-up – called Juliette – scaled 1:5 was built ( F i g - u r e 6 ) . In addition to the RPV mock-up, this model included all main cooling lines. For the simulation of the pump rotations, swirl pro-moters with the same characteristics as a main coolant pump were installed. As a mock-up of the core, each location fuel assembly was rep-resented by a Venturi meter to model a repre-sentative part of pressure drop and to measure the local flow rates. To understand the veloci-ty field in the lower plenum, PIV and LDA measurements were performed. In addition to Juliette regarding the lower plenum, tests for the EPRTM reactor were run for investigation of the upper plenum behaviour mock-up at the same scale as Juliette (EPR RPV Lower ple-num mock-up) and called ROMEO (EPR RPV Upper plenum mock-up) and for RPV internal fluid induced vibrations mock-up called Hydravib for FIV reason at 1:8 scale).
Virtual test facilities and boundary condition setting
For the proper design of test facilities or to evaluate concepts, computational fluid dy-namics (CFD) methods and pipe system anal-ysis programs are part of the field of activities and competence of the inspection body.
In addition, CFD is an essential tool for the understanding of the general flow conditions. It is a common process for complex flow con-ditions to optimise the test design including the measurement concept based on the under-standing of flow conditions. F i g u r e 7 indi-cates a case where it has been the purpose of the test to have a homogenous flow entering
the test object. As real test set-ups have a lim-ited size of homogenisation length a flow straightener has been installed in front of the test object itself. This design has been opti-mised with CFD methods. The homogenous flow distribution in front of the test object itself has been qualified with LDA measure-ments.
On-site services
In addition to the pure testing in the laborato-ries and related modelling, it is also part of the accreditation to perform diagnostics, tests and related inspections e.g. for valves on-site – at power plants or component suppliers. These on-site services as well as the labora-tory activities are within the accredited meas-urement range.
As an example of the valve diagnostics and valve services activities mobile torque test benches (Mobiler Drehmoment Prüfstand, MDP) are designed, qualified and manufac-tured in the laboratory ( F i g u r e 8 ). The faulty operation of a valve often shows at an early stage through a change in the torque or switching behaviour of the actuator. It is therefore useful to determine the torques on a regular basis. Essentially, the MDP consists of an electromagnetic brake. Amperage is pro-portional to braking force. After switching off, the braking action is inhibited by the re-sidual magnetism. In this way, a precise in-crease and decrease of the actuator braking torque can be ensured. Upon adjustment of the travel limit switch, the valve is ready for operation again. The MDP is also linked to the valve monitoring system “Armaturen Di-agnose- und Auswert-Methode” (ADAM®). Whereas with ADAM® the function stand-by of the complete system ranging from power supply and control system to shutoff device of the valve is periodically being inspected and compared with the corresponding baseline measurement. The valve monitoring system is based on the proportionality of the active power of the actuator and the torque during valve operation. It ensures that all parameters relevant for valve and actuator performance are reliably monitored.
Cross velocity in m/s
Figure 7. Modeling of the flow entering a test object, left side flow pathes and right side cross velocities.
Figure 8. ADAM® system with MDP test benches and control panel in a work shop.
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Summary
AREVA has a worldwide unique testing and qualification platform focused on thermal hy-draulic tasks. To guarantee the high quality standards, AREVA GmbH positioned the re-lated organisation in such a way that the DAkkS GmbH (German accreditation body) could accredit it as test and inspection body. Therefore, AREVA makes sure that persons involved in tests and inspection will not be in-fluenced by any political, economic or social interests. Combined with the guarantee of a very high level of confidentiality, this ensures independency of the results. The accreditation also represents a qualified opening of the worldwide unique test and qualification infra-
structure for component-suppliers, engineer-ing companies, utilities and research centres. In case they have to run test or inspection pro-grams, it is an advantage to avoid the costs for the construction of an own infrastructure. In this way, AREVA offers support to the part-ners in the nuclear community to guarantee high security standards which is in the joint interest of all participants.
References
[1] Leyer, S., Maisberger, F., Lineva, N., Wagner, T., Doll, M., Herbst, V., and Wich, M.: Full scaled tests of the KERENATM containment cooling condenser at the INKA test facility, Annular Meeting on Nuclear Technology, Mai 2010, Berlin, Deutschland.
[2] Wagner, T., Wich, M., Doll, M., Herbst, V., and Uhrig S.: Tests with the Emergency Condenser at the Integral Test Stand Karlstein for KE- RENATM, Annular Meeting on Nuclear Tech-nology, Mai 2010, Berlin, Deutschland.
[3] Kreuter, D., Wich, M., Imbert, P., and Pruitt, D.: KATHY: FRAMATOME ANP’s Thermal Hy-draulic Test Loop, 6th International Conference on Nuclear Thermal Hydraulics, Operations and Safety (NUTHOS-6) Nara, Japan, October 4-8, 2004.
[4] Ganzmann, I., Hille, D., and Staude, U.: Peter Loop Multifunktionsversuchsstand zur thermo-hydraulischen Untersuchung von DWR Bren-nelementen, Annular Meeting on Nuclear Tech-nology, Mai 2009, Dresden, Deutschland.
[5] Schmidt H.: Large scale verification of external RPV cooling in the case of severe accident, Proceedings of the ICAPP 2004, Pittsburg, USA. ∙
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Explosion Protection in
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International Journal
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Volume 85/2005 · ISSN 1435-3199
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International Edition
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Kopswerk II –
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Arklow Bank
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The EU-Water
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Focus: Safety at Work
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International Journal
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VGB Po wer Tech – www.vgb.orgThe generation of electricity and the disposal of heat is in all parts of the world a central topic of technology, economy, politics and daily live. Experts are responsible for the construction and operation of power plants, their development and monitoring as well as for various tasks in connection with service and management.
The technical journal VGB PowerTech is a competent and internationally accepted publication for power plant engineering. It appears with 11 bilingual issues (German/English) annually. VGB PowerTech informs with technical/scientific papers and up-to-date news on all important questions of electricity and heat generation.
VGB PowerTech appears with VGB PowerTech Service GmbH, publishing house of technical-scientific publications.
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