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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 Date 12-15.01.2015

Test Facilities in Germany


Test Facilities and Projects in Germany


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


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


- type helical tubing integrated, steam inside tubes


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


- type helical tubing

- max. pressure differenze Primary/Secondary under normal conditions 2 bar


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


Vessel Steel for Pressure Boundary


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)


Graphite Internals


Materials for Components

IHX



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


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


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)



Isolation Valves (secondary side)

Direction of

movement on

closure

Double seal

system

Valve

seat

Valve

seat

Direction of

movement on

closure



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


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


Test Components inside KVK

KVK Hot Gas Duct


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






Hot Gas Duct (ceramic design)

pictures from manufacturing

Horizontal test tube



flow diameter 700 mm Core Connection

System test tube




IHX (U-Tube-Type), demension for 170 MW but

tubing only for 10 MW

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



IHX (Helical-Tube-Type), dimension for 170 MW

but tubing only for 10 MW




in back: IHX-Helical-Type

in front: SG for KVK

10 MW decay heat cooler for KVK (steam

generator)



Isolation Valves (secondary

side)

axial valve type,


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