• Journal of the Korean Society for Nondestructive Testing
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• v.26 no.3
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• pp.174-180
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• 2006

Steam generator (SG) tubes are expanded inside tubesheet holes by using explosive or hydraulic methods to be fixed in a tubesheet. In the tube expansion process, it is important to minimize the crevice gap between expanded tube and tube sheet. In this paper, absolute and differential signals are computed by a numerical method for several different locations of tube expansion inside and outside a tubesheet and signal variations due to tubesheet, tube expansion and operating frequencies are observed. Results show that low frequency is good for detecting tubesheet location in both types of signals and high frequency is suitable for sizing of tube diameter as well as the detection of transition region. Also learned is that the absolute signal is good for measuring tube diameter, while the differential signal is good for locating the top of tubesheet and both ends of the transition region. In the case of mingled anomaly with tube expansion and tubesheet, low frequency inspection is found to be useful to analyze the mixed signal.

• Transactions of the Korean Society of Pressure Vessels and Piping
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• v.15 no.1
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• pp.18-27
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• 2019

The Advanced Power Reactor 1400 (APR1400) Steam Generator (SG) uses alloy 690 as a tube material and SA-508 Grade 3 Class 1 as a tubesheet material to form tube-to-tubesheet joint through hydraulic expansion process. In this paper, the residual stresses in the SG tube-to-tubesheet contact area was investigated by applying Model-Based System Engineering (MBSE) methodology and the V-model. The use of MBSE transform system description into diagrams which clearly describe the logical interaction between functions hence minimizes the risk of ambiguity. A theoretical and Finite Element Methodology (FEM) was used to assess and compare the residual stresses in the tube-to-tubesheet contact area. Additionally, the axial strength of the tube to tubesheet joint based on the pull-out force against the contact joint force was evaluated and recommended optimum autofrettage pressure to minimize residual stresses in the transition zone given. A single U-tube hole and tubesheet with ligament thickness was taken as a single cylinder and plane strain condition was assumed. An iterative method was used in FEM simulation to find the limit autofrettage pressure at which pull-out force and contact force are of the same magnitude. The joint contact force was estimated to be 20 times more than the pull-out force and the limit autofrettage pressure was estimated to be 141.85MPa.

• Proceedings of the KWS Conference
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• 1996.05a
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• pp.34-37
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• 1996

The expanding method of tube to tubesheet joint part on neclear steam generators are classified into three classes of roller expanding, explosive expanding and hydraulic expanding. After the expanded Mock-Up specimen are made by the three expanding method. The general properties, microstructure/microvickers hardness, pull-out strength, hydraulic leak pressure, of tube to tubesheet joint part were inspected. and We evaluated the operation efficiency of expansion, reproduction of expanded joint about three expanding method. Through the overall evaluation of tube to tubesheet joint part, The hydraukic expanding and explosive expanding could be certificated more useful expanding method.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.176-179
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• 2006

Large tubesheet forgings of the steam generator for the 1,400MW nuclear power plant has been developed. Steam Generator is one of the most important structural part for nuclear power plant. It is manufactured by various steel forgings such as shell, head, torus and tubesheet. These steel forgings have been made by open die forging process. After steel melting and ingot making, open die forging has been carried out to get a good quality which means high soundness and homogeniety of the steel forgings by using high capacity hydraulic press. This paper introduced the forging process development and manufacturing experience of large tubesheet forgings which will be used for the steam generator of 1,400MW nuclear power plant.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.23 no.11 s.170
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• pp.1896-1903
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• 1999

The basic requirements to improve the joints quality of tube-to-tubesheet for heat exchangers are to obtain high residual contact pressures between the tubes and the tubesheet as well as low residual stresses in the transition zone of the tubes. The residual contact pressures and residual stresses which govern the joint quality are influenced by parameters such as material properties, geometric dimension of tube and tubesheet and expansion pressures. There are two types of tube layout patterns, triangular and square, which are frequently used for heat exchangers. The purpose of the present work is to examine the superior tube layout patterns considering the joints quality by comparing numerical results from sensitivity analyses which were performed for both of tube layout patterns.

• Transactions of the Korean Society of Pressure Vessels and Piping
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• v.10 no.1
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• pp.7-14
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• 2014

There has been extensive experience associated with the operation of SGs wherein it was believed, based on NDE, that throughwall tube indications were present within the tubesheet. The installation of the SG tubes usually involves the development of a short interference fit, referred to as the tack expansion, at the bottom of the tubesheet. The tack expansion was usually effected by a hard rolling process and thereafter, in most instance, by the expansion of a urethane plug inserted into the tube end and compressed in the axial direction. The rolling process by its very nature is considered to be intensive with regard to metalworking at the inside surface of the tube and would be expected to lead to higher residual surface stresses. Alternate repair criteria(ARC) in the tack expansion area have been developed and applied to nuclear power plants in USA, however domestic nuclear power plants have not applied ARC for tubes in tubeheet area yet. In consideration of the degradation characteristics of tubes in the Steam Generator tubesheet, this paper suggests ARC application for tubes in the steam generator tubesheet of the domestic nuclear power plants in order to assure life time of the steam generator as well as nuclear power plants.

• Journal of Welding and Joining
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• v.27 no.2
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• pp.63-68
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• 2009

Microminiature heat exchanger has been applied to the gas turbine in order to increase energy efficiency. During the production of microminiature heat exchanger, however, it is very difficult to weld tube to tubesheet. In this study, therefore, welding process of resistance ring projection was used, and weld tensile tests were performed. Sound weld joint was obtained as a result of applying resistance ring projection welding to microminiature heat exchanger to tubesheet. Cold weld occurred at under 1600A. Even though tensile strength was increased with increasing current, splash occurred and tensile strength decreased at 2000A due to the excessive current. Therefore it was determine that the optimal current is 1900A. As result of tensile tests based on ASME code for tube to tubesheet weldment, rupture position was weldment due to Fs(Fractured section) of nugget, which was smaller than tube thickness (t), and it was proven as a partial strength welding because of the average joint efficiency fr = 0.90.

• Proceedings of the Korea Information Processing Society Conference
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• 2001.04b
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• pp.751-754
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• 2001

열교환기(Heat Exchanger)는 원전 운영에 핵심적인 설비이다. 따라서 열교환기 전열관의 건전성 유무를 판단키 위해 정기적으로 비파괴검사의 일종인 와전류검사(ECT, Eddy Current Testing)를 수행하고 있다. 이러한 와전류검사 공정은 크게 3가지로 분류할 수 있다. 첫 번째는 전열관 상태검사를 위한 신호데이터 취득공정이고, 두 번째는 취득된 신호를 판독하여 전열관의 건전성 여부를 진단하는 평가공정, 마지막으로 평가공정에서 발생하는 방대한 데이터를 토대로 추이분석 자료를 제공할 수 있는 공정이 필요하다. 본 논문에서는 세 번째 공정에서 필요한 열교환기 Tubesheet를 사용자 정의에 따라 자동으로 구현할 수 있는 기능을 정의하고, 평가공정에서 발생한 데이터를 직접 Tubesheet상에 Mapping 처리하여 시각적으로 전열관 상태를 확인할 수 있는 프로그램 구현방법을 제시한다.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.333-337
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• 2004

Steam Generator is one of the most important structural part of nuclear power plant. It is manufactured by various steel forgings such as shell, head, torus and tubesheet. These steel forgings have been made by open die forging process. After steel melting and ingot making, open die forging has been carried out to get a good quality which means high soundness and homogeniety of the steel forgings by using high capacity hydraulic press. This paper introduced the open die forging process and manufacturing experience of large tubesheet forgings which will be used for the steam generator of 1,400MW nuclear power plant.

• Transactions of the Korean Society of Pressure Vessels and Piping
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• v.4 no.2
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• pp.29-33
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• 2008

As the measures of nuclear power plant utilities and manufacturers to reduce the defects of tube expansion region during manufacturing steam generators, many types of NDEs(Non-Destructive Examinations) are conducted to inspect the expansion region. The expansion region of tube is subject to degrade because of stress concentration induced by tube expansion, sludge pile and high temperature. So the inspections for tube expansion region have been reinforced. Liquid penetrant test, helium leak test, Bobbin profile test and hydraulic test are performed to confirm the integrity of tube expanded by hydraulic expansion method. Liquid penetrant test and helium leak test are used to inspect seal weld region on tubesheet end part. Bobbin Profile test is used to inspect fully the expanded region of steam generator tube. Hydraulic test finally verifies the integrity of seal weld region on tubesheet end part.