1

Boiling Water Test LoopUniversity of Idaho

Dakota Nickerson, Kyle Pflueger, Adam Leschber, Andrew Dahlke

M.E. Undergrad

2

What We Want to Accomplish Today

Provide Insights found for Initial BWTL

Provide Insights found for Proposed BWTL

Verify Deliverable for this Project

Verify Component Selection

3

BWTL

BWTL- Boiling Water Test Loop

A closed steam loop system that simulates the conditions seen in a Boiling Water Reactor for the purpose of testing nuclear fuel rods in the Advanced Test Reactor (ATR).

4

BWTL Design Recieved

Condenser or quench tank

Dem

inera

lizer

Booster Pump

CondensatePump

Circulating Water

Pressure Control Valve

Flow Elements

IsolationValve

Line heater

Heate

r Ele

ment

TE

TE

TE

TE

PI

Temp – 530FPress – 1050 psig

Temp – 100FPress – 2 psig

Temp – 110FPress – 160 psig

PI

Line heater

Feedwater pump

Temp – 400FPress – 1050 psig

Temp – 120FPress – 600 psig

Temp – 545FPress – 1020 psig

5

Problem Identification

The purpose of this project is to design and build a scaled boiling water test loop

that can be used to verify the boiling regime while controlling inlet and outlet

steam qualities.

6

Proposed BWTL Design

Line heater

He

ate

r Ele

me

nt

Temp – 295 ± 5 FPress – 60 psig

Pressure Relief Valve

Heat Exchanger

PETE

Pump

Temp – 295 ± 5 FPress – 60 psig

PETE

TE

Temp –290 ± 5 FPress – 60 psig

Temp 290 ± 5 FPress – 60 psig

TE

ASME Expansion Tank

1

2

3

456

7

Value Gained From This Project

1st Pass Prototype that will provide insight into critical design aspects associated with a Boiling Water Test Loop.

8

1: Cartridge Heater

A Chromalox cartridge heater has been chosen to simulate the 18” nuclear fuel rod.

Dimensions are: 18” length, .500” diameter. The manufacturer has told us we can expect 5.6 kW/ft.

9

2: Test Section

Option 1: Transparent High Temp Plastic Tube

Poly-Sulfone Rated to 300 F ID of 0.75 in, and OD of 1.00 in. Cost is approximately $100.

10

2: Test Section

Option 2: Sight Glass Tube

Glass Pressure vessel.

Can be threaded or flanged directly to pipe.

Rated to 500F and 500 psi

Cost: $600

Recommended Design

11

3: Heater

Circular Flow Heater Will Provide 15 kW of energy into system. Accompanied with Control panel that will provide

inlet and outlet temperature.

12

4: Pump

Recommended Pump:Manufacturer Model Nominal Capacity at

Maximum SpeedMaximum DifferentialPressure

MaximumTemperature

Cost

GPM PSI ˚F $Viking Pump Heavy duty series-

FH C323 200 800 300-350

13

5: Heat Exchanger

Cross flow, shell and tube heat exchanger

Capacity in excess of 20 kW

14

6: Expansion Tank

ASME pressure vessel

Will allow room for water to turn to vapor

15

Analysis

Linear Heat Rate From The Chromalox Heater:

5.65 kW/ft Required exit quality:

14.6% Assuming inlet quality:

7.5% Expected Scaled Loop Flow Rate:

0.89 gallons per minute

16

Critical Heat Flux

Critical Heat Flux is 1944 kW/m2

Our heat flux is 464 kW/m2

Therefore our critical linear heat rate is 23.6 kW/ft – well below heater output

17

Design Concerns

Line heater Outlet steam management Pump life Control system Safety Costs

18

Total Cost

Cartridge Heater: $200 Sight Glass/Test tube: $600 Heater: $1000 Heater Control: N/A Pump: $350 Pump Motor and Speed Control: N/A Heat Exchanger: $1100 Expansion Tank: $800 Stainless Steel Tubing 30 ft: $150 Fittings: $450 Mounting System: $350 Tubing Insulation: $100 Sensors: N/A

Total≈ $5100 + sensors, pump motor, and sensors/control

19

Spring 2010 Timeline

Detailed design package completed by January 29

All parts ordered by February 5. Apparatus built by April 9. Trouble shooting and Testing April 16 –

May 7

20

SpecificaitonsDescription Function Specification

1 Test Section Heater Simulates nuclear fuel rod. 220 V and 300 W/in2

2 Transparent Test Section Allows a person to see the boiling regime on the heater

Polysulfone plastic, operates at 295 ±5 F and vapor pressure of water at 295 ± 5 F.

3. Line Heater Adds energy to the water so that the quality of the water at the test section inlet can be adjusted.

Operates at vapor pressure of water at 295 ± 5 F, and has a 15 kW capacity.

4 Pump Pressurizes test section and circulates water

Operates at the vapor pressure of water at 295 ± 5 ˚F and can support the head seen in the system while maintaining the satisfying a flow rate varying from 0.0-3.0 gpm.

5 Heat Exchanger Takes energy out of the circulating water

Operates at vapor pressure of water at 295 ±5 F and removes up to 20 kW energy from water.

6 Expansion Tank Allows for expansion of the water in the loop when vapor occurs

Operates at vapor pressure of water at 295 ±5 F and supplies excess volume in loop for steam expansion.

Temp. Elements Measures the temperature at different places in the loop.

Operates at vapor pressure of water at 295 ±5 F sends an electrical signal which can be input to a data acquisition system. Likely a J type thermo couple.

Pressure Elements Measures the pressure at different places in the loop.

Operates at vapor pressure of water at 295 ± 5 F and sends an electrical signal which can be input to a data acquisition system.