Thermal loads and their effect on integrity of mechanical systems and components

The initial step to establish a required quality status of systems and components is performed during the state of design. Main goal of the design is to consider every possible damage mechanism of the future operation (by specification of loads, medium and environment and the selection of the materials). The knowledge during the state of design determines the reliability of the component. Regarding the thermal loads, especially, only global parameters are specified usually (transients of flow and temperature connected to specified operation). These global transients are analyzed according to the standards. In operation, the safety (integrity) resp. remaining life of a component is determined by the real operation history. As experience showed, failures, defects and not specified (new) loads were discovered during operation, e.g. stratification effects in feedwater pipes and in surge lines or thermal effects in the region of valves due to switching or internal leakage. Standard surveillance in operation is performed using plant transducers that can only monitor global loads. However, problems usually are of local nature. Thermal loads like - turbulent temperatures due to mixing of media with different temperatures - temperature differences across shells or in regions of nozzles/thermal sleeves - temperature differences in piping cross sections (local and global stratification effects) - temperature differences along sections of piping systems have to be monitored by use of local instrumentation. During analysis, both the local loads and construction details have to be considered, in detail, using appropriate calculation / analysis tools. The complexity of the loads requires a comprehensive procedure: - determine the types of loads resulting from measured temperature transients - perform sensitivity studies to identify the load type that results in relevant stresses - evaluate the stresses of the significant loads - assess these stresses according to component integrity - determine measures to control the loads. Only extensive monitoring of the mechanical and thermal loads, evaluated and assessed regularly, provides possibilities to react in time and to control or at least minimize damage mechanisms. (orig.)