Tube failures in moisture separator-reheater tube bundles due to restrained thermal expansion

In a nuclear power plant, moisture separator-reheater components (MSRs) are used to dry and superheat the exhaust steam from the high pressure turbine before admitting this steam to the low pressure turbines. MSRs have experienced numerous problems which have caused loss of plant thermal efficiency, poor unit availability and high maintenance costs. The most serious problem has been the progressive failure of the U-tubes, which has necessitated replacement of MSR tube bundles at several plants. This paper presents an explanation of the failure mode and identifies critical operational and geometric parameters as to their respective roles in the process. Detailed thermal-hydraulic analytic modeling enables the calculation of tube wall temperatures along the length of each tube for selected power levels. These temperature data are input to finite element models of the tube bundle which yield interactive displacements, rotations and stresses. The results of these studies provide the rational basis for the tube failure mechanism, which is supported by data acquired from inspection of in-service MSRs