Experimental and numerical study of hydrodynamics of flow-accelerated corrosion in CANDU primary coolant

In CANDU-6 reactors, the pressurised high-temperature coolant flows through 380 fuel channels passing horizontally through the core. Each end of a fuel channel has a stainless steel annular end-fitting connected to a carbon steel feeder pipe. The outlet coolant, which is at 310oC with up to 0.30 steam voidage, turns through 90o as it passes from flow in the annular end-fitting to pipe flow in the feeder via a Grayloc connector. Since 1996, several CANDU stations reported excessive corrosion of their outlet feeder pipes, especially over the first metre, which consists of single or double bends. Early studies related the attack to the hydrodynamics of the coolant and verified that it was a type of flow-accelerated corrosion (FAC). Local shear stress, which is believed to be one of the important factors contributing to FAC, was approximated in the studies with standard empirical correlations. In order to understand the hydrodynamics of the coolant in the outlet feeders, flow-visualisation studies were done at AECL and UNB. At AECL, the observations were confined to a transparent simulation of an outlet feeder bend but at UNB a full-scale transparent test section simulating the geometry and orientation of an outlet feeder bend with its upstream annular end-fitting was fabricated. The feeder consisted of a 54 mm (inside diameter) acrylic pipe with a 73o bend, connected to an acrylic simulation of a Grayloc flanged fitting and annular end-fitting. The annular end-fitting consisted of an inner pipe, 110 mm outside diameter, and an outer pipe, 150 mm inside diameter, both 1.907 m long. The tests were performed with water and air at atmospheric pressure and room temperature. The maximum water volumetric flow rate was 0.019 m3/s and the volume fraction of air varied from 0.05 to 0.56. In characterizing the flow in the UNB study, particular attention was paid to the patterns at the inside of the bend, where a CFD (computational fluid dynamics) code - Fluent 6.1- had failed to predict a liquid film in the AECL study. The phase distributions within the feeder pipe and along the length of the annulus were investigated with a digital video recorder. Size, concentration and velocity of the air bubbles at particular locations were studied with a high-speed digital still camera and a high-speed digital video camera. The unstable nature of the flow and local air bubble velocities were used to approximate the local shear stress along the feeder. Methods were suggested to modify the CFD code to predict the phase distribution within the outlet feeder bend. (author)