Prosiding Seminar Nasional Teknologi Energi Nuklir 2016 ISSN: 2355-7524

Batam, 4-5 Agustus 2016

PASSIVE SYSTEM SIMULATION FACILITY (FASSIP) LOOP

FOR NATURAL CIRCULATION STUDY
*
Mulya Juarsa , Giarno, G.B. Heru K., Dedy Haryanto, Joko Prasetio
Center for Nuclear Reactor Technology and Safety,
National Nuclear Energy Agency of Indonesia (BATAN)
*email: juars@batan.go.id

ABSTRACT
PASSIVE SYSTEM SIMULATION FACILITY (FASSIP) LOOP FOR NATURAL
CIRCULATION STUDY. The necessity for an experiments facility to simulate passive
cooling phenomenon has become a part of the research on nuclear reactor safety
technology after the Fukushima Daiichi NPP accident. Thus, the medium-scale experimental
facilities have been built for investigation purposes on the phenomena that occur in natural
circulation passive cooling systems of NPP in order to improve their safety performance. The
purpose of this paper is to explain FASSIP-01 facilities that have been designed, constructed
and characterized. The methodology used is the design and construction with the base
material of the pipe material SS304 and drawn with a 3D drawing program including the
characterization of heating capability in heater tank and cooling capability in pre-cooler tank.
Derivates the equations to calculate the average and local natural circulation flow rate.. The
results show the design and construction of loop FASSIP-01. Then the average equation of
natural circulation flow rate in rectangular loop and the local equation of mass flow rate in the
heater tank and cooler tank have been derived. The characteristic of heater tank in static
condition shows that the power control for a period time related to experiment scenario can
conducted begin electrical voltage at 180 volt. The performance of heater tank to heated-up
o
water until 90 C was good for periodic time 1900 s – 2400 s. Characteristic of pre-cooler in
o
static condition has a capability to cooling down water inside pre-cooler until 3 C for 1 hour
and 145 minutes and this time is sufficient for experiment scenario.
Keywords: loop, passive, natural circulation, experimental, design and construction

ABSTRAK
UNTAI FASILITAS SIMULASI SISTEM PASIF (FASSIP) UNTUK STUDI SIRKULASI
ALAMI. Kebutuhan akan sarana eksperimen untuk mensimulasikan fenomena pendinginan
pasif menjadi bagian dari penelitian keselamatan reaktor nuklir pasca kecelakaan PLTN
Fukushima Daiichi. Sehingga, fasilitas eksperimen skala menengah telah dibangun untuk
tujuan investigasi fenomena sirkulasi alamai yang terjadi dalam sistem pendingin pasif PLTN
dalam rangka meningkatkan performa keselamatannya. Tujuan penulisan ini adalah untuk
menjelaskan fasilitas FASSIP-01 yang telah didesain, dikonstruksi dan karakterisasi
sebagian komponen. Metodologi yang digunakan adalah desain dan konstruksi dengan
bahan dasar material pipa SS304 dan digambar dengan program gambar 3D. Kemudian,
melakukan karakterisasi kemampuan pemanasan tangki heater dan pendinginan tangki pre-
cooler. Menurunkan persamaan untuk menghitung laju aliran sirkulasi alamiah rata-rata dan
lokal. Hasil penelitian adalah diperolehnya konstruksi Untai FASSIP-01. Kemudian diperoleh
persamaan laju aliran sirkulasi alami rata-rata diseluruh pipa dan persamaan lokal laju aliran
massa di daerah tangki heater dan tangki cooler. Karakteristik tangki pemanas dalam
kondisi statis menunjukkan bahwa kontrol daya untuk periode waktu yang terkait dengan
skenario eksperimen dapat dilakukan mulai dari tegangan listrik di 180 volt. Kinerja tangki
o
pemanas air panas-sampai 90 C baik untuk waktu periodik 1900 s - 2400 s. Karakteristik
o
pre-cooler dalam kondisi statis memiliki kemampuan untuk pendinginan air hingga 3 C
selama 1 jam dan 145 menit dan waktu pendingin sesuai dengan skenario eksperimen.
Kata kunci: untai, pasif, sirkulasi alami, desain dan konstruksi, eksperimental

INTRODUCTION
The incident of Fukushima Daiichi nuclear power plant (NPP) accident in Japan at
year 2011 becomes a reference in the activities of R&D of nuclear reactor safety technology
in the world. Fukushima Daiichi NPP’s accident led to the worst conditions in most reactor
experienced core-meltdown and there is damage in the reactor pressure vessel. The
condition occurs due to failure of the active cooling system (pump) due to no power supply

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Mulya Juarsa, dkk

caused generators submerged by sea water during tsunami. The reactor cooling failure can
be considered as a failure of the reactor safety systems in the term of thermal management
after the accident. Thus, the anticipation of similar incidents in the future is to do R&D
focusing on reactor cooling system without power supply (known as non-electrical cooling
system), one of which is the use of passive cooling system (natural circulation).
Some researchers have been investigating the phenomenon of natural circulation
that will be applied to the new of passive residual heat removal system (PRHRS) into
advanced NPP. One of the studies that have been done is the effects of buoyancy force,
loss of pressure and friction in the pipes against the driving force of fluid flow has been done
by Welander [1]. Later, Dobson filed a schematic of a simple equation that shows the
character of non-linear and transient in the rectangular loop during natural circulation flow to
explain the single-phase flow conditions and laminar [2], but in this case the flow instability
has not been studied. Furthermore, the stability and instability of oscillation flow in the loop
has been investigated by experiments and computer simulations [3-5], using small size
geometrical parameters, but still the boundary conditions are still not investigated.
Meanwhile, several researchers such as K. Vijayan et al. [5], Grief [6] and Zvirin [7] have
been investigated the natural circulation flow by varying geometry. The research was
conducted using a small rectangular loop by loop condition open (open-loop) and loop
closed (closed loop), sizes length 2.6 meter and 0.7 meter wide using pipe with diameter 1
inch. An investigation has been carried out for the steady flow and transient flow by
analyzing the stability of the system is based on variations of heating and cooling. Then,
Missal et al. [8], has been considering the differences thermal boundary conditions, such as
the difference in height between the area heater and cooler regions. The effect of heat
transfer in the pipeline towards the mass flow rate parameters during natural circulation has
been studied by several researchers [9-13]. However, the condition referred to research is
still in a steady state and still using the experimental facility with a small-scale geometry.
Also, author has been conducted preliminary research to investigate natural circulation
phenomenon using the Loop USSA-FT01 with the geometry of rectangular loop is 1.5 x 1.0
meters using SS316 pipe with diameter 1 inch [15-16]. Then, in year 2014 using Loop NC-
QUEEN with geometry of loop rectangular loop is 2.7 x 0.5 meters with diameter 1 inch
SS304 tube [17].
Experimental research using large-scale facility has been widely applied in some
countries, such as South Korea KAERI make large-scale experimental facilities, called
ATLAS (Advanced Thermal-Hydraulics Test Loop for Accident Simulation). ATLAS itself
refers to the type of APR-1400 reactors (Advanced Power Reactor-1400MWe) which will
implement a passive cooling system on its safety features [18]. In addition to post-LOCA
experiments, ATLAS also used to experiment with the natural circulation sized 3 inch pipe.
Object of experiments focused on identifying characteristics of the loop of the reactor coolant
system (RCS) and compare the results with computer code. In addition to ATLAS, some
large-scale experimental facilities and medium whose purpose was to investigate the
phenomenon of natural circulation is PANDA and LINX [19] which is owned by Thermal
Hydraulics Laboratory, Paul Scherrer Institute, Switzerland. PANDA facility was able to
simulate in RPV's natural circulation BWR reactor type. While, the LINX (Large scale
Investigation of Natural circulation and miXing) is a medium-scale experimental facilities
devoted to the investigation of passive cooling system. In addition there are a lot of good
experimental facilities in large, medium and small scales in several countries Japan, Europe
and America. However, it is very difficult to obtain information and comparison data such as
geometric data, primary data from those researches, the variation of working fluid and also
power magnitude which was used as well as experimental results from these facilities.
After knowing the condition of natural circulation research as presented above, the
research to investigated natural circulation phenomenon become necessary. In the
framework of understanding and mastering of the basic engineering to apply the natural
circulation characteristics into passive cooling system for advanced nuclear reactors, it need
to be made and carried out research using experimental facilities for the simulation of a
passive cooling system. Thus, the objective of this paper is to explain FASSIP-01 Loop
facilities that have been designed, constructed and characterized.. The facility was named
Loop FASSIP-01 (the extension of FAsilitas Simulasi SIstem Pasif) unit. Until now, no
experiments were performed using Loop FASSIP-01. Some preparation before the
experiment is being conducted and the experiment will run until the end of this year.

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METHODOLOGY
Design and Construction
There are several parameters influences into natural circulation flow. Thermal
hydraulics parameter as variables in this research is fluid temperature (T) then as
geometrical parameters are height differences between heater and cooler (H), total loop
length (L) and pipe diameter (D). Constanta K is loss frictional for pipe base on elbow, tee,
enlargements and contractions, it be the value which affects the flow rate. Then, then the
design of FASSIP-01 was divided base on components and equipments related to thermal
hydraulics and geometrical parameters. Design was done using 3D drawing software.
Construction and installation were established by thermal hydraulics member during 10
moths from July 2015 until April 2016.

Derivation of Analytical Equations

Some reference related to natural circulation flow and heat transfer was used to
derivate analytical equation of natural circulation flow. The average of natural circulation
along pipe in rectangular loop was derivates using buoyancy force and retarding frictional
force. Then, thermal energy balance equation was used to derivate local natural circulation
flow in cooler area and heater area. Analytical framework describes in Figure 1.

m C , m H

Figure 1. Framework Analytical

Heater and Cooler Characterization

Preliminary step after the calibration of measurement unit is doing characterization
on the Loop FASSIP-01 main components. The heating capability of water inside heater tank
is performed to determine the appropriate value of voltage related to experimental scenarios.
Then, the characterization of pre-cooler for cooling capability, especially in static conditions
(no water flow) was done by turn-on the refrigerator until a desire value of low temperature in
o
water inside pre-cooler tank (below 10 C).

RESULTS AND DISCUSSION

Experiment Facility of Loop FASSIP-01
Using 3D software, the design of Loop FASSIP-01 was made as shown in
Figure 2. The photograph of FASSIP-01 Loop is shows in Figure 3.

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Loop FASSIP-01

Cooler tank

Heater tank

Heat sink ver.01

Figure 2. Design Loop FASSIP-01 Figure 3. Photograph of Loop FASSIP-01

As described in Figure 1 and Figure 2, the arrangement of equipments and components had
shown in Table 1 and Table 2. Table 1 shows the equipments of loop and Table 2 shows the
components of Loop FASSIP-01.

Table 1. Equipments of Loop FASSIP-01

No Component Quantity Data Remarks
1 Heater 4 unit heater element Installed in heater tank
@P=5000 watt
2 Refrigrator 1 unit Daya 2 pk Integrated with BETA test
loop, flow variation using
inverter pump, called Heat-
Sink System (HSS)
3 Thermo 108 points Type K Already for use 64 points
couples
4 Differential 1 unit P=5 mbar Installed at outlet heater tank
Pressure and inlet cooler tank
Transmiter
(DPT)
5 Flow Meter 1 unit Low flow (propeller) Installed at the bottom of
Qmax = 500 mL/m rectangular loop horizontally
1 unit High flow (EM)
Qmax=15 L/m
6 Expansion 1 unit Acrylics tank to compensate Installed at the top of
Tank a pressure fluctuation during rectangular loop vertically
experiment

Table 2. Components of Loop FASSIP-01

No Component Dimensions Material Qnt Remarks
1 Section L=50 cm Pipa dan 40 Including flanges with
Dia. 1 inch; Pipa sch.10 flange sections thickness 10 mm
SS304
2 Rektangular Height=600 cm SS304 1 unit An integration of

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No Component Dimensions Material Qnt Remarks

loop Wide=350 cm several sections
3 Heater tank Dia. 16 inch; Bahan 1 unit As heating equipment
Sch. 40 Pipa with total power 20
Height = 800 mm SS304 kW
4 Cooler tank Dia. 16 inch;Sch. 40 Bahan 1 unit As cooling equipment
Height = 800 mm Pipa
SS304
5 Expansion Dia. 6 inch, acrylics, 1 unit Sudah tersedia
tank Height=490 mm flange Jarak tabung ke inlet
flange dia.=510mm, flange SS304 di loop FASSIP-01 50
thickness=20mm cm
6 Support Height=700 cm, Carbon 1 unit As support for
Wide=350 cm. U form with Steel rectangular loop and
sizes 10x5 cm and 5x3 cm. installed in the
building wall in
vertically

Equations for Analysis

a. Average natural circulation flow base on natural law
The concept of passive systems is the system which circulating the cooling fluid
inside a loop without any intervention from outside forces and based on natural laws. The
phenomenon of this fluid flow rate in the passive system called natural circulation, which
occur due to differences in fluid density in hot and cold region [19]. Effect of fluid density
changes in hot regions will lead to buoyancy force and the effect of fluid density changes in
cold will cause the gravitational force. Thus, the implementation of passive systems in a
nuclear power plant can be used for normal and non-normal condition (condition accident,
transient) [20]. Figure 4 shows the simple concept of natural circulation based on buoyancy
force and retarding frictional force with cold region in the top and hot region in the bottom of
rectangular loop [5,6,8,10,13,19].

Figure 4. Natural circulation rectangular loop

Base on Figure 4 and in steady state condition, a phenomenon that occurs can be described
by equation (1). In the left side of equation (1) is buoyancy force and in the right side of
equation (1) is retarding frictional force.
R m 2 (1)
 g  dz  h
2
-4
With the total hydro dynamics resistance is Rh [m ] as in equation (2)

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N
 f L  1
Rh     K 2 (2)
i 1  D A

Then, equation (2) could be reform like as equation (3)

 f L  (3)
Rh A 2   K
 D 

by substituting the Boussinesq approximation    o [1   (T  To )] into equation (1), As

an integration result, equation (1) become equation (4),
R m 2 (4)
g o  (Th  Tc ) H  h
2
 h  o Th
c  o Tc

Then, the equation (4) become

R m 2
g ( h  c )H  h
2
2 g (    c )H (5)
m 2  h
Rh
The final equation for mass flow rate to analyzed natural circulation flow become,
0 ,5
 2 g (  h   c ) H  (6)
m   
 Rh 

Whereas, flow rate [m/s] derived from equation (6) using m   vA ,

0, 5
 2 gH (  h   c )  (7)
v 
 Rh A2 

By substituted equation (3) into equation (7),

0, 5
 
 
2 gH (  h   c )  (8)
v
  fL  
    K  
  Dh  

In this case, the moody chart is unusual to be use. The flow rate derivates using pipe
frictional coefficient for laminar flow. Then, equation (9) substituted into equation (3) become
64 (9)
f 
D v

The new equation for hydrodynamics resistance is

64  L  D 2  vK (10)
Rh 
D 2  vA2

Base on equation (7),

0, 5
 2 gH (  h   c ) 
v 
 Rh A2 
2 gH ( h  c ) (11)
Rh 
v2  A2
So that by equalizing equation (10) and equation (11),
2 gH (  h   c ) 64  L  D 2  vK

v D2

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Simplification of the following equation is

( D 2  K ) v 2  (64  L ) v  2 gH (  h   c ) D 2  0 (12)

Flow rate equation for natural circulation become

 64  L 
2
64  L   4( D 2  K )( 2 gH (  h   c ) D 2 )
v ,
2( D 2  K )

Then, simply be simply be

 64  L 
2
64  L   8 gHK  (  h   c ) D 4
v (13)
2D2  K

Equation (13) is natural circulation flow rate inside pipe rectangular loop derivate from to
natural laws as mention in Figure 4. It is mean that, all parameters consisting of total loop
length, height differences between heater and cooler, pipe diameter, temperature and
constantan K have influenced into flow rate.

b. local natural circulation mass flow base on energy balance

The wall of cooler tank and heater tank were assumes as an adiabatic wall as in
Figure 5. Then the energy balance can be applied.

(a). cooler tank (b). heater tank

Figure 5. Temperature flow of energy balance

Equations in cooler tank describes as follow [21]. For thermal energy rate in heat sink
system as shown in Figure 5a,
(14)

For thermal energy rate in pipe inside cooler tank is

(15)

Because the adiabatic condition, the heat transferred from heat sink into rectangular pipe
inside cooler tank with the same amount.

(16)

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When mass flow rate in heat sink system derived from the data volume flow rate
measurements using electromagnetic flow meter based on varying pump rotational speed.
In heater tank (Figure 5b), natural circulation flow rate local describes as follow,
(17)

When heat transfer equal to the electric power for 4 heaters submerged in water inside
heater tank. Assuming that there is no boundary of heat transferred from water in heater tank
into water inside pipe in heater area. The relationship between electrical and heat transfer
shows in equation (18).
q H  VI (18)

Then, from equation (17) and equation (18) can be derived into equation (19) for local
natural circulation flow rate.
(19)

The average natural circulation mass flow also could be determined using equation (16) and
(19),
(20)

Partial Characterizations of Heater and Cooler

The characterization of heater tank and pre-cooler was done as a preliminary test for
each component to make sure the performance of components in basic condition.

30
digital measurement (Ta-dg)
Water temperature, Tw [ C]

analog measurement (Ta-gg)

o

25

20

15

10

5 2
date: 19/04/16

Ta-dg = 23,97-0,0048t --> R =0,96165

2
Ta-gg = 24,28-0,0045t --> R =0,95352
0
0 1000 2000 3000 4000 5000

time, t [s]
Figure 6. Pre-cooler cooling capacity characteristics

Figure 6 shows temperature decrease in water inside pre-cooler tank for water temperature
versus time using digital temperature measurement (thermocouples) and analog
temperature measurement (temperature gauge). Then, Figure 7 and Figure 8 show the
characteristic of heating process base on electrical input variables to period time for heating.
Figure 6 explains that in static condition for water inside pre-cooler has experiences cooling
o o
from room temperature around 28 C until 3 C for around 4500 second (1 hour and 15
minutes). The equation for the cooling characteristics of pre-cooler are, T  23.97  0.0048 t
with r square error is 0.96 (around 96% the data was accepted as linier equation).
Figure 7 show heating period base on variation of electrical voltage variations. The
electrical voltage is the control parameter for power during the experiment. Starting point for
electrical voltage value was decided start from 180 volt until 220 volt, because the period
time for this range of voltage is not to long (around 1900 s – 2400 s). This mean that, to
o
increase water temperature from room temperature until 90 C was need time around 1900 s
– 2400 s.

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2500 2500

2400 2400 +15,27%

measurement time, t [s]

heating period, t [s]
V=200 volt
2300 2300
x
2200 2200 y=

2100 2100

2000 2000

1900 1900 +0,24%

V=220 volt
1800 1800

1700 measurement 1700

1600 calculation 1600

data
1500 1500
180 190 200 210 220 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500

electrical voltage, V [volt] calculation time, t [s]

Figure 7. Heater tank characteristics Figure 8. Measurement and calculation error

Figure 7 also explain two comparison data from measurement and calculation using
electrical power equation (P=VI), it’s seem that the error from measurement and calculation
is not to high, the error around 0.24% - 15.27%.

CONCLUSION
In order to conduct the experiment to simulate phenomenon of passive cooling
system using apparatus, an experimental facility name passive system simulation facility
(FASSIP) loop for natural circulation study has been design and constructed. Some equation
to analyze natural circulation flow rate was derivates from several equation related to natural
circulation phenomenon and heat transfer inside pipe. The characteristic of heater tank in
static condition shows that the power control for a period time related to experiment scenario
can conducted begin electrical voltage at 180 volt. The performance of heater tank to
o
heated-up water until 90 C was good for periodic time 1900 s – 2400 s. Characteristic of pre-
o
cooler in static condition has a capability to cooling down water inside pre-cooler until 3 C for
1 hour and 145 minutes and this time is sufficient for experiment scenario.

ACKNOWLEDGEMENT
This research was funded by DIPA PTKRN BATAN with identity number SP DIPA-
080.01.1.450310/2015. Authors would like to thank to Thermal Hydraulics Experimental
Laboratory of PTKRN BATAN members for their support during construction, installation and
characterization.

NOMENCLATURE
2 2
g : Gravitational acceleration, g=9.8 m/s [m/s ]
H : Differences height of heater and cooler [m]
3
 : Average water density [kg/m ]
3
h : Water density in heater area [kg/m ]
3
c : Water density in cooler area [kg/m ]
f : Frictional coefficient [-]
L : Total loop length [m]
Dh : Pipe hydraulics diameter [m]
K : Loss coefficient (elbow, tee, katup, dll) [-]
cp : Heat specific [kJ/kg.K]
2
 : Dynamic viscosity [Ns/m ]
v : Natural circulation flow rate [m/s]
: Mass flow rate [kg/s]

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