Design analysis before operation

Before commissioning and operation of the plant, a catalogue of thermal transients is compiled. These thermal transients are considered as design transients in contrast with the real transients based on temperature measured during operation. In the past, the anticipated transients were covering 40 years of plant operation. Now, the period to be covered is 60 years. Moreover, the specification is done for normal, upset, emergency and testing conditions. The design thermal transients are specified according to different plant models and experiences. They should always be conservative concerning frequency of occurrences, temperature range, rate of temperature change and load type (thermal stratification, thermal shock). Due to this conservatism, the usage factor calculated in the design phase, under normal circumstances, will be more severe than the results of the detailed fatigue calculation performed at a later operation stage taking into account the real operational thermal loads. As a consequence, usage factors around 1.0 are still tolerable in the design phase. They indicate the fatigue sensitive positions. These locations are selected for future instrumentation and non-destructive testing. Design improvements of components, depending on the calculated fatigue usage factors, can also be taken into account at this early stage. Additionally, optimization of operating modes can be considered. Thermal transients with low influence on fatigue behavior are identified as well. Depending on the different design codes [1], [4], [5], some procedures can allow the exemption of non significant loads. In the end, the predicted fatigue usage factors, which were calculated with design transients, shall be verified and the fatigue status shall be updated during lifetime operation.