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The scope of the work included the 3D model and the analysis of the piping systems with the calculation program Rohr2 (Sigma) according to FDBR including the verification of the steel structure for the load bearing limit condition according to DIN 18800. The design parameters were 500°C and 110bar. In this phase of the project, a seismic load condition did not have to be taken into account but it was taken into account by KAH in subsequent calculations.
Based on the initial planning of a pipeline route for the pilot plant from KIT, Kraftanlagen Heidelberg first optimised the pipeline routing of the initially planned pipelines and then that of pipelines added as the project progressed. This allowed the entire plant to meet the pipeline certification according to FDBR and the support certificate according to DIN 18800.
Since the pipes in the hot part of the circuit featured thick insulation, the aim was to avoid a collision of pipelines and then ensure that the individual pipes were positioned in a way that supports could also be attached to the existing steel construction.
An additional challenge that arose during the project was the analysis of a helium-mix fitting. This component mixes hot helium (T = 750 K) with cold helium (T = 300 K). In light of its planned service life, it had to be designed to handle alternating stresses while in operation. The original design, which did not meet that requirement, was constructively optimised and verified via targeted calculations (CVX fluid analysis coupled with an FEM structural analysis).