Case Study: TÜV NORD achieves accurate fatigue and fracture prediction and optimized fast‑cycling power plant operations with Dassault Systemes' Abaqus

Helping Power Providers Manage Energy Ups and Downs

TÜV NORD was tasked with assessing and mitigating fatigue and fracture in thick-walled steam-line and process-vessel components as power plants move to frequent start-stop cycling to balance renewable generation. To get realistic heat-transfer, stress and crack-growth predictions, TÜV NORD used Abaqus finite element analysis from Dassault Systemes’ SIMULIA brand as the core tool for its Cycle Optimized Operation (COOP) program.

Using Dassault Systemes’ Abaqus, TÜV NORD ran fluid–structure interaction and sequential temperature–stress analyses, applied XFEM and contour-integral crack-propagation studies, and performed shape optimization of expansion joints. The simulations identified peak stresses (~1,150 MPa), predicted component life (~400 cycles or ~2 years), closely matched physical strain and crack measurements (showing prior methods overestimated crack growth), and enabled design and operating changes that reduce stresses, extend service life, improve inspection timing, and can save up to €200,000 on a single valve replacement.

TÜV NORD

Axel Schulz

TÜV NORD