A study of spherical tubesheet design for APR1400 and AP1000 steam generators

• This study explores the use of spherical tube sheets as a more efficient alternative to conventional flat tube sheets in APR1400 and AP1000 SG. • Spherical tube sheets leverage structural strength , potentially reducing material consumption, manufacturing costs, and construction time. • Finite Element Method (FEM) simulations were conducted to assess deformation behavior under high-temperature and high-pressure conditions. • Optimal thicknesses of tubesheet were found to be approximately 20–30% reduction for APR1400 and 40–50% for AP1000. • The spherical design may improve thermal efficiency by reducing variations in heat transfer tube lengths, promoting uniform heat distribution. This research investigates the potential of spherical tube sheets as a more efficient alternative to conventional flat tube sheets in APR1400 and AP1000 steam generators. By leveraging the inherent strength of spherical structures, we aim to reduce material consumption, manufacturing costs, and construction time. Finite Element Method simulations were employed to compare the deformation behavior of flat and spherical tube sheets under high-temperature and high-pressure conditions. The analysis identified optimal spherical tube sheet thicknesses that maintained structural integrity while achieving significant reductions in thickness: approximately 20–30 % for APR1400 and 40–50 % for AP1000. Moreover, the spherical design can enhance thermal efficiency by minimizing variations in heat transfer tube lengths, leading to more uniform heat distribution.