Secondary separators (steam dryers) are used in boiling water reactor vessels as the final stage of moisture removal to provide the highest possible quality steam. Over the past decades many distinct designs were successfully created and put into service. New computational fluid dynamics (CFD) analysis tools and advanced test facilities have been utilized to design higher capacity dryers. These tools have also been utilized for upgrading existing steam dryers and designing new compact dryers, resulting in improved plant efficiency, and better control of radioactivity within the steam loop. Such upgrades are especially attractive to nuclear plant operators and utilities in their evaluation of plant performance, power uprates, and to justify re-licensing efforts. A recent study pertaining to a steam dryer upgrade is discussed for two identical BWRs. The challenges, the analysis tools and considerations from the operator’s perspective are highlighted.

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