This study subjected nuclear-grade 20# pipeline steel to cyclic freeze–thaw ice plugging tests, simulating the plastic deformation experienced by pipes during ice plug removal procedures. Subsequently, the dislocation morphology and mechanical properties of the specimens post cyclic ice plugging were examined. The cyclic ice plugging process led to an increase in the dislocation density within the specimens. After 20 and 40 cycles of ice plugging, the internal dislocation structures evolved from individual dislocation lines and dislocation tangles to high-density dislocation walls and dislocation cells. These high-density dislocation walls and cells hindered dislocation motion, giving rise to strain hardening phenomena, thereby resulting in increased strength and hardness of the specimens with an increasing number of ice plugging cycles. In addition, a large stress field was generated around the dislocation buildup, which reduced the pipe material’s plastic toughness. The findings elucidate the effects of cyclic ice plugging on the microstructure and properties of nuclear-grade 20# pipeline steel, aiming to provide a theoretical basis for the safe and stable application of ice plugging technology in nuclear piping systems.

Nuclear energy, as an important component of the power system, has become a key focus of future energy development research. Various equipment and pipelines in nuclear power plants require regular inspection, maintenance, and repair. The pipelines in nuclear power plants are typically large, necessitating a device that can locally isolate sections of the pipeline during maintenance operations. Ice plug freezing technology, an economical and efficient method for maintaining and replacing equipment without shutdown, has been widely applied in nuclear power plants. The structure of the ice plug jacket, a type of low-temperature jacket heat exchanger, affects the flow path of the working fluid within the jacket and consequently impacts heat transfer. This study utilizes Computational Fluid Dynamics (CFD) to establish five types of jacket structures: standard, center-offset (center-in, side-out), helical, helical fin, and labyrinth. The effects of different structures on the freezing characteristics of ice plugs are analyzed and compared. The research indicates that the labyrinth jacket enhances the heat transfer performance between liquid nitrogen and the liquid inside the pipe, forming a larger ice layer at the same liquid nitrogen flow rate. Additionally, the standard jacket has the shortest sealing time at high liquid nitrogen flow rates.

Ice plug technology is an effective method for isolating the pipeline system, which are promising methods utilized in the nuclear, chemical, and power industries. To reduce the cold energy consumption and temperature stress, the multi-stage (1–10) of time-dependent thermal boundary conditions was proposed for the formation of ice plug, while the gradient cooling wall temperature of multi-stage was applied. A numerical model considering the liquid–solid phase change, heat transfer, and time-dependent thermal boundary condition has been established. The effects of the ratio of length and diameter of the cooling wall l_c/d (1–9) on the formation rate and heat flux of ice plug in the pipe has been investigated. The fastest formation rate of ice plug with 800 mm in the axial direction (7.47 cm³/s) was observed in the pipe with the l_c/d of 5. The formation rate of ice plug and the ice formation volume under unit energy consumption VE under various stages (1–10) of cooling wall temperature have been compared. The VE of eight temperature stages (1.45 cm³/kJ) was 1.16 times than the VE of one temperature stage, which satisfied the freezing rate at the same time. This investigation provides insight for proposing an energy-saving system for the formation of ice plug.