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A p-version embedded model for simulation of concretetemperature fields with cooling pipes Sheng Qianga,b,* , Zhi-qiang Xiea,c, Rui Zhongd a College of Water Conservancy and Hydropower E

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A p-version embedded model for simulation of concrete

temperature fields with cooling pipes

Sheng Qianga,b,* , Zhi-qiang Xiea,c, Rui Zhongd a

College of Water Conservancy and Hydropower Engineering, Hohai University, Nanjing 210098, PR China

b

Lyles School of Civil Engineering, Purdue University, West Lafayette 47907, USA

c Department of Material and Structure, Changjiang River Scientific Research Institute, Wuhan 430010, PR China

d School of Engineering, University of Connecticut, Storrs 06269-3037, USA Received 14 December 2013; accepted 10 October 2014

Available online 13 August 2015

Abstract

Pipe cooling is an effective method of mass concrete temperature control, but its accurate and convenient numerical simulation is still a cumbersome problem An improved embedded model, considering the water temperature variation along the pipe, was proposed for simulating the temperature field of early-age concrete structures containing cooling pipes The improved model was verified with an engineering example Then, the p-version self-adaption algorithm for the improved embedded model was deduced, and the initial values and boundary conditions were examined Comparison of some numerical samples shows that the proposed model can provide satisfying precision and a higher efficiency The analysis efficiency can be doubled at the same precision, even for a large-scale element The p-version algorithm can fit grids of different sizes for the temperature field simulation The convenience of the proposed algorithm lies in the possibility of locating more pipe segments in one element without the need of so regular a shape as in the explicit model

© 2015 Hohai University Production and hosting by Elsevier B.V This is an open access article under the CC BY-NC-ND license (http:// creativecommons.org/licenses/by-nc-nd/4.0/)

Keywords: Concrete temperature field; Cooling pipe; Embedded model; p-version; Numerical simulation

1 Introduction

Prevention and mitigation of cracks in concrete is currently

receiving significant focus in both research and application

Most cracks tend to form at early ages of concrete (Hossain

and Weiss, 2004) The crack causal factors at early ages

mainly include the humidity gradient, autogenous shrinkage,

temperature gradient, structure restraint, and shape and size of

block casting Material researchers have made great

achieve-ments in curing some types of shrinkage (Bentz and Weiss,

2008; Weiss et al., 2012) Structure and construction

researchers put more emphasis on the latter three factors (Bureau of Reclamation, 1988) Before concrete casting, ma-terials and structures have usually been optimized by de-signers In general, small volumes of concrete casting lead to more cold joints and longer construction periods, affecting the structural appearance and economic efficiency, while casting large volumes of concrete at one time induces some cracks in mass concrete Temperature control plays the most important role in eliminating cracks during mass concrete construction Material pre-cooling, insulation, and interior cooling are the main methods of temperature control during this period (Townsend, 1981; Abbas and Al-Mahaidi, 2007)

Pipe cooling was first applied in the construction of the Hoover Dam in the 1930s After decades of application, the cooling measures have been implemented in some thin wall mass concrete structures as well Factors influencing on-site control of concrete temperature include the pipe water flow

Water Science and Engineering

journal homepage: http://www.waterjournal.cn

This work was supported by the National Natural Science Foundation of

China (Grant No 51109071).

* Corresponding author.

E-mail address: sqiang2118@163.com (Sheng Qiang).

Peer review under responsibility of Hohai University.

http://dx.doi.org/10.1016/j.wse.2015.08.001

1674-2370/ © 2015 Hohai University Production and hosting by Elsevier B.V This is an open access article under the CC BY-NC-ND license ( http:// creativecommons.org/licenses/by-nc-nd/4.0/ ).

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rate and direction, inlet water temperature, space and layout of

pipes, pipe material type, pipe wall thickness, pipe length and

diameter, and cooling start and end times in different stages,

all of which need to be taken into account in the simulation

Because of the complexity of cooling control, an intelligent

cooling control system for mass concrete has been developed

to reduce the error of manual control (Lin et al., 2014)

As a mature simulation tool, the finite element method

(FEM) has shown its powerful capacity in research of

tem-perature control and prediction of cracking in mass concrete

The simulation results are always considered an important

basis for determining reasonable temperature control

mea-sures Selection of a suitable algorithm for the simulation of

temperature fields in mass concrete structures containing

cooling pipes is always one of the problems in the FEM

simulation (Myers et al., 2009; Chen et al., 2011; Yang et al.,

2012) At present, the algorithms mainly include the

equiva-lent model, the explicit model, the embedded model, and the

substructure model (Zhu et al., 2013)

The equivalent model of pipe cooling was put forward by

Zhu (1999) The main principle is to generate an even pipe

cooling effect in the cooling area The explicit model was

proposed and improved byZhu (1999)andZhu et al (2004)

In this model, the pipe and its surrounding area, with a large

temperature gradient, are divided into elements In order to

improve the computational efficiency of the explicit model,

the substructure idea was incorporated into it, and the elements

surrounding the pipe were considered a substructure

super-element (Liu and Liu, 1997) The embedded model of pipe

cooling was put forward byChen (2009) The main principle

is that the element containing a pipe segment is considered an

embedded model element, and the pipe segment in the element

is treated as a virtual cooling boundary (Chen, 2009) Grid

refinement for the pipe segment is unnecessary in this model

The merit of the embedded model is the same as that of the

equivalent model However, its precision is higher than that of

the equivalent model, and the computational load significantly

decreases as compared with that of the explicit model and

substructure model Mai (1998) put forward a method

combining the theoretical solution and FEM It is feasible in a

relatively simple situation but has not been applied to any

practical engineering projects till now Kim et al (2001)

proposed a line element method to simulate the cooling

pipe In this method, the pipe line must pass through the

element line or node

In this paper, a new model is proposed and verified by

incorporating the pipe water temperature formula, embedded

model, and p-version self-adaption algorithm The new model

is more convenient in grid generation, consuming less time in

computation but with the same accuracy as the explicit model

2 Improvement of embedded model

Of the models described above, the embedded model can

achieve the best balance between the efficiency and precision

However, the obvious disadvantage is that the water temperature

along the pipe is not considered, which may decrease the

temperature field precision and make it difficult to determine the time when the water flow direction changes during the cooling course This disadvantage limits the application of the model in many engineering projects, especially those using a long pipe In this study, the embedded model was improved by incorporating the pipe water temperature formula and introducing the tem-perature field iterative algorithm The model showed a higher precision and enabled a wider scope of application

2.1 Algorithm improvement

A pipe may be very long in an actual application, and the pipe inlet and outlet water temperatures may vary signifi-cantly If the temperature variation along the pipe is not properly considered, the analysis results will conflict with the physical truth

Fig 1shows the ith pipe segment in an embedded model element The water temperature formula along the pipe is deduced below

The heat from concrete to pipe water is given by

DQc¼ ðð

G

qdsdt¼ l

ðð

G

vT

where q is the heat flux through the pipe wall (kJ/(m2$h)), l is the thermal conductivity of the pipe (kJ/(h$m$C)), vT/vn is the temperature gradient along the maximum heat flow di-rection (C/m), s is the area of the interface (m2

), t is time (h), andG is the pipe wall surface

The heat absorbed by water at the inlet of the pipe segment is

DQin¼ cwrwTinqwdt ð2Þ where cwis the specific heat of water (kJ/(kg$C)),rwis the water density (kg/m3), Tinis the water temperature at the inlet

of the pipe segment (C), and q

wis the flux of cooling water (m3/h)

The heat released at the outlet of the pipe segment is

DQout¼ cwrwToutqwdt ð3Þ where Tout is the water temperature at the outlet of the pipe segment (C).

The heat change of water in the pipe segment is

DQw¼ ððð

U

cwrw

vTwi

where Twi is the water temperature in the ith pipe segment (C), v is the water volume (m3) , andU is the volume of the pipe segment

Fig 1 Embedded model element containing cooling pipe segment

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If the heat change of the pipe wall is ignored, the equivalent

condition of heat in the pipe water can be expressed as

DQw¼ DQinþ DQc DQout ð5Þ

Substituting Eq.(1)through Eq.(4)into Eq.(5) yields the

water temperature increment of the ith pipe segment as

DTwi¼ l

cwrwqw

ðð

G

vT

vnds

1

qw

ððð

U

vTwi

Considering that the water volume and water temperature

variations in the pipe segment are small, Eq (6) can be

simplified as

DTwi¼ l

cwrwqw

ðð

G

vT

Because the pipe in the embedded model is virtual, which

means that the heat exchange boundary does not actually exist

in the finite element, Eq (7) has to be modified The heat

exchange boundary of the pipe is defined as the third-type

boundary condition Therefore,

vT

vn¼

b

where b is the surface heat exchange coefficient of the pipe

wall (kJ/(h$m2$C)), and k is the thermal conductivity of

concrete (kJ/(h$m$C)).

Eq (8) is substituted into Eq (7), and then the water

temperature increment can be expressed as

DTwi¼ l

cwrwqw

ðð

G

b

kðT  TwiÞds ð9Þ Because the water temperature variation in one

pipe-embedded element is so little over one time step that it can

be ignored, the water temperature increment can be

approxi-mated as

DTwiz2pallb

cwrwqwkðT0 TwiÞ ð10Þ

where a is the pipe radius (m), l is the length of the pipe

segment in the element (m), and T0is the temperature of the

pipe wall (C).

If a cooling pipe is divided into m segments, and the water

temperature at the pipe inlet is Tw0, then the water temperature

in the ith pipe segment is

Twi¼ Tw0þX

i

i ¼1

DTwi i¼ 1; 2; $$$; m ð11Þ

The following steps are conducted in the calculation of the

concrete temperature field with the embedded model, taking

into account the water temperature variation along the pipe:

(1) It is assumed that the initial water temperature in all

pipe segments equals the inlet water temperature of the pipe

Then, the water temperature Tð1Þ

wi for a time step is obtained with Eq.(10)and Eq.(11)

(2) The water temperature along the pipe at the previous step is considered the boundary condition for the next iterative step The water temperature Tð2Þ

wi for the next iterative step is calculated again

(3) The water temperatures from the two iterations are compared If the maximum difference satisfies a designated toleranceε, i.e.,

max

i



Twið2Þ Tð1Þ

the iteration at the current time step is completed Otherwise, the above steps should be repeated

2.2 Verification with a practical project

In order to evaluate the precision of the improved embedded model, both the explicit model with high precision and the on-site measured data from a pumping station base board were used The base board on the field and the initial finite element model without pipes are shown in Fig 2 The finite element model included 12 504 elements and 14 632 nodes Because of the symmetry, only half of the board was modeled The length, width, and thickness of the base board were 36.0 m, 14.0 m, and 1.5 m, respectively There was a 0.3 m-thick concrete cushion under the base board The di-mensions of the rock base under the board were

150 m 75 m  50 m (length  width  thickness) The concrete adiabatic temperature rise curve is shown in Fig 3 The thermal conductivities of concrete and the rock base were 9.50 and 6.92 kJ/(h$m$C), respectively The ther-mal diffusivities of concrete and the rock base were 0.003 3 and 0.004 2 m2/h, respectively The construction process in the

Fig 2 Base board in construction and its finite element model

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simulation was the same as that in the practical situation.

The concrete surface was covered with geotextile in the

first 14 d Then, the covering material was removed The

surface heat exchange coefficients of concrete were 28.3 and

48.91 kJ/(h$m2$C) with and without the covering material,

respectively The initial temperature of concrete was 31.0C.

The pipe cooling treatment remained for 5 d after the casting

of concrete The measured air temperature, which was used in

the numerical simulation, is shown inFig 4

The explicit model and improved embedded model were

respectively employed to simulate four cooling pipes in the

base board After the explicit model was inserted into the

initial finite element model, the numbers of elements and

nodes increased to 17 016 and 19 728, respectively, while, for

the improved embedded model, the numbers of elements and

nodes remained unchanged

To verify the validity and evaluate the precision of the

improved embedded model, three temperature sensors, A, B,

and C, were embedded at different depths on the feature

section of the base board (Fig 5), but sensor C was damaged

during the construction

Fig 6shows the simulation results of temperature variation

at the locations of sensors A and B in the two models

Ac-cording to measured data, the peak temperature from sensor B

appears at 1.08 d, while the calculated peak temperature

oc-curs at 1.00 d The measured peak temperature from sensor B

and the simulated values from the explicit model and the

improved embedded model are 51.0C, 52.0C, and 51.7C,

respectively The error of the two numerical methods can

satisfy the engineering requirements

During the test, the same inlet temperature was adopted for different cooling pipes, and there was little difference between the outlet temperatures of different pipes Thus, we used the middle cooling pipe in the base board as an example for comparative analysis As can be seen from Fig 7, the pipe outlet water temperatures from two numerical methods agree

Fig 3 Adiabatic temperature rise curve of concrete

Fig 4 Air temperature for first 14 d

Fig 5 Locations of three sensors on feature section

Fig 6 Temperature duration curves at locations of sensors A and B

Fig 7 Water temperature duration curves at pipe inlet and outlet

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with each other The maximum difference is 1.2C The

measured outlet water temperature varies significantly with

age because of air temperature and sunlight The calculated

curves develop along the middle path of these scattered

measured values, and can reflect the water temperature

vari-ation law

Because the element number of the improved embedded

model is much less than that of the explicit model, the time

cost in analysis greatly decreases with the improved embedded

model Therefore, the improved model is applicable to

high-efficiency simulation of temperature fields in engineering

projects

3 p-version improved embedded model

The spatial temperature gradient around the pipe varies

sharply during the cooling process However, in the

pipe-embedded element, the temperature field is fitted with a

linear function The computation error is large if a common

linear element with a large size is used It is necessary to

improve the precision of temperature field calculation based

on large pipe-embedded elements in large-scale concrete

structures, such as concrete dams or bridge abutments

The principle of the p-version FEM to improve the

computation precision is the addition of base functions in

some elements instead of grid refinement (Zienkiewicz et al.,

1983) In recent years, this method has been introduced into

structural mechanics analysis (Chen and Chen, 1999, 2001;

Fei and Chen, 2003), seepage analysis (Fei and Chen, 2003;

Xu and Chen, 2006), rock engineering analysis (Fei et al.,

2004), nonlinear vibrations (Ribeiro and Bellizzi, 2010;

Stojanovic et al., 2013), and composite structure analysis

(Yazdani et al., 2014) The p-version FEM has even been

introduced into the boundary element method (Holm et al.,

2008)

On the basis of the p-version FEM for an unsteady

tem-perature field simulation (Zhang and Qiang, 2009), the

p-version concept was introduced into the embedded model in

this study The pipe-embedded element was treated as the

hierarchical element The most common element in the

simulation of the temperature field and stress field is the

hexahedron element The hierarchical format of the

hexahe-dron element will therefore be explained in detail

As for the concrete temperature field with the hierarchical element employed in this study, the temperature field function can be defined as

Tp¼X

f e ðpÞ

i ¼1

wherefiis the ith base function in an element, Tiis the corre-sponding temperature, and fe( p) is the number of base functions

in the element, including the point base function, line base function, face base function, and volume base function (Chen and Chen, 1999; Vu and Deeks, 2008; Chen et al., 2010)

It is worth mentioning that the number of base functions may be different in different elements However, the number

of entity nodes for an element is a constant, and the co-ordinates of arbitrary points in the element can be obtained by interpolation with the eight entity nodes

During the self-adaption course, the temperature field computation error, based onChen and Chen (2001), is defined as

where T* is the analytical solution of temperature.

Based on the algorithm above, the p-version self-adaption code for the temperature field simulation using the improved embedded model is compiled with the Fortran language

4 Numerical sample verification 4.1 Finite element model

As shown inFig 8, four different finite element models of a concrete abutment with the dimensions of 12.0 m 9.0 m  13.0 m (length width  height) were created The thickness

of the rock base was 13.0 m along the Z axis There were eight cooling pipes embedded in the concrete structure (Fig 9) Both the horizontal and vertical distances between the cooling pipes were 1.5 m

The explicit model of cooling pipes was applied in model 1,

as shown inFig 8(a) In the explicit model, the grid around the pipe was refined with two circles, three circles, and five circles

of elements in the pipe cooling cases Every circle around the

Fig 8 Four different finite element models

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pipe includes four hexahedron elements Detailed element and

node numbers of different refined grids are listed inTable 1

The p-version improved embedded model was applied in

models 2 through 4 The surface elements in these models

were not refined Compared with model 2, the element number

along the X axis was reduced in model 3, and the element

number along the Z axis was further reduced in model 4 In

model 2, there was one pipe segment in one pipe-embedded

element, while in model 3 and model 4, the numbers were

two and four in one pipe-embedded element, meaning that an

element with larger size contains more pipe segments,

requiring a higher-order FEM for computation

4.2 Boundary conditions and material parameters

The initial temperature of the rock base was 18C All

surfaces of the rock base except for the top surface were

insulated The air temperature Ta is set by the following

equation:

Ta¼ 14:4 þ 15:4 cos

 pðt  6:8Þ

6:0



ð15Þ

where t is time (month)

The concrete adiabatic temperature rise is

qðtÞ ¼ 30:581 e0:69t 0:56

ð16Þ wheret is the concrete age (d)

The thermal conductivities of the concrete abutment and

rock base were 11.87 and 12.29 kJ/(h$m2$C), respectively.

The thermal diffusivities of the concrete abutment and rock

base were 0.005 1 and 0.005 3 m2/h, respectively

4.3 Case analysis Four different cases were designed for temperature field simulation using different models in different situations

In case 1, the thickness of each concrete layer was 3.0 m, and the time interval between the casting of two successive layers was 4 d The initial concrete temperature was 20.0C In the first 2 d of casting of each layer, insulation measures were taken No pipe cooling measures were applied in this case

In case 2, the casting course was the same as that in case 1, and two plastic pipes, with both horizontal and vertical dis-tances of 1.5 m, were inserted during the casting of each layer Cooling began at 1 d after the casting of each layer and lasted for 7 d The flow direction of pipe water was unchanged during the cooling process The flux remained 20 m3/s The water temperature at every pipe inlet remained 5.0C.

In case 3 and case 4, the inlet water temperatures were 10.0C and 20.0C, respectively Other conditions were the same as those in case 2

Some feature points were used in the results analysis The locations of these points are listed inTable 2

4.4 Results and discussion (1) No pipe cooling measures were applied in case 1 The grid densities near the surface of the four models were different Temperature duration curves at feature point 1 from four models in case 1 are shown inFig 10 It can be seen that once the cast layer with point 1 located is covered by an upper cast layer, the curves agree with one another The difference between temperature peaks from model 2 and model 3 was about 0.3C, and the difference between the values from model 2 and model 4 was about 0.2C, indicating that the p-version algorithm can fit grids with different sizes well in the temperature field simulation

(2) In case 2, different grid refinement schemes of model

1 were applied around the cooling pipe Fig 11shows the temperature difference duration curve at feature point 5 near the center of the concrete abutment The figure indicates that the computed temperature difference between two grid refinement schemes is less than 0.1C, when the numbers of circles in the two grid refinement schemes are not less than three Considering that the time cost in the five-circle grid refinement scheme is much greater than that in the three-circle grid refinement scheme, the latter is relatively efficient, and

Fig 9 Layout of cooling pipes in two different models

Table 1

Information on test models.

Number

of model

Finite element model Element

number

Node number

Element size (length  width  height)

1 Explicit model (no cooling pipe) 3 756 4 754 1.5 m  1.0 m  1.5 m*

Explicit model (two-circle grid refinement around cooling pipe) 7 420 8 914

Explicit model (three-circle grid refinement around cooling pipe) 9 468 10 994

Explicit model (five-circle grid refinement around cooling pipe) 13 564 15 154

2 p-version improved embedded model (one pipe segment in one element) 3 300 4 212 1.5 m  1.0 m  1.5 m

3 p-version improved embedded model (two pipe segments in one element) 2 751 3 564 3.0 m  1.0 m  1.5 m

4 p-version improved embedded model (four pipe segments in one element) 2 571 3 324 3.0 m  1.0 m  3.0 m

Note: * means the initial element size.

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can be used for comparison with the p-version improved

embedded model

(3) The peak temperatures at feature points 1 and 4 from

four models in four cases are listed inTable 3 It can be seen

that the temperature difference near the upstream concrete

surface in different cases is less than 1.0C, and the value near

the center of the horizontal cross-section of the concrete

abutment is less than 0.5C From the comparison of peak

temperatures and temperature duration curves, it can be

concluded that the method proposed in this paper can obtain

satisfying precision for a mass concrete structure containing

cooling pipes

(4)Fig 12shows the temperature contours of the y¼ 4.5 m

section 13.5 d after the casting of the last concrete layer in

case 2 The dots inFig 12(a) show the cross-section of cooling

pipes It can be seen that the contour shape and numerical

values from the four models are similar It should be pointed

out that the contour post-processing of the four models still relies on the simulation results of the entity point, because no suitable post-processing tool has been developed for the p-version FEM

(5) The total time costs of different models in cases 2 through 4 are listed in Table 4, showing that the p-version improved embedded model saves a significant amount of time throughout the analysis For example, the time cost of model 1

in case 2, using the three-circle grid refinement scheme, is 750.16 s, while the time cost of model 4 is 335.15 s, meaning that the total analysis efficiency using the p-version embedded model is doubled, while precision remains the same At the same time, the preprocessing course of the finite element model can be simplified The test sample in this paper is a

Fig 10 Temperature duration curves at feature point 1 from different

models in case 1

Fig 11 Temperature difference duration curves at feature point 5

from different grid refinement schemes of model 1 in case 2

Table 3 Peak temperatures at feature points.

Case Point Peak temperature (C) Maximum

difference (C) Model 1 Model 2 Model 3 Model 4

1 1 33.97 34.49 34.16 34.28 0.52

4 37.63 38.09 38.04 38.12 0.49

2 1 32.26 32.51 33.18 33.21 0.95

4 33.37 33.21 33.32 33.57 0.36

3 1 32.58 32.86 32.91 33.55 0.97

4 34.04 34.14 33.92 34.27 0.35

4 1 32.93 33.27 33.62 33.91 0.98

4 35.54 35.46 35.42 35.77 0.35 Note: Temperatures from model 1 are obtained by the three-circle grid refinement scheme in cases 2 through 4.

Table 2

Coordinates of feature points.

Point Coordinate (m) Point Coordinate (m)

1 1.5 5.0 3.0 4 4.5 5.0 3.0

2 1.5 5.0 6.0 5 4.5 5.0 6.0

3 1.5 5.0 12.0 6 4.5 5.0 12.0

Fig 12 Temperature fields of y¼ 4.5 m section 13.5 d after casting

of last concrete layer in case 2 from different models (units:C)

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relatively small structure When the proposed method is

applied to a larger engineering structure, such as a large

concrete dam, the efficiency improvement in model

con-struction and analysis will be much more remarkable

5 Conclusions

The p-version self-adaption idea was introduced into the

improved embedded model for the simulation of concrete

temperature fields containing cooling pipes The

correspond-ing algorithm was deduced, and the initial values and

boundary conditions were investigated Based on the

algo-rithm, the program was compiled with the Fortran language

The comparison of some numerical samples shows that the

proposed model can provide satisfying precision and a higher

efficiency

The proposed approach creates greater convenience in the

preprocessing of the finite element model from two aspects

First, more than one pipe segment can be arranged in one

embedded model element, which is a pronounced

improve-ment When different pipe layout schemes in a concrete

structure need to be simulated, it is unnecessary to create

different grids in the structure to accommodate every kind of

pipe layout Second, the element that contains pipe segments

does not need so regular a shape as in the explicit model,

decreasing the difficulty in modeling and grid creation,

espe-cially for complicated structures

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Table 4

Computation time cost by different models in different cases.

Number

of model

Finite element model Computation time (s)

Case 2 Case 3 Case 4

1 Explicit model (two-circle grid

refinement around cooling pipe)

571.06 565.51 553.96 Explicit model (three-circle grid

refinement around cooling pipe)

750.16 757.38 754.59 Explicit model (five-circle grid

refinement around cooling pipe)

1 289.61 1 207.08 1 173.81

2 p-version improved embedded

model (one pipe segment in

one element)

663.99 661.37 658.64

3 p-version improved embedded

model (two pipe segments in

one element)

446.79 445.03 443.19

4 p-version improved embedded

model (four pipe segments in

one element)

335.15 333.82 332.45

Trang 9

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