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A 3D discrete FEM iterative algorithm for solving the water pipe cooling problems of massive concrete structures

Water pipe cooling has been widely used for the temperature control and crack prevention of massive concrete structures such as high dams. Because both under‐cooling and over‐cooling may reduce the efficiency of crack prevention, or even lead to great harm to structures, we need an accurate and robust numerical tool for the prediction of cooling effect. Here, a 3D discrete FEM Iterative Algorithm is introduced, which can simulate the concrete temperature gradient near the pipes, as well as the water temperature rising along the pipes. On the basis of the heat balance between water and concrete, the whole temperature field of the problem can be computed exactly within a few iteration steps. Providing the pipe meshing tool for building the FE model, this algorithm can take account of the water pipe distribution, the variation of water flow, water temperature, and other factors, while the traditional equivalent algorithm based on semi‐theoretical solutions can only solve problems with constant water flow and water temperature. The validation and convergence are proved by comparing the simulated results and analytical solutions of two standard second‐stage cooling problems. Then, a practical concrete block with different cooling schemes is analyzed and the influences of cooling factors are investigated. In the end, detailed guidance for pipe system optimization is provided. Copyright © 2015 John Wiley & Sons, Ltd.