Experiments and calculations on crack opening and leak rate of a pipe branch within the HDR-Program

1994 ◽  
Vol 147 (1) ◽  
pp. 79-84 ◽  
Author(s):  
H. Grebner ◽  
H. Hunger ◽  
A. Höfler
Keyword(s):  
Crack Opening ◽  
Leak Rate

Crack-Opening Displacement and Leak-Rate Calculations for Full Structural Weld Overlays

2009 ◽  
Author(s):  
D.-J. Shim ◽  
E. Kurth ◽  
F. Brust ◽  
G. Wilkowski ◽  
A. Csontos ◽  
...  
Keyword(s):  
Crack Opening ◽  
Nuclear Industry ◽  
Leak Rate ◽  
Opening Displacement ◽  
Primary Coolant ◽  
Pressurized Water ◽  
Weld Overlay ◽  
Water Reactors ◽  
The Impact ◽  
Weld Overlays

Full structural weld overlays have been used in the U.S. nuclear power industry for over twenty years in boiling water reactors (BWRs). Primary water stress corrosion cracking (PWSCC) in nickel-based dissimilar metal welds (DMWs) has been experienced in pressurized water reactors (PWRs) since the early 1990s. As a result, the nuclear industry is implementing full structural weld overlays (FSWOL) as a PWSCC mitigation technique that may be used on primary coolant lines previously approved for Leak-Before-Break (LBB). This work investigates the effect of the FSWOL on the leakage behavior of these lines with postulated defects. In this paper, finite element (FE) based crack-opening displacements (CODs) were developed for pipes with a FSWOL with postulated complex cracks. The COD solutions were then employed in standard leak-rate calculations, where equivalent crack morphology parameters were developed to consider a flow through two different crack morphologies, i.e., PWSCC through the DMW and corrosion fatigue through the weld overlay. The results of the sensitivity study and a discussion on the impact of the weld overlay on the leakage behavior concludes this paper.

Experimental and Analytical Leak Characterization for Axial Through-Wall Cracks in a Liquids Pipeline

2014 ◽  
Author(s):  
Mohamed R. Chebaro ◽  
Nader Yoosef-Ghodsi ◽  
David M. Norfleet ◽  
Jason H. Bergman ◽  
Aaron C. Sutton
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Internal Pressure ◽  
Crack Opening ◽  
Full Scale ◽  
Leak Rate ◽  
Propagation Mechanism ◽  
Element Analysis ◽  
Fea Model ◽  
Experimental Findings

Three pipeline sections containing defects of interest were non-destructively tested in the field, cut out and shipped to a structural laboratory to undergo full-scale testing. The common objectives of the experiments were to determine (1) the leak initiation pressure and (2) the leak rate at various specified internal pressures. While two spools (Specimens A and B) contained through-wall cracks, the third (Specimen C) had a partial through-wall crack with similar characteristics. The capacity of through-wall defects to withstand a level of internal pressure without leaking is due to the resultant local, compressive hoop residual stresses. Specimen C underwent full-scale pressure cycling to further comprehend the crack propagation mechanism in order to correlate it to field operation and analytical fatigue life predictions. To enhance the understanding of the physical crack behaviour as a function of internal pressure, a comprehensive finite element analysis (FEA) model was built using SIMULIA’s Abaqus software. The model inputs incorporated results from the above-mentioned laboratory tests, in addition to extensive radial, circumferential and axial residual stress measurements using the X-ray diffraction (XRD) technique, obtained on three pipe spools cut out from the same line. The resulting crack opening parameters from FEA were input into a closed-form fluid mechanics (FM) model, which was calibrated against a computational fluid dynamics (CFD) model, to determine the corresponding leak initiation pressures and leak rates. These outcomes were then compared to experimental findings. The FEA and FM models were subsequently employed to carry out a parametric study for plausible combinations of feature geometries, material properties, operational pressures and residual stresses to replicate field conditions. The key outcome from this study is the experimental and analytical demonstration that, for given fluid properties and pressures, the leak threshold and leak rate for through-wall cracks are primarily dependent upon the crack geometry and local residual stress distributions.

Development of a Crack Opening Displacement Assessment Procedure Considering Change of Compliance at a Crack Part in Thin Wall Pipes Made of Modified 9Cr-1Mo Steel

2018 ◽  
Author(s):  
Takashi Wakai ◽  
Hideo Machida ◽  
Manabu Arakawa ◽  
Seiji Yanagihara ◽  
Ryosuke Suzuki ◽  
...  
Keyword(s):  
Crack Opening Displacement ◽  
Work Hardening ◽  
Crack Opening ◽  
Large Diameter ◽  
Assessment Method ◽  
Leak Rate ◽  
Thin Wall ◽  
Opening Displacement ◽  
Thin Walled ◽  
Small Work

This study was carried out to establish crack opening displacement (COD) evaluation methods used in Leak-Before-Break (LBB) assessment of thin-walled large-diameter pipes of the Sodium cooled Fast Reactors (SFRs). For the pipes of SFR, the continuous leak monitoring will be adopted as an alternative to a volumetric test of the weld joints under conditions that satisfy LBB. The sodium pipes are made of ASME Gr.91 (modified 9Cr-1Mo steel). Thickness of the pipes is small, because the internal pressure is very small. Modified 9Cr-1Mo steel has a relatively large yield stress and small work hardening coefficient comparing to the austenitic stainless steels which are currently used in the conventional plants. In order to assess the LBB behavior of the sodium pipes made of modified 9Cr-1Mo steel, the coolant leak rate from a through wall crack must be estimated properly. Since the leak rate is strongly related to the crack opening displacement (COD), an appropriate COD assessment method must be established to perform LBB assessment. However, COD assessment method applicable for SFR pipes — having thin wall thickness and made of small work hardening material — has not been proposed yet. Thus, a COD assessment method applicable to thin walled large diameter pipe made of modified 9Cr-1Mo steel was proposed in this study. In this method, COD was calculated by classifying the components of COD; elastic, local plastic and fully plastic. In addition, the verification of this method was performed by comparing with the results of a series of four-point bending tests using modified 9Cr-1Mo steel pipe having a circumferential through wall notch. As a result, in some cases, COD were overestimated especially for large cracks. Although the elastic component of COD, δEE, is still over-estimated for large cracks, leak evaluation from small cracks is much more important in LBB assessment. Therefore, this study recommends that only the elastic component of COD, δEE, should be adopted in LBB assessment of SFR pipes.

Leak Rates Through Complex Crack Paths: Update on the Latest Developments From the European Project ATLAS+

2019 ◽  
Author(s):  
Peter Gill ◽  
Tomas Nicak ◽  
Brian Daniels ◽  
Florian Obermeier
Keyword(s):  
Crack Opening ◽  
Crack Size ◽  
Weld Interface ◽  
Leak Rate ◽  
Test Case ◽  
Two Phase ◽  
European Project ◽  
Fea Model ◽  
Rate Calculation ◽  
Leak Before Break

Abstract Leak-before-Break assessments require a reliable method to obtain leakage rates from narrow cracks. The ability to predict leakage accurately is crucial to the overall success of Leak-before-Break arguments as the detection capability and limiting crack size are often very small. This can make it difficult to achieve the desired margin between limiting defect size and the crack size required for detectable leakage. The resulting narrow flow paths (< 0.1mm) relative to the wall thickness (> 10mm) necessitates the use of complex thermodynamic and friction models in the leak rate calculation. A method to calculate leakage rates through complex paths was presented in PVP2015-45468 using an ordinary differential equation (ODE) for Mach number. This model was developed to account for crack opening displacements that vary non-linearly through the wall of a pipe. This situation typically arises when there is a through wall crack at a weld, where significant residual stresses are present. This paper considers an FEA model of a plate with a weld residual stress (WRS) profile applied. The WRS is prescribed with nodal displacements, and the COD is calculated from post processing of the elastic stress analysis solution. This results in a COD function in terms of the distance through the wall, which can then be used in the leak rate calculation. Comparisons are made with the R6 methodology recommended software DAFTCAT and the benefits of using the ODE method are discussed. In collaboration with Framatome, Germany, a test case based on the previous European project STYLE was considered. The test case involves a Type 316L Stainless Steel pipe with a girth weld, and the FEA model includes postulated through wall defects at the weld interface to assess crack opening displacements. This model will be used to extract crack opening displacements and calculate leak rates using various methods. Two phase flow will be considered for this test case as the pipe geometry is very relevant to PWRs.

Development of LBB Assessment Method for Japan Sodium Cooled Fast Reactor (JSFR) Pipes (4): Verification of Crack Opening Displacement Assessment Method for Thin Wall Pipes Made of Mod.9Cr-1Mo Steel

2011 ◽  
Author(s):  
Takashi Wakai ◽  
Hideo Machida ◽  
Shinji Yoshida ◽  
Fumiko Kawashima ◽  
Koichi Kikuchi ◽  
...  
Keyword(s):  
Crack Opening Displacement ◽  
Fast Reactor ◽  
Work Hardening ◽  
Crack Opening ◽  
Assessment Method ◽  
Experimental Results ◽  
Leak Rate ◽  
Thin Wall ◽  
Opening Displacement ◽  
Small Work

For sodium pipes of Japan Sodium cooled Fast Reactor (JSFR), the continuous leak monitoring will be adopted as an alternative to a volumetric test of the weld joints under conditions that satisfy Leak-Before-Break (LBB). The sodium pipes are made of ASME Gr.91 (modified 9Cr-1Mo) steel. Thickness of the pipes is small, because the internal pressure is very low. Modified 9Cr-1Mo steel has a relatively large yield stress and small work hardening coefficient comparing to the austenitic stainless steels which are currently used in the conventional plants. In order to discuss about the LBB of the sodium pipes made of modified 9Cr-1Mo steel, the coolant leak rate from a through wall crack must be estimated properly. Since the leak rate is strongly related to the crack opening displacement (COD), an appropriate COD assessment method must be established to perform LBB assessment. However, COD assessment method applicable for JSFR sodium pipes — thin wall and small work hardening material — has not been proposed yet. Therefore, the authors have proposed a COD assessment method applicable to thin walled large diameter pipe made of modified 9Cr-1Mo steel. In this method, COD is calculated by classifying into three components of elastic, local plastic and fully plastic. This paper describes the improved COD assessment method and verifies the validity of the method based on the results of a series of four-point bending tests at elevated temperature using thin wall modified 9Cr-1Mo steel pipe containing a circumferential through wall crack. As a result, COD values calculated by the proposed method were in a good agreement with the experimental results for the uniform pipe without weld. In the case that the crack was machined at weld metal or heat affected zone (HAZ), proposed method predicted relatively larger COD than the experimental results. The causes of such discrepancies were discussed comparing with the results of finite element analyses. Based on these examinations, the rational leak rate evaluation method in LBB assessment was proposed.

A Coupled Fluid-Solid Model to Investigate Leak Rates for Leak-Before-Break Assessments

2014 ◽  
Author(s):  
Peter Gill ◽  
Keith Davey ◽  
John Sharples
Keyword(s):  
Finite Element ◽  
Nuclear Power ◽  
Power Plants ◽  
Structural Model ◽  
Fluid Model ◽  
Crack Opening ◽  
Element Model ◽  
Leak Rate ◽  
Solid Model ◽  
Leak Before Break

A multiscale model is discussed here which incorporates fluid mechanics into a structural model. This is so that leak rates can be output from a crack in a finite element model without any complex meshing or post processing. The model can be implemented into any standard finite element solver, meaning leak rates can be investigated for cracks in realistic components. Crack opening area is obtained directly from the special elements that surround the crack, and leak rate is output with the solution. By adopting this holistic approach, it makes the calculation of leak rate more efficient, with the added benefit of higher accuracy. Furthermore, this provides a tool to investigate thermal interactions between the fluid and solid. Presented in this paper is a description of the physical model, and an outline of the numerical solution procedure. Leak rates are also discussed for the case of crack in a plate. The numerical tool provides an effective way of coupling a fluid model with microscale effects, to a macroscale solid model. Investigations using this new method have the potential to reduce uncertainty in leak rate evaluation. Also, by reducing the uncertainty, it is suggested that there would be an increase in the number of situations where Leak-before-Break could be applied in Nuclear Power Plants.

Leak Rate Computation: Flow Resistance vs. Thermal-Hydraulic Aspect

2018 ◽  
Author(s):  
Klaus Heckmann ◽  
Jürgen Sievers ◽  
Fabian Weyermann
Keyword(s):  
Flow Resistance ◽  
Discharge Rate ◽  
Crack Opening ◽  
Hydraulic Modeling ◽  
Leak Rate ◽  
Equilibrium Models ◽  
Flow Rates ◽  
Flow Models ◽  
Critical Discharge ◽  
Non Equilibrium

The computation of mass flow rates through crack-like defects in piping systems of light water reactors requires typically the description of two-phase flow conditions. The computed discharge rate depends on the crack opening area, the thermal-hydraulic modeling of the flow, and the flow resistance of the crack. Several models have been proposed to characterize the critical flow through crack-like defects. An evaluation of advantages and shortcomings of the different models with regard to the interaction of the three different parts (crack opening area, thermal-hydraulic modeling, flow resistance) has been performed. In this paper, the flow resistance modeling from several approaches is discussed, and compared with a database from eight different testing programs. Five different flow models are applied to analyze a database of more than 800 leak rate measurements for subcooled water from twelve different experimental programs. It is shown that the correct modeling of the flow resistance is crucial for a best estimate reproduction of the measured data. It turns out that generally, equilibrium models are about as good as non-equilibrium models. The data were processed with the GRS software WinLeck which includes different analytical approaches for the calculation of crack sizes and leak rates in piping components. The most reliable results within the model selection are produced by the CDR model (Critical Discharge Rate) of the ATHLET code (Analysis of Thermal-hydraulics of Leaks and Transients) developed by GRS. As a conclusion, the accurate modeling of form losses and frictional pressure losses for critical discharge flow rates through crack-like leaks are essential for a reliable prediction of flow rates. Uncertainties in leak rate computations results arise due to the lack of information about the flow geometry and its associated drag. The assumed flow resistance of a through-wall crack influences the computed leak rate as significant as the phase-change- and flow-models. The manifest difference between equilibrium models (Pana, Estorf) and non-equilibrium models (Henry, ATHLET-CDR) seems to be less significant than the pressure loss issue. One can conjecture that, for crack-like through-wall defects, friction effects play a more important role than non-equilibrium effects.

Development of Leak-Before-Break Assessment Method for Japan Sodium Cooled Fast Reactor Pipe—Part 1 Crack Opening Displacement Assessment of Thin Wall Pipes Made of Modified 9Cr-1Mo Steel

2012 ◽  
Vol 135 (1) ◽  
Author(s):  
Takashi Wakai ◽  
Hideo Machida ◽  
Manabu Arakawa ◽  
Shinji Yoshida ◽  
Yasuhiro Enuma
Keyword(s):  
Crack Opening Displacement ◽  
Fast Reactor ◽  
Work Hardening ◽  
Crack Opening ◽  
Assessment Method ◽  
Leak Rate ◽  
Thin Wall ◽  
Opening Displacement ◽  
Leak Before Break ◽  
Small Work

This was carried out to establish crack opening displacement (COD) evaluation methods used in leak-before-break (LBB) assessment of sodium pipes of the Japan sodium cooled fast reactor (JSFR). For sodium pipes of JSFR, the continuous leak monitoring will be adopted as an alternative to a volumetric test of the weld joints under conditions that satisfy LBB. The sodium pipes are made of ASME Gr.91 (modified 9Cr-1Mo steel). Thickness of the pipes is small, because the internal pressure is very low. Modified 9Cr-1Mo steel has a relatively large yield stress and small work hardening coefficient comparing to the austenitic stainless steels which are currently used in the conventional plants. In order to assess the LBB behavior of the sodium pipes made of modified 9Cr-1Mo steel, the coolant leak rate from a through-wall crack must be estimated properly. Since the leak rate is strongly related to the COD, an appropriate COD assessment method must be established to perform LBB assessment. However, COD assessment method applicable for JSFR sodium pipes—thin wall and small work hardening material—has not been proposed yet. Thus, a COD assessment method applicable to thin walled large diameter pipe made of modified 9Cr-1Mo steel was proposed in this study. In this method, COD was calculated by classifying the components of COD; elastic, local plastic, and fully plastic. In addition, the verification of this method was performed by comparing with the results of a series of four-point bending tests at elevated temperature using thin wall modified 9Cr-1Mo steel pipe containing a circumferential through-wall crack. As a result, COD values calculated by the proposed method were in a good agreement with the experimental results for the uniform pipe without a weld. In the case that the crack was machined in the weld metal or heat affected zone (HAZ), the proposed method predicted relatively larger COD than the experimental results. The causes of such discrepancies were discussed by comparing with the results of finite element analyses. Based on these examinations, the rational leak rate evaluation method in LBB assessment was proposed.

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