Failure Pressure for Steam Generator Tube With Two Different Collinear Axial Through-Wall Cracks

2006 ◽  
Author(s):  
Nam-Su Huh ◽  
Yoon-Suk Chang ◽  
Young-Jin Kim
Keyword(s):  
Steam Generator ◽  
Complex Shape ◽  
Structural Integrity ◽  
Failure Behavior ◽  
Multiple Cracks ◽  
Single Crack ◽  
Steam Generator Tube ◽  
3 Dimensional ◽  
Failure Pressure ◽  
Steam Generator Tubes

To maintain the structural integrity of steam generator tubes, 40% of wall thickness plugging criterion has been developed. The approach is for the steam generator tube with single crack, so that the interaction effect of multiple cracks can not be considered. Although, recently, several approaches has been proposed to assess the integrity of steam generator tube with two identical cracks whilst actual multiple cracks reveal more complex shape. In this paper, the failure pressure of steam generator tube containing multiple cracks of different length is evaluated based on the detailed 3-dimensional elastic-plastic finite element (FE) analyses. In terms of the crack shape, two collinear axial through-wall cracks with different length were considered. Furthermore, the resulting FE failure pressures are compared with FE failure pressures and experimental results for two identical collinear axial through-wall cracks to quantify the effect of crack length ratio on failure behavior of steam generator tube with multiple cracks.

Structural Integrity Assessment of Steam Generator Tube by the Use of Heterogeneous Finite Element Method

2008 ◽  
Vol 130 (4) ◽  
Author(s):  
Xinjian Duan ◽  
Michael J. Kozluk ◽  
Sandra Pagan ◽  
Brian Mills
Keyword(s):  
Finite Element ◽  
Steam Generator ◽  
Failure Modes ◽  
Structural Integrity ◽  
Fretting Wear ◽  
Defect Depth ◽  
Steam Generator Tube ◽  
Integrity Assessment ◽  
Failure Pressure ◽  
Steam Generator Tubes

Aging steam generator tubes have been experiencing a variety of degradations such as pitting, fretting wear, erosion-corrosion, thinning, cracking, and denting. To assist with steam generator life cycle management, some defect-specific flaw models have been developed from burst pressure testing results. In this work, an alternative approach; heterogeneous finite element model (HFEM), is explored. The HFEM is first validated by comparing the predicted failure modes and failure pressure with experimental measurements of several tubes. Several issues related to the finite element analyses such as temporal convergence, mesh size effect, and the determination of critical failure parameters are detailed. The HFEM is then applied to predict the failure pressure for use in a fitness-for-service condition monitoring assessment of one removed steam generator tube. HFEM not only calculates the correct failure pressure for a variety of defects, but also predicts the correct change of failure mode. The Taguchi experimental design method is also applied to prioritize the flaw dimensions that affect the integrity of degraded steam generator tubes such as the defect length, depth, and width. It has been shown that the defect depth is the dominant parameter controlling the failure pressure. The failure pressure varies almost linearly with defect depth when the defect length is greater than two times the tube diameter. An axial slot specific flaw model is finally developed.

Evaluation of the Creep Rupture Behavior of Alloy 690 Steam Generator Tubes Considering the Pressure Ramp Rate

2021 ◽  
Author(s):  
Jongmin Kim ◽  
Min-Chul Kim ◽  
Joonyeop Kwon
Keyword(s):  
Steam Generator ◽  
Creep Rupture ◽  
Parameter Method ◽  
Alloy 600 ◽  
Steam Generator Tube ◽  
Failure Pressure ◽  
Alloy 690 ◽  
Rupture Model ◽  
Temperature And Pressure ◽  
Steam Generator Tubes

Abstract The materials used previously for steam generator tubes around the world have been replaced and will be replaced by Alloy 690 given its improved corrosion resistance relative to that of Alloy 600. However, studies of the high- temperature creep and creep-rupture characteristics of steam generator tubes made of Alloy 690 are insufficient compared to those focusing on Alloy 600. In this study, several creep tests were conducted using half tube shape specimens of the Alloy 690 material at temperatures ranging from 650 to 850C and stresses in the range of 30 to 350 MPa, with failure times to creep rupture ranging from 3 to 870 hours. Based on the creep test results, creep life predictions were then made using the well-known Larson Miller Parameter method. Steam generator tube rupture tests were also conducted under the conditions of a constant temperature and pressure ramp using steam generator tube specimens. The rupture test equipment was designed and manufactured to simulate the transient state (rapid temperature and pressure changes) in the event of a severe accident condition. After the rupture test, the damage to the steam generator tubes was predicted using a creep rupture model and a flow stress model. A modified creep rupture model for Alloy 690 steam generator tube material is proposed based on the experimental results. A correction factor of 1.7 in the modified creep rupture model was derived for the Alloy 690 material. The predicted failure pressure was in good agreement with the experimental failure pressure.

Evaluation of Interaction Effects on Part-Through Cracks in Steam Generator Tubes

2013 ◽  
Author(s):  
Yong-Seok Kang ◽  
Hong-Deok Kim ◽  
Kuk-Hee Lee ◽  
Jai-Hak Park
Keyword(s):  
Steam Generator ◽  
Interaction Effect ◽  
Structural Integrity ◽  
Structural Parameters ◽  
Interaction Effects ◽  
Multiple Cracks ◽  
Performance Limit ◽  
Steam Generator Tubing ◽  
Steam Generator Tubes

Degraded steam generator tubing can affect its safety functions. Therefore, its integrity should be maintained for each degradation form and all detected degradation must be assessed to verify that if adequate integrity is retained. Determination of tube integrity limits includes identifying acceptable structural parameters such as flaw length, depth, and amplitude of signals. If we consider just single-cracked tubes, short and deep flaws are not likely to threaten structural integrity of tubes. But if it has multiple-cracks, we have to consider interaction effects of multiple adjacent cracks on its burst pressure. Because adjacent multiple cracks can be merged due to the crack growth then it can challenge against the structural performance limit. There are some studies on the interaction effects of adjacent cracks. However, existing works on the interaction effect consider only through-wall cracks. No study has been carried out on the interaction effects of part-through cracks. Most cracks existing in real steam generator tubing are not through-wall cracks but part-through cracks. Hence, integrity of part-through cracks is more practical issue than that of through-wall cracks. This paper presents experimental burst test results with steam generator tubing for evaluation of interaction effects with axial oriented two collinear and parallel part-through cracks. The interaction effect between two adjacent cracks disappeared when the distance exceeds about 2 mm.

Structural Integrity Estimates of Steam Generator Tubes Containing Wear-Type Defects

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
Yoon-Suk Chang ◽  
Jong-Min Kim ◽  
Nam-Su Huh ◽  
Young-Jin Kim ◽  
Seong-Sik Hwang ◽  
...  
Keyword(s):  
Steam Generator ◽  
Structural Integrity ◽  
Equivalent Stress ◽  
Three Dimensional ◽  
Plastic Instability ◽  
Failure Behavior ◽  
Dimensional Finite Element ◽  
Tapered Angle ◽  
Three Dimensional Finite Element ◽  
Steam Generator Tubes

It is requested that steam generator tubes with defects exceeding 40% of wall thickness in depth should be plugged to sustain all postulated loads with appropriate margin. This critical defect size has been determined based on a concept of plastic instability, however, which is known to be too conservative for some locations and types of defects. The application of this concept may even cause premature retirement of steam generator tubes. In reality, a reliable structural integrity estimation for steam generator tubes containing a defect has received increasing attention. Although several guidelines have been developed and used for assessing defect containing tubes, most of these guidelines are focused on stress corrosion cracking or wall-thinning phenomena. Because some of steam generator tubes fail due to fretting and so on, specific integrity estimation schemes for relevant defects are required. In this paper, more than a hundred three-dimensional finite element analyses of steam generator tubes under internal pressure condition are carried out to simulate the failure behavior of steam generator tubes with specific defect configurations: elliptical wear-type, tapered wedge-type, and flat wear-type defects. After investigating the effect of key parameters such as defect depth, defect length, and wrap or tapered angle on equivalent stress across the ligament thickness, burst pressure estimation equations are proposed in relation to material strengths. Predicted burst pressures agreeded well with the corresponding experimental data, so the proposed equations can be used to assess the structural integrity of steam generator tubes with wear-type defects.

Failure Behavior of Multiple-Axial Part-Through-Wall Flaws in Alloy 690TT Steam Generator Tubes

2015 ◽  
Vol 138 (2) ◽  
Author(s):  
Ki Hyeon Eom ◽  
Jin Weon Kim ◽  
Yun Jae Kim ◽  
Jong Sung Kim
Keyword(s):  
Experimental Data ◽  
Failure Mode ◽  
Steam Generator ◽  
Interaction Effect ◽  
Room Temperature ◽  
Failure Behavior ◽  
Constant Depth ◽  
Failure Pressure ◽  
Axial Part ◽  
Steam Generator Tubes

This study investigates the interaction effect of multiple-axial part-through-wall (PTW) flaws on the failure behavior of Alloy 690TT steam generator (SG) tubes. Burst tests of tubes with single and multiple flaws were conducted at room temperature (RT). The flaws were made by the electrodischarge machining (EDM) method on the outer surface of the specimens. Six different configurations of multiple flaws were considered to see the interaction effect; two and three collinear, two and three parallel, and two and three nonaligned flaws. In all cases, an axial flaw with a constant depth of 50% wall-thickness was considered, and the following variables were systematically varied; the axial and/or circumferential separating ligament lengths between flaws, the flaw length, and the number of flaws. Effects of these variables on the failure pressure and failure mode were investigated based on experimental data. The effects of separating ligament lengths and flaw lengths on the failure pressure were dependent on the type of flaw configuration. For collinear and nonaligned flaws, the decrease in failure pressure by the interaction of multiple flaws became significant as the number of flaws increased. The failure mode of multiple flaws was strongly dependent on the length of the flaws.

Experimental Investigation of Subcooled Choking Flow in a Steam Generator Tube Crack

2016 ◽  
Author(s):  
Hung Nguyen ◽  
Mark Brown ◽  
Shripad T. Revankar ◽  
Jovica Riznic
Keyword(s):  
Power Plant ◽  
Nuclear Power Plant ◽  
Steam Generator ◽  
Nuclear Power ◽  
Test Facility ◽  
Experimental Program ◽  
Steam Generators ◽  
Steam Generator Tube ◽  
Loss Of Coolant ◽  
Steam Generator Tubes

Steam generator tubes have a history of small cracks and even ruptures, which lead to a loss of coolant from the primary side to the secondary side. These tubes have an important role in reactor safety since they serve as one of the barriers between radioactive and non-radioactive materials of a nuclear power plant. A rupture then signifies the loss of the integrity of the tube itself. Therefore, choking flow plays an integral part not only in the engineered safeguards of a nuclear power plant, but also to everyday operation. There is limited data on actual steam generators tube wall cracks. Here experiments were conducted on choked flow of subcooled water through two samples of axial cracks of steam generator tubes taken from US PWR steam generators. The purpose of the experimental program was to develop database on critical flow through actual steam generator tube cracks with subcooled liquid flow at the entrance. The knowledge of this maximum flow rate through a crack in the steam generator tubes of a pressurized water nuclear reactor will allow designers to calculate leak rates and design inventory levels accordingly while limiting losses during loss of coolant accidents. The test facility design is modular so that various steam generator tube cracks can be studied. Two sets of PWR steam generators tubes were studied whose wall thickness is 1.285 mm. Tests were carried out at stagnation pressure up to 6.89 MPa and range of subcoolings 16.2–59°C. Based on these new choking flow data, the applicability of analytical models to highlight the importance of non-equilibrium effects was examined.

Coalescence Pressure Evaluation of Multiple Through-Wall Cracks in Steam Generator Tube Using Elastic-Plastic Finite Element Analyses

2015 ◽  
Author(s):  
Jin-Won Hong ◽  
Jae-Boong Choi ◽  
Nam-Su Huh
Keyword(s):  
Finite Element ◽  
Steam Generator ◽  
Interaction Effect ◽  
Evaluation Model ◽  
Multiple Cracks ◽  
Crack Interaction ◽  
Collinear Cracks ◽  
Elastic Plastic ◽  
Parallel Cracks ◽  
Steam Generator Tubes

During an in-service inspection, if multiple cracks have been found in a nuclear component, the crack interaction effect due to adjacent cracks should be taken into account to characterize the detected multiple cracks into equivalent single combined crack or independent single crack. However, there must be many factors to be considered to quantify crack interaction effect, many experimental and numerical works should be made to propose robust guidelines on crack interaction effect depending on material characteristics of interest. Although many works have been made during the past few years to evaluate crack interaction effect of steam generator tubes with multiple cracks, the robust guidelines are still lacking. In this study, systematic 3-dimensional (3D) elastic-plastic finite element (FE) analyses are performed for steam generator tubes with multiple through-wall cracks. As for geometries of multiple through-wall cracks, four different cases are considered; axial collinear cracks, axial parallel cracks, circumferential collinear cracks, and circumferential parallel cracks. The geometric variables affecting the Pc (coalescence pressure), i.e. crack length and distance between multiple cracks, are systematically varied in the present study. Based on the coalescence pressure evaluation model proposed by authors in the previous study and the present FE results, the Pc of steam generator tubes with multiple cracks are investigated.

Coalescence Criterion of Part-Through Wall Cracks in Steam Generator Tubes of Nuclear Power Plants

2004 ◽  
Author(s):  
Jeries Abou-Hanna ◽  
Timothy McGreevy ◽  
Saurin Majumdar ◽  
Amit J. Trivedi ◽  
Ashraf Al-Hayek
Keyword(s):  
Finite Element ◽  
Steam Generator ◽  
Nuclear Power ◽  
Power Plants ◽  
Nuclear Power Plants ◽  
Local Instability ◽  
Element Analysis ◽  
Failure Pressure ◽  
Ligament Failure ◽  
Steam Generator Tubes

In scheduling inspection and repair of nuclear power plants, it is important to predict failure pressure of cracked steam generator tubes. Nondestructive evaluation (NDE) of cracks often reveals two neighboring cracks. If two neighboring part-through cracks interact, the tube pressure, under which the ligament between the two cracks fails, could be much different than the critical burst pressure of an individual equivalent part-through crack. The ability to accurately predict the ligament failure pressure, called “coalescence pressure,” is important. The coalescence criterion, established earlier for 100% through cracks using nonlinear finite element analyses [1–3], was extended to two part-through-wall axial collinear and offset cracks cases. The ligament failure is caused by local instability of the radial and axial ligaments. As a result of this local instability, the thickness of both radial and axial ligaments decreases abruptly at a certain tube pressure. Good correlation of finite element analysis with experiments (at Argonne National Laboratory’s Energy Technology Division) was obtained. Correlation revealed that nonlinear FEM analyses are capable of predicting the coalescence pressure accurately for part-through-wall cracks. This failure criterion and FEA work have been extended to axial cracks of varying ligament width, crack length, and cases where cracks are offset by axial or circumferential ligaments. The study revealed that rupture of the radial ligament occurs at a pressure equal to the coalescence pressure in the case of axial ligament with collinear cracks. However, rupture pressure of the radial ligament is different from coalescence pressure in the case of circumferential ligament, and it depends on the length of the ligament relative to crack dimension.

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