Further Development of the Nonlocal Damage Model of Rousselier for the Transition Regime of Fracture Toughness and Different Stress States

In nuclear power engineering failure has to be excluded for components with high safety relevance. Currently, safety assessments mainly use fracture mechanics concepts. Especially in the transition region of fracture toughness where limited stable crack extension may appear before cleavage fracture the currently applied methods are limited. This Paper deals with the development and verification of a closed concept for safety assessment of components over the whole range from the lower shelf to the upper shelf of fracture toughness. The results of classical used local damage mechanics models depend on the element size of the numerical model. This disadvantage can be avoided using an element size depending on microstructure. With high stress gradients and small crack growth rates usually smaller elements are required. This is in conflict with an element size depending on microstructure. By including the damage gradient as an additional degree of freedom in the damage mechanics model the results depend no longer at the element size. In the paper damage mechanics computations with a nonlocal formulation of the Rousselier model are carried out for the evaluation of the upper transition area. For the prediction of fracture toughness from the ductile to brittle transition area the nonlocal Rousselier model is coupled with the Beremin model. Thus ductile crack growth and failure by brittle fracture can be described in parallel. The numerical prediction of the behaviour of fracture toughness specimens (C(T)-specimens and SE(B)-specimens with and without side grooves) and the experimental results are highly concordant. The load displacement behavior of the specimens and the developed crack front from the ductile to brittle transition area can be well calculated with the nonlocal damage model. The instability in relation to temperature calculated with the coupled damage mechanics model predicts the variations of the experimental results very well. For further application of the nonlocal Rousselier model experiments and numerical calculations of specimens with different stress states and multi-axiality are carried out. Modified fracture toughness specimens like CTS-specimens (compact tension shear specimens) are taken to investigate the applicability of the nonlocal damage model of Rousselier to mixed mode fracture.

Measurement of High Amplitude Relief Valve Noise for Acoustically Induced Vibration and Comparison to Predictive Methods

The prediction of acoustically induced vibration (AIV) failures in the design or redesign of piping systems requires an accurate estimate of the excitation source. Furthermore, the next generation of AIV analysis may require a physics-based noise-generation predictive technique, which entails the need for validation via direct measurements. The noise generated by a pressure relief valve (PRV) during a full-scale AIV blowdown test was measured inside a pipe downstream of the valve. A maximum flow rate of 33.5 kg/s was achieved using nitrogen gas through a 3×4″ relief valve generating a peak dynamic pressure level exceeding 650 kPa and sustained levels of 450 kPa (peak). Measurements are compared to existing noise calculation techniques which appear to under-predict the generated noise.

A Novel High Cycle Fatigue Assessment of Small-Bore Side Branches: Tailor-Made Acceptable Vibration Levels Based on the Remaining Life of Existing Structures

In the process systems of offshore installations, welded small-bore side branches can prove vulnerable to high-cycle fatigue failure due to vibrations. This is especially the case for welded connections at tie-in points to the main pipe which are often critical details. International standards and guidelines therefore provide maximum acceptable vibration levels to ensure long term safe operation. In some guidelines, however, these acceptable vibration levels are phrased in terms of screening levels and in practice can be unduly conservative. Process pipework might then unjustly be regarded as unsafe based on measured vibrations in the field. This is especially true for offshore systems, which are characterized by low mechanical damping in the structure. This may result in overdesigned piping or over-conservative operational limits in order to keep vibration levels within the acceptable range. Furthermore, the screening methods and any detailed fatigue assessments typically use established stress-life (S-N) based fatigue design methods where uncertainty exists in the very high-cycle regime. This paper describes a novel and advanced tailor-made fatigue assessment method whereby acceptable vibration levels are based on maximum acceptable stress ranges for individual side branches. The acceptable stress ranges for each critical welded connection are based on a fracture mechanics analysis of fatigue crack growth. This method also minimizes the cantilevered (overhung) mass of small-bore side branches, whilst remaining safe for long-term operation. To illustrate the strength of the assessment methodology in practice, this paper describes the application of the procedure to a 2″ side branch connected to a main piping system. A fracture mechanics model and a detailed 3D finite element model are made. By comparing the stress ranges from the fracture mechanics model with the normalized stress ranges obtained from the dynamic FE analysis, maximum acceptable vibration levels for this particular side branch have been derived. The method is validated with experimental modal analysis and strain gauge measurements.

Estimation of Graphite Dust Production in a Pebble-Bed Type Nuclear Reflector

In this study, an estimation method of graphite dust production in the pebble-bed type reflector region of Korean HCSB (Helium-Cooled Solid Breeder) TBM (Test Blanket Module) in the ITER (International Thermonuclear Experimental Reactor) project using FEM (Finite Element Method) was proposed and the amount of dust production was calculated. A unit-cell model of uniformly arranged pebbles was defined with appropriate thermal and mechanical loadings. A commercial FEM program, Abaqus V6.10 was used to model and solve the stress field under multiple contact constraints between pebbles in the unit-cell. Resulting normal contact forces and slip distances on contact points were applied into the Archard adhesive wear equation to calculate the amount of graphite dust. The friction effect on contact points was investigated. The calculation result showed that the amount of graphite dust production was estimated to 2.22∼3.67e−4 g/m3 which was almost linearly proportional to the friction coefficient. The analysis results will be used as the basis data for the consecutive study of dust explosion.

A Study on Development of Optimum FE Analysis Model on Welding Stress Analysis for CEDM Penetration Nozzle

For decades, the PWSCC on the penetration nozzles like BMI and CEDM nozzles are widely occurred all around the world. The PWSCC is dependent on the tensile stress condition, specific materials and chemical environment. Therefore, to evaluate the severity of the PWSCC, prediction of the welding residual stress on the J-groove welding part in the penetration nozzles is essential. Residual stress can be measured by using experimental methods like deep-hole drilling and X-ray diffraction, etc. However, the results of experimental methods are quite doubtable and these methods are hard to apply on the actual equipment. Therefore, computational approach like the FE analysis has been considered. The FE analysis results are very sensitive to the FE model density and analysis conditions. In this paper the optimized FE model for the residual stress analysis will be developed in the case of CEDM penetration nozzle. The optimized parameters contains bead number and mesh density. The bead numbers along the longitudinal and circumferential directions are considered and the mesh density in each the bead is also considered. The model will be verified by numerical error control.

Statistical Analyses of High Cycle Fatigue French Data for Austenitic SS

In the 2009 version of the ASME BPV Code, a set of new design fatigue curves were proposed to cover the various steels of the code. These changes occurred in the wake of publications [1] showing that the mean air curve used to build the former ASME fatigue curve did not always represent accurately laboratory results. The starting point for the methodology to build the design curve is the mean air curve obtained through laboratory testing: coefficients are then applied to the mean air curve in order to bridge the gap between experimental testing and reactor conditions. These coefficients on the number of cycles and on the strain amplitude are equal to 12 and 2 respectively in the 2009 ASME BPV code, using the mean air curve proposal from NUREG/CR-6909 [1]. Internationally, with the same mean air curve, other proposals have emerged and especially in France [2]-[3] where a consensus seems to be reached on the reduction of the coefficient on strain amplitude. This paper provides statistical analyses of the experimental data obtained in France at high-cycle for austenitic stainless steels. It enables to bring arguments for the selection of a coefficient on strain amplitude in the French RCC-M code, where less scatter on the data is witnessed due to fewer material grades.

Determination of Updated Fatigue Properties of PE 4710 Cell Classification 445574C High Density Polyethylene

For corroded piping in low temperature systems, such as service water systems in nuclear power plants, replacement of carbon steel piping with high density polyethylene (HDPE) is a cost-effective solution. Polyethylene pipe can be installed at much lower labor costs that carbon steel pipe and HDPE pipe has a much greater resistance to corrosion. The ASME Boiler and Pressure Vessel Code, Section III, Division 1 currently permits the use of non-metallic piping in buried safety Class 3 piping systems. Additionally, HDPE pipe has been successfully used in non-safety-related systems in nuclear power facilities and is commonly used in other industries such as water mains and natural gas pipelines. This report presents the results of updated fatigue testing of PE 4710 cell classification 445574C pipe compliant with the specific Code requirements. This information was developed to support and provide a strong technical basis for material properties of HDPE pipe for use in ASME Boiler and Pressure Vessel Code, Section III New Construction and Section XI repair or replacement activities. The data may also be useful for applications of HDPE pipe in commercial electric power generation facilities and chemical, process and waste water plants via its possible use in the B31 series piping codes. The report provides fatigue data in the form of Code S-N curves for fusion butt joints in PE 4710 cell classification 445574C HDPE pipe.

Effect of Specimen Geometry on the Predicted Mechanical Behavior of Polyethylene Pipe Material

The primary objective of the present paper is to depict the mechanical behavior of high density polyethylene, (HDPE), pipes under different loading conditions with different specimen geometries to provide the designer with reliable design data relevant to practical applications. Therefore, it is necessary to study the effect of strain rate, ring configuration, and grip or fixture type on the mechanical behavior of dumb-bell-shaped, (DBS), and ring specimens made from HDPE pipe material. DBS and ring specimens are cut from the pipe in longitudinally, and circumferential (transverse) direction respectively. On the other hand, the ring specimen configuration is classified into two types; full ring, (FR), and notched ring, (NR) (equal double notch from two sides of notched ring specimen) specimens according to ASTM D 2290-12 standard. Tensile tests are conducted on specimens cut out from the pipe with thickness 10 mm at different crosshead speeds (10–1000 mm/min), and ambient temperature, Ta = 20 °C to investigate the mechanical properties of DBS, and ring specimens. In the case of test specimens taken from longitudinal direction from the pipe a necking phenomenon before failure appears at different locations along the gauge section. On the other hand, the fracture of NR specimens occurs at one notched side. The results demonstrated that the NR specimen has higher yield stress than DBS, and FR specimens at all crosshead speeds. The present experimental work reveals that the crosshead speed has a significant effect on the mechanical behavior of both DBS, and ring specimens. The fixture type plays an important role in the mechanical behavior for both FR and NR specimens at all crosshead speeds.

Fatigue Behavior of Butt Weld Seams: Experimental Investigation and Numerical Simulation

Austenitic stainless steel of type X6CrNiNb18-10 (1.4550) is a widely used material in piping and components of nuclear power plants. The fatigue behavior of these components is often operationally determined by thermomechanical strains and corresponding stresses. Welded structures lead to complex stresses in the component and potential fatigue lifetime reductions. Various geometrical and microstructural inhomogeneities in welded structures represent the main factors of influence. Nevertheless, clear identification and quantification of various factors of influence are issues still to be resolved. Within the framework of an ongoing research project, the experimental investigation comprises uniaxial and biaxial fatigue experiments on welded joints which cover temperatures from 25°C to 350°C. Furthermore, a key issue deals with the thermomechanical fatigue behavior of machined and unmachined butt weld seams. A special focus is set on typical low cycle fatigue (LCF) tests in order to explain the behavior of the base material and the weld material to identify the influence of microstructural inhomogeneities. In addition, specimens manufactured directly from the pipe components are tested to examine the influence of the butt weld seam geometry. For a better understanding of the local strain effects, optical strain field measurements (OSFM) are conducted and used to validate numerical simulation. The finite element method (FEM) is utilized to expand the parameter space and identify the main parameters. Experimental and numerical results show that fatigue failure occurs either in the base metal in the vicinity of the welded zone or in the top layer of the weld, depending on the loading conditions. This knowledge is used to develop an approach to fatigue lifetime estimation.

Numerical Estimation of Flow Penetrating Depth Into Stagnant Branch Pipes for Thermal Fatigue Prediction

In the nuclear power plants, there are many branch pipes with closed-end which are attached vertically to the main pipe. We consider a situation in which the high temperature water is transported in the main pipe, the branch pipe is filled with stagnant water which has lower temperature than the main flow, and the end of the branch pipe is closed. At the branch connection part, it is known that a cavity flow is induced by the shear force of the boundary layer which separates from the leading edge of the branch pipe along the main pipe wall. In cases where the high temperature water penetrates into the branch pipe, there is a possibility that a steep and large temperature gradient field, called “thermal stratification layer” is formed at the boundary between high and low temperature water in the branch pipe. If the thermal stratification layer is formed in a bend pipe, which is used for connecting the vertical branch pipe and to a horizontal pipe, at the same time, the temperature fluctuation by the thermal stratification layer motion occurs, there may cause the thermal stress in the piping material. Furthermore, keeping the piping material under the thermal stress, there might be a possibility of a crack on the surface of the bend pipe. For this reason, the evaluation of the position where the thermal stratification layer reaches is very important during early piping design process. And, deeply understanding regarding the phenomena, is also important. However, because of the complexities of the phenomena, it is difficult to immediately clarify the whole mechanisms of the thermal stress arising due to the temperature fluctuation by the thermal stratification layer change. The complete prediction method for the position of the thermal stratification layer based on the mechanisms that is able to be applied to any piping system, any temperature and any velocity conditions, is also difficult. Therefore, a practical approach is required. The authors attempt to develop the practical estimation method for the thermal stratification layer position using the three-dimensional Navier-Stokes simulation which was based on the Reynolds-average in order to reduce the computational costs. In this paper, three different configurations of the piping were simulated and the simulation results were compared with the experimental results obtained by the other research group.