Presentation of RCC-MRx Code 2010 for Sodium Reactors (SFR), Research Reactor (RR) and Fusion (ITER): General Overview and CEN-Workshop

A draft of the fifth edition of the RCC-MR code, named RCC-MRx 2010, has been issued in French and English versions on December 2010 by AFCEN (Association Franc¸aise pour les re`gles de Conception et de Construction des Mate´riels des Chaudie`res Electro-nucle´aires). This RCC-MRx Code is the result of the merger of the RCC-MX 2008 developed in the context of the research reactor Jules Horowitz Reactor project, in the RCC-MR 2007 which set up rules applicable to the design of components operating at high temperature and to the Vacuum Vessel of ITER. This is a non-public document established in order to prepare the fifth edition which will be published in French and English by AFCEN and will be named RCC-MRx 2012. By this next edition, AFCEN try to bring together all the relevant stakeholders in a CEN-Workshop (CEN-WS-MRx) in order to develop, on the RCC-MRx basis, the European code for the design and fabrication of mechanical equipments for ESNII innovative nuclear installations. This CEN Workshop (whose duration is 18 months, from January 2011) will allow the Workshop members to consider the RCC-MRx 2010 and to propose modifications to be included in the RCC-MRx 2012 edition to meet the needs of MYRRHA and ASTRID projects and to prepare the design and construction of ALFRED and ALLEGRO. This paper presents the code evolutions from the 2007 edition of the RCC-MR and describes the organization of the Workshop.

Probability of Initial Failure for Spring Operated Relief Valves

We present clear and convincing evidence that, for new spring operated relief valves (SORV) that are not proof tested by the user shortly before installation, there is a non-trivial probability that the SORV will be installed in the fail-to-open (stuck shut) failure mode. Using the results of over 4800 new ASME Boiler and Pressure Vessel Code Section VIII SORV proof tests, we estimate the probability of initial failure (PIF) due to manufacturer/assembly anomalies, as well as PIF due to in-storage aging of SORV based on their material composition. We indicate how PIF can be reduced by various preinstallation activities that may be undertaken by the user. We show how to compute values of PIF to be used in calculating the average probability of fail danger (PFDavg) (as required by IEC61508 and similar safety standards in order to determine a safety integrity level (SIL)) which accounts for both the SORV material composition and the pre-installation activities undertaken. For four typical SORV of different material compositions we show how pre-installation activities influence the achievable SIL. We discuss the implication of these findings for estimating PIF for used (previously installed) SORV. We close with recommendations to further address PIF.

Simplified Analysis Methods for Primary Load Designs at Elevated Temperatures

The use of “simplified” (reference stress) analysis methods is discussed and illustrated for primary load high temperature design. Elastic methods are the basis of the ASME Section III, Subsection NH primary load design procedure. There are practical drawbacks with this current NH approach, particularly for complex geometries and temperature gradients. The paper describes an approach which addresses these difficulties through the use of temperature-dependent elastic, perfectly-plastic analysis. Traditionally difficulties associated with discontinuity stresses, inelastic strain concentrations and multiaxiality are addressed. A procedure is identified to provide insight into how this approach could be implemented. Though preliminary in nature, it is intended to provide a basis for further development and eventual Code adaptation.

Effects of Weld Overlays on Leak-Before-Break Margins

Weld overlays have been used to remedy intergranular stress corrosion cracking (IGSCC) in boiling water reactors (BWRs) since the 1980s. Overlays have also been applied in the last few years in pressurized water reactors (PWRs) where primary water stress corrosion cracking (PWSCC) has developed. The weld overlay provides a structural reinforcement with SCC resistant material and favorable residual stresses at the ID of the overlaid component. Leak-before-break (LBB) had been applied to several piping systems in PWRs prior to recognizing the PWSCC susceptibility of Alloy 82/182 welds. The application of the weld overlay changes the geometric configuration of the component and as such, the original LBB evaluation is updated to reflect the new configuration at the susceptible weld. This paper describes a generic leak-before-break (LBB) analysis program which demonstrates that the application of weld overlays always improves LBB margins, relative to un-overlaid, PWSCC susceptible welds when all the other parameters or variables of the analyses (loads, geometry, operating conditions, analysis method, etc…) are kept equal. Analyses are performed using LBB methodology previously approved by the US NRC for weld overlaid components. The analyses are performed for a range of nozzle sizes (from 6″ to 34″) spanning the nominal pipe sizes to which LBB has been commonly applied, using associated representative loads and operating conditions. The analyses are performed for both overlaid and un-overlaid configurations of the same nozzles, and using both fatigue and PWSCC crack morphologies in the leakage rate calculations and the LBB margins are compared to show the benefit of the weld overlays.

New Computational Procedures for Evaluation of Fracture Surfaces of the Drop Weight Tear Test of the Piping Steel

Drop weight tear test (DWTT) is one of the standard methods for evaluation of the ductility of large-dimensional structural components, such as pipelines used for gas and/or oil transportation. In general, the pipelines are even used in places with temperatures close to −40 °C, and in such environments, it is necessary to guarantee the resistance of the material used for pipeline against the initiation of unstable fracture. Currently, the percentage portion of the ductile fracture of the DWTT specimen is determined by an expert evaluator. The objective of this paper is to introduce new procedures working on the principle of deterministic, statistical and fractal description of the fracture surface. For the proposed computational procedures, the fracture surface of the test specimen is scanned at the macroscopic level using the 3D-Cam scanner. The newly investigated procedures show highly sensitive to the determination of the percentage portion of the ductile fracture on the tested DWTT specimens. The developed procedures to assess the fracture surfaces of the DWTT specimens contributes to making the results of this test more correct, objective and also increases the reliability and safety of the manufactured pipelines.

Local Ratcheting by Elastic-Plastic FEA: Criteria and Code Based Approaches

Emanating from a discussion of local ratcheting effects and appropriate limiting criteria this paper examines existing ratcheting rules based on local (or material) response that are currently in Section III of the ASME B&PV Code, German KTA rules, and other design codes. The objective is to offer clarification of the rules that may be useful to the designer, their bases and practical application. Among these rules, different ratcheting checks are required that use different ratcheting measures. The paper considers only the rules for which the ratcheting checks can be evaluated by a direct cycle-by-cycle elastic-plastic FEA. Examples are provided to illustrate the procedures.

Effect of Flaw Dimensions on Ductile Fracture Behavior of Non-Aligned Multiple Flaws in a Plate

The fitness-for-service codes require the characterization of non-aligned multiple flaws for flaw evaluation, which is performed using a flaw proximity rule. Worldwide, almost all such codes provide their own proximity rule, often with unclear technical bases of the application of proximity rule to ductile or fully plastic fracture. In particular, the effect of flaw dimensions of multiple surface flaws on fully plastic fracture of non-aligned multiple flaws had not been clear. To clarify the effect of the difference of part through-wall and through-wall flaws on the behavior of fully plastic fracture, the fracture tests of flat plate specimens with non-aligned multiple part through-wall flaws were conducted. When the flaw depth a was shallow with 0.4 in ratio of a to thickness t, the maximum load Pmax occurred at penetration of multiple flaws and the effect of vertical distance of non-aligned multiple flaws H on Pmax was not so significant. However, when flaw depth was deep with 0.8 in a/t, Pmax occurred after penetration of flaws and the effect of H on Pmax could be seen clearly. It was judged that the through-wall flaw tests were appropriate for discussion of the effect of H on Pmax and the alignment rule of multiple flaws. In addition, in order to clarify the appropriate length parameter to estimate Pmax of test specimens with dissimilar non-aligned through-wall multiple flaws, the fracture tests of plate specimens were also conducted. The effect of different flaw length on Pmax was discussed with maximum, minimum and averages of dissimilar non-aligned multiple flaw lengths. Experimental results showed that the maximum length lmax would be an appropriate length parameter to estimate Pmax, when the non-aligned multiple through-wall flaws were dissimilar.

Research on Quantitative Method and 3D Finite Element Analysis of Tank Bottom Corrosion Defect Leakage Magnetic Field

According to the principle of magnetic flux leakage testing and the finite element numerical simulation, 3D finite element model (FEM) for MFL testing of tank bottom was established. Through simulative analysis, influence law between defect size and defect magnetic flux leakage field and the relationship curve of defect leakage magnetic field change with its size was obtained. The result showed that: When the length vary with sequence, the peak valley length of defects leakage magnetic signal increase with the increase of defect length, the relationship curve between each other is approximate linear; When the depth vary with sequence, the relationship between peak valley height of defects leakage magnetic signal and defect depth is also approximate linear, but this relationship was different with different length; When the width vary with sequence, on the defect symmetry plane, the peak of magnetic flux density along the width direction corresponded with the defect edge, and the length of the two peaks were equal to the width of the defect. According to simulation data and theory of regression analysis linear regression equation and relation surface between defect length depth and the characteristic quantity of its signal was established, quantitative method of defects signal was also proposed. Then experimental study was carried out in the Laboratory, the result show that the quantitative size was consistent with the actual defect size.

Fatigue Crack Growth Behavior of Threaded Pipe Couplings

Threaded couplings are used in various applications to connect steel pipes. To maintain a secure connection, such couplings are preloaded and during service additional dynamic loads can act on the connections. The coupling’s threads act as stress raisers, initiating fatigue cracks, which can cause the connection to fail in time. Accurate knowledge of the fatigue behavior, taking into account crack initiation and propagation is necessary to understand the fatigue mechanisms involved. In this study, the fatigue behavior of tapered couplings with NPT threads is studied. This is done by analyzing the results of an experimental four-point bending test. The fatigue crack propagation is monitored using an optical dynamic 3D displacement measurement device and LVDTs to measure the crack opening. At certain times during the test, the load ratio is changed to apply a number of beach marking cycles. This way a fine line is marked in the fracture surface. These marked crack shapes are used as input for a finite element model. The measured deflection and crack opening are compared to the results of the numerical simulations. Using this methodology a distinction is made between fatigue crack initiation and propagation. By analyzing the fracture surface it was observed that once the crack is initiated, it propagates over a wide segment of the pipe’s circumference and subsequently rapidly penetrates the wall of the pipe. The observed crack growth rates are confirmed by a fracture mechanics analysis. Since the appearing long shallow crack is difficult to detect at an early stage the importance is demonstrated of accurate knowledge of the fatigue behavior of threaded connections in order to define acceptable flaw sizes and inspection intervals.

Application of RBI Method to Increase the Efficiency of Furnace B-1201 Belonging to ENAP Aconcagua Refinery, Chile

The Chilean company ENAP has a complex refining system in Conco´n, with important equipments like the furnace B-1201, belonging to the Hydrocracking Plant, and responsible for the partial conversion of vacuum gasoil into lighter products. This equipment works in a temperatures range between 300 and 400°C. During this process, the equipment is exposed to factors causing the decreased in its operative life and catastrophic failures. These results are reported as a decrease in equipment efficiency and significant financial loss. Energy costs represent 80% of operating costs. This paper presents an analysis of risk for furnace B-1201 in the superior limit of design for this equipment, to verify its current load behavior and the possibility of increasing its efficiency by 20% over the security level. Additionally there is the application of a new inspection system. The study applied is based on the RBI methodology, according to the API-580 and API-581, and was used the simulation software HTRI® as a support tool to obtain the maximum temperature of the furnace tube metal B-1201. Results are reported as comparative data analysis of probability of failure in the short and long term, risk matrix, and proposed plans for the various cases in study.