Anda di halaman 1dari 8

NUCLEAR ENGINEERING AND DESIGN 22 (1912) 318-325.

NORTH·HOLLAND PUBLISHING COMPANY

A METHOD OF COMPUTING STRESS RANGE AND


FATIGUE DAMAGE IN A NUCLEAR PIPING SYSTEM

Wallace B. WRIGlIT
Westinghouse Electric Corporation, Nuclur Energy Systems, PWR System« Division,
Pittsburgh. Pennsylvania l 5230, USA

and

Everett C. RODABAUGH
Battelle Memorial Institute. Applied MecharUc~Secrion. Columbus, Ohio 43201, USA

Received 10 January 1972

The ASME Boiler and Pressure Vessel Code, Section III (l9il) employs stress range and fatigue evaluation as
part of the total stress evaluation of piping systems. One method of computing this stress range and the resultant
fatigue damage using the basic equations of the Code is presented here. This method is then illustrated by examples
and discussed in detail

1. Introduction two stress transients, The technique of combining


stress ranges and computing fatigue damage in a
The ASME Boiler and Pressure Vessel Code, Sec- manner compatible with Article N"B3600 of the Code
tion III (1971) [l] ,is written as a guide to cover the is then illustrated by formula and a detailed compu-
following subjects: design, analysis, fabrication, erec- tation illustrating this formula.
tion, and inspection of nuclear components. The Code
.treats each of these subjects in separate sections.
The piping analysis section of the Code is written 2. Relation of plant operation to transient stress
to be used for the evaluation of primary, secondary,
and peak stresses at selected points in the piping sys- 2.1 . Plant operations relating to piping loading
tem, The secondary and peak (fatigue) stresses are Fig. 1 is an illustration of the operating cycles ex-
based on a stress range concept and a comprehensive perienced by a plant during its operational life. The
discussion of this subject may be found in the fore- numbers one through six on this figure represent op-
word of ref. 12J. The purpose of this paper is twofold; erating cycles that are hypothesized to be experienced
to present a method for computing stress range and, by the plant in a random manner during its operation-
in turn, using the stress range to compute fatigue allife.
damage. Number 1 in fig. 1 represents a .hydrotest operation-
To accomplish the stated purpose, this paperis al cycle on the plant piping that will occur J 00 times
divided into several sections. The first section discus- during the total life of plant operation. Number 2 re-
SC5 power plant operating transients and their effect presents a hypothetical earthquake that will occur
on stresses in a plant's piping system. The cyclic stres- five times with each occurrence having ten significant
ses in the piping system are then combined to give a vibrational cycles which will occur during plant shut-
range of stress as illustrated by a simple example of down, The sloping line that rises to number 3 repre-
W.B. Wright and t.e. Rodabaugh, Stress rrmge and fat/gue damage in nuclear piptworks 319

First, the values of temperature and pressure resulting


from the various plant operating cycles are presented
in the Design Specification (which is the basis for the
I analysis) as a series of time history plots. An example
of one of these plots is illustrated by fig. 2 which re-
presents operational cycle number 4 of fig. 1. Addi-
tionally, the seismic disturbance that may occur at
the plant site is defined in the Design Specification
as a set of response spectra to be used in computing
dynamic loads.
POSTULATED CONDITIONS
2.2. Stress transient history
Prior to the evaluation of metal fatigue from stress


Fig. 1. Plant hypothetical operating history.
caused by the plant operational cycles it is instructive
to examine three possible types of plant stress history,
sents plant startup and the leveling off at number 3 each resulting from a separate type of operational
indicates steady state operation. There are 60 of these cycle.
startups which are one-half of the total operational First, examining fig. 2 note that it illustrates an
start up-shutdown cycle. The surge up and down and appropriate sine wave response of one cycle duration.
back to normal operation at number 4 represents a Superimposed on the plant transient is the stress time
turbine trip that occurs 38 times. The sharp slope to history at a point in the piping system that is shown
number 5 and return to normal operation represents in fig. 3.
an overpressure of the system from which the plant Alternately, looking at an operational plant tran-
returns to normal operation and there are 13 such sient cycle (that includes both temperature and pres-
operational cycles in the plant's history. The slope sure} with the superimposed stress transient as shown
from number 6 to plant shutdown occurs sixty times in fig, 4, note that the plant operational cycle has the
and is the other half of the start up-shut down cycle. characteristic sine wave response arid consequently,
These operational cycles are assumed to represent the there is a stress response that takes the approximate
total plant hypothetical operating history. Associated form of the transient as before but now the stress
with this operating history will be a stress history of transient contains several stress cycles.
the plant. For illustrative purposes we will examine It is impractical to compute the total stress time
the stress history at one point in one of the plant's history of each instant in time, therefore, a judgment

e. main piping systems. is made as to maximum and minimum loads within the

z 300
g 100 r ".
•...
9

Lt
e
ii
4:
>
•...
'";:)
V> NORMAL
'"•...
IX
OPERATION
<1.
~ ·300

-
TIME

FiB- 2. Typical temperature-pressure MIpODSe to an operatiOnalcycle.


320 'W.E. Wright and E.C Rodfibaugh, Stress rrmge and fatigue dal1llllt. ill nuc/etll' pipeworks

NORMAL
OPERATION
PRESSUREJ
~J
I~MAtP
, OPERATION
~
/
L PLANT iRlI,lo,ISIENT

-TIME

Fig. 3. Stress transient superimposed on plant operational -


TIME


cycle.
Hg. 4. Stress transient superimposed on plant's multiple
operational cycle. In the first instance shown by fig. cycle. operating transient,
3 there is one maximum and one minimum value. In
the second instance shown by fig. 4 there are several terms will be used shortly in table 4 to identify stress
significant stress cycles, two maximum and two mini- values and the number of occurrences of various
mum. stress cycles as range-transient combinations are for-
A third possibility is that only one maximum and med.
one minimum value may exist, but Liley are embedded To best operate with these stress ranges they are
in the transient and are not readily discernable. This reordered in descending value and are presented by
third type of transient will be included and illustrated table 3.
by the detailed example on fatigue evaluation. A new table, table 4, is now constructed that as-
sociates the sequence number with its related number
of cycles by use of the letters i and [, The number of
3. Example of transient stresses converted to stress occurrences of each stress range is computed by de-
range termining the maximum number of times each set i,
j can occur in combination. From each of these max-
3.1 . Combining cyclic stress imum numbers of combinations, progressing from top
To illustrate the basic concept of combining stres- to bottom, one number (i or j) is eliminated and the
ses to establish the range of stresses and determining other is adjusted downward to represent the number

'e the number of stress cycles for fatigue evaluation a


first example involving two operational cycles will be
used. Assume for the discussion in this section that
of times it can now form in new combination with
other i,j values. There is an orderly progression of
reducing the number of cycles until they have each
the maximum and minimum stress associated with formed in combination with others until all Significant
the two operational cycles is known. The stress values
and number of cycles are presented by table 1 with
the maximum and minimum stress values assigned a
number for bookkeeping purposes. Table 1
To establish the range of stress between the several Maximum and minimum cyclic stress values.
values given in table 1 a computation of stress differ-
set ,
ences is made by subtracting combinations of stress as
shown by table 2. This table introduces the notation
i and i in the column "Number combination". The in-
t,
Openltional
cycle
11\ \ 0 \ ~eiX
Number

1
Stress
(psi)

15000
Number of
cycles of
occurrence

1000
dividual i and j values permit a record to be kept dur-
2 60000
ing computation as the values of stress are formed in 2 3 3S 000 10000
all possible combinations. Additionany. the i andj 4 10000
w,e. Wright and E.C. Rodabaugh, Stress !'ange and fatigue damt1gt in nuclear pipe works 3:21

Table 2
Stress ranges. Stress ranges !~~magnitude.

Number Stress range Number Stress range


combination (Absolute values) combination (Absolute values)

i j i i
1-2 4S 000 2-4 50000
1-3 20000 1-2 45000
1 ~4 S 000 2-3 2S 000
2-3 25000 3-4 25000
2-4 50000 1-3 20000
3-4 25000 1-4 SOOO

• combinations are eliminated. The combination of


maximum possible stress ranges will form a conser-
vative approximation of the usage factor because
this method gives "worst" combinations of stress
cycles.
Sn
PoDo
= Cl2J"
DO

+ C3EablQ:aTa

and peak stresses are computed by:


I
+ C22i Mi + 2(1-11) EQ:!aT 1 !

- Q:bTbl (10)

S v C PoDo K C Do MIl' t: . T
4. Detailed computation of loads to give stress range
. p ::::Al 1-.,-+
_t
2 2--::;-/'
•..
i + ')t'l _. fi3(.;;Q:IA11
•• - •..)
and fatigue evaluations
+ 1~1I E~i~T21+ K3C3EablCXaTa - ClbThl, (J 1)
4.1. Computation of stress range using equations of
ASME Section III ( 1971) where:
Section NB 3650 of Section III (l971) presents C1• C2• C3 ::::secondary stress indices for the specific
the equations for computing secondary and peak component under investigation,
stresses. These equations are repeated here for com- K l' K 2, K 3 = peak stress indices for the specific com-
pleteness, Secondary stresses are computed by: ponent under investigation,

Table 4
Sequence and number of occurrences of stress ranges.

Number Stress Number of Number of Number of Comments


combination range transients occurrences occurrences
of stress range of transient left

i j i j i j
2-4 50000 1000 10000 1000 2-none 4-9000 2 has formed in max-
imum number and is
eliminated
1·2 45000 1000 1000 0
2-3 25000 1000 10000 0
3-4 25000 10000 9000 9000 3-1000 4-none 4 has formed in max-
imum number and is
eliminated
1- 3 20000 1000 1000 1000 1-none 3~nQne 1 and 3 have formed
in maximum number
and are eliminated
322 W.B. Wright and £.C. Rodabaugh. Stress range and filtigue ikmllge in nu clear pipeworks

Po •• range of operating pressure [psi],


Do = outside diameter of pipe [in]
t = nominal wall thickness of component The '" denotes the pivotal value and the subscript j
{in] • denotes the values that are formed in combination
I = moment of inertia [in4]. with the pivotal value.
Mi = range of moment loading [in=Ib] , For the fatigue evaluation that follows, the load
J.I :: Poisson's ratio =0.3, values given in table 5 will be used in combination
Ea. = modulus of elasticity (E) times the with constants that represent the product terms in
mean coefficient of thermal expansion eq. (11 lit). The value of these product constants is
(0:) [psitF], taken to be:
tJ.T} :: range of absolute value (without regard
to sign) of the temperature difference K1C1DO!(2t) = 20.773,


assuming moment-generating equivalent K2C2Do/(2I) = 3.071,
linear temperature distribution [OF}, K3Eo:/2(I-IJ) = 520.714,
aT 2 = range of absolute value (without regard Eaf(1-v) = 347.143.
to sign) for that portion of the nonlinear
thermal gradient through the wall thick- 4.2. Fatigue damage
ness rF], One method of evaluating fatigue damage in a struc-
Eab :::the average modulus of elasticity of the ture is by use of the theory of Linear Cumulative Dam-
two parts of the gross discontinuity [psi], age (LCD), the method adopted by Section III. This
(ka = mean coefficient of expansion of side a theory was first proposed by Palmgren [3] and
of a gross discontinuity [in/in "F] , Langer [4 J and subsequently adapted to structures by
Ta :: range of average temperature on side a Miner [5].
of a gross discontinuity [OF], In other words, this theory states that a random
~ :: mean coefficient of expansion on side b series of stress cycles of variable amplitude contributes
of a gross discontinuity [in/in "Fj, to the fatigue damage of a structure in a linear manner.
Sm :: allowable stress [psi], Therefore, if a stress range, S r- occurs 71} times but
Sn :: primary plus secondary stress range [psi], could occur Nl times, then the contribution of Sl to
Sp = peak stress range [psi]. the fatigue damage is computed by taking the ratio
Examination of these two equations, (J 0) and (11), nl/Nl . The value of Nl comes from the Code's SIN
show the variables Po, Mi, ~Tl' Ta and Tb are com- cyclic stress fatigue curve. Similar stress-fatigue-eval-
mon to both equations. Their stress values vary only uations may be made for each stress range (S) from 1
by a constant (K) value. Additionally, eq, (I 1) has a to k and the sum of the ratios of "j/Nj produces the
!)'T2 term which is similar to ~Tl for determining total LCD of the piping system at a point. This total
stress ranges. Therefore, we may discuss stress range summation is to be equal to or less than 1.0. Sym-
using eq. (11) and this discussion will be applicable bolically this may be written
to eq. (10). k
For the stress range computation eq. (H) is modi-
fied to read: LCD = E nlNt~ 1.0,
i= I -

where the summation is over the repeated index i, The


value of the upper limit of the summation,' k, repre-
sents the number of combinations of stress resulting
(M; - Mxj)2 + (My - My}2 + (Mi - Mtj)2]ll'2. from plant operating transients.

K3ECi Eo: , 43. Structural load history to stress evaluation


+ 2(I-v)I11- Tijl + (I-v) !Ti - T2j! We are now in a position to begin the evaluation of
W.B. WrighT and E. C. Rodabaugh, Stress range and fanglif; damage in nuclear pipe works 323

Table 5

lOf-Ct EPl V\ \ \ 0 Components of loading at a selected point in a piping system resulting


from the operation cycles.
~e. , \bdeX
Sequence Operational Number of Mx M M: p AT} AT2 Ea(Ta-Tb)
numbet cycle cycles [in-Ib] !~-lbJ [in-lb} {psil [OF] {OFI (psi)

1 (1) 100 0 0 0 0 0 0 0
2 500 300 -400 2000 0 0 0
3 (2) so 1000 500 750 0 0 0 0
4 -1000 -SOO -750 0 0 0 0
5 (3) 60 0 0 0 0 0 0 0
6 8000 6000 -1700 1000 32 18 0
7 (4) 38 8500 6300 -1800 1900 60 38 0
8 8900 6400 -11!9O 2000 63 41 0


9 7500 6000 -1000 1700 -60 -38 0
10 500 6300 -1800 1900 25 14 0
11 (5) 13 10000 BOOO -2000 2300 90 120 0
12 8500 6300 -1800 1900 -90 -120 0

.
secondary and peak loads, the resulting stress ranges . .. ,2-12 are formed in combination, then 3-4, ... ,
and the fatigue damage in a manner compatible with 3-12, etc. until the total of 11+10+9+ ... +1=66 stress
Section III (1971) definitions. The series of loads reo combinations has been formed.
sulting from the various operational cycles are corn- Due to the large amount of computation required,
puted and put in tabular form (see table 5) for a se- the calculations of stress combinations were made by
lected point in the piping system. The selected point computer with the results noted in table 6. The full
for this set of computed loads is not at a gross discon- set of information is presented in table 6 to establish
tinuity, therefore, the value in the right-hand column a maximum stress range for a transient and each range
of table 5 is zero. is the maximum value denoted in a particular compu-
The first column in table 5 is numbered from I to ter pass.
12 for convenience in identifying the loads during se- In this example, 11 and 12 happen to be the maxi-
lected times in the various operational cycles. The op- mum and minimum of the stress range of all com-
erational cycles (1), (2), (3), and (5) in table 5 each binations and they are both generated in the same
have a maximum and minimum value listed that re- transient. The next maxima and minima occur in com-
presents the extremum loadings of each operational bination of the second and the fourth transient, se·
cycle. The operational cycle (4) is a notable exception quence numbers 4 and 8. This operation then contin-
to the above. This operational cycle is complex enough ues through a total of eight computer passes, as noted
in loading that it is not possible to pick a clear cut set in table 6.
of extreme loading values, hence this complex opera- An interesting consequence of making the judgment
tional cycle is judged to require four separate loads in that more than two (actually an infinite number of
time to be representative of the operating cycle. These loading occurs) significant points of loading occur
win be formed in combinations with other loads des- during a plant operational cycle is.that intermediate
cribed by the sequence number. Their sequential com- load points may contribute to cyclic fatigue.
bination is arbitrary, but they are limited in number For example, we have four load sets that have been
to 38 cycles for any sequence number (7) through (to) calculated for transient number 4. However, this tran-
and a total of 76 cycles of stress for any combination. sient will occur 38 times. Therefore, in this transient
The loads associated with the sequence numbers are we can have 38 minimum ami 38 maximum stress
formed in combination 1-2, 1-3,1-4, ... ,1-12 values. Which 76 of the 152 (4 X 38) cycles that we
using eq. (II·) to give stress values for each combina- have listed in this transient do we use? The answer to
tion.ln turn the sequence numbers 2-3,2-4,2-5, this question must come from the detailed analysis by
324 w'B. Ji.'right and E. C Rodllbaugh. Sire$!! rtlftgt and fatigue dDmage in nuclear pipeWOl'k$

Table 6 Computer pass No.6


Results of computer search for
1-2 43720
maximum stress range combinations.
2-3 45450 < < < 5CYv
3-4 4130
Number* combination Stress range Cycles
Compu ter pass No. 1
Computer pass No.1
1-11 116 100
1-2 43720 < < < 14"v
2-3 43120
2-11 132 600
3-11 173300
Computer pass No.8
4-11 119200
5-11 176100 1-2 43720«< 36"-
6-12 115300
1-12 133 QOO '"Reordering the number combinations from one computer


8-12 138900 pass to the next to reflect updating means no correspondence
9-11 155700 exists in the numbering between computer passes.
10-12 131000
11-12 192300 < < < 13"-
forming all possible combinations of loads. At this
Computer pass No.2 point it suffices to say that, of the four conditions, we
1- 8 122100 must exercise care not to use anyone value of stress
2- ,8 79250 over 38 times and no combination of stresses from the
3- 8 119900 total loads of this transient over 76 times.
4- 8 125 SOO << < 38"- ~
S- 8 122700
6- 9 72 060
4.4. Fatigue evaluation
7- 9 97060 Table 7 presents the final results of maximum stress
8- 9 102900, ranges shown in table 6 plus the individual usage fac-
9-10 88120 tors. These usage factors were computed assuming
stainless steel material and the fatigue curve for this
Computer pass No.3
metal from ASME Section III (I 971) was applied.
1-7 116900
As an interesting sidelight note that a summation
2-8 78450
3-7 114100 of the number of cycles in table 5 is 26]. When ranges
4-7 119900 <<< 12"- are formed in table 7 and the number of cycles sum-
5-7 116900 med the value is 249. This clearly indicates the vari-
6-8 72060 anee that may exist between operational cycles and
7-8 97060
stress cycles.
8-9 88120

Computer pass No.4 Table?


1-6 116900 < < < LCD computation from suess ranges.
26"- ~
2-1 78450
Number Strell Deslgn Operating LCD
3-6 114100
4-6 116900 combination range cycles cycles value
5-7 72 060
IV; "i
6-7 97 060
7-8 88120 11-12 192300 188 13 0.0691
4- 8 125 SOO 648 38' 0.0586
4- 7 119900 752 12 0.0160
Computer pass No.5
1- 6 116900 815 26 0.0139
I-S 91450 < < < 6O'\t 1-5 91450 1816 60 o.osso
2-5 S6270 2- 3 4S 450 29250 50 0.0017
3-5 88660 1- 2 43720 35280 14 0.0004
4-5 91450 1- 2 43120 35280 U 0.0010
W,s.. Wright and E. C Rodabtrugh. StresS rangf and fatigue damagf in nuclear plpeWOl'ks 325

s. Summary house Nuclear Energy Systems for generating the com-


puter code necessary to make the detailed logical com-
Two examples of transient loading at a point in a putation presented here.
piping system have been presented. The first was a
simple example to illustrate the concept of transients
forming in combination to produce stress ranges.The References
second example dealt with more complex transients
and included the use of eq. (11*). This second exam- 11 J Nuclear Power Plant Components. ASME Boiler and Pres-
ple then used the results of eq. (11-) to compute the sure Vessel Code, Section III, 1971, published by the Am-
linear cumulative damage (LCD). erican Society of Medtanical Engineers, N.Y .• N.Y.
[2] Nuclear Power Piping, ANSI B31.7, 1969. published by
The method of computing LCD uses the hypothe- the American Society ofMecha!uca! Engineers, N.Y., N.Y.
sis of linear damage causing fatigue failure for a ran- P} A. Palmgren, "Die Lebenadauer von KugeUagem, Ver.
dom series of stress cycles. deut. lngenieure 14 (l924} 339.

t Acknowledgement
[4] B.F. Langer, Fatigue Failure from Stress Cycles of Varying
Amplitude, Trans. ASME S9 (1937) AlSO.
(5) M.A. Miner. Cumulative Damage in Fatigue, J.A.M. 12
(September, 1945) A159.

The authors thank Mr. Tom Williams of Westing-

Anda mungkin juga menyukai