International Journal of Pressure Vessels and Piping 78 (2001) 69±83

www.elsevier.com/locate/ijpvp

Methodology for the pressurized thermal shock evaluation: recent

improvements in French RPV PTS assessment
D. Moinereau a,*, G. Bezdikian b,1, C. Faidy c,2
a
Electricite de France, Research and Development Division, MTC Department, Site des RenardieÁres, Route de Sens, 77818 Moret-sur-Loing cedex, France
b
Electricite de France, Generation and Transmission Division, EPN, Cap AmpeÁre, 1 place Pleyel, 93207 Saint-Denis cedex, France
c
Electricite de France, Engineering and Construction Division, SEPTEN, 12±14 avenue Dutrievoz, 69628 Villeurbanne cedex, France
Received 18 July 2000; revised 20 December 2000; accepted 30 January 2001

Abstract
An extensive work was conducted in France related to the structural integrity re-assessment of the French 900 and 1300 MW reactor
pressure vessels in order to increase their lifetime. Within the framework of this programme, numerous developments have been imple-
mented related to the methodology used for the assessment of ¯aws during a pressurized thermal shock (PTS) event. This extensive work
includes the development of new simpli®ed approaches, with their validations by two-dimensional (2D) and three-dimensional (3D) ®nite
element computations, the development of 3D elastic and elastic±plastic analyses, and ®nally the evaluation of the in¯uence of the stainless
steel cladding in a PTS analysis.
A new simpli®ed methodology Ð based on an elastic approach including a speci®c plasticity correction (b correction) taking into account
the cladding yielded during a severe PTS transient Ð has been developed for the assessment of shallow subclad ¯aws, derived from 2D
elastic and elastic±plastic computations. This new approach is described and compared to results obtained by reference 2D and 3D ®nite
element elastic and elastic±plastic computations. This methodology is validated with reasonable margins and a suf®cient level of accuracy.
A similar work has been conducted related to the assessment of embedded shallow ¯aws located in the ®rst layer of the stainless steel
cladding. A new approach has been proposed, more realistic and less conservative than the methodology previously used for this kind of ¯aw.
These two methodologies have been accepted by the French Safety Authority and are now used in the RPV structural integrity assessment
in progress.
Some 3D ®nite element analyses have been also performed in order to study the behaviour of several cracks (shallow subclad ¯aws and
through-clad surface cracks) in a French RPV during a severe overcooling transient. Several through-clad surface cracks have been compared
to shallow subclad ¯aws located at the cladding±base metal interface, and the in¯uence of cladding in a PTS has been evaluated. The main
results are presented. A RPV structural integrity assessment based on through-clad surface cracks appears much more severe than the speci®c
French approach based on more realistic shallow subclad ¯aws. The in¯uence of the cladding is particularly signi®cant on the margins,
regarding the risk of cleavage initiation along the crack front in the base metal of the vessel, by signi®cantly decreasing the level of the stress
intensity factor and consequently increasing the maximum allowable end-of-life RTNDT. q 2001 Elsevier Science Ltd. All rights reserved.
Keywords: RPV; Pressurized thermal shock analysis; Cladding; Flaws; Fracture mechanics; Three-dimensional ®nite element computations

1. Introduction according to the reference codes and standards applied in

The innocuity of ¯aws, such as surface or embedded
cracks, has to be demonstrated in a RPV structural integrity
assessment, particularly in case of severe overcooling pres-
surized thermal shocks (PTS). Several approaches are used
around the world, which can be similar in several aspects,
* Corresponding author. Tel.: 133-1-60-73-67-90; fax: 133-1-60-73-65-
59.
E-mail addresses: dominique.moinereau@edf.fr (D. Moinereau),
georges.bezdikian@edf.fr (G. Bezdikian), claude.faidy@edf.fr (C. Faidy).
1
Tel.: 133-1-43-69-38-48; fax: 133-1-43-69-34-82.
2
Tel.: 133-4-72-82-72-79; fax: 133-4-72-82-76-99.
0308-0161/01/$ - see front matter q 2001 Elsevier Science Ltd. All rights reserved.
PII: S 0308-016 1(01)00023-0
the RPV PTS assessment (ASME in the USA, RCCM in
France, KTA in Germany). These approaches can also be
different in some aspects, like ¯aw size, ¯aw location, role
of cladding and safety margins.
The French approach for RPV PTS assessment is de®ned
in the RCCM code [1]. This approach is very speci®c, by
taking into account some realistic ¯aws (located in the
cladding or in the base metal) and the role of cladding in
the structural integrity analysis (both on thermal and
mechanical aspects) [2±5]. The RPV structural assessment
is mainly based on the use of simpli®ed methods (`engineer-
ing approach') instead of a more sophisticated approach
70 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83

such as three-dimensional (3D) ®nite element elastic±

plastic computations.
An extensive study has been conducted in France related
to the PTS re-assessment of 900 and 1300 MW reactor
pressure vessels in order to increase their lifetime. Within
the framework of this programme, numerous developments
have been performed related to the methodology used for
the assessment of ¯aws during a PTS event. It includes the
proposal of new simpli®ed approaches with their validations
by two-dimensional (2D) and 3D ®nite element com-
putations, the development of more sophisticated analyses
(based on 3D elastic and elastic±plastic analyses), and
®nally the evaluation of the in¯uence of the cladding in a
PTS analysis.
The main results deduced from this work are summarized
in the present paper.

2. A few words about previous French RPV PTS

assessment

2.1. A speci®c RPV PTS assessment methodology

As previously indicated in the introduction, the French

RPV PTS assessment methodology is very speci®c, with the
main following characteristics: Fig. 1. Reference defects for vessel beltline (dimensions in mm).

² a deterministic approach based on the computation of the

stress intensity factor and its comparison to the material
fracture toughness (KIc for the base metal, KJc for the
cladding);
² the taking into account of realistic ¯aws (size and
location), based on manufacturing and in-service inspec-
tions, located in the cladding or in the base metal of the
vessel (Fig. 1);
² the taking into consideration of the stainless steel clad-
ding in the structural integrity assessment, both on ther-
mal and mechanical computations;
² the use of a generic simpli®ed approach based on 1D or 2D
®nite element computations, instead of more sophisticated
analyses (such as 3D ®nite element computations);
² a same generic simpli®ed approach for the embedded
¯aws, whatever their location in the vessel (subclad
¯aw, ¯aw located in the ®rst layer of the cladding).
This methodology is described in the French RCCM code
[1]. More details can also be found in several papers and
reports [2±5].
factors. Some additional plasticity corrections are applied
to the pure elastic stress intensity factor in order to take into
account, plasticity at the crack tips (Irwin correction) and
cladding yielding (b correction) due to the PTS event.
The elastic stress intensity factor KI is calculated at
each crack tip A, B (embedded ¯aws) (see Scheme 1,
showing a subclad crack) in a ®rst step with 2D ®nite
element computation, using the G energy release rate or
thep
nodes displacements.
 The IRWIN correction …Kcp ˆ
KI …2a 1 ra 1 rb †=2a† is then applied to take into
account plasticity at the crack tips:
r
2a 1 ra 1 rb
Kcp ˆ KI
2a
with 2a, crack depth (embedded ¯aw); ra, plasticity
correction-clad side; rb, plasticity correction-base metal
side; ra and rb obtained by: r ˆ 1=6p…KI =s y †2 ; s y, yield
strength of the corresponding material.
Due to cladding yielding which can be non negligible, the
Irwin correction is not suf®cient as soon as the plastic zone

2.2. An engineering approach based on linear elastic

analyses with additional plasticity corrections

The French RPV PTS assessment methodology is deter-

ministic, based on the computation of the elastic stress
intensity factor KI at the crack tips (for an embedded ¯aw)
and its comparison to the material fracture toughness KIc
(for the crack tip in base metal), including some safety Scheme 1.
 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83 71

Fig. 2. Thermal transient on a cladded vessel containing a shallow subclad ¯aw. Comparison between elastic (Kcp with b correction) and elastic±plastic (KJ)
stress intensity factors at the crack tip in base metal.

at the crack tip reaches a notable proportion of the thickness of the component). Within this framework,
remaining ligament. So, a second additional correction numerous elastic±plastic computations have been
(b correction) is applied: performed and compared to the elastic approach with the
r plasticity corrections, including several geometries and
2a 1 ra 1 rb loadings.
K cp ˆ aKI
2a For embedded ¯aws located under the cladding (subclad
a is a coef®cient depending on the plastic zone radius (ra or ¯aws) and whatever the type of loading, these comparisons
rb) and the remaining ligament value b between the crack tip between the stress intensity factors deduced from the elastic
and the surface. This coef®cient a is determined by: analyses (Kcp) and the elastic±plastic analyses (KJ) show
8 that the elastic approach with plasticity corrections is
<1
> if r , 0:05b always very conservative compared to an elastic±plastic
 2
aˆ r 2 0:05b approach as soon as the cladding yielding occurs
>
: 1 1 0:15 if 0:05b , r < 0:085b
0:035b (Kcp . KJ) [5±7]. This conservatism is due to the b correc-
tion previously de®ned being too strong as soon as the
When the condition r ˆ 0:085b is exceeded, a is the lowest plastic zone at the cladding side crack tip reaches a notable
of the value given by the above expression and the limiting proportion of the remaining ligament. This b correction is
value 1.6 according to the following expression: however necessary because elastic approach only, is not
8 suf®cient and can greatly underestimate the crack opening
< 1:6
>
  in the base metal when plastic straining of the cladding
a ˆ min r 2 0:05b 2
>
: 1 1 0:15 occurs, the Irwin correction alone is not suf®cient:
0:035b
r
As mentioned earlier, the approach is the same for all kinds 2a 1 ra 1 rb
Kcp ˆ KI , KJ
of embedded ¯aws, whatever their location (cladding or 2a
base metal).
This excessive conservatism of the elastic approach with
2.3. A very conservative approach for embedded ¯aws plasticity corrections is clearly illustrated by the two
examples shown in Fig. 2 (thermal transient on a cladded
The validity and the corresponding conservatism of such vessel containing a shallow subclad ¯aw) and Fig. 3
an approach has been evaluated in detail, by comparison (cladded specimen with a shallow subclad ¯aw under a
with a reference approach based on 2D elastic±plastic ®nite four point bending test).
element analyses (in this case, the elastic±plastic stress The same conservatism is noticed for the analysis of
intensity factor KJ is deduced from the numerical com- embedded ¯aws located in the ®rst layer of the cladding
putation of the G energy release rate by the well-known
p [8]. This aspect will be discussed in more detail in
plane strain formula: KJ ˆ …EG†=…1 2 n2 † due to strong Section 3.
72 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83

Fig. 3. Cladded specimen with a shallow subclad ¯aw submitted to a four point bending loading. Comparison between elastic (Kcp with b correction) and
elastic±plastic (KJ) stress intensity factors at the crack tip in base metal.

3. New engineering methods for assessing shallow b depending on the ryA =b ratio (plastic zone size ryA at the
embedded ¯aws crack tip in cladding divided by the remaining ligament b in
cladding). The corrected elastic stress intensity factors Kcp at
To reduce the conservatism and improve the level of the crack tips A (cladding) and B (base metal) (embedded
accuracy of this RPV PTS assessment methodology, some ¯aw) are given by the following expressions:
signi®cant developments have been made, leading to new For an increasing loading …dKI =dt . 0; KI # KI max†
proposals of engineering methods related to the assessment At the crack tip A in cladding
of embedded ¯aws [9±11]. This work has been performed
A
by Electricite de France (EDF) and FRAMATOME within Kcp ˆ bA KIA
the framework of the studies in progress, related to the
French 900 MW RPV structural integrity re-assessment with bA ˆ 1 1 0:3 ‰tan h…36ryA =b†Š
[12±14]. At the crack tip B in base metal
B
Kcp ˆ bB KIB
3.1. Assessment of shallow subclad ¯aws (Scheme 2)
with bB ˆ 1 1 0:5 ‰tan h…36ryA =b†Š
3.1.1. A new plasticity correction in the elastic approach
For a decreasing loading …dKI =dt , 0; KI # KI max†
(b correction)
At the crack tip A in cladding
Based on numerous 2D ®nite element computations
involving mechanical (cladded specimens in bending or A
Kcp ˆ KIA 1 …bA max 2 1†KIA max
tension) and thermal loadings (cladded vessels under a
PTS event), a new plasticity correction has been developed with bA ˆ 1 1 0:3 ‰tan h…36ryA =b†Š
for the elastic analysis of embedded subclad ¯aws [9±11]. At the crack tip B in base metal
This correction (b correction), applied to the elastic stress B
intensity factor KI, is based on the calculation of a parameter Kcp ˆ KIB 1 …bB max 2 1†KIB max

with bB ˆ 1 1 0:5 ‰tan h…36ryA =b†Š

For each crack tip (A or B), this proposal can be

summarized by:

(
b KI if KI # KI max and dKI =dt . 0
Kcp ˆ
Scheme 2. KI 1 …b max 2 1†KI max if KI # KI max and dKI =dt , 0
 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83 73

Fig. 4. PTS transient on a cladded vessel containing a shallow subclad ¯aw (4.2 mm). Comparison between elastic (Kcp with b correction) and elastic±plastic
(KJ) stress intensity factors at the crack tip in base metal.

KI max and b max are the maximum values of the elastic
stress intensity factor KI and the correction coef®cient b
during the loading at each crack tip (A or B). In contrast
to the previous plasticity corrections (see previous section),
the Irwin correction is not taken into account in this new
proposal. The maximum values of the b parameter are 1.3
for the crack tip A (near cladding) and 1.5 for the crack tip B
(base metal). These values are less than the previous value
of b correction (b # 1.6).
3.1.2. Validation of b plasticity correction by comparison
with 2D elastic±plastic computations
To validate this new proposal of plasticity correction,
complementary ®nite element computations have been
performed including 2D elastic (KI and Kcp) and elastic±
plastic computations (KJ), taking into account several
geometries and loadings [9±11]. The elastic stress intensity
factors (KI and Kcp) have been compared to the reference
elastic±plastic stress intensity factors (KJ) in each case.

Fig. 5. PTS transient on a cladded vessel containing a shallow subclad ¯aw (12.2 mm). Comparison between elastic (Kcp with b correction) and elastic±plastic
(KJ) stress intensity factors at the crack tip in base metal.
74 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83
Scheme 3.
Whatever the type of loading, these comparisons between
the stress intensity factors deduced from the elastic analyses
…Kcp ˆ bKI † and the elastic±plastic analyses (KJ) show
that the elastic approach with the new b plasticity
correction is always conservative compared to the elas-
tic±plastic approach as soon as the cladding yielding
occurs …Kcp . KJ † and more accurate that the previous
plasticity corrections  based on the b parameter Kcp ˆ
p
aKI …2a 1 ra 1 rb †=2a: Some examples of validation are
shown in Fig. 4 (4.2 mm subclad ¯aw in RPV) and
Fig. 5 (12.2 mm subclad ¯aw in RPV).
These comparisons show also that the previous b
correction, always very conservative during the increas-
ing part of the loading …Kcp …a† . Kcp …b† . KJ †; was not
necessarily conservative during the decreasing part of
the loading, as in the case of a PTS transient …Kcp …a† ,
KJ , Kcp …b††:
3.1.3. Validation by comparison with reference 3D elastic±
plastic computations
Most of the defects taken into account in the French PWR
structural integrity assessment are modelled by ellipses
(Fig. 1) [2]. For this kind of subclad defect, the elastic stress
Fig. 6. Analysis of a 4 mm subclad ¯aw in RPV. Comparison between the 3D elastic-approach (KJ) and the simpli®ed elastic approach (Kcp with b correction).
intensity factors KIA (near the interface with cladding) and
KIB (deepest point in base metal) can be easily calculated
according the following expressions based on the elliptical
correction factors fA and fB taking into account the elliptical
shape of the defect [3]:
KIA ˆ fA FA K 0I A
KIB ˆ fB FB K 0I B
K 0A 0B
I and K I are the stress intensity factors for the strip in an
in®nite plate loaded by the stress distribution existing in the
trace of the crack in the uncracked vessel (according to the
superposition method). FA and FB account for the effect of
the proximity of the free surface for a strip in plane strain
under a uniform tensile loading, and are given by the stress
intensity factors handbooks. Afterwards, the b plasticity
correction is applied to obtain the ®nal stress intensity
A B
factors Kcp and Kcp according to the methodology
previously described.
The validity and the accuracy of this simpli®ed elastic
approach has been evaluated on a typical geometry of a
French 900 MW RPV by comparison with a reference
approach based on 3D elastic±plastic ®nite element com-
putations. Three subclad ¯aws have been taken into account,
a ®rst one with depth a ˆ 4 mm and width 2c ˆ 60 mm; a
second one with depth a ˆ 6 mm and width 2c ˆ 60 mm;
and a third one with depth a ˆ 12 mm and width 2c ˆ
72 mm: The loading is a typical PTS transient correspond-
ing to a 3 inch break in the primary circuit and the
materials properties are the same as data used in the
French 900 MW PWR structural integrity assessment
in progress [9,15,16].
The assessment of the three different ¯aws is performed
 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83 75

Fig. 7. Analysis of a 6 mm subclad ¯aw in RPV. Comparison between the 3D elastic-approach (KJ) and the simpli®ed elastic approach (Kcp with b correction).

using both the simpli®ed elastic approach with the b correc-
tion (considering an elliptical shape of each ¯aw) and the
3D elastic±plastic approach (considering a semi-elliptical
shape of the ¯aw with the same depth and width as the
corresponding elliptical crack) (Scheme 3).
Most of the details and results of analyses can be
found in papers [9,15,16]. Nevertheless, the main results
are shown in Fig. 6 (4 mm subclad ¯aw), Fig. 7 (6 mm
subclad ¯aw) and Fig. 8 (12 mm subclad ¯aw) with the
comparison Ð at the deepest point of the crack Ð between
the stress intensity factors deduced from the simpli®ed
elastic approach based on the b plasticity correction (Kcp)
and the 3D elastic±plastic approach (KJ). The RPV PTS
assessment methodology based on a simpli®ed elastic
approach with a unique b plasticity correction appears
conservative during all the transient in comparison with
the 3D elastic±plastic approach …Kcp . KJ † for the different
cracks. This conservatism seems reasonable.

Fig. 8. Analysis of a 12 mm subclad ¯aw in RPV. Comparison between the 3D elastic-approach (KJ) and the simpli®ed elastic approach (Kcp with b correction).
76 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83
Considering all these results, we can consider that the
methodology developed for the assessment of shallow
subclad ¯aws in RPV Ð based on an elastic approach
with a unique plasticity correction (b correction) to take
into account cladding yielding during a PTS event Ð is
well validated with a suf®cient level of accuracy compared
to a reference approach based on elastic±plastic calculations.
3.2. Assessment of embedded ¯aws located in the ®rst layer
of the cladding (Scheme 4)
Scheme 4.
Embedded ¯aws located in the cladding (particularly in
the ®rst layer of the stainless steel cladding) have to be taken
into account in the French RPV PTS integrity assessment.
Although the occurrence probability of such ¯aws is very
low, the assessment of these kinds of ¯aws is not necessarily
easy, particularly for the crack tip B located at the interface
between cladding and base metal. This is due to a fracture
mechanics methodology not necessarily well adapted.
3.2.1. Necessity to improve the methodology to reduce its
excessive conservatism
Due to the very small remaining ligament in cladding
(<3 mm) and strong cladding yielding induced by the
Fig. 9. Analysis of a 4.2 mm ¯aw located in cladding of a RPV. Comparison between the elastic approach (Kcp with b correction) and the elastic±plastic
approach (KJ) at the crack tip in base metal.
thermal loading, the elastic approach based on the a correction
(Section 1) Ð initially developed for the assessment of the
subclad ¯aws Ð appears to be extremely conservative for this
kind of ¯aw compared to an elastic±plastic approach [8]. This
conservatism is worst (higher) in this case (embedded crack
located in cladding) than for subclad ¯aws.
It can be easily shown in Fig. 9 with the 2D analysis of a
4.2 mm embedded ¯aw (4.2 mm ¯aw with 4 mm in cladding
and 0.2 mm in base metal in order to calculate the stress
intensity factor at this crack tip) located in the ®rst layer of
cladding of a PWR vessel (total thickness of cladding:
7.5 mm). The loading is a typical PTS transient correspond-
ing to a small break on the primary circuit. The comparison
between the elastic approach (based on a correction) and
the elastic±plastic approach is very clear for both crack tips
(in cladding and base metal), given higher values of the
stress intensity factor in the elastic approach due to Irwin
and b corrections …Kcp @ KJ †:
3.2.2. A new methodology proposed for the analysis of
embedded ¯aws located in the cladding
In the case of embedded ¯aws located in the cladding
(with a crack tip B at the interface between cladding and
base metal), very speci®c results are obtained in comparison
with the now well known case of subclad ¯aws, if results
just presented are examined with great care. When the ¯aws
are located in cladding with strong cladding yielding during
the loading, we notice that the elastic analysis, even without
some plasticity corrections, is still conservative compared to
the elastic±plastic approach, KI . KJ, for both crack tips A,
B (cladding and base metal) [8,9].
Using this important result, a new methodology has been
proposed for the analysis of embedded ¯aws located in the
 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83
®rst layer of cladding in RPV, based on the only use of the
elastic stress intensity factor without any plasticity
corrections [8,9]. We consider that a single elastic approach
based on the computation of the elastic stress intensity
factor KI without any plasticity corrections is still conserva-
tive and gives higher values of KI compared to the elastic±
plastic approach based on the computation of KJ(KI . KJ). It
is not necessary to apply in this case some additional plas-
ticity corrections, as in the case of subclad ¯aws where
opposite results are obtained (elastic approach without
plasticity corrections are non conservative compared to an
elastic±plastic approach, KI , KJ).
In the new methodology proposed for the assessment of
embedded ¯aws located in cladding of RPV, the RPV PTS
assessment of such ¯aws is based on the comparison of the
pure elastic stress intensity factor KI with the material
fracture toughness (KJc for the crack tip A in cladding, KIc
for the crack tip B located at the interface between cladding
and base metal). This approach presents two advantages:
®rstly, the elastic analysis is conservative and easier to
use than an elastic±plastic approach, secondly the use of
an elastic approach avoids speci®c problems to elastic±
plastic approaches with the computation of the elastic±
plastic stress intensity factor KJ during unloading (results
tend not to become path independent).
3.2.3. Validation of the methodology by 2D numerical
computations
In order to con®rm and validate the methodology
proposed for the assessment of ¯aws located in cladding,
several 2D elastic and elastic±plastic computations have
been performed using the EDF ®nite element programme
Code_Aster. The geometry taken into account is a typical
Fig. 10. Analysis of a 4.2 mm ¯aw located in cladding of a RPV. Comparison between the elastic approach (KI without plasticity correction) and the elastic±
plastic approach (KJ) at the crack tip in base metal.
77
French 900 MW reactor pressure vessel containing a
4.2 mm ¯aw located in the ®rst layer of cladding (4 mm
in cladding and 0.2 mm in base metal in order to calculate
the elastic and elastic plastic stress intensity factors KI and
KJ). The thickness of cladding and base metal are, respec-
tively, 7 and 200 mm. Two thermal transients have been
considered, a pure thermal transient without pressure
(decreasing of the temperature from 280 to 208C in 20 s)
and a severe representative PTS transient (corresponding to
a small break on the primary circuit).
Several types of mechanical computations have been
conducted, including notably:
² an elastic approach without any additional plasticity
corrections;
² an elastic±plastic approach without taking into account
the residual stresses in the vessel after the stress relief
heat treatment (SRHT) (main assumption, no residual
stress at the beginning of the transient);
² an elastic-approach including the SRHT before the PTS
transient (residual stresses are taken into account in this
case);
² a non linear elastic approach without taking into account
residual stresses.
In each case, the stress intensity factor has been calculated at
crack tips A and B (cladding and base metal).
Main results are presented in the reports [8,9] and some
results are shown in Figs. 10 and 11. All the results con®rm
the validity of the methodology proposed for the assessment
of embedded ¯aws located in the cladding. The elastic
approach, based on the computation of the elastic stress
intensity factor KI without any additional plasticity correc-
tions, is always conservative compared to other approaches
78 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83
Fig. 11. Analysis of a 4.2 mm ¯aw located in cladding of a RPV. Comparison between the elastic approach (KI without plasticity correction) and the non linear
elastic approach (KENL) at the crack tip in base metal.
(elastic±plastic and non linear approaches) and gives higher
values of the stress intensity factor (KI . KJ). For embedded
¯aws located in cladding, it is not necessary to apply an
additional plasticity correction, as in the case of subclad
¯aws where opposite results were obtained (elastic approach
without plasticity corrections are non conservative
compared to the reference approach based on elastic±plastic
computations, KI , KJ).
4. In¯uence of cladding in three-dimensional RPV PTS
assessment
In support to the French RPV re-assessment and the
corresponding development of engineering approaches,
several 3D analyses have been conducted Ð using the
EDF F.E. programme Code_Aster Ð including elastic and
elastic±plastic ®nite element computations whose partial
results have been described already in previous sections.
Two kinds of ¯aws have been studied, ®rstly of course,
some semi-elliptical shallow subclad ¯aws in order to vali-
date the methodologies which have been proposed for such
¯aws, and secondly some non usual surface cracks in order
to evaluate the role of the cladding in a PTS evaluation by
comparison with results obtained with the subclad ¯aws.
Most of the results can be found in papers [15±18]. Main
characteristics and results of these analyses will be shortly
summarized in this section.
This integrity assessment is based on the computation of
the elastic±plastic stress intensity factor KJ and its com-
parison to the fracture toughness KIc curve, both for
increasing and decreasing load paths (WPS). It is well
known that the values of the stess intensity factor KJ during
the decreasing part of the loading are not validated from a pure
theoretical point of view. However, these values have been
previously veri®ed to be path independent, at least in the main
part of the decreasing path of the loading. This practice is very
usual in RPV structural integrity assessments. This approach is
also conservative, compared with an approach based on the
comparison between the KIc fracture toughness curve and
the maximum value of the stress intensity factor.
4.1. Main characteristics of the three-dimensional analyses
4.1.1. RPV geometry, materials properties, loading and ¯aws
The RPV taken into account is a classical French
900 MW PWR vessel:
inner radius Rinner: 1992.5 mm;
wall total thickness: 207.5 mm;
cladding thickness: 7.5 mm.
The loading is a typical overcooling PTS transient
corresponding to a small break (3 in.) on the primary circuit.
The material properties are data used in the French 900 MW
RPV structural integrity assessment in progress [12±14].
Two kinds of ¯aws have been taken into account in these
computations, including shallow subclad ¯aws and through-
clad surface ¯aws:
² three semi-elliptical shallow subclad ¯aws
± 4 £ 60 mm ¯aw (depth a ˆ 4 mm and width
2c ˆ 60 mm)
 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83
± 6 £ 60 mm ¯aw (depth a ˆ 6 mm and width
2c ˆ 60 mm)
± 12 £ 72 mm ¯aw (depth a ˆ 12 mm and width
2c ˆ 72 mm);
² three semi-elliptical through-clad surface cracks
± 13.5 £ 81 mm ¯aw (depth a ˆ 13.5 mm and width
2c ˆ 81 mm)
± 25 £ 150 mm ¯aw (depth a ˆ 25 mm and width
2c ˆ 150 mm)
± 50 £ 300 mm ¯aw (depth a ˆ 50 mm and width
2c ˆ 300 mm).
4.1.2. Three-dimensional modelling of the vessel
The thermal and mechanical analyses are conducted
using a 3D modelling of the vessel. The 3D meshes,
generated using the GIBI and IDEAS mesh generating
tools, contain approximately 6000 elements and 20 000
nodes. For symmetry conditions, only 1/8 of the vessel is
modelled. The mesh re®nement is important near the crack
tip in order to obtain a good evaluation of the stress intensity
factor along the crack front. Some examples of meshes are
shown in Fig. 12 (subclad ¯aw) and Fig. 13 (through-clad
surface crack).
The 3D ®nite element analyses, including the thermal and
mechanical calculations, have been performed using the
Code_Aster ®nite element code developed by ElectriciteÂ
de France (EDF). For each geometrical con®guration, the
stress intensity factor (elastic KI and elastic±plastic KJ),
deduced from the calculation of the G energyprelease rate
by the classical plane strain formula K ˆ …EG†= 1 2 n2 due
to the strong thickness of the component, is calculated along
the crack front in the base metal and compared to the base
metal fracture toughness KIc (derived from KIc fracture
toughness curve given by RCC-M code [1]).
Fig. 12. Three-dimensional mesh of a cladded vessel containing a 6 mm subclad ¯aw.
79
4.2. Main results related to the subclad ¯aws
All the results are presented in details in the papers
[15,16]. However, it is possible to highlight the main
conclusions deduced from the 3D analysis of the three
subclad ¯aws:
² In the case of such ¯aws, a strong evolution of the elastic
(KI) and elastic±plastic (KJ) stress intensity factors (SIF)
is noticed along the crack front. The maximum values of
the SIF KI and KJ are always obtained at the deepest point
of the crack (F ˆ 908) after about 1600 s.
² In the case of subclad ¯aws, a pure elastic approach with-
out any additional plasticity correction is non conserva-
tive compared to an elastic±plastic approach (KI ! KJ)
due to the cladding yielding during the transient. The
cladding yielding leads to a strong increase (<20±
40%) of the elastic±plastic SIF KJ compared to the
pure elastic SIF KI. The necessity of a plasticity correc-
tion in an elastic approach regarding the assessment of
subclad ¯aws in a PTS evaluation, such as b plasticity
correction, is thus justi®ed.
² The allowable RTNDT have been evaluated from the 3D
elastic±plastic analyses by comparison between the SIF
KJ and the base metal fracture toughness KIc (with differ-
ent assumptions on the RTNDT). By taking into account
the expected end-of-life (EOL) RTNDT for French
900 MW RPV (778C , EOL RTNDT , 868C, [12,13]),
there is no risk of crack initiation by cleavage in base
metal along all the crack front during the transient. The
`theoretical' margins regarding the cleavage initiation are
very comfortable:
± no risk of initiation for the 4 £ 60 mm subclad ¯aw
whatever the RTNDT;
80 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83

Fig. 13. Three-dimensional mesh of a cladded vessel containing a 13.5 mm deep through clad surface crack.

± risk of initiation only for very high RTNDT
(RTNDT < 1658C) for the 6 £ 60 mm subclad ¯aw
(Fig. 14);
± risk of initiation only for RTNDT . < 1078C for the
deepest subclad ¯aw (12 £ 72 mm) (Fig. 15).
² The lowest margins are always obtained during the
decreasing of the SIF KJ. The cleavage initiation would
thus not occur due to the warm pre-stress (WPS) effect if
taken into account.
² The simpli®ed approach developed for the assessment of
the subclad ¯aws, based on the b plasticity correction, is
validated by comparison to the 3D approach (Figs. 6±8).

Fig. 14. Comparison between the elastic±plastic stress intensity factor KJ and the base metal fracture toughness KIc (6 £ 60 mm 2 subclad ¯aw).
 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83
Fig. 15. Comparison between the elastic±plastic stress intensity factor KJ and the base metal fracture toughness KIc (12 £ 72 mm 2 subclad ¯aw).
The level of accuracy is quite satisfactory and reasonable
compared to a more sophisticated approach based on 3D
elastic±plastic computations.
4.3. Main results related to the surface cracks
Although these kinds of ¯aws are not taken into account
in the French RPV PTS assessment codi®ed in RCCM
code [1], complementary analyses have been conducted
regarding the behaviour of some semi-elliptical through
clad surface cracks more or less deep (13.5 £ 81 mm,
25 £ 150 mm, 50 £ 300 mm). The objective was to evaluate
the potential effect of the stainless steel cladding on the
safety margins regarding the risk of cleavage initiation, by
comparison between subclad ¯aws (RCCM type approach)
and through clad surface cracks (ASME type approach).
All the results are presented in detail in the papers [17,18].
However, it is possible to highlight the main conclusions
deduced from the 3D analysis of these three surface cracks:
² With the increase of the surface crack depth, the
evolution of the elastic±plastic SIF KJ along the crack
front tends to become less signi®cant, KJ is relatively
constant along the crack front (it is very different from
the behaviour of shallow subclad ¯aws).
² If the WPS effect is not taken into account, crack
initiation by cleavage is possible along the crack front
whatever the assumptions on the expected EOL RTNDT
(658C , RTNDT , 1258C).
² The bene®cial effect of the WPS is not so signi®cant as in
81
the case of the previous subclad ¯aws:
± crack initiation possible for RTNDT $ <868C in the
case of the 13.5 mm deep crack;
± crack initiation possible for RTNDT $ <778C in the
case of the 25 mm deep crack;
± unlike all other defects, there is no potential bene®cial
effect for the deepest through clad surface crack
(depth 50 mm).
4.4. Bene®cial effect of the cladding in a pressurized
thermal shock evaluation
The potential bene®cial effect of the cladding in a PTS
evaluation can be easily deduced from the comparison
between subclad ¯aws and through clad surface cracks
(Fig. 16). The in¯uence of the cladding in a PTS evaluation,
by taking into account shallow subclad ¯aws instead of
through clad surface cracks, is particularly signi®cant on
the margins regarding the risk of cleavage initiation along
the crack front in the base metal, as it
² signi®cantly decreases the level of the stress intensity
factor along the crack front;
² and thus signi®cantly increases the maximum allowable
EOL RTNDT.
A RPV PTS assessment based on through clad surface
cracks (such an ASME type approach) appears much more
severe than an approach mainly based on the behaviour of
more realistic ¯aws, such as shallow subclad ¯aws based on
actual manufacturing and in-service inspections.
82 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83
Fig. 16. Comparison between through clad surface cracks and shallow subclad ¯aws.
5. Conclusions
Within the framework of the French RPV PTS
re-assessment in progress, a signi®cant work has been
conducted regarding the improvement of the PTS evaluation
methodology. Based mainly on numerical computations,
some new methods have been developed for the assessment
of shallow embedded ¯aws located in the base metal under
the cladding near the interface with cladding (subclad ¯aws)
or located in the ®rst layer of cladding.
Regarding the subclad ¯aws, a new simpli®ed approach
has been proposed in order to evaluate the elastic stress
intensity factor Kcp at the crack tips (cladding side and
base metal side). This approach is based on a speci®c
plasticity correction (`b correction') depending on the
computation of a single correction parameter b . This
method has been validated by numerous 2D and 3D
®nite element computations. It appears quite satisfac-
tory, always conservative compared to an elastic±plastic
approach, and more accurate than the previous approach
based on the b parameter. The level of accuracy is
quite satisfactory and reasonable by comparison with a
more sophisticated approach based on 3D elastic±plastic
computations.
A similar work has been conducted regarding the
embedded ¯aws located in the cladding. A new metho-
dology has also been proposed, always conservative
compared to elastic±plastic or non linear elastic approaches,
based only on the computation of the pure elastic stress
intensity factor KI without any plasticity correction.
These two `engineering approaches' Ðfor embedded
¯aws located in the base metal or located in the cladding
Ð have been accepted by the French Safety Authority and
are now currently used.
In support to the development of such `engineering
approaches', several 3D elastic and elastic±plastic ®nite
element computations have been performed taking into
account both shallow subclad ¯aws and through clad surface
cracks. The behaviour of such ¯aws has been compared in
order to evaluate the potential effect of the stainless steel
cladding on the safety margins regarding the risk of clea-
vage initiation. A RPV PTS assessment based on through
clad surface cracks appears much more severe than an
approach mainly based on the behaviour of more realistic
¯aws, such as shallow subclad ¯aws. The in¯uence of the
cladding, by taking into account shallow subclad ¯aws
instead of through clad surface cracks, is particularly
signi®cant on the margins regarding the risk of cleavage
initiation along the crack front in the base metal of the
vessel, as it signi®cantly decreases the level of the stress
intensity factor along the crack front, and thus signi®cantly
increases the maximum allowable EOL RTNDT.
Regarding more precisely the assessment of the shallow
subclad ¯aws, the results obtained have shown that there is
no risk of crack initiation by cleavage in the base along all
the crack front by taking into account the expected EOL
 D. Moinereau et al. / International Journal of Pressure Vessels and Piping 78 (2001) 69±83
RTNDT for French 900 MW RPV. The `theoretical' margins
regarding the cleavage initiation are very comfortable.
These analyses again con®rm the non conservatism of a
pure elastic approach Ð without any additional plasticity
corrections Ð compared to an elastic±plastic approach in
case of subclad ¯aws.
References
[1] RCCM code Ð January 1988 ed. Design and construction rules for
mechanical components of PWR nuclear islands. RCCM code,
AFCEN France.
[2] Pellissier-Tanon A, Grandemange J, Houssin B, Buchalet C. French
experience on the veri®cation of pressurized water reactor vessels
integrity. EPRI Research Project 2975-2, 1989.
[3] Pellissier-Tanon A, Bhandari S, Vagner J. Practical methods for
surface and sub-surface cracks in reactor pressure vessels. ASME
Pressure Vessels and Piping Conference, San Diego, 1991.
[4] Churier-Bossennec H, Fayolle P, Faidy C. Reactor pressure vessel
behaviour with a small crack in the cladding. ASME Pressure Vessels
and Piping Conference, Nashville, 1990.
[5] Moinereau D, Faidy C, Valeta MP, Bhandari S, Guichard D.
Evaluation of fracture mechanics analyses used in RPV integrity
assessment regarding brittle fracture. Methodology for pressurised
thermal shock evaluation. IAEA Meeting, Esztergom, Hungary, 5±
8 May 1997.
[6] Moinereau D, Rousselier G, Bethmont M. Behaviour of underclad
cracks in RPV. Evaluation of mechanical analyses used in French
RPV integrity assessment by cleavage fracture tests on large scale
plates. ASME Pressure Vessels and Piping Conference, Denver, 1993.
[7] Moinereau D, Brochard J, Guichard D, Bhandari S, Sherry A, France
C. Local approach of cleavage fracture applied to a vessel with
subclad ¯aw. A benchmark on computational simulation. ASME
Pressure Vessels and Piping Conference, Montreal, 1996.
[8] Messelier-Gouze C, Moinereau D. Action tripartite 3477. Analyse
d'une virole reveÃtue comportant un deÂfaut de 4,2 mm situe dans la
premieÁre couche du reveÃtement inoxydable. EDF report HT-2C/97/
024/A, 1997.
83
[9] Moinereau D, Messelier-Gouze C, Bezdikian G, Ternon-Morin F,
Meziere Y, Faidy C, Pellissier-Tanon A, Vagner J, Guichard D.
Some recent developments in French reactor pressure vessel
structural integrity assessment. ASME Pressure Vessels and Piping
Conference, San Diego, 1998.
[10] Moinereau D, MeÂzieÁre Y. DeÂfauts sous reveÃtement dans les cuves
REP. Correction de plasticite dans les analyses meÂcaniques eÂlas-
tiques. EDF report HT-2C/97/004/A, 1997.
[11] Pellissier-Tanon A. Correction de deÂformation plastique pour
l'analyse des DSR dans les cuves. Framatome report EEDC0031,
1996.
[12] Bezdikian G, Moinereau D, Faidy C, Ternon-Morin F, Champigny C.
PWR pressure vessel life management. French approach for integrity
assessment and maintenance strategy. ASME Pressure Vessels and
Piping Conference, San Diego, 1998.
[13] Ternon-Morin F, Meister E, Bezdikian G, Moinereau D, Heuze A,
Vagner J. Integrity assessment of French RPV. A state of the art safety
margin evaluation. ASME Pressure Vessels and Piping Conference,
San Diego, 1998.
[14] Bezdikian G, Barbier G, Moinereau D, Faidy C, Ternon-Morin F,
Churier-Bossennec H. French nuclear plants PWR vessel integrity
assessment and life management. ICONE 8 Conference, Baltimore,
2000.
[15] Moinereau D, Lefevre W. Analyses tridimensionnelles de deÂfauts
sous reveÃtement dans une cuve REP 900 MW soumise au transitoire
petite breÁche primaire 3 pouces. EDF internal report HT-2C/97/037/
A, 1997.
[16] Moinereau D, Bezdikian G, Faidy C. Three-dimensional analyses of
shallow subclad ¯aws in a PWR vessel submitted to a severe over-
cooling transient. ASME Pressure Vessels and Piping Conference,
Boston, 1999.
[17] Moinereau D, Barbier G, Gouillou C. Analyses tridimensionnelles de
deÂfauts deÂbouchants dans une cuve REP 900 MW soumise au
transitoire petite breÁche primaire 3 pouces. EDF internal report HT-
2C/99/030/A, 1999.
[18] Moinereau D, Bezdikian G, Faidy C. Three-dimensional assessment
of ¯aws in a French PWR vessel submitted to a severe overcooling
transient: the effect of cladding. ASME Pressure Vessels and Piping
Conference, Seattle, 2000.