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ASME STP-PT-089 - 2020 Creep-Fatigue Flaw Growth Analysis to Support Elevated Temperature Flaw Size Acceptance Criteria, 2020
- TABLE OF CONTENTS
- FOREWORD
- ABSTRACT
- 1 SCOPE
- 2 INPUTS [Go to Page]
- 2.1 Configurations
- 2.2 Flaw Configuration
- 2.3 Analysis Methods
- 2.4 Units
- 2.5 Modeling Approach
- 2.6 Geometry
- 2.7 Boundary and Initial Conditions
- 2.8 Loading Conditions
- 2.9 Operational Life and Load Cycles
- 3 STRESS ANALYSIS RESULTS [Go to Page]
- 3.1 Finite Element Modeling Strategy
- 3.2 Stress Analysis Results and Stress Linearization
- 3.3 Transient Heat Transfer and Stress Analyses
- 3.4 Implementation Validation
- 4 ASSUMPTIONS [Go to Page]
- 4.1 American Petroleum Institute (API) 579-1 / ASME FFS-1
- 4.2 Electricite de France (EDF) Recommended Procedure R5 V4/5
- 4.3 Electric Power Research Institute (EPRI) Boiler Life Evaluation and Simulation System (BLESS)
- 5 ANALYSIS METHODOLOGIES [Go to Page]
- 5.1 Dissection of loading condition into loading cycles for analyses
- 5.2 Convergence criterion to find ac
- 5.3 American Petroleum Institute (API) 579-1 / ASME FFS-1
- 5.4 Electricite de France (EDF) Recommended Procedure R5 V4/5
- 5.5 Electric Power Research Institute (EPRI) Boiler Life Evaluation and Simulation System (BLESS)
- 6 RESULTS [Go to Page]
- 6.1 Results using the API 579-1 / ASME FFS-1 methodology
- 6.2 Results using the R5 V4/5 methodology
- 6.3 Results using the BLESS methodology
- 6.4 Supporting information
- 7 VERIFICATION VIA HAND CALCULATIONS [Go to Page]
- 7.1 Hand calculation using API 579-1/ASME FFS-1
- 7.2 Hand calculation using R5 V4/5
- 7.3 Hand calculation using BLESS
- 8 DISCUSSION [Go to Page]
- 8.1 Creep crack initiation and growth with R5 V4/5
- 8.2 Faster crack growth for semi-elliptical than infinite length flaws in BLESS
- 9 CONCLUSIONS
- Figures [Go to Page]
- Figure 2-1. Flaw #1: Inside Surface Crack, Circumferential Direction, Infinite Length
- Figure 2-2. Flaw #2: Inside Surface Crack, Circumferential Direction, Semi-Elliptical Shape
- Figure 2-3. Flaw #3: Outside Surface Crack, Circumferential Direction, Infinite Length
- Figure 2-4. Flaw #4: Outside Surface Crack, Circumferential Direction, Semi-Elliptical Shape
- Figure 2-5. Flaw #5: Embedded Crack, Circumferential Direction, Infinite Length
- Figure 2-6. Flaw #6: Embedded Crack, Circumferential Direction, Semi-Elliptical Shape
- Figure 2-7. Flaw #7: Inside Surface Crack, Longitudinal Direction, Infinite Length
- Figure 2-8. Flaw #8: Inside Surface Crack, Longitudinal Direction, Semi-Elliptical Shape
- Figure 2-9. Flaw #9: Outside Surface Crack, Longitudinal Direction, Infinite Length
- Figure 2-10. Flaw #10: Outside Surface Crack, Longitudinal Direction, Semi-Elliptical Shape
- Figure 2-11. Flaw #11: Embedded Crack, Longitudinal Direction, Infinite Length
- Figure 2-12. Flaw #12 Embedded Crack, Longitudinal Direction, Semi-Elliptical Shape
- Figure 2-13. Geometry Modelling Approach
- Figure 2-14. Models’ Constraining and Initial Conditions for Axisymmetric Model
- Figure 2-15. Applied Loading Conditions
- Figure 2-16. Modulus of Elasticity as a Function of Temperature [4]
- Figure 2-17. Density as a Function of Temperature [4]
- Figure 2-18. Thermal Diffusivity as a Function of Temperature [4]
- Figure 2-19. Thermal Conductivity as a Function of Temperature [4]
- Figure 2-20. Specific Heat Capacity as a Function of Temperature
- Figure 2-21. Mean Coefficient of Thermal Expansion as a Function of Temperature. Reference Temperature = 20 °C [4]
- Figure 3-1. Typical Finite Element Model and Mesh Density
- Figure 3-2. S22 (Longitudinal) and S33 (Hoop) Stress at the Inner, Middle, and Outer Location through the Thickness Plotted versus Time for SHT_Gr22 and the Cold Start Up Cycle
- Figure 3-3. Stress Distribution through the Thickness for SHT_Gr22 at Approximately 50%, 75% and End of the Cold Start Up Cycle in the Axial (Left) and Hoop (Right) Directions
- Figure 3-4. S22 (Longitudinal) and S33 (Hoop) Stress at The Inner, Middle, and Outer Location through the Thickness Plotted Versus Time for RHT_Gr22 and the Cold Start Up Cycle, Steady State Solution
- Figure 3-5. S22 (Longitudinal) and S33 (Hoop) Stress at the Inner, Middle, and Outer Location through the Thickness Plotted versus Time for RHT_Gr22 and the Cold Start Up Cycle, Transient Solution
- Figure 3-6. S22 (Longitudinal) and S33 (Hoop) Stress at the Inner, Middle, and Outer Location through the Thickness Plotted versus Time for SHP_Gr22 and the Cold Start Up Cycle, Steady State Solution
- Figure 3-7. Temperature at the Inner and Outer Point through the Thickness and Average Temperature (Left) and Temperature Difference between Inner and Outer Points for SHP_Gr22 and the Cold Start Up Cycle, Transient Solution
- Figure 3-8. S22 (Longitudinal) And S33 (Hoop) Stress at the Inner, Middle, And Outer Location through the Thickness Plotted versus Time for SHP_Gr22 and the Cold Start Up Cycle. Transient Solution
- Figure 3-9. Axial Stress Distribution through Time at Selected Points through the Thickness (Top) and Applied Temperature at Inner Surface through Time Distribution for Comparison
- Figure 3-10. Dimensions and Boundary Conditions for Simplified Heat Transfer Model
- Figure 3-11. Longitudinal and Hoop Stresses at the Inner and Outer Location through the Thickness Plotted versus Time for SHP_Gr22 and the Cold Start Up Cycle for Transient Solution
- Figure 5-1. First 30 Entries of Cycle List of Equation 5-2
- Figure 5-2. API 579-1/ASME FFS-1 Methodology Applied in an Iterative Fashion
- Figure 5-3. R5 V4/5 Methodology Applied in an Iterative Fashion
- Figure 5-4. EPRI BLESS Methodology Applied in an Iterative Fashion
- Figure 5-5. Visual Representation of Flaw Configurations Associated with Case 3 – 5 from Zahoor
- Figure 5-6. Visual Representation of Buchalet [22] Idealization for Flaw 11
- Figure 8-1. Calculated Crack Growth for Sht_Gr22_Long_Mid_Infinite Configuration Solved With R5 V4/5 with A Starting Flaw Size of a/t = 20%
- Figure 8-2. Typical Shapes for Creep Crack Growth Curves from [23]
- Figure 8-3. Crack Depth versus Time for Rht_Gr22_Long_Inside_Semiellipt Using the BLESS Methodology and an Initial Crack of a/t = 2%
- Figure 8-4. Crack Depth versus Time for Rht_Gr22_Long_Inside_Infinite Using the BLESS Methodology and an Initial Crack of a/t = 2%
- Figure 8-5. Normalized Fully-Plastic J-Integral Solutions versus a/t
- Tables [Go to Page]
- Table 2-1. Components with Dimensions and Loading in Imperial and SI Units
- Table 2-2. Flaw Configurations and Numbering
- Table 2-3. Normalized Transient Temperature Conditions in [°F/°F] for all Start Up Cycles
- Table 2-4. Normalized Transient Temperature Conditions in [°C/°C] for all the Cold Start Cycle
- Table 2-5. Normalized Transient Temperature Conditions in [°C/°C] for all the Warm Start Cycle
- Table 2-6. Normalized Transient Temperature Conditions in [°C/°C] for all the Hot Start Cycle
- Table 2-7. Normalized Transient Temperature Conditions in [°F/°F] for all the Shutdown Cycles
- Table 2-8. Normalized Transient Temperature Conditions in [°C/°C] for all the Shutdown Cycles Tube Components
- Table 2-9. Normalized Transient Temperature Conditions in [°C/°C] for all the Shutdown Cycles Pipe Components
- Table 2-10. Normalized Transient Pressure Conditions in for all Start Up Cycles
- Table 2-11. Normalized Transient Pressure Conditions in for all Shut Down Cycles
- Table 2-12. Material Utilized in the Analyses
- Table 5-1. Sources for Material Properties as Allowed by API 579-1
- Table 5-2. Flaw Configurations and Corresponding Reference Stress Solution
- Table 5-3. Sources for Material Properties as Allowed by R5 V4/5
- Table 5-4. Sources for Creep Rupture Data for All Materials
- Table 5-5. Creep Crack Growth Data from BS 7910 [13]
- Table 5-6. Material Properties used in BLESS Calculation for Gr22 in [ksi, in, hrs, °F]
- Table 5-7. Material Properties used in BLESS Calculation for Gr91 in [ksi, in, hrs, °F]
- Table 5-8. Stress Intensity, Fully Plastic J-Integral (Jp), and Steady State Creep Crack Driving Force (C*) Solutions for Each Flaw Configuration Case
- Table 5-9. Pipe/Tube Radius to Wall Thickness Ratios
- Table 6-1. Maximum Allowable Flaw Sizes for the Configurations of Interest Analyzed with the API 579-1/ASME FFS-1 Methodology
- Table 6-2. Maximum Allowable Flaw Sizes for the Configurations of Interest Analyzed with the R5 V4/5methodology
- Table 6-3. Maximum Allowable Flaw Sizes for the Configurations of Interest Analyzed with the EPRI BLESS Methodology
- Table 8-1. Comparison of BLESS Solutions for Longitudinal Semi-Elliptical versus Full LengthCracks for the Grade 22 Reheater Tube
- REFERENCES
- APPENDIX A: STATEMENT OF WORK (SOW) [Go to Page]