Characteristics of allowable axial cracks for pressurized pipes governed by limit load criteria

Hasegawa, Kunio; Li, Y.; Udyawar, A.*; Lacroix, V.*

International Journal of Pressure Vessels and Piping, 204, p.104952_1 - 104952_7, 2023/08

https://doi.org/10.1016/j.ijpvp.2023.104952

When axial cracks were detected in pipes, failure stresses for high toughness pipes are estimated using the Limit Load Criteria. The allowable stresses for the cracked pipes are derived from the combination of the failure stresses and safety factors. The allowable sizes of crack depths and lengths are determined from the allowable stresses. From the comparison of the allowable and failure stresses for through-wall cracks, the allowable cracks are not uniform. They can be separated into three different characteristics, i) leak-before-break (LBB) and crack growth stability, ii) non-LBB and crack growth stability and iii) non-LBB and crack growth instability. Inspectors and users should pay special attention to allowable cracks with the third characteristic to prevent unexpected failure, particularly for thin-wall pipes. The allowable crack depths and lengths that require special attention can be expressed by appropriate equations.

Towards an improvement of allowable planar flaws of ASME Code Section XI acceptance standards for ferritic steel materials

Lacroix, V.*; Dulieu, P.*; Hasegawa, Kunio

Proceedings of ASME 2023 Pressure Vessels and Piping Conference (PVP 2023) (Internet), 5 Pages, 2023/07

In case of flaw detection during In-Service inspection of nuclear components, ASME Code Section XI provides Acceptance Standards. For ferritic steel materials, the size of allowable planar flaws is given in Table IWB-3510-1. The allowable flaw size only depends on three parameters: the component thickness, the flaw aspect ratio and the proximity of the flaw to the surface. However, a graphical analysis of the impact of those parameters highlights some inconsistencies. Consequently, the need to revise the allowable planar flaws of ASME Code Section XI Acceptance Standards using a robust technical basis is brought to light. This paper details the inconsistencies related to the present allowable planar flaws table and proposes improvement points to revise the allowable planar flaw Table IWB-3510-1.

Safety assessment of allowable through-wall crack angles for pipes subjected to tensile loading

Hasegawa, Kunio; Strnadel, B.*; Lacroix, V.*; Udyawar, A.*

International Journal of Pressure Vessels and Piping, 199, p.104722_1 - 104722_5, 2022/10

https://doi.org/10.1016/j.ijpvp.2022.104722

Fully plastic collapse stresses for high toughness pipes with circumferential cracks subjected to tensile loading can be predicted by Limit Load Criteria. The Limit Load Criteria are provided by the ASME Code Section XI. Allowable membrane stresses for part-through cracks were determined by plastic collapse stresses in combination with safety factors. The allowable stresses decrease with increasing angles of the part-through cracks. When crack angles are large, the allowable stresses of the part-through cracks are larger than the collapse stresses of through-wall cracks. For such large cracks, allowable stresses greater than the collapse stresses cause instability, and are thus detrimental to pipe integrity, especially in thin-wall pipes. In order to avoid the anxiety, it is necessary to establish maximum allowable crack angles. This paper proposes maximum allowable crack angles for allowable stresses.

Empirical correction factor to estimate the plastic collapse bending moment of pipes with circumferential surface flaw

Lacroix, V.*; Hasegawa, Kunio; Li, Y.; Yamaguchi, Yoshihito

Proceedings of ASME 2022 Pressure Vessels and Piping Conference (PVP 2022) (Internet), 7 Pages, 2022/07

Improvement of the ASME B&PV code resolution of nonplanar flaws in pressure retaining components

Lacroix, V.*; Dulieu, P.*; Hasegawa, Kunio; Mares, V.*

Proceedings of ASME 2022 Pressure Vessels and Piping Conference (PVP 2022) (Internet), 7 Pages, 2022/07

In the ASME Code Section XI, a simplified approach is proposed: a nonplanar flaw is resolved into two planar flaws by projection of the flaw area into planes normal to the maximum principal stress. However, simplified resolution of nonplanar flaws is not conservative for all types of loading and flaw inclinations. Consequently, an improvement of the resolutions of nonplanar flaws must be provided in the ASME Code Section XI. This paper carries out an exhaustive assessment of the conservatism of the ASME approach and then proposes an alternative approach to deal with nonplanar flaws allowing to overcome the non-suitability of current ASME Code.

Assessment of the resolution of nonplanar flaws in pressure retaining components in terms of stress intensity factors

Lacroix, V.*; Dulieu, P.*; Hasegawa, Kunio

Proceedings of ASME 2021 Pressure Vessels and Piping Conference (PVP 2021) (Internet), 5 Pages, 2021/07

When flaws are detected, assessments are done to demonstrate the fitness-for-service. The first step is the flaw characterization determining the flaw geometry for analyses. This key step is done by flaw characterization rules provided in FFS Codes. According to the flaw characterization rules of ASME Code Section XI, a nonplanar flaw shall be resolved into two planar flaws by projection of the flaw area into planes normal to the maximum principal stresses. This approach allows to simplify the flaw assessment but remains conservative. Therefore, the conservatisms by the simplified projection for nonplanar flaws are investigated in this paper. Current computations have been improved so that the modelling of nonplanar flaws are not significant difficulty. This paper compares the stress intensity factors (SIF) of projected nonplanar flaws and the mixed mode SIF of actual nonplanar flaws. The scope is to quantify how the flaw projection into planes normal to the maximum principal stresses is conservative.

Fatigue crack growth for ferritic steel under negative stress ratio

Yamaguchi, Yoshihito; Hasegawa, Kunio; Li, Y.

Journal of Pressure Vessel Technology, 142(4), p.041507_1 - 041507_6, 2020/08

https://doi.org/10.1115/1.4046768

The phenomenon of crack closure is important in the prediction of fatigue crack growth. Several experimental data indicate the closing of fatigue cracks both under negative and positive loads at constant amplitude loading cycles, depending on the magnitude of stress amplitude and stress ratio. Appendix A-4300 of the ASME Code Section XI provides two equations of fatigue crack growth rates expressed by the stress intensity factor range for ferritic steels under negative stress ratio. The boundary of two fatigue crack growth rates is classified with the magnitude of applied stress intensity factor range, in consideration of the crack closure. The boundary value provided by the ASME Code Section XI is validated in this study through an investigation of the influence of the magnitude of the applied stress intensity factor range on crack closure, with the application of fatigue crack growth tests using ferritic steel specimens in air environment at room and high temperatures. Crack closures are obtained as a parameter of stress ratio, and herein, were found to occur at a smaller applied stress intensity factor range, as opposed to the definition given by Appendix A-4300.

Assessment of flaw interaction under combined tensile and bending stresses; Suitability of ASME code case N877-1

Dulieu, P.*; Lacroix, V.*; Hasegawa, Kunio

Proceedings of ASME 2020 Pressure Vessels and Piping Conference (PVP 2020) (Internet), 7 Pages, 2020/08

https://doi.org/10.1115/PVP2020-21452

When detected flaws are in close proximity, proximity rules given in the Fitness-foe Service codes require to combine the interacting flaws into a single flaw. ASME Code Case N877-1 provides alternative proximity rules for multiple radial oriented planar flaws. The calculations of flaw interaction have been performed under pure membrane stress. However, actual loading conditions induce non-uniform stresses in the component thickness direction. The objective of this paper is assess the suitability of ASME Code Case N877-1 with regards to the presence of a bending part in the applied stress distribution. For that purpose, various applied stress profiles and flaw configurations are covered. The effect on flaw interaction is assessed trough three-dimensional XFEM analyses.

Application scope of limit load criterion for ductile material pipes with circumferentially external cracks

Hasegawa, Kunio; Li, Y.; Lacroix, V.*; Mare, V.*

Journal of Pressure Vessel Technology, 142(3), p.031506_1 - 031506_7, 2020/06

https://doi.org/10.1115/1.4046055

Bending stress at plastic collapse for a circumferentially cracked pipe is predicted by limit load criterion provided by the Appendix C of the ASME Code Section XI. The equation of the Appendix C is applicable for pipes with both external and internal surface cracks. On the other hand, the authors have developed a more precise equation. From the comparison of Appendix C equation and the new equation, the plastic collapse stress estimated by the Appendix C equation gives less conservative bending capacity prediction for external cracked pipes with thick wall thickness and large crack angle. This paper discusses the limitation scope to use the limit load criterion of the Appendix C equation.

Consideration on fatigue crack growth thresholds under negative stress ratio

Hasegawa, Kunio; Usami, Saburo*; Lacroix, V.*

Proceedings of 2019 ASME Pressure Vessels and Piping Conference (PVP 2019) (Internet), 6 Pages, 2019/07

Fatigue crack growth thresholds are provided by several fitness-for-service (FFS) codes. When evaluating cracked components subjected to cyclic loading, maximum stress intensity factor and/or minimum stress intensity factor are required. However, the definitions of the thresholds under negative stress ratio are not clearly written. In addition, the thresholds are given by constant values under negative . This paper shows that the maximum stress intensity factor converted by the thresholds obtained by experimental data are not constant values under negative . The thresholds for the FFS codes are less conservative. The definition of the thresholds under negative ratio are discussed.