Development of an LP Rotor

Rim-Attachment Cracking Life

Assessment Code (LPRimLife)
EPRI Project Managers
D. Gandy
R. Viswanathan
EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com
Development of an LP Rotor
Rim-Attachment Cracking Life
Assessment Code (LPRimLife)
TR-110407
Final Report, December 1999
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES
THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN
ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH
INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE
ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM:
(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I)
WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR
SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR
INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL
PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S
CIRCUMSTANCE; OR
(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER
(INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE
HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR
SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD,
PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT.
ORGANIZATION(S) THAT PREPARED THIS DOCUMENT
Structural Integrity Associates
EPRI Repair and Replacement Applications Center
ORDERING INFORMATION
Requests for copies of this report should be directed to the EPRI Distribution Center, 207 Coggins
Drive, P.O. Box 23205, Pleasant Hill, CA 94523, (800) 313-3774.
Electric Power Research Institute and EPRI are registered service marks of the Electric Power
Research Institute, Inc. EPRI. POWERING PROGRESS is a service mark of the Electric Power
Research Institute, Inc.
COPYRIGHT 1999 ELECTRIC POWER RESEARCH INSTITUTE, INC. ALL RIGHTS RESERVED.
iii
CITATIONS
This report was prepared by
Structural Integrity Associates
3315 Almaden Expressway, Suite 24
San Jose, California 95118-1557
Principal Investigators
D. Rosario
P. Riccardella
S. Tang
EPRI Repair and Replacement Applications Center
1300 W.T. Harris Boulevard
Charlotte, NC 28262
Principal Investigators
D. Gandy
R. Viswanathan
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Development of an LP Rotor Rim-Attachment Cracking Life Assessment Code (LPRimLife),
EPRI, Palo Alto, CA: 1999. TR-110407.
v
REPORT SUMMARY
Report Summary
Most of the domestic turbine fleet has reached the 50,000-hour range of service operation.
Unfortunately, above this level of operational hours, a number of turbines have begun to
experience low-pressure (LP) rim-attachment cracking. A computer code developed by EPRI,
LPRimLife, provides utilities with a methodology for assessing the remaining life of LP rim
attachments with known or suspected cracking.
Background
The first documented incidence of stress corrosion cracking in blade rim attachments in nuclear
LP steam turbine discs occurred in the late 1970s in a U.S. pressurized water reactor (PWR)
power plant. Since that occurrence, EPRI has performed two surveys (one in 1980 and the most
recent in 1995) to review industry experience with rim-attachment cracking. The latter
documented that of 109 boiling water reactor (BWR) and PWR operating units surveyed, 38%
had experienced cracking. Based upon this experience, EPRI, along with the input and direction
of several key utilities, began the development of a life assessment tool (LPRimLife) to assist in
addressing rim-attachment cracking.
Objectives
To develop a software package with which utility personnel can determine the probability of
failure for low-pressure rotor rim attachments
To provide utilities with a tool for evaluating the condition and disposition of LP rotor rim
attachments for their turbines
To acquire geometry and dimensional information for both straddle-mount (GE) and axial-
entry (Westinghouse) style attachments to be used in generating a library of individual stress
solutions
Approach
The development of the life assessment code, LPRimLife, was split into two phases to separately
address cracking for the two rim-attachment configurations. Phase I addressed the straddle-
mount attachments and is now complete. Phase II is currently in development and addresses
Westinghouse axial-entry attachments. The methodology employed for development of the code
was to generate individual modules to address specific aspects of the cracking problem. The
modules include the following:
Built-in stress solutions for problematic GE/Westinghouse rim attachments
Materials properties (unit-specific or default values)
vi
Crack initiation and growth
Operating and inspection data inputs
Fracture mechanics
Load redistribution and ligament overload checks
Deterministic and probabilistic analysis options
Each module was then integrated into a single package (LPRimLife) for predicting remaining
life.
Results
LPRimLife integrates a variety of factors to assess critical crack size, to address load
redistribution between individual steeples/ligaments, and to predict remaining life of LP rotor
rim attachments with known or suspected cracking. Geometrical and dimensional data have been
obtained for a number of different problematic straddle-mount and axial-entry designs. From this
information, specific finite element stress solutions have been developed for each design.
EPRI Perspective
The LPRimLife computer code combines the appropriate stress analysis information, material
property data, and fracture mechanics algorithms with applicable material degradation data into
an integrated methodology to assess the remaining life of LP rotors with rim-attachment
cracking. For the first time, utilities can now predict the remaining life of rim attachments from
both a deterministic and a probabilistic standpoint. Critical crack size can be assessed, and
maintenance/repair schedules can be more effectively planned. In conjunction with recent
advances made in ultrasonic inspection of rim attachments using phased array technologies,
LPRimLife provides utilities with the ability to more effectively monitor their turbines.
Furthermore, it assists utilities in planning effective maintenance strategies for continued
operation of LP rotor rim attachments with known or suspected cracking.
TR-110407
Keywords
Steam turbines
Low-pressure steam turbines
Rim attachment cracking
Blade attachment cracking
LPRimLife
EPRI Licensed Material
vii
ABSTRACT
Stress corrosion cracking (SCC) in the blade attachment region of low-pressure (LP) turbine
rotors has emerged as one of the most significant problems affecting steam turbine rotors today.
In response to an expressed utility need for a life prediction tool, EPRI has sponsored the
development of an easy-to-use PC-based computer program, LPRimLife, which enables utility
personnel to perform a rapid remaining life assessment of LP rotors with known or suspected
cracking. The first phase of development, incorporating the methodology for evaluating cracking
in GE dovetail (straddle-mount) attachments, is complete. The next phase, to address cracking in
Westinghouse axial-entry attachments, is currently in development.
The LPRimLife computer code, developed for EPRI by Structural Integrity Associates, combines
the necessary stress analysis, material property data, and fracture mechanics algorithms with
applicable material degradation data into an integrated methodology to assess the remaining life
of LP rotors with rim-attachment cracking. Features built into the PC-based code include the
following:
Easy-to-use Windows graphical user interface with pull-down menus and dialog boxes
Built-in library of stress solutions which can easily expand to incorporate user-specific
attachment geometries
A fracture mechanics stress intensity factor calculator for arbitrary crack aspect ratios
Material properties module with built-in fracture toughness data
An algorithm to account for redistribution of load between top, middle, and bottom hooks
with cracking
An algorithm to check for overload of a cracked ligament in addition to fracture toughness
limit
SCC threshold to simulate crack arrest if stress intensity factors drop below the threshold
Deterministic and probabilistic calculation options and built-in graphics and plotting
capability to view and modify presentation of results
With comprehensive on-line help, the program facilitates rapid life assessments and parametric
studies to be performed by non-experts with minimal introduction to the software.
EPRI Licensed Material
ix
ACKNOWLEDGMENTS
The authors would like to thank all the tailored collaboration utility participants who funded this
program and provided valuable input, guidance and feedback from the initial stages of the
program development through the testing and release of the of the first phase software.
T. Alley Duke Power Company
G. Beckerdite Kansas City Power and Light
R. Bundt Southern Nuclear
J. Johnson Alliant/IES Utilities
P. Klein Baltimore Gas and Electric
M. Metzger Nebraska Public Power District
A. Mosquada Pacific Gas and Electric
D. Wright Baltimore Gas and Electric
The authors would also like to thank members of the TurboCare team which has partnered with
EPRI in a sister program, Development of Repair Technology for Shrunkon Discs and
Monoblock Rotors. Dimensional information generated under that program and independently
by TurboCare has been incorporated into this report and into the LPRimLife program. Specific
members of the TurboCare team involved in this project include the following:
J. Beverly
B. Catlow
P. DiCristoforo
S. Hecker
EPRI Licensed Material
xi
CONTENTS
1 INTRODUCTION.................................................................................................................. 1-1
2 METHODOLOGY................................................................................................................. 2-1
3 PROGRAM MODULES........................................................................................................ 3-1
3.1 Stress Analysis.......................................................................................................... 3-1
3.2 Crack Initiation and Growth....................................................................................... 3-5
3.3 SCC Growth Threshold (K
ISCC
) ................................................................................... 3-6
3.4 Critical Crack Size..................................................................................................... 3-6
3.4.1 Load Redistribution............................................................................................... 3-7
3.5 Remaining Life (Deterministic Versus Probabilistic)................................................... 3-8
4 GEOMETRICAL AND DIMENSIONAL MEASUREMENTS ................................................. 4-1
5 LPRIMLIFE SOFTWARE..................................................................................................... 5-1
5.1 Description................................................................................................................ 5-1
5.2 Analysis .................................................................................................................... 5-3
5.3 Results...................................................................................................................... 5-3
6 CONCLUSIONS .................................................................................................................. 6-1
7 FUTURE DEVELOPMENTS................................................................................................ 7-1
8 REFERENCES .................................................................................................................... 8-1
EPRI Licensed Material
xiii
LIST OF FIGURES
Figure 1-1 Rim Attachment Cracking in Nuclear Units by Reactor Type and Manufacturer ..... 1-2
Figure 1-2 Rim Attachment Cracking in Fossil Units by Steam Type (Supercritical or
Subcritical) ...................................................................................................................... 1-3
Figure 2-1 Schematic of Rim-Attachment Configurations Illustrating Typical Locations of
Cracking.......................................................................................................................... 2-2
Figure 2-2 Flowchart of LPRimLife Software........................................................................... 2-3
Figure 3-1 Typical FE Analysis Model of Disk and Blade Attachment Region With Non-
Linear Contact (Gap) Elements ....................................................................................... 3-2
Figure 3-2 Geometry and Loading Data for a Built-In Attachment Geometry........................... 3-4
Figure 3-3 Stress Gradients Normal to Crack Incorporated in Built-In Library of FE Stress
Results ............................................................................................................................ 3-4
Figure 3-4 Critical Crack Size Determination Flow Diagram.................................................... 3-7
Figure 3-5 Illustration of Load Redistribution as a Function of Crack Depth (a) to Hook
Width (W) Ratio. .............................................................................................................. 3-8
Figure 3-6 Flowchart for Probabilistic Calculations.................................................................. 3-9
Figure 4-1 Axial-Entry (Westinghouse) Root Types................................................................. 4-6
Figure 4-2 Axial-Entry (Westinghouse) Steeple Groove Dimensions....................................... 4-7
Figure 5-1 LPRimLife Splash Screen and Main Menu Options................................................ 5-1
Figure 5-2 Typical Solution Procedure .................................................................................... 5-2
Figure 5-3 Calculation and Print Controls Data Input Window................................................. 5-3
Figure 5-4 Deterministic Analysis Results Output Window...................................................... 5-4
Figure 5-5 Probabilistic Analysis Results Output Window........................................................ 5-4
Figure 5-6 Cumulative Probability of Failure Plot Option From the View Main Menu ............... 5-5
EPRI Licensed Material
xv
LIST OF TABLES
Table 3-1 Phase I Straddle-Mount (GE) Dovetail Geometries ................................................. 3-3
Table 3-2 Phase 2 Axial-Entry (Westinghouse) Geometries.................................................... 3-3
Table 4-1 Summary of Straddle-Mount (GE) Dimensional and Loading Data.......................... 4-2
Table 4-2 Summary of Axial-Entry (Westinghouse) Dimensional and Loading Data................ 4-4
EPRI Licensed Material
1-1
1

INTRODUCTION
The problem of stress corrosion cracking (SCC) in the blade attachment region of nuclear low
pressure steam turbine disks was first identified in the United States at a nuclear pressurized
water reactor (PWR) plant around the late '70s. Additional discoveries of cracking in disk rim
attachments, bores and keyways, and hub and web locations in nuclear LP turbines led to the
development of EPRI Research Project 1398 [1]. Task 5 of this project included a survey of U.S.
and foreign experience with LP disk cracking as of mid-1980. The 1980 survey documented disk
rim attachment cracking instances in Westinghouse LP turbines of seven nuclear units and no
instances of cracking in General Electric nuclear turbines.
Industry concern with regard to LP rotor rim cracking has increased over the last five to ten years
with an increasing number of rotors requiring repair or replacement. These concerns led to the
recent data collection effort on LP rotor rim cracking which was performed under EPRI Research
Project 9005-01 [2]. Data was collected through 1995 to document the location, extent, and
mechanism of cracking; to document repair methods used; and to investigate possible
relationships between cracking experience and various design and operating parameters. Disk
cracking experience in U.S. nuclear utilities and several fossil utilities was determined from a
review of literature data and a questionnaire survey mailed to the utilities. Information on rotor
repair methods was obtained from a separate survey of repair vendors and original equipment
manufacturers (OEMs).
Reflecting industry concerns, the 1995 survey reported a significant increase in the incidence of
rim cracking compared with the 1980 survey. Nuclear utility operators surveyed reported LP
rim-attachment cracking in 41 of 109 currently operating units in the United States
(see Figure 1-1) [2]. The cracking mechanism reported was predominantly stress corrosion
cracking with a few instances of corrosion-fatigue and one incident of high-cycle fatigue. Based
on the survey data, the incidence of cracking did not appear to be related to generator or turbine
manufacturer or power rating. Higher incidences of cracking were reported in units with longer
last stage blades. Data was insufficient to establish a relationship between the incidence of rim
cracking and operating variables, such as operating time, number of startups, type of water
treatment, oxygen levels, condenser cooling water, and condenser leakage rate. Limited rim-
attachment crack growth data suggested that use of an equation first proposed by Clark et al of
Westinghouse [3] to estimate crack growth rates is adequate for the purpose of life prediction.
Compared with the results of the 1980 survey, the new data showed a significant shift in the
number of cracks by row number to downstream rows and a significant rate of cracking in
General Electric rotors which was not reported in the earlier survey.
EPRI Licensed Material
Introduction
1-2
Figure 1-1
Rim Attachment Cracking in Nuclear Units by Reactor Type and Manufacturer
Of the 757 fossil units surveyed, the incidence of cracking was ten times higher in supercritical
units with once-through boilers (26%) than in subcritical units (3%) (see Figure 1-2).
EPRI Licensed Material
Introduction
1-3
Figure 1-2
Rim Attachment Cracking in Fossil Units by Steam Type (Supercritical or Subcritical)
The cracking mechanism reported was predominantly SCC, with a few instances of corrosion
fatigue and reportedly excessive attachment stress. In GE units, more instances of rim cracking
were reported in the L-1 and L-2 rows; in Westinghouse units, more cracking was reported in the
L-0 and L-1 rows.
Life prediction methods have been successfully applied to rim attachments by OEMs and
consultants. However, until now no analytical tool has been available that would allow utility
personnel to perform these assessments. Therefore, several utilities expressed the need for a user-
friendly integrated software code that would allow utility personnel to perform a remaining life
assessment for LP rotors with known or suspected rim-attachment cracking. The 1989 EPRI
guidelines [4] provided a step in this direction, but the lack of an integrated software tool for use
by utility personnel was still apparent.
In response to utility concerns with regard to rim cracking, EPRI initiated Tailored Collaboration
program RP4597-01 [5] to develop a computer code that would combine the necessary stress
analysis and fracture mechanics algorithms with applicable material degradation data into an
integrated methodology to assess the remaining life of LP rotors with rim-attachment cracking.
The resulting computer program, LPRimLife [6] is described in this report.
EPRI Licensed Material
2-1
2

METHODOLOGY
The development effort for the life assessment code, LPRimLife, was split into two phases to
address separately rim-attachment cracking for the two configurations shown in Figure 2-1.
Phase I, which includes the assessment of straddle-mount attachments (see Figure 2-1b), is
complete; and Phase II, which addresses cracking in Westinghouse axial-entry attachments (see
Figure 2-1a), is currently in development.
EPRI Licensed Material
Methodology
2-2
Figure 2-1
Schematic of Rim-Attachment Configurations Illustrating Typical Locations of Cracking
A flow chart of the LPRimLife computer code is provided in Figure 2-2.
EPRI Licensed Material
Methodology
2-3
Geometry
- Select
Dimensions
- View/Scale
Loading/Stresses
- View/Scale
NDE Data
- Location, Size
Material
Properties
Operating Data
- Temperature
- Hrs, Overspeed
Crack Initiation
Model
Crack Growth
Model
Time-to-Failure
- Deterministic
- Probabilistic
Predefined
Geometries:
- GE (Phase I)
- Westinghouse
(Phase II)
Finite Element
Stress Analyses
Develop Library of Rim Attachment Geometries
and Stresses
Critical Crack Size
(Toughness, Overload,
Vibratory)
Load
Redistribution
Algorithm
Vibratory
Threshold
Figure 2-2
Flowchart of LPRimLife Software
A brief description of the inputs and calculation procedures is given below.
Geometry and Stresses
1. First, the user defines the type of attachment to be evaluated (GE straddle-mount or
Westinghouse axial-entry).
2. Next, the user has the option of (1) selecting appropriate geometry and stress data from a pre-
defined (built-in) library of geometry and finite element stress solutions or (2) inputting
appropriate geometry and stress data for the attachment to be evaluated.
3. In addition, using scale factors, pre-defined geometry and loading data can be modified to
approximate the desired geometry.
EPRI Licensed Material
Methodology
2-4
Other Inputs
4. Next, the user defines various inputs required for the life assessment calculation. These
inputs fall into the following major categories:
Operating Data
Inspection Data
Material Properties
Initiation and Crack Growth Data
Calculation/Print Controls
Calculations
5. Once all the necessary inputs have been defined, the user has the option of performing the
remaining life calculations either deterministically or probabilistically. Remaining life is the
sum of initiation time (if applicable) and time to reach critical size. Calculations performed
include the following:
Estimate initiation time (if cracking was not detected).
Simulate growth of initiated or detected cracks due to stress corrosion cracking (SCC).
Account for redistribution of loading between hooks as crack growth progresses.
Check for crack arrest below defined SCC threshold.
Determine minimum critical crack size for fracture toughness limit, remaining ligament
overload, or user-defined depth limit.
Results
6. After the calculations are completed, detailed results are available for review in an output
text file along with the option to plot key inputs and results. Results include the following:
Stresses, including the effect of load redistribution due to cracking
Stress intensity factors (without and with scale factors and load redistribution)
Crack size versus time
Remaining life
Initiation and Failure Probabilistic results
EPRI Licensed Material
3-1
3

PROGRAM MODULES
To facilitate the assembly of the LPRimLife software, a number of interlinked modules were
developed. Key modules include the following:
Stress analysis
Crack initiation and growth
Stress corrosion cracking (SCC) growth threshold
Critical crack size
Remaining life (deterministic and probabilistic)
Each of these modules will be discussed in this section of the report.
3.1 Stress Analysis
The program incorporates a built-in library of finite element (FE) stress results required for
evaluation of rim-attachment cracking. This eliminates the complexity associated with
performing a typical FE analysis using non-linear contact elements (see Figure 3-1).
EPRI Licensed Material
Program Modules
3-2
Figure 3-1
Typical FE Analysis Model of Disk and Blade Attachment Region With Non-Linear Contact
(Gap) Elements
EPRI Licensed Material
Program Modules
3-3
Stress analysis results for the Phase I dovetail geometries shown in Table 3-1 are built into the
software program.
Table 3-1
Phase I Straddle-Mount (GE) Dovetail Geometries
Turbine Size/Rating LP Configuration
1
Row
GE 920 MW TC6F38 L-2, L-3
GE 1300MW TC6F43 L-2, L-3
GE 540 MW TC4F38 L-2, L-3
GE 858 MW
2
TC4F43 L-2, L-3
GE 1220 MW
2
TC6F43 L-2, L-3
Notes
1: TC6F38 = Tandem-Compound, 6-Flows (3 LPs), with 38-inch last blades
2: To be incorporated in next software release.
Phase II is currently in development and will incorporate the axial-entry stress analysis results
shown in Table 3-2.
Table 3-2
Phase 2 Axial-Entry (Westinghouse) Geometries
Turbine Size/Rating LP Configuration Row
WH 1080MW, BB81 TC6F44 L-0, L-1
WH 764MW, BB81 TC4F44 L-0, L-1
WH BB281 TC6F44 L-0, L-1
WH 893MW, BB276 TC4F28 L-0, L-1
Key geometry and loading information are incorporated in the built-in library and can be viewed
by the user (see Figure 3-2). Appropriate stress gradient results normal to the crack (see Figure
3-3) are also built into the library. These stresses are defined for locations away from the notch-
entry position. The local stress increase at the notch-entry position must be accounted for using a
load/stress scale factor which can be modified by the user. For example, to increase stresses at
the notch-entry position by 50%, this factor must be changed to 1.5. A separate Library module
allows the user to expand the existing library to include additional attachment
geometry/loading/stress data.
EPRI Licensed Material
Program Modules
3-4
Figure 3-2
Geometry and Loading Data for a Built-In Attachment Geometry
Figure 3-3
Stress Gradients Normal to Crack Incorporated in Built-In Library of FE Stress Results
EPRI Licensed Material
Program Modules
3-5
3.2 Crack Initiation and Growth
An industry review of available stress corrosion cracking (SCC) initiation data and models is
provided by Rosario [7]. Since no quantitative model currently exists to predict SCC initiation as
a function of the principal governing material, stress, and environment variables, the software
allows the user to specify an industry experienced-based statistical probability of initiation as a
function of total operating time for a given fleet or design of low-pressure (LP) rotor.
Crack growth due to SCC is the dominant crack growth mechanism simulated within the
software. Low cycle fatigue due to unit start/stops is typically very small relative to SCC growth
rates. The most widely accepted model for SCC crack growth rate [3] is expressed by the
following equation:
y
0.0278 + (7302/T) - C = )
dt
da
(
1
ln (Eq. 3-1)
where
C
1
= Material constant with a mean value of -4.968 and a standard deviation of 0.587
T = Operating temperature of the disk in R (F+460)
y = Yield strength in ksi
da/dt = Growth rate in inches/hour
The 1995 EPRI survey of rim-attachment cracking [2] has shown that this equation also provides
reasonable estimates of crack growth rates for disk rim attachments. Data presented by
Holdsworth [8] and Speidel [9] at the most recent EPRI Steam Turbine Stress Corrosion
Cracking Conference in March 1997 also confirms that SCC growth rates, for typical disk steels
with yield strengths below 160 ksi, are a function of only yield strength and temperature.
To allow flexibility in defining the SCC growth rate, the following generic form of eq. 3-1 is
incorporated in the software program:
y
C + T) (C - C = )
dt
da
(
3 2 1
/ ln (Eq. 3-2)
where the material constants C
1
, C
2
, and C
3
can be defined by the user.
EPRI Licensed Material
Program Modules
3-6
3.3 SCC Growth Threshold (K
ISCC
)
Eq. 3-1 applies to the SCC growth region, called the plateau region, which is independent of
the stress intensity factor [9]. However, for stress intensity factors below the threshold (K
ISCC
),
which is in the range of 10 to 20 ksi inch, crack growth is insignificant [9]. With load
redistribution, stress intensity factors may fall below the threshold, and SCC crack growth will
cease. To incorporate this effect, SCC crack growth is terminated when, K
I
< K
ISCC
. To activate
this threshold effect, the user must define a mean and standard deviation for K
ISCC
; this feature
can be deactivated by setting both mean and standard deviation values to zero.
3.4 Critical Crack Size
The critical crack size computed by the software is the minimum value for the following failure
criteria:
The applied stress intensity factor (K
I
) exceeding the material toughness (K
Ic
)
Plastic overload of the remaining ligament
The crack depth exceeding a user-specified limit
In future software releases, a vibratory limit will be included to address the possibility of
terminal high cycle fatigue failure. A flow diagram for critical crack size determination is shown
in Figure 3-4.
EPRI Licensed Material
Program Modules
3-7
Figure 3-4
Critical Crack Size Determination Flow Diagram
Stress intensity factor solutions for a semi-elliptic surface-connected crack in finite width plate
[10] are incorporated in the software. Any combination of user-specified depth (a) and length (l)
can be evaluated. Unit-specific disk fracture toughness values can be specified by the user, or
default values in the software code from literature data [11] can be used. The lower bound disk
toughness values are estimated based on a startup temperature for the disk and are input by the
user. Plastic overload of the remaining ligament is calculated based on the combined membrane,
bending, and shear stresses in the ligament using a similar approach to that given by Cipolla et al
[12].
3.4.1 Load Redistribution
An algorithm to account for load redistribution between the hooks due to cracking has been
developed and incorporated into the software program. This algorithm uses a numerical
interpolation scheme to predict load redistribution based on the results of several FE analyses
EPRI Licensed Material
Program Modules
3-8
simulating various combinations of cracks depths in the top, middle, and bottom hooks. A
graphical illustration of this load redistribution feature is shown in Figure 3-5 for the special case
of single cracks in each of the hooks. Load redistribution is computed for any arbitrary
combination of crack sizes in the top, middle, and bottom hooks.
Load Redistribution with Cracking
0
0.2
0.4
0.6
0.8
1
1.2
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
(Crack Depth/Hook Width) = (a/W)
L
o
a
d

R
e
l
a
t
i
v
e

t
o

U
n
c
r
a
c
k
e
d

V
a
l
u
e
Top
Mid
Bot
Figure 3-5
Illustration of Load Redistribution as a Function of Crack Depth (a) to Hook Width (W)
Ratio.
3.5 Remaining Life (Deterministic Versus Probabilistic)
For a deterministic analysis, remaining life (t
rem
) is computed using the following relationship:
da/dt
a
-
a
t =
t
i cr
ini rem
+ (Eq. 3-3)
where
t
ini
= Remaining initiation time (if applicable)
a
i
= Initiated or detected crack size
a
cr
= Critical crack size
da/dt = Crack growth rate
Because of the non-linear dependency of load redistribution on crack size, crack-growth
simulations must be performed in small increments of crack size, and critical size must be
determined when one of the above failure criterion is met.
EPRI Licensed Material
Program Modules
3-9
Deterministically predicted remaining lives typically yield a large scatter in results for worst-case
versus mean data, suggesting that variability in modeled data cannot be adequately characterized
deterministically. The use of worst-case assumptions stacks conservatisms with results in an
overly pessimistic estimate of remaining life and does not represent a realistic outcome. It is
unlikely that all of the worst case conditions would occur simultaneously; therefore, a
probabilistic analysis that considers position in the scatterband can provide a more realistic
assessment of remaining life.
A probabilistic evaluation requires identification of appropriate random variables and
determination of a statistical distribution associated with each variable. The generation of
probabilistic results can then be accomplished using a technique such as Monte Carlo, which
involves successive deterministic remaining life calculations using randomly selected values of
inputs. The probabilistic approach is illustrated schematically in Figure 3-6.
Figure 3-6
Flowchart for Probabilistic Calculations
EPRI Licensed Material
Program Modules
3-10
Probabilistic calculations are performed using the Monte Carlo technique for a user-specified
number of iterations. A summary of random variables, which can be defined using the various
sub-menus under the Input main menu option, is provided below:
1. Scale factor for load/stresses (normal distribution)
2. Overspeed level (normal distribution)
3. Disk startup temperature (normal distribution)
4. Disk steady-state operating temperature (normal distribution)
5. Crack depth (normal distribution)top
6. Crack depth (normal distribution)middle
7. Crack depth (normal distribution)bottom
8. Crack aspect ratiodepth/length (normal distribution)top
9. Crack aspect ratiodepth/length (normal distribution) middle
10. Crack aspect ratiodepth/length (normal distribution)bottom
11. Yield strength (normal distribution)
12. Lower Bound Fracture Toughness (normal distribution)
13. FATT (normal distribution)
14. Fracture Toughness (normal distribution) vs. (T-FATT)
15. Crack initiation time (user-defined tabular)
16. SCC Growth Rate Constant, C
1
(log normal distribution)
17. SCC Growth Threshold, K
ISCC
(normal distribution)
EPRI Licensed Material
4-1
4

GEOMETRICAL AND DIMENSIONAL MEASUREMENTS
One of the keys to the successful development of the LPRimLife software was to secure accurate
geometrical and dimensional information for blade attachments. This information would be used
to develop the library of built-in finite element stress results required for the evaluation of rim-
attachment cracking. For the straddle-mount (GE) blade attachments, this information was made
available by the tailored collaboration participants who funded the EPRI program. However, for
the axial-entry blade attachments, this information was not readily available and had to be
secured through measurements. Participants were asked to remove or provide spare blades which
were, in turn, forwarded to an aftermarket vendor for dimensioning.
As mentioned in Section 3.1, five different geometries were incorporated into the stress analysis
module for the straddle-mount (GE) attachments. For each of these five geometries, two rows
L-2 and L-3 rowswere incorporated. L-2 and L-3 represent the most problematic attachments
locations to date. The dimensional data for the straddle-mount attachments is shown in
Table 4-1.
EPRI Licensed Material
Geometrical and Dimensional Measurements
4-2
Table 4-1
Summary of Straddle-Mount (GE) Dimensional and Loading Data
SUMMARY OF GE DOVETAIL DIMENSIONAL AND LOADING DATA
1 Type
2 MW
3 Turbine Mfg.
4 Turbine Type
Nuclear
1300
GE
TC6F43
Nuclear
920
GE
TC6F38
Nuclear
538
GE
TC4F38
5 Stage/Row # L-2 L-3 L-2 L-3 L-2 L-3
DESCRIPTION PARA-
METER
1
Inches Inches Inches Inches Inches Inches
Dovetail
6 Disk Outside
Rad
R0 45.5 46.375 44.887 45.75 45.5 45.75
7 Base Width dZ7 5.125 4.462 4.45 3.877 4.691 3.88
Top Lug
8 Lug Width dZ1 2.015 1.6695 1.685 1.478 1.68 1.475
9 Neck Width dZ2 1.3655 1.0645 1.0906 1.104 1.1 1.01
10 Fillet Radius r1 0.0938 0.0781 0.1181 0.063 0.094 0.063
11 Radial Coord. R1 44.915 45.888 44.414 45.381 45 45.35
12 Max. Crack W1 0.74 0.6 0.61 0.5 0.6 0.45
Middle Lug
13 Lug Width dZ3 3.0475 2.578 2.5787 2.226 2.595 2.225
14 Neck Width dZ4 2.363 1.989 1.9882 1.764 2.008 1.76
15 Fillet Radius r2 0.0938 0.0781 0.1181 0.063 0.094 0.063
16 Radial Coord. R2 43.915 44.903 43.446 44.663 44.03 44.68
17 Max. Crack W2 0.77 0.68 0.68 0.5 0.6 0.45
Bottom Lug
18 Lug Width dZ5 4.049 3.484 3.5157 2.976 3.5 2.974
19 Neck Width dZ6 3.373 2.92 2.9134 2.5 2.91 2.499
20 Fillet Radius r3 0.0938 0.0781 0.1181 0.063 0.094 0.063
21 Radial Coord. R3 42.915 43.918 42.477 43.945 43.07 43.93
22 Max. Crack W3 0.77 0.68 0.68 0.5 0.7 0.53
Side Tang
23 Tang Width dZ_tang 0.38 0.336 0.35 0.287 0.447 0.3
24 Fillet Radius r4 0.0938 0.0938 0.09 0.09 0.094 0.063
25 Radial Coord. R4 42.4675 43.436 41.8973 43.445 42.56 43.49
26 Tang Height H_tang 0.3 0.248 0.2 0.2 0.253 0.25
Blade
27 Height to foils H_blade 4.575 4.483 4.687 3.533 4.5 3.6
28 Width at Top dZ0 4.005 3.51 3.758 3.265 3.8 3.3
Rim Load
29 # blades --- --- 135 170 136 157
30 Blade Wt (lbs) --- --- 19.53 9.558 17.88 9
31 Rim Load (kips) 10,000 6,000 11,787 7,068 11,277 6,349
32 % Top Hook 44.40% 42.40% 40.60% 41.40% 41.63% 39.91%
33 % Middle Hook 31.10% 31.70% 32.40% 31.40% 31.26% 32.32%
34 % Bottom Hook 24.50% 25.80% 27.00% 27.20% 27.11% 27.77%
Note: Refer to Figure 3-2 for a description of each parameter.
EPRI Licensed Material
Geometrical and Dimensional Measurements
4-3
Measured geometrical information recorded for the axial-entry (Westinghouse) attachments
included three separate machine designs:
BB81
BB281
BB276
Dimensional data for the BB81 and BB276 designs are shown in Table 4-2. At the printing of
this document, blades had been secured, and the BB281 dimensional/geometrical information
was being obtained through direct measurements.
EPRI Licensed Material
Geometrical and Dimensional Measurements
4-4
Table 4-2
Summary of Axial-Entry (Westinghouse) Dimensional and Loading Data
SUMMARY OF WH STEEPLE DIMENSIONAL & LOADING DATA
1 Type: Fossil Nuclear
2 MW 740 1137 (Unit 1),
1164 (Unit 2)
3 Turbine Mfg.: WH WH
4 Turbine Type: TC4F28 TC6F44
5 Stage/Row #: L-1 L-0 L-4 (new) L-3 (new) L-4 L-3 L-2 L-1 L-0
DESCRIPTION PARAMETER
Disk Overall Dimensions (inches):
6 Disk Outside Dia. OD 59.372 - - - - - - -
7 Disk Width W 4 - 2.309 3.238 4.994 6.992
8 Root Type (S=Straight, SK=Skewed, C=Curved) Curved Skewed Skewed Curved Curved Curved Curved Curved
8a Skew Angle (SK) Alpha - n/a - - - - n/a - - n/a - - n/a - - n/a - - n/a -
8b Radius of Curvature (C) Rc 4.8 - n/a - - n/a - - 3.162 4.610 6.375 6.310
8c Offset from Disk Inlet Face (C) Wo 0.7 - n/a - - n/a - - 0.495 0.859 1.202 3.501
Groove Angles (degrees): Groove Angles Same for These Rows
9 Overall Angle Theta1 13.2 28.3208
10 Lug Angle Theta2 58.2 26.7072
Groove Width Dimensions (inches): Groove Dimensions Same for These Rows
11 Blade: Top Neck A 0.702 0.702
12 Steeple: Top Neck B 1.025 1.025
13 Blade: Middle Neck (2) C2
14 Blade: Middle Neck C 0.518 0.518
15 Steeple: Middle Neck D 0.826 0.826
16 Blade: Bottom Neck (2) E2
17 Blade: Bottom Neck E 0.354 0.354
18 Steeple: Bottom Neck F 0.636 0.636
Groove Height Dimensions (inches):
19 Blade: Top Neck G 0.122 0.122
20 Steeple: Top Neck J 0.239 0.239
21 Blade: Middle Neck (2) H2
22 Blade: Middle Neck H 0.545 0.545
EPRI Licensed Material
Geometrical and Dimensional Measurements
4-5
Table 4-2 (continued)
Summary of Axial-Entry (Westinghouse) Dimensional and Loading Data
SUMMARY OF WH STEEPLE DIMENSIONAL & LOADING DATA
1 Type: Fossil Nuclear
2 MW 740 1137 (Unit 1),
1164 (Unit 2)
3 Turbine Mfg.: WH WH
4 Turbine Type: TC4F28 TC6F44
5 Stage/Row #: L-1 L-0 L-4 (new) L-3 (new) L-4 L-3 L-2 L-1 L-0
DESCRIPTION PARAMETER
23 Steeple: Middle Neck K 0.635 0.635
24 Blade: Bottom Neck (2) I2
25 Blade: Bottom Neck I 0.925 0.925
26 Steeple: Bottom Neck L 1.011 1.011
27 Overall Groove Depth M 1.168 1.168
Groove Radii (inches):
28 Blade Top Fillet R1 0.062 0.0625
29 Blade Middle Fillet R2 0.031 0.0312
30 Blade Bottom Fillet R3 0.031 0.0312
31 Steeple Top Fillet R4 0.031 0.0312
32 Steeple Middle Fillet R5 0.031 0.0312
33 Steeple Bottom Fillet R6 0.031 0.0312
34 Steeple Top R7 0.157 0.1406
35 Steeple Bottom of Groove R8 0.167 0.120
Rim Load Data:
36 # blades 120 114 - - - - - - -
37 Blade Wt (lbs) 6.01 - - - - - - -
38 Rim Load (kips) 7368 - - - - - - -
39 % Top Hook 33.17% - - - - - - -
40 % Middle Hook 33.29% - - - - - - -
41 % Bottom Hook 33.54% - - - - - - -
Figures 4-1 and 4-2 provide the steeple details that correspond to Table 4-1.
EPRI Licensed Material
Geometrical and Dimensional Measurements
4-6
Figure 4-1
Axial-Entry (Westinghouse) Root Types
EPRI Licensed Material
Geometrical and Dimensional Measurements
4-7
Figure 4-2
Axial-Entry (Westinghouse) Steeple Groove Dimensions
EPRI Licensed Material
5-1
5

LPRIMLIFE SOFTWARE
The LPRimLife software program was written in Microsoft C++ for operation on a personal
computer (PC) in a Windows environment (see Figure 5-1).
Figure 5-1
LPRimLife Splash Screen and Main Menu Options
5.1 Description
The software program incorporates an easy-to-use graphical user interface with comprehensive
on-line help. Main menu options (see Figure 5-1) and their use are as follows:
The File option should be selected by the user when the program is first executed to define
whether a new analysis is to be performed or an existing analysis file is to be opened.
The Edit option is currently limited to searching for text (using Find) in the standard output
file once an analysis has been performed.
The Input option contains all of the necessary inputs that must be defined by the user prior to
performing an analysis.
EPRI Licensed Material
LPRimLife Software
5-2
The Analysis option offers the user the choice of performing a deterministic or probabilistic
analysis and starts the calculations.
The View option allows the user to view the output of the analysis in text or graphical form.
The Library option is a special tool that allows the user to add or modify items in the default
library of geometry and stress data.
The Help option allows the user to access Help Topics, which cover the entire content of the
software users manual, and to invoke the About LPRimLife pop-up window, which provides
details about the version number of the program and software support. Context-specific help
can also be accessed using the F1 function key from any dialog box.
A typical solution procedure, consisting of defining inputs, selecting an analysis type, and
viewing results, is illustrated in Figure 5-2.
Inputs Analysis View Results
Figure 5-2
Typical Solution Procedure
An example of the input data format for calculation and print controls is shown in Figure 5-3.
EPRI Licensed Material
LPRimLife Software
5-3
Figure 5-3
Calculation and Print Controls Data Input Window
Before proceeding to the Analysis option, the user must define the calculation and print controls
shown in Figure 5-3. The Total Simulation Time is the total number of operating hours into the
future over which remaining life calculations will be performed. A Calculation Increment of 100
to 500 hours is recommended for accuracy because the failure criteria and stress corrosion
cracking (SCC) threshold feature are a non-linear function of crack size. To limit the size of the
output file, a Print Increment in excess of 1000 hours should be used. For a probabilistic
analysis, the number of iterations should be at least one order of magnitude greater than the
reciprocal of the desired failure probability level; that is, to demonstrate a failure probability less
than 10
-3
, the number of iterations should be at least 10
4
.
5.2 Analysis
A deterministic analysis takes only a few seconds to run on a personal computer with a Pentium
processor. A probabilistic analysis with 10
4
iterations runs in about 5 to 10 minutes.
5.3 Results
After an analysis is completed, results can be viewed either in a detailed output text file or in
graphical format. Sample output file results for deterministic and probabilistic analysis runs are
shown in Figures 5-4 and 5-5.
EPRI Licensed Material
LPRimLife Software
5-4
Figure 5-4
Deterministic Analysis Results Output Window
Figure 5-5
Probabilistic Analysis Results Output Window
Various key inputs and results can also be plotted using a graphics capability built into the
software code. The user can modify any of the plot elementssuch as title, legend, and
markersby clicking the right mouse button anywhere within the plot. For example, the tabular
EPRI Licensed Material
LPRimLife Software
5-5
probabilistic analysis results shown in Figure 5-5 are plotted in Figure 5-6 using the Failure Plot
option from the View main menu.
Figure 5-6
Cumulative Probability of Failure Plot Option From the View Main Menu
EPRI Licensed Material
6-1
6

CONCLUSIONS
A Windows-based personal computer software program, LPRimLife, has been developed for
performing a remaining life assessment of disk rim attachments with known or suspected
cracking. The code combines the necessary stress analysis, fracture mechanics algorithms, and
material degradation data into an easy-to-use software tool to predict the appropriate failure
mode and remaining life of rim attachments with cracking. The first phase of software
development, which includes the methodology for evaluating cracking in GE dovetail
attachments, is complete. The next phase, to evaluate cracking in Westinghouse axial-entry
attachments, is currently in development with completion expected in 1999. With comprehensive
on-line help and built-in graphics and plotting capability, the program facilitates rapid life
assessments by non-experts with minimal introduction to the software.
EPRI Licensed Material
7-1
7

FUTURE DEVELOPMENTS
Future developments will include the evaluation of cracking in GE finger-pinned attachments
and the addition of an economics-based decision analysis module to assist with run/repair/replace
decision-making.
EPRI Licensed Material
8-1
8

REFERENCES
1. EPRI Report NP-2429, Steam Turbine Disk Cracking Experience, Volumes 1 through 7,
Research Project 1398-5, June 1982.
2. D. A. Rosario, C. H. Wells, G. J. Licina, LP Rotor Rim-Attachment Cracking Survey of
Utility Experience, EPRI Research Project 9005-01, Final Report TR-107088, January
1997.
3. W. G. Clark, B. B. Seth, and D. M. Shaffer, Procedures for Estimating the Probability of
Steam Turbine Disc Rupture from Stress Corrosion Cracking, presented at Joint
ASME/IEEE Power Generation Conference, October 1981.
4. EPRI Report NP-6444, Guidelines for Predicting the Life of Steam Turbine Disks
Exhibiting Stress Corrosion Cracking, Volumes 1 and 2, Research Projects 1929-16/14,
2518-1, July 1989.
5. LP Rotor Rim-Attachment Cracking - Development of a Life Assessment Code, Project
Agreement WO4597-01 between Electric Power Research Institute (EPRI) and Structural
Integrity Associates, Inc., May, 1997.
6. LP Rotor Rim-Attachment Cracking Computer Code (LPRimLife) Software Users
Manual, prepared for EPRI by Structural Integrity Associates, Inc., Report No. SIR-97-111,
Rev.1, November 1998.
7. D. A. Rosario, R. Viswanathan, C.H. Wells and G. J. Licina, Stress Corrosion Cracking of
Steam Turbine Rotors, 1998 NACE International, CORROSION- Vol.54, No. 7, pp. 531-
545.
8. S. R. Holdsworth, et al, Laboratory Stress Corrosion Cracking Experience in Steam Turbine
Disc Steels, Proceedings of the EPRI Steam Turbine Stress Corrosion Cracking Workshop,
March 1997.
9. M. O. Speidel and R. Magdowski, Major Influences on the Growth Rates of Stress
Corrosion Cracks in Steam Turbine Rotor and Blade Materials, Proceedings of the EPRI
Steam Turbine Stress Corrosion Cracking Workshop, March 1997.
10. pc-CRACK for Windows, Version 3.0-3/27/97, Structural Integrity Associates, 1997.
11 R. C. Schwant and D. P. Timo, Life Assessment of General Electric Large Steam Turbine
Rotors, EPRI CS-4160, Proceedings of the Seminar on Life Assessment and Improvement
EPRI Licensed Material
References
8-2
of Turbo-Generator Rotors for Fossil Plants, September 12-14, 1984, Raleigh, North
Carolina.
12. R. C. Cipolla, J. F. Lesiuk, M. A. Melton and T. J. Szumski, Safe-Life Evaluation and
Repair Acceptance Criteria for Dovetail Cracking in Low Pressure Rotors, Proceedings of
the 5
th
EPRI Steam Turbine/Generator Workshop, July 29-August 1, 1997, Lake Buena Vista,
Florida.