Proceedings of the ASME 2016 Pressure Vessels and Piping Conference
PVP2016 July 17-21, 2016, Vancouver, British Columbia, Canada
PVP2016-63040
A Comparison of Different Design Codes on Fatigue Life Assessment Methods
Jinhua Shi Liwu Wei
Amec Foster Wheeler Amec Foster Wheeler 19B Brighouse Court 19B Brighouse Court Barnett Way Barnett Way Gloucester, GL4 3RT, UK Gloucester, GL4 3RT, UK
Claude Faidy Andrew Wasylyk Nawal Prinja
Consultant - CF Int Engineering CORDEL, WNA Amec Foster Wheeler Intgrit-vieillissement des Structures Tower House, 10 Booths Park Codes et Normes-Sret Nuclaire Southampton Street, Knutsford France London WC2E 7HA, UK Cheshire, WA16 8QZ, UK
ABSTRACT expected to have an infinite fatigue life. Although this empirical
Different pressure vessel and piping design codes and method has found widespread use in fatigue analysis, it does not standards have adopted different fatigue analysis methods. In provide a realistic account of fatigue life when considerable order to make some contribution to current efforts to harmonize plastic deformation occurs during cyclic loading. Realizing the international design codes and standards, a review of fatigue important role of plastic strains in inducing permanent fatigue analysis methods for a number of selected nuclear and non- damage, Coffin [2] and Manson [3] independently proposed nuclear design codes and standards has been carried out. The plastic strain-based continuum characterization of fatigue life. selected design codes and standards are ASME Boiler and The stress range based method is used in a number of Pressure Vessel Code Section III Subsection NB and Section design codes, such as the ASME Boiler and Pressure Vessel VIII Division 2, EN 12952, EN 13445, EN 13480, PD 5500, Code Section III Subsection NB [4], Section VIII Division 2 RCC-M, RCC-MRx, JSME, PNAEG and R5. This paper [5], BS EN 12952-3 [6], BS EN 13445-3 [7], BS EN 13480-3 presents the initial review results. [8], BS EN 1993-2 [9] and PD 5500 [10]. A comparison of the The results of the study could be used as part of the on- selected design codes and standards is carried out in Section 2. going work of the Codes and Standards Task Force of the World The strain range based method is used by the ASME Nuclear Association (WNA) Cooperation in Reactor Design Section III Subsection NH [11] and the structural integrity Evaluation and Licensing (CORDEL) Working Group. assessment procedure R5 [12]. RCC-M [13] uses a combined strain and stress approach. A comparison of these approaches is conducted in Section 3. 1 INTRODUCTION After a discussion conducted in Section 4 on harmonizing international codes and standards, conclusions are drawn in The total fatigue life can be defined as a function of the Section 5. applied stress range, strain range, mean stress and environment. In the stress range based or strain range based methods, the fatigue life of a component is defined as the total number of 2 STRESS RANGE BASED METHOD cycles to induce fatigue damage and to initiate a dominant fatigue flaw which propagates to final failure. The philosophy This section describes the stress range based method used underlying the cyclic stress-based and strain-based approaches in different design codes and standards. is distinctly different from that of defect-tolerant methods. The stress-life approach to fatigue was first introduced in the 1960s by Wohler [1]. Out of this work evolved the concept of an endurance limit, which characterizes the applied stress amplitude below which a (nominal defect-free) material is
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2.1 ASME Section III, Subsection NB Annex 3-F.1 specifies the smooth bar design fatigue curves for a number of materials based on the stress amplitude, Sa. ASME III, NB-3222.4 details the analysis for cyclic Metal temperature limits and minimum specified ultimate operation. The conditions and procedures of ASME III NB- tensile strength values are presented in Table 1. 3222.4 are based on a comparison of peak stresses with strain Welded joint design fatigue curves are detailed in Annex 3- cycling fatigue data. The strain cycling fatigue data are F.2 for a number of materials based on the computed equivalent represented by design fatigue strength curves. As defined in stress range. Again, metal temperature limits and minimum NB-3213.17, a fatigue strength reduction factor is a stress specified ultimate tensile strength values are presented in Table intensification factor which accounts for the effect of a local 1. Furthermore, coefficients for the welded joint fatigue curves structural discontinuity (stress concentration) on the fatigue are given not only for mean curve, but also for the lower bound strength. Values for some specific cases, based on experiment, and upper bound. In addition to the effect of the elastic are given in NB-3338, NB-3339 and NB-3680. In the absence modulus, the effects of environment other than ambient air are of experimental data, the theoretical stress concentration factor also accounted by an environmental modification factor, fE. It is may be used. NB-3222.4 (e-2) indicates, for instance, that a stated that a value of fE = 4.0 shall be used unless there is fatigue strength reduction factor of no less than five should be specific information to justify an alternate value based on the used. severity of the material/environmental interaction. ASME Section III Appendices, Mandatory Appendix I, Figures I-9.1 through I-9.8 contain the applicable fatigue design curves for the materials permitted by Subsection NB. When 2.3 PD 5500 more than one curve is presented for a given material, the applicability of each is identified. Where curves for various Assessment of pressure vessels subject to fatigue is detailed strength levels of a material are given, linear interpolation may in Annex C of [7] to ensure that the vessel is designed to have a be used for intermediate strength levels of these materials. The fatigue life which is at least as high as the required service life. strength level is the specified minimum room temperature The fatigue strength of a pressure vessel is usually value. A in Fig. 1. These curves show the allowable amplitude governed by the fatigue strength of details (e.g. openings, Sa of the alternating stress intensity component (one-half of the welds, bolting, attachments) and is assessed on the basis of the alternating stress intensity range) plotted against the number of fatigue behaviour of test specimens containing weld details cycles. This stress intensity amplitude is calculated on the similar to those under consideration, using SN curves, in which assumption of elastic behaviour and, hence, has the dimensions the fluctuating or repeated stress range, Sr, is plotted against of stress, but it does not represent a real stress when the elastic number of cycles to failure, N. SN curves based on fatigue test range is exceeded. The fatigue curves are obtained from data obtained from plain material, to be used in conjunction uniaxial strain cycling data in which the imposed strains have with appropriate stress concentration or fatigue stress reduction been multiplied by the elastic modulus and a design margin has factors, are used to assess bolts and un-welded material. been provided so as to make the calculated stress intensity The design SN curves for the assessment of weld details given amplitude and the allowable stress intensity amplitude directly in Fig. 2 have been derived from fatigue test data obtained from comparable. Where necessary, the curves have been adjusted to welded specimens, fabricated to normal standards of include the maximum effects of mean stress, which is the workmanship, tested under load-control or, for applied strains condition where the stress fluctuates about a mean value that is exceeding yield (low-cycle fatigue), under strain control. different from zero. As a consequence of this procedure, it is Continuity from the low- to high-cycle regime is achieved by essential that the requirements of the primary plus secondary expressing the low-cycle data in terms of the pseudo-elastic stress intensity be satisfied at all times with transient stresses stress range (i.e. strain range multiplied by elastic modulus). included, and that the calculated value of the alternating stress Such data are compatible with results obtained from intensity be proportional to the actual strain amplitude. To pressure cycling tests on actual vessels when they are expressed evaluate the effect of alternating stresses of varying amplitudes, in terms of the nominal stress range in the region of fatigue a linear damage relation is assumed. cracking. The curves are used in conjunction with the The effect of the elastic modulus is also considered by fluctuating stress range, Sr, regardless of applied mean stress. multiplying the alternating stress intensity by the ratio of the Regression analysis of the fatigue test data gave the mean modulus of elasticity given on the design fatigue curve to the SN curve and standard deviation of log N. The curves in Fig. 2 value of the modulus of elasticity used in the analysis. are two standard deviations below the mean, representing Effects of environment are specified in Code Cases N-761 approximately 95.4% probability of survival. Comparison of and N-792 [14, 15] and also described in [16] and [17]. More these SN curves and fatigue test data obtained from cyclic information is presented in Table 1. pressure tests on welded vessels indicates that they are conservative, but not excessively so. The design procedures given in Annex C.2 and C.3.4 2.2 ASME Section VIII Division 2 incorporate SN curves three standard deviations below the Design fatigue curves for non-welded and for welded mean, representing approximately 99.7% probability of construction are provided in ASME VIII Division 2, Annex 3-F survival. More information is detailed in Table 1. in terms of polynomial functions
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on the total creep-fatigue damage accumulated at failure, as shown in Fig. 4. 2.4 BS EN 12952-3 Fatigue design curves are given in Figures NH-T-1420-1A to NH-T-1420-1E corresponding to the maximum metal Chapter 13 of BS EN 12932-3 states that due to the temperature occurring during the cycle for steels of 304 SS, 316 simplicity of the fatigue analysis, the life prediction calculated SS, Ni-Fe-Cr Alloy 800H, 2Cr-1Mo and 9Cr-1Mo-V. The may in some cases be overly conservative. More complex design fatigue curves were determined from completely methods, such as finite element analysis, may be applied to reversed loading conditions at strain rates greater than, or equal obtain more accurate life predictions should the need arise. to, those noted on the curves. An equivalent strain range is used A complete load cycle which includes a period of steady to evaluate the fatigue damage sum for both elastic and inelastic state, shutdown, start-up and a further period of steady state analysis. should be examined, primarily examining the effects of pressure and temperature. During thermal transient events, temperature differences between the header and branch can be obtained 3.2 R5 either by deriving the temperature difference between the branch and the main shell or by using the steam temperature R5 is an established structural integrity assessment ramp rate. procedure which is frequently used in the structural integrity The material properties of a component are a function of assessments of Advanced Gas-Cooled Reactor (AGR) the cyclic temperature and these should constantly change components operating in the creep range in the UK. The throughout the cycle. During a load cycle, in the case of BS EN procedure is also relevant to high temperature plants outside the 12952-3, this is simplified to the input of a single temperature, nuclear power generation industry. Furthermore, R5 is under defined as the reference temperature. The stress concentration continually development and further development areas are factors, m, and t,, due to pressure and thermal loadings are under regularly review. Therefore, in this Section the current R5 included in calculating cyclic stress ranges. The calculated fatigue method is described first in Subsection 3.2.1 and then cyclic stress ranges can be then further refined using a series of the proposed methodology is given in Subsection 3.2.2. equations depending on whether the calculated stress range is elastic, partly plastic or fully plastic. The fatigue curves are shown in Fig. 3: Rm is the tensile 3.2.1 Previous R5 fatigue life calculation strength at room temperature and 2fa the stress range. More information is given in Table 1 for the comparison. The total creep-fatigue damage, D, at the assessment location: D is defined as the linear sum of damage due to fatigue (Df) and creep (Dc). Crack initiation is conceded when the total damage D=1. 3 STRAIN RANGE BASED METHOD The process of fatigue damage is considered to consist of The strain range based method has been used in ASME III two stages. The first corresponds to the formation of a defect of Subsection NH and R5 for high temperature applications. size, ai = 0.02mm (20m). The second stage is the growth of this defect to a specified depth, a0, which corresponds to the initiation criterion. This separation enables assessments to be 3.1 ASME III Subsection NH made for thin sections in which a0 must be specified to be smaller than the crack size, a , corresponding to failure in a NH-3213.16 defines that strain cycle is a condition in laboratory specimen. The separation also enables allowance to which the strain goes from an initial value, through an algebraic be made for the order in which cycles are applied and for the maximum value and an algebraic minimum value and then different effects of multiaxial stress state on the formation and returns to the initial value. In cases where creep or ratcheting is growth processes. present in the cycle, there will not be a return to the initial strain For thick section components, set a0 equal to a . For thin- value. Instead the designer will have to examine the hysteresis section components, set a0 equal to a small fraction (typically loop for inelastic analysis and the stress history for elastic less than 10%) of the cross-section so that uncracked body analysis to determine the end point of the cycle. NH-T-1413 stress analysis is appropriate. A convenient choice is often the provides the method of combining cycles for fatigue analysis. A extent of the cyclic plastic zone, rp. The reasons for the choice single service cycle may result in one or more strain cycles. of a0 should be reported. The total strain range tot during a cycle is simply given by Dynamic effects shall also be considered as strain cycles. Fatigue strength reduction factors currently exist only for cycles that do not involve significant creep effects. Fatigue damage is the sum of the elastic, plastic, volumetric and creep that part of the total material damage caused by cyclic components, where the elastic-plastic point lies on the deformation that is independent of time effects (e.g., stress intersection of the cyclic stress-strain curves and the Neuber hold-time, strain hold-time, frequency). hyperbola from the elastic equivalent surface stress. The damage is expressed in terms of a cycle ratio. Creep- For weldments, the total strain range is enhanced by a fatigue fatigue interaction is the effect of combined creep and fatigue strength reduction factor (FSRF), based on weld types and whether or not the weld being dressed (profiled) or undressed
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(as-welded), and also enhanced by a thickness factor of as the ones for fatigue described in this paper. Harmonisation (section thickness/22mm)0.25. of codes and standards is an attractive concept for several reasons, and can bring clear benefits such as a common level of quality and standardised designs. 3.2.2 Current R5 fatigue life calculation To carry out harmonisation of nuclear codes and standards, three organisations have been set up: The current approach as proposed in [18] involves splitting the existing FSRF into a Weldment Endurance Reduction World Nuclear Association / Cooperation in Reactor (WER), which accounts for reduced fatigue endurance due to Design Evaluation and Licensing (CORDEL) weld imperfections, and a Weldment Strain Enhacement Factor Standards Development Organisations (SDOs) Code (WSEF), which accounts for material mismatch and local geometry. It should be noted that the proposed new approach Convergence Board makes no distinction between dressed and un-dressed welds. As Multinational Design Evaluation Program (MDEP) described in [18], the WSEFs can be derived such that the parent mean fatigue curve, factored by the WSEF and WER, By creating these three groups, then the key stakeholders provides a mean fit to the weldment fatigue data assuming a log involved, i.e., industry (CORDEL), code writing bodies (SDO normal distribution of fatigue life. Convergence Board) and regulators (MDEP) are all represented in harmonisation of codes and standards. In addition, the Western European Nuclear Regulators Association (WENRA) is 3.3 RCC-M ANNEX Z D also a regulators association and has certain objectives relating to harmonisation of safety in nuclear facilities. The interface ANNEX Z D, RCC-M [13] provides a combined strain and between MDEP and WENRA has been defined in order to stress approach to fatigue damage assessment, and concerns the avoid any duplication of tasks or objectives, see Reference [19]. acceptable rules for analyzing fatigue behaviour in zones with The particular topic for harmonisation that is of direct geometrical discontinuities similar to crack-type discontinuities. relevance to this paper has been identified by WNA CORDEL The rules specified in this annex use the fatigue initiation factor as being Non-Linear Analysis [20]. to calculate an allowable number of cycles before the For non-linear analysis, the CORDEL Design Methodology appearance of fatigue damage, (i.e. before fatigue crack and Limits Expert Group concentrates on the convergence of initiation). The evaluation method of the fatigue initiation factor five issues related to the mechanical design of power plants: is detailed in ANNEX Z D 2220. Table Z D 2300 gives fatigue initiation curves for three different types of steel (low alloy Plastic analysis, harmonising the finite element steel, stainless steel and Ni-Cr-Fe alloy) in Air and PWR techniques employed to assess strength (limit load environment, which can be used if no other data are available. analysis), shakedown (direct shakedown prediction) With ANNEX Z D 3000, the permissible number of cycles and fatigue (ratcheting and strain based fatigue can also be determined by calculating the local strain as analysis) methodologies used internationally, follows: Stress Classification, concentrating on the - Evaluation of the product . with the following standardisation of definitions and terms used in stress formula: .d t m, n 2 classifications, E Definition of events, loads and load combinations, - Determination of the corresponding to the product concentrating on harmonisation of definition of events ., using the cyclic strain hardening curve for the and methodologies of load combinations, material (or a simplified low envelope of this curve), Stress and strain limits, and giving the relationship between . and the strain Analysis and assessment of extreme dynamic events. amplitude . Note that until these cyclic hardening curves are not integrated in the code, the curves used Comparative studies, such as the one presented in this must be substantiated on a case by case basis. paper, could be used by CORDEL as the basis for progress in - Evaluation of the allowable number of cycles using the harmonization of rules for ratcheting and strain based fatigue S-N fatigue curves in ANNEX ZI and using the analysis. E relationship: Sa . 3 5 REMARKS This paper has summarized the different approaches to 4 INTERNATIONAL CODES AND fatigue design in various national and international codes and STANDARDS HARMONIZATION standards. It is evident that differences in the rules have arisen as national standards have developed in isolation. Therefore, In an increasingly global industry, there are several obvious the paper has put this in context by highlighting the ongoing benefits to harmonising the rules in codes and standards, such efforts by various international groups to limit further
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divergence and encourage convergence of the technical rules in essels, Division 2, Alterative Rules. Two Park Avenue, codes and standards worldwide. Technical remarks can be New York. obtained as follows: [6] BSi (2011): BS EN 12952-3:2011, Water-tube boilers and auxiliary installations. Part 3: Design and The design fatigue curves presented in this paper calculation for pressure parts of the boiler. mainly concentrate on low cycle fatigue (LCF). [7] BSi (2012): BS EN 13445-3:2009+A1:2012, Unfired The stress range based approach is relatively simple to pressure vessels. Part 3: Design. use. However, apart from BS EN12952-3, the method [8] BSi (2012): BS EN 13480-3:2012, Metal industry has been used in the design codes below creep regime. piping. Part 3: Design and calculation. The strain range based method is more complex and [9] BSi (2010): BS EN 1993-2:2006, Eurocode 3 - Design has been mainly adopted by high temperature design of steel structures Part 2: Steel bridges. codes and assessment procedures. [10] BSi (2012): PD 5500:2012, Specification for unfired fusion welded pressure vessels. Weldments are important components and have been [11] The American Society of Mechanical Engineers considered in most design codes. (2015): ASME Boiler and Pressure Vessel Code, Most design codes and assessment procedures are Section III, Rules for Construction of Nuclear Facility based on elastic stress analyses; however, inelastic Components, Division 1 - Subsection NH, Class 1 stress analyses can be used. Components in Elevated Temperature Service. R5 is less conservative than design codes, as it is an [12] EDF Energy Generation (2003), R5, Assessment assessment procedure not a design code, thus it does Procedure for the High Temperature Response of not contain inherent design safety margins. Structures, Issue 3, Revision 1. [13] AFCEN (2007): RCC-M - Edition 2007 Addendum ASME III Subsection NH and R5 have focused more December 2008: Design and Construction Rules for on creep and creep-fatigue interaction. Mechanical Components of PWR Nuclear Islands. RCC-M is based on a combined strain and stress [14] The American Society of Mechanical Engineers approach. (2010): ASME Boiler and Pressure Vessel Code, Code Cases: Nuclear Components. Case N-761 Fatigue Design Curves for Light Water Reactor (LWR) 6 ACKNOWLEDGMENTS Environments, Section III, Division 1. This paper is published by the permission of AMEC Foster [15] The American Society of Mechanical Engineers Wheeler. (2010): ASME Boiler and Pressure Vessel Code, Code Cases: Nuclear Components. Case N-792 Fatigue Evaluations Including Environmental Effects, Section 7 REFERENCES III, Division 1. [16] Chopra, O.K.; Shack, W.J. (2007): Effect of LWR [1] Wohler, A. (1860): Versuche uber die Festigkeit der Coolant Environments on the Fatigue Life of Reactor Eisenbahnwagenachsen. Zeitsschrift fur Bauwesen 10; Materials, NUREG/CR-6909. English summary (1867). Engineering 4, pp. 160-161. [17] de Haan de Wilde, F.H.E; Hannink, M.H.C.; [2] Coffin, F.F. (1954): A study of the effects of cyclic Blom, F.J. (2013): Overview of international thermal stresses on a ductile metal. Transactions of the implementation of environmental fatigue. Proceedings American Society of Mechanical Engineers 76, pp. of the ASME 2013 Pressure Vessels and Piping 931-950. Conference, PVP2013-97695. [3] Manson, S.S. (1954): Behavior of materials under [18] Dean, D.; Spindler, M.W.; Chevalier, M.; N G conditions of thermal stress. National Advisory Smith, N.G. (2013): Recent Developments in the R5 Commission on Aeronautics: Report 1170. Cleveland: Volume 2/3 Procedures for Assessing Creep-Fatigue Lewis Flight Propulsion Laboratory. Initiation in Defect-Free Components Operating at [4] The American Society of Mechanical Engineers High Temperatures. Proceedings of the ASME 2013 (2013): ASME Boiler and Pressure Vessel Code, Pressure Vessels and Piping Conference, PVP2013- Section III, Rules for Construction of Nuclear Facility 98134. Components, Division 1 - Subsection NB, Class 1 [19] WENRA website, http://www.wenra.org. Components. Two Park Avenue, New York. [20] WNA Report: Cooperation in Reactor Design [5] The American Society of Mechanical Engineers Evaluation and Licensing (CORDEL). Working Group (2011): ASME Boiler and Pressure Vessel Code, Annual Report 2011-2012. Section VIII, Rules for Construction of Pressure V
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Temperature Yield Stress, Smooth Effect of Elastic Effect of Effect of Mean LB UB Code/Standard Material Limit, C MPa UTS, MPa Bar Weld Stress Modulus Environment Thickness Curve Curve Curve ASME III Subsection NB Carbon, low alloy and high tensile steels 370 Y 552 Y Y Amplitude Y [13-16] Y Carbon, low alloy and high tensile steels 370 Y 793 - 896 Y Y Amplitude Y [13-16] Y Austenitic steels, nickel-chromium-iron alloy, nickel-iron-chromium alloy and nickel-copper alloy 425 All All Y Y Amplitude Y [13-16] Y High Strength Steel Bolting 370 All All Amplitude Y Y Carbon, Low Alloy, Series 4xx, and High ASME VIII Division 2 Tensile Strength Steels 371 552 Y Amplitude Y Y Carbon, Low Alloy, Series 4xx, and High Tensile Strength Steels 371 793 - 892 Y Amplitude Y Y Series 3xx High Alloy Steels, Nickel-Chromium- Iron Alloy, Nickel-Iron-Chromium Alloy, and Nickel-Copper Alloy 427 All Y Amplitude Y Y Nickel-Chromium-Molybdenum-Iron, Alloys X, G, C-4, And C-276 427 All Y Amplitude Y Y High Strength Steel Bolting 371 All Y Amplitude Y Y Carbon, Low Alloy, Series 4xx, and High Tensile Strength Steels 371 All Y Range Y Y Y Y Y Series 3xx High Alloy Steels, Nickel-Chromium- Iron Alloy, Nickel-Iron-Chromium Alloy, and Nickel-Copper Alloy 427 All Y Range Y Y Y Y Y Nickel-Chromium-Molybdenum-Iron, Alloys X, G, C-4, and C-276 427 All Y Range Y Y Y Y Y BS EN 12952-3 All steels 800 All All Y Y Range Y Y Y PD 5500 Ferritic steels 350 All All Y Y Range Y Y Y Austenitic steels 430 All All Y Y Range Y Y Y Nickel alloys 450 All All Y Y Range Y Y Y Bolts As above All All Y Range Y Y Y
Table 1: Comparison of stress based design codes
Figure 1: One of ASME III fatigue curves
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Figure 2: Fatigue design S-N curves for welds from PD 5500
Figure 3: Number of cycles for crack initiation from BS EN 12952-3
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Figure 4: Creep-fatigue damage envelope, reproduced from Figure NH-T-1420-2
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