EUROPEAN COMMISSION

JOINT RESEARCH CENTRE

HSE
Health & Safety
Executive
;
*
NESC-I
Project Overview
Editors
R. Bass, J. Wintle, R.C. Hurst, N. Taylor
Net work for Evaluating Structural Components
EUR 19051 EN
The mission of the JRC is to provide custoTier-driven scien-
tific and technical support for the conception, development,
implementation and moni tori ng of EU policies.
As a service of the European Commission, the JRC func-
tions as a reference centre of science and technology for
the Uni on. Close to the pol i cy-maki ng process, it serves the
common interest of the Member States, whi l e bei ng inde-
pendent of special interests, whether private or nati onal ."
Final Report
NESC-I
Project Overview
Editors
R. Bass, J. Wi ntl e R.C. Hurst, N. Taylor
EUR 19051 EN
LEGAL NOTICE
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HSE
lli'ullh & Safei
Ki crop
I n t / j w
FOREWORD
The present document is one of a series of reports summarising the results of the NESC-1
project. The complete list of the titles and respective authors is as follows:
Task Group Final Reports
Inspection (Task Group 1. TGI )
Materials Characterisation (TG2)
Thermal and Mechanical Structural Analyses
(TG 3)
Instrumentation (TG 4)
Destructive Examination Advisory Group
Project Evaluation Reports
Constraint
Cladding
Sensitivity Analysis
Crack Arrest
Residual Stresses
Probabilistic Approach
Consistency in Fracture Assessment Criteria
Relevance for Reactor Transients
Codes and Standards
Relation to other Large Scale Projects
Technology Transfer to other Nuclear and
Non Nuclear Plant
Lessons from Networking
Summary Report
Final NESC Overview Report
R. Murgatroyd & B. Eriksen
R. Rintamaa
S. Bhandari & N. Taylor
H. Kockelmann & J. Hedderley
J. Hedderly, N. Taylor & P. Minnebo
D. Lidbury
R. Bass, C. Faidy & R. Murgatroyd
H. Schulz & J. Sievers
R. Gillot & C. Wiesner
E. Keim
J. Wintle
R. Rintamaa, K. Wallin & U. Ehrnsten
C. Faidy
P. Mignot
R. Bass, S. Crutzen & R. Murgatroyd
F. Boydon
F. Boydon
R. Bass, J. Wintle, R. Hurst, N. Taylor
These reports are available to NESC network members from the NESC operating agent:
European Commission Joint Research Centre, Petten, The Netherlands.
HS E
Health & Seiet>
Acknowledgements
This Overview Report, as with all the NESC reports, represents a synthesis of a collective
effort of an international team of experts. For NESC1. in addition to gratefully recognising
the significant support of the UK Health and Safety Executive and the European Commission
Joint Research Centre, very sincere thanks are due to all those persons and organisations who
contributed to the project, for the most part on a contributioninkind basis. The following list
hopefully leaves no one out:
Dr. G. Airey, British Energy pic; Dr. L. Andersson, Oliscila Ingenjrsbyr AB; Prof. J.D.
Atkinson, Sheffield Hallam University; Mr. T. Bann, AEA Sonomatic; Dr. R. Bass. Oak Ridge
National Laboratory; Dr. M. Beghini, Universit degli Studi di Pisa; Dr. W.P. Belcher, British
Energy pic; Dr. S. Bhandari, Framatome; Dr. M. Blake, Health and Safety Executive; Dr. J.G.
Blauel, Fraunhofer IWM; Mr. G.J. Bollini, Tecnatom S.A.; Dr. N. Bonora, University of
Cassino; Mr. B.R. Bowdler, AEA Technology pic; Mr. F. Boydon, Health & Safety Executive;
Dr. J. Brochard, C.E.A. - Saclay; Dr. Brcker, Preussen Elektra AG; Mr. L. Brusa, ENEL spa;
Mr. F. Champigny, EDF; Dr. R.K. Chapman. British Energy pic; Mr. S. Crutzen, EC. DG-
JRC; Dr. C. CuetoFelgueroso, Tecnatom S.A.; Ir. M. I. de Vries, NRG; Mr. M. Deffrennes,
European Commission, DG XVII; Dr. J. Devos, C.E.A. - Saclay; Mr. S. Doctor, Battelli'
Pacific Northwest Labs; Mr. K. Dressier, ABB Reaktor GmbH; Ms. U. Ehrnsten, VTT
Manufacturing Technology; Mr. G. Engl, Siemens AG; Mr. A. Erhard, BAM; Mr. . Eriksen,
European Commission, DG-JRC; Dr. C. Faidy, EDF-Septen; Dr. G. Fedeli, ENEL DCO;
Mr. H. Fierz, Basler & Hofmann; Ir. J.H. Fokkens, NRG; Mr. W. Frank, Aistom Energie
GmbH; Mr. R. Gerard, Tractebel; Dr. R. Gillot, MPA Stuttgart; Mr. D. Guichard, Framatome;
Mr. J. Guinovart, EC, DG XI; Dr. M.K.T. Hansch, Preussen Elektra AG; Mr. J.C. Hedderly,
EC, DG-JRC; Dr. G. Hedner, Swedish Nuclear Power Inspectorate; Dr. J. Heerens, GKSS;
Mr. D. Heinrich, Aistom Energie GmbH; Dr. B. Hemsworth, Brian Hemsworth and
Associates; Mr. A. Henoch, Vattenfall AB; Dr. L. Hodulak, Fraunhofer IWM; Ir. M.G.
Horsten, NRG; Dr. B. Houssin, Framatome; Mr. R. Houghton, EC, DG-JRC; Prof. R.C.
Hurst, EC, DG-JRC; Mr. I. Iacono, EC, DG-JRC; Dr. T. Isozaki, Japan Atomic Energy
Research Inst.; Ms. D. Jackson, NRC; Dr. K.H. Katerbau, MPA Stuttgart; Dr. P. Kauppinen,
VTT - Technical Research Centre of Finland; Ms. J. Keeney. Oak Ridge National Laboratory;
Dr. E. Keim, Siemens-AG; Mr. H. Keinnen, VTT - Technical Research Centre of Finland;
Prof. J. Knott, University of Birmingham; Dr. H. Kockelmann, MPA Stuttgart; Prof. K.
Kussmaul, MPA Stuttgart; Mr. P. Lemaitre, EC, DG-JRC; Dr. D.P.G. Lidbury. AEA
Technology plc; Mr. V.N. Lovchev, Kola NPP; Mr. T. Marshall, Rolls Royce Ltd.; Dr. B.
Marini, CEA; Mr. C. Marugg, Basier and Hofmann; Dr. A.S. McAllister, EC, DG-JRC now
DG XIII; Mr. D. McGarry, EC, DG-JRC; Mr. L. Metten, EC, DG-JRC; Mr. P. Mignot, AVN;
Mr. P. Minnebo, EC, DG-JRC; Mr. F. Mohr, Siemens AG; Dr. D. Moinereau, EDF/DER;
Mr. R. Murgatroyd, Inspection Reliability Consultancy; Mr. G. Nagel, PreussenElektra
HSE
Health & Salet}
^c
Kernkraft; Dr. R. Nicholson. HSE Health & Safety Executive (Nil); Dr. P. Nurkkala, IVO
Technology Centre Power Plant Technologies; Dr. T.R. Palframan, Rolls-Royce Ltd; Ms. . .
PersAnderson, ABB Tekniska Rntgencentr.AB; Mr. . Persson, Vattenfall AB; Dtt. A. Pini,
AN ; Mr. . Planman, VTT - Technical Research Centre of Finland; Dr. JW. Rensman,
NRG; Dr. R. Rintamaa, VTT - Technical Research Centre of Finland; Prof. E. Roos, MPA
Stuttgart; Dr. I. SattariFar, SAQ Kontroll, SAQ Inspection Ltd.; Dr. Schimpfke, GRS -
Gesellschaft fr Anlagen- und Reaktorsicherheit; Mr. V. Schmitz, Fraunhofer IZP; Dr. J.
Schofield, Rolls-Royce Ltd; Dr. H. Schulz, GRS; Mr. E. Schuring, Energie Centrum
Nederland; Mr. M. Serre, CEA/CEREM; Dr. F. Sevini, EC, DG-JRC; Dr. A. Sherry, AEA
Technology pie; Dr. D. Siegele, Fraunhofer IWM; Dr. J. Sievers, GRS; Mr. R. Slominski,
Health & Safety Executive; Dr. M.C. Smith, British Energy plc; Dr. L. Stumpfrock, MPA
Stuttgart; Mr. D.I. Swan, Rolls Royce Ltd.; Ms. H. Talja, VTT; Dr. N. Taylor, EC, DG-JRC;
Prof. K. Trrnen, VTT now EC, DG-JRC; Mr. H. Trautmann, ABB Reaktor GmbH; Ms. M.
P. Valeta, CEA; Prof. T. Varga, Technische Universitt - Vienna; Mr. P. Vergucht, EC, DG-
JRC; Dr. U. von Estorff, EC, DG-JRC; Dr. O. Wachter, PreussenElektra Kernkraft; Prof. K.
Wallin, VTT Technical Research Centre of Finland; Dr. G. Wardle, AEA Technology plc;
Dr. P. Williams, Oak Ridge National Laboratoiy; Mr. J.B. Wintle, The Welding Institute;
Mr. G.S. Woodcock, British Energy pic; Mr. K. Xanthopoulos, Swedish Nuclear Power
Inspectorate.
** *#
* *
* . *
UE
HS E
H. . Ji l i & Sa f e
N
c
The Network for Evaluating Structural Components
Safe and efficient operation of nuclear power plant can be enhanced through better integration
of the key structural integrity assessment technologies. To meet this challenge, the Network
for Evaluation of Structural Components (NESC) was launched in 1992. Its objectives are:
to create an international network to undertake collaborative projects capable of validating
the entire structural integrity process.
to work towards best practice and the harmonisation of international standards.
to improve codes and standards for structural integrity assessment and to transfer the tech-
nology to industrial applications.
A 90-member network has been established. Operators, manufacturers, regulators, service
companies and R&D organisations collaborate to perform large-scale experimental projects
capable of serving as international benchmarks. The European Commission's Joint Research
Centre acts as independent operating agent. The projects are designed to combine all aspects
of structural integrity assessment including inspection, materials characterisation, fracture
mechanics and instrumentation.
NESC-I looks at the exploitation of the integrated approach to provide a robust safety case
for pressurised thermal shock (PTS) of an aged, defect containing, reactor pressure vessel. It
is unique insofar as the inspection and fracture mechanics analyses have been carried out
without exact knowledge of the defects, as is the case for operational plant. The test was
performed in March 1997 and the evaluation of the results was completed in 2000.
NESC-II also features the PTS problem, but with the focus on the brittle fracture behaviour
of shallow, sub-clad defects. Two large-scale experiments were conducted in 1999 at MPA
Stuttgart. The results are presently being analysed.
NESC-III was launched in autumn 2000 and will focus on applying the integrated approach
to structural integrity assessment of dissimilar metal welds in pipe sections.
SS NESC
Ili-aliti Safei
Contents
Executive Summary 9
Abbreviations 11
1 Introduction 12
2 The NESC Network 14
3 Review of Nuclear Pressure Vessel Integrity Issues 16
4 The NESC-I Project 21
4.1 Objectives of the Project 21
4.2 Organisation of NESC and the NESC-I Project 21
4.3 Project Focus 25
5 Manufacture of the Cylinder with Inserted Defects 30
5.1 Meeting the Project's Objectives 30
5.2 Procurement of a Suitable Cylinder 31
5.3 Reference Inspection and Weld Qualifications 32
5.4 Generation of the Sub-clad Fatigue Crack 33
5.5 Introduction of EDM Defects and Realistic Under-clad Cracks 35
5.6 Cladding of the Cylinder 36
5.7 Post Cladding Heat Treatment 37
5.8 Introduction of the First Through Clad Defected 38
5.9 Final Machining and Heat Treatment 38
5.10 Reference Inspection and Description of the Defects 38
5.11 Introduction of the Second Through-clad Defected 39
6 Materials Evaluation 41
6.1 Requirements of the Materials Evaluation Programme 41
6.2 Participating Organisations and Work Allocations 41
6.3 Source oftest Material 42
6.4 Materials Property Data 44
7 Engineering the Spinning Cylinder Test 54
7.1 Temperature Measurement 54
7.2 Strain Gauges for the Detection of Crack Growth 56
7.3 Other Instrumentation 57
7.4 Rig Engineering 57
7.5 Rig Trials 60
7.6 Development of the Thermal Blanket and Sealing of the Defect 62
7.7 Data Acquisition System and Test Control 64
HSE
Health & Safety
i=sr>4<,-
7.8 The Spinning CylinderTest 64
7.9 Post-test Observations 66
7.10 Test Instrumentation Evaluation 68
8 Destructive Examination 70
8.1 Objectives 70
8.2 Sectioning the Cylinder 70
8.3 Defect Sizing 71
8.4 Microstructrual Examination 73
8.5 Fractographic Examination 73
8.6 Discussion of Fractography Results 79
9 Inspection 82
9.1 Requirements of the Inspection Program 82
9.2 Round Robin Inspection 82
9.3 Results and Discussion 86
9.4 Summary 93
10 Evaluation of Thermal and Structural Analyses 94
10.1 Introduction 94
10.2 Design Analyses of the Cylinder and the Loading Transient 94
10.3 Pre-test Predictions of the Cylinder Behaviour 96
10.4 Post-test Analyses 103
10.5 Factors Influencing Defect Assessments 1 12
10.6 Sensitivity Analyses 116
11 Integrated Assessment 120
11.1 Elements of the Integrated Assessment Process 120
11.2 Networking Between the Disciplines 128
12 Conclusions and Recommendations 130
12.1 Scope of Project 130
12.2 The Role of Networking 131
12.3 Outcome of the Spinning Cylinder Test 131
12.4 Principal Technical Conclusions 132
12.5 Key Reccommendations for Best Practice 134
APPENDIX A 135
HS E
EXECUTIVE SUMMARY
The overall objective of the NESC network is to examine the reliability of the entire process of
structural integrity assessment within an international framework. Simulation of a pressurised
thermal shock (PTS) transient of an aged reactor pressure vessel (RPV) containing postulated
flaws represents a logical choice for such a study because of the substantial structural asses-
sment challenges posed by the problem. This objective has been accomplished through the
NESC-I project by organising the assessment process into component disciplines and exami-
ning topics that included NDE accuracy and reliability, material properties data requirements,
test measurement techniques, and appropriate levels of complexity for thermal/structural
analyses and fracture assessments. The effectiveness of those disciplines in fulfilling their
functions was evaluated using data generated during all phases of a highly structured program.
The experimental validation at the heart of the project has centred on a unique spinning cylin-
der test system. The test piece itself consisted of an internally clad, 7 tonne steel cylinder into
which a total of 18 defects, differing widely in fabrication method, size and location, were
introduced. Details of the defects were withheld from the inspection teams and fracture analy-
sts in the pre-test phase. The specimen was subject to mechanical loads due to high-speed
rotation and thermal shock loads resulting from a cold water quench directed at the inner sur-
face of the heated cylinder. The test was successfully performed in March 1997 and realised
the planned cleavage run-and-arrest event in the large through-clad defect. In the case of the
large sub-clad defect no cleavage occurred, although it was found to have grown along the
entire initial crack front.
The NESC-I Overview Report provides a condensed description of the project activities. In
particular it details the principal findings which have emerged from an exhaustive evaluation
of the pre- and post-test analyses. These can be summarised as follows:
For the specific NESC-I conditions, defects of up to 74 mm depth in material related to that
of an ageing RPV would not propagate to cause catastrophic failure under a severe PTS-
type thermal shock. This outcome was fully in line with the pre-test analysis forecasts.
The blind inspection trials showed that the detection and sizing performance with ultrasonic
techniques was good. The results show that in fourteen out of the seventeen inspections,
teams detected all the defects. Three teams failed to detect some defects with a through-wall
extent in the range 2.5 to 13.5 mm. In general, the detection performances were better than
those in the comparable PISC II trials a decade earlier, indicating the considerable progress
made. For sizing of through-wall extent, the tip-diffracted wave procedure proved particu-
larly effective. However since inspection teams using this technique did not all perform
equally well, it is concluded that qualification of the inspection system and personnel are of
considerable importance. Eddy current probes proved less reliable, although this technique
may not be appropriate for the full range of NESC defects.
H S K
In terms of the structural analysis procedures, refined analyses using detailed 3-D finite ele-
ment modelling of the critical defect allowed accurate prediction of the actual time of the
cleavage event in the transient and its location, as well as a precise estimate of the extent of
prior ductile tearing. The detailed finite element analyses also made it possible to rationalise
the absence of cleavage within the HAZ region, by taking into consideration factors such as
loss of constraint, higher toughness of the HAZ, the reduced effective crack-front width and
cladding effects. The anticipated cleavage event at the largest sub-clad defect did not occur,
but the significance of this is mitigated by the intervention of an intergranular growth
mechanism. Simplified engineering methods produced relatively conservative results, as
anticipated. However these were calibrated and their safety margins assessed by comparison
with the detailed 3-D finite element simulations.
The greatest source of uncertainty in the assessment process proved to be variability in the
material toughness data, linked to the intrinsically statistical nature of cleavage in the transi-
tion range. Statistical representation of actual fracture toughness data, in particular the
master curve approach, has proved most instructive in interpreting the test results. Variations
in driving force estimate has a considerably lesser impact on the analysis result and could
frequently be rationalised in terms of the method applied i.e. simplified or complex 3-D.
The uncertainty in reported defect sizes was found to be relatively uncritical, in particular
for the larger defects.
Support is recommended for further work aimed at providing quantitative procedures for rela-
ting fracture test data on specific specimen geometries to local constraint parameters estima-
ted from 3-D finite element simulations. Analysis methods capable of simulating the micro-
mechanisms in ductile tearing and cleavage offer the most promising route for obtaining such
improvements. A step has been made in this direction, and the local approach Weibull proba-
bilistic calculation of the NESC-I test produced reliable results for cleavage fracture.
The Master Curve approach allowed the limited available data for the sub-clad HAZ region
to be exploited in the assessment process. The increased toughness of the HAZ cannot be
adequately represented in the RT
NDT
approach since the small material volume precludes
generation of the test data required in determining that parameter. The results of the test
strongly support the use of statistical approaches to describe the risk for local cleavage
events in RPV integrity assessment. These approaches offer potential for considerable
further development as part of detailed simulations of defects using the local approach and
other advanced methodologies.
Strict application of nuclear safety codes for the assessing in-service defects to the NESC-I
spinning cylinder would allow defects with a maximum depth in the range 1 to 9 mm. This
was shown by the test outcome to include an apparently large margin of conservatism.
In conclusion, the success of the project underlines the benefits of the network approach to
tackling multi-disciplinary problems. Its strength relied on combining the expertise and expe-
rience of key regulators, utilities, manufacturers, service companies and R&D organisations
to examine the integrated structural integrity assessment within the context of a single, care-
fully defined experiment.
10
HSE
Health & Sul n
Mi r c o
ABBREVIATIONS
ACPD
AEAT
AG
AMES
ASTM
CSNI
CT
DAG
DEAG
EC
ECN
EDM
ENIQ
EOL
ET
ETF
FALSIRE
FBH
FDF
FE
HAZ
HSE
IAEA
IAM
IVO
JRC
MPA
NDE
NESC
NGSAW
NRC
OA
OECD
ORNL
PISC
Alternating Current Potential Drop
AEA Technology pic
Archives Group
Aged Materials Evaluations and Studies
(network)
American Society for Testing and
Materials
Committee on the Safety of Nuclear
Installations (OECD)
Compact Tension
Data Analysis Group
Destructive Evaluation Advisory Group
European Commission
Netherlands Energy Research
Foundation
Electro-Discharge Machining
European Network on Inspection and
Qualification
End Of Life
Evaluation Task
Evaluation Task Force
Project for Fracture Analysis of Large-
Scale International Reference
Experiments
Flat Bottomed Hole
Flaw Detection Frequency
Finite Element
Heat Affected Zone
Health and Safety Executive
International Atomic Energy Agency
Institute for Advanced Materials of the
JRC
Imatran Voima Oy (Finland) (now
FORTUM)
Joint Research Centre of the European
Commission
MPA Stuttgart
Non-destructive evaluation
Network for the Evaluation of Structural
Components
Narrow-Gap Submerged Arc Welding
Nuclear Regulatory Commission
Operating Agent
Organisation for Economic Co-operation
and Development
Oak Ridge National Laboratory
Programme for the Inspection of Steel
Components
PTS
PWG
PWHT
PWR
RG
RL
RPV
RRA
SAG
SC
SIF
TG
TOFD
TWE
TWI
VTT
WPS
WWER
Pressurised Thermal Shock
Principal Working Group
Post-Weld Heat Treatment
Pressurlsed Water Reactor
Referee Group
Reference Laboratory
Reactor pressure vessel
Rolls Royce and Associates (now Rolls
Royce Ltd.)
Senior Advisory Group
Steering Committee or Spinning Cylinder
Stress Intensity Factor
Task Group
Time of Flight Diffraction
Through Wall Extent
The Welding Institute
Technical Research Centre of Finland
Warm Pre-Stress
Russian Pressurised Water Reactor
I 1
H S K Mfc
1 . INTRODUCTION
The Network for Evaluating Structural Components (NESC) was launched to promote and
manage collaborative international projects that focus on the validation of the entire process
of structural integrity assessment. The first NESC project, i.e., NESC-I, provided a unique
framework for evaluating the interactions among various technical disciplines applied to the
integrity assessment of a large-scale thermally-shocked spinning cylinder experiment. The
experiment was designed to simulate selected conditions associated with an ageing, flawed
reactor pressure vessel (RPV) subjected to pressurised-thermal-shock (PTS) loading. The
broad range of disciplines brought to the project included non-destructive evaluation (NDE).
material properties characterisation, test measurements, thermal/structural analyses, fracture
assessments and destructive examinations. It was always intended that the benefits of NESC-I
should extend to both nuclear and non-nuclear technologies by providing an assessment fra-
mework that can be utilised over a wide spectrum of structural integrity applications. The
NESC-I project was sponsored jointly by the UK Health and Safety Executive (HSE) and the
European Commission (EC). The countries participating in NESC-I were predominantly
European (Austria, Belgium, Finland, France, Germany, Italy, Netherlands, Spain, Sweden,
Switzerland, United Kingdom), along with Japan and the United States. Within those coun-
tries, more than 50 organisations have contributed to the NESC-I project since the launch of
NESC in 1993.
The purpose of this report is to provide a concise, but comprehensive, overview of the NESC-I
project. It focused on the total process of structural integrity assessment as applied to a frac-
ture experiment involving a large, heated cylindrical specimen containing sharp defects
(cracks) at or near the inner surface. A unique feature of the project was the inclusion of NDE
as an integral part of a large-scale PTS fracture experiment, thus highlighting the influence of
inspection data on RPV integrity assessments performed by structural analysts. The experi-
ment was conducted at AEA Technology, Risley, UK, during March 1997, in which the speci-
men was subjected to mechanical loads due to high-speed rotation and thermal-shock loads
resulting from a cold water spray directed at the inner surface of the heated cylinder (Fig. I. I ).
This report includes an emphasis on numerous factors that distinguish NESC-I from the sub-
stantial number of large-scale PTS projects that have been conducted world-wide. Initial chap-
ters describe the formation of the NESC network, the nuclear integrity assessment issues that
relate to the PTS problem studied in NESC-I, followed by the objectives and organisation of
the NESC-I project. Subsequent chapters provide an overview of all phases of NESC-I, inclu-
ding the manufacture, testing, materials characterisation, instrumentation, non-destructive and
destructive examinations, and structural/fracture assessments of the cylinder. This is followed
by an integrated assessment of the project, including an evaluation of interdisciplinary factors,
relevance to reactor transients, technology transfer to nuclear and non-nuclear plant, and
implications for national codes and standards. Contributions of the NESC-I project to refine-
I2
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i l , . ii . & Saft-ty
I H L - J U
ment of methodologies for structural integrity assessment are discussed. Finally, some conclu-
sions and recommendations are derived from the outcome of the NESC-I project that highlight
benefits of the "network" structure.
The discussions, results and conclusions presented in this report draw heavily upon the large
bibliography of Task Group and Evaluation Task reports that were produced by the many par-
ticipants throughout the history of the NESC-I project.
Heater 290 C
5C Water
1 Underclad fatigue defect
2 Through clad fatigue defect
3 Natural underclad defects
4 Type "A" defects
Front View
Fig. 1.1: Schematic of the NESC-I spinning cylinder test.
13
NESC
IL. . . i i i . & Sa f e i
2 THE NESC NETWORK
The formation of the NESC network was a logical progression from two previously succes-
sful large-scale network programmes that were conducted in the area of structural integrity
[2.1]. The first of these was the Programme for the Inspection of Steel Components (PISC); a
European network organised under the sponsorship of the EC and the Organisation for
Economic Co-operation and Development (OECD). PISC was launched in 1974 with objecti-
ves of assessing and improving inspection reliability for steel structures. In the PISC exerci-
ses, realistic defects were introduced into steel components and the performance of inspection
teams was evaluated in detecting and sizing these defects. The success of the original PISC I
provided motivation for renewal of the programme in two additional phases, i.e., PISC II and
PISC III. These PISC exercises resulted in major contributions to improving the effectiveness
and reliability of inspections and the procedures used to conduct these inspections. Extensive
documentation is available on PISC (for example, see [2.2]).
Methodologies for RPV structural integrity assessment were evaluated in a second international
programme, i.e.. the Project for Fracture Analysis of Large-Scale International Reference
Experiments (FALSIRE). Project FALSIRE was organised in 1988 under the auspices of the
OECD/NEA's CSNI Principal Working Group No. 3 (PWG-3) for the purpose of evaluating
fracture prediction capabilities used in the safety assessment of nuclear reactor components.
Motivation for the project was derived from recognition of inconsistencies in predictive capabili-
ties of a variety of fracture assessment methods utilised in the nuclear industry. In FALSIRE I.
selected fracture methodologies were assessed through detailed interpretative analyses of six
large-scale thermal-shock experiments [2.3]. Generally, these experiments examined various
aspects of fracture initiation and ductile crack growth in RPV steels under PTS loading condi-
tions. Interpretations of comparative fracture assessments performed by 19 organisations were
used to formulate recommendations concerning applications and future development of ductile
fracture methodologies as applied to RPVs. The follow-on (FALSIRE II) programme examined
various aspects of the cleavage fracture process in RPV steels for a wide range of materials,
crack geometries, constraint and loading conditions [2.4]. Predictions of structural response for
the test specimens in FALSIRE II demonstrated a marked improvement over the results achieved
in FALSIRE I. Conclusions derived from the FALSIRE project focused attention on important
aspects of RPV integrity assessments, e.g. modelling of structural behaviour, proper constitutive
models, material and fracture toughness properties, and applications of dual parameters fracture
models to represent loss-of-constraint conditions for surface cracks.
Key concepts employed in the organisation of these networks included the use of an indepen-
dent Operating Agent and Reference Laboratory and the division of individual tasks into Task
Groups to keep them at a manageable size. The work of these Task Groups was supported pri-
marily by "in-kind" contributions from the participating organisations. In 1992. these concepts
were incorporated into a new generation of networks organised by the European Commission's
14
U S E
MCOP
Joint Research Centre/Institute for Advanced Materials (JRC/IAM) Petten. Netherlands. This
new generation was launched with the founding of two networks, i.e., the European Network
on Inspection and Qualification (ENIQ) and the Aged Materials Evaluation and Studies
(AMES). These networks adopted the PISC "club type" arrangement, but with improved defi-
nitions of individual contributions and control of intellectual property. Collaboration agree-
ments for the new networks were constructed around the following principles:
Support from participants by contributions "in kind";
Representation of all participating organisations on a Steering Committee;
Development of an international consensus for achieving results;
A neutral independent Reference Laboratory
A neutral independent Operating Agent for daily management and refereeing;
Projects focusing on structural integrity of ageing components.
Concurrent with these developments, the HSE in the UK expressed concern that while the
previous networks had performed significant work on selected elements of the overall structu-
ral integrity assessment process, the process as a whole was yet to be addressed. For example,
no experiments performed to date had attempted to evaluate the influence of NDE data provi-
ded by inspection teams on RPV integrity assessments carried out by structural analysts.
Consequently, the decision was made to form a third new network project, i.e., NESC, which
would build upon PISC and FALSIRE by examining the entire process of structural integrity
assessment. The NESC network was activated at the headquarters of the HSE in Sheffield.
England, during September 1993. As with ENIQ and AMES, the network structure of NESC
utilised principles derived from the PISC experience.
Study of the structural integrity assessment process was initiated within the NESC network
through a large-scale PTS experiment, i.e., NESC-I, that was also launched at Sheffield in
1993. The requirement for funding of this large complex experiment represented a major dif-
ference between the NESC network as compared with the PISC and FALSIRE projects.
Primary sponsorship for the NESC-I experiment was provided by the HSE, with the JRC,
Petten. Netherlands, providing the Reference Laboratory and acting as Operating Agent.
REFERENCES
12.11 Hurst. R.C. et al., "NESC-Past, Present and Fulure'. PVP-Vol. 362. Proceedings of 1998 ASME
Pressure Vessel and Piping Division Conference. San Diego. California. July 1998. pp. 213-220.
| 2.2| Borloo. E. and Lemaitre. P. eds., "Non-Destructive Examination Practices and Results", Proceedings of
the Joint CEC/OECD/IAEA Specialists Meeting. Petten. 8-10 March 1994. Commission of European
Communities Report. EUR 15906 EN.
[2.3] Bass. B.R.. Pugh. CE. , and Keeney-Walker. J.. Schulz. H., and Sievers, J.. CSNI Project for Fracture
Analyses of Large-Scale International Reference Experiments (Project FALSIRE), NUREG/CR-5997
(ORNL/TM-12307). Oak Ridge National Laboratory, December 1992.
[2.4] Bass. B.R.. Pugh. C.E.. Keeney. J.. Schul/.. H., and Sievers. J.. CSNI Project for Fracture Analyses of
Luxe-Scale International Reference Experiments (FALSIRE II). NUREG/CR-6460 (ORNL/TM-
13207). Oak Ridge National Laboratory. April 1996.
15
ws! NESC
3 REVIEW OF NUCLEAR PRESSURE VESSEL
INTEGRITY ISSUES
In a pressurised-water reactor (PWR) plant, the RPV provides containment for the reactor
core and primary system coolant under operating conditions of prescribed temperature and
internal pressure. The integrity of the RPV must be assured under both operating and postula-
ted accident conditions throughout the plant operation (until end-of-life) to protect the general
public from potential hazards of a significant radiation release. Thus, the continued safe ope-
ration of the PWR plant is dependent in large measure upon determining and refining the
margins against failure for the RPV.
Davies and Lyssakov [3.1] concisely summarise the potential threat to RPV integrity that ari-
ses from a combination of three elements usually associated with the so-called "pressurised-
thermal-shock" problem:
Degraded fracture toughness of the vessel wall due to neutron irradiation;
Transient cooling of the inner surface of the RPV wall, either concurrent with or followed
by re-pressurisation, producing high thermal-mechanical loading in the inner surface of the
vessel wall;
The presence of defects in the near-surface region having a size, geometry and orientation
that are conducive to initiation and propagation when subjected to the high thermal-mecha-
nical loading of the RPV wall.
In the core or beltline region of the RPV, neutron irradiation degrades the fracture toughness
properties of the plate or forging material and the fabrication welds that constitute the vessel
wall. The thin austenitic cladding overlay, which serves to protect the inner surface of the ves-
sel wall and to minimise contaminants in the primary coolant, is also affected by irradiation.
The pronounced sensitivity of high-copper and high-nickel fabrication welds to irradiation
embrittlement in some older Western RPVs has been well documented (see, for example, Ref.
3.2). The extent of this radiation damage in the vessel wall depends upon the neutron fluence
received at a given point and, consequently, varies with location and time. Generally, the level
of embrittlement will be greatest in the base material at the inner surface and will attenuate
with increasing depth into the vessel wall.
Such irradiation embrittlement has important implications for RPV integrity under PTS con-
ditions arising from an accident that produces a rapid decrease in reactor coolant temperature
and, possibly, a concurrent re-pressurisation of the system. These postulated accidents could
be precipitated under a range of circumstances, some examples being a loss-of-coolant due to
pressure boundary rupture, a steam-line break, or a stuck-open pressurise safety valve.
Emergency cooling water injection into the system as a result of these events leads to quen-
ching of the inside surface of the vessel from the operating temperature. Severe temperature
gradients are imposed on the inner portion of the vessel wall where cladding, base/weld metal
and heat-affected zones (HAZ) are characterised by temperature- and spatially-dependent
16
HSE N ES G
material and fracture toughness properties. The resultant thermal and pressure stresses are
superimposed on residual stresses from the vessel fabrication and those that arise due to
clad/base-metal differential thermal expansion. Thus, a PTS event gives rise to complex stres-
ses that are multiaxial, transient in time, and most severe at (and near) the inner surface of the
RPV where fracture toughness degradation is the greatest due to radiation exposure.
Integrity assessments of PWR plants, earned out to determine margins against failure under
postulated PTS loading conditions, involve the following steps:
Step 1 Determine the possible system transients;
Step 2 Perform thermal-hydraulics (T-H) analyses of transients using suitable computer
codes to determine temperature, pressure and heat transfer coefficient time histories
for input to structural analyses;
Step 3 Apply plant inspection techniques to compile actual defect data;
Step 4 Perform structural/fracture analyses of the RPV utilising T-H analysis results, mate-
rials/fracture toughness data, and postulated or actual flaw/defect data.
Assessment of the RPV can be performed using either deterministic or probabilistic analytical
techniques. The deterministic approach is based on analyses of selected flaws having a speci-
fied location, geometry and size that are subjected to certain postulated transients in the RPV.
Results obtained from assessments of these flaws and transients are evaluated in the context of
country-specific codes and standards regarding acceptability of the flaws. In the probabilistic
approach, selected input variables of the problem (for example, flaw density, fracture tough-
ness, reference temperature RT
NDT
, etc.) are specified by a statistical distribution. These varia-
bles are then sampled for many thousands of vessels to compute the conditional probability of
failure for the specified transient. (The probability is "conditional" because the transient is
assumed to occur in the plant). In the U.S.A., these probabilities are computed for a full range
of transients to determine an overall failure probability. The methodology of U.S. Nuclear
Regulatory Commission Regulatory Guide 1.154 [3.1] is applied with the objective of predic-
ting a frequency of RPV failure due to PTS of less than 5 IO"
6
failures per reactor year.
In the past two decades, recognition of the importance of PTS issues has led the international
nuclear technology community to devote considerable research effort to the above steps in the
integrity assessment process. Integrated PTS evaluations focusing on three U.S. plants were
carried out in studies sponsored by the U.S. Nuclear Regulatory Commission (NRC) [3.4-
3.6]. Shallow flaws having depths of the order of the combined thickness of the cladding and
clad/HAZ layers dominated the frequency distribution of flaws assumed in these assessments,
which were based on probabilistic fracture mechanics models. The initiation probabilities
associated with these flaws under PTS loading conditions strongly influenced the predicted
failure probabilities for the RPVs considered in the NRC studies. Behaviour of these flaws
during a PTS transient are influenced by the material/fracture properties and mechanical inte-
ractions associated with the cladding, the clad/HAZ, and near-surface base/weld material.
More recently, international analytical exercises focusing on an integrated approach to PTS
assessment have been organised separately under the OECD' s Committee on the Safety of
17
H S K
Nuclear Installations (CSNI) and the International Atomic Energy Agency (IAEA) Extra bud-
getary Project on WWER Safety. Under the auspices of OECD/CSNI, the International
Comparative Assessment Study (CAS) of PTS examined interactions between the thermal-
hydraulic and structural/fracture analyses of Western-type four-loop reactor vessels for seve-
ral classes of transients [3.7]. A similar effort was conducted on a WWER-440/213 plant
under the IAEA WWER PTS Benchmark Exercise (WPB), based on transients resulting from a
stuck-open pressuriser safety valve [3.8], The latter WPB utilised the 'Guidelines on PTS
Analysis for WWER NPPs' [3.9] that was published under the IAEA Extrabudgetary Project.
Investigators at a number of laboratories in Europe, Japan and the U.S. have concentrated
their efforts on the above Step 4 by conducting large-scale experiments to better understand
how specific factors influence flaw behaviour under generic PTS loading conditions [3.10].
Influencing factors studied in these experiments include constraint (for example, effects of
free surfaces), cladding fabrication processes, material inhomogeneities and warm prestres-
sing. The objective is to understand how these factors influence the propensity for shallow
flaws to initiate and propagate into the wall of an RPV under PTS-type loading. If crack pro-
pagation is initiated, then will the running crack arrest, will it be stable after arrest (or will
propagation be reinitiated), how can mode conversion occur, and what are the implications to
vessel rupture? Pugh and Bass [3.14] identified the following factors as potential contributors
to RPV integrity assessments under PTS loading conditions:
Flaw Characterisation The size (length and depth), location (surface, sub-clad, or embed-
ded), orientation (relationship of major and minor axes to loadings) and frequency distribu-
tion will affect propensity for initiation in a PTS event. An important issue influencing inte-
grity assessment is the accuracy and reliability of the inspection techniques and procedures
used to acquire the flaw data.
Constraint Effects Crack-tip constraint is influenced by flaw depth, flaw geometry, material
properties, and loading conditions. An important product of this work will be the develop-
ment of constraint-based methodologies to improve transferability of fracture toughness
data (in the brittle-to-ductile transition temperature region) from small-scale (e.g. surveil-
lance-sized) specimens to full-scale RPVs.
Material Property Sensitivity Metallurgical variability induced by both the structural wel-
ding and cladding application processes influence tensile/fracture toughness properties. The
beltline embrittlement database for the vessel wall provides an essential input element for
estimating fracture toughness properties.
Fracture-Mode Conversion Attention must be given to modelling the process of significant duc-
tile flaw growth followed by a fracture-mode conversion to cleavage, which has been observed
in RPV materials in the lower-to-upper transition region of the fracture toughness curve. The
material failure by cleavage after some amount of ductile tearing has been characterised as a
combined effect of a deterministic stable-tearing process and a probabilistic cleavage process.
Residual Stresses Structural welding processes and clad/base metal differential thermal
expansion introduce residual stresses that, in turn, influence the effective initiation tough-
ness for shallow flaws in the vessel wall.
IS
HS E
MCOP
Warm-Prestressing Several types of warm-prestressing have been observed in experiments
that can delay or negate the onset of cleavage initiation in a PTS transient.
Role of Crack Arrest Several factors related to arrest of a fast-fracture event can influence
PTS assessments, including arrest in a rising K-field, propensity for re-initiation of an arre-
sted crack and relationship of crack arrest to mode conversion (to stable or unstable tearing)
in the mid-to upper-transition region.
Cladding/HAZ Effects Factors influencing shallow flaw behaviour in this region include
variations in tensile properties and fracture toughness properties (includes both cleavage and
ductile tearing). Sub-clad flaws are susceptible to locally-induced strain-ageing embrittle-
ment as a by-product of the cladding process
Table 3.1 summarises these factors, which in turn must be linked to issues concerning the
reliability and accuracy of NDE techniques and procedures used to characterise flaw data in
the near-surface region of the vessel wall. The influence of the latter factors on the outcome
of the NESC-I project was examined in detail within NESC; results from these studies are
highlighted in subsequent chapters.
Table 3.1: Potential integrity-influencing factors in PTS.
RPV Integrity Influencing Factors
1. Flaw Characterisation
2. Constraint Conditions
3. Material Properties Sensitivity
4. Ductile/Cleavage Mode Conversion
5. Residual Stresses
6. Warm Prestressing
7. Role of Crack Arrest
8. Cladding/HAZ Effects
Characterising Aspects
- size (length and depth)
- location (surface, underclad, or embedded)
- orientation (relationship of major and minor axes to loadings)
- effects of shallow flaws on effective toughness
- effects of multiaxial loading on fracture toughness
- effectiveness of single- and dual-parameter fracture prediction methods
- low upper-shelf toughness
- weld verses base metal
- high transition temperature
- conversion from cleavage propagation to ductile tearing
- effects of pre-cleavage ductile tearing
- predictions of mode conversion to cleavage
- effects of structural welds
- effects of clad/base metal coeff. thermal expansion
- types of warm prestressing observed in experiments
- effects on delaying onset of cleavage initiation
-arrest in rising K fields
- reinitiation of arrested cracks
- relationship to mode conversion
- effects of variations in tensile properties
- effects of variations in fracture toughness properties (includes both cleavage
and ductile tearing)
- effects on shallow flaw initiation
- locally-induced strain-ageing embrittlement
19
HSE
U call h & Suf f l i
REFERENCES
[3.1 ] Davies. L.M. and Lyssakov, V.. "Pressurised Thermal Shock", appearing in Technical Report Series on
Pressurised Thermal Shock. International Atomic Energy Agency (to be published).
[3.2] Nanstad. R.K. et al., "Effects of Irradiation on KIc Curves for High-Copper Welds", pp. 214-33 in
Effects on Radiation on Materials. 14"' International Symposium. ASTP STP 1046. Vol. 11. ed. N.H.
Packan. R.E. Stoller. and A.S. Kumar. American Society for Testing and Materials. Philadelphia. 1990.
[3.3] U.S. Nuclear Regulatory Commission. Regulatory Guide 1.154. "Format and Content of Plant-Specific
Pressurised Thermal Shock Safety Analysis Reports for Pressurised Water Reactors", 1987.
[3.4] Burns. T.J.. et al., Martin Marietta Energy Systems. Inc.. Oak Ridge National Laboratory. "Pressurised
Thermal Shock Evaluation of the Oconee-1 Nuclear Power Plant". NUREG/CR-3770 (ORNL/TM-
9176). May 1986.
[3.5] Selby, D.L. et al.. Martin Marietta Energy Systems. Inc.. Oak Ridge National Laboratory. "Pressurised
Thermal Shock Evaluation of the Calvert Cliffs Unit I Nuclear Power Plant". NUREG/CR-4022
(ORNL/TM-9408). September 1985.
[3.6] Selby, D.L. et al.. Martin Marietta Energy Systems. Inc.. Oak Ridge National Laboratory. "Pressurised
Thermal Shock Evaluation of the H.B. Robinson Unit 2 Nuclear Power Plant". NUREG/CR-4183
(ORNL/TM-9567). Vols. 1 and 2. September 1985.
[3.7] Sievers. J., Schulz. H.. Bass, B.R. and Pugh. C.E.. "Final Report on the International Comparative
Assessment Study of Pressurised-Thermal-Shock in Reactor Pressure Vessels", Organisation for
Economic Co-operation and Development, Paris. France. Report NEA/CSNI/R(99)3 (to be published).
[3.8] WWER-440/213 RPV Pressurised Thermal Shock Analysis Benchmark Exercise (WPB): Terms of
Reference, WWER-SC-205. IAEA. November 1997.
[3.9] Guidelines on Pressurised Thermal Shock Analysis for WWER Nuclear Power Plants, IAEA-EBP-
WWER-08, IAEA. April 1997.
[3.10] Pugh. CE. and Bass. B.R. "Chapter 12: Supporting Experiments", appearing in Technical Report
Series on Pressurised Thermal Shock. International Atomic Energy Agency (to be published).
20
f si NESC
4 THE NESC-I PROJECT
4.1 OBJECTIVES OF THE PROJECT
The overall objective of NESC was to study the reliability of the entire process of structural
integrity assessment within an international framework. Simulation of PTS transient loading
of a flawed RPV represents a logical choice for the focus of that study because of the sub-
stantial structural assessment challenges posed by the problem. The objective was accompli-
shed through NESC-I by organising the assessment process into component disciplines and
examining topics that included NDE accuracy and reliability, material properties data require-
ments, test measurement techniques, and appropriate levels of complexity for thermal/structu-
ral analyses and fracture assessments. The effectiveness of those disciplines in fulfilling their
functions was evaluated using data generated during all phases of a highly structured pro-
gram. An important goal of the study was to reach a better understanding of the inter-depen-
dencies among the component disciplines. In addition, results from those evaluations have
been used to:
determine sensitivity of the integrity assessment outcome to input from the component
disciplines:
identify deficiencies within current techniques that could benefit from further research;
identify important areas of uncertainty in the assessment process;
identify methodologies that are effective in application and make recommendations on best-
practice techniques;
explore the levels of conservatism within existing structural integrity codes and standards
and, where appropriate, to provide input for development of improved versions.
The foregoing discussion noted the origin of NESC-I as an experiment conducted within the
framework of nuclear technology. However, it is anticipated that the benefits of NESC-I for
structural integrity analysis are sufficiently general that they can be applied over a wide spec-
trum of components and industries [4.1].
4.2 ORGANISATION OF NESC AND THE NESC-I PROJECT
The organisational structure of NESC is shown in Fig. 4. 1, along with the current roster of
NESC officers. The European Commission's Joint Research Centre/Institute for Advanced
Materials provides technical and administrative management. As such, they are designated as
the NESC Operating Agent (OA) and the Reference Laboratory (RL). It is envisaged that
several NESC projects can be managed concurrently. The role of the Steering Committee
(SC) is to define the technical requirements, interact with the Project Manager, co-ordinate
joint activities, and monitor progress. The activities themselves are undertaken by the partici-
pating organisations collaborating within functionally defined Task Groups.
21
HSE
lirulili & Safei;
KI CQp
The JRC, acting as the RL, plays a major role in formulating and maintaining the overall
structure of NESC. It has responsibility for providing administrative support, ensuring the
viability of the individual NESC projects, organising the respective Task Groups and maintai-
ning liaison between NESC and any other related national and international programs. Also.
Senior Advisory Group (SAG)
Chairman K. Tr r nen, J RC
Members from
A, B, D, E, F, FIN, S, UK, NL, IT
Steering Committee ( SO
Chainnan B. Hemsworth/R. Rintamaa
R. Bass, E. Keim
Vice Chairmen
Network Manager
Network Secretary
Members
Project Manager
Operating Agent
R.C. Hurst/N. Taylor
D. McGarry
A, B, D, E, F, FIN, 1
NL, S, UK, USA
J. Wintle
EC/JRC, IAM
Reference Laboratory (RL)
EC/JRC, IAM
Archives Group (AG) b
EC/JRC, IAM |
Referee Group (RG)
EC/JRC, IAM
NESC-I PROJECT, Sponsor
Task Group
TGI Inspection
TG2 Materials
TG3 Structural Analysis
TG4 Instrumentation
TG5 Evaluation
ETF
Chairmen
R. Murgatroyd
R. Rintamaa
S. Bhandari
H. Kockelmann
H. Schulz
R. Hurst
HSE, Host AEA
Co-Chairmen
P. Lemaitre/B. Eriksen
U.VonEstorff/F. Sevini
S. McAllistcr/N. Taylor
J. Hedderly
R. Hurst
R. Bass
Fig. 4.1: Organization and structure of the Network for Evaluating Structural Components.
22
HSE
Health Safen
Ki r r op
the JRC measures the effectiveness of contributions by each participating organisation within
the Network. Where appropriate, the JRC contributes to NESC as a laboratory of excellence.
Specific examples of the latter activity include several key steps related to fabrication and
testing of the NESC-I cylinder specimen: introduction of defects into the cylinder; baseline
inspection of the cylinder following fabrication; development and evaluation of instrumenta-
tion; and destructive examination following the test. Another important function of the JRC is
to provide the means for collecting, storing, and evaluating data produced on a confidential
and neutral basis. For example, the JRC was the only organisation within the Network that
was cognisant of what defects had been introduced into the NESC-I cylinder. By maintaining
full confidentiality, the JRC insured that all non-destructive inspections of the cylinder were
"blind", and that all pre-test predictions were based on structural/fracture analyses of these
inspection data, as would be the case in an actual integrity assessment.
For the NESC-I Project, the Task Groups set up to carry out the work of the Network were as
follows:
TGI - Inspection/Non-Destructive Evaluation (NDE),
TG2 - Material Properties,
TG3 - Structural Analysis,
TG4 - Instrumentation,
TG5 - Co-ordination,
ETF - Evaluation Task Force, and
DEAG - Destructive Examination Advisory Group.
Major responsibilities assigned to these groups are summarised briefly below.
Task Group 1 The TGI was responsible for organising the pre-test and post-test inspections of
the cylinder, as well as assembling, interpreting and reporting the data base of inspection
results. A significant logistical effort was required to make arrangements for transport of the
cylinder to several locations in Europe and to co-ordinate these arrangements with the available
inspection windows for the international teams that performed the inspections. A total of seven
ultrasonic inspections were performed pre-test and ten post-test by the participating organisa-
tions. Two teams inspected the cylinder using post-test using eddy current techniques. The pre-
test inspection data were evaluated by TGI and the RL to provide best-estimate data on the
defects to analysts in TG3 for use in designing the test conditions and making test predictions.
Task Group 2 The TG2 had responsibility for developing the material properties data base and
reporting it to the TG3 for use in structural and fracture mechanics analyses of the experiment.
At the beginning of the project, TG2 engaged in a major effort to study effects of heat treatment
on material toughness and to specify the required heat treatment following fabrication of the
NESC-I cylinder from remnants of cylinders SC-4 and SC-6. Additional activities included lite-
rature surveys and extensive testing programs to determine thermal and physical properties, as
well as tensile and fracture toughness properties, of the cladding, the clad/HAZ and base mate-
rial. The testing program was carried out using material from a run-off (prolongation) of the test
cylinder that was clad using the same procedure as that applied to the cylinder.
23
NESC
Hritllll Sefcl'
Task Group 3 The TG3 was responsible for prescribing the actual test conditions that would
achieve the project objectives, based on the inspection data provided by TGI and the material pro-
perties data base developed by TG2. Furthermore, members of TG3 were charged with perfor-
ming individual pre-test and post-test analyses, the latter being based on actual test data. The
scope of the work included analyses of all defects in the cylinder that were perceived to be signifi-
cant, using analytical techniques that ranged from the very simplified to the highly sophisticated.
Task Group 4 The TG4 had responsibility for the full range of instrumentation attached to the
cylinder during the test, and for determination of residual stresses in the cylinder before and
after the test. A major challenge confronting this group was choosing the type and exact pla-
cement of transducers on the cylinder, given that there were a limited number of available
transducer channels from the test rig. Another problem addressed by TG4 was the require-
ment to design a seal for a large surface-breaking defect on the inner surface that had been
initiated from a machined slot. A seal was necessary to limit water ingress to the defect
during the test, even if the defect should experience propagation.
Task Group 5 The TG5 had the role of co-ordinating the activities of the other four TGs, and
acting as a forum where project-wide problems could be discussed, priorities set and solutions
proposed the Steering Committee of NESC. The Evaluation Task Force superseded TG5in 1998.
Evaluation Task Force The ETF was organised to ensure that the evaluation phase of NESC-I
should be conducted as thoroughly as possible, consistent with the constraints of time and resour-
ces. A full range of evaluation tasks was compiled by the ETF, each one of which was designated
the responsibility of a member of NESC. In some cases, these tasks were carried out within the
bounds of a specific TG, while other cases required more interaction between the TGs.
Destructive Examination Advisory Group The DEAG was set up in 1998 to support the RL in
the destructive examination of the cylinder. The mission of the DEAG was to determine the
precise location and dimensions of all the defects, and to conduct detailed assessments of all
fracture events, based on metallographic/fractographic examinations.
The responsibilities of some other entities shown in Fig. 4.1 are summarised below:
Steering Committee The Steering Committee (SC) represents the highest authority regarding
important decisions affecting NESC. All TGs report to the SC. Responsibilities of the SC
include defining the technical requirements, interacting with the Project Manager, co-ordina-
ting joint activities, and monitoring progress of the Project. The activities themselves are
undertaken by the participating organisations within the TGs.
Archives Group The AG is designated by the Operating Agent to record all important steps
and events of the Network, with the objective of fully documenting its progress and results.
Referee Group Members of the RG are drawn from the ranks of the Reference Laboratory
and are given responsibility for ensuring the confidentiality of data, results and procedures of
any TG member. Also, the RG has responsibility for all decisions that must be kept confiden-
tial from TG members in the best interest of the Project.
Senior Advisory Group The SAG is charged with advising the SC or TGs on any matter of
importance, placing emphasis on the correct orientation of the NESC Project with respect to
execution and presentation of results.
24
HSE
II...Uh X SaieU
isicop
Members participate in activities of the NESC at their own expense and are expected to make
"in-kind" contributions. Expenses related to management of the NESC and collaborative acti-
vities are borne by the Operating Agent and the RL. Particular projects, such as the large-
scale test described herein, are sponsored by individual members of the NESC.
The 13 countries participating in NESC include a strong representation from Europe (Austria,
Belgium, Finland, France, Germany, Italy, Netherlands, Spain, Sweden, Switzerland, United
Kingdom), as well as Japan and the United States. Membership is comprised of the 33 organi-
sations listed in Table 4. 1.
4.3 PROJECT FOCUS
The initial focus of NESC was on a research project funded by HSE to evaluate the total pro-
cess of structural integrity assessments of aged RPVs. A suitable strategy for examining that
process was the simulation and analysis of a PTS transient in an RPV. The PTS transient is a
particular concern to the nuclear industry because of issues presented in Chapter 3. In NESC-
I, a reference PTS experiment was studied by a group of international organisations using a
range of technical disciplines involved in RPV assessment. This was accomplished by means
of fabrication, inspection, testing, analysis and destructive examination of a spinning cylinder
test that was performed at the AEA Technology (AEAT) facility at Risley, UK. The project
consisted of the several phases illustrated in Fig. 4.2.
Table 4.1: Organisations contributing to the NESC-I Project and Task Groups.
Cylinder
Manufacture
HSE Nil
AEA Technology
Framatome
Ed F
CEA
MPA
EC JRC
Inspection (TG1)
AEA Technology
CEA
EdF
BAM
IzFP
Preussen Elektra
ABB-ZAQ
Nuclear Electric
RRA
Siemens
ABB-TRC
VTT
Battelle PNL
EC JRC
GECAIsthom
Kola NPP
Materials (TG2)
FORTUM
Framatome
MPA
IWM
Preussen Elektra
HSE Nil
Nuclear Electric
RRA
ENEL
ECN
EC JRC
AEA Technology
Analysis (TG3)
Framatome
CEA
EdF
GRS
Preussen Elektra
MPA
HSE Nil
AEA Technology
Nuclear Electric
TWI
RRA
Vattenfal Ringhals
SKI
VTT
ENEA
Tractabel
ORNL
Jaeri
CEC JRC
Instrumentation
(TG4)
MPA
CEA
HSE Nil
AEAT Technology
Sheffield Hallam
FORTUM
EC JRC
Evaluation
(TG5)
GRS
AEA
VTT
Framatome
Preussen Elektra
MPA
ORNL
EC JRC
AVN
23
HS E
Health & Safety
Mcr op
Materi al Testi ng
O
O
Testi ng (1997)
Fabrication Inspecti on (1996)
NDE
t:
^ N
Instrumentati on Pretest Anal ysi s
Strain Gages
Thermocouples
etc
Data
Acquisition
System
Predicted
Initiation
Posttest Anal ysi s
Temperat ure
Destructi ve Exam

Kic
Measured
Initiation
Temperat ure
Fig 4.2: Schematic of NESC-I project phases.
The test cylinder was manufactured from halves taken from the SC-4 and SC-6 (A 508 class 3)
forgings previously tested at AEAT, with the yielded material machined from the inner surface.
The specimen was welded in Germany, clad internally with austenitic steel in France, and
finally heat-treated and machined in the UK. A total of 18 defects of varying sizes and types
were introduced into the inner surface of the cylinder [4.2]:
Five Class A EDM notches were fabricated prior to the cladding process. Three had a
length/depth ratio of three, while the remaining two had a ratio of six.
26
f si N ESG
Hiul. h & Saft*.
Three large fatigue defects were included. Internal pressurisation of a starter notch was used
to fabricate a sub-clad defect prior to the cladding process and a through-clad defect after
that process. Because the through-clad defect inadvertently experienced complex branching,
a second thorough-clad defect was installed by mechanical fatigue sharpening of an EDM
notch, the latter accomplished using diametrical compression of the cylinder.
Ten cracks were installed sub-clad in two groups to simulate cold cracks (two cracks) and
hot cracks (eight defects).
Installation of these defects was earned out by MPA-Stuttgart, Framatome and JRC/AEAT
All information regarding the fabrication, size and location of the defects was maintained
secret throughout the pre-test and post-test NDE trials organised within the NESC-I project,
as well as the pre-test structural/fracture assessments.
The common source material for the SC-4, SC-6 and NESC-I cylinders provided a unique
opportunity to assess the effects of cladding on inhibiting defect extension under simulated
PTS loading conditions. Post-weld and post-clad heat treatments of the NESC-I cylinder were
conducted to essentially preserve the material and fracture toughness properties of SC-4 and
SC-6. The SC-4 and SC-6 cylinders also contained semi-elliptical surface-breaking defects,
but they did not have cladding. The SC-4 specimen was tested at a low rotational speed (500
rpm) using a high flow-rate quench for the thermal shock. The SC-6 was subjected to a high
spin speed (2000 rpm) but with a low flow-rate quench.
The pre-test inspection phase was conducted in a manner similar to that of the PISC trials to
evaluate the effectiveness of current and proposed NDE procedures. The teams employed
NDE methods used for in-service inspection of actual RPVs and applied them under condi-
tions that were as prototypical as possible. Teams from Finland, France, Germany, UK,
Russia, Sweden, and the USA conducted inspections of the cylinder and reported their fin-
dings to the RL. The anonymity of these teams was strictly observed in publications of all
inspection results.
A comprehensive materials characterisation program was organised and conducted by eight
European laboratories. Characterisation blocks were fabricated in parallel with the cylinder
for determination of tensile and fracture-toughness properties of the cladding, heat-affected
zone (HAZ), and base material. These efforts provided materials data essential for planning
and interpretation of the experiment, and culminated in a materials characterisation data
handbook for the cylinder forging.
Utilising materials characterisation and pre-test inspection data, sixteen organisations from
ten countries performed detailed analyses to provide recommendations for test conditions and
to predict defect behaviour during the test in terms of extension by cleavage or ductile tea-
ring. A major objective of the experiment was to achieve cleavage initiation and arrest for one
of the large sub-clad or through-clad defects. The analysis methods ranged from simple
analytical calculations based on code requirements to complex three-dimensional non-linear
finite-element formulations. A unique feature of the project was that pre-test analyses were
conducted using only the NDE inspection results, i.e., without exact knowledge of the size of
the defects in the cylinder.
27
HSE N F
H. .ill li & Suf i - t ,
The test was conducted by AEAT in March 1997. The facility, fully described in Chapter 7,
suspends the specimen about its axis of revolution and is capable of rotational speeds up to 2500
rpm. Prior to start of the test, the cylinder was heated uniformly to upper-shelf temperatures (293
C). The planned thermal shock was applied by a water spray quench (2 C) of the inner surface
which was initiated when the cylinder reached a rotational speed of 2,100 rpm. The quench conti-
nued for 12 minutes during which time the rotational speed was increased to a maximum of 2.400
rpm. A step change in output from certain strain gages was observed between 213 and 217 s and
implied that the large through-clad flaw had experienced cleavage initiation at one end.
A post-test round of inspections was conducted following the test to detect and measure any
changes in the dimensions of the defects. The participants in that post-test phase included the
same seven teams from the pre-test round-robin, augmented by new teams from Germany and
the UK. Again, the results were submitted to the RL for subsequent evaluation of the relative
performance of the different inspection teams and methods.
The large defects were opened at low temperature (in liquid nitrogen) to permit
metallographic/fractographic studies of the fracture surfaces. Selected smaller notches were also
opened for study, while others were left unopened and evaluated using high-quality X-ray images
of the individual blocks. The DEAG organised an extensive examination program that was carried
out on the defects revealed during the sectioning. These examinations confirmed that the large
through-clad flaw exhibited ductile tearing in the base and clad/HAZ material, which tripped to
cleavage at one end under the clad/HAZ layer. The cleavage event arrested following a total flaw
extension of approximately 12-15 mm just below the clad/HAZ region, thus confirming that a
major objective of the experiment had been achieved. An unexpected result from these studies was
the identification of substantial regions of intergranular fracture around the large sub-clad defect.
The Evaluation Task Force (ETF) was organised with a membership that represented interested
safety authorities, regulators, electric power utilities, and plant manufacturers. The ETF defined a
series of comprehensive evaluation tasks (Fig. 4.3) with a number of objectives. These included
(1) achieving a greater understanding of interactions among the disciplines of NDE. materials,
structural/fracture analysis and instrumentation (for example, the influence that NDE data from
inspection teams can have on RPV integrity assessments performed by structural analysts); (2)
evaluating the results in the context of nuclear industry needs; and (3) providing recommendations
regarding codes and standards employed in regulation of nuclear and non-nuclear plant. These
evaluation tasks have culminated in a series of reports, including the present final overview report.
A schedule of key events for the NESC-I project is given in Table 4.2. This culminated with
an international seminar held in Paris in March 2000. designed to showcase the unique contri-
butions of NESC-I to achieving a greater understanding of the total integrity assessment pro-
cess for ageing RPVs.
REFERENCES
[4.1 ] Boydon. F.M.D.. "Technology Transfer to Other Nuclear and Non-Nuclear Plant". NESCDOC ETF (99 ) 34.
[4.2] Hurst. R.C.. McGarry. D.. Taylor, N.. Wintle. J.B. and Hemsworth. B., "NESC-I Project: Progress Since
the Spinning Cylinder Test". 1999 ASME PVP Conference. Boston. MA. August 1999.
28
HSE
Health Saar
crop
TG4 Instrumentation
TG3 Structural
Analysis
Strain gauge
performance
limits
Pre & Post
Test Analysis
Performance
Analysis
Critical
factors
Human Errors
TG1 Inspection
PROJECT EVAL. TASKS
Constraint, Cladding
Sensitivity Analysis - Best Practice
Crack Arrest, Residual Stresses
Relation to Other Large Scale Projects
Probabilistic Approach
Fracture Assessment Criteria
Reactor Transient Relevance
Warm Pre \ Codes and Standards
Stressing \ Technology Transfer
Probabilistic \ Lessons from Networking
Approaches / \ Overview Report
Constraint
Effects
Codes &
Standards
Cladding
Effects
Defects for ISP
qualification
Best Practice '
Failure
behaviour
Verification
of arc props/
Prioritise data,
Statistical
methods
Testing
standards
Sampling
inaccuracies
Shallow flaw
effects
TG2 Mat er i al s
Characterisation
Fig. 4.3: Evaluation tasks defined by the Evaluation Task Force.
Table 4.2: Schedule of key events for NESC-I Project.
Event
Completion of Cylinder
Inspection Trials (TG1 )
Material Characterisation Program (TG2)
Specification of Test Conditions 0~G3)
Specification of Instrumentation (TG4)
Complete Rig Trial Testing Program
Residual Stress Measurements (TG4)
Pretest Structural Analysis (TG3)
Spinning Cylinder Test
Posttest Inspections (TG1)
Destructive Examination (RL)
Detailed Evaluation of Results
NESCI Symposium
Codes and Standards Applications
Date
October 1995
November 1995June 1996
February 1995December 1995
December 1996
March 1996
August 1996
August 1996
April 1996January 1997
March 20, 1997
April 1997November1997
January 1998 December 1999
January 1998 December 1999
2728 March 2000
2000+
29
HSE NESC
] K . i i i i . .. S a ft t i
5 MANUFACTURE OF THE CYLINDER
WITH INSERTED DEFECTS
5.1 MEETING THE PROJECT'S OBJECTIVES
The objectives of the project required a large thick cylinder that would represem the characte-
ristics of an aged reactor pressure vessel for inspection and its behaviour in a full scale test
simulating pressurised thermal shock. The cylinder needed to be of sufficient thickness to
generate a realistic temperature and stress field during the spinning cylinder test and to cor-
rectly model the constraint on a deep defect in a RPV.
Appropriate material properties of the cylinder were required. At least one of the defects was
intended to initiate by cleavage and arrest in order to validate fracture mechanics predictions,
yet there could be no risk of catastrophic failure of the cylinder during the test. In addition, the
cylinder material also had to be suitable for the purposes of carrying out blind inspection trials.
The defects to be deliberately inserted in the cylinder had to meet the requirements of a num-
ber of project objectives. In particular, the combination of defects had to:
Be capable of growth by cleavage fracture
Be of interest for codes and standards
Create a practical challenge for detection and sizing by NDE
Include defects simulating real underclad cracks.
One of the original objectives was to produce cleavage growth of a subclad crack. However, it
was realised at an early stage that cleavage growth from a subclad crack could not be guaran-
teed with high confidence within the practical constraints imposed by the testing method.
Therefore, the decision was made to include a through clad crack, in addition to a subclad
crack, where there was greater confidence that cleavage growth would occur.
Cleavage fracture initiation in the cylinder required a large sharp crack to be generated. Large
sub-clad and through clad defects were to be grown by fatigue at MPA Stuttgart. An additio-
nal large through clad defect was to be introduced by electro-discharge machining at JRC
Ispra and sharpened by fatigue at AEA Technology.
The challenge for inspection was to demonstrate the performance in detection and sizing sub-
clad cracks before and after a thermal shock. The defect sizes needed to be closely controlled
so as to provide an accurate benchmark against which sizing performance could be judged.
The use of fine electro-machined slots with a narrow tip had been previously used with suc-
cess in PISC and was therefore be used again.
The simulated under-clad cracks were aimed to be representative of cracking detected in
some early reactor pressure vessels This required a detailed knowledge of the morphology
and characteristics of this type of cracking. Responsibility for simulating this was taken by
30
HSE
IlL-nlih S j ft t >
NESC
Framatome which had propriety methods based on creating cold cracking and local brittle
zones in weld deposits.
5.2 PROCUREMENT OF A SUITABLE CYLINDER
At the start of the NESC-I Project, the cylinder under consideration was the last of eight
cylinders ordered in 1985 from Sheffield Forgemasters for the UK' s spinning cylinder test
programme [5.1]. This was known as cylinder 7. Six cylinders had already been tested and
one other cylinder had been used extensively for the commissioning of the rig and generating
heat transfer data. The cylinders had been obtained in pairs from four initial forgings. All the
cylinders were to A508 Class 3 specification, but with small modifications to the impurity
level and manufacturing route.
During 1992/93, a feasibility study was carried out to determine whether the fracture tough-
ness properties of cylinder 7 material would be suitable for a test in which cleavage fracture
was planned. The results indicated that the ductile to cleavage transition temperature would
be too low to obtain cleavage fracture in a rig where the specimens were cooled by water.
Although attempts were made to increase the ductile to cleavage transition temperature by
different heat treatments, these were not successful. The Network Steering Committee the-
refore made the decision to abandon test cylinder 7 as it did not meet the objectives of the
NESC-I Project.
This decision had significant consequences for both the project and the network. For the
project, it created a delay to the programme and caused an extra strain on scarce resources,
which required good project management to overcome. For the network, it was a problem to
be shared and generated excellent co-operation between the participants.
It was known that the cylinders used for the spinning cylinder tests 4 and 6 were from the
same single forging and had been specially manufactured by Sheffield Forgemasters for tests
designed to investigate cleavage crack growth. The detailed testing programme that had been
carried out in support of these tests had shown the material to have suitably low fracture tou-
ghness properties. Large arcs of these cylinders remained after the narrow sections containing
the longitudinal defects used for tests 4 and 6 had been removed.
As a result, it was decided to try to fabricate a new cylinder by welding together the two
semicircular arcs from the remaining cylinders 4 and 6 with full thickness welds. As these
cylinders had already been tempered at 580 C, it might be possible to post weld heat treat the
welds after cladding without increasing the forging toughness, albeit at a lower temperature
than that of conventional commercial practice. Residual stresses due to yielding of the inner
surface layers during the thermal shock tests on cylinders 4 and 6 could be eliminated by
removal of the top 25 mm of material from the inner surface.
A feasibility study was performed to determine the most suitable method of welding two
semi-circular arcs from cylinders 4 and 6 to form a new cylinder 200 mm thick. Both electron
beam and narrow gap submerged arc welding were considered.
31
HJ NESC
IK .Ulli S a l c i
A trial electron beam weld was made by TWI in the UK between blocks of cylinder material
200 mm thick. Examination of the trial weld demonstrated the absence of flaws and the feasi
bility of making a successful weld with adequate fracture toughness in this thickness of mate
rial. The use of electron beam welding would minimise the risk of distortion and the small
heat affected zone would allow the widest choice for implanting defects in forging material.
There would, however, have been the necessity to demagnetise the arcs so as to avoid any risk
of the beam straying from its path and creating unintended defects.
Narrow gap submerged arc welding had become well proven in recent years for fabricating
thick pressure vessels and the decision was eventually made to form the new cylinder using
this technique. Although the heat affected zone regions were slightly larger than with an elec
tron beam weld, there was still plenty of room for the defects to be introduced into the cylin
der to be situated away from the weld. The fracture toughness properties of the weld were
expected from past experience to be good and these would be validated.
Welding of the cylinder was undertaken by MAN GHH in Germany to a submerged arc nar
row gap welding procedure drawn up to be consistent with the requirements of the Code KTA
3201.1 and to the quality assurance requirements for the fabrication of primary components,
[5.2]. The two remaining arcs from test cylinders 4 and 6 were each machined to 180. The
remaining pieces were retained and later used for the NESC materials evaluation programme,
described in Chapter 6.
After longitudinal weld preparations (single V with I
o
angle of bevel) were machined, the
cylinder halves were aligned with a separation of 20 mm and held together with welded bra
cing plates for the welding. This used a wire/flux combination comprising Bohler (TD) S3
NiMolUP and Oerlikon OP41TT consumables.
The standard weld procedure prescribed a post weld heat treatment temperature of 600C.
However, PWHT at this temperature would have affected the toughness of the rest of the
cylinder making it less susceptible to cleavage fracture. It was therefore necessary to qualify
the weld fracture properties for a lower heat treatment temperature. In order to produce weld
material that could be tested in the finally selected PWHT condition, the runon and runoff
ends of welds were provided with suitable extensions. After welding, the inside and outside
surfaces of the cylinder were machined concentrically.
5.3 REFERENCE INSPECTION AND WELD QUALIFICATION
The welds were inspected by MAN GHH using approved dye penetrant and ultrasonic techni
ques. These inspections revealed no defects. The cylinder was then transported to the
Reference Laboratory at the JRC Petten where the welds were given a second ultrasonic
inspection and a radiographic inspection with Xrays using a linear accelerator of 1 Mev to
penetrate the 200 mm wall thickness. The results of these inspections confirmed that the
welds were of very good quality containing only very small levels of porosity. The runon and
runoff weld extensions were then separated from the cylinder.
32
HSE NESC
Testing of the weld extensions was carried out by VTT in Finland after they had been heat
treated to the final heat treatment condition of the cylinder (see below). The impact tensile
and impact fracture properties were determined using conventional specimens. The results
showed that these properties of the weld material were satisfactory and no less than those of
the parent forging. Although this type of welding is now standard practice, the application in
this instance has provided a good demonstration of the high quality that can be obtained.
The blind inspection trials and the fracture mechanics benchmark required that the defects
should be introduced into cylinder forging material that contained no inclusions or porosity.
The Reference Laboratory carried out a detailed inspection of the cylinder forging material
using ultrasonic immersion probes at 10 MHz. The detection sensitivity was set just above the
noise level. The results showed that the forging material was of very high quality and contai-
ned no significant inclusions or porosity with large areas of completely flaw free material
available as sites for introducing defects for the purposes of the NESC Project.
After completion of the reference inspection the cylinder was transported to MPA Stuttgart
for the introduction of fatigue and machined defects.
5.4 GENERATION OF THE SUB-CLAD FATIGUE CRACK
Fatigue cracks can be grown from machined notches in structural test pieces by applying
cyclic loading. Sometimes, a conventional testing machine can be used to apply cyclic tensile
or bending loads. For large samples, this method is difficult because it requires applying high
loads in a large testing machine with controlled fatigue loading capability. Several years ago,
the suggestion was made to seal the notch on the surface and to subject it to pulsating internal
pressure until a fatigue crack develops and grows to the desired dimensions [5.3, 5.4]. An
advantage of using this method is that the crack grows evenly around the boundary.
Internal pressure in the starter notch creates stress concentration at the notch boundary which
when cycled can lead to the initiation of a fatigue crack. Crack initiation and extension
depend on the stress intensity. If it is too low the crack does not initiate or extend; if it is too
high a plastic zone develops in front of the crack tip, the crack blunts, and a sharp crack is not
achieved. Therefore, the internal pressure required to generate a stress intensity factor K, to
initiate and grow a crack had to be assessed and the adjusted as the crack grew. In order to be
confident that there was an adequate margin to the fracture toughness of the material
(K,> 100 MPaVm), it was necessary to heat the cylinder to a temperature of 150 C while
pressure was being applied to avoid any risk of brittle fracture.
A semi-circular longitudinal starter notch of 25 mm radius was introduced into the inside sur-
face of the cylinder using electro-discharge machining. The notch was covered by a sealing
plate with a concave face into which oil was pumped from a pulsator with a pressure intensi-
fier capable of generating pressures inside the notch up to 2000 bar. An external force was
applied to the plate from a jack mounted across the cylinder diameter in order to effect a seal,
Fig. 5.1.
33
HS E
Uh & Sa ft t;
N
I C O !
The ultrasonic amplitude modulation technique was used to measure and monitor the fatigue
crack extension around the complete crack boundary as cycling proceeded [5.5]. The techni-
que uses a standard ultrasonic search unit coupled to the surface opposite to the starter notch,
Fig 5.2. During fatigue cracking, microscopic deformations occur in the area of the crack tip
and the crack lace. This causes a change in the amplitudes of the echoes from these regions
and a zone with a modulated signal characterising the area between the crack tip and the
notch tip is visible on the screen. The advantages of the amplitude modulation technique lie
in its precision as well as in the possibility to observe the crack growth on-line.
Because of the temperature limits of the ultrasonic probes, it was not possible to apply the
method and measure growth while fatiguing at 150 C. Therefore, at intervals the cylinder
was cooled to room temperature and crack
growth measured by cycling the crack at
lower pressure in order to avoid any risk of
fracture.
EXTERNAI . LOADING
INTERNAL PRESSURE
GROOVE (AREAA)
FATIGUE CRACK
Fig. 5.1: Arrangement for fatigue sharpening the
sub-clad defect using internal pressure.
The number of cycles expected to grow the
starter notch to the target crack depth was
estimated to be less than 100,000. Against
all expectations, a fatigue crack had not
been initiated after a total of 455,000
cycles at higher K, values. A calculation of
the compressive hoop stress on the notch
resulting from the load of the hydraulic
cylinder revealed only low values (1 MPa)
so that another reason had to be found.
As thermal shock tests had previously been
carried out on the material from which the
cylinder had been fabricated, it was realised
that compressive residual stress would be
present at the inner surface. The surface
residual stress was measured in the plane of
the starter notch and confirmed by elastic
plastic finite element analysis. It was found
that residual compressive stresses in the
region of 250 to 360 N/mm were present in
the hoop direction which of course affected
the initiation and growth of a fatigue crack.
In order to overcome this problem, the cylin-
der was placed in a testing machine which
applied a constant external load of between
5.0 and 5.5 MN cross the diameter of the
cylinder to create extra tensile hoop stress at
34
U S E
v i r r cp
E

3

CRACK NOTCH
TIP TIP
LOAD PULSATION
MODULATION OF SIGNALS NORMALLY NOT
EXCEEDING NOISE:
- CRACK TIP ECHO
SIGNALS OF CRACK SURFACES
- OTHER EFFECTS
- GRAIN BOUNDARY SOUND REFLECTIONS IN
A SMALL AREA AROUND THE CRACK TIP
SUBJECTED TO ALTERNATING PLASTIFICATIONS
NC
CO
ta
ISE
NST
ta
'
I
i
M<

NO
) 0 U
'
SE
JkT
J.
ED
t
B
i '

ft
A

I
V_9_
8 10 J V 0
8 io y
Fig.5.2: Ultrasonic amplitude modulation method for crack size measurement.
the inner wall in the vicinity of the defect. At the same time, the internal jacking of the sealing
plate was maintained and fatigue cracking continued using the pulsator. With this setup. the
fatigue crack was initiated and grown. Destructive examination later revealed that this crack had
a maximum depth of 81.4 mm and a length of 256 mm at the time of the test when all manufac
turing operations on the cylinder had been completed. The sizing accuracy of the amplitude
modulation technique was better than 10% in length and depth.
5.5 INTRODUCTION OF EDM DEFECTS AND REALISTIC UNDER-CLAD CRACKS
The test cylinder was machined to an internal diameter of 1052 mm thereby removing the
starter notch and leaving just the fatigue crack. This operation also removed the zone of pla
stically deformed material giving rise to the compressive residual stress. This stress was the
refore not present to affect the behaviour of the defects during the NESC test. MPA then
introduced five defects by electrodischarge machining at other locations on the inside sur
face. The sizes and positions of these defects are shown in Fig 5.3.
35
us i :
Health &Safely
K i c o p
Top of
cylinder Q
250
E
E
II
c
.2 500
t'
'
o
Q .
^ 750
Z3
'
C
O
1000
Bottom of
cylinder
1250
45
Circumferential position [degrees]
90 135 180 225
C'
Hot Cracking
Area I
TUTttlr
B
Large
Fatigue
.E
- 0
RL
Large
Fatigue
270 315 360
I "X" I Smooth planar EDM Notch (PISC type A)
| "X" | Realistic underclad cracks
["X"] Large fatigue defects
Cold Cracking
Area
t
0
f
,
Fig. 5.3: Map of the defects inserted into the cylinder.
Hot Cracking
Area II
a.

On completion of the work at MPA the
cylinder was taken to Framatome's works at
Chaln sur Soane for the introduction of
realistic underclad cracks. These were
introduced using proprietary methods based
on creating cold cracking and local brittle
zones in small weld deposits, Fig 5.4.
5.6 CLADDING THE CYLINDER
The cladding of the cylinder was under
taken by Framatome using a procedure
consistent with industrial practice for early
reactor pressure vessels up to 1982, Figs
5.5 & 5.6. This procedure was based on
strip cladding using an electroslag techni
que. Specified preheat and interpass tem
peratures were closely controlled using thermocouples attached to the cylinder.
In order to demonstrate the cladding procedure before it was applied to the cylinder, an arc of
remaining material from the original cylinder forging was clad using the same procedure. This
Fig. 5.4: Preparations for the Insertion of local
brittle zone defects.
36
HS E i ce,
Fig. 5.5: Cladding the NESC Cylinder.
Fig 5.6: Detail of the submerged arc strip cladding
process.
power manual metal arc welding to a height 25
mm wide by 250 mm long. This built up zone
from which a defect would be grown by fatigue
inspected and no defects were detected.
arc, together with a second arc from the
same forging which was left unclad, were
heat treated in the same way as planned for
the cylinder. This material was used to pro-
vide specimens for the materials characteri-
sation programme. The microstructure of
the cladding and heat affected zone of the
clad arc were determined early in the pro-
gramme. The thickness of the heat affected
zone varied between 5 to 10 mm into the
forging, highest in the middle of each strip
where the heat input was the greatest and
lowest at the ends where the strips overlap-
ped. A full microstructural and hardness
survey of the clad-ferritic interface was
undertaken and is reported in Chapter 8.
An average cladding thickness of 10-11
mm was achieved with two layers of stain-
less steel (308 and 309) strip cladding. The
cladding was not applied to the whole
length of the cylinder but was terminated
60 mm from the upper cylinder surface to
enable the support disc loading pockets to
be machined. The cladding was ultrasoni-
cally inspected for de-bonding and other
defects: no defects were detected. A special
zone was then prepared in which extra
cladding material was deposited using low
mm above the surface and over an area of 100
was for the introduction of a machined notch
through the clad. The zone was ultrasonically
5.7 POST CLADDING HEAT TREATMENT
The Materials Task Group recommended a lengthy exposure time of 12 hours at 550 C in
order to achieve a compromise between the equivalent stress relief after cladding which
would be obtained following commercial procedures yet without increasing the toughness
properties. Fracture toughness tests showed that this PWHT had no "deleterious" effect on the
toughness required to achieve success with the project. As the additional machining of the
cladding to provide a final thickness of 4 mm could induce unwanted stresses in the cladding,
it was decided to divide the heat treatment into two sessions of 6 hours each at 550 C, one
after cladding and one after final machining.
37
HSE
I I I -il i li & Saf c t i
M ESC
After cladding, the cylinder was given a stress relief heat treatment at 500 C for six hours
and then at 550 C for a revised time of 5 hrs 40 minutes to produce the effect of a single heat
treatment at 550 C for six hours as intended. The cylinder was then taken to MPA Stuttgart
for the introduction of a through clad fatigue defect from a starter notch machined into the
special built-up zone of the cladding.
5.8 INTRODUCTION OF THE FIRST THROUGH CLAD DEFECT
After cladding the cylinder was returned to MPA where a through clad crack was generated
by fatigue in the way described above. This time the fatiguing proceeded without apparent
difficulty. The size and profile of the defect was intended to match the large fatigue defect
introduced before cladding and now subclad.
5.9 FINAL MACHINING AND HEAT TREATMENT
The cylinder was packed and transported to the UK for final machining and heat treatment at
British Steel's works at Workington, Cumbria. The final machining was to remove the built
up zone of the cladding and to machine the whole cladding surface to a thickness of 4 mm.
Special consideration was given to obtaining a high degree of concentricity. Following machi-
ning, the cylinder was given the second and final stage of stress relief heat treatment at a tem-
perature of 550 C for 6 hours. On completion of machining and heat treatment, the final
dimensions of the cylinder were accurately measured to be:
Outer diameter 1,395 mm
Inner diameter 1,045 mm
Thickness 175 mm
Length 1,296 mm
After the work was completed, the cylinder was delivered to the EC Joint Research Centre at
Petten for the Reference Inspection.
5.10 REFERENCE INSPECTION AND DESCRIPTION OF DEFECTS
A detailed inspection of the cylinder was carried out by the Reference Laboratory using
advanced NDE techniques. The exact position and size of each defect was logged and compa-
red with the manufacturing records. Since the cylinder was to be used for a blind inspection
trial, the results of the inspection were kept confidential at the time. However, a detailed map
of the defects was created and this is shown in Fig 5.3.
During the reference inspection it became apparent that the first through clad defect introdu-
ced after the cladding was more complex than had been intended. This complexity was attri-
buted to the stress field created by the limited width of the built up area of cladding. It was
concluded that this defect was not suitable for validating fracture mechanics analyses which
was an objective of the project, although the blind inspection trials could proceed.
38
I I S I .
ii*, .ii t ii & Saft-ty
NI CO

The decision was taken to introduce a new through clad defect for fracture mechanics valida-
tion. The new defect would be created by electro-discharge machining a notch that could then
be sharpened by fatigue cracking around its boundary by a different method. Calculations
were carried out to find a site for this defect where fatigue sharpening by diametral loading in
a testing machine would not affect the other defects.
5.11 INTRODUCTION OF THE SECOND THROUGH-CLAD DEFECT
The new notch was machined by the EC JRC' s Institute of Advanced Materials at their Ispra
laboratories. It had a maximum opening of 3 mm in the centre so that the EDM tool could pro-
duce a tight radius at the notch tip. After machining, the dimensions of the new defect were
measured by replication. The cylinder was then transported to AEA Technology at Risley UK.
Fatigue sharpening of the through clad EDM notch was performed by placing the cylinder
horizontally in a 6.3 MN servo hydraulic test machine, Fig 5.7, with the notch in the vertical
plane. Load was applied across the diameter of the cylinder compressing it and generating
hoop bending stress through the wall which was tensile on the notch. The load was cycled at 1
Hz frequency. In order to avoid the possibility of brittle cracking, the cylinder was maintained
at a temperature of 150 C during fatiguing
using heating blankets and insulation.
Alternating current potential difference
(ACPD) probes were attached across the
middle and ends of the notch in order to
monitor fatigue crack growth during load
cycling. The ACPD from all three probes
increased as fatiguing proceeded with the
change at the ends of the notch greater than
that at the deepest point as expected. While
the fatigue crack could be seen visually run-
ning along the surface from each end of the
notch, it was not certain that cracking exten-
ded round to the deepest point. It was consi-
dered possible that the smaller ACPD
increase from the middle probe could have
been due to the vigorous fatigue cracking at
the ends of the notch.
Prior to commencing the fatigue cracking,
the position of the deepest point of the
notch was determined using ultrasonic time
of flight diffraction from the outer surface
to provide a datum from which fatigue
Fig 5.7: Sharpening the through-clad defect by
h c o u
,
d b e m e a s u r e d A t i n t e r v a l s
diametral load fatigue cycling.
39
si i NESC
Ili-aliti & Sa fit
during the fatiguing, the cylinder was cooled and the extent of cracking was determined using
time of flight diffraction (TOFD). and also by pulse echo and creep wave methods.
The TOFD data suggested that a fatigue crack had initiated from the deepest point but the
amount of growth was less than 2 mm and could not be accurately quantified. The TOFD
technique used was not able to profile the cracking beyond the region of the deepest point.
Cracking along and close to the surface was measured using pulse echo and creep wave
methods and this showed that the cracking extended around the notch boundary to more than
20 mm below the surface.
Fatigue cycling was stopped when it had been confirmed that a sharp fatigue crack had been
generated around the boundary to beyond where crack initiation was expected to occur during
the spinning cylinder test. A total of 225.000 load cycles had been applied when this condi-
tion was reached. The cylinder was then ready for installation of the test instrumentation
without further heat treatment.
REFERENCES
[5.1] Clayton A.M., Leckenby R.E.. Reading K.. Robins E.J., White W.R. "Tests on thick sedioli steel lo
determine fracture toughness for comparison with conventional assessment methods". Pre seminar on
the assessment of fracture prediction technology: piping and pressure vessels. NUREG/CP-0037
Nashville Tennessee. July 1990.
[5.2] Hantsch H., Million K.. Zimmermann . "Submerged arc narrow gap welding of thick walled compo-
nents". Welding Journal. July 1982 pp. 27-34.
[5.3] Abbatiello A.A. and Derby R.W.: "Notch Sharpening in a Large Tensile Specimen bx Local Fatigue".
ONRL Report TM-3925-1980.
[5.4] Molz, P.P.: "Flaw Preparations for HSST Program Vessel Fracture Mechanics Testing: Mechanical-
Cycling Pumping and Electron-Beam Weld-Hydrogen-Charge Cracking Schemes". NUREG/CR-1274,
ORNL/NUREG/TM-369. 1980.
[5.5] Steinmill, H. and Mletzko U.: "Risstiefenmessung mit hoher Genauigkeit an pulsierend beanspruchten
Rissen in Proben fur brumechanische und mechanisch-technologische Versuche" DGzfP-Tagung,
Erlangen. 1985.
40
US E
vieroi
6 MATERIALS EVALUATION
6.1 REQUIREMENTS OF THE MATERIALS EVALUATION PROGRAMME
The Materials Task Group (TG2) of NESC was responsible for conducting a comprehensive
materials characterisation-testing programme to determine the physical, mechanical and frac-
ture toughness properties of the forging, heat-affected zone (HAZ) and cladding of the cylin-
der specimen. Those data provided an essential part of the required input for thermal, structu-
ral and fracture mechanics analyses that were carried out by the Structural Analysis Task
Group (TG3) during the pre-test and post-test phases of the project. Results of the materials
characterisation programme have been reported extensively by TG2 [6.1-6.3]. The Group
focused on the following objectives:
Provide adequate and reliable data as required by TG3 to carry out thermal/structural/frac-
ture analyses of the cylinder;
Study constraint effects on fracture toughness of the forging material;
Evaluate the effects of an extra tempering treatment (post-weld heat treatment) on fracture
toughness of the forging material and on the properties of the cladding and heat-affected zone;
Assure qualification of the narrow-gap submerged arc welding (NGSAW) procedure used for
fabrication of the NESC-I cylinder from parts of previously tested cylinders SC-4 and SC-6.
Those objectives of the materials characterisation programme were developed through close
consultation with the members of TG3.
6.2 PARTICIPATING ORGANISATIONS AND WORK ALLOCATION
All organisations participating in the launch phase of the NESC-I project were invited to par-
ticipate in the materials characterisation-testing programme. The nine organisations that con-
tributed to the work are given in Table 6.1 ; a detailed work allocation for those organisations
is provided in Ref. 6.1. The material characterisation programme included the measurement
of physical, mechanical and fracture toughness properties of the cladding, HAZ and the base
material in the NESC-I cylinder.
For each task of the material characterisation programme, participating organisations provi-
ded reports that include the raw data, as well as descriptions of the test performance and data
evaluation. Those data were forwarded to the Reference Laboratory and subjected to compila-
tion and analysis by two teams:
Subgroup A, consisting of ENEL, RRA and team leader AEA Technology, which compiled
and analysed the tensile test data. ECN provided support regarding data interpretation.
Subgroup B, consisting of Framatome, MPA and team leader VTT, which analysed the K
Jc
,
J-R and K
la
data.
The complete data report [6.1] was the joint responsibility of the JRC and VTT, with assi-
stance provided by ECN, AEA Technology and RRA.
41
HSE
11 i a li li & Safti
Mnr op
Institut fur Werkstoffmechanik (IWM), Germany
ENEL, Italy
AEA Technology/Rolls Royce and Associates (AEA/RRA), United Kingdom
VTT Manufacturing Technology (VTT), Finland
MPA Stuttgart, Germany
Framatome, France
Energy Centre of the Netherlands (ECN), Netherlands
Siemens-KWU, Germany
Table 6.1: Organisations
participating in the NESC-I materials
characterisation programme.
6.3 SOURCE OF TEST MATERIAL
The NESC-I cylinder specimen was fabricated from A 508 Class 3 steel subjected to a non-
standard heat treatment to simulate radiation embrittlement of an RPV steel [6.4]. The chemi-
cal compositions of the base metal and the cladding material applied to the inner surface of
the NESC-I cylinder are given in Table 6.2. The fabrication process utilised the remaining
arcs of previously tested cylinders SC-4 and SC-6, which were manufactured from one for-
ging produced by Forgemasters Engineering Ltd. Those arc segments were reconstituted into
a cylinder using the NGSAW process. Summaries of the fabrication histories for the test
cylinders SC-4/6 and the NESC-I cylinder are given in Tables 6.3 and 6.4, respectively.
(Additional information concerning the history of the NESC-I source material is included in
Appendix A). A segment of the SC-4 cylinder also provided source material for the characte-
risation programme. The characterisation segment was subjected to the same fabrication pro-
cesses as the NESC-I test cylinder, except that the clad thickness was left at 8 mm (cladding
in the NESC-I cylinder was machined to a thickness of 4 mm). After fabrication, the characte-
risation segment was cut into blocks according to the sectioning plan depicted in Fig. 6.1. The
blocks were distributed to participants in the characterisation programme according to the
designations given in Fig. 6.1. with the size of the block dependent on the type of testing.
Table 6.2: Chemical composition of the base material and cladding in the NESC-I cylinder.
C Si Mn S Cr Mo
Base Material 0.23 0.23 1.32 0.011 0.012 0.08 0.50
Cladding 0.025 1.50 2.0 0.025 0.03 19.0
Ni
0.73
10.0
Forging produced by Forgemasters Engineering, Ltd., Sheffield, UK
Heat treatment
- Austenlzation: 6 h at 950 C
- Quench: Water quench from 950 C
-Temper: 8 hat580C 10'C
Spinning cylinder tests at AEA Technology, Risley, UK
- Quench, initial temperature: 300 C
- maximum rotational speed: 530 rpm (SC-4); 2000 rpm (SC-6)
- maximum heat transfer coeff.: 22,000 W/m 'C
Table 6.3: History of test cylinders
SC-4 and SC-6.
42
HS E NESC
160
L
ti
MPA
Spare part
ECN
AEA I WM
"-
O
<-
ENEL
VTT
NESC 1.3 . ' NESC 1.4 . *
150 , | , 1 5 0 , 1 , ISO J ISO J
Designation of each
steel piece will be made
only on the front side
and left side
I On the
front side
of each
steel piece
On the left side
of each steel piece
NESC 1.1 to ECN
NESC 1.2 to AEA
NESC 1.3 to IWM
NESC 1.4 to FRAMATOME
NESC 1.5 to VTT
NESC 1.6 to ENEL
NESC 1.7 to MPA
Fig. 6.1: Partition of the NESC1 material test arc for the participating institutes.
Table 6.4: History of test cylinder NESC-I.
Formed by narrowgap submerged arc welding (NGSAW) of halves of SC4 and SC6 (MAN/GHH)
NGSAW preheat temperature: 150 C
NGSAW interpass temperature: 250 C
No postweld heat treatment after welding
Local fatigue growth of underclad defect at 150 C (MPAStuttgart)
1
Machined removal of 25 mm of material from inside
' Twolayer 308/309 strip cladding averaging 11 mm total thickness (Framatome)
Cladding preheating temperature: 160 C
Cladding interpass temperature: 250 C
Cladding postheating: 4 h at 280 C
Deposition of raised block of MMA weld 25 mm above cladding
1
Post cladding stress relief 1:6 h /500 C (max. heating/cooling rate 557h)
Post cladding stress relief II: 5 h407550
C
C (max. heating/cooling rate 557h)
Local fatigue growth of the complex defect at 150 C (MPAStuttgart)
Machining to remove outer cladding layer to leave cladding thickness of 4 mm (British Steel)
' Final stress relief: 6 h at 550 C
Fatigue cycling (225,000 c/s) of throughclad defect by diametric compression (2 MN) at 150 'C (AEA Technology)
43
HSE
Health & Suret:
6.4 MATERIAL PROPERTY DATA
6.4.1 Test Specimens
The thickness dimensions of the clad and clad/HAZ layers in the NESC-I cylinder specimen
necessitated the use of miniaturised and reduced thickness specimens in various test techni-
ques. Miniature tensile specimens were taken from the clad layer in the L orientation with
respect to the welding direction. Tensile specimens were drawn from the HAZ in the L orien-
tation referenced to the main forming direction during forging. The HAZ layer varied in thick-
ness from 5 to 10 mm and the specimens were extracted at slightly different depths to sample
material in four distinguishable categories defined for the HAZ [6.2].
Tensile tests for the base material forging were conducted according to the standard EN 10
002. Standard test specimens having a circular cross section were cut in L orientations that cor-
responds in the cylinder to circumferential.
Plane-sided compact-tension (CT) specimens having thickness of 2.5 and 5 mm (see Fig. 6.2)
were taken from the clad layer in the L-T orientation. Specimens were fabricated from the base
material and HAZ with thickness of 2.5 mm, 5 mm and 10 mm.
Physical measurements were made using rods that were 6.5 mm in diameter and taken in the
short transverse direction through the cladding, HAZ and base material. The rods were then
sectioned according to the specific material zone that was to be characterised.
6.4.2 Elastic and Thermal Properties
Properties of Young's Modulus (E). Poisson ratio (v), coefficient of thermal expansion (a), thermal
conductivity (), specific heat capacity (c
p
) and density (p) were determined at temperatures of 25
C and 300 C. Sources for these properties were based on published handbook values or data pro-
specimens
Fig. 6.2: Location of fracture specimen machined from the test arc.
44
HSE
Health & Safely
NESC
Table 6.5: Temperature dependence of elastic and thermal material properties for NESC-I cylinder materials.
Property
Young's Modulus, E
Poisson ratio,
thermal conductivity,
specific heat capacity, c
p
coefficient of thermal expansion,
density,
(GPa)
(W/m C)
(kJ/kg C)
(pm/m C)
(kg/m3)
Base/HAZ
211.7 0.0682T f C)
0.28
40.60.0097T(C)
4.1x10"
4
T +0.432
11.6 + 0.014TfC)
7800 (20 C)
7720 (290 C)
Cladding
150.20.0862T(C)
0.28
13.9 +0.018T f C)
4.110"
4
+ 0.432
15.7 + 0.0096TCC)
7720 (20 C)
7610 (290 C)
1200
1100
1000
900
800
700
600
. 1 . 1
;
; 1
' SF
500
, ,
>
rf
, ,
Base Material 20
I I I I
For :

= 7

f " * " *
' - J - '


I I 1 .
I I I I
> 0.08
43.54 + 55
I I I I
c
, . , ,
:
t-
- - ' ' "
; < 0.0
B
536.69 (34) + 960.19 c
P
O 7C3
I I I I
1.6 2
O 1.6,4
1.6/8
+ 13AGU
Mean True Stress
r Bound
Lower Bound
, , , , 1 , , , , I , , , , 1 , .
-
-

:
;
-

-
"

, ,
400
vided by participating organisations through
limited experiments. Those temperature
dependent data are tabulated for the base
metal forging, the HAZ and cladding material
in Ref. 6.1. Linear relations approximating the
temperature dependence of the elastic and
thermal properties are given in Table 6.5. A
test run of the commissioning cylinder was
used to more accurately determine the heat
transfer by calculating the heat loss during the
quench from the temperature profile and
equating this to the heat flow across the inside
surface. A heat transfer rate between 9000
W/m
2
C and. 15000 W/m
2
C across the sur
face was measured and this value was subse
quently used for test design calculations.
6.4.3 Tensile Tests
0.2 0.3 0.4
True Plastic Strain
o.e
Fig. 6.3: True stress - true plastic strain curves of
the base metal at room temperature.
True stress versus true plasticstrain curves
were constructed from tensile test data as
functions of temperature for the base forging,
HAZ and clad layers. The tensile tests were
performed at a strain rate of 5xl0~
4
/s, and at
test temperatures of RT (room temperature), 150 C and 300 C in an air environment. Mean
curves fitted to the tensile data from the base forging are depicted in Fig. 6.3.
Tensile data from the HAZ specimens exhibited substantial variability that depended on the posi
tion of the specimen in the HAZ layer. The range of this variation is shown in Fig. 6.4, which
depicts the fitted true stress versus true plasticstrain curves of single HAZ specimens tested at
room temperature. At plastic strains of 0.05, the tensile stress values ranged from 700 MPa to
more than 900 MPa.
45
H SK
MCTO p
HAZ Material 20 'C
1200
1000
800
600
400
E664 Soft HAZ
E665 Weak HAZ
EE70
13BV/L
7A1
7A2
Upper Bound
Mean
Lower Bound
Linear Fir 0.1 <
_J L
0.1 0.2 0.3 0.4
True Plastic Strair
0.5 0.6
Fig
the
6.4: True stress - true plastic strain curves of
HAZ material at room temperature.

A
A 1
A
ladd
[add
ladd
ng
ng
ng

1
True plastic strain
Fig. 6.5: True stress - true plastic strain mean
curves for HAZ and cladding (the HAZ curves are
the three highest curves, showing no decrease with
rising temperature).
The mean true stress versus true plasticstrain
curves for both the cladding and the HAZ are
depicted in Fig. 6.5 for all test temperatures.
The less ductile HAZ curves showed essen
tially no sensitivity to variations in test tem
perature. The highly ductile cladding curves
demonstrated a significantly reduced stress
response as the test temperature was increa
sed from room temperature to 150 C.
6.4.4 Hardness Measurements
Hardness measurements and optical micro
scopy were performed by AEA and VTT to
determine the shape and thickness of the
cladding and HAZ. The thickness of the
HAZ varied in the range from 5 to 10 mm,
as shown in the etched cross section of a
test block (Fig. 6.6). Curves depicted in
Fig. 6.7 illustrate the elevation in hardness
measured across the maximum HAZ width
position. Hardness values in the thin part of
the HAZ were slightly higher than those in
the thickest part.
6.4.5 I mpact Testi ng
Charpy impact energy versus temperature
data and loaddeflection curves were genera
ted from instrumented impact tests carried
out according to the DIN 50115 and the
ES1S Draft 9 procedure. The lateral expan
sion and the percentage shear fracture were
measured from tested specimens. The tempe
rature range for these tests was from 20 C to
150 C. In Fig. 6.8, Charpy test data are com
pared with the SC4 data provided by AEA
Technology. The transition temperatures cor
responding to an impact energy of 41 J, a
lateral expansion of 0.89 mm, and 50 percent
shear fracture appearance were 78 C, 97 C,
and 92 C, respectively.
The nilductility transition temperature (T
NDT
) was determined from dropweight (Peliini)
tests conducted according to ASTM Standard E20895. Those data provided a T
NDT
value of
approximately 35 C for the cylinder forging material.
4ft
11 SK l \ L_. \ j V/
Base met al
HAZ
10 mm max.
mtp991.dsf
Fig. 6.6: Schematic diagram of longitudinal wall section showing the cladding and the heat-affected
zone (min. HAZ depth appr. 5 mm).
>
320
300
280
260 -
240
220
200
180
160

- c
D
Mean
value
- * - VTT
(HV5)
-
r. /
; \ V
V " \
\f
- "
-
Parent
materi al
A 5083
J/ W
C
Heat "3
affected
zone

_ l
At
1
cl
Layer 2
j steni tc
ddi ng

The reference nilductility transition tempe

rature (RT
NDT
) defined according to ASME
Section III. NB2331, was governed by the
Charpy data. The transition temperature cor
responding to an absorbed energy of 68 J
was T
6SJ
= 134 C, thus providing an RT
NDT
value of 101 C.
15 10 5 0 5 10
Distance from Ferritic/Austenitic Interface (mm)
Also, Charpy tests were conducted on speci
mens taken from the narrow submerged arc
weld (NGSAW). The transition temperature
was considerably lower than that of the base
metal.
6. 4. 6 St at i c Fr act ur e Toughness Testi ng
Fig. 6.7: Hardness distribution measured across
the HAZ located under the cladding. AEA and
VTT measured the data.
Static fracture toughness testing was carried
out using the ESIS P292 and ASTM l 152
87 standards applied to CT specimens and
threepoint bend specimens (thickness of 10
and 25 mm) having 10 percent sidegrooving
on each side of the specimen. Those specimens were fabricated in the LT orientation, where
L and T are circumferential and axial directions in the cylinder, respectively (see Fig. 6.1).
The temperature range for these tests varied from room temperature to 150 C. Toughness
data obtained from deepcrack specimens (a/W from 0.45 to 0.55) are given in Figs. 6.9 and
6.10 for the base metal and the HAZ, respectively. Values for the base metal were approxima
tely equal to those of the original SC4 and SC6 cylinders.
The fracture toughness data were analysed by the Master Curve Approach [6.5], which defi
nes a reference temperature, T
0
, corresponding to a mean toughness of K = 100 MPaVm for
47
HS K
Char py- V t est r esul t s of AEA and VTT.
specimens which are size-adjusted to a thickness = 25 mm. Fracture toughness curves cor-
responding to the 5, 50 and 95 percent fracture probabilities are given by the equations
K
Jc
= 25.4 + 37.80exp[0.019(T - T
0
)] (5%)
K
Jc
= 30.0 + 70.00exp[0.019(T - T
0
)] (50%)
K
Jc
= 34.6 + 102.2exp[0.019(T - T
0
)] (95%)
The reference temperature for the base
metal and the HAZ were determined to be
T
0
= 68 C and 16 C, respectively.
Tests were also conducted on the base
material using three-point bend specimens
(thickness of 25 mm) with a/W ratios of 0.1
and 0.5 to study shallow crack effects on
cleavage fracture toughness in the transition
temperature region. The shallow crack data
generated from the a/W = 0.1 specimens
are presented in Fig. 6.11 and imply a tran-
sition temperature of T
0
= 32 C.
60
50
AEA, top 0
1
pos
O AEA, bottom
180
s
pos.
VTT
Fit to VTT
results
X
6
3*^
d
J r E - 0.5x76.5x(l+tanh(lT-74|/ 57|)
d = ductile
40 60 80
Temperature PC)
Fig. 6.8: Charpy data measured on the base metal of
the NESC cylinder compared to the data of the
spinning cylinder 4 material.
250
150 -
100
I I I
Size corroded to = 25 mm
T
0
= 68C (VTT and ENEL results)
= 10 mm: n= 18(VTT)
= 25 min: = 9 (VTT)
25 mm: n = 9(ENEL) 951%
Fig. 6.9: Static fracture toughness of the base metal
with specimen thickness 10 mm and 25 mm,
analysed to correspond to 25 mm. Crack depth of
a/W=0.5. Symbols: ENEL results: B, VTT results (B=
10 mm): and (ductile), VTT results (B=25 mm):0.
6.4.7 Dynamic Fracture Toughness
The inverted impact pendulum and test
procedures of VTT were used to conduct
the K
Jc
tests on specimens that were fati-
gue-pre-cracked to a nominal initial length
of 5 mm and side-grooved (10 percent) on
each side. Specimens were fabricated from
base metal in the L-T orientation. Dynamic
fracture toughness (K
Id
) was estimated
from the absorbed energy at the onset of
cleavage fracture initiation and from calcu-
lation of the corresponding J value. The
dynamic fracture toughness results given in
Fig. 6.12 imply a reference temperature of
T
0
= 68 C, which was also the value deter-
mined from the static testing programme.
6.4.8 Crack Arrest Toughness
Crack arrest testing was conducted by MPA-
Stuttgart according to the ASTM standard
E1221-88 using a specimen with dimensions
150 mm 150 mm 25 mm. Crack arrest
toughness was also estimated from a VTT
48
HS E
Iliulth & Sactv
N
I CQ*
correlation of valid K
Ia
data and crack arrest force versus temperature dependence measured in
instrumented Charpy tests. The estimates of crack arrest toughness were evaluated by VTT.
The crack arrest tests produced ten valid K
Ia
values at temperatures that ranged from room
temperature to 120 C. Application of the Master Curve methodology to the data set is illustra
ted in Fig. 6.13, which produced a reference temperature of T
0
= 93 C. The crack arrest tou
ghness was also estimated from the transition temperature corresponding to the crack arrest
force of 4 kN. The VTTdeveloped correlation produced a crack arrest fracture toughness refe
rence temperature of 84 C.
251)
201)
150
50
1 1
Size corrected lo = 25 mm
T0 = 16 C
l i 10 mm (n= 10)
95%
/
s
J? Ujf
^^*^ ^-^-^0 .S*
1 1
V
50%,
/ ' /
/
' /
5%/
= ductile
1

60 2 0 2 0 60 10C
( C)
Fig. 6.10: Static fracture toughness of the heat-
affected zone with specimen thickness 10 mm,
analysed to correspond to 25 mm. Crack depth
a/W=0.5.
aAV O . I
MEASURED BY FRAMATOME
ANALYSED BY V I T
_ l I I
4(1 60
(C)
80 100
Fig. 6.11: Static fracture toughness of the base
metal measured using shallow crack (alW=0.1)
3-point bend specimens (B=25 mm) [9].
6.4.9 JResistance Testing
The Jresistance data for the cladding, HAZ
and base metal were determined according to
the ESIS P292 procedure utilising the single
specimen technique that allows for crack
growth. Testing was conducted by ECN, ENEL
and IWM. The fracture toughness data for each
material were recorded in terms of JAa curves
obtained from threepoint bend and CT speci
mens with mm minimum thickness. Mean
power law fits to the data were defined in terms
of a constant and an exponent:
J =AAa
B
Where J and a have units of kJ/m
2
and mm,
respectively. The results for the cladding. HAZ
and base metal were combined by VTT for all
test temperatures to produce the power law fits
plotted in Fig. 6.14. Those results indicate a
temperature effect for the cladding, whereas lit
tle temperature effect is observed for the HAZ
and base metal.
6.5 POST-TEST CHECK OF THE
SPINNING CYLINDER PROPERTIES
After the spinning cylinder experiment the
cylinder was sectioned and specimens were pre
pared for additional tests at ECN. VTT and JRC
labs. The purpose was to check that the proper
ties of the test cylinder were consistent with
those of the test arc used in the pretest material
characterisation programme described above.
49
HS E
400
160
Fig. 6.12: Dynamic fracture toughness of the base
metal measured with Charpy size specimens. The
curves show the mean, 5% and 95% fracture
probability.
NESC 1
K,, = 30 + 70-exp{0.019-(T-Tr<, ^ )}
= 19.4%
-80 -60 -40
T-Trv
-20
ft]
20
Fig. 6.13: Crack arrest fracture toughness K
ia
vs.
temperature. The curves show the mean, 5% and
95% fracture probability. The 100 MPa^Jm reference
temperature is 93 "C (standard deviation is 19%).
6.5.1 Tensile properties and impact
toughness
The mechanical properties were measured
using tensile specimens taken at a depth of
40 mm from the inside surface of the cylin-
der where no effect on the properties would
be expected from the PTS experiment. The
stress-strain curves fell within the 95%
confidence bounds of the test arc results
even at 300 C where the deviation
between the materials was largest. On this
basis the mechanical strength properties the
cylinder material are judged fully compara-
ble to those of the test arc material.
Similarly the results of the Charpy-V test
series conducted on the cylinder base mate-
rial confirm that both the transition tempe-
ratures and the upper-shelf energy are equi-
valent to those of the arc (Fig. 6.15).
6.5.2 Fracture Toughness
The post-test fracture toughness tests were
performed by VTT with 10 mm three-point
bend specimens taken at a depth of 40 mm
from the inside surface of the cylinder. The
measured data and the fracture probability
curves are shown in Fig. 6.16. The value of
T
0
calculated for these results was 5 C
lower than the value for the test arc (64
C). Given this small difference the test arc
can be regarded as representative of the
cylinder material also with respect to frac-
ture toughness.
6.6 DISCUSSION
Table 6.6 provides a summary of the T
0
reference temperatures determined from
static, dynamic and crack arrest tests, as
well as the 41 J impact energy transition temperature measured for the base material. Static
and dynamic values of T
()
are essentially equal, while the crack arrest value is approximately
25 C higher. The value of T
0
measured for the HAZ was approximately 50 C lower than the
50
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Health & Safou
N
C O I
Table 6.6: Comparison of 100 MPa m transition temperatures T
0
and the T
(41J)
and T
(6SJ)
values
determined from Charpy data.
Base
HAZ under cladding
VC)
from K
jc
68
16
VO
f rom K
Jd
68
vo
f rom K
!a
93
T,41J) (C)
78
T
(68J) (
C
)
134
Delta a ( mm)
Fig. 6.14: Mean J-Aa curves for the base metal,
HAZ and cladding.
Fil to VTT results
D AEA. top 0" pos
O AEA. bottom 180'
VTT results
pos
Fit to JRC results (cylinder)
JRC (cylinder)
D

Br
1 /
^^^*
" > "
D
d
*
0
s's
'

..>

d ducti l e
70
3 60
en
I 50
40
30
20
10
-20 0 20 40 60 80 100 120 140 160 180 200 TL
Temperature CC)
Fig. 6.15: Comparison of K
jc
and K
la
vs.
temperature (the mean fracture toughness)
calculated from the measured K
jc
and K
la
test data.
The dependence estimated from the proposed
Charpy arrest force correlation is also shown.
base metal forging underneath the HAZ.
This significant difference in transition
temperatures, when combined with pretest
analysis results, suggested that cleavage
crack initiation was unlikely to occur
within the HAZ extending 5 to 10 mm
below the cladding.
As discussed in subsequent chapters, the
NESCI experiment exhibited stable tea
ring in a thick specimen prior to cleavage
fracture of the base metal in the transition
temperature regime. The greatest source of
uncertainty in pretest and posttest asses
sments of that experiment was judged to be
variability in the material toughness data.
However, statistical representations of the
smallspecimen fracture toughness data,
specifically the master curve approach to
determining reference temperature T
0
pro
ved most instructive in interpreting the test
[6.6]. The approach provided the crack ini
tiation and arrest fracture toughness curves
shown in Fig. 6.17, which correspond to
50% fracture probability for the base metal.
These curves are part of a comprehensive
material properties data set that, when
combined with advanced analysis techni
ques, allowed accurate prediction of the
actual time and location of a cleavage event
in the spinning cylinder test transient. Also,
within that data set, fracture tests on speci
mens from the HAZ (see Fig. 6.10) proved
crucial for refining the pretest analysis
predictions in terms of timing and location
51
HSE
Health Safety
h
I C Q p
NESC1-B4 BASE METAL n = 5 0 0 MP a = 10 mm 3-PB
200

g
o.
'100

' 1
O CLEAVAGE
DUCTILE
, = 59 C
, = 25 mm
M = 30
: o
VTT K
JC
95% S'
/ / -
1 1
40 20 0 20 40
T- T[ C]
Fig. 6.16: Static fracture toughness of the cylinder
base metal compared to the scatter bands
determined for test arc.
COMPARISON OF MEAN
JC
AND H,
K = 30+70*exp[0.019*(Tj)]
E 150
100
NESC 1.5 and 1.7
Results of VTT and MPA
K(
a
(from the correlation.VTT
T =8 4C
30 50 70
TEMPERATURA)
Fig. 6.17: Comparison of the temperature
dependence of the mean static and crack arrest
fracture toughness. The trend estimated from a
Charpy arrest force correlation is also shown.
of the cleavage event. Precise estimates of
the extent of prior ductile tearing were
made using the tearing toughness data
depicted in Fig. 6.14. Posttest assessments
of cleavage crack arrest were shown to be
consistent with the crack arrest data gene
rated from smallspecimen tests (see Fig.
6.13). Specific applications of the material
properties data set to interpret the experi
ment are described in Chapter 10.
With regard to the representativeness of the
NESC test piece, it is noted that the cylin
der was austenised at a high temperature
and tempered at a low temperature to simu
late irradiation embrittlement. As a result of
this treatment, the base metal showed high
static and dynamic ductiletobrittle transi
tion temperatures and a low uppershelf
impact toughness, as is possible in the case
of an irradiated ferritic reactor pressure ves
sel steel in the endoflife condition. The
steel must not, however, be regarded as
being similar in all respects to an irradiated
steel, although the changes of mechanical
properties and fracture toughness caused by
neutron irradiation and temper embrittle
ment are basically due to related micro
structural processes. It is however stressed
that the project goal was not to achieve a
material condition as far as possible similar
to an irradiated one, but only a condition
with the ductiletobrittle transition tempe
ratures corresponding to those of a typical
reactor pressure vessel at endoflife.
REFERENCES
[6.1] Rintamaa, R. and Planman, T. "NESC-I Spinning Cylinder Test -Report Evaluation Report of Material
Characterisation Programme", Network for Evaluating Steel Components, Materials Task Group TG2
NESCDOC TG2 (99) 03.
[6.2] Rintamaa, R., Von Estorff, U., Fedeli, G., Gillot, R., Houssin, B. "Comprehensive Pretest
Characterisation: A View to Cleavage Fracture of the NESC-I Spinning Cylinder", PVPVol. 362,
Severe Accidents and Topics in the NESC Project, ASME 1998, pp. 221227.
52
HSE
alili & Safei)
Mcrop
[6.3] Rensman. J. et al.. "Comprehensive Pre-Test Material Characterisation: Results of the Characterisation
of lhe HAZ and the Cladding in view of Ductile Fracture of the NESC-I Spinning Cylinder". PVP-Vol.
362. Severe Accidents and Topics in the NESC Project. ASME 1998. pp. 229-235.
[6.4] Wintle. J.B.. and Hurst. R.C. "Manufacture of the NESC Test Cylinder". PVP-Vol. 362, Severe
Accidents and Topics in the NESC Project. ASME 1998. pp. 299-304.
[6.5] ASTM Standard E1921. "Test Method for the Determination of Reference Temperature, T
0
, for Ferrine
Steels in the Transition Range". American Society for Testing and Materials. Philadelphia. 1998.
[6.6] Wallin, K., Rintamaa, R. and Ehrsten, U. Consistency of Fracture Assessment Criteria in the NESC-I
Test. NESCDOC ETF (99) 35.
53
H NESC
7 ENGINEERING THE SPINNING CYLINDER TEST
7.1 TEMPERATURE MEASUREMENT
The NESC cylinder was instrumented with 21 thermocouples for the following purposes:
to measure the through wall temperature distribution through the test.
to determine differences between the temperatures of the upper and lower cylinder halves
to measure the temperatures inside the machined surface breaking defect
to measure the inside surface temperature close to the strain gauges near the defects
to measure the water outflow temperature at the top and bottom of the cylinder
to create a breaking wire system for the detection of excessive crack growth
The provision of the thermocouples on the cylinder is shown in Fig 7.1. All thermocouples
used were of the Chromel-Alumel K type enclosed in 1 mm diameter stainless steel sheaths.
The thermocouples were individually calibrated at 100 C, 200 C and 300 C, traceable to
the UK National Physical Laboratory.
Measurement of the through wall temperature distribution through the test was by an array of
9 thermocouples arranged horizontally in the upper half of the cylinder above the level of the
machined surface breaking defect. A corresponding array of 4 thermocouples was located
beneath the upper array in the lower half of the cylinder and by comparison these were used
to determine any temperature differences between the upper and lower halves. The two ther-
mocouples on the inside surface were positioned 80 mm above and below the tips of the
"complex" defect and flange welded horizontally for 130 mm to act additionally as breaking
wire gauges for the detection of excessive crack growth.
As well as thermocouples on the inner and outer surfaces. 7 thermocouples were located
within the material at depths graduated to correspond with the expected non linear tempera-
ture profile. The thermocouples within the material were located into blind socket holes dril-
led from the outside surface. All the thermocouple wires were well secured against the centri-
fugal forces using individual shim strips continuously spot welded to the surface. Three ther-
mocouples were located within the machined surface breaking defect, one near the deepest
point (approximately 72 mm from the surface) and the others close ( 15 mm) to the surface at
each end of the defect in the region where cleavage initiation was expected. The wires from
these thermocouples were routed around the ends of the plugging blade.
On the bore of the cylinder, one thermocouple was located above the major sub clad defect at
mid height. The water outflow temperatures from the top and bottom of the cylinder were
measured by one thermocouple at each end. Thermocouples were also positioned 80 mm
above and below the tips of the machined surface breaking defect and Hange welded horizon-
tally for 130 mm to act additionally as breaking wire gauges for the detection of excessive
crack growth.
54
HSE
Health . Salet}
SHAFT
175
s
K
s
s
s
s
s
s
*
;
^
V

\
-.
;
,
,
\
TC9 '
m C
n
M T i mi
ILS ( 1JUIII
~ _ ,
K, \y
TC

SUPPORT LHV.

| J
-
TC21
UPPER EFFLUENT TC
THERMOCOUPLES LM
POCKETS DRILLED FROM
OUTER DIAMETER
/
\
i )
)mm)
5 (60mm)
r* c c i . , , m i
CLADDING
TC ARRAY \
Tv..,
VJJ
..j 7 LOCATED M

,,.!
r
"'TC 13
TC 1"* C
TC4 (20mm)
TC3 (10mm)
TC2 (4mm)
TCI
/
950mm
FROM
BOTTOM
f TC 14 (BW) <
EDM J TC 15 (15mm)
TCs S
TC 19
SUB CLAD
DEFECT TC
TC 16 (72mm)
TC 17 (15mm)
^ TC 18 (BW)
N.
1
TC ARRAY
50mm) k LOCATED
11 I mml / 45 0mm ROTATING BLANKET
I L n ^zurnmj
TC10
/
FROM \
BOTTOM
LOWER EFFLUENT TC
TC20
1
"""^
'
;
-*^,''
HEIGHT 1296 mm
\
.
s
*

S

>
i
*

>
*
^
3
3
**
>


>
>

11


*

.
>
>
* 1
BORE 1044 mm
O.D. 1395 mm
Fig. 7.1: Locations of thermocouples through the cylinder wall.
55
HS E
[ NESC
7.2 STRAIN GAUGES FOR THE DETECTION OF CRACK GROWTH
One of the key tasks of the instrumentation was to detect the moment of rapid crack growth
by cleavage that was expected during the test, and hence the time of initiation after commen-
cement of the quench.
In previous spinning cylinder tests, alternating current potential difference (ACPD) methods
had been used to detect crack growth. However, these had not proved very satisfactory in that
the change in output due to crack growth was small when the crack tunnelled beneath the sur-
face and could not be easily distinguished from thermal effects. For these reasons, the NESC
Instrumentation Task Group concluded that the application of ACPD to a cylinder where tun-
nelling was expected beneath 4 mm thick stainless steel cladding would not be successful.
The initial plan was to detect crack growth by measuring the change in crack mouth opening
using strain gauges spanning the mouth of the surface breaking machined defect. This techni-
que had been successfully applied by the Finnish utility IVO to measure crack growth in the
Promotey PTS tests [7.1]. A laboratory trial by IVO had shown that an Ailtech Type SG 325
high temperature strain gauge could give a continuously increasing output up to a strain of
over 10% although they were only guaranteed to a value to 2%. These gauges had flanged
lengths of 28 mm for spot welding, but were welded for only 8 mm at each end.
Since Ailtech gauges were no longer available, comparable high temperature strain gauges
were ordered. Tests on these gauges showed that the strain to failure was much less than the
10% predicted across the defect mouth during the NESC test and therefore spanning gauges
were likely to fail before any growth occurred. Investigations of other gauges available world-
wide indicated that no better performance could be guaranteed.
A second approach for the detection of tunnelling crack growth was based on detecting the change
in strain on the surface beyond the ends of the original defect. Finite element calculations at Oak
Ridge National Laboratory showed that the maximum mean hoop strain in uncracked material
would be about 0.4% over a 12 mm gauge length, and that this would increase by nearly an order
of magnitude to 3-4% due to crack tunnelling, Fig 7.2. There was confidence that strain gauges
mounted over uncracked material would survive the test and that the moment of crack growth
would be detected by a discontinuous change in strain or by gauge failure. Reliance for the detec-
tion of crack growth was therefore placed on gauges placed beyond the ends of the defects.
Gauges were symmetrically mounted beyond the ends of the through and sub clad defects at
distances of 5, 15 and 40 mm from the defect tips along the line of the defects, Figs 7.3 and 7.4.
A further single gauge was placed 40 mm beyond the upper end of the complex defect. These
gauges were end welded. Trials showed that 8 mm of spot welding at each end of the gauge avoi-
ded flange failure leaving a 10-12 mm free gauge length in the centre. As the gauges were prima-
rily intended for the detection of crack growth their actual output had only limited significance.
Since the opening of the through-clad defects and the change in strain over the major sub clad
defect were of interest to validate finite element models during the spinning phase before the
thermal shock, a total of four gauges were also placed across the centre of these defects. Two
56
HS E
[j\
i c c p
35
30
25
20
15
10 -
5 -

s
s
/
t
f
I
1
i
Crack
growt h
1 ^ -
1 />
1/

Extensi on
12mm
Fig. 7.2: Maximum mean
strain before and after
crack tunneling.
150 200 250 300
Time (sees)
350
further gauges were continuously welded to the cylinder at the centre line remote from any
defects to measure the hoop and axial strains on the cladding surface. This completed the
total complement of 19 gauges, Fig 7.5.
7.3 OTHER INSTRUMENTATION
The speed of the NESC test cylinder was measured by means of two digital tachometers. A
60 tooth gear wheel was mounted on the shaft above the cylinder. Electromagnetic pulses
were counted by means of an inductive sensor linked to a quartz controlled digital frequency
meter. A second tachometer providing back up with diversity was also used. This relied on an
infra red breaking beam sensor also linked to the gear wheel.
The temperature of the quench water was measured by a calibrated mercury in glass thermometer
lowered into the quench tank. The water was stirred in the tank by means of the circulation of the
cooling system. The level in the quench tank was measured by a sight glass with scale. The
change in level was converged into a flow rate using the cross sectional area of the tank. This was
considered to be a much more accurate method of measuring flow than a flow meter. The initial
level was marked at the start of the test and then at one minute intervals during the quench.
7.4 RIG ENGINEERING
The construction of the spinning cylinder test facility took place between 1985 and 1986 fol
lowing trials on a quarter scale mockup. Fig 7.6 shows the facility where the cylinder is con
tained in an enclosed pit below ground. The cylinder is suspended by a flexible steel shaft
from a single pivoted bearing and is free to rotate about a vertical axis.
57
H S E
H v..lili Safei
i c e
SC
TOP OF CYLINDER
130
TC14
DEFECT g
APERTURE
M
BREAKING WIRE CRACK DETECTION
GAUGE/THERMOCOUPLE
WATER FLOW
TC18
ALL GAUGES END WELDED
INNER ROW 8mm AT 10 JOU LES
OUTER ROW 7mm AT 20 JOULES
AILTECH SG355 (0.45mm)
HEAT SL100N-H120 (0.13mm)
130
TYPICAL
MINIMUM
EXTENSIONS
VIEW FROM BORE
DRAWN TO SCALE
90
ALL DIMENSIONS IN mm
Fig. 7.3: Instrumentation associated with the through clad fatigue defect.
58
U S E
VICC/
TOP OF CYLINDER
~r
DEFECT o
APERTURE
N
VIEW FROM BORE
DRAWN TO SCALE
SG13
SG14
3S
WATER FLOW
ALL GAUGES END WELDED
INNER ROW 8mm AT 10 JOULES
OUTER ROW 7mm AT 20 JOULES
AILTECH SG355 (0.45mm)
-
HEAT SL100NH120 (0.13mm)
I I
TYPICAL
MINIMUM
EXTENSIONS
Fig. 7.4: Instrumentation associated with the subclad fatigue defect.
59
HS E
M, ..Uli S Sari't:
RRF.AK1NC WlRETHiiRMOCOUPLES
WEI.
0 DATUM _ J
CENTRELINE
HOOP & AXIAL
GAUGES
THERMOCOUPLE
ARRAYS
Fig. 7.5: Surface locations of strain gauges and thermocouples.
The driving power is provided by a 560 kW DC electric motor mounted on a horizontal pede-
stal, and is transmitted via a right angled gear box with a 2:1 step up ratio. The cylinder is
heated by eight 3 KW heating elements mounted vertically within it. The quench water is
pumped from an external tank along piping to sprays inside the cylinder, and the outflow falls
into a sump.
The connecting wires from strain gauges and thermocouples are routed up the inside surface
of the cylinder, across the support disc and through the hollow drive shaft to the 100-ring slip
ring unit above the gear box. The outputs from the slip ring are connected to a multi-channel
data logger and graphical screen displays for on-line monitoring of strain during the test. The
rig is controlled from an adjacent room.
7.5 RIG TRIALS
From the design analysis for the test, it was recognised that high speeds combined with a
severe thermal shock would be needed to generate crack growth. In previous tests a maximum
rotational speed of 3000 rpm had been obtained without quench and speeds of over 2000 rpm
with a low flow quench. However, the rig had not been proven for the combination of speeds
60
HS E vi cei
375kW _
DC Motor
Support Shaft
Support Disc .
100-way
Slip Ring Unit
Junction Box
Right-Angle
Gear Box
(2:1 Step Up)
Gymbal-Mounted
Support Bearing
8x3kW Heaters
Cylinder Specimen
Water Spray Pipes
Thermal Shield Hatch
Inspection Chamber
Fig. 7.6: Spinning Cylinder Test Facility.
61
[VIC
HSE N
Ul ul i l i & Saf e l y
up to 2500 rpm and the high flow rate quench required to generate the necessary heat transfer
conditions. A programme of rig trials was therefore commissioned to validate the rig for the
conditions expected in the NESC test.
The rig trials were an opportunity to test the performance of thermocouples inserted into
pockets drilled from the outside surface of the cylinder. This was a departure from previous
practice where all the pocketed thermocouples had been located in holes drilled from the
inside. External thermocouples had the advantage of eliminating the effects of water ingress
and would not interfere with the cladding. Another new feature of the instrumentation was the
proposed use of high temperature strain gauges for the detection of crack growth. The strain
gauges would be spot welded at their ends to reduce the possibility of premature failure cau-
sed by localised high strains. It was important to show that gauges welded in this way would
perform correctly.
At the same time it was decided to make a direct determination of the heat transfer for the
specific conditions during the test. Values of the heat transfer coefficient determined empiri-
cally from previous tests could not be guaranteed because the NESC test conditions were
markedly different. This aspect was allowed for by including sufficient thermocouples
through the thickness so as to be able to provide a detailed temperature profile for heat tran-
sfer analysis.
A programme of rig trials was undertaken during which a series of spins led to a validation of
the rig and instrumentation for the NESC test conditions. The cylinder used for the trials was
the cylinder used for the original commissioning of the rig, and contained no implanted defects.
The cylinder was instrumented with 11 thermocouples through the wall thickness and with two
strain gauges, one continuously welded, the other end welded. The trials also had the additional
benefit of retraining the rig operators to have complete familiarity with the equipment.
7.6 DEVELOPMENT OF THE THERMAL BLANKET AND SEALING OF THE
DEFECT
In order to minimise heat loss from the cylinder, the outside surface was covered with a ther-
mal insulating blanket. This consisted of a 3 mm layer of fibrous insulation kept in place by
bands of thin metal sheeting. The ends of the sheet were gripped around three clamps bolted
into the cylinder wall that applied tension to the sheet when the bolts were tightened. In spin-
ning cylinder tests 1 to 6, the sheet material was of carbon steel. However, the sheets failed
between 1900 and 2000 rpm towards the end of tests 3 and 6, and a programme of work was
therefore undertaken to find an alternative material and design that would retain integrity at
the higher speeds and temperatures required for the NESC test.
A programme of tensile trial tests was carried out on full width sheets of 316 stainless steel
and alternative high nickel alloy materials at ambient temperature and at 300 C using the
same system of clamps for gripping as applied on the cylinder. The tests identified INCONEL
718 alloy sheet. 0.2 mm thick, as being capable of withstanding the stresses at speeds of over
2450 rpm. A further development was to use four clamps per band instead of three so as to
62
HSE
Mc e p
reduce the bending loads on the draw bars. This design and material was used on the NESC
cylinder and successfully survived the test which reached speeds of 2450 rpm.
From the early days of the spinning cylinder project, it had been recognised that the ingress
of cold water into a surface breaking defect could increase the cooling of the defect and alter
the temperature distribution in its vicinity. Localised excess cooling of the defect could possi-
bly initiate a premature cleavage fracture. Water ingress would also apply pressure to the
crack faces as a result of the spin. Measures were therefore taken to limit the ingress of water
in order to limit any enhanced cooling during the NESC test.
In test 4. the surface breaking semi elliptical defects were covered with a surface shim of thin
metal, spot welded around the edges. However, a thermocouple placed inside the defect indi-
cated that water entered the defect after 2 minutes into the quench. In test 6, the semi-ellipti-
cal defects were packed with an inert dense fibrous material and plugged at the surface with a
weighted metal blade which was progressively driven into the defect as the cylinder accelera-
ted and quenched. The evidence from thermocouples placed inside the defects was that a
small amount of water entered the defects early into the quench, but that there was little
increased cooling during the critical period of the transient.
For the NESC test, the Evaluation Task Group decided that the best option was to combine
the methods used in tests 4 and 6. As a result, the defect was to be packed with a nuclear
grade inert packing material plugged with a weighted blade, and covered with a surface shim,
.STUFFING BLADE INITIALLY
JUST BELOW SURFACE
Fig. 7.7: Sealing arrangement for the through clad fatigue defect.
63
HSE
Hi al l h & Safclj
NES
Fig 7.7. The effectiveness of this arrangement was demonstrated by a laboratory trial using a
mock-up of the defect. This method was implemented on the machined through clad defect
on the NESC cylinder. The other surface breaking defect, "the complex defect", was covered
with a flat surface mounted shim bellows. These measures proved to be generally effective
during the test and are reviewed in section 7.10.
7.7 DATA ACQUISITION SYSTEM AND TEST CONTROL
Data logging was undertaken using an Intercole Spectra logging system with a single analo-
gue to digital converter. The system was calibrated on all scales and ranges used in the NESC
test at Risley's UK NAMAS approved centre. The K type thermocouple voltages were con-
verted to Celsius according to BS4937 Part 4 (IEC-584-1).
After the completion of instrumentation on the cylinder and assembly of the thermal blanket,
the cylinder was loaded into the spinning cylinder rig and the drive train connected.
Connections were made to the slip ring unit and the datalogger and the functionality of all the
equipment was checked. Rig operating procedures and schedules of responsibility for the
control of testing had been prepared and approved.
The rig was controlled and monitored by a team of five operators. The Rig Engineer control-
led the rig panel and took overall responsibility for the rig. The Deputy Rig Engineer monito-
red the time into the quench and temperatures from the thermocouples, and maintained a log
of all of the rig performance indicators. Three other operators were responsible for monito-
ring the motor power, the quench system, and the rig air cooling system.
The behaviour of the defects in the cylinder was monitored at a control desk in the eastern
half of the laboratory, Fig 7.8. Television screens showed views of the thermocouple displays,
vibration response and the rig area. The strain gauge outputs from the three main defects
(EDM, sub clad and complex) were displayed on three VDUs watched by three Defect
Monitors. The Deputy Test Manager collated the information displayed on the screens. The
Project Manager took responsibility for the test as a whole.
A series of pre-test spins was carried out to a speed of 800 rpm. During this phase the con-
centricity of the cylinder to the drive train was verified and the tachometers and vibration
indicators were tested. For the benefit of operator training, conditions of excessive crack
growth were simulated. The cylinder was then heated to 250 C three days prior to the test
and further dry spins carried out to verify the performance of the instrumentation at high tem-
peratures.
7.8 THE SPINNING CYLINDER TEST
The NESC spinning cylinder test was carried out at 14.15 on 20 March 1997 at AEA
Technology's Laboratories at Risley in the United Kingdom. Over 50 people from seven
countries were present to witness the test. These included representatives of the Health and
Safety Executive and the other project sponsors, the Network management and NESC 1
64
HSE
Health & Safen
Mnrep
project team, and the four technical Task Groups. The test was preceded by a short series of
presentations in which the background, contributions and achievements of the project as a
whole were highlighted.
The test was earned out according to the prepared procedure, Fig 7.9. The cylinder tempera-
ture prior to the quench was 293 C and the temperature of the quench water was 2.0 C. The
cylinder was raised from rest to a hold speed at 1200 rpm at a rate of 100 rpm/min. A series
of checks were carried out, and the cylinder speed was increased to 1,800 rpm for final
checks. The acceleration demand was then raised to 170 rpm/min and a target speed of 2600
rpm set. The rig had reached full power (1,200 amps armature current) and the cylinder was
at maximum acceleration when the quench was fired at 2,100 rpm.
The acceleration demand was progressively backed off so that the armature current did not
exceed 1,200 amps. The quench continued for 12 minutes during which time the speed increased
to reach a maximum of 2,400 rpm. The speed profile attained was close to that specified. After 12
minutes the quench was switched off and by this time the level in the quench tank had dropped
498 mm corresponding to flow rate of 44 m-Vhr (162 gal/min). The cylinder responded to the
reduced drag by accelerating to 2,430 rpm. The cylinder was then brought to rest at 150 rpm/min.
Data logging was terminated and the test data copied onto floppy discs. This concluded the test.
After the test, the cylinder was allowed to cool slowly in the pit. It was then carefully unloa-
ded from the rig and visually inspected, Fig 7.10. The thermal blanket had remained intact
although there were signs of straining at the clamps, Fig 7.11. The cylinder was then packed
and transported to JRC Petten for more detailed examination.
RIG AREA VIEWS
ON TELEVISION
MONITORS
U-^-_Ua^CT)
L' i-^l
EDM SUB CLAD
STRAIN
GAUGE
o
jfr"
T--*f
^ T ^ O
COMPLEX
TIME AND
THERMOCOUPLES
* ! e
OPERATORS ONLY
SPEED
PRECESSION
VISITORS VI EWI NG AREA
Fig. 7.8: Layout of test control room.
65
HS E
Iltal th Safer
NESC
7.9 POST-TEST OBSERVATIONS
The Reference Laboratory at JRC Petten carried out the first detailed inspection of the cylin
der after the spinning cylinder test. On arrival, all the internal surfaces over and adjacent to
the major defects were cleaned, dried and protected with a polyethylene film. The support
disc, shaft and external blanket were removed, together with the connecting leads and
packing weights, after examination of the transducer connections and photographing the
instrumented defects. A detailed visual examination of the cylinder surface together with the
condition of each defect and transducer was made.
The examination revealed the following features:
There were marks of surface straining above some of the sub clad defects, Fig 7.12
All functioning transducers remained firmly secured to the cladding
The strain gauges spanning the surface breaking cracks had buckled during cooldown after yiel
ding in tension during the test
The shims over the major surface breaking defect were in place
The cladding above the subclad fatigue defect had split and blistered at one point towards
the lower end, tearing a non active strain gauge away from the cladding surface. Fig 7.13
Discolouration on the line of the sub clad defect indicated possible failure of the cladding
The packing blade in the EDM slot had been driven into the slot, compressing the packing
compound. This had resulted in the loosening of the clamping arrangement, Fig 7.14
The final crack opening of the EDM slot was measured at several positions together with the
buckling of the strain gauges. This enabled the maximum opening during the test to be esti
mated and served as a useful benchmark for the finite element analyses. The defects were
again photographed after the shims, packing blade and transducers had been removed. The
3500
3000
2500
2000
1500
1000
500
.
;
~
1 , . ,
Initial cylinder temp 290 C
Quench temp. 36 C
Flow rate 150gal/mm
'_
:
Hold
checks
@ 1200 rpm
/
^r
/
- ^ r Start
r .
, '
Full Fire
Power Quench
Hold
cnecks \
1800 rpm
( @2 10 0 rpml
V ^
r/""^
/
/
S
Test Duration
12 minutes
<

I
-
Quench
y :
" , Controlled .
Run down
>

,
'. -

|
Fig. 7.9:
Test procedure
-20 -10 0
T i m e (minutes)
10 20
66
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visual examination and a dye penetrant test did not reveal any conclusive signs of new
cracking on the surface. The defects and their surroundings were cleaned again using ethyl
alcohol and the surface breaking defect was sealed with acid free silicon sealant. The cylinder
was then ready for the post test inspection trials.
POST NESC TEST
Fig. 7.10: Cylinder and blanket post test. Fig. 7.11: Detail of the thermal blanket clamps
post test.
Fig. 7.12: Surface above subclad fatigue defect
post test.
Fig. 7.13: Detail of cladding blistering above
subclad fatigue defect.
67
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7.10 TEST INSTRUMENTATION EVALUATION
Evaluation by the NESC Instrumentation Task Group of the strain gauge and thermocouple
outputs found that all the strain gauges and thermocouples survived the test except those
spanning the major defects. These failed early into the quench as a result of the strains excee-
ding their working range,. These failures were expected from the pre-test calculations. The
gauges beyond the ends of the major defects showed signs of buckling during cooldown after
yielding in tension during the test.
The thermocouple data confirmed the transient delivered and showed the cooldown rates in the
cylinder (Fig. 7.15). There was evidence of water ingress early during the quench from the ther-
mocouples located inside the surface breaking defect,
(Fig 7.16) but the outputs showed that the temperatures
had normalised well before the time at which the clea-
vage event was expected. The implications for the frac-
ture mechanics analyses are further discussed in section
10.5.2.
Between 213 and 217 seconds (the time step of the
data logger), the three strain gauges beyond one end
of the major surface breaking defect showed a
distinct step change in output indicative of a cleavage
event, Fig 7.17. Confirmation of cleavage crack
growth was subsequently made by destructive exami-
nation.
The outputs from several of the strain gauges after the
application of the quench were erratic. Although the
gauges appeared to have succeeded in their primary
Fig. 7.14: Detail of sealing arrangement
for through clad fatigue defect post test.
TC1 (Inner surfflcc)
TC2 [4mm)
TC3 (10mm>
TC4 (20mrn)
TC5 (35mm)
TC6 (60mm)
TC7 (90mm)
TC8 (130mm)
TCQ (Outer surface)
Fig. 7.15: Temperature
distribution from the
Upper Array
Thermocouples.
TC9
TC5
TCA
TC3
TC2
TCI
240 300 36C 420
Ti me f r o m q u e n c h { sec)
720 780
END OF
QUENCH
68
I I S I .
KIIZC
*.\

3
S
r
E

3 s e

1
t
I
I
1
;i\r- -.^
"~"-^W-.
^ s ^
'""***-

TC15 (upper 15mm
TC1 ( 72mm deep)
leep)
TC17 (lower 15mm deep)
- __
S
Fig. 7.16: Temperatures
in the EDM Defect.
TC15
' CI 7
240 300 360 420 480
Time from quench (sec)
720 780
END OF
QUENCH
Fig. 7.17: EDM Defect
Strain Gauge Data.
SG( 15mm)
150 200 250
Time into quench (sees)
task of detecting cleavage initiation, their performance under the severe conditions of the
thermal shock test is an area for further investigation and trials. Increasing the working range
of the strain gauges spanning the defects is another area where further development would be
beneficial.
REFERENCES
[7.1] Nurkella P., "Misuse of spot weldable strain gauges as a crack mouth opening displacement measuring
technique", IVO Report G330 5, 1994.
69
f sf NESC
11. . i l . ! . & Saf . l v
8 DESTRUCTIVE EXAMINATION
8.1 OBJECTIVES
The destructive examination of the NESC-I cylinder was performed to determine the precise
position and dimensions of each defect in the cylinder and to critically examine those regions
where fracture events had occurred. The Reference Laboratory was entrusted with this task,
supported by a Destructive Examination Advisory Group (DEAG) drawn from the network
members. The work encompassed the following activities:
sectioning the cylinder to isolate the defects
detailed NDE by ultrasound and radiography
sizing of the defects
metallographic examination of the cylinder material
fractographic studies of selected defect surfaces
overall assessment and final report.
Organisations, which have contributed to the destructive examination, include: CEA (France),
ECN (The Netherlands), Fraunhofer Institut fr Werkstoffmechanik (Germany): MPA
(Germany), NRG (The Netherlands). Rolls-Royce (UK), University of Birmingham (UK) and
VTT (Finland). Full details of the activities are given in the DEAG Final Report [8.1 ]. which
is summarised in the following sections.
8.2 SECTIONING THE CYLINDER
As explained in detail in Chapter 5, a total of 18 defects had been fabricated in the cylinder at
the positions shown in Fig. 5.3. These can be subdivided into three groups:
three large defects - A sub-clad defect (B) was fabricated by internally pressurising a starter
notch. Fabrication of a through-clad notch by this process inadvertently resulted in a multi-
branch complex defect (H), which was excluded from the evaluation process. A new
through-clad notch (R) was produced by mechanical fatigue sharpening of an EDM notch.
ten "realistic" defects - These comprised simulated cold cracks (one group of two defects: I
and J) and hot cracks (two groups of four defects: C to F and M to P) that were implanted
before the cladding process.
five "PISC type A" EDM notches - These were machined by spark erosion and situated
under the cladding. Three were low-aspect ratio notches (length/depth ratio of three: defects
A, G and K) and two high-aspect ratio notches (length /depth ratio of six: defects L and Q).
After the post-test inspection round had been completed, the cylinder was returned to the JRC
Petten to commence the destructive examination. The initial step was to confirm the locations
of the defects by ultrasound NDE measurements and X-ray techniques. The cylinder was then
cut into nine segments by band sawing longitudinally between areas on the cylinder known or
suspected to contain defects (Fig. 8.1 ). The position of each cut was chosen to leave at least
70
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100 mm between the cut and the known extremity of each defect. The cutting plan was
further refined before these nine blocks were cut into smaller blocks that contained one or a
group of defects. Additional NDE was used to optimise the size of the smaller blocks and to
ensure that none of the defects was accidentally sectioned (Figs. 8.2a and b).
Fig. 8.1: The first step in the destructive examination:
the cylinder is cut lengthways into segments.
8.3 DEFECT SIZING
The lengths of all defects were determined
from highquality radiographic images, pro
gressively refined as material was removed
from the blocks. The depth or throughwall
extent was then determined according to the
following procedures:
The large fatigue cracks (B and R) were
cut transversely into several beams (Fig.
8.3). These were then fractured at low
temperature to permit measurement of
crack extension along the prefatigued
defect front and fractographic examina
tion of the surface (Fig. 8.4).
The PISC type EDM notches (A, G, K,
L and Q) were cut in half by wire erosion
to establish the exact defect depth. One
half of each low ratio defect was opened at
low temperature (liquid nitrogen) and the
surfaces were examined. The smaller high
aspect ratio notches were left unopened.
NESC CYLINDER DEFECT INSPECTION
CUT SECTOR N.A4.2
10MHz immersion 2" locused transducer LEUELS
MfiX= 22 poi nt a
^m - i dB
^m 3 dB
I i 6 dB
^ H 12 dB
I 1 2 4 dB
^m < 24dB
JOINT RESEARCH CENTRE
Instrtuleforlhi Ad*anced Mitenals
C I UMT PETTEN
Fig. 8.2: Techniques employed in the destructive examination: (a) X-ray images provide accurate
measurements of the defect length; (b) ultrasound scans are used to guide the sectioning process.
71
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Fig. 8.3: The larger defects are isolated and
sectioned as a series of beams.
Fig. 8.4: The larger defects are split opened at liquid
nitrogen temperature to reveal the defect surface.
All the implanted realistic defects (C to F, I,
J and M to P) were cut through the deepest
point, using wire erosion. The resulting sec-
tions were used to measure the depth and
width of these cracks (Fig. 8.5).
Table 8.1 summarises the pre- and post-test
dimensions of all the defects. Differences
were observed for three flaws: the large fati-
gued defect and the through-clad EDM
defect R, as well as the deepest of the sub-
clad EDM defects (K).
The DEAG created a reference document
[8.2] that provides all available information
regarding the various defects in the NESC-I
cylinder. This Defect Atlas is organised to
present schematic overviews of the defects,
grouped according to family (sub-clad/
through-clad, fatigue/EDM/realistic notch)
and location in the cylinder. It also provides
more detailed information for each defect,
covering the NDE results, dimensions of the
defect envelope derived from destructive exa-
minations, as well as macroscopic and fracto-
graphic examination results.
A bibliography identifies other NESC-I
documents that contain more specific details
regarding the defects.
Fig. 8.5: Cross-sections are used to determine the depth and form of each defect: (a) a sub-clad EDM
notch and (b) a simulated "realistic" sub-clad defect.
72
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8.4 MICROSTRUCTURAL EXAMINATION
The destructive examination of the cylinder provided the first opportunity to check the micro-
structure. The aim of this study [8.3] was to assess the condition of the cylinder material
(including the clad and associated HAZ) and to compare it with the arc section used for the
materials characterisation tests (see Chapter 6). The results indicate that the A508 Class 3 base
material and HAZ of the test arc and the NESC-I cylinder show similar microstructures and
hardness values. Thus, from a metallurgical viewpoint, similar mechanical behaviour would be
expected for specimens from the two sources. The base material has an overall bainitic micro-
structure with carbide clusters and segregation bands uniformly distributed throughout the wall
thickness. Two microstructural features with potentially reduced toughness were identified: the
martensitic interface at the fusion line between base material and cladding and the tempered
martensitic segregation bands in the HAZ. The width of the HAZ was 7.5 to 8.8 mm.
8.5 FRACTOGRAPHIC EXAMINATION
The initial examination of the blocks containing the defects confirmed the results of the post-
test inspections, showing that significant crack extension had occurred in the two largest
Table 8.1: Overview of the dimensions of the defects present in the NESC-I cylinder.
Defect No
A

C
D
E
F
G
I
J

L
M
N
0
P
Q
R
Defect Type
Sub-clad PISC Type A EDM notch
Sub-clad fatigue crack
Sub-clad realistic hot crack
Sub-clad realistic hot crack
Sub-clad realistic hot crack
Sub-clad realistic hot crack
Sub-clad PISC Type A EDM notch
Sub-clad realistic cold crack
Sub-clad realistic cold crack
Sub-clad PISC Type A EDM notch
Sub-clad PISC Type A EDM notch
Sub-clad realistic hot crack
Sub-clad realistic hot crack
Sub-clad realistic hot crack
Sub-clad realistic hot crack
Sub-clad PISC Type A EDM notch
Fatigued through-clad EDM notch
Pre-test dimensions - mm
Length
19
261
30
25
22
28
47
55
38
69
17
25
27
25
21
37
208
Depth
10
81
10
12
11
11
18
26
24
29
7
8
9
10
8
9
74
Post-test dimensions - mm
Length
19
276
30
25
22
28
47
55
38
69
17
25
27
25
21
37
224
Depth
10
86
10
12
11
11
18
26
24
30
7
8
9
10
8
9
75
Note: The depth of a sub-clad defect is the vertical distance between the
deepest point of the notch and the inner clad surface. The length is the
overall distance between the defect extremities in the circumferential
direction (defects F and P) or in the longitudinal direction (other defects).
depth
73
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.iiii. & Safety
,icre<
defects, namely "", the large sub-clad defect, and "R", the large through-clad defect.
Detailed examination of the smaller defects revealed that the EDM notches and G had also
extended slightly. The sections below provide an overview of the results of the fractographic
studies on the areas of crack extension in these defects.
8.5.1 Through-Clad Defect R
Crack extension was observed along the entire crack front of defect R as depicted in Fig. 8.6.
Initial tearing was followed by a significant local cleavage event in the region just below the clad
HAZ, as can be seen in the upper part in Fig. 8.7a. In this region, the maximum crack extension
was measured to be 17 mm. The point of initiation for this cleavage event is about 16.5 mm
Defect centre X=705.5
Bin m R5 Beam R4 Beam R3
Beam R2 Beam Rl
EDM notch
fatigue crack
post test defect
Fig. 8.6: Schematic of the large through-clad defect R after sectioning and opening, showing the extent
of crack growth.
74
HS E i ce*
(a)
BP^C^JS
fep
W A M .'. ^Ks
ffisf ^ i ^ ^ '
g 10 um
S SS&ei i sl
Fig. 8.7: Fracture surface of defect R showing: (a) the area
of maximum crack propagation and the cleavage event
site; (b) the initial ductile fracture surface; (c) the cleavage
fracture.
Fig. 8.8: A detail of the defect extension at the
deepest point of R, where small cleavage pockets
were observed.
below the clad surface. In order to establish
the mechanism of crack growth, it was
necessary to chemically remove the oxide
from the fracture surface. The subsequent
SEM examination confirmed that the initial
extension was by ductile tearing (Fig. 8.7b)
before the cleavage event was triggered, lea-
ding to the classical facetted morphology of
brittle cleavage fracture as shown in Fig.
8.7c. Within the HAZ little ductile tearing is
evident. However, a finger of brittle intergra-
nular fracture can be seen in Fig. 8.7a that
propagated in the axial direction of the cylin-
der; this may be linked to a more brittle
segregated zone. Some debonding of the
cladding occurred both at the crack end and
further along the clad interface. In the region
of maximum flaw depth (Fig. 8.8), the crack
extension was irregular, with pockets of clea-
vage that are approximately 1 mm deep.
75
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8.5.2 Sub-Clad Defect
Defect Extension
Crack extension occurred along the entire initial crack front in the large subclad defect B, as
illustrated schematically in Fig. 8.9. Compositions of macro and microphotographs of the frac
ture surface at one extremity of the defect are shown in Fig. 8.10. The maximum crack extension
of 15 mm had occurred just below the HAZ. At the deepest part of the defect, the crack exten
sion was up to 4.5 mm. As in the case of defect R, the fracture surface was oxidised and required
chemical cleaning to reveal details of the fracture morphology. Its relatively dark colour suggests
that it was formed at a temperature above ambient, rather than being simply an accumulation of
rust from the posttest phase when the defect would have been exposed to air and water. At the
end of the defect corresponding to beam 1 in Fig. 8.9, the mechanism of extension was mainly
intergranular cracking (Fig. 8.10b), whereas at the opposite end it was initially intergranular, fol
lowed by evidence of ductile tearing (Fig. 8.10c). At deeper positions of the defect front the duc
tile tearing mode became predominant. Along the tip of the fatigue defect there was evidence of
a large stretch zone, indicating that a considerable driving force was needed to initiate the crack
advance. It is worth noting that the areas of ductile tearing are characterised by a highly irregular
Xposition: 510 (12.5
Beam ltd Iteam B5 I . ..in IM lienm lil
pre test ( fatigue) crack
post test crack
Fig. 8.9: Schematic of the large sub-clad defect after sectioning and opening, showing the extent of
crack growth.
76
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Nicrep

10 mm
Fig. 8.10: Detail of the fracture surface of defect showing: (a) the area of maximum extension; (b) the
intergranular fracture surface and (c) the ductile tearing surface.
fatigue crack
cold cleavage
Fig. 8.11: Picture showing the highly irregular
"stepped" ductile tearing area near the deepest
point of defect B.
"stepped" fracture surface containing 200
1000 mm sized facets (Fig. 8.11 ). Cross sec
tions of this zone produced evidence of pla
stic deformation, confirming the ductile cha
racter of the fracture mode. No evidence of
plastic deformation was observed in the
crosssections next to the intergranular
cracking. However, immediately below the
intergranular fracture path, many of the
grain boundaries were dotted with small
cavities (Fig. 8.12).
Clad Rupture
As described in the posttest visual check in
section 7.9, the clad surface was deformed
during the test along the entire length of
77
H S E
Health Safct)
.ure > c
defect . The crosssections through the defect prepared for the destructive examination con
firmed that the cladding had locally experienced severe straining and necking, together with
some ductile tearing that progressed from the interior toward the free surface. Near the centre
of the defect this tearing extends nearly through the clad layer, as evident from Fig. 8.13. It
was difficult to determine the extent of actual rupture since the surfaces were subjected to
compressive stresses as the cylinder cooled.
laboratory fracture fatigue crack
20
Fig. 8.12: Evidence of micro-cavitation on grain
boundaries below the intergranular fracture path in
defect B.
At a point about 30 mm from the end of the
defect, a blisterlike protrusion formed
where the cladding had completely ruptu
red. The photograph in Fig. 7.13 of the
cylinder inner surface shows the clad rup
ture; the lighter band running through the
blister coincides with the deformed clad
ding over the defect. It has been postulated
that the formation of this blister was linked
to the ingress of cooling water into the
defect when the cladding ruptured and that
the subsequent contraction and resealing
of the defect, as the cylinder cooled, produ
ced a high internal hydraulic pressure, suf
ficient to locally deform the cladding.
Examination of crosssections through the
blister shows an intergranular onset of frac
ture from the clad/HAZ interface towards
the inner surface of the cylinder via recry
stallised grains in the cladding. Recrystal
lisation in austenitic materials is not expec
ted below 600 C and during the test the
maximum temperature was approximately
300 C. Therefore since such grains were
absent in the other sections of the cladding
examined, it is concluded that a localised
zone of microcracking was already present
at this location as a result of the welding
over the defect, and that this contributed to
the formation of the blister.
8.5.3 Sub-Clad Defect
Defect was a subclad EDM notch of
depth 29 mm and was the largest of a
group inserted primarily as a reference
defect for the inspection task. During the
7S
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Health & Safetj
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sizing activity of the destructive examination, a limited amount of defect extension was obser-
ved. This extension varied from approximately 1 mm at the deepest point to no extension at
the clad/HAZ interface (see schematic in Fig. 8.14). Fractographic examination indicated that
the fracture path was intergranular and comparable to that identified in the large sub-clad
defect B. Furthermore, detailed examination of a cross-section through this zone revealed evi-
dence of grain boundary micro-cavitation as in the large sub-clad defect, B.
8.5.4 Sub-Clad Defect G
Defect G was also present as a reference defect for the NDE task, but somewhat shallower
than defect K, with a depth of 18 mm. The destructive examination revealed small pockets of
intergranular defect extension (approximately 0.5 mm maximum) on the EDM notch rim
close to the deepest point (Fig. 8.15).
crack extension In
clad layer
~ necking
Fig. 8.13: Cross-section taken near the centre of
defect showing ductile tearing that extends nearly
through the clad layer.
8.6 DISCUSSION OF
FRACTOGRAPHY RESULTS
During the planning of the NESC-I experi-
ment, the anticipated mode of crack exten-
sion was ductile tearing followed by clea-
vage at the lateral ends of the two deepest
defects. In the case of the large through-
clad defect R, this result was successfully
achieved. However the intervention of
intergranular fracture, as found in the sub-
clad defects B, G and K, was not conside-
red. As a consequence, the DEAG invested
significant effort in exploring possible
mm
mm
EDM note
post test crack
. . .
Fig. 8.14: Crack extension observed in defect (nominal depth is 29 mm).
79
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I *L_._>W
mm
;^
tf$Er
lZrafcrSfj
s 4r?L*Jw! J " f
1 mm
explanations for the unanticipated occur
rence of this phenomenon. These investiga
tions revealed extensive areas of intergra
nular crack extension around the Haw front
of the large subclad fatigue defect and.
to a much lesser extent, around the sub
clad EDM notches and G.
Intergranular fracture was not found in any
of the fracture mechanics tests performed by
the material characterisation task group
(TG2), even after a detailed recheck of spe
cimens tested in the relevant temperature
range. Furthermore, the fracture surface of
the large throughclad fatigue defect R did
not show any evidence of this intergranular
mode. This defect was inserted just prior to
the NESCI test i.e. after the various post
clad stressrelief heat treatments.
Notwithstanding intensive investigations, it
is not yet possible to properly explain the
occurrence of the intergranular cracking.
The fact that this phenomenon was detec
ted only for subclad defects strongly indi
cates that the cladding process and/or the
subsequent stress relief heat treatments
played a role. That said, there is extensive documentation in the literature to show that the
cladding process itself should not produce such an effect, also because the stresses generated
by the cladbase material thermal expansion mismatch would not extend sufficiently into the
cylinder wall. Furthermore, there are two pieces of experimental evidence, which suggest that
the crack growth in defect occurred during the test:
The defect profile measured in the pretest inspection conforms with the asfabricated semi
elliptical shape, whereas the posttest measurements show that growth took place.
Furthermore this profile is that which would be expected (and was observed on defect R) as
the result of a severe PTS transient.
The data from the strain gauges mounted on the inner clad surface at defect indicate that
an event occurred, with an initial disturbance at 100 seconds into the transient.
What remains as a possibility is that the microstructure ahead of the defect tip was in some way
degraded during the cladding and PWHT and that this then facilitated the defect growth during
the PTS transient. It appears to be linked to the formation of the intergranular damage identified
in grains in the vicinity of the intergranular fracture path. This was unforeseen and appears rela
ted to the unique conditions under which the NESCI cylinder was fabricated, the defects inser
W ".". .'ih'JZ ' *Vr- ''' ; " , -
t % # M r W i 7
Fig. 8.15: Centrai cross-section through defect G
showing evidence of initiation of crack growth at
the tip of the EDM notch.
80
HSE NESC
II. & Sar :
ted and the time point during manufacturing when they were inserted. At present it is postulated
that the grain boundary damage occurred at the sub-clad defects due to the synergistic combina-
tion of stress relief (creep) and environmental effects during the post-clad stress relief heat
treatments. The latter is thought to be related to the presence of humid air, water or even resi-
dual oil from the insertion process which was trapped in the defects during the cladding deposi-
tion. These products could have acted as hydrogen sources, as would have the dissolved hydro-
gen from the steel making and absorbed hydrogen from the welding process.
The DEAG has discarded a number of other possible effects. For instance, if the heat treat-
ments performed on the cylinder material in order to arrive at a low toughness aged condition
or the post-clad heat treatments had induced temper embrittlement, this would be expected to
have affected the entire cylinder. On the contrary, the absence of intergranular fracture on
defect R and the fact that the fracture toughness tests performed on the cylinder after the PTS
tests show no shift in transition temperature rule this out. Likewise concern was initially
expressed that the intergranular crack extension could have occurred during the fatigue shar-
pening of defect R. However if this were the case, a transgranular mode would be expected.
In any case analysis has shown that the loading configuration used should have given near
zero or negative DK values at the defects. The possibility that discrete bands of residual
segregation from the casting caused the intergranular cracking mechanism has also been rai-
sed. However, investigations to date have failed to produce evidence of local chemistry diffe-
rences or local heat treatment anomalies that could have led to weakening of the grain boun-
daries along the sub-clad defects. Sulphur prints made prior to welding together of the two
cylinder halves show some evidence of segregation banding. However, it is extremely
unlikely that these would coincide in position and orientation with defects , K and G, but
not for defect R.
It is now proposed to perform a series of tests to simulate the thermo-mechanical history of
the sub-clad defects using fracture mechanics specimens and to provide an indirect verifica-
tion of hypotheses concerning intergranular fracture in NESC-I. Should this step be succes-
sful, it implies that the intergranular defect growth can be attributed to the test-piece manufac-
turing process of the NESC cylinder.
REFERENCES
[8.1 ] "Final Report on the Examination of the NESC-I Spinning Cylinder". NESC DOC DEAG (99) 04.
[8.2] "Description of the Defects Present in lhe NESC-I Cylinder", NESC DOC DEAG (99) 01.
(8.3 J Schuring. E.W. "Metallographic and Fractographic Investigations for NESC-I: pre- and post-test cha-
racterisation of cladding, base material and large through- and under-clad defects and R". ECN-R
98-024. NESC DOC DEAG (98) 20.
81
Hsl NESC
n. .iin & Safety
9 INSPECTION
9.1 REQUIREMENTS OF THE INSPECTION PROGRAM
Overall aim of the Inspection Task Group (TGI) were to determine the effectiveness of typi-
cal in-service inspection procedures and examine the interaction of the inspection results with
the structural integrity assessment codes used to predict the growth behaviour of defects in
the test cylinder. Specific objectives of the task group were to:
evaluate the effectiveness of current ISI procedures and contribute to an evaluation of the
conservatism of the entire structural integrity analysis process
investigate how the inspection data are interpreted by structural analysis methods
provide information on best practices
transfer technology to industry
give guidance on improving relevant codes and standards, and harmonising international standards.
Six evaluation tasks were specified to ensure that these were achieved:
ET l analyse the detection and sizing performances of the inspection teams and determine
the accuracy of the inspection data
ET 2 determine the factors influencing inspection performance
ET 3 assess the impact of human error
ET 4 make recommendations on best practice for ISI
ET 5 comment on the suitability of the defects used in the NESC inspections for wider use in
ISI qualification
ET 6 produce a TGI final report.
9.2 ROUND ROBIN INSPECTIONS
Prior to commencement of the blind round robin inspections, the inspection teams were pro-
vided with sufficient information on the NESC cylinder to enable them to plan their inspec-
tions. Those data were communicated to the teams without breaching confidentiality concer-
ning the defect parameters. Also, guidelines were issued for reporting the inspection data. The
identities of the inspection teams were kept completely confidential by setting up a Referee
Group (RG) within the JRC-Petten. The responsibilities of the RG were to observe the on-site
inspections, receive and verify the results, and analyse the inspection data reported by the
teams. A member of the RG made at least one visit to each team during its inspection to com-
pile additional information on the inspection procedures.
9.2.1 Def ect s used f or t he i nspect i on eval uati on
As describe in detail in Chapter 5. 17 defects were inserted intentionally into the cylinder
before the first pre-test round robin trial. After the first inspection and before the spinning-test
82
HSE
Health & Safet;
MES'G
of the cylinder an additional large defect was inserted into the cylinder. Of all these, three
were not considered for the evaluation of the inspection performance; two (F and P) were cir-
cumferential defects, which the teams had not been requested to find: defect (H) was the large
fatigue defect with complex nature. Table 9.1 shows the different categories of defects used in
the evaluation of the inspection performance, together with the numbers and range of sizes.
Table 9.1: Catagories and sizes of the defects present in the NESC 1 cylinder used for analysis of the
inspection performance.
Defect category
Large fatigue
Smooth planar EDM
(PISC type A)
Realistic underclad defects
Number of defects
2
5
8
(two groups of 3 and one
group of 2 defects)
Range in through wall
extent [mm]
74.5 to 81. 5
2.5 to 25.5
3.5 to 21.5
Range in length [mm]
224 to 276
17 to 69
22 to 55
9.2.2 Pre-Test round robin inspection
The inspection of the cylinder was carried out in two phases, the first occurring before the
spin test of the cylinder and the second after it. The first phase began in December 1995 and
was completed in July 1996. Seven teams participated in the first phase using ultrasonic tech-
niques, and these are identified in Table 9.2.
Table 9.2: Teams participating in the pre-test inspection of the NESC 1.
Company
ABB-TRC
Battelle/NRC
CEA
Kola NPP
RRA
Siemens KWU
VTT
Country
Sweden
USA
France
Russia
United Kingdom
Germany
Finland
Comments
Inspection performed at JRC-Petten (The Netherlands)
Inspection performed at VTT (Finland)
9.2.3 Post-Test round robin inspection
After the successful execution of the spin test in March 1997, the cylinder was re-circulated to
the inspection teams for the post-test inspections. Those inspections were initiated in May
1997 and completed in December 1997. Five additional teams augmented the seven original
teams in this post-spin phase. Three of these teams used ultrasonic techniques and two teams
used eddy current techniques to perform the inspection. A thirteenth team provided additional
S3
HSE
aliti & Sfet)
Table 9.3: Teams participating in the post-test inspection of the NESC-I.
Team
ABB-TRC
ABB-ZAQ
AEA Sonomatic
Aistom Energie
BAM
Battelle
CEA
IZfP
Kola NPP
Siemens KWU
VTT
Country
Sweden
Germany
United Kingdom
Germany
Germany
USA
France
Germany
Russia
Germany
Finland
Comments
New team participating in the post-test inspection
New subcontactor participating in the post-test inspection
New team participating in the post-test inspection
New team participating in the post-test inspection
Inspection performed at JRC-Petten (The Netherlands)
New team participating in the post-test inspection
Inspection performed at VTT (Finland)
sizing results for the defect using ultrasonic inspection data collected by one of the 10 ultra-
sonic teams. A summary of the teams taking part in the second phase is given in Table 9.3.
9.2.4 Techniques used
The following NDT-techniques were applied by the inspection teams in the NESC 1 project.
Pulse Echo (both shear and longitudinal wave modes)
Pulse Echo SAFT (Synthetic Aperture Focussing Technique)
Focussed Probes
Phased Arrays
Tandem Techniques
TOFD (Time Of Flight Diffraction)
Eddy Current
A more detailed overview of the techniques is given in Table 9.4.
9.2.5 Analysis methodology
The parameters used to evaluate the performances of the inspection teams were:
detection rate and false call rate;
accuracy of sizing the through-wall extent and length of the defects
capability to measure crack growth and profile the contours of the larger defects.
A Data Analysis Group (TGI-DAG) was instituted as a sub-group of TGI, consisting mainly
of technical experts from the various teams. The DAG had primary responsibility for spe-
cifying the rules and guidelines that would be used to analyse the inspection data, and for
discussing and approving the final results. Detailed information on the procedure for analy-
sing the inspection data is contained in the TGI final report [9.1 ].
84
Table 9.4. Summary of the inspection techniques used in the NESC-I program.
Detection
Scan.
side of
cylinder
Inside &
Outside
Inside
Inside
Inside
Outside
Inside
Inside
Inside
Inside &
Outside
Inside &
Outside
Outside
Inside
Inside
Technique used
for detection
3
'
SC-Sh(2), SC-Lo(1), DC-
Loll), Creeping wave(1)
SC-1.0(1)
[focussing probe]
Phased array (Long = 8,
Shear = 6),DC-Lo(1)
SC- Sh(2)
SC-Sii(2), SC-Lo(2)
SC-Sh(1),DC-Lo(1),
DC-Sh(1),Tandem-
Technique(2)
Low frequency ET(2),
Standard ET(1)
SC-Sh(1),DC-Lo(1),
Creeping wave(1)
SC-Sh(2),DC-Lo(1),
T0FD(4)
SC-ShDC-Lo(l)
SC-Sh(3)
Standard ET(1)
SC-Sh(3), SC-Lo(2),
DC-Lo(2)
Frequencies
used for
detection [MHz]
1.8
2.5
5
1.3
2.0
1.0 2.0
1.0
2.0
1.0
2.0
0.5/2.8/5.0 kHz
50/280/600 kHz
2.0 2.5
1.0,2.0
2.25, 5.0
2.0
3.5
1.5
40/50/75/100 kHz
2.0
4.0
Angles used
for detection

0,40,
50,"90"
55
35 - 70,
70
45
28,30,
35,39
45,70
-
45,70, "90"
38,45,70,
35,45
45,
70
22,31,41
-
0,45,
60,70
Detection
Level
FBH = (A =
5 mm
2
)
Noise level
a) 25% DAC SDH
03mm b) 10 mm
slot + 6 dB
Noise level
Noise level
NESC D 7x51 mm
slot+13/ 15 dB
NESC ET
Calibration Blocks
Noise level
25% DAC SDH
08 mm, & NESC
A,B,C slots
Thermal Fatigue
cracks in block
B-2289-1-1000
Noise level
NESC Eddy Current
Calibration Blocks
10% DAC, SDH
08 mm + 4 dB
Length sizing
Main
technique
Length Sizing
Recording level
& 6 dB drop
6 dB drop
6 dB drop
6 dB drop
+Conturing
6 dB drop
6 dB drop
-
6 dB drop
6 dB drop
Loss of
signal
Loss of
signal
6 dB drop
Twe sizing
Main
technique
TWE sizing
Amplitude & PE Crack
Tip PE [0 deg]
PE Crack Tip
Amplitude & PE Crack
Tip PE Crack Tip
(Ph Ar.)
PE Crack Tip (SAF)
TOFD & PE Crack Tip
Crack Tip (Ph Ar)
PE [0 deg]
PE Crack Tip

TOFD &PE Crack Tip
TOFD & PE
[0 deg]
PE Crack Tip
(SAFT)
PE Crack Tip
(SAFT) PE [0 deg]
-
TOFD & PE Crack Tip
General
Inspectlon(s)
performed
by team
Pre-test &
Post-test
Pre-test &
Post-test
Pre-test &
Post-test
Post-test
Post-test
Post-test
Post-test
Post-test
Pre-test &
Post-test
Pre-test &
Post-test
Pre-test &
Post-test
Post-test
Pre-test
Scanning
type used
by team
Manual
Automatic
Automatic
Automatic
Automatic
Automatic
Automatic
Automatic
Automatic
Manual &
Automatic
Automatic
Automatic
Automatic
Comment
This team did not
inspect the whole
? i siili
[mil
(a) SC-Sh: Single Crystal Pulse Echo in Shear Wave Mode SC-Lo: Single Crystal Pulse Echo in Longitudinal Wave Mode
DC-Sh: Dual Crystal Pulse Echo in Shear Wave Mode DC-Lo: Dual Crystal Pulse Echo in Longitudinal Wave Mode
Additional two teams (not shown in this table) performed only additional length and depth sizing of inspection data recorded by a team in this table.
rn
co
O
usi-:

I *L_.\_O
9.3 RESULTS AND DISCUSSION
9.3.1 Detection Performance
Detection performance was generally good, with five of the seven teams detecting all the
defects in the pretest inspection (Fig. 9.1), and eight of the ten teams in the posttest inspec
tions (Fig. 9.2). One of the two teams not achieving 100 percent detection was the same in both
the pretest and posttest phases. The other teams missing defects were different in the two pha
ses of the inspections. One team, using manual techniques, did not detect a group of three
underclad cracks during the pretest inspection, but detected them in the posttest. Training
during the intervening period and an addition of personnel to the manual inspection team for
the posttest inspection may have contributed to the improvement in detection performance of
this team. The second team, using automated scanning, reported a group of underclad cracks in
the first inspection but failed to detect them in the second. It is significant that the same staff,
equipment and procedures were used in both phases of the inspections. The latter observation
Fig. 9.1: Detection
performance in the
NESC-I pre-test
inspections.
0. 9-
O
u-

7
"
0.5
c
o
0.4 -
u
s
u. '
2
"
I FDF values
10/14 12 / 14
BB130010
0.71
CC130010
0.86
14/ 14
DD130010
1
14/14
KK 130010
1
14/14
MM130010
1
14/ 14
NN130010
1
14 / 14
m 30010
1
Team Codes
15/15 13/15 11/15 11/11 15/15 15/15 15/15 15/15 15/15 15/15 11/15 6/15
Fig. 9.2: Detection
performance in the
NESC-I post-test
inspections.
Team Codes
86
HSE
al t h & Sufr}
NESC
suggests the techniques employed in the inspection phase were inherently capable of detecting
the defects, and that failure to do so was due to some other cause. Possible sources were human
error in setting up the equipment, scanning or interpreting the data.
The detection performances in the post test (Fig.
good as the ultrasonic teams, one detecting only
=r
ICC
v
5 Teams
DD, KK, M M / N N & TT
: BB
BB130010
CC130010
DD130010
KK130010
* MM130010
NN130010
30010
0 0.2 0.4 0.6 0.8 1
False Call Rate Detection (FCRD)
Fig. 9.3: Detection Frequency (safety) versus False
Call Rate (economical) for the pre-test inspection.
(1
cc
HH

8 T e a ms
BB, EE, FF
KK, MM &
PP
GG, J J ,
NN
DD
BB130020
CC130020
DD130020
EE130020
FFI 30020
GG130020
J J l 30020
KK130020
MM130 0 2 0
- NNI 30 0 2 0
HH213020
A PP214020
False Call Rate in Detection (FCRD)
Fig. 9.4: Detection Frequency (safety) versus False
Call Rate (economical) for the post-test inspection.
9.2) of the two eddy current teams were not as
6 out of 15 defects and the other 11 out of 15.
However, it must be recognised that the
defects in the NESC 1 cylinder were not
entirely suitable for eddy current techniques.
The ultrasonic inspection teams made no
false calls in the pretest inspections, and
only 1 of the 10 teams made any false calls
in the posttest inspections. Both of the eddy
current teams made some false calls in the
posttest inspections. It must though be reco
gnised that the Eddy Current techniques are
capable of picking up microstructural chan
ges in the materials. When detection reliabi
lity is related to the concept of unnecessary
repairs as a result of false calls, it is found
that the ideal result of 100% detection with
no false calls was achieved by five teams in
the pretest inspections (Fig. 9.3) and eight
teams in the posttest inspection (Fig. 9.4).
9.3.2 Through-Wall Extent Sizing
Performance
Sizing accuracy was good for the majority
of the teams; the results achieved in the
pretest inspections are shown in Fig. 9.5.
The mean error in sizing the throughwall
extent of the defects was 2 mm or less for 5
of the 7 teams. Data from four of the teams
had a standard deviation of less than (3
mm, which is an excellent achievement in
blind trial tests. The fifth team had also a
good mean error result of 0.1 mm, but a
standard deviation of 7.6 mm. However,
the two remaining teams significantly
undersized most of the defects in their pre
test inspections, including the large sub
clad fatigue crack (defect B).
87
HS K
NESC
100
1
BB130010
CCI 30010
DD130010
KK130010
* MM130010
NN130010
TT130
t/
Jt
Sr*
310



S

The results for the posttest inspections are shown in Fig. 9.6. Four teams sized the through
wall extent of the defects accurately, with a mean error of less than 1 mm and a standard devia
tion of (2.5 mm or less. Five other teams achieved a similar mean error with a standard devia
tion less than (7 mm. The remaining team reported significant undersizing and a large standard
deviation, a result that was consistent with their pretest inspection performance.
The results indicate that very good sizing accuracy of the throughwall extent of the defects
was achieved using the diffracted signal from the crack tip. Most of the teams used techni
ques based on detecting the tipdiffracted
wave. Thus, to some extent, the variability
in sizing accuracy appears to stem from the
system, the procedure, or the personnel of
the teams, rather than the technique itself.
Not all the teams participated in both pha
ses of the round robin inspections.
In Table 9.5 the TWE sizing performances of
the teams which participated both in the pre
test and posttest inspection are compared.
Four teams, (CC KK. MM. NN) achieved
very good sizing results in both phases,
with KK's results being excellent, as noted
above, as were those of CC. Team NN ten
ded to oversize some of the smaller defects
in both phases, but nevertheless achieved
good results. Team MM also showed a sli
ght tendency to oversize.
Team exhibited some variability in sizing
the smaller defects in both phases, but
showed a remarkable improvement in sizing
the large defects in the posttest inspections.
This is attributed to some training being
given to the team members between the
inspection phases and a new member joining
the team for the posttest inspection. DD had
the same tendency to grossly undersize the
large defects in both phases but showed some
reduction in the undersizing of small defects
posttest. The reason for the relatively poor
TWE sizing results obtained by team DD on
the larger defects is as previously described
attributed to incorrect selection of the sizing
technique parameter's at the design stage.
0 2 0 40 60 8 0 10C
Reference TWE [mm]
Fig. 9.5: Measured TWE versus Reference TWE for
all defects in pre-test inspections.
1
BB130020
CC130020
DDl 30020
O EE 130020
FF130020
GG130020
j . mnn:>n
KK130020
MM130020
NNI 30020
t
r


/
/
m
0 20 40 60 80 10(
Reference TWE [ mm]
Fig. 9.6: Measured TWE versus Reference TWE for
all defects in post-test inspections.
<S8
******
HSE
H, . Mi l i S a
Kwcuiivt'
I * ~. * ~> W
Table 9.5: Comparison between pre-test and post-test TWE sizing performance.
Team
BB
CC
DD
KK
MM
NN
Time of
inspection
Pretest
Posttest
Pretest
Posttest
Pretest
Posttest
Pretest
Posttest
Pretest
Posttest
Pretest
Posttest
Average
error [mm]
-11.9
1.9
0.7
-0.1
-5.9
10.3
-0.2
0.6
1.4
2.8
2.0
0.7
Standard
deviation [mm]
13.9
4.5
2.5
1.8
15.5
23.7
1.3
1.1
2.2
2.3
2.9
2.5
RMS-
error [mm]
17.6
4.7
2.5
1.8
16.1
24.6
1.2
1.2
2.5
3.6
3.4
2.4
Max
overslzing [mm]
-3.0
8.5
4.5
3.5
3.0
4.5
2.0
2.0
7.0
7.5
7.0
5.5
Max
undersizing [mm]
-43
-5.4
-3.5
-2.5
-58.5
-54.5
-3.0
-2.0
-3.5
-1.5
-2.0
-1.5
9.3.3 Length Sizing Performance
In the pretest inspection four teams sized well, particularly team CC (). Two of the remaining
teams (BB, NN)) significantly oversized several defects and one of these also undersized two
defects. Team (TT) consistently oversized all the defects.
The results for the posttest inspections are shown in Fig. 9.8. The figure shows that three
teams CC, JJ and MM achieved excellent results, but three teams, BB, EE and NN, oversized
the length of some of the defects significantly. The two eddy current teams HH and PP syste
matically undersized the length of all the defects.
The length sizing performance of the teams
that participated in both the pretest and post
test inspection is compared in Table 9.6.
The maximum oversizing reported by
teams BB and NN (see note 1 in Table 9.6)
is occurring when they report neighbouring
defects as a group, as permitted under TGI
rules
From Table 9.6 it can further be deduced
that the length sizing performance remai
ned more or less the same for all teams.
Note in this respect the outstanding good
length sizing performance achieved by
team CC. The two eddy current teams HH
and PP systematically undersized the
length of all the defects.
300
E
OJ
c
"-
o
o

100
50
D
BB130010
CC130010
DD130010
KK130010
o MM130010
NN130010
TT130010

B
e


0 s
Fig. 9.
for all
Reference length [mmj
.7: Measured length versus reference length
defects in pre-test inspections.
89
HS E
M C O P
I ML_. * _/ 0
E
2 G0

D)
C
a;
"D
O
Q.

5 0
9
0

M'
JE/T
X
X
0
O
A
*

/
/ i
o
*/
X
L
BB13DD20 * J J 130020
OD13Q020 MM13002
O EE130020 * NN130020
* FF130020 HH213020
GG130020
A
PP214020
100 150 200
Ref erence l engt h [ mm]
Fig. 9.8: Measured length versus reference length
for all defects in post-test inspections.
9. 3. 4 Cr ack Gr owt h Measur ement
The throughwall sizes reported for the sub
clad defect (B) from the pre and posttest
inspections are compared in Figure 9.9.
Values of crack, growth derived from the
reported data are shown in Figure 9.10.
Among the six teams that participated in
both phases of the round robins, two were
very accurate, with measurements within 0.5
mm of the actual crack growth of 5 mm. Two
teams reported only small changes and the
remaining two made significant sizing errors.
9.3.5 Crack Profiling
Destructive examination of the cylinder after
the final inspections showed clearly that both
of the large defects (RL and B) grew during the spin test. Most of that extension occurred in an
axial direction just below the cladding/base metal interface, giving lobes at both ends of the sub
clad fatigue crack (defect B). and one lobe at the end of the throughclad crack (defect RL).
Five teams provided profiles for both of the large defects at the pretest inspection stage, and
eight gave profiles at the posttest stage. Generally, the profiles were good and conformed to
the profile of the cracks in the deeper regions. The profiling of one team in the posttest
inspections was outstanding, as illustrated for the large subclad fatigue crack (B) in Fig.
9.11. This team used focussed probes to accurately follow contours of the lobes on both of
the large cracks.
Table 9.6: Comparison between pre-test and post-test length sizing performance.
Team
BB
CC
DD
KK
MM
NN
Time of
inspection
Pretest
Posttest
Pretest
Posttest
Pretest
Posttest
Pretest
Posttest
Pretest
Posttest
Pretest
Posttest
Average
error [mm]
37
35
-1
0
-4
8
-3
-1
-3
3
25
24
Standard
deviation [mm]
31
44
3
3
7
4
4
7
5
5
42
39
RMS-
error [mm]
47
55
3
3
8
9
4
7
6
5
47
45
Max
oversizing [mm]
88
141
s1
3
5
7
15
3
8
5
9
111
#1
108
1
Max
undersizing [mm]
1
19
7
7
19
N/A
14
18
13
7
20
28
#1 Max oversizing value with grouped defects.
90
HSE
Heal t h Safei
NESC
Pre tesi dala
DPosi test data
Team Codes
-

s
C
a>

c
ra
-C

"C

D
ra
red erad
50-
40
30
20
10
0
-10
; . - : :

RpIPrp
5
BB130010
53
CC130010
-1
DD130010
IB
KK130O1O
5
MM 130010
5.5
NN130010
1 5
Fig. 9.9: Comparison of
through-wall sizes
reported for the sub-clad
defect (B) from the
NESC-I pre-test and
post-test inspections.
Fig. 9.10: Crack growth
values in TWE derived
from the NESC-I
inspection data.
Team Codes
Sf

- ^ " " 1
" ^

Fig. 9.11: Comparison of
post-test inspection
profile with actual profile
of the large sub-clad
fatigue crack (B) in the
NESC-I cylinder.
91
usi :
Health Safer
K I C C p
9.3.6 Influence of defects
Results from the NESCI inspection exercise indicate that subclad EDM notches with sharp
tips appeared to be at least as difficult to size as realistic fatigue cracks (Fig. 9.12). This
makes them suitable for use in inspection qualification testing, but care is needed to avoid the
development of porosity in the cladding above the defect during the cladding process. Careful
specification of the defects in qualification test pieces is necessary to ensure that they meet
the test requirements. However, the analysis of the NESC 1 inspection data has confirmed the
necessity of verifying in detail the parameter of the defects used in test assemblies.
9.3.7 Factors influencing performance
The conditions for the NESC inspections were more favourable than those encountered on
site at a real plant. The inspections were carried out in laboratorytype conditions that gave
the teams ready access to both the inside and outside surfaces of the cylinder. This is not the
case for some nuclear pressure vessels. With respect to the influence of inspection surface
(inside or outside) on sizing accuracy there is insufficient data available in the present study
to draw conclusions. This is a factor that could be included in any further study of parameters
influencing performance. Another possible influential factor was the number of techniques
used by a team, since a larger number of probes should give more chances of obtaining a
signal. Examination of the inspection results indicated no significant difference in perfor
mance between teams using one or two techniques and those using five to seven.
The scanning raster or grid employed by some team at the detection stage in NESCI was
smaller than that which would be expected in an onsite inspection. However, from the limi
ted available data, this does not appear to have been a significant factor influencing detection.
For sizing, it is common practice for inspectors to use small raster scans, so the sizing proce
dures used in NESCI conform to the procedure used in practice.
M, N, C, O, E, D
1
0.9
n -
0 3 X 0
Q
A
A A
L A
C
J
A
G
><y-



Large fatigue defect
^ Underclad defects
A Smooth planar defects
(PISC TYPE A)
Fig. 9.12: Detection
probabilities for defects
in the NESC-I cylinder.
10 20 30 40 50
TWE [ mm]
60 70 80 90
92
f sf N ESG
M, ..it;. Nuft-t
To some extent, the smooth-machined surface finish and reduced thickness of the cladding (4-
mm) probably contributed to the good results achieved in the NESC-I inspections. Other stu-
dies have shown that considerable variability in beam amplitude and direction can result from
inspecting through an as-clad surface finish [9.2].
9.4 SUMMARY
9.4.1 Factors for good performance
From the NESC l inspections, it is concluded that the following key elements contributed to
the good inspection performance observed:
The use of crack tip diffraction techniques for sizing the through-wall extent of the defects
The application of well-based inspection procedures by knowledgeable operators
Good inspection conditions
The main reasons why some teams did less well are considered to be:
The occurrence of human error, which probably accounted for the non-detection of some of
the smaller defects and the undersizing of the larger fatigue cracks.
The limited inherent capability of the specific techniques employed, which are illustrated by:
- the results achieved in sizing the through-wall extent ultrasonically using amplitude based
methods
- the oversizing of defect length by one team using full skip sound path
9.4.2 Inspection Qualification
The results show that it is important to verify the capability of an entire inspection system,
including the inspection procedures and personnel, using inspection qualification methodolo-
gies relevant to the specific inspection application.
9.4.3 Further work
Since many of the teams used similar detection and sizing techniques yet obtained different
results, further analysis of the data should be made to address this specific aspect. Such a
study should investigate the influence of factors such as the quality of the inspectors; the
scanner and equipment; and the data processing equipment and software, on performance.
REFERENCES
[9.1] Murgatroyd. R.. Eriksen. .. Houghton. R.. Lemaitre, P.. "Inspection Task Group Final Report, Part I:
Analysis of the Inspection Results from the Pre- and Post-test Round Robin Trials". NESC.DOC
TGI (99)3 (to be published).
[9.2] Bass. B.R.. Williams. P.T.. Pugh. CE. . Murgatroyd. R.. and Faidy. C. "Effects of Cladding in the NESC-
I Project". NESC ETF DOC (99) I4. (to be published).
93
si i NESC
II. ..III. & S . f c l j
10 EVALUATION OF THERMAL AND
STRUCTURAL ANALYSES
10.1 INTRODUCTION
Primary responsibility for performing the extensive thermal and structural analyses required
in NESC-I was given to the structural integrity task group, TG3. During the project this group
contributed the following specific activities [10.1]:
Advised the Steering Committee on the range oftest conditions required to achieve test objectives;
Interacted with the materials characterisation task group (TG2) to identify the material pro-
perties of the steel cylinder and clad layer essential for design and analysis;
Performed preliminary calculations on a matrix of defect geometries to rank their propensity
for extension under the proposed test conditions: the results contributed to the selection of
the actual defect sizes implanted in the cylinder;
Performed pre-test calculations to predict crack extension behaviour during the experiment,
based solely on inspection estimates of defect dimensions:
Performed post-test calculations to determine the actual loading conditions achieved during
the experiment;
Performed post-test defect assessments based on initial dimensions of the defects as deter-
mined from post-test destructive examination of the cylinder:
Conducted an extensive post-test evaluation of the experiment that focused on topics rele-
vant to defect assessment that included codes and standards approaches, application of pro-
babilistic methodologies, sensitivity studies and a range of technical issues.
Participation in TG3 was open to technical organisations of excellence concerned with the
methods and practice of structural integrity assessment. These organisations included utilities
and plant operators, organisations supporting plant operators, regulatory bodies, and research
laboratories. More than 20 participants drawn from such organisations in Europe. Japan and
the United States contributed to the achievements of the group.
10.2 DESIGN ANALYSES OF THE CYLINDER AND LOADING TRANSIENT
The initial responsibility of TG3 was to provide recommendations concerning crucial design
parameters for the cylinder and loading transient that would lead to a cleavage event in the
NESC-I experiment. The group met this challenge by organising two pre-test analysis phases
during which both simplified and sophisticated analytical techniques were utilised to eluci-
date the influence of various parameters on the planned experiment.
10.2.1 Fi rst phase anal ysi s
The NESC structural analysis activities were initiated at a meeting of prospective group mem-
bers during August 1993. Initial discussions revealed limited experience with the design and
94
f f NESC
analysis of an experiment based on the spinning cylinder concept. Thus, it was considered
essential that the individual participants should first perform a series of preliminary calcula-
tions to establish a basic understanding of the problem. A specification for the proposed cylin-
der loading conditions and material properties was compiled to support this action. Results
from this first phase of analyses were presented at the NESC launch meeting at Risley in
September 1993. The majority of the analysis techniques utilised a common simplified metho-
dology based upon either thermo-elastic or thermo-elastic-plastic analyses of uncracked-body
stresses, combined with weight-function estimates of the crack-tip stress-intensity factors
(SIFs). The significant findings from this series of analyses were given as follows:
Cleavage was not predicted from the deepest point of any defect size due to the temperature
gradient in the cylinder wall;
The highest probability of cleavage initiation for all cracks was predicted for the near-sur-
face crack front position during the time interval from 200 to 300 seconds;
Elastic analyses predicted that a 50 mm-deep semi-elliptical surface breaking defect might
initiate at the near-surface crack front position during the proposed transient;
Calculations suggested that the potential for cleavage initiation could be increased by redu-
cing the cladding thickness, lowering the inlet coolant temperature and increasing the rota-
tional velocity of the cylinder.
The results highlighted a number of problems associated with the realisation of a cleavage
event in the proposed experiment. First, it was apparent that the simplified analysis methodo-
logies could not satisfactorily model the influence of cladding on crack driving force for
either the sub-clad or surface defects. Modelling these effects required that three-dimensional
finite-element analyses be performed on cracked-body representations of the cylinder speci-
men. Moreover, because of constraint-loss effects and fracture toughness properties of the
cylinder, the group could not recommend with certainty that even the largest defect conside-
red in the analysis matrix (approx. 50 mm depth) would initiate during the proposed transient.
Furthermore, the shallow gradient of the crack driving force curves at the intersection point
with the material toughness curves implied that warm-prestressing effects could further
reduce the probability of a cleavage initiation event.
In parallel TG2 reported serious difficulties with the process to degrade the toughness of the
cylinder by heat treatment to the target level of 100 MPa.Vm at 50 C. The possibility was rai-
sed that cleavage initiation would not be realised in a cylinder having the toughness proper-
ties achieved to that point, even under more severe loading conditions. Consequently, the
Steering Committee made the decision to substitute another cylinder that would be reconstitu-
ted from remnants of two previous spinning cylinder experiments as detailed in Chapter 5. A
major advantage of that strategy was that material properties of these remnants were known
within a specific range. Additionally, it was decided that the cladding thickness would be
reduced to 4 mm. the inlet coolant temperature set at 5 C (with a feasibility study to examine
the potential for subzero cooling) and the rotational velocity increased to 2500 rpm. Specific
benefits derived from the latter changes included an increase in peak value and downward
shift in temperature of the crack driving force curve for large through-clad flaws (Fig. 10.1).
95
H SK
MCOP
I *L-. '_/W
400
300
250
50
Spinning Cyli
/ Toughness.
Modi fi ed Conditions / /
2500 rpm / '/
4 mm cladding ^^^ / /
5 C water quench ^ " " - f r - ^ B / * " " - W /
/ / / *
I / / *
/ / '
/ / '
/ PEL
/ ^ ^ ,
0
^^^
/ / ^ ' <*
. / cr '
/ z
3
/ /
^ / ^ X ^ * *
JT jT
^ ^ *
-
i der 4
CT25 Tough
I
*
#
/
*
^

ness
*
Original Conditions
2000 rpm
7 mm cladding
20 C water quench
Fig. 10.1: Comparison of
crack driving force
curves computed for
initial and modified
geometry and loading
conditions.
50 100
Temperature, C
10. 2. 2 Second Phase Anal ysi s
Based on findings from the first phase, a more detailed series of both simplified and 3-D cracked-
body finite-element calculations were commissioned to develop a better understanding of the
influence of test variables on cleavage initiation. These studies utilised the more severe loading
conditions that had been recommended to the Steering Committee. Individual groups were encou-
raged to perform parametric analyses of experimental variables that included the following:
rotational speed and acceleration
initial cylinder and inlet water temperature
cladding thickness
modified loading conditions
defect aspect ratio
cladding yield strength
change in geometry.
The results obtained from these analyses [10.2] permitted TG3 to advise the Steering
Committee on defect sizes that would have a high probability of experiencing a successful
cleavage initiation. The details ofthat proposal were kept confidential because of the impen-
ding pre-test NDE exercise that focused on identifying and sizing the inserted defects.
10.3 PRE-TEST PREDICTIONS OF THE CYLINDER BEHAVIOUR
A series of thermal, structural and fracture mechanics analyses [10.3] were performed by 16
organisations within TG3 to generate pre-test predictions for defect behaviour during the propo-
sed spinning cylinder test. These analyses were based on the defect dimensions recorded during
96
HS E
Health Safcl]
MC C P
Defect Pre-test Dimensions mm Defect Type
208 .,
R C

74
261
^L7
1T
19
fatigued
through-clad
EDM notch
sub-clad
fatigue crack
]
>
sub-clad
PISC Type A
EDM notch
gir
Fig. 10.2: Defects considered in the pre-test
analysis phase.
the inspection trials conducted by TGI and
on the material properties database develo
ped by TG2. Predictions were given in
terms of the extent of crack growth by duc
tile tearing and the time to cleavage initia
tion during the thermal shock transient. The
analysis matrix included those defects in the
cylinder that were perceived to have signifi
cance for the structural integrity assessment
process. Analysis techniques ranged from
simplified engineering methods to multi
dimensional finiteelement models incorpo
rating nonlinear constitutive formulations
and finitestrain theory.
The pretest analyses focused on five
defects given in Fig. 10.2. The location of
these defects is given Fig. 5.3. Table 10.1
provides a listing of the participating orga
nisations and their individual contributions
to the analysis effort. Some of the partici
pants employing simplified analysis techni
ques were able to address the full range of
flaws given in the matrix. By contrast.
Table 10.1: Analysis matrix for the pre-test analyses.
Code
S01
S02
S03
S04
S05
S06
S07
S08
C01
C02
C03
C04
C05
C06
C07
C08
Team
Framatome
VTT
Basler & Hofmann
Nuclear Electric
Siemens
TWI
Rolls Royce
IWM
Vattenfall AB
ORNL
ECN
EDF
SAQ
GRS
AEAT
CEA
Defects

X
-
X
-
X
-
X
X
X
-
-
X
X
-
-
X
R
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

X
-
X
-
X
-
X
X
-
-
X
-
-
-
-
-
G

-
-
-
-


-
-
-
-
-
-
-


-
-
-
-
-


-
-
-
-
-
-
-
-
97
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Health & Safei)
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those analysts utilising 3-D finite-element techniques concentrated on the large through-clad
defect R and, to a lesser extent, on the large sub-clad defect B. Early in the analysis effort, it
was perceived that defect R had the highest probability for cleavage initiation and, conse-
quently, it received the greatest emphasis in the TG3 analysis matrix. An alphanumeric code
was defined for each organisation in Table 10.1 to identify analysis results presented later in
this section. A summary of the analysis methods and computer programs applied to the defect
matrix is given in Table 10.2.
Comparisons of thermal and stress analyses performed for the pre-test analysis matrix are
provided in Figs. 10.3 and 10.4. respectively. In Fig. 10.23 temperature distributions compu-
ted through the wall thickness of the spinning cylinder at 300 seconds into the transient show
good agreement. Some differences observed among the techniques used to model the tran-
sient were due in part to limitations of the computer codes. However, those differences had
little effect on the temperature calculations after approximately 30 s into the transient. Figure
10.4 shows comparisons of the circumferential stress through the wall thickness of the
(uncracked) spinning cylinder at 300 seconds into the transient. Differences in the stress
distributions near the inside surface of the cylinder are due to variations in approach to
modelling of the clad and HAZ regions.
In Fig. 10.5 the methodology for predicting extension by ductile tearing and cleavage fracture
mechanisms is depicted in the form of K versus crack tip temperature curves for a finite-ele-
ment model of through-clad defect R [10.4]. Figure 10.5b includes the cleavage fracture tou-
ghness confidence curves (5-95%) from small-specimen data and the ductile tearing tough-
Table 10.2: Summary of analysis methods and computer programs used in the pre-test analyses of
NESC-I experiments.
501 Simplified methods using Influence functions (CALORI)
502 Simplified methods using weight functions (MASI)
503 Elastic and elasto-plastic 2-D FE-analyses + influence coefficients (ALGOR)
504 Elastic and elasto-plastic 2-D FE-analyses + the R6 procedure (ABAQUS & R6)
505 Elastic 2-D FE-analysis + K calculation with SSY correction (ADINA)
506 Elastic 2-D FE-analysis + BSI PD 6493:1991 level 2 assessment (ABAQUS)
507 Elastic and elasto-plastic 2-D FE-analyses + R6 procedure (ABAQUS & R6)
508 Elastic and elasto-plastic 2-D FE-analyses + BESIT (ADINA & BESIT)
C01 Elasto-plastic 3-D FE-analyses (ADINA)
C02 Elasto-plastic 3-D FE-analysis (ABAQUS)
C03 Elasto-plastic 3-D FE-analyses (MARC)
C04 Elasto-plastic 3-D FE-analyses (ASTER)
C05 Elasto-plastic 3-D FE-analyses (ABAQUS)
C06 Elasto-plastic 3-D FE-analyses (ADINA)
C07 Large strain elasto-plastic 3-D FE-analysis + local approach model (T0MECH)
C08 Elasto-plastic 3-D FE-analyses (CASTEM 2000)
98
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Ileal Ih & Safei)
N
icro
300
0 20 40 60 80 100 120 140 160
Di stance t hr ough t he cyl i nder wal l f r om t he Inner surface [ mm ]
Fig. 10.3: Through-wall temperature distributions computed at 300 seconds in pre-test analyses of
NESC-I experiment.
180
(0
c
0)

0.00
- - -f r
*-
-
B -
"
-
-
-S02-2100rpm
- S03
- S04
- S05
- S06
- S07
- S08
- C06
-500.00
0.00 25.00 50.00 75.00 100.00 125.00 150.00 175.00
Position in wall [ mm ]
Fig. 10.4: Through-wall circumferential stress distribution computed at 300 seconds in pre-test analyses
of NESC-I experiment
99
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Health & Safei)
d e e p
ness curves corresponding to 0.1, 0.5 and 2 mm crack growth. Also, crack driving force cur
ves are shown for three points around the perimeter of the defect. At the deepest point (PI5),
the K, values reach the K
u
tearing toughness curve corresponding to 0.1 mm crack growth,
indicating that only blunting with no significant ductile tearing was predicted at that position.
At a position 43 mm from the inner surface (P9), a small amount of stable crack growth
(approximately 0.5 mm) was predicted in the time interval 75 to 300 s. No brittle fracture ini
tiation was expected at P9 because only the decreasing branch of K, intersects the scatter
band of cleavage fracture toughness, indicating a warm prestressed condition. At a position
Positions on crack front
648 mm
Ranes fixed in
Zdirection
IJUt'pffl '
:-
~Z^^ - ' i
2 10 0 2 2 8 0 rpm
Rane fixed in
Xdirection
P2: Clod/HAZ Interface
P3: mi d of HAZ
Pd: HAZ 11.5 mm away
from inner surface
P5: HAZ/ase Interface
P6: Base 16.5 mm away
from i msr surface
Bese 19.0 mm away
from inner surface
Base 43 mm av ay
from inner surface
PIO: Base 53 mm away
from inner surface
P15: Base deepest point
P7
P9.
300
a
a.
2 250
i
| 200

s

E

KJC (Base) from TPB-tests wtth a/w-0. t
(fracture probabcSt/10-90%)/ /
KJC (Basa) fracture
probability 5%
100 150 200
Temperature al crack tip node [ " C ]
Posioon
P 6
* P 9
* P 1 5
(b)
P6: Base material 2.5 mm away from HAZ.
16.5 mm away from inner surface
P9: Base material 43 mm away from inner
surface
P15: Base material deepest point of crackfront.
74 mm away from inner surface
Fig. 10.5: Pre-test fracture assessment of different crack front positions in base metal of defect R: (a)
finite element model; (b) fracture assessment.
100
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N
ur ei
closer to the inner surface (i.e., at P6 located 2.5 mm below the HAZ or 16.5 mm from the
inner surface), the fracture assessment predicted stable crack growth that starts at 30 s and
exceeds 2 mm during the transient. Furthermore, comparison of the applied K, curve for point
P6 with the fracture toughness confidence curves implies a high probability of cleavage frac
ture initiation after approximately 150 s.
Figure 10.6 depicts a summary of fracture assessments performed for the large throughclad
defect R at (or near) the HAZ/base metal interface. Analysis results in the form of K, versus
cracktip temperature computed for a benchmark transient are compare with the 595 percent
confidence limits. The spread in results for the simplified approaches is larger than that for
the 3D finiteelement analyses. Some participants that performed 3D finiteelement analy
ses did not correctly specify the thermal expansion coefficient with respect to the stressfree
temperature of 290 C. When the latter results were corrected, the spread among the 3D
finiteelement analyses was further reduced. An analogous fracture assessment for the deepest
point of defect R. shown in Fig. 10.7, implies that a cleavage initiation would not be predicted
for that region. In Fig. 10.8, fracture assessments for the subclad defect are compared at
the HAZ/base metal interface. The results exhibit a smaller spread than those for defect R,
although the number of contributed analyses is also smaller.
The pretest fracture assessments predicted that the large defects in the spinning cylinder
would initiate in the base metal immediately beneath the HAZ and extend in the axial direc
tion; no cleavage extension was predicted in the radial direction (i.e., into the cylinder wall).
In Ref. 10.5. a cleavage initiation was projected for defect R at 226 seconds from start of the
transient in the base metal region just below the HAZ. That prediction was based on the time
450
. . . p. .
- -
. . A.
. . 4 . .
.-.
0


coi
C02
C03
C04
CO 5
C06
C07
C08
S 0 4 . b
^ = S 0 4 . C
S 0 5
^ ^ S 0 7
S0 8
f..
1
25 50 75 100 125 150 175 200
Temperature [C ]
225 250 275 300
Fig. 10.6: Computed
stress-intensity factor
versus crack-tip
temperature at HAZ/base
metal interface of defect
R in pre-test post-
inspection analyses of
NESC-I experiment.
I0I
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Health & Surti
N

450
Fig. 10.7: Computed
stress-intensity factor
versus crack-tip
temperature at deepest
point of defect R in pre-
test post-inspection
analyses of NESC-I
experiment
100 125 150 175
Temperature [ C ]
300
4UU -
350 -
300 -
Kjc haz
25 50 75 100 125 150 175
Temperature [ C ]
200 225 250 275 300
Fig. 10.8: Computed stress-intensity factor versus crack-tip temperature at HAZ/base metal interface of
defect in pre-test post-inspection analyses of NESC-I experiment.
102
US E
Nicer*
S08
SI I /
SI IH
Slib
SI 14
sin
sm
IH
1:0/
1:1 IK
C05
CIM
1 m
tin











Event det ect ed by
strai n gauges
/
1
I
S)
100 150 200
Ti me of Cleavage [sees]
Figure 10.9: Pre-test
prediction for the time for
cleavage initiation at the
large through-clad defect
during the NESC-I
transient.
at which the crack driving force intersected the mean fracture toughness confidence curve.
Among the TG3 predictions, it ranked closest to the measured initiation time of 217 seconds.
Several other analyses, including a local approach model and some of the simplified methods,
also predicted cleavage event times close to the observed value
10.4 POST-TEST ANALYSES
Post-test analyses were performed that are relevant to evaluating the outcome of the experi-
ment. Those analyses incorporated the loading conditions recorded during the test and the ini-
tial defect dimensions determined during the destructive examination of the cylinder. Fracture
assessments were carried out both in the context of a Master Curve methodology and a cou-
pled cleavage-ductile local approach formulation. Consideration was given to other factors
that were likely to have influenced behaviour of the large defects during the thermal shock
transient.
10.4.1 Assessment based on Master Curve
The majority of the post-test studies exploited the Master Curve description of material tou-
ghness to infer the probability of a cleavage event. This approach, which is based on Weibull
weakest link statistics, provides a direct route to assessing the probability of cleavage, P
f
, for
given values of crack tip temperature and driving force [10.6]. At a given temperature T, a
value of was calculated deterministically, either from a simplified approach involving 2-D
finite element analysis of the un-cracked body and weight function techniques, or from a 3-D
elastic-plastic finite element model of the actual crack geometry. To obtain cleavage probabi-
lities, the K-T pair was then substituted into the Master Curve equation given by:
= D,(P
f
) + D
2
(P
t
) e
,0.0I9[7"-T]
103
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Health Safei

which was inverted and solved for P
f
. Here T
0
is the temperature at which the mean fracture
toughness level is 100 MPaVm for 25 mm-thick specimens, while D
;
and D-, are functions of
probability level.
In Ref. 10.7 detailed analyses were evaluated in the context of the Master Curve methodology
to generate probabilities of cleavage failure at selected points on the crack front of the large
defects R and B. The requisite crack-tip . pairs were taken from the post-test 3-D finite-
element analyses performed at ORNL [10.8], VTT [10.9J and IWM [10.10]; two pre-test
analyses [10.11, 10.12] provided additional information, particularly on constraint parameters.
In the case of defect R, values of K, at the time of cleavage initiation (i.e. 217 seconds) were
derived by interpolation of reported results. An additional analysis considered the conditions
at 311 seconds when peak values of crack driving force were experienced at the HAZ/base
metal interface. For the sub-clad defect B, only the peak loading condition was considered
since it showed no cleavage event. Particular attention was paid to the base metal (BM) close
to the HAZ/BM interface, since this was the site of cleavage initiation in defect R. Shallow-
notched base metal (BM-SN) data were treated distinctly from those of deeply-notched base
metal (BM-DN), so that an assessment could be made as to low or high constraint data better
described the observed behaviour. As detailed in Chapter 6, deep-notch and shallow-notch
data generated from three-point bend specimens (a/W=0.5 and 0.1) provided transition tem-
perature values of T
()
= 68 C and 32 C respectively.
A schematic drawing of the idealised defect R is shown in Fig. 10.10a. The two near-surface crack
tips are asymmetrically sited in 'narrow' HAZ (nominally 5mm) as seen on the left and 'wide'
HAZ (nominally 10mm) as seen on the right. Points on the crack front are designated by suffix N
in the narrow-HAZ and W in the wide-HAZ side of defect R. The transgranular cleavage event
was observed only on the narrow-HAZ side. Selected driving force and temperature profiles for
the narrow-HAZ model analysed in Ref. 10.8 are shown in Fig. 10.11. Values of crack-tip tempe-
rature T. driving force K, probability of cleavage initiation f^and extent of ductile tearing compu-
ted at 217 s for various points on the narrow-HAZ side of the defect are shown in Fig. 10.12.
The following features are noted for the narrow-HAZ end of the defect R:
At point 6 (located 11.5mm below surface in BM and near HAZ/BM interface), the BM-DN
results predict a failure probability of P. = 1.0; the temperature range is such that ductile tea-
Fig. 10.10a: Schematic
drawings of the
through-clad defect R.
5mm HAZ (Beam R1) 4mm cl addi ng 10mm HAZ (Beam R5)
74mm
'
104
U S E
M C O P
1 ^L. . ^0
264mm
Fig. 10.10b: Schematic
drawings of the sub-clad
defect B.
5mm HAZ (Beam R1) 4mm cladding 10mm HAZ (Beam R5)
-KJat184
KJ at 226
KJat311
350
300
- - Temp at 184
---Temp at 226
Temp at 311
E
TO
B- 250
200
150
312MPa|mat3l1s
; 306MPamat 226 s
A t 299MPamat 184 s
/; : di SK- *
I : i "9 0><:-1
;
: : Ar*
: i ; \ 16.5
- Up"\
mm
" O B 92 C et 311 s
J 102*Cal226s
J f
:
"Cat1S4a
1
:
|
. . . J 1 . . . i . 1 . . . . . . . . . ,
o<*2,
"V' ' S^
s
XV*
8
5 mm HAZ
. . . 1 . . . . 1 . . . . 1 . . . . '
300
10 20 30 40 50 60
Distance from surface (mm)
150
100
50
70 80
05/20/99 K2 [Xw
ring would be expected before failure by
cleavage. The actual behaviour was that no
cleavage was observed, although several
millimetres of tearing occurred at this point.
The amount of ductile tearing was predic
ted to be greater than 5 mm, based on BM
DN data at 150 C.
At point X (located 16.5mm below surface
at cleavage initiation site), the BMDN
results indicate P
f
- 1.0 for probability of
cleavage fracture. Conversely. BMSN data
indicate a relatively low probability (P.- =
0.48) of cleavage initiation. The actual
event at point X was initiation of a cleavage
fracture after some 3 mm of stable tearing.
At point 9 (28mm below surface), the
BMDN results predicting low cleavage
probability and ~4 mm of stable tearing
are consistent with observed behaviour.
At position 17 (approximately 70 mm below the surface), the BMDN results predict zero
probability of cleavage initiation; the temperature is sufficiently high that only ductile tea
ring would be expected. The actual fracture surface shows small cleavage facets close to the
base of the crack, although the calculated temperature in this region was too high to initiate
brittle fracture. A small amount of stable tearing was predicted along the crack front exten
ding from the deepest part through position 17.
In Fig. 10.12, estimates of crack tip values for T, K, P and (a are given at the time of peak
driving force, t = 31 1 s, for points at the wideHAZ end of defect R, denoted by 6W, Y, 9W
and 17W in Fig. 10.10a. These points are opposite 6N, X, 9N and 17N at the narrowHAZ
end. A high probability of cleavage fracture is predicted even in the HAZ, where the cleavage
fracture toughness is higher than in the BM. At point Y, the probability of initiation P
f
= 1.0 if
Fig. 10.11: Driving force transients for the through
clad defect R assuming a narrow, 5 mm HAZ.
105
H S E
N
crc<
Narrow-HAZ
distance
from inner
surface
11.5 mm
(pt. 6)
16.5 mm
(pt. )
28 mm
(pt. 9)
70 mm
(pt. 17)
(a)
16.5 mm
(pt. Y)
28 mm
(pt. 9)
70 mm
(pt. 17)
(b)
(MPa m
( f C)
K = 308
T = 85
= 305
= 104
= 274
= 150
= 194
= 250
11. 5mm = 308
(pt. 6) = 75
= 285
= 88


262
120
= 198
= 208
analysis
predictions
fracture toughness
data (source)
Pf = 0.01
Pf = 0.17
BM-SN
BM-DN
del ta-a = 4 mm
Pf =0
delta-a = 0
BM-DN
Pf =
Pf =
delta
Pf =
Pf =
delta
0.94
1.00
-a > 5
0.48
1.00
a > 5
mm
mm
BM-SN
BM-DN
BM-SN
BM-DN
observed event
start of cl eavage
f acet s; not i ni ti ati on
site
cl eavage i ni ti ati on
after 3 mm duct i l e
t eari ng
5 mm duct i l e
t ear i ng, no
cl eavage
duct i l e t eari ng,
t hen smal l
cl eavage facets
Pf =
delta
Pf =
Pf =
"delta
Pf =
Pf =
delta
\
Pf =
delta-
Wide -HAZ
0.83
-a = 5 mm
0.79
1.00
-a = 5.5 mm
0.09
0.77
-a = 3.5 mm
0
a = 0.5 m m
HAZ
BM-SN
BM-DN
BM-SN
BM-D
BM-D
M
M
duct i l e t eari ng onl y
Fig. 10.12: Predictions for behaviour of defect R during the thermal shock transient: (a) narrow-HAZ
model at 217 seconds; (b) wide-HAZ model at 311 seconds.
106
HSE
Hinit Ii & S u a n
NESC
distance
from inner
surface
9 mm
(pt. 5)
14 mm
(pt. 6)
K(MPa| m)
T(tG)
K = 365
= 65
= 250
= 75
22 mm
(pt. 9)
(a)
9 mm
(pt. 27)
23 mm
(pt. 23)
deepest
part of
crack
= 285
T= 1 1 0
analysis
predictions
fracture toughness
data (source)
= 272
= 73
= 260
T = 110
= 186
= 200
Pf = 1.00 HAZ
deltaa > 5 mm
Pf =0.51
Pf = 0.90
Pf = 7.00
HAZ
BMSN |
BMDN
deltaa = 2.5 mm
Pf =0.26
Pf = 0.99
BMSN
BMDN
deltaa = 4 mm
observed events
no cleavage
initiation over any
part of crack front;
intergranular
fracture followed
by ductile tearing
Pf =
delta
Pf =
Pf =
delta
Pf =
delta
0.70
a = 3 mm
0.18
0.95
a = 3 mm
0
a = 0.5 mm
HAZ
BMSN
BMDN
BMDI M
(b)
Fig. 10.13: Predictions for behaviour of defect B at t = 311 seconds during the thermal shock transient:
a) ORNL [10.81 and b) VTT[10.9].
BMDN data are assumed to apply, but pf = 0.79 if BMSN data apply. Approximately 5 mm
of stable tearing is predicted within the HAZ and base material at positions 6 and Y, respecti
vely. Smaller amounts of tearing are predicted at positions 9 (3.5 mm) and 17 (0.5 mm).
The predicted amounts of tearing around the defect are consistent with that measured on the
narrowHAZ side of the defect.
Analysis of defect B required estimates of K, T under peak driving force conditions since no
cleavage event could be identified. Results depicted in Fig. 10.13 provide some evidence of
possible constraint effects up to a distance approximately 14 mm into the cylinder wall, i.e.
up to the HAZ/BM interface. At a point 9 mm below the surface (in the middle of the HAZ),
predictions were for stable tearing in excess of 5 mm, followed by a cleavage event (P
f
= 1.0).
107
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Health & Safei
MCTOP
I *L_. _/ 0
While no cleavage occurred, ductile tearing up to 4.5 mm was observed. Predictions based on
the post-test analysis earned out by VTT [10.12] are summarised in Fig. 10.13. The predicted
driving forces are somewhat lower for a given position than the values predicted by the
ORNL analysis. Consequently, the probability of initiation is lower in the VTT analysis (com-
pare behaviour at 9 mm and 22-23 mm below the surface). Differences between VTT and
ORNL in predictions of stable tearing are due to differences in the calculated peak crack dri-
ving force. It is also noted that in the predictions based on the analyses performed by IWM
[10.10], the calculated K results are somewhat higher than results from VTT. The predicted
probability of cleavage initiation are comparable with the other analyses, whereas the evalua-
tion points in the HAZ and in the neighbouring BM slightly differ. The amounts of stable tea-
ring are between the ORNL and VTT estimations. It is noted that the observed crack exten-
sion behaviour in defect is consistent with the fracture mode observed in the materials charac-
terisation tests performed by TG2 [10.13].
In Ref. 10.6, probabilities of cleavage were evaluated for defect R using the Master Curve
approach and two different sources for the crack driving force K: (1) estimation schemes
based on 2-D elastic analyses of an un-cracked body, and (2) a complex 3-D finite element
analysis of a cracked cylinder previously performed by GRS [10.11]. Two specific positions
on the crack front were considered:
the near-surface region in the base metal just beneath the HAZ where the major cleavage
event initiated during the transient.
the deepest point where a number of small cleavage initiation facets were also observed.
Probabilities of cleavage computed at the near-surface location from various estimation sche-
mes and from the 3-D cracked-body finite element analysis are summarised in Table 10.3. A
best estimate probability of P, = 0.97 was obtained from application of the 3-D cracked-body
analysis to determine K and the Master Curve function derived from high-constraint BM-DN
specimens. Use of low constraint BM-SN data reduced the failure probability to P
f
- 0.23.
However, detailed analyses of local constraint conditions at this depth (see Ref. 10.7) indicate
that small scale yielding conditions should prevail: therefore, the higher constraint BM-DN data
Table 10.3: Probability of cleavage in the near-surface base material region for defect R at 217 seconds
into the PTS transient.
Analysis Description
1)PD6493
2) 2-0 FE + weight function
3) As 2 but with reduced residual stress
4) R6 Appendix 4
5) 3-D elasto-plastic FE analysis (high constraint data, standard crack front
normalising parameter)
6) As no. 5, but with low constraint toughness data
7) As no. 5, but with reduced Master Curve crack front normalising parameter (10 mm)
Crack driving
force at 217 sees
420 MPa.Vm
350 MPa.%/m
320 MPa.N/m
310MPa.Vm
260 MPa.-^m
260 MPa.Vm
260 MPa.Vm
Probability
of Cleavage
1
0.999996
0.9999
0.9996
0.97
0.23
0.77
108
HSE
I l cu It h & Safcl'
NESC
are appropriate. A failure probability of 0.97 is above the level at which a cleavage event could
reasonably be expected in a single test, implying that cleavage initiation could have been antici
pated at an earlier time in the transient and at a lower K value. The simplified engineering
methods given in Table 10.3 provided more conservative predictions of crack driving force at
the nearsurface location and, hence, even higher probabilities of cleavage than the 3D analysis
model. At the deepest point of the defect, the bestestimate probability of cleavage was calcula
ted to be P, <0.05. implying that a cleavage event would not be expected in a single test.
10.4.2 Assessment based on Local Approach
In Ref. 10.14 a coupled cleavageductile local approach formulation was combined with a 3
D elasticplastic finiteelement model in a fracture assessment of defect R. Parameters for the
Beremin cleavage and Rousselier ductile models were calibrated for each material region
(i.e., cladding, HAZ and base material) based on a combination of notched and cracked speci
men data. Curves describing the predicted P. as a function of transient time for the HAZ, the
base metal and the cylinder as a whole are depicted in Fig. 10.14. For t < 190 s, the probability
, in the base material exceeds that in the HAZ and is the dominant contributor to the combi
ned probability curve. At t = 190 s, the probability of cleavage in the base metal is P
r
= 0.81
and the crack driving force is given as Kj = 211 MPavW For t >190 s, similar high values of
cleavage probability are computed for both the HAZ and BM regions. In Fig. 10.14, the clea
vage probability curves are compared with strain gauge data recorded during the test at gau
ges SG1SG3, which were located on the inner surface of the cylinder ahead of defect R. The
strain gauge readings showed a "step" change in the surface strain at t = 217 s into the tran
sient, which was interpreted as signalling a cleavage event at that end of defect R. The clea
vage probability curves are consistent with that interpretation of the strain gauge data. The
extent of precleavage ductile tearing predicted by the Rousselier model (approximately 1
mm) was substantially less than the tearing observed in the fracture surfaces.
1 ,
08
0 7
n s
0 5
0 4
0 3
0 2
0 I
;
Combined probability of
cleavage in the structure
Probability of
cleavage in base
Probability of
cleavage in HAZ
'.
/ " " " "
\X xi
^C-' ' /
y . - - \ /.
"; / / 7
V
0
/ /
" /
Defec
' s s s
11
50 100 150 200
Ti me s
250 300 350 4
9 . 0 0 0
7, 000
5 , 0 0 0
3, 000
1.000
X)
c
'n
o
S

Fig. 10.14: Probability of
cleavage fracture for
defect R generated by
the local approach
analysis.
109
H S E
M C O P
I * L _ . \ J O
Position 1 Position
Defect B: Hoop Stresses in Cladding
CO 600
Q.
en
</) 400
0J
k.
4-"
J/) 300
Q.
O 200
o

too (b)
jyocu^- Position 1
8 Position 2 \
* \
>
N
\
\
V \
% \
\
\
. .
V
\ l
-
-
;

. 1 . . .
0 200 400 600 800 1000 1200 1400
Time (sec) 07/02/99.K1 ptw
Defect B: Plastic Strains in Cladding
Position 2
* . *
200 400 600 800 1000 1200 1400
Time (sec)
07/02/99.K3 ptw
Fig. 10.15: Evolution of hoop stresses and effective
plastic strain at two positions in cladding over the
large sub-clad defect.
10. 4. 3 St ruct ural Assessment of t he
Local Cl addi ng Fai l ure
Two positions in the cladding above sub
clad defect B were studied to assess the
potential for failure of the cladding during
(and after) the transient [10.8]. These are
shown in Fig. 10.15a. where position l
corresponds approximately to the mid
plane of defect B and position 2 is located
near the intersection of the flaw front with
the cladding. The time histories of the cir
cumferential stress and effective plastic
strain in the cladding at these two positions
are plotted in Figs. 10.15b and c, respecti
vely. Beyond approximately 900 seconds
into the transient, the hoop stresses at both
positions become compressive. The high
stresses at position l produce high levels
of plastic straining that level off at
approximately l l % after the peak stress
has passed. A cooldown period was
applied to take the cylinder to 20 C. The
resulting residual stresses produced the
increased plastic straining from 1200 to
1300 seconds shown in Fig. 10.15c. The
analysis indicates that the cladding above
defect B experienced very high circumfe
rential stresses and high levels of plastic
deformation during the test. For the clad
ding above the deepest point of the defect,
these stresses were sufficiently high to pro
duce conditions for plastic collapse and
rupture. These calculations are consistent
with the extent of deformation and failure
actually incurred by the cladding over
defect B during the experiment, as descri
bed in Chapter 8.
10. 4. 4 Cr ack Arrest
Although the focus of the NESCI project
has been on validation of a failure preven
tion concept based on avoidance of fracture
NO
HSE
Health Sulet
M C Q P
I *~.\_>0
initiation, the spinning cylinder test result can potentially serve as a benchmark for crack
arrest assessment [10.15]. This complementary approach to integrity is particularly useful for
nuclear applications where additional assurance is required and localised inservice embrittle
ment may occur. To allow for this possibility, a series of crack arrest tests were included in
the materials characterisation program as described in Chapter 6. This led to the determina
tion of the crack arrest fracture toughness K
Ia
as a function of temperature in the range
between ambient and 100 C.
The NESCI K
la
data were used by TWI in posttest analytical studies [10.16] of the cleavage
initiation/arrest event observed at one end of defect R. These were aimed at:
comparing stressintensity factors (SIFs) computed around the front of defect R in its arre
sted configuration with the measured crackarrest toughness;
evaluating results in the context of factors such as dynamic and/or scale effects, testing pro
cedures and modelling assumptions.
Threedimensional finiteelement models of both the initial and arrested configurations of
defect R were analysed with the appropriate rotational and thermal shock loading applied at
the time of the cleavage event (i.e., 217 s into the transient). From analysis results, it was
determined that dynamic effects on K, values for the run/arrest event were not significant,
because the new surface created by crack extension was very small in comparison to the un
cracked area. These findings justified use of static SIFs as the driving force parameter for
crack propagation, and static planestrain crackarrest toughness as the resistance parameter
for crackarrest evaluations. Figure 10.16 depicts K| versus distance from the inner surface
computed for the initial and arrested configurations of defect R at time t = 217 s, as well as
the 5 and 95percentile curves for the measured K
Ic
and K
l a
data for the base material.
. ._-
. . .
5
95
Kj
Kj
S'A
95
K l a
Kla
Initial Crack
Arrested Crack
K l c
Kl c
KJ(or da
KJ(or da
= 0.2mm
: 3mm
TIP OF THE ARRESTED
FINGERNAIL SHAPED
CRACK
Fig. 10.16: Variation of
crack driving force over
the initial and arrested
profiles of defect R at
217 seconds, compared
with the base material
fracture initiation and
arrest data.
Distance from the Inner surface (mm)
I I I
H S E
Health & Sufr
MCOP
Applied SIFs were reduced significantly for the lobeshaped arrested crack that developed
from the initially semielliptical surface crack during the localised cleavage propagation. At
the cleavage initiation site, i.e., 16.5 mm from inner surface, the relevant K, values fall inside
the range of measured crackarrest toughness. Thus, a reduction in crack driving force is the
most likely reason for cleavage arrest of the running crack.
10.5 FACTORS INFLUENCING DEFECT ASSESSMENTS
Characteristics of the thermalmechanical loading conditions applied to the cylinder by the
spinningcylinder rig were such that the highest probability for extension of the large flaws
was in the complex nearsurface region. Analyses within that region presented significant
challenges to fracture assessment methodologies due to modelling complexities associated
with flawtip constraint, effective crack front width, gradients in material and fracture tough
ness properties, warm prestressing effects, cladding effects, crack arrest, as well as residual
stresses. The potential influence of these factors is briefly assessed in the following.
10.5.1 Constraint Effects
Constraint is a key factor in the transferability of fracture toughness data generated on stan
dard specimens to defects in actual components. The conventional approach of applying frac
ture data relevant to plane strain (i.e., high constraint conditions) may introduce an unneces
sary level of conservatism in many situations. Threedimensional finite element analysis
offers the possibility to calculate additional parameters designed to quantify the local level of
constraint around the defect boundary, and so help bridge this gap.
In analysing defects R and in the NESC cylinder, several teams have assessed the level of
constraint using the parameters Q and H. The Q parameter quantifies the departure of crack
opening stresses ahead of the crack tip in a finite body from those corresponding to small
scale yielding (SSY) under the same (J) loading conditions. The parameter describes the
stress triaxiality ahead of the crack tip in a
finite body relative to that predicted under
SSY conditions.
i.o
0.5
0.0
o
1.0
; |
. 1

I
! '
-, 1
. y
[
:// 1
d
HAZ Q
.
Clad
SSY solution
^ ^
' _____ :
' '
~
Surface crack:, t = 240 s \
30
5
, O
60 50
Fig. 10.17: Variation of constraint parameters and
Q along the boundary of the large thrcugh-clad
defect, showing the area of loss of constraint close
to the surface
Figure 10.17 (from Ref. 10.12) depicts the
variation of the constraint parameters
around the boundary of the large through
clad defect R, indicating that the lowcon
straint region extends just beyond the
HAZ/BM interface. That prediction is rea
sonably consistent with the observation
that no cleavage initiation occurred close to
the HAZ boundary in either of the defects
R and B, although it would have been
expected from computed failure probabili
112
HS E
Health & Safen
k I C O p
ties based on deep-notch fracture toughness data. The cleavage event that occurred in defect
R at a location 16.5mm below the inner surface of the cylinder (at the narrow-HAZ side) may
be explained in terms of high-constraint fracture toughness data. Since the constraint parame-
ters are close to SSY conditions at this location, constraint loss is unlikely to have influenced
the defect behaviour. The absence of a cleavage event at the other side of defect R, i.e., at the
wide-HAZ side, is likely to have been due the higher toughness of material in that region (see
section 10.5.3 below).
10.5.2 Effective Crack Front Width
Predictions of cleavage fracture described earlier in Section 10.4.1 relate to the Master Curve
characterisation of fracture toughness behaviour based on 25 mm-thick test specimens. Thus,
the applications implicitly assumed that fracture behaviour at different locations around the
circumference of defects R and conformed to a crack-front width of 25 mm. Implications
for that assumption were examined for the location at defect R corresponding the cleavage
initiation site [ 10.6]. The study demonstrates an influence of assumed crack-front length on
the predicted cleavage probability. A reduction from 25 to 10 mm leads to a decrease of
approximately 20% in probability from 0.97 to 0.77 based on high-constraint deep-flaw (BM-
DN) data. The is approximately 15 percent if the fracture toughness model is based on shal-
low-flaw (BM-SN) data, from 0.23 to 0.09. At the deepest point of defect R, an increase in
the effective crack front width from 25 mm to 200 mm produced a small increase in the pro-
bability of cleavage. It has been postulated that the combined influence of an increased effec-
tive crack-front width with a local reduction in crack-tip temperature could explain the small
cleavage facets observed in the fracture surface near the maximum depth region of this defect.
10.5.3 Gradients in material properties
The fact that defect R did not initiate in cleavage at the wide HAZ end, although it was pre-
dicted to do so prior to t = 311 s, cannot be explained satisfactorily either in terms of reduced
crack-tip constraint at that location compared with position X, or by the modest reduction in
the driving force due to the increased HAZ thickness. Instead the absence of a cleavage event
is thought likely to be linked to the fact that even below the HAZ, the toughness will decrease
gradually back to the nominal base material level. Where the HAZ is deepest, this region
could have extended over the region in which a cleavage event was anticipated. Post-test exa-
minations confirm that the base material hardness was modified to a depth of approximately
10 mm below the visible HAZ boundary (Fig. 10.18).
10.5.4 Evidence For Warm Pre-Stressing Effects
In PTS analysis of RPVs, WPS effects refer to the delaying of cleavage initiation in the latter
stages of the transient during which both the crack driving force and the temperature are
decreasing. Since the NESC-I test was designed to achieve a cleavage event at the large
defects, care was taken avoid WPS by choosing a lower starting temperature and by accelera-
ting the spin velocity at an appropriate moment to maintain an increasing crack driving force.
113
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Itti & Sufi1 >
M C O p
A508 Class 3 base material
15 20 25
Distance (mm)
Fig. 10.18: Post-test measurements of the variation in hardness in the sub-clad material.
KJc (Base 5%)
KJc (Base 9 5
[
i )
KJc BASE Shallow Cri. (5%)
KJc BASE Shallow Cht (95%)
KJ t or. \ a = 0.1
KJ (Ot \ a = 0 5
KJtor.sa = 2 0
KJ for 3 = 3 0
21 Def ect B (Base Material)
17 Del ect R (Base Material)
150
Temp. (C)
250 300
01.15.^9 K2ptw
Fig. 10.19: Comparison between defects R and
of applied crack driving force paths within the base
material 70 mm from the inner surface.
The fact that the desired cleavage event
was achieved at the large throughclad
defect R shows that WPS effects were
absent (or not significant) at that position at
the moment of initiation. Therefore, the
assessment of the role of WPS was limited
to areas where no cleavage occurred, i.e. in
the BM of the cylinder wall located away
from the HAZ/BM interface. In Fig. I0.19,
curves of crack driving force versus crack
tip temperature are compared at similar
positions within the base material for
defects R and B. The applied values are
shown to peak (at a high temperature) well
before reaching the point of intersection
with the 5% cleavage fracture toughness
curve. Since the driving forces after this
point are decreasing with decreasing tem
perature, WPS effects would preclude sub
sequent cleavage initiation.
114
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Health & Safe
fvicrop
10.5.5 Cladding Effects
In terms of structural analysis, the cladding is important in several ways:
The severity of the PTS can be diminished on account of the lower thermal conductivity of
the austenitic clad with respect to the ferritic BM.
Beneficial warm prestressing effects (WPS) are more likely since the crack driving force
reaches a maximum at a higher temperature.
The presence of cladding above subclad defects can mechanically impede their opening.
The clad residual stresses arising from thermal mismatch can influence the driving force
estimates.
For many codes and standards assessment procedures, the cladding mechanical properties
cannot be taken into account, however the overall assumed defect depth must include the
clad thickness. For small subclad defect this can be a significant penalising factor..
The effect of the cladding to reduce the heat transfer to the base material of the NESCI cylin
der was demonstrated by thermal analyses of clad and unclad models. At the critical HAZ/BM
interface at 217 seconds into the transient, the model that incorporates the clad predicted a tem
perature 30 C higher than that of the unclad cylinder [10.8]. The latter result can be linked
with the WPS effect. In Ref. 10.8, crack driving force curves were computed for the large sub
clad defect simulated firstly as a throughclad flaw and then with an intact clad layer. The
presence of the intact clad produced a clear upward shift in the temperature at which the driving
force peaks, potentially allowing WPS to come into play.
With regard to point (c), defect has been
simulated as both a through and subclad
flaw to quantify this beneficial influence of
the cladding on crack driving forces in the
nearsurface region. As shown in Table 10.5,
an intact cladding above defect reduces
the local crack driving forces by up to 24%,
thus reducing the probability of cleavage.
en
; 600
1 o
200

- 0
D
CLAD
- . . . . -
BASE MATERIAL
\
\
\
. " " " " " *~ . . M
Pre-lest
PosMest
Position relative to cladbase interface, mm
Fig. 10.20: Cladding residual stress in the pre-test
and post-test condition.
10.5.6 Residual Stresses
The presence of residual stress can be a cri
tical factor in assessing the behaviour (and
Table 10.5: Comparison of crack driving forces for defect analysed as a sub-clad and through-clad
defect.
Location
4 mm from surface
9 mm from surface
22 mm from surface
Peak Kj at defect, MPaA/m
Sub-clad
250
365
285
Through-clad
310
425
300
% difference
+24%
+16%
+5%
115
M NESC
, ,, & Na i i - l ,
also detection) of under-clad cracks in RPVs. At the manufacturing stage, a clad vessel typi-
cally experiences a final PWHT at a temperature above 600 C for about 20 hours, which can
effectively release the cladding residual stresses. However, due to significant differences in
thermal expansion coefficient and mechanical properties of the cladding and the BM. new
stresses are created during the cool-down to the ambient temperature. In the case of the NESC-
I component, the post-clad stress relief treatments were performed at a somewhat lower tem-
perature of 550 C. Also, there was some doubt as to the presence of additional residual stres-
ses arising from the welding together of the two (SC4 and SC6) cylinder halves, although it is
expected that these would have been dissipated during the stress-relief heat treatments.
The above factors prompted residual stress measurements to be performed using the well-known
ring core method on the inner surface of the cylinder, both before and after the test [10.17].
Figure 10.20 compares the stress profiles generated. The pre-test data imply tensile stresses on
the order of the yield stress in the cladding and a steep gradient to much lower levels in the base
material. After the PTS transient, the stresses in the cladding are seen to be reduced to a low level.
A number of the TG3 teams examined the effects on the driving force values of varying the level
of residual stresses for the large through-clad defect R. Only the lateral, sub-HAZ position was
considered, since the effects at the deepest point are negligible. For simplified analyses based on
un-cracked body finite element analyses, the peak driving force values were increased by less
than 10%. In the case of full 3-D simulations, the increased was even less pronounced in the cri-
tical region of the transient. It was concluded that, at least for the large defects present in the
NESC cylinder, modelling of the cladding residual stresses had a small effect on driving force.
10.6 SENSITIVITY ANALYSES
The results of stress and fracture assessment procedures are recognised as being sensitive to
variations in a wide range of parameters. The influence of the most important of these were
studied as part of the TG3 pre-test and post-test analyses [I0.18]. The objective was to quan-
tify how variations in fracture assessment input data could impact the results, especially pre-
dictions for crack driving forces and transient times for cleavage initiation events.
10.6.1 Mat eri al Fracture Toughness
The material fracture toughness appears the single largest source of uncertainty in fracture
assessments such as the NESC-I spinning cylinder. This is well demonstrated by the results of
the sensitivity analyses for the large sub-clad defect B, as summarised by the comparison of
the crack tip driving force - time trajectories in Fig. 10.21, together with the 5% and 95
c
/c
cleavage probability curves. The overriding importance of this factor has also been confirmed
in a series of parametric calculations performed to determine how variations in crack depth
and reference temperature RT
NDT
affected the critical temperature for onset of cleavage.
Variability in material toughness properties was simulated by using values of RT
NDT
( C.
86 C and 116 C) that correspond to the upper, mean and lower bounds to the fracture tough-
ness data set at the 68 J level. The variation in predicted value of temperature for cleavage
along the transient path is approximately 1 1 % for the all the defect sizes considered.
116
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Health X Sa fi-1
cop
10.6.2 Defect Sizing
The above parametric sensitivity study also considered the role of variability in defect size
using upper and lower bound values of crack depth based on inspection results for the rele-
vant defects. The sensitivity of large defects to possible errors in defect sizing is relatively
low (see Table 10.6) and has been confirmed by 3-D analyses.
10.6.3 Detailed modeling of the sub-clad HAZ
Modelling the mechanical properties of the HAZ is found to reduce the calculated crack dri-
ving force in the sub-surface region by about 10%. but, as would expected, has no effect on
KI at the deepest point of the large defects where the behaviour is governed by the based.
The depth of the HAZ also varies from 5 to 10 mm at the cylinder inner surface. In Ref.
[10.8] this aspect was considered in regard to the large through-clad defect R, whereby one
end of the defect was at a minimum HAZ depth position and the other at a maximum (Fig.
10.10(a)). The larger HAZ produced a 3-4 percent reduction in peak driving force. As noted
above, the larger HAZ was also associated with a relatively higher toughness below the
HAZ/base material interface that possibly preclude cleavage initiation at one end of defect R.
Elapsed Transient Time [sec]
Fig. 10.21:
the middle
different 3-
Comparison of the crack driving force at
of the cladding HAZ obtained from
D FE analyses.
10.6.4 Heat Transfer Coefficient
Two independent studies have shown that
reducing the heat transfer coefficient by up
to 50 percent does not significantly
influence the crack driving force and the
crack tip temperature during the transient.
This result was of particular relevance since
the pre-test predicted temperature distribu-
tions are slightly more severe than those
recorded by the test instrumentation.
However, post-test analyses conducted with
heat transfer coefficient values that were
reduced to match the test temperature profi-
les produced only modest variations in
crack driving force.
Table 10.6: Effect of varying defect size of the predicted cleavage temperature.
NDE Upper Bound
84
26
17.5
9.5
NDE Lower bound
76.5
9.5
9.5
7
NDE Best estimate
80.7
21.3
14
7.9
Predicted variation in T
c
.
Bavage
negligible
8%
3%
< 1 %
117
ski NESC
10.6.5 AnalysistoAnalysis Variations
The outcome of any fracture assessment can be influenced by socalled soft factors:
different software packages and associated solution algorithms:
human judgement related to the modelling assumptions and interpretation of the results.
The significance of such variability can be difficult to assess and the causes are generally dif
ficult and timeconsuming to identify. The NESCI pretest analyses offer a useful benchmark
in this respect, in that a number of teams analysed a welldefined problem. While the thermal
and stress analysis results proved highly compatible (see Figs. 10.3 and 10.4), the estimates
of crack driving force contain a substantial degree of variability (Fig. 10.610.8). A large part
of this can be attributed to differences in the assessment procedures i.e. as the complexity
increases from simplified engineering methods to complex 3D finite element analysis, the
conservatism is reduced and the peak crack driving forces systematically decrease.
Comparisons among the 3D analyses have been done on the basis of the peak driving force
at the HAZbase material interface for the surface braking defect, R. The average value is 271
MPa.Vm, with a standard deviation of approximately 18 MPa.vm (corresponding to 7% of the
mean). Such variation is comparable with results obtained from international benchmarking
activities. However, it also indicates that scope for improvement exists in this area and that
the expertise and experience of the analyst is a critical factor in ensuring reliable results.
REFERENCES
[ 10.1 ] S. Bhandari et al.. Thermal and Structural Analysis: Final Report. NESCDOC TG3 (99).
[10.2] S. Bhandari et al.. Designing for Crack Growth in NESCI Spinning Cylinder. ASME PVP Vol. 362.
pp. 243250. July 1998.
[10.3] J.H. Fokkens and D. Vonka, NESCI PostInspection PreTest Analyses, NESCDOC TG3 (99) 01.
[10.4] J. Sievers et al.. German fracture mechanics pretest analyses on the NESC cylinder. ASME PVP Vol.
362. pp. 289296. July 1998.
[10.5] J.A. Keeney et al., Pretest Fracture Evaluation of the NESCI Spinning Cylinder Experiment. ASME
PVP Vol. 362. pp. 253260. July 1998.
[ 10.61 John S. Schofield and David I. Swan. Probabilistic assessment of the NESCI spinning cylinder expe
riment. NESCDOC TG3 (99) 06.
[10.7] I. Hadley (TWI). D.P.G. Lidbury & A.H. Sherry (AEA Technology). Interpretation of Results of NESC
1 Spinning Cylinder Test: Assessment of Shallow Crack Effect Final Report. NESCDOC ETF (99) 10.
[10.8] B.R. Bass et al.. Effects of Cladding in the NESCI Project. NESCDOC ETF (99) 14
[10.9] H. Keinnen. "Posttest analyses of NESCI experiment". Report VALC556 revl. March 1999
(NESCDOC TG3 (99) xx)
[10.10] D. Siegele et af. Post Test Analysis of NESC 1 Spinning Cylinder Experiment. Defect B. Fraunhofer
IWM Report 2/2000. February 2000
[10.1 1 ] T. Schimpfke and J. Sievers. Pretest Fracture Analyses of the NESC Spinning Cylinder Test. NESC
DOC TG3 (97) 2.
[10.12] I. SattariFar and L. Dahlberg. 1998. "Pretest fracture assessment of the NESCI spinning cylinder
under a PTS transient". Int. Jour. Pres Ves & Piping. Vol. 75. pp. 203212.
HSE mop
[ 10.13] . Wallin. R. Rintamaa and U. Erhnsten. Consistency of Fracture Assessment Criteria in the NESC-I
test. NESCDOC ETF (99) 35.
[10.14]A.H. Sherry et al., The Application of Local Approach to Predict the Outcome of the NESC
Experiment. ASME PVP Vol. 365. pp. 75-84. July 1998.
[ 10.15] R. Gillot and C. Wiesner. "Crack Arrest" NESCDOC ETF (99) 08.
[10.16] W. Xu, J.B. Wintle. CS. Wiesner and D.G. Turner. "Evaluation of Stress Intensity Factors for NESC-
I Defect R. at Crack Arrest". TWI Report No. 12554/1/00, February 2000.
[ 10.17] E. Keim. "Residual Stress Measurements". NESCDOC (99) 21.
[10.18] I. Sattari-Far et al.. "A Sensitivity Study on the Fracture Analysis of the NESC-I Spinning Cylinder
Experiment" NESCDOC TG3 (99) 09.
119
H NESC
1 1 ,. . Il li . . Sfrl%
11 INTEGRATED ASSESSMENT
11.1 ELEMENTS OF THE INTEGRATED ASSESSMENT PROCESS
The central concept of the NESC-I spinning cylinder project was to evaluate the entire pro-
cess of structural integrity assessment of a thick cylinder containing defects. It was postulated
that future service would subject this cylinder to a severe thermal shock while loaded by pri-
mary stresses at the same time. The process of assessment followed that which would occur
in practice for a component of real nuclear plant where cracking was postulated or suspected.
This involved the following steps:
Detecting, locating, characterising and sizing the defects by NDE
Establishing the relevant material properties
Defining the limiting loading conditions
Calculating the relevant stresses and fracture mechanics parameters
Determining the acceptability of the defects according to existing codes and standards
Predicting the growth behaviour of the defects under thermal shock loading and the margins
to catastrophic failure of the cylinder.
A level of realism was achieved by the fact that knowledge of the geometry and sizes of the
defects in the cylinder was deliberately withheld from both the inspection teams and the
assessment analysts. The assessment by the analysts was made on the basis of the defect data
measured by the inspection teams under blind trial conditions. Analysts had therefore to inter-
pret the inspection data for the purposes of assessment. This interaction between assessment
analysts and inspection teams was a unique feature of this project.
The assessment process brought together the particular information that was known about the
defects, material properties and loading conditions for the purposes of determining the accep-
tability of the defects and predicting their behaviour.
11.1.1 The assessment conditions
The process of structural integrity assessment of defects within this project was by necessity
undertaken under somewhat idealised conditions compared with those which might occur in
practice. It therefore represents the limits of what is achievable under the conditions where:
Time pressure is not a limiting factor
Data from multiple inspections is available
Detailed materials data is available
The component is not irradiated
The loading conditions are well defined
The assessment process up to the test took place over a period of approximately three years
between 1994 and 1997. This allowed a full understanding of the problem to be gained, detailed
120
NESC
analytical models to be developed, and a comprehensive database of material specific properties
to be compiled. In practice, many structural integrity assessments have to be performed within a
few weeks during an outage where there is pressure to reach a decision based on limited data.
Before the test, the data about the defects obtained from eight inspection teams were made availa-
ble for the assessment. It should be recognised that the inspections were undertaken under condi-
tions somewhat different to those typically encountered in practice. Although two weeks was
allowed for the inspections, it appeared that many teams experienced time pressure in completing
the sizing of the indications detected due to the relatively large number of defects present in the
cylinder. It was therefore concluded that the length of time allowed was not a particularly benefi-
cial factor. Manual access to both inside and outside walls was permitted which is not always the
case with irradiated components in-service. The cladding would normally tend to make the
inspection of sub surface defects more difficult compared to unclad components. Unlike the clad-
ding of many reactors, the surface of the clad cylinder had been machined to a good finish and
this would have benefited the inspection. Despite this, the assessment teams had to consider seve-
ral sets of inspection data where there were significant differences in the estimated sizing.
In practice, knowledge of the fracture toughness of irradiated reactor pressure vessel material
may depend on relatively few test specimens. In contrast, many tests had been carried out on
the NESC-I cylinder, and the knowledge of the material properties, whilst never perfect, was
nevertheless very good. In particular, the Charpy and fracture toughness temperature transi-
tion properties of the base material were well defined and could be reasonably assumed to be
homogeneous. In an irradiated vessel where there is through wall attenuation this cannot be
assumed. The representiveness of the NESC-I cylinder condition to the fracture toughness in
the beltline region of an operational RPV has been assessed based on US data. If the RT
NDT
parameter is set to 50 C. the resulting mean K
lc
. curve intersects the master curve at 60 C
and a mean K
Jc
of 100 MPa.vm. Based on a sampling of 4 US domestic PWRs. such an
RT
NDT
value would correspond to approximately 50-60% end of Licensing period, typically
32 effective full power years [11.1].
In the NESC-I experiment, the loading conditions could be well controlled and were therefore
more predictable than in many plant situations. The performance of the equipment was determi-
ned in advance during the rig trials, and the instrumentation installed was able to measure the
relevant speeds and temperatures during the test. Despite limited water ingress into defect R
during the early part of the test, the test transient could be determined with considerable accuracy.
When considering the use of code and standards to assess defects in plant, it should be borne
in mind that the near ideal conditions described above do not always prevail in practice.
Conservatism within the codes to allow for uncertainties should therefore be expected.
11.1.2 Codes and st andards assessment s of def ect accept abi l i t y
Defects found during manufacture or operation are normally assessed using the rules of the
appropriate national design or defect assessment code. These rules are designed to provide
conservative results to ensure that adequate safety margins to cover uncertainties are maintai-
121
HS E
ned in service. However, it is important to understand the actual levels of conservatism in
these code-based defect assessment procedures, and to appreciate that they are not suited for
making best-estimate predictions.
The NESC-I experiment provided an opportunity to compare code-based assessments with
the behaviour of real defects and the results of best-estimate analytical procedures. As part of
the post-test assessment process, Task Group 3 used national codes to assess the maximum
size of defect that could be allowed in the NESC-I cylinder if it were a safety critical nuclear
plant component. Detailed results of the assessment are reported in Refs. 11.4 and 11.5.
Comparisons of the code applications were based on data submitted by the contributing orga-
nisations, and not on detailed comparison of the specific codes. Thus, the results reflect varia-
tions not only in the codes themselves, but also in the judgement of the participating analysts
and limitations of the available analytical tools. The results summary presented in Table 11.1
indicates that all the analyses predicted very small limiting defect depths.
Either explicitly or by implication, all code analyses categorised all defects detected in the
cylinder as unacceptable if they were to occur in a safety critical nuclear plant component.
Only very small defects with depths in the range of 1 to 9 mm deep were found to be allowa-
ble by the code assessments. Future service of the cylinder, if it were a nuclear reactor pres-
sure vessel containing any one of the defects, would therefore not be permitted without
further assessment or repair.
11. 1. 3 Evaluation of codes and standards assessments
When the cylinder was subject to the thermal shock only the larger defects exhibited limited
growth before arresting. Unambiguous crack growth occurred at the two largest defects, which
were in excess of 70 mm deep and 200 mm length; crack extension was limited and ended in
crack arrest. None of the other smaller defects showed any significant growth. Clearly, the
Table 11.1: Critical defect sizes predicted by a range of assessment codes for the NESC-I cylinder and
test conditions.
Code
R6
SKIFS 1994:1
KTA
ASME Section XI
PD6493:1991
RCCM
Limiting defect depth
1.8 mm (maximum depth point)
6.8 mm (surface point)
1.2 mm (normal/upset rules)
5.7 mm (emergency/faulted rules)
3 mm (no warm pre-stress effect)
9 mm (warm pre-stress allowed)
14 mm (no safety factors, no WPS effect)
1.2 mm
1.5 mm
2 mm
<1 mm
Fracture Toughness Data Applied
NESC-I deep crack 5% failure probability lines for
HAZ (surface point) and base (max depth)
K| based on RTNDT=101 C; K,
a
max
is 220 MPa^m
Base material shallow flaw 50% failure probability
with safety factor
ASME K
IC
(emergency/faulted), RT
NDT
=115 C
NESC-I deep crack 5% failure probability lines for base
material
NESC-I deep crack 50% failure probability lines for base
material
K|
C
from RCCM code with RT
N0T
=101 C.
I22
HSE NESC
M. . l i t. .C Snf cl
code assessments appear to be conservative when compared with the actual defect behaviour
during the NESC-I test. This observation demonstrates the margins that exist within the whole
assessment process in terms of the treatment of the basic input information within the metho-
dology and the inherent and explicit safety factors. If the cylinder had failed as a result of one
or more of the large defects, the codes would still have been said to be valid, but conservative.
The range of sizes for the smaller defects covered in this experiment showed the insensitivity to
this parameter under the conditions of the experiment. On the contrary, some assessments pro-
duce allowable crack sizes below the limits of detectability. It might be suggested from the test
result that present inspection targets are therefore more than adequate. Before this conclusion
can be drawn, it is necessary to understand the reasons for the high degree of conservatism in
the code-base assessments in terms of the other variables. In Ref 11.5 these were divided into
conservatism in crack driving force predictions and conservatism in material response.
ConseiTcitism in crack driving force predictions
Two major sources in this category were given: the handling of secondary stresses when
extensive plastic flow occurs, and the flaw model used.
Any method that uses elastic analysis to estimate thermal shock stresses is liable to overesti-
mate their contribution to crack driving force under the conditions of the NESC-I test. In
practice, however, an elastic analysis is much easier to carry out and interpret than any ela-
stic-plastic treatment and is usually the first option in any assessment. Some code asses-
sments linearise the non linear elastic secondary stress field and this can further over-esti-
mate the stress in the near surface regions.
Most code assessments assume that sub-clad flaws are surface breaking and generally
ignore the presence of the cladding. For large sub-clad defects, the cladding ligament has
virtually no effect on the crack driving force at the maximum depth point and there is little
effect of applying more complex approaches. In the near surface region, the effect of the
cladding ligament is to reduce the crack driving force, making both standard code asses-
sments conservative. For smaller sub-clad defects, standard code assessment methods
become very conservative compared with cracked-body analyses. The assumption in codes
that cladding is ineffective in cleavage fracture has been shown by the NESC-I experiment
to be manifestly untrue. The NESC-I cylinder contained two defects (B and R) of the same
size, but one was sub clad and the other through clad. Under conditions of identical loading
and temperature, through clad defect R was observed to undergo a limited amount of clea-
vage fracture whereas sub clad defect B showed no signs of cleavage.
For large surface-breaking defects that breach the cladding, standard assessment procedures
such as R6 provide a good estimate of the crack driving force at the maximum depth point.
There is little advantage in using more sophisticated methodologies such as cracked-body
analysis. At points on the crack front near the near the surface, however, standard code asses-
sments become unrealistic and possibly overly conservative. This is mainly due to the simpli-
fied methods and solutions used for estimating the crack driving force combined with the ela-
stic and idealised treatment of the secondary stresses.
123
si i NESC
The two main issues are given as the selection of a fracture toughness reference curve and the
treatment of complex material response factors, for example, constraint.
Most code assessments deliberately use lower bound fracture toughness data, either as measured
5 percent failure probability curves or as a lower bound design curve. Some codes then apply
additional safety factors on the lower bound data. The effect of these measures is to create mar-
gins for acceptability that ensure that the failure probability is extremely low. Modern approa-
ches to the probability of cleavage fracture provide a better understanding of these margins.
Additionally, codes apply RT
NDT
temperature as a reference temperature. The NESC investiga-
tions showed that this parameter is poorly suited for indexing fracture toughness data.
One of the reasons for the very small acceptable defect depths calculated by the code asses-
sments is the possible "cliff-edge" in fracture toughness caused by the fall in temperature
near the inner surface. Even though the driving force falls for small defects, the toughness
falls even faster, and it can become difficult to show that any size of defect is acceptable.
The level of conservatism in the code assessments increases as the defect depth decreases.
The high variability in the cleavage fracture toughness, its sensitivity to small changes in
temperature, and the statistical nature of cleavage fracture mean that a relatively small shift
in the temperature can produce a large change in the susceptibility of defects to cleavage
fracture and arrest. In reality, the temperature margins before the cliff-edge of cleavage frac-
ture are much larger than the code assessments would indicate. The driving forces are lower
than predicted and the material fracture resistance in the near surface regions is likely to be
higher. Constraint effects and the enhanced fracture properties of the cladding heat affected
zone are difficult to quantify and are generally ignored in code assessments. They influence
shallow defects and the near-surface region of large defects and make cleavage fracture less
likely but to an extent that is difficult to quantify
The NESC-I experiment does not allow any conclusions to be drawn about the exact level of
conservatism in code assessments of shallow defects. No unambiguous crack growth occurred
from the embedded defects, and no shallow through-clad defects were present. However, the
experiment has supported the view that margins for integrity are best addressed by quan-
tifying the variability in material response rather than imposing ever-tighter requirements on
the detectability and sizing of flaws.
It was not possible within the scope of the project to investigate experimentally the sensitivity
of fracture behaviour to temperature. This would have required a number of tests to have been
carried out at different temperatures. In practice, it will require greater confidence in the
material response, by for example statistical treatments, to enable the current stringent requi-
rements for the inspection to be relaxed.
11.1.4 Inspection results prior to the thermal shock in relation to code assessments
Seven teams inspected the NESC-I cylinder before the test with the view to detecting and
sizing the defects without prior knowledge of them. The cylinder contained 17 defects of
varying sizes at the time of the pre-test inspection. The large through clad defect R was added
after the pre-test inspection, and was detected by all teams in the post-test inspections. For the
124
M NESC
M, ,, .C Sari-I;
purposes of assessing inspection performance in relation to codes and standards assessments,
14 of the pre-test defects and 15 defects post-test were considered. A detailed analysis of the
results of the inspection trials is given in Chapter 9. It can. however, be noted that:
five of the seven pre-test ultrasonic inspections achieved 100% defect detection rate, while
the other two inspections achieved detection rates of 86% (two defects missed out of 14)
and 719c (four defects missed out of 14)
eight of the ten post-test ultrasonic inspections achieved 100% defect detection rate, while
the other two inspections achieved detection rates of 87% (two defects missed out of 15)
and 73% (four defects missed out of 15)
all defects greater than 13.5 mm in through wall extent were detected. By implication the
defects that were missed by a small number of teams were all less than or equal to 13.5 mm
and greater than 2.5 mm in through wall extent
These results are considered to be typical of the current limits of inspection performance
achievable under idealized conditions. However, only very small defects with depths in the
range of 1 to 9 mm deep were found to be allowable by the code assessments. There is the-
refore an apparent gap in terms of the defects that have been detected with 100% reliability
and those that would be allowable by code assessments within the context of this project.
11.1.5 Crack Arrest
In the spinning cylinder test, the large surface breaking defect (R) grew by ductile tearing,
reverted to sideways cleavage extension, and finally arrested in a stable condition. The arrest
of a pre-existing flaw after relatively small amounts of growth in a large-scale component test
has potentially beneficial implications for the safety cases of nuclear reactor plant under com-
parable conditions. It is important, therefore, that the reasons for crack arrest are fully under-
stood in this case so that the theory can be applied elsewhere.
The currently accepted theory is that a cleaving crack will arrest when the crack driving force
of the moving crack front falls below the crack arrest toughness of the material. Strictly
speaking, a dynamic analysis is required, but for small relative dimensions, static computa-
tions of crack driving force have been shown to be appropriate. The results from the spinning
cylinder test can be used to verify the theory of crack arrest and assess whether crack arrests
are predictable. To do this, the stress intensity factor around the front of the extended
through-clad defect R at the time of arrest has been compared with the measured crack arrest
toughness at the appropriate temperature. The results confirm that the applied stress intensity
factor is reduced significantly for the lobe-shaped arrested crack that developed from the ini-
tial semi-elliptical surface crack as a result of the localised cleavage crack propagation. Local
change in the curvature of the defect was shown to be the main reason for this reduction since
the stress and temperature remained constant for a given depth. This reduction in crack dri-
ving force is considered to be the main reason for crack arrest.
This analysis of the NESC-I test results justifies the use of the static elastic stress intensity
factor as the crack propagation driving force parameter and the static plane strain crack arrest
125
HS E
NES(
toughness as the resistance parameter for crack arrest evaluations. The principle that crack
arrest will take place if the applied crack driving force falls below the crack arrest toughness
is supported by the test. Dynamic effects on K, values of the run-and-arrest event of defect R
are not considered important in this case, because the newly created crack surface by cleavage
crack extension is very small in comparison with the un-cracked area.
11.1.6 Assessment after the thermal shock
The project was not intended specifically to address questions concerning the acceptability of
a reactor pressure vessel for future service after a pressurised thermal shock. The stability of
defects in the event was not studied and is an area for further consideration. The scenario
could, however, be envisaged in practice where a utility might be reluctant to abandon a vessel
after a minor accident involving injection of core cooling. In this event, it is likely that a com-
prehensive inspection would be carried out to show the vessel was free of significant flaws.
The post-test inspection trials have provided valuable new data that realistic defects existing
in the cylinder or a vessel after a thermal shock can be detected and accurately sized. There
was no evidence that the compressive stresses produced by thermal shock in the near surface
regions had closed the flaws and reduced the effectiveness of the inspection. The most advan-
ced inspection techniques were shown to be able to detect and profile cleavage crack growth
that had tunnelled beneath the cladding.
11.1.7 Relevance of NESC as a single experiment
One question that could be asked of the NESC project is that it is but one experiment invol-
ving a single unique component, and therefore, how much can its results be considered to be
generically applicable, particularly in terms of modifying codes and standards? In response to
this question, it should be recalled that the NESC project is in fact a series of experiments
relating to different aspects of the whole process of structural integrity assessment. The cylin-
der and the test were but platforms around which these experiments were conducted.
For the purposes of investigating current levels of inspection performance, twelve nuclear
inspection teams examined the cylinder using a range of techniques to detect and characterise
fifteen defects of different sizes and aspect ratios. The procedures and techniques used were
typical of those for in-service inspection of reactor pressure vessels and the defects included
realistic underclad cracking and large sub clad fatigue defects. This sample is sufficiently
broad and relevant for the resulting inspection performance data to be considered by codes
and standards bodies developing future inspection policy.
For the purposes of determining the response of defects of different types and sizes to com-
bine primary and secondary stresses produced by thermal shock conditions, all fifteen defects
were tested in exactly the same way at the same time. All the defects were located within the
homogeneity of the cylinder base material with the same nominal material properties. The
singularity of the test is in fact a strength since it eliminates any potential differences if the
results were obtained from separate tests.
126
HS E NES<
The probability of fracture and the spread of fracture toughness are dependent on the length
of the defect front sampling local variations in properties ahead of the defects. A long defect
front tends to reduce the median fracture toughness and the spread about the mean. Some of
the defect fronts included in the NESC cylinder were extremely long and the results can the-
refore be argued to be more consistent and conservative with respect to small scale tests sam-
pling the same amount of material.
This is, of course, too simplistic as it is recognised that the stress and temperature conditions
varied considerably around the defect front and that in terms of defect type there was only
one large through clad defect and a large sub clad. The observations of ductile crack growth,
cleavage fracture and arrest were unique to these two defects. That growth of this type was
not observed on any of the other defects is also a significant experimental result.
It should also be borne in mind that the NESC cylinder material is one of the most highly
characterised pieces of material of all time in terms of the database of material properties that
has been obtained. The test was extensively instrumented and detailed post test examination
and metallography performed. All of this work was supervised and agreed by some of the lea-
ding structural integrity experts in the world.
Any set of experimental results in support of a theory only ever represents a datum in time
and never absolves the need to test the repeatability of the theory for different conditions. The
NESC results may only be a single though extensive datum in the rich history of evaluating of
inspection performance and fracture mechanics. It is, however, possible to have a very high
degree of confidence in the accuracy and consistency of this datum, and for these reasons, it
is a landmark experiment in the field with significance for codes and standards and the valida-
tion of structural integrity assessment.
11.1.8 Rel evance of t he NESC-I t ransi ent t o nucl ear pl ant.
The relevance of the PTS transient simulated in the NESC-I experiment was evaluated by
comparing it with generic transients studied previously during RPV integrity assessments of
real plants [1I.4]. Parameters considered included vessel geometry, fabrication processes,
material properties, transient loading and fracture assessment margins. Three specific tran-
sients were selected from evaluations of real PWR plants, including a large-break loss-of-
coolant accident (LBLOCA), small-break LOCA (SBLOCA), and steam-line break (SLB).
All computations required to apply these transients to real plant were carried out using the
French RES-M procedure [l 1.5].
The evaluation compared the crack driving force versus temperature curves computed from
NESC-I with those from the real plant transients. Results depicted in Fig. 11.1 indicate that no
crack initiation is predicted at the deepest point of a 74 mm deep through-clad crack (such as
defect R) for either the NESC-I transient or the SLB transient applied to a three-loop PWR. Also,
the comparisons show the NESC-I transient to be slightly more severe than the SLB transient.
Other analyses showed the NESC-I transient to be substantially more severe than the generic
LBLOCA and SBLOCA transients, again as applied to a PWR vessel containing a 74 mm
127
HS E
Health & Sefci
.*_/
350
300
250
tn
? 200
E
re
| 150
2"
100
50
K(T) f or SL B and NESC P TS
Kl
Kep
Kj
* - Kc5%
* Kjc50%
- - Kfc_FT[hdt87| /
/ i
- - <
50 100
150 200
T(C)
250 300 350
Fig. 11.1: Comparison of
the crack driving force
trends at the deepest
point of a 74 mm deep
through-clad flaw, where
Kj is the applied K for the
NESC-I experiment
conditions and K
cp
is the
applied K for a PWR
plant subjected to a
steam line break.
deep defect. The same methodology was applied to smaller underclad defects (with depths of
6, 16, and 26 mm) that were placed in the NESC-I cylinder, but did not initiate during the
PTS event. Large safety factors (expressed in terms of K, and K
Ic
) were calculated for all
transient loadings applied to these smaller defects.
11.2 NETWORKING BETWEEN THE DISCIPLINES
The NESC-I project has highlighted the multi-disciplinary nature of the structural integrity
assessment process. It has brought together inspection teams, materials testing laboratories,
assessment analysts and testing and instrumentation engineers within the scope of a single
project. It was necessary for all the constituent disciplines to be aware of the use that will be
made of their data in the later steps of the assessment process. An appreciation of the whole
process and its limitations and accuracy was therefore needed. In practice, communication
between the disciplines was the key to achieving this.
The project was designed to encourage this communication and increase the awareness of the
disciplines of each other within the whole assessment process. Four Task Groups (inspection,
materials, analysis and instrumentation) were created to undertake the work to obtain the
information of the first four steps of the assessment. An Evaluation Task Group was also for-
med containing representatives of each discipline and this was primarily responsible for inte-
grating the information and making the assessment.
In the beginning these groups worked largely independently. As the project proceeded, howe-
ver, there became an increasing need to find out what information was required and the use to
which the information would be put. For example, the Materials Task Group needed to know
128
HSE NESC
I l val t h . Sr, t ,
the most relevant testing temperatures. The discipline representatives transmitted this aware-
ness through the Evaluation Task Group.
Joint meetings of some of the Task Groups were held. This interaction was particularly strong
between Tasks Groups 2 and 3 (materials and analysis) and between Groups 3 and 4 (analysis
and instrumentation), and progress was made in increasing the awareness of Task Group 1
(inspection) of the work of the other task groups. For some Task Group members, this was
their first opportunity to become involved in the whole assessment process. The communica-
tion and education obtained between the different task group disciplines is an important
achievement of this project. Nowhere was this more obvious than within the Evaluation Task
Group itself.
The NESC-I project has demonstrated that structural integrity assessment needs to be a multi-
disciplinary team based process. Knowledge of the whole assessment process by specialists in
the individual disciplines is improving and at senior levels there is a much greater awareness.
For those taking part, the project has promoted this understanding. Further initiatives to
encourage interdisciplinary interaction within the assessment process would be of benefit.
REFERENCES
[11.1] Bass. R... Oak Ridge National Laboratory, private communication
[11.2] Mignot, P.. Project Evaluation Task Codes and Standards and Regulatory Aspects. NESCDOC ETF
(99) 12
[1 1.3] Smith.M.. Codes and Standards Assessments of the NESC-1 Spinning Cylinder Test. NESCDOC ETF
(99) 08
[11.4] Faidy. C. NESC-I Spinning Cylinder Tesi: Relevance for Reactor Transient Relevance. NESCDOC
ETF (99) 26
[11.5] RSE-M: In-Senice Inspection Rules for the Mechanical Components of PWR Nuclear Islands.
AFCEN. 1997 edition + 1998 addenda.
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12 CONCLUSIONS AND RECOMMENDATIONS
12.1 SCOPE OF PROJECT
NESC-I has been the first large scale project to evaluate the reliability of the entire process of
structural integrity assessment, by examining all the key components including inspection
accuracy and reliability, material properties data requirements, test measurement techniques,
and the appropriate levels of complexity for thermal/structural analysis and fracture asses-
sments. It is the first major project of the international Network for Evaluating Structural
Components, which was set up in 1993.
The project has centred on a simulated pressurised thermal shock experiment, conducted
using a unique spinning cylinder system. The experiment was designed to simulate selected
conditions associated with an ageing, flawed reactor pressure vessel (RPV) subjected to
severe pressurised thermal shock (PTS) loading. The principal aim of the project was to vali-
date the combination of non-destructive inspection and structural mechanics assessment pro-
cedures for evaluating the integrity of such an aged structure containing postulated flaws.
The test piece consisted in an internally clad, 7 tonne steel cylinder, of outer diameter 1395
mm and a total wall thickness of 175 mm. A total of 18 defects, differing widely in fabrica-
tion method, size and location, were introduced into the test specimen. The defect set was
designed to provide a challenge to both the inspection teams and to the structural/fracture
analysts responsible for designing the PTS transient. It included a range of sub-clad defects
and a large through-clad defect dimensioned in such a way that a cleavage fracture event
might be expected. The test therefore represented a far more complex (and prototypical)
situation than have prior PTS experiments.
The pre-test structural integrity analyses were based solely on defect sizes supplied by the inspec-
tion group, who had no prior access to the details of the defects present. These inspections were
conducted using a range of procedures typical of current in-service practice. Seven leading
European laboratories carried out a comprehensive material-testing programme, which resulted in
the test component becoming one of the most thoroughly characterised in the nuclear industry.
The spinning cylinder test itself was successfully performed in March 1997 and realised the plan-
ned cleavage run-and-arrest event at the large through-clad defect. All the analysts accurately
forecast the defect growth, and indeed the best prediction of the time in the transient for cleavage
fracture was within ten seconds of the actual event recorded during the twelve-minute transient.
The NESC-I test may only be a single datum for the evaluation of inspection performance
and fracture mechanics, but the number and size of the defects, the world-class inspection and
assessment teams, the comprehensiveness of the material properties database and the accu-
racy of the data give the results special significance.
It should also be emphasised that NESC-I was intended to benefit non-nuclear as well as nuclear
industries, by providing results relevant to a wide spectrum of structural integrity applications.
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For example, findings concerning the inspection process, the structural/fracture assessments, and
the synergistic relationship between these are applicable to any steel structure or component.
12.2 THE ROLE OF NETWORKING
The network approach has supported the project in a number of important ways:
a) It has provided a flexible framework for combining the expertise and experience of key
regulators, utilities, manufacturers, service companies and R&D organisations to examine
the integrated structural integrity assessment within the context of a single, carefully defi-
ned experiment.
b) The range of results provide a best estimate of the accuracy that could be anticipated from
a full-scale structural integrity assessment of an RPV in a nuclear plant.
c) Inspection and integrity assessment methods have been benchmarked against one another,
contributing significantly to better understanding of the sensitivity of the integrated process to
each controlling factor, and setting a basis for future harmonisation of codes and standards.
d) The financing of NESC-I has relied on two key elements: a) the strong support of sponsor
organisations in initiating the project and maintaining its momentum, and b) the in-kind
contribution of the network members. Against this background, it has been possible to tai-
lor the resources (which have exceeded 10 million Euro) to meet the project's demands as
these have evolved in the course of the seven-year programme.
e) The results of the project are described in a comprehensive set of technical reports dealing
systematically with the technical issues involved in the integrated structural assessment
process. These have been approved by the NESC Network Steering Committee and repre-
sent a consensus view of the findings and related recommendations.
12.3 OUTCOME OF THE SPINNING CYLINDER TEST
The NESC-I test has demonstrated that, for the specific conditions considered, defects of up
to 74 mm depth in material related to that of an ageing RPV would not propagate to cause
catastrophic failure under a severe PTS-type thermal shock. This outcome was fully in line
with the pre-test analysis forecasts.
The large through-clad defect produced several millimetres of ductile tearing, which procee-
ded the triggering of a local cleavage event at one end of the defect just below the HAZ at
216 seconds into the PTS transient. This result further demonstrates that stable tearing con-
sistent with small scale testing behaviour can occur in a thick component prior to cleavage
fracture in the transition regime.
In the case of the large sub-clad defect no cleavage occurred, although it was found to have
grown along the entire initial crack front. Fractographic investigations determined that a
major part of this growth was by an unanticipated and as yet unexplained intergranular frac-
ture mode. This should be further investigated to understand the conditions that gave rise to
this mechanism in NESC-I sub-clad defects.
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The small amount of defect growth found in the three smaller sub-clad defects was also
found to be intergranular in nature. The remaining defects, all below 12 mm in depth,
showed no evidence of extension.
The results demonstrate the beneficial effect of the cladding in inhibiting cleavage initiation
in the near-surface regions of the NESC-I cylinder. Comparison of the results with those
from a previous spinning cylinder test, which did not contain cladding, demonstrates that it
requires relatively higher loading to obtain cleavage fracture with cladding present.
12.4 PRINCIPAL TECHNICAL CONCLUSIONS
The following sections provide a brief synthesis of the most significant conclusions emerging
from the project, based on the more detailed description of the technical findings presented in
the foregoing chapters.
12.4.1 Non Destructive Inspection
The inspection trials undertaken without knowledge of what defects were present showed
that the detection and sizing performance with ultrasonic techniques was good. In general,
the detection performances achieved were better than the results obtained in the comparable
PISC II trials a decade earlier, demonstrating the lessons learned and the good progress
made.
Fourteen out of the seventeen inspection teams detected all the defects. Three teams missed
some defects with a through-wall extent in the range 2.5 to 13.5 mm.
The good NDE performance is considered to be due firstly to the selection of optimum tech-
niques, well adapted for the purpose; secondly to the ability of the inspectors, and thirdly to
the ability to reduce the occurrence of human error.
Most teams showed an ability to profile the deeper contours of the two large fatigue cracks;
however, one team using focussed probes showed that it was even capable of accurately
contouring the profile of the defect extension developed during the test.
In the post-test inspections, the change in stress and material conditions produced by the
thermal shock did not significantly affect the inspection performance with regard to both
detection and sizing.
12.4.2 Materials Characterisation
The comprehensive materials properties test programme, in particular the dynamic and static
fracture toughness tests and crack arrest tests, demonstrated that the toughness of NESC-I
cylinder base material corresponds satisfactorily to an aged reactor pressure vessel condition.
Fracture tests on specimens machined from the sub-clad HAZ showed that the toughness
was increased i.e. the transition temperature was lowered, with respect to the base cylinder
material. Consideration of this effect proved crucial for refining the pre-test analysis predic-
tions in terms of location and timing of the cleavage event
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The Master Curve approach allowed the limited available data for the sub-clad HAZ region
to be exploited in the assessment process. The increased toughness of the HAZ cannot be
adequately represented in the RT
NDT
approach since the small material volume precludes
generation of the test data required in determining that parameter.
12.4.3 Structural Analysis and Fracture Assessment
Simplified engineering methods produced relatively conservative results, as anticipated.
Refined analyses using detailed 3-D finite element modelling of the critical defect allowed
accurate prediction of the actual time of the cleavage event in the transient and its location,
as well as precise estimate of the extent of prior ductile tearing. The anticipated cleavage
event at the largest sub-clad defect did not occur, but the significance of this is mitigated by
the intervention of an intergranular growth mechanism.
The crack driving force estimates were found to vary by 10% in the case of the detailed
3-D finite element analyses. In the case of the simplified analyses, considerable spread in
maximum predicted CDF values was found. Some estimates obtained by suitably calibrated
procedures were in line with those generated by the 3-D finite element analyses, whereas
more basic approaches produced rather conservative predictions, by a factor of up to 50%.
The cleavage event that occurred in the large surface-breaking defect, 16.5 mm below the
inner surface of the cylinder is best interpreted using standard, high constraint fracture tou-
ghness data. Detailed FE analysis has shown that the constraint parameters are close to
small-scale yielding conditions at this location, so that constraint loss is unlikely to have
influenced the cleavage behaviour.
The information obtained from detailed finite element analyses made it possible to rationa-
lise the absence of cleavage within the HAZ region, by taking into consideration factors
such as loss of constraint, higher toughness of the HAZ, the reduced effective crack-front
width and cladding effects.
Strict application of nuclear safety codes for the in-service assessment of the defects in the
NESC-I spinning cylinder would typically allow defects with a maximum depth in the range
of 1 to 9 mm. This is shown by the test outcome to include an apparently large margin of
conservatism, and is attributed to the use of substantial safety factors as well as a lower-
bound representation of material fracture toughness.
12.4.4 The Integrated Approach
By combining the defect sizing information supplied from blind inspections trials, the com-
prehensive materials data set generated for the NESC-I component and a range of structural
analysis tools, it has been possible to accurately predict the occurrence of the cleavage event
in a large surface-breaking defect.
The major source of uncertainty in the assessment process proved to be the variability in the
material toughness data, linked to the intrinsically statistical nature of cleavage in the transi-
tion range. Statistical representation of actual fracture toughness data, in particular the master
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curve approach, has proved most instructive in interpreting the test results. Variations in the
estimate of driving force has a lesser impact on the analysis result and could frequently be
rationalised in terms of the method applied i.e. simplified or complex 3-D. The uncertainty in
reported defect sizes was found to be relatively uncritical, in particular for the larger defects.
Indeed the blind inspection trials have shown that the defect sizing capability of the inspec-
tion teams was sufficiently accurate for the purpose of structural integrity analyses.
12.5 KEY RECOMMENDATIONS FOR BEST PRACTICE
NESC-I has produced a number of important recommendations for structural integrity asses-
sment:
For ultrasonic inspection the tip-diffracted wave from a defect should be employed for accu-
rate sizing of through-wall extent. Four teams using this approach in the NESC-I study
performed outstandingly well, with a RMS error of 2.4 mm or less. However, since all
inspection teams using this technique did not perform equally well, it is recommended that
the inspection system and personnel should be suitably qualified.
In applying inspection procedures, precautions should be taken to reduce the incidence of
human error as far as possible. This aim will be enabled by well-written, unambiguous pro-
cedures both for data acquisition and data analysis, good quality control and training (inclu-
ding on-the-job training) of the inspection personnel.
Where at all possible, fracture toughness data should be used for determining the reference
temperature for the ductile to brittle transition behaviour. Indeed, it may be the only means
to adequately describe behaviour in critical locations such as the thin near-surface region,
for which formulations such as the ASME RT
NDT
parameter cannot be applied due to the
inability to obtain appropriate test data required by that parameter.
The results of the NESC-I test strongly support the use of statistical approaches to describe
the risk for local cleavage events in RPV integrity assessment. These approaches offer
potential for considerable further development as part of detailed simulations of defects
using the local approach and other advanced methodologies.
For the integrated assessment process, the benefits from further work appear most evident in
the area of materials characterisation. Scope for improved fracture analysis procedures has
also been identified, while in the area of inspection focus should be directed to improving a)
accuracy for small defects and b) measurement reliability.
The NESC-I results should be actively promoted as an international benchmark to that part
of the technology community having an interest in refinement of inspection and integrity
assessment methodologies for structures.
The success of NESC-I emphasises the benefits of the network approach to tackling multi-
disciplinary problems. The network structure should be exploited for disseminating the
project results and for further developing the integrated structural integrity approach via
successor large-scale projects.
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t c r
APPENDIX A
Brief History of Spinning Cylinder Test Program and NESC-I Source Material
In December 1979, the UK government proposed the construction of a nuclear power station
that would incorporate a pressurised water reactor (PWR) as the basis for the design. In
conjunction with that proposal, Walter Marshall was invited in 1980 to reconstitute a study
group that focused on the safety of light-water reactor pressure vessels. At the same time,
increased emphasis was given to research programs for PWR safety, including studies of
materials and structural integrity issues. Through the latter programs, the UK spinning cylin-
der test facility was conceived in 1981 at AEA Technology, Risley.
The spinning cylinder concept allowed a high primary stress to be generated in a thickness of
material matching that of an RPV in a commercial PWR. The advantage of rotation over simple
pressurisation of a thick cylinder was that the through-thickness distribution of the stress field
was more uniform. Thus, a better approximation of the stress field produced in a commercially-
sized RPV could be achieved in the spinning cylinder rig. In addition, the rig also allowed for
the possibility of applying a sustained thermal shock with a high heat-transfer coefficient pro-
duced by surface entrapment. After a series of small-scale experiments, the decision was taken
to order the full-size test facility in 1984. The facility was available for use in 1986.
Although the complete test program had not been planned in detail, it was recognised that the
early tests would address ductile tearing issues through study of materials well on the upper
shelf. Validation of predictions for cleavage fracture in the transition region was not a priority
until later in the program, after publication of the Hirsch report in 1987. An order for cylinder
specimens was placed in 1985 to support a test matrix that would demonstrate the following
technical propositions in full-section material:
enhancement of crack growth resistance with increasing ductile tearing and the validation of
the conservatism of JR curves obtained from standard CT and SENB tests;
achievement of at least 2 mm of ductile tearing and high toughness without intervention of
cleavage or ductile instability.
The test program was based on eight cylinders with 200-mm wall thickness produced from
four forgings (two cylinders per forging), manufactured by Forgemasters Engineering Ltd. in
Sheffield, UK. Three of the four forgings were intended for ductile tearing tests. Thus, those
forgings had a chemical composition, manufacture and heat treatment consistent with a mate-
rial that would be on the upper shelf above room temperature. The other forging was intended
to investigate cleavage fracture and transition region behaviour at temperatures of about
100C; thus, it had a different composition and fabrication. One of the ductile cylinders,
without any implanted defects, was used to commission the rig. Six of the cylinders had lon-
gitudinal machined surface defects, which were sharpened by fatigue (loading by diametral
compression), and then tested as follows:
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J C O l
Test SC1 ductile tearing test on an extended defect with rotation only;
Test SC2 ductile tearing test on an extended defect with thermal shock only:
Test SC3 ductile tearing test on an extended defect with rotation and thermal shock:
Test SC4 cleavage fracture test on two semielliptical defects with rotation and thermal
shock;
Test SC5 ductile tearing test (similar to Test 3) on an extended defect in a full length stress
relieved weld;
Test SC6 cleavage fracture test on two semielliptical defects with rotation and thermal
shock.
Completion of the foregoing test matrix left one cylinder from a ductile forging that was avai
lable for use by the NESCI project beginning in 1993. Subsequently, that cylinder was given
a special heat treatment in support of a major objective of NESCI, i.e., achieving cleavage
initiation of a throughclad defect within the loading capabilities of the test rig. However, that
heat treatment did not produce a sufficiently high transition temperature in the base metal to
render cleavage initiation likely for existing rig capabilities. Consequently, the Steering
Committee of NESC approved fabrication of a new NESCI cylinder from the remaining hal
ves of the two cylinders used in tests SC4 and SC6, in which cleavage initiation had been
successfully realised. As noted elsewhere in this report, postweld and postclad heat treat
ments of the reconstituted NESCI cylinder were carried out to preserve the original material
and fracture toughness properties of the SC4 and SC6 forging.
(36
European Commission
EUR 19051 - NESC-I Project Overview - Final Report
R. Bass, J. Wintle, R.C. Hurst, N. Taylor
2001 - 138 p p . - 17 x 2 4 cm
Institute for Advanced Materials
European Commission - Joint Research Centre
The Institute is the "European Commission' s Corporate
Laboratory for structural integrity and performance of
materials assessment in components and surfaces".
The mission statement of 1AM s as follows:
"The Mission of the Institute is to support the sustainable
development and competitiveness of European industry
through research on the structural integrity and perfor-
mance of materials in components in areas of concern to
the public. The pri me applications are in the sectors of
energy, transport and chemical processes. The Institute
manages the High Flux Reactor for the benefit of the
European nuclear industry and supports nuclear appl i ca-
tions in medi ci ne".
/ftes
1
-Tufa
EUNA19051ENC
Net wor k for Eval uati ng Structural Components
The NESC-I Project Overview
Structural integrity assessment of industrial components containing cracks or defects is a multidisciplinary activity that in
today's global industrial environment requires internationally accepted procedures. Practices used in different countries to
inspect and assess the fitness for purpose of critical components such as pressure vessels and piping vary. It is the interac
tion between the disciplines in the technical decisionmaking process that is often crucial to the outcome of the assessment as
a whole.
With these challenges in mind, the Network tor Evaluating Structural Components (NESC) was created to improve interna
tional practice for integrated structural integrity assessment. The NESCI Project set out to validate NDE and structural
mechanics assessment procedures for PWR reactor pressure vessels under pressurised thermal shock (PTS) conditions by
means of a large scale spinning cylinder simulation test. While the cylinder with its implanted defects has formed the focal
point of an international nondestructive inspection round robin, the test itself has created an important benchmark for the
understanding and validation of fracture assessment methodologies.
This overview report presents the results, conclusions and recommendations gained from
the project, and systemically covers the key elements of the integrated
structural integrity approach. It is aimed at technology managers and
engineers responsible for plant safety. Although the results
have been gained from a nuclear oriented programme,
the knowledge gained in inspection performance,
materials characterisation, instrumentation as
well as stress and fracture analysis is widely
applicable to critical components in
many industrial applications e.g.
fossil fuel power generation plant,
petrochemical installations,
processing plant, pressure
equipment etc.
for
~~ Advanced
f Materials
For further information please contact
Mr. Darren McGarry (NESC secretary), European Commission DG JRC
Joint Research Centre, Insilitute for Advanced Materials, P.O. Box 2, 1755 ZG Pellen,
THe Netherlands. Tel: +31 224 565278, Fax +31 224 561568, E-mail: mcgarTyrc.nl