DETERMINATION OF SAFE OPERATIONAL

PRESSURE-TEMPERATURE LIMITS FOR REACTOR

PRESSURE VESSEL OF A TYPICAL PWR
By:
Ankur Katiyar
Mechanical Engineering

Under the Guidance

of
Shri R.N. Sen(SO/H+) & Shri Vivek Shrivastav(SO/F)

OUTLINE

INTRODUCTION
OBJECTIVES
METHODOLOGY
RESULTS
CONCLUSION

INTRODUCTION
RPV subject to non ductile fracture due to irradiation embrittlement.
LEFM design criteria, KI KIc/FOS.
ASME III, App G Protection Against Non Ductile Fracture
demonstrate structural integrity.
Additionally, USNRC 10 CFR Part 50, App G- Fracture Toughness
Requirements P-T Limits determination.

OBJECTIVES
The specific objectives of the present project include:

To perform structural integrity analysis for stability of postulated crack in

RPV Core-Belt region under planned heat up & cool down transients.

To determine the allowable Pressure-Temperature (P-T) limits, for different

stages of RPV life, considering the shift in RTNDT due to neutron fluence.

LOAD CASES ANALYSED

Design Condition :
Design Pressure: 18.1 Mpa
Design Temperature: 350C
Planned Heat-up : 50C/hr
Planned Cool-down :

Operating press : 16.2 MPa

Operating temp : 265 C
Time(s)

Pressure
(MPa)

Time (s)

Inlet Temp (C)

0 (Steady
State)

16.2

0(steady state)

265

1900

14.2

3800

13.0

5700

12.0

8600

11.0

20000

11.0

8500

50

20000

50

Table 1: Planned Cool-down Transient

MATERIAL PROPERTIES
RPV Material Cr-Mo-V Nuclear Grade Low Alloy Steel
Temp
(C)

Thermal
Conductivity

Density
(kg/m3)

(kcal/hr.mC)

Specific
Heat

Youngs
Modulus

(kcal/kgC)

(GPa)

Poissons
Ratio

Coeff. of
Th. Exp.
(C-1)

20

34.56

7814

.108

210

0.3

11.3X10-6

350

32.01

7715

.0135

190

0.3

13.4X10-6

Table 2: Material Properties for RPV Base Metal

Postulation of Crack
FE Modelling

Inner Side of RPV

6a

METHODOLOGY
Figure 1: Configuration
of postulated crack

Thermal Analysis
Stress Analysis
Fracture Calculations
Structural Integrity Assessment
Pressure and Temperature Limits
Calculations

2KIm+KIt KIc
KIc=36.5 + 22.783exp[.036(T-RTNDT)] MPa. m0.5
ART = Initial RTNDT + RTNDT + Margin
RTNDT = CF*ff
ff = function of fluence
CF = function of base metal geometry
Requirements of USNRC 10 CFR part 50 app G
for P-T limitsMargin of 40 deg F when core is
critical

Thermal, stress and fracture analyses are validated through simpler problems with known
solutions.

MODELLING & MESHING

3D model of shell region along with postulated crack is created in a FEM
package (as shown in following figure):
Plane of Symmetry

Figure 2: Meshed model and Mesh Pattern

near the Crack

CRAC
K
FRON

MODELLING OF CRACK TIP

SINGULARITY

KI =

k = 3-4 for plain strain

Figure 3: Quarter Point Elements around

the Crack Tip

k=(

BOUNDARY CONDITIONS FOR

THERMAL & STRESS ANALYSIS
For Thermal Analysis:
Time dependent temperature on the inner surface of
RPV.
Convective heat transfer coefficient (h) on the outer
surface of RPV with bulk temperature of 50C.
For Stress Analysis:
Symmetry boundary conditions on all cut sections of
the vessel excluding crack face and top face.
Internal pressure on inner surface of RPV.
Longitudinal stress on the top face.
The instantaneous temperature distribution from the
thermal analysis (in case of thermal stress analysis).

Figure 4: 3D Model of Shell

with Postulated Crack

RESULTS FOR STRUCTURAL

INTEGRITY ASSESSMENT OF RPV
Planned Heat-up Transient:
5000
4500
4000
3500
3000

K (MPa.mm0.5)

KIc vs Temp for 0% of life

2500

2KIM vs temp

2000

KIc vs temp for 100% of life

1500
1000
500
0
0

30

60

90

120 150 180 210 240 270 300

Temp C

Figure 5: K vs T during planned

Heat up Transient

Planned Cool-down Transient:

10000
9000
8000
7000

K (MPa.mm0.5)

6000

KIc vs T for 0 % life

5000

2KIM+KIT

4000

KIc vs T for 100% life

3000
2000
1000
0
30

60

90

120

150

180

210

240

270

Temp C

Figure 6: K vs T during planned

cool-down Transient

300

EVALUATION FOR SAFE OPERATING

P-T LIMITS
P-T limits for Heat-up transient:
60
55
50
45

Pressure (MPa)

0% LIFE

40

25% LIFE

35

50% LIFE

30

75% LIFE

25

100% LIFE

20

OPERATING P-T CURVE

15

DESIGN PRESSURE

10
5
0
0

25

50

75

100 125 150 175 200 225 250 275 300

Temp (deg.C)

Figure 7: P-T limits during Planned Heat up when

core is not critical

50
45
0% OF LIFE

Pressure (MPa)

40

25% OF LIFE

35

50% OF LIFE

30

75% OF LIFE

25

100% OF LIFE

20

OPERATING P-T CURVE

15

DESIGN PRESSURE

10
5
0
0

25

50

75

100

125

150

175

200

225

250

275

300

Temp (deg.C)

Figure 8: P-T limits during Planned Heat up when

core is critical

P-T limits for cool-down transient:

50
45
40
35

Pressure (MPa)

0% OF LIFE
25% OF LIFE

30

50% OF LIFE

25

75% OF LIFE
100% OF LIFE

20

OPERATING P-T CURVE

15

DESIGN PRESSURE

10
5
0
0

25

50

75

100 125 150 175 200 225 250 275 300

Temp (deg.C)

Figure 9: P-T limits during Planned cool down

when core is not critical

60
55
50
0% LIFE

Pressure (MPa)

45
40

25% OF LIFE

35

50% OF LIFE

30

75% OF LIFE

25

100% OF LIFE

20

OPERATING P-T CURVE

15

DESIGN PRESSURE

10
5
0
0

25

50

75

100 125 150 175 200 225 250 275 300 325

Temp (deg.C)

Figure 10: P-T limits during Planned cool down

when core is critical

CONCLUSION

Structural integrity of the RPV is maintained under planned heat up

transient.
Under planned cool down transient, structural integrity of RPV is not
demonstrated (with factor of safety of 2.0) towards end of life.
Operating regime for planned heat-up is well within the safe operating P-T
limits throughout the life.
Operating regime for planned cool-down is well within the safe operating
P-T limits in the beginning of life, however after exposure to irradiation
(even at 25% of life), the operating regime needs to be modified.

THANK YOU

Back up Slides
h Calculation:
The problem over here is taken as laminar, therefore h will be calculated for laminar flow over vertical cylinder.

Case I: Value of h at the beginning of the Transient

The ambient temperature of air outside the pressure vessel is taken to be equal to 50C. In order to calculate the value of h at the
beginning of the transient for laminar boundary layer the outer wall temperature T W is taken to be same as the inner wall
temperature for steady state condition which 265C
Therefore,
T = TW - T = 215C
Putting these values in we get the value of h max = 7.64 X 10-3 N/mm.K
Case II: Value of h at the end of the steady Transient
The ambient temperature of air is taken to be 50C. In order to calculate the value of h at the end of the transient for laminar
boundary layer the outer wall temperature T W is equal to 50C.
Therefore,
T = 0C
hmin = 0C
Thus, the values for h at end of the transient is taken as the average of both the h.
Therefore,
h = 3.82X10-3 N/mm.K

Calculation of Shift in RTNDT with

respect to Fluence
Where,

ART = Initial RTNDT + RTNDT + Margin

Initial RTNDT is taken as 0 0C.

CF = chemistry factor which depends on % of Ni and Cu by weight in RPV steels

f = fluence at a particular depth of RPV.
fsurf = influence at 1 MeV
Margin = the quantity in F which to be added to obtain conservative ARTNDT

I is the standard deviation for initial RTNDT which is taken as zero, since the initial value of RTNDT taken as 0
0
C is the minimum guaranteed value for the grade of steel under consideration,
= standard deviation for RTNDT which is taken as 17F for base metal and it need not exceed 0.5 times the
mean value of RTNDT.

Validation Problems

Problem Definition:
A thick wall cylinder with inner radius b = 2075 mm and outer radius c = 2325 mm is subjected to
an internal pressure P. The generated hoop stress is calculated in Finite Element software and the
solution obtained is then compared with Lame's formula to check the validity of mechanical stress
calculations.
According to Lame's formula the hoop stresses under internal pressure P on the inner surface of
the cylinder wall are given as follows:
At the inner surface
At the outer surface

Location

Lame's Formula
Stress (in MPa)

FEA Solution
Stress (in MPa)

Error (%)

Inner Surface

132.43

132.45

0.015 (higher)

Outer Surface

117.43

117.45

0.017 (higher)

Steady State Thermal Stress Analysis

Problem Definition:

A hollow
thick wall cylinder of inner radius b and outer radius c has the outer surface at the
uniform temperature T2 and the inner surface at the uniform temperature T1. It is known from the
theory that after the steady-state heat flow is established the temperature within the cylinder
decreases logarithmically with radius r and the maximum stresses, which are circumferential and
which occur at the inner and outer surfaces, are given in the Handbook as follows:
Tangential Stress on outer surface (tensile stress)

Tangential Stress on inner surface (compressive stress)

Temperature at any distance x is given by the formula

where,

= Thermal expansion coefficient of the material

x = radial distance into the wall thickness from the inner radius b
TX = Temperature at that location
Temperature from Temperature from

Location

Error (%)

X = 9.625 mm

standard
formula(in C)
97.3918

FEA solution
(in C)
97.394

2.25* 10-3 (higher)

X = 182.88 mm

52.3962

52.397

3.435*10-3 (higher)

Location
Inner Surface
Outer Surface

Handbook
FEA Solution
Solution
Stress (in MPa)
Stress (in MPa)
87.54
(compressive)
81.15 (tensile)

93.23
(compressive)
77.52 (tensile)

Error (%)
6.49 (higher)
4.47 (lower)

Transient Thermal Analysis

A hollow
cylinder of inner radius b and outer radius c has the temperature of the outer surface raised at the
Problem Definition:

uniform rate of C/S. After a steady rate of temperature rise has been reached throughout, the maximum
tangential stresses which are circumferential and which occur at the inner and outer surface are given in the
Handbook as follows:
Handbook
FEA
Error
Solution
Solution
(%)

where, = Thermal expansion coefficient of the material

A= Thermal diffusivity of the material

Inner
Surface

Stress (in
MPa)

Stress(in
MPa)

107.89
(tensile)

98.34
(tensile)

8.85
(lower)

185.25(compressive)

8.82
(lower)

203.18
The loads and boundary conditions applied for thermal analysisOuter
are:
Surface
(compressive)

1. A steady rate of temperature rise of 0.3 C/S on the outer wall for 10000 seconds.
2.

Convective heat transfer coefficient of h = 6.5*10-4N/mm.K on the inner wall

Validation of Fracture Calculations

Compact Tension Specimen

The standard formula of K1 for a compact tension specimen is taken from ASTM E1820:
Where,
P = Applied load
B = Thickness of the specimen
W = Width of the specimen

Handbook
Solution
Location
Applied Ki (in
MPa.m().5)
Crack Tip

13.73

FEA Solution
Applied K 1 (in
Mpa.m)

Error
(%)

14.21

3.49

Finite Length Axial Part-through Wall Flaw

in Cylinder Wall Thickness

A cylinder with a semi-elliptical crack in the wall thickness is shown in the Figure. The cylinder is
under internal pressure P. The stress intensity factor K, at the deepest penetration point on the
semi-elliptical crack is given by the following Handbook formula:
Where,

The formula is applicable under the following conditions:

0.05 a/t 0.85
0.1 a/c 1
0.2
1 Ri/t 10

Fig. Sectional View of a Cylinder

with Semi-elliptical Flaw

Where , a = crack depth in radial direction

2c = crack length in the axial direction
t = thickness of wall
Ri = inner radius of cylinder

Location
Crack Tip

Handbook
Solution
Applied K1 (in
MPa.m0.5)
1026.77

ANSYS Solution
Applied K 1 (in
MPa.m0.5)
964.69

Error (%)
6.05
(lower)