Analysis of ASME Boiler, Pressure Vessel, and Nuclear Components in the Creep Range

Analysis of ASME Boiler, Pressure Vessel, and Nuclear Components in the Creep Range

Second Edition

The latest edition of the leading resource on elevated temperature design

In the newly revised Second Edition of Analysis of ASME Boiler, Pressure Vessel, and Nuclear Components in the Creep Range, a team of distinguished engineers delivers an authoritative introduction to the principles of design at elevated temperatures. The authors draw on over 50 years of experience, explaining the methodology for accomplishing a safe and economical design for boiler and pressure vessel components operating at high temperatures. The text includes extensive references, offering the reader the opportunity to further their understanding of the subject.

In this latest edition, each chapter has been updated and two brand-new chapters added—the first is Creep Analysis Using the Remaining Life Method, and the second is Requirements for Nuclear Components. Numerous examples are included to illustrate the practical application of the presented design and analysis methods. It also offers:

• A thorough introduction to creep-fatigue analysis of pressure vessel components using the concept of load-controlled and strain-deformation controlled limits
• An introduction to the creep requirements in API 579/ASME FFS-1 “Remaining Life Method”
• A summary of creep-fatigue analysis requirements in nuclear components
• Detailed procedure for designing cylindrical and spherical components of boilers and pressure vessels due to axial and external pressure in the creep regime
• A section on using finite element analysis to approximate fatigue in structural members in tension and bending

Perfect for mechanical engineers and researchers working in mechanical engineering, Analysis of ASME Boiler, Pressure Vessel, and Nuclear Components in the Creep Range will also earn a place in the libraries of graduate students studying mechanical engineering, technical staff in industry, and industry analysts and researchers.

Maan H. Jawad, PhD, is President of Global Engineering and Technology in the United States, a firm that offers engineering consulting to the pressure vessel, power, petrochemical, and nuclear industries. Previously, he served as Director of Engineering at the Nooter Corporation that fabricates pressure vessels for the boiler, petrochemical, and nuclear industries.

Robert I. Jetter has over 50 years of experience in the design and structural evaluation of nuclear components and systems for elevated temperature service. He participated in and directed design of early sodium cooled reactors and space power plants through all the US LMFBR programs. He currently consults on the development and application of elevated temperature design criteria for advanced nuclear applications.

Preface xvii

Acknowledgement for the Original Edition xxi

Acknowledgement for this Edition xxiii

Abbreviations for Organizations xxv

1 Basic Concepts 1

1.1 Introduction 2

1.2 Creep in Metals 3

1.2.1 Description and Measurement 3

1.2.2 Elevated Temperature Material Behavior 5

1.2.3 Creep Characteristics 7

1.3 Allowable Stress 12

1.3.1 ASME Boiler and Pressure Vessel Code 12

1.3.2 European Standard EN 13445 14

1.4 Creep Properties 17

1.4.1 ASME Code Methodology 17

1.4.2 Larson-Miller Parameter 18

1.4.3 Omega Method 20

1.4.4 Negligible Creep Criteria 20

1.4.5 Environmental Effects 22

1.4.6 Monkman-Grant Strain 23

1.5 Required Pressure-Retaining Wall Thickness 23

1.5.1 Design by Rule 23

1.5.2 Design by Analysis 24

1.5.3 Approximate Methods 24

1.5.3.1 Stationary Creep – Elastic Analog 24

1.5.3.2 Reference Stress 25

1.6 Effects of Structural Discontinuities and Cyclic Loading 30

1.6.1 Elastic Follow-Up 30

1.6.2 Pressure-Induced Discontinuity Stresses 33

1.6.3 Shakedown and Ratcheting 35

1.6.4 Fatigue and Creep-Fatigue 41

1.6.4.1 Linear Life Fraction – Time Fraction 44

1.6.4.2 Ductility Exhaustion 44

1.7 Buckling and Instability 45

Problems 46

2 Axially Loaded Structural Members 47

2.1 Introduction 48

2.2 Stress Analysis 53

2.3 Design of Structural Components Using ASME I and VIII-1 as a Guide 60

2.4 Temperature Effect 62

2.5 Design of Structural Components Using ASME I, III-5, and VIII as a Guide – Creep Life and Deformation Limits 64

2.6 Reference Stress Method 71

2.7 Elastic Follow-up 72

Problems 77

3 Structural Members in Bending 79

3.1 Introduction 80

3.2 Bending of Beams 80

3.2.1 Rectangular Cross Sections 82

3.2.2 Circular Cross Sections 82

3.3 Shape Factors 85

3.3.1 Rectangular Cross Sections 86

3.3.2 Circular Cross Sections 88

3.4 Deflection of Beams 89

3.5 Stress Analysis 92

3.5.1 Commercial Programs 99

3.6 Reference Stress Method 100

3.7 Piping Analysis – ASME B31.1 and B31.3 102

3.7.1 Introduction 102

3.7.2 Design Categories and Allowable Stresses 102

3.7.2.1 Pressure Design 103

3.7.2.2 Sustained and Occasional Loading 103

3.7.2.3 Thermal Expansion 103

3.7.3 Creep Effects 105

3.7.3.1 Weld Strength Reduction Factors 105

3.7.3.2 Elastic Follow-Up 105

3.7.3.3 Cyclic Life Degradation 106

3.8 Circular Plates 106

Problem 108

4 Analysis of ASME Pressure Vessel Components: Load-Controlled Limits 109

4.1 Introduction 109

4.2 Design Thickness 111

4.2.1 Asme I 112

4.2.2 Asme VIII 113

4.3 Stress Categories 117

4.3.1 Primary Stress 118

4.3.1.1 General Primary Membrane Stress (P m) 118

4.3.1.2 Local Primary Membrane Stress (P L) 119

4.3.1.3 Primary Bending Stress (P b) 119

4.3.2 Secondary Stress, Q 119

4.3.3 Peak Stress, F 120

4.3.4 Separation of Stresses 120

4.3.5 Thermal Stress 126

4.4 Equivalent Stress Limits for Design and Operating Conditions 126

4.5 Load-Controlled Limits for Components Operating in the Creep Range 133

4.6 Reference Stress Method 143

4.6.1 Cylindrical Shells 143

4.6.2 Spherical Shells 152

Problems 153

5 Analysis of Components: Strain and Deformation-Controlled Limits 155

5.1 Introduction 155

5.2 Strain and Deformation-Controlled Limits 156

5.3 Elastic Analysis 157

5.3.1 Test A- 1 157

5.3.2 Test A- 2 161

5.3.3 Test A- 3 161

5.4 Simplified Inelastic Analysis 169

5.4.1 Tests B-1 and B- 2 173

5.4.2 Test B- 1 173

5.4.3 Test B- 2 174

Problems 179

6 Creep-Fatigue Analysis 181

6.1 Introduction 181

6.2 Creep-Fatigue Evaluation Using Elastic Analysis 182

6.3 Welded Components 211

6.4 Variable Cyclic Loads 211

6.5 Equivalent Stress Range Determination 213

6.5.1 Equivalent Strain Range Determination – Applicable to Rotating Principal Strains 213

6.5.2 Equivalent Strain Range Determination – Applicable When Principal Strains Do Not Rotate 214

6.5.3 Equivalent Strain Range Determination – Acceptable Alternate When Performing Elastic Analysis 215

6.5.3.1 Constant Principal Stress Direction 215

6.5.3.2 Rotating Principal Stress Direction 215

6.5.3.3 Variable Cycles 215

Problems 221

7 Creep-Fatigue Analysis Using the Remaining Life Method 223

7.1 Basic Equations 223

7.2 Equations for Creep-Fatigue Interaction 225

7.3 Equations for Constructing Ishochronous Stress-Strain Curves 232

8 Nuclear Components Operating in the Creep Regime 237

8.1 Introduction 237

8.2 High Temperature Reactor Characteristics 239

8.3 Materials and Design of Class A Components 241

8.3.1 Materials 241

8.3.1.1 Thermal Aging Effects 242

8.3.1.2 Creep-Fatigue Acceptance Test 242

8.3.1.3 Restricted Material Specifications to Improve Performance 242

8.3.2 Design by Analysis 243

8.3.2.1 Equivalent Stress Definition 243

8.3.2.2 Rules for Bolting 245

8.3.2.3 Weldment Strength Reduction Factors 246

8.3.2.4 Constitutive Models for Inelastic Analysis 246

8.3.2.5 A-1, A-2, and A-3 Test Order 246

8.3.2.6 Determination of Relaxation Stress, S r 246

8.3.2.7 Buckling and Instability 247

8.3.2.8 d diagram differences 248

8.3.2.9 Isochronous Stress-Strain Curve Differences 248

8.3.3 Component Design Rules 248

8.4 Class B Components 249

8.4.1 Materials 249

8.4.2 Design 250

8.5 Core Support Structures 251

9 Members in Compression 253

9.1 Introduction 253

9.2 Construction of External Pressure Charts (EPC) Using Isochronous Stress-Strain Curves 254

9.3 Cylindrical Shells Under Axial Compression 259

9.4 Cylindrical Shells Under External Pressure 263

9.5 Spherical Shells Under External Pressure 266

9.6 Design of Structural Columns 269

9.7 Construction of External Pressure Charts (EPC) Using the Remaining Life Method 273

Appendix A: ASME VIII-2 Supplemental Rules for Creep Analysis 279

Case 2843-2 279

Analysis of Class 2 Components in the Time-Dependent Regime 279

Section VIII, Division 2 279

1 Scope 279

2 Strain Deformation Method 281

3 Materials and other Properties 281

3.1 Materials 281

3.2 Weld Materials 282

3.3 Design Fatigue Strain Range 282

3.4 Stress Values 283

3.5 Stress Terms 284

4 Design Criteria 284

4.1 Short-Term Loads 284

5 Load-Controlled Limits 285

5.1 Design Load Limits 285

5.2 Operating Load Limits 286

6 Strain Limits 288

6.1 Test A-1 Alternative Rules if Creep Effects are Negligible 288

6.2 Strain Limits – Elastic Analysis 291

6.2.1 General Requirements 291

6.2.2 Test A- 2 293

6.2.3 Test A- 3 293

6.3 Strain Limits – Simplified Inelastic Analysis 293

6.3.1 General Requirements 293

6.3.2 General Requirements for Tests B-1 and B- 2 293

6.3.3 Applicability of Tests B-1 and B- 2 296

6.3.3.1 Test B- 1 296

6.3.3.2 Test B- 2 297

6.4 Strain Limits – Inelastic Analysis 297

7 Creep Fatigue Evaluation 297

7.1 General Requirements 297

7.2 Creep Fatigue Procedure 298

7.2.1 Creep Procedure 298

7.2.2 Fatigue Procedure 302

7.2.3 Creep-Fatigue Interaction 303

8 Nomenclature 304

Appendix B: Equations for Average Isochronous Stress-Strain Curves 307

B. 1 Type 304 Stainless Steel Material 307

B.1. 1 304 Customary Units 307

B.1. 2 304 SI Units 310

B. 2 Type 316 Stainless Steel Material 313

B.2. 1 316 Customary Units 313

B.2. 2 316 SI Units 316

B. 3 Low Alloy 2.25Cr–1Mo Annealed Steel 321

B.3. 1 2.25Cr–1Mo Customary Units 321

B.3. 2 2.25 Cr–1Mo Steel SI Units 324

B. 4 Low Alloy 9Cr–1Mo-V Steel 328

B.4. 1 9Cr–1Mo-V Customary Units 328

B.4. 2 9Cr–1Mo-V SI Units 330

B. 5 Nickel Alloy 800H 332

B.5. 1 Alloy 800H Customary Units 332

B.5. 2 Alloy 800H SI Units 334

Appendix C: Equations for Tangent Modulus, E t 337

C.1 Tangent Modulus, E t 337

C.2 Type 304 Stainless Steel Material 337

Appendix D: Background of the Bree Diagram 343

D. 1 Basic Bree Diagram Derivation 343

Zone E 343

Zone S 1 347

Zone S 2 350

Zone P 351

Zone R 1 352

Zone R 2 355

Appendix E: Factors for the Remaining Life Method 357

Appendix F: Conversion Factors 363

References 365

Bibliography of Some Publications Related to Creep in Addition to Those Cited in the References 369

Index 371

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