ML20091P598
| ML20091P598 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 01/11/1983 |
| From: | Latischa Hanson DRESSER INDUSTRIES, INC. |
| To: | |
| Shared Package | |
| ML20091P591 | List: |
| References | |
| NUDOCS 8406130111 | |
| Download: ML20091P598 (139) | |
Text
D MRLYSIS OF INIERfEDIATE COVER SIZE 3", TYPE JHP, 11 STAGE PACIFIC PGIP SAFEIY INJECTION SERVICE SFOP ORDERS J-49738 AND J-49871 SERIAL N&EERS 51667/668 R O 51928/929 TEXAS 17FILITIES - COMA!DE PEAK 1 AND 2 A
O n n By: NM L M'%
Ll'oyd D7Hanscm, P.E.
Senior Design Engineer Pacific Ptz:ps Division Dresser Industries, Inc.
Date: dAAhu1AMlI,b9h L - c' b@ _
- py)m6mm C 1
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PUR__J g,.. ,.%w.--%.,a we m -;- a eee amme hie ===.p ==r6y + , e ,*= - ++ e.% - y
T BLE OF CONTENTS Section 1: Contents Section 2: Discussion Section 3: Stress Analysis Section 4: Phase I Metallurgical Report (June 15,1982)
Section 5: Phase II Metallurgical Report (November 18, 1982)
Section 6: Reference Material
- Assembly Drawing
- Outline Drawing
- - Pump Photo (typical)
I(' - Intermediate Cover Photo
- Performance Curves Section 7: - Indication Survey Section 8: - Installation Lists Section 9: - Field Recommendations
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DISCUSSICN T IJNEAR INDICATIONS AND 'IEEIR tmd ON PLMP OPERABILITY 4 Visible linear indications on the shroud separating and supporting the diffuser vanes and return guide vanes have been found in the JhF type punps supplied to Texas Utilities - Omanche Peak Station. 'Ihese indi-cations exceeded the inspection maximm of 1/16" (beyond which an internal rejected material report (RMR) and engineering disposition is required) and ranged in surface size frm 1/8 inch to in excess of 1 inch. It is our opinion that these indications resulted frm casting processes and have always been present in the castings and in no way affect the operability of the peps. They are merely more visible now due to the operational testing and subsequent cleaning operations of the p eps.
Since we now know of these inspection findings, an RMR has been written on the elenent frm pep serial nmber 51667 and others and given the engineering disposition "USE AS IS". '1he purpose of this docment is to support that disposition and show that these indications do not effect the operation of the p ups. 'Ihe specific considerations are as follows:
- 1. 'Ihe cause of the indications is well understood.
- . 2. The stress levels in the part are quite
'O 1ew.
- 3. These parts are designed and manufactured the sane way as thousands of nearly identi-cal parts used in similar pmps without failure.
- 4. The arrangenent of the pmp is such that even iould a shroud be broken in tso, the pitees are constrained so that they would ccotinue to function in channeling the fluid flow and would not interfere with the operation of the pep.
l
- IE E: 'Ihe dimensions given above are the lengths as they appear on the l , curved surface. 'Ibe depth as discussed in the Field Rea:mmendations never ex W 1/2" in the radial direction. (See Section 9.)
(1)
DISCUSSION OF LINEAR INDICATIONS AND THEIR tu u X ON PUMP OPERABILITY The indications seen on these intercovers are examples of casting process effects. As such, they are associated with the original solidification and cooling of the casting. Our experience in the use of castings of these alloys is that such indications are camon and are quite often seen during receiving inspection of raw castings. Once the parts have cooled and are properly heat treated, no driving force r e alns to cause new or extend the existing indications. Included in Section 4 of this report is a report by our metallurgical consultant which presents evidence to support the conclusion drawn above.
The cmplex gemetry in the region of the part'where the indications are found necessitated the use of the finite elment method to calculate the stresses. A discussion of this analysis and the results are presented in Section 3 of this report. Basically, it is our opinion that these low stresses cannot cause crack initiation or propagation in these parts.
Section 5 of this report is a second report by our metallurgical consultant which uses the stresses we have calculated along with load history data h obtained frcm the N.S.S.S. supplier to analyze crack propagation and life U projections using the methods of fracture mechanics. his analysis supports the opinion expressed above and the resulting catclusion that the integrity of these parts is not affected by the presence of the indications. One additional consideration is that the primary stress causing load, the hydrostatic end force, varies frm a minimtrn at the lith stage and is maxi-nun at the 1st stage. Asstrning that the indications are caused or made worse by operating stress, then the parts having the greatest munber of indications would be in the first few stages. This is not the case. Instead, the list in Section 7 shows a randcm distribution of indicaticrs.
Pacific Ptmps has designed and built pumps having essentially identical diffuser /intercover design for mcre than 30 years. S e materials used for these punp parts have included cast iron, bronze, and various steels including the martensitic stainless steel used for these parts. No failure has occurred in these pumps due to material failure in the diffuser intercover shroud. Section 8 of this report includes lists of operating pturps with similar internal construction.
(2)
DISCUSSION OF LINEAR INDICATIONS AND THEIR mu;r 01 PUMP OPERABILITY e
4_
As discussed in the stress calculations, during operation these parts are pressed together by hyarostatic forces so that the end face of each diffuser blade is loaded in ompression. Fractures in the shrouds yield-ina nieces that included diffuse _r vanes would be held in olace by these catrr:essive loads and the return passace vane which is intearally cast between the shroud and the thick section of the intercover. It is not clausible that a niece could break off between blades since such a piece would have a negligibly small load on it.
It is our opinion that the above discussion and associated attachments are sufficient to justify the use of these parts as is. We recamend that these elsnents be reassembled and returned to service. In addition, Section 9 of this report presents sme recmmendations for field inspection and criteria for further action.
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(3)
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f SELTICN III STRESS A'mLYSIS In this section we will review the loads carried by the 3" JHF pump intennediate cover and present the results of a finite elment stress ;
analysis. The purpose of this work was both to show the generally low condition of stress in the area of the indications and to provide data which could be used in a fracture mechanics analysis. This analysis is docmented in Mettek Report #220431-2. dated Novmber 18.
1982, with the results that it is likely that the indications are below the threshold for propagation and are conservatively below any failure criterion over the service life of the pump.
The next page is a sketch of the intarmnM ate cover. Referring to this sketch and the pump assm bly drawing included in Section 6, we can dis-cuss the loads on the part. These covers are assmbled at the same time as the impellers to form an internal el m ent bundle which is then placed between the upper and 1mer halves of the pump case.
The water enters the first stage impeller (part #C001 on the left side of the ass ably drawing) and is pumped to higher pressure levels at each stage. As a result each " cover" (see sketch) has one stage of differential pressure across it. It becanes, in effect, a piston hydrostatically loaded
^
by the pressure buildup of the p mo. This load is carried by the return guide vane, shroud, and diffuser vane into the next lower stage cover (or into the case at the first stage).
This is the only significant source of load on these parts; h w ever, we have considered this load to be made up of two superimposed cmoonents. First, is a " static" omponent represented by the required design pressure increase in each stage of approximately 145 psi. Second, is a high frequency dynamic cmponent caused bu the blade nassane of the imneller. Exnerience shows this to be tunicallo 1% of the develcred nressure but fnr our purooses we used an upper bound of 3%. Sin the loads accumulate frm stage to . stage, we have performed the finite elment analysis assuming that the full pmp differential pressure of 1590 psi acts across one cover. Other sources of ;
stress such as hydrodynamic forces or thermal cycling have been considered I to be much less than the pressure forces discussed above. In particular, the possibility of significant thermal stresses and thermal fatigue are precluded by the fact that the section is flooded on all sides and is i relatively thin. In addition, the ptnp goes through very few significant thermal cycles.
l For the actual analysis, the equivalent pressure load ^was acclied to the cover end of the part with the diffuser vane end fixed in the axial i l
direction. % ree models were run to see if any significant redistribution of local stresses occurs due to the presence of the indicatim in the part.
The indication was sinulated by reovire thin elments to create a notch-type void in two of the models. S e third model includes the ocuplete D. section.
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t N LIMITS ON ALL FINISH DIMENSIONS uNtess oTwcRwisc sPECirito. PACIFIC PUMPS FRACTION AL 1 Y64 DMSON OF INDUSTRIES ANCULAR 1 Y4*
PAPALLEL i .002 IN 30" '
- CONCENTRIC WiTH:N .002 F.fR.
g' BREAK OR BURR ALL MACHINED g SHAPP CORNER 3 APPP0X.C:Or45 CAM 6 /8/ DATE UNLES3 OTHE'1WISC $PECIFIED CKD. APPROVED -
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SECTICN III STRESS ANALYSIS l
On the next three pages we see the relevant results of these analyses.
In each sketch the elsent ntmber is shown in parenthesis and the stress as either a positive or negative nunber. We have used the standard convention of positive ntsnbers repmsenting tension and negativ numbers representing otrnpression.
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g 3" JHF INT &EDIATE COVER CIRCLIFEREiTIAL sitisSES I
_g (PSI)
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(225) (220) (212) (202) (203) (204) hcm l 2500 2500 1600 900 950 900 (206 800 500 (230) (182) G78) G59) G60) (161) (162) (163)
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1 SELTION III STRESS ANAINSIS As can be seen frun these sketches, the stress distribution in the shroud is mostly due to a bending load acting across the section. This agrees with what we expect since the load path is predminantly frun the return vane to the diffuser vane and is intr % M into the shroud as bending from the forces applied by adjacent vanes. In addition, we see that absence or presence of the indication does not significantly alter the stresses. h magnitude of the stresses are quite small especially shen we consider that we are dealing with an alloy (CAeN) havino a minimm yield strength of 80000 psi and minim m ultinate tensile of 110000 psi.
Ibr reference, the ASME B&W allowable for this alloy is 27500 psi.
In simnary, we have calculated stresses of approximately 2000 psi. For purpose of further analysis, we will add conservatism by t. sing 3000 osi for the " static" cmponent and 100 psi (approximately 3% of 3000) for the "dynmic" u wsent. N " static" w .ent is really not static since it is applied many times over the life of the plant; specifically, each time the pm p is started. Frm the N.S.S.S. vendor (Westinghouse) we have data that indicates that a reasonable upper bound for the starts and stops is 2500 cycles. h cycles for the " dynamic" omponent has been similarly determined by considering the expected maximmioperating time of the pmp and the total n of blade passings that would occur.
t '1his nmber turned out to be 2 x 10 cycles. h above data was given O to aettex =a u ea su *te tr cture ca nic 1vsi to n ta t the presence of the indication will not lead to cart failure.
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ETT MATERIALS ENGINEEPING TECHNOLOGY LABORATORIES l
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PACIFIC PUMP P.O. 74450 i
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1 ANALYSIS OF LINEAR INDICATIONS t ON SHROUD SECTION OF INTERMEDIATE COVER 9th STAGE 1 j S.I. PUMP SERIAL NO. 51928 l SIZE 3", MODEL JHF, 11 STAGE I l
l Prepared by:
L. Raymond, Ph.D. '
METTEK Report #220431-/
+
^
FINAL REPORT 15 JUNE 1982 Prepared for:
} PACIFIC PUMP DIVISION DRESSER INDUSTRIES, INC. l HUNTINGTON PARK, CA 90255
{ 'tA) l lRVINE INDUSTRIAL COMPLEX
, 1806 E. Comegio Avenue
- Santa Ana, CA 92706 * (714) 6491083 e
MATERIALS ENGINEERING TECHNOLOGY LABORATORIES 15 June 1982 Pacific Pumps S
5715 Bickett Street Huntington Park, CA 90255
, .; Attention: Ceorge Morrisey 13
SUBJECT:
ANALYSIS OF LINEAR INDICATIONS ON SHROUD SECTION w
OF INTERMEDIATE COVER (Ref. Pattern Drawing C-17519 ix m PURPOSE: To determine whether or not linear indications in
, q!
the shroud section of the intermediate cover were due to
, hot tearing in the casting processes rather than sam thm delay j cracking phenomenon.
An intermediate cover from a safety pump was submitted for analysis because recently, linear indications were visually detected in the shroud section. The part was cast in 1977 by fS Quali-Cast Corp., Chehalis, Washington (S.O. 2820/1-19-77).
J The material was specified as ASTM A296 GR CA-6NM. Any required weld repair was by shielded manual metal are per ASME Section IX. The weld electrode was AWS E410 di Mo-16.
, The casting was austenitized at 1750 F, air cooled and tempered at 1100F. At Quali-Cast, the intermediate cover P'
was tested after fabrication and was accepted after 100%
visual inspection of accessible areas and 100% magnetic particle inspection of excavations.
Linear indications were visually detected on the surface near the edge of the shroud and near the base of the dir'fuser vane.
Generally, the length of the indications did not exceed 0.25-inch and only one two occasions did the indication extend along the side of the shroud. Typical indications are illustrated on sketches appended to this report. These indications are simi-l n{ lar in nature to those found on the first pump that was inspected; l [(]_,' but were fewer in number, with one indication being somewhat longer.
r IRVINE INDUSTRl4L COMPLEX ti 1805 E. Cornegie Avenue
- Sente Ana, CA 92705 * (714) 5461083
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Pega Two Mattok Rsport d() TEST PLAN The test plan was to remove the shroud and vanes from the diffuser section using an horizontal band saw. The shroud was radio-i graphically inspected to delineate the internal profile of the surface indications. Concurrently, the diffuser cover was l
cut into segments at 900 intervals (See Fig. 15) that were used to produce four substze (R3) tensile coupons, four standard Charpy V-notched impact specimens per ASTM A3704 on mechanical testing of steel products, and one chemical i analysis. Other segments of the diffuser section were macro-etched to identify the grain structure and the extent of
- weld repair.
1 S
The shroud section had each vane identified sequentially from position 1 to position 9. The most pronounced indications
} from x-ray radiography were saw cut and removed to be charac-terized metallographically with the scanning electron micro-a(]) scope (SEM) after the pieces were broken open along the plane of the indications. Two additional Charpy specimens were
] '
machined with their fracture plane oriented parallel to the plane of the indications. These CVN specimens were then fatigue pre-cracked and used to measure the fracture toughness (KIc) per ASTM E399. From the remaining segments of the shroud section two standard R1 tensile coupons per ASTM A370 were used to determine the tensile properties in compliance with ASTM A296, the specification for the CA-6NM casting alloy.
RESULTS Sectionina of Intermediate pume Each vane on the. shroud section was identified with scribe marks 1-9 as shown on the Figures 1 5
thnxch 12. The indications at the base of the vanes are high-lighted in Figures 5thnxqh 12. The separation of the cover from I the diffuser prior to cutting test couponsis shown in Figures 13
'({,- and 14 After the saw cuts, the remaining pieces were re-
's Freewe usenemos e esses cerrosen . Penwe Anae rese 4
Pcgo Thros i
Mattok Rsport O
assembled and illustrated in Figures 17 through 20.
i 4
X-ray Radioaranhv The attempt to delineate the internal
, profile of the linear indication was not successful. Only a direct shot of the entire diffuser section was used to
- identify the extent of the depth of the linear indication
} by the contrast noted at the respective positions; i.e.,
, a definitive dark line on the x-ray film implied a deep crack j as compared to a very faint line on the x-ray film which suggested a shallow surface crack. On this basis, five of j'
the 9 vane locations were identified as having cracks.
Location 6 (Fig. 6 ) was interpreted to be most severe, and lj positions 3 and 8 were interpreted to be less severe and the remaining 4 and 5 were interpreted to be surface indica-tions. Position 2 was not detected by x-ray although noted O vi = 1tv-Tensile Pronerties The results of tensile tests are listed in
] Table 1. The minimum values taken from AS M A 296 are also listed for comparison. As noted, the minimum yield strength I and tensile strength are exceeded. In all cases the ductility I
parameters of elongation in 2 inches and reduction in area are only met by sample B from the R1 specimen. The other samples appear to be slightly below the minimum specified 154 elongation. These values also compared well with the original test report by Quali-Cast Corp.
charow T===ct Test The results from the Charpy Impact Tests (Type A) at room temperature measured 20, 26, 16 and 18 ft-lbs with the corresponding lateral expansion in mils of 17, 18, 11 and 12 respectively. No inpact are specified in ASTM A296, but numbers from climax Molybdonum's literature suggest that a
Premweessenemse . enesecenemen . reswe aaeree r
PEga Four Mattsk Rsport I
impact energy at room temperature could be as high as f
60 ft-lbs.
+
Chemical Analvais The spectrochemical analysis shows the composition as listed in Table 2 and compared to the require-ments in ASTM A296. As noted, the chemistry is within speci-
. fication and again compares favorably to the Quali-Cast
.e material test report for these castings.
g Fracture Touchness is not a requirement for the casting 2
alloy CA-6NM but an attempt was made to measure the fracture
- toughness in order to estimate the damage tolerances of the
@ casting by other means than the Charpy Impact energy. As noted in Table 3, the material was extremely tough because ;
j a valid brittle fracture toughness test could not be produced in the 3-point, slow bend test. The significance of the measurement is that a minimum value for fracture toughness can be estimated. This minimum value, in turn, can be used to calculate the critical stresses required for rapid crack propagation. This stress, in turn, can be compared to the anticipated stresses that the part will see in service.
l This approach shows the critical stress to exceed 80 kai, for an y 0.25-inch edge defect through the tip of the shroud.
Metalloaranhv Three metallographic mounts were taken from the piece shown in Figure 21 which is from vane #6 after it was broken open at the position of the linear indication. The depth profile of the defect can be seen in Figure 22 and is
$ delineated by comparing the dark area to the bright region that has metallic lustre. Mount #1 is shown in Figure 23 and it i
f represents a transverse section through the fracture face previously shown. As noted, the grain flow,is typical of the y corner-of a casting and at high magnifications,the microstructure was seen to be tempered martensite .as anticipated. Figures 23 through2s show the fracture face both in the. dark region and messw. uswenee e esser conseen . Penw aass,
+
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Paga Fivo Mattek Report I l
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O ** rr *2r 5 r a "rr c - '*
an oxide film as shown in Figure a rx < 91== c =
25, where secondary crack-a 'r ing was also found to exist (Fig. 24 ) . The decarburization
.5 located along the secondary cracks suggest that the cracks ;
existed prior to heat treatment. The oxide film being black l a
> in coloring also suggests a high temperature oxide. These i
i features are typical of all phenomenon described as a hot l
} tear which is comonly observed in the 400 series of casting alloys. A second mount was taken at a section parallel to i
the fracture face and, again, the grain flow and microstruc-
}# ture was as normally expected. The third mount was taken
- q from the fracture pieces of a Charpy specimen and l J again shows the consistency of the grain flow and microstruc- :
ture throughout the casting. The indications at #2 and #8 are exposed in Figures 33 and 34.. ,
SEM/Fractocranhv Figurer 29 and 30 show the surface of the dark area and bright metallic area as examined with the SEM. -
v, As noted, the dark area has many products of high temperature oxidation as compared to the fracture area which shows the classic features of dimple rupture. No slow growth crack i
. extention was noted beyond the dark zone. A typical surface ;
. weld repair is shown in Figures 31 and 32. The inclusion was
,B identified by x-ray microprobe (XRN) analysis..
AER/.XBM A series of x-ray spectra were obtained by scanning ;
the different regions of the fracture face and weld repair nugget area. . Trace 1 shows.the peaks typical of the base metal' consistent with the CA-6MM alloy. Trace 3 shows a ;
.) comparison of the x-ray spectra of the black oxide area in 3 ,
order to identify any surface contamination.- other than ,
potassium (K) , calcium (Ca) , Land phosphorus (P) ,, , no unusual
]'
contamination was observed, consistent with the discolora-y; ; tion being-caused by oxidation instead of corrosion.- The
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Paga Six I Mettok Rsport l remaining spectra are of the weld repair nugget (Traces 5-7) and they identify the inclusion to be titanium (Ti) , probably a cutting on 'the weld repair electrode.
CONCLUSIONS / RECOMMENDATIONS
- 1. The linear indications are generally superficial in nature '
except for the one located at vane #6 which was almost 1/4 of an inch deep and through the tip of the shroud.
- 2. CA-6NM casting material meets the requirements of ASTM I
specification A296 with regard to chemistry and tensile tests.
Additional Charpy impact and fracture toughness tests showed I
the material to be extremely damage tolerant.
- 3. No indications of slow crack growth by any time delay mechanism is suggested. The residual stresses as noted by
_ opening of the diffuser shroud during the cutting operation was found to be non-existent; i.e., no changes in dimensions were observed with cutting.
- 4. The linear indications were caused by hot tear cracks introduced during the original casting operation.
- 5. A fracture analysis might be performed to convincingly establish that the existing hot tear cracks are not a potential safety hazard. This would require better stress analysis of the part and definition of anticipated service loads.
Respectfully submitted,
! METTEK Laboratories
.p I Gt P L. Raymond, Ph.D.
Consulting Engineer dr 6
Freewe Mecommes e swees corresen e Fe&e Analyess W 4 e < --
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TABLE 1 TENSILE PROPERTIES PER ASTM A370 m
Y.S.* T.S.* Elongation Reduction ja Source (ksi) (ksi) (%) of Area (i) 3, ASTM A296 80 min. 110 min. 15 min. 35 min.
S Quali-Cast 99.9 126.8 15.7 40.7
, Test Report j 3659 A
R3 (0. 25-in) 89.6 122.0 10.5 50.4 jj 91.6 120.2 10.0 53.7 g 89.6 122.2 11.5 50.4 90.7 120.9 11.5 43.8 2 - R1 (0.50-in) 97.0 120.6 10.0 24.5 98.2 121.5 18.5 45.1 C' .
I
- Y.S. = Yield Strength
- T.S. = Tensile Strength
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- TABLE 2 I CHEMICAL ANALYSIS Source C Mn Si P S Cr Ni Mo ASTM A296 0.06 max 1.0 max 1.0 max .04 max .04 max 11.5/14.0 3.5/4.5 0.4/1.0 Quali-cast 0.05 .40 .75 .020 .024 12.5 4.0 0.65 Test Report 3659 '
85lTTEK 0.06 .60 .71 .017 .023 12.7 4.5 0.74
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- TABLE 3 J
FRACTURE TOUGHNESS ESTIMATES
't i
i 1
Location B W A s pmax Peq Keq (in) (in) (in) (in) (kips) (kips) (ksi En)
Vane #2 .395 . 395 .201 1.9 1.21 2.44 140 7
2_ Vane #8 .395 .393 .198 3.9 1.20 2.57 146 0
Type of Test: Slow bend precracked Charpy per ASTM E399-81 q
Temp = 74F Rel Hum = 51% Kf (max) = 28 ksi M BIc = 5-inches 5.
- KIc Test Invalid per E399; therefore, equivalent energy estimate of fracture toughness (Keq) based on assumption of crack initiation at max load.
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I l
f ;I [ ![
j g
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> l_. .i. I ' ll d i . II . !l ' ! f ii l ! ji' il ; .k) i d I
i ! II l } Li !]. I! [N I2 ! j d '. !
l l di . !
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} l] l'T ][ (( { j]l qlil% }F!. jl.[l ][ {- g] ll
' ' ~
p f "r! l i g [ [ [M n p p il l ijji t!f lj ' j j' amLml f IN I E il Ii -
M 2 4 6 8 10 12 14 16 18 20 0 0
X-RAY ENERGY IN kev U Trace 1 X-ray spectrum of bright area on fracture face of Fig. 2., Location Vane #6, consistent with the chemistry in CA-6NM.
~ ~
~ A 7 T 7 E] Q R f7 E T1 ED C E L ,
()l V KII4 VOLTS W W FULL SCALE 1030 SECONDS OF COUNT 100 JOB ORDER NUMBER 220431 Matenals Engawenng Tutmoogy Latwatones MAGNIFICATION 250x " '* * *** * "'**" " " "*" "
12 ' -
I I -
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lu llcl:ii; %Ilp nnM 2 o
2 4 6 8 10 12 14 16 18 20 Y o
X-RAY ENERGY IN kev Trace 2 Same as Trace 1, but with scale expanded to show minor contaminated peaks of aluminum (A1) and calcium (Ca).
Thirtc:n i
t8 3-E +t o EG:
e a .-
\_/ m E@ 3 4
v C
-l U
m ._ r
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=
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2.:=_
r . c . t.
_ l: :.
t r -
u.:
r
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q:-
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2- ? .:
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N a
O n -=.. -.:- q, . _
g _==_ 1:_ .2
...; . a. - . - ._u_ .n-
, . = =: . z u:--- .- . ;.:- ::. - :.r; C
_' - 9.:
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= p=.
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co
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7 dri F_T~ si--5$ ~t r55 M= ~%il-d5 TE5; a ~~N b O
m ;. .
-=;
. . ._1_: +:= _ :_.tr. .= L _:.-
~==-
r=. - - -
- - 2.:
- , c 2=_ m
=_.. === =r M 35
~=
&g 3-
_=_-L=.._'.~i._~_ ._ :- t._ =_ E. _ _:_:r _.-_:a _ . ; - _:. . :. . =i _..
. .. ~*iD_L t.=. =+ - - . . . =.... E
=== ..: r- - _:= :- : = ..=: r r. - . = = -
=:= = .=,= =- O
==- - --- = ==::-
=:: = . .: =. _ - - - - 2.:_ ,2 :::= w= __c._=_ e y
-r_ : .: = ==.. ==r: - ;= _:.::= M %
. ..: -- t-- r. r= =.g=r.:=;z::. :._ =.rm -u:= 1. = ;;: ;
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=;*'~~.
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- _'~ U
- g . .,. ..
- y,- . - . . _;;, ;_-.- g y_;f ;1 .-_7__
-_; +=; =;---. =t;=;1 -- n .= .; ;; - 1:
33;
= T-- w:: .a ~~.Ic =. =p w
.-_r_:
. _ . _ . __ __=-.. _^ _.- . . . g
._m .-_. . . ~.. _
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- t._ =. . . .=_ [=. . _a-.. :-._-- .. .::
_. . . 1 - .
. ._ gge 'Q
.r. - 1: m._. :~.: =r-: y: . _.: : =1=;. . ._ : . . --
- . M
- . r_=. = ~ . = . ..:'z .a :--12m.
_ _: - - ==_: --w :~ = :: r- :: r- . =r- w
. -- :.y. - . =; _r .r. : =~r =_- . e. =_. -..::= ... r. . ~ . . .- . - .~_
n
.: .2_: . ~.-- _ - _ . . ~ . .x.
_ t -
u._ . _t _. _
y _ . - . _ ... p-- 0
-1_3 mt:=._- := =r2 =r= =m ._; . ac : . :- ; _ _.u22- _, ._
- - c 4
.=r :4 :t= .=.:.== >g U
__ ; ._ [ -. - . . -_tr. .=.r..-
._ g_. = .r.- ~~'~g+
_Q ; .:... . -4r.. g r._. j: . a.
y c
_ u . :. -+ ~ w u . ; . ._ = ;;; -_ 1 ..- t -- -- - --
w
. :- .c_:;.2..=:---d :. = ,=."T-. . . = h._ -
.r.7 - . :_ r _ _2a : :Lr :;c xr; c
- rr z c=;=- n:=
m t: . _ . _I _: me t .=. 2q 2. .
(,3 : rn. =: :=.- r-. tu - --J :: tr - t: - rrr- _c.r- - :t q _= - :: . .= u -r - s L v) 1- ;3
\ L:.t_ :: ~ . : ..:... :.z z : n.u .:
- r= t-- 1=-
t
==- . -- = t __
t...
_-.j:.:.: . ._ .: } z .:= . ;.=
...a _
==
y Q 3_- n U
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. v 7_.. m .=--
.g e4 Uh.. --. _._*dbb._~.
4 .' ' - ~ .I.=.*:._.*. b,b_"b. b.E.2_ . bbr_- .. . b. S. t _ . d b.. '
- _,f.3. .,b.. b,.
M M =_.g = = =1. - - -- +- "-
w = . = ==.}== =-- :t = =. W+=..= =h- -:.=- :.-r - =-k- - := = -; - - --n.
b c
p n
~~
= Ib C ;=~ E b.h .
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~
mmg 1 '
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r- =--w-- a ^ r rw'- acQ-u x, r* G3 9 E 2 : :==t= =.1 = r_t 1.: mr r t. n :: rt- mf:- + -
a_. g N U O -%ar" '
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-- - .-_.u1 g g h 52 E _ _. i .7jE J.Z Q ~_. .:-l'r :~j ' =i- : =j= rrb=C M
e ogg =EZt==:= .+
1 =i ; E-ts"
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=M @ j4 d..dr-
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=. p.;=m
- =
e4 O U2 H
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;_ ,7= =. =
- _ E, = ;_ . ;,.
- t;:-_ :: . ..- _.b;;, _. J_ . __EE{~~-
_ n,
> 0H
=t . _ _
-~; H g
t= _ = _.=_a=- =- : 2 _.1 : = ... :: = =. ---:; =... =
=;- =-- y z .n .=..
_ = ==-== == =- - - == == -- - - - -
3 y 43 -
== r-- :- ==. = = = 2; = = :: 122- = ;--- =
H D En3 0 ---t - .= . _ - ~ _
.--, =: rr = --
r --
H=
y M In. M b =g
_= = -
-or- = - t = = = = = = T
. , - _= . _ . = ~ ===..= ,
-._w
=_=_=_A:=.: ==...a=== . . . -_. ..=_. .r . r N@
._.. . . .... .. .. . i_ ._._ .._. . _ . . , . . ...m,_ ._. ... _.. -
=_ :, =_=_ L=_. = _ .= _ . =_=_ = . .= . . ..=...{_ ._ .. .._.
....y .
- z.=.;== =---
p
. =. =
t
_= =r_*==
.- = ==
=
=
. . . = ==r-
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qg yC
- i..-.=. - - - = -. = =
. ee ..
= ==--- r. ~: = i,-- == r
.. ..e z- -~- ;- p
- e. . 7. . . ,
- -_,; d ,4
=r- =.= .=== =t= ==-- = = =. . . . = .= 2 N gy
-t=
=--- _. -.. ._ = --
= == = == n= m ---
=: .
. = ...-- -r 3 e l.i
} 5E !.Ei ;bb: : [..b 5. ,5f 'i .- $ N. [-kd. f. [ :-d ' [bt m
( ..
E_U.=_;.=...E_.L.. .d. - ..
.. m . . . . _
E.E:E_E_".i. _E- 5. . . - l' E_J_i..
2;i di._:
~.
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- E. . .Lu. _i- z.iH.' FE r
d W g
ga:= n :.= .= ::; = =:= :- :::r= . H;: = ,g.c;; =tw _.h.
9 H
N v4 H
M o e e t~ w m w m N m M
SIING AWYM118W NI AJ.ISN21NI AW-X
. s ~ . .=
- w -
_ 8J x- )
KII4 VOLTS 27.5 FULL SCALE 1030 SECONDS OF COUNT 100 JOB ORDER NUMBER 220431 Ma*a*'5 Waa=9 M'*8o9r Labma'**5 250x som c ,.a .s , ca mos er ..m eon MAGNIFICATION 12 n. . ,s m .so cr., ..,3a
- : , r i, :: ',
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t is e 10 10: :ii ! i En # ."! Eng ,J. L.i Y, j.
k.M m ..6,,,iy ;
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n :y ;. j r. a .4 ,a m ,
m a.g.,, i
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2 4 6 8 10 12 14 16 18 20 3 X-RAY ENERGY IN kev Trace 4 Sasee as Trace 3 but with scale expanded to show minor peaks of phosphorous (P),
calcium (Ca), and potassiun (K).
_p .. 'D T C.3 O Y C
id n i J G KIIDVOLTS 27.5 FULL SCALE 8440 SECONDS OF COUNT 100 JOB ORDER MUp6ER 220431 m'*'s Ease =9 M*o'o9r L*6***5 250x mu ca a s.- a-. ca mowwaaion2 MAGNIFICATION 12 . .
n Ji o a;.
a.;' . p. e.l . ' .! a %
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.. 3.t a ea aa a 1 E.+2 Law Ela i.Er w E-N O4 0 DIFFUSER VANE SHROUD RETURN GUIDE VANE DIFFUSER VANE COVER RETURN GUIDE VANE SHROUD ,
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l Sketch of indication at edge of shroud near base of diffuser vane #2, blades number sequentially clockwise 1 through 9. Profile of hot tear crack is sketched to illustrate appearance after piece was broken open at indication (2/3 scale).
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Sketch of indication at edge of shroud near base of diffuser vane #8, blades number sequentially clockwise 1 through 9. Profile of hot tear crack is sketched to illustrate appearance after piece was broken open at indication (2/3 scale).
9 MATERIALS ENGINEERING TECHNOLOGY LABORATORIES f i l t t PACIFIC PUMP P.O. 74450 l l DEVELOP ACCEPTANCE CRITERIA BASED ON FRACTURE MECHANICS ANALYSIS OF LINEAR SURFACE INDICATIONS ON SHROUD SECTION OF INTERMEDIATE COVER 9TH-STAGE // S.I. PUMP SERIAL No. 51928 SIZE 3-INCH, MODEL JHF, 11 STAGE
- l l
, Prepared by:
L. Raymond, Ph.D. METTEK Report #220431-2 ~ SUPPLEMENT / PHASE II 18 November 1982 F
' e i Prepared for:
PACIFIC PIMP DIVISION i I DRESSER INDUSTRIES, INC. t l HUNTINGTON PARK, CA 90255 i
}' )
- r IRVINE INDUSTRIAL COMPLEX is0S E. Cornesis Avenue
- Sene Ana, CA 92M5 * (714) 5401983
MATERIALS ENGINEERING TECHNOLOGY LABORATORIES O i 18 November 1982 Pacific Pumps 5715 Bickette Street Huntington Park, CA 92055 Attention: G. Morrissy
SUBJECT:
DEVELOP ACCEPTANCE CRITERIA BASED ON FRACTURE MECHANICS ANALYSIS OF LINEAR SURFACE INDICATIONS ON SHROUD SECTION OF INTERMEDIATE COVER (Ref. Pattern Drawing C-17519) ABSTRACT Q An initial investigation identified linear surface indications on the shroud section of an intermediate cover to be hot tears and not due to any time delay cracking phenomenon. The tears were essentially superficial, loca-ted radially near the edge at the tip of vanes. This phase of the study was used to characterize a CA-6NM casting alloy by machining test specimens from an actual interme-diate pump cover and measure the material properties with-in the framework of fracture mechanics. The test results were used to perform a safe-life cycle analysis from which 4 it was concluded from the most conservative analysis that took into account the worst case operating conditions, the safety of the pump was not being jeopardized, primarily because of the low operating stresses producing a below threshold operating fatigue stress intensity range. Ib tV 4 IRVINE INDUSTRIAL COMPLEX 1905 E. Comesie Avenue
- sente Ans. CA 92705 * (714) 5401083
em [ 1 '.O I
1.0 INTRODUCTION
I A previous METTEK Report #220431-1 (PHASE I) identified the
; source of the linear surface indications to be hot tears or
, a surface separation occuring during solidification because of tensile stresses in the skin produced when the surface begins
. to solidify and contract ahead of the remainder of the section. CA-6NM is an alloy modification to the widely used CA-15. One purpose for the modifications is to decrease the sensitivity of commonly detected surface separations that occur during solidifi-cations thereby minimizing the cost of weld repair, which is a common and an acceptable practice for this family of casting ~ O alloys. This report covers the additional work performed at METTEK Labs in order to develop an acceptance criteria for the intermediate covers found to contain the linear surface indications. The approach was to: e characterize the CA-619f casting alloy with regard to the size, shape and location i of the hot tears found in'the intermediate covers, specifically in the shroud sections e characterize the ca-6MM casting alloy from an intermediate cover by selectively sectioning: fo Fessewe namensmes . sneseconemen . rain. anser
'5 L.._~_ , , ,
- - Pega Thres .i i
([]) an actual cover and machining test specimens I for determination of the yield strength (YS), I { tensile strength (UTS), fracture toughness (KIc), fatigue crack growth rate (da/dN) in air and a boric acid solution (corrosion fatigue), and the threshold stress intensity for sustained load crack growth rate in a boric acid solution 1 (KIscc). . e determine the load history profile for start-up and on-line pressure pulses for a projected 40-year lifes e analyze for the safe design life employing () fracture mechanics. The entire approach throughout this phase of the program was to take a WORST-CASE approach to the analysis. ALL values selected in the safe-life design analysis were to be selected to provide an extremely conservative approach to the analysis i.e., maximum , anticipated stresses, lowest fracture toughness, highest crack growth rates, largest possible size and shape of the hot . tear, j located radially to the circularly shapedL shroud section. l 1 r' .
\O me.sw.namen .. snes o . r an ,
eng,
Pcgs Four 1 (:) I The results of the safe-life prediction analysis are presented { graphically in order to visually illustrate the relative location of the maximum anticipated operating stresses in the intermediate
~
cover relative to the safe-life design envelope. It is the intention of this study to analytically and graphically illustrate the margin of safety existing in the current design of the intermediate cover when linear surface indications are located radially at the edge of the shroud section, near the tip of thz diffuser. The approach was to use finite element analysis to i establish the operating stresses and fracture mechanics test (]) methods to measure the important parameters that can cause suberitical crack growth or crack extension. Then, a fracture mechanics analysis employing the current state-of-the-art tech-niques and incorporating an extremely conservative approach was used to predict the safe-life operating conditions. It is within this framework that any. potential hazard of operating the pump with the existing linear surface indications was evaluated. 1 4 i ( c namenense .. ' meseconeeen . ran,e aneiro.
Pogs Fiva J l 1 (
}
2.0 BACKGROUND
l As previously shown in the first (PHASE I) METTEK report
#220431-1, the CA-6NM casting did satisfy the chemical, tensile, and hardness requirements of ASTM STD A296-74 for corrosion-resistant, iron-chromium-nickel-molybdenum alloy castings.
The workmanship and quality, which specifies visual examination of the surfaces to locate adhering " sand, scale, cracks, and hot-tears", satisfied all requirements. Magnetic particle inspec-l tion of this alloy casting is only upon agreement between the manufacturer and purchaser. During the original manufacture of the intermediate pump covers, only visual examination was required. Of the parts in question, the diffuser with the largest number, size, and density of surface indications was selected for destructive examination. On metallurgical examination, no microstructural anomalies were found and internal shrinkage cavities were few in number and were well within acceptable limits.
'X-ray radiographs suggested that the linear indications were .
primarily_ surface indications except-for the vane' labelled #6.- All indications were located-at the edge of the shroud cover,: l near the tip of the vane, essentially radially oriented. i D. p.m.,. as n .. sc . p aass, 4
Page Six O I Weld repairs were found on the surface of the cover section 4 i and were considered minor, which per ASTM STD A296 means that i the depth of the cavity after preparation for repair does not
. exceed 20% of the actual thickness or 0.16-. inch for the shroud.
Minor weld repairs can be made by the manufacturer without prior approval of the purchaser. Since the linear indications in question were not detected
, during any previous inspection, one question addressed in the first phase of this study was if the linear surface indications were due to some time delay cracking phenomenon. Residual .
stresses were found to be non-existent by selective cutting techniques. No indication of slow' growth by any time delay i I t mechanism was suggested by examination with the scanning elec- l tron microscopes therefore, the only remaining conclusion was that the linear indications existed from time of manufacture. A possible reason that they were overlooked was the, presence-of smeared metal on the surface that was introduced during the routine surface cleaning operation of the intermediate cover prior to visual inspection. J
+
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I O l 3.0 APPROACH I Every reasonable attempt was made to orient the test specimens such that they are representive of the material in the location and direction that a hot tear might extend by fatigue or stress corrosion. For example, the Charpy impact specimens were machined from pieces taken directly behind the region containing the linear surface indication at the radial edge of the sh?;oud with the fracture plane of the Charpy specimen defined by the notch, loca-ted parallel to the plane defined by the linear surface indication. ' In retrospect, the mechanical properties established the fact that . s+- the casting is homogeneous throughout, both within the shroud and O cover sections. For completeness, the results of the chemical analysis and tensile properties taken from the Phase I report are again included as j Tables 1 and 2, respectively. The chemistry is seen to meet ASTM STD 296 from all aspects. The tensile properties show the tensile strength to be the same in both the shroud and cover sections. A
, lower yield strength is obtained with the sub-size R3-tensile j specimens machined from the cover section. In all cases, the mini- l num yield and tensile strength are exceeded but the ductility Parameters of elongation and reduction in area are only satisfied by one. standard sized (Rl) tensile specimen machined from the
(} shroud section. No serious violations of.the mechanical property
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O TA3121. CNNICAL ANALYSIS i source e m si y a cr Ni ano AS198 A296 0.06 max 1.0 max 1.0 max .04 max .e4 max 11.5/14.0 3.5/4.5 0.4/1.0 Duali. cast 0.05 .40 .75 .020 .024 12.5 4.0 0.65 Test Report 3659 METTEX 0.06 .60 .71 .017 .023 12.7 4.5 0.74
-a TABLE 2. TENS *.LZ PROPERTIES PER AS7M STD A370 Y.S.* T.S.* Elongation Reduction source fkat) ihmil (m) of Area it)
ASTM A296 80 min. 110 min. 15 min. 35 min. Qua12 cast 99.9 126.8 15.7 40.7 7tst Report 3459 R3 (O.25 1a) 89.6 122.0 10.5 50.4 i COVER 91.6 120.2 10.0 53.7 89.6 122.2 11.5 50.4 90.7 120.9 11.5 43.8 R1 (0.50-in) 97.0 120.6 10.0 24.5 SHR02 90.2 121.5 18.5 45.1 W.S. = Yield Strength t
*T.S. = 7ene11e Strength .- ~
v 1 l F= m . an e c- . r,.,,,,,,, l l l l
rmge zight t l j measurements are noted and the variations are to be expected in' comparison to a separately cast test bar commonly used to i verify the mechanical properties of a casting. i The remainder of this report will present the Laboratory test Program results obtained during this phase of the investigation
, and the resulting analysis. Mechanical properties that were measured for safe-life design analysis were:
e FRACTURE TOUGHNESS
- three point bend per ASTM STD E399 @ OF & RT dynamic, instrumented impact per ASTM STD 819-81 @
O OF. 30F. 60F. & 90F correlation with STD-CVN per ASTM STD E23-81 @ OF, 30F, 60F, 90F, 200F & 400F e FATIGUE CRACK GROWIH RATE per ASTM STD E647-81
- Air @ RT
- Boric Acid Solution @ RT e SYRESS CORROSION THRESHOLD Boric Acid Solution @ RT o'
l l re cw . u.ca n . so c a . Fewe aasiv STD = standard CVN = Charpy V-notched Impact
Pcgo Nina i 4.0 RESULTS P 4.1- FRACTURE TOUGHNESS l i ! j 4.1.1 Three Point Bend per ASTM STD E399 Charpy-sized fatigue precracked specimens were tested per ASTM SU) f399-81@ OF and RT. The displacement was monitored both by load-line and clip-gage-opening-displacement (COD) techniques. The purpose for these measurements was the possible utilization i of non-linear fracture mechanics estimates of fracture toughness such as the J-intergral, the British COD, or the equivalent A energy methods in case a valid, linear-elastic solution could (]} not be obtained. The load-displacement traces are shown on Fig. 1. The two room temperature samples were machined from the shroud directly behind the linear indications at the base of vane #2 and vane #8. The exceptionally high ductility is apparent. The frac-ture toughness per E399 is invalid
- suggesting an absolute mini-mum of KIc > hB/2.5* YS = 40 Ksi 6 .3 but implying a n.uch higher toughness because of the large amount of plasticity exhibited during the fracture process. ,
i \ i The two 0F samples were machined from the cover section. They were again fatigue precracked and tested with a COD-gage to monitor displacement. Because of smaller span (S) between l supports, a variation in the load-displacement curve was observed l (Figare 1). A computer printout for the analysis per ASTM f,TD {("~.
)
E399-81 is attached. a , .-p g St 4 eda +y* ev
. Page 9A i
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- Pmax=1.45 Kips S=1. 6-in)
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-We.4 1 10' 20 30 40 50 COD, mils Figure'I. Load-displacement traces of 3-point bend fracture toughness tests per ASTM E399-81 using precracked Charpy-sized specimens. The load-displacement curves vary because the span (S) between supports varied.
I Also, the room temperature'(R.T.) tests were conducted under displacement control whereas the OF specimens
-were tested under load control.
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9 . PnRa 9B SAMPLE COMPUTER PRINT OUT OF BEND E399-81 TEST RESULTS- R.T.
- l BEND E399-81 TEST RESLLTS BEND E399-81 TEST RESULTS IlruT DATA ISPUT DATA l ID NO: 82 ID NO: #8 ORIENTATION: 2 ORIENTATION: S TEMPERATURE: 74F TEMPERATURE: 74F
- ! LOADING RATE: SLOW LOADING RATE: SLOW REL HUMIDITY: 51% REL HUMIDITY: 51%
DIMENSIONS (INCH) DIMENSIONS (INCH) (S) SPAN: 1.9 (S) SPAN 1.9 (B) THICKNESS: .395 (B) THICKNESS: .395 (W) DEPTH: .395 (W) DEPTH: .393 (F) RATIO BF/B 1 (F) RATIO BF/B: 1 CRACK LENGTH (INCH) CRACK LENGTH (INCH) (M1) -MIDWAY 1: .202 (M1) -MIDWAY 1: .201 (C) -CENTER: .202 (C) -CENTER: .199 (M2) -MIDWAY 2: .198 (M2) -MIDWAY 2 .195 t (A) AVERAGE: .201 (A) AVERAGE: .198
0.9 AVERAGE
.181 0.9 AVERAGE: .179 (S1) SURFACE 1: .190 (S1) SURFACE 1: .192 (S2) SURFACE 2 .184 (S2) SURFACE 2 .181 YS(KSI): 98 YS(KSI): 98 E(KSI): 30000 E(KSI): 30000 PF(KIPS): .4 PF(KIPS): .4 PQ(KIPS): .92 PQ(KIPS): .895 PMAX(KIPS): 1.21 PMAX(KIPS): 1. ~2 i SUCCESS' CRITERIA SUCCESS CRITERIA (M1-C)/0.05A < 1 0 (M1-C)/O.05A < 1 : .2 (M2-C)/0.05A < 1 .4 (M2-C)/0.05A < 1 : .4 (M2-M1)/0.05A <'1 : .4 (M2-M1)/0.05A < 1 : .61
.9A / S1 < 1 : .95 .9A / S1 < 1 .93
.9A / S2-< 1 .98 .9A / S2 < 1 .99
'(0.45W) / A< 1 : .89 (0.45W) / A <-1 .89 A/ (0.55W) < 1 : .92- A/ (0.55W)-< 1 : .92 KF/0.6KQ < 1 ~ . 72 KF/0.6KG < 1 : .74 KF/O.002E < 1 .35 KF/0.002E < 1 : .35 l
, BIC/B < 1 : 1.56 .BIC/B <.1 : 1.49 PMAX/1.1PQ < 1a 1.2 PMAX/1.1PQ < 1.: ~1.22 CALCULATIONS CALCULATIONS KG(KSI.IN^0.5): 48.7- KG (KSI . IN^0. 5) : 47.5
~ Reg .2 RSS : 3.9 L SIC (INCH) : .6 BICi!NCH) : - .' 6 -
]
Li' FRACTURE APPEARANCE FRACTUREiAPPEARANCE
- % OSLIGLE: ' O - X.OSLIQUE: .0
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SAMPLE COMPUTER PRINT OUT OF BEND E399-81 TEST RESULTS- 0F. BEND E399-81 TEST RESULTS BEND E399-81 TEST RESULTS IWUT DATA IDPUT DATA ID NO: #1A ID NO: #2A ORIENTATION: 1 TEMPERATURE: OF ORIENTATION: 2 I TEMPERATURE: OF i LOADING RATE: SLOW REL HUMIDITY:-20% LOADING RATE: SLOW
.'tE L H U M I D I T Y : 20/.
DIMENSIONS (INCH) DIMENSIONS (INCH) (S) SPAN: 1.6 (R) SPAN: 1.6 (B) THICKNESS: .395 (B) i (W) THICKNESS: .395 DEPTH: .395 (W) DEPTH: .395
; (F) RATIO BF/B 1 (F) RATIO BF/B: 1 CRACK LENGTH (INCH) CRACK LENGTH (INCH)
(M1) -MIDWAY la .205 (M1) (C) -CENTER: .211
-MIDWAY 1: .208 (C) -CENTER: .207 (M2) -MIDWAY 2: .201 (H2)
(A) AVERAGE: .206
-MIDWAY 2: .202 (A) AVERAGE: .206 0.TAVERAGE: .185 O.9 AVERAGE: .195 (91) SURFACE la .195 (S1) SURFACE 13 .198 (S2) SURFACE 2: .188 (S2) SURFACE 2 .188 YS(KSI): 100
. E(KSI): 30000 YS(KSI): 100 PF(KIPS): E(KSI): 30000 O PQ(KIPS): 1.2
.4 PF(KIPS):
PQ (KIF S) : 1.3
.4 PMAX(KIPS): 1.45 PMAX(KIPS): 1.44 SUCCESS CRITERIA SUCCESS CRITERIA (M1-C)/O.05A < 1 : .58 (M1-C)/O.05A < 1 : .1 (M2-C)/0.05A < 1 : .97 (M2-C)/0.05A < 1 : .49 (M2-M1)/O.05A < 1 : .39 (M2-M1)/0.05A < 1 .58
.9A / S1 < 1 .95 .9A / S1 < 1 : .93
.9A / S2 < 1 : .98 .9A / S2 < 1 .99 (0.45W) / A< 1 : .86 (0.45W) / A< 1 .86 A/ (0.55W) <1 : .95 i A/ (0.55W) < 1 : .95 KF/O.6KQ < 1 .56 KF/0.6KQ < 1 .51 KF/O.002E < 1 : .31 KF/0.002E < 1 : .31 f
i BIC/B < 1 1.97 BIC/B < 1 2.31 PMAX/1.1PQ < 1 1.1 PMAX/1.IPQ < 1 1.01 CALCULATIONS CALCULATIONS
' KG(KSI.IN^0.5): 55.7- 'KG(MSI.IN^0.5): 60.4 RSS : 2.4 RSB : 2.4
- .L BIC(INCH) .3 BIC(INCH)
- .9 j FRACTtmE APPEARANCE FRACTURE APPEARANCE X OBLIGUE: 0 X OBl.IQUE: 0
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I Pcas 10 l \ l l l One estimate of fracture toughness is based on the specimen strength ratio Rab* or KIcE 0.3 Rsb*YS=60Ksi % . Another i estimate based on a single specimen COD test, assuming that I crack initiation occurs at maximum load, is calculated to be between 139 and 150 Ksi % . The difference in the two t estimates is that the COD approach takes the additional plasticity into account. Dynamic fracture toughness, measured subsequently, is also based only on the maximum load and there-fore ignores the additional plasticity during local yielding as the speciman approaches maximum load. Finally, an equivalent energy method proposed by Witt is used
- to estimate KIc. The results of which are listed in Table 3 and found to agree quite well with the elastic-plastic COD analysis.
Since the estimates of fracture toughness are not used in sub-sequent calculations, the accuracy of the estimate is academic other than serving the purpose of suggesting a margin of safety , on toughness. In this report, only a lower limit or minimum value of fracture toughness is used to calculate critical stresses
, and predict safe-life cycles. ; ; , I A computer print out of'the COD analysis per British Standards are attached.
l l
- i. .I
* . Rapid Inexpensive tests-for determining fracture toughness
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i SAMPLE COMPUTER PRINT OUT OF COD ANALYSIS PER STANDARD BRITISH O I KCOD 3-PT TEST KCOD 3-PT TEST SAMPLE NO #2 SAMPLE ND #8 TEMP 74F TEMP A/W .509 74F A/W .501 1 DN/B el BN/B
' YS(KSI) 398 1 CODP(MILS):10 YS(KSI) 398 PMAX(KIPS):1.21 CODP(MILS) 12
! PMAX(KIPS):1.2 i S 1.6 B:.394 S 1.6
- W:.394 B:.394 Z .06 W .394 (Y DR N):N Z:.06 S 1. 9 (Y OR N):N Br.395 S:1.9 W:.395 B3.395 23.05 W .393 K(COD) 3139.2 23.05 K(CDD) 3150.3
,~
O KCOD 3-PT TEST KCDD 3-PT TEST SAMPLE NO #1A TEMP :OF SAMPLE NO #2A A/W TEMP OF
.505 BN/B 1 A/W .510 YS(MSI) :100 BN/B :1 CODP(MILS):B.75 YS(KS!) :100 PMAX(KIPS):1.450 CODP(MILS):12 S:1.6 PMAX(KIPS):1.~440 Bs.394 S 1.6 We.394 B3.394.
Z .06 W .394 -s (Y OR N):N 23.06 l [ S 1.6 (Y OR N):N Bs.395 S:1.6 Ws.395 33.395 Z . 05 We.395 K(COD) :133.& Z3.05 K(COO) :150.9
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.O I TABLE 3. FRACTURE TOUGHNEF'i ESTIMATES I
l ' USING EQUIVALENT ENERGY, ANALYSIS i
. Location B W A S Pmax Peq Keq (in) (in) (in) (in) (kips) (kips) (ksi En)
Vane #2 .395 .395 .201 1.9 1.21 2.44 140 i Vane #8 .395 .393 .198 1.9 1.20 m 2.57 146 . , 'O Type of Test: Slow bend precracked Charpy per ASTM E399-81 Temp = 74F Rel Hum = 514 Kf(max) = 28 kai G BIe = 5-inches
*KIc Test Invalid per E399; therefore, equivalent energy
.' estimate of. fracture toughness (Keg) based ~on assumption of crack initiation at-max load. l
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Pogo Elsysn 4.1.2 Dynamic Fracture Toughness P In order to determine the effects of strain or loading rate, instrumented impact tests per ASTM STD E812-81 and conventional Charpy Impact Tests per ASTM STD E23-81 were conducted. The samples we're all machined from the cover section. Typical i results are attached (pp 11A-11D) Table 4 summarizes the test data and compares the results and two loading rates and over a
, range of temperatures. The data is plotted on Fig. 2. From these results the minimum value of toughnest; at the upper shelf was conservatively estimated to be 75 Ksi h and the minimum fracture toughness on the lower shelf was 4516:.in*with a trans-ition temperature at about 100F. These minimum values were used in all subsequent analysis.
4.1.3 STANDARD CHARPY IMPACT The standard Charpy impact tests were correlated to the fatigue precracked, dynamic fracture toughness tests by using a correlation where: kid 2 = SE e CVN where E=30 Mai and CVN is in units of ft-lbs: chen, kid-is in units of Ksi $ . The relationship appears to be quite good on examining
- -' Figure 2 and Table 4.
I kJ
*1Larson/Rolfe " Fracture and Fatigue Control in Structures" 1977
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i - - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _____ . - _____._______ _______ ___________________ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - . _
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Table 4., SulWWtY OF FftACTURE TOUGHNESS DATA. i O 30 60 RT 90 200 400 METHOD Klc -- -- -- -- -- KIc -- -- -- -- -- --
- Precracked - E395 Cherpy slow send K(asb) 72,72 60.58 [
K(C00) 133,151 139,150 -- -- -- -- -- -- K(Eq) 140,146 9T11AMIC CVN Kid CVN Kid CVN Kid CVN Kid CVN Kld CVN Kid kid CVN Procracked E812 Charpy lepect -- 65.4 -- 81.5 -- 81 -- -- -- 84.3 -- -- -- -- Standard E23 24 60.0 30 67.i 26 62.$ 26 62.4' 41 78.$ 40 77.$ 43 80 3 Charpy' impact
- 16 49.0*
CVN
- Charpy V-Itotched impact energy in f t-lbs, Kid = Estimated by equivalent energy, C00 technique -- Ksi /In. -
KID = dynamic Kic, either measured or
- calculated from Kid = SEe CVN (Ksldin.) *w m
E = Elastic Modulus = 30 Msl g w M
Pcg3 11F I CA-6NM TOUGHNESS TRANSITION
. 50 - METTEK 08/18/82 ,
i a
'85 5
i 0 - 80 40 - D UPPER SHELF m j - T 7 75'7 t h .70 30 - D g " y, ce
- E O Ob 65$!
O b g - 60ij w
^ f 20 -
4
$ 4 ASTM STD d x - kid - E812-81 3
n. A o - KIc - E399-81 - 50 U j D - CVN - E 23-81 I h LOWER SHELF A - CVN - IMPACT ---# = u 10 = 45Q 40 u E
- 20 8
1-
...l.... i' ..!. _ . _ . ..
- O
- 100 200- 300 400 LAST TEMPERATURE - (F)
, FIGURE 2. Summary of fracture toughness data, plotted to delineate transition temperature behavior in addition to providing absolute minimus fracture toughness used for subsequent safe-life cycle
( analysis. p u suna. . so canea e r w e aaeres e
Pcg2 Twalva 3 0 .2 Fmourcucxc-en or. Fatigue testing for crack growth rates as a function of
- the crack-tip stress intensity range (6 K) was done accord-I ing to ASTM STD E647-81 using a compact type specimen with i
the thickness (B) equal to 0.5-inches and the width (W) equal to 1.5-inches. During tests the crack length was 9 measured optically from both sides with a travelling micro-scope. The average crack length (a) was used in calculating the rates. Testing was at a frequency range of 10-60Hz ' depending on the applied stress intensity range. The stress ratio (R) was 0.1 and the temperature was ambient or about - Q 80F. Fatigue crack extension was monitored as a function of the number of fatigue cycles (N). The incremental polynominal method, a recommended curve smoothing technique described-in the Appendix of ASTM E6 7-81 was used to analyze the data and calculate the slope or rate of crack extension. An Apple computer was used to perform the analysis and plot the re-sults as shown on Figure 3. e e f I
~O n ensame. . an.e. ommesa . Panne w
,' e ' '
._ -~
. . . ~ . . .
O, O _O g ._ DA/DH US. DELTA K.- SPECIMEN 6 ,! COMPACT SPECIMEN
," B = .498 in.
- J W = 1.50 in. .
lQ . 9 ' m e [ ENVIRON:4ENT Ambient Air '
%, $ Temp = 800F Q CONDIT~ONS g _ _
4E 1-60 Hs ,i Q T 1 Kip = Pmax ; 4 ,
- 0.1 - -
O.01 - - - l- - -
-}-
l lO DOO ? DELTA K y ( Ksl- In.'/2) FIGURE 3. Measured fatigue-crack growth rate in air per ASTM STD E64'-81 ~
. of CA-6NM Casting Alloy.
~ ~~ '
Ucg2 'utNirtocn In addition to conduct..g the test in air, a corrosion-g O fa,tigue study in a boric acid solution representing the refueling water in the storage tank. The purity of the water was maintained by using distilled water and adding l boric acid to provide 2000-4000 ppa of boron. The pH of i the solution was between 4.0 and 4.7 as called for in the specification supplied by Westinghouse. The oxygen was
, not controlled during test thereby again representing i
worst-case condition by using a ' system that was not de-ox-ygenated. The test results are plotted on Figure 4. On comparison, they are seen to overlay the test results in air (Fig. 3). Therefore, it can be concluded that the boric _ acid refueling water solution does not represent a more O asstessive cerresien-fatisee environment. noch sets of data are represented by a conservative upper-limit curve given by: da/dN (Micro-inches)= 2.57 x 10~0 m (A K)3.0 Eqn. 1 with 4K in units of Kai(Tn' 4 I i (i O b' i mesi e nesenemme . esses cessenen -. resw. anser 9
-- 4-.m aba -s e smuscav e v.em,=y 3 eme mm e w e-eye e se e,-.4e+ .og g--- e**,e c-+a+ ,+ ww
- - - - - --- ' . ~ \ . . . . . _ _. . _ _ . ___
~
i DA/DN US. DELTA K - SPECIMEN 2 - 100- .
, COMPACT SPECIMEN
' " "5 2"-
=
10 - -
, a W = 1.500 in.
e a ENVIRONMENT E Boric Acid Solution
" e 8 Temp = 800F gA 1- -
CONDITIONS 10 Hz [.9 I 1 Kip = Pmax
,: 0.5 - - ,
/
m 0.01 i s - f
-{-
1 10 100 DELTA K !* (Ks1-in.112) FIGURE 4. Measured corrosion fatigue-crack growth rates per ASTM STD E647-81 in a boric acid solution (pH4-4.7)I of CA -6NM casting
Pcg2 Fourtocn 4.3 STRESS CORROSION / BORIC ACID t I An accelerated stress corrosion testing method developed I at METTEK=was used to determine the threshold stress inten sity for sustained load crack growth in a boric acid solu-tion. Again, the system was not de-oxygenated, representing I the most agressive environment. One test specimen was broken in air for comparison. The results showed no environmentally assisted crack growths i.e., KIscc/KIc 3r0.9. i The test method employs a Charpy-sized specimen, loaded by a rising step method. A potential 9 -1.2V vs SCE is used to ' (} generate an aggressive hydrogen environment that has been shown to induce stress corrosion cracking in the high toughness HY-140 ship steels. 4 This same method of testing could not produce any environmentally assisted cracking in the CA-6NM casting alloy.
*Accarerated, Low-Cost Test Method for Measuring the Susceptibility of HY-Steel to Hydrosten Embrittlement. By L. Raymond,_Ph.D. , ASM Conference, Washington, D.C. November 1982 -
I m- . sneen onneena e Pensre aanwee
~s -
Pcgo Fiftocn 4 5.0 SAFE-LIFE ANALYSIS l l A conservative analysis for safe-life operating cycles
; of the inteomediate cover of the S.I. Pump requires know-I ; ledge of the largest possible size of hot tear and the operational stresses in addition to the data obtained in this test program.
1 5.1 HOT TEAR CHARACTERIZATION i The size and shape of the hot-tears were carefully identi-fled in the PHASE I report. The radial location of the hot . 4
) tear near the tip of the blade and the superficial, shallow surface shape is indicated in Figure 5 for vane f2. Figure 6 shows the worst tear that was found and coincidently, it is identified as vane #6. Again consistent with the worst case analysis, the largest imaginable tear would be represen-ted by a 0.5-inch deep, through the thickness (13/16-inch) radially oriented edge crack. Because of the geometry of the diffuser vanes in the shroud section, whereby they cross
; at about 1-inch from the edge of the shroud, it is not anti-
' ~ cipated that extension of the hot-tear would exceed this l value. These observations are consistent with the stress I l V O i prenewe aseenene . amens opemen . ren,e armer e. i-r l 1 e mm a
DIFFUSER VANE SM0W arTum solDE vane DIFF WER %UE CDVER RETulul GUIDE VANE K \% N _k
~' v s=o. % . s g - ,.
N .
. sN
, c -
m ,...-.5 x N .' s \ ',' s __k s
,: i
- V- --
ys A 1o ,
' % s se
, s .N Ns
/ -l -
N
\
f !. 'l s \ M M/
- f. \
g'g ..' Q
- ,/ ' . y ,/
s
./
/
p 4 u s \ __.
\
! / s
\. \\
\\
N s N
\\
==.m.en n.. PACIFIC PUSIPS
- W =g t .ogg g g e-m n 6 es, mas fanaLLEL E E E IEEEIAE E 8
, esseCENT4s0 WIfeent Act .Ja.
amma en sans au. anasmuses einer annuras asenow.aeses. eum usz ese 2-m W I las.ESS WhamWWE WEergge em '
. = . --
,m= m B 7I T
FIGURE 5. Sketch of indication at edge of shroud near base of diffuser vane #2, y blades number sequentially clockwise 1 through 9. Profile of hot tear crack is sketched to illustrate appearance after piece was broken open at indication (2/3 scale).
DIFFUSER VANE SHRDW KTIM GulK vm BIFFUSER VAIE: gggs
, -RETINul GulK VANE i M
F , N.
., g , \. 'N
. N , ' '-
m N . g's -s ,N s., 7 , , , ,
.., .N
. _ a \, ,\ A p, l _
~%. , ,
M' : ; .; ! '
\ \ \
.l x N \\
.. \ \, .
~
O 4 s.
\
N
\. .
\\ \
\. sN N
- LasTe SN aLL Penne ess.smes
==.m mie=== ne. PACIFIC PuggPs W *$g ,ggg g gp gemas a sL smens e 6 emusans g
essecanvase smeme men Psa. 3' M INTElW O IATE CD WR
, ameast en muas an enamesses meAAP eelusene acqueegr.anosgge M E/e2 eER 'm um.ses omsauces aseenes em. ' '
I = -
- = e m.,i. __.
assumes
. "3 e
on to FIGURE 6. Sketch of indication at edge of shroud near base of diffuser vane N6, blades number sequentially clockwise 1 through 9. Profile of hot tear vi
" l crack is sketched to illustrate appearance after piece was broken open at indication (2/3 scale).
Pegs Sixtocn Ol analysis. Therefore, for the safe-life analysis, the
' hot tear will be analyzed in fracture mechanics jargon as
- a single edge notch specimen with the initial depth of crack not exceeding 0.5-inches. .
5.2 CRITICAL STRESS CALCULATIONS I Based on the conservative estbaates of fracture toughness on both the upper and lower shelves, the fracture strength l curve of the CA-6NM alloy are shown in Figure 7. The curves
?
are derived from a fracture mechanics relationship for a single edge notch specimen where, ' KIc=1.1O'Ykta or i KIc E 2 7W Eqn. 2 i I where KIc 5 plane strain fracture toughness i per ASTM E399-81 CFB applied far field or gross stress a a depth of crack from edge I I I i Fosew.assen . eseen o . p mes, I I r 1
1
.l i
Pcg2 16A e UTS=120 Kai SEN SPECIMEN KIc = 2 Ffa' ~ f 100 -< ~ YS=100Ksi - - Lower Shelf 80 " KIc=45Ksi 6 -
~
m .'
~
E KIc=75 Ksi C d 60 - Upper Shelf E u m <53.0Ks_i 3 i
- $u 40 -
I I u 37.5Ksi - 1 8Ksi_ _ _ _ _ _ i 1 - l 20 - 22.5Ksi l , 1 1
~
I i i i l i i i l I 3 0 0.2 0.4 0.5 0.6 0.8 1.0 Depth, Inches FIGURE 7. Estimated strength of the shroud section of the i diffuser with a radially oriented edge crack, 'f ru i F, w. anew . m cm . rw. % i e
Pcg2 Savantcen Examining Figure 7 shows the critical stress to be 31.8 Kai and 53 Ksi for the lower and upper shelf, respectively. If i the tear were to extend to one-inch, the critical stresses
, would then be lowered to 22.5 and 37.5 Kai, respectively.
i 5.3 OPERATING STRESSES t The actual stresses the shroud experiences under operating conditions has been carefully detailed in another section of this report. Finite element analysis has shown that the stress history profiles can be characterized as shown in Figure 8 Two aspects of'the analysis are considered, start-up and on-line pressure pulses. Conservatively, the start-up stresses can be described an d F= 3Ksi and R = 0: whereas the on-line stresses are A T = 0.1 Ksi and R = 0.97. In essence, a tensile stress component of 3 Kai is never exceeded. Immediately, it should be noted that this stress level is far below the critical stresses described in the previous sections i.e., for the worst case the critical stress exceeds the operating stress by a factor of 7: 1.e. 22.5/3. t I f s9 i nessw.essenene. . mensomne n . rei,.aney 9
~w .4e -*
- r* qf e.
Faga 17A
' START-UP t
i . T l DC35 i _7_ v . tr 1 L t
, FREQUENCY :
2 MAXIMUM-2500 Cycles /40yr R= 0 i , ,_.. ON-LINE .g p,g gg t. l
""r ' ' 'f ^r". _a _
i i c
$sIKsi 6
FREQUENCY:
; MAKIMtM-2x1010 Cycles /40yr R= 0.97 f
I, FIGURE 8. Stress history profile intermediate puunp. noen,.es nm . so conesen . renne w 9 t i ni
.g
Pcgo Eightecn l l i 3 O ' 5.4 FATIGUE THRESHOLD I From the data of Figure 3 and 4, a fatigue-crack growth I threshold stress intensity Kthreshold f r crack growth : is suggested to be about 4K = 8 Kai $. Figure 9A shows an ideal fatigue-crack growth curve that identifies various > regions. ; Figure 9B provides some data on other steels sup-porting the fact that the value of 8 Ksi4 in is reasonable ' considering the fact that we are working with a CA-6NM ' casting alloy and the data of Figure 9 Bis for both low-strength and high-strength low alloy carbon steels. ;
~O Examining equation 2, the following is derived:
6K = 260'f ' 9
. Eqn. 3 or for 6 (T = 3 Kai and a = 0.5-inches t
, A K = 4.2 Kai V in 6 K th Max-operationalt threshold l
t 1
,p kJ m es nm . enessomessa e Penne **res
e Paga 18A pn
,sesweene, r
) wa tasten.A J ma ,
L , i em === = iemne
. mi
. .. m ,, C 4 .a s.a. ewe t a am.m. .e.sumpu.ar.e I =
S . s. sm m
====.===.=
m . .w
) 1ir -
i / -
- B
- E I4 . '
,we
"'""* T.s ',,
is* g A ;- 1 4% leg &K
; Figure 9A. scw m a gm totes (de/dN) with ahernetag stress isteesity (AK),
at a. . e.e 3.te Opemoet
.. es ? e t 4 1 2
~
iri i e s I i
. . is it -
M
=
0* *
- es e. . . .
( , e pe.ge.g e ase a fe.aur Ih.eest ,,g ie g i L 9W e'* einst 69 La. sees.e.. e.e.a. - a e08' e' ieg 8830#fil * ' e3a ' 8 8#'e"s"I ese e*- e a +3 = 0 y je. -
*h t
;.. %, , e _
.. .e, . ..se -, . e
~ '
p.
- s j . . . .
0 se se e
; See 590 o e.t. ... e#60 ,..
Figureseests.8"- 9B. Variesise et sheesheid at wh6 yede sies ter
.1 et new-eneessi$ senses are toeween j AISI:;;.
ese MM se,d NOP, esespeshises ct W sessin 2,Asse ees. I I'( Pi/
'f
, g ,see os,,ssen o powe w
Pega Ninctocn I O t at== == ca =ci sie =* e en -er eie 1 ativi== force or stress intensity for fatigue-crack extension of . l the largest possible hot-tear is below the threshold stress
, intensity for fatigu. crack extension. This means that no i
crack extension of the hot tear will occur in fatigue be-cause the driving force is too low, similar to operating below the endurance limit in a classical fatigue S-N curve l analysis. 5.5 SAFE-LIFE CYCLE DIAGRAMS l Continuing in a very conservative vein, if it is assumed i that a threshold stress intensity range does not exist, but instead, the measured crack growth rate of Figures 3 and 4 can be extrapolated along the straight line on the log 2 (da/dN) vs log (A K) plots i.e., m (da/dN) = A (4 K) Eqn. 4 applies: then the conditions for safe-life cycles can be calculated by substituting Eqn. 3 into Eqn. 4 and integrating ors m- - - - , , ,_ ___
; , ,._a . a!.,. 4.!.,.. l ,- -
,,n .,
i - - a.-===ms.
'O '
#,- ===h= t gets a hahme 4..m.wws
,a y, a (s.sWW'.4 s * ** s.ee}t*2ll
- g=h.e4 ovest eine se faites a Mfen Y Q #8 80s8 - **
f Pcg2 Tw:;nty l l Using the safe-life cycle or requirement specified by the contractor, I l N (start-up)= 2500 cycles /40 yrs
. 10 N (operational) = 2 x 10 cycles /40 yrs i
t and calculating the number of cycles for a hot-tear to 4 extend to 1-inch i.e., a4 = 1-inch where for the material constants _ 1 N4 = (4A 673) e (ao 1) Eqn. 6 ,
'O where A = 2.57 x 10-10 and AU" = 3 Kai (start up) and 0.1 Ksi (on-line)
Then the number of cycles to extend the hot tear to 1-inch is shown on Figures 10 and 11. As noted over 100 yrs of-
, projected on-line pressure pulses would be required and over 40,000 years of projected start-up cycles would be required
,I to extend the hot tear to 1-inch radial length. I
!. - j
! - 1
.i If)
IG .I p, u n ne. . so c.ne.ma ..- F.*,e *w res ! e
* = 4 w o -s- w y w# -- m e c=a d e y,* we n-, - , - eep- ,e s *v v m.~,g
U@ ww l 109 a f a 1.5 Ks Aa - 3 ni Hunsta or EvcLts K,e = 45 h i-in.% I To 1 secH Caaca. - I . -
. i 8
10 i
- N
- : s N
g s -
" 7
- 10 r N
g '. N START - UP 40.000 yr* 3
- 2.5 x 10 Cvetts a 40 YEARS I
0 0.25 05 0.75 1.00 CaAca knGTH, IN. FIGURE 10. Predicted number of start-up fatigue cycles required to extend a radially oriented edge crack to 1-inch in length. Initial size or ' , depth of hot tear is indicated on horizontal axis. j 1 i i(\ jA/ Frac 8we Mechames e Spees Corsemen e Fedwo Analyse 1 a m w uyr _-,a e- .-m 1 m .,-q.e'- wwp p
Paga 20B
.I l
1 i O' e.
- a. -3Kai
.' A a - 0.1 x:
Kee = 45 Kst-in% N ' 1012 _ N N
- N N i f
u 1011 - I t
,-- 100 vtARs ou - unc
- lluMBER OF CYCLES O- u g ,,,, TO 1 INCH CRACK. l 1010 - n , ,
0 0.25 0.5 0.75 1.00 Caaca Lansru, su. l l FIGURE 11. Predicted number of on-line fatigue cycles required ! to extend a radially oriented edge crack to 1-inch in length. Initial size or depth of hot tear is l indicated on horizontal axis.
?
I {O l jJ
' mesw.ne emmes I
. smess coneeen . F.4,,. m i
N A design envelope similar to the modified Goodman diagram can also be calculated, although further modified to incor-porate initial size of the hot tear. The Goodman diagram
, is essentially a constant finite-life diagram, plotting the stress range (40") vs. U'mean. If values of 1 x 100 i or a factor of safety of 4 is used on the start-up cycles i
over the 40 yr period and 2 x 1010 cycles are used for the on-line pressure pulses, then the following may be calculated 9 by rearranging Eqn. 5 and incorporating Eqn. 2.
- -g T mean = (0.5 KIc) a o - (2N
- KIc e A e hy3 + M /2) Eqn. 7 where for ao = 0.25, 0.5 or l'.0-inch KIc = 45 Ksi 6 0 N = 1 x 10 0 or 2 x 1010 i and A = 2.57 x 10-10, The stress range 47 and 7"mean can be delineated as shown in the fracture mechanics modified Goodman diagrams of
, Figures 12 and 13.
, As observed on studying Figures 11 and 12, the operational j ) stresses are far'below any combination of mean and alterna-ting stress range that would exceed the safe-life zone'de-lineated by the lines for ao = 0.25, 0.50, or 1.0-inches.
Obviously these zones decrease in size as the assumed initial
./~ size of the hot tear increases.-
[' reame, assenemme .- seems comessa . res,. anser s.
.I y
Pcg2 21A 1 3 0 ' ! g - O. e N = 10,000 Cyc R Ki e - 45 Kst-In.gES
. ~
t 30 - 4 O. t$ b y i o N -
'
- N@
G b t; o e r ; 10 - t i d 3 i i t 1 3 S I
' 10 20 30 40 50 . 60
-t
' l IEAN STESS, Fe (Kss) ' l l
l ! p-FIGURE 12. . Safe-life design envelope for.a projected l
,1v :
10,000 start-up. cycles. -Circle indicates 1 j; . actual operating conditions. i
., . 1
~.;~;.
- u. . _
PcAs 21B (
<O I
l I O. 2 i i 0.5" N = 2 x 1010 Cycles Ki c = 45 Kst-in.h l
+ 0.4 -
; **q 50.3- 8 t
.O s ,ve
~
o E . N 0.2 W
"' (
i 0.1 0
-i i i , ,
i 10 20 30 - 40 50 PEAll STRESS, Fu (Kst)-
'h
'[
.g FIGURE 13. Safe-life design envelope =for e projected 20,000 -
mitlion cycles of on-line pressure pulses'.
- c. Circle indicates actuel operating conditions'.
e < 6
* -vI s .
, . _ . . , , , , . JR- '
l l , Peg 2 Tw:nty- two l ! :h
6.0 CONCLUSION
S l 6.1 Under the worst possible operating conditions, the largest observed hot tear would not extend to near critical f values within the projected 40 year operational conditions
, of the intermediate pump cover.
6.2 i Because of the low projected operating stresses, the operating stress intensity range is below threshold for fatigue-crack extension. Even assuming no threshold exists, extension from 0.5-inch to 1-inch would take over 100 years for on-line pressure pulse conditions and even longer for the other considerations. 6.3 The storage tank refueling water would not aggravate the conditions by causing accelerated conditions of corrosion-fatigue or stress corrosion crack, even without de-oxygenation of the boric acid solution. i j 6.4
, The minimum conceivable fracture toughness under low-temperature, high-loading rate conditons would not prc, duce fracture unless the tear extended radially to 1-inch i and the operating stresses exeeeded 20 Ksis whereas it is calculated that the actual operating stresses do not rJ
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PART , PART M AT ERI AL MAT E RI AL NUMBER NAME OF PART NUMBER j, NAME OF PART f% 416
- Dl DO46 iMPL R SPACE R SLV, 3RD STG AS82
'g, il [2 [4] AOOs CASE ASStutiLY , SFACE R SLV, 4TH STG AS82 416 43} 0047 IMPLR [l'[ } AOO4-4 C ASE - uPPE R HALF sat 82 F304 SPAC E R SLV, STH STG AS82 4t6 JS] 0048 IMPLR {C ;i] AOOt-2 C ASE- LOWER HALF SA182 F304 h3i D049 iMPLR SPACE R SLV, 6TH STG AS82 4 t6 lt* J] ADOI- 3 C ASE- SUCTION FL ANGE SAiO2 F304 AS82 416 l}] 0050 iMPLR SPACE R SLV, 7TH STG {l} Il
- AOOn 4 CASE- DISCHARGE FLANGE SAi82 F304 iMPL R SPAC E R SLV, 87H STG ASR2 416 PRESSURE REDUCING BUSHING A276 4404 D] DOSS d AOSS DJ DOS 2 lMPLR SPACER SLV, 9TH STG AS82 486 ASOS DOWEL A276 304 416 D] DOS 3 IMPL R SPACER SLV, IOTH STG AS82 _,
PIN, TAPER - AS21 Id A522 ALIGNING OOWEL A434 BC (CODE CASE 6644-4) DO66 SUCT ION SPACER A296 CAbNM 4404 [13} DOG 8 SUC TION SPACER WE ARING RING A276 SA36 1G3 AS24 A276 304 ASSe ALIGNWG FARitNG KEY , GA$KET FLANGE [5] D069 LOCKING KEY 0072 INTERMEDIATE COVE R A296 CA6NM 7.l} A6:3 COVER SAiS2 F304 l [4] 0003 COVER DIFFUSER ASSEMBLY t] A614 PLUG LE AKOFF PASSAGE SA193 BT A296 CA6NM 14 ] 008S1 INTERMEDIATE COVE R -DISCHARGE A6IS CASKE T 16] A296 CA6NM g SA193 87 l4] 0083 2 DIFFUSER OtSCHARGE h [ A721 CASE STUD SAi93 87 0004 SPACER RING A276 304 OR A182 F304
. )] A?22 CASE SiUD A276 440A CASE CAP NUT $A(94 T M 0006 INTMD COVER WE ARING RING
' [13 A758 0087 LOCKING KEY A276 304
- (1) A7$2 CASE CAP' NUT sal 94 7 INTMD COVER BUSHING A276 440A l A7 76 SLUG
[t)] 0089 DO90 LOCKING KEY A276 304 l A772 SLUG , # 0095 0-RING (7) A780 WASHER A276 ' 304 DSOt SET SCREW %- A783 WASHEA A276 304 SA182 F304 0$07 DOWEL
- 31) BOOD SEAL HOUSING, INBOARD DSO8 DO*EL A276 304 fl] 6002 SEAL HOUSING OUTBOARD sal 82 F304 A276 304 HlG BOLTING, INBOARO SAi93 B6 DSit dowel ll! 8711 SE AL EOOf BE ARING HOUSING, INBOARD A216 WCB k 8} B763 - SEAL HSG BOLTING OUTBOARD SAi93 86 E007 SHEE T CASF E T, BRG HOUSING , ,
4( COOT WELLER, (ST STAGE A296 CA40 ' E020 DE ARING SLEEVE, INBOARD O' f4 COO 4 IMPEL L E R, 2ND STAGE A296 CA40 A296 CA40 E024 OL BAFFLE - OUTER 14 COO 8 IMPE L LE R, 3RD STAGE A296 CA40 E02S Olt BAFFLE - INNER 4; CO2 supe LLE R, 4T H STAGE E029 DEFLECTOR RING J41 CQ6 tuPELLER,STH STAGE A296 CA40 A216 WCB FOOL BE ARING HOUSING OUTBOARD 44 CO2 .uPF LLE R, 6TH STAGE A296 CA40 FOO7 SHEE T CASKET, BRG HOUSING M CO2S IMPELLER, 7TH STAGE A296 CA40 FOl? BE ARING SLEEVE, OUTBOARD
}4} CO29 auPELLER, STH S TAGE A296 CA40 A296 CA40 F020 OIL BAFFLE _
_ - i.4} CO33' sueCLLER,9TH STAGE A296 CA40 F022 DEFLECTOR RING
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F037 THRUST COLLAR C007 IMPELLER MEY A276 304 l A276 420 F038 THRUST COLLAH KEY M 34l D00 PRESSORE REDUCWG SLV THRu$i COLLAR SPACE R F039 o 00 3 D014
-PRESSURE HDCG SLEE vE KEY FLE xlBLE COUPLING FEY A276 304
- f040 THHUST NUT PACIFIC FUMPS DIVISIOf4 .
MEWR WWMHES, K dlj A276 40 . rO42 RE i A n.E R PL ATt -iNNe R
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_t $ DC>l4 tUPLN SPACE R SLV, $ST STG AS82 416 7043 RE TAINE R PLAT E - OJT E R PUMP ASSEMBLY , j 486 F045 GEAR PUMP HOUS NG Si:E TElWGNf6M NJ 5.JTT REV , 1% C04S iMPLR SPRER SLV, 2ND STG AS82 ' D 500 -J4C7? 9 2 oF 6 t
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F046 ' I GE AR MJMP COVER SUC TION NOZ 2 L E D 042-2-6000-2 6000-2 REVI X ,X b }tr FOS 2 SHEET CASKE T . GE AR PUMP
- 042-2-6000-2 6000-2 REW t X X ,
X X Dl%HARGE NOZZLE FOS 4 WORM (2) 042 600$ - 0 NOT REQ'O X X LOCMING FEYS FOSS ' WORM KEY @ (042 2 S440-2 NOT REQ'O X X PwHT RE PAtR COVERS FOS 6 LOCKNUT & WASHER (4) (042-2-5920 2 NOT REO'D X X NO PeHT AND Ot F F USE RS. FOS 8 GEAR PUMP SHAFT 042-2-S230-l NOT REQ'D X X iMPE LL E R RE PAIR FOS 9 GEAR' RJuP THRUST COLLAR @ (g) 042 2 S440-2 5440-3 RE V O ' X PwH T . DISCH D6F F USER TO FOCO WOR *t GEAR ~ DISCH INT COVER F064 WORM GEAR KEY 042-2-6000-2 6000-T REV 4 X X ORIFICE PLATES ! F062 LOCKNUT & WASHER @ F005 CEAR PUMP (SHO*N ON ShtET 5) 042-2-6000-2 6000-10 REV O X X ORiflCE PL AT ES TO TUBE F006 GEAR PUMP lt.EY @ IOLER , GEAR SHAFT (SHOWN ON $ HEE T 5)
'41 F06T (of ,H 042-2 580-0 SSO-6 REV O X X X PWHT COMPONENT SUPPORT
[4] F068 tOLER , GEAR w/5810 4 DE TAILS SHOWN l81 GOO 2 SEAL C C REV O X X X to PwHT ON SHEET 6. j GOOS NE TAINE R PLATE @G 042-2-5170-2 517 0 -1 GOO 9 SOCKET HEAD CAP SCRE W ' Goll SOCKE T ' HEAD . CAP SCRE W GOl2 $EAL SHAFT SLE EVE [3] GO44 ' PIN GOIS SHAF T SLV COLLAR GOl6 SET SCREW CUP POIN T ' b GotT SET SCREW . HALF OOG POINT GOt8 SHAFT SLEEVE KEY A276 304 GOI9 SPHtNG PlN jd NOOl-4 BASE CRADLE SA36 , 14 HOO2. HEX HEAD CAPSCRE w SA193 87 h003 WASHER - PL AIN 8 HO30 CENTLRING PIN SA36 ; tOSI ALIGNING DOwfL LUG SA36 I, ttOT9 CCUPLING - PUMP HALF ROO3 OIL RESERVOIR S' ROO4 SHEET GASKET Ott RESERVOIR ROIS HEX HEAD- CAPSCREW sal 93 ST RO2O WASHER - PL AIN ~ s
$O03 THERMOMETER SOO3-e THERMOMETER WELL 5003-2 THENMOMETER A'DAPTER v005 MINIMUM . FLOW ORIFICE VOOS-1 ORsFICE PL ATES SA4T9- WL 304 OR 36 v005-2 ORif tCE TUBE SA3:2 3C4 OR 386, OR S A4 79 304 OR 31 6 PACIFIC PUMPS DIVISION DRESSE R tNDUSTRIE S, INC.
PUMP ASSEMBLY SIZ E 6 HODUCT E NG DWu NO SHEET RLv D SOO .I407?ft , 3 or 6 > e t -. , , ,, , , , . W - - - _ _ _ _ _
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SJSOO31 S2229/30 GBE -SI APSI-O / 02 .; SJSOO30 52227/28 LMP-SI APSt-Ol /02 q @ HORIZONT/4 LY SPLIT CASE, TOP V1Ew. SOLTING AND PARTING SJ49728 51647/48 SAP-$1 APSI-Ol /02 i FL ANGE GASKET ARE $HOWN ON SHEET 5. 4 5J49729 Si(49/SO SEP-Si APSI-01/O2 SJ49730 516SI/S2 SCP-SI APSI.Ol /02
@ FOR PUMP ALfGNING ARRANGEMENT SEE SHEET 6 SDP SI APSI-Q /02 SJ49731 Si653/54 ~
j $1655/56 SFP SI APSI-OI/02
' SJ49732
@ MUST 8E ORDERED A$ AN ASSEMBLY WITH MATING PART(S). 51666/62 NAH-Si APSI.01/02 l SJ49735 SJ49736 51663/64 NCH-SI APSt-Cl/02 l @) COM.%ESSED ASBESTOS SHEET.-CHLONIDE AND/OR FLUOR'OE CONTENT SHALL $J49738 58667/68 T8x-SI APSI-Ol /02 i NOT EXCELO 200 PPM.
SJ49869 S1924/25 LLP-$1 AP SI-OI /02 SJ49870 S1926/27 NEU-$1 APSI-Ol /02
@ SPIRAL WOUNO ASSESTOS/304SS LFLExlTALLICL-CHLORICE ANO/OR FLUORIOC SJ49871 SI928/29 TCx-SIAPSI Ol/02 g g CONTENT SHALL ICT ExCEEO 200 PPM. II h ETHYL PHOPYLENE "O" RANGS.- ASTM O-2000 2BA,8sO412.Ft7 CHLOMDE AND/OR FLOORtOE CONTE NT SHALL NOT EXCEED 200 PPM.
@ SEE !EAL OR/.AING FOR SEAL DETAIL AND MATERIAL OF mRTS FURNISt(D BY J. CRANE CO, .
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@ A276 410 (Af#i ALED) wiTH 0.003/0D05 CR Ox10E PER LINDE PROCESS LC-4 i
@ COUPONE T SUPPOHT (ASMt- CODE SECT 51, SUB SECT NF ),
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@ JOeNT 9 ANO 10 AHE SUBSECTION NF WELDS. EITHE'R PT OR MT WILL ele PERFORMED. -
. @ TEMPEHf D AT A TEMPERATURE GRE ATER THAN 1100*.
3 {5} TE Mr'LHED AT A TEMPERATURE LESS THAN 1100*. [4] FLAME HARDENED. CONTRACTOR- WESTINGHOUSE NES SERylCE SAF E TY INJECTION PUMP SIZE / TYPE 3*-JHF-11 STAGES f t I
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PACIFIL PUMPS UlVISIOff ORESSE R INDUST H'E S, INC. ! PUMP ASSE MBLY SI2 L PHODUCT f '.G (% No SHE E T- REV D 500-J49728 4 or 6 , 34 1 33 sa ~ f~ m ! TR I 37 1 36 I 35 4
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D {C 2<e/:M E bhy;r h SECT 30se A-A SECT 60N s-s s lk SECTION 0-0 (32 PLACES 3 (6 PLACES 3 . (2 PLACES) I SO. NO SE RI AL NO PLANT B S*.N NO S SJ50032 52231/32 GAE- SI APSI-Ol /02
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- f l S JSOO 31 52229/30 GhE-SI APSI-O /02 C
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5J49732 SJ49735 StG55/56 51661/62 SFP.$1 APSI-OI /02 Nf H-SI APSI- Ot /02 [--
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4 , O D 713 SJ49736 51663/64 NCH-SI APSI Ct /02 N4 - sEE CASE 80LTING SEQUENCE g g { s Ag a TORQUE DATA
}- 5J49738 *d 667/b8 Th4-St AP51-Ol /02 L L P 4t AP hl-Ol /02
- SJ49869 51924/25 0 @ o @@@@@@@@)@@@@@\ $@Q@ G C'*e; ?> ' '/
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CASE' tiOLTING SEQUENCE 3 . TORQUE DATA , CONTRACTOR. WESTINGHOUSE N E.S SERVICE SAFETY INJt.CTION PUMP t NutsesERS I to 3e REPRESENT THE , y F W NM _ TIGHTENING SEQUENCE CF CASE - / 80LTI8eG. N / 2.8@lvlDUAL NUTS AhD BOLTS TO E' bP BE TIGHTENLO IN A SER2ES OF 4 PftOCHES$1VE STEP 3 OF' 25%,50%. * - - - -
- - - " M -- $
75 % AND 300% OF F=AL Tusecut LOAO- ]I u A
% 3 wnElecN TomouE LOAD: ,voo) PACIFIC PUMPS DIVISION DRESSE R INGUST HIE S, INC.
A/bs - 2} -82N- 5 CAP teJT irW) Fits. , , TiTt E A
; S2 - i-a -3 CAP nut .+>o ri ts. PUMP ASSE MBLY
,,7,3} . WJNC- 3 CAP SCR 400 FTLa SIZ E PRODUCT t NG e*G ho SHE E T REV w4 - rG 3 CAP SC4 f5 F T LB -(A6:4 SWwN ON S EET o l D SCO-J49728 5 Or 6 (
b 56 55 $4 J 33 _ _ jZ_E.~ 7. _SL_. _ L da l_ . , 3 7 ,,,,,,_ ,j ,,, l _ L .
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65 l 64 l 63 l 62 l 61 68 l 67 l 66 l LEGE ND. AOO! - A LET TE R F O' LO*f D bY Y nHE C (41 MOPE NvYBE RS th0fC ATES PART y \ NUMBER FOR CE SCRiPTION ANO M ATE hl AL SE L SME E T 2. h 4 NOMut R BOaED 'NO4 CATES NOTE. gM g Lg__ R g If tj
. s-l Q ON SHE E T 2A NUM8F R CtRCLE D INDIC ATES WEL D PROCLCURE j s-g)
. [ moron Hoto B B A i4 )YJ A O
- h. DooN nOLT (4) PL ACES fT -
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l C A J C 21-COMPONE T SUPPORT l *' '9 E4] C,4j M D 4 D (ASME COOC StCTION tu, SUBSECitON NF) 2 -PART AS22 is A TlGHTLY FIT TE D I,0*E L TO SE cuHE POSITIVE
g--- 4 .__,,) ALIGNME NT Af PvMP INbOARO E ND I I s E h l ,
h-PART A524 IS A IE E T DE SIGNLD TO SE CUR E PUMP Ara 4L AttGNME N T AND AT THE SAME TIME TO ALLOW FON CASE THERMAL e E X 6ANSION _
}* _ h-SCPL wS ARE FON ASSE MBLY PURPOSE ONLY AND E,0 NOT CARRT Amr STPLSS LOA 05 J [
9 @-DRIP POCKET OR A:N CONNECTION P-04 GN Puf/P AND MOTON OUTL INL DR AWING 9
- Oa NF NF 2 - T Ht$ PL AT E IS NON-NF. HOmE vE N MATEHiAL e5 r4F LISTED AND y
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l =l e a ANO MOTOR OUTLINE DR AWING. i Q s m. . .
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'f SJ49130 Si65uS2 S& - S' APSI - OaO2 SFCTION Ai - A, SE CTION C-C SJ49711 % *, S/S 4 SDP - 5A0 51 - Ov02 h (TYP) SECTION A- A SJ49732 %SS/b6 SF l* - St APSI - Ov02 q SECT 60N B-8 ,3
[TYP (4) PL ACES] SJ4973S SifA4 /62 N AH - 54 APSI- OUO2 ' SJ49736 Set t, S / t.4 NCH - 51APSI- 0 /02 - 2e { Lua0 COOLER ' SJ49738 M6 f/68 Tex - SI APSI - OWO2 g ,p po,,g g CONTRACTOR. SE RvlCE WESTINGPOUSE NES SAF E T Y INJECTION PUMP g49gg .W 4 /23 L L P - 01 APSI - OUO 2
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