ECCC

ECCC RECOMMENDATIONS - VOLUME 9 Part III [Issue 1]

HIGH TEMPERATURE COMPONENT ANALYSIS

DATABASE OF COMPONENT TESTS AND
ASSESSMENTS
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AC/MC/105 [Issue 1]
15/08/05
 ECCC RECOMMENDATIONS - VOLUME 9 Part III [Issue 1]

HIGH TEMPERATURE COMPONENT ASSESSMENT

DATABASE OF COMPONENT TESTS AND ASSESSMENTS

PREPARED BY ECCC-WG4

Mr P Auerkari VTT, Finland (2001- ) [Convenor]

Mr T B Brown Mitsui Babcock (2001- )
Dr D Dean British Energy, UK (2001- )
Prof B Dogan GKSS, Germany (2004- )
Dr R Hales ETD, UK (2001-04)
Dr S R Holdsworth ALSTOM Power, UK (2001- )
Dr-Ing A Klenk MPA Stuttgart, Germany (2001- )
Dr N Le Mat Hamata ETD, UK (2004- ) [Secretary]
Dr R Patel British Energy (2001- )
Dr A Thomas Siempelkamp, Germany (2001- )
Dr A Tonti ISPESL, Italy (2001- )
Mr T Vilhelmsen ELSAM, Denmark (2001-03)

EDITED BY: R Patel

APPROVED DATE 31/8/05

On behalf of ECCC

AC/MC/105 [Issue 1]
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AC/MC/105 [Issue 1]
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 ABSTRACT

Volume 9 Part III provides an overview of the component testing experience of members of
the ECCC-WG4 (Components) working group.

ECCC Recommendations Volume 9 Part III user feedback is encouraged and should be sent
to:

Mr R Patel [Document Controller]

British Energy
Barnett Way
Barnwood
Gloucester, GL4 3RS, UK
Tel: +44 1452 65 3716
Fax: +44 1452 65 3025
E-mail: rajesh.patel@british-energy.com

ECCC may from time to time re-issue this document in response to new developments. The
user is advised to consult the Document Controller for confirmation that reference is being
made to the latest issue.

This document shall not be published without the written permission of

the ECCC Management Committee

AC/MC/105 [Issue 1]
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AC/MC/105 [Issue 1]
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BACKGROUND AND INTRODUCTION
High temperature component tests provide a valuable means of:
i) characterising a materials resistance to damage and crack development under
representative service conditions, and more importantly
ii) validating high temperature defect-free and defect assessment procedures.

However, such tests are invariably costly to prepare and run, even with the availabilty of
appropriate testing facilities. At least 2 recent surveys have shown that the number of
facilities capable of peforming component tests has been in rapid decline in recent years
[1,2]. The purpose of the WG4 review of existing component testing experience was to
ascertain the availability of existing case study material which could be first evaluated before
embarking on a costly test programme

The accompanying tables provide a catalogue of summary details for 36 high temperature
components tests, involving ferritic and austenitic steels, with an indication of the
assessment route(s) performed where appropriate.

REFERENCES
1 ECCC Recommendations Volume 3, 2005, 'Part V: Testing practices for multi-axial
features and components', eds. Brown, T.B. & Holdsworth, S.R.
2 Holdsworth, S.R., 2002, 'Overview of activities of the Structural Mechanics Cluster of the
Plant Life Assessment Network', Materials at High Temperature, 19(2), 69-74.

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AC/MC/105 [Issue 1]
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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

1 Ferritic MEL Vessel FM1 0.5CrMoV Various circ. 565C P = 62.5 MPa 1.6kh (total failure at Creep strain (a) Coleman, Price and R5
Ri = 115mm parent Notches site of deepest fully Strain gauges Williams, ICF4, 649-662,
t = 60mm circ.notch) Notch CMOD 1977.
Crack size (b) Ainsworth & Coleman,
DCPD Fat. Fract. Eng. Mater.
Ultrasonics Struct., 10, 129-140, 1987.
Post test exam.

2 Ferritic MEL Vessel FM2 0.5CrMoV Various 565C P = 35 MPa 46kh Creep strain Jones & Coleman, R5
Ri = 115mm parent defects spark (steam leak) Creep pips (a) RD/B/6242/R89
t = 60mm 2.25Cr1Mo machined in Strain gauges (b) CFEMS4, 605-619,
welds (AW & circ. welds Crack size 1990.
SR) (HAZ & Type Ultrasonics Budden
IV zones). Post test exam. TIGM/REP/0088/93

3 Ferritic MEL Vessel 0.5CrMoV Various 565C P = 35 MPa 54kh Creep strain Budden R5
FM2A parent defects spark (steam leak) Creep pips (a) TIGM/REP/0089/93
Ri = 115mm 2.25Cr1Mo machined in Strain gauges (b) Int. J. Pres. Vess. &
t = 60mm welds (AW & circ. welds Crack size Piping, 75, 509-519 1998.
SR) (HAZ & Type Ultrasonics
IV zones). Post test exam.

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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

4 Ferritic MEL Vessel 0.5CrMoV None 575C P = 7 MPa 47kh Creep strain Budden R5
TWMC1A parent (steam leak due to Creep pips (a) EPD/GEN/REP/0297/98
Ri = 212mm 2.25Cr1Mo Type IV crack in end Strain gauges (b) Int. J. Pres. Vess. &
t = 28mm welds (AW & cap weld) Crack size Piping, 75, 509-519 1998.
SR) Ultrasonics
Post test exam.

5 Ferritic MEL Vessel 0.5CrMoV None 575C P = 7 MPa 59kh Creep strain Budden R5
TWMC2 parent (steam leak due to Creep pips (a) EPD/GEN/REP/0297/98
Ri = 230mm 2.25Cr1Mo Type IV crack in end Strain gauges (b) Int. J. Pres. Vess. &
t = 28mm welds (AW & cap weld) Crack size Piping, 75, 509-519 1998.
SR) Ultrasonics
Post test exam.

6 Ferritic Large Bore 0.5CrMoV None 585C P = 3.6 MPa 11.7kh Creep strain Al Laham R5
Branch parent (535C in (stopped NDT Creep pips EPD/GEN/REP/0371/98
Ri = 229mm 2.25Cr1Mo service) Out-of-plane moment = indication of deep Strain gauges P J Budden, Creep Crack
T = 32mm weld (SR) 30kNm Type IV crack at Crack size Growth Assessment of the
ri = 146mm tensile flank) Ultrasonics Large Bore Branch Vessel
t = 16mm Post test exam. Test, E/EAN/GEN/0023/00,
2000.
R D Patel, S Al Laham and
P J Budden, R5 Creep
Assessment of Welded
Trunnion & Large Bore
Branch Components,
CFEMS Ap

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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

7 Ferritic Medium Bore 0.5CrMoV None 590C P = 4.0 MPa 20.038kh Creep strain R D Patel, R5 Medium Bore R5
Branch parent (completed, Creep pips Branch Life Assessment,
Ri = 210mm 2.25Cr1Mo transverse through- Strain gauges BEGL Report
T = 18mm weld (SR) wall crotch crack ) Crack size E/REP/ATEC/0005/GEN/01
ri = 56mm Ultrasonics Post test examination
t = 8mm Post test exam. results:
E/EAN/MATS/0024/AGR/01

8 Ferritic Pipework 0.5CrMoV None 585C P = 3.5 MPa 15.4kh Creep strain R D Patel, R5 Trunnion Life R5
Trunnion parent (527C in (stopped) Creep pips Assessment, BEGL Report
Ri = 232mm 2.25Cr1Mo service) In-plane moment = 11kNm Strain gauges E/REP/GEN/0036/00,
T = 26mm weld (SR) Crack size October 2000.
ri = 149mm Ex-service Ultrasonics R D Patel, S Al Laham and
t = 16mm (91.7kh) Post test exam. P J Budden, R5 Creep
Assessment of Welded
Trunnion & Large Bore
Branch Components,
CFEMS April 2001

9 Austenitic BRITE 2147 316L(N) None 510C- P = 63 MPa 14.7 kh Creep strain Budden R5
Vessel 1 parent 620C (stopped) Creep pips TIGM/REP/0069/93
Ri = 75mm and welds Strain gauges ODonnell
t = 40mm (AW & SR) Crack size EPD/GEN/REP/0287/98
Ultrasonics

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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

10 Austenitic BRITE 2147 316L(N) Various 510C- P = 63 MPa 11.5 kh Creep strain Budden R5
Vessel 2 parent defects spark 620C (stopped increase Creep pips TIGM/REP/0069/93
Ri = 75mm and welds machined in in hoop strain at SR Strain gauges ODonnell
t = 40mm (AW & SR) centre line of weld but NDT did not Crack size (a) EPD/GEN/REP/0287/98
circ. welds reveal any cracking) Ultrasonics (b) EPD/GEN/REP/0319/98

11 Austenitic HYA Superheater 316H parent Reheat crack 550C P = 18.8 MPa 8.8 kh Creep strain -
Header (1C1/4) and weld Max depth ~ + 17 thermal shocks Strain gauges
Lead Joint (AW) 20mm Nozzle end load = 15.4 kN (stopped) Crack size
Ri = 152.4mm Thermal Shocks (510C- Ultrasonics
T = 63.5mm Ex-service 330C in 1h) every 500 h Post test exam.
ri = 51.6mm
t = 62.7mm
(tapered)

12 Austenitic HYA Superheater 316H parent Reheat crack 550C P = 18.8 MPa 20 kh (planned) Creep strain -
Header (2A1/1) and weld Strain gauges
Pressure Only (AW) Crack size
Ri = 152.4mm Ultrasonics
T = 63.5mm Ex-service Post test exam.
ri = 51.6mm
t = 62.7mm
(tapered)

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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

13 Austenitic Full scale 347 Casting Yes Tmin=20C 50 refuelling cycles:- 6 khrs approx. Crack size IJS (draft) R5
gimbals feature 347 Weld Tmax=650C charge/discharge transient acpc (inelastic route)
test. 321 Tube EDM in centre 120 hr creep dwell (50 x 120 hrs) destructive
of weld 10 ECD elastic cycles examination

14 Transition EE Mk III Vessel Transition None 550C P = 11.5 MPa 11.5 kh Crack size ODonnell R5
Ri = 152.5mm joint (initiation and growth Ultrasonics EPD/GEN/REP/0192/97
t = 27.5mm (2.25Cr/316/3 (540C, 3.9 Axial load = 1565 kN of a single semi-
16) MPa elliptical crack in HAZ
pressure in on the ferritic
Ex-service service) interface. Failure was
94 khrs non-catastrophic )

15 Transition Inconel DMW Transition None 540C P = 32 MPa 21,887 hrs Crack size Patel R5,
joint (Failure by initiation Dye pen. EPD/GEN/REP/0282/98 Vol. 6
(2.25Cr/ End load = 1058kN and growth of a crack Ultrasonics
Inconel/316) at the Weld E
interface.

16 Austenitic Welded Parent and None 570C Constant axial load = Test stopped after ? P Booth, R5, Vols. 2 and
18Cr11Ni wide weld are 304 10MPa & bending cycles 117 cycles (4680 TEM/MEM/0016/95. BRITE-3
plate test stainless steel of +0.2% and -0.2% with hrs). Evidence of EURAM C-FAT, PROJECT
creep dwell of 40hrs. micro-cracking and NO: BE 5245, Task 5.
mirco-crack
coalescence within
the transverse weld
metal.

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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

17 Austenitic Welded German None 570C Constant axial load = Test stopped after ? U. Lohse, S-KWU Siemens/
18Cr11Ni wide designation 10MPa & bending cycles 117 cycles (4680 NLS3/93/0079. BRITE- INTERATOM
plate test X6 Cr Ni 18 of +0.2% and -0.2% with hrs). Evidence of EURAM C-FAT, PROJECT procedure.
11, DIN no. creep dwell of 40hrs. micro-cracking and NO: BE 5245, Task 5.
1.4948. mirco-crack
coalescence within
the transverse weld
metal.

18 Austenitic Welded
18Cr11Ni wide
plate test

19 Ferritic BRITE 2341 P91 ? 600C 49MPa 8000 hrs Strain OBTAINED FROM ?
Circumferentially measurements list_tommy_13_03_02.doc,
welded vessel (WG4/meeting3 folder in
diXt = 126X65 my_f_disk)
(Question - what
does this mean?
I.e is it internal
diameter?)

20 Ferritic BE-1702 HIDA P91/P22 ? 565C/ Up to 25MPa Up to 8400 hrs Creep crack growth OBTAINED FROM ?
bendings 625C and strain list_tommy_13_03_02.doc,
diXt = 190X23 (WG4/meeting3 folder in
(same question my_f_disk)
as above) -
units? four
vessels two P91
and two P22

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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

21 Ferritic Belgian vessel P91/P22 ? Up to 610C Up to 20MPa Up to 10000 hrs Strain OBTAINED FROM ?
Circumferentially measurements list_tommy_13_03_02.doc,
welded vessel (WG4/meeting3 folder in
diXt = 240X30 my_f_disk)
(same question
as above) -
units? 3 vessels

22 Ferritic BW48 Mitsui 1CrMo ? ? ? ? ? OBTAINED FROM ?

babcock T- list_tommy_13_03_02.doc,
junction and (WG4/meeting3 folder in
circomferentially my_f_disk)
w. Di=210
units? 3
vessels, data not
complete

23 MPA bending 14MoV 6 3 ? 550C ? Up to 25000 hrs Strain OBTAINED FROM ?

bendings and X20 measurements list_tommy_13_03_02.doc,
diXt = 175X30 (WG4/meeting3 folder in
(what does this my_f_disk)
mean and what
are the units?)
2 vessels, only
paper available

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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

24 Pipe bend tests P91 In longitudinal 625C 15 MPa 1300 hrs (no cracks) Thermocouples BE-1702 HIDA Two-Criteria
Ri = 225 mm (P91/B1) direction: 20 MPa 1460hrs (stopped Load deflection (CC initiation)
t = 20 mm static end- 3 at bend without failure) measurements C*, sigamref, K
90 bend constraint extrados X, Y, AC-PD (CCG) acc. BS7910
Z HT strain gauges (CCG)
3 in neutral post test exam.:
axis Q, R Metallography a.o.

25 Pipe bend tests P91 In longitudinal 625C 16 MPa 2840 hrs Thermocouples BE-1702 HIDA Two-Criteria
Ri = 225 mm (P91/B2) direction: Load deflection (CC initiation)
t = 20 mm static without 3 at bend measurements C*, sigmaref, K
90 bend constraint extrados X, Y, AC-PD (CCG) acc. BS7910
Z HT strain gauges (CCG)
3 in neutral post test exam.:
axis Q, R Metallography a.o.

26 Pipe bend tests P22 In longitudinal 565C 15 MPa 1300 hrs (no cracks) Thermocouples BE-1702 HIDA Two-Criteria
Ri = 156 mm (P22/B1) direction: 20 MPa 8440 hrs Load deflection (CC initiation)
t = 20 mm static end- 3 at bend measurements C*, sigmaref, K
90 bend constraint extrados X, Y, AC-PD (CCG) acc. BS7910
Z HT strain gauges (CCG)
3 in neutral post test exam.:
axis Q, R Metallography a.o.

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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

27 Pipe bend tests P22 In longitudinal 565C 25 MPa 3600 hrs Thermocouples BE-1702 HIDA Two-Criteria
Ri = 156 mm (P22/B2) direction: Load deflection (CC initiation)
t = 20 mm static without 3 at bend measurements C*, sigmaref, K
90 bend constraint extrados X, Y, AC-PD (CCG) acc. BS7910
Z HT strain gauges (CCG)
3 in neutral post test exam.:
axis Q, R Metallography a.o.

28 4-Point bending P91 In circumfer. 625C Pi = 20 MPa 3648 hrs (no crack Thermocouples BE-1702 HIDA Two-Criteria
Ri = 156 mm (P91/P1) direction: Fext.= 96 kN growth) Load deflection (CC initiation)
t = 20 mm Creep Crack 2 at parent measurements C*, sigmaref, K
Growth CCG metal (A, C) Pi = 20 MPa 1440 hrs (leakage in AC-PD (CCG) acc. BS7910
1 in HAZ (B) Fext.= 120 kN weld) HT strain gauges (CCG)
(notch opening)
post test exam.:
Metallography a.o.

29 4-Point bending P91 In circumfer. 625C Pi = 20 MPa 3648 h/ 12740 cycl. Thermocouples BE-1702 HIDA Two-Criteria
Ri = 156 mm (P91/P2) direction: deltaFext.= 96 kN (no crack growth) Load deflection (CC initiation)
t = 20 mm creep/fatigue 2 at parent measurements C*, sigmaref, K
crack growth metal (A, C) Pi = 20 MPa 1440 h/ 4634 cycl. AC-PD (CCG) acc. BS7910
CFG 1 in HAZ (B) deltaFext.= 120 kN HT strain gauges (CCG)
f= 0,001 Hz post test exam.:
Metallography a.o.

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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

30 4-Point bending P22 In circumfer. 565C Pi = 20 MPa 5020 h(no crack Thermocouples BE-1702 HIDA Two-Criteria
Ri = 156 mm (P22/P1) direction: Fext.= 47 kN growth) Load deflection (CC initiation)
t = 20 mm Creep Crack 2 at parent measurements C*, sigmaref, K
Growth CCG metal (A, C) Pi = 20 MPa 2800 h(test stop) AC-PD (CCG) acc. BS7910
1 in HAZ (B) Fext.= 90 kN post test exam.: (CCG)
Metallography a.o.

31 4-Point bending P22 In circumfer. 565C Pi = 20 MPa 5020 h/ 16420 cycl. Thermocouples BE-1702 HIDA Two-Criteria
Ri = 156 mm (P22/P2) direction: deltaFext.= 47 kN (no crack growth) Load deflection (CC initiation)
t = 20 mm Creep/Fatigue 2 at parent measurements C*, sigmaref, K
Crack Growth metal (A, C) Pi = 20 MPa 2800 h/ 9655 cycl. AC-PD (CCG) acc. BS7910
CFG 1 in HAZ (B) deltaFext.= 90 kN (test stop) post test exam.: (CCG)
f= 0,001 Hz Metallography a.o.

32 Ferritic SENB specimen Cast 1CrMoV 6mm radius, 550C 3 loadings: 10 tests performed - Direct current BRITE-EURAM C-FAT, Volume 3 of R5
Length=450mm single edged, 1) pure fatigue ranged from 153 to potential drop Task 5 Milestone report.
Width=100mm semi-circular 2) creep-fatigue with a 4000 cylcles technique (DCPD) Development & validation of
t=75mm section notch dwell of either 30mins or creep-fatigue assessment
on the 100mm 16hrs at max methodologies (AEAT -
face displacement. 3) 0483)
a single case of a creep-
fatigue cycle with a
superimposed constant
end stress to simulate
primary loading.

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 TEST STARTER MONITORING ANALYSIS
No TYPE MATERIAL TEMP LOADING DURATION REFERENCES
DESCRIPTION CRACK(S) INFORMATION ROUTE

33 Ferritic SENB specimen Cast 1CrMoV 6mm radius, 550C 3 loadings: 6 tests analysed: Direct current BRITE-EURAM C-FAT, R5 Volumes 2
Length=450mm single edged, 1) pure fatigue ranged from 177 to potential drop Task 5 Milestone report. &3
Width = 100mm semi-circular 2) creep-fatigue with a 4000 cycles technique (DCPD) Development & validation of
t=75mm section notch dwell of either 30mins or creep-fatigue assessment
on the 100mm 16hrs at max methodologies (Nuclear
face displacement. Electric
3) a single case of a creep- EPD/GEN/REP/0095/96)
fatigue cycle with a
superimposed constant
end stress to simulate
primary loading.

34 Ferritic LICON 1:1 E011, None 625C P1 = 10.21MPa P1: 1078hr (90 flank Creep Strain: Strain Russell, G, Hack, R, ?
Tee junction, Thyssen P2 = 5.88MPa 7.5mm deep defect) gauges, creep pips Fleming, A and McMillan, G
Ri = 142.5mm, MTS011 weld P3 = 8.5MPa P2: 620hr Crack size: ACPD, LICON: Task 5 Final Report
t = 21.925mm metal P3: 4482hr (90 flank ultrasonics, post Mitsui Babcock Report
indication), 7218hr test examination E/00/115
(90 flank 150mm,
0.5mm defect)

35 Static pressure Le Mat Hamata & Shibli (a)

3 EDM semi- p=15MPa 5.88kH Int. J. Pres. Vess. & Piping,
elliptical Thremocouples, 78, 819-826 2001. (b) Int.
p=17.5MPa 4.32kH
HIDA seam- 2.25Cr1Mo defects J. Pres. Vess. & Piping, 778,
DC-PD gauges
Ferritic welded straight Parent & machined one 565C Cyclic pressure 827-836 2001. R5, BS7910
pipe welds in the HAZ and
Capacitance
p= 0 - 17.5MPa 4.62kH-1540cycl
2 in the base gauges
p= 0 - 20MPa 1.60kH -533cycl
material
freq=10-4
36 Static pressure Le Mat Hamata & Shibli (a)
3 spark Int. J. Pres. Vess. & Piping,
machined p=15MPa 1.43kH Thremocouples,
HIDA seam- 78, 819-826 2001. (b) Int.
P91 Parent & defects, one in DC-PD gauges J. Pres. Vess. & Piping, 778, R5, BS7911
Bainitic welded straight 625C Cyclic pressure
pipe
welds the HAZ and Capacitance 827-836 2001.
two in the base p= 0 - 11MPa 5.55kH -1850cycl gauges
material freq=10-4

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