Proceedings of the ASME 2013 Pressure Vessels and Piping Conference
PVP2013
NUCLEAR REACTOR PRESSURE VESSEL INTEGRITY ASSESSMENT:
ENHANCEMENT PROVIDED BY 3D MODELING FLAW STABILITY CALCULATIONS
Adolfo ARRIETA-RUIZ Eric MEISTER
EDF - SEPTEN EDF - SEPTEN
Villeurbanne, France Villeurbanne, France
adolfo.arrieta-ruiz@edf.fr
ABSTRACT
Structural integrity of the Reactor Pressure Vessel (RPV) is
one of the main considerations regarding safety and lifetime of
Nuclear Power Plants (NPP) since this component is considered
as not reasonably replaceable. Brittle fracture risk associated
with the embrittlement of RPV steel in irradiated areas is the
main potential damage.
In France, deterministic integrity assessment for RPV is
based on the crack initiation stage. The stability of an under-
clad postulated flaw in the core area is currently evaluated
under a Pressurized Thermal Shock (PTS) through a fracture
mechanics simplified method.
One of the axes of EDF’s implemented strategy for NPP
lifetime extension is the improvement of the deterministic
approach with regards to the input data and methods so as to
reduce conservatisms. In this context, 3D finite element elastic-
plastic calculations with flaw modelling have been carried out
recently in order to quantify the enhancement provided by a
more realistic approach in the most severe events.
The aim of this paper is to present both simplified and 3D
modelling flaw stability evaluation methods and the results
obtained by running a small break LOCA event.
INTRODUCTION
With the concrete containment, the Reactor Pressure Vessel
is one of the two components which have a direct impact on the
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July 14-18, 2013, Paris, France
PVP2013-97291
Henriette CHURIER
EDF - SEPTEN
Villeurbanne, France
lifetime of the whole NPP since they are considered as not
reasonably replaceable.
The RPV core area is subjected to a cumulative neutron
irradiation exposure over its operating life, resulting in
embrittlement of steel. Under a PTS event, the aggregate effect
of embrittlement and stresses caused by rapid cooling and
pressure is an increase in the potential for brittle fracture,
accepted as being the main possible damage, if a pre-existing
fabrication or inservice-induced flaw is present. Under-clad
flaws are of primary concern as far as the PTS event produces
most serious cooling in the inner vessel wall and the fracture
toughness is lower in this region. Therefore, the integrity
assessment for RPV is based on the stability evaluation, through
a fracture mechanics simplified method, of an under-clad
postulated flaw in the core area under a PTS event.
EDF’s implemented strategy for NPP lifetime extension
beyond 40 years favours as many improvements as possible of
the deterministic approach with regards to the input data and
analysis methods so as to reduce conservatisms. 3D finite
element elastic-plastic calculations with flaw modelling are one
of the improvements that are intended.
This paper presents both simplified and 3D modelling flaw
stability evaluation methods and compares the results obtained
by running a small break LOCA event for a generic postulated
under-clad flaw.
1 Copyright © 2013 by ASME
 NOMENCLATURE
KI Elastic stress intensity factor (MPa. m1/2) 1.1. Thermal hydraulic events studied
The thermal hydraulic system transients in a PWR are
Maximum of K I during the duration of the classified according to the estimated frequency in which they
KI max
transient corresponding to t = tmax can be expected to occur.
Elastic stress intensity factor including a plastic Temporal variation of temperature, pressure and heat
K CP
correction (MPa. m1/2) transfer coefficient in the RPV downcomer characterize the
Maximum of K CP during the duration of the thermal hydraulic transients considered for the mechanical
K CP max analysis, which are a selection of the most serious transients in
transient corresponding to t = tmax
each category of situations.
KJ Plastic stress intensity factor (MPa.m1/2)
Irwin plastic zone radius: 1.2. Thermal mechanical analysis
Ry
Ry = (1/(6*π)) (KI/Sy)2 (mm) The thermal problem to be solved is non-linear and
Sy Yield stress (MPa) involves two different materials (cladding and base metal)
tclad Thickness of the cladding (mm) which properties are depending on the temperature. As a
tbm Thickness of the base metal (mm) consequence of the assumed homogeneous nature of the thermal
a Total depth of the semi-elliptical flaw (mm) hydraulic loading and the rotational symmetry of the geometry
2c Total length of the semi-elliptical flaw (mm) considered, the heat flow through the RPV wall has only a
T Temperature (°C) radial component, as shown on Fig. 1.
P Pressure (MPa)
t Time (s)
H Heat transfer coefficient (W/mm²/°C)
Cs Safety coefficient
RTNDT Reference Temperature for Nil Ductile Transition
φ Neutron fluence E>1Mev (n/cm²)

1. INTEGRITY ASSESSMENT FOR RPV: AN

OVERVIEW OF THE CURRENT SIMPLIFIED “1D”
APPROACH
The deterministic approach is the foundation of the
integrity assessment for RPV. As far as brittle fracture risk
under a pressurized thermal shock event is accepted as being
the main potential damage, the RPV integrity demonstration, in
which the input parameters and the conservatisms are taken into
Fig. 1: ONE-DIMENSIONAL THERMAL PROBLEM
account in a conservative manner, includes two analyses of flaw
REPRESENTATION
stability under a PTS event:
- The generic study of a crack whose dimensions cover the
Thus, the temperature field in the wall thickness is a
detectable guaranteed minimum, which is placed at the most
solution of the following one-dimensional unsteady heat
stressed and irradiated position of the vessel with highest RTNDT
conduction equation in cylindrical coordinates:
among the Pressurized Water Reactor (PWR) French fleet,
- The study of the few inservice-detected cracks that are
larger than the minimum detectable and for which their size, ∂Ψ & ∂ 2T  k ∂k  ∂T
T = k 2 + +  (1)
and position and the RTNDT of the vessel concerned are taken ∂T ∂r  r ∂r  ∂r
into account.
Three levels of transients are studied in both cases: level
Boundary conditions presented on the figure above result in
A-B (corresponding to normal and upset situations), level C
Eq. (2) and Eq. (3) :
(emergency situations) and level D (faulted situations), level D
having the lowest probability of occurrence but the most
∂T
important mechanical impact =0 (2)
Regulatory safety coefficients (see TABLE 1) are taken ∂r r = Re xt
into account.

The following description is taken from [1], [2] and [3].

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 ∂T
[ ]
From the stress field previously calculated, the elastic stress
−k = H T r = R int − T fluid (3) intensity factors in both cladding (tips A and C) and base metal
∂r r = R int side (tip B) of the flaw are calculated by the “influence
Once the temperature field is known through the RPV wall functions” simplified method detailed in the French RSE-M
thickness, elastic stresses are calculated by solving the Code [4]. Only the K I open mode is analyzed (neither K II
equilibrium equation:
nor K III open modes have consequences on an under-clad
σ = λ ⋅ tr (ε ) ⋅1 + 2µ ε − (3λ + 2 µ ) ⋅ α ⋅ ∆T 1 (4) longitudinal flaw). In respect of the cladding side study, the
highest value between K IA et K IC is selected.
Where λ and µ are the Lamé coefficients:
K Iclad = max( K IA , K IC ) (6)
 E ⋅ν
λ = (1 +ν )(1 − 2ν ) Plasticity is considered through a plastic correction (based
 on 3D elastic-plastic calculations for longitudinal flaws
 (5)
configuration) for the stress intensity factor.
µ = E
For t < t max :
 2(1 +ν )
K CP (t ) = βK I (t ) (7)
This is done by means of a finite difference method code.
For t > t max :
1.3. Fracture mechanics simplified method

( )
Generic and inservice-detected flaw analyses are both
based on the same fracture mechanics simplified approach. In K CP (t ) = K I (t ) + K CP max
− KI max
(8)
the following paragraphs, only the generic study is considered.
In accordance with the performance of in-service Where:
inspection methods (qualified ultrasonic process), the
 36 ⋅ ryclad 
dimensions for the generic analysis crack are 5mm x 25mm. It
β = 1 + C ⋅ tanh  (8)
is an under-clad longitudinally postulated flaw placed at the
most stressed and irradiated position in the RPV ring of the
 tclad 
vessel with highest RTNDT among the PWR French fleet.
2
Consistently with the latest hypotheses assumed for the 1  K Iclad 
structural integrity demonstration of the French 1300 MWe ryclad =   (9)
PWR, the flaw is considered as semi-elliptical, as shown on Fig. 6π  Syclad 
2 (a=5mm, 2c=25mm).
For a longitudinal flaw, C = 0.465*(1+a/100) for the base
metal side analysis.
According to the French regulations, loads are multiplied
by safety coefficients Cs.
In the brittle range, the safety coefficients are defined in the
table below:

Level Cs
A-B (normal and upset situations) 2
C (emergency situations) 1.6
D (faulted situations) 1.2
TABLE 1: SAFETY COEFFICIENTS IN THE BRITTLE
RANGE

1.4. Margins calculation

The neutron fluence φ is a parameter affecting the RPV
throughout its operating life directly on the Reference
Temperature for Nil Ductile Transition RTNDT. A RTNDT shift is
Fig. 2: ASSUMED UNDER-CLAD FLAW calculated to take into account the operating life. The fracture

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 toughness is directly dependent on the RTNDT. The deterministic
margin is the ratio between the fracture toughness K IC of the
RPV and the load including safety coefficients K CP (Cs ) . The
current integrity assessment rule can be described as follows:
K IC
Fm = ≥1
K CP (Cs )
2.2. Meshes
Three meshes have been generated in order to ensure the
stability of results on the metal base tip with regard to the mesh.
They differ about mesh accuracy in the flaw vicinity. Meshes 1,
2 and 3 comprise about 55 000, 84 000 and 138 000 nodes
respectively. They are shown on Fig. 4, Fig. 5 and Fig. 6.
(10) Fig. 4 shows the mesh detail in the flaw area (flaw
perimeter is indicated by the red line).

2. 3D F. E. FLAW MODELING
As part of EDF’s implemented strategy for NPP lifetime
extension beyond 40 years for the deterministic approach, 3D
finite element elastic-plastic calculations with flaw modelling
have been carried out recently. They are presented in this
section.

2.1. Presentation of model

The aim of the study presented here is to evaluate the
stability of the under-clad assumed flaw shown on Fig. 2 for a
French 1300MWe RPV representative geometry.
The considered zone is a 1m high ring whose dimensions
are representative of a 1300 MWe RPV core area. Symmetry
can be used so as to include in the modelling only 1/8 of this
zone, and, as a consequence, only 1/4 of the semi-elliptical flaw,
as shown on Fig. 3. Imposed displacements are DZ=0 on the
surface parallel to the XY plane, DX=0 on the bottom surface
and, finally, DY=0 on the surface parallel to the XZ plane (flaw
excepted).

Fig. 4: MESH 1 VIEW IN THE FLAW VECINITY

Fig. 3: 3D MODELING AND SEMI-ELLIPTICAL FLAW Fig. 5: MESH 2 VIEW IN THE FLAW VECINITY
VIEW

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 Fig. 6: MESH 3 VIEW IN THE FLAW VECINITY
2.3. Materials properties
Thermal ( λ , ρ cp ) and mechanical ( α , E ,ν , S y )
properties are taken from [5] and [6] for both cladding (308L
austenitic stainless steel) and base metal (16MDN5 alloy steel).
They are dependent on temperature. Linear interpolation is
performed between the given values.
With regard to the mechanical behaviour of the materials
for the elastic-plastic calculations, an isotropic nonlinear
hardening is used.
2.4. Loading conditions
In all calculations, a small break LOCA event (a level C
transient) for a French 1300MWe RPV is considered. In a
conservative manner, it is assumed that the thermal hydraulic
loading is homogeneous in the RPV downcomer. Temporal
variation of temperature, pressure and heat transfer coefficient
is given in Fig. 7.
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Fig. 7: PTS EVENT – TEMPORAL VARIATION OF
TEMPERATURE, PRESSURE AND HEAT TRANSFER
COEFFICIENT
Thermal loadings are given by the temporal variation of
temperature and heat transfer in the inner wall of the RPV. As
shown on the Fig. 1, outer wall is equipped with thermal
insulation.
Mechanical loadings are given by the symmetry conditions
shown on Fig. 3 and the temporal variation of pressure P
(which is applied on the inner wall) presented above.
It is assumed that the considered zone is far enough from
the vessel ends so as to exclude any boundary effects. Thus, a
uniform X-displacement is imposed on the top surface. In
addition, closed ends of the vessel are taken into account by
means of a pressure PEF representing the end loads. P and
PEF values obey the equation:
2
Rint
PEF = P. (11)
Rext − Rint
2 2
Mechanical loadings appear on Fig. 8.
5 Copyright © 2013 by ASME
 F. E. calculations are carried out using the EDF open
source Code_Aster software [7]. The local energy release rate
G in the metal side tip is calculated using the G-theta method
available in the code. In elasticity, three different paths are
studied so as to ensure the path-independent nature of the G
value. In the same manner, six paths are studied in plasticity.

Fig. 10 shows a zoom on the maximum G values obtained

in the elasticity case with Mesh 1. A very good agreement is
Fig. 8: MECHANICAL LOADINGS observed between the different paths studied.
2.5. Reference solution determination
Before running the 3D F.E. calculations, a reference
solution for the elastic stress intensity factor is established using
a simplified approach.
An EDF finite difference method code (CUVE1D) is used
to calculate the hoop stresses opening the longitudinally
postulated flaw under the PTS event. The thermal mechanical
analysis is described in paragraph 1.2. Only the K I opening
mode is considered.
From this stress field, the temporal variation of the elastic
stress intensity factor K IB in the base metal side of the flaw
(tip B in Fig. 2) is calculated by the “influence functions”
simplified method detailed in the French RSE-M Code [4]. The
solution provided by this method is shown on Fig. 9.

Fig. 10: G-ELASTIC VALUES OBTAINED FOR

DIFFERENT PATHS – MESH 1

In all cases, the average value of G is adopted for the

stress intensity factor calculation. The link between G and K I
is made according to the equation established by Irwin (plane
strain assumption):

E.G
KI = (12)
1 −ν 2
Fig. 11 shows the temporal evolution of both K IB
(obtained by simplified method) and K IB−3 D (provided by 3D
F. E. calculation) in the same graphic.
Fig. 9: REFERENCE SOLUTION FOR THE ELASTIC
STRESS INTENSITY FACTOR K IB IN THE BASE A very good agreement is obtained between these two
METAL TIP quantities: the difference between K IB max
and K IB −3D max
is
less than 1%.
2.6. 3D F. E. modelling – elastic case validation
The 3D F.E. modelling is thus verified in the elastic case by
The next step is to determine the K IB−3 D values provided comparison to the reference value of the stress intensity factor.
by 3D F.E. calculation.

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 Elastic
reference Mesh 2 Mesh 3
Mesh
solution Mesh 1 (comparison (comparison
Result (comparison to to Mesh 1) to Mesh 1)
Mesh 1)
K IB max 62.39 62.94
(MPa. m )
62.79 -
(-0.7%) (+0.3%)

K JB max 78.49 78.74

(MPa. m )
- 77.62
(+1.2%) (+1.5%)

TABLE 2: STABILTY RESULTS ON BASE METAL TIP

WITH REGARD TO THE MESH

Finally, in order to compare the enhancement provided by

the 3D F.E. elastic-plastic calculations in regard to the stress
intensity factor K CP provided by the plastic correction method
(based on 3D elastic-plastic calculations for longitudinal flaws
configuration), K CP is also calculated according to the method
described in paragraph 1.3.

Fig. 12 shows the temporal evolution of K IB , K CP and

K JB−3 D during the loading phase.

We can notice that K CP max

= 92.85 MPa. m is about
20% higher than K JB −3 D max
= 77.62 MPa. m .

Fig. 11: PTS EVENT - K IB AND K IB −3 D TEMPORAL

VARIATION EVOLUTION COMPARISON

2.7. 3D F. E. modelling - elastic-plastic results

The elastic-plastic stress intensity factor K JB −3 D in metal
base side of the flaw is obtained using the method described in
paragraph 2.6.
As mentioned in paragraph 2.2, a study has been performed
in order to ensure that the results on the metal base tip are stable
with regard to the mesh. TABLE 2 shows the results obtained
for each mesh.
The largest discrepancy observed is about 1,5%.
Fig. 12: PTS EVENT - K IB , K CP AND K JB−3 D
The stability of results on base metal tip is thus verified. TEMPORAL VARIATION EVOLUTION COMPARISON

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 These values confirm the expected enhancement provided
by 3D flaw modelling calculations.

3. Conclusion
In France, deterministic integrity assessment for RPV is
based on the crack initiation stage. The stability of an under-
clad postulated flaw in the core area is currently evaluated
under a Pressurized Thermal Shock (PTS) through a fracture
mechanics simplified method.
One of the axes of EDF’s implemented strategy for NPP
lifetime extension is the improvement of the deterministic
approach with regards to the input data and methods so as to
reduce conservatisms. In this context, 3D finite element elastic-
plastic calculations with flaw modelling have been carried out
recently in order to quantify the enhancement provided by a
more realistic approach in the most severe events. They are one
of the improvements that are intended since they could provide
a gain on the final results.
This paper presents both simplified and 3D modelling flaw
stability evaluation methods and compares the results obtained
by running a small break LOCA event for a generic postulated
under-clad flaw. The geometry chosen is representative of a
French 1300MWe RPV.
A gain of 20% has been obtained for the maximum value of
the elastic-plastic stress intensity factor. A similar gain can be
expected on the margins calculation.
In this example, 3D Modelling Flaw Calculations meet the
objectives expected.

ACKNOWLEDGMENTS
The authors are grateful to the EDF R&D and AREVA
correspondents who worked on this subject.

REFERENCES
[1] Beaufils R. et al. “Using a probabilistic approach in the
brittle fracture deterministic integrity assessment of a
nuclear reactor pressure vessel”, 2011 ASME PVP,
Baltimore, Maryland, USA
[2] Churier H. et al. “French nuclear reactor pressure vessel
integrity assessment and life management strategy”,
2011 ASME PVP, Baltimore, Maryland, USA.
[3] Churier H. “French reactor vessel integrity”, 2012
ASME PVP, Toronto, Ontario, Canada.
[4] Appendix 5.4 of the RSE-M Code, 2010, AFCEN.
[5] Appendix ZI of the RCC-M Code, 2000 and addendum
2007.
[6] Appendix 5.6 of the RSE-M Code, 2010, AFCEN.
[7] www.code-aster.org

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