3 4456 0577452 B NUREG /CR-3243

(ORNL/Sub/82-22252/ 1
’k .)

Comparisons of ASME Code Fatigue

Evaluation Methods for Nuclear
Class 1 Piping with Class 2
or 3 Piping

E. C. Rodabaugh

1
.

Work Performed for

U.S. Nuclear Regulatory Commission
Office of Nuclear Regulatory Research
under
DOE interagency Agreement No. 40-550-75
 .

States of America Available from

National Technical Information Service
U S Department of Commerce
5285 Port Royal Road, Springfield, Virginla 22161

Av,, I I;i t i le f rorri

GPO Stiltis P r o q r a m
Division of TwIjtIi(-;i\ i r ; f o t t n a ~ i o i ~ Document Control
U.S. Nuclt?;ir Regulatory Commission
Wast.!inyton, D.C. 20555

~~ ~

This report was prepared as an account of work spoisored by an agency of the

UnitedStatesGovernment Neither theUnitedStatesGovernment nor any agency
thereof nor any of their employees makes any warranty, express or implied, or
.
assumes any legal liability or responsibility for the accuracy completeness or
usefulness of any information apparatus product or process disclosed or
represents that its use would not infringeprrvately owned rights Reference herein
to any specific commercial product process or service by trade name trademark
manufacturer or otherwise does not necessarily constitute or imply its
endorsement recommendation O i favoring by the United States Government or
any agency thereof The views arid opinions of authors expressed herein do not
necessarily state or reflec: those o f the I l r i i t e d StatesGovernment or any agency
thereof
 NvREG/CR-3243
ORNL/Sub/82-22252/1
D i s t . Category AN

E n g i n e e r i n g Technology D i v i s i o n

COMPARISONS OF ASME CODE FATIGUE EVALUATION METHODS FOR

NUCLEAR CLASS 1 PIPING W I T H CLASS 2 OR 3 PIPING

E. C. Rodabaugh

Manuscript Completed - May 2 3 , 1983

Date P u b l i s h e d -
J u n e 1983

Report P r e p a r e d by
E. C. Rodabaugh A s s o c i a t e s , I n c .
4625 Cemetery Road
H i l l i a r d , Ohio 43026
under
S u b c o n t r a c t No. 19X-22252C

Work Performed f o r
U.S. N u c l e a r R e g u l a t o r y Commission
O f f i c e of N u c l e a r R e g u l a t o r y Research
under
DOE I n t e r a g e n c y Agreement No. 40-550-75

NRC FIN No. BO474

OAK RIDGE NATIONAL LABORATORY

Oak Ridge, Tennessee 37830
o p e r a t e d by
UNION CARBIDE CORPORATION
f o r the
U. S. DEPARTMENT OF ENERGY
under C o n t r a c t No. W-7405-eng-26
 -' iii

CONTENTS

NOMENCLA'lURE ...................................................... V

ABSTRACT .......................................................... 1
1 . JNTRODUCTION .................................................. 1
2 . CODE 1 BASIS .................................................. 4
3 . CODE 2 BASIS .................................................. 6
4 . CORRELATIONS RE'IWEEN CODES 1 AND 2 ............................ 12
4 . 1 R e l a t i o n s h i p Between i and C2K2 .......................... 12
4.2 Comparison of Code 1 w i t h Code 2 B a s i s . SA106 Grade R
up t o 400°F .............................................. 13
4.3 O t h e r F e r r i t i c M a t e r i a l s and Temperatures ................ 15
4.4 A u s t e n i t i c S t e e l s . A l l o y s 600 and 800 .................... 17
4.5 Temperature E f f e c t . P i p i n g P r o d u c t T e s t s ................. 19
4 . 6 Mean S t r e s s e s ............................................ 19
5 . HIGH-CYCLE FATIGUE ............................................ 21
6 . TEES .......................................................... 25
7. CODE 2 COVERAGE OF LOADINGS O'IHER THAN MOMENTS ................ 28
7.1 Allowance f o r C y c l i c P r e s s u r e ............................ 28
7.2 Allowance f o r Thermal G r a d i e n t s .......................... 29
7.3 Use of Eq . (2) f o r Combined Loadings ..................... 29
7.4 Code 2 Cumulative Usage E q u a t i o n ......................... 30
7.5 Primary S t r e s s P r o t e c t i o n . H i g h Temperatures ............. 31
8 . SUMMARY ....................................................... 32
8.1 C h a p t e r s 2-4. F a t i g u e E v a l u a t i o n up t o lo6 C y c l e s ........ 32
8.2 ............................
Chapter 5. High-Cycle F a t i g u e 32
8.3 C h a p t e r 6. Tees .......................................... 32
8.4 Chapter 7. Loadings O t h e r t h a n Moments ................... 32
REFERENCES ........................................................ 33
APPENDIX A . RACKGROUND OF THE Ke FACTOR .......................... 35
APPENDIX B . RASIS OF CODE 1 FATIGUE DESIGN CURVES ................ 43
APPENDIX C . COMPARISONS OF CARBON STEEL AND AUSTENITIC STAINLESS
STEFL PIPING PRODUCT MOMENT FATIGUE TESTS ............ 51
 NOMENCLATURE

c, primary-plus-secondary s t r e s s indices f o r pressure

c2 primary-plus-secondary s t r e s s i n d i c e s f o r moment

c3 primary-plus-secondary s t r e s s i n d i c e s f o r thermal g r a d i e n t s
p r imary-pl us- secondary s t r e s s i n d e x , moment 1oading, t e e b r a n c h
'zb
C primary-plus-secondary s t r e s s index, moment l o a d i n g , t e e r u n
2r
p i p e OD
DO
E modulus of e l a s t i c i t y
f Code 2 cycle-dependent f a c t o r r a n g i n g from 1 . 0 f o r 7,000 c y c l e s t o
0.5 f o r 100,000 c y c l e s or more
h elbow p a r a m e t e r , t R / r Z
i Code 2 s t r e s s i n t e n s i f i c a t i o n f a c t o r

Kl peak s t r e s s i n d i c e s f o r p r e s s u r e

KZ peak s t r e s s i n d i c e s f o r moment

K3 peak s t r e s s i n d i c e s f o r thermal g r a d i e n t s
peak s t r e s s i n d e x , moment l o a d i n g , t e e b r a n c h
'2b
Ka r peak s t r e s s i n d e x , moment l o a d i n g , t e e r u n
Ke elastic-plastic a d j u s t m e n t f a c t o r , s e e Eq. ( 3 )
M moment
Mi range of r e s u l t a n t moment
range of r e s u l t a n t moment caused by thermal e x p a n s i o n
MC
N number of d e s i g n c y c l e s
number of c y c l e s t o f a i l u r e
Nf
range of s e r v i c e p r e s s u r e
P internal pressure
r mean r a d i u s of p i p e , b r a n c h p i p e f o r t e e s
R mean r a d i u s of p i p e , run p i p e f o r t e e s , or bend r a d i u s for elbows
Code 1 f a t i g u e d e s i g n s t r e s s a m p l i t u d e
'a
Code 2 a l l o w a b l e s t r e s s a t c o l d (100OF) t e m p e r a t u r e
sC
d e s i g n s t r e s s w i t h f a c t o r of s a f e t y of 2 on S
'
d f
S endurance l i m i t ( f a t i g u e s t r e n g t h a t -10l1 c y c l e s )
e
Code 2 c a l c u l a t e d s t r e s s r a n g e
sE
f a i l u r e s t r e s s , c o r r e l a t e d w i t h Nf
sf
Code 2 a l l o w a b l e s t r e s s a t h o t (maximum) t e m p e r a t u r e
'h
 vi

S Code 1 a l l o w a b l e s t r e s s i n t e n s i t y
m
S c a l c u l a t e d primary-plus-secondary s t r e s s range, s e e Eq. (1)
n
S c a l c u l a t e d peak s t r e s s r a n g e r s e e Eq. ( 2 )
P
S
S
Code 2 s u s t a i n e d l o a d s t r e s s r s e e &. ( 6 )
S u l t i m a t e t e n s i l e s t r e n g t h of m a t e r i a l
U
S y i e l d s t r e n g t h of m a t e r i a l
Y
t w a l l t h i c k n e s s of p i p e , b r a n c h p i p e f o r t e e s
T w a l l t h i c k n e s s of p i p e , run p i p e f o r t e e s
U f a t i g u e usage f a c t o r
X (1 - n)/En(m - 111, s e e Eq. ( 1 9 )
Z s e c t i o n modulus of p i p e
s e c t i o n modulus of t e e b r a n c h p i p e
b'
Z s e c t i o n modulus of t e e run pipe
r
a c o e f f i c i e n t of thermal e x p a n s i o n
*TI thermal g r a d i e n t s , s e e Code 1 for d e t a i l e d d e f i n i t i o n s

AT, thermal g r a d i e n t s , s e e Code 1 for d e t a i l e d d e f i n i t i o n s

T thermal g r a d i e n t s , see Code 1 for d e t a i l e d d e f i n i t i o n s
a
thermal g r a d i e n t s , s e e Code 1 for d e t a i l e d d e f i n i t i o n s
Tb
V Poisson's r a t i o
 COMPARISONS OF ASME CODE FATIGUE EVALUATION METHODS FOR
NUCLEAR CLASS 1 PIPING WITH CLASS 2 OR 3 PIPING

E. C. Rodabaugh*

ABSTRACT

The f a t i g u e e v a l u a t i o n p r o c e d u r e used i n t h e ASME B o i l e r

and Pressure Veseel Code, S e c t . 111, Nuclear Power Plant Com-
ponents, f o r C l a s s 1 p i p i n g i s d i f f e r e n t from t h e p r o c e d u r e
used f o r C l a s s 2 o r 3 p i p i n g . The b a s i s f o r each p r o c e d u r e
i s d e s c r i b e d , and c o r r e l a t i o n s between t h e two p r o c e d u r e s a r e
presented. C o n d i t i o n s under which e i t h e r p r o c e d u r e or b o t h
may be u n c o n s e r v a t i v e a r e noted.
P o t e n t i a l changes i n t h e C l a s s 2 o r 3 p i p i n g p r o c e d u r e
t o e x p l i c i t l y cover a l l l o a d i n g s a r e d i s c u s s e d . However, t h e
r e p o r t i s i n t e n d e d t o be i n f o r m a t i v e , and w h i l e t h e c o n t e n t s
of t h e r e p o r t may guide f u t u r e Code changes, s p e c i f i c recom-
mendations a r e n o t g i v e n h e r e i n .

1. INTRODUCTION

Fatigue-based c r i t e r i a f o r t h e e v a l u a t i o n of p i p i n g were i n t r o d u c e d
i n t o t h e P i p i n g Code, t h e n American S t a n d a r d s A s s o c i a t i o n (ASA) B31.1,t
i n t h e 1955 e d i t i o n . These c r i t e r i a were b a s e d on moment f a t i g u e t e s t s
on p i p i n g components by Markl, Markl and George, and Markl. The c r i -
t e r i a i n v o l v e use of s t r e s s i n t e n s i f i c a t i o n f a c t o r s ( i - f a c t o r s ) and s t r e s s
l i m i t s r e l a t e d t o c o l d (Sc) and h o t (Sh) a l l o w a b l e s t r e s s e s , m o d i f i e d by
a f a c t o r f , which depends upon t h e number of d e s i g n c y c l e s .
n e American S o c i e t y f o r Mechanical E n g i n e e r s (ASME) Boiler and Pres-
sure Veseel Code, S e c t . 111, Nuclear V e s s e l s , was i n i t i a t e d i n 1963. It
covered C l a s s A, B, and C v e s s e l s , now c a l l e d C l a s s 1, 2 , and 3 v e s s e l s .
T h i s Code, f o r C l a s s A v e s s e l s , used a f a t i g u e e v a l u a t i o n method t h a t i s
b a s e d on f a t i g u e t e s t s of p o l i s h e d b a r s . It u s e s d e s i g n f a t i g u e c u r v e s
i n which t h e a l l o w a b l e d e s i g n s t r e s s S i s p l o t t e d a g a i n s t t h e number of
a
d e s i g n c y c l e s N. S t r e s s i n d i c e s were i n t r o d u c e d i n t h e 1963 Code f o r t h e
p a r t i c u l a r c a s e of n o z z l e s w i t h c y c l i c p r e s s u r e l o a d i n g .
I n 1969, ANSI B31.7, Nuclear Power Piping was p u b l i s h e d . It c o v e r e d
C l a s s 1, 2 , and 3 p i p i n g . For C l a s s 1 p i p i n g , B31.7 adopted a f a t i g u e
-
*E. C. Rodabaugh A s s o c i a t e s , I n c . , B i l l i a r d , Ohio.
t I o 1955, B31.1 c o v e r e d a l l i n d u s t r i a l p i p i n g . L a t e r , i t was s p l i t
i n t o American N a t i o n a l S t a n d a r d s I n s t i t u t e (ANSI) B31.1, Power Piping;
ANSI B31.3, Chemical Plant and Petroleum Refinery Piping; ANSI B31.4,
R e f r i g e r a t i o n Piping; and ANSI B31.8, Gas Transmission and D i s t r i b u t i o n
Piping.
 2

a n a l y s i s method a n a l o g o u s t o t h a t u s e d i n t h e N u c l e a r V e s s e l Code. The

c o n c e p t of ' ' s t r e s s i n d i c e s " was expanded t o cover p r e s s u r e , moment, and
thermal g r a d i e n t l o a d s f o r commonly u s e d p i p i n g components. For C l a s s 2
and 3 p i p i n g , ANSI B31.7 c o n t i n u e d t o use t h e f a t i g u e e v a l u a t i o n method
o r i g i n a l l y i n t r o d u c e d i n ASA B31.1 i n 1955.
In 1971, S e c t . I11 of t h e ASME Code was expanded t o i n c l u d e v e s s e l s ,
pumps, v a l v e s , and p i p i n g ; t h e t i t l e was changed from NucZear VesseZs t o
Nuclear Power Ptant Components. With r e s p e c t t o t h e f a t i g u e e v a l u a t i o n
methods f o r p i p i n g , S e c t . 111 a d o p t e d , w i t h one d i f f e r e n c e , t h e r u l e s
c o n t a i n e d i n ANSI B31.7-1969. The d i f f e r e n c e c o n c e r n s t h e a d j u s t m e n t f o r
s t r e s s e s t h a t e x c e e d 3s ( c o n c e p t u a l l y , exceed t h e shakedown l i m i t ) . This
m
a d j u s t m e n t , a s w i l l become a p p a r e n t i n t h i s r e p o r t , i s h i g h l y s i g n i f i c a n t
i n c o r r e l a t i o n s between C l a s s 1 and C l a s s 2 o r 3 p i p i n g f a t i g u e e v a l u a t i o n
methods. The method u s e d i n ANSI B31.7 i s d e s c r i b e d i n Appendix A, a l o n g
w i t h a background d i s c u s s i o n of t h e e q u i v a l e n t K f a c t o r i n t r o d u c e d i n
e
S e c t . 111-1971 and c u r r e n t l y used.
The p r e s e n t (1982) s t a t u s of f a t i g u e e v a l u a t i o n methods u s e d i n
S e c t . I11 c a n be b r i e f l y summarized a s f o l l o w s :

C l a s s components Fatigue evaluation b a s i s

-I- .-
C l a s s 1 v e s s e l s , pumps, v a l v e s , Design f a t i g u e c u r v e s d e r i v e d
and p i p i n g from p o l i s h e d b a r f a t i g u e t e s t
data, with K adjustment
e
C l a s s 2 and 3 v e s s e l s , * pumps, None
and v a l v e s
C l a s s 2 and 3 p i p i n g P i p i n g component f a t i g u e t e s t s ,
using s t r e s s i n t e n s i f i c a t i o n
f a c t o r s , moment l o a d i n g o n l y

The o b j e c t i v e of t h i s r e p o r t i s t o show how t h e f a t i g u e e v a l u a t i o n

method f o r C l a s s 1 p i p i n g c o r r e l a t e s w i t h t h a t for C l a s s 2 or 3 p i p i n g .
The methods f o r C l a s s 2 and 3 p i p i n g a r e i d e n t i c a l . For b r e v i t y , we w i l l
i d e n t i f y t h o s e methods a s "Code 2"; t h o s e f o r C l a s s 1 p i p i n g a r e i d e n t i -
f i e d B S "Code 1."
C h a p t e r s 2 and 3 of t h i s r e p o r t d e s c r i b e t h e f a t i g u e e v a l u a t i o n
p r o c e d u r e s f o r Code 1 and Code 2 , r e s p e c t i v e l y . Chapter 4 i n d i c a t e s t h e
c o r r e l a t i o n s between Codes 1 and 2 . These c o r r e l a t i o n s a r e n e c e s s a r i l y
l i m i t e d t o moment l o a d i n g s , because Code 2 c o v e r s o n l y moment l o a d i n g .
Chapter 5 on h i g h - c y c l e f a t i g u e i s t r e a t e d s e p a r a t e l y , b e c a u s e i t i s
not a p p a r e n t t h a t e i t h e r Code 1 or Code 2 a d e q u a t e l y c o v e r s t h e f a t i g u e
e v a l u a t i o n of accumulated c y c l e s of 10' o r more. Chapter 6 d i s c u s s e s a
d i f f e r e n c e between Codes 1 and 2 t h a t i s a p p l i c a b l e o n l y t o t e e s . Chapter
7 c o n t a i n s a n e x p l o r a t o r y d i s c u s s i o n of t h e p o s s i b i l i t y of e x t e n d i n g Code
2 f a t i g u e e v a l u a t i o n t o cover ( o r more e x p l i c i t l y c o v e r ) l o a d i n g s o t h e r
t h a n moments.

*A f a t i g u e e v a l u a t i o n may be r e q u i r e d f o r v e s s e l s d e s i g n e d t o t h e
a l t e r n a t i v e r u l e s of NC-3200 ( e q u i v a l e n t t o ASME B o i l e r and P r e s s u r e Ves-
s e l Code, S e c t . V I I I , Div. 2 ) .
 3

Chapter 8 summarizes t h e o b s e r v a t i o n s c o n t a i n e d i n Chaps. 2-7. The

r e p o r t i s i n t e n d e d t o be i n f o r m a t i v e and may p r o v i d e a b a s i s f o r f u t u r e
Code changes. However, no recommendations f o r such changes a r e i n c l u d e d
herein.
In r e a d i n g t h e subsequent s e c t i o n s of t h i s r e p o r t , t h e e x p e r t on
f a t i g u e e v a l u a t i o n methods w i l l r e c o g n i z e t h a t , i n b o t h Code 1 and 2
methods, many simp1 i f y i n g a p p r o x i m a t i o n s a r e i n v o l v e d . For example, use
of t h e l i n e a r c u m u l a t i v e damage h y p o t h e s i s can be i n a c c u r a t e f o r c e r t a i n
sequences of l o a d i n g . However, i n a d d i t i o n t o and p e r h a p s j u s t i f y i n g t h e
s i m p l i f y i n g a p p r o x i m a t i o n s , t h e o p e r a t i n g h i s t o r y of t h e p i p i n g systems
must be p o s t u l a t e d . Because t h e o p e r a t i n g h i s t o r y e x t e n d s 20 t o 4 0 y e a r s
i n t o t h e f u t u r e , i t s p o s t u l a t e d d e t a i l s a r e deemed t o be t h e most uncer-
t a i n a s p e c t of t h e f a t i g u e e v a l u a t i o n method. The f a t i g u e e v a l u a t i o n
methods a r e b a s e d on t e s t d a t a i n an environment l i k e d r y a i r . Environ-
mental e f f e c t s , such a s c o r r o s i o n o r s t r e s s - c o r r o s i o n - c r a c k i n g , a r e not
covered or, a t b e s t , a r e only p a r t i a l l y covered by f a c t o r s of s a f e t y on
the t e s t data.
 4

2. CODE 1 BASIS

The Code 1 f a t i g u e e v a l u a t i o n method* i n v o l v e s t h e c a l c u l a t i o n of t h e

primary-plus-secondary s t r e s s r a n g e Sn by t h e e q u a t i o n :

PODO Mi
sn = C 1 x + c2 + T - a T I ,
a a b b

and t h e peak s t r e s s r a n g e by t h e e q u a t i o n :

1
PODO Mi
S
P
= KICl -
2t + K2c2 z- + - -
2(1 - v )
K3EalATl I

1
+ K C E laT - a T l + -
3 3 a b a a b b 1 - V
E ~ A TI
2
. (2)

If S A 3Sm ( c o n c e p t u a l l y , 2s , t h e shakedown l i m i t ) , S i s d i v i d e d by 2
l3 Y P
t o c o n v e r t from s t r e s s r a n g e t o s t r e s s a m p l i t u d e . The Code 1 d e s i g n f a -
t i g u e c u r v e s ( F i g s . 1-9.1, 1-9.2, o r 1-9.3, depending upon t h e m a t e r i a l )
a r e e n t e r e d w i t h S 1 2 , and d e s i g n c y c l e s N a r e r e a d from t h e c u r v e s . If
P
t h e a n t i c i p a t e d number of c u m u l a t i v e f a t i g u e c y c l e s i n o p e r a t i o n i s l e s s
t h a n N, t h e n t h e p i p i n g p r o d u c t ( e . g . , g i r t h b u t t weld, elbow) i s deemed
t o be acceptable.
I f Sn > 3Sm, t h e s t r a i n r a n g e c o r r e s p o n d i n g t o t h e e l a s t i c - b a s e d
c a l c u l a t i o n of s t r e s s r a n g e may be t o o low. With primary-plus-secondary
s t r e s s e s t h a t e x c e e d 2s shakedown t o e l a s t i c r e s p o n s e may n o t o c c u r and
Y'
p l a s t i c s t r a i n s , i n a d d i t i o n t o t h e c a l c u l a t e d e l a s t i c s t r a i n s , may o c c u r
d u r i n g e a c h c y c l e . To p r o v i d e a s i m p l e way t o d e a l w i t h t h i s c o n d i t i o n ,
Code 1 (NB-3228.3) p e r m i t s t h e use of a s i m p l i f i e d e l a s t i c - p l a s t i c analy-
s i s t h a t i n v o l v e s m u l t i p l y i n g S P by Ke, where ICe i s g i v e n by

K
e
= l/n f o r Sn > 3mSm .
-----
*Code 1 p e r m i t s t h e use of t h e more g e n e r a l r u l e s g i v e n i n NB-3200;
t h i s r e p o r t i s r e s t r i c t e d t o t h e r u l e s g i v e n i n NB-3650, " A n a l y s i s of
I1
P i p i r g Products.
 5

V a l u e s of m and n a r e

Mater i a1 m n

Carbon s t e e l 3.0 0.2

Low-alloy s t e e l and m a r t e n s i t i c s t a i n l e s s s t e e l 2.0 0.2
A u s t e n i t i c s t a i n l e s s s t e e l , nickel-chrome-iron, 1.7 0.3
and n i c k e l - c o p p e r

T a g a r t h a s p r e p a r e d a d e s c r i p t i o n ' of t h e b a s i s of Jiq. (31, which i s

i n c l u d e d h e r e i n a s Appendix A.
Code 1 F i g s . 1-9.1, 1-9.2, and 1-9.3 a r e b a s e d on s t r a i n - c o n t r o l l e d ,
z e r o mean s t r a i n , f a t i g u e t e s t s of p o l i s h e d b a r s . The d e s i g n f a t i g u e
c u r v e s were d e r i v e d from t h e f a i l u r e c u r v e s by i n c o r p o r a t i n g a f a c t o r of
s a f e t y of 2 on s t r e s s o r 20 on c y c l e s , whichever i s more c o n s e r v a t i v e .
(The 20 on c y c l e s c o n t r o l s a t low c y c l e s , t h e 2 on s t r e s s c o n t r o l s a t
h i g h c y c l e s . ) An a d j u s t m e n t f o r t h e e f f e c t of mean s t r e s s i s i n c l u d e d
i n F i g . 1-9.1 f o r u l t i m a t e t e n s i l e s t r e n g t h (UTSI i 80 k s i . Appendix B
c o n t a i n s a d e t a i l e d d i s c u s s i o n of F i g s . 1-9.1 and 1-9.2.
Code 1 u s e s t h e l i n e a r c u m u l a t i v e damage h y p o t h e s i s a s e x p r e s s e d by:

j ni
u= -<l.O 8 (4)
i Ni

where

n = number of c y c l e s w i t h amplitude S
i is
Ni = a l l o w a b l e number of c y c l e s from Code 1 F i g . 1-9.0 f o r Si.

Each type of s t r e s s c y c l e w i t h amplitude S must be i d e n t i f i e d from t h e

i
p o s t u l a t e d o p e r a t i n g h i s t o r y of t h e p i p i n g system. There a r e u s u a l l y t e n
o r more of such i d e n t i f i a b l e c y c l e s , each o c c u r r i n g n t i m e s . The t o t a l
i
number of t y p e s of c y c l e s i s j.
 6

3. CODE 2 BASIS

The Code 2 f a t i g u e e v a l u a t i o n method i n v o l v e s t h e c a l c u l a t i o n of t h e

s t r e s s range S by t h e e q u a t i o n
E
SE = i M / Z
C
.
I f SE s a t i s f i e s t h e e q u a t i o n

SE 1 f[1.25(Sh + Sc) - Ssl I (6)

and Ss Sh, t h e p i p i n g component i s deemed t o be a c c e p t a b l e from a

fatigue evaluation standpoint.
The Code 2 method i s b a s e d on t h e r e s u l t s of moment-loading f a t i g u e
t e s t s g i v e n by Mark1,l Mark1 and G e o r g e , a and Markl.3 The t e s t a r r a n g e -
ment f o r v a r i o u s p i p i n g p r o d u c t s i s i n d i c a t e d i n F i g . 1. T e s t a s s e m b l i e s
were mounted i n t h e f a t i g u e t e s t machine and s u b j e c t e d t o a p r e l i m i n a r y
load-deflection calibration. The a s s e m b l i e s were f i l l e d w i t h w a t e r t o

ORNL-DWG 83-4595 ETD

P: GIRTH BUTT WELD P: ELBOW

PLAIN PIPE PIPE BEND
FLANGED JOINT ( f i l l e t weld) MITER
CONCENTRIC REDUCER TEE, MOMENT THROUGH BRANCH
TEE, MOMENT THROUGH RUN

MARK L/G EO RGE COR R E L A T l ON EQUATION :

iM/Z = 490,000 N, --'.'

i STRESS INTENSIFICATION FACTOR, i = 1.0 FOR TYPICAL GIRTH BUTT WELD

M MOMENT RANGE, ELASTICALLY CALCULATED FROM TEST LOAD VS
DISPLACEMENT CALIBRATION
2 SECTION MODULUS OF PIPE
Nf CYCLES-TO-FAILURE, THROUGH WALL CRACK

F i g . 1. D i s p l a c e m e n t - c o n t r o l l e d , c o m p l e t e l y r e v e r s e d c y c l i c moment
t e s t s on 4-in. nominal s i z e , SA106 Grade B p i p i n g p r o d u c t s a t room tem-
perature. Source: Refs. 1-3.
 7

p r o v i d e a r e a d y means f o r d e t e c t i n g f a i l u r e and were t h e n f l e x e d c y c l i -

c a l l y (completely reversed displacements) through a predetermined dis-
placement u n t i l a l e a k t h a t i n d i c a t e d a c r a c k t h r o u g h t h e w a l l developed.
The r e s u l t s were r e p o r t e d a s p o i n t s on S v s Nf p l o t s . N i s t h e
f f
number of c y c l e s t o f a i l u r e ( c r a c k t h r o u g h t h e w a l l ) . The c o r r e s p o n d i n g
nominal s t r e s s was computed by t h e o r d i n a r y beam f o r m u l a , Sf = WLJZ. The
l o a d r a n g e W was t a k e n from t h e l o a d - d e f l e c t i o n c a l i b r a t i o n , or f o r l o a d s
c a u s i n g p l a s t i c d e f o r m a t i o n , from s t r a i g h t - l i n e e x t r a p o l a t i o n of t h e e l a s -
t i c p o r t i o n of t h e l o a d - d e f l e c t i o n c a l i b r a t i o n . The l e v e r arm L was mea-
s u r e d from t h e p o i n t of l o a d a p p l i c a t i o n t o t h e p o i n t of i n i t i a l f a i l u r e .
The t e s t method i s c o n s i s t e n t w i t h an e l a s t i c a n a l y s i s of a p i p i n g
system, even though c a l c u l a t e d s t r e s s e s may be above t h e m a t e r i a l y i e l d
s t r e n g t h and some p l a s t i c d e f o r m a t i o n may o c c u r . A c c o r d i n g l y , an a d j u s t -
ment analogous t o t h e K u s e d i n Code 1 is n o t needed.
e
A l l t e s t s were run on 4-in. nominal s i z e p i p i n g components a t room
t e m p e r a t u r e . The m a t e r i a l u s e d t o make t h e t e s t specimens was American
S o c i e t y of T e s t i n g M a t e r i a l s (ASTM) A106 Grade B. The t e n s i l e s t r e n g t h s
r a n g e d from 62,400 t o 86,300 p s i ; y i e l d s t r e n g t h s r a n g e d from 38,900 t o
56,200 p s i ; and e l o n g a t i o n f o r 2-in. gage s e c t i o n r a n g e d from 3 2 t o 55%.
A l l w e l d i n g was done manually u s i n g F l e e t w e l d No. 5 e l e c t r o d e s . Most
11 11
specimens were t e s t e d a s welded. A few g i r t h b u t t weld specimens were
s t r e s s r e l i e v e d a f t e r w e l d i n g and b e f o r e t e s t i n g w i t h no d e t e c t a b l e d i f -
ferences i n the t e s t r e s u l t s .
To make t h e t e s t i n f o r m a t i o n u s e f u l t o t h e p i p i n g d e s i g n e r , Mark1
d e v e l o p e d a c o r r e l a t i o n of t h e form

-b
isf = aN
f ,
(7)

where a and b a r e c o n s t a n t s developed from t h e t e s t d a t a . R e s u l t s of

t e s t s f o r g i r t h b u t t w e l d s a r e shown i n Fig. 2 , i n which Sf and Nf a r e
p l o t t e d on l o g s c a l e s . M u a t i o n ( 7 ) i s shown i n F i g . 2 . It i s a b e s t
f i t of t h e t e s t d a t a w i t h b = 0 . 2 . The v a l u e of b = 0 . 2 was s e l e c t e d
a f t e r e v a l u a t i n g t e s t d a t a f o r a l l t y p e s of p i p i n g p r o d u c t s . Individual
t e s t s e r i e s gave v a l u e s of b r a n g i n g from 0.1 t o 0.3, but most v a l u e s
were w i t h i n 20% of 0 . 2 , which r e p r e s e n t s a f a i r average. For g i r t h b u t t
w e l d s , t h e b e s t f i t v a l u e of a i s 490,000. Accordingly, Eq. ( 7 ) f o r a
g i r t h b u t t weld i s

Sf = 490,000 Nf’Ooa ( p s i , range) . (8)

Markl’s more g e n e r a l e q u a t i o n i s

isf = 490,000 Nf-Oo2 ( p s i , range) , (9)

where i 1 1.0 f o r a g i r t h b u t t weld and i i s t h e f a t i g u e - b a s e d s t r e s s

i n t e n s i f i c a t i o n f a c t o r f o r piping products o t h e r than g i r t h b u t t welds.
 8

ORNL-DWG 83-4596 ETD

300
._
-
Y)
Y
200
1
160
a
=
v,
120
v,
u
[r
ao
2 60
Z
-
H
0 40
Z
30
102 103 104 105 106
CYCLES TO FAILURE, N f

Fig. 2. R e s u l t s of moment f a t i g u e t e s t s on g i r t h b u t t welds.

Source: Ref. 3 .

E q u a t i o n ( 9 ) d o e s n o t a p p e a r i n Code 2 . The b a s i s f o r t h e c r i t e r i a
c o n t a i n e d i n Code 2 w a s d i s c u s s e d by Markl.s H i s concept was t h a t t h e
c a l c u l a t e d s t r e s s r a n g e SE s h o u l d be l i m i t e d t o

SE i 1 . 6 ( S c + Sh) (10)

where S i s t h e a l l o w a b l e s t r e s s a t t h e minimum t e m p e r a t u r e i n t h e c y c l e
C
and Sh is t h e a l l o w a b l e s t r e s s a t t h e maximum t e m p e r a t u r e i n t h e c y c l e .
A t t h a t time (19551, t h e a l l o w a b l e s t r e s s e s i n t h e Power P i p i n g Code were
limited t o (5/8)S where S i s t h e m a t e r i a l y i e l d s t r e n g t h a t o p e r a t i n g
YB
temperature. Accordingly, $.(10) i s c o n c e p t u a l l y e q u i v a l e n t t o

where S i s t h e a v e r a g e of t h e h o t and c o l d y i e l d s t r e n g t h s . U s e r s of
Ya
Code 1 w i l l r e c o g n i z e t h a t Eq. (11) i s t h e e q u i v a l e n t of t h e shakedown
c r i t e r i a i m p l i e d by S < 3Sm. However, t h e e q u i v a l e n c e is n o t t h a t
n-
s t r a i g h t f o r w a r d , b e c a u s e SE i n c l u d e s peak s t r e s s e s , whereas S does n o t .
n
F u r t h e r , because t h e i ' s a r e r e f e r e n c e d t o t h e f a t i g u e s t r e n g t h of a
t y p i c a l g i r t h b u t t weld, S i s n o t e q u a l t o e i t h e r S o r S ( a s d i s c u s s e d
l a t e r , i = C,K2/2). E n P
E q u a t i o n (11) i s an i n t e r e s t i n g s t e p on t h e way t o t h e Code 2 c r i -
t e r i a , Eq. ( 6 ) . However, t h e w r i t e r s of t h e p i p i n g code i n 1955 were
f a c e d w i t h t h e b r o a d problem of i n t e g r a t i n g room t e m p e r a t u r e t e s t d a t a
on t h e f a t i g u e l i f e of A106 Grade B p i p i n g components i n t o d e s i g n guidance
f o r many m a t e r i a l s and t e m p e r a t u r e s . How t o 1i m i t s u s t a i n e d (noncycl i c )
s t r e s s e s , such a s t h o s e caused by p r e s s u r e and w e i g h t , was one a s p e c t .
 9

A p p l i c a b i l i t y of t h e d e s i g n guidance a t e l e v a t e d t e m p e r a t u r e s , where s i g -
n i f i c a n t c r e e p o c c u r s , was a major concern. Eventually, a f t e r consider-
a t i o n of s e v e r a l proposed c r i t e r i a , t h e c r i t e r i a i n d i c a t e d by Eq. ( 6 )
were p u b l i s h e d i n ASA B31.1-1955, Code for Pressure Piping.
E q u a t i o n s ( 6 ) and ( 9 ) a r e compared i n Fig. 3 . Noting t h a t Eq. ( 9 ) i s
f o r c y c l e 8 t o f a i z u r e , a f a c t o r of s a f e t y i s needed f o r d e s i g n guidance.
II
F i g u r e 3 i n c l u d e s a d e s i g n " l i n e r e p r e s e n t i n g Eq. ( 9 ) w i t h a f a c t o r of
s a f e t y of 2 on s t r e s s , analogous t o t h e f a c t o r of s a f e t y of 2 on s t r e s s
used i n Code 1. (The f a c t o r of 20 on c y c l e s i s a l s o s a t i s f i e d because
25 = 32.) The d e s i g n e q u a t i o n i s t h e n

isd = 245,000 P O g a ( p s i , range) . (12)

Assuming, a s i n Code 1, t h a t f a t i g u e a t t e m p e r a t u r e s up t o 6500F i s

n o t s i g n i f i c a n t l y d i f f e r e n t from t h a t a t room t e m p e r a t u r e , t h e n F i g . 3
i n d i c a t e s t h a t even f o r Ss = 0 , Eq. ( 6 ) f o r A106 Grade B m a t e r i a l a t
t e m p e r a t u r e s up t o 650°F ( S = Sh = 15,000 p s i ) h a s a f a c t o r of s a f e t y of
C
2 o r g r e a t e r up t o -400,000 c y c l e s . The f - f a c t o r , which v a r i e s between
1 f o r 7,000 c y c l e s t o 0.5 f o r 100,000 or more c y c l e s , g i v e s t h e s t e p p e d
v a r i a t i o n between 7,000 and 100,000 c y c l e s . The f a c t o r of s a f e t y i s h i g h
a t low c y c l e s (e.g., 5.2 a t 100 c y c l e s ) . Comparisons between Eqs. ( 9 ) and
(12) f o r m a t e r i a l s o t h e r t h a n SA106 Grade B a r e d i s c u s s e d i n S e c t s . 4.3
and 4.4.

- F O R A 1 0 6 G R A D E 8 UP T O 65OOF
w
m
5 -
S C = S h = 1 5 k s i P E R 831.1
-

1 - I I I I 1 I I I ~
1~~

10 102 103 104 105 106

c CYCLES

Fig. 3. Comparison of Eq. ( 9 ) w i t h Code 2 a l l o w a b l e s t r e s s e s f o r

SA106 Grade B m a t e r i a l .
 10

Code 2 , l i k e Code 1, u s e s t h e l i n e a r c u m u l a t i v e damage h y p o t h e s i s a s

e x p r e s s e d by t h e e q u a t i o n g i v e n i n NC-3611.2(e)(3):

N = NE + r:(N1) + r5(N
2 2
1 + ..... r 5n( N n ) , (13)

where

NE = number of c y c l e s a t r u n t e m p e r a t u r e change AT f o r
E
which t h e e x p a n s i o n s t r e s s S , h a s been c a l c u l a t e d ;
N1, N 2 , ... 0
N n = number of c y c l e s f o r s m a l l e r t e m p e r a t u r e changes,
AT1, AT2, ...
ATn;
r
1
, r2 , ... r = ATXIATE, AT /ATE
n 2
...
ATn/ATE.

The exponent of t h e r ' s , assuming S i s p r o p o r t i o n a l t o AT f o l l o w s from

E E'
t h e exponent of N i n Eq. ( 9 ) . Note t h a t Eq. ( 1 3 ) d o e s n o t i n c l u d e c y c l i c
moments c a u s e d by o t h e r t h a n r e s t r a i n t of f r e e thermal e x p a n s i o n ( e . g . ,
c y c l i c moments c a u s e d by r e l i e f v a l v e d i s c h a r g e ) . E q u a t i o n ( 1 3 ) i m p l i e s
t h a t t h e r e i s no endurance l i m i t ( s t r e s s below which f a t i g u e damage d o e s
n o t o c c u r ) . T h i s i s deemed t o be a l r i g h t p r o v i d e d t h e N's a r e n o t g r e a t e r
t h a n l o 6 c y c l e s . E q u a t i o n (131, of c o u r s e , d o e s n o t e x p l i c i t l y c o v e r
l o a d i n g s such a s p r e s s u r e o r thermal g r a d i e n t s ( S e c t . 7 . 4 ) .
Equation ( 6 ) represents the f a t i g u e evaluation introduced i n t o the
p i p i n g code i n 1955. The r i g h t - h a n d s i d e of Fq. ( 6 ) i n c l u d e s t h e c a l -
c u l a t e d s t r e s s S t h a t was d e f i n e d a s ' I . . . t h e sum of t h e l o n g i t u d i n a l
S
s t r e s s e s due t o p r e s s u r e , w e i g h t and o t h e r s u s t a i n e d l o a d s . " An e q u a t i o n
was g i v e n f o r c a l c u l a t i n g t h e l o n g i t u d i n a l p r e s s u r e s t r e s s : S = pd2/
SP
( D 2 - d 2 ) , where p = i n t e r n a l p r e s s u r e , d = p i p e I D , and D = p i p e OD.
T h i s e q u a t i o n i s r e a s o n a b l y c o r r e c t f o r s t r a i g h t and c u r v e d p i p e ; i t i s
not d e f i n e d f o r r e d u c i n g o u t l e t t e e s . ( A r e the branch p i p e o r the run
p i p e d i m e n s i o n s t o b e u s e d ? ) An a p p r o p r i a t e method t o b e u s e d i n c a l c u -
l a t i n g t h e " l o n g i t u d i n a l s t r e s s e s due t o w e i g h t and o t h e r s u s t a i n e d l o a d s "
was n o t g i v e n . Except f o r s t r a i g h t p i p e , t h e l o n g i t u d i n a l s t r e s s c a u s e d
by a moment l o a d i n g i s not g i v e n by M/Z. Indeed, f o r elbows s u b j e c t e d t o
a n in-plane b e n d i n g moment, t h e maximum s t r e s s c a u s i n g f a t i g u e f a i l u r e i s
i n t h e hoop d i r e c t i o n . To q u a n t i f y how t o c a l c u l a t e S s , Code 2 now u s e s
the c r i t e r i a equation:

PD /4T
0
+ 0.75iMA/Z + iIGc/Z Sh + f ( 1 . 2 5 S
C
+ 0.25Sh) , (14)

where

P = design pressure,
Ef = r e s u l t a n t moment c a u s e d by w e i g h t and o t h e r s u s t a i n e d l o a d s ,
b$ = r a n g e of r e s u l t a n t moment c a u s e d by thermal e x p a n s i o n .
 11

The i n t e n t w a s t h a t S = PDo/4T + 0.75iMA/Z. With t h a t e q u i v a l e n c e ,

S
Eqs. (6) and ( 1 4 ) a r e the same f o r f = 1 . 0 . In most a p p l i c a t i o n s , f i s
taken t o be u n i t y . The s i g n i f i c a n c e of S i n a f a t i g u e e v a l u a t i o n i s d i s -
S
c u s s e d f u r t h e r i n S e c t s . 4 . 6 and 4 . 1 .
 12

4. CORRELATIONS* BETWEEN CODES 1 AND 2

4.1 R e l a t i o n s h i p Between i and C z K z

Note under Eq. ( 9 ) t h a t i i s u n i t y f o r a g i r t h b u t t weld. "be welds

t e s t e d by Markl were t y p i c a l of i n d u s t r i a l p r a c t i c e f o r w e l d s i n c a r b o n
s t e e l p i p i n g . The r o o t s of t h e w e l d s were n o t snooth, and t h e w e l d over-
l a y on t h e o u t s i d e s u r f a c e was t y p i c a l l y i r r e g u l a r and presumably i n c l u d e d
minor u n d e r c u t t i n g . Such w e l d s a r e not t h e e q u i v a l e n t of p o l i s h e d b a r s
t h a t form t h e b a s i s f o r Code 1 f a t i g u e e v a l u a t i o n w i t h t h e a s s o c i a t e d C,
and K, moment-loading s t r e s s i n d e x e s . A c c o r d i n g l y , t o compare Code 2 and
Code 1 f a t i g u e e v a l u a t i o n s , a r e l a t i o n s h i p between i and C 2 K 2 must be
established.
For elbows s u b j e c t e d t o in-plane moment, t h e maximum p r i n c i p a l s t r e s s
ts i s g i v e n by t h e o r y ( f o r t h e elbow p a r a m e t e r h l e s s t h a n a b o u t one) a s
m

The v a l i d i t y of Eq. ( 1 5 ) h a s been confirmed by numerous t e s t s i n which

s t r a i n g a g e s were p l a c e d on elbows s u b j e c t e d t o in-plane moment. The
i - f a c t o r f o r elbows, w i t h i = 1 . 0 f o r a t y p i c a l g i r t h b u t t weld, i s

i = 0.9Ih 213 . (16)

The f a t i g u e t e s t s 3 t h a t l e d t o Eq. ( 1 6 ) were in-plane moment t e s t s . T h e

f a t i g u e f a i l u r e l o c a t i o n s and d i r e c t i o n s a g r e e d v e r y w e l l w i t h t h e theo-
r e t i c a l l o c a t i o n and d i r e c t i o n of t h e maximum p r i n c i p a l s t r e s s . However,
a/=
i i s e x a c t l y one-half of 1 . 8 / h - C,. Because t h e f a i l u r e s o c c u r r e d ir
t h e body of t h e elbows remote from w e l d s , K, = 1 . 0 and

i = C,K,/2 . (17)

E q u a t i o n ( 1 7 ) i s i n c l u d e d i n Code 2 , NC-3673.2(b).
T h e elbow t h e o r y and f a t i g u e t e s t s p r o v i d e t h e fundamental b a s i s f o r
J3q. ( 1 7 ) . However, o t h e r e v i d e n c e e x i s t s t o c o n f i r m i t s g e n e r a l v a l i d i t y
a s discussed i n the following.
I f i = 1 . 0 f o r a t y p i c a l g i r t h b u t t w e l d and Eq. ( 1 7 ) i s g e n e r a l l y
a p p l i c a b l e , t h e n we would e x p e c t t h a t i = 0 . 5 f o r f a t i g u e t e s t s r u n on a
s t r a i g h t p i p e w i t h p o l i s h e d s u r f a c e s , b e c a u s e C, = K, = 1.0. Such t e s t s
a r e n o t a v a i l a b l e , b u t hiark13 i n c l u d e d t e s t s of " p l a i n s t r a i g h t p i p e . "
The r e s u l t i n g i - f a c t o r was 0.64. F a t i g u e t e s t s of a p l a i n s t r a i g h t p i p e ,
w i t h t h e f a t i g u e machine u s e d by Markl, p o s e s a problem because a l m o s t
------
* C o r r e l a t i o n s a r e r e s t r i c t e d t o moment l o a d i n g s , because Code 2
c o v e r s o n l y moment l o a d i n g s . See Chap. 7 f o r d i s c u s s i o n of t h i s a s p e c t .
 13

any f e a s i b l e way of a n c h o r i n g t h e p i p e t o t h e t e s t frame w i l l i n t r o d u c e

a s t r e s s concentration. Mark1 s o l v e d t h e problem by u s i n g a t a p e r e d - w a l l
f o r g i n g , w i t h about a 1 : l O t a p e r going from 0.237-in. nominal w a l l t o
-0.6-in. nominal w a l l anchored-end. The s u r f a c e of t h e t e s t s e c t i o n was
l e f t "as-forged" t o s i m u l a t e a t y p i c a l c a r b o n s t e e l p i p e s u r f a c e . Oth-
e r s J 6 J 7 u s i n g r e s o n a n t bending t e s t i n g i n which t h e p i p e i s v i b r a t e d i n
t h e " f r e e - f r e e " mode w i t h t h e p i p e s u p p o r t e d a t t h e node p o i n t s , a l s o
o b t a i n e d i - f a c t o r s f o r c a r b o n s t e e l p i p e of about 0 . 6 5 . R e f e r e n c e 7
a l s o t e s t e d t y p e 304 a u s t e n i t i c s t e e l p i p e and o b t a i n e d a n i - f a c t o r of
0 . 5 5 , p e r h a p s because of t h e b e t t e r s u r f a c e f i n i s h of a u s t e n i t i c s t e e l
pipe.
Moment f a t i g u e t e s t s 7 - 0 on g i r t h b u t t w e l d s w i t h f u s i o n r o o t p a s s
a n d f o r t h e weld o v e r l a y ground f l u s h a l s o gave i - f a c t o r s l e s s t h a n one.
R e f e r e n c e s 10-15 g i v e r e s u l t s of t e s t s on b r a n c h c o n n e c t i o n s o r t e e s
i n which s t r e s s e s c a u s e d by b r a n c h moment l o a d s were measured w i t h s t r a i n
gages, a f t e r which t h e b r a n c h c o n n e c t i o n s o r t e e s were s u b j e c t e d t o branch-
l o a d i n g c y c l i c moment f a t i g u e t e s t s . These t e s t s a l s o i n d i c a t e t h a t i
CzKz/2 (more s p e c i f i c a l l y , i 2 C K / 2 ) .
zb zb

4.2 Comparison of Code 1 w i t h Code 2 B a s i s ,

SA106 Grade B UR t o 4000F

Having t h e r e l a t i o n s h i p i = CzK2/2 and Ke a s d e f i n e d by Eq. ( 3 1 ,

comparisons can be made between Code 1 and Eq. ( 1 2 ) . The Code 1 Sa v s N
c u r v e s can b e a d j u s t e d f o r t h e K f a c t o r a s d e s c r i b e d i n t h e f o l l o w i n g
p a r a g r a p h . We s t a r t w i t h t h e e q t a t i o n

K S = 2s (ranges)
e P a
, (18)

where Sa i s o b t a i n e d from Code 1 F i g s . 1 - 9 . 1 , 1 - 9 . 2 , o r 1-9.3 f o r t h e

g i v e n number of c y c l e s N. For example, f o r N ( d e s i g n c y c l e s ) = 1 0 , S =
a
580 k s i f o r c a r b o n s t e e l s w i t h UTS L 80 k s i . Because S = K S and w i t h
P 231
Ke d e f i n e d by Eq. ( 3 1 , Eq. (18) becomes:

[ l + X(Sn/3S
m
- l)lKzSn = 2 s
a
; f o r 3Sm Sn 3,S, , (19)

where X = ( 1 - n)/[n(m -111. S o l v i n g Eq. (19) f o r S gives

n

S
n
= {(X - 1)K
2
+ C(X - 1 I 2 K Z + 8XK S /3S 11/z}/(2XK / 3 S
2 z a m 2 m
. (20)

A1 so,
.
Sn = 2nSa/Kz; f o r Sn > 3mSm , (21)
 14

and

'n
= 2sa /K2 ; f o r Sn < 3s
m
. (22)

A f t e r d e t e r m i n i n g Sn by Eq. ( 2 0 ) , t h e peak s t r e s s i s

S
P
= K S
a n
. (23)

F i g u r e 4 shows t h e Code 1 Sa v s N curve, Code Fig. 1-9.1, f o r UTS

80 k s i . Also shown, a s dashed l i n e s , a r e t h e a d j u s t e d ( f o r K e ) c u r v e s
f o r a carbon s t e e l w i t h Sm = 20 k s i , m = 3 , n = 0 . 2 , X = 2 . 0 , such a s
SA106 Grade B a t t e m p e r a t u r e s up t o 400OF. An example of t h e development
of t h e dashed c u r v e s , f o r N = IO3, K 2 = 2 . 0 , i s :

1. A t N = 103, Sa = 83 k s i (from Code T a b l e 1 - 9 . 1 ) .

2. E q u a t i o n ( 2 0 ) w i t h X = 2 . 0 , K2 = 2 . 0 , and 3Sm = 6 0 k s i g i v e s S n =
[2 + ( 4 + 3 2 x 8 3 / 6 0 ) 1 ' 2 1 / ( 8 / 6 0 ) = 6 7 . 1 k s i .
3. Because S > 3Sm, Fiq. ( 2 0 ) a p p l i e s ; n o t Eq. ( 2 1 ) o r ( 2 2 ) .
n
4. E q u a t i o n ( 2 3 ) : S = 2 x 6 7 . 1 = 134 k s i .
5. S is plotted a t = l o 3 t o e s t a b l i s h a p o i n t on t h e dashed l i n e
P
l a b e l e d Kz = 2 .

T h i s procedure i s r e p e a t e d t o o b t a i n o t h e r p o i n t s on t h e dashed l i n e s i n
F i g . 4 . The Ke a d j u s t m e n t s t o p s t o t h e r i g h t when S n = 3sm and t h e r e i s a
p o r t i o n of t h e dashed c u r v e s a t t h e extreme l e f t where Eq. (21) controls.

ORNL-DWG 83-4598 ETD

1000

-
'.G 500 - -
Y
I

Lu
C3
z C O D E 1 A D J U S T E D FOR K 2 = 2.0
a
LL
*
v) 100 -
w
[r
I-
*
Y
50 -
a
w
a

10 a
I I I I I I I I
10 102 103 104 105 106
DESIGN C Y C L E S , N

Fig. 4 . Comparison of Eq. ( 2 4 ) w i t h Code 1 i n c l u d i n g Ke a d j u s t m e n t ,

SA106 Grade B up t o 4000F.
 15

E q u a t i o n (121, f o r Code 2 , i s a d e s i g n c y c l e s e q u a t i o n w i t h a f a c -
t o r of s a f e t y of 2 on s t r e s s . However, because of t h e r e l a t i o n s h i p of
E q . (171, i = C2K2/2, t h e a p p r o p r i a t e comparison i s between 2 i S and S =
K S : d P
a n

F i g u r e 4 i n c l u d e s Eq. ( 2 4 ) . It i s a p p a r e n t i n F i g . 4 t h a t agreement
between 2 i S and S f o r K, = 2 i s good up t o -20,000 c y c l e s . K, = 2 i s
d P
a p p r o x i m a t e l y t h a t used f o r a g i r t h b u t t weld. For IC, = 1, Code 1 i s more
c o n s e r v a t i v e t h a n Eq. ( 2 4 ) . 9, = 1 i s used f o r elbows; d i r e c t comparison
of elbow f a t i g u e t e s t s w i t h Code 1 f a t i g u e e v a l u a t i o n a l s o i n d i c a t e s t h a t
Code 1 i s c o n s e r v a t i v e a s a p p l i e d t o c a r b o n s t e e l e l b o w s . 1 6 r x 7
The high-cycle end of F i g . 4 w i l l be d i s c u s s e d i n Chap. 5 .

4.3 O t h e r F e r r i t i c M a t e r i a l s and Temperatures

F i g u r e 4 c o n s t i t u t e s t h e most s i g n i f i c a n t c o r r e l a t i o n between Codes 2

and 1, because M a r k l ' s f a t i g u e t e s t s were r u n on p i p i n g components made of
SA106 Grade B c a r b o n s t e e l a t room t e m p e r a t u r e and because Code 1 d e s i g n
f a t i g u e c u r v e s i n F i g . 1-9.1 f o r UTS 80 k s i , a s d i s c u s s e d i n Appendix B,
a r e b a s e d on t e s t s a t room t e m p e r a t u r e of m a t e r i a l s l i k e SA106 Grade €3.
T a b l e 1 shows c o r r e l a t i o n s between Codes 2 and 1 in t h e form of ra-
t i o s of d e s i g n f a t i g u e s t r e s s e s t o Eq. ( 2 4 ) . For Code 2 , Fq. ( 2 4 ) i s mul-
t i p l i e d by ( S c + ShImt/(Sc + ShIr, where t h e s u b s c r i p t " m t " i n d i c a t e s t h e
v a l u e s of S and Sh f o r t h e i n d i c a t e d m a t e r i a l and t e m p e r a t u r e ; s u b s c r i p t
C
I1 I1
r i n d i c a t e s t h e r e f e r e n c e SA106 Grade B a t l O O O F (Sc = Sh = 1 5 k s i ) .
Code 1 b a s i c d e s i g n f a t i g u e c u r v e s group m a t e r i a l s ( e . g . , SA106
Grades A, B, and C ) do n o t depend on t e m p e r a t u r e . * However, t h e d e s i g n
f a t i g u e s t r e s s e s a r e m a t e r i a l and t e m p e r a t u r e dependent when t h e K f a c -
e
t o r i s i n v o l v e d , because K i s a f u n c t i o n of S which i s m a t e r i a l and
e m'
t e m p e r a t u r e dependent.
T a b l e 1 r a t i o s a r e numerical a n a l o g s of e i g h t g r a p h s l i k e F i g . 4 . We
p r e v i o u s l y n o t e d t h a t F i g . 4 showed t h a t t h e agreement between Eq. ( 2 4 )
and S f o r K, = 2 . 0 f o r A106 Grade B carbon s t e e l was good up t o -20,000
P
cycles. In T a b l e 1 t h e r a t i o s a r e shown: 0 . 9 6 , 0.97, 1 . 0 9 , and 0.98 f o r
N = 1 0 , l o 2 , 1 0 3 , and l o 4 , r e s p e c t i v e l y .
Code 2 r a t i o s a r e independent of c y c l e s N whereas t h e Code 1 r a t i o s
depend upon N. For small N, K may be equal t o l / n , i n which c a s e t h e
r a t i o s a r e independent of S ad : t h u s i n d e p e n d e n t of t h e m a t e r i a l ( w i t h i n
m
t h e group) and t e m p e r a t u r e . For l a r g e N, K = 1 . 0 , i n which c a s e t h e
e
r a t i o s a r e a l s o i n d e p e n d e n t of S and t h u s i n d e p e n d e n t of t h e m a t e r i a l
m
( w i t h i n t h e group) and t e m p e r a t u r e . W i t h i n t h e range between Ke = l / n and

*Provided E u s e d i n c a l c u l a t i n g t h e s t r e s s e s i s t h e same a s t h o s e
shown i n Code 1 F i g . 1-9.0.
 16

Table 1. Ratios' of d e s i g n f a t i g u e s t r e s s e s t o Eq. ( 2 4 ) f o r f e r r i t i c m a t e r i a l s

Temperature Temper a t u r e
lOOOF 700°F
Nb BasisC
( S)
SAl06A SAl06B SAl06C :if' SAl06A SAl06B SAl06C
SA67 2-
Jloo
~ ~~
~

10 Code 2 0.80 1.oo 1.17 1.67 0.79 0.98 1.14 1.67

(309) Code 1. K, = 1 0.75 0.7Sd 0,7Sd 0.64 0.75d 0.7 gd 0.7 gd 0.64
Code 1, K, = 2 0.85 0.96 1.04 1.oo 0.80 0.87 0.93 1.oo
10' Code 2 0.80 1.oo 1.17 1.67 0.79 0.98 1.14 1.67
(195) Code 1, K, = 1 0.57 0.65 0.71 0.72 0.54 0.59 0.64 0.72
Code 1, K, = 2 0.85 0.97 1.07 1.19 0.80 0.88 0.95 1.19
10' Code 2 0.80 1.00 1.17 1.67 0.79 0.98 1.14 1.67
(123) Code 1, K, = 1 0.62 0.71 0.78 0.90 0.58 0.64 0.69 0.90
Code 1, K, = 2 0.95 1.09 1.20 1.30' 0.89 0.98 1.06 1.30e
104 Code 2 0.80 1 .oo 1.17 1.67 0.79 0.98 1.14 1.67
(77.7) Code 1, K, = 1 0.73 0.84 0.93 1.07' 0.68 0.75 0.82 1.07e
Code 1. K, = 2 0.98e 0.98' 0.98e 1.07e 0.9Ee 0.98e 0.98e 1.07e
10' Code 2 0.80 1.oo 1.17 1.67 0.79 0.98 1.14 1.67
(49.0) Code 1, K, = 1 0.82e 0.82e 0.82e 0.96e 0.82e 0.82e 0.82' 0.96'
Code 1, K , = 2 0.82e 0.82e 0.82e 0.96e 0.82e 0.82e 0.82e 0.96e
10' Code 2 0.80 1.oo 1.17 1.67 0.79 0.98 1.14 1.67
(30.9) Code 1, K, = 1 0,81e 0.81e 0.81e l.Oge 0.81" 0.81e 0.81e l.Oge
Code 1, K, = 2 0.81e 0.81e 0.81e l.Oge 0.81e 0.81e 0.81e l.Oge
-
a
Ratios t o S = 2 i S
d
= 490.000 N-O", Eq. ( 2 4 ) .
bS = 490 N - O " . hi.
'Code 2 , ~ q .( 2 4 ) x (sC+ S h ) m t / ( S c + s ~ ) s e~e .t e x t .
Code 1, Sp by Eq. ( 2 3 ) .
d I n d i c a t e s t h a t Sn ) 3mSm, Ke = l / n , and S = 2nSa. Sa = f a t i g u e d e s i g n s t r e s s from
P
Code 1 Table 1-9.1 f o r l i s t e d N, i n t e r p o l a t e d f o r SA672-J100.
e I n d i c a t e s t h a t S, ( 3Sm, Ke = 1 . 0 , and sp = 2sa.

ICe = 1.0, Codes 2 and 1 g i v e s i m i l a r changes i n d e s i g n f a t i g u e s t r e s s e s a s

a f u n c t i o n of m a t e r i a l and t e m p e r a t u r e .
SA672-J100 i s a low-alloy s t e e l , welded p i p e m a t e r i a l . I t i s seldom
used i n n u c l e a r power p l a n t p i p i n g b u t was i n c l u d e d t o i l l u s t r a t e a poten-
t i a l h a z a r d i n t h e Code 2 f a t i g u e e v a l u a t i o n p r o c e d u r e . SA672-5100 h a s a
s p e c i f i e d minimum S of 100 k s i , S of 83 k s i , Sc = S = 25 k s i , and Sm =
U Y h
33.3 k s i . Being l i s t e d a s a low-alloy s t e e l , m = 2, 1: = 0.2, and X = 4 as
c o n t r a s t e d t o SA106 Grades A, B, and C f o r which m = 3 , n = 0.2, and X =
2 . V a l u e s of S were o b t a i n e d from Code T a b l e J-9.1 by l i n e a r i n t e r p o l a -
a
t i o n between v a l u e s g i v e n f o r UTS 80 and UTS = 115-130 ( S of 80 and 115
U
were used i n t h e i n t e r p o l a t i o n ) .
I t c a n be s e e n i n T a b l e 1 t h a t Code 2 p e r m i t s a f a t i g u e d e s i g n s t r e s s
f o r SA672-J100 t h a t i s 1.67 t i m e s t h a t g i v e n by Eq. (24) f o r SA106 Grade B
a t 1000F. In c o n t r a s t , Code 1, f o r K, = 2.0 ( e . g . , a g i r t h b u t t w e l d ) ,
p e r m i t s a f a t i g u e d e s i g n s t r e s s t h a t i s , f o r most N, about e q u a l t o t h a t
f o r SA106 Grade B at. 100°F. U n f o r t u n a t e l y , no t e s t s a r e a v a i l a b l e on
g i r t h b u t t w e l d s i n SA672-Jl00 p i p e . As mentioned p r e v i o u s l y , Markl' s
 17

t e s t s were r u n on p i p i n g components made of m a t e r i a l s w i t h S r a n g i n g from

62.4 t o 86.3 k s i , and S r a n g i n g from 38.9 t o 56.2 k s i . Howher, fatigue
Y
f a i l u r e s i n g i r t h b u t t w e l d s may be r e l a t e d to t h e p r o p e r t i e s of t h e weld
m e t a l o r h e a t - a f f e c t e d zone r a t h e r t h a n t h e b a s e m e t a l . We would specu-
l a t e t h a t g i r t h b u t t w e l d s i n SA672-J100 p i p e would n o t be much b e t t e r
t h a n g i r t h b u t t w e l d s i n SA106 Grade B, and i n t h i s p a r t i c u l a r r e s p e c t ,
Code 1 i s p r o b a b l y more a c c u r a t e t h a n Code 2 . Note, however, t h a t r a t i o s
in T a b l e 1 a r e t o t h e b a s i c p i p i n g p r o d u c t f a t i g u e c u r v e , E q . ( 2 4 ) , and
t h a t Code 2 a l l o w a b l e f a t i g u e d e s i g n s t r e s s e s , a s i l l u s t r a t e d i n F i g . 3 ,
c o n t a i n a l a r g e margin f o r a l o w number of c y c l e s .
A somewhat analogous s i t u a t i o n e x i s t s i n ANSI B31.3-1980, fiemicaZ
E'lant and Petroleum Refinery Piping, where changing t h e a l l o w a b l e s t r e s s
b a s i s from a f a c t o r of 114 t o 1 1 3 on Su i n c r e a s e d a l l o w a b l e d e s i g n f a t i g u e
s t r e s s e s by a f a c t o r of 413 f o r some m a t e r i a l s and t e m p e r a t u r e s ( e . g . ,
f o r A106 Grade B from 15 to 20 k s i f o r t e m p e r a t u r e s up t o 400OF).

4.4 A u s t e n i t i c S t e e l s , A l l o y s 600 and 800

A v a i l a b l e f a t i g u e t e s t d a t a on p i p i n g components made of t y p e 304

a u s t e n i t i c s t a i n l e s s s t e e l aI?d dimensional e q u i v a l e n t p i p i n g components
made of SA106 Grade B c a r b o n s t e e l a r e a b s t r a c t e d i n Appendix C. Tbese
d a t a i n d i c a t e t h a t SA106 Grade B components a r e s l i g h t l y s t r o n g e r t h a n
t y p e 304 components. A c c o r d i n g l y , i t i s p e r t i n e n t t o c o n t i n u e compari-
sons w i t h Eq. ( 2 4 ) .
F i g u r e 5 shows comparisons between Eq. ( 2 4 ) , 2 i S = 490,000
d
and Eq. ( 2 3 ) , S = K S .
2 n
F i g u r e 5 i s f o r an a u s t e n i t i c s t e e l w i t h S =
m
20 k s i ( e . g . , S k 1 2 t y p e 304 a t 1 0 0 0 F ) . For a u s t e n i t i c s t e e l s ( a n d a l l o y s
600 and 800), m = 1 . 7 , n = 0 . 3 , and X = 3.333.

ORNL-DWG 83-4599 ETD

103

-
.- ,CODE 1 J
-w
Y)
Y

W
z
a
a
g 102
w
[r

n
rY
z
n

10
10 102 103 104 105 106
DESIGN C Y C L E S , N

F i g . 5 . Comparison of Eq. ( 2 4 ) w i t h Code 1 i n c l u d i n g ICe a d j u s t m e n t ,

SA312 t y p e 304 a t 10O0F.
 18

F i g u r e 5 i n d i c a t e s t h a t f a i r agreement e x i s t s between Eq. (24) and

S f o r K, = 2.0 up t o lo3 c y c l e s . However, f o r N > l o 4 , Code 1 a l l o w a b l e
P
s t r e s s e s a r e 1.5 t o 1.7 t i m e s t h o s e g i v e n by Eq. (24). If, a s s u g g e s t e d
by t h e d a t a i n Appendix C, Eq. (24) i s about r i g h t or s l i g h t l y unconser-
v a t i v e f o r 304 m a t e r i a l a t 100°F, t h e n Code 1 i s u n c o n s e r v a t i v e . A simi-
l a r r e l a t i o n s h i p i s a p p a r e n t f o r Kz = 1 . 0 f o r N g r e a t e r t h a n -10; c y c l e s .
T a b l e 2, l i k e T a b l e 1, shows c o r r e l a t i o n s between Code 2 and Code 1
in t h e form of r a t i o s of d e s i g n f a t i g u e s t r e s s e s t o Eq. (24). W e pre-
v i o u s l y noted t h a t F i g . 5 showed agreement between Eq. (24) and S f o r 3 0 4
P
a t l O O O F and K, = 2.0 up t o l o 3 c y c l e s . I n T a b l e 2 t h e r a t i o s a r e shown:
1.26, 0.92, and 1.14 f o r N = 1 0 , l o 2 , and lo3 c y c l e s , r e s p e c t i v e l y .
J t i s a p p a r e n t i n T a b l e 2 t h a t Code 2 a l s o a s s i g n s h i g h e r a l l o w a b l e
f a t i g u e d e s i g n s t r e s s e s t o 304 t h a n t o SA106 Grade B, by a f a c t o r of 1.25.
T h i s i s c o n t r a d i c t o r y t o t h e t e s t d a t a on p i p i n g p r o d u c t s shown i n Appen-
d i x C.

T a b l e 2 . R a t i o s a of d e s i g n f a t i g u e s t r e s s e s t o Eq. ( 2 4 ) f o r 304
a u s t e n i t i c s t a i n l e s s s t e e l s and a l l o y s 600 and 800

Temperature Temperature
b 100°F 8000F
N c
Basis
(S)
304 304L 304 304L
600 aoo 600 800

10 Code 2 1.25 1.05 1.33 1.25 1.13 0.96 1.18 1.24

(309) Code 1, K, = 1 1.26d 1.26d 1.26d 1.26d 1.26d 1.26d 1.26d 1.26d
Code 1, K, = 2 1.26d 1.26d 1.26d 1.26d 1.26d 1.26d 1.26 d 1.26d
10' Code 2 1.25 1.05 1.33 1.25 1.13 0.96 1.18 1.24
(195) Code 1, K, = 1 0.74d 0.74d 0.74d 0.74 d 0 .74d 0.74$ 0.74d 0.74d
Code 1, K, = 2 0.92 0.82 0.92 0.92 0.77 0.74 0.92 0.92
10' Code 2 1.25 1.05 1.33 1.25 1.13 0.96 1.18 1.24
(123) Code 1, K, = 1 0.71 0.63 0.71 0.71 0.59 0.54 0.71 0.71
Code 1, K, = 2 1.14 1.oo 1.14 1.14 0.94 o .a4 1.14 1.14
104 Code 2 1.25 1.05 1.33 1.25 1.13 0.96 1. i a 1.24
(77.7) Code 1, K, = 1 0.92 0.81 0.92 0.92 0.76 0.69 0.92 0.92
Code 1, K, = 2 1.52' 1.34 1.52' 1.52e 1.25 1.ll 1.52e 1.52e
104 Code 2 1.25 1.05 1.33 1.25 1.13 0.96 1.18 1.24
(49.0) Code 1, K, = 1 1.29 1.13 1.29 1.29 1.06 0.94 1.29 1.29
Code 1, K, = 2 1.53e 1.53e 1.53' 1.53' 1.53e 1.53e 1.53e 1.53e
10' Code 2 1.25 1.05 1.33 1.25 1.13 0.96 1. i a 1.24
(30.9) Code 1. K, = 1 1.6ae 1.64 1 .6ae 1.6ae 1.52 1.35 1.6ae 1.6ae
Code 1, K, = 2 1.68' 1.6ae 1. 6 a e 1. 6 a e 1.6ae 1.6Se 1. 6 a e 1.6Se
~ ~ ~~~~

a
R a t i o s t o S = 2 i S = 490,000 N-O", F!q. (24).
d
bS = 490 N-O", ksi.
c
Code 2 , h. ( 2 4 ) x ( S c + Sh),,,t/(Sc + S h ) r . see text.
Code 1, Sp by Eq. ( 2 3 ) .
d I n d i c a t e s t h a t Sn > 3mSm, Ke = l / n , and S = 2nSa. Sa = f a t i g u e d e s i g n s t r e s s
P
from Code 1 T a b l e 1-9.1 f o r l i s t e d N.
e
I n d i c a t e s t h a t Sn < 3Sm, Ke = 1 . 0 , and S p = 2Sa.
 19

4.5 Temperature E f f e c t , P i p i n n P r o d u c t T e s t s

. As d i s c u s s e d i n Appendix B, Code 1 d e s i g n f a t i g u e c u r v e s a r e depen-

d e n t on t e m p e r a t u r e through t h e dependence on modulus of e l a s t i c i t y E.
Code 1, IW-3222.4(e)(4) , i n d i c a t e s t h a t t h e c a l c u l a t e d v a l u e of s t r e s s
a m p l i t u d e s h o u l d be m u l t i p l i e d by E/E', where E' i s t h e modulus used i n
t h e c a l c u l a t i o n and E i s t h e modulus g i v e n on t h e d e s i g n f a t i g u e curve.
I n C l a s s 1 p i p i n g (IW-3672.51, t h e p i p i n g system a n a l y s e s a r e b a s e d on
t h e h o t modulus E b u t c a l c u l a t i o n s of e x p a n s i o n s t r e s s e s a r e m u l t i p l i e d
h'
by Ec/Eh, where E i s t h e c o l d modulus. To t h e e x t e n t t h a t E g i v e n on
C
t h e d e s i g n f a t i g u e c u r v e s i s E , NB-3222.4(e)(4) and NB-3672.5 a g r e e w i t h
C
e a c h o t h e r . However, t h i s i s n o t q u i t e t h e c a s e a t p r e s e n t (19821, f o r
example, f o r 304 s t a i n l e s s s t e e l a t 70°F, E = 28.3 x l o 6 p s i , whereas t h e
v a l u e of E shown on t h e d e s i g n f a t i g u e c u r v e i s 26.0 x l o 6 p s i .
R e f e r e n c e s 18-20 i n c l u d e a few f a t i g u e t e s t s of g i r t h b u t t w e l d s and
elbows a t room t e m p e r a t u r e and a t 55O0F. There i s no a p p a r e n t e f f e c t of a
t e m p e r a t u r e of 550°F w i t h r e s p e c t t o room t e m p e r a t u r e t e s t s . The r a t i o s
of room t e m p e r a t u r e modulus t o t h e 550°F modulus a r e about 1.1 f o r b o t h
SA106 Grade B and t y p e 304 s t a i n l e s s s t e e l .

4.6 Mean S t r e s s e s

A s d i s c u s s e d i n Appendix B, Code 1 d e s i g n f a t i g u e c u r v e s i n c l u d e an
a d j u s t m e n t f o r t h e maximum e f f e c t of mean s t r e s s . The S term i n Eq. ( 6 )
S
might a l s o be c o n s i d e r e d a s a mean s t r e s s a d j u s t m e n t . However, i f so con-
s i d e r e d , i t would a p p l y f o r a l l c y c l e s t r e s s l e v e l s and would be more se-
v e r e t h a n Code 1. For example, a s i n d i c a t e d i n F i g . 3 , i f S s = Sh ( t h e
maximum p e r m i s s i b l e v a l u e of S 1 , t h e a l l o w a b l e d e s i g n f a t i g u e s t r e s s e s
a r e r e d u c e d t o 60% of t h o s e p e g m i t t e d w i t h S s = 0 .
I n p i p i n g systems, e a c h time t h e r e i s a s t a r t - u p and shutdown, which
p r o d u c e s t h e ( u s u a l l y ) major c y c l e of e x p a n s i o n s t r e s s r a n g e , t h e pres-
s u r e a l s o c y c l e s from z e r o t o t h e o p e r a t i n g p r e s s u r e and back t o z e r o
and t h e r e i s a l s o a c y c l e of thermal g r a d i e n t s . Noting t h a t S i n c l u d e s
S
w e i g h t l o a d i n g , and t h a t a t e a c h s t a r t - u p and shutdown c y c l e , t h e con-
t a i n e d f l u i d w e i g h t might change s i g n i f i c a n t l y , t h a t p o r t i o n of S might
S
a l s o "cycle.'' Accordingly, S might be viewed a s a c r u d e allowance f o r
S
c y c l i c l o a d s o t h e r t h a n c y c l i c moments. The r o l e of S i n a f a t i g u e eval-
S
u a t i o n i s d i s c u s s e d f u r t h e r i n Chap. 7 .
Most f a t i g u e t e s t d a t a on p i p i n g p r o d u c t s have been r u n on specimens
w i t h t h e w e l d s "as-welded" and, hence, had h i g h mean s t r e s s e s from r e s i d -
u a l weld s t r e s s e s . To t h e e x t e n t t h a t f a i l u r e s o c c u r r e d a t w e l d s ( g i r t h
b u t t w e l d s , g i r t h f i l l e t w e l d s , and w e l d s i n f a b r i c a t e d t e e s ) , t h e s e t e s t s
( e v e n though c o m p l e t e l y r e v e r s e d d i s p l a c e m e n t o r l o a d ) may have i n c l u d e d
some e f f e c t of mean s t r e s s .
Some moment p i p i n g p r o d u c t f a t i g u e t e s t s have been r u n w i t h a con-
s t a n t p re s s u re i n s i d e the t e s t I n t h e s e t e s t s , in-
t e r n a l p r e s s u r e s were a p p r o x i m a t e l y equal t o t h e maximum d e s i g n p r e s s u r e .
The c o n s t a n t p r e s s u r e p r o d u c e s a mean s t r e s s , a l t h o u g h t h e maximum s t r e s s
 20

c a u s e d by p r e s s u r e was u s u a l l y s i g n i f i c a n t l y l e s s t h a n t h a t c a u s e d by t h e
moment r a n g e , and t h e maximum p r e s s u r e - s t r e s s l o c a t i o n and d i r e c t i o n d o e s
n o t c o i n c i d e w i t h t h e maximum moment-stress l o c a t i o n and d i r e c t i o n . Ac-
c o r d i n g l y , t h e e f f e c t of mean s t r e s s c a u s e d by i n t e r n a l p r e s s u r e would be
e x p e c t e d t o be s m a l l , and i n d e e d , t h e t e s t d a t a i n d i c a t e no s i g n i f i c a n t
.
d i f f e r e n c e between t e s t s w i t h and w i t h o u t i n t e r n a l p r e s s u r e .
R e f e r e n c e 22 a l s o i n c l u d e s t e s t s o n c a r b o n s t e e l b r a n c h c o n n e c t i o n s
i n which s i m u l a t e d m i s a l i g n m e n t s t r e s s e s of W/Z = 10, 15, 20, o r 25 k s i
were imposed a l o n g w i t h c y c l i c s t r e s s a m p l i t u d e s of 3 t o 5 k s i . These
were h i g h - c y c l e f a t i g u e t e s t s ( N between 5 x l o 5 snd l o 7 ) , and mean
f
s t r e s s e s were h i g h compared w i t h c y c l i c s t r e s s e s . N e v e r t h e l e s s , t h e r e
was no s i g n i f i c a n t d i f f e r e n c e between r e s u l t s w i t h t h e l o w e s t and h i g h e s t
mean s t r e s s .
I n summary, a v a i l a b l e t e s t d a t a on p i p i n g p r o d u c t s do n o t i n d i c a t e
t h a t mean s t r e s s e s a r e s i g n i f i c a n t . I n a l l c a s e s t h e s t r e s s r a n g e was
the s i g n i f i c a n t aspect i n the piping product t e s t f a t i g u e f a i l u r e s .
 21

5. HIGH-CYCLE FATIGUE

A s i g n i f i c a n t number of f a t i g u e f a i l u r e s ( l e a k s ) have o c c u r r e d i n
s m a l l - s i z e d n u c l e a r power p l a n t p i p i n g . These have been r e l a t e d t o v i -
b r a t i o n of t h e p i p i n g where t h e number of accumulated c y c l e s can be v e r y
l a r g e i n a r e l a t i v e l y s h o r t p e r i o d of c a l e n d a r time. For example, a t a
v i b r a t i o n f r e q u e n c y of 100 Hz, 3.2 x l o 9 c y c l e s accumulate i n 1 y e a r .
Large numbers of accumulated c y c l e s can be c a u s e d by t u r b u l e n t mixing of
h o t and c o l d f l u i d s o r by flow-induced s t r u c t u r a l v i b r a t i o n ( e . g . , i n
steam g e n e r a t o r t u b e s ) .
The c o n d i t i o n s l e a d i n g t o h i g h accumulated c y c l e s a r e d i f f i c u l t t o
a n t i c i p a t e and have n o t been i n c l u d e d i n r o u t i n e e v a l u a t i o n s of n u c l e a r
power p l a n t p i p i n g . However, i f v i b r a t i o n i s o b s e r v e d i n p r e o p e r a t i o n a l
t e s t i n g or i n s e r v i c e , a p p r o p r i a t e d e s i g n f a t i g u e s t r e s s l i m i t s a r e needed
t o a s s e s s t h e s i g n i f i c a n c e of such v i b r a t i o n s .
Code 1 d e s i g n c u r v e s p r o v i d e v a l u e s f o r a l l o w a b l e s t r e s s a m p l i t u d e
S f o r up t o l o c c y c l e s . NB-3222.4 and NB-3653 .5 c o n t a i n i m p l i c a t i o n s
a
t h a t S a t l o 6 c y c l e s i s a d e s i g n endurance l i m i t . Furthermore, t h e f o o t -
a
n o t e t o N3-3222.5 s a y s , "The endurance l i m i t s h a l l be t a k e n a s two t i m e s
t h e S v a l u e a t l o 6 c y c l e s i n t h e a p p l i c a b l e f a t i g u e c u r v e of F i g . 1-9.0."
The f t c t o r of 2 h e r e removes t h e s a f e t y f a c t o r i n F i g . 1-9.0.
U s i n g Sa a t 106 c y c l e s a s an endurance l i m i t l e a d s t o a usage f a c t o r
U of z e r o f o r any s t r e s s a m p l i t u d e l e s s t h a n S a t l o 6 , r e g a r d l e s s of t h e
a
number of c y c l e s . For example, i f S were c a l c u l a t e d t o be 50,000 p s i i n
P
a 304 s t a i n l e s s s t e e l p i p i n g component, t h e n U = 0 even f o r 109 c y c l e s .
A s d i s c u s s e d i n Appendix B, a more d e f e n s i b l e v a l u e of a l l o w a b l e d e s i g n
s t r e s s a m p l i t u d e S f o r 304 m a t e r i a l a t l o 9 c y c l e s (Curve C ) i s 13,900
a
psi. By u s i n g S a t l o 6 c y c l e s = 26,000 p s i a s an endurance l i m i t , t h e
f a c t o r of s a f e t y a o f 2 on s t r e s s might be f u l l y used up and f a i l u r e ( l e a k )
would be about a 50% p r o b a b i l i t y f o r t h i s example w i t h S = 50,000 p s i ,
N = l o 9 c y c l e s , 304 m a t e r i a l . P
Code 2 a l l o w a b l e d e s i g n s t r e s s e s f o r N > 10s a r e g i v e n by Eq. (6)
w i t h f = 0.5. Comparisons between Codes 1 and 2 ( r a n g e b a s i s ) a r e shown
i n T a b l e 3. The l a s t column of T a b l e 3 shows our e s t i m a t e of an appro-
p r i a t e v a l u e of t h e endurance l i m i t S f o r an e f f e c t i v e l y i n f i n i t e number
of c y c l e s (N = l o l l ) , where S i s a d j z s t e d f o r t h e maximum e f f e c t of mean
e
s t r e s s and c o n t a i n s a f a c t o r of s a f e t y of 2 on s t r e s s . For type 304
s t a i n l e s s s t e e l s , t h e e s t i m a t e comes from Appendix B.* Our e s t i m a t e of
S f o r f e r r i t i c s t e e l s i s discussed i n the following paragraphs.
e
E q u a t i o n ( 9 ) i s b a s e d on M a r k l ' s t e s t d a t a t h a t covered a range of
c y c l e s from 1 0 t o l o 6 . Mark1 n o t e d t h a t h i s d a t a on p i p i n g p r o d u c t s ,
o t h e r t h a n p l a i n s t r a i g h t p i p e , gave no e v i d e n c e a t a l l of t r e n d i n g t o
a n a s y m p t o t i c v a l u e (endurance l i m i t ) w i t h i n t h e range of c y c l e s covered.
F a t i g u e t e s t r e s u l t s on b r a n c h c o n n e c t i o n s i n Ref. 22 i n d i c a t e t h a t Eq.
( 9 ) i s v a l i d up t o l o 7 c y c l e s , w i t h some i n d i c a t i o n of an endurance l i m i t

*The e s t i m a t e d v a l u e i s t h e v a l u e a t 1 0 l 1 c y c l e s on t h e proposed
Curve C.
 22

T a b l e 3 . Comparisons of a l l o w a b l e d e s i g n s t r e s s r a n g e s a t
h i g h c y c l e s and e s t i m a t e of endurance l i m i t Se
.

Allowable d e s i g n
s t r e s s range Endurance

Material

SA106 Grade B -<650 25 .O 37.5 22.5 14

SA106 Grade A -(650 25 .O 30 .O 18.0 14
SA106 Grade C -<650 25 .O 43.8 26.2 14
SA672- J 1 0 0 -< 650 40 .O 62.5 37.5 14?
SA312 t y p e 304 100 52 .O 47 .o 28.2 27
800 52 .O 42.5 27.3 27
SA312 t y p e 304L 100 50.5: 39.2 23.6 27
800 41.8 35.9 22.9 27
a
V a l u e s of 2Sa a t lo6 cycles. The f a c t o r of 2 c o n v e r t s a m p l i t u d e
t o range.
bValues of 2SE by Eq. (6). The f a c t o r of 2 i n c o r p o r a t e s t h e
r e l a t i o n s h i p 2 i = C,K, and t h e Code 2 f - f a c t o r f o r N > 100,000 i s 0 . 5 ,
hence 2SE = 1 . 2 5 ( S c + Sh) - Ss.
C
K e a d j ustment i s a p p l i c a b l e.

around 10' c y c l e s . A t 10' c y c l e s , Eq. ( 9 ) g i v e s isf = 1 2 . 3 k s i . Dividing

t h i s by 2 , t o o b t a i n a f a c t o r of s a f e t y of 2 on s t r e s s , aEd m u l t i p l y i n g
by 2 , t o a c c o u n t f o r 2i = C,K,, l e a d s t o a n e s t i m a t e of S ( r a n g e ) of
e
12.3 k s i .
High-cycle f a t i g u e f o r a u s t e n i t i c s t e e l s i s d i s c u s s e d i n Appendix B.
One of t h e p r o p o s e d c u r v e s (Curve A) i s simply an e x t r a p o l a t i o n of t h e
p r e s e n t Code 1 u s i n g t h e e q u a t i o n ( f o r E = 28.3 x 106 p s i ) :

sa = 9 1 5 9 / f l + 47.35 . (25)

I n t h i s e x t r a p o l a t i o n , a d j u s t m e n t for mean s t r e s s was n o t c o n s i d e r e d

n e c e s s a r y , b e c a u s e S was presumed t o be g r e a t e r t h a n t h e y i e l d s t r e n g t h
a
of t h e m a t e r i a l .
If we s i m i l a r l y e x t r a p o l a t e t h e p r e s e n t Code 1 c u r v e of F i g . 1-9.1
f o r UTS 80 k s i and a p p l y t h e a d j u s t m e n t f o r maximum e f f e c t of mean
s t r e s s ( s e e Appendix B, T a b l e B . l ) , t h e n we o b t a i n S = 7.43 k s i a t l o l l
a
 23

c y c l e s . T h i s l e a d s t o a n e s t i m a t e of S ( r a n g e ) of 2 x 7.43 = 14.8 k s i v s
e
12.3 k s i by Eq. ( 9 ) a t 10' c y c l e s .
Some a d d i t i o n a l guidance can be o b t a i n e d from f a t i g u e t e s t s of b u t t -
welded j o i n t s i n p l a t e s . R e f e r e n c e 23 c o n t a i n s a c o m p i l a t i o n of such
data. In p a r t i c u l a r , F i g . B6 of Ref. 23 c o v e r s b u t t w e l d s ( r e i n f o r c e m e n t
l e f t on) i n s t r u c t u r a l c a r b o n s t e e l s , w i t h f a i l u r e p o i n t s o u t t o 2 x lo6
cycles. The d a t a , l i k e M a r k l ' s , show no e v i d e n c e of an endurance l i m i t .
b
E x p r e s s e d i n t h e form S = aNf , t h e b e s t - f i t c o n s t a n t s a and b g i v e
f

sf
= 920 N-0*276
f
ksi . (26)

R e f e r e n c e 23 d a t a cover from l o 4 t o 2 x l o 6 c y c l e s ; w h e r e a s M a r k l ' s d a t a

cover from 2 x l o 3 t o 4 x l o s c y c l e s . In t h e r e g i o n of o v e r l a p , Eqs. ( 9 )
and (26) a g r e e f a i r l y w e l l w i t h each o t h e r even though a b u t t weld i n
p l a t e i s n o t t h e same a s a g i r t h b u t t weld i n p i p e . Reference 23 d a t a
a r e h e a v i l y w e i g h t e d by r e s u l t s between N = 5 x l o 5 and N f = 2 x l o 6 .
f
For Nf = 1 0 7 , i t g i v e s S = 10.8 k s i , which c o r r e s p o n d s t o S = 10.8 k s i ,
f e
a f t e r d i v i d i n g by 2 f o r t h e f a c t o r of s a f e t y and m u l t i p l y i n g by 2 f o r
2 i = C,K,.
R e f e r e n c e 24 g i v e s d a t a on f a t i g u e p r o p e r t i e s f o r butt-welded j o i n t s
i n SM50 B h i g h t e n s i l e s t r u c t u r a l s t e e l p l a t e s ( S = 82.7 k s i and S =
U Y
7 1 k s i ) . These d a t a cover t h e range from N = l o 4 t o Nf = l o 7 , w i t h a few
f
llrunoutll p o i n t s a t 2 x 107 c y c l e s . These t e s t s a l s o g i v e lower s t r e s s e s
t h a n Eq. ( 9 ) a t lo7 c y c l e s [-14.5 k s i v s t h e Eq. ( 9 ) v a l u e of 19.5 k s i l .
R e f e r e n c e 24 d a t a s u g g e s t a v a l u e f o r Se of -14.5 k s i .
R e f e r e n c e s 23 and 24 t e s t s were r u n i n r e v e r s e d t e n s i o n ; hence, t h e y
i n c l u d e a mean s t r e s s e f f e c t . M a r k l ' s t e s t s were r e v e r s e d bending. Pos-
s i b l y t h i s mean s t r e s s e f f e c t i s a major r e a s o n f o r lower f a t i g u e f a i l u r e
s t r e s s r a n g e s a t h i g h c y c l e s i n R e f s . 23 and 24 t h a n o b t a i n e d from Eq.
(9).
SA672-J100 i s a h i g h - s t r e n g t h , low-alloy f e r r i t i c s t e e l w i t h s p e c i -
f i e d minimum S = 100 k s i and S = 83 k s i . R e f e r e n c e 25, i n p a r t i c u l a r
U Y
Fig. 5 t h e r e i n , i n d i c a t e s t h e v a r i a t i o n i n S a t 2 x 106 c y c l e s w i t h UTS
f
f o r b u t t w e l d s ( r e i n f o r c e m e n t l e f t on) i n f e r r i t i c s t e e l p l a t e s . The d a t a
cover a range of S from 55 t o 150 k s i . There i s , on t h e a v e r a g e , an in-
U
c r e a s e i n S w i t h Su of -60% between S of 55 and 100 k s i and p o s s i b l y a
f U
decrease i n S with f u r t h e r increases i n S However, t h e s c a t t e r of t h e
f U'
d a t a a t Su = 100 k s i i s such t h a t i t m i g h t be imprudent t o depend upon any
increase i n S with S
f
.
U
R e f e r e n c e 25 d a t a i n d i c a t e t h a t , f o r 0 t o t e n s i o n
l o a d i n g , 2 x lo6 c y c l e s , S i s n o t l e s s t h a n 1 7 k s i f o r a l l UTS v a l u e s
f
covered. When d i v i d e d by 2 , f o r a f a c t o r of s a f e t y , and m u l t i p l i e d by 2
f o r 2 i = C,Kz, t h e v a l u e of 2 s a t 2 x lo6 c y c l e s i s 1 7 k s i . Our e s t i m a t e
d
t h a t Se = 1 4 k s i . i n r e l a t i o n t o Ref. 25 d a t a , i m p l i e s a r e d u c t i o n i n f a -
t i g u e s t r e n g t h by a f a c t o r of 1 4 / 1 7 = 0.82 between 2 x l o 6 and lo1* cy-
cles. In view of Ref. 25 d a t a , we have shown S f o r SA672-3'100 i n T a b l e 3
e
 24

a s 14 k s i , w i t h a q u e s t i o n mark t o i n d i c a t e t h a t Code 1, Fig. 1-9.1 i n d i -

c a t e s t h a t h i g h - s t r e n g t h s t e e l i s 20112.5 = 1.6 t i m e s a s s t r o n g a s low-
s t r e n g t h s t e e l s a t lo6 c y c l e s .
The r e l a t i v e v a l u e s of Se i n T a b l e 3 f o r f e r r i t i c and 304 a u s t e n i t i c
s t e e l s i s worthy of comment i n view of Appendix C, which i n d i c a t e s t h a t
g i r t h b u t t w e l d s i n c a r b o n s t e e l p i p e a r e a t l e a s t a s good a s g i r t h b u t t
welds i n t y p e 304 s t a i n l e s s p i p e . U n f o r t u n a t e l y , t h e d a t a in Appendix C
a r e f o r r e l a t i v e l y low-cycle and do n o t r e s o l v e t h e S q u e s t i o n . Refer-
ence I g i v e s r e s u l t s of resonance bending t e s t s on p i i e and g i r t h b u t t
welds i n t h e pipe. These r e s u l t s i n d i c a t e t h a t g i r t h b u t t welds i n t y p e
304 s t a i n l e s s s t e e l p i p e a r e s l i g h t l y (10 t o 20%) s t r o n g e r t h a n g i r t h b u t t
w e l d s i n carbon s t e e l p i p e , c o n t r a r y t o t h e d a t a i n Appendix C, b u t n o t by
t h e f a c t o r of 27.2114 = 1.94 i n d i c a t e d by t h e r a t i o s of S i n T a b l e 3 .
e
It i s a p p a r e n t from t h e p r e c e d i n g d i s c u s s i o n t h a t c o n s i d e r a b l e un-
c e r t a i n t y e x i s t s c o n c e r n i n g a n a p p r o p r i a t e v a l u e f o r t h e endurance range
l i m i t S f o r e v a l u a t i o n of high-cycle f a t i g u e of p i p i n g components. How-
e v e r , t8 t h e e x t e n t t h a t t h e Se e s t i m a t e s a r e v a l i d , T a b l e 3 i n d i c a t e s
t h a t (1) Code 1, u s i n g 2Sa a t lo6 c y c l e s f o r S , i s u n c o n s e r v a t i v e ; and
e
(2) Code 2 i s u n c o n s e r v a t i v e f o r f e r r i t i c m a t e r i a l s and a l s o f o r austen-
i t i c m a t e r i a l s i f S i s taken a s zero.
S
 25

6. TEES*

. In a d d i t i o n t o t h e d i f f e r e n c e s between Codes 1 and 2 f a t i g u e evalua-

t i o n methods d i s c u s s e d i n t h e p r e c e d i n g , t h e r e i s a d i f f e r e n c e i n t h e way
s t r e s s e s a r e calculated f o r tees. In Code 1 a n a l y s i s , t h e s t r e s s range
caused by a s e t of moment r a n g e s a s d e f i n e d i n Fig. 6 i s c a l c u l a t e d by:

S 1 = KabCabM,,/Zb + K a r C a rM r / Z r . (27)

--
T h e term "Tees" used h e r e i n c l u d e s f a b r i c a t e d branch c o n n e c t i o n s
and ANSI B16.9 manufactured t e e s .

ORNL-DWG 83-4600 ETD

CODE 1

M, = (M: + M: + M:)",

Mr = (M:r + Mr: + M:r)'

IF Mlll AND Ml12HAVE DIFFERENT SIGNS,

THEN MII IS THE SMALLER OF MII, AND

I F Mlll AND MI12HAVE THE SAME SIGNS,

THEN MII = 0 WHERE II =or, ir, OR t r .

CODE 2

EACH END OF THE TEE IS EVALUATED SEPARATELY, WITH:

M, = (M: t M:+ M:),'

Mrl = ( M t r , + M5, + Mfr, 1%.

2 %
M r 2 = (M:r2 + M2
: + Mtr2) .

Fig. 6 . D e f i n i t i o n of moments f o r t e e s and code methods f o r

c a l c u l a t i n g M,,, MI, M r1 , and M r a .
 26

In Code 2 a n a l y s i s ,

S
a
= maximum of i ( t / T ) Mb/Zb, i M ri /Zr, iMra/Zr . (28 1

E q u a t i o n s (27) a n d ( 2 8 ) s h o u l d n o t g i v e t h e same c a l c u l a t e d s t r e s s e s ,
b u t from t h e s t a n d p o i n t of f a t i g u e e v a l u a t i o n , t h e y s h o u l d g i v e equiva-
lent results. T h a t e q u i v a l e n c e , on a n i n d i v i d u a l moment b a s i s , i s ex-
p r e s s e d by 2 i = CaKa. As w i l l become a p p a r e n t i n t h e f o l l o w i n g para-
g r a p h s , t h i s e q u i v a l e n c e d o e s n o t e x i s t f o r some moment c o m b i n a t i o n s .
The d e f i n i t i o n of M (Fig. 6 ) i s such t h a t M may be z e r o f o r one
r r
s e t of moments i n t h e same d i r e c t i o n ( e . g . , Mo, Mtrl, and M t r a ) b u t non-
z e r o f o r a n o t h e r s e t of moments i n t h e same d i r e c t i o n (e.g., M i , M i r l ,
and M i r a ) . A c c o r d i n g l y , t o make comparisons between Codes 1 and 2, i t
i s n e c e s s a r y t o examine t h e t h r e e s e t s of moments i n t h e same d i r e c t i o n .
These t h r e e s e t s of moments a r e i d e n t i f i e d a s M,, M a , and M,, where M,
and M a a r e t h e moments on t h e r u n , and M, i s t h e moment on t h e branch.
Equations ( 2 7 ) and ( 2 8 ) c a n be e x p r e s s e d a s :

S
1P = QblM31/Zb + Qr M r / Z r , (29)

and

s = maximum of Q~IM,I/z~, Q~IM,I/z~, or Q ~ I Ma l/zr , (30)

2P

where Qb = K a b C a b or 2 i t / T , Qr = K a r C a r o r 2 i . A l e t t e r "p" h a s been

added t o t h e s u b s c r i p t s of S, and S a t o emphasize t h a t t h e s t r e s s e s ob-
t a i n e d by Eqs. ( 2 9 ) and (30) a r e o n l y p a r t of S, and S,; t h e o t h e r two
s e t s of s a m e - d i r e c t i o n moments must a l s o be e v a l u a t e d .
If t h e signs of M, and Ma a r e t h e same, t h e n Mr = 0 and Eq. ( 2 9 )
gives S = QblM31/Zb. To show t h a t Code 2 S i s t h e same a s S we
1P 2P 1P'
f i r s t n o t e t h a t , from s t a t i c e q u i l i b r i u m , M, = -(M, + h i a ) ; hence, lM,I 2
I M a l and l M 3 1 2 IM,l. We t h e n i n t r o d u c e t h e p a r a m e t e r Z ' :

and n o t e t h a t Z ' i 1.0, because Z < Z and Qr i $. I f Z ' i 1, t h e n

b - r
QrlMxI/Zb and Q r l M l / Z r w i l l be l e s s t h a n Q IM l / Z and Eq. ( 3 0 ) w i l l
a b 3 b
give s
ZP
= Q,,IM)I/z~= s
1P'
A c c o r d i n g l y , t h e nonequival ence between
Codes 1 and 2 o c c u r s onZy i f t h e s i g n s of M, and M, a r e d i f f e r e n t .
For M, and Ma w i t h d i f f e r e n t signs. we t a k e I M a l 2 IM,l. Then M =
I M l l and l M 3 1 = l M x + M a l . E q u a t i o n (30) becomes: r

S
ZP
= maximum of QblM3 I /Zb o r Qr IM a I /Zr . (32)
 27

The r a t i o of S fS can t h e n be c a l c u l a t e d by:

1P aP

. S
ZP
/S
ap
= l e s s e r of (A - M')/A or A - M' . (33)

If M' = M,/M,, t h e n M' i s n e g a t i v e and v a r i e s between 0 and -1, and

A = (M' + l ) / Z ' .
For any M' between 0 and -1, t h e r e i s a maximum i n S /S g i v e n by
XP zp

(S /S = l - M ' a t Z ' = l + W ' . (34)

i p ap mar

N o t i n g t h a t M' a p p r o a c h e s -1 a s Z ' - 0 f o r a small b r a n c h i n a l a r g e r u n ,

Eq. ( 3 4 ) i n d i c a t e s t h a t t h e nonequivalence between Codes 1 and 2 c a n be
a s much a s a f a c t o r of 2 w i t h Code 1 always b e i n g more c o n s e r v a t i v e t h a n
Code 2 .
Which i s more a c c u r a t e , Code 1 o r Code 2 ? In a p h y s i c a l s e n s e , Code
1 i m p l i e s t h a t t h e s t r e s s caused by M,, r e a c t e d by e i t h e r M, o r M,, adds
t o t h e s t r e s s c a u s e d by Mi r e a c t e d by M,. T h i s i s p r o b a b l y t o o conser-
v a t i v e ; i t i m p l i e s t h a t t h e maximum s t r e s s c a u s e d by t h e two s o u r c e s a r e
a t t h e same p o i n t and i n t h e same d i r e c t i o n . Code 2 , on t h e o t h e r hand,
i m p l i e s t h a t t h e s t r e s s e s c a u s e d by t h e t w o s o u r c e s do n o t add t o e a c h
other a t a l l .
The p r e c e d i n g d i s c u s s i o n , i n which i t was shown t h a t Code 1 might be
more c o n s e r v a t i v e t h a n Code 2 by a s much a s a f a c t o r of 2 , was b a s e d on
t h e e q u i v a l e n c e s Q = K Cab = 2 i ( t / T ) and Qr = K z r C 2 = 2 i . However,
b
t h i s e q u i v a l e n c e d o e s nbk e x i s t f o r r u n moments on f a g r i c a t e d t e e s . The
d i f f e r e n c e i s i l l u s t r a t e d by t h e f o l l o w i n g example.
Consider a 24-in.-OD by 0.375-in. nominal w a l l r u n p i p e w i t h a
1.315-in.-OD by 0.133-in. nominal w a l l d r a i n c o n n e c t i o n . There a r e no
moments on t h e d r a i n ; hence, S w i l l be c o n t r o l l e d by i l l / Z r = i M / Z
2 rl .
rz r
The v a l u e of i i s 0.9 ( R / T ) ' l 3 = 8 . 9 8 . For Code 1, because M and Mra
ri
have t h e same s i g n s , Si = C K M /Zr = C z r I(a r M ra / Z r
a r a r ri . The v a l u e of Car

i s 1.15 [ ( R / T ) ( r / R ) / ( t / ~ ) ] " ' = 1.67; t h e v a l u e of K a r i s 1 75, g i v i n g

K a r C 2r = 2.92. In t h i s example, 2 i i s e q u a l t o 6.15 C zrK 2r hence, Code 2
i s f a r more c o n s e r v a t i v e t h a n Code 1.
 7. CODE 2 COVERAGE OF LOADINGS O’IHFB ’IHAN MOMENTS

A s n o t e d i n Chap. 1 and s e v e r a l o t h e r p l a c e s i n t h e p r e c e d i n g t e x t ,
Code 2 c o v e r s o n l y moment l o a d i n g . However, a s a l s o n o t e d i n Chap. 1, no
f a t i g u e a n a l y s i s i s r e q u i r e d f o r C l a s s 2 o r 3 v e s s e l s , pumps, o r v a l v e s ,
and i n t h i s s e n s e , Code 2 i s more complete t h a n r e q u i r e d f o r o t h e r C l a s s
2 o r 3 components. D e s p i t e t h e p r e c e d i n g s e n t e n c e , which might be t a k e n
a s i n d i c a t i n g t h a t Code 2 i s s u f f i c i e n t l y complete, i n t h i s c h a p t e r we
d i s c u s s t h e e x t e n t t h a t t h e p r e s e n t r u l e s cover c y c l i c p r e s s u r e and t h e r -
mal g r a d i e n t s and p r o c e e d w i t h an e x p l o r a t o r y d i s c u s s i o n of how Code 2
might be e x t e n d e d t o more e x p l i c i t l y c o v e r l o a d i n g s o t h e r t h a n moment
1o a d i ngs.
The s i g n i f i c a n c e of S s i n Eq. (6) was d i s c u s s e d i n S e c t . 4.6, where
i t was concluded t h a t S i n a f a t i g u e e v a l u a t i o n d o e s n o t make much s e n s e
S
a s a mean s t r e s s . R a t h e r , S a p p e a r s t o s e r v e a s a n a l l o w a n c e f o r c y c l i c
S
l o a d i n g s o t h e r t h a n c y c l i c moments.

7.1 Allowance f o r C y c l i c P r e s s u r e

The e q u a t i o n f o r S e x p l i c i t l y i n c l u d e s p r e s s u r e l o a d i n g i n t h e form
S
= pd’/(DZ - d z ) , where p = i n t e r n a l p r e s s u r e , d = p i p e I D , and D =
SP
p i p e OD. Considering t h e crude approximations involved i n i t s use,
might w e l l be c a l c u l a t e d by t h e s i m p l e r form used i n Eq. (141, Ssp = SP
pDo/4T, where Do = o u t s i d e d i a m e t e r of p i p e and T = nominal w a l l t h i c k -
n e s s of p i p e . However, t h e s i g n i f i c a n t a s p e c t h e r e i s t h a t S i n c l u d e s
S
t h e a x i a l s t r e s s c a u s e d by i n t e r n a l p r e s s u r e i n ( c a p p e d ) s t r a i g h t p i p e .
A s a bound, we w i l l examine t h e q u e s t i o n : I s S A S s u f f i c i e n t t o guard
S h
a g a i n s t f a t i g u e f a i l u r e c a u s e d by c y c l i c p r e s s u r e ?
The most s e n s i t i v e p i p i n g p r o d u c t t o c y c l i c p r e s s u r e is u s u a l l y
branch c o n n e c t i o n s o r t e e s . Code 1 g i v e s C, and K, s t r e s s i n d e x e s such
t h a t t h e C,Kl p r o d u c t i s u n l i k e l y t o exceed 6. T h i s means t h a t t h e maxi-
mum peak s t r e s s S i s n o t l i k e l y t o exceed 12 t i m e s pD /4T. I f Sh = 15
P 0
k s i (SA106 Grade B up t o 65O0F) and p i s such t h a t pD /4T = 7.5 k s i cor-
0
r e s p o n d i n g t o t h e maximum a l l o w a b l e hoop s t r e s s of 15 k s i f o r p r e s s u r e
d e s i g n , t h e n S = 12 x 7.5 = 90 k s i range. From Eq. (24). i t can be seen
P
t h a t a peak s t r e s s r a n g e of 90 k s i c o r r e s p o n d s t o an a l l o w a b l e N of -5000
cycles. Accordingly, i t appears t h e S = S c o n t a i n s a n allowance f o r
s h
c y c l i c p r e s s u r e l o a d i n g of -5000 c y c l e s from z e r o t o t h e maximum permis-
s i b l e d e s i g n p r e s s u r e and back t o z e r o . If S includes significant
S
w e i g h t s t r e s s e s and t h e w e i g h t ( f l u i d c o n t e n t s ) i s c o n s t a n t , t h e n an ad-
d i t i o n a l margin i s p r o v i d e d f o r c y c l i c p r e s s u r e s .
For o t h e r m a t e r i a l and t e m p e r a t u r e s , t h e allowance f o r c y c l i c p r e s -
s u r e would v a r y w i t h t h e v a l u e of Sh; f o r example, f o r SA106 Grade C up
t o 650°F, Sh = 17.5 k s i , S = 6 x 17.5 = 105 k s i , and N [by Eq. (24)l i s
P
(490/105)’ = 2200 c y c l e s from z e r o t o t h e maximum d e s i g n p r e s s u r e and
back t o z e r o .
 29

7.2 Allowance f o r Thermal G r a d i e n t s

The e q u a t i o n f o r Ss d o e s n o t i n c l u d e thermal g r a d i e n t s a n a l o g o u s t o
t h e l a s t t h r e e t e r m s i n Eq. ( 2 ) . However, a s i n d i c a t e d i n Fig. 3 , t h e r e
i s a margin f o r thermal g r a d i e n t s up t o N of about 7000. For example, a t
N = 100 of b o t h moment and p r e s s u r e c y c l e s , t h e margin between Eq. ( 2 4 )
and t h e l i n e i d e n t i f i e d a s S = 0 i s 490/100°'2 - 1 . 2 5 ( 1 5 + 1 5 ) = 1 5 8
S
ksi. T h i s margin, f o r example, would p r o v i d e an a l l o w a n c e f o r t h e ATz
thermal g r a d i e n t term of Eq. ( 2 1 , o c c u r r i n g 100 t i m e s , o f :

AT = 158,000 x (0.7/180) = 6140F ,

2

where (1 - v) = 0.7 and Ea = 180 psi1OF. Of c o u r s e , f o r l a r g e r numbers

of c y c l e s ( e i t h e r of moment, p r e s s u r e , and thermal g r a d i e n t s s i m u l t a -
n e o u s l y o r i n d e p e n d e n t l y ) , t h e a v a i l a b l e margin f o r thermal g r a d i e n t s be-
comes s m a l l e r and e s s e n t i a l l y v a n i s h e s a t and above 7000 c y c l e s of moment
andlor pressure cycles.

7.3 Use of Ea. ( 2 ) f o r Combined Loadings

T h i s s e c t i o n , and t h e f o l l o w i n g S e c t . 7.4, c o n t a i n s an e x p l o r a t o r y
d i s c u s s i o n of how Code 2 f a t i g u e e v a l u a t i o n c o u l d be improved i n com-
p l e t e n e s s and c o n s i s t e n c y . Firm recommendations would r e q u i r e f u r t h e r
s t u d y of such a s p e c t s a s t h e d i f f e r e n c e between Codes 1 and 2 i n t h e
e v a l u a t i o n of t e e s , a p p r o p r i a t e v a l u e s of S and t h e v a l i d i t y of assump-
e'
t i o n s involved i n the following discussion.
Code 2 f a t i g u e e v a l u a t i o n c o u l d be improved i n c o m p l e t e n e s s and con-
s i s t e n c y by (1) c a l c u l a t i n g S by &. ( 2 ) and ( 2 ) l i m i t i n g SE by Eq. ( 2 4 ) .
E
T h i s , i n e f f e c t , assumes t h a t t h e r e l a t i o n s h i p 2 i = C2Kz i s more gener-
a l l y v a l i d ( i . e . , 2 i = CIKl = C,K2 = C3K3). The a d v a n t a g e s of t h i s ap-
proach, a s compared w i t h a Code 1 f a t i g u e e v a l u a t i o n , a r e t h a t t h e r e i s
no need t o c a l c u l a t e S s e p a r a t e l y and t h e K a d j u s t m e n t i s n o t needed.
n e
There a r e t e s t d a t a on p i p i n g p r o d u c t s t h a t c o u l d be u s e d t o examine
t h e v a l i d i t y of 2 i = C,Kl f o r p r e s s u r e l o a d i n g . However, t e s t d a t a on
p i p i n g p r o d u c t s a r e n o t a v a i l a b l e f o r examining t h e v a l i d i t y of 2 i = C 3 K 3
f o r thermal g r a d i e n t l o a d i n g . Also, no t e s t d a t a on p i p i n g p r o d u c t s a r e
a v a i l a b l e i n which t h e r e were c o m b i n a t i o n s of c y c l i c moments, p r e s s u r e ,
o r thermal g r a d i e n t s .
E q u a t i o n ( 2 ) i n v o l v e s t h e i m p l i e d a s s u m p t i o n t h a t maximum s t r e s s e s
c a u s e d by p r e s s u r e , moments, and thermal g r a d i e n t s o c c u r a t t h e same l o c a -
t i o n i n a p i p i n g p r o d u c t , and i n a d i r e c t i o n so t h a t t h e y add t o e a c h
o t h e r t o form t h e t o t a l s t r e s s . In S e c t s . 7.1 and 7.2, t h a t t a c i t as-
sumption was a l s o made.
In t h e c a s e of combined p r e s s u r e and moment l o a d i n g on b r a n c h con-
n e c t i o n s o r t e e s , u s u a l l y t h e s t r e s s c a u s e d by p r e s s u r e i s r e l a t i v e l y l o w
a t t h e l o c a t i o n of maximum s t r e s s c a u s e d by moment; and v i c e v e r s a . Ac-
c o r d i n g l y , t h e assumption of s t r e s s c o i n c i d e n c e may c o n t a i n s i g n i f i c a n t
c o n s e r v a t i s m . However, i n t h e c a s e of a g i r t h b u t t weld i n s t r a i g h t
 30

p i p e , t h e a x i a l s t r e s s adds d i r e c t l y t o t h e moment s t r e s s . Similarly,

thermal g r a d i e n t s t r e s s e s may o r may n o t be c o i n c i d e n t w i t h l o c a t i o n s of
masimum s t r e s s e s caused by p r e s s u r e a n d / o r moment.

7.4 Code 2 Cumulative Usage E q u a t i o n

The Code 2 c u m u l a t i v e damage r u l e i s d i s c u s s e d a t t h e end of Chap. 3

[ s e e Eq. (1311. I f Code 2 were changed a l o n g t h e l i n e s s u g g e s t e d i n
S e c t . 7.3, a c o r r e s p o n d i n g c u m u l a t i v e damage r u l e c o u l d be

i=k
N = N + (Si/Sr)’ Ni , (35)
r
i=l

where

N = t o t a l number of a n t i c i p a t e d c y c l e s i n o p e r a t i o n , which
d e t e r m i n e s t h e v a l u e of t h e s t r e s s r a n g e r e d u c t i o n f a c t o r
f i n Eq. ( 6 ) ;
N = number of a n t i c i p a t e d c y c l e s of an a r b i t r a r i l y s e l e c t e d
*p a r t i c u l a r l o a d c y c l e w i t h a c a l c u l a t e d s t r e s s r a n g e Sr;
= number of a n t i c i p a t e d c y c l e s w i t h t h e s t r e s s r a n g e S
Ni i’
If Sr o r Si i s l e s s t h a n t w i c e S e J t h e n N o r N. may be t a k e n a s z e r o .
r 1
For f a t i g u e e v a l u a t i o n a c c e p t a b i l i t y , &. (36) must be s a t i s f i e d :

N (49O/Sr)’, w i t h Sr i n k s i . (36)

V a l u e s of S would have t o be i n c l u d e d in Code 2. S and S i would

r
be c a l c u l a t e d bye&. (2).
The f o l l o w i n g example i l l u s t r a t e s t h e p r o c e d u r e . Assume S = 14
k s i , Sr = 50 k s i , Nr = 200, and t h e f o l l o w i n g v a l u e s f o r S andeNi:
i

Cycle
t Y Pe ‘i Ni
- I _ -

1 130 100
2 90 40 0
3 40 6000
4 13 109

For t h i s esample,

N = 200 + (130/50)s x 100 + ( 9 0 / 5 0 I s x 400 + (40/50)’

x 6000 + (13/50)’ x 0,

N = 200 + 11881 + 7558 + 1966 + 0 = 21605.

 31

From Eq. (361, ( 4 9 0 / 5 0 I s = 90390, and because 21605 < 90390, t h e p a r t i c u -

l a r p i p i n g p r o d u c t i n v o l v e d i n t h i s example would be a c c e p t a b l e from a
f a t i g u e evaluation standpoint.

7.5 Primary S t r e s s P r o t e c t i o n , Hiah TernDeratures

Throughout t h i s r e p o r t , and p a r t i c u l a r l y i n S e c t s . 7.3 and 7.4, t h e

f o c u s h a s been on f a t i g u e e v a l u a t i o n s . Note t h a t Code 2 , NC/ND-3640,
c o n t a i n s r u l e s f o r p r e s s u r e d e s i g n and n o t h i n g i n t h i s r e p o r t i s i n t e n d e d
t o s u g g e s t any changes i n NC/ND-3640. Code 2 (Winter 1981 Addenda) Eqs.
( 8 ) and ( 9 ) f u n c t i o n t o a v o i d g r o s s p l a s t i c d e f o r m a t i o n s under combined
p r e s s u r e and moment l o a d s , u s i n g t h e B, and B, i n d e x e s . No change i n
t h e s e Code 2 e q u a t i o n s i s i n t e n d e d by t h i s r e p o r t . Indeed, w i t h t h e po-
t e n t i a l changes d i s c u s s e d i n 7.3, Code 2 Eqs. ( 8 ) and ( 9 ) become even
more s i g n i f i c a n t and may o f t e n be t h e c o n t r o l l i n g f a c t o r r a t h e r t h a n t h e
f a t i g u e evaluation.
I n d u s t r i a l p i p i n g codes ( e . g . , ANSI B31.1 and B31.3) cover tempera-
t u r e s h i g h e r t h a n 700°F f o r f e r r i t i c s t e e l s and 8000F f o r a u s t e n i t i c
s t e e l s and o t h e r h i g h a l l o y s . The s u g g e s t i o n i n S e c t . 7.3 i n v o l v e s t h e
i m p l i c i t assumption t h a t Eq. ( 2 4 ) i s v a l i d f o r a l l m a t e r i a l s and tempera-
t u r e s up t o 700 o r 800°F f o r s t r e s s e s down t o Se. T h i s assumption i s n o t
Val i d f o r h i g h e r t e m p e r a t u r e s , hence i n d u s t r i a l p i p i n g codes s h o u l d not
f o l l o w t h e s u g g e s t i o n i n S e c t . 7.3 f o r a l l of t h e i r t e m p e r a t u r e s . Also,
i n d u s t r i a l p i p i n g codes would have t o make s u r e t h e y have a d e q u a t e pro-
t e c t i o n a g a i n s t g r o s s p l a s t i c d e f o r m a t i o n s e q u i v a l e n t t o Code 2 Eqs. ( 8 )
and ( 9 ) .
 32

8. SUMMARY

8.1 ChaDter 2-4. F t i a u e E v a l u a t i UP t 106 C v c l e s

C o n s i d e r i n g t h e e n t i r e l y d i f f e r e n t approaches used i n Codes 1 and 2,

t h e agreement between t h e two approaches i s g r a t i f y i n g l y good. The K
e
f a c t o r i s mainly r e s p o n s i b l e f o r t h i s r e l a t i v e l y good agreement. How-
e v e r , Code 2 a p p e a r s t o be p o t e n t i a l l y u n c o n s e r v a t i v e f o r h i g h - s t r e n g t h
m a t e r i a l s 1i k e SA672-J100. Code 1 a p p e a r s t o be p o t e n t i a l l y m c o n s e r v a -
t i v e f o r type 304 m a t e r i a l f o r M 2 l o 4 , K2 = 2 , and f o r N 2 105, K2 = 1.

8.2 ChaDter 5 , Hiah-Cycle F a t i g u e

Both Code 1 ( u s i n g Sa a t l o 6 c y c l e s a s a n endurance l i m i t a m p l i t u d e )

and Code 2 ( u s i n g SE w i t h f = 0 . 5 ) a p p e a r t o be p o t e n t i a l l y unconserva-
t i v e f o r e v a l u a t i o n of accumulated c y c l e s of about 10' o r more. Table 3
shows our e s t i m a t e d v a l u e of S (endurance l i m i t r a n g e ) f o r an e f f e c -
e
t i v e l y i n f i n i t e number of c y c l e s .

8.3 C h a p t e r 6. Tees

S t r e s s e s i n t e e s a r e e v a l u a t e d d i f f e r e n t l y i n Codes 1 and 2 . Under

c e r t a i n combinations of moments, Code 1 c a n be more c o n s e r v a t i v e t h a n
Code 2 by a f a c t o r of up t o 2. However, f o r e v a l u a t i n g s t r e s s e s caused
by run moments, Code 2 c a n be much more c o n s e r v a t i v e t h a n Code 1.

8.4 Chapter 7. Loadinns Other t h a n Moments

C h a p t e r s 2 6 a r e concerned w i t h c o r r e l a t i o n s between f a t i g u e evalua-

t i o n f o r moment l o a d i n g s , because Code 2 e x p l i c i t l y c o v e r s o n l y moment
loadings, It a p p e a r s t h a t Code 2 r u l e s , a s p r e s e n t l y w r i t t e n , have a
s u b s t a n t i a l allowance f o r c y c l i c p r e s s u r e and, f o r a l o w number of de-
s i g n c y c l e s (e.g. , 100), a s u b s t a n t i a l allowance f o r thermal g r a d i e n t s .
I n S e c t s . 7.3 and 7.4, e x p l o r a t o r y comments and s u g g e s t i o n s a r e
g i v e n c o n c e r n i n g Code 2 m o d i f i c a t i o n s t h a t would e x p l i c i t l y cover p r e s -
s u r e and thermal g r a d i e n t s a s w e l l a s moments. The major a d d i t i o n a l work
i n v o l v e d i n r o u t i n e f a t i g u e e v a l u a t i o n s would c o n s i s t of t h e determina-
t i o n of t h e thermal g r a d i e n t s , AT,, AT2, Tal and T In S e c t . 7.5, n o t e
b'
i s made t h a t t h i s r e p o r t i s concerned w i t h f a t i g u e e v a l u a t i o n and t h a t
Code r u l e s f o r p r e s s u r e d e s i g n and Code e q u a t i o n s f o r p r o t e c t i o n a g a i n s t
g r o s s p l a s t i c d e f o r m a t i o n must be observed a s w e l l .
 33

REFERENCES

1. A. R. C. Markl, " F a t i g u e T e s t s of Welding Elbows and Comparable

Double-Miter Bends," Trans. ASME 69, 869-79 (1947).

2. A. R. C. Markl and E. H. George, " F a t i g u e T e s t s on Flanged Assem-

b l i e s , " Trans. ASME 72, 77-87 (1950).

3. A. R. C. Markl, " F a t i g u e T e s t s of P i p i n g Components," Trans. ASME

74, 287-303 (1952).

4. S. W. T a g a r t , " B a s i s f o r P a r a g r a p h NB-3228.3 of ASME S e c t i o n I11

S i m p l i f i e d E l a s t i c - P l a s t i c A n a l y s i s , " A p r i l 16, 1976.

5. A. It. C. Markl, " P i p i n g F l e x i b i l i t y A n a l y s i s , " Trans. ASME 77,

419-41 (1955).

6. R. P. Newman, "The I n f l u e n c e of Weld F a u l t s on F a t i g u e S t r e n g t h w i t h

R e f e r e n c e t o B u t t J o i n t s i n P i p e L i n e s , " Trans. I n s t . Mar. Eng. 168,
153 (1956).

7. W. G. O'Toole and E. C. Rodabaugh, Fatigue T e s t s on 4" S t d . W t .

Carbon and S t a i n l e s s S t e e l Pipe and Circumferential Butt Weld
J o i n t s , Tube Turns, L o u i s v i l l e , Ky. , Report No. 8.031 ( O c t o b e r
1961).

8. R. P. M e i s t e r e t a l . , E f f e c t s of Weld-Joint Imperfections on Piping

Performance, B a t t e l l e Memorial I n s t i t u t e ( J u l y 31, 1964).

9. M. G. Dawes, " F a t i g u e S t r e n g t h of Tubes B u t t Welded Using a Ceramic

Coated Backing Member," B r . WeZd. J. 14, 304-12 (1967).

10. D. E. Aardenbergh, S. Y. Zamrick, and A. J. Edmondson, " E x p e r i m e n t a l

I n v e s t i g a t i o n of S t r e s s e s i n N o z z l e s i n C y l i n d r i c a l P r e s s u r e
V e s s e l s , ' ' Weld. Res. Come. BUZZ. 89 ( J u l y 1963).

11. A. G. P i c k e t t e t a l . , Low CycZe Fatigue of One-Half Scale Mode2

Pressure Ve8se18, P r o g r e s s R e p o r t s Nos. 9-12, Southwest R e s e a r c h
I n s t i t u t e , San Antonio, Tex. ( J u l y 1964-January 1965).

12. T. F o r t e and C. E. J a s k e , Fatigue Evaluation of 14x6 I n s e r t WeZdolet

Branch Connections i n Carbon S t e e l Pipe, Battelle-Columbus R e p o r t
t o Bonney Forge, Allentown, Pa., A p r i l 30, 1981.

13. R. A. Weed and N. E. Johnson, Experimental S t r e s s Analysis and

Fatigue Test of ANSI Standard B16.9 Tees, ORNL-Sub-4356 ( u n d a t e d
draft).

14. J. K. Hayes and B. R o b e r t s , "Experimental S t r e s s A n a l y s i s of 24-in

T e e s (T10) , ' I Trans. ASME, J . Eng. Ind., pp. 919-28 (November 1971).
 34

15. J. K. Hayes and S. E. Moore, "Experimental S t r e s s A n a l y s i s f o r Four

24-in ANSI S t a n d a r d B16.9 Tees (T11, T l 2 , T13 , T l 6 ) , I 1 Trans. ASME,
J. of Pressure VesseZ TechnoZogy, pp. 537-52 (November 1 9 7 7 ) .
16. E. C. Rodabaugh and S . E . Moore, Comparisons of T e s t Data w i t h Code
Methods of Fatigue EvaZuation, ORNL/TM-3520 (November 1 9 7 1 ) .

17. M. E. Mayfield, E. C. Rodabaugh, and R. J. E i b e r , ReZeoance of

Fatigue T e s t s t o CoZd Leg P i p i n g , NUREX;/CR-0325 (September 1 9 7 8 ) .

18. J. D. Heald and E. Kiss, Low CycZe Fatigue of Prototype Pipe Compo-
n e n t s , General E l e c t r i c (San J o s e ) R e p o r t GEAP-10763 ( J a n u a r y 1 9 7 3 ) .

19. E. Kiss, J. D. Heald, and D. A. Hale, Low-CycZe Fatigue of Proto-

t y p e Piping, General E l e c t r i c (San J o s e ) R e p o r t GEAP.10135 ( J a n u a r y
1970).

20. J. D. Reald and E. Kiss, "Low Cycle F a t i g u e of Nuclear P i p e Compo-

n e n t s , " Trans. ASME, J. of Pressure Vessel TechnoZogy 9 6 ( 3 ) , 1 7 1 1 6
(August 1 9 7 4 ) .

21. J. S. B l a i r , "Reinforcement of Branch P i e c e s , ' ' Engineering, London

(1947).

22. E. J. Mills, T. J. A t t e r b u r y , and G. M. McClure, AGA Project NG-11,

Study of E f f e c t s of CycZic Bending Loads on Performance of Branch
Connections, Battelle-Columbus R e p o r t t o American Gas A s s o c i a t i o n
(May 1 9 6 2 ) .

23. T. R. Gurney and S. J. Maddox, "A Re-Analysis of F a t i g u e Data f o r

Welded J o i n t s i n S t e e l ,I' WeZd. Res. I n t . 3 ( 4 ) , 1-54 ( 1 9 7 3 ) .

24. N a t i o n a l R e s e a r c h I n s t i t u t e f o r M e t a l s , Tokyo, J a p a n , " N R I M F a t i g u e

Data S h e e t No. 5 , Data S h e e t s on F a t i g u e P r o p e r t i e s f o r Butt-welded
J o i n t s of SMOB High T e n s i l e S t r u c t u r a l S t e e l P l a t e s , " 1978.
11
25. B. P o l l a r d and R. J. Cover, F a t i g u e of S t e e l Weldments," WeZd.
Res. SuppZement (November 1972) .
 35

Appendix A

BACKGROUND OF THE Ke FACTOR

.
The purpose of t h e 3Sm l i m i t on t h e r a n g e of primary-plus-secondary
s t r e s s S is t o e n s u r e t h e v a l i d i t y of t h e S v a l u e used i n t h e f a t i g u e
n
evaluation. C o n c e p t u a l l y , t h e l i m i t i s t h e thakedown l i m i t of 2 s be-
cause Sm = ( 2 / 3 ) S y and 3Sm = 2 s y . Y
A c t u a l l y , f o r most m a t e r i a l s and tem-
p e r a t u r e s , t h e v a l u e of Sm i s n o t ( 2 / 3 ) S where S i s t h e Code-tabu-
YC, YC
l a t e d o r e x p e c t e d ( a t t e m p e r a t u r e s above room t e m p e r a t u r e ) minimum y i e l d
strength. Examples a r e (1) Sm f o r SA106 Grade B a t 100°F = 20 k s i , S =
YC
3 5 k s i , Sm = 0.57 S * and ( 2 ) Sm f o r SA312 type 304 a t 5000F = 17.5 k s i ,
YC'
S = 19.4 k s i , S = 0.90 S
YC m YC'
The shakedown c r i t e r i a of S < 2s a r e b a s e d on an i d e a l i z e d , e l a s -
n - v
t i c p e r f e c t l y p l a s t i c m a t e r i a l ; most p i p i n g m a t e r i a l s a r e n o t r e a l l y
such i d e a l i z e d m a t e r i a l s . Furthermore, S i s a minimum; t y p i c a l y i e l d
s t r e n g t h s a r e about 20% h i g h e r t h a n S
YC
. YC
Therefore, it i s apparent t h a t
t h e 3 s l i m i t i s o n l y a rough a p p r o x i m a t i o n of t h e shakedown l i m i t .
P F i o r t o t h e s t a r t of work on C l a s s 1 p i p i n g f o r ANSI B31.7, a s i m -
p l e p r o c e d u r e f o r f a t i g u e e v a l u a t i o n when S > 3 s d i d n o t e x i s t . Writ-
m
e r s of ANSI B31.7, a t t h a t time, n o t e d t h a t n

1. S t r e s s e s caused by a 1i n e a r through-the-wall t e m p e r a t u r e g r a d i e n t AT,

. s h o u l d be c o n s i d e r e d t o be p a r t of Sn. Indeed, i n t h e B r e e l shake-
down e v a l u a t i o n , AT, is t h e s o u r c e of bending s t r e s s e s t h a t , i n com-
b i n a t i o n w i t h a membrane s t r e s s ( e . g . , from p r e s s u r e ) , can cause
cyclic plasticity or ratchetting.
2. T e s t d a t a on p i p i n g p r o d u c t s were a v a i l a b l e ( e . g . , M a r k l a ) t o c l e a r l y
show t h a t , even f o r S > 3Sm, t h e p r o d u c t could w i t h s t a n d a s i g n i f i -
n
c a n t number of c y c l e s w i t h o u t f a i l u r e . E q u a t i o n ( 2 4 ) of t h e t e x t a s
a p p l i e d t o an elbow i l l u s t r a t e s t h i s . For an elbow, Ka = 1; hence,
2 i S i s e q u i v a l e n t t o Sn. With 2 i S d = S = 6Sm = 180 k s i , Eq. ( 2 4 )
d n
g i v e s N of 150 c y c l e s ; N f = 32 x 150 = 4800 c y c l e s .

Making AT, s t r e s s e s p a r t of S i n c r e a s e d t h e f r e q u e n c y of S > 3 s

n n m
i n d e s i g n e d p i p i n g systems. R e c o g n i t i o n t h a t , even i f S > 3Sm, s i g -
n
n i f i c a n t f a t i g u e c y c l e s c o u l d be w i t h s t o o d m o t i v a t e d t h e development and
a c c e p t a n c e of a I 1 simp1 i f i e d e l a s t i c - p l a s t i c " e v a l u a t i o n p r o c e d u r e f o r
sn > 3sm.
ANSI B31.7-1969 f o r Sn > 3Sm r e q u i r e d t h a t :

where M. was t h e r e s u l t a n t moment range caused by r e s t r a i n t of thermal

1
 36

expansion. I f Eq. ( A . 1 ) was met, t h e n :

= (1/2)[S + A(S - Sn)l(Sn/3Sm) , (A. 2 1

'a1 t P P .
where Salt was t h e c a l c u l a t e d s t r e s s a m p l i t u d e t o be used t o e n t e r t h e
Code d e s i g n f a t i g u e c u r v e s . The v a l u e of A was o b t a i n e d from ANSI B31.7
Fig. D-201, i n c l u d e d h e r e a s Fig. A . l . The use of Eq. (A.2) was re-
s t r i c t e d t o <250 c y c l e s of Sn ) 3Sm. T a g a r t ' d i s c u s s e s t h e development

ORNL-DWG 83-4601 ETD

(a)
A CARBON STEEL
P-NUMBER 1
ASME Tx

(6)
A 2 1/4 Cr-1 Mo S T E E L
P-NUMBER 5
ASME IX

1 4
0.8 A = 0.7

(C)
A 0.4 304 STAINLESS STEEL
P-NUMBER 8
ASME SX
0
1 2 3 4

Fig. A . l . A-factors f o r use i n Eq. (A.2). Source: American S o c i e t y

of Mechanical E n g i n e e r s , Nudear Power Piping, USAS B31.7-1969.
 37

of Eq. (A.2) and t h e 250-cycle l i m i t . The b a s i s f o r Eq. ( A . 1 ) i s more

nebulous; i t came i n l a r g e p a r t from t h e d e s i r e t o l i m i t e x p a n s i o n
s t r e s s e s t o t h e same " b a l l park" a s t h o s e p e r m i t t e d i n i n d u s t r i a l p i p i n g
code 8 .
Code Case 1441, "Waiving of 3Sm L i m i t f o r S e c t i o n I11 C o n s t r u c t i o n , "
was p u b l i s h e d i n 1970. It gave r u l e s t h a t a r e almost t h e same a s t h o s e
now i n Code 1 ( s e e Chap. 2 of t h e t e x t ) . Tho e x c e p t i o n s were: (1) t h e
number of c y c l e s w i t h S ) 3 s was l i m i t e d t o 1000, ( 2 ) t h e v a l u e of n,
n m
f o r a u s t e n i t i c s t a i n l e s s s t e e l s , was 0.5 r a t h e r t h a n t h e p r e s e n t n = 0.3.
T a b l e A.l shows comparisons between Code Case 1441 (1970) and Code 1
(1980) f o r s t a i n l e s s s t e e l s ; Case 1441 u s e s n = 0.5 r a t h e r t h a n t h e p r e s -
e n t n = 0.3. It c a n be s e e n t h a t use of n = 0 . 5 g i v e s v e r y h i g h allow-
a b l e f a t i g u e d e s i g n s t r e s s e s f o r low c y c l e s ; t h e n = 0.5 was soon (1971)
changed t o i t s p r e s e n t v a l u e of 0.3.
T a b l e A.2 shows comparisons between ANSI B31.7-1969 and Code 1.
C o n s i d e r i n g t h e o r d e r of accuracy i n v o l v e d , t h e method used i n ANSI B31.7-
1969 f o r f a t i g u e e v a l u a t i o n f o r S ) 3s i s e q u i v a l e n t t o t h e K f a c t o r
n m e
used i n Code 1.
T a g a r t * h a s p r e p a r e d a d e s c r i p t i o n of t h e b a s i s f o r t h e K f a c t o r .
e
Because, t o our knowledge, i t h a s n o t been p u b l i s h e d and because ques-
t i o n s regarding the b a s i s f o r the K f a c t o r frequently a r i s e , T a g a r t ' s
e
d i s c u s s i o n is q u o t e d in f u l l i n t h e f o l l o w i n g p a r a g r a p h s . In a d d i t i o n

Table A.l. Comparisons of a l l o w a b l e v a l u e s

of S ( k s i ) , Code Case 1441 and Code 1
P
----.-I-- --
SA312 type 304 a t lOOOF

N Ka = 1 Ka = 2
--
Case 1441 Code 1 Case 1441 Code 1
~~~

10 650a 3 90' 6 SOa 3 90a

loa 240a 144a 240' 17 9
103 loga 87.1 155 140
b
104 80 .o 71.6 llgb 118
b b
1 05 65.8 63.3 75 .O 75 .O
b b b
106 52 .O 52 .O 52.0 52 .O
a
I n d i c a t e s t h a t Sn ) 3mSm, K = lln,
S
P
= 2nS
r a
. e

D I n d i c a t e s t h a t Sn < 3Sm, Ke = 1 . 0 ,
s = 2sa.
P
 38

Table A.2. Comparisons of a l l o w a b l e v a l u e s of S (ksi),

ANSI B31.7-1969 and Code 1 P

SA106 Grade B a t 1 0 0 ° F SA312 type 304 a t lOOOF

--
N IC2 = 1 K, = 2 K2 = 1 K2 = 2
- --PI- --
B31.7 Code 1 B31.7 Code 1 B31.7 Code 1 B31.7 Code 1
--e - I

10 264 23 2' 288 2 96 27 9 3 90' 3 40 3 90'

102 157 127 181 190 170 144a 207 17 9
103 99.8 87.0 121 134 114 87.1 1 39 140
104 63.5 65.0 76.0 76.0 84.1 71.6 llsb llgb
10 40 .O 40.0 40.0 40.0 67.1 63.3 75.0b 75.0"
52.0" 52.0h 52.0 b
106 25 .O 25.c 25.0 25.0 52.0
- -y_-I
- I
I_------I .---
a
I n d i c a t e s t h a t Sn > 3mSm, Ke = l l n , S
P
= 2nSa.

b I n d i c a t e s t h a t Sn < 3Sm, Ke = 1 . 0 , S = 2s
P a
.

t o t h e r e f e r e n c e s c i t e d by T a g a r t , Refs. 5 and 6 c o n t a i n more e x t e n s i v e

and d i r e c t c o r r e l a t i o n s between f a t i g u e t e s t s on p i p i n g p r o d u c t s and t h e
Code 1 w i t h ICe method of f a t i g u e e v a l u a t i o n .

BASIS FOR PARAGRAPH NB 3228.3 OF

ASME SECTION I11 SIMPLIFIED ELASTIC-PLASTIC ANALYSIS*

The r u l e s c u r r e n t l y a p p e a r i n g i n t h e ASME S e c t i o n I11

Code c o n c e r n i n g s i m p l i f i e d e l a s t i c - p l a s t i c a n a l y s i s have t h e i r
o r i g i n i n t h e development of d e t a i l e d s t r e s s a n a l y s i s f o r nu-
c l e a r power p i p i n g components under t h e former USAS B31.7 Nu-
c l e a r Power P i p i n g Code. In t h e p r o c e s s of d e v e l o p i n g t h a t
code, t h e f r e q u e n t l y o c c u r r i n g l a r g e primary p l u s secondary
s t r e s s e s which r e s u l t i n p i p i n g components gave need f o r a
s i m p l i f i e d procedure t o evaluate these e f f e c t s . A d e t a i l e d
p r o c e d u r e was implemented i n t o t h e B31.7 code and r e f e r e n c e d
by Paper 68-WP-3, l i s t e d a s Reference 1 [Ref. 3 of t h i s Ap-
pendix]. T h i s development r e l i e d on t e s t s of notched b a r
specimens which measured t h e s t r a i n c o n c e n t r a t i n g e f f e c t when
t h e 3s l i m i t was exceeded. Although i t was g e n e r a l l y a g r e e d
m
*O r i g i n a l t e x t by S. W. T a g a r t .
 39

t h a t t h e recommended p r o c e d u r e s p r e s e n t e d i n t h i s p a p e r were
s a f e and c o n s e r v a t i v e by t h o s e who r e v i e w e d them i n d e t a i l ,
f u r t h e r developments of simp1 i f i e d f o r m u l a s o c c u r r e d when t h e
p i p i n g code was combined i n t o ASME S e c t i o n 111. Due t o t h e
c o m p l e x i t y of t h e e l a s t i c - p l a s t i c b e h a v i o r , no s i m p l e f o r m u l a
c o u l d be d e v e l o p e d which would a c c u r a t e l y r e p r e s e n t e v e r y t h i n g
which g o e s on.
In s i m p l e terms, t h e s t r a i n c o n c e n t r a t i o n phenomena which
o c c u r s i s i l l u s t r a t e d by F i g u r e 1 [ F i g . A.2 of t h i s Appendix].
Here we s e e a p l o t of t h e peak s t r a i n c o n c e n t r a t i o n f a c t o r i n
e i t h e r a n o t c h e d member o r a member w i t h some o t h e r type of
s t r e s s c o n c e n t r a t i o n . The peak s t r a i n c o n c e n t r a t i o n r e m a i n s
c o n s t a n t from 0 t o A where t h e m a t e r i a l b e h a v i o r i s p e r f e c t l y
e l a s t i c . A t P o i n t A, t h e s t r a i n c o n c e n t r a t i o n b e g i n s t o ex-
ceed t h e e l a s t i c s t r e s s c o n c e n t r a t i o n , ICt, and c o n t i n u e s t o
r i s e anti1 some P o i n t B i s r e a c h e d a t which a maximum s t r a i n
c o n c e n t r a t i o n occurs.
If d e f l e c t i o n i s c o n t i n u e d , t h e s t r a i n c o n c e n t r a t i o n be-
g i n s t o d r o p o f f a s shown by P o i n t C. Langer, i n R e f e r e n c e 2
[Ref. 7 of t h i s Appendix], h a s e s t i m a t e d t h e g e n e r a l i z e d maxi-
mum s t r a i n c o n c e n t r a t i o n which c a n o c c u r a t a p o i n t such as B.
Ee i l l u s t r a t e s t h a t t h e s t r a i n c o n c e n t r a t i o n f a c t o r K i s ap-
E
p r o x i m a t e l y l / n , where n i s t h e s t r a i n h a r d e n i n g exponent of
the material. T h i s maximum v a l u e of s t r a i n c o n c e n t r a t i o n i s
t h e b a s i s f o r t h e assumed shape of t h e gE c o r r e c t i o n f a c t o r
which a p p e a r s i n t h e Code. The s p e c i f i c Code f o r m u l a shown
h e r e a s e q u a t i o n 1 which q u a n t i t a t i v e l y e x p r e s s e s t h i s s t r a i n
c o n c e n t r a t i o n , c o n t a i n s two m a t e r i a l t e r m s , n and m. The m
term was i n t r o d u c e d i n t o t h e f o r m u l a i n o r d e r t o produce any

ORNL-DWG 83-4602 ETD

I
DE F LECT I ON

F i g . A.2. Schematic i l l u s t r a t i o n of p e a k - s t r a i n c o n c e n t r a t i o n in a
notched beam a s a f u n c t i o n of d e f l e c t i o n . Source: Ref. 4 .
 40

d e s i r e d s l o p e on t h e f a c t o r i n r e g i o n A of F i g u r e 2 [Fig.
A.3 of t h i s Appendix]. Thus, t h e form of e q u a t i o n 1 was se-
l e c t e d i n o r d e r t o p r o v i d e two f e a t u r e s : 1) a maximum c o r r e c -
t i o n f o r t h e s t r a i n c o n c e n t r a t i o n of l / n and 2 ) any e x p e r i -
m e n t a l l y o b s e r v e d s l o p e of t h e 5 c o r r e c t i o n i n r e g i o n A.
While t h e s t r a i n h a r d e n i n g exponent n i s e a s i l y o b t a i n e d f o r
t h e s t a t i c c a s e by measuring t h e uniform e l o n g a t i o n a t maximum
l o a d d u r i n g t h e t e n s i l e t e s t , such v a l u e s of n may n o t r e f l e c t
a c c u r a t e l y t h e b e h a v i o r which o c c u r s i n a f a t i g u e s i t u a t i o n .
T h e r e f o r e , t h e v a l u e s of n which appear i n t h e code f o r t h i s
p r o c e d u r e a r e only approximate v a l u e s of t h e s t r a i n h a r d e n i n g
exponent a s compared w i t h t h o s e from a t e n s i l e t e s t . There i s
no s t r a i g h t f o r w a r d method f o r measuring m w i t h o u t u s i n g t h e re-
s u l t s of f a t i g u e t e s t s . The method which was used t o e s t a b -
l i s h t h e v a l i d i t y of t h e c o r r e c t i o n f a c t o r KE s u p p l i e d by
e q u a t i o n 1 f o r s p e c i f i c m and n v a l u e s was through comparison
w i t h f a t i g u e t e s t r e s u l t s . Other methods a r e p o s s i b l e , b u t a
s t a n d a r d method h a s n o t been developed a t t h e p r e s e n t time.
Nmnerous f a t i g u e t e s t s have been r u n and t h e r e s u l t s of t h e s e
t e s t s have been p u b l i s h e d and have demonstrated t h a t t h e cor-
r e c t i o n p r e d i c t e d i s c o n s e r v a t i v e f o r use w i t h t h e Code.
R e f e r e n c e s 3 through 8 [Refs. 7-13 of t h i s Appendix] il-
l u s t r a t e some of t h e s o u r c e s of v e r i f y i n g t h e c u r r e n t e l a s t i c -
p l a s t i c d e s i g n f o r m u l a s . For example, F i g u r e 1 5 of Reference
8 [Ref. 1 3 of t h i s Appendix] shows a d i r e c t comparison between

ORNL-DWG 83-4603 ETD

K, = 1.0 (S,< 3Sm)

(3Sm < s, < 3 , S , )
(1)

K, = l / n

KE
4 1/n

1 .o

Fig. A.3. Schematic i l l u s t r a t i o n of t h e v a r i a t i o n of Ke a s a

f u n c t i o n of primary-plus-secondary s t r e s s . Source: Ref. 4 .
 41

t h e s t r a i n c o n c e n t r a t i o n f a c t o r s used i n t h e Code and t h e v a l -

u e s o b t a i n e d from t e s t s on type 304 s t a i n l e s s s t e e l . In the
o r i g i n a l concept of t h e e l a s t i c - p l a s t i c c o r r e c t i o n a s pre-
s e n t e d i n Reference 1 [Ref. 3 of t h i s Appendix], a l i m i t of
250 c y c l e s i s s u g g e s t e d below which no s p e c i f i c account was
r e q u i r e d t o a s s u r e t h a t r a t c h e t i n g would be n e g l i g i b l e . The
c u r r e n t r u l e s of ASME S e c t i o n I11 have no such l i m i t a t i o n s ;
however, i t should be noted t h a t i n NB3223.3, P a r a g r a p h ( a ) , a
range of primary p l u s secondary membrane bending s t r e s s i n t e n -
s i t y e x c l u d i n g thermal bending s t r e s s e s must always be l e s s
t h a n 3Sm.
Paragraph ( d ) r e q u i r e s t h a t t h e through w a l l thermal
g r a d i e n t e f f e c t s meet t h e r e q u i r e m e n t s of NB 3222.5 f o r r a t c h -
e t i n g due t o p r e s s u r e and thermal e f f e c t s . In a d d i t i o n , t h e
c o n s e r v a t i v e v a l u e s of t h e K f a c t o r d r a s t i c a l l y r e d u c e s t h e
E
a l l o w a b l e f a t i g u e 1i f e c y c l e s . S a t i s f y i n g these requirements
p r o v i d e s a s s u r a n c e t h a t a n e g l i g i b l e amount of r a t c b e t i n g can
o c c u r , t h e r e f o r e , no a d d i t i o n a l r e q u i r e m e n t f o r 1i m i t i n g .cy-
c l e s due t o r a t c h e t i n g i s n e c e s s a r y .

References

1. J. Bree, " E l a s t i c - P l a s t i c Behavior of Thin Tubes S u b j e c t e d t o I n t e r -

n a l P r e s s u r e and I n t e r m i t t e n t High-Heat F l u x e s w i t h A p p l i c a t i o n t o
Fast-Nuclear Fuel Elements," J. S t r o i n AnaZ. 2(3), 226-238 (1967).

2. A. R. C. Markl, " F a t i g u e T e s t s of P i p i n g Components," Trans. ASME 74,

287-303 (1952).

3. S. W. T a g a r t , " P l a s t i c F a t i g u e A n a l y s i s of P r e s s u r e Components," ASME

Paper No. 68-PVP-3, pp. 209326 i n Vol. 1 of ASME A ~ c o m r cVesseZs
and Piping: Design and AnaZysis, A Decade of Progress, New York,
1972.

4. S. W. T a g a r t , " B a s i s f o r Paragraph NB-3228.3 of ASME S e c t i o n I11 Sim-

p l i f i e d E l a s t i c - P l a s t i c A n a l y s i s , " A p r i l 16, 1976.

5. E. C. Rodabaugh and S . E. Moore, Comparisons of T e s t Data w i t h Code

Methods of Fatigue EuaZuution, ORNLlTM-3520 (November 1971).

6. M. E. Mayfield, E. C. Rodabaugh, and R. J. E i b e r , ReZevance of Fa-

t i g u e T e s t s t o CoZd Leg Piping, NUREx;/CR-0325 (September 1978).

7. B. F. Langer, "Design-Stress B a s i s f o r P r e s s u r e V e s s e l s , " EX^. Mech.

84(3), 389-402 ( J a n u a r y 1971).

8. E. Kiss, J. D. Beald, and D. A. Bale, "Low-Cycle F a t i g u e of Proto-

type P i p i n g , " General E l e c t r i c (San J o s e ) Report GEAP-10135 ( J a n u a r y
1970).
 42

9. J. D. Heald and E. Kiss, "Low Cycle F a t i g u e of N u c l e a r P i p e Com-

p o n e n t s , " Trans. ASME J. of Pressure VesseZ TechnoZogy 96(3), 171-176
(August 1974).

10. E. C. Rodabaugh, Phase R e p o r t No. 115-2 ( F e b r u a r y 1969).

11. T. L. G e r b e r , " E f f e c t of C o n s t r a i n t and Loading Mode on Lm-Cycle

-
F a t i g u e Crack I n i t i a t i o n Comparison w i t h Code Design R u l e s , " GEAP-
20662 ( O c t o b e r 1974).

12. T. Udoguchi and Y. Asada, " I n i t i a t i o n of Low Cycle F a t i g u e S t r e n g t h

of P i p i n g Components, p a p e r p r e s e n t e d a t Second I n t e r n a t i o n a l Con-
f e r e n c e on P r e s s u r e V e s s e l Technology, San Antonio, Texas, October
1973.

13. Y. Ando e t a l . , "Low Q c l e F a t i g u e S t r e n g t h of P i p i n g Components,"

p a p e r p r e s e n t e d a t Second I n t e r n a t i o n a l Conference on P r e s s u r e V e s s e l
Technology, San Antonio, Texas, October 1973.
 43

Appendix B

BASIS OF CODE 1 FATIGUE DESIGN CURVES

B a s i c T e s t Data. Carbon and Low-Allov Steels

F i g u r e B . l shows t h e b a s i c data used t o e s t a b l i s h the design f a t i g u e

curve i n Code Fig. 1-9.1, UTS 80 k s i . F i g u r e B . l c o n s i s t s of F i g s . 9
and 1 0 of t h e C r i t e r i a . = The d a t a i n Fig. R.l a r e from s t r a i n - c o n t r o l l e d ,
z e r o mean s t r a i n , f a t i g u e t e s t s of p o l i s h e d b a r s a t ( p r o b a b l y ) room tem-
perature. An e q u a t i o n of t h e form

S = IE/(4f)l In IlOO/(lOO - A)] + B (B.1)

ORNL-DWG 83-4604 ETD

1o7

106
"BEST FIT" CURVE A = 88.5%,

1o5

ADJUSTED FOR MEAN STRESS

It

Fig. B . l . Basic t e s t data: (a) c a r b o n and ( b ) low-alloy s t e e l s .

SouPce: Ref. 3 3 .
 44

was f i t t e d t o t h e average of t h e t e s t d a t a by s e l e c t i o n of A and B. The

p e r c e n t r e d u c t i o n i n a r e a i s sometimes used f o r A, b u t i n g e n e r a l , A i s
simply a c u r v e f i t t i n g p a r a m e t e r . The v a l u e of B is a n endurance
s t r e n g t h , t h a t i s , a v a l u e of S below which f a t i g u e f a i l u r e w i l l n o t oc-
c u r in a p o l i s h e d b a r i n dry a i r o r e q u i v a l e n t environment. The d e s i g n
f a t i g u e c u r v e i s o b t a i n e d from Eq. ( B . 1 ) by: (1) a p p l y i n g a n a d j u s t m e n t
f o r mean s t r e s s e f f e c t , and ( 2 ) a p p l y i n g a f a c t o r of s a f e t y of 2 on
s t r e s s o r 20 on c y c l e s , whichever g i v e s t h e lower f a t i g u e d e s i g n s t r e s s .

Mean S t r e s s Adiustment

Because of r e s i d u a l s t r e s s e s a t welds and o t h e r p o s s i b l e s o u r c e s of

mean s t r e s s such a s i n s t a l l a t i o n misalignment i n p i p i n g , t h e Code h a s
t a k e n t h e approach of a d j u s t i n g t h e t e s t r e s u l t s f o r t h e maximum p o s s i b l e
e f f e c t of mean s t r e s s . The a d j u s t m e n t procedure i s d e s c r i b e d i n t h e C r i -
teria.' The procedure i s based on t h e Goodman diagram and t h e concept
t h a t t h e sum of t h e mean s t r e s s and r e v e r s e d s t r e s s amplitude cannot ex-
ceed t h e y i e l d s t r e n g t h of t h e m a t e r i a l . The e q u i v a l e n t c o m p l e t e l y
r e v e r s e d s t r e s s S' is o b t a i n e d by:

S' = S[(Su - Sy)/(Su - SI1 , for S < S

Y
; (B.2)

and

S ' = S , f o r S > S ; (B.3)

Y

where

S' = e q u i v a l e n t c o m p l e t e l y r e v e r s e d s t r e s s a m p l i t u d e ,
S = r e v e r s e d s t r e s s amplitude [Eq. ( B . 1 1 1 ,
S = u l t i m a t e t e n s i l e s t r e n g t h of m a t e r i a l ,
Su = y i e l d s t r e n g t h of m a t e r i a l .
Y

To make t h e a d j u s t m e n t i n d i c a t e d by Eq. ( B . 2 1 , v a l u e s f Su and S

Y
must be s e l e c t e d . These a r e n o t n e c e s s a r i l y t h e minimum s p e c i f i e d
s t r e n g t h s , and a judgment must be made a s t o t h e a p p r o p r i a t e v a l u e s . The
C r i t e r i a does n o t i d e n t i f y t h e v a l u e s of S and S used t o o b t a i n t h e
U Y
a d j u s t m e n t s ( d a s h e d l i n e s i n Fig. B.11, b u t working backward, i t a p p e a r s
t h a t t h e f o l l o w i n g v a l u e s were used.

Carbon s t e e l s 80 k s i 40 k s i
Low-alloy s t e e l s 100 k s i 70 k s i

Having made t h e a d j u s t m e n t f o r mean s t r e s s , t h e d e s i g n f a t i g u e curve S

a
 45

v s N i s o b t a i n e d by a p p l y i n g t h e f a c t o r of s a f e t y of 2 on s t r e s s o r 20
on c y c l e s .
The p r o c e d u r e d e s c r i b e d i n t h e p r e c e d i n g p a r a g r a p h s i s i l l u s t r a t e d
i n Table B . l . The v a l u e of t h e modulus of e l a s t i c i t y E was t a k e n a s 3 x
l o 7 p s i ; t h i s i s t h e v a l u e shown i n Code F i g . 1-9.1. The v a l u e of E i s
s i g n i f i c a n t i n t h a t s t r e s s e s a r e equal t o Ee, where e i s t h e c o n t r o l l e d
s t r a i n . In p r i n c i p l e , t h e v a l u e of E used i n t h e a n a l y s i s l e . g . , t o de-
termine M. i n Eq. (1) of t h e t e x t 1 s h o u l d be t h e same a s E used t o de-
l
velop the design f a t i g u e curve. A l t e r n a t i v e l y , the design f a t i g u e curves
can be m o d i f i e d by m u l t i p l y i n g t h e s t r e s s e s i n t h e curve by E'/E, where
E' is t h e modulus used i n t h e a n a l y s i s . However, q u i t e o f t e n t h e c y c l e s
o c c u r over a range of t e m p e r a t u r e s , and p a r t of a p i p i n g system may be a t
a d i f f e r e n t t e m p e r a t u r e t h a n a n o t h e r p a r t of t h e same system. Accord-
i n g l y , an a p p r o x i m a t i o n of an a p p r o p r i a t e E i s o f t e n n e c e s s a r y . Fortu-
n a t e l y , t h e v a r i a t i o n of E w i t h t e m p e r a t u r e over t h e range of t e m p e r a t u r e
covered i s r e l a t i v e l y small and t h e r e f o r e i s n o t a major s o u r c e of uncer-
t a i n t y i n a fatigue analysis.
It may be observed i n T a b l e B . l t h a t t h e Code-tabulated v a l u e s of
f a t i g u e d e s i g n s t r e s s e s a g r e e r e a s o n a b l y w e l l w i t h t h e average of t h e two
s e t s of S . The C r i t e r i a s t a t e s , "A s i n g l e d e s i g n curve i s used f o r car-
bon and l & - a l l o y s t e e l below 80,000 p s i u l t i m a t e t e n s i l e s t r e n g t h be-
cause . ...
i d e n t i c a l 'I1
t h e a d j u s t e d c u r v e s f o r t h e s e c l a s s e s of m a t e r i a l were n e a r l y

High-Alloy M a t e r i a l s

The C r i t e r i a 1 i n c l u d e s d a t a f o r 18-8 s t a i n l e s s - s t e e l s w i t h an
a v e r a g e - f i t e q u a t i o n i n t h e form of l?q. ( B . 1 ) :

where E = 2.6 x l o 7 p s i ( t h e v a l u e shown on Fig. 1-9.2). The correspon-

dence between t h e C r i t e r i a e q u a t i o n and Code-tabulated v a l u e s i s shown i n
T a b l e B.2. Because S a t lo' c y c l e s i s 51,915 p s i , which was assumed t o
be g r e a t e r t h a n S t h e r e i s no mean s t r e s s c o r r e c t i o n i n Code Fig. 1-9.2.
Y*
As can be seen i n T a b l e B.2, t h e v a l u e s of S d e r i v e d from Eq. (B.4) a r e
a
i n r e a s o n a b l e agreement w i t h t h e Code-tabulated v a l u e s .
Although t h e C r i t e r i a 1 g i v e s d a t a only f o r 18-8 s t a i n l e s s s t e e l s ,
t h e Code i n i t s f i r s t (1963) e d i t i o n i n d i c a t e d t h a t F i g . 1-9.2 was ap-
p l i c a b l e t o nickel-chrome-iron a l l o y s . The p r e s e n t (1980) Code i n d i c a t e s
t h a t Fig. 1-9.2 i s a p p l i c a b l e t o a u s t e n i t i c s t a i n l e s s s t e e l s , n i c k e l -
chrome-iron a l l o y ( e . g . SB167 Alloy 600), nickel-iron-chrome a l l o y
( e . $ . , SB407 Alloy 8 0 0 ) , and nickel-copper a l l o y ( e . g . , SB165 Alloy 4 0 0 ) .
The b a s i s f o r i n c l u d i n g t h e o t h e r - t h a n - a u s t e n i t i c s t e e l s i n F i g . 1-9.2 i s
n o t av a i 1ab1 e .
About 1975, t h e need a r o s e t o e x t e n d t h e Code d e s i g n f a t i g u e c u r v e 5
t o h i g h e r t h a n l o 6 c y c l e s . J a s k e and O'DonnellZ p u b l i s h e d t h e r e s u l t s of
t h e i r review of f a t i g u e t e s t d a t a on 300 s e r i e s a u s t e n i t i c s t e e l s , n i c k e l -
 46

T a b l e B.l. I l l u s t r a t i o n of method of d e v e l o p i n g d e s i g n f a t i g u e c u r v e s
from c o m p l e t e l y r e v e r s e d f a t i g u e t e s t d a t a ( s t r e s s e s i n k s i )

N b d
Se S2 0 Slf Sa Code'

10 2761 634 634 2296 543 543 5 80

20 1959 455 455 1635 3 95 3 95 41 0
50 1247 296 296 1048 264 264 27 5
100 888 21 5 21 5 752 198 198 20 5
200 634 159 159 543 151 151 155
500 409 108 108 3 58 110 110 105
1000 296 82.9 82.9 264 89.0 89 .o 83
2000 21 5 65 .O 65 .O 198 74.2 74.2 64
5000 144 49.0 49.0 13 9 61.1 61.1 48
1 x 104 108 41 .O 41 .O 110 54.5 54. 5h 38
2 x 104 82.9 35.3 35.3h 89 .O 49.8 44 .5h 31
5 x 104 60.4 30.3 30.2 70.4 45.6 35.2 23
h h
20
1 x 105 49 .O 27.8 24.5h 61.1 43.5 47.1 23 .5h
2 x 105 41 .O 26 .O 20 .5h 54.5 42.1 36.0 17.9 16.5
5 x 105 33.9 24.4 29.4 14.7 48.6 40.8 28.4 14.2 13.5
h h
1 x 106 30.3 23.6 24.4 12.2 h 45.6 40.1 25.2 12.6 12.5
1 x 10' 24.4 22.3 17.5 8.77h
1 x 108 22.5 21.8 15.7 7.83
h
1 x 109 21.9 21.7 15.1 7 .55h
1 x 1010 21.7 21.7 14.9 7.46,,
1 x 1011 21.7 21.7 14.9 7.43
~ __ ~ ~

aE q u a t i o n (B.l) w i t h E = 3 x 10' p s i , A = 68.5, B = 21,645 p s i ; S =

8,664Ifi + 21.645 k s i .
b
S,, = s t r e s s f o r N = 20 t i m e s v a l u e shown; t h a t i s , f a c t o r of s a f e t y
of 20 on c y c l e s .
C
E q u a t i o n (€3.2) w i t h Su = 80 k s i , S = 40 k s i .
Y
d~
a
= l e s s e r of SI^, sz0, or ~ 1 1 2 .
e
Equation (E.1) with E = 3 x lo7 p s i , A = 61.4, B = 38,500 p s i ; S =
7,139Ifi + 38.5 k s i .
f E q u a t i o n (B.2) w i t h SII = 100 k s i , S = 70 k s i .
Y
'Value of Sa t a b u l a t e d i n Code 1, T a b l e 1-9.1 f o r F i g . 1-9.1, UTS 80
ksi.
h
F a c t o r of s a f e t y of 2 on s t r e s s c o n t r o l s .
 47

Table B.2. Comparisons of f a t i g u e d e s i g n s t r e s s e s f o r

18-8 a u s t e n i t i c s t a i n l e s s s t e e l s ( s t r e s s e s i n k s i )
-

b d e Proposed
N Sa Sa o sac Code
c u r v e Af

10 2705 63 9 639 6 50
20 1925 464 464 47 0
50 1234 310 310 3 17
100 885 23 2 23 2 240
200 63 9 177 177 185
500 420 128 128 1 36
1000 31 0 103 103 109
2000 23 2 85.6 85.6 89
5000 163 70.1 70.1 70
1 8 104 128 62.3 62.3 59
2 x 104 103 56.8 51.5$ 51
5 x 104 81.1 51.9 40 .6' 42.5
1 x 105 70.1 49.5 35.1' 37.5
2 x 105 62.3 47.7 3 1 .2' 33 .o
5 8 105 55.4 46.2 21.79 28.5
1 x 106 51.9 45.4 26 'O. 26.0 28.3' 28.3
2 x 106 26.9' 26.9
5 x 106 25.7' 25.7
1 x 107 25.1' 25.1
2 x 107 24.7' 24.7
5 s 107 24.3' 24.3
1 x 10' 24.1f 24.1
1 x 109 23.8' 23.8
1 x 1010 23.7' 23.7
1 x 10x1 23.7' 23.7
a
Q u a t i o n (B.1) w i t h E = 2.6 x 107, A = 72.6, B =
43,500 p s i ; S = 8 , 4 1 5 1 f i + 43.5 k s i .
b
S,, = s t r e s s f o r N = 20 t i m e s v a l u e shown; t h a t i s ,
f a c t o r of s a f e t y of 20 on c y c l e s .
C
Sa l e s s e r of SI2 o r S z o .

dValue of S t a b u l a t e d i n Code T a b l e 1-9.1 f o r Fig.

a
1-9.2.
e
S is S a d j u s t e d f o r E = 2.83 x 107 p s i .
aa a
fProposed c u r v e A ( s e e t e x t ) .
actor of s a f e t y of 2 on s t r e s s c o n t r o l s .
 48

iron-chrome A l l o y 800, nickel-chrome-iron A l l o y 600, and nickel-chrome

A l l o y 718. One d a t a p o i n t a t 108 c y c l e s was i n c l u d e d . The h i g h - s t r e s s
d a t a p o i n t s were s t r a i n c o n t r o l l e d ; some of t h e l o w - s t r e s s d a t a p o i n t s
were l o a d c o n t r o l l e d . T e s t s were r u n a t v a r i o u s t e m p e r a t u r e s up t o
8000F. According t o L a n g e r D 3 t h e C r i t e r i a d a t a on 18-8 s t a i n l e s s s t e e l
i n c l u d e d t e s t s a t t e m p e r a t u r e s up t o 660OF.
The J a s k e and O'Donnell p a p e r g i v e s s e p a r a t e c u r v e s i n t h e form of
Eq. ( B . 1 ) f o r t h e 300 s e r i e s s t a i n l e s s s t e e l s , A l l o y 800, A l l o y 600, and
A l l o y 718. They found t h a t t h e 300 s e r i e s s t a i n l e s s s t e e l s , A l l o y 800,
and A l l o y 600 c o u l d be grouped t o g e t h e r f o r t h e purpose of d e s i g n guid-
ance. They t h e n a p p l i e d mean s t r e s s a d j u s t m e n t i n t h e form of Eq. ( B . 2 )
w i t h S = 94 k s i and S = 44 k s i . They u s e d E = 2.83 x 107 p s i r a t h e r
t h a n Eu= 2.6 x l o 7 psiy,, used i n Code F i g . 1-9.2. Numerical comparisons
f o r t h e t h r e e m a t e r i a l s and t h e combined t h r e e m a t e r i a l s a r e shown i n
T a b l e B.3.
For N l o 6 c y c l e s ( p r e s e n t Code c o v e r a g e ) , i t c a n be s e e n i n T a b l e
B.3 t h a t t h e J a s k e and O'Donnell d e s i g n f a t i g u e s t r e s s e s a r e g e n e r a l l y
lower t h a n t h e p r e s e n t Code ( a d j u s t e d f o r E. = 2.83 x l o 7 i n s t e a d of E =
2.6 x 1 0 7 ) . A s an e x t r e m e example, f o r 300 s e r i e s s t a i n l e s s s t e e l s a t
N = 2 x l o 5 c y c l e s , t h e Code a l l o w a b l e s t r e s s i s 1.39 t i m e s t h e J a s k e and
O'Donnell b e s t - f i t c u r v e . However, c o n s i d e r i n g t h e c o n s e r v a t i s m s t h a t
u s u a l l y e x i s t i n e s t i m a t i n g t h e o p e r a t i n g h i s t o r y and i n c a l c u l a t i o n of
s t r e s s e s , t h i s p o s s i b l e unconservatism i s r e l a t i v e l y small.
A t p r e s e n t ( J u l y 19821, a p r o p o s e d m o d i f i c a t i o n t o Code F i g . 1-9.2
i s under c o n s i d e r a t i o n by t h e ASME B o i l e r and P r e s s u r e V e s s e l Committee.
T h i s p r o p o s a l * m a i n t a i n s t h e p r e s e n t Code c u r v e f o r N A l o 6 c y c l e s .
Above N = lo', t h r e e c u r v e s , i d e n t i f i e d a s A, B, and C a r e proposed.
The A c u r v e i s simply an e x t r a p o l a t i o n of t h e p r e s e n t Code u s i n g t h e
equation

S = (84151% + 4 3 . 5 ) x (2.8312.60) .
V a l u e s a r e shown i n T a b l e B.2 on t h e two r i g h t columns f o r N 2 l o 6 .
The B c u r v e i s f a i r e d - i n between t h e p r e s e n t Code s t r e s s a t N = l o 6
and J a s k e and O'Donnell "combined" c u r v e , w i t h o u t any a d j u s t m e n t f o r mean
stress.
The C c u r v e i s f a i r e d - i n between t h e p r e s e n t Code s t r e s s a t N = 106
and t h e J a s k e and O'Donnell "combined" c u r v e , w i t h a d j u s t m e n t f o r t h e
maximum e f f e c t of mean s t r e s s . A comparison i s shown i n T a b l e B.3 on t h e
two r i g h t columns f o r N 2 l o 6 .
The q u e s t i o n a r i s e s a s t o which of t h e t h r e e p r o p o s e d c u r v e s i s most
a p p r o p r i a t e f o r p i p i n g e v a l u a t i o n i n c o n j u n c t i o n w i t h Eqs. (1) and ( 2 ) of
the text. The q u e s t i o n i s n o t t r i v i a l because f o r N = 1 0 8 , t h e C c u r v e
g i v e s s t r e s s e s t h a t a r e -60% of t h o s e from t h e A c u r v e . O p e r a t i o n a l cy-
c l e s t h a t add up t o 10' o r more do n o t come from t h e k i n d s of t r a n s i e n t s
n o r m a l l y c o n s i d e r e d i n t h e e v a l u a t i o n of p i p i n g . However, when v i b r a t i o n
o c c u r s , t h e number of c y c l e s c a n e a s i l y add up t o > l o 8 .
-----.-

*The p r o p o s a l i n c l u d e s t h e f o r m a l i s t i c s t e p of changing E from

2.6 x l o 7 t o 2.83 x l o 7 p s i ; hence p r e s e n t Code-tabulated s t r e s s e s f o r
F i g . 1-9.2 would be m u l t i p l i e d by 2.8312.60.
 49

Table B.3. Jaske and O'Donnell d e s i g n f a t i g u e s t r e s s e s

f o r high-alloy s t e e l s ( s t r e s s e s i n k s i )

300 Serie; d
A l l o y 800 A l l o y 600' Combined
st a i n l e s s e
N Code
Saf S a' 9 'a S a' 9 saf s;g saf S;g

lo 647 644 774 674 708

20 4 86 466 559 4 86 512
so 31 9 3 09 3 68 3 19 345
100 23 5 23 0 27 2 23 6 261
200 17 5 174 204 17 6 201
500 122 124 143 124 148
1000 95.8 99.0 113 97.1 119
2000 77 .o 81.3 91.2 78.3 96.9
5000 63.7 65.5 72.1 61.7 76.2.
1 x 104 51.9 57 .6h 62.4 53.3 64.2
2 104 45 .gh 49.5h 55.6h 47.4 55.5
5 104 38.5 38.4 42.8 36.8 46.3
30.2hh 32.8hh h 30.8hh
1 x 105 36 .Oh 40.8
2 x 105 25 .gh 28.8,, 31.2h 26 .7h 35.9
5 105 22.2 25.3 26.9 22.9 31.0
h h 24.8hh
1 x 106 20.3h 19.1 23 .Sh 21.1h 20.3 28.3
2 x 106 h
19.0h 17.0 22.3h 23 .3h 19.7h 18.1 22.8
5 x 106 17.8 15.3 21.2 20.5 21.9 21.9 18.6 16.3 18.4
h h h h
1 x 107 17.2h 14.5 20.6h 19.5 21.2h 20.6 18.0h 15.5 16.4
2 x 107 16.8,, 13.9 20.2h 18.9 20.8h 19.8 17.5h 14.9 15.2
5 x 107 16.4 13.4 19.9 18.3 20.3 19.1 17.2 14.4 14.3
h h h
1 x 10' 16.2h 13.2 19.7h 18.0 20.1h 18.7 17.0h 14.1 14.1
1 x 109 35.9 12.8 19.4h 17.5 19.gh 18.1 16.7 13.7 13 . 9
h h h
1 x 1010 15.gh 12.7 19.3h 17.4 19.7h 18.0 16.6h 13.6 13.7
1 x 1011 15.8 12.7 19.3 17.4 19.6 17.9 16.5 13.6 13.6
a
S = 9,081/l% + 31.59 ksi.
b S = 8 , 5 5 7 1 f i + 38.50 k s i .
C
S = 1 0 , 3 9 3 1 G + 39.2 k s i .
d S = 9,058/l% + 33.05 ksi.
e
From Table 1-9.1 f o r F i g . 1-9.2, m u l t i p l i e d by 28.3126.0 for E
change. For N > l o 6 , from proposed C c u r v e .
f L e s s e r of SI^ or s~,,.
9Adjusted f o r mean s t r e s s , Eq. ( B . 2 ) w i t h S = 94 k s i , S = 44 k s i .
U Y
hFactor of s a f e t y of 2 on s t r e s s c o n t r o l s .
 Because J a s k e and O'Donnell i n c l u d e c o n s i d e r a b l e d a t a i n t h e r a n g e
of l o c t o 108 c y c l e s and use a more complete s e t of d a t a t h a n t h e o r i g i -
n a l C r i t e r i a , t h e use of t h e proposed A c u r v e a p p e a r s q u e s t i o n a b l e .
The c h o i c e between t h e B and C c u r v e s depends o n w h e t h e r mean s t r e s s e s
w i l l e x i s t . Welds t h a t a r e n o t a n n e a l e d a f t e r w e l d i n g w i l l have y i e l d -
s t r e n g t h l e v e l s of r e s i d u a l s t r e s s . Futhermore, because of i n s t a l l a t i o n
m i s a l i g n m e n t s , i t would be d i f f i c u l t t o e s t a b l i s h t h a t any p a r t of a pip-
It
i n g system i s f r e e of mean s t r e s s a s i n s t a l l e d . " A c c o r d i n g l y , i t a p p e a r s
t h a t t h e C c u r v e s h o u l d be u s e d i n p i p i n g system f a t i g u e e v a l u a t i o n ( e . g . ,
f o r e v a l u a t i o n of p r e o p e r a t i o n a l t e s t i n g ) .

Temperature Dependence

The C r i t e r i a 1 does n o t i n d i c a t e what t e m p e r a t u r e s were i n v o l v e d i n

t h e f a t i g u e t e s t s . However, Langer3 i n d i c a t e s t h a t t e s t s a t tempera-
t u r e s up t o 6500F were i n c l u d e d f o r 18-8 s t a i n l e s s s t e e l s . J a s k e and
O'Donnell' i n c l u d e t e s t s a t t e m p e r a t u r e s up t o 800OF. Tbey c o n v e r t e d
s t r a i n s t o s t r e s s e s by u s i n g t h e f o l l o w i n g room t e m p e r a t u r e moduli:

300 s e r i e s s t a i n l e s s s t e e l s 28.3 x lo6 p s i

Alloy 800 27.6 x lo6 p s i
A l l o y 600 31.7 x lo6 p s i

They used E = 2.83 x l o 7 p s i i n t h e i r combined c u r v e . I n p r i n c i p l e , the

d e s i g n f a t i g u e c u r v e s a r e t e m p e r a t u r e dependent because E i s t e m p e r a t u r e
de pendent.
J a s k e 4 p r e s e n t s p o l i s h e d b a r , f a t i g u e t e s t d a t a on c a r b o n s t e e l
[American I r o n and S t e e l I n s t i t u t e (AIS11 10101, which s u g g e s t t h a t f a -
t i g u e s t r e n g t h i n c r e a s e s s l i g h t l y between 70 and 400°F, t h e n d e c r e a s e s
between 400 and 7000F. However, c o n s i d e r i n g t h e g e n e r a l o r d e r of accu-
r a c y i n v o l v e d i n t h e f a t i g u e e v a l u a t i o n s , i t a p p e a r s a p p r o p r i a t e t o con-
s i d e r d e s i g n f a t i g u e s t r e s s e s f o r c a r b o n s t e e l s t o be independent of t e m -
p e r a t u r e up t o 7000F e x c e p t a s m o d i f i e d by E.

References

1. American S o c i e t y of Mechanical E n g i n e e r s , " C r i t e r i a of t h e ASME

B o i l e r and P r e s s u r e V e s s e l Code f o r Design by A n a l y s i s i n S e c t i o n s
I11 and V I I I , D i v i s i o n 2," New York, 1969.

2. C. E. J a s k e and W. J. O'Donnell, " F a t i g u e Design P r o c e d u r e f o r Pres-

s u r e V e s s e l A l l o y s , " Trans. ASME, J . of Pressure VesseZ Technotogy
99(4) , 5%-f'S? (November 1977).

3. B. F. Langer, "Design of P r e s s u r e V e s s e l s f o r Low-Cycle F a t i g u e , "

ASME T r a n s , J. Basic Eng. 84(3), 389-402 (1962).

4, C. E. J a s k e , "Low-Cycle F a t i g u e of AIS1 1010 S t e e l a t Temperatures

It
up t o 1200F (649C1, Trans. ASME, J . of Pressure VesseZ Technology
99(3) , 432-443 (August 1977).
 51

Appendix C

COMPARISONS OF CARBON STEEL. AND AUSTENITIC STAINLESS

STEEL PIPING PRODUCT MOMENT FATIGUE TESTS

R e f e r e n c e s 1-3 g i v e r e s u l t s of moment f a t i g u e t e s t s on p i p i n g prod-

u c t s made of carbon s t e e l and t y p e 304 s t a i n l e s s s t e e l . The t e s t s were
s i m i l a r t o Markl’s t e s t s 4 i n t h a t d i s p l a c e m e n t s were c o n t r o l l e d . All
t e s t s were r u n on 6-in. nominal s i z e p r o d u c t s . R e s u l t s of t h e s e t e s t s
a r e summarized i n T a b l e C . l .
T a b l e C . l c o n t a i n s s i x s e t s of comparable r e s u l t s . Because t h e t e s t s
were r u n a t d i f f e r e n t nominal s t r e s s l e v e l s , t h e y have b e e n “ n o r m a l i z e d ”
by t h e urse of Eq. ( 9 ) t o o b t a i n i - f a c t o r s . The f a t i g u e s t r e n g t h , of
course, i s inversely proportional t o the i-factors. The l a s t column shows
average r a t i o s , i / i
c s
. I f t h i s r a t i o i s <1.00, i t means t h a t c a r b o n s t e e l
p r o d u c t s were s t r o n g e r t h a n t y p e 304 s t a i n l e s s s t e e l p r o d u c t s . I t can
be s e e n i n T a b l e C . l t h a t i c / i i s <1.00 f o r a l l s i x s e t s of d a t a .
S
T a b l e C.2 shows Code 1 c a r b o n s t e e l t o s t a i n l e s s s t e e l r a t i o s of fa-
t i g u e d e s i g n s t r e s s e s and t h e r a t i o s i m p l i e d by t h e d a t a i n T a b l e C . l . In
t h e r e g i o n of 10’ t o l o 4 d e s i g n c y c l e s , t h e K f a c t o r a d j u s t s t h e b a s i c
e
r a t i o s so a s t o be i n b e t t e r agreement w i t h T a b l e C . l . We have shown t h e
r a t i o s from T a b l e C . l a s a p p l y i n g t o N = l o 3 and l o 4 . Noting t h a t T a b l e
C.l i s related t o f a i l u r e cycles N whereas Code 1 d a t a a r e d e s i g n c y c l e s
N, t h e r a t i o s from T a b l e C . l might f more ’
a p p r o p r i a t e l y be t a k e n a s apply-
i n g t o N = 10’ and 10’. Also, t h e J a s k e and O’Donnel15 b a s e d a t a f o r
s t a i n l e s s s t e e l indicate carbon t o s t a i n l e s s r a t i o s closer t o unity ( s e e
Appendix B). However, t h e anomaly s t i l l e x i s t s : t e s t d a t a on p i p i n g
p r o d u c t s i n d i c a t e c a r b o n s t e e l i s s t r o n g e r t h a n s t a i n l e s s s t e e l , whereas
Code 1, even w i t h t h e K a d j u s t m e n t , g e n e r a l l y i n d i c a t e s t h e o p p o s i t e .
e
While t h e p r e c e d i n g c o n s t i t u t e s t h e main r e a s o n f o r i n c l u d i n g t h i s
Appendix, t h e f o l l o w i n g i s a more d e t a i l e d d i s c u s s i o n of T a b l e C . l .

G i r t h B u t t Welds

11
Markl’s t e s t s ‘ were on t y p i c a l ” g i r t h b u t t w e l d s i n 4.5-in.-OD by
0.237-in.-wall p i p e . T a b l e C . l t e s t s were on g i r t h b u t t w e l d s i n 6.625-
in.-OD p i p e w i t h 0.280-, 0.432-, o r 0.718-in.-wall p i p e . D e t a i l s of t h e
welds a r e not a v a i l a b l e . That the i - f a c t o r s a r e c l o s e t o u n i t y i n d i c a t e s
t h a t Markl’s i = 1.0 i s r a t h e r b r o a d l y a p p l i c a b l e .

Elbows

The Code 2 i - f a c t o r f o r 6.625-in.-OC by 0.280-in.-wall by 6-in.-bend

r a d i u s elbows i s

i = 0.9(r2/tR)’/’ = 0.9(3.17252/0.280 x 6)’” = 2.97 . (C.1)

 52

Table C.l. Comparisons of c a r b o n s t e e l w i t h a u s t e n i t i c

s t a i n l e s s s t e e l p i p i n g p r o d u c t c y c l i c moment f a t i g u e
t e s t s ( d a t a from Refs. 1-3)

a c
Product Test b
identity
Material
Nfe if i c / i s9

4 0 Weld HW-1 C 58.2 35,740 1.03

Hw-3 A S 61.1 6,950 1.37 0.75
1 6 0 We1 d CC-160-1 C 101.6 7,456 0.81
p = 1050 p s i CS-160-1 S 95.8 7,724 0.85 0.95
80 Weld Hw-15 C 117.6 3,209 0.83
5500F HW-14 C 97.3 7,278 0.95
HW-12 S 93.8 2,894 1.06
Hw-11 S 64.2 14,858 1.12
Hw-10 S 79 .O 9 ,200 1.oo 0.84
40 SR Elbow CCLS-1 C 43.6 1,176 2.73
p = 1050 p s i CCL s- 2 C 42.6 7,899 1.91
CSLS-1 S 42.2 6,838 1.99
CSL s- 2 S 44.2 907 2.84 0.96
40 SR Elbow HCL S- 1 C 43.5 7 60 2.99
550°F HCLS-2 C 43.1 26,100 1.49
HSLS-1 S 28 .O 2,200 3.75
HSLS-2 S 42.2 1,870 2.57 0.71
40 6 x 6 Tee cas-1 C 68.2 21,079 0.98
cas-2 C 70.6 9,367 1.11
CSTS-1 S 68.7 4,575 1.32
CSTS-2 S 67.8 3.3 1 0 1.43
CSTS-3 S 72.7 3,675 1.30 0.77
~ -
a40 Weld: g i r t h b u t t w e l d i n sched.-40 p i p e ; 160 weld: g i r t h
b u t t w e l d i n sched.-160 p i p e ; 80 Weld: g i r t h b u t t weld i n sched.-80
p i p e ; 40 SR elbow: sched.-4O s h o r t r a d i u s ( R 6 in.) elbow, 6-in.
nominal s i z e ; 40 6 x 6 t e e : sched.-40 ANSI B19.9 t e e , moment t h r o u g h
b r a n c h . U n l e s s o t h e r w i s e i n d i c a t e d , t e s t s were r u n a t room t e m p e r a t u r e
with zero internal pressure. Moments were "in-plane" f o r b o t h elbows
and t e e s .
b I d e n t i f i c a t i o n s used i n R e f s . 1-3.
C
C: c a r b o n s t e e l , SA106 Grade B; S : s t a i n l e s s s t e e l , SA312
t y p e 304.
dSf = M/Z, M = moment r a n g e ( c o m p l e t e l y r e v e r s e d ) .
e
Nf = c y c l e s t o f a i l u r e (through-wall crack).

f i = 490/(S Sf i n ksi [ s e e Eq. ( 9 1 1 .

f f
g i = a v e r a g e of i s f o r c a r b o n s t e e l ; i = a v e r a g e of i s f ' o r
s t a i n l e Cs s s t e e l . S
 53

T a b l e C.2. Code 1 r a t i o s of f a t i g u e
design s t r e s s e s f o r carbon s t e e l
and a u s t e n i t i c s t a i n l e s s s t e e l

Ratios
b
With Ke a d j u s t m e n t
Basic From
a
curves ICz = 1 Kz = 2 Table C . l

10 0.89 0.60' 0.76'

lo2 0.85 0.88' 1.05
103 0.76 1.oo 0.96 1.04 t o 1.41
d
104 0.64 0.91 0.64 1.04 t o 1 . 4 1
d
10s 0.53 0.64 0.53
d
106 0.48 0.48 0.48
a
R a t i o s o b t a i n e d from Code 1 T a b l e 1-9.1;
Fig. 1-9.1, UTS 80 k s i f o r c a r b o n s t e e l ;
Fig. 1-9.2 f o r a u s t e n i t i c s t a i n l e s s s t e e l .
bRatioa a r e s p e c i f i c a l l y f o r SA106 Grade B a t
l O O O F t o SA312 type 304 a t 10O0F.
C
S
n
> 3mS f o r one o r b o t h m a t e r i a l s .
m
dS
n
< 3Sm f o r one or b o t h m a t e r i a l s .

Table C . l i n d i c a t e s t h a t t h e a v e r a g e v a l u e of i i s 2.53, about 85% of

t h e v a l u e given by Eq. ( C . 1 ) . T h i s i s e s s e n t i a l l y t h e same a s M a r k l ' s
in-plane moment r e s u l t s f o r 4.5-in.-OD by 0.072- or 0.241-in.-wall,
cl-in.-bend r a d i u s elbows; t h a t i s , t h e e x p e r i m e n t a l i was a b o u t 0.85
t i m e s t h e i g i v e n by Eq. ( C . 1 ) . T h i s s l i g h t r e d u c t i o n from " t h e o r e t i c a l "
i s deemed t o be m a i n l y caused by end e f f e c t s of t h e p i p e s welded t o t h e
elbows.

-
Tees

The Code 2 i - f a c t o r f o r 6.625-in.-OD by 0.280-in.-wall, f u l l outlet

ANSI B16.9 t e e i s

i = 0.9(r/4.4t)z'3 = 0.9(3.1725/4.4 x 0 . 2 8 0 ) 2 ' 3 = 1.69 . ((2.2)

 54

T a b l e C.l i n d i c a t e s t h a t t h e a v e r a g e v a l u e of i is 1.23, about 73% of t h e

v a l u e g i v e n by Eq. (C.2). M a r k l ' s r e s u l t s gave i - f a c t o r s f o r in-plane
moments r a n g i n g from 78 t o 103% of i g i v e n by Eq. (C.2), t h e r a t i o de-
pending on d e t a i l s such a s t h e t r a n s i t i o n r a d i i and w a l l t h i c k n e s s e s of
the tees.

References

1. J. D. Heald and E. Kiss, "Low Cycle F a t i g u e of P r o t o t y p e Pipe Com-

p o n e n t s , " General E . l e c t r i c (San J o s e ) R e p o r t GEAP-10763 ( J a n u a r y
1973).

2. E. Kiss, J. D. Heald, and D. A. Hale, "Low-Cycle F a t i g u e of P r o t o t y p e

P i p i n g , " General E l e c t r i c (San J o s e ) R e p o r t GEAP-10135 ( J a n u a r y 1970).

3. J. D. Reald and E. Kiss, "Low Cycle F a t i g u e of N u c l e a r Pipe Compo-

n e n t s , " Trans. ASME, J. of Pressure Vessel Technology 96(3), 171-176
(August 1974).

4. A. R. C. Markl, " F a t i g u e T e s t s of P i p i n g Components," Trans. ASME 7 4 .

287-303 (1952).

5. C. E. J a s k e and W. J. O'Donnell, " F a t i g u e Design P r o c e d u r e f o r Pres-

s u r e V e s s e l A l l o y s , " Trans. ASME, J. of Pressure Vessel Technology
99(4), 584-592 (November 1977).
 55

NUREG / CR-3 243

O W /Sub/82-22252/1
D i s t . Category AN

Internal Distribution

1. C. R. B r i n h a n 13. C. E. Pugh
2. J. A. C1 h a r d 14. E. E. Trammel1
3. J. M. Cor um 15. G. D. Whitman
4. D. S. G r i f f i t h 16-20. G. T. Yahr
5. R. C. Gwal t n e y 21-24. S t r u c t u r a l Design C r i t e r i a ,
6. F. J. Homan 9204-1, MS 11
7. R. L. Huddl e st on 25. ORNL P a t e n t O f f i c e
8. Y. L. L i n 26. C e n t r a l Research L i b r a r y
9. A. I,. L o t t s 27. Document R e f e r e n c e S e c t i o n
10. s. s. Manson ( C o n s u l t a n t 1 28-29. L a b o r a t o r y Records Department
11. W. J. McAf e e 30. L a b o r a t o r y Records (RC)
12. S. E. Moor e

External Distribution

31. O f f i c e of A s s i s t a n t Manager for Energy R e s e a r c h and Development,

Department of Energy, ORO, Oak Ridge, TN 37830
32-33. T e c h n i c a l I n f o r m a t i o n C e n t e r , DOE, Oak Ridge, TN 37830
34-133. Given d i s t r i b u t i o n a s shown under c a t e g o r y AN (NTIS-10)
134-233. S p e c i a l ASME Code D i s t r i b u t i o n (by NRC)
NRC
I11 811 335 U.S. NUCLEAR REGULATORY COMMISSION
BIBLIOGRAPHIC DATA SHEET
I
1. REPORT NUMeEA /Asslgnedby DOC/
NUREG/CR-3243
ORNL/Sub/82-2225211
II
T I T L E A N D S U B T I T L E (Add Volume NO.,1 f e ~ p r o p r t 8 r e /
Comparisons of ASME Code Fatigue Evaluation Methods for [2 (Leave blank/

Nuclear Class 1 Piping with Class 2 or 3 Piping

3. RECIPIENT'S ACCESSION NO.

7. A U T H O R 6 1 E. C. Rodabaugh 5. D A T E REPORT COMPLETED

MONTH YEAR
March 1983
1. P E R F O R M I N G O R G A N I Z A T I O N N A M E A N D M A I L I N G ADDRESS (Include Z I P Code) D A T E REPORT ISSUED
E. Rodabaugh Associates, Inc.
C. MONTH YEAR
4625 Cemetery Road
Hilliard, Ohio 43026 6 (Leave bldnkl

8 . (Leave b lank]
12. SPONSORING O R G A N I Z A T I O N N A M E A N D M A I L I N G ADDRESS (Include Z l p Codel
10 P R O J E C T i T A S K l W O R K U N I T N O
Division of Engineering Technology
Office of Nuclear Regulatory Research
1 1 . FIN NO.
U.S. Nuclear Regulatory Commission
Washington, DC 20555
13. TYPE OF REPORT
I
I

PE R l O D C O V E R E D /Inclusive dares)

Topical

15 SUPPLEMENTARY NOTES 14 (Leave o lank)

16. A B S T R A C T (200 words or less)

The fatigue evaluation procedure used in the ASME Boiler and Pressure Vessel
Code, Section 111, Nuclear Power Plant Components, for Class 1 piping is different
from the procedure used for Class 2 or 3 piping. The basis for each procedure is
described and correlations between the two procedures are presented. Conditions
under which either procedure, or both, may be unconservative are noted.

Potential changes in the Class 2 or 3 piping procedure t o explicitly cover all

loadings are discussed. However, the report is intended to be informatory and,
while the contents of the report may guide future Code changes, specific recommenda-
tions are not given herein.

I 7 K E Y WORDS A N D D O C U M E N T A N A L Y S I S 1 7 a DESCRIPTORS

1711 I D E N T I F I E R S OPEN E N D E D TERMS

8 A V A l L A B I Ll TY S T A T E M E N T I9 SECURITY CLASS (ThtsrepOrrl 2 1 N O OF P A G E S

Unlimited Unclassified
20 SECURITY CLi\ S /Th,sDaye/ 22 PRICE
Unc lassi?ied S