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1 Executive Summary
GD Tech commissioned its branch AP Dynamics to perform a Finite Element Analysis (FEA) of the
vessel cap component of the ITMRR000086 reactor vessel fabricated by AutoClave France for Total
Energy.
AP Dynamics and GDTech have previously completed the analysis of the pressure boundary of the
reactor using PV Elite to verify conformance of the reactor pressure vessel design when considering a
higher design temperature of 200 °C (from 150 °C). The vessel cap was not evaluated since it does not
fit any standard components covered by ASME Section VIII Division 1.
The purpose of the FEA is to determine the maximum stresses on the vessel cap under design
conditions for comparison against the calculated allowable design stresses for the materials of
construction as per ASME Section VIII Division 2 Part 5, Design by Analysis requirements. The
assessment covers a check against the following failure modes using the elastic-plastic stress analysis
method:
a) Protection against plastic collapse.
b) Protection against local failure.
c) Ratchetting assessment.
The analysis results presented in this technical memo demonstrate that the design of the vessel cap
component is compliant with the requirements of ASME Section VIII Division 2 Part 5 for protection
against the above failure modes.
In addition, an assessment of the quick disconnect collar in accordance to ASME Section VIII Division 1
Appendix 24 is also presented in Section 5. It is demonstrated that the collar design satisfies the
requirements of the code in terms of bolting and design stresses under the new design conditions.
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2 Model Parameters
2.1 Geometry
GD Tech generated a 3D CAD model of the vessel cap and provided this to AP Dynamics in a STEP file
format (coming from the project STR/2022/TOTAL/002). The STEP file was imported into ABAQUS
CAE for pre-processing. Figure 1 illustrates a cross-section of the reactor vessel, highlighting the vessel
cap considered in the analysis. Some discrepancies were found between the drawing received by the
customer and the result of the scanning of the component. The dimensions from the scanned 3D model
and the drawings of GDTech in project STR/TOTAL/2022/002 have been used. Figure 2 shows the FE
model geometry used for the vessel cap analysis.

Figure 1: Reactor Vessel Cross-Section

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Figure 2: Vessel Cap Model Geometry

2.2 Geometry Simplifications
The following simplifications to the geometry have been made in the FE models:
a) All chamfers at the bolt locations were omitted.
b) O-ring/gasket groove at the central bore was omitted.
2.3 Materials
From drawing A-555366 in the ITMRR00086 package, the material for the vessel cap is specified to be
316L. Material properties for 316L (Alloy Designation: S31603) at 200 °C was obtained from ASME
Section II Part D, with the referenced tables summarized below:
a) Material Density and Poisson’s Ratio: High Alloy Steel (300 Series) from Table PRD.
b) Elastic Modulus: Material Group G from Table TM-1.
c) Coefficient of Thermal Expansion: Material Group 3A from Table TE-1.
d) Material Plasticity: True Stress-Strain curve derived for 316L material at 200 °C using the
Ramberg-Osgood equation (see Figure 3).
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Figure 3: True Stress-Strain Curve for 316L at 200 °C

2.4 Boundary Conditions

The boundary conditions used in the FE models are summarised below:
a) Encastre boundary condition at the cap face in contact with the vessel clamp.
b) A predefined temperature of 200 °C applied to the whole model.

Figure 4: Vessel Cap Face in Contact with Clamp

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2.5 Loads
2.5.1 Load Cases
Elastic-plastic stress analysis was performed to evaluate the vessel cap for protection against plastic
collapse and local failure. This method provides a more accurate assessment because the actual
structural behaviour of the component is more closely approximated. The redistribution of stress that
occurs as a result of plasticity and deformation characteristics of the component are considered
directly in the analysis.
ASME Section VIII, Division 2 Part 5 requires the consideration of the load case combinations and load
factors when using the elastic-plastic analysis approach (see Figure 5). The following load case
combinations are considered in the analysis:
a) Plastic Collapse Assessment: β(P+ Ps + D).
b) Local Failure Assessment: 1.7(P+ Ps + D).
In both cases, Ps is zero. D is the dead load on the vessel cap and will be due to the self-weight of the
vessel cap and the weight of the magnetic drive-spindle assembly. The weight of the magnetic drive-
spindle assembly is unknown therefore a conservative estimated weight of 24.8 Kg, similar to the
empty weight of the reactor vessel, was used. β is defined as 3.0 for a Class 1 vessel design factor.

Figure 5: Load Case Combinations and Load Factors for an Elastic-Plastic Analysis.
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2.5.2 Temperature & Pressure Loads

The temperature of all parts has been increased to 200 °C in accordance with the specified design
conditions.
Pressure load have been applied to the wetted surfaces of the vessel cap as shown in Figure 6. As the
vessel cap have multiple bores to accommodate the shaft and bolts, additional end cap loads are
applied at these locations to simulate the vessel in a sealed condition. A summary of the additional
loads is presented below:
a) An end cap pressure load applied at the central bore (see Figure 7).
b) Surface traction loads applied at the slanted threaded bolt holes, including the offset bolt hole
(see Figure 7) to represent loading at the bolt threads due to pressure.
A pressure load based on an initial value 6 MPa was used in the analysis as per the design conditions of
the vessel. A factor of 3.0 and 1.7 was applied to the nominal pressure value for the plastic collapse and
local failure load cases respectively, as per Table 5.5 of ASME Section VIII Part 5.
Appropriate scale factors were applied to the nominal pressure value for the end cap and surface
traction loads based on the ratio of the bore cross-sectional area and the applied surfaces.

Figure 6: Pressure Wetted Surface (Highlighted in Green)

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Figure 7: End Cap Pressure Load and Surface Traction Load Locations
2.5.3 Dead Loads
The dead load on the vessel cap will be due to the self-weight of the vessel cap and the weight of the
magnetic drive-spindle assembly (see Figure 8). The self-weight of the vessel cap is included by
applying a gravity body load to the model. The total weight of the magnetic drive-spindle assembly is
unknown therefore an estimate was assumed based on the total empty weight of the reactor vessel.
This is expected to be conservative.
A nominal weight of 243.2 N was calculated based on an assumed mass of 24.8 kg. The mass of 24.8 kg
was derived from the PV Elite model total mass for the inner and outer cylindrical shells. The load was
applied at the interface between the spindle assembly and the vessel cap as shown in Figure 9.

Figure 8: Vessel Assembly

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Figure 9: Dead Load Application

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3 Acceptance Criteria
3.1 Protection against Plastic Collapse
Protection against plastic collapse is evaluated by determining the plastic collapse load of the
component using an elastic-plastic stress analysis. The allowable on the component is established by
applying a design factor to the calculated plastic collapse load.
The plastic collapse load is the load that causes overall structural instability due to formation of plastic
hinges. This point is indicated by the inability to achieve an equilibrium solution for a small increase in
load. In the FEA, this means that if the analysis fails to converge, it is indicative that the plastic collapse
load was reached and therefore the component being assessed is considered to have failed the
evaluation for protection against plastic collapse.
3.2 Protection against Local Failure
Protection against local failure is evaluated using Equation 5.6 in Paragraph 5.3.3.1 of ASME Section
VIII Division 2, Part 5 below:
𝜀𝑝𝑒𝑞 + 𝜀𝑐𝑓 ≤ 𝜀𝐿
Where the variables above are defined as:
a) 𝜀𝑝𝑒𝑞 is the equivalent plastic strain calculated in the model.
b) 𝜀𝑐𝑓 is the forming strain which is based on the material and fabrication method in accordance
with Part 6. This is defined as zero in this case as the vessel cap was machined.
c) 𝜀𝐿 is the triaxial strain limit, calculated using the following equation:
𝛼𝑠𝑙 𝜎1 + 𝜎2 + 𝜎3 1
𝜀𝐿 = 𝜀𝐿𝑢 ∙ 𝑒𝑥𝑝 [− ( ) ({ } − )]
1 + 𝑚2 3𝜎𝑒 3
𝜎1 + 𝜎2 + 𝜎3 are the principal stresses and 𝜎𝑒 is the equivalent stress defined by the following
equation:
1
𝜎𝑒 = [(𝜎1 − 𝜎2 )2 + (𝜎2 − 𝜎3 )2 + (𝜎3 − 𝜎1 )2 ]0.5
√2
The values used for 𝜀𝐿𝑢 , 𝛼𝑠𝑙 and 𝑚2 are determined from Table 5.7 in ASME Section VIII Division 2,
Part 5 (see Figure 10), for “Stainless steel and nickel base alloys” and are as follows:
a) 𝜀𝐿𝑢 = 1.009
b) 𝛼𝑠𝑙 = 0.600
c) 𝑚2 = 0.487
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Figure 10: Uniaxial Strain Limit for Use in Multiaxial Strain Limit Criterion
3.3 Ratchetting Assessment
Protection against ratchetting is evaluated by the application, removal, and re-application of the
applied loadings. The ratcheting criteria is evaluated after a minimum of three complete repetitions of
the loading cycle. The criteria for protection against ratchetting is provided below:
a) There is no plastic action (i.e. zero plastic strains incurred) in the component.
b) There is an elastic core in the primary-load-bearing boundary of the component.
c) There is not a permanent change in the overall dimension of the component.
A screening criterion is considered in the analysis wherein if the maximum von Mises stress in the
vessel cap is shown not to exceed yield at nominal load magnitudes (as opposed to the factored values
used in the analysis), then ratchetting is not considered an issue. This is because ratchetting failure is
due to cumulative plastic strain. If yield is not reached, then plastic deformation does not occur. In this
scenario, the application of the loading cycle stated in the code is deemed to be not necessary.
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4 Results
4.1 Protection against Plastic Collapse
Analysis convergence was reached with the specified load combinations and factors for evaluating
plastic collapse (see Section 2.5.1). Figure 11 shows the summary of the completed analysis. It is
demonstrated that the analysis progressed smoothly without having to cut-back in time step. As
convergence was reached, it means that the plastic collapse load was not reached and therefore failure
due to plastic collapse will not occur under the specified design conditions considered in the analysis.

Figure 11: Analysis Summary for Plastic Collapse Analysis

4.2 Protection against Local Failure
Figure 12 illustrates a plot of the ratio between the calculate triaxial strain limit, 𝜀𝐿 in Section 3.2 and
the equivalent plastic strains, 𝜀𝑝𝑒𝑞 in the model. It is shown that the highest ratio is 1.0E-04. This is
well below unity and therefore it is demonstrated that failure of the vessel cap due to local failure will
not occur.
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Figure 12: Strain Limit Ratio

4.3 Protection against Ratchetting
Figure 13 illustrates a plot of von Mises stress in the model at a step time of 0.35 s when the applied
load is equal to the nominal load magnitude (as opposed to the factored loads). It is shown that the
maximum von Mises stress at this time is 76.1 MPa which is below the yield stress for 316L (121 MPa
at 200 °C). This demonstrates that there is no plastic action and therefore failure due to ratchetting
will not occur.

Figure 13: Von Mises Stress Plot

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5 Collar Assessment
5.1 Introduction
An assessment of the quick disconnect collar (see Figure 14) to ASME Section VIII Division 1 Appendix
24. The quick disconnect collar clamps the cap to the shell of the reactor vessel as shown in Figure 1. A
previous assessment of the collar design is presented in the ITMRR000086 document package that was
provided to AP Dynamics. The previous assessment considers the collar under a design temperature of
150 °C. The new assessment presented in this report will consider a higher design temperature of
200 °C as per the client requirements.

Figure 14: Quick Disconnect Collar

5.2 Clamp Connection Design
The rules provided in Appendix 24 of ASME Section VIII Division 1 apply specifically to the design of
clamp connections for pressure vessels and vessel parts. The design of the clamp connection involves
the selection of the gasket, bolting, hub and clamp geometry. All calculations performed shall be made
based on dimensions in the corroded condition. The input parameters for the calculations are taken
from the document ITMRR000086 provided by the client.
5.2.1 Bolting Design Criteria
Bolting shall be selected to satisfy the requirements in Paragraph 24-4 in Appendix 24. The minimum
required total bolt load for the following items are calculated to derive the design bolt load required
for the clamp connection.
a) Bolt load for the operating condition, Wm1 (see Equation 5.1).
b) Bolt load for gasket seating, Wm2 (see Equation 5.2).
c) Bolt load for the assembly, Wm3 (see Equation 5.3).
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𝑊𝑚1 = 0.637(𝐻 + 𝐻𝑝 ) tan(∅ − 𝜇) [𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 5.1]

𝑊𝑚2 = 0.637𝐻𝑚 tan (∅ + 𝜇) [𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 5.2]
𝑊𝑚3 = 0.637(𝐻 + 𝐻𝑝 ) tan(∅ + 𝜇) [𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 5.3]
The total cross-sectional area of bolting AmL required shall be the greater of the values calculated for
the bolt loads above as follows:
𝑊𝑚1
𝐴𝑚1 = [𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 5.4]
2𝑆𝑏
𝑊𝑚2
𝐴𝑚2 = [𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 5.5]
2𝑆𝑎
𝑊𝑚3
𝐴𝑚3 = [𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 5.6]
2𝑆𝑎
Where Sa and Sb are the allowable bolt stresses at room and design temperatures respectively.
The bolt load required for the clamp connection shall be the values obtained from Equation 5.7 and
Equation 5.8.
Operating Conditions:
𝑊𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 𝑊𝑚1 [𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 5.7]
Assembly Conditions:
𝑊𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 = (𝐴𝑚𝐿 + 𝐴𝑏𝐿 )𝑆𝑎 [𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 5.8]
Where AbL is the total cross-sectional area of the bolts per clamp lug using the smaller of the root
diameter of the thread or least diameter of unthreaded portion. The required bolting cross-sectional
areas in Equation 5.8 are calculated to be:
a) 𝐴𝑚𝐿 = 105.5 mm2.
b) 𝐴𝑏𝐿 = 227.0 mm2.
Based on the geometry of the collar sub-assembly and the specified conditions, the total required bolt
load for the operating and assembly conditions are calculated below:
𝑊𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 13.21 𝑘𝑁
𝑊𝑎𝑠𝑠𝑒𝑚𝑏𝑙𝑦 = 59.84 𝑘
5.2.2 Clamp and Hub Design Criteria
It shall be demonstrated that the calculated stresses in the clamp and hub in accordance with
Paragraphs 24-6 and 24-7 do not exceed the allowable stresses specified in Table 24-8 in Appendix 24
(see Figure 15).
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Stress category S1 to S4 are related to hub stresses whilst S5 to S9 are related to clamp stresses.

Figure 15: Allowable Design Stress for Clamp Connections

The calculated nominal allowable design stresses SAC, SAH, SOC, and SOH are shown in Table 1. The
material of construction used for the hub and clamp are as follows:
a) Hub: EN 10088-3 X2 Cr Ni Mo 17-12-2 (1.4404).
b) Clamp: EN 10088-3 X4 Cr Ni Mo 16-5-1 (1.4418).
Table 1: Calculated Allowable Design Stress for Clamp Connections

Design Stress Allowable Stress (MPa)

SAC 141.6
SAH 99.4
SOC 300.0
SAH 300.0

The assembly condition is defined as:

a) Temperature: 20 °C.
b) Pressure: Atmospheric.
The operating condition is defined as:
a) Temperature: 200 °C.
b) Pressure: 60 bar.
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The calculated allowable stress for each category in Figure 15, based on an assembly condition
(at 20 °C) and at the operating condition (at 200 °C) is presented in Table 2.
Table 2: Calculated Allowable Design Stress for Clamp Connections
Stress (MPa)
Stress Category Assembly Operating
(20 °C) (200 °C)

S1 212.3 149.1
S2 99.4 99.4
S3 113.3 79.5
S4 113.3 79.5
S5 450.0 450.0
S6 450.0 450.0
S7 240.0 240.0
S8 300.0 300.0
S9 159.0 159.0

The hub moments used to determine the hub stresses are provided as follows:
For the operating condition, the design moment Mo is the sum of the six individual moments MD, MG,
MT, MF, MP and MR, as defined in Paragraph 24-3 in Appendix 24 of ASME Section VIII Division 1. The
bolt load used in the moment calculations is Woperating, as defined in Section 5.2.1.
For the assembly condition, the design moment Mo is based on Equation 5.9 below, using the bolt load
Wassembly, as defined in Section 5.2.1.
0.785𝑊(𝐶 − 𝐺)
𝑀𝑂 = [𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛 5.9]
tan (∅ + 𝜇)

The calculation of the hub stresses shall be determined for both the operating and the assembly
condition and are calculated from the following equations:
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The calculation of the clamp stresses shall be determined for both the operating and the assembly
condition and are calculated from the following equations:

In addition, a bearing stress calculation shall be made at the clamp-to-hub contact using the following
equation:
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5.2.2.1 Assessment Result

Table 3 presents the comparison of the calculated hub and clamp stresses against each of the stress
categories (see Figure 15). It is demonstrated that the design of the collar satisfies the requirements of
Appendix 24 of ASME Section VIII Division 1.
Table 3: Assessment of Hub and Clamp Stresses
Assembly Condition Operating Condition
Stress (Stress, MPa) (Stress, MPa)
Status Status
Category
Allowable Calculated Allowable Calculated
S1 212.3 88.1 Pass 149.1 105.4 Pass
S2 99.4 0.0 Pass 99.4 38.9 Pass
S3 113.3 43.5 Pass 79.5 27.6 Pass
S4 113.3 11.6 Pass 79.5 11.7 Pass
S5 450.0 114.8 Pass 450.0 72.8 Pass
S6 450.0 80.0 Pass 450.0 17.7 Pass
S7 240.0 54.9 Pass 240.0 34.9 Pass
S8 300.0 N/A1 - 300.0 N/A1 -
S9 159.0 42.9 Pass 159.0 27.2 Pass
[1] In
accordance with the extant calculation in document ITMRR000086, the clamp lug bending
stress S8 is not considered applicable.
It should be noted the clamp design comprises of more than two circumferential segments and does
not encompass the full circumference of the hub geometry. As such, a correction factor was applied to
the nominal results for S5 to S9 to increase the clamp stresses in accordance with the extant calculation
presented in ITMRR000086. The correction factor is based on the number of clamp sections and the
sectional angle covered by one clamp (47°) was calculated as follows:
360°
𝐹𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 = = 1.91
4 ∗ 47°
Table 4 presents the clamp stresses with the correction factor applied. It is demonstrated that the
clamp stresses are still within the allowable limits for the relevant stress categories.
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Table 4: Corrected Clamp Stresses

Assembly Condition Operating Condition
Stress (Stress, MPa) (Stress, MPa)
Status Status
Category
Allowable Calculated Allowable Calculated
S5 450.0 219.7 Pass 450.0 139.4 Pass
S6 450.0 153.3 Pass 450.0 33.8 Pass
S7 240.0 105.2 Pass 240.0 66.8 Pass
S8 300.0 N/A1 - 300.0 N/A1 -
S9 159.0 82.1 Pass 159.0 52.1 Pass

5.2.3 Additional Verifications for an Articulated Clamp

Additional verification for the clamp in terms of stress in link and the pure shear of axis was performed
in accordance with the extant calculations in ITMRR00086 document package. Table 5 presents the
results of the calculations. It is demonstrated that the clamp design is within the allowable for the
stress components considered.
Table 5: Additional Verification for Clamp
Assembly Condition Operating Condition
Component (Stress, MPa) Status (Stress, MPa) Status
Allowable Calculated Allowable Calculated
Stress in
300.0 213.7 Pass 300.0 47.2 Pass
Link
Pure Shear
150.0 117.6 Pass 150.0 26.0 Pass
of Axis
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6 Bibliography
ASME. (2017). ASME Boiler and Pressure Vessel Code Section VIII Division 2. New York: The American
Society of Mechanical Engineers.
ASME. (2021). ASME Boiler and Pressure Code, Section VIII Division 1: Rules for Construction of Pressure
Vessels. New York: The American Society of Mechanical Engineers.
ASME. (2021). ASME Boiler and Pressure Vessel Code, Section II: Materials - Part D: Properties. New
York, NY: The American Society of Mechanical Engineers.

6.1 Client Supplied References

1. ITMRR000086_00.PDF - Document package for drawings and documents relevant to the
reactor vessel.
2. couvercle.STEP – 3D model of the reactor vessel cap.
3. R-82000 Vessel Internal Vessel_Rev5(200°C) – Outer Shell.pv – PV Elite model of the outer
shell.
4. R-82000 Vessel Internal Vessel_Rev5(200°C).pv – PV Elite model of the inner shell.
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7 Approvals
Results provided in this document are preliminary. Final results with a professional engineer’s seal
will be provided as part of the full stress analysis report.

Rev Date Description By Reviewed Approved

0 2023-JAN-17 Issued for Use DDC JH JH

Jan 17, 2023

Prepared by: Date:
Name: Dency Dela Cruz
Title: Stress Engineer

Jan 17, 2023

Reviewed by: Date:
Name: Jaspreet Hothi
Title: Stress Engineering
Manager

Jan 17, 2023

Approved by: Date:
Name: Jaspreet Hothi
Title: Stress Engineering
Manager

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