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DISCLAIMER

CONF-870917—3
DE87 014413
This report was prepared as an account of work sponsored by an agency of the United States
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and opinions of authors expressed herein do not necessarily state or reflect those of the
United States Government or any agency thereof.

RECOMMENDED PRACTICES IN ELEVATED TEMPERATURE DESIGN:


A COMPENDIUM OF BREEDER REACTOR EXPERIENCES (1970-1986)

AN OVERVIEW**

B. C. Wei*
W. L. Cooper, Jr.
A. K. Dhalla0

I. INTRODUCTION | This paper shall present an overview and


I describe the highlights of the work. Given
below are excerpts from works in Chapters 2-9.
Significant experiences have been accumu- I
lated in the establishment of design methods j
II. PRELIMINARY DESIGN PROCEDURE
and criteria applicable to the design of Liquid!
Metal Fast Breeder Reactor (LMFBR) components. \
Experience in the LMFBR program has shown
The Subcommittee of the Elevated Temperature
that, if early in the program, a viable pre-
Design under the Pressure Vessel Research .
liminary design and analysis effort is not
Council (PVRC) has undertaken to collect, on an
existent, serious technical problems Might have
international basis, design experience gained,
been overlooked. When these problems are
and the lessons learned, to provide guidelines
eventually recognized la'.sr, they can be most
for next generation advanced reactor designs. ;
difficult, if not impossible, to solve. These
The complete work consists of ten chapters problems result in cost overruns, schedule
and five appendices as follows: slippage, and, in the extreme, can jeopardize
the success of the program. Many of these
Ch. 1. Introduction problems can be eliminated or minimized in
2. Preliminary Design Procedures their impact by a proper preliminary design
3. Simplified Methods effort.
A. Detailed Inelastic Analysis
5. Simplified Stress Classification In order to develop the preliminary design [
Procedure procedure for elevated temperature design, the I
6. Elevated Temperature Design Codes following items are included as recommended f
7. Fracture Mechanics practices: j
8. Nonlinear Collapse
9. Current Issues and Future Directions ,o Document Review j
in Elevated Temperature Design
10. Summary o Developing Structural Evaluation Flan
I
App. A. Breeder Reactor Components and Design i o Design and Analysis Guidelines OP
Specifications j c:
B. Capabilities of General Purpose Finite: o Load Controlled Elastic Analysis
Element Computer Programs |
C. Example of Detailed Inelastic Analysis; o Deformation Controlled Elastic Analysis
of a Pressure Vessel Component j
D. Example of Detailed Inelastic Analysis The second item will be discussed more in •2
of a Piping System detail here. The purpose of the Structural ho
E. Bibliography of Selected Elevated ; Evaluation Plan (SEP) is to present the overall
Temperature Design and Analysis
Publications - 1970 and 1985

B. C. Wei, U. S. Dept. of Energy, NE-54, Washington, DC, 20545, USA


MASTER CO
W. I. Cooper, Jr., Oak Ridge National Laboratory, ".0. Box Y, Oak Ridge, TN. 37831, USA
A. K. Dhalla, Westinghouse Electric Corp., P. 0. Box 158, Madison, PA, 15663, USA

**Research performed under Subcontract No, 12Y-97347C with Pressure Vessel


Research Committee under Martin Marietta Energy Systems, Inc., contract
DE-AC05-84OR21400 with the U.S. Department of Energy.
organizational plan used in the elevated A. Thick Cylinder Formulation '
temperature structural design and analysis. The thick cylinder formulation is appro-
The SEF defines the necessary tasks to be priate to analyze a structural component which !
performed in order to demonstrate that the can be geometrically idealized as an infinitely
component will comply with the structural and long cylinder subjected to through-the-wall ;
functional criteria of the Equipment Design temperature gradient and to arbitrary time
Specification. The plan should be modified and varying axisymmetric axial and pressure loads.
updated as the design and analysis progress. A The method is based upon an exact (classical)
flow diagram for the various tasks under the boundary value formulation of a thick cylinder.j
SEP is shown in Figure 1. The two available boundary conditions at the j
inside and outside surfaces of the cylinder are
III. SIMPLIFIED METHODS used to solve for two basic variables which are
conveniently selected to formulate two first ,
During the last 15 years, a number of order differential equations. The elastic- I
simplified or approximate inelastic structural plastic-creep rate formulation is in terns of
analysis methods have been developed to the deviatoric stress rates S r and S e in the
evaluate the structural integrity of breeder radial and circumferential directions, respec-
reactor components. These methods have been tively. Two basic governing differential
effectively used: a) to optimize conceptual equations are derived from the compatibility
designs, b) to estimate design margins, c) to condition and the radial equilibrium condition.
procure long lead structural forgings, d) to
release fabrication drawings for final machin- 1. Recommended Use of Thick Cylinder
ing, and e) to identify critical areas for a Formulation. The accuracy for design applica-
detailed inelastic analysis. Being easy to use tion is governed by the geometric and loading
and less expensive than a detailed inelastic idealizations embedded in the thick cylinder I
analysis, a simplified method is ideally suited formulation. The predictions are "exact" f
to perform sensitivity studies of material and (within the bounds of numerical tolerances used i
geometric parameters. The simplifications in the computer program) for a thick cylinder •
include idealization of complex geometric or under plane strain or generalized plane strain ;
material models of structural components and/or conditions. In design applications, the I
approximation of an LMFBR plant operating accuracy of predictions depends upon the j
history. Consequently, careful selection of an simulated deviations from geometric and loading
appropriate simplified method is necessary for idealizations assumed in the thick cylinder ,
each application to avoid unconservative formulation. The simplified aethod can be. j
predictions. applied to structures when: '.

This section provides a brief description a. The geonetry and loadings are axisynaetric.
of each of the simplified methods successfully
used in the breeder reactor component design, b. The predoainant thermal loading on the
and recommends correct usage by specific structure is through-the-thickness tempera-
application examples. Verification of these ture variation, and the longitudinal
simplified methods by comparison to detailed variation of mechanical and theraal loading
inelastic analysis and/or experimental data is is small.
also included.
c. The longitudinal interaction between
The simplified methods are based upon various portions of the structure is saall, !
numerical integration of classical elastic- and the geometric variation of the simu-
plastic -creep differential equations formulated lated component is gradual.
for an infinitely long thick cylinder and a
finite length thin cylinder. These methods d. The plastic regions are confined by
have been developed to accommodate the compli- surrounding elastic material; that is,
cated mechanical and thermal loading histories gross through-the-wall plasticity is
encountered in breeder reactor plant operation; absent.
hence, they are applicable to LMFBR pressure
vessel components whose geometries could be Conversely, the simplified aethod should ,
idealized as cylinders or cones. Typical not be used when: J
elevated temperature failure modes investigated
are: a) incremental ratchetting strain accumu- a. The longitudinal variation of theraal or '
lation, and b) creep-rupture damage and fatigue mechanical loading is significant. >
damage accumulation due.to cyclic thermal and
mechanical loadings. Only geometric idealiza- b. The structural shape changes .abruptly or
tion of a thick or a thin cylinder is con- ; three dimensional effects are significant;.
sldered in the classical formulation. Examples include flange to shell junctions,,
tubesheets, and nozzle penetrations near 1
flanged supports.
DOCUMENTS REVIEW

PREPARE STRUCTURAL
EVALUATION PLAN

ESTA8LISH INITIAL DESIGN

PERFORM ELASTIC LOAD


CONTROLLED STRUCTURAL
EVALUATION

DESIGN REVIEW
MODIFY DESIGN WITH OWNER

PERFORM ELASTIC MATERIAL PROCUREMENT


DEFORMATION CONTROLLED
STRUCTURAL EVALUATION RELEASE

PASS CODE ^V^ YES


MODIFY DESIGN CRITERIA ?

PERFORM SIMPLIFIED
INELASTIC ANALYSIS

NO

WILL
^DETAILED IN^>
' ELASTIC ANALYSIS"
PASS CODE
.CRITERIA?^

YES

DETAILED INELASTIC
ANALYSIS IOR TESTING)

REMOVE ANALYTICAL DESIGN REVIEW


CONSERVATISMS WITH OWNER

PREPARE DESIGN REPORT FABRICATION RELEASE

Figure 1. Structural Evaluation Plan Overall Approach to Elevated


Temperature Design and Analysis
c. The mechanical loading imposes either an C. Inelastic Buckling of Cylinders.
axisymmetric or an overall bending moment The buckling charts presented in Sections
on the structure. Examples include vessel \ III and VIII of the ASME Boiler and Pressure
shell to head junctions, axisymmetric Y or Vessel Code are primarily based upon experi-
Z junctions, and elbows which ovalize under mental and analytical investigations performed
external loadings. in the 1930's and the empirical correlations
derived therefrom in the early 1950's. Since
B. Finite Length Thin Cylinder Formula- then, considerable progress has been made by
tion Axisymmetric Loading. Gerard who has presented varipus closed form
The rate formulation for a finite length solutions, based upon classical shell theory,
thin cylinder is similar to the thick cylinder to predict bifurcation buckling load in the
formulation. The thin cylinder formulation plastic range. The available literature since
permits mechanical and thermal loads to vary i 1950 indicates that Section III and VIII design
with time along the length of the cylinder, ; charts are conservative for plastic local
this longitudinal variation was a major (shell) buckling of cylinders in axial compres-
limitation of the thick cylinder formulation. sion and bending, but do not maintain the same
However, thin cylinder formulation is not degree of conservatism over the range of
applicable to cases where the predominant ' parameters addressed. The buckling rules for
thermal loading is due to a through-the- : elevated temperature nuclear components are
thickness temperature variation. The radial ! specified in Code Case N-47.
stress is neglected in this thin shell theory,
and the two non-zero stress components o z and This section is to recommend a simple,
Og are in the axial and hoop directions, verified method that can be used to predict
respectively. Similarly, the three non-zero ! local shell buckling load for cylindrical
strain components are e , £„, and e r in the I
pressure vessel components subjected to axial
axial, hoop, and radial directions, and they
compressive and bending loads. The local shell
are determined by inelastic constitutive
buckling mode has been found to be design
relationships.
limiting for loop type LMFBR pressure vessel
components with radius-to-thickness ratio, r/t,
1. Recommended Use of Thin Cylinder in the range of 10 to 50. The length-to-radius
Formulation. Thr-thin cylinder formulation can ratio, L/r, for these components is generally
be used to simulate gross structural discon- less than 5; consequently, failure in the
tinuity when: column buckling mode is not a consideration.

a. The meridional or longitudinal temperature 1. Recommended Use of Simplified


variation between a thick section (or Buckling Formula. Gerard's buckling formula is
support) and a thin shell introduces an recommended for design use for cylindrical
axisymmetric meridional bending at the pressure vessels with L/r (length-to-radius)
structural discontinuity. ratio less than 10 and r/t (radius-to-thick-
ness) ratio between 10 and 50. Gerard's
b. Axisymmetric temporal history of con- | formula agrees with detailed nonlinear finite
straints at the structural discontinuity •| element analysis predictions and it generally i
can be obtained from elastic analysis of a provides a close lower bound estimate of J
detailed structural model. experimental buckling loads. Experimental '
observations reported in the literature ;
c. The operational through-the-thickness indicate that plastic buckling of a cylinder
temperature variation can be represented as subjected to a bending moment is initiated in a -
a linear temperature gradient. bellows mode similar to the wrinkling or
axisymmetric mode in axial compression. Thus,
d. Through-the-thickness radial stress effectsj Gerard's axial buckling formula can also be
in a thin shell can be neglected. I used to conservatively predict the plastic
buckling moment for a cylinder subjected to \
Conversely, the thin cylinder formulation lateral loads. Although the simplified method
should not be used when: was verified for idealized cylinders, the
method will conservatively predict a lower
a. The spread of plastic zones and ratchetting bound buckling load for a cylindrical pressure
is caused primarily by ehrough-the-thick- vessel with varying thickness if the minimum
ness temperature distributions. thickness is used in the simplified formula.

b. The temporal history of constraints at the


The simplified plastic buckling formula is
structural discontinuity cannot be estab-
also recommended for predicting creep buckling
lished by elastic analysis because the
times for cylinders if the instantaneous
cross section undergoes large shear
stress-strain curve (t - o hours) is replaced
deformations and/or plastic stress redis-
by an appropriate isochronous stress strain
tribution.
curve. The main report also describes the
simplified inelastic analysis of 2-1/4 Cr-lMo j 2.0 GENERAL REQUIREMENT AND ASSUMPTIONS
steam generator and the use of the simplified FOR INELASTIC ANALYSIS
notched strength formula. For simplicity,
these are omitted in this overview paper. 2.1 Recommended Method for
Inelastic Analysis
IV. DETAILED INELASTIC ANALYSIS 2.2 Computer Programs
2.3 Material Properties
A. Introduction 2.4 Load Histogram
The elastic design rules in the elevated
temperature ASHE Code Case N-47 (and possibly 3.0 NUMERICAL EVALUATION • •
other international codes) are conservative.
Consequently, the most highly stressed com- 3.1 General Procedure
ponents operating at elevated temperature 3.2 Selection of an Accurate but
(above ASME Section III temperature limits) may Economical Mesh
not satisfy the Code design limits using only 3.3 Thermal Analysis
elastic analysis and/or simplified inelastic 3.3.1 Discussion of Heat
analysis. Therefore, to comply with the Code Transfer Analysis
design limits it is sometimes necessary to Results
perform detailed inelastic analysis of critical 3.3.2 Selection of Thermal
structural components. Steps for Stress
Analysis
Inelastic analysis methodology can be
considered as a mature technology for applica- 3.4 Stress Analysis
tion to future LMRs, although the current 3.4.1 Elastic Analysis
methodology has not been completely verified 3.*.2 Inelastic Analysis
and validated by long-term tests at elevated 3.4.3 Screening of Inelastic
temperature. Experience has shown that the Analysis Results
inelastic analysis methodology is cost effec-
tive. For example, about forty detailed 4.0 DISCUSSION OF RESULTS
inelastic analyses were successfully performed
on Fast Flux Test Facility (FFTF) structural 4.1 Stress-Strain Histories
components to qualify the design of critical Excluding Thermal Strains
areas in the Intermediate Heat Exchanger (IHX)
and primary piping system. FFTF experience has i 5.0 CREEP-FATIGUE DAMAGE AND STRAIN
shown that the inelastic analyses costs were j ACCUMULATION
about 13 percent of the total elevated temper- ,
ature design/analysis costs, and total design/- | 5.1 Creep-Rupture Damage
analysis costs were about 2.3 percent of total 5.2 Fatigue Damage
FFTF capital costs. 5.3 Strain Accumulation

This section describes a procedure used in 6.0 CONCLUSIONS


the U.S. to perform and evaluate inelastic
analysis results and to document voluminous 7.0 RECOMMENDATIONS
information generated by inelastic analysis in !
preparation of a final stress report. Table 1 I 8.0 REFERENCES
shows an outline of a typical inelastic j
analysis stress report, which complies with the: APPENDIX A Relevant Input Data Extracted
Structural Evaluation Plan (SEP). j fron Equipment Specifications
(E-Spec)

APPENDIX B Preliminary Elastic Analyses "


to Establish Adequacy of the
Finite Element Mesh (Conver- j
Table I
gence Study) •
AN OUTLINE OF FINAL STRESS REPORT
APPENDIX C Selection of Material
1.0 INTRODUCTION
Properties and Component
Specific Environment Effects
1.1 Purpose
1.2 Scope
1.3 Background Documents APPENDIX D Record of Analysis to Comply j
with Structural Evaluation j
Plan (SEP)
Table I (Contd.) For elastic-plastic analysis the recom-
mended constitutive equations are based upon
the Von Mises yield criterion, its associated
APPENDIX E Temperature Contour Plots as flow rule and classical non-isothermal kine-
Selected Steps in Heat matic hardening with the a-reset procedure for
Transfer Analysis clastic-plastic time dependent analysis. The
observed cyclic plastic hardening due to
APPENDIX F Stress and Strain Contour continuous thermal cycles and creep hold tine
Plots at Selected Load Steps postulated for reactor operation is accom-
to Identify Highly Stressed modated through isotropic expansion of the
Regions yield surface to the tenth cycle stress-strain
curve measured in a uniaxial continuous cycle
APPENDIX G Deformed Geometry Plots to test, without creep-hold period.
Verify Boundary Conditions
and Qualitatively Assess
The virgin, as well as the tenth cycle,
Analysis Results
stress-strain curve is bilinearized such that
the strain energy represented by the idealized
APPENDIX H Tine History Plots of
curve is approximately the same as that
Temperature, Stress and
observed under the measured curve. For simpli-
Strain Variables to Evaluate
city, the bilinearization of the virgin stress-
Creep-Rupture Danage and
strain curve is based upon the maximum strain
Inelastic Strain Accumulation
anticipated in monotonic loading; the bilinear-I
ization of the tenth cycle stress-strain curve
APPENDIX I Cyclic Stress-Strain History
is based upon one-half of the maximum strain
Plots to Evaluate Cyclic
anticipated in cyclic loading.
Strain Growth and Fatigue
Damage
For time-dependent creep analysis the
recommended constitutive equations are based :
upon the classical equation-of-state approach.
A modified strain hardening approach is used to
Typically, a breeder reactor structural related components of creep strain rates to the
component is subjected to cyclic thermal, deviatoric stress, temperature, and accumulated
mechanical, and seismic loadings postulated in i creep strain. Auxiliary rules, in the fora of
the Equipment Specifications (E-Specs). It is dual origins, are provided for determining the
preferable to describe incidental but essential | measure of strain hardening under reversed
:
details in Appendices of the final stress creep loadings. The effect of prior plasticity
report, as illustrated in Table I. The | on subsequent creep is simulated through the
relevant input data necessary for inelastic I B-option. That is, the creep strain accumula-
analysis should include geometry, boundary j
tion (creep strain hardening) in cyclic loading
conditions, loadings, and material data.
is negated by an equal amount of prior (half-
Details on the selection of adequate geometric
cycle) plastic strain accumulation.
and appropriate material models depend upon
the numerical idealization required for
specific computer program and material con- The tine-independent plasticity computa-
stitutive equation formulation. tions are performed independently of the tine-
dependent creep calculations. Therefore, in
some reactor structural component analysis, thej
B. Summary of the Recommended Method. creep effects may have to be included during a j
In summary, the recommended method for few hours at the end of heat-up but before
inelastic analysis is based upon the funda- steady state conditions are reached. For
mental assumption that the total strain is the example, the elapsed time between the end of
sun of the independent strain components: heat-r.p and steady state operation may be as
elastic, plastic, creep, thermal, and any other nuch as 20 hours when non-uniforn longitudinal
inelastic strain, such as irradiation swelling temperature differentials are encountered in
strain. Classical plasticity and creep pool-type reactor components such as a reactor
theories are augmented by ad hoc rules to vessel with a specified hot sodium level,
analytically simulate the experimentally relatively cold support flanges in thin-walled
observed creep-plasticity interaction in type heat exchangers and stean generators, and
300 series stainless steel and 2-1/4 Cr-lHo fluid-head penetrations through cold concrete
steel at elevated temperatures. The standard barriers. The calculated elastic stress
assumptions of the classical creep and plas- Intensity at the end of heat-up nay be con-
ticity theory of isotropic homogeneous material siderably higher than the stress intensity
and snail incompressible inelastic strains are during steady state operation. To include
included. creep effects before steady state conditions
are reached, the analyst nay perform a creep
analysis for 20 hours after the end of heat-up
and then switch to elastic-plastic analysis to VI. ELEVATED TEMPERATURE DESIGN CODES
calculate steady state stresses. The rest of
the postulated creep hold time between thermal A. The U.S. Structural Design Code
cycles can then be analyzed for full power
steady state conditions. Thus, the higher This section presents the rules and
creep-rupture damage at the end of heat-up can criteria for the design of elevated temperature
be captured in the structural evaluation. nuclear components as presently used in the
United States. The American Society of i
V. SIMPLIFIED STRESS CLASSIFICATION PROCEDURE Mechanical Engineers Boiler a'nd Pressure Vessel <
Code Section III Division 1 presents the rules
A. Statement of Problem for design of Class 1 pressure boundary com-
The design criteria for Class 1 nuclear ponents intended for nuclear service. In those
components are given in Section III of the ASME instances where the operating temperatures
Boiler and Pressure Vessel Code supplemented by exceed the temperatures for which allowable
Code Case N-47 for elevated temperature stresses are presented in Section III, Code I
service. The definitions of primary (load- Case N-47 is invoked for the design and
controlled) and secondary (deformation-con- analysis of Class 1 nuclear components in
trolled) stresses for elevated temperature elevated temperature service. ;
service in Code Case N-47-3213 are essentially ,
the same as those presented for low temperature 1. Failure Modes. The basic
service in NB-3213 with one exception: the philosophy of Code Case N-47 is to provide
secondary stresses due to "...a large amount of quantitative margins of safety by requiring
elastic follow-up" are to be considered primaryj analyses to be performed to demonstrate struc-
for elevated temperature service even if the i tural adequacy against the specified elevated
deformation limits in Code Case N-47-3250 are I temperature failure modes. The failure nodes
satisfied. Although it is conservative to ' of concern in Code Case 11-47 are based on the
assume that stresses from thermal expansion and' Section III failure modes and supplemented by
axial thermal gradient are primary for design the time dependent (creep) failure modes. The
calculations, in practice, it is seldom failure nodes addressed by Code Case N-47
possible to comply with the code limits if such therefore include: ••
assumption is used. .
a. Ductile rupture fron short-tern loadings.
This section presents a method to ;
classify, into primary and secondary stress j b. Creep rupture froa long-tern loadings.
categories, the thermal stresses in piping
systems and the bending stresses due to j c. Creep-fatigue failure.
internal pressure in pressure vessels at !
structural discontinuities. The method uses a d. Gross distortion due to incremental
reduced elastic modulus procedure to classify collapse and ratchetting.
clamp induced pipe stresses and extends to
quantify elastic follow-up thermal stresses in . e. Loss of function due to excessive deforaa-
elevated temperature piping systems. The tion.
•ethod treats creep strains as time-independent
inelastic strains by use of isochronous stress- f. Buckling due to short-tera loadings.
strain curves. The proposed procedure has been
verified by detailed creep analysis of a piping , g. Creep buckling due to long-tera loadings.
systea subjected to thermal expansion and !
displacement. : 2. Load Categories. The load-con-
trolled quantities are stress intensities which
B. Concluding Remarks result froa equilibrium with applied loads i
A stress classification procedure is during plant operation. As in Section III,
described in this section to quantify the Code Case N-47 defines stress intensity as
prinary-secondary split of discontinuity twice the aaxinua shear stress, and it is equal
stresses in piping systems and pressure to the largest algebraic difference between any
vessels. Three illustrative examples are also two of the three principal stresses. The load-
presented. The method utilizes the concept of controlled quantities are determined using
a reduced elastic (scant) modulus. The concept linearly elastic material models. The aost
was developed to classify clamp induced commonly encountered prinary stress intensities
stresses into primary and secondary categories are due to the applied pressure, deadweight,
as defined in the ASME Code. The proposed wind, seisaic, and pipe loads.
nethod is verified by comparing the predictions
from reduced (secant) modulus elastic analyses Deforaation-controlled quantities are
to those predicted from detailed Inelastic ana- stresses, strains, and deformations which
lyses . result froa load deflection and strain coa-
patibllity. These quantities nay vary with
both time and the applied loads, and creep a. Two-thirds of the minimum stress to cause
effects may be a major time-dependent creep rupture in tine t;
influence. Thus, accurate analytical evalua-
tion of deformation-controlled quantities b. 80 percent of the minimum stress to \
requires inelastic stress analysis when creep cause the onset of tertiary creep in time,'
effects are significant. t, and

In addition to differentiating between c. The minimum stress to produce one percent


load controlled and deformation controlled total strain in time, t.
quantities, Code Case N-47 utilizes the Section
III design by analysis philosophy of categoriz- Code Case N-47 defines the allowable
ing load conditions as Design, Normal (Level stress limit S rat as the lower of Sa and
A ) , Upset (Level B ) , Emergency Level (Level C) S t at the particular time and temperature under
and Faulted (Level D ) . consideration.

3. Load Controlled Criteria. The The specific Code Case N-47 load con-
basic feature of a load controlled stress is trolled prinary stresses for the Design,
that, it is necessary to maintain equilibrium Normal, Upset, Emergency, and Faulted Condi-
of the structure under the applied loads. As a tions are summarized in Figure 2. Code Case N-
result, deformations will not relieve load j 47 has two sets of primary stress allowables,
controlled stresses. These load controlled j one for Design Conditions, and the other for
stresses are denoted as "Primary Stresses" in : Operating Conditions. j
Code Case N-47. ,
To account for varying loads at
The time independent primary stresses variable times and temperatures, a linear '
result from loads which have the capacity to . damage use fraction approach is used by the
cause structural failure in a single load Code. The linear damage use fraction is
application. The Code limits the average defined as follows: l
primary (membrane) stress intensity in any
cross-section to the lower of:

a. 33.3 percent of the minimum specified


ultimate tensile strength at room tempera-
ture. where:

b. 33.3 percent of the (tabulated) elevated I t£ - the total duration of time at a


temperature ultimate tensile strength. I particular stress level and
temperature during the service
c. 66.7 percent of the minimum specified yield life of the component
strength at room temperature. !
t
ia ~ the allowable tine of operation at
d. 66.7 percent of (tabulated) elevated > the sane stress level and temperature
temperature yield strength. For austenitic
stainless steels the code permits 90 ' B -factor which is equal to unity or,
percent of the yield strength at tempera- | alternately, it can be specified to be
Cure. less than unity in the Design Specifica
tions to account for nonlinearities in
The first two quantities preclude plastic the use-fraction rule
tensile instability. The last two quantities
preclude gross plastic flow. The resulting B. Salient Features of Design Codes
stress limit is termed "S m ". (France)

Code Case N-47 also defines load con- 1. RCC-HR, French Code for FBR
trolled stress limits based on the duration or Components. The French Code is called RCC-MR,
time of the applied elevated temperature which means "Design and Construction Rules for
loading event. These are denoted as time Mechanical Components of Fast Breeder Reactor
dependent primary stress limits. The introduc- Nuclear Islands" and the first edition was
tion of time dependent Code Case N-47 prinary published in June 1985. It is edited by
stress limits that depend on both the load Association Francaise pour les Regies de
duration and temperature provide important Conception et de Construction des Materials des
design flexibility for the conditions typical Chaudieres Electro-Nucleaires (AFCEN).
of LHFBR service. The Code time dependent
primary stress allowable is denoted as S c . The
S t values are the least of three quantities: /
Figure 2. Code Case N-47 Elevated Temperature
Analysis Flow Diagram
This code is the result of experience RB 3111.2 Immediate Plastic Instability i
gained through design, manufacturing, erection,
and operation of Rhapsodie, Phenix, and Super When, in the previous case, the loading con-
Fhenix. A part of this experience is the large tinues to increase the behavior of the struc-
R&O program on Structural Mechanics launched as ture depends on any variations in its shape and
a part of the French lilFBR program. the strain hardening increase of the yield
strength of the material. These two effects
Most of- the design sections were written rapidly become counteracting and any change in
by a "tripartite committee" including experts shape tends to weaken the structure whereas an
from manufacturers, research organization, and increase in the yield strength of the material
utility. The publication of the first edition tends, on the contrary, to reinforce it. As
has not stopped this work and many additions long as the first effect is dominated by the
and amendments are in preparation. second, the structure is deformed in a stable
manner, when the first becomes dominant,
2. Direct Reference to Modes of deformation is unstable and fracture is not far
Failure. Prevention of failures of various behind if the loading is maintained.
modes is clearly the aid of the design rules.
For components of class 1, modes of failures RB 3111.3 Time-dependent Excessive
are given in RB 3140. For instance, for level Deformation
A criteria_it._is written as follows:
When a structure is subjected to loadings
RB 3141 Level A Criteria maintained for a sufficiently long tine at high
temperatures, deformations evolve with time and
The aim of level A criteria is to protect the can consequently produce excessive deformation.
equipment against the following damages: This type of damage is called a time-dependent :
excessive deformation. ;
Instantaneous or time-dependent excessive
deformation, RB 3111. A Time-dependent Plastic
- Instantaneous or time-dependent plastic Instability
instability,
- Time dependent fracture, Although inducing no immediate damage when
: applied, a loading can, because of creep,
- Elastic or elastoplastic instability,
immediate or time-dependent, induce plastic instability over a certain
Progressive deformation, period of time. This type of damage is called
- Fatigue time-dependent plastic instability.

RB 3111 P Type Damage RB 3111.5 Time-dependent Fracture

Types of damage referred to in this chapter by1 In certain conditions, changes in shape prior
the expression "P type damage" are those which to fracture can be snail. Sometimes consid- j
can result from the application to a structure erable reduction in the elongation at the tine•
of a steadily and regularly increasing loading; of rupture means that this phenomenon oust be
or a constant loading. ] taken into account both globally (under Che
effect of external forces) and locally (frac-
RB 3111.1 Immediate Excessive ture before complete release of internal
Deformation stresses).

If we take a structure comprising an elastic, RB 3111.6 Elastic or Elastoplastic


ductile material to which is applied a loading Instability
multiplied by a gradually increasing coeffi-
cient, the following behavior can be observed: Apart from the instabilities described above,
with lower coefficient values, the structure : other elastic or elastoplastic instabilities
behaves elastically and deformation is rever- may occur, in which elastic deformation, by the
sible. At higher values, irreversible plastic changes in shape it induces, considerably
deformations occur such that if the loading weakens the strength of a structure and its '
were to be cancelled, the structure would not i ability to withstand the applied loading. The
return to its original dimensions or shape. | typical case of this type of damage is buckl-
These plastic deformations are firstly con- ' ing.
tained by elastic zones which limit them and
then, the plastic zones being sufficiently RB 3112 S Type Damage '
extended, yielding takes place easily. The
overall permanent deformation of the structure
Types of damage described in this chapter by
thus increases faster the higher the loading
the expression "S type damage" are those which
coefficient. It is when the overall permanent I
can only result from repeated application of
deformation begins to increase rapidly that it ,
loadings.
is said to be excessive. I
RB 3112.1 Progressive Deformation The existence of other external (imposed
displacements) or internal (temperatures)
When we consider a structure subjected to loadings, act simultaneously with the imposed
cyclic loading, at the end of the first cycle, loads to modify the imposed loading leading to
the structure may show signs of permanent buckling.
defoliation. During the following cycles, two
cases nay arise: RB 3113.2 Strain Controlled Buckling

o Either, after a few cycles, the overall Buckling is said to be strain controlled only
permanent deformation is stable, if the imposed loads, whatever their intensity,
could not on their own produce it. In all
o or, the permanent overall deformation other cases, buckling is said to be load
continues to increase as every loading controlled.
cycle induces additional deformation and
the structure gradually changes from its RB 3113.3 Time-dependent Buckling
original shape. This behavior is called
progressive deformation. At high temperatures, maintained loadings could
cause time-dependent buckling chiefly because
RB 3112.2 Fatigue (Progressive of the evolution of the properties of the
Cranking) material and the shape of the structures with
time (amplification geometrical defects)
When the loading applied to a structure evolves I
with time, in particular in a cyclic fashion, j RB 3114 Fast Fracture
the material is subjected to deformation
variations. These variations, if sufficiently Fast fracture is any fracture which occurs
numerous and if of large amplitude, are capable without being preceded by an applicable global
of causing cracking. The damage here is deformation. Two types of fast fractures are
defined by the appearance of small macroscopic generally considered, one by ductile tearing,
cracks which do not compromise the strength of : the other by fragile or semi-fragile tearing.
the structure with regard to the other types of
damage to be considered. j Ductile tearing is the result of a small volume
of material being subjected to stresses
when the temperature is sufficiently high, ' inducing its fracture through instability
creep deformation occurs during each cycle thus• whereas the rest of the structure still behaves
accelerating the appearance of cracking. { elastically and is consequently liable to
withstand these stresses.
RB 3113 Buckling
VII. FRACTURE MECHANICS
Buckling is a phenomenon which can occur in
structures with an average centerline or A. Introduction
average surface area. It consists of the The assessment of the structural Integrity
development of deformation different from those of systems and components in elevated tempera-
which manifest themselves at low loading I ture service is one of the most important
levels. They can lead to instability as well recommendations with respect to safety and
as considerable levels of deformation or economics for fast breeder reactors. To ,
exaggeration of variations in local deforma- demonstrate the structural integrity, an
tion. extended evaluation is needed considering the
behavior of flaws which are either accepted to
Buckling is not strictly speaking a type of be left in a structure after fabrication or
damage but its appearance generally induces postulated to be left undetected by final
damage such as elastoplastic instability or inspection.
excessive deformation or fatigue. Geometrical
imperfections resulting from acceptable Taking into account the relevant design,
manufacturing tolerances are likely to accel- operating and loading conditions of LMFBR
erate and aggravate buckling. structures, fracture mechanics methods have to
be extended into the elastic-plastic regime.
RB 3113.1 Load Controlled Buckling The objective of fracture mechanics investiga-
j tions is as follows:
Buckling is said to be load controlled when it
is the result of imposed loads which cannot be o Demonstrate that initial defects far above
reduced by the deformations associated witn sizes which can be detected by Nondestruc-
buckling. tive Examination (NDE) will not grow
significantly during the service life of
the structure.
o If significant crack propagation is , o Decide if flaws which are detected during
postulated to occur - applying the speci- fabrication exceeding specified acceptance
fied design load cycles of the service life levels may be tolerated, provided that they
continuously - it should be shown that are not harmful to the structural
cracks will grow through the wall, its integrity.
length remaining stable with respect to
i'racture mechanics stability criteria. Procedures to evaluate the structural
integrity are somewhat different in various
To be successful in the application of countries.
fracture mechanics methods, the following basic
requirements should be fulfilled: C. Industrial Practice in the United
States.
o Structural materials should be selected to The leak before break rationale has been
be high-qualified. Its ductility should accepted as design basis for FBR's. Sodium
remain sufficiently high throughout the ' systems are considered as Moderate Energy Fluid
service life. j Systems (MEFS) according to the U.S.-NRC
Standard Review Plan. This position was
o Design and structural analysis should be I accepted for the Clinch River Breeder Reactor
performed in accordance with existing codes' Plant (CRBRP), stating that no sodium systems
and standards (e.g. ASME-Code, RCC-MR), [ operate with any significant amount of internal
considering the special features and i fluid-stored energy.
operating conditions of FBR's.
A reference through crack length of about
o A comprehensive quality assurance should 100 mm is recommended based upon fatigue crack
exist throughout fabrication and installa- growth calculations and a leakage area of about
tion. 1 cm has been computed by- crack opening con-
siderations. The design basis leakage area has
Based on these requirements, the following been established to be about 10 cm, using a
failure modes should generally be excluded from safety factor of 10. The decision is also
design: based upon a large amount of experimental
investigations together with crack growth
.o Brittle fracture ; calculations.

o Ductile fracture by excessive plastic ! Crack Growth Analysis was performed \


deformation assuming hypothetical flaws at most highly-.
stressed areas. They are characterized by \
o Gross failure due to deficiencies during stress gradient over the wall thickness due to
fabrication and installation. ' thermal transients and are generic in nature.
Axial, circumferential and shear components of
Within the limits of these conditions, an stresses were calculated in each piping run,
extended evaluation of the structural integrity using finite element programs. The maximum
using elastoplastic fracture mechanics methods - stresses were found to be at the elbow
is recommended. j sections. The initial flaw parameters for the.
Fast Flux Test Facility (FFTF) and for the ;
B. Application Techniques. j CRBRP were taken as follows:
The design work for LMFBR'a is based on :
the assumption that defects are not present in
&
the structures being designed and specifica- t c
tions are defined to assure the quality of j FFTF 0.22 0.164
manufactured components. Although a large CRBRP 0.25 0.167
amount of results from fracture mechanics
investigations is available, there exists no where
set of rules for its application in elevated a - crack depth
temperature service. The principal items of :
c - half crack length
fracture mechanics integrity evaluation are
t - wall thickness
listed below: I
They are regarded to be far above crack con-
o Establish the leak before break rationale figurations which can be detected by NDE
as design basis for the coolant boundary. methods.

o Demonstrate the structural integrity in The results show that crack extension over
case of postulated flaws and define design the lifetime of the plants applying the design
basis leakage areas. basis load cycles is not significant.
D. Industrial Practice in European A joint French-German R&D program on ,
Countries fracture mechanics investigations has been
The state-of-the-art reports are under initiated to validate theoretical methods by
preparation dealing with applications of component tests.
fracture mechanics concepts to LMFBR components
below the creep range and within the creep The position In Germany is characterized
range. The major objectives are as follows: by extended fracture mechanics investigations,
which have partially been accepted for SNR-300.
o Review current methods and available The results are being applied-to propose a
theoretical and experimental work on a consistent concept in structural integrity for
world-wide basis. the demonstration plant SNR-2. The principal
elements of the concept are as follows:
o Show how improved fracture mechanics
methods can be of benefit to design o Initial defects can be evaluated (e.g. 1 mn
engineers. depth x 30 mm length) which are far above
indications from nondestructive examination
o Define materials data requirements. during and after fabrication. They will be
shown to grow not significantly during the
The French approach with respect to service life of the plant.
fracture mechanics application can be sum-
marized as follows: o If crack propagation is postulated to
occur - applying the specific design load
Instability analysis: cycles of the service life continuously -
cracks will be shown to grow through the
Critical crack length are evaluated on flow- wall, its length remaining stable with \
stress type criteria since the phenomenon is respect to fracture mechanics stability \
instability controlled rather than toughness criteria. \
controlled. This approach is being validated
under complex stress situations. Comparison is' o To demonstrate that at areas in vhich leak
made with other criteria like J-integral, ! detection is not possible (e.g. internal
tearing modulus concept and the CEGB R6 assess- structures of the pool vessel) the crack
ment procedure. length of through wall cracks remain stable
during the whole service life.
Fatigue analysis: j
Tn the United Kingdom the structural
Fatigue is analyzed using strain intensity integrity for the Commercial Demonstration Fast
factor approach which results from the applica- Reactor (CDFR) is demonstrated using fracture
tion of Green's function to a pseudo-elastic mechanics methods similar to other countries.
stress field related to total applied deforma- Combined experimental and analytical programs
tions. This approach is being validated for are applied to show that tolerable defect sizes
situations where sharp stress gradients exist j are well above the U n i t s of detection by
like at the base of notches. , ,inspection nethods used in both fabrication and
i service. •
Creep analysts: ;
Analytical approaches were applied includ- j"
Presently, the analysis is conducted using net ing the CEGB R6 nethod which has been shown •
section and C* versus crack rate curves. Creep experimentally to fulfill its ain of providing j
crack initiation and propagation has been realistic failure prediction, and the British •
studied recently on type 316 stainless steel. Standard Crack Opening Displacement Curve,
In general the following approach has been which is a conservative nethod with safety
proposed: factors built in.

o Prevention of defects by careful fabrica- , These nethods have been compared with an
tlon and control. inelastic finite element analysis which shows
that the R6 nethod agrees with the inelastic
o Calculation of the extension of undetected ' analysis but with a degree of conservatism.
defects during the service life.
Three point bend specimen tests were
o Demonstration of non-criticality of defects performed on welds and parent naterial to
under seismic loads. obtain fracture aechanics resistance curves.
The analytical methods are also compared with a
o Design of pool internals in such a way that series of wide plate tests to deteraine the
critical cracks will not cause a influence of residual stress on failure initia-
catastrophic failure by fast fracture. tion. The experimental results are in reason-
able agreement with predictions by fracture
mechanics theory. They strongly support the The buckling problems encountered in pool
leak before break concept for the coolant type LMFBRs are more complex than those
boundary. encountered in loop type LMFBRs. The collapse
load calculations in pool type LMFBRs are
VIII. NONLINEAR COLLAPSE complicated by two principal factors: a)
Imperfection sensitivity of the slender
A. Introduction (150 < r/t < 650) pool type reactor vessel and
The radius-to-thickness (r/t) ratios of internals as compared to relatively thick loop
typical pool type LMFBR reactor vessel and type pressure vessels and piping components
internals components range from 150 to 650. (10 < r/t < 5 0 ) , b) thermally induced progres-
The corresponding r/t ratios for loop type sive ratchetting and flow induced vibrations or
LMFBR Structural Components in the primary and fluid structural interaction in very thin
intermediate Heat Transport System (HTS) range structures (r/t > 100). The prediction of
from 10 to 50. The loop type LMFBR structural buckling or collapse load in such complex thin-
components operate in the creep range of walled slender shell structures is further
the material, whereas the pool type LMFBRs complicated by discrepancies between an i
experience temperatures in creep range only idealized response and the actual failure due
during accident conditions. | to postulated accidental overloads. The
discrepancies originate in the analytical
At elevated temperature operation thin- idealizations which are different from the j
walled structural components may collapse (or following realistic variations encountered in j
due to the reduced yield strength of the as-built structures: a) initial (geonetric) I
material and creep deformation at elevated fabrication imperfections, b ) scatter in !
temperature. Thus, failed modes such as material properties at operating temperatures,
plastic and creep collapse and incremental \, c) residual stress introduced during fabrica-
collapse due to plastic or creep ratchetting ' tion, and d) variations in boundary conditions
require verified analysis procedures to assure due to a fabricated connection and interactions
the structural integrity of LMFBR plants for a among different shell structures during
20 to 40 year design life. For simplicity, the operation.
word "collapse" is used here to designate only
the post-buckling stable, gradual instability j In addition to the inaccuracies introduced!
due to the interaction of both material and ; in the calculations of buckling or collapse
geometric nonlinearities; "buckling" is used loads, the evaluation of safety nargins against
generically to identify either gradual or unstable buckling failure is complicated by
catastrophic buckling with or without inelastic interaction between geometrically induced
deformations at incipient geometric critical buckling deformation nodes and
instability. material dependent failure modes such as creep-
fatigue, ratchetting, and plastic instability.
The structural components in LMFBR plants The evaluation of a margin of safety requires
are significantly thinner than those designed investigation of hypothetical behavior rather
for a Pressurized Water Reactor (PWR) plant. than actual behavior under- postulated normal,
The thickness of PWR pressure vessel and piping, upset, and accident conditions. Buckling is an
components is primarily dictated by the instability phenomenon which sometimes occurs
internal pressure loading. In contrast, LMFBR instantaneously (primarily in the elastic
pressure vessels and piping components operate range) rather than gradually, as in plastic or
at a very low pressure, hence their thickness creep collapse. Consequently, to assure
is not dictated by internal pressure. Predomi- structural integrity with an adequate margin of
nant operating loads on LMFBR components are ' safety during plant operation, it is necessary
due to temperature differentials between j to conservatively evaluate various hypothetical
various portions of the structure. Theoretic- ! combinations and sequences of postulated
ally, it is beneficial to design LMFBR struc- i loadings.
tural components to be as thin as possible, to •
reduce through-the-wall temperature differen- j
B. Recommended Buckling Analysis
tials and the corresponding thermal stresses.
Procedures for Large Pool Type LMFBRs.
However, the relative thinness of LMFBR
In the 1970's, nonlinear general purpose
structures makes them more susceptible to
computer programs were developed to compute the
buckling failure due to compressive seismic
buckling loads of complex structures in
loads. Thus, the wall thickness of LMFBR
pressure vessels is in some cases dictated by inelastic (plastic and creep) regime. However,
the buckling limits specified in the French detailed nonlinear collapse analysis of complex
Construction Code RCC-MR and the U.S. ASME pool type LMFBR structures subjected to dynamic
Boiler and Pressure Vessel Code. In very thin loading is expensive and tine consuming. The
LMFBR components (r/t > 100), thermally induced calendar time required for detailed analysis
ratchetting, fluid structural interaction and aakes it impractical for use in routine design
flow induced vibrations complicate calculations of structural components. Simplified methods
of collapse load. are needed, especially in the preliminary
stages of design, for scoping the effects of These LMFBR structures experience elevated
design parameters and assessing alternate temperatures well above the creep range of the
design configurations. component material either during accident
conditions or during normal operation. The I
A simplified method is included in the relative thinness of LMFBR structures is mainly '
French Construction Code RCC-MR. The method . due to the small thickness required to contain
requires calculations of classical elastic low normal operating pressures, which are less
bifurcation buckling load \e and the load A y at than 1.4 MPa for loop-type primary heat
:
which a highly stressed location in a structure1 transport system pressure vesssal and piping
experiences plastic deformations. Design system components, or hydrostatic pressures in
charts are provided to calculate the buckling both loop- and pool-type reactor vessels. Thin
load of real structures with a range of initial components are preferable not only for effi-
imperfections and material modifications cient and economical use of material, but also
introduced during fabrication. The method has to reduce secondary stresses in structures due •
been validated by comparing the simplified to severe thermal transients and temperature
predictions to the experimentally observed fluctuations encountered in LMFBRs.
collapse load of scaled models.
Structural design for elevated temperature
IX. CURRENT ISSUES AND FUTURE DIRECTIONS IN service is not a new concept as demonstrated by
ELEVATED TEMPERATURE DESIGN successful and reliable operation of petro-
chemical structures designed to Section VIII oft
A. Key Technological Issues the ASME Boiler and Pressure Vessel Code. !
During the past ten years, the high Also, very thin-walled shell structures
temperature technology development has been j (200 r/t 2000) have been successfully designed
extensive, and the basic structural criteria ' for aerospace structures in the past. What is
and procedures adopted in the design of LMFBR ; different about the LMFBR structures is the j
components have generally been accepted as \ combination of geometry, loadings, environment,}
adequate during the licensing review process. • and stringent design criteria, which present
new challenges not encountered in conventional .
Based upon the international design nuclear and non-nuclear power and petrochemical
experience, key structural technological issues plants or aerospace structures. Fornalized and
nay be divided Into the following three focused structural development programs in
categories: various countries were pursued to support
design of large-scale LMFBRs. Direct technol-
o Stable and Defensible Design Methods. ;
ogy transfer frcn other Industrial practices
Three areas identified are weldments, was not feasible due to the following design
flawed components and validation of considerations unique to LMFBRs:
inelastic analysis methodology.
1. Design for long-life operation (200,000 to ,
o Improved Guidelines and Procedures for 300,000 hours) sometimes at elevated
Design Application. Both the U.S. perspec- temperature w'.ihout continuous access to j
tive and the European concerns are physical inspection, repair, or replacement
described in detail. j of structural components.

o Cost reduction of future LMFBR's. Four ' 2. Protection of public health and safety
areas are identified and discussed. These i during accident conditions.
include:
3. Assurance of structural integrity during
1. Simplified Analysis Procedures. seisnic and other plant related postulated
excursion events.
2. Application of Advanced Materials.
4. Consideration of dynaaic response charac-
3. Buckling Rules. teristics during fluid structural interac-
tion.
4. Design Criteria for Non-Safety-
Related LMFBR Components. 5. Consideration of material and geoaetric
nonlinearities with excessive deformations
X. SUMMARY and loss of function of critical
components.
When compared to conventional nuclear
power plants, LMFBR primary structures can be 6. Inclusion of naterial property variations
characterized as relatively thin-walled shell during plant operation due to LMFBR
structures (radius-to-thickness ratio ranging specific environment and loading.
from 20 to 500), which contain liquid metal
radioactive coolant as a heat transfer medium.
Although there are some differences in Mr. B. C. Ezra
operating conditions among LMFBRs currently Foster Wheeler Energy Corporation
operating in various nations, the overall USA
similarity of the above mentioned design
considerations have resulted in the selection Dr. I. W. Goodall
of generally similar materials of construction: Central Electricity Generating Board
stainless steel for primary and intermediate Great Britain
heat transport systems and chrome alloys for
secondary systems. Dr. R. L. Roche
i Commissariat a l'Energie Atomique
Similarities among structural design and France
development programs pursued by various nations
also confirm the commonality of purpose and Dr. H. Zeibig
Technische Beratung
consensus on the technology development needs '
Federal Republic of Germany
over the past years. This consensus, although
independently reached, has been fostered by
formal and informal exchanges and contacts j
between various national programs and among
individual participants. However, the design
practice in various countries may differ In the
emphasis placed upon design criteria to
preclude anticipated failure modes, analysis
approach used in ensuring structural integrity
for long-term safe operation, and priority
assigned to resolve structural design problems
through additional testing and detailed
numerical analysis.
Similarities in LMFBR primary beat transp-
ort system material selection and operating
conditions facilitate documentation of current
design practices. Therefore, much of the
report is written from the U.S. viewpoint,
which is consistent with international design
practice. Significant differences in design
practices due to emphasis on loop-or pool-type
LMFBRs are appropriately addressed in the
report. It should be recognized that technical
opinions expressed in the report. It should be
:
recognized that technical opinions
expressed in the report are those of individual
authors based upon individual perception and ,
emphasis. Significant differences may well :
exist among different national practices and '
the recommendations in the report are not to be
construed as universally accepted design
practices for LMFBRs.

XI. ACKNOWLEDGEMENTS r
The authors wish to express their
gratitude to the Pressure Vessel Research
Council (PVRC) for the permission to publish
this overview. Also, thanks are due to the
following members of the PVRC Task Group on
Recommended Practices who contributed writings
of individual chapters of the complete task.

Mr. A. Angerbaur
Interaton
Federal Republic of Germany

Dr. A. K. Dhalla, Task Group Chairman


Westinghouse Electric Corporation

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