Int. J. Pres. Ves.

& Piping 33 (1988) 165-196

Results of the Pretest Analysis and Start-up of the JRC

Ispra Pressurised Thermal Shock Experiment: Nozzle
Corner Crack Behaviour

A. J o v a n o v i 6 *

Staatliche Materialpriifungsanstalt--MPA, Universit~t Stuttgart, Pfaffenwaldring 32,

7000 Stuttgart 80, FRG

G. V o l t a & A. C. L u c i a

Commission of the European Communities, JRC--Joint Research Centre Ispra,

SER Division, 21020 Ispra (Va), Italy

(Received 16 November 1987; accepted 26 November 1987)

ABSTRACT

This paper presents some general and practical aspects of the analytical and
experimental work performed within the JRC lspra P T S (Pressurised
Thermal Shock) research. Main elements of the structural reliability
assessment performed for the scaled pressure vessel model exposed to
repetitive P T S loads have been highlighted, andfirst results regarding the pre-
experiment analysis and the start-up phase of the experiment given (stress
analysis, damage mechanics, fracture mechanics, etc.). The paper also
presents the basic method andfirst applications regarding treatment of uncer-
tainties, and use of artificial intelligence tools in planning and management of
the experiment.

NOTATION

a Crack length (m)

A Surface (m 2)
B Damage
D Diameter (m)
* Formerly visiting scientist at JRC Ispra.
165
Int. J. Pres. Ves. & Piping 0308-0161/88/$03'50 © 1988 Elsevier Applied Science Publishers
Ltd, England, Printed in Great Britain
166 A. Jovanovi?, G. Volta, A. C. Lucia

E Young's modulus (MPa)

F Failure criterion, plastic potential
I1 Heat transfer coefficient (W/m2K)
J, Jk Vector of the J integral in a 3-D body (J/m 2)
K Stress intensity factor (MPax/m)
n Normal vector
N Number of cycle in fatigue; necessity
P Hardening variable
P Probability
Q Flow (m3/2)
R Reliability; real number space; hardening
S Integration surface (m 2)
t Time (s)
T Temperature (K)
U Vector of Cartesian displacements (m)
dV Volume element (m 3)
W Strain energy density (J/m 3)
x Vector of Cartesian co-ordinates (m)

Coefficient of thermal expansion (I/K)

Damage variable
Aa Crack growth (m)
Strain tensor
Coefficient of heat conduction (W/InK)
P Membership function
v Poisson's ratio
7~ Possibility
P Density (kg/m 3)
cr Stress tensor (MPa)
4, Reference function

Subscripts
a Related to the crack tip
bm Base metal
C Critical
cl Cladding
eq Equivalent
h Coolant
i Input, internal
I Opening mode of fracture of type I
mech Mechanical
nc Nozzle corner
 JRC Ispra pressurised thermal shock experiment 167

th Thermal
w Wall
y Yield
Superscripts
a Recurrent index
e Elastic
eq Equivalent ('effective')
p Plastic
Other notation
Vectors, tensors: e.g. x
Recurring indexes: e.g. aii= o-~ + o-22 + o'33
~2Ui
Partial derivatives: e.g. Ui,jk- ~Xj ~Xk

ACRONYMS
AI Artificial intelligence
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
DAS Data Acquisition System
ECC Emergency core cooling
EPFM Elastic plastic fracture mechanics
FCG Fatigue crack growth
FE Finite element
HTC Heat transfer coefficient
JRC Joint Research Center
KB Knowledge base
KE Knowledge Engineering
LEFM Linear elastic fracture mechanics
MPA Materialprfifungsanstalt
NDE Non-destructive examination
PTS Pressurised thermal shock
PWR Pressurised water reactor
QM Qualitative modelling
3-D Three-dimensional

1 INTRODUCTION

A complete assessment of reactor pressure vessel structural reliability has to

include analysis of the behaviour of existing or assumed cracks under the
168 A. Jovanovi?', G. Volta, A. C. Lucia

loads and conditions imposed by the PTS (Pressurised Thermal Shock)

events and the corresponding local thermal transients. The PTS is usually
defined as an event, or a transient, in pressurised water reactors (PWRs)
causing severe overcooling (thermal shock) concurrent with, or followed by,
significant pressure in the reactor vessel. There are several important aspects
of PTS events: the thermal hydraulical one, the 'material science' one, the
operational one, etc., but PTS is, by definition, mostly related to the
structural safety and reliability of the vessel. Therefore, PTS has to be
analysed within an 'integral' approach, taking all these aspects into account
(Fig. 1). This tendency has become evident in most of the recent research
programmes, as well as in practice (see e.g. Meyer et al.2), and it is evident
also in the JRC Ispra PTS research presented in this paper. As the
possibilities for the full-scale PTS component tests are restricted, the scaled-
down ones, such as that of the JRC, appear as a more reasonable solution.
Previous investigations (reviewed and analysed in the work of Jovanovi~ 3)
have shown that a single thermal loading (thermal shock), cannot cause a full
penetration of the vessel wall, starting from reasonably assumable 'worst
case' defect dimensions and loading conditions. But, in the presence of
pressure or other mechanical loads and/or due to the repetitive PTS loads, a

Obtain plant data Construct event trees Develop model

THERMAL
HYDRAULIC
ANALYSIS

Estimate probability
1
Estimate conditional

PRA PTS EVENT-SEQUENCE

ANALYSIS

&&
of events

,/
wobabiltty of vessel failure
PROBABILISTIC
FRACTURE
MECHANICS
ANALYSIS
(INCLUDINGFCG)
0 EFPY 32

Estimate frequency
of vessel failure

STRUCTURALRELIABILITY 1 I ,/-//~//f
ASSESSMENT ~, , ~~/ / / " ~

0 EFPY 32
Fig. I. General procedure for evaluating the risk of vessel failure under PTS loads. 1
 J R C Ispra pressurised thermal shock experiment 169

hypothesis of a complete wall penetration cannot be completely excluded.

This has been one of the reasons which led to the research on the repetitive
PTS in the JRC Ispra structural reliability research programme. Frequency
and types of repetitive PTS loadings had been re-examined, because it was
shown 4 that although many PTS-like events are normally included in the
PWR design specifications, other PTS events have been experienced in
practice too.
2 JRC ISPRA PTS EXPERIMENT

2.1 Description and planning of the experiment

In the period since June 1985, the JRC Ispra PTS experiment has progressed
from the feasibility study 3 to the start-up of the experimental work. The
EX

i ]

- ~ 2500
I
0
0
¢N
~794 -
! 45.3

n C1 C1
o, \ \ /
,\ / ?,',, \
E1

, I , , fi t...J [("d 11 11 II II II

Fig. 2. JRC Ispra PTS experimental facility.

170 A. Jovanovik, G. Volta, A. C. Luc&

/
Pl "~(

Fig. 3. Locations examined: nozzle corner (PI) and safe end (P2).

work performed has included a large number of activities, ranging from the
procurement of the components and site preparation, to the pre-
experimental analyses.
The experiment is a follow-up to the continuing JRC research and
experiments on scaled PWR vessel models. 5 The model vessels are at 1:5
scale, with an internal diameter of 800 mm and a wall thickness of 48 mm
(SA 533 welded plates), cladded with a 3 mm thick cladding (AISI 347),
containing two forged nozzles (SA 508) and being designed for a maximum
pressure of 300 bar. Some of the results related to the room temperature
pressure cycling of these vessels (up to 220 bar max. pressure) have been also
used when tackling PTS problems; for instance, in the fields of damage and
fracture mechanics, 6'7 or for scaling problems. 8
The PTS experimental rig is aimed towards the examination of the
problem of the structural safety and reliability assessment of a pressure
vessel (with cracks at the nozzle corner and safe end), exposed to repetitive
PTS loads (Figs. 2 and 3). The pressure load is simulated by hydraulic
actuators (Fig. 4), heating of the testpiece is obtained by the resistance and
induction heaters, while the cooling medium is water at room temperature.
At present, data can be acquired at 182 points (40 strain gauges and 142
thermocouple/microthermocouple/thermistors). The testpiece represents
the cylindrical part of the P W R vessel, with a nozzle and the safe end, at 1 : 5
scale. The basic idea of the experimental design is to reproduce (around the
 JRC Ispra pressurised thermal shock experiment 171

nozzle c o r n e r c o o l i n g water test pi~

Fig. 4. Technical solution of the device for cooling of the nozzle corner and safe-end zones
of the J R C Ispra PTS testpiece. A = hydraulic actuators.

cracks in the mentioned zones) temperature and stress fields similar to those
in a full-scale vessel.
The research programme is summarised in Tables 1-3, while the results
obtained so far have particular reference to:
(a) temperature distribution analysis;
(b) stress analysis (mechanical and thermal stresses);
(c) microcracknucleation analysis;
(d) fracture mechanics analysis;
(e) application of advanced concepts in data acquisition;
(f) application of artificial intelligence tools; and
(g) pre-experiments related to initial crack production and system
testing.

A series of crack sizes (the same crack growing under PTS loads), under
various PTS loads is to be examined, with the final goal being to reach a
'best estimate', rather than a conservative structural reliability assessment.
Avoiding internal pressurisation by pressurised water (use of hydraulic
actuators) has been estimated as a factor with a positive influence on the cost
and feasibility of measurements. The final choice of the scale (1:5) satisfies
the requirements regarding goals, scope, organisation and realisation of the
experiment, which had to be matched with the 'internal' phenomenological
aspects of the types of PTS events examined.
 TABLE 1
JRC lspra Pressurised Thermal Shock Experiment: Programme of the Analytical and
Experimental Research

Phase Main research goals

0 Feasibility study phase Verification of the basic idea

I Construction and procurement
phase
2 Pre-experimental phase
3 Experimental phase
4 Post-experimental phase
5 Conclusion phase
Initial layout of the experimental rig
Preliminary calculations
DAS verification
Crack production experimental rig
Pre-test calculations and analyses
Start-up
Repeated PTS
Long-term cooling PTS experiments
Combined experiments
"On-line" analyses
Detailed analytical research
NDE data analysis
Metallography
Experimental vs analytical results
Summary of the research results
Matching of PTS experiment results with results
of the 1: 5 scale experiment
Proposal for further research

TABLE 2
JRC Ispra PTS Experimental Programme

Experiment Short description of the experiment

1 PTSEI Thermal-mechanical, repetitive loading of the nozzle corner region (up to

300 loadings max.); formation of the 'PTS' crack
PTSE2 Long-term cooling (J-controlled) PTS experiment, in the nozzle corner
region
PTSE3 Chained combination ofPTSE 1 and PTSE2 experiments (dynamics of the
experiment to be finally defined according to the results of the PTSEI
and PTSE2)
PTSE4 Through-crack creation experiment---examination of necessary loading
conditions leading to a structural failure (leak)
5 PTSEI 1 As PTSE1, but including the safe-end cracks
6 PTSEI2 As PTSE3, but including the safe-end cracks
 JRC lspra pressurised thermal shock experiment 173

TABLE 3
JRC Ispra PTS Analysis Programme

Phase Main research goals

0 Feasibility study phase Probability and main causes of PTS events

Pre-experimental phase
2 Experimental phase
Post-experimental phase
4 Conclusion
PTS event trees
Preliminary HTC estimation
Temperature field analysis
Thermal stress field analysis
Simulation of internal pressure
feasibility analysis
EPFM analysis of the nozzle corner crack behaviour
under combined thermal and mechanical loading
Parametric analyses with constant and variable HTC (in
space and time)
Temperature field analysis
Thermal stress field analysis
Mechanical loads stress analysis
Combined loads stress analysis
EPFM analysis (nozzle corner and safe-end cracks under
combined loads--J integral
Study and development of an incremental EPFM
parameter post-processor (e.g. T*)
Examination of applicability of a KE shell
As above, with measured input values
Verification of assumptions
Comparison between the J and T* integral approaches
Application of the KE shell
Detailed analysis based on NDE and metallography
results
Final comparison: experiment vs analytical results
Summary of the research results

2.2 Physical background

T h e p h e n o m e n o l o g y o f the e x p e r i m e n t is s h o w n schematically in Fig. 5.
C o o l i n g w a t e r is s p r a y e d in the z o n e o f the nozzle c o r n e r (Qh) a n d in the z o n e
o f the safe-end (Qs), w h e r e the c o r r e s p o n d i n g cracks are a s s u m e d (either
those c r e a t e d b y n u c l e a t i o n u n d e r the repetitive P T S loads, o r those
deliberately induced). D u e to the gap f, which can be regulated, the flow Qh is
divided into the p a r t which cools the nozzle interior (Qh~) a n d the p a r t
c o o l i n g the cylindrical p a r t o f the P T S testpiece (Qh2). R e g u l a t i n g the g a p f
o n e also regulates the ratio m:
m = Qhl/Qh = m ( f ) (1)
174 A. Jovanovi~, G. Volta, A. C. Lucia

COOLING WATER DEFLECTOR

Z
Y/ Qh~mI,.~

Fig. 5. JRC Ispra PTS experiment: the cooling device flow distribution, sg, Strain gauges; tc,
thermocouples.

and hence, the cooling conditions of the nozzle corner (flows Qh and Qs can
also be regulated. It can be supposed that the heat transfer coefficient (h.c)
will depend only on Qhl, at the chosen point in space and time (for other
conditions unchanged).
The gradient of the temperature field in the PTS testpiece depends on
h.c(rn):
V T.,~ V T(h.~(m)) (2)
and so do thermal stress and strain tensors
a,h = O,n(E, Ao¢.)~bm, 2¢/, V T(h.~(rn)) (3)
and
~'th = ~'th(E, V, As, 2bin, 2el , V T(h.,(rn)) (4)
The first approximation for h.~ in the JRC Ispra PTS experiment has been
made using the simplified correlation, for which Levy and Healzer 9 has
demonstrated (within given limitations) the applicability in the ECC
conditions:
~- - 0"23 Pr 0"33 (5)

This can be rewritten as a function of the two principal unknown

parameters, the ratio m and the equivalent density Peq, in the following way:

h.c = 0-023 2 (Qh/Ah l)°'Spr o.33(mPeq)O.8 (6)

Leo
 JRC Ispra pressurised thermal shock experiment 175

The thermal stress and strain tensors, determined on the basis of h.c as
defined above, are to be added to mechanical ones, in order to calculate the
fracture mechanics parameters K and Jk (the crack dimension a, as the third
important unknown, is discussed later, and here is taken as a deterministic
part of the input):
K = K(amech,CTth(hnc),x/a) (7)
Jk = Jk(amech, ath(h.c), £mech, ~:,h(h.c)) (8)
These two LEFM and EPFM parameters are then used, either in the failure
criteria:
K(o, ~/a) < K,, (9)
J(~r, ~,) < Ju (1 O)
or in the fatigue crack growth criterion (lifetime estimation):

a= ~ __<aaUowed < a~ (11)

where

da da
dN - f ( A K ) or d--N = f ( A J ) (12)

The criteria (9)-(11) are further applied in the general assessment of

structural reliability, which can be described by means of the general
equation:t°
A

R(t, x) = ~ Pt,x("f(q) < "~)P(F.) (13)

a=t

2.3 Scaling

Phenomena to be scaled in the PTS experiment impose many 'feasibility

limits' which usually'contradict the desirability of using small-scale rigs
(which, on the other hand, have many advantages regarding simplicity, costs,
etc.). Therefore, the final scale of a PTS experiment is always a compromise.
Scaling for a cracked structure has a further, built-in, limitation resulting
from the definition of the stress intensity factor, which describes the state at
the crack tip by means of the equation:
K = K(a,x/a ) = g(O'therm, O'mech, N/a) (14)
The results of the performed pre-experimental analyses confirm that the
176 A. Jovanovi?, G. Volta, A. C. Lucia

SMALL SIZE TEST I INTERMEDIATE

SPECIMEN I SIZE VESSELS
SA 533 .SA 5 0 8
F shape effect a n a l y s i s ~

..AIS1304,AIS1316,AIS1347 JRC 1:5 Scale V~ssels

SPECIAL EFFECT
EXPERIMENTAL
FACILITIES
__~.__.
o~
r- "~" 0794 1 - 4 8 + 3

q0
,,$

U JL_ ..~ _ ~
JRC PTS Experiment
- thermal shock
FULL SIZE
- safe-end eff. VESSEL
~ 7 - seismic loads
V
LARGE SCALE
TEST SPECIMEN
s0ecl
analysis~

shape effect analysis~ ' ii

I
05000
I
I
k J ~
1
Fig. 6. JRC Ispra PTS experiment as a part of the PWR vessel structural reliability research
pattern.

JRC rig allows good scaling, maintaining the simplicity and accessibility of a
small scale rig. a G o o d scaling is a necessary condition in order to match the
experiment and its results with other elements of the experimental research
related to the structural reliability assessment for the full-scale vessel (Fig. 6).

3 A P P R O A C H TO T H E A N A L Y S I S

A practical structural reliability analysis can be carried out at different

'levels', according to the available data and the state of experimentation. The
 JRC lspra pressurised thermal shock experiment 177

following levels have been identified in the JRC Ispra experiments:

(a) The 'nucleation level': the analysis starts from the 'zero' state, i.e. it
includes the microcrack nucleation and growth and, on the basis of
these results, continues with the macrocrack analysis.
(b) The 'NDE data level': the analysis starts with the data provided by the
NDEs, from the continuous monitoring and periodic ('in-service')
inspections (ultrasonics, acoustic emission, etc.).
(c) The 'backward analysis level': the analysis starts from the final state,
e.g. from the through crack at the nozzle corner, and goes backwards,
to the initial stages.
These assumptions correspond, respectively, to three types of safety
analysis, namely:
(a) The pre-service analysis (example: the detailed manufacturer's or
user's pre-service inspection data are available, but no defects are
found).
(b) The in-service analysis (example: the vessel is already in service, an
estimation of the residual life has to be carried out, but the data about
real dimensions of the cracks include uncertainties).
(c) The post-accidental analysis (example: the structural failure has
occurred, the final dimensions of the crack are known, and the crack
growth history should be reconstructed).
On the other hand, the JRC Ispra PTS experiment is a component test, and
so the following issues had to be tackled, too:
(a) Interaction of different phenomena (this is the sense of experimen-
tation on real structures)--separation of single phenomenon is not
wanted.
(b) Difficulties in direct measurements of the relevant parameters (crack
dimensions for instance).
(c) The necessity of including uncertainties in all the considerations.

4 SPECIFIC CONSIDERATIONS A N D FIRST RESULTS

4.1 Structural reliability assessment procedure

Any structural reliability assessment can be thought of as a global procedure

relying on a number of steps or single procedures to be concatenated: non-
destructive testing, material characterisation, analysis of loads, stress
analysis, fracture mechanics analysis, crack growth analysis and failure
analysis. The necessity of including such a large number of elements makes
178 A. JovanoviO, G. Volta, A. C. Lucia

P T S TEST VESSEL

MATERIAL ANALYSIS OF PTS LOADS DEFECT =_~

CHARACTERISATION (HEAT TRANSFER ANALYSIS) DIMENSIONING

STRESS ANALYSIS
J;
DAMAGE ACCUMULATION ANALYSIS EXPERIMENTAL l
(ELASTIC-PLASTIC, FE, 3-D) REGARDING THE CRACK NUCLEATION STRESS ANALYSIS

NUMERICAL ANALYSIS OF DAMAGE ACCUMULATION ANALYSIS --7

L FRACTURE MECHANICS PARAMETERS

( J . J*. ~ , T~ INTEGRALS)

I1
REGARDING THE
CRACK GROWTH

CRACK GROWTH ~ FAILURE

ANALYSIS ~L ANALYSIS

STRUCTURAL RELIABILITY ASSESSMENT I

i

Fig. 7. Applied structural reliability assessment procedure.

the assessment complex and usually leads to a need to use the best available
methods and techniques. The structural reliability assessment procedure
applied in the JRC Ispra PTS experiment (Fig. 7) has implied a organisation
of analytical tools, e.g. of computer codes (Fig. 8).

4.2 Material characterisation

For the PTS testpiece, attention has been focused on the problem of real, as-
built-in characteristics, and so an examination of relevant properties has
been performed (materials: SA533, SA508 and AISI347). However, a more
comprehensive characterisation should be carried out later.

4.3 N D E issues

Out of a larger number of N D E techniques used for the 1:5 scale

experimental vessel in the PTS experiment, the following have been foreseen:
periodic ultrasonic testing (manual (ASME) and automatic (ultrasonic
focused probes)), continuous ultrasonic monitoring, liquid penetrants,
acoustic emission and potential probes.
Significant problems are expected to be encountered in the application of
the methods, especially on the level of dimensioning of cracks, mainly due to:
(a) the complex geometry of the nozzle and the safe-end region;
 JRC lspra pressurised thermal shock experiment 179

EXPERIMENTAL INSTALLATION
! ! t !
VESSEL GEOMETRY P T S LOADS CRACKS [ MATERIAL
FE PREPROCESSING: THERMAL HYDRAULIC I NDE- I CHARACTE-
- PATRAN ANALYSIS AND MO- CRACK LOCA- RISATION
- ADINA-IN DELL NG TION AND DI-
- ABAQUS MENSIONS
- MESH GEN

=
t
THERMAL ANALYSIS I
=
- ABAQUS I
- ADINAT
- STRUDL

NON-STATION, 3-D TEMP. FIELD

_1 STRESS ANALYSIS 12
~i MICRO-CRACK
NUCLEATION
- ADINA
- ABAQUS
- MIC CODE
- STRUDL

L
NON-STATIONARY, 3-D
STRESS-STRAIN FIELD

t E.PPF_._~NALYSIS i . . . . . .

- CONTOUR INTEGRAL CODES

- ABAQUS NEW CRACK DIMENSIONS

FPROBASILISTIC CRACK GROWTH ANALYSIS I I

I LIFE TIME ESTIMATION

t
I STROCTURALREL,,S,LIT,ASSESSMENTI
Fig. 8. Use of computer codes in structural reliability assessment in the JRC Ispra PTS
experiment.7'8

(b) the relatively poor accessibility of the zones; and

(c) the nature o f the expected defects (PTS-induced cracks).
Manual ultrasonic examinations o f the nozzle corner zone of the testpiece
are to be carried out following the principal scheme shown in Fig. 9. A
similar approach has been adopted for the continuous monitoring. The
approximate position of the ultrasonic probes for continuous monitoring is
shown in Fig. 10. Identifying the crack tip diffraction and the crack root
reflection ultrasonic signals, it is possible to reconstruct the change of
180 A. Jovanovi?, G. Volta, A. C. Lucia

nozzle openingcircle__~
re

radial crock
~ t r a ~ m i t t e r tra~

Fig. 9. Ultrasonic manual examination of the nozzle corner cracks.

amplitude corresponding to crack growth during PTS loading. For the

automatic examination, the scanner shown in Fig. 11 and focused probes are
used.

4.4 Analysisof PTSloads

In a real nuclear power plant, PTS loadings of the vessel have three major
components that need to be analysed:
(a) pressure in the primary loop (vs time);
(b) temperature of the coolant (Th) in time and space coordinates);
(c) heat transfer coefficient on the exposed surface (nozzle corner and
safe-end regions, h,c in time and space co-ordinates).
In the JRC experiment, the internal pressure loads are simulated by loads of
hydraulic actuators and these loads can be arbitrarily imposed, but the
induced mechanical stresses had to be analysed separately and in detail. The
mean coolant temperature in the experiment can be measured and, in the
first approximation, can be assumed constant (max. total flow is over 50 l/s).
The determination of the heat transfer coefficient remains the main issue of
interest in the analysis of PTS loads in the JRC Ispra experiment. In the
majority of other PTS experiments, this has not been the case as, due to
usualy very simple geometry, it was possible to 'measure' the HTC, by
choosing the value which gave the best fit to the measured temperature
profiles.
In other words, no heat and mass transfer analysis has been performed.
Furthermore, a complete analysis also has to take into account the
Fig. 10. Approximate position of the probes for the continuous monitoring in the 1:5 scale
JRC experiment.

u lX I i

LB " }1 LB
i

Fig. 11. Use of the automatic scanner in the JRC Ispra PTS experiment, for examination of
the nozzle region (focused probes technique). LB, Lower bases of the testpiece; W, water; C,
cylindrical part of the testpiece (PTS); N, nozzle; E, safe end; P, 'piping'; U, upper support of
the scanner; X2, scanner; H, arm of the scanner (ultrasonic focussed probes).
182 A. Jovanovi?, G. Volta, A. C. Lucia

significant fluctuations of the local coolant temperature, 11 and their

cumulative effects, during one single PTS event. The fluctuations appear in
the real plant too and, together with frequencies and cumulative effects of
'overlooked', 'unpredicted' and/or 'unreported' PTS events (the latter
appearing in experienced cases when multiple concatenated PTS events were
registered and reported as a single one4).

4.5 Stress analysis

The JRC Ispra analysis is based on the 3-D, 20 node, finite elements, with
3 × 3 Gauss points. For the crack tip simulation in the mesh, the '1/4 length'
elements have been used. The crack shape has been fully simulated by the
shape elements in the FE mesh (a plane crack in a 3-D body), while the crack
growth has been simulated through the mesh redefinition (Fig. 12).
The analysis has been initiated starting from the preliminary calculated
values of the heat transfer coefficient (between 5000 and 10 000 W/m 2, in the
regions of interest). Although the parametric calculations for a range of heat
transfer coefficient values have also been carried out, as in other PTS
experiments, the final results of the pre-test analysis are based on non-
stationary, in 3-D variable, HTC values (coolant inlet temperature 20°C,
cladding effects included in the analysis). One of the results obtained for
these conditions is shown in Fig. 13.

Fig. 12. 3-D finite element mesh (with the crack) of the nozzle corner region of the JRC
lspra PTS experiment testpiece (simplified representation). A, Crack nucleation point; B, leak
location experienced on the 1:5 scale vessel.6
 JRC lspra pressurised thermal shock experiment 183

0 0.Ssec 2zec 5zec

3O0 :~:z:~:~:!:i:

~ 200 ,

50 .::!i
.!!!!.~:1 .

0 10 20 30 I~0 50 60 mm 70
DEPTH
Fig. 13. Section through the 3-D transient temperature field in the nozzle corner region.

First measurements (external and internal wall surface temperature

measurements) are in accordance with the heat transfer analysis results. The
thermal stress analysis, based on these results, shows that during the first 30
seconds of the cooling, a thermal stress (equivalent, elastic) of over 500 MPa
would appear at the most stressed points in the vicinity of the nozzle corner.
Results of stress analysis regarding the internal pressure loads, simulated
by the actuators acting at two points only (the 'cross-like' layout has been
adopted in the final solution), show a good similarity between the PTS
experimental piece, the scaled PWR vessel and the full-scale PWR vessel, as
shown in Fig. 14.

4.6 Crack nucleation problem

Research into the nozzle corner crack behaviour implies research into the
problem of crack nucleation. In principle, there are two possible ways to
analyse the process of crack nucleation under repetitive loading: using the
S - N or e - N curves, or using the damage mechanics.
The method based on S - N curves did not offer a satisfactory solution in
our case, so an alternative approach has been examined. This led to an
analytical model and the corresponding computer code. 6 The model has two
parts: one based on single void growth and the other based on the increase of
the volumetric void fraction. The intention has been to find a reasonable
relationship between the parameters of the damage and the duration of the
crack nucleation phase.
The models take their input from the finite element, three-dimensional
non-linear stress analysis (the 3-D strain field in the examined zone). The
184 A. JovanoviO, G. Volta, A. C. Lucia

a) c)~
Noz/le vessel
200
t,0 0 ~ ~ , , - - 250
. 350 300

~ vessel
° --t oo

veisel
~ ~ (~ 0), (hoop) stress (MPa)
Fig.14. Pre-experimentalanalysisresultsfor the JRC IspraPTS testpiecepressure
simulation: (a) full scale vessel;(b) experimental vessel--internal pressure; (c) experimental
vessel--hydraulic actuators.

models have been developed by extending works and models developed for
creep and ductile rupture.
The single void (isotropic cavity) growth model is based on Rice and
Tracey's equation: 12
1 dR de p (3P)
~ - 0.558-d-Tsinh ~-~ (15)

where R is the void radius, P is the 'tensile pressure' and Yis the 'current yield
strength'. The equation has been used in the form:

l d R . 0,283 ~pqexp (3o-m'] (16)

R dt \2aeq/

where
am = trill3 (17)
and ge% is the equivalent plastic strain rate. As for the volumetric void
 JRC Ispra pressurised thermal shock experiment 185

fraction model, we have assumed that in the case of repeated (mechanical

and thermal low-cycle fatigue) loading, one can approximate
N
(/3eS)total = ~ ' P load --~ N(eeVq)sing.load
(/3eq)single (18)
I

and, with appropriate limitations,

gPeq"~ deP~/dN ~- const. (19)
(there are no creep effects in JRC Ispra experiments). Assumption (19) is a very
rough one and should be replaced by an analytically or empirically
determined relationship
e~q = g~q(N) (20)

Two effects are considered important for the nucleation of the nozzle corner
crack; namely the effect of triaxiality (am/O'eq),and the effect of accumulation
of plastic strain (Z eP).
The same assumptions are made for the part of the nucleation model
which considers the volumetric void fraction (void density) growth. This part
of the model is based on the works of Roussellier and co-workers, la'la in
which the ductile crack growth is assumed to be the result of a permanent
competition between the hardening R(p) and damage B(fl). The damage can
be expressed as a function of the initial volume fraction of cavities ()Co),of the
effective stress which has to be related to the resistance of the metal matrix
containing voids, and of the damage variable fl:
alfoexpfl
B(fl) = (21)
1 - f o + f o exp fl
Further on this approach yields the increase in the volumetric fraction of
voids:

v= - p(1 - p + pfo) De~exp(~m/PCrO (22)

Material properties a~ and f0 are determined by material testing (slightly

modified tensile tests and metallography), while the change in density can be
neglected. Therefore, with an adequate choice of constants, both eqns (16)
and (22) lead to the same type of analytical expression. One should bear in
mind, however, that the two expressions are derived in a different way, the
second one being more general.
In the JRC experiments, the elaboration of the data onfo, for the SA508
steel, is carried out using probabilistic treatment, combining the metallo-
graphic input data on sulphuric inclusion probability distributions
186 A. Jovanovik, G. Volta, A. C. Lucia

(histograms) in three perpendicular examination planes, as dependent

stochastic variables.
The corresponding computer code (MIC) has been developed for the
needs of the JRC Ispra experiments (written in C language) and its single
void growth option has been successfully applied in the post-test analysis of
the nozzle corner crack nucleation in the JRC Ispra 1:5 scale experiment 7's
(it was assumed, and indicated by the acoustic emission, that the fatigue
crack developed from a large, underclad inclusion). This suggests the
application of the approach in the PTS experiment too.

4.7 Fracture mechanics analysis

In the JRS Ispra experiment, first pre-experimental results are based on

LEFM (Fig. 15) but more adequate concepts are to be applied later. The
concepts based both on the deformation theory and on the incremental
theory of plasticity have been examined. The first group of solutions
presents the parameters such as the J integral with the 'thermal term'
added, 15 or the J* integral. 16
In the second group, attention has been focused on the T* integral, 17
defined for the incremental potential A V over an arbitrary closed contour F
(and the enclosed volume), not enclosing the crack tip, as:

(AT*)1 = f_ [AWn~ - (ti + Ati) Aui.x - Atiu~.~] dS

dl E

=fr + Sc V
[AWnl-(ti + Ati)Aui'l -Atiu~'l]dS

"~~ [Aaij(~.ij,1
'~-lAg.ij,1)--A~ij((~ij,1
+ ½Aaij,O ] d V (23)
dv F - Ve

Moran and Shin x8 expressed some doubts about the usefulness of the T*
integrals, but the incremental integrals remain the main practical way to deal
with arbitrary (i.e. repetitive) PTS loads. However, at present, the most
widespread E P F M parameter in the PTS analysis is still the J integral with
the thermal term added, defined for the 2-D case as:

Jth = fr (Wnl - T,u,,Ods + fA tr'Je'*'x dA (24)

where the strain energy (stress energy density, in a more general case) is
W = ~ ~ijd(eij- e*)
and e* denotes the thermal strain.
 JRC lspra pressurised thermal shock experiment ] 87

t,O : :~ctodding I min 2 min

30

2,,,

0 10 20 30 ~.0 mm 50
CRACK DEPTH
Fig. 15. K/,,erm values for the nozzle corner crack.

In the JRC experiment the concept has to be applied in the 3-D finite
element mesh and the triaxial stress state, which entails the use o f general,
3-D, solutions like as, for instance, the integral domain one: 19

j= .iS {[(TijHj, k -- W~ki]qk, i d- [O~tTiiOk --fiUi.k]qk} d V (25)

in which qk is an introduced function having 0-value on the far-field
integration contour (surface) and value l k at the integration contour (surface)
at the crack tip, and in which the crack face (surfaces S + and S - ) term
("
AJc1~ = -- | (a2jUj.km2qk) d S (26)
Js * + S
is to be added, if relevant (m2 = _ 1 on the crack faces).
Presented EPFM concepts encounter difficulties when applied to the
prediction of the nozzle corner crack behaviour in the JRC Ispra testpiece,
such as:
(a) the crack is exposed to repetitive loading;
(b) the integration contours/domains/areas normally have to include the
interface between the cladding and the base metal (with possible,
other than crack tip singularities);
(c) the temperature change related non-linearity of the cladding and the
base metal material heat properties should not be neglected.
The main difficulty is the fact that the J integral is valid under the
assumption that the strain energy density (stress working density) is a single
valued function of strain. The applicability of the deformation theory of
plasticity being assumed, which is mathematically equivalent to a non-linear
theory of elasticity, the Jintegral still characterises the crack tip field and still
188 A. Jovanovik, G. Volta, A. C. Lucia

remains path-independent, but it is theoretically valid only for monotonic

loading and it precludes unloading (i.e. repetitive PTS). Incremental
parameters (T*) allow avoidance of most of the difficulties, but still cannot
handle other than the crack tip singularity. Finally, each of the above-
mentioned EPFM parameters can (so far) be related to only one
standardised, EPFM material characteristic, which is Jlc (determined, for
instance, according to ASTM standards). Determination of the crack
behaviour from the condition J > J1c is clear, but it is less straightforward to
deduce what happens when other than J integrals are used.

5 U N C E R T A I N T I E S IN THE ANALYSIS

5.1 Uncertainties in NDEs

Previous experience in the JRC Ispra experiments has revealed considerable

problems regarding the dimensioning of defects; for examination of the
welds of the 1:5 scale experimental vessel, four ultrasonic methods have been
used in parallel, and their results compared, showing significant differences
(up to 100% in the crack depth, for instance). The significance of such
differences in the N D E dimensioning, has been analysed, 2° showing that
even an error much smaller than the quoted differences can cause extremely
large differences in the lifetime estimation. The difficulties expected in the
PTS experiment should be even larger. In PTS research the problem of
uncertainties in N D E results could, for instance, 21 be treated using
possibility theory.

5.2 Uncertainty related to h.c

The physical nature of the examined transient phenomena appears to be the

main source of uncertainty in the determination of the heat transfer
coefficient. Increasing the complexity of the experiment, the possibility of
formulating precise but significant statements decreases and it becomes
necessary, as in normal human reasoning, to manage a resumed
representation of reality. The use of possibility theory 22 offers a general
means by which to deal with the problem, allowing us to treat imprecision
and uncertainty through the application of fuzzy arithmetic.23 The practical
application of fuzzy algebra in the PTS experiment implies application of the
basic relations of possibility theory:
P(A) + P(,4) = 1 (27)
N(A) + N(ff) <_ 1 (28)
~z(A) + rt(A) >_ 1 (29)
Obviously, while the probability of A defines ,4 completely, necessity and
 J R C Ispra pressurised thermal shock experiment 189

IJ.A(x)
A

1.0
F ~ X-mA ~ / ~"~ FR(-_~)
x
I ~. "A

,i
rnlA mA m2A X
Fig. 16. Representation of m and Peq in the form of the L - R fuzzy number with a flat (A).

possibility give only a weak link between the two. In the JRC Ispra PTS
experiment, such a situation can be observed with (at least) two mentioned
parameters: heat transfer coefficient and crack size.
When treating the uncertainties of the heat transfer coefficient, one can
start from eqn (6) and define h,c as a function o f fuzzy quantities m and Pe~"
These two can be understood as fuzzy intervals, i.e. fuzzy quantities having a
normalised membership function pQ on R in [0, 1]:
Vu, v V we [u, v] Po(w) >_ min (izo(u), i~o(v)) (30)
Function #Q can be seen as a possibility distribution of values that can be
taken by the variable (the limiting case of a fuzzy interval, for an interval
with the single modal value, is a fuzzy number). One can reach the same
definition in a more empirical way, through the levels of confidence or levels
of presumption and the corresponding intervals. 23 A way to represent these
two quantities would be to represent them as L - R (convex and normal) fuzzy
numbers with a flat (Fig. 16). The numbers are defined for reference function
~b as:
for x ' e R , ~be(O, 1):
ck(x') = F,.(x'), - oo < x ' < 0

= 1, x' = 0 (31)
= FR(x') 0 < x' < oo
The function enables us to construct a fuzzy number:
V x~R:
p(x) = FL((x - - rna)/ua) --o0 <x <m A
=1 x=m a (32)
= FR((x -- ma)/vA) m A < X < +O 0
190 .4. Jovanovik, G. Volta, A. C. Lucia

PA
A

o1 02 03 a~
Fig. 17. Representation of m and Peq in form of the trapezoidal fuzzy number A (TrFN A).

which can be represented non-unimodally as

= ( m l A , m2A , 1XA, UA) (33)

For practical PTS experiment calculations, it would be reasonable to reduce

the L - R fuzzy representation to a simular trapezoidal fuzzy number
representation (Fig. 17)
A = (al, a2, a3, a,) (34)
Numerical values for m = (ml, m2, ma, m4) and for Peq = (Peql, Peq2, Peq3, Peq4)
will be assessed during the PTS experiments (Fig. 18).

1.0,

=Q--T

I mmin
I
o) I
T

1,0 m

b, 0 / o1
i
0.2 03

Fig. 18. Expected change of m vs z ( f = f ( z ) ) and the corresponding membership function

and TrFN.
 JRC Ispra pressurised thermal shock experiment 191

5.3 Application of the AI tools

Application o f the artifical intelligence (AI) methods and tools has not been
foreseen in the PTS experiment feasibility study. 3 However, AI-related
needs have been better identified later and the application o f AI has been
considered and initialised. 3° The application has been foreseen for the needs
listed in Table 4 and enhanced by the availability of the necessary computer
background in the SER Division of JRC Ispra.
The PTS analysis concerns three main levels of AI application, which are:
(a) the qualitative modelling o f PTS phenomena, both in the experi-
mental installation and in a real plant;
(b) the treatment o f fuzziness in the acquired data, including the
propagation of fuzziness; and
(c) the m a n - m a c h i n e (man-plant) interaction modelling.
The problem o f qualitative modelling (QM) in the PTS experiment should be
treated in order to:
(a) improve planning of the experiment; and
(b) offer the decision aid during the conduct of the experiment (the
experimental installation is designed to allow at least 2500 PTS load
cycles, while the mechanical and thermal loading conditions are
controllable).
Qualitative simulation should enable rapid analysis of a large number o f
scenarios and optimisation o f postulated decisions. The works of Kuipers, 2s
Iwasaki and Simon 26 and of De Kleer and Brown 27 provided the main

TABLE 4
Typical PTS Problems Requiring AI Application

PTS research problem AI (possible) response

(I) "Causes"of a PTS event: Man-plant interaction

PTS event tree modelling and
determination of its parameters
(probability of occurrence, etc.)
(2) Phenomenological analysis of a PTS
Local heat transfer transient analysis,
crack behaviour, etc.
(3) Planning of the PTS experiment
(4) Performance of the experiment
(operator behaviour modelling)
Fuzzy sets, logic, algebra
Qualitative modelling (QM)
Man-plant interaction QM
Treatment of fuzziness in the data
QM-based decision aid
192 A. Jovanovid, G. Volta, A. C. Lucia

Ti (~ Qh!_(m),Th

o ~ vessel
ATw watt
Tout

Omech

INPUT'~ Th_.~h
L ",,,
PRECEOiNG;T, "~-~Tinew~u
STATE ~1 Ta_~ATw .~r'1 =_Oth /~l ~,~h
L T:u,
Fig. 19. Simplified causal structure for the crack growth in the PTS testpiece.

guidelines for definition of the causal structure (Fig. 19) and the system of
qualitative equations, related to the JRC Ispra PTS experiment (A is the
QM proportional operator):
Am = AQh 1
AH=cl A m + c 2 A Th
A (ATw) = c3 A Th + c4 A h (35)
A trth = C5 A (ATw)
A K l t h = C6 A a + c7 A tr,h
A a = c 8 A (Knh + K1mech)
The treatment of fuzziness is briefly described in section 5.2, while the
foreseen way to model the man-plant interaction (the operator's role) is
through an expert system containing:
(a) a knowledge base of the engineering system (either that of the
experimental rig or that of a real plant);
(b) a rule base regarding the procedures to follow;
(c) a cognitive learning and decision model of the operator's behaviour.
Starting from given scenarios, the expert system can be used as 'PTS load
generator' for a whole class of PTS events.
 JRC Ispra pressurised thermal shock experiment 193

STRUCTURAL RELIAS. ANALYSIS OF A VESSEL EXPOSED TO PTS ('CLASSICAL" COMPUTERS AND CODES) I

PTS EXPERIMENT PLANNING

I PTS EXPERIMENT OPERATOR/SUPERVISOR

i i ;
DECISION SUPPORT INFORMATION DECISIONS
I

HUMAN MAN-MACHINE
i ----1TREAT-I
QUALITATIVE
I
I
HIGH-LEVEL J
INTERACTIVE INTERACTION MODELLING MENT OF PROCESS
COMPUTER MODELLING OF THE PTS FUZZY
I
CONTROL
(SYMBOLICS 3640- DATA EXPERIMENTAL DATA
I
KEE3 SOFTWARE)
I
INSTALLATION
I

[- - - r
! J
TASK REAL TIM~-E- LOW-LEVEL I
INTERACTIVE PROCESS I
DATA ACQUISITION
I
COMPUTER AND ELABORATION CONTROL
(HP 9300-HP-UX, (PLUS OFF - LINE I
REAL TIME, C LANG., ELABORATION AND I
PLANNED: ADA) DATA STORAGE) J
I r

PTS EXPERIMENT ( PROCESS )

Fig. 20. Matching of the AI tools in the overall experimentation, and the analysis flowchart
(see Figs 7 and 8).

AI tools are practically applied in the experiment as a follow-up to the

procedure shown in Figs 7 and 8 ('classical' computer codes). Figure 20
shows how the considered AI issues are matched with these 'classical' codes
and how they are structured within the PTS experiment. The AI tools are
incorporated at the level of a 'human interactive computer', acting as a
connection between the experiment supervisor/operator and the task
interactive computer. This allows a three-level process control, containing
the operator's (supervisor's) level, the human interactive computer level
(high level control) and the task interactive computer level (low level
control).
The level-II control is performed through Symbolics 3640 hardware and a
KEE3 set of software tools. 28 The set enables one to cope better with
problems which are poorly specified, difficult to define and heavily
dependent on heuristics.
The PTS knowledge base (KB) represents the PTS installation and related
knowledge through discrete objects. The objects of the KB are: the physical
parts o f the i n s t a l l a t i o n (e.g. t a n k s , p u m p s , testpiece, etc.); a n d e v e n t s (e.g.
possible leaks, faults, etc.) and rules.
The objects (units) are grouped in a hierarchical scheme and they contain a
collection of characteristics of a given object.
To describe these characteristics, the following predefined facets have
been used: inheritance, value class; cardinality (min. and max.), and values.
194 A. Jovanovi?, G. Volta, A. C. Lucia

COMPRESSED. AIR, SUPPLY / RESISTANCE No. 1

'FRESH. WATER. SUPPLY HEATING ~/~-~'~-~ ~ "-~---•
Y ..~.'~L~------ ~------- RESISTANCE No. 5
S STEM ....... INDUCTION
J
ELECTRICAL ~'--- MOTORS
/ COMPONENTS~INDICATORS
/ DATA. ACQUISITION ALARMS ~ ACTUATOR No. 1
/ / SYSTEM / /~;'~:
///•
//
/ / ,.,TEST. PIECE ;
TSCO"TAIN'" ,,:'.: ..ACTUATOR.o,.
//,;'///~ "
////
/ / / I '~--,'~
.... RIGHPRESSORE
\\\\ PUMP
SYSTEM % HIGH PRESSURE

LINES
MECHANICAL
PTS-EXPERIM.INSTALLATIO-N- COMPONENTS-- COMPONENTS
I~ T M ~ ' ~ FEEDWATER TANK
//~ \ CONTAINMENT DUMP
I ~\ ~ AUXILIARY PUMP
~PUMPS < ~ MAIN PUMP

------ CHILD LINKS / t'PIPING MAIN LINE 2

' ~ " BYPASS LINE
I ~ /MANUAL
CHECK VALVES ~ MAiN LINE VALVE
I-
ELECTRIC.suPPLy
POWER VALVES~---PNEUMATIC < _ _ _ BYPASS VALVE
\VALVES ~ FV SUPPLY VALVE
\ ELECTRO
vALVES
Fig. 21. PTS experiment knowledge base (simplified layout).
The elements of the hierarchy are classes, superclasses, subclasses and
members.
The simplified layout of the JRC Ispra PTS-KB is shown in Fig. 21.

6 CONCLUSIONS

Pressurised thermal shock is an experienced, existing and envisaged,

important problem of PWR safety. Within the research at JRC Ispra, which
is explained here, the problem is examined both at the level of the basic
phenomenology (cracks in the nozzle corner and safe end regions), and at the
level of the application of advanced technological tools (e.g. AI). First
results confirm the importance of cracks in the nozzle corner region. Their
nucleation and propagation are the result of the structural damage
accumulation processes, which cannot be easily modelled and are hardly
detectable. The application of the new experimental concepts and advanced
analytical (EPFM) modelling of the nozzle corner crack behaviour in the
 JRC Ispra pressurised thermal shock experiment 195

vessel exposed to the combined mechanical and thermal loads are the issues
of major interest in the next phases o f the JRC Ispra PTS experiment;
always, however, examined and applied within the described 'integral
approach'.

ACKNOWLEDGEMENTS

Most of the results presented in the paper refer to the period 1983-7, in
which the first author participated in the J R C Ispra research programme.
The collaboration of all the JRC staff, and especially of M r U. Schwartz, in
the preparation and execution of the experiments is highly appreciated. The
manuscript has been prepared at M P A Stuttgart, thanks to the co-operation
of Professor K. Kussmaul and M r A. Sauter.

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