Piping dynamic reliability and code rule change recommendations

The conservative nuclear piping design criteria for seismic and dynamic loads have led to piping systems with excessive numbers of snubbers. To improve this undesirable situation, a Piping and Fitting Dynamic Reliability Program was initiated by the Electric Power Research Institute (EPRI) in 1985 with cooperation from the U.S. Nuclear Regulatory Commission (NRC). The objective of the program is to develop improved, realistic, and defensible ASME design rules by taking advantage of the inherent dynamic margins in the nuclear piping system. The research results have demonstrated that piping systems have large reserve dynamic capacity and the dynamic failure mode is due to fatigue or fatigue-ratcheting rather than plastic collapse. Based on such physical evidence, a set of code rule change recommendations is suggested in its preliminary form.     

Response of piping system on friction support to bi-directional excitation

Installation of friction devices between a piping system and its supporting medium is an effective way of energy dissipation in the piping systems. In this paper, seismic effectiveness of friction type support for a piping system subjected to two horizontal components of earthquake motion is investigated. The interaction between the mobilized restoring forces of the friction support is duly considered. The non-linear behavior of the restoring forces of the support is modeled as an elastic-perfectly plastic system with a very high value of initial stiffness. Such an idealization avoids keeping track of transitional rules (as required in conventional modeling of friction systems) under arbitrary dynamic loading. The frictional forces mobilized at the friction support are assumed to be dependent on the sliding velocity and instantaneous normal force acting on the support. A detailed systematic procedure for analysis of piping systems supported on friction support considering the effects of bi-directional interaction of the frictional forces is presented. The proposed procedure is validated by comparing the analytical seismic responses of a spatial piping system supported on a friction support with the corresponding experimental results. The responses of the piping system and the frictional forces of the support are observed to be in close agreement with the experimental results validating the proposed analysis procedure. It was also observed that the friction supports are very effective in reducing the seismic response of piping systems. In order to investigate the effects of bi-directional interaction of the frictional forces, the seismic responses of the piping system are compared by considering and ignoring the interaction under few narrow-band and broad-band (real earthquake) ground motions. The bi-directional interaction of the frictional forces has significant effects on the response of piping system and should be included in the analysis of piping systems supported on friction supports. Further, it was also observed that the velocity dependence of the friction coefficient does not have noticeable effects on the peak responses of the piping system.     

The IPIRG dynamic pipe loop test facility

The International Piping Integrity Research Group (IPIRG) Program was a group program conducted at Battelle, managed by the U.S. Nuclear Regulatory Commission, and funded by a consortium of organizations from nine nations. A unique pipe loop test facility was designed and constructed for the program to evaluate the behavior of nuclear piping containing flaws and subjected to high rate loading typical of high amplitude seismic events. The facility was carefully designed with rigid anchors and special support bearings to provide well-controlled boundary conditions that can be accurately modelled in numerical analyses. Extensive instrumentation provided pipe system response data and pipe fracture data that serve as a test bed to evaluate various structural and fracture analyses.     

Effects of ductility on seismic response of piping systems and their implication on design and qualification

This study is concerned with the inelastic seismic response of nuclear power plant piping systems. Two systems are examined. The first one is an idealized four-equal-span pipe run and the second one consists of two configurations modified from an existing pipe run. Detailed finite element seismic time history analyses are performed using the computer program. By varying the various geometrical and physical parameters, calculations are made for a total of 76 cases. The results show that ductility generally contributes to reducing the response of piping systems. An empirical relation between the support load reduction factor and support ductility demand is given and a chart and simple procedures are suggested for the design and qualification of piping supports taking ductility into consideration.     

Further development of the load coefficient method, lcm, for rational seismic design of nuclear facilities

The purpose of this paper is to present the results of a study conducted to compare the results of the Load Coefficient Method, LCM, proposed for seismic load determination, to modal analysis and the equivalent static load methods as defined in Section 3.7.2 of the U.S. Nuclear Regulatory Commission Standard Review Plan. The comparison is conducted using a number of nuclear power plant piping systems which used response spectra modal analysis input in their original design.The real piping systems studied are considered to be representative of ASME Section III nuclear Class 2 and 3 piping systems required to be designed to resist currently defined seismic loadings. Section 2 of this paper provides numerical comparisons of the application of LCM, Response Spectrum and Equivalent Static Load Methods.     

Analysis and test correlation of flexible and stiff piping systems

An in situ pipe test program was conducted to provide a basis for evaluating piping analysis methodologies and design philosophies. In this program, a 20.3-cm boiler feedwater line with two fundamentally different support systems was tested and analyzed. One system employed hanger supports and was very flexible. The second system employed strut and snubber supports and was relatively stiff. Snapback and forced vibration tests were performed on the piping systems. The test results were used to determine piping damping values and to correlate with analyses. These analyses were used to evaluate current piping analysis methodologies and their analytical models. Also, parametric studies were performed with the analytical models to evaluate the effect of different support systems on the pipe behavior for thermal and seismic loads. In addition, the seismic analysis results were compared to quantify the differences between direct time integration and response spectra analysis methods.     

Nuclear piping system damping data studies

A program has been conducted at the Idaho National Engineering Laboratory to study structural damping data for nuclear piping systems and to evaluate if changes in allowable damping values for structural seismic analyses are justified. The existing pipe damping data base was examined, from which a conclusion was made that there were several sets of data to support higher allowable values. The parameters which most influence pipe damping were identified and an analytical investigation demonstrated that increased damping would reduce the required number of seismic supports. A series of tests on several laboratory piping systems was used to determine the effect of various parameters such as types of supports, amplitude of vibration, frequency, insulation, and pressure on damping. A multiple regression analysis was used to statistically assess the influence of the various parameters on damping, and an international pipe damping data bank has been formed.     

Piping research overview

The USNRC Piping Review Committee (PRC) was formed in 1983 with a charter to review NRC piping criteria, to recommend changes to this criteria, and to identify areas that would benefit from future research. This overview will outline the NRC-sponsored research being conducted to address those PRC recommendations concerning the design of nuclear piping systems to withstand dynamic loads. A key element of this research is the joint EPRI/NRC “Piping and Fitting Reliability Research Program.” This program consists of dynamic capacity testing of piping at the system, component, and specimen levels, plus analyses needed to support recommendations for changes to the ASME Code. As part of NRC's contribution to the EPRI/NRC program, a pipe system capacity test will be conducted at ETEC. The “Nonlinear Piping Response Prediction” project at HEDL is evaluating nonlinear response prediction techniques with differing degrees of complexity and will compare the various analytical results both with each other and with physical benchmarks such as the ETEC test. An ORNL project is developing nozzle design guidance that will provide a more realistic basis for evaluating the higher nozzle loads that will result from the more flexible piping systems design that are being considered. INEL will evaluate high frequency damping by considering the existing high frequency data and by conducting high frequency/high stress tests on two piping systems. LLNL is now conducting studies to more completely assess the uncertainties in the seismic response of building structures and piping systems. As a follow-on to the research efforts reported in NUREG/CR-3811, BNL will conduct additional studies to improve combinational procedures for piping response spectra analyses.     

Performance of a piping system and equipment in the HDR simulated seismic experiments

This paper describes a portion of the analysis and results of the United States Nuclear Regulatory Commission/Idaho National Engineering Laboratory (USNRC/INEL) participation in the SHAG (Shakergebaude) Seismic Research Program conducted by Kernforschungszentrum Karlsruhe (KfK) at the Heissdampfreaktor (HDR), a decommissioned nuclear reactor. The program analyzed the responses of a piping system and associated line-mounted equipment when subjected to various seismic and hydraulic loadings. Of interest was to evaluate the influence that piping support system flexibility has on piping system responses. The results of the studies will contribute to the technical basis for assessing the responses of light water reactor (LWR) piping and fine-mounted equipment to earthquakes.     

Positive use of damping devices for piping systems — Some experiences and new proposals

An increase of the damping ratio is known to be very effective for the seismic design of a piping system. It is reported that the energy dissipation in piping supports contributes to increase the damping ratio of the piping system. In this paper, with regard to increasing the damping and reducing the seismic response of the piping system, three application methods of damping devices used in other engineering fields are reviewed: (1) direct damper, (2) dynamic vibration absorber, and (3) connecting damper. Based on the results of this review, the following three types of damping devices for piping systems are introduced: (1) visco-elastic dampler (direct damper), (2) elasto-plastic damper (direct damper), and (3) compact dynamic absorber (dynamic vibration absorber). The dynamic characteristics of these damping devices are investigated by a component test and the applicability of them to the piping system was confirmed by the vibration test using a three-dimensional piping model. These damping devices are more effective than mechanical snubbers to suppress the vibration of the piping system.     

塑性变形对管系地震动力响应的影响

在评述线弹性分析方法的基础上,阐明了在管系特别是核管系动力响应分析中考虑塑性变形影响的重要性,介绍了现有考虑塑性影响的方法及其存在的问题.指出要降低现行规范的保守性,提出合理的管系抗震设计方法,     

Simplified seismic analysis methods in Belgium

Seismic design and analysis of nuclear plant systems, structures and components have requested huge effort and tremendous costs in the past two decades. The extended use of sophisticated, linear response type methods (modal analysis, spectral response) and the associated conservatism are responsible for the significant stiffening of the piping systems and the multiplication of supports and snubbers. The remedy used against the seismic risk seems worse than the pain itself, and safety might be impaired rather than improved. Indeed, system stiffening increases the average load level in normal operation (stresses, fatigue, nozzle loads, etc.); supports do not behave ideally as assumed (friction, rust, etc.) and snubbers are remarkably unreliable. On the other hand, experience with actual earthquakes shows that industrial facilities designed using very simplistic seismic techniques, or even no seismic requirement at all, suffer essentially no damage, even in the case of a large earthquake. This paradox challenges the traditional seismic design techniques, and appeals for revised seismic qualification methods of piping systems. When the assumption of the occurrence of an earthquake event is made in a plant in operation, which has not been designed against seismic criteria, the use of the standard seismic qualification techniques is still more questionable; simplified (quasi-static) techniques offer in this case a valuable and economically justified alternative. The paper describes the application of the quasi-static “modified load coefficient method” to the seismic assessment of the piping in a nuclear plant in operation, designed during the pre-seismic era.     

Enhanced seismic criteria for piping

In situ or laboratory experiments have shown that piping systems exhibit satisfactory seismic behavior. Seismic motion is not severe enough to significantly damage piping systems unless large differential motions of anchorage are imposed. Nevertheless, present design criteria for piping are very severe and require a large number of supports, which creates overly rigid piping systems. CEA, in collaboration with EDF, FRAMATOME and IRSN, has launched a large R&D program on enhanced design methods which will be less severe, but still conservative, and compatible with defect justification during operation. This paper presents the background of the R&D work on this matter, and CEA proposed equations.Our approach is based on the difference between the real behavior (or the best estimated computed one) with the one supposed by codified methods. Codified criteria are applied on an elastically calculated behavior that can be significantly different from the real one: the effect of plasticity may be very meaningful, even with low incursion in the plastic domain. Moreover, and particularly in piping systems, the elastic follow-up effect affects stress distribution for both seismic and thermal loads.For seismic load, we have proposed to modify the elastic moment limitation, based on the interpretation of experimental results on piping systems. The methods have been validated on more industrial cases, and some of the consequences of the changes have been studied: modification of the drawings and of the number of supports, global displacements, forces in the supports, stability of potential defects, etc.The basic aim of the studies undertaken is to make a decision on the stress classification problem, one that is not limited to seismic induced stresses, and to propose simplified methods for its solution.     

The steamhammer problem: dynamic shock loading of critical reactor piping systems

In the course of both pre-operational testing and power operation of commercial nuclear power plants, relatively large amplitude transient vibrations of steam piping systems have been experienced with damage to the piping supports in at least one recent case. These transient vibrations result from ‘steamhammer’ or dynamic shock loading induced by pressure and momentum transient conditions generated in the piping by sudden changes to the flow conditions, such as are produced by sudden valve opening or closure. In particular, vibrations have been experienced in by-pass and discharge lines as a result of relief valve discharge, and in main steam lines as a result of sudden main stop valve closure. Piping in both BWR and PWR reactor systems has been found to be susceptible to these conditions.This paper is concerned with the evaluation of the pressure and momentum transients resulting from sudden valve operation, and the determination of the dynamic response of the piping to the induced transient loading. The characteristics of the transient conditions existing immediately following both sudden valve opening and closure as encountered in BWR and PWR plants are discussed. The procedures used to calculate the transient time history functions are outlined. The derivation of the loading induced in the piping by the pressure and momentum transients is discussed and the determination of the dynamic response of the piping is presented. The procedures described in the paper are illustrated by actual examples from BWR and PWR plants, and the significance of steamhammer effects relative to other loading conditions is discussed.     

Response spectrum analysis of piping systems with elastic-plastic gap supports

A new seismic support device and its application in piping systems is described. The device, E-BAR (patented), can be cost effectively used for snubber replacement programs, mitigation of hydraulic transients, pipe whip and as a thermal stop. The device has pre-set gaps to allow free thermal movement. During a seismic or other dynamic load event, if the pipe movement exceeds the gap dimension, the device acts as an elastic or elastic-plastic restraint. The device also has a unique design feature for not exceeding the restraint force beyond a specified limit design value. To analyze piping systems with gap supports having elastic-plastic characteristics, modal analysis procedures for both response spectrum and time history methods are developed. The comparison of responses obtained from the procedures with nonlinear time history analysis and test results available in the literature shows excellent correlation. A pilot program conducted for snubber replacement with E-BARs demonstrates that the limit force feature of E-BAR makes them very attractive for snubber replacement. This is because a particular E-BAR with a specified limit design force can be selected, such that, the E-BAR replacing the snubber does not require any modifications be made to the existing support steel and hardware.     

Automated analysis of multiple-support excitation piping problems

An automated solution algorithm is presented for the treatment of multiple-support excitation piping problems. The method is an extension of the well-known response spectrum analysis method which is routinely used for seismic analysis of structural systems. The new algorithm was incorporated in Kraftwerk Union's proprietary computer code KWUROHR for static and dynamic analysis of piping systems.In this paper the numerical results from the use of envelope and multiple-support acceleration input spectra are presented for two typical piping systems in nuclear power plants. From the comparison of these results it becomes obvious that the multiple-support excitation method should be recommended as standard analysis procedure for systems attached to support points which are subjected to different acceleration spectra. The additional computer cost is negligible.     

Impact of structural steel flexibility and restraints gaps on the dynamic behaviour of piping

The effect of gaps present in the seismic supports of nuclear piping systems and of the flexibility of the steel structure to which intermediate supports are attached, is studied in this paper. An actual piping system is used to investigate the impact of structural steel and mechanical snubber gaps on the dynamic behaviour of piping. An evaluation is thus performed of the finite element modeling techniques employed by the designers in the dynamic analysis of piping systems.     

Seismic stops vs. snubbers, a reliable alternative

The Seismic Stops methodology has been developed to provide a reliable alternative for providing seismic support to nuclear power plant piping. The concept is based on using rigid passive supports with large clearances. These gaps permit unrestrained thermal expansion while limiting excessive seismic displacements. This type of restraint has performed successfully in fossil fueled power plants.A simplified production analysis tool has been developed which evaluates the nonlinear piping response including the effect of the gapped supports. The methodology utilizes the response spectrum approach and has been incorporated into a piping analysis computer program RLCA-GAP.Full scale shake table tests of piping specimens were performed to provide test correlation with the developed methodology. Analyses using RLCA-GAP were in good agreement with test results. A sample piping system was evaluated using the Seismic Stops methodology to replace the existing snubbers with passive gapped supports. To provide further correlation data, the sample system was also evaluated using nonlinear time history analysis. The correlation comparisons showed RLCA-GAP to be a viable methodology and a reliable alternative for snubber optimization and elimination.     

Unsteady piping forces caused by hot water discharge from suddenly opened safety/relief valves

Various fluid transients in nuclear pressure vessels create the possibility of liquid discharge from safety/relief valves designed for steam release. Piping systems which carry the flow from safety/relief valves to an appropriate discharge environment are designed to withstand the unsteady reaction forces associated with steam flows. If liquid discharge occurs, the piping system may be subject to different unsteady reaction forces. This study provides a means of estimating discharge rates for saturated and subcooled water and resulting pipe forces, for the limiting case of a suddenly opened valve. It was found that pipe forces caused by the moving shock are about the same for either steam or water discharge. Pipe forces caused by a moving steam-water/air interface during water discharge may exceed those forces caused by the steam-air interface resulting from steam discharge. It was determined that water discharge would result in a longer opening time for a piston-type valve. It is therefore expected that with realistic estimates of valve opening time, the magnitude of water discharge forces will be approximately the same as steam discharge piping forces.     

Seismic behaviour of piping systems with and without defects: experimental and numerical evaluations

Based on important experimental and analytical programs, CEA has developed a wide expertise in the domain of the seismic studies of piping. The specific behaviour of piping systems, with and without flaw, under seismic loading, has been analysed. CEA has evaluated the margins coming from present design procedures, that are shown to be greatly conservative, and has developed analytical methods devoted to a better evaluation of the global behaviour (internal moments in the piping system or reactions in supports, displacements, rotations). Non-linear time–history procedures have been built that allow for accurate modelisation, with and without defect. For industrial purposes or for sensitivity analyses, simplified methods have been proposed that are much less time consuming than non-linear time–history calculations, but much more accurate than linear methods.