Fracture mechanics and full scale pipe break testing for the Department of Energy's new production reactor-heavy water reactor

Abstract Oak Ridge National Laboratory (ORNL) has completed a major task for the US Department of Energy (DOE) in the demonstration that the primary piping of the proposed new production reactor-heavy water reactor (NPR-HWR), with its relatively moderate temperature and pressure, should not suffer an instantaneous double-ended guillotine break (DEGB) under design basis loadings and conditions. The growth of possible small pre-existing defects in the piping wall was estimated over a plant life of 60 years. This worst-case flaw was then evaluated using fracture mechanics methods. It was calculated that this worst-case flaw would increase in size by at least 14 times before pipe instability during a safe shutdown earthquake (SSE) would even begin to be possible. The approach to showing the improbability of an instantaneous DEGB for HWR primary piping required a major facility (pipe impact test facility, PITF) to apply all possible design loads, including an equivalent major earthquake (called the SSE earthquake). The facility was designed and built at ORNL in 6 months. The test article was 6.1 m long, 406 mm diameter, 13 mm thick pipe of stainless steel 316LN material that was fabricated to exacting standards and inspections following the nuclear industry standard practices. A flaw was machined and fatigued into the pipe at a tungsten inert gas (TIG) butt weld (ER316L weld wire) as an initial condition. The flaw-crack was sized to be beyond the worst-case flaw that HWR piping could see in 60 years of service—if all leak detection systems and if all crack inspection systems failed to notice the flaw's existence. Starting October 1991, the first test article was subjected to considerable overloadings. The pipe was impacted 104 times at levels equal to and well beyond the SSE loadings. In addition, over 560 000 fatigue cycles and numerous purposeful static overloads were applied in order to extend the flaw to establish the data necessary to confirm fracture mechanics theories, and more importantly, to demonstrate simply that instantaneous DEGB is highly improbable for the relatively moderate energy system.