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The Leak-Before-Break (LBB) behaviour of a piping component is a desirable property that ensures the safety and integrity of the component. It means that if a crack develops in the pipe wall, it will cause a detectable leak before it grows to a critical size that could lead to a catastrophic failure. The LBB-concept of Siemens/KWU is a methodology that uses computer codes to calculate the critical crack size, the crack opening displacement, the leakage area and the leakage rate for a given pipe geometry, material and loading condition. These codes are based on fracture mechanics principles and take into account the effects of stress intensity factors, plasticity, crack closure and residual stresses. The output of the fracture mechanics analysis is then used as an input for the thermal-hydraulic analysis, which simulates the fluid flow and heat transfer in the pipe and evaluates the impact of the leak on the system performance. By comparing the calculated leakage rate as a function of crack size with the minimum detectable values of leakage rate and crack size by different methods, two criteria can be established to determine whether the pipe exhibits LBB-behaviour or not: - The critical crack size must be larger than the crack size that can be safely detected by leakage monitoring systems (LMS), which are devices that measure the pressure, temperature, flow rate or acoustic signals in the pipe and alert the operators in case of abnormal changes. - The critical crack size must be larger than the crack size that can be safely detected by non-destructive examination (NDE), which are techniques that inspect the pipe surface or wall thickness for defects using ultrasonic, eddy current, radiographic or magnetic methods. This LBB-concept is applied to steam generator (SG) tubes, which are thin-walled tubes that transfer heat from the primary coolant to the secondary coolant in a nuclear power plant. Two examples, which will be presented in this paper, demonstrate how this concept can be used to predict and verify the LBB-behaviour of SG tubes under various operating conditions and degradation mechanisms. (Author)
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The first example considers the LBB-behaviour of SG tubes subjected to primary water stress corrosion cracking (PWSCC), which is a degradation mechanism that causes intergranular cracks to initiate and propagate in the tube material due to the combined effects of tensile stress, high temperature and corrosive environment. The LBB-concept of Siemens/KWU was applied to a typical SG tube with a U-bend geometry and a nominal wall thickness of 1.09 mm. The fracture mechanics analysis was performed using the code KORC, which calculates the stress intensity factor and the crack growth rate for a semi-elliptical surface crack in a cylindrical shell. The thermal-hydraulic analysis was performed using the code LEAK, which calculates the leakage rate and the pressure drop for a through-wall crack in a pipe. The results showed that the critical crack size for LBB-behaviour was about 60% of the tube circumference, while the crack size detectable by LMS and NDE was about 10% and 20% of the tube circumference, respectively. Therefore, both criteria for LBB-behaviour were satisfied and the SG tube was considered to be safe from rupture due to PWSCC.
The second example considers the LBB-behaviour of SG tubes subjected to denting, which is a deformation mechanism that causes local reduction of the tube wall thickness due to the contact pressure from the tube support plates. The denting can lead to increased stress concentration and reduced fatigue strength in the tube material, which can facilitate the initiation and propagation of cracks. The LBB-concept of Siemens/KWU was applied to a typical SG tube with a straight geometry and a nominal wall thickness of 0.91 mm. The fracture mechanics analysis was performed using the code KORC, which calculates the stress intensity factor and the crack growth rate for a semi-elliptical surface crack in a cylindrical shell with an oval cross-section. The thermal-hydraulic analysis was performed using the code LEAK, which calculates the leakage rate and the pressure drop for a through-wall crack in a pipe with an oval cross-section. The results showed that the critical crack size for LBB-behaviour was about 40% of the tube circumference, while the crack size detectable by LMS and NDE was about 5% and 15% of the tube circumference, respectively. Therefore, both criteria for LBB-behaviour were satisfied and the SG tube was considered to be safe from rupture due to denting. e0e6b7cb5c