operated by

U N I O N CARBIDE CORPORATION
for the
U . S . A T O M I C ENERGY C O M M I S S I O N

ORNL- TM- 78'- 5

THERMAL-STRE SS A N D STRAIN-FATIGUE ANALY S E S OF THE

MSRE FUEL A N D COOLANT PUMP TANKS

C. G , Gabbard

NOTICE
T h i s document c o n t a i n s information of a preliminary nature and was prepared
p r i m a r i l y for i n t e r n a l use a t the Oak Ridge N a t i o n a l Laboratory.
I t i s subject
t o r e v i s i o n or correction and therefore does n o t represent a f i n a l report.
The
information i s not t o be abstracted, reprinted or otherwise g i v e n p u b l i c d i s semination without the approval of the O R N L patent branch, L e g a l and Information Control Deportment.

iq

L E G A L NOTICE

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prepared

as a n o c c o u n t of Government s p o n s o r e d work.

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nor t h e C o m m i s s i o n , nor mny parson o c t i n g on b e h a l f o f t h e C o m m i s s i o n :

A.

Mokes

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or

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C o n t r a c t No. W-7405-eng-26

Reactor D i v i s i o n

THERMAL-STRESS AND STRAIN-FATIGUE ANALYSES OF THE

MSRE FUEL AND COOLANT PUMP TANKS
C . H. Gabbard

DATE ISSUED

OAK RIDGE NATIONAL LABORATORY

Oak Ridge, Tennessee
o p e r a t e d by
UNION CARBIDE CORPORATION
f o r the
U. S. ATOMIC ENERGY COMMISSION

iii

CONTENTS
Abstract

.......................................................

...................................................
C a l c u l a t i o n a l Procedures .......................................
S t r a i n Cycles ...............................................
Introduction

...................................
Temperature D i s t r i b u t i o n C w e F i t t i n g ......................
Thermal-Stress Analysis .....................................
Temperature D i s t r i b u t i o n s

.......................................
R e s u l t s ........................................................
Temperature D i s t r i b u t i o n s ...................................
Thermal S t r e s s e s ............................................
Strain-Cycle Analysis

...............................................
Pressure and Mechanical S t r e s s e s ............................
Recommendations ................................................
Conclusions ....................................................
S t r a i n Cycles

.....................................................
Appendix A . D i s t r i b u t i o n of Fission-Product-Gas
Beta Energy ...................................................
Energy F l u x a t Pump Tank Outer Surface ......................

References

Energy F l u x a t t h e Volute Support Cylinder Outer Surface

....

....
Appendix B . Estimation of Outer Surface Temperatures and
Heat T r a n s f e r C o e f f i c i e n t s ....................................
Appendix C . Derivation of Boundary and Compatibility
Equations f o r Thermal S t r e s s C a l c u l a t i o n s .....................
Appendix D . Explanation of Procedure Used t o Evaluate
t h e E f f e c t s of Cyclic S t r a i n s i n t h e MSRE Pumps ...............
Nomenclature ...................................................
Energy F l u x a t t h e Volute Support Cylinder I n n e r s u r f a c e

THERMAL-STRESS AND STRAIN-FATIGUE ANALYSES OF THE

MSRE FUEL AND COOLANT PUMP TANKS
C

. H.

Gabbard

Abstract

Thermal-stress and s t r a i n - f a t i g u e analyses of t h e MSRE

f u e l and coolant pump tanks were completed f o r determining
t h e q u a n t i t y of cooling a i r required t o o b t a i n t h e maximum
l i f e of t h e pump tanks and t o determine t h e a c c e p t a b i l i t y of
t h e pump tanks f o r t h e intended service of 100 heating c y c l e s
from room temperature t o 1200F and 500 r e a c t o r power-change
c y c l e s from zero t o 10 Mw.
A c o o l i n g - a i r flow r a t e of 200 cfm f o r the f u e l pump tank
was found t o be an optimum value t h a t provided an ample margin
of s a f e t y . The coolant pump tank was found t o be capable of
t h e required s e r v i c e without a i r cooling.

Introduction
The f u e l pump f o r t h e Molten S a l t Reactor ~ x p e r i m e n t ' ( M S R E ) i s a
sump-type c e n t r i f u g a l pump composed of a s t a t i o n a r y pump tank and volute
and a r o t a t i n g assembly (see Fig. 1 ) .
i s constructed of INOR-8 (72%N i ,

The pump tank and volute, which

16%Mo, 7% C r , 5% F e ) , i s a p a r t of t h e

primary containment system, and t h e r e f o r e t h e highest degree of r e l i a b i l i t y i s required.

The pump i s s i m i l a r t o o t h e r high-temperature

molten-salt and liquid-metal pumps t h a t have accumulated many thousands

of hours i n nonnuclear t e s t -loop service .2

Although t h e s e nonnuclear

pumps have been highly successful, they have not been subjected t o the
degree of thermal cycling which may occur i n a nuclear p l a n t .

It t h e r e -

f o r e cannot be assumed from t h e operating records t h a t pumps of t h i s type

w i l l be adequate f o r t h e MEBE.
S t r e s s calculations* were completed i n accordance with t h e ASME
Boiler and Pressure Vessel Code f o r determining the w a l l thicknesses and
nozzle reinforcements required t o s a f e l y withstand an i n t e r n a l pressure

*Performed by L. V. Wilson.

UNCLASSlFlED

ORNL- LR- D W G - 5 6 0 4 3 - A

SHAFT
COUPLING\

WATER
COOLED

SHAFT SEAL

LEAK

DETECTOR

L U B E OIL I N
L U B E O I L BREATHER
SHAFT S E A L

L U B E O I L OUT

LEAK

DETECTOR

SHIELDING PLUG

BUBBLER T Y P E
L E V E L INDICATOR
XENON

BUOYANCY
LEVEL
INDICATOR

F i g . 1. MSRE Fuel Pump G e n e r a l A s s e m b l y D r a w i n g .

STRIP PER

of 50 p s i .

I n addition t o these pressure s t r e s s e s , t h e f u e l pump tank

w i l l be subjected t o r e l a t i v e l y high thermal s t r e s s e s because of the high

thermal gradients which w i l l be imposed by nuclear heating and t h e large
temperature difference between t h e top flange, which w i l l be a t 250 t o
300F, and the pool of molten salt i n t h e tank, which w i l l be a t 1225F.
Although t h e coolant pump w i l l not be subjected t o nuclear heating, there
w i l l be a large temperature difference between t h e top flange and the

molten s a l t i n the pump tank.

Since the ASME Pressure Vessel Code and Code Case I n t e r p r e t a t i o n s
do not adequately cover t h e design of a vessel a t creep range temperat u r e s under r e l a t i v e l y high cyclic thermal s t r e s s , the thermal s t r e s s
evaluation was conducted under the r u l e s of t h e Navy Code.
Code covers t h e design of pre ssurized-water reactor systems.

The Navy
The problems

of design i n t h e creep range are not e x p l i c i t l y covered, but design c r i t e r i a are established f o r vessels subjected t o thermal s t r e s s and cyclic
plastic strain.

Thermal s t r e s s e s a r e considered a s t r a n s i e n t i n the Navy

Code and must be evaluated on a fatigue b a s i s using the estimated maximum

numbers of various operational cycles and Miner's accumulative damage
theorem a s t h e design

riter ria.^

Automatic flow control of the cooling a i r t o t h e upper pump tank

surface was i n i t i a l l y proposed so t h a t t h e temperature gradient on t h e
spherical s h e l l would remain r e l a t i v e l y constant a t various operating
conditions.

The complexity and possible lack of r e l i a b i l i t y of the auto-

matic control system made it desirable, however, t o determine whether a

fixed a i r flow could be used f o r a l l the operating conditions of t h e pump.
Calculations were therefore made f o r establishing the temperature
d i s t r i b u t i o n s , thermal stresses, pressure stresses, and permissible number of operational cycles f o r various modes of operation and various
cooling a i r flow r a t e s .

From t h i s information, it was possible t o s e l e c t

operating conditions t h a t would permit the maximum number of operational

cycles and provide an ample f a c t o r of s a f e t y above the 100 heating and
500 power-change cycles anticipated f o r t h e MSRE.

Calculational Procedure s
S t r a i n Cycles
Since thermal s t r e s s e s a r e considered t o be t r a n s i e n t and i n some
cases subject t o r e l i e f by s t r e s s r e l a x a t i o n a t operating temperatures,
they must be evaluated on a s t r a i n - f a t i g u e basis, a s required by t h e Navy
Code.

Two types of s t r a i n cycles w i l l occur during normal operation of

t h e pump:
1. heating and cooling when t h e r e a c t o r system i s heated from room tem-

perature t o operating temperature and returned t o room temperature,

and
2.

power-change cycles when t h e r e a c t o r power i s r a i s e d from zero t o 10

Mw and returned t o zero.

The change i n s t r a i n must a l s o be considered f o r a loss-of-cooling

a i r incident i n which t h e operating conditions would change from ( 1 ) r e a c t o r power operation a t 10 Mw with design a i r flow t o ( 2 ) operation a t
10 Mw with no a i r flow t o (3) zero power operation with no a i r flow.
Temperature D i s t r i b u t i o n s
The i n i t i a l s t e p i n t h e thermal-stress and s t r a i n - f a t i g u e analyses
was t o determine t h e temperature d i s t r i b u t i o n s i n t h e pump tank f o r various
operating conditions based on t h e e f f e c t s of i n t e r n a l heat generation,
conductive heat flow, convective and r a d i a t i v e heat t r a n s f e r with t h e
s a l t , and cooling of t h e shielding plug and upper pump tank surface.

The

generalized heat conduction code4 (GHT Code) was used t o obtain t h e temperature d i s t r i b u t i o n s .

During reaotor power operation, t h e f u e l pump

tank w i l l be heated by gamma, r a d i a t i o n from both the r e a c t o r v e s s e l and

t h e f u e l s a l t i n t h e pump tank and by b e t a r a d i a t i o n from t h e f i s s i o n product gases.

The maximum gamma heat-generation r a t e during r e a c t o r

operation a t 10 Mw was calculated* t o be 18.70 ~ t u / h r - i n . at t h e inner

surface of t h e upper portion of t h e pump tank, giving an average heating
r a t e through t h e 1/2-in. -thick pump tank wall of 16.23 ~ t u / h r - i n3. .
g a m heat-generation r a t e i n t h e shielding plug above t h e pump tank
%alcul.ated by B. W . Kinyon and H. J. Westsik.

The

was calculated a t increments of 1/2 i n . based on an exponential decrease

i n t h e heating r a t e .

The beta heating, which varied from 4.80 t o 22.22

~ t u / h r i. n .2, was estimated by d i s t r i b u t i n g the t o t a l b e t a energy emitted

i n t h e pump tank over t h e pump-tank surface exposed t o t h e fission-product
gases (see Appendix A ) .
Preliminary c a l c u l a t i o n s with t h e GHT Code indicated t h a t controlled
cooling of t h e upper pump tank surface was necessary, not only t o lower
t h e tnaximum temperature, but a l s o t o reduce t h e temperature gradient i n
t h e spherical portion of t h e pump tank near i t s junction with t h e volute
support c y l i n d e r i n order t o achieve acceptable thermal s t r e s s e s

These

c a l c u l a t i o n s a l s o predicted excessively high temperatures i n t h e volute

support cylinder between t h e pump tank and t h e pump volute.

These high

temperatures were caused by a s e r i e s of p o r t s i n t h e volute support c y l i n der w a l l f o r draining t h e s h a f t l a b y r i n t h leakage back i n t o t h e pump tank.
The d r a i n p o r t s were o r i g i n a l l y located at t h e bottom of t h e cylinder
and r e s t r i c t e d the conduction of heat downward i n t o t h e s a l t .

The maxi-

mum temperatures were reduced t o an acceptable l e v e l by centering t h e

d r a i n p o r t s between t h e pump tank and t h e pump volute so t h a t heat conduction would be u n r e s t r i c t e d i n t h e both d i r e c t i o n s .

F i n a l temperature

d i s t r i b u t i o n s f o r zero power operation a t 1200F, zero power operation

a t 1300F, and 10-Mw operation a t 1225F were obtained f o r various coolinga i r flow r a t e s by varying t h e e f f e c t i v e outer-surface heat t r a n s f e r coefficient.

Temperature d i s t r i b u t i o n s were a l s o calculated f o r 10-Mw opera-

t i o n a t 1225'F,

zero power operation a t 1200F, zero power operation a t

1300F, and zero power operation a t 1025F without e x t e r n a l cooling.

The

method of obtaining t h e e f f e c t i v e outer-surface heat t r a n s f e r c o e f f i c i e n t s

f o r t h e various conditions i s described i n Appendix B.

The pump tank and

volute support cylinder geometry considered i n t h e s e c a l c u l a t i o n s i s

shown i n Fig. 2.
Temperature D i s t r i b u t i o n Curve F i t t i n g
Before t h e meridional and axial temperature d i s t r i b u t i o n s of t h e
pump tank can be used i n t h e thermal s t r e s s equations, they must be ex-

pressed a s equations of t h e following form (see p. 66 f o r nomenclature):

UNCLASSI F I E 0
ORNL-LR-DWG 64494 R

TOP F L A N G E

/ VOLUTE

SUPPORT
CYLINDER

PUMP TANK
SPHERICAL
SHELL

CYLINDER

A\[

LlQUlD
LEVEL-

Fig. 2.

LIQUID L E V E L

Pump Tank and Volute Support Cylinder Geometry.

I n t e r n a l Volute Support Cylinder "A"

Pump Tank Spherical S h e l l

For t h e i n t e r n a l cylinder and t h e spherical s h e l l , t h e GHT temperat u r e d i s t r i b u t i o n d a t a were f i t t e d t o t h e equation by t h e use of a l e a s t squares c u r v e - f i t t i n g program.5

For t h e e x t e r n a l cylinder, manually f i t

equations containing only t h e exponential terms were found ko f i t exc e p t i o n a l l y w e l l t o within about 2.5 i n . of t h e t o p flange, where excessive e r r o r s were encountered.

On t h e other hand, t h e l e a s t - s q u a r e s - f i t

equations containing a l l t h e terms f i t very w e l l i n t h e v i c i n i t y of t h e

t o p flange but deviated near t h e cylinder-to-shell junction.

A comparison

of the d a t a obtained with t h e two f i t t i n g methods and t h e GHT d a t a f o r

the e x t e r n a l cylinder i s shown i n Fig. 3 .

Since t h e c y l i n d e r - t o - s h e l l

junction i s considered t o be t h e most c r i t i c a l a r e a because of i t s high

operating temperature, t h e manually f i t equations were used f o r t h e ext e r n a l cylinder.

The points on Figs. 4 and 5 show the " f i t " obtained f o r

t y p i c a l s e t s of GHT temperature-distribution data.

Thermal-Stress Analvsis
I n order t o c a l c u l a t e t h e thermal s t r e s s e s , t h e pump tank and volute
support c y l i n d e r were considered t o be composed of t h e following members,
a s shown i n Fig. 2:
1. an i n t e r n a l cylinder extending from t h e volute t o t h e junction with

t h e s p h e r i c a l s h e l l , cylinder "A,

"

Fig. 3 . Comparison of "Hand-Fit" and "Least -Square-Fit" Temperat u r e Data with GHT Data f o r Cylinder "B. "
UNCLASSIFIED
ORNL-LR-DWG

64492R

VOLUTE

-----

- 1 0 0 0 ---A

FUEL PUMP, 10-Mw POWER, 2 0 0 - c f m

-4

FUEL AND COOLANT PUMP, ZERO

POWER, NO EXTERNAL COOLING

COOLING AIR FLOW

40

8
AXIAL POSITION :In.

12

14

46

Fig. 4 . Axial Temperature D i s t r i b u t i o n of Volute Support Cylinder

a t Various Operating Conditions.

UNCLASSIFIED
ORNL- -4-DWG 6 1 1 9 3 R
2000

,I

AND
INDICATE T E M P E R A T U R E S P R E D I C T E D B Y THE
T E M P E R A T U R E EQUATIONS FOR THE 0 A N D t o - M w
POWER CGSES W I T H 2 0 0 - c f m COOLING AIR F L O W 0

CYLINDER
JUNCTION

1
I

FUEL PUMP, qO-Mw POWER, N O E X T E R N A L COOLING

600

6
8
10
M E R O I G N A L POSITION (in.)

12

!4

16

Fig. 5. Meridional Temperature D i s t r i b u t i o n s of t h e T o r i s p h e r i c a l

S h e l l a t Various Operating Conditions.
2.

an e x t e r n a l c y l i n d e r extending from t h e junction with t h e s p h e r i c a l

s h e l l t o t h e t o p flange, cylinder "B,

3.

I'

and

t h e pump tank s p h e r i c a l s h e l l .
An Oracle program* was used t o obtain t h e pressure s t r e s s e s , t h e

s t r e s s e s from t h e a x i a l load on t h e cylinder, t h e thermal s t r e s s e s r e s u l t i n g from temperature g r a d i e n t s i n e i t h e r o r both cylinders, and any
combination of t h e s e loadings.
continuous ( i . e . ,

The Program assumes t h a t t h e sphere i s

has no boundary o t h e r than t h e cylinder junction) and

i s at zero temperature.

The zero-temperature assumption required that

the temperature functions of t h e c y l i n d e r s be adjusted t o provide t h e

proper temperature r e l a t i o n s h i p between t h e t h r e e members.

The boundary

conditions f o r t h e ends of the two cylinders s p e c i f i e d t h a t t h e slope of

the cylinder walls was zero and t h a t t h e r a d i a l displacements would be
V h e Oracle program f o r a n a l y s i s of symmetrically loaded, r a d i a l l y
joined, cylinder-to-sphere attachments was developed by M. E Laverne and
F. J. W i t t of ORNL.

equal t o the f r e e thermal expansion of the members a t t h e i r p a r t i c u l a r

temperatures.

It was recognized a t the beginning t h a t some degree of

e r r o r i n t h e thermal-stress calculations would be introduced by t h e absence of a thermal gradient on the sphere; but i n t h e cases where a i r
cooling was used t o l i m i t the gradient, t h e r e s u l t s were believed t o be
reasonably accurate.

Later calculations showed, however, t h a t the

s t r e s s e s were very sensitive t o t h e temperature gradient on t h e sphere,

and therefore t h e Oracle code was used only t o evaluate the pressure
s t r e s s e s and t h e s t r e s s e s from a x i a l loads.
I n order t o calculate the thermal s t r e s s e s , including t h e e f f e c t s
of the thermal gradient on the sphere, it was necessary t o s u b s t i t u t e a
conical s h e l l f o r t h e sphere.

The angle of i n t e r s e c t i o n between the cone

and cylinders was made equal t o the equivalent angle of i n t e r s e c t i o n on

the a c t u a l structure.

This s u b s t i t u t i o n was required because moment,

displacement, slope, and force equations were not available f o r thermals t r e s s analysis of spherical s h e l l s with meridional thermal gradients.
Thermal s t r e s s e s i n t h e two cylinders and the cone were calculated
by t h e use of the equations and procedures outlined i n r e f s . 6-9.

In

order t o evaluate the four integration constants required f o r each of

the three members, it was necessary t o solve the 12 simultaneous equat i o n s which described the following boundary and compatibility conditions
of the structure:
Cylinder "A" a t Volute Attachment.

The slope of cylinder "A" was

taken a s zero and t h e deflection a s - d l .

Cylinder "B" a t Top Flange.

The slope of cylinder "B" was taken a s

zero and the deflection a s - d l .

Cone a t Outside Edge.

The slope of the cone was taken a s zero and

the meridional force was taken a s zero.

Junction of Cylinder "A," Cylinder "B," and Cone.

The sunmation of

moments was taken a s zero; the summation of r a d i a l forces was taken a s

zero; the slopes of cylinder "A,"

cylinder "B," and the cone were taken

t o be equal; and the deflections of cylinder "A,"

cone were taken t o be equal.

cylinder "B," and the

The following 12 equations, which are more completely derived i n

Appendix C, describe t h e boundary and c o m p a t i b i l i t y c o n d i t i o n s given
above :

where

aB

Bc

tc

- CCnaW/n - - t a n2

#J

CncWAc

= 1484.65Ta2 +

I n these equations,

Equations (1)through (12) are arranged so t h a t the l e f t side containing the unknown integration constants i s dependent only on the specific
pump tank configuration, while the r i g h t side containing the thermalgradient terms w i l l vaxy f o r each case.
After obtaining the four integration constants f o r each member, the
bending and membrane s t r e s s e s can be calculated using the following equat i o n s f o r e i t h e r cylinder or the cone:

For t h e principal meridional and circumferential stresses the applicable

equations are:

For cylinder "A, "

N*=O

For cylinder "B,

"

For t h e cone,
M9 =

C Cn cMy n + J1K 2 + 1.3J2 + 2.3J3P1

+ 2.2J4P3

I n order t o f a c i l i t a t e t h e solution of several cases and t o reduce

the amount of time involved i n calculating complete s t r e s s d i s t r i b u t i o n s ,
an IBM 7090 program was written f o r the MSRE pump configuration.

The

program c a l c u l a t e s t h e temperature-dependent constants of t h e 12 simultaneous equations, solves t h e equations f o r t h e 12 i n t e g r a t i o n constants,

and c a l c u l a t e s the bending, membrane, and principal. s t r e s s e s a t 65 locations.

Up t o 25 cases can be solved, and t h e number of cases t o be

solved and the constants i n t h e temperature d i s t r i b u t i o n equations a r e

included a s input data.

A s e t of general input d a t a i s a l s o required

t h a t contains the left-hand members of the simultaneous equations and t h e

position functions tabulated i n r e f s . 7 and 9.
A special t e s t case with a uniform-temperature conical s h e l l was

prepared f o r t h e IBM 7090 program t o check the v a l i d i t y of s u b s t i t u t i n g

the conical s h e l l f o r t h e spherical s h e l l and t o obtain an o v e r - a l l comparison between t h e r e s u l t s of t h e IBM and Oracle programs.

The compara-

t i v e r e s u l t s a r e shown i n Table 1 f o r t h e junction of t h e three members.

As may be seen, the cone s t r e s s e s agreed s a t i s f a c t o r i l y a t t h e junction
where they were a maximum.

Deviations between the r e s u l t s of the two

programs a t other meridional positions were not considered important f o r

t h e cases of i n t e r e s t .

Table 1. Comparative R e s u l t s f o r Conical and S p h e r i c a l Representation

Axial o r Meridional P r i n c i p a l
Stress (psi)

IBM 7090 programa

Circumferential P r i n c i p a l
Stress (psi)

Oracle programb

IBM 7090 Program

Oracle Program

Cylinder "A"

-3 276

-3 374

-3 047

-3 351

Cylinder "B"

7 091

7 365

-& 018

-4 548

-25 196

-25 703

-3 572

-3 967

Cone o r sphere

%or cylinder-to-cone Junction.

b ~ o rcylinder-to-sphere junction.

Thermal-stress calculations were completed f o r t h e various operating

conditions l i s t e d previously i n the section on temperature d i s t r i b u t i o n s .
Strain-Cycle Analysis

I n order t o determine t h e optimum cooling-air flow r a t e and the l i f e

of the pump tank, it was necessary t o determine t h e allowable number of
each type of operational cycle (heating and power change) f o r each of

..., pn a r e t h e anticipated
values f o r t h e various operational cycles and N
..., Nn a r e t h e
1' *2'
several cooling-air flow r a t e s .

If pl,

p2,

allowable number of cycles determined from the thermal-stress and s t r a i n fatigue data, the "usage factor" i s defined a s

A design a i r

flow can then be selected t o minimize t h e usage f a c t o r and give t h e maximum pump-tank l i f e .

The permissible number of each type of operational cycle i s d e t e r mined by comparing the maximum s t r e s s amplitude f o r each type of cycle
with t h e design fatigue curves.

The maximum s t r e s s amplitude includes

t h e thermal s t r e s s e s caused by meridional thermal gradients, the thermal

s t r e s s e s caused by transverse thermal gradients, and t h e pressure s t r e s s e s
caused by t h e 50-psi i n t e r n a l pressure.
A discussion of t h e various types of s t r e s s e s (primary, secondary,

local, and thermal) and the e f f e c t s of each on the design of t h e pump

tanks i s given i n Appendix D.

A discussion of t h e procedure used i n

determining t h e allowable number of cycles i s presented, and t h e design

fatigue curves of INOR-8 a r e included.
Result s
Temperature Distributions
The r e s u l t s of the GHT temperature d i s t r i b u t i o n calculations f o r
pertinent operating conditions a r e shown i n Figs. 4 and 5 f o r the f u e l
and coolant pumps.

The spherical s h e l l rneridional temperature d i s t r i b u -

t i o n s f o r the f u e l pump a t various cooling a i r flow r a t e s and reactor

power l e v e l s of zero and 10 Mw a r e shown i n Figs. 6 and 7.
Thermal Stresses
Typical thermal-stress p r o f i l e s of the f u e l pump at a cooling-air
flow r a t e of 200 cfm with t h e r e a c t o r power a t zero and 10 Mw a r e shown
i n Figs. 8 and 9; similar p r o f i l e s of t h e coolant pwrrp a r e shown i n Figs.
10 and 11, The r e l a t i v e l y high s t r e s s e s at the top flange a r e believed
t o be caused by the poor f i t of the temperature equations i n t h a t area,
a s shown i n Fig. 3.

The s t r e s s a t t h e top flange was calculated t o be

1 5 000 p s i when the least-squares-fit tem-perature equation was used.

It

was found, however, t h a t t h i s equation introduced s t r e s s e r r o r s a t t h e

cone-to-cylinder junction.

Therefore, the a c t u a l s t r e s s p r o f i l e s along

the e n t i r e length of the external cylinder would probably be b e t t e r

UNCLASSIFIED
ORNL-LR- DWG 6 4 4 9 4 R

6
8
10
MERlDlONAL POSITION O n . )

42

44

16

Fig. 6. Meridional Temperature D i s t r i b u t i o n s of the Torispherical

S h e l l a t a Reactor Power of 10 Mw and Various Cooling-Air Flow Rates.

UNCLASSIFIED
O R N L - L R - DWG 6 4 4 9 5 R

i400

----I
1
I

CYLINDER

6
8
40
MERlDlONAi POSITION ( ~ n . )

i2

44

16

Fig. 7. Meridional Temperature D i s t r i b u t i o n s of the Torispherical

S h e l l a t Zero Reactor Power and Various Cooling-Air Flow Rates.

UNCLASSIFIED
64496R

ORNL-LR-DWG

30,000

-6

-4

-2

0
2
AXIAL POSITION (in.)

Fig. 8. Fuel Pump Principal Thermal Stresses a t Cylinders "A" and

"B" f o r Operation a t Zero Power and at 10 Ivfw with a Cooling-Air Flow Rate
of 200 cfm.
UNCLASSIFIED
ORNL-LR-DWG 64497

12,000

2
3
4
MERIDIONAL POSITION (in.)

Fig. 9. Fuel Pump Princip al Thermal S t r e s s e s a t Spherical Shell

f o r Operation a t Zero Power and a t 10 Mw with a Cooling-Air Flow Rate of
200 cfm.

UNCLASSIFIED
ORNL-LR-DWG 64498

VOLUTE

20,000

301000

.-

-2
V)

">
W

10 Mw,NO E X T E R N A L COOLING

01

-30,000

-6

/I0

Mw,NO EXTERNALCOOLING

'ZERO POWER,NO EXTERNAL

I
-4

-2

A X I A L POSITION h n )

Fig, 10. Coolant Pump P r i n c i p a l Thermal S t r e s s e s a t Cylind

and "B" f o r Operation a t Zero Power and a t 10 Mw.

UNCLASSIFIEO
ORNL-LR-DWG 6 4 4 9 9 R

M E R l D l O N A L P O S I T I O N (in.)

Fig. 11. Coolant Pump P r i n c i p a l Thermal S t r e s s e s a t Spherical S h e l l

f o r Operation at Zero Power and a t 10 Mw.

represented by a composite of t h e two s t r e s s p r o f i l e s ; t h a t i s , it would

be b e s t t o use t h e s t r e s s p r o f i l e s from the manually f i t temperature funct i o n s near t h e junction and from t h e least-squares functions near the t o p
flange.

Since t h e cone-to-cylinder junction i s the more c r i t i c a l a r e a

and since the s t r e s s e s a t t h e t o p flange do not l i m i t t h e number of permissible s t r a i n cycles, t h e s t r e s s e s from t h e manually f i t equations were
used i n completing t h e s t r a i n - c y c l e a n a l y s i s .

The c y l i n d e r i s s u f f i c i e n t l y

long t h a t t h e temperature e r r o r a t t h e t o p flange has a r e l a t i v e l y small

e f f e c t on t h e s t r e s s e s a t t h e c y l i n d e r - t o - s h e l l junction.
S t r a i n Cycles
The r e s u l t s of t h e s t r a i n - f a t i g u e analyses a r e presented i n Tables
2, 3, and 4 .

A predicted usage f a c t o r of 0.8 o r l e s s i n d i c a t e s a s a f e

Table 2.

Air
Flow
(cfm>

Maximum
Stress
Intensity
(psi

>

Fuel Pump S t r a i n Data f o r Heating Cycle

Stress
Arnplitude
( p s i1

Allowable
Cycle s

Cycle
Fraction
Per
Cycle

Heating Cycle t o 1200F

Heating Cycle t o 1300F

Loss-of-Cooling-Air Accident

Cycle
Fraction i n
100 Cycles,
P, /N,

Table 3.

Air

(cfm)

stress
Range
(psi )

Fuel Pump S t r a i n Data f o r Power-Change

Cycle from Zero t o 10 Mw

Stress
Amplitude
( p s i)

Table 4.

Allowable

cycles

Cycle
Cycle
Total
F r a c t i o n Fraction i n
Usage
Per
500 Cycles, Factor,
cyc l e
P2/N.2
2P ~ / N ~

Coolant Pump S t r a i n Data f o r Heating

and Power-C hange Cycle s
Heating Cycles
To 1200F

To 1300F

Power Change
from Zero
t o 10 Mw

Maximum s t r e s s i n t e n s i t y , p s i
S t r e s s amplitude, p s i
Allowable cycles
Total relaxation
P a r t i a l relaxation
Cycle f r a c t i o n per cycle
Total r e l a x a t i o n
P a r t i a l relaxation
Cycle f r a c t i o n i n 100 cycles
Total relaxation
P a r t i a l relaxation
Cycle f r a c t i o n i n 500 cycles
Total usage f a c t o r a
Total r e l a x a t i o n
P a r t i a l relaxation
?For 100 heating cycles t o 1200F and 500 power cycles from zero t o
10 Mw.

operating condition f o r t h e desired number of heating and power-change

cycles.

The r e s u l t s a r e based on t h e assumption of t o t a l s t r e s s relaxa-

t i o n a t each operating condition and a r e therefore conservative.

'

The

location of maximum s t r e s s i n t e n s i t y during t h e heating cycle i s not

necessarily the same a s t h e location of maximum s t r e s s range during the
power-change cycle.

This a l s o provides conservative r e s u l t s , since t h e

maximum s t r a i n s f o r each type of cycle were added t o determine the usage

factor, and t h e t o t a l s t r a i n a t t h e a c t u a l point of maximum s t r a i n would
be l e s s than t h e s t r a i n value used.

Since t h e pump tank w i l l safely en-

dure t h e desired number of heating and power cycles with t h i s conservative

approach, it was not considered necessary t o locate and determine t h e
a c t u a l maximum t o t a l s t r a i n .

The coolant pump w i l l operate a t a lower

temperature than the f u e l pump, so t h e s t r e s s relaxation during each

cycle w i l l probably be incomplete and therefore a l a r g e r number of cycles

w i l l be permissible.

As shown i n Table 4, t h e assumption of p a r t i a l r e -

laxation r a t h e r than t o t a l relaxation permits more than twice' t h e number

of heating cycles.

For t h e f u e l pump, thermal-stress and p l a s t i c - s t r a i n

calculations were a l s o made f o r the short 36-in.-diam cylinder ~ o n n e c t -

ing the two t o r i s p h e r i c a l heads.

The permissible number of cycles a t

t h i s location was found t o be greater than those shown i n Table 2, and,

therefore, t h e cycles i n t h e cylinder do not l i m i t the l i f e of t h e
tank.
Pressure and Mechanical Stresses
The r e s u l t s of the pressure s t r e s s calculations made with t h e Oracle
program are shown i n Figs. 12 and 13.

The stresses, which include both

primary and discontinuity stresses, a r e f o r a pressure of 1.0 p s i and a r e

d i r e c t l y proportional t o pressure.

The maximum s t r e s s from t h e a x i a l

load e x i s t s a t t h e suction nozzle attachment and i s equal t o 1.766 times

t h e load i n pounds.
Recommendations
The strain-cycle data of Tables 2, 3, and 4 indicate that t h e desired number of s t r a i n cycles on the f u e l pmp can be safely t o l e r a t e d

UNCLASSIFIED
ORNL- LR - DWG 64500

I00
I

PRESSURE = 1.0 psi

STRESS A T ' P " PRESSURE =

. INTERNAL

D,=MERIDIONAL
STRESS
De=CIRCUMFERENTIAL STRESS
I =INSIDE
0 =OUTSIDE

+-f

-6 0
I

S P H E R l c A L S H E L L JUNCTION

- 100
-4

-6

-2

A X I A L POSITION ( i n )

Fig. 12.
and "B "

Fuel and Coolant Pump Pressure S t r e s s e s a t Cylinders "A"

UNCLASSIFIED
ORNL-LR-DWG 64501
INTERNAL PRESSURE=1.0 psi
STRESS A T ' ~ " P R E S S U R E= PXSTRESS
AT j.0 psi
I
w - - - - - d - - - - . + - - - -----+--'

---- ----

u+=MERIDIONAL STRESS
ug=CIRCUMFERENTIAL STRESS]

I = INSIDE

CYLINDER
JUNCTION

0 1
0

I
3

O =OUTSIDE
I
4

MERlDlONAL POSITION ( i n )

Fig. 13.
Shell.

Fuel and Coolant Pump Pressure S t r e s s e s a t Spherical

when any cooling a i r flow between 100 and 300 cfm i s used; and, t h e r e f o r e , t h e a i r cooling can be c o n t r o l l e d manually by a remotely operated
c o n t r o l valve.

A c o o l i n g - a i r flow r a t e of approximately 200 cfm i s recom-

mended f o r t h e following reasons:

1. The p r e d i c t e d usage f a c t o r i s reasonably near t h e minimum value.

2.

There i s a wide range of acceptable flow r a t e s on e i t h e r s i d e

of t h i s design air flow r a t e .

3.

A t a i r flow r a t e s g r e a t e r than 200 cfm, t h e maximum s t r e s s i n -

t e n s i t y during zero power operation i n c r e a s e s r e l a t i v e l y r a p i d l y and dec r e a s e s t h e permissible number of heating cycles.
Since t h e r e i s a p o s s i b i l i t y of e r r o r i n t h e temperature d i s t r i b u t i o n c a l c u l a t i o n s because of u n c e r t a i n t i e s i n t h e heat generation r a t e s
and heat t r a n s f e r c o e f f i c i e n t s , it i s recomm.ended t h a t t h e temperature
gradient on t h e s p h e r i c a l s h e l l be monitored by using two thermocouples
spaced 6 i n . a p a r t r a d i a l l y .

This g i v e s t h e maximum temperature d i f -

ference between t h e two thermocouples and t h e r e f o r e reduces t h e e f f e c t

of any thermocouple e r r o r .

Since t h e thermal g r a d i e n t of t h e s p h e r i c a l

s h e l l near t h e junction i s of primary importance i n determining t h e t h e r m a l s t r e s s e s , t h e d i f f e r e n t i a l temperature measurements and t h e d a t a of

Figs. 6 and 7 can be used t o s e t t h e a c t u a l c o o l i n g - a i r flow r a t e on t h e

pump.

This method has t h e disadvantage of r e q u i r i n g s e v e r a l adjustments

a s t h e temperature and power l e v e l a r e r a i s e d t o t h e o p e r a t i n g p o i n t .

I f d i r e c t measurement of t h e flow r a t e were p o s s i b l e minor adjustments

could be made a f t e r t h e system reached operating conditions.

Since no

c o o l i n g - a i r flow measuring equipment i s planned f o r t h e f u e l pump a t t h e

present time, a preoperational c a l i b r a t i o n of t h e c o o l i n g - a i r flow r a t e
versus valve p o s i t i o n should be made t o permit t h e approximate a i r flow
r a t e t o be s e t p r i o r t o high-temperature operation.
The design temperature d i f f e r e n c e between t h e two thermocouples f o r
monitoring t h e thermal gradient i s 100F a t a power l e v e l of 10 Mw and
a thermocouple spacing of 6 i n .

The maximum allowable temperature d i f -

ference i s 200F f o r 10-Mw operation.

A f t e r t h e c o o l i n g - a i r flow r a t e

has been s e t f o r 10-Mw operation, a readjustment of t h e flow should be

made, i f necessary, a t zero power operation t o prevent a negative thermal
g r a d i e n t on t h e sphere.

This a d j u s t e d c o o l i n g - a i r flow should t h e n become

t h e operating value.

During t h e p r e c r i t i c a l t e s t i n g and power operation

of t h e r e a c t o r it should be kept i n mind t h a t any s i g n i f i c a n t change i n

t h e f u e l pump cooling-air flow r a t e w i l l c o n s t i t u t e a s t r a i n cycle and

w i l l represent a decrease i n t h e usable l i f e of t h e pump tank.

Therefore,

an e f f o r t should be made t o keep t h e number of c o o l i n g - a i r flow r a t e adjustments t o a minimum.

The e f f e c t of heating t h e system t o 1300F i s a l s o shown i n Tables

2, 3, and 4 .

The f u e l and coolant pumps can s a f e l y endure only about

half a s many heating cycles t o 1300F a s t o 1200F.

For t h e coolant

pump, 100 heating cycles t o 1300F would e s s e n t i a l l y consume t h e l i f e of

t h e pump tank.

A t 1300F t h e assumption of t o t a l s t r e s s r e l a x a t i o n i s

r e a l i s t i c , and no a d d i t i o n a l conservatism should be claimed by i t s use.

Therefore, it i s recommended t h a t t h e system not be heated t o 1300F on
a routine basis

Since t h e f u e l and coolant pump tanks a r e primary containment members, t h e maximum value of t h e usage f a c t o r must not exceed 0.8, which
i s the acceptable upper l i m i t .

To avoid exceeding t h i s l i m i t , an accu-

r a t e and up-to-date record should be maintained of t h e usage f a c t o r and

t h e complete s t r a i n cycle h i s t o r y of both t h e f u e l and t h e coolant pumps.
I n c a l c u l a t i n g t h e usage f a c t o r , p a r t i a l power-change cycles i n which
r e a c t o r power i s increased only a f r a c t i o n of t h e t o t a l power should be
considered a s complete power cycles unless t h e number of p a r t i a l cycles
i s a l a r g e f r a c t i o n of t h e t o t a l when a pump tank has passed through t h e
permitted number of cycles.

I n t h i s case, a d d i t i o n a l thermal s t r e s s

c a l c u l a t i o n s should be made t o determine the proper e f f e c t of the p a r t i a l

cycles.
Although t h e s t r a i n - c y c l e d a t a i n d i c a t e t h a t t h e coolant pump i s
acceptable f o r t h e s p e c i f i e d number of s t r a i n cycles, t h e s t r e s s i n t e n s i t y
i s uncomfortably high.

These s t r e s s e s can be reduced by lowering t h e

thermal gradient on t h e s p h e r i c a l s h e l l by using a reduced thickness of

i n s u l a t i o n on t h e upper surface of t h e pump tank.

Since nuclear heating

i s not involved i n t h e coolant pump, the proper amount of i n s u l a t i o n can

b e s t be determined on t h e Fuel Pump Prototype Test F a c i l i t y , which i s
p r e s e n t l y under construction.

26

Conclusions
The s t r a i n - c y c l e a n a l y s i s i n d i c a t e s t h a t t h e f u e l pump w i l l be s a t i s f a c t o r y f o r t h e intended l i f e of 100 h e a t i n g c y c l e s and 500 power-change
c y c l e s i f it i s a i r cooled.
coolant pump.

No s p e c i a l cooling w i l l be required f o r t h e

A conservative design i s provided by t h e use of standard

s a f e t y f a c t o r s i n t h e s t r a i n - f a t i g u e d a t a and i n t h e usage f a c t o r .

Ad-

d i t i o n a l conservatism of an unknown magnitude i s provided by t h e assumpt i o n of t o t a l s t r e s s r e l a x a t i o n a t each operating c o n d i t i o n and by t h e

f a c t t h a t t h e a c t u a l maximum s t r a i n should be l e s s t h a n t h e c a l c u l a t e d
maximum s t r a i n .
I n a d d i t i o n t o t h e s a f e t y f a c t o r s o u t l i n e d above, t h e f u e l and coola n t p u p t a n k s a r e capable of exceeding t h e i r required s e r v i c e l i f e by
f a c t o r s of 2.2 and 1.4, r e s p e c t i v e l y , before the maximum permissible usage
f a c t o r i s exceeded.

References

1. Molten-Salt Reactor Program Q u a r t e r l y Progress Report f o r Period Ending J u l y 31, 1960, ORNL-3014.

2.

A. G. G r i n d e l l , W. F. Boudreau, and H. W. Savage, "~evelopmentof

Centrifugal Pumps f o r Operation with Liquid Metals and Molten S a l t s

a t 140C-1500 F,
3.

" Nuclear S c i . and Eng. 7 ( 1 ) , 83 (1960).

Tentative S t r u c t u r a l Design B a s i s f o r Reactor Pressure Vessels and

D i r e c t l y Associated Components ( ~ r esurized,
s
Water-Cooled Systems )

esp. p. 31, PB 151987 ( ~ e c .1, 1958), U. S. Dept. of Commerce, Office

of Technical Services.
T. B. Fowler, Generalized Heat Conduction Code f o r t h e IBM 704 Com-

puter, ORNL-2734 ( 0 c t . 14, 1959), and supplement ORNL CF 61-2-33

P. B. Wood, NLLS:

A 704 Program f o r F i t t i n g Non-Linear Curves by

Least Squares, K-1440

a an.

28, 1960), Oak Ridge Gaseous P l a n t ;

SHARE D i s t r i b u t i o n No. 8371838.

F. J. W i t t , Thermal S t r e s s Analysis of C y l i n d r i c a l S h e l l s , ORNL
CF 59-1-33 (Mar. 26, 1959).
F. J. Stanek, S t r e s s Analysis of C y l i n d r i c a l S h e l l s , ORNL CF 58-9-2
( ~ u l y22, 1959).
F. J. W i t t , Thermal Analysis of Conical S h e l l s , ORNL CF 61-5-80
( J u l y 7, 1961).
F. J. Stanek, S t r e s s Analysis of Conical S h e l l s , ORNL CF 58-6-52
( ~ u g .28, 1958).

C . W . Nestor, Reactor Physics Calculations f o r t h e MSRE, ORNL

CF 60-7-96

(JU~Y

26, 1960).

T . Rockwell ( e d . ) , Reactor Shielding Design Manual, p 392, McGrawH i l l , New York, 1956.

M. Jakob, Heat Transfer, Vol. I, p 168, Wiley, 1949.

A. I . Brown and S. M. Marco, I n t r o d u c t i o n t o Heat Transfer, p 64,

McGraw-Hill, New York, 1942.
I b i d , p 91.

15.

B. F. Lange, "Design Values f o r Thermal S t r e s s i n D u c t i l e M a t e r i a l s , "

Welding Journal Re s e a r c h Supplement, 411 (1958).

16.

S. S. Manson, "Cyclic L i f e of D u c t i l e M a t e r i a l s , " Machine Design -732

13%

( ~ u 7,l ~1960).

APPENDIX A
D i s t r i b u t i o n of Fission-Product-Gas Beta Energy
The t o t a l energy t h a t w i l l be r e l e a s e d i n t h e f u e l pump tank by t h e
fission-product gases has been r e p o r t e d l o by Nestor t o be 1 5 kw. T h i s
energy w i l l not be uniformly deposited on t h e surface a r e a exposed t o
gas, however, so it was necessary t o determine i t s d i s t r i b u t i o n over t h e
s u r f a c e s of t h e pump tank.

The pump tank was assumed t o be of s t r a i g h t

c y l i n d r i c a l geometry, a s shown i n Fig. A.1,

and t h e d i s t r i b u t i o n of t h e

energy f l u x a t t h e c y l i n d r i c a l w a l l s was c a l c u l a t e d a s o u t l i n e d i n t h e
following s e c t i o n s .

The d i s t r i b u t i o n of energy t o t h e upper surface was

approximated by assuming a d i s t r i b u t i o n s i m i l a r t o t h a t f o r t h e outside

wall.
Energy Flux a t Pump Tank Outer Surface
It was assumed that t h e r e was no s e l f - s h i e l d i n g o r shi'elding from
t h e volute support cylinder, and t h e l i n e source (dy,dx) was i n t e g r a t e d
over t h e enclosed volume (see Fig. ~ . 2 ) l ' t o o b t a i n t h e energy f l u x

UNCLASSIFIED
ORNL- LR-DWG 68993

3 6 in. D I A

45 in.

--

DlA

F i g . A.1.

--

- -

Assumed Pump Tank Geometry.

UNCLASSIFIED
ORNL-LR-DWG 68994

Fig. A.2.
Surface

Diagram f o r Determining Energy Flux a t Pump Tank Outer

where

-1
2
2-112
=tan
hl(x + y )

= tan

-1 h2(x2

2 -1/2

+ y )

,
,

S = energy source per u n i t volume

v

Energy Flux a t t h e Volute Support; Cylinder Outer Surface

Figure A.3 and t h e following equation were used f o r determining t h e
energy f l u x a t t h e o u t e r surface, P2, of t h e v o l u t e support cylinder:

where

8 = tan
2

-1

Enerm Flux a t t h e Volute SuDDort Cvlinder I n n e r Surface

The energy f l u x a t P3, a s shown on Fig. A.3, was approximated by
c a l c u l a t i n g t h e f l u x a t PI using equation A.2 and t h e appropriate values
3
This value was then c o r r e c t e d f o r t h e a d d i t i o n a l volume
of R1 and R
0

visyble t o P by t h e d i r e c t c r o s s - s e c t i o n a r e a r a t i o and t h e inverse

3

square ratio of the center-of-gravity distance:

The values of

9 at Pl, Pa, and P; were evaluated as functions of

and h2 by the Numerical Analysis Section of ORGDP. The beta-energy distribution is shown in Fig. A . 4 .

Diagram for Determining Energy Flux at Outer and Inner

Fig. A.3.

Surfaces of the Volute Support Cylinder

Vp

4000

UNCLASSIFIED
6450ZR

ORNL-LR-DWG

TORISPHERICAL SHELL. INSIDE

I.A X I A L POSITION OF CYLINDER"A"

5000

IS MEASURED FROM SPHERE-TOCYLINDER JUNCTION

'I$
, *-\\{+

2. RADIAL POSITIONS OF SHIELDING

PLUG FACE AND TORISPHERICAL
SHELL AREMEASUREDFROM
P U M P CENTER L I N E

VOLUTE SUPPORT CYLINDER'K,INSIDE

1I

(0

I2

I
14

16

18

POSITION (in )

Fig. A . 4 . Beta-Energy Distribution of Fuel Pump Tank, Volute Support Cylinder, and Shielding Plug.

Estimation of Outer Surface Temperatures and

Heat Transfer C o e f f i c i e n t s
The GHT Code f o r c a l c u l a t i n g t h e complete temperature d i s t r i b u t i o n
of t h e pump tank could not consider t h e e f f e c t s of t h e flowing a i r stream
on t h e temperature d i s t r i b u t i o n of t h e pump tank because of t h e temperat u r e r i s e of t h e cooling air along t h e pwnp tank s u r f a c e .

I n order t o

o b t a i n t h e temperature d i s t r i b u t i o n , i t was necessary t o couple t h e pump

tank surface with t h e surroundings by use of an e f f e c t i v e heat t r a n s f e r
c o e f f i c i e n t (hce) and t h e ambient temperature.

It was i m p r a c t i c a l t o

obtain an e f f e c t i v e c o e f f i c i e n t a t each p o i n t along t h e surface, and

t h e r e f o r e t h e value of hce was c a l c u l a t e d a t t h e c y l i n d e r - t o - s h e l l junct i o n , where t h e thermal s t r e s s problem was most severe, and then a p p l i e d
over t h e e n t i r e upper surface of t h e pump tank.
The a i r - c o o l e d upper p o r t i o n of the f u e l pump tank i s shown schem a t i c a l l y i n F i g . B.1.

The pump tank i s s u b j e c t t o thermal r a d i a t i o n

and convection heating from t h e f u e l s a l t , f ission-product b e t a heating,

This heat i s conducted t o t h e

and gamma-radiation i n t e r n a l heating.

UNCLASSIFIED
ORNL- LR- DWG 68996

,COOLING-AIR

SHROUD

INSULATION

I
'84

\PUMP

47

TANK WALL

q = h , (8,-8,)
f

Fig. B.1.
Wall.

Schematic Diagram of Cooling-Air Shroud and Pump Tank

pump tank surface where it i s transferred t o the cooling a i r by two paths:

( 1 ) d i r e c t forced convection t o t h e cooling a i r and ( 2 ) r a d i a t i o n t o t h e

cooling shroud and forced convection t o t h e same cooling a i r .

Heat i s

a l s o conducted p a r a l l e l t o the pump tank surface, but t h i s heat t r a n s f e r

i s assumed t o be zero i n estimating the surface temperature and heat
t r a n s f e r coefficients.
The temperature d i s t r i b u t i o n through the pump tank wall can be calculated12 a s outlined below, assuming a constant gamma heat-generation r a t e
through the wall

A t the i n t e r i o r w a l l , where x = 0,

and theref ore

and f o r any place within t h e w a l l , t h a t i s , x # 0,

The temperature i s then

A t t h e i n t e r i o r w a l l x = 0, and t h e r e f o r e

and

If t h e heat t r a n s f e r from t h e o u t e r surface i s expressed by an e f -

f e c t i v e c o e f f i c i e n t with respect t o t h e ambient temperature r a t h e r than

t h e a c t u a l forced-convection cooling system temperature, t h e o u t e r surface temperature can be c a l c u l a t e d a s follows from Eq. ( ~ . 6 )with x = t :

where

and

where 8
i s t h e e f f e c t i v e ambient temperature, and
4e

Solving Eqs. (B.10)'

( B . ) , and (B.12) simultaneously f o r

following equation:

Solving Eq. ( ~ . 1 3 )f o r hce m d rearranging the terms gives

e3

yields the

The d i f f i c u l t y i n c a l c u l a t i n g t h e o u t e r surface temperature ( 9 )

3
from Eq. (B.13) r e s u l t s from t h e f a c t t h a t t h e heat t r a n s f e r c o e f f i c i e n t s
and h a r e highly temperature dependent, and .Q3must be known before
hc e
f
accurate c o e f f i c i e n t s can be c a l c u l a t e d . However, f o r a given s e t of r e a c t o r operating conditions, it i s evident from t h e preceding equations
t h a t t h e s e l e c t i o n of an a r b i t r a r y value of 8

w i l l result i n a particular
3
value of t h e t o t a l heat t r a n s f e r a c r o s s t h e o u t e r surface, and a p a r t i c u -

l a r value of h

i s required t o d i s s i p a t e t h i s q u a n t i t y of heat t o t h e
ce
surroundings. Since t h e temperature drop a c r o s s t h e pump tank w a l l i s

small f o r t h e c a s e s of i n t e r e s t , 8 can be used t o compute t h e value of

3
t h e i n t e r n a l surface heat t r a n s f e r c o e f f i c i e n t ( h ), and t h e value of
f
can then be c a l c u l a t e d by Eq. (B . l 4 )
hc e
The following procedure was used t o estimate t h e e f f e c t i v e o u t e r

surface heat t r a n s f e r c o e f f i c i e n t s f o r various c o o l i n g - a i r flow r a t e s :

1. Values of h versus i n n e r surface temperature (8 ) were calcuf
2
l a t e d by Eq. (B.15), below, and p l o t t e d on Fig. B . ~ : I ~

hf

2.

4
F F (el
r e a

- G 42 )
+ 1.5

- O2

The t o t a l heat t r a n s f e r r e d

(I+)

was c a l c u l a t e d versus t h e o u t e r

s u r f a c e temperature ( 8 ) by Eq. (B.16), below, a f t e r f i r s t c a l c u l a t i n g

3

UNCLASSIFIED
ORNL- L R - OWG 64503

600

700

800

900

4000

(100

4200

1300

4400

SURFACE TEMPERATURE IDF)

Fig. B.2. Pump Tank I n n e r Surface Heat Transfer C o e f f i c i e n t Versus

Outer Surface Temperature.

hce by Eq. (B.14) :

The f o r c e d convection h e a t t r a n s f e r c o e f f i c i e n t s f o r t h e pump

3.

tank o u t e r s u r f a c e and t h e cooling shroud were c a l c u l a t e d as a f u n c t i o n

of a i r flow by Eq. (B.17) and p l o t t e d on Fig. B.3:14

The h e a t t r a n s f e r r e d t o t h e cooling shroud by thermal r a d i a t i o n

4.

was c a l c u l a t e d versus shroud temperature f o r each of s e v e r a l values of

Q3 and p l o t t e d on Fig. B.3.
A t equilibrium conditions, t h e heat r a d i a t e d t o t h e shroud (q3 -

p l u s t h e h e a t t r a n s f e r r e d d i r e c t l y t o t h e cooling a i r (q3- 5 ) must equal

t h e t o t a l heat t r a n s f e r r e d (q,),

and t h e h e a t t r a n s f e r r e d from t h e shroud

UNCLASSIFIED
ORNL-LR-DWG 6 4 5 0 4

4150

I050

950

100

200

COOLING SHROUD TEMPERATURE (OF)

850
750
650
550

450

350

6000
c
,

<5 0 0 0
L

0
3
LT
0

4000

J
0

3000

W
n

LT
LT

:
2000
w
z
a

F
LT

4000

S
0

300
400
500
COOLING AIR FLOW ( c t m )

600

700

800

Fig. B.3. Convective Heat Transfer C o e f f i c i e n t Versus A i r Flow and

Heat Transferred t o Shroud Versus Shroud Temperature.

) must be equal t o t h e h e a t t r a n s f e r r e d t o t h e
t o t h e cooling a i r ( q
4-5
shroud from t h e pump tank. Therefore, f o r each assumed value of 8 3' t h e
heat t r a n s f e r r e d t o t h e shroud i s c a l c u l a t e d versus cooling a i r flow
r a t e from t h e expression

where

and

The p a r t i c u l a r shroud temperature required t o accept t h e heat ( q

3 -4 )

from t h e p m p tank surface i s obtained from Fig. B.3.

The heat t r a n s f e r -

r e d from t h e shroud t o t h e cooling a i r i s then c a l c u l a t e d :

q4-5

hc(e4

- 0,)

For each value of 8

and q4-5 a r e p l o t t e d v e r s u s c o o l i n g - a i r flow

3' q3 -43
r a t e a s shown on F i g . B.4, and t h e i n t e r s e c t i o n of t h e two curves d e t e r -

mines t h e c o o l i n g - a i r flow r a t e t h a t w i l l produce t h e p a r t i c u l a r value

of

e3.

A p l o t of

e3

versus c o o l i n g - a i r flow r a t e can t h e n be made a s

i n F i g . B.5, and t h e e f f e c t i v e surface heat t r a n s f e r c o e f f i c i e n t s h

ce
f o r use i n t h e GJTC Code can be c a l c u l a t e d f o r any a i r flow r a t e using
Eq. ( ~ . 1 4 ) .

Fig. B.4.

100

200
300
4 00
COOLING A I R F L O W (cfrn)

500

600

Shroud Heat Transfer Versus Cooling A i r Flow.

UNCLASSIFIED
64506

ORNL-LR-DWG

-0

100

200

300

400

500

600

700

AIR F L O W ( c f r n )

Fig, B.5.

Nominal Surface Temperature Versus Cooling A i r Flow.

41
APPENDIX C
Derivation of Boundary and Compatibility Equations
f o r Thermal S t r e s s Calculations
The procedures f o r calculating thermal s t r e s s e s i n cylinders and
cones a r e f u l l y described i n r e f s . 6 through 9.

The general layout of

t h e pump tank s t r u c t u r e and t h e sign convention used i n t h e s t r e s s

analysis a r e shown i n Fig. C . l .
t o be r i g i d .

The cone-to-cylinder j o i n t i s assumed

It i s necessary t o evaluate four i n t e g r a t i o n constants f o r

each of t h e t h r e e members by solving 12 simultaneous equations describing

t h e boundary conditions of t h e structure and t h e compatibility conditions
which i n t e r r e l a t e t h e three members a t t h e i r junction.

Since the posi-

t i o n functions f o r cylinders a r e tabulated i n r e f . 8 only f o r positive

values of L, the cone-to-cylinder junction i s made t h e o r i g i n and t h e
cylinder a x i s i s assumed t o be p o s i t i v e i n e i t h e r d i r e c t i o n .

This

UNCLASSIFIED
ORNL-LR-DWG 6 4 5 0 7

TOP FLANGE

JOINT
DETAl L

u
d

11 -"

CONE

CYL. A

Fig. C . 1 .
t ure .

Schematic Diagram and Sign Convention of Pump Tank Struc-

assumption r e q u i r e s t h a t t h e slope and t h e shear f o r c e equat

f i e d by a sign change t o compensate f o r t h e reversed s i g n o
cylinders.
Derivations of t h e 12 simultaneous equations from t h e
boundary o r c o m p a t i b i l i t y conditions a r e given below.

The

t i o n s f o r moment, displacement, slope, and shear f o r c e were

r e f . 6 f o r t h e cylinders and r e f . 8 f o r t h e cone.

The coni

t i o n s d i f f e r somewhat from those presented i n r e f . 8 becaus

nary version of t h e r e p o r t was used t h a t d i d not include t
a thermal g r a d i e n t through t h e wall.

A l l t h e terms consid

f e c t s of i n t e r n a l pressure and mechanical loading were omi

t h e c y l i n d r i c a l and conical s h e l l equations.
The following m a t e r i a l constants, geometric constants
s t a n t s , and a u x i l i a r y functions a r e used i n t h e boundary a
equations :

It was necessary t o a d j u s t t h e pump tank configuration s l i g h t l y so

t h a t t h e boundaries of the separate members would coincide with tabulated
values f o r t h e cone and cylinders:

cot

= 78.5 deg

= 0.2035

,
,

= 7.125 i n .

Ycl

i
sin 4

Yc2 = 18.0 i n .

7.271

The values of Xcl

and Xc2 were adjusted t o the nearest value

i n r e f . 9:

The cylinder mean radius

Lai

%.1
The values of y
i n r e f . 7.

ai

11

a I I was then corrected:

= 6.5 i n .

= 8.0 i n .

and y
were adjusted t o the nearest t a b
bi

a t e d values

The following cylinder position functions were taken from r e f . 7:

Volute,
Function
M1

M2
M3

M4

a'

= 3.6

Junction,
Y a b = O

Top Flange,
yb = 4.4

0.049

-2 .O

-0.02418

0.007546
-0.02337

-65.64

+2 .O

-50.065

32.39

155.02

The following cone position functions were taken from r e f . 9:

Function

Junction,
Xcl = 6.3

Cone Outer Surface,

Xc2 = 9.9

Junction,
= 6.3

Function

Cone Outer Surface,

Xc2 = 9.9

Xcl

10.1451

'61

-54.918

4,47331

'62

-108.588
-0.00008719

-0.0014f44

'63

The cone a u x i l i a r y temperature functions were obtained from t h e

following expressions :

E t c a cot

J2

- Tc3)

4
PC

- 2 F t p cot

(r
72Tc5

6
PC

= 459.95Tc5

4
Tc4

= -17. 183Tc4

- 11.555Tcj

The temperature d i s t r i b u t i o n s f o r t h e c y l i n d e r s and cone were expressed i n t h e following forms:

Cylinder "A"

Cylinder "B"

Cone "C I t

= -T c l
Yc

Tc2

Tc3Yc

2
Tc4yc

3
Tc5Yc

A t t h e pump v o l u t e (ya = 3 . 6 ) , t h e slope of c y l i n d e r "A" = 0, and

dw
aB
- -a - 0 = dL

Et

w/ - aa
na n

A t t h e pump v o l u t e (ya = 3.6), t h e r a d i a l displacement of "A" =

and

-aC@

1'

and t h e r e f o r e

A t t h e cone-cylinder junction, t h e summation of moments = 0, t h a t i s ,

Ma-%+Mc=0
and

A t t h e cone-cylinder junction, t h e summation of h o r i z o n t a l and v e r t i c a l

f o r c e s = 0, and t h e r e f o r e , f o r the v e r t i c a l f o r c e s ,

Qc s i n $ + Nc cos $ = 0

cos q5

Qc = *c

sin

For t h e h o r i z o n t a l forces,

Qc cos

9+

Nc s i n

2
-N

'OS

c sin

'

N~ s i n

= N

sin

- c0s2
sin

For t h e summation of h o r i z o n t a l f o r c e s on both t h e c y l i n d e r s and t h e

cone,

and

+ 6DaQTb4 - Db y e

4aB

na n
+

'

~nb~n)

p: t a n 6 (sin 9

-)
:
f
Y

2: c

6.2094(79.38~+
~ 3 . 0 ~ ~ )

344. 12 (Ta4 + Tb4) + 229.41Tb5 b

1

(C.4)

A t t h e junction, t h e slope of Cylinder "A" =

slope of Cylinder "B,

"

and

C CnaWn ' + C C n bWn' = -

Eta
f3

Et
-dy
(Ta2CTb2)-qbye

A t t h e junction, t h e slope of Cylinder "A" = slope of t h e Cone llC,l' and

aB

- C cnaW'n
t

E
2
-B'r
tan $ C
C

cncwAc

A t t h e junction,

t h e displacement of Cylinder "A" = t h e displacement of

Cylinder "B," t h a t i s ,

and

A t t h e junction, t h e displacement of Cylinder "A" = t h e displacement of

t h e Cone, and

w = ucos 4 - V
a

8
Et

CnaNn

- ma, =

sin

cos

-u

sin

cncvnc - JlK3

Etc

sin

(Tcl + Tc2Yc

J~ loge pC +

Tc3y% + Tc4y:

Tc5y,)

-t C 'naNn

sin

(Tcl

sinL 4
tc cos 4

C cnc(vnc - W nc

+T Y +
c2 c

... + Tc5Y4c )

=Ernc s i n

0,
=Emal

theref ore

and

A t the outer surface of t h e cone,, t h e slope = 0, and

A t t h e cone o u t e r surface, t h e meridional membrane f o r c e = 0, and

Nc =

PC t a n

#J

(- z

CncQnc

+ 8P1J4

A t t h e t o p flange, t h e slope of Cylinder

cnbw/
=
n

+ 3J3)

"B"

= 0

= 0, and

2 7 9 . 0 4 ( ~+~15.94Tb3
~
+ 190.56~~
-~ )

- 1116.2Tb5

b
2

A t t h e t o p flange, t h e displacement of Cylinder

"B"

= -0

I'

and

(c.11)

The f i n a l forms of these 1 2 equations a r e arranged s o t h a t t h e l e f t

hand s i d e containing t h e unknown i n t e g r a t i o n c o n s t a n t s i s dependent only
on t h e s p e c i f i c p m p tank configuration, while t h e r i g h t s i d e containing
t h e temperature d i s t r i b u t i o n terms w i l l v a r y f o r each o p e r a t i n g c o n d i t i o n .
The matrix of i n t e g r a t i o n constant c o e f f i c i e n t s f o r t h e 12 equations i s
shown i n Table C .l.

Table C .l. Simultaneous Equation Matrix

-

C o e f f i c i e n t s of Unknown I n t e g r a t i o n Constants C
Equation
Number
la

'2a

3a

lb

C2b

3b

na' 'nb.'
'4b

and Cnc
Clc

C2c

3c

C4c

APPENDIX D

Explanation of Procedure Used t o Evaluate t h e E f f e c t s of

Cyclic S t r a i n s i n t h e MSRE Pumps

An e s s e n t i a l d i f f e r e n c e i n s t r u c t u r a l design f o r high-temperature
o p e r a t i o n a s compared with design f o r more modest c o n d i t i o n s i s t h e need
t o consider c r e e p and r e l a x a t i o n of t h e s t r u c t u r a l m a t e r i a l .

Many of t h e

methods and procedures p r e s e n t l y s p e c i f i e d a s a s t r u c t u r a l design b a s i s

i n t h e ASME B o i l e r and Pressure Vessel Code, Unfired Pressure Vessels,
Section V I I I , and i n t h e preliminary design b a s i s developed by t h e ~
become meaningless a t high temperatures.

Thus a r e v i s e d design b a s i s

must be formulated when high-temperature conditions a r e considered.

The

o p e r a t i n g program of any component must be examined, and t h e design b a s i s

s e l e c t e d must be used t o determine whether t h e number of o p e r a t i o n a l cycles
which can be s a f e l y t o l e r a t e d exceeds t h e number of t h e c y c l e s which i s
d e s i r e d during t h e l i f e of t h e component.

I f necessary, t h e number of

o p e r a t i o n a l c y c l e s of t h e component must be l i m i t e d t o t h e value which

can be s a f e l y t o l e r a t e d .

As may be seen, t h e d e t a i l s of t h e operating

program a r e extremely important and must be s e l e c t e d with considerable

care.
The concept of s t r e s s i s used here a s a convenience i n d i s c u s s i n g
t h e e f f e c t s of c y c l i c s t r a i n s because it i s t h e p r i n c i p a l v a r i a b l e i n
conventional problems of e l a s t i c i t y .

Properly, however, t h e d i s c u s s i o n

should be i n terms of s t r a i n s when d e a l i n g with high temperatures and,

e s p e c i a l l y , i n d e s c r i b i n g thermal e f f e c t s i n s t r u c t u r e s .

With t h e s e

f a c t o r s i n mind, f o u r general t y p e s of s t r e s s e s were considered i n e s t a b l i s h i n g a design b a s i s f o r t h e MSRF pumps which w i l l operate a t temp e r a t u r e s w i t h i n t h e creep and r e l a x a t i o n range; t h e s e a r e primary,
secondary, l o c a l o r peak, and thermal.

The primary s t r e s s e s a r e d i r e c t

o r shear s t r e s s e s , developed by t h e imposed loading, which a r e necessary

t o s a t i s f y only t h e simple laws of equilibrium of e x t e r n a l and i n t e r n a l
f o r c e s and moments.

When primary s t r e s s e s exceed t h e y i e l d s t r e n g t h of

t h e material, y i e l d i n g w i l l continue u n t i l t h e member breaks, unless

s t r a i n hardening o r r e d i s t r i b u t i o n of s t r e s s e s l i m i t s t h e deformation.
Secondary s t r e s s e s a r e d i r e c t o r shear s t r e s s e s developed by t h e cons t r a i n t of adjacent p a r t s o r by s e l f - c o n s t r a i n t of t h e s t r u c t u r e .

Sec-

ondary s t r e s s e s d i f f e r from primary s t r e s s e s i n t h a t y i e l d i n g of t h e mat e r i a l r e s u l t s i n r e l a x a t i o n of t h e s t r e s s e s .

Local o r peak s t r e s s e s

a r e t h e highest s t r e s s e s i n t h e region being studied.

They do not cause

even noticeable minor d i s t o r t i o n s and a r e objectionable only a s a poss i b l e source of f a t i g u e cracks.

Thermal s t r e s s e s a r e i n t e r n a l s t r e s s e s

produced by c o n s t r a i n t of thermal expansion.

Thermal s t r e s s e s which i n -

volve no general d i s t o r t i o n were considered t o be l o c a l s t r e s s e s .

Thermal

s t r e s s e s which cause gross d i s t o r t i o n , such a s those r e s u l t i n g from t h e

temperature d i f f e r e n c e between s h e l l s a t a junction, were considered t o
be secondary s t r e s s e s .
I n t h e present examination, f o u r sources of s t r e s s e s were considered.
Pressure d i f f e r e n c e s a c r o s s t h e s h e l l s w i l l produce membrane pressure
stresses.

These s t r e s s e s a r e primary membrane s t r e s s e s .

The pressure

d i f f e r e n c e s w i l l a l s o produce d i s c o n t i n u i t y s t r e s s e s , which a r e secondary

bending s t r e s s e s .

Temperature g r a d i e n t s along t h e s h e l l s w i l l produce

s t r e s s e s which a r e due both t o t h e temperature v a r i a t i o n s and t o t h e d i f ferential-expansion-induced d i s c o n t i n u i t i e s a t t h e s h e l l junctions.

s t r e s s e s a r e secondary bending s t r e s s e s .

These

Temperature g r a d i e n t s a c r o s s

t h e w a l l s of t h e s h e l l s w i l l produce thermal s t r e s s e s which a r e assumed

t o be l o c a l s t r e s s e s .
The ASME Code i s g e n e r a l l y accepted a s t h e b a s i s f o r evaluating p r i mary membrane s t r e s s e s , and t h e allowable s t r e s s e s f o r INOR-8 a t t h e ope r a t i n g temperatures of t h e pumps were obtained from t h e c r i t e r i a s e t
f o r t h i n t h e code, with one exception.

A reduction f a c t o r of two-thirds
was applied t o t h e s t r e s s t o produce a creep r a t e of 0.1% i n 10 000 hr
i n order t o avoid p o s s i b l e problems a s s o c i a t e d w i t h t h e e f f e c t of i r r a d i a t i o n on t h e creep r a t e . *

The maximum allowable s t r e s s a t 1300F i s 2750

p s i , and t h e primary membrane s t r e s s e s were l i m i t e d t o t h i s value.

*Based on d a t a from R . W . Swindeman, ORNL.

The

primary s t r e s s e s were not considered f u r t h e r except from t h e standpoint

of excessive deformations produced by primary p l u s secondary s t r e s s e s .
I n order t o evaluate t h e e f f e c t s of secondary and l o c a l s t r e s s e s ,
r e p e t i t i v e loading and temperature c y c l e s must be considered because
f r a c t u r e s produced by t h e s e t y p e s of s t r e s s a r e u s u a l l y t h e r e s u l t of
strain fatigue.

Data which give t h e c y c l e s - t o - f a i l u r e v e r s u s t h e t o t a l

o r p l a s t i c s t r a i n range p e r cycle may be used f o r studying c y c l i c conditions.

.

The t o t a l s t r a i n range per cycle i s defined a s t h e e l a s t i c p l u s

p l a s t i c s t r a i n range t o which t h e member i s subjected during each c y c l e .

The p l a s t i c s t r a i n range per cycle i s t h e p l a s t i c component of t h e t o t a l
s t r a i n range per cycle.

The s t r a i n - c y c l i n g information may be compared

with t h e c a l c u l a t e d c y c l i c s t r a i n s i n t h e member.

Since most formulas

express s t r e s s r a t h e r than s t r a i n a s a f u n c t i o n of loading o r temperat u r e d i s t r i b u t i o n , assuming e l a s t i c behavior of t h e m a t e r i a l , it i s convenient, a s s t a t e d before, t o transform t h e t e s t d a t a from t h e form of
s t r a i n versus c y c l e s - t o - f a i l u r e t o t h e form of s t r e s s versus cycles-tof a i l u r e by multiplying t h e s t r a i n values by t h e e l a s t i c modulus of t h e
material.

The r e s u l t i n g values have t h e dimensions of s t r e s s but, s i n c e

t h e t e s t s were made i n t h e p l a s t i c range, t h e y do not r e p r e s e n t a c t u a l

stresses.
.

When t h e a n a l y s i s of s t r e s s e s i n a member r e v e a l s a b i a x i a l o r t r i -

a x i a l s t r e s s condition, it i s necessary t o make some assumption regarding

t h e f a i l u r e c r i t e r i o n t o be used.

I n t h e p l a s t i c range, where most of

t h e s i g n i f i c a n t secondary and l o c a l s t r e s s e s l i e , t h e r e i s no experim.enta1

evidence t o i n d i c a t e which theory of f a i l u r e i s most accurate.

There-

f o r e , it has been recommended15 t h a t t h e maximum shear t h e o r y be used,

since it i s a l i t t l e more conservative and r e s u l t s i n simpler mathematic a l expressions.

The following s t e p s used i n developing t h e procedure

were taken from r e f . 3:

1. Calculate t h e t h r e e p r i n c i p a l s t r e s s e s (al, a2, a3 ) a t a given

point.

2.

Determine t h e maximum shear s t r e s s which i s t h e l a r g e s t of t h e

three quantities

3.

blultiply t h e maximum shear s t r e s s by two t o give t h e "maximum

i n t e n s i t y of combined s t r e s s . "

4.

Compare t h i s q u a n t i t y with t h e E AE values obtained from uni-

axial strain-cycling t e s t s .
S t a t e d more simply, t h e procedure i s t o use t h e s t r e s s i n t e n s i t y
representing t h e l a r g e s t a l g e b r a i c d i f f e r e n c e between any two of t h e t h r e e
principal stresses

The procedure o u t l i n e d above f o r evaluating t h e e f f e c t s of c y c l i c

loadings and c y c l i c thermal s t r a i n s was used t o examine t h e c y c l i c secondary and l o c a l s t r e s s e s which w i l l be produced i n p o r t i o n s of t h e MSRE
pumps.

The procedure i s e s s e n t i a l l y t h a t s p e c i f i e d by t h e Navy Code;

however, t h e Navy Code was developed p r i m a r i l y f o r a p p l i c a t i o n s i n which

t h e maximum temperatures would be below those necessary f o r creep and r e l a x a t i o n of t h e m a t e r i a l .

Thus, s e v e r a l of t h e s t e p s o u t l i n e d i n t h e

Navy Code were m.odified f o r t h e present evaluation.

The assumption was made t h a t t h e temperatures were s u f f i c i e n t l y high
and t h a t t h e times a t t h e s e temperatures were s u f f i c i e n t l y long f o r comp l e t e s t r e s s r e l a x a t i o n t o occur.

Thus t h e s t r a i n s which t h e e l a s t i c a l l y

c a l c u l a t e d s t r e s s e s represented were taken a s e n t i r e l y p l a s t i c .

On t h i s

b a s i s , s t r a i n cycling d a t a i n t h e form of p l a s t i c r a t h e r t h a n t o t a l s t r a i n
range per cycle versus c y c l e s - t o - f a i l u r e were used.

Figures D . l and D.2,

which give s t r a i n f a t i g u e d a t a f o r INOR-8 a t 1200 and 1300F, were obt a i n e d from a l i m i t e d number of s t r a i n - c y c l i n g t e s t s performed by t h e
ORNL Metallurgy Division.

The dashed curves were obtained from t h e p l a s -

t i c s t r a i n range p e r cycle curves and r e p r e s e n t a conservative estimate

S t r a i n F a t i g u e Curves f o r INOR-8 a t 1200F.

Fig. D . 1 .

UNCLASSIFIED
ORNL-LR-DWG 6 4 5 0 9

10~

-i

lo-'

\
W

5
>
E
W

iw la2

k 10-3
5
2

!o-~
10-I

100 2

10'

102 2

{o3 2

lo4

lo5

lo6

N, CYCLES TO FAILURE

F i g . D.2.

S t r a i n F a t i g u e Curves f o r INOR-8 a t 1300F.

of t h e t o t a l s t r a i n range per cycle.

It was assumed t h a t t h e m a t e r i a l

e x h i b i t s p e r f e c t p l a s t i c i t y above t h e p r o p o r t i o n a l l i m i t (no s t r a i n
hardening), and t h e e l a s t i c s t r a i n a t t h e p r o p o r t i o n a l limit was added
t o t h e p l a s t i c s t r a i n range a t each p o i n t .

The dashed curves were used

t o o b t a i n an estimate of t h e c y c l e s - t o - f a i l u r e ,
t i o n o r strain-hardening occurs.

assuming t h a t no r e l a x a -

S t r a i n hardening would d i s p l a c e t h e

dashed curves upward.

Figures D.3 and D.4, which give t h e s t r e s s amplitude versus number
of cycles f o r INOR-8 a t 1200 and 1300F with complete r e l a x a t i o n , were
derived from t h e s o l i d curves f o r Figs. D . l and D.2 by multiplying t h e
p l a s t i c s t r a i n range by E t o o b t a i n a pseudo s t r e s s range and then d i viding by 2 t o o b t a i n t h e a l t e r n a t i n g s t r e s s .

The dashed curves i n F i g s .

D.3 and D.4 r e p r e s e n t t h e r e s u l t s of t h i s operation.

The s o l i d curves

represent t h e allowable values of a l t e r n a t i n g s t r e s s and were constructed

by placing a f a c t o r of s a f e t y of a t l e a s t 10 on c y c l e s and a f a c t o r of
s a f e t y of a t l e a s t 1 . 5 based on s t r e s s .

The s a f e t y f a c t o r of 10 on c y c l e s

i s based on u n c e r t a i n t i e s i n t h e c a l c u l a t i o n s , s c a t t e r of t e s t data, s i z e
e f f e c t s , surface f i n i s h , atmosphere, e t c .

These reduction f a c t o r s a r e

l e s s conservative t h a n those s p e c i f i e d by t h e Navy Code.

However, t h e y

have been used i n high-temperature design f o r s e v e r a l years a t ORNL, and

t h e c u r r e n t f e e l i n g of one of t h e o r i g i n a t o r s of t h e Navy Code i s t h a t
t h e reduction f a c t o r s s p e c i f i e d i n t h a t document a r e over-conservative
and w i l l be reduced t o those used i n t h i s i n v e s t i g a t i o n . *

F i g u r e s D.5

and D.6 were obtained i n t h e manner a s F i g s . D.3 and D.4 b u t were based
on t o t a l s t r a i n r a t h e r t h a n p l a s t i c s t r a i n .

They r e p r e s e n t allowable

values of a l t e r n a t i n g s t r e s s i f no r e l a x a t i o n occurs.
The l i f e of a component undergoing c y c l i c s t r a i n depends on mean
s t r a i n a s w e l l a s c y c l i c s t r a i n ; however, f o r most a p p l i c a t i o n s i n which
t h e loading i s almost e n t i r e l y due t o thermal cycling and no severe
s t r a i n - c o n c e n t r a t i o n s e x i s t , t h e e f f e c t of mean s t r a i n can be expected
t o be secondary t o t h a t of c y c l i c s t r a i n .

For t h e s e a p p l i c a t i o n s , c y c l i c

l i f e can be determined d i r e c t l y from s t r a i n range computations .16

The

*Personal communications between B. F. Langer of Westinghouse E l e c t r i c

Corp., B e t t i s P l a n t , and B. L. Greenstreet, ORNL.

UNCLASSIFIED
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405

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S t r e s s Amplitude Versus Number of Cycles f o r INOR-8 a t

Fig. D.3.
1200F with Complete S t r e s s Relaxation.

Fig. D.4. S t r e s s Amplitude Versus Number of Cycles f o r INOR-8 a t

1300F with Complete S t r e s s Relaxation.

UNCLnSSlFlED
ORNL-LR-DWG 6 4 3 2

S t r e s s Amplitude Versus Number of Cycles f o r INOR-8 a t

Fig. D . 5 .
1200F w i t h No Relaxation.

UNCLnSSlFlED
ORNL-LR-DWG 6 4 5 1 3

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N, NUMBER O F C Y C L E S

Fig. D . 6 .
S t r e s s Amplitude Versus Number of Cycles f o r INOR-8 a t
1300F w i t h No Relaxation.

e f f e c t of mean s t r a i n i s f u r t h e r reduced when g r o s s r e l a x a t i o n t a k e s place

during each cycle, a s i s expected i n t h e p r e s e n t case.

Thus f o r t h e MSRE

pump s t r e s s evaluation, t h e mean s t r a i n was assumed i n a l l c a s e s t o be

zero, and t h e e f f e c t of c y c l i c s t r e s s e s was determined d i r e c t l y from t h e
p l o t s of t h e allowable a l t e r n a t i n g s t r e s s versus t h e number of cycles.
Each of t h e components examined w i l l be subjected t o s e v e r a l operat i n g conditions.

Since s t r a i n s w i l l occur t h a t a r e beyond t h e e l a s t i c

l i m i t , t h e s t r u c t u r a l evaluation was based on a f i n i t e l i f e , and t h e

damaging e f f e c t of a l l s i g n i f i c a n t s t r a i n s was considered.

Suppose, f o r example, t h a t t h e s t r e s s e s produced by n d i f f e r e n t ope r a t i n g conditions have been determined and t h a t it has been found that
t h e s e s t r e s s e s w i l l produce values of Salt
Sl,

S2,

,.. Sn .

which can be designated a s

It i s a l s o known t h a t Sl i s repeated p

times during t h e
1
times, e t c . ' From F i g s . D . 3

l i f e of t h e component, and S i s repeated p

2
2
N a r e t h e allowable c y c l e s f o r each
and D . 4 it i s found t h a t N1, N2,
n
of t h e c a l c u l a t e d s t r e s s e s . The values P1/~l, P ~ / N ~ , p n / ~ , a r e c a l l e d

...

...

cycle r a t i o s because they r e p r e s e n t t h e f r a c t i o n of t h e t o t a l l i f e which

i s used a t each s t r e s s value.

A s a f i r s t approximation, an a p p l i c a t i o n

might be considered s a t i s f a c t o r y i f

Fatigue t e s t s have shown, however, t h a t f a i l u r e can occur a t cumulative

cycle r a t i o summations d i f f e r e n t from u n i t y .

I f t h e lower s t r e s s values

a r e applied f i r s t and followed by t h e higher s t r e s s values, t h e cycle

r a t i o summation a t f a i l u r e can be "coaxed" a s high a s 5.

On t h e o t h e r

hand, i f t h e most damaging s t r e s s e s a r e a l l applied f i r s t , f a i l u r e can

occur a t cycle r a t i o summations a s low a s 0.6, o r even lower.

These a r e

extreme conditions and a r e based on low-temperature f a t i g u e d a t a which

may o r may not be r e p r e s e n t a t i v e of behavior under s t r a i n cycling.

For

random combinations, c y c l e - r a t i o summations u s u a l l y average-close t o

unity.

Therefore, 0.8 was used i n t h e present evaluation a s a conserva-

t i v e allowable l i m i t .

It should be noted t h a t i n c o r r e c t l y applying any design c r i t e r i a ,

a point-by-point a n a l y s i s must be made.

That i s , t h e complete operating

h i s t o r y f o r each s i n g l e point must be examined.

Short c u t s may sometimes

be taken, but they must n e c e s s a r i l y lead t o overly conservative r e s u l t s .

I n swnmary, t h e permissible cycles of each type were determined f o r
t h e MSRE f u e l and coolant pumps by combining t h e secondary and l o c a l
s t r e s s e s a t each p o i n t .

P o i n t s were then found which gave maximum values

f o r t h e "maximum i n t e n s i t y of combined s t r e s s . "

divided by 2 t o obtain t h e a l t e r n a t i n g s t r e s s .

These l a t t e r values were

The allowable number of

cycles f o r each a l t e r n a t i n g s t r e s s were obtained from F i g s . D.3 o r D.4,

assuming complete r e l a x a t i o n .

The cycle r a t i o s were then obtained t h a t

were based on t h e expected number of times each s t r e s s w i l l be repeated,

and various combinations of t h e cycle r a t i o s were summed a t a p a r t i c u l a r
point and compared with t h e 0.8 l i m i t .

To i n v e s t i g a t e t h e i n c r e a s e i n

l i f e i f no r e l a x a t i o n occurred, Figs. D.5 and D.6 were used i n place of

Figs. D.3 and D . 4 .

NOMENCLATURE
Volute support cylinder mean r a d i u s
Exponential constant i n c y l i n d e r "B" temperat u r e equation
I n t e g r a t i o n constants
I n t e g r a t i o n constants f o r c y l i n d e r "A"
(n = 1, 2, 3, 4 )
I n t e g r a t i o n constants f o r c y l i n d e r "B"
( n = 1,
4)

...,

I n t e g r a t i o n constants f o r cone ( n = 1,

..., 4 )

Flexural r i g i d i t y of cylinder
Dimensionless temperature parameter
Modulus of e l a s t i c i t y

Geometric constants f o r r a d i a t i o n heat t r a n s f e r

Forced convection heat t r a n s f e r c o e f f i c i e n t
E f f e c t i v e heat t r a n s f e r c o e f f i c i e n t of pump
tank o u t e r surface
Heat t r a n s f e r c o e f f i c i e n t of pump tank i n n e r
surface
Auxiliary temperature functions f o r cone
( n = 1,
4)

...,

Thermal conductivity of INOR-8

Auxiliary s t r e s s functions f o r conical s h e l l s
4)
(n = 1,

...,

Axial cylinder p o s i t i o n from cone-to-cylinder

junction
Bending moment

Bending moment f u n c t i o n s f o r c y l i n d e r ( n = 1,

..., 4 )

Bending moment f u n c t i o n s f o r meridional plane

of cone (n = 1,
4)

...,

Bending moment f u n c t i o n s f o r c i r c u m f e r e n t i a l
4)
plane of cone ( n = 1,

...,

Membrane f o r c e
Membrane f o r c e f u n c t i o n s f o r c y l i n d e r ( n = 1,

..., 4 )

Membrane f o r c e f u n c t i o n s f o r c i r c u m f e r e n t i a l
plane of cone ( n = 1,
4)

...,

Auxiliary s t r e s s f u n c t i o n s f o r c o n i c a l s h e l l s
( n = 1,
4)

...,

P r a n d t l number
Normal shear f o r c e
Shear f o r c e f u n c t i o n s f o r c y l i n d e r (n = 1,

...) 4 )

Shear f o r c e f u n c t i o n s f o r cone ( n = 1,

..., 4 )

Heat t r a n s f e r r e d a c r o s s i n n e r pump t a n k surface

Heat t r a n s f e r r e d a c r o s s o u t e r pump t a n k surface
Heat input t o i n n e r pump t a n k surface by f i s s i o n product-gas b e t a r a d i a t i o n
I n t e r n a l heat generation r a t e from gamma r a d i a tion
Heat t r a n s f e r r e d from o u t e r pump tank surface
t o cooling shroud
Heat t r a n s f e r r e d from o u t e r pump tank surface
t o cooling a i r
Heat t r a n s f e r r e d from t h e cooling shroud t o t h e
cooling a i r
Reynold ' s number
Constants i n c y l i n d e r "A" temperature equation
( n = 1,
4)

...,

Constants in cylinder "B" temperature equation

5)
(n = 1,

...,

Constants in cone temperature equation (n = 1,

..., 5 )

Wall thickness of cylinder

Wall thickness of cone

tc

Thickness of cooling air gap

t
g

Displacement of cone perpendicular to surface

Meridional displacement of cone
Displacement functions for cone (n = 1,

..., 4 )

Radial displacement
W
nc

Displacement functions for cone (n = 1,

Slope functions for cylinder (n = 1,
Slope functions for cone (n = 1,

..., 4 )

..., 4 )

Distance through pump tank wall

Dimensionless coordinate of cone
Y = PL

Dimensionless coordinate of cylinder

YC

Meridional position on cone from apex

Coefficient of thermal expansion

f,

(-314

Characteristic length of cylinder

Temperature
Local temperature

..., 4 )

One h a l f of cone v e r t e x angle

Poisson's r a t i o
Bending s t r e s s
Membrane s t r e s s
P r i n c i p a l meridional s t r e s s e s i n s i d e and o u t side
P r i n c i p a l c i r c u m f e r e n t i a l s t r e s s e s i n s i d e and
out s i d e
Stefan-Boltzman constant
Subscripts
a

Cylinder "A" ( i n t e r n a l volute support c y l i n d e r )

Cylinder "B" ( e x t e r n a l volute support c y l i n d e r )

Cone ( s u b s t i t u t e f o r pump tank s p h e r i c a l s h e l l

i n thermal s t r e s s c a l c u l a t i o n s )
Meridional plane
Circumferential plane

ACKNOWLEDGMENTS
The author wishes t o acknowledge t h e work of J. M. Corum i n t h e
preparation of Appendix D, "Procedure Used t o Evaluate t h e E f f e c t s of
Cyclic S t r a i n s i n t h e MSRE Pumps."

The Oracle S t r e s s Analysis Program

used t o determine s t r e s s e s produced by pressure and a x i a l l o a d s was

prepared by M. E. Laverne.

The a s s i s t a n c e of F. J. W i t t i n regard t o

t h e thermal s t r e s s c a l c u l a t i o n s i s a l s o acknowledged.

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