Practice Workbook

This workbook is designed for use in Live instructor-led training and for OnDemand self-study. The explanations
and demonstrations are provided by the instructor in the classroom, or in the OnDemand eLectures of this course
available on the Bentley LEARNserver (learn.bentley.com).

This practice workbook is formatted for on-screen viewing using a PDF reader. It is also available as a PDF
document in the dataset for this course.

Fatigue Analysis for ASME NB

This workbook contains exercises to introduce you to fatigue analysis for ASME NB nuclear safety critical piping
using the AutoPIPE Nuclear edition.

TRNC03399-1/0001

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Description and Objectives

Course Description

This workbook contains exercises to introduce you to fatigue analysis for ASME NB nuclear safety critical piping using the AutoPIPE Nuclear
edition.

Skills Taught

• Loading a model ready for fatigue analysis

• Defining the Analysis Sets

• Creating the Stress Summary and the effect on the combinations

• Understanding the fatigue output

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Ex 1 – Fatigue Analysis
In this exercise, you will open a model and create the stress summary for a fatigue analysis, review and understand the fatigue report.

1. Launch AutoPIPE from the Desktop Icon

2. Select OpenAutoPIPE Database (*.dat) from the Application Button or use Open from the File Ribbon Tab.

3. In the Open dialog, navigate to the dataset file fatigue analysis.dat that was supplied with this training and select Open.

4. Save the model with a new name so that the original remains, using Save AsAutoPIPE Dataset (*.dat) from the File Ribbon Tab or from
the Application Button and use fatigue analysis working.dat or similar for the name.

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 Note: This model has already got the following static loading applied.
OPERATING TEMPERATURE AND PRESSURE DATA
STRESSES IN psi

POINT PRESS. TEMPER EXPAN. MODULUS YIELD DELTA T1 DELTA T2

NAME CASE psi deg F in/100ft E6 psi STRESS deg F deg F
---- ---- ------ ------ -------- ------- ------ -------- --------

*** SEGMENT A
A00 T1 300 140 0.726 27.924 28000 160.00 90.00
T2 250 670 6.946 24.950 17820 175.00 110.00
T3 355 550 5.440 25.550 18800 155.00 80.00
T4 375 600 6.060 25.300 18200 150.00 90.00

5. In the Menu Bar, click Load > Static Analysis Sets…

Note: If the Analysis Sets are not set up as above then use Create Default SetsMultiple analysis sets (one GR). Notice the colour coding
that provides a visual indication of the status of the analysis.

Note: For an ASME NB analysis the thermal cases must all be in individual load cases so that the correct temperature can be assigned to the
creation of the Hot Modulus stiffness matrix.

Then click OK to accept.

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6. Answer Yes when asked Do you want to analyze the model?

Note: If you are not asked then select AnalyzeAll from the Analysis Ribbon Tab. If you are asked to review the Consistency Report
say No.

7. Review the Combinations using SetupCombinations from the Result Ribbon Tab.

 Select Code Comb tab

Note: The analysed Load Cases are listed in the Load Case tab. The number in the bracket represents the Static Load Set that this result
came from.

Note: Unlike other analysis codes the Code Combinations for ASME NB are not created automatically. They are managed by the Stress
Summary which also defines the fatigue analysis. Once defined the Combinations used in the Stress Summary are highlighted in
Yellow, they can no longer be deleted. These form the Full Verification results.

Note: The stress results listed in the Code Combinations tab are known as Pre Verification stresses and representative of the load case taken
in isolation and not ranged with any other zero.

Then click OK or Cancel to accept.

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8. Create the Stress Summary using SetupStress Summary from the Result Ribbon Tab.

 Select New

 Select A for Service Level from the drop down.

 Assign the load cases as below

The Stress Summary combines the various load cases together that describes each specific plant operating event in line with the code
requirements and assigns number of cycles that each event (or load pair) occurs during the plant lifetime. The program automatically calculates
the maximum equation stress results and determines the incremental usage factor based on the maximum occurrence of each load pair. The
definitions in the stress summary form the basis of the full verification and fatigue analysis.

Note: Only the combinations required by each code equation appear in the drop down. All other equation take their definition from the
definition of Equation 9 and 10 automatically as required.
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 • The Primary Stress Intensity, Equation 9 combines the Gravity (including pressure) and other design mechanical loads.

• Primary Plus Secondary Stress Intensity Range, Equation 10 combines the Thermal (including pressure) load cases that describe
each individual event and assign the number of occurrences (No of Cycles figure). Other non-thermal load cases effecting fatigue
can also be included.

• The Zero Moment Case is the cold condition with no temperature or pressure moments and is used to simulate the boundary
condition associated with the cold installation stage.

Hint: When using Zero Moment Case the Design Pressure is pessimistically used in the Ratchet calculation if the maximum load pair includes
the zero case. This can cause a stress limit problem so a specific thermal case can also be defined to represent the cold condition.

Then click OK to accept.

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9. Notice the change in the combination by selecting SetupCombinations from the Result Ribbon Tab. The load case combinations used
in the Stress Summary are now highlighted in Yellow, they can no longer be deleted.

 Select Code Comb tab

 The load case combinations used in the Stress Summary are now highlighted in Yellow, they can no longer be deleted.

Then click OK or Cancel to accept.

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10. Open the Fatigue Report from ReportsOutput Report from the Results Ribbon Tab.

• Fatigue Report: Check

• All other reports: None

Click OK to accept.
Stress Summary #1 - NODE A00 , SEGMENT A
ASME NB (2010)
------------------------------

F A T I G U E E V A L U A T I O N - I T E R A T I O N # 1

LOAD SETS AVAILABLE FOR EQUATION 10

LOAD RUN MX RUN MY RUN MZ BRAN MX BRAN MY BRAN MZ PRESS. DEL-T1 DEL-T2 GRS-DIS
SET INDEX CYCLE COMBINATION ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb psi deg F deg F psi
--- ----- ----- ------------------------ ------- ------- ------- ------- ------- ------- ------ ------ ------ -------
1 2 50 Thermal 1{2} 0 247 0 0 0 0 300 160.0 90.0 0
2 2 50 Thermal 2{3} 0 2513 0 0 0 0 250 175.0 110.0 0
3 3 6000 Thermal 2{3} 0 2513 0 0 0 0 250 175.0 110.0 0
4 4 1000 Thermal 2{3} 0 2513 0 0 0 0 250 175.0 110.0 0
5 3 6000 Thermal 3{4} 0 1986 0 0 0 0 355 155.0 80.0 0
6 4 1000 Thermal 3{4} 0 1986 0 0 0 0 355 155.0 80.0 0
7 4 1000 Thermal 4{5} 0 2239 0 0 0 0 375 150.0 90.0 0
8 2 50 ZERO 0 0 0 0 0 0 0 0.0 0.0 0

EXTERNAL (MECHANICAL) LOAD SETS AVAILABLE FOR EQUATION 9, 12 AND 13

LOAD RUN MX RUN MY RUN MZ BRAN MX BRAN MY BRAN MZ PRESS.

SET COMBINATION ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb psi
--- ------------------------ ------- ------- ------- ------- ------- ------- ------
9 Gravity{1} -77 0 1833 0 0 0 375
10 Static Seismic 1{1} 15 709 367 0 0 0 375

The first table of the Fatigue Report is the Fatigue Evaluation for Iteration 1. It takes the information from the Stress Summary and extracts the
maximum results from the analysis at each point in turn (A00 in this example). Consider the table with the Stress Summary definition from
Section 8 above, each of the load case combination defined in the Stress Summary are given a separate line in the Fatigue Evaluation table and
are assigned the a unique Load Set Number (ringed in red). The Index number next to the Load Set corresponds to the Equation Index (or line
number) from the Stress Summary. The number of Cycles that the specific combination can occur for that particular event is also taken from the
Stress Summary and recorded (ringed in green). Finally the maximum results for each node are then assigned to each of the Load Sets (ringed
in blue).

Note: Thermal 2{3} and Thermal 3{4} appear more than once as more than one transient event uses them (i.e. they appear multiple times in
the Stress Summary under different Equation Indices). The Index number for these repeated occurrences will be different as it is not
permitted to have the same combination in the same Equation Index more than once.

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 Note: Equation Index 2 includes three combinations, Thermal 1{2}, Thermal 2{3}, and ZERO, each with 50 cycles, so appears three times

Following the accepted procedures for combining load sets so that the maximum range is determined and not applied in an overly conservative
manner, the program will pair each Load Set with all other Load Sets using the following rules:

• Each unique Load Set starting with 1 is paired with all other Load Sets. The Load Set Pair that gives highest alternating stress S-ALT is
determined and will be reported in the pairing table. For this example pair 1-3 was the most critical from all Load Sets paired with
Load Set 1. This procedure is repeated for all available Load Sets and the summary table for iteration 1 written.
SECTION III STRESS SUMMARY FOR THE MAXIMUM VALUE OF ALTERNATING STRESS

LOAD SET |------------EQUATION 10----------------|--------------EQUATION 11 --------------| Stresses in psi

PAIR PRESS. MOMENT DISCON WL-GRD TOTAL PRESS. MOMENT DISCON WL-GRD TOTAL S-ALT EQN.12 EQN.13 KE
-------- ------ ------ ------ ------ ----- ------ ------ ------ ------ ----- ----- ------ ------ -----
1 - 3 670 1618 0 0 2288 670 1618 0 67869 70157 35079 0 0 1.000
2 - 8 3348 1794 0 0 5143 3348 1794 0 67869 73012 36506 0 0 1.000
3 - 8 3348 1794 0 0 5143 3348 1794 0 67869 73012 36506 0 0 1.000
4 - 8 3348 1794 0 0 5143 3348 1794 0 67869 73012 36506 0 0 1.000
5 - 8 4754 1418 0 0 6172 4754 1418 0 54124 60296 30148 0 0 1.000
6 - 8 4754 1418 0 0 6172 4754 1418 0 54124 60296 30148 0 0 1.000
7 - 8 5022 1598 0 0 6621 5022 1598 0 56701 63322 31661 0 0 1.000

• The critical Load Set Pair (2 - 8) with highest alternating stress S-ALT is identified and will be added to Usage Summary table.

• For next iteration, the Load Set in the critical Load Set Pair (2 - 8) with lowest number of cycles will be completely removed from basic
Load Sets in the Fatigue Evaluation table for the next iteration (ie all cycles are used). If both have the same number of cycles, then
both load sets will be removed. So for this case as 2 and 8 have the same number of cycles they are both removed. If the Load Sets
have different numbers of cycles, then the left over cycles will be carried over to the next iteration.

• The Fatigue Evaluation table for iteration 2 is compiled. Only the Load Sets for Equation 10 form the fatigue analysis so those for
Equation 9 are not re-written.
F A T I G U E E V A L U A T I O N - I T E R A T I O N # 2

LOAD SETS AVAILABLE FOR EQUATION 10

LOAD RUN MX RUN MY RUN MZ BRAN MX BRAN MY BRAN MZ PRESS. DEL-T1 DEL-T2 GRS-DIS
SET INDEX CYCLE COMBINATION ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb psi deg F deg F psi
--- ----- ----- ------------------------ ------- ------- ------- ------- ------- ------- ------ ------ ------ -------
3 3 6000 Thermal 2{3} 0 2513 0 0 0 0 250 175.0 110.0 0
4 4 1000 Thermal 2{3} 0 2513 0 0 0 0 250 175.0 110.0 0
5 3 6000 Thermal 3{4} 0 1986 0 0 0 0 355 155.0 80.0 0
6 4 1000 Thermal 3{4} 0 1986 0 0 0 0 355 155.0 80.0 0
7 4 1000 Thermal 4{5} 0 2239 0 0 0 0 375 150.0 90.0 0

• If a transient (or equation index) has more than 2 load sets, and two of those load sets have been exhausted, the rest will also be
removed. This is due to the fact that in a transient with N cycles, there are N minima and N maxima and hence when 2N cycles have

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 been used in the transient (by 2 load sets) no more cycles remain. So for this example Load Set 1 is also removed as it belongs to
Equation Index 2 the same as Load Sets 2 and 8.

• The same pairing process as above is now performed with the remaining Load Sets and cycles and the pairing table for iteration 2
produced.
LOAD SET |------------EQUATION 10----------------|--------------EQUATION 11 --------------| Stresses in psi
PAIR PRESS. MOMENT DISCON WL-GRD TOTAL PRESS. MOMENT DISCON WL-GRD TOTAL S-ALT EQN.12 EQN.13 KE
-------- ------ ------ ------ ------ ----- ------ ------ ------ ------ ----- ----- ------ ------ -----
3 - 7 1674 196 0 0 1870 1674 196 0 67869 69740 34870 0 0 1.000
4 - 7 1674 196 0 0 1870 1674 196 0 67869 69740 34870 0 0 1.000
5 - 7 268 180 0 0 448 268 180 0 57560 58008 29004 0 0 1.000
6 - 7 268 180 0 0 448 268 180 0 57560 58008 29004 0 0 1.000
6 - 7 268 180 0 0 0 268 180 0 57560 58008 -1 0 0 1.000

• The worst pair from the above is Load Set Pair (3 - 7) since it has the highest S-ALT and will be added to Usage Summary table.
The Load Set with the lowest number of cycles is Load Set 7 so all 1000 cycles are used up and Load Set 7 will be removed in the
next iteration. Load Set 3 will have 1000 cycles deducted from its allocation so 6000 - 1000 = 5000 cycles remain for Load Set 3.

• The Fatigue Evaluation table for iteration 3 is compiled.

F A T I G U E E V A L U A T I O N - I T E R A T I O N # 3

LOAD SETS AVAILABLE FOR EQUATION 10

LOAD RUN MX RUN MY RUN MZ BRAN MX BRAN MY BRAN MZ PRESS. DEL-T1 DEL-T2 GRS-DIS
SET INDEX CYCLE COMBINATION ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb psi deg F deg F psi
--- ----- ----- ------------------------ ------- ------- ------- ------- ------- ------- ------ ------ ------ -------
3 3 5000 Thermal 2{3} 0 2513 0 0 0 0 250 175.0 110.0 0
4 4 1000 Thermal 2{3} 0 2513 0 0 0 0 250 175.0 110.0 0
5 3 6000 Thermal 3{4} 0 1986 0 0 0 0 355 155.0 80.0 0
6 4 1000 Thermal 3{4} 0 1986 0 0 0 0 355 155.0 80.0 0

• The same pairing process as above is now performed with the remaining Load Sets and cycles and the pairing table for iteration 3
produced.
LOAD SET |------------EQUATION 10----------------|--------------EQUATION 11 --------------| Stresses in psi
PAIR PRESS. MOMENT DISCON WL-GRD TOTAL PRESS. MOMENT DISCON WL-GRD TOTAL S-ALT EQN.12 EQN.13 KE
-------- ------ ------ ------ ------ ----- ------ ------ ------ ------ ----- ----- ------ ------ -----
3 - 5 1406 376 0 0 1783 1406 376 0 67869 69652 34826 0 0 1.000
4 - 5 1406 376 0 0 1783 1406 376 0 67869 69652 34826 0 0 1.000
5 - 6 0 0 0 0 0 0 0 0 54124 54124 27062 0 0 1.000
5 - 6 0 0 0 0 0 0 0 0 54124 54124 -1 0 0 1.000

• The worst pair from the above is Load Set Pair (3 - 5) since it has the highest S-ALT and will be added to Usage Summary table.
The Load Set with the lowest number of cycles is Load Set 3 so all 5000 cycles are used up and Load Set 3 will be removed in the
next iteration. Load Set 5 will have 5000 cycles deducted from its allocation so 6000 - 5000 = 1000 cycles remain for Load Set 5.

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 • Fatigue Evaluation table for iteration 4 is compiled.
F A T I G U E E V A L U A T I O N - I T E R A T I O N # 4

LOAD SETS AVAILABLE FOR EQUATION 10

LOAD RUN MX RUN MY RUN MZ BRAN MX BRAN MY BRAN MZ PRESS. DEL-T1 DEL-T2 GRS-DIS
SET INDEX CYCLE COMBINATION ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb psi deg F deg F psi
--- ----- ----- ------------------------ ------- ------- ------- ------- ------- ------- ------ ------ ------ -------
4 4 1000 Thermal 2{3} 0 2513 0 0 0 0 250 175.0 110.0 0
5 3 1000 Thermal 3{4} 0 1986 0 0 0 0 355 155.0 80.0 0
6 4 1000 Thermal 3{4} 0 1986 0 0 0 0 355 155.0 80.0 0

• The same pairing process as above is now performed with the remaining Load Sets and cycles and the pairing table for iteration 4
produced.
LOAD SET |------------EQUATION 10----------------|--------------EQUATION 11 --------------| Stresses in psi
PAIR PRESS. MOMENT DISCON WL-GRD TOTAL PRESS. MOMENT DISCON WL-GRD TOTAL S-ALT EQN.12 EQN.13 KE
-------- ------ ------ ------ ------ ----- ------ ------ ------ ------ ----- ----- ------ ------ -----
4 - 5 1406 376 0 0 1783 1406 376 0 67869 69652 34826 0 0 1.000
5 - 6 0 0 0 0 0 0 0 0 54124 54124 27062 0 0 1.000
5 - 6 0 0 0 0 0 0 0 0 54124 54124 -1 0 0 1.000

• The worst pair from the above is Load Set Pair (4 - 5) since it has the highest S-ALT and will be added to Usage Summary table.
Each Load Set has the same number of cycles 1000 so both Load Set 4 and 5 are removed. Since 2 Load Sets of Equation Index 4
has been removed (4 and 5), the rest Load Set 6 will also be removed.

• This completes the iteration process and the Usage Factor summary is compiled and written.
SECTION III STRESS AND USAGE FACTOR SUMMARY FOR EACH TABLE OF LOAD SETS

LOAD SET Stresses in psi -----CYCLES----- ----USAGE FACTOR--

PAIR EQN.10 EQN.11 EQN.12 EQN.13 S-ALT KE ACTUAL ALLOWED INCREMENTAL TOTAL LOAD RANGE
-------- ------ ------ ------ ------ ----- ----- ------ ------- ----------- ------ -------------------
2 - 8 5143 73012 0 0 36506 1.000 50 182661 0.0003 0.0003 Thermal 2{3}-ZERO
3 - 7 1870 69740 0 0 34870 1.000 1000 239872 0.0042 0.0044 Thermal 2{3}-Thermal 4{5}
3 - 5 1783 69652 0 0 34826 1.000 5000 241764 0.0207 0.0251 Thermal 2{3}-Thermal 3{4}
4 - 5 1783 69652 0 0 34826 1.000 1000 241764 0.0041 0.0293 Thermal 2{3}-Thermal 3{4}

The Cumulative Usage factor value is the value found in the Full Verification Stress Report.
ASME NB (2010) STRESS SUMMARY #1 LEVEL A

Point (Stresses in psi , Ratchet in deg F ) Usage

Name EQ.9 EQ.10 EQ.11 EQ.12 EQ.13 Ratchet Leakage EQ.14 Factor Notes
------ -------- ------- ------- ------- ------- ------- ------- ------- ------- -----

*** Segment A begin ***

A00 Stress 4162 6621 73012 - - 175.00 6621 36506 0.0293
Allowable 23700 54900 - - - 489.24 - -
Ratio 0.176 0.121 - - - 0.358 - -

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