DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

DRAFT - API Recommended Practice For Fitness-For-Service

APPENDIX E - Residual Stresses in a Fitness-For-Service Evaluation

(DRAFT - Revision 11 - MS Word 7.0)

E.1 General

E.1.1 This appendix provides guidance for determining the level of residual stresses caused by welded joints.
This information is required as input to perform a fitness-for-service assessment of a component
containing a crack-like flaw (see section 9.0).

E.1.2 The residual stress information from this appendix is used to compute the fracture driving force
associated with secondary stresses, and also serves as input data for determination of the ρ-factor
(see Section 9.0) which quantifies the fracture driving force that occurs under situations of combined
loading (i.e. primary, secondary and residual stress).

E.2 Applicability and Limitations of the Procedures

E.2.1 The procedures provided herein apply to weld joints located in equipment that has been in-service, as
well as to new construction.

E.2.2 Different types of welded configurations common to pressure vessels, piping and tankage are
addressed in this appendix. Guidance is provided for the following situations:
• Paragraph E.4: Full Penetration Welds in Piping and Pressure Vessel Cylindrical Shells
• Paragraph E.5: Full Penetration Welds in Spheres and Pressure Vessel Heads
• Paragraph E.6: Full Penetration Welds in Storage Tanks
• Paragraph E.7: Full Penetration and Fillet Welds at Corner Joints
• Paragraph E.8: Full Penetration and Fillet Welds at Tee Joints
• Paragraph E.9: Repair Welds

The basis for the recommendations of Paragraphs E.4 and E.9 is provided in reference (E.10). Further
work is needed to provide definitive guidance for Paragraphs E.5 through E.8. The recommendations
given in these paragraphs are, therefore, conservative. These recommendations will be updated in
future revisions of this Recommended Practice.

E.2.3 The residual stress distribution results in this appendix are based on a uniform PWHT temperature
applied to the component. Uncontrolled and/or local PWHT may result in significantly higher residual
stresses. If the type of PWHT cannot be established, yield level membrane stress through the wall
thickness of the component should be used for the residual stress distribution.

E.2.4 Currently, a distinction is not made concerning the material of construction. These recommendations
are based on a database which includes information on ferritic steel only. It is currently assumed that
stainless steel weldments can be assessed with equal accuracy using these equations. This
assumption will be addressed in future revisions to the Recommended Practice.

E.2.5 The residual stress distributions presented in this appendix are based on extensive numerical analyses
and literature survey of published results. The results obtained from the literature survey indicate
substantial scatter in reported results. The residual stress distributions in this appendix where
obtained by developing an upper based on these results. Residual stress distributions from a single
source should no be used unless specific information is available to confirm there accuracy.

E.2.6 The use of alternative residual stress distributions may be determined by numerical analysis. All
assumptions used in this analysis should be documented with the assessment results.

E-1
DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

E.3 Data Requirements and Definition of Variables

E.3.1 The following data is required to estimate the residual stress field caused by a welded joint.

E.3.1.1 The minimum data requirements are as follows:

a. The material in question,

b. The specified minimum yield strength of the material in question,

c. The location where the weld was made (e.g. shop or field),

d. The design wall thickness of the component,

e. The type of weld (i.e. girth or circumferential joint, longitudinal seam, repair weld, or attachment
weld).

E.3.1.2 Availability of the following information will improve the accuracy of the residual stress estimate:

a. The number of weld passes, and

b. Whether the weld has experienced any of the following procedures aimed at reducing the
residual stress level;

1. Hydrotest to 150% of the maximum allowable working pressure (MAWP) as per ASME
Section VIII, and/or

2. Post weld heat treatment per the original construction code.

E.3.2 Definition of symbols- the following variables are used in this appendix;
Cys = Yield stress correction factor for the residual stress distribution calculation: 1.2 for
carbon steel, and 1.5 for alloy steel,
Cul = units conversion constant; equal 1.0 if the thickness is expressed in mm, 25.4 if the
thickness is expressed in inches,
2
Cus = units conversion constant; equal 1.0 if the stress is expressed in N/mm and
-3
6.894757(10 ) if the stress is expressed in psi,
qv = Heat input of weld run adjacent to the flaw, J/mm,
t = Nominal wall thickness of the component, in:mm,
x = Local coordinate defined through the wall thickness of the component to define the
residual stress distribution, in:mm,
σ ys = Specified minimum yield strength, psi:MPa,

σ rys = The magnitude of the yield strength to be used to estimate the residual stress at a
welded joint, psi:MPa,
σ i
p
= Primary stress at the inner surface resulting from a hydrotest, psi:MPa,
σ o
p
= Primary stress at the outer surface resulting from a hydrotest, psi:MPa,
σ r
i = Residual stress at the inner surface, psi:MPa,
σ r
o = Residual stress at the outer surface, psi:MPa,
σ rh
i = Residual stress at the inner surface including the effects of hydrotest, psi:MPa,
σ rh
o = Residual stress at the outer surface including the effects of hydrotest, psi:MPa,
σ r
m = Membrane component of the residual stress, psi:MPa, and

E-2
 DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

σ br = Bending component of the residual stress, psi:MPa.

E.3 In order to estimate the magnitude of the residual stress distribution at a weld joint, an estimate of the
actual yield strength of the material must be made. If actual data does not exist or cannot be
determined, the following equation may be used to estimate the magnitude of the yield strength. The
elevation of the effective yield strength above the specified minimum yield strength accounts for the
typical elevation of actual properties above minimum requirements.

σ rys = C ysσ ys (E.1)

E.4 Full Penetration Welds in Piping and Pressure Vessel Cylindrical Shells

E.4.1 Circumferential (Girth) Welds (see Figure E.1)

E.4.1.1 Residual Stress Perpendicular to The Weld Direction

a. Residual Stress Distribution - the residual stress distribution for this category of weld made
remote from all geometric discontinuities can be approximated using the following equation. The
local coordinate x for the stress distribution is measured from the inside surface.

σ r ( x ) = σ ir + (σ or − σ ir )
x
(E.2)
t
with,

σ or = 0.2σ ysr (E.3)

for welds made with a heat input less than or equal to 50kJ/in:

σ ir = σ ysr for t ≤ 20 mm (E.4)

 t  r
σ ir = 132
. − 016
. σ for 20 mm < t < 20 mm (E.5)
 Cul  ys

σ ir = 0.2σ rys for t ≥ 70 mm (E.6)

and for welds made with a heat input greater than 50kJ/in:

σ ir = σ ysr for t ≤ 50 mm (E.7)

 t  r
σ ir = 180
. − 016
. σ for 50 mm < t < 100 mm (E.8)
 Cul  ys

σ ir = 0.2σ rys for t ≥ 100 mm (E.9)

The membrane and bending components of the residual stress distribution are:

E-3
DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

σ ir + σ or
σ mr = (E.10)
2

σ ir − σ or
σ br = (E.11)
2
b. Effects of hydrotest - if the weld is known to have been subject to a hydrotest of 150% of the
MAWP typical of many construction codes (e.g. ASME Section VIII, Division 1 and Division 2),
the magnitude of the transverse residual stress at the inner and outer surfaces, σ i and σ o ,
r r

respectively, can be reduced using the following equations. The residual stress distributions are
then determined using the procedures outlined in subparagraph (a) above, except the reduced
values or residual stress and the inner and outer surfaces, denoted σ irh and σ orh , are used in
place of σ ir and σ or , respectively.

[ (
σ irh = min σ ir , 14
. σ rys − σ ip )] and σ irh ≥ 0.0 (E.12)

σ orh = min[ σ , (14

.σ r
o
r
ys − σ op )] and σ orh ≥ 0.0 (E.13)

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 20% of the distribution
provided in subparagraph (a) above.

E.4.1.2 Residual Stress Parallel to The Weld Direction

a. Residual Stress Distribution - the residual stress distribution for this category of weld made
remote from all geometric discontinuities can be approximated using the following equation. .
The local coordinate x for the stress distribution is measured from the inside surface.

σ r ( x ) = σ ir + (σ or − σ ir )
x
(E.14)
t
with,

σ or = σ ysr (E.15)

and,

σ ir = σ ysr for t ≤ 20 mm (E.16)

 t  r
σ ir = 128
. − 014
. σ for 20 mm < t < 70 mm (E.17)
 Cul  ys

σ ir = 0.3σ rys for t ≥ 70 mm (E.18)

b. Effects of hydrotest - if the weld is known to have been subject to a hydrotest of 150% of the
MAWP typical of many construction codes (e.g. ASME Section VIII, Division 1 and Division 2),

E-4
 DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

the magnitude of the transverse residual stress at the inner and outer surfaces, σ i and σ or ,
r

respectively, can be reduced using the procedure described in paragraph E.4.1.1.b.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 30% of the distribution
provided in subparagraph (a) above.

E.4.2 Longitudinal (Seam) Welds (see Figure E.1)

E.4.2.1 Residual Stress Perpendicular to The Weld Direction

a. Residual Stress Distribution - the residual stress distribution for this category of weld made
remote from all geometric discontinuities can be approximated using the following equations.
The residual stress distribution is approximated as two linear stress distributions intersecting at
the mid-wall position. The residual stresses at the inner and outer surfaces are equal to the yield
strength, and the residual stress at the mid-thickness is zero. The transverse residual stress
varies linearly from the mid-wall position to the inner and outer surfaces. Note that this stress
distribution is discontinuous. The local coordinate x for the stress distribution is measured from
the inside surface.

x t
σ r ( x ) = σ ir − 2σ ir for x≤ (E.19)
t 2

x t
σ r ( x ) = 2σ 0r − σ or for <x ≤t (E.20)
t 2
with,

σ or = σ rys (E.21)

σ ir = σ ysr (E.22)

For internal surface cracks with a t < 0.5 , the membrane and bending stress components of
the residual stress distribution can be taken as:

σ ir
σ mr = (E.23)
2

σ ir
σ =
r
b (E.24)
2

For external surface cracks with a t < 0.5 , the membrane and bending stress components of
the residual stress distribution can be taken as:

σ or
σ =
r
m (E.25)
2

σ or
σ br = (E.26)
2

E-5
DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

For external surface cracks with a t > 0.5 or embedded cracks, the general stress distribution
can be established by using stress linearization (see Appendix B).

b. Effects of hydrotest - if the weld is known to have been subject to a hydrotest of 150% of the
MAWP typical of many construction codes (e.g. ASME Section VIII, Division 1 and Division 2),
the magnitude of the transverse residual stress at the inner and outer surfaces, σ i and σ or ,
r

respectively, can be reduced using the procedure described in paragraph E.4.1.1.b.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 20% of the distribution
provided in subparagraph (a) above.

E.4.2.2 Residual Stress Parallel To The Weld Direction

a. Residual Stress Distribution:

σ r ( x ) = σ ysr (E.27)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 30% of the distribution
provided in (a) above.

E.5 Full Penetration Welds in Spheres and Pressure Vessel Heads

Note: Further work is needed to provide definitive guidance; the recommendations given will be
updated in future revisions of this Recommended Practice.

E.5.1 Circumferential Welds (see Figure E.2)

E.5.1.1 Residual Stress Perpendicular to The Weld Direction

a. Residual Stress Distribution:

σ r ( x ) = σ ysr (E.28)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 20% of the distribution
provided in (a) above.

E.5.1.2 Residual Stress Parallel to The Weld Direction

a. Residual Stress Distribution:

σ r ( x ) = σ ysr (E.29)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

E-6
 DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 30% of the distribution
provided in (a) above.

E.5.2 Meridional (Seam) Welds (see Figure E.2) - The magnitude and distribution of the residual stress is
assumed to be the same as that given in paragraph E.5.1.

E.6 Full Penetration Welds in Storage Tanks

Note: Further work is needed to provide definitive guidance; the recommendations given will be
updated in future revisions of this Recommended Practice.

E.6.1 Circumferential (Girth) Welds (see Figure E.1)

E.6.1.1 Residual Stress Perpendicular to The Weld Direction

a. Residual Stress Distribution:

σ r ( x ) = σ ysr (E.30)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 20% of the distribution
provided in (a) above.

E.6.1.2 Residual Stress Parallel to The Weld Direction

a. Residual Stress Distribution:

σ r ( x ) = σ ysr (E.31)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 30% of the distribution
provided in (a) above.

E.6.2 Longitudinal (Seam) Welds (see Figure E.1)

E.6.2.1 Residual Stress Perpendicular to The Weld Direction

a. Residual Stress Distribution:

σ r ( x ) = σ ysr (E.32)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 20% of the distribution
provided in (a) above.

E-7
DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

E.6.2.2 Residual Stress Parallel To The Weld Direction

a. Residual Stress Distribution:

σ r ( x ) = σ ysr (E.33)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 30% of the distribution
provided in (a) above.

E.7 Full Penetration Welds at Corner Joints

Note: Further work is needed to provide definitive guidance; the recommendations given will be
updated in future revisions of this Recommended Practice.

E.7.1 Corner Joint (see Figure E.3)

E.7.1.1 Residual Stress Perpendicular to The Weld Direction

a. Residual Stress Distribution:

σ r ( x ) = σ ysr (E.34)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 20% of the distribution
provided in (a) above.

E.7.1.2 Residual Stress Parallel To The Weld Direction

a. Residual Stress Distribution:

σ r ( x ) = σ ysr (E.35)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 30% of the distribution
provided in (a) above.

E.7.2 Nozzle Fillet Weld (see Figure E.3) - the results from paragraph E.8.1 can be used for this
configuration.

E.7.3 Shell Fillet Weld With A Reinforcing Pad (see Figure E.3) ) - the results from paragraph E.8.1 can be
used for this configuration.

E-8
 DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

E.8 Full Penetration and Fillet Welds at a Tee Joint

Note: Further work is needed to provide definitive guidance; the recommendations given will be
updated in future revisions of this Recommended Practice.

E.8.1 Main Plate (see Figure E.4)

E.8.1.1 Residual Stress Transverse to The Weld Direction

a. Residual Stress Distribution - the residual stress acting transverse to the weld direction in the
plane of the fillet weld toe in the main plate is based on the welding parameters. The local
coordinate x is defined in Figure E.4.

for xo ≥ t or if qv cannot be established

σ r ( x ) = σ ysr (E.36)

for xo < t

  x 
σ r ( x ) = σ ysr 1 −    if x ≤ x o (E.37)
  xo  

σ r ( x ) = 0.0 if x > x o (E.38)

where

122qv
xo = (E.39)
σ rys Cus

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 20% of the distribution
provided in subparagraph (a) above.

E.8.1.2 Residual Stress Parallel To The Weld Direction

a. Residual Stress Distribution - the residual stress acting parallel to the weld direction is:

σ r ( x ) = σ ysr (E.40)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 30% of the distribution
provided in (a) above.

E.8.2 Stay Plate (see Figure E.4)

E.8.2.1 Residual Stress Transverse to the Weld

E-9
DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

a. Residual Stress Distribution - the residual stress acting transverse to the weld is:

σ r ( x ) = σ ysr (E.41)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 20% of the distribution
provided in (a) above.

E.8.2.2 Residual Stress Parallel To The Weld Direction

a. Residual Stress Distribution - the residual stress acting parallel to the weld direction is:

σ r ( x ) = σ ysr (E.42)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 30% of the distribution
provided in (a) above.

E.9 Repair Welds

E.9.1 Seam Welds

E.9.1.1 Residual Stress Perpendicular to The Weld Direction

a. Residual Stress Distribution - if the weld being assessed is a part-through wall repair weld, or is
considered to have been made under conditions of high restraint, then the residual stresses
acting both perpendicular and parallel to the weld is a membrane stress of yield level magnitude,
or

σ r ( x ) = σ ysr (E.43)

b. Effects of Hydrotest - the methodology used to reduce the secondary membrane stress (i.e.
residual stress) after overload testing is covered in Section 9.0.

c. Effects of PWHT - if the weld is known to have been subject to post weld heat treatment per the
original construction code, then the residual stress distribution is equal to 30% of the distribution
provided in (a) above.

E.9.1.2 Residual Stress Parallel To The Weld Direction - The magnitude and distribution of the residual stress
is assumed to be the same as that given in paragraph E.8.1.1.

E.9.2 Corner Welds - The magnitude and distribution of the residual stress is assumed to be the same as
that given in paragraph E.8.1.

E.9 References

E.9.1 BSI, “Guidance For Assessing The Acceptability Of Flaws In Fusion Welded Structures,” PD-6493:
1991, British Standards Institute, Aug. 1991.

E-10
 DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

E.9.2 Burdekin, F.M., “Local Stress Relief of Circumferential Butt Welds in Cylinders,” British Welding
Journal, September 1963, pp. 483-490.

E.9.3 Downey, J.C., Hood, D.W., and Keiser, D.D., “Shrinkage in Mechanized Welded 16 Inch Stainless
Pipe,” Welding Journal, March 1975, pp. 170-175.

E.9.4 Fujita, Y., Nomoto, T., and Hasegawa, H., “Deformations and Residual Stresses in Butt-Welded Pipes
and Spheres,” IIW Doc. X-963-80, April 1980.

E.9.5 Fujita, Y., Nomoto, T., and Hasegawa, H., “Welding Deformations and Residual Stresses Due to
Circumferential Welds at the Joint Between Cylindrical Drum and Hemispherical Head Plate,” IIW Doc.
X-985-81, July 1981.

E.9.6 Guan Q., and Liu, J.D., “Residual Stress and Distortion in Cylindrical Shells Caused by a Single-Pass
Circumferential Butt Weld - A Discussion with Appropriate Calculation Method,” IIW Document X92979.

E.9.7 Japan High Pressure Gas Institute as reported by T. Tanaka in "Local PWHT for Pressure Vessels" at
the Spring 1991 API Refining Meeting, Nashville, Tennessee.

E.9.8 Josefson, B.L., “Residual Stresses and Their Redistribution During Annealing of a Girth-Butt Welded
Thin-Walled Pipe,” Transactions of the ASME, Journal of Pressure Vessel Technology, August 1982,
pp. 245-250.

E.9.9 Kim, D.S., and Smith, J.D., “Residual Stress Measurements of Tension Leg Platform Tendon Welds,”
Offshore Mechanics and Arctic Engineering Conference, Houston, Texas, Vol. III, pp. 31-36, 1994.

E.9.9 Kirk, M.T., Mohr, W.R., and Michaleris, P., “Guidelines for Estimating the Residual Stresses Caused by
Butt Welding of Pipes and Other Cylindrical Geometries,” ASME, to appear.

E.9.10 Lazor, R.B., Leggatt, R.H., and Glover, A.G., “Experimental Stress Analysis of Pipeline Girth Welds,”
American Gas Association Catalog No. L51490, August 1985.

E.9.11 Leggatt, R.H., “Residual Stresses at Circumferential Welds in Pipes,” TWI Research Bulletin, June
1982, pp. 181-188.

E.9.12 Leggatt, R.H., “Residual Stresses at Girth Welds in Pipes,” Welding in Energy-Related Projects,
Welding Institute of Canada, Pergamon Press, 1984.

E.9.13 Makhnenko, V.I., Shekera, V.M., and L. A. Izbenko, L.A., “Special Features of the Distribution of
Stresses and Strains Caused by Making Circumferential Welds in Cylindrical Shells,” Automatic
Welding, 1970, No., 12, pp. 43-47.

E.9.14 McGaughy, T.H., “Effects of Repair Welding on the Residual Stress Distribution and Fracture
Toughness in Pipeline Girth Welds", Pipeline Research Committee final report PR-185-9104, August
1992.

E.9.15 McGaughy, T.H., and Boyles, L., “Significance of Changes in Residual Stresses and Mechanical
Properties Due to SMAW Repair of Girth Welds in Linepipe,” Pipeline Research Committee final report
PR-185-905, October 1990.

E.9.16 Michaleris, P., “Incorporation of Residual Stresses into Fracture Assessment Models,” EWI Report
7412, 1996.

E.9.17 Michaleris, P., Kirk, M., and Laverty, K. “Incorporation of Residual Stresses into Fracture Assessment
Models,” MPC FS-30, Materials Properties Council, August 1996.

E-11
DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

E.9.18 Mohr, W., “Internal Surface Residual Stresses in Girth butt-Welded Steel Pipes,” Proceeding of ASME
Pressure Vessel and Pipe Conference, PVP-Vol. 327, Residual Stresses in Design, Fabrication,
Assessment and Repair, 1996.

E.9.19 Roelens, J.B., “Numerical Simulation of Some Multipass Submerged Arc Welding Determ ination of the
Residual Stresses and Comparison with Experimental Measurements,” IIW Document XIII-1549-94.

E.9.20 Rybicki, E.F., Groom, J.J., Lemcoe, M.M., Mischler, H.W., Rodebaugh, E.C., Schmuster, D.W.,
Stonesifer, R.B., and Strenkowski, J.S., “Residual Stresses at Girth-Butt Welds in Pipes and Pressure
Vessels,” NUREG Report 0376, November 1977.

E.9.21 Scaramangas, A., “Residual Stresses in Girth Butt Welded Pipes,” Ph.D. dissertation, Cambridge
University, May 1984.

E.9.22 Ueda, Y., Fukuda, K., Nishimura, I., Iiyama, H., Chiba, N., and Fukuda, M., “Three Dimensional Cold
2
Bending and Welding Residual Stresses in Penstock of 80 kgf/mm Class High Strength Steel Plate,”
Transactions of the JWRI, Vol. 12, No. 2, 1983 pp. 117-126.

E.9.23 Umemoto, T., and Furuya, S., “A Simplified Approach to Assess Weld Residual Stress Distribution
Through Pipe Wall,” Nuclear Engineering and Design, Vol. 111, 1989, pp. 159171.

E.9.24 Umemoto, T., and Tanaka, S., “A Simplified Approach to Calculate Weld Residual Stresses in a Pipe,”
Ishikawajima-Harima Heavy Industries Engineering Review, Vol. 17, No. 3, 1984.

E-12
 DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

Figure E.1
Weld Locations and Stress Directions In A Cylindrical Shell

Longitudinal
or Seam Weld
Longitudinal
or Seam Weld

Circumferential
(or Girth) Weld

(a) Identification of Welds

Longitudinal
Stress

Circumferential or
Hoop Stress

(b) Identification of Stresses

Definition Of Stress Directions

Weld Seam Stress Component Perpendicular To Stress Component Parallel To The

The Weld Seam Weld Seam

Longitudinal Circumferential (Hoop) Stress Longitudinal Stress

Circumferential (Girth) Longitudinal Stress Circumferential (Hoop) Stress

E-13
DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

Figure E.2
Weld Locations and Stress Directions In A Spherical Shell or Formed Head

Meridional Weld

Circumferential
Weld

(a) Identification of Welds

Circumferential
Stress
Meridianal
Stress

(b) Identification of Stresses

Definition of Stress Directions

Weld Seam Stress Component Perpendicular To Stress Component Parallel To The

The Weld Seam Weld Seam

Meridional Circumferential Stress Meridional Stress

Circumferential Meridional Stress Circumferential Stress

E-14
 DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

Figure E.3
Weld Locations and Stress Directions In A Corner Joint (Nozzle Attachment)

C
L C
L

Nozzle Nozzle

Nozzle Fillet Weld

Reinforcing Pad
Nozzle Fillet Weld
x Reinforcing Pad
x Shell Fillet Weld
Vessel Shell

x x x x

Corner Joint

(a) Identification of Welds

Nozzle

1
Reinforcing Pad

2 Vessel Shell

1 - Stress Perpendicular to the

2 Weld Direction

2 - Stress Parallel to the

Weld Direction

(b) Identification of Stresses

E-15
DRAFT - Appendix E: Residual Stresses For A FFS Assessment Of Crack-Like Flaws

Figure E.4
Weld Locations and Stress Directions In A Tee Joint

Stay Plate

Plane Containing
the Toe of the
Fillet Weld in the
Stay Plate
1
2

1
x

Plane Containing
Main Plate
the Fillet Weld
Toe in the Main Plate

1 - Stress Perpendicular to the

Weld Direction

2 - Stress Parallel to the

Weld Direction

E-16