Computational Fracture Mechanics: Evaluation of the Structural Integrity in a Penstock Applying the BS7910 Standard and Finite Element Analysis

Abstract

The present work aims to determine the structural integrity of penstocks, applying the BS7910 standard and finite element analysis (FEA). For the study of fracture mechanics in thin-walled cylinders that have defects inside, the structural integrity of the element is determined through a failure assessment diagram (FAD) where the fracture failure index (Kr) is graphed versus plastic collapse index (Lr). Based on the locus of the initial point of failure, the safety factor is calculated, and it is defined if the element is fit for service or if corrective action must be taken to continue operating; later, crack growth is analyzed, where the critical point of rupture of the penstock and therefore its useful life is determined. To contrast results, a simulation of fracture mechanics is performed in ANSYS, where the stress intensity factor (KI) is determined using the fracture tool, and the useful life of the element is also calculated through a fatigue analysis. The use of tetrahedral elements is recommended for the overall meshing and a cobweb configuration for meshing at crack-tip. Finally, the results obtained are compared, where the mean average percentage error of 3.24% was obtained, denoting the usefulness of the two methods as well as the simplicity of the Paris' law.