An industry-government collaborative program was carried out with an aim to promoting the acceptance of fracture mechanics-based fitness-for-service assessment methodology for a service-damaged pressure vessel. A collaborative round robin exercise was carried out to predict the fracture behavior of a vessel containing hydrogen damage, fabrication-related lack-of-fusion defects, an artificially induced fatigue crack, and a localized thinned area. The fracture assessment procedures used include the U.S. ASME Material Property Council’s PREFIS Program based on the British Standard (BS) Published Document (PD) 6493, ASME Section XI and The Central Electricity Generating Board (CEGB) R6 approach, The Welding Institute (TWI) CRACKWISE program (based on BS PD6493 Level 2 approach), a variant of the R6 approach, J-tearing instability approaches, various J-estimation schemes, LEFM approach, and simplified stress analysis. Assessments were compared with the results obtained from a hydrogen-charged burst test of the vessel. Predictions, based on the J-tearing approach, compared well with the actual burst test results. Actual burst pressure was about five times the operating pressure.

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