4 asme pastor code analysis

7/28/2019 4 ASME Pastor Code Analysis

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ASME BPVC and Process

Piping Code Application andAnalysis

HDICE In Beam Cryostat Project

Orlando Pastor, Jr.Structural Engineer

March 30, 2011


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ASME BPVC

! Department of Energy contractors must ensure pressurevessels meet the requirements of the ASME BPVC

! Section 6151 of JLAB Environmental Safety and Health(ES&H) manual governs pressure vessels

! Pressure Vessels ASME Section 8 Div 1 (SVIII Div 1)! Vessels within the scope of SVIII Div 1 Include! Vessels with an internal or external operating pressure

exceeding 15 psi

! Vessels with an inside diameter, width, height, or crosssection diagonal greater than 6 inches

! Piping Process Piping Code ASME B31.3

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HDICE IBC System Pressure Map

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HDICE IBC System Thermal Map

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HDice In Beam Cryostat (IBC) FEA

! Component Selection for FEA! Outer Vacuum Can (OVC) Assembly! Liquid Helium Can Assembly! Mixing Chamber! Miscellaneous Piping! Still Body! 1K Pot

! Primary Loads! Gravity! External/Internal Pressures! Thrust Reaction Loads! Temperature Changes

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HDice IBC LHe Can Analysis

! Initial Conditions! Initial Temperature: 293K! Internal Pressure: 0 psid

! Loading! Operating Temperature: Varying! Internal Pressure: 30 psid

! Properties! Temperature Dependent CTE! Temperature Dependent Modulus

of Elasticity

! Detailed analysis of nose weld area

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Miscellaneous Piping Analysis

! Piping was analyzed inaccordance with ASME B31.3

! Minimum wall thickness wasdetermined using hand

calculations

! Effects of temperature andpressure were determined by FEA

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ASME Code Compliance Issues

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ASME Code Compliance Issues (continued)

10

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Electron Beam Welding of Mixing Chamber

!

Test Sample to Simulate PressureLoading

! FEA performed to compare stressesdue to pressure loading and tensile

loading

! Component stresses were similar inmagnitude and distribution

! Pull test performed by Applied TestingServices (ATS)

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Fillet Weld at Corner Joint in LHe Can

! Construction of LHe can did notallow interior weld at the root, this is

the final weld in the assembly

! A joint of this type is not permittedby the Code without reinforcement

! Weld geometry was included inFEM, stresses in the weld are low

! Extensive experience with this typeof joint in similar temperature and

loading environments at JLAB

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Stainless Steel to Aluminum Transitions

!

Provided by Meyer Tool! ASME Certifications for material

strength included

! No certification as to jointacceptance per ASME BPVC

! Stresses are driven by the differentcoefficient s of thermal expansion,

not pressure! A cold test was performed at 77K to

assess the joint fusion.

! Dye penetrant (PT) test wasperformed prior to cooling and after

pieces were allowed to warm to room

temperature Max Shear: 6.4 ksi

Avg Shear: 3.2 ksi

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Alloy C10100 Tensile Testing

! Tensile Testing Alloy C10100! Test material brazed or brazed and sintered! Material from brazed joint test & mixing chamber (MXC) lots! Spare MXC material (Lot# VA198774) lost strength

! Yield strength impact most severe! Ultimate strength impact ~ 10% below expected 30 ksi

! Impact to still body/1K pot material unknown! No material testing after thermal processing! FEA shows stress levels in parts very low! Worst case outcome localized yielding in stress

concentrations

! Considered acceptable risk to proceed

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Mixing Chamber Pressure Testing

!

IBC MXC not tested IAW ASME BPVC! Risk to sintered material internal to MXC

too great if pressurized to 165 psi

! IBC MXC will be included in pressure testwith liquid helium piping (33 psia vs. 165

psia)

! Duplicate MXC unit tested IAW ASME BPVC! Upstream End Both from same lot! Stainless Steel Tubes Both from

same lot

! Downstream base from differentlots

! Both Units EB welded in the same setup! Same brazing profile followed forstainless tubes

! Material strengths were verified with tensiletests from duplicate MXC after pressure test

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Joint Tracking

J 1100 - 03

Drawing Number

Incremental Joint NumberJoint

! Created joint numbers for weldinspectors to track joint! Welder! Procedure! Inspection Required

! Officially documented joint number

!All joints are assigned numbers

! ASME BPVC! B31.3 Piping! Structural! Vacuum! Non-structural

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Pressure Test Liquid Helium Piping

! IBC will be pressure tested in accordancewith ASME BPVC and B31.3 requirements! PHY-11-004-TOSP prepared for pressure

testing liquid helium piping circuits

! Test schedule TBD but before IBC isloaded into Hall B

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Analysis Reports

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Conclusion

! Stresses in HDice IBC are below the allowable stressesas specified by the ASME BPVC

! Areas not in compliance have been tested and/oranalyzed to verify factors of safety in accordance withthe ASME BPVC

! Design of the HDice IBC is in accordance with the ASMEBPVC

! Analysis and testing documented and provided to JLAB! IBC will be pressure tested in accordance with ASME

BPVC and B31.3

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BACK-UP SLIDES

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DOE Pressure Systems Requirements

! Pressure Systems at Thomas Jefferson National Accelerator Facility (JLAB)! Title 10 of the Code of Federal Regulations, Part 851 (10 CFR 851)

requires Department of Energy (DOE) sites to establish Worker Safetyand Health Program (WSHP)

! 10 CFR 851 requires DOE contractors to ensure pressure systemsconform to applicable section of the American Society of MechanicalEngineers (ASME) Code Pressure Systems

! Section 6151 of the JLAB Environmental Safety and Health Manual (ES&H)Governs Pressure Systems at JLAB

! Section 6151 Pressure System Design Requirements! Pressure Vessels - ASME Boiler and Pressure Vessel (BPVC) Section

VIII! Piping Design ASME Pressure Piping Code B31.3 Process Piping

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ASME Code Section Selection

! Pressure Vessel Code! ASME BPVC SVIII Div 1! ASME BPVC SVIII Div 2

! Part 4 - Design by Rule Requirements! ASME BPVC SVIII Div 1 - Selected for Simplicity

! Basic Fundamental Calculations! Lower Allowable Stress Limit on Ultimate Strength! SVIII Div 2 Part 4 - Requires 0.0625 min thickness for ferrous

alloys

!

Piping Design Code! ASME Pressure Piping Code B31.3 Process Piping

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ASME BPVC SVIII Div 1 Scope (continued)

! Vacuum Systems Are Outside the Scope of ASMEBPVC SVIII Div 1

! ASME BPVC SVIII Div 1 Paragraph U-1(c)(1) recognizesauthority of government entities to invoke the ASME

Code

! 10 CFR 851 Appendix A.4(c) Vacuum systems areoutside of the national consensus codes

! Design documentation is peer reviewed! Fabrication accomplished by qualified technicians! Documentation maintained for each unique vessel

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ASME SVIII Div 1 Material Toughness

! Material Toughness!Aluminum

! Wrought Aluminum approved by ASME SVIII Div 1Paragraph UNF-65 for temperatures down to

-452F (4.26k)! Not possible to conduct impact tests at the

minimum design metal temp(MDMT) (1K)

! No known physics to alter behavior of aluminum! Considered acceptable if room temperaturetoughness is validated

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! Copper!Approved by ASME SVIII Div 1 Paragraph UNF-65

for temperatures down to -325F (74.8k)

! Conflicts with ASME B31.3 which allowstemperatures down to -452F (4.26K) (See Table323.2.2 and Table A-1)

! No known physics to alter behavior of copper! Considered acceptable if room temperature

toughness is validated

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! Stainless Steel! UHA-51(g) Exemption From Impact Testing

Because of Low Stress

! Stainless steel stress threshold is 0.35*SE

!S is the primary stress in the part (Hoop, direct tension,etc.)

! E is weld joint efficiency where applicable! Stress levels of stainless steel HDice Cryostat

components kept below the threshold

! Welding filler metal for joints at cryogenic temp! Stainless steel alloy 316 (low ferrite)! Qualified by JLAB to meet ASME toughness

requirements

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ASME BPVC Fatigue Screening

!

Fatigue Screen Method A ASME BPVC Section VIII Division 2 (SVIII Div 2)! Material Ultimate Tensile Strength ! 80 ksi

! Estimate Pressure & Temperature Cycles! Full Range Pressure Cycles (N

!FP)

! Operating Pressure Cycles > 20% of Maximum Allowable WorkingPressure (MAWP) for Integral Construction (N

!PO)

! Operating Temperature Changes (N!TE)! Temperature cycles between material of different CTE (N

!T")

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Alloy C10100 Tensile Testing

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HDice IBC Still Assembly Analysis


! Loading! Operating Temperature: 0.7K! Internal Pressure: 30 psid


of Elasticity

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HDice IBC 1K Pot Analysis

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! Loading! Operating Temperature: 0.7K! Internal Pressure: 30 psid


of Elasticity


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Still Body/1K Pot Covers Brazed Joints Tensile/

Bend Tests

! Testing was performed to verify thejoint strength requirements for the Still

and 1K Pot cover brazed joints

! Samples were fabricated IAW ASMEBPVC Section IX

! Tensile and bend tests were performedby ATS

! Specimens met the strengthrequirements

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Stainless Steel to Copper Brazes

!

Testing was performed to verify thejoint strength requirements for thestainless steel to copper furnacebrazed joints

! Samples were fabricated IAW ASMEBPVC Section IX

! Tensile and section tests wereperformed by ATS

! Failure in the stainless tube vs. brazedjoint required for acceptance

! Two sets of test! 0.020 thick wall tube! 0.006 thick wall tube

! ASME BPVC allows for testing ofdissimilar metals which qualifies

brazing of similar metal! Specimens met the strength

requirements

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HDICE IBC System Overpressure Cases

Pump Line Overpressure

Outer Vacuum Can Overpressure

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