ASME code analysis (O. Pastor)

ASME BPVC and Process

Piping Code Application and

Analysis

HDICE In Beam Cryostat Project

Orlando Pastor, Jr.

Structural Engineer

March 30, 2011

Introduction

•! Review current IBC design for compliance with ASME

BPVC and B31.3

•! Analyze components to determine stresses to compare

with requirements of BPVC

•! Identify areas not in compliance with BPVC

•! Determine plans for showing problem areas meet intent

of the BPVC

•! Document analysis and tests verifying compliance with

the BPVC

2

ASME BPVC

•! Department of Energy contractors must ensure pressure

vessels 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 cross

section diagonal greater than 6 inches

•! Piping – Process Piping Code – ASME B31.3

3

HDICE IBC System Pressure Map

4

HDICE IBC System Thermal Map

5

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

6

HDice IBC LHe Can Analysis

•! Initial Conditions

–! Initial Temperature: 293K

–! Internal Pressure: 0 psid

•! Loading

–! Operating Temperature: Varying


•! Properties

–! Temperature Dependent CTE

–! Temperature Dependent Modulus

of Elasticity

•! Detailed analysis of nose weld area

7

Miscellaneous Piping Analysis

•! Piping was analyzed in

accordance with ASME B31.3

•! Minimum wall thickness was

determined using hand

calculations

•! Effects of temperature and

pressure were determined by FEA

8

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 Pressure

Loading

•! FEA performed to compare stresses

due to pressure loading and tensile

loading

•! Component stresses were similar in

magnitude and distribution

•! Pull test performed by Applied Testing

Services (ATS)

11

Fillet Weld at Corner Joint in LHe Can

•! Construction of LHe can did not

allow interior weld at the root, this is

the final weld in the assembly

•! A joint of this type is not permitted

by the Code without reinforcement

•! Weld geometry was included in

FEM, stresses in the weld are low

•! Extensive experience with this type

of joint in similar temperature and

loading environments at JLAB

12

Stainless Steel to Aluminum Transitions

•! Provided by Meyer Tool

•! ASME Certifications for material

strength included

•! No certification as to joint

acceptance per ASME BPVC

•! Stresses are driven by the different

coefficient s of thermal expansion,

not pressure

•! A “cold” test was performed at 77K to

assess the joint fusion.

•! Dye penetrant (PT) test was

performed prior to cooling and after

pieces were allowed to warm to room

temperature Max Shear: 6.4 ksi

Avg Shear: 3.2 ksi

13

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

14

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 test

with 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 different

lots

–! Both Units EB welded in the same setup

–! Same brazing profile followed for

stainless tubes

•! Material strengths were verified with tensile

tests from duplicate MXC after pressure test

15

Joint Tracking

J – 1100 - 03

Drawing Number

Incremental Joint Number “Joint”

•! Created joint numbers for weld

inspectors 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

16

Pressure Test Liquid Helium Piping

•! IBC will be pressure tested in accordance

with ASME BPVC and B31.3 requirements

•! PHY-11-004-TOSP prepared for pressure

testing liquid helium piping circuits

•! Test schedule TBD but before IBC is

loaded into Hall B

17

Analysis Reports

18

Conclusion

•! Stresses in HDice IBC are below the allowable stresses

as specified by the ASME BPVC

•! Areas not in compliance have been tested and/or

analyzed to verify factors of safety in accordance with

the ASME BPVC

•! Design of the HDice IBC is in accordance with the ASME

BPVC

•! Analysis and testing documented and provided to JLAB

•! IBC will be pressure tested in accordance with ASME

BPVC and B31.3

19

BACK-UP SLIDES

20

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 Safety and Health Program (WSHP)

–! 10 CFR 851 requires DOE contractors to ensure pressure systems

conform to applicable section of the American Society of Mechanical Engineers (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

21

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

22

ASME BPVC SVIII Div 1 Scope (continued)

•! Vacuum Systems Are Outside the Scope of ASME

BPVC SVIII Div 1

•! ASME BPVC SVIII Div 1 Paragraph U-1(c)(1) recognizes

authority of government entities to invoke the ASME

Code

•! 10 CFR 851 – Appendix A.4(c) – Vacuum systems are

outside of the national consensus codes

–! Design documentation is peer reviewed

–! Fabrication accomplished by qualified technicians

–! Documentation maintained for each unique vessel

23

ASME SVIII Div 1 Material Toughness

•! Material Toughness

–!Aluminum

•! Wrought Aluminum approved by ASME SVIII Div 1

Paragraph 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 temperature

toughness is validated

24


–!Copper

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

for temperatures down to -325F (74.8k)

•! Conflicts with ASME B31.3 which allows

temperatures down to -452F (4.26K) (See Table 323.2.2 and Table A-1)

•! No known physics to alter behavior of copper

•! Considered acceptable if room temperature

toughness is validated

25


–!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

26

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 Working

Pressure (MAWP) for Integral Construction (N!PO)

–! Operating Temperature Changes (N!TE)

–! Temperature cycles between material of different CTE (N!T")

27

Alloy C10100 Tensile Testing

28

HDice IBC Still Assembly Analysis




•! Loading

–! Operating Temperature: 0.7K


•! Properties



of Elasticity

29

HDice IBC 1K Pot Analysis

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•! Loading

–! Operating Temperature: 0.7K


•! Properties



of Elasticity

Still Body/1K Pot Covers Brazed Joints Tensile/

Bend Tests

•! Testing was performed to verify the

joint strength requirements for the Still

and 1K Pot cover brazed joints

•! Samples were fabricated IAW ASME

BPVC Section IX

•! Tensile and bend tests were performed

by ATS

•! Specimens met the strength

requirements

31

Stainless Steel to Copper Brazes

•! Testing was performed to verify the joint strength requirements for the stainless steel to copper furnace brazed joints

•! Samples were fabricated IAW ASME BPVC Section IX

•! Tensile and section tests were performed by ATS

•! Failure in the stainless tube vs. brazed joint required for acceptance

•! Two sets of test

•! 0.020” thick wall tube

•! 0.006” thick wall tube

•! ASME BPVC allows for testing of dissimilar metals which qualifies brazing of similar metal

•! Specimens met the strength requirements

32

HDICE IBC System Overpressure Cases

Pump Line Overpressure

Outer Vacuum Can Overpressure

33

ASME code analysis (O. Pastor)

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