Certification, Testing, Approval and R&D work on the Absorber Safety

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Silvester Webster
6 years ago
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1 , Testing, Approval and R&D work on the Absorber Safety A discussion document prepared for the Safety Review rehearsal talk on Monday the 17 th of November 2003

2 1 and its scope needed? Design Material certification Design drawings, design calculations and FEA calculations demonstrating the design meets the relevant Pressure Vessel Code requirements; On parent materials used for the component fabrication; On welding materials; On sealing material; On any bought-in pipe; On any Stainless to Aluminium transition joint Remarks / Issues: QA certificate on software tools also needed To ensure that standards & specified in ASME VIII or BS5500 have been followed View graphs available during review meeting Instrument certification Certificate must show material meeting the required mechanical properties; Consistency and reliability of material at working temperature range; Material identification; Compatibility with hydrogen On monitoring instrument showing valid calibrations; On burst disc and relief valves Compatibility with hydrogen Stamp / Cert Coupons to be kept for the life of the component Stamp or Cert. from manufacturer

3 Facility certification Other Certifying body Hydrogen storage unit Hydrogen safety system including the buffer tank and its instruments Hydrogen connect pipes Meeting QA requirements; Meeting Cleanliness requirements Meeting contamination acceptance level Design Fabrication Operation Stamp / Cert Stamp / Cert from supplier, manufacture & cryogenic standards for pipes Depends on what QA and cleanliness standard needed External review to okay fabrication. RAL safety to approve operation.

4 2 Testing, Inspection & Approval Is test already done 2a Testing Test Description on test pressure specified by pressure Burst tests Production tests Acceptance test Fermilab safety group Showing the test set up on torispherical window design; Test including Photogrammetry technique; comparison of results with FEA simulation Remarks / Issue Is this acceptable to RAL? Evolution of the window shape and geometry; Validation of new design by FEA Burst test of new windows 4 tests will be performed on each window geometry (if Welding control parameters on Al / Al welds SS / SS welds Pipe welds Hydro-test of warm vessel Pressure test of absorber unit with window attached Pressure test of safety windows & large end flange Pressure test of pipe joints Leak test at all the seal joints different) Any mitre joint on pipes should be tested for welding quality This is the test required to prove the equipment before and after fitted into the magnet bore prior to operation commencement. View graphs available during review meeting Pictures showing NIU s test set up; the test results; the Photogrammetry setup, its principles and result interpretation; FEA results and comparison Picture on window shape evolution; FEA simulation results

5 2b 2c Inspection Approval Test Operation Factory inspection Final inspection Approval of suppliers Design & Pressure Parts Hydrogen system To define the extend and level of tests Pressure test level & Vacuum test level & Leak test rate & Including test required when liquid absorber is changed to solid absorber, and back etc. Hydrogen venting U/S on warm vessel seam welds Visual inspection on all welded joints Dimensional survey on finished products Dimensional tolerance check QA system and of supplier s works Design drawing and design calculations On welding ; On welder qualification On Inspection ; Inspection points (on production plan); All the test described above Hydrogen operating (filling & venting) Hydrogen Safety & evacuation procedure Completion of HAZOP for absorber and hydrogen system We shall seek approval of these documents prior to the start of production This will be done by an External review body

6 3 R & D Is this ready? 3a R&D Bolted Performance of Seal at room & LN2 Partly done work on Window & temperature (repeated cycles) the its integrity Performance of seal at working Preferred condition using GHe for leak test on option window flange Performance of seal at thermal shock condition on latest window flange size using GHe for leak test Remarks / Issues Prototype testing on a 21cm absorber has gone through some of the test and shown positive results. Prototype test on the actual window dimension will be carried out in 2004 View graphs available during review meeting As per Shigeru s presentation at the MICE meeting I will go through the slides in Shigeru s MICE talk at the Review meeting 3b R&D work on the back up option Welded window & its integrity Welding control set-up and nib weld geometry and integrity using T6061/T6061 weld; Prototyping on window nib weld with bayonet Prototyping on window nib weld without bayonet and with a re-machined nib All subject to the same test conditions as those applied to the bolted window Partly done Prototyping and test will be done in parallel with the R&D work on the bolted window As per WWL s presentation at the MICE meeting. Also including the trial test pieces shown at the RAL MICE meeting Note: To be done

QUALITY ASSURANCE PROTOCOL (QAP)

QUALITY ASSURANCE PROTOCOL (QAP) PREFACE This Standard details the level of documentation that PVT.LTD (IET) will provide during a contract for fabricating tank(s) or portable equipment s. Extensive documentation is required for this