ASME BPVC.CC.BPV.S Approval Date: October 7, 2015

Transcription

1 CASE Approval Date: October 7, 2015 Code Cases will remain available for use until annulled by the applicable Standards Committee. Case Manufacture of a Hoop-Wrapped, Wire-Reinforced Cylindrical Pressure Vessel Section VIII, Division 3 Inquiry: Under what conditions may a hoop-wrapped, wire-reinforced cylindrical pressure vessel whose cylindrical shell carries the pressure end load be produced using the rules of Section VIII, Division 3? Reply: It is the opinion of the Committee that a hoopwrapped, wire-reinforced cylindrical pressure vessel whose shell carries the end load may be produced using the rules of Section VIII, Division 3, provided the following additional requirements are met: (a) The vessel shall be comprised of a monobloc cylindrical seamless shell with integrally forged heads. (b) The shell shall meet the Charpy V-notch impact requirements of Table KM-234.2(a). (c) The vessel heads shall not be wrapped. (d) The vessel shall be wound in the hoop direction with a helix angle of the winding less than 1 deg. (e) The maximum gap between the wires in the longitudinal direction of the vessel shall be the lesser of 5% of the wire width or in. (0.25 mm). (f) The cylindrical shell shall carry the end load due to pressure. (g) The design temperature shall not exceed 200 F (93 C). (h) No welding is permitted on the vessel, including the shell with integrally formed heads, or the wire. The wire winding shall be a single continuous length of wire. (i) Thedesignpressureoftheshellwiththewire wraps shall be demonstrated using finite element analysis in accordance with the rules of KD-230 or Mandatory Appendix 9. (j) Under design conditions, the average stress intensity over the cross section of each individual wire at any point in the winding shall not exceed the yield strength of the wire, S y. Under all operational loading conditions, including hydrostatic loading, each individual wire at any point in the winding shall not exceed the yield strength of the wire, S y. (k) The calculated collapse pressure of the shell alone shall be equal to or greater than 120% of the design pressure of the vessel. The calculation shall be performed using the minimum specified values of yield and tensile strengths. If an elastic-plastic analysis is used, strain hardening may be considered. (l) The design fatigue life of the winding shall be calculated in accordance with KD-933. A design fatigue curve derived in accordance with KD-932 shall be used. For environmental conditions not covered by the derived design fatigue curve, the Manufacturer shall obtain supplementary fatigue test data. (m) For all components other than the winding, the number of design cycles shall be determined in accordance with KD-140. (n) For every combination of essential variables used in production of the vessel, a unique Wire Winding Procedure Specification shall be prepared. The essential variables shall include the following: (1) wire specification, grade, and size (2) volumetric expansion of the prototype vessel (3) vessel dimensions (4) description of the winding machine (5) how tension is applied, controlled, and measured during winding. The application of the winding onto the cylinder shall be carried out in a special winding machine equipped with devices that are able to control and measure the tensile force used for applying the wire. This force shall also be recorded on a diagram that shall be filed by the Manufacturer for each vessel. The measuring devices shall be calibrated at least every six months or any time there is reason to believe that the measurements are erroneous. The wire end shall be properly locked to prevent unwrapping. (o) Wire Winding Procedure Specification Qualification. It shall be the Manufacturer s responsibility to qualify thewirewindingprocedurespecificationaccordingto the requirements of this Case and document the results. Requalification shall follow the same procedure as the original qualification. Refer to Form WWPV-1. (1) Vessels used to qualify the Wire Winding Procedure Specification shall be designated as prototype vessels. Prototype vessels used to qualify or requalify a The Committee s function is to establish rules of safety, relating only to pressure integrity, governing the construction of boilers, pressure vessels, transport tanks and nuclear components, and inservice inspection for pressure integrity of nuclear components and transport tanks, and to interpret these rules when questions arise regarding their intent. This Code does not address other safety issues relating to the construction of boilers, pressure vessels, transport tanks and nuclear components, and the inservice inspection of nuclear components and transport tanks. The user of the Code should refer to other pertinent codes, standards, laws, regulations or other relevant documents. 1 () BPV SUPP. 4

2 CASE (continued) ASME BPVC.CC.BPV.S Wire Winding Procedure Specification shall meet all of the requirements of Division 3 but shall not be Code stamped. (2) Each vessel used for qualifying or requalifying the Wire Winding Procedure Specification shall be fabricated and examined in accordance with the requirements that follow, and the results documented on a Manufacturer s Data Report with the notation Prototype Qualification. (p) Volumetric Expansion Tests. Each vessel produced, including the prototype vessel, shall be subjected to a volumetric expansion test using a test fluid that complies with the requirements of KT-320. (1) The volume of liquid used to fill the vessel at atmospheric pressure and temperature shall be compared with that required to fill it at the design pressure and at the same temperature. Care shall be taken to eliminate air pockets to ensure accuracy. The volume of liquid used in each instance shall be determined by any appropriate means, such as a weigh tank that has been calibrated to an accuracy of ±0.2%. The results of this test shall be subsequently used in the production volumetric expansion test. (2) Alternatively, the volumetric expansion may be determined by measuring the overall length of the vessel and its circumference at 5 ft (1.5 m) intervals along its length, with a minimum of three such determinations being made. All measurements shall be made with instruments that have been calibrated to an accuracy of ±0.05%. These measurements shall be taken with the vessel filled with liquid at atmospheric pressure and at design pressure, both at the same temperature. The measurements thus made shall be subsequently used in the production volumetric expansion test. (3) Acceptance criteria shall be in accordance with (q)(2) of this Case. (q) Production Testing. Each vessel produced shall be subject to the tests required by (1) and (2) and shall conform to the specified requirements with results recorded on the Production Test Reports. (1) Hydrostatic Test. For vessels to be installed at a fixed location, a hydrostatic test to a pressure at least 1.25 times the design pressure shall be performed on each vessel. For vessels to be used in transport service, a hydrostatic test to a pressure at least 1.25 times the design pressure or 1.5 times the service or working pressure, whichever is greater, shall be performed on each vessel; see KT-310. This test may be combined with any hydrostatic pressurization procedure used to provide a prestress in the individual layers. The hydrostatic test shall be staged with examinations in (r) of this Case before the production volumetric expansion test. The vessel Production Test Report shall become part of the Manufacturer s Construction Records. (2) Volumetric Expansion Test. A volumetric expansion test shall be performed on every vessel in accordance with the requirements of the Wire Winding Procedure Specification Qualification; see (o) and (p) of this Case. The results of these tests shall not differ by more than 5% from the values recorded in the original Prototype Qualification Test Report and Wire Winding Procedure Specification after correcting for any variance in material properties. (r) Examinations. Each vessel shall be subjected to the examinations required by (1) and (2) and shall conform to the specified requirements, with results recorded in Production Test Reports. Examinations detailed in (1) and (2) shall be carried out before the hydrostatic test and the examination in Article KT-5 shall be carried out after the hydrostatic test. The Vessel Production Test Report shall become part of the Manufacturer s Construction Records. (1) Design Dimensions Examination. Each vessel shall be examined for conformance with dimensions and tolerances shown on the design drawings. (2) Metallic Surface Examination After Hydrostatic Test. The requirements of KE-400 cannot be applied to these vessels as examination of internal surfaces and external surfaces under the winding are not practical after hydrostatic test. The external surface of the vessel shall be inspected before winding of the vessel. The internal surfaces shall be inspected prior to forming of the heads on the end of the vessel. It shall be demonstrated by a fracture mechanics approach that the minimum detectable flaw size will not grow during the hydrostatic test to a size not accounted for in the analysis. (s) Manufacturer s Data Report Form WWPV-2 shall be completed for vessels produced under this Case. Refer to Table 1 for instructions. BPV SUPP. 4 2 ()

3 CASE (continued) FORM WWPV-1 RECOMMENDED FORM FOR QUALIFYING THE WIRE WINDING DESIGN AND THE WIRE WINDING PROCEDURE SPECIFICATION USED IN MANUFACTURING WIRE WOUND REINFORCED PRESSURE VESSELS As required by the Provisions of the ASME Boiler and Pressure Vessel Code, Section VIII, Division 3, Case Qualification Test Report No. Wire Winding Procedure No. A change in any of the essential variables denoted by an asterisk below requires a new Wire Winding Procedure Specification. *Wire Spec / Grade / Size *Variables of Winding Process Helix Angle (measured on cylinder between axis and band path) Tension: Per strand (End), Roving, or Band (specify which) per Method of Control Program *Inner Shell [Material, Grade, and Thickness, See Note (1)] *Shell Size and Configuration [OD, Length, Head Configuration (spherical, elliptical, etc.)] *Volumetric Expansion Qualification Vessel Designation Number Design Report Number Original Qualification Report Number If Requalification, Requalification Report Number ASME BOILER AND PRESSURE VESSEL CODE, Section VIII, Division 3 (Year, Case No.) We certify that the statements in this Specification are correct: Date Signed By Certificate of Authorization Number NOTE: (1) Where range of values or a tolerance applies, state the applicable range or tolerance. CERTIFICATION BY SHOP INSPECTOR OF QUALIFICATION OF WIRE WINDING DESIGN AND WIRE WINDING PROCEDURE SPECIFICATION Wire Winding Procedure Specification of at for process of manufacturing vessel(s) described in User s Design Specification Number Manufacturer s Design Report Number and I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and employed by of have inspected the pressure vessel and witnessed tests described in the Qualification Test Report of the Wire Winding Design and Wire Winding Procedure Specification and state that, to the best of my knowledge and belief, the Manufacturer has constructed this part in accordance with the ASME BOILER AND PRESSURE VESSEL CODE, Section VIII, Division 3, and the Wire Winding Design and Wire Winding Procedure Specification being qualified. By signing this certificate, neither the inspector nor his employer make any warranty, expressed or implied, concerning the design or procedure covered by this Qualification Test Report. Furthermore, neither the Inspector nor his employer shall be liable in any manner for any personal injury or property damage or loss of any kind arising from or connected with this inspection. Date Signed (Authorized Inspector) Commissions [National Board (incl. endorsements)] 3 () BPV SUPP. 4

4 CASE (continued) ASME BPVC.CC.BPV.S FORM WWPV-2 MANUFACTURER S DATA REPORT FOR WIRE WOUND PRESSURE VESSELS As Required by the Provisions of the ASME Boiler and Pressure Vessel Code, Section VIII, Division 3, Case 1. Manufactured and certified by 2. Manufactured for F 1 (name and address of Manufacturer) F 2 (name and address of purchaser) 3. Operating location F 3 (where installed and where transported) 4. Type Drawing no. F 4 (horizontal/vertical) F 8 F 5 (Manufacturer s serial no.) F 6 F 7 (CRN) Prepared by (National Board No.) F 9 (year built) 5. User s Design Specification on file at F 10 F 10 F 11 Certified by P.E. state Reg. no. 6. Manufacturer s Design Report on file at F 10 F 10 F 11 Certified by P.E. state Reg. no. 6a. Wire Winding Procedure Specification on file at F 10 Qualification Report No. Dated, Latest requalification date, F Material Impact tested at F 8. ASME BOILER AND PRESSURE VESSEL CODE, Section VIII, Division 3 9. Service F 15 F 13 (year) F 13 [Addenda (if applicable) (date)] F 14 (Code Case no.) 10. Restrictions and warnings F 16 F 17 F Construction cycles at psig at F F 19 F 20 F 21 Prestress method F Size and configuration F 23 (I.D.) F 24 F 25 (length) (thickness) (cylindrical, spherical, other) 13. Supports and attachments F 26 F 27 F Design pressure psi at maximum coincident metal temperature F Service pressure 29F at vessel/contents temperature of 70 F (20 C) Maximum metal vessel temperature F 28 F at F 28 psi F 30 F 30 Minimum design metal vessel temperature F at psi F 31 F 31 F Test pressure psi at Performed in the 16. Closures F 31 (horiz./vertical) 17. Connections, or provisions, for overpressure relief position (pneum./hydro./combination) F 33 F 32 (describe) [fluid(s) used in test] F (2/16) BPV SUPP. 4 4 ()

5 CASE (continued) 18. Nozzles and connections FORM WWPV-2 (Back) Purpose (Inlet, Outlet Drain) Quantity Diameter or Size Type Material Nominal Thickness Reinforcement Material How Attached Location F 33 F 34 F 35 F 34 F 34 F 36 F 12 F 25 F Manufacturer s Partial Data Reports, properly identified and signed by commissioned Inspectors, have been furnished for the following compo- F 37 nents 20. Remarks F 16 F 41 CERTIFICATE OF SHOP COMPLIANCE We certify that the statements in this report are correct and that all details of design, material, construction, and workmanship of this vessel conform to the ASME BOILER AND PRESSURE VESSEL CODE, Section VIII, Division 3, Case. U3 Certificate of Authorization no. expires,. (Stamped U3 only) Date Co. name Signed (Manufacturer) F38 F38 (representative) CERTIFICATE OF SHOP INSPECTION I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the State or Province of and employed by of, have inspected the pressure vessel described in this Manufacturer's Data Report on,, and state that, to the best of my knowledge and belief, the Manufacturer has constructed this part in accordance with the ASME BOILER AND PRESSURE VESSEL CODE, Section VIII, Division 3, Case. By signing this certificate, neither the Inspector nor his employer makes any warranty, expressed or implied, concerning the part described in this Manufacturer's Data Report. Furthermore, neither the Inspector nor his employer shall be liable in any manner for any personal injury or property damage or a loss of any kind arising from or connected with this inspection. Date Signed F Commissions (Authorized Inspector) 39 F 40 [National Board (incl. endorsements), state, prov., and no.] (2/16) 5 () BPV SUPP. 4

6 CASE (continued) ASME BPVC.CC.BPV.S Ref. to Circled No. in the Form Table 1 Instructions for the Preparation of Manufacturer s Data Report Form WWPV-2 Instruction (1) Name and street address of Manufacturer, as shown on Manufacturer's ASME Code Certificate of Authorization. (2) Name and address of purchaser. (3) Name of user and address of the Owner of the vessel. (4) Type of vessel, such as horizontal or vertical, separator, heat exchanger, reactor, storage, etc. (5) An identifying Manufacturer's serial number marked on the vessel (or vessel part) (see KS-120). (6) Canadian registration number where applicable. (7) Where applicable, National Board Number from Manufacturer's Series of National Board Numbers. National Board Number shall not be used for owner-inspected vessels. (8) Indicate drawing numbers, including revision numbers, which cover general assembly and list materials. For Canadian registration, also include the number of the drawing approved by Provincial authorities. (9) Organization that prepared drawing. (10) To be completed by the Manufacturer to show the disposition of the User's Design Specification and the Manufacturer's Design Report, and to identify the registered Professional Engineers who certify them. (11) State of the U.S.A. or province of Canada, as applicable. (12) Show the complete ASME specification number and grade of the actual material used in the vessel part. Material is to be as designated in Section VIII, Division 3. Exceptions: A specification number for a material not identical to an ASME specification may be shown only if such material meets the criteria in the Foreword of Section VIII, Division 3. When material is accepted through a Code Case, the applicable Case number shall be shown. (13) Issue date of Section VIII, Division 3 and Addenda (if applicable) under which vessel or vessel part was manufactured. (14) All Code Case numbers when vessel is manufactured according to any Cases. (15) Describe contents or service of the vessel. (16) Additional comments, including any Code restrictions on the vessel or any unusual Code or jurisdictional requirements that have been met, such as those noted in (17), (18), (20), (21), and (31). Indicate corrosion or erosion allowance. (17) Show need for start-up or shutdown temperature and/or controlled rate of heating or cooling, maximum temperature of any part. (18) Show results of fatigue analysis, number of cycles, limitations, or restrictions. (19) Type of longitudinal joint in cylindrical section, or any joint in a sphere (e.g., Type No. 1 butt or seamless). (20) When heat treatment is performed by the Manufacturer, give temperature and time. Explain any special cooling procedure and other pertinent heating during fabrication. (21) Indicate examination applied. Methods, location, and results should be included under Remarks. (22) Prestress, method, verification, etc. (23) Indicate inside diameter. (24) The shell length shall be shown as the overall length between closure. (25) Thickness is the nominal thickness of the material used in the fabrication of the vessel. It includes corrosion allowance. (26) Indicate provisions for support of the vessel and any attachments for superimposed equipment. (27) Show design pressure for which vessel is constructed (see KG-311). Other internal or external pressures with coincident temperatures shall be listed where applicable. (28), (29) Show maximum coincident metal temperatures permitted for vessel at the design pressures. (30) Show minimum design metal temperature at coincident pressure. List if more than one set. (31) Show hydrostatic or other tests made with specified test pressure at top of vessel in the test position that applies (pneumatic, hydrostatic, or combination test pressure). Indicate if vessel was tested in the vertical position. (32) Bolts used to secure removable head(s), closures, or seals of vessel. (33) Indicate nozzle or other opening that is designated for pressure relief (see Part KR). (34) Show other nozzles and openings by size, type, and purpose. See (36). (35) Show opening designated for inspection. Show location. (36) Data entries with descriptions acceptable to Inspector. Abbreviations, coded identification, or reference to Code figure and sketch number may be used to define any generic name. For ASME B16.5 flanges, the class should be identified. Flange facing and attachment to neck is not required. Some typical abbreviations: Flanged fabricated nozzle Cl. 300 flg Long weld neck flange Cl. 300 lwn Weld end fabricated nozzle w.e. (37) To be completed when one or more parts of the vessel are furnished by others and certified on Data Report Form K-2 as required by KS-301. The part manufacturer's name and serial number should be indicated. BPV SUPP. 4 6 ()

7 CASE (continued) Ref. to Circled No. in the Form Table 1 Instructions for the Preparation of Manufacturer s Data Report Form WWPV-2 (Cont'd) Instruction (38) Certificate of compliance block is to show the name of the Manufacturer as shown on Manufacturer's ASME Code Certificate of Authorization. This should be signed in accordance with organizational authority defined in the Quality Control System (see Appendix 2). (39) To be completed by the Manufacturer and signed by the Authorized Inspector who performs the shop Inspection or signs Form WWPV-2 for the completed vessel. Attach any applicable K-2 forms. (40) The Inspector's National Board Commission Number must be shown when the vessel is stamped National Board. Otherwise, show only Inspector's state or province commission number. (41) If additional thickness is provided as a protective or sacrificial layer beyond the thickness specified in (25), then that additional thickness shall be indicated here. GENERAL NOTE: units. Any quantity to which units of measure are needed shall be entered on the Manufacturer's Data Report with the chosen 7 () BPV SUPP. 4