HDICE In Beam Cryostat Project

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1 HDICE In Beam Cryostat Project ASME BPVC and Process Piping Code Application and Analysis Orlando Pastor, Jr. Structural Engineer March 30, 2011

2 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

3 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

4 HDICE IBC System Pressure Map 4

5 HDICE IBC System Thermal Map 5

6 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!

7 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 7

8 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

9 ASME Code Compliance Issues!"#$%&'( ()"*+,$(,-(."/%-0%&'( 122#%345#"(6"3*%,&(78(( 9#"3*/,&(:"4;(!"#$%&'(,-()%<%&'(=+4;5"/( 9#"3*/,&(:"4;(!"#$%&'(,-(EF"(=4&(G,?"( =,/&"/(H%##"*(!"#$(( I/"J%,K?(9<2"/%"&3"LH91( A( :/4M%&'( 6*%##(4&$(CN(I,*(=,J"/(*,(:,$0(O,%&*( 6*4%&#"??(?*""#(*K5"(*,(6*%##(O,%&*( 6*4%&#"??(?*""#(*K5"(*,()%<%&'(=+4;5"/(O,%&*( :,&$%&'( 6*4%&#"??(6*""#(*,(1#K;%&K;(>/4&?%*%,&?( =,#$(6+,3SLI>( A( 9

10 ASME Code Compliance Issues (continued) )4*"/%4#( )"*+,$(,-(."/%-0%&'( >+"/;4#(2/,3"??%&'(,-(=CPCPP(/"$K3"?(?*/"&'*+(5"#,T(16)9(:I.=(J4#K"?( >"&?%#"(*"?*?(,&(*+"/;4##0( 2/,3"??"$(?4;2#"?( A( I/"??K/"(>"?*%&'( FU%3"(7:=()%<%&'(=+4;5"/(G,*(I/"??K/"( >"?*"$(2"/(16)9(=,$"( I/"??K/"(>"?*(,-( 9VK%J4#"&*()%<%&'( =+4;5"/(*,(CQD(2?%4((( 7:=()%<%&'(=+4;5"/( I/"??K/"(>"?*"$(*,(]](2?%4( T%*+(?0?*";(2%2%&'( IFWACCAPPCA >X6IYZ"JP( [=,;2#"*"$\( IFWACCAPP^A >X6IYZ"JP( 10

loading and tensile loading Component stresses were similar in

11 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

12 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

acceptance per ASME BPVC Stresses are driven by the different coefficient s

13 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

14 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

15 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

16 Joint Tracking 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 J Joint Drawing Number Incremental Joint Number 16

17 Pressure Test Liquid Helium Piping IBC will be pressure tested in accordance with ASME BPVC and B31.3 requirements PHY TOSP prepared for pressure testing liquid helium piping circuits Test schedule TBD but before IBC is loaded into Hall B 17

18 Analysis Reports 18

19 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 B

20 BACK-UP SLIDES 20

21 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

22 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 min thickness for ferrous alloys Piping Design Code! ASME Pressure Piping Code B31.3 Process Piping 22

23 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

24 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

25 !Copper ASME SVIII Div 1 Material Toughness 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 and Table A-1) No known physics to alter behavior of copper Considered acceptable if room temperature toughness is validated 25

26 ASME SVIII Div 1 Material Toughness!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

27 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

28 Alloy C10100 Tensile Testing 28

HDice IBC Still Assembly Analysis Initial

29 HDice IBC Still Assembly Analysis Initial Conditions! Initial Temperature: 293K! Internal Pressure: 0 psid Loading! Operating Temperature: 0.7K! Internal Pressure: 30 psid Properties! Temperature Dependent CTE! Temperature Dependent Modulus of Elasticity 29

30 HDice IBC 1K Pot Analysis Initial Conditions! Initial Temperature: 293K! Internal Pressure: 0 psid Loading! Operating Temperature: 0.7K! Internal Pressure: 30 psid Properties! Temperature Dependent CTE! Temperature Dependent Modulus of Elasticity 30

Still Body/1K Pot Covers Brazed Joints Tensile/

joint strength requirements for the Still and 1K

IAW ASME BPVC Section IX Tensile and bend tests

31 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

32 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 thick wall tube thick wall tube ASME BPVC allows for testing of dissimilar metals which qualifies brazing of similar metal Specimens met the strength requirements 32

33 HDICE IBC System Overpressure Cases Pump Line Overpressure Outer Vacuum Can Overpressure 33

Argonne Engineering Professionals Seminar Series September 30, 2009 Argonne National Laboratory Argonne, IL

Argonne Engineering Professionals Seminar Series September 30, 2009 Argonne National Laboratory Argonne, IL Presentation of Case Study Manufacture of a Helium/Hydrogen Heat Exchanger to the ASME Code presented