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Slide 1 of 54 Pressure System Seminar Part 2, 15 May, 2009 PRESSURE SYSTEM SEMINAR – PART 2 CEBAF CENTER L102/104 15 May 2009 9:30-11:00 A.M. AGENDA WelcomeW.

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Presentation on theme: "Slide 1 of 54 Pressure System Seminar Part 2, 15 May, 2009 PRESSURE SYSTEM SEMINAR – PART 2 CEBAF CENTER L102/104 15 May 2009 9:30-11:00 A.M. AGENDA WelcomeW."— Presentation transcript:

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2 Slide 1 of 54 Pressure System Seminar Part 2, 15 May, 2009 PRESSURE SYSTEM SEMINAR – PART 2 CEBAF CENTER L102/ May :30-11:00 A.M. AGENDA WelcomeW. Oren Qweak Hydrogen Target System PS-TGT D. Meekins CHL Oil Removal Relief Repair PS-CRY E. Yuksek DOE Site Office Review of JLab Pressure System Program K. Dixon Pressure Systems, Chapter 6151, Updates, Policy Changes and Chapter Edits W. Oren

3 Slide 2 of 54 Pressure System Seminar Part 2, 15 May, 2009 Qweak Hydrogen Target System PS-TGT Pressure System Lessons Learned Dave Meekins and Ed Daly

4 Slide 3 of 54 Pressure System Seminar Part 2, 15 May, 2009 System Overview Hx Cell Pump Heater JT valves Motion System 1.Heat Exchanger 2.Cell 3.Pump 4.Heater 5.Hydrogen loop plumbing 6.Hydrogen gas handling system (not shown) 7.He refrigeration plumbing 8.Instrumentation (not shown) Loop plumbing The system is a cryogenic liquid hydrogen target for Qweak experiment in Hall C. System Fluids are H2 (target fluid) and He (CHL/ESR refrigerant). Temperatures are low, 4K (He) and 20K liquid H2. Major Components

5 Slide 4 of 54 Pressure System Seminar Part 2, 15 May, 2009 How to Implement JLab Pressure Policies? Some of the design and fabrication work started before January What do we do with components under construction? What policies do we have to comply with for new designs? How do we treat the non standard components in the system? Scheduling and budgetary constraints were applying pressure to continue with business as usual. Asked the Pressure Committee for guidance.

6 Slide 5 of 54 Pressure System Seminar Part 2, 15 May, 2009 Breakdown of the System Gas handling system Storage vessels (6000 gal) Cell Pump Hydrogen loop plumbing Heater Heat Exchanger Refrigeration Plumbing T=120 F MAWP=100psig B31.3 and VIII D1 T=-433F MAWP=100 psig Code does not apply. Use equivalent measures and peer review. T=-433F MAWP=100 psig B31.3 T=-453F MAWP=300 psig VIII D1 STAMP REQUIRED T=-453F MAWP=300 psig B31.3 TemperatureTemperature

7 Slide 6 of 54 Pressure System Seminar Part 2, 15 May, 2009 Heat Exchanger UA of HX was established to provide more than 2.5 kW at 20 K. Designed in house and sent out for bids at 2 code shops. We provided the necessary code calculations (saved money). –Meyer Tool: Found design conflict with code. (UW-2b low temperature) –Eden Cryogenics: Lowest bidder but missed the error. –This caused procurement headache. Statement of work: Used the language lowest price technically acceptable. Language using Best value would have made it easier to reject unsuitable vendor.

8 Slide 7 of 54 Pressure System Seminar Part 2, 15 May, 2009 HX Section View

9 Slide 8 of 54 Pressure System Seminar Part 2, 15 May, 2009 HX Head Modification Welds not full penetration Interior structure not a pressure boundary Pressure boundary UW2 requires full penetration welds for our case Full penetration with integral backing

10 Slide 9 of 54 Pressure System Seminar Part 2, 15 May, 2009 HX at Meyer Tool

11 Slide 10 of 54 Pressure System Seminar Part 2, 15 May, 2009 Cell and Pump The Codes do not apply. Pump case and cell body are made from unlisted aluminum alloys. –Weld procedures are needed. –Design strength of welds are unknown. –WPS was developed and tested. Used lowest pull test values for design. –Using design basis in B31.3 for unlisted materials where possible. More complex analysis was needed for non standard geometries. –FEA (VIII D2) –Reviewed hand calculations Rely on testing for unlisted materials/geometries: –Pressure testing of components B13.3 where possible Use sound engineering judgment/peer review –Sensitive He leak check in reverse. Thin cell apertures are being extensively tested. No impact testing was performed.

12 Slide 11 of 54 Pressure System Seminar Part 2, 15 May, 2009 Qweak Cell Entrance window Exit window e-

13 Slide 12 of 54 Pressure System Seminar Part 2, 15 May, 2009 Entrance Window in Burst pressure exceeded 500 psig

14 Slide 13 of 54 Pressure System Seminar Part 2, 15 May, 2009 Hydrogen and Refrigeration Plumbing This plumbing has been designed and fabricated to B31.3 The Minimum Design Metal Temperature (MDMT) is -452 F. There are non standard components in the system (Conflat flanges, unlisted materials…) Parts of the system are contained in an large insulating vacuum vessel. Parts of the system are already existing. Expansion joints (flexible metal hose) were used to alleviate stress from temperature gradients, misalignments, seismic and other loads. A complex flexibility analysis can be simplified (B ). How should seismic loads be quantified and treated?

15 Slide 14 of 54 Pressure System Seminar Part 2, 15 May, 2009 Implications of low MDMT B31.3 requires impact testing for SST304 at this temperature. Tests are required for base metal, weld metal, and HAZ. St Louis Testing Lab is capable of doing this. Section VIII has 2 provisions which can be helpful. –UHA-51g allows for exemption from impact testing for low stress in high alloy steels. B31.3 has a similar exemption but with a temperature limitation. –Div 1 and 2 have a provision that impact testing may be performed at 77K for SST304 when 316L welding rod is used with an F number less than 5. B31.3 does not have such a provision. Only components thick enough are required to be tested.

16 Slide 15 of 54 Pressure System Seminar Part 2, 15 May, 2009 B31.3 Conflat (CF) Flanges Conflat (CF) flanges have been used extensively in the past. They provide a reliable seal at design temperature. Allow for quick replacement and modification of system components. Eliminate RadCon issues from welding/grinding/brazing. B31.3 references VIII Appendix 2. Flange bolt loads and gasket seating forces were measured for a variety of geometries and gasket materials. Off the shelf CF flanges and bolts are not compliant with Appendix 2 (at least in a conservative analysis) when using standard copper gaskets. MDC will supply COC but not CMTRs. Flanges may not be made from bar stock (UG-14). Bolt stress exceeds code allowable for SST.

17 Slide 16 of 54 Pressure System Seminar Part 2, 15 May, 2009 Lessons Learned Code may apply to some components and not others. Where the code does apply it must be used. Use caution when writing statements of work to allow for changes and mistakes. Low MDMT can lead to challenges –Charpy tests –Subtleties in the code Unlisted materials can be useful but require some type of analysis/testing to determine design criteria. Policy/guidance regarding seismic analysis would be useful.

18 Slide 17 of 54 Pressure System Seminar Part 2, 15 May, 2009 Questions?

19 Slide 18 of 54 Pressure System Seminar Part 2, 15 May, 2009 CHL Oil Removal Relief Repair PS-CRY Errol Yuksek 15 May 09

20 Slide 19 of 54 Pressure System Seminar Part 2, 15 May, 2009 The Event September 08 Relief valve activated to keep pressure under control Branch separation

21 Slide 20 of 54 Pressure System Seminar Part 2, 15 May, 2009 Layout Oil Removal Compressors 4K Cold Box GHe Storage Tanks Relief Controller card failure

22 Slide 21 of 54 Pressure System Seminar Part 2, 15 May, 2009 Relief Valve Set-point of 300 psi Helium flow capacity 2.8 kg/s Protects the CHL main compressor and oil removal systems 20 ft elevation

23 Slide 22 of 54 Pressure System Seminar Part 2, 15 May, 2009 Immediate Repair Isolate the leak Immediate repair crucial Sound engineering judgment Defer code analysis Improve upon the repair if needed

24 Slide 23 of 54 Pressure System Seminar Part 2, 15 May, 2009 Failed Installation Long outlet pipe - moment arm produces larger stress at base Inadequate reinforcement at base

25 Slide 24 of 54 Pressure System Seminar Part 2, 15 May, 2009 Repair Process Bench Test – verify relief set pressure Reduce the stresses –Increase moment of inertia at the base –Shorten relief outlet –Add external support Gather materials on hand In-Process Examinations – qualified weld examiner (not welders) Leak Check – intermediate checks and final check at operating pressure

26 Slide 25 of 54 Pressure System Seminar Part 2, 15 May, 2009 Branch Reinforcement Calculation Twice as much reinforcement was installed than required by B31.3

27 Slide 26 of 54 Pressure System Seminar Part 2, 15 May, 2009 Stress at Inlet 59 ksi > Yield Stress of 304L 25 ksi Stress Analysis of Old Installation Stress after repair 33 ksi improvement required

28 Slide 27 of 54 Pressure System Seminar Part 2, 15 May, 2009 Improved Installation Outlet Tee – momentum cancelling

29 Slide 28 of 54 Pressure System Seminar Part 2, 15 May, 2009 Stress at Inlet 3.7 ksi < Allowable Stress of 304L 16.7 ksi P. Knudsen Stress Analysis of New Installation

30 Slide 29 of 54 Pressure System Seminar Part 2, 15 May, 2009 Repair or Modification? ESH&Q Ch ¶6.8 Repairing or Modifying a Pressure System –Repairs to piping systems shall be made using sound engineering principles. –Modifications to piping systems shall be made using current ASME Codes and/or documented equivalent measures. –Changing the service of a pressure vessel or piping system is also viewed as a modification. Changing the service can mean any change in the application or change in the location of the vessel or piping if the structural support is affected. Neither application or location were changed. Interpreted as a repair of the piping system.

31 Slide 30 of 54 Pressure System Seminar Part 2, 15 May, 2009 Material Stainless steel did not have certifications –Spectrum analyzer –Does not distinguish between 304 and 304L –304L assumed for conservative analysis (allowable stress of 16.7 ksi as opposed to 20 ksi).

32 Slide 31 of 54 Pressure System Seminar Part 2, 15 May, 2009 Root Cause October 04 Engineering change No record of a walk-down Lack of an established, controlled process for verification of engineering changes resulted in unchanged outlet pipe Implementation of ESH&Q Chapter 6151 establishes multiple checks to prevent such occurrences 04 Installation Drawing

33 Slide 32 of 54 Pressure System Seminar Part 2, 15 May, 2009 Questions? Many thanks to Dave Kashy, Ed Daly, and Michael Bevins for their assistance in the repair process.

34 Slide 33 of 54 Pressure System Seminar Part 2, 15 May, 2009 DOE QA Program Review Kelly Dixon 15 May 09

35 Slide 34 of 54 Pressure System Seminar Part 2, 15 May, 2009 P2 Findings Four findings: –JSA Training Program not compliant –Corrective actions for DOE external assessment findings not adequately tracked and closed –Documents and record management not compliant with QA program for some JSA orgs –FIND-DES-P2-004

36 Slide 35 of 54 Pressure System Seminar Part 2, 15 May, 2009 FIND-DES-P2-004 PS records management –not compliant w/ ES&H Chapter 6151 –doesnt ensure control between design specs, p. testing and final installation –extent of condition unknown

37 Slide 36 of 54 Pressure System Seminar Part 2, 15 May, Male Bayonet

38 Slide 37 of 54 Pressure System Seminar Part 2, 15 May, Bayonet Test Can 100 psi Rating

39 Slide 38 of 54 Pressure System Seminar Part 2, 15 May, Bayonet Test Can 350 psi Rating

40 Slide 39 of 54 Pressure System Seminar Part 2, 15 May, 2009 Reviewed Documents Training records Gas tank specification from another ongoing project PS-CRY (Docushare folders) –Design calculations –Traveler –Pressure test procedure and records –Drawings –DA completion statement PS-CRY folders –Design calculations –Pressure test records –Drawings

41 Slide 40 of 54 Pressure System Seminar Part 2, 15 May, 2009 Basis for Finding Specifically: –Drawing folder included an item that may not have been built –Modified item test records not in designated project folder (ESR 80K Bed U-Tube Mods) –Design documents not signed in file containing upgraded design –Signed DA completion statement states system has been installed and in operating condition

42 Slide 41 of 54 Pressure System Seminar Part 2, 15 May, 2009 Basis for Finding (cont.) –Also noted: Pressure test records not consistent where some are hand written Wide range of content and formats within PS documents Ch 6151 T1, titled Pressure System Project Implementation and Documentation Guidance imparts an advisory nature contrary to mandatory recordkeeping language

43 Slide 42 of 54 Pressure System Seminar Part 2, 15 May, 2009 Lessons Learned Maintain consistency in forms and process Verify all completed items, no matter how simple they are Ch 6151 T1, renamed to Pressure System Project Implementation and Documentation Requirements

44 Slide 43 of 54 Pressure System Seminar Part 2, 15 May, 2009 Lessons Learned (cont.) QA inspector must verify all documents –Ref Ch 6151 T1, ¶ 4.13 Final System Walkthrough: The QA representative shall perform the final safety walk-through for the pressure system before it can be released for operation. This effort shall include reviewing the Pressure System Checklist and DocuShare Folder for completeness, and ensuring that pressure system marking is consistent with applicable code requirements.

45 Slide 44 of 54 Pressure System Seminar Part 2, 15 May, 2009

46 Slide 45 of 54 Pressure System Seminar Part 2, 15 May, 2009 Pressure Systems, Chapter 6151 Updates Policy Changes and Chapter Edits Will Oren for the Pressure Systems Committee May 15, 2009

47 Slide 46 of 54 Pressure System Seminar Part 2, 15 May, 2009 Change/Enhancement Summary Chapter 6151 –Pressure system definition –Identifying if you have a pressure system –Vessel stamping requirements –Vacuum vessels –Repairs & modifications Appendix T1 –Guidance changed to requirements –Upfront peer review for equivalent measures –System inspection requirements Appendix T2 – Scope section is changed Appendix T3 – Foam windows Appendix T5 – Vacuum Systems ** NEW**

48 Slide 47 of 54 Pressure System Seminar Part 2, 15 May, 2009 Chapter 6151Changes Section- Key Terms – Pressure System: 0 psig or greater unless all the following hold: 1.<15psig 2.Non-flammable/toxic per ASME 31.3 paragraph Temperature between -20˚ and 366˚ F (Vac. systems w/ pressure source must relieve at <15psig) Section- Program and Procedure Summary –Vacuum systems are more explicitly dealt with; some relieved below 15 psi may have new requirements if there are personnel or economic risks. –If the vessel can be stamped it must be stamped.

49 Slide 48 of 54 Pressure System Seminar Part 2, 15 May, 2009 Chapter 6151Changes Section- Program and Procedure Summary, 6.1 Identifying a Pressure System –3 Steps 1.Is it one by definition? –Is it a vacuum system? (T5) 2.If it is, initiate the required project folder (T1) 3.Identify/choose the applicable code. If equivalent measures to be used a peer review is required at this point! Section- Program and Procedure Summary, 6.7, Inspecting a Pressure System after Initial Operation Vessels inspected by Facilities contractor System inspection intervals for all others as defined by DA. (This implies that all systems have folders, even the grandfathered ones)

50 Slide 49 of 54 Pressure System Seminar Part 2, 15 May, 2009 Chapter 6151Changes Section- Program and Procedure Summary, 6.9 Repairing or Modifying a Pressure System Repairs & Mods made to the code of record, if not known, use sound engineering judgment Non-welding maintenance can be completed by competent technical staff.

51 Slide 50 of 54 Pressure System Seminar Part 2, 15 May, 2009 Appendix T1 Changes Appendix Title: Pressure System Project Implementation and Documentation REQUIREMENTS Section- Scope –Read this section carefully, how repairs and modifications on new and existing systems is discussed. Section- Responsibilities –New position: Pressure Systems Committee Designee is there to help you with system number assignments, documentation input, inspection reminders, etc… (Bridget please stand up!)

52 Slide 51 of 54 Pressure System Seminar Part 2, 15 May, 2009 Appendix T1 Changes Section- Process Steps and Expectations –Read the entire section carefully; –A couple of highlights: Utilized design codes must be identified/documented If equivalent measures are being applied this must be peer reviewed at the time of this decision.

53 Slide 52 of 54 Pressure System Seminar Part 2, 15 May, 2009 Appendices T2-4 Changes Appendix T2: Design Program: –Exclusions from main chapter moved to scope section Appendix T3: Thin Window Design –Foam windows added Appendix T4: Pressure Testing –No significant changes

54 Slide 53 of 54 Pressure System Seminar Part 2, 15 May, 2009 Appendix T5 Appendix T5: Requirements for Vacuum Systems –Totally new appendix based on ASW consensus program for vacuum chambers. (BNL tech note) –3 Catagories: Cat 1: Vacuum systems in which the differential operating pressure can never exceed 15 psi Cat 2: Vacuum systems which can be protected from pressurization exceeding 15 psig through engineering controls. (transfer lines, coldboxes..) Cat 3: Vacuum systems which are not or cannot be protected against pressurization exceeding 15psig. (use the pressure system policy to build these)

55 Slide 54 of 54 Pressure System Seminar Part 2, 15 May, 2009 Conclusion Draft copies of the new chapter, T1 and T5 are at the door. This draft is headed to DSC for approval You need to read the new material Thanks to the speakers; this is distracting to your ongoing work but important. Thanks for taking the time to prepare and present. Thanks for coming and I hope this was helpful!

56 Slide 55 of 54 Pressure System Seminar Part 2, 15 May, 2009


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