ASME CC N-808 Frank J Schaaf, Jr

Sterling Refrigeration Corp

NRC “Drop In” Meeting Washington DC 17 April 2013

ASME CC N-808 Disclaimer

This presentation is the intellectual property

of Frank Schaaf. The comments made are his alone, Project Manager of CC N-808, and are not an ASME official position.

ASME CC N-808

Presentation Elements Reason for N-755 Separation Code Case Format Fusing UT Examination

During approval of Revision 1 of CC N-755, negative was received, requiring Owners to procure PE material in accordance with Section III requirements.

The negative could not be cleared, Individual felt Owner’s should procure same method as Section

III. The Chairmen of Section III and Section XI decided

to separate CC N-755 into two Code Cases.

First effort had N-808 detailing only the differences between Section XI (Owner) and Section III Both Cases were locked, so the technical requirements were

matched and locked together. Section XI, added UT examination based on Appendix VIII

and Callaway experience. Approval of N-808 was taking longer and impacted N-755

revision

At the February BNCS meeting it was decided to remove the lock on both Code Cases, and each Section would pursue their own Case.

ASME CC N-808 Code Case Format

Case Layout (Based on Section III) CC Inquiry & Reply (Buried Pipe Only) 1000 General Requirements (IWA, NCA and ND) 2000 Material (Technical and QA) 3000 Design 4000 Installation (Section IX – Fusing) 5000 NDE (UT Examination) 6000 Pressure Test 8000 Stamping

ASME CC N-808 Code Case Format

Case Layout (Based on Section III) Appendixes

• Mandatory Appendix I – Forms Required for fabricated product off site using the fusing

process

• Non-Mandatory Appendix A – Unacceptable Fused Joints

Required to support visual examination

ASME CC N-808 Code Case Format

Case N-755 Appendixes eliminated Appendixes - Mandatory

• Mandatory Appendix I Fusing – Adopted Section IX to be published in July 2013

• Mandatory Appendix II Standards – Moved to General Requirements

• Mandatory III Forms – Moved to Appendix I

• Mandatory IV PE Material – Moved to -2000 of Case

ASME CC N-808 Code Case Format

Case N-755 Appendixes eliminated Appendixes – Non-Mandatory

• Appendix A, Training – Adopted Section IX • Appendix B, Data Logger Review – Eliminated, may add the

Section IX, Data Logger Review sheet to -5000.

• Appendix C, Unacceptable Joints – Moved to Appendix A • Appendix D, NONMANDATORY METHOD – Eliminated

ASME CC N-808 Fusing

Incorporation of Section IX, FUSING (2013 ED.) • No nuclear extras • Essential Variables • Thermal Butt fusion & Electro-fusion (future) • Fusion Data comes from the PE Material Manufacturer (TR-

33 (PPI) Standard Fusion Procedure Specification) • Uses Fusion Procedure Specification (FPS), • Has the requirements for different FPS development (PQR) • Qualification of both Procedures and Personnel • Uses ASTM’s, Section IX has acceptance criteria

ASME CC N-808 Fusing - Experience

Poor Material Fusing Problem – Major Problem

• Material will not fuse correctly • Coupons using project material at the site and test facility

failed all tests. • Tensile – Impact Test • ISO Tensile Test • DVS (German) Tensile Test

• Pipe manufacturer could not fuse the pipe and pass tensile-impact tests (fusion box numbers)

ASME CC N-808 Fusing - Experience

Tensile – Impact (T-I) Test Pipe maker felt the test was misleading yet signed

letter in TR-33 that their material passed T-I tests Follow on testing showed that this test is a good

indicator for condition of PE material; • Poor or defective resin • PE product form defective • FPS not followed

ASME CC N-808 Fusing - Experience

PE Material ASTM’s don’t have acceptance criteria NOT ALL PE 4710 RESINS ARE EQUAL

• Material Properties are very different

NOT ALL PIPE MANUFACTURERS ARE EQUAL • Old equipment (windows) in pipe wall • QA program

TR-33 Data sometimes is not repeatable Need method to confirm material is fusible

ASME CC N-808 FUSING

Fusing Callaway Relief Request, fusing process was

reviewed by the NRC as an NDE procedure Any variable identified in an NDE procedure is an

“essential” variable Section IX – defines essential variable as; Essential variables - are those which will affect the

mechanical properties of the fused joint, if changed, and require requalification of the FPS when any change exceeds the specified limits of the values recorded in the FPS for that variable.

.

ASME CC N-808 FUSING

Fusing Essential Variables

ASME CC N-808 FUSING

Fusing Essential Variables

ASME CC N-808 FUSING

Fusing PE Material Conformation -2600 POLYETHYLENE MATERIAL FUSING

QUALIFICATION TESTING • Use Project Material • Test each corner of Fusion Box

• A. 60 psi – 400oF • B. 60 psi – 450oF • C. 90 psi – 400oF • D. 90 psi – 450oF

• Use Tensile-Impact Test • Test each combination of different manufacturers product

form

ASME CC N-808 UT Examination - History

UT Examination – Callaway Project Used UT examination for ease in examination of

joints versa destructive test • Pipe is 175 lb/ft (Crane service) • No testing machine on site

Callaway used Time-of-Flight (TOF) tested over 200 joints (no miters)

No indications in any joint Performed Section V, Article 14, performance

demonstration of TOF technique

ASME CC N-808 UT Examination - Incorporation

UT Examination Requires UT exam on > 4 inch product form Requires Phased-Array technique Can examine all joints, including miters Common technique so little training is required All UT examiners will be trained as fusion machine

operator, Requires Section V, Article 14, performance

demonstration of technique, intermediate rigor

ASME CC N-808 UT Examination - Incorporation

UT Examination Acceptance Criteria No indication or response No evaluation of data allowed Detailed coupons for Section V, demonstration of

technique to ensure adequate coverage No repairs allowed

ASME CC N-808 Future

Approval Final Approval November, 2013 Will seek approval from the NRC (partial)

ASME CC N-755 THE END

Thank you for listening

Any Questions?????