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WIR SCHAFFEN WISSEN – HEUTE FÜR MORGEN
Conformity Assessment Procedure forboth Detectors DMC und CHARM
Dieter Graf :: Techniker für Maschinenbau HF :: Paul Scherrer Institut
DENIM VIII, September 17-19, 2019 in North Bethesda, MD
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• Overview of DMC
• Basics for our designWhat exists and what is in operation
• Conformity Assessment ProcedureCourse of actionMaterial inspectionPressure proof test
• Conclusion and Experience
Table of Contents
Seite 2
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Orientation about DMC
Seite 3
Picture Archive PSI
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Schematic Representation for DMC
Seite 4
Picture from Lukas Keller, PSI
From Instrument Side for DMC, PSI
Old Detector
Solid Angle
New Detector
Solid Angle
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Basics for our Design
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Picture downloaded from Ansto, Instrument Side «Wombat»
Wand2, Oak Ridge National Laboratory (ORNL) - Picture copied from LANSCE_ND120_Owners_Manual-1
Picture from Karl Zeitelhack, TUM
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Difference between Generations
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1. Generation 2. Generation
Instrument Wand2 / Wombat DMC / CHARM
Standard ASME AD2000
Vessel Material EN AW-7075EN AW AlZn5.5MgCu
EN AW-5083EN AW AlMg4.5Mn0.7
Elastic Limit 260-470 N/mm2 105-125 N/mm2
Strain to Rupture 2-8% Min. 12%
Flange Material 1.4301 1.4404
Sealings NBR Metallic
Screws Grade 8 (10.9) BUMAX 88 (1.4435)
AD2000 Regulations: specify all basic safety and conformity regulations that must be observedin accordance with the European Pressure Equipment Directive (PED) 2014/68/EU ASME: American Society of Mechanical Engineers, ASME Boiler and Pressure Vessel CodeDatas from « Metall Service Menziken »
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Challenge from our side
Mental blockade concerning
Detectors in use and defined design
Prototype in use with certification through ILL
• First calculation for our aluminum alloy and redesign window area
• After Assignment of a mission for supervision and certification for TÜV-CH
• Discussion about influence from AD2000 for the design
Pressure proof 10bar or 7.7bar
Inspection conditions non-destructiv tests
Choose right aluminium alloy EN AW-5083 one and only
Dimension and appropriate material for the screws «A4-70 or A4-80» or «8.8 or 10.9»
Selection for the metal sealings coating material, quantity of screws, forces or after all «rubber»
Conformity Assessment Procedure
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Redesign CAD CATIA
Conformity Assessment Procedure
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Original Window Window-Modifications
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Calculation Analysis for Pressure of 7bar
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According to AD2000:
Minimal elastic limit needed 125N/mm2
by 14% elongation in x,y,z-direction
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• According to AD2000
1.43 x PB (Liquid) oder 1.1 x PB (Gas)?
95% from elastic limit (direction ?!)
Conformity Assessment ProcedureDefinition Test Pressure
Seite 10
By 1.43xPB is elastic limit Rp0.2 overrun
for EN AW-5083 sheetsElastic Limits
Rp0.2Tensile strenght
RmThickness
Raw material = forged ring
Table: DIN EN 485-2:2009-01
Elongation
%
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• Material properties to test in all main direction
• Recalculation
• Material Certification used aluminium alloy
• Basic material free from defects
• US-test according to DIN EN 10288-3; Classe 4
• Dye Penetration Process DIN 10228-2 in the window
As Consequence of the calculation and AD2000
Seite 11
2 US-tests = 2 Results for defects
IMBACH ≠ ALCA
Position for the defects is not clear
Cause of defects is high
no guaranty by new order
Cast process unknown
Risk by purchaser
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Risk is up to the Purchaser
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Dye Penetration Process DIN 10228-2
Seite 13
Located defects are not correlated with the US test.
Our Interpretation: Cracks from milling
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Conformity Assessment ProcedureMaterial-Specific-Values
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Test specimen for tensil test and charpy test in all 3 direction
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Conformity Assessment ProcedureTensile Test Results
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Probe-Kennzeichnung
Strain to Rupture εin %
Tensile StrenghtRmin N/mm2
Elastic Limit Rp0.2
in N/mm2
X3 36.4 302 122Y2 29.8 324 142Z1 17.7 305 134
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• Vacuum proof by ALCA
• Pressure test with 10bar in PSI and TUM for electric flanges (still in progress)
• Pressure vessel with blind flanges with 7.7bar proof pressure by PSI
Proof Pressure Process
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Test Procedure with Nitrogen
• 0.5bar leak test
• 3.8bar view and sound control
• 7.7bar Endpressure for 30min
Additional
• Measurement the deformation for the
window
• Measurement for the broadening on the side
• Measurement the acoustic emission
Pressure Test
Seite 17
DeformationWindow (mm)
Broadening left(mm)
Broadening right(mm)
DMC 0.64 1.04 0.24CHARM 0.69 0.86 0.35
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Material for Screws
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Conditions:
Material for screws with very deep Permeability µ < 1.1
Smallest dimension M4 (certificate of exemption)
AD2000 compatibility
Not allowed/ not enough:
Stainless screw A4-80 (AD2000-B8)
Screws with strength class 10.9 or higher (AD2000-W7)
Screws must be more than M6 (AD2000-B7)
Chosen and accredited:
BUMAX A4-88 (> 800N/mm2)Elastic limits
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Screw Material
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DIN 4762-M5x18-A4-BUMAX88DIN 4762-M4x16-A4-BUMAX88
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• All sealings have to be in metal quality from Technetics
Sealings
Seite 20
Photo from Technetics: https://technetics.com/produkte/dichtungslosungen/metalldichtungen/helicoflex/
downloaded
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• Dokumentations
- Test results
- Declaration of
conformity
- user manual for
- Gas cleaning
- maintenance and
revision
Open Works
Seite 21
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• Team-Work- Person in Charge for DMC
- Design Engineer
- Detector Developer
- Mechanics
- Vacuum engineer
- Pressure Test Responsible
- Materials Science
- Engineer for FEM-Calculation
• TÜV-Switzerland Certification office
from start
• Open Mind for the Certification process
• Communication between- all project involved people
- all Project responsible people
- all suppliers
• Time-consuming
• Standards AD2000 und EN ISO DIN
• Collective Responsibility for Decisions
• Exchange for Experiences and Knowledge
Conclusion and Experience
Seite 22
DIN EN 1591-1Flanges and their joints
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Wir schaffen Wissen – heute für morgen
My Thanks goes to
• TÜV SwitzerlandCh. Mikusky
T. Häntzka
• TUMK. Zeitelhack
• ALCA TechnologyM. Cencherle
F. Anselmi
• PSIL. Keller
M. Hiltebrand
M. Mähr
P. Spätig
and a lot more
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Seite 24
Wir schaffen Wissen – heute für morgen
Questions?