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

• 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

Orientation about DMC

Seite 3

Picture Archive PSI

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

Basics for our Design

Seite 5

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

Difference between Generations

Seite 6

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 »

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

Seite 7

Redesign CAD CATIA

Conformity Assessment Procedure

Seite 8

Original Window Window-Modifications

Calculation Analysis for Pressure of 7bar

Seite 9

According to AD2000:

Minimal elastic limit needed 125N/mm2

by 14% elongation in x,y,z-direction

• 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

%

• 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

Risk is up to the Purchaser

Seite 12

Dye Penetration Process DIN 10228-2

Seite 13

Located defects are not correlated with the US test.

Our Interpretation: Cracks from milling

Conformity Assessment ProcedureMaterial-Specific-Values

Seite 14

Test specimen for tensil test and charpy test in all 3 direction

Conformity Assessment ProcedureTensile Test Results

Seite 15

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

• 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

Seite 16

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

Material for Screws

Seite 18

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

Screw Material

Seite 19

DIN 4762-M5x18-A4-BUMAX88DIN 4762-M4x16-A4-BUMAX88

• All sealings have to be in metal quality from Technetics

Sealings

Seite 20

Photo from Technetics: https://technetics.com/produkte/dichtungslosungen/metalldichtungen/helicoflex/

downloaded

• Dokumentations

- Test results

- Declaration of

conformity

- user manual for

- Gas cleaning

- maintenance and

revision

Open Works

Seite 21

• 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

Seite 23

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

Seite 24

Wir schaffen Wissen – heute für morgen

Questions?