impex 2009 iwt - Dillinger · 2015. 12. 10. · IMPEX 2009 – Improving the European pressure...
Transcript of impex 2009 iwt - Dillinger · 2015. 12. 10. · IMPEX 2009 – Improving the European pressure...
IMPEX 2009 – Improving the European pressure vessel standard EN13445-2 by means of pre-normative research
Dr. Peter LangenbergIWTprojects Ltd
7th Dillinger Pressure Vessel ColloquiumSeptember 2012
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Overview
1. Overview on actual status of European Standardisation of pressurised components
2. Principles of the European method for selecting steels to avoid brittle fracture
3. What is IMPEX 2009 project about?
4. Ways, Means and Achievements
5. Conclusions
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Development of European Standards for pressurised Components
1990: Harmonisation process started. CENTC 54: pressure vessels; CENTC 267: Piping
1997: PED 97/23/EC was published by EU as legal frameAim: Harmonisation of European markets CE marking
2002: First publication of EN13445 (PV) and EN13480 (Piping)
2009: Consolidated Version published of EN13445Containing all corrections and ammendments, published in issues 1 to 32.New Issues are published every year.
2012: Consolidated Version of EN13480 will be published
2013: EN13445: Issue 4 will contain results from IMPEX pre-normative research
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Impact of pre-normative research projects for standardisation
Major changes of EN13445-2 (Materials) from 2002 to 2009
1. Change in philosophy as concerns steels for warm and cold going vessels
2. Inclusion of High Strength Steel with Yield Strength up to 690 MPa and Duplex Stainless Steels (ECOPRESS European Research Project from 2000 to 2003)
3. Improved method 2 (ECOPRESS)
4. Improved method 1 (ECOPRESS)
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Overview
1. Overview on actual status of European Standardisation of pressurised components
2. Principles of the European method for selecting steels to avoid brittle fracture
3. What is IMPEX 2009 project about?
4. Ways, Means and Achievements
5. Conclusions
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General approach: Requierement on Charpy toughness
0
27J
Ker
bsch
laga
rbei
t A [J
]V
Temperatur [K]
Hochlage
TieflageÜbergangs-
bereich
AVmax/2
TÜ27JTÜAVmax/2
Lower shelf
Upper shelf
Transition
Cha
rpy
toug
hnes
in J
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The Fracture Mechanics approach
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Failure depth a, mm
thickness t, mm
EN13445:2009ASMEEurocode 3
ASMElimited @ 7 inch
EN13445limit @ 110 mm
EN1993 (EC3)limit @ 200 mm
ad
2cd
Comparison of EN13445-ASME-Eurocode 3
1. Crack assumption2. Quantification of toughness requierments in terms of fracture toughness.3. Contradiction to practical situation of charpy requirements ?????
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Practical Solution: FAD plus Master Curve Concept
CEGB R6 Option 2KR=
KIKmat
LR=σBruttoσFließ
Kmat= KR
KI
LIMIT STATEnot safe
safe
MASTER CURVE[MPa m]
CORRELATION
Loads
Resistance
Limit Condition
FAD: Failure Assessment Diagram, e.g. in BS7910
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Result: Toughness requirements in EN13445/EN 13480
Des
ign
Ref
eren
ce T
empe
ratu
re, T
R
Charpy Test Temperature TKV
Method 2Method 1
Condition: TR = T KV
Limiting max. thicknessfor EN steel grades
given in tables
Method 3
Individual Fracture Mechanics Analysis
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Main achievements
1. The new and practical handling of steels from Harmonised European Standard
2. The reduction of test efforts on working plates.
3. The full revision of method 2 and method 1 including a new fracture mechanics based calculation model and extending to higher strength and austenitic-ferritic steels.
4. The consideration and acceptance of operation experienceinstead of the calculation model where appropriate.
5. The differentiation after materials for warm and cold goingvessels, where for warmgoing vessels no extra low temperature testing is required anymore.
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But !!!!!!, Still industrial need for improvements in 2009
1. Extension of Nomograms to plate thickness higher than 110 mm (Ferritic) up to 200 mm.
2. Temperature benefit factor TS for consideration of lower pressure utilisation is treated rather conservative in the EN standard.
3. The calibration of the calculation model to experience for low strength grades required (overcome dotted line for Steels with Re ≤ 355 MPa)
Consequence:3 new Work Items introduced on TC54 level in 2009.
Target dates depend on results from pre-normative research.
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The solution: pre-normative Research IMPEX 2009
No. Name Industry area Country
1 Arcelor Mittal (Industeel)
Steel France
2 Voest Alpine Steel Austria
3 Sandvick Steel Sweden
4 Otokumpu Steel Sweden
5 Dillinger Huette Steel Germany
6 Thyssen Krupp Steel Germany
7 Linde AG Engineering Germany
8 BASF End user Germany
Start of the project: 01.01.2009Duration: 12 monthWorking group: KTH (Sandstroem), RWTH (Muenstermann), IWT(Langenberg)Coordination: IWTprojects Ltd
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Work Items Overview
1. Extension of thickness limitations (tmax = 200 mm)2. Improvement of design benefit for Vessels with
reduced stress utilisation (TS –factor in EN 13445)3. Calibration of experience with low strength steels to
the design model
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Parameters to be considered
Input:
A. Material• Strength: f (TD)• Toughness f(T27J, T40J)
B. Stresses and Temperature• Primary Stresses σp• Secondary Stresses σs• Interaction rules• Design Temperature TD
C. Geometry• Failure assumption a/c = 0,33
and a = 0,25 t (>30 mm)• Thickness t (Weibull, Constraint)
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D. FAD• Stress intensity factor• Limit Load
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Comparison of failure assumptions in different codes
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New crack assumption
Crack depth a for EN13445 calculation model
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crac
k de
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alim = 15alim =20alim = 25a = 1/4t
EN13445:2009
NEW
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Verification by FEM calculations: effect of crack depth
Stress Triaxility
J-Integral
t = 60 – 200 mm
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Result:for a/t < 0,22 no effect of thickness on crack driving force
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Effect on toughness requirements
P355 Comparison NEW with EN13445:2009
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TD
EN13445-2:2009NEW proposal
55 mm, 40 J for t up to 110 mm
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ΔT = 2 K
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Result WI 1: Practical proposal for EN13445-2
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355 Mpa, EN
< 450 MPa,ASME
235 Mpa, EN
< 550 MPa, ASME
< 550 MPa, EN
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TRANSFER: New Design Table B2.15 in EN13445 included in Method 1
Specified minimum yield strength of base material
Required Impact energy KV (on 10x10 mm specimen) at
TR
max. thickness
MPa J mm
Re ≤ 275 MPa 27 200
Re ≤ 355 MPa 40 70 - 200
Re ≤ 460 MPa 60 65 - 200
Re ≤ 500 MPa 60 60 - 200
P355 : no dotted line P460
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Simplified steel selection within wide range of thickness
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WI 2: Improvement of design benefit or Vessels with reduced stress utilisation
Ratio of pressure induced principal membrane stress andmaximum allowable design stress
Membrane stress b
Condition > 75 % > 50 % ≤ 75 % ≤ 50 % ≤ 50 N/mm2
Non welded,post-weld heat treatedcondition a
0 °C + 10 °C + 25 °C + 50 °C
As welded conditionand reference thickness< 30 mm
0 °C 0 °C 0 °C + 40 °C
a Also applicable for equipment where all nozzles and non-temporary welded attachments are first welded to vessel components and these sub-assemblies are post-weld heat treated before being assembled into the equipment by butt-welding, but the main seams are not subsequently post-weld heat treated.b The membrane stress shall take account of internal and external pressure and dead weight. For walls and pipes of heat exchangers the restraint of free end displacement of the heat exchanger pipes should also be taken into account.
Table B2.12EN13445:2009
1. Background for stress reduction, what are the relevant parameters?2. Comparison among different codes, philosophies?3. Change of model to calculate effect of stress reduction?4. Role of secondary stresses?5. Performance of tests?
Hypothesis: With the help of the model the stress utilisation can be optimised.
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WI2: Comparison of TS in EN with other Standards
TS in °C 10 20 25 30 40 50 60 70 80
EN 13445 PWHT
Stress between 50% and
75%
---- Stress <
50%
---- ---- Membrane Stress
< 50MPa
---- ---- ----
EN 13445 AW ---- ---- ---- ---- Membrane Stress < 50MPa
---- ---- ---- ----
ASME VIII /1 0.82 0.64 0.57 0.52 0.44 0.41 0.38 0.36 0.35
PD 5500 2fn/3 ---- ---- ---- ---- Membrane Stress
< 50MPa
ADM W10 ---- ---- ---- ---- ---- Pressure < 75% or Pressure < 50%
---- ---- Pressure < 25%
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TS: comparison of standards, PWHT
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EN13445 PWHT, ≤ 50 MPaEN13445 PWHT, > 50 MPaASME, PWHTAD > 20 mm, with PWHTPD 5500, PWHT, ≤ 50 MPaPD 5500, PWHT, > 50 MPaAD > 10 mm, with PWHT
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Application of new calculation model
IWT, P355GH PWHTEffect of stress Reduction
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Change from T27 J to T40J
20 K
40 K
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NEW and TRANSFER: Proposal for change of TS for PWHT
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Conclusions
1. European Pressure vessel standards contain latest technology in design and material requierments !!
2. Active standardisation development requires support from industry !!!
3. Pre-normative research allows a fast transfer of new technologies into the standard.
4. Joint Industry Projects are an optimal instrument to improve standards on the fast track.
So, become part of the team.Join us and help us to make
standards economical, safe and sustainable.
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Thank you for your attention
IWTprojects Ltd and IWT Aachen (Ingenieurbuero)Mail: [email protected]: www.i-w-t.deWeb: www.bruchmechanik.infoPhone: +49 (0) 241 16 82 859
For further information, discussion and questions please contact me.