SATPC0035160 Tab 04 3 Specification_Redacted.pdf

SPECIFICATIONS FOR PROCUREMENT OF

E1 TEST STAND EXPANSION JOINTS FOR THE

LIQUID HYDROGEN VENT LINE

200GK-GM27

JOHN C. STENNIS SPACE CENTER

SSC, MISSISSIPPI 39529

PREPARED BY:

NASA

NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

Specification No: 200GK-GM27 Revision No: 0

TABLE OF CONTENTS

GENERAL REQUIREMENTS:

1.1 SUMMARY:

1.2 REFERENCES:

1.3 SUBMITTALS:

1.4 REQUIREMENTS:

1.5 QUALITY ASSURANCE

1.6 WELDING PROCEDURE AND WELDING OPERATOR QUALIFICATIONS:

1.7 GUARANTEE

1.8 PAINTING:

1.9 TESTING:

1.10 CLEANING AND PACKAGING:

APPENDICES:

APPENDIX A: EXPANSION JOINT DATA SHEETS

-- End of Project Table of Contents –

GENERAL REQUIREMENTS:

1.1 SUMMARY:

The specification provides the requirements for the design, fabrication, inspection, testing, cleaning, packaging, and delivery of the expansion joints indicated in the data sheets in the Appendix A.

1.2 REFERENCES:

The design, fabrication, testing, cleaning, and packaging shall be in accordance with the applicable sections of the following codes and standards, latest edition:

American Society of Mechanical Engineers (ASME) ASME B31.3 Process Piping, B31.3 ASME BPVC-V Section V, Nondestructive Examination ASME BPVC-IX Section IX, Welding and Brazing Qualifications ASME B36.10 Welded and Seamless Wrought Steel Pipe ASME B16.5 Pipe Flanges and Flanged Fittings ASME B16.47 Large Diameter Steel Flanges Expansion Joint Manufacturers’ Association (EJMA) EJMA Standards Standards of the Expansion Joint Manufacturers Association, Inc. (Latest Edition) National Aeronautics and Space Administration (NASA) RPTSTD-8070-0001 Surface Cleanliness Standard of Fluid Systems for Rocket

Engine Test Facilities of the NASA Rocket Propulsion Test Program

1.3 SUBMITTALS:

The following shall be submitted to the Contracting Officers Representative (COR) in sufficient detail to show full compliance with the specification. See Section 1.5 for requirements for surveillance and approvals:

1. Due within three weeks after award of contract:

Design calculations of the bellows and hardware including cycle life calculations Completed individual data sheets or an equivalent manufacturer’s document listing maximum design movements (axial, transverse, angular) that can be absorbed by the joint at the design pressure and temperature, expansion joint and all attachment materials, bellow material thickness, number of convolutions and weight of expansion joints.

Fabrication, Testing, and Inspection Schedule for each expansion joint The contractor shall provide informal updates at major milestones via email to the

COR on the status of each expansion joint.

2. Prior to Start of Fabrication:

Shop Fabrication Drawings of each expansion joint, which should include at a minimum the following:

o General arrangement o All dimensions and details of construction hardware, including end to end dimensions o Liners with drain hole pattern and dimensions o Tie rods and their respective tie rod ring guides o Design Pressure rating o Total weight of expansion joint o Bill of Materials, including material of construction o Weld Map

WPS – Welding Procedure Specifications PQR – Procedure Qualification Records WQT/WPQ – Welder Qualification Test / Welder Performance Qualifications Painting Specifications and Procedures (if applicable) Hydrostatic Leak Test Procedures per Section 1.9 of this specification Cleaning Procedures per Section 1.10 of this specification

3. Immediately after inspection and examination for review and approval by the

NASA Level III Inspector or designee:

100% Visual Inspection Report 100% Radiograph film and reports of all welds 100% Dye Pen of all welds that cannot be radiographed (if applicable) Hydrostatic Leak Test Report including test set-up configuration and log of time versus pressure The manufacturer shall furnish one hard copy and scanned copies of all certification and test reports to NASA within one week after completion of the work. Failure to meet any of the above specified tests’ requirements shall result in rejection of the equipment under test.

4. Prior to Shipment

Final electronic PDF binder for each expansion joint that includes a detailed as-built configuration drawing and all material certifications, inspection reports, functional test reports, and any other applicable documentation.

Detailed shipping list Contractor Guarantee Letter per Section 1.7: “The Contractor shall acknowledge his responsibility under these guarantee provisions by letter, stating the inclusive dates of the guarantee period for which the equipment and materials referred herein are guaranteed.”

A manufacturer that commences work without a NASA review to ensure compliance of the submittal with the specification assumes all risks associated with rework, delay and other effects resulting from a nonconforming article should a subsequent review reveal that the vendor’s submittal did not comply with the requirements of the specification.

1.4 REQUIREMENTS:

Each expansion joint shall be designed, fabricated, tested, cleaned, and delivered in accordance with the detailed requirements of this specification and the attached data sheets. The Contractor shall meet or exceed the requirements. The Contractor shall take whatever additional measures are necessary in his design, fabrication, inspection, and testing to produce an expansion joint, which will satisfactorily pass the tests specified herein without damage.

Where specific requirements are set forth, and where such specific requirements depart from requirements or alternatives contained in any documents referenced herein, the specific requirements contained herein shall govern and take precedence. The general requirements for each type of expansion joint are provided within the body of this specification with specific requirements for each expansion joint type provided in data sheets located in the appendices.

1.4.1 DESIGN

The following requirements shall be met for the design of metal expansion joints.

The bellows are to be designed in accordance with the referenced standards and codes in Section 1.2 of this specification.

Bellows material shall be specified and must be compatible with the flowing medium, the external environment, and the operating temperature.

The expansion joint shall be free of all control devices such as self-equalizing rings.

The tie-rods, or external hinge mechanisms, of the universal expansion joint shall be designed to take pressure thrust force plus an additional 5000 pounds of thrust force.

The tie-rods or external hinge mechanisms shall also be designed as the support for the whole unit. The vendor shall advise the customer if additional support is required.

If tie-rods are used, double nuts shall be provided with permanent locks to prevent unwanted movement.

Lifting lugs shall be provided for expansion joint weight of more than 200 pounds. If more than one lug, each lug should be designed to carry the entire weight.

Tie-rods and external hinge mechanism attachments that completely constrain circumferential expansion or contraction of the pipe are not permitted.

A purge connection shall be provided at the upstream side of each bellows section on each expansion joint assembly such that cleaning agents can be sprayed into the annulus section between the respective bellows and the liner and such that purge gases can be supplied into and vented out of the same annulus. Each of these purge connections shall be an SAE AS5202-16 (one inch) boss.

1.4.2 FABRICATION

Customer approval of drawings shall not relieve the manufacturer of responsibility for the bellow design.

When an internal liner or sleeve is required, a flow arrow indicating the direction of flow shall be plainly visible on the outside of the expansion joint.

A stainless steel name plate should be attached to the expansion joint permanently which shall have the information specified on the data sheet under Markings.

Noticeable punch or die marks resulting from thin expansion joints shall be cause of rejection.

Sheet material for bellows shall be free from flaws. No repairs of any nature shall be permitted.

1.5 QUALITY ASSURANCE:

The Contract Administrator and Government reserve the right for an authorized representative to inspect all work at all times during and upon completion of fabrication and to witness any or all tests. The Contractor shall notify the SSC COR or Government prior to start of fabrication as well as when the expansion joints are completed and ready for final inspection and test. The Contractor shall cooperate fully to enable the SSC COR or Government designated representative to be present at the performance of any or all tests and any other activity as specifically requested. The Contractor shall furnish all equipment and materials for all tests except where specially stated otherwise. The Contractor shall notify the COR fourteen calendar (14) calendar days prior to performance of any and all tests.

As a minimum, the following hold points shall apply:

Item No.

Surveillance Required for Before Proceeding to Requirement to satisfy

Hold Point

1 Design Calculations Fabrication Review and approval by NASA COR via email.

2 Fabrication Drawings Fabrication Review and approval by NASA COR via email.

WPS – Welding Procedure Specifications, PQR – Procedure

Qualification Records, and WQT/WPQ – Welder

Qualification Test/Welder Performance Qualifications

Fabrication

Review and approval by NASA COR via email.

Radiography Reader Sheets, and Material Test Reports (MTRs) for all metal parts (pressure containing parts as well as parts under load)

Examination and testing

Review and approval by NASA COR via email.

5 Review of Radiographs Forming of convolutions NASA Level III Inspector, Review and Approval

Hydrostatic Proof Test

Shipment On-site witness by NASA appointed representative.

Review of Examinations, and all Final Inspection Reports Shipment

NASA Level III Inspector, Review and Approval

1.6 WELDING PROCEDURE AND WELDING OPERATOR QUALIFICATIONS:

Welding procedure and welders qualifications shall be performed in accordance with Section IX of the ASME Boiler and Pressure Vessel Code.

All welds, including seam welds, shall be 100% radiographed in accordance with ASME B31.3 normal fluid service. Radiographs shall be submitted for approval prior to forming the convolutions. Welds that cannot be radiographically inspected shall be dye penetrant inspected using a solvent or water removal type penetrants. All welds shall be in accordance with ASME Section IX.

The longitudinal weld seams of the bellows shall be 100 percent radiographed before forming and 100 percent liquid penetrative examined after forming.

1.7 GUARANTEE:

All equipment to be furnished under this specification shall be guaranteed against defective materials, design, and workmanship for a period of one year from receipt of the expansion joint(s). Upon receipt of notice of failure of any part of the guaranteed equipment during the guarantee period, new replacement parts shall be furnished and installed promptly by the Contractor at no additional cost. The Contractor shall acknowledge his responsibility under these guarantee provisions by letter, stating the inclusive dates of the guarantee period for which the equipment and materials referred herein are guaranteed.

1.8 PAINTING:

Stainless steel or nickel base alloy shall not be painted.

1.9 TESTING:

Expansion joint testing shall be in accordance with the following:

A hydrostatic pressure test shall be performed by the manufacturer upon completion of the expansion joint fabrication, in accordance with ASME B31.3.

In performing the test, care must be taken to use test water of a temperature which will not cause sweating in hot humid weather. The Contractor must ensure that such water will not be detrimental or cause stress corrosion to the bellows material.

1.10 CLEANING AND PACKAGING:

Expansion joint cleaning shall be in accordance with the following:

Expansion joints shall be cleaned to the level indicated on the data sheet(s) per RPTSTD-8070-0001. Cleaning procedures shall be submitted and approved by NASA prior to expansion joint cleaning.

Expansion joint packaging and shipping shall be in accordance with the following:

A shipping bar shall be furnished to maintain proper shipping length and alignment.

The shipping bar shall be painted yellow.

Each expansion joint shall be tagged with recommended installation instructions.

Openings shall be covered with a protective plate.

Adequate packaging of parts and components shall be provided as required, in addition to the packaging hereinafter specified, to protect the parts and components during handling, shipping, and storage in accordance with RPTSTD-8070-0001.

The manufacturer shall be responsible for shipment of expansion joints such that they arrive undamaged, with cleanliness intact, and suitable for six months of outdoor storage.

-- End of Section --

APPENDICES:

APPENDIX A: EXPANSION JOINT DATA SHEETS

30” Universal Tied Expansion Joint Data Sheet

QUANTITY REQUIRED 1

LOCATOR (TAG) NUMBER EJ-10A14-HV

FUNCTION Expansion Joint

SERVICE MEDIA

Compatibility Liquid and Gaseous Hydrogen, Methane, and Natural Gas

PRESSURE

Design Pressure (max) 150 psig

TEMPERATURE

Design Temperature Range -423 °F to +150 °F

Tie-In (Ambient) 40 - 100 °F

FLOW CONDITION Worst Case: GH2 at 500-560 R, 32.5- 89 PSIA, 2000 FPS Normal Case: GH2 at 37 - 60 R, 20 - 25 PSIA, 450 FPS

PIPE DIAMETER

SCH/THICKNESS

30”

SCH 5S

END CONNECTIONS (Inlet/Outlet) 150# ASME B16.47 Series B Raised Face Flange Weld Neck, 2-hole, bored for SCH 5S. Flange face shall contain 90 degree “V” groove rings and serrations per the following: concentric 24 to 35 per inch (10 to-14 cm); Depth approx. 0.008 to 0.015 in (0.02 to

0.038 mm) the resultant surface finish shall have a 125 to 250 µin (3.2 to 6.3 µm) Ra. A 0.015” radius machine tool tip will achieve the serration depth.

LINER Yes

LENGTH, END TO END 15’- 4 1/4”

ENVIRONMENT

External Operating Environment Expansion Joint will be outdoors, exposed to 0 °F to 120 °F and 100% maximum relative humidity

MATERIALS

Body ASTM A358 TP304L CL5

Bellows ASTM A240-321

Flange ASTM A182 GR304L

Liner Stainless Steel –-304/304L Dual Rated, liners shall include drain holes on the inlet side of each liner

Collar Stainless Steel –-304/304L Dual Rated

Rods/Nuts/Tie Plates Stainless Steel – 304

MOVEMENTS AND LIFE CYCLE (DESIGN)

Axial (Ext) 0.6”

Lateral (Nominal) +/- 6”

Number of Cycles (EJMA) 5000

X PERM REACTIONS

Lateral (see note 1) 2000 lbs

TIE RODS/EXTERNAL HINGE

MECHANISM

3 tie rods minimum or upper and lower external hinge mechanisms with hinge for each bellows section

SPRING CONSTANT

Axial 3000 lb/in, maximum

Lateral 240 lb/in, maximum

Angular 6,000 in-lbs/deg, maximum

Torsional 1 x 107 in-lbs/deg, maximum

INSTALLATION Horizontal

VIBRATION No

INSPECTION/EXAMINATION

Welds All welds shall meet ASME B31.3 Process Piping and Boiler and Pressure Vessel Code, Div. 1 Sections V, IX.

Shielding/Backing gas shall be Argon only.

Visual All pressure containing parts

Radiography All welds on pressure containing parts

Dye Penetrant All welds that cannot be fully radiographed (if applicable)

CLEANING VC per RPTSTD-8070-0001

MARKINGS ꞏ Manufacturer Name

ꞏ EJ #

ꞏ Serial # ꞏ Nominal Size ꞏ Design Pressure ꞏ Temperature Rating ꞏ Flow Arrow ꞏ Weight ꞏ Date of Manufacture

COMMENTS FOR 30” UNIVERSAL TIED EXPANSION JOINT:

Note 1. 12” Lateral movement with a consideration of 6” cold spring. The EJ will be installed at 6” offset on one side and offset in the opposite direction 6” during operation.

Note 2. An additional tensile load of 5,000 lb shall be added to the tie rod design.

Note 3. Manufacturer shall preset the EJ to a lateral offset of 5 ½”.

42” Universal Tied Expansion Joint Data Sheet

QUANTITY REQUIRED 1

LOCATOR NUMBER(S) EJ-10A05-HV

LINE DESCRIPTION 42”-GH-0074-NCK3, to flare FK-10A05-HV

SERVICE MEDIA

Compatibility Liquid and Gaseous Hydrogen, Methane, and Natural Gas

PRESSURES

Design Pressure 150 psig

TEMPERATURE

Design Temperature Range -423 °F to +150 °F

Tie-In (Ambient) 40 - 100 °F

FLOW CONDITION Worst Case: GH2 at 500-520 R, 32.5- 42 PSIA, 2700 FPS Normal Case: GH2 at 37- 60 R, 16 - 20 PSIA, 300-350 FPS

PIPE DIAMETER

SCH/THICKNESS

42”

STD

END CONNECTIONS (Inlet/Outlet) 150# ASME B16.47 Series B Raised Face Flange Weld Neck, 2-hole, bored for SCH STD pipe. Flange face shall contain 90 degree “V” groove rings and serrations per the following: concentric 24 to 35 per inch (10 to-14 cm); Depth approx. 0.008 to 0.015 in (0.02 to

0.038 mm) the resultant surface finish shall have a 125 to 250 µin (3.2 to 6.3 µm) Ra. A 0.015” radius machine tool tip will achieve the serration depth.

LINER Yes

OVERALL LENGTH 14’-0”

ENVIRONMENT

External Operating Environment Expansion Joint will be outdoors, exposed to 0 °F to 120 °F and 100% maximum relative humidity

MATERIALS

Body ASTM A358 TP304L CL5

Bellows ASTM A240-321

Flange ASTM A182 GR304L

Liner Stainless Steel –-304/304L Dual Rated, liners shall include drain holes on the inlet side of each liner

Collar Stainless Steel –-304/304L Dual Rated

Rods/Nuts/Tie Plates Stainless Steel – 304

MOVEMENTS AND LIFE CYCLE (DESIGN)

Axial (Ext) (see note 1) 0.6”

Lateral (Nominal) (see note 2) +/- 6.5”

Number of Cycles (EJMA) 4300

X PERM REACTIONS

Lateral 2500 lbs

TIE RODS/EXTERNAL HINGE

MECHANISM

3 tie rods minimum or upper and lower external hinge mechanisms with hinge for each bellows section

SPRING CONSTANT

Axial 2000 lb/in, maximum

Lateral 1,000 lb/in, maximum

Angular 20,000 in-lbs/deg, maximum

Torsional 1.2 x 109 in-lbs/deg, maximum

INSTALLATION Horizontal

VIBRATION No

INSPECTION/EXAMINATION

Welds All welds shall meet ASME B31.3 Process Piping and Boiler and Pressure Vessel Code, Div. 1 Sections V, IX.

Shielding/Backing gas shall be Argon only.

Visual All pressure containing parts

Radiography All welds on pressure containing parts Dye Penetrant All welds that cannot be fully radiographed (if applicable)

TESTING

Pressure Test See Section 1.9 of this specification.

Leak Test See Section 1.9 of this specification.

CLEANING VC per RPTSTD-8070-0001 MARKINGS ꞏ Manufacturer Name

ꞏ EJ #

ꞏ Serial # ꞏ Nominal Size ꞏ Design Pressure ꞏ Temperature Rating ꞏ Flow Arrow ꞏ Weight ꞏ Date of Manufacture

COMMENTS FOR 42” UNIVERSAL TIED EXPANSION JOINT:

Note 1. EJ design must allow for longitudinal and lateral movements between tie rods to enable lateral offsets specified in Note 2 without interferences, bending, or overstressing of the tie rods.

Note 2. 13” Lateral movement with a consideration of 6” cold spring. The EJ will be installed at 6” offset on one side and offset in the opposite direction 7” during operation.

Note 3. Manufacturer shall preset the EJ to offset 5 ¾”

THIS PAGE INTENTIONALLY LEFT BLANK