An Overview of Pressure Boundary Integrity Requirements

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your success is our goal
SEC III - An Overview

Richard W. Barnes, M. Eng. Sc., P.E., FASME
Pressure Boundary Integrity

The principal technical requirements are contained in the
ASME BPV Code, Section III, Div. 1
The approach to pressure boundary integrity is

ANRIC
“No Pressure Boundary Failure”

CODE WORDS: “The objective of the rules is to afford reasonably
certain protection of life and property, and to provide a margin for
deterioration in service to give a reasonably long, safe period of
usefulness.”
1
Integrity of The Nuclear Power Plant
Pressure Boundary
The integrity of the Pressure Boundary is

achieved through a
Controlled, Systematic Approach
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Control & Systematic
 What do we mean by control?

 Defined requirements which are required to be implemented
What do we mean by systematic?

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
 Repeatable steps of recognized processes that produce the
pressure boundary integrity required
2
Control
Embodies the concepts of:
 Responsibility
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 Accountability
 Compliance and enforcement
Systematic
Basic Elements Addressed
 Materials
 Design
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 Fabrication & installation

 Examination
 Testing
 Overpressure
 Quality management system
3
The Whole Item
 Materials
 Design
 Fabrication & Installation
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 Examination
 Testing
 Quality Assurance
 Stamping
Underlying Assumption
Personnel involved in the implementation of these principles are

people who
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“WANT to produce a SAFE product”
4
Organization of Section III
 Division 1 - Metallic Components
 Division 2 - Concrete Containments

ANRIC
 Division 3 - Containment for Transportation and Storage of Spent Nuclear

Fuel and High Level Radioactive Material and Waste
 Division 4 - Fusion Facilities
 Division 5 - High Temperature Reactors
Books of Section III, Div. 1

Subsection NCA General Requirements for Div.1 & 2
Subsection NB Class 1 Components
Subsection NC Class 2 Components
Subsection ND Class 3 Components
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Subsection NE Class MC Components

Subsection NF Supports
Subsection NG Core Support Structures
Subsection NH Class 1 Components in Elevated Temperature Service
Appendices & Code Cases - Nuclear Components
5
Related Sections
 Section II Materials
 Section V Nondestructive Examination

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 Section IX Welding, Brazing and Fusing
 Section XI Nuclear Inservice Inspection
Foreword
 Important guidance
 Objective of the rules
 The code is NOT a handbook
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 Official interpretations
 Does not endorse method of design or form of construction
6
Fundamental Concepts
 Code Class - What is Code Class?

 CSA N285.0 Definition
ANRIC
 ASME Definition NCA-9000
Code Classes in N285.0-12
Class 1 - Systems that directly cool the fuel and could result in Loss of
Coolant Accident (LOCA).
Class 2 - Systems penetrating the containment

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Class 3 - System other than class 1, 2, that contain fluid with > 2Ci/kg
Class 4 - Containment components
Class 6 - System that contain fluid with activity level ≤ 2Ci/kg
7
Code Class - NCA-9200
Code Class:
“the classification, specified by the Owner (or his
designee) and included in the Design Specification, that
ANRIC
establishes the rules for design and construction of

items.”
NCA- 2120
Purpose of Classification
CODE WORDS:
“Within these systems the Code recognizes the different levels of

importance associated with the function of each item as related
ANRIC
to the safe operation of the nuclear power plant.
The Code classes allow a choice of rules that provide assurance

of structural integrity and quality commensurate with the relative
importance assigned to the individual items of the nuclear power
plant.”
8
Other Important Terms
Glossary: NCA-9000
 Certificate of Authorization, Certificate of Compliance
 Certification, Certified material Test Report
 Data Report, Load Capacity Data Sheet
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 Design Limits & Service Limits, Jurisdictional Boundaries

 Material Organization (Manufacture & Supply)
 Piping System
Section III
IS A COMPONENT CODE
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9
Basic Concepts
 Material
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 Component
What is Material
Material:
For Section III, Division 1,
metallic materials manufactured to an SA, SB, SFA, or any other
material specification permitted in Section III and that are
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manufactured, identified, and certified in accordance with the

requirements of Section III.
For Section III, Division 2,
metallic materials, as well as nonmetallic materials, conforming to the
specifications permitted in Section III.
10
What is a Component
Component:
A vessel, concrete containment, pump, pressure relief valve,
line valve, storage tank, piping system, or core support
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structure that is designed, constructed, and stamped in

accordance with the rules of this section
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ASME Section III

Materials
11
Section III Material Requirements
 Material Specification
 Section II: Parts A, B, C, & D
 Control of Material
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 Section III: NCA-3800

 Special Material Requirements
 Section III: NX-2000
Important Concepts
TRACEABILITY
 Identification
NCA-3856 Identification, Marking, and Material Control
NB-4122 Material Identification
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 Certification of Material
NCA-3861 Certification Requirements for Material Organizations
NCA-3862 Certification of Material
12
Material Requirements:
NB-2000
 NB-2100 General Requirements for Materials
 NB-2200 Material Test Coupons and Specimens for Ferritic Steel
 NB-2300 Fracture Toughness Requirements for Materials
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 NB-2400 Welding Material

 NB-2500 Examination and Repair of Pressure Retaining Material
 NB-2600 Material Organizations’ Quality System Programs
 NB-2700 Dimensional Standards
NB-2121
Permitted Material Specifications
 Pressure retaining material shall conform to the
specifications in Section II, Part D, Subpart 1, Tables 2A
and 2B and to all the requirements of Article NB-2000
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13
ANRIC
Control of Material
NCA-3800
Material Control: NCA-3800

 Scope and Applicability: NCA-3810
 Limitations: NCA-3811
 Exclusions: NCA-3812
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 Certification or Qualification of Material Organizations: NCA-3820

 Responsibilities of Material Organizations: NCA-3830
14
Material Control: NCA-3800
 Evaluation of the Program: NCA-3840
 Evaluation by the Society: NCA-3841
 Evaluation by Parties other than the Society: NCA-3842
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Quality System Program Requirements: NCA-3850

 Certification Requirements: NCA-3860
Entities
 Certificate Holders
 Material Organizations
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 Approved Suppliers
15
Activities of Entities
 Performance of :
 Operations
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 Processes
 Services
Activities Associated with
 Procurement
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 Manufacture
 Supply
16
Entities Supply
 Material
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 Source Material
 Unqualified Source Material
Furnish Material Type

 Supply of Material
 MO or CH
 Supply of Qualified Source Material

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 MO, CH, AS
 Supply of Services
 MO, CH, AS
17
PROCESS OF APPROVAL
The Society
Accredits
Material
Manufacturer
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Organization
Qualifies
Material Material
Organization Organization
Approves
Approved Approved
Supplier Supplier
NB-2100
Other Requirements
 Special requirements conflicting with permitted material
specifications - NB-2122
 Certification of material: NB 2130
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 Welding material: NB 2140

 Material identification: NB 2150
18
NB-2610
Other Requirements
NB–2600 Material Organizations’ Quality System Programs
NB -2610 Documentation and Maintenance of Quality
System Programs
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ASME Section III

Components
19
Components
 The types, responsibilities and duties of Certificate Holders
 Design
 Fabrication, Examination and Testing
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 Quality Assurance
 Authorized Inspection
 Overpressure Protection
 Stamping
NCA-3000
Responsibilities and Duties
NCA-3100 General
NCA-3200 Owner's Responsibilities
NCA-3500 Responsibility of an N Certificate Holder -Division 1

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NCA-3600 Responsibilities of an NPT Certificate Holder
NCA-3680 Responsibilities of an NS Certificate Holder
NCA-3700 Responsibilities of an NA Certificate Holder
20
Important Concepts
 Code Responsibilities vs Legal Liabilities
 Types of Accreditation,
Table: NCA-8100-1
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 Subcontracted Services
Responsibility of the Owner

Categories of owner's responsibility
 Owner's certificate
 Provision of adequate supporting structures
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 Provision of design specification

 Review of design report
 Overpressure protection report
 Owner's data report and filing
 Owner's responsibility for records
21
Definition
N Certificate Holder
The organization assuming responsibility for Code
Compliance with respect to, material, design,
fabrication, installation, examination, testing,
inspection, certification, and stamping for items
ANRIC
requiring a Certification Mark with N Designator.
NCA-3500
Responsibility N Certificate Holder
Categories of the N Certificate Holder’s Responsibilities
 Obtaining a Certificate
 Compliance with this Section
Requirements for Design Output Documents
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
 Responsibility for quality assurance

 Scope of Responsibilities
 Documentation of Quality Assurance Program
 Filing of Quality Assurance Manual
 Data Report
22
NCA-3550
The drawings used for construction shall comply with the

Design Specifications and the rules of this Section and shall
be in agreement with the other design output documents.
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NCA-3550
Specific Requirements:
 Design Report
 Load Capacity Data Sheet
 Certified Design Report Summary
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 Design Output Documents for Parts

 Design Output Document for Appurtenances
 Modification of Documents and Reconciliation with Design Report
 Certification of Design Report
 Submittal of Design Report
23
Definition
NPT Certificate Holder
The organization that fabricates parts, piping
subassemblies, or appurtenances requiring a
Certification Mark with NPT Designator.
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NCA-3600
Responsibilities NPT Certificate Holder
Categories of the NPT Certificate Holder’s responsibilities
 Compliance with this section
Design Documents for Appurtenances
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 Responsibility for Quality Assurance Program

 Data report
24
Definition
NS Certificate Holder
The organization holding a valid NS Certificate of
Authorization issued by the Society that constructs,
including construction by welding of all classes of
supports, and all classes of standard supports. The NS
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Certificate Holder is not required to apply a

Certification Mark.
NCA-3680
Responsibilities NS Certificate Holder
Categories of the NS Certificate Holder’s responsibilities
 Compliance with this section
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 Scope of Responsibilities
 Filing of Quality Assurance Program
 NS-1 Certificate of Conformance
 Certificate of Compliance
25
ANRIC
ASME Section III

Fabrication
NB-4000
Fabrication and Installation
NB-4100 General Requirements
NB-4200 Forming, Fitting and Aligning
NB-4300 Welding Qualifications
NB-4400 Rules Governing Making, Examining and Repairing Welds
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NB-4500 Brazing
NB-4600 Heat Treatment
NB-4700 Mechanical Joints
26
ND-4000
Fabrication and Installation
ND-4100 General Requirements
ND-4200 Forming, Fitting and Aligning
ND-4300 Welding Qualifications
ND-4400 Rules Governing Making, Examining and Repairing Welds
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ND-4500 Brazing
ND-4600 Heat Treatment
ND-4700 Mechanical Joints
ND-4800 Expansion Joints
Fabrication
A Few Important Aspects
NB-4120 Certification of Material and Fabrication by the certificate
Holder
NB-4122 Material Identification
NB-4130 Repair of Material
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NB-4240 Requirements for Weld Joints in Components- Relationship

of Design, Fabrication and Examination -
NB-4250 Welding End Transitions Maximum Envelope
NB-4430 Welding of Attachments
27
NB-3350
Design of Welded Construction for Vessels
Welded Joint Category Permissible Types of

 Category A Welded Joints
 Category B  Joints of Category A
Category C
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Joints of Category B
 
 Category D  Joints of Category C

 Joints of Category D
Figure NB-3351-1
Welded Joint Locations Typical of Categories A, B, C, and D
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28
Design, Fabrication, Examination
NB-4240
Requirements for Weld Joints in Components
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NB-5200
Required Examination of Welds
Other Articles
NB-4250
Welding End Transitions Maximum Envelope
NB-4430
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Welding of Attachments
29
PIPE WELD
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F ig u re N B -4 2 5 0 -1
W e ld in g E n d T ra n s itio n s — M a xim u m E n v e lo p e
t m in
2 1 1 / 2 t min
Outside
Radius of at least 0.05tmin
45 deg max. Radiu s no t m an datory
30 deg max.
Component or Fitting
M a xim um [N ote (1)]

tn o m t m in M inimu m (1.0tm in )
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30 deg max.
Note (2)
Maxim u m slope 1:3
Radius of at least 0.05tmin

Inside
2tm in
Transition reg ion
G E N ERA L N O TE S:
(a) Weld bevel is shown for illustration only.
(b) The w eld re inforceme nt perm itted by N B -4426 m ay lie outside the m aximum envelope.
NOTES:
(1) The maxim um thickness at the end of the com ponent is:
(a) the greater of t m i n + 0.15 in. (3.8 m m ) or 1.15 t m i n w hen ordered on a minim um wall basis;
(b) the greater of tm i n + 0.15 in. (3.8 m m) or 1.0t nom when ordered on a nom inal wall basis.
(2) The value of t m i n is w hichever of the following is applicable:
(a) the minim um ordered wa ll thickness of the pipe;
(b) 0.875 tim es the nom inal wall thickness of pipe ordered to a pipe sche dule w all thickne ss which has an unde r toleranc e of 12.5%;
(c) the m inim um ordered wall th ickness of the cylindrical welding end o f a c om ponent or fitting (or the thinner of the tw o) w hen th e
joint is between tw o com ponents.
30
ANRIC
ASME Section III

Examination
NB-5000 Examination
General Requirements (NB-5100)
Examination of Welds (NB-5200)
Acceptance Standards (NB-5300)
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Final Examination of Vessels (NB-5400)

Qualification and Certification of NDE Personnel (NB-5500)
31
NB-5110
Methods, NDE Procedures and Cleaning
NB-5111 NDE conducted in accordance with Section V, Article 2,
except as modified by NB-5000
NB-5112 NDE performed detailed written procedures proven by actual

demonstration to the satisfaction of the inspector. Procedure shall
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comply with the appropriate Article of Section V.
NB-5113 NDE requiring application of examination materials, the piece

shall be thoroughly cleaned in accordance with material or procedure
specification
NB-5130
Weld Edge Preparation Surfaces
All full penetration weld edge preparation surfaces for joint categories
A,B,C & D and similar joints in material 2” thick or greater shall be
examined by MP or LP
ANRIC
32
NB-5140
Welds and Adjacent Base Material
Surface examination of Category A, B, C and D and the equivalent
welded joints in piping, pumps and valves shall include the external,
and accessible internal weld surfaces and adjacent base material for at
least ½” on each side of the weld
ANRIC
Acceptance standards for the weld Article NB-5000 while for base
material it shall be NB-2500
NB-5200
Butt Welds - Radiographic & LP or MP
 Cat. A Vessel & Long. welded joints other components
 Cat. B Vessel & cir. joints (butt) piping, pumps & valves
 Cat. C (butt) Vessel & similar joints in other components
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 Cat. D (butt) Full penetration vessel nozzle, branch & piping

connections
33
NB-5200
Other Welds - Ultrasonic, MP, LP, Visual
 Corner welds (Ultrasonic & MP or LP)
 Fillet, partial penetration, and socket welded joints (LP or MP)
Structural attachment (MP or LP), weld metal cladding (LP),
ANRIC

Tube-to-tube-sheet (LP), hard surfacing (LP), brazed

(Visual), electroslag welds (Ultrasonic)
NB-5300
Acceptance Standards
 Radiographic
 Ultrasonic
 Magnetic Particle
ANRIC
 Liquid Penetrant
 Visual Acceptance
 Gas Bubble Testing
34
NB-5500
Qualification and Certification
ASME references SNT-TC-1A

ANRIC
N285.0 references CGSB 48.9712
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ASME Section III

Design
35
Design Basis: NCA-2140
 Consideration of Plant and System Operating & Test Conditions
 Establishment of Design, Service, and Test loadings and Limits:
 Design Loadings
ANRIC
 Service Loadings
 Test Loadings
 Design, Service and Test Limits
 Acceptance Criteria
Stress / Strain Curve

ANRIC
36
ANRIC
ANRIC
Fatigue Curve
Loads & Limits
37
NX-1130
Boundaries of Jurisdiction
 Boundary between components
 Boundary between components and attachments

 Attachment type & requirements
ANRIC
 Jurisdictional requirements
 Other requirements
Design NB-3000
NB-3100 General Design
NB-3200 Design by Analysis
NB-3300 Vessel Design
ANRIC
NB-3400 Pump Design

NB-3500 Valve Design
NB-3600 Piping Design
38
Design NC-3000
NC-3100 General Design
NC-3200 Alternate Design Rules for Vessels
NC-3300 Vessel Design
NC-3400 Pump Design
ANRIC
NC-3500 Valve Design

NC-3600 Piping Design
NC-3700 Electrical and Mechanical Penetration Assemblies
NC-3800 Atmospheric Storage Tanks
NC-3900 Storage Tanks 0-15 psig (0-103 kPa)
Design ND-3000
ND-3100 General Design
ND-3300 Vessel Design
ND-3400 Pump Design
ND-3500 Valve Design
ANRIC
ND-3600 Piping Design

ND-3700 Electrical and Mechanical Penetration Assemblies
ND-3800 Atmospheric Storage Tanks
ND-3900 Storage Tanks 0-15 psig (0-103 kPa)
39
Theories of Failures
 Maximum Shear Stress Theory
 Class 1 Design by analysis
 Class 2 Design by analysis
ANRIC
 Maximum Stress Theory

 Class 2 Design by rule
 Class 3 Design by rule
NB-3200
Design by Analysis
 Stress Categories
 Primary, Secondary and Peak
 Classification of Stress Intensity

ANRIC
 Limits on Stress Intensity

 Design limits
 Service limits
40
Stress Categories
There are 3 stress categories which must be considered under
the design by analysis rules.
PRIMARY STRESS - divided into 3 separate categories

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 General primary membrane stress

 Local primary membrane stress
 Primary bending stress
Idealized Stress-
Strain Relationship
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41
Chief Characteristics Of Stress
Categories
NB-3213.8: Primary stress is any normal stress or a shear
stress developed by an imposed loading which is necessary to
satisfy the laws of equilibrium of external and internal forces and
moments. The basic characteristic of a primary stress is that it is
ANRIC
not self-limiting.
Primary stresses which considerably exceed the yield strength
will result in failure or, at least, in gross distortion. A thermal
stress is not classified as a primary stress.

Categories
Primary membrane stress is divided into general and local
categories. A general primary membrane stress is one which is so
distributed in the structure that no redistribution of load occurs as
a result of yielding. Examples of primary stresses are:
ANRIC
(a) general membrane stress in a circular cylindrical or a spherical shell

due to internal pressure or to distributed live loads;
(b) bending stress in the central portion of a flat head due to pressure.
42
Stress Categories
SECONDARY STRESS - determines whether elastic or
Plastic cycling occurs
PEAK STRESS - for fatigue evaluation

ANRIC

Categories…
NB-3213.9: Secondary stress is a normal stress or a shear stress
developed by the constraint of adjacent material or by self-constraint
of the structure.
The basic characteristic of a secondary stress is that it is self-limiting.
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Local yielding and minor distortions can satisfy the conditions which
cause the stress to occur and failure from one application of the stress
is not to be expected.
43
Categories…
Examples of secondary stresses are:
(a) General thermal stress NB-3213.13(a);
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(b) Bending stress at a gross structural discontinuity.
Saddle
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44
Categories…
NB-3213.11: Peak stress is that increment of stress which is
additive to the primary plus secondary stresses by reason of local
discontinuities or local thermal stress [NB-3213.13(b)] including the
effects, if any, of stress concentrations.
ANRIC
The basic characteristic of a peak stress is that it does not cause any
noticeable distortion and is objectionable only as a possible source of a
fatigue crack or a brittle fracture.

Categories…
A stress which is not highly localized falls into this category if it is of a
type which cannot cause noticeable distortion. Examples of peak
stresses are:
 The thermal stress in the austenitic steel cladding of a carbon steel
component;
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 Certain thermal stresses which may cause fatigue but not distortion;
 The stress at a local structural discontinuity;
 Surface stresses produced by thermal shock.
45
Local Membrane Stress
NB-3213.10: Local membrane stress causes arise in which a
membrane stress produced by pressure or other mechanical loading
and associated with a discontinuity would, if not limited, produce
excessive distortion in the transfer of load to other portions of the
structure.
ANRIC
Conservatism requires that such a stress be classified as a local

primary membrane stress even though it has some characteristics of a
secondary stress.
Local Membrane Stress

A stressed region may be considered local if the distance over which
the membrane stress intensity exceeds 1.1Sm does not extend in the
meridional direction more than 1.0 (Rt)^0.5, where R is the minimum
midsurface radius of curvature and t is the minimum thickness in the
region considered.
ANRIC
46
Thermal Stresses
Thermal stresses are never classified as primary stresses but are in
both the secondary and peak category. Thermal stresses which can
produce distortion of the structure are placed in the secondary
category and thermal stresses which result from almost complete
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suppression of the differential expansion are placed in the peak

category since no significant distortion occurs.
Thermal Stresses
Stress Classification Tables
The following tables are taken from section III and provide
examples of stress intensities and allowable stresses for some
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typical cases. The footnotes, are important to review.

47
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48
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BEYOND YIELD
CODE LIMITS
STRAIN HISTORY
49
Design and Service Limits Stress
Categories
Primary Stress Limits are intended to prevent plastic deformation and to
provide a nominal factor of safety on the ductile burst pressure.
Primary plus Secondary Stress Limits are intended to prevent excessive

plastic deformation leading to incremental collapse, and to validate the
application of elastic analysis when performing the fatigue evaluation.
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Peak Stress Limit is intended to prevent fatigue failure as a result of cyclic

loadings.
Special Stress Limits are provided for elastic and inelastic instability.
F ig u re N B -3 2 2 1 -1
Stress Categories and Limits of Stress Intensity for Design Conditions
ANRIC
NOTES:
(1 ) B end ing com pon ent o f prim ary stress for pip ing shall be the stress prop ortion al to the distance from centroid of p ipe cross section.
(2 ) The symbols Pm , P L , and Pb do not represent single quantities, but rather sets of six quantities representing the six stress components σ t ,
σ l , σ r , τ l t , τ l r , an d τ r t .
50
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Limit Stress for

Combined Tension
and Bending
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(rectangular section)
51
Failure Mechanisms & Strain
 Vessels
 Valves
ANRIC
 Pumps
 Piping
52

An Overview of Pressure Boundary Integrity Requirements

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An Overview of Pressure Boundary Integrity Requirements

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ANRIC

your success is our goal

SEC III - An Overview

Pressure Boundary Integrity

The approach to pressure boundary integrity is

“No Pressure Boundary Failure”

The integrity of the Pressure Boundary is

Control & Systematic

 What do we mean by control?

What do we mean by systematic?

Embodies the concepts of:

 Compliance and enforcement

 Fabrication & installation

Personnel involved in the implementation of these principles are

“WANT to produce a SAFE product”

 Division 2 - Concrete Containments

 Division 3 - Containment for Transportation and Storage of Spent Nuclear

 Division 4 - Fusion Facilities

 Division 5 - High Temperature Reactors

Books of Section III, Div. 1

Subsection NE Class MC Components

 Section V Nondestructive Examination

 Section IX Welding, Brazing and Fusing

 Section XI Nuclear Inservice Inspection

 Code Class - What is Code Class?

 ASME Definition NCA-9000

Code Classes in N285.0-12

Class 2 - Systems penetrating the containment

Class 4 - Containment components

Class 6 - System that contain fluid with activity level ≤ 2Ci/kg

establishes the rules for design and construction of

“Within these systems the Code recognizes the different levels of

to the safe operation of the nuclear power plant.

The Code classes allow a choice of rules that provide assurance

 Design Limits & Service Limits, Jurisdictional Boundaries

manufactured, identified, and certified in accordance with the

structure that is designed, constructed, and stamped in

ASME Section III

 Section III: NCA-3800

 NB-2400 Welding Material

Material Control: NCA-3800

 Certification or Qualification of Material Organizations: NCA-3820

Quality System Program Requirements: NCA-3850

 Certification Requirements: NCA-3860

Activities Associated with

 Unqualified Source Material

Furnish Material Type

 Supply of Qualified Source Material

 Welding material: NB 2140

ASME Section III

NCA-3200 Owner's Responsibilities

NCA-3500 Responsibility of an N Certificate Holder -Division 1

NCA-3600 Responsibilities of an NPT Certificate Holder

NCA-3680 Responsibilities of an NS Certificate Holder

NCA-3700 Responsibilities of an NA Certificate Holder

Responsibility of the Owner

 Provision of design specification

requiring a Certification Mark with N Designator.

 Responsibility for quality assurance

The drawings used for construction shall comply with the

 Design Output Documents for Parts

 Responsibility for Quality Assurance Program

Certificate Holder is not required to apply a