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A technical overview and information on metallic pressure containment vessels and tanks is given. The intent is to provide Occupational Safety and Health Administration (OSHA) personnel and other persons with information to assist in the evaluation of the safety of operating pressure vessels and low pressure storage tanks. The scope is limited to general industrial application vessels and tanks constructed of carbon or low alloy steels and used at temperatures between -75 and 315 C (-100 and 600 F). Information on design codes, materials, fabrication processes, inspection and testing applicable to the vessels and tanks are presented. The majority of the vessels and tanks are made to the rules and requirements of ASME Code Section VIII or API Standard 620. The causes of deterioration and damage in operation are described and methods and capabilities of detecting serious damage and cracking are discussed. Guidelines and recommendations formulated by various groups to inspect for the damages being found and to mitigate the causes and effects of the problems are presented.

This three-year project (FY12-14) will design and demonstrate the ability of new Magnetic Stress Gages for the measurement of stresses on the inner diameter of a Composite Overwrapped Pressure Vessel overwrap. The sensors are being tested at White Sands Testing Facility (WSTF) where the results will be correlated with a known nondestructive technique acoustic emission. The gages will be produced utilizing Meandering Winding Magnetometer (MWM) and/or MWM array eddy current technology. The ultimate goal is to utilize this technology for the health monitoring of Composite Overwrapped Pressure Vessels for all future flight programs. The first full-scale pressurization test was performed at WSTF in June 2012. The goals of this test were to determine adaptations of the magnetic stress gauge instrumentation that would be necessary to allow multiple sensors to monitor the vessel's condition simultaneously and to determine how the sensor response changes with sensor selection and orientation. The second full scale pressurization test was performed at WSTF in August 2012. The goals of this test were to monitor the vessel's condition with multiple sensors simultaneously, to determine the viability of the multiplexing units (MUX) for the application, and to determine if the sensor responses in different orientations are repeatable. For both sets of tests the vessel was pressured up to 6,000 psi to simulate maximum operating pressure. Acoustic events were observed during the first pressurization cycle. This suggested that the extended storage period prior to use of this bottle led to a relaxation of the residual stresses imparted during auto-frettage. The pressurization tests successfully demonstrated the use of multiplexers with multiple MWM arrays to monitor a vessel. It was discovered that depending upon the sensor orientation, the frequencies, and the sense element, the MWM arrays can provide a variety of complementary information about the composite overwrapped pressure

Fiber reinforced polymer composite materials with their higher specific strength, moduli and tailorability characteristics will result in reduction of weight of the structure. The composite pressure vessels with integrated end domes develop hoop stresses that are twice longitudinal stresses and when isotropic materials like metals are used for development of the hardware and the material is not fully utilized in the longitudinal/meridional direction resulting in over weight components. The determination of a proper winding angles and thickness is very important to decrease manufacturing difficulties and to increase structural efficiency. In the present study a methodology is developed to understand structural characteristics of filament wound pressure vessels with integrated end domes. Progressive ply wise failure analysis of composite pressure vessel with geodesic end domes is carried out to determine matrix crack failure, burst pressure values at various positions of the shell. A three dimensional finite element analysis is computed to predict the deformations and stresses in the composite pressure vessel. The proposed method could save the time to design filament wound structures, to check whether the ply design is safe for the given input conditions and also can be adapted to non-geodesic structures. The results can be utilized to understand structural characteristics of filament wound pressure vessels with integrated end domes. This approach can be adopted for various applications like solid rocket motor casings, automobile fuel storage tanks and chemical storage tanks. Based on the predictions a composite pressure vessel is designed and developed. Hydraulic test is performed on the composite pressure vessel till the burst pressure.

This report documents recent progress in developing a tool that uses the Grizzly and RAVEN codes to perform probabilistic fracture mechanics analyses of reactor pressure vessels in light water reactor nuclear power plants. The Grizzly code is being developed with the goal of creating a general tool that can be applied to study a variety of degradation mechanisms in nuclear power plant components. Because of the central role of the reactor pressure vessel (RPV) in a nuclear power plant, particular emphasis is being placed on developing capabilities to model fracture in embrittled RPVs to aid in the process surrounding decisionmore making relating to life extension of existing plants. A typical RPV contains a large population of pre-existing flaws introduced during the manufacturing process. The use of probabilistic techniques is necessary to assess the likelihood of crack initiation at one or more of these flaws during a transient event. This report documents development and initial testing of a capability to perform probabilistic fracture mechanics of large populations of flaws in RPVs using reduced order models to compute fracture parameters. The work documented here builds on prior efforts to perform probabilistic analyses of a single flaw with uncertain parameters, as well as earlier work to develop deterministic capabilities to model the thermo-mechanical response of the RPV under transient events, and compute fracture mechanics parameters at locations of pre-defined flaws. The capabilities developed as part of this work provide a foundation for future work, which will develop a platform that provides the flexibility needed to consider scenarios that cannot be addressed with the tools used in current practice. less 153554b96e

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