1、RCC-M-Edition 2007 SECTION V FABRICATION_FABRICATIONSECTION V DESIGN AND CONSTRUCTION RULESFOR MECHANICAL COMPONENTS OF PWRNUCLEAR ISLANDSRCC-MRCC-M - Edition 2007 Section V - F F 1000 INTRODUCTION It is impossible to provide rules for manufacture and production which are sufficiently detailed to en
2、sure satisfactory results. Successful manufacture basically depends on the know-how and means of each individual Manufacturer. The rules given in SECTION V FABRICATION are the minimum requirements to be met: the Manufacturer shall make all additional provisions he may consider necessary to ensure th
3、e quality of his product. In addition, the Manufacturer shall respect all tolerances and supplementary requirements specified in SECTION I or stipulated in the equipment specifications. n 113-2007 F 1000 / 1 RCC-M - Edition 2007 Section V - F F 1000 / 2 n 113-2007 RCC-M - Edition 2007 Section V - F
4、F 2000 MARKING PROCEDURE F 2100 GENERAL REQUIREMENTS a) The methods used for marking shall not result in contamination of the material, significant strain hardening, or sharp discontinuities. b) Items shall be marked in areas which are subjected to minimum loading and shall not be marked in areas wh
5、ere there is stress concentration (particularly in areas where there are discontinuities in shape) or in weld heat affected zones. Marking must not adversely affect the interpretation of the results of non-destructive examination. F 2200 METHODS a) All methods which meet the requirements of F 2100 a
6、) and the following requirements may be used for temporary and definitive marking. b) The use of electric arc marking pencils is forbidden. c) Stamping is permitted on materials more than 6 mm in thickness. Metal stamps shall be round nosed or ball type. d) Electrolytic etching shall be permitted bu
7、t shall preferably be used for parts of small dimensions and thickness. When this method is used, the concentration of S, Hg, Zn and Pb in the etching solution shall not exceed 250 ppm, and the halogen content shall not exceed 250 ppm. Etching shall immediately be followed by neutralizing, rinsing a
8、nd drying. The Manufacturer shall draw up an etching procedure prior to any marking operation. e) A vibrating marking tool may be used for thickness less than 6 mm. The tool shall be carbide tipped and the depth of the indentation shall be approximately 0.25 mm or less. However, since this type of m
9、arking may be erased on ferritic non-stainless steels, a different method of marking should be used. For example, a temporary marking code may be painted onto individual components and the code markings tabulated for the finished item of equipment. n 113-2007 F 2000 / 1 RCC-M - Edition 2007 Section
10、V - F F 2300 LETTERS OR SYMBOLS The recommended height for characters is 4 to 6 mm for pipes dia. 350 mm in diameter and from 8 to 12 mm for components and pipes dia. 350 mm in diameter. For very small parts, the characters shall be as large as it is possible to make them. F 2400 TEMPORARY MARKING I
11、nk stamps, indelible ink and paint may be used for temporary marking during manufacture in accordance with the following criteria for austenitic stainless steels and nickel base alloys. a) Parts shall only be marked in this way provided that the marking may be removed afterwards. b) The inks, paints
12、, etc. used shall not contain any contaminants prohibited in F 6000. c) These markings shall be eliminated prior to any heat treatment whenever there is a risk of their causing surface contamination. F 2000 / 2 n 113-2007 RCC-M - Edition 2007 Section V - F F 3000 CUTTING REPAIR WITHOUT WELDING F 310
13、0 GENERAL All materials may be cut to shape and sized or prepared for welding by machining, grinding or thermal cutting. Shearing of plates shall be permitted, subject to the provisions of F 3200. F 3200 SHEARING Plates less than 25 mm thick may be cut by shearing, provided that the strain hardened
14、zone is subsequently eliminated by machining or grinding. Weld edges may be prepared by shearing provided that the provision given above is respected. However, for plates less than 10 mm in thickness, it is sufficient that cross-sections of the welded procedure test joint demonstrate that the strain
15、 hardened zone has been eliminated. F 3300 OXY-GAS CUTTING a) Preheating shall be performed before oxy-gas cutting when preheating before welding is specified in S 1321, S 1322 or S 1323. However, for carbon steels listed in S 1321, the Manufacturer may dispense with preheating before oxy-gas cuttin
16、g when he is satisfied that this will not result in cracking. b) Oxidized surfaces shall be carefully deburred and all traces of oxide removed by brushing or grinding. When the surface remains as-cut, the use of oxy-gas cutting shall not adversely affect the mechanical properties of the material (ha
17、rdness, for example). c) Oxy-gas cut surfaces shall be carefully checked for cracks. d) After all wrinkles resulting from oxy-gas cutting have been eliminated by grinding or machining, the weld edges prepared by oxy-gas cutting shall be examined in accordance with the requirements of chapters B, C a
18、nd D 4000 (see S 7330 c). In addition, the Manufacturer shall use the test coupons for the welding procedure test to check that the maximum hardness value is satisfactory. If not, the affected zone is eliminated by mechanical means (grinding or machining). n 113-2007 F 3000 / 1 RCC-M - Edition 2007
19、Section V - F F 3400 PLASMA ARC AND GAS TUNGSTEN ARC CUTTING a) When plasma arc cutting is used to cut a part to its final shape and size, all residual traces such as metal roll-over and grooves etc. shall be removed from the faces of the cut. Approximately 1 mm of metal shall be removed from the fa
20、ce of the cut by grinding or machining. The same provisions shall be made when gas tungsten arc cutting is utilized for parts of small thickness. For austenitic stainless steels, grinding or machining may be replaced by deburring followed by chemical pickling (see F 6000). b) However, when a plasma
21、arc is used to prepare weld edges on austenitic stainless steels, surface preparation after cutting may be limited to the requirements for examination of weld edges prescribed in SECTION I. F 3500 CARBON ARC CUTTING AND GOUGING (See S 7330). F 3600 REPAIR WITHOUT WELDING F 3610 GENERAL This paragrap
22、h covers the repair of defects detected on parts which have already been accepted in accordance with the requirements of SECTION II MATERIALS and which are revealed or produced during a manufacturing or installation operation. Defects of this type are usually surface defects. These defects shall not
23、 be repaired by welding when they meet the criteria listed below. F 3620 PROVISIONS FOR REPAIR WITHOUT WELDING a) The defect shall be removed by grinding, chipping (followed by grinding), or machining. The use of thermal processes is prohibited. b) The defect shall be removed or reduced to an accept
24、able size in accordance with the criteria given in SECTION II for parts and products in SECTION IV chapter S 7350 for weld edges and surfaces on which weld metal will be deposited. c) After removal or reduction of the defect, the remaining thickness of the metal shall be sufficient to meet stress cr
25、iteria in accordance with the applicable design methods given in SECTION I. In addition, the surface condition shall meet the requirements for assembly and non destructive examination. d) Connection with the surrounding area shall be progressively and uniformly blended, taper being 0.25 at most. F 3
26、000 / 2 n 113-2007 RCC-M - Edition 2007 Section V - F n 113-2007 F 4000 / 1 F 4000 FORMING AND DIMENSIONAL TOLERANCES F 4100 FORMING F 4110 GENERAL F 4111 SCOPE a) The forming procedure comprises all the thermomechanical operations (thermal cycle, deformation and any heat treatment performed subsequ
27、ent to forming) applied to a part or product to obtain a given component. b) The use of any forming procedure whatsoever shall not cause a reduction in properties of the material of a component below minimum required values. Thus, heat treatment shall be performed subsequent to forming, if necessary
28、, to restore the properties of the material so as to conform to the above-mentioned requirements. c) For this purpose, the forming procedure qualification tests are designed to demonstrate that the required characteristics stipulated in the acceptance specification for the product prior to forming a
29、re complied with in the finished product. d) Whatever the forming procedure used for welded plates, the welding procedure qualification shall take into account the heat treatments associated with forming. F 4112 REQUIRED DOCUMENTS a) All forming procedures shall be performed in accordance with the r
30、equirements defined in a set of duly identified documents comprising at least the following: - the forming procedure specification used, and for manufacturing operations, the reference of the corresponding qualification report, - the examinations to be performed during and after forming. b) Content
31、of the forming procedure specification The forming procedure specification shall: 1) enumerate all of the variables defined in F 4120 as conditioning the range of approval when qualification of the forming procedure is required. RCC-M - Edition 2007 Section V - F F 4000 / 2 n 113-2007 2) provide, fo
32、r information purposes: - either the technical parameters adopted for the forming operation, - or reference to an internal procedure containing this information. In the case of bending of tubes by induction, for example, the following in particular shall be specified: - bending rate, - electrical pa
33、rameters (current, voltage, frequency, etc), - cooling parameters, - method used for measuring temperature, - where applicable, the location prescribed for the welded zone undergoing the forming operation. 3) The reference to the qualification of the forming procedure shall appear in the forming pro
34、cedure data sheet. F 4113 METHOD FOR EVALUATING ELONGATION a) The elongation of a formed part is calculated by means of the following formulas: cylindersfor RoRf1Rfe50%A?= % 1 n deformatiofor RoRf1Rfe65%A ?o?, the weld shall be qualified at the time of bending of the test piece on the extrados of th
35、e bend. In this case, high values for ? qualify lower values for ?. 2) Plates In particular, bending and dishing of plates joined prior to forming. As for pipes, the weld shall be qualified at the time of forming of the test piece if deformation exceeds a value of 5% for carbon steels or alloy steel
36、s, except in the case of austenitic stainless steels where this value is increased to 10%. In such cases, high deformation values qualify lower deformation values. b) Welding processes Welding processes as defined in S 3120 and qualified in accordance with the RCC-M, SECTION IV, constitute a main va
37、riable. In particular, heat treatment of the weld prior to forming, as defined in S 3X19, is a main variable (S 3219, S 3319, etc). F 4123.4 Geometrical criteria a) Plates and pipes Deformation High deformation values as defined by F 4113 qualify lower values. Thicknesses Qualification of a forming
38、procedure is valid for thicknesses between 0.75 e and 1.25 e + 3 mm (where e is the thickness of the test piece). F 4000 / 6 n 113-2007 RCC-M - Edition 2007 Section V - F FIGURE F 4123.3 n 113-2007 F 4000 /7 RCC-M - Edition 2007 Section V - F F 4000 / 8 n 113-2007 b) Pipes Diameter In each of the ar
39、eas defined below, the outside diameters of the pipes are considered as equivalent: : - dia. 50 mm - 50 mm 450 MPa, - thicknesses 10 mm The practice may be tolerated for other materials, by way of exception, in accordance with a pre-defined procedure. The following requirements shall be observed: -
40、all impurities (oxides, paint, grease, etc) shall be removed from the surface to be heated, - in the event of heating by oxyacetylene torch, the flame shall be regulated as close as possible to neutral, - heating in a flame shall not be allowable for stainless steels. F 4000 / 16 n 113-2007 RCC-M -
41、Edition 2007 Section V - F - the temperature shall be measured by infrared optical pyrometer (or a heat sensitive crayon for carbon steels) excluding contact thermocouples. The temperature shall not exceed 425C for stainless steels and 700C for carbon steels, - the heated zone shall be cooled in sti
42、ll air, - only one thermal contraction operation shall be authorized at the same location on the equipment, In any event, the Manufacturer shall prepare a procedure for the thermal contraction operation prior to its performance. The identification marking and welding isometric shall provide clear in
43、dication of the thermal contraction and its location. The quality plan shall include: - a reference to the procedure for performance of the thermal contraction, - temperature measurement, - examination following performance. C - Examinations The surface of the heated zone and the area immediately su
44、rrounding it shall be subjected to the following examinations: - a visual examination and in case of doubt following the latter, magnetic particle examination for class 3 equipment, - a visual examination and magnetic particle examination for class 2 equipment. If it is not possible to perform magne
45、tic particle examination, the latter may be replaced by liquid penetrant examination. If heating affects a weld, in addition, a radiographic examination of the weld is required. D - Criteria The visual inspection shall reveal a uniform surface, free from tears, blisters, weld craters, cracks, overla
46、ps. In all cases the acceptance criteria are those defined in S 7700, according to the equipment class. The dimensional criteria to be observed during thermal contraction are those defined by the dimensional tolerances established by the pipe procurement standard. F 4150 NOT USED n 113-2007 F 4000 /
47、 17 RCC-M - Edition 2007 Section V - F F 4160 BENDING TUBES FOR CLASS 2 AND CLASS 3 HEAT EXCHANGERS F 4161 GENERAL a) This paragraph only deals with tubes for heat exchanger bundles for which qualification of the bending procedure is required, whatever the elongation values. b) for the bending of th
48、ese tubes, the requirements of the other chapters of F 4000 shall be supplemented by those of this paragraph, unless otherwise indicated. F 4162 DIMENSIONAL TOLERANCES AFTER BENDING a) After bending, the thickness of the tube on the bend shall satisfy the requirements of C and D 3320 as regards thic
49、kness and reduction of thickness. b) The ovalization of the tube on the bend shall be at most equal to 7% calculated in accordance with the following formula: 100dmindmaxdN?dN = nominal diameter of the tube. c) The deviation tolerances between the legs of a U-tube are specified by the heat exchanger Manufacturer. Depending on the design of the heat exchanger, these tolerances shal
