ML20044D453

Technical Proposal for Deluge Valve. W/One Oversize Drawing

ML20044D453
Person / Time
Site:	05200004
Issue date:	03/26/1992
From:	Frederick D, Kafadar C OEA, INC.
To:
Shared Package
ML20044D433	List: ML20044D432 ML20044D453 ML20044D458 ML20044D459
References
76583, NUDOCS 9305190151
Download: ML20044D453 (18)

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{{#Wiki_filter:. TECHNICAL PROPOSAL FOR DELUGE VALVE Pyronetics PN 1132 MOD GE Specification: 23ATBD Pyronetics Proposal 76583 P Prepared By: OEA Pyronetics Division Denver, Colorado CAGE Code: 19689 Prepared For: GE Nuclear San Jose, California Issue Date: 26 March 1992 l l 9305190151 930514 l PDR ADDCK 05200004 A PDR

76583 TECHNICAL PROPOSAL FOR DELUGE VALVE ? Pyronetics Proposal 76583

SUMMARY

Pyronetics is pleased to submit this proposal in response to the GE Nuclear RFP. We propose to provide the required valve completely in accordance with the preliminary GE Specification 23ATBD except as noted herein. The proposed valve (see drawing 76583) is a modified version of our PN 1132 valve which was designed and developed for GE Nuclear. The existing valve (see Figure 1) would be scaled down from the 7" inlet to the 4" size required for the Deluge

Valve, and would incorporate dual thermistors.

Wo are proposing a squib operated valve instead of a fusible link valve for the fel Mwirg reasons: a) A mechanical lit kage device will not prevent leakage through the valve for the required service life. b) A minimum of fifteen (15) fusable links in parallel would be required. l l c) We consider the reliability of a fusable link valve to be less than for our standard squib valves. d) Our squib valve (PN 1132) has successfully met the GE requirements for a depressurization valve which are nearly the same as for the Deluge Valve. e) Our squib actuated deluge valve may be externally exposed to the 400*F submersion temperature requirement for five (5) hours without any degradation of the initiator or booster. f) A dual redundant thermistor in conjunction with a DC battery supply will operate the valve to the open position when either of the thermistors are exposed to 500*F. g) Should GE procure the squib valves with the deluge valves from Pyronetics, then a cost savings would be realized, by GE, since the initiator and booster for the squib and l deluge valves could be manufactured and tested l simultaneously. ii

J 76583 i 1 h) Significant nonrecurring development and testing would be saved because we are proposing the use of our PN 113250 j Booster Assembly (used on the previous valve, PN 1132) { 3 without any modifications, t l 1 Pyronetics has the necessary technical and manufacturing j expertise in design, development, and testing to ensure that the j Valve Program will be completed on schedule. I If additional details are required for the evaluation of this ) proposal, they can be promptly supplied. We will be glad to j 'j undertake this program as proposed or to consider any modification j which may be required to our design approach or to GE's l specification, j The Pyronetics' personnel who contributed to this proposal l j j include: C. B.

Kafadar, D.

C. Frederick, J. L. Hubbard, and { S. P. Tripathi. Respectfully Submitted, i OEA Pyronetics Division l a c.S u D. C. Frederick i j General Manger l l APPROVED: i l i i a l b \\:WIL L/ b \\. h \\ w / j l j C. B. Kafadar President-l t I k l f 4 l r I i iii t I

i 1 4 I 76583 l TABLE OF CONTENTS l l 6 e i j SECTION DESCRIPTION PAGE NO } i

1.0 INTRODUCTION

1 1.1 Backaround and Eroerience 1 2.0 TECHNICAL PRESENTATION 2 i j 2.1 Desion Descriotion. 2 2.2 Performance Characteristics and Analysis 2 4 l 2.3 Test Procran. 6 l 2.4-Weicht 7 i 2.5 Life. 7 2.6 Maintainability / Human Enaineirinq 8 l l 2.7 Safety .8 2.8 Related Exoerience. 8 ] 2.9 Reliability 8 j 2.10 Potential Problem Areas 8 l 2.11 Comments. Clarifications. and Exceotions 8 4 TABLE I Squib Valves 10 i TABLE II Comparison of GE and PN 1132 17 } TABLE III Review of Required Specifications. 18 l J TABLE IV Schedule 28 i i FIGURE 1 PN 1132 29 i l FIGURE 2 PN 1166 31 i FIGURE 3 PN 3579 32 t 4 1 ? 1 1 1 I I l 'i ) 8 F 1 W t i iv i i i i w .--.-e s-,-.. .,.w. ---,-._n-., x.m1e-.y. e w. ,~.,s.. m - 1

4 l 76583 L TECHNICAL PROPOSAL I r FOR \\ DELUGE VALVE i Pyronetics Proposal 76583 I i

1.0 INTRODUCTION

1 This document outlines Pyronetics' proposed design and l delivery of the Deluge Valve completely in accordance with the preliminary GE Specification 23ATBD. I 1 The proposed valve (see drawing 76583), PN 1132 Modified, is I manufactured primarily from 304L stainless steel. One initiator in conjunction with a booster charge provides the energy necessary to actuate the valve. The proposed valve has the simplicity, compactness, and low pressure loss exhibited by other valves designed and qualified by Pyronetics. i 1.1 Backcround and Experience In preparing this proposal, Pyronetics has drawn-upon the l continuous experience of its personnel since'1969, in the design F and development of high reliability devices for commercial use and military missile and spacecraft applications. Pyronetics' y background is especially suited for the development, testing, and manufacture of Deluge Valves. The experience gained by Pyronetics i on the previous Depressurization Valve for GE Nuclear (a 7 inch l flow path) may be applied directly to the scaled down version of~ this valve. I l The actuator subassembly of the existing Depressurization Valve, PN 1132 (see Figure 1), will be reduced in size, except the 4 initiator and booster assembly shall be identical to that of the [ prior valve. In particular, the piston (PN 113227) diameter will i be reduced from 6.495 in. to 5.595 in. so that the gas force from i the booster assembly will be appropriately reduced. (Reducing the booster propellant weight is not weight-or cost-effective in view of the extensive testing already done on the PN 113250 Booster Assembly). A welded strap will be added to prevent rotation of the actuator subassembly during environmental testing exposure. The valve body and nipple subassembly will be scaled down to a 4" valve from the 7" (PN 1132) valve previously manufactured. The PN 1132 was previously scaled up from our 2" valve, PN 1166 (see Figure 2). Therefore, this transition of down sizing is easily accomplished. The nipple shear section area will be reduced accordingly. This will reduce the generated loads as a result of actuation and simplify the system mounting requirements. Because of the extensive development program fur the PN 1132 valve, and because of the great similarity between the proposed valve and the 1132, the development for the proposed valve would be a very low risk. 1

4 76583 Table I gives a partial listing of normally closed squib valves. The proposed valve is similar to numerous valves previously built and qualified by Pyronetics as shown in Table I and is a smaller version of v: r PN 1132 valve which was designed and developed for GE. These valves are nearly in continuous production. We are therefore not faced with phase-in and phase-out problems. Our personnel in every department have the expertise and experience necessary to support the development program for the Deluge Valve. 2.0 TECHNICAL PRESENTATION GE's Request for Proposal gives the requirements for the performance, design, development, and test of the deluge valves. Pyronetics accepts every paragraph of the GE specification 23ATBD except as noted herein. A cross-reference table correlating the valve requirements of the GE specification with those of this proposal, is given in Table III herein. 2.1 Desian Description The valve performs the following basic operations when the inlet and outlet are in the vertical position (valve inlet up): a) When closed, the valve prevents any leakage through the valve under all environmental conditions of storage and handling. b) When actnated, the valve provides a straight through flow path without restriction. c) The valve will open when the air temperature reaches a pre-set temperature. NOTE: GE shall provide the DC batteries necessary for valve function. The thermistors will be provided by Pyronetics. i Our proposed valve, PN 76583, is a smaller version of our PN 1132 GE Valve. See Table II for a comparison of GE Specification requirements to the previous PN 1132 GE Valve requirements. The differences between the proposed valve and the 1132 GE Nuclear valve are as follows: a) The housing (PN 113201), nipple (PN 113202), and actuator subassembly (PN 113225) are

reduced, in

size, to accommodate a 4 inch flow passage (versus 7 inch in our PN 1132), different flange interfaces, and to reduce the unit weight.

NOTES: 1. The same initiator (PN 3579) and booster assembly (PN 113250) will be used as-is. I 2

76583 2. The overall weight of the valve is reduced dramatically (from 3700 lb for the PN 1132 valve to approximately 2000 lb for the proposed valve). b) Dual redundant thermistors c) Welded straps to prevent rotation of the actuator subassembly during environmental testing. ] Key features and benefits of the proposed design are as follows: a) Commonality of design features to a long list of highly successful valves. b) The materials and processed employed are common to numerous Pyronetics valves and devices. c) Integrally machined nipple (or diaphragm) on the inlet provides maximum assurance for zero leakage (complete with 100% proof testing and 100% inspection for high reliability). d) Straight through passage between inlet and outlet after actuation. e) Positive retention of the nipple end after actuation to preclude flow blockage at the outlet end of the valve. f) Use of bolts for the installation of the inlet nipple to the housing to provide both rigidity of construction and to provide a means of refurbishment after valve actua-tion. g) 0-ring seals not requiring age life controls (all metal). h) Eye bolts provide for ease of assembly / disassembly. i i) A lug on the housing allows for lifting during transportation. j) An electrical switch is provided to monitor valve position in the control room. GE shall provide the control room nonitoring equipment. k) A substantial amount of testing already completed by Pyronetics and GE Nuclear has already verified the valve's and propellant material's ability to meet virtually all of the GE requirements. 1) Development costs will be dramatically reduced based upon the prior testing program having already been successfully completed. m) The valve is refurbishable. 3 i

4 76583 2.2 Performance Characteristics and Analysis 2.2.1 Valve Operation Upon actuation of the initiator, a pyrotechnic booster charge is ignited and hot gases are produced. When these gases reach a designed pressure, a tension bolt holding a piston breaks allowing the piston to travel downward until it impacts the nipple shear cap. Once the piston impacts the nipple shear cap, the nipple is sheared. The shear cap is then driven forward and a full open flow path is provided. A switch on the bottom of the valve provides a method of indication to the control room of an actuated valve. This switch is a modified version of our PN 1132 switch. The shear nipple section is designed to produce clean shear planes. This feature is not degraded by long term environments and is fully qualified in numerous Air

Force, Navy,

Army, and space applications.

The piston is allowed to back up after shearing the nipple. This design concept for the piston (not locked in place after actuation) is used by Pyronetics for all our squib valves used with a high pressure compressed gas system (e.g., our PN 3339-4 for TRW on the Tomahawk Program and in our previous PN 1132 for GE Nuclear). Standard metal seals are installed on the piston to reduce the potential of ballistic products from entering the flow path. The proposed valve is completely refurbishable. The refurbishment can be performed within the GE specified time frame which was previously verified on the 1132 valve. A refurb procedure will be provided after contract award. 2.2.2 Valve Materials and Processes The housing,

nipple, adapter

flanges, actuator housing, indicator switch body, indicator plunger, head cap,

coupling, collar and adapter are machined from 304L CRES.

This material is entirely suited to the proposed design. This material as well as all other materials outlined for usage and described herein for our proposed valve is identical to the materials used on the previous GE Nuclear Depressurization Valve. The piston and tension bolt will be made from 17-4PH heat treated to H1075. This material was chosen because of the strength requirements necessary, for these parts, during valve function. The inlet and outlet studs will be made from ASME SA 193B7 1CrO.2Mo. The inlet and outlet nuts will made from ASME SA 194 Grade 7 1CrO.2Mo. 4

l i 76583 2.2.3 Initiator / Booster Assembly 2.2.3.1 Summarv Our proposed initiator and booster will be identical to that i i used in the PN 1132 GE Nuclear Valve. l All components of the initiator and booster will be assembled and tested at OEA. OEA demonstrated initiator / cartridge experience includes over 6,900,000 units delivered. Since OEA and Pyronetics j are located in the same facility, this leads'to easy coordination of the initiator and booster activities to insure that the GE l' schedule requirements for the valve, initiator and booster are met. The initiator is based on technology OEA has amply demonstrated for qualified initiator / cartridges used on the F-4, 767, MX, NSI-2, Firebee II, Mercedes, GM Air Bag Program etc. and has been proven by testing in nuclear environments similar to those applicable to the GE program requirements. { Our proposed booster assembly will contain the same propellant as our booster assembly used by GE Nuclear on the 7" normally l closed Depressurization Valve. The booster assembly temperatures j are maintained at levels below the maximum permitted, by GE, by the cooling fins which are part of the actuator subassembly and valve housing. Our proposed booster and initiator can be exposed to an I external temperature of 400*F for five (5) hours without any l degradation of performance. 2 In the areas of design, manufacture, inspection and quality assurance of propellant and explosive actuated devices, OEA's ~ capabilities have been recognized and OEA's facilities approved, by NASA, Army, Navy, Air Force, and the major aerospace companies. } Therefore, we are confident that OEA's team of specialists can 1 supply initiators and boosters meeting the GE specification in a minimum amount of time. 2.2.3.2 Desian Recuirements The major design requirements for the existing initiator will l be identical to those used in all PN 1132 valves (e.g., electrical,

leakage, output, etc.)

and will -meet all the GE specified requirements. 2 2.2.3.3 Desian Descriotion i The proposed initiator is shown in OEA drawing 3579 (see [ Figure 3). The initiator will be identical to that used previously for GE Nuclear for the Depressurization Valve. l 5 I

I { 76583 2.2.3.4 Initiator Body Subassembly j our proposed initiator body has the following noteworthy design features: a) Integral charge holder (ceramic and epory not required) b) Hermetic seal The initiator hermetic sealing operation is performed by the Glass Seal Division of OEA. The sealing processes used by OEA will meet all the temperature and environmental extremes specified in l j the GE Specification. i 2.2.3.5 Pressure Droo l The proposed valve will provide the 4" configuration required. l 2.2.3.6 Stress Analysis t Our preliminary stress analysis has been completed. The proposed valve will meet all the required structural and i environmental requirements. 2.3 Test Procram Pyronetics proposed test program is modeled around that acceptable to GE on the 7" Depressurization Valve. Therefore, production acceptance tests and development tests will be performed as specified below. The qualification tests in accordance with Appendix 10 of 23ATBD shall be performed, if necessary, by GE. j 2.3.1 Individual Production Tests A) Initiator / Booster Assembly The testing proposed for the initiator and booster would be identical to that detailed in our 7-3579 Acceptance Test Procedure (see our Technical Proposal 76581). B) Sauib Valve The testing proposed for the valve will be the same as those tests detailed in-para. 3.0 of Document 7-1132 (see our Technical Proposal 76581). The testing will be modified to agree with those i changes necessary as a result of new specification requirements. 2.3.2 Encineerine Development Tests (Ref. Appendix 10 of 23ATBD) A) Pyronetics will perform the following tests as specified: 6

76583 1) Two Functional Tests: One with a nominal booster and one with a downloaded booster (80%). The testing will be performed in a manner similar to that shown in Para. 4.0 of Document 7-1132 (see our Technical Proposal 76581), except the unit will be fired twice (total) and the testing will be modified to incorporate the new valve requirements (e.g., pressure application, thermistor operation, etc.). Water available at Pyronetics will be used as required in lieu of the water chemistry specified in the GE specification. B) A heat transfer test will be performed to determine the temperature at the booster / initiator in a manner similar to that which we used on the Depressurization Valve (see Para. 3.1 of Document 17-1132 and our Technical Proposal 76581). C) Eighty (80) closed bomb tests on the - initiators and boosters were performed during the Depressurization Valve Program. It shall be GE's responsibility to perform irradiation, thermal aging and LOCA tests and to specify the number of tests units if testing is required. A cost impact to GE would apply. Pyronetics recommends that GE delete these tests for the following reasons: 1) We will be using the exact same Booster Assembly, PN 113250, as was used on the Depressurization Valve. Therefore, GE should review the past program testing requirements, and determine how many, if not all of those tests can be deleted at a cost sav.ings'to GE. 2) Our previous closed bomb testing verified our initiator / booster ability to meet the GE requirements. See document 17-3579 on file at GE. D) Flow testing shall be performed, by GE, as it was on the Depressurization Valve. 2.3.3 Oualification Tests (Ref. Appendix 10 of 23ATBD) i All testing for qualification shall be GE's responsibility. I 2.4 Weicht i The weight of our proposed valves is approximately 1800 pounds. 2.5 Life Based upon the materials of construction and the use of all metal o-rings, the valve will have no difficulty meeting a 60 year service life. However, the initiators and boosters will require l replacement after each ten year period (this meets the GE j specification requirement). The DC batteries shall be replaced on an as needed basis by GE. j i l 7 i i

1' 76583 2.6 Maintainabilitv/ Human Enoineerina Our proposed valve has been designed to provide maintenance-free service. Valve construction and components have been kept as simple as possible, consistent with required function. No field maintenance or servicing is required throughout the valve's service life except for the replacement of the initiator and booster assemblies at the required time intervals. The valve can be i refurbished after actuation within the required time established by GE provided the necessary refurbish kit is on hand and available at the GE facility. l l 2.7 Safety The valve's sealing provisions ensure that no spark, flame, gas or other effluent will be expelled during operation. The piston and sheared nipple are the only moving parts and are completely contained. During normal firing, no shrapnel or projectiles are produced. However, the valve with the initiators and booster installed, should be treated with the normal precautions to avoid accidental ignition from such sources as stray currents, static electricity, heat or open flames. l 2.8 Related Exoerience As noted in section 1.1, 2.1 and 2.2.3.1, much of the experience from our PN 1132 valve is directly applicable to that proposed herein. All the disciplines - - - such as design, material selection, stress analysis, and reliability - - - required for the proposed i valve have been employed in the

design, development, and l

qualification of the valves shown in Table I which are similar to the proposed valve. We are therefore confident that we have the experience and knowledge to successfully complete the Valve i Program. 2.9 Reliability We have a demonstrated reliability of 0.9987 at a confidence level of 90% for our normally closed valves. 2.10 Potential Problem Areas t There are no potential problem areas provided a schedule similar to that shown in Table IV is acceptable. 2.11 Comments. Clarifications, and Exceptions a) Pricing does not include N-Stamp requirements as required by the ASME. This stamp was not required on the prior program. l 8

76583 l b) We take exception to the ASME code for the alpple shear i section. By design, this part must be excluded if proper l valve function is to be achieved. This exception was acceptable to GE on the Depressurization Valve. i c) 17-4PH and Inconel are required for some components. l These materials were used on the GE Valve. However, this is not a 300 series or carbon steel material. t i d) The requirements for sensitization testing per E50YP20 l may lead to more than one mill run of material. Our pricing is based upon successful results the first time. l Should the raw materials not meet the applicable l requirementh of E50YP20, then an additional mill-run or runs will be required. The additional costs associated with i.his effort would be passed on to GE. We recommend that the sensitization requirement be deleted for the development program. 'l i t I I i I i 1 1 I i 9

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