ML20104A960

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Reactor Vessel Cavity Seal Test Results
ML20104A960
Person / Time
Site: Mcguire, Catawba, McGuire, 05000000
Issue date: 01/18/1985
From:
DUKE POWER CO.
To:
Shared Package
ML20104A941 List:
References
IEB-84-03, IEB-84-3, NUDOCS 8502010598
Download: ML20104A960 (21)
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T CATAWBA NUCLEAR STATION UNITS'l AND 2 MCGUIRE NUCLEAR STATION UNITS 1 AND 2 Reactor Vessel Cavity.

~ Seal Test Results January 18, 1985

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INTRODUCTION As a result of a failure of the refueling cavity water seal at Haddam Neck Plant, described in NRC IE Bulletin No. 84-03, " Refueling Cavity Water Seal", all power reactor facilities are required to evaluate the potential for and the consequences of a refueling cavity water seal failure. The response to the bulletin was transmitted to the NRC via Mr. H. B. Tucker's letter dated Novem-ber 21,1984. In this response, Duke committed to perform a series of tests designed to determine the ultimate capacity of the seals. The objective of this test program is to subject the seal configuration used at Catawba and McGuire to a series at tests to determine the ultimate capacity of the seals.

The minimum acceptance criteria,as stated in the bulletin response, will be a seal capacity to withstand twice the normal static head of water, with cavity full of water.

SCOPE Perform seal capacity tests in accordance with Appendix A, Reactor Vessel Cavity Seal Testing Procedure. Ultimate capacity of seals shall be detentined for varying widths and differential elevations of annulus opening. The varying widths and elevations are intended to envelope as-built dimensions of all units at Catawba and McGuire. From the test results, safety factors based on the normal head of water, can be determined for each unit and compared to the minimum acceptance critera.

CONCLUSIONS

1. The seal layout with horizontal and vertical alignment as shown in the cross section in Figure 1 has a safety factor greater than four. Testing was stopped when a safety factor of four was reached.
2. The minimum safety factor based on the worst case as-built dimensional conditions for McGuire and Catawba Units are as follows:

McGuire Unit 1 - Minimum Safety Factor = 2.2 McGuire Unit 2 - As-built dimensions have not been recorded, this is scheduled for the next outage.

Catawba Unit 1 - Mininum Safety Factor = 3.0 Catawba Unit 2 Under Construction Duke is commit

  • ad to maintain the minimub acceptance criteria of a seal capacity to wi;hstand twice the normal staiic head of water.

RECOMMENDATIONS

1) McGuire Unit 1 and Catawba Unit 1 meet the minimum acceptance criteria with regard to seal capacity, seal modifications are not required.
2) McGuire Unit 2, as-built dimensions are scheduled to be recorded during the next outage. As-built dimensions will be evaluated against the test results to determine the minimum factor of safety and compared to the minimum acceptance criteria.

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DISCUSSION

1. Test Fixture

+ The test fixture was fabricated in accordance with drawing number DBF-1, contained in Appendix B. The test was constructed to represent the actual seal _ seating surfaces as shown in the cross section in Figure 1. Figure 3 compares.the Reactor Vessel cavity seal installation to the head of the test fixture. Note, the dimensions and shape of both the primary shield wall and

_the' reactor vessel flange are maintained. The head of the test fixture is

adjustable allowing the annulus width and the top elevations to be varied. A series of tests were conducted varying these parameters to obtain results that will envelope the as-built conditions. A hydraulic device was utilized to apply load through a loading bar to a portion of the seal surface to simulate the normal hydrostatic loads.

The total load and loading increments are monitored by a digital multimeter

_and a. strip recorder through a load cell. The-load cell is placed between the hydraulic device and loading bar. Table 5 provides a summary of all equipment used in the tests.

'2. Seal Test Specimens Test specimens of the Catawba-McGuire_ cavity seal were obtained from Presray Company of Pauling, New York. The test specimens were fabricated to the exact specifications of the actual seal construction. The elastomer used _is EDPM E603 a-Presray_ material with a durameter rating of 60. Three test specimens were used for the testing. Specimen No. 1 and No. 2 were 48 inche's long and fitted for inflation. Specimen No. -5 was 24 inches long and was not inflatable.

' Figure 2 provides dimensions measured from the actual test specimens.

3. Seal Tes' ting Procedure.

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The seal testing was performed in accordance with Appendix A, Reactor Cavity Seal.. Testing Procedure. Tables 1 through 4 summarize the tests conditions. .

Table No. I lists the test head setup and seal conditions for each test. Table ye No. 2 and_3 list the test head setup for vertical and horizontal alignment and

-the-test seal conditions respectively. Table No. 4-list the testing failure criteria. Test 1 through 10-are pull through test using seal No. 5, uninflated.

Tests 11 through 18 are push through test using seal No. I and variations-in air pressure. Test 19 through 24 are also push.through test but seal No. 2 is used in place of seal No. 1. It should be noted that the pull through loading 7 is applied through a 1/2"O bar and the push through loading is applied at the-h center of the top flange of the seal specimen by a 3/4"O bar.

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CAVITY SEAL

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-TEST SETUP _CORRESP0fl0ENCE TABLE

- Tes t' . Te'st Head Setup. Test Seal Condition

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(See Table 2) (See Table 3)

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TABLE 2 TEST HEAD SETUP

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Setup' Vertical Alignment No. Horizontal Alignment

- , . . _ . . . - . . . . _ _ _ Diff. In~Elev.'In Inches Gao Width In Inches _.

End 1 End 1 .

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1. A':' Inflate seal to design pressure of 35 psi.
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.;2. . .A: Inflate seal to.desi'n pressure of 35 psi.

LB. Load seal through loading head with 3/4"O rod 2 only.

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.C:. Deflate'se'al as 'loadingJapproaches a sustained maximum loat-D: Continue loading seal to a new sustained maximum load.

E: binflate seal and load until a-sustained maximum load i is reached.

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B: : Load seal through loading head with 3/4"9 rod

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. C: Test;to be carried to at sustained maximum load is reached:

1 4.  : A:- Load seal with pull through device.

' m B: Test to b'e carried.to failure,'or unti' alsustained maximum load is reached.

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r TABLE 4 FAILURE CRITERIA e ' 1. Seal is'. forced through' opening.

2. Seal material:is damaged in such a way as;to be incapable of fearrying additional. load or substantial leakage would be expected

'in-_ operati on.

3. Considering the nature.of the test load, if it becomes reasonable to

-expect that the: seal would fail in actual operation or that leakage would become substantial, the test shall be stopped and the load recorded to that. point will be called the failure load.

. 4. -When a loading cycle is stabilized at a'value which yields a safety factor of 4.0 or-above, the test may be stopped.

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TABLE NO. 5 EQUIPMENT DATA SHEET:

tLoad Cell:

Make: Strainsert-

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bniversal Flat Load Cell Capacity: .25. kips .

Model: .FL25U(c) 25PMT

S/ft
> 05384-1:

. Digital.Multimeter: . . .

-Itake: ',liewlett - Packard s

flodel: :3466A-

S/N: .. 01843 -

' S' trip 'Re' corder:

..;. Make: Heath Model: ,SR206

~ S/ft: 39772-

-Power Supply:

Make: - ACOPIAll flodel: K20050 m.

Air ~ Supply: .

(Field Built)

Make:

u -S/N: MCIAC26631, calibrated.10-1-84 -

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' Loading. Jack:

hake: 0WAT0flNA Tool Co.

. Capacity: 100 tons r

- . Pull-Device:

, j. Weight: 54 lbs.

Pushing Device:

' Weight: 108 lbs.

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' .'s, I }. 3 APPENDIX A

- - Reactor Vessel Cavity Seal Testing Procedure 3.,

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REACTOR VESSEL CAVITY SEAL TESTING PROCEDURE 4-

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Revision:. 1-W7 -

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3 Date:' 1/2/85

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Revision No. 1 Date: 1/2/85 REACTOR VESSEL CAVITY SEAL TESTING PROCEDURE

.g PURPOSE-The purpose of this procedure is to establish the ultimate capacity of the reactor vessel cavity seal. This procedure provides the design of a testing

. fixture, the required tests, test methods, and the needed documentation as -

means to this end. 'It also serves as a partial response to IEB 84-03.

. SCOPE This ~ procedure applies only to the Catawba and McCuire reactor vessel cavity seals. Units 1 and 2 of both plants use the same ~ type of seal.

RESPONSIBILITIES J A. Design Engineering:

Design Engineering _ shall be responsible for the design of the tests, testing fixture, and evaluation.of the test results. Design shall' also aid McGuire-Nuclear. Production in the execution of the testing.

B. 'McGuire Nuclear Production:

McGuire Nuclear Production shall be' responsible for construction of the test fixture, execution of the testing, and collection of the test data._

Ca McGuire Nuclear Station Calibration Lab:

The. Calibration Lab shall be responsible for the calibration of all

-test ga'ges and the establishment of the pressure vs. force relationship for. the loading system.

EQUIPfiENT ' '

.' ~A. . Testing Fixture:

The testing shall be conducted using the test fixture shown on drawing DBF-1. The test head of the fixture shall be set up in accordance with-the instructions in the procedures section of this procedure.

B. ~ Test Air Supply: '

. An' air supply is required for _the implementation of the testing. The

. supply.shall be capable of at.least 55 psig and shall be adjustable over

.the range 0 to 55 psig. The supply shall be complete with a gage readable

. in ,1 psig increments, accurate;to + 1% of the face reading, and connected

in.such a way as to read the pressure in the test seal.

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Revision 1 Date: 1-2-85 .

C. ' Load Application Device:

The-load DBF-1 shall be applied hydraulicly through the test head'shown on drawing This device shall be capable of applying at least 5000 lbs. to the

' test head at a rate no greater than 1000 lbs./ min.

4 D. Load Cell and Load Cell Monitoring Devices

The load application device shall be fitted-with a calibrated load cell.

The load cell shall be capab.le of accurately sensing loads in the 0-5000 pound range to a tolerance of +1% of the measured load. The load call shall be monitored by a digital multimeter calibrated to read directly in pounds and a strip recorder.

The strip recorder shall plot the load application history-so'that force in_the machine's X-axis is recording time and the Y-axis is recording pounds.

E. Test Seals:

Five' test seals will be provided by the presray Co. Seals number 1 to 4 will be four feet long and fitted with air connections.

These four seals can be used interchangeably in the test number 1 to 4 as outlined.in the procedures section.. Seal number 5 will be 2 feet _long and be open at both ends. Seal 5 will be used only in test number 5 as outlined in the procedures section.

PROCEDURES -

Table

-to No.1 lists all required tests and the conditions under which the tests are be run.

is to be applied to any test specimen.The loading rate of 1000 lbs./ min. is the m Table No.-4 lists the criterion by which failure-is to be judged._

be listed as the failure pressure.The pressure corresponding to any of the criterion shall Da.ta shall be recorded.on the test data sheets provided in appendix A of this pro-cedure.

in.the-blanks provided. General 'information about the test should= be recorded at the Load values shall be noted at the beginning and end of any significant seal deformation cycles, along with the necessary remarks to des-

- cribe the particular features of the cycle.

bered and attached to the. corresponding data sheet. Strip recorder records shall be num- '

Table No. 5 lists water head, uniform specimens useseal pressure, for-these tests.applied force, and implied safety for the seal It is provided for reference only.

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TABLE 1

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-TEST SETUP.CORRESPO!!DEllCE TABLE Test- Test Head Setu No. -(See Table 2)p Test Seal Condtion (See Table 3) 11 1

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'7 7 4 8 8 4

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'13 13 3 14- 14 - l'

15 15 2
161 16 2.

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TABLE 2

. TEST HEAD SETUP Setup Vertical Alignment Horizontal Alignment

-No. Diff. In Elev. In Inches Gap Width In Inches End 1 End 1 .

1 0.0 2" 2" 2- 0.0 .

2 1/4 21/4 3

0.0 2 1/2 4

21/2 0.0 2 3/4 5

2 3/4 3/8 (Lower Lip Side')

6 "

2 3/4 2 3/4 .'

3/8 2 1/2 2 1/2 7

3/8 "

2 1/4 8-

-2 1/4 1/2. "

2 1/4 9-2 1/4 1/2 -

2 1/2

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2 3/4 2 3/4 11 0.0 2 2 L12 0.0 2 2 13 0.0

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5 - -14 0.0 2 1/4. 2 1/4 15 0.0 -

2 1/2 2 1/2 16 O.0 2 3/4 2 3/4 .

17 1/4 (Lower, Lip Side) 2 3/4 2 3/4 ,

18 1/4 "

2 1/2 2 1/2 19- 1/4 a 2 1/4 2 1/4 20 1/4- -"

2 2 21 '"

1/2 2 2 22 "

1/2 2 1/4 da 23 2 1/4 1/2 '"

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table 3 TEIT SEAL CONDITICNS Condition

' No.

Seal Condition 1.- A:

s Inflate seal to design F.ressure of 35 I:si.

8: Load seal through loading head wit' 3/4"E .od cnly. .

C:

Test to be carried to a stable maximum load is reached.

.2.

A: . Inflate real to design pressure of 35 psi.

B. ' Load seal through loading head with 3/4"O rod only.

T' C:' Deflate seal as loading approaches a stable maximum.

D:

Continue loading seal to a new stable maximul load.

E:

Reinflate is reached. seal and load until a stable maximum load *

3. A: Seal uninflated.

B: Lcad seal-through leading head with 3/4"O rod only.

. C: Test to be carried to a stable maximum load is reached.

42 A
Load seal with pull through device.

B: Test to be carried to failure, or until a stable maximum load is reached.

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TABLE 4 FAILURE CRITERIA

1. Seal is forced through opening. .-

?. Seal material is damaged in such a way as to be incapable of carryin'g additional load or substantial leakage would be expected in operation.

3 .' Considering the nature of the test load, if it becomes reasonable to expect that.the seal would fail in ~ actual operation or that leakage would become substantial, the test shall be stopped and the load recorded to that point will be called the failure load.

~ 4.

When a loading cycle is stabilized at a value which yields a safety -

_ ' factor of 4.0 or above, the test may be stopped. -

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a TABLE 5 '

EQUIVALENT SEAL LOADS

. Loading by a-3/4" rod 43 3/4" long iAnnulus opening 2" Water Pressure

-

  • Force Safety '

.(psi)

. Head (lbs) Factor

24' 10.4. 910.0 1.

30' 13.0 u.

1137.5 1.25

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40 17.3 1513.8 1.67 50' 1

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60'

21.7 1898.8 2.08 ,'

26.0 2275.0 2.50 70' :30.3 2651.3 2.92 80'

'34.7 3036.3 3.33 m 190' 39.0- ~3412.5 3.75 100' 43.3

' ' 3788.8 4.17 v .

Loading by a bar. 23 3/4" 1ong ' -

Annulus opening 2"

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, Water Pressure ' Force Safety '

' Head (psi) (1bs) Factor p ,

24' 10.4 494.0: 1.0 vy 30' 13.0' 617.5 1.25 40' 17.3 821.8 1.67 50' - 21.7 1030.8

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2.08 160'. 26.0 1235.0 2.50 .

~70' 30.3 1439.3 2.92 180' 34.7- 1648.3 '

3.33 90' 39.0- 1852.5 3.75

. [ 100' 43.3 2056.8 4.17 E

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APPENDIX B Test Fixture Drawing DBF-1

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