ML20206M284

Rev F to Qualification Plan 58960, Environ Qualification Test Plan & Procedure for Gaskets & Sealant/Adhesive of HVAC Duct Assemblies for Use in South Texas Project Electric Generating Station Units 1 & 2

ML20206M284
Person / Time
Site:	South Texas
Issue date:	05/20/1986
From:	WYLE LABORATORIES
To:
Shared Package
ML20206M077	List: ML20206M107 ML20206M129 ML20206M240 ML20206M284 ML20206M358 ML20206M421 ML20206M461 ML20206M528 ML20206M639 ML20206M984 ML20206N270 ML20266F530 ML20266F586 ML20266F592 ML20266F602 ST-HL-AE-2070, Forwards Documentation Excerpted from Plant Mechanical Equipment Qualification Program for Evaluation,Per H Walker Request.Brief Explanation & Instruction for Use of Excerpts Encl
References
58960, NUDOCS 8704200078
Download: ML20206M284 (54)

Text

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SCIENTIFIC SERVICES 8: SYSTEMS Proposat No. 58960 ID LABORATORIES GROUP V *s= nst = E=i=i= ==ias 3*d'""**^"""**""*'C""***"

QUALIFICATION Dat0: February 19, 1985 TWX 9104321204 Telecopy (714) 737&'I PLAN Revision A May 17, 1985 -

Revision B August 30, 1985

. ENVIRONMENTAL QUALIFICATION TEST PLAN AND PROCEDURE FOR Revision C THE GASKETS AND SEALANT / ADHESIVE OF THE HVAC DUCT ASSEMBLIES October 25, 1985 FOR USE IN SOUTH TEXAS PROJECT Revision D ELECTRIC GENERATING STATION UNITS 1 AND 2 January 6, 1986 Revision E February 3, 1986 Revision F May 20, 1986 APPROVED BY APPROVED BY We FOR: FOR: "L' L^aoaAWlU q

APPROVED BY: APPROVED BY: Ir ww FOR: FOR: # MLE LA*oaAWlu

(; ' APPROVEN BY: PREPALED BY A E a OS -

. FOR

eta tAnonAroein I REYl510NS

I li APPROVAt PAGES S-REY. NO. DATE SY OfPT. QA CUST. AFFECTED DESCttPflON OF CHANGES l

O 8704200078 870415 PDR

^

ADOCK 05000498 PDR 2

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LABORATORIES SCIENTIFIC SERVICES & SYSTEMS GROUP Page i REVISIONS p>

% .1 ,

7 Rev.No. Date Pages Affected Preparer Reviewer, QA PE Description of Changes A 5/17/85 3.5,6,7,8,9,10,11 ), h I

1. M f//g Incorporated Customer's 12.13,14,15,16,17. / Concents 18,19,20.24,25,26, 27,28,30,31,32,33, -

34,35,36,37,40,41, 44 52 E! 8/30/85 2, 12, 14, 15, 16, g g Incorporated Customer's NE ((A 18, 23, 23a, 45, 46 Comments per Aug. 6.1985, -

meeting.

C i

'25/85

/ 12, 14, 15, 16 23 h [.0 [ '

Incorporated custmer's ecrinents, dated 10-17-85 p.

D 1/06/86 2, 9, 12, 13, 15, i, Ircorporated changes to 15a 16,17,18, 20, /[- )u - Seismic and Accident Envir-23, 24, 25, 26, 28i, f.,78 onments l 30, 31, 34, 37, 40 -

l l P42 & 43 '

. E 2/03/86 2, 4, 7-9, 15-19, f, %, //$ p Afh Incorporated customer's

.)23-24b, 42-43a y pf comments F 5/21/86 2, 4, 7, 9, 12, 15,  ;#J /g ^Jh Incorporated customer's 15a, 16, 16a, 16b, 17, 23, 41, 42

( g,jf / comments Pages 43. 43a de-leted. Page 44 changed to 43. 45 changed to'44.

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58960 OUAUFICATioN PLAN 2

P WYLE useaavaans sewc asmess e svros enow Revision F TABLE OF CONTENTS Page No.

1.0 Scope .............................'................................... 3 1 1.1 O b j e c ti v e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3

1.2 Applicable Standards, Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 and Documents

• 1.3 E quip men t De scrip ton . . . .'. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.0 Definition of Service Condit ons i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.1 In side Con tainm e n t Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.2 Outside Containment Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.0 Qualification Program Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.1 T e st C on di t ion s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

i 3.2 T e s t E qui p m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 j 3.3 Margins............................................................... 10

g. 4.0 T e s t D a ta an d R e por t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 4.1 T e s t R e po r t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 J 4.2 Photographs and Notices of Anomaly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4.3 Te st W i t n e ssin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1 5.0 - A ccep tance Crite ria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 l 6.0 Q uali fica tion Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 l

. D 's '

6.1 Qualification Test Se quence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 g 6.2 Receiving Inspection and Assembly . . . . . . . . . - ........................... 13 6.3 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . ............................ 13 6.4 F u n c ti onal Te s t . . . . . . . . . . . . . . . . . .' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L. -

i 6.5 R a dia tio n A gin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 j,i -

6.6 T he r m al A gi ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 Seismic...............................................................

14 15 6.8 A cci de n t Te s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6.9 Inside Containment Gasket and Sealant Qualification . . . . . . . . . . . . . . . . . . . . . . . 17 7.0 References............................................................ 18 FIGURE 1 HVAC Duct Assembly Test Specimen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 FIGURE 2 Worst Case Accident Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FIGURE 3 LOC A/MSLB Accident Pressure Profile, . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inside Containment FIGURE 4 LOC A/MSLB Accident Temperature Profile, . . . . . . . . . . . . . . . . . . . . . . . 22

+ , inside Containment FIGURE Sa Seismic Accident Test Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FIGURE Sb Seismic Accident Test Set-Up .................................. 24 FIGURE Sc Seismic Configuration Test Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24a FIGURE 3d Seismic Configuration Test Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24b Ui APPEN DIX A A ging A naly sis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 i APPENDIX B Optional Test Plan and Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 APPENDIX C Axial Preload Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 s

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s 58960 OuALWICATeoN PLAN 3

PAos No.

Moneoans u seemec saavcas a svsvius onow ,

Revision A l

l 1.0 SCOPE F

l This document was prepared by Wyle ' Laboratories for Bechtel Energy l Corporation (BEC) hereinaf ter referred to as BEC, for equipment used in South Texas Project Electric Generating Station Units 1 and 2.

l l Successful implementation of this Qualification Test Plan and Procedure will result in qualified equipment.

I t 1.1 Objectives r The purpose of this Qualification Test Plan and Procedure is to present the

approach, methods, philosophies, and general procedures for qualifying gasket, 1

3 scalants for the HVAC duct assembly, for use in nuclear power generating stations in accordance with IEEE 323-1974, IEEE 344-75, and BEC Specifications 4A479ES1018, Rev. 2 and 4A479ES1024, Rev.1.

Nuclear environmental qualification of any safety-related device to meet the requirements of IEEE 323-1974 is usually a three-step process; i.e.,1) radiation aging exposure (including accident dose); 2) thermal aging; and 3) design basis event testing (seismic and accident). The purpose of the first two steps is to i

put the qualification test specimen into a condition that represents the worst state of deterioration that a plant operator will permit prior to taking c corrective action, i.e., its end-of-qualified-life condition. The third step demonstrates that the specimen still has adequate integrity to withstand the

[ stresses of specified design basis events and continue to perform its safety-

, related functions.

The necessary applicable elements of qualification have been defined during the development of this Qualification Test Plan and Procedure. These elements include functional test criteria, acceptance criteria, definition of artificial aging procedures, and seismic test criteria. This Plan provides the rationale and justification for the specified qualification process.

It is the client's responsibility to assure that the components and materials contained in the equipment actually placed into service are the same as those qualified by implementing this plan.

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58960 ouALIFICATeoN PLAN 4

g- sc..cmensasawow PAGE No. ,,

Revision F O

1.0 SCOPE, (Continued) 1.2 Applicable Standards, Specification and Documents o IEEE 323-1974, "lEEE Standard for . Qualifying Class IE Equipment for r

Nuclear Power Generating Stations"

! o IEEE 344-1975, "IEEE Recommended Practices for Seismic Qualification of Class IE Equipment for Nuclear Power Generating Stations" l o NUREG 0588, Category I i

o Reg. Guides 1.89 and 1.100

. o Wyle 380 Rev. D Quality Assurance Manual dated 15 April 1984

( o BEC Specification, " Specification For the Environmental Qualification i

of Safety Related Electrical and Mechanical Equipment 4A479ES1018 for the Houston Lighting & Power Company South Texas Project Electric Generating Station o BEC Specification, " Specification for Seismic Qualification Requirements for Class IE Control and Instrumentation Devices i 4A479ES1025 for the Houston Lighting & Power Company South Texas Project Electric Generating Station 1.3 Equipment Description The subjects of this qualification program are sealing gaskets and sealant.

8 Table I describes the gaskets and sealant. Table 1, Items 1, 2 and 3 will be f qualified by type testing for outside containment use. Appendix A contains an j, , aging analysis of these items to determine the accelerated aging conditions to be applied during the qualification testing. Table 11 describes the various

,. installation configurations of items I, 2 and 3. The effect of the containment

. environment on items 3,4,5 and 6 will be analyzed. Appendix A describes the l* analysis, and its results.

i Samples of Items 1, 2 and 3 of the following list (Table 1) will be supplied by ,

BEC to Wyle Laboratories. Wyle will design and fabricate five HVAC ductwork flange assemblies for testing purposes. Items 4,5, and 6 will not be subjected '

, to Qualification testing.

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58960 OuAUFICATION PLAN 5

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uncaa==s sc===c smets a sysmes ww Revisson A v

I 1.0 SCOPE, (Continued) 1.3 Equipment Description, (Continued)

I TABLE I

, HVAC GASKET AND SEALANT DESCRIPTION l

Item Part, Application R. Vendor / Manufacturer Description Location 1 Gasket Tape, TREMCO,440A Pre-shimmed, OC

HVAC Duct; Size:l/4" thick x 1/2" wide

.[ Tremco 2 Gasket Tape, TREMCO,440 (Without shim) OC HVAC Duct; Size: 1/4" thick x 1/2" wide Tremco

, 3 Sealant, HVAC Dow Corning Silicone No. 999 IC/OC Duct Dow Corning O

4 Gasket, HVAC NEOPRENE,1/4" thick x 1" wide, IC/OC Access Panet/ in accordance with either of Door the following ASTM (1983) Standards:

ASTM D2000 type 1BC410 or

. ASTM D1056 Grade RE-42 5 Gasket, Circular EPDM,1/4" thick, in accordance IC

{

1-Duct; with ASTM D2000 (1983 Edition)

Coastal Rubber Type: 3BA515A14B13 with Adherence Protection 40 to 60 i

Shore A Durometer Tolerance

31/8" (diam.)

1

, OC = Outside Containment IC = Inside Containment e

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l 58960 OOALIFICATION PLAN 6

M uno===s scamecu=usasvsmsow PAos No.

Revision A TABLE 1, (Continued)

HVAC GASKET AND SEALANT DESCRIPTION l

item Part, Application

g. Vendor / Manufacturer Description Location

, 6 Punched Gasket EPDM,in a'ccordance with ASTM IC Strip, HVAC Duct D2000 (1983 Edition)

Coastal Rubber Type:

' Type: 3BA515A14B13 with adherence protection 40 to 60 Shore A Darometer Size: 1/4" thick x 2" wide f

Size: 1/4" thick x 3" wide Size: 1/4" thick x 4" wide i

' TABLEll I O d GASKET AND SEALANT INSTALLATION CONFIGURATION NO. CONFIGURATION REFERENCE DR AWING

, 1. Tremco 440A Gasket Tape, Pre-shimmed, 5-V-01-0-M-28709

! with Duct Assembly

a. Using Lockwasher compressed down l

l .l until it is flattened l 2. Tremco 440 Gasket Tape, without shim, with Duct Assembly

a. Compressed down until metal-to-metal 5-V-01-0-M-28704 contact is achieved

b. Compressed down to 1/16" 5-V-01-0-M-28704

c. Compressed down to 1/8" 5-V-01-0-M-28704 .

3. Tremco Gasket Tape and Dow Corning No 999 Sealant with Duct Assembly O

. : 8 w +- -+,,-f . , - , . -----w y-,

e r - # , u c- -,-g,g.p- y--g w i----r+ w-,----, w----,-.m -w w i r--,,-y -,.w

o 58960 QUALtFICATioN PLAN 7

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Momones sceuweseamasasysuus=

q u Revision F 1.0 SCOPE, (Continued) 1.3 Equipment Description, (Continued)

. 1.3.1 Test Specimens This qualification program requires five test specimens. The test specimens

- were designed considering the various installed configurations. Each test i i specimen will be assembled per BEC drawings 5-V-01-M-28709 Rev. I and 5-V-01-0-M-28704 (Table II). Table 111 describes each test specimen.

TABLE III TEST SPECIMEN DESCRIPTION Specimen Configuration Requirements i

A.I.a TREMCO 440A Gasket Tape Lockwashers compressed until flattened.

Pre-Shimmed with EPDM Core j i, 3 A.2.a TREMCO 440 Gasket Tape Gasket material compressed until metal-to-( (without EPDM Core) metal contact is achieved between duct com-panion flange surfaces. Specimen is also used

' for checkout test sequence described in Sec-tion 6.7.1.

A.2.c TREMCO 440 Gasket Tape Gasket material compressed until a 1/8-

.. . (without EPDM Core) inch gap is obtained between duct compan-l ion flange surfaces. Placed on hold for

( future testing per BEC Conference J.

Notes dated 6 August 1985.

B.I.a TREMCO 440 Gasket Tape Gasket material compressed until metal-to-(without EPDM Core) and metal contact is achieved between duct Dow Corning No. 999 flange surfaces. Dow Corning No. 999 seal-Sealant ant bead installed around flange contact.

4 A.2.b TREMCO 440 Gasket Tape Gasket material compressed until a 1/16 inch (without EPDM Core) gap is obtained between duct companion flange surfaces.

Note: All specimen will utilize a 12" X 36" rectangular duct configuration as shown on Figure 1.

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58960 l

' ouALIFICATIoM PLAN 8

PAos No. .,

Monmanne ses.mac semes e avs,see snow Reviston E u

I.0 SCOPE, (Continued)

1.3 Equipment Description, (Continued) 1.3.2 Safety Function The safety-related function of the HVAC ductwork is to distribute cooling air to safety-related areas and to maintain desigh environment. The safety-related '

function of the gasket and sealant is to maintain pressure boundary and to prevent excessive air leakage into or out from the duct work.

1

!j. 2.0 DEFINITION OF SERVICE CONDITIONS The following environmental service conditions are as noted in Reference 1.

I The air duct gaskets and sealant will be used in HVAC ductwork located inside and outside of the containment as identified in Table 1. The duct assembly will be subjected to the following worst-case harsh environmental service

' I', . conditions.

!, 2.1 Inside Containment Service Normal Conditions Accident Conditions Pressure: 0.3 psig (max) 48.4 psig (max) *

-0.1 psig (min) -3.1 psig (min)

(See Profile LOCA/MSLB Figure 3) i

' 3230F

- Temperature: 650F (min) 1200F (max) (See Profile for

,( LOCA/MSLB Figure 4)

Radiation: 2.0 x 107 rads 1.4 x 108 rads (40 years) (180 days) l Relative Humidity: 0-80 percent 100 percent Radiation Type: Gamma Gamma and Beta Chemical Spray: N/A See below Vertical downward spray of 2000-4000 ppm boron concentrate (as boric ar.:d) and sodium hydroxide as required to make an initial pH of 10.5 and a subsequenj pH ranging from 8.5 to 10.5, with chemical spray at the rate of 0.5 gal / min /f t for first 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> minimum.

• Design pressure for safety class ducts is ; 2.0 psi o 10

--w-, y- w,-e-Y a -, em . --p,--~- , - m er, w-,,,-,--,,,-, --n w.,~,m,-mmm._-. __m__ _ . . - - - , - - , _wn-a--- -

58960 QUAUFacATION PLAN 9

Muscanones sce=recseancasmsmsw PAot No.

Revision F b

b 2.0 DEFINITION OF SERVICE CONDITIONS, (Continued) 2.2 Outside Containment Service 2.2.1 Worst Case Harsh Environmental Conditions enveloping all areas in IVC cubicles (excluding accident condition), EAB, DGB and MAB rooms IS,18A,33, 39 and 62:

Normal Abnormal Accident Conditions Conditions Conditions Temperature: 1350F (max) 1350F (max) Max 1400F (See 500F (min) 500F (min) Profile, Figure 2) 24 hrs / year Pressure: Atm. N/A 0.6 psig

• Relative 80 percent (max) N/A 100 percent Humidity: 20 percent (min)

Radiation: 107 rads (max) N/A 100 rads (40 years) (180 days)

Radiation Type: Gamma N/A Gamma 2.2.2 Worst-Case Harsh Environmental Conditions Enveloping Fuel Handling Building and Control Room (Inaccessible Areas)

Normal Abnormal Accident Conditions Conditions Conditions i Temperature: 1040F (max) 1200F (max) 1200F 500F (min) 650F (min) (30 days)

(24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> / year)

Pressure: Slightly Negative N/A -0.125 "Wg" (max)

• l Slightly Negative (min)

! Relative 80 percent (max) N/A 80 percent

l Humidity: 20 percent (min)

Radiation: 2 x 103 N/A 8 x 106 rads (40 years) (180 days)

Radiation Type: Gamma N/A Camma

• The design pressure for safety class ducts is f,0.43 psi

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58960 OuAUFICATK)N PLAN

' 10 PAGE No.

mm scense semis a svstaus

• Revision A

3.0 QUALIFICATION TEST PROGRAM OBJECTIVE The qualification TEST program described herein has been configured to verify the intended safety function of the HVAC ductwork Tremco gasket tape and gasket tape with sealant

to maintain pressure boundary integrity within the specified limits. The requirement of Outside Containment harsh environment and Fuel Handling Building was enveloped ,to design three test programs for various installed gasket and sealant configurations. The successful completion of the first program (Program A) qualifies the two types of Tremco gaskets to 40 years normal / abnormal / accident conditions for Outside Containment. The I second program (Program B) qualifies a Tremco gasket with sealant to 40 years l normal / abnormal / accident conditions in the Fuel Handling Building and to 6 years normal / abnormal / accident conditions for Outside Containment. An

[

optional test program for qualifying the test specimen with the Tremco 440 L gasket tape and sealant to 40 years normal / abnormal / accident conditions for Outside Containment is presented in Appendix B. BEC will decide to implement this option af ter the completion of Programs A and B.

f' 3.1 Test Conditions Unless otherwise specified herein, all tests shall be performed at room ambient conditions defined as a temperature of 801200F (26.7 ! II. loc), a relative p!

d humidity up to 95 percent, and a barometric pressure of 3012 inches of mercury.

3.2 Test Equipment The Test Report shall document all equipment used in the test program including range, accuracy, calibration intervals and calibration due dates. All equipment and instrumentation used during testing shall be calibrated, as required, in accordance with MIL-C-45662A and shall be traceable to the National Bureau of Standards (NBS). The NBS traceability records are

!- maintained on file in the Wyle Quality Assurance Office, and is available for audit.

3.3 Margins Margins have been incorporated into the nominal values presented in the text of this procedure. The margins shown below have been added to the most severe service conditions that the HVAC duct assembly is anticipated to experience in the nuclear power plant. They define type test parameters that take into account normal variations in commercial equipment production and a degree of uncertainty in defining satisfactory performance, as required by lEEE 323-1974.

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58960 QUALIFICATION PLAN 11 Paar No.

M ueoncoans ses mese=cassivmwoaow Revision A

.)

i 3.0 QUALIFICATION PROGRAM OBJECTIVE (CONTINUED) i 3.3 Margins (Cont'd) 0 Radiation +10% (on accident dose)

O Peak Pressure +10% of gauge (but not more than 10 psig) 0 Vibration +10% added to the acceleration

! of the response spectrum at the mounting point of the equipment O Peak Temperature +150F (on accident condition) o Time +10% Non transient part of accident O Environmental Transients The initial transient and dwell at peak

'! temperature shall be applied twice 4.0 TEST DATA AND REPORT 4.1 Test Report I !' Three copies of the final Test Report shall be submitted to Bechtel Energy Corporation on completion of testing. The report will include the test setups and description of each test, followed by test results.

All test data, results, and calculations shall be presented in the final report in either a tabular or appended format. The report shall be prepared in accordance with the requirements of IEEE 323-1974 and shall describe the qualification test program.

[ The report shall include the analyses and any justification required to establish 7 qualification.

4.2 Photographs and Notices of Anomaly Representative photographs of each test setup shall be included in the final report.

Any visual damage or deterioration of the specimen resulting from testing shall be documented by photograph. Any alteration or deviation from this test procedure shall be described in detail by Wyle Notice of Anomaly per Wyle Quality Assurance Manual.

1 4.3 Test Witnessing All tests are subject to observation by representatives of BEC.

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M usammaans scism csaavcesasys== aaow Revision F f%

5.0 ACCEPTANCE CRITERIA The HVAC ductwork gaskets and sealant are required to maintain their pressure -

boundary sealing function at an allowable leak rate of not more than 0.004 CFM per square feet of duct surface area per ANSI 509, 1930. The maximum acceptable leak rate is based on a duct length of 3 feet (plant specification) and a test specimen perimeter of 8 feet, resulting in a surface area of 24 square a

feet. Therefore, the maximum allowable leak rate is 0.096 CFM at dif ferential pressure of 8 inches water gage.

i 6.0 QUALIFICATION TEST The following paragraphs describe the qualification test sequence and j description of each test program.

. 6.1 Qualification Test Sequence y?.

ji 6.1.1 Qualification Program for Outside Containment Harsh Environment and Fuel Handling Building Harsh Environment, Tremco 440 and 440A Gasket tapes:

1 Program A.

a) VisualInspection

' - b) Baseline Functional Test c) Radiation Exposure (Normal and Accident) l d) Functional Test e) Thermal Aging (Normal and Accident) f) FunctionalTest

- g) Seismic h) Functional Test i

6.1.1.1 Test Specimens f

i Test specimens A.I.a, A.2.a, A.2.b and A.2.c shall be subjected to the test

- sequence of Program A.

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l 58960 1 OUAUFicATioN PLAN 13  !

O W u.a comes acamesmcisasysnusoaow M "O- ..

Revisson D 6.0 QUALIFICATION TEST, (Continued) 6.1 Qualification Test Sequence, (Continued)

- 6.1.2 Qualification Program for Outside Containment Harsh Environment and Fuel Handling Building Harsh Environment, Tremco 440 Gasket tape and Dow Corning Sealant: Program B. ,

I a) VisualInspection b) Baseline Functional Test i c) Radiation Exposure (Normal & Accident)

d) Functional Test e) Thermal Aging (Normal & Accident) f) Functional Test g) Seismic l .

h) Functional Test 6.1.2.1 Test Specimens Test specimen B.I.a shall be subjected to the test sequence of Program B.

6.2 Receiving Inspection and Assembly An inspection will be performed upon receipt of the test sample specimens at

, the test facility. This inspection shall assure that the gasket tape and sealant received are as described in Paragraph 1.3. Applicable manufacturer's identification codes shall be verified. Specimens shall be labeled, as deemed necessary by the Project Engineer, to facilitate identification of the specimens

}

during all phases of the qualification testing program. The results of the inspection (specimen identification, quantities, etc.) shall be recorded on Wyle i

Form W614. The subject test sample specimens shall be installed in the Wyle i fabricated HVAC duct flange assemblies per Paragraph 1.3.1, Table III of this report and per BEC supplied plant installation procedure. The fixtures thus constructed shall constitute the five test specimens.

6.3 Visual Inspection

• A visual inspection of the test specimen shall be performed by Wyle Laboratories. This inspection shaji ensure that the gasket tape and sealant have no obvious visible damage ant'. that there is no obvious visible material deterioration. Observuions shall be recorded on Wyle Form W614.

O

l 15

38960 OuALFICATioN PLAN 14

'"0-O M Q usannonne ecs

.wese=cesasvinusonow Rev. .ision C 6.0 QUALIFICATION TEST, (Continued) 6.4 Functional Test The functional test will be performed per test sequence of Paragraphs 6.1.1 and 6.1.2. Three functional tests are required at step f: first, af ter thermal aging;

,~ second, prior to the application of the axial tensile force; and third, after application of the tensile force just prior to seismic testing.

I 1. Test specimens A.I.a, A.2.a, A.2.b, A.2.c and B.I.a shall be pressurized to a maximum leak test pressure of 8.0 inch w.g.

2. Measure and record the leak rate at 8 inches w.g.

- 3. Record pressure decay for each test specimen.

- 4. Record time duration.

The leak rate is calculated based on pressure decay from the equation (Ref.2)

L =V (Pi p,) , where (407.3% PR

' L is the leakage (CFM)

V = 1.5 FT3 the volume of the specimens

. i Pi = pressure at start of test, inches w.g.

' P2 = Pressure at end of the test, Inches w.g.

P , p, . p7 is the average test pressure, inches w.g.

, i

.. t t is time of pressure decay measurement, minutes Radiation Aging

( 6.5 7

Test specimens A.I.a, A.2.a, A.2.b, A.2.c shall be irradiated to 1.03 x 10 rads l' gamma. Test specimen B.I.a shall be irradiated to 8.802 x 106 rads gamma.

Dose rate and total dose will be measured at each test specimen's geometric

' centerline, unless otherwise specified.

- 6.6 Thermal Aging Accelerated thermal aging shall be performed in the following manner:

O 16

4 58960 OuAuFICATeoN PL4N I

15 caos No.

Revision F a

\s unsaam seeme-namouseaw 6.6.1 Program A Install test specimens A.I.a, A.2.a, A.2.b and A.2.c in a preheated (950C) aging chamber. These test specimens shall remain in the chamber for !$4 hours.

Program B 6.6.2 This test Install test specimen B.I.a in a preheated (1050C) aging chamber.

specimen shall remain in the chamber for 25 days.

The test chamber temperature will Thermal aging is performed with dry heat.

continuously be monitored. Percent relative humidity is small in aging chamber and thus not monitored.

l6 ll Seismic l 6.7 I

During the seismic testing, the specimens will be pressurized to 8 inch w.g.,

f I the pressure and leak rate values before and af ter the test will be recorde constant tenslie force of 1740 pounds will be applied to the specimens along

their axial, Z, direction.

i- The seismic test for each test specimen will be performed by applying dynamic 1

load in two steps for low and high loads as specified in Table V. The loads sha not be applied staticly prior to the dynamic loading. Prior to seismic testing o

l the pre-aged specimens, a number of checkout tests shall be performed per section 6.7.1 using unaged Tremco gasket material as specified in Table VI. Th l

:

i '

seismic testing of the aged specimens will be determined after completion of checkout tests.

Ii

'i

, l' During each cycle all bending moments, axial a

, envelope the required interface loads of BEC(Ref. 3), for bot i low and high elevations with a perimeter of 96 inches for the OBE and SSE.

l

' Prior to seismic testing of the pre-aged specimens, the existing nuts and f

lockwasher of specimen A.2.b will be replaced with locking type or jam nut. -

l This arrangement will permit the test The specimen to maintain same procedure may be the 1/16 used as inch gap j between the flanges during seismic test.

necessary for other specimens to maintain the original gap.

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58960 l ouAUFICATeoN PLAN 15a

.. PAos wo.

Revision F OM b mass semaecn=cesasvsmasoaow 1

6.7 Seismic (continued)

In order to provide appropriate load transfer during seismic testing, it will be necessary to replace the existing bolts in the test specimens with longer bolts using a double nut arrangement as shown in Figure Sa. The currently instal bolts in test specimen A.I.a, A.2.b and B.I.a will be carefully removed, one It isat a time, and replaced with Grade 5, 3/16 inch bolts, 2-1/2 inch long.

anticipated that some gasket material may adhere to the installed bolts during Should this occur, an approximately equivalent amount of aged removal.

f i

TREMCO gasket material obtained from testAfter specimen A.2.a will be placed into the new bolt has been the bolt hole prior to insertion of the new bolt.

F installed and the appropriate gap setting has been maintained, the next bolt will be replaced in a similar manner.

I TABLE IV

1. MAXIMUM REQUIRED LOADS

Moment (kips-inches)

Load Force (kips)

Transverse Axial Mx My Py Px Pz 17.61 112.43

.31 2.22 6.83 High 17.43 78.56

.51 1.05 3.48 Low j

in order to prop (erly simulate incoherence Additionalof the s other four load components. These values are given in Table V.at l adjustment of transverse force Px1.55 Kips should be performed 6

ll I

both types of seismic loads.

The weight of 1615 pounds, f The test setup is shown in Figure 5a & 5b. combined with an j constant axial tensile force of 1740 pounds on the test specimen.

I maximum transverse force of 0.516 kips Hydrocylinder No. I will generateresulting in a bending moment of applied for both the low and high level tests. Hydrocylinder No. 2 will a load of 2.085 kips at an angle of 4807' for the low level test and 3 an angle of 3907' for the high level test. The test loading moments of 78.55 and 112.37 kips-inches, respectively.

conditions are summarized in Table V.

1 O

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a d TABLEV i

i TEST LOADING 1

1

' Cylinder Arm Angle Force Force Component Bending Load No. Inches Kips Kips Moment Case i 0.4 Pz Px Kips - inches i

l 1

Low 1 34.1 900  ! 0.516 N/A N/A i 17.60 Load 2- 50.6 480 7' 32085 31 39 31 55  ; 78.55 High 1 34.1 900 30516 N/A N/A 3 17.60 i

2 50.6 390 7' +3.520 +2.73 +2.22 +112.37 Load 1 .

j

! High Load Low Load i

Applicable for ducts in: Applicable for ducts in:

\

o FHB above elevation 30 feet o FHB elevation 30 feet and below x) j o RCB elevation 108 feet and below E

o RCB above elevation 108 feet E l o DGB above elevation 55 feet o DGB elevation 55 feet and below l o Other buildings all elevations y'

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58960 QuAUFicATION PLAN )

16 l PAGE NO.

u amataans see.macsumsaavsvousenou. Revision F 6.0 QUALIFICATION TEST, (Continued) 6.7 Seismic, (Continued)

A total of 750 sinusoidal load cycles will be generated by hydrocylinders No. I and 2 simultaneously at a frequency of 10 Hz. Therefore, the duration of the ,

seismic testing will be 75 seconds for each specimen.

6.7.1 Seismic Checkout Tests ,

The purpose of these tests is to provide an initial assessment of different gasket installation techniques as specified in Table III without depleting the limited supply of aged specimens. The sequence of the checkout tests is shown in Table VI. All tests will utilize test specimen holder A.2.a for the gasket installation.

Position of Hydrocylinder No. 2 will correspond to the angular requirements given in Table V.

6.7.1.1 Initial Checkout Series The initial series of four tests (Tests 1 - 4) will use TREMCO 440 without EPDM core and TREMCO 440A with core. The purpose of this series is to establish the sealing capability of the two tapes under the Table V loading conditions.

Two installation conditions will be simulated, first metal-to-metal contact, and then the lockwashers compressed until flattened.

6.7.1.2 Metal Shim Installation Tests 5,6,9 and 10 will evaluate the TREMCO gaskets where the installation will provide metal-to-metal contact in the flange area through the insertion of 14 gauge shim stock in the gap area. Torquing of the bolts will be to about 90 in-lbs. Applied force levels will be to the requirements specified in Table V.

l 6.7.1.3 Fragility Tests with Lockwashers Compressed i

Special loading requirements exist for the fragility tests 7 and 8. These tests are intended to establish the load level to which the TREMCO EPDM core gasket can be qualified without requiring the installation of metal shims between the duct flanges. For tests 7 and 8, Hydrocylinder I will be held at a force output of 3, 0.48 kips. Hydrocylinder 2 will be installed at the 4807' l angular position as defined in Figure Sa. The initial load level (Level 1) will be l at 0.85 kips for Cylinder 2. This results in 2/3 of the My requirement, corresponding to the SSE level for the lowest anticipated seismic environment.

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58960 ouAUFICATeoN PLAN 16a PAGE No.

u.awo= sce=c as=cas a sys=s mour Revision F (G

l 6.0 QUALIFICATION TEST, (Continued) 6.7 Seismic, (Continued) ,

6.7.1.3 Fragility Tests with Lockwashers Compressed This target load shall be attained within 5 seconds. The target load attained within 5 seconds which may be greater than or less than 0.85 kips is to be maintained for 75 seconds while continually monitoring the test specimen internal pressure. If specimen passes, i.e, leak rate is acceptable, proceed to load level 2 which results in 100% of My at the lowest seismic level. Maintain this load level for 15 seconds. If leak rate is acceptable, continue on to succeeding load levels as shown in Table Yll. Because any damage effect on the gasket is considered to be cumulative, load levels 2 through 6 need only be maintained for 15 seconds or until the leak rate exceeds 0.096 CFM t.s specified in section 5 of this plan. Record the leakage rate at each level beginning with 2 through 6 (Table Vil). If failure of the test specimen occurs prior to completing the sequence of loads shown in Table Vil, the test specimen is to be refurbished and the fragility test will be continued starting with the highest load level at which the previous gasket assembly passed. This level is to be maintained for 75 seconds, followed by the next level for 15 seconds, etc. If specimen fails at load level 1, then it shall be tested to 75% of load level 1.

p 6.7.1.4 Minimum Gap Setting Tests 11 and 12 will evaluate the TREMCO 440 gasket without an EPDM core in installations where the gap setting is equal to or less than 1/16 inch. Test 11 will be a Fragility Test and the requirements of section 6.7.1.3 shall be met.

After successfully passing the Fragility Test, the specimen shall then be tested to the high levelload conditions specified in Table V.

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58960 )

ouAtiricATion PLAN 16b PAos No.

( }g monas scum cse=cisamnussaow Rev,ision F TABLE VI CHECKOUT TEST SEQUENCE Test Gasket Installation Loading Condition No. Material 1 TREMCO 440 Metal-to-Metal Table V Low Level without EPDM Core Contact

~

!* 2 TREMCO 440 Metal-to-Me tal - Table V High Level without EPDM Core Contact

. 3 TREMCO 440A Lockwashers com- Table V Low Level with EPDM Core pressed until flattened 4 TREMCO 440A Lockwashers com- Table V High Level with EPDM Core pressed until flattened i 5 TREMCO 440A 14 Gauge Metal Shim Table V Low Level l{

with EPDM Core Lockwashers com-pressed 6 TREMCO 440A 14 Gauge Metal Shim Table V High Load v with EPDM Core Lockwashers com-pressed

i. 7 TREMCO 440A Lockwashers com- Fragility Test with EPDM Core pressed until flattened I

8 TREMCO 440A Lockwashers com- Continuation of Fragility with EPDM Core pressed until Test flattened c

9 TREMCO 440 14 Gauge Metal Shim Table V Low Level

( without EPDM Core Lockwashers Com-l pressed

- 10 TREMCO 440 14 Gauge Metal Shim Table V High Level without EPDM Core Lockwashers Com-pressed 11 TREMCO 440 Gap less than 1/16 Fragility Test without EPDM Core 12 TREMCO 440 Gap less than 1/16 Table V High Level

without EPDM Core Note

All checkout Tests utilize Test Specimen Holder A.2.a for gasket installation.

.. 22

38960 QUALIFICAT;ON PLAN 16c PAos No.

O, g usouvomas seewwe ==ces a svstaus same Rev,s, i ion E 6.0 QUALIFICATION TEST, (Continued)

TABLE VII FRAGILITY TEST LOAD LEVELS FOR HYDROSHAKER NO. 2 e

Px Total Force Duration Load My (kips) Shaker 2 (seconds)

Level (Kips-inches (kips) 0.63 0.85 75

! 31.95 i

1.27 15 2 47.92 0.95 1.40 15 3 52.64 1.04 1

1.56 15 4 58.92 1.16 1.92 15 5 72.28 1.43 2.08 15

' 6 78.56 1.55 i

i Note: Moment Arm for Hydrocylinder 2 equals 50.6 inches.

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58960 OuALIFICATioN PLAN 17

• • "O Rev..ision F OvuM.au mnas sca m se w isanvs m seaow 6.0 QU ALIFICATION TEST, (Continued) 6J Accident Test This profile was developed from Figure 2 is the worst case accident profile.

HELB profiles A-1, A-2, A-4 and A-7 (Ref. 4E019NQ1009, Rev. 5, App. TheA). This

- profile shows that the maximum temperature is 1400F for 10 minutes.

temperature decreases to ambient 1040F within 1.15 hours1.736111e-4 days <br />0.00417 hours <br />2.480159e-5 weeks <br />5.7075e-6 months <br />.

$ The degrading effects of 10 minutes at 5400F are insignificant. The aging 4

program will show that the material is capable of withstanding a temperature

of 1400F.

' The effect of 100 percent relative humidity for a duration of 613 seconds is also insignificant since the area of the gasket exposed to humidity is very small.

Furthermore, the gasket material is designed for high humidity applications i (Ref. 4).

6.9 Inside Containment Gasket and Sealant Qualification l! The EPDM and Neoprene gasket materials were analyzed thermal, radiation aging and chemical spray.

EPDM is fornotthe significantly effects of affected by thermal, radiation and chemical spray and therefore qualified for O 40 years service inside containment. NeopreneDow not qualified for inside containment application.

is radiation Corningsensitive sealant isand not thus used in a safety related application and therefore was only analyzed for compatibility. The sealant was found compatible with EPDM and Neoprene gasket material. Appendix A contains the detailed analysis.

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P 24

58960 ouALIFICATioN PLAN 18 PAos No.

M Rev,s, i son E O usammaans see.<mewwssasven= enow

7.0 REFERENCES

1. Task No. 0387EQl, Rev. No. 4, Bechtel Energy Corporation.

2. Bechtel Specification 5V279VS 1003 Rev. 4.

3. Bechtel Dnwing SKC-630:

Sheet No.1, Revision B -

{

Sheet No. 2, Revision C i

Sheet No. 3, Revision C )

i Sheet No. 4, Revision A 0

' Sheet No. 5, Revision A \

4. Tremco Laboratory Certification Report, AAMA 804.1.

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58960 OUALIFICATION PLAN 19 PAos No.

g-nm see.cnc se=cis a smaus ow Revision E GASK E T t 1. Gasket installed between

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b.lind flange and specimen.

/ /, 2. For gasket installation requirements, see Table 111.

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58960 ouAmcAnoN Pt.AN

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= 'a WYLE usammonas seeanvc wavcas a syswas ow Rev..isson D I *

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WORST CASE ACCIDENT PROFILE 27 L ._. . _ . _ _ . _ , . _ _ _ . . _ _ _ - _ . _ _ _ - . _ _ _ . , _ . _ _ . _ . - - - _ - . _ , . -

58960 QUALIFICATION PLAN M MMO SCIENT87H: SinWCis AND SYSTEMS Gnour PAGE NO.

O J

(100 SEC.,48.4 PS1_G ) - ( 500 SEC.,48.4 PSIG) -

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' (10 SEC.,41 PSIG ) (5,000 SEC.,4O PSIG )

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• (I DAY,10 PSIG)

(Il DAYS 8.5 PSIG) l

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(30 DAYS,0 PSIG)

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LOCA/MSLB ACCIDENT PRESSURE PROFILE,INSIDE CONTAINMENT FIGURE 3 O

28

58960 QUALWBCAT3ON PLAN 22 e= ao.

Q,G soeurwic M LABWtATWtlB sanwets Ano sysvaus caove (10 SEC.,323* E)

- (100 SEC. 323* E) 7 (5000 SEC.,280* E)

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(11 DAYS,175' F.)

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LOCA/MSLB ACCIDENT TEMPERATURE PROFILE,INSIDE CONTAINMENT FIGURE 4 0 .

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58960

, OUALIFICATION PLAN 23 PAGE NO.

-ones sce. ave u=ces a svinus one, Revision F

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Ancher SEISMIC ACCIDENT TEST SET-UP (ELEVATION VIEW)

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58960 OUALIFICATeoN PLAN 24a PAos No.

[ M m uom wawcumisa mias "

Revision E

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t Configurations for Specimen A.1.0, 8.1.o I

Seismic Configuration Test Set-up I (Bolt Pottern)

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58960 OUALftCATiON PLAN 24b PAos no.

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Configurations for Specimen A.2.0, A.2.b, A.2.c Seismic Configuration Test Set-up (Bolt Pottern)

O risure se 33

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l 58960 QUALW6 CATION PUW 25 PM 980

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APPENDIX A AGING ANALYSIS 1

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58960 OuALIFICATeoN PLAN 26 PAot mo.

p M Revis, ion A d u onmaans see.necse=cssasvsmsonow A. I . Scope The scope of this appendix is an aging analysis of the neoprene. EPDM, Tremco gasket tapes and Dow Corning sealant as used in the HVAC ductwork flange assemblies for use in the South Texas Project Electrical Generating Station, Unit I and Unit 2.

. A.l .1 Objective ,,

I The purpose of this appendix is to present the analyses of the subject gaskets and sealing material to: a) calculate the accelerated aging period for gaskets I and sealant qualified by type testing to the Outside Containment and Fuel

,' Handling Building worst case harsh environmental requirements, and, b) determine the effect of the radiation, chemical spray and material compatibility for gaskets used Inside Containment, and, c) analyze the effect of

., ( the time / temperature aging and calculate expected life of the gaskets and sealant used inside containment, d) analyze the compatibility of Dow Corning sealant with gasket materials.

. ; The items located Inside Containment are analyzed for normal / abnormal /acci-j l. dent environmental conditions. The gasket materials are used as static seals in the HVAC duct assemblies. The expected failure mode is loss of sealing

)

capability due to excessive compression set. Therefore, all analyses on gasket v materials are performed using compression set data.

The sealant material performs a non-safety related supportive function for in i

containment application. The function of Dow Corning sealant is to hold the gasket in its place until the ducts are assembled. The sealant is only analyzed 8 for compatibility with gasket materials.

i A.I.2 Sumrnary After investigating the effects of thermal aging, radiation aging, material l

(- compatibility and chemical spray on the gasket materials and sealant / adhesive, the following conclusions are presented:

I

. o Thermal Aging, Outside Containment and Fuel Handling Building r For test specimens A.I.a, A.2.a, A.2.b and A.2.c the aging time was calculated to be 154 hours0.00178 days <br />0.0428 hours <br />2.546296e-4 weeks <br />5.8597e-5 months <br /> at 950C.

For test specimen B.I.a, the aging time was calculatd to be 25 days at 1050C.

O 35

58960 ouAUFICATeoN PLAN 27 Mumancomu sce=cmamsaannusom, PAGE No Revision D v

A.I.2 Summary, (Continued) -

o Radiation Aging, Outside Containment and Fuel Handling Building Test specimens A.I.a, A.2.a, A.2.b, A.2.c radiation damage thresholds do not envelope the specified radiation requirements, therefore they will be subjected to a total dose of 1.029x107rads gamma, in two steps.

Test specimen B.I.a will be subjected to a total dose of 3.802x106 rads gamma in one step. ,

o EPDM and Neoprene Gasket Materials inside Containment EPDM was analyzed and found to be acceptable for the specified normal / abnormal / accident conditions inside Containment.

Neoprene was analyzed and found not acceptable for the specified normal / abnormal / accident radiation conditions inside Containment.

o Material Compatibility of Dow Corning No. 999 Sealant with Tremco Gasket Tapes, EPDM and Neoprene Gasket Materials The Dow Corning No. 999 Sealant was found to be compatible with Tremco, Neoprene and EPDM gasket material.

o Chemical Spray Effects on EPDM and Neoprene Gasket Materials The boric acid and sodium hydroxide used in the chemical spray was found to have insignificant effect on the subject gasket materials.

o Data was not available for evaluating the synergistic effects on Tremco gasket, Dow Corning RTV and EPDM gasket material. Aged and unaged Neoprene degraded in the same manner when subjected to accident test.

O as l

l

58960 oVALFICA78oN PLAN 28 PAGE No.

gusonawes sesevese=cesnevsmsonow Rev,s, i ion D A.I.3 Material Description

• Table A.!

Manufacturer / Vendor Material Item Description Tremco Polyisobutylene-Butyl 1 Gasket Tape, Shimmed, i Rubber Tremco 440A ,

Tremco Polyisobutylene-Butyl

- 2 Gasket Tape, Rubber Tremco 440 Coastal Rubber Ethylene-propylene 3 Gasket, EPDM Dienyl Terpolymer l

Unknown Chloroprene 4 Gasket, Neoprene Dow Corning Silicone Rubber, 5 Sealant / Adhesive One-part Dow Corning No. 999

j 1, .

A.2.0 Aging Analysis Table A.I contains a list of the organic gasket materials used in the HVAC duct assemblies. The Wyle Laboratories Aging Library was used to obtain the radiation data and the activation energy most appropriate to the material From this information the aging I application of each gasket material.

parameters required for later type testing were determined for the Tremco a! gasket tapes and Dow Corning Sealant / Adhesive and the expected qualifed li of the EPDM and Neoprene gasket materials used inside containment were i determined.

The . gasket materials are enclosed and not affected by ambient relative

l. humidity. This analysis assumes that gaskets and sealant are stored per manufacturer recommendation and used prior to the end of its shelf life.

.!l',

A.2.1 Time / Temperature Eifects Methodology For many polymeric materials, it is known that the degradation process can be a single temperature / dependent reaction that follows the Arrhenius defined equation, by(Ref. I and 2).

(1) k = A exp (-(Ea/kg T))

where k = reaction rate A -= frequency factor exp = exponent to base e Ea = activation energy kg = Boltzmann's Constant T = absolute temperature i, 37

38960 oVAllHCATioN PLAN 29 PAos wo.

hM .

ls l uso===s seececu=casamnusamme Revision A l l

h Time / Temperature Eifects Methodology, (Continued)

A.2.1 It is further noted that, for many reactions, the activation energy can beEquatio ~

considered to be constant over the applicable temperature range.

can be transformed into a form which yields an acceleration factor to define a given amount of thermal degradation. ,

(2)

I t1/t2 = exp (Ea/kgX1/T1 - 1/T2) where,

= accelerated aging time at temperature T1 11

= normal service time at temperature T2 t2 exp = exponent to base e

= activation energy (eV)

Ea Boltzmann's Constant (8.617 x 10-S e y/g) kg =

= accelerated aging temperature (K)

T1 normal service temperature (K) j =

T2 l

Equation (1) can also be transformed into a slope-intercept form of a linear js equation which yields an expected life.

(3)

In(life)= (Ea/kg)(1/T) + Constant Ea = activation energy (eV)

, I kB = Boltzmann's Constant T = normal service temperature (K)

Constant = Intercept (always a negative number)

' For example, Dow Corning #732 Silicone Rubber, the expected life is:

t G in(liie) = (8956.8356) T! - 11.4988 for a baseline temperature of 313oK (1040F) 3 expected life = 3.09 x 10 years It is concluded from this calculation that the material does not significantly degrade in 40 years.

l 5

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58960 oVAUFICAT6oN PLAN 30 i PAGE No.

O u oaco u sce.n.c omisasysnusso, Rev,sion i D A.2.2 Time / Temperature Effects The result of time / temperature aging analysis or gaskets material and sealant used in HVAC ducts are presented in the following paragraphs. The objective of this analysis is twofold, a) design an accelerated aging test for Tremco gasket

, materials and Dow Corning Sealant for outside containment application, b) calculate the expected life of EPDM and. Neoprene gasket material for inside containment application.

Paragraphs A.2.2.1 and A.2.2.2 discuss the thermal aging of Tremco gasket materials and Dow Corning sealant.

Paragraphs A.2.2.3 through A.2.2.3.2.2 discuss the thermal aging and expected life of EPDM and Neoprene gasket material for application inside the containment.

A.2.2.1 Thermal Aging Period Calculation for Tremco 440 and 440A Gasket Tapes, OC and FHB The desired qualified life of the Tremco gasket tapes is 40 years for Outside of N Containment and in the Fuel Handling Building. The age sensitive organic

) material of these tapes is polyisobutylene butyl rubber. The activation energy of this material is 2.13 eV (Ref. 3). Based on a thermal aging temperature of 950C, the accelerated aging duration is 154 hours0.00178 days <br />0.0428 hours <br />2.546296e-4 weeks <br />5.8597e-5 months <br />. Therefore, the test specimens containing the Tremco gasket tapes shall be subjected to thermal aging for 154 hours0.00178 days <br />0.0428 hours <br />2.546296e-4 weeks <br />5.8597e-5 months <br /> at 950C to simulate an installed life of 40 years Outside of Containment.

I O -

39

58960 oUAUFicATKMi PLAN 31 I

PAar no.

gu on oes sce=wese=cisnomewenow Revis,on i D A.2.2.2 Thermal Aging Period Calculation for Tremco 440 Gasket Tape and Dow Corning No. 999 sealant, OC and FHB.

The desired qualified life of the gasket tape and sealant is 40 years in the Fuel Handling Building and Outside Containment. The Dow Corning Sealant is more age-sensitive than the Tremco gasket tape. The activation energy of the Dow Corning 999 sealant was not avaitalbe for this analysis. The sealant activation j

energy. was conservatively assumed to be 1.0 eV. This assumption is based on t

non-metallic material activation energy distribution shown in Figure A.1 (Ref.

I 2). This figure shows an average activation energy of 1.2 eV. It also shows a greater number of materials with activation energies of I or more. Based on a thermal aging tempert:ure of 1050C, the accelerated aging duration is 25 days.

(

'~l Therefore, the test specimen with the Dow Corning Sealant shall be subjected to thermal aging for 25 days at 1050C to simulate an installed life of 40 years in the Fuel Handling Building. This thermal aging program qualifies the gasket and sealant for 6 years use in Outside Containment Harsh Environment (OCHE), since normal service temperature for OCHE is higher than the Fuel Handling Building.

t A.2.2.3 Expected Life Analysis i

A.2.2.3.1EPDM Gasket,Inside Containment The EPDM gasket material has an activation energy of 1.47 eV and an intercept of -36.76 (Ref. 4).

A.2.2.3.1.1 Normal / Abnormal Conditions i}

The expected qualified life of the EPDM gasket material for use Inside l Containment enveloping the normal / abnormal environmental conditions t

was calculated using Equation 3. The worst-case maximum temperature is 1200F (321.90K). This calculation shows that the EPDM gasket material l degrades insignificantly in 40 years.

A.2.2.3.1.2 Normal / Abnormal Plus Accident Conditions The expected qualified life of the EPDM gasket material for use Inside Containment enveloping the Accident and worst-case normal / abnormal environmental conditions was calculated using Equations 2 and 3. The worst-case maximum accident temperature is 323op (434,yoK), however, this peak temperature transient lasts for only 1.5 minutes (Figure 4) and decreasing to 1200F over the next 30 days. These calculations show that the EPDM gasket material degrades insignificantly in 40 years normal / abnormal plus 30 days accident conditions.

O 40

58960 l l

ouAuncATioN PLAN 32

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WYL.E Revision A m ua scen cwmessamnusoe,

)

A.2.2.3.2 Neoprene Gasket,Inside Containment The Neoprene gasket material has an activation energy of 1.05 eV and an intercept of -24.09 (Ref.5).

A.2.2.3.2.1 Normal / Abnormal Conditions

' The expected qualified life of the Neoprene gasket material for use Inside Containment enveloping the normal / abnormal worst-case environmental conditions was calculated using Equation 3. The worst-case maximum i

temperature is 1200F (321.90K). This calculation shows that the Neoprene Therefore, it is

' gasket material degrades significantly in 100 years.

recommended that the Neoprene gaskets be replaced at 30 year intervals, based on a safety factor of 3.

l i

$ A.2.2.3.2.2 Normal / Abnormal Plus Accident Conditions t

The expected qualified life of the Neoprene gasket material for use Inside Containment enveloping the Accident and worst-case normal / abnormal

' environmental conditions was calculated using Equations 2 and 3. The worst-case maximum accident temperature is 3230F (434.70K) with a i

' duration of 1.5 minutes. The temperature decreases to 1200F over the next 30 days. These calculations show that the Neoprene gasket should be replaced every 23.5 years.

A.3 Radiation Effects The objective of the radiation analysis is twofold, a) identify the radiation test level for Tremco gasket material and Dow Corning sealant and b) determine a period during which the effects of inside containment radiation on EPDM and Neoprene gasket material is insignificant. Paragraphs A.3.1 through A.3.1.2 discuss the outside containment radiation test requirements. Paragraphs A.3.2 I to A.3.2.2.2 discuss the effect of radiation on EPDM and Neoprene gasket material for use inside containment.

A.3.1 Type Test Analysis i - Radiation aging analysis was performed on test specimens A.I.a, A.2.a, A.2.b, A.2.c and B.I.a to design the radiation portion of the test plan and procedure.

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58960 OuAUFICATioN PLAN 33 S-mas see.macsewnasys=saos Rev. .iston A

.A.3.1.1 Tremco 440A and 440 Gasket Tapes

• The Tremco 440A and 440 gasket tapes are constructed of polyisobutylene-butyl 5

rubber. The radiation damage threAoid for this material is 7 x 10 rads gamma, 8 (Ref. 6). Although Tremco 440 gasket tape has been radiation tested to lx10 rads gamma some degradation was observed (Ref. 7). Derefore, test specimens l A.1.a, A.2.a, A.2.b and A.2.c shall be subjected to the required total radiation Step dosage of 1.029 x 10 7 rads gamma. This will be accomplished in two steps:7 rads i 1, prior to thermal aging the test specimens shall be irradiated to 1x10 l i gamma; Step 2, following seismic testing, the test specimens shall be irradiated '

to 2.9 x 105rads gamma.

A.3.1.2 Dow Corning No. 999 Sealant / Adhesive

The Dow Corning No. 999 Sealant is a ready to use, one-part silicone rubber i

r product. It cures in ambient environment and does not need6 a curing agent (the second part). The radiation damage threshold for this materialis 1.3 x 10 rads t

gamma (Ref. 6). Degradation of the silicone material is expe 1

in paragraph A.2.2.2 (Program B) qualified the specimen B.I.a for a 6 year use in outside containment worst case harsh environment. The 6 year normal radiation for this application is 1.5 x 10 6 rads gamma (1 x 107 x 6/40). The total O integrated 10 r dose for outside containment worst 6 case harsh envir 6 rads gamma gamma. Therefore specimen B.I.a sha!! be irradiated to 8.802 x 10 in one step.

l ,

A.3.2 Expected I.ife Analysis,Inside Containment

( Radiation analyses were performed on the EPDM and Neoprene gasket materials I

l The maximum radigtion exposure expected for 40 used Inside Containment. The maximum

^

8 rads I

years normal / abnormal conditions is 2.0 X 10' rads gamma. radia gamma and beta. De required total integrated dose (TID) for 40 years normal / abnormal / accident conditions is 1.6 x 108 rads gamma and8 beta.

However, most of the accident TID is beta radiation. Of the TID,1.17 x 10 rads is the beta dose and only 4.3 7x 10 rads represents the gamma dose (Ref. 8).

Beta radiation doses are generally less significant than gamma radiation doses 7 Beta radiation is effectively stopped by a thin for equipment qualification. metal barrier. This is due to the low penetrating power metal flange configuration of the HVAC duct assembly will effectively shield the gaskets from the airborne beta radiation on two of its surfaces. Only the small exposed radiation.

surface area between the outer flange faces will be e l methodo!ogy of Reference 9, which is concerned with the penetration depth of f beta radiation in organic materials. Thus, assuming an extremely conservative f depth of only 1/4 inch (250 mils) for the gasket material, the conservative beta 8 rads will be reduced by a factor of 100 at a 70 mits surface dose of 1.17 x 10 J 42

58960

', ouAssicanoN pun 34 PAGE No. ,,

usomona scawwc as=ces a sysnus oaos Revision D depth. Therefore, the effective beta radiation dose reduces to 1.17 x 106 rads

beta. Factoring this reduced dose into the TID gives a total effective accident dose of 4.417 x 107rads gamma and beta.

The following radiation doses were used for the EPDM and neoprene gasket materials analyses:

Normal (40 Years) 2.0x107Rads Gamma i

' Accident (180 Days) 2.6587x107 Rads Gamma and Beta (including 10% Margin) j A.3.2.1 EPDM Gasket Material s

Reference 10 and 11 are test reports comparing the effects of total radiation dose to percent compression set for several samples of EPDM sealing materials.

l 90% compression set was considered to be the failure criteria. Table A.2 g" summarized the test results.

I TABLE A.2

(,

RADIATION INDUCED COMPRESSION SET DATA FOR EPDM R ADI ATION DOSE, G AMM A COMPRESSION SET, %

9,7 1 X 106 Li 1 x 107 28.6 33.3 1

35.7 1 x 108 84.7 90.5 1 x 109 98.1 l

At lx10 6 rads gamma, there was no significant compression set. 8Atrads lx107 rads

~

gamma, the samples had not taken a severe set. However, at lx10 gamma, the samples had taken a high compression set, which was considered to be too

• severe for continued service as a sea' ling material. The data points from these tests were plotted to give a curve of radiation dose versus percent compression set (see Figure A.1). This curve was used to extrapolate percent compression set at the expected radiation levels o' normal conditions and normal / accident conditions. From the curve it can be seen that about 50% compression set is expected at the normal conditions of 2.0x107 ads r gamma, and that about 70%

compression set is expected at the normal /accidesit dose of 4.6587x107 rads gamma and beta.

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38960 OuALWICATBoN PLAN 35

• • = ao ..

( Revision A p( WYLE unommaans seswwsemisasvsmsenow i

Based on this analysis, it is concluded that the EPDM gasket material degrades in I

the specified radiation environment, however, h will maintain its safety function l for the 40 years normal radiation condition plus 180 days accident radiation condition. .

A.3.2.2 Neoprene Table I lists the two types of neoprene gasket material that are used in the ASTM D2000 Type 1BC410 is a solid HVAC duct access door assemblies. ASTM D1056 Grade RE-42 is a closed ce neoprene rubber.

I rubber. The sponge is much less dense than the solid rubber.

1 Crosslinking at high radiation Radiation exposure degrades neoprene rubber.6 rads) increases hardness and doses (greater than Ix10 At extremely high radiation doses decreasing elasticity and tensile strength.

, g 9 (greater than Ix10 rads) theOxidation tensile strength increases until the neoprene rubber becomes a glass (Ref.14). is also a degradation mechanism for neoprene. The presence of oxygen in the radiation environment significantly increases degradation of the mechanical prooerties of neoprene (Ref.15).

i i t Because neoprene becomes hard and brittle following high radiation doses, its ability to maintain a static seal under any seismic disturbances becomes O compromised. A 60% compression set was conservatively chosen as the failure criteria for this sealing material in its application as a static seal. The radiation7 damage threshold is 2x106 rads gamma; 60% compression set occurs at 2.5x10 i rads gamma (Ref.12).

llt Li A.3.2.2.l Normal / Abnormal Conditions

,e p 7 rads) is less than The required normal radiation dose plus 10% margin (2.2x10 Therefore, the radiation damage threshold level for 60% compression set.

Neoprene will not reach 60 % compression set after 40 years use in i ,

normal / abnormal inside containment condition.

j; A.3.2.2.2 Normal / Abnormal Plus Accident Conditions The available radiation exposure test data for neoprene does not support the l

qualification of this material by analysis for use inside Containment. Therefore, l

it is recommended that neoprene gaskets not be used Inside Containment unless qualified by testing to the specified environmental conditions.

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38960 oVAUFICATeoN Pt.AN 36 PAoE No.

N Rev,s_on ii A u.a se .n c se= css a sysnus enou, A.4 Material Compatibility The Dow Corning No. 999 silicone glazing sealant is compatible with Tremco gasket, EPDM and Neoprene (Ref. 13). For optimum performance, the manufacturer recommends that the application surface be cleaned by solvent wipe (industrial solvent such as mineral spirits, naptha or ketones; do not use

' alcohol) and then primered with Dow Corning No. 1205 Primer prior to application of the Dow Corning No. 999 scalarit.

(

I A.5 Chemical Spray According to Reference 16, boric acid and sodium hydroxide have insignificant

'( effect on the EPDM and neoprene gasket materials. References 17 and 18 recommend EPDM be used for applications requiring contact with boric acid and l sodium hydroxide.

5 A.6 Synergism 3

I Data was not available for evaluating the synergistic effects on Tremco gasket, 1( Oow Corning RTV and EPDM. Synergistic effect on Neoprene was studied in a t

loss of coolant accident simulation test program (Ref.19). Samples of aged and unaged Neoprene were subjected to the accident test. In both cases, tensile property of Neoprene was degraded signficantly when oxygen was present during O. accident test.

A.7 References

))

?-

1) Institute of Electrical and Electronic Engineering, Inc. "lEEE Guide for the Statistical Analysis of Thermal Life Test Data," IEEE 101-1972, Library Code 265-80.

2) Carfagno, S.P. and R.3. Gibson,"A Review of Equipment Aging Theory and t Technology," Electrical Power Research Institute Report No. RP 890-1,

Library Code 600-82.

1 3) Thermal Degradation of Organic Polymers, Samuel L. Madorsky, Interscience Publishers (John Wuley and Sons), New York, p. 303, Table CLII, Library Code 082-788.

Design Guide for Reactor Cover Gas Elastomer Seals. Atomics 4)

International, Division of Rockwell International.

5) " Wires and Cords for Original Equipment Manufacturers," General Electric Company, No. WCC-2, Library Code 185-79A.

6) "The Effect of Nuclear Radiation on Elastomeric and Plastic Matrials," R.

W. King, et al., Battelle Radiation Eifects Center, REIC Report No. 21,

' September 1,1961, Library Code 286-80.

I 45

58960 ouauncAnow et.Au 37 PAos No.

~ W gusou==s scamcwwcasasamesaw ,,

Revision D A.7 References, (Continued)

7) Report No. 791-097 XRG-30, National Bureau of Standards Report of Calibration for Tremco, August 28,1978.

8) BEC Task Description, " Environmental and Seismic Qualification for Tremco Gaskets, Sealants and Adhe,slye used in Safety Related HVAC

• Ducts", Task No. 0387 EQl, Rev. 4.

9) 1.E. Bulletin 79-OlB, January 14,1980.

I J 10) "An Investigation into the Radiation Resistance of Selected Compounds,"

Parker Seal Company, #K10.063A, May 24,1973, Library Code 403-81.

'! 11) "A Further Investigation Into the Radiation Resistance of Selected I Compounds," Parker Seal Company, #K10.063B, March 25, 1975, Library Code 404-81.

(

12) " Radiation Damage to Elastomers, Plastics, and Organic Liquids," C.G.

Collins and V.P. Cackins, Apex-261 pp.1-245, Library Code 500-81. ,

13) "Information about Silicone Construction Sealants," Dow Corning,1981.

14) "The Use of Plastics and Elastomers in Nuclear Radiation," W.W. Parkinson i and O. Sisman, Library Code 438-81.

I

15) " Loss of Collant Accident (LOCA) Simulatin Tests on Polymers: The j

Importance of Including Oxygen" K.T. Gillen et al, Sand 82-1071 (NUREG/CR-2763), Snadia National Laboratories July 1982.

(

6

' 16) " Engineering Guide to DuPont Elastomers, E-61063, E.I. duPont De 1

Nemours & Company,Inc.

l

'ji 17) " Design Engineer's Elastomer Guide", Syntex Rubber Corporation.

18) Seals Fact Book / Design Guide, Minnesota Rubber Company, January 1979.

- 19) " Loss of Coolant Accident Simulation Tests on Polymers", NUREG ICR-l 276-3, Library Code 671-82.

i l

l lO 46

I I

58960 OUALIFICATION PLAN )

i 38 4 7, PAGE NO. _ .

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EPDM: GAMMA IRRADIATION VS COMPRESSION SET O

\ 1 N/

' AN A E

l 58960 QUALIFtCATDON PLAN 39 PAGE NO.

O LAnomatomas scentwcsamvetsaseusm Revision A

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APPENDIX B OPTIONAL TEST PLAN AND PROCEDURE FOR TREMCO 440 GASKET TAPE AND DOW CORNING NO. 999 SEALANT QUALIFICATION FOR OUTSIDE CONTAINMENT WORST-CASE HARSH ENVIRONMENT O

i

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• i lO 48 I

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58960

• QUALIFICATeoN PLAN

- 40 PAos No.

Og u.on sce=wcumcisnovowsoaow Revision D B.1 Test Plan and Procedure Objective i

This optional test plan and procedure is designed to qualify the Tremco 440 999 sealant 40 years gasket tape and Dow Corning No. to normal / abnormal / accident conditions for Outside Containment, Harsh Environment.

l B.2 Qualification Test The following paragraphs describe the qualification test sequence and description l l of each test program.

t B.2.1 Qualification Test Sequence B.2.1.1 Qualification Program for Outside Containment Harsh Environment Tremco 440

.' Gasket tape and Dow Corning Sealant: Program C ll a) VisualInspection

,(. b) Baseline Functional Test c) Radiation Exposure (Normal) d) Functional Test O e) Thermal Aging (Normal and Accident) f) Functional Test g) Seismic h} Functional Test B.2.1.1.1 Test Specimens I'

s Test specimen B.I.a of Table III of the text shall be subjected to the test sequence of Program C.

B.2.2 Receiving Inspection and Assembly i

An inspection will be performed upon receipt of the test sample specimens at the i test facility. This inspection shall assure that the gasket tape and sealant received are as described in Paragraph 1.3. Applicable manufacturer's identification codes shall be verified. Specimens shall be labeled, as deemed r necessary by the Project Engineer, to facilitate identification of the specimens during all phases of the qualification testing program. The results of the inspection (specimen identification, quantities, etc.) shall be recorded on Wyle O

U 49

38960 OuAUFICATioN PLAN 41

- g-Rev..ision F u onamms scearcss=casasmiusow .

1 B.2.2 Visual Inspection, (Continued)

Form W614. The subject test sample specimens shall be installed in the Wyle fabricated HVAC duct flange assemblies per Paragraph 1.3.1, The Table III ofthus fixtures this report and per BEC supplied plant installation procedure.

constructed shall constitute the five test specimens.

i B.2.3 VisualInspection A visual inspection of the test specimen shall be performed by Wyle 1

Laboratories. This inspection shall ensure that the gasket tape and sealant have no obvious visible damage and that there is no obvious visible material deterioration. Observations shall be recorded on Wyle Form W614.

47 6

' B.2.4 Functional Test 1 1) Test specimen B.I.a shall be pressurized to the leak test pressure of 8 inch w.g. (max.)

D 2) Measure the leak rate of the test specimen (see Paragraph 5.0, Acceptance

[d Criteria).

3) Record observations of each test specimen.

This functional test will be performed per test sequence of paragraphs B.2.1.1 B.2.5 Radiation Aging i

7 ads gamma prior to thermal

. t The test specimen shall be irradiated to 1.03 x 10 r aging. Dose rate and total dose will be measured at each test specimen's geometric centerline, unless otherwise specified.

B.2.6 Thermal Aging i

Accelerated thermal aging shall be performed in the following manner: '

7 l

. 50

. - - , - -.,, - - - - , , , - - - , - . , - - - - - - . - , - , . . - - . --,----,_,c-. - - - - . , - , - , , - - - - . - - - - - ,

58960 QUALIFICATION PLAN 42 PAGE NO.

gunommones see.m c u acesasvsn .s m __

Revision F B.2.6.1 Program C Install test specimen B.I.a in a preheated (1050C) aging chamber. This test specimen shall remain in the chamber for 168 days.

B.2.7 Seismic j Seismic testing will be performed per section 6.7 unless otherwise specified.

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58960 ouaurcation ps.4w 43 f

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Revision A ~

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O APPENDIX C AX1AL PRELOAD EVALUATION O

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Bechtel Power Corporation provided measurements of the bolt torque for three different configurations of the duct flange as follows:

1. Unshimmed Tremco 440 gasket tape compressed down to 1/16" gap.

Total of 22 bolts (5/16" dia.) are torqued in the range 1 to 10.5 IN.LB.

- The mean torque value is calculated to be 4.18 IN.LB.

2. Preshimmed Tremco 440A gasket tape compressed down to 1/16" gap.

Total of 18 bolts (5/16" dia.) are tightened with torque values ranging from 0 to 18 IN.LB. The mean calculated torque is 6.08 IN.LB.

3. Unshimmed Tremco 440 tape is compressed down until " metal-to-metal" contact is achieved. Total of thirty 5/16" diametr bolts are tightened with torque values ranging from 0.5 to 7.5 IN.LB.

Only in the first configuration does the measured bolt torque correspond directly to the tensile loading of the duct assembly, since the required force for compression of the unshimmed Tremco gasket to the 1/16" gap is negligible. For the other two configurations, the bolt torque is caused by a combination of the tensile loading of the duct assembly and the force required to compress the preshimmed gasket to the 1/16" gap or to compress the unshimmed gasket until

" metal-to' metal contact is obtained.

Therefore, the bolt torque from the first configuration is used for evaluation of the tensile load of the duct specimen. The tensile load on each bolt is calculated from T = 0.2 dP, where T = 4.18 IN.LB (torque) d = 0.3125 IN (bolt diameter)

P is the desired axial' force i

l l P , T , 4.18 66.9 LBS 0.2d 0.2.0.3125 l

Total axial loading on the specimen with 26 bolts is f PT = 26 x 66.8 = 1740 LBS i

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