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QUALITY CONTROL PROCEDURE TITLE:
Silicone Foam Installation Page 1
of 5
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APPROVED:
Date:
ProfEct O perintendent APPROVED:
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Plan * ~uperinten ent APPROVED:
Date:
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l.0 SCOPE 1.1 This procedure outlines the method, requirements and responsibilities for the installation and inspection of silicone foam and lead-impregnated silicone foam.
2.0 RESPONSIBILITY 4
21 The Project Superintendent is responsible for implementing this procedure.
2.2 The Resident Engineers are responsible for assigning the construction wort.
and for providing the construction installation requirements per the lates approved design documents.
2.3 In all areas of this procedure, supervisory personnel who have been assigned responsibility for a task have the authority to delegate performance of that task to subordinates.
This delegation shall be by written job description or by specific written assignment.
3.0 _A.PPL ICATION 3.1 This procedure applies to all fire stops using silicone foam, or lead-impregnated silicone foam.
4.0 PROCEDURE 4.1 Prior to installing either type of silicone foam, the areas where foam is to be applied shall be cleaned and a dam constructed.
- 3.,
4.1.1 For penetrations and cable tray, the dam shall be constructed as fellows:
hB1 29 870814 DEVINEe4-743 pyg s
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4.1.1.1
'All'daming material to be cut shall be marked for cutting l
slightly larger (+1/4 in. 'for. blanket-type and +1/8 'in.
-for board-types) on all edges.
This will facilitate a.
snug fit of, the -daming materials in the penetration anc help prevent leakage of liquid materials,from inside.
.4.1.1.2 Care shall _ be taken while cutting and fitting not to bend, crack, break, or mar the damming materials.
4.1.1.3 Damming material for floor penetrations sh' ll have anchors a
. inserted through the board-type and blanket-type daming materials spaced one piece for every 36 square inch'sectu of damming material, using a' minimum of.two pieces per sec l
tion.
4.1.1.4 Cables shall be separated in penetrations, as much as practical, and loose fiber damming material shall be packed tightly between cables and between the raceway walls and the cables.
The dam shall be one inch thick i
and even with the rest of the daming material.
4.1.1.5 Ths. board-type damming materials shall be fitted into the penetration first, Crevices around the edge of the pene-
.tration and between sections of the board-type da cing materials which unevenly butt up against each other shall
.be tightly packed with loose fiber damming material.
All joints shall be covered with tape spanning the entire length of the penetration plus 10 inches on each end.
Tape shall be'en the outside surface of the daming ma-
.terials only.
l 4.1.1.6 Fiexible blanket-type damming material shall be insert'ed into the remaining open space at the top of each dam for wall penetrations.
Crevices around the edges of materiali i
used for damming shall be packed with loose fiber camin; material and taped to strengthen the overall dam.
j 4.1.1.7 Where boxing is required to extend the overall thickness i
i of the penetration seal, a wooden box shall be constructe:
around the penetration.
The inside dimensions of the box shall be approximately 8 inches wider and longer than the i
Center the box around the penetration and-tape all. joints thoroughly using tape wound completely J
around the box several times.
Banding material may be substnuted for tape.
Secure the box to the ("loor using
)
L duct tape.
The box shall be lined the entire thickness (depth) of the seal with board-type damming material.
l-4.1.2 For conduits, the dam shall be constructed as follows:
4.1.2.1 Conduits and -leeves in walls shall have loose fiber-type
^
damming material stuffed between all the wires and the wa of the conduit and/or sleeve to a total thickness of apprt mately 9 inches from the end of the conduit.
(The entire a
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a Page
'3' of 5
thickness of the seal will only.be'9 inches; 1 inch'of j
a damming material, and 8 inches of solid silicone foam).
After the dam is:in place, tape the end of-the conduit forming an outer dam.
An open' space approximately 1/2 inch shall.be left at the top of the. tape dam tc dispense the foam.
4.1.2.2. Conduits and sleeves in floors shall have loose fiber-type damming material stuffed between all the wires and the conduit 'or sleeve walls for a total thickness of 1 inch.
If possible, the damming' material shall be stuffed into the conduit 8 inches below the floor surface level.
In
. sleeves or' conduits that extend more than 10-12 inches, damming shall only be stuffed 8 inches down from the end of the sleeve or conduit.
4,1.2.3 Conduits er sleeves in ceilings or cabinets shall have
- i loose. fiber-type damming material stuffed between'all i
the wires and corduit wall 8 inches from the end of tne sleeve or conduit.
Tapc~shall be used as a dam placed over'the bottom end of the' conduit or sleeve.
An. opening of approximately 1/2 inch shall be made in the dam for the dispensing of foam.
4.1.3 Dams shall'be. inspected for ccmpliance to'the-above requirements prior to installing foam.
The inspection shall be documented on a Fire Stop Inspection Report (Diablo Canyon Form QA-7).
4.2 The silico.ne foam shall be mixed in accordance with the following, as applicable:
4.2.1 Due to the' development of hydrogen gas during foaming and curing, the foam shall not be mixed or applied near sparks or open flame.
4.2.1.1 Special forced air ventilation shall be provided if a ea:
e of installation have less than two cubic feet of free air space per pound of liquid mixture being foamed.
4.2.2 If tubes of foam are used, the two components shall be mixed until the mixture is uniform in color (approximately 30 seconds).
4.2.2.1 A small piece of foam shall be removed from the fire stop and inspected.
Reference attachment no. 7.4, " Cell Struc-ture Comparison Chart" for acceptance criteria.
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4.2.3 If automatic dispensing equipment is used, the Parts A and B con-ponents shall be thoroughly agitated prior to use.
The equip-ment shall be checked a minimum of once daily, prior to startup, to assure a proper ratio balance and thorough mixing.
No other ingredients shall be added to the mixture unless specifically e[7 approved for use.
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4.2.4 The components for lead-impregnated silicone foam shall be hand-L mixed.
The amount of lead powder to be added shall be determined E
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O Page 4
of 5
4 by test to attain the density value required in paragraph 4.3.2.4.
One-half the cmount of lead powder shall be add e o equal parts of A and B.
The parts shall be agitated separaVy to evenly disperse the lead, then mixed until a uniform color is obtained.
A catalyst may be added to adjust the snap time as required.
I 4.3 If automatic dispensing equipment or hand-mixing methods are used, a smal!
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test pour shall be mace at least once daily and when a new lot of material is added.
The test shall be made in either a Lily cup #6LT6 or a five-sided metal box measuring 3" x 3" x 3".
The following tests and inspectic shall be documented on a Silicone Foam Test Report (Diablo Canyon Form QA-4.3.1 The snap time shall be between one and three minutes long for silic foam, and less than 30 minutes for lead-impregnated silicone foam.
Snap time is defined as the time from mixing to when the foam star" rising.
4.3.2 The density shall be determined.
A 3.2.1 The foam shall be trimmed flush witn the top of the con-tainer after the sample has cured a minimum of fif teen minutes for silicone fum and 45 minutes for lead foam.
4.3.2.2 The density in pounds per cubic foot of the sample taken in the Lily cup shall be ccmputed by subtracting the gram weight of the cup (5.80 grams) from the total gram weight of the sample and multiplying the result by 0.289.
4.3.2.3 The density in pounds per cubic foot of the sample taken in the metal box shall be computed by multiplying the gram weight of the samole bv 0141 r
'M The density of silicone foam shall be 14-to 20 pounds per) 4.3.2.4 cubic foot.
The density of lead foam shall be 150 to 180
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pounds per cubic foot.
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3
,j' 4.3.2.5 The scale used to measure the weight of the sample shall be calibrated in accordance with the requirements defined in General Construction Quality Assurance Program Proce-dure GCP-10.1, " Control of Measuring and Test Equipment".
l 4.3.3 The color of lead-free samples shall be compared with Attachment 7
" Color Comparison Chart",
l 4.3.4 The cell structure of lead-free samples shall be compared with Att, ment 7.4, " Cell Structure Comparison Chart".
4.4 The silicone foam shall be installed in accordance with the following re -
quirements:
4.4.1 The liquid mixture shall not be continuously added for a time inte-val (shot) that exceeds 30 seconds for silicone foam and 15 minute' for lead foam, j
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Page-5 of 5
t 4.4.1.1-As size permits, small fire stops shall be completely foam-sealed with one shot' application.
4.4.1.2 Large fire stops that require several separai.e. shots shall i '
have a minimum of fifteen minutes cure time-between each L
shot for silicone foam and 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> for lead foam.
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'4.4.2 Sufficient foam shall be added to insure that the fire stop is com-i pletely filled and tightly sealed.
4.4.3 Changes, modifications, repairs to damaged, foam, removal of pene-trating components, or addition of new penetrating components shali L
be performed in accordance with the requirements of this procedure.
4.4.4 Foam shall got be installgd when the temperature of either liquid is ba h.; 55 e v above 80 F.
?.4.5 The foam shall be allowed'to cure a minimum of 24. hours prior to removing the damming forms.
4.4.5.1 Fire retardant damming forms shall be left in place and shall have the tape removed.
4.4.6 :After a minimum of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, the fire stop. shall be inspected for tightness of seal.,
Areas of inadequate seal shall be injected witt e
additional foam.
The inspection shall be documented on the Fire 4
l' Stop Inspection Report.
f 5.' 0 DOCUMENTATION
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~ d 5.1 Fire Stop Inspection Reports and Silicone Foam. Test Reports shall be filed j
2 by Quality Control for disposal or inclusion in the Records Management System.
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6.0 REFERENCES
6.1 Dow Corning Application Guide Specifications for 3-6548 Silicone RTV Foam Penetration Seal System 6.2 Dow Corning Sylgard 170 A & B Silicone Elastomer Information & Instruction Sheet I
7.0 ATTACHMENTS 7.1 Diablo Canyon Form QA-7, Fire Stop Inspection Report 7.2 Diablo Canyon Form QA-8, Silicone Foam Test Report 7.3 Dow Corning Form 61-337, Color Comparison Chart 7.4 Dow Corning Form 61-339, Cell Structure Comparison Chart L
FlRE STOP INSPECTION REPORT UN!T #
AREA ELEVATION G-93 #
Fire Stop Location j
Date &. Time Poured Tubes / Automatic Equipme.
REQUIREMENTS ACPT/REJ REQUIREMENTS ACPT/R'-
DAM CONSTRUCTION 4.1.1 4.1.2 SILICONE F0AM INSTALLATION 4.4.6 CELL STRUCTURE 4.2.2 (for types only)
AC DESCRIPTION CORRECTIVE ACTION 1
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REMARKS:
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DATE:
QA-7 (10/80)
REF. DCP-2
SILICONE FOAM TEST REFORT G-93 #
Part A Lot No.
Part B Lot No.
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Scale No.
Cal Due Date REQUIREMENTS
'ACPT/REJ REQUIREMENTS ACPT/R' Snap Time 4.3.1 Densi ty 4.3.2 Color 4.3.3 Cell Structure 4.3.4 fC TAG DESCRIPTION CORRECTIVE ACTION D
REMARKS:
l TESTED BY:
DATE l
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QA-8 (10/80)
Ref. DCP-2 1
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range shown in 3 and 4 acove when check your equipment mix ratio. You properly mixed.
should also check the original A and i
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j the temperature of the A and B liquid components before and af ter mixing.
These temperature readings should be between SE'F and 80*F and the snap time between 1 and 3 minutes fJr optimum reSults.
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REVISION Pacific Gas and Electric Company 9/23/83 DATE 1 0F 5 P@jJ3 PLANT OPERATIONS 1 AND 2IMPORTANf PAGE DEPARTMENT OF NUCLEAR NT UNIT NO(S)T,0 DIABLO CANYON POWER PLA PENETRATIONS SAFETY SURVEILLANCE TEST PROCEDUREI l
. TiTLi:
1 hb-DATE
- l LANT MANAGJR 7f s
APPROVEO;
)
/
ll fire
/
of a visual inspection of adoors and
/
ding conduit penetrations, fire
/
SCOPE This surveillance test consists taining to requires i
walls encompassing areas conThis procedure and barrier penetrations inclu
/
fire dampers in firesafety-related equipment.
PSRC review.
review and esponsible for the roblems l
RESPONSIBILITIES evaluation of the inspection rsenior QC i i
The A.
encountered.
l for:
/
QC inspector (s) shall be responsib e inspections.
Coordinating and/ur conductinghift security supervisor o f
B.
Notifying shift foreman and s l
I.
inspections, as required.
j 2.
responsible for l
Inspectors shall be qualified and preparing and re f
d shall be conducting the inspection, an f
C.
r results to the QC inspecto.
i ification 3/4.7.10, Fire B r erll b DISCUSSION As required by Technical SpecPenetrations, insp i ns shall be performed by areceived train A.
Fire barrier penetration inspect orsonnel who havevisual ex qualified QC inspectnr or pepassed a qualific tion and a 8.
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DC0134 IIV N~
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I N
1 AND 2 R
ON y
IABLO CANYON POWER PLANT, UNIT NO(S)
DATE 9/23/83 O
PAGE 2 0F 5 g
INSPECTION OF FIRE BARRIER PENETRATIONS TITLE:
This test consists of a visual inspection of the fire barrier
}l.
penetration seals, including conduit and piping, fire doors, C.
including door, door frame, hardware and actuator, and I
penetrations for ventilation, including dampers in and out of theg}I During the initial inspection, baseline data They
}
will be generated and as-built drawings will be prepared.
ducts and walls.
The areas
,~
will be used in subsequent inspections as checklists.
to be inspected are defined in Attachment A.
PREREQUISITES.
Obtain appropriate clearances or special work permits to A.
accomplish procedure as required.
Assign trained qualified personnel to conduct the inspection.
i i
I 8.
Obtain necessary equipment and supplies; i.e., ladders, I
C.
flashlight, torque-seal lacquer.
Notify shif t security supervisor, or delegate, before l
D.
I (Attachment B).
Notify shif t foreman, or delegate, before certain ventilation dampers which are " armed" for control room annunciation are E.
exercised.
The inspection of some fire barrier penetrations may involve the DO NOT ALLOW T001.5 OR BODY TO F.
opening of energized switchgear. Call shift foreman for assistance.
ENTER LIVE SWITCHGEAR.
NOTIFY SHIFT FOREMAN IMMEDIATELY OF ANY NON BARRIERS 50 THAT A FIRE WATCH CAN BE ESTABLISHED.
G.
515562 through Obtain latest revision of fire protection drawings H.
f 515580.
I I
ACCEPTANCE CRITERIA _
All fire barrier penetrations, including cable penetration barriers, fire doors and fire dampers in fire zon A.
l DC0134 21V g
)lABLO CANYON POWER PLANT UNLT NO(S) 1 AND'2 ON l
DATE 9/23/83 1
PAGE 3 0F 5 j
7 TITLE: INSPECTION OF FIRE BARRIER PENETRATIONS
{
1.
Fire doors shall be intact, normally closed and latched properly.
Additionally, their individual automatic closing mechanisms shall function as required by the National Fire Codes. A fire door is considered functional if it is capable of being closed.
2.
Fire dampers shall be intact, normally open and functional, and capable of shutting off air flow when tripped.
3.
Fire barrier penetrations shall be intact and be sealed with fire retardant where they pass through fire barriers.
Additionally, all electrical conduits or boxes that terminate or have openings within 24 inches of the fire barrier shall be foamed in accordance with PGandE drawing 050029 and Specification 8767 (Furnishing and Installation of Flexible Boots and Silicone Foam Penetration Seals).
8.
Fire Barriers shall be inspected in accordance with the latest revision of the FIRE PROTECTION.irawings referenced in
" PREREQUISITES" section H.
J PROCEDURE A.
Obtain torque-seal to mark the penetration for each inspection.
The color should be varied to provide traceability during future inspections.
B.
The penet'ations shall be numbered sequentially left to right.
C.
Each room in an area shall be treated individually.
Inspect the floors, walls, ceiling fire barrier penetrations, fire doors, and ventilation penetrations.
Open boards, panels, cabinets and switchgear cubicles when necessary to inspect penetrations.
D.
When a conduit pullbox is installed on a fire barrier, its cover shall be removed and internals inspected. All conduit penetrations with elbows or covers within 24 inches from the fire barrier penetration must be opened and internals inspected.
Once a cover is replaced after inspection, it shall be sealed with torque-seal or equivalent.
The internal inspection is to ensure compliance with above-mentioned fire retardant specification.
NOTE:
If the seal is found intact during subsequent inspections, removal of that cover shall not be required.
)
DC0134 31V 4
d i
DIABLO CANVON POWER PLANT UNIT NO(S)1 AND 2 ON y
DATE 9/23/83 PAGE 4 0F 5 INSPECTION OF FIRE SARRIER PENETRATIONS
\\
UTLE; E.
Graph paper will be provided to make approximate sketches of the penetration location on the walls, ceilings and floors. ' Drawings for these _ areas will be provided, if available.
F.
Conduits and piping that are to be inspected shall be listed by their conduit or line number. They shall be listed in the same way as the penetrations, left to right and north to south.
G.
As the penetration, etc., is recorded, a dab of torque-seal shall be placed in the screw slot and the joint of the conduit cover, the right side of the penetration, the inside of the fire door jam and on the ventilation damper top right and also on the switch arm.
H.
Ventilation dampers are listed by room, duct, wall, position switch, etc. All dampers shall be tested by disconnecting their link or actuating device, and shall be restored to armed condition prior to activating the damper.
In this instance, contact the Control Room prior to any activity so that any annunciation will be noted as a test and not a fire activation.
I.
All fire doors shall be operated to verify their operability and their integrity.
Any fire door without signs shall be noted.
This shall include sliding doors, which are to be operated by activating their_ release mechanism.
They shall remain intact and in good working order and be restored to the armed condition prior to the test.
Fire doors shall be documented by door number, wall and location.
J.
A NPPR or GC form E-21 shall be written to correct and track any fire barrier found inoperative or open; also, an information tag (Attachment G) shall be installed.
K.
As an area is completed, the completed sheets (Attachments 0 through G, as applicable) with the inspector's initials or stamp and date will be forwarded to the QC inspector for review.
L.
When the STP M-70 inspection review is complete, the inspection I
sheets, drawings and results shall be forwarded to the Senior QC inspector for evaluation and follow up on any problems encountered.
eI DC0134 4IV
~5 f Aaa ication Guice
' Sae.fications n3m333 ci
- neum, DOW CORNING @ 3-6548 SILICONE RTV FOAMWOlD A. PRICE 8 CO.,INC.
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PENETRATION SEAL SYSTEM nicSaOND77,'4802
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235 5343 981 2877 PATENT POSITION installer, Any substantial for containment during deviations from this foaming only and must A method of preparing foam by specification guide shall be bw terr,oved from the mixing Part A and Part B of Dow referred to the manufacturer final completed pene-Corningt 3-6548 silicone RTV foam or its representative.
tration seal system, and tne foams produced thereby are claimed in Dow Corning's U.S.
2.0 MATERIALS / PRODUCTS 3.0 DELIVERY AND STORAGE Patent No. 3.923,705. Dow Corning g
g g
intends to enforce that patent, but g
will offer licenses thereunder, if a license is needed, Dow Corning will as supplied by Dow Corning containers or unopened Corporation, Midland, packages, all clearly labeled ship the products in containers Michigan 48640, its authorized with the manufacturers name, which bear a labellicense and the distributor, applicator, or product identification, and lot no u
as e other approved source, and numbers where appropriate.
e shall,nclude the following-3.2 Dow Corning 3-6548 sitioone i
written request Dow Corning will cffer'a license agreement at a 2.1.7 Dow Corning 3-6548 RTV foam shall be celivered comparable royalty rate under silicone RTV foam -
in two component kits which the licensee may handle his Penetration fill material containing a Part A and own accouqting of royalties due,
- comprising liquid;.
Part B component in each kit.
I regardless of tne source of component Part A.'
3.3 Materials sh'all be stored out material.
(Black) and liquid
- of the weather,in their component Part B (off-original, tightly sealed GENERAL white).
containers, or unopened The following application guide 2.7.2 Dow Corninge 96-081 packages, as recommended specification is provided for the RTV silicone adhesive by the manufacturer, convenience cf the architect /speci-sealant - caulking for 4.0 CO M AC M
- fier, small cracks and It is recomrnenced that the d0 tailed adhesive for flexible 4.7 Foam and damming shall both penetration seal system be boot lap-seals.
be applied by a competent f
specified with the penetration seal 2.7.3 Mineral fiber board, contractor or applicator.
. vstem installer under a separate mineral fiber matting, 4.2 Contractor of applicator shall cocument.
and mineral fiber putty be responsible for selecting
- forming and damming and supplying alllabor and 1.0 SCOPE materials used to supervision as well as 7.7 This specification guide contain the liquid 3-6548 furnishing all materials covers the application of Dow mixture prior to and required to complete the job Corning 3-6548 silicone RTV during foam-filling satisf actorily in accordance foam in penetration seal penetrations - fire with the written specifications, i
systems for new building tested and functionally j
constructions or in sealing approved forming 5.0 PREPARATION AND l
and upgrading the Capabilities materials Can be left in DAMMING of older existing building place to become an 5.1 See Architectural Details structures, integral part of the Section for typical floor and i
The key items in this guide foamed penetration seal.
wall penetration seal systems.
l shall be incorporated in the 2.7.4 Plywood sheet, particle 5.2, Penetration seal preparations cetailed specification covering board, or otner shallinclude use of the application and Qt'ality control combustible forming procedures, techniques and procedures of the selected materials - forming and quality control staridards
___~--
~ -
i l
l j
5.3 Preparation shallinclude but silicone RTV foam mixture shcIl be add:d to 1
not be limited to:
Part A and Part B, shall be insure that the pnetration 5.3.7 Removing all16cidental thoroughly agitated by opening is completely filled l
Combustible materials stirring or recirculat,on and tightly sealed with the i
and loose impediment in order to redisperse cured foam elastomer, from the penetration any solid filler or 8.6 After a foam penetration seat opening and involved pigment that may have has besp installed, a minimum g,g,7 settlad during storage or of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> shall be required after standing longer before any damming forms i
5.3.2, Removal of free h,qu,ds than four hours" i
are removed or the cured 7.2.3 The Part A and Part B foam is trimmed, rf ces nd pe t at on components.
liquid components of 8.7 After a minimum of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, 3-6548 foam shall be the final penetration seal shall i
5.3.3 Installation of the thoroughly blended in a be inspected for tightness of l
specified dammin9 one to one ratio by materials to accomadate seal of the cured foam, either weight or volume.
and insure the proper Should an area of non-tight thickness / fire rating requirements and dispensing equipment shall be injected with freshly shall be checked a applied 3 6548 liquid mixture provide containment g
g aeg.
( rior to start up) to
- seal, 5.3.4 Removal of all ensure a proper ratio j
combustible dammin9 balance and thorough 9.0 RETROFIT AND materials or materials mixing.
MAINTANENCE not intended for the final foam penetration seal 7.2.5 A four step, in lins 9.7 Changes, modification, repairs quality control check to damaged foam, removal of system.
(see Table l}
penetrating components, or 6.0 PRIMING shall be made at addition of new penetrating least once daily, or component can be readily 6.7 Priming of surfaces and Upon changing to a,
made to existing foam penetrating components is
[(:
new lot of material to penetration seafs. The cured
usually not required since the ensure the performance elastomer foam can be easily 3-6548 foam develops removed or poked thru and of both dispensing [i considerable compression and equipment and foar refoamed and sealed with the forms a tight mechanical seat product prior to injection of freshly mixed when properly installed, installing penetrati6n 3-6548 liquid components.
7.0 FOAM MIXING AND 10.0 CLEAN UP DISPENSING EQUIPMENT B.0 FO AM INSTALLATION USE 10.7 A high-flash mineral spirit B.7 Properly mixed and dispensed solvent is recommended for 7.7 Material may be hand mixed Part A and B liquid mixture clean up of the 3-6548 Part A -
so as to conform to the 4 step shall be added (inkcted) into and B liquid components, quality control procedure a reperly formed and 70.2 The cured foam can be cut listed in Table 1.
dammed penetration opening and trimmed with a sharp 7.2 Specific equipment handling producing a tight foamed-in*
knife or blade, and operating procedures place penetration seal.
shall be as specified in the 70.3 Application and mixing 8.2 The 3-6548 liquid mixture foam applicators quality equipment shall be in good, shall not be continuously clean operating condition.
control and operating added for a time interval procedures manual. These Daily cleaning of the mixing (shot) that exceeds its and dispensing gun procedures shallinclude but measured snap time (three assemblies is essential.
not be limited to:
minu;es maximum).
7.2.1 Dow Corning 3-654b 10.4 Upon completion of all work 8.3 Smaller penetration openings covered in the specification, P
and Pa B shall be can often be completely foam the applicator / installer shall e
used as supplied by the remog aH eqdpM.
applications.
matenal and debris leaving manuf acturer. Outside ingredients should not B.4 Larger penetration openings the area in an acceptable and
/
be added unless their may require several separate undamaged condition, i
l specific mixture has shots. Each shot shall be I
been qualified with given a minimurn of fifteen 11.0 SAFETY REQUIREMENTS f
appropriate testing.
minutes cure time before tne 17.7 Dow Corning 3-6548 silicone
[
7,2.2 Prior to use, containers next shot is added.
RTn/ foam Part A and B liquid
- m cs _ _ o _
oo o m-
~~a
j 2
- wil solvents. Toxicological using any ?!Ianing silv::nts.
f:r applying 3-6548 f:cm (55
't 1"
1 cf the liquid 13 80 F), the temper ture cf 4
(. ;onents or their cured 12.0 GUARANTEE AND the Part A and B liquid mixture does not suggest any LIMITATION components should be significant ha2ard incidental to 12.7 Dow Corning Corporation adjusted to obtain the industrial iiandling, warrants that each quantity of specified snap time of one to Minimal eye protection should Dow Corning 3-6548 silicone three minutes.
be adequate, however safety RTV foam product or Dow 72.4 Specialopenings or glasses with side shields are Corning 96-081 RTV silicone clearances less than % inch recommended for industrial adhesive / sealant product may be difficult to enter with e' environments. Masks or delivered shall be the kind typical 3-6548 dispensing respira1Ns should not be designated or specified by it, equipment. Fire tested and required for normal industrial and no other warranty (except approved elastomeric caulking handling purposes.
by title) shall be applied, materials, such as Dow Corning 96-081 RTV silicone 77.2 Spills of the liquid 3-6548 72.2 Certain chemicalingredients Pan A and B components can in some synthetic material;, or adhesive / sealant should be become extremely slippery, substrates can inhibit or used in lieu of thi foam for Sawdust should be temporarily retard the cure of small openings.
Immediately applied to any 3-6548 foam resulting in a 72.5 This specification guide does liquid spill for temporary relief tacky surface at the involved not cover all construction and the spill removed with interface. Complete cure details for foam penetration high flash mineral spirits.
Usually results after several seal systems. Shop drawbgs days. A small scale showing proposed damming 7 f.3 CAUTION: Due to the compatibility test is matenals, anchorage and evolution of hydrogen gas recommended when suitability fastenings will be required.
during foaming and curing, to a particular application is in 72.6 Openings to be sealed on appropriate caution should be question. More detailed raw sMaces couW be exercised. Dow Corning information is contained in h"* * 'd "** tf I ** *I'd 3-6548 silicone RTV foam Dow Corning 3-6548 silicone Wea a h.
should be mixed and applied RTV foam Information Sheet.
a, su aW suuctural away from sparks or open Form Number 61320B 77, flame. Special forced air
,inishing plates with 6
' ventilation shall be provided if 72.3 When the ambient temper-appropriate anchorage must areas of installation have less ature exceeds the range deal be installed.
than two cubic feet of free air y
space per pound of liquid 5
mixture being foamed.
j; 77.4 CAUTION: On direct contact, TABLE 1: FOUR STEP OUALITY CONTROL REQUIREMENTS FOR CHECKING DOW CORNING 3 6548 SILICONE RTV FOAM AND DISPENSING '
Dow Corninge 96-081 RTV silicone adhesive / sealant EQUI.PRENT irritates eyes,in case of eye
- 1. S n a p Ti m e, m i n u t e s............................................. 1 -3 contact, flush immediately
- 2. Free Foera Density, Ibs/ft$..................................... 14-20 with plenty of water and
- 3. Color Chart Comparison.
consult a physician. Avoid (Dow Corning Form No.61-337)................................. Pass prolonged or repeated skin
- 4. Cell Structure Chart Comparison, contact.
(Dow Corning Form No. 61339)................................. Pass 17.5 C.)nsult the. - manufacturer's safe handling procedures for ('
~
~
-~'~
the specific mineral fiber damming materials or other penetration forming materials TABLE 11: SUGGESTED GUIDE FOR DESIGNING MINIMUM PENETRATION u's e'd.
THICKNESSES FOR DESIGNATED FIRE RATINGS 17.6 Coveralls, safety shoes and (Data extracted from results of severallarge scale E-119-76 fire tests of gloves are recommended for different Dow Corning 3-6548 silicone RTV foam penetration seal systems in applicator / installers. Hard both ficor and wall test structures.)
hats, safety belts and other Fire Rating auxiliarly safety equipment
, g0u, y g0u, 3 g0u, may often be required to g, g g,
g satisfy specific area requirements.
Th.ckness of Dow Corning 3-6548 j
silicone MTV foam alone.......
4 inches 8 inches 12 inches j
17.7 Follow all label directions ThWess of Dow Cornsg >698 concerning flammability, e
am N P d ventilation, and any other safe fire approved damming material 3 inches 6 inches.
9 inches handling procedures when
(-
FIGURE 1: SNAP TIME VS. TEMPERATURE AFTER MIXING l$
l.
13 Temperature,
$nsp Time.
'I
~
degrees minutes 11 32 F (O C) 13.2 43 F (6 C) 6.7 l
10 72 F (23 Cl 1.5 l,
100 F (37 C) 0.3
~~
9 122 F (50 C) 0 25 c) 9 2 0 E
E 7 i5 6
&: s en 4
3 t
2-t I
1. ____ --__--
J----
I i
I t
i I
it i
.C 0
20 40 60 80 100 u0 Te mperature, *F i
FIGURE II: HYDROGEN EVOLUTION
}
'E.
e 8-
- i 9
7-Results after m ring 1 Part A with 1 s,l Part B by volume:
fh 6 ~~
Total Accumulated Mr Gas Evolved
- g Tome.
Al 5. 7.P., parts e
}s, 5 5~
minutes by volume s
1 1 *-
s 1
0.9 h
5 1.2 4
gm to 14
<g 20 20 60 4.8 l
f 3-
~
95 6.3 o
o 120 67 w
200 7.5
/
2~
240 18 f
i 270 80 340 84 l
.j i
1
--4 400 8.5 500 87 O
I I
I I
I I
O 100 200 300 400 500 Time, minutes
,/
l O
ARCHITECTURAL DETAILS
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' CulDE ZCOR.
I WALL OPENING 'P'ROTECTIVE.
SYSTEM NO. 7
, - MULTIPLE-CABLE SYSTEMS FIRE RATING - 2 HR.
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GUIDE ZCOR ALTERNATE CONSTRUCTION WALL OPENING PROTECTIVE.
SYSTEM NO. 7 MULTIPLE CABLE SYSTEMS FIRE RATING - 2 HR
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SYSTEM NO. 6 MULTIPLE CABLE SYSTEMS FIRE RATING - 2 HR.
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- 2. cables
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WALL OPENING PROTECTIVE.
. SYSTEM NO. B MULTIPLE-CABLE SYSTEMS FIRE RATING - 2 HR.
I l
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SYSTEM NO. 22 MULTIPLE-CABLE SYSTEMS FIRE RATING - 2 HR.
b L
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- 1. floor
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- 2. steel pipef g
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- 3. mineral
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GUIDE 2COR WALL OR FLOOR OPENING PROTECTIVE, SYSTEM NO. 21 MULTIPLE-CABLE SYSTEMS FIRE RATING - 2 HR.
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- 2. conduit
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- 3. mineral composition Mlkh 5
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MIDLAND, MICHIGAN 48640
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Revised Response to Question 5 (cont'd)
As a result of. PGandE's review of its fire protection pt9 gram, in excess of 80 doors have been replaced at Diablo Canyon to
{
attain labeled fire doors in fire zone boundaries. Those remaining doors that are unlabeled have been evaluated and are felt to provide adequate fire protection for the hazards in question, b.
Pipe penetration seals As discussed in our response to Question 18, three-hour rated penetration seals will be provided for the containment pipe penetration.
Pipe penetrations through fire barriers are sealed with materials subjected to a three-hour test in accordance with ASTM E-119-1973.
Test reports are provided in our response to Question 33.
Electrical penetration seals Containment electrical penetrations consist of 12-inch or 24-inch diameter schedule 40 pipe sleeves 5 feet long through the concrete containment. Elec'trical conductors run inside the sleeves. At each end of the 5-foot long sleeve, the electrical conductors pass through steel header plates and are completely encased in self-extinguishing epoxy. The assembly of steel and epoxy is approximately 4 inches thick. The epoxy has been tested in ac;.ordance with Method 2021, Federal Test Method Standard No. 406 (identical to ASTM-D 635 test for flammability of rigid plastics). The space within the sleeve between the two seals is pressurized with dry nitrogen.
The cabling is enclosed in steel junction boxes at end of the penetration sleeves and is run in steel conduit from there. For a fire to propagate through the containment, it would have to breach the junction box, progress through the steel header plate, burn along five feet of electrical conductor in an oxygen-free atmosphere, progress through the other steel header plate and the other junction box. While not having a specific fire rating, these containment penetrations are felt to be adequate fire barriers.
Electr2 cal penetrations through fire barriers (other than containment) are either sealed with grout or silicone foam. The silicone foam has been subjected to a three-hour fire test in accordance.with ASTM-E-119-1973. The grout used is a fine. aggregate concrete and as such bas the same fire rating as concrete. The grout is injected to completely fill the void in the fire barrier between the electrical conduits and the poured concrete walls. The configuration of the grout and/or silicone foam is such that the electrical penetration seals have three-hour ratings.
4=
1 i
i
\\. \\
4 (cont' d)
"" i except conduits h
redundant electrical run in trical cabling is de i
F_,4r,ats_ top _s _,in spreading rooms, theitchgear only one All-safety related eleczones that containthe 4.16 kV cabled the 480 vo ys containare installed as '
in those firedivision (specifically,and inverter rooms, an of the plant, cable tra stops Cable tray fire on horizontal areas switchgear all other d cabling, vertical trays, 10 feet All cable
- ings, areas, andsealed, In rooms).only nonsafety-relate 5 feet of cable tray crossspreading room, contr l room of 4 feet on rooms are intervals h se two trays, and within entrances between t e48 silicone at cable entrances to theinterconnecting cable of Dow Corning Q3-6533 for test reports). silico For made response to Question he The are Marinite boards ' surround tcabling above th stops stop.
he Cable tray fire-our foam (refer tovertical cable trays, extend out 8 inches d vertical of the in ignition to prevent Marinite boards ring stops in horizontal andE's Department of En cable tray.
l of cable trd fire The test was were 'conddeted by PGan30?,000 Bru/ hour flameof the The firestop for was stop stop.
Fire tests of the fire stops-orientations A
side one Res earch in 1975, cable insulation on one on
)
cable insulation oximately 20 minutes.of the fire other side he terminated once t the completely burssd (appr spread of fire to thed vertical cable trays.
was vented the both the horizontal an fire rating ofProcurement pre are UL listed with a fire dampers), called for fire dampe rs Ventilation fire dampersmaximum UL listng for d.
label is for 1-1/2 hours, system of has ' indicated that none ventilation 1 1/2 hours (thespecifications for t e i
therefore, the UL h
of 1-1/2 hours. excess of the fire dampers in excess a fire test and not fire doors, manufacturerline had been tested inwould pass j
the fire dampers The their product zone However, he f elt used as part of fire The s
which fire damperslectrical equipment area, sufficien of 1-1/2 hours, are to be loading dampers is felt e low fuel areas inare predominantly e boundaries rating for the firenot warranted for thes The are T-1-1/2 hour doors three-hour fire ical fire dampers.
a drawing showing typ l
areas.
}
+
Attached is
F.
i 1
e Information about j
"~
Silicone RTV Foam 1
4
=-
j
=
DESCRIPTION DOW CORNING @ 3-6548 Dow Corning 3-e548 suicone RTv foam is a medium-density, two part SILICONE RTV FOAM product supplied as A and B liquid Type,...
Two-component sihcone components. The A component is Physical Form, black and the B component is off-
. as supphed.
,. Thin tiQuid white for easy identification and as cured.
... Flexible foam inspection of mix. When the A and Special Properties.
. Cures at room temperature, reversion j
B components are thoroughly resistant non-conosivt improved fire resistance l
'T mixed in a 1:1 ratio by either weight or volume, the product will expand and cure to a foamed elastomer at TYPICAL PROPERTIES room ternperature in 1-3 mintues.
These values are not intended for use en prepanng specihcations Only a mild exotherm of 36 F (20 C) maximum internal temperature rise is As Supplied
)
exhibited during the curing reaction.
Parf A - Physical CTM 0176 Appearance Black, liquid PATENT POSITION CTM 0097 Specific Gravity at 77 F (25 C) 1.05 CTM 0050 Viscosity, Brookfield Model HAF A method of preparing foam by mixing Part A and Part B of Dow spindle No. 3 at 10 rpm, poises 45 CTM 0006 Flash Point, degrees 470 F (243 C)
Corning
- 3-6548 silicone RTV foam CTM 0006 Fire Point, degrees
, > 650 F (>344 C) and the foams produced thereby are CTM 0787 Sulfur Content, ppm
,<2 claimed in Dow Corning's U.S. Patent CTM 0787 Chlorine Content, ppm.
, <4 No. 3,923,705. Dow Corning intends CTM 0787 Bromine Content, ppm
...<5 to enforce that patent, but will offer CTM 0787 lodine hntent, ppm
.<6 licenses thereunder. If a license is nseded, Dow Corning will ship the Parf A - Electrical-products in containers which bear a CTM 0149 Dielectric Strength, volts / mil 680 tabel license and the invoice will CTM 0210 Dielectric Constant.100 Hz 3.08 include a statement of the royalty CTM 0210 Dissipation Factor.100 Hz 000103 due. Alternatively, upon written CTM 0272 Volume Resistivity,500 volts DC, ohm-cm.
3 23 x 10'2 request Dow Corning will offer a As SuppIled licenso agreement at a comparable i
royalty rate under which the licensee Part B - Physical j
may handle his own accounting of CTM 0176 Appearance..
Off-white liquid royalties due, regardless of the CTM 0097 Specific Gravity at 77 F (25 C) 1.05 source of material.
CTM 0050 Viscosity, Brookfield Model HAF spindle No. 3 at 10 rpms, poises 60
)
USES CTM 0006 Flash Point. degrees 270 F (133 C)
CTM 0006 Fire Point. degrees 390 F (199 C)
Dow Corning 3-6548 silicone RTV CTM 0787 Sulfur Content, ppm
<2 foam is specially formulated to have CTM 0787 Chlorinr* Content. pdm
<4 irnpr ved fire resistance properties CTM 0787 Bromine Content. ppm.
.<5 As a result, it is ideal for preparr.y CTM 0787 lodine Content, ppm
<6 fire resistant penetration seals.
Parf 8 - Electrical' The suitability of Dow Corning 3-6548 silicone RTV foam for wall CTM 0149 Dielectric Strength, volts / mil 900 and floor penetration seals, is CTM 0210 Dielectric Constant.100 Hz 3.29 svidenced by the results of Fire CTM 0210 Dissipation Factor.100 Hz 0 0034 Endurance Testing as defined in CTM 0272 Volume Resistivity. 500 volts DC chm-cm 3 38 x 10 o
a
(
. TYPICAL PROPERTIES - Continued ASTM E 119 73 (standard for fire.
tests of building construction and As Cured - Physical, materials).The material successfully CTM 0176 Appearance
. Dark grey -
withstood three hours of fire i
black elastomeric foam exposure. The testing was CTM 092A Snap Time'. minutes............................. 1.5 conducted at Abe National Gypsum CTM 0812 Density'. Ibs/tt' 17 Company and witnessed by a CTM 0826 Cell Structure 5. closed cell, percent..
... > 50 representative of the Factory
. CTM 0137A Tensile Strength, psi....
. 33.0 Mutual Research Corporation. A CTM 0243 Lap Shear (Cohesive) Tensile Strength, psi.
35.0 formal report is available by CTM 0293 Peel Strength (180' Cohesive), ppi...,
2.0
. requesting Factory Mutual Report CTM 0525 Compression Deflection, psi No. 26543 from Dow Corning I
at 20% compression 5.2 Corporation.
at 40% compression.
10.1 Dow Corning 3-6548 silicone RTV fa s a % dassM mamnal for CTM 0544 Spec c He t cal
'C j
use in fire rated penetration seals. It i
25'C 0 328 50" C 0336 also has been assigned a F:pe 75'C l.,
.ll l...
0.345 Spread Rating of 20 when uted in accordance with the provisions of 0
ASTM Designation E-84-76a, j
' 0' 150"C..'
0.370
" Standard Method of Test for Surface CTM 0224 Thermal Conductivi!y'. cal cm/sec sq cm 'C.
1.8 x 10
- g characteristics of Building Burnm.
Materials. Details of these tests are CTM 0740 K Factor.17 lb/cu f t foam. BTU-m/hr ft2.o F 0 542
.similarly available from Dow Corning CTM 0585 Linear Coefficient of Thermal Expansion.
Corporation.
(-25 to 150 C), cm/cm 'C.
3.2 x 10
- CTM 0585 Volume Coefficient of Thermal Expansion.
it should be specifically noted that
( 25 to ' ISO C), cu em/cu em 'C 9 6 x 10..
not all silicone foams have i
CTM 0316A Flammability *, vertical burn:
improved fire resistant properties.
The use of the generic term Time in name Average T<me To Average weg, seconos Stame Glow Our seconos Loss cercent
" Silicone Foam" should be avoided when referencing this product or 15 7.2 1.3 data This test data is valid only to 60 15 6 13.5 this product by its specific name CTM 0780 Limiting Oxygen index. LOI rating....
... 35 and number designation, namely As Cured - Electrical
- Dow Corning 3-6548 silicot.e RTV i
foam.
l CTM 0114 Dielectric Strength. volts / mil 165 CTM 0112 Dielectric Constant.100 Hz 1.95 Dow Corning 3-6548 silicone RTV l
CTM 0112 Dissipation Factor.100 Hz 0.00505 foam has demonstrated utility in a l
CTM 0249 Volume Resistivity ohm-cm 2.24 x 10'$
vanety of other applications tnat CTM 0525 Radiation Resistance.
require sealability, improved fire Moour s at toa, resistance, insulation against neat n oosure u
megaraos compression. ps' and cold, and relatively low 0
0 628 toxicity.' It is particularly useful 6
0.672 where stability at higher and lower 22 0.92 temperatures is required A list of 49 2.00 application requirements. and the 124 2.32 related pertinent properties for which data are or will be available Still resilient on Dow Corning 3-6548 silicone so mos iiavia RTV foam, is given in the table one part A inorougmy mined witn one part 8 and curea at n F 125 Ci ior 24 nrs entitled " Typical Application and Time to non-pour conaition Aiso time to Degen ioam rise
' Power mined for 30 seconos and cured in non contaneo conoitien Property Requirements of Dow ereeinabmty memoa Corning Silicone RTV Foam?
'Cenco liten method Tests claims representations. and descriptions regarding flammability are Dased on standard sma;i scale taooratory tests Sucn tests are not reinacle for cetermming evaivatmg predrctmg or describing tne fiammab iity or Durnmg characteristics of tne product under actual fire conditions whelmer the proauct is useo alone or m comomation witn otner proovets
'The na2ardous decompositeor' procucts I
Curi'd 'am samose tnicaness t?s mas evoived from entreme nea* or hv r'ma of m,
e Specification Writers: Please contact Dow Corning Corporation. Midiand. Michigan..
procact are s.or Coz av r.nes,
before writing specifications on this product.
mcompletely Durneo caroon proaucts k
l l'3 TYPICAL APPLICATION AND PROPEWTY REQUIREMENTS OF DOW CORNING SILICONE RTV FOAM Applicaflon Requirement Related Property l
Seatabihty.........,.
.......... Closed cell structure.
Expansion ratio during cure 2.
Insulation against hot and cold...
........ Thermal conductivity; K factor High-temperature stability..
Thermal agrng.
Reversion resistance Low temperature stability
, Stiffening temperature l
Flame retardancy (cured foam)
Vertical burn:
Limiting oxygen index Flammability of liquid components Flash point; Fire point Toxicity Toxicity of by products; Toxicity of product Nuclear applications Radiation resistance.
Halogen content HOW TO USEt 3-6548 sikcone RTV foam, add an
- I"9 equal quantity of Part A with an equal quantity of Part B by eitner Upon standing. some filler may weight or volume. For batch mixing settle to the bot?om of the A and by hand or power mix, vigorous the 8 component containers To and thorough mixing should be insure a uniform product mix. the maintained for 30 to 60 seconds.
materialin the A and B containers The mixed product should then be should be thoroughly mixed prior quickly transferred and poured into to use-the desired application site For To properly catalyze Dow Cormng larger volume applications, the use of suitable automatic mixing, tuse of the componenis A and B and or the metering, and dispensing
. metnoes disciosed in inis cata sneet may M s memMed reamre a lice ns e from Dow Corning Corporaison under u S Patent 3 923 70s FIGURE 1: SNAP TIME VS. TEMPERATURE AFTER MIXING 13 y
12
~
Temperature.
Snap hme, degrees mmutes 11 32 F (O C) 13 2 43 F (6 C) 67 10 72 F (23 C) 15 t00 F (37 C) 03 9
122 F 150 C) 0.25 h8 E
i 1 4
[6 a; 5 v>
4 3 - - - - - - - - - - - - - - -
I
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i 0
20 40 60 80 100 120 Te mpe rrture,
- F
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FIGURE II: HYDROGEN EVOLUTION.
w 8-
^'
7-s Results after mosung 1 Part A with 1 Q
Part B by volume:
hi 0~
Total Accumulated y
He Gas Evolved
-Z Tome.
At S. T.P., parts en y%
5-manutes by volume
- a
~g 1
09 5-4_
5 1.2 8 v) to 14
<q 20 20 3 7 3_
60 48 0
95 63 20 120 6.7 w
200 7.5 2 ""
240 7.8 i
270 80 340 84 1 -1 400 85 500 8.7 I
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100 200 300 400 500 Time, minutes The type or degree of mixing can As shown in Figure I, temperatures significantly affect the cell structure lower than 72 F (23 C) will result in and dsnsity of the final foam significantly longer cure rates, product. The introduction of air while temperatures higher than 72 F during the mixing action is (23 C) will result in significantly desirable to obtain a more uniform shorter cure rates Snap times cell structure, maximum expansion faster than 1 minute and longer ratio and volume efficiency. Typical than 3 minutes can result in a less batch hand mixing will generally uniform foam cell structure and a result in a foam density of about 20 lower expansion ratio.
Ibs/ft' Batch power mixing will generally result in a density of Repairability i
l about 17 lbs/ft). Automatic mixing.
Once cured in place, Dow Corning metering and dispensing equipment, 3-6548 silicone RTV foam can be with introduction of auxiliary air into the mix. can result in foam removed with relative ease, repairs densities as low as 15 lbs/ft).
or charges rnade, and the repaired l
Likewise, the expansion ratios of area refoamed in place with j
additional product. Since this foam volume to liquid volume can vary from 2.5:1 to 4:1 depending on product develops good adhesion to the type and degree of mixing.
itself, the repaired region will When cured under significant become an integral part of the confinement and restriction, foam onginal foan l
densities packed as high as 30 lbs/f t 3 Adhesion j
can result.
Upon curing. Dow Corning 3-6548 silicone RTV foam exhibits good CmRm adhesion to most common As supplied and properly mixed, substrates. Substrates to which Dow Corning 3-6548 silicone RTV good adhesion is not normally foam has a snap time, or workin9 obtained include Teflon '
l time, of 12 minutes at 77 F (25 C) polyethylene, polypropylene, and
)
l and 50 percent relative humidity. A related materials Adhesion to most l
l typical snap time would be about substrates can be improved with t b minutes. The cure rate or snap the use of Dow Corning? 1200 RTV l
time is very dependent upon the tampstature of the A and B
-Tefton" is a registered trademark of components after they are mixed E I DuPont da Na'"ours
i
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z prime cost. Good adhesion cannot dunng the first three minutes after b3 gxptcied to substrates known to the A and B components are mixed inhibit the cure of Dow Cornmg together. Since the foam has a 3-6548 silicone RTV foam.
closed ceu structure, the gas is initially retained and then released as shown in Figure 11. Figure ll CAUTION shows that one part by volume of 4
Dow Corning 1200 RTV pnme coat part A mixed with one part by
]
is flammable. Keep away from heat volume of Part B will release 8.7
)
and open flame. Use only with parts by volume of hydrogen gas at adsqutte ventilation.
S T.P. during the first 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />. More inhibition of Cure
- an one haU of N tdal gas 1
evolution is released from the foam
' Certain matenals. chemicals. cunn9 dunng the first hour subsequent to agents. and plasticizer can inhibit mixing the A and B components.
the cure of Dow Corning 3-6548 For estimation purposes. the silicone RTV foam The most following formula can be used to notable include:
calculate the total volume of
- Organo tin and other organo.
hydrogen gas released from a metalkc compounds given weight of the hquid components: (0.0664) (pounds of j
- Silicone rubber containing Part A + pounds of Part B) r cubic
)
organo-tin catalyst
limit of hydrogen gas in air (4 percent
- mi s, urethanes, and amine by volume) would be approached containing materials only if the total gas from one pound of
- Unsaturated hydrocarbon the liquid mixture were totally plasticizer confmed within approximately two if a substrate or materialis cubic feetof air.Whereverthisdegree questionable with respect to of a r volume restraint exists, causing potentialinhibition of adequate ventilation should be cura, it is recommended that a provided to prevent localized buitoup -
small scale compatibikty test be run of gas, and appropnate caution to ascertain suitabihty in a given should be exercised.
apphcation. The presence of hquid or uncured product at the interface CAUTION betweer the questionable substrate immediately upon mixing the A and and the cured Dow Corning 3-6548 B components of Dow Corning silicone RTV foam, would indicate 3-6548 sihcone RTV foam, a cure incompatibihty and inhibition of reaction takis place that results in cure the evblution of hydrogen gas.
4 Appropnate caution should be Gas Evolution exercised. Keep away from sparks Immediately upon mixing the A and and flame. Adequate ventilation
{
B components of Dow Corning should be providad to prevent 3-6548 silicone RTV foam, a cure locahzed buildup of gas.
reaction takes place that results in TOXICOLOGICAL INFORMATION the evolution of hydrogen gas. The Toxicological studies indicate Dow product then cures to an elastomer omng 3@8 sWcone m in the presence of the evolved gas re-f am has an acute oral ALDw of 15 sulting in a solid flexible, elastomeric g
g body weigM m aho rats.
foam. Since the foam is greater This value indicates no significant than 50 percent closed cell, the gas is not immediately released to the azad DManng to qgestion of amounts incWMal to mdustnal surrounding atmosphere, but h ndhng instead is released over a penoc o, time by diffusion. The total volume Eye irritation studies suggest that this of gas is essentially generated matenal does not cause significant
j i
trritation. These results indicate PACKAGING
, hazard to the eyes is probably nil.
Dow Corning 3-6548 silicone RTV Minimal eye protection should be foam is packaged in 100- and 900-adequate for industrial handling ib (45-and 409-kg) kits, net weight purposes.
Additionally, prolonged or repeated USERS PLEASE READ skin contact should not produce The information and data contained erntation. There is no evidence that herein are believed to be accurate Dow Corning 3 6548 silicone RTV and reliable; however, it is the j
foam'as absorbed through the skin user's responsibility to determine in acutely toxic amounts. No suitability of use. Since Dow spec 8l handling precautions Corning cannot know all of the appear necessary to use this uses to which its products may be material safely.
put or the conditions of use,it l
Note: Comprehensive data makes no warranties concerning l
concerning the nature of toxicity of the fitness or suitability of its gases from burning or smoldenng products for a particular use or Dow Corning 3-6548 silicone RTV purpose.
foam is not available. However, it is You should thoroughly test any known that the major proposed use of our products and decomposition byproducts are SiO2 independently conclude satisfactory CO2, CO, N2 and some incompletely performance in your application.
burned hydrocarbons.
Likewise,if the manner in which SHIPPING LIMITATIONS our pr ducts are used requires governmental approval or None.
clearance, you must obtain it.
Dow Corning warrants only that its STORAGE AND SHELF LIFE products will meet its Dow Corning 3-6548 silicone RTV specifications. There is no warranty S
foam should be stored in closed of merchantability of fitness for use, i
containers at or below 90 F (32 C).
nor any other express or implied When stored in the original warranties. The user's exclusive unopened containers at this remedy and Dow Corning's sole temperature, the shelf life is liability is limited to refund of the 12 months from date of shipment.
purchase price or replacement of Storage at temperatures lower than any product shown to be otherwise 90 F (32 C) willlengthen the useful than as warranted. Dow Corning
- life, will not be liable for consequential damages of any kind.
Prior to use, after standing longer than one day. the liquid Suggestions of uses should not be components (both Part A and Part taken as inducements to infringe B) should be thoroughly stirred to any patents.
uniformly redisperse any fillers or pigments that may have settled.
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DOWCORNING
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DOW CORNING CORPORATION, MIDLAND, MICHIGAN 48640 m
Atiania Bocca Brusse'vorm Chic ago Cieve'and Danas De"oit G
s To'calo 'eensDo'o i
Les ange'es Ne*
Saa srancisco Svanev f o=ve Doe. C m -..* a ee2 re'*o trao.9 mark of Ove Corning Corpo<ai.on c.
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PA.C IFI C GAS AND E LE C T R,IC.C C M PANY pew]F,
-4 m unct starst sgggegauroama enn. om m.mi== m.m.uw Avila Beach, California 93424 (805)595-2324
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January 28, 1984 B1500 c/o PTGC Diablo Canyon Prvject
- Trailer Number 64 Avila Beach, California 93424 Attention:
Lance Sims Diablo Canyon Project Penetration Seals 8
DCl-AE-15558 c...
Dear Mr. Sims:
.In reference to penetration scal Nc.105 es identified on the above DCN:
The pressure seal installation necessitates the pouring of Bisco Seal against the aluminum tape used around the pipe in this penetration for j
heat tracing.
No" procedure or testing has been established for this installation.
Engineering is satisfied that the seal formed will meet the pressure requirements Penetration No.125 Penetration No.124 is not coverec' under the Bisco contract.
is covered with a steel plate and is adequate for the pressure requirements.
F.M.Germano/J.Gibbs
]
1 Attachment Reply Requested: No I
e 6
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- E'"O-PActfIC GAS AND Et.(C1fitC COWANY Su f"?-
G'ENERAL C O.M P U T A T I O N $ H E'E Ts.o<a,..
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-Januar) 23, 10F4 i,
Mr, it.
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P..el w.1 1 boarcti Industrial scivices. Inc.
l'ac i (i e C.:e r s. l'l vet s i e en.
P.
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Box 1 1 '/
'""'""""""d""u parb songo nunous cot Avala Deach, CA 93424 orpi,v ery.
rev. :sta: t.. ann.<s l
Attn: Mr. John Gabbr
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subject: Diablo carryon Project Pr coeure Seal s - It1SCO Job f 3269 l
Pl ant Modi f ica t. ion 140. DC1-EA-1555F Peference: regiu st fr r J h f et ina t s or: th. 1 I
Gr'n t I cinen :
The followino inferv.ation is requested by IUSCO:
P3SCO has l oca t ed reine el ec t : ical conduitr that penet r at e t hr-15.7 wall en l a.*t h sides of the floor r, lab on t he f< 5 ' - 0 "
elevation.
1)
De there penetrating items require a prer.r.6 e c e n 3 *-
21 Do t he r.r p< net i a t i nci itons r<.quiie a fjre r e a l '.'
These i'enns are ready for product.2cn release an(* inust be riarified i antned i a t el y so t.ba t further production delay P.ar be avoided.
Fincerely, l
11RAlit) Ilil10STR1hl, SE RV 3 CES, ] tic.
t 4O h '-~.
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.l.ahee Siluro::, l'I ej'. c t Ma ha(le r FIF,CO Cont l.ruct ion Group cc:
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Gibbr 1;. Dukes /
D. Cichy A.
Trecrnan v/ k I
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?&FPCE MEMORANOUM Ntoso S
DiaNoCanyonProjectg;W Q lI PActflC GAS /ND El.ECTRIC COMPANY
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BECHTEL POWER CORPORATION
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February @ l984 u
Isle TO FILE Dua v
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D. Rockwell/R. Cook /K. Dukes o, ss General
- Construction s.w. Contract #Z26P25683 o,
g, Diablo Canyon E. - 3312 REFT BISCO Allegation Contract Number (226P25683 Een Dukes:
Mr. Lance Sims, Project Manager of BISCO Company, arrived onsite December 9, 1983, with an engineer and proceeded to walkdown DCN 1-EA-1558 to identify the scope of all boots and seals.
Af ter Mr. Sims arrival, he charted questioning Plan t-Tho rpc 's method of installing silicone foam.
At this time, Mr. Sims was told to sub::iit any concerns in writing.
Mr.
Sims continually and forcefully raised questions on penetrations that were previously foamed by other contractors.
There were three other contractors who put silicone foan in at Diablo Canyon.
In the meeting, it was arranged between Mr. John Gibbs, Mr. Lance Sims and myself to discuss his concern.
At this meeting, Mr. Cibbs informed Mr. Sims that if be had concerns, he should document. them and forward this letter to Mr. Cibbs.
During the next two months that Mr. Sims was onsite, we raceived only one information notice asking for clarification on penetrations 105, 124 and 125.
This information notice was answered on J:auary 28, 1984 by Mr. John Gibbs.
To other correspondence was received from Mr. Lance Sims.
Ken Dukes on January 30, 1984, received a telephone call from Mr. Clay Brown concerning rumors that I was trying to hire BISCO employees.
At that time, I informed Mr. Brown that it is a Bechtel policy that we tolked employment to no one that is employed by a sub-contractor.
Four of BISCO's employees went to Bechtel Personnel and picked up employment applications and submitted them to me along with their termination notices.
I never discussed any type of employment with Bechtel with these men who vere employed by BISCO.
Mr. Sims vss not aware that the specification require that conduit be foan on one side of the fire wall not both sides as be believed.
0110r/
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Esady Cook 1
On Jaemary 18, 1984, Mr. Kan Dukes went to Mr. Randy Cook and expressed that Mr.1.ance Sims would like to review the procedures for instal. ling cill'coes foam.
1, Randy Cook, told Mr. Kan Dukas that the Resident Electrical Engineer was not in and that all Mr. Sims' concerns should go through the Resident Enginer.
Approximately one hours later, Mr. Sims and Mr'.. Ken Dukes returned again expressing Mr. Sims' concern.
At this
[
time, I contacted Mr. Don Rockwell, and informed him of the situation.
Me dircetep me to get Nr. Sims and Mr. Dukes to come to his office for a meeting. The meeting results are in Mr. Rockwell's statement.
1 During the last week in January, I had another meeting with Mr. Sims, Mr.
Gibbs (PTGC), Mr. Dukes (PTCC), Mr. Bob Beach of PTGC, and Don 1.arrabee from Quality Assurance.
This meeting was about electrical raceways that Mr. Sims felt ;should have been fosaed and were not.
I informed Mr. Sims that FICC had foamed all raceways that were required by our designs and
, th2y had been inspected by inspectors and NPO QA Department.
Don Rockwell:
1, Don Rockwell, met with Mr. Lance Sims, Project Manager of BISCO, on Jaxuary 18, 1984.
Also, present were Mr. Randy Cook and Mr. Ken Dukes.
Wa discussed Mr.
Sims' concerns on quality problems with existing cilicone foam installations and his conce.rn with the qualification of Plcut-Thorpe to install silicone foa=,
I explained to Mr. Sims that the work performed by Plant-Thorpe was in accordance with the design required by Specification 2552 and that the f oa= va s tested for density, cellular structure and snap test time prior to beginning pours and after each codition of silicone foan material to the mixing tanks.
Inspections have been performed on all fire walls to insure that the openings have been sceled in accordance with Specification 2552 requirements.
Mr. Sims expressed concern that he had received instruction not to report problems to management.
I inf ormed him if he had any problem related to qu:lity on new or existing work, to please put this in writing and submit to myself.
One quality probles was submitted (See Attachment 1).
The cuswer was submitted. (See Attachment 2).
Whas Mr. Sims said that he had direct cosaunication with the Fire Mrshall, I requested that if he had a requirement or wish to discuss a problem with the Fire Marshall, please contact me and I would arrange a meeting, at such a time, that it would not conflict with the on going work.
I c1so,. pet with Mr. Sims on February 1,
1984, at approximately 1900 hturs and asked hin if he had any quality related concerns.
He expressed to me that he was fully satisfied with the responses he had rectived.
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_-________-______________-___-______-_______a
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Mr. Randy Kohout, NPO Fire Marshall, stated be had discussed with Mr.
Sims gus11ty related problem be stated, that if Mr. Sims had any quality related problem, please write these problema on a piece of paper and submit to Mr. Randy Kohout for his corrective action.
Mr. Kohout received no gus11ty related problems from Mr. Sims.
D.
A.
Rockwell' on February 2,
1984, was informed that Mr.
R, C.
PG&E Senior Buyer, received a telephone call from Mr. Clay McInerney, Brown from BISCO in regards to the same allegation (See Attachment 3).
D. A. Rockwell Project Field Engineer DARockwellskdg Rasponse required: No ee:
GVCranston RDEtzler HBFriend FGermano WKGlenn JBBoch JRManning GEDioore LERosetta
Dow Corning
- 3-6548
(
Silicone RTV Foam Cell Structure Comparison Chart Unacceptable Cell Optimum Cell Structure Range Structure Range f/
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the temperature of the A and B liquid y'
components before and after mixing.
These temperature readings should be between 55*F and 80*F and the
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snap time between 1 and 3 minutes 4
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Form No.61 339-76
Dow Corning
- 3-6548
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Silicone RTV Foam Cell Structure Com aarison Chart Unacceptable Cell Optimum Cell Structure Range Structure Range Q.'
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the temperature of the A and B liquid components before and af ter mixing.
These temperature readings should be between 55^F and 80'F and the snap time between 1 and 3 mi.7utes j
for optimum results.
Form No 61-329-76
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9 Dow Corning *3-6548 8
Silicone RTV Foam Color Comparison Charf 1
l Unacceptable Optimum Color Range Color Range 1.
3.
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- 3 6548 Silicone both samples 1 and 2 above. If your RTV Foam should be in the color foam sample is in this color range, range shown in 3 and 4 above when check your equipment mix ratio. You properly mixed.
should also check the original A and B containers as well as the equipment A and B containers of the 3-6548 liquid components to see that the 5
fillers and pigments were well dis-persed before pouring or mixing.
Form No. 61337
Dow Corning *3-6548 C
Silicone RTV Foam Color Comparison Chart Unacceptable Optimum Color Range Color Range 1.
3.
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The cured foam color is too light in Cured Dow Corning
- 3-6548 Silicone both samples 1 and 2 above. If your FTV Foam should be in the color foam sample is in t*';
- lor range, range shown in 3 and 4 above when check your equipment mix ratio. You properly mixed.
should also check the original A and B containers as well as the equipment A and B containers of the 3-6548 liquid components to see that the
(
fillers and pigments were well dis-persed before pouring or mixing.
l l
Form No. 61337
~
_________-_____________________--D
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u.s. wuctsaa neoumoar coMM2scu ALLE9ATION DA.TA F.ORM ennennene en se.,se me
' senc hs. m it t<3 nicamma orries Docket Number (if applicable)
I INemel I
6 5 O.
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- 1. Feetutylleel inwohrod:
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- 2. Functional Area (s) Involved:
onsite health and safety operations schest answeenew besteel1 offsite health and safety n
construction emergency preparedness safeguards i
other (specifyl I
I al4l l I IIMIPirlol 01< WI 1i inl5 l-Het / I I Ictivt i lo Inl IFil IrleI Isl11e 101 leloidI 15lelal /lalnl11 I I I J
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- s. Description:==
II III1II IiIIIIIIII II I I I I IJ liIIIIIIIIIIIIIIIIIIIIIIIJ 4
- 4. Source of Allegation:
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security guard contractor employee scheck appropriate noir news media licensee employee private citizen NRC employee organization tspecity) other (specity)
MM DD YY
- 5. Date Allegation Received:
triest two inistei. and te. names Me b W bdO b UM-M
- 6. Name of Individual Receiving Allegation:
- 7. Office:
g g ACTION OFFICE O
r
- 8. Action Office
Contact:
triest two initiet. and tes, name, g
3 9, FTS Telephone Number:
9 9 g
- 10. Status:
Open. If followup actions are pending or in progress scheck one)
Closed,if followup ections are completed MM DD YY 11.1 Document Nos.
- 11. Date Closed:
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INTEROFFICE MEMORANDUM I ' 'd Diablo CanyonProject Djih.~
PACIFIC GAS AND ELECTRIC COMPANY
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BECHTEL POWER CORPQ. RATION f
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ROCKWELL February 2,1984 h '"
R. G. McInerney O'
Purchasing 5"tre' Bisco - Pipe Penetrations Contract No. Z26P25683 f
A' Diablo Canyonbtenoon 3113 on Fe brua ry 2,
1984, Clay Brown of Bisco phone number (312) 29S-1200 called in regards to pipe penetrations and explained the following:
Mentioned that Ken Dukes of Bechtel asked their Mr. Sims to leave the jobsite on 02-01-84 and if not he would ask security to escort Mr. Sims from the site.
Mentioned that Bechtel was not co-operative and that some of the pipe penetrations existing were not put in properly.
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Mentioned that his Q.A. supervisors were told not to report any problems even if they dealt with 10CFR21 requirements and_ to consider the fact that it was reported to Bechtel enough.
Mentioned that the PG6E Fire Marshall requested information on pipe penetrations and that Mr. Sims was told not to furnish the inf o rma t ion.
Mentioned that the Silicone Foam installed by Plant Thorpe was incorrect and discussions with the plant Thorpe Toam Installer revealed that he had no previous training with installing this material.
Mentioned that the Silicone Foam used has to be mixed properly or it will give off excess hydrogen while curing.
Therefore, trained people should install this material.
Mentioned that Bechtel was trying to convince Bisco ecployees to go to work for them.
Bisco employees wrote reports to the Home Office about such instances.
Mentioned that Frank Germano was notified of the above and that Bisco would write a report to him.
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.. G. McInerney j
Senior Buyer
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Problem Statement 1
Allegation Non.:
185, 186, 187
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l ATS No:
RV-84-A-0023
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Allegation No.
Verbatim Statement or Reference 185
'No QA is being practiced during installation.
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i 186 One installer does not know how to operate the i
equipment that actually formulates the two-component silicone foam.
187 Many of the foam seals are clearly no good.
Commentary The alleger is concerned about the installation of fire stop foam at Diablo Canyon by the contractor Plant-Thorp.
These concerns were addressed specifically to the NRC.
In addition, other concerns were addressed by the alleger to the licensee, similar to the ones stated above, but including an allegation that QA supervisors were told not to report any problems to management even if they dealt with 10 CFR 21 requirements. This is an apparent violation of the Atomic Energy Act.
We. recommend this be turned over to OI for follow-up action.
,h Date Thir Statement was Completed March 6, 1984
( ( ; /d N'/M Tectinical Reviewer Signature e
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Task:
Allegation or Concern No. 184 F I L E
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ATS No:
RV-84-A-0023 i
Cliara cterization:
Unqualified fire stop designs are being used.
Implied Significance to Plant Design, Construction or Operation:
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Because fire may affect safe shutdown systems, the need to limit fire damage to systems required to achieve and maintain' safe shutdown conditions is necessary and must be assured through the use of adequately designed, manufactured and installed fire barriers.
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Assessment of Safety Significance:
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The alleger is concerned that the design of the fire stops being used is l
unqualified. Since this area is part of the licensing application previously evaluated by the Office of Nuclear Reactor Regulations (NRR), the staff reviewed related documents and discussed with the licensing reviewer at NRR to determine the validity of this allegation.
The staff found that the fire stop design was evaluated extensively by NRR.
During that evaluation, PG&E stibmitted evidence that the fire stop has the required three hour rating. NRR determined that both the fire barriers cable penetration seals and Pycrocrete 102 fire barriers used were acceptable.
.I Along with the resolution of other fire protection related items, NRR concluded that all matters relating to the fire protection program had been resolved. This design approval is documented in NUREG-0675, " Safety Evaluation Report related to the operation.of Diablo Canyon Nuclear Power
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Station Unit I and 2, Supplement No.
9", June 1980, page 9-2.
In addition, th'e staff found no apparent practice by PG&E deviating from the approved design.
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Staff Position Based on the NRR's evaluation and the additional assessment, the staff concluded that this' allegation is not substantiated.
Action Required None.
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l symbolize this particular weld joint in more than one way. The meaning of the effective throat. As discussed in the original response, it is acceptable to weld symbol used in this instance is clear and there was no out of code practice.
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GAP #183 and 184, Petition at 7.
It is alleged that:
In 1981 P6&E neutralized a corrective action program by l
accepting welds that. failed an NT (magnetic particle) test, based on results from previously-discredited tests that had l
accepted the same welds. The current selector switch on a-1 testing machine had erroneously been installed backwards, l
to run at alternating current (AC) rather than on direct current (DC). AC, unlike DC, cannot detect subsurface c rac ks.~ Pullman and PME both require the use of DC for this reason. After 80 welds had been approved with the l
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machine in an AC mode, the problem was discovered. When a I
sample of eight erroneously approved welds were retested, three failed because of subsurface flaws. Nonetheless, l
P6&E directed Pullman to aci:ept these three welds, based on l
the earlier inadequate approvals with AC.
(citina 2/25/84 Anon. Af f.' at 9-10 and related Exhibits 15-19.) One such weld had " linear indications", suggesting possible cracks, as long as 3 inches."
(citina 2/25/84 Anon. Af f. at 9-10 l
and related Exhibits 17 and 19.)
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In the same' case, PME directed Pullman to accept welds that had never been properly tested. Rather than retesting the remainder of the 80 welds that had been erroneously accepted using an improper testing method, PG&E directed Pullman to accept all of them without retesting, based on l
the AC tests. The reason PME gave for this was the 1
cryptic statement that 'the ability of DC to detect subsurface defects is limited in our configurations."
(citina 2/25/84 Anon. Aff, at 9-10 and related Exhibit 18.) As described above, PG&E offered this excuse in spite of the fact that a retest with DC had failed more than a third of the sample, a result that PG&E's Torstrom called
' inconclusive" (citina 2/25/84 Anon. Aff. at 10 and related j
Exhibit 18.)
The difference between the Petition and Attachment 2 is the reference to the i
memo from Mr. McDermott to Mr. Spanner, dated August 26, 1981, requesting an i
explanation of the Disposition of Pullman 0.R.'s 4350 and 4352 and the
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inclusion of the memo as Exhibit 29 to Attachment 2.
The affiant then states, "Although I worked at Pullman another year, I never got a reply," creating the l
impression that the matter was ignored.
Contrary to Attachment 2, a review of Pullman files has produced a copy of Ex'hibit 29 with a timely reply from Mr. Spanner of P6andE's Department of Engineering Research to Mr. McDermott explaining the last sentence of the telecon in question (see Attachment 2, Exhibit 27). Whether Mr. McDernott received a copy of the reply is unknown.
GAP #109. Petition at 9.
It is alleged that:
Harassment of this individual did not stop after he was fired as a QC inspector, but continued in 1983 when he j
attempted to obtain a job as a welder. During the welding test, someone_twice tampered with his welding machine by increasing the amperage.
This made it more difficult to weld. After the witness obtained a QC inspector to watch the welding machine until he finished the root pass, the welder passed the test.
(citina 2/25/84 Anon. Aff. at 14.)
The difference between the Petition and Attachment 2 is the reference on Page 27 of the Attachment to Mr. McDermott's alleged conversation with Pullman QC Inspector Bill Bailey concerning Mr. Karner's alleged threat to " personally observe' Mr. McDermott's welder qualification test and Mr. Bailey's and the union shop steward's alleged intervention to prevent Mr. Karner from being present.
Contrary to the attachment, neither Mr. Bailey, nor the shop steward approached Mr. Karner to encourage him not to attend Mr. McDermott's testing.
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Problem Statement Allegation No.:
184 ATS No.
RV-84-A-0023
'RN:
Problem Statement Silicone foam seal is used on the penetration to prevent the fire from propagative across the barriers.
The alleger's concern is that unqualified fire stop designs are being used.
Commentary The alleger initially called D. Notley of the office of Nuclear Regulatory l
Research to express his continuing concerns with the installation practices of RTV silicone foam penetration fire stops in several nuclear pow p1gnts in general but at Diablo Canyon in particular. His concerns were our ' fold.
The other three are addressed separately. The alleger then conta ed A. Johnson of NRC/RV to express the same concern.
e The allegpr participated in a telephone conference call with T. D'Angelo and C. Sorensgn of NRC/RV to clarify his concern. The alleger mentioned the type of qualification tests which were accepted by the American Nuclear Insurers (ANI) were different from that of Nuclear Material Limited.
In his opinion, the NML's qualification tests for fire stop design is less strigent than that of ANI.
Since Diablo Canyon is insured by NML and adopts NML's practice, the alleger concluded Diablo Canyon uses unqualified fire stop design.
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Date This Statement was Completed ) / 7 8^
L. M. Hon Technical Reviewer Signature A
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FILE CTFY
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Task:
Allegation or Concern Nos. 185, 186 and 187 ATS No.: RV-84-A-0023 BN No.
Characterization:
These allegations concern improper foam fire stop insc.allation techniques by the contractor, Plant-Thorpe, at Diablo Canyon.
Specifically, 1) no QA is being practiced during installation of fire stops, 2) one installer does not know how to properly operate the equipment that actually formulates the two-component silicone foam and, 3) many of the foam seals are clearly no good.
Implied Significance to Plant Design, Construction or Operation:
Because fire may affect safe shutdown systems, the need to limit fire damage in systems required to achieve and maintain safe shutdown conditions is necessary and must be assured through the use of adequately designed,
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manufactured and installed fire stops.
Assessment of Safety Significance to determine the validity of these allegations, the staff reviewed the foam seal specifications, installation procedure, and quality control and assurance re' cords. The staff also interviewed one of the foam seal equipment operators to determine their training and experience. Furthermore, the staff
independently inspected a small sample of foam seals in Unit 1.
The allegations will be addressed one at a time.
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Concerning Quality Assurance, the staff discovered that the installing contractor does not have a quality assurance program of its own. The arrangement is for the licensee (PG&E) to provide the quality assurance program. The inspector verified they are performing quality control inspections of the contractor's installed foam seals.
Quality Control Procedure #DCP-2 entitled " Silicone Foam Installation" is the applicable procedure used by the licensee's quality control inspector performing inspections of the foam fire stops.
Foam quality is documented on a " Silicone Foam Test Report" and individual fire stop integrity is documented on a " Fire Stop Inspection Report". The staff reviewed 50 Fire Stop Inspection Reports and Silicone Foam Test Reports for compliance with quality control procedure DCP-2.
No procedural violations were identified that were not corrected.
i Although the individual alleged to be incompetent was not available for interview at the time, one of the available operators was interviewed to determine the extent of their training, experience and knowledge. The individual interviewed indicated that there are currently only three people installing fire stop foam for the contractor at Diablo Canyon.
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indicated that although they had no formal classroom training, all three had received on the job training and he believed that all were competent I
in installing fire stop foam.
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Also, the resident inspector was able to observe the alleged individual 1
operate the equipment and dispense some fire stop form. He concluded that the individual was familiar with the equipment and the procedures, i.
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and that his proficiency was satisfactory based on the quality of the foam dispensed.
l Concerning many of the foam seals being no good, the staff noted that the
' licensee has performed a 100% inspection of all fire stops which were 1
used in nuclear safety related compartments. This inspection was l
conducted by nuclear plant operations (NPO) personnel who were trained specifically for this activity, and is required at least once per 18 l
months by the Technical Specifications, The staff reviewed inspection reports generated for three fire zones at random, and all reports reviewed revealed either adequate foam fire stops or, if deficiencies were identifico, they were documented and corrected.
In addition, the staff independently inspected 30 foam fire seals at random (approximately 1%) used for safety related cable penetrations in Unit 1.
All of the seals insp.u ted appeared acceptable.
Staff Position 1)
Although the contractor does not have his own quality assurance program, the staff concludes that the licensee's quality assurance program appears adequate to ensure the quality of the foam fire stops being installed.
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2)
Based on the aforementioned interview and the resident inspector's observation of the alleged individual, the staff concludes that the operators have adequate knowledge to properly dispense the fire stop fosa.
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3)
Based on the 100% inspection performed by the licensee and the independent inspection performed by the staff, there is a high degree of confidence in the quality of the existing foam fire stops.
i In summary, the staff did not identify any obvious instances of wrongdoing and no significant breakdown of quality control procedures.
Action Required i
None.
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NUREG4675 Supplement No. 9 m'
Safety Eva!uation Report related to the operation of Diablo Canyon Nuclear Power Station Units 1 and 2 Docket Nos. 50-275 and 50-323 Pacific Gas and Electric Company Supplement No. 9
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June 1980 Of fice of Nuclear Reactor Rer;ulation U.S. Nuclear Regulatory Cominission y.* *%,,,
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i 9.' O AUXILIARY SYSTEMS i
9.6 1 Fire orotection l
In SEf? Supplement 8 we stated the following items had not been resolved:
(1) The applicant has not electrically supervised all valves in the fire water system that are necessary to ensure the fire water supply to the areas containing safety related 1
equipment.
(2) The applicant has not shown that alternate plant shutdown capability is independent of the cable spreading room and control room, (3), The applicant has not demonstrated that a failure of recently installed non-seismic fire protection equipment will not af fect the safe cold shutdown of the plant.
(4) The applicant has installed some fire barrier cable penetration seals that have not
. passed'a three-hour fire barrier test.
-(5) The applicant's small scale fire tests of Pyrocrete 102 are not representative of actual field installation.
I Our evaluation and ' conclusions are noted below for each of the items listed:
(1) The Branch Technical Position ASB BTP 9.5.1 requires that key valves in the fire water
- supply system. be electrically supervised or that th,ey be locked open. In submittal dated July 18, 1979, the applicant has committed to lock open the above cited valves.
We find that this alternate means of assuring the supply of fire water to areas con-taining safety related equipment acceptable. We consider this matter t'esolved.
(2) In a submittal dated November 13, 1978 the applicant provided information that decon-strated that the alternate shutdown capability is independent of the cable spreading and control room and would not be affected by eitner a fire in the control room or in the cable spreading room. Based on our review of the above information, we find that in the event of a fire in'the control room or the cable spreading room the plant can be brought to a cold shutdown using the hot shutdown panel.
~(3). In the submittal dated November 13, 1978, the applicant committed to seismically sup-i porting non-seismic fire protection equipment in safety related areas so that this equipment will remain in place after the safe shutdown earthquake. We have reviewed the applicant's design cd find the installation of the recently installed fire protec-tion equipment acceptable in this regird.
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(4) In the submittal dated November 13, 1978 the applicant referenced acceptable standards to which the electrical penetrations were fire testeo. The test conducted by the
. applicant demonstrated that the penetrations have a three hour rating. Therefore, the fire barriers cable penetration seals are now acceptable.
(5) The applicant described in detail the field installation of the Pyrocrate 102 fire N
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barriers and referenced the fire test results on Pyrocrete barriers of similar construc-tion. Based en the test results of similar barriers, we now find the Pyrocrete 102 l
l fire barriers acceptable.
l In Supplement 8 we reported that the applict it had committed to install Seismic Category I fire dampers in the supply ducting to the 'k switchgear rooms. These fire dampers have now been installed, therefore we consider thi-matter resolved. All matters relating to the fire protection program have now been resilved.
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ygt b tXf) -fo SSERf Sinca the fire detectors are non-seismic in order to detect fires af ter an earthquake, we will require in the piant Technical Spec: fica-tions that the applicant inspect the plant for fires within two hou-s following an ear tnquake.
Since safe shutdewn system are protected by barriers rated at two hours or more, any fire after an earthquake should be detected by this inspection before redundant safe sr.utdown system would be affected.
Based on our review and the. Techn'ical Speci-fications requirements, we find the detection of fires af ter an earth-quake acceptable.
V.
RTHER ITE"5 RELATING TO THE STATION FIRE PROTECTION PROGRAW A.
Penetration Fire Stops The penetration fires stops are provided to prevent the movement of fire from one area to another along the elec.-
trical cables which run through these fire areas.
Silicone foam sealant and powdered lead poured in and around the cable trays and conduits where they penetrate fire barriers make up the penetration fire stops.
The. applicant has cited applicable generic test data for the piping (
l tration fire stops which show that the fire barrier sealant materials in this application provide a 3-hour fire resistance to an ASTM E-115 type fire exposure.
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applicant has pmvided qualification data for cable penetrations,
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Th which differ from the design of the piping penetrations.
As stated in our trip report dated March 29, 1978, the applicant committed to 4
verify that electrical penetrations through fire barriers have three-hour ra tings.
Although the applicant has used silicone foam that has passed an acceptable three-hour fire test in some of_these penetra-tions. he has installed untested materials such as grout in other penetra tions.
We will require the applicant to provide the necessary information to show that all alt <:trical penetrations through fire barriers have three-hour ratings. We will report on this item in a supplement to the SER.
Firt Dcors and Fire Dampers We have reviewed tne placement of the fire doors to ensure that fire doors of proper fire rating are provided.
The applicant's Fire Hazard Analysis identified a number of fire areas where the door's rating was less than fire barrier in which it was installed.
As stated in our Trip Reported dated March 29,
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