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Accession #: Dl96030823

Document #: SD-WM-ATR-169

TitlelDesc: ACCEPTANCE TEST REPORT 241AW AIR INLET FILTER STATION PRESSURE DECAY TEST

Pages: 41

WHC-SD-WM-ATR-169, Rev. 0

Acceptance Test Report, 241-AW Air Inlet Filter Station Pressure Decay Test

James A. Tuck WHC, Richland, WA 99352 U.S. Department o f Energy Contract DE-AC06-87RL10930

EDT/ECN: EDT 614412 UC: 506 Org Code: 5A620 Charge Code: C47634/F81XD4 B&R Code: EW3120071 Tota l Pages: y 3 a r m k Key Words: Test ing, ASME N509

Ven t i l a t i on , Confinement, Nuclear A i r Treatment, Leak

Abst ract : Th i s i s t h e acceptance t e s t r e p o r t f o r pressure decay t e s t s performed on newly - ins ta l led 241-AW Tank Farm pr imary v e n t i l a t i o n system a i r i n l e t f i l t e r s ta t i ons .

TRADEWRK DISCLAIMER. Refcrmce herein t o any specif ic c m r c i a l product, process, or service by trade m, tradanark, manufacturer, or otherwise, does not necessarily c w t i t u t e or inp ly i t s andorsenmt, reconnwdstion, or favoring by the United States Govarrment or any agency thereof o r i t s contractors or subcontractors.

Printed in the United States of Anrrica. To obtain copies of t h i s document, contact: UHC/BCS D o c M n t Control Services, P.O. Box 1970, Mailstop H6-08. Richlard UA 99352. Phwv (509) 372-2420;

(509) 376-49a9. r

Approved for Public Release A-6400-073 (10195) GEF321

WHC-SO-WM-ATR-169 REV. 0

ACCEPTANCE TEST REPORT, 241-AH AIR INLET FILTER STATION PRESSURE DECAY TEST

1.0 INTRODUCTION

S i x p r i m a r y v e n t i l a t i o n system a i r i n l e t f i l t e r s t a t i o n assembl ies were f a b r i c a t e d and i n s t a l l e d as p a r t o f a v e n t i l a t i o n upgrade i n t h e 241-AW Tank Farm (WHC 1995; V i t r o 1977). A p ressu re decay t e s t was per fo rmed as p a r t o f acceptance t e s t i n g on each o f t h e completed i n s t a l l a t i o n s , i n accordance w i t h a work package procedure (WHC 1996a). appendix t o t h i s document, f o r r e f e r e n c e .

Tank Farm. The Cogn izant Eng ineer was D a n i e l J. M i n t e e r o f TWRS M i t i g a t i o n Systems I n t e g r a t i o n , Westinghouse Hanford Company. The T e s t D i r e c t o r was Rober t L. B e i r e i s o f TWRS Opera t i ons Support , Westinghouse Hanford Company. Ass i s tance was p r o v i d e d i n t h e f i e l d by Jack F . Thompson, Engineer, and personne l f rom t h e 200 West Area Sheet Me ta l F a b r i c a t i o n Shop, ICF-Kaiser Hanford Company. A d d i t i o n a l suppor t was p r o v i d e d by t h e Vent and Balance o r g a n i z a t i o n and TWRS East Tank Farms Opera t ions , b o t h o f Westinghouse Hanford Company.

The decay t e s t procedure i n c l u d e s a d e s c r i p t i o n o f t h e t e s t and a l i s t o f equipment r e q u i r e d , as w e l l as s p e c i f y i n g an a l l o w a b l e l e a k r a t e and documenting i t s b a s i s i n ASME N509 (ASME 1989a). B r i e f l y , t h e t e s t c o n s i s t e d o f t h e f o l l o w i n g elements:

The procedure i s a t t a c h e d as an

The p r e s s u r e decay t e s t was per fo rmed 15-16 February 1996, i n t h e 241-AW

I s o l a t e / s e a l o f f t h e a i r s t a t i o n f rom t h e t a n k and t h e atmosphere; Per fo rm v i s u a l i n s p e c t i o n s o f ductwork, housings, f i l t e r s , connect ions , and gaskets , and s e a l s f o r s i g n s o f damage o r improper i n s t a l 1 a t i on; P r e s s u r i z e t h e a i r s t a t i o n , a l l o w t o s t a b i l i z e a t a s p e c i f i e d t e s t p ressu re , and r e c o r d p ressu re and tempera ture read ings (as w e l l as e lapsed t i m e ) w h i l e p ressu re decays; C a l c u l a t e a l e a k r a t e pe r ASME N510 (ASME 1989b) based on da ta , an$ compare w i t h s p e c i f i e d acceptance c r i t e r i o n o f 0.14 s tandard f t /min (SCFM); I f u n i t exceeds acceptance c r i t e r i o n ( f a i l s ) , l o c a t e and r e p a i r l e a k s and r e t e s t as o f t e n as necessary; Document r e s u l t s .

2.0 RESULTS AND DISCUSSION

The r e s u l t s o f t e s t i n g t h e A i r S t a t i o n s a r e t a b u l a t e d below. p ressure , s p e c i f i e d i n t h e procedure, was +7.5 i n . w.g. s o l u t i o n p r o v i d e d v i s u a l evidence t h a t v i r t u a l l y a l l t h e measured leakage occu r red on t h e i n l e t s i d e o f t h e assembly, i. e. t h e s i d e o f t h e f i l t e r s o p p o s i t e t h e tank . t a n k s i d e connec t ions (see App. A, p rocedure Sec. 4.1 and F i g . 1 f o r e x p l a n a t i o n o f " t a n k s i d e " ) . t o t a l l e a k r a t e , b e i n g t h e es t ima ted p r o p o r t i o n o f t o t a l leakage o c c u r r i n g on t h e t a n k s i d e o f t h e HEPA f i l t e r , i s c o n s e r v a t i v e . i n c l u d e d i n t h e t a b u l a t e d da ta .

The t e s t The use o f a bubb le

No leakage was d e t e c t e d u s i n g t h e bubb le s o l u t i o n on any

There fore , a l e a k f a c t o r o f 10% a p p l i e d t o t h e

The l e a k f a c t o r i s

1

WHC-SD-WM-ATR-169 REV. 0

APPENDIX A:

PRESSURE DECAY TEST PROCEDURE

SUPPLERENTAL INFORMATION, INCLUDlNG FLOW, SURFACE AREA, AND VOLUME CALCULATIONS

FROM WORK PACKAGE 2E-96-00103/M (WHC 1996) AND

A- 1

WHC-SD-WM-ATR-I69 REV. 0

6.0 T88T PROCBDURP

Record a11 test data and test exceptiona on Data Sheeta 1 and 2, and the Record of Temt Exception mheets (attached).

NOTE: Steps 6.1 through 6.4 may be performod for a11 six filter housing/duct asmemblism prior to continuing with the remaining mtepm for each assembly.

6.1

6.2

6.3

6.4

6.5

6.6

6.7

6.8

6.9

6.10

Verify that the 12" butterfly valve locatsd between the filter housing and tank riser is in the closed position.

Vlsually inaprct a11 equipnt/pip./duct and connections from the tank rlaer to the air flow controller for obvious signs of damage, mim-allg~nt, or functional problem.. This is an external inmpection only. Enmure that paint im not providing a meal on any connectionm between the filter housing and the expanmion joint.

Remove the filter houming doors and inspect the M P A filtsr, filter houming, and the filtsr housing door. and their meal. for obvious signs of damage. Note that these components have been examined during the fabrication and final assembly procesm. This step i m only meant as a final moundness check before further testing. Thus, the filters need not be removed for thim inspection unlesm damage is muspected. Repair/replace components as necessary.

Enmure that the HEPA filter is properly locked against its sealing fr- and that the filter housing doors (pre-filter and HEPA filter) are secured. General manufacturer instructions for installing the HEPA filter are to initially torque the clamping bolt. to produce 50% gasket compresmion and then to retorque them one or two week. later to a total compresmion of 80%. Door latches are hand tightened in a gradual, equal mequence.

Seal the openings on the vacuum breaker and flow controller (see drawing 8-2-85614) and provide temporary sealing for other joints, as necessary, on "clean side- (pre-filter side) of HEPA filter.

Isolate differential pressure indicators VTP-PDI-212, -213, -214, and -215 from the tested volume.

Install and seal temperature measuring instrument into one of the ports on the filter housing assembly (see Figure 1 for recommended location). Record equipnent information on Data Sheet 1.

Install and meal pressure meamuring instrument into one of the ports on the filter housing assembly (see Figure 1 for recommended location). Record equipment information on Data Sheet 1.

Inatall air mupply line (with safety/relief mechanism, imolation valve, and pressure reducer) into one of the ports on the filter housing aseembly (see Figure 1 for recommended location).

Positive Premsure Decay Test

6.10.1 Premsurize test housing/duct aesembly to +1.5" wg +/- 0.5' wg. Locate (using suitable bubble solution) and meal (mea Section 4.1) a11 leaks as best as practical. Note any remaining leakags from the HEPA filter door and a11 ports/openingm and

Wort Rcbgo 2&960010[1/)4

A-4

USE 1" FEMALE NPT CONNECTION ON SIDE OF HOUSING FOR AIR SUPPLY (INCLUDES SAFETY RELIEF, ISOLATION VALVE, AND PRESSURE REDUCER) 7

USE 3 /4" MALE NPT CONNECTION ON TOP OF HOUSING FOR TEMPERATURE MEASUREMENT

TO i A N K

DATE I

WHC-SD-WM-ATR-169 REV. 0

DATA SEE= 1 - POSITIV. PRSS- DECAY ZEST TANK: 241-AW- RETEST #I

6.1

6.2 -

6.3

6.4

6.5

6.6

6.7

- - -

6.8

6.9

6.10.1 -

6.10.2

6.10.3

- 6.10.4

6.10.5

6.10.6

6.11 - -

TEST DIRBCTOR (print name and sign):

OTHERS ( t i t l e , pr int name and aign):

A-7

WHC-SD-WM-ATR-I69 REV. 0

DESIGN CALCULATION

(10)

PROBLEM:

ASSUMPTIONS:

Determine the air flow rate through the air control station (see drawing H-2-85614) given a tank pressure of t7" WG (corresponds to the housing/duct assembly leak test pressure).

1. Assume that the most restrictive orifice plate (for the air flow controller) which would be used in the field is a 3" I.D. (rated for 95 scfm) and it is installed.

2. Assume relatively clean filters. 3 . Assume standard air conditions.

CALCULATIONS: The total pressure loss through the air control station (pipe, fittings, filters, and orifice plate) is calculated at various flow rates until the pressure loss equals 7" WG. This occurs at 400 scfm. This set of calculations is shown below. All references are to the 1993 ASHRAE Fundamentals Handbook, I-P Edition. American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc., Atlanta, GA .

SYSTEM FLOW RATE lscfm) TOTAL PRESSURE LOSSES (inches WG)

400 7.0

I PIPE 12" tank riser pipe

pipe dia Id), inches 12 duct area, ft-2 0.785 duct length ILL feet 25 Velocity IV), fpm. = flow rate/area 510 Vel Press IPv). IN WG - density(V11096.51'2 Reynolds number IReI. std air, - 8.56dV Rouohnerr Factor lrl. ft, mad. smooth Friction Factor, f f' - 0.111112r/d~+168/Re~~^.25 and f-f ' i f f '>/- 0.018

0.016 PQ 13.14, eqn 15 52341 PQ 32.5, eqn 23 0.0003 PQ 32.5, Tabla 1 0.022 PQ 32.5, eqn 21

0.021 PO 32.5, eqn 21 Note: If 1' < 0.018, then use f - 0.851' t 0.0028 Input frlctlon factor used 0.022

pipe pressure loss, IN WG, = fll2Ud)Pv 0.009 pp 32.4, eqn 19

A-10

WHC-SD-WM-ATR-169 REV. 0

I FllTlNGS 12' tees whlanked branch I2x - at riser pipe and flow controller) 12' butterfly valve, fully open

transitlon. 12' round to 24' squara

transition, housing to flow controller

entrance to flow controller pon

flow controller Inlet screens (2x1

c o - I (assumed conservative) c o = 1 (assumed conservative)

pressure losa assumed negligible at this flow

Co 1 conservative, p 32.29, t/D=O. LID-0

c o = 2 (assumed conservative)

Co - 0.6 conservative, p 32.28, Al lAo-1. n-0.76 total Co 7 \ Vel Press, Pv, IN WG 0.016 (from above) fitting pressure iosses, iN WG, - ICO)(PV) 0.113 pg 32.6, eqn 30

TIL I t m HEPA filter, rated 1 IN WG loss @ 600 cfm

pressure loss, assume linear

other filters, assume 0.26 IN WG total losses @ 600 cfm pressure loss, assume linear 0.2

r ORIFICE PLATE 3' Air Flow Controller Orifice Plate

Orifice Dia (in) Area Isq ft) Velocity Wmin) Vel Press (IN WG) = (V/40061 2

I DP (IN WG) - 1.421V.I Prrsal 3

0.049 8153 4.14 p 6.88

3.14, eqn 6

1 (bared on test data, WHC-SD-WM-TRP-247)

A - I 1

WHC-SD-WM-ATR-169 REV. 0 DES I GN CALCU LATlO N

(Scb PAGE 6 ) . A-16

WHC-SD-WM-ATR-169 REV. 0 DESIGN CALCULATION

IZDO 1.0..

r

A - 2 1

WHC-SD-WM-ATR-169 REV. 0

APPENDIX B:

TEST DATA SHEETS

B- 1

WHC-SD-WM-ATR-169 REV. 0 DATA SHEET 1 - POSITIVE PRESSURE DECAY TEST

DATE: 2- 15- 9b TANK: 241-AW- 101 RETEST t r MA

Work Package 2E-96M)IO)M

8-2

WHC-SD-WM-ATR-169 REV. 0 DATA SEEET 2 - LEAKAGE lUTE CALCULATION

DATE: 2-15-76 TANK: ZPI-AW- 102 RETEST I : I\) 9 Beginning pressure in inches WG: 7.2 Beginning pressure in psig (A/27.7): 0.26

Beginning barometric pressure in psi (IN Hg x 0.491): / q . g J Ua...&.rb vJe=.+br Zq.555"#~ Beginning duct pressure in psfa (E + C)144: 2/27 Beginning temperature in deg F: 54 Beginning temperature in deg R (D + 460): 5 19 Ending pressure in inches WG:

Ending pressure in psig (E/27.7): 0 . 1 4 Ending barometric pressure in psi (IN Hg x 0.491): / ~ ) , 5 ) /-lo&rd Neath& 2 9 . 5 5 5 ' b / ? Ending duct pressure in psfa (F + 6)144: Ending temperature in deg F: 5'7 Ending temperature in deg R (H + 460):

Test Volume in cubic feet (entire assembly shown in H-2-85614, from flow controller to 12" butterfly valve): 24.7

R, gas constant, in ft lb/(lb*degR): 53.35

5.2

2/17

5 / 7

Test Duration in minutes: I O 5 % _ = 0.167

Average total housing leakage rate in standard cubic feet per minute (per ASME N510-1989, Section 6.5.3.9):

Q = (Pl/Tl - P2/T2)V/(R AT . 0 7 5 )

= 0.71 Leak Factor (based on an evaluation of individual leaks present ueing the bubble leak location method, the proportion of leakage on "tank side" of HEPA filter): 0.1 L ~ ~ , ; A ~ ~ ~ A c c n x r v r s + i v c 5 i k c no / c a k e c w a 5 AeCrrfcd li? f 6 - K r r d e co-me&A-s, S-kp 6.10, I Average "tank side" housing leakage rate (connections and access doors/ports between 12" butterfly valve and EEPA filter seal) in scfm = (P)(LF): & i ' t ) ( . / ) = O . O ? /

9

(4) Allowable Leak Rate in standard cubic feet per minute: 0.14

TEST DIRECTOR (print name and sign): R C @L;c&5 A&&'. , OTHERS (title, print name and sign): & cm D>E.1;.,+,,, 077;" 5 - 9

Work Piehpc 289660103A4

8-5

WHC-SO-WM-ATR-169 REV. 0 DATA SKEET 1 - POSITIVE PRESSURE DECAY TEST

DATE: Z-IG-qb TANK: 241-AW- I O 5 RETEST #: N A -

6.1

6.2 -

6.3

6.4

6.5

6.6

6.7

- - -

6.8

6.9

6.10.1 -

6.10.2

~

6.10.3

- 6.10.4

- 6.103

6.10.6

6.11 - -

b s N

D s n

D T M D rn

8-10

WHC-SO-WM-ATR-169 REV. 0 DATA SHEET 2 - LEAKAGE FSTE CALCULATION

TANK1 241-AW- l O d =TEST # I hl A Beginning pressure in inches WG: 7,&

Beginning pressure in psig (A/27.7): 0.27

Beginning barometric pressure in psi (IN Hg x 0.491): Iy.rlZ cCo,Gc& ukotCrr 21.76 " H3 Beginning duct pressure in psfa (B + C)144: 2 1 1 5

Beginning temperature in deg F: 70

Beginning temperature in deg R (D + 460): Ending pressure in inches WG: 5.2

5 3 0

Ending pressure in psig (E/27.7): 0.17 Ending barometric pressure in psi (IN Hg x 0.491): Jq.Yz

Z f p q l&qcdd ulc&h& 9 . 3 6 " H 3 Ending duct pressure in psfa (F + G)144: Ending temperature in deg F: 70

Ending temperature in deg R (H + 460):

Test Volume in cubic feet (entire assembly shown in H-2-85614, from flow controller to 12" butterfly valve): 24.7 R, gas constant, in ft lb/(lb*degR): 53.35

5 3 0

d r y Teat Duration in minutes: t o = 1.07 Average total housing leakage rate in standard cubic feet per minute (per ASME N510-1989, Section 6.5.3.9):

Q = (Pl/T1 - PZ/T2)V/(R AT * . 0 7 5 )

= 0.12 Leak Factor (based on an evaluation of individual leaks present using the bubble leak location method, the proportion of leakage on "tank aide" of HEPA filter): 0.1 Co-s idereA c-seruo+;uc i- +ahK 5;dc c c - . r e r f r ~ - S , 5+ep 6 . 1 0 . 1

ne /ea k y c u r ~ dcf+c+cd

Average "tank side" housing leakage rate (connections and access doors/ports between 12" butterflp valve and HEPA filter seal) in scfm = (P)(LF): ( *~Z) (e l ) = O.O/z

(L,) Allowable Laak Fate in standard cubic feet per minute: 0.14

wort mckapc 2E%d010)/M

8-13