sPJ', ClF ' ICATIO\ NO . C0000 •- 90571-T11

SSME SU: SiSTEMd TEST FACILITY

MODIFICA] IO :~ OF 45, 000 GAJ LON 1 ,1 12 VESSEL , V-109

For

COCA 1 TEST STAN D

SANTA SL'SANA FIELI ) L.iBOR.\TORY , CAI :IFORNIA

R0 CKE TDYKEA Division of North American Rockwell Corporation

6635 Canoga Ave ., Canoga Park, California

Facil itie s Engi neeriil Departmen t

L 1✓ e c C--L. Skoosta d

"s Manage rFacilities Engineering

F . MooreJ . H . Ntonaghan

Manager Manager

S:EME Subsystem Test SSME Facilities

Noveaher 6, 1972

BNA0521935 0HDMSe00181675

Specification No .000OO-9C',;1-II

Page 1

j

1 . SCOPE OF WORK

1 .1 The Builder shall furnish all labor, materials, tools and equipment,

and perform all operations required to modify and relocate the . 45,000

gallon liauidd hydrogen vessel identified as vessel No . V-109 in accor-

dance with this specification .

1 .2 The Sketch 00000-90871-SKI, Rev . 0, dated September 13, 1972 is for

reneral configuration of the vessel . The Builder may, at his option,

provide alternate design details .

1 .3 The vessel shall be modified in place at CTL III as shove on the

vicinity map, page 11 .

2 . CODES AND SPECIFICATI ONS

2 .1 The latest editions of the following codes and specifications, with

their current revisions, shall form a part of this specification .

2,1 .1 ASME Boiler and Pressure Code, Sections VIII aid I .X .

2 .1 .2 ASTM Standards, Part 1, "Steel Piping, Tubing and Fittings" .

2 .1 .3 ASTM Standards, Part 3, "Steel Sheet, Strip, Bar, Rod, Wire ; Metalli c

Coated Products" .

2 .1 .4 AS`1T1 Standards Part 4, "Steel-Prressure Vessel , Forgings , Railway ,U)

Reinforcing, Structural" .

2 .1 .5 American National Standard Institute Code for Pressure Piping

ANSI B31,3 .

2 .1 .6 California Administrative Code , Title 8, Chapter 4, Industrial

Safety Code .

uiuiumui mBNA0521935 1

HDMSe00181676

Specification No . 00000-9U ;1-:11

Page 2

2 .1 .7 Occupational . Safety and Health Act .

3 .0 MOI)IF'ICATIC1\PF'SI(:ti ltT(~[Iti+r`,'I

3 .1 Design calculations and drawings shall carry the approval of a Mechani-

cal Engineer licensed to practice in the State of California .

3,2 The Builder shall prepare and submit, within 30 calendar days after

award of contracts six copies of design calculations and drawings

for approval .

3 .2 .1 Approved design calculations and drawings shall be in reproducibl e

form .

3 .2 .2 Shop drawings shall show dimensions, tolerances, materials, fabri-

cations methods and finishes .

3 .2 .3 Approval of calculations and drawings by NR shall in no way relieve

the Builder of the responsibility for conformance in all respects

with the requirements of this specification .

3 .2 .4 The Builder is cautioned that work accomplished prior to drawing

approval is subject to rejection if it does not comply with the

requirements of the approved shop drawings .

4 .0 GENERAL RE1.,OC :UION rL\D MODTFI Cr!T'1 ON RFQUIRXE-N-T S

4 .1 A 12-inch diameter hole may be cut in the outer shell near the

bottom head for removing perlite from the annular space .

4 .1 .1 Remove in closed vans, approximately 3,500 cubic feet of perlite

from the annular space by a process to avoid expelling the perlit

to the atmosphere .

4 .1 .2 The perlite shall be removed from NR premises.

4 .1 .3 After penile removal a flush insert plate shall be welded in the

access openinig .

uiuiuuiui mBNA0521935 2

HDMSe00181677

Specification No . 00000-90 1- !_1 Page

4 .2 Remove the following and transport to area designated by the Nk Field

Representative :(a) The escape pole and platform

(b) The jib crane and vent stack .

(c) All presso.rizine, run and vent piping, valves and

associated equipment .

4 . 3

4 . It

Remove the vertical ladder and platform, store in the area for

reinstallation at the new location .

Shut off all vacuum valves at the vessel, remove the equipment for

servicing as follows, before reinstalling at, new location .

(a) Check out all wiring and electrical equipment, repair alnd,or

replace as required and reinstall .

(b) Clean and flush out tue vacuum pump and fill with clean,

new oil per manufacturer's instructions .

(c) Clean and service all valves, repair as required and

reinstall .

(d) Remove the vacuum, pressure and liquid level display guage .s .

Deliver to Nit Field Representative for calibration . Re in--

stall the gauges .

Clean and reinstall the vacuum pump oil trap and filter .

Furnish and install a synchro-start Model GSU Underspeed

Governor with explosion proof enclosure on the vacuum pump

shaft or belt . Wire into the existing 120 VAG Valve Control

System, set at 1500- ..i-pm . ._

(e)

(f )

4 .5 The vessel shall be moved and reinstalled on Coca 1 Test Stand at

elevation of 45' - 0" above the roadway .

4 .6 After modification, relocation, cleaning and testing are completed,

the annular space between the inner and outer vessels shall be filled

with perlite, 8 lb . cu . ft. compacted density .

4 .6 .1 The perlite shall be installed dry by the vacuum pack process .

4 .7 Both inner and outer vessels shall be recoded in accordance with

Boiler and Pressure Vessel Code, Section VIII .

3

BNA0521935 3HDMSe00181678

Specification No, CCO0O-908"; 1-T11Page h

5.0 KKFEP .1ALt

5.1 Materials shall conforci to their respective designated s1iecificat.ions

as follows :

Existing, Inner Shell . . . . . . . .A-STM A240-304

Existing Outer Shell . . . . .

.. . .ASTht A2d5-C

Pipe . . . . . . . . . . . . . . . . ASTM A312-TP304

Flanges . . . . . . . . . . . . . . ASTM Al'o2-F304

Fittings . . . . . . . . . . . . . . . A.131M A403-WP304

Plate and Clips . . . . . . . . . .ASTM A240-30'f

Gas1ubs . . . . . . . . . . . . . .Flurogreeu E-600, 3/32 inch thick

Expansion Joints . . . . . . . . . .Laminated, Convoluted Type 321 or

347 Stainless Stee l

Studs and Bolts . . . . . . . . .ASTM A 320-BSF (cold dratir)

Nuts . . . . . . . . . . . . . ASTM A194- 8

Safety Wire . . . . . . . . . . . . 18-8 Stainless Steel 1/16 inch

diameter

Tubing . . . . . . . . . . . . . . .M1L-T-b38O8A, Type 304 or 32 1

seamless

Vacuum Gaskets . . . . . . . . . . . Buna "N" 0-Rings

6 .0 1,-ELJ)I\G

6 .1 All welding and welder qualification procedures shall be performed

in accordance with the applicable paragraphs of the ASME Code,

Section VIII and TX for the material being welded .

6 .1 .1 Before starting fabrication, the Builder shall submit for review

and approval, five copies each of all proposed welding procedures .

6.2 Welds of carbon steel to stainless steel shall be made with F-310

or E-309 electrodes .

E .3 The root pass of butt welds on corrosion resistant steel components

that are welded from one side only shall. be made by an inert gas

shielded are method with helium or argon the shielding- gas . An

inert gas back purge on the root pass shall be maintained during

all welding of stainless steel until weld is cool . Subsequent

I IBNA0521935 4

HDMSe00181679

Spec iffication No . 00000-906 ;1-111

Page j

passes may be made by other approved shielded are methods .

6 .4 All pressure retaining welds shall be full penetration .

6 .5 Gas welding gill not be pcrr;it.t.ed .

7 .0 FAI3RICATIO`r AND LNSTA T.AJION

7 .1 Ql`I1lA? ,

7 .1 .1 All material and personnel qualifications, including fabrication

procedures, will be witnessed and approved by personnel designated

by NR .

7 .1 .2 On all operations where flame cutting, are cutting or are air goug-

ing are used, 1/64 inch of material below the scarfing marks shalt

be removed .

7 .2 The Builder shall perform all shipping and unloading operations,

and the installation of the vessel .

7 .3 The Builder shall install, level and adjust the vessel at the Coca 1 job

site on a support structure provided by NB. .

7 .3 .1 Before final tightening (after the joint is snub-tight), the cuter

face of each nut shall be match marked with the protruding bolt

point to afford a visual means of noting the actual nut rotation .

7 .3 .2 Marks shall be made permanent by scribing a line on the matching

par is .

7 .3 .3 The Builder shall furnish all bolts, nuts, shims, and mounting;

bardware required to install the vessel .

uiuiuuui I IBNA0521935 5

HDMSe00181680

Specification No . CCO0O-91037 1-Ti lPage 6

7 .4 All new and i.,odified material shall be sandblasted, etched and

chemically cleaned . All existing surfaces contaminated by the

fabrication effort shall be degreased and flushed in accordance

with Paragraph 8 .7 .

8.Q CLEANIN G

E .1 The Builder shall perform all cleaning operations indicated .

8.2 Protect all sealing surfaces during blast and chemical cleaning .

8.3 All cleaning and rinse solutions shall be sprayed, circulated, or

applied in a manner that shall completely wet all surfaces of the

system to be cleaned . Rinse water shall not he reused .

8.4 Once water solutions have been introduced into the system, the

surfaces to be cleaned shall . not be allowed to become dry bettieen

the steps of the procedure until the drying step has started .

8.5 All sections of the system to be cleaned that can trap or retain

any liquid shall be drained or emptied between the application

of each different solution or chemical mixture . During or after

the final rinse and prior to the drying step, each flange con-

nection shall be loosened or opened .to assure the removal of all

contamination from between flange faces .

8.6 The Builder shall seal all, systems, following cleanliness inspections

and, shall provide closures for all openings .

8.7 Cleaning Sequence

8 .7 .1 New and modified surfaces :

8 .7 .1 .1 Blast clean

8 .7 .1 .2 Degrease

8 .7 .1 .3 Flush, if degreased with alkaline cleaner

uiuiuuu i I IBNA0521935 6

HDMSe00181681

Specification No . 00000-90h-1-T11

Page 7

8 .7 .1 .4 Etch

8 .7 .1,5 Flush

8 .7 .1 .6 Dry

8 .7 .1 .7 Inspect, using white nylon cloth examination

8 .7 .1 .8 Seal

8 .3 Blast Cleanin g

8,8 .1 Carbon-free and iron-free sand (#1110 mesh) or alundum grit (#60 to

#320 mesh), neither of which has been used before on other metal,

shall be used in all blast cleaning operations .

8 .8 .2 Blast metal surfaces to remove all mill scale, weld flux, foreign

metals or other foreign matter . Remove all dust grit from the meta

8 .9 Chemical Cleaning Materials

8 .9 .1 Trichloroeth ine 1,1, 1, solvent : Stabilized, vapor degreasing and

solvent flushing grade .

8 .9 .2 Milk Alkaline Cleaner : Detergent type cleaner such as Turco No . 4090,

as manufactured by Turco Products, Division of Purex, 24500 S . Main,

Carson, California .

8 .10 Chemical Cleaning Processe s

8 .1.0 .1 Degrease : Flush or swab with a mild . alkaline cleaner solution at a

minimura temperature of 140°F or trichloroethane solvent until all

traces of oil and grease are removed .

8 .10 .2 Flush : Rinse or swab with distilled or deionized water until effluen t

water pII and influent water pH are equivalent .

8 .10 .3 Etch : Etch for a. period of 5 to . 30 minutes with a mixture of 3%

technical grade hydrofluoric acid, 10, technical grade nitric acid

(by weight.) and the remainder deionized or distilled water .

BNA0521935 7UI I I

HDMSe00181682

Spec tficac ou No . CCOOG-9Oo-1-Ti?

Page a

8 .10 .11 Flush : Rinse or swan with distilled or deionized water until

effluent water pH and influent water p1I are equivalent .

8 .10 .5 Dry : Puree with dry nitrogen until a dew point of minus 50°F is

reached or until moisture content of discharged nitrogen is 30 pini

by volume . Test dew point, with a Consolidated Electrodynamic .

Corporation '•ioisture rionitor, Type 26-3U1 .

8 .10 .6 Inspect : Inspect by visual examination, and wipe the cleoned

surface with a clean white nylon cloth . After wiping, no evidence

of oil, stain, rust, scale, solid particles, or any foreign material

on the cloth will be accepted .

8 .10 .7 Seal : Seal all openings against contain ination by appropriate AN

plugs and AN 0-rings . Flanges and other openings shall be sealed with

blind flanges and caps .

8 .11 Authority for determining adequacy of cleanliness of all work rests

with Nit Field Representative .

9 .0 TESTS

9 .1 PNELTLtTIC TEST

9 .1 .1 The inner vessel shallbe pneumatically tested at 133 psig . The

pressure shall be maintained with no decrease for 30 minutes .

Pressure shall be built up gradually to maximiun test pressur e

with continual inspection to prevent damage to the system .

9 .2 Vacuum Retention Tes t

9 .2 .1 Before insulation is installed, the annular space shall be

evacuated to 10 microns and the pump shut off . After 24-hours

under these conditions, the total. pressure increase shall not

exceed one micron of mercury per hour .

uiuiuuu i ii iBNA0521935 8

HDMSe00181683

Specification ; No . CC000-90c• ; 1-T11Page 9

9 . 2 .2 After perilte insulation is installed, the Builder shall evacuate

the annular space to 100 microns and shut the pump off . A rough--

ing pu,np and cold trap may be used for this requirement .

9 .3 All leaks shall be repaired by the Builder, and the tests repeated .

10 .0 INSPECTION

10 .1 All new inner vessel nozzles attachments and piping to the firs t

connection beyond the outer jacket, shall be 100j radiographically

inspected . The radiographing shall be performed in accordance

with the applicable paragraphs of the A .SME Code, Section VIII .

10 .2 Exposed film density shall be 1 .7 to 3 .7 H & D with optimum film

density at 2 .5 H & P .

10 .2 .1 The interpretation of radiographic negatives shall be the respon-

sibility of NR .

10 .5 Dye penetrant inspection shall be performed on all stainless steel

welds not radiographically inspected .

10 .4 Inspection procedures and fabrication shall be witncased by al t

and approved as required by authorized State or Municipal Inspectors,

AS1'LE and Insurance Inspectors, and shall be subject to the approval

of NR for final acceptance .

10 .5 The Builder shall notify Mt in writing 72 hours in advance of

cleanliness inspections .

10 .6 Final acceptance of cleanliness shall be by NR .

11 .0 PAINTIN G

Wire brush and paint to match existing all damaged areas resulting

from modification of vessel .

BNA0521935 9HDMSe00181684

Specification No . 00000-90 ;1-T11Page 1 0

11 .2 Stainless steel surfaces shall not be painted .

11 .3 The Builder shall protect all- equipment and material adjacent to the

work area by suitable drop cloths or other means .

11 .'= At the conclusion of the wort ., the Builder shall clean and remove

all print spots or stains, remove all waste materials, excess painf,-

ing material and dirt or debris from the area, and leave the premises

in a clean and neat condition .

uiiiuuiu mBNA0521936 0

HDMSe00181685

SANTA SLJSAN A FF! .D LA BORATOR Y

VICIN!TYMA P