-j:!.!)) f$f^^'-i^¥^

LIQUID ROCKET PLANT

FINAL TEST REPORT NO. 1.9.5-lE

VOLUME 4

MECHANICAL IRRADIATION TEST

8/LOOl

STATIC FLANGE SEAL ASSEMBLY

16 March 1964 i f if- ^L " S fc ** F* T

DISCLAIMER

This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency Thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

DISCLAIMER Portions of this document may be illegible in electronic image products. Images are produced from the best available original document.

T'XP/^^^'"'^^

00053 FINAL TEST REPORT NO. 1,9*5-1E

VOLUME '

MECHANICAL IRRADIATICN TEST

No« 8/LOOl

STATIC FLANGE SEAL ASSEMBLY

Reviewed bys

', ^- Jr/uM-. R M Beattie^, Manager Radiation Test System Dept» NEHVA Rocket Operations Liquid Rocket Plant

Prepared by:

M H Warner Radiation Test System Dept, NERVA Rocket Operations Liquid Rocket Plant

Approved byj

y P W Rcwe Assis tant Technical Manager NERVA Rocket Operations Liquid Rocket Plant

NOTICE-This report was prepared as an account of work sponsored by the United States Government. Neither the United States nor the United States Energy Research and Deveiopment Administration, nor any of their employees, nor any of their contractors, , subcontractors, or tlieir employees, makes any warranty, express or implied, or assumes any legal | liability or responsibility for the accuracy, completeness | or usefulness of any information, apparatus, product or I process disclosed, or represents that its use would not infringe privately owned rights.

5616

ipwwTion or Qfii mmm mmn^

parksb

Text Box

PAGE BLANK ii

Report 1.9.5-lE^ Volume k

ABSTRACT

Mechanical Irradiation Test 8/LOOI was designed to determine the effects

of radiation on seals and flanges at LH^ temperatures. The test was conducted

in a test reactor at General Dynamics Aerospace Systems, Fort Worth, Texas, on

17 July 1963.

Three combinations of stainless steel and aluminum flanges with aluminum

or stainless steel gaskets were exposed to between 3»7 x 10 and 9-0 x 10 n/cm 7 7

of fast neutrons (E > 2»9 Mev) and a gamma radiation of from I.3 x 10 to 8.1 x 10

ergs/gm(c). Temperature and pressure of the H was monitored during the test, and

leak checks and visual inspections were conducted during pre- and post-irradiation

tests. No apparent damage to seals or flanges resulted from the irradiation test.

There was an apparent change of bolt torque values on joints between pre- and post-

irradiation tests accompanied by an increase in leak rate for the joints affected.

This anomaly is not attributed to radiation effects.

113

Report 1.9.5-IE, Volume k

TABLE OF CONTENTS

Introduction

Experiment Identification

Purpose of the Experiment

Test Description

Test Procedures

Nuclear Measurements

Test Results

Discussion of Test Results

Conclusions and Recommendations

References

Pag(

1

1

2

3 k

5 7 10

10

12

APPENDIXES

Photographs

Dosimetry

Test Data—10 Sec Run

Test Data—3OO Sec Irradiation Test

Calibration Data

Iv

Report 1 .9 .5 - IE , Volume k

I. INTRODUCTION

The radiation effects test program is designed to obtain preliminary infor­

mation regarding the effects of a combined radiation and cryogenic environment on

NERVA engine non-nuclear components. The first experiment on flanges and seals,

as reported herein, was to evaluate the performance and integrity of various com­

binations of stainless steel and aluminum flanges and seals in a radiation and

cryogenic environment, representative of the NERVA engine operation.

The NERVA engine is a rocket engine using hydrogen as the propulsion fluid

and a controlled nuclear reaction as a heat source. The use of many flange and

seal applications in the engine dictates the need for developing reliable radiation

resistant hardware. It is felt that the flange and seal problems will not be great,

but in view of the scarcity of radiation effects information in a combined cryogenic

and radiation environment, a program to provide such information is necessary.

II. EXPERIMENT IDENTIFICATION

A. TEST PLAN REFERENCE

8/LOOI Static Flange Seal Assembly

B. SPONSOR

NERVA Rocket Operations

Liquid Rocket Plant (LRP)

Aerojet-General Corporation

Sacramento, California

Page 1

Report 1.9.5-IE, Volume k

II, Experiment Identification (cont.)

C. TEST FACILITIES

1. Pre- and Post-Irradiation Tests

NERVA Rocket Operations

Liquid Rocket Plant (LRP)

Aerojet-General Corporation

Sacramento, California

2. Irradiation Test

Aerospace Systems Test Reactor

Nuclear Aerospace Research Facility

General Dynamics Corporation (GD/FW)

Fort Worth, Texas

D. TEST DATES

1. Pre-Irradiation test, I3 March 19^3

2. Irradiation test, 17 July I963

3. Post-irradiation test, August I963

III. PURPOSE OF THE EXPERIMENT

This experiment was designed to provide early preliminary information on the

performance and integrity of various seal and flange combinations in a combined

cryogenic and radiation environment. The first test maintained Hp in the static

flange and seal assembly (SFSA) under 220 psl and a low-flow rate (approximately

0,1 lb/sec). Possible permanent deformation and resulting increase in leakage rate

would be determined by comparison between the pre and posttest examination and leak

tests.

Page 2

Report 1.9-5-IE, Volume h

IV. TEST DESCRIPTION

An assembly of Aeroquip Corporation Conoseal-type flanges made of stainless

steel and aluminum was designed to Include a 6-in. aluminum-to-aluminum joint with

an aluminum Conoseal, a 6-in. aluminum-to-stainless steel joint with an aluminuim

Conoseal, a 6-in. stainless steel-to-stalnless steel joint with a stainless steel

Conoseal, a 2-in. aluminum-to-stainless steel joint with an aluminum seal, and a

2-in. aluminum-to-aluminum joint with an aluminum seal. This test assembly,

PN 263685 (Figure A-l), was mounted on a test pallet, P/N 255802-19, and subjected

to the sequence of tests in Section II,D. The pre-irradiation test was a functional

checkout conducted at LRP Test Zone G-7- (See Figure A-2.) Hydrogen was flowed

through this assembly and then through an orifice into the tank shut-off valve (TSOV)

cryostat (Figure C-l). By design, the flow was to be controlled by the liquid level

sensors in the TSOV cryostat; this was only sufficient to replace the boil-off. The

GHp in the cryostat was ducted to an atmospheric vent.

Instrumentation of the SFSA included a Rosemont 13^-CT RTT at the inlet end,

a CEC 170209-0100 pressure transducer at the outlet end, and a chromel-alumel thermo­

couple on the pressure transducer case.

The test pallet was positioned so that the SFSA was to the left of the reactor

center line when extended through the pallet. A detailed description of the test

pallet and special test equipment provided is included in Volume V of this report.

Briefly, the test pallet consisted of an aluminum structural portion designed to

support the SFSA in the desired position relative to the reactor radiation field and

to contain the necessary valves, regulators, filters, relief systems, and instrumen­

tation. The pallet controlled the fluid and electrical supplies to the test components.

Liquid hydrogen pressure at the test pallet was controlled at the LH2 supply Dewar.

The Dewar was provided with pressurlzation, purge, vent, and water deluge systems

(Figure A-3). A gas distribution system supplied gaseous helium and hydrogen to the

pallet for containment vessel purging and valve actuation of the containing vessel

(Figure A-k).

Page 3

Report 1.9.5-IE, Volume k

IV, Test Description (cont.)

Control of this test equipment was accomplished through a master sequencer

checker mounted in a control console along with an event recorder, a power panel,

an output amplifier, and a signal conditioning unit.

The data acquisition system consisted of an analog magnetic tape system,

video tape system, visual meter panels, and four ^-channel Sanborn recorders.

Critical parameters were monitored visually on the meter panels. In addition,

all critical and "kill" parameters were wired directly to the Sanborn recorders.

All test measurements were recorded on analog tapes. The analog magnetic tape

system included twenty-four tape channels, each of which could record six separate

parameters.

V. TEST PROCEDURES

Report No. 9il-ij-0-lSA, Test Procedure No. 1.9-5-10 presents the data handling

requirements and the detailed irradiation test operating procedures, incluaing the

pre and post ones. „ Briefly, the following sequence of major events was followed

at GD/FW. The test pallet and associated control equipment was set up and fuinctionally

tested in the laboratory prior to its installation at the reactor site. Once the test

equipment was installed at ASTR, electrical checks, system leak checks, functional

tests, and a liquid nitrogen flow test were performed to ascertain that all systems

were operational. At this point the storage Dewar was loaded with liquid hydrogen,

a cooldown sequence was followed and a 10 sec control run was initiated. Normal

shut down procedures were then followed and preparations were made for the irradia­

tion test. When the Dewar was refilled, the cooldown sequence was repeated, the

reactor was elevated into position, the reactor power was increased to 10 Mw, and

the irradiation test was started. The reactor was turned off after 327 sec of oper­

ation and a normal shut down procedure followed.

As soon as practicable after the conclusion of the irradiation test the shroud

cover was removed and all pressure transducers were recalibrated using the same Heise

Page k

Report 1.9.5-IE, Volume k

V, Test Procedures (cont.)

gage that was used for the original calibrations. All irradiation test parameters

were plotted using the posttest calibration data because the conditions existing

during the posttest calibration were more nearly like those during the irradiation

test. Appendix E presents the calibration curves used in conjxmction with the

oscillograph charts.

The SFSA was removed from the pallet and shipped to the Liquid Rocket Plant.

Proof and bubble chamber leak tests were performed on the SFSA. Flange couplings

were checked for residual torque, retorqued as necessary to design values, and

again leak tested. The test cell was then disassembled, measured, and inspected

for damage. Thicker Conoseals (.040 in. vs .032 in.) were installed and another

leak check was performed.

A complete materials analysis of the irradiated SFSA was planned, but had

not been completed prior to the cessation of the NERVA static flange and seal

development program.

It was also planned to run a test with .032 x .280 in. Conoseals in these

flanges, but this was also cut off by the stoppage of the development program.

VI. NUCLEAR MEASUREMENTS

A. NEUTRON

The neutron flux was monitored during the test at 19 locations (Table B-Il) .

Neutron flux measurements were made with the threshold detectors: sulfur for energy

^2.9 Mev and aluminum for energy ^8.1 Mev; phosphorus pellets (bare and cadmium)

were used to measure the thermal flux. (See Table B-I.)

Page 5

Report 1.9.5-IE, Volume k

VI, A, Neutron (cont.)

Detectors were mounted on 3-l/2 x 3 in. aluminum holders, which in turn

were mounted on or near the components. All foils were counted and the data reduced

by an IBM 709O digital computer program.

B. GAMMA

The gamma dose measurements were made with nitrous oxide (NpO) dosimeters,

chemical dosimeters, and cobalt glass.

1. Nitrous Oxide Dosimeters

The nitrous oxide dosimeters used at GD/FW consist of a quartz shell

forming a volume of about 2h cc which is filled with a measured quantity of NpO gas

before the dosimeter is flame-sealed. Upon exposure to gamma radiation, the following

reaction is produced in the gas:

NgO ^ ^2 ^ °2 ^ °2

The dose is determined by measuring the moles of Np + Op produced per mole of original

NpO, and then relating this quantity to dose on a calibration curve.

Energy dependence of the N O system is air-equivalent (within 10' )

from 150 kev to 5 Mev. The dosimeters are usable in the dose and temperature ranges 8 12

of from 10 to 10 ergs/gm(c) and -90° to +120°C, respectively. The dosimeters

have a reproducibility of 7^ to 9^.

2. Chemical Dosimeters

The chemical dosimeters are the chlorinated hydrocarbon type

developed originally by Taplin-Sigaloff and modified at GD/FW. They consist of

0.8 ml of tetrachloroethyLene overlaid with 0.2 ml of water. The dosimeters.

Page 6

Report 1.9.5-IE, Volume k

VI, B, Gamma (cont.)

sensitive to gamma energies from 65 kev to 10 Mev, have a usable gamma dose range 5 8

from 10 to 10 ergs/gm(c), a temperature range from 5 to 50°C, and a precision of

5 to 6^ at the 95' confidence level.

3. Cobalt Glass Dosimeters

These dosimeters are cobalt-activated borosilicate glass plates,

15 "by 6 by I.5 mm, manufactured by Bausch and Lomb Inc. Exposure to ionizing radi­

ation darkens the glass. The change in optical density measured at 390 m\i versus

the dose was plotted; the plot was compared with similar plots of calibrated glass

plates to obtain the dose. The recommended range of the dosimeters is from 10 to o

2.6 X 10 ergs/gm(c).

These dosimeters were enclosed in a I/16 in.-thick thermal neutron

shield of the following composition: 33/0 by weight B.C (92fo enriched B ), 33/0

Epon 828, and 33/0 Versamid""" °.

VII. TEST RESULTS

As described in Section IV, provisions were made for measurement of various

parameters during pre- and post-irradiation tests; the pressure, temperature, and

radiation dosages were monitored during the irradiation test.

Comparisons of the pre-irradiation test leak checks, which were performed

with a mass spectrometer having a sniffer attachment, and the post-irradiation

test leak checks, which were performed with a bubble chamber, are as follows;

Page 7

Report 1 .9 .5 - IE , Volxime k

VII , Test Resu l t s ( c o n t . )

Joint

6 in.

Alum-Alum

Test

Pre-

1st Post-

2nd Post-

3rd Post-

Test Fluid Press lire

(psig)

630

500

500

500

Test Fluid

G He

II

TI

II

Bolt Torque (in.-lb)

260

21+0

260

260

Leakage

<^1.27 X 10 sec/sec

No bubbles^

No bubbles**

Thicker Conoseal. -3 XXX <10

:/= sec/sec

b m .

Al-CRES Pre-

1st Post-

2nd Post-

3rd Post-

630

500

500

500

260 <5..27 X 10" sec/sec

280 Excessive*

260 Excessive**

260 Thicker Conoseal. -2 /

4.6 X 10 sec/sec***

m. CRESrCRES . Pre-

1st Post-

2nd Post-

3rd Post-

630

500

500

500

1+30 <^1.27 X 10" s ec / s ec

310 Excess ive*

i+30 Excess ive**

i|-30 Thicker Conoseal .

^lO"-^ s ec / sec***

2 in.

Al-CRES Pre-

1st Post-

2nd Post-

3rd Post-

630

500

500

500

80 <yL.27 X 10" sec/sec

65 No bubbles*

80 No bubbles**

80 ^10"-^ sec/sec***

*^ 4Hf ***^ See next page for footnotes,

Page 8

Report 1 .9 .5 - IE , Volimie i+

VII, Test Results (cont.)

Joint

2 in.

Al-Al

Test

Pre-

1st Post-

2nd Post-

3rd Post-

Test Fluid Pressure (psi?)

630

500

500

500

Test Fluid

G He II

II

II

Bolt Torque (in.-lb)

60

50

60

60

Leakage

<(l.27 X 10" sec/sec

No bubbles*

No bubbles**

<10"3 sec/sec***

NOTES:

*Entire cell was immersed and bubbles were observed only from 6 in. Al-CRES and 6 in. ORES-ORES joints. Total leakage was 60 sec/sec.

**Entire cell was Immersed and bubbles were observed only from 6 in. Al-CRES and 6 In. Al-CRES and 6 in. CRES-CRES joints. Total leakage was again 60 sec/sec.

***Leakage from 6 in. Al-CRES joint determined from bubble count. Leakage from all other joints in 3 d post irradiation test totaled less than 10"3 sec/sec.

During the Irradiation test, the temperature of the H2 in the SFSA averaged -395°F. (See Figure D-2.) The pressure remained at approximately 23O psig until the LHpS valve was manually closed at FS, + 2^1 sec, (See Figure D-1.)

Integrated doses received were; (l) from 9-0 x 10 to 3*7 x 10 n/cm fast neutrons (E=»-2.9 Mev), and (2) from I.3 x lo' to 8.1 x 10' ergs/gm(c) gamma. These values (see Appendix B) are interpreted and adjusted in Reference 5«

No leakage measurement was planned nor accomplished during the irradiation test.

The dimensional check of flange diameters and groove depths indicated that all dimensions were within design tolerances. No measurements of flange flatness, bolt length, nor clamp dimensions were taken.

Page 9

Report 1.9.5-IE, Volume k

VIII. DISCUSSION OF TEST RESULTS

The test data tabulation of Section VII indicates a reduction of flange

coupling bolt torque values on four of the five joints and an increase on one.

There was no detailed procedure for inspection of these torque values before or

after each of the several functional or system leak tests which were conducted.

It is therefore difficult to assess when or how coupling bolt torque relaxation

occurred.

The reduction of leakage during the post-irradiation testing after the

.032 in. Conoseals were replaced by .Ol+O in. Conoseals supports the Aeroquip

Corporation recommendation to use the .0^0 x .275 in. Conoseals in flange line

sizes of 6 to 10 in. However, the leak rate after the heavier Conoseals were

installed was still greater than that prior to the irradiation test series.

Insufficient data was obtained upon which to base any conclusion concerning

the cause of the increased leakage. This is partly because of the design of the

SFSA, partly to lack of radiation qualified instrumentation, and partly to incom­

plete detail in test planning.

IX. CONCLUSIONS AND RECOMMENDATIONS

A. It is concluded that:

1. A static flange seal assembly leakage rate Increase may have been

caused by a combined radiation and cryogenic environment, or by the radiation en­

vironment imposed.

2. Further static flange seal testing should be delayed until instru­

mentation can be properly evaluated in a radiation environment and the accuracy and

reliability of such instruments during Irradiation are known.

Page 10

Report 1.9.5-IE, Volume h

IX, Conclusions and Recommendations (cont.)

3. Test planning did not provide for sufficient information to isolate

the causes of the failure of static flanges and seals.

B. It is recommended that:

1. Additional nonradiation and radiation testing of static flange

seals be undertaken.

2. Test planning should ensure that data is obtained at appropriate

intervals during a complicated test series to permit isolation of effects and causes.

3. Further testing of static flanges and seals be accomplished when

instrumentation capabilities in a combined cryogenic and radiation environment

are better defined.

h. The flange and seal test cell be redesigned to provide for in-test

monitoring of leak rates and critical stresses.

5. Pre and posttest materials properties tests should be conducted.

Page 11

Report 1.9.5-IE, Volume k

REFERENCES

Test Procedures No. 1.9«5-1; Mechanical Irradiation Test No. 901,

Aerojet-General Corporation Reports 9^40-IS and 9440-lSA.

Final Test Specifications for ASTR Mechanical Pallet Tests of 15 June I963,

Aerojet-General Corporation Report 2569.

Preliminary Report ASTR-1 Irradiation Test, I7 July 1963? General Dynamics,

Fort Worth.

NERVA Components Irradiation Program Volume 2; ASTR Test 1, General Dynamics,

Fort Worth, Report FZK-170-2.

Radiation Analysis of Mechanical Irradiation Tests 9OI thru 904 (u). Aerojet-

General Corporation, Report No. RN-S-OO5O, January 1964 (Conf. Restricted Data).

Preliminary Report SCR #159^ Mechanical Controls Department Report, Systems

and Controls Division, Aerojet-General Corporation.

Page 12

Report 1.9.5-IE, Volume k

APPENDIX A

PHOTOGRAPHS

Report 1.9.5-IE, Volume 4, Appendix A

FIGURE LIST

Figure

Static Flange Seal Assembly A-l

Test Pallet on Test Stand at G-7 A-2

LHp Supply Dewar with Pressurization, Water Deluge, and

Vent Systems A-3

Gas Distribution System A-4

11

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Report 1 . 9 .5 - IE , Voliome k

APPENDIX B

DOSIMETRY

I I

Report 1.9.5-lE, Volume k, Appendix B

TABLE LIST

Dosimetry Results

Dosimetry Locations

Table

B-1

B-2

11

Report 1.9.5-1E, Volume 4, Appendix B

DOSIMgrRY

Nineteen dosinetry packets were attached to the various cosponents on the test pallet to neasure the Integrated dose received by each component* Table 1 contains the dose measured by each of the dosimetry packets* Table 2 contains the location description and number of the dosinetry packets for each of the conponentlb*

TABLE B->

Dosinetry Results

Packet Oansna Neutrons/cn Neutrons/cn Thermal ej?gs/gn(C) B ^ . l Mev E*2 .9 Mev Neutrons/cm^

E«0*U8 ev

1 .

2.

3 .

U.

5 .

6.

7.

8.

9*

10.

1 1 .

12.

13 .

l i i .

15.

17.

18.

19*

20*

8*1

3.8

1.3

l . l

2*1

3.8

1*8

1.7

l.U

1.7

8*1

5.14

l.h

2*2

8*1

5.ii

7.0

li.O

2.9

(7)*

(7)

(7)

(8)

(6)

(8) 1

(8)

(7)

(7)

(7)

(6)

(6)

(7)

(7)

(7)

(7)

(6)

(7)

(7)

*8*1 (7) denoted 8*1

6.2 (11)

3.5 (11)

1.3 (12)

2.3 (12)

2.5 (12)

2.1i (1&)

1.1 (12)

1.8 (11)

1.8 (11)

1.0 (11)

6.0 (10)

1.3 (10)

7.9 (11)

3.2 (11)

7.9 (11)

8.0 (11)

2.6 (11)

1.7 (11)

2.7 (11)

X 10*7

1.8 (13)

1.1 (13)

3.7 (13)

8.3 (13)

9.2 (13)

8.1 (13)

3.5 (13)

5.2 (12)

5.2 (12)

3.6 (12)

1.7 (12)

6*0 (11)

2*5 (13)

1.0 (13)

2.5 (13)

2.8 (13)

1.3 (12)

9.0 (12)

6.6 (12)

2.8 (12)

2.5 (12)

3.2 (12)

3 .1 (12)

2.7 (12)

2.1 (12)

1.6 (12)

2*Ii (12)

2.1 (12)

2.5 (12)

2.8 (12)

Table B-1

Report 1.9.5-1E, Volume 4, Appendix B

TABLE B-2

Dosimetry Locations

Static Flange Seal Assembly

Packet No, 1

Packet No* 3

Packet No* 19

Tank Shut-Off Valve

Packet No* 19

Packet No* 20

Bearing Tester

Packet No* k

Packet No. 17

Packet No* 18

On horizontal centerllne, 6 Inches from left end, on front face.

On horizontal centerllne, 12 Inches from left end, on front face*

On horizontal centerllne, 8^ inches from left end, on back face.

On '««rtlcal centerllne, front face, directly behind Static Flange Seal Assembly*

Directly behind No. 19 on back face of TSOV.

On front face, vertical and horizontal centerlines.

Mounted on rear surface of flange at top*

Mounted on rear surface of Bearing Tester Motor

Turbine Punp Control Valve Actuator

On front face

On rear face

Packet No* 13

Packet No. Ik

Turbine Punp Control Valve

packet No* 15 On front face

Packet No* 2 On rear face

Shroud (outside dosimetry 6" up from base)

Front face left to right distance from left side of shroud

2 ^ 25" 3U«

Table B-2

Report 1.9.5-IE, Volume k

APPENDIX C

TEST DATA--10 SEC RUN

Report 1.9.5-IE, Volimie k, Appendix C

FIGURE LIST

Figure

Flow Diagram MIT #901 Pallet C-1

Pressure of LH^ in the Static Flange Seal Assembly C-2

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