. . .. J ERDA 76-21 Distribution Categories UC-11, 70 NUCLEAR AIR CLEANING DESIGN, CONSTRUCTION, AND TESTING OF HIGH -EFFICIENCY AIR CLEAN IN G SYSTEMS FOR NUCLEAR APPkATlON /- C. A. Burchsted This document is J. E. Kahn PUBLICLY RELEASABLE A. B. Fuller - % W Authorizing Official Date: 5- 4 -0 C 'r- mi was prepared as an mount of work sponsored by the United Statu Covernrnent. Neither the United Stater nor the United Stltu Energy Research and Dcvelopmnt Adminirtntion, nor Of their employetr, nor any of their contractors. wbmnlncton. or their employees. makes any wliarbnilnityt yi r crxespproenus iboirl ityim foprl itehde, aocre uarsaseuym, ceosr napnlyc telneesds 01 usefulness of any information, spparatlu. product or pmeeu dirdorcd, 01 represents that its we wauld not infringe privately owned rights. Contract No. W -7405-en g -26 OAK RIDGE NATIONAL LABORATORY Oak Ridge, Tennessee 37830 OPERATED BY UNION CARBIDE CORPORATION FOR THE ENERGY RESEARCH AND DEVELOPMENT ADMINISTRATION 'DISTRIBUTIONO F THIS DOCUMENT IS UNLIMITED 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. Forew ord to Second Edition This handbook is a revision of ORNL/NSIC-65, of ANSI Committee N45-8 who, perhaps un- Design, Construction, and Testing of High-Efficiency knowingly, supplied certain data and served as a Air Filtration Systems for Nuclear Application, sounding board for some of the concepts presented in which was issued in January 1970. For simplification, the handbook. We wish to thank the many vendors the title has been shortened to Nuclear Air Cleaning and ERDA contractors who supplied drawings and Handbook, and the report has been issued under an photographs used in the book. We also acknowledge ERDA number. the work of Oak Ridge National Laboratory’s Technical Publications Department, particularly The new edition updates the information of the that of the Composition and Makeup groups, that of orginal volume, corrects some errors that appeared in R. H. Powell who provided editorial assistance, and it, and adds some new material, particularly in the especially that of P. J. Patton who edited and areas of sand filters, deep-bed glass fiber filters, and coordinated publication of this handbook. requirements for plutonium and reprocessing plants. Reviewers who contributed in the technical review Although A. B. Fuller was unable to contribute of particular sections of the handbook include directly to this edition, his earlier material on single- filter installation and glove boxes has been largely retained, though rewritten and updated. With this R. L. Alley, American Warming and Ventilating issue, J. E. Kahn of the Union Carbide Corporation Company Nuclear Division’s (UCCND) Engineering staff joins J. E. Beavers, Union Carbide Corporation Nuclear the writing team, contributing particularly in up- Division dating the material on glove boxes and writing the R. R. Bellamy, Nuclear Regulatory Commission sections on sand filters and deep-bed glass fiber filters R. E. Blanco, Oak Ridge National Laboratory in Chap. 9. Others who have contributed to this P. J. Breman, Union Carbide Corporation Nuclear edition include J. C. Little, UCCND Engineering, Division and a host of reviewers who provided technical C. L. Cheever, Argonne National Laboratory evaluation of the draft. Particular thanks are due Dr. J. C. Elder, Los Alamos Scientific Laboratory M. W. First of the Harvard University School of A. G. Evans, Savannah River Laboratory Public Health, and Mr. Humphrey Gilbert, consul- H. F. Farquhar, Lau Blower Company tant to the Energy Research and Development S. S. Freeman, Mound Laboratory Administration (ERDA) and the Nuclear Regulatory R. T. Goulet, Cambridge Filter Corporation Commission (NRC) and former safety engineer with R. K. Hilliard, Hanford Engineering Development the U.S. Atomic Energy Commission, for their Laboratory detailed and thorough review of the complete draft. D. J. Keigher, Los Alamos Scientific Laboratory Others who reviewed the complete draft were J. F. C. Lambert, Bechtel Power Corporation Fish, chairman of ANSI Committee N45-8; J. C. F. D. Leckie, Nuclear Containment Systems, Inc. Little, UCCND Engineering; J. C. Dempsey, ERDA H. A. Lee, Atlantic Richfield Hanford Company Division of Nuclear Fuel Cycle and Production; A. B. J. Lipera, Lawrence Livermore Laboratory Fuller, president of Fuller Engineering; and J. T. R. A. Lorenz, Oak Ridge National Laboratory Collins of NRC. Thanks are also due to the members W. Ng, Lawrence Livermore Laboratory ... 111 W. C. Schimdt, Atlantic Richfield Hanford Com- Sheet Metal and Air Conditioning Coqtractors’ PanY National Association F. R. Schwartz, Jr., North American Carbon A. A. Weintraub, Energy Research and Develop- Company ment Administration A. Shacter, U.S. Army, Aberdeen Proving R. E. Yoder, Rocky Flats Plant Ground-EA D. P. Zippler, Savannah River Plant C. A. Burchsted Oak Ridge, Tennessee March 31, 1976 iv Foreword to First Edition This handbook fills a large gap in the literature systems the kind of problems that an operator faces concerning air cleaning and filtration, the gap that and what he, the designer, must do to preclude or encompasses design, construction, and testing of very alleviate them. We have purposely pointed out some high-efficiency air cleaning systems. The project was poor practices in current design in addition to our originally conceived by Mr. Humphrey Gilbert of the recommendations in the hope that such practices will USAEC and was sponsored by the Division of go no further. To give “do’s’’ without “don’ts” may Reactor Development and Technology of the encourage some designers to offer a poor design USAEC. In preparing for the project we surveyed air- because he mistakenly believes that “it worked cleaning systems at atomic energy facilities and before.” industrial installations throughout the United States Those who have contributed to the handbook and Canada. We visited AEC production reactors, number literally in the hundreds and include those we commercial power reactors, laboratories, consulted with and those who have given of their time radiochemical plants, reactor fuel manufacturers, in reviewing drafts or have supplied specific bits and clean rooms, equipment manufacturers, and one pieces of information. We take this opportunity to chemical-biological warfare installation. The pur- thank the many friends we have made in the course of poses of these visits were to review current practices this project, particularly for their candidness in in high efficiency air cleaning and to define the discussing problems and ways of solving those problems in operating, maintaining, and controlling problems, and for their help in supplying contamination release from very high-efficiency air- photographs and information. In particular we want cleaning systems from experienced people who were to thank Mr. Humphrey Gilbert and I. Craig Roberts dealing with such problems daily. The handbook of the USAEC for their guidance, W. B. Cottrell of reflects a consensus of our findings in these travels, in ORNL for his help in getting the book published, addition to information gleaned from the available T. F. Davis of the USAEC‘s Division of Technical literature. Information for his assistance in indexing the The handbook is addressed primarily to designers material, J. H. Waggoner of ORNL for doing the and architectengineers. We frequently observed a illustrations, and Dr. M. W. First of Harvard lack of communication and feedback from people University for his meticulous page-by-page review of with problems in the field to designers. Our intention the draft and suggestions for this final issue, is to bring to the attention of designers of future C. A. Burchsted A. B. Fuller Oak Ridge, Tennessee July 10, 1969 V n Preface This handbook is another step in the continuing evaluate it, and to provide guidance to the engineer effort of the Energy Research and Development and technologist in the design of future facilities. The Administration to ensure the safe operation of book is an update of the earlier ORNL/NSIC-65, nuclear facilities. Gaseous effluents from these issued through the Nuclear Safety Information facilities are among the more difficult to control, and Center at Oak Ridge National Laboratory, and has the AEC, now ERDA, has long carried on an been prepared under the direction of the ERDA intensive program aimed at their effective control. Division of Nuclear Fuel Cycle and Production. The The record of this program is available in the previous edition has received worldwide recognition proceedings of the biennial AEC Air Cleaning as the authoritative text in the field of nuclear air Conferences, the first of which was held in 1952 and cleaning system design. We believe that publication the fourteenth to be held this year in Idaho. These of this new edition by ERDA is a significant proceedings,and numerous technical reports issued contribution to the technical literature. on this topic describe research, development, and experience in sp’ecific facilities. In most cases they do Frank P. Baranowski, Director not provide general or coordinated guidance for the Division of Nuclear Fuel Cycle designer. and Production, Energy The purpose of this handbook is to draw on the Research and Development wealth of background data available, to digest and Administration vi Contents FOREWORD TO SECOND EDITION ................................................................................................ 1.1.1. FOREWORD TO FIRST EDITION ..................................................................................................... v PREFACE ............................................................................................................................................. vii 1. INTRODUCTION .............................................................................................................................. 1 1.1 Background .................................................................................................................................. 1 1.2 Purpose and Scope ...................................................................................................................... 1 1.3 Design Considerations ................................................................................................................. 2 1.4 Space Considerations ................................................................................................................... 3 1.5 System Flexibility ........................................................................................................................ 3 1.6 Coordination of Design and Construction ................................................................................... 3 1.7 Cost Considerations ..................................................................................................................... 4 1.8 Purpose of the Handbook ............................................................................................................ 4 1.9 Glossary ....................................................................................................................................... 5 1.9.1 Dictionary of Acronyms ................................................................................................... 5 1.9.2 Units of Measure and Metric Equivalents Used in This Handbook ................................. 6 1.9.3 Terms and Phrases ............................................................................................................ 7 2 . SYSTEM CONSIDERATIONS .......................................................................................................... 12 Introduction ................................................................................................................................. 12 Environmental Considerations ..................................................................................................... 12 2.2.1 Zoning ............................................................................................................................... 12 2.2.2 Airborne Particulates and Gases ....................................................................................... 17 2.2.3 Moisture ............................................................................................................................ 19 2.2.4 Heat and Hot Air ............................................................................................................. 20 2.2.5 Corrosion .......................................................................................................................... 20 2.2.6 Vibration ........................................................................................................................... 21 Operational Considerations .......................................................................................................... 21 2.3.1 Operating Mode ................................................................................................................ 21 2.3.2 Filter Change Frequency ................................................................................................... 21 2.3.3 Building Supply Filters ..................................................................................................... 22 2.3.4 Prefilters ............................................................................................................................ 22 2.3.5 Operation to High Pressure Drop ..................................................................................... 23 2.3.6 Underrating ....................................................................................................................... 24 2.3.7 Uniformity of Airflow ....................................................................................................... 25 2.3.8 Maintainability, Testability ............................................................................................... 26 vii 2.4 System Configuration-Nomenclature ................. ... ............ .. ........... ......... .. .. .. . .... .. .... .... .............. 2.4.1 Component ....................................................................................................................... 2.4.2 Air Cleaning Unit ............................................................................................................. 28 2.4.3 Air Cleaning System ......................................................................................................... 28 2.4.4 Ventilation System ........ .... ..... .... ......................... ......... .... ..... ............. .... ... ........ ........ .. .... .. 29 2.4.5 Filter or Adsorber Bank ................................................................................................... 29 2.4.6 Array .................................................................................................................. .. ..... ........ 29 2.4.7 Air Cleaning Stage ............................................................................................................ 29 2.4.8 Installed Capacity ..................................... ........ ........ ................ .......... .............................. 29 2.4.9 Shgle-Component Air Cleaning Unit ............................................................................... 29 2.4.10 Single-Path System ........................................................................................................... 29 2.4.1 1 Parallel System ......... .. .. . ... .. ............... .. .. .... .. .. .. .. .... ... ........ ........ .... .... .......... .. .................... 29 2.4.12 Segmented System .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .... .. . . . . . .. . . . .. . .. .. .. .... ... ............ 29 2.4.13 Redundant System ........................................................................................................ .... 29 2.4.14 Branched System ............................................................................................................... 29 2.4.15 Isolable Unit ................................................................................................................. .... 29 2.4.16 Compartmented Unit ........................................................................................................ 29 2.5 Emergency Considerations .. .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. .... .. . ... .. . . ... . ............... .... ..... ........ 31 2.5.1 Shock and Overpressure ................................................................................................... 31 2.5.2 Fire and Hot Air ............................................................................................................... 33 2.5.3 Power and Equipment Outage .......................................................................................... 34 2.5.4 Air Cleaning System Layout Considerations .................................................................... 34 2.6 Multistage Filtration .. .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . . . .. . . .. .. .. . . . .. .. ... .. . . . . .. . . .. .. . . . . . .. . ...... 37 2.6.1 Series Redundancy ............................................................................................................ 37 2.6.2 Increased Decontamination Factor (DF) .......................................................................... 38 2.7 Air Sampling ................................................................................................................................ 40 3. INTERNAL COMPONENTS .... .... .... ...... .............. ........ .. .. ...... .. ........ ...... ........ .. .... ......................... .... 42 3.1 Introduction ................................................................................................................................. 42 3.2 HEPA Filters ............................................................................................................................... 42 3.2.1 Performance Characteristics.. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. .. . . . . .. . . . . ... .. . . . . . . . . . . .. . . . . ... .. 42 3.2.2 Construction .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 3.2.3 Weight of HEPA Filters ................................................................................................... 46 3 2.4 Mechanical Properties.. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 46 3.2.5 Fire Resistance .................................................................................................................. 48 3.2.6 Environmental Properties ..... ................... .. ........... .... .. .. ........... ...... .. ..... ...... ...................... 48 3.2.7 Costs ................................................................................................................................. 50 3.3 Prefilters.. .. . .. . . . . . . . .... .. . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. .. .. . . . . . .. . .. . . . . . .. .. .. . ... .... .. ...... ........ ....... .. . ...... 50 3.3.1 Classification ..................................................................................................................... 50 3.3.2 Performance ...................................................................................................................... 50 3.3.3 Construction .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. .. .. .. . .. ..... .. . . . . . . . . . .. . . . . . . .. . . . ... ....... .. . ...... 51 3.3.4 Fire Resistance .. .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . ... . . . . . . . . . .. . . . . .. .. . . . . . . . . . . . . . . .. . . . .. . 53 . . . 3.3.5 Hot Air Resistance ................................................................................... ...... ...... .......... 53 3.3.6 Maintenance Considerations ... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . 54 3.3.7 Operational Considerations ........ ........... ...... .. .... .... .. .. ..... .............. ......................... ........ 54 ..?. 3.4 Radioiodine Adsorbers ................................................................................................................ 54 3.4.1 Introduction ...................................................................................................................... 54 3.4.2 Performance of Adsorption Systems ................................................................................. 55 3.4.3 Adsorber Unit Design and Construction .......................................................................... 58 3.4.4 Adsorbents .................................................... ................................................................... 60 ... Vlll 3.4.5 Inorganic Adsorbents ........................................................................................................ 61 .. 3.4.6 Adsorption System Design ................................................................................................ 62 3.5 Demisters ................................. ................................................................................................... 64 3.5.1 Introduction ...................................................................................................................... 64 3.5.2 Demisters for Reactor Applications .................................................................................. 65 3.5.3 Performance ...................................................................................................................... 66 3.5.4 Normal Off-Gas Demisters for Radiochemical Service ..................................................... 69 4 . HOUSING DESIGN AND LAYOUT ................................................................................................. 74 4.1 Introduction ................................................................................................................................. 74 4.2 Component Installation ............................................................................................................... 75 4.3 HEPA Filter. Adsorber Cell. and Demister Mounting Frames ................................................... 77 4.3.1 Structural Requirements ................................................................................................... 78 4.3.2 Mounting Frame Configuration ........................................................................................ 79 4.3.3 Frame Fabrication ............................................................................................................ 81 4.3.4 Filter Clamping and Sealing ............................................................................................. 84 4.3.5 Filter Support ................................................................................................................... 88 4.4 Size and Arrangement of Filter and Adsorber Banks .................................................................. 90 4.4.1 Vertical Filter Banks ......................................................................................................... 90 4.4.2 Horizontal Filter Banks .................................................................................................... 92 4.4.3 Location of Filters on Mounting Frame ........................................................................... 92 4.4.4 Size of Banks .................................................................................................................... 94 4.4.5 Arrangement of Banks ...................................................................................................... 94 4.4.6 Floor Plan of Filter Banks ................................................................................................ 94 4.5 Housings ...................................................................................................................................... 95 4.5.1 General .............................................................................................................................. 95 4.5.2 Arrangement and Location ............................................................................................... 95 4.5.3 Steel Housings .................................................................................................................. 98 4.5.4 Masonry and Concrete Housings ...................................................................................... 100 4.5.5 Seal Between Mounting Frame and Housing ................................................................... 101 4.5.6 Housing Floor ................................................................................................................... 101 4.5.7 Housing Doors. ................................................................................................................. 102 4.5.8 Housing Drains ................................................................................................................. 105 4.5.9 Housing Leaktightness ...................................................................................................... 105 4.5.10 Other Housing Requirements ............................................................................................ 105 4.5.11 Paints and Coatings .......................................................................................................... 106 5 . EXTERNAL COMPONENTS ............................................................................................................ 109 5.1 Introduction ................................................................................................................................. 109 5.2 Ductwork ..................................................................................................................................... 109 5.2.1 Functional Design ............................................................................................................. 109 5.2.2 Mechanical Design ............................................................................................................ 109 5.2.3 Engineering Analysis ......................................................................................................... 114 5.2.4 Materials of Construction ................................................................................................. 115 5.2.5 Paints and Protective Coatings ......................................................................................... 115 5.2.6 Hangers, Supports, and Anchors ....................................................................................... 115 5.2.7 Acoustic Treatment of Duct ............................................................................................. 115 5.2.8 Duct Leakage .................................................................................................................... 116 ix