Text

Enclosure 3 to E-52931, Revision 1 - Safety Analysis Report for the Liqui-Rad Transport Unit, Revision 9
	ML19015A366
Person / Time
Site:	07109291
Issue date:	05/31/2018
From:	; Orano USA, TN Americas LLC
To:	; Office of Nuclear Material Safety and Safeguards
Shared Package
ML19015A399	List: ML19015A366; ML19015A370; ML19015A372; ML19015A373; ML19015A377;
References
	E-52931, Rev. 1
	Download: ML19015A366 (57)
	v • d • e

Enclosure 3 to E-52931 Consolidated LR Transportation Packaging SAR (PUBLIC)

Safety Analysis Report (SAR) for the LIQUI-RAD TRANSPORT UNIT (Revision 9, May 2018)

Submitted by:

TN Americas, LLC 7135 Minstrel Way Columbia, MD 21045

TABLE OF CONTENTS 1

GENE~ INFORMA._TION...........................................................,............... 1... 1

1.1 INTRODUCTION

..................................................................................... 1-1 1.2 PACKAGE DESCI&TION.................................................................... 1-2 1.2.1 Packaging.. -................................................................................... 1-2 1.2.2 Operational Features.................................................................... 1-4 1.2.3 Contents of Packaging................................................................. 1-4 1.3 APPENDICES......................................................................................... 1-4 1.3.l Drawing Number LR-SAR Sheets 1, 2, 3, & 4 for the Liqui-Rad Transport Unit.............................................................................. 1-7 1.3.2 Epoxy Primer Specifications....................................................... 1-8 1.3.3 CHT-6/8FOAM, Closed-Cell Foam ~ulation Specification..... 1-9 1.3.4 ESP-CFI-2, Ceramic Fiber Insulation Specification.................. 1-10 2

STRUCT'lJRA.L EVALUATION.................................................................... -.. 2-1 2.1 STRUCTIJRAL DESIGN.,.................................................................,.... 2-1 2.2 2.3 2.4 2.5 2.6 2.7 2.1.1 Discussion.................................................................................... 2-1 2.1.2 Design Criteria............................................................................. 2-1 WEIGHTS AND CENTERS OF ORA VITY.......................................... 2-1 MECHANICAL PROPERTIES OF MATERIALS................................ 2-1 GENERAL ST AND ARDS FOR ALL PACKAGES............................ :. 2-2

2.4.1 Minimum Size....................................................... :..................... 2-2 2.4.2 Tamperproof Peature.......................................................... :........ 2-2 2.4.3 Positive Closure............................................................................ 2-2 2.4.4 Chemical and Galvanic Reactions................................................ 2-2 LIFI1NG AND TIE-DOWN................................................................... 2-5 2.5. l Lifting Devices............................................................................ 2-5 2.5.2 Tie-down Devices..........................................,............................. 2-5 NORMAL CONDITIONS OF TRANSPORT....................... ~................ 2-6 2.6.l Heat........................ '...................................................................... 2-6 2.6.2 Cold............................................................................................... 2-7 2.6.3 Reduced ExtemaI*Pressure................................................ -........ 2-7 2.6.4 Increased External Pressure... :.. :..... :.......................... :......... *.."..":... 2-7 2.6.5 Vibration...................................................................................... 2-7 2.6.6 Water Spray................................................................................. 2-7 2.6.7 Free Drop...................................................................................... 2-7 "2.6.8 Comer Drop*................................................................................. 2-8 2.6.9 Compression................................................................................ 2-8 2.6.10 Penetration................................................................................. 2-11 2.6.11.Conclusion................................................................................. 2-11

. HYPOTHETICAL ACCIDENT CONDITIONS............................. :.... 2-11

. 2.7.1 Prototype Testing....................................................................... 2-11 2.7.2 Summary of Pressures and Temperatures.........................,....... :2-15

2. 7.3 Immersion - Fissile Mat~rial..................................................... 2-15 LiquiRad-SARRev. 8 1

I.

TABLE OF CONTENTS, Cont.

2. 7.4 Inm1ersion - All Packages......................................................... 2-15 2.7.5 Summary of Damage................................................................. 2-15 2.8 SPECIAL FORM................................................................................... 2-16 2.9 FUEL RODS.......................................................................................... 2-16 2.10 APPENDICES....................................................................................... 2-16 2.10.1 Center of Gravity Report........................................................... 2-19 2.10.2 Material Performance Testing to Determine Worst Case Drop Test Conditions.................................................................................. 2-20 2.10.3 Chemical and Galvanic Reactions Analysis.............................. 2-21 2.10.4 Soutlnvest Research Institute Hypothetical Accident Testing of Uranyl Nitrate Shipping Containers for Title 10CFR Pati 71.73.......... 2-22 2.10.5 Finite Element Analysis for Drop Test Position........................ 2-23 2.10.6 Evaluation of the Impacts on Package Performance Using the Latest Revision of the Foam Insulation Specification.......................... 2-24 2.10.7 Finite Element Analysis Joi* 50 foot Immersion Test................ 2-25

2. l 0.8 Alternative Secondary Lid Closure Equivalency....................... 2-26 2.10.9 Alternative Secondary Lid Leak Test Poti Perfo1mance........... 2-27 3

THERI\\fAL EVALUATION............................................................................. 3-1 3.1 DISCUSSION.......................................................................................... 3-1

3.2 DESCRIPTION

OF THERlvfAL DESIGN............................................. 3-1 3.2.1 Design Features............................................................................ 3-1 3.2.2 Contents Decay Heat................................................................... 3-1 3.2.3 Maximum 'Vorking Pressure and Temperature........................... 3-1 3.3 THERMAL EVALUATION FOR NORMAL CONDITIONS OF TRANSPORT.......................................................................................... 3-2 3.3.1 Maximum Package and Content Temperatures........................... 3-2 3.3.2 Minimum Package and Content Temperatures............................ 3-3 3.3.3 Maximum Normal Operating Pressure........................................ 3-3 3.3.4 Maximum Thermal Stresses........................................................ 3-3 3.4 THERMAL EVALUATION FOR HYPOTHETICAL ACCIDENT...... 3-3 3.4.1 Initial Conditions......................................................................... 3-3 3.4.2 Package Temperatures................................................................. 3-4 3.4.3 Maximum Inte1nal Pressure......................................................... 3-4 3.4.4 Maximum Thermal Stresses........................................................ 3-4 3.5 APPENDIX.............................................................................................. 3-4 3.5.l Report of Thermal Evaluation..................................................... 3-8 4

CONTAINJ\\'1ENT............................................................................................... 4-1 4.1 CONTAINMENT BOUNDARY............................................................ 4-1 4.1.1 Containmentvessel...................................................................... 4-1 4.1.2 Containment Penetrations............................................................ 4-l 4.1.3 Seals and Welds........................................................................... 4-1 4.l.4 Closure......................................................................................... 4-1 4.2 REQUIREMENTS FOR NORMAL CONDITIONS OF TRANSPORT 4-1 4.2. l Containment of Radioactive Material.......................................... 4-1 4.2.2 Pressurization of Containment Vessel......................................... 4-2 4.2.3 Containment Criterion................................................................. 4-3 11

TABLE OF CONTENTS, Cont.

4.3 CONTAINMENT REQUIREMENTS FOR HYPOTHETICAL ACCIDENT CONDITIONS......................................................................................... 4-3 4.3.1 Fission Gas Products.................................................................... 4-3 4.3.2 Containment of Radioactive Material.......................................... 4-3 4.3.3 Containment Criterion................................................................. 4-4 5

SIIlELDING EVALUATION........................................................................... 5-1 6

CRITICALITY EVALUATION....................................................................... 6-1 6.1 DISCUSSION AND RESULTS.............................................................. 6-1 6.2 PACKAGE FUEL LOADING................................................................ 6-1 6.3 MODEL SPECIFICATION..................................................................... 6-2 6.3.1 Description of Calculation al Model............................................. 6-2 6.3.2 Package Regional Densities......................................................... 6-4 6.4 CRITICALITY CALCULATION........................................................... 6-4 6.4.1 Calculational Method................................................................... 6-4 6.4.2 Loading Optimization.................................................................. 6-4 6.4.3 Criticality Results........................................................................ 6-4 6.5 CRITICAL BENCHMARK EXPERIMENTS........................................ 6-5 6.6 APPENDIX.............................................................................................. 6-5

6.7 REFERENCES

....................................................................................... 6-9 7

OPERATING PROCEDURES......................................................................... 7-1 7.1 PROCEDURES FOR LOADING THE LR............................................ 7-1 7.2 PROCEDURES FOR UNLOADING THE LR....................................... 7-2 7.3 PREPARATION OF EMPTY LR FOR TRANSPORT.......................... 7-3 7.4 USE OF THE MVE FEATURE.............................................................. 7-3 8

ACCEPTANCE AND :MAINTENANCE PROGRAMS................................ 8-1 8.1 ACCEPTANCE TESTS.......................................................................... 8-1 8.2 MAINTENANCE PROGRAMS............................................................. 8-1 TABLE 1-1 TABLE 1-2 TABLE 1-3 TABLE 2-1 TABLE2-2 TABLE2-3 TABLE 3-1 TABLE 3-2 TABLE 3-3 TABLE 3-4 TABLE 3-5 LIST OFT ABLES AND FIGURES LIQUI-RAD WEIGHTS AND VOLUMES............................................ 1-5 MATERIALS OF CONSTRUCTION.................................................... 1-5 URANYL NITRATE SOLUTION SPECIFICATIONS......................... 1-6 LIQUl-RAD

SUMMARY

OF THE STRUCTURAL EVALUATION, DESIGN CRITERIA, AND RESULTS OF THE EVALUATION..................................................................................... 2-17 MECHANICAL Iv1ATERIAL PROPERTIES FOR STAINLESS AND CARBON STEEL COMPONENTS...................................................... 2-18 MECHANICAL MATERIAL PROPERTIES FOR INSULATION..... 2-18 THERMAL ANALYSIS AND TEST RES UL TS................................... 3-5 RELEVANT THERMAL MATERIAL PROPERTIES.......................... 3-5 PACKAGE DIMENSIONS..................................................................... 3-6 APPLIED HEAT LOADS AND INITIAL CONDITIONS.................... 3-6 THERMAL DECAY HEAT.................................................................... 3-7 lll

LIST OF TABLES AND FIGURES, con't TABLE 4-1 PACKAGE TOTAL l\\1AXIMIBvf RADIOACTIVITY.......................... 4-5 TABLE 4-2 MIXTURE A1CALCULATION............................................................. 4-6 TABLE 4-3 NOR1v1AL CONDITION FLUID PROPERTIES................................... 4-7 TABLE 4-4 HAC FLUID PROPERTIES.................................................................... 4-7 TABLE 6-1 QUANTITY OF FISSILE ISOTOPES EVALUATED......................... 6-10 TABLE 6-2 SUlV11VfARY OF RESULTS.................................................................. 6-11 TABLE 6-3 PACKAGE FUEL LOADING.............................................................. 6-12 TABLE 6-4 LIQUI-RAD MATERIALS OF CONSTRUCTION AND RELEVANT DIMENSIONS....................................................... 6-13 FIGURE 6-1 LIQUl-RAD UNIT MODEL FOR NORMAL CONDITIONS............ 6-14 FIGURE 6-2 HAC 1 UNIT MODEL-PRECIPITATION AND LAYERED FREEZING........................................................................ 6-15 FIGURE 6-3 HAC 2 UNIT MODEL - FREEZING..................................................... 6-16 FIGURE 6-4 MULTIPLICATION FACTOR AS A FUNCTION OF INTERSPERED MODERATION................................................................................. 6-17 IV

Ceramic Fiber Blanket Ceramic Fiber Board Framing system Leak tight Load p01t LR MVEValve MVE Outer Lid Foam Insulation Prhrnuy lid Secondary lid Studding outlet.

UN LiquiRad SAR Rev. *8 Glossary of Terms Insulation material used in the side walls of the packaging (ESP specification ESP-CFI-1).

Insulation material used in outer lid of the packaging (ESP Specification ESP-CFI-1).

The rectangular frame constructed of steel angle and bar that is used to support the cylindrical vessel.

Free from leaks as defined by ANSIN14.5-1997.

The valve and fittings that are located on the primary lid and allow filling of the containment vessel.

The Liqui-Rad Packaging.

The valve located in the Manual Vent Enclosure.

Manual Vent Enclosure - valve provided in the enclosure contained in the outer lid that contains a leak detection valve used as an overcheck of the containment boundary integrity The lid that secures the outer vessel. This lid is not a part of the containment boundary.

Insulation material used around the heads of the containment vessel (ESP specifications ESP-FP-2).

The primary lid for the containment vessel. This lid (excluding the portion inside the secondary wall) is a part of the containment boundary.

The lid that is located between the primary lid and the outer lid and provides an enclosure for the load p01t.

The annular steel block that is welded to the upper head of the containment vessel and provides a means of securing the primary lid to the containment vessel.

Uranyl Nitrate.

v

Glossa1)' of Terms, con't.

Outer Vessel Containment Vessel MVELid Annulus Area 0-ring Containment Boundary LiquiRad SAR Rev. 8 The rectangular prism that conspires the exterior steel wells of the packaging.

The cylindrical vessel that contains the payload.

The 9" x 6" lid over the MVE.

The air space outside of the containment bounda1y but inside the insulated outer vessel.

A doughnut shaped gasket made of Viton or silicone rubber that is compressed between the lid and the base to provide a sealed closure.

The containment vessel, primary lid (excluding the portion inside the secondary wall) and secondary lid and seal.

vi I

I

SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS 1

GENERAL INFORI\\IATION.................................................................................................................. 1-1

1.1 INTRODUCTION

.................................................................................................................................. 1-l 1.2 PACKAGEDESCRIPTION..................................................................................................................... 1-2 1.2. 1 Packaging.................................................................................................................................... 1-2 1.2.2 Operational Features................................................................................................................... 1-4 1.2.3 Contents of Packaging................................................................................................................. 1-4 1.3 APPENDICES...................................................................................................................................... 1-4 1.3.l Drawing Number LR-SAR. Sheets 1, 2, 3, & 4for the Liqui-Rad Transport Unit....................... 1-7 1.3.2 EpO.\\)' Primer Specifications........................................................................................................ 1-8

1. 3. 3 CHT-6/BFOAM, Closed-Cell Foam Insulation Spec{ficatio11...................................................... 1-9 1.3.4 ESP-CFl-2, Ceramic Fiber lnsulation Spec(ficatfon................................................................. 1-10 LIST OF TABLES TABLE 1-1 LIQUI-RAD WEIGHTS AND VOLU1'.1ES.................................................................... 1-5 TABLE 1-2 MATERIALSOFCONSTRUCTION............................................................................. 1-5 TABLE 1-3 URANYL NITRATE SOLUTION SPECIFICATIONS...................................................... 1-6 LiquiRad SAR Rev. 6 as supplemented 1-i

SAFETY ANALYSIS REPORT FOR PACKAGING LIQUI-RAD TRANSPORT UNIT (Revision 9, May 2018)

Submitted by:

TN Americas, LLC Columbia, Maryland 21045 1 GENERAL INFORMATION This Safety Analysis Report for Packaging (SARP) for the Liqui-Rad (LR) Transport Unit is submitted in support of Columbiana Hi Tech's request for licensing of the subject package and issuance of a Type B Fissile Material Certificate of Compliance. The LR has been designed and evaluated in accordance with the requirements of the United States Code of Federal Regulations (Title 10 and 49) and IAEA Safety Standards (Series No. ST-1, 1996 edition). The application is explicitly limited to the transportation of Uranyl Nitrate (UN) solution as described in the chemical and radioactive characteristics set forth in Section 1.2.3.

1.1 Introduction The LR represents an innovative approach to the shipment of UN solution. The LR utilizes integral thermal and impact limiting systems to protect the containment vessel and prevent inadvertent discharge of the lading under Normal and Hypothetical Accident Conditions. The primary structural components of the LR packaging consist of a stainless steel containment vessel, a carbon steel outer vessel and a carbon steel framing system. Although the containment vesselis not stamped as such, it is built in accordance with the ASME Pressure Vessel Code (Section VIII, Division 1 ). Double 0-ring seals located on the containment vessel's primary and secondary lids provide a complete and testable containment boundary.

A flat gasket at the outer lid provides a seal against water and dust. As an additional feature, an optional valve is provided to check the pressure in the annulus space, and to vent the annulus space if required prior to removal of the outer lid. Two (2) tamper-proof seals are located on the outer lid. A strong, lightweight, closed-cell foam insulation surrounds the top and bottom head area of the containment vessel and ceramic fiber blanket and board insulation are used in the sidewalls and outer lid to limit thermal influences and impact forces. The maximum cargo capacity is limited to 230 gallons (870 liters), maintaining a minimum ullage of 33 gallons.

LiquiRad SAR Rev. 9 1-1

Liqui-Rad SAR Rev. 9 1-1 SAFETY ANALYSIS REPORT FOR PACKAGING LIQUI-RAD TRANSPORT UNIT (Revision 9 May 2018)

Submitted by:

TN Americas, LLC Columbia, Maryland 21045 1 GENERAL INFORMATION This Safety Analysis Report for Packaging (SARP) for the Liqui-Rad (LR) Transport Unit is submitted in support of Columbiana Hi Tech's request for licensing of the subject package and issuance of a Type B Fissile Material Certificate of Compliance. The LR has been designed and evaluated in accordance with the requirements of the United States Code of Federal Regulations (Title 10 and 49) and IAEA Safety Standards (Series No. ST-1, 1996 edition). The application is explicitly limited to the transportation of Uranyl Nitrate (UN) solution as described in the chemical and radioactive characteristics set forth in Section 1.2.3.

1.1 Introduction The LR represents an innovative approach to the shipment of UN solution. The LR utilizes integral thermal and impact limiting systems to protect the containment vessel and prevent inadvertent discharge of the lading under Normal and Hypothetical Accident Conditions. The primary structural components of the LR packaging consist of a stainless steel containment vessel, a carbon steel outer vessel and a carbon steel framing system. Although the containment vessel is not stamped as such, it is built in accordance with the ASME Pressure Vessel Code (Section VIII, Division 1). Double O-ring seals located on the containment vessel's primary and secondary lids provide a complete and testable containment boundary.

A flat gasket at the outer lid provides a seal against water and dust. As an additional feature, an optional valve is provided to check the pressure in the annulus space, and to vent the annulus space if required prior to removal of the outer lid. Two (2) tamper-proof seals are located on the outer lid. A strong, lightweight, closed-cell foam insulation surrounds the top and bottom head area of the containment vessel and ceramic fiber blanket and board insulation are used in the sidewalls and outer lid to limit thermal influences and impact forces. The maximum cargo capacity is limited to 230 gallons (870 liters), maintaining a minimum ullage of 33 gallons.

Liqui-Rad SAR Rev. 9 1-2 1.2 Package Description 1.2.1 Packaging 1.2.1.1 Overall Construction As shown in the drawings provided in Appendix 1.3.1 (LR-SAR, sheets 1, 2, 3 and 4), the LR is a cylindrical package set in a rectangular angle frame having a foot print of 56" x 56" and a height of 73". The weights and volumes of the LR and contents are provided in Table 1-1.

Table 1-2 provides a list of the materials of construction.

The outer vessel is constructed of welded 10 gauge carbon steel. The containment vessel is constructed of 1/4 thick 304 or 316 stainless steel with 1/4 thick flanged and dished heads.

The containment vessel, although not stamped as such, is built in accordance with the ASME Pressure Vessel Code (Section VIII, Division 1) and is rated for an internal pressure of 50 psig and an external pressure of 30 psig. Lightweight, closed-cell foam insulation (CHT-6/8FOAM), and ceramic fiber insulation (ESP-CFI-2) (see Appendences 1.3.3 and 1.3.4 for specifications) are sandwiched between the containment vessel and outer shell to provide thermal insulation and limit impact effects. These insulation materials are inflammable and non-reactive with the steel components of the vessels.

The package is designed to be leak tight (maximum allowable leak rate of 10-7 ref-cm3/sec) at the primary closure. The containment vessel's primary closure is at the primary lid. The primary closure is sealed using a double O-ring and is secured by sixteen 5/8" stainless steel studs. The primary lid includes a fill port consisting of a valve and stainless steel threaded (plugged) quick-disconnect fittings. The secondary lid provides a sealed enclosure around the valving and fittings on the primary lid. The secondary lid is sealed using a double O-ring and is secured by twelve 5/8" stainless steel bolts and nuts.

The outer lid consists of a steel-lined ceramic fiber plug and is secured with twelve 5/8" stainless steel studs. An optional manual valve enclosure (MVE) lid is secured with four 5/8" stainless steel bolts and nuts. These outer lid and MVE lid are not a part of the containment boundary, and thus need not be leak tight. A flat gasket provides a seal to prevent water and dust from conditions incident to routine transport from entering the annulus space between the outer protective packaging and containment vessel. The MVE valve is used to check the pressure in the annulus space and to vent the annulus space if required.

Four one-inch diameter plastic plugs, designed to melt away between 300° and 400° F and vent any gases that may be generated by the insulation during a fire event, are positioned at mid-height at 90° intervals along the circumference of the package. Additional plugs are located on the base and top of the unit. The plugs are protected by the framework of the package and do not penetrate the containment vessel.

All valves and fittings are provided within sealed enclosures to contain any leakage due to valve failure. The valves are protected from impact and temperature influences by the outer vessel and the insulation contained between the inner and outer vessels.

Liqui-Rad SAR Rev. 9 1-3 1.2.1.2 Lifting and Tie down Devices The LR may be lifted either by means of four shackles attached to the top angle frame or by forklift tines placed under the unit's reinforced bottom. The LR may be bolted to a conveyance and further secured by strapping over the top of the LR. After loading of the package, shackles shall be secured to the top angle with nylon tie to prevent shackle from being used as tie down. Package shall be stenciled "SHACKLE NOT FOR TIE DOWN". The packaging and cargo weights and volumes are provided in Table 1-1.

1.2.1.3 Shielding Shielding is not required for the contents of the LR Transport Unit. For further discussion of shielding requirements, see Section 5.

1.2.1.4 Pressure Relief Systems The LR uses only one type of pressure relief device: a plastic plug, designed to melt away between 300° and 400° F during a fire event to release any gases generated by the insulation due to the high temperature. This device vents the annulus between the containment vessel and outer shell only; it does not penetrate the containment boundary. Pressure relief of the containment vessel is unnecessary, since the contents do not present a pressure buildup during Normal or Hypothetical Accident Conditions. See Sections 2, 3, 4, and 7 for information with respect to internal pressure.

1.2.1.5 Closures The containment vessel is secured by bolting the 5/8" thick primary lid to the vessel with sixteen 5/8" diameter studs and nuts. The primary lid is sealed with a double O-ring. The secondary lid is sealed using twelve 5/8 diameter bolts and nuts or, as a design option, the secondary lid flange is threaded and the secondary lid is secured to it using twelve (12) 5/8" diameter bolts and a double O-ring. A valve, enclosed in the sealed annulus space between the primary lid and secondary lid, is used in conjunction with a threaded (plugged) quick disconnect fitting for filling and discharge functions.

All seals are silicone rubber or Viton and are rated for continuous service up to 400°F.

1.2.1.6 Containment The containment boundary is defined by the containment vessel, primary lid (excluding the portion inside the secondary wall) and seal, and secondary lid and seal. The containment vessel has 1/4 thick stainless steel walls and 1/4 thick ASME flanged and dished heads and is designed to provide leak tight conditions. Post fabrication the containment boundary is demonstrated to be leak-tight (per ANSI N14.5-1997s definition, leakage rate less than 1E-07 ref-cc/sec). Pre-shipment and periodic maintenance testing of the containment boundary assures that the containment boundary maintains a working leakage rate less than the maximum allowable rates specified by 10CFR71.51 as specified in Section 4. Leak test are performed as specified in Sections 7 and 8.

1.2.2 Operational Features

Liqui-Rad SAR Rev. 9 1-4 The LR combines a highly secure and reliable pressure vessel with integral thermal and impact limiting systems to prevent breach of containment und er Normal and Hypothetical Accident Conditions. The primary operational features of the LR include:

i.)

A pressure vessel built in accordance with the ASME Code ii.)

An outer vessel, framing, and insulation to provide protection and stability for the containment system iii.) A total of twenty-eight (28) 5/8 diameter studs/bolts and nuts to provide positive closure of the primary lid and secondary lid, iv.) Silicone Rubber or Viton double O-ring seals at the primary lid and secondary lid rated for continuous service up to 400° F to provide leak tight seals, and test ports for leak testing the seals, v.)

The fill valve and quick disconnect fitting are provided within the containment boundary to preclude leakage due to valve failure, vi.) A bolted secondary lid that provides access to the fill valve.

vii.) A bolted outer lid that provides protection for the containment vessel and access to the secondary lid.

viii.) An optional valve on the outer lid for venting the annulus between the outer lid and containment vessel primary lid and secondary lid.

1.2.3 Contents of Packaging The LR is used for the safe transport of low enriched UN solutions that meet the specifications presented in Table 1-3. Additionally, the UN solution temperature must be maintained below 210°F. The uranium concentration must be less than or equal to 125 gU/liter with an enrichment less than or equal to 5.0wt% U-235. Non-fissile chemical impurities do not adversely impact the criticality safety of the packaging; therefore, they may be present in any quantity up to the chemical impurity specification. Fissile isotopes are limited to the quantities specified in Table 1-3. Any number of packages may be transported together in any arrangement in either a vertical or horizontal orientation; therefore, the Criticality Safety Index (CSI) is 0. The maximum UN solution cargo per package is 1imited to 230 gallons (870 liters), maintaining a minimum ullage of 33 gallons.

1.3 Appendices 1.3.1 Drawing Number LR-SAR, Sheets 1, 2, 3, & 4 for the Liqui-Rad Transport Unit 1.3.2 Epoxy Primer Specifications 1.3.3 CHT-6/8FOAM, Closed-Cell Foam Insulation Specification 1.3.4 ESP-CFI-2, Ceramic Fiber Insulation Specification

Table 1-1 Liqui-Rad Weights and Volumes Empty LR Tare Weight 2900 lb (1315 kg)

+/-2501b Loaded Packa,ge Maximum Gross Weight 5692 lb (2582 kg)

NIA Containment Vessel Volume 263 gal (996 It)

+141-0 gal Maximum Cargo Volume 230 gal (870 It)

NIA Table 1-2 Materials of Construction

\\ff:{~;;w ~!'im)ion'e'iit~&:is~; ~.,,,,,,.........

ratenalhf.."'onsrru\\ r;r;~

Containment Vessel Plate ASTM A240 3041316 SS Heads ASTM A240 304/316 SS Primary Lid ASTM A240 304/316 SS Secondary Lid ASTM A240 304/316 SS Valve Velan HB-2000 Ball Valve, SS Piping ASTM A312 304/316 SS Fittings ASTM A276 304/316 SS Bolts/Studs' ASME SA193 B8.M, Class 2 316 SS Nuts/Washers ASME SA194 B8M, Class 2 316 SS Thread Inserts 300 Series or 18-8 SS 0-Rings Silicone Rubber or Viton, 70-80 Durometer, temp rated for continuous use at -40 to 400F Alternative Test Port Self-sealing Hex Head Screw, 18-8/300 series stainless steel or Brass Connections Swagelok elbow with cap, ASTM B-283 (forging) or NPT Plug, ASTM A 276 304/316 SS Insulation Ceramic Fiber Blanket ESP-CFI-2 Foam CHT-6/8FOAM Outer Vessel Plate ASTM A!Ol l CS-> or ASTM A1008 CS*

Flat Bar ASTM A36CS Angle ASTMA36CS Square Tubin~

ASTM A500 Grade B CS Studs' ASME SA193 B8M, Class 2 316 SS Nuts/Washers ASME SA194 B8M, Class 2 316 SS Thread Inserts 300 Series or 18-8 SS Lifting Shackles Forged Carbon/Alloy steel rated at 6,000 lbs with a safety factor of 4.0 Flat Gasket Silicone Rubber or Viton, 70-80 Durometer, temp rated for continuous use at -40 to 400F Vent Plugs Plastic, melt temp from 300 to 400F Outer Lid Plate ASTM AIOI I CS; or ASTM Al008 CS*

or ASTM A240 304/316 SS 5 Ceramic Fiber Board ESP-CFl-2 Lid Handles Forged CS rated at 250 lbs with a safety factor of 4.0 Valve Velan HB-2000 Ball Valve, SS Studs' ASME SA193 B8M, Class 2 316 SS Nuts/Washers ASME SA194 B8M, Class 2 316 SS Thread Inserts 300 Series or 18-8 SS I.

Approved equivalents may be used.

2.

All studs use thread inserts.

3.

The LR performance test prototypes described in Appendix 2.10.4 were constructed using ASTM A569 CS; however, this specification was discontinued by ASTM in August 2000 and was replaced with A 1011. The chemical composition and mechanical properties of A IOI I CS are equivalent to the discontinued A569 specifications.

4.

The chemical composition of ASTM A 1008 is equivalent to that of ASTM A I 011 CS and A569 CS. The yield strength typical range of the A I 008 CS grades is slightly less (20ksi in comparison to the 30ksi listed for A IOI I); however, the typical ductility of the A I 008 CS is slightly higher (30% in comparison with the 25% listed for A I 011). For this application, the controlling property is the ductility, since the components serve to distribute any impact loads over the impact limiter below, rather than bearing the load itself. Therefore, A I 008 CS is a suitable alternative material of construction for these components.

5.

The use of stainless steel is given as an option, since it improves the corrosion resistance of this removable part. The mechanical properties of the steel are acceptable, since the yield strength minimum is within the typical range specified for AIOI I and the ductility is greater than that that of the A IOI I carbon steel.

1-5

\\

Table 1-3 Uranyl Nitrate Solution Specifications Item Specification...

Solution Density

1.17 glee Chemical Impurities

1500 µg/gU Nitric Acid Normality 0.1 - 0.7 Uranium Concentration i

125 gU/l

~.. -----**------- --------------------------*---------l-- - ---------------- -----~-... ------*- ------------------------------------------------------------------

1 U-232

2.0E-03 µg/gU

0~23*4--------------- ------;--- -----------T------- --------~-------------~2-~o-E~o3-~~~u------ ------------------- ------- ---

~ ------------ --- -- -- ---..... ~---~---- ----------------------------r------ ~------------ ----------------- - ------------ -------*--- ------------------~----*-.. * *~- * -- --- -

U-235

0.05 g/gU i ( 12 lb [5.4 kg] maximum quantity of U-235 per LR)

~-----... -...... ---- - -- -------------- - --------------------:---------- ---- -- ------------- - --------------- ------ ----------------~ ---- -... - - ----------- --~- ----------

U-236 j

2.5E+04 µg/gU

t--**--------------------------------------------------------------------------------------------------

U-238 Pu/Np Alpha Activity Gamma Emmiters

! i remainder of uranium

93 Bq/gU 0.515E-O 1 Ci 1-6

I

-'.#'/

Appendix 1.3.1 Drawing Number LR-SAR, Sheets 1, 2, 3, & 4 for the Liqui-Rad Transport Unit LiquiRad SAR Rev. 8 August 2013 1-7

Appendix 1.3.2 Epoxy Primer Specifications 1-8

PRODUCT DESCRIPTION Catalyzed Epoxy Primer E61 R C22N66 T C1 is a two-componenl epoxy primer system offering excellent adhesion and corrosion resiSlance. hs' fast dry makes it ideal for production line applicalion. It is especially suitable for use under POLANE" Polyurethane topcoats where superior corrosion resistance is needed.

Advantages:

Very fast drying for a catalyzed epoxy.

Excellent corrosion resistance.

No "sweat*in" time required* can be applied immedialely after mixing.

Long working pot life.

Free ollead hazards.

Recommended primer under POLANE$

Polyurethanes for best corrosion resistance on metal.

Meets transformer specifications when lop-coated wilh POLANE.

HS.

Ideal primer for structural sleet. farm and con*

struction equipment, railroad equipmenr.

machineiy, lransformers. castings. etc. when lopcoated with POLANE Polyurethanes.

Excellent chemical resistance.

Ideal for application to untreated sleel.

\\

CG-.l12 7194 2001435 0 The Sh~W.l!arrm Cotrp.vJy CHEMICAL COATINGS PRODUCT DATA CC-A12 CATALYZED EPOXY PRIMER CHARACTERISTICS Color:

Gloss:

Mix Ratio:

Volum1 Soll~:

Calalyzed and Reduced:

Viscosity:

Spreading Rate:

Catalyzed and Reduced:

Working Pot Life:

Package Life:

Drying:

To Touch:

Tack Free:

To Recoat:

Force Dry:

FluhPoint:

Air auallty Data:

Red Oxide Under 30 units 4 parts E61 R C22 1 partV66TCl 2 parts R7 K 54 E61RC22*44%+/- 2%

V66 T C 1

39% +/- 2%

30.7%

E61 R C22

30 to 50 seconds Zahn #5 V66TC1 -10to20 seconds Zahn 115 480 sq.ft./gal. at 1 mil (dry film. no application loss) a hours 1 year Air dry 77°F, (25°C) 50% RH, 1.5 m1ts dry film 20-30 minutes 1*2hours 1*2 hours 20' at 140°F Under 100°F Photochemically Reactive. Volatile Organic Com*

pounds (VOC)

E61 R C22 as packaged (maximum) 4.0 lb/gal (4BO gms/ltr) V66TC1 as packaged (max*

imum) 4. 15 lbfgal (490 gms/Jtr). Catalyzed 4: 1 and reduced 500/o(maximum) with R7 K 54 - 5.60 lb/gal (672 gmslltr}. Free of lead hazards. Contains chromates.

Product Limitations:

1. Topcoat only with POLANE Polyurethanes and catalyzed epoxy topcoats.

2. If primed parts are stored outside for long periods before topcoaling, the chalk must be removed before pa1ntmg or re prime with a Ihm coat of catalyzed epoxy pnmer.

3. On sand blasted surfaces. primer thickness musl be 1 mil greater than the profile to insure bestcorro'S1on resistance. Multiple coats may be required.

PART A - RED OXIDE PART B - CATALYST E61 A C22 V66 T.C1 SPECIFICATIONS Surlace Preparation:

Metal:

Apply to properly deaned and/or treated metal sur-lace. T realment may consist d a proprietlfy rurface chemical treatment (Zinc or Iron Phosphate). See also Metal Preparaliorl Brochure CC*T1.

Aluminum:

P1ime with Industrial Wasti Primef P60 G 2.

Galvanized Iron:

Apply E61 R C22N65 T Cl directly to aged weathered galvanize. It n8'# galvaf1ize, prime with Industrial Wash Primer P60 G 2.

Blasted Surlaces:

Dryfilmthicknessmustbe 1 milgreaterthandepth of profile for best corrosion resistance.

Application:

Recommended Film Thickness:

Wet: 4*6 mils Dry: 1.2-1.a mils Conventional Spray: Reduce 30-40% with A7 K 54 to 30-45 seconds Zahn 112.

Airless Spray: Reduce 0* 10% with R7 K 54. For smooth appearance and good film build operate at 1800-2200 PSI with a.013 tip.

Clean Up:

Use R7 K 54 MSDS; If a Material Safety DataSheel is required. contact your local Sherwm-W1lhams Represenlahve.

Safety Cautions:

DANGER! Conten1s are FLAMMABLE. Vapors maycau se Hash fires. Keep away from heal. sparks.

and open Mame. During use and until all vapors are gone: Keep area ventilaled-Do not smoke -

Ex-tinguish all flames. pile! lights. and heaters -

Turn otf stoves. eleclric tools and appliances. and any Olher sources of ignition.

CONTAINS.VOLATILE ORGANIC COMPOUNDS ALCOHOLS, EPOXY RESIN POL YAMIDE RESIN. STRONTIUM CHROMATE HARMFUL IF INHALED -

MAY AFFECT THE BRAIN OR NERVOUS SYSTEM. CAUSING DIZ*

ZINESS. HEADACHE OR NAUSEA. IRRITATES EYES. SKIN AND RESPIRATORY TRACT. MAY CAUSE AL LERGtC SKIN REACTION. CAN BE AB-SORBED THROUGH THE SKIN.

Use only with adequale ventilation. Wear an ap*

propr1ate properly fined vapor/particulate respiralor (continued on back)

CC*Al2 (continued from column 3)

{NIOSH/ MSHA approved) during and alter applica-tion, unless air monitoring demonstrates vapor/mist levels are below applicablel1mits. Follow respirator manufacturer's directions for respirator use.

Do not permit contact with skin and eyes. Com*

ponents and mixed product can be absorbed through the skin and may cause allergic skin reac*

tion. Wear neoprene gloves and goggles. Wash hands al1er using. Keep contain er closed when not in use. Do not transfer contents to other containers for storage.

FIRST AID:

U INHALED: II affected, remove from exposure.

Restore breathing. Keep warm and quiet.

II on SKIN: Wash attectedareathoroughlywith soap and water. Removecontaminateddothing. Launder before re-use.

II in EYES: Flush eyes wilh large amounts of water for 15 minutes. Get medical attention.

If SWALLOWED: Getmedicalanentionimmediately.

SPILL AND WASTE Remove all sources ol ignition. Ventilate and remove with inert absorbent. Incinerate in approved lacili-ty. Do notinc1ne1ate closed container. Dispose of in accordance wilh Federal, Slate, and Local regula-lion regarding pollution.

DELAYED EFFECTS FROM LONG TERM OVEREXPOSURE: Contains solvents which can cause permanent b1ain and nervous system damage Intentional misuse l:l'j deliberately concen-trating and inhaling the contents can be harmful or fatal.

Contains Strontium Chromate which can cause cancer.

This product must be mixed before use. Before opening the packages. READ AND FOLLOW WAR*

NING LABELS ON ALL COMPONEN1S.

DO NOT TAKE INTERNALLY KEEP OUT OF THE REACH OF CHILDREN FOR INDUSTRIAL USE ONLY NOTE:

The informa~on. rating and opinions stated here per-tain to the material currently offered and represent the results of tests believed to be reliable. However.

due to variations in customer handling and methods ol appJicationwhich are nOI krlONn or under OU1 con-trol. The Sherwin.Williams Company cannot make any warranties 01 guarantees as to the end result.

PRODUCT DATA WEARCOA T 497 Description Three component, high solids zmc filled epoxy-polyamide primer.

Color Zinc gray Packaging One and five gallon units (kits),

premeasured for easy blending at jobsite.

Kits are provided so as to yield a full one or five gallon unit upon mixing all components.

Technical Data Suggested Number of Coats:

Minimum Dry Film Thickness:

Theoretical Coverage@ 3.0 mils Dry Film Thickness:

% Zinc in Dry Film:

Dry Time*:

Thinner:

Spray:

Brushing:

Pot Life:

Temperature Limitation:

Thinning:

Volume Solids:

Weight Solids:

Minimum Application Temperature:

Method of Application:

Shelf Life:

Mix Ratio:

Induction Time:

Depending upon temperature and humidity Surface Preparation Prior to sandblasting, all grease, oil and other contaminants must be removed by suitable method such as solvent cleaning or Uses An organic zinc rich primer used for cathodic protection to steel surfaces in salt environments.

WEARCOAT 497 is designed for use as a

primer for WEARCOAT epoxy and URETHABOND urethane topcoats. The specific topcoat is selected on the basis of the environmental and performance requirements of the project at hand:

Generally, corrosion resistant topcoats are selected to provide a high performance total coating system.

Vinyl topcoats may also be used.

One 3.0 mils 290 sq. ft./gallon Approximately 90%

To touch: 1.5 hours5.787037e-5 days 0.00139 hours 8.267196e-6 weeks 1.9025e-6 months To topcoat: 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months CFI 719 CFI 718 Minimum 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months @ 72°F 215°F. Continuous Dry Up to one quarUgallon 53.75%

84%

40°F.

Spray preferred (pressure pot should be equipped with agitator).

6 months 3 to 1 30 - 45 minutes chemical cleaners. Surface should then be sandblasted to SSPC-SP-10 near white blast for optimum results.

/

Mixing Instructions Using a power mixer, slowly agitate Pait A until thoroughly mixed, then slowly add Part B while mixing. Add Part C. Allow to stand 30 to 45 minutes before using. Ideally material should be kept under slow agitation while standing.

Spray Equipment DeVilbliss JGA gun with H.D. Fluid Tip and Needle with #64 Air Cap. This is an external mix gun. Other equivalent spray equipment can be used.

Safety Precautions Contains flammable solvents. Keep away from

heat, sparks and open flames.

HARMFUL OR FATAL IF SWALLOWED.

Vapor Harmful, Eye Irritant. If swallowed, do not induce vonutmg.

Call physician immediately.

Avoid prolonged contact with skin, do not breathe vapor or spray mist. In case of contact with eyes, flush repeatedly with water and contact a physician.

Use with adequate ventilation. In confined areas, use adequate forced ventilation during application and drying. If appl.ication is by spray method suitable protective vapor/particulate respirator (such as #871 I mfg. by 3M Co.) should be worn by all personnel in the area. In poorly ventilated enclosed areas or when airborne concentrations exceed TL V (ceiling), a fresh air supplied mask should be worn (such as

W-292 mfg. by 3M Co.). In all cases, observe OSHA regulations for respirator use (29CFR 1910.134) whenever a respirator is used.

The h1formation presented herein while not guaranteed, is to the best of our knowledge true and correct. No warranty or guarantee, express or hnplied is made regardh1g performance of any product since the manner of use and application is beyond our control.

WEARCOAT & URETHABOND are trademarks of COATINGS FOR INDUSTRY, INC.

for coating compositions.

CFI Bulletin 497. I Revised 9-87

Appendix 1.3.3 CHT-6/SFOAM, Rev. 0, Closed-Cell Foam Insulation 1111 Specification 1-9

SPECIFICA TIO.N:

PROCEDURE TYPE:

DESCRIPTION:

COLUMBIANA HI TECH COLUMBIANA, OHIO CHT-6/8FOAM MATERIAL AND EQUIPMENT SPECIFICATION CLOSED-CELL IMPACT-ABSORBING FOAM INSULATION This page is a record of revisions to this specification. Remarks indicate a brief description of the revision and are not a pat1 of the specification.

REVISION DATE AFFECTED PAGE(s)

REMARKS 0

6/14/02 ALL ORIGINAL - REPLACED ESP-PF-2, Rev. 4 - IN ITS ENTIRETY APPROVALS

(.. -/'{- 0 -z_..

QAMANAGER PRODUCT MANAGER

(

1.0 Scope This document provides the technical specification for rigid, impact-absorbing foam that is used as a permanent or removable design feature for packages fabricated by Columbiana Hi Tech.

2.0 Physical Properties 6114/02 Requirements set forth in this section shall be verified by test to qualify a material for use. Prior to tests (and any fm1her conditioning specified therein), specimens shall be prepared and conditioned at 70 to 80°F and 40 - 60% relative humidity for 12 hours1.388889e-4 days 0.00333 hours 1.984127e-5 weeks 4.566e-6 months minimum.

2. 1~

The insulation may be polyurethane or phenolic foam, and the finished foam product shall be rigid, closed-cell, and self-extinguishing. The foam is formed as a reaction product of the primary chemicals. The foam shall be greater than 85%

closed-cell configuration to ensure the foam is not susceptible to significant water absorption.

2.2 Chemical Composition The basic chemical components of the foam may include hydrogen, carbon, nitrogen, aluminum, oxygen, phosphorus, and silicone. The total chloride content of the foam resin and the cured product shall be less than 200 ppm for phenolic foam and less than 1800 ppm for polyurethane foam, and the teachable chlorides from the cured product shall be less than 45ppm. The teachable chloride content may be tested using either EPA 300.0 or 325.3. The foam shall not include halogen-containing flame retardant or trichloromonoflouromethane (Freon 11).

2.3 Density The density shall be 6.0 to 8.0 pounds per cubic foot (pct). The density of each foam lot shall be veified using the methods provided in ASTM D-1622. The average foam density per installation may be calculated based on the weight of the foam installed and the nominal cavity volume.

2.4 Mechanical Properties The compressive strength of each pour lot shall be verified using the methodology provided by ASTM D-1621 at a temperature of 75°F +/- 5°F and 30-70% relative humidity. The compressive strength range shall be 84 - 300psi.

1of8 CHT-6/8FOAM

2.5 Thermal Properties 2.5.1 Thermal Conductivity Testing shall be performed using ASTM C-518. At an ambient temperature of 75°F +/- 5°F and 30-70% relative humidity, the allowable range is 0.013 to 0.046 Btu/hr-ft-°F (0.155-0.380 BTU-in/hr-ft2-°F) 2.5.2 Specific Heat A digital scanning calorimeter (DSC) should be used to measure the specific heat of the sample. Calibration records for the DSC should be submitted with the test results. At an ambient temperature of 122°F +/- 5°F and 30-70% relative humidity, the aJJowable range is 0.200 to 0.535 Btu/lb-°F 2.6 Flame Retardant Characteristics Testing shall be performed using ASTM F-501 or D-3806 as a guideline. The foam shall self-extinguish within five minutes of removal from active flame.

Char length shall be less than 6 inches.

2.7 Water Absmption The average water absorption by the foam observed by testing using ASTM D-2842 or C-209 shall be less than 1.9% by volume. No correction shall be made for cut or open cells in the specimen's volume calculations.

3.0 Material Installation 6/14/02

3. 1 The foam mix ratio is to be formulated to produce a dry cured foam. Free water should not be present in the final product.

3.2 The component chemicals may be summarized as an NB system. The mix ratio will be in the prop011ion used to qualify the material for use to this specification.

The mix ratio variation shall not exceed+/- 5.0% for each component.

3.3 The liquid material shall be "poured in place" within the package cavities. The liquid components must react to form the rigid foam and rise in such a way that the required volume is filled with expanded foam. The average foam density shall be evaluated and compared with the corresponding average pour density to detennine if significant voids exist.

3.4 As an alternative to 3.3, the liquid foam-fanning materials may be poured into molds. The average foam density of the resulting bun shall be evaluated using core samples and compared to the overall bun density to determine if significant 2 of8 CHT-6/8FOAM

voids exist on the interior of the bun. The foam bun may be machined for shape (if necessary) and inse1ted into the package void. Foam pieces may be joined by gluing with waterproof adhesive.

3.5 All foam resin shall be stored in airtight containers and refrigerated prior to mixing. The shelf life of the un-reacted resin is 6 months. The date of manufacture and use of the resin shall be recorded on the ce1tificate of compliance.

Foam buns shall be marked with the date of manufacture and shall be stored in an area with a low relative humidity. Foam buns shall be installed within three years of the date of manufacture.

3.6 The temperature of the mixed foam components should be maintained at a steady temperature during pouring to assure consistency of the product. Additionally, the walls of the assembly or mold being foamed shall be heated and/or insulated as necessary to provide optimum conditions for the foam installation.

3.7 Steel surfaces that will contact the foam must be clean and dry to provide a consistent interface between the foam and the steel. If the foam is a phenolic-based product, all smfaces in contact with the foam shall be coated with a red oxide primer (2 mil minimum) in accordance with the manufacturer's application instrnctions.

3.8 Shoring

Bracing and shoring for all surrounding assembly walls shall be provided as necessary to prevent distortion due to internal foaming pressures.

The method used must allow the container to meet its required dimensions and dimensional tolerances.

4.0 Quality Assurance 6/14/02

4. 1 Production Prior to production of the foam, Quality Assurance or Engineering shall establish the correct weight of the foam materials to be installed. Quality Assurance shall verify that the density of the foam bun installed in each package is correct when received. QA shall also record the package wieght before and after the foam installation and divide the difference by the calculated nominal volume of the foam cavity to determine the average foam density. The average foam density is used as a comparison with the rep011ed lot densities. An average foam density that is significantly less than the average of the lot densities indicates a void in the material that requires further evaluation.

4.2 Test Requirements See Table A for a summary of foam testing requirements.

3 of 8 CHT-6/8FOAM

TABLE A MATERIAL REQUIREMENT TEST FREQUENCY (MINIMUM)

Compressive Strength Per pour Density Per pour Flame Retardancy Qualification Only Leachable Chlorides Per Batch Specific Heat Per Batch Thermal Conductivity Per Batch Total Chlorides Per Batch Water Absorption Qualification Only Notes on Table A.

1.

"Qualification Only" means that the test shall be performed to qualify the foam formulation and resulting foam characteristics. These foam characteristics need only be tested at the formulation level (a fixed ratio of resin and catalyst, a fixed chemical composition of resin and catalyst, and a specific basic method of foam manufacture).

2.

"Per Batch" means that the test shall be performed on the final foam product for each unique lot of foam resin and catalyst.

3.

"Per pour" means that the test shall be performed on the final foam product for each unique mixture of resin and catalyst poured in succession from the same batch of foam, with the exception that if an order-of-magnitude change occurs for the container volume or any single dimension of the container being filled (e.g.,

Container 1 is 1 ft3 and Container 2 is 10 ft3, the order-of-magnitude change from Container l to 2 is l), a new "pour" shall be declared.

4. All test data shall be recorded and presented to the buyer's Quality Assurance representative for review and verification that the properties are within specified limits. No changes in the approved product formulation, critical raw materials, or basic methods of manufacture are allowed unless re-qualification is performed and approved.

5.0 Records 6/14/02 A foaming record (see Appendix A as a guideline) must be completed for the foam installation of individual packages and shall become a part of the final QA record. This record shall include, as a minimum, the foam components, weights before and after foaming, and QA verifications.

4 of8 CHT-6/8FOAM

6.0 References 6.1 EPA 300.0, Revision 2.1: "Detennination of Inorganic Anions by Ion Chromatography" 6.2 EPA 325.3-83: "Chloride, Titrimetric, Mercuric Nitrate" 6.3 ASTM D 1622-98: "Standard Test Method for Apparent Density of Rigid Cellular Plastics" 6.4 ASTM Dl621-00: "Compressive Properties of Rigid Cellular Plastics" 6.5 ASTM C518-98: "Standard Test Method for Steady-State The1mal Transmission Properties by Means of the Heat Flow Meter Apparatus" 6.6 ASTM F-501-93: "Aerospace Materials Response to Flame, With Vertical Test Specimen (For Aerospace Vehicles Standard Conditions)"

6.7 ASTM D3806-98: "Standard Test Method of Small-Scale Evaluation of Fire-Retardant Paints (2-Foot Tunnel Method)"

6.8 ASTM C-209-98, "Standard Test Method for Cellulosic Fiber Insulating Board" 6.9 ASTM D2842-97: "Standard Test Method for Water Absorption of Rigid Cellular Plastics" 7.0 Appendices Appendix A, Sample Foam Installation Record 6/14/02 5of8 CHT-6/8FOAM

(

Appendix A Sample Foam Installation Record 6/14/02 6 of 8 CHT-6/8FOAM

Columbiana Hi Tech Foam Installation Record - Pour In Place Method Batch#

Foam Productio*n Date Date of Resin Manufacture Pour#

Pour Density

. Pout Compressive Strength.

Pour Average Calculated Batch Testing Results:

Installed density Thermal conductivity Flame Retarc:lancy Nominal Cavity Specific Heat volume Total Chlorides Leachable Chlorides Installed foam weight Water Absorption 6/14/02 7 of8 CHT-6/8FOAM

Columbiana Hi Tech Foam Installation Record - Bun Method Batch#

Foam Production Date

Pours to complete Bun Bun Installation Date Date of Resin Manufacture Bun Core Sample # & *

sample Density.

Sample Compressiv*e Stre1:lgth

lbcation on Bun Sample Average Calculated Batch Testing Results:

Installed density The1mal conductivity Flame Retardancy Nominal Cavity Specific Heat volume Total Chlorides Leachable Chlorides Installed foam weight Water Absorption 6114/02 8of8 CHT-6/8FOAM

Appendix 1.3.4 ESP-CFI-2, Rev. 1, Ceramic Fiber Insulation Specification 11111 1-JO

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COLUMBIANA HI TECH MATERIAL AND EQUIPMENT SPECIFICATION ESP-CFI-2 CERAMIC FIBER INSULATION SPECIFICATION II 111

COLUl.WBIANA HI TECH MATERIAL AND EQUIPMENT SPECIFICATION ESP-CFI-2 CERAMIC FIBER INSULATION REVISION NO: 1 EFFECTIVE DATE: 08/12/02 PAGE20F4 HISTORY OF REVISIONS REVISION EFFECTIVE PAGES NUMBER DATE REVISED DESCRIPTION OF CHANGES 0

01/11/00 All Original I

8/12/02 All Changed company name, revision level and effective date; revised thermal conductivity allowables for paper and board (REVIEWRD BY)

(APPROVED 13Y)

COLUMBIANA HI TECH MATERIAL AND EQUIP~illNT SPECIFICATION ESP-CFI-2 CERAMIC FIBER INSULATION REVISION NO: 1 EFFECTIVE DATE: 08/12/02 PAGE30F4 SCOPE This specification shall cover the material requirements for the installation of both ceramic fiber paper, blnnket and board insulation for the Eco-Pnk Products.

BASIC PHYSICAL PROPERTIES Ceramic Fiber Paper shall meet the basic physical properties as listed below:

Density = 10-12 lbs/ft3 Thickness= 0.13 jn.

Thermal Conductivity= 1.26 Btu-in/hr-ft2 Fat 2000°F The physical property vnlues listed represent the nominal values unless a tolerance is provided.

Cermnic Fiber Board shall meet the basic physical properties as listed below.

Density = 15-18 lbs/ft3 Thickness = 0.25 in - 2" Thermal Conductivity= maximum 1.53 Btu-in/hr-ft2 °F at 1800°F Blanket Ceramic Fiber Blanket shall meet the basic physical properties as listed below.

Density = 6-8 lb/fl3 Average Tensile Strength = 9.9 lb/itl-12.5 lb/in2 Specific Heat=@ 2000°F 0.27 Btu/lb °F STORAGE REQUIREMENTS Store the Ceramic Fiber Paper, Blanket and Board insulntion in an area with relatively low humidity at ambient tempcn1ture.

COLUMBIANA HI TECH MATERIAL AND EQUIPMENT SPECIFICATION ESP-CFI-2 CERAMIC FIBER INSULATION REVISION NO: 1 EFFECTIVE DATE: 08/12/02 PAGE40F4 QUALITY ASSURANCE Quality Assurance shall verify that the density and thickness of the cernmic fiber insulation is correct when received and prior to installation.

Records A cernmic fiber insulation record (Attachment 1) must be completed for each individm1l package and shall become n pnrt of the final QA record. This record shall include at n minimum: verification of density and thickness and verification that each required piece of insulation was installed.

ATTACHMENTS

1.

Ceramic Fiber Insulation Instnllation Record

-*.* - ~*

~

SECTIOl'{ TWO STRUCTURAL EVALUATION TABLE OF CONTENTS 2

STRUCTURAL EVALUATION............................................................................................................. 2-1 2.1 STRUCTURALDESIGN............................................................................................................................... 2-1 2.1.l Discussion..................................................................................................................................... 2-l 2.1.2.

Design Criteria............................................................................................................................. 2-1 2.2 WEIGHTS AND CENIBRS OF GRAVITY..................................................................................................... 2-1 2.3 MECHANICAL PROPERTIES OF MATERIALS.............................................................................................. 2-1 2.4 GENERAL STANDARDS FOR ALLPACKAGES............................................................................................ 2-2 2.4.l Minimum Size............................................................................................................................... 2-2 2.4.2 Tamperp.roof Feature..................................................................... :.............................................. 2-2 2.4.3 Positive Closure............................................................................................................................ 2-2 2.4.4 Chemical and Galvanic Reactions................................................................................................ 2-2 2.5 LIFTING AND T!EcDO\\VN......................................................................................,................................... 2-5 2.5.l Lifting Devices.............................................................................................................................. 2-5 2.5.2 Tie-down Devices.........,.................................................................. :............................................. 2-5 2.6 NORMAL CONDITIONS OF TRANSPORT.................................................................................................... 2-6 2.6.l Heat

........................................................................................................................................ 2-6 2.6.2 Cold

........................................................................................................................................ 2-7 2.6.3 Redu.r;ed External Pressure........................................................................................................... 2-7 2.6.4 Increased External Pressure......................................................................................................... 2-7 2.6.5 Vibration................................................................................................................................. :..... 2-7 2.6.'6 Water Spray........................................................................................ ~......................................... 2-7 2.6.7 Free Drop..................................................................................................................................... 2-7 2.6.8 Comer Drop................................................................................................................................. 2-8

2.6.9 Compression................................................................................................................................. 2-8 2.6.10 Penetration............................................................................... :................................................. 2-ll 2.6.11 Conclusion.................................................................................................................................. 2-11 2.7 HYPOTHETICAL ACCIDENT CONDITIONS............................................................................................... 2-11

2. 7.1 Prototype Testing........................................................................................................'................ 2-11 2.7.2 Summary of Pressures and Temperatures............................................................................. :.... 2-15 2.7,3 Immersion -Fissile Materia'l................................................................................. :.................... 2-15 2.7.4 Immersion -All Packages......................... :................................................................................ 2-15 2.7.5 Summary of Damage................................................................................................................... 2-15 2.8 SPECIAL FORM.............................................................................................. :......................... ~............. 2-16 2.9 FuELRODS............................................................................................................................................ 2-16 2.10 APPENDICES...............'...................................................................................................................... 2-16 2.10.1 Center of Gravity Report............................................................................................................ 2-19 2.10.2 Material Perfonnance Testing to Determine Worst Case Drop Test Conditions.... ;.................. 2-20 2.10.3 Chemical and Galvanic Reactions Analysis............................................................................... 2-21 2.10.4 Southwest Research Institute Hypothetical Accident Testing of Uranyl Nitrate Shipping Containers for Title 10CFR Part 71.71............................... :...................................................... 2-22 2.10.5 Finite Element Analysis for Drop Test Position......................................................................... 2-23 2

10 6

~:~~:t~;~ ~~!~;Jc:~~~~.. ~.~.~~~~~.~.~.~.~~~~~~-~~~~~.~;.~:~~-~~~.~~~~:.~~--~~.~~.~.. ~~~~-... 2-24 1111 2.10.7 Finite Element Analysis for 50foot lmmersion Test................................ :........,......................... 2-25 2.10.8 Alternative Secondary Lid Closure Equivalency........................................................................ 2-26 LiquiRad SAR Rev. 8 2-i

SECTION TWO STRUCTURAL EVALUATION LIST OF TABLES TABLE 2-1 LIQUl-RAD Sut.nvlARY OP THE STRUCTURAL EVALUATION, DESIGN CRITERIA, AND RESULTS OF THE TABLEE;~L~;;[~:L*M*~~~~~;*~~~*M:~~~*~~~*p;~~;~~;;~;*~~*~*s~~;~~~~~*~~;;*c:~~~;~*s;~~~*c~~.;;~~*~*~~~*:::: ~~: t Ill TAilLE 2-3 MECHANICAL MATERIAL PROPER flES FOR INSULATION....................................................................... 2-1~

2-ii

I

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2.1 Structural Design 2.1.1 Discussion 2 STRUCTURAL EVALUATION The LR is a cylindrical package set in a rectangular angle frame having a foot print of 56" x 56" and a height of73". The loaded package maxlmum gross weight of the LR is provided in Table 1-1.

Table 1-2 provides a list of the materials of constrnction. A comprehensive description of the packaging is provided in Section 1.2, and drawings are provided in Appendix 1.3.l. The primary structural components of the packaging are the inner and outer vessels and the angle frame. The insulation functions structurally as an impact limiter. Positive closure of the packaging is provided using stainless steel bolts/studs at each of the lids.

2.1.2 Design Criteria The LR is designed to meet all of the performance requirements of 10CFR71, Subpa1i E for Type B fissile materials. The containment boundary is defined as the containment vessel, the primary lid (excluding the p01tion inside the secondary wall) and seal, and* the secondary lid and seal. While the package is not stamped as an ASME pressure vessel, the containment vessel is constrncted in accordance with ASME Pressure Vessel Code (Section VIII) procedures, calculations, and design criteria, with a maximum internal design pressure of 50 psig and a maximum external design pressure of 30 psig. The LR is designed to allow transpo1t of UN solution in a safe manner under N01mal and Hypothetical Accident Conditions. Table 2-1 provides a summary of the structural evaluation, design criteria, and results of the evaluation.

The LR is manufactured under a quality assurance program that meets the requirements of 10CFR7 l, Subpa1i H. All welding is completed by ASME Section IX-qualified welders using acceptable welding procedures.

2.2 Weights and Centers of Gravity The weights and centers of gravity of the LR Transport Unit and its contents are tabulated in Table 2-1. Based on properties of the materials of construction and the maximum contents, the center of gravity was determined to be located 36.59 inches from the absolute base (including the legs) of the package along a ve1tical axis in the physical center of the package (See Appendix 2.10.1) 2.3 Mechanical Properties of Materials II The mechanical material properties used in the structural evaluation are provided in Tables 2-2 and 2-3. Metal samples were subjected to Charpy "V" impact test at+ l 00°F, 67-74°F and -20°F to evaluate the effects of temperature on the material properties. Foam insulation samples were tested IUI for compressive strength at+ 100°F, 67-74°F and -20°F to evaluate any temperature effects on the foam's compressive strength. The result of these tests can be found in Appendix 2.10.2.

LiquiRad SAR Rev. 8 2-1

2.4 General Standards for All Packages The LR meets the general stm1dards for all packages as specified by I OCFR71.43.

2.4.1 Minimum Size The LR exceeds the minimum package size requirements specified by l OCFR71.

2.4.2 Tamperproof Feature The LR has two tabs for tmnper-proof seals located on the outer lid and the primary lid (see Drawing Number LR-SAR, for the Liqui-Rad Transport Unit, Appendix 1.3. l). These seals utilize individually numbered foces, and any unauthorized entry into the package is visible at the tmuper-proof seal locations.

2.4.3 Positive Closure The LR outer lid is closed with a total of twelve ( 12) 518 11 diameter studs and nuts. The primary lid is closed with a total of sixteen ( 16) 5/8" diameter studs and nuts. The secondary lid is closed using a total of twelve (12) 5/8u diameter bolts and nuts or, as a design option the secondary lid flange is threaded and the secondary lid is secured to it using twelve (12) 5/8" diameter bolts. All of these studs/bolts and nuts represent positive closure of the packaging.

2.4.4 Chemical and Galvanic Reactions 2.4.4.1 Galvanic Reactions 11111 Only three combinations of LR materials have the potential to react galvanically. The first combination is carbon steel, primer, ceramic fiber, and ceramic fiber blanket. The second combination is stainless steel, primer and foam insulation. The third combination is the 1111 contents and the containment boundary.

To address galvanic reactions for the first and second material combinations, accelerated crnrnsion testing (see Appendix 2.10.3) was performed on samples representing the most reactive cross-section of the transport unit (CS/CFI-2 sample and SS/PF-2 sample). The accelerated test represents a 20-year service life. For conservatism, the exterior top coating normally present on the steel surfaces was omitted. Therefore, the testing performed was significantly more severe than the expected LR operating conditions over a 20-year service life.

Law Engineering, in conjunction with the Materials Engineering Department at Auburn University, conducted Humid Atmosphere Primer Adhesion and Ferric Chloride Solution Corrosion tests. Weight loss and corrosion results were favorable for the CS/CFI-2 samples in these water, water vapor and chloride rich environments. Although there was significant blistering of the primer during the 30-day Humid Atmosphere Test, there was zero weight loss. The water/chlorine euvironment was followed with a highly corrosive ferric chloride test environment. As a result of the second test, additional primer blistering occurred; however, the weight loss experienced was only 0.75%.

A significant amount of weight loss was measured in the SS/PF-2 specimens due to etching under the rubber band that was used to hold the combination samples !ogether. The etching is 2-2

/

nttributed to oxygen depletion due to the presence of the rubber band. The majority of the weight loss recorded for the SS/PF-2 samples occurred in this aren.

The third combination of materinls, the contents nnd containment boundary, consist of a ve1y weak nitric acid solution (approximately I wt%), stainless steel, and Viton or silicone rubber.

Stainless steel nnd Viton nre rated as having excellent chemical resistance to nitric acid al c:ill concentrations. Silicone rubber, while not recommended for use with nitric acid concentrations above 5%, is adequately resistant to the low concentrations of nitric acid present in the specified UN solution.

2.4.4.2 Chemical Reactions The contents of the pncknge produce hydrogen gns due to radiolytic decomposition of the solution. The volume of hydrogen generated does not impc:ict the safe operation of the packaging, since the pressure remains below the design pressure of the package and the hydrogen concentration renrnins below the lower flnmmability limit of hydrogen in air. The package must be unloaded within one year of loading consistent with the requirements of Section 7 lo assure these design limits are not exceeded.

The hydrogen generated by radiolysis of the UN solution can be estimated using the correlations presented by Bibler' for nqueous nitrate solutions. Walter2 provides a discussion and overview of the calculc:ition methodology, using Bibler's graph to estimate the hydrogen generation rate in a highly enriched UN solution. According to Walter, use of this graph is conservative, since the presence of the uranium in the solution tends to depress the hydrogen generation rate.

Jn order to estimate the maximum volume of hydrogen generated by the contents of the LR, the maximum uranium solution concentration of 125 gU/l is used, conservatively assuming that there is no free nitric acid in solution (a lower nitrate concentn1tion resulls in a higher hydrogen gris generation rate). The nitrate concentration of the LR UN solution is (-12-Sg_U_ l l_it_ei_*) = 1.05 males Nitrate I liter 23SgU ! mole Using the graph provided by Bibler, a conservative estinrntc of the hydrogen gas generation rate for 1.05 moles/liter nitrate concentration is approximately 0.40 molecules H2/IOO eV.

The maximum decay energy available for the reaction is less thrin 0.18 BTU/hr (see Section 3.2.2). The number of moles of hydrogen generated is therefore:

1 Bibler, N.E., Radiolytic Hydrogen Production.from Process Vessels in HB Line, WSRC-RP-92-1312, November 12, 1992.

2 Waller, S.R. and R. Colwell, Calrnlation <l Hydrogen Acrnmulation in U-235 Tanks, SRW-009-96, January, 1996.

2-3

[

I 1~1~1/e r 0.40111ofec11fes H 2 xO. J 8 fJTU y 6.588.r I 0 15 i'vle\\1 y 10 6 e\\I l

= 7_88.r I 0_6 moles H 2 6.023.rlO-* 1110/ec11/es IOOe\\I Irr

~

BTU A Me\\1 fir Converting to an annual basis yields 0.069 moles H2/year.

One mole of hydrogen occupies 24.6 liters at standard temperature and pressure; therefore, the volume of hydrogen is

(

0.0691110/esH 2 )( 24.6/iters) = 1.70 liters H 2 year mole year Assuming that the solution remains in the package for the nrnximum time of one year and that the package contents arc frozen after hydrogen genen1tion (reduced headspace from 33 gallons to 12 gallons) yields

---~-

(IOO) = 3.74%/lwlrogen co11ce11tratw11

[

1.70 liters HI.ear]( 1 r;aflon )

12gallom 3.785 liter Thus, assuming the maximum decay heat, the worst-case contents, the minimum ullagc, and no leakage from the packnge yields a hydrogen concentration of 3.74% after the maximum allownble transport time. This concentration is below the lower flammability limit of hydrogen in nir (4.0%).

The incrense in internal pressure due to the ndditional gas is calculated using the ideal gas law. The amount of air trnpped in the ullngc when the packaging is filled is llair = (33 gal)(0.073 lb/fr1)/(28.97 g Air/mole)= 5.00 moles of nir.

Adding the moles of hydrogen genernted and reducing the volume to that of the frozen condition, the pressure in the ullagc space is where p

Hair llhycJrogcn UGC T

v P = (Hair+ llhydrog~n)(UGC)(T)/ (V) = 2. l 3 atm = 31.4 psia is the pressure in the ullage due to the reduced volume and additional gas is the number of moles of air in the ullage at normal fill tempernture nnd pressure is the number of moles of hydrogen generated, 0.069 is the universal gns constant, 0.0821 liter-atm/mole-K is the Normal Cold temperature, 233 K is the reduced ullage volume, 12 gallons (45.425 liter) 2-4

Thus, the maximum pressure of the packaging after one year of radiolytic hydrogen generation is 31.4 psia.

2.5 Lifting and Tie-down 2.5.1 Lifting Devices Handling of the LR is accomplished either by forklift or crane. The reinforced bottom, angle framing, and legs of the unit allow access and stability for the forklift tines. Only one package may be moved at a time using a forklift. Four shackles, attached to the LR's frame provide lifting capability. The shackles are fabricated from V2" diameter carbon steel stock and a 5/8" diameter steel pin. Each shackle must support a load equivalent to 1.4 of the weight of one loaded LR, 1,423 lb. The working load limit for each 1h-inch shackle is 6,000 pounds; therefore, the factor of safety (F.S.) for a fully loaded LR is:

F.S. = 6000 I 1423 = 4.2.

The welds that are used to attach the shackles to the angle frame must also carry ~ of the weight of one loaded LR. Because the base metal (A36 CS) is not as strong as the weld metal used (308 LSI), the yield strength used in the weld evaluation is 40% of the yield strength of the base metal, 14,400 psi (0.4

36,000 psi). Each shackle is welded to the frame with a 4" long W' fillet weld. The stress on the weld is:

1,423 lb I (0.707

0.25"

4") = 2,013 psi.

The factor of safety is therefore:

14,400 psi I 2,013 psi= 7.2.

After loading of the package, shackles shall be secured to top angle with nylon tie to prevent shackle from being used as tie down. Package shall be stenciled "SHACKLE NOT FOR TIE DOWN".

2.5.2 Tie-down Devices The LR is secured for transport by bolting it to the conveyance. Eight holes are provided in the lower frame of the LR for 3/4" diameter bolts. The bolts used may be carbon, alloy, or stainless steel and must have a yield strength greater than or equal to 105,000 psi. The bolts are torqued to a preload value determined by the shipper consistent with the proof strength of the bolts. For permanent bolted connections, the recommended axial bolt pre-load stress is usually from 60 to 80% of the yield strength of the bolt. Since these connections are removable features, the necessary preload stress may be lower. For unlubricated 3/4" diameter bolts having a yield strength of 105,000 psi, the preload torque producing an axial stress of 60% of the yield stress is 132 ft-lb When subjected to the acceleration loads specified in 10CFR7 l.45, the shearing force on the bolts is the square root sum of the squares of the lOg acceleration along the direction of vehicle travel and the 5g transverse acceleration:

F = ~(l Og(weigllt))

2 + (5g(weigllt))

2 = 63,640/b 1.

This force is resisted in shear by the eight bolts (tensile stress area= 0.334 in2, Mark's Standard Handbook for Mechanical Engineers, 101h Edition) and the worst case stress on each bolt is:

63,640 lbr I (8 (0.334 in2)) = 23,820 psi.

2-5

Per l OCFR7 I.45, the actual stress must not exceed the yield strength of the material; however, ASME recommends using 40% of the yield strength as the failure criteria for shear loading.

Tlrns, the factor of safety against bolt shear is:

F.S. = (105,000 psi)(40%) I 23,820 psi= 1.8.

Additionally, the acceleration loads create a coupling moment through the center of gravity, placing a vertical load on the bolts on one side of the package. Combining the horizontal and lateral loads, the total vertical load created by the coupling moment is :

(36.5_9"/28")( 15g)(56921b)/ 4 bolts= 27,890 lbr.

The general tensile stress on the bolt is therefore:

27,890 lb1 I 0.334 in2 = 83,500 psi.

The factor of safety against general tensile failure is therefore:

F.S. = 105,000 psi I 83,500 psi= 1.3.

The load is also carried by the bolt threads. The stress distribution is dependent on the number of engaged threads. The 3/4" diameter bolts used have l 0 threads per inch for a thread pitch of 0.10". The thickness of the plates is greater than W', therefore, it is assumed that at least 5 threads are engaged. The stripping stress on the threads is:

27,890 lb11(5)(2rc(0.6309")(0.10"/2))=28,140 psi.

Therefore, the factor of safety against stripping the bolts for the 1 OCFR7 l.45 required loads is:

F.S. = (105,000 psi)(0.40) /28,140 psi= 1.5.

The bar used must also resist tear out of the bolts. The W' bar stock used has a yield strength of 36,000 psi, and the bolt hole is placed so that at least l" of material remains above the hole to bear the load. The worst case shear applied to the material of the angle adjacent to the bolt hole is:

(27,890 lb1!4 bolts) I (l"

1/2"

2 shear planes)= 6,973 psi.

The factor of safety is:

F.S. = (36,000 psi)(0.40) I 6,973 psi = 2.1.

2.6 Normal Conditions of Transport 2.6.1 Heat The maximum temperature of the packaging is l 79°F (82 °C). The material properties of the 2-6

packaging remain nominal at these temperatures. Effects from heat due to normal conditions of transport are described in Section 3.3. Under normal conditions, the temperature of the contents does not exceed 179°F (82°C).

2.6.2 Cold An ambient temperature of -40°F with no insolation and no decay heat results in a package with a II f I uniform temperature of-40°F. An ambient temperature of-40°F will not have an adverse effect on the LR, since temperatures in this range do not materially affect the ductility of the steel in the package.

Charpy impact test results are provided in Appendix 2.10.2.

At temperatures below 0°C, the contents of the package freeze. Because the contents are largely water, expansion occurs with the phase change. The 33-gallon ullage provided is sufficient for expansion of the contents and allows additional space for the air in the head space to avoid pressurization above the 50 psig design pressure rating. Tue compression of the closure on the 0-ring assures that normal 11111 thermal effects do not produce leaks.

2.6.3 Reduced External Pressure The internal pressure of a filled containment vessel ranges from 14. 7 to 32 psia (see Section 3). A reduced external pressure of 3.5 psia results in a maximum differential pressure of 28.5 psi. This pressure is well within the 50 psig internal design pressure of the LR.

2.6.4 Increased External Pressure The internal pressure of a filled containment vessel ranges from 14.7 to 32 psia (see Section 3). An increased external pressure of 20 psia results in a maximum differential pressure of 12 psi. This pressure is well within the 30 psig external design pressure of the LR. The increased external pressure of20 psia is bounded by the immersion pressure evaluated in Section 2.7.4 for the outer vessel. The factor of safety calculated for immersion is 1. 73.

2.6.5 Vibration Vibration due to n01mal transport conditions has no measurable effect on the LR, excluding optional component, e.g., draw pipe. All closures are tightly bolted (75ft/lbs.+10/-0) to prevent loosening due to vibration. The insulation does not settle or compact appreciably due to vibration, nor does vibration cause the contents to settle.

2.6.6 Water Spray A one-hour water spray simulating rainfall at a rate of 2 in/hr will have no effect on the LR, as the outer vessel is impervious to water and is designed to withstand exterior pressure loads much higher than those applied by the water spray. The stainless steel containment vessel is sealed with a double 0-ring designed to prevent water inleakage during normal transportation; therefore, the exterior water spray has no effect on the containment vessel or contents. Because it is clear that it would have no effect on the package or contents, the water spray test was not conducted during the battery of drop and fire test.

2.6. 7 Free Drop The LR was subjected to HAC drop testing as specified by 10CFR71 and the conditions and results of the test are provided in Appendix 2.10.4. When subjected to a free drop from a LiquiRad SAR Rev. 8

height greater than 4 feet ( 1.2 meters) onto a flat, essentially unyielding horizontal surface, the package maintains both structural integrity nnd containment. Therefore, there is no significant increase in externnl surface radiation levels due to free drop damage.

2.6.8 Corner Drop The LR was subjected to HAC drop testing as specified by l OCFR7 l nnd the conditions and results of the tests arc provided in Appendix 2. I 0.4 nnd those conditions bound the corner drop. When subjected to a corner drop from n height greater than l foot (0.3 meters) onto a flnt, essentially unyielding horizontal surface, the packnge maintains both stmcturnl integrity and contninment. Therefore, there is no significant increase in external surface radiation levels due to free drop damage.

2.6.9 Compression 10CFR7 l.7 l requires that the packaging be capable of withstanding a compressive load of five times the weight of the pnckaging (5x compressive load), uniformly npplied to the top and bottom of the packaging, for twenty-four hours.

The fiber bJanket insulation located in the walls of the LR does not support the compression loading; therefore, the bearing area above the blanket insulation is neglected. Thus, the minimum compressive load bearing area is:

(1t(462)/ 4 = 1,662 in 2

Five times the weight of the packnge is:

(5) (5,692 lb)= 28,460 lb.

This is equivalent to a pressure of:

28,460lb/ l,662in2 = 17.1 psi.

This pressure is lower than thnt analyzed for immersion of the packaging (see Section 2.7.4).

Provided thnt buckling of the pnckaging does not occur for the unsupported sides, tbe immersion evaluation bounds the compression loading.

The following subsections evaluate the major load bearing components for general and local buckling, as well ns bearing stress nnd bending stress, where npplicable. The results of the compression evaluation show that the package is cnpablc of withstnnding the 5x compression load without general or local buckling, nnd thnt the bearing and bending stresses are well within the allowable stress for the packaging components.

2.6.9.1 Gross Package Response First, it is necessary to examine the behavior of the overall packnge. Under an axial compression force, there are three possible modes of failure: general elastic instability (general buckling), locnl eJastic instability (local buckling), or yielding when the maximum allowable fiber stress is exceeded.

2-8

(

The possibilily of failure due to general elastic instability can be rnled out by determining the critical general buckling load for the steel outer vessel (neglecling the foam, blanket insulation, and containment vessel). Evaluation of the hoJlow outer vessel provides the lowest possible critical general buckling load for the packaging, since any stiffening provided by the foam and steel inside is neglected. The slenderness ratio for the hoJlow outer vessel is:

L/r = (7 l ")/[(0.707)(56"/2)] = 3.6.

Where Lis the length of lhe outer vessel and r is the least radius of gyration of the seclion.

Thus the hollow outer vessel is determined to behave as a short column, and the critical genenil buckling stress, using the Rankine Formula3, is:

. er rri/irn/ =

er

? = 57,850 psi l +</>(LI 1Y where:

aai1irnl is the critical general buckling stress a

is the ultimate strength of the material, 58,000 psi

<P is a!Tr2 E, where Eis the the modulus of elasticity, 29E6 psi.

Assuming the entire compression load is canied by lhe holfow outer vessel, the actual compression stress produced by the 5x loading is:

28,460 lb I (n(56")(0. I 25")) = 1,294 psi.

The factor of safety against general elastic instability (general buck.Jing) is:

F.S. = 57,850 psi I 1,294 psi= 44.7.

Local buckling of the thin hoJlow outer vessel may occur <it a load less than that required to cm1se general buckling of the vessel. Young provides a conservative estinrnte of the criticril unit compressive stress required to induce local buckling (Table 35, Case I 5, p.688):

. 0.3Et er =

= 38 840 psi R

where a

is the critical local buckling stress E

is the modulus of elasticity (29E6 psi) t is the thickness of the wall (O. l 25")

R is the radius of the outer vessel (56"/2).

Thus lhe factor of srifety rigriinst local buckling of the hollow outer shell wrill is:

38,840 psi I 1,294 psi = 30.0.

3 Young, Warren C. Rorirk's Formulas for Stress and Strnin, 6 1h Edition, McGraw-Hill, New York, l 989, p.489.

2-9

The factor of safety against yielding due exceeding the maximum allowable fiber stress is:

F.S. = 36,000 psi I 1,294 psi = 27.8.

Therefore, it is determined that the steel outer vessel (and thus the packaging as a whole) does not fail due to the 5x compressive stress and the minimum factor of safety against failure is 27.8.

2.6.9.2 Rigid Foam Response The majority of the load is carried by the rigid foam insulation located above and below the 1111 containment vessel. Elastic instability is not a concern for the foam, as the geometric forms are much wider than they are tall (i.e., the slenderness ratios of the foam pieces are very low).

The foam does not yield under the 5x compression loading, since it is well below the foam's minimum compressive strength. The factor of safety against crushing the foam under the 5x compressive load is:

F.S. = (84/17.1) =4.9.

2.6.9.3 Containment Vessel Response The pressure load is transmitted from the foam to the heads of the containment vessel. Due to the geometry of the containment vessel and the surrounding materials, the vessel will fail due to bending stresses on the upper head before compression yielding, local or general buckling of the vessel walls. The bending stress developed in the upper head bounds the stress developed in the lower head, since the upper head is discontinuous at the transition to the studding outlet. The upper head is analyzed using the flat plate fommla presented by Young (Table 24, Case 2e) for an annular plate of uniform thickness, fixed at the outer edge and free at the inner edge, with a unifonnly distributed pressure applied:

ab= 6M/t2 = 3,024 psi.

where ab is the bending stress M

is the bending moment, k q a2 = 0.08 ( 17.1 psi)(23")2 = 31.5 in-lb/in, where k is a constant based on the inner and outer radii of the plate (0.08),

q is the unit pressure, and a is the outer radius of the plate is the plate thickness, 0.25".

Therefore, the factor of safety against failure of the upper head due to bending stresses induced by the 5x compression load is:

F.S. = 75,000 psi I 3,024 psi = 24.8.

2.6.9.4 Frame Response The frame is constructed from 2" x 2" x 1A" carbon steel angle stock. The pressure loading on the cross-members ( 17.1 psi) is well within the allowable for the short beam span and is not a concern. Additionally, the pressure load applied as an axial load is well within the yield strength of the steel used. Thus, the only analysis required for the frame elements is the 2-10

\\

J

~-"'

evaluation of the-critical general *buckling-load for-the uprights. The slenderness ratio*for the frame uprights is:

Ur= 64 %"I 0-39" = 166.

Where Lis the length of the upright and r is the least radius of gyration of the section. Thus the uprights behave as a long column and the Euler formula is used to detertnine the critical,

general buckling stress:

<Ycritical== n n2 E I (1Jr)2 = 41,550 psi.

where

<Ycritical is the critical general buckling stress n

is the end constant for both ends fixed, 4 E

is the modulus of elasticity, 29E6 psi Ur is the slenderness ratio, 166.

Assuming the entire load is carried by the four frame uprights, the stress due to the 5x compression load is:

28,460 lb/ 4 (0.94 in2) = 7,569 psi The factor of safety against failure of the frame uprights due to general buckling is:

F.S. = ~1,550 psi/ 7,569 psi= 5.5.

2.6.10 Penetration Puncture drop ~ests conducted as part of the hypothetical accident testing (see Appendix 2.10.4) showed that minimal damage was done to the package's integrity as a result of these severe tests. Because the more severe hypothetical accident testing did not produce appreciable damage to the package, it is reasonable to assume that the much lighter impact of a 13 pound rod as described in 10CFR71 has a negligible effect on the LR' s ability to provide containment of the package contents.

2.6.11 Conclusion Analytical evaluation and extrapolation of the results of hypothetical accident tests show that packaging remains intact under all normal conditions. The containment vessel provides absolu~e containment during* all normal condition events; therefore, the LR meets the requir~ments for Normal Conditions of Transport.

2.7 Hypothetical Accident Conditions 2.7.1 Prototype Testing A full-scale LR prototype contain,ing a simulated load was subjected to the sequence of drop, puncture and fire tests of the hypothetical accident conditions of 10CFR7l.73. The prototype was fabricated to the drawings provided in Appendix 1.3.1, using the procedures described throughout this SARP. *-A detailed report of the LR Compliance Test Program is provided in Appendix 2.10.4.

LiquiRad.SAR Rev. 8 2-11

~*.~<

~--!:.:..-*

The test article consisted of the 263 gallon LR prototype, loaded with salt water and steel shot to simulate a typical payload. The total weight of the package tested was 5,692 lb (2582 kg). The orientations used for the drop tests were dete1mined to be the most damaging based on preliminary drop tests and finite element modeling (see Appendix 2.10.5). Either polyurethane or phenolic foam may be used as strnctural insulation, and current specifications for the foam insulation differ from that used in the prototype testing. However, these changes do not impact the results of the test of performance of the package, for a full explanation see Appendix 2.10.6. Additionally, a closure design option and leak test port option for the Secondary Lid was not tested. Calculations are provided in Appendix 2.10.8 and Appendix 2.10.9 demonstrating that these design options are equivalent to the tested configuration, and based on the analytical results, additional performance testing with these design options is unnecessa1y. The draw pipe is optional in the revised design, but the previous tested configuration with draw pipe is still valid and conservative since the weight of the previous tested configuration is slightly higher than the revised configuration, and hence no additional drop test are necessa1y. The leak test is also unnecessary since the draw pipe is not part of containment boundary.

2.7.1.1 Prototype Drop Tests All drop test were performed on the same 10' x 10' x 6' reinforced concrete target pad. Al" thick steel plate is attached to the top of the target pad using J-bolts. The estimated weight of the target pad is approximately 95,000 pounds. A plywood panel, set behind the test pad, was painted with a 1 foot grid pattern to allow gross reference measurements. A quick release mechanism (a D-ring pin in mechanical jaws with pneumatic actuation) was used to release the prototype from the drop height without imparting rotational or translational motion to the prototype. For the puncture drop, a puncture ram was attached to the center of the test pad using eight bolts. The ram is a 6 inch diameter by 16 inch long right circular cylinder with radiused ends, fabricated from mild steel and welded to a 2 inch thick steel plate. The test were videotaped and photographed, and post-drop damage measurements were recorded after each drop.

2.7.1.1.1 Initial Conditions In order to determine the worst-case initial temperature conditions for the drop tests, the perfo1mance characteristics of the prima1y LR fabrication materials were evaluated at various temperatures. Metal samples were subjected to Charpy "V" impact tests and ESP-PF-2 foam insulation samples were tested for compressive strength at+ 100°F, 67-74°F and -20°F (See Appendix 2.10.2). The physical characteristics of the foam samples remained essentially unaffected by the different temperatures; however, metal samples tested at the -20°F range exhibited reduced impact strength; therefore, test packages were maintained at a temperature below -20°F prior to testing. Additionally, polyurethane generally has a higher compressive strength at all temperatures than phenolic insulation; therefore, the use of phenolic foam insulation for the perf01mance tests is conservative.

LiquiRad SARRev. 8 2-12 I

11

The LR was loaded with approximately 1421 kg of steel shot and saltwater solution to simulate the maximum load to be canied by the LR (this load corresponds to a specific gravity of 1.5). Because the UN solution to be shipped in the LR is mainly water, the nrnterial properties of the sail water solution are a conservative representation of the UN solution's material properties. The decay heat generated by the contents is less than I BTU/hr; therefore, heat generated by the contents was not simulated.

In preparation for the fire sequence, the LR was fitted with heat sensitive tempernture-recording tapes. The LR was secured following the torque sequence described in Section 7.

Leak tests were performed to insure that the containment vessel closures (primary Jid and secondary lid) were leak tight to a minimum of 1.0 x 10-7 ref-cm3/sec leak rate. The LR was then cooled to a temperature of approximately -32°F in a cooling chamber.

2.7. l.1.2 End Drop After cooling, the LR was subjected to a 30-foot drop onto an essentially unyielding, horizontal surface onto the top end of the package. This orientation is one of two (End Drop and Corner Drop) that was pre-determined to be the most damaging to the packaging. While some buckling of the outer vessel occurred along the circumference of the top plate, no tears or breaks were observed at the condusion of the end drop test. The outer lid remained intact.

Pre-and post-test photographs are provided in Appendix 2.10.4.

2.7.1. J.3 Side Drop Preliminary drop testing and analytical data showed that a side drop was not as damaging as a comer or end drop; therefore, this test was not required.

2.7.1.1.4 Corner Drop A 30 ft. inve11ed corner drop test onto an essentially unyielding, horizontal surface was completed following the end drop test, using the same prototype package. This orientation is one of two (end Drop and Corner Drop) that were pre-determined to be the most damaging to the packaging. Post drop inspection of the package showed that, while the impact did crush the corner to an approximate depth of 18 inches on-side, no tears or breaks in the outer vessel were observed. The MVE lid and outer lid remained intact. Photographs of the test item pre-and post-test are provided in Appendix 2.10.4.

2.7.1.1.5 Puncture Drop Because the ends of the LR are reinforced, the side of the package was determined to be the most damaging location for a puncture drop. The same prototype package used in the end and corner drops was subjected to a 40-inch puncture drop. The package was suspended, 1.5° from horizontal, above a puncture ram fixed into an essentially unyielding, horizontnl surface per the requirements of 10CFR7 l.73. The package impacted the bar at a point dose to the midpoint of the side. The puncture drop test resulted in a crnsh radius of approximately 15 inches to a depth of approximately 5.5 inches. A minor tear, approximately 7 inches in length and through the depth of the outer vessel, was observed at the puncture bar indention.

Photographs of the test item pre-and post-test are provided in Appendix 2. l 0.4.

2-13

2.7.1. l.6 Summary of Drop Test Results The drop tests completed were performed for the worst case package orientations, worst case temperature and material properties, and with a maximum payload on board. The outer vessel was moderately crushed at the impact sites, and one small tear in the outer vessel w<1s observed. All lids remained intact, and cont<1inment w<1s maintained throughout the tests.

None of the essential valves and fittings were damaged at the conclusion of the drop tests.

2.7.1.2 Prototype Fire Testing The prototype used for the fire testing was the same article that was subjected to the drop tests described in Section 2.7.1.1. The pack<lge was not opened or repaired prior to the fire test.

The damaged prototype was exposed to a fully-engulfing hydrocarbon fuel/air fire for 30 minutes.

2.7.J.2. l Initial Conditions Thermocouples were installed after the drops to the exterior of the package and the interior by drilling through the outer shell. Heat sensitive temperature recording tapes were fitted on the interior surfaces prior to drop testing. The LR was heated to an average of J00°F nfter the drop test, in preparntion for the 30-minute fire test.

2.7.1.2.2 Fire Tests Due to uncooperative ambient conditions, the prototype was subjected to two fire tests.

During the performance of the first fire test, a sustained wind caused the package to be partially uncovered, resulting in conditions that did not fully meet the requirements of I OCFR7 l (e). The detnils of the first test are available in Appendix 2.10.4. The heat from the first fire caused the bottom of the package to sag slightly, nnd a hairline opening in the weld of the steel foam plug appenred (on the bottom of the package). Prior to retesting, the weld fracture was repaired, since it was a result of the first 30-minute fire.

The following day, the LR was subjected to a second 30-minute fire test. The package was preheated to l00°F. FoJlowing the preheat, the pnckage was moved to the burn pad. The package was simply supported, with the base 40 inches from the fuel source. The average wind speed measured nt the test site during the test was 3. l mph. The avernge flame temperature during the test was 137 5°F. Packnge and content temperatures were monitored throughout the test and for 20 minutes foJlowing. Data collected during the test, and pre-and post-test photos are avnilable in Appendix 2.10.4. After sufficient cool-time had elapsed, the outer lid was opened and a leak test was performed on the containment vessel closures (primary lid and secondary lid).

2.7. 1.2.3 Fire Test Results The maximum bulk tempernture of the contents dming the fire was l 48°F, and the maximum temperature reached by the packaging was l 150°F. These temperatures arc well within the allowable working temperatures of the packnge. The primary lid 0-ring was maintained below the maximum service temperature of 400°F at <111 times. Containment was maintained throughout and following the fire test sequence.

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2.7.2 Summary of Pressures and Temperatures Under normal hot conditions of transport the maximum tcmpen1ture reached by the pack11ging is l 79°F and the nrnximum temperature of the pack11ge contents is less than I 79°F. Under nornial cold conditions of transport, the minimum temperature of both the contents rind packriging are -40°F. During the hypothetical fire accident, the maximum bulk temperature of the contents and the containment boundary is 148°F, and the nrnximum temperature reached by the packaging is 1, 150°F. The maximum internril pressure is 32 psi a, and the minimum internal pressure is 14. 7 psia.

2.7.2.1 Differential Thermal Expansion The design of the LR allows the components of the package to expand and contract independently where the materiril properties are significantly different. The 33-gallon ullage allows for thennal expansion of the contents at temperatures below freezing.

2.7.2.2 Thermal Stresses Because the design of the package is such that the containment vessel and outer shell are not restrained from thermal expansion, thermal stresses during normal and hypothetical accident conditions are negligible.

2.7.3 Immersion - Fissile Material The criticality analysis presented in Section 6 assumes optimum moderation conditions; therefore, 3-foot immersion testing was not required per 10CFR7 l.73c(5).

2. 7.4 Immersion - All Packages Per l OCFR 7 1. 73c( 6), an evaluation was pe1fonned for an undamaged package under an external pressure 21.7 psig, simulating 50 feet of water. A finite element model wns created, and the external pressure load was applied equally on the elements that would come in contact with water. The model was constrained at the conrniner top corner nodes. Additional information concerning the finite clement model and applied loads are available in Appendix 2.10.7. The maximum calculated stress is 20.8 ksi at the top plate of the package. The maximum calculated deflection at the same location is 0.122 inches. The factor of safety is:

SF= 36/20.8 = 1.73.

2.7.5 Summary of Damage Damage from the full compljance testing is documented through photographs (Appendix

2. 10.4) and video. The drop tests produced a crushed corner, a cmshed side, and side buckling around the circumference of the package top. The puncture test resulted in a small tear in the outer vessel, and the fire test produced a small weld crack and a sagging bottom.

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The containment boundary was not breached in any way during any of the tests, and the maximum bulk content temperature was 148°F during the fire test. The post-test containment boundary helium leak tests produced acceptable results (Jess than 10-7 std-cm3/sec). Based on these results, the LR successfully protects the containment vessel and meets the requirements of 10CFR7l.

2.8 Special Form The LR contents are not special form materials; therefore, evaluation for special form was not included.

2.9 Fuel Rods Fuel rods will not be shipped in the LR; therefore, evaluation for fuel rod cladding breach is not included.

2. 1 D Appendices 2.10. l Center of Gravity Report 2.10.2 Material Performance Testing to Detennine Worst Case Drop Test Conditions 2.10.3 Chemical and Galvanic Reactions Analysis 2.10.4 Southwest Research Institute Hypothetical Accident Testing of Uranyl Nitrate Shipping Containers for Title 10CFR Part 71.73 2.10.5 Finite Element Analysis for Drop Test Position 2.10.6 Evaluation of the Impacts on Package Performance Using the Latest Revision of the Foam Insulation Specification 2.10.7 Finite Element Analysis for 50 foot Immersion Test 2.10.8 AJternative Secondary Lid Closure Equivalency 2.10.9 Alternative Secondary Lid Leak Test Port Perfo1mance 2-16 m11

Table 2-1 Liqui-Rad Summary of the Structural Evaluation, Design Criteria, and Results of the Evaluation Empty LR Tare Weight Maximum Gross Weight of.

Loaded Package Minimum ackage size Center of Gravity Tam pet roof feature Positive Closure Chemical and Galvanic Reactions Lifting Devices Tie-down Heat Cold Reduced External Pressure Increased External Pressure Vibration Free Drop Puncture Com ression Fire Immersion 2900 lb (1315 kg) 5692 lb (2582 kg) 56" x 56" x 73" located 36.59 inches from the absolute base (including the legs) of the ackage along a vertical axis 4 lids, 44 studs/bolts No significant material loss due to galvanic reaction Max. hydrogen concentration due to chemical reaction equals 3.74%

Max. internal pressure due to hydrogen generation equals 31.4 sia Shackles F.S. = 4.2 Shackle weld F.S. = 7.2 Bolted down, F.S. Bolt shear = l.8, F.S. tensile failure= l.3, F.S.

sh*ipping = 1.5, F.S. Bolt tear out = 2.1 Max. content temp. < l 79°F Max. ackage tem. = l 79°F Min. content temp. = -40°F Min. package temp. = -40°F Expansion of Contents

. due to freezing Max. differential pressure = 28.5 sig Max. differential external pressure =

12 psig No impact to package or contents Damage to outer vessel and insulation only; containment maintained Damage to outer vessel and insulation only; containment maintained Minimum F.S. = 4.9 Damage to outer vessel and insulation only; containment maintained; temperature of contents below 210°F F.S. = l.7 2-17 NIA NIA 10CFR7l.43(a)

NIA IOCFR7l.43(b IOCFR71.43(c) 10CFR7l.43(d) lower explosive limit of hydrogen nd air (4%)

max. service pressure on the containment vessel (50 psia) 1 OCFR7 l.45(a) 10CFR71.45(b) 40% of yield strength Max. service temp. of material Min. service temp. of material, sufficient ullage available for expansion Max. Service Pressure Max. Service Pressure Effects on package perfonnance 10CFR71.5 l IOCFR71.59 10CFR71.51 IOCFR7l.59 Bucklin or Yeild IOCFR71.51 IOCFR7l.59 Yield of outer vessel NIA Pass NIA Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass

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Table 2-2 Typical Mechanical Material Properties for Stainless and Carbon Steel 11111 Components Min Yield Strength 30 36 (psi x 1,000)

Min Tensile Strength 75 58-80 125 (psi x 1,000)

Elongation in 2" (%)

40 21-23 12*

Elongation in 4D (%)

Table 2-3 Mechanical Material Properties for Insulation Specification Density (Jb/cu-ft)

Thermal Conductivity (Btu/hr sq-ft °F/in)

Compressive strength (psi)

CHT-6/8FOAM 6.0-8.0 0.155-0.38 84-300 2-18 ESP-CFI-2 ESP-CFI-2 16 8.0 0.62 0.27 NIA NIA 1111 1111

ML19015A366

Text

1.1 INTRODUCTION

3.2 DESCRIPTION

6.7 REFERENCES

SUMMARY

1.1 INTRODUCTION

3.8 Shoring

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