ML19207B032
| ML19207B032 | |
| Person / Time | |
|---|---|
| Site: | 07001100 |
| Issue date: | 08/07/1979 |
| From: | Pianki F ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY |
| To: | Rouse L NRC OFFICE OF NUCLEAR MATERIAL SAFETY & SAFEGUARDS (NMSS) |
| References | |
| NUDOCS 7908230240 | |
| Download: ML19207B032 (18) | |
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C-E Power Systems Tel 203/C881911 Cornbustion Engineering. Inc.
Telce 99297 1000 Proscect Hui Acad Wincsor. Connecticut C6095 4
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U. S. Nuclear Regulatory Commission
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License SNM-lC67 s
Washington, D. C.
20555
_0ccket 70-1100 Attention: Mr. L. C. Rouse, Chief Fuel Processing & Fabrication Branch Division of Fuel Cycle & Materia' Safety Gentle:nen:
This is in response to your request for additional information and clarifica-tion to support our amendment application dated April 23, 1979. This informa-tion is hereby submitted as revised pages as listed below.
In addition, althougn Figure E-1 is referred to in numerous places in our aoplication, the wording " Figure E-1" was inadvertently deleted from the drawing when it was being reissued with a company drawing number.
Drawing NFM-J-4077 is Figure E-1.
Please add the words " Figure E-1" to your copies of NFM-J-4077.
If you have any questions concerning this amendment application, please contact Mr. G. J. Bakevich of my staff on extension 3150.
DELETE PAGES ADD PAGES XIV-2, Rev. 10, 3/22/79 XIV-2, Rev.11, 7/16/79 XV-6, Rev. 03, 3/15/74 XV-6, Rev. 04, 7/16/79 XV-13, Rev. 01, 4/16/73 XV-13, Rev. 02, 7/16/79 XIX-3, Rev. 01, 6/27/79 XIX-3, Rev. 02, 7/16/79 XIX-5, Rev. 00, 3/22/79 XIX-5, Rev. 01, 7/16/79 XIX-6, Rev. 01, 6/27/79 XIX-6, Rev. 02, 7/16/79 C-1, Rev. 00, 3/22/79 C-1, Rev. 01, 7/16/79 C-4, Rev. 00, 3/22/79 C-4, Rev. 01, 7/16/79 C-5, Rev. 01, 3/22/79 C-5, Rev. 02, 7/16/79 C-6, Rev. 01, 6/27/79 C-6, Rev. 02, 7/16/79 C-17, P '. 00, 3/22/79 C-17, Rev. 01, 7/16/79 C-19, Pev. 01, 6/27/79 C-19, Rev. 02, 7/16/79 C-19a, Rey. 00, 6/27/79 C-19a, Rev. 01, 7/16/79 C-19b, Rev. 00, 7/16/79 C-26, Rev. 00, 3/22/79 C-26, Rev. 01, 7/16/79 D-7, Rev. 00, 3/22/79 D-7, Rev. 01, 7/16/79 0-50, Rev. 00, 6/8,/9 D-50, Rev. 01, 7/16/79 Very truly yours,
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3 F. J. Punki, Geheral Manacer u
Nuclear Fuel Manufacturing'
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Fluorometric analyses for measuring trace contaminants, such as uranium and beryllium, and determining their content in wastes.
Combustion techniques for carbon, hydrogen,and oxygen in uranium-containing
.,odies and cladding.
Spectrophotometric determination of uranium content of salvage materials.
14.3 OUTSIDE WASTE STORAGE AREA Combustion has provided an outside pad for the storage of low level contam-inated scrap.
The pad is 14' x 80' and is contiguous to the south wall of the Building #21 warehouse. This pad is designated on Figure V-1 as Waste Pad 14' x 80', and is contained within an 8' high chain link fence.
Records are maintained to assure that no more than 500 grams of U235,$)j be stored here and no single package will contain more than 100 grams of 235 U
All packages will be placed on callets and package stacking will be limited to two high. Maximum residence time of a package on'the pad will be six months. Packages will not be opened outside the building under any circumstances. Packages will contain no liquid wastes.
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.,C, License No. SNM-1067, Occket 70-1100 Revision:
11 Date: 7/16/79 Page: XIV-2
15.3.4 Health Physics Restricted Areas A Health Physics Restricted Area is an area in which more than 235 350 grams of U as unclad U0 may be processed, and /or in 2
which the radiation level exceeds 2.5 mr/hr. A removable alpha 2
level of 5000 dpm/100 cm requires clean up within 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, 2
and a level of 10,000 dpm/.100 cm requires immediate clean up.
15.3.5 Clean Area A Clean Area is an area which is free of radioactive contamination or ionizing radiation levels significantly greater than background.
No radicactive contaminated equipment or clothing will be brought into a Clean Area unless authorized by the Radiological Safety Officer or the Nuclear Licensing and Safety Supervisor.
2 A maximum removable alpha level of 100 dpm/100 cm is permitted.
License No. SNM-1067, Docket 70-1100 Revision: 4 Date 7/16/79 Page: XV-6 s,
15.8 Instruments The radiation protection services discussed in 15.6, and 15.7, are implemented using instrumentation which has the capabilities listed below:
Monitoring Instruments 4
Alpha 0 - 5 x 10 c/m Portabh Survey Instruments 6
Alpha 0 - 2 x 10 cpm 3
Beta-Gamma 0.01 mr/hr - 10 R/hr Neutrons 0 - 8 x 10 cpm Laboratory Instruments Alpha
> 1.0 cpm The detectors for the criticality alarm system (described in Section 18) are calibrated quarterly and following major repair.
All other instruments are calibrated twice per year, and following major repair. Counting equipment will be checked daily to verify background and efficiency.
15.9 Personnel Protection Equipment All persons regularly employed in Health Physics restricted areas shall wear protective clothing and special shoes or shoe covers.
Uranium handlers shall also use gloves. Visitors shall use lab coats and shoe covers.
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License No. SNM-1067, Occket 70-1100 Revision:
2 Date: 7/16/79 Page: XV-13
TABLE 19.1 Safe Individual Unit Limits for 14.1% enriched UO at optimum 2
moderation. All Mass and Volume limits adjusted to provide con-stant spacing areas for the enrichment shown. Heterogeneous limits have been developed with optimum rod sizes (up to 0.4" diameter) taken to allow for pellet chips, etc.
HOMOGENEOUS HETEROGENE0US Limit f*
Limit f*
Mass (Kg UO )
2 235
<2.5 % U 54
.19 50
.26 2.5-3.0 41
.23 38
.29 3.0-3.2 36
.23 36
.29 3.2-3.4 35
.25 33
.29 3.4-3.6 32
.26 30
.30 3.6-3.8 28
.26 27
.29 3.8-4.1 24
.25 24
.27 Volume (liters)**
<3.5%
31
.39 22
.40 3.5-4.1 25
.38 18
.38 Cylinder Diameter (inches)
<3.5%
10.7
.34 9.5
.36 3.5-4.1 9.8
.33 8.9
.34 Slab Thickness (inches)
<3.5%
5.1
.36 4.1
.22 3.5-4.1 4.6
.32 3.7
.20 Fraction of the equivalent unreflected critical spherical volume or mass.
Includes all available container volumes.
e. r, License No. SNM-1067. Docket 70-1100 Revision: 2 Date: 7/16/79 Page: XIX-3
TABLE 19.2 Spacing requirements for mass, volume, or cylinder SIU's specified in Table 19.1.
Spacing areas will be established to provide equal distances from the edges of the units to the spacing boundary in all directions. Co-planar slabs specified in Table 19.1 require no additional spacing.
Limit Spacino Area 2
Mass 3.5 ft Volume 9.0 ft 2
Cylinder (per ft. of length) 5.0 ft For two story operations, a 3/8 inch steel deck,10' above the floor separates the operating levels. Spacing is as follows:
2 Mass 7.0 ft Cylinders 235 2
(11" t x 40" 19., <3.5% U only) 27 ft Justification for this spacing criteria is provided in Section 2.2 of Exhibit D.
.,7 License No. SNM-lC67, Occket 70-1100 Revision:
1 Date: 7/16/79 Page: XIX-5
(THIS PAGE INTENTIONALLY LEFT BLANK)
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'1 License No SNM-1067, Occket 70-1100 Revision:
2 Date: 7/16/79 Page: XIX-6
EXHIBIT C NUCLEAR PRODUCTS MANUFACTURING OPERATIONS AND PROCESSES This exhibit contains detailed descriptions of all operations in the Manufacturing Facility (Buildings #17 and #21).
Sufficient detail is provided to permit an independent verification of the adequacy of the controls for the purpose of assuring safe operations.
Nuclear criticality limits are taken from Section 19. However, in certain operations, the intricacies of the equipment require further analysis, which is provided herein.
Details of specific calculations used to support various aspects of this analysis, and several statements and considerations in Section 19 are discussed in Exhibit D.
This exhibit is considered to provide a typical analysis for operations conducted within the scope of this license.
Present arrangements of the equipment in the pelletizing facility are shown in Figure E-1.
This arrangement may ce changed in accordance with the procedures of Section 8 and the limits provided in Section 19.
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a license No. SNM-1067, Docket 70-1100 Revision:
1 Date: 7/16/79 Page: C-1
3.0 U0 POWDER PROCCSSING 2
3.1 Receipt of Material All 002 p wder is received in licensed shipping containers from C-E's dry process oxide conversion plant at Hematite, Missouri. The as-received 9.75" diameter inner stainless steel UO p wder cans to be stored in the 2
virgin powder storage area (W.S. P-1 in Figure E-1) shall be sampled before being placed in the storage area to demonstrate on a 95/95 confidence level that the moisture content of powder lots is less than 5 wt.%.
In addition, all damaged packages will be sampled.
3.2 VIRGIN POWDER STORAGE AREA The virgin powder storage area is isolated from the remainder of the plant on all sides by concrete block walls, a double steel roof, and a metal fire door. This door is normally in the open position, and is automatically closed upon activation of the fire alarm, and on failure of electrical power.
(The automatic closing of this door snall be checked quarterly and records shall be maintained). This is considered adequate to exclude the introduc-tion of water in the event of a fire. This area will be kept free of combus-tibles, and is located such that there are no potentially hazardous items such as boilers in the vicinity of the area. An ammonia cracker is housed in a concrete block building which is located some 25 feet northwest of Building
- 17.
In view of its many redundant safety features, it is wt viewed as a potentially hazardous item.
The storage area itself is a 5 x 6 array of par:11el roller conveyors, each 128 inches long. The steel structure associated with the conveyors provides a minimum edge-to-edge separation distance of 12 inches between all powder containers, both horizontally and vertically.
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License No. SNM-1067, Docket 70-11M Revision:
1 Date: 7/16/79 Page: C-4
Criticality Safety Analysis The following conservative assumptions were incorporated into the calcu-lational model of the Virgin Powder Storage Area:
- 1) All steel structural materials were neglected.
- 2) The fuel was assumed to be a homogeneous mixture of UO containing 2
7.0 wt.% H 0.
2
- 3) The rack was filled to capacity (33u cans of UO2 p wder) and each individual can was assumed to be full.
- 4) Effects of interspersed water moderation and flooding were not addressed.
The KENO-IV Code with sixteen group Hansen-Roach cross sections was used to determine the reactivity of the Virgin Powder Storage Area under the conditions noted above. Dimensional details of the model are provided in Section 1.1 of the demonstration section of this license. Ak f 0.9338 0.0077 was obtained for eff an infinite system in the horizontal direction.
3.3 Batch Make-Voo Powder containers are removed from the virgin powder storage area and placed on a conveyor (W.S. P-2) (safe cylinder limit) for transfer to the Batch Make-Up Hood (W.S. P-3).
A maximum of three 9.75 inch diameter x 11 inch long stainless steel powder containers shall be clamped to fixtures in the hood (safe geometry) where an appropriate batch of less than 35 kg U0 is weighed out and put into 5-2 gallon pails. The batch weights and enrichment are recorded on the container.
A water tight cover is secured to these batch containers and they are then conveyed (W.S. P-4) to a lift (W.S. P-5) for transfer to the blender hoods (W.S. P-6).
The batch make-up operation is enclosed in a ventilated hood. Sufficient negative pres-sure is provided to assure a minimum face velocity of 100 fpm.
Criticality Safety Analysis The following conservative assumptions were incorporated into the calculational model of the Batch Make-Up Hood and associated conveyors (W.S. P-3 and P-4':
- 1) The 3 stainless steel UO2 powder cans (safe cylinders) inside the hood were considered to be full at optimum moderation and maximum enrichment (4.1",
wt.% U235),
- 2) The 5-gallon batch make-up bucket inside the hood was assumed to contain UO2 powder at optimum moderation and maximum enrichment (4.1 wt.%.U 35),
License No. SNM-10C7, Docket 70-1100 Revision: 2 Date: 7/16/79 Page: C-5
(3) The stainless steel of the 9.75" diameter x 11" long powder con-tainers was modeled. All other structural steel in the hood was neglected.
(4) All sealed containers of UO n conveyors (W.S. P-2 and P-4) 2 adjacent to the hood were assumed to contain 7.0 wt.% H 0.
2 The KENO-IV Code with 16 group Hansen-Roach cross sections was used to determine the reactivity of the system under various conditions of moderation.
Optimum moderation of the fuel containers within the hood occurred at a fuel concentration of 1.8 gm U/cc in water, assuming no external mist. The highest reactivity of 0.7934 0.0070 for an infinite system (at 1.8 gm U/cc in water) occurred for the full flood case. Additional calculations for the external full flood condition were run for various cancentrations of fuel in water ranging from 1.2 - 3.5 gm U/cc. The peak system react.. ity of 0.8595 t 0.0117 for tre flooded cases occurred at a fuel concentration of 2.6 gm U/cc in water.
Dimen-sional details of the calculational model and results of the calculations are discussed in Section 1.2 of the demonstration section of this license.
3.4 Powder Preparation and Blending UO2 p wder from one sealed batch container (moderation control assurred) is transferred to a blender where it is mixed with a binder (U.S. P-6).
Two separate blenders feed a comon powder spread funnel by means of individual powder tr.insfer pipes entering at a 45 angle. An identical powder prep line runs parallel :o this one at a centerline distance of 13 feet.
The blending operation is enclosed in a ventilated hood. Sufficient negative pr essure is provided to assure a minimum face velocity of 100 fpm.
3.4.1 Drying Agglomerated UO2 p wder is spread onto the dryer belt (W.S. P-7) from the powder spread funnel to a controlled depth of 1/2". A completa enclosure is pro-vided around the dryer belt assembly and this enclosure is maintained at a slight negative pressure. The discharge end of the dryer belt utilizes a wiper blade to prevent the flow of significant amounts of material to the plenum under the bel t.
Nevertheless, the wiper blade and plenum shall be inspected once per week to assure that the wiper blade is functicning properly and no fual in accumulating in the plenum below the belt.
Records of these inspections are train 11ined.
License No. SNM-lC67, Docket 70-1100 Revision:
2 Date: 7/16/79 Page: C-6 c,c_
1 l '_
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diameter pellets is 6.7".
Applying a safety factor of 1.2 yields a slab limit of 5.5 inches.
6.3 Transfer of Material Material may be transferred on carts which accommodate one mass or slab limited SIU, or may be transferred by hand, one SIU at a time. Carts used for mass limited SIU's shall provide for centering of the unit, and shall measure at least three feet on a side.
Because most spacing areas do not extend beyond the physical boundary of the equipment, spacing between transfer carts and the equipment is of no concern.
In cases where the spacing area extends beyond the equipment boundaries, such as the storage facilities, the spacing boundary will be indicated with colored tape. The tape may be crossed by carts only when they contain no more than one mass or volume limited SIU, and then only to permit an operator to transfer that SIU to an available storage position.
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License No. SNM-1067, Occket 70-1100 Revision:
1 Date: 7/16/79 Page: C-17
8.0 R00 LOADING AND ASSEMBLY FABRICATION 8.1 Pellet Alignment and Drying Pellets from the pellet fabrication facility, or from outside vendors are placed on a downdraft table (W.S.100) where they are loaded for place-ment into 2 drying furnaces (W.S.101 and 102). On the table, the pellet configuration is limited to a 3.7 inch slab thickness. The U02 pellets are placed on aluminum troughs in approximately 12 foot lengths before being loaded into furnaces for drying under a vacuum.
Each furnace contains 216 locations, 200 of which may be occupied by fuel pellet stacks. The remaining 16 locations contain 8 C poison rods which 4
are fixed in place and blocked off to prevent introduction of any fuel.
The poison material is B C powder packed into 5/8" 0.D. x 20 ga. Type 304 4
stainless steel tubes (nominal
.555" I.D. x.035" wall). The B C powder in 4
each tube shall be packed to a minimum density of 1.15 gm/cc B C (46% of 4
theoretical density), and the minimum active poison length shall be 157 inches. The B C powder shall be analyzed and certified to demonstrate and 4
document that 1) the B C content is >95% and 2) the B concentration is 4
10 that of natural boron. The tubes shall be weighed before and after loading with the B C powder to assure that the minimum density requirement has been 4
met. Records of these weighings shall be maintained. The end of the tubes shall be sealed by welding to assure no subsequent loss of B C.
The tubes 4
shall be removed from the furnace at least once every two years and visually examined and weighed to assure that no physical damace to the tubes or loss of B C has been experienced. The tubes will be replaced if indications of 4
damage (cracks, discoloration, etc.) are detected or a change in weight occurs.
This is adequate since the maximum operating temperature of the furnace does not exceed 350 F, and the atmosphere the tubes will experience is air, vac-uum, or argon. Type 304 stainless steel will operate almost indefinitely under these conditions. The poison tubes are larger than any of the Zr-4 fuel tubes being used, making them easily identifiable. All poison rod end caps will be legibly marked as B C and serial numbered 01-32. Each poison 4
rod will then be placed in those locations of the drying furnaces marked as
' poison" on drawing NFM-E-4080 Rev. 01, dated 6/13/79.
"iE License No. SNM-1067, Docket 70-1100 Revision:
2 Date: 7/16/79 page: C-19
Aluminum plates will then be welded to each end of the fernace positions holding the poison rods to prevent their removal at any time. To provide assurance of the continued presence of the B C poison rods, a quarterly 4
visual inspect.'on will be performed to ascertain that each location which is required to be poisoned contains a serial numbered B.C rod and that no damage has been done to the welded end plates.
Records of the B C rod load-4 ing and the periodic inspections will be maintained.
The inside diameter of the furnaces is 20 inches with an overall length of 13 feet. The furnaces are dry and about 12 inches above the floor level.
Water entry is possible only when the doors at either end are open; how-ever, under this condition, free drainage will occur. With the doors closed, the furnace is a sealed chamber and moderation control is assured.
CRITICAllTY SAFETY ANALYSIS The following conservative assumptions were incorporated into the calculational model of the pellet drying furnaces:
1)
It was assumed that the 200 pellet storage positions were fully loaded with maximum diameter pellets (0.3765") at a maximum enrichment of 4.1 wt.% U235,
- 2) The remaining 16 furnace locations were modeled with B C powder at 45%
4 of theoretical density (although it " pours" to a greater T.D.).
All SS tubes were omitted in the calculations for additional conservatism.
- 3) The furnaces were assumed to be infinitely long and spaced 36.5" on cen-ter. An intinite array was assumed, although there are only two furnaces.
4)
Variable density water mist was introduced to determine peak reactivity of the system.
- 5) All aluminum pellet troughs were omitted and the variable density mist was substituted in their place.
6)
Four group cross sections were generated using the CEPAK Code for the fuel and poison regions of the model and for the concrete floor and ceiling.
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License No. SNM-1067, Docket 70-1100 Revision: 1 Date:
7/16/79 Pag : C-19a
The KENO-IV Code was used to determine the reactivity of the Pellet Drying Furnaces under various external mist conditions with and without the fixed B C poison rods in place. The peak reactivity of the furnaces, keff" 4
0.8693 : 0.0057, occurred for the full density water condition.
Additional calculations were performed assuming loss of all poison. The margin of safety is unacceptable only for mist densities exceeding 30%.
(Fire hoses are not permitted in this area). These conditions were not considered credible. The furnaces draii freely to the floor and could not retain this amount of water.
Dimensional daails of the calculational model and results obtained are pre-sented in S^ tion 1.7 of the demonstration section of this license.
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9 License No. SNM-1067, Docket 70-1100 Revision: 0 01te: 7/16/79 Page: C-19b
initially loaded into the assembly skeletons, a vertical wash tank (W.S.132) where the assemblies receive a final demineralized water rinse, two fixed ver-tical inspection stands equipped with elevator platforms (W.S.131 and 133) to allow final Q.C. dimensional checks, and two marked floor areas where the assemblies are loaded into shipping containers prior to outdoor storage. Each of these stations is physically limited to one fuel assembly except the ship-ping containers which hold two. The assembly storage room can thus contain a maximum of 111 fuel assemblies (94 storage positions, plus 17 additional loca-tions). All assemblies outside of shipping containers shall be stored verti-cally within the design spacing criteria of the Assembly Storage Room shown on drawing NFM-E-4074, Revision 1, dated 12/20/78.
- 1) A 10 x 13 array of assemblies was modeled at the design spacing. This effec-tively brings the 17 additional assemblies closer together and provides greater interaction with the 94 assemblies in the storage area than is actually pos-sible. The array contains 130 assemblies while the maximum number in the room is limited to 111.
- 2) All steel construction material was neglected.
- 3) Variable density water mist was introduced within and between the assemblies to determine peak reactivity of the system under optimum conditions.
4)
Four graup cross sections were generated using the CEPAK Code for the 3 regions of the assemblies; fuel, water holes, and external water mist between assemblies. These 3 regions were then smeared over the entire array using the 00T Code to obtain one set of flux weighted lattice c.ross sections.
5)
Four group cross sections were generated using the CEPAK Code for the 8" concrete walls,16" concrete floor, and the external water mist between the top of the fuel assemblies and the ceiling. The ceiling was considered to be 8 inch thick concrete, though 4 inches is usually assumed.
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License No. SNM-1067, Docket 70-1100 Revision: 1 Cate: 7/16/79 Page: C-26
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TABLE 4 Calculated keff Val;es Monte Carlo Expt #
Tyre Pcisen Plate Keff 6(STD Deviation) 15 Ncne 1.00227
.00534 04 None 0.99912
.00540 49 None 1.00221
.00473 18 None 1.00813
.00489 21 None 0.99589
.00461 28 304 S Steel 0.0 w/o Boron 1.G0393
.00308 05 304 S Steel 0.0 w/o Baron 1.00329
.00303 29 304 S Steel n.0 w/o Boron 1.00271
.00302 27 304 S Steel 0.0 w/o Boren 1.00418
.00273 26 304 S Steel 0.0 u/o Boron 0.99811
.00279
'4 304 S Steel 0.0 w/o Beren 0.99793
.00297 35 304 S Steel 0.0 w/o Baron 1.00436
.00290 32 304 S Steel 1.05 w/o Boren 0.99970
.00524 33 304 S Steel 1.05 w/o Boron 1.01173
.00491 38 304 S Steel 1.62 w/o Boren 1.00289
.00512 39 304 S Steel 1.62 w/o Boron 1.00208
.00506 20 Boral 0.99585
.00301 16 Boral 1.00020
.00288 17 Boral 0.99519
.00286 Mea.' Keff Value 1.00157 Std. deviation
.00419
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License No. SNM-1067, Occket 70-1100 Revision 1 Date: 7/16/79 Page:
D-53