ML19273B571

Forwards Comments & Drawings Re Packages AL-M3 & AL-M6 in Response to NRC 781101 Memos.Believes Current Practices Conform to Accepted Criteria

ML19273B571
Person / Time
Site:	07105791
Issue date:	01/30/1979
From:	Roeder J ENERGY, DEPT. OF
To:	Macdonald C NRC OFFICE OF NUCLEAR MATERIAL SAFETY & SAFEGUARDS (NMSS)
References
NUDOCS 7904090225
Download: ML19273B571 (20)

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)Gl-G~l k([ 2. N Department of Energy Albuquerque Operations Office ) P.O. Box 5400 y; Albuquerque, New Mexico 87115 g. JAti 3 ; 1979 1 d j Charles E. MacDonald, Division of Fuel Cycle and Material Safety, Nuclear Regulatory Commission L.-. NRC COMMENTS ON PACKAGES AL-M3 AND AL-M6 This refers to your memos of November 1,1978, regarding subject packages. Attached are comments and drawings which respond to referenced memos. We believc that our current practices as outlined in the attachments are in compliance with currently accepted criteria. Your review and comments are greatly appreciated. ack R. oeder, Director WOR:ELB perational Safety Division

Enclosure:

As stated cc: W. A. Brobst, ECT/HQ, w/o encl. Jack Stevens, DAO, w/o enc 1. C n -m m ., / % g L C -q ? ) \\ fI ?.T".7 f:r,c p:, % 9f / fff lU ; ' ' N o yg., .....o a gf @af }inp y 2904000

\\ .) \\ Vonsanto MOUND FACit.lTY Open.ted for the United states Depadment of Energy January 15, 1979 Mr. Harry N Hill, Area Manager U. S. Department of Energy - Dayton Area Office Post Office Box 66 Miamisburg, Ohio 45342

Dear Mr. Hill:

NRC Conments on Packages Letter, Hill to McClain, 11/30/78 The following information is offered in response to the letter referenced above concerning NRC comments on Mound containers Al-M3 and Al-M6. NRC COMMENT DRAWIrr,S AND SPECIFICATIONS l. Provid.e Mound Research Corporation Drawing No. AYD750138 for the Model No. Al-M3 shipping container. The drawing should identify all significant safety features, e.g., dimensions, materials of construction, welds and seals. MRC Response Mound will provide two copies each of the following Mound drawings: AYD750138, Issue D and AYD750140, Issue D, both of the Al-M3 shipping container, and AYD750148, Issue C and AYD750150 Issue A, both of the Al-M6 shipping container. These are the most recent issues'of'the drawings and reflect recent changes to provide increased reliability in welds and in the top seal design of the inner container and they will therefore not necessarily exactly reflect the drawings and dimensions in the SARP. NRC' COMMENT 2. Provide the Acceptance and Reuse Inspections specification, Mound Research Corporation Drawing No. SPA 740977. 1W95 Monsanto Hesearch Corporation P. O. Box 32 Miamisburg, Ohio 45312 (513) 8CG-7444 a subsidiary of Motivoto Company

Mr. Harry 4 Hill January 15, 1979-MRC RetDonse Mound dlll provide two copies of Mound drawing SPA 740977. NRC COMMENT STRUCTURAL Provide an 4ssessment of the Model No. Al-M3 containment vessel for the

30. foot bottom end drop test.

MRC RE!Donse We are not aware of a formal requirement for a 30 foot bottom end drop test. The 30 foot drop test performed was on the top edge at the closure for the cover as that was assessed to be the most vulnerable point. NRC is evidently concerned that the bottom of the inner container might fail in a bottom drop test. Based on our engineering review of this containar, a 30 foot drop on the bottom of the total package would cause no da age to the inner containment vessel. NRC COMMENT CONTAINMEST Show that the containment capabilities of the package following normal conditions of transport and accident damage conditions are sufficient for packaging containing plutonium oxide power. Regulatory Guide 7.4 should be used to develop an acceptable test to demonstrate adequate containment for the packaging subjected to the accident damage test sequence. The test or analysis ut.t address the actual environment predicted for the accident damage test sequence. We also note that the requirements of 10 CFR 571.42 should be addressed. MRC Ee'Ponse All c:nt ainers of radioactive material that are placed inside the Al-M3 containment vessel are wiped prior to being placed inside the Al-M3 containment vessel. These wipes must show 20 dpm or less (essentially " cold') before they 7tr: accepted for packaging for shipment. In s i . ~.

~f Mr. Harry N Hill ' q January 15, 1979 5 addition, the limit of acceptable leak rate for an MRC containment s vessel prior to first use is several orders of magnitude better than the Regulatory Guide 7.4 minimum requirement. The wide spectrum of containers used inside the Al-M3 containment vessel preclude their individual submittal for approval. The SARP provides the details of the hypothetical accident conditions and shows that there was no damage to the containment vessel during the test sequence. NRC COMMENT _ TESTING AND MAINTENANCE Discuss the leak testing and maintenance program to be used to ensure the package containment capability initially and under continued use. Tests should include initial, periodic and preshipment leak tests to be used on the containment system. The maintenance schedule should include the inspection, test and replacement schedule for components that comprise the containment system. ~ Regulatory Guide 7.4 may be used for leak tests before first use end for periodic leak testing. For assembly verification testing, it is recommended that a test of sufficient sensitivity to detect a leak of 1 x l';-3 2 atm-cm /sec be used. The leak tests should be applied to the <.ontainment vessel and the separate inner container as defined in 10 CFR 5 'l.42. MRC Response The initiel acceptance specification is attached to this package. We have also included copies of ;he most recent issue of SPA 760488 which defines the leak tert. The parameters of the leak test are also provided in the receiving inspection section of SPA 740977, page 14 anc page 18. This seal is verified on each container when received at Mound. In addition, if, during any inspection conducted prior to use, the inspector observed a condition which is unusual or which may cause him to question whether a seal can be obtained, he will submit the container to the Nondestructive Test group for another leak test. The present maintenance program employed at Mound requires that s d d me

l Mr. Harry N Hill January 15, 1979 \\ immediately prior to each packaging operation the following operations are conducted on the containment vessel of the Al-M3 shipping container: Verification of presence and legibility of the serial number; Overall visual examination for defects. such as cracks, presence of foreign matter, etc., visual examination of "0" ring seal; Examination of "0" ring groove and lid seal area for presence of scratches, dents or foreign matter; Examination of threads in lid and body; Functional fit of lid to body. In addition, the container which is placed inside the containment vessel is visually inspected for physical defects and both the container and i the containment vessels are wiped and radiation levels of the wipes are required to be below 20 dpm before they are approved for shipment. In addition to these inspections the outer components of the Al-M3 shipping container ~ such as the drum, the centering material, bolt threads, closure ring are checked for dents, rust, chips, cracks, etc. These components are also checked for contamination. Mound believes and experience ha: verified that these precautions have been adequate to prevent the use of ini:rior containers and the release of radioactive material during shipments. NRC COMMENT CRITICALITY In order for any package to qualify as Fissile Class I it is necessary to demonstrate that the requirements of 10 CFR 571.38 are met. In practice, Fissile Class I indicates that controls for criticality in transport are not required. This is possible since there is essentially no neutron interaction between packages Jnder normal conditions of transport and at least 250 damaged packages are qubcritical. It should be recognized that Fissile Class I packages could be commingled with other Fissile packages. In the case of the subject package it has not been shcwn that any number (infinite array) of packages are subcritical for the normal conditions of transport. In this regard, we need a description of the criticality model and analysis and results which support a Fissile Class I designation. MRC Response While it is true that the criticality analyses for the subject packages s o

Mr. Harry N Hill I January 15, 1979 f did not consider an infinite array, in che real world an array consisting ~ of 2500 packages is commonly accepted within the criticality safety community as being the equivalent of an infinite array. In fact, Hugh Paxton, a recognized criticality expert at LASL, has stated that if an ar:ay of as few as 250 packages is demonstrated to be subcritical then an infinite array will also be subcritical.1 One is hard-pressed to imagine an autual shipment array even beginning to approach 2500. It is doubtful that there exist in the world a total of 2500 packages certified for Fissile Class I use. In addition, criticality evaluations are traditionally heavily saturated with conservatism and worst possible case scenarios. As a basis for comparison, an additional calculation was made on one of these containers using the ANISN Code to calculate a K=. The infinite array was subcritical. This type of analysis is not planned for any other package evaluations past, present, or future. We recognize that Fissile Class I packages could be commingled with Fissile Class II packages on a shipment. D0T Tariff Part 173.396(C)- (Se) clearly permits this. The question has been the subject of panel discussions of criticality experts with a meeting at Vienna in 1969 particularly coming to mind. It was concluded that-this type of mixing ~ is an academic problem only. There is a much more than adequate margin of safety for even the most improbable situations. Mound Facility would like to invite an NRC representative or representatives to visit Mound so that basic concepts and design criteria may be reviewed and discussed freely. Observation of Mound's containers and test farisities along with discussions of Mound's Quality Program should provide a much better mutual understanding of the overall requirements for a safe package for the containment.of radioactive material during shipment. Moreov,er, 2 Criticality Control in Operations with Fissile Material, H. C. Paxton, LA-3366 (Rev) 1972 \\

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I ~ f January 15, 1979 Mr. Harry N Hill 3 such a meeting would pave the way for a more expedient evaluation and acceptance of future shipping containers which may be developed by Mound. If you need additional information, please feel free to call me. a. Very truly yours, U h-(13) W. T. Cave, Director Nuclear Operations WTC:js Enclosures c.c: Mr. Harry N Hill, DA0/ DOE (2)- 7.:5 ee 6 9 e h I 3 6 e \\ \\ d ~ 1._ 2 7.. _. - ~ ~

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..c.. .n. .....-.-.-, 3 ,..y.~ l I \\, TABLE OF CONTENTS SECTION 1 Scope 2 Welding 3 Visual i;-amination 4 Dye Penetrant Examination 5 Helium Leak Test 6 Certification I i 1 i i i I I f8 I ... Al l l l l i 5

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2.3 Welds - The fillet weld shall have continuour complete fusion at the root of the weld joint. The butt weld shall have continuous complete penetration through the tube wall. (Standard AWS welding symbols have been used on the drawing.) 2.4 Welding operator qualification - It shall be the responsibility of the vendor to assure that the assigned welding operator s are competent, experienced and qualified to perform welding on carbon steel. 3. VISUAL EXAMINAT IONS. 3.1 A detailed visual inspection of each entire weld shall be made using magnifying equipment with a 4X to 20X magnification reading glass. Any defect greater than those listed in 3.2 to 3.7 shall be cause for rejection: 2 3.2 Cracks - There shall be no cracks in the welds or in the adjacent base metal. ~2 Ai i !: i i cc;e m s. n.a .;,5

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.. _ _. _ ~ -_.~,..n I l l \\ 3.3 Surface Pores - There shall be no surf ace pores greater than.012" diameter. 3.4 Surface Contour - The surface of the weld shall be uniform in appearance. 3.5 Weld Size - The fillet weld shall be gaged to assure that it meets or exceeds the drawing requirement. 3.6 Cold Overlaps - There shall be no cold overlaps. 3.7 Undercuts - There shall be no undercuts. 4. DYE PENETRANT EXAMINATION. 4.1 A detailed fluorescent dye penetrant examination of each entire weld shall be made Any def ect greater than those listed in 4.2 and 4.3 shall ba cause for rejection. 4.2 Cracks - There shall be no crack indication's in the welds or adjacent base metal. 4.3 Surface Pores - There shall be no surface pores greater than .012" dia=cter. 5. HELIUM LEAK TEST. 5.1 The container shall be successfully heliun leak tested in the presence of an MRC representative. 5.2 The vendor will establish that he can obtain the services of a qualified, experienced operator and the equipment to conduct the helium leak test. 5.3 All welds and fittings must have no detectable leak greater than 1 X 10-5 (STP) cc/sec and a cetal o-ring seal (or similar cetal to metal seal) must have no detectable leak greater than 1 X 10-5 (STP) cc/sec. The entire container most not leak more than 1 X 10-5 (STP) cc/sec when sealed l with a Viton or equivalent o-ring or 1 X 10-5 (STP) cc/sec when sealed with a metal o-ring or similar metal to cetal seal. 5.4 The leak detector used for the test must be standardized just prior to the tect against a standard Icak tube in the appropriate range. 3 1 1 s? i$UN M.bNb Al l l i I j i i i j l 3 5t C C E ICE *G '.> ) t wa v /. 'i NO SPA 760488 +7 4 3,..a_en .,,y, c ", N T.J 'j t w., s ; i s... ;... e,to.-- , ? :, s ;: -, c;..,,. a v, , 4, s,2. ed

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CERTIFICATION. 6.1 The attached fabrication and inspection certification or a facsimile of it shall be completed by an approprince supplier representative and transmitted to MRC. This shall constitute certification of the container as meeting minimum requirements. 6.2 Each item on the f abrication and inspection certification s':all be signed and dated when all of the necessary operations for that particular item have been completed. It is intended that the inspection will be performed in the sequenca listed. FABMICATION AND INSPECTION CERTIFICATION FABRICATED BY CONTAINER SERIAL NUMBER CONTAINER DRANING NO. DATE SIGNATURE CO !PLETED 1. Component and materials as specified. 2. Welded as specified (Section 2). 3. Visual weld examination acceptable (Section 3). 4. Dye penetrant examination acceptable (Section 4). 5. Dimensions as specified. 6. O-ring surf ace finish as. specified. 7. Container can be assenbled properly. 8. Helium leak test acceptable 1 (Section 5). i 5 A I l l i l ! l l I i l { i t e t.r ,3 2

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