ML19282C221
| ML19282C221 | |
| Person / Time | |
|---|---|
| Site: | 07109090 |
| Issue date: | 02/26/1979 |
| From: | Blue S, Odom T, Stitt D UNION CARBIDE CORP. |
| To: | |
| Shared Package | |
| ML19282C220 | List: |
| References | |
| KY-697, W-7405ENG-26, NUDOCS 7903220241 | |
| Download: ML19282C221 (48) | |
Text
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UtHON CARCIDE CG2PORAT!0h 7/-fd}y Nb HUCLUR DIVISION v
I r.o. nox 24to. neucm wentocu cea f
March G,1979 a
f TO HOLDERS OF REPORT KY-697 Ch:nnes in Recort KY-697 " License A9911 cation For Type 4eHX Cvlinder Yor sd cent of unuras assay bie.".
B: sed on the certified value:o of each Type 4PllX cylinder as reported by the mnufccturer, the contents watcht should be increased from 26,0C0 lbs contents weight to 27.030 msxir~.xn UF6 weight. Thase nic.bers cppear in the folic'.ving places:
Pace 5,p:recr:ph(s)(3).line0 Paga 5, paragraph (b)(1)
The n2ainal cylinder tare v3fe,ht should ba changed from 3,150 to 3,120 Ibs nominal tare naight. Thb nt: cer cppars ta tua following picco:
Page 5, parecraph (s)(3), line 2 Gased on the mximum contcats eeight and cre wat;ht the cylinder gross weight should te changed frca 30.010 to 33,150 lbs gross weight. These n @ rs appear in the following places:
Page 5. parcaraph (a)(1)
Page 6, parc.grsph (b)(5), lina 1 Page 8, lira 4 Page 16. paragraph 2, lino 1 Da page 13. lina 1. ch:nge 132 ft3 to 133 ft.
3 On page 13. line 2, change 139 ft3 to 140 ft.
8 Errsta sheets covering the above changes will be issued as soon as possible.
0 f 0 Wy' D.11. Stitt, C-720 PGDP (228)
D:45:PJ.X:cp a.....,
79 03220 @//
"/$ Sh/77 KY-697 LICENSE APPLICATI0ft FOR TYPE 48HX CYLIf4 DER FOR SHIPMEf1T OF f1ATURAL ASSAY UF6 S. C. Blue T. R. Odom D. H. Stitt G*o -
PADUCAH GASEOlJS OtF#USION PLANT -
8 PADUCAH MENTUCKY '
~
prepared for the U.S. DEPARTMENT OF ENERGY under U.S. GOVER NMENT Contract W-7405 eng 2G "a
a NOTICE THIS R E POR T W AS PR E P AR E D AS AN ACCOUNT OF WORK S PO N SOR E D O Y AN AGENCY OF sHE UNITED STATES GOVERNMENT, NEITHER THE U NITED STATES GOVERN =
MENT NOR ANY AG ENCY THER EOF, NOR ANY OF THEIR E M PLOY E E, NOR ANY OF TH E IR CONTRACTORS. SUS-CONTRACTOHS, OR TH E R R EMPLOYEES, MAKES ANY W AR R ANTY, E X PR E SS OR I M PLI E D, NOR ASSUMES ANY LEG AL LI ABILITY CH H E S PO N S I D I LI TY FOR ANY THIRO P A R TY' S U S E OF TH E R E SULTS OF SUCH U SE OF ANY INFOR M ATION, APPARATUS, PRO DU CT OR PROCESS DI SC LO S E D IN THI S R E POR T, NOR REPRESENTS THAT ITS USC DY SUCH THIRD PARTY WOULD NOT INFRlNG E PR I V ATE LY OW N E D ei e GH T S, e
4 a
0
Date of Issue:
February 26, 1979 Report Number:
KY-697 Subject Category: Special 4
LICENSE APPLICATIC!i FOR TYPE 48HX CYLINDER FOR SHIPMENT OF NATURAL ASSAY UFn S. C. BLUE T. R. ODOM D. H. STITT UNION CARBIDE CORPORATIGri NUCLEAR DIVISION Paducah Gaseous Diffusion Plant Paducah, Kentucky Prepared for the Energy Research and Develooment Administration under U.S. Government Contract W-7405 eng 26 s
Report Number:
KY -697 Date of Issue: February 26, 1979 ABSTRACT Sudden unpredicted changer in the operating plan of the Gaseous Diffusion Plants percipitated a requirement for additional 14-ton cylinders for shipment of nonenriched ilF. The large quantity of A-516 steel normally specified g
for these cylinders was unavailable in the required time so ASTM A-285 Grade C was specified for the shell. This report provides documentation of tests and evaluations done to assure compliance of the cylinder fabricated from the new material to 10 CFR 71.
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CONTENTS Page Abstract.
1 1.
Introduction...
3 2.
Di s cu s s io n o f 10 C FR 71......................
4 3.
Appendix I:
Charpy V-notch Performance of Steels Used to Fabricate UF Cylinders......................
18 6
4.
Appendix II:
Drop Test of 48HX Cylinder.
25 5.
Appendix III:
Drawing Efi-14864B, Revision 0...........
31 6.
Appendix IV:
Speci fica tion ES-CMD-14864-2............ 32 7.
Appendix V:
48HX UF Limited Shipment and Long-Term Storage g
Cyl inder Procurement (QA-E-ll A).................. 42
==
INTRODUCTION This report provides support for a request to modify Model Number 48G to a configuration we have termed Model Number 48HX, and to use these cylinders for snipment of :alural UF to the GDPs.
The SSHX is very similar in design g
and method of construction to the Model 48 OM cylinder now used for shipment of natural assay UF by private industry and approved under Certificate of 6
Compliance 9090. The principal difference between the cylinders is the material used; A-516 Grade 70 steel in the 48 OM and A-285 Grade C steel in the 48HX. The shell thickness, head to shell joint configuration, pressure ratings and other important design details are identical.
Regardless of the steel used, both cylinder models are ASME code stamped and acceptable for use by ASME Boiler and Pressure Vessel Code,Section VIII, Division I, for use at any temperature between -20*F and 650*F. Neither cylinder is acceptable by the ASME code for use below -20*F due to design, testing and fabrication not in accordance with Code paragraphs UCS-65, UCS-67, UCS-75 and UCS-85.
A testing program has been carried out to verifv that the Model 48HX cylinder complies with the requirements of 10 CFR 71 and 49 CFR 170-189. A summary of Charpy V-notch impact testing on several heats of A-285 steel as used in Model 48HX cylinders and a Model 48T cylinder is included as Appendix I.
A summary report covering tests in which a Model 48HX cylinder was dropped onto a non-yielding surface is included as Appendix II.
DISCUSSIONS OF 10 CFR 71 SUBPART B - LICENSE APPLICATIONS 71.21 CONTENTS OF APPLICATIONS No comment is required.
71.22 PACKAGE DESCRIPTION The Model Number 48HX cylinder is alternately described as a Type 48HX cylinder.
It is fully described by Union Carbide Corporation-Nuclear Division Drawing Efi-148643, Revision 0, included as Appendix III, and Specification ES-CMD-14864-2, included as Appendix IV.
Each cylinder is identified as a Type 48HX on the stainless steel name tag welded to the shell.
(The original plan to procure cylinders for this use required the ut a of ASTM A-516 steel. When it became apparent that this material was unavailable in the recuired time an attempt was made to deviate the material requirement to mill certi fied ASTri A-285 in order to use steel originally procured as part of a contract to fabricate Type 48G cylinders. Since that effort to deviate the material has escalated to a license application, the above listed drawing and specification have been prepared so that documents which stand alone for this particular activity are provided. To clarify, new documents have uean prepared to eliminate the confusion of deviations from old documents and are being injected into the ongoing procurement.)
Approximately 1,000 Type 48HX cylinders will be procured.
Each will be ASME code stamped in accordance with ASME Boiler and Pressure Vessel Code,Section VIII, Division I, as mentioned in the introduction.
(a)(1) 30,010 lbs gross weight (a)(2) Model Number 48HX (a)(3) 48 in. ID x 145-1/2 in. long, 5/16 in. wall thickness 3,150 lbs nominal tare weight 26,860 lbs contents weight The shell is fabricated from ASTM A-285 Grade C steel.
Stiffening rings and skirts are ASTM A-36 steel.
(a)(3)(i) The cylinder itself is the primary receptacle.
(a)(3)(ii) Not applicable.
(a)(3)(iii)
The cylindrical shell is stiffened by three rings, 7/8 x 2-1/2 in. rolled around the cylinder at its center and at 41 in. from the center on both sides and skirts, 5/8 in. thick on both ends.
(a)(3)(iv)
The valve on the cylinder is the standare 1 in. UF 6
cylinder valve described in OR0 651, Revision 4, Page 58, and ANSI N14.1-1971, Page 32.
It is covered and sealed for shipment.
(a)(3)(v)
Not applicable.
(a)(4) Not applicable.
(b)(1) The cylinder contains 5.6 curies when filled with 26,860 lbs of natural assay uranium hexafluoride.
(b)(2) Not applicable.
(b)(3) The cylinder contains UF which is always shipped in solid 6
form. Approximately 35% of the volume is void when shipr,ed.
(b)(4) Not applicable.
(b)(5) The nominal gross weight is 30,010 lbs. There may be very small deviations in this weight when shipped due to cylinder weight variations of a few pounds or a slight underfilled condition, but the shipping weight will always be within a few pounds of the nominal weight.
(b)(6) There is no decay heat.
71.23 PACKAGE EVALUATION (a)
Satisfaction of the standards set forth in Subpart C is assured and will be demonstrated in narrative under Subpart C.
(b)
Not applicable.
(c)
Not applicable.
71.24 QUALITY ASSURANCE (a)
A quality assurance plan has been prepared for the procurement of Model 48HX cylinders and is included as Appendix V.
(b)
Each cylinder is fabricated in accordance with ASME Boiler and Pressure Vessel Code.
They will be used in the same manner as the Model 48 OM cylinders in accordance with Certificate of Compliance 9090 except that no enriched material will be shipped.
(c)
All Type 48HX cylinders are subjected to well defined and established acceptance criteria for code 7 tamped pressure vessels as set forth in QA-E-llA, Appendix V of this report.
Additional impact testing has been done to develop assurance that steel used in these cylinders is typical of ASTM A-285 Grade C.
71.25 ADDITIONAL INFORMATION Not applicable.
SUBPART C - PACKAGE STANDARDS 71.31 GENERAL STANDARDS FOR ALL PACKAGES (a)
The compatibility of the materials of construction with the contents is demonstrated by many years of continuous service of similar cylinders containing solid UF. The ASTM A-285 6
steel has been used for years for fabrication of many types of UF cylinders without problem. Approximately 20,000 tails 6
storage cylinders have been fabricated from this steel during the operation of the gaseous diffusion plants.
(b)
The cylinder is equipped with a standard 1 in. UF valve for g
filling and emptying. [See 71.22(a)(3)(iv).] The valve is equipped with a security seal and covered with a valve protec-ter during transport.
(c)(1) The lifting device that is a structural part of the cylinder consists of four lugs fabricated from 1 in. ASTM A-36 steel plate with a 1-1/2 in. hole through which clevis pins are inserted. The total shear area, assuming double shear of the pin through the metal above the hole is 4 lugs x 2 sides per hole x 1 in. x 2 in. = 16 in.2 The minimum yield per ASTM Standards,1978, Part 4, is 36,000 psi. Assuming the shear yield to be 57% of the tensile yield gives a yield generating 2
load of:
16 in.
x 36,000 psi x.57 = 328,000 lbs. This is approximately 11 times the weight (30,010 lbs) of a fully loaded cylinder.
(c)(2) Not applicable.
(c)(3) The only means by which the cylinder can be lifted is by attachment of the lifting lugs.
There are no other protrusions which could be employed.
(c)(4) As calculated in (c)(1) above, the shear area of the four lugs is 16 in.2 The area of weld attaching the lug to the shell and stiffening ring is approximately 18 in.2 The area of steel shell and stiffening ring that would have to be sheared to allow breach of the cylinder wall is approximately 46 in.2, The predicted mode of failure is therefore shear of the lug through the holes.
The containment would not be impaired by failure of the lifting device.
(d)(1) There is no system of tie down devices which is a structural part of the cylinder. The cylinder is positioned in a cradle on a flat bed truck and secured by passing two cables over it.
The cables are tightened witn a ratchet binder.
(d)(2) The lifting lugs are exposed during transit, but no system for using them for tie downs exists as part of the transport system.
(d)(3) Not applicable.
71.32 STRUCTURAL STANDARDS FOR TYPE B AND LARGE QUANTITY PACKAGING Not applicable.
71.33 CRITICALITY STANDARDS FOR FISSILE MATERIAL PACKAGES Not applicable.
The cylinder is used only for nonfissile nonenriched assay UF shipments.
c 71.34 EVALUATION OF A SINGLE PACKAGE (a)
The effect of the transport environment is evaluated as follows:
(a)(1) The effects of normal heat and cold are demonstrated to be nil through years of service of similar cylinders. Cylinders of 14-ton capacity made of A-285 steel with a 5/15 in, wall thickness have been used for many years at the three gaseous diffusion plants as depleted UF storage cylinders. As 6
previously mentioned, approximately 20,000 similar cylinders have seen routine service and occasionally have been shipped between plant sites. While several transport accidents have occurred involving these cylinders, none have ever been breached and there has never been a release of contained material during transport.
Additionally, the cylinder subjected to the drop test reported in Appendix II of this document, was immersed in a trichloro-ethane and dry ice bath at temperatures of acproximately
~
-105 F for approximately two and a half days while cooling down for the test. Routine handling at these temperatures created no problems or unusual conditions.
_g.
The cylinder is designed and code stamped to accept and external working pressure of one atmosphere which is twice the requirement of this paragraph.
The effects of vibration and water spray are demonstrated to be nil through the service of similar cylinders described above.
The effects of the free drop have been assessed by actual tests, including three drops at -20*F or below. The results are included as Appendix II.
(a)(2) Not applicable. The cylinder contains only low specific activity material as defined in 71.4(g) and is transported on a motor vehicle assigned for sole use.
(b)
The cylinder has been evaluated without the transporting vehicle.
(c)
Normal conditions of transport as specified in 71.35 have been used to evaluate the cylinder.
71.35 STANDARDS FOR NORMAL CONDITIONS OF TRANSPORT FOR A SINGLE PACKAGE (a)
The cylinder has been subjected to the normal conditions of transport specified in Appendix A of 10 CFR 71 by test, analysis or through actual truck or rail transport and:
(a)(1) There would have been no release of radioactive material from the cylinder.
(a)(2) The effectiveness of the package would not be reduced.
(a)(3) There is no mixtu e of gases or vapors in the cylinder which could, through any credible increase of pressure or explosion, significantly reduce the effectiveness of the package.
(a)(4) Not applicable.
(a)(5) Not applicable.
There is no coolant.
(b)
Not applicable.
(c)
The cylinder is so designed and constructed that under the normal conditions of transport specified in Appendix A of 10 CFR 71, it is not vented directly to the atmosphere.
71.36 STANDARDS FOR HYPOTHETICAL ACCIDENT CONDITIONS FOR A SINGLE PACKAGE Not applicable.
[See 71.34(a)(2).]
71.37 EVALUATION OF ANY ARRAY OF PACKAGES OF FISSILE MATERIAL Not applicable.
71.38 SPECIFIC STANDARDS FOR A FISSILE CLASS I PACKAGE Not applicable.
71.39 SPECIFIC STANDARDS FOR A FISSILE CLASS II PACKAGE Not applicable.
71.40 SPECIFIC STANDARDS FOR A FISSILE CLASS III SHIPMENT Not applicable.
71.41 PREVIOUSLY CONSTRUCTED PACKAGE 5 FOR IRRADIATED SOLID NUCLEAR FUEL Not applicable.
71.42 SPECIAL REQUIREMENTS FOR PLUTONIUM SHIPMENTS AFTER JUNE 17, 1978 Not applicable.
SUBPART D - OPERATING PROCEDURES The Model 48HX cylinders will be used in accordance with Certificate of Compliance USA /9090/A and OR0-651 " Uranium Hexafluoride Handling Procedures and Container Criteria",
(latest revision), except that no enriched material will be shipped. All new cylinders are fabricated in accordance with a QA plan similar to QA-E-llA which is included as Appendix V.
APPENDIX A NORMAL CONDITIONS OF TRANSPORT 1.
HEAT.
Direct sunlight at an ambient temperature of 130*F could possibly although this is oroduce a phase change of some of the contained UFg very remote.
In any case, the temperature and oressure would certainly stabilize at something less than the design salues of 100 psig at 235*F.
2.
COLD.
I ow temperature is the single ambient condition which could impair the ability of the Model 48HX cylinder to perform in a manner equal to the Model 48 OM mentioned in the introduction.
Neither 48HX or the 48 OM are designed and fabricated in accordance with the ASME Boiler and Pressure Vessel C'de.Section VIII, Division I, for temperatures below -20*F.
However, since these are really not pressure vessels once they are filled and valved off, both should function satisfactorily at -40 F so long as external loading which could generate tensile stress fields, are avoided.
Fracture of the A-285 steel at this temperature would be brittle.
These cylinders are evacuated prior to filling. Approximately 132 ft3 3
of liquid UF is then drained into the cylinder volume of 139 f t. The 6
vapor pressure, while liquid, is above atmospheric.
As the material cools and solidifies, the vapor pressure drops to below 3
atmospheric and the material shrinks to about 96 ft. OR0-651 does not permit shipment until the material is in solid form and the cylinder pressure is less than atmospheric.
If a cylinder and its contents were cooled to -40*F the cylinder pressure would drop to less than 0.1 psia.
The cylinder volume is then 31% in vacuum and 69% full of solid UF -6 Since the UF contracts on cooling and the vessel is below atmospheric 6
pressure it is difficult to postulate any tensile stresses developing, except those resulting from external forces, that might impair the performance of the cylinder.
3.
PRESSURE.
The cylinder is designed and fabricated to withstand 1 atmo-sphere external and 100 psig internal pressure at 235"F. As per ASME Boiler and Pressure Vessel Code,Section VIII, Division I, the cylinder should withstand that oressure at any temperature between -20*F and 650 F.
4.
VIBRATION. Type 48G cylinders containing depleted UF have been shipped g
from Portsmouth, Ohio and Oak Ridge, Tennessee to the Paducah Gaseous Diffusion Plant on occasion without incident due to vibration.
=
5.
WATER SPRAY.
Similar cylinders have sat outside for over 20 years with no ill effects of rain.
Some external corrosion does occur with extended exposure. Hot cylinders are routinely placed under a continuous water spray for several days to speed cool down and solidification.
6.
FREE DROP.
Several drop tests were conducted on 14-ton Type 0 and Type OM c'..nders in 1968 and reported in KY-549, " Testing of Fourteen-Ton Uranium Hexafluoride Cylinders".
Type OM at that time meant that a Type 0 cylinder was modified to a different stiffening ring configu.ation.
There were no skirts on these cylinders. They were fabricated from ASTM A-285 steel with a 5/16 in, wall thickness.
They are 48 in. in diameter and 145 in. long. The tests reported in KY-549 are tabulated below.
They were all conducted at outdoor ambient temperature.
Type Drop Cylinder Gross Wt, Test Height Number Lbs Remarks Impact 30 ft 13041 30,589 Dropped in horizontal attitude.
Impact 30 ft 16880 31,046 Dropped in horizontal attitude.
Piston 1m 13041 30,589 Impacted piston 1-1/4 in. from valve end stiffening channel.
Valve 1 ft 13041 30,589 Dropped on valve guard and steel valve cover.
Piston 1m 16880 31,046 Impacted piston 1-1/4 in. from center stiffening ring.
Valve 1m 16880 31,046 Dropped on valve guard and steel valve cover.
Valve Im 13041 30,589 Dropped on valve quard and alu-minum valve cover.
Other 5/16 in, wall thickness cylinders, 10-ton capacity, were drop tested in various configurations in 1965 and reported in KY-500,
" Testing of Ten-Ton Uranium Hexafluoride Cylinders".
Type 48T cylinders were used in these tests. They are constructed of ASTM A-285 steel, 5/16 in. wall thickness, 48 in. diameter and 120 in. long. The tests are tabulated below.
Type Drop Cylir. der Gross Wt, Test Height Number Lbs Remarks Impact 4 ft 5480 24,195 Dropped in horizontal attitude.
Impact 10 f t 5491 23,663 Dropped in horizontal attitude.
Impact 10 f t 6751 23,806 Dropped in horizontal attitude.
Impact 20 f t 6751 23,806 Propped in horizontal attitude.
Valve 4 ft 12 lb steel rod dropped on valve.
Puncture 40 in.
5480 24,008 Impacted center of piston 5-1/2 in.
from center ring.
Puncture 40 in.
5491 23,988 Impacted center of piston on center stiffening ring.
Impact 30 ft 6231 24,026 Dropped in horizontal attitude.
Puncture 40 in.
6231 24,026 Low temperature test.
Impacted center of piston 3 in, from center ring.
The various types of 5/16 in. wall thickness cylinders have been drop tested 16 times; three times from 30 feet, once from 20 feet, twice from 10 feet, once from 4 feet, four times from 40 in. onto the piston, and four times on the valve from one foot, one meter and four feet. A 12 ib cyl;ndrical weight was dropped onto the valve from a height of four feet.
The steel shell was not breached in any of these tests. The most serious consequence was a loosening of the valve in the threads.
A summary report of a series of drop tests conducted on a Type 48HX cylinder is included as Appendix II of this report. These tests were performed with the cylinder wall temperature at -20"F or colder. The cylinder, weighing 30,293 lbs loaded with uranium metal and frozen water ballast was dropped one foot to the lowest part of the cylinder rotated to a 35 degree horizontal angle, one foot horizontally, and four feet to the lowest point of the cylinder rotated to a 35 degree horizontal angle.
Details are in the report included as Appendix II.
The one foot drop tests meet the requirements of 10 CFR 71 for a 30,010 lb container.
In these tests:
a) There was no release of contained material. The cylinder wall was not breached.
b) The effectiveness of the cylinder to function as required was not substantially reduced.
In an effort to produce a fracture for analysis and to determine how severe the fracture might be when it occurred, the cylinder was subjected to the angle four foot drop listed above. The cylinder head did fracture in the four foot drop as shown on photographs and sketches included in Appendix II.
The total energy in this fall was approximately 226,000 ft-lbs or seven and one-half times the energy in a flat one foot drop. The drop was four times the required one foot.
As predicted, the fracture tended to be brittle and originated in an area of the cylinder where tensile stress was magnified by qeometric disconti-nuities.
The crack arrested when the tensile stress dropped to a level that would not support propagation.
While the Type 48HX cylinder is not " fracture proof" it has adequate resistance to meet the requirements of 10 CFR 71 even when tested under the most stringent conditions possible.
Fracture occurs at energy levels far greater than those stipulated in the regulations, in an acceptable manner with no massive destruction of the containment vessel.
The design of the Type 4CHX c/ inder, the material used for construction, l
the fabrication techniques and quality control have provided a test cylinder which met all of the Type A package requirements when subjected to actual tests at -20 F.
Similar 5/16 in. wall thickness cylinders have met the Type B package drop test requirements.
m m
e APPENDIX I
APPENDIX I CHARPY V-NOTCH PERFORMANCE OF STEELS USED TO FABRICATE UF6 CYLINDERS Seven heats of ASTM A-285 Grade C steel were tested; the 5/16 in. mill slabs are being used at Modern Welding to fabricate shells of Type 48HX cylinders.
Results are presented for comparison with results for steels from two cylinder drop tests. Cylinder No. 6231 is a Type 48T cylinder which was drop tested at +20 F.
Cylinder No. 150050 is a Type 48HX cylinder which was drop tested at -20 F.
The rolling direction for mill slabs, cylinder heads, cylinder shells, and appendage skirts was determined metallographically for all pieces from which Charpy V-notch samples were machined.
Specimens are referenced to the rolling direction, so those with the long axis (55 m) running parallel to the rolling direction are designated longitudinal.
Standard size and 3/4 size specimens were prepared and tested in accordance with ASTM A370-75.
In all cases, specimens were prepared with the length of the notch perpendicular to the plane of the plate being tested.
The cylindrical shell and both skirts of drop cylinder No. 150050 had the rolling direction coinciding with the circumferential direction of the cylinder.
The plug end head had the rolling direction coinciding with the vertical, while the valve end head had the rolling direction 30 degrees counterclockwise from the vertical, as viewed from the valve end. A slight difference is noted between the transverse specimen impact values from the fabricated shell of cylinder No. 150050 (Table V) and the transverse speci-men impact values from the mill slab (first heat in Table III) from which the shell was made. The test results (Table III) for heats used in cylinder manufacture show the current supply of 5/16 in. plate to be rather uniform in its impact test performance.
As a majority of the data presented in Tables I, III, and V deals with ASTM standard subsize impact specimens, some consideration is given to com-parison of this with data from standard size specinens. Present subsize specimens represent 94% of plate thickness. The 3/4 size specimens accu-rately reflect the impact behavior of this plate thickness, because the brittle fracture of structural plate deper.ds, among other things, on the triaxiality of the state of stress which is affected by thickness.
9 TABLE I 3/4 SIZE CHARPY V-NOTCH ENERGY ABSORPTIONI F0P, ASTM A-285 GRADE C STEELS TESTED IN TWO ORIENTATIONS FROM CYLINDER NO. 62312 Valve End Head _3 Temp.
Shell of Cylinder 10m x 7.1mm 10mn x 7.4m Plug End Head F
Longitudinal Transverse Longitudinal Transverse Longitudinal Transverse 120 56/55 32/30 85/71 34/33 84/76 40/31 100 49/43 31/31 80 44/42 29/27 b
60 27/25 18/18 10/10 12/11 26/17 27/21 40 16/9 26/14 8/8 6/5 9/8 20/7 20 13/12 11/10 5/4 6/6 16/6 7/7 10 11/10 9/7 0
9/9 8/8
-10 9/8 7/7
-20 6/6 6/5 2/2 3/2 3/2 3/3 1 Average /minimun values in ft-lbs for three specimen sets.
2 Drop test cylinder at +20 F, Pedigo, W.R., et al., Testing of Ten-Ton Uranium Hexafluoride Cylinders, Union Carbide Corporation, Nuclear Division, Paducah, Ky., October 22, 1965, (KY-500) Unclassified.
3 Specimens are modified subsize due to corrosion and curvature of head.
TABLE II MECHANICAL PROPERTIES AND SPECTR0 CHEMICAL ANALYSIS OF STEELS FROM CYLINDER NO. 62311 Shell Valve End Head Plug End Head UTS (Kpsi) 64 Yield Point (Kpsi) 52
% Elongation in 2 in.
27 Carbon 2, wt %
0.16 0.11 0.10 g
Aluminum, wt %
<0.01
<0.01
<0.01 Copper, wt %
0.3 0.1 0.1 Manganese, wt %
0.4 0.5 0.4 Nickel, wt %
0.15 0.05 0.05 Silicon, wt %
<0.01
<0.01
<0.01 1 Drop test cylinder at +20 F, Pedigo, W.R., et al., Testing of Ten-Ton Uranium Hexafluoride Cylinders, Union Carbide Corporation, Nuclear Division, Paducah, Ky.,
October 22, 1965, (KY-500) Unclassified.
2By combustion - gravimetric.
TABLE III 3/4 SIZE CHARPY V-NOTCH ENERGY ABSORPTIONI FOR SEVEN HEATS OF ASTM A-285 GRADE C STEEL CURRENTLY USED IN THE FABRICATION OF 48HX LYLINDERS AND TESTED WITH TRANSVERSE SPECIMENS Heat 2 Heat Heat Heat Heat Heat Heat R7410895 R7410901 R7410869 R7420997 R7410864 R7420917 R7410907 Temp.
Piece Piece Piece Piece Piece Piece Piece F
122 23 9983 203 9962 9922 128 120 26/24 b
20 18/15 25/25 17/15 15/15 15/13 14/13 13/13 10 26/25 10/10 12/11 11/10 0
11/11 22/21 11/9 12/11 10/9 10/9 10/9
-10 9/8 14/10 9/8 8/8 9/8 9/9 9/8
-20 7/7 11/8 8/7 8/7 7/7 8/8 7/7 1 Average / Minimum values in ft-lbs for three specimen sets.
2This mill slab was used to fabricate the shell of drop tested cylinder No. 150050.
TABLE IV MECHANICAL PROPERTIES AND ANALYSIS OF ASTM A-285 GRADE C STEEL CURRENTLY USED IN THE FABRICATION OF 48HX CYLINDERS Heat Heat Heat Heat Heat Heat Heat R7410895 R7410901 R7410869 R7420997 R7410864 R7420917 R7410907 Piece Piece Piece Piece Piece Piece Piece 122 23 9983 203 9962 9922 128 UTS (Kpsi) 59 58 61 59 58 59 57 Yield Point (Kpsi) 41 40 39 41 41 42 39
% Elongation 4
in 8 in.
27 27 27 26 29 31 29 w'
- Carbon, wt %
0.15 0.14 0.13 0.14 0.14 0.15 0.14
- Aluminum, wt %
<0.01
<0.01
<0.01
<0.01
- Copper, wt %
0.1 0.1 0.1 0.1 Manganese, wt %
0.43 0.45 0.43 0.40 0.42 0.45 0.42
- Nickel, wt %
0.04 0.04 0.04 0.04
- Silicon, wt %
0.06 0.06 0.06 0.06
TABLE V 3/4 SIZE AND STANDARD SIZE CHARPY V-NOTCH ENERGY ABSORPTIONI FOR STEELS TESTED IN TWO ORIENTATIONS FROM CYLINDER NO. 150050 ASTM A-285 GRADE C STEEL ASTM A-36 STEEL Shell of Cylinder Valve End Head Plug End Head Valve End Skirt Plug End Skirt Temp.
3/4 Size 3/4 Size 3/4 Size Standard Size Standard Size F
L_ong.
Transv.
Long.
Transv.
Long. Transv.
Long.
Transv.
Long. Transv.
120 85/81 54/46 54/52 54/52 44/30 33/31 43/40 30/28 g
60 47/43 31/30 96/75 26/24 87/85 24/22 18/17 16/15 17/16 14/13 20 16/15 14/13 39/112 14/13 67/58 13/11 7/6 10/9 10/9 6/5 0
8/6 8/8 7/6 8/6 34/13 11/10 5/4 5/4 6/4 7/6
-20 5/4 6/5 4/3 6/6 7/4 8/7 3/2 4/4 4/4 4/3 1Average / Minimum values in ft-lbs for three specimen sets.
2Average and mininum of six specimens.
e APPENDIX II
APPENDIX 11 DROP TEST OF 48HX CYLINDER
SUMMARY
The drop test was planned and conducted to insure that all critical requirements would be met:
1.
Tests were conducted to insure that the material of con-struction was typical of other vessels in this series.
2.
The vessel was loaded in a nanner to simulate the effect of a frozen mass of UF6 and to insure that the structural in-tegrity of the vessel would not be degraded by an internal contact with a hard member.
3.
The one-foot qualification drops were made with all members of the structure at or below -20 F.
4.
The impacted surfacts were carefully inspected and dimensionally located after each drop.
The drop test series demonstrates that the Type 48HX cylinder can be dropped either horizontally or inclined from one foot at -20 F without cracking or breaching the skin. The deformation observed along the bottom of the cylinder indicates that the structure will plastically yield at
-20 F without the onset of brittle fracture.
DROP TEST OF 48HX CYLINDER TEST PROCEDURE The test cylinder was selected from a regular shipment of similar vessels which had been fabricated, tested, and inspected by normal shop practice (Table I).
The cylinder was chosen on the basis of prior notch toughness tests of samples of steel plate supplied from the fabricator. The shell of the test cylinder, No. 150050, had been formed from Sheet No. 122 of Heat No. 7410895. The notch toughness of this heat of steel is typical of most material going into fabrication of these vessels. The nontypical material appears to consist of a small quantity of steel having a higher notch toughness than that used in the test cylinder.
The test cylinder was modified to allow uranium metal derbies to be placed in it (Figure 1). Small holes were also cut into the top of the vessel for insertion of thermocouples. Copper-constantan thermocouples were peened into the outside surface and tied to the derby frames to monitor the vessel temperature (Figure 2).
During the test, thermocouple outputs were recorded by a Doric Model 220 data logger. A special detachable fixture was fabricated so that deformation of the bottom of the cylinder could be measured between drops (Figure 3).
The vessel was loaded with the uranium derbies after a layer of ice had been frozen in the bottom of the cylinder. After derbies had been put in place, openings were welded shut and the cylinder was transferred to a 36-in. deep concrete tank where it was cooled in a trichloroethane-dry ice bath. Water was slowly added through an opening in the top of the vessel until ice formed within 7 in, of the top. Approximately one-half of the cylinder was submerged in the bath as shown in Figure 4.
The No. 2 thermo-couple inside the cylinder was assumed to be in error. The steel-covered drop pad, next to the cooling bath, was previously constructed for tests of other cylinders.1 A custom-built release system employing an explosive nut mechanism was used for the tests.
- 1. R. Pedigo, et al., Testing of Ten-Ton Uranium Hexafluoride W
Cylinders, Union Carbide Corporation, Nuclear Division, Paducah, Ky.,
October 22, 1965, (KY-500) Unclassified.
Prior to the first drop, the cylinder was remcved from the bath and the inspection fixture was attached so that a set of reference readings could be made across the bottom cf the cooled cylinder. At this time the skin ten-perature at the cylinder bottom was below -90 F (Figure 5).
The cylinder was allowed to warmup until a thermocouple inserted in the recess between the skirt and head read -20 F and the lower skin temperature was -40"F.
The cylinder was then dropped one foot on the plug end at a 35-degree angle (Figure 6). A view of the test site with the cylinder in position to drop is shown in Figure 7.
The checkered panel furnished a background for high-speed movies of the drop. The cylinder was inspected, measured, and dropped again from one foot in the horizontal position. At the time of the second drop, the lower skin temperature was about -33 F.
The cylinder was reinspected, measured, and returned to the cooling bath.
The inspection of the cylinder after each one-foot drop did not reveal evi-dence of cracks in any part of the structure (Figures 8, 9, and 10).
Measurements of the bottom surface (Table II) indicated that the skirt on the piug end, point (J), and shell next to opposite stiffening ring (B) had been deformed after the first drop. The horizontal drop produced further deformation; 9/32 - 13/32 in. of the shell at points next to the stiffening rings.
After the cylinder was cooled to a skin temperature of -60 F, as indicated by thermocouples 3 and 4, it was removed from the bath (Figure 11) and rigged for a four-foot, 35-degree drop (Figure 6).
The skin temperature rose rapidly so that when the cylinder was dropped, the lower skin tem-perature was about -13 F.
After the cylinder was dropped, it was reinspected and measured.
Several cracks had propagated from a small weep hole in the skirt into the head of the vessel and into the skirt (Figures 12 and 13).
Another crack was later discovered when the damaged area was cut out of the vessel (Figure 14).
Examination of the stiffening rings revealed that the ring on the plug end had been driven far enough into the vessel to break the cylinder wall (Figures 15 and 16). Dimensional inspec-tion of the vessel bottom indicated that the third drop had driven the ring an additional 1 1/2 in., point (H), into the cylinder for a total deformation of 2 in. (Table II).
After the third drop, the vessel was weighed and moved to the shop so that material could be cut to make test specimens as discussed in Appendix I.
The gross weight of the vessel was 30,293 lbs.
Twenty-four hours after the test, the ice mass was still frozen after the cylinder upper portion was cut off (Figure 17).
E P. O. 88G-53277-V Job 7528 Cylinder f/6ddId TABLE 1 FORM U 1A MANUFACTURERS' DATA REPORT FOR PRESSURE VESSELS (Alternate Form for Single Chamber. Completely Shcp Fabricated Vessets Only)
As Required by the Provisions of the ASME Code Rules. Section Vill. Division 1 Modern Weldin rr C o m pa t)v r
UplOn C a rbLdc Corpof at16n, Inc.
- 1. Mano,:tured by
- Owensboro
- Nuclea r DLViSlon. Kentticky
- Oak Ridge. Tennessee
- 2. Manufacti.: red for a Locanon of fnsia%t.on OR, P L GAT Gaseous Diffuai Plants IMfp a, cr/pi N.n l L-2.5 SS gyear saim 1979
- 4. Type horizontal gi O (Hons. or vart tant l ICRN)
(Draw.ng No )
(Nat'l Brd No )
- 5. The chemcal and phys. cal propert es of ad parts m :et the requirements of material specifications of the ASME BOILER AND PRESSURE VESSEL CODE. The rksign. constru 3 on, and wornmanship conform to ASME Rules. Section Vm. Devision 1 3 9I E and Addenda toWIn te r I9 77 an
- Code Cue Nos cr ear s to ie Special Service per UG-120(d)
Manufacturers' Partial Data Reports properly ident.fied and signed by Commissioned Inspectors have been furnished for the fo' lowing items of the report N n
- 6. Shell: Matt S A -2 85 -C
.3125
'a 0 48
,n.tgtn. 9 fi 07/8 in.
in. A in o;am.
(Spec No.. Grad.)
- 7. Seamt Long Dbl Butt R T.
e pot E fficiency 85
. H T. Temp.
F Time hr fW eided. Du. Sngl. Lap. Butt)
(Spot or Full)
Gir.h Offs et R.T.
spot No. of courses I m.id.d. Du. Sne. t.o. eun) isnot. Pen..i. or ruii)
S A - 2 8 5 - C,.c. N,. c,.d.
N Materiai S A -2 8 5 -C
.c. No.. c,.d.)
e Heaes. (a) Materisi is asc i=.
u..
c.,
n
.r...
co,-.,
ri.i s.a. co r..~.
.c -
o.
ro r,m ~.,
m
..w.
o Ap.eA v.
R.eirs oin CO.ew.e er Cover ***l-Ends 5/16" min.
2:1 concave c,,
(b) ff remSvable, bolts used (describe other fastenings)
(Maierial. Spec. No. Gr. Site. No1
- 9. Cons:ructed for man. allowable worOng pressure FVR,100 ps; at m3,. temp. 235 F. Min temp. (when less t* an -20 F)
F. Hydrostanc tecicnixxxtDctiincNDrMest pressure 2 0 0. __ _ psi.
- 10. Safew vaive outtets: Number Sue i ncai.on in piping by customer
- 11. Noues anct inspect:on Openings-
- ,s...
n, Nu
- a. r.
- w. ce t o. o %
5,.
t, u,.
m ui
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Inlet 1
1" cou pli ng S A - 105 6000g inherent welded head Outlet 1
1" co upling SA-105 6000# inhe re nt welded head
- 12. Suppoes; $brt no lugs no Legs no Other none
. Attached lyes or nel N) tNo )
(Desu.t,o)
(Wher. and howl
- 13. Remarks TVge "48 H" Cylinder built in accorda nce with ASME Code. Section.VIII.
Div 1 19 77 r.dition.
Ileat Numbe ts:
8 8 MA e2/, f88 2 ~a2/,
7&O8FS~
CERTIFICATE OF COMPLIANCE we cert 'y that sne statements rnad. in this report are corrett and thni att detaels of design, material, construction, and up o 'hg vesset confog. lodern h(efotng drssure Vesseh. S tion Vill. Di :
in the ASP C je for P v.orm nc
.*,,. M
/.L 77 Signed onipany p Date /
(u,g..,i
.a.
"U" bc %f.cate of Authorization No empire Feb i ry 2
, is 80 CERTIFICATE OF SHOP INSPECTION vessei made by Modern Welding Company Owensboro.. Kentucky.
at l, the unde's gned, holding a valid comrres:, ion issued by the National Board of Boiler and Pressure Vessel Inspectors endor twe State or Province of Kcntucky on.i..npiovert byThe H S I - I Coiave inspected the pressu e ve: sci descr4 bed in this Mar ofacturers' Data Report on
/ /2 -. 13 M. and state that, r
to the t.est of my linowledge and belief, the Ma mfacturer has constructed this press,re vessel in accordance with ASME Ct.de. Section VM. Division 1. By signing ins cen.ficate neither the In.pectuc nor his emp' oyer makes any warranty.
empreszd or impl.ed. con <ermng the pressure vess. l d %Cr br d in the Mannhcturers' Data Report. Furthermore, neithcr the inspector nor tys employer shalt be hable in ar.y manner fnt any persona! inpry or property damage or a foss of any k'nd at s r'g fr
' Nr $nnette Dare / # M. cormn.ssions
/
ith sp ?ction KY #684 S.one s on. to.1 (Nat'l Br+a,d Stat.. Prow.nce and No l 11761 h.e f arm t(0011h rosy t a ob%ned from the Ord.r Dept. ASME. 345 L ahh St. New York. N y.13017 TABLE II CYLII; DER DEFORMATION STATION AND LOCATIONI O
A B
C D
E F
G H
I J
Drop Series
_ 0 24 32 48 66 73 90 108 114 126 148 No. 1, 1 ft, 35,
Plug End
+4/322 0
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+2/32
+2/32
-3/32
+2/32
+1/32
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-4/32
-4/32
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-3/32
-15/32
-1/32
-2/32
-16/32 0
-2 2,
No. 3, 4 ft, 35,
5) on Valve End
-8 13/32
-5/32
-1 13/32 -2/32
-6/32
-31/32
-6/32
-10/32
-1 30/32 -6/32
-2 1/32 10 is coincident with the edge of shirt on valve end; locations are given in inches from station 0; J is coincident with the edge of shirt on plug end, as shown in Figure 3.
2Positive values indicate radius increase; negative values indicate radius decrease (in inches).
/000* DERBY (4 RE0'O PER FRAME) 20 TOTAL DERBIES TO BE WRAPPED IN PL ASTIC BEFORE BEING STEEL FRAME PLACED IN FRAME 1
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APPENDIX IV
EQUIPMENT SPECIFICATION SP E C 8 FI C A TION NO.
REV ES-CMD-14864-2 UH10N CARBIDE CORPOR ATION I SSU F DATE R E vi SION DATE NUCLEAR DIVISION 2-20-79 WORK ORDER NO *E50 ETCI O AK RIDGE. TENN.
P ADUC AH, KY.
ESO 14864 SPE CIFIC A TICN FOR PHO CURED BY IN S T A L L ED SY Type 48 HX UFs Cylinder UCC-ND UCC-ND P ROJ E C T (JO B) TITL[
D UI L din G PLANT UFs Tails Cylinders and Storage Yards, Phase I Area PGDP ENGINEERING AND PLANT APPROVALS SIGN ATURE DATEU l
SIGN ATURE DATE Prepored By F G. Guzzy
'P,inci pal En g.
E. E. Brown fgl y,~~/
l2,20 -?l/
) -) l ~ 7T
~
4,,,ov, By B
A. Kress
~ roc,i,,y(e,..c,3 ens,n..,
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)b hw i,i S itt
.c
,i' 7/ - 71 dh 2 w i7
_0. 4 e,, >.,o...n )
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l Plant Divi s.on e
_.l_ __
,._ _\\
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G_..h.v%. opu
& 21 - 7 9_
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PROJECT APPROV ALS St GN ATURE DATE SIGN ATURE DATE 9
REVISIONS l
l l
I l
e
~ ~ - ~., -
m-.
.,m-~.w.-
-_ U CN 11191 (1238 5-7 4 t
EQUIPMENT SPECIFICATION UNION CARBlDE CdRPORATION
_ LS-CM_-14864-2 D
' SSU E DATE REvlBiOH DATE NUCLEAR DIVISION 2-20-79 O AK RIDGE, T ENN.
P ADuC AH, KY.
PLANT PAGE SPECIFIC A TION F OR Type _4_8__HX__U_Fs Storage Cylinders TABLE OF CONTENTS SECTION PAGE 1.
SCOPE....
2 2.
APPLICABLE CODES, STANDARDS, AND...
2 DRAWIf4GS..............
3.
DESIGN SPECIFICATIONS........
2 4.
QUALITY CONTROL..
4 5.
MANUFACTURIflG....
5 6.
CERTIFICATION.
7 7.
DEFECT REPAIR.
8 8.
ACCEPTANCE..............
8 9.
SHOP DRAWINGS AND MANUFACTURER's... 8 DATA........
Manufacturer's Data Required.....
9
. U C N-119 9 2 i1235 9-7 e t
EQUIPMENT SPECIFICATION SP ECi FI C A TION NO
- REV, UNION CARBlDE CORPORATION ES-CMD-14864-2 NUCLEAR DIVISION o AK RIDGE, T ENN. - P ADuC AH, KY.
,[ y "
PGDP 2 or 9
1.
SCOPE 1.1 This specification establishes the requirements for the fabrication, cleaning, testing, painting, and inspecti7n of Type 48HX cylinders which are to be used for limited shipment and long term storage of UF.
6 2.
APPLICABLE CODES, STANDARDS, AND DRAWINGS 2.1 The following are referred to herein and the applicable portions of the latest revisions of the references form a part of this specification.
ANSI B2.1 Pipe Threads (except Dryseal)
ANSI B16.11 Forged Steel Fittings, Socket-Welding and Threaded ANSI B57.1 Compressed Gas Cylinder Valve Outlet and Inlet Connections ASTM A-36 Structural Steel ASTM A-105 Forgings, Carbon Steel, for Pipe Components ASTM A-167 Stainless and Heat-Resisting Chrcmium-Nickel Steel Plate, Sheet, and Strip ASTM A-285 Pressure Vessel Plates, Carbon Steel, Low-and Intermediate-Tensile Strength ASTM A-331 Steel Bars, Alloy, Cold-Finished ASTM B-32 Solder Metal ASTM B-150 Aluminum Bronze Rod, Bar, and Shapes ASME Code Boiler and Pressure Vessel Code ("The Code")
Sec VIII Div 1 Pressure Vessels Sec IX Welding and Brazing Qualifications UCC-ND Dwg.
Cylinder, Type 48HX E-M-14864-B UCC-ND Dwg.
One-Inch Size Valve for UF Cylinder 6
E-J-11246 3.
DESIGN SPECIFICATIONS 3.1 Workina Pressure The cylinder shall be constructed to withstand working pressures of 100 psig internal at 235 F, and 15 psig external at 2350F.
3.2 Materials of Construction 3.2.1 Cylinder Shell and Head Steel shall conform to ASTM A-285, Grade C.
All other steel shall conform to ASTM A-36, unless otherwise noted. u C ~. i i i.,
19239 6 74l
EQUIPMENT SPECIFICATION SP E CI FI C A TION NO REV.
UH10H CARBIDE CORPORATION ES-CMD-14864-2 NUCLEAR DIVISION 2-20-79 o AK RIDGE, T ENN. - P ADuC AH, KY.
gu,,,
PGDP 3
or 9 3.2.2 Pipe Plug Upset forged or extruded or extruded and drawn aluminum bronze CDA Alloy 614 conforming to ASTM B-150 with 0.2-0.3% tin by weight.
Plugs shall have solid hex-head, with one-inch -
11-1/2 NPT (National Pipe Threads) conforming to ANSI B2.1.
After machining, the plugs shall be stress relieved for at least one hour at 8000F minimum.
3.2.3 Couplings Forged steel conforming to ASTM A-105, one-inch half-coupling, 6,000-pound, conforming to ANSI B16.11.
The couplings shall be tapped with a one-inch 1/2 NPT (National Pipe Thread) tap.
Proportions and limits of the threads shall be as described in ANSI B57.1.
Couplings shall be counterbored as detailed on drawing E-M-14864-B.
(Also see 5.4 - Valve and Plug Installation.)
3.2.4 Solder ASTM B-32, Tin-Lead Alloy 50A.
3.2.5 Nameplate Stainless steel,13 gage, ASTM A-167, Type 304.
3.2.6 Valve Guard Carbon steel, ASTM A-285, Grade C.
Set screw shall be alloy steel bar, ASTM A-331, Grade 4140.
3.3 Testing 3.3.1 Hydrostatic Each cylinder shall be tested at 200 psig cylinder pressure.
The test pressure shall be maintained during inspection of all joints.
If leakage is detected, repairs shall be made only as permitted by and in accordance with the ASME Code, and the cylinder shall be retested af ter the repairs are complete.
. UCN111,3 11239 5-741
EQUIPMENT SPECIFICATION sp ECI FI C A TION NO.
REV.
UNION CARBIDE CORPORATION ES-CMD-14864-2 NUCLEAR DIVISION
~
O AK RIDGE, TENN. - P ADUC AH, KY.
pu,s, pg PGDP 4
or 9
3.3.2 Air Following the cleaning, hydrostatic testing, drying and plug and valve installation, each cylinder shall be pressurized to 10 psig using filtered dry air (-400F dew point as measured with an Alnor dew point meter).
The cylinders shall be soap tested for leaks around the valve and plug threads and then pressurized to 50 psig. While under 50 psig pressure, all welds and the plug and valve connections shall be soap tested with no leakage being permitted. Any welded repair must be followed by reapplication of the hydrostatic test, cleaning, drying, and air test.
3.3.3 Vacuum The cylinder shall be prepared for painting and shipment by reducing the pressure to 20-inches Hg vacuum minimum. An air jet ejector is suggested for this purpose.
4.
QUALITY CONTROL 4.1 Procedures 4.1.1 The Seller shall establish and maintain written quality control procedures for manufacturing, cleaning, inspecting, equipment calibration, and testing to assure that the finished product meets the requirements of this specification. Such procedures may consist of, or be based upon, the Seller's written specifications for like practices; or, shall be developed to meet the requirements of this specification.
Industry standards, together with a program of frequent inspection and verification of the Seller's adherence to such standards are acceptable.
4.2 Approvals 4.2.1 The Seller shall, prior to the start of fabrication, submit copies of his proposed procedures to the Company for approval.
Changes in approved procedures may not be made during manufacture without prior written approval by the Company. The Company shall be notified five days in advance of the start of fabrication to allow a Company representative to witness initial production, and shall be permitted access to the manufacturing facilities at any reasonable time to verify that the quality control procedures are being implemented in manufacturing. uC~.,,,,,
(,235 & 741
EQUIPMENT SPECIFICATION SP E Ct t C A TION NO.
REY.
UNION CARBIDE CORPORATION ES-CMD-14864-2 NUCL. EAR OtVISION o AK RIDGE, T ENN. - P ADuC AH, KY.
$n ~
p p,e 9
PGDP 5
O-4.3 Subcontractors 4.3.1 The requirements for certification of materials and control of quality through inspection shall be imposed by the Seller on his subcontractors, if any.
5.
MANUFACTURING 5.1 Fabrication 5.1.1 Cylinders shall be fabricated in accordance with Section VIII, Division 1, " Pressure Vessels," of the latest edition of the ASME Boiler and Pressure Vessel Code and shall be code stamped.
All welders and welding procedures shall be qualified in accordance with Section IX, " Welding and Brazing Qualifications,"
of the same code.
5.2 X-Ray Examination 5.2.1 f minimun of one spot X-ray examination per cylinder shall be made in accordance with Section UW-52 of the Code using a fine grain X-ray film (Kodak Type AA, or Company approved equivalent).
Unless otherwise directed by the Code Inspector, locations of the spot shall be at the juncture of the longitudinal seam and the circumferential head weld, alternating ends for successive cylinders.
Any weld imperfections indicated by the radiographs shall not exceed those permitted by Section UW-52 (except for rounded indications, which shall be required to meet UW-51) of the Code.
5.3 Cleaning 5.3.1 The inside of the cylinder shall be thoroughly cleaned of all grease, oil, scale, slag, loose oxides, dirt, moisture, and other foreign matter.
The surfaces shall be left clean, dry, and free of all contamination, except a thin coating of iron oxide from hydro-testing.
The detailed cleaning procedure proposed shall be submitted for the Company's approval before fabrication is started. A signed cleaning certification form for each cylinder shall be subnitted to the Company.
- U C N+ t 19 9, 11239 8-741
EQUIPMENT SPECIFICATION SP E CI FI C A TION NO R E v.
UNION CARBIDE CORPORATION gg_yg g NUCLEAR DIVISION o AK RIDGE, T ENN. - P ADUC AH, KY.
[,",
p p.g PGDP 6
9 0,
5.4 Valve and Plug Installation 5.4.1 Valves will be supplied to the Seller by the Company with valve threads already tinned with a thin uniform coating of ASTM B-32, Alloy 50A solder. The dimensions of the valves are shown on the referenced drawing. The threaded portion of the valve which will be installed in the cylinder coupling is cut with approximately 13-14 complete threads.
5.4.2 Plugs and couplings shall be furnished by the Seller.
Plug threads shall be tinned with a thin unifonn coating of ASTM B-32, Alloy SOA solder before installation. The one-inch 6,000-pound half-couplings into which the valve and plug are to be installed shall be threaded as specified under Section 3.2.3.
5.4.3 The valve and plug coupling threads shall be chased with a one-inch 1/2 NGT tap after being welded to the vessel hed' 5.4.4 The valve and plug thread engagement shall be obtained using a minimum of 150 and not more than 400 ft-lb of wrench torque.
Torque wrench shall be applied to the valve body and not to the bonnet nut. An indicating torque wrench shall be used for valve and plug installation.
No material of any kind, other than the specified solder, shall be used on the threads to facilitate installation. A minimum of seven and a maximum of 12 valve threads shall be engaged.
For the plug, a minimum of five and a maximum of eight threads shall be engaged.
5.5 Cylinder Capacity 5.5.1 The Seller shall determine the capacity of each cylinder by completely rilling the cylinder with water.
The weight of water contained in the cylinder and the water temperature shall be recorded. The cylinder shall have a minimum water capacity (corrected to 60 F) of 8,670-pounds of water (139.0 ft ).
3 Upon completion of fabrication, painting, and evacuation of the cylinder, the tare weight of each cylinder shall be determined.
The water capacity in pounds of water at 60oF af ter tare weight shall be stamped on the nameplate of the cylinder.
The Seller shall submit to the Company for approval the procedure for this operation before starting fabrication. ucN. m..
19239 9 741
EQUIPMENT SPECIFICATION SP ECI FI C A TION NO REV-UNION CARBIDE CORPORATION ES-CMD-14864 2 NUCl. EAR DIVISION 2-20-79 O AK RIDGE, T ENN. - P ADUC AH, KY.
pu,sy
,,,o PGDP 7
9 Or 5.6 Identification 5.6.1 Each cylinder shall have a stainless steel nameplate, as shown on the referenced drawing, permanently attached to the cylinder.
The nameplate shall state the serial number of each cylinder, numbered consecutively, starting with a six digit number specified by the Company.
5.7 Painting 5.7.1 After interior cleaning and all testing has been completed, the exterior of the cylinder shall be cleaned and prepared for painting.
Before painting, the exterior surface shall be free from all foreign material such as oil, grease, soap, loose mill scale, welding slag, and moisture.
The cylinder shall be primed with one coat of zinc chromate, Pittsburgh No. 6-204, or approved equal, and finish painted with one coat of Avocado, Pittsburgh No.54-304, or approved equal.
The valve and nameplate shall be completely masked so that no part is painted.
6.
CERTIFICATION 6.1 Mill Tests 6.1.1 The Seller shall furnish to the Company one certified copy of mill test reports including chemical and physical analyses on each heat of material used in fabricating cylinders.
Serial numbers of cylinders shall be identified as to heat number of materials used in the cylinder fabrication.
6.2 Inspection and Testing 6.2.1 The Seller shall furnish to the Company one completed copy of the manufacturer's data sheet ASME Form U-1 for each cylinder.
The Seller shall also furnish to the Company certification that each cylinder has passed the air-soap test as specified in 3.3.2.
6.3 Capacity Statement 6.3.1 The Seller shall submit to the Company the calculations used to determine the water capacity of each cylinder. U C N. I l l6 3 (1239 6 741
EQUIPMENT SPECIFICATION ha E Ci FI C A TION NO REV-UNION CARBIDE CORPORATION ES-CMD-14864-2 NUCLEAR DIVISION O AK RIDGE, TENN. - P ADUC AH, KY.
,y y,,,
PGDP 8
9 Or 6.4 Miscellaneous Cer_tifications 6.4.1 The Seller shall submit to the Company for each cylinder a verification of performance for:
a.
Section 5.2 "X-Ray Examination" b.
Section 5.3 " Cleaning" c.
Section 5.4 " Valve and Plug Installation," data indicating the actual torque applied and the actual number of threads showing after installation.
6.5 Certification Package 6.5.1 The Seller shall submit to the Company all required certification data, as a " Package," identified by the Company cylinder number.
7.
DEFECT REPAIR 7.1 Repair of all defects failing to comply with this specification and retesting shall be at the Seller's expense.
8.
ACCEPTAf1CE 8.1 Final acceptance will be at the designated DOE plant. Acceptance will be based on (1) review of the Seller's certified test reports; (2) visual inspection of workmanship, cleanliness, and the condition of all attachments; (3) cylinder dimensicl inspection; and (4) cylinder vacuum check.
Failure to meet
'e bove requirements shall be cause for rejection of the cyl 9.
SHOP DRAWINGS AND Mt.NUFACTURER'S DAT!
9.1 The Seller shall furnish the Company. op drawings and manufacturer's data as specified on the " Manufacturer Dat, Required" torm on page 9 of this specification.
Only after t.ie Compaay's approval shall the Seller proceed with fabrication.
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19239 5 74)
M ANUFACTURER'S DATA REQUIRED
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UNION CARBIDE CORPORATION sa a c. on o a r a e r wo.
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J" nucLL AR DiwS:ON ES-CMD-14864-2 Wr, vsaa
- o. nu m,,w un n 9
o rr 9
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o~. o wu.~. ~ 1 ~ ~ e o. s HUMBER OF COPIES Type 48HX UFc Storage Cylinders
$"t[$iN
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t, a t, 7
m ge
,e THE SELLER SHALL FURNISH h.*
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- a x
c.
c o 3 D AT A BELOW IN QU ANTITIES SHOWN i
a
<d 22
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OU TLINE DlMENSION DAG. -- INCLUDE TOTAL WT. OF EQUIPMENT 3
1 ASSEMDLY DRAWINGS 3
1 DETAll DR AnlNGS - MECH ANICAL FLOW DI AGRAMS PANEL WIRING DI AGR AMS ELEMENT ARY WlRING DI AGR AL
( A ccord*ng to torns Indus erral Counc ol Srd. t INTE RCONNECTING WIRING DIAGR AMS
( Ae<ord,ng so Jo rne Indusernal Councal Std.)
~ _ - - _.
MATERI AL CERTIFICATION
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%ELDif4G PROCEDURES 3
1 OPERATING DATA AND PERFORMANCE CURVES TEST REPORTS
]
MANUF ACTURERS DAT A REPORT ON UNFIRED PRESSURE VESSELS INorronal Doord Cern f aanon of Inspec t.on FORM U.11 SPARE PARTS LIST - INCLUDING RECOMVENDATIONS FOR 1 YEAR (Cos h part o s e, he desc rohed and ode,,sofred in ssll < >e..r de roul to permer procurement from
--the oro gunal man viac turer, or from any s uppl,er).
OPERATING AND MAINTENANCE INSTRUCTIONS LUBRICATION INSTRUCTIONS RECO'. WENDED PIPING AND INSTRUMENTATION INSTALLATION INSTRUCTIONS SCHE MATIC OF LOGIC DI AGRAMS f En< F. v on.pc., e< s,n.oll be de n r obed and udent f ed an s uff re n ent deroel ro permit proc uremen t I,<., he r..s...a,...e., e.., e e,
- s., f,o,, o,,,, m,s.,,..
Proposed Quality Control PrOCedur_e_s_ _ _.
3 1
Welding Qualifications 3
1 Certifications (X-ray, Cleaning, valve and plug 1
installation)
GENER AL F40TES.
1.
Wa rh a wee k s ofree on ard of subcontrac e the SeIIer shall furnish the requored number of dato and dro-ungs "For Approvol" an d ' < r ' A dv o.v Engmeerung' as ourioned on the roble above. Subsequent reves nons shall also be opproved.
2.
"Cers I.cd Correc r dura and dro..ngs are reev, red preor to dolovery of equ.pment and / or morernal. Each copy of enformorion sl.a'l Le n-ork ed so onda are Compor.y's Purc ha se Order No., Eq. opes,r No. ond Man ufac tu er's Mooel and Sersal No.
r U r_ N. i ; 4 4 a: m
d APPEtlDIX V e
Number QA-E-11A
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Quality Assurance oa, 2-20 m UNION CARBIDE CORPORATION Revised NUCLEAR DIVISION Page 1
Of 6
PADUCAH, KENTUCKY e
Subjeet:
4811X UF LIMITED SilIPMENT AND LONG-TERM STORAGE CYLINDER PROCUREMENT 6
1.
SCOPE This document describes the quality assurance plan for the procurecent of 14-ton Model /*81IX cylinders for limited shipment end long-term storage of UFs. The plan identifies the systematic actions to be taken and the responsibilities of those taking the actions to assure that the purchased cylinder meets the specified requirements and is fit for the intended use.
2.
REFERENCE DOCUMENTS (Latest Revisions Apply) 2.1 QA-E-1, Quality Assurance Program, Plant Engineering 2.2 ANSI N14.1, Packaging of Uranium Ilexafluoride for Transport 2.3 UCC Drawing, E-M-14864-B, PGDP, Model 4811X UFs Cylinder 2.4 ES-CMD-14864-2, Sepcification for Model 48HX Cylinder 2.5 JSP-532, PGDP, Specification for 1" Angle Drum Valve for UF6 Service 2.6 ME6I Procedure No. 68, PGDP, Inspection - Type 48HX Cylinder 3.
P(7FENTIAL SIGNIFICANT QUALITY FAILURES The Model 481IX UF cylincar is assigned quality assurance level two as 6
defined in Plant Engineering QA Program, QA-E-1, indicating that the project involves unusual features for which quality cannot be assured through the application of normal standards and procedures. Failure or malfunction of these features could result in a monetary loss, damage to the cylinders or occasional releases of UFs to the immediate surroundings.
Specific areas in which a quality failure would be significant are as follows:
3.1 Welding The scam welds in the body of a cylinder and the head welds to the body must conform to the codes specified in the reference documents in Section 2 to preclude weld failures and subsequent UF release during operational use, handling, or shipping. In 6
most handling operations, the 4811X cylinder is lifted by the lift-ing lugs. The lifting lugs can also serve as tie-down devices Approved by b.
6LU M
Pr e p a r e d by D r
F[
DI Vi$10N Q A CQO R DIN A TO R ucs.oec is o.n
Number Q A-E- 11 A Date
_$ ~ 2 0 -)_2 Revised Page 2
og 6
Subject:
48HX UF LIMITED SilIPMENT AND LONG-TERM STORAGE CYLIiOER PROCUREMENT during shipment of the cylinder. Therefore, the welding of tne cylinder stiffening rings and the welding of the lifting lugs to the cylinder shell must be designed with sufficient safety factor to preclude weld failure and associated cylinder damage.
3.2 Cylinder Volume When the cylinder is filled to the prescribed limits with UF, the 6
UF in the cylinder can be in a liquid-solid state. When the filled 6
cylinder is subsequently heated prior to being sampled or emptied, the UF contents can be entirely in liquid form, and at a lower density 6
than the average UF density at the time the cylinder is filled. There-6 fore, the internal volume of each cylinder must be known to assure that the design safety factor is sufficient to preclude hydraulic pressure build-up within the cylinder. This volume is to be certified and docu-mented.
The water weight in pounds for this volume is to be stamped on the nameplate.
3.3 Cicanliness The interior of each cylinder must be free of all contamination except for the light iron oxide film formed during hydrotest. UF6 will react with all hydrocarbons and moisture to form solid uranium compounds and other by products. These products, as well as foreign matter, Ocn lead to such problems as improper cylinder valve seating or piogged valves.
3.4 valve Installation The valve inlet nozzle must be engaged in the coupling for a minimum of seven threads and a maximum of twelve threads using a torque of 150 foot pounds minimum and 400 foot-pounds maximum. The minimum of seven threads engagement assures that sufficient cross-sectional area of the valve is engaged in the coupling. A maximum of twelve threads engagement assures sufficient clearance for attaching a pigtail to the valve outlet nozzle. The lower torque limit is adequate for the cylinder hydrostatic test and the upper limit assures no damage to the threaded inlet nozzle or valve body by overtorquing.
4.
GENERAL CONCEIT AND RESPONSIBILITY Variable operating conditions of the gaseous diffusion complex may extend the agreed time frame for emptying and returning customer owned cylinders to the customer. To meet the agreed time period for return of the customer's Number QA-E-11A Date 2-20-79 Revised Page 3
of 6
e
Subject:
481[X UF LIMITED SilIPMENT AND LONC-TERM STORAGE CYLINDER PROCUREMENT 6
cylinder, a liquid transfer of UF, to DOE cylinders would be necessary.
To preclude this transfer, DOE cylinders, Type 48HX, will be procured and sent to the customer to be filled with normal UFs and returned to the gaseous dif fusion complex for extended storage. Procurement of these cylinders will be made through a purchase order originated by the Paducah Plant.
Procurement of UF c'linders will be conducted in a manner consistent 6
with Union Carbide quality assurance policies. The objective is to prevent significant quality failures through proper design, adequate planning, clear placement of responsibility and systematic follow-up at minimum overall cost.
Drawings and specifications are referenced in Section 2.
Execution of procurement action will be primarily the responsibility of the UCC-ND Central Purchasing Division at Oak Ridge with Paducah Purchasing serving as liaison. Paducah Plant Engineering will coordinate those activities associated with the establishment and maintenance of this quality a surance plan. Section 5 describes the standard quality assurance measures to be applied and designates the person or organization having the primary responsibility for each of the quality assurance activities.
5.
STANDARD ACTIVITIES 3.1 Engineering Criteria - Primary Responsibility:
Principal Engineer Engineering criteria in the form of drawings and specifications have been prepared. Test and inspection instructions for critical features and dimensions will be prepared for use in Company source surveillance and receiving inspection. These criteria and instruc-tions will be reviewed for completeness and adequacy by the several organizations at the Paducah Plant who use or maintain these cylinders.
The equipment specification, ES-CMD-148 64-2, contains minimum requirements for quality contrcl to be placed upon the vendor and defines the basis for acceptance in keeping with the objec-tives of this document.
5.2 Source Selection - Primary Responsibility: UCC-ND Purchasing The UCC-ND Central Purchesing Division will select potential sup-pliers on the basis of demonstrated capability to provide similar Number QA-E-11A Date 2-20-79 Revised Page 4
of 6
Subject:
48HX UF LIMITED SilIPMENT AND LONG-TERM STORACE CYLINDER PROCUREMENT 6
products of appropriate quality. Only those deemed capabic of quality performance will be invited to bid. The knowledge and experience of persons in other groups will be used in the selection process. Central Purchasing will be responsibic for imposing the qualit'/ rer,uirements on the vendor through the appropriate contract language.
5.3 Technical Liaison - Primary Responsibility:
Principal Engineer Technical Support and review will be provided by personnel in the PGDP Engineering, Operations, Maintenance, Technical Services, and Inspection organization at the Paducah Plant. The Principal Engineer will coordinate the activities of all technical support personnel.
/
5.4 Vendor Quality Control - Primary Responsibility: Vendor Administration of this aspect of the contract will be in accordance with ES-CMD-148 64-2.
In determining vendor conformance to quality requirements, UCC-ND Central Purchasing will be the of ficial contact channel with the vendor regarding nonconformities.
If technical re-view is indicated, the request will be forwarded to the Principal Engineer for review.
5.5 vendor Surveillance - Primary Responsibility:
Paducah FE&I Dept.-
Material Handling and Pressure Vessel Section Vendor surveillance is a systematic watch over procuction and quality control operat ions, including occasional tests and mea-surements performed by a Company representative at the vendor's site.
An inspector from the Paducah Plant Metallurgical Engineering and Inspection Department (ME&I Dept.) will be at the vendor site at the time that fabrication and testing of the cylinders are initiated to assure adherence to the latest revision to specification ES-CMD-14864-2, drawing E-M-14864-B, ASME Code, and any special test and inspection instructions furnished by the Principal Engineer.
Sur-veillance will include checking scale calibration with test weights as required by the specification. The Principal Engineer will re-ceive a copy of the vendor surveillance report.
Number QA-E-11 A Date 2-20-79 Revised Page 5
of 6
Subject:
48HX UF LIMITED SHIPMENT AND LONG-TERM STORACE CYLINDER PROCUREMENT 6
When there is evidence that fabrication, assembly and testing activities are consistently producing specification cylinders, the Company inspector will leave the vendor's site.
The Company will then periodically send an inspector to the vendor's site for surveillance during the contract duration.
5.6 Receiving Inspection - Primary Responsibility:
Paducah FE&I Dept.
Material Handling and Pressure Vessel Section Receiving inspection will be conducted on a sampling basis upon receipt at Paducah. The Inspection Department will be responsibic for conducting the cylinder inspections using the drawings, speci-fications, and sampling plans furnished by the Principal Engineer (Ref. Section 5.1).
An acceptable cylinder inspection procedure is referenced in Section 2.6.
5.7 Acceptance of Nonconforming Material - Primary Responsibility:
Principal Engineer The Paducah ME6I Dept. will obtain disposition of nonconformities as follows:
a.
Cylinders found to be out of conformance to the ASME Boiler and Presrure vessel Code will be returned to the vendor, b.
Cylinders with other features found to be out of conformance to the drawings and specifications during receiving inspection will be placed under control pending technical evaluation by the Principal Engineer. Acceptance of cylinders with these nonconformities and documentation of the deviation will be the responsibility of the Principal Engineer.
5.8 Quality Evidence - Primary Responsibility: FE&I Dept. - Material Handling and Pressure Vessel Section Evidence of vendor quality is a part of ES-CMD-14864-2, and the folloaing certifications will be furnished by the vendor to the Company for each cylinder:
a.
Materials of construction b.
Measured capacity Number QA-E-11A Date 2-20-79 Revised Page 6
of 6
Subject:
481DC UF LIMITED SilIPMENT AND LONG-TERM STORAGE CYLINDER PROCUREMENT 6
c.
Cylinder cleanliness d.
Valve installation c.
Air-soap test f.
ASME Form U-1 g.
X-ray examination The Paducah ME&I Department has the responsibility for maintaining the file point for all cylinder fabrication, inspection and QA records. Files will be maintained by Purchase Order and serial number for future reference. Nonconforming material inspection reports are handled by the Principal Engineer. Nonconforming material reports are sent to ME&I.
5.9 Audits - Primary Responsibility: Engineering QA Coordinator Audits of this plan and associated procedures will be made at speci-fled times by a team selected by the Engineering QA Coordinator with the approval of the Mechanical Engineering Department Superintendent.
Spot audits may be conducted at any time as desired.
DISTRIBUTION PGDP R. C. Baker D. H. Stitt H. D. Bewley W. C. Taylor S. C. Blue A. M. Tuholsky D. L. Castro E. A. Waggoner J. C. Gillespie C. W. Walter F. G. Guzzy P. D. Wright G. T. Hull C. D. Zerby F. E. Kosinski Library - RC T. R. Odom m
DOE - ORO Y-12 W. A. Pryor (25)
J. D. Griffin
.