ML19296A040
| ML19296A040 | |
| Person / Time | |
|---|---|
| Site: | 07109023 |
| Issue date: | 10/10/1978 |
| From: | Williams C NL CHEMICALS (USA), INC. |
| To: | Macdonald C NRC OFFICE OF NUCLEAR MATERIAL SAFETY & SAFEGUARDS (NMSS) |
| References | |
| NUDOCS 7810270230 | |
| Download: ML19296A040 (213) | |
Text
Rev.3 9/78 Allowable Stresses for 6061-T6 Temperature of the Spacer is determined by an average of the Inner plate of inner closure and the top end of the basket.
(Ref. Sect. VIII -
Appendix D) 355 + 425
390 oF t
2 From Ref: 27, Figure 3.6.1.2.1 (a)
Table 3.6.1.0 (f)
Percent of Ult at temp. considered =
68%
FTU = 42,000 psi Allowable tensile stress (Saa = 0.9Su ) for A1.6061 T6 at 390 oF from Sect. 1.1 under cask internal structure and Sect. 1.2 equals.68 (42,000) (.9) =
STA = 25,704 psi A!!cuable Shear stress (.55, = 0.5dSu) for A1. 6061 T6 at 390 oF 3
from Sect. 1.1 under cask internal structure and Sect. 1.2 equals Ssa =.68(.54) (42,000) = 15,422 psi Allowable Bearing Stress = Sbr = (.68) (.90) (67,000) = 41,004 psi Allowable Weld Stress In a welding operation, dealing with either a strain.
hardened or heat tempered aluminum alloy, it is impossible to reduce T6 temper to a value less than 0 condition temper. Therefore, the computation of weld allowables may use 0 condition stress allowables as a conservative minimum in the applicalbe equations.
For the O Condition FTU = 18,000 psi (Ref.14)
Allowable Shear in Weld = 90% (.68) (.6) (18,000) = 6,610 psi Allowable Tension in Welc.
00% (.68) (18,000) = li,016 psi pj $ O)-3D XI-4-68
Rev. 3 - 9/78 PWR Fuel Element The PWR Fuel Element maintains structural integrity in the top impact condition due to load transmission in the pure compressive mode.
The basic fuel bundle is tied together by seven spring clip grids that transmit compression to the guide thimbles which in turn resolve the load vectors into the adaptor plate or the top nozzle assembly.
The adaptor plate is a structural component which allows the upper spacer to pick up axial loads on the spacer plug compression legs located at two of the four local hard points. If structural failure were to take place in the Zircaloy-4 Guide Thimbles, the relative movement of the fuel bundle to the absorber sleeve would be limited to less than one inch by the adaptor plate assembly. In all probability, the most severe failure mode that would occur in the top end impact would be a local crippling phenomenon in the guide tubes which would not pose any relative motion problems.
XI-4-69
Rev. 3 - 9/78
. Adjacent hard pctnts on the Fuel have two holes in each bearing surface, one being.875 in diameter and the other having a diameter of.555.
555 PM
/
Top View of Fuel Pick-Up Point
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2 (1.1)(1.17) -Tr (.555 ) -
(.38)2 Area =
/,j7
'9 4 ' '
^
7bP V/E~k/ of" FUEL Pick u P 51,000 Po/^/ 7 - FULL SC4LE 4 x.932 = 13,680 psi Sbr
=
~
41,004 _ 1 = 1,99
-a-3 4--
M.S
=
13,680
~
Q
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s N'
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(.3)2 Area = (1.0)2 _7p (
\\'/
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2 Area = 1.0
.601
.0706 =.328 in
+/. O +
51,000 br 4 x.328 M.S'. 41004 - 1 =.054 38871 XI-4-70
,/
Rev.3 9/78
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XI-4-71 i
Rev. 3 - 9/7 e
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XI-4-72 3
Rev. 4 - 9/78 e
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XI-1-73
Rev. 4 9/78 Blocks'as simple beams:
F/2 = 1700 x 30 = 25,500 lbs
+eysw M = 25,500 x 4-1/8 = 105,188 in lbs.
2 Z = 8k x 1.75 4.21 in3
=
6 1
S = 105.188 = 24,980 psi 1 4 b
fg 4.21 4
25,704 a
n lp lyg M.S=24,980 -1 =.029 (Conservative)
Plate and Ring in Compression
/
4 O
~ 3/ O'a.
Wr. 200 *
'7bT A 1.
Total load against closure head = 952,650 + 30 (2001 = 958,650 lbs.
area plate and ring = (3/8tf 31) + (3/8 x 30.25) = 47.86 in2 S = 958,650 = 20,030 psi c
47.86 M.S.= 25,704
-1 =.283 20,030 Stability of cylinder Roark - Table XVI -Case M-ends not constrained (conservative) 51 =.3 E t/r =.3(10,500,000) 3/8 = 76,210 psi (critical) 15.5 Actual Sc = 20,030 psi 0K All welds are in compression, if considered loaded at all, since stack-up of members allows direct contact for transmission of loads.
XI-4-74
ev.
7 INTENTIONALLY LEFT BLANK Also the following pages:
XI-4-76 Rev. 4 77 3.
78 4
79 4
80 4
81 3
Bla 1
81b 1
XI-4-75
Rev. 2 - 9/78 4.4.8 Containment Vessel Valves Each containment vessel valve assembly consists of a quick-disconnect valved nipple, a base plate and a cover.
Details of the assembly, in-cluding seals and mounting bolts, are given in drawing 70651F.
Four bolts, 3/8 - 16 UNC, hold the assembly in place on the top forging and provide ample clamping force to maintain the seal under all normal and accident conditions of transport.
Cask accC : ration in the top end impact is 309 General configuration of valve assembly:
y Forging Cover
/
l k-2. I ->/
No.785
+O.785<l-4.62
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30G Weight and C.G. location of valve assembly are as'follows:
Q/D W1 = 1.9 lb. ; Yj = 2.5 in.
Base W2 = (.285)(4.38)(6.19)(1) = 7.7 lb. ; Y2 = 0.5 in.
XI-4-91
Rev. 2 - 9/78 2
2 Cover W3 = (.285) (4.375 )(3.63) - (#/4)(2.96 )(3)
= 13.9 lb.
Y3 =.19.8(2.8) - 5.9(2.5) (1/13.9) = 2.9 in.
Tctal weight, W = 1.9 + 7.7 + 13.9 = 23.5 lb.
C.G. location, Yo = (1/23.5).5(7.7) + 2.5 (1.9) + 2.S(13.9)
= 2.1 in.
Impact load 030g, P1 = 30 (23.5) = 705 lb.
2 Pressure load, P2 = (#/4) (3.094 ) (72.9) = 548 lb. (Sect. 3.3.2)
Seal load, P3 = #(3.094) (700) = 6804 lb.
(see section VI for seal seating load of 700 lb/in)
Total load, P = 705 + 54C + 6804 = 8057 lb.
load / bolt, F= 8057/4 = 2014 lb.
Since the bolts are each preloaded to 2533 lb (Sect. 4.6.4), the valve as'sembly remains clamped against the f01 gin 9 in the top end impact and the seal is maintained.
M.S. = (2533/2014) - 1 = 0.26 XI-4-92
Rev.5 9/78 4.5.6 Bottcm Support ;or Basket - M',R The support for the Aluminum Basket, Absorber Sleeves, and Spent Fuel Elements consists of a lower 1/2 inch plate, an outer ring of 1/4 inch thickness and 1/2 inch thick Aluminum (6061-T6) plate welded together into a H configuration (NLI drawing 70652F).
See sketch on page XI 109 which shows the C & E, Westinghouse and Babcock and Wilcox Fuel foot-prints with a superimposed outline of support H.
The support H is in direct compression from loads due to the bottom end shock forces, the 1/2 inch thick lower plate merely acts as a device to position and main-tain the orientation of the supports relative to the fuel foot print locations. The support H's are welded to the 1/2 inch circular plate.
The geometry of the support H also allows the sleeve loads to be carried in direct compression.
The absorber sleeves and fuel elements are reacted at two diametrically opposed corners.
Both the sleeves and the fuel elements are sufficiently supported and due to the structural integrity of both units, any differen-tial shear within either the fuel or sleeves is negligible.
XI-4-108
Rev.4 9/78 F1)EL BUNDLE OUILINE
/'
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A
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Rev. 4 9/78 6
Detennination of Properties Assume an end impact load of 30 vrith a fuel element design weight at g
1700 pounds.
Assune an equal distribution of shock loads to each two H supports, and uniform loading over H section because of t inch plate.
R1 = 30(1700)(1/2) = 25,500 pounds for fuel R2 = 30( 770)(1/2) = 11,511 pounds for sleeve 37,011 2
Itan Area y
Ay d
Ad yn 1
8xl/2 = 4
.25 1.0
.75 2.25
.083 2
2xl/2 = 1 1.5 1.5
.5
.25
.333 3
3x1/2 = 1.5 2.75 4.125 1.75 4.59
.031 6.5 6.625 7.09
+
.447 Iy = 7.09 +.447 = 7.537 Z = 7.537 = 3.77 at edge of iten 3 2
A110wabic stress (Saa = 0.9 Su for Al. 60Gl-TG at 4380F from Sect. 1.1 under cask internals structure and Sect.1.2 equals to (.9)(.43*)(38000) = 1470Gpsi Refer to Ref. 27, Table 3.6.1.0(e) and Fig. 3.6.1.2.l(a) t
- Tanperature correction factor (Ref. 27 - t = 4380F XI-4-110
Rev. 4 9/78 Analysis of various fuel stress conditions For h'estinghouse fuel - eccentricity is + 1.125 in.
Sr = 11 = 25,500 x 1.125 = 7609 psi z
3.77' Sc = P_ = 37,011
= 5691 psi A
6.5 Total
= 13,303 11.S. = 14,70G -1 =.105 13,303 For Combustion Engineering fuel - eccentricity is
.5 in.
Sf = 25,500 x.5 = 3,382 psi 3.77 Se =
5,691 psi
'Ibtal = 9,076 psi h!.S. = 14,706 -1 =.62 9,076 ForBabcock and %'ilcox fuel - eccentricity is
.25 in.
Sf = 25,500 x.25 = 1,691 psi 3.77 Se=
5,691 psi
'Ibtal = 7,385 psi 11.S. = 14,70G -1 =.99 7,385 XI-4-111
Rev. 1 9/78 BLN E PAGE XI-4-ll2
Rev. a 9/78 BIANK PAGE XI-4-112a
Rev. 5 9/72 BIANK PAGE XI-1-112b
Rev. 5 - 9/78 4.6 Side Impact 4.6.1.
Outer Closure IIcad During the side impact the outer closure head is subjected to an acceleration of 81 g in the plane of the closure.
Integrity of outer closure must be maintained to protect containment vessel valves, s
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IMPACT LIMITER S
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Weight of outer closure = 2328 lbs.
Lateral force on closure F = 81 >: 2328 = 188568 lbs.
Analysis of bolts in shear:
Outer closure is bolted down with 28 I!; !n. dia, bolts.
Yield strength of bolts at250 F is 85,000 psi (Sect.1.2)
Ultimate tensile strength at 250*F is 130,000 psi (Sect.1.2)
Shear area of 11.;-8 bolts at the shear plane is 0.9408 in.
XI 114
Rev. 5 - 9/78 I
188,.% 8
= 7,158 psi Shear Stress S
=
=
s 28A 28 x 0.9408 Tensile stress in the bolts from preload is 12158 psi.
(Sect. 3.11)
Effective Stress (0 - 0)2 + (0 - 12,158 )2 + ( 12,158 - 0) + 6(7,158)2
=
Sg S 2 = 17,3G1 psi.
e During the impact accident condition, the Allowable Stress for the bolts is conservatively set at the static yield strength of 85,000 psi. This is well below the' accident allowchic stress of 0.9 S
.1) and assures an u
adequate margin of strength in the bolts during the subsequent puncture acci-dent condition (Sect. 4.8.1).
85000 M*S*=
1 3.90
=
173G1 XI-4-115
Rev. 4 9/78 4.6.1.1 Inner Closure During the side impact the inner closure is subjected to an acceleration of 81 g in the plane of the closure. Integrity ofinner closure must be maintained to provide the desired containment of the cask contents.
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Surface i
N f l/
p
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w 58" Dia.
Weight of Inner Closure =7400 lbs.
Lateral force on closure, F = (81) (7400)
F = 599,400 This force will not be taken by the bolts in shear since the radial clearance between the closure head and the cask forging is less than the radial clearance between the stud and the bolt hole in the. closure.
XI-4-llo
Rev. 5 9/78 Calculating bearing stress on the 304 S.S.
h forging 2
b=f=
= 5,512-psi A = 1.875 x 58 = 108.75 in S
A 108.75 Bearing stress allowabic (S rd = 1.35 Syd) for 304 S/S at 3250 b
from Sect.1.1 and Sect.1.2 equals 1.35 '(41200)= 55620 psi 55620 M.S. =
5512 i
Lateral movement of the inner closure before contact with the cask top forging is limited to the diametral clearance of 0.010 in.
(See Dwg. 70651F, Sheet 4). The sealing surfaces of closure, forging and silver-platea G-ring seal are wide enough, radially, so that lateral displacements of 0.010 inch will not cause loss of seal integrity according to the seal manufacturer (Ref. 84). IIence, the pressure seal will be maintained for the snall lateral nove-nonts of the closure that are possible.
4.6.2 Bending of Containment Shells During the side impact the cask is subjected to a 81 G acceleration which produces large bending moments in the cask containment structure. These moments are resisted by the inner and outer containment shells and by the water jacket shell.
Conservatively, additional support from the lead and the end forgings for this analysis is ignored. Stresses on the shells are within the allowables based on ultimate strengths.
Hence, the containment feature of the cask design is main-tained and retention of the contents is assured.
XI-4-116a
Rev. 2 - 9/78 4.6.4 Containment Vessel Valves In the side impact the cask acceleration of 819 acts in a transverse direction to the valve assembly, which causes a moment tending to open the joint between the valve assembly and the forging.
Loading is as follows: y
', Fo res i ns p-2.1 ->
/ 26
- ] See Sect. 4.4.8 for weight,
/
96_
/
dimensions, pressure and seal 9
3,4j
/
loads.
/2fz1 A - rotation axis of joint.
V Blw
/,/ ^ o.97]_ y.
F2 = (.97/3.41)F1 = 0.28446F1 1
A /gOf 6 Taking moments about A:
(2.1) (81) (23.5) = 3.41(2F ) + 0.97(2 F ) = 6.82F1 + 1.94 (0.28446)F1 1
2 F1 = 3997/7.37 = 542 lb.
Adding pressure and seal loads gives F max = (1/4)(680a + 548) + S42 = 2380 lb.
Bolt preload torque is set at 2001 10 in-lb to provide a minimum bolt load of 190/(.2)(.375) = 2533 lb. and thus maintain the joint seal in the side impact. Allowable bolt stress 03250F = (2/3)(88000) = 58667 psi. (Sect. 1.2.24)
At maximum preload the tensile stress is 210/(.075)(.9775) = 36129 psi.
M.S. = (58667/36129) - 1 = 0.62 XI-4-123
Rev. 5 - 9/78 4.6.5.2 Support under sincle PWR Sleeve (Case 2)
This support consists of a 3/8 in. S.S. top plate 95 in. vide and 161 in. long beneath the sleeve, combined with 5 velded 1/4 in, thick S.S.
plates on edge to form a water passage, and a botton S.S. plate 1/4 thick.
J bsorber Sleeve W=1700 M
770 9.705 Hole in Basket 3/8
-2h70#
9.633 Sleeve 3.
[0 T' 8.80 Plate p' i
_[
-1 i,
k typical 7
-){
g 2" t g 50 plate g
Load per fuel stiacer crid (7 divisions of 23 in length) 2h70 x 81g F
=
28,581 lbs.
=
7 P
p
- 3090 lbs/in
=
g 9 25 Since the slope over each longitudinal. stz.it is zero, the effcet is that of fixed ends for the 2" vide section of the support plate.
Such a beam can be considered as 2 end cantilever sections with a central length which is simply supported between the points of inflection.
I S.S. Beam
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Moment Diagra Y
XI 123 L
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Rev. 5 - 9/78 Bearing on alt minum licament of S.S. strut plates While the.tc au a om the fuel elements is applied to the strut plates at intervals of 23 inches, the stiffness of these plates as deep beams is very effective in distributing this load into the supporting aluminum ligament. This is checked by calculating the deflection of a 23 inch segment of a continuous beam under uniform loading with fixed ends. In this case the actual load lines become reaction supports in the application of formula from Ref. 3, Table III Case 33 Load on each strut plate over 23 in. lengta and 2 in. width W
3090lbs/in x 2"
=
6180lbs per strut plate
=
7 1
in this case represents a waviness of contacting edge.
3f4 EI
]3 23 12167. in3
=
=
6 26.3 x 10 pc1 E
=
I it calculated for the T shape shown in the sketch.
To find Neutral Axis Area Moment (3/8 x 2) (3/16) + (1/4 x 3.375 (2.1325) = li799
= i l
p.375 4
q Yc 1.79
= 1.1045 in.
=
_s
. 75"+.87875 I
S.515 1.1045 2 x.3753 +.25 x 3.3753 +.75 (1.1045.1875)2 I
=
12 12
~25
+
.87875 (2.1325-1.1045)2 i
2:3688 in4 I
=
Max. deflection of strut.
5180 x 12167
=.00314 n y
384 x 26.3 x 106 x 2.3688 XI-4-1230
Rev. 4 - 9/78 "b
11520 2 (32341-11520)2 8
2
+ 6(8240)
+ 6(4120)
+ 32341
+
t
.7071 (46059) 32568 osi
=
=
0.63 M. S., =
53100
-1
=
32568 Euckling Analysis of strut plates A series of 5 strut plates extend the full 161 in. length of the support. The section of each is 3.515 in. high by.250 in. thick.
Each plate passes under the transvcrse foot of the fuel spacers, giv1ng a minimun projected 2
loaded area of 1.5 in x.25 in =.375 in in the strut plate.
This part of the strut plate is very conservatively treated as a column standing alone under the fuel siacer load, without benefit from the adjacent material in the continuous plate.
The dynamic elastic limit is taken as 60% of the dynamic yield strength (Ref. 5, Se ct. III App. I Table I-2.14)
At h66 F the ultimate tensile strength of 301 s/s = 59000 pai and the dynamic yield strength = 2/3 x 59000 = 39,333 psi (Sect. 1.1 and 1.2).
Thus the dynamic elastic limit =.60. 39,333 = 23,600 usi Load in each plate from foot = 2 x P 2 x 3090 : 6180 lbs
=
The critical load for a strut with one end fixed (Ref. 3, Table XV-Case 1) is 2
2 6
3 P'
TT EI g (26.3) (10 ) (1.5 x.25 ) = 11,109 lbs
=
=
4f2 12 M.S. = 11,109 -1 =.798 4.x 3.3752 6180
_ Compressive stress in colu'v1 s
=
6180 16480. psi
=
c 1.5 x.25
.432 23600
_1 M.S.
=
=
16480 XI 1-123q 4
Rev. 2 - 9/78 Since the applied load of 6180is less than the critical elastic buck 31ng load of 11,109 lbs and the compressive stress of 16480 pai is less than the elastic limit of 23,600 pai, buckling of the strut plate vill not occur.
Conclusions The principal function of the above spacer and support is to maintain the given volume of water between the fuel sleeves or between a fuel sleeve and the basket material. The above analyses show that the construction and stresses are satisfactory under the 81g side impact and Any deformation of the structures will not occur to reduce the water content in the holes.
l e
XI h-123r
Rev. 3 - 9/78
- 4. 7 Corner Impact 4.7.1 Inner Closure Rotation During the corner impact the inner closure head is subjected to an acceleration of 30g at an angle of 15.2 (Section 4. 3. 4) 7.867 W 3
&O m
od 9 $@
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't y
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54" Dia. BC W =^ 7400 lbs. Closure weight W=W1-W2 1
W2 = 34100 lbs. Contents weight W = 7400 + 34100 = 41500 lbs.
F = Wl38.95) = 41500 x 28.95 = 1201425 lbs.
t
= W (7. 8 67) = 'teu0 x 7. 867 = 58216 lb s.
F 1
XI 124
Rev. 4 - 9/78 During the corner imi act the lateral load Ft = 58216 lbs will not be taken by the bolts in shear. It will be taken by the forging in bearing as shown it.' section 4.6.1.1 (81 G side impact analysis).
Bearing stresses in this case are much lower than stresses that will occur during the side impact.
The axial force F will be taken by the bolts in ta nsion; the joint t
analysis and bending stresses of the inner closure head are calcul-ated in section 4.4.1 for the 30g top end impact, which is a more severe loading than the corner impact.
XI-4-125
Rev. 4 - 9/78 4.7.1.1 Outer Closure Rotation.
During the corner impact the outer closure is subjected to an ac-celeration of 30g at an angle of 15. 2 (Section 4. 3. 4) c' o
B S
O I
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er %
o d
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n v
c"al 0
Lt 4 i (
4
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ug
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r F
7-62" Dia. (B.C.)
- g L
=
Weight of outer closure = 2328 lbs.
Loading from pressure between inner and outer closures is 18265 lbs.
(Sect. 3.11)
To be h!ghly conservative, assume that only 5 bolts resist the combined inertial and pressure loads P = 28.95 (2328) + 18,265 = 85,661 lbs.
6 in-lbs.
Moment on joint, Mo = 31(85661) = (2.6555)10 XI-4-12 6
Rev. 5 - 9/78 Joint resisting noment from only 5 bolts is Mg = 31 FB 2 + (cos f +1)2 + (cos 2 99 + 1) wheref=6.428 degrees (anglebetweenbolts).
FB = maximum bolt force.
Feluating MO to Mg and soh ing for FB gives (2.6555)106 = 31 F 2 + (1.9937)2 + (1,9749)2 B
B=(2.6555)10/(31)(9.875)=8675lbs.
~
6 F
Mininun bolt preload = 10,450 lbs. (Sect. 3.11)
M.S. = (10150j'8675)-1 = 0.205 Since the outer closure can withstand the larger bending loads of the top end inpact (Sect. 4.4.1.1), its integrity and that of the bolts and seal are unintained in the corner impact.
XI-4-127
Rev. 5 - 9/78 Mininun preload on the bolts fran Sect 3.11 is 10,450 lbs. This c1tunping force of 10,450 is higher than F = 4210 lbs. Hence o
no added stress will be applied to the bolts during the puncture edge loadinC 10150 M.S. =
- 1 = 1.48 4210 Theouter closure plate will take the bending stress due to its inertial forces (See Sect. 4.4.1.1)
XI-4-137a
Rev"3 - 9/78 4.9.9 Containment Vessel Valves The containment vessel valve assembly uses two metal 0-ring seals to provide leaktight joints between base plate, cover and forging (Drawing 70651F).
Elastomer 0-ring seals are also provided at these joints to facilitate operational checks of the metal seals.
The metal 0-rings are silver plated Inconel, which will withstand temperatures up to 13000F.
Temperatures at the valve assembly location in the fire and post fire conditions will not exceed 6000F (See section VIII).
At the seal seating load of 700 lb/ inch provided by the bolting preload, the helium leak rate of the seal will be 10-6 cc/sec or less (p.VI-22, Ref. 83)
Maximum pressure in the containment vessel from the fire accident is 85.8 psig. (sect 4.9.1).
The resulting load on the valve assembly joint 2
P; = (T /4)(3.094 )(85.8) = 645 lb.
is-seal seating loaa, P2 = 6804 lb.
(Sect. 4.4.8) total load per bolt, F =' (645 + 6804)/4 = 1862 lb.
"ince the bolts are each preloaded to 2533 lb (sect. 4.6.4), the joint seal is maintained in the fire accident.
M.S. = (2533/1862) -1 = 0.36 XI-4-186
Rev. 2 - 9/78 16.
Baumeis te r and Marks, " Standard Handbook for Mechanical Engineers",
l 7th Ed., McGraw-Hill Book Co., New York, 1967.
17.
Tipton, C. R. Jr., (Edit. ), "Reactcr Handbook", 2nd Ed., Vol. 1, p. 124, Interscience Publisher, Inc., New York, 1960.
18.
Goldsmith, A., et. al, " Handbook of Thermophysical Properties of Solid Materials", revised Ed., Vol.1, The MacMillan Co., New York,1961.
19.
Anderson, W. K. and Theilacker, J. S. (Edit. ), " Neutron Absorber Mater-ials for Reactor Control", United States Atomic Energy Commission, 1962.
20.
Tietz, E. Thomas, " Determination of the Mechanical Properties of a High Purity Lead and a 0. 05% Copper-lead Alloy", Stanford Research Institute, Menlo Park, California, April 1958, WADC Technical Report 57-695, ASTIA Document No. 151165.
21.
W. Hoffman, " Lead and Lead Alloys", English Translation of the second re-vised German Edition, Springer-Verlag, New York - Heidelber, Berlin 1970.
22.
Calvert - Cliffs, Unit I and 2 FSAR, Baltimore Gas and Electric Co.,
Dockett 50-317.
23.
"I50wtherm SR-1 Heat Transfer Fluid Catalug", Dow Cliemical Co., 1970.
24.
"1972 Annual Book of ASTM Standards" Part 1, Steel Piping, Tubing, and Fittings American Society for Testing and Materials, Philade:phia, 1972.
25.
" Republic Precipitation Hardenable Stainless Steels", Republic Steel Corp-oration, Copyright 1962.
26.
"The Influence of_ Impact Velocity on the Tensile Characteriatics of Some Aircraft Metals and Alloys", NACA-TN-868, Washington, October 1942, 27.
" Strength of Metal Aircraft Elements", Military Handbook, MIL:-HDBK-5, Armed Forces Supply Support Center, Washington,25, D. C.
28.
"Ricon", Technical Data Bulletin No. RAD. 100, The Richardson Company, 2700 Lake Street, Melrose Park, Illinois 60160.
29.
"Polybutadiene, Polyetnylene Copolymer Sheets, Virgin and Borated",
MIL-P-24468 (Ships), October 20, 1972.
30.
Scott, D. B., " Physical and Mechanical Properties of Zircaloy 2 and Zircaloy 4", WCAP-3269-41, May 1965.
XI-5-2
Rev. 2 - 9/78 31.
"The Engineering Properties of Viton Fluoroelastomer", E. I. duPont l
dcNemours and Co. (Inc. ), Elastomers Chemical Department, Wilming-ton, Delaware 19898.
32.
" Stresses From Radial Loads and External Moments in Cylindrical Pres-sure Ves seIs",
P. P. Bijlaard Kelding Research Supplcment, Deccmber 1955.
33.
Bruhn, E. F. " Analysis and Desi ) of Flight Vehicle Structures", Tri-State Offset Co., Cincinnati, Ohiv.
34.
Timoshenko, " Theory of Plates and Shells", First Edition, Mc Graw-Hill Book Co., New York,1940.
35.
Kaufman, J. G., " Summary Report, The Effects of High Strain Rates on the Mechanical Properties of Aluminum Alloys", Alcoa Research Labora-tories, Report No. 9-60-31 (1960), ASTIA, Document No. AD 249-964.
36.
Harris and Crede (Edit. ), " Shock and Vibration Handbook", Vol.
1, p. 14, and Vol. 3, pp. 45-21 thru 45-39, McGraw-Hill Book Co., New York 1961.
37.
Guins and Tack (Edit. ), " Anthology of Rail Vehicle Dynamic s",
Vol. 1 Freight Car Impact and Vol. 2 Eff cts of Train Action and Rail Car Vibra-tion, ASME, New York, 1971.
38.
Settles, J. C., " Vibration and Shocks in Freight Cars as Causes of Load-ing Damage", pp. 1622-1628, ASME Trans., November 1958.
39.
Lahood, J. W., " Shock and Vibration Data Obtained From Trucks and Rail Shipment", pp.99-108, Shock and Vibration Bulletin No. 33 part IV March 1964.
40.
New York Central Railroad, "The Railroad Environment - A Guide for Ship-pers and Railrcad Personnel", 9-17 Section II, III, IV, 1960.
41.
Gens, M. B., "The Rail Transport Environment", pp.14-20, Journal En-vironment Science, July - August 1970.
42.
Clarke and Reddi, " Structural Integrity of Shipping Containers for Radio-active Materials, Part I : Study of Transport Operation and Container Construction" pp. 5-16, USAEC Report NYO-9859, July 1962.
43.
" Aerospace Structural Metals Hardbook" Revised March 1967.
XI-5-3
Rev. 2 - 9/78 44.
" A survey of Environmental Conditions Incident to the Transportation of Materials" - General Transportation Corporation - October 1971 (NTIS PB-204 442) 45.
"1974 Annual Book of ASTM Standards" Part 4, Steel Structural, Rein-forcing Pressure Vessel Railway, American Society for Testing and Materials, Philadelphia,1974.
46.
"1974 Annual Book of ASTM Standards, Part 6, Copper and Copper Alloys, American Society for Testing and Materials, Philadelphia,1974.
47.
" ilk Porter Co.," Themoid Div. Trenton New Jersey.
48.
Baron, H. G., "The Stress-Strain Curves of Some Material and Alloys at Low Temperatures and High Rates of Strain", Metallurgy Report 22/54, Armament Research Establishment, Ministry of Supply, UK, August 1954 (ASTIA AD No. 40921) 49.
Manjoine, M J., " Influence of Rate of Strain and Temperature on Yield Stresses of Mild Steel", I. Appl. Mech., December 1944.
50.
Clark and Wood, "The Tensile Impact Properties of Some Metals and Alloys", Trans. ASM, V. 42, pp. 45-74 (1950).
51.
Goldsmith, Werner, " Impact", Edward Arnold Publ., London (1960) 52.
Cristescu, N., " Dynamic Plasticity", North-Holland Publ. G.,
Amsterdam (J. Wiley & Sons, N.Y.) (1967).
53.
Timoshenko, " Theory of clasticity", First Ed., Mc Graw-Hill Book Company, Inc., New York and London,1934.
54.
" Creep of Engineering Materials" by Finale and Heller,1959.
McGraw-Hill Book Company.
55.
Manson, S. S., " Thermal Stress and Low-Cycle Fatigue,"
Mc Graw-Hill Book Co., New York (1966).
56.
Norris et. al. " Structural Design for Dynamic Loads," McGraw-Hill Book Co., New York,1959.
57.
R. Szilard, " Theory and Analysis of Plates", Prentice-Hall, Inc.,
Englewood Cliffs, N. J.
58.
S. Timoshenko, " Theory of Elasticity", McGraw-Hill Book Co.,Inc.,
New York and London,1936.
XI-5-4
Pav. 1 - 9/78 73.
North Ame rican Aviation, Inc., Vol. 2, Los Angles Division, Report Number Ref. CP-4694, Jan.1957.
74.
Union Carbide and Carbon Research Laboratory data, as quoted in Metals Handbook, Am. Soc. Metals, 1948, p. 204.
75.
" Mechanical and Physical Properties of the Austenitic Chromium-Nickel Stainless Steels at Sub-Zero Temperatures". The Interna-tional Nickel Company, Inc., New York, 3rd Ed., March 1970.
76.
" Handbook on Mate rials for Supercenducting Machine ry".
Metals and Ce ramics Information Cente r. Battelle, Columbus Laboratories, Report No. NCIC-HB-04.
77.
C. J. Guntne r and R. P. Reed: " Mechanical Properties of Four Austenitic Stainless Steels at Temperatures Town to D K. "
Advances in Cryogenic Engineering, Plenurr. Press, New York, Vol. 6, 1961.
78.
Nerva Program, Material Data Book, Aerojet General (1964).
79.
R., Michael McClintock and Hugh P. Gibbons; " Mechanical Propertier of Structural Materials at Low Temperature", National Bureau of Standards, Monograph 13, Issued June 1,1960.
80.
John L. Eve rhart, W. Ear Lindlief, James Kanegis, Pearl G.
Weissler and Freida Sieget. " Mechanical P ecpe rties of Metals and A lloy s", United States, Washington Printing Office. Wa shington, 1943.
81.
NL Industries internal test report on tensile properties of chemical Icad at elevated temperatures, C. Gallagher, Central Research Laboratory, Hightstown, N. J.
(Feb. 1976) 82.
Parker 0-Ring IIandbook, OR 5700, Jan.1975, Parker Seal Co.,
Inxington, Ky.
83.
Kalasky, James E., " Characteristics of Metal 0-Rings and Relationship to Scaling Capabilitica", Nat'l. Conf. on Fluid Power & Fluid Power Society, Oct. 1970.
XI-5-6
9/78
&1.
Conmunication of June 7,1978 from J. H. Sunrtz 03. cites 2000 lb/in.
seating laod for United Aircraft Products seal P/N U79175G Imr K. hbralles, UAP, Dayton, 011o; also, closure lateral novenent of 0.010 in, will not affect seal integrity.
85.
Biach Industries, Inc., Cranford, N. J. : Operating and Maintenance Manual for Stud Tensioner Abdel No. 1-30471 (Biach Job No. 3G39)
XI-5-7
9/78 SEL'fION XII CODIJNG SYSTDI DESIGN INIlh] DUCTION
'Ihis section discusses the operation and perfonmnce of a redun-dant auxiliary cooling systan.
Subsequent events in the paclage design resulted in a lower decay heat load limit. Consequently the package tal;eratures became less important to the facility receiving spent fuel and the need for auxiliary cooling becanes optional.
'Ihe following section has not been revised and/or expanded to cover the optional arranganents since package integrity is not dependent on auxiliary cooling.
i
Thermal Test Procedure Rev. 3 - 9/78 The thermal tests are to be performed within an area which will be protected against drafts and large temperature changes.
The cask shall be completely assembled on the rail car, i.e., the fuel basket installed in the cask cavity, closure head mockup with heater and thermocouple leads in place. The assembled cask will be positioned horizontally on the rail car to simulate the shipping attitude.
The cooling system will be in-operative and drained for this test.
The assembled shipping cask will be instrumented so that temperatures e:1d pressures of the various elements of the system can be monitored and at established time intervals all data will be recorded.
To obtain the necessary temperature data, thermocouples will be installed inside the PWR fuel basket cavities, on the outer surface of the outer shell on the outside surface of the water jacket shell and on the ends of the cask.
The tnermocouple locations and heater locations in the basket are shown in Figures 1 and 2.
The following thermocouple will also be attached to the cask.
(See Figure 3) 1.
Seven sets of three thermocouples will be mounted circumfer-entially on the cask surface and on the outer surface of the outer shell on a plane equidistant from the ends of the heater active zone. As viewed from the end of the cask, one set would be U
0 mounted in the 00 and then every 30 to the 180 position.
2.
A thermocouple at each end of the cask at the center of the top and bottom head.
XV-2
Rev. 5 - 9/78 SECTION XV THERMAL TEST PROCEDURE Thermal tests will be perF]rmed in accordance with detailed thermal test procedure to verify the thermal performance of the shipping cask. The thermal tests will also be used to establish operational parameters relative to preparing a loaded cask for shipment and unloading the cask at the repro-cessing plant.
Both fuel basket types, i.e., PWR and BWR, will be thermally tested. This section describes the thermal test used to verify cask performance and the temperatures used in the thermal stress analysis.
As established in Section VIII, " Thermal Analysis," the thermal response of the cask to PWR end BWR loadings are approximately equal.
Therefore, the heat source for the thermal test shall be equivalent to the calculated decay heat source for the ten (10) PWR cask loading of 70kw.
The heat source shall be provided by electrical heaters designed and located to simulate the active region of a fuel assembly.
The heaters will be positioned such that the 144 inch active length falls within the limits of the neut on shield water jacket. A mockup of the cask closure heads shall be provided which will ther-mally simulate the top end of the cask.
There will be additional penetrations in.the closure head mockups to provide for heater leads and thermocouple wire installation.
XV-1
Rev. 3 - 9/78 Functional Testing valve. Monitor pressure gage for 30 minutes.
Followed by a visual inspection of all joints.
Any drop in test pressure or leaks will be cause for rejection.
4.3 Water Jacket Expansion Tank 4.3.1 Remove relief valve and replace with calibrated pressure gage and vent valve assembly.
Connect pump and supply of distilled water to inlet on expansion tank.
Fill expansion tank with distilled water until overflow occurs through vent valve.
Close vent valve and pressurize expansion tank to 300 psig.
Close water supply valve. Monitor pressure gage for 30 minutes.
Followed by a visual inspection of all joints.
Any drop in test pressure or leaks will be cause for rejection.
4.4 Containment Vessel Valves The containment valves are made up of three comronents; base plate, valved quick disconnect fitting and a cap which com-pletely encloses the quick disconnect fitting and is bolted the base plate. The primary containment seals are those seals which seal the base plate to the cask flange and the cap to the base plate. The base plate and cap seals shall be sub-jected to the following leak tests.
XIV-5
Rev. 5 - 9/78 Functional Testing The base plate shall be bolted to the cask flange and a helium leak test performed at this level of assembly.
After the base plate has been tested and accepted the cap shall be bolted in place and the cap seal subjected to a helium leak test. A leak rate greater than 1 x 10-6 STP cc/sec will be cause for rejection. Acceptance criteria applies to both components and is a test of the metal "0" ring seals used in both com-ponents.
4.5 Water Jacket and Expansion Tank Relief Valves The relief valves; (1) Water Jacket, (1) Expansion Tank; shall be bench tested to verify cracking and reseating pressures. Allowable variation is + 5% of 220 psig nominal cracking pressure.
4.6 Cask Cavity Hydrostatic Pressure Test Full cask cavity with distilled water.
Pressurize cask cavity thru cavity drain valve to 350 psig. and hold pressure for 30 minutes.
There shall be no evidence of leakage or pressure drop during the test period.
4.7 Impact Limiter Housing Both front and rear impact limiter housings will be tested for leak tightness.
Each limiter housing will be purged and filled with dry helium at 10 psig.
All weld joints will be bubble tested and shall exhibit no evidence of leakage.
XIV - 6
Rev. 3 - 9/78 Functional Testing support saddle. Install tie-down link pin.
Assure the following :
5.1.1 Free engagement of trunnions in bearing blocks.
5.1.2 Operation of hydraulic jacks.
5.1.3 Engagement of top and bottom end of cask in support saddle 5.1.4 Fit of tie-down link pins.
5.1.5 Clearances between the cask and the lift yoke when cask is lowered into horizontal position.
5.1.6 Fit of top and bottom impact limiters.
5.1.7 The cask clears the sides of the personnel barrier as it is being lowered to the horizontal position.
5.2 Bring the roof sections of the personnel barrier into their closed position. Assure that there is no interference be-tween the cask and the personnel barrier roof.
6.0 Thermal Test The thermal test is outlined in Section XV. If the rail system is equipped With auxiliary cooling the functional test of the cooling system will be carried out as part of the thermal test procedure.
7.0 Disassembly Upon completion of all the tests, the cask shall be removed from the Rail Car, disassembled, cleaned, reassembled, and returned XIV-7
Rev. 3 - 9/78 Functional Te sting and the cask wall, moving at a rate not to exceed 15 inches per minute. A leak rate greater than 1 X 10-6 STP cc/sec. will be cause for rejection.
4.1.2 Outer Closure Head Seal Both closure head and seals are to be in place during this test. Using the closure head cavity drain line pressurize the cask cavity between the inner and outer head to 5 psig using clean dry helium. Using a sniffer probe connected to a mass spectrometer, scan the joint between the outer head diameter and the cask wall, moving at a rate not to exceed 15 inches per minute. A leak rate greater than 1 X 10-6 STP cc/sec, will be cause for rejection.
4.2 Water Jacket 4.2.1 Remove relief valve and replace with a calibrated pressure gage. Connect pump and supply of distilled water to the quick disconnect valved coupling on the water jacket. Open the vent line at the top end of water jacket. Fill the water jacket with distilled water until overflow occurs through vent line. Close vent line and pressurize water jacket to300 p sig. Close water supply XIV-4
Rev. 2 - 9/78 OPERATING PROCEDURES A.
Preparation of Cask for Loading at Reactor Site 1.
Health Physics survey railcar and personnel barrier.
2.
Visually inspect railcar and equipment for signs of damage. Note any discrepancy on shipping document.
3.
Open personnel barrier.
4.
Health Physics survey cask and adjacent surfaces of car.
NOTE "A" If the neutron shield tank is connected to expansion tank, then Step 5 must be perforne d.
5.
Disconnect water jacket expansion line from water tacket.
i 6.
Position car for removal of cask. Set hand brakes and block wheels against movement in either direction.
7.
Inspect cask and tie-downs for signs of damage. Complete receiving inspection portion of shipping document.
8.
Release lifting yoke from its tie-down on railcar.
NOTE "B" When the cask is shipped in an " Unloaded" condition, auxiliary cooling system does not operate, nor is it connected to the cask, Therefore,
no connection between cask and cooling system need be broken at this time.
XVI-2
Rev. 2 - 9/78 9.
Ibleve rear ("B" End of car) tie-down pin and raise rear end (bottom of Cask). Renove impact limiter then nove turning fixture into position and lower cask turning trunnions into the turning fixture bearing blocks, by retracting thc ear jack.
10.
Rmove front ("A" End of car) tie-down pin ind raise front end of cask. Renove front (top of cask) impact limiter.
11.
Attach lift yoke to the lifting trunnions and raise cask to vertical position.
Lift cask from car and set down in designated work area. Remove lifting yoke.
12.
Rmove outer closure head bolts.
Renove 3 threaded plugs from top of closure head and replace with 3 threaded eyebolts.
13.
Using shackles, attach lifting slings to 3 eyebolts on outer closure head. Renove outer closure head and set it on supports which are suitable for radiological control and nnintaining the cleanliness of closure head. Carefully inspect outer head gasket.
If seal shows any damage replace it.
Be certain gasket is properly installed and seated. Note any damage or repairs in shipping docunent.
14.
Remove nuts from inner closure head studs. Using shackles, attach lifting slings to 3 eyebolts on inner closure head. Renove inner closure head and set down on a clean surface for radiological con-trol and unintaining the cleanliness of the closure head. Carefully inspect inner closure head gasket.
If seal shows any dannge, replace it.
Be certain that replacenent gasket is properly installed and seated.
Note any dannge or repairs on shipping document.
15.
Renove containment vN31 valve caps. Remo'e closure head cavity drain valve cover which is located at top side of cask.
XVI-3
Rev.3 - 9/78 Operating Procedures 16.
Renove fuel assembly spacer plug and set down on supIx)rts which are suitable for radiological control and nnintabling of cleanliness of spacer plug.
17.
Survey cask internals. Visually inspect cask cavity for foreign nnterial, damage, etc. Note any discrepancy or repairs on shipping docunent.
18.
01eck specific gravity (by hydroneter) of fluid in neutron shield tank.
The specific gravity must fall within the limits shown on the graph on page XVI-17. If the specific gravity is outside the required limits, add water or anti-freeze as necessary to adjust specific gravity.
If fluid lesal is low, add antifreeze mixture in the proper concentrn ion to fill the neutron shield tank.
19.
Fill cask cavity with danineralized water up to level of inner closure head flange.
20.
Engage cask lifting yoke with cask trunnions and pick up cask.
21.
Position cask vver spent fuel storage pool and slowly lower cask to bottom of pool. Wet cask surface using demineralized water prior to placing cask in storage pool.
22.
Disengage lifting yoke from cask anu remove yoke from spent fuel storage pool.
B.
Loading Fuel Into Cask at Reactor Site 1.
Re'ad identification number on top of fuel assembly. Record identifi-cation number on shipping docunent.
2.
Pick up fuel assorbly, using refueling grapple on refueling bridge.
3.
Position refueling bridge over cask. Center fuel assenbly over cask cavity. Careful ; lower fuel assembly into cask. Release XVI-4
Rev. 4 - 9/78 Operating Procedures grapple from fuel assembly and raise to full up position.
Confinn that fuel assembly is fully seated in cask. Move refueling bridge clear of cask. Record location of fuel assembly in fuel basket.
4.
Repeat steps (1) through (3) above until cask is fully loaded.
C.
Iknoval of Cask From Reactor Site Spent Fuel Pool and Preparation for Shipment 1.
Install fuel assembly spacer plug into cask.
2.
Attach three-legged sling to cask lifting yoke. Move over cask inner closure head. Attach three-legged sling to lifting eyes on outer sur-face of inner closure head using shackles.
3.
Ibsition inner closure head over cask and slowly lower onto cask flange. Guide pins of varying heights are located in the cask flange to provide initial and final alignnent. Visually confinn that closure hcad is seated.
4.
Iower cask handling yoke to slacken closure head cables which, in turn, locates yoke relative to cask trunnions. Engage cask trunnions and begin lifting.
5.
Raise cask until closure head cavity drain valve is above water.
Install all inner closure head nuts hand tight.
6.
' Hose cask down with demineralized water.
Monitor radiation dose rate as cask emerges from pool. When all cask surfaces I ve been hosed, innediately move cask out of Fuel Pool to Decontamination Area. Set cask down. Renove lifting yoke and closure head lifting cables.
7.
Cbnnect hoce fmm demineralized unter supply to quick disconnect fitting on cavity fill line. Connect hose to quick disconnect fitting on cavity drain line with free end placed in pool water or contami-nated drain. Open domineralized water supply valve and conmence XVI-5
Rev. 3 - 9/78 Operating Procedures flushing the cask cavity.
8.
Connect domineralized unter supply to auxiliary cooling inlet at top of cask.
Attach hose to auxiliary cooling outlet at top of cask. Discharge end of hose to be directed to suitable drain. Open demineralized water supply valve and continue to circulate unter to drain.
9.
Tighten all inner closure head nuts to specified torque.
10.
Close demineralized unter supply valve to cask cavity. Discon-nect hese from domineralized unter supply. Connect T-fitting with pressure gage and iolation valve to quick disconnect fitting on cavity fill line.
11.
Connect helium bottle (with pressure regulated to 10 psig) to quick disconnect on isolation valve assembly. Open fill valve and isolation valve. Open helium supply valve for a few minutes to allow helium to push out a quantity of water from the cavity.
12.
Pressurize cavity to 10 psig minimum.
Rmove drain hose from cavity drain line. Renove helium hose from cavity fill line.
Flood closure head cavity until seal and all valves are com-pletely covered. Hold for 10 minutes and untch for bubbles indicating leaks at closure head seal.
If bubbles indicate leaks follow special instructions for correction.
If not, drain closure head cavity, re-connect drain and helium supply lines.
13.
Open helium supply valve. Allow helium flow to force out rcmaining cavity unter until ther'e is no further discharge from the cavity drain line. As unter is flowing from cavity measure tmperature of effluent.
0 If unter temperature is below 80 F, stop flow and unit for heat in 0
fuel to raise water tcnperature to 80 F.
Then apply helium pressure XVI-G
Rev. 2 - 9/78 Operating Procedures and expel water until bubbles from discharge hose indicate that all water has been forced from cask. Close cavity fill and drain valves. Close helium supply valve. Renove helium supply line.
14.
Pressure test seals in cavity fill and drain line valve bam plates by pressurizing annulus betumn the double seal to 5 psig. IIold pressure for 10 minutes.
If there is no drop in pressure seals are satisfactory.
15.
Crack cavity arain valve and bleen off excess pressure, vent to plant off gas system. Connect vacuum gauge to this valve and open it wide.
Connect vacuum pump to cavity fill valve with line having vacuum gauge attached. Start pump and open valve.
Evacuate cavity until pressure falls below 1" of IIg (.5 psi) on both gauges and ranains there for 15 minutes. Valve off pump and hold static vacuum for 15 min.
If pressure increase is negligible, close both valves. llecon-nect helium line, open fill valve and recharge cavity with helium to just above atmospheric pressure. Close fill valve and disconnect helium line.
16.
Decontamination procedures are to be carried out while the above operations are taking place.
17.
Install valve caps on drain and fill valves. Pressure test seals in valve caps by pressurizing annulus between the double seal to 5 psig. Ilold pressure for 10 minutes.
If there is no drop in pressure seals are satisfactory.
18.
Attach three-legged sling to eyebolts on outer closure head.
position outer closure head on cask.
XVI-7
Rev. 3 9/78 Operating Procedures 19.
Renove eyebolts frun outer closure head and insert threaded metal plugs. Torque closure head bolts to specified foot-pounds.
20.
Connect vacuum pump to closure head cavity drain valve. Connect exhaust side of vacuum pump to contaminated off gas system.
Open the closure head cavity drain valve.
Start vacuum punp and pump closure head cavity to 1.0 inch of nercury. IIold for 15 minutes.
Operation must continue until supervisor determines that the vacuum gauge reads 1.0 inch of nercury. The supervisor shall verify that the operation has been perfonned correctly and will sign off the appropriate check list accordingly. Stop and disconnect vacuum ptmp. Allow pressure in closure head cavity to return to atnnspheric. Close closure head cavity drain valve.
21.
Connect pressure gage and isolation valve assenbly to cavity drain valve. Uonnect conpressoci air supply line to isolation valve.
Open isolation valve, open cavity drain valve.
22.
Open compressed air supply and pressurize closure head cavity to 10 psig. Close air supply valve. Hold pressure for 10 minutes.
If there is no drop in pressure, the outer closure head seal is satisfactory.
Record results on shipping document.
23.
Open isolation valve to relieve pressure in cavity.
Rcnovo pressure gage and isolation valve assembly.
24.
IIcalth Physics survey cask for surface contamination and radiation dose rates.
If values are higher than those specified in shipping doctunent, continue decontamination. Record final values on shipping docunent.
25.
Install valve cover on the closure head cavity drain valve pocket.
XVI--8
Rev. 3 - 9/78 Operating Procedures 26.
Attach lifting yoke to cask trunnions. Lift and nove cask to railcar location and position cask over turning fixture bearing blocks.
27.
Inner cask to railcar. Engage bearing blocks on turning fixture with trunnions on bottom end of cask. Iower cask to horizontal position, noving crane as required to keep crane cables vertical. Disengage cask lifitng yoke from cask trunniens and set aside.
28.
Elevate bottom end of cask using car nounted jacks.
Disengage bearing blocks on turning fixture and nove turning fixture to storage position.
29.
Install bottom impact structure. Irwer cask using jacks until im-pact structure seats in saddles.
Install hold down pin.
30.
Install top impact structure.
Iruer cask using jack until inpact structure seats in saddles.
Install hold down pin.
31.
Connect cask unter jacket to expansion tank by connecting flexible netal hose from expansion tank to quick disconnect fitting on water jacket.
32.
Connect flexible pipe from auxiliary cooling unit to quick discon-nects near top of cask. Open isolation valves. Start pump on auxiliary cooling unit No.1.
Check level in system expansion tank and fill low level mark with danincralized unter, if required.
Start fans on auxiliary cooling unit No. 1.
32.
Repeat Step 32 for auxiliary cooling unit No. 2 when shipping configuration incli. as optional redundant syatan. Perforn: opera-tional checks per check list to assure all components are function-ing properly. Turn unit No. 2 off.
31.
Close personnel barrier.
35.
Paste shipping placards to outside of personnel barrier as required by 49 CFR 173.399.
XVI-9
Rev.
/7 Operating Procedures 36.
Perform final Health Physics survey of railcar systan.
37.
Return all decontaminated service equipment to storage.
38.
Station Supervisor review shipping document for completeness and accuracy. Sign off as ready for shipment.
D.
Preparation of Cask for Unloading at Fuel Reprocessing Site 1.
Health Physics survey railcar and personnel barrier.
2.
Inspect railcar and personnel barrier for damage. Note any discrepancy on shipping document.
3.
Position railcar for renoval of cask. Set handbrakes and block wheels against car mvoenent in either direction.
4.
Open personnel barrier.
5.
Health Physics smear test cask for surface contamination and adjacent surfaces of the railcar. Complete receiving portion of shipping document.
6.
Disconnect water jacket expansion line from water jacket.
7.
Inspect cask and tie downs for darmge. Complbte cask /railcar inspec-tion portion of shipping document.
8.
Renove rear ("B" End of Car) tie-down pin and raise rear end (bottom of cask). Renove impact limiter then nove turning fixture into Imsi-tion and lower cask to engage turning trunnions in turning fixture bearing blocks by retracting the rear jacks.
9.
Renove front ("A" End of car) tie, lown pin and raise front end of cask. Renove front (top of cask) inpact limiter.
10.
Shutdown auxiliary cooling units No. 1 and No. 2.
Renove inlet and outlet flexible pipes.
11.
Attach lift yoke to the lifting trunnions and raise cask to vertical position. Lift cask from car and set down in designated work area.
Renove lifting yoke.
XVI-10
Rev.
- /
Operating Procedures 12.
Wash dawn cask surfaces, as required, prior to entry into spent fuel pool.
13.
Remove cover plate from cavity drain valve.
14.
Connect pressure gauge and isolation valve assembly to closure head cavity drain valve. Observe and record pressure. Attach cot pressed air line to isolation valve. Pressurize closure head cavity to 10 psi above observed pressure. Hole. pressure for 10 minutes and watch for pressure drop. Record observations.
15.
Remove all outer closure head bolts.
16.
Renovo three (3) threaded inserts from top of outer closure head and replace with three (3) eyebolts.
Using slings and shackles, connect closure head eyebolts and cask lifting yoke.
Rennve outer closure head and set outer closure head on stand in Decontamination Area for radiological control and nointaining cleanliness of closure head.
Carefully inspect gasket seal in underside of closure head.
If gasket shows any dannge, replace.
17.
Connect cooldown inlet line (hot water supply line) to quick disconnect fitting on drain valve. Connect cooldown outlet line to fill valve. Open fill valve and vent cask thru cooldown system to plant off gas system.
Equalize cask pressure to cooldown system feed pressure thru cask fill line.
CAUfION
'Ibe hot gases exiting from the fill valve could be highly radioactive.
The exhaust gases must therefore be contained and disposed of accordingly.
XVI-ll
Rev. 2 - 9/78 Operating Procedures Any systan for cooling down the package shall be provided with a pressure relief device set so that the nnxinun pressure in the containment vessel does not ex-ceed the nnxinun allowable oper-ating pressure of the containment vessel.
18.
Open suction drain valve and begin cooldown procedure.
CAUTION Coolant flow rates must be controlled to avoid thermal shock to the cask internals.
19.
Continue cooldown procedure until cask cavity is conpletely filled with unter.
20.
Ramve all but four closure head bolts, leaving cooldown systan lines still connected and operating.
21.
Using lifting yoke with slings attached, engage the cask lift trunnions and connect slings to lifting eyes on inner closure head.
22.
Renove cooldown lines. Attach a hose to inner closure head fill valve with free end placed in spent fuel pool.
Close inner closure head drain valve.
(This approach is taken in the event of steam build-up in cavity prior to insertion in pool.)
23.
position cask over spent fuel storage pool and lower cask until top of inner closure head is about one foot under water. Ramve remain-ing four (4) closure head bolts. Wet cask surfaces with daninoraliz-ed water prior to placing cask in storage pool.
XVI-12
Rev. 2 - 9/78 Operating Procedures Remove hose from fill valve. Open both cavity fill and drain valves.
Above operations are performed using long handled tools.
24.
Slowly lower cask to rest on bottom of spent fuel storage pool. Dis-engage lifting yoke and slowly raise lifting yoke until inner closure head is raised clear of cask.
25.
Set inner closure head on stand in Decontamination Area for radiclo-gical control and for maintaining cleanliness.
Carefully inspect gasket on underside of closure head.
If gasket shows any damage, rep] ace it.
Be certain that replacement gasket is properly installed and seated.
26.
Renove fuel assembly spacer plug and set on supports suito.ble for radiological control.
E.
Unloading Fuel from Olsk at Reprocessing Site 1.
Read identification number on top surface of fuel assembly.
Record identification number on receiving doctmont.
2.
Pick up fuel assembly using fuel grapple.
3.
Set fuel assembly in pool storage rack.
Release grapple from fuel assembly.
4.
Repeat. steps (1) through (3) above until all fuel has been rcroved from cask.
F.
Preparation for Returning Unloaded Cask to Reactor Sito 1.
Install fuel assembly spacer plug into cask.
2.
Attach three-legged sling to cask lifting yoke.
Position cask lifting yoke over cask inner closure head. Attach three-legged sling to lifting eyes on outer surface of inner closure head, using shackles.
XVI-13
v.
- /
Operating Procedures 3.
position inner closure head over the cask and slowly lower onto cask flange. Guide pins of varying heights are located in cask flange to provide initial and final alignment. Visually confirm that closure head is seated.
4.
Lower cask handling yoke to slacken the closure head cables which, in turn, locates yoke legs relative to ca d trunnions.
Engage cask trunnions and commnce cask lift.
5.
Raise cask until cavity drain valve is above unter.
Install at least four inner closure head bolts. After pool water has drained from the closure head cavity, close the cavity drain valve.
6.
Comnence hosing cask down with domineralized unter.
When all sur-faces have been hosed, nove cask to Decontamination Area and set down.
Continue cask decontamination.
7.
Connect hose from danineralized unter supply to quick disconnect fitting on cavity fill valve.
Connect a hose to cavity drain valve with free end of hose placed in contaminated drain. Open danineralized unter supply valve. Open fill valve and drain valve and proceed to flush cavity for two (2) complete flushes. Close cavity fill valve and drain valve. Dis-connect domineralized unter supply line.
8.
Install rencining inner closure bolts and torque to specified foot-pounds.
Connect a hose to drain valve with free end of hose placed in contaminated drain. Connnect T-fitting with pressure gage and isola-tion valve assembly to quick disconnect on cavity fill valve.
XVI-14
ev.
- //
Operating Procedures 9.
Connect conpressed air (regulated to 10 psig) to quick disconnect on isolation valve. Open drain valve and open compressed air supply and rmove water from cavity. Ibrave hoses as well as pressure gage and isolation valve assembly.
Install drain and fill line valve caps.
10.
Attach three-legged lift sling to eye bolts on outer closure head. Lift outer closure head and position outer closure head on cask flange.
Visually confirm that outer closure head is seated.
Renove closure head lift cables, 11.
Renove eye bolts from outer closure head and insert threaded metal plugs. Torque closure head bolts to specified foot-Imunds.
12.
Chcck concentration of anti-freeze in neutron water jacket.
See instruction.
A.23.
13.
Health Physics survey entire cask for surface contanunation.
If values are higher than those specified in shipping document, continue decon-tamination. Record final values on shipping document.
14.
Install valve cover on cavity drain valve cavity.
15.
Attach the lifting yoke to cask. Move cask to railcar location and position cask over turning fixture bearing blocks.
16.
lower cask to railcar.
Engage bearing blocks on turning fixture with trunnions on bottom end of cask. Iower cask to horizontal position, noving lifting yoke as required to keep crane cables vertical.
Disengage cask lif ting yoke from cask trunnions and set aside.
17.
Elevate bottom end of cask using car nounted jacks. Disengage bearing blocks on turning fixt.ure and nove turning fixture to storage position.
XVI-15
Rev. 2 - 9/78 Operating Procedures 18.
Install bottom inpact stlucture. Lowr cask using jacks until inpact structure seats in saddles.
Inst.all hold down pin.
19.
Install top inpact structure. Iower cask using jack until inpact structure seats in saddles.
Install hold down pin.
20.
IIealth Physics survey cask for surface contamination to assure compliance with IX7f Regulations 173.393 (a).
Record final values on shipping
- document, hUfE "A" hhen cask is shipped in an " Unloaded" condition, auxiliary cooling system does not operate nor is it connected to the cask. Therefore, no connections betwen cask and cooling systm) need be nude at this tine.
21.
Connect v. uter jacket and expansion tank, by connecting flexible netal hose from expansion tank to quick disconnect fitting on vent valve. Check expansion tank valves open.
Be sure drain cock is closed.
m "B" The neutron shield tank need only be connected to the expansion tank when severe temperature changes are ex-pected in transit.
22.
Close personnel barrier.
23.
Paste "DIFIY" sliipping placards to outside of personnel barrier as required by 49 CFR 173.399, 24.
Transportation supervisor re"lew shipping docunent for completeness and accuracy. Sign off as ready for shipnent.
XVI-16
Rev. 3-9/78
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,1 XVI-17
Rev. 4 - 9/78 Cask Component Period Test / Action Containnent Vessel Valve Assanbly Base Plate Seals Each Shipment
- Gas pressure test to 5 psig~
Annually
- IIelium Leak Check Valve Cap Seals Each Shipment
- Gas pressure test to 5 psig Annually
- IIelium Irak Check Inner Closure IIcad Seal Each Shipment Gas Bubble Test - 10 psig Annually
- IIelium Irak Check Annually IIydrostatic Test to 121 psig Drain Line Gasket Quarterly Replacement Outer Closure Head Seal Each Shipment Gas pressure test to 10 psig Annually Helium Leak Check Neutron Shield Jacket Annually Hydrostatic Test to and Expansion Tank 300 psig System Neutron Shield Jacket Annually Verify cracking and Relief Valve rescating pressures.
Allowable variation is + 5% of nominal cracking pressure Expansion Tank Relief Annually Verify cracking and Valve rescating pressures Allowable variation is + 5% of nominal cracking pressure.
Impact limiters Anually Gas Bubble Test - 10 psig
- See Section XVI, Part C, Step 14 and 17
- See Section XIV, 4.4
- See Section XIV, 4.1.1 XVII-2
Rev. 8 - 9/78 SECTION XVIII ENGINEERING DRAWINGS h
70650F Sheet 1 Rev. 4 General Arrangement 10/24 Rail Cask 70651 F Sheet 1 Rev. 4 10/24 Rail Cask Details Sheet 2 Rev. 5 10/24 Rail Cask Details Sheet 3 Rev. 5 10/24 Rail Cask Details Sheet 4 Rev. 5 10/24 Rail Cask Details Sheet 5 Rev. 3 10/24 Rail Cask Details Sheet 6 DELETED Sheet 7 Rev. 2 10/24 Rail Cask Details 70652F Sheet 1 Rev. 7 PWR Fuel Basket 10/24 Rail Cask Sheet 2 Rev. 5 PWR Fuel Basket 10/24 Rail Cask 70653F Sheet 1 Rev. 7 BWR Fuel bcsket 10/24 Rail Cask Sheet 2 Rev. 5 BWR Fuel Basket 10/24 Rail Cask 70654F Sheet 1 Rev. 5 NLI 10/24 Cask & Rail Car General Arrangement Sheet 2 Rev. 2 Piping Plans & Details Rail-road Cask-Cooling System Sheet 3 DELETED 70655F Sheet 1 Rev. 4 PWR Spacer Plug 10/24 Rail Cask 70656F Sheet 1 Rev. 4 BWR Spacer Plug 10/24 Rail Cask XVIII-l
Rev. 7 - 9/78 Engineering Drawings 70540F Sheet 1 DELETED 70665F Sheet 1 Rev. 4 Neutron Shield Expansion Tanks 10/24 Rail Cask 70666F Sheet 1 Rev. 5 10/24 Rail Cask Impact Structure Assembly & Details Sheet 2 Rev. 4 10/24 Rail Cask Front Impact StrJcture Ring Details Sheet 3 Rev. 3 10/24 Rail Cask Rear Impact Structure Ring Detail Sheet 4 DELETED 70567F Sheet 1 Rev. 5 10/24 Rail Cask Support Structure Details Sheet 2 Rev. 4 10/24 Rail Cask Front Support and Tie Down Details Sheet 3 Rev. 4 10/2A Rail Cask Rear Support and Tie Down Details Sheet 4 DELETED 70708F Sheet 1 Rev. 2 10/24 Rail Cask Alternate Construction 70899F Sheet 1 Rev. 1 Cask, Car Tie-down Arrangement 10/24 Rail Cask OC-459-l*
Rev. E General Arrangement - 150 Ton Cask Transfer Car
- Ortner Freight Car Drawing XVIII-2
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