ML19329G340

Application for Renewal of Certificate of Compliance 6294 for Model UNC-2901 Shipping Package.Three Oversize Drawings Encl

ML19329G340
Person / Time
Site:	07106294
Issue date:	06/20/1980
From:	ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY
To:
Shared Package
ML19329G339	List: ML19329G338 ML19329G340
References
16649, NUDOCS 8007140620
Download: ML19329G340 (51)

Text

{{#Wiki_filter:.- 3-4 LOL LO i-APPLICATION FOR RENEWAL OF i CERTIFICATE OF COMPLIANCE N0. 6294 FOR THE MODEL NO. UNC-2901 SHIPPING PACKAGE t t i-i 1 i l 1-i!O i i l J i 1, ) I COMBUSTION ENGINEERING, INC. 1 HEMATITE, MISSOURI June.1980 i A i f i s l4 449 - 8007140 M M

'1. INTRODUCTION <3 V . The' UNC 2901 container is designed for shipment of uranium dioxide pellets manufactured, inspected and certified in accordance with reactor fuel specifications. It can also be used for the shipment of dry uranium compounds such as uranium dioxide powder and rejected pellets (hard scrap). i The maximum number of containers per shipment shall be limited to: Fissile Class I - None Transport index is 2.0 units per Fissile Class II container (Maximum 25 containers r for total 50 Transport units per shipment). Fissile Class III - Maximum 50 containers 2. PACKAGE DESCRIPTION . O The UNC 2901 container consists of a standard 55 gallon steel drum with a 10 3/4" square inner container centered in the drum. The inner container is centered by hardboard support rings. Asbestos, plywood and fiberlite insulation provide thermal protection to the inner container. The inner container closure is fitted with a gasket capable of wi thstanding temperatures up to at least 500 F. Details of contruction and assenbly are sho.:n on drawings: D 5007-8086, Rev. 3 0 5008-8192, Rev. 5 B 5007-8112 . 2. PACKAGE DESCRIPTION (continued) 2.1 Package for Certified Pellets v The uranium dioxide pellet package consists of corrugated, 22 gauge steel trays coated with a thin rubber or similar . soft material. The pellets are aligned in the corrugations with one layer of pellets per tray. The trays are stacked together; a sponge rubber (or similar material) and hardboard or plywood cover is placed at the tip and bottom of the stack. This stack is strapped together to form the pellet package. For handling purposes, the pellet package may be limited in size such that four packages will fit in the inner container. It is possible, however, for some requirements the tray and package dimensions (A and B on Drawing D 5008-8192) may be varied up to the limits of the inner container such that only one or two packages are required. 2.2 Package for Dry Compounds and Reject Pellets { The uranium dioxide powder package consists of modified re-usable metal drums as per Specification MIL D-50448, Part No. MS 24347-8. Modifications include: (1) increased depth of 13-1/4 inches, (2) a steel ring added to the top lip of the container, and (3) welding the locking lugs in addition to being riveted. 3. CONTENTS OF PACKAGING 3.1 - Certified Pellets _ i \\ A. Maximum Enrichment 4.1% B. Type Material: Sintered (high fired) uranium dioxide pellets. - C. Maximum quantity per container: .i n WI. _ L

' 3. . CONTENTS OF PACKAGING .r 3.1 Certihed Pellets-(continued) C. a) Maximum net weight: Pellets and packaging material (contents of inner F container) 427 pounds. Maximum net weight of pellets: 320' pounds UO2 up to 3.75 enriched. 240 pounds U02 3.75 to 4.1% enriched. b) Gross Weight Gross weight of the container as assenbled for shipment shall not exceed 655

• 5 pounds.

3.2 Dry' Compounds and Reject Pellets A. Maximum enrichment 4.1% B.. Type Material: Uranium Dioxide powder or reject pellets, a) Maximum net weight: Powder 'and packaging material (contents of inner . container) 229.5 pounds Maximum-net weight of powder: 220 pounds b) Gross Weight Gross weight of container as assembled for shipment .shall not exceed 457 2 5 pounds. 4. . STRUCTURAL EVALUATION-The' container was subjected to the hypothetical accident test condition in accordance with 10CFR71.36 and 49CFR173.398(c). The actual tests and results are discussed in detail in the ( )_ report." Design and Structural Evaluation of a low Enriched UO2 Pellet and Powder Shipping Package, Model UNC 2901;", dated ' April 1970.. (Appendix. A). j.

4. -

STRUCTURAL EVALUATION (continued) The container was again subjected to a thirty foot drop test while loaded with the powder drums. The actual tests and results are set-forth in the supplement to the above referenced report. The supplement is dated Novenber 1970. (Appendix B). 6-5. CRITICALITY EVALUATION 5.1 Certified Pellets The complete nuclear criticality analysis of the containers is reported 'in-NED-ll54, " Criticality Safety Analysis of UNC Type 2901 Shipping Container for 4.1 w/o U-235 Yankee Rowe Fuel Pellets". (AppendixC) A. Individual Container ~ The individual container is safe with maximum water moderation and full water reflection.. Reference NED-ll54. B. Array of Containers a) Normal Transportation The hypothetical accident test demonstrated that water cannot enter the inner container. Therefore, the pellets remain dry and moderation is only that provided by the packaging materials. A reflected rectangular array of 144' containers ( 6 x 6 x 4) has a Kfff of approximately 0.85. Reference NED-ll54. A'pplying the standard safety factor (5 for Fissile Class II) the allowable number of co.ntainers would be: Fissile Class II 28 containers Fissile Class III 56 containers a bb i C

5.1 Certified Pellets (continued) V b) Accident Conditions The hypothetical accident test demonstrated that:

1) Water cannot enter the inner container.

2) The total container remained intact.

3) The inner container is not deformed.

4) The pellet / tray package remained intact and in its original assent >1ed configuration.

Therefore, moderation is only as provided by the packaging materials and water interspersed between the inner containers. A reflected rectangular array of 50 containers (5 x 5 x 2) has a K of api. 'ximately 0.96. Reference NED-1154. eff Applying the standard safety factor (2 for Fissile Claes II) the allowable number of containers would be: Fissile Class II 25 O rissi'e ciass tti so c) Based on the above the accident condition is the most restrictive and 25 containers could be shipped safely as ] Fissile Class II and 50 containers as Fissile Class III. 5.2 Dry Compounds and Reject Pellets Using the zero rod size data in Appendices B and C, OP-1014, the critical bucklings are smaller than for comparable " lumped" systems with rod sizes equal to or greater than 0.1 inches. Also, the critical masses, volumes, cylinder diameters, and slab widths are larger than. for lumped systems. This applies to all enrichments up to and including 5.0%. Therefore, the certified pellets are more reactive than the powder and will be the limiting case. Thus the above listed transport indexes will be used. O EV

6. OPERATING PROCEDURES O Specific operating procedures are followed in loading and unloading the UNC-2901 package. Operating personnel complete a packaging check list which includes inspection of structural integrity and proper closure. 7. ACCEPTANCE TESTS AND MAINTENANCE PROGRAM Containers will, be fabricated only in accordance with approved drawings and specifications. Source inspections will be performed 4 as appropriate at the vendor's facility. Any changes in design which fall outside of the safety envelope specified in this application will be submitted to NRC for approval. Repair and maintenance will also be performed only in accordance with approved drawings and specifications. 4 .U ' I s_s.

em. w-am-*%m 4 am.a.uhem.-Aar -w em ar-4m.4.4mm aa_r_mae a .a ___us ...-._e_m.,m-__rm.w-._m+>- e-+%_.- .m -w. - -.a-- _m.m ---.w-se. m. e ] L e ,i 1i I I 5 i 1 l r i I i j r i t 1 i j APPENDIX A I l L i i l i If t I e 1 6 4 t e e e I e f 4 l 4 d h i il }, f 4 ll h I. E

HMTBD o INTER-OFFICE M ElA O UJY $M.9dE,ig[gg COMPOREGON NED-1154 can April 12, 1971 o R. Kropp at V(N enom E. Fass at corvto Criticality Safety Analysis of UNC Type

svanc, 2901 Shipping Container for 4.1 w/o U235 Yankee Rowc Fuel Pc11 cts. (2749-521) 1.0 Summary and Conclusions An.anplysis has been performed to determino the criticality safety of arrays of UNC Type 2901 shipping containers.

Each container was loaded with 240.0 lbs of UNC dr/o Yankee fuel pc11ets according the scheme of 4.1 w awing D-5008-8192 Rev. 3. Individual containers were found to be safe for all degrecs of internal and external flooding. Under normal transp' ort conditions, i.e., an inner container HfU235 = 110 provided by packing materials and no water in'the outer container, a safe array contains at 1 cast 144. containers in a cubic configuration with full water reficction on all sides. Q,s. Under accident transport conditions, the most reactive unit for producing the highest array multi-plication factor was determined to be a' unit with the inner container flooded and the outer container dry. An array of 50 such units in an approximate cubic con-figuration with full water reficction on all sides was found to be suberitical. 2.0 Description of Containers The Type 2001 container is a modification of the UNC Type 2000 shipping container. The modification consisted of replacing the inner cylindrical container with a square container with a 10.75'! inside side length. UO2 pellets are prepared foi shipment by placing the pollets into the grooves of corrogated, polyethyleno coated, steel trays. The trays are plac.ed one on top of the other until.a convenient handling size is reached (10 layers of pc11 cts maximum). The stack of' trays is wr,apped with a sheet of gum rubber, sandwiched betwoon two 1/2" hard maple boards and taped together. Four such stacks are assembled into one pellot package which will fit into the innor container, any void volume betwoon L (~} v w b e .g

-s pc11ct stacks is filled by further use of hard maplc (N boards. L.] 3.0 Method of Analysis Reactivity Icycls for individual containers and infinite arrays were calculated using th DTF code (1). The 16 group Hansen-Roach cross sections 2) were used and linear anisotropic hydrogen scattering was accounted for in the S4 approximation to the transport equation. The calculational model assumed infinitely long cylinders containing-homogoncous mixtures of materials (sco Table 1). Reactivity Icycis for finite reficcted arrays were calculated using the KENO (3) multigroup Monte Carlo criticality code. The 16 group Hanson-Roach cross sections were used and P1 linear anisotropic hydrogen scattering was used, other nuclei were assumed to scatter isotropically in the laboratory system at all energies. The calcula-tional model for KENO assumed homogencous regions of materials as in the DTF model but the three dimensional geometry more faithfully describes the shipping container (sco Figure 1). The reactivity. of' the containers.is deporillo'nt on the 7-moderating ratio and the pollet dimensions because of U the U238 resonance captures. The homogenization pro-coedure for the inner container must take account for this offect by an appropriate choice of the U238 cross section set. The nominal pollet OD for the Yanhoe fuel is 0.3105"; the nominal enrichment is 4.0 wfo U235 but in the interest of conservatism an upper limit of 4.1 wjo was used in this analysis. A previous analys Icycls of Yankee fuel rods in water {.g)of the reactivity has given th.c offective resonance integral and resonance escape pro-babilitics as a function of moderation ratio (sco Figure 2). The codo used was UNC's LOCALUX-2 (5), an improved version of the LASER (G) code, which calculates resonance data by the method of Strawbridge and Barry (7). The U238 cross section set for both DTF and KENO were determined by the offectivo potential scattering cross section por resonance JC /g4 It is determined absorber atom, i. c., 07 L p from the resonanco data by: E ~~ y f

• c-r t>y =
• P lIlp "

} ~ Ng k 'e r e e

The value of I is not appreciably affected by the (' ~) presence of heavy nuclei and it was assumed that \\s' could be adequately represented by 3[H2O - 0.95, a 2 conservative assumption when the U 38 cross section set is chocen. The DTF problems were run in order to determine the most reactive unit in an infinite array and then to use that unit in the KENO investigation of finite arrays. In order to represent infinito arrays of containers in DTF, reficction boundary conditions were applied at the out-side of the cell. The DTF problems were run for varying amounts of water in tne inner and outer container. The minimum H/U235 in the inner container is 113 and is pro-vided by tio polothylene, rubber, and wood packing materials. The maximu a is 205 and is accomplished by flooding of all availabic void space and absorption of an additional 0.054 gm/cm3 by the maple boards (8)..The hydrogen concentration in the ou ter container can range from zero to that of full-density 9ater depending on the amount of water absorbed in the Fiberlite. It will be seen however, that the addition of water to the Fiberlito always decreases the reactivity of an array an observation which has been made previously (9). 'An investigation of the reactivity level of an indi-73 (j vidual container was,made with DTF assuming A'ull water flooding of the Fiberlite and a zero flux boundary con-dition at the outside wall. c 4.0 Nuclear Safety Evaluation-Normal Transport Condition Under normal transport conditions, an array of shipping containers was evaluated assuming that the nominal O.D. of each container was 22.G"~and 144 containers ucre arranged in a G x 6 x 4 rectangular array. The outside of the array was surrounded by a 15cm thick water reflector. The array shape fac tor i.e., the array height,/Qbase arca, was 1.05. The inner container H)U235 = 113 is provided by hydrogenous packing material and a 6]>100bwas used for the U238 cross section set. KENO was run for this array for a total of 12,000 neutron histories. The first three batches (or 525 neutron historics) were shipped to minimize initial source effects from the calculation. KENO calculated a keff = 0.8G4 i 0.007 for this array. U e p

5.0 Nuc1 car Safety Evaluation - Accident Conditions ( ') For the KENO investigation of 'the accident '~ ~ it was assumed that the containers were damaged condition, such tl.at the other mean diameter is reduced for 22.6" to 21.1", this was determined from drop tests of the 2001 shipping container. ( 10 ) The DTF calculations for infinite arrays were performed for various amounts of water in the inner and ' outer container, the results of these calculations were shown,-in Tabic 2 and Figure 3. The O.D. of the shipping container was maintained at 22.6" since the lattice spacing of fissile units does not alter k for an infinite array. The Sotential scattering cross section per resonanco absorber atum was kept at 100 barns throughout the range of flooding of the inner container. Although &p increases to 200 barns for full flooding, switching cross section sets leads to a discontunity in'the curves, the overesti-mato.of the km by DTF at full flooding of the inner con-tainer by retaining C'p=100 barns is approximately 57o. Hero we are not interested in an exact estimate of km but .s. only the individual container configuration which gives the highest b relative to other configurations. From Figure 3 it is scen that the shipping container with the fueled zone flooded and the Fiberlite dry makes the most {} reactivo array unit. KENO was run for 50 such shipping containers in a 5 x 5 x 2 array giving an array shape factor of 0.67. c Each container had an outer mean diameter of 21.1". Figure 1 indicates that the pollet packago does not measure up to the full height of the inner container, the void space betwoon the top of the pellet pachage and inner container lid was assumed to be filled with water.. The array was surrounded on all sides by a 15cm thick water reflector. The U238 cross section set designated &'p=200 barns was selected. KENO was again run for 12,000 neutron histories with the first three batches being skipped in averaging keff. The KENO calculated hoff for this array is 0.955 1 0.00G. In a previous study of th.c Yankee Rowe fuct it was'found that the maximum critical buckling occurs at an H/U 35=240. It is possibic that the containers could be 2 i loaded with less fuel or have some pollet rows Icft empty by workmen, etc, such that, under*an accident condition, an inner container H/U235=240 could conceivably be achieved. Thoroford, as above, a KENO was run for an array of 50 reflected shipping containers, cach with an inner container ' H/U235=240; the calculated koff was 0.939 + 0.006. p Evidently, moving to a more optimum H/U235 ratio in the (), inner-container shifted the neutre spectrum such that increased absorptions in.the container stcol walls decreased the finite array Hoff. w. e -.w- ~ - ~ h

A' final DTF calculation was performed to check /~T the reactivity level of an individual container under ~ k/ optimum moderation and reficction conditions. The inner - container HlU235 = 240 was provided by full flooding and decreased fuel loading of that~ region. The outer container was also flooded to provide full reflection. The infinito cylinder representation of the 2901 had a DTF the neutron migration area found in /'o at an For Yankee fuel of 4.1 w calculated'k = 0.890. a previous H/U235-240 study 00 is 34cm2 The estimated unit hoff, assuming an axial reflector savings of 6.5cm, is then: k k 'ff = 1 + B c M z 0.890 1+(0.00158)34 = 0.845 9 A ' E'. Fass EF:ah attachments N e e e + e 9 S to

REFERENCES () 1. Carlson, B. G., et. al., DTF Users Manual, United Nuclear Corporation, UNC Pliysics afath 3321, Vol. 1 (November 1963) ; Vol. II (May 1964). 2.

Hansen, G.E.,

and Roach, W.H., "Six and Sixtcon Group Cross Section-for Fast and Intermediate Critical Assemblics", LAMS-2543, Los Alamos Scientific Laboratory (December 1960). 3. Whites, ides, G.E., and Cross, N.F., " KENO-A Multigroup Monte Carlo Criticality Program", CTC-5, Union Carbide Corpor' tion, Nuclear Division, Computing Tech'nology a Center, Oak Ridge, Tennessee, (September 1969). 4.

Fass, E., " Criticality of Yankee Puol Rods During Pickling and Corrosion", United Nuclear Corporation, UNC Memo NED-1083, (February 1971).

5.

Fisec11a, J.M., "LOCALUX-2 Program ' Description - Revision 3 of Physics Math 5201", United Nuclear Corporation, UNC Memo NED-725, (July 1970).

G.

Poncolet, C.G.,

" LASER a Dcpletion Program for Lattico Calculations based on MUFT and THERMOS", WCAP-G073, (196G). (m %) 7. Strawbridge, L.E., and Barry, R.F., " Criticality Calculations for Uniform Water-Moder~ated Lattices", Nuclear Science and Engineering, Vol. 23, No. 1 (19G5). 8. Strong, Ralph K, editor, Kingzett's Chemical Encyclopedia, Bailliere, Tindall and Cox, London, 8th edition (1952). 9. I* ass, E., and Tomonto, J.R., " Criticality Safety Analysis of UNC Type 2001 Shipping Container for UO2 Pellets", United Nuclear Corporation, UNC Memo NED-550 (April 1970). 10 Personnel Communication with L. Swallow, United Nuclear Corporation, Hemitite Missori, March, 1970.

1. 8 e

fy ne' 0 9 mg@m e, s. ,.g m a d ^- M--*W' b

O - I) C) ~ Table 1 'DTF Calculational Model - Region Material. Outer Radius, Components dnd em Number Density 1 UO2e.. steel trays, gum 15.405 N 235 - 0.00020467 U rubber, maple boards, N 238 - 0.0047272 polyethylene U N - 0.0054935 Fo N - 0.'013705 C N - 0.02320.7 H N - 0.012453 O O.01866 Interspersed water NJI variable, o.o to (when present) .hO 0.009333 2 . Steel inner container 15.619 N - 0.08359 Fe wall 5 3 Fiberlite insulating 28.575 N - 0.000026 material N - 0.000026 A1 N = 0.000G9 9 N - 0.000013 Ca N - 0.000079 g1 Interspersed water N .06686 g (when present)

variable, 0.0 to") 03343 y.O

(. ~ 1 4 Stoc1 outer container 28.697 N - 0.08359 Fe wall e a o

Table 2 DTF Calculated Multipfication Factors for an Array of 2001 Containers, Each Loaded with 240 ~ lbs of Yanhec Howo Fuel Pellets as a Function of the Amount of Water 1Ln the Fuel and Fiberlito Regions O H/U235, 113 in inner container Outer; container H (atoms barr-cm) km 0.0 1.199 O.0037G4' 1.148 0.0077G2 1.052 0.01199 0.962 235 H/U = 13G in inner container Outcr' Container H km 0.0 1.235 0.003764 1.175 235 H /U - 159 in inner container Outer Container H km 0.0 1.259 O.0037G4 1.199 0.0077G2 1.113 '-s O.01199 1.033 35 'H /U = 182 in inner container () Outer Container H km 0.0 1.278 0.003764 1.217 235 H /U - 205 in inner container (6p/NA=200 barns) Outer Container H km km 0.0 1.290 1.230 0.003764 1.230 1.181 0.007762 1.154 1.100 0.01199 1.089 1.049 0 0 4 e 9 4 9 e M e" .g m ,m e _ ha e a h.

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0 i 4 9 l APPENDIX B f O \\ i 1

DESIGN AND STRUCTURAL EVALUATION OF A LOW ENRICHED U0 PELLET AND POWDER SHIPPING PACKAGE 2 1.0

SUMMARY

A shipping package was designed for shipment of low enriched U0,3 pellets and powder. The package' consisted basically of a square metal inner cc:itainer supported and insulated inside an s55 gallon steel outer drum. Pellets were packaged inside the inner container on Polyethylene coated corrugated trays. The shipping package was subjected to a series of drop, fire, and water tests to evaluate its structural stability. The re-sults indicated that a structurally sound, fire-proof, leak resistant package had been developed.

2.0 DESCRIPTION

OF SHIPPING PACKAGE Details of the shipping container and pellet package are illus-trated on the attached drawings'#D-5007-8086, Revision 1 and D-5008-8192, Revision 2. The shipping container is to be iden-tified as a UNC Moder 2901. ] The basic components of the shipping pacx'qe are: 1. A 10.75" square inner container with a 1/2" thick flange and cover. C. Twelve 1/2" diameter bolts securing the cover to the flange. 3. A full-faced 1/8" thick asbestos gasket on the inner container. 4. Three 1-1/2" thick hardboard support rings. 5. Angle iron welde.s completely around inner container for securing the hardi: card. -f 6. A 1/8" thick a,bestos sheet on top and bottom outer drum. 7. .1" Thick plywood on bottom and 1-1/4" thick plywood on top of drum. 8. Fiberlite insulation,.75#/ft.3, between inner and outer container. P.U I is

y Design and Structural Evaluation of a ( Low Enriched U0 Pellet and Powder Shipping Package 2 -s '(j Page Two t 2.0 Description of Shipping Package (continued) The pellet package consisted of Polyethylene coated corrugated metal trays encascd in gum rubber and hardboard as shown on the aforementioned drawings. The pellet loaded trays were held in compression and securely banded to insure no movement of pellets. The exact size and UO, capacity is dependent on the pellet diam-eter. The packaging Besign allows for one or mcre individual packages inside the inner container with the overall size not exceeding the 10.75" square. 3.0 STRUCTURAL EVALUATION 3.1 Condi tions The shipping package was subjected to the hypothetical accident conditions of the tests specified in 10 CFR 71.36 and 49 CFR 173.398(c). Tests were conducted at two different loading levels. One package of depleted -pellets, assembled as shown on drawing number D-5008-8192 Revision 2, and three lead-filled wood boxes comprised Cc the test load for Test #1. The second test was cerformed at a greater loading, but with only the lead fi f ied boxes. The weight conditions tested were as follows-Test #1 Test #2 Tare Weight (Assembled Container Without Product Packages) 231 Lbs. 228 Lbs. Net Weight (Pellets & Packaging) [2273 " [427.}, "" 313 302 Equiv. Pellet Weight Equiv. Pellet Packaging Weight [ 86 ) " tl25[ " Total Gross Weight 544 Lbs. 655 lbs. 3.2 Discussion of Results Pictures of the package in its various stages of assembly and test are included in the Appendix of this report. .x~ -u-

l 1 l Design and Structural Evaluation of a Low Enriched U0 Pellet and Powder Shipping Package 2 Page Three V,,. 3.0 Structural Evaluation (continued) 3.2 Discussion of Rasults (continued) 3.2.1 Thirty 1oot Drop Test Conditions - The impact of the 30 foot drop was elesigned to occur at approximately 45' on the top corner of the drum aligned with a corner of the square inner container. The selected corner for the first test condition was the corner containing the actual pellet ~ package. These conditions were chosen as the most severe for the following reasons: 1. Experience from the same tests performed on other packages indicated that maximum damage occurs from angular impact. 2. Impact on the top end was most likely to break loose the outer drum lid and expose the inner container during the fire and O water tests. b 3. Impact on the top end subjected the flange of the inner container to the maximum force c and the seal on the gasket to the greatest potential for destruction. 4. The weld on the bottom olate was evaluated to be stronger than the parent metal, therefore, the point of failure from dropping on the bottom would have been the sides of the inner container., By dropping on the top corner, the sides were subjected to the same load and equal conditions existed. 5. The corners of the square insert had the least support. Therefore, impact at this point was directly on the weakest member. a l

Design and Structural Evaluation of a Low Enriched UO Pellet and Powder Shipping Package 2 Page Four~ -O 3.0 Structural Evaluation (continued) 3.2 Discussion of Results (continued) 3.2.1 Thirty Foot Drep Test (continued) 6..- Striking at ~an angle caused a greater rebounding effect and a minimum degree of suppert surface. (i.e., the top . corner hit first and then the bottom as oppo;ed to a single flat hit on side or.endonly.) A flat hit would allow an equal support distribution by the hardboard, plywood, cushioning, etc. and eliminate a greater concentrated force on one point. 7. The pellet package was subjected to i brunt of impact' from both the initial hit and the weight of the three simu-lated packages atop it. Results - The damage to the outer drum for Test #1 .h-in drum diameter as a result of impact was a maxi-(544 lbs.) is depicted i_n picture 3. The decrease mum of 1-1/2" on the top corner. The sm'all hole i l just below the lid retainer ring was inflicted by a small bolt which had been tied to a measuring-cord used to verify the 30 foot height. Damage to the plywood and hardboard supports for ' the inner container was not detrimental. The two 1" thick plywood disks encasing the inner contain-er flange cracked on the corners but remained in position. The bottom hardboard support broke on three corners and the middle hardboard broke on

the corner of impact. However, all pieces stayed in place and there was no warpage or shifting of the inner container.

(Seepicturesll, 13, 14, 17 and 18.) The hardboard supports' remained bolted to the angle iron and all welds between the inner container.and angle iron were sound.. ~ All f1ange bolts were in tact and securely tightened. There was no deformation of the flanged closure. A .h: .O o h

Design and Structrual Evaluation of a Low Enriched UO., Pellet and Powder Shipping Package Page Five %) 3.0 Structural Evaluation (continued) 3.2 Discussion of Results (continued) 3.2.1 Thirty Foot Drop Test (cor.tinued) The condition of the drum in Test #2 (655 lbs.) is shown in picture 3A. The nuter drum deformed s2" in diameter at the point of contact only, but otherwise showed no significant ciamage. Since the pellet package proved to uphold its tray-pellet-tray arrangement in the first test, it was not neces-sary to re-evaluate its stability a7d, therefore, theload was composed solely of lead-filled boxes. As was the case for Test #1, a few of the plywood and hardboard supports cracked but no damage occur-red to the inner container. (See pictures 58, SC, 50 and SE) All welds and bolts remained in tact and there was no shifting of either the inner con-tainer of thc supports. The increased loading had no significant effect on the integrity of the inner container following the drop test. g(/ 3.2.2 Piston Drop Test Conditions - For both 1oading conditions, the drum was dropped 5 ft. on to a 6" diameter x 8" long concrete piston. In Test #1, the point of impact was approximately midway between the center and upper hardboard support. This location was selected to determine if the outer drum would puncture and permit the piston to penetrate to the inner container. For Test #2, the selected impact point was directly on the center hardboard. This condition was evaluated to determine if the direct impact on the hardboard would drive it inward and deform the inner container. Results - The condition of the outer drum after the piston drop for Tests #1 and #2 is shown in pictures 5 and SA. In Test #1, a semi-circular hole was punc-tured through the outer drum in line with a corner of the inner container. No insulation or support material was lost through the hole and no damage was incurred by the inner container. A

w . Design and Structural Evaluation of 'a Law. Enriched. 00 Pellet and Powder Shipping Package 2 Page Six 3.0. Structural Evaluation (continued) l 3.'2 Discussion of Results- (continued) 3.2.2 ' Piston Drop (centinued) ~ For Test #2 (Picture 5-A), the piston hit. dire ~c-tly on the hardboard and only a small hole, sl/2" in diameter, was punctured in the outer drum. The hardboard was broken and chipped away for approximately a 3" x 2" area, but not completely through to the inner container (pictures SC and SD). The inner container-suffered a minor crease 9 /32" high and 3" long at the point where the hard-1 board was supported against the insert. The inner container suffered no major damage and remained in its original position. 3.2.3 Fire Test Conditions - The fire test was conducted using diesel fuel fed through piping manifolds placed n lengthwise down each side of the shipping package. -(> The flame was directed upward so it engulfed sides, top, and bottom of the package. The location and condition of. the package before, during and after the fire test is shown in pictures 6, 7, and 8. c The shipping package was placed with the-punctured hole facing upward on a grated metal framework s6" above the ground. - The flame temperature as read on an optical pyrometer was in excess of 1650*F throughout the 30 minute test. It is probable that the flame was well above this, as intense black smoke tended to bias the reading 1,0w. The fire test was conducted only for the Test #1 loading condition. _ Since the extra loading had no significant effect on the package condition after drop and piston testing, the parameters of the fire 'and water test were identical for both cases. There-fore,.the fire and water test results of Test #1 were also applicable for the loading condition of Test #2. g-o e o j -P:

Design and Structural Evaluation of a Low Enriched UO Pellet and Powder Shipping Package 2 Page Seven oU 3.0 Structural Evaluation (continued) 3.2 Discussion of Results (continued) 3.2.3 Fire Test (continued) Results - Pictures 9-18 illustrate the condition of the shipping package after all the tests were completed. As shown in picture 9, the 1/8" thick asbestos sheet and top 5/8" thick plywood were completely charr;d. The remaining plywood disks, pictures 10 and 11, were charred only around the edges, from 2-4 inches radially inward for the outermost piece and 3/4" to 1" for the inner disk. The uniform burn completely around the perifery of the plywood indicated an even heat distribu-tion throughout the package. The hardboard was c_harred slightly as indicated in pictures 12-16, but no substantial loss in strength resulted. Similar results were found on the bottom. As shown in picture 13, the Fiberlite insulation was charred radially inward front the outer container (n) for approximately 2 inches. However, the insula-tion in contact with the inner container was unim-paired. The temperatures reached on the inside wall of the inner container are indicated in figure c 1, page 9 The temperature template on the under-side of the container during the test registered 180 F. A template on the top side during the test showed that portion of the container reached 200 F. (These temperatures verify that the heat was well distributed from top to bottom.) This temperature range had no detrimental effect on the Ethafoam cushioning inside the inner container. Pictures 15 and 16 show the undamaged condition of the cushion-ing. The asbestos flange gasket and pellet package were undamaged by toe fire test; which is very ap- , parent in Picture 15. m)

Design and Structural Evaluation of a Low Enriched U0 Pellet and Powder Shipping Package 2 Page Eight 3.0 Structural Evaluation (continued) 3.2 Discussion of Results (continued) 3.2.4 Water Immersion Test Conditions - The drum was immersed in the hori-zontal position so that a minimum of three feet of water completely covered the shipping package. Results - Since the outer container had been punctured in the piston drop, the outer drum was thoroughly flooded. However, the inner container did not show any evidence of leakage after immersion for 8 hours. Some of the Etha-foam cushioning material had been crimped under the asbestos gasket during. assembly, but even so, no leakage occurred. Pictures 17 and 18, which were taken imediately after the water test, show no evidence of leakage. 3.2.5 Condition of Pellet Package 3(V The condition of the inner container contents af ter completion of the tests is shown in pic-tures 16-22. Although about 25% of the pellets were cracked or broken, (picture 22), the pel-let package remained in tact, (Pictures 19 and 20), and less than 1/2% of the pellets became dislodged (picture 21). Picture 19 shows the ends and center of the trays crimped together where the hardboard supports were located. The general condition of the pellet package was " good" with the pellet-tray arrangement remaining un-changed from the original assembled configura-ti on. Picture 23 shows the loaded pellet trays before assembly. Picture 22 shows the same gen-eral configuration after completion of the tests. All four packages remained in the exact position in which they were loaded (picture 15) and the inside of the inner container was not damaged in any manner. O kf. V F

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EVALUATION OF U0 POWDER DRUMS' 2 FOR USE IN MODEL UNC 2901 SHIPPING PACKAGE n 't s 1.0.

SUMMARY

A metal drum and inner cushfons were designed for the shipment of low enriched UO Powder in the Model UNC 2901 shipping con-2 tainer. The drums were filled with the maximum test weight and packaged inside the shipping container. The shipping container ~ was subjected to a 30 foot drop test to evaluate the structural . stabili ty of' the U02 powder drum. The results indicated that the po der drum was structurally sound for U02 powder shipments.

2.0 DESCRIPTION

. OF 00 POWDER DRUMS & INNER CUSHION 2 Details of the U0 powder shipping container assembly are illus-trated on the a.tt$ched drawing, #A-5007-20ll. MIL specifications of the drum and drawing #A-5007-8111 of the inner cushion are shown in the Appendix. The basic components of the shipping assembly are: ( l. Two (2) re-usable metal shipping drums as per Specifica-tion MIL D-50443, Part No. MS 24347-8. The drum was modified in the following manner to meet UNC require-ments. a. The inside depth was increased to 13-1/4 inches. b. A steel ring was added to the top lip of the container. c. The locking lugs were welded in addition to being rivi ted. 2. Three (3) 10-3/4 inches square x 1 inch thick Ethafoam. 3. Two (2) inner cushions of large bead Polystyrene. ,) ' w t: a

i Evaluation of UO2 Powder Drums for use in Model UNC 2901 Shipping Package Page Two ,. p uj 3.0 STRUCTURAL EVALUATION 3.1 Condi tions The shipping package was subjected to one of the hypothetical accident conditions of the tests specified in 10 CFR 71.36 and 49 CFR 173.398 (c). This test was the 30 foot drop test. Original testing performed for the pellet shipment has demonstrated structural integrity of the inner and outer cont'ainer including the ability to pre-vent water in-leakage. The net weight of the contents in that test was 427 pounds. Since the net weight of contents for UO2 powder is only 229.5 pounds, the original fire test, water test and " piston" drop test is applicable to this re-quirement; current testing was performed to demon-strate the ability of the powder drum to retain its contents. One test w'as conducted. The 2901 container was .{} - assembled with two U02 powder druns. Each was filled with 110 pounds of lead shot and sand. The weight conditions were as follows: t l Tare Weight (Assembled Container without Product Package) 227.5 pounds Net Weight (Sand, Lead Shot, Drums & Packaging) 229.5 pounds Equivalent Powder Weight 220.0 pounds Equivalent Drum & Cushion Weight 9.5 pounds Total Gross Weight 457.0 pounds 3.2 Discussion of Results Photographs of the shipping drum and cushioning in its various stages of assembly are included in the Appendix of this report. i , - we a 4-IU

Evaluation of UO Powder Drums 2 for use in Model UtiC 2901' Shipping Package Page Three ,19 v 3.0 Structural Evaluation (continued) 3.2 Discussion of Results (continued) 3.2.1 Thirty Foot Drop Test Conditions _ - The impact of the 30 foot drop test was designed to occur at ap-proximately 45 on the top corner of the drum aligned with the side of the square inner c.ontainer. The lugs of the powder druns were centered on that side of the inner container. The conditions were chosen as the most severe conditions for the following reasons: 1. Experience from the same test performed on other packages in-dicated that maximum damage occurs from angular impact.

2. ' The lugs on the locking ring n

were indicated to be the weak-U est structural point ci the po.vder drum. -3. Striking at an angle caused a greater rebounding effect and a minimum degree of support sur-face (i.e. the top corner hit first and then the bottom as opposed to a single flat hit on side or end only). A flat hit would allo.1 an equal support distribution by' the. cushions and metal drums and eliminate a greater concentrated force on one point. 4. The top powder drum was subjec-ted to the brunt of impact from both the initial hit and the weight of the seccnd drum. Results - The decrease in drum diameter as a result of impact was a maximum of 1-3/4 inches on the top corner. The drum,' drum I' lid and the locking ring remained intact. j b) No significant damage to-the plywood discs 4 was noted. All flange bolts were intact and securely fastened. There was no defor-mation of the flanged closure. m 9

Evaluation of U0 Powder Drums 2 for use in Model UNC 2901 Shipping Package i Page Four (~y v 3.0 Structural Evaluation (continued) 3.2 Discussion of Results (continued) 3.2.1 Thirty Foot Drop Test (continued) Results (continued) The top & center 1 inch thick Ethafoam cushions were conpletely severed by the iinpact of the powder drums. Both of the polystyrene cushions were broken in-to two pieces. Deformation of the cushion was not severe and both po.vder drums were securely in place. The locking ring and top flange of both powder drums were deformed. The bottom of the top powder drun. was also badly de-forned by the inpact of the bottom powder drum. Although the drune were deforned, the locking rings and lid *emained in place. There was no leakage noted at the drum lid or bottom seam. .O s -{c) f -.

1 - l: i l J p I 1(g f. APPENDIX t i= i k i. j 1. 00 Powder Shipping Container Assembly - A-5007-2011 2 2. U0 Powder Drum Specifications - MIL D-6055 2 1 1 3. . Ins'ert Pail Cushion - A-5007-8111 I. 4. Photographs t 4' i j-lO i-1 i' a bj. i f i I 5 3 i-ii i ? 1 A i i 3 !f' s i.. ~ ..e .c s

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