Text

QA Program 21PF-1 Overpack Mods. W/Four Oversize Drawings
	ML20043D345
Person / Time
Site:	07100700
Issue date:	05/30/1990
From:	Goertzen D; BRAUNKOHLE TRANSPORT USA, INC.
To:	;
Shared Package
ML20043D341	List: ML20043D340; ML20043D345; ML20261B018; ML20261B023; ML20261B026;
References
	NUDOCS 9006070404
	Download: ML20043D345 (91)
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4 21PF-1 Overpack Modifications 4

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I BRAUNKOHLE TRANSPORT USA INC.

QUALITY ASSURANC_R POLICY I

It is company policy to perform work or contract work on items i m por'.cn t to safety in accordance with the requirements of Subpart H of 10CFR Part 71 as described in the Quality Assurance program plan-and implemented in Quality Assurance Manuals.

Either the Vice President or President are delegated with the authority for implementing and revising the provisions of the described Quality Assurance Program and regularly assessing the scope, status, imp 1em.ntat1on ene offect1.n.ss o, the oua11ty Assuranc.,rogr.m.

PRESIDENT E

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_2 VICE. PRESIDENT I

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TABLE OF CONTENTS - MODIFICATIONS 1.0 Organi=ational Charts I

1.1 Organizational Chart #1 - Purchaser 1.2 Organizational Chart #2 - Manufacturer (Fabricator)

I 2.0 Procurement Document Control 2.1 Produrement Document Control - Purchaser 2.2 Procurement Document Control Fabricator i

3.0 Receiving of Incoming Materials 4.0 Dealing with Production Defects and Non-compliance 5.0 Documentation Control - Modifications l

6.0 Modifications to Existing DOT 21PF-1 Shipping Containers l

REPORTS AND INSPECTIONS l

4.7.1 Corrective Action Report

5.4.1 Non-conformance Report 5.4.2

" Job Number" Record I

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6.1.1 Drawing No. S1E-31536 J1 Rev.

D.

l 6.1.2 Drawing No. S1A-31536 V1 Rev. 0 I

6.1.3 Drawing No. E-S-31536 J Rev. 10 or 11 6.1.4 Bill of Material, Martin Marietta Energy Systems Number S-31536-16, Rev. 2 6.1.5 Fire Resistant Phenolic Foam SP-9-Rev. 1 6.1.6 Renovation of DOT Specification 21PF-1 Protective Shipping Packages K-2057, Rev. 1 l

6.3.1 Procedure for Drying & Weighing Specification 21PF-1 Overpacks (Excerpt from K-2057) Rev. 1)

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i 6.3.2 Fabrication checklist for modifying Model 21PF-1 shipping containers.

G.3.3 Receiving inspection report for materials used in modifying 21PF-1 shipping containers 6.3.4 Final Inspection Checklist - Modifications I

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I 1.

ORGANIZATIONAL CHARTS I

1.1 ORGANIZATIONAL CHART #1: PURCHASER I

BRAUNKOHLE TRANSPORT U.S.A.

INC.

I PRESIDEMI 1.

Implementing revising &

assessing the Quality Assurance Program I

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l l-2.

Issue and Review of-Purchase Orders.

3.

Approval or Disapproval on Non-conformance.

yl_C_E-PRESIDENT 4.

Approval of Final l

Inspection and related

)

Documentation.

BRANCR Eb} LAGER 5.

Inspection of Documents F_4BRICATOR 6.

See Organizational Chart

2.

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I 1.2 ORGANIZATIONAL CHART #2:

MANUFACTURER (FABRICATOR) i i

GETCHELL AND SONS INC.

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PRESIDENT 1.

Issuing and Review of

)

Purchase Orders.

E QUf1L.J1Y. bySURANCE 2.

Approval c,r Disapproval l'

l MANAGER of Non-conformances (with BTUSA)

I 3.

Inspections at hold point-points during-manufacturing.

l I SHOP FORMAN Receiving and Inspecting.

Incoming Materials.

I SUB-CONTRACTOR Compliance with Specifications and providing cerifications of same.

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2.

PROCUREMENT DOCUMENT CONTROL 2.1 PROCUREMENT DOCUMENT CONTROL - BTUSA (PURCHASER) 2.1.1 Purchase orders are to be issued to the fabricator specifically outlining the scope of work to be performed.

2.1.2 Purchase orders must specifically state the technical requirement I

including the applicable regulatory requirements, material and component identification requirements, drawings, specifications, codes and standards, special process instructions and test and inspection requirements.

2.1.3 Purchase orders issued to the fabricator are to state the requirements of BTUSA in so far as the fabricator's

'I responsibility to follow and comply with all requirements as specified in the Quality Assurance Manuals.

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2.1. 4 Purchase orders issued to the fabricator will require permission 3

to gain access to their or their subcontractor's plant l

facilities and records for inspection or audit purposes.

2.1.5 Purchase orders issued to the fabricator will specify the L

documentation that must be prepared, maintained and submitted for L

approval.

These will include such items as:

Materials Receiving Inspection Reports Inspection Checklists at Specified Hold Points Verification of conformance to Specifications 2.1.6 Purchase orders issued to the fabricator will identify those records that must be retained, controlled and maintained by the I

fabricator and its subontractors and also what records or verifications must be delivered to BTUSA prior to final inspection by BTUSA or its agent; of the unit.

2.1.7 Purchase orders must specify that the fabricator must report to BTUSA any nonconformances to specifications immediately upon becoming aware of some.

The order will state that the fabricator must not furthor proceed with the particular area of nonconformance until approval for same is issued in writing by an authoriced official of BTUSA.

- I-2.1.8 Purchase orders and a revision or change to any purchase order must be received and issued by an authoriced official of the company before issue.

The officials must date and sign his/her approval on the purchase order before release.

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2.1.9 Purchase orders will require the fabricator to enable the l

I complete traceablity of certain raw materials used by the fabricator or its sub-contractors, such as the ones relative to safety including in this instance the stainless steel, angle iron, phenolic foam insulation.

2.1.10 Purchase orders will require the fabricator to use only certified welders and processes in the production of the unit.

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I 2.1.11 Purchase orders will require the fabricator to provide

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inspections at specified hold points during the manufacturing I

processes. These inspections will be required to be carried out and certified on inspection checklists by a qualified inspector.

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2.2 PRr.0UREMENT DOCUMENT CONTROL - FABRICATOR 2.2.1' Purchase orders are to be issued to the. subcontractors and I

suppliers specifically outlining the scope of work to be performed and/or the technical requirements including the applicable regulatory requirements, material and component identifications, codes and standards, special process instructions and test and inspection requirements.

H2.2.2 Purchase orders issued to the subcontractor are to state the I

requirements of BTUSA in so far as the subcontractor's responsibility to follow and comply with all requirements as specified in the Quality Control and Quality Assurance Manuals.

2.2.3 Purchase orders issued to the subcontractor will require permission to gain access to their or their subcontractor's plant facilities and records for inspection or audit purposes.

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2.2.4 Purchase orders' issued to the subcontractor will specify the documentation that must be prepared, maintained and submitted for I.

approval.

These will include such items as:

verification of conformance to specifications bills of lading shipping documents specifying technical details of materials shipped.

L 2.2.5 Purchase orders issued to subcontractors must identify what l g records must be retained, controlled and maintained by the I

sub ntract r and which records of these which must be delivered to the purchaser prior to installation of the material or i

hardware.

i 2.2.6 Purchase orders must specify that the subcontractor or supplier must report to the fabricator any non-conformance with specifications immediately.

The order will state that the subcontractor or supplier must not further proceed until approval for same is issued in writing by an euthoriced official of the I

fabricator.

2.2.7 Purchase orders and a revision or change to any purchase order must be received and issued by an authoriced official of the l

company before issue.

Both officials must date and sign their

, a approval on the purchase order before relecae.

I 2.2.8 Purchase orders will require the subcontractors to enable the complete traceability of raw materials used or supplied if they relate to the safety of the unit.

In this instance the traceability of the angle iron, stainless steel and phenolic foam I

must be available.

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1 3.

RECEIVING OF INCOMING MATERIALS I

3.1 Receiving report for materials to be used in the manufacturing, repair, or modification for shipping containers for 30" UF6 cylinders will be completed for each Job Number.

3.2 All incoming items are to be inspected for quality and conformance to procurement document requirements.

3.3 After inspection, the items will be recorded on the Receiving l

Inspection Report and verified by the inspector.

Any nonconformance must be reported at this time by the inspector to the Quality Assurance Manager on a non-conformance report.(5.4.1 Attached) l j

3.4 Mark or tag all incoming items with the appropriate " Job Humber".

Ig Attach " Reject" tags to all nonconforming items and isolate for return g

to vendor or disposition by management.

Ll 3.5 Ascertain that each stainless steel item is marked with its " Heat l

Number" and that a matching material test report, which demonstrates l"

compliance with the applicable specification, is received and filed.

Copies of these material test reports are to be submitted to the purchaser at time of final approval for acceptance.

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'4.0 DEALING WITH PRODUCTION DEFECTS AND NON-CONFORMANCE 4.1 Any conditions which may affect quality such as deficaencies, deviations, defective material and equipment arid noncenformances must be promptly identified and corrected.

4.2 In the event of a condition which would be adverse to quality, the fabricator will require all applicable personnel to notify the Quality Assurance Manager immediately of the condition and a Repert is to be prepared recording the condition, the cause of the-condition once it is determined and the methods used to correct the condition and avoid the occurance of the condition in any~ future applications.

4.3 The Corrective Action is to be reported by the Quality Assurance Manager to the Purchaser to show the handling of the condition before acceptance of the peckage by the Purchaser.

(See Correction Action Report 4.7.1) 4.4 The Purchaser must specify on the procurement documents that the regulations pursuant to 10 CFR Part 21 apply to che menufacture of the unit.

4.5 The fabricator will be required to post Section 206 of the Energy l

Reorganication Act of 1974 and a notice which describes the procedures including the name of the individual to whom reports may be made and where they can be examined.

4.6 In the event that a deviation or defect has not been corrected and I

this does not comply with the specification, the fabricator will be instructed to notify a responsible officer of the Purchaser.

This responsible officer of the Purchaser will then attend to the notification of the Nuclear Regulatory Commission if the defect falls within the reporting requirements of 10 CFR Part 21.

l 4.7 Attachements 4.7.1 Corrective Action Report

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I 4.7.1 CORRECTIVE ACTION REPORT

. DATE:

JOB NO:

4 CONDITION OR ACTIVITY AFFECTING QUALITY:

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. DETERMINED CAUSE:

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METHOD OF CORRECTION:

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DATE:

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DOCUMENTATION CONTROL - MODIFICATIONS 5.1' Copies of ell applicable Receiving Inspection Reports, Non-Conformance reports, Production Inspection Reports, Final Inspection Reports will be submitted to the Purchaser after completion of the units

.by Job No. for verification and approval.

1 9.2 Each order for these overpacks will be issued a Job Number by the fabricator.

The fabricator will keep a list of numerical job numbers per the attached form to cross-reference purchase orders, materials and the finished product.

See " Job-Number" record attached.

Each unit will be cross-referenced on the Record by its Serial Nunmber.

5.3 The Fabricator will keep copies of all documentation and samples l

associated with the production of each package for not less seven years after the completion of the package.

Before destroying such documents, the fabricator will contact BTUSA for approval of same.

3

5.4 Attachments

3 5.4.1 Non-Conformance Report 5.4.2 " Job Number" Record

1 I-Pl..

5.4.2

" JOB: NUMBER" RECORD BTUSA UNIT SERIAL Date Job No.

Customer Name P.O.

NO.

GETOO1

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6. MODIFICATIONS TO EXISTING DOT 21PF-1 SHIPPING CONTAINERS 6.1 REFERENCE INFORMATION 6.1.1 Drawings No.

S1E-31536 J1 Rev.

D.

a.

Modifications to existing shipping containers for 30" dia.

UF6 tank.

6.1.2 Drawing No.

S1A31536 V1 Rev.

O a.

Package Identification Plates for 21PF-1 A&B Shipping Containers 6.1.3 Drawing No.

E-S-31536 J Rev.

10 or 12 6.1.4 Bill of Material, Martin Marietta Evergy Systima Number S-31536-16, Rev.

2.

6.1.5 Fire Resistant Phenoic Foam SP-9-Rev.

1.

6.1.6 Renovation of DOT Specification 21PF-1, crote;tive Shipping Packages K-2057, Rev.

1.

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1 6.2 Procedures for Modification 6.2.1 a.-

Container shall have the water removed from the foam insulation in accordance with Martin Marietta Energy Systems Report K-2057, Rev.

1 " Renovation of DOT apecification 21PF-1 Protective Shipping Packages" See attachment 6.3.2.

Verify procedure on checklist.

6.2.2 Inspect outer shell joint to ensure flatness.

If within 1/16" for cover and bottom elements record same on inspection checklist.

If not, procedures to bring this to proper flatness are to be done and then recorded on checklist.

6.2.3 Corrosion of tho' outer shell, inner liner or support framing shell be aanded or ground out and removed to new metal. The extent and depth of corrosion shall be measured (use a pit gage and an ultrasonic thickness measurement instrument to determine the depth of corrosion) areas of corrosion as large as six square inches and as deep as 030" shall be repaired by welding a steel patch (at least 060" thick) over the defective area.

Also any area pitted as deep as 045" any fashion, using steel of I

adequate thickness existing welds that are broken or cracked, shall be ground out and repaired.

Record on checklist what procedures were carried out for each package.

6.2.4 Welding & welder qualifications shall conform to ANSI /AWS DI 1 SECTION 5, use E70XX welding rod at step joint welds and patch _ welds use wet rags in front and behind welds to reduce heat to a minimum and welds shall conform to l

ANSI /AWS DI 1 Section linear defects over 1/16"shall be ground out and repaired.

Record visual inspection on checklist and final approval of verifying linear defects are not in excess of 1/16".

L 6.2.5 Seal holes in pop rivets at owner's & package identification plates and reseal around all nails and j

screws in inner liner and outer shell (cover & bottom elements - 190 places) as needed, with metalset A4 Epoxy remove paint and foreign matter from around vent holes redrill the holes to 1/4" dia, and seal them with plastic l

with hardener No.

951, from CIBA Products Co.

Fairlawn, plugs set in epoxy (epoxy - such as Araldite No.

502

[

NJ and plugs - such as capluga No. BPF-1/4, polyethylene, ll from Protective Closures Co.,

Buffalo, NY) Verify

'E procedure on checklist.

6.2.6 Drill drain holes in stiffener angles.

Verify procedure on checklist.

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6.2.7 Thoroughly clean, degrease, and paint both face of the O

I step joint cover, except 1" from welds, with one coat of primer (ALB1 #487S).

Let it air dry for one hour, and

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install.the joint over. Verify procedure on checklist.

6.2.8 Straighten or replace, as needed, the L1X1X1/8 cover support legs and weld securely to the cover.shell and to the 1/4 x 3 corner band.

Verify procedure on checklist

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and indicate what procedure was taken eg. atraighten or

. replace.

f 6.2.9.

Remove other rust spots, scratches, loose paint, etc. and l

I paint these areas and the patched areas with primer and finish coats of paint that are compatible with, and match, existing paint.

Verify procedure on checklist.

6.2.10 Seal joints between stiffeners and outer shell (see detail 8 on Drawing No.

S1E-31536 J1 Rev.

D.

Verify procedure on checklist.

6.2.11 Install gaskets and paint stepped joints - see I

instructions on Drawing No.

S1E-31536 J1 Rev.

D.. Verify procedure on checklist.

6.2.12 Verify that existing bolts, nuts, washers, and bolt keeper l

cotter pins are are specified on drawing E-S-3iS36 J, Rev. 10 or 11.

Replace any of these items that are missing or different than specified (eg. bolts and nuts ll with wrong marking or visibly damaged threads.) Verify a

procedures on checklist.

6.2.13 Weigh in 1bs.

-(and in kgs.) the modified cover, bottom element and a saembled package (bolts, nts, and shackles j

with bottom element, without inner cylinder, tol=+ 5 lbs.

or + 2 kgs.) using these weights, relabel the cover and ll mark new package identification plates as noted.

Verify

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procedure on checklist.

l 6.2.14 Final inspection of unit to be carried out by Quality E

Assurance Manager or President to verify procedures have been carried out per specifications and that unit meets

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the acceptable standards per the specifications.

E 6.3 Attachments 6.3.1 Procedure for Drying & Weighing Specification 21PF-7 Overpacks.

6.3.2 Fabrication checklist for modifying Model 21PF-1 shipping containers.

lE, 6.3.3 Receiving inspection report for materials used in E

modifying 21PF-1 shipping containers.

6.3.4 Final Inspection Checklist - Modifications I

I 6.3.1 EXCERPT FROM K-2057 REV. 1 Procedure for Drying and Weighting Specification 21PF-1 Overpacks I

1.

Drill out or otherwise clean the plug material from the vent holes originally provided for foam expansion.

See drawing S1E-31536J1, Rev.D for locations.

I 2.

Weigh each package half separately to an accuracy of +5 pounds and record weights.

3.

Place in drying oven; maintain temperature between 190 and 210 F in I

the vicinity of the package units.

The oven should have a provision for air exchange or other means of removing moisture driven from the foam structure.

4.

Maintain parts and furnace at temperature for 72 hours8.333333e-4 days 0.02 hours 1.190476e-4 weeks 2.7396e-5 months minimum before first weight check.

5.

Drying may be discounted at this point if weight is within 25 pounds of nameplate weight for the package half.

If higher water content is indicated, continue drying until the weight target is reached I

or until the loss rate is below 2.5 pounds per day. (See K-2057 Revision 1 attached.)

6.

As an alternative moisture check, a calibrated moisture meter reading for 20 percent maximum water content may be used to indicate an end point in the drying cyle.

7.

Following drying, each overpack half (top and bottom) is to be weighed to an accuracy of +5 pounds and the individual weight stamped on the appropriate indentification plate.

See drawing S1E-31535J1, Rev. D for details.

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I 6.3.2 Checklist for Modifying existing shipping container for 30" diameter UF6 tank.

I Package Serial No.:__________________

Order No.:___________________

Job No.:_____________________

Verification of Procedures I

1) Removal of water per procedures-L Original weight of container top : _______________ lbs. _____________ Kgs Original weight of container bottom: ____________ lbs.____________ Kgs Date & Time entered drying unit: ____/____/____

____:.___ am /pm Date & Time of ist weight check: ____/____/____

____:____ am / pm I

ist Weight check of container top:

lbs.______________ Kgs 1st Weight check of container bottom: _______ lbs.___________ Kgs Date & Time of 2nd Weight check:

____/____/____

____:____ am / pm 2nd-Weight check of Container top:

lbs.______________ Kgs lei. Weight check of Container bottom:

lbs.____________ Kgs Date & Time of 3rd Weight check: ____/____/____

____:____ am / pm I

3rd Weight check of container top:

lbs. _____________ Kgs L

3rd Weight check of container bottom:

lbs. __________ Kgs Verification of drying to required specifications per K-2057 /rev.

1.

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cI QUALITY ASSURANCE MANAGER

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6.3.2 CHECKLIST FOR MODIFYING PAGE 2 2)

Verify Outer shell joint within 1/16" flatness __________ Initial.

Procedures used:________________________________________________________

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3) Verify final condition of following components have been measured &

repaired as per:

Outer Shell

______ Intl.

Procedure:_________________________________________________________

Inner Liner Inti ll I

support framing

______ Inti Procedure:

4)

Visual inspection of new welds conforms to ANSI /AWS D1 1 Section 6 no linear defects over 1/16" Intl.

I 5)

Procedures carried out per specifications on Drawing No.

S1E-31536 J1 Rev.

D.

All vent holes sealed Inti.

6)

Verification of Procedure 6.2.6 Drain holes drilled

_____ Inti.

7)

Verification of Procedure 6.2.7 Paint step joint cover _____ Intl.

& install joint.

8)

Verification of Procedure 6.2.8 Straighten or replace Inti.

9)

Verification of Procedure 6.2.9

_____ Inti.

10) Verification of Procedure 6.2.10 Seal joints between Intl.

stiffeners and outer shell.

11) Verification of Procedure 6.2.11 Installation of Intl.

gaskets & paint stepped joints

12) Verification of Procedure 6.2.12 Bolts, nuts, washers

_____ Intl.

& cotter pins are per specifications.

13) Final weight OK DATE Modification cover

_________ lbs. _________ Kgs.

Bottom element

_____________ lbs. _________ Kgs.

Assemble Package ____________ lbs. _________ Kgs.

j Package I.D.

Plates Installed

_____ Inti.

Cover Relabelled

_____ Intl.

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[MUST BE VERIFIED BY QUALITY ASSURANCE MANAGER 3 P E6EEE ~~~~~~~~~~~~~

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DATE:______________

DATE:_____________

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6.3.3 Receiving Inspection Report for material used in Modifying 21PF-1 shipping containers.

JOB NO:_______________

MATERIAL & DESCRIPTION QUANTITY INSPECTION I

ORDERED RECEIVED OK DATE Sheet, hot rolled steel, 14 Ga. x 2'-6" x8'-0" Lg. ASTM A-570, Grade 30, 33 or 36, ASTM A-606 Type 2 or 4, or ASTM A-569.

1 Epoxy, Araldite #502, CIBA Products Co.,

l Fairlawn, NJ.

Hardener, CIBA Products Co.,

951 Paint, Primer, ALBI #4875, (ALBI Mfgr.

Co.,

East Berlin, CT).

Paint, Primer, PPG Zine Chromate, Iron Oxide 17-6.

Paint, Finish, PPG Ironhide Metal Paint, Light Grey I

Silicone Rubber Sealant, 732 RTV, S11astic, Room Temp. Vulcani=ing, General

.I Purpose Color White, Dow Corning 10.3 oz.

Cartridge.

1 g

Rubber, RTV Moldiing, S11astic E, with

B Catalyst, 11 lb. per uit, by Dow corning (Alternate - use 1 1/2" x 1/4" thick x 42' - 0" Lg. Closed Cell, Medium Density Silicone Sponge rated for continuous use at.> 400 F)

Paint, Fire Ratardant, ALE, 107A, White Paint, Finish, ALBI #144, White Pina, Cotter, Spring Steel, 1/8" x 1 1/2" Caplugs, Polyethylene, Protective Closures ______

I Co.,

Buffalo, NY, #BPF - 1/4" I-Heavy Hex Head Screw, 3/4"-10 NC 2A.

6" Lg.______

ANSI B18.2.1, ASTM A-193 Grade B7 with proper marking and material certification.

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i PAG 5 2 6.3.3 RECEIVING INSPECTION REPORT FOR MODIFICATION TO 21PF-1 SHIPPING I

CONTAINER Lock Washers, 3/4" Cadium Plated Steel, U.S.

standard Washers, Flat, Steel, 1 1/4" O.D.

x 9/16" I.D. x 3/32" thk.

Washers, Flat 3/4" Cadium Plated Steel, U.S.

Standard l

Nuta, 3/4" - 10 UNC 2B, ASTM A-194, Grade 2H ANSI std. B 18.2.2, SF, Heavy Hex with proper marking and material certification l

Sheet, 20 Ga. x 11" x 2'-6",

ASTM A-240, Type 304L, #2B finish.

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6.3.4 FINAL INSPECTION CHECKLIST - MODIFICATIONS I

Package Serial Number:

Order No:

Job No:

A.

Welds I

OK DATE Re-inspection of all visible - conform to specifications B.

Flatness of outer shell joint surfaces within 1/16" C.

Weights:

lbs.

Kgs.

Inti.

Date Finished Cover Tare Weight I

Finished Lower Tare Weight Assembled Package Tare Weight (Conforms with Specifications)

OK DATE D.

Vent holes sealed E.

Fit of cover to body F.

Verification of Modification Checklist Report that all procedures and inspections which should have been conducted at either stages have been performed and data is acceptable.

G.

Stencils & Nameplates Package Tare Weight stamped on I-nameplate & is same as final inspection weight.

Package markings in appropriate places I

We certify herewith that the above-described package has been modified in accordance with the specifications provided on the drawings and purchase order and conform to same.

I QUALITY ASSURANCE MANAGER DATE:

I

+

L OVERSIZE

)

L JDOCUMENT L PAGE PULLED j

SEE APERTURE CARDS NUMBER OF OVERSIZE PAGES FILMED ON APERTURE CARDS 6

v.

APERTURE CARD / NARD COPY AVAILABLE FROM DECORDS AND REPORTS MANAGEMENT BRANCH

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6.I.2 l

PACKAGE IDENTIFICATION PLATE I

A.

PLATE SHALL BE 11" WIDE X 15" i.ONG X 16 '!O 20 GAGE STAINLESS STEEL SHEET, AS'IM A-240, TYPE 304L.

J B.

ENGRAVE PLATE WITH LETTERS 1/2" HIGH AS FOIRES:

USA-DC7f-UUU*

RADIOACTIVE MATERIAL-TYPE AF I

V--V*

)

SERIAL NO. XXX*

NIC-YYY*

TARE WP. (W/O INNER CYL) IN LBS (AND KGS):

I DATEt COVER:

BCTI' ION (W/SHKLS

'IOTAL PKG LBS (KGS)

BLTS, NUTS) : LBS (KGS)

LBS (KGS)

DDD*

WWW* (ZZZ)

WWW*(ZZZ)

I g

--______._____.__________.._..___g (6-LEAVE THE BCTI'ICM 8" X 11" BLANK FOR FLTTURE DATES & WEIGHTS)

I C.

ATTACH PLATE 'IO C0tfrAINER AS SPECIFIED ON FABRICATION DRAWING.

'UUU-SPICIFIC DCrt SPECIFICATION NUMBER [ EXAMPLE: USA-DOT-2.9F-1B,304L-SS (IF S/S INNER LINER IS USID)).

V---V - NAME OR SYMBOL, APPROVED BY THE ASSOC. DIR. OF MT, DOT, OF MAKER OR PARTY CERTIFYING COMPLIANCE WITH SPICIFICATION REQUIRD4ENTS; AND DATE OF MANUFACWRE (EXAMPLE: m-ES, K-25, OAK RIDGE, TENN. 9-67).

I XXX - SERIAL NO. OF INDIVIDUAL CONTAIhER (EXAMPLE: 123-001)

YYY - USNRC TRANSPORTATION QUALITY ASSURA!CE PROGRAM APPROVAL NUMBER (EXAMPLE: NRC APPRL NO. 9999).

DDD - DATE OF WEIGHING (EXAMPLE: 9-86).

I WWW - ACWAL TARE WEIGHT OF AN ELEMERf OR AN ASSD4BLID PACKAGE IN LBS. (Tol=+ 5 LBS)

ZZZ - ACWAL TARE WEIGHT OF AN ELEMENT OR AN ASSEMBLED PACKAGE IN KGS. (Tol=[ 2 KGS)

REFERENCE DRAWINGS: ES-31536J, SlE-31536J1, f. SlE-3153632; LATEST REVISIONS I

CAPE-1662 (Rev. 1) Suppl. 1

.4 I

0 ISSUED FOR 00T SPECIFICATION FWS FWS

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Page 2 of 2 13, 1 Lot Heavy Hex Head Screw. 3/4".10 NC 2A. 6" Lg.

I AN$1 B18.2.1. A$TM A.193 Grade 87 with Proper Marking and Material Certification 14.

1 Lot Lock Washers. 3/4" Cadium Plated $ teel. U.S.

Standard 15.

1 Lot Washers. Flat. Steel. I 1/4" 0.0. m 9/16" !.D.

a 3/32" thk.

I 16.

1 Lc,t Washers. Flat. 3/4" Cadmium Plated Steel. U.S.

Standard 17.

1 Lot Nuts. 3/4".10 UNC 28. ASTM A.194. Grace 2H I

ANSI $td. B 18.2.2. $F. Heavy Hex with Proper Marking and Material Certification 18.

1 Pc,

$heet. 20 Ga. x 11" x 2'.6". ASTM A.240.

Type 304L. f28 Finish I

I I

I

6.1.5 STANDAllO REFERENCE INMNtMATION wum WMON CAMSE CORPORADON J8-31536-1 R2v. 1

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3-28-6B FIRE RESI511UIT PMENOLIC FTRM a..e nm This specification shall evver materisls and procedures for mixing and applying fotaed-in. place fire resistant phenolic foam where specified on the drawings.

I-MTERIALS AND PROP 0RTIOg,-

All materials used in the fire resistant foam shall be as listed below and shall be prepared by blending, screening $etc., as defined. Sub-stitutions of matbrials may be made only where noted.

Total quantity of materials shall be as required to fill the container cavities and

,I' -

provide the finished foam weight as defined on the drawings.

Individual s

weight quantity of each component material shall be such to provide a j

finished roam material alxture of the proportionate blend specified below.

1 Cceponent Welght per 100 Lb. of Matl.

Material Vendor. Trade Name (Lbs.)

[

Liquid Caponents-Phenolic Resin UCC Plastics Division 65.8 + 0.2

~

BRL-2760 (Toam Denaity

[_

1.8 E.0 Lbs./Pt.3)

I)',

Surfactant UCC flastics Division 2.0 + 0.1 Silicone Surfactant L-330, or equal Refrigerant 113 '

DuPont Freon 113, or 6.6 + 0.1 Powder C aponents Boric Anhydride Varlaeoid Chemical 14.1 + 0.1 (th0 ), Powder, Company No. 1136, or

~

3 I;'

Reagent Grade, equal

-100 + 200. Mesh

Resin foam value as determined by method used at the Marietta chio Plsnt of the UCC Plastics Division.

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STANDARD REFERENCE INFORMADON J8-31536 1 Rev. 1

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Camponent Weight per I

100 Lb. of Matl.

(Lbs.)

Dendor - Trade Ramos Material Poster Campanente (Contd)

Varlacoid Chemical k.1 f,0.1 Borie Anhydride (8,0 )-

Campany No.1137, or 3

Powder, Reagent Orade, -200 Mesh equal.

,/

I]l 8.2 + 0.1 Ozalic Acid, H C o,

Baker and Adamson 2pg No. 1135, or o ps.1 Anhydrous Powder, Reagent Orsde i

Reinforcina C aponent Owens Co-ning Fiberglas 9 2 + 0.1

[

F.iberglass Rovings No. 805 (HSI), or egal 1/k"ChoppedLengths MATERIAL 81DRAGE REEtTIRDit:NT8 5

Phenolic Resin Store in airtight storado container.

1.

Maximum shelf life is three months fra date of manufacture if 2.

stored at room temperature.

PtLximum shelf life is six aanths fram date of manufacture at a tempersture of 40 f,, 50P.

Date of manufacture should be marked a the storage ecmtainer.

NOTE:

Pre-blended Liauid Campenents The three liquid caponents any be pre-biended or stored separately.

If pre-blended, the liquid airture any be stored in airtight storage 0 + So i

3 containers at's temperature of 40 l

ceeding one month prior to final blending, provided thi If the liquid components are stored separately, the same storage re-quirenents must be observed for the phenolic resin etsponent.

s:

Powder Components _

All powders shal.1 be stored in airtight storage conta ji l

I

- l moisture.

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STANDARD REFERENCE INFORMATioN a=aa

_J8-31536-1 Rev. 1 ov

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3-28 66 3-28-68 FIRE RE81E' TART P}tER0LIC FMM

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1 3

3 All Other Materis,la Store all other component materials in airtight storage containers at roam tenperature until ready for blending.

_ PREPARATION OF RECEIVER CONTAIKD AND ACCTSSORIts Contai_r.el In preparing a container for receiving the foamed-in place filling, all loose inner pieces shall be securely anchored in place to prevent dis-placement by the feas, and vent holes to prevent voids in the finished roam and to provide gas reiter when expored to high heat shall be drilled as defined on the drawings.

The necessary blocking, framing, bracing, etc., shall be installed to h.31d in place the container shell, ende.

lininge etc*, as applicable, s.nd prevent distertion to eat-of-tolerance condition during the fcaming creratio:1.

q Molds Holdo to shape exposed surfaces of foaa shall te installed and necured in position,just after the fir.a1 fcam raw estarial is placed so f Jen enn expand into thy sold. Air vent holes not exceeding 1/l " in diarw'.cr r.ny 4

be made at intervals in a mold to allow for escaping air and ther4y prevent veld spaces in the finlahed eurface. Molds shall be e.ada or r.urh strength to prever.t distortion to eat-of-tolarance condition durint. *ho foaming cperation.

A mold reletoe (e.g. Dnernon n,nd Cuming sold releare cm.poand Nc.122S or Inpont Tefim) che,11 be applied to sold hurfaces whith will contact Team material so that the anid ca.n be removed witho'it dama6 ng the finished roam surface.

1 C,}eani,r3} gore Tcsatng All sawdust, bits of vcod, metal filinge, water droplets, grease. oil, and cther foreign particles shall be removed frce the molds or con *,alhtr cavities before fcam rsw material is added.

MIXING PROCEDUPES Pro-Blending

Liquid Compenerg - Pre-blend liquid components in any order by ccut,ining the in6redients and stirring to a uniforia consistency.

Temperature of the phenolic resin shall be 603 +, 5'r when it in added to the mix. If

. final blending is to be delayed, reseal the blended ccuponente no e,

atmospheric exposure is reduced to a minimum.

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-.3 STANDARD REFERENCE INFORMATION ma* = =

J8 31536-1 Rev. 1 es,s 3-28-66 eva,e s,

esmee 3 26-66 FIRE REBIS'DutT PRENOLIC FQu(

7:res 4

5 Powder Cceronents Screen au ccasponents through a sieve (National Dureau of Standards No. 40) and pre-blend to a uniform consistency. Reseal blended components so atmospheric exposure is reduced to a mir.imum.

Final Blending 1.

Add liquid ccaponents or pre-blended liquid ccaponents to mixer tub and stir to a uniform censistency, abeJt 2 minutes for pre-blended etaponent s.

Temperature of the phenolic resin or pre-blended liqui =.

ccaponents shall be 600 1 5"T when it is added to the mix.

Add fibe glass hd mix to a uniform censisten:y.

2.

3 Add the pre biended powder ccanponents rat,1dly and mix to a uniform consistency, 30 to 60 seconds.

I h.

Cuickly transfer the mixed raw riterial to the receiver container so l

thst the foaming acticn takes place within the container.

PLAr:1NG AND CURING FOAM MATERQL, The mixed fcam raw materiki shall be spread evenly over the bottem ourfaer of the receiver cer.tainer so roam exrands in relatively uniform Inyern.

The first pcur of bottca section shculd be tamped. tenediately af ter fee-ing begins to minimite size of void spacen. Air ture at room te:nrerature for at least one hour to LLlow for full expansion cf Tcea.

After teaming action and curits is ccepleted on a pear, the next pour or material can be spread evenly en t op of the previous expanded layer. All sequential paars, shaU pro:eed with a minimum delay so that atmospheric exposure of the interns 1 f.i.bers is minimited.

The number of pouro shall be as specified on the drawings. Af ter the finni peur, the foam shall t.e allowed to cure at least fetar hoArs at roam temperature before bracing, molds, and accessories are removed.

NOTE!

SequentiL1 pcJrs are self bonding to the previcras pcrJr with no apparent velds or cleavage planen.

REMOVAL or BRACING. MgIS, AND ACCESSORIES AND FINISifING WORK General All brsseing, molds., a,nd any at:essories not part of the finished container, as defined on the drawings, shall be removed after foaming and curin6 opera-

!i tions are completed. Any extruded fosa materiti (e.g. extrusions thro;gh b

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9 6.1.6 K-2057 Distribution Category:

R'VISiOR I Transportation of Nuclear Materials, UC-71 h

Renovation of 00T Specification 21PF-1 Protective Shipping Packages b

November 21, 1986 h

Authors:

C. R. Barlow K. T. Ziehlke' A-W. A. Pryor, DOE **

W. R. Housholder, NCl***

Martin Marietta Energy Systems, Inc.

Oak Ridge, Tennessee ~37831

Martin Marietta Orlando Aerospace, Orlando, Florida

- United States Department of Energy, Oak Ridge Operations

" Nuclear Containers, Inc., Elizabethton, Tennessee 4

3 ABSTO CT Protective shipping packages for isotopically enriched uranium hexafluoride show deterioration with extended service, principally, structural damage f rom rough handling, and rust damage f rom exposure to weather and f rem storage practices which may promote absorption of water by the insulating foam.

This report summarizes and references work which has been done to eval-uate the integrity of the phenolic foam insulation in used shipping pack-ages and outlines the process developed for drying the foam prior to rework of the containers.

Mechanical and thermal properties of the foam are not adversely affected by the presence of limited amounts of water, nor are they degraded by the removal process.

Rework of the packages, huwever, must be preceded by moisture removal to slow or avoid continuing rust damage, and tests have shown that drying can be ef fected by heating at 190'F and above for periods of three days or more.

Drying progress is monitored by weight loss and/or by use of a moisture meter.

E '

4 R

CONTENTS E

Page Introduction..........................

S Summary and Conclusions 7

g o,e,1-nt.i

,x Results and Discussion.....................

10 Appendix............................

21

5 J

Introduction

]

U.S. Department of Transportation Specification 21PF-1 protective over-packs for interstate and international shipment of cylinders of isotopi.

cally enriched uranium hexafluoride consist of a fire-retardant plastic l.

f oam encased in a wood-reinforced steel shell, Figure 1.

In the 15 to 20 j

years these protective packages have been in use, some relatively minor 1

l problems have manifested themselves, and some design improvements have been implemented.

Enhanced environmental and safety concerns which have

]

developed I,ince the packages were first placed into service have dictated ji the advisability of further evaluation of the properties of the foam, in particular to answer the question of whether these properties are degraded by the service environments.

It is quite apparent that these environments are capable of degrading the steel container shell and exposing the foam s

to moisture; such external damage is repairable but in cader to justify l

repairs, the foam properties in these packages must be evaluated and com-

,J pared with the original foam properties.

The original concept of a protective overpack for shipping cylinders 1

proposed to enhance the survivability of full cylinders in accidental fire exposure.

The mechanical strength of the foam structure, needed '. sup-port the cylinder in the package, would confer an added benefit ;; srotec-tion against the mechanical shock of transport accidents, sucP collision or dropping.

Among the commercially available foam a tems, that with the best inherent fire resistance was a reaction type phenolic.

l which, with the use of an acid catalyst, could be foamed in place to a y

wide range of densities.

The attractive heat resistance and dimensional stability properties were enhanced by the use of a boric / oxalic acid catalyst which further improved the phenolic foam's inherent good fire resistance.

The phenolic foam has an "open cell" structure which is strengthened by the formatiun of a harder, higher density outer skin, whose presence also reduces the tendencj of the structure to absorb water through shell openings.

Even the use of " closed cell" foams such as the urethanes cannot be fully relied upon to exclude water since the cell iso-lation of these foams is affected by the addition of the chemicals which function to provide self-extinguishing properties in exposure to open flame.

The outstanding superiority of the boric / oxalic acid catalyzed phenolic foam in fire resistance was therefore the controlling f actor in its selection for the 21PF-1 package.

The acid-catalyzed foams were developed in the mid-1960s and the boric / oxalic acid catalyzed modifica-tton was patented by Union Carbide Corporation in 1967.

Development of the chopped glass-filled foam for protective shipping package use took place at the Oak Ridge Gaseous Dif fusion Plant in 1966.

Protective packages that have been in service fv 8 to 10 years have been selected f rom those received in the Toll Enrichmeat Facility at the Oak Ridge Gaseous Dif f usion Plant (0RGDP) as representative of the extremes of deterioration that can take place in service.

As a result of the inspec-tion process at ORGDP, these overpacks had been removed from service and were scheduled for scrapping.

Some of the overpacks. in overseas service and noted as containing seawater on earlier trips through the f acility, showed severe rusting damage to the steel cover and around the joint plane

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at the package centerline.

Based on the nominal package tare weight, d

those packages had absorbed 800 to 900 pounds of water.

A second group of Specification 21PF-1 packages, in both domestic and overseas service for about the same period of time, did not show the rust damage characteristic i

of the other packages, but did exhibit varying degrees of handling damage.

The irdicated water absorption for these packages was in the neighborhood of 250 to 300 pounds.

These packages have been the subject of drying tests to develop suitable means for removing the bulk of the contained water prior to renovation of the package exterior surf aces.

In addition, foam samples have been removed from several packages to serve as a basis for estimating the total water content independent of the nominal tare weight method.

The foam samples have also been subjected to mechanical and physical property tests to assess whether any significant deterioration has occurred as a result of the service histories cf the packages.

Also, independent studies of the foam thermal conductivity properties have been referenced.

Summary and Conclusions Weighing observations on protective shipping packages af ter long periods of service show that large amounts of water may be taken up by the foam insulation, as much as 900 pounds per package in the course of exposure to the service environment. Drying tests, both full-scale and on separate samples of foam, show that it is practical to remove most of the absorbed water, and mechanical testing has shown that the foam properties are not degraded by long-term exposure to water.

Similarly, testing of dried foam revealed no degradation of the thennal conductivity characteristics when compared with virgin foam.

Computer modeling has shown that the foam in the overpack is ef f ective as an insulator even while wet, but con-siderations of metal corrosion and structural wood deterioration dictate that the overpacks should be maintained in as dry a state as practical in order to maximize their service life.

Protective shipping packages should be dried if the weights are found to exceed the new weights by 50 pounds (25 pounds per package half).

At the 25-pound level the water is contained as a film on the open-pore foam structure.

It is not detrimental to the thermal properties of the f oam, it will not result in excessive pressure buildup in the package in the event of fire exposure, and it will not aff ect mechanical properties of the foam.

The drying temperature must be above 190'F for practical removal rates, and the cycle should be continued to the point where the removal rate shows that drying is approaching completion (less than 21/2 pounds / day) or until the tare weight indicates that the package half con-tains less than 25 pounds of water.

A household moisture meter also proved effective in determining the wet / dry condition of the foam and can be used to supplement the other tests.

Regardless of weight loss or weight loss rate, however, the drying cycle should span a full three days at a minimum to dry or redistribute any water which may be concentrated in pockets.

i 0

I O

Observations have shown that many packages have not been properly 8

assembled during transit or outdoor storage when empty.

These have a ten-dency to collect water in the bottom half which can result in saturation of the foam through leaks in the inner steel liner.

It is therefore 8

recommended that all overpacks be fully assembled in the closed position during transit and outdoor storage.

Experimental Wo_rk Specification 21PF-1 protective shipping packages f rom two sources were selected f rom traf fic into the ORGDP Toll Enrichment Facility as test 8

vehicles for the renovation study.

One group consisted of three packages used in overseas service, which were f abricated in 1973-197b and which had been in continuous service since that tisie. Above-deck transport by ship 8

had resulted in f requent exposure to salt water and the Toll Enrichment records had noted the presence of sea water in the containers on previous use cycles through the facility.

These packages were selected as represen-e extensively corroded exterior sheet metal including rust penetration of tative of the most severe level of deterioration through use, showing many areas, particularly on the end panels adjacent to the package center plane (Figure 2).

The second group of three packages, owned by another firm, had been in both domestic and overseas service since they were fabricated in 1971-1977.

4 They showed only minor rusting, but exhibited sheet metal damage and penetration from mechanical causes.

4 Initial weight data, the first weighing upon removal from service, showed weight increases (based on the nominal tare weights) of 795 to 916 pounds f or the first group of packages and of 248 to 308 pounds for the other 4

units. Drying tests were carried out on these six units in a commercial lumber kiln in order to develop a feasible time-temperature cycle for drying and possible renovation of the used packages.

Initial tests carried out at the normal kiln operating temperature of 160-170*F were inef fective, and the balance of the tests were done at a control point of 190'F.

Total drying time at about 190'F was about 16 days, with weights being determined at several intermediate steps.

Immediately prior to the 190*F drying tests, samples of foam insulation were removed f rom several of the package halves.

These samples were weighed and dried to assess the effectiveness of the kiln drying process on the parent structures.

They were also used for mechanical tests to evaluate changes in structural properties of the foam resulting from the service exposures ta moisture.

These results were compared to the proper-ties of new foam prepared to the same range of target densities.

Properties of wet foam and frozen foam were also determined at several moisture levels.

The data derived f rom the drying tests indicated that moisture removal is feasible.

Prior to ef f ecting structural repairs, the package should be dried to a level of 50 pounds or less of contained moisture, i.e., less i

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Moisture removal is facilitated by pro-viding maximum exchange area, which is done by drilling out the plug material f rom the vent holes provided for foam expansion during package manufacture.

Drying should be carried out at a temperature of 190'F or higher, and the temperature cycle should be maintained at least until the waiight of the package half has f allen to 25 pounds above the nameplate tare weight.

If an exact tare weight is not available (NCI packages manu-f actured prior to 1984 were marked with a calculated nominal tare weight of 820 pounds for the top and 980 pounds for the bottom sections, rather than with an individually determined welpht) drying should continue until F

the removal rate indicates a low residual water content, it is suggested that a weight loss rate of 21/2 pounds per day is approximately equiva-lent to a 25-pound residual moisture content.

Regardless of the initial weight loss or weight loss ral,e, however, a minimum cycle of three days (72 t

hours) at the drying temperature is required to assure heating throughout the foam and drying or redistribution of any pockets of water.

Results and Discussion Progressive deterioration of protective shipping packages in UF6 transport service has prompted some package owners to request the builders to supply refurbishment services.

The concept of restoring the packages to their original specifications presents the need to reexamine the design criteria and to reevaluate the construction materials to those criteria.

The pre-sent condition of packages in service covers a wide range, with many showing little or no evidence of deterioration in use, while others exhibit dents and punctures in the steel covers and some show large rusted areas to the extent that the shell has been penetrated to expose the plastic foam insulation.

The construction of the existing packages is such that water cannot be excluded absolutely f rom the open-cell foam insulation, and handling practices often appear to promote water absorption.

Water absorp-tion rates will increase as access points are created by penetration of the shell, most likely in direct proportion to the area of foam exposed by rust-through or by mechanical damage.

The foam is capable of absorbing Iarge amounts of water, in theory as much as about 600 pounds per package half.

Packages representing the worst rust damage were selected from those at the Oak Ridge Toll Enrichment Facility, to determine the amount of con-tained water and to investigate methods f or its removal.

These packages, owned by a foreign government atomic energy agency and in full-time use in overseas shipments showed rust penetration through the 14-gauge shell in several areas, in one package totaling more than 20 square inches.

The containers were observed to contain salt water on several occasions when returned for reuse, and when selected for the drying tests were weighed at an average of 840 pounds above a nominal 1,750 pound new weight.

A second group of three protective shipping packages, owned by a domestic broker in enrichment services, was added to the study to illustrate the ef fects of mechanical damage.

These packages were in good condition from a rust

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f I

11 standpoint but showed several impact sites where objects had dented or penetrated the steel shell.

These packages had been in service from 1971 R

to 1977, and showed weight increases averaging 280 pounds over the nominal new weight.

N Drying tests were conducted with the six package units, using a commercial lumber-drying kiln operated at 190-200'F.

The weep holes in the shells, plugged af ter the plastic foaming reaction was completed during package manufacture, were reopened and cleaned, and additional holes (serial num-bers 012 and 013 only) were provided in the wood structure to allow for venting of moisture.

The packages were weighed at the start of the test and at several times over the 16-day duration of the drying efforts.

The drying test was not continuous, but was interrupted several times, once with a lapse of several months before continuing the test.

The weight loss dato indicated removal of large amounts of water, lacking although the lack of an exact tare weight lef t the final results somewhat in precision.

The weight data are presented in Table 1, and assuming the original package weight to be about 17b0 pounds (top weight 770 pounds, bottom 980 pounds), the remaining water contents range from zero (309-top) to 284 pounds (012-bottom).

These extrapolations of the weight data are summarized in Table 11, and were used along with the loss rate information (Figure 3) to establish the drying cycle recommendations given in the

" Procedure for Drying and Weighing Specification 21PF-1 Overpacks" appen-dix to this report.

The lumber drying kiln was used in these tests as a matter of availability and convenience; other sources of heat for moisture removal, or other means of moisture removal, are not excluded from con-sideration.

Physical and electrical limitations prevented the use of higher drying temperatures (the normal lumber drying cycle is carried out in the range of 160-170'F and the kiln was desigried for this temperature level), and it is likely that higher temperatures could be used to advan-tage provided that they did not result in damage to the wood parts in the protective shipping package.

Analysis of the package weight data shows that the bottom halves of the containers exhibit a greater weight gain in service than do the tops, and that they retain more of this weight through the drying cycle.

Empty shipping packages have been received in the Toll Enrichment Facility with large volumes of water in the cylinder cavity.

This water has been emptied, only to be renewed by drainage from the open-pore structure of the insulating foam (Figures 4 and 5).

It is apparent that a large portion

. of this water must come from open storage of the package (the two halves separated) during idle time.

The bottom half of the package collects and absorbs rainf all through leaks in the liner when in its normal position, where the top half sheds most of the incident rainf all, thus showing signi-ficantly lower weight gains over long periods of service.

It thus seems appropriate, from the standpoint of minimizing maintenance requirements and extending package life expectancy, to store the packages in their assembled configuration with bolts tightened to compress the gasket. Storage pro-tected from the weather is preferred over unprotected storage, and either

12

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4 hI Table I N

SPECIFICATION 21PF 1 OVERPACK DRYING TEST RESULTS 1

....... ~.........

BOTTOMS:

fu DAYS 0

1 1.5 2.5 3.3 5.3 8

14.8 15.5 PSP NO.

BOTTOM WElGHTS,Ib ll 001 1497 1444 1420 1389 1376 1344 1291 1239 1231 012 1689 1557 1524 1479 1456 1412 1356 1275 1264 013 1467 1412 1353 1341 1292 1233 1108 1099 309 1207 1182 1168 1163 1132 1099 1023 1015 324 1166 1160 1152 1150 1131 1113 1068 1064 329 1204 1188 1181 1170 1170 1157 1134 1101 1098 11 il TOPS:

DAYS 0

1 1.5 2.5 3.3 5.3 8

14.8 15.5 PSP NO.

TOP WElGHTS, Ib 001 1048 1022 1008 976 962 928 892 833 824 012 976 949 946 919 909 885 856 802 798 013 1094 1071 1013 1000 953 908 826 818 309 818 810 800 798 786 779 766 765 324 832 824 822 820 815 805 791 787

5 329 854 847 844 838 837 830 821 814 811 11

I il

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Table ll RESULTS OF KILN DRYING CYCLE

..no.mi....

eve FIN AL B

PACKAGE WElGHT, lb WATER WATER LOSS RATE NUMBER ORIG.

FINAL LOSS, Ib CONTENT,Ib' AT 16 DAYS *

R 001 T 1048 824 224 54 9 lb/ DAY 012.T 976 798 178 28 4

013.T 1094 818 276 48 8

001 B 1497 1231 266 251 8

012B 1689 1264 425 284 11 013.B 1467 1099 368 119 9

309 T 818 765 53

(-5) 1 324 T 832 787 45 17 4

329 T 854 811 43 41 3

3098 1207 1015 192 35 8

324 B 1166 1064 102 84 4

3298 1204 1098 106 118 3

'THE FINAL WATER CONTENT IS BASED ON AN ORIGINAL CONTAINER WEIGHT OF 1750 POUNDS: 770 lb TOP AND 980 lb BOTTOM SECTION,

- THE DRYING RATE AT THE END OF THE TEST PERIOD IS THE WEIGHT LOSS ON THE FINAL DRYING DAY. SEE TABLE I.

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ir'A f '- T VENT HOLES IN OUTER SHELL Rust streaks from open i

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wn 4-i.6cate w ation of insulating foam. High moisture ! eve!s at the shell surfaces pro, 9 u: ^

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a shortens the package service life expectancy.

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of these methods would exclude the major source of water pickup and mini-mize the potential for corrosion damage to the steel shell.

Damage to the b

gasket or warping of the wood structure along the step joint at the package g

center-plane can also admit water to the foam or to the package interior even while it is closed, but these sources are seen as of lesser signifi-cance than is the practice of open storage.

Shortly af ter beginning drying tests on the six package units, foam samples were extracted from five of the 12 package halves to evaluate I

changes in foam properties which might have taken place in servicN These samples were oven-dried to constant weight, a process which wok f rom 90 to 180 hours0.00208 days 0.05 hours 2.97619e-4 weeks 6.849e-5 months (3 3/4 to 71/2 days) at 190-200*F, with 00 obr n c-tions to moisture exchange at the sample surf aces.

Initial drying rates I

were high, with 70 to 95 percent of the total moisture being lost in the first day of heating.

Af ter drying to constant weight, foam densities were calculated and replicate specimens were cut from each sample for I

determination of mechanical strength.

Samples of newly-prepared foam were also tested after being saturated to several levels of moisture up to 100 percent of the dry foam weight.

Testing of wet samples was performed.

3 both at room temperature and with the samples frozen.

The strength data were all plotted as a function of dry foam density, as given in Figure 6.

The data gave a straight line relationship of compressive strength versus density, and'the strength appeared to be unaffected by the service seen by the protective shipping packages, or by the presence of small amounts of moisture either in the liquid state or frozen.

The insulating foam which is produced by incorporating a blowing agent and a surfactant in the phenolic resin, then adding an acid catalyst (boric anhydride / oxalic acid, consists of an open-cell structure whose mechanical properties depend on the strength of the cell walls, and hence on the overall density.

The addition of the boric anhydride and oxalic acid is also beneficial for nuclear and fire control purposes.

The inert additi-ves may have some influence on strength, but since they are added in constant proportion, their influence should also be proportionate to the foam density. The shell of a protective shipping package is filled with 3

foam that is reacted in place to a target density of about 6.0 lb/f t,

The actual local density, however, is controlled by restraints on free expansion, and if the foam were free to react without restraint, the den-sity would be much lower. The 6.0 lb/ft3 overall density la a balance between a high-density skin and a more freely-expanded core.

Thus, samples taken from the used protective shipping packages did not match the average density, since the selection of test specimens of uniform texture and properties avoided the skin effects encountered at the package sur-f aces, resulting in densities mostly at the low end of the spectrum, New foam, reacted to a wide range of densities, was prepared to compare mechanical properties with those of specimens obtained f rom the used pro-tective overpacks.

Samples of new foam were also infiltrated with moisture and were tested wet and also frozen.

Results of the various tests, within the limits of scatter in the individual data points, indi-cate that the used foam has suf fered no degradation in mechanical

N l-18 strength.. The used specimens show the same proportionality of strength to-density as do the new foam samples, and the presence of small amounts of moisture, liquid or solid, does not affect strength, it may be concluded lI f rom the tests, therefore, that the foam in a dried shipping package con-f ers the same degree of mechanical protection to a shipping cylinder as is i

l given, by that in a new package.

Figure 6 is this report revision inclu-I des additional data to support this conclusion.

The bulk sample from 012-bottom does not fit the straight line function I

established by the rest of the samples from the used protective shipping packages or the new water-containing samples, although the data from this I

t'imple were consistent with each other and exhibited the same degree of scatter as was seen in the other sample groups.

While this package half I

was the heaviest in the test group (see Table 1) the final dried weight l"

was comparable with that of the two similar package units, as was the i

estimated final water content (Table 11).

The sample does not appear _to I

be representative of the package from which it was taken, and the strength l

data point was therefore given no weight in drawing the straight line of f

Figure 6.

From the drying data and the compressive strength information, it appears practical to restore protective shipping packages by drying, i

g replacing mechanically damaged areas of foam if these are extensive enough to affect the functional integrity of the package and then repairing any damage to the wood structure, the steel shell, and the external supports.

l The Specification 21PF-1 shipping package is built with kiln-dried lumber and with foam ingredients which nominally contain no moisture; thus, the

.I finished package is very low in total moisture content.

In order to mini-l mize the potential for moisture damage to the steel snell or to the wood structures at the closure f aces, it would be desirable to return the foam to its original dry state.

Since the moisture removal / exchange area was severely limited, this could not be achieved quickly with available equip-ment.

in addition, a precise moisture content of the foam could not be I

measured by simple weight loss unless an exact tare weight had been:

available.

Weight loss data, however, does indicate the removal of substantial amounts of water - f rom 43 to 425 pounds per package half in the approximately 21/2 weeks of drying time in the lumber kiln.

l Drying to the approximately 20 percent moisture level (residual moisture weight equals 20 percent of dry foam weight) resulted in a foam surface dry to the touch, and at this moisture level the foam would be expected'to transfer little or no moisture to the wood structures that form part of L

the protective shipping package.

Thus, from estimating final results of the kiln drying tests in terms of the nominal tare weight, it appears reasonable to continue drying of a package half until it is within 25 pounds of the original tare weight.

Alternatively, for packages which do not carry an exact tare weight on the identification label a low rate of moisture removal should indicate a suitably near approach to dryness.

Although measurements have not been made to relate weight loss rates to overall moisture content, an appropriate rate for purposes of package rehabilitation has been defined as 21/2 pounds per day per package half.

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e o o VIRGIN FOAM SEPARATE POURS e REMOVED FROM OVERPACK AND ORIED 2

a WET,12100% OF DRY WEIGHT TESTED WET a WET,25100% OF DRY WElGHT TESTED FROZEN 0

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10 20 30 40 50 60 COMPRESSIVE STRENGTH, psi Figure 6 MECHANICAL STRENGTH OF THE PHENOLIC FOAM AS A FUNCTION OF (DRY FOAM) DENSITY I

t

e.

20 It will be seen from Table 11 that only two package halves (309-top and 324-top) meet the 25-pound (20 percent) final water content criterion, E

wnile only one (309 top) is within the 21/2 pound per day loss rate guideline. It would therefore be necessary to continue the drying of the remaining package halves to meet these criteria, I

e The use of a commercially available moisture meter has been investigated on a cursory basis to determine whether such instruments can furnish adequate I

information regarding the moisture condition of the foam in a used protec-tive shipping package.

A moisture detector of the type used to monitor soil moisture in house plant containers was found to indicate qualitative differences in moisture content of the test foams used in this investiga-8

. tion, and gave an approximate mid-scale reading at the 20 percent moisture level (which corresponds to 25 pounds per package half).

Such a meter, possibly calibrated with samples of known moisture content, might be used to determine an end point to a drying cycle for package rehabilitation.

4 The meter investigated operates by measuring the galvanic current generated by dissimilar metals while in the presence of an electrolyte.

The meter l-was not calibrated, but merely indicated soil moisture as dry, moist, or wet.

Guarded hot-plate data in the range of RT to 1475'F indicated substantially identical thermal conductivities for dry foam and foam that had been exposed to water and then subjected to freeze-thaw cycling.

Conductivities increased in a linear fashion over the range of 200 to 1000*F and at greater rates at temperatures approaching the standard fire test temperature of 147b'F. Twenty-f our-hour exposures to 600'F showed no appreciable charring, _while at 800'F extensive charring and enhanced f

brittleness were noted.

Short exposure times at 147b*F resulted in exten-sive decomposition and produced an unbonded ash.

The standard fire expo-sure, 30 minutes at 1475*F, caused surface charring of both new and used f

dried foam under the steel sheath, which penetrated for less than 1/2 inch.

Ikat discoloration extended less than one inch from the heat source interface, and the temperature rise at the cylinder surf ace was limited to

<200'F at the end of a full one-hour exposure.

These results are sup-ported by the original full-scale instrumented fire test and by recent furnace tests of thermocouple-equipped test segments simulating the over-pack step joint and wall.

6

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II T

II APPENDIX PROCEDURE FOR DRYING AND WEIGHING SPECIFICATION 21PF-1 OVERPACKS I

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I

' 'i 22 l-Procedure for Drying and Weighing Specification 21PF-1 Overpacks 1.

Drill out or otherwise clean the plug material from the vent holes originally provided for foam expansion.

See drawing SIE-31536J1 Rev. D for locationt,.

2.

Weigh each package half separately to an accuracy of 15 pounds and record weights.

3.

P1 ace in drying oven; maintain temperature between 190 and 210*F in t

the vicinity of the package units.

The oven should have a provision for air exchange or other means of removing moisture driven from the foam structure.

4 Maintain parts and furnace at temperature for 72 hours8.333333e-4 days 0.02 hours 1.190476e-4 weeks 2.7396e-5 months minimum before first weight check.

5.

Drying may be discontinued at thls point if weight is within 25 pounds of nameplate weight for the package half.

If higher water content is indicated, continue dryin until the weight target is reached or until the loss rate is below 2.

pounds per day (see text).

6.

As an alternative moisture check, a calibrated moisture meter reading for 20 percent maximum water content may be used to indicate an end point in the drying cycle (see text).

7.

Following drying, each ovepack half (top and bottom) is to be weighed to an accuracy of 15 pounds and the individual weight' stamped on the appropriate identification plate.

See drawing SIE-31536J1, Rev. D for details.

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4 21PF-1 Overpack Manufacture 4

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I BRAUNKOHLE TRANSPORT USA INC.

O QUALITY ASSURANCE POLICY It is company policy to perform work or contract work on items l

I I

important to safety in accordance with the requirements of Subpart H of 10CFR Part 71 as described in the Quality Assurance program plan and implemented in Quality Assurance Manuals.

L l-Either the Vice President or President are delegated with the 1

authority for implementing and revising the provisions of the described I

Quality Assurance Program and regularly assessing the scope, status, implementation and effectiveness of the Quality Assurance program.

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Q PRESIDENT 7-

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1 VICE PRESIP"riT

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QUALITY ASSURANCE MANUAL TABLE OF CONTENTS - MANUFACTUREA 1.0 Organizational Charts

' 1.1 Organi=stional Chart #1: Purchaser 1.2 Organi=ational Chart #2: Manufacturer (Fabricator) 2.0 Procurement Document Control I

2.1 Procurement Document Control - Purchaser 2.2 Procurement Document Control - Fabricator 3.0 Receiving of Incoming Materials 4.0 Dealing with Production Defects and Non-compliance 5.0 Documentation Control Manufacture 6.0 Production Procedures & Inspections - Fabricator 7.0 Maintenance Repair & Inspection 7.1 Tie-down/ Securement of 21PF-1 Overpack I

7.2 User Maintenane & Inspection 7.3 Annual User Inspections REPORTS & INSPECTIONS 4.7.1 Corrective Action Report 5.6.1 "Non-Conformance" Report 5.6.2

" Job Number" Record 6.15.1 Production Inspection Checklist for Model 21PF-1 Protective Shipping Packages.

6.15.2 Receiving Inspection Report for Model 21PF-1 Protective Shipping Packages.

6.15.3 Final Inspection Report.

I I

I

I I

1.

ORGANIZATIONAL CHARTS I

1.1 ORGANIZATIONAL CHART #1: PURCHASER i

BRAUNKOHLE TRANSPORT U.S.A.

INC.-

PRESIDENT 1.

Implementing revising &

assessing the Quality Assurance Program I

2.

Issue and Review of Purchase Orders.

3.

Approval or Disapproval'on Non-conformance.

VICE-PRESIDENT 4.

Approval of Final i

Inspection and related Documentation.

I BRANCH MANAGER 5.

Inspection of Documents FABRICATOR 6.

See Organizational Chart

2.

I i

I ll 1.2 ORGANIZATIONAL CHART #2:

MANUFACTURER (FABRICATOR)

E GETCHELL AND SONS INC.

I PRESIDENT Issuing and Review of Purchase Orders.

QUALITY ASSURANCE 2.

Approval or Disapproval MANAGER of Non-conformances (with BTUSA)

I 3.

Inspections at hold point points during manufacturing.

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SHOP FORMAN R e c e i'v i n g a n d I n s p e c t i n g Incoming Materials.

I

$UB-CONTRACTOR Compliance with Specifications and providing cerifications of same.

I

.I

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1; 1

2.

PROCUREMENT DOCUMENT CONTROL 2.1 PROCUREMENT DOCUMENT CONTROL - BTUSA (PURCHASER) l --

2.1.1 Purchase orders are to be issued to the fabricator specifically L

outlining the_ scope of work to be performed.

2.1.2 Purchase orders must specifically state the technical requirement including the applicable regulatory requirements, material and L

component identification requirements, drawings, specifications, l

codes and standards, special process instructions and test and I

inspection requirements.

ll5 2.1.3 Purchase orders issued to the fabricator are to state the requirements of BTUSA in so far as the fabricator's responsibility to follow and comply with all requirements as I-r specified in the Quality Assurance Manuals.

2.1.4 Purchase orders issued to the fabricator will require permission to gain access.to their or their subcontractor's plant' facilities and records for inspection or audit purposes.

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-2.1.5 Purchase orders issued to the fabricator will specify the documentation that must be prepared, maintained and submitted for approval.

These will include such items as:

- Materials Receiving Inspection Reports

- Inspection Checklists at Specified Hold Points

- Verification of conformance to Specifications l

2.1.6 Purchase orders issued to the fabricator will identify those records that must be retained, controlled and maintained by the fabricator and its subontractors and also what records or verifications must be delivered to BTUSA prior to final inspection by BTUSA or its agent; of the unit.

'2.1.7 Purchase orders must specify that the fabricator must report to BTUSA any nonconformances to specifications immediately upon becoming aware of some.

The order will state that the fabricator must not further proceed with the particular area of nonconformance until approval for same is issued in writing by an authorized official of BTUSA.

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g 2.1.8 Purchase orders and a revision or change to any purchase order must be received and issued by an authorized official of the company before issue.

The officials must date and sign his/her I_

approval on the purchase order before release.

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I 2.1.9 Purchase orders will require the fabricator to enable the complete traceablity of certain raw materials used by the I

fabricator or its sub-contractors, such as the ones relative to safety including in this instance the stainless steel, angle iron, phenolic foam insulation.

2.1.10 Purchase orders will require the fabricator to use only certified welders and processes in the production of the unit.

2.1.11 Purchase orders will require the fabricator to provide inspections at specified hold points during the manufacturing processes. These inspections will be required to_be carried out and certified on inspection checklists by a qualified inspector.

2.1.12 Procurement Documents will also specify that the regulations

'E pursuant to 10 CFR Part 21 apply to the manufacture or g

modifications of the units.

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2.2 PROCUREMENT DOCUMENT CONTROL - FABRICATOR 2.2.1 Purchase orders are to be issued to the subcontractors and I

suppliers specifically outlining the scope of work to be performed and/or the technical requirements including the applicable regulatory requirements, material and component

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identifications, codes and standards, special process instructions and test and inspection requirements.

2.2.2 Purchase orders issued to the subcontractor are to state the requirements of BTUSA in so far as the subcontractor's responsibility to follow and comply with all requirements as specified in the Quality Control and Quality Assuranca Manuals.

2.2.3 Purchase orders issued to the subcontractor will require permission to gain access to their or their subcontractor's plant facilities and records for inspection or audit purposes.

2.2.4 Purchece orders issued to the subcontractor will specify the documentation that must be prepared, maintained and submitted for approval.

These will include such items as:

- verification of conformance to specifications

- billa of lading shipping documents specifying technical I

details of materials shipped.

2.2.5 Purchase orders issued to subcontractors must identify what records must be retained, controlled and maintained by the subcontractor and which records of these which must be delivered to the purchaser prior to installation of the material or hardware.

2.2.6 Purchase orders must specify that the subcontractor or supplier must report to the fabricator any non-conformance with I

specifications immediately.

The order will state that the-subcontractor or supplier must not further proceed until approval for same is issued in writing by an authorized official of the fabricator.

2.2.7 Purchase orders and a revision or change to any purchase order E

must be received and issued by an authorized official of the L3 company before issue.

Both officials must date and sign their approval on the purchase order before release.

2.2.8 Purchase orders will require the subcontractors to enable the complete traceability of raw materials used or supplied if they relate to the safety of the unit.

In this instance the traceability of the angle iron, stainless steel and phenolic foam must be available.

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3.

RECEIVING OF INCOMING MATERIALS l'

3.1 Receiving report for materials to be used in the manufacturing, repair, or modification for shipping containers for 30" UF6 cylinders will be completed for each Job Number. (6.15.2) 3.2 All incoming items are to be inspected for quality and conformance to procurement document requirements.

3.3 After inspection, the items will be recorded on the Receiving Inspection Report and verified by the inspector.

Any nonconformance must be reported at this time by the inspector to the Quality Assurance Manager on a non-conformance report.(5.6.1 Attached) 3.4 Mark or tag all incoming items with the appropriate " Job Number".

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et'cach " Reject" tags to all nonconforming items and isolate for return to vendor or disposition by management, l

3.5 Ascertain that each stainless steel item is marked with its " Heat l

Number" and that a matching material test report, which demonstrates Ll compliance with the applicable specification, is received and filed.

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Copies of these material test reports are to be submitted to the L 5 purchaser at time of final approval for acceptance.

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4.0 DEALING WITH PRODUCTION DEFECTS AND NON-CONFORMANCE 4.2'Any conditions which may affect quality such as deficiencies, deviations, defective material and equipment and nonconformances must be promptly identified and corrected.

Jg 4.2 In the event of a condition which would be adverse to quality, the fabricator will require all applicable personnel to notify the Quality Assurance Manager immediataly of the condition and a Report I

is to be prepared recording the condition, the cause of the condition once it is determined and the methods used to correct the condition and avoid the occurence of the condition in any future applications.

4.3 The Corrective Action is to be reported by the Quality Assurance I=

Manager to the Purchaser to show the handling of the condition-before acceptance of the package by the Purchaser.

(See Correction Action Report 4.7.1) 4.4 The Purchaser must specify on the procurement documents that the regulations pursuant to 10 CFR Part 21 apply to the manufacture of the unit.

L 4.5 The fabricator will be required to post Section 206 of the Energy Reorgani=ation Act of 1974 and a notice which describes the procedures including the name of the individual to whom reports may be made and where they can be examined.

4.6 In the event that a deviation or defect has not been corrected and L

this does not comply with the specification, the fabricator will be instructed to notify a responsible officer of the Purchaser.

This responsible officer of the Purchaser will then attend to the

[l notification of the Nuclear Regulatory Commission if the defect

, W falls within the reporting requirements of 10 CFR Part 21.

4.7 Attachements 4.7.1 Corrective Action Report I

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iP 4.7.1 CORRECTIVE ACTION REPORT.

- DATE:

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JOB NO:

CONDITION OR ACTIVITY AFFECTING QUALITY:

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I DETERMINED CAUSE:

---____--__-------___-------_-_----___----____-____-----_-_____~_----

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METHOD OF CORRdCTION: -------------___-------____-_---------_-----__-

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DATE:

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DOCUMENTATION CONTROL-FABRICATOR 5.1 Manufacturing Procedures I

The fabricator will submit to the purchaser a flow sheet of the manufacturing procedure and test and inspection procedure together with the names of major equipment.

Management of welding procedure and welders shall also be included.

5.2 Serial Numbers - Each specific numbers shall be assigned to each container, which will be advised by purchaser.

Such number shall be described on the number plate specified by the purchaser.

If such number is different from manufacturing number, corresponding table between manufacturing number and such serial number shall be submitted.

5.3 Copies of all applicable Receiving. Inspection Reports, Non-conformance reports, Production Inspection Reports, Final Inspection Reports will be' submitted to the Purchaser after l

completion of the units by Job. No. for verification and approval.

5.4 Each order for these overpacks will be issued a Job Number by the fabricator.

The fabricator will keep a list of numerical job numbers per the attached form to cross-reference purchase orders, materials and the finished product.

See " Job Number" Record attached. (5.6.2) 5.5 The Fabricator will keep copies of all documentation and samples associated with the production of each package for not less than seven years after the completion of the package.

Before destroying such documents, the fabricator will contact BTUSA for approval of name.

5.6 Attachments

5.6.1 "Non-conformance" Report 5.6.2

" Job Number" Record l

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5.6.1 NON-CONFORMANCE REPORT DATE: _

JOB NO.:

'P.O.

NO:

SUPPLIER NAME:

i Item No. &

Description:

Nature of Non-conformance:

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I Comments:

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[.To'be passed immediately to Quality Assurance Manager)

QUALITY ASSURANCE MANAGER Notification sent to Purhaser.

Date:

19__

s.

Materials returned to Supplier as Rejected Date:

_ 19 Materials accepted as is upon verification by Purchaser I..

Date: _

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I QUALITY ASSURANCE MANAGER Date: __,__ ___ 19__

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'5.6.2

" JOB NUMBER" RECORD BTUSA UNIT SERIAL Job No.

Customer Name P.O.

NO.

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,Date GET001 I

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6. PRODUCTION PROCEDURES & INSPECTIONS-FABRICATOR I

6.1 MANUFACTURING PROCEDURES - The fabricator will submit a flow sheet of the manufacturing procedure and test & inspection procedure together with the names of major equipment.

Management of welding procedure and welders shall be also included.

6.2 WOOD REQUIREMENTS-A.

The Fabricator will inspect each lot to verify that:

I Wood for-side' rails and end caps are select grade oak or hard maple with less than 20% moisture content and shall be surfaced both sides to 1-1/2" and 13/16" thicknesses, respectively.

B.New wood surfaces are coated with fire-retardant (intumescent) paint prior to installation.

6.3 METAL REQUIREMENTS-A.

Inspect each lot of metal and determine that all materials are properly marked with job numbers and that matching material test reports are obtained and flied demonstration

l B.

Mill test reports must be obtained and maintained on file for all stainless ateel raw materials including sheet, plate, angles, flat bar, pipe and pipe fittings, and casting metal for cast toggle components.

C.

Manufacturer's certifications must be obtained and= maintained on file for gasket materials and for bolts and nuts.

D. All sheet metal and plate are ASTM A-240, Type 304 or 304

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stainless steel.

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-All shapes including angle and flat bar are ASTM.A-276, Type 304 or 304 stainless steel.

. I 6.4 ASSEMBLY INSPECTIONS - Mandatory hold points shall be established by the fabricator to insure the inspection of the following assembly operations:

A.

All weld in spections.

B.

Inspection and installation of wood per drawings.

m C.

Installation of fire retardant phenolic foam per drawings SP-9 Rev.

1, record pre-foaming weights, post-foaming weights, and actual foaming weights by difference for each package lid and bottom.

D.

Application of fire retardant intumescent paint to wood and to wood cover plates.

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Installation of wood cover plates.

F.

Installation of pads and gaskets.

G.

Installation of vent port seals and caulking.

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6.5 WELDS-The fabricator will inspect each package as follows:

A.

Ascertain that all welds are by GTAW or GMAW processes which are quellfied per Section IX, ASME Boiler and Pressure Vessel Code.

B.

All. welds are-made by welders who are qualified for the weld procedure and position used per Section IX, ASME Boiler and Pressure Vessel Code.

C.

Unless otherwise specified, all welds shall be full penetration welds, shall develop the full strength of the weakest member

- I joined, and shall be equal to the thinner of two metals joined.

All welds shall be free from cracks and from excessive undercutting, pits, or spatter, and shall not be oxid1=ed beyond normal discoloration which can easily be removed by wire brushing.

L D. The fabricator will visually examine new welds (including heat pg affected :ones) to assure freedom from cracks or other defects E

which might indicate unsound welds as follows:

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1) 100% inspect seam welds joining the lengthened inner and outer

- I shells.

2) 100% inspect the miter joint welds joining the side and end panel moldings.

I 3)

Spot check. fillet welds joining:the inner and outer shells with the side and end panel moldings.

Discovery of defective welds i

I during spot checking shall be cause for 100% examination of all adjacent' welds.

E. Welds shall be inspected in accordance with Section V, Article 9 of the ASME Code; the inner liner, outer shell, and wood cover I

seems shall be inspected visually--linear defects over 1/16" shall be ground out and repaired, other welds shall meet the minimum requirements indicated.

F. Do not weld over foam materials; weld over wood only when it has been coated with fire retardant intumescent paint and then use appropriate means to reduce heat to a minimum to protect the wood.

G.

All stainless steel wire brushes, grinding wheels, and cutting discs which are used for stainless steel shall be used for stain-I less steel only and shall be so marked.

Carbon steel wire brushes shall not be used on stainless steel.

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6.6 FOAM REQUIREMENTS - Inspect each package as follows:

The fire resistant phenolic foam is fabricated using materials'and.

I procedurca per Specification SP-9, Rev.

1, as modified by Supplements K/TL-729 dated 3/1/78'and K/P-6567 dated 4/28/80.

Minimum of 110 10 lbs finished foam installed in the package;

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additional smaller pours may be used to fill volds.-

l Inspect all vent holes in the shell in the area of the foam to I

determine.that there are no voids; volds must be filled using additional foam pours as necessary.

6.7 GASKETS - The fabricator will inspect each package me follows:

1/4" thick x 6" x 9" Neoprene Pada (40 to 50 Durometer) are bonded I

to the top inner shell in four places over the wooden support blocks.

3/16" thick x 6" x9" Neoprene Pada (50 to 60 Durometer) are bonded to the bottom inner shell in four places over the wooden support blocks.

I 6.8 DIMENSIONS - The fabricator will inspect each package and record actual dimensions on Inspection Checklists as follows:

Inside length of inner shell:

82-3/4" 1/8".

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!H Outside length of outer shell:

91" 1/8".-

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20'each. 1/4" vent holes in each half.

1 Dimensional Tolerances Adequate Inspection shall be required to Insure compliance with dimensional tolerances specified on the drawings or unless otherwise specified shall be established for critical dimensions for which records must be maintained as 1

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.follows:

1.

Inner cylinder cavity dimensions.

2.

Outer shell dimensions.

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1/4"~ vent holes per drawing.

4.

Flatness of gasket surfaces.

6.9 WEIGHTS -The fabricator will determine the following weights for each package and record on Inspection Checklist as indicated:

,3 Top and bottom package halves (including 5" square cover plates and JEf Pop rivets) before foaming; record weights on Inspection Checklist.

Top and bottom package halves after foaming; record weights on Inspection Checklist.

Weight of foam in each package half by difference; record foam 4

weight in each package half on Inspection Checklist.

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Weight of finished package assembly (Package Tare Weight); record on Inspection Checklist and atamp on stainless steel " USA /4909/A()F Nameplate.-

6.10 FINAL FINISH - Inspect each completed package and document

-compliance with specifications as follows:

A.

All vent holes are mealed with plastic cap plugs and silicone I

RTV caulking.

B.

Final dimensions per 5.8 above.

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C.

Installation of gaskets and cylinder support pads.

D.

Lid to body fit.

E.

Actual tare weights of lid and bottom halves.

F.

Final assembled tare weight.

G.' Proper permanent marking and nameplates per 10CFR71.85(c),

49CFR1178.121-5, and ANSI N14.1 (latest revision) 6.11 STENCILS AND NAMEPLATES - The fabricator will inspect each package and document that:

The actual package tare weigh has been stamped on each nameplate and. recorded on the Inspection Checklist.

'The package markings have been stenciled in_the-appropriate places.

For new packages, identification plate shall not be attached until accepted by BTUSA.

6.12 WITNESS-INSPECTIONS:

A. The purchaser shall have the option to witness at the manufacturing factory during manufacturing and after completion I

for inspection purposes and compliance to Quality Assurance.

6.13 SUB-CONTRACT OF FIRE RESISTANT PHENOLIC FOAM -

A.

Procurement documents are to provide supplier with a copy of

-SP-9 Rev. 1 with requirements of conformance with this specification.

B.

-Supplier will provide contractor (Fabricator) with copy of receiving checklist for materials and a verification of conformance, both referring to the applicable " Job Number".

C.

Supplier will provide Contractor with4" x 4" x 2" sample of foam used for each 0.P.P.

referencing " Job Number".

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I 6.14 The Fabricator will provide documentation regarding the training and certification of special process employees such as welders.

6.15 ATTACHMENTS: 6.15.1-Production' inspection checklist for Model 21PF-1 Protective Shipping Packages.

6.15.2 Receiving Inspection Report for materials & sub-contracted

. items for Model 21PF-1 Protective Shipping Packages.

6.15.3 Final Inspection Report.

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6.15.1. PRODUCTION INSPECTION CHECKLIST Package Serial Number:

' Order No:

Job No:

A.

Welds (Visual Inspection Oi' DATE Inner shell seems (100%)

Outer shell seems (100%)

Panel moldings miters (100x)

I-i Panel moldings seems I

B.

Dimensions (conform to drawings)

OK DATE

g Inner length C 3

g Outer-shell length [

3 1/4" vent holes per Dwy m

l Flatness of. gasket surfaces L l.

.C. Weishta:

lbs.

Kos.

Intl.

Date'

E Upper Assembly before foaming L

Upper-Assembley after foaming

! gc Foam upper half (110 + 10-lbs.)

LE-

'owar ^==== blay bafora fo== ins Lower Assembley after foaming Foam lower half (110 + 10 lbs.)

Finished Cover Tare Weight Assembled Package Tare Wt.

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D.

Finishing:

OK Date Vent holes-sealed with plastic plugs g

and silicone RTV caulking.

g.

j OK Date E. Wood-Wood & cover plates coated with

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-fire-retardent (intumescent) paint prior to installation.

Installed as per drawings

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6.15.1 PRODUCTION. INSPECTION. CHECKLIST PAGE.2 OK-DATE I

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F'.. Foam;- installed as per drawings and per SP-9 Revision l' Samples received and inspected.

Minimum of 110 +-10 lbs. finished foam I

Al'1Lvent holes in the shelf where foam is installed in package q

- has'no voids.

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Gasket!s - 1/4" thich x 6" x 9" Neoprene

- pads bonded to the top inner shell in four i

i places over the wooden support blocks.

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i 3/16" ~ thick x 6" x 9'.' Neoprene pads are

-l bonded to the bottom inner shell in four l

places over the wooden support blocks.

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I 6.15.2 RECEIVING INSPECTION REPORT FOR MATERIALS AND SUBCONTRACT SUPPLIER (MANUFACTURE OF 21PF-1B)

Complete this receiving report for materials to be used in the manufacturing of Model 21PF-1B PSP's in accordance with drawings No.

E-S-31536 J, Rev. P and $1E-31536 J2, Rev. B, See Bill of Material for further specifications.

Mark all incoming item with the appropriate " Job Num.ber" per QC program I

requirements.

Attach " REJECT" tags on all nonconforming items and isolate for return to vendor or disposition by management.

Qusntity Inspection Item No.

& Description (Specification)

Ordered Received OK Date l

1.

16 ga. sheet (ASTMA-240, Type 304L,

(

2B finish Size: _____________ Heat #

2.

16 ga. sheet (ASTMA-240, Type 304L,

2B finish

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Size:

Heat #

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14 ga. shot (ASTMA-240, Type 304L,)

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1 finish I

Size:

Heat #

4.

14 ga. sheet (ASTMA-240, Type 304L,)

1 finish Size:

Heat # __________

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Angle ASTM a-276, Type 304L,) Hot i g rolled, annealed & pickled Size:

Heat #

6.

Angle ASTM a-276, Type 304L,) Het rolled, annealed & pickled Size:

Heat #

7.

Flat bar - ASTM A-276, Type 304L,)

Hot rolled, Annealed & Pickled Size: _____________ Heat #

8.

Flat bar - ASTM A-276, Type 304L,)

I Hot rolled, Annealed & Pickled Size:

Heat #

9.

Plate 1/2" Size:

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RECEIVING INSPECTION REPORT (MANUFACTURE)

PAGE 2 10.

Plate 1/4" Size:

11.

White oak or better grade soistura content less than 204 I

Si=e:

Size:

12.

Plywood, Douglas Fir, 1/2" x 3*6" x 3'6" any grade 13.

Weldwood Plastic Resin Waterproof l

glue 14.

Lag screws, 1/4" dia. x 2" 1g.

sq. hd. Type 18-8 or 300 series stainless steel I

1 15.

Heavy Hex Head Screw 16.

Nuts, 3/4" 27.

Lock washers, 3/4" U.S.

std.

18.

Washers, Flat i 1/4" 0.0x 9/16" 19.

Washers, flat 3/4" U.S.

std.

20.

Boat nails, pisin flat head 21.

Pina, cotter 22.

Shackles, screw anchor 23.

Dowels, Hardwood 24.

Pads, Sponge rubber I

25.

Pads, Neoprene 26.

Paint, Fire Retardent ALBI lI 27.

Epoxy, Araldite #502 l

28.

Hardener, CIBA Products Co#951 29.

Adhesive, Metalset A4 30.

Rubber RTV Molding

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I RECEIVING INSPECTION REPORT (MANUFACTURE)

PAGE 3 31.

Silicone Rubber Sealant, 732 RTV 32.

Paint, primer ALBIW4875 t

33.

Paint, Finish, ALBIW144, White 34.

Capluga, Polyethelene, No.BPF

-1/4" I

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Fire Resistent Phenolic Foam Subcontractor's Name ___________________________

Subcontractor *a Verification of Conformance to Specifications of SP-9 Rev. 1 Received and inspected Samples checked ____________

1,s,.ct.e,,

o.te.___________________

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'6.15.3 FINAL INSPECTIO.' CHECKLIST Package Serial Number: ______________

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Order No:___,,_________

Job No._______________

A.

Welds O.E P_6.Il Re-inspection of all visible I

B.

Dimensions (Comply with tolerances) i I

Lower Inner cylinder cavity length I 3

Lower Inner cylinder cavity width

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Upper Inner cylinder cavity length (

)

Upper Inner cylinder cavity width

(

3 Lower Outer cylinder length 3

I Lower Outer cylinder width

(

3 Upper Outer cylinder length

(

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Upper Outer cylinder width

(

)

1/4" vent holes per drawings i

Flatness of gasket surfaces C.

Weights:

lbs.

Kgs.

Intl.

Date Finished Cover Tare Weight Finished Lower Tare Weight Assembled package Tare Weight i

D.

Vent holes sealed OK DATE E.

Fit of cover to body F.

Verification of Production Inspection Report that all inspections which should have been conducted at either stages have been performed and data is acceptable.

G.

Stencils & Nameplates package Tare Weight stamped on nameplate & is same as final inspection weight.

Package markings in appropriate places I

I 6.15.3 FINAL INSPECTION CHECKLIST PAGE 2 We certify herewith that the above-described package has been manufactured in accordance with the specifications provided on the drawings and purchase order and conform to same.

I PRESIDENT DATE:

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I 7.0 MAINTENANCE REPAIR AND INSPECTION I

7.1 TIE-DOWN/ SECUREMENT of Model 21PF-1 Overpack Bolts, 1/2" in diameter and approximately 4 " long, are inserted through the base support of the overpack and the floor o+f the transport vehicle.

I Steel plates are placed over the bolts on the underside o** the transport vehicle floor (one plate per base support end).

A self-locking nut is affixed to each bolt and tightened.

If self-locking nuts are not available, a locking washer and nut can be I

used.

In this case, after tightening -- and to ensure that the bolt and nut do not come loose during transport -- the exposed threads of the bolt are marked, using a hammer and chisel, thus damaging the threads.

Only a great deal of force could then remove the nut.

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I 7.2 USER MAINENTANCE & INSPECTION I

The user shall inspect these packages in accordance with written procedures prior to every outgoing shipment and upon receiptof every incoming shipment to assure the following:

i 7.2.1 Package base and supports are sound with no broken welds or I

components, and they are bolted tightly to trailer.

7.2.2 Package is intact with no broken welds and no holes, tears, or cracks, greater than 1/2".

7.2.3 Inner liner is free of debris and standing water and is intact with no holes, tears, cracks, or broken welds.

7.2.4 Gaskets and cylinder support pads are in place and intact and are not in a deterrorated or damaged condition.

Gaskets shall be replaced I

every 12 months or more often if found deteriorated or damaged.

7.2.5 Wood cover plates and welds are sound and undamaged.

7.2.6 Package halves fit together properly with no gaps.

7.2.7 Closure devices are properly adjusted for tight closure and coupling / adjusting nuts are properly locked.

7.2.8 All vent seals / plugs are securely in places vent plugs shall be I

relaced whenever they are found missing.

7.2.9 Packages which are rejected during any of the above routine inspections shall be repaired and reinspected conforming to drawing requirements per the above QC Acceptance Tests and to the requirements of ORO-651 and ANSI N14.1 (latest revisions).

7.2.10 Detsermine A2 value for each shipment and assure that it will not exceed 6,200 at any time during the shipment.

I 7.2.11 Make radiation survey and assure compliance with regulations including 10CFR71.47.

I 7.2.12 Corrosion can be minim 1=ed by:

a.

Protection form the weather by storing under cover.

7.2.13 Accumulation of moisture within the insulation will be minim 1=ed I

by the following actions, a.

Assure that gaskets at the closure interface are in good condition and in place.

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Always ship and store overpacks in closed conditions with all closure bolts in place and tighened.

c.

Maintain epoxy seal over vent holes at all times.

d.

Inspect inner and outer skin for holes and tears.

Repair immediately.

e.

Weigh overpack after each overseas shipment.

Domestic shipments should be weighed at least every six months or when moisture accumulation in the insulation is suspected.

If the overpack has had a weight gain, which indicates moisture accumulation, in excess of 10 lbs. it should not be returned to the toll enrichment facility for loading.

7.2.14 Condition of base supports.

The base supports should be inspected and repaired after each trip.

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I 7.3 ANNUAL USER INSPECTIONS I

7.3.1 Lifting / stacking frames, closure devices and tie-down supports are sound and free from weld cracks, damage, and deterioration.

I 7.3.2 Closure devices are properly adjusted and locked.

7.3.3 All vents are properly sealed.

7.3.4 Gaskets are replaced every 12 months and are in place, intact, and not damaged or deteriorated.

7.3.5 Inner and outer shells are free of holes, cracks, tears, and broken welds, and the inner shells are free of debris and standing water.

7.3.6 Wood cover plates are sound and undamaged, and gasket sealing surfaces meet drawing requirements.

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PACI* AGE ' IDENTIFICATION PLATE A.

PLATE SHALL BE 11" WIDE X 15" IONG X 16 'IO 20 GAGE STAINLESS STEEL SHEET, AS'IM A-240, TYPE 304L.

t B.

ENGRAVE PLATE WITH LETTERS 1/2" HIGH AS FOLtoWS:

L USA-DOT-UUU*

l RADIOACTIVE MATERIAL-TYPE AF V--V*

SERIAL NO. XXX*

NIC-YYY*

TARE WP. (W/O INNER CYL) IN LBS (AND KGS):

DATE:

COVER:

BCTI' TOM (W/SHKLS TOTAL PKG LBS (KGS)

BLTS,NLTTS) : LBS (KGS)

LBS (KGS)

DoD*

WWW* (ZZZ)

WWW*(ZZZ) e

--g

($-LTAVE THE BCYPIO18" X 11" BLANK FOR FtJTURE DATES & WEIGHTS)

C.

ATTACH PLATE TO COtfrAINER AS SPICIFIED ON FABRICATION DRAWING.

UUU-SPECIFIC DOT SPECIFICATION NUMBER [ EXAMPLE: USA-DOT-21PF-1B,304L-SS (IF S/S INNER LINER IS USID)}.

V--V - NAME OR SYMBOL, APPROVED BY THE ASSOC. DIR. OF FNT, DOT, OF MAKER OR PARTY CERTIFYING COMPLIANCE WITH SPECIFICATION REOUIRIMENTS; AND DATE OF MANUFACTURE (EXAMPLE: M1-ES, K-25, OAK RIDGE, TENN. 9-67).

XXX - SERIAL NO. OF INDIVIDUAL CONTAINER (EXAMPLE: 123-001)

YYY - USNRC TRANSPORTATION 00ALITY ASSURAfCE PROGRN1 APPROVAL NUMBER (EXAMPLE: N)C l

APPRL NO. 9999).

l DDD - DATE OF WEIGHING (EXAMPLE: 9-86).

WWW - ACWAL TARE WEIGHT OF AN ELEMDfr OR AN ASSINBLED PACKAGE IN LBS. (Tol=+ 5 LBS)

ZZZ - ACWAL TARE WEIGHT OF AN ELEMDfr OR AN ASSEMBLED PACKAGE IN KGS. (Tol=[ 2 KG REFERDCE DRAWINGS: ES-31536J, SlE-31536J1, & SlE-31536J2; LATEST REVISIONS CAPE-1662 (Rev. 1) Suppl. 1

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PACKAGE IDENTIFICAT10H' PLATES FOR 21 PF-1 ALB SHIPPli1G CONTAI!!ERS

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material sp1& abed.oute.e..sq) des &" surfaced.of thi edatainer shall be reeved.

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STANDARD REFERENCE INFORMATION

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JS-31536 1 Rev. 1 e.,e ownesse 3-28-66 me,,ee s 3-28-68 FIRE RESI8'DutT PHrJt0LIC F00(

...e Powder C apanents Screen all empenents through a sieve (National Bureau of Standards No. W) ed pre-blend to a unifera consistency.

Reseal blended empenents so atmospheric exposure is reduced to a minimum.

Final Elendins

!l 1.

Add liquid c aponents or pre-blended liquid c aponents to mixer tub and stir to a uniferin censistency, abeat 2 minutes for pre-blended cepenent s.

Temperature of the phenolic resin or pre-blended liquid components shall be 60C 1 $0T when it is added to the mix.

2.

Add fibergansa a6d mix to a uniform consistency.

3 Add the pre-blended powder components rat,1dly u.d mix to a unifom consistency, 30 to 60 seconds.

)

I h.

Cuickly tre.nsfer the mixed raw m'sterial to the re ceiver container so that the foaming acticn takes place within the container.

PIACING ATTD CtfRDC TCAM_ MATERQL_

The mixed fcam raw materia,1 shall be spread evenly e.er the bottem outrace l

of the receiver container so roam expands in relatien.y unifom layern.

The first peur of bottest section-she.:Id be tamped immediately af ter fuur-ing begins to minimize size of void spaces. Air cure at rom temperature for at least one hwr to a,Llow for full expansion of fees.

l After roaming action and curir6 is empleted o. a peur, the next pour or material car, be spread everly m t op of the previous expanded layer. All sequential pours shall pro:eed with a alnimum delay so that atmospheric exposure of the interns,1 fibers is minimited.

The number of pours shall be as spe,cified en the drawings. Af ter the final peur, the foam shall to allowed to cure at least fcetr he.tra at rom temperature before bracing, molds, and accessories sre removed.

j NOTE Sequentis,1 pears are self boncling to the previous pour with no apparent velds or cleava6e places.

Rf.MOVAL Of BRACDt, MOLDS. AND ACCESSORIES AND FINIS!!IrlG WORK ceneral I-All bracing, solde u.d any ac:essories not part of the finished container, I

l25 as defined on the drawings, shall be removed after foaming and curing opera-e tions are empleted. Any extr.ided foam material (e.g. extrusions thrmgh 4

isl i

APPMoveo eY C-

, (.r* m r

. 1,.'

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STANDARD RElrERENCE INFORMATION

~ ~ * * *

-+,

_Js-31536-1 Rev. 1

,.a uso e

3-28-66

[

3-28 68 FIRE RESIE'Dut? FIEN0LIC F04.M

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~

1 3

5 I

All Other Materials Store all other component materials in airtight storage containers at g

roam temperature until ready for blending.

l PREPARATION OF RECEIVER CONTAINER AND ACCESSORIES Container In preparing a ccr.tainer for ret.eiving the foamed-in-place filling, all loose inner pieces shall be securely anchored in place to prevent dis-placement by the fosus, and vent holes to prevent volds in the finished foam snd to provide gas relief when expored to high heat shall be drilled

.i as defined on the drawings.

The necesr.ary blocking, framing, bracing, etc., shall be installed to h.11d in place the container shell, endr.,

lining, et:,, as applicable, s.nd prevent distortion to cat-of. tolerance condition during the fcaming on ration.

Holds Holds to shape exposed surfaces of roaa shall te installed and ce,ured in position just af ter the Tir.a1 Tenta rav estarial is placed so fe. enn expand into thy mold. Air vent holes not exceeding 1/h" in dia::v'.cr e.ny be made at intervals in a mold to allow for escaping air and thernby prevent void synes in the fininhed surface.

Holds shall be made of nurh strength to prever.t distortion to cr.it of-tolarance condition durtne '.hn foamirs cperation.

A mold release (e.g. fr.erson and Cuming scid re leace ccupoind Nc.122S or DuPont Tefien) cha11 he applied to mold nurfacen l

I which will contact team materia) so that the mold can be removed without dama.ging the finished roam surface.

Cleaj.,rL Bg o_re Toaming All sawdust, bits of wood, metal filings. water droplets, grease, oil, and cther foreign particles shall be removed fra the molds or container cavities before fems tsw materia.1 is added.

MIXING PROCED'JPES Pre -Blending '

Liquid Compenents - Pre-blend liquid ccuponents in any order by cer:binin;.

the ingrecuents a,nd stirring to a unifor9n consistency.

Temperature of the phenolle resin shall be 600 + 5'r when it in added to the r.1x, If final blending is to be delayed, reseal the blended cenponents no g

atmospheric exposure is reduced to a mini =um.

asjo 1

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STANDARD REFERENCE INFOR98AT10N J8 31536 1 Rav. 1 L y;j l

c eave 3-28-66 l 1 sensee 3 28-68 4, 'swa.eet woes F DE REB 18thlrf PW50LIC 700(

2 s

5 tj.

? f.

Caponent Weight per 100 Lb. of mtl.

(Lbs.)

tendor - Trade Waaes Material PW caussements (Contd) variaccid Chasticed.

b.1 f, 0.1 Boric Anhydride (3,0 )-

Ccampany No.1137, or 3

g q

Powder, Reagent Orade, -200 Mesh equal.

f 8.2 f,0.1 osalle Acid, H U o,

Baker and Adamson 22k No. 1135, or aque1

)

Anhydrous Powder, Reagent Grade o

l Reinforcina Ccaipement l

Owens-Cerning Tiberglas 9,2 ~4 0.1 F.iberglass Rovings No. 805 (HsI),or equal 1/b"ChoppedLengths MATERIAL G'IVRAGE RMUDDENTS phenolic Resin i

Store in airtight storage container.

1.

Maximum shelf life is three months fram date of annufacture 2.

stored at rocia temperature.

Maximum shelf life is six months from date of annufactur at a temperature of 40 f,50F.

0 Date of manufacture should be marked cm the storage cantainer.

NOTE:

I Pre-blended Liauid Camoceents The three liquid components any be pre blanded or stored separately.

If pre-blended, the liquid airture may be stored La ti.rt i

3 ceeding one month prior to final blending, provided this additional i

time does not exceed the maximum storage life for the phenolic res n.

If the liquid components are stored separately, the same storage re-quirements must be observed for the phenolic resia campcment.

,a Powder Ccapon-nta All powdtre shall be stored in s,irtight storage cantain a

g I8l neiature 5P9-J[.pg.:Q

'"'""*['

II-

STAl#ARD REFERDICE MAN 7

/ !,

UBBOR SA M OE 00RPeneften J8-31536 1 Rev. 1

.i}: ' -

esuctaan omsson

asop, oaa messe. temmassa s. Paouc am. ma n ueur 3-28866 a= wee t

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I?

.m 3 28 68 jl9 FIRE RESI51Nt? PHENOLIC FtAM 1

5 IE9.E

'l This specification shall evver materials and procedures for mixing and applying foamed-in. place fire resistant phenolic room where specified on the drawings.

MATERIALS AND PROPORTIONS-l5..'

All materials used in the fire resistar.t roaa shall be as listed below and shan be prepared by blending, screening $etc., as defined.

Sub-stitutions of mattrials may be made only where noted.

Total quantity '

of materials sha n be as required to fill the container cavities and e-4 provide the finished fama weight as defined on the drawings.

Individual L

weight quantity of each component material shall be such to provide a

{j finished roaa material alature of the proportionate blend specified below.

Camponent Weight per 100 Lb. of Mati.

Material vender - Trade Name (Lbs.)

Liquid C a ponents-1 Phenolic Resin UCC Plastics Division 65 8 + 0.2

~

BRL-2760 (roam Density l

1.8-2.0 Lts./tt.3)'

},

Surfactant UCC Flastics Division 2.0 + 0.1

~

l Silicone Surfactant L-530, or equal

{

4 Refrigerant H3 '

DuPont Freon H3 or 6.6 + 0.1

'W Powder Camponents Boric Anhydride Varlaccid Chemical h.1 + 0.1 (Eg0 ), Powder, Capany No. H36, or

~

3 Reagent Grade, equal

-100 + 200. Mesh

Resin foam value as determined by method used at the P rietta Ohio Plant of the UCC Plastics Division.

$k t*

i

$U t

^^ h f A>98Reyes 9vs,

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BILL or FATERIAL Page 1 of 3

(

Martin Marietta Energy Systems NJeer S-31536-4, Rev. 9 Unitt Horizontal leading Snippirg Container for 30" Dia,eter Ur Tank (heference - Martin Marietta Energy Systems Drawirq E-S-31536 J, Rev. P. ard $1E-31536 J2, Rev. B).

Ooantities are for one shippirq container..

Metal items 1 thru 18 shall be stainless steel as follows:

a.

Sheet - ASm A-240 Tyre 304L, 02B rinish b.

Plate - ASm A-240. Type 304L, el rinish c.

Angle and Flat Bar - Asm A-276, Type 304L, Hot Rolled, Annealed, ard Pickled, ften Quantity gterial ard Description 1.

2 Pe.

Sheet, 14 Ga. m 7'-0 x 8'-0 2

2 Pc.

Sheet, 16 GA. x $'-0 x 7'-0 3.

2 Pc.

Sheet, 14 Ga. m 4'-0 x 4'-0 4.

1 Pe.

Sheet, 16 Ga. x 3'-0 x 7'-0 5.

4 Pe.

Sheet, 14 Ga. x 0'-B" x B'-0 6.

4 Pc.

Sneet, 14 Ga. : 0'-6" x 4'-0" 7.

4 Ea, Angle, 3" x 2" x 1/4" x 10'-0" Lg.

(Alternate Use 3" x 3" x 1/4" or 21/2" i

x 2 1/2" x 1/4" 8.

2 Ea.

Angle, 31/2" x 31/2" x 3/8" x 10 -0" Lg.

9.

2 Ea.

Angle, 2" x 2" x 3/16" x B '-0" Lg.

10, 2 Ea.

Argle, 3" x 3" x 3/B" x 4 '-8" Lg.

11.

4 Ea, Argle, 2" x 2" x 1/4" x l'-0" Lg.

12.

4 Ea.

Argl e, 3" x 2" x 1/4 " x 3 '-8" 1.

4 (Alternate Use Angle 3" x 3" x 1/4" or 2 1/2" x 2 1/2" x 1/4 "

13.

28 Ea, Angle, 2" x 2" x 3/8" x 0'-

21/4" 19, 14.

16 Ea.

Angle,1 1/2" x 1 1/2" x 16 Ga. x O'-7" 14 15.

2 Ea.

Plate,1/2" x 6" x 3'-7" 16.

2 Ea.

Plate, 1/4" x 4'-0 x 4'-0 l

-i D

Page 2 of 3 17, 4 Pes.

bar 1/4" a 3" a 7'-0" 18.

8 ta.

Bar, 3/8" a 2" x 2" 19.

6 ta.

14rnber, 6" x 8" N:xa m O'-9" Lg. White Oak or tetter grade, moisture content less than 20%

20.

4 ta.

tarnber, 3" a 8" x 8'-0* Eg. White Oak select or better grade,fnoisture content less than 20%

21.

24 Ls, Lumter, 2" x 6" a 8'-0" 14. White Oak select or tatter grade, moisture content less than 201 (for laminated timbers) 22.

1 Pe.

Plywood, Douglas rir, 1/2" thk a 3'-6" x 3'-6" any grade 23.

1 Can Adhesive weldwood waterproof plastic resin glue, 10 lbs, as manufactured by U.S. Plywood Corporation 24 140 ta.

Lag Serews, 1/4" dia.

2" 4. fq. Hd., Type 18-8 or 300 series stainless steel 25.

14 La.

Heavy Hex Hen $ Screw, 3/4"-10 IC 2A, 6" 4 ANSI B18.2.1. Asm A-193, Grade B7 with proper merking and material certification (Alternate - same except ASm A-19), Gr. B8, Class 2 marked) 26.

14 ta.

kata, 3/4"-10 Unc 26, ASm A-194, Grade 2H ANSI B18.2.2. SF, Heavy Hex, with proper marking ard material certification (Alternate same except AS M A-194, Gr. 8A Marked) 27 14 Ea.

tock Washers, 3/4" U.S. Std., Type 18-8 or 300 Series Stainless Steel 28.

4 ta.

Washers, riat, 1 1/4" 0.0. m 9/16" 1.D. m 3/32" m k., type 18-8 or 300 Series stainless Steel 29 14 ta.

Washers, Flat, 3/4" U.S. Std., Type 10-8 cr 300 Series stainless Stael

30. 100 to.

Boat Nails, Plain Flat Head, 610 a 21/2" Q.

Type 10-8 or 300 Series Stainless Steel 31.

14 ta.

Pins, Cotter, Spring Stainless Steel,1/8" x 1 1/2" Q.

e Page 3 of 3 g

32.

4 E4.

Shackles, Screw Anchor, forge $ Stainless Steel 3/4" Stock Diameter, 7/8" Max. Pin Diameter, rdnimJrn Safe Allwsble lead $300 lbs. with a

(({

&afety rector of 6 33.

24 Sa.

Dowels, Hardwood, 3/4" Dia.

6" 14 34.

4 Pos.

Pads. Sponge hbber, Medi a Density, 6" s 9" a 1/2" thk.

l 35.

4 Pes.

Pads, Neoprene, 50-60 Duraneter A, 6" s 9" x 1

3/16" 'thk.

36.

1 Cal.

Paint, Fire netardent, At.at #107A (AIAI Manaf acturing Co., East herlin, Com.)

37, 220 lbs.

Anw Materials for Fire hesistant Phenolic roam Insulation per AEC Material ard Equipment Specification SP9, hev. 1.

30 1 Pt.

Ipony, Araldite 6502, C2hA Products Co.,

Fairlawn, N.J.

39. 1/8 Pt.

Hardener, CIBA Products Co., 9951.

40.

2 Sets Adnesive, Metalset A4, Consisting of 1 hbe of Metalset A ard 1 Tube of Metalset 8,11 ca.

Tubes

41. 1/2 Kit Rabber, IrN Molding, Silastic E, with Catalyst 11 lb. per Kit by W Corning (Alternate = Use 1 1/2" x 1/e" a 20'.0" 14. Closed Cell, Mudie Density, Silicone Sponge - Rated for continuous use at > 400 F) 42.

8 Cartridges Silleone Abber Sealant, 732 RTV, Silastic, Roan Teprature Vulcanizing, General Purpse, Color White, W Corning, 10.3 03. Cartridge 43.

1 Ot.

Paint, Primer, Atal 6487S 44.

1 Ot.

Paint, rinish Aial 6144, White

45. 48 Ea.

Caplugs, Polyethlylene, No. BPr-1/4",

Preteetf ve Closures Co., Daf f alo, N.Y.

l

o m

c-I f

OVERSIZE j

LDOCUMENT 1

EPAGE PULLED i

j SEE APERTURE CARDS 3

3. :.. _.. 7. : :.. -

c.. x. : ;.....

k i

i NUMBER OF OVERSIZE PAGES' FILMED ON APERTURE CARDS-1 l

j b

t.

.{

L E

1 ;-.

.i 2

~ APERTURE CARD /MARD COPY AVAILABLE FROM t

lE DECORDS AND REPORTS BRANAGEMENT BRANCH j

g l

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i 1

7 4

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ML20043D345

Contents

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ML20043D345

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