ML20128A832

Application for Renewal of Certificate of Compliance 9932 for Model UC-609.SAR on Model UC-609 Encl

ML20128A832
Person / Time
Site:	07109932
Issue date:	06/03/1985
From:	Garrison R ENERGY, DEPT. OF
To:	Macdonald C NRC OFFICE OF NUCLEAR MATERIAL SAFETY & SAFEGUARDS (NMSS)
References
25360, UCRL-52424, NUDOCS 8507030041
Download: ML20128A832 (2)

Text

{{#Wiki_filter:& 71 - W s 2. PDIT Department of Energy Wr) Washington, D.C. 20545 g RECEIVED 1 [g' 1 JUN 101985 > Z Mr. Charles E. MacDonald, Chief Transportation Certification Branch 5 u.s.Nuctuastcutscu -2 Division of Fuel Cycle and Materials Safety, NMSS L comtxucs U.S. Nuclear Regulatory Commission y$ g Washington, DC 205So o3 cn

Dear Mr. MacDonalo:

This is to request the renewal of NRC certificate USA /9932/B( JF, whicn expired on September 3D, 1984. A copy of the Safety-Analysis Report on Model UC-609 Shipping Package, aated August 1977, is enclosed. Please contact Cnaries Mauck on 353-6176 or Joanne Passaglia on 303-2972 if there are any questions. Sincerely, i A Ry . Garrison Chief of Transportation Operations and Traffic Division Defense Programs Enclosure 0 cc: 4 R. Brecaerman, SAN 3 C. DanKowski, SAN t0088 B ust$0 Q\\\\\\ 9 E, inga[ '/g d' p,g7oienEh" C

i ~ DOC 1GT NO. O[) CONTROL 130._ DATE OF D00.... [/ h j 83 I/ DATE RCVD. PDR FCUP LPDR FCAF ISE REF._ WM SAFEGUARDS k'MUR OTIIER FCTC DMCRIPTION: U G?1i f a & J.s/ w lDbd//Wunwaf!d< - i/ L

w-me UCRL-52424 Safety Analysis Report on Model UC-609 Shipping Package R. R. Sandberg August 1977 g,

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. s DISCLAIMER ' Ibis docuammt man prepared as se account af work sponsored by an agency of the United States Governament. Neither the United States Governament nor the University of California nor any of their employees, snakes any marranty, empress er implied, or assunees any legal liability er responsibility for the accuracy,., :., or morfalmese of any islerematies, apparague, product. er process disclosed, er represents that its see noeld not infringe ~ privately enned rights. Reference herein to any specifk comunercial products, process, er service by trade namie, trademierk, manefacturer, or otherwise, does met neceenarily cemetitute er imply its endorsemiest, receaunendaties, or favoring by the Umbed States Governorat er the University of California. The views and opinions of authors espreseed hereia de not necessarily state er reflect these of the United States Governament er the University of f Califersia, and shall not be used for advertising er product enderwoest purpows. e i Merk performed under the auspkes of the US. Ikpartment of Faersy by laurence I.ivermore National laboratory under Contract E7494-Eng4.

UCRL-52424 Distribution Category UC-71 Safety Analysis Report on Model UC-609 Shipping Package R. R. Sandberg Manuscript date: August 1977 s LAWRENCE LIVERMORE LABORATORYE University of California Livermore, California

• 94550W Available from: National Technical information Service e U.S. Department of Commerce

$285 Port Royal Road e Springfield, VA 22161 e $10.00 per copy e (Microfiche $4.50 )

CONTENTS I Abstract I 1.0 Introduction I 1.1 General Information I 1.2 Package Description. I 1.2.1 Packaging. .... 6 1.2.2 Operating Features ... 6 1.2.3 Contents of Packaging e 2.0 Structural Evaluation ...... 7 .7 2.1 Structural Design 7 2.1.1 Structural Members .7 2.1.2 Design Criteria 8 2.2 Weights and Center of Gravity 8 2.3 Mechanical Properties of Materials 2.4 General Standards for All Packages .. 8 2.4.1 Chemical and Galvanic Reactions 8 2.4.2 Positive Closure .... 8 8 2.4.3 Lifting Devices 2.4.4 Tie.Down Devices .8 9 2.5 Standards for Type.B and Large-Quantity Packaging 2.5.1 Load Resistance 9 9 2.5.2 External Pressure 2.6 Normal Conditions of Transport ....... 9 2.6.1 Heat. ...... 9 .. 9 2.6.1.1 Summary of Pressures and Temperatures 2.6.l.2 Differential Thermal Expansion ........ 9 2.6.1.3 Stress Calculations ..... 9 2.6.1.3.1 Cylindrical Section .... 10 . 10 2.6.1.3.2 Formed Ellipsoidial Heads 2.6.1.3.3 Cover Bolts ... 10 2.6.1.3.4 Flanges 11 2.6.1.4 Comparison with Allowable Stresses ... 11 2.6.2 Cold ..... 11 2.6.3 Pressure 12 2.6.4 Vibration . 12 2.6.5 Water Spray ...... 12 2.6.6 Free Drop . 12 2.6.7 Corner Drop ... 12 2.6.8 Penetration, ........ 12 2.6.9 Compression . 12 2.7 flypothetical Accident Conditions ............12 2.7.1 Free Drop 12 1 2.7.2 Puncture 18 2.7.3 Thermal... 18 2.7.3.1 Summary of Pressures and Temperatures 18 2.7.3.2 Differential Thermal Expansion 18 2.7.3.3 Stress Calculations.. 18 2.7.3.4 Comparison with Allowable Stresses 19 2.7.4 Water immersion 19 2.7.5 Summary of Damage 19 2.8 Special Form 19 2.9 Fuel Rods 20 3.0 Thermal Evaluation 20 3.1 Discussion 20 iii

3.1.1 Normal Transport Conditions ............................20 3.1.2 Hypothetical Accident Conditions ..........................20 3.2 Summary of Thermal Properties of Materials .......................21 3.3 Technical Specifications of Components ..........................21 3.4 Thermal Evaluation for Normal Conditions of Transport.................21 3.4.1 Thermal Model.................................... 21 3.4.1.1 - Analytical Model................................ 21 3.4.1.2 Test Model................................... 25 3.4.2 Maximum Temperatures ...............................25 3.4.3 Minimum Temperatures ...............................25 3.4.4 Maximum Internal Pressure .............................25 3.4.5 Maximum Thermal Stress ..............................25 3.4.6 Evaluation of Package Performance .........................26 3.5 Hypothetical Thermal Accident Evaluation......................... 26 3.5.1 Thermal Model.................................... 26 3.5.1.1 A nalytical M odel................................ 26 3.5.1.2 Test M odel................................... 26 3.5.2 Package Conditions and Environment........................26 3.5.3 Package Temperature Calculations......,................... 26 3.5.3.1 Containment Vessel ..............................30 3.5.3.2 Storage Vessel .............................30 3.5.4 Maximum Internal Pressure .............................30 3.5.5 Maximum Thermal Stresses .............................31 3.5.6 Evaluation of Package Performance .........................31 4.0 Containment...........................................31 4.1 Containment Boundary...................................31 4.1.1 Containment Vessel.................................. 31 4.1.2 Containment Penetration............................... 31 4.1.3 Seals and Welds ...................................31 4.1.4 Closure........................................31 4.2 Requirements for Normal Conditions of Transport ....................31 4.2.1 ~ Release of Radioactive Material...........................32 4.2.1.1 Permeation through Stainless Steel ......................32 4.2.1.2 Permeation through Copper Gasket...................... 32 4.2.1.3 Total Release for Normal Transport .....................32 4.2.2 Pressurization of Containment Vessel ........................33 4.2.3 Coolant Contamination................................ 33 4.2.4 Coolant Loss.....................................33 Containment Requirements for the Hy 4.3 Accident Conditions..........pothetical ...........................33 4.3.1 Fission Gas Products.,............................... 33 4.3.2 Release of Contents .................................33 4.3.2.1 Permeation through Stainless Steel ......................33 4.3.2.2 Permeation through Copper Gasket...................... 33 4.3.2.3 Total Release for Accident Conditions ....................33 5.0 Shielding Ev alu ation....................................... 33 5.1 Discussion and Results ......,...........................34 5.2 So urce Specification..................................... 34 5.3 M odel Specification..................................... 34 5.4 Shielding Evaluation ....................................34 6.0 Criticality Evaluation ......................................34 6.1 Discussion and Results...................................34 6.2 Package Fuel Loading.................................... 34 6.3 Model Specification.....................................34 6.4 Criticality Calculations and Experiments..........................34 iv

? 6.5 Critical Benchmark Experiments ..............................34 7.0 Operating Procedures ................35 7.1 Procedure for Loading the Package............................. 35 7.2 Procedure for Unloading the Package ...........................35 7.3 ' Preparation of an Empty Package for Transport...................... 35 35 8.0 Acceptance Tests and Maintenance Program 8.1 ' Acceptance Tests ......................................35 8.1.1. Visual Inspection...................................35 8.1.2 Structural and Pressure Tests............................. 35 8.1.3 Leak Testing .....................................36 8.1.4 Componen t Tests................................... 36 - 8.1.4.1 Valves .....................................36 8.1.4.2 G aske ts..................................... 36 8.1.4.3 Miscellaneous .................................36 8.1.5 Test for Shielding Integrity.............................. 36 8.1.6 Thermal Acceptance Test...................... 36 8.2 Maintenance Program............ .......................36 8.2.1 Structural and Pressure Tests............................. 36 8.2.2 Leak Tests ......................................36 8.2.3 Subsystem Maintenance ...............................36 8.2.4 Valves, Rupture Disks, and Gaskets on 36 Containment Vessel .................................36 8.2.5 Shielding .......................................36 8.2.6 Ther m al........................................ 36 8.2.7 M iscellaneous..................................... 37 9.0 Quality Assurance Requirements ................................37 9.1 General Informa tio n.................................... 37 9.2 Organization........................................37 9.3 Quality Assurance Program .............................37 9.3.1 Proced u res...................................... 3 7 9.3.2 A pp ro val....................................... 40 9.3.3 Safety.Related items................................. 40 9.3.4 Training.......................................40 9.4 Design Review ...........,..........................40 9.5 Procurement Document Control... ..........................40 9.6 Instructions, Procedures, and Drawings..........................40 9.7 Document Control..,.................................. 40 9.8 Control of Purchased Material, Equipment, Parts, and Serv ices........................................... 40 9.9 Identification and Control of Materials, Parts, and Components........................................41 9.10 Control of Special Processes.,.............................. 41 9.11 Inspection .........................................41 9.12 Test Con t rol........................................ 41 9.12.1 Preoperational Test Program ............................41 9.12.2 Acceptance Tests and Maintenance Program.................... 41 9.13 Control of Measuring and Test Equipment........................41 9.13.1 Calibra tio n...................................... 41 9.13.2 Standards .....................................41 9.14 liandling, Storage, and Shipping .............................41 9.15 Inspection, Test, and Operating Status .....................41 9.16 Nonconforming Material, Parts, or Components .....................42 9.16.1 Disposition .....................................42 9.16.2 Acceptance............,,...... .................42 9.17 Corrective Action .....................................42 o V

9.18 Quality Assurance Records ................................42 9.19 Audits ...........................................42 References...............................................43 Appendix A: Engineering Note s................................... 44 END 77-16, UC 609 Shipping Container, Fabrication Specifications.............. 45 END 77-18, UC-609 Shipping Container, Pressure Test Report................. 50 END 7719, UC-609 Shipping Container, Assembly Fabrication Record............ 51 END 77-20, UC-609 Shipping Container, Component Inspection Form............ 52 END 77-21, UC-609 Shipping Container, Packing and Test Procedure............. 53 END 77 22, UC 609 Shipping Container, Packing Ch'eck List .................59 Appendix B: Fabrication Drawings.................................62 AAA77-105111 Drawing List................................ 63 AAA76-109771 Model UC-609 Shipping Container.................... 64 AAA75-il3967 Containment Vessel, Leak Test Assembly................. 65 AAA75-ll3083 Vessel Assembly.............................. 66 AAA77102165 Cover Assembly..............................67 AAA77-ll2930 Vessel Carrier Assembly.......................... 68 AAA77-104161 Insulation Cover Assembly ........................69 AAA77104165 Drum Assembly.............................. 70 AAA77104163 In sulation, Body.............................. 71 e vi

SAFETY ANALYSIS REPORT ON MODEL UC-609 SHIPPING PACKAGE ABSTRACT This Safety Analysis Report for Packaging demonstrates that model UC-609 shipping package can safely transport tritium in any ofits forms. The report describes the package and its contents. It also evaluates the package when subjected to the transport conditions specified in the Code of Federal Regulations, Title 10, Part 71. Finally, it discusses com-pliance with these regulations.

1.0 INTRODUCTION

1.1 General Information The model UC-609 shipping package will be used to provide containment and offer impact and thermal resistance for shipments containing tritium during transport under both normal and accident conditions. Any tritium to be shipped will be placed in an appropriate storage vessel. That vessel will be placed within a stainless steel containment vessel, and the containment vessel placed within an insulated steel drum. Each package will contain either a type-B quantity or a large quantity of tritium in any form, as defined in the Code of Federal Regulations, Title 10, Part 71 (10 CFR 71). All shipments will comply with the ap-propriate sections of these regulations. No exemptions are claimed. The following points constitute the design basis of the UC-609 shipping package: o The containment vessel is considered to be the primary containment boundary and will contain the tritium when the package is exposed to the normal or hypothetical accident conditions specified in 10 CFR 71. e Tritium will never be loaded directly into the containment vessel but will be put into a storage vessel. o For design and analysis purposes the storage vessel will receive no credit for tritium containment. e Although the storage vessels receive no credit for containment, they are to be designed, certified, and tested to provide the maximum assurance of containment under all shipping conditions. 1.2 Package Description 1.2. I Packaging The total package weighs 500 lb. The external dimensions are 25 in. in diameter X 55 in high (see Fig.1). Fabrication drawings of this package are presented in Appendix A.The major components,i.e., drum, insula-tion, and containment vessel, are described in the following paragraphs. The drum is fabricated from 16-gauge carbon steel to the dimensions of 24.0-in. i.d. X 52.5-in. inside height per military standard MS 27683. Two I-in.-diam holes near the center of the drum lid prevent package rupture from internal pressure during an accidental fire. These holes are scaled weathertight by inserting molded plastic plugs. Eight 3/16-in. thick stainless brackets secure the cover to the drum with 3/8-in. diam a stainless steel bolts (see Fig. 2). The insulation that cradles the containment vessel within the drum is Celotex laminated military packing board (a product of the Ce!otex Corp.) per military specification MIL-F-26862. The insulation is fabricated into disks and annular pieces of varying thickness. When the insulation pieces are installed in the drum, an in-ternal cavity 18 in. in diameter and 44 in. long is formed. For case in handling, the pieces of Celotex that must be removed to gain access to the containment vessel are glued into an assembly. Laminated into that assembly is a 1/2 in.-thick disk of plywood that will prevent the ring on the containment vessel cover from penetrating the Celotex if the package is dropped on the top end. It is necessary to prevent this pentration because of I

Heat shield 9 Plastic plug Cerabianket insulation 5.0. on e ch end x' 3.7 in. on sides 'N ,......9 f/ l\\ \\ \\ // i i / Carbon steel drum y 24 in. Inside diameter 9 52% in. inside height _[:k b / Rubber pads .- ) y Vessel carrier azzzsa < w - my V gg 54.5 in. / 7 ,/ Storage vessel total height / sM {u j ( R== l \\) N ME5 H-3 g // w E Containment vessei 'g g Type-316 stainless steel G N M 18 in. outside diameter .\\' 1/8-in.-thick wall N -. =r;_- Cavity 10 in. diam x 31 in. long iEEE D {l l 4l l 'N Aluminum tube h s / on d i 4.0 in. on each end Cavity 18 in, diam x 44 in. long 25 in. max diam Fig.1. Model UC-609 shipping package. possible damage to the valves and gauge on the cover. A sheet metal heat shield covers the top edge of the Celotex cover. The function of this part is to protect the Celotex from burning if a gap occurs between the drum and its cover as a result of an accidental drop. 2

3/8-in.-diam stainless steel bolt nr mm Cover bracket wwsl lV axw y ,I o It i I ii l i kswswwwwws wsw wwwd4% / -Drum cover Drum body / Fig. 2. Detail of drum cover bracket. A disk of 1/2-in. thick Cerablanket (a porous refractory fiber insulation produced by the Johns. Man tille Corp.) is placed between the Celotex and the drum cover.This refractory fiber insulation performs tbc follow-ing functions: o Protects the Celotex from direct exposure to flame, e Allows venting of the internal pressure, e Limits the inflow of air to the drum to prevent the Celotex from smoldering after exposure to fire, e Prevents separation of the Celotex by filling the gap between the drum cover and the Celotex. The containment vessel consists of two parts, the body and the cover. Both are 1/8 in.-thick type-316 stainless steel. The body of the vesselis made by tungsten-inert-gas welding American Society of Mechanical Engineers elliptical heads to each end of a rolled and welded tube. The head on the top end of the container body has a flange welded into it. The mating flange is part of the welded cover assembly The primary seal be-tween the body and cover is made when opposed knife edges on the mating flanges are forced into an an-nealed, oxygen free, high-conductivity copper gasket by the torquing of eight 3/8-in. alloy steel bolts. A Viton 0 ring backs up the primary seal and allows a leak check of the primary seal with a mass spectrometer leak detector (see Fig. 3). 3

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/ in this port I! l l1l Containment 1 vessel body N i l ' \\ \\ \\ \\ N x g* N il FlL_sll ~ l L \\ 2 s r. n 5% N N h / Copper gasket Aluminum N / (primary seal) honeycomb g% l \\ / ? Aluminum tube 10 in. Inside diameter Fig. 3. Detail of containment vessel cover-to-body seal. The cover assembly has two penetrations. One is a 1/8 in. national pipe tapered-thread female pipe port = that connects to the small volume between the primary and secondary seals. A valve designated the leak test valve is screwed into the port. The second port is in the center of the cover and connects to the main container volume. A manifold containing a 200-psi gauge and a valve is welded into this port. Both valves, the manifold, and the gauge components expoted to the container gas are type-316 stainless steel. The connections on both the valves are 1/4-in. tube, 37' male flare fittings (see Fig. 4). Aluminum honeycomb (IIcxcel Corp. designation Al-1/4-5052-0015P-3.4),3.7 in. thick on the sides and 5 in, thick on the ends, lines the containment vessel. This honeycomb will prevent the storage vessel from im-pacting against the containment vessel shell if the package is accidentally dropped. The maximum force that can be transmitted through the honeycomb is its crush strength, which is 150 psi. A 10 in. i.d. aluminum tube protects the inner surface of the honeycomb. The cavity formed within the containment vesselis 10 in,in diameter x 31 in. long (see Fig. 5). 4

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The vessel carrier is temolly a mounting, handling, and locating fixture for the storage vessel (see Fig. 6), but the major functian in the package design is to distribute any forces transmitted by the storage vessel over the entke area of the end pieces of the honeycomb. The vessel carrier may be redesigned in the future to ac-commodate storage vessel configurations not yet anticipated. The following restrictions must be observed in any redesign: e Load-distributing aluminum (6061-T6) plates 1/2 in, or thicker are required between the storage vessel and the end pieces of honeycomb. e The total weight of the storage vessel plus the vessel carrier cannot exceed 120 lb. e if materials less dense than aluminum are used for the vessel carrier, the total volume of the compo- ~ nents to be installed in the containment vessel must be considered (see Sec.1.2.3). The vessel carrier is held in position by a close fit with the aluminum tube described previously. A gap in the long axis prevents interference due to tolerance buildup. Lightly compressed rubber pads fill the gap. This method of positioning provides both axial and traverse support and restricts the movement of the vessel carrier during transport. 1.2.2 Operating Features The operational features of this packaging are described in Ch. 7.0, Operating Procedures, l.2.3 Contents of Packaging The radioactive contents of this package will be tritium in any ofits forms. The following restrictions ap-ply to the use of the container: Maximum total gas contents 30 mole Maximum tritium contents 25 mole I t?5 << U ~ R i i .c 6 D., .l 4 ..]. \\ / 'E. O; f) i b = ..q =,, _ M [~ f .( t i l l

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Maximum radioactive decay heat 48 W Maximum combined weight of storage vessel and vessel carrier 120 lb Maximum combined volume of storage vessel and vessel carrier 20 litres A maximum weight of 120 lb will limit the combined volume of the storage vessel and vessel carrier to 20 litres if the materials of construction are at least as dense as aluminum (0.098 lb/in. 3). If materials less dense than aluminum are used, either the maximum total volume of the vessel and the carrier or the maximum total gas contents must be reduced. New limits may be calculated using the following equation: N = 34.48 - 0.224 V. T wherc N = maximum number of moles of material, VT = total volume of vessel and carrier. l l 2.0 STRUCTURAL EVALUATION l 2.1 Structural Design 2.1.1 Structural Members The principal structural members of the model UC 609 shipping package are the stainless steel contain-ment vessel lined with impact-absorbing honeycomb, the Celotex insulation, and the carbon steel drum. The containment vessel has a removabic cover that is held in place by eight alloy steel bolts.These bolts, when tightened, force knife edges on the mating flanges into a copper gasket, providing the primary closure seal. A secondary seal is provided by an 0-nng. Two valves penetrate the cover. The first, called the fill valve, is part of a gauge manifold that is welded into the cover. This valve is used to pressurize or evacuate the container and to monitor the vessel contents. The second, called the leak test valve, is screwed into a port that connects to the volume between the primary and secondary seals. By connecting a mass spectrometer to this valve and pressurizing the container through the fill valve, it is possible to make a very sensitive leak check of the primary seal. The aluminum honc3 comb that lines the interior of the containment vessel prevents the storage vessel from impacting against the vessel walls. A l/8 in. thick aluminum tube protects the honeycomb surface and acts as a load distribution member in the radial direction. Aluminum disks 1/2-in. thick act as load distribu. tion members in the longitudinal direction. The Celotex not only insulates but centralizes the containment vessel within the steel drum that forms the outer surface of the package. The drum cover is held on by eight special brackets secured by 3/8-in. diam stainless steel bolts. 2.1.2 Design Criteria The load criteria for the containment vessel are: Maximum internal pressure 110 psig Maximum external pressure 25 psig Maximum combined pressure load 260 psig The calculated maximum pressure that could occur during a normal shipment is 103 psig (see Sec. 3.4.4). The 110-psig pressure is used for conservatism. An accidental drop of the package may result in localized crushing of the honeycomb that lines the con-tainment vessel. If that occurs, the 150 psi crush strength of the honeycomb will be added to the 110-psig inter-nal gas pressure. The maximum stress in the containment vessel shellis 25% of the minimum material tensile strength. This is the value specified in the ASM E Bollerand Pressure VesselCode, I Appendix P p. 365. The maximum stress in the bolts used to secure the cover to the containment vessel is 60% of the minimum tensile strength. The Sturtevant forque Alanual,2 p. 41, recommends a fastener tension between 60 and 70% of the minimum tensile streogth. 7

2.2 Weights and Center of Gravity Weights, in pounds, of the component parts of the model UC-609 package are: Storage vessel plus vessel carrier 120 maximum Celotex 110 Containment vessel 170 Drum 100 Total 500 maximum The center of gravity of the package, assuming that the storage vessel is located centrally on the vessel carrier, is on the centerline of the drum and within 2 in. of the center of the long axis of the drum. 2.3 Mechanical Properties of Materials The ASME Boiler and Pressure Vessel Code. Table UHA-23, pp.182-183, specifies that the minimum yidd strength of type-316 stainless steel is 30,000 psi, the minimum ultimate tensile strength is 70,000 psi, and the maximum design stress at temperatures between 93 and 149'C (200 and 300*F) is 14,600 psi. The crush strength of the aluminum honeycomb is 150 psi. 3 The specified minimum tensile strength for the cover retaining bolts is 170,000 psi. 2.4 General Standards for All Packages 2.4.1 Chenilcal and Galvanic Reactions There is no reaction between the packaging and contents, flowever, some tritium can permeate through the wall of the containment vessel (see Ch. 4.0, Containment). Also there will be no significant reaction be-tween any of the parts of the packaging. The following materials are used in the package construction: e Aluminum o Carbon steel e Celotex e Cerabianket e Copper o Epoxy paint e Nylon e Polyurethane rubber e Silicone rubber e Stainlese steel e Tellon a Viton rubber e Wood 2.4.2 Positive Closure The closure system has two distinct levels, neither of which can be inadvertently opened. The drum cover is fastened to the drum with eight brackets, each held in place by one bolt.Two of these bolts are secured with tamper seals. The containment vessel cover is secured with eight bolts that may be secured with tamper seals if required for in plant control. The two valves on the cover and the caps on their fittings also have provisions for tamper seats. 2.4.3 Lifting Devkes Not applicabic. There are no lifting devices on the drum. 2.4.4 Tie-Down Devices Not applicable. There are no tie-down devices on the drum. 8

Ir 2.5 Standards for Type-B and Large-Quantity Packaging 2.5.1 Load Resistance A drum identical to the one used on this package is used on the JP 157S shipping package. 4For qualifica-tion of that package, bags oflead shot totaling 2400 lb were stacked uniformly inside an empty drum along one side. Afler the lid was installed, the drum was carefully laid on its side and brought to rest with only the rim at each extreme end in contact with supporting timbers. No deformation or damage resulted. That 2400-lb test was only 100 lb less than would be required for the model UC-609 package [5 X the weight of UC-609 (500 lb) = 2500 lb). In actual use the drum is stiffened considerably by being filled with Celo*cx and could certainly support an additional 100 lb without damage. 2.5.2 External Pressure External pressure will affect only the stainless steel containment vessel, because it is the only scaled volume in the package. The weakest part of that vessel from an external pressure is the cylindrical shell be-tween the two end heads. The method for calculating the maximum allowable working pressure is outlined in the ASME Bot /cr and Pressure Vessel Code, paragraph UG 28, p.15: D = outside diam of cylindrical shell = 18.0in., o t = thickness of cylindrical shell = 0.125 in., L = design length of cylindrical section = distance between head bend lines + 1/3 of the depth of each head = 35 + 2[l/3(4.5)] = 38. To be conservative, use L = 40. To find Factor B for temperatures up to 204'C (400'F), use values for L/D and D /t in Fig. UllA 28.2 o o of the Pressure Vessel Code, p. 303. ( 4j - 2.22, " 0. 5" After finding that Factor B = 4500, calculate the maximum allowable external pressure (Pa) up to 204'C: = 31.25 psi. Pa = D /t " 144 2.6 Normal Conditions of Transport 2.6.1 liest 2.6.1.1 Summary of Pressures and Temperatures. The maximum temperature of the containment vessel during normal transport is 76'C (see Sec. 3.4.2). The maximum pressure in the containment vessel during normal transport is 103 psig (see Sec. 3.4.4). 2.6.1.2 Differential Thermal Expansion. liypothetical accident tests did not cause any damage at-tributable to differential thermal expansion (see Sec. 2.7.3.2). Conditions of normal transport are much less severe. Thus, no problems will be encountered during normal transport or actual transport conditions. 2.6.I.3 Stress Calculations. Calculatiens of the stresses and maximum working pressure of the cylin-drical body and the formed heads of the containment vessel were made using methods specified in the ASME Boiler and Pressure Vessel Code. For conservatism we used an internal pressure of 110 psig rather than the ac-tual pressure of 103 psig. 9

2.6.l.3.1 Cynedrieel Section. (Ref.1, paragraph UG4, p.14) P=R+ .6t where P = pressure = 110 psig. E = Joint efficiency (Ref.1, Table UW 12, p.14, butt joint fully radiographed) = 100%, ~ S = stress,. t = shell thickness = 0.125 in., R = inside radius = 8.875 in. Solving for stress, S=P + 0.6t),110 [8.875 + 0.6 @.12E = 7876 psi. Et 1.0 (0.125) 2.6.l.3.2 Fernwd Empseldal Heads. (R*f 1. paragraph UA4, pp. 226 228) F"KDo - 2t - 0.I) where D. = outside diameter =.18.0 in., t = shell thickness '= 0.125 in., S =. stress, K = ellipsoidal head factor for head with (D/2h = 2)(Ref.1, Table UA 4.1, p. 228), K = 1.0, - 5 P = pressure = 110 psig. Solving for stress, 10 [I (18.0) - 2 (0.125 0 - 0.1)] ~ ~ = 7821 pd. S= = 2t 2 (0.125) 1.6.1.J.J Cowr Belts. The cover to. vessel joint is assumed to be rigid. That is, we assume little or no spring effect from the copper gasket. This is a reasonable assumption, since the gasket is very thin and is plastically yielded when the joint is tightened. Therefore, any clastic recovery of the gasket will be very small relative to the bolts. With a properly tightened rigid joint, internal pressure effects on the bolts can be eliminated and the stresses on the bolts limited to the amount caused by initial tightening. 2 To achieve this condition, the total tension in the eight bolts must be greater than the total pressure force on the cover. The force (F) on the cover due to internal pressure is calculated as follows: 10 1

F = f (D ),, 2 where D = diam at gasket seal = 10.5 in., P = internal pressure = 110 psig. F = { (10,5)2 (110) = 9524 lb. The initial tension (L) in the bolts from torquing can be calculated as follows: T L = g,z9) (Ref. 5, p. 34), where D = bolt diam =.0.375 in., T = torque = 45(12) in.-lb 00 m per Mt. L=0. 75) = The total force on the cover from the eight bolts is $7,600 lb, which is much greater than the pressure force of 9524 lb. The stress (S) on the bolts from initial tightening is: S=k, where - L = initial tension = 7200 lb, A = tensile stress area at root of thread (Ref. 5) = 0.0878 in. 2 = 82,000 psi, S=0 8 2.6.1.M Flanges. A finite element analysis of the flange assembly was made. 6At an internal pressure of 110 psig, the maxim;m stress was 13,000 psi. To verify the adequacy of the flange design, one of the prototype containers was hydraulically pressurized to failure with the following result: e At 425 pais the primary (copper gasket) seal began to leak. The secondary (0-ring) seal held. e At 650 psia the flange had deformed to the point that the O ring blew out, releasing the pressure. None of the bolts failed. Although all were slightly bent from the deformation of the flanges, they were easily unscrewed and removed. 2.6.l.4 Cx-M : with Allowable Stresses. The most highly stressed area in the 316 stainless steel con-tainment vessel is the flanges. The 13,000-psi stress calculated for that area is approximately 90% of the max-imum allowable stress of 14,600 psi per the ASME Pressure Vessel Code (see Sec. 2.6.1.3). The maximum bolt stress was calculated at 82,000 psi. The Sturtevant Toryue Manual (p. 41) recom-mands a maximum stress of 60% of the tensile strength, or 0.60 x 170,000 = 102,000 psi.The 82,000 psist6ess is approximately 80% of that value. .2.6.2 Cold The effectiveness of the packaging material is not significantly impaired by a temperature of-40'C. The tensile strength and ductility of the materials do not change significantly at -40'C. In fact, the tensile strength of the type 316 stainless steel used for the containment vessel increases without a loss in ductility, 11 f

2.6.3 Pressure Reduction of the external pressure to 7.4 psia (0.5 atm) would give a maximum differential pressure across the containment vessel wall of i10.0 + 7.4 = 117.4 psig. Each vessel is tested at 200 psig and therefore would not be damaged at a pressure of 118 psig. 2.6.4 Vibration A vibration test on one prototype package simulated transportation by common carrier as secured cargo. 7The package was vibrated in the upright position in a sweep from 5 to 200 to 5 liz,12 min up and 12 min down, for a total of 84 min. The acceleration level was 1.5 g. The tightness of all fastenings was checked before and after the test. No changes were found. The primary seal was tested before and after the test at 120 psig. No leakage was found on a mass spectrometer with a sen-3 sitivity in the 10-'atm-cm /s/div range. 2.6.5 Water Spray The closed steel drum with the vent holes scaled by plastic plugs is impervious to water spray and is not significantly affected. 2.6.6 Free Drop The requirements of the free-drop condition for normal transport are less severe than those for the free-drop condition of the hypothetical accident to which the prototype shipping package was actually subjected. In fact, one package was dropped twice from 30 ft with no resulting damage to the containment vessel. The results of these impact tests provide the basis for the conclusion that the package complies with the free-drop requirements for normal transport. 2.6.7 Corner Drop Since this package is constructed primarily of metal, not wood or fiberboard, and because it weighs more than 110 lb, this test is not applicable. 2.6.8 Penetration The required penetration test was performed on the JP 157S package, which uses the same drum and Celotex insulation as is used for the model UC-609 shipping psckage (Ref. 4, pp.18). In those tests, max-imum deflection to the drum surface was less than 1/4 in, with no damage to the Celotex insulation. 2.6.9 Compression A drum identical to the one used on this package is used on the JP 157S shipping package (Ref.4, pp. I-3). To qualify that package, an empty drum was loaded to 2400 lb, and no visible damage or deformation oc-curred. That 2400-lb test was only 100 lb less than would be required for the model UC-609 package [5 X the weight of UC-609 (500 lb) = 2500 lb). In actual use the drum is completely filled with Celotex and could cer-tainly support 100 lb more than an empty drum without damage. 2.7 Hypthetical Accident Conditions Records of tests made to verify adequacy of the design when subjected to the hypthetical accident condi-tions are contained in Engineering Note END 78-004 (UC-609 test records). 2.7.1 Free Drop In 'he process of developir g a satisfactory method of securing the drum cover, a total of seven 30-ft free drops were made on the two prototype containment vessels. The impact surface was a 1 in.-thick steel plate resting on an asphalt roadway for the first three drops and a 6-in. thick steel plate resting on concrete for the last four. Five drops impacted the package on the edge of the drum cover with the center of gravity directly above the impact point (see Fig. 7). One drop impacted on the long axis of the drum. In all but one instance, the drum and any damaged Celotex were replaced before making another drop. In the one exception, one package was dropped on the cover and then on the side of the drum with no repair or replacement between drops. 12

R 7 e l 1 4 i 'i i .l i i l l i Fig. 7. Orientati<m of package on free drop. A 100-lb weight (a steel bar 5 in, diam X 18 in long) was used to simulate the heaviest storage vessel j i allowed for the package. On three drops this 100-lb weight was loose within the containment vessel cavity. On the other drops the weight was securely attached to the vessel carrier. The last drop was onto the edge of the drum cover with the final drum closure system in use. On this last i drop the corner was crushed about 3 in., but no opening occurred and no significant loss ofinsulating capacity resulted (see Figs. 8-12). None of the drops resulted in damage to the containment vessels that impaired leak tightness. The j greatest effect on the containment vessel was caused by the horizontal drop impacting on the long axis of the drum. This Dattened the containment vessel to a maximum depth of I in. along one side. There was no !oss of insulation thickness. The copper gasket-to-flange sral was tested before and after each drop with the container pressurized to l l 120 psia with helium. No leakage was detectable on a mass spectrometer with a sensitivity in the 10-9 atm-i cm /s/div range. All drops were made with the container at approximately 20 psia. 3 l l l 13 I

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i 2.7.2 l' uncture The package used for the final drop test was dropped 40 in. onto a 6-in.-diam steel post 10 in. high. The side of the dr m was indented no more than 1 in. (see Figs.15 and 16). l 2.7.3 Thermal 2.7.3.1 Summary of l'ressures and Temperatures. Assumed maximum ambient temperature before fire 38 C Maximum containment vessel temperature 141 C (See Sec. 3.5.3.1.1) Maximum storage vessel temperature 170'C (See Sec. 3.5.3.1.2) Maximum containment vessel pressure 125 psig (See Sec. 3.5.4.) 2.7.3.2 I)ifferential Thermal Expansion. The furnace test (see Sec. 3.5.1) did not cause any damage that could be attributed to differential thermal expansion. There is no rigid structural coupling of mate. rials having dissimilar expansion rates or important temperature gradients. The clearances, the temperature differentials involved and the thermal expansion coefficient of the materials will minimize the effects of thermal expansion. 2.7.3.3 Stress Calculations. The effective internal pressure of the containment vessel may be temporarily increased to 260 psig as a result of a free drop. This would happen only if the honeycomb lining were crushed. At the location where crushing occurs. the 150-psi crush strength would be added to the 110-psig normal con-ditions pressure. Subjecting the package to the fire enivornment would increase the containment vessel tem-perature to 141*C and thereby increase the internal pressure to 125 psig (see Sec. 3.5.4). The greatest stress on the containment vessel occurs on the flanges (see Sec. 2.6.1.3.4). At 260 psig the calculated maximum stress is 30,600 psi. 6 k

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'.t { : ] e 'Q^ ' ~ www m-l4l t .[ } e l': L', ~, f[?J j & f' S % g- [h,s -) w E l5 k j ~ .{ ' Y?k l f [Ik g-yf!fll9fls pl - ('. '; k l^ ; i % 7l,.r # , - p p? ;li - -i 1 U.As ~i Q+ ,W _7 ( J y,. (Y. h :. e. g 7. ( l ig. 16. Impact point for penetration test. l The force on the coser, calculated as in Sec. 2.6.1.3.3, at 260 psig is 22,513 lb. The total initial bolt tension l of 57,600 lb (see Sec. 2.6.1.3.3) is much greater than the 22.513-lb force on the head. Therefore. increasing the containment sessel pressure to 260 psi will not increase the bolt stress. 2.7.3.4 Comparis<m with Allowable Stresses. The calculated maximum stress of 30.600 psi on the con-tainment sessel flanges is slightly greater than the specified minimum yield of 30.000 psi that is listed in the Pressure l'enel Code (Table Ull A-23, p.182). A more meaningful number is that the 260-psig pressure is 619 of the 425-psia pressure that was required to cause the primary seal to leak (see Sec. 2.6.l.3.4). 2.7.4 Water immersion Not applicable. There is no fissionable material in this package. 2.7.5 Summary of Damage A complete package was dropped on a flat surface and on a piston. Then it was heated in a furnacein the manner prescribed in Appendis B of 10 CFR 71. The appearance of the package after the drops is shown in Figs. 8-11. The package was not significantly damaged from these tests. The Celotex insulation was in good ~ condition after the furnace test, as shown in Fig.13. The temperatcre rise in the test was low enough that the tritium permeation and leakage are less than the 10-Ci release lin it (see Sec. 4.3L 28 Special Form Not applicable. No special form is claimed. 19

2.9 Fuel Rods Not applicable. There are no fuel rods in the shipment. 3.0 THERMAL EVALUATION 3.1 Discussion - The significant thermal design feature of the UC-609 package is the Celotex insulated shipping drum. A minimum of 2.88 in. of Celotex insulation completely surrounds the containment vessel (primary containment boundary). This thickness of Celotex adequately protects the package contents during both normal transport and hypothetical accident conditions. Similar packaging, the JP157S,4has been used for numerous shipments over a period of several years without adverse effects due to heat. The maximum decay heat load is 48 W. The minimum heat load is zero. Significant results of the thermal analysis follow in Secs. 3.1.1 and 3.1.2. 3.1.1 Normal Transport Conditions Ambient air temperature 54.4*C Maximum containment vessel temperature 76.0*C Maximum storage vessel temperature 106.0*C' Containment vessel pressure 103 psig 3.1.2 Hypothetical Accident Conditions Assumed maximum ambient temperature before accident 38'C Measured containment vessel temperature rise during furnace test 79'C Measured temperature difference between ambient air and containment vessel 24'C Measured temperature difference between containment vessel and storage vessel 29'C Calculated containment vessel temperature after hypothetical fire 141*C Calculated storage vessel temperature after hypothetical fire 170*C* Containment vessel pressure 125 psig

• The analysis of the UC-609 package is based on the hypothetical escape of tritium from the storage vessel into the containment vessel. If that occurred. the temperature of the two venels would be essentially the same. The temperatures noted are for the case in which all tritium remains within the storage vessel and are included as information only.

20

3.2 Summary of Thermal Properties of Materials The thermal properties of Celotex and stainless steel are summarized in Table 1. Table 1. Summary of thermal properties of materials. 2 ' thermal conduetivity, cal /s-cm _.C Densi Specific heat Material g/cm cal /g 30"C 49.9'c 100*C 150* C I Celotex,9 0.25 0.3 1.78 x 10-4 1.89 x 10 2.03 x 10'4 1.59 x 10-4 l 8 4 \\ Stainless steel 8.0 0.12 0.04 at all temperatures l 10 used in the thermal calculations for heat transfer to or Heat transfer coefficients and emissivity values from the external surfaces are: Free convection, cal /s-cm2 *C Emissivity l l Top (end) surface 8.000 x 10-5 0.8 Cylindrical surface 7.000 x 10-5 0.8 l l 3.3 Technical Specification of Components Celotex is fiberboard made from sugar cane fibers bonded with organic glue per MIL-F-26862. It is stable to 120*C. 3 Cerablanket is a loosely spun alumina-silica refractory material 1/2 in. thick with a density of 4 lb/ft. It is stable to 1260*C. 3.4 Thermal Evaluation for Normal Conditions of Transport 3.4.1 Thermal Model 3.4.1.1 Analytical Model 33. In making the thermal analysis of the UC-609 package, we assumed that the container was resting on an insulated surface in a vertical position. in this position the solar input on the horizontal top surface depends only on the relative angle between the sun rays and vertical.12 This angle varies during the day, but the solar input never goes to zero during the daylight hours. The solar input on the vertical sides depends additionally on the orientation of the surface with respect to the east-west plane. For a specific vertical surface element this angle varies during the day, and the solar input can actually be zero dur-ing daylight. The azimuth angle of the sun, which varies with the time of day, location on the earth, time of the year, and solar declination, also affects the solar flux.13 We obtained appropriate relationships between the ~ various angles and the time of day for a position at 30' north latitude from May to August. We combined these with the vertical cylinder geometry and wrote a small computer code 13to evaluate the solar flux incident on the exterior surfaces. At sea level. at the location specified above, the normal solar flux at noon on a clear day (attenuated by the atmosphere) is approximately 356 BTU /h/ft,12 We obtained calculations for a 2 specified zone structure of the sides and top from sunrise to sunset. We then used this information as the solar heat input for the thermal model of the structure. The daily total integrated solar flux on the package surface is shown in Fig.17. We assumed that the sky was clear during daylight and that a cloud cover existed at night. This assump-tion maximizes the radiation input during the day and minimizes the radiation loss at night. 21

'875 i i g i 4 33 m $2 .c 5 1 Sl I I I I I I I a 0 y 0 2 4 6 8 10 12 14 16 6 a.m. Noon 6 p.m. Time - h Summary of daily accumulated solar heat Top surface (end) 3.3 Mcal Cylindrical walls 1.6 Mcal Total 4.9 Mcal Hg.17. Daily solar heat accumulation for entire package. The air temperature input to the model varied sinusoidally between a maximum of 54.4*C (130*F) and a minimum of 26.7'C (80"F) over repeating 24-h cycles. The maximum temperature occurred 3 h after solar noon. To properly input the solar radiation flux, we used a three-dimensional thermal model from the outer sur-face through the Celotex insulation. We used a two-dimensional thermal model to simulate the inner portion (containment vessel to storage vessel) of the package. Using a two-dimensional model inside the Celotex causes the radial gradients at the inner surface of the Celotex to smooth out to an average uniform tem-perature in the stainless steel wall of the containment vessel. This is reasonable, especially when the aluminum honeycomb that backs up the stainless is considered. The integrated thermal model is shown in Fig.18. We used a free convection coefficient and a radiation coefficient (see Sec. 3.2) to connect the exposed outer surface of the thermal model to the cycling boundary. (Note: The surface emissivity value used represents that of new, oxide-free, light-color paint.) There are two major areas of thermal resistance between the outer surface of the package and the internal storage vessel. The dominating thermal resistance is in the Celotex insulation material between the outer steel drum and the containment vessel. In this closed-end cylindrical part, the thermal resistance between the outer surface and the containment vessel depends almost completely on the thermal conductivity coefficient of the Celotex. The thermal resistance of the thin outer metal wall (steel drum) is negligible compared to the thick Celotex and was not used in the thermal model. We made the Celotex thickness in the thermal model equal to the space between the outer drum and the containment vessel.This compcasates for any air-gap resistances at the interfaces. The other area of major thermal resistance is between the containment vessel and the storage vessel. The heat path between these two vessels is such a complicated network of conduction, convection, and radiation that the thermal coefficients for the path cannot be reliably calculated. However, using temperature data from an experiment with constant boundary conditions and selected internal-heat-generation rates (see Sec. 3.4.1.2), we determined an equivalent convection coefficient. We used this value to calculate the storage vessel temperature for the condition in which the tritium remains within that vessel. We used the TRUMP I4 computer program for the thermal calculations. This Lawrence Livermore Laboratory (LLL)-developed code has been thoroughly checked out and has been used for a number of years at LLL and at other agencies throughout the U.S. and abroad. Figures 19-21 show the results of the computer calculations. 22

/// // Containment vessel -0.125 in. i (stainless steel) 12.0 in. Storage vessel \\\\ \\\\\\\\\\\\\\h /d Aga 0.125 in. centerIme -4.0 in.- Length /2 = 25 in. Fig.18. Thermal model for UC-609 package. 110 i i i i 110 / g (heat era o 90 in storage vmsel) 48W--- 80 80 o o o l e g 70 j 70 3 Containment vessel E e E 60 E* 60 5 ~ Ambient air - F Containment vessel F 50 (heat generation in 50 storage or 40 containment vessel) 30 40 l i'I I I 'I 20 i 30 6 a.m. Noon 6 p.m. Midnight 6 a.m. 0 10 20 30 40 50 Time Internal heat generation - W Fig.19. Daily temperature response of LJ-609 package contain-lag 48.W heat load after exposure to desert environment for three Fig. 20. Vessel temperatures after UC-609 package has been ex-1 consecutive days. posed to desert environment for three consecutive days. 23 i

80 i i g Experiment -- - - Calculated 70 ........ Extended data f AT = 29*C 60 between vessels o Storage vessel o i 2 B so e / a 5 / F' Y / .6 / 40 / / AT = 24 C / ambient air Containment vessel to vessel 30 / ,/ / l I l l 20 O 10 20 30 40 50 Internal heat load - Watts Fig. 21. Model (JC-609 steady-state temperatures with constant 21*C boundary condition. ~ Figure 19 is the daily temperature fluctuation for both the containment and storage vessels with a 48-W heat load. The temperature cycles shown are calculated after three consecutive days in the sun and will repeat daily as long as the boundary conditions remain the same. The storage vessel curve is only for the case in which the tritium remains within that vessel and is included as information only. Figure 20 shows the maximum daily temperatures for both vessels for internal heat loads from 0 to 50 W. As in Fig.19, the maximum temperatures are achieved only after three consecutive days in the sun. 24

3A.I.2 Test Model. We tested a prototype package identical to that described in Sec.1.2.1 to determine the temperature distribution through the package at steady-state conditions under several internal heat loads with constant boundary conditions. The test was run as follows. We attached a storage vessel containing a resistance wire to the vessel carrier. We installed the storage vessel in the containment vessel, which was in turn put in a Celotex-insulated drum. The volume inside the containment vessel was then filled with helium to 15 psia. We put the assembled package in a temperature-controlled room and applied electrical energy to the resistance wire. Thermocouples recorded the tem-peratures at numerous points throughout the package. Figure 21 compares the results of the test with com- . puter calculations. The good agreement between the test data and the calculations shows that the thermal model is good and that the values used for conductivity through the Celotex and for convection between the two vessels are accurate. 3A.2 Maximum Temperatures Figure 19 shows that the maximum temperatures for normal transport condition are 76.0'C for the con-tainment vessel with a 48-W heat load and 106*C for the storage vessel with the same heat load in the storage vessel. 3A.3 Minimum Temperatures The UC-609 package contains no materials harmfully affecteo by a temperature of-40'C. 3AA Maximum laternal Pressure Maximum initial gas contents of storage vessel 30 moles

• Measured volume of containment vessel 154 litres Maximum initial pressure in containment vessel I atm at O'C Maximum temperature of containment vessel 76'C (349K)

Calculated volume of 120-lb aluminum (storage vessel + vessel carrier) 20.0 litres if all the material in the storage vessel leaks into the containment vessel, the maximum pressure is calculated as follows: pfinal, pinitial, Number of moles X volume of 1 mole at standard temperature and pressure Volume of container - volume of contents ,3 , 31.4 moles X 22.4 litres / mole 154 litres - 20 litres =.6.25 atm at 0*C (273K). 3 P at 76*C = 6.25 X = 8 atm 1r 118 psia = 103 psig. 3A.5 Maximum Thermal Stress The temperature differentials throughout the package are relatively small and will cause no significant thermal stresses. There is no rigid constraint among the steel, aluminum, and other packaging elements. 'Some of the tritium will decay into helium-3 within one year, thereby increasir.g the original 30 moles of material to 31.4 moles. 25

= _ _. 3.4.6 Evaluation of Package Performance The package will not be affected by full sunlight and a temperature of 54*C, because the maximum tem-perature of the containment vessel will not exceed 76*C. It is well under the 120*C temperature that affects the Celotex and well within the temperature capabilities of the other package components. The minimum tem-perature of-40'C will produce no detrimental effects on the package. The containment materials are of the type that increase in strength and retain ductility at low temperature. An internal pressure of 103 psig or an external pressure of 25 psig will not damage the containment vessel (see Secs. 2.5.2 and 2.6.1.4). Vibration and water spray will not affect the package (see Secs 2.6.4 and 2.6.5). Free drops and penetration will have no significant effect on the package (see Secs. 2.6.7 and 2.6.8). The compression test will produce no damage to the package (see Sec. 2.6.9). 3.5 Hypothetical Thermal Accident Evaluation 3.5.1 Thermal Model 3.5.1.1 Analytical Model. The maximum temperatures achieved during the fire are based entirely on ex-perimental results. 3.5.1.2 Test Model. The model used for both the drop and thermal tests was identical to the packaging described in Sec.1.2.1. A complete package was dropped on a fiat unyielding surface and on a piston, then heated in a heat-treating furnace in the manner prescribed in Appendix B of 10 CFR 71. The furnace was heated to 1475'F (802*C). The package was inserted for 30 min, then removed and allowed to cool (Fig. 22). The maximum temperatures that various points inside and outside the containment vessel reached were determined by the conditions of Tempilabels (manufactured by Tempil Corp. of New York, NY). The Tem-pilabels have indicator spots that permanently change color at specific temperatures. The color change occurs within 1% of the indicated temperature. Figure 23 shows Tempilabel installation inside containment vessel. The package tested contained no radioactive materials. The containment vessel was pressurized to ap-proximately 20 psia during both the drops and fire tests. A separate test was performed to determine the effectiveness of the flange-to-copper-gasket seal when subjected to both pressure and temperatures. The cover and top end of one of the prototype containment vessels were heated to 121*C and pressurized internally with helium to 150 psig.The maximum leakage across atm-cm /s. The leak rate increased slowly with temperature and decreased to below 3 the seal was 3.0 X 10-9 3 atm-cm /s/div) as the package cooled. the sensitivity of the mass spectrometer (5 X 10-Il 3.5.2 Package Conditions and Environment The condition of the package during disassembly after the drops and fire tests is shown in Figs.24-27. The 100-lb weight, which simulated the storage vessel, crushed the end piece of honeycomb slightly, dented the aluminum tube, and deformed the vessel carrier (see Figs. 25 and 26). The containment vessel shell was un-damaged by any of the six drops. Before and after each drop the containment vessel was pressurized to 120 psia and the metal.to-metal seal leak-tested with a mass spectrometer leak detector. No leakage was observed 3 on a leak detector with sensitivity in the 10 -9atm-cm /s/div range. The drop test did not significantly damage the Celotex and therefore was not detrimental to the container during the furnace test. Note in Figs. 24 and 27 the good (uncharred) Celotex adjacent to the containment vessel. 3.5.3 Package Temperature Calculations Based on Tempilabel data, the maximum temperature reached c / the UC-609 containment vessel in the furnue test was as follows, with no decay heat load: Outer wall of vessel (5 places): greater than 90*C, less than 104*C; Aluminum tube lining vessel (2 places): greater than 71'C, less than 77 C; Mock storage vessel (I place): less than 66'C. Note: The Tempilabel sensors change color at specific temperatures. The " greater than" temperatures are the highest value that changed color, and the "less than" temperatures are the next higher sensor that did not change. 26

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,. - =. 2 L&, ~- i [ f ' 3 C . L 'i, > :+ .i b ?QGw1' s " < k -' yf j = p ar;: ~ ~,[:1 ) .c. Y 5,/~ ~ s ,ang e p ->_ W E*W ~ - ~ w ~ i l [ J ) s ~ y is.. u; .gn ww & u-w Fig. 27. Insulation cond. tion after drops and fire tests. The maximum temperature of the containment vessel and the storage vessel with the 48-W decay heat load can be calculated as follows: 3.5.3.1 Containment Vessel (lleat load in either storage vessel or containment vessel). The maximum temperature of the containment vessel is a sum of the following: Assumed maximum ambient temperature before fire 38 C Nicasured containment vessel temperature rise during fire (104 C - 25 C) 79 C N1easured temperature difference between ambient air and containment vessel (see 1 ig. 20 at 4S W) _ 24 C N1aximum temperature of containment vessel 141 C 3.5.3.2 Storage Vessel (licat load in storage vessel). The maximum temperature of the storage vessel with the heat load in that sesselis the sum of the maximum temperature of the containment vessel, determined j above, plus the measured temperature difference between the containment and storage vessels. Ntaximum containment vessel temperature 141 C Temperature difference between containment vessel and storage sessel (Fig. 20 at 48 W)

2) C N1aximum temperature of storage sessel 170 C 3.5.4 Niaximum Internal l'ressure From Sec. 3.4.4. the maximum pressure within the containment sessel with 30 moles of gas at 0 C is 6.25 atm.

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P at 141 C (415K) = P at 0 C (273K) X = 6.25 atm X = 9.50 atm = 140 psia = 125 psig The containment vessels will be proof tested at 200 psig. Therefore,125 psig can easily be tolerated. 3.5.5 Maximum Thermal Stress The temperature differential throughout the package is relatively small and will cause no significant ther-mal stress. There is no rigid constraint between the stainless steel vessel and the aluminum honeycomb that lines it. a 3.5.6 Evaluation of Package Performance The package evaluation indicates that it will withstand the accident conditions described in Appendix B of 10 CFR 71. The package was not significantly damaged during the free drop and puncture tests. The water immersion test was not done because there is no fissile material in the package. The greatest thermal effect is in the area of the seal made on the copper gasket. Because of the different thermal expansions of the copper, the stainless steel flanges, and the alloy steel bolts, there is a slight lessening 4 3 of the sealing force on the gasket at 141'C. The result is a small amount of leakage (3 X 10 atm-cm /s), which stops when the container cools. This leakage rate is acceptable, especially when the secondary 0-ring seal is considered (see Sec. 4.3.2). 4.0 CONTAINMENT 4.1 Containment Boundary The containment boundary for the UC-609 package is the containment vessel. 4.1.1 Containment Vessel The containment vessel is a cylinder 18 in. (45.7 cm) o.d. X 40 in. (101.6 cm) long made of 1/8-in. (0.317 cm) thick type-316 stainless steel. The vessel is made by welding formed semielliptical heads to each end of a rolled and welded cylinder. Access into the vessel is through a 10-in. (25.4 cm) i.d. flange that is welded into one head. A cover assembly containing a mating flange closes the opening. Alljoints require full penetration welds made by the tungsten insert gas process. 4.1.2 Containment Penetration The only penetration into the containment vesselis the valve gauge manifold that is welded into the cover assembly. 4.1.3 Seals and Welds The integrity of the containment vesselis checked by a proof test at 200 psig and a leak test at 150 psig im-mediately after manufacture and every two years thereafter. The integrity of the cover-to-vessel seal and the fill-valve closure seal will be checked before each shipment at 1.5 times the maximum pressure that would result if the contents of the storage vessel leaked into the containment vessel. Leakage greater than 1 X 10-8 3 atm-cm /s will not be accepted. 4.1.4 Closure The seal between the containment vessel and its cover is made by forcing knife edges on the mating flanges into the opposite sides of a copper gasket. Eight 3/8-in.-diam alloy steel bolts, torqued to 45 ft-lb, maintain the seal during both normal and accident conditions of transport. 4.2 Requirements for Normal Conditions of Transport Only superficial mechanical damage was sustained on similar packages when subjected to tests simulating normal conditions of transport (see Secs. 2.6.1 - 2.6.9 and 3.4). 31 )

4.2.1 Release of Radioactive Material Gaseous tritium permeates the material of construction at rates dependent upon pressure, temperature, concentration, and other factors. Therefore, the requirement in 10 CFR 71.35 (a) (i) that there be no release from the containment vessel during normal conditions of transport is considered to be satisfied by compliance with International Atomic Energy Agency (IAEA) regulations, paragraph 230 (a).This regulation restricts the loss of contents to no more than Factor A X 10-6/h.15 Factor A for tritium equals 1000 Ci(Ref.15, Table 2 2 Vill), and the permissible release is I 3 = 1.08 X 10-7 cm /s 3 (1000 X 10-6 Ci/h) X X 57 4.2.1.1 Permention through Stainless Steel. Steady-state permeation through the containment vessel wall is assumed to have been reached when = 0.45 (Ref.16), where t = time in s, L = thickness of diffusion barrier = 0.317 cm (0.125 in.), D = diffusion ratein cm /s = 4.7 X 10-3e -(12900/RT)(gg[,17), 2 R = 1.987 cal / mole K, T = temperature = 349K (76*C) (see Sec. 3.1.1). The above relationship shows that the time to reach steady state is 10 days. Since the time for normal 4 transport is considered to last not more than 30 days, the nonsteady-state situation applies. The flowrate through the container wall for very short times can be calculated using the following equation: In F = In 2C (Ref.16), i where C = surfaceconcentration = CWatm-cm /cm 3 (Ref.17), 3 i C = 1.28 e -(1400/RT) atm-cm /atm /2-cm 3 1 P = internal pressure = 8.0 atm,118.0 psia (see Sec. 3.4.4), T = 349K (see Sec. 3.1.1), D = diffusion ratein cm /s = 4.7 X 10-3 -(12900/RT) 2 e R = 1.987 cal / mole K, L = thickness = 0.317 cm, 3 2 F = flowrate,atm-cm of tritium (T )/s/cm. 2 Using a containment vessel area of 1.8 X 10 cm (a right circular cylinder 18 in. diam X 40in. Iong), the 4 2 atm-cm Tys, which is far below the allowable 1.08 3 flow through the vessel wall at 30 days is less than 10-100 Tys. Therefore, there is no problem with permeation through the containment vessel walls X 10 -7 atm-cm 3 during normal transport. 4.2.1.3 Permention through Copper Gasket. Because permeation of tritium through copper is less than through stainless steel, and the area for permeation through copper is so much smaller, the diffusion through the gasket is too small to have an effect. 4.2.1.3 Total Release for Normal Transport. The total release during tre.nsport is the sum of permeation through the stainless steel and the copper gasketylus any leakage. 3 Permeation through stainless steel < 1 X 10 -1 an-cm Tgs 3 Permeation through copper gasket << 1 X 10-100atm-cm Tgs 3 Leakne past gasket (see Sec. 7.1) < 1 X 10 -8atm-cm Tgs 3 Leakage from total vessel (see Sec. 8.1.3) < 1 x 10-8atm-cm Tgs 32

3 The total release from all the above is less than 2 X 10-8 atm-cm Tys,which is less than the allowable 1.08x 10-7atm-cm 3Tys; therefore, the normal transport mode is acceptable. 4.2.2 Pressurization of Containment Vessel Although tritium decay produces two volumes of helium for each volume of tritium lost, the increase in pressure is negligible because of the short duration. of a shipment (30 days or less). The gases within the containment vessel cannot ignite or explode because no oxygen is present. The con-tainer volume is pumped out and backfilled with helium before each shipment. D 4.23 Coolant Contamination There is no coolant in the UC-609 package. ~ 4.2.4 Coolant Loss Not applicable. 4.3 Containment Requirements for the Hypothetical Accident Conditions The performance of the package during the hypothetical accident tests is given in Secs. 2.7.1 - 2.7.5. The results indicate that the package can withstand the mechanical abuse and fire that these tests comprise. 43.1 Fission Gas Products Not applicable. There are no fission gas products in this package. 43.2 Release of Contents For purpose of analysis the accident conditions 141*C and 9.10 atm (see Secs. 3.53.1 and 3.5.4) are con-sidered to exist for 12 h. (This is conservative because the regulations permit artificial cooling of the package after 3 h.) During and as a result of the hypothetical accident conditions, the regulations [10 CFR 71.36 (a)(2), ii) specify a maximum release of 10 Ci for Group IV radionuclides. No leak rates are specified for tritium in Group Vil; however, tritium is also a Group IV material, so the Group IV leak rate is used.) The release rate 3 required to lose 10 Ciin 12 h is 9 X 10 -5atm-cm Tys. 43.2.1 Permention through Stainless Steel. The time required to reach steady-state permeation through the containment vessel wall at a temperature of 141*C was found to be approximately 700 days. Since the time of concern is much shorter, we must do a short-time calculation as in Sec. 4.2.1.1. The flowrate then becomes less than 1.8 X 10-96 3 atm-cm Tys after 12 h at 141*C. 43.2.2 Permeation through Copper Gasket. The permeation through the copper gasket is less than through the steel, so it is negligible in this case. 43.23 Total Release for Accident Conditions. For the accident condition, total release is the sum of all permeation and leaks. Permeation through stainless steel < 1 X 10 -95atm-cm Tgs 3 3 Permeation through copper gasket << 1 X 10-95atm-cm Tys 3 Leakage past gasket (see Sec. 7.1) < 1 X 10 -8atm-cm Tys 3 ~ Leakage total vessel (see Sec. 8.13) < 1 X 10 -8atm-cm Tys 3 The total release from all of the above is less than 2 X 10-8 atm-cm Tys, which is much less than the 9 3 Tys that is allawable. Therefore, the containment vessel meets the requirements for the X 10 -5 atm-cm assumed accident conditions. 5.0 SHIELDING EVALUATION It is unnecessary to evaluate shielding for this package, since the radioactive material (tritium)is a weak beta emitter and gives off no penetrating radiation, and the resultant bremsstrahlung radiation is insignificant. 33 i

5.1 Discussion and Results Not applicable. 5.2 Source Specification Not applicable. 5.3 Model Specification Not applicable. i 5.4 Shielding Evaluation Not applicable.

6.0 CRITICALITY EVALUATION

The radioactive material (tritium)in this package is not fissile. Therefore nuclear criticality safety is of no concern in the shipment of this package. 6.1 Discussion and Results Not appl able. 6.2 Package Fut! Loading Not applicable. 63 Model Specification l Not applicable. 6.4 Criticality Calculations and Experiments Not applicable. l 6.5 Critical Benchmark Experiments Not applicable. ( l t 34 f

7.0 OPERATING PROCEDURES 7.1 Procedure for Loading the Package The model UC-609 package is loaded per END 77-21. An empty containment vessel is visually inspected for damage with special attention to assure that e the internal cavity is clean and free of foreign material, e the O-ring and metal gasket sealing surfaces are clean and undamaged, e the valves and the gauge on the cover are in good condition. 4 3 A tritium-loaded storage vessel with a leak rate ofless than 1 X 10 atm-cm /s is mounted on the vessel carrier. That assembly is put into the containment vessel, and the cover is installed with a new copper gasket. The containment vessel is evacuated, then pressurized with helium through the fill valve to a minimum of 1 1/2 times the pressure that would occur if the storage vessel vented into the containment vessel. (The max-imum test pressure is 170 psia for a storage vessel containing 30 moles of gas.) A mass spectrometer leak detec-tor is connected to the open leak-test valve, and the leak rate across the copper gasket is measured. To be ac-ceptable, the leak rate must be less than I X 10 -8 3 atm-cm /s. Upon completion of the test, the pressure is ven-ted to atmospheric and both valves are closed and capped. The valve caps and cover bolts have provisions for lockwire. Tamper seals may be installed if required for in-plant control. The shipping drum is opened and inspected for significant defects or damage. The scaled containment vessel is then placed within the overpack, the insulation cover is installed, and the Cerablanket insulation is put in place. Finally the drum cover is installed. The cover is held on by eight special brackets, which are secured by eight bolts. Two of the cover retaining bolts are scaled with tamper seals. After attachment of the necessary labels, the sealed overpack is ready for shipment. 7.2 Procedure for Unloading the Package After monitoring the exterior of the package for radioactivity, the seals on the lid retaining bolts are broken and the lid and insulation cover are removed. A sample of the gas within the container is monitored by metering through the fill valve. When the gas is ascertained to be " clean," the bolts can be removed and the cover lifted. Removal of the storage vessel from the carrier completes the unloading procedure. 7.3 Preparation of an Empty Package for Transport No special procedures are required to prepare an empty model UC-609 package for transport. Any con-tainer that becomes radioactively contaminated will be removed from service. 8.0 ACCEPTANCE TESTS AND MAINTENANCE PROGRAM 8.1 Acceptance Tests 8.1.1 Visual Inspection Upon receipt, the containment vessel will be inspected for bulges, dents, mars, or other obvious defects. The shipping packaging will be inspected for obvious damage such as cracks or voids in the insulation or damage to the drum. The acceptance criteria for the various components and assemblies that make up the package are specified on the applicable fabrication drawings. Noncomplying parts are to be rejected for rework or replacement. 8.1.2 Structural and Pressure Tests Each containment vessel is to be proof tested at 200 psig with helium for a minimum of 4 h beforeits first use and every 2 years thereafter. Before each shipment, the container is proof tested at 1.5 times the maximum pressure possible during the shipment. 35

8.1.3 Leak Testing Each containment vessel will be leak tested with helium before its first usage at 150 psig. Maximum 3 leakage allowable is less than I X 10 -8atm-cm /s. Before each shipment, the primary seal will be leak tested at 1.5 times the maximum pressure that could 3 occur during the shipment. Maximum leakage allowable is less than I X 10 -8atm-cm /s. 8.1.4 Component Tests 8.1.4.1 Valves. The valves on the containment vessel cover will be checked for leakage during shipping preparations (see Secs. 7.1 and 8.1.3). To qualify the fill and leak-test valves for usage at temperature, three of each were pressurized to 105 psig 3 at 121*C. No leakage was detected on a mass spectrometer with a sensitivity of 1.9 x 10 -Il atm-cm /s/div. 8.1.4.2 Gaskets. The primary and secondary cover seals will be tested prior to each use by vacuum and pressure tests (see Secs. 7.1 and 8.1.3). To qualify the primary and secondary seals at temperature, the following test was run. The cover area of a prototype containment vessel was heeted to 121*C and then pressurized to 150 psig. A maximum leakage of atm-cm /s was observed across the primary seal. This leak stopped as the temperature decreased. 3 3.1 X 10-9 The secondary seal held the vacuum required for the use of a mass spectrometer. The above leakage can be tolerated (see Sec. 4.2.2). 8.1.4.3 Miscellaneous. The bourdon tube gauge that is part of the fill valve manifold will be leak tested before cach shipment in the same mar.ner as the valves and gaskets. The high-temperature test of the gaskets described in Sec. 8.1.4.2 included the valves and the gauge that are on the containment vessel cover. No leakage from either the gauge or the valves was found. 8.1.5 Test for Shielding Integrity Not applicable. 8.1.6 Thermal Acceptance Test The thickness and condition of the Celotex insulation will be checked as the packages are received. No further testing is necessary, based on results found during development of this packaging. 8 8.2 Maintenance Program 8.2.1 Structural and Pressure Tests The containment vessels are to be pressure tested prior to each shipment (see Sec. 8.1.3). The pressure is l measured on a lieise gauge, which is accurate to 1 psi. I 8.2.2 Leak Tests The containment vessel will be leak tested at the same time it is pressure tested prior to each shipment. The sensitivity of the tests is the sensitivity of a mass spectrometer leak detector, typically between 1 X 10 -10 and I X 10-9atm-cm /s. 3 8.2.3 Subsystems Maintenance ~ Not applicable. There are no subsystems requiring periodic maintenance. 8.2.4 Valves, Rupture Disks, and Gaskets on Containment Vessel The valves will be tested before each usage and replaced as necessary. A new copper gasket is to be used for each shipment. The O-ring will be inspected before each use and replaced as necessary. l 8.2.5 Shielding Not applicable. 8.2.6 Thermal f The insulation and drum are to be inspected for moisture, voids, or cracks prior to loading the contain-l ment vessel into the package. Damaged items will not be used for shipment. l l 36

8.2.7 Miscellaneous The containment vessel is to be retested at 200 psig every two years. 9.0 QUALITY ASSURANCE REQUIREMENTS 9.1 General Information The quality assurance functions for the UC-609 package are the inspection tests and certifications that are required during fabrication and over the entire life of the package (see Fig. 28). The most important criterion that th ; package must meet ifit is to operate safely and successfully is that the containment vessel be leaktight and structurally sound That criterion is met as follows: The drawings require that the manfacturer provide certificatioa of the materials used for structural e components.That certification along with the dimensionalinspection data is reviewed by the project engineer before the components can be used in assemblies.

Reference:

END 77 20, Components inspection Form. e Structural welds are made and inspected per the requirements of the ASME Pressure Vessel Code. The nondestructive test reports plus other assembly data is reviewed by the project engineer before a package is released for use.

Reference:

END 77-19, Assembly and Fabrication Record. Every completed containment vessel is pressure tested at 200 psig and leak tested at 150 psig before o the first usage and every two years thereafter.

Reference:

END 77-914, Containment Vessel Safety Note. Before each shipment the copper gasket seal is leak tested at 1.5 times the maximum pressure that e would occur if all the gas in the shipment were released into the containment vessel.

Reference:

END 77-21, Packing and Test Procedure. A second important criterion for successful operation is that the package not deteriorate with use. That criterion is achieved as follows: All structural parts that may come in contact with hydrogen during shipping are made from materials e that are not affected by hydrogen (type-316 stainless steel and oxygen-free, high-conductivity copper). Before each shipment, the entire package is completely inspected and any damaged or nonconforming e components are replaced.

References:

END 77-21, Packing and Test Procedure; END 77-22, Packing Check List. e Every two years the containment vessel is completely inspected and pressure tested by a group com-pletely independent of the users. The third important criterion for successful use is that the package must be used correctly and within the design limits that have been approved. This is accomplished by having all packing, testing, and maintenance operatioas performed according to written procedures with a check list that covers each step of the procedure. All operations are performed by trained technicians. A qualified professional (engineer, chemist, health physicist, etc.) inspects and approves all work. 9.2 Organization Mechanical Engineering Department management is responsible for quality assurance of the UC.609 package at LLL. Quality assurance is an integral part of the design-fabrication-operational system in each working engineering group at LLL. This system also includes an independent check at all organizational levels. Personnel in the various groups shown on the organization chart (Fig. 29) have been trained and have ac-quired expertise in their respective fields. Fabrication, shipping, and testing operations are performed with approved procedures. 9.3 Quality Assurance Program 9.3.1 Procedures The fabrication and testing of the UC-609 shipping package is covered by a written procedure.

Reference:

END 77-16, Fabrication Specification. Quality assurance is also incorporated into the operating and main-tenance procedures. 37

Information transfer Container <s, Project accomplishment ^ Organizational Design p d# *E b " - - d ie e r w 1 Design { documentation Purchasing Procurement 2 l h l l Field inspections l Component certification Material certification pg;

9 Environmental l

I laboratory ~ tests l l 1 I Delivery 1 I Mechanical High-pressure Engineering - -l - - laboratory l tests Department l l Test results Preoperational l l l testing Chemistry + light isotopes l { Shipping status Release for l shipping l 1 Health and Inspection reports Routine Safety inspections ~ l Department O i ( Disposal documents Ratirement l ir Quality assurance file Hg. 28. Inspection tests and certificates required by quality assurance program for UC-609 package. 38

Mechanical Engineering Division Head Supervisor, Health and Safety receiving r Department inspection u i Mechanical L. _ _ _ _ - - Engineering group leader Supervisor, precision r inspection v Responsible (project) = engineer

Engineer, nondestructive 2

testing Supervisor, l mechanical technicians (high-prcssure laboratory)

Engineer, environmental testing Mechanical technicians

Engineer, material r

evaluation inspector, pressure testing I l I

Chemist, light isotopes group Fig. 29. Organisation chart for LLL Mechanical Engineering Department.

39

93.2 Approvals Quality assurance functions are incorporated into the fabrication and operating procedures. The procedures are reviewed and approved by the engineering group leader. 93.3 Safety-Related items Safety-related or "Q items" are the containment vessel, the insulation, and the shipping drums. The "non-Q item" is the storage vessel. 93.4 Training The mechanical technicians that will perform the various operations involved in fabricating, testing, and shipping are trained by mechanical engineers using approved procedures. 9.4 Design Review The UC-609 shipping package has been independently reviewed by the Separations and the Separations Technology Departments of the Savannah River Plant of E.1. duPont de Nemours and Co. 9.5 Procurement Document Control The component and assembly drawings are the procurement documents that specify the minimum acceptable quality. 9.6 Instruction, Procedures, and Drawings . All fabrication, testing, shipping, and maintenance are performed in accordance with written procedures. Activities that affect the quality of a shipment are certified on "use every time" procedures or certification sheets. Refer to Ch. 7.0, Operating Procedures, for specific information relating to procedures governing ac-tivities with this packaging. 9.7 Document Control Operating procedures and drawings are given an independent review by the engineering group supervisor and by the technician group supervisor. The reviewers thoroughly understand that quality assurance is an in-tegral part of the design, construction, and operations at LLL. Documents to be controlled are LLL drawings and procedures. Drawing and procedure changes must be approved by the engineering group leader. It is his responsibility to verify that any proposed change will not violate the substance of the Safety Analysis Report on Packaging. The Mechanical Engineering Department records section maintains a file of the latest revisions. The master files reflect the latert revisions and is up-dated as soon as changes are released. Newly revised copies of documents are issued to the appropriate groups as soon as released. 9.8 Control of Purchased Material, Equipment Parts, and Services The drawings require that fabricators provide mill test reports for the critical materials used. At LLL, dimensional inspections and radiographic examinations are made. Only after the above data have been reviewed and approved by the project engineer are the parts tagged and stored for use in a secure, limited-access storage area. The results of these inspections will be included in the quality assurance record file. 40

m 9.9 Identification and Control of Materials, Parts, and Components Verification of material and identification of parts for use on the UC-609 shipping package are discussed in Sec. 9.8. 9.10 Control of Special Processes The welding on the containment vessel is controlled by visual and radiographic inspections. All welding must meet the requirements of the ASME Boiler and Pressure Vessel Code. Sec. Vill, paragraph UW-51. Radiographic inspections will be made by LLL by qualified personnel in the nondestructive test section of Mechanical Engineering Department. 9.11 Inspection Each lot of parts will be inspected and the inspection results reviewed before the parts are released for use. See Sec. 9.7. 9.12 Test Control 9.12.1 Preoperational Test Program The only preoperational tests required for the UC-609 shipping package are the proof test and the leak test of the containment vessel. That testing will be accomplished using written test procedures that have been approved by engineering supervision. The tests will be performed at LLL by high-pressure technicians and ob-served by a pressure inspector. The project engineer must review and certify that the test results meet the re-quirements before the container can be used. 9.12.2 Acceptance Tests and Maintenance Program See Sees. 8.2.1 and 8.2.2 for discussion. 9.13 Control of Measuring and Test Equipment 9.13.1 Calibration Standard helium leaks used in calibrating mass spectrometer leak detectors are purchased from reputable manufacturers who certify the leak rate of each unit. a.13.2 Standards The Heise gauges used to pressurize the containment vessel are periodically calibrated on dead-weight testers. 9.14 liandling, Storage, and Shipping Written operating procedures in Ch. 7 cover the handling and storage of UC-609 packaging components. Shipment of UC-609 packages will comply with U.S. Department of Energy and Department of Transportation requirements. On receipt, all packaging is visually inspected for obvious damage. 9.15 Inspection, Test, and Operational Status The status of each UC-609 package is maintained by a procedure which outlines and records each re-quired step in the preparation of a package for shipment. See Ch. 7. A tag indicating that the containment vessel has been successfully proof tested and leak tested is attached by the pressure inspector.1he packaging is not complex, and its status is determined per Ch. 7 and 8. 41

9.16 Nonconforming Materials, Parts, or Components 9.16.1 Disposition Nonconforming packaging will be tagged, removed from service as soon as it is identified, and replaced with a spare. The nonconforming packaging, if repaired, will be repaired using an approved procedure and standard maintenance techniques. 9.16.2 Acceptance Inspections of packaging at the vendor's shop or upon receipt may result in rejection of material. 9.17 Corrective Action Nonconforming packaging may be repaired by the vendor or by LLL, depending on the cost and pay-ment allocations made between the purchasing department and the vendor. Repairs are to be made using ap-proved procedures. 9.18 Quality Assurance Records The records for the UC-609 containm-nt package will be kept on permanent file at LLL. 9.19 Audits LLL Materials Management will make annual audits to determine if the packaging is being used in an ap-proved manner. J e 42

REFERENCES 1. American Society of Mechanical Engineers, Boiler and Pressure Vessel Code (American Society of Mechanical Engineers, New York,1974), Sec. VIII, Div.1. 2. L. A. Sturtevant, Torque Manual (P. A. Sturtevant Co., Addison, IL), pp. 33-41.

3. Mechanical Properties of Hexcel Honeycomb Materials, Document No. TSB 120 (Hexcel Corporation,

- Dublin, CA,1974), p.16. 4. A. A. Gates and P. G. McCarthy, Safety Analysis Report - Packages, JP157S Packages, Savannah River Plant, Aiken, SC, Rept. DPSPWD 76-124-2 (title U, report SRD) (1976), pp.1-3. 5. H. A. Rothbart, Mechanical Design and Systems Handbook (McGraw-Hill Book Co., New York,1964), Table 20.2, p. 20-7. 6. M. S. Burger, General Purpose Shipping Container Stress Analysis, Lawrence Livermore Laboratory, Rept. END 77-10_(1977). 7. Environmental Test Methods, U.S. Department of Defense, Rept. MIL-STD-810C (Fig. 514.2-7, p. 514.2.40; Table 514.2-V1I, p. 514.2-39). 8. R. C. Lum, Thermal Conductivity of Celotex, Lawrence Livermore Laboratory, Job No. 240388 (1975). 9. D. Ornellas, private communication (1978). 10. J. P. Ilolman, Heat Transfer (McGraw-Hill Book Co., New York,1968), 2nd ed., pp. 199, 385. 1I. G. C. Sehaack and D. A. Schauer, Thermal Study of Tritium Transfer Container, Lawrence Livermore Laboratory, Rept. END 77-15 (1977). 12. F. Krieth, Principles of Heat Transfer (International Textbook Co., Scranton, PA,1962) pp. 217-226. I3. D. A. Schauer, FED - A Computer Program to Generate Geometric Input for the Heat Transfer Code TRUMP, Lawrence Livermore Laboratory, Rept. UCRL-50816, Rev.1 (1973). 14. A. L. Edwards, TRUMP - A Contputer Programfor Transient and Steady-State Temperature Distribu-tion in Multidimensional Systems, Lawrence Livermore Laboratory, Rept. UCRL-14754, Rev. 2 (1%9). I 5. International Atomic Energy Agency, Regulationsfor the Safe Transportation of Radioactive Materials, Safety Series No. 6 Rev. ed. (1973).

16. J. Crank, Mathematics of Diffusion,2nd ed. (Clarendon Press, Oxford,1975), pp. 51-52.

17. M. R. Loutham and R. G. Derrick, Hydrogen Transport in Austenitic Stainless Steel, Savannah River Plant, Aiken, SC, Rept. DP-MS-73-10 (1973). RW 43

APPENDIX A: ENGINEERING NOTES O e

a LAWRfMCE LIVEIRe0RE LA00RATORY UNIVERSITY OF CALIFORNI A FILE 30. P AGE ENGINEERING NOTE END 77-16 "" July 7.1977 UC-609 SHIPPING CONTAINER FABRICATION SPECIFICATION by Ronald R. Sandberg Approved by: LL-30 (MV.041) 45

4 LAWRENCE LIVERasORE LABORATORY UNIVERSITY OF CALIFORNI A f f LE me, P ACE ENGINEERING - NOTE END 77-16 2 UC-609 SHIPPING CONTAINER " " R. Sandberc FABRICATION SPECIFICATION " July 7.1977 4 1.0 SCOPE This specification covers the fabrication, inspection, examination, and testing of Model UC-609 shipping containers. The container shall be manufactured in accordance with the listed drawings and the requirements of this specification. 2.0 APPLICABLE DOCUMENTS. 2.1 Assembly Drawinas Title Number Model UC-609 shipping Container AAA76-109771 Vessel Assembly-AAA75-113083 Leak Test Assenbly AAA75-113967' Cover Assembly AAA77-102165 Insulation Cover Assembly AAA77-104161 Insulation, Body AAA77-104163 Drum Assembly AAA77-104165 Vessel Carrier Assembly AAA75-ll2930 2.2 Sub-Assembly and Detail Drawings Gaske t AAA75-108816 Liner Honeycomb Assembly AAA77-103369 Containment Vessel Liner AAA75-113591 Honeycomb Segment AAA77-103389 Honeycomb Plug AAA75-lll105 Head to Cylinder Weldment AAA75-111306 LL-30 (EV.0/71) 46

a k LAWRENCE UVtale0RE LADORATORY. UNIVERSITY OF CALIFORNI A FILE me. P AGE ENGINEERING NOTE END 77-16 3 R. Saneerg UC-609 SHIPPING CONTAINER FABRICATION SPECIFICATION Julv 7.1977 2.2 cont'd + Top Head AAA75-104814 Semi-Elliptical Head AAA75-113082 Cover Machined and Welded AAA75-104817 Plug Backing Plate AAA77-102164 Fill Valve Assembly AAA76-106629 Nupro Valve tiod. AAA76-106627 Weld Tee (Rework) AAA76-106619 Plug (Reworked) AAA76-106618 Leak Test Valve Assently AAA76-106616 Hoke Valve (Rework) AAA76-106617 Insulation Cover AAA77-104164 Heat Shield AAA77-104162 End Flange AAA75-ll2931 Mounting Plate AAA75-104815 Brace AAA75-112928 Spacer Block AAA76-118323 Identification Plate AAA77-104603 Bracket - Drum Cover AAA76-ll5288 Handle Assembly AAA77-101635 1 2.3 Documents Model UC-609 Pressure Test Report END 77-18 Assembly Fab. Record END 77-19 Component Inspect. Form END 77-20 a Packing & Test Procedure END 77-21 Packing Check List END 77-22 Safety Note END 77-914 J LL-394 (MV.8/76) 47

4 FILE NO. P ast LAWRENCE LIVERheORE LARORATORY UMlVERSITY OF CALIFORNI A ENGINEERING NOTE ENo 77-is 4 UC-609 SHIPPING CONTAINER ""' R. Sandbero FABRICATION SPECIFICATION " July 7, 1977 3.0 i4ATERIAL All materials used in fabricating the containment package must be certified by the supplier as meeting the drawing requirements. Where required by the drgwings, a mill test report shall be provided. The mill test report shall include the ASTM specification nunber. Type, grade, finish, manufacturers name, the heat number, and the results of chemical analysis and mechanical properties tests. 4.0 WELDING Welding shall be done using methods and materials specified on the applicable drawings. 4.1 Fittino and A11onment_ Edges to be welded shall be uniform and free of foreign materials. Parts to be welded shall be fitted, aligned, and retained in position during the welding operation so that the full penetration required by the drawings is obtained. 4.2 Cleanino of Surfaces to be Welded Surfaces to be welded shall be free of foreign materials such as grease, oil lubricants, and marking paints. 4.3 Repair of Weld Defects Visible defects such as cracks, pinholes, and incomplete fusion, as well as defects that can only be detected by prescribed examinations or tests, shall be removed. Then the joint shall be rewelded. The repaired weld shall be retested as required of the original weld and to be acceptable must meet the quality require-ments of the original weld. Lt 30 (Ev.Shu 48

FILE no. Past LAWRENCE LIVf AssORE L AOORATORY UNIVERSITY OF CALIFORMI A ENGINEERING NOTE END 77-16 5 UC-609 SHIPPING CONTAINER R. Sandberg FABRICATION SPECIFICATION July 7. 1977 5.0 INSPECTION AND TEST CERTIFICATION A component inspection form (END 77-20) and/or an assembly fabrication record (END 77-19) must be completed for each lot of components or assemblies. (A lot is defined as a series of parts / assemblies made from one drawing at the same time.) Each completed inspection document must be reviewed and signed by the engineer responsible for directing the fabrication of the containers before the parts are released for use. Hon-conforming parts are to be returned to the supplier for rework or replacement as required. The acceptance proof and leak test must be documented by the completien of a pressure test report (END 77-18). The pressure test report must contain the signature of the responsible engineer before the parts are released for use. 5.0 RECORDS A permanent QA file shall be started and maintained for each container manufactured. As a minimum that file must contain: 1. Results of acceptance inspections (END 77-19 END 77-20) 2. Proof and Leak Test Certifications (END 77-18) 3. Records of periodic inspections and retests 4. Use record copies of packing check lists (END 77-22) 5. Records of any rework or component replacement. 6. Weld radiography records. LL-34 (MV.841) 49 )

P ast Tl ft t e pite me, END 77-18 1 MODEL UC-609 SHIPPING CONTAINER "' "[ Sandberg 7/ /77 a PRESSURE TEST REPORT c., u ev

Reference:

Drawing AAA75-113967. Safety Note END 77-914 Container Serial No. 1. Sensitivity of mass spectrometer: atmcc/s/div.(handprobe) atm cc/s/div. (integrated leak test) Standard Leak No. with a leak rate of 2. Proof pressure psig for hr 3. Leak test pressure psig 4. Leak rates: Across Cu gasket atm cc/s External atm cc/s (total must be less than 1 x 10~0 atmcc/s) Tested by Date Inspector: Pressure tested label applied: Date Approved for use Date 50

fi f t E s FOLE 100 Pa6f FND 77-19 1 "' . " San dbe ro MODEL UC-609 SHIPPING CONTAINER R 5/77 ASSEMBLY FABRICATION RECORD e i e o ~ Assembly Drawing No. Lot No. Size of Lot List Serial Nos. Supplier LLL P.O. No. Cost $ each ITEM SPECIFICATION REMARKS 1 Component parts inspected and approved for use (attach inspection forms END77-20) 2 _ % of asser611es inspected for dimensional compliance 3 General coments on workmanship and quality of assernblies 4 Acceptable assemblies tagged with LLL P.O. No. and Lot No. Inspection: Accepted Date N.D. Tests Accepted Date Date Approved for use Date 51

P ASC TITtts pegg so. END 77-20 1

• • "' $ Saneerg Y[5/77 MODEL UC-609 SHIPPING CONTAINER R

COMPONENT INSPECTION FORM M, L % i..k, h8 Part Drawing No. - i Lot No. Size of Lot List Serial Nos. Supplier LLL P.O. No. Cost $ each ITEM SPECIFICATION RElmRKS 1 Material - meets drawing requirements, certification attached 2 _% of parts inspected for dimensional compliance. Sumary attached. 3 General coments on workmanship and quality of parts 4 Acceptable parts tagged with LLL P.O. No. and Lot No. Inspection: Accepted Date N.D. Tests Accepted Date Date Approved for use Date 52

LAs#EhCE R ADI ATION L ABOR ATORY. UNivtRSITY OF C AL 6 FORNI A 'thE #U.

• • 6*

ENGINEERING NOTE ..,, 3, g, END 77-21 1 ...u. July 5.1977 o MODEL UC-609 SHIPPING CONTAINER PACKING & TEST PROCECJRE BY RON SANDBERG July 5.1977 Approved by: RS:jm it. s.. <... v., i 53

F I L E "9 - P AGE LAW 8tthCE R ADI ATION L ABOR ATORY. UNIVERSITY OF CALIFORNI A ENGINEERING NOTE END 77-21 2 "' R. Sandberg MODEL UC-609 SHIPPING CONTAINER PACKING & TEST PROCEDURE ,,,, July 5,1977 Reference assembly drawing AAA76-109771. 1. Packing check list END 77-22 to be completed by individuals assen-bling container for shipment. Mount storage vessel on vessel carrier per users written procedure. 2. Record pertinent infomation about storage vessel on check list. Inspect interior of contairunent vessel, seal areas of flanges, and 3. cover valves for cleanliness and damage. Clean or replace parts as required. 4. Inspect "0" ring and copper gasket for nicks, cuts, scratches, etc. (A new copper gasket is to be used fcr each shipment.) Coat "0" ring with a light film of silicone vacuum grease. 5. Install vessel carrier into container. Use care to avoid dame.ging sealing surface on flange. Verify that the rubber pads on the container cover are compressed 6. a minimum of 0.06 inches when the cover is in place. Add additional pads if necessary. 7. Install and torque cover bolts as follows: A. Verify that bolts meet drawing requirements. (170,000 psi min.uittensitstr.) 8. Coat bolt threads and under-side of heads with "Kopr-Kote". Torque bolts in order stamped next to holes to 20 Ft - Lb. C. Go around pattern twice. D. Increase torque to 45 Ft - Lb. Go around pattern until no bolt movement is observed. ii..... i s,,,.f n 54

F ett me. P a6s LAsRENCE R40t AT10N L ABORA*0RY

• UNIVERSITY OF C ALIFORNI A ENGINEERING NOTE EnD 77-21 3

.. R. Sandberg ...m. MDDEL UC-609 SHIPPING CONTAINER PACKING & TEST PROCEDURE

• • " July 5,1977 8.

Leak test container as follows: A. Evacuate the container volune (through the fill valve) to less than 150 Torr (3 psia). B. Pressurize through the fill valve with helium to the pressure determined from the table on page 5. Close the fill valve. C. Determine the sensitivity of a mass spectrometer leak detector with a standard leak. D. Connect the leak detector to the open leak check valve and to the closed fill valve. Measure leakage across gasket and across fill valve seat. E. Vent pressure to atmospheric. F. Close both valves, and cap fittings. 9. If required for in plant control install tamper seals on cover bolts and on valves. 10. Inspect celotex insulation, drum, drum cover and drum cover brackets for damage. Replace parts as necessary. Remove any old shipping labels. 11. Verify that plastic plugs are in place in drum cover. 12. Install container into insulating overpack. Use enough i inch s thick ceroblanket disks on top of the insulation cover so that approximately 100 pounds force must be applied to the cover to engage the cover brackets. 13. Torque bolts securing drum cover to 20 ft.-lb. and install tamper seals on two bolts 180 apart. 2 14. Monitor package for contaraination: must be less thhn 150 d/m/100 cm o beta-ganina. 55

P LAURENCE UVf Ale 0RE L A00RATORT.UNiyER$aTY OF CALIFORNI A FOLS N8. P AGE ENGINEERING NOTE END n-ri 4 M)9EL UC-609 SHIPPING CONTAINER PACKING & TESTING PROCEDUR' " R. Sandbero "" July 5.1977 15. Install appropriate labels in conforrance with DOT regulations. Also attach tag identifying shipment. 16. Lt.see isv eno

• u. e. or on ies -vet ***

56

w f lLE NO. P A48 LAWRENCE RADI ATION L ADOR ATORY. UNivtRSITY OF CAL 4FORNI A ENGINEERING NOTE EE 77-21 5 ...m. R. Sa h ro MODEL UC-609 SHIPPING CONTAINER PACKING & TESTING PROCE0VRE ..,.July 5.1977 MODEL UC-609 SHIPPING CONTAINER TABLE OF PRESSURES & TD4P. FOR VARIOUS QUANTITIES OF GAS Quantity Decay Contairunent vessel Pressure (psia)(3) of gas heat load Temp (2) Equilibrium Test (4) moles (1) watts C K 2 3.8 54.8 327.8 23.5 35.s 4 7:7 56.7 329.7 29 6 45 6 11.5 58.5 331.5 35.7 54 8 15.4 60.4 333.4 41.9 63 10 19.2 62.2 335.2 48.2 73 12 23.0 64.0 l 337.0 54.5 82 14 26.9 65.9 338.9 60.9 92 16 30.7 67.7 340.7 67.4 102 18 34.6 69.6 342.6 73,9 111 20 38.4 71.4 344.4 80.5 121 22 42.2 73.2 346.2 87.2 131 24 46.1 75.1 348.1 93.9 141 25 48.0 76.0 349.0 97.3 146 26 48.0 76.0 349.0 100.5 151 28 42.0 76.0 349.0 106.8 161 30 48.0 76.0 349.0 113 170 st.s.. < a...v e n $7

FI6E no. PAGE LABIIEfeCE RAOl Afl0N L A80R ATORY e WNivERSifY OF CALIFORNI A ENGINEERING NOTE END 77-21 s ...,, 3,,,,,,, ... m. M) DEL UC-609 SHIPPING CONTAINER PACKING & TEST PROCEDURE July 5.1977 ..n Notes: (1) Gas is considered to be 100% tritium up to 25 moles of gas. For quantities greater than 25 moles the amount over 25 moles is considered to have no decay heat load. (21 Temperatures are the maximums for " normal" conditions of transport. Equilibrium pressure is calculated as if all of the gas in the shipment were within the containment vessel at the listed temperature. The following equation was used: '4I h (14.7) 1+ P = Nurter of Moles of Material where N = T= Max. Temp For Normal Transport Net Volume of Containment Vessel Mth to g@e

• 134

= Storage vessel & carrier inside. (120 lb total - Aluminum) (4) Test pressure is 1.5 times the equilibrium pressure. a6... l... e e, i 58

" " ' END 77-22 vi,t a. Model UC-609 Shipping Container R. Sandberg 7/6/77 Packing Check List c <e

Reference:

Dvg. AAA76-109771 Procedure END 77-21 Coretainer Serial No. Storage Vessel: Serial No. Dwg. No. Contents a moles (125 g moles T,130 g moles total) 2 Leak rate (<1 x 10~9 atmcc/s) Weight (5100 pounds) Certified by date Item Speci f1catton Remarks 1 Storage vessel mounted to vessel carrier per users written procedure (Attach signed copy) 2 Interior of container, flanges, and valves clean and free of defects: 'tecord Retest Date 3 "0" Ring and new copper gas.et inspected. "0" Ring coated with vac grease 4 Rubber pads on cover compressed against vessel carrier a minimum of 0.06 inch when the cover is in place 5 Cover bolts: Use certified parts only from bonded storage. 6 Cover bolts torqued to 45 f t-lb 7 Pressure Test: a) Container evacuated to less than 150 torr Actual Pressure torr b) Pressurized to psia (see END 77-21 Table on Page5 59

END 77-22 "2 rins. ens me. =ai ma e' .ars Model UC-609 Shipping Container R. Saneem 7/6/77 Packing Check List eata c,ec....v Item Speci fication Remarkt 7 cont'd c) Sensitivity of leak detector: atm cc/s/Div. Standard leak No. Leak rate d) Leak rate: Across gasket Across fill valve seat (Must be less than 1 x 10~0 atm/cc/stotal) e) Container vented to atmospheric pressure, valves closed, and fittings capped 8 Tamper seals on cover if reautred: Record Locations *, Record No's. if Applicable 9 Drum, Celotex, and drum closure brackets in-spected. Plastic plugs in place in drum cover 10 Ceroblanket disks in place on top of insulation cover 11 Bolts on drum cover brackets torqued to 20 ft-lb Tayr seals on two cover securing bolts 12 180 apart. Record No's. if Applicable. 13 Package monitored for radioactjvity must be less than 150 d/m/mi 100 cm beta-gama 14 Approoriate 00T labels and tag identifying shipment in place. 15 60

4 T 4 74 8 s IILI "O

• END 77-22 3

.. r ie.., .. v. Model UC-609 Shipping Container R. Sandbero 7/6/77 Packing Check List o cascaso e< Shipment Packed and Tested by Date Inspected and Approved by Light Isotopes Chemist LLL Materials Management O e 61

APPENDIX B: FABRICATION DRAWINGS 44 O O 62

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