ML20196B425
| ML20196B425 | |
| Person / Time | |
|---|---|
| Site: | 07104909 |
| Issue date: | 10/30/1987 |
| From: | Nardi A WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP. |
| To: | Macdonald C NRC OFFICE OF NUCLEAR MATERIAL SAFETY & SAFEGUARDS (NMSS) |
| References | |
| 28734, LA-87-75, NUDOCS 8802110250 | |
| Download: ML20196B425 (23) | |
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. RECEIVED 3
U. S. Nuclear Regulatory Commission 3
NOV 41987 E ATTN: Mr. Charles E. MacDonald, Chief I' u.s.wctIAR trcutucar p Transportation Certification Branch
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Division of Fuel Cycle and Material Safety
'q W8 ktka O I'g\\ j Office of Nuclear Material Safety and Safeguards
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Washington, D.C.
20555 Gentlemen:
Subject:
Application for Renewal of W-21PF-1 Shipping
- Package, Certificate of Compliance tunber 4909, Docket 71-4909 The Westinghouse Electric Corporation hereby submits this application for renewal of Certificate of Compliance to. 4909 for the W-21PF-1 Shipping Package (Package Identification No. USA /4909/B( )F).
Attached is a revised license application document to support this request.
This submittal is complete in itself and therefore replaces in entirety all previous submittals.
A check in the amount of $150.00 is encloseo as payment of the application fee specifieo in 10CFFtl70.31 for this request.
If you have any questions concerning this application, please contact me l
at the above.'acoress or telephone (412) 374-4652.
Very truly yours,
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.i TABLE OF CONTENTS 1.0 Discussion This document provides a general history of the evolution of the W-21PF-1 design and documents by reference the nuclear criticality safety and structural evaiuations.
2.0 Reference Drawings Five drawings are included in this package which replace all previously submi tted drawings.
These revised drawings describe both the original overpack design and the modifications requested in a
previous submittal.
Additional corrections were made as necessary to accurately reflect the overpack design.
3.0 Acceptance Criteria for New and Renovated Model W-21PF-1 Protective Shipping Packages This section identifies the inspection plans used to demonstrate that each Model W-21PF-1 PSP has been manufactured, repaired or modified in accordance with Westinghouse Drawing No. 360F05E001.
4.0 Renovation of W-21PF-1 Protective Shipping Packages This section summarizes by reference, work which has been done to l
evaluate the integrity of the phenolic foam insulation.
5.0 Operating and Periodic inspections This document presents typical operating procedures to assure safe handling of UF during loading and preparation for shipment.
Quality overchecks defined in these procedures assure that each packaging is in compliance with all shipping specifications.
6.0 Model W-21PF-1 Mo,
't t;on To Dimensional Conformance This document describes the procedure, acceptance criteria and
(
engineering evaluations for modification of Model W-21PF-1 to l
dimensional conformance.
1 1
7.0 References l
This document lists the applicable reports used to justify the W-21PF-1 overpack design.
l l
r i
1.0 Discussion The 21PF-1 outer protective package for Fissile Class ll shipment of Model - 30 UF.
cylinders containing -moderation controlled u ranium hexafluoride was developed at the Oak Ridge Gaseous Diffusion Plant.'
A high temperature phenolic foam plastic with a fiber glass additive is used as fire-resistant material between the liner and shell.'
Based on the nuclear evaluation,' ten of the packagings may be enrichment.* ported as trans a unit to a maximum 5.0 weight percent U-235 Engineering assessment (0ak Ridge) of the drop test and fire damage to the prototype packaging resulted in several design improvement) which were incorporated into the final 21PF-1 design.
An actual fire test was not conducted of the modified design; however, based on the drop tests conducted, it was determined that any unit fabricated in accordance with the modified design would provide considerably greater protection against fire hazards than the prototype tested.
The original 21PF-1 package was constructed of carbon steel using tack welds (as opposed to full, continuous welds) on the shell and angle stiffeners with a
step-down gasket seal.
This
- design, being constructed of carbon steel, was susceptible to corrosion which was accelerated by water retention behind angle stiffeners.
Water in-leakage was also observed due to the step-down gasket seal design.
A further design modification of the 21PF-1 package was undertaken in order to correct the above identified problems.
To prevent water in-leakage, a step-up seal was provided.
Corrosion and rusting was eliminated by constructing the package enti rely of stainless steel.
Full, continuous welds were also incorporated into the design for the shell and angle stiffeners.
In addition, the liner was constructed of 14 GA stainless steel as opposed to 16 GA as used in previous designs.
A supplement to the previous Safety Analysis Report included these changes in design and materials of construction.'
This report concluded that these changes would increase the useful life of the package and not compromise the protective features of the 21PF-1 overpack design.
The evolved package design, W-21PF-1, has been in use since 1983.
During this time, the packages have been free from damage and major maintenance.
Maintenance thus far has involved replacement of gaskets, pins and fasteners.
In addition, water has never leaked f rom or been observed inside these packages.
The packages, since being fabricated of SS304, have been corrosion free.
_1
--, s i
t' Reference Drawings 2.0 2.1 Drawing No. 360F05E001, sheet 1 of 4, sub. 11 a.
Added original reference dimensions to inner and outer shells.
b.
Revised weld symbols on inner and outer shells to continuous full penetration welds.
c.
Revised weld symbols on all angle bars to continuous full penetration welds.
2.2 Drawing No. 360F05E001, sheet 2 of 4, sub. 11 a.
Changed to sub. 11 to be consistent.
2.3 Drawing No. 360F052001, sheet 3 of 4, sub. 11 a.
Changed to sub. 11 to be consistent.
2.4 Drawing No. 360F05E001, sheet 4 of 5, sub.11 a.
Added original reference dimensions to inner and outer shell.
2.5 Drawing No. C2720045, sheet 1 of 1, sub. 7 a.
No changes were made to this drawing.
2-l f
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! l
i 3.0 Acceptance Criterla For New and Renovated Model W-21PF-1 Protective Shipping Packages The following inspection plan is used to demonstrate that each Model W-21PF-1 PSP has been manufactured, repaired or modified in accordance with the requirements of Westinghouse Drawing No. 360F05EC01, and meets
'the requirements of 49CFR178.121, specification 21PF-1 except as specified in Nuclear Regulatory Commission Certification of Compliance No. USA /4909/B()F.
3.1 Wood Requirements - Inspect each lot to verify that:
3.1.1 Wood for side rails and end caps are select grade oak or hard maple with less than 15% moisture content and shall be surfaced both sides to 1-1/2" and 13/16" thicknesses, respectively.
3.1.2 New wood surfaces are coated with fire-retardant (intumescent) paint prior to installation.
3.2 Metal Requi rements - Inspect each lot of metal and determine that all materials are properly marked with Job and Heat Numbers and that matching material test reports are obtained and filed demonstrating:
3.2.1 All sheet metal and plate are ASTM A-240, Type 304 or 304L stainless steel.
3.2.2 All st. apes including angle and flat bar are ASTM A-276, Type 304 or 304L stainless steel.
3.3 Welds - Inspect each package as follows:
3.3.1 Ascertain that all welds are by GTAW or GMAW processes which are qualified per Section IX, ASME Boiler and Pressure Vessel Code.
3.3.2 All welds are made by welders who are qualified for the weld procedure and position used per Section IX, ASME Boiler and Pressure Vessel Code.
3.3.3 Unless otherwise specified, all welds shall be full penetratico welds, shall develop the full strength of the weakest member joined, and shall be equal to the thinner of tro metals joined.
3.3.4 Visually examine new welds (including heat af fected zones) at 3X to assure freedom from cracks or other defects which might indicate unsound welds as follows:
(a) 100% inspect seam welds joining the lengthened inner and outer shells.
(b) 100% inspect the miter joint welds joining the side and end panel moldings.
(c)
Spot check fillet welds joining the inner and outer shells with the side and end panel moldings.
Discovery of defective welds during spot checking shall be cause for 100% examination of all adjacent welds.
3.3.5 Defective welds must be repaired by grinding away all defective metal, rewelding, and re-inspecting..
. ).4 Foam Requirements - Inspect each package as follows:
3.4.1 The fire resistant phenolic foam is fabricated using materials and procedures per Specification SP-9, Rev.
1, as modi fied by Supplements K/TL-729 dated 3/1/78 and K/P-6567 dated 4/28/80.
3.4.2 Minimum of 110 + 10 lbs finis,hed -foam installed in the package; additional smaller pours may be used to fili voids (see 3.4.3 and 3.7.3 below).
3.4.3 Inspect all vent holes in the shell in the area of the foam to determine that there are no voids; voids must be filled using additional foam pours as necessary.
3.5 Gaskets - Inspect each package as follows:
3.5.1 Nominal 1" Dia. Neoprene 0-ring Gaskets (50 to 70 Durometer, Spec, AMS-3209; certification required) are inserted in the inner and outer 0-ring grooves of the side and end panel moldings of the top half after foaming.
3.5.2 1/4" thick X 6" X 9" Neoprene Pads (40 to 50 Durometer) are bonded to the top inner shell in four places over the wooden
~
support blocks.
3.5.3 3/16" thick X 6" X 9" Neoprene Pads (50 to 60 Durometer) are bonded to the bottom inner shell in four places over the wooden support blocks.
3.6 Dimensions - Inspect each package and record actual dimensions on Ins [.ection Checklist as follows:
3.6.10-ring grooves in side panel moldings match 0-ring grooves in end panel moldings to within 1/32".
3.6.2 Inside length of inner shell: 82-5/8" i 1/8".
3.6.3 Outside length of outer shell: 91" i 1/8".
3.6.4 20 each. 1/4" vent holes in each half.
3.7 Weights - Determine the following weights for each package and record on inspection Checklist as indicated:
3.7.1 Top and bottom package halves (including 5" square cover platea and pop rivets) before foaming; record weights on Inspection Checklist.
3.7.2 Top and bottom package halves af ter foaming; record weights on inspection Checklist.
3.7.3 Weight of foam in each package half by dif ference (3.7.2 minus 3.7.1 must be 110 10 lbs); record foam weight in each package half on inspection CheckIist.
l 3.7.4 Weight of finished package assembly (Package Tare Weight); record on inspection Checklist and stamp on stainless steel "USA /4909/8()F" Nameplate (see 3.9.1 below).
3.8 Final Finishing - Inspect each package and document that:
3.8.1 All vent holes are sealed with plastic cap plugs and silicone RTV caulking.
3.8.2 All new metal surfaces cleaned and sandblasted to blend wt th existing surfaces.
Note that newly sandblasted surfaces will have brighter appearance than the existing surfaces which have darkened with age. t l
l
i 3.9 Stencils and Nameplates - Inspect each package and document that:
3.9.1 The actual package tare weight has been stamped on each namcplate and recorded on the inspection Checklist (see 3.7.5 above).
3.9.2 The package markings have been stenciled in the appropriate places.
1 3.9.3 For new packages, identification plate shall not be attached until accepted by Westinghouse.
3.10 Attachments 3.10.1
' Inspection checklist for Repaired Model W-21PF-1 Protective Shipping Packages.
3.10.2 Receiving Inspection Report for Manufactured, Modi fied or Repaired Model W-21PF-1 Protective Shipping Packages.
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I 1
INSPECTION CHECKLIST FOR MANUFACTURED, REPAIRED, OR MODIFIED MODEL W-21PF-1 PROTECTIVE SHIPPING PACKAGES WESTINGHOUSE NUCLEAR FUEL DIVISION COLUMBIA, SOUTH CAROLINA PACKAGE SERIAL NUMBER:
Order No.
Job NO.
MATERIALS:
- Attach Receiving inspect on Reports-Foam Waterials (SP-9 Spec.)
Wood--Oak or Hard Maple 304 (304L) Stainless Steel Gaskets, etc.
WELDS (Visual Inspection at 3X):
~l inner Shell Seams (100%)
Outer Shell Seams (100%)
Panel Moldings Miters (100%)
Panel Moldings Seams (Spot Ck.)
GASKETS:
Nominal 1" Dia. Neoprene 0-rings DIMENSIONS:
Old and New 0-ring Grooves match within 1/32" Inner Lgth--82-5/8" i 1/8"*
Outer Shell Length--91" 1/8"*
1/4" Vent Holes per Dwg.
WElGHTS Lb (
)
Kg (
)
Upper Assembly before foaming" l
Upper Assembly after foaming
- Foam upper half (110 i 10 lbs.)*
Lower Assembly before foaming
- Lower Assembly after foaming
- Foam upper half (110 1 10 lbs.)*
Finished Cover Tare Weight
- Assembled Package Tare Wt*
FINISHING:
Vent holes sealed New surfaces sandblasted MARKING:
2 each package tare s, tights 2 each cover tare weights NOTE: Record actual dimension, weight, etc. for all i tems mr.rked wi th (*),
otherwise, (check) if satisfactory or (X) if unsatisfactory.
INSPECTED BY:
DATE:.
RECEIVING INSPECTION REPORT FOR MANUFACTURED, REPAIRED OR M00lFIED MODEL W-21PF-1 PROTECTIVE SHIPPING PACKAGES WESTINGHOUSE NUCLEAR FUEL DIVISION COLUMBIA, SOUTH CAROLINA Complete this receiving report for materials to be used in the manufacturing, repair or modification of Model W-21PF-1 PSP's in cccordance with the requirements of Westinghouse Drawing No. 360F05E001.
Mark all incoming items wi th the appropriate "Job Number" per 00 Program requirements.
Ascertain that each stainless steel item is marked with its "Heat Number" and that a matching material test report, which demonstrates compliance with the applicable specification, is received and filed.
Attach "REJECT" tags on all noncomforming items and isolate for return to vendor or dispositiori by management.
Quant!ty inspection Item No. & Description (Specification)
Ordered Received OK Date 1.
15 ga Sheet (ASTM A-240, Type 304 SS*)
Size Heat #
2.
10 ga Sheet (ASTM A-240, Type 304 SS*)
Size Heat #
3.
8/4 Oak or Hard Maple (Select,<15% H20, 1-1/2"tk X 8' or 12 length x >6"width) 4.
4/4 Oak or Hard Maple (Select, <15% H20 13/16" tk X 8' or 12' Igth x random width) 5.
3/4" Hardwood Dowels (36" lengths) 6.
Albi 107A Fire Retardant Coating or equal 7.
Weldwood Plastic Resin Waterproof Glue 8.
1/8" x 3/16" Pop Rivets (stainless *)
9.
Phenolic Resin (UCC BRL2760 or equal)
- 10. Silicone Surfactant (UCC Y6663 or equal)
- 11. Refrigerant (Freon 113 or equal)
- 12. Boric Anhydride (Practical Gr, -60 mesh)
- 13. Anhydrous Oxalic Acid (Tech Gr, -40 mesh)
- 14. 1/4" Fiberglass Rovings (0 wens Corning 833HSI or equal)
- 15. 1" dia x'8' Ig Neoprene 0-ring (50 to 70 Duro, Spec AMS-3209) Cert
- 16. Rubber Contact Adhesive (Goodyear Pliobond or 3m 08004 or equal)
- 17. 1/4" Polyethylene Cap-Plugs (Protective Closures No. BPF-1/4)
- 18. Silicone RTV Caulking Type 304L stainless steel may be used anywhere Type 304 stainless steel is specified.
If not otherwise specified, stainless steel may be 18-8 or 300 series stainless steel.
INSPECTED BY:
DATE: _
4.0 -
Renovation of W-21PF-1 Protective Shipping Packages The materials used in W-21PF-1 overpack design consisted of a
fire-resistant phenolic form.'
Since many of the specified materials were no longer available, compatibiiity evaluations of substitute materials were provided by Oak Ridge.'
Testing of the mechanical properties demonstrated the equivalence in the shock absorbability of the two foam types specified in SP-9 and K/TL-729.7 Future foam additions to W-21PF-1 overpacks will be conducted in accordance with material specifications in K/TL-729.
Extensive testing was also performed to evaluate the integrity of the insulating foam and determine a the foam prior to renovation of overpacks. practical means for drying The tests conducted in the above specified report indicated that drying the overpacks at a minimum temperature of 190 F was practical.
Mechanical testing also indicated that the foam properties were not degraded by long-term exposure to water with subsequent drying.
In addition, no degradation of thermal conductivity characteristics was found when compared to virgin foam.
Thus, the drying procedure discussed in K-2057, revision 1,
will be utilized during overpack renovation, as necessary.
Renovated W-21PF-1 Protective shipping packages will also be subject to the acceptance criteria described in Section 3.0.
4.-.
a 5.0 Operating and Periodic Inspections Operating and periodic inspections of W-21PF-1 overpacks wili be conducted.in accordance with criteria specified in ANSI N14.1 (latest edition).
Typical operating procedures for the W-21PF-1 package for inservice inspection and maintenance to ensure package compliance are provided as attachments to this section.
.g_
6.0 W-21PF-1 Modificatio'n to Dimensional Conformance As a result of W-21PF-1 packages (20) having been built below the defined tolerance (81.60" 0.13"),
the packages were lengthened in order to accommodate UF. cylinders f abricated at the upper range of their tolerance.
The procedure for the W-21PF-1 modification to dimensional conformance is described in Attachment A.
In this attachment, a method is described for removing one end of the package and lengthening the package by the addition of 3" (typical) strips with 2"
backup bars of 14 GA SS304.
These backup bars provide weld rein forcement and container alignment prior to final welding.
Once repaired, the package is backfilled with phenolic foam.
Acceptance criteria for foam aadi tion is given in Attachment B.
This criteria will ensure correct foam density and weight.
Attachment C provides justification for a 0.15" reduction in the phenolic foam thickness as a result of the backup bars on the shell and liner.
This foam reduction was shown to be insignificant in terms of a fractional temperature increase based upon data provided in the design basis thermal accident.
The comparison also indicated that the cylinder temperature will still remain within the allowed service temperature of 250"F.'
-10
SECTION 6.0 ATTACHMENT A PROCEDURE FOR THE W-21PF-1 M00lFICATl0N TO DIMENSIONAL CONFORMANCE
REFERENCES:
1.
W Drawing No. 360F05E001, Sheets 1 through 4.
2.
AEC Material and Equipment Specification No. SP9, Rev.
1, for Fire Resistant Phenolic Foam as modified by Supplements K/TL-729 (3/1/78) and K/P-6567 (4/28/80).
CERTIFICATION REQUIREMENTS:
1.
GTAW and GMAW Weld Procedures and Procedure Qualification per ASME Section IX.
2.
Welders to be qualified per ASME Section IX for all procedures used.
MATERIAL REQUIREMENTS:
1.
All stainless steel sheet material shall be ASTM A-240 Type 304 and 304L and shall be marked with its heat number and be traceable to its material test report as required above.
2.
Wood rails shall be made f rom select grade oak containing no more than 20%
moisture.
3.
Wood glue shall be waterproof plastic resin glue (Weldwood or equal).
4.
Foam insulation shalI be fire-resistant phenolic foam (with average density of 10 1 pcf) which is fabricated using materials and procedures per Reference #2.
5.
Vent hole seals shall be 1/4" polyethylene cap plugs (protective closures BPF-1/4 or equal).
6.
0-ring seals shall be neoprene 50-70 durometer Spec. A!.iS-3209 and shall be sized to properly fit the 0-ring grooves (i.e.,
about 1"
diameter cross section).
PROCEDURE:
Step #1: Remove the 0-ring seals and then remove the formed side mating surface plates (Items 17 and 18) by grinding away welds inside and outside and at the miter joints joining the side and end mating surface plates:
chisel to break any residual welds.
l Step #2: Cut inner liner (item 26) as shown in Figure 1 (2" from inside end);
l cutting may be by friction disc or plasma cutter.
Step #3: Cut outer shell (I tem #10) as shown in Figure 2 (2" from inside end);
cutting may be by friction disc or plasma cutter.
l l
Step #4: Saw through the wooden side rails at the cuts in the inner liner and outer shell; remove the end assembly. i
Step #5: Remove the foam to about a 2" depth from both exposed surfaces.
Step #6: Grind all cut stainless steel edges smooth and straight, removing the heat affected zone of plasma cut edges.
Step #7: Remove the remaining sections of wooden side rail f roa both the end assembly and the side assembly.
Step #8: Roll form 14 GA Type 304 stainless steel strips which, when welded into the gaps in the inner liners, will make the inside length of each package 82-5/8" 1/8".
See Figure 3.
Step #9: Roll form 14 GA Type 304 stainless steel strips which when welded into the gaps in the outer shells, will make the outside shell length 91" i 1/8".
See Figure 4.
Step #10: Roll 2"
wide, 14 GA Type 304 stainless steel strips to be used as backing strips when. welding in the inner and outer filler strips from Step #8 and #9.
Tack weld backing strips to inner liner and outer shell on each side assembly as shown on Figures 3 and 4.
Step #11: Install new wooden side rail, cut to the correct length to correspond with an outer shell length of 81" i 1/8".
Use new dowel rods and reglue the joints.
This rejoins the end and side assemblies leaving a void in the fcam insulation of approximately 5" and leaving approximately 1" gaps in the inner liner and outer shell where weld backing strips are in place for the installation of filler strips at these gaps.
Step #12: Weld filler strips f rom Step #8 and #9 as shown in Figures 3 and 4; use GTAW weld process, achieve 100% penetration, but limit weld reinforcement to 1/32".
Step #13: Visually inspect welds in inner liners and outer shells for cracks or porosity; repair as needed.
Step #14: Form new side mating surface plates (Items 17 & 18) of 10 GA Type 304 stainless steel and cut the correct shape and length to match the 91" i 1/8" outer shells.
Step #15: Install the new plates f rom Step #14 and reweld using GMAW weld process; l
achieve 100% penetration at the mitered joints with the end mating surface plates and 3/32" fillets at the inner liners and outer shells.
1 Step #16: Grind miter welds, flush and inspect alI new welds for cracks and porosity; repair as needed.
Step #17: Cut 4"
square hole in outer shell on either side at 45 from the l
centerline, and centered over the 5"
void in the foam insulation resulting f rom Step #11.
Drill four (4) 1/4" diameter vent holes at four (4) circumferential locations in each half-section of the outer shell.
l The four locations being 6 1/2" f rom the end of the outer shell.
The l
four holes at each of these circumferential locations are as follows:
I one at each side 4" f rom the mating surf ace, one at each side at 45 l
and one near the centerline.
l l
Step #18: Make a 5" squire cover plate f rom 14 GA Type 304 stainless steel for each 4" square hole cut in Step #17. Drill eight (8) 1/8" rivet holes in each cover plate on 2 1/4" centers around the perimeter, and drill one (1) 1/4" vent hole in the center of each plate.
Roll form each plate to
' match the curvature of the outer shell. Match drill the 1/8" rivet holes at each 4" square hole in the outer shell.
Step.#19: Reinsulate the 5" void (see Attachment Il-B) created in Step #11 with Phenolic Foam at a density of 10 11 pcf per AEC Specification SP9 (see Material Requirements item #4):
install the foam through the 4" square holes from Step #17.
Step #20: Immediately following Step #19, cover the 4" square holes by pop riveting a 5" square cover plate over each hole:
use eight (8) stainless steel pop rivets for each cover.
Stop #21: After foaming operation is complete, inspect the five (5) vent holes associated with newly installed foam to insure the foam has properly filled the entire void; refoam as needed.
Step #22: Seal weld each cover plate installed in Step #20 using GTAW weld process.
Visually inspect all cover plate welds for cracks and porosity; repair as needed.
Step #23: Seal all 1/4" vent holes in each package half-section with RTV silicone caulking and 1/4" plasMc cap plugs. See Material Requirements, item #5.
Step #24: Sandblast alI new metal surfaces to match existing metal surfaces.
Step #25: Install new 0-ring seals (see Material Requirements item #6) of the correct length and assemble the package; inspect the seals and overall fit up.
ATTACHMENTS:
1.
Figure 1 and Figure 2.
l 2.
Figure 3 and Figure 4 i
I l
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SECTION 6.0 ATTACHMENT B ACCEPTANCE CRITERIA FOR PHENOLIC F0AM ADDITIONS TO M00lFIED W-21PF-1 SHIPPING CONTAINER
REFERENCES:
1; W Drawing No. 360F05E001, Sheets 1 through 4.
2-AEC Material and Equipment Specification No. SP9, Rev.
1, for Fire Resistant Phenoli Foam as modified by Supplements K/TL-729 (3/1/78) and K/P-6567
_(4/28/80).
MATERIAL REQUIREMENTS:
1.
Foam insulation shall be fire resistant phenolic foam (with average density of 10 i pcf) which is fabricated using materials and procedures per Reference #2.
2.
4" diameter PVC pipe, or approved equal, with one end butted, tare weighed to en accuracy of 0.1% (to be used for foam density check).
DENSITY _ ACCEPTANCE CRITERIA:
1.
Select a simple geometry pipe with butted end.
2.
Determine volume to which foam can occupy based on pipe dimensions.
3.
Tare weigh pipe to an accuracy of 0
1 1%.
4.
Pour foam in pipe.
5.
After foaming has set, gross weigh to an accuracy of 0
1 1%.
6.
Determine the net weight of foam added by gross and tare weight comparisons.
7.
Calculate ths density of the foam in the pipe based on a net foam weight and pipe volume comparison.
8.
Foam density shall meet Material Requirements #1 prior to foaming of containers.
W-21PF-1 FOAM WElGHT ACCEPTANCE CRITERIA:
1.
Based on depth of the the foam void, calculate the volume for foam addition and determine the weight to be added to each overpack.
2.
Tare weigh each section of modified W-21PF-1 overpack to an accuracy of 11%
0 prior to addition of foam.
3.
Af ter density acceptance criteria has been established, foam top and bottom of container in accordance with procedure described in Attachment A.
4.
Af ter foon has set, gross weigh each section of overpack (prior to vent plug replacement) to an accuracy of 0
1 1%
5.
Detersine net reight of foam addition to each section of gross and tare weight comparisons.
6.
Determine the deviation of measured-to-calculated foam weights.
Deviation shall be less than 10%.
i I
i I
4 4
4 i
4 __._
4 SECTION 6.0 ATTACHMENT C JUSilFICATION FOR REDUCTION OF PHENOLIC F0AM BY 0.15" ALONG A 2" STRIP DESCRIPTION:
This analysis involves a calculation requiring Fourier's equation for a plane wall for steady-state conditions.
CRITERIA:
i.
Fourier's Equation: 0 = -KA aT aL where 0 is the heat conducted into a volume element K is the heat capacity constant A is the cross-sectional area.
and AT/al is the temperature differential li.
- 4Xi, ATi, represent the full foam thickness and temperature di f ferential (aX, = 6").
iii. aX,,
AT,,
represent the reduced foam thickness and temperature differential (aX, = AXi - 0.15).
iv. Oi = 0, for steady state conditions.
CALCULATIONS:
1.
Oi = 0, 2.
-kA AT, = -kA AT, oli al, 3.
ATi= AT1 ali al, 4.
ATial, = AT,ali 5.
aX, = AX, - 0.15 6.
ATi(aX, - 0.15) = AT,aX, 7.
ATiaX, - ATi(0.15) = ATr Xi a
8.
AXi(AT, - AT,) = ATi(0.15) 9.
.aT,-AT,=
0.15 ATi AXi.
4 10.
AT, - AT, = 0.025, Fractional Temperature Increase ATi CONCLUSIONS:
Since the average temperature of the inner cylinder for the design basis fire test was about 200 F, the 2.5% increase is insignificant in terms of an actual temperature increase.
Based on this analysis, the inner UF. cylinders, within the W-21PF-1 package, will remain within the 250 F maximum permissible temperature.
I l -
.J
7.0 References 7.1 A. J. Mallet and C. E. Newlon, Protective Shipping Packages for 30-inch Diameter UF6 Cylindera, K-1686, Union Carbide Corporation, Nuclear Division, Oak Ridge Gaseous Diffusion Plant, April 13, 1967.
7.2 U.
S. Atomic Energy Commission Material and Equipment Specification SP-9, Fire Resistant Phenolic Foam, March 28,1%8.
7.3 C.E. Newton and A. J. Mallet, Hydrogen Moderation - A Primary Nuc. ear Safety Control for Handling and Transporting Low-Enrichment UF6, K-1663, Union Carbide Corporation, Nuclear Division, Oak Ridge Gaseous Diffusion Plant, May 31, 1966.
7.4 American National Standard for Packaging of Uranium Hexafluoride for Transport, ANSI N14.1 - 1982.
7Property "ANSI code" (as page type) with input value "ANSI N14.1 - 1982.</br></br>7" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process..5 W.R.
- McCauley, Safety Analysis Report for Modified UF6 Cylinder Shipping Package, D0T Specification 21P?-1, K/D-5400, Revision 3,
Martin Marietta Energy Systems, Inc., Oak Ridge, Tennessee, December 1986.
7.6 C.E. Daugherty et al, Evaluation of Materials Used in Fire - Resistant Phenolic Foam, K/TL-729, Union Carbide Corporation, Oak Ridge Gaseous Diffusion Plant, March 1, 1978.
7.7 C.R.
Barlow et al, Renovation of DOT Speci fication 21PF-1 Protective Shipping Packages, K-2057, Revision 1, Martin Mariet ta Energy Systems, Inc., Oak Ridge, Tennessee, November 21, 1986.
7.8 C.R.
Barlow and W.
D.
Urunk, Cylinder Overpack Phenolic Foam Shock
- Testing, K/P-6567, Union Carbide Corporation, Oak Ridge Gaseous Diffusion Plant, April 28, 1980.
7.9 Uranium Hexafluoride:
Handling Procedures and Container Descriptions, OR0-651, Revision 5, Oak Ridge Operations, United States Department of Energy, Oak Ridge, Tennessee, September 1987. WP1775E:3
I i
LNCONTROLED C0)Y 4
CHEMICAL OPERATING PROCEDURE UF. PAD AREA PROCEDURE NO:
COP-851004 lSSUE DATE:
4-3-87 A/
REVISION:
5 PAGE:
1 of 6 FINAL APPROVAL:
I ENGINEER APPROVAL.
SCo#b/d 7
CONTROLLED COPY:
TITLE: SHIPMENT OF UF. CYLINDERS IN PROTECTIVE OVERPAKS
1.0 PURPOSE
To specify the procedure for shipping UF. cylinders in protective overpaks.
2.0 REFERENCES
2.1 Replaces COP-851004, Rev. 4 2.2 COP-851001, "Item Control - 'UF. Pad".
2.3 COP-851012. "UF. Overpak in-Service inspection and Maintenance" 3.0 TERMS / DEFINITIONS:
3.1 ICS:
Item Control System.
4.0 RESPONSIBILITIES
4.1 Area Supervisor:
1, Assure proper labels and placards are applied per specification.
2.
Verify shipping paperwork is completed.
3.
Perform overcheck.
(To be performed by personnel not responsible for loading of trailer.)
4.2 Health Physics Personnel.
1.
Conduct cylinder release survey.
2.
Veri fy truck ineets shipping requirements.
5.0 REGULATORY REQUIREMENTS:
5.1 Safeguards
1.
Entire procedure is of Safeguards significance.
2.
UF. cylinders are item control items and must be transacted per COP-851001.
5.2 Radiation Protection and Criticality:
1.
Ensure cylinder valve covers are in place when moving and storing cy l i nde r s_.
2.
Ensure overpak meets external radiation level limits according to Form PE-114 prior to shipment.
(Maximum of 10.0 at 1 meter reading.)
3.
Assure overpack is properly labeled.
4.
Ensure overcheck is performed by personnel not responsible for loading of trailer.
(Traffic Manager or deaignee.)
0219A
&YbYYW
(*
i J
UNCONTROLLED C0)Y PROCEDURE NO:
COP-851004 CHEMICAL OPERATING PROCEDURE REVISION:
5 UF. PAD AREA PAGE:
2 of 6 ISSUE DATE:
4-3-g7 6.0 SPECIAL PRECAUTIONS:
6.1 INSPECT TRUCK TRAILER FOR DAMAGE / DEFECT BEFORE LOADING CYLINDERS.
6.2 OPERATE OVERHEAD H0IST ONLY IF TRAINED AND CARRYlNG VAllD OPERATOR'S PERMIT.
(S)
7.0 PROCEDURE
1.
IDENTIFY CAO NUMBER, PROJECT REFERENCE, SHIPMENT DESTINATION, DATE AND CARRIER ON "RADI0 ACTIVE MATERIAL UF. HEELS SHIPMENT RECORD",
FORM PE-114.
2.
IDENTIFY UF CYLINDERS WITH NET WEIGHTS EXCEEDING 25 POUNDS IN UF STORAGE PAD AREA TO BE SHIPPED BY COMPLETING CYLINDER NUMBER, WEIGHT AND LOCATION COLUMNS ON "UF. HEEL LOG" 0F FORM PE-114.
3.
ISSUE HEALTH PHYSICS WORK REQUEST FOR SURVEILLANCE OF EACH CYLINDER.
(Health Physics will~ identify exposure rates for each container on surface and at a distance of 1 meter.)
4.
IDENTIFY APPRCPRIATE LABELS, TRANSPORT INDEX AND CURIES FOR EACH CYLINDER FER FORM PE-114
~ (Minimum Transport Index for cylinder exceeding 25 pounds net UF. is 5.0.)
5.
HAVE TRAFFIC ADMINISTRATOR OR DESIGNEE PERFORM IN-SERVICE INSPECTION OF OVERPAK PER COP-851012.
6.
ENSURE TRAFFIC ADMINISTRATOR OR DESIGNEE TAKES FOLLOWING ACTIONS PRIOR TO LOADING TRUCK.
A.
VERIFY THAT ALL CYLINDERS HAVE BEEN RELEASED BY HEALTH PHve B.
INSPECT EACH CYLINDER VISUALLY FOR EXTERNAL DAMAGE.
(e.g., cracks, gouges, valve bent or distorted.)
C.
VERIFY VALVE COVERS ARE SECURED.
D.
VERIFY RADI0 ACTIVE LABELS WITH TRANSPORT INDEX AND CURIES HAVE BEEN IDENTIFIED FOR EACH CYLINDER.
E.
CHECK EXPORT SHIPMENTS FOR "FISSILE CLASS 11" DESIGNATION.
[ USA /4909/B( )F certificate must accompany shipment.]
F.
VERIFY OVERPAKS INSPECTED PER COP-851012.
- 7.. PERFORM "LOAD ' TRUCK" TRANSACTION ON ICS SYSTEM.
8.
PLACE CYLINDERS IN OVERPAKS USING OVERHEAD H0IST.
9.
ATTACH APPROPRIATE LABELS ON EACH END OF OVERPAK AS OUTLINED ON FORM PE-114.
10.
POSITION AND FASTEN TOP OVERPAK AND APPLY SEALS.
11.
PLACE PROPER PLACARDS ON SIDES AND BACK OF TRAILER. IF REQUIRED, AS INDICATED ON FORM PE-114.
12.
ENSURE CARRIER HAS SECURED ALL OVERPAK BOTTOMS IN PLACE ON TRAILE AND HAS APPLIED PROPER PLACARDS TO TRACTOR.
l
- 13. REQUEST HEALTH PHYSICS SURVEILLANCE OF LOADED TRUCK.
14.
ENSURE HEALTH PHYSICS COMPLETES FORM PE-114 INDICATING TRUCK SUR RESULTS AND PERFORM ICS "RELEASE H.P." TRANSACTION.
l
A.
INSPECT FOR OVERPAK DAMAGE.
B.
ENSURE CYLINDERS RELEASED BY HEALTH PHYSICS.
0219A
i a
LNGIROLLED COPY CHEMICAL OPERATING PROCEDURE PROCEDURE NO:
COP-851004 UF. PAD AREA REVISION:
5 ISSUE DATE:
4-3-87 PAGE:
3 of 6 (S)
7.0 PROCEDURE
(Continued)
(Continued)
C.
CHECK OVERPAK MARKINGS:
(Name plate.)
1.
W-21PF-1 2.
URANIUM HEXAFLUORIDE FISSILE UN2977 3.
USA /4909/8( )F 4.
TYPE B 5.
GROSS. WEIGHT POUNDS 6.
TARE WEIGHT POUNDS 7.
MODEL NUV8ER OR-30.
D.
ENSURE OVERPAKS PROPERLY BOLTED TO TRAILER BED.
E.
ENSURE PLACARpS. RADI0 ACTIVE AND CORR 0SIVE, ON SIDES AND REAR OF TRAILER AND FRONT OF TRACTOR, IF REQUIRED.
F.
ENSURE RADIOACTIVE AND CORROStVE LABELS, IF REQUIRED, ON OPPOSITE ENDS OF CONTAINERS WITH APPROPRIATE TRANSPORT INDEX,
-CURIES AND CONTENT IDENTIFICATION.
~
(Taped at edges.)
G.-
CHECK CONDITION OF TRAILER BED.
H.
CHECK CONDITION OF TIRES:
1.
ENSURE TRAILER TIRES MINIMUM TREAD 2/32 INCH.
2.
ENSURE FRONT TIRES MINIMUM TREAD 4/32 INCH.
l.
COMPLETE FORM PE-241. "0VERPAK SHIPMENT CHECKLIST", SIGN AND FILE WITH SHIPPING DOCUVENTS.
- 16. PERFORM !CS "SHIP TRUCK OFF-SITE" TRANSACTION.
8.0 ATTACHMENTS
8.1 Form PE-114 Rev. 1, Page 1 of 2. "Rad;oactive Material UF. Heels Shipment Record".
8.2 Form PE-114, Rev. 1, Page 2 of 2, "Radioactive Material UF.. Heels Shipment Record -- UF. Heel Log".
8.3 Form PE-241, Rev. O. "Overpak Shipment Checklist" l
1 e
0219A
o a
j, NCONTROLLED. COPY
- PROCEDURE NO:
~
CHEMICAL OPERATING PROCEDU4E COP-851004 UFe PAD AREA REVISION:
5
, _. PAGE:
4 of 6 ISSUE DATE:
4-3-87 8.1 Form PE-114, Rev. 1, Page 1 of 2. "Radioactive Material UF. Heels Shipment Record".
settingwse hFD, Colustia. S. C.
F0FW PE-114 REY. 1 RA010ACitvE IAATERIAL OF. HEELS SHIPWENT REC 0fC 02/09/87 PAGE 1 CF 2 Project Ref erence CAO seuseer fe:
Carrier.
Date:
EXTERNAL RA0f Af fC4 LEYEkj:
A. O Container Surface istEWM (200 Was)
B. 01 Wete) From Sur,f ace WEW(NR (10 Was)
C. 0 2 Weters From veM cle aftEW/HR (to taar)
O. O Cab Position tetfWM (2 tian)
..n RA0f 0AC51YE CONTAWINAfiON LEVELS F0ft C08sTA18eERS AND YEMICLE:
aipfte DPtU100 Qi' (220 Was.)
OfW100 CM' (220 Wan.)
Beta-ga m LA9f t'N0 Alc PLACAACS:
Latei Lee:
shite I if (Al is 4 0.5 Yeilow II 6f ( Al as > 0.5 but c 50 and (8) is i 1.0 Yellos lit if (A) is > 50.0 er T86 is 1.0
_ Corrosive Pigegr( bge
- CCf4IOStVE" and "RADICACTIVE* (if Radioactive Yello. - lit'f ateis applied to cylinders.)
Date Snapping Departsest Representative Date Health Physics Re9tesentative greaterthan
( isss than
> greater than er equal to i Iess than er eqsal to m2m 0219A
i s.
. CHEMICAL OPERATING PROCEDURE OCEDURE N0:
COP-851004 Ue. eAD ARe^
UNCON ROLLED C0P ev'Sio":
5 AGE:
5 of 6 ISSUE.DATE:
4-3-J7, _..
8.2 Form PE-114, Rev. 1, Page 2 of 2, "Radioactive Material UF. Heels Shipment Record -- UF. Heel Log".
RADICACflVE MATERIAL UF. HEELS SHIPutNT RECORD F0ms'PE.tta UF. HEEL LOG C $9/07 PAGE 2 0F 2 CTLINCER WElGHT Ep0SURE f orem/hr t TRAMSPORT NLM MR (LBS i LOCAtl0N
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0219A
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CHEMICAL OPERATING PROCEDURE CEDURE NO:
C00-851004 j
UNCONTROLLED C0P "GE:
's'o":
5 UF. PAD AREA A
6 of 6
' ISSUE DATE:
4-3-87 8.3 Form PE-241, Rev. O, "Overpak Shipment Checklist",
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LNCONTR0!1E) 00PX CHEMICAL OPERATING PROCEDURE UF. PAD AREA ISSUE DATE:
4-3-87 PROCEDURE N0:
COP-851012 REVISION:
0
/
PAGF*
1 of 3 FINAL APPROVAL:
/
5 C.4f h /d CONTROLLED COPY:
ENGINEER APPROVAL p
pp
/
TITLE: UF. OVERPAK IN-SERVICE INSPECTION AND MAINTENANCE
1.0 PURPOSE
To specify operational and periodic in-service inspection and maintenance requirements for UF. overpaks.
2.0 REFERENCES
2.1 This is a new procedure.
3.0 TERMS / DEFINITIONS:
3.1 Operational In-service inspections:
Inspections required prior to use.
5.2 Periodic In-service inspections:
inspections required within frequency of-2 years to ensure compliance with NRC certificate USA /4909/B( )F and Westinghouse drawing 360F05E001, 4.0 RESPONSIBILITIES:_ None.
5.0 REGULATORY REOUIREVENTS: None.
6.0 SPECIAL FRECAUTIONS: None.
7.0 PROCEDURE
1.
IDENTIFY OVERPAKS TO BE SHIPPED AS EMPTY OR LOADED WITH UF. CYLINDERS EXCEEDING 25-P00ND NET WEIGHT 2.
IDENTIFY IN-SERVICE INSPECTION TO BE DERFORMED.
(Operational o.r periodic.)
3.
HAVE TRAFFIC ADMINISTRATOR OR DESIGNEE PERFORM IN-SERVICE INSPECTIONS AS PER FORM PE-240.
(Operational in-service inspections are required on all overpaks to be loaded with UF. cylinders exceeding net weight of 25 pounds and those offered for transportation to return full cylinders to Westinghouse.)
4.
PERFORM OPERATIONAL IN-SERVICE INSPECTION AS FOLLOWS:
A.
VERIFY NO EXCESSIVE WARPING, DISTORTION OR OTHER DAMAGE OF LINER OR SHELL THAT WOULD PREVENT TIGHT CLOSURE OF OVERPAK OR ALLOW EXCESSIVC CLCADANCES FRCf! INNER CYLINDER WITHiN LINER.
B.
VERIFY THERE IS NO DAMAGE THAT WOULD REDUCE OVERPAh FASTENER STRENGTH OF CONTAINER.
(Missing threads on fasteners, cracked welds on fasten 6r-related hardware.)
0206A ggQpfd-WMh hf.'
,y i
_NCONTROJD C.0)Y.
CHEMICAL OPERATING PROCEDURE PROCEDURE NO:
COP-851012 UF. PAD AREA REVISION:
0 ISSUE DATE: 4-3-87 PACE:
2 of 3_.
7.0 PROCEDURE
-(Continued) 4 PERFORM'0PERATIONot IN-SERVICE !NSPECTION AS FOLLOWS:
(Continued)
C.
VERIFY THERE ARE N0 DENTS IN LINER OR SHELL THAT WOULO REDUCE THERMAL INSULATION THICKNESS IN ANY AREA OR OTHER#lSE MAKE INTEGRITY OF OVERPAK OUESil0NABLE AS FIRE AND SHOCK-RESISTANT HOUSING.
D.
INSPECT VISUALLY ALL WELOS TO ENSURE THEIR INTEGRITY.
(No cracks or gouges.)
E.
INSPECT FOR EVIDENCE OF IN-LEAKAGE OF WATER INTO OVERPAK.
(Moistened internal welds, water in overpak inner liner or water dricping'from overpak.)
F.
INSPECT OVERPA4 GASKET SEALS AND REPLACE IF INSPF.CTION SHOWS ANY DEFECTS SUCH AS CRACKING, SLITS OR GOUGES OR EVERY 12 MONTHS, WHICHEVER OCCURS F,lRST.
G.
INSPECT ALI. SillCONE-SEALED JOINTS (l.E., VENT HOLES) TO ENSURE THEIR INTIGRITY AGAINST WATER IN-LEAKAGE.
H.
NOTE NON CONFORMING CONDITIONS ON FORM PE-240.
5.
CONDUCT INVEdilGATION OF AMOUNT OF WATER PRESENT WHEN EVIDENCE OF IN-LEAKAGE OF WATER INTO OVERPAK IS NOTED.
A.
WEIGH OVERPAK TO ACCURACY WITHIN + 1.0 POUNOS.
B.
DISPOSITION OVERPAK FOR CONTI AJED'USE IF OVERPAK IS WITHIN +20 POUNDS OF ORIGINAL CERTIFIED (ARE WEIGHT.
(No further actions are reqsired.)
C.
DISPOSITION OVERPAK.FOR REPAlR IF BEYOND +20-POUND RANGE (Remove water pr.io't to repair by removal of vent hole plugs coupled by hea{ing,to bring over,pak to within 20-pound weight 6.
HAVE TRAFFI INISTRAT h 0 DESIGt)EE PERFORM PERIODIC IN-SERVICE INSPECTION AS FOLLOWS:
A.
PERFORM INSPECTION AND. WEIGHING DEFINF9 IN STEPS 7.0.3 AND 7.0.5.
B INSPECT VISUALLY ALL WELOS TO 3X MAGNIFICAT!ON FOR PRESENCE OF CRACKS.
(Any weld defeo4 shall be repaired in accordance with W drawing 360F05E001.')
C.
ENSURE OVERPAK IS LABELEO IN ACCORDANCE WITH W ORAWING 360F05E001.
D.
NOTE NON-CONFORMING'C0tIDITIONS ON FORM PE-2407 7.
EVALUATEANYNON-CONFORM)NGCONDITIONSFOUNDBYTRAFFICADMINISTRATOROR HIS DESIGNEE FOR CONTINUED USE, REPAIR OR CONDEMNATION OF OVERPAK.
(Overpak repairs shall be in accordance with W d awing 360F05E001.)
8.0 ATTACHMENTS
8.1 Form PE-240, Rev. O, "In-Service Inspection and Maintenance".
e 0206A
6-o LNCONTRO__D COPY 6
CHEMICAL OPERATING PROCEDURE PROCEDURE N0:
' COP-851012 REVISION:
0 UF. FAD AREA ISSUE DATE:
4-3-87 PAGE:
3 of 3 _
8.1 Form PE-240, Rev. De "In-Service inspection and Maintenance".
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