Text

Test Plan 84, Model 865 Underwater Projector
	ML20207D268
Person / Time
Site:	07106613, 07109187
Issue date:	02/28/1999
From:	Holfen G, Rarok M, Tremblay M; AEA TECHNOLOGY
To:	;
Shared Package
ML20207D229	List: ML20207D225; ML20207D268; ML20207D281;
References
	84, NUDOCS 9903090286
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d l j + TEST PLAN 84 MODEL 865 l UNDERWATER PROJECTOR February 1999 Prepared For: M. TREMBLAY AEAT/QSA Prepared By: Date G.V. HOLDEN GESL Checked By: Date M.RAROK GESL Approved By: Date l P.E. CULLUM GESL l l

rr'- AEAT/QSA Febmary 1999 Burlington, Massechusetts Page i Contents S ECTIO N 1 1 NTR O D U CTIO N................................................................................. 1 SECTION 2 TRANSPORT PACKAGE DESCRIPTION............................................ 2 S ECTION 3 REG U LATORY COMPLIANCE............................................................ 5 SECTION 4 DISCUSSIUN ON SYSTEM FAILURE MODES OF INTEREST.......... 7 4.1 General; .7 4.2 Normal and Accident Conditions of Transport.. =7 SECTION 5 ASSESSMENT OF PACKAGE CONFORMANCE.......,...................... 8 5.1 Regulatory Requirements - 8 5.1.1 Normal Conditions of Transport Tests (71.43(f)).. .. 8 5.1.2 Hypothetical Accident Conditions (71.51(a)).- 8 5.2 Test Package Contents = 8 SECTION 6 CONSTRUCTION AND CONDITION OF TEST SPECIMENS............. 9 SECTION 7 MATERIAL AND EQUIPMENT LIST.................................................10 S ECTION 8 TEST PROC E DU RE........................................................................... 11 8.1 General. .. I1 8.2 Roles and Responsibilities - 12 8.3 Test Specimen PreparaQn and Inspection.- . 13 8.4 S U MMARY OF TE ST SCH ED U LE.................................................................. 14 8.5 COMPRESSION TEST (10 CFR 71.71(C)(9)).............................................. 16 8.5.1 Compression Test Set-up _

16 8.5.2 Specimens TP84(A) and TP84(B) Orientation for Compression Test.......

17 8.5.3 Compression Test Assessment ~

18 8.6 PENETRATION TEST (10 CFR 71.71(C)(10)).............................................19 8.6.1 Penetration Test Set-up..

19 8.6.2 Orientation for Penetration Test - 20 8.6.3 Penetration Test Assessment = - 20 8.7 1.2M FREE DROP TEST (10 CFR 71.71(C)(7))........................................... 22 8.7.1 1.2m Free Drop Test Set.up z . 22 8.7.2 Specimen TP84(A) Orientation for 1.2m Free Drop Test. . 23 8.7.3 Specimen TP84(L) Orientation for 1.2m Free Drop Test.. . 24 8.7.4 1.An Drop Test Assessment __ . 25

AEAT/QSA February 1999 Burlington, Mossachusetts Page ii 1 8.8 INTERMEDIATE TEST IN SPECTION.............................................................. 25 8.9 9M (30 FOOT) FREE DROP TEST (10 CFR 71.73(C)(1))............................... 26 8.9.1 9m Free Drop Test Set-up.. ... 26 8.9.2 Specimen TP84A) Orientation for the 9m (30 foot) Drop Test. _; 27 8.9.3 Specimen TP84(B) Orientation for the 9m (30 foot) Drop Test.. . 28 i 8.9.4 9m (30 foot) Free Drop Test Assessment - . 29 8.10 PU NCTU RE TEST (10 C FR 71.73(C)(3))..................................................... 30 8.10.1 Puncture Test Set-up -- 30 8.10.2 Specimen TP84(A) Orientation for the Puncture Test.. . 31 8.10.3 Specimen TP84(B) Orientation for the Puncture Test - - 32 8.10.4 Puncture Test Assessment.-- ,33 8.11 FI N A L TE ST I N S P ECTiO N.......................................................................... 3 4 i S E CTIO N 9 WO R K S H E ETS.................................................................................. 3 5 APPENDIX A Drawing R86590 Rev. A i 1 i l I l l l

i AEAT/QSA February 1999 L Burlington, Missachusetts. Page iii List of Figures and Tables Fig. 2.1 Schematic of the Model 865 Underwater Projector Fig. 8.5.2.1 Specimens TP84(A) and TP84(B) Orientation for the Compression ) Test. l l - Fig. 8.6.2.1. Specimen TP84(B) Orientation for the Penetration Test. Fig. 8.7.2.1 Speci, men TP84(A) Orientation for the 1.2m Drop Test 1 Fig. 8.7.3.1 Specimen TP84(B) Orientation for the 1.2m Drop Test Fig. 8.9.2.1 Specimen TP84(A) Orientation for the 9m Drop Test Fig. 8.9.3.1 Specimen TP84(B) Orientation for the 9m Drop Test. Fig. 8.10.2.1 Specimen TP84(A) Orientation for the Puncture Test Fig. 8.10.3.1. Specimen TP84(B) Orientation for the Puncture Test [ l 1 ) I l

SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page1of47 AEAT/QSA Test Plan No. 84 Section 1 Introduction This document describes the mechanical test plan for the Model 865 Projector to meet NRC requirements for Type B(U) packages as described in the Code of Federal Regulations,10 CFR Part 71, revised as of January 1,1997. The test plan also covers the criteria stated in the IAEA Regulations for the Safe Transport of Radioactive Material, Sa'ety Series No.61985 Edition,(As Amended 1990). The Model 865 is currently approved for use under Certificate of Compliance 9187. This document describes the test package specification, testing equipment, testing scenario, justifies the package orientations for the different test specimens and provides test worksheets to record key steps in the testing sequence, i

SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 2 of 47 Section 2 Transport Package Description The Model 865 Projector (Figure 2.1) consists of the following major components: Nickel plated tungsten source rod and capsule holder enclosed in a depleted-i urtnium shie!d 1/8" thick stainless steel projector weldment j e Actuator cylinder e 1/8" thick stainless steel shipping cover 2 stainless steel housing supports 1/16" thick stainless steel actuator guard Stainless steel handle Stainless steel lock assembly The shield assembly consists of a 3/8" nominal outside diameter brass source tube around which is cast the depleted uranium shield. The source tube is closed at one end by a silver soldered brass end cap and sealed against water ingress at the actuator by means of a buna-N rubber 0-ring rated for operation at temperatures between -400F and +1250F. Two machined brass support rings are pressed onto the depleted uranium shield. The brass rings locate into a rabbeted stainless steel plate at each end of the shield. The plates are welded to the ends of a stainless steel cylinder and the whole forms the projector weldment. The source is manoeuvred by the pneumatically controlled actuator assembly which is fixed to the projector weldment with four 5/16"-18 x 5" long hex head stainless steel bolts. The source is made fail safe by means of a return spring should the pneumatic control system fail. The source rod is inserted into the source tube. Radial cs.:nce between the source tube and rod allows a slip fit to facilitate assembly and free movement of the source rod in operation. A locking pin secures the source rod and source within the shielding when not in use. The lock is key operated and the locking pin is manually activated. J j The source is contained in a Special Form capsule. The lock and actuator assemblies are protected by a 1/8" thick stainless steel shipping cover which is fixed to the projector weldment and actuator guard weldment with four M6 x 12mm long hex head stainless steel bolts. l

y; 4 SENTINEL Test Plan 84 AEAT/QSA - February 1999 Burlington, Massachusetts. Page 3 or47 ~ The depleted-uranium shield provides the primary radiation protection for the Model 865 underwater projector. The shield accomplishes.this by limiting the trasmission of gamma rays to a maximum dose level of 200 mR/hr at the package surface and limiting the dose level to a maximum of 10mR/hr at one meter from the surface of the package. The gross weight of the Model 865 is approximately 59 lb. 1 i i I i l i i l i 4.- l

SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 4 of 47 l Projector Weldment Handle \\ Upper Brass Support Ring I I Depleted Uraniam Shick! '/' 4-r Lower Shield Collar N \\ l _/ / SSteel Shippinit Cover x \\ - X Lowr Brass Support Ring K ll Nl /,::"El':,E 3: u,

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SENTINEL.. Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 5 of 47 Section 3 Regulatory Compliance i The purpose of this plan, which was developed in accordance with AEAT/QSA SOP-E005, is to demonstrate that the Model 865 underwater projector complies with the Type B(U) transport package test requirements of 10 CFR 71 and the IAEA Safety ) Series No.6. The tests for I ormal Conditions of Transport (10 CFR 71.71) to be performed are the compression test, penetration test and 1.2m (four foot) free drop test. The water spray preconditioning of the package is not performed as the Model 865 underwater projector is constructed of waterproof materials throughout. The water spray would not contribute to any degradation in structural integrity. The Hyl othetical Accident Tests (10 CFR 71.73) to be performed are the 9m (30 foot) free drop test and the puncture test. l The crush test (10 CFR 71.73(c)(2)) will not be performed because the radioactive j contents are qualified as Special-Form radioactive material. The thermal test of 10 CFR 71.73(c)(4) has been excluded from the series of tests following an appraisal of the package design and materials used in its production. The main components of the package and their respective melting points are listed below: Material. Melting Point. - Stainless steel 1390*C ] Depleted uranium i135 C Copper 1083 C No components apart from the O-ring seals will degrade at temperatures of 800 C, the thermal test temperature. The depleted uranium shield is surrounded by a small closed volume of air. Testing of the package under normal and hypothetical accident conditions of transport are not expected to cause a breach of this sealed containment. Subject to a damage assessment ) following the hypothetical accident conditions testing there will be no mechanism for a free supply of oxygen to reach the shield and thereby cause it to burn. During a fire test limited oxidation only will occur due to the small volume of oxygen present following assembly of the package and melting of the rubber O-rings and silver solder which seals the brass end cap onto the source tube.

~ SENTINEL Test Plan 84 AEAT/QSA Februt > 1999 Burlington, Massachusetts Page 6 of 47' The sh eld is completely encased and secured within a stainless steel weldment. Severe disruption of the weldment must occur for the shied to be displaced with relation to the source. In addition, the source capsule is held within the shield by a rod which is secured mechanically by a plunger lock and a spring located within the actuator. Both mechanisms must be removed to allow the rod to become free and the source to move out of the shield. As neither of these events are likely, as shown through experimental testing and analysis, the shield will not move relative to the source during thermal testing. In the event' that either of these catastrophic events occur during testing, the requirement for a thermal test will be re-assessed. 4 }

i l I SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 7 of 47 Section 4 Discussion on System Failure Modes of Interest 4.1 General-The tests in this plan focus on damaging those components of the package which could cause displacement of the source from its stored position within the depleted uranium shield and which affect the integrity of the shield itself 4.2 Normal and Accident Conditions of Transport The modes of failure under normal and accident conditions which could lead to elevated dose rates include the following: 4.2.1 Fracture or penetration of the projector weldment. 4.2.2 Displacement of the shield within the projector weldment and distortion or fracture of the source. 4.2.3 Simultaneous failure of the locking pin and actuator assembly. The test conditions specified in this Test Plan are intended to challenge the ability of the Model 865 package with respect to these failure modes. The orientation in Figure 8.7.2.1 is intended to challenge the shield and source through the maximum deceleration (fr.ilure mode 4.2.2) and thus maximum energy input to the shield and weldment. The orientation in Figure 8.7.3.1 is intended to challenge the shield containment (failure mode 4.2.1) by imparting snaximum energy to the edge of the weldment, inducing sufficient damage as to displace the shield or open a large enough path for oxygen ingress. Experimental data and analysis shows that the shipping and protective covers can not be displaced by the 30 foot drop. In addition, the covers deform, providing ' a relatively slow deceleration absorbing much of the energy. Therefore, this orientation was not considered critical.

SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 8 of 47 Section 5 Assessment of Package Conformance 5.1 Regulatory Requirements i 5.1.1 Normal Conditions of Transport Tests (71.43(f)) There should be no loss or dispersal of radioactive contents, no signincant increase in external surface radiation levels and no substantial reduction in the effectiveness of the packaging. 1 5.1.2 Hypothetical Accident Conditions (71.51(a)) 1 There should be no escape of radioactive materials greater than A in one week 2 and no external dose rate greater than 1 R/hr at im from the external surface with the maximum radioactive contents which the package is designed to carry. ) 5.2 Test Package Contents The Model 865 underwater projector is designed to carry a Special Form l Source. Containment of the radicactive source is tested at manufacture. The source capsule design has been certified by the US DOT in accordance with the performance requirements for Special Form as specified in 49 CFR. This test plan therefore does not discuss /specify tests of the containment of the l radioactive source. The purpose of the tests is to demonstrate that the shielding remains effective within the limits specified by the regulations. A simulated source will be used during testing of the package. The radiation levels after test will be monitored by replacing the simulated source with an active source. l i i { l

SENTINEL l Test Plan 84 I AEAT/QSA February 1999 Burlington, Massachusetts Page 9 of 47 - Section 6 Construction and Condition of Test Specimens Two test specimens built to Drawing 86590 Rev. A and the AEAT/QSA Quality Assurance Program are to be tested. They are to be designated TP84(A) and TP84(B). The weight of the test units will be a minimum of 59 lbs. i The Model 865 is constructed principally from Type 304 stainiess steel, which is not susceptible to embrittlement at low temperatures. Additionally, the effect of the j difference between 38 C and ambient, nominally 20 C, on the mechanical properties is insignificant. Therefore, the testing will be performed under ambient temperature conditions. I l \\ s t I

.. -.. = . -. ~...... h SENTINEL Test Plan 84 i AEAT/QSA February 1999 k Burlington, Massachusetts ' Page 10 or47 - k Section 7 Material and Equipment List l i The test worksheets in Section 9 list the equipment to the specification required by 10 CFR 71 and all other necessary equipment and measuring instruments needed to perform the tests. Additional materials anil equipment may be used to facilitate the tests. i l l 1 I t 1 1 l

SENTINEL Test Plen 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 11 of 47 ) Section 8 Test Procedure l l 8.1 General 1 1 Two units are to be tested in the sequence presented belc,w. Each test has been i designed to check the integrity of various : components of the package. An assessment of transport integrity of the p e.kage can be made, based on the cumulative effect of the tests performed on die package. Since these units may experience rough handling prior to transportation and 3 during normal use, the specimens will be subjected to normal conditions of transport tests in sequence with the hypothetical accident condition tests. The tests have the following sequences: Test sequence 1. (Specimen TP84(A)) Normal Conditions of Transport Tests. ) 1 1. Test specimen preparation and inspection i 2. Compression test (10 CFR 71.71(c)(9)) 3. Penetration test (10 CFR 71.71(c)(10)) 4. 1.2m (Four-foot) free drop test (10 CFR 71.71(c)(7)) l 5. First, intermediate test inspection Hypothetical Accident Conditions Tests. 5. 9m (30-foot) free drop test (10 CFR 71.73(c)(1)) 6. Puncture test (10 CFR 71.73(c)(3)) i 7. Final test inspection and evaluation for thermal test

%d. SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 12 or47 Test sequence 2. (Specimen TP84(B)) l l Normal Conditions Tests. 1. - Test specimen preperation and inspection 2. Compression test (10 CFR 71.71(c)(9))

3.

Penetration test (10 CFR 71.71(c)(10)) 4. 1.2m (Four-foot) free drop test (10 CFR 71.71(c)(7)) 5. First, intermediate test inspection Hypothetical Accident Conditions Tests. 6. 9m (30-foot) free drop test (10 CFR 71.73(c)(1)) 7. Puncture test (10 CFR 71.73(c)(3)) 8. Final test inspection and evaluation for thermal test l 8.2 - Roles and Responsibilities The responsibilities of the groups identined in this plan are: Engineering executes the tests according to the test plan and summarises the test results. Engineering also provides technical input to assist Regulatory Affairs and Quality Assurance as needed. Regulatory Affairs ' monitors the tests and reviews test reports for compliance with regulatory requirements, Quality Assurance oversees test execution and test report generation to assure compliance with the AEAT Quality Assurance Programme. Engineering, Regulatory Affairs and Quality Assurance are jointly l responsible for assessing test and specimen conditions relative to 10 CFR 71. Quality Control is responsible for measuring and recording test and specimen data throughout the test cycle, i l l .-j

SENTINEL Test Plan 84 AEAT/QSA February 1999 l Burlington, Massachusetts Page 13 or47 l 8.3 Test Specimen Preparation and Inspection Use Checklist 1: Specimen Preparation andInspection. To prepare the test units:

1. Manufacture two standard Model 865 underwater projectors. Clearly and indelibly mark the Test Specimens TP84(A) and TP84(B).

2. M6asure and record the weight of each package.

3. Inspect the test units to ensure that:

All fabrication and inspection records are documented in accordance with the AEAT Quality Assurance Program.
The test units comply with the requirements of Drawing R86590 Rev A.

4. Perform and record the radiation profile in accordance with AEAT/QSA Work Instmetion WI-Q09.

5. Engineering, Regulatory Affairs and Quality Assurance will jointly i

verify that the test specimens comply with Drawing R86590 Rev. A and the AEAT/QSA Quality Assurance Program.

6. Prepare the packages for transport in accordance with the operating manual.

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~. 1 l SENTINEL Test Plan 84 i AEAT/QSA February 1999 Burlington, Massachusetts Page 14 of 47 i i 8.4 Summary of Test Schedule Normal Conditions Para. Specimen Diagram Test Compression. 71.71(c)(9) TP84(A) I And ~ ~' TP84(B) [h ( 4 4._ ) ) ') Penetration. 71.71(c)(10) TP84(A) x And TP84(B) l w M5kj , +49 11 I n- - -+ i i t ) 1.2m Drop 1. 71.71(c)(7) TP84(A) II t J l lllL ; 1 ~l 2:s i L

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s i ) 1.2m Drop 2. 71.71(c)(7) TP84(B) / / .s j;fy4 ' / f k':/ g..e M: + 1 \\ i

7 - SENTINEL Test Plan 84 ' AEAT/QSA Febmary 1999 Burlington, Massachusetts Page 15 of 47 Accident Conditions Para. Specimen Diagram Test 9m Drop 1. 71.73(c)(1) TP84(A) Jll,l t L/ !g) -= any r } _. 3MQ ) ) 9m Drop 2. 71.73(c)(1) TP84(B) fjh e_ -= I ) Puncture 1. 71.73(c)(3) TP84(A) t J;, u I L .= i m :r Lcq x i 3i:qiiV s i ) ) Puncture 2. 71.73(c)(3) TP84(B) /- ) l i

SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 16 of 47 8.5 Compression Test (10 CFR 71.71(c)(9)) The first test carried out on both specimens is the compression test of 10 CFR 71.71(c)(9). This requires a package to be subjected, for a period of 24 hours to a compressive load applied uniformly to the top and bottom of the package j in the position in which the package would normally be transported. The comprvssive load must be the greater of the following: 1. The equivalent of 5 times the weight of the package = 5x59 lbs. = 295 lbs.; or II. The equivalent of 13kPa (2 lbf/in2) multiplied by the vertically projected area of the package = (5x12.25)x2 = 122. 51b. Use Checklist 2: Compression Test to ensure that the test sequence is followed. Date and initial all action items and record required data. NOTE: The worksheets identify steps which must be witnessed by Engineering, Regulatory Afairs and Quality Assurance. 8.5.1 Compression Test Set-up This test requires that the compressive load is applied to the package in the position in which the package would normally be transported. To facilitate application of a compressive load, the two specimens are to be placed side by side with a suitable platform placed on top of their handles. As the compressive load will be shared between the two specimens it needs to be increased by a factor of two. This will ensure that each specimen is subjected to the load required in 10 CFR 71.71(c)(9). NOTE: Because each test is designed to add to damage inflected on a specific component or assembly in the proceeding test, it is important that each specimen maintain its identity throughout the battery of tests and that the set-up instructions specific to the specimen are strictlyfollowed To prepare a specimen for the compression test: 1. Position specimens according to the orientation described below. I I

SENTINEL Test Plan 84 AEAT/QSA ' February 1999 Burlington, Massachusetts Page 17 of 47 l 2. Record the overall dimensions of the packages pre-test.

3. Position the load platform onto the specimens and apply the test load of the equivalent of at least five times the mass of both projectors combined projector (greater than 590 lbs).

4. Record applied load and photograph the test set-up.

5. Re* cord the overall dimensions of the packages post test.

6. After 24 hours remove the load.

Record the damage and take a photagraphic record. 8.5.2 ' Specimens TP84(A) and TP84(B) Orientation for Compression Test No specific ' orientation of the package for transportation is recommended. Therefore, after examination of the package shape and method of carrying, the following orientation is considered representative of a probable transportation position. I f Specimens TP84(A) and TP84(B) are placed side by side on their housi.ig supports so that their handles are at the top. A support platform is placed across the handles, the load being applied on top of this frame (figure 8.5.2.1). l t l W" l u i i V V %g 'N k [ A==bf [fq Q A=>; h q[W

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\\ L.>' ]p l \\ CVl /% f /%f 5 \\ 's 4( b ( e Figure 8.5.2.1: Specimens TP84(A) and TP84(B) Orientation for the Compression Test i

3 SENTINEL Test Plin 84

AEAT/QSA

' February 1999 Burlington, Massachusetts Page 18 of 47 i i. L [ 8.5.3 Compression Test Assessment Upon completion of the test, Engineering, Regulatory Amirs and Quality Assurance team members willjointly take the following actions: Review the test execution to ensure that the test was performed in accordance with 10 CFR 71. Make a preliminary evaluation of each specimen relative to the requirements of 10 CFR 71.

Assess the damage to each specimen to decide whether testing is to continue.

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i SENTINEL Test Plan 84 AEAT/QSA. I February 1999 Burlington, Massachusetts Page 19 of 47 l 8.6 Penetration Test (10 CFR 71.71(c)(10)) The second test carried out on specimens TP84(A) and TP84(B) is the penetration test as described in 10 CFR 71.71(c)(10), in which a penetration bar is dropped from a height of im (40") to impact a specified point on the package. The bar is dropped through free air through a guide tube. Use C,hecklist 3 Penetration Test to ensure that the test sequence is followed. Date and initial all action items and record required data. i NOTE: The worksheets identify steps which must be witnessed by Engineering, Regulatory Afairs and Quality Assurance. ) l 8.6.1 Penetration Test Set-up There is a specific orientation for the specimen so that the penetration bar is aimed at the component or assembly ofinterest. NOTE: Because each test is designed to add to damage inflicted on a specific component or assembly in the proceeding test, it is important that each specimen maintain its identity throughout the battery of tests and that the set-up instructions specific to the specimen are strictlyfollowed. To prepare a specimen for the penetration test:

1. Place the specimen on the drop surface and position it according to the specimen-specific orientation described below.

2. Position the guide tube directly above the specified point of impact, and raise the penetration bar im (40") above the target. Photograph the test set-up.

3. Measure and record the ambient temperature.

4. Start the video recorder.

5. Drop the test bar. Record damage and take photographic record.

L l

s SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts. Page 20 or47 1 8.6.2 Orientation for Penetration Test - The penetration target is the beam port in the projector weldment. Penetration of the projector weldment might increase the external dose rate above regulatory limits. The specimen is placed on its handle and supported in this position so that t'. beam port faces upwards as shown. The guide tube and penetration bar are arrang,ed such that the impact point is above the beam port (figure 8.6.2.1). - c. Guide Tube Penetration Bar l \\ Impact Pc mt: Beam Port wk-) _ i r.diliiiiiiiii: a k l!!!!!!!!!!!!!!!!!![ A T-

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~~~ V 1B !'!!!!!!!!!!!!!!:!!!!!!!!!!I** _ _ p' Mjii,iiiiii,iii:' = ) l I 5 \\ ~ c ^ s Figure 8.6.2.1: Orientation for the Penetration Test t 8.6.3 Penetration Test Assessment t l l-Upon completion of the test, Engineering, Regulatory Affairs and Quality Assuranee team members willjointly take the following actions: l l

l . SENTINEL Test Plan 84 - AEAT/QSA February 1999 Burlington, Massachusetts ~ Page 21 of 47 Review the test execution 'to ensure that $- test was performed ir accordance with 10 CFR 71. Make a preliminary evaluation of the specimen relative to the requirements - of10 CFR 71. Assess the damage to the specimen to decide whether testing of that specimen is to continue. Eviluate the condition of the specimen to determine what changes, if any, are necessary in package orientation for the 1.2 meter (4-foot) drop to achieve maximum damage. 4 t-

SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 22 or47 8.7 1.2m Free Drop Test (10 CFR 71.71(c)(7)) l The next Normal Transport Conditions test is the 1.2m (4 foot) drop test as described in 10 CFR 71.71(c)(7). This drop compounds any damage caused by the compression test for both specimens and the penetration test. Use Checklist 4: 1.2m (4 foot) Drop Test to ensure that the test sequence is followed. Date and initial all action items and record required data on the worksheet. I I NOTE: The worksheet identipes those steps which must be witnessed by Engineering, Regulatory Afairs and Quality Assurance. 8.7.1 1.2m Free Drop Test Set-up In this test, the package is released from a height of 1.2m (4 foot) and lands on the steel drop surface. There is a specific orientation for the specimen so that the package lands on the component or assembly ofinterest. l NOTE: Because each test is designed to add to damage inflicted on a specific component or assembly in the preceding test, it is important that each specimen maintains its identity throughout the battery oftests and that the set-up instructions specific to the specimen are strictlyfollowed. l To set up a package for the 1.2m (4 foot) drop test:

1. Place the specimen on the drop surface and position it according to the specimen-specific orientation described below.

2. The lifting mechanism / system shall be arranged such that the center of gravity for each package is as shown in either Figure 8.7.2.1 or Figure 8.7.3.1. (Unless orientation is changed by assessment)

3. Measure and record the ambient temperature.

4. Raise the package so that the impact target is 1.2m (4.0 feet) above the

' drop surface. Ensure center of gravity is over impact point.

5. Photograph the set-up.

SENTINEL Test Plan 84 AEAT/QSA. February 1999 Burlington, Massacho.-us Page 23 or47

6.. Start the video recorder.

. 7., Drop the package. Record the damage to the package and take a photographic record. 8.7.2 Specimen TP84(A) Orientation for 1.2m Free Dror Test The 1.2m (4 foot) drop te>t set-up for Specimen TP84(A) is shown in Figure 8.7.2.1. The object of the drop is to cause deformation of the shield and apply stress to the lower shield collar and its retaining welds. The specimen will be dropped in an axial direction onto its lower end. It is important to position test specimen TP84(A) so that its centre of gravity is directly above the impact point. t c-- b 45 d Gi pt$5 - $j th pr 3 caro + gli i e) (( jjjn. Lo**r ShieltGo_Dar Mh jl F k oro, s.r. 4 N, u 4 e <1 ( Figure 8.7.2.1: Specimen TP84(A) Orientation for the 1.2m (4 foot) Drop Test t.....

..m. ' SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 24 of47 8.7.3 Specimen TP84(B) Orientation for 1.2m Free Drop Test The projector weldment will strike the drop surface on.its lower edge. The object here is to cause local crushing and crumpling to the projector weldment exerting forces on the lower shield collar and supponing weld to the projector ' hcusing. It is irnportant to ensure that the impact point is on the edge of the projector w eldment rather than the edges of the weldment supports. ' As its lower edge makes contact with the drop surface the weldment will deform. Should this result in permanent deformation of the lower shield collar, c:isplacement of the shield may occur, with subsequent damege or distonion of the source rod. A l o CofG / 7 / wx ~ / ) i

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' !~. Weldment Supports i -: :::;,: s, ~ } h nmp surrx. E E .) \\N u y 5 \\ \\ } <d d ( Figure 8.7.3.1: Specimen TP84(B) Orientation for the 1.2m (4 foot) Free Drop Test

e l SENTINEL Test Plan 84 i AEAT/QSA l'ebruary 1999 Burlington, Massachusetts I l Page 25 or47 8.7.4 1.2m Drop Test Assessment Upon completion of the test, Engineering, Regulatory Affairs and Quality Assurance team members willjointly take the following actions: Review the test execution to ensure that the test was performed in accordance with 10 CFR 71. Ass'ess the damage to the specimen. Evaluate the condition of the specimens to determine whether the testing is to proceed further. 8.8 Intermediate Test inspection An intermediate test inspection after the 1.2m (4 foot) drop tests will be i performed on each specimen.

1. Measure and record any damage to each test specimen.

i Engineering, Regulatory Affairs and Quality Assurance team members will { make an assessment of the test specimen and jointly determine whether the l specimen meets the requirements of 10 CFR 71.71 set out in section 5, para. { S.1.1. l l l l l j

i SENTIN'iL Test Plan 84 AEAT/QSA February 1999 l Burlington, Massachusetts Page 26 of 47 8.9 9m (30 foot) Free Drop Test (10 CFR 71.73(c)(1)) l-The first Hypothetical Accident Test is the 9m (30 foot) free drop test as described in 10 CFR 71.73(c)(1). I Use Checklist 5: 9m Drop Test to ensure that the test sequence is followed. Date and initial all action items, and record required data on the worksheet. I NOTE: The worksheet identifies those steps which must be witnessed by Engineering, Regulatory Afairs and Quality Assurance. Figure 8.9.2.1 and Figure 8.9.3.1 illustrate the anticipated orientations for the two test units. 8.9.1 9m Free Drop Test Set-up To set up a package for the 9m (30-foot) drop test:

1. Measure and record the weight of each of the two test specimens.

2. Place each specimen on the drop surface and position it according to the specimen-specific orientation described below.

3. The lifting mechanism / system shall be ananged such that the centre of gravity is as shown in Figure 8.9.2.1 or Figure 8.9.3.1.

4. Raise the package so that the impact target is 9m (30 feet) above the drop surface. Ensure center of gravity is over impact point.

5. Measure and record the ambient temperature.

6. Photograph the set-up. 7. Start the video recorder.

8. Drop the package.

9. Record the damage to the package and take a photographic record.

~ ..~ SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 27 or47 8.9.2 Specimen TP84(A) Orientation for the 9m (30 foot) Drop. Test Figure 8.9.2.1 shows the package orientation for Specimen TP84(A). He object of the drop is to cause deformation of the shield and apply stress to the lower shield collar and its retaining welds, ne intention is also to test the integrity of the depleted uranium shield itself to see if fracture occurs. l The sp'ecimen will be dropped in an axial direction onto its lower end. It is

important to positior, test specimen TP84(A) so that its centre of gravity is directly above the impact point.

t a i 4 l I -u f!n g @ {j,a th 'M 7 C of G ND ../ / 4 I (( Of ' f';h.. (H Lower Shield Coltu ,/ 's b pd" ]b:'7y h E oro, sur=. U A i ~ s \\ \\ \\ h 4 ( 1 Figure 8.9.2.1: Specimen TP84(A) Orientation for the 9m (30 foot) Drop Test l l l

l l SENTINEL Test Plan 84 AEAT/QSA February 1999 j Burlington, Massachusetts - Page 28 of 47 l I 1 8.9.3 Specimen TP84(B) Orientation for the 9m (30 foot) Drop Test Figure 8.9.3.1 shows the package orientation for Specimen TP84(B). The object of this drop is to test the integrity of the housing supports and to determine the effect of the drop on the depleted uranium shield. i The specimen will be dropped with its axis parallel to the drop surface onto the housing supports so that the beam port faces down. l l l l i i p i ) E-.._ .v2 1 l ,.:!His j - Q, j ',rr: ! h

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~_ $.:N.::$:h!"Ib'[!![ Y j R !?.!! !F ]\\ l -( y:.L: / I / coro 5 Drop Surface N i 1 5 \\ 4 L i l Figure 8.9.3.1: Specimen TP84(B) Orientation for th t 9m (30 foot) Drop Test l l l l

l SENTINEL Test Plan 84 AEAT/QSA Februarv 1999 j Burlington, Massachusetts Page 29 of 47 i l 8.9.4 9m (30 foot) Free Drop Test Assessment Upon completion of each test, Engineering, Regulatory Affairs and Quality ) Assurance team members willjointly take the following actions: i l Review the test execution to ensure that each test was pei ormed in 1 e aceo, rdance with 10 CFR 71.73. Make a preliminary evaluation of the specimens relative to the requirements of 10 CFR 71. Assess the damage to each specimen to decide whether testing of that e specimen is to continue. i Evaluate the condition of each specimen to determine what changes, if any, e are necessary in package orientation in the puncture test to achieve ) maximum damage. 4 I I I l \\ r 1 i

) j SENTINEL - Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts Page 30 of 47 8.10 Puncture Test (10 CFR 71.73(c)(3)) The 9m free drop test is followed by the puncture test of 10 CFR 71.73(c)(3), in which a package is dropped from a height of im (40") onto the puncture billet. The billet is to be bolted to the drop surface used in the drop tests. Use Checklist 6: Puncture Test to ensure that the test sequence is followed. Date and initial all action items and record required data on the worksheet. 1 NOTE: The worksheet identifies those steps which must be witnessed by Engineering. Regulatory Afairs and Quality Assurance. 8.10.1 Puncture Test Set-up There is a specific orientation for each specimen so that the package lands on the component or assembly of interest. NOTE: Because each test is designed to add to damage inflicted on a specific component or assembly in the preceding test, it is important that each \\ specimen maintain its identity throughout the battery oftests and that j the set-up instructions specific to the specimen are strictlyfollowed. This test uses the 12" high puncture billet. The billet meets the minimum j height (8") required in 10 CFR 71.73(c)(3). The specimen has no projections or ) overhanging members longer than 12" which could act as impact absorbers, 1 thus allowing the billet to cause the maximum damage to the specimen. l To set up a package for the puncture test:

1. Measure and record the ambient temperature.

i l

2. Position the test package according to the specimen-specific orientation shown in figures 8.10.2.1 and 8.10.3.1.

3. Check the alignment of the center of gravity with the targeted point of impact.

1 d l' L ',

.. ~. - - . - ~. SENTINEL Test Plan 84 AEAT/QSA February 1999 Burlington, Massachusetts - Page 31 of 47

4. Raise the package so that there is Im (40") between the impact point on the package and the top of the puncture billet.

5. Photograph the set-up.

6. Start the video recorder.

7.' Drop the package. I

8. Record the damage to the package and take a photographic record.

Figures 8.10.2.1 and 8.10.3.1 illustrate the puncture test package orientation for Specimens TP84(A) and TP84(B), respectively. The justification for each orientation is the same as the orientation for the specimen's drop test. 8.10.2 Specimen TP84(A) Orientation for the Puncture Test The objective of this drop orientation (Figure 8.10.2.1) is to continue the damage inflicted on the specimen by the 9m drop test. y:g, l t t "Qh } I i i .. Q { 5 i E s s s i I s ( ( ) t s., l Figure 8.10.2.1: Specimen TP84(A) Orientation for the Puncture Test i f I' I

.. -. - -. -.....-.~ - -- SENTINEL - Test Plan 84 ' AEAT/QSA February 1999 Burlington, Massachusetts P Page 32 of 47 l l l 1 8.10.3 Specimen TP84(B) Orientation for the Puncture Test The objective of this drop orientation (Figure 8.10.3.1) is to fracture the shield l l Cover. j i l l l 1 L '.l / C ofG i ,/ ,qh. s c/ / h I n E i Jf l u i l. @n_s.e Elist i I l i-i i 4 e

4 l

4 Figure 8.10.3.1: Specimen TP84(B) Orientation for the Fr.acture Test l

~ SENTINEL Test Plan 84 - i AEAT/QSA February 1999 Burlington, Massachusetts Page 33 of 47 1 I 8.10.4 Puncture Test Assessment Upon completion of the test, Engineering, Regulatory Affairs and Quality Assurance team members willjointly take the following actions: ) Review the test execution to ensure that the tests was performed in e accordance with 10 CFR 71.73. Make a preliminary evaluation of each specimen relative to the requirements of10 CFR 71. Make a assessment to verify whether a thennal test need to be performed. l l-i r

SENTINEL Test Plan 84 . AEAT/QSA February 1999 Burlington, Massachusetts Page 34 or47 8.11 Final Test inspection Perform the final test inspection after the puncture tests 1. Measure and record the damage to each of the test specimens. 2. Remove and assess the condition of the simulated source. Re' assemble the packages using a representative active source, making sure 3. that the source rod position and the package configuration are the same as they were immediately after the puncture test.

4. Measure and record a radiation profile of each test specimen in accordance with AEAT/QSA Work Instruction WI-Q08.

5. Assess the significance of any change in radiation at the surface and at one meter from the packages.

6. Determine whether it is necessary to dismantle either of the test specimens for inspection of hidden component damage or failure.

7. If the decision is taken to proceed with the inspection, record and photograph the process of removing any component. 8. Measure and record any damage or failure found in the process of dismantling the test specimens. Engineering, Regulatory Affairs, and Quality Assurance team members will make a final assessment of each test specimen and jointly determine whether the specimen meets the requirements of 10 CFR 71. j i f J \\

L AEAT/QSA Fcbruary 1999 Burlington, Massachusetts Page 35 or47 l l Section 9 Worksheets L Use the following worksheets for executing the tests of section 8. There are two worksheets for each test, an equipment list and a test procedure checklist. l 1 l Use the test equipment list to record the model number and serial number of each j measurement device used. Attach a copy of the relevant inspection report or calibration certificate 'after the range and accuracy of the equipment has been verified. Quality Control will initial each step on the check list as it is executed and record i data as required. The Engineering, Regulatory Affairs and Quality Assurance representatives must witness all testing to ensure that it is performed in accordance with this test plan and 10 CFR 71. l l l \\ l 1 l-

AEAT/QSA February 1999 Burlington, Massachusetts Page 36 or47 Checklist 1: Specimen Preparation andInspection Step TP84(A) TP84(B) 1. Total package weight (ib.). 2. Are all fabrication and inspection records ' documented in accordance with the AEAT Q.A. Programme? 3. Does the test unit comply with the requirements of Drawing R86590 Rev. A. 4. Has the radiation profile been recorded in accordance with AEAT/QSA Work Instruments WI-Q097 5. Is the package prepared for transport? Steps I through 5 witnessed and verified by: Print Name Signature Date Engin'eering: Regulatory Affairs: Q.A.: I L l l L

g; AEAT/QSA February 1999 Burlington, Massachusetts Page 37 of 47 i t Equipuent List 1: Compression Test Equipment Description Enter the Model and Attach Inspection 1 Serial Number ' Report or Calibration Certificate Compression Test Loading Plate. i Test Weights. Test Surface. Record any additional tools used to facilitate the test and attach the appropriate inspection report or calibration certificate i 1 Print Name Date Completed by: Verified by: l' l

AEAT/QSA February 1999 j Burlington, Massachusetts Page 38 of 47 Checklist 2: Compression Test Test Location: Step Specimen TP84(A) Specimen TP84(B) 1. Position the specimens as shown in the referenced Figure 8.5.2.1 figure. 2. Record the ambient temperature: 3. Record applied load. 4. Note the instrument used for the temperature measurement:

5. Measure and record each specimens overall dimensions pre-test.

6. Place the weights onto the loading platform and leave for 24 hours.

7. Measure and record each specimens overall dimensions post-test.

8. Record damage to the test specimen on a separate sheet and attach. { Test Witnessed by: Signature: Print Name Date Engineering: j Regulatory Affairs: Quality Assurance: i l I t

b j l AEAT/QSA Februsy 1999 i Burlington, Massachusetts Page 39 of 47 i l I i Equipment List 2: Penetration Test Equipment i Description Enter the Model and Attach Inspection j Serial Number Report or Calibration Certificate Penetration Bar. i Drop Strface. Record any additional tools used to facilitate the test and attach the appropriate inspection report or calibration certificate i i Signature Print Name Date Completed by: Checked by: l l

j - AEAT/QSA February 1999 i Burlington, Massachusetts Page 40 of 47 I.- i l l' Checklist 3: Penetration Test Test Location: i Step. Specimen TP84(B) Specimen TP84(B) 1' l. Position the specimen as shown in the referenced figure. Figure 8.6.2.1 Figure 8.6.2.1 2. Inspect the orientation set-up and verify the bar height. l 3. Record the ambient temperature. l 4. Note the instrument used for the temperature ) measurerrent: S. Start the video recorder. 6. Release the penetration bar. Check to ensure that the penetration bar hit the specified area. i 7. Record damage to the test specimen on a separate sheet and attach. 8. Engineering, Regulatory Affairs and Quality Assurance make preliminary assessment relative to 10 CFR 71. Record the assessment on a separate sheet and attach. Determine what changes, if any, are necessary in package orientation for the 1.2m drop test to achieve maximum damage. Test witnessed by: Signature: Print Name I Engineering-J Regulatory Affairs: Quality Assurance: s a

.~ l AEAT/QSA February 1999 Burlington, Massachusetts Page 41 of 47 Equipuent List 3: 1.2m (4 foot) Drop Equipment List Description Enter the Model and Attach Inspection Serial Number Report or Calibration Drop Surface. Record and additional tools used to facilitate the test and attach the appropriate inspection report or calibration - certificate i ) 1 I i I Signature Print Name Date t Completed by: Verified by: 1 i

r AEAT/QSA February 1999 t Burlington, Massachusetts Page 42 of 47 i l Checklist 4: 1.2m (4 foot) Free Drop Test Location Step Specimen TP84(A) Specimen TP84(B) 1. Measure and record the ambient temperature ( C). 2. Note the instrument used: 3. Attach the test specimen to the release mechanism. 4. Lift and orientate the test specimen as shown in the Figure 8.7.2.1 Figure 8.7.3.1 referenced figure for the specimen. 5. Inspect the orientation set-up and verify the drop height. 6. Photograph the set-up in at least two perpendicular planes. 7. Begin video recording of the test so that impact is recorded. 8. Release the test specimen. 9. Record the damage to the test specimen on a separate sheet and attach.

10. Engineering, Regulatory Affairs and Quality Assurance make a preliminary assessment relative to 10 CFR

71. Record the assessment on a separate sheet and attach. Determine what changes, if any, are necessary in package orientation for the 30-foot free drop test to achieve maximum damage.

Test witnessed by: Signature Print Name Date Engineering: Regulatory AtTairs: Quality Assurance: i l l I i

AEAT/QSA February 1999 Burlington, Massachusetts Pcge 43 or47 ) Equipuent List 4: 9m (30 foot) Drop Equipment List Description Enter the Model and Attach inspection SerialNumber Report or Calibration Certificate Drop Surface. Thermometer Record any additional tools used to facilitate the test and attach the appropriate inspection report or calibration certificate i i Signature Print Name Date 1 Completed by: Verified by: ) i I l l i l l l l

AEAT/QSA February 1999 Burlington, Massachusetts Page 44 of 47 Checklist 5: 9m (30 foot) Drop Test Location: Step Specimen TP84(A) Specimen TP84(B) 1. Measure and record the ambient temperature. ('C) Note the instrument used: i 2. Attach the test specimen to the release mechanism. i 3. Lift and orientate the test specimen as shown in the Figure 8.9.2.1 Figure 8.9.3.1 referenced figure for the specimen. 4. Inspect the orientation set-up and verify the drop height. 5. Photograph the set-up in at least two perpendicular planes. t l 6. Begin video recording of the test so that impact is recorded. 7. Release the test specimen 8. Pause the video recorder. Ensure that the point ofimpact and the orientation specified in the plan have been achieved and recorded. 'i 9. Record the damage to the test specimen on a separate sheet and attach.

10. Engineering, Regulatory Affairs and Quality Assurmee make a preliminary assessment relative to 10CFR l

71. Record the assessment on a separate sheet and attach. Determine what changes, if any, are necessary in package orientation for the puncture test to achieve maximum damage.

i Test witnessed by (Signature) Print Name Date Engineering: ) I Regulatory Affairs: Quality Assurance: i i l

AEAT/QSA . February 1999 Burlington, Massachusetts Page 45 of 47 1 i Equipment List 5: Puncture Test Equipment b Description Enter the Model and Attach Inspection Serial Number Report or Calibration Certificate Drop Surface. Puncture Billet. j Thermometer i l Record any additional tools used to facilitate the test and attach the appropriate inspection report or calibration certificate Signature Print Name Date 1 Completed by: i Verified by: l i s }

AEAT/QSA February 1999 Burlington, Massachusetts Page 46 of 47 l \\ ~ Checklist 6: Puncture Test Test Location: Step Specimen 84(A) Specimen 84(B) 1. Measure and record the ambient temperature ('C). Note the instrument used: 2. Attach the test specimen to the release mechanism 3. Lift and orientate the test specimen as shown in the Figure 8.10.2.1 Figure 8.10.3.1 referenced figure for the specimen. 4. Inspect the orientation set-up and verify the drop height. 1 5. Photograph the set-up in at least two perpendicular planes. 6. Begin video recording of test so that the impact is recorded. 7. Release the test specimen. 8. Pause the video recorder. Ensure that the point of impact and orientation specified in the plan have been achieved and recorded. 9. Record damage to test specimen on a separate sheet and attach.

10. Engineering, Regulatory Affairs and Quality Assurance make a preliminary assessment relative to 10 CFR

71. Record the assessment on a separate sheet and attach.

Test witnessed by: Signature - Print Name Date Engineering: Regulatory Affairs: Quality Assurance:

...~ -. ~....._... .' AEAT/QSA Ftbruary 1999 Burlington, Massachusetts Test Plan 84 Data Sheet ( Test Unit Model/ Serial No.: Specimen /Fest: Test Date: l Test Time: Test Plan Step No.: Describe drop orientation and drop height: l Describe impact (location, rotation, etc.): Describe on-site inspection (damage, broken parts, etc.): On-site assessment: Engineering: Regulatory: QA: Describe any post-test disassembly and inspection: Describe any change in source position: Describe results of radiography: l. Completed by: l Date:

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