ML20236Q935

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Suppl 1,Rev 2 to SAR for Packaging (Oak Ridge Y-12 Plant Model DT-14A Package for Enriched U.)
ML20236Q935
Person / Time
Site: 07109860
Issue date: 07/17/1987
From: Cadelli G, William Kennedy
E.I. DU PONT DE NEMOURS & CO., INC.
To:
Shared Package
ML20236Q843 List:
References
DPSPU-85-124-3, DPSPU-85-124-3-S1-R2, NUDOCS 8711200368
Download: ML20236Q935 (36)
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{{#Wiki_filter:DPSPU 85-124 3 Rev 2 - 7/87 g n SAFETY ANA[YSIS REPO.RT FOR PAC (AGING (Oa cRic ge Y-12 P ant. Moc el' DT-1L^L Pac < age For Enriclec Uranium) .Y/DD-326 Suaalement No.1 (Rev.4 G. CADELLI W. R. KENNEDY, JR. a s (P0D E.1. du Pont de Nemours & Company Savannah River Plant i .(' 1 July 17,1987 8711200368 871103 PDR ADOCK 0710} O PREPARED FOR THE U.S. DEPARTMENT OF ENERGY UNDER CONTRACT DE.AC09 76SR00001 d

DPSPU-85-124-3 REV 2, 7/87 r t SAFETY ANALYSIS REPORT'FOR PACKAGING .(OAK RIDGE.Y-12 PLANT.MODEL DT-14A PACKAGE FOR ENRICHED URANIUM). j Y/DD-326 j SUPPLEMENT'NO..1 (REV. 2) JULY 17, 1987 I l l l G. CADELLI W. R. KENNEDY, JR. -{ E. I. du PONT de NEMOURS AND'CO., INC. ] SAVANNAH RIVER PLANT 1 AIKEN, SOUTH CAROLINA 29808 l l 1 I PREPARED FOR THE U.S. DEPARTMENT OF ENERGY UNDER CONTRACT DE-AC09-76SR00001 9 l .i i I 1

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~.. CONTENTS PAGE 1.0 General Information....................................... 3 2.0 Structural Evaluation.......................'.............. 4 i 1 3 '. 0 Thermal Evaluation........................................'. 8' 4.0 ' Containment................................................ 9 j i 5.0 Shielding Evaluation...................'................... 10, 6.0 Criticality Evaluation.................................... 11 l 1 -7. 0 Operating Procedures .....................c................ 12 j i 8.0 Acceptance Tests and Maintenance Program.................. 14 9.0 Quality Assurance ...........................................17 h l 1 i l a 9 2 l s ^ ________m.i.________.__

i 1.0 GENERAL INFORMATION 1.1 Introduction J This Supplement to the Safety Analysis-.Keport Y/DD-326 [1.4.1] was '~ prepared in accordance with U.S. NRC Regulatory Guide.7.9.to address ] the Naval Fuel contents to be shipped in the DT-14A packaging..New chapters were written for Structural,cShielding, criticality and. Quality Assurance. Independent reviews. ware obtained for each'of-these chapters and.for a product leakage analysis. referenced in Chapter 4.0 of this document. Other chapters invoke.the Y/DD-326: SARP with minor changes or additions as indicated in1the Supplement. All references.to form or composition of.the fuel are' classified Confidential,.RIN 'NNPI in the interest of national security. 1.2 Package Description-j l The overpack and inner containment vessel are described on pages 7, 11 and 12 of reference 1.4.1. j l 1.3 Contents of Packaging- ] The DT-14A package will be used to ship a maximum of 9 kg:of U235 in f the form described in references 1.4.2 and'l.4.3.- The: uranium may-be enriched to any degree in the U235 isotope. Maximum quantities:' 9kg of U235; 0.05w/o U233; 2.0w/o.U234 and 0.05W/o U236 The maximum curie content will be 1.6 curies. A' maximum of.five; screw-top metal cans with a. nominal wall thickness'of 0.030 inch will be placed in the inner containment vessel and cushioned with celotex or other materials approved by the SARP. The fuel will be handled and shipped according to the requirements for metals and l alloys listed in Table 1, page 7 of reference 1.4.1, and will comply with the product leakage analysis referencedLin Chapter =4.0.of this-document. All other conditions of the certificate cf-Compliance and the DT-14A.SARP (Y/DD-326) will be met. q i 1.4 References 1.4.1 Safety Analysis Report for Packaging-(Oak Ridge'Y-12 Plant Model DT-14A Package for Enriched Uranium), j Y/DD-326. 1.4.2 Naval Fuel Packaging Data, NSS-2110, Classified. j Confidential, RD, NNPI. 1.4.3 Naval Fuel Packaging Data,.NSS-2110, Revision 1, l Classified Confidential, RD, NNPI. i i 1 -l

2.0' STRUCTURAL EVALUATION, 2.1 Summary D3 sign, tests, standards and analyses'are in Y/DD-326,'pages 11-18' ~ Since-the DT-14A SARP; references,-(under' normal condition of transport),. a reduced external;pressurelof 0.5 times standard atmosphereLpressure, the,followi'ng calculations will address the 10CFR 71.71c(3) requirement, of a reduced external pressure of 3.5: psia.' .An. independent review ~(2.2.1) verified the calculations. The internal pressure of the containment vessel is assumedLto~be. . atmospheric at-ambient temperature.of 750F. At 1000F the' internal pressure is. ,l 1 P oo4.-P75_T100 = 14.7-(560) ='15.4 psia. l l ~T75 535 3 A)- Using Ref. 2.2.4 (UG-27 for cylindrical shell)' l. The minimum thickness. of cylindrical shell' due tct circumferential' l stress is: t= PR ]j SE-0.6P where: S = maximum' allowable stress value, psi'(from UCS-23, for SA-36 (Ref. 2.2.4)) = 12,700 psi j E = joint efficiency (UW-12) = 0.70 t = minimum required thickness, inches P = design pressure, psi = (15.4. '3.5) = ll.9 psi R = inside radius of shall: = 3.25 in. thereforei t= PR . 11. 9 : (3.25) =.005 in." 1 SE-0.6F 12.7x10J(.70)-0.6(ll.9) ] (actual thickness is 0.25") (item 4A,'Ref. 2.2.5)- l b i l I 4

2. The minimum thicknoce:of cylindrical.chs11 duo to. longitudinal stress is: t= PR 11.9 (3.25) =.003 in. 2SE+0.4P 2 (12. 7 x10J ) (. 70 ) +0. 4 (11. 9 ) B) Using Ref. 2.2.4 (UG-34, Unstayed flat heads and covers) l. The minimum ~ required thickness of' flat unstayed circular bottom. plate of containment vessel (item 4B, ref. 2.2.5) is: t = d /CP/SE where: t = minimum required thickness'of bottom flat plate. d = diameter = 6.5 in. c = factor of attachment (from Ref. 2'.2.4 Figure UG-34, sketch [f)' c =.33 m where m = tr =.004 =.016; therefore, use C = 0.20 ts .25 P = design pressure = 11.9 psi S = maximum allowable stress value = 12,700 psi E = joint efficiency'(from Table UW-12) =.80 therefore, t = 6.5 / (. 2 0) (11.9)/12,700 (.80). =.10 inch (actual thickness is 0.375 inch I 2. The minimum required thickness of flat unstayed circular cover of containment vessel (item 4E, ref. 2.2.5) is: from UG-34 3 t = d /CP/SE + 1.9 Whg/ sed where: t = minimum required thickness of cover, in, d = diameter = 7.654 in. C = attachment factor (Fig. UG-34 k) = 0.3 P = design pressure = 11.9 psi S = max. allowable stress value ='12,700 psi E = joint efficiency Table UW-12 (radiographer)'=.0.90 W = total bolt load, lbs. from ref.'2.2.4, 2-Se-j (use larger of operating or gasket seating-l conditions) l. hg = gasket moment arm, (radial distance from centerline of bolts to line.of gasket reaction) = 527 inch 1 5

A. For cp3 rating : conditions, ' W~ =. Wml: and from :2-5c(1) - t 2 Wal = 0.785G P + '(2b X 3.14 GmP)- 1 where: G = diameter at location of gasket--load reaction, and from Table 2-5.2, bo.=.307 =.038 < 1/4:in.- 8 l therefore, G = 7.807'in. P'= design' pressure =.11.9 psi- .4 b = effective joint contact surfaceqseating' width = bo =.038Ein.: m = gasket factor-(Table 2-5.1) = 0 for "O" ring-therefore: Wm1 = 0.785'(7.807)2 11. 9 + 2 (. 03 8 );-'3.14 (7. 8 07).. 0 (11. 9 ) = 570 lbs. B. For gasket seating, W = ( Am + Ab )- S a i 2. 1, 1) where Am = total required cross-sectional area of bolts, in2 ] Am = larger value: of Am1 or. Am2-Aml = total area of bolts for.cperatingl condition {Wml/Sb: i l Sb = allowable bolt stress at design temp. l (Table UHA-2 3 for SA-193 bolt at 1000F) = :15. 6. ksi a therefore, Am1 "._.570 =.037 in2 j 15,600 Am2 = total area of bolts for gasket seating = Wm2/Sa 'i i where: Wm2 = minimum required bolt load for gasket seating, lbs. l [from ref. 2.2.4, 2-5 (c) (2 )') Wm2 = 3.14 bGy where: y = joint contact surface. unit seating load, psi .I (from Table 2-5.1),. "O" ring y = 0 therefore, Wm2 = 0 and., Am " Aml =.037 in2.- .2) Where: Ab = cross-sectional area of bolt-(root diameter), in2. j (from Marks Handbook, SST 3/8-16NC bolt (ref. 5, item 4E) has area of 0.0678-in2) Sa = allowable bolt stress at atmos temperature (at'75 F) 0 = 15.6 ksi i 6 ~ 'l I l

therefore, W = (.037 +.0678) 15,600 2 and, W = 817 lbs. therefore, gasket seating governs, use W =_817 lbs. t = 7. 654 /0.3 (11.9)/12,700 (0.90)+1.9 (817) (.527)/12,700 (0.90) (7. 654) 3 t =.167 inch (minimum required thickness) (actual thickness is 0.5 inch) The DT-14A containment vessel is adequate for service at 1000F with a reduced external pressure of 3.5 psia and internal atmospheric pressure j and thereby conforms to NRC requirements (10CFR71.71(c)3] for normal l conditions of transport. 2.2 References 2.2.1 Independent Review of DT-14A Reduced ernal Pressure Calculations, Document No. NSS-4088, 11-10-86 2.2.2 Oak Ridge Y-12 Plant Model DT-14A SARP Y/DD-326 I 2.2.3 Model DT-14A SARP Supplement No. l'(Rev. 1) October 1986 2.2.4 ASME.1986 Pressure Vessel Code Section VIII,_Div. 1 2.2.5 Oak Ridge Y-12 Plant Drawing #T2E-117028, Sheet 2, Rev. E. 3 DT-14A Fissile Material Container j l l ( i i 1 e 7

^ 3.0 ' THERMAL EVALUATION- -r 3.1 Summary -Tho contents of.this package will be well under the weight and thermal limits on page 7 of Y/DD-326. Temperatures will not exceed those under normal' conditions of transport'or hypothetical accident conditions 'doccribed in Y/DD-326. ) 1 l 1 l e 8 ( _m______-

p 4.0 CONTAINMENT I 4.1 Summary. 1 Containment of the product is as described in Y/DD-326, pages:7, ll1and' 12. Tests of the packaging under' normal conditions of transport andi 1 hypothetical accident conditions are described on pages 13-18 of Y/DD-326. The metal inner. fuel' product cans, 0.030 inch nominal thickness, have a screw top closure with an elastomer seal._ These product. cans ] (non-containment);are placed inside the inner containment vessel. An analysis conducted as described in reference 4.2.1 establishes compliance with containment requirements specified in ANSI 14.5._-Actual' product characteristics from several years of production were used'in the calculations. This analysis verifies containment atLassembly for. shipment of Naval Fuel material in the DT-14A package.without a post-loading leak test. An independent review-[4.2.2] substantiated the analysis. 4.2 References 4.2.1 Calculation for Shipping Package Assembly Leakage Test, Document No. NSS-2163-1, Rev. 3, 10/2/8G, Classified Confidential, RD, NNPI. j 4.2.2 Independent Review of Naval Fuel.DT-14A Shipping Package Assembly Leakage Test, Document No. DPST-85-685-TL-REV.3, j 10-28-86. 9 t-

5.0 SHIELDING EVALUATION 5.1 Summary ~ Shielding analysis of the DT-14A shipping package is presented according to the U.S. NRC Regulatory Guide 7.9 in Document No. HPM-85-082 [5.2.1]. ) M2ximum dose rates were calculated to be < 5.5 mrem /hr. for normal and i hypothetical accident conditions. Actual dose rates should be less l bscause of conservative assumptions. I 1 An independent review [5.2.2] concluded that the analysis is conservative. l 5.2 References 5.2.1 Shielding Analysis of DT-14A Shipping Package, Document No. j HPM-85-082, Classified Confidential, RD, NNPI. l 5.2.2 Independent Review of Shielding Analysis DT-14A Shipping Package, 9-27-85, by D. R. Finch, Savannah River Laboratory. 1 i I l j l l d D 10 .___w

i 6.0 CRITICALITY EVALDATION l l 6.1 Summary Criticality analysis of the DT-14A shipping package with Naval Fuel ~* material is presented according to the U.S. NRC Regulatory Guide 7.9'in l Document No. DPST-85-143-8 (6.2.1]. l Computational evaluation of the DT-14A package leaded with 13.21 kg of Naval Fuel shows that it qualifies for shipment under Fissile Class I l regulations. 1 The highest reactivity calculated in.the undamaged and damaged infinite 1 array analyses was for a. maximum loading of 13.21 kg of material. Under l worst case conditions the infinite arrays retained a safety margin of at i least 0.35 in KEFF.' Any amount of' interspersed hydrogenous moderator reduced'the reactivity coefficient. An independent review (6.2.2] concluded that the analysis is valid. 6.2 References l I 6.2.1 FMF Criticality Safety Evaluation No. 18, Chapter 6 - Safety. Analysis Report for Packaging (DT-14A Package with Type 3 Naval Fuel Material), Document No. DPST-35-143-8,. Classified l Confidential, RD, NNPI. 6.2.2 Independent Review of Naval Fuel DT-14A Criticality Safety i Analysis, 8-29-85, by H. K. Clark, Savannah River Laboratory, i l l i i 0 4 11

7.0 OPERATING PROCEDURES h I Loading and unloading the package.and' preparation for shipment of' empty,. partially full, or full packages will.be.according to the following guidelines.. 1 7.1 Loading and preparations for' shipment of full andicartially full packages -7.1.1 Ensure the inspections andLstructural'and-leakage testsL 1 specified.in Section 8.2 for the containment vessel and drum' 1 have been performed as required. i 7.1.2 -Place a' maximum ofifive screw top metal? cans with a.nominalE wall thickness of 0.030-~1nch' in containment 1 vessel.. cushion the cans with;celotex or.other material 1 approved by the SARP. 7.1.3 Ensure total weight of U235 in package'does notLexcesd 9ckg. ] ~ 7.1.4 Verify the following items are-satisfied. LAn' independent ] inspector shall also; inspect-and document-theffollowing:- ' ring groove on the container vessel is' clean. 1 ring groove and mating surfaces on.the containment'vesseli i and lid are free of.. scratches. - Neoprene 0-ring - (8. 02 0.D.. x 7.47 'I.D. x.27) ' is - installed..'The 0-ring.cannotLba damaged, i.e.fcut, flattened spots, or fine-line' cracks present. 7.1.5 Secure the containment lid withLeight boltsetorquedLto 30-35' in-lbs. The~ bolts must be-304 SST ASTM A-193 Grade B8"(ANSI STD 818.2) and 3/8 -16NC x 1" long.. An independent inspector-shall' inspect'and document the bolts.are torqued to the-correct value. 7.1.6 The containment vessel bolts'and-0-rings shall_be controlled j as required in Section 9. 7.1.7 Place containment vessel into the'celotex drum cavity 1 ensuring the bottom plywood ir. pact-plate is in place. Place the calotex insulation top assembly with upper plywood impact 1 plate over the containment vessel. ji 7.1.8 Verify four. Vent holes-in drum are covered with either a-i weatherproof tape or fusible plug, or an equivalent ' device. 1 7.1.9 Place.the drum cover and locking ring on the~ drum'andstighten to'40-ft-lb with tapping of ring during tightening. ' Secure-the jam nut. 12 l

I i e 7.1.10 Apply a SGcurity; con 1 to nha.lceking ring.

0 7.1.11 Survey the drum for'radiat ion per 10CFR71.47 and 10CFR71.871 4

and attach appropriate radiation tags and labels. 7.2 Unloading full and partially full packages 7.2.1 Verify security seal is intact.: 7.2.2 Open drum vent holes and check for pressurization and air activity. 1 7.2.3 Check for pressurization and air activity when removing. I containment vessel lid. q 7.3 Preparations for-shipment of empty packages ~ 7.3.1 If shipping the: package contaminated, prepare as specified in -j 49CFR173.421 or 49CFR173.427. i 7.3.2 If shipping the package clean, verify the 49CFR173.427C limits are not exceeded. i ) 13 L---- -

8.O ACCEPTANCE TESTS AND MAINTENANCE PROGRAM Acceptance tests will be performed prior to the first use of a package.. The maintenance program will ensure continued performance of the packaging. 8.'1 Acceptance Tests The acceptance tests required prior to the first use of a package are dsscribed in this section. 8.1.1 Visual Inspection Verify that materials and physical dimensions of the overpack and containment vessel have been measured and recorded and are within prescribed tolerances. 8.1.2 Structural and Pressure Tests All inner containment vessel welds.shall be airtight. The top and bottom welds of the containment vessel shall be examined by nondestructive methods using dye penetrant techniques and shall meet the. requirements of Section VIII of the ASME Boiler and Pressure Vessel Code. Top and bottom welds of the. inner containment vessel shall be I pressure tested to 60 psig internal pressure and show no visible signs of leakage. 8.1.3 Leak Testing Prior to the first use of each new DT-14A package, the inner 1 i containment vessel is leak tested to 1 x 10-7 atm-cm /sec at 3 standard test conditions of ANSI N14.5.- The DT-14A package must pass the leak test before being used. 8.1.4 Component Tests i 8.1.4.1 Valves, Rupture Discs and Fluid Transport Devices. No above-mentioned devices are used on the'DT-14A. 8.1.4.2 Gaskets containment vessel 0-rings must be procured under a quality assurance program as outlined'in Section 9.0. 8.1.5 Tests for Shielding Integrity All new containment vessels will be tested after fabrication to verify the presence of cadmium. The test is described on I page 25 of reference 8.3.1. 14 ._ __J

8.1.6 Thermal Acceptanco Toct To ensure that the containment vessel design temperature and insulation design temperatures are not exceeded during normal conditions of transport, a representative package was tested as described in Reference 8.3.1, pages 14-15. 8.2 Maintenance Program This section describes the maintenance program used to ensure continued performance of the packaging. 8.2.1 Structural and Pressure Tests The hydrostatic pressure test of the inner containment vessel, specified in.Section 8.1.2, shall be repeated after any structural modifications. 8.2.2 Leak Tests After the third usage, and within one year from the last inspection date thereafter, the containment vessels are leak tested to 1 x 10~7 atm-cm /sec at standard test conditions of 3 ANSI N14.5. 8.2.3 Subsystem Maintenance No auxiliary cooling system, etc., are used. 8.2.4 valves, Rupture Discs and Gaskets No valves or rupture discs are used cn the DT-14A. The I following shall be verified prior to each use: - Sealing gasket on the drum lid is present, free of cuts and functionable. ring groove on the containment vessel is clean. 'l ring and mating surfaces on the containment vessel and l lid are free of scratches. - Neoprene 0-ring (8.02 0.D. x 7.47 I.D. x.27) is installed. . ring is not damaged, i.e. -cut, flattened spots, or l fine-line cracks. 0-rings shall be procured under a quality assurance program as outlined in Section 9.0. 8.2.5 Shielding Inspect the urethane liner for cracks, cleanliness or deterioration before each use. Any cracks er deterioration in liner are reason for rejection and before reuse, the package must pass shielding test described in Section 8.1.5. 15

8.2.6 Thcrmal Inspect calotex liner.for physical; damage before each use. a Check calotex fo'r cracks, broken.or deterioration, to pointt of not'being functionable. Depressions that do-not show evidence of material removed are not cause.for rejection. Functionable calotex must have a minimum'of three inches of non-damaged material between the containment vessel and the drum. 8.2.7 Visual Inspection The following items must be completed before each use: a) Ensure four vent holes in drum are covered with either a weatherproof tape or fusible plug or equivalent device, b) Remove old shipping labels from drum. c) Ensure metal nameplate is on drum. 4 f d) Ensure the locking ring and bolt on the drum lid do not have damaged threads. e) Ensure there are no dents larger than three inches long, d two inches wide, and 1/2 inch deep in the drum. l 8.3 References 8.3.1 DT-14A SARP OR-Y12 Plant Y/DD-326 i 0 16 .]

9c0 QUALITY ASSURANCE REQUIREMENTS INDEX 9.1 ORGANIZATION 9.1.1 Du Pont Savannah River Plant (SRP)' 1 9.1.2 Naval Fuel 9.2 QUALITY ASSURANCE PROGRAM 9.2.1 General I i 9.2.2 Naval Fuel Program f 9.3 DESIGN CONTROL 9.4 PROCUREMENT DOCUMENT CONTROL j 1 9.5 INSTRUCTIONS, PROCEDURES AND DRAWINGS 9.5.1 Preparation and Use 9.5.2 Changes 9.5.3 Maintenance 9.6 DOCUMENT CONTROL 9.7 CONTROL OF PURCHASED MATERIALS, EQUIPMENT AND SERVICES l l 9.8 IDENTIFICATION AND CONTROL OF MATERIALS, PARTS AND COMPONENTS 9.8.1 Safety Assessment of Packaging Items 9.8.1.1 0.R. 7-12 Plant Drawing T2E-117028 Sheet 1-9.8.1.2 0.R. Y-12 Plant Drawing T2E-ll7028 Sheet.2 ) 9.8.1.3 0.R. Y-12 Plant Drawing T2E-ll7028 Sheet'3 ) i 9.8.1.4 0.R. Y-12 Plant Drawing T2E-ll7028 Sheet 4 9.8.1.5 SRP Drawing S5-2-14556 9.8.1.6 SRP Drawing S5-2-14557 9.9 CONTROL OF SPECIAL PROCESSES 9.10 INSPECTION 9.11 TEST CONTROL 9.11.1 General i 9.11.2 Acceptance Tests 9.11.3 Maintenance Program 9.11.4 Post-Loading Leak Tests 9.11.5 Rejected Containers 17 1 L

'l 9.12' -CONTROL'OF MEASURINGJAND TEST EQUIPMENT

9.13 HANDLING,' STORING AND SHIPPING..

9.14-INSPECTION, TEST'AND; OPERATING STATUS 9.15 NONCONFORMING MATERIALS, J PARTS ' OR UNACCEPTABLE? ACTIVITIES 9.15.1. Identification 9.15.2 Segregation 9.' 15. 3 : Disposition 9.15.4 Evaluation. .9.15.5 Exception- ^ 9.16 CORRECTIVE ACTION: 9.17. QUALITY' ASSURANCE RECORDS 9.17.1' General. 9.17.~ 2 - NonpermanentLRecord' Examples, 9.17.3 Permanent Record Examples-9.17.4 Storage, Preservation and Safekeeping' 9.18 AUDITS 9.19 REFERENCES i 18 ~~* _Q

a I 1 9.1-Organization 9.1.1 Du P:nt? Savannah River' Plant (SRP). ) All Du'Pont Company activity for.the U.S.?Departmentlof- ~ j Energy is. performed under Contract,DE-AC09-76SR00001.-'Du i 'Pont's basicLpolicy, described'in"the Savannah-River .i 'QualityLAssurance Plan DPW-82-lll-2i(9.19.1) states that; all1 activities shall;be conducted 1to achieve a highfquality) Y; of product and-performance,Lconsistent"with the safety of? employees.andLthe generalipublic. The Savannah River' Plant Quality Assurance Manual.DPW-83-111-3'(S 19.2]^1s the. detailed guide for achieving these1 objectives. The ~ SuperintendentLof Quality.reportsTdirectly to'.theLPlant-Facilities and Services' Manager andLisfrasponsible:for'thei plant overall. program. 9.1. 2 L Naval Fuel' The Naval Fuel Product Team.is' organized under;theJPMT-. i: management concept headed by a-general superintendentLwith I Naval Fuel' Production,. Works EngineeringJand Technology; 9 Departments. A Quality Assurance Group. Coordinator land his staff report.to the Naval. Fuel Technology Superintendent;.. ol they are responsible for~ ensuring implementation of the SR7' j QA program specific to;the' Naval Fuel' Facility..The: Naval Fuel Product Team is responsible:for daily activities 1that- ? will ensure' continued. integrity of;the packages. 9.2 Quality Assurance Program 1 9.2.1 General l The Savannah River. Quality Assurance. Program, based ant U.S. DOE Order 5480.3'.(9'19.3): and the'U.S.7 NRC Regulatory Guide 7.10 [9.19.4] consists of the Savannah River 1 Quality Assurance Plan, SRP QA Manual and other applicable manuals' ~ ~ procedures and instructions. It-includes-activities-related to design, fabrication, construction, maintenance, and modification. A11'Du:Pont employees.are responsible for effective implementation ofLthe SRP QA Manual within l the' limits of their job assignments. ;SRP management l assesses at least annually the adequacyLand. effectiveness of the QA program.to ensure proper implementation. 1 Documentary evidence and independent verification where appropriate are required to demonstrate that spacific objectives are' achieved. -l = L f. [._-

, i, >k' 29.2.2 NavallFu01< Program 'l The DT-14A-packaging was designed andLtested asidescribed: in the Safety Analysis L. Report for Packaging (SARP) Y/DD-326. [9.19.5).. Quality Assurance activities are limited-to; procurement, fabrication, useaandJaaintenance!.to ensure: established standards and continued safe shipping. Items and activities to.beLcontrolled and documented are described herein. QAffor design is covered in SectionJ9.3.- The SRP QALmanual'in conjunction!withiprocedureslto:be. .specifically written,to: cover: specific shipping activities 1 will be used-by theLappropriata NavaitFuel' Department;. , Training <of personnel will be accomplishedLprimarily.by . Naval Fuel supervision, with assistance from;the' Site.QA Group.as needed. Independent? monitoring;. review:and-auditing of QA activities willabe provided by the Site QA> Group. 9.3 Design Control, l .\\ Design of the DT-14A shipping packaging is described:in the1DT-14A SARP l Y/DD-326. j Dasign changas including field changes that affect: safety _orLfunctionalJ safety of the-DT-14A,.must be, identified,. justified, authorized,- controlled and documented in the'same manner,as the initial design, according to reference 9.19.2, QAP 3-2 and 3-3'and must;be approved. through racertification-to DOE-CertifyingLAgency. 9.4 Procurement Document Control. Purchase Order documents contain the applicable Du-Pont and vendor j requirements including, as appropriate, design' bases,-standards, specifications, codes,_ documentation and any other special conditions. 1 They prescribe the necessary inspections, hold' points,.. tests, and other partinent QA considerations, and specify the packing, shipping; and handling requirements'when needed (reference 9'.19.2,JQAP 4-1). The initiator of a purchase requisition or order-request is responsible for including applicable QA requirements and for obtaining proper approval signatures. Specifications:in particular will contain actual requirements, not the intent of the purchaser. j i 20 .2 __J

j p -4 I chang 0c.to-purchaso order r0guircm:ntslsuct b3 authorized by tnot. i individual, organization or designated representative who authorized.the original documents. Procurement of replacement parts is, handled 11n the same~ manner <as initial-packaging procurement. 9.5. Instructions, Procedures and Drawings 9.5.1 Preparation and Use Activities concerning~ loading,' packaging ~and' shipping are performed in.accordance.with, written operating: procedures (DPSOL's,. manuals;or;other approved-documents developed by: 1 Naval; Fuel). Necessaryfrequirements, including sequential-j steps, technical' constraints, acceptance ~limitsLandl references are:specified.. A preplanned and documented inspection will;be conducted to, ensure that each package is-ready for delivery to~the carrier-9.5.2 Changes Changes in temporary;and operating procedures'that, affect the process must be approved at the same? supervisory (level: j as the initial issue. 9.5.3 Maintenance 1 Written procedures.or instructions for repair,-rework and: R maintenance.of packagings and components will be prepared and approved before'the-work begins. ' Inspection, testing f and independent verification if required will be. included. q in the procedures or instructions. 4 9.6 Document Control The Naval Fuel Product Team is responsible for establishment,. development, review, approval,, distribution, revision;and retention of. its documents, classified and unclassified. Documents requiring control, j the level of control, and the personnel, positions or organizations 1 responsible for preparing, reviewing, approving and issuing' documents are identified. QA document distribution should be specified inLthe purchase requisition. Shipping package documents to be controlled include as.a minimum: q 1 o QA and QC Manuals o Operating Procedures o Maintenance Procedures: o Inspection and Test Procedures I t i 6 21 k '] I

o ' Loading and' Unloading. Procedures ~ ^ o Packaging for Transport Procedures-o Repair Procedures. o Specifications o Drawings of Packaging and' Components o 'SARP'and Supplement F.cvisions.are handled inLa like manner as the original issue. Only tha t 1ctest revisions should be available for.use.in the facility. Documentation received from the supplier'for each packaging must be filed, 'by serial' number. Notations regarding maintenance, inspection, repair,. otc., are.added to the-file. These' records are maintained in the user's-facility as long as the packaging is in service. At least one. set off vendor. records is included.with each container andione set sant to the -Naval Fuel QA Coordinator.. 9.7 Control of Purchased Materials, Equipment, Services Tcsts have shown that this shipping package as' designed and constructed' will retain its radioactive contents during normal'transportationiand.in svent of a hypothetical' accident. The main objective is to ensure L containment l integrity and ' safe delivery of the product.. Consequently, practices are established to ensure that purchased 1 materials, equipment-and services conform to procurement document requirements. Thetpurchasing agent has the lead responsibility for prequalification and selection of suppliers. This.is accomplished through the combined activity of~the-purchasing agent, design' engineer, QA engineer, manufacturing engineer or others as appropriate. Vendors who have proven satisfactory performance records in supplying this type of! equipment are acceptable. New vendors must submit a copy of their Administrative Procedural Controls and a Manufacturing.and Inspection (M&I) Plan.for review and approval by the user before starting manufacture. Prequalification of the new vendor's and their subcontractor supplier's facilities is required. The vendor's M & I plan should include such items'as: o Material certification o -Welding procedure specifications o Procedure qualification records o Walder qualification records Type of inspections to be performed and by whom o e. 22 _ _ _ _ _ _ _ _ = _ _ - _ - _ _ _ _ _ _ _ - - _ _ _ _ _ _ - _ _ _ - - _. _ _ _D

~ l i Qualification-'rocords of parsonnol'p3rforming o nondestructive examinations 4 o Record of weld inspections, radiograph, dye' penetrant inspections or others o Certified dimensional inspection reports o Documentation of cleaning procedures and any.special' assembly or processesz o-Inspection hold-points and.special instructions o Nonconformance Report procedure 4 -1 Supplier deviation requests are_ resolved by the requesting organizational representative and formalized by the purchasing-agent. Any' containers-not meeting specifications will be marked and set aside for disposition. Documentation sets furnished by the supplier for each' packaging will be specified on the purchase requisition and distributed by the purchasing agent. Reference 9.19.2, QAP 7-1, 7-2 describes actions and' responsibilities in' detail. 9.8 Identification and Control of Materials, Parts and Components Items that have unique characteristics or functions that-must be protected to ensure their intended use must be identified and controlled throughout fabrication and assembly to ensure traceability. The individual authorizing procurement is responsible for identifying those parts and the level of control to be maintained. Each containment vessel is identified with a serial number in such a manner that is permanent and does not affect design function. Any vessel l that does not meet specifications is set aside, marked accordingly and must not be loaded until disposition has been made by the responsible authority. An external package nameplate for Naval Fuel Department use (Figure 1, Section 9.19) identifies custodian, serial number, contents, etc. Replacement parts must be identified to ensure correct application. Items such as elastomer seals must be procured from stock verified to be within shelf life limits. Bolts must be segregated from other materials and fasteners to prevent misuse and chloride contamination. Classification of all packaging parts according to effect on safety and relative safety significance are shown in 9.8.1. The items are listed.by ORNL or SRP drawing numbers and identify the "Q" items as essential to 23 = L

ccfety with categories of A, B and C. (Ref. 9.19.4, Appendix A.) Items l marked with Category "A" are critical to safe operation, "B" are items with a major impact on safety, and "C" with a minor impact on safety. . Items not safety related are indicated as non "Q". Under the 4 . verification column, "V" refers to qualified vendor; "M" material i certification; "T" test resultst "I" qualified inspector, "W" qualified j wolder and "L" leak test. 9.8.1 Safety Assessment of Packaging Items 9.8.1.1 0.R. Y-12 Plant Drawing T2E-117028 Sheet 1 l Structure Component Category Verification j l l DOT-17H Drum Q-A V,M,T Closure ring bolt Q-C M (strength and material) ID plate material non "Q" M content non "Q" I welding to drum Q-B I Vent holes in drum Q-C I Cover vent holes with Q-B I tape 9.8.1.2 0.R. Y-12 Plant Drawing T2E-117028 Sheet 2 Structure Component Category Verification Containment Vocsel Q-A V,M,L,I,W .l SST flange bolts C-B M (material and' strength) I torque Q-A I Cadmium (material and Q-A M thickness) l installation Q-A T,I O-ring (material and Q-A M size) installation Q-A I containment Vessel Body (material) Q-B M Weld of flange to body Q-A W,I Weld of bottom plate to body Q-A W,I 24 -J

Structura Component Category Verification 0-ring groove' Q-A I (flange flatness, sealing surface finish) Containment. Vessel Top (material) Q-B M (flatness, sealing surface finish) Q-A I Weld of handle to top non "Q" I Monothane Material Q-C M Thickness Q-B I 1/4" pipe plug Q-C FPG Machine Gray 'non "Q" Enamel 9.8.1.3 0.R. Y-12 Plant Drawing T2E-117028 Sheet 3 Structure Component Category Verification Celetex Fiber Insulation Q-B Celotex material Q-B M dimension Q-B I V1-AC Mastic 1-C551 Weather Coating Q-C Rope Q-C Plywood Q-C " PPG" Speedhide Latex Fire Retardant Paint Q-B M " Miracle" Type-M Black Magic Adhesive Q-B M 9.8.1.4 0.R. Y-12 Plant Drawing T2E-117028 Sheet 4 Structure Component Category Verification l Mold Assembly Q-B l Mold Nose Item 7A Material Q-C M Dimension Q-B I 25

} Structurn Componnnt . Category verification Mold Top Item.7B Material Q-C' M' Dimension Q-B I' i Mold' Bolt Item 7C' Material Q-C. M Dimension Q-B' I Bolt Item 7D non "Q" Eyebolt Item 7E non "Q" 9.8.1.5 SRP Drawing S5-2-14556 - i 4 Structure Comqonent Category Verification l Fuel Shipping container Q-C i container material non "Q" M l dimensions non "Q" I 9.8.1.6 SRp Drawing SS-2-15257 Structure Component Category Verification Colotex Packaging Material Q-B Celotex material Q-C M dimensions Q-B I " Miracle" Type-M Black Magic Adhesive Q-C M Vl-AC Mastic l-C551 Weather Coating Q-C-M 9.9 Control of Special Processes Spscial processes-such as welding, heat treating and nondestructive-l examination that affect the quality of a system or its parts must be done by qualified personnel using qualified procedures per applicable codes and standards. Controls must ensure that process parameters are controlled and specified environmental conditions are maintained. Psrsonnel training and qualification records must be up to date.- S 26

Welders and procedures shall be qualificd'in accordanca with Ssetion IX,- ~ of the ASME Boiler and Pressure Vessel Code (9.19.6]. The top and bottom welds of the inner containment vessel shall be examined by: nondestructive methods using dye' penetrant techniques'and shall meet the requirements of Appendix 8 of Section VIII of the ASME Boiler and. Pressure Vessel Code [9.19.9].- Examination personnel shall be qualified and-certified to Level II in accordance with ASNT Recommended Practice No. SNT-TC-1 (9.19.10] for the examination method being used. Specific acceptance criteria shall be established. Results should be' verified by an independent certified inspector. 9.10 Inspection There are two. types of inspections: (1) in-process inspections performed by the fabricator and (2) independent inspections performed by individuals or organizations outside the fabricator. Individuals performing inspection functions must be qualified as attested by qualification records. The initiator of the purchase requisition should determine the' type and extent of inspections needed to ensure a quality product. Requirements should be specified in the Manufacturing and Inspection Plan (Section 9'.7 of this chapter), including hold points if applicable and who will perform the inspections. In-process inspections may be documented if requested by the buyer; independent inspections must be documented. Inspections performed independently by Naval Fuel personnel. include: Receipt - visual to ensure compliance with procurement-o documents, and nondestructive examination of welds as-appropriate. o Maintenance - to ensure adequate maintenance of packaging o Final - to verify proper assembly, marking, proper shipping papers, any special instructions 9.11 Test Control 9.11.1 General Test requirements and acceptable limits are determined by the organization responsible for design and operation of the equipment being tested. Personnel conducting the test and the test equipment must be qualified, with appropriate documentation (reference 9.19.2, QAP 10-3, 12-1). 9.11.2 Acceptance Tests (a) Ihe fabricator will supply a certified quality assurance verification for the fabrication of each container in accordance with the applicable drawings, specifications and other written requirements. 27

9 4 3 l-- e 1 . (b)L Cadinium)linor thicknoco 'l'n tho innar.centsinm:nt voasol'- 'will-belverified"as directed inireferenceL9.19.5, and l o h ' documented. (c) Prior to-first.use/ after the third'use and within one year from the last-inspection,Jtha inner. containment? -vessel will-be leak tested'to 1 x110-7 ata.t ec/sec, per? ANSI 14. 5 (9.19. 7 ]. - TheLinspections and. tests shall be documented,: including a record of the' usage. u

l 9.11.3 Maintenance Program' (a) visually: inspect each container to meet-reprocessing requirements according to reference;9.19.5. : Pay:

1 particular attention.to.the 0-ringLseal~and. sealing; surfaces"of;the inner' containment vessel...Ificorrosion is evident, polish.the: sealing surfaces:and reinspect to original specifications. j (b) Follow Naval Fuel operating; procedures to ensure proper; -bolt torques, handling methods, drum l closure,-etc. '(c) Be'sure'each of the four.vant'holas'nearfthe topiof"the. ] drum are covered. 9.11.4 Post Loading Leak Tests j 1 Calculations with independent review and concurrence, were! -{ made to ensure. containment'inclieu-of physical ~ tests on 4 each container (9'.19.8]. LHealth Protection personnel;will survey each package before release to the carrier. 9.11.5 Rejected Containers Containers.not meeting inspection criteria above will be set aside, marked or tagged and not used untilithe Nonconformance' Report disposition has been determined by the' responsible Naval Fuel organization. 9.12 Control of Measuring and Test Equipment Measuring and test equipment essential to ascertaining acceptability of an item or activity must be controlled. Scheduled: calibration 1 frequency. and accuracy range are predetermined and documented by. designated. Naval: Fuel personnel. All instruments are evaluated'to' determine. frequency of calibration with standards maintained by the SRL Standards Laboratory and tracsable to the: National Bureau of' Standards or other acceptable.-

documented standard.

.v s 28 i

'Any equipment conoistsntly out of. calibration.will'b3 rcpsirci or i replaced. Parts measured by equipment found'to be out of calibration chall be remessured with calibrated' equipment. Containers measured with aquipment out of calibration and not available for measurement shall be recorded on a Nonconformance Report for disposition. 9.13. Handling, Storage and Shipping Packagings and spara components will be stored-in.a designated repository. that will ensure cleanliness and freedom from damage'. Specifically designated handling and lifting equipment will be used to. move packaging I from one station to another.. Bolts will^be in segregated storage to prevent ~ misuse and chloride contamination. In preparing for shipment, handling and loading will'be done~according.to ( Naval Fuel procedures to ensure.that all: requirements have been met prior I to delivery to a carrier. A package ready for. shipment must conform to j J its shipping paper. Empty packagings should be checked, decontaminated if required and ) inspected. Each one should be inspected, reconditioned or repaired as appropriate before storing or loading. Those packagingsinot ready for loading will be set aside and marked. 9.14 Inspection, Test and Operating Status Measures will b.e established to ensure that: (1) the status of inspections, tests and operating conditions are known by the organizations responsible for QA, (2) no controlled items are overlooked, I and (3) documentation is complete. Strict adherence to specifications, DPSOL's and other instructions should accomplish these objectives. 9.15 Nonconforming Materials, Parts or Unacceptable Activities j 9.15.1 Identification Measures are established to identify and document the l nonconforming item or activity. The Naval Fuel QA i coordinator or his designate is responsible'for approval of the disposition of nonconformances. A Nonconformance Report form is illustrated and explained in reference l I 9.19.2, QAP 15-1. l 9.15.2 Segregation i Nonconforming items are marked, tagged, segregated and placed in controlled hold areas until' disposition is completed. i 29 a i 1 l i

i I 9.15.3 Dicpccition i The-QA coordinator, with'other appropriate personnel, evaluates the situation and takes one of.the following i actions: 1 I o Return forJre-inspection the original or:another j inspector may be used and test equipment may be j . recalibrates. o Rework or repair - if there is prospect of restoring ~the item to specifications. Reinspect after rework, o Reject - maintain identification:and either discard, return to the. manufacturer or use for test' purposes only. 1 o Use as is - a deviation report must be. approved and issued. In every case of action taken, final disposition.of_ nonconformances must be identified, documented and placed 1 in the container file. 9.15.4 Evaluation Nonconformance Reports should be analyzed by QA personnel j to determine quality trends'for appropriate management review and assessment. 9.15.5 Exception I A Nonconformance Report is not required if a departmental Incident Report, Unusual Occurrence Report or other standard report prescribed by existing procedures.is issued, l J 9.16 Corrective Action Nonconforming items or activities are promptly' identified,~ corrected and the cause determined to prevent repetition. Investigation must be conducted to a level that ensures that corrective actions are established to preclude recurrence. Work with suppliers, including appropriate. follow up, may be needed to ensure _ consistent quality products. l 30 i i

~ The Naval' Fuel QA Coordinator is responsible for concluding andL ' documenting corrective action-investigations. ~ d A Corrective Action Report form is illustrated and' explained in reference'- j 9.19.2,1 QAP 16-1. ] 9.17 Quality Assurance Records- '1 9.17.1 General' Written procedures describe and specify how shipping documents are identified'and controlled.. Retention period. ) for nonpermanent. records 1are specified. Normally only j documents containing recorded data require; authentications. A file.should be maintained'on each package by serial number.. j ~ 9.17.2 Nonpermanent' Record Examples o Status reports,. J o Evidence of delivery.of packages to.a. carrier. o Discontinued' activities not-relatedEto current activities o certification of~ personnel o Instrument calibration 9.17.3 Permanent Record Examples o Package design and production related records generated l through design and fabrication- -{i o Demonstrated evidence of operational capability o verification of; repair, rework, replacement, rejection-or. f other disposition. o Corrective investigations and actions. o other QA actions 1related to the package. o Audit plans and reports-1 o Information used as a baseline for maintenance-o Operating procedures ' current' revision 9.17.4 Storage, Preservation and Safekeeping. Designated facilities used'to-store records are constructed' h to minimize the risk from damage or destruction from I natural causes, temperature, humidity, insect or mold. Special records such as radiographs, microfilm, magnetic tapes, etc., are protected.from excessive. light, electromagnetic fields and temperature.-.If: dual. facilities are developed, they will be sufficiently remote'from each 1 other to. preclude damage to both from a single event such as fire or flood. Security systems and classification of facility activities are established to prevent access to' records by-unauthorized personnel. { a 31 j ) ____1___________________________.__-

l I complete records to be retained for specified'per'iodstof l time will be sent to Records Management in Building'703-A. 9.18 Audits M3asures are established to ensure that. audits are performed in accordance with pre-established. written procedures or check lists. L Audits are conducted by. qualified personnel not having direct responsibility in the areas.being audited. Personne1'having responsibility.and authority for corrective-actions are identified. D3ficient areas are revisited <nt a timely basis to ensure compliance with . I audit findings.' i Naval Fuel personnel make periodic' internal audits and= evaluations.of chipping related. procedures;and activities. At least annually formal: cudits are conducted by.the DOE Nuclear Safety Branch, Du Pont-Wilmington Division of Fire and Safety, and the SRP " RHYTHM" Committee. All audit findings and corrective action' reports are documented. R3ference 9.19.2, QAP 18-1 and 18-2' describe audit procedures, training cnd qualification'. 9.19 References 9.19.1 Savannah River-Quality Assurance Plan, DPW 82-111-2. l 9.19.2 Savannah River Plant Quality Assurance Manual,'DPW.83-111-3. 9.19.3 U.S. DOE Order 5480.3.. 9.19.4 U.S. Nuclear Regulatory Commission Regulatory Guide 7.10, " Establishing Quality Assurance Programs for Packaging Used in the Transport of Radioactive Material". 9.19.5 Safety Analysis Report for Packaging (Oak Ridge Y-12 Plant model DT14A Package for Enriched Uranium) Y/DD-326. 9.19.6 ASME Boiler and Pressure Vessel Code, Section IX,.1986 Edition. l 9.19.7 American National Standard for Leak Tests of Packages for Shipment of Radioactive Materials, ANSI N14.5, 1977. 9.19.8 Calculation For Shipping Package Assembly Leakage Test - l NSS-2163-1, Rev. 3, 10-2-86, Classified Confidential, RD, NNPI. l l 9 d 32 a

9'.19.9 ASME Bo11or.and Proccura Vaccol Codo, 50ction VIII, 1986 Edition. 9.19.10 American Society for Nondestructive Testing, Recommended. Practice No. SNT-TC-1A,'1980 Idition. 4 1 t a 1 i l ( 1 h W s 33 l '. ____________________m

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