Text

Enclosure 2 - ORNL/RRD/INT-173, Rev. 1, Test Plan for Normal Conditions of Transport and Hypothetical Accident Condition Tests Oak Ridge National Laboratory Package Design USA/5797/B(U)F-96
	ML21292A223
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Site:	07105797
Issue date:	08/31/2021
From:	Blanton P, Shuler J; Oak Ridge, US Dept of Energy (DOE)
To:	John Mckirgan; Storage and Transportation Licensing Branch
	P SAVEROT NRC/NMSS/DFM/STLB 3014157505
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ML21292A221	List: ML21292A222; ML21292A223; ML21292A224;
References
	ORNL/RRD/INT-173, Rev. 1
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	v • d • e

ORNL/RRD/INT-173, Rev. 1 ORNL IS MANAGED BY UT-BATTELLE LLC FOR THE US DEPARTMENT OF ENERGY Test Plan for Normal Conditions of Transport and Hypothetical Accident Condition Tests Oak Ridge National Laboratory Package Design USA/5797/B(U)F-96 Paul Blanton August 2021

ORNL/RRD/INT-173, Rev. 1 Research Reactors Division TEST PLAN FOR NORMAL CONDITIONS OF TRANSPORT AND HYPOTHETICAL ACCIDENT CONDITION TESTS OAK RIDGE NATIONAL LABORATORY PACKAGE DESIGN USA/5797/B(U)F-96 Paul Blanton August 2021 Prepared by OAK RIDGE NATIONAL LABORATORY Oak Ridge, TN 37831-6283 managed by UT-BATTELLE LLC for the US DEPARTMENT OF ENERGY under contract DE-AC05-00OR22725

Test Plan for Normal Conditions of Transport and Hypothetical Accident Condition Tests Oak Ridge National Laboratory Package Design USA/5797/B(U)F-96 Prepared by:

Paul S. Blanton - Testing Lead, ORNL, Research Reactor Division (RRD)

Reviewed by:

Larry D. Proctor - Fuel Shipping Cask Support, RRD Reviewed by:

W. Brandon Kendrick - SARP Coordinator, RRD Reviewed by:

David L. Shuter - Quality Representative, RRD Approved by:

Young Soo Kwon - Plant Life Extension Manager, RRD Paul Blanton Digitally signed by Paul Blanton Date: 2021.09.02 12:34:55 -04'00' Larry D. Proctor Digitally signed by Larry D. Proctor Date: 2021.09.01 08:51:40 -04'00' William Kendrick Digitally signed by William Kendrick Date: 2021.09.01 08:18:36 -04'00' Digitally signed by David L. Shuter Date: 2021.09.01 08:32:59 -04'00' Young Soo Kwon Digitally signed by Young Soo Kwon Date: 2021.09.02 12:48:56 -04'00'

iii Revision Log Revision Description 1

A. Incorporated changes as follows addressing comments received from the DOE Packaging Certification Program review of revision 0. See memorandum from Dr. James M. Shuler, Manager, DOE Packaging Certification Program (PCP), to Herman E. Radke III, DOE Oak Ridge Site Office,

Subject:

Comments/Corrections from Review of HFIR Test Plan, dated August 16, 2021.

1. Section 1, Abstract: Deleted last sentence.

Basis: Addresses PCP comment 5

2. Section 2,

Introduction:

Added the second paragraph comparing the pertinent parameters of the inner and outer fuel element shipping containers to the criteria stated in 10 CFR 71.73(c)(2) to provide a basis for stating that the crush test is required.

Basis: Addresses PCP comment 1.

3. Section 3, General, first paragraph: Cited reference 6.2, which provides the bases for selecting package drop orientations, etc.

Basis: Addresses PCP comment 2.

4. Section 4, Quality Assurance Program: Added new section on quality assurance requirements and renumbered following sections.

Basis: Addresses PCP comment 6.

5. Section 5 (Previous Section 4), Test Plan, first paragraph: Changed second sentence from: It is the responsibility of the contracted testing company to ensure that test procedures, test equipment, and facility infrastructure (unyielding surface, crush plate, puncture bar, thermal facility, etc.) comply with regulatory requirements. To: It is the responsibility of ORNL to ensure that the contracted testing companys (or testing organizations) test procedures, test equipment, and facility infrastructure (unyielding surface, crush plate, puncture bar, thermal facility, etc.) comply with regulatory requirements. The contracted testing company shall provide evidence sufficient to allow ORNL to make that determination.

Basis: This addresses PCP comment 3.

6. Section 5.2.4 (Previous Section 4.2.4), Second sentence and Note: Deleted Note and rephrased sentence to clarify that the contracted Test Company must provide the listed information as part of the test documentation.

Basis: Addresses PCP comment 5.

7. Section 5.4 (Previous Section 4.4), Normal Conditions of Transport Tests, first sentence:

Corrected CFR citation.

Basis: Addresses PCP comment 4.

iv

8. Sections 5.6 through 5.9 (Previous sections 4.6 through 4.9): Rephrased as needed to eliminate blank testing company procedure numbers and clarify that procedures used will be reviewed and approved by ORNL.

Basis: Addresses PCP comment 5.

9. Section 6,

References:

Added new section to list cited references.

Basis: Clarification.

B. Incorporated changes address to comments received from internal ORNL review, as follows.

10. Section 5.2.2 (Previous section 4.2.2), Weights: Clarified that post-tests weights of container assembly will be measured following the spray test, at the conclusion of the NCT tests, and after the HAC tests. Contents and component post-test weights will be taken as practical depending on damage to the container.

Basis: Clarifies the pre-and post-test weights that will be measured.

11. Section 5.2.4 (Previous section 4.2.4), Instrumentation and Devices, first paragraph: Added documentation of traceability to the list of information that should be included in the test documentation.

Basis: Clarification

12. Section 5.3 (Previous section 4.3), Test Documentation, first paragraph: Clarified that test documentation will include calibration and traceability documentation of M&TE and that the test report must be signed by the testing company person or persons responsible for conducting the test.

Basis: Clarification

13. Section 5.5.5 (Previous section 4.5.5), Thermal Test: Added Artificial cooling may not be applied after cessation of external heat input, and any combustion of materials of construction, must be allowed to proceed until it terminates naturally.

Basis: Better consistency with 10 CFR 71.73(c)(4).

14. Section 5.7.6 (Previous section 4.7.6), Compression Test Procedure: Added and instrumentation associated with compression loading equipment.

Basis: Clarifies that compression loading equipment instrumentation must also be traceable to NIST.

C. Changes not tracked in document:

Changes to address PCP comments 7 & 8 which involved improving the legibility of attached drawings and correcting page orientation in the pdf version of the document. Various other minor editorial changes and corrections of typographical errors.

Basis: Changes make no substantive change to the content or meaning of the text.

0 Initial Issue

v CONTENTS CONTENTS.................................................................................................................................................. v

1.

ABSTRACT............................................................................................................................................. 1

2.

INTRODUCTION..................................................................................................................................... 1

3.

GENERAL............................................................................................................................................... 1

4.

QUALITY ASSURANCE PROGRAM......................................................................................................... 4 4.1 Quality assurance requirements................................................................................................. 4 4.2 Quality category.......................................................................................................................... 4 4.3 Quality assurance records........................................................................................................... 4

5.

TEST PLAN............................................................................................................................................. 4 5.1 Prototype Packaging and Content Description........................................................................... 5 5.1.1 Prototype Packaging...................................................................................................... 5 5.1.2 Prototype Fuel Elements................................................................................................ 7 5.2 Prototype Preparation and Records for Testing....................................................................... 12 5.2.1 Measurements............................................................................................................. 12 5.2.2 Weights........................................................................................................................ 12 5.2.3 Marking (Packaging and Content)................................................................................ 12 5.2.4 Instrumentation and Devices....................................................................................... 13 5.2.5 Video and Photography............................................................................................... 14 5.3 Test Documentation................................................................................................................. 15 5.4 Normal Conditions of Transport Tests...................................................................................... 15 5.4.1 Initial Conditions.......................................................................................................... 15 5.4.2 NCT Conditions and Tests............................................................................................ 15 5.5 Hypothetical Accident Condition (HAC) Tests........................................................................... 17 5.5.1 Initial Conditions.......................................................................................................... 17 5.5.2 Free Drop 30-Feet § 71.73(c)(1)................................................................................... 17 5.5.3 Crush § 71.73(c)(2)....................................................................................................... 17 5.5.4 Puncture Test § 71.73(c)(3).......................................................................................... 17 5.5.5 Thermal Test § 71.73(c)(4)........................................................................................... 18 5.5.6 Immersion Test(s) § 71.73(c)(4) & (5).......................................................................... 18 5.6 Procedures................................................................................................................................ 18 5.6.1 Package Assembly Procedure...................................................................................... 18 5.6.2 Content Verification Procedure................................................................................... 18 5.7 Normal Conditions Of Transport Procedures........................................................................... 19 5.7.1 Initial Conditions Procedure........................................................................................ 19 5.7.2 Cold Condition Procedure............................................................................................ 19 5.7.3 Vibration Procedure..................................................................................................... 19 5.7.4 Water Spray Procedure................................................................................................ 19 5.7.5 Free Drop Procedure.................................................................................................... 19 5.7.6 Compression Test Procedure....................................................................................... 21 5.7.7 Penetration Test Procedure......................................................................................... 21 5.8 Hypothetical Accident Condition Test Procedures................................................................... 21 5.8.1 HAC 30-Ft Drop Procedure........................................................................................... 21 5.8.2 HAC 30-Ft Crush Test Procedure.................................................................................. 24 5.8.3 Puncture Test Procedure............................................................................................. 26

vi 5.9 Thermal Test Procedure............................................................................................................ 26 5.10 Test Unit Inspections................................................................................................................. 27

6.

REFERENCES................................................................................................................................... 28

7.

APPENDICES........................................................................................................................................ 28 APPENDIX A. Inner and Outer HFIR Fuel Assembly Packaging Test Unit Drawings............ A-1 APPENDIX B. HFIR Production Fuel Element Drawings....................................................... B-1 APPENDIX C. HFIR Mock and Simulated Inner and Outer Fuel Element Designs............... C-1 APPENDIX D. Instrumentation, Measurements, and Weights............................................ D-1 APPENDIX E. Example Fuel Element Data Sheet................................................................. E-1

vii List of Tables Table 1. USA/5797/B(U)F-96 Testing Matrix................................................................................................ 2 List of Figures Figure 1. 5797 Inner and Outer HFIR Unirradiated Fuel Element Shipping Containers............................... 6 Figure 2. 5797 Inner and Outer HFIR Unirradiated Fuel Element Shipping Container Cross Sections............................................................................................................................................ 6 Figure 3. Production Inner and Outer HFIR Fuel Elements and Assembly Mock Elements.................... 10 Figure 4. Simulated Inner and Outer HFIR Fuel Content............................................................................ 11 Figure 5. Inner-1 and Outer-1 NCT 4-Ft CGT Drop Orientation.................................................................. 20 Figure 6. Inner-2 NCT 4-Ft TD Drop Orientation......................................................................................... 20 Figure 7. Outer-2 NCT 4-Ft Horizontal Drop Orientation............................................................................ 20 Figure 8. Inner-1 and Outer-1 NCT VTU Compression Test........................................................................ 21 Figure 9. Inner-1 HAC 30-Ft CGT Drop Orientation..................................................................................... 22 Figure 10. Outer-1 HAC 30-Ft CGB Drop Orientation................................................................................. 22 Figure 11. Inner-2 HAC 30-Ft CGT Drop Orientation.................................................................................. 23 Figure 12. Outer-2 HAC 30-Ft Shallow Angle TSD Drop Orientation.......................................................... 23 Figure 14. Outer-1 HAC Crush Test CGB Drop Orientation......................................................................... 24 Figure 15. Inner-2 HAC Crush Test Horizontal Drop Orientation................................................................ 25 Figure 16. Outer-2 HAC Crush Test Horizontal Drop Orientation............................................................... 25 Figure 17. Typical Drop Configuration for Puncture Test........................................................................... 26 Figure 18. Thermal Test Orientations......................................................................................................... 26

viii Acronyms A

Ambient temperature AS As specified by ORNL Testing Lead (TL) based on evaluation of sequential damage CGB Center of Gravity over Bottom Container Rim CGT Center of Gravity over Top Container Rim CFR Code of Federal Regulations EBA Evaluation by analysis HAC Hypothetical Accident Conditions H

Horizontal HFIR High Flux Isotope Reactor IAEA International Atomic Energy Agency M&TE Measuring and test equipment MNOP Maximum Normal Operating Pressure NIST National Institute of Standards and Technology NA Not applicable NCT Normal Conditions of Transport NRC Nuclear Regulatory Commission ORNL Oak Ridge National Laboratory TL ORNL/RRD Testing Lead TSD Top Slap Down VTU Vertical Top Up RRD Research Reactor Division

1

1.

ABSTRACT This test plan describes the testing configurations for the ORNL High Flux Isotope Reactor (HFIR) Inner and Outer Unirradiated Fuel Element Shipping Containers to be performed to demonstrate compliance with the requirements of 10 CFR 71.71, Normal Conditions of Transport and § 71.73 Hypothetical Accident Conditions of Transport of a -96 Shipping Package. Four test packages will be subjected to one or more of the required 10 CFR 71 tests.

2.

INTRODUCTION The inner and outer HFIR unirradiated fuel element shipping container designs were developed by ORNL in the 1960s. The ORNL Research Reactors Division (RRD) is the design authority for the packagings. The companion Safety Analysis Report for Packaging (SARP), Safety Analysis Report for Packaging: The ORNL HFIR Unirradiated Fuel Element Shipping Container, ORNL/TM-11656, (Reference 6.1) documenting compliance with 10 CFR 71, has not been updated to demonstrate compliance with the current (-96) requirements. Changes in regulatory requirements necessitate that each design be demonstrated to meet the most current conditions for (-96) package approval by the Nuclear Regulatory Commission (NRC). The principal change to the regulations requiring revaluation is the harmonization of the CFR to the International Atomic Energy Agency (IAEA) with the inclusion of the crush test. Though the IAEA requires performance of either a 30-ft drop or a crush test, the NRC requires demonstration of both.

The crush test, as specified in 10 CFR 71.73(c)(2), is required when the specimen has a mass not greater than 500 kg (1100 lb), an overall density not greater than 1000 kg/m3 (62.4 lb/ft3) based on external dimension, and radioactive contents greater than 1000 A2 not as special form radioactive material. For packages containing fissile material, the radioactive contents greater than 1000 A2 criterion does not apply. Both the inner fuel element shipping container and the outer fuel element shipping container weigh less than 1100 lb and have an overall density less than that specified in the regulations. Because the contents are fissile material, the A2 criterion does not apply. Therefore, both containers must be subjected to the crush test.

To demonstrate compliance, four prototype HFIR unirradiated fuel element shipping containers; two inner fuel element packages and two outer fuel element packages, will be fabricated and tested to 10 CFR 71 normal conditions of transport (NCT) and hypothetical accident conditions (HAC). Packages will be loaded with dummy fabricated fuel elements. The dummy elements are nearly identical to production fuel without uranium. Minor differences between the package content and production fuel elements are discussed in Section 5.1.2. In this test plan, the term content is synonymous with the inner or outer dummy fuel element, as applicable.

3.

GENERAL The following test matrix, Table 1, identifies the regulatory conditions and tests that are planned for each shipping container. It does not necessarily specify the required sequence. Procedures detail the test sequences, methods, and system requirements for measuring and recording results during and after each test. Package loading, closing and destructive and non-destructive examinations are also addressed. Specific tests, test conditions, orientations, etc. were selected based on regulatory requirements, evaluations currently included in the SARP, and engineering judgment developed from tests on similar packaging (See reference 6.2).

2 Based on the results of a test, the orientation specified within the matrix for the sequential test may be revised by the RRD Testing Lead (TL). Isometric views of the two test packages are illustrated in Figure 1.

Sectional views, Figure 2, illustrate the inner and outer HFIR fuel elements loaded within each packaging. Packaging dimensions and materials of construction are identified in Figures 1 and 2, respectively, and in the drawings included as Appendix A. All test procedures and reports shall use the nomenclature provided in this test plan and/or the packaging drawings, as applicable.

Table 1. USA/5797/B(U)F-96 Testing Matrix Test Unit ID CFR Ref.

Inner-1 Inner-1 Outer-1 Inner-2 Outer-2 Prototype Preparation Content measurements and weight x

x x

Package Measurements and weights x

x x

Package Marking x

x x

Instrumentation x

x x

Normal Conditions of Transport 10 CFR 71.71 Initial Conditions

(-20 to 100)

(b)*

A A

Maximum Normal Operating Pressure (MNOP)

(b)

Note 1 Note 1 Note 1 Note 1 Note 1 Conditions and Tests (c)

Heat (100/w solar)

(c)(1)

EBA EBA EBA EBA Cold

(-40)

(c)(2)

-40 Increased external pressure (c)(4)

Note 1 Note 1 Note 1 Note 1 Reduced external pressure (c)(3)

Note 1 Note 1 Note 1 Note 1 Vibration (c)(5)

(c)(5)

VTU (Note 4&7)

Water Spray (c)(6)

VTU VTU Free Drop (4-ft)

(c)(7)

CGT CGT TD H

Corner Drop (1-ft)

(c)(8)

Note 1 Note 1 Note 1 Note 1 Compression (c)(9)

VTU VTU Penetration (c)(10)

AS AS AS AS Hypothetical Accident Conditions 10CFR71.73 Test Conditions

(-20 to 100)

(b)

-20

-20 100 100 Tests (c)

Free Drop (30-ft)

(c)(1)

CGT CGB CGT TSD Note 9 Crush Test (30-ft) 1,100 lb plate (c)(2)

H Note 5 CGB H

Note 8 H

Note 10 Puncture Test (40-in)

(c)(3)

AS AS AS AS Thermal (c)(4)

AS AS Immersion-Fissile (3-ft)

(c)(5)

EBA EBA EBA EBA Immersion-all (50-ft)

(c)(6)

EBA EBA EBA EBA Special Requirements Type B (290psi) 10CFR71.

61 Note 11 Note 11 Note 11 Note 11

3 Test Unit ID CFR Ref.

Inner-1 Inner-1 Outer-1 Inner-2 Outer-2 Post Test Evaluation Non-Destructive Note 2 Note 3 Note 3 Note 3 Note 3 Destructive Note 6 Note 6 Note 6 Note 6

initial conditions are also applicable to HAC 10 CFR 71.73(b) x designates required

- designates not applicable Table Notes:

1. As discussed in Section 5.4 or 5.5 (as applicable), test will not be done.

2. Following -40 test; inspect and reassemble for NCT/HAC testing.

3. External inspection; dimensional measurements, weight, verification of no broken bolts, cracked welds, drum breaches, etc.

4. Use ORNL designed tie-down to secure drum in as-shipped configuration.

5. 30-ft CGT damage facing crush plate

6. Internal inspection; open or section container for internal diameter measurements, remove dummy fuel whole and inspect for damage.

7. Internal inspection; open container; inspect fuel element and packaging; reassemble for continued NCT/HAC testing.

8. Horizontal crush; damaged side from CGT against pad.

9. 15-degree shallow angle drop; 2 diameter post positioned at 12 oclock position, opposite secondary 30-ft drop impact point.

10. Horizontal crush; 2 diameter post at 12 oclock position damaged side from TSD facing pad

11. The contents of the shipping containers are less than 105A2. Therefore, this test is not applicable.

4

4.

QUALITY ASSURANCE PROGRAM 4.1 QUALITY ASSURANCE REQUIREMENTS The Quality Assurance (QA) program utilized for the testing shall comply with 10 CFR 71 Subpart H.

ORNL will ensure that the testing company flows down QA requirements applicable to the test program described in this test plan to any sub-tier suppliers that may perform work for the testing company in support of the test program.

4.2 QUALITY CATEGORY ORNL implements a transportation quality assurance program using a graded approach. Structures, systems, components, and activities have been categorized according to their importance to safety as recommended by NRC Regulatory Guide 7.10, Establishing Quality Assurance Programs for Packaging Used in Transport of Radioactive Material. Testing to be conducted as described in the test plan is considered to be a QA Category A activity.

QA Category A includes items and activities that could directly have an impact on public radiological health and safety. This classification includes items and activities for which omission, error, or failure could result in consequences exceeding the requirements specified in or based upon applicable federal regulations. These items and activities are critical to safety. Items that are critical to safe operation include items and activities whose failure or malfunction could result directly in a condition adversely affecting the public health and safety.

4.3 QUALITY ASSURANCE RECORDS All data, procedures, inspection reports, training records, calibration records, and other information generated as part of the test program are considered to be quality assurance records and shall be provided to RRD at the conclusion of the program.

5.

TEST PLAN The test plan specifies the tests to be conducted and the minimum test measurements that will be made. Test results provide an objective evaluation of package design response to required regulatory testing. It is the responsibility of ORNL to ensure that the contracted testing companys (or testing organizations) test procedures, test equipment, and facility infrastructure (unyielding surface, crush plate, puncture bar, thermal facility, etc.) comply with regulatory requirements. The contracted testing company shall provide evidence sufficient to allow ORNL to make that determination. Detailed test procedures shall be developed based on the test plan for each container. Test procedures shall provide sufficient specificity to ensure safety during all operations, inspections, loading, instrumentation, impact testing, post-test measurements and evaluations, etc. Quality assurance inspections of the packaging and its contents prior to and after testing is paramount and shall be explicitly defined in applicable test procedures.

5 5.1 PROTOTYPE PACKAGING AND CONTENT DESCRIPTION To demonstrate compliance with 10 CFR 71 NCT and HAC requirements, four prototype HFIR unirradiated fuel element shipping containers; two inner fuel element packagings and two outer fuel element packagings, will be fabricated to the same specifications as the existing, certified containers and tested. Where materials specified for the existing certified containers are no longer available, equivalent materials will be substituted. Packagings will be loaded with simulated and mock fuel elements for contents. Test packaging and content descriptions are provided below. The mock elements are dimensionally identical to production fuel but U-235 fissile loading is omitted. Other differences between the package contents are discussed under Section 5.1.2.

5.1.1 Prototype Packaging Prototype test package designs are detailed in Appendix A for the inner and outer HFIR unirradiated fuel element shipping containers. There are no exceptions taken to the referenced package design specifications in Appendix A for regulatory testing. Figure 1 illustrates isometric renderings of the inner and outer HFIR fuel element shipping containers. Figure 2 shows cross sectional views of the packages with fuel.

5.1.1.1 Inner Fuel Element Packaging The HFIR inner fuel element shipping container is composed of a carbon steel reinforced shell weldment with a bolted closure lid which, when assembled, is nominally 35-inches in diameter and 45-inches high.

Top and bottom subassemblies, composed of laminated Douglas fir plywood and positioned within the fabricated shell, provide impact and thermal protection to the inner fuel element during NCT and HAC.

The top wood subassembly is removable, for loading and unloading fuel elements. The internal cavity formed by the wood assembly is lined with high density polyethylene to mitigate vibration and shock to the fuel element during NCT. Empty packaging weight is approximately 557 lbs and gross weight is 660 lbs.

5.1.1.2 Outer Fuel Element Packaging The HFIR outer fuel element shipping container is similarly composed of a carbon steel reinforced shell weldment and bolted closure lid and is nominally 45-inches in diameter by 48-inches high assembled.

Like the inner fuel element package, top and bottom fir subassemblies provide impact and thermal protection to the outer fuel element during transport and HAC. High density polyethylene is also used to mitigate shock and vibration loads to the fuel element during NCT. In addition to the wood subassemblies, a wooden post is added to the bottom wooden subassembly to prevent loading of an inner fuel element in a loaded outer fuel element package. Empty packaging weight is approximately 845 lbs. with a gross weight of 1,050 lbs.

6 Figure 1. 5797 Inner and Outer HFIR Unirradiated Fuel Element Shipping Containers Figure 2. 5797 Inner and Outer HFIR Unirradiated Fuel Element Shipping Container Cross Sections

7 5.1.2 Prototype Fuel Elements Prototypical inner and outer HFIR fuel element designs are detailed in Appendix B. The prototypical mock fuel and simulated fuel elements used as content for testing are non-radiological, i.e., fabricated without uranium.

The mock elements are recently fabricated by the production fuel fabricator, BWXT, Lynchburg and are dimensionally identical to production fuel, but the U-235 fissile loading is omitted. Figure 3 illustrates production inner and outer HFIR fuel elements as listed in Appendix B, which also represent the mock elements used for testing. Mock fuel elements will be used as content for test units Inner-2 and Outer-2.

The simulated fuel elements are of a design proposed during development of the HFIR. They are similar in mass and approximate the shape of a production fuel element but differ somewhat in fabrication processes from production elements. The simulated elements were most recently used as display pieces at an ORNL museum. Simulated fuel elements will be used as content for test units Inner-1 and Outer-1. Specific differences between each of the package contents used for testing are discussed below and summarized in Tables 2 and 3.

5.1.2.1 Inner HFIR Fuel Element Mock Content The inner HFIR fuel BWXT prototypical (mock) content is identified as DUM 19-04 and is dimensionally identical to a production fuel element except that the U-235 fuel loading and burnable poison are omitted. It is 11.75 inches in diameter by 30.25 inches high and weighs 98 lbs. One hundred seventy one (171) equidistantly spaced, arched, rectangular fuel plates, 50-mil thick by approximately 4 inches wide by 24 inches long, are radially joined (welded) between inner and outer aluminum cylinders (i.e.

side plates). The 24-inch long fuel plates are positioned approximately mid-height of the 30.25 inch high assembly. The equidistantly spaced fuel plates produce an approximately 50-mil wide open channel between each fuel plate. The production inner fuel element certification drawing is provided in Appendix B.

A HFIR production inner fuel element is fabricated with approximately 5.8 lbs of U-235 and a burnable poison (B4C) equally distributed within the element fuel plates. Each of the 171 fuel plates has a maximum fuel loading of 15.33 grams U-235. The nominal weight of an inner fuel element with uranium fuel is 103.5 lbs.

For the mock fuel element to equal the full weight of an unirradiated (uranium bearing) inner fuel element, approximately 7 lbs of lead tape is applied to the mock content. Section 5.2.2, Weights, provides detail for lead tape addition.

5.1.2.2 Outer HFIR Fuel Element Mock Content The outer HFIR fuel mock content is identified as DUM 19-03 and is dimensionally identical to a production fuel element except that the U-235 fuel loading is omitted. The outer HFIR fuel mock content is 17.14 inches in diameter by 31.125 inches high and weighs approximately 189.8 lbs. Three hundred and sixty nine (369) equidistantly spaced, arched, rectangular fuel plates, 50-mil thick by approximately 4 inches wide by 24 inches long, are radially joined (welded) between inner and outer aluminum cylinders (i.e. side plates). The 24-inch fuel plates are positioned about mid-height of the 31.125 inch high assembly. The equidistantly spaced fuel plates produce an approximately 50-mil wide

8 open channel between each fuel plate. The production outer fuel element certification drawing is provided in Appendix B.

A HFIR production fuel element is fabricated with approximately 15.2 lbs of U-235 equally distributed within the assembly fuel plates. Each of the 369 fuel plates has a maximum fuel loading of 18.62 grams U-235. The nominal weight of an outer fuel element with uranium fuel is of 205 lbs.

For the mock fuel element to equal the full weight of an unirradiated (uranium bearing) outer fuel element, approximately 15 lbs of lead tape is applied to the mock element. Section 5.2.2, Weights, provides detail for lead tape addition.

5.1.2.3 Inner HFIR Fuel Element Simulated Content The inner HFIR simulated fuel element is of a design proposed during development of the HFIR and differs slightly from production fuel elements both dimensionally and in fabrication methods. The element bears the identification mark, Dummy 66, and is 11.75 inches (nominal) in diameter by 28.5 inches (nominal) high and weighs approximately 96 lbs. One hundred seventy one (171) equidistantly spaced, arched, rectangular fuel plates, 50-mil thick by approximately 4 inches wide by 24 inches long, are radially joined between inner and outer aluminum cylinders. The 24-inch long fuel plates are positioned approximately mid-height of the element. The fuel element end adapter design differs from that of a production fuel element as well as the fuel plate connection to the outer side plate, as can be seen in Figure 4 and by comparing Figure 4 to the production fuel element certification drawing in Appendix B. The equidistantly spaced fuel plates produce an approximately 50-mil wide open channel between each fuel plate when joined to the inner side plate; the channel radially tapers to zero where the fuel plate is joined to the outer side plate. Measurements of the simulated inner element are provided in Appendix C. A comparative summary of the difference between the inner mock and simulated fuel elements is provided in Table 2.

For the simulated fuel element to equal the full weight of an unirradiated (uranium bearing) inner fuel element, approximately 8 lbs of 3M' Lead Foil Tape 420 will be applied axially and of equal lengths to the center section of the element prior to testing.

5.1.2.4 Outer HFIR Fuel Element Simulated Content The outer HFIR simulated fuel element is of a design proposed during development of the HFIR and differs slightly from a production fuel element both dimensionally and in fabrication methods. The simulated fuel element is also identified as Dummy 66. A unique identifier will be applied prior to testing. The element is 17.1 inches in diameter by 31.1 inches high and weighs approximately 186 lbs.

Three hundred and sixty nine (369) equidistantly spaced, arched, rectangular fuel plates, 50-mil thick by approximately 4 inches wide by 24 inches long, are radially joined between inner and outer aluminum cylinders (side plates). The 24-inch fuel plates are positioned about mid-height of the element.

The fuel plate connection to the outer side plate differs from that of a production fuel element as shown in Figure 4. The equidistantly spaced fuel plates produce an approximately 50-mil wide open channel between each fuel plate when joined to the inner side plate; the channel radially tapers to zero where the fuel is joined to the outer side plate. The simulated fuel element end adapter design also differs from that of a production fuel element in that the upper end adapter of the production element is slightly tapered, whereas the end adapter of the simulated element is not. Measurements of the

9 simulated outer element are provided in Appendix C. A comparative summary of the difference between the outer mock and simulated fuel elements is provided in Table 3.

For the simulated fuel element to equal the full weight of an unirradiated (uranium bearing) outer fuel element, approximately 19 lbs of 3M' Lead Foil Tape 420 will be applied axially and of equal lengths to the center section of the element prior to testing.

Table 2. Summary Comparison of Mock and Simulated Content to Production Inner Fuel Element Outer Diameter (inches)

Height (inches)

Number of fuel plates &

channel width (inches)

Fissile loading (kilograms U-235)

Weight (lb)

Other differences from Production Element Production inner element 11.75 30.25 171 0.050 2.621 (max) 103.5 NA Mock content 11.75 30.25 171 0.050 0

98 NA Simulated content 11.74 28.49 171 0.050 0

96 (1) Lower end adapter cylindrical; (2) Flow channel tapers to zero at outer side plate Table 3. Summary Comparison of Mock and Simulated Content to Production Outer Fuel Element Outer Diameter (inches)

Height (inches)

Number of fuel plates &

channel width (inches)

Fissile loading (kilograms U-235)

Weight (lb)

Other differences from Production Element Production outer element 17.14 31.12 369 0.050 6.871 (max) 205 NA Mock content 17.14 31.12 369 0.050 0

189.8 End adapter-to-element body weld differs from production element Simulated content 17.1 31.1 369 0.050 0

186 (1) Upper end adapter cylindrical; (2) Flow channel tapers to zero at outer side plate

10 Figure 3. Production Inner and Outer HFIR Fuel Elements and Assembly Mock Elements HFIR Fuel Assembly as Configured in Reactor HFIR Inner Fuel Element HFIR Outer Fuel Element

11 Figure 4. Simulated Inner and Outer HFIR Fuel Content Inner & Outer Simulated Fuel Elements Inner Simulated Fuel Element - Post Machining Production Fuel Element Outer Side Plate Connection Simulated Fuel Element Outer Side Plate Connection

12 5.2 PROTOTYPE PREPARATION AND RECORDS FOR TESTING 5.2.1 Measurements Before and after each test that could alter the test unit dimensions, axial and radial distance measurements will be made utilizing the marked locations on the test units. Measurements may be made by fixed measuring tools and or scanning instrumentation. Test damage will be measured as appropriate to quantify deformations following each test. All measurements (dimensional, weight) will be witnessed by independent QA personnel.

5.2.2 Weights The weight of all components, contents, and packaging assemblies will be recorded before package testing. Post-test weights will identify the test or test sequence (NCT or HAC) for which a recorded weight was made. At a minimum, post-test weight of the package assembly will be recorded following the water spray test, at the conclusion of the NCT tests, and at the conclusion of the HAC tests. If practical (considering damage caused by a test), post-test weight of contents and any removable components (e.g. lid assembly) will also be recorded. For comparison, pre-and post-test measurements will be recorded on the same data sheet. An example weight data sheet is provided in Appendix D.

5.2.2.1 Inner Mock/Simulated Fuel Element Prior to testing, approximately 7 lbs and 8 lbs of 3M Lead Foil Tape 420 will be applied uniformly to the center section of the inner mock and simulated fuel elements, respectively. The lead tape will be applied so the approximate center of mass for each fuel element is unchanged.

5.2.2.2 Outer Mock/Simulated Fuel Element Prior to testing, approximately 15 lbs and 19 lbs of 3M Lead Foil Tape 420 will be applied uniformly to the center section of the outer mock and simulated fuel elements, respectively. The lead tape will be applied so the approximate center of mass for each fuel element is unchanged.

5.2.3 Marking (Packaging and Content)

All lettering, numbering and symbols applied to the package will be decals, stenciled, or otherwise made legible (not handwritten).

5.2.3.1 Packaging The surface of each 5797 packaging test unit will be marked as follows:

The packaging test unit number will be marked on the lid, body and bottom of each test unit, e.g.,

Inner-1, Outer-1, Inner-2, or Outer-2.

A 1/4 wide axial line will be marked on each container body (top to bottom) every 90 degrees, with 0° located at the container body under the lid reinforcing angle just clockwise from the Tamper Indicating Device (TID) position when viewed from the container top. Degree (0, 90, 180, 270) will

13 be marked on the lid and bottom of the test containers and on the top and bottom sides of each container.

The lid and body of each test unit will be marked with lid alignment indicators to ensure that the lid can be re-installed in the same orientation each time it is removed.

The outer test unit lids will be marked with a 2-inch diameter circle corresponding to the position of the safety post.

A 1/4circumferential line will be marked at the center of gravity for each test unit.

A CG symbol will be marked (decal) where the 0 degree and 180 degree axial and circumferential lines intersect. (CG of each test package may be measured via load cell or calculated.)

5.2.3.2 Contents (Mock and Simulated Fuel Elements)

The test unit number will be marked on each content element, e.g. (Inner-1, Outer-2, etc.). Note, the outer mock fuel element is marked Dum 19-03; the inner mock fuel element is marked Dum 19-04; and the inner and outer simulated fuel element are marked Dummy 66.

A 1/4 wide axial line will be marked on each dummy element OD every 90 degrees, (0, 90, 180, 270).

A 1/4circumferential line will be marked at the center of gravity for each dummy element.

A CG symbol will be marked where the 0 degree and 180 degree axial and circumferential lines intersect. (CG of each test assembly may be measured via load cell or calculated.)

5.2.4 Instrumentation and Devices A summary of equipment, infrastructure, and instrumentation devices expected to be used for testing is described below. Where applicable, equipment description, specifications, manufacturer, calibration data, documentation of traceability, drawings, infrastructure details, etc. shall be provided by the testing company as part of the test documentation.

Environmental chamber Temperature indicating labels Thermocouples Temperature I-buttons or equivalent Water spray station Load cells or scale(s)

Electromagnetic release mechanism Accelerometers (remote or wired)

14 Cameras (remote)

LVDT (remote)

Level(s)

Go-no-go gauges Torque wrenches Static weights or compression tester vibration system penetration bar puncture bar unyielding surface (drop pad) crush plate scanning devices thermal support structure Hi (min 1000 frames per second) and low speed video (minimum 120 frames per second)

Digital photography (35 mm minimum 12 Mpixel) 5.2.5 Video and Photography Photographs and video will be made to document all tests. Photographs will be taken of the test unit top, bottom and four quadrants before and after each test with relative orientation remaining the same for ease of comparison. Pre-test test unit orientations will be photographed. Gauges (rulers, coins, etc.)

will be used to mark damaged areas for relative comparison of the damage. All photographs taken of a test unit will show the date, time, test unit identification and test sequence.

Video documentation will include both high speed (minimum 1,000 frames per second) and low speed (120 frames per second) cameras. Adequate lighting will be provided for high speed video documentation. Video will be taken from a minimum of two positions, each 90 degrees apart. At a minimum, low speed video for the NCT drop and high speed video for HAC drop and crush will be used.

Low speed video will be used after each test to document (verbally and visually) damage in addition to still photography.

Where possible, video recordings and photography will be performed by the same individual(s).

15 5.3 TEST DOCUMENTATION A test report, signed by the testing company person(s) responsible for generating the report, will be produced documenting the Test Plan. The report will include a detailed summary of the performance testing so as to determine the effect on the design to the conditions and tests of NCT and HAC. At a minimum, the test report will include: photographs, completed procedures, data sheets, drawings, notes taken during testing, and reference to electronic media and files. The electronic test report will link edited video segments (low and high) of the dynamic testing (4-ft drop, penetration, 30-ft drop, crush, and puncture). Test documentation will include: the test report, unedited video files, instrumentation data, including measuring and test equipment (M&TE) calibration and traceability to NIST, as applicable, training or certification records of test personnel, and all other electronic evidence of testing. The test report will draw no conclusions on test results but will provide a summary of any extenuating conditions that could have affected a test result. The testing company will retain a copy of the test report and all electronic media for a minimum of 3-years. All original test documentation, completed procedures, data sheets, unedited videos, etc., will be provided to ORNL for retention as quality assurance records.

5.4 NORMAL CONDITIONS OF TRANSPORT TESTS The Code of Federal Regulations Title 10 Part 71 specifies that each package design must be evaluated to determine the effect on that design to the conditions and tests of normal conditions of transport.

The inner and outer test units will be tested as described in this section to demonstrate their performance to NCT testing.

5.4.1 Initial Conditions Unless specified otherwise, all tests will be performed under the inside or outside ambient temperature conditions of the test facility. MNOP for testing is not applicable for the 5797 packages because the package containment does not produce an operating pressure differential due to the contents negligible heat load.

Following cold condition testing (-40°F), test unit Inner-1 will be opened and inspected.

5.4.2 NCT Conditions and Tests 5.4.2.1 Heat Condition § 71.71(c)(1)

No heat condition (100 with insolation) will be applied to the tested packages. The SARP addresses package performance to the heat condition.

5.4.2.2 Cold Condition § 71.71(c)(2)

Test Unit Inner-1 will be chilled to a temperature of -40°F to -45 for a minimum of 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months and confirmed steady state is reached.

5.4.2.3 Increased external pressure § 71.71(c)(4)

Increased external pressure is not simulated for the tested units; evaluation is performed by analysis.

16 5.4.2.4 Reduced external pressure § 71.71(c)(3)

Reduced external pressure is not simulated for the tested units; evaluation is performed by analysis.

5.4.2.5 Vibration § 71.71(c)(5)

For vibration normally incident to transport, test units Inner-2 and Outer-2 will be subject to the NNSA secure transport shock and vibration spectrum for a minimum of 1 hour1.157407e-5 days 2.777778e-4 hours 1.653439e-6 weeks 3.805e-7 months .

5.4.2.6 Water Spray § 71.71(c)(6)

The water spray test will simulate exposure to rainfall of approximately 2 in/h for at least 1 hour1.157407e-5 days 2.777778e-4 hours 1.653439e-6 weeks 3.805e-7 months . Test units Inner-1 and Outer-1 will be tested.

5.4.2.7 Free Drop 4-ft § 71.71(c)(7)

A 4-ft free drop onto a flat, essentially unyielding, horizontal surface, striking the surface in a position for which maximum damage is expected is required. All test units will be tested at ambient conditions. Test units Inner-1 and Outer-1 will be tested between 1.5 and 2.5 hours5.787037e-5 days 0.00139 hours 8.267196e-6 weeks 1.9025e-6 months after the conclusion of the water spray test.

5.4.2.8 Corner Drop 1-ft § 71.71(c)(8)

No corner drops will be performed on the test units. The regulations do not require corner drops for packages of this design that exceed 220 lbs.

5.4.2.9 Compression § 71.71(c)(9)

A compressive load of 5 times the gross weight of the package will be applied uniformly to the top of a vertically standing package. Inner-1 and Outer-1 will be tested with minimum package loading of 3,300 lbs and 5,250 lbs, respectively. Dead weight or compression equipment may be used for loading.

Loading shall be applied for a minimum of 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months .

5.4.2.10 Penetration § 71.71(c)(10)

Impact of the hemispherical end of a vertical steel cylinder of 1.25 in diameter and 13 lbs mass, dropped from a height of 40 in onto the exposed surface of the package that is expected to be most vulnerable to puncture will be performed. The long axis of the cylinder must be perpendicular to the package surface.

The penetration test will be performed on all test units. Test unit orientation to the vertical steel cylinder that is expected to be most vulnerable to package puncture will be identified following each 4-ft drop.

17 5.5 HYPOTHETICAL ACCIDENT CONDITION (HAC) TESTS The Regulations (10 CFR 71.73) specify that each package design must be evaluated to determine the effect on that design to the conditions and HAC tests. The inner and outer test units will be tested as described in this section to demonstrate their performance to HAC testing.

5.5.1 Initial Conditions Inner test unit 1 and outer test unit 1 testing will be performed at -20. Inner test unit 2 and outer test unit 2 testing will be performed at 100. MNOP for testing is not applicable for the 5797 packages because the package containment does not produce an operating pressure differential due to the contents negligible heat load.

5.5.2 Free Drop 30-Feet § 71.73(c)(1)

A free drop of the test packages through a distance of 30 ft onto a flat, essentially unyielding, horizontal surface, striking the surface in a position for which maximum damage is expected will be performed.

Inner test unit 1 and outer test unit 1 will be chilled to less than -20 for the free drop. Inner test unit 2 and outer test unit 2 will be heated to 100 for structural testing.

Test units removed from the environmental chamber will be wrapped in insulation to minimize temperature change and tested within 45 minutes. Following post-test package measurements and weights the package will be re-insulated and crush tested as soon as practical.

Section 5.8.1 identifies the procedure and orientation for the package drops.

5.5.3 Crush § 71.73(c)(2)

All test units will undergo a dynamic crush test by positioning the test unit on a flat, essentially unyielding horizontal surface so as to suffer maximum damage by the drop of a 1100-lb mass from 30 ft onto the package.

Section 5.8.2 identifies the procedure and orientation for the package crush.

5.5.4 Puncture Test § 71.73(c)(3)

The puncture test is a free drop of the specimen through a distance of 40 in in a position for which maximum damage is expected, onto the upper end of a solid, vertical, cylindrical, mild steel bar mounted on an essentially unyielding, horizontal surface.

All test units will be tested. Test unit orientation to the vertical steel cylinder that is expected to be most vulnerable to package puncture will be identified following the crush test; see also Section 5.8.3.

18 5.5.5 Thermal Test § 71.73(c)(4)

The thermal test is exposure of the test package in a fully engulfing hydrocarbon fuel/air fire of sufficient extent, and in sufficiently quiescent ambient conditions, to provide an average emissivity coefficient of at least 0.9, with an average flame temperature of at least 1475°F for a period of 30 minutes, or any other thermal test that provides the equivalent total heat input to the package and which provides a time averaged environmental temperature of 1475°F. Artificial cooling may not be applied after cessation of external heat input, and any combustion of materials of construction, must be allowed to proceed until it terminates naturally.

Inner test unit 2 and outer test unit 2 may be thermally tested if cumulative NCT/HAC damage results in a container breach away from the package closure. A breach, for example, at the bottom of the package, could induce a chimney effect during the post-fire cool down where complete charring/combustion of the wooden sub-assemblies could ensue.

Section 5.9 provides the procedure and orientation for the package thermal test.

5.5.6 Immersion Test(s) § 71.73(c)(4) & (5)

No immersion tests will be performed because the containers are not leak tight. The criticality evaluation in the SARP assumed water inleakage.

5.6 PROCEDURES The contracted testing company shall submit implementing procedures for Sections 5.6 through 5.8 of this test plan to ORNL (RRD) for review and acceptance prior to testing.

5.6.1 Package Assembly Procedure Packages will be loaded and assembled per a testing company procedure approved by ORNL. Assembly consists of marking and wrapping the simulated and or mock contents in plastic, orienting them inside the inner or outer packaging based on test configuration and installing the closure lid and bolting closed to prescribed torque and sequence. Prior to closing a container for testing, QA personnel will verify all marking, wrapping, instrumentation (temperature indicating labels, thermocouples, accelerometers, etc.) and or measurements required prior to closure have been performed and M&TE calibration is current.

5.6.2 Content Verification Procedure Prior to loading contents, baseline measurements will be made to characterize the content dimensionally and by weight. Each content will be marked to identify it in subsequent post-test inspections and for identifying it with a test container ID. Photographs of each prototypical fuel element shall be made from the top, bottom and each quadrant. Fabrication inspections may be used for these measurements with QA oversight. Mock content flow channels will be inspected visually and by use of go-no-go gauge(s) between flow channels. All content measurements and observations will be documented using a Fuel Element Data Sheet similar to the attached example (Appendix E).

19 5.7 NORMAL CONDITIONS OF TRANSPORT PROCEDURES Procedures will include necessary data sheets that record each test initial conditions and the results of each test. At a minimum, the information specified in Section 5.3 will be detailed in the procedures and data sheets as necessary. All packages will be measured and photographed before and after testing.

Dynamic testing will be video recorded per section 5.2.5.

5.7.1 Initial Conditions Procedure Packages requiring heating/cooling will follow a testing company procedure approved by ORNL.

Packages subject to precondition heating or cooling (100/-20) will be outfitted with fixed thermo-couples or remote measuring devices that demonstrate the package (packaging and content) achieve the required steady state temperature prior to testing. To ensure temperature conditioning is met, packages will be heated or cooled by +/-5 as necessary. To stabilize temperature prior to testing, packages will be immediately insulated.

5.7.2 Cold Condition Procedure Packages requiring cooling to -40 will follow a testing company procedure approved by ORNL. The package subject to the CFR cold test will be outfitted with fixed thermo-couples and/or remote measuring devices that demonstrate the package (packaging and content) achieve a steady state temperature of -40. Following the cold test, the package will be opened and the packaging and its content inspected before further testing.

5.7.3 Vibration Procedure Packages requiring vibration normally incident to transport will follow a testing company procedure approved by ORNL. Test units Inner-2 and Outer-2 will be subjected to the NNSA secure transport shock and vibration spectrum for a minimum of 1 hour1.157407e-5 days 2.777778e-4 hours 1.653439e-6 weeks 3.805e-7 months . The packages will be anchored using ORNL HFIR package rigging. Following the test, each package will be opened and the packaging and its content inspected before further testing.

5.7.4 Water Spray Procedure Packages requiring water spray will follow a testing company procedure approved by ORNL. Packages will be tested vertically. Following each test the package will be weighed to evaluate if water infiltrated the package. Water collected on surfaces of the package will be removed/dried before weighing. Paper will be applied to the drop pad to identify any water loss from packages inverted (top down) for the 4-ft drop test.

5.7.5 Free Drop Procedure Packages requiring a free drop will follow a testing company procedure approved by ORNL. Package drop orientations are specified in Table 1. All inner and outer prototype units will be tested. The following figures specify the orientation for each package drop.

Inner-1 and Outer-1 will be dropped CGT (Center of Gravity over Top) targeting the TID section of the package closure where there is no 2 x 2 x 0.12 angle reinforcement of the closure lid. Refer to Figure 5, following.

20 Figure 5. Inner-1 and Outer-1 NCT 4-Ft CGT Drop Orientation As depicted in Figure 6, test unit Inner-2 will be dropped TD (Top Down) targeting the package closure.

Figure 6. Inner-2 NCT 4-Ft TD Drop Orientation Test unit Outer-2 will be dropped Horizontal, targeting the package unreinforced closure (Figure 7).

Figure 7. Outer-2 NCT 4-Ft Horizontal Drop Orientation Angle based on CG +- 3 degrees 4-foot drop Open section of 2 x 2 x 0.12 angle Angle +- 3 degrees 4-foot drop Package closure Open section of 2 x 2 x.12 angle Angle +- 3 degrees 4-foot drop Unyielding Surface Unyielding Surface Unyielding Surface

21 5.7.6 Compression Test Procedure Packages requiring a compression test will follow a testing company procedure approved by ORNL. Test units Inner-1 and Outer-1 will be tested standing vertically (VTU) for a minimum of 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months (Figure 8).

Testing may be performed with balanced dead weight(s) or with compression loading equipment. Dead weights and instrumentation associated with compression loading equipment will be traceable to the National Institute of Standards and Technology (NIST).

Figure 8. Inner-1 and Outer-1 NCT VTU Compression Test 5.7.7 Penetration Test Procedure All test units will be subject to a penetration test as specified in a testing company procedure approved by ORNL. The penetration bar will target the most vulnerable area of damage following the 4-ft drop.

5.8 HYPOTHETICAL ACCIDENT CONDITION TEST PROCEDURES Procedures will include necessary data sheets that record the results of each test. At a minimum, the information specified in section 5.3 will be detailed in the procedures and data sheets as necessary. All packages will be measured and photographed before and after testing. Dynamic testing will be video recorded per section 5.2.5.

5.8.1 HAC 30-Ft Drop Procedure The 30-ft free drop test will be conducted as specified in a testing company procedure approved by ORNL. Package drop orientations are specified in Table 1. All inner and outer test units will be tested.

The following figures specify the orientation for each package drop.

Test Weights Compression Plate

22 Inner-1 will be dropped CGT (Center of Gravity over Top) targeting the TID section of the package closure where there is no 2 x 2 x 0.12 angle reinforcement of the closure lid (Figure 9).

Figure 9. Inner-1 HAC 30-Ft CGT Drop Orientation Outer-1 will be dropped CGB (Center of Gravity over Bottom) targeting the unreinforced bottom of the package (Figure 10). The 2-inch diameter pine wood safety post (used to prevent loading of the inner fuel assembly with the outer fuel assembly) will be positioned 180 degrees from impact.

Figure 10. Outer-1 HAC 30-Ft CGB Drop Orientation 30-foot drop Open section of 2 x 2 x 0.12 angle Angle based on CG +- 3 degrees 30-foot drop Angle based on CG

+- 3 degrees Safety Post Package bottom Unyielding Surface Unyielding Surface

23 As shown in Figure 11, Inner-2 will be dropped CGT (Center of Gravity over Top) targeting the TID section of the package closure where there is no 2 x 2 x 0.12 angle reinforcement of the closure lid.

Figure 11. Inner-2 HAC 30-Ft CGT Drop Orientation Outer-2 will be dropped shallow angle TSD (Top Slap Down) impacting the package closure. The unreinforced TID section of the lid will be at about the 5 oclock position (22 degrees from impact). The 2-inch diameter pine wood safety post (used to prevent loading of the inner fuel assembly with the outer fuel assembly) will be positioned 180 degrees from impact. Refer to Figure 12.

Figure 12. Outer-2 HAC 30-Ft Shallow Angle TSD Drop Orientation Open section of 2 x 2 x 0.12 angle Angle based on CG

+- 3 degrees 30-foot drop Unyielding Surface Package top Safety Post 15 degree angle

+- 3 degrees 30-foot drop Unyielding Surface

24 5.8.2 HAC 30-Ft Crush Test Procedure The 30-ft crush test will be conducted as specified in a testing company procedure approved by ORNL.

Package orientations are specified in Table 1. All inner and outer test units will be tested. The following figures specify the orientation for each package crush. Strings or similar support means to balance a package as required for a crush test will not interfere with package performance.

Test unit Inner-1 will be crushed in the horizontal position with the damage to the unreinforced closure from the 30-ft CGT test facing the crush plate (Figure 13). The crush plate will target the center of the damaged package.

Figure 13. Inner-1 HAC Crush Test Horizontal Drop Orientation Test unit Outer-1 will be crushed in the CGB position with the unreinforced closure facing the crush plate and damage from the 30-ft drop against the unyielding surface (Figure 14). The crush plate will target the CG of the package.

Figure 14. Outer-1 HAC Crush Test CGB Drop Orientation 1,100 lb Crush Plate (40 x 40)

Damaged open section of 2 x 2 x 0.12 angle 30-feet 1,100 lb. Crush Plate 40x40 30-ft Angle based on CG

+- 3 degrees Damaged package bottom Safety Post Unyielding Surface

25 As shown in Figure 15, test unit Inner-2 will be crushed in the horizontal position with the damage to the unreinforced closure from the 30-ft CGT facing the unyielding surface. The crush plate will target the center of the damaged package.

Figure 15. Inner-2 HAC Crush Test Horizontal Drop Orientation Test unit Outer-2 will be crushed in the horizontal position with the damage from the 30-ft shallow angle drop facing the unyielding surface (Figure 16). The 2 diameter pine post will be positioned 180 degrees from the unyielding surface. The crush plate will target the center of the damaged package.

Figure 16. Outer-2 HAC Crush Test Horizontal Drop Orientation Damaged open section of 2 x 2 x.12 angle 30-feet 1,100 lb Crush Plate (40 x 40)

Unyielding Surface Damaged package top Safety Post Unyielding Surface 1,100 lb Crush Plate 40x40 30-Feet

26 5.8.3 Puncture Test Procedure The puncture test will be conducted as specified in a testing company procedure approved by ORNL. All inner and outer test units will be subject to a puncture test. The most vulnerable package damage from drop and crush testing will be targeted to maximize package damage. Figure 17 illustrates a typical puncture test.

Figure 17. Typical Drop Configuration for Puncture Test 5.9 THERMAL TEST PROCEDURE Packages requiring a Thermal test will follow a testing company procedure approved by ORNL. Package orientations are specified in Table 1. As necessary Inner-2 and Outer-2 will be thermally evaluated via a pool fire or furnace testing. Cribbing will be constructed to support each package and insulated as required to minimize its post-test thermal signature. Figure 18 illustrates the typical horizontal and vertical orientations selected for the thermal test.

Figure 18. Thermal Test Orientations 40-inch to point of impact Unyielding Surface 6 diameter puncture bar; minimum 8 long.

Insulation wrapped cribbing

27 5.10 TEST UNIT INSPECTIONS The tested prototypes will be examined both externally and internally post-testing. Disassembly may be performed non-destructively depending on the extent of package damage. If destructive disassembly is required for internal examinations, the method selected for disassembly will ensure no damage to the contents.

At a minimum, when internal inspections are required, the following will be performed:

Breakaway torques for the lid closure bolts, Lid gasket inspection for cuts and gouges, Foam adhesion, Fuel gap measurements, Verification of no debris within the container, e.g., aluminum filings, foam, etc., and General package damage, cuts, gouges.

28

6.

REFERENCES

1. ORNL/TM-11656, Volumes 1 & 2, Revision 13, Safety Analysis Report for Packaging: The ORNL HFIR Unirradiated Fuel Element Shipping Container.

2. ORNL/RRD/INT-174, Revision 0, Test Plan for Normal Conditions of Transport and Hypothetical Accident Condition Tests, Oak Ridge National Laboratory Package Design USA/5797/B(U)F-96:

Bases for Selecting Tests, Orientations, and Test Conditions.

7.

APPENDICES A. Inner and Outer HFIR Fuel Assembly Packaging Test Unit Drawings B. HFIR Production Fuel Element Drawings C. HFIR Mock and Simulated Inner and Outer Fuel Element Designs D. Instrumentation, Measurements and Weights E. Sample Fuel Element Data Sheet

A-1 APPENDIX A.

Inner and Outer HFIR Fuel Assembly Packaging Test Unit Drawings Inner Fuel Element Packaging Drawing No Revision Sheet Title M-20978-EL-003A 0

1/1 HFIR Unirradiated Inner Fuel Element Shipping Container Assembly (Test Unit)

M-20978-EL-003B 0

1/4 HFIR Unirradiated Inner Fuel Element Shipping Container Assembly & Details (Test Unit) 0 2/4 HFIR Unirradiated Inner Fuel Element Shipping Container Assembly & Details (Test Unit) 0 3/4 HFIR Unirradiated Inner Fuel Element Shipping Container Assembly & Details (Test Unit) 0 4/4 HFIR Unirradiated Inner Fuel Element Shipping Container Assembly & Details (Test Unit)

M-20978-EL-003C 0

1/4 HFIR Unirradiated Inner Fuel Element Shipping Container Lid Assembly (Test Unit) 0 2/4 HFIR Unirradiated Inner Fuel Element Shipping Container Lid Assembly (Test Unit) 0 3/4 HFIR Unirradiated Inner Fuel Element Shipping Container Lid Assembly (Test Unit) 0 4/4 HFIR Unirradiated Inner Fuel Element Shipping Container Lid Assembly (Test Unit)

M-20978-EL-008A 0

1/1 HFIR Unirradiated Inner/Outer Fuel Element Shipping Container Detail (Test Unit)

Outer Fuel Element Packaging Drawing No Revision Sheet Title M-20978-EL-002A 0

1/1 HFIR Unirradiated Outer Fuel Element Shipping Container Assembly (Test Unit)

M-20978-EL-002B 0

1/4 HFIR Unirradiated Outer Fuel Element Shipping Container Assembly & Details (Test Unit) 0 2/4 HFIR Unirradiated Outer Fuel Element Shipping Container Assembly & Details (Test Unit) 0 3/4 HFIR Unirradiated Outer Fuel Element Shipping Container Assembly & Details (Test Unit) 0 4/4 HFIR Unirradiated Outer Fuel Element Shipping Container Assembly & Details (Test Unit)

M-20978-EL-002C 0

1/4 HFIR Unirradiated Outer Fuel Element Shipping Container Lid Assembly & Details (Test Unit) 0 2/4 HFIR Unirradiated Outer Fuel Element Shipping Container Lid Assembly & Details (Test Unit) 0 3/4 HFIR Unirradiated Outer Fuel Element Shipping Container Lid Assembly & Details (Test Unit) 0 4/4 HFIR Unirradiated Outer Fuel Element Shipping Container Lid Assembly & Details (Test Unit)

A-2

A-3

A-4

A-5

A-6

A-7

A-8

A-9

A-10

A-11

A-12

A-13

A-14

A-15

A-16

A-17

A-18

A-19

A-20

B-1 APPENDIX B.

HFIR Production Fuel Element Drawings Drawing No Revision Sheet Title M-11524-OH-106 4

1/1 HFIR Inner Fuel Element Certification Drawing M-11524-OH-107 4

1/1 HFIR Outer Fuel Element Certification Drawing

B-2

B-3

C-1 APPENDIX C.

HFIR Mock and Simulated Inner and Outer Fuel Element Designs Drawing No Revision Sheet Title M-11524-OH-106 4

1/1 Inner HFIR Mock Fuel Element*

M-11524-OH-107 4

1/1 Outer HFIR Mock Fuel Element*

Refer to Appendix B. Mock inner and outer fuel element design is identical to the design of the production fuel elements except as noted in Section 5.1.2, above.

Inner HFIR Simulated Fuel Element Design Parameter Simulated fuel element Production fuel element Material 6061 Al 6061 Al Outer side plate outer diameter 10.495 in.

10.580 in.

Inner side plate inner diameter 5.069 in.

5.069 in.

Height 28.491 in.

30.250 in.

Fuel plate length 23.923 in.

24.000 in.

Flow channel width (average) 0.05 in.

0.05 in.

Weight 96.4 lb.

103.5 lb.

Outer HFIR Simulated Fuel Element Design Parameter Simulated fuel element Production fuel element Material 6061 Al 6061 Al Outer side plate outer diameter 17.119 in.

17.139 in.

Inner side plate inner diameter 11.254 in.

11.235 in.

Height 31.092 in.

31.125 in.

Fuel plate length 24.000 in.

24.000 in.

Flow channel width (average) 0.05 in.

0.05 in.

Weight 186.3 lb.lb.

205 lb.

D-1 APPENDIX D.

Instrumentation, Measurements, and Weights WEIGHTS - Inner/Outer HFIR Fuel Element Package Test Unit ID Pre Test Wt (lbs)

Post Test Wt (lbs)

NCT HAC compression vibration water spray 4-ft drop penetration 30-ft drop crush puncture thermal Pkg Component(s)*

Container Lid Assembly with fasteners Container Body Container Assembly Container Packing Materials**

Fuel Assembly Circle mock/simulated

Enter N/A if test damage prevents measurement. ** Provide description of all packing materials

D-2 M&TE Quality Assurance Record M&TE Description Range M&TE No.

Expiration Date NIST Traceability #

Identify M&TE used for each measurement; item weight should not be within 10% of scale range Test Engineer:

Date:

QA Check:

Date:

E-1 APPENDIX E.

Example Fuel Element Data Sheet

ML21292A223

Text

Subject:

Introduction:

References:

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