Text

Request for Authorization of One-Time Shipment of Model No. Halfpact Crediting the Outer Confinement Vessel as the Containment Boundary
	ML23046A454
Person / Time
Site:	07109279
Issue date:	02/15/2023
From:	Sellmer T; Salado Isolation Mining Contractors (SIMCO) LLC, US Dept of Energy, Carlsbad Field Office
To:	; Office of Nuclear Material Safety and Safeguards, Document Control Desk
References
	TS:23:03006, UFC:5822.00
	Download: ML23046A454 (1)
	v • d • e

P.O. Box 2078 z Carlsbad, New Mexico USA 88221-2078 Phone: (575) 234-7200 z Fax: (575) 234-7083 TS:23:03006 UFC: 5822.00 February 15, 2023 ATTN: Document Control Desk Director, Spent Fuel Project Office Office of Nuclear Material Safety and Safeguards U. S. Nuclear Regulatory Commission Washington, DC 20555-0001

Subject:

HalfPACT DOCKET NO. 71-9279, REQUEST FOR AUTHORIZATION OF ONE-TIME SHIPMENT OF MODEL NO. HalfPACT CREDITING THE OUTER CONFINEMENT VESSEL AS THE CONTAINMENT BOUNDARY

Dear Ms. Diaz-Sanabria:

Salado Isolation Mining Contractors (SIMCO) LLC, on behalf of the U. S. Department of Energy Carlsbad Field Office (DOE/CBFO), is submitting this request for the authorization for a one-time shipment of a single HalfPACT package crediting the outer confinement vessel (OCV) as the containment boundary instead of the inner containment vessel (ICV). The HalfPACT packaging is licensed under the U.S. Nuclear Regulatory Commission (NRC) Certificate of Compliance (CofC) No. 9279, Revision 11.

HalfPACT 506 with Payload SRE033 was sent from the Savannah River Site (SRS) on August 25, 2022, and received on August 26, 2022, at the Waste Isolation Pilot Plant (WIPP) (Shipment SR220010). During the processing of the package, which includes venting and sampling of the ICV headspace prior to ICV lid removal, internal airborne plutonium-238 and americium-241 contamination was detected. WIPP safety protocol prevents opening the potentially contaminated ICV and dictates its return to SRS for investigation into the possible contamination source. The ability to return HalfPACT 506 is currently precluded, because its mandatory 5-year maintenance certification expired on September 1, 2022, such that the unit is out of compliance with CofC No. 9279, condition 11(b).

This request seeks a one-time authorization to use the outer confinement assembly (OCA) of another HalfPACT unit to transport the HalfPACT 506 ICV (ICV 506) as its authorized content, while crediting the OCV as the containment boundary. Crediting the OCV as the containment boundary is not without precedence. Prior to CofC No. 9279, Revision 7, both the OCV and ICV were credited as containment boundaries. Use of the OCV as the containment boundary is supported through application of targeted acceptance tests, maintenance activities, and operating procedures specific to this shipment. All other applicable requirements identified in CofC No. 9279 will be met for this shipment, as described in Attachment A.

This one-time shipment will originate at WIPP and terminate at SRS. Due to WIPP Hazardous Waste Facility Permit limitations on aboveground storage durations (expiring

Document Control Desk TS:23:03006 P.O. Box 2078 z Carlsbad, New Mexico USA 88221-2078 Phone: (575) 234-7200 z Fax: (575) 234-7083 on May 21, 2023), DOE/CBFO is requesting the authorization for this one-time shipment from the Commission on or before May 17, 2023.

The following documents are attached to support this request:

x Attachment A - Roadmap of HalfPACT Certificate of Compliance No. 9279 Conditions Evaluation x Attachment B - HPT-PRO-0003, Containment for One-Time Shipment Supporting ICV 506 x Attachment C - HPT-PRO-0001, Operating Procedures for One-Time Shipment Supporting ICV 506 x Attachment D - HPT-PRO-0002, Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506 x Attachment E -ICV 506 Payload SRE033 Flammable Gas Concentration Initial Condition x Attachment F - References o PLD-CAL-0007, Flammable Gas Concentration Evaluation for HalfPACT Payload SRE033 o HPT-CAL-0001, Loaded HalfPACT ICV Lifting Evaluation Attachment A provides the description of how this one-time shipment complies with CofC No. 9279 with the exception that the OCV instead of the ICV is established as the containment boundary. Attachment B presents the containment conditions for the shipment of ICV 506. Attachments C and D detail the revised operating procedures and acceptance tests and maintenance program necessary to support the shipment of ICV 506. Attachment E demonstrates that the CH-TRAMPAC compliance determination for the ICV 506 payload is unaffected by the conditions for the return shipment of the same payload. Attachment F includes calculations referenced in Attachments C and E. These attachments demonstrate that this one-time shipment can be made in a safe and compliant manner that fully protects the public and the environment.

If you have any questions or require additional information regarding this request, please contact me at (575) 234-7396 or via cell phone at (575) 302-7583.

Sincerely, T. E. Sellmer, Manager Packaging and Information Systems TES:clm TODD SELLMER (Affiliate)

Digitally signed by TODD SELLMER (Affiliate)

Date: 2023.02.15 13:40:53 -07'00'

Document Control Desk TS:23:03006 P.O. Box 2078 z Carlsbad, New Mexico USA 88221-2078 Phone: (575) 234-7200 z Fax: (575) 234-7083 cc: D. Bamper, CBFO M. Bollinger, CBFO D. C. Gadbury, CBFO K. E. Princen, CBFO D. M. Smith, CBFO D. L. Standiford, CBFO M. Toothman, CBFO J. A. Walker, CBFO J. Shuler, EM-4.24 J. Shenk, EM-4.24 L. F. Gelder, SRRC M. Bowers, SRS M. Budney, SRS H. Crapse, DOE/SRS K. Crawford, SRS M. Garrett, SRS V. Kay, NNSS/SRS P. Kilroy, SRS M. Maxted, NNSA/SRS S. Protzman, SRS Y. K. Diaz-Sanabria, USNRC N. Garcia Santos, USNRC B. H. White, USNRC

Document Control Desk TS:23:03006 P.O. Box 2078 z Carlsbad, New Mexico USA 88221-2078 Phone: (575) 234-7200 z Fax: (575) 234-7083 The following table summarizes the components of this submittal. No deviations occur from the NRC-prescribed PDF formatting for the submitted files. Please contact Ms. C. L. Morrison at (505) 350-3693 or cindy.morrison@wipp.ws to resolve any discrepancies in this submittal.

File Name File Size (MB)

Release Level Submittal Type 001 Request for One-Time Shipment.pdf 5.64 Publicly Available EIE

Attachment A Roadmap of Certificate of Compliance No. 9279 Conditions Evaluation

A-1 ATTACHMENT A ROADMAP OF HALFPACT CERTIFICATE OF COMPLIANCE NO. 9279 CONDITIONS EVALUATION The following is provided as an evaluation roadmap for the one-time HalfPACT shipment crediting the outer confinement vessel (OCV) as the containment boundary against the HalfPACT Certificate of Compliance (CofC) No. 9279 conditions, based on the HalfPACT Safety Analysis Report (SAR) and the CH-TRU Waste Authorized Methods for Payload Control (CH-TRAMPAC). An evaluation of the HalfPACT SAR and CH-TRAMPAC requirements is provided below and shows no impact to CofC No. 9279 conditions, with the exception that the OCV instead of the inner containment vessel (ICV) is established as the containment boundary.

HalfPACT SAR Section Analysis Evaluation of Compliance 2.0 Structural Evaluation There are no structural impacts to the HalfPACT packaging resulting from the one-time shipment of the HalfPACT crediting the OCV as the containment boundary.

As described in HalfPACT SAR Section 2.10.3, the OCV is configured as a secondary confinement boundary when its optional O-ring seals are utilized. For this shipment, the leak-tight capability of the OCV as the containment boundary will be ensured by using Category A butyl rubber O-ring seals that meet the performance requirements specified in Section 2.10.2 of the HalfPACT SAR and confirmed by leakage rate testing as described in Attachments B through D.

A-2 HalfPACT SAR Section Analysis Evaluation of Compliance 3.0 Thermal Evaluation There is no thermal impact to the HalfPACT packaging for either normal or hypothetical accident conditions of transport resulting from the one-time shipment of the HalfPACT crediting the OCV as the containment boundary.

The thermal limit for the one-time shipment of the HalfPACT remains the same as discussed in HalfPACT SAR Chapter 3.0.

4.0 Containment The one-time shipment of the HalfPACT credits the OCV as the containment boundary instead of the ICV as described in HalfPACT SAR Chapter 4.0. Attachment B, HPT-PRO-0003, Containment for One-Time Shipment Supporting ICV 506, provides the conditions to establish the OCV as the containment boundary for this shipment. Due to the out-of-date mandatory 5-year maintenance activities for the loaded ICV 506, the containment criteria defined by HalfPACT SAR Chapter 4.0 is applied to the OCV containment boundary instead of the ICV for this one-time shipment. Prior to shipment, the leak-tight containment of the OCV containment boundary will be verified by leakage rate testing as described in Attachment C, HPT-PRO-0001, Operating Procedures for One-Time Shipment Supporting ICV 506.

5.0 Shielding Evaluation There is no shielding impact to the HalfPACT packaging resulting from the one-time shipment of the HalfPACT crediting the OCV as the containment boundary.

The HalfPACT package activity limits demonstrating that the regulatory dose rate requirements are satisfied for this one-time shipment of the HalfPACT remain the same as those specified in HalfPACT SAR Chapter 5.0.

6.0 Criticality Evaluation There is no criticality impact to the HalfPACT packaging resulting from the one-time shipment of the HalfPACT crediting the OCV as the containment boundary.

The Pu-239 fissile gram equivalent limits applied to this one-time shipment of the HalfPACT are the same as those specified in HalfPACT SAR Chapter 6.0 and ensure that this HalfPACT package is safely subcritical.

A-3 HalfPACT SAR Section Analysis Evaluation of Compliance 7.0 Operating Procedures The one-time shipment of the HalfPACT requires the implementation of operating procedures that differ from those detailed in HalfPACT SAR Chapter 7.0. Attachment C, HPT-PRO-0001, Operating Procedures for One-Time Shipment Supporting ICV 506, details the instructions to be followed for transferring the loaded ICV 506 to the outer confinement assembly, including the OCV, of a different HalfPACT unit. The OCV lid installation process detailed in HalfPACT SAR Section 7.0 is modified as explained in Attachment C to include leakage rate testing to establish the OCV as the containment boundary for this shipment.

8.0 Acceptance Tests and Maintenance Program The one-time shipment of the HalfPACT requires implementation of the acceptance tests and maintenance program to establish the OCV as the containment boundary instead of the ICV.

Attachment D, HPT-PRO-0002, Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506, details the performance of the acceptance tests and maintenance program that differs from that described by HalfPACT SAR Chapter 8.0.

9.0 Quality Assurance Use of the HalfPACT for the one-time shipment crediting the OCV as the containment boundary is subject to the same quality assurance requirements summarized in HalfPACT SAR Chapter 9.0 in accordance with 10 CFR 71, Subpart H.

A-4 CH-TRAMPAC Evaluation of Compliance Users of the HalfPACT package shall comply with all payload requirements outlined in the CH-TRAMPAC. ICV 506 Payload SRE033 is compliant with CH-TRAMPAC requirements.

Payload SRE033 was previously certified to CH-TRAMPAC requirements and compliantly shipped in HalfPACT 506 from the Savannah River Site (SRS) to the Waste Isolation Pilot Plant (WIPP). Payload SRE033 remains loaded ICV 506. Because the payload data properties are unchanged, Payload SRE033 will be certified for shipment of ICV 506 from WIPP to SRS using the same CH-TRAMPAC compliance determination.

Because ICV 506 has been stored in a sealed condition since the identification of potential contamination, an evaluation was performed to demonstrate that the altered initial condition for Payload SRE033 (i.e., sealed in ICV 506) does not change the previous CH-TRAMPAC compliance determination (see Attachment E).

Attachment B HPT-PRO-0003, Containment for One-Time Shipment Supporting ICV 506

Document Preparer S. A. Porter Signature Date Independent Reviewer R. S. Burns Signature Date Cognizant Manager T. E. Sellmer Signature Date Quality Assurance D. S. Tanner Signature Date Containment for One-Time Shipment Supporting ICV 506 Prepared by:

Prepared for:

SIMCO Transportation Packaging Group Document Number:

HPT-PRO-0003, Rev. 1 February 2023 Digitally signed by ROBERT BURNS (Affiliate)

Date: 2023.02.08 10:44:21 -07'00' Digitally signed by STEVEN PORTER (Affiliate)

Date: 2023.02.08 10:38:45 -08'00' David S. Tanner Digitally signed by David S. Tanner Date: 2023.02.08 13:17:28 -07'00' TODD SELLMER (Affiliate)

Digitally signed by TODD SELLMER (Affiliate)

Date: 2023.02.08 13:44:04 -07'00'

This page intentionally left blank to facilitate duplex printing.

HPT-PRO-0003, Rev. 1 February 2023 iii TABLE OF CONTENTS

1.0 INTRODUCTION

................................................................................................................. 1 1.1 Purpose............................................................................................................................. 1 1.2 Background...................................................................................................................... 1 1.3 Format.............................................................................................................................. 1 4.0 CONTAINMENT.................................................................................................................. 2 4.1 Containment Boundary.................................................................................................... 2 4.1.1 Containment Vessel............................................................................................. 2 4.1.2 Containment Penetrations.................................................................................... 2 4.1.3 Seals and Welds................................................................................................... 3 4.1.4 Closure................................................................................................................. 3 4.2 Containment Requirements for Normal Conditions of Transport................................... 5 4.2.1 Containment of Radioactive Material.................................................................. 5 4.2.2 Pressurization of Containment Vessel................................................................. 5 4.2.3 Containment Criterion......................................................................................... 5 4.3 Containment Requirements for Hypothetical Accident Conditions................................ 6 4.3.1 Fission Gas Products............................................................................................ 6 4.3.2 Containment of Radioactive Material.................................................................. 6 4.3.3 Containment Criterion......................................................................................... 6 4.4 Special Requirements....................................................................................................... 7 4.4.1 Plutonium Shipments........................................................................................... 7 4.4.2 Interchangeability................................................................................................ 7

HPT-PRO-0003, Rev. 1 February 2023 iv TABLE OF REVISIONS Revision Number Pages Affected Revision Description 0

All New issue.

1 1 - 4, 6, 7 Revised to clarify terminology regarding confinement and containment and a few additional minor editorials.

HPT-PRO-0003, Rev. 1 February 2023 1

1.0 INTRODUCTION

1.1 Purpose The purpose of this document is to discuss the containment requirements to be implemented on the HalfPACT packaging prior to the one-time shipment supporting ICV 506. The Outer Confinement Vessel (OCV) shall serve as the containment boundary for this one-time shipment.

Previous revisions of the HalfPACT Safety Analysis Report (SAR) (up to and including Revision 5) discussed two independent levels of containment established within the HalfPACT package. The primary level of containment was the Outer Containment Assembly, and the secondary level of containment was the Inner Containment Vessel (ICV). In March 2013, the HalfPACT SAR (Revision 6) was revised from requiring two independent levels of containment to requiring single containment, where the ICV was credited as the containment boundary. This allowed for the use of O-ring seals previously required on the OCV to credit containment to become optional. Without the use of the Category A butyl rubber O-ring seals on the OCV, it cannot be credited as a containment boundary. The Category A butyl rubber O-ring seals will be used on the OCV for this one-time shipment supporting ICV 506.

1.2 Background

HalfPACT 506 with Payload SRE033 was sent from the Savannah River Site (SRS) on August 25, 2022, and received on August 26, 2022, at the Waste Isolation Pilot Plant (WIPP)

(Shipment SR220010). During the processing of the package, which includes venting and sampling of the ICV headspace prior to ICV lid removal, internal airborne plutonium-238 and americium-241 contamination was detected. WIPP safety protocol prevents opening the potentially contaminated ICV and dictates its return to SRS for investigation into the possible contamination source. The ability to return HalfPACT 506 is currently precluded because its mandatory 5-year maintenance certification expired on September 1, 2022, such that the unit is out of compliance with Certificate of Compliance (CofC) No. 9279.

In order to return ICV 506 with its payload to SRS, the loaded ICV 506 will be transferred from HalfPACT 506 Outer Confinement Assembly (OCA) to a different HalfPACT OCA. Use of an alternate HalfPACT OCA is supported through the application of targeted acceptance tests, maintenance activities, and operating procedures to credit the OCAs OCV as the containment boundary for this one-time shipment.

1.3 Format The format of this document will utilize a format similar to Chapter 4.0, Containment, of the HalfPACT SAR, including identical section numbering to facilitate ease of review. Sections that are not applicable due to the situation of this one-time shipment are noted accordingly. Change bars are included for information that is different than the currently approved HalfPACT SAR, Revision 9, but specific to this one-time shipment authorization.

HPT-PRO-0003, Rev. 1 February 2023 2

4.0 CONTAINMENT 4.1 Containment Boundary 4.1.1 Containment Vessel One level of containment is established within the HalfPACT package for this one-time shipment supporting ICV 506. In general, the containment and confinement vessels are constructed primarily of ASTM A240, Type 304, austenitic stainless steel. The exceptions to the use of ASTM A240, Type 304, stainless steel are so noted in the following detailed descriptions.

4.1.1.1 Outer Confinement Assembly (Primary Containment)

The containment boundary of the outer confinement vessel (OCV), provided as part of the outer confinement assembly (OCA), consists of the inner stainless steel vessel comprised of a mating lid and body, plus the uppermost (innermost, of Category A butyl rubber) of two required main O-ring seals between them. In addition, the containment boundary includes an ASTM B16, Alloy 360, brass OCV vent port plug with a mating required O-ring seal of Category A butyl rubber. A more detailed description of the OCV containment boundary is provided in Section 1.2.1.1.1, Outer Confinement Assembly (OCA), and in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

The non-stainless steel components utilized in the OCV containment boundary are the required upper (inner) butyl O-ring seal, the brass vent port plug, and the required butyl O-ring seal on the vent port plug.

4.1.1.2 Inner Containment Vessel (Containment - Not Credited)

The containment boundary of the Inner Containment Vessel (ICV) consists of a stainless steel vessel comprised of a mating lid and body, plus the uppermost (innermost) of the two main O-ring seals between them. In addition, the containment boundary includes an ASTM B16, Alloy 360, brass ICV outer vent port plug with a mating butyl O-ring seal. A more detailed description of the ICV containment boundary is provided in Section 1.2.1.1.2, Inner Containment Vessel (ICV) Assembly, and in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

The non-stainless steel components utilized in the ICV containment boundary are the upper (inner) butyl O-ring seal, the brass outer vent port plug, and the butyl O-ring seal on the vent port plug.

4.1.2 Containment Penetrations The only containment boundary penetrations into the OCV containment vessel is the lid itself, and its corresponding vent port. Each penetration is designed to demonstrate leaktight sealing integrity, i.e., a leakage rate not to exceed 1 x 10-7 standard cubic centimeters per second (scc/sec), air, as defined in ANSI N14.51.

1Property "ANSI code" (as page type) with input value "ANSI N14.51.1" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process. ANSI N14.5-1997, American National Standard for Radioactive Materials - Leakage Tests on Packages for Shipment, American National Standards Institute, Inc. (ANSI).

HPT-PRO-0003, Rev. 1 February 2023 3

4.1.3 Seals and Welds 4.1.3.1 Seals Seals affecting containment are described above. A summary of seal testing prior to first use, during routine maintenance, and upon assembly for transportation is as follows.

4.1.3.1.1 Fabrication Leakage Rate Tests During fabrication and following the pressure testing per Section 8.1.2.2, Pressure Testing, of HPT-PRO-0002,2 the OCV (primary containment) shall be leakage rate tested as delineated in Section 8.1.3, Fabrication Leakage Rate Tests, of HPT-PRO-0002.2 The fabrication leakage rate tests are consistent with the guidelines of Section 7.3 of ANSI N14.5. This leakage rate test verifies the containment integrity of the HalfPACT packages OCV to a leakage rate not to exceed 1 x 10-7 scc/sec, air.

4.1.3.1.2 Maintenance/Periodic Leakage Rate Tests Annually, or at the time of damaged containment seal replacement or sealing surface repair, the OCV O-ring containment seals shall be leakage rate tested as delineated in Section 8.2.2, Maintenance/Periodic Leakage Rate Tests, of HPT-PRO-0002.2 The maintenance/periodic leakage rate tests are consistent with the guidelines of Sections 7.4 and 7.5 of ANSI N14.5. This test verifies the sealing integrity of the HalfPACT packages OCV lid and vent port containment seals to a leakage rate not to exceed 1 x 10-7 scc/sec, air.

4.1.3.1.3 Preshipment Leakage Rate Tests Prior to shipment of the loaded HalfPACT package, the main (containment) O-ring seal and vent port plug O-ring seal for the OCV shall be leakage rate tested per Section 8.2.2, Maintenance/Periodic Leakage Rate Tests, of HPT-PRO-0002.2 This test verifies the sealing integrity of the HalfPACT packages OCV lid and vent port containment seals to a leakage rate sensitivity of 1 x 10-7 scc/sec, air, or less.

4.1.3.2 Welds All containment vessel body welds are full penetration welds that have been radiographed to ensure structural and containment integrity. Non-radiographed, safety related welds such as those that attach the OCV vent port coupling to its containment shell are examined using liquid penetrant testing on the final pass or both the root and final passes, as applicable. All containment boundary welds are confirmed to be leaktight, as delineated in Section 8.1.3, Fabrication Leakage Rate Tests, of HPT-PRO-0002.2 4.1.4 Closure 4.1.4.1 Outer Confinement Assembly (OCA) Closure With reference to Figure 1.1-1 and Figure 1.1-2 in Chapter 1.0, General Information, of the HalfPACT SAR, the OCA lid is secured to the OCA body via an OCV locking ring assembly 2 HPT-PRO-0002, Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506, Current Revision, Salado Isolation Mining Contractors LLC, Carlsbad, NM.

HPT-PRO-0003, Rev. 1 February 2023 4

located at the outer diameter of the OCV upper (lid) and lower (body) seal flanges. The upper end of the OCV locking ring is a continuous ring that mates with the OCV upper seal flange (also a continuous ring). The lower end of the OCV locking ring is comprised of 18 tabs that mate with a corresponding set of 18 tabs on the OCV lower seal flange. The OCV locking ring and OCV upper seal flange are an assembly that normally does not disassemble.

Figure 1.2-1 from Section 1.2, Package Description, of the HalfPACT SAR illustrates ICV/OCA lid installation in five steps:

1. As an option, lightly lubricate the main O-ring seals with vacuum grease and install the main O-ring seals into the O-ring seal grooves located in the OCV lower seal flange.

2. Using external alignment stripes as a guide, align the OCA lids OCV locking ring tabs with the OCV lower seal flange tab spaces.

3. Install the OCA lid; if necessary, evacuate the OCV cavity through the OCV vent port to fully seat the OCA lid and allow free movement of the OCV locking ring.

4. Rotate the OCV locking ring to the locked position, again using external alignment stripes as a guide. The locked position aligns the OCV locking rings tabs with the OCV lower seal flanges tabs. A locking Z-flange is bolted to the bottom end of the OCV locking ring and extends radially outward to the exterior of the HalfPACT package. The exterior flange of the locking Z-flange is attached to an outer thermal shield. This Z-flange/thermal shield assembly allows external operation of the OCV locking ring.

5. Install six 1/2-inch diameter lock bolts (socket head cap screws) through the outer thermal shield and into the exterior surface of the OCA to secure the OCV locking ring assembly in the locked position.

4.1.4.2 Inner Containment Vessel (ICV) Closure Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, shipped from SRS on August 25, 2022, and received at WIPP on August 26, 2022. Because potential for airborne contamination was identified during the venting of the unit upon receipt at WIPP, ICV 506 was re-sealed for temporary storage and remains sealed.

HPT-PRO-0003, Rev. 1 February 2023 5

4.2 Containment Requirements for Normal Conditions of Transport 4.2.1 Containment of Radioactive Material The results of the normal conditions of transport (NCT) structural and thermal evaluations performed in Section 2.6, Normal Conditions of Transport, and Section 3.4, Thermal Evaluation for Normal Conditions of Transport, of the HalfPACT SAR, respectively, and the results of the full-scale, structural testing presented in Appendix 2.10.3, Certification Tests, of the HalfPACT SAR, verify that there will be no release of radioactive materials per the leaktight definition of ANSI N14.51 under any of the NCT tests described in 10 CFR §71.712.

4.2.2 Pressurization of Containment Vessel The maximum normal operating pressure (MNOP) of both the OCV and ICV is 50 psig per Section 3.4.4, Maximum Internal Pressure, of the HalfPACT SAR. The design pressure of both the OCV and ICV is 50 psig. Based on the structural evaluations performed in Chapter 2.0, Structural Evaluation, of the HalfPACT SAR, pressure increases to 50 psig will not reduce the effectiveness of the HalfPACT package to maintain containment integrity per Section 4.2.1, Containment of Radioactive Material, of the HalfPACT SAR.

4.2.3 Containment Criterion At the completion of fabrication, both the OCV and ICV shall be leakage rate tested as described in Section 4.1.3.1.1, Fabrication Leakage Rate Tests. For annual maintenance, the OCV shall be leakage rate tested as described in Section 4.1.3.1.2, Maintenance/Periodic Leakage Rate Tests.

In addition, at the time of seal replacement if other than during routine maintenance (e.g., if damage during assembly necessitates seal replacement), maintenance/ periodic leakage rate testing shall be performed for that seal. For verification of proper assembly prior to shipment, the OCV shall be leakage rate tested as described in Section 4.1.3.1.3, Preshipment Leakage Rate Tests.

1 ANSI N14.5-1997, American National Standard for Radioactive Materials - Leakage Tests on Packages for Shipment, American National Standards Institute, Inc. (ANSI).

2 Title 10, Code of Federal Regulations, Part 71 (10 CFR 71), Packaging and Transportation of Radioactive Material, 01-01-19 Edition.

HPT-PRO-0003, Rev. 1 February 2023 6

4.3 Containment Requirements for Hypothetical Accident Conditions 4.3.1 Fission Gas Products There are no fission gas products in the HalfPACT package payload.

4.3.2 Containment of Radioactive Material The results of the hypothetical accident condition (HAC) structural and thermal evaluations performed in Section 2.7, Hypothetical Accident Conditions, and Section 3.5, Thermal Evaluation for Hypothetical Accident Conditions, of the HalfPACT SAR, respectively, and the results of the full-scale, structural and thermal testing presented in Appendix 2.10.3, Certification Tests, of the HalfPACT SAR verify that there will be no release of radioactive materials per the leaktight definition of ANSI N14.51 under any of the HAC tests described in 10 CFR §71.732.

4.3.3 Containment Criterion The HalfPACT package has been designed, and has been verified by leakage rate testing both prior to and following structural and thermal certification testing as presented in Appendix 2.10.3, Certification Tests, of the HalfPACT SAR to meet the leaktight definition of ANSI N14.5.

1Property "ANSI code" (as page type) with input value "ANSI N14.5.1" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process. ANSI N14.5-1997, American National Standard for Radioactive Materials - Leakage Tests on Packages for Shipment, American National Standards Institute, Inc. (ANSI).

2 Title 10, Code of Federal Regulations, Part 71 (10 CFR 71), Packaging and Transportation of Radioactive Material, 01-01-19 Edition.

HPT-PRO-0003, Rev. 1 February 2023 7

4.4 Special Requirements 4.4.1 Plutonium Shipments The HalfPACT package was designed and structurally and thermally tested as a Type B(U),

double containment package meeting the requirements of 10 CFR §71.631 for plutonium shipments. With the designation of the outer confinement vessel (OCV) as the primary containment boundary when its Category A butyl rubber containment O-ring seals are utilized the HalfPACT package is a Type B(U), single containment package meeting the requirements of 10 CFR §71.63 for plutonium shipments. Both the inner containment vessel (ICV) and OCV are shown on the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR, and described in Section 4.1.1.1, Outer Confinement Assembly (Primary Containment), and Section 4.1.1.2, Inner Containment Vessel (Containment - Not Credited).

Further, the HalfPACT package has been designed, and has been verified by leakage rate testing both prior to and following structural and thermal certification testing as presented in Appendix 2.10.3, Certification Tests, of the HalfPACT SAR to meet the leaktight definition of ANSI N14.5.2 4.4.2 Interchangeability Section not applicable. ICV 506 with matching ICV lid and body assemblies will be transferred to a different HalfPACT OCA with matching lid and body assemblies for this one-time shipment. The ICV or OCV interchangeability options will not be exercised.

1 Title 10, Code of Federal Regulations, Part 71 (10 CFR 71), Packaging and Transportation of Radioactive Material, 01-01-19 Edition.

2 ANSI N14.5-1997, American National Standard for Radioactive Materials - Leakage Tests on Packages for Shipment, American National Standards Institute, Inc. (ANSI).

Attachment C HPT-PRO-0001, Operating Procedures for One-Time Shipment Supporting ICV 506

Document Preparer R. S. Burns Signature Date Independent Reviewer S. A. Porter Signature Date Cognizant Manager T. E. Sellmer Signature Date Quality Assurance D. S. Tanner Signature Date Operating Procedures for One-Time Shipment Supporting ICV 506 Prepared by:

Prepared for:

SIMCO Transportation Packaging Group Document Number:

HPT-PRO-0001, Rev. 1 February 2023 Digitally signed by ROBERT BURNS (Affiliate)

Date: 2023.02.08 10:39:36 -07'00' Digitally signed by STEVEN PORTER (Affiliate)

Date: 2023.02.08 10:26:49 -08'00' David S. Tanner Digitally signed by David S. Tanner Date: 2023.02.08 12:49:09 -07'00' TODD SELLMER (Affiliate)

Digitally signed by TODD SELLMER (Affiliate)

Date: 2023.02.08 13:41:51 -07'00'

This page intentionally left blank to facilitate duplex printing

HPT-PRO-0001, Rev. 1 February 2023 i

TABLE OF CONTENTS

1.0 INTRODUCTION

................................................................................................................... 1 1.1 Purpose........................................................................................................................... 1 1.2 Background.................................................................................................................... 1 1.3 Format............................................................................................................................ 1 7.0 OPERATING PROCEDURES............................................................................................ 2 7.1 Procedures for Loading the Package.............................................................................. 2 7.1.1 Removal of the HalfPACT Package from the Transport Trailer/Railcar........... 2 7.1.2 Outer Confinement Assembly (OCA) Lid Removal.......................................... 2 7.1.3 Inner Containment Vessel (ICV) Lid Removal.................................................. 3 7.1.4 Loading the Payload into the HalfPACT Package............................................. 3 7.1.5 Inner Containment Vessel (ICV) Lid Installation.............................................. 3 7.1.6 Outer Confinement Assembly (OCA) Lid Installation...................................... 4 7.1.7 Final Package Preparations for Transport (Loaded)........................................... 5 7.2 Procedures for Unloading the Package.......................................................................... 7 7.2.1 Removal of the HalfPACT Package from the Transport Trailer/Railcar........... 7 7.2.2 Outer Confinement Assembly (OCA) Lid Removal.......................................... 7 7.2.3 Inner Containment Vessel (ICV) Lid Removal.................................................. 8 7.2.4 Unloading the Payload from the HalfPACT Package........................................ 8 7.2.5 Inner Containment Vessel (ICV) Lid Installation.............................................. 8 7.2.6 Outer Confinement Assembly (OCA) Lid Installation...................................... 9 7.2.7 Final Package Preparations for Transport (Unloaded)..................................... 10 7.3 Preparation of an Empty Package for Transport.......................................................... 11 7.4 Preshipment Leakage Rate Test................................................................................... 12 7.4.1 Gas Pressure Rise Leakage Rate Test Acceptance Criteria.............................. 12 7.4.2 Determining the Test Volume and Test Time.................................................. 12 7.4.3 Performing the Gas Pressure Rise Leakage Rate Test..................................... 12 7.4.4 Preshipment Leakage Rate Test for One-Time Shipment of ICV 506............. 12

HPT-PRO-0001, Rev. 1 February 2023 ii TABLE OF REVISIONS Revision Number Pages Affected Revision Description 0

All New issue.

1 1, 3, 4, and 12 Revised to clarify footnote references and a few additional minor editorials.

HPT-PRO-0001, Rev. 1 February 2023 1

1.0 INTRODUCTION

1.1 Purpose The purpose of this procedure is to support transferring Inner Containment Vessel (ICV) 506, containing Payload SRE033, to a different Outer Confinement Vessel (OCV)/Outer Confinement Assembly (OCA) and preparing the HalfPACT package for a one-time shipment by performing a helium leak test on the OCV.

The OCV shall serve as the containment boundary for this one-time shipment.

1.2 Background

HalfPACT 506 with Payload SRE033 was sent from the Savannah River Site (SRS) on August 25, 2022, and received on August 26, 2022, at the Waste Isolation Pilot Plant (WIPP)

(Shipment SR220010). During the processing of the package, which includes venting and sampling of the ICV headspace prior to ICV lid removal, internal airborne plutonium-238 and americium-241 contamination was detected. WIPP safety protocol prevents opening the potentially contaminated ICV and dictates its return to SRS for investigation into the possible contamination source. The ability to return HalfPACT 506 is currently precluded because its mandatory 5-year maintenance certification expired on September 1, 2022, such that the unit is out of compliance with Certificate of Compliance (CofC) No. 9279.

In order to return ICV 506 with its payload to SRS, the loaded ICV 506 will be transferred from HalfPACT 506 OCA to a different HalfPACT OCA. Use of an alternate HalfPACT OCA is supported through the application of targeted acceptance tests, maintenance activities, and operating procedures to credit the OCAs OCV as the containment boundary for this one-time shipment.

1.3 Format The format of this document will utilize a format similar to Chapter 7.0, Operating Procedures, of the HalfPACT Safety Analysis Report (SAR) including identical section numbering to facilitate ease of review. Sections that may not be applicable due to the situation of this one-time shipment are noted accordingly. Change bars are included for information that is different than the currently approved HalfPACT SAR, Revision 9, but specific to this one-time shipment authorization.

HPT-PRO-0001, Rev. 1 February 2023 2

7.0 OPERATING PROCEDURES 7.1 Procedures for Loading the Package This section delineates the procedures for loading a payload into the HalfPACT packaging, and leakage rate testing the outer confinement vessel (OCV). Hereafter, reference to specific HalfPACT packaging components may be found in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

The loading operation shall be performed in a dry environment. In the event of precipitation during outdoor loading operations, precautions, such as covering the OCV cavity shall be implemented to prevent water or precipitation from entering the cavity. If precipitation enters the cavity, the free-standing water shall be removed prior to loading the payload.

Based on the current configuration of the HalfPACT packaging when preparing for loading, begin at the section applicable to the following criteria:

x If the HalfPACT package will be loaded while on the transport trailer or railcar, proceed directly to Section 7.1.2, Outer Confinement Assembly (OCA) Lid Removal.

x If the outer confinement assembly (OCA) lid has already been removed, proceed directly to Section 7.1.3, Inner Containment Vessel (ICV) Lid Removal.

x If the OCA lid has already been removed, proceed directly to Section 7.1.4, Loading the Payload into the HalfPACT Package.

7.1.1 Removal of the HalfPACT Package from the Transport Trailer/Railcar

1. Uncover the forklift pockets located at the base of the OCA body.

2. Disengage each of the four (4) tie-down devices on the transport trailer or railcar from the corresponding tie-down lugs on the package.

CAUTION: Failure to disengage the tie-down devices may cause damage to the packaging and/or transport trailer/railcar.

3. Using a forklift of appropriate size, position the forklifts forks inside the forklift pockets.

4. Lift the package from the transport trailer or railcar and move the package to the loading station.

5. Place the package in the loading station and remove the forklift.

7.1.2 Outer Confinement Assembly (OCA) Lid Removal

1. If necessary, clean the surfaces around the joint between the OCA lid and body as required.

2. Remove the OCV seal test port access plug, OCV seal test port thermal plug, and OCV seal test port plug.

3. Remove the OCV vent port access plug, OCV vent port thermal plug, and OCV vent port cover.

4. Remove the OCV vent port plug to vent the OCV cavity to ambient atmospheric pressure.

HPT-PRO-0001, Rev. 1 February 2023 3

5. Remove the six 1/2-inch lock bolts (socket head cap screws) from the exterior of the OCA thermal shield.

6. Optionally install a vacuum pump to the OCV vent port and evacuate the OCV cavity sufficiently to allow the OCV locking ring to freely rotate. Rotate the OCV locking ring approximately 10º counterclockwise until the exterior alignment mark indicates the unlocked position. If used, disconnect the vacuum system and equalize pressure to the OCV cavity.

7. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the OCA lid. Engage the lift fixture and remove the OCA lid from the OCA body. Store the OCA lid in a manner such that potential damage to the OCA lids sealing region is minimized.

7.1.3 Inner Containment Vessel (ICV) Lid Removal Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, shipped from SRS on August 25, 2022, and received at WIPP on August 26, 2022. Because potential for airborne contamination was identified during the venting of the unit upon receipt at WIPP, ICV 506 was re-sealed for temporary storage and remains sealed.

7.1.4 Loading the Payload into the HalfPACT Package ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. ICV 506 with Payload SRE033 remains sealed. This section describes the procedures for transferring the loaded ICV 506 into an OCV capable of serving as a containment boundary.

HPT-CAL-00011 documents the lifting analysis performed to ensure the as-loaded ICV can be lifted and placed into an alternate OCV. The original fabrication traveler required a load test be performed on the ICV lids with the requirement of 7500 pounds, +1000/-0.

1. Connect an appropriate lifting device to ICV 506.

2. Balance the ICV to ensure it does not damage the OCV sealing region during the loading operation.

3. Lower the ICV into the OCV cavity; disconnect and remove the lifting device.

7.1.5 Inner Containment Vessel (ICV) Lid Installation Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, shipped from SRS on August 25, 2022, and received at WIPP on August 26, 2022. Because potential for airborne contamination was identified during the venting of the unit upon receipt at WIPP, ICV 506 was re-sealed for temporary storage and remains sealed.

1 HPT-CAL-0001, Loaded HalfPACT ICV Lifting Evaluation, Current Revision, Salado Isolation Mining Contractors LLC, Carlsbad, NM, February 2023.

HPT-PRO-0001, Rev. 1 February 2023 4

7.1.6 Outer Confinement Assembly (OCA) Lid Installation

1. Visually inspect each of the following OCA components for wear or damage that could impair their function and, if necessary, replace or repair per the requirements of the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

a. OCV seal test port plug and, if used, the accompanying O-ring seal

b. OCV vent port cover and, if used, the accompanying O-ring seal

c. Lock bolts

2. Visually inspect both OCV main O-ring seals. If necessary, remove the O-ring seal(s) and clean the seal(s) and sealing surface(s) on the OCA lid and body to remove contamination.

If, during the visual examination, it is determined that damage to the O-ring seal(s) and/or sealing surface(s) is sufficient to impair OCV containment integrity, replace the damaged seal(s) and/or repair the damaged sealing surface(s) per Section 8.2.3.3.1, Seal Area Routine Inspection and Repair, of HPT-PRO-00022.

3. Visually inspect the O-ring seal on the OCV vent port plug. If necessary, remove the O-ring seal and clean the seal and sealing surfaces on the OCV vent port plug and in the OCV vent port to remove contamination. If, during the visual examination, it is determined that damage to the O-ring seal and/or sealing surface(s) is sufficient to impair OCV containment integrity, replace the damaged seal and/or repair the damaged sealing surface(s) per Section 8.2.3.3.1, Seal Area Routine Inspection and Repair, of HPT-PRO-00022.

4. As an option, sparingly apply vacuum grease to the O-ring seals and install into the appropriate O-ring seal grooves in the OCV body, OCV seal test port plug, and OCV vent port plug.

5. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the OCA lid. Engage the lift fixture and install the OCA lid onto the OCA body. Remove the lift fixture.

6. Optionally install a vacuum pump to the OCV vent port and evacuate the OCV cavity sufficiently to allow the OCV locking ring to freely rotate. Rotate the OCV locking ring approximately 10º clockwise until the alignment mark indicates the locked position. After rotating the OCV locking ring, disconnect the vacuum system and equalize pressure to the OCV cavity.

7. Install the six 1/2-inch lock bolts (socket head cap screws) through the cutouts in the OCA outer thermal shield to secure the OCV locking ring in the locked position. Tighten the lock bolts to 28 - 32 lb-ft torque, lubricated.

8. Leakage rate testing of the OCV main O-ring seal shall be performed based on the following criteria:

a. Perform preshipment leakage rate testing per Section 7.4.4, Preshipment Leakage Rate Test for One-Time Shipment of ICV 506.

2 HPT-PRO-0002, Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506, Current Revision, Salado Isolation Mining Contractors LLC, February 2023.

HPT-PRO-0001, Rev. 1 February 2023 5

9. Install the OCV seal test port plug; tighten to 55 - 65 lb-in torque. Install the OCV seal test port thermal plug and the OCV seal test port access plug; tighten to 28 - 32 lb-ft torque.

10. Install the OCV vent port plug; tighten to 55 - 65 lb-in torque.

11. Leakage rate testing of the OCV vent port plug O-ring seal shall be performed based on the following criteria:

a. Perform preshipment leakage rate testing per Section 7.4.4, Preshipment Leakage Rate Test for One-Time Shipment of ICV 506.

12. Install the OCV vent port cover; tighten to 55 - 65 lb-in torque.

13. Install the OCV vent port thermal plug and the OCV vent port access plug; tighten to 28 - 32 lb-ft torque.

7.1.7 Final Package Preparations for Transport (Loaded)

1. Install the two tamper-indicating devices (security seals). One security seal is located at the OCA vent port access plug; the second is located at an OCA lock bolt.

2. If the HalfPACT package is not already loaded onto the transport trailer or railcar, perform the following steps:

a. Using a forklift of appropriate size, position the forklifts forks inside the forklift pockets.

b. Lift the loaded HalfPACT package, aligning the packaging over the tie-down points on the transport trailer or railcar.

c. Secure the loaded HalfPACT package to the transport trailer or railcar using the appropriate tie-down devices.

d. Load as many as three HalfPACT packages per transport trailer or up to seven HalfPACT packages per railcar.

e. Install forklift pocket covers over the four forklift pockets located at the base of the OCA body.

3. Monitor external radiation for each loaded HalfPACT package per the guidelines of 49 CFR

§173.4413.

4. Determine that surface contamination levels for each loaded HalfPACT package are per the guidelines of 49 CFR §173.443.

5. Determine the shielding Transport Index (TI) for each loaded HalfPACT package per the guidelines of 49 CFR §173.403.

6. Complete all necessary shipping papers in accordance with Subpart C of 49 CFR 1724.

3 Title 49, Code of Federal Regulations, Part 173 (49 CFR 173), Shippers-General Requirements for Shipments and Packagings, Current Version.

4 Title 49, Code of Federal Regulations, Part 172 (49 CFR 172), Hazardous Materials Tables and Hazardous Communications Regulations, Current Version.

HPT-PRO-0001, Rev. 1 February 2023 6

7. HalfPACT package marking shall be in accordance with 10 CFR §71.85(c)5 and Subpart D of 49 CFR 172. Package labeling shall be in accordance with Subpart E of 49 CFR 172.

Package placarding shall be in accordance with Subpart F of 49 CFR 172.

5 Title 10, Code of Federal Regulations, Part 71 (10 CFR 71), Packaging and Transportation of Radioactive Material, 01-01-19 Edition.

HPT-PRO-0001, Rev. 1 February 2023 7

7.2 Procedures for Unloading the Package This section delineates the procedures for unloading a payload from the HalfPACT packaging.

Hereafter, reference to specific HalfPACT packaging components may be found in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

The unloading operation shall be performed in a dry environment. In the event of precipitation during outdoor unloading operations, precautions, such as covering the outer confinement vessel (OCV) and inner containment vessel (ICV) cavities shall be implemented to prevent water or precipitation from entering the cavities. If precipitation enters the cavities, the free-standing water shall be removed prior to installing the lids.

x If the HalfPACT package will be unloaded while on the transport trailer or railcar, proceed directly to Section 7.2.2, Outer Confinement Assembly (OCA) Lid Removal.

7.2.1 Removal of the HalfPACT Package from the Transport Trailer/Railcar

1. Uncover the forklift pockets located at the base of the OCA body.

2. Disengage each of the four (4) tie-down devices on the transport trailer or railcar from the corresponding tie-down lugs on the package.

CAUTION: Failure to disengage the tie-down devices may cause damage to the packaging and/or transport trailer/railcar.

3. Using a forklift of appropriate size, position the forklifts forks inside the forklift pockets.

4. Lift the package from the transport trailer or railcar and move the package to the loading station.

5. Place the package in the loading station and remove the forklift.

7.2.2 Outer Confinement Assembly (OCA) Lid Removal

1. If necessary, clean the surfaces around the joint between the OCA lid and body as required.

2. Remove the OCV seal test port access plug, OCV seal test port thermal plug, and OCV seal test port plug.

3. Remove the OCV vent port access plug, OCV vent port thermal plug, and OCV vent port cover.

4. Remove the OCV vent port plug to vent the OCV cavity to ambient atmospheric pressure.

5. Remove the six 1/2-inch lock bolts (socket head cap screws) from the exterior of the OCA thermal shield.

6. Optionally install a vacuum pump to the OCV vent port and evacuate the OCV cavity sufficiently to allow the OCV locking ring to freely rotate. Rotate the OCV locking ring approximately 10º counterclockwise until the exterior alignment mark indicates the unlocked position. If used, disconnect the vacuum system and equalize pressure to the OCV cavity.

HPT-PRO-0001, Rev. 1 February 2023 8

7. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the OCA lid. Engage the lift fixture and remove the OCA lid from the OCA body. Store the OCA lid in a manner such that potential damage to the OCA lids sealing region is minimized.

7.2.3 Inner Containment Vessel (ICV) Lid Removal

1. Remove the ICV vent port cover, the ICV outer vent port plug, and ICV inner vent port plug to vent the ICV cavity to ambient atmospheric pressure.

2. Remove the ICV seal test port plug.

3. Remove the three 1/2-inch lock bolts (socket head cap screws) from the exterior of the ICV locking ring.

4. Install a vacuum pump to the ICV vent port and evacuate the ICV cavity sufficiently to allow the ICV locking ring to freely rotate. Rotate the ICV locking ring approximately 10º counterclockwise until the alignment mark indicates the unlocked position. Disconnect the vacuum system and equalize pressure to the ICV cavity.

5. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the ICV lid. Engage the lift fixture and remove the ICV lid from the ICV body. Store the ICV lid in a manner such that potential damage to the ICV lids sealing region and ICV upper aluminum honeycomb spacer assembly is minimized.

7.2.4 Unloading the Payload from the HalfPACT Package

1. Connect an appropriate lifting device to the payload assembly.

2. Balance the payload assembly sufficiently to ensure the payload does not damage either the ICV or the OCV sealing regions during the unloading operation.

3. Remove the payload assembly from the ICV cavity; disconnect and remove the lifting device.

7.2.5 Inner Containment Vessel (ICV) Lid Installation

1. Visually inspect each of the following ICV components for wear or damage that could impair their function and, if necessary, replace or repair per the requirements of the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

a. ICV debris shield

b. ICV wiper O-ring seal and wiper O-ring holder

c. ICV main O-ring seals and sealing surfaces

d. ICV seal test port plug and accompanying O-ring seal

e. ICV inner and outer vent port plugs and accompanying O-ring seals

f. ICV vent port cover and accompanying seal (O-ring or gasket)

g. Lock bolts

HPT-PRO-0001, Rev. 1 February 2023 9

2. As an option, sparingly apply vacuum grease to the O-ring seals and install into the appropriate O-ring seal grooves in the ICV body, ICV seal test port and vent port plugs.

3. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the ICV lid. Engage the lift fixture and install the ICV lid onto the ICV body. Remove the lift fixture.

4. Install a vacuum pump to the ICV vent port and evacuate the ICV cavity sufficiently to allow the ICV locking ring to freely rotate. Rotate the ICV locking ring approximately 10º clockwise until the alignment mark indicates the locked position. After rotating the ICV locking ring, disconnect the vacuum system and equalize pressure to the ICV cavity.

5. Install the three 1/2-inch lock bolts (socket head cap screws) through the cutouts in the ICV locking ring to secure the ICV locking ring in the locked position. Tighten the lock bolts to 28 - 32 lb-ft torque, lubricated.

6. Install the ICV seal test port plug; tighten to 55 - 65 lb-in torque.

7. Install the ICV inner and outer vent port plugs, followed by the ICV vent port cover; tighten each to 55 - 65 lb-in torque.

7.2.6 Outer Confinement Assembly (OCA) Lid Installation

1. Visually inspect each of the following OCA components for wear or damage that could impair their function and, if necessary, replace or repair per the requirements of the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

a. OCV main O-ring seals, if used, and sealing surfaces

b. OCV seal test port plug and, if used, the accompanying O-ring seal

c. OCV vent port plug and, if used, the accompanying O-ring seal

d. OCV vent port cover and, if used, the accompanying O-ring seal

e. Lock bolts

2. As an option and if O-ring seals are used, sparingly apply vacuum grease to the O-ring seals and install into the appropriate O-ring seal grooves in the OCV body, OCV seal test port and vent port plugs.

3. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the OCA lid. Engage the lift fixture and install the OCA lid onto the OCA body. Remove the lift fixture.

4. Optionally install a vacuum pump to the OCV vent port and evacuate the OCV cavity sufficiently to allow the OCV locking ring to freely rotate. Rotate the OCV locking ring approximately 10º clockwise until the alignment mark indicates the locked position. After rotating the OCV locking ring, disconnect the vacuum system and equalize pressure to the OCV cavity.

5. Install the six 1/2-inch lock bolts (socket head cap screws) through the cutouts in the OCA outer thermal shield to secure the OCV locking ring in the locked position. Tighten the lock bolts to 28 - 32 lb-ft torque, lubricated.

HPT-PRO-0001, Rev. 1 February 2023 10

6. Install the OCV seal test port plug; tighten to 55 - 65 lb-in torque. Install the OCV seal test port thermal plug and the OCV seal test port access plug; tighten to 28 - 32 lb-ft torque.

7. Install the OCV vent port plug and OCV vent port cover; tighten each to 55 - 65 lb-in torque.

Install the OCV vent port thermal plug and the OCV vent port access plug; tighten to 28 - 32 lb-ft torque.

7.2.7 Final Package Preparations for Transport (Unloaded)

1. If the HalfPACT package is not already loaded onto the transport trailer or railcar, perform the following steps:

a. Using a forklift of appropriate size, position the forklifts forks inside the forklift pockets.

b. Lift the HalfPACT package, aligning the packaging over the tie-down points on the transport trailer or railcar.

c. Secure the HalfPACT package to the transport trailer or railcar using the appropriate tie-down devices.

d. Load as many as three HalfPACT packages per transport trailer or up to seven HalfPACT packages per railcar.

e. Install forklift pocket covers over the four forklift pockets located at the base of the OCA body.

2. Transport the HalfPACT package in accordance with Section 7.3, Preparation of an Empty Package for Transport.

HPT-PRO-0001, Rev. 1 February 2023 11 7.3 Preparation of an Empty Package for Transport Previously used and empty HalfPACT packagings shall be prepared and transported per the requirements of 49 CFR §173.4281.

1 Title 49, Code of Federal Regulations, Part 173 (49 CFR 173), Shippers-General Requirements for Shipments and Packagings, Current Version.

HPT-PRO-0001, Rev. 1 February 2023 12 7.4 Preshipment Leakage Rate Test After the HalfPACT package is assembled and prior to shipment, leakage rate testing shall be performed to confirm proper assembly of the package following the guidelines of Section 7.6, Preshipment Leakage Rate Test, and Appendix A.5.2, Gas Pressure Rise, of ANSI N14.51.

The leak test for this one-time shipment shall confirm the OCV can serve as the containment boundary.

7.4.1 Gas Pressure Rise Leakage Rate Test Acceptance Criteria Section not applicable. A helium leak test per Section 7.4.4, Preshipment Leakage Rate Test for One-Time Shipment of ICV 506, is required.

7.4.2 Determining the Test Volume and Test Time Section not applicable. A helium leak test per Section 7.4.4, Preshipment Leakage Rate Test for One-Time Shipment of ICV 506, is required.

7.4.3 Performing the Gas Pressure Rise Leakage Rate Test Section not applicable. A helium leak test per Section 7.4.4, Preshipment Leakage Rate Test for One-Time Shipment of ICV 506, is required.

7.4.4 Preshipment Leakage Rate Test for One-Time Shipment of ICV 506 Section 8.2.2, Maintenance/Periodic Leakage Rate Tests, of HPT-PRO-00022, shall be performed on the OCV. Section 7.4.4.1, Helium Leakage Rate Testing the OCV Main O-ring Seal Integrity and Section 7.4.4.2, Helium Leakage Rate Testing the OCV Vent Port Plug O-ring Seal Integrity, provide the requirements from Section 8.1.3.6, Helium Leakage Rate Testing the OCV Main O-ring Seal integrity, and Section 8.1.3.7, Helium Leakage Rate Testing of the OCV Vent Port Plug O-ring Seal Integrity, of HPT-PRO-00022, for preshipment leak testing required for this one-time shipment.

7.4.4.1 Helium Leakage Rate Testing the OCV Main O-ring Seal Integrity

1. The fabrication leakage rate test of the OCV main O-ring seal shall be performed following the guidelines of Section A.5.4, Evacuated Envelope - Gas Detector, of ANSI N14.5.

2. The OCA shall be assembled with both main O-ring seals installed into the OCV lower seal flange. Assembly is as shown in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

1 ANSI N14.5-1997, American National Standard for Radioactive Materials - Leakage Tests on Packages for Shipment, American National Standards Institute, Inc. (ANSI).

2 HPT-PRO-0002, Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506, Current Revision, Salado Isolation Mining Contractors LLC, February 2023.

HPT-PRO-0001, Rev. 1 February 2023 13

3. Remove the OCV vent port access plug, OCV vent port thermal plug, OCV vent port cover, and OCV vent port plug.

4. Connect a vacuum pump to the OCV vent port and evacuate the OCV cavity to 90% vacuum or better (i.e., d10% ambient atmospheric pressure).

5. Remove the OCV seal test port access plug, OCV seal test port thermal plug, and OCV seal test port plug, and install a helium mass spectrometer leak detector to the OCV seal test port.

Evacuate through the OCV seal test port until the vacuum is sufficient to operate the helium mass spectrometer leak detector.

6. Provide a helium atmosphere inside the OCV cavity by backfilling with helium gas to a pressure slightly greater than atmospheric pressure (+1 psi, -0 psi).

7. Perform the helium leakage rate test to the requirements of Section 7.4.4.3, Fabrication Leakage Rate Test Acceptance Criteria, below. If, after repeated attempts, the OCV main O-ring seal fails to pass the leakage rate test, isolate the leak path and, prior to repairing the leak path and repeating the leakage rate test, record on a nonconformance report and disposition prior to final acceptance in accordance with the cognizant quality assurance program.

7.4.4.2 Helium Leakage Rate Testing the OCV Vent Port Plug O-ring Seal Integrity

1. The fabrication leakage rate test of the OCV vent port plug O-ring seal shall be performed following the guidelines of Section A.5.4, Evacuated Envelope - Gas Detector, of ANSI N14.5.

2. The OCV shall be assembled with both main O-ring seals installed into the OCV lower seal flange. Assembly is as shown in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

3. Remove the OCV vent port access plug, OCV vent port thermal plug, OCV vent port cover, and OCV vent port plug.

4. Connect a vacuum pump to the OCV vent port and evacuate the OCV cavity to 90% vacuum or better (i.e., d10% ambient atmospheric pressure).

5. Provide a helium atmosphere inside the OCV cavity by backfilling with helium gas to a pressure slightly greater than atmospheric pressure (+1 psi, -0 psi).

6. Install the OCV vent port plug; tighten to 55 - 65 lb-in torque.

7. Install a helium mass spectrometer leak detector to the OCV vent port. Evacuate through the OCV vent port until the vacuum is sufficient to operate the helium mass spectrometer leak detector.

8. Perform the helium leakage rate test to the requirements of Section 7.4.4.3, Fabrication Leakage Rate Test Acceptance Criteria, below. If, after repeated attempts, the OCV vent port plug O-ring seal fails to pass the leakage rate test, isolate the leak path and, prior to repairing the leak path and repeating the leakage rate test, record on a nonconformance report and disposition prior to final acceptance in accordance with the cognizant quality assurance program.

HPT-PRO-0001, Rev. 1 February 2023 14 7.4.4.3 Fabrication Leakage Rate Test Acceptance Criteria

1. To be acceptable, each leakage rate test shall demonstrate a leaktight leakage rate of 1 x 10-7 reference cubic centimeters per second (scc/s), air, or less, per Section 6.3, Application of Referenced Air Leakage Rate (LR), of ANSI N14.5.

2. In order to demonstrate a leaktight leakage rate, the sensitivity of the leakage rate test procedure shall be 5 x 10-8 scc/s, air, or less, per Section 8.4, Sensitivity, of ANSI N14.5.

Attachment D HPT-PRO-0002, Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506

Document Preparer R. S. Burns Signature Date Independent Reviewer S. A. Porter Signature Date Cognizant Manager T. E. Sellmer Signature Date Quality Assurance D. S. Tanner Signature Date Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506 Prepared by:

Prepared for:

SIMCO Transportation Packaging Group Document Number:

HPT-PRO-0002, Rev. 1 February 2023 Digitally signed by ROBERT BURNS (Affiliate)

Date: 2023.02.07 16:17:48 -07'00' Digitally signed by STEVEN PORTER (Affiliate)

Date: 2023.02.08 10:32:51 -08'00' David S. Tanner Digitally signed by David S. Tanner Date: 2023.02.08 12:52:52 -07'00' TODD SELLMER (Affiliate)

Digitally signed by TODD SELLMER (Affiliate)

Date: 2023.02.08 13:42:59 -07'00'

This page intentionally left blank to facilitate duplex printing

HPT-PRO-0002, Rev. 1 February 2023 i

TABLE OF CONTENTS

1.0 INTRODUCTION

................................................................................................................. 1 1.1 Purpose........................................................................................................................... 1 1.2 Background.................................................................................................................... 1 1.3 Format............................................................................................................................ 1 8.0 ACCEPTANCE TESTS AND MAINTENANCE PROGRAM........................................ 2 8.1 Acceptance Tests............................................................................................................ 2 8.1.1 Visual Inspection................................................................................................ 2 8.1.2 Structural and Pressure Tests............................................................................. 2 8.1.3 Fabrication Leakage Rate Tests......................................................................... 3 8.1.4 Component Tests................................................................................................ 6 8.1.5 Tests for Shielding Integrity............................................................................. 19 8.1.6 Thermal Acceptance Test................................................................................. 20 8.2 Maintenance Program................................................................................................... 21 8.2.1 Structural and Pressure Tests........................................................................... 21 8.2.2 Maintenance/Periodic Leakage Rate Tests....................................................... 21 8.2.3 Subsystems Maintenance................................................................................. 22 8.2.4 Valves, Rupture Discs, and Gaskets................................................................. 25 8.2.5 Shielding........................................................................................................... 25 8.2.6 Thermal............................................................................................................ 25

HPT-PRO-0002, Rev. 1 February 2023 ii TABLE OF REVISIONS Revision Number Pages Affected Revision Description 0

All New issue.

1 1, 3, 4, 19, 20, 21 Revised to clarify leakage rate testing on the OCV in Section 8.2.1.1 and a few additional minor editorials.

HPT-PRO-0002, Rev. 1 February 2023 1

1.0 INTRODUCTION

1.1 Purpose The purpose of this document is to discuss the acceptance tests and maintenance program required to be implemented on the HalfPACT packaging prior to the one-time shipment supporting ICV 506.

1.2 Background

HalfPACT 506 with Payload SRE033 was sent from the Savannah River Site (SRS) on August 25, 2022, and received on August 26, 2022, at the Waste Isolation Pilot Plant (WIPP)

(Shipment SR220010). During the processing of the package, which includes venting and sampling of the inner containment vessel (ICV) headspace prior to ICV lid removal, internal airborne plutonium-238 and americium-241 contamination was detected. WIPP safety protocol prevents opening the potentially contaminated ICV and dictates its return to SRS for investigation into the possible contamination source. The ability to return HalfPACT 506 is currently precluded because its mandatory 5-year maintenance certification expired on September 1, 2022 such that the unit is out of compliance with Certificate of Compliance (CofC)

No. 9279.

In order to return ICV 506 with its payload to SRS, the loaded ICV 506 will be transferred from HalfPACT 506 OCA to a different HalfPACT OCA. Use of an alternate HalfPACT OCA is supported through the application of targeted acceptance tests, maintenance activities, and operating procedures to credit the OCAs OCV as the containment boundary for this one-time shipment.

1.3 Format The format of this document will utilize a format similar to Chapter 8.0, Acceptance Tests and Maintenance Program, of the HalfPACT Safety Analysis Report (SAR), including section numbers, to facilitate ease of review. Sections that may not be applicable due to the situation of this one-time shipment are noted accordingly. Change bars are included for information that is different than the currently approved HalfPACT SAR, Revision 9, but specific to this one-time shipment authorization.

HPT-PRO-0002, Rev. 1 February 2023 2

8.0 ACCEPTANCE TESTS AND MAINTENANCE PROGRAM 8.1 Acceptance Tests Per the requirements of 10 CFR §71.851, this section discusses the inspections and tests to be performed on the HalfPACT packaging prior to the one-time shipment supporting ICV 506.

8.1.1 Visual Inspection All HalfPACT packaging materials of construction and welds shall be examined in accordance with requirements delineated on the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR, per the requirements of 10 CFR §71.85(a).

Furthermore, the inspections and tests of Section 8.2.3.3, Seal Areas and Grooves, shall be performed prior to pressure and leakage rate testing.

8.1.2 Structural and Pressure Tests 8.1.2.1 Lifting Device Load Testing The bounding design load of the outer confinement assembly (OCA) lid lifting devices is 7,500 pounds total, or 2,500 pounds per lifting point. Load test each set of OCA lid lifting devices to 150% of their bounding design load, 11,250 pounds total, or 3,750 pounds per lifting point.

Perform load testing of the OCA lid lifting devices prior to polyurethane foam installation.

Following OCA load testing, all accessible base material and welds and adjacent base metal (minimum 1/2 inch on each side of the weld) directly related to OCA load testing shall be visually inspected for plastic deformation or cracking, and liquid penetrant inspected per ASME Boiler and Pressure Vessel Code, Section V2, Article 6, and ASME Boiler and Pressure Vessel Code, Section III3, Division 1, Subsection NF, Article NF-5000. Indications of cracking or distortion shall be recorded on a nonconformance report and dispositioned prior to final acceptance in accordance with the cognizant quality assurance program.

The bounding design load of the inner containment vessel (ICV) lifting sockets is 5,000 pounds total, or 1,667 pounds per lifting socket. Load test each set of ICV lifting sockets to 150% of their bounding design load, 7,500 pounds total, or 2,500 pounds per lifting socket.

Following ICV load testing, all accessible base material and welds and adjacent base metal (minimum 1/2 inch on each side of the weld) directly related to ICV load testing shall be visually inspected for plastic deformation or cracking, and liquid penetrant inspected per ASME Boiler and Pressure Vessel Code, Section V2, Article 6, and ASME Boiler and Pressure Vessel Code, Section III3, Division 1, Subsection NB, Article NB-5000. Indications of cracking or distortion 1 Title 10, Code of Federal Regulations, Part 71 (10 CFR 71), Packaging and Transportation of Radioactive Material, 01-01-19 Edition.

2 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code,Section V, Nondestructive Examination, 1995 Edition, 1997 Addenda.

3 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code,Section III, Rules for Construction of Nuclear Power Plant Components, 1995 Edition, 1997 Addenda.

HPT-PRO-0002, Rev. 1 February 2023 3

shall be recorded on a nonconformance report and dispositioned prior to final acceptance in accordance with the cognizant quality assurance program.

8.1.2.2 Pressure Testing The outer confinement vessel (OCV) shall be pressure tested to 150% of the maximum normal operating pressure (MNOP) to verify structural integrity. The MNOP of the OCV is equal to the 50 psig design pressure. Thus, the OCV shall be pressure tested to 50 x 1.5 = 75 psig.

Following OCV pressure testing, all accessible welds and adjacent base metal (minimum 1/2 inch on each side of the weld) directly related to the pressure testing of the OCV shall be visually inspected for plastic deformation or cracking, and liquid penetrant inspected per ASME Boiler and Pressure Vessel Code,Section V, Article 6, and ASME Boiler and Pressure Vessel Code,Section III, Division 1, Subsection NF, Article NF-5000, as delineated on the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR. Indications of cracking or distortion shall be recorded on a nonconformance report and dispositioned prior to final acceptance in accordance with the cognizant quality assurance program.

Leakage rate testing per Section 8.1.3, Fabrication Leakage Rate Tests, shall be performed on the OCV after completion of pressure testing to verify package configuration and performance to design criteria.

8.1.3 Fabrication Leakage Rate Tests This section provides the generalized procedure for fabrication leakage rate testing of the containment vessel boundary and penetrations following the completion of fabrication.

Fabrication leakage rate testing shall follow the guidelines of Section 7.3, Fabrication Leakage Rate Test, of ANSI N14.54.

Prior to leakage rate testing, internal components such as the payload and spacer pallets, ICV aluminum honeycomb spacer assemblies, etc., shall be removed. For ease of leakage rate testing, each vessel should be thoroughly cleaned.

Fabrication leakage rate testing shall be performed on the OCV. Three separate tests comprise the series of tests on the OCV. Each test shall meet the acceptance criteria delineated in Section 8.1.3.1, Fabrication Leakage Rate Test Acceptance Criteria.

8.1.3.1 Fabrication Leakage Rate Test Acceptance Criteria

1. To be acceptable, each leakage rate test shall demonstrate a leaktight leakage rate of 1 x 10-7 reference cubic centimeters per second (scc/s), air, or less, per Section 6.3, Application of Referenced Air Leakage Rate (LR), of ANSI N14.5.

2. In order to demonstrate a leaktight leakage rate, the sensitivity of the leakage rate test procedure shall be 5 x 10-8 scc/s, air, or less, per Section 8.4, Sensitivity, of ANSI N14.5.

4Property "ANSI code" (as page type) with input value "ANSI N14.5.4" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process. ANSI N14.5-1997, American National Standard for Radioactive Materials - Leakage Tests on Packages for Shipment, American National Standards Institute, Inc. (ANSI).

HPT-PRO-0002, Rev. 1 February 2023 4

8.1.3.2 Helium Leakage Rate Testing the ICV Structure Integrity Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. Credit will not be taken for containment provided by the ICV.

8.1.3.3 Helium Leakage Rate Testing the ICV Main O-ring Seal Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. Credit will not be taken for containment provided by the ICV.

8.1.3.4 Helium Leakage Rate Testing the ICV Outer Vent Port Plug O-ring Seal Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. Credit will not be taken for containment provided by the ICV.

8.1.3.5 Helium Leakage Rate Testing the OCV Structure Integrity

1. The fabrication leakage rate test of the OCV structure shall be performed following the guidelines of Section A.5.3, Gas Filled Envelope - Gas Detector, of ANSI N14.5.

2. Remove the OCV vent port access plug, OCV vent port thermal plug, OCV vent port cover, and OCV vent port plug.

3. Install the OCV lid with both main O-ring seals installed into the OCV lower seal flange. As an option, an assembled ICV may be placed within the OCV cavity for volume reduction.

Assembly is as shown in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

4. Install a helium mass spectrometer leak detector to the OCV vent port. Evacuate through the OCV vent port until the vacuum is sufficient to operate the helium mass spectrometer leak detector.

5. Surround the assembled OCV with an envelope filled with helium.

6. Perform the helium leakage rate test to the requirements of Section 8.1.3.1, Fabrication Leakage Rate Test Acceptance Criteria. If, after repeated attempts, the OCV structure fails to pass the leakage rate test, isolate the leak path and, prior to repairing the leak path and repeating the leakage rate test, record on a nonconformance report and disposition prior to final acceptance in accordance with the cognizant quality assurance program.

8.1.3.6 Helium Leakage Rate Testing the OCV Main O-ring Seal Integrity

1. The fabrication leakage rate test of the OCV main O-ring seal shall be performed following the guidelines of Section A.5.4, Evacuated Envelope - Gas Detector, of ANSI N14.5.

2. The OCA shall be assembled with both main O-ring seals installed into the OCV lower seal flange. Assembly is as shown in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

3. Remove the OCV vent port access plug, OCV vent port thermal plug, OCV vent port cover, and OCV vent port plug.

HPT-PRO-0002, Rev. 1 February 2023 5

4. Connect a vacuum pump to the OCV vent port and evacuate the OCV cavity to 90% vacuum or better (i.e., d10% ambient atmospheric pressure).

5. Remove the OCV seal test port access plug, OCV seal test port thermal plug, and OCV seal test port plug and install a helium mass spectrometer leak detector to the OCV seal test port.

Evacuate through the OCV seal test port until the vacuum is sufficient to operate the helium mass spectrometer leak detector.

6. Provide a helium atmosphere inside the OCV cavity by backfilling with helium gas to a pressure slightly greater than atmospheric pressure (+1 psi, -0 psi).

7. Perform the helium leakage rate test to the requirements of Section 8.1.3.1, Fabrication Leakage Rate Test Acceptance Criteria. If, after repeated attempts, the OCV main O-ring seal fails to pass the leakage rate test, isolate the leak path and, prior to repairing the leak path and repeating the leakage rate test, record on a nonconformance report and disposition prior to final acceptance in accordance with the cognizant quality assurance program.

8.1.3.7 Helium Leakage Rate Testing the OCV Vent Port Plug O-ring Seal Integrity

1. The fabrication leakage rate test of the OCV vent port plug O-ring seal shall be performed following the guidelines of Section A.5.4, Evacuated Envelope - Gas Detector, of ANSI N14.5.

2. The OCV shall be assembled with both main O-ring seals installed into the OCV lower seal flange. Assembly is as shown in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.

3. Remove the OCV vent port access plug, OCV vent port thermal plug, OCV vent port cover, and OCV vent port plug.

4. Connect a vacuum pump to the OCV vent port and evacuate the OCV cavity to 90% vacuum or better (i.e., d10% ambient atmospheric pressure).

5. Provide a helium atmosphere inside the OCV cavity by backfilling with helium gas to a pressure slightly greater than atmospheric pressure (+1 psi, -0 psi).

6. Install the OCV vent port plug; tighten to 55 - 65 lb-in torque.

7. Install a helium mass spectrometer leak detector to the OCV vent port. Evacuate through the OCV vent port until the vacuum is sufficient to operate the helium mass spectrometer leak detector.

8. Perform the helium leakage rate test to the requirements of Section 8.1.3.1, Fabrication Leakage Rate Test Acceptance Criteria. If, after repeated attempts, the OCV vent port plug O-ring seal fails to pass the leakage rate test, isolate the leak path and, prior to repairing the leak path and repeating the leakage rate test, record on a nonconformance report and disposition prior to final acceptance in accordance with the cognizant quality assurance program.

HPT-PRO-0002, Rev. 1 February 2023 6

8.1.4 Component Tests 8.1.4.1 Polyurethane Foam This section establishes the requirements and acceptance criteria for installation, inspection, and testing of rigid, closed-cell, polyurethane foam utilized within the HalfPACT packaging.

8.1.4.1.1 Introduction and General Requirements The polyurethane foam used within the HalfPACT packaging is comprised of a specific formulation of foam constituents that, when properly apportioned, mixed, and reacted, produce a polyurethane foam material with physical characteristics consistent with the requirements given in this section. In practice, the chemical constituents are batched into multiple parts (e.g.,

parts A and B) for later mixing in accordance with a formulation. Therefore, a foam batch is considered to be a specific grouping and apportionment of chemical constituents into separate and controlled vats or bins for each foam formulation part. Portions from each batch part are combined in accordance with the foam formulation requirements to produce the liquid foam material for pouring into a component. Thus, a foam pour is defined as apportioning and mixing the batch parts into a desired quantity for subsequent installation (pouring).

The following sections describe the general requirements for chemical composition, constituent storage, foamed component preparation, foam material installation, and foam pour and test data records.

8.1.4.1.1.1 Polyurethane Foam Chemical Composition The foam supplier shall certify that the chemical composition of the polyurethane foam is as delineated below, with the chemical component weight percents falling within the specified ranges. In addition, the foam supplier shall certify that the finished (cured) polyurethane foam does not contain halogen-type flame retardants or trichloromonofluoromethane (Freon 11).

Carbon....................... 50% - 70%

Phosphorus.................... 0% - 2%

Oxygen...................... 14% - 34%

Silicon................................. < 1%

Nitrogen...................... 4% - 12%

Chlorine............................... < 1%

Hydrogen..................... 4% - 10%

Other................................... < 1%

8.1.4.1.1.2 Polyurethane Foam Constituent Storage The foam supplier shall certify that the polyurethane foam constituents have been properly stored prior to use, and that the polyurethane foam constituents have been used within their shelf life.

HPT-PRO-0002, Rev. 1 February 2023 7

8.1.4.1.1.3 Foamed Component Preparation Prior to polyurethane foam installation, the foam supplier shall visually verify to the extent possible (i.e., looking through the foam fill ports) that the ceramic fiber insulation is still attached to the component shell interior surfaces. In addition, due to the internal pressures generated during the foam pouring/curing process, the foam supplier shall visually verify that adequate bracing/shoring of the component shells is provided to maintain the dimensional configuration throughout the foam pouring/curing process.

8.1.4.1.1.4 Polyurethane Foam Installation As illustrated in the accompanying illustration, the direction of foam rise shall be vertically aligned with the shell component axis.

The surrounding walls of the component shell where the liquid foam material is to be installed shall be between 55 ºF and 95 ºF prior to foam installation. Measure and record the component shell temperature to an accuracy of +/-2 ºF prior to foam installation.

In the case of multiple pours into a single foamed component, the cured level of each pour shall be measured and recorded to an accuracy of +/-1 inch.

Measure and record the weight of liquid foam material installed during each pour to an accuracy of +/-10 pounds.

All test samples shall be poured into disposable containers at the same time as the actual pour it represents, clearly marking the test sample container with the pour date and a unique pour identification number. All test samples shall be cut from a larger block to obtain freshly cut faces. Prior to physical testing, each test sample shall be cleaned of superfluous foam dust.

8.1.4.1.1.5 Polyurethane Foam Pour and Test Data Records A production pour and testing record shall be compiled by the foam supplier during the foam pouring operation and subsequent physical testing. Upon completion of production and testing, the foam supplier shall issue certification referencing the production record data and test data pertaining to each foamed component. At a minimum, relevant pour and test data shall include:

x formulation, batch, and pour numbers, with foam material traceability, and pour date, x foamed component description, part number, and serial number, x instrumentation description, serial number, and calibration due date,

HPT-PRO-0002, Rev. 1 February 2023 8

x pour and test data (e.g., date, temperature, dimensional, and/or weight measurements, compressive modulus, thermal conductivity, compressive stress, etc., as applicable), and x technician and Quality Assurance/Quality Control (QA/QC) sign-off.

8.1.4.1.2 Physical Characteristics The following subsections define the required physical characteristics of the polyurethane foam material used for the HalfPACT packaging design.

Testing for the various polyurethane foam physical characteristics is based on a formulation, batch, or pour, as appropriate, as defined in Section 8.1.4.1.1, Introduction and General Requirements. The physical characteristics determined for a specific foam formulation are relatively insensitive to small variations in chemical constituents and/or environmental conditions, and therefore include physical testing for compressive modulus, Poissons ratio, thermal expansion coefficient, thermal conductivity, and specific heat. Similarly, the physical characteristics determined for a batch are only slightly sensitive to small changes in formulation and/or environmental conditions during batch mixing, and therefore include physical testing for flame retardancy, intumescence, and leachable chlorides. Finally, the physical characteristics determined for a pour are also only slightly sensitive to small changes in formulation and slightly more sensitive to variations in environmental conditions during pour mixing, and therefore include physical testing for density and compressive stress.

8.1.4.1.2.1 Physical Characteristics Determined for a Foam Formulation Foam material physical characteristics for the following parameters shall be determined once for a particular foam formulation. If multiple components are to be foamed utilizing a specific foam formulation, then additional physical testing, as defined below, need not be performed.

8.1.4.1.2.1.1 Parallel-to-Rise Compressive Modulus

1. Three (3) test samples shall be taken from the sample pour. Each test sample shall be a rectangular prism with nominal dimensions of 1.0 inch thick (T) u 2.0 inches wide (W) u 2.0 inches long (L). The thickness dimension shall be in the parallel-to-rise direction.

2. Place the test samples in a room (ambient) temperature environment (i.e., 65 ºF to 85 ºF) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 ºF.

3. Measure and record the thickness, width, and length of each test sample to an accuracy of +/-0.001 inches.

4. Compute and record the surface area of each test sample by multiplying the width by the length (i.e., W u L).

5. Place a test sample in a Universal Testing Machine. Lower the machines crosshead until it touches the test sample. Set the machines parameters for the thickness of the test sample.

HPT-PRO-0002, Rev. 1 February 2023 9

6. Apply a compressive load to each test sample at a rate of 0.10 r0.05 inches/minute until the compressive stress somewhat exceeds the elastic range of the foam material (i.e., the elastic range is typically 0% - 6% strain). Plot the compressive stress versus strain for each test sample.

7. Determine and record the parallel-to-rise compressive modulus, E, of each test sample by computing the slope in the linear region of the elastic range of the stress-strain curve, where Hi and Hj, and Vi and Vj are the strain and compressive stress at two selected points i and j, respectively, in the linear region of the stress-strain curve (see example curve to right) as follows:

psi E

i j

H

H V

V

8. Determine and record the average parallel-to-rise compressive modulus of the three test samples. The numerically averaged, parallel-to-rise compressive modulus of the three test samples shall be 6,810 psi

+/-20% (i.e., within the range of 5,448 to 8,172 psi).

0 50 100 150 200 250 300 0

5 10 15 Strain (%)

Compressive Stress (psi)

Yield Region Linear Region i

j V

V i

j H

H iH jH j

V i

V

HPT-PRO-0002, Rev. 1 February 2023 10 8.1.4.1.2.1.2 Perpendicular-to-Rise Compressive Modulus

1. Three (3) test samples shall be taken from the sample pour. Each test sample shall be a rectangular prism with nominal dimensions of 1.0 inch thick (T) u 2.0 inches wide (W) u 2.0 inches long (L). The thickness dimension shall be in the perpendicular-to-rise direction.

2. Place the test samples in a room (ambient) temperature environment (i.e., 65 ºF to 85 ºF) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 ºF.

3. Measure and record the thickness, width, and length of each test sample to an accuracy of +/-0.001 inches.

4. Compute and record the surface area of each test sample by multiplying the width by the length (i.e., W u L).

5. Place a test sample in a Universal Testing Machine. Lower the machines crosshead until it touches the test sample. Set the machines parameters for the thickness of the test sample.

6. Apply a compressive load to each test sample at a rate of 0.10 r0.05 inches/minute until the compressive stress somewhat exceeds the elastic range of the foam material (i.e., the elastic range is typically 0% - 6% strain). Plot the compressive stress versus strain for each test sample.

7. Determine and record the perpendicular-to-rise compressive modulus, E, of each test sample by computing the slope in the linear region of the elastic range of the stress-strain curve, where Hi and Hj, and Vi and Vj are the strain and compressive stress at two selected points i and j, respectively, in the linear region of the stress-strain curve (see example curve to right) as follows:

psi E

i j

H

H V

V

8. Determine and record the average perpendicular-to-rise compressive modulus of the three test samples. The numerically averaged, perpendicular-to-rise compressive modulus of the three test samples shall be 4,773 psi

+/-20% (i.e., within the range of 3,818 to 5,728 psi).

0 50 100 150 200 250 300 0

5 10 15 Strain (%)

Compressive Stress (psi)

Yield Region Linear Region i

j V

V i

j H

H iH jH j

V i

V

HPT-PRO-0002, Rev. 1 February 2023 11 8.1.4.1.2.1.3 Poissons Ratio

1. Three (3) test samples shall be taken from the sample pour.

Each test sample shall be a rectangular prism with nominal dimensions of 2.0 inches thick (T) u 2.0 inches wide (W) u 2.0 inches long (L). The thickness dimension shall be in the parallel-to-rise direction.

2. Place the test samples in a room (ambient) temperature environment (i.e., 65 ºF to 85 ºF) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 ºF.

3. Measure and record the thickness, width, and length of each test sample to an accuracy of +/-0.001 inches.

4. Place a test sample in a Universal Testing Machine. Lower the machines crosshead until it touches the test sample. Set the machines parameters for the thickness of the test sample.

5. As illustrated below, place two orthogonally oriented dial indicators at the mid-plane of one width face and one length face of the test sample to record the lateral deflections. The dial indicators shall be capable of measuring to an accuracy of +/-0.001 inches.

6. Apply a compressive load to each test sample so that the strain remains within the elastic range of the material, as determined in Section 8.1.4.1.2.1.1, Parallel-to-Rise Compressive Modulus. Record the axial crosshead displacement (GT) and both dial indicator displacements (GW and GL) at one strain point within the elastic range for each test sample.

7. Determine and record Poissons ratio of each test sample as follows:

T L

W T

L W

G G

G P

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8. Determine and record the average Poissons ratio of the three test samples. The numerically averaged Poissons ratio of the three test samples shall be 0.33 +/-20% (i.e., within the range of 0.26 to 0.40).

8.1.4.1.2.1.4 Thermal Expansion Coefficient

1. Three (3) test samples shall be taken from the sample pour. Each test sample shall be a rectangular prism with a nominal cross-section of 1.0 inch square and a nominal length of 6.0 inches.

2. Place the test samples in a room (ambient) temperature environment (i.e., 65 ºF to 85 ºF) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature (TRT) to an accuracy of r2 ºF.

3. Measure and record the room temperature length (LRT) of each test sample to an accuracy of

+/-0.001 inches.

4. Place the test samples in a -40 ºF to -60 ºF cold environment for a minimum of three hours.

Measure and record the cold environment temperature (TC) to an accuracy of r2 ºF.

5. Measure and record the cold environment length (LC) of each test sample to an accuracy of

+/-0.001 inches.

6. Determine and record the cold environment thermal expansion coefficient for each test sample as follows:

F in/in/

T T

L L

L o

RT C

RT RT C

C

D

7. Place the test samples in a 180 ºF to 200 ºF hot environment for a minimum of three hours.

Measure and record the hot environment temperature (TH) to an accuracy of r2 ºF.

8. Measure and record the hot environment length (LH) of each test sample to an accuracy of

+/-0.001 inches.

9. Determine and record the hot environment thermal expansion coefficient for each test sample as follows:

F in/in/

T T

L L

L o

RT H

RT RT H

H

D

10. Determine and record the average thermal expansion coefficient of each test sample as follows:

F in/in/

2 o

H C

D

D D

11. Determine and record the average thermal expansion coefficient of the three test samples. The numerically averaged thermal expansion coefficient of the three test samples shall be 3.5 x 10-5 in/in/ºF +/-20% (i.e., within the range of 2.8 x 10-5 to 4.2 x 10-5 in/in/ºF).

8.1.4.1.2.1.5 Thermal Conductivity

1. The thermal conductivity test shall be performed using a heat flux meter (HFM) apparatus.

The HFM establishes steady state unidirectional heat flux through a test specimen between

HPT-PRO-0002, Rev. 1 February 2023 13 two parallel plates at constant but different temperatures. By measurement of the plate temperatures and plate separation, Fouriers law of heat conduction is used by the HFM to automatically calculate thermal conductivity. Description of a typical HFM is provided in ASTM C5185. The HFM shall be calibrated against a traceable reference specimen per the HFM manufacturer's operating instructions.

2. Three (3) test samples shall be taken from the sample pour. Each test sample shall be of sufficient size to enable testing per the HFM manufacturer's operating instructions.

3. Measure and record the necessary test sample parameters as input data to the HFM per the HFM manufacturer's operating instructions.

4. Perform thermal conductivity testing and record the measured thermal conductivity for each test sample following the HFM manufacturer's operating instructions.

5. Determine and record the average thermal conductivity of the three test samples. The numerically averaged thermal conductivity of the three test samples shall be 0.230 Btu-in/hr-ft2-ºF +/-20% (i.e., within the range of 0.184 to 0.276 Btu-in/hr-ft2-ºF).

8.1.4.1.2.1.6 Specific Heat

1. The specific heat test shall be performed using a differential scanning calorimeter (DSC) apparatus. The DSC establishes a constant heating rate and measures the differential heat flow into both a test specimen and a reference specimen. Description of a typical DSC is provided in ASTM E12696. The DSC shall be calibrated against a traceable reference specimen per the DSC manufacturer's operating instructions.

2. Three (3) test samples shall be taken from the sample pour. Each test sample shall be of sufficient size to enable testing per the DSC manufacturer's operating instructions.

3. Measure and record the necessary test sample parameters as input data to the DSC per the DSC manufacturer's operating instructions.

4. Perform specific heat testing and record the measured specific heat for each test sample following the DSC manufacturer's operating instructions.

5. Determine and record the average specific heat of the three test specimens. The numerically averaged specific heat at 77 ºF of the three test samples shall be 0.30 Btu/lb-ºF +/-20% (i.e.,

within the range of 0.24 to 0.36 Btu/lb-ºF).

8.1.4.1.2.2 Physical Characteristics Determined for a Foam Batch Foam material physical characteristics for the following parameters shall be determined once for a particular foam batch based on the batch definition from Section 8.1.4.1.1, Introduction and General Requirements. If a single or multiple components are to be poured utilizing multiple pours from a single foam batch, then additional physical testing, as defined below, need not be performed for each foam pour.

5 ASTM C518, Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Heat Flux Meter Apparatus, American Society of Testing and Materials (ASTM).

6 ASTM E1269, Standard Test Method for Determining Specific Heat Capacity by Differential Scanning Calorimetry, American Society of Testing and Materials (ASTM).

HPT-PRO-0002, Rev. 1 February 2023 14 8.1.4.1.2.2.1 Flame Retardancy

1. Three (3) test samples shall be taken from a pour from each foam batch. Each test sample shall be a rectangular prism with nominal dimensions of 0.5 inches thick, 3.0 inches wide, and a minimum length of 6.0 inches. In addition, individual sample lengths must not be less than the total burn length observed for the sample when tested.

2. Place the test samples in a room (ambient) temperature environment (i.e., 65 ºF to 85

ºF) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 ºF.

3. Measure and record the length of each test sample to an accuracy of +/-0.1 inches.

4. Install a Ø3/8 inches (10 mm), or larger, Bunsen or Tirrill burner inside an enclosure of sufficient size to perform flame retardancy testing. Adjust the burner flame height to 11/2 r1/8 inches. Verify that the burner flame temperature is 1,550 ºF, minimum.

5. Support the test sample with the long axis oriented vertically within the enclosure such that the test samples bottom edge will be 3/4 r1/16 inches above the top edge of the burner.

6. Move the burner flame under the test sample for an elapsed time of 60 r2 seconds. As illustrated, align the burner flame with the front edge of the test sample thickness and the center of the test sample width.

7. Immediately after removal of the test sample from the burner flame, measure and record the following data:

a. Measure and record, to the nearest second, the elapsed time until flames from the test sample extinguish.

b. Measure and record, to the nearest second, the elapsed time from the occurrence of drips, if any, until drips from the test sample extinguish.

c. Measure and record, to the nearest 0.1 inches, the burn length following cessation of all visible burning and smoking.

8. Flame retardancy testing acceptance is based on the following criteria:

a. The numerically averaged flame extinguishment time of the three test samples shall not exceed fifteen (15) seconds.

b. The numerically averaged flame extinguishment time of drips from the three test samples shall not exceed three (3) seconds.

c. The numerically averaged burn length of the three test samples shall not exceed six (6) inches.

HPT-PRO-0002, Rev. 1 February 2023 15 8.1.4.1.2.2.2 Intumescence

1. Three (3) test samples shall be taken from a pour from each foam batch. Each test sample shall be a cube with nominal dimensions of 2.0 inches.

2. Place the test samples in a room (ambient) temperature environment (i.e., 65 ºF to 85 ºF) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 ºF.

3. Preheat a furnace to 1,475 ºF r18 ºF.

4. Identify two opposite faces on each test sample as the thickness direction. The thickness dimension shall be in the parallel-to-rise direction. Measure and record the initial thickness (ti) of each test sample to an accuracy of +/-0.01 inches.

5. Mount a test sample onto a fire resistant fiberboard, with one face of the thickness direction contacting to the board. As illustrated above, the test samples may be mounted by installing onto a 12 to 16 gauge wire (Ø0.105 to Ø0.063 inches, respectively) of sufficient length, oriented perpendicular to the fiberboard face. The test samples may be pre-drilled with an undersized hole to allow installation onto the wire.

6. Locate the test sample/fiberboard assembly over the opening of the pre-heated furnace for a 90 r3 second duration. After removal of the test sample/fiberboard assembly from the furnace, gently extinguish any remaining flames and allow the test sample to cool.

7. Measure and record the final thickness (tf) of the test sample to an accuracy of +/-0.1 inches.

8. For each sample tested, determine and record the intumescence, I, as a percentage of the original sample length as follows:

100 t

t t

= I i

i f

u

¸¸

¹

¨¨

©

§

9. Determine and record the average intumescence of the three test samples. The numerically averaged intumescence of the three test samples shall be a minimum of 50%.

8.1.4.1.2.2.3 Leachable Chlorides

1. The leachable chlorides test shall be performed using an ion chromatograph (IC) apparatus.

The IC measures inorganic anions of interest (i.e., chlorides) in water. Description of a typical IC is provided in EPA Method 300.07. The IC shall be calibrated against a traceable reference specimen per the IC manufacturer's operating instructions.

2. One (1) test sample shall be taken from the sample pour. The test sample shall be a cube with dimensions of 2.00 r0.03 inches.

7 EPA Method 300.0, Determination of Inorganic Anions in Water by Ion Chromatography, U.S. Environmental Protection Agency.

HPT-PRO-0002, Rev. 1 February 2023 16

3. Place the test sample in a room (ambient) temperature environment (i.e., 65 ºF to 85 ºF) for sufficient time to thermally stabilize the test sample. Measure and record the room temperature to an accuracy of r2 ºF.

4. Measure and record the thickness, width, and length of each test sample to an accuracy of

+/-0.001 inches.

5. Obtain a minimum of 550 ml of distilled or de-ionized water for testing. The test water shall be from a single source to ensure consistent anionic properties for testing control.

6. Obtain a 400 ml, or larger, contaminant free container that is capable of being sealed. Fill the container with 262 r3 ml of test water. Fully immerse the test sample inside the container for a duration of 72 r3 hours. If necessary, use an inert standoff to ensure the test sample is completely immersed for the full test duration. Seal the container prior to the 72 hour8.333333e-4 days 0.02 hours 1.190476e-4 weeks 2.7396e-5 months duration.

7. Obtain a second, identical container to use as a control. Fill the control container with 262 r3 ml of the same test water. Seal the control container for a 72 +/-3 hour duration.

8. At the end of the test period, measure and record the leachable chlorides in the test water per the IC manufacturer's operating instructions. The leachable chlorides in the test water shall not exceed one part per million (1 ppm).

9. Should leachable chlorides in the test water exceed 1 ppm, measure and record the leachable chlorides in the test water from the control container. The difference in leachable chlorides from the test water and control water sample shall not exceed 1 ppm.

8.1.4.1.2.3 Physical Characteristics Determined for a Foam Pour Foam material physical characteristics for the following parameters shall be determined for each foam pour based on the pour definition from Section 8.1.4.1.1, Introduction and General Requirements.

8.1.4.1.2.3.1 Density

1. Three (3) test samples shall be taken from the foam pour. Each test sample shall be a rectangular prism with nominal dimensions of 1.0 inch thick (T) u 2.0 inches wide (W) u 2.0 inches long (L).

2. Place the test samples in a room (ambient) temperature environment (i.e., 65 ºF to 85 ºF) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 ºF.

3. Measure and record the weight of each test sample to an accuracy of +/-0.01 grams.

4. Measure and record the thickness, width, and length of each test sample to an accuracy of

+/-0.001 inches.

5. Determine and record the room temperature density of each test sample utilizing the following formula:

Ufoam

/ft W

L in u

u u

Weight, g 453.6 g/lb 1,728 in T

, pcf 3

3 3

HPT-PRO-0002, Rev. 1 February 2023 17

6. Determine and record the average density of the three test samples. The numerically averaged density of the three test samples shall be 81/4 pcf +/-15% (i.e., within the range of 7 to 91/2 pcf).

8.1.4.1.2.3.2 Parallel-to-Rise Compressive Stress

1. Three (3) test samples shall be taken from the foam pour. Each test sample shall be a rectangular prism with nominal dimensions of 1.0 inch thick (T) u 2.0 inches wide (W) u 2.0 inches long (L). The thickness dimension shall be the parallel-to-rise direction.

2. Place the test samples in a room (ambient) temperature environment (i.e., 65 ºF to 85 ºF) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 ºF.

3. Measure and record the thickness, width, and length of each test sample to an accuracy of +/-0.001 inches.

4. Compute and record the surface area of each test sample by multiplying the width by the length (i.e., W u L).

5. Place a test sample in a Universal Testing Machine. Lower the machines crosshead until it touches the test sample. Set the machines parameters for the thickness of the test sample.

6. Apply a compressive load to each test sample at a rate of 0.10 r0.05 inches/minute until a strain of 70%, or greater, is achieved. For each test sample, plot the compressive stress versus strain and record the compressive stress at strains of 10%, 40%, and 70%.

7. Determine and record the average parallel-to-rise compressive stress of the three test samples from each pour. As delineated in Table 8.1-1, the average parallel-to-rise compressive stress for each pour shall be the nominal compressive stress +/-20% at strains of 10%, 40%, and 70%.

8. Determine and record the average parallel-to-rise compressive stress of all test samples from each foamed component. As delineated in Table 8.1-1, the average parallel-to-rise compressive stress for a foamed component shall be the nominal compressive stress +/-15% at strains of 10%, 40%, and 70%.

HPT-PRO-0002, Rev. 1 February 2023 18 8.1.4.1.2.3.3 Perpendicular-to-Rise Compressive Stress

1. Three (3) test samples shall be taken from the foam pour. Each test sample shall be a rectangular prism with nominal dimensions of 1.0 inch thick (T) u 2.0 inches wide (W) u 2.0 inches long (L). The thickness dimension shall be the perpendicular-to-rise direction.

2. Place the test samples in a room (ambient) temperature environment (i.e., 65 ºF to 85 ºF) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 ºF.

3. Measure and record the thickness, width, and length of each test sample to an accuracy of +/-0.001 inches.

4. Compute and record the surface area of each test sample by multiplying the width by the length (i.e., W u L).

5. Place a test sample in a Universal Testing Machine. Lower the machines crosshead until it touches the test sample. Set the machines parameters for the thickness of the test sample.

6. Apply a compressive load to each test sample at a rate of 0.10 r0.05 inches/minute until a strain of 70%, or greater, is achieved. For each test sample, plot the compressive stress versus strain and record the compressive stress at strains of 10%, 40%, and 70%.

7. Determine and record the average perpendicular-to-rise compressive stress of the three test samples from each pour. As delineated in Table 8.1-1, the average perpendicular-to-rise compressive stress for each pour shall be the nominal compressive stress +/-20% at strains of 10%, 40%, and 70%.

8. Determine and record the average perpendicular-to-rise compressive stress of all test samples from each foamed component. As delineated in Table 8.1-1, the average perpendicular-to-rise compressive stress for a foamed component shall be the nominal compressive stress

+/-15% at strains of 10%, 40%, and 70%.

Table 8.1 Acceptable Compressive Stress Ranges for Foam (psi)

Sample Range Parallel-to-Rise at Strain, HH//

Perpendicular-to-Rise at Strain, HHA H=10%

H=40%

H=70%

H=10%

H=40%

H=70%

Nominal -20%

188 216 544 156 188 536 Nominal -15%

200 230 578 166 200 570 Nominal 235 270 680 195 235 670 Nominal +15%

270 311 782 224 270 771 Nominal +20%

282 324 816 234 282 804

HPT-PRO-0002, Rev. 1 February 2023 19 8.1.5 Tests for Shielding Integrity Section not applicable. The HalfPACT packaging does not contain any biological shielding.

ICV 506 does not contain a shielded container. It was loaded with Payload SRE033, comprised of one standard waste box, in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022.

HPT-PRO-0002, Rev. 1 February 2023 20 8.1.6 Thermal Acceptance Test Material properties utilized in Chapter 3.0, Thermal Evaluation, of the HalfPACT SAR are consistently conservative for the normal conditions of transport (NCT) and hypothetical accident condition (HAC) thermal analyses performed. In addition, HAC fire certification testing of the HalfPACT package (see Appendix 2.10.3, Certification Tests, of the HalfPACT SAR) served to verify material performance in the HAC thermal environment. As such, with the exception of the tests required for polyurethane foam, as shown in Section 8.1.4, Component Tests, specific acceptance tests for material thermal properties are not performed.

HPT-PRO-0002, Rev. 1 February 2023 21 8.2 Maintenance Program This section describes the maintenance program used to ensure continued performance of the HalfPACT package.

8.2.1 Structural and Pressure Tests 8.2.1.1 Pressure Testing Perform structural pressure testing on the outer confinement vessel (OCV) per the requirements of Section 8.1.2.2, Pressure Testing, once every five years. Upon completing the structural pressure test, perform leakage rate testing on the OCV per the requirements of Section 8.1.3, Fabrication Leakage Rate Tests.

8.2.1.2 ICV Interior Surfaces Inspection Section not applicable. ICV 506 was loaded with Payload Assembly SRE033 in compliance with CofC 9279 on 08/23/2022 and received at WIPP on 08/26/2022. Credit will not be taken for containment provided by the ICV.

8.2.2 Maintenance/Periodic Leakage Rate Tests This section provides the generalized procedure for maintenance and periodic leakage rate testing of the vessel penetrations during routine maintenance, or at the time of seal replacement or seal area repair. Maintenance/periodic leakage rate testing shall follow the guidelines of Section 7.4, Maintenance Leakage Rate Test, and Section 7.5, Periodic Leakage Rate Test, of ANSI N14.51.

Leakage rate testing of the outer confinement vessel (OCV) main O-ring seal and OCV vent port plug shall be performed in accordance with Section 8.1.3.6, Helium Leakage Rate Testing the OCV Main O-ring Seal Integrity, and Section 8.1.3.7, Helium Leakage Rate Testing the OCV Vent Port Plug O-ring Seal Integrity. Each leakage rate test shall meet the acceptance criteria delineated in Section 8.2.2.1, Maintenance/Periodic Leakage Rate Test Acceptance Criteria.

8.2.2.1 Maintenance/Periodic Leakage Rate Test Acceptance Criteria Maintenance/periodic leakage rate test acceptance criteria are identical to the criteria delineated in Section 8.1.3.1, Fabrication Leakage Rate Test Acceptance Criteria.

8.2.2.2 Helium Leakage Rate Testing the ICV Main O-ring Seal Section not applicable. ICV 506 was loaded with Payload Assembly SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. Credit will not be taken for containment provided by the ICV.

1 ANSI N14.5-1997, American National Standard for Radioactive Materials - Leakage Tests on Packages for Shipment, American National Standards Institute, Inc. (ANSI).

HPT-PRO-0002, Rev. 1 February 2023 22 8.2.2.3 Helium Leakage Rate Testing the ICV Outer Vent Port Plug O-ring Seal Section not applicable. ICV 506 was loaded with Payload Assembly SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. Credit will not be taken for containment provided by the ICV.

8.2.3 Subsystems Maintenance 8.2.3.1 Fasteners All threaded components shall be inspected annually for deformed or stripped threads. Damaged components shall be repaired or replaced prior to further use. The threaded components to be visually inspected include the lock bolts, the OCV and ICV seal test port and vent port plugs, the OCV and ICV vent port covers, and OCV access plugs.

8.2.3.2 Locking Rings Before each use, inspect the OCV and ICV locking ring assemblies for restrained motion. Any motion-impairing components shall be corrected prior to further use.

8.2.3.3 Seal Areas and Grooves 8.2.3.3.1 Seal Area Routine Inspection and Repair Before each use and at the time of seal replacement, the OCV sealing surfaces shall be visually inspected for damage that could impair the sealing capabilities of the HalfPACT packaging.

Damage shall be corrected prior to further use (e.g., using emery cloth restore sealing surfaces) to the surface finish specified in Section 8.2.3.3.2.4, Surface Finish of Sealing Areas.

Upon completion of OCV seal area repairs, verify depth of O-ring groove does not exceed the value in Section 8.2.3.3.2.5, O-ring Groove Depth, when repairs are in the O-ring groove; perform leakage rate test per the applicable section of Section 8.2.2, Maintenance/Periodic Leakage Rate Tests.

8.2.3.3.2 Annual Seal Area Dimensional Inspection In order to demonstrate compliance of the OCV main O-ring seal regions, annual inspection of sealing area dimensions and surface finishes shall be performed as defined in Section 8.2.3.3.2.1, Groove Widths, through Section 8.2.3.3.2.5, O-ring Groove Depth.

Allowable OCV measurements for these dimensions are based on a minimum O-ring compression of 10.73%, which will ensure leaktight seals are maintained (see calculation in Appendix 2.10.2, Elastomer O-ring Seal Performance Tests, of the HalfPACT SAR, for the ICV seal flanges; this calculation is also applicable to the OCV seal flanges since their cross-sectional geometry is intentionally identical).

All OCV measurement results shall be recorded and retained as part of the overall inspection record for the HalfPACT package. OCV measurements not in compliance with the following dimensional requirements require repairs. Upon completion of OCV repairs, perform a maintenance/periodic leakage rate test per the applicable section of Section 8.2.2, Maintenance/Periodic Leakage Rate Tests.

HPT-PRO-0002, Rev. 1 February 2023 23 8.2.3.3.2.1 Groove Widths The method of measuring the OCV upper (lid) seal flange groove width is illustrated in Figure 8.2-1. As an option, the lid may be inverted to facilitate the measurement process. The measuring equipment includes a Ø0.560 +/-0.001 inch pin gauge of any convenient length, and a

Ø0.250 +/-0.001 inch ball. With reference to Figure 8.2-1, the pin gauge is aligned parallel with the inner lip of the upper seal flange. Acceptability is based on the following conditions:

x Having contact at location c-c and a gap at location d-d is a NO-GO condition indicating that the upper seal flange groove width is acceptable.

x Having contact or a gap at location c-c and contact at location d-d is a GO condition indicating that the upper seal flange groove width is unacceptable.

The method of measuring the OCV lower (body) seal flange groove width is illustrated in Figure 8.2-2. The measuring equipment includes a Ø0.273 +/-0.001 inch pin gauge of any convenient length, and a Ø0.250 +/-0.001 inch ball. With reference to Figure 8.2-2, the pin gauge is aligned parallel with the outer lip of the lower seal flange. Acceptability is based on the following conditions:

x Having contact at location c-c and a gap at location d-d is a NO-GO condition indicating that the lower seal flange groove width is acceptable.

x Having contact or a gap at location c-c and contact at location d-d is a GO condition indicating that the lower seal flange groove width is unacceptable.

Groove width measurements shall be taken and recorded at six equally spaced locations around the circumference of the seal flanges.

8.2.3.3.2.2 Tab Widths The method of measuring the OCV upper (lid) seal flange tab width is illustrated in Figure 8.2-3.

As an option, the lid may be inverted to facilitate the measurement process. The measuring device is a tab width gauge of any convenient size, with a 0.234 +/-0.001 inch inside width u 0.428 +/-0.001 inch inside height u 0.375 +/-0.005 inch thickness. With reference to Figure 8.2-3, the tab width gauge is aligned parallel with the lowermost lip of the upper seal flange.

Acceptability is based on the following conditions:

x Having contact at location c-c and a gap at location d-d is a NO-GO condition indicating that the upper seal flange tab width is acceptable.

x Having contact or a gap at location c-c and contact at location d-d is a GO condition indicating that the upper seal flange tab width is unacceptable.

The method of measuring the OCV lower (body) seal flange tab width is illustrated in Figure 8.2-4. The measuring device is a 0.494 +/-0.001 inch inside width u 0.250 +/-0.001 inch inside height u 0.375 +/-0.005 inch thick tab width gauge of any convenient size. With reference to Figure 8.2-4, the tab width gauge is aligned parallel with the uppermost lip of the lower seal flange.

Acceptability is based on the following conditions:

x Having contact at location c-c and a gap at location d-d is a NO-GO condition indicating that the lower seal flange tab width is acceptable.

HPT-PRO-0002, Rev. 1 February 2023 24 x Having contact or a gap at location c-c and contact at location d-d is a GO condition indicating that the lower seal flange tab width is unacceptable.

Tab width measurements shall be taken and recorded at six equally spaced locations around the circumference of the seal flanges.

8.2.3.3.2.3 Axial Play Measurement of axial play shall be performed to ensure that O-ring compression is sufficient to maintain package configuration and performance to design criteria. Axial play is the maximum axial distance that a lid can move relative to a body. Because the seal flange sealing surfaces are tapered, any axial movement where the lid moves away from the body results in a separation of the sealing surfaces and a slight reduction in O-ring compression. The procedure for measuring OCV axial play is as follows:

1. Remove the vent port access plug (OCV only), vent port thermal plug (OCV only), vent port cover, and vent port plug(s).

2. Assemble the lid onto the body.

3. Locate a minimum of six equally spaced locations around the exterior circumference of the lid and body. At each location, place vertically aligned temporary reference marks on the lid and body.

4. Install a vacuum pump to the vent port and evacuate the vessel sufficiently to fully compress the upper seal flange to the lower seal flange.

5. At each location, scribe a horizontal mark that intersects both the lid and the body vertical marks.

6. Install a source of pressure to the vent port and pressurize the vessel sufficiently to fully separate the upper seal flange from the lower seal flange.

7. At each location, scribe a second horizontal mark that intersects either the lid or the body vertical mark (select either the lid or body mark as a base point).

8. Measure and record the difference between the initial and final horizontal marks at each location. The maximum acceptable axial play at any location is 0.153 inch.

9. Other measuring devices, such as dial indicators, digital calipers, etc., may be used in lieu of the reference marking method, provided that the axial play is measured at a minimum of six equally spaced locations.

8.2.3.3.2.4 Surface Finish of Sealing Areas The surface finish in the OCV main O-ring sealing regions shall be a 125 micro-inch finish, or better, to maintain package configuration and performance to design criteria. Perform OCV surface finish inspections for the bottom of the grooves on the lower seal flange and the mating sealing surfaces on the upper seal flange. If the OCV surface condition is determined to exceed 125 micro-inch, repair the surface per the requirements of Section 8.2.3.3.1, Seal Area Routine Inspection and Repair.

HPT-PRO-0002, Rev. 1 February 2023 25 8.2.3.3.2.5 O-ring Groove Depth Verify the OCV O-ring groove depth to be less than 0.253 inches at six equally spaced locations around the circumference of the seal flanges.

8.2.4 Valves, Rupture Discs, and Gaskets 8.2.4.1 Valves The HalfPACT packaging does not contain any valves.

8.2.4.2 Rupture Discs The HalfPACT packaging does not contain any rupture discs.

8.2.4.3 Gaskets OCV containment boundary O-ring seals shall be replaced within the 12-month period prior to shipment or when damaged (whichever is sooner), per the size and material requirements delineated on the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR. Following OCV containment O-ring seal replacement and prior to a loaded shipment, the new seals shall be leakage rate tested to the requirements of Section 8.2.2, Maintenance/Periodic Leakage Rate Tests.

8.2.5 Shielding The HalfPACT packaging does not contain any biological shielding. ICV 506 does not contain a shielded container. It was loaded with Payload SRE033, comprised of one standard waste box, in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022.

8.2.6 Thermal No thermal tests are necessary to ensure continued performance of the HalfPACT packaging.

HPT-PRO-0002, Rev. 1 February 2023 26 Figure 8.2 Method of Measuring Upper Seal Flange Groove Widths

HPT-PRO-0002, Rev. 1 February 2023 27 Figure 8.2 Method of Measuring Lower Seal Flange Groove Widths

HPT-PRO-0002, Rev. 1 February 2023 28 Figure 8.2 Method of Measuring Upper Seal Flange Tab Widths

HPT-PRO-0002, Rev. 1 February 2023 29 Figure 8.2 Method of Measuring Lower Seal Flange Tab Widths

Attachment E ICV 506 Payload SRE033 Flammable Gas Concentration Initial Condition

E-1 Attachment E ICV 506 Payload SRE033 Flammable Gas Concentration Initial Condition Issue Inner containment vessel (ICV) 506 contains Payload SRE033 (solid organic transuranic waste packaged in a plastic liner bag within one filtered standard waste box

[SWB] [SWD12275]). As required by CH-TRAMPAC Section 5.0, Gas Generation Requirements:

Gas generation, concentrations, and pressures during transport of CH-TRU wastes in aHalfPACT payload are restricted as follows:

For any package containing water and/or organic substances that could radiolytically generate combustible gases, determination must be made by tests and measurements or by analysis of a representative package such that the following criterion is met over a period of time that is twice the expected shipment time: The hydrogen generated must be limited to a molar quantity that would be no more than 5 percent by volume of the innermost layer of confinementif present at standard temperature and pressure.

The gases generated in the payload and released into the ICV cavity shall be controlled to maintain the pressure within the TRUPACT-II or HalfPACT ICV cavity below the acceptable design pressure of 50 pounds per square inch gauge.

Payload SRE033 was previously certified to CH-TRAMPAC requirements, including the above, and was compliantly shipped in HalfPACT 506 from the Savannah River Site (SRS) to the Waste Isolation Pilot Plant (WIPP). Payload SRE033 is unchanged, and the same CH-TRAMPAC compliance determination applies to its return shipment under the one-time authorization crediting the outer confinement vessel as the containment boundary. However, because ICV 506 with Payload SRE033 has been stored in a sealed condition, an evaluation was performed to confirm that the altered initial condition for Payload SRE033 (i.e., sealed in ICV 506) does not change the CH-TRAMPAC compliance determination.

Evaluation and Conclusion Flammable gas measurement data collected from the headspace of SWB No.

SWD12275 as required by CH-TRAMPAC Section 5.0 was used to model and evaluate the potential build-up of flammable gases within the innermost confinement layer of the SWB while sealed within the HalfPACT ICV. From the headspace flammable gas measurement data obtained on May 28, 2013, SWB No. SWD12275 contained flammable volatile organic compounds (VOC) less than 500 ppm and low hydrogen plus methane concentrations (15.06 ppm). Although ICV 506 was vented upon receipt at WIPP and re-sealed for temporary storage, for this evaluation it is assumed that the ICV

E-2 with Payload SRE033 has remained sealed since its initial closure on August 23, 2022, prior to shipment from SRS. The flammable gas generation rate and time-dependent flammable gas concentration within the innermost layer of confinement of the SWB within ICV 506 was determined through the solution of mass transport differential equations that model the transport of gases in the layer resistance network via diffusion and permeation mechanisms. The evaluation details including modeling methodology and assumptions are documented in PLD-CAL-0007.1 Modeling results are summarized as follows:

The flammable gas generation rate within SWB No. SWD12275 was calculated to be 3.6553E-10 mol/sec based on a headspace gas measurement of 15.06 ppm obtained 69 days after the SWB payload was configured.

At the end of the authorized shipping duration for Shipment SR220010

(<60 days), the flammable gas concentration of the SWB No. SWD12275 innermost confinement layer sealed within the HalfPACT ICV was determined to be 0.009%.

SWB No. SWD12275 innermost confinement layer flammable gas concentration will remain less than or equal to the CH-TRAMPAC Section 5.0 limit of 5% if sealed for an additional 110,421 days (~300 years) beyond the authorized shipping duration for Shipment SR220010.

The CH-TRAMPAC Section 5.0 restrictions on gas generation, concentrations, and pressures during transport of ICV 506 with Payload SRE033 will be met for the proposed one-time authorization shipment as follows:

Due to the insignificant flammable gas generation rate, the CH-TRAMPAC Section 5.0 flammable gas concentration limit of less than or equal to 5% will continue to be met for the proposed one-time authorization to return the loaded ICV 506 to SRS from WIPP. Because Payload SRE033 will remain safely nonflammable for ~300 years, it will easily meet this condition during the shorter authorized shipping duration of 60 days for the shipment from WIPP to SRS.

As detailed in CH-TRAMPAC Section 5.2.5.3.3., Determine Compliance with the Packaging Design Pressure Limit by Theoretical Analysis, compliance with the HalfPACT design pressure limit of 50 psig can be demonstrated by conservative theoretical analysis. With a flammable gas generation rate of 3.6553E-10 mol/sec, the flammable gas concentration of the innermost layer of SWB No. SWD12275 will remain less than 5% during the return shipment from WIPP to SRS. Per CH-TRAMPAC Section 5.2.5.3.3, the ratio of total gas generation rate to flammable gas generation rate is such that if the 5% by volume flammable 1 PLD-CAL-0007, Flammable Gas Concentration Evaluation for HalfPACT Payload SRE033, Revision 1, dated January 11, 2023.

E-3 gas concentration limit is met, the pressure limit is also met. SWB No.

SWD12275 with a flammable gas generation rate of 3.6553E-10 mol/sec and a flammable gas concentration of less than 5% by volume will have a similarly low total gas generation rate and associated pressure increase and will easily comply with the 50 psig HalfPACT design pressure limit.

Attachment F References

PLD-CAL-0007, Flammable Gas Concentration Evaluation for HalfPACT Payload SRE033

HPT-CAL-0001, Loaded HalfPACT ICV Lifting Evaluation

Calculation Cover Sheet

1. Document

Title:

2. System Number:

Flammable Gas Concentration Evaluation for HalfPACT Payload SRE033 PT00

3. Document Number:

4. Document Revision:

5. Page:

PLD-CAL-0007 1

1 of 28

6. Summary Description This calculation report documents a bounding evaluation of the transient flammable gas concentrations in HalfPACT payload SRE033, which consists of one direct-load standard waste box (SWB) container SWD12275. The flammable gas generation rate within the SWB is calculated from the pre-shipment headspace gas sample data to be 3.6553e-10 mol/sec and that rate is used to assess the transient buildup of flammable gas within the innermost confinement layer to 0.009% when the SWB is fully sealed within the HalfPACT inner containment vessel (ICV) for 59 days. The allowable elapsed time that the SWB could be fully sealed within the ICV with the flammable gas concentrations safely remaining less than or equal to the lower flammability limit (LFL) of 5% is determined to be an additional 110,421 days from the end of the shipping duration, or 110,480 days from the data of initial ICV closure on August 23, 2022.

7. Software Usage Software Name Version

1. Python (qualified per WP 16-2 through STP-PLN-0006 on March 11, 2020) 3.7

2.

3.

4.

8. Preparer Name Signature Date Brad Day

9. Independent Reviewer(s)

Name Signature Date Kyle Moyant Jennifer Biedscheid

10. Project Manager Name Signature Date Murthy Devarakonda

11. QA Manager Name Signature Date D. Steve Tanner (Designee)

Digitally signed by BRAD DAY (Affiliate)

Date: 2023.01.10 10:22:36 -07'00' KYLE MOYANT (Affiliate)

Digitally signed by KYLE MOYANT (Affiliate)

Date: 2023.01.10 10:39:05 -07'00' JENNIFER BIEDSCHEID (Affiliate)

Digitally signed by JENNIFER BIEDSCHEID (Affiliate)

Date: 2023.01.11 07:49:50 -07'00' MURTHY DEVARAKONDA (Affiliate)

Digitally signed by MURTHY DEVARAKONDA (Affiliate)

Date: 2023.01.11 09:37:05 -07'00' David S. Tanner Digitally signed by David S. Tanner Date: 2023.01.11 17:30:40 -07'00'

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2 of 28 TABLE OF CONTENTS

1.0 INTRODUCTION

................................................................................................................ 5 2.0

SUMMARY

OF RESULTS................................................................................................ 6 3.0 METHODOLOGY.............................................................................................................. 7 3.1 Method................................................................................................................................ 7 3.2 Inputs................................................................................................................................... 8 3.2.1 Layers of Confinement................................................................................................ 8 3.3 Significant Assumptions..................................................................................................... 9 3.4 Acceptance Criteria............................................................................................................. 9 4.0 ANALYSIS......................................................................................................................... 10 4.1 Model Input Parameters.................................................................................................... 10 4.1.1 Initial Conditions....................................................................................................... 10 4.1.2 Input Parameters........................................................................................................ 10 4.2 Analysis and Results......................................................................................................... 11 4.3 Summary and Conclusions............................................................................................... 11

5.0 REFERENCES

................................................................................................................... 12 APPENDIX A.............................................................................................................................. 13 A.1 Computer Run Listing....................................................................................................... 13 A.1.1 SWB Flammable Gas Generation Rate..................................................................... 13 A.1.2 Flammable Gas Concentrations Over Time in Sealed HalfPACT ICV.................... 15 A.2 Python Script Listing........................................................................................................ 17

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3 of 28 LIST OF TABLES Table 1 - Layer of Confinement Descriptions.................................................................................8 Table 2 - Resistance Factors..........................................................................................................10 LIST OF FIGURES N/A

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4 of 28 TABLE OF REVISIONS Revision Number Pages Affected Revision Description 0

All New Issue 1

8 Corrected typo in NF019D filter diffusivity from 1.85E05 to 1.85E-5.

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1.0 INTRODUCTION

HalfPACT payload SRE033 was initially sealed at the generator site on August 23, 2022 and qualified as a 60-day shipment from the Savannah River Site (SRS) to the Waste Isolation Pilot Plant (WIPP). The payload consisted of one direct-load standard waste box (SWB) assigned to CH-TRUCON code SR 225C. The payload was qualified per the CH-TRAMPAC utilizing the Waste Data System (WDS) payload evaluation [Ref. 1]. The SR220010 shipment was sent from SRS on August 25, 2022 and received on August 26, 2022 at WIPP. During processing of the package and sampling of the ICV contents, internal contamination was detected. Out of an abundance of caution in relation to the identified contamination, the package is being further evaluated for disposition, prompting a desire for assessment of the build-up of flammable gas within the ICV to ensure that the sealed ICV is managed such that it will not experience flammable concentrations of gases were the ICV to remain sealed.

The payload was certified for shipment utilizing the analytical flammable gas compliance methodology. From the headspace gas measurement data obtained on May 28, 2013, the SWB did not contain flammable volatile organic compounds (VOC) that exceeded 500 ppm and exhibited low hydrogen plus methane concentrations within the SWB headspace [Ref. 2]. The flammable gas generation rate and time-dependent flammable gas concentration within the innermost layer of confinement of the SWB within the HalfPACT can be determined through the solution of mass transport differential equations that model the transport of gases in the layer resistance network via diffusion and permeation mechanisms [Ref. 3].

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6 of 28 2.0

SUMMARY

OF RESULTS Through utilization of the headspace gas measurement data, the flammable gas generation rate associated with a 69-day vent-to-sample duration for the SWB was determined to be 3.6553e-10 mol/sec and subsequently employed to evaluate the build-up of flammable gas within the innermost confinement layer of the SWB when sealed within the HalfPACT ICV. At the end of the authorized shipping duration, the flammable gas concentration of the SWB innermost confinement layer when sealed for 59 days within the HalfPACT ICV was determined to be 0.009%. The SWB innermost confinement layer flammable gas concentration was further determined to remain less than or equal to the LFL of 5% if sealed for an additional 110,421 days beyond the authorized shipping duration. Thus, a total sealed ICV duration of 110,480 days from the date of ICV closure will be safely non-flammable.

The layer of confinement descriptions, modeling methodology, assumptions, and detailed modeling results are provided in Section 4.0. Note that the results provided herein are specific to the SRE033 payload and a bounding assumption that the HalfPACT ICV remains sealed from the initial ICV closure data until the innermost confinement layer flammable gas concentration reaches the LFL. Venting of the package through any mechanism that allows release of gas from the ICV would increase the reported allowable sealed time duration and reduce the flammable gas concentrations.

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7 of 28 3.0 METHODOLOGY 3.1 Method Following the AltMeth methodology defined in the CH-TRU Payload Appendix 3.10 [Ref. 3],

the mass transport of hydrogen across serial layers of confinement via diffusion through the various closure types or filter vents and permeation through plastic bag layers are defined generally as follows for i = 1, n layers:

g i

i i

i 1 i

i C RT dX Q

sec 86,400 X

X dt VP day V

§

¨

¸

©

¹

i 1 i

i 1 i 1 i 2 i 1 i 1 dX Q

Q X

X X

X dt V

V

n n 1 n

n 1 n

n n 1 n

n dX Q

Q X

X X

X dt V

V

0 where:

Cg

= innermost layer gas generation rate (mole/sec)

Qi

= release rate of gas across layer i (liters/day)

Vi

= void volume inside layer i (liters)

Xi

= mole fraction of gas within the void space layer i (mf)

P

= pressure (atm)

R

= gas constant = 0.08206 atm-liter/mole-K T

= temperature (K)

This system of equations are solved simultaneously by numerical integration through the use of an ordinary differential equation (ODE) solver (Python Scipy ODEINT) to determine the transport of hydrogen from the innermost confinement layer in which it is assumed to be generated across the defined layers of confinement.

Note that a more general form of the above equations are implemented in the Python script and solved numerically utilizing a nodal network model that allows for the solution of the mass balance as defined by the serial and/or parallel communication of gas between the interconnected nodes without the necessity to have the resistance factor and gas generation rate of parallel nodes identical.

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8 of 28 3.2 Inputs 3.2.1 Layers of Confinement The modeled layers of confinement are defined by the SR 225C TRUCON code that is represented in container SWD12275 under shipping category 3003400041. Table 1 lists the prescribed layers of confinement and closure/filter attributes.

Table 1 - Layer of Confinement Descriptions TRUCON Code /

Shipping Category Layer of Confinement Description SR 225C /

3003400041 SWB with a 7.4E-6 mol/s/mf filter vent and liner bag. Note the actual filter vent installed on the SWB is an NF019D with a filter diffusivity of 1.85E-5 mol/s/mf.

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9 of 28 3.3 Significant Assumptions The modeling assumptions used to implement solution of the governing equations defined in Section 3.1 are as follows:

1. Per CH-TRAMPAC requirements, the payload containers were at steady-state conditions prior to placement and sealed within the HalfPACT at the generator site.

2. Gas transport ignores pressure-induced flow from barometric pressure or diurnal temperature changes (i.e., diffusion is the only transport mechanisms modeled).

3. Hydrogen resistance factors are taken from CH-TRU Payload Appendix 2.2 [Ref. 3].

4. Where indicated by the WDS Payload Data Report, the SWB filter resistance was based on the as-installed filter vent model rather than the CH-TRUCON specification [Ref. 1].

5. Layer of confinement void volumes are taken from the AltMeth 3-Volume model for the SWB, consistent with those utilized in WDS when calculating the FGGR under the measurement methodology.

3.4 Acceptance Criteria There is no explicit acceptance criteria for this calculation report. However, a flammable gas concentration less than 5% is below the NRC-accepted transportation limit to demonstrate a non-flammable mixture within the HalfPACT ICV.

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10 of 28 4.0 ANALYSIS 4.1 Model Input Parameters 4.1.1 Initial Conditions 4.1.1.1 SWB Flammable Gas Generation Rate Initial conditions for the concentration of flammable gas within the SWB when loaded and vented at the generator site is zero. The simulation is conducted under ambient conditions of 1 atm pressure and 77 qF (298.15 K) utilizing an ideal gas constant R = 0.08206 (atm L)/(mol K).

4.1.1.2 Flammable Gas Concentrations Over Time in Sealed HalfPACT ICV Initial conditions for the concentration of flammable gas within the HalfPACT ICV when sealed at the generator site is zero, with the SWB and associated layers of confinement at steady-state with respect to the given hydrogen gas generation rate. The simulation is conducted under ambient conditions of 1 atm pressure and 77 qF (298.15 K) utilizing an ideal gas constant R = 0.08206 (atm L)/(mol K).

4.1.2 Input Parameters Hydrogen-based diffusion resistance factors for various filter specifications and layers of confinement types are provided in CH-TRU Payload Appendix 2.2 [Ref. 3]. The relevant hydrogen resistance factors employed herein are summarized in Table 2.

Table 2 - Resistance Factors Resistance Factor Layer Description 412 1.85E-5 mol/s/mf SWB filter with 5.79E-6 SWB gasket release acting in parallel 541 1.85E-5 mol/s/mf SWB filter 1257 Fold-and-Tape SWB liner bag

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11 of 28 The HalfPACT void volume is taken from the HalfPACT maximum normal operating pressure (MNOP) evaluation from Section 3.4.4 of the HalfPACT Safety Analysis Report [Ref. 3]. Void volumes for the SWB and layers of confinement from the AltMeth 3-Volume model are summarized as follows:

x HalfPACT = 1496 L x SWB = 187.7 L x Bag Layer (IL) = 2.0 L The headspace gas vent-to-sample duration was 69 days with a measured hydrogen plus methane headspace concentration of 15.06 ppm [Ref. 2].

The authorized shipping duration based on the shipping category is 60 days with the package conservatively schedule for venting at 59 days [Ref. 3].

4.2 Analysis and Results The input parameters calculated in Section 4.1 were configured as text input decks for use by the Python 3.7 script provided in Appendix A.2, which were executed on a Windows 10 workstation (S028540) to solve the governing equations defined in Section 3.1 for two configurations: a)

SWB exposed to ambient conditions over the prescribed vent-to-sample duration to determine the flammable gas generation rate (FGGR) that achieves the 15.06 ppm measured headspace concentration at 69 days and b) SWB sealed within the HalfPACT over the 59-day shipping duration and then a calculated number of days until the SWB innermost confinement layer reaches the LFL of 5%. The input decks and associated output files are provided in Appendix A.1 for each analysis case. Section 2.0 summarizes the results of the calculations.

4.3 Summary and Conclusions The flammable gas generation rate within the SWB is determined to be 3.6553e-10 mol/sec and limited to a concentration of 0.009% when the SWB is fully sealed within the HalfPACT ICV at the end of the authorized shipping duration. The SWB could be fully sealed within the ICV for 110,480 days from the data of initial ICV closure on August 23, 2022 with the flammable gas concentrations safely remaining less than or equal to the LFL of 5%.

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5.0 REFERENCES

1. Waste Data System, Waste Isolation Pilot Plant Payload Data Report for Payload Number SRE033, Report Version 3.1, generated on October 3, 2022.

2. Waste Data System, Waste Isolation Pilot Plant Container Data Report for Container Number SWD12275, Report Version 3.1, generated on October 3, 2022.

3. U.S. Department of Energy, Carlsbad Field Office, HalfPACT Certificate of Compliance, NRC Docket 71-9279, Rev 10, June 2022.

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13 of 28 APPENDIX A A.1 Computer Run Listing A.1.1 SWB Flammable Gas Generation Rate Input File: SWD12275.i SWD12275 AltMeth Check 69 day sample T1,T2,R,P,nday,lconc,ltest,start,end 294.0,294.0,0.08206,1.0,69.0,0.001506,1,1,1 node,parent,descr,vvol,lqty,rfac,rqty,cg 1,0,SWB,187.7,1,412.0,1,0.0000E+00 2,1,IL,2.0,1,1257.0,1,1.0E-8 Output File: SWD12275.o COBRA2.1 for Python - executed @ 2022-10-05 10:57:54.346112

Title:

SWD12275 AltMeth Check 69 day sample Initial Conditions - zero concentrations with outermost layer present (1)

Transient Duration: 69 days to reach0.001506% in layer 1 with cg scaled by 0.0365534 Input Summary ----------------------

node parent layer description vvol lqty rfac rqty cg 1 0 1 SWB 188 1 412 1 0 2 1 2 IL 2 1 1.26e+03 1 3.6553e-10 Results Summary ----------------------

node description xci xc xz pss 1 SWB 0.000 0.002 0.002 1e+02 2 IL 0.000 0.006 0.006 1e+02 Run completed (elapsed time): 0:00:00.891480 Network Map:

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14 of 28 Transient Plot:

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15 of 28 A.1.2 Flammable Gas Concentrations Over Time in Sealed HalfPACT ICV Input File: SRE033.i Phase 1 SRE033 shipping duration T1,T2,R,P,nday,lconc,ltest,start,end 294.0,294.0,0.08206,1.0,59.0,5.0,3,0,0 node,parent,descr,vvol,lqty,rfac,rqty,cg 1,0,HalfPACT,1496.0,1,0.0,1,0.0000E+00 2,1,SWB,187.7,1,541.0,1,0.0000E+00 3,2,IL,2.0,1,1257.0,1,3.6553e-10 Phase 2 SRE033 allowable sealed days T1,T2,R,P,nday,lconc,ltest,start,end 294.0,294.0,0.08206,1.0,0.0,5.0,3,0,0 node,parent,descr,vvol,lqty,rfac,rqty,cg 1,0,HalfPACT,1496.0,1,0.0,1,0.0000E+00 2,1,SWB,187.7,1,541.0,1,0.0000E+00 3,2,IL,2.0,1,1257.0,1,3.6553e-10 Output File: SRE033.o Code: COBRA2.1 for Python - executed @ 2022-10-05 10:57:56.199777

Title:

SRE033 shipping duration Initial Conditions - steady-state concentrations with outermost layer not present (0)

Transient Duration: 59 days Input Summary ----------------------

node parent layer description vvol lqty rfac rqty cg 1 0 1 HalfPACT 1.5e+03 1 0 1 0 2 1 2 SWB 188 1 541 1 0 3 2 3 IL 2 1 1.26e+03 1 3.6553e-10 Results Summary ----------------------

node description xci xc xz pss 1 HalfPACT 0.000 0.000 0.003 0 2 SWB 0.000 0.002 0.004 2.2e+02 3 IL 0.000 0.007 0.009 1.4e+02

Title:

SRE033 allowable sealed days Initial Conditions - as prescribed with outermost layer present (2)

Transient Duration: 110421 days to increase above 5% in layer 3 Input Summary ----------------------

node parent layer description vvol lqty rfac rqty cg 1 0 1 HalfPACT 1.5e+03 1 0 1 0 2 1 2 SWB 188 1 541 1 0 3 2 3 IL 2 1 1.26e+03 1 3.6553e-10 Results Summary ----------------------

node description xci xc xz pss 1 HalfPACT 0.003 0.000 4.994 0 2 SWB 0.004 0.002 4.995 2.5e+05 3 IL 0.009 0.007 5.000 7.6e+04 Run completed (elapsed time): 0:00:13.857362

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16 of 28 Network Map:

Transient Plot:

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17 of 28 A.2 Python Script Listing

""" cobra2.1.py - Python Implementation of AltMeth Coded by: Brad Day, Nuclear Waste Partnership Date: 9/14/2016 Last: 11/12/2019 - conversion from Python 2.7 to Python 3.7; add integration controls

Description:

Command Line: python cobra2.1.py -i inputfile -o outputfile -p plotflag -l legendloc

[optional: -m mxstep -r rtol -a atol -n tmin -x tmax]

Model of diffusion gas transport across a network of layers of confinement calculates the time to achieve a defined gas concentration in a specified layer of confinement for a given set of layers and gas generation rates, or calculates the gas generation rates required to achieve a specified gas concentration for a given set of layers and time, or simply determines the gas concentrations resulting from a given set of layers, gas generation rates, and time; initial conditions can be specified as start at zero concentration with all layers present (start = 1) or start at steady state concentration with outermost layer not present (start = 0), or start at a given concentration with all layers present (start = 2)

This program is written in Python and utilizes SciPy subroutine for mathematical applications. The SciPy subroutine solves a series of first-order ordinary differential equations.

Expanded to write output to word document.

Revised to read in initial concentrations when start flag = 2 Revised to read input file that has multiple concentration buildup phases and aggregate concentration history from results of prior phases, feeding the starting concentrations of previous into subsequent phases.

Also added ability to specify lconc as a percentage of the steady state value.

Adjusted print operations to properly deal with 2-phase buildup to stop conditions Added options to specify integration controls from command line import argparse import datetime import os import sys import numpy as np import scipy.optimize from scipy import integrate import networkx as nx import matplotlib.pyplot as plt from docx import Document from docx.shared import Inches def fss(x, node, parent, layer, cggr, rcon, nnum):

Define steady-state system of equations for mass flow via diffusion

Variables:

- fin = mass flow into node

- fout = mass flow out of node

- fx = equation for total mass flow in/out of a node, including internal generation fin = np.zeros(nnum) fout = np.zeros(nnum) fx = np.zeros(nnum)

Calculate inflow for i in range(0,nnum):

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18 of 28 for j in range(0,nnum):

if layer[i] != np.amax(layer):

if parent[j]== node[i]:

fin[i] = fin[i] + rcon[j]*(x[j]-x[i])

if layer[i]== np.amax(layer):

fin[i] = 0.

Calculate outflow for i in range(0,nnum):

for j in range(0,nnum):

if layer[i] != np.amin(layer):

if parent[i]== node[j]:

fout[i] = rcon[i]*(x[i]-x[j])

if layer[i]== np.amin(layer):

fout[i] = rcon[i]*(x[i])

Generate mass balance sums fx = cggr + fin - fout return fx def xprime(x, t, xp, node, parent, vvol, layer, cggr, rcon, nnum):

Define transient system of equations for mass flow via diffusion

Variables:

- fin = mass fraction flow into node

- fout = mass fraction flow out of node

- fx = equation for total mass fraction flow in/out of a node, including internal generation fin = np.zeros(nnum) fout = np.zeros(nnum)

Calculate inflow for i in range(0,nnum):

for j in range(0,nnum):

if layer[i] != np.amax(layer):

if parent[j]== node[i]:

fin[i] = fin[i] + rcon[j]*(x[j]-x[i])/vvol[i]

if layer[i]== np.amax(layer):

fin[i] = 0.

Calculate outflow for i in range(0,nnum):

for j in range(0,nnum):

if layer[i] != np.amin(layer):

if parent[i]== node[j]:

fout[i] = rcon[i]*(x[i]-x[j])/vvol[i]

if layer[i]== np.amin(layer):

fout[i] = rcon[i]*(x[i])/vvol[i]

Generate mass balance sums xp = cggr/vvol + fin - fout return xp def calcss(start, vvol, node, parent, layer, cggr, rcon, nnum):

Determine steady-state results based on start condition (0 = outermost layer not present,

1 or 2 = outermost layer present) and set initial conditions for transient calculations based

on start condition (0 - SS ICs in all but outermost layer, 1 = zero ICs for all layers, 2 =

as prescribed)

Variables:

- tmp* = temporary variables to hold outermost layer when removed from steady-state evaluation if start== 0:

xinit = np.zeros(nnum) xc = np.zeros(nnum) tmprcon = rcon[0]

tmpvvol = vvol[0]

rcon[0] = 1.e12 vvol[0] = 1.e12

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19 of 28 olstatus = "Initial Conditions - steady-state concentrations with outermost layer not present (0)"

xc = 100.*scipy.optimize.fsolve(fss, xinit, args=(node, parent, layer, cggr, rcon, nnum))

rcon[0] = tmprcon vvol[0] = tmpvvol xinit = xc/100.

else:

xinit = np.zeros(nnum) xc = np.zeros(nnum) if start== 1:

olstatus = "Initial Conditions - zero concentrations with outermost layer present (1)"

else:

olstatus = "Initial Conditions - as prescribed with outermost layer present (2)"

xc = 100.*scipy.optimize.fsolve(fss, xinit, args=(node, parent, layer, cggr, rcon, nnum))

return xc, olstatus, xinit def readin(ifname):

Read input from data file specified by the command line

Variables:

- fi = input file handle

- title = user-defined title of evaluation

- si* = temporary variables to facilitate input file reads

- T1 = temperature for gas generation rates(K)

- T2 = temperature for release rates (K)

- R = gas constant (L atm / mol K)

- P = pressure (atm)

- nday = number of days requested for transient evaluation (0. = run until lconc/ltest satisfied)

- lconc = concentration (%) to use as stop condition for transient run

- ltest = layer (#) to evaluate the concentration test against

- start = flag to indicate transient initial condition type (0 = start at steady-state for all internal

layers, outermost layer ignored; 1 = start at zero for all layers, outermost layer present)

- end = flag to indicate whether gas generation rates should be scaled to achieve the specified lconc

and ltest conditions (0 = no scale, 1 = scale)

- data = temporary variable to red input lines

- node = list of node numbers (i = 0, nnum-1)

- parent = list of parent node numbers associated with each node (i = 0, nnum-1)

- layer = list of layers numbers counting from outside in (1 = outermost, 2 = next outermost,

...)

- descr = string describing node characteristics, layers of confinement, etc. (i = 0, nnum-1)

- vvol = void volume for node (i = 0, nnum-1)

- lqty = number of duplicate layers of confinement represented by the node (i = 0, nnum-1)

- rfac = resistance factor for node, see CH-TRU Payload Appendix 2.2 (i = 0, nnum-1)

- rqty = quantity of rfac applied to node, e.g., number of filters/punctures (i = 0, nnum-1)

- cg = gas generation rate within each node (mol/sec) (i = 0, nnum-1)

- xci = initial concentration within each node (%) (i = 0, nnum-1)

- lconctmp - temporary variable to determine if condition is entered as % of SS value

- percss - flag to specify how lconc is to be interpreted (0 = as concentration, 1 = as % of SS) fi = open(ifname, "r")

title = fi.readline().rstrip('\\n')

si1 = fi.readline().strip().split(',')

si2 = fi.readline().strip().split(',')

T1 = float(si2[0])

T2 = float(si2[1])

R = float(si2[2])

P = float(si2[3])

nday = float(si2[4])

lconctmp = str(si2[5])

if lconctmp[-1]== "%":

lconc = float(lconctmp[:-1]) / 100.

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20 of 28 percss = 1 else:

lconc = float(si2[5])

percss = 0 ltest = int(si2[6])

start = int(si2[7])

end = int(si2[8])

data = np.loadtxt(ifname, dtype='str', delimiter=",", comments="#", skiprows=4) node = np.array(data[:,0], dtype='int')

parent = np.array(data[:,1], dtype='int')

descr = np.array(data[:,2], dtype='str')

vvol = np.array(data[:,3], dtype='float')

lqty = np.array(data[:,4], dtype='int')

rfac = np.array(data[:,5], dtype='float')

rqty = np.array(data[:,6], dtype='int')

cg = np.array(data[:,7], dtype='float')

if start== 2:

xci = np.array(data[:,8], dtype='float')

else:

xci = np.zeros(len(node))

fi.close()

return title, T1, T2, R, P, nday, lconc, ltest, start, end, node, parent, descr, vvol, lqty,

\\

rfac, rqty, cg, xci, percss def findpar(nask, nnum, node, parent):

Lookup the parent associated with a specified node

Variables:

- nask = node given for search

- parans = associated parent node given as answer for i in range(0,nnum):

if node[i]== nask:

parans = parent[i]

return parans def netmap(nnum, parent, node, npar, ofname, plotflag):

Create network adjacency list, read as graph, and plot

Variables:

- hds, hdf, G = variables to store hierarchical association of nodes and parents in graph form hds = []

for i in range(0,nnum):

tmp = []

k = 0 for j in range(0,nnum):

if parent[j]== node[i]:

if k== 0:

tmp.append(parent[j])

tmp.append(node[j])

k = k + 1 else:

tmp.append(node[j])

hds.append(tmp) hdf = [e for e in hds if e]

if plotflag== 'True' or plotflag== 'T' or plotflag== '1':

ft = open(".tmphdf", "w")

for i in range (0,npar):

ft.write(str(hdf[i])[1:-1].replace(',', ) + '\\n')

ft.close()

fh = open(".tmphdf", 'rb')

G = nx.read_adjlist(fh,create_using=nx.DiGraph())

fh.close()

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21 of 28 os.remove(".tmphdf")

nodechart = nx.nx_agraph.to_agraph(G) nodechart.layout('dot')

nodechart.draw(ofname + ".png")

return def phasefileprep(ifname):

Write temporary input files if input file contains more than one phase

Variables:

- phasenum = counter for number of phases contained in primary input file

- phaseflag = flag to indicate whether multiple phases are required (0 = no, 1 = yes) phaseflag = 0 phasenum = 0 fi = open(ifname, 'r')

line = fi.readline()

if line[:5]== "Phase":

phaseflag = 1 phasenum = phasenum + 1 fo = open("." + ifname + "_phase" + str(phasenum), "w")

while line:

line = fi.readline()

if line[:5]== "Phase":

fo.close()

phasenum = phasenum + 1 fo = open("." + ifname + "_phase" + str(phasenum), "w")

else:

fo.write(line) if phaseflag== 1: fo.close()

fi.close()

return phasenum, phaseflag def main():

Calculate steady-state concentrations and transient buildup

Variables:

- args = list of arguments passed from command line input

- ifname = input file name

- ofname = output file name

- plotflag = flat to indicate desire to plot nodal connectivity and transient buildup

(T/1 = true, F/0 = false)

- nnum = count of number of nodes

- npar = count of number of unique parents

- conv = conversion constant from mol/sec to L/day

- rcon = flow conductance (L/day) (i = 0, nnum-1)

- cggr = gas generation rate within each node (L/day) (i = 0, nnum-1)

- xinit = initial concentrations (%) for each node (i = 0, nnum-1)

- xc = final steady-state concentrations (%) for each node (%) (i = 0, nnum-1)

- olstatus = string to summarize start condition flag application to steady-state evaluation

- tinit = start time (day), 0

- ndayf = final day for evaluation, set to 1. if nday is 0. and then incremented until condition met

- tend = final time (day)

- time = array defining time with output increment = nday + 1

- xp = derivative of xz transient concentrations (%) with respect to time for each node (i =

0, nnum-1)

- xz = transient concentrations (%) at each node (i = 0, nnum-1; time)

- pss = percent of steady-state reached by xz at the final time (%)

- ltmp*, lmax* = temporary variables to determine maximum concentration reached at the end of time

for the layer being tracked

- endf = flag to indicate end of incrementing days

- lnum = array index associated with the ltest condition

- now = current date and time at start of run

- now2 = current date and time and end of run

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- lconctst = layer concentration test

- timehistory - concatenation of time history

- conchistory - concatenation of concentration history

- plottitle - plot title

- plotsubtitle - plot subtitle

- mxstep - maximum number of integration steps for solver

- atol - absolute integration error tolerance for solver

- rtol - relative integration error tolerance for solver

- tmin - minimum absolute time step for solver

- tmax - maximum absolute time step for solver

Get date and time now = datetime.datetime.now()

Read command line arguments parser = argparse.ArgumentParser(description='cobra2.1 for python')

parser.add_argument('-i','--input', help='Input file name', required=True) parser.add_argument('-o','--output',help='Output file name', required=True) parser.add_argument('-p','--plotting',help='Plotting flag', required=True) parser.add_argument('-l','--legend',help='Legend location', required=False) parser.add_argument('-m','--mxstep',help='Maximum number of integration steps',

required=False) parser.add_argument('-r','--rtol',help='Relative integration error tolerance',

required=False) parser.add_argument('-a','--atol',help='Absolute integration error tolerance',

required=False) parser.add_argument('-n','--tmin',help='Min absolute time step', required=False) parser.add_argument('-x','--tmax',help='Max absolute time step', required=False) args = parser.parse_args()

ifname = args.input ofname = args.output plotflag = args.plotting if args.legend== None:

legendloc = 0 else:

legendloc = int(args.legend) mxstep = args.mxstep rtol = args.rtol atol = args.atol tmin = args.tmin tmax = args.tmax

Set integration options based on command line inputs if mxstep== None:

mxstep = 0 else:

mxstep = int(mxstep) if rtol== None:

rtol = 1.49012e-8 else:

rtol = float(rtol) if atol== None:

atol = 1.49012e-8 else:

atol = float(atol) if tmin== None:

tmin = 0 else:

tmin = float(tmin) if tmax== None:

tmax = 0 else:

tmax = float(tmin)

Open files for writing results fo = open(ofname, "w")

dfi = open(ifname, "r")

dfo = open(ofname, "r")

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23 of 28

Read data file to determine phase type phasenum, phaseflag = phasefileprep(ifname)

Loop over the number of concentration buildup phases if phaseflag== 0:

phasenum = 1 for phases in range(0, phasenum):

Read input from data file if phaseflag== 1:

ifpname = "." + ifname + "_phase" + str(phases+1) title, T1, T2, R, P, nday, lconc, ltest, start, end, node, parent, descr, vvol, lqty,

\\

rfac, rqty, cg, xci, percss = readin(ifpname) else:

title, T1, T2, R, P, nday, lconc, ltest, start, end, node, parent, descr, vvol, lqty,

\\

rfac, rqty, cg, xci, percss = readin(ifname)

Determine number of nodes and unique parents nnum = len(node) npar = len(np.unique(parent))-1

Determine layer level of each node tmplayer = np.zeros(nnum) for i in range(0,nnum):

nask = node[i]

while True:

parans = findpar(nask, nnum, node, parent) if parans== 0:

break nask = parans tmplayer[i] = tmplayer[i] + 1 layer = tmplayer + 1

Determine index of lconc test layer and save original lconc as lconctst lconctst = lconc for i in range(0,nnum):

if layer[i]== ltest:

lnum = i

Conversion for gas generation rates from mol/s to L/day at T1 conv1 = R

T1

86400 / P

Conversion for release rates from mol/s to L/day at T2 conv2 = R

T2

86400 / P

Convert resistance factors to conductance in L/day at T2 rcon = np.zeros(nnum) for i in range(0,nnum):

if rfac[i]== 0.:

rcon[i] = 0.

else:

rcon[i] = ((1./(lqty[i]*rfac[i]*100.))*rqty[i])*conv2

Loop to scale gas generation rates to meet end condition (0 = no scale, 1 = scale) endf = 0 while True:

Convert gas generation rate from mol/sec to L/day at T1 cggr = cg*conv1

Calculate steady-state conditions xc, olstatus, xinit = calcss(start, vvol, node, parent, layer, cggr, rcon, nnum)

Calculation Continuation Sheet

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2. System Number:

Flammable Gas Concentration Evaluation for HalfPACT Payload SRE033 PT00

3. Document Number:

4. Document Revision:

5. Page:

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24 of 28

Initialize time variables tinit = 0.

if nday== 0.:

ndayf = 1.

else:

ndayf = nday tend = ndayf

Overwrite initial conditions if conditions are specified in input file (start = 2) or

analysis phases dictate using previous run final transient conditions as initial conditions;

set initial conditions for printing equal to those set in SS calculation (start = 0) if start== 2 and phaseflag== 0 and phases== 0:

xinit = xci/100.

if start== 0 and phaseflag== 0 and phases== 0:

xci = xinit*100.

if phaseflag== 1 and phases > 0:

start== 2 olstatus = "Initial Conditions - as prescribed with outermost layer present (2)"

xci = np.zeros(nnum) for i in range(0, nnum):

xci[i] = xz[nfinal,i]

xinit = xci/100.

Integrate system of equations to get transient concentrations while True:

time = np.linspace(tinit, tend, int(ndayf + 1))

xp = np.zeros(nnum) xz = integrate.odeint(xprime, xinit, time, \\

args=(xp, node, parent, vvol, layer, cggr, rcon, nnum), \\

mxstep = mxstep, rtol = rtol, atol = atol, hmin = tmin, hmax = tmax) xz = 100.*xz

Calculate lconc as percent of SS in specified layer and determine concentration slope if ndayf <= 1. or nday != 0.:

if ltest== 0:

concslope = xz[int(ndayf),0] - xz[int(ndayf)-1,0]

else:

concslope = xz[int(ndayf),lnum] - xz[int(ndayf)-1,lnum]

if concslope > 0. and endf== 0 and percss== 1:

lconc = xc[lnum]*lconctst if concslope < 0. and endf== 0 and percss== 1:

lconc = xc[lnum]/lconctst

Determine if concentration in specified layer and end of the analysis reaches the defined

value,

if it can or has reached the specified stop conditions if nday== 0. and end== 0:

if concslope > 0.:

if xz[int(ndayf),lnum] >= lconc:

print("Concentrations increased to stop concentration")

break if xc[lnum] < 0.999*lconc and start== 1:

print("Error: Steady-state concentration > stop concentration")

break if xz[int(ndayf),lnum] > 1.001*xc[lnum] and start== 1:

print("Error: Transient concentration > steady-state concentration")

break if concslope < 0.:

if xz[int(ndayf),lnum] <= lconc:

print("Concentrations decreased to stop concentration")

break if xc[lnum] > 1.001*lconc and start== 1:

print("Error: Steady-state concentration < stop concentration")

break if xz[int(ndayf),lnum] < 0.999*xc[lnum] and start== 1:

print("Error: Transient concentration < steady-state concentration")

break

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2. System Number:

Flammable Gas Concentration Evaluation for HalfPACT Payload SRE033 PT00

3. Document Number:

4. Document Revision:

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25 of 28 if ndayf== nday:

print("Transient duration stop condition reached")

break ndayf = ndayf + 100.

tend = ndayf if nday== 0. and end== 1:

print("Error: Scaling cgs requires defined transient duration (nday <> 0)")

break if nday != 0.:

break print("Days computed...", ndayf)

Determine time at which solution meets the stop condition if nday== 0.:

for i in range(0, int(ndayf)):

if concslope > 0. and xz[i, lnum] > lconc:

nfinal = i break elif concslope < 0. and xz[i, lnum] < lconc:

nfinal = i break else:

nfinal = int(ndayf) else:

nfinal = int(ndayf) print("Days to satisfy stop condition = ", nfinal)

Calculate transient end concentration as a percent of steady-state (based on direction approached) if start== 0:

pss = np.zeros(nnum) for i in range(1,nnum):

if concslope > 0:

pss[i] = (xz[nfinal,i]/xc[i])*100.

elif concslope < 0:

pss[i] = (xc[i]/xz[nfinal,i])*100.

else:

if concslope >= 0:

pss = (xz[nfinal]/xc)*100.

if concslope < 0:

pss = (xc/xz[nfinal])*100.

Scale gas generation rates as required if nday== 0. or endf != 0:

break if nday != 0. and end== 0:

break if nday != 0. and end== 1:

lscale = lconc/xz[int(nfinal),lnum]

cg = cg

lscale endf = endf + 1 print("Scaling gas generation rates to meet conditions...")

Write results to output file if phases > 0:

fo.write('\\n' + '\\n')

else:

fo.write("Code: COBRA2.1 for Python - executed @ " + str(now) + '\\n' + '\\n')

fo.write("Title: " + title + '\\n' + '\\n')

fo.write(olstatus + '\\n' + '\\n')

print("nday = ", nday) print("start = ", start) print("ltest = ", ltest) print("lconc = ", lconc) if ltest== 0:

print("ltrans = ", xz[int(nfinal),0])

print("lsteady = ", xc[0])

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2. System Number:

Flammable Gas Concentration Evaluation for HalfPACT Payload SRE033 PT00

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26 of 28 else:

print("ltrans = ", xz[int(nfinal),lnum])

print("lsteady = ", xc[lnum])

print("nfinal = ", nfinal) print("end = ", end) if nday== 0 and concslope > 0 and xz[nfinal,lnum] > lconc and end== 0:

stopsummary = "Transient Duration: " + '%-7.0f'%nfinal + " days" + " to increase above" + '%8.4g'%lconc + \\

"% in layer " + '%-4i'%ltest if nday== 0 and concslope < 0 and xz[nfinal,lnum] < lconc and end== 0:

stopsummary = "Transient Duration: " + '%-7.0f'%nfinal + " days" + " to decrease below" + '%8.4g'%lconc + \\

"% in layer " + '%-4i'%ltest if nday== 0 and concslope > 0 and xc[lnum] < lconc and start== 1 and end== 0:

stopsummary = "Transient Duration: " + '%-7.0f'%nfinal + " days" + " analyzed, can't reach" + \\

'%8.4g'%lconc + "% in layer " + '%-4i'%ltest if nday== 0 and concslope < 0 and xc[lnum] > lconc and start== 1 and end== 0:

stopsummary = "Transient Duration: " + '%-7.0f'%nfinal + " days" + " analyzed, can't reach" + \\

'%8.4g'%lconc + "% in layer " + '%-4i'%ltest if ndayf== nday and end== 0:

stopsummary = "Transient Duration: " + '%-7.0f'%nfinal + " days" if ndayf== nday and end != 0:

stopsummary = "Transient Duration: " + '%-7.0f'%nfinal + " days" + " to reach" +

'%8.4g'%lconc + \\

"% in layer " + '%-4i'%ltest + "with cg scaled by " + '%12.6g'%lscale if nday== 0 and xz[nfinal,lnum] > xc[lnum] and start== 1 and end != 0:

stopsummary = "Transient Duration: " + '%-7.0f'%nfinal + " days" + " to reach" +

'%8.4g'%lconc + \\

"% in layer " + '%-4i'%ltest if nday== 0 and end== 1:

stopsummary = "Transient Duration: " + '%-7.0f'%nfinal + " days analyzed - must specify transient" + \\

" duration, nday <> 0" stopsum = " ".join(stopsummary.split())

fo.write(stopsum + '\\n' + '\\n')

fo.write("Input Summary ----------------------" + '\\n')

fo.write("node parent layer description vvol lqty rfac" + \\

" rqty cg" + '\\n')

for i in range(0, nnum):

fo.write('%4i'%node[i] + " " + '%4i'%parent[i] + " " + '%4i'%layer[i] + " " + \\

'%-24s'%descr[i] + " " + '%9.3g'%vvol[i] + " " + '%4i'%lqty[i] + " " +

'%9.3g'%rfac[i] + \\

" " + '%4i'%rqty[i] + " " + '%12.5g'%cg[i] + " " + '\\n')

fo.write('\\n' + '\\n')

fo.write("Results Summary ----------------------" + '\\n')

fo.write("node description xci xc xz pss" + '\\n')

for i in range(0, nnum):

fo.write('%4i'%node[i] + " " + '%-24s'%descr[i] + " " + '%7.3f'%xci[i] + " " + \\

'%7.3f'%xc[i] + " " + '%7.3f'%xz[nfinal,i] + " " + '%7.2g'%pss[i] + '\\n')

Concatenate time and concentration histories for plotting if phases== 0:

timehistory = time[:nfinal+1]

conchistory = np.zeros((nfinal+1,nnum))

for i in range(0,nnum):

for j in range(0,nfinal+1):

conchistory[j,i] = xz[j,i]

plottitle = title if phaseflag== 1:

plotsubtitle = "Phase " + str(phases+1) + " - " + stopsum else:

plotsubtitle = stopsum if phases > 0:

time = time[:nfinal] + float(len(timehistory))

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27 of 28 timehistory = np.hstack([timehistory,time])

conchistorytmp = np.zeros((nfinal,nnum))

for i in range(0,nnum):

for j in range(1,nfinal+1):

conchistorytmp[j-1,i] = xz[j,i]

conchistory = np.vstack([conchistory,conchistorytmp])

plottitle = plottitle + "\\n" + title plotsubtitle = plotsubtitle + "\\n" + "Phase " + str(phases+1) + " - " + stopsum

Create and plot network map (last phase, as applicable) netmap(nnum, parent, node, npar, ofname, plotflag)

Plot transient results to png files lloc = ('best', 'upper right', 'upper left', 'lower left', 'lower right', 'right', \\

'center left', 'center right', 'lower center', 'upper center', 'center')

plt.clf()

if plotflag== 'True' or plotflag== 'T' or plotflag== '1':

fig, ax = plt.subplots()

colormap = plt.cm.rainbow plt.gca().set_prop_cycle('color', [colormap(i) for i in np.linspace(0, 0.9, nnum)])

for i in range(nnum-1, -1, -1):

plt.plot(timehistory, conchistory[:,i], label=str(node[i]) + " - " + descr[i])

if phases== 0:

fig.suptitle(plottitle, fontsize=14, fontweight='bold')

fig.subplots_adjust(top=0.85) else:

fig.suptitle(plottitle, fontsize=10, fontweight='bold')

fig.subplots_adjust(top=0.85-0.05*float(phases))

ax.set_title(plotsubtitle, fontsize=8) ax.set_xlabel('Time (days)')

ax.set_ylabel('H2 Concentration (%)')

plt.grid(True, linestyle='dotted')

art = []

if nnum < 12:

legend = plt.legend(title = "Node", loc=lloc[legendloc], labelspacing=0.1) else:

legend = plt.legend(title = "Node", loc='center', labelspacing=0.1, bbox_to_anchor=(0.5, -0.5), ncol=4) for label in legend.get_texts():

label.set_fontsize('x-small')

if nnum >= 12:

art.append(legend) plt.savefig(ofname + "_trans" + ".png", dpi=600, additional_artists=art, bbox_inches="tight")

else:

plt.savefig(ofname + "_trans" + ".png", dpi=600)

Get date and time and write elapsed and close output file now2 = datetime.datetime.now()

fo.write('\\n' + "Run completed (elapsed time): " + '%12s'%(now2-now) + '\\n')

fo.close()

Write data to a word document, including figures document = Document()

if phaseflag== 1:

document.add_heading(plottitle, level=0) else:

document.add_heading(title, level=0) intxt = dfi.read()

document.add_heading(str("Input File: " + ifname), level=1) pinput = document.add_paragraph(intxt, style="Code")

outxt = dfo.read()

document.add_heading(str("Output File: " + ofname), level=1) poutput = document.add_paragraph(outxt, style="Code")

document.add_heading("Network Map:", level=1) document.add_picture(str(ofname + ".png"), height=Inches(2.00))

document.add_heading("Transient Plot:", level=1) document.add_picture(str(ofname + "_trans.png"), width=Inches(6.00))

Calculation Continuation Sheet

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2. System Number:

Flammable Gas Concentration Evaluation for HalfPACT Payload SRE033 PT00

3. Document Number:

4. Document Revision:

5. Page:

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28 of 28 document.save(str(ofname + ".docx"))

Close remaining files, delete any temp files, and finish up dfi.close()

fo.close()

if phases > 0:

for i in range(0,phasenum):

os.remove("." + ifname + "_phase" + str(i+1))

if __name__== '__main__':

main()

Calculation Cover Sheet

1. Document

Title:

Loaded HalfPACT ICV Lifting Evaluation

2. Document Number:

HPT-CAL-0001

3. Document Revision:

0

4. Page:

1 of 13

5. Summary Description This calculation evaluates a loaded HalfPACT inner containment vessel (ICV) to the requirements of 49 CFR §173.410(b), as specified in Section 3.1.4 of SDD PT00, to determine the maximum allowable lifting load for a one-time shipment supporting ICV 506. These requirements are consistent with the lifting requirements specified in 10 CFR §71.45(a).

6. Software Usage Software Name Version

1. ANSYS 2022 R2.03

2.

3.

4.

5.

7. Preparer Name Signature Date Steve Porter

8. Independent Reviewer(s)

Name Signature Date Kyle Moyant

9. Project Representative Name Signature Date Scott Burns

10. QA Representative Name Signature Date Steve Tanner Digitally signed by STEVEN PORTER (Affiliate)

Date: 2023.02.14 15:18:26 -08'00' KYLE MOYANT (Affiliate)

Digitally signed by KYLE MOYANT (Affiliate)

Date: 2023.02.14 16:34:14 -07'00' Digitally signed by ROBERT BURNS (Affiliate)

Date: 2023.02.14 16:39:35 -07'00' David S. Tanner Digitally signed by David S. Tanner Date: 2023.02.15 06:10:27 -07'00'

Calculation Continuation Sheet

1. Document

Title:

Loaded HalfPACT ICV Lifting Evaluation

2. Document Number:

HPT-CAL-0001

3. Document Revision:

0

4. Page:

2 of 13 TABLE OF CONTENTS

1.0 INTRODUCTION

................................................................................................................... 4 2.0 DESIGN DESCRIPTION...................................................................................................... 4 3.0 ALLOWABLE STRESSES................................................................................................... 6 3.1 Material Properties................................................................................................................. 6 3.2 Design Criteria....................................................................................................................... 6 4.0 STRUCTURAL EVALUATION........................................................................................... 7 4.1 Loads...................................................................................................................................... 7 4.2 Evaluations............................................................................................................................. 7 4.2.1 ICV Lift Pocket Region Evaluation................................................................................. 7 4.2.2 ICV Lift Pin Evaluation................................................................................................. 11 4.2.3 ICV Lift Overload Evaluation....................................................................................... 13 5.0

SUMMARY

........................................................................................................................... 13 LIST OF TABLES Table 1 - Material Properties for Structural Components...............................................................6 LIST OF FIGURES Figure 1 - HalfPACT ICV Section View........................................................................................5 Figure 2 - HalfPACT ICV Lid Lift Pocket Detail (Upper Honeycomb Spacer Removed for Clarity)...............................................................................................................................5 Figure 3 - Overall ICV Structural Model........................................................................................8 Figure 4 - ICV Lift Pocket Detail....................................................................................................9 Figure 5 - Lift Pin Reaction Force for an Empty ICV Lift...........................................................10 Figure 6 - Equivalent Stress in the Lift Pocket Region for an Empty ICV...................................10 Figure 7 - Equivalent Stress in the Lift Pocket Region for a Loaded ICV...................................11 Figure 8 - ICV Lift Pin Model......................................................................................................12 Figure 9 - ICV Lift Pin Equivalent Stress Results........................................................................12 Figure 10 - ICV Lift Pin Linearized Equivalent Stress Results....................................................13

Calculation Continuation Sheet

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Title:

Loaded HalfPACT ICV Lifting Evaluation

2. Document Number:

HPT-CAL-0001

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3 of 13 TABLE OF REVISIONS Revision Number Pages Affected Revision Description 0

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Calculation Continuation Sheet

1. Document

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Loaded HalfPACT ICV Lifting Evaluation

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1.0 INTRODUCTION

As discussed in Section 2.5.1, Lifting, of the HalfPACT Safety Analysis Report,1 the three lift pockets in the HalfPACT inner containment vessel (ICV) lid are designed for lifting either the ICV lid or empty ICV assembly (i.e., lid and body with upper and lower aluminum honeycomb spacers installed).

The lift pockets and surrounding structural components are evaluated to determine the maximum allowable gross weight (i.e., ICV weight plus payload weight) while meeting the requirements of 49 CFR §173.410(b)2 for DOT Type A packages. These requirements are consistent with the lifting requirements specified in 10 CFR §71.45(a).3 2.0 DESIGN DESCRIPTION As depicted in Figure 1 and Figure 2, and in HalfPACT SAR drawing 707-SAR, the ICV lid lift pockets are comprised of a 4-inch, Schedule 80, pipe (4.500-inch outside diameter x 3.826-inch inside diameter; 4.163-inch mean diameter), a 1/4-inch thick x 41/2-inch outside diameter bottom plate, and a 3/8-inch thick x 8-inch outside diameter doubler plate. The lift pocket lift pin is a 7/8-inch diameter round bar with two, 1/8-inch wide x 0.470/0.460-inch diameter radial reliefs spaced 3.563 inches apart; the radial reliefs are designed to be the overload failure point rather than the containment boundary structure.

According to records, the empty weight of ICV 506 is 2,215 pounds.

1 U.S. Department of Energy (DOE), Safety Analysis Report for the HalfPACT Shipping Package, USNRC Certificate of Compliance 71-9279, U.S. Department of Energy, Carlsbad Field Office, Carlsbad, New Mexico.

2 Title 49, Code of Federal Regulations, Part 173 (49 CFR 173), Shippers - General Requirements for Shipments and Packagings, 10-01-20 Edition.

3 Title 10, Code of Federal Regulations, Part 71 (10 CFR 71), Packaging and Transportation of Radioactive Material, 10-01-20 Edition.

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5 of 13 Figure 1 - HalfPACT ICV Section View Figure 2 - HalfPACT ICV Lid Lift Pocket Detail (Upper Honeycomb Spacer Removed for Clarity)

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6 of 13 3.0 ALLOWABLE STRESSES 3.1 Material Properties The ICV is fabricated entirely of ASTM A240,4 ASTM A312,5 ASTM A376,6 or ASTM A479,7 Type 304, stainless steel plate, pipe, and bar stock. Material properties are correspondingly delineated in Table 1 as taken from Section 2.5 of the HalfPACT SAR.

Table 1 - Material Properties for Structural Components Material Poissons Ratio Elastic Modulus (psi)

Yield Strength (psi)

Ultimate Strength (psi)

Type 304 Stainless Steel 0.3 28,300,000 30,000 70,000 3.2 Design Criteria The ICV lift pockets are evaluated to the requirements of 49 CFR §173.410(b) for DOT Type A packages, and is consistent with the lifting requirements specified in 10 CFR §71.45(a).

Per Section 2-3 of ASME BTH-1,8 Service Class 0 applies for 1 to 20,000 load cycles over the life of a lifting device. Analyzing for fatigue is not required for a Service Class 0 lifting device and not deemed necessary here since ICV 506 will only be lifted once or twice to satisfy its safe return for disposition via the one-time shipment that is requested. Therefore, determination of the maximum load capacity of the ICV lifting components shall be based on combined membrane-plus-bending stresses that are limited to one-third of the materials yield strength, i.e., 30,000/3 =

10,000 psi.

Equivalent stress results are determined by combining stresses based on the distortion-energy (von Mises-Hencky) theory and compared to the allowable stress limit of 10,000 psi.

4 ASTM A240, Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and General Applications, ASTM International, West Conshohocken, PA.

5 ASTM A312, Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes, ASTM International, West Conshohocken, PA.

6 ASTM A376, Standard Specification for Seamless Austenitic Steel Pipe for High-Temperature Service, ASTM International, West Conshohocken, PA.

7 ASTM A479, Standard Specification for Stainless Steel Bars and Shapes for Use in Boilers and Other Pressure Vessels, ASTM International, West Conshohocken, PA.

8 ASME BTH-1-2020, Design of Below-The-Hook Lifting Devices, American Society of Mechanical Engineers, Two Park Avenue, New York, NY, June 2021.

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7 of 13 4.0 STRUCTURAL EVALUATION 4.1 Loads The empty weight of the ICV 506 is 2,215 pounds. The material density for the analysis models use an adjusted value resulting in a lift interface reaction force that totals 2,215 pounds.

To determine the maximum load capacity of the ICV lift pockets, a downward force is applied at the lower edge of the bodys cylindrical shell transition to simulate the payload weight.

4.2 Evaluations Two ANSYS9 finite element analysis (FEA) models are utilized to determine the maximum load capacity of the ICV lift pockets.

The first FEA model of the ICV lift pocket region evaluates the components in the load path beyond the ICV lift pin, i.e., the lift pocket, lift pocket doubler, and torispherical head structure.

The second FEA model of the ICV lift pin is a highly refined model that includes the two radial grooves that are used to limit stresses by being the shear-failure point in an excessive overload condition. Each FEA model is discussed in more detail below.

4.2.1 ICV Lift Pocket Region Evaluation As shown in Figure 3 and Figure 4, the overall ICV structural model accurately depicts the entire ICV structure without its internal components such as the aluminum honeycomb end spacers and pallet. The ICV structural model is a 1/6 representation of the entire ICV, and uses symmetry boundary conditions along its radial cut edges for continuity.

The entire ICV lid structure, including the lift pocket, is comprised of solid elements. Given the relatively thin shell structures, quadratic elements are used to ensure accurate results for shell bending stresses. The ICV seal flanges and locking ring are also solid elements. The ICV body cylindrical shell and torispherical head are modeled using shell elements.

With one exception, all parts of the model are bonded together. The lift pocket doubler plate is bonded at its edges: the inside edge to the lift pocket to simulate the full penetration weld, and the outside edge to the torispherical head dome to simulate the fillet weld. The interface between the top surface of the doubler plate and bottom surface of the head dome is set to frictionless which allows the surfaces to move relative to each other.

Although the lift pin is included in the model, its only purpose is to provide the load path to the remainder of the model. Each of the ICVs three lift fixture leg weldments10 have a locking bar that engages the lift pin at a 3.00-inch diameter and provide for a straight vertical lift. Given the locking bars relatively greater strength and rigidity compared to the lift pin, the lift pin may be reasonably evaluated having two concentrated loads spaced 3.00 inches apart.

9 ANSYS Simulation Software, Version 2022 R2.03, Ansys, Inc., Canonsburg, PA.

10 Washington TRU Solutions, 412-L-082, Rev. E, Adjustable Center of Gravity Lift Fixture (ACGLF) Leg Weldment

& Miscellaneous Details; Lift Leg Weldment.

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8 of 13 Figure 3 - Overall ICV Structural Model

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9 of 13 Figure 4 - ICV Lift Pocket Detail For this model, the lift pin is restrained in the vertical (Z) direction 1.50 inches inward from the axisymmetric cut plane, and gravity is applied to the model to determine stresses both empty and when loaded to its maximum capacity. Figure 5 illustrates the reaction force vector in the vertical direction for the initial analysis case with an empty ICV (369.17-pound reaction force; multiply by six to get the total reaction load, i.e., 6 x 369.17 = 2,215.02 pounds).

With reference to Figure 6, the maximum equivalent stress in the empty ICV structure is 2,834.2 pounds, and occurs at inside-top edge interface between the bottom of the doubler plate and the outside surface of the lift pocket.

Payload weight is simulated by applying a downward vertical force around the periphery of the ICV bodys cylindrical-to-torispherical shell interface. The force simulating the payload weight is increased until the maximum allowable stress is achieved. A payload weight of 5,485 pounds was found to result in a maximum equivalent stress of 9,999.4 psi, slightly under the 10,000-psi allowable stress limit. The equivalent stress plot is provided in Figure 7.

Given an empty ICV weight of 2,215 pounds, and a maximum payload weight of 5,485 pounds, the maximum gross lifting weight limit is 2,215 + 5,485 = 7,700 pounds.

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10 of 13 Figure 5 - Lift Pin Reaction Force for an Empty ICV Lift Figure 6 - Equivalent Stress in the Lift Pocket Region for an Empty ICV

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11 of 13 Figure 7 - Equivalent Stress in the Lift Pocket Region for a Loaded ICV 4.2.2 ICV Lift Pin Evaluation As shown on Sheet 8 of HalfPACT SAR drawing 707-SAR, the lift pin is subject to bending and shear loads due to the vertical load applied by ICVs lift fixture.10 As discussed in the previous section, the lift pin may be reasonably evaluated having two concentrated loads spaced 3.00 inches apart.

Since the lift pin is fully welded into the lift pocket, the lift pin may be treated as a fixed-fixed cylindrical beam in bending and shear, with the beams length based on the inside diameter of the lift pockets 4-inch, Schedule 80, pipe (4.500-inch outside diameter x 3.826-inch inside diameter).

To perform this evaluation, a localized ANSYS FEA model of the lift pin is used. The lift pins geometry, as shown in Figure 8, includes its two 1/8-inch wide radial grooves with a full 1/16-inch radius at the bottom. A unit (1.0-pound) lifting load was applied at two locations 3.00 inches apart, i.e., 0.5 pounds at each location perpendicular to the axis of the lift pin.

Figure 9 presents the equivalent stress results by combining stresses based on the distortion-energy (von Mises-Hencky) theory. A resulting maximum stress of 11.392 psi/pound of load occurs at the surface of the 1/16-inch radius in the grooves. Since the stress distribution through the pins thickness clearly shows these stresses to be peak stresses, the center section through the center of the groove was linearized to separate primary membrane-plus-bending stresses from peak stresses.

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12 of 13 As shown in Figure 10, the resulting maximum equivalent stresseq, for membrane-plus-bending is 5.9865 psi/pound of load. *LYHQDQDOORZDEOHVWUHVVa = 10,000 psi, for the Type 304 stainless steel lift pin material, the maximum load capacity, Pmax, for each lift pocket lift pin is:

a max eq 10,000 P

1,670.4 lb/pocket 5.9865 V

V Thus, the total lift capacity of all three lift pocket lift pins, Ptotal = 3 x 1,670.4 = 5,011 pounds.

Figure 8 - ICV Lift Pin Model Figure 9 - ICV Lift Pin Equivalent Stress Results

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13 of 13 Figure 10 - ICV Lift Pin Linearized Equivalent Stress Results 4.2.3 ICV Lift Overload Evaluation Since the materials of construction are identical for all of the ICV structural components, and since the load capacity of the ICV lift pocket structure exceeds the load capacity of the lift pin by greater than 50%, failure will occur in the lift pins radial grooves, as intended, long before ICV containment integrity is compromised due to failure of any other components in the lift pocket region that comprise the containment vessel structure.

5.0

SUMMARY

Including measurement error, the payload weight for ICV 506 is 1,110.9 pounds,11 for a total gross lifting weight of 2,215 + 1,110.9 = 3,325.9 pounds. The minimum lifting margin for this payload is 5,011/3,325.9 - 1 = 51%. Furthermore, per Section 8.1.2.1 of the HalfPACT SAR, the bounding design load of the ICV lifting sockets is 5,000 pounds, and load testing to 7,500 pounds is required. Successful load testing coupled with the validation this evaluation provides ensures that the ICV lifting features will operate safety as designed for the loaded ICV 506.

11 WIPP Payload Data Report SRE033, Waste Data System, Waste Isolation Pilot Plant, Carlsbad, NM.

v t e Letter Sequence Request
EPID:L-2023-LLA-0030, Request for Authorization of One-Time Shipment of Model No. Halfpact Crediting the Outer Confinement Vessel as the Containment Boundary (Open) CAC:001029, (Approved, Closed)
Initiation Request Acceptance... Administration Questions 29 March 2023 29 March 2023 17 April 2023 17 April 2023 Answers 27 April 2023 Results Approval... Other: ML23067A436, ML23137A441
MONTHYEAR2023-05-30 [Table View]

ML23046A454

Text

Subject:

Dear Ms. Diaz-Sanabria:

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