ML24253A157

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Alpha-Omega Services, Inc., SAR FM9054 Revision J-4 (Revised Sections Only)
ML24253A157
Person / Time
Site: 07109316
Issue date: 09/09/2024
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Alpha-Omega Services
To:
Office of Nuclear Material Safety and Safeguards
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ML24253A154 List:
References
FM9006.1-092024-002 AOS-FM9054, Rev J-4
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AOS-FM9054 Rev. J-4, September 9, 2024 (Docket No. 71-9316)

Radioactive Material Transport Packaging System Safety Analysis Report

for Model AOS-025, AOS-050, and AOS-100 Transport Packages

Prepared by Alpha-Omega Services, Inc.

Bellflower, CA Revision Date Description of Changes

  • Clarified Special Form Sources - replaced encapsulated by with certified as, 4x J-4 September 9, 2024* Redefined seal replacement schedule
  • Aligned terminology used in certification drawing item descriptions
  • Applied miscellaneous corrections (table of changes included with cover page of the submittal)

When the radioactive contents are certified as Special Form sources, containment is provided by the sealed source. For Normal Form material, containment for the AOS Transport Packaging System (containment boundary) is provided within the cask component. The dashed lines in Figure 4-1, Containment Boundary (Cask Lid Metallic Seal Shown), illustrate the containment boundary, typical to all transport package models. There are two (2) penetration s into the cask cavity, located within the casks top and bottom regions of the side surface. These cavity penetrations are used to drain and vent the cavity.

A third penetration, located in the cask lid, is used for testing the seals leak tightness. Pre-shipment leak testing is performed by way of the cask lid test port for shipments of Normal and Special Form material.

(For further details, refer to Chapter 4, Containment. )

To augment the AOS Transport Packaging Systems shielding characteristics, the AOS Transport Packaging System models may require the use of a liner, axial shielding plates, and/or cavity spacer plates, depending on the model, to convey certain quantities of radioactive materials. These liners, axial shielding plates, and cavity spacer plates are referenced in Table 1-5. To meet temperature regulation requirements, a shipping cage structure (refer to Paragraph 1.2.1.4) is used during package transport.

The AOS Transport Packaging System design does not require specific arrangem ent of the contents, other than those previously discussed, within the cavity. However, a basket or rack device can be used to shore the payload. These baskets or racks are typically made of aluminum or stainless steel material, and designed for the specific payload geometry.

1.2.1.2 Impact Limiter

The impact limiter is a major component consisting of a thin-walled cylindrical shell, with a dish head at one end and a flat disk at the other end. At the flat-disk end, there is a cylindrical recess, with an internal profile identical to that of the cask end profile. This cavity accommodates the cask in the transport configuration.

Figure 2-5, Isometric View - Typical Impact Limiter, presents an isometric view of the impact limiter.

Twelve (12) squared ribs are attached to the inside wall of the cylindrical recess section. Eight (8) of these ribs extend beyond the flat disk plate, which are used as turnbuckl e attachment points. The turnbuckles are used to join the impact limiters and to partially enclose the cask component. For the Model AOS-025, the two (2) impact limiters entire ly cover the cask, and the turnbuckles are replaced with J hooks.

The transport package exterior incorporates one (1) or more tamper-indicating devices, that are not readily breakable. While intact (that is, not broken), these devices provide evidence that the package has not been opened by unauthorized persons. (For further details regarding the tamper-indicating devices, refer to Chapter 7, Package Operations. )

1-10 Radioactive Material Transport P ackaging System Safety Analysis Report for Model AOS-025, AOS-050, and AOS-10 0 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 1.3 APPENDIX

1.3.1 AOS Transport Packaging System, Certification Drawings Table 1-5 lists the certification drawings for the AOS Transport Packaging Systems assembly, impact limiter, cask, liner, axial shielding plates, and cavity spacer plates, by model.

Table 1-5. AOS Transport Packaging System Certification Drawing List - All Models

Drawing Part Number and Revision, by Model

Component AOS-025A AOS-050A AOS-100A AOS-100B AOS-100A-S Assembly 166D8142 K 105E9718 K 105E9711 L 105E9711 L 105E9711 L Impact Limiter 105E9722 J 166D8138 I 105E9713 J 105E9713 J 105E9713 J Caska 166D8143 K 166D8137 K 105E9712G001 Pb 105E9712G002 Pb 105E9719 Pb Liner 183C8485 H - - - - - - - -

Axial Shielding - - 183C8519 A 183C8491 I - - 183C8491 I Plates Cavity Spacer - - - - 183C8518 B - - 183C8518 B Plates

a. The G00x number appended to select drawing numbers represents a group within the drawing.
b. Revision O is not used.

Radioactive Material Transport Packag ing System Safety Analysis Report 1-23 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

SHIPPING CAGE CASK LID ATTACHMENT BOLTS, CASK LID, CASK LID SEAL, CASK LID PLUG IMPACT LIMITER

CASK

SHIELDING TRUNNION MATERIAL (TUNGSTEN ALLOY OR CARBON STEEL)

TIE-DOWN TURNBUCKLE IMPACT LIMITER

SHIPPING CRADLE PALLET

Figure 2-3. Assembled Transport Package Cutaway - Models AOS-100A and AOS-100B

Note: Model AOS-100A-S is not shown, because of its similarity to the Model AOS-100A.

Radioactive Material Transport Packag ing System Safety Analysis Report 2-5 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

2.5.1.1 Cask Lifting Analysis - Trunnion Screw Evaluation

The vertical force, F V, applied to each trunnion is defined as:

FV = (DLF

  • 1.0
  • package weight) / 2

where:

DLF = Dynamic Load Factor, 1.2

The horizontal force, F h, is located at the bottom of the trunnion, and is defined as:

FH =FV

  • tan30°

The effects of forces FV and FH are transferred from their location at the bottom of the trunnion to the screw centroid, located within the interface of the trunnion and cask. The trunnion design is made such that the vertical force, FV, is reacted to by the cask in bearing and does not load the screws in shear.

Moment about the screw centroid x-axis is:

Mx =FV * (B + C + L/2) + FH

  • E/2

Tensile force in the screw furthest away from the scr ew centroid about the x-axis due to moment, and assumes each screw area is equal to 1.0:

Fb =(Mx

  • CL) / Ix-x

where:

Ix-x = (ry)2

Radioactive Material Transport Packag ing System Safety Analysis Report 2-45 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

Tensile force in each screw due to horizontal force is:

Ft =FH / 6

The resulting load on the screw is (from Reference [2.28]):

FB =( k b / (kb + km) )

  • P + Fpreload

where:

kb = Screw stiffness =

  • D2nominal
  • Escrew / (4
  • l)

km = Member stiffness = 2 *

  • D2nominal
  • Emember / l

P = Maximum total load on the fastened assembly= F b + Ft

Fpreload = Pre-torque / (0.2

  • D nominal)

Maximum total screw tensile stress is:

ST =Fb / Atensile

Factor of safety is defined as:

FS = Sy / ST

2-46 Radioactive Material Transport P ackaging System Safety Analysis Report for Model AOS-025, AOS-050, and AOS-10 0 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

Table 2-20. Lifting Load Analysis - All Models

Model

AOS-025A AOS-050A AOS-100Aa Item Units Metric English Metric English Metric English Weight kg lbs. 76 168 536 1,181 4,314 9,510 A cm in. 4.14 1.63 8.26 3.25 16.51 6.50 B cm in. 0.84 0.33 1.65 0.65 3.30 1.30 C cm in. 0.19 0.08 0.41 0.16 0.84 0.33 D cm in. 1.65 0.65 3.30 1.30 6.60 2.60 E cm in. 1.91 0.75 3.81 1.50 7.65 3.01 L cm in. 0.71 0.28 1.45 0.57 2.69 1.06 1/2L cm in. 0.36 0.14 0.72 0.29 1.35 0.53 FT N lbf. 518 116 3,640 818 29,308 6,589

FH N lbf. 259 58 1,820 409 14,654 3,294

FV N lbf. 448 101 3,152 709 25,382 5,706 Screw Size 1/4-28 UNF - 2A x 0.5L 3/8 - 24 UNF - 2A x 0.75L 3/4 - 16 UNF-2A x 1.50L Material SA 193 Grade B6 SA 193 Grade B6 SA 193 Grade B6 Pre-Torque Nm lbf-ft. 5.42 4 16.27 12 135.58 100 Bolt Circle cm in. 2.90 1.14 5.77 2.27 10.80 4.25 Su MPa ksi 758 110 758 110 758 110

Sy Pa psi 5.86E+08 8.50E+04 5.86E+08 8.50E+04 5.86E+08 8.50E+04

Quantity 6 6 6

Keensert KNH 428J KNH 624J KNH 1216J1/4-28 UNF - 3B x 0.37 3/8-24 UNF - 3B x 0.50 3/4-16 UNF - 3B x 1.12

Dnominal cm in. 0.64 0.25 0.95 0.38 1.91 0.75

Atensile cm2 in2 0.23 0.036 0.57 0.088 2.41 0.373

Mx Nm lbf-in. 9 77 122 1,083 1,953 17,283 CL cm in. 1.25 0.49 2.50 0.98 4.67 1.84

Ix-x per unit areab cm2 in2 6.29E+00 9.75E-01 2.49E+01 3.86E+00 8.74E+01 1.35E+01 Fb N lbf. 1.73E+02 3.89E+01 1.22E+03 2.75E+02 1.04E+04 2.35E+03 Ft N lbf. 4.31E+01 9.70E+00 3.03E+02 6.82E+01 2.44E+03 5.49E+02

Escrew Pa psi 2.01E+11 2.92E+07 2.01E+11 2.92E+07 2.01E+11 2.92E+07

Emember Pa psi 1.95E+11 2.83E+07 1.95E+11 2.83E+07 1.95E+11 2.83E+07 I cm in. 9.40E-01 3.70E-01 1.27E+00 5.00E-01 2.84E+00 1.12E+00 kb N/m lbf/in. 6.78E+08 3.87E+06 1.13E+09 6.45E+06 2.02E+09 1.15E+07

km N/m lbf/in. 5.26E+09 3.00E+07 8.76E+09 5.00E+07 1.56E+10 8.93E+07

kb / (kb + km) 1.14E-01 1.14E-01 1.14E-01 1.14E-01 1.14E-01 1.14E-01

Radioactive Material Transport Packag ing System Safety Analysis Report 2-47 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

Table 2-20. Lifting Load Analysis - All Models (Continued)

Model

AOS-025A AOS-050A AOS-100Aa Item Units Metric English Metric English Metric English P N lbf. 2.16E+02 4.86E+01 1.53E+03 3.44E+02 1.29E+04 2.90E+03 Fpreload N lbf. 4.27E+03 9.60E+02 8.54E+03 1.92E+03 3.56E+04 8.00E+03

FB N lbf. 4.29E+03 9.66E+02 8.72E+03 1.96E+03 3.71E+04 8.33E+03

ST Pa psi 1.83E+08 2.65E+04 1.54E+08 2.23E+04 1.54E+08 2.23E+04 FS = Sy / ST 3.20 3.20 3.81 3.81 3.81 3.81

a. Model AOS-100A is the heaviest of the AOS-100 models and is therefore the bounding case.
b. This method is shown in Equation 6-25, Section 6.12 of Reference [2.28].

Typically in a fastened joint design, a preload torque is assigned to the screw(s). This is to ensure that the joint will have the capability to react to the applied working lo ad. Therefore, the working load in the screw must be within the magnitude of, or less than, the resu ltant load from the preload. In the analysis presented in Table 2-20, the resultant screw load due to the preload (F preload) is 8.00E+03 lbf., while the working load is 330 lbf.a Hence, the preload value of 100 lbf-ft is an adequate value applied to the Model AOS-100 trunnion design. In addition to applying a preload, t he screws are coated with anti-vibration compound prior to installation, to enhance the fastened joints efficiency.

a. The working load value of 330 lbf. is obtained by subtracting the preload force (Fpreload) value of 8.00E+03 lbf.

from the total force (Fb) of 8.33E+03 lbf [2.28].

2-48 Radioactive Material Transport P ackaging System Safety Analysis Report for Model AOS-025, AOS-050, and AOS-10 0 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 4 CONTAINMENT

This chapter identifies the AOS Transport Packagin g System containment systems and describes how the Packages comply with the containment requirements of 10 CFR 71 [4.1], under Normal Conditions of Transport (NCT) and Hypothetical Accident C onditions (HAC) of Transport, as well as 49 CFR 173 [4.2],

and the International Atomic Energy Agency Safety Standards Series No. TS-R-1 (IAEA TS-R-1) [4.3].

4.1 DESCRIPTION

OF THE CONTAINMENT SYSTEM This section identifies and describes the AOS Transport Package containment systems, including the welds, seals, lids, cover plates, and closure devices. The AOS Transport Packaging System is designed to meet the leak-tight criteria specified the American Na tional Standards Institute, ANSI N14.5-2014 [4.4],

for the transportation of activated material in Normal and Special Form.

When the radioactive contents are certified as Special Form sources, containment is provided by the sealed source. For Normal Form material, containment is provided by the casks Containment Boundary, as described in the following section.

4.1.1 Containment Boundary The AOS transport package containment boundary (loc ated within the cask of the transport package) is composed of the following:

  • Cask cavity shell
  • Cask lid elastomeric and metallic seal co mponents of the AOS Transport Pack aging System cask

The containment boundary loops along the cask cavity shell walls and port plug walls, across the port opening, between its pipe plug and plug cover, throug h the cask lid material and across the cask lid seal joint between the two (2) retainer rings (elastomeric seal) or C cross-sections (metallic seal). The dashed lines in Figure 4-1 illustrate the containment boundary (located within the cask unit of the transport package).

The cask unit is constructed of 3 00 series stainless steel (SS300) material. Tungsten alloy or carbon steel material is embedded within the cask body and cask lid plug, to enhance the assembled cask shielding capability. Shielding material options are variable within the AOS Transport Packaging System models.

There are two (2) penetrations into the cavity region of the cask - the cask drain port and cask vent port. These ports are comprised of a lower seal, a th readed pipe plug, a silicone material O-Ring, and a port cap, as discussed in Section 4.1.2.

The cask lid seals use either a pair of elastomeric O-Rings captured within one (1) or two (2) SS300 series flat rings, or a metallic double C cross-section arra ngement, as discussed in Section 4.1.3. Figure 4-1 illustrates the general arrangement of these systems. The cask lid seals used on the AOS Transport Packaging System models are included in Appendix 4.5.1.

Radioactive Material Transport Packag ing System Safety Analysis Report 4-1 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

The seal replacement schedule is as follows:

  • Metallic Seal
  • Normal Form material - Single use only.
  • Special Form material - Once every twelve (12) uses -or-every twelve (12) months, whichever comes first, or if damaged.
  • Elastomeric Seal - Once every twelve (12) uses -or-every twelve (12) months, whichever comes first, or if damaged.
  • 37° Conical Seal - Only when damaged. This seal is expected to last a long time; however, it must be monitored during the periodic inspection. Replacement of this seal entails machining of the weld that secures the port plug in place, as well as removal of the port plug and its re-installation and testing, per original requirements. It is important to note that the port plug design was dropped three (3) times, without failu re, during the 165 prototypes Drop Test.

Therefore, it can be expected that Normal conditions of transport will have minimum impact on this seal.

3/8-18NPT HEX SOC.3/8-18NPT HEX SOC.

THREADS TO CONFORMTHREADS TO CONFORM 6.38 TO ASME B1.20.3-1976TO ANSI B1.20.3 TORQUE: 30 LB-FT (41 N-m)TORQUE: 30 LB-FT (41 N-m)1.23 PORT PLUG 3/32 DIA. O-RING SPACER 0.73 CROSS-SECTION Ø1.21 37° CONICAL SEAL

Ø15/16 OD

0.30

PORT COVER TORQUE: 55 LB-FT (75 N-M)25 ft-lb (34 N-m) 1-12 UNF - 2A THREADS CONFORM TO ASME B1.20.3-1976 1-12 UNF - 2A THREADS TORQUE: 230 LB-FT 1/8-27NPT CONFORM TO ANSI B1.20.3 PIPE PLUG 1/8-27NPT HEX SOC. (312 N-m) (LUB)

Ø.125 THRU TORQUE: 230 LB-FT TORQUE: 75 LB-IN (8.5 N-M) (LUB) AT INSTALLATION PORT PLUG (25.98 N-m) (LUB)

2X PT ROOT (1/8) &FINAL

Figure 4-3. Typical Port Plug Configuration

Note: All dimensions are in inches for the Model AOS-100.

Radioactive Material Transport Packag ing System Safety Analysis Report 4-5 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 4.2 CONTAINMENT UNDER NORMAL CONDITIONS OF TRANSPORT This section presents the evaluation of the AO S containment system under Normal Conditions of Transport for the chemical and physical form s of the approved contents, documented in Subsection 1.2.2, Contents. and evaluated in Subsection 3.3.2, Maximum Normal Operating Pressure.

4.2.1 Containment of Radioactive Material When the radioactive contents are certified as Special Form sources, containment under Normal Conditions of Transport is provided by the sealed source. For Normal Form material, containment is provided by the casks containmen t system. The ability of the casks containment system to withstand Normal Conditions of Transport is presented below.

The AOS Transport Packaging System containment is designed so that no release, loss, or dispersal of radioactive materials can occur under all conditions of transport, nor will there be any significant increase in external radiation or reduction in package effectiveness. This conclusion is supported by the analyses and various component qualification tests presented throughout this SAR.

4.2.2 Pressurization of Containment Boundary The AOS transport packages have been designed to withstand pressures and temperatures in excess of those encountered during Normal Conditions of Tran sport. The maximum Normal Conditions of Transport pressures encountered are well within the Design Pressure of each transport package, documented in Subsection 3.3.2, Maximum No rmal Operating Pressure.

The only mechanism for pressurization of the cask cavity is that due to temperature change. There are no other mechanisms of gas generation from the approved contents, or from interaction with the environment in the casks cavity. None of the approved contents undergo alpha decay in any appreciable amount, nor is there helium generation from boron captures, be cause there are no neutron emitters nor boron in the system.

The structural evaluation provided in Subsection 2.6.11, Structural Evaluation Results Summary and Minimum Margins of Safety under Normal Conditions of Transport, shows low stress values throughout the cask structure, especially in the cask lid seal area, under Normal Conditions of Transport. In addition, the maximum temperatures shown in Table 3-3, Maximum Temperature Summary, Normal Conditions of Transport - All Models, are lower than the corresponding limits of the containment boundary materials; therefore, they do not pose a threat to containment integrity.

Radioactive Material Transport Packag ing System Safety Analysis Report 4-29 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 4.3 CONTAINMENT UNDER HYPOTHETICAL ACCIDENT CONDITIONS When the radioactive contents are certified as Special Form sources, containment under Hypothetical Accident Conditions of Transport is provided by the sealed source. For Normal Form material, containment is provided by the casks containm ent system. The ability of the casks containment system to withstand Hypothetical Accident Conditions of Transport is presented below.

This section presents the evaluations performed on the AOS Transport Package containment system under Hypothetical Accident Conditio ns of Transport and documents th at the Package design meets the containment requirements of 10 CFR 71.51(a)(2) [4.1] under Hypothetical Accident Conditions of Transport, specifically, the structural performance of the containment system, including the cask lid seal, cask lid attachment bolts, cask cavity shell, and penetrations. These results are documented in Subsection 2.7.8, Summary of Damages. Temperature distributions unde r these conditions are listed in Table 3-4, Maximum Temperature Summary, Hypothetical Accident Conditions of Transport (Condition 3)

- All Models.

Under Hypothetical Accident Conditions of Transpor t, the pressure within the AOS Transport Packaging System models cask cavity is well below the design pressures listed in Table 4-7. Temperatures at the cask lid elastomeric or metallic seal and port cover se al are also below the temperature criteria for the applicable seal material listed in Table 3-4, Maximum Temperature Summary, Hypothetical Accident Conditions of Transport (Condition 3) - All Models.

Table 4-7 summarizes the maximum temperatures obtained during the Fire Transient evaluation, for each transport package model. The analytical evaluations under Hypothetical Accident Conditions of Transport, presented in Chapter 2, Structural Evaluation, show that the stresses throughout the cask structure are below the materials failure criteria. This is also demonstrated by the results of the AOS-165A prototype Free-Drop test, presented in Appendix 2.12.6, Impact (Free-Drop) Test Report. During the test, the cask structure did not suffer any measurable deformation on its entire surface and the cask leak tightness was maintained, despite the fact that the cask was dropped three (3) times.

Radioactive Material Transport Packag ing System Safety Analysis Report 4-31 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 4.3.1 Containment of Radioactive Material The results of the structural an d thermal analyses presented in Chapter 2, Structural Evaluation, and Chapter 3, Thermal Evaluation, respectively, and the Free-Drop test results presented in Appendix 2.12.6.2, Free-Drop Test Activity Record - Pre-and Post-Leak Test, verify that the AOS transport packages are capable of withstanding the Hy pothetical Accident Conditions of Transport that meet the containment criter ia specified in Reference [4.4].

4.3.2 Containment Criterion The AOS Transport Packaging System containments are designed, and verified by Leak test, to meet the leak-tight criteria established in Reference [4.4], for the transportation of activated material in Normal Form.

4.3.3 Fission Gas Products Not applicable. The authorized content of the AOS Transport Packaging System does not include any fission product gases, nor materials t hat can produce them, during transport.

4.4 LEAKAGE RATE TESTS FOR TYPE B PACKAGES Pre-shipment and periodic Leakage tests, meeting the requirements of Reference [4.4], are used to demonstrate that the AOS transport packages meet the containment requirements of 10 CFR 71.51 [4.1]

are delineated in Subsection 8.2.2, L eakage Tests [8.4], for Normal Form and Special Form shipments.

4-32 Radioactive Material Transport P ackaging System Safety Analysis Report for Model AOS-025, AOS-050, and AOS-10 0 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 7.1.1.2 Removing the Transport Package from the Transport Vehicle

To remove the transport package from the transport vehicle:

a. Position the transport vehicle, in the job staging area, for transport package remo val.

This operation can be aided by the use of a overhead crane or forklift truck.

b. Position the spreader bar or forks, then connect the appropriate slings and shac kles to remove the shipping cage.
c. Remove the shipping cage and tie-down hardware.
d. Verify that the radiation and external contamination levels are in compliance with regulatory requirements IAEA TS-R-1, Paragraph 508, 10 CFR 71.87(i), 49 CFR 173.428, and 10 CFR 20.1906 (References [7.1], [7.2], [7.3], and [7.4], respectively).

Note: The transport packages bottom surface is not ac cessible until the transport package is removed from the pallet. As a result, when measurements are required, the radiation and external contamination levels on the transport packages bottom surface ar e assessed after the shipping cask is removed in step g.

e. Record any finding(s), and notify the Job S upervisor for disposition of the finding( s).

Findings must be evaluated against 10 CFR 71.95 [7.2], to determine whether th ey require regulatory notification, so that prope r action can be taken. The Job Supervisor is responsible for direct oversight of th e personnel that are performing the work.

f. Depending upon site-specific cons traints, do one of the following:
  • Remove the upper impact limiter from the cask, then place the impact limiter into temporary storage.
  • Install trunnions. Prior to the installation, apply an anti-vibration compound on the trunnion screw threads.
  • Lift and remove the entire package from the transport vehicle, then set down the package in an appropriate location. Next, remove the im pact limiters from the shipping cask, then place the impact limiters in temporary storage.
g. Remove the cask, using the appropriate rigging equipment.
h. Transfer the cask to the loading area.

Radioactive Material Transport Packag ing System Safety Analysis Report 7-7 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 7.1.2 Loading of Contents 7.1.2.1 Preparing for Loading

To prepare the transport package for loading:

a. Verify that the content to be loaded is authorized by the current transport packages Cert ificate of Compliance. (Refer to the Pre-Sh ipment Engineering Evaluation in Section 7.1 and guidance in Appendix 7.5.1.)
b. Perform a visual inspection. Note any damage or unusual conditions. If part functio nality is impaired, repair or replace the part, as required, and document the repair or replacemen t, then re-inspect the part. Notification and approva l of AOS is required. Replacement or repa ir of any component requires that all original examinations and tests initially prescrib ed be performed.
c. Depending upon the particular transport package model, remove the trunnions from each side of the shipping cask and install a lifting device specific to the facility. If using a forklift to transport the cask, protect the cask surface a nd secure the cask to the forks with straps. If lifting by crane, with or without a spreader bar, th e lifting slings must not make an angle greate r than 30°, measured from the vertical.
d. With proper radiological protection and monitoring, remove the cask lid and cask lid plug for visual inspection of the cavity.
e. Record any finding(s), and notify the Job S upervisor for disposition of the finding( s).

Findings must be evaluated against 10 CFR 71.95 [7.2], to determine whether th ey require regulatory notification, so that proper action can be taken.

f. Visually inspect the cask and cask lid sea ling surfaces for damage or foreign material.

The presence of foreign material and/or deep r adial scratches that may result in a failed Pre-Shipment Leakage Rate test must be properly cleaned and/or repaired -or-the affected component must be replaced, as required, and AOS is to be notified for written disposition.

g. Remove the cask drain port, test port, and cask vent port covers, and pipe plugs. Comp letely remove all thread sealant from the pipe plugs.
h. Optional - Install the lid guide pins, 90° apart. Use of the lid guide pins is mainly needed for proper alignment of the cask lid with the cask lid attachment bolt holes. The lid guide pins also protect the cask lid elasto meric or metallic seal.

7.1.2.2 Loading Irradiated Hardware or Other Contents

To load contents:

a. Place the radioactive contents to be shipped into a shoring device (such as a ra ck, basket, or other such device).

The liner, axial shielding plates, and/or cavity s pacer plates are used as necessary, per th e requirements listed in Table 7-1.

b. Shore the load within the cavity, if needed.
c. Place the cask lid plug into the cask.

7-8 Radioactive Material Transport P ackaging System Safety Analysis Report for Model AOS-025, AOS-050, and AOS-10 0 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

Table 7-1. Additional Required Shielding -

Models AOS-025A, AOS-050A, AOS-100A, and AOS-100A-S

Certification Model Component Drawinga Comments Shielding liner is mandatory for all contents. (Refer to the AOS-025A Liner 183C8485current revision of the current revision of the NRC Certificate of Compliance 9316.)

Axial AOS-050A Shielding 183C8519 Used when shipping Ir-192 and Ir-194 isotopes. (Refer to the current revision of the NRC Certificate of Compliance 9316.)

Platesb Axial Shielding 183C8491 Used when additional shielding is required for Co-60. (Refer to AOS-100A Plates the current revision of the current revision of the NRC Certificate AOS-100A-S Cavity of Compliance 9316.)

Spacer 183C8518 Plates

a. Refer to Table 1-5, AOS Transport Packaging System Certification Drawing List - All Models, for drawing revision levels.
b. If the Model AOS-050A axial shielding plates include threaded screw holes, each hole must be filled with a setscrew during shipment.

7.1.2.3 Installing the Cask Lid

Note: Visually inspect the cask and lid sealing surfaces, as well as the cask lid seal to be used, for damage that can prevent proper sealing of the sealing joint. Refer to Subsection 8.2.2, Leakage Tests

[8.4], for detailed inspection of thes e items. If the cask lid metallic se al is replac ed, prior to the shipment of Normal Form material, a Maintenance Test must be performed in accordance with ANSI N14.5 (Reference [7.8]).

For the shipment of Special Form material, a new or previously used cask lid elastomeric s eal -or-new or previously used cask lid metallic seal may be used:

  • When the radioactive contents are c ertified as Special Form sources and containment is provided by the sealed source, and
  • After a Pre-Shipment Leak test has been performed (refer to Paragraph 7.1.3.3, Pre-Shipment Leak Testing, Test A1 or A2, as appropriate

To install the cask lid, after verifying that the cask lid seal is properly installed, use proper rigging to slowly lower the cask lid onto the cask. Carefully monitor this operation to ensure that the cask lid is properly aligned. During the placement of the cask lid, two lid guide pins may be installed in the cask lid threaded holes perpendicular to each other to maintain alignm ent of the cask lid attachment bolt holes with the cask lid threaded holes.

The cask lid attachment bolts must be lubricated with a lubricant such as Neolube No. 2 (note that the lubricant must be approved by AOS).

Radioactive Material Transport Packag ing System Safety Analysis Report 7-9 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 7.1.3 Preparation for Transport 7.1.3.1 Securing the Cask Lid

To secure the cask lid, in preparation for transport:

Note: Torque sequence is stamped on top surface of the cask lid, about the bolt location.

a. Lubricate the cask lid attachment bolts with a l ubricant such as Neolube No. 2. The lubrican t must be approved by AOS. In th e case of wet loading, the lubricant must be applied after the cask has been removed from the pool and dried.
1. If the cask was dry loaded - Install the cask lid attachment bolts and torque the bolts in a crisscross pattern, with a final pass all the way around, to ensure even seal compression.
2. If the cask was wet loaded - To torque the cask lid attachment bolts:
a. Install the cask lid and a minimum of at least five (5) bolts in the cask lid, as the cask breaks the waters surface. Note that this step may be skipped with the approval of Radiation Protection.
b. Drain the cask over the pool area. After the water has drained from the cask, move the cask to the decontamination pad.
c. Remove the bolts (previously installed for the transfer) and cask lid.
d. Dry the cask lid attachment bolts and then lubricate with a lubricant such as Neolube No. 2.
e. Dry the sealing surfaces and the bolt threaded holes.
f. Visually inspect and install the cask lid seal. For shipments of Normal Form material, a new cask lid metallic seal must be used. For shipments of Special Form material, a new or previously used cask lid elastomeric seal -or-new or previous ly used cask lid metallic seal may be used. Re-install the cask lid attachment bolts and torque the bolts in a crisscross pattern, with a final pass all the way around,

to ensure even seal compression.

Note: For shipments of Special Form material, a Maintenance Leak test is not necessary after replacing a cask lid elastomeric -or-metallic seal, prov ided that a Periodic Leak test has been performed on the casks containment system within the past twelve (12) months.

7-10 Radioactive Material Transport P ackaging System Safety Analysis Report for Model AOS-025, AOS-050, and AOS-10 0 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 7.1.3.2 Removing the Cask from the Loading Area

To remove the cask from the loading area, in preparation for transport:

a. Carefully measure the cask radiation levels, wh ile removing the cask from the storage basin or cell area.
b. Decontaminate the cask to a level consistent with IAEA TS-R-1, Paragraph 508,

10 CFR 71.87(i), and 49 CFR 173.443 (References [7.1], [7.2], and [7.3], respectively).

7.1.3.3 Pre-Shipment Leak Testing

To verify that the transport packages containment system is properly assembled for shipment, perform one of the following Pre-Shipment Leak tests - Test A1, A2, or B - depending on the content and cask lid seal type. Tests A1 and A2 (with el astomeric -or-metallic seals) are mi nimum requirements for shipments that contain Special Form content. Test B (with a metallic seal only) is the minimum test required for shipments that contain Normal Form content. However, Test B can be performed in lieu of Test A1 or A2.

Notes: A Periodic or Maintenance Leak test performed on a loaded cask in accordance with Subsection 8.2.2 may be acceptable as a Pre-Shipment Leak test, provided that the test meets or exceeds the requirements for Pre-Shipment Leak testing described below.

When the Model AOS-100A-S is used, both cask lid seals must be leak tested.

Test A1 - Gas Pressure Rise: For Special Form Contents

[Tests: Cask Lid(s), Vent and Drain Ports]

To perform a pre-shipment verification of the cask lid elastomeric -or-metallic seal:

a. Perform the test by evacuati ng the space between the cask lid seals elastomeric O-Ring seal s

-or-metallic double C cross-se ction seal, -or-the cavities outside the cask vent and drain ports, and then measuring the pressure rise.

Notes: The cask vent port and cask drain port need to be leak tested only if the ports have been opened since they were last tested.

The Gas Pressure Rise Leak test is performed using a test manifold, isolation valve, vacuum gauge, and vacuum pump. Use the test apparatus described in the test procedure or equivalent.

b. Connect the test manifold to the test port. Ev acuate the test volume to the required level.

and then close the isolation valve.

c. Disconnect the vacuum pump and then wait for the prescribed test time. After the test time, the acceptance criterion is a pressure rise that corresponds to no detectable leakage.

7-12 Radioactive Material Transport P ackaging System Safety Analysis Report for Model AOS-025, AOS-050, and AOS-10 0 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

Test A2 - Gas Pressure Drop: For Special Form Contents

[Tests: Cask Lid(s), Vent and Drain Ports]

To perform a pre-shipment verification of the cask lid elastomeric -or-metallic seal:

a. Perform the test by pressurizing the space be tween the cask lid seals elastomeric O-Ring seals -or-metallic double C cross-section seal, -or-the ca vities outside the cask vent and drain ports, and then measuring the pressure drop.

Notes: The cask vent port and cask drain port need to be leak tested only if the ports have been opened since they were last tested.

The Gas Pressure Drop Leak test is performed using a test manifold, isolation valve, pressure gauge, and pressure supply. Use the test apparatus described in the test procedure or equivalent.

b. Connect the test manifold to the test port. Ev acuate the test volume to the required level.

and then close the isolation valve.

c. Disconnect the pressure supply and then wait fo r the prescribed test time. After the test time, the acceptance criterion is a pressure drop that corresponds to no detectable leakage.

Test B - Helium Mass Spectrometer Leak Test: For Normal Form Contents

[Tests: Cask Lid Metallic Seal, Vent and Drain Port Pipe Plugs]

To leak test the containment system:

a. The cask lid metallic double C cross-section seal, and thr eaded cask vent and drain port pipe plugs must be leak-test ed in accordance with test method A.5.3 or A.5.4 from ANSI N14.5-2014 [7.8]. The acceptance criteria is 1 x 10 -7 ref-cm3/sec air at an upstream pressure of a minimum of 1 atmosphere and downstream pressure of 0.01 atmosphere absolute or less. The test procedure sensitivity must be one-half of the reference air leakag e rate (i.e., 5 x 10-8 ref-cm3/sec of air) or less.

Radioactive Material Transport Packag ing System Safety Analysis Report 7-13 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

j. Complete the radiological survey of the tran sport package and transport vehicle, consiste nt with IAEA TS-R-1, Paragraphs 530 through 532, 10 CFR 71.47 and 71.87(j), an d 49 CFR 173.441 (References [7.1], [7.2], and [7.3], respectively).

Note: For the 1-m TI dose rate, the 1-m distance is from the transport package surface (that is, the shipping cask or impact limiter surface), not the shipping cage surface.

k. Install the shipping cage. If the shipping cage in cludes the optional lifting bar, install the lifting bar guards so that the lifting bar cannot be used for lifting of the entire package or for tie down.

If the security seals were not applied in step i, apply two (2) security seals betwe en the shipping cage and pallet, on opposing sides.

l. Apply any additional shipping label or marking that might be required to properly represen t the transport package and its content, in accordance with Reference [7.3].
m. Apply the security seal, if used, to the shipping cage, as illustrated in Figure 7-7.

SECURITY SEAL 2 (MIN.) LATCH PINS

Figure 7-5. Impact Limiter Latch Pin Security Seal (Model AOS-025)

Radioactive Material Transport Packag ing System Safety Analysis Report 7-15 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

SECURITY SEAL 2 (MIN.) IMPACT LIMITER TURNBUCKLE

Figure 7-6. Impact Limiter Turnbuckle Security Seal (Models AOS-050 and AOS-100)

7-16 Radioactive Material Transport P ackaging System Safety Analysis Report for Model AOS-025, AOS-050, and AOS-10 0 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 7.2.1 Receipt of Package from Carrier To receive the transport package from the carrier:

a. Verify the integrity of the tran sport packages security seals. If seals are broken, indicating package tampering, isolate the transport packa ge and immediately notify the sites Safeguar ds organization, then wait for their in structions. Otherwise, if the secu rity seals are on the shipping cage, remove the security seals by cutting the wires, then properly dispose of the se curity seals. If the security seals are connected to t he impact limiters, remove the seals afte r the shipping cage is detached.

Note: Safeguards organization refers to the organiza tion or person at the facility responsible for radioactive material control and accounting.

b. Position the transport vehicle in the Receiving Inspection area.
c. Visually inspect the transport package for damage and proper labeling and mark ing.

Refer to the shipping paper for shipment category and compare the marking and labe ls on the package to the requirement of Reference [7.3].

d. Position the transport vehicle in the job staging area, for transport package re moval.

This operation can be aided by the use of an overhead crane or forklift truck.

e. Position the spreader bar or forks, then connect the appropriate slings and shac kles to remove the shipping cage.
f. Remove the shipping cage and tie-down hardware.
g. Verify that the radiation and external co ntamination levels are in compliance with regulatory requirements IAEA TS-R-1, Paragraphs 508 and 530 through 532, 10 CFR 71.47 and 71.87(i), 49 CFR 173.441 and 173.443, and 10 CFR 20.1906 (References [7.1], [7.2],

[7.3], and [7.4], respectively).

Note: The transport packages bottom surface is not ac cessible until the transport package is removed from the pallet. As a result, when measurements are required, the radiation and external contamination levels on the transport packages bottom surface are assessed after the shipping cask is removed in step j.

h. Record any finding(s), and notify the Job S upervisor for disposition of the finding( s).

Findings must be evaluated against 10 CFR 71.95 [7.2], to determine whether th ey require regulatory notification, so that prope r action can be taken. The Job Supervisor is responsible for direct oversight of th e personnel that are performing the work.

i. Depending upon site-specific cons traints, do one of the following:
  • Remove the upper impact limiter from the cask, then place the impact limiter into temporary storage.
  • Install trunnions. Prior to the installation, apply an anti-vibration compound on the trunnion screw threads.
  • Lift and remove the entire transport package from the transport vehicle, then set down th e package in an appropriate location. Next, remove the impact limiters from the shipping cask, then place the impact limiters in temporary storage.
j. Remove the cask, using the appropriate rigging equipment.
k. Perform radiological and smear surveys of the cask surfaces, as described in step a in Paragraph 7.2.2.

Radioactive Material Transport Packag ing System Safety Analysis Report 7-19 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316) 8.2 MAINTENANCE PROGRAM The cask maintenance program is described, in detail, in an Engineering Specification provided to all AOS Transport Packaging System users. This Specification shall implement the requirements established in this chapter. Packaging System operators can develop procedures of their own, to include site-specific requirements, if they remain within the Engineering Specification requirements.

Pre-shipment Inspections are conducted prior to each shipment. These inspections include visual checks of the packaging and any support structure(s) or device(s) required to properly assemble the transport package. They might also include pressurization of the cask cavity, which is part of the Leak test for Normal Form content. Additionally, more detailed inspections are conducted annually, or prior to being used after a storage period of more than one (1) year, as detailed in Subsection 8.2.2(b).

8.2.1 Structural and Pressure Tests The only periodic pressure test performed on th e AOS Transport Packaging Syst em is the Le ak te st detailed in Subsection 8.2.2(b).

8.2.2 Leakage Tests [8.4]

Prior to leak testing, the cask lid seal, sealing surfaces, cask lid attachment bolts, and seal attachment screws must be inspected for damage such as scratches, dents, dirt, and oil residue. Also, the female thread holes for the cask lid attachment bolts and seal attachment screws must be checked. After completing the inspection, and repairing or replacing any damaged components, the seal is installed on the cask lid groove by the four (4) seal attachment screws, as illustrated in Figure 8-2 for the cask lid metallic seal, which also shows the location of the leak-testing hole.

Note: For Special Form material shipments only - The O-Rings used in the cask lid elastomeric seals,

-or-reused cask lid metallic seals, must be visually inspected for cuts, blemishes, debris, and/or permane nt local deformation on the sealing surfac e. Damaged seals must be replaced. Elastomeric O-Rings -or-reused cask lid metallic seals must be replaced every twelve (12) uses -or-every twelve (12) months, whichever comes first, or if damaged.

a. Pre-shipment Leak Testing Pre-shipment leak testing must be performed befo re each shipment, after the content is loaded and the containment system is assemble d. Perform the test as described in Paragraph 7.1.3.3, Pre-Shipment Leak Testing - Test A1 or A2 ( Special Form content) -or-Test B (Normal Form content).
b. Periodic Leak Testing Periodic leak testing must be performed prior to the transport packages first use, after its third use, annually, and/or prior to the transp ort package being used after a storage period of more than one (1) year. The cask lid metallic seal, threaded cask vent and drain port pipe plugs, and the port plug conical seal must be leak-tested in accordance with ANSI N14.5-2014

[8.4]. The acceptance criteria is 1 x 10 -7 ref-cm3/sec air at an upstream pressure of 1 atmosphere and downstream pressure of 0.01 atmosphere absolute or less.

The test procedure sensitivity must be one-half of the reference air leakage rate (i.e., 5 x 10-8 ref-cm3/sec of air) or less.

Radioactive Material Transport Packag ing System Safety Analysis Report 8-17 for Model AOS-025, AOS-050, and AOS-100 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

c. Maintenance Leak Testing Maintenance leak testing is performed to confir m that maintenance, repair, and/or replacement of components has not degraded containmen t system performance. The portion of th e containment system affected by the maint enance, repair and/or co mponent replacem ent must be leak-tested using a cask lid metallic seal in accordance with ANSI N14.5-2014 [8.4].

The acceptance criteria is 1 x 10 -7 ref-cm3/sec air at an upstream pressure of 1 atmospher e and downstream pressure of 0.01 atmosphere abso lute or less. The test procedure se nsitivity must be one-half of the reference air leakage rate (i.e., 5 x 10 -8 ref-cm3/sec of air) or less.

Notes: For Special Form material shipments only - A Maintenance Leak test is not necessary after replacement of a cask lid elastomeric seal -or-reused cask lid metallic seal, provided that a Periodic Leak test has been performed on the casks containment system within the past twelve (12) months and a Pre-Shipment Leak test is performed in accordance with Paragraph 7.1.3.3, Pre-Shipment Leak Testing.

Periodic and Maintenance Leak testing on casks prior to April 2016 may have been performed in accordance with the 1997 edition of ANSI N14.5.

8-17a Radioactive Material Transport P ackaging System Safety Analysis Report for Model AOS-025, AOS-050, and AOS-10 0 Transport Packages, Rev. J-4, September 9, 2024 (Docket No. 71-9316)

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