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| issue date = 08/30/2011
| issue date = 08/30/2011
| title = Response to Question 1 of the Referenced RAI
| title = Response to Question 1 of the Referenced RAI
| author name = DeBey T
| author name = Debey T
| author affiliation = US Dept of Interior, Geological Survey (USGS)
| author affiliation = US Dept of Interior, Geological Survey (USGS)
| addressee name =  
| addressee name =  
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=Text=
=Text=
{{#Wiki_filter:-USGS science for a changing world Department of the Interior US Geological Survey PO Box 25046 MS 974 Denver, CO 80225-0046 August 30, 2011 U.S. Nuclear Regulatory Commission Document Control Desk Washington, DC 20555  
{{#Wiki_filter:-USGS science for a changingworld Department of the Interior US Geological Survey PO Box 25046 MS 974 Denver, CO 80225-0046 August 30, 2011 U.S. Nuclear Regulatory Commission Document Control Desk Washington, DC 20555


==Reference:==
==Reference:==
U.S. Geological Survey TRIGA Reactor (GSTR), Docket 50-274, License R-1 13 Request for Additional Information (RAI) dated September 29, 2010


U.S. Geological Survey TRIGA Reactor (GSTR), Docket 50-274, License R-1 13 Request for Additional Information (RAI) dated September 29, 2010
==Subject:==
Response to Question 1 of the Referenced RAI Mr. Wertz:
Question 1: The ISG requires the NRC staff to review significant changes to the facility, including those done in accordance with the provisions of Title 10 of the Code of Federal Regulations Section (10 CFR)
Section 50.59. In 1988, changes to the GSTR were made which involved the installation of a new reactor tank liner. The details of this change are not provided in the GSTR Safety Analysis Report (SAR). As such, please provide a description of the new tank liner, the applicable design and construction criteria, and any associated additional instrumentation or equipment added as a result of the new tank liner. In addition, please describe any analyses of accidents and malfunctions associated with the new tank liner.
Response: Twenty three years ago, in 1988, corrosion and the resultant water leakage in the original, aluminum reactor tank was resolved by installing a tank liner inside the leaking tank. The tank liner has a slightly (4") smaller diameter than the original tank so it could be easily slipped into place. The tank liner is constructed of 6061-T6 aluminum with an overall height of 25' 3" and with an outer diameter of 7' 7.25". The bottom of the tank liner is supported by twelve ribs that are welded to the outer surface of the liner. These twelve ribs are welded to the liner in a spoke pattern, at a 300 spacing. The ribs are 4" tall, 1" thick, and 32" long. The floor of the liner is one inch thick, and the wall thickness varies from 3/8" near the bottom to 1/4" at 90.375" up from the bottom.
The reactor core structure is supported by a triangular base. The base connects to the floor of the tank liner at three pads that are located 30.625" from the center and separated from each other by 1200. These pads are supported by the ribs on the underside of the tank, with each pad centered directly over a rib.
The pads are 4" wide, 8.5" long, and 1" thick. The triangular base is connected to the pads through adjusting screws that allow for the base to be leveled manually. The triangular shape is reinforced by crossing support beams. The reactor core structure sits on the crossing support beams of the triangular base and is connected via nuts and bolts.


==Subject:==
Design and Construction Criteria The ASME pressure vessel code was used as the basis for the reasonable, safe and economical design of the tank. The design included seismic, strength and thermal calculations for the mechanical and structural integrity of the tank liner and lifting lugs.
Response to Question 1 of the Referenced RAI Mr. Wertz: Question 1: The ISG requires the NRC staff to review significant changes to the facility, including those done in accordance with the provisions of Title 10 of the Code of Federal Regulations Section (10 CFR)Section 50.59. In 1988, changes to the GSTR were made which involved the installation of a new reactor tank liner. The details of this change are not provided in the GSTR Safety Analysis Report (SAR). As such, please provide a description of the new tank liner, the applicable design and construction criteria, and any associated additional instrumentation or equipment added as a result of the new tank liner. In addition, please describe any analyses of accidents and malfunctions associated with the new tank liner.Response:
Pressure: Int:10.83 PSI EXT: 1.184 PSI Temp: Max: 150 0 F Min: 50 0 F Liquid Level: Full of water Corrosion Allowance: None Joint Efficiency: 1.0 (100% X-Ray)
Twenty three years ago, in 1988, corrosion and the resultant water leakage in the original, aluminum reactor tank was resolved by installing a tank liner inside the leaking tank. The tank liner has a slightly (4") smaller diameter than the original tank so it could be easily slipped into place. The tank liner is constructed of 6061-T6 aluminum with an overall height of 25' 3" and with an outer diameter of 7'7.25". The bottom of the tank liner is supported by twelve ribs that are welded to the outer surface of the liner. These twelve ribs are welded to the liner in a spoke pattern, at a 300 spacing. The ribs are 4" tall, 1" thick, and 32" long. The floor of the liner is one inch thick, and the wall thickness varies from 3/8" near the bottom to 1/4" at 90.375" up from the bottom.The reactor core structure is supported by a triangular base. The base connects to the floor of the tank liner at three pads that are located 30.625" from the center and separated from each other by 1200. These pads are supported by the ribs on the underside of the tank, with each pad centered directly over a rib.The pads are 4" wide, 8.5" long, and 1" thick. The triangular base is connected to the pads through adjusting screws that allow for the base to be leveled manually.
Specific Gravity of Contents : 1.0 (Water)
The triangular shape is reinforced by crossing support beams. The reactor core structure sits on the crossing support beams of the triangular base and is connected via nuts and bolts.
Seismic: PER API 650, APP'E' , Zone 1 A copy of the design specifications is provided as Attachment 1.
Design and Construction Criteria The ASME pressure vessel code was used as the basis for the reasonable, safe and economical design of the tank. The design included seismic, strength and thermal calculations for the mechanical and structural integrity of the tank liner and lifting lugs.Pressure:
Added instrumentation or Equipment Because of Change The only equipment that was added because of the change was a "pump tube" located at the liner's edge in the SE quadrant of the tank liner. This tube is an aluminum tube, 6" diameter at the top and 3" diameter for the lower 5 feet. This tube penetrates the bottom of the tank liner so that access can be gained into the bottom annulus between the original tank and the tank liner. This access is needed to check the annulus for water accumulation and to allow removal of any accumulated water. An eductor pump system was purchased to fit in the pump tube for the removal of accumulated water. The pump is only located in the tube when water is being removed; otherwise the pump tube is empty. A radiation shield plug is located at the top of the pump tube to prevent radiation streaming into accessible locations.
Int:10.83 PSI EXT: 1.184 PSI Temp: Max: 150 0 F Min: 50 0 F Liquid Level: Full of water Corrosion Allowance:
None Joint Efficiency:
1.0 (100% X-Ray)Specific Gravity of Contents : 1.0 (Water)Seismic: PER API 650, APP'E' , Zone 1 A copy of the design specifications is provided as Attachment 1.Added instrumentation or Equipment Because of Change The only equipment that was added because of the change was a "pump tube" located at the liner's edge in the SE quadrant of the tank liner. This tube is an aluminum tube, 6" diameter at the top and 3" diameter for the lower 5 feet. This tube penetrates the bottom of the tank liner so that access can be gained into the bottom annulus between the original tank and the tank liner. This access is needed to check the annulus for water accumulation and to allow removal of any accumulated water. An eductor pump system was purchased to fit in the pump tube for the removal of accumulated water. The pump is only located in the tube when water is being removed; otherwise the pump tube is empty. A radiation shield plug is located at the top of the pump tube to prevent radiation streaming into accessible locations.
The pump tube is checked regularly, when the reactor is shutdown, for water accumulation.
The pump tube is checked regularly, when the reactor is shutdown, for water accumulation.
Accident and/or Malfunction Analyses A copy of the design calculations for the tank liner is attached as Attachment  
Accident and/or Malfunction Analyses A copy of the design calculations for the tank liner is attached as Attachment 2. These accident/malfunction calculations include static and dynamic pressures that could result from water pressure, lifting and placement, and a design basis (0.2 G force) earthquake.
: 2. These accident/malfunction calculations include static and dynamic pressures that could result from water pressure, lifting and placement, and a design basis (0.2 G force) earthquake.
Additional Preliminary Responses Based on Information Received from the Colorado School of Mines:
Additional Preliminary Responses Based on Information Received from the Colorado School of Mines: Question 8. The technical parameters of the GSTR are being analyzed using the MCNP version 5 and RELAP version 5, mod 3.3. These analyses are being performed using the Oregon State University relicensing work as a starting point for the methodology.
Question 8. The technical parameters of the GSTR are being analyzed using the MCNP version 5 and RELAP version 5, mod 3.3. These analyses are being performed using the Oregon State University relicensing work as a starting point for the methodology. The code results will be benchmarked to the GSTR operating data. After the existing core model is finalized, the limiting core configuration will be modeled and analyzed. These models are being worked on and we expect to have final neutronic and thermal hydraulic results by October 31, 2011.
The code results will be benchmarked to the GSTR operating data. After the existing core model is finalized, the limiting core configuration will be modeled and analyzed.
Question 9. We have a limiting core configuration determined, which will include a number of new 12 weight% fuel elements in the center of the core. However, since our neutronic and thermal hydraulic models are not completed, we do not have control rod worths or excess reactivities calculated for all configurations. Again, we expect to have these results by October 31, 2011.
These models are being worked on and we expect to have final neutronic and thermal hydraulic results by October 31, 2011.Question 9. We have a limiting core configuration determined, which will include a number of new 12 weight% fuel elements in the center of the core. However, since our neutronic and thermal hydraulic models are not completed, we do not have control rod worths or excess reactivities calculated for all configurations.
 
Again, we expect to have these results by October 31, 2011.
Question 10. The fuel and moderator temperatures that are used are 293 K for low power operations and 600 K for full power operations. The void and power coefficients will be determined by October 31, 2011.
Question 10. The fuel and moderator temperatures that are used are 293 K for low power operations and 600 K for full power operations.
Question 12. The DNBR analysis will be done using RELAP version 5, mod 3.3. The model used for the GSTR was received from the Oregon State University relicensing effort and has been adapted for the GSTR conditions. These results will be available by October 31, 2011.
The void and power coefficients will be determined by October 31, 2011.Question 12. The DNBR analysis will be done using RELAP version 5, mod 3.3. The model used for the GSTR was received from the Oregon State University relicensing effort and has been adapted for the GSTR conditions.
Question 15.1 The power density values given in our original license renewal submission are being recalculated with the MCNP version 5 model. Preliminary MCNP results are showing power peaks around 17 kW per element in the existing core. The limiting core will obviously have higher values. We expect that the peak power per element will stay below 22 kW for all core configurations. These results will be available by October 31, 2011.
These results will be available by October 31, 2011.Question 15.1 The power density values given in our original license renewal submission are being recalculated with the MCNP version 5 model. Preliminary MCNP results are showing power peaks around 17 kW per element in the existing core. The limiting core will obviously have higher values. We expect that the peak power per element will stay below 22 kW for all core configurations.
Sincerely, C
These results will be available by October 31, 2011.Sincerely, C Tim DeBey Qý07---USGS Reactor Supervisor I declare under penalty of perjury that the foregoing is true and correct.Executed on 8/30/11 Attachment 1: TRIGA Reactor Aluminum Tank Liner Specifications Attachment 2: Design Calculations for United States Geological Survey 1MW Mark I TRIGA Reactor -Tank Liner Copy to: Betty Adrian, Reactor Administrator, MS 975 USGS Reactor Operations Committee Attachment 1: TRIGA Reactor Aluminum Tank Liner Specifications TRIGA REACTOR ALUMINUM TANK LINER SPECIFICATIONS FOR UNITED STATES GEOLOGICAL SURVEY FEDERAL CENTER 6TH & KIPLING LAKEWOOD, CO BY GILLAN'S ENGINEERING, INC.5126 W 38TH AVE DENVER, CO 80212 (303) 480-0471 (revised original tank specification) 9-25-87 Part 1. General A. Definitions.
Tim DeBey Qý07---
Whenever used in any part Of this specification, the following shall have the respective meanings set forth below: 1. Purchaser shall mearn an authorized representative of the organization issuing the contfact for the work contained herein.2. Fabricator shall mean the successful bidder for the work, material, and equipment included under this specification.
USGS Reactor Supervisor I declare under penalty of perjury that the foregoing is true and correct.
: 3. Ins2ector shall mean an authorized representative of the Purchaser.
Executed on 8/30/11 : TRIGA Reactor Aluminum Tank Liner Specifications : Design Calculations for United States Geological Survey 1MW Mark I TRIGA Reactor         -
B. Drawings arid Sg ecifications.
Tank Liner Copy to:
The Purchaser-vill furnish to the Fabricator, free of charge, such numbers of drawings and specifications reasonably necessary for the execution of the work. The drawings accompany the specifications and they are by this reference incorporated into and shall become a part of the specifications.
Betty Adrian, Reactor Administrator, MS 975 USGS Reactor Operations Committee
C. Tests and Inspection.
: TRIGA Reactor Aluminum Tank Liner Specifications TRIGA REACTOR ALUMINUM TANK LINER SPECIFICATIONS FOR UNITED   STATES GEOLOGICAL             SURVEY FEDERAL CENTER 6TH & KIPLING LAKEWOOD,     CO BY GILLAN'S ENGINEERING,                 INC.
Where tests are required by the specifications, arrangements for- the conduction of such tests shall be made and all expenses in connection therewith shall be borne by the Fabricator.
5126 W 38TH AVE DENVER,       CO   80212 (303) 480-0471 (revised     original         tank specification) 9-25-87
Such tests and inspections shall be made by an independently qualified inspection firm or agency approved by the Purchaser-.
 
All tests shall be witnessed by the Purchaser.
Part     1. General A.       Definitions.             Whenever         used     in   any part         Of   this specification,                   the following shall                 have the respective meanings           set     forth     below:
The Fabricator shall review, certify and submit to Purchaser for r eview all inspection reports, radiographs and material certifications.
: 1.       Purchaser         shall       mearn an       authorized representative of   the     organization             issuing         the     contfact         for     the     work contained herein.
It shall be the responsibility of the fabricator to notify the Purchaser five (5) working days in advance so witnessing of tests can be arranged without delaying the work.D. QualitY of Work and Materials.
: 2.       Fabricator shall               mean the successful bidder                           for the work,             material, and equipment included under this specification.
All materials, parts and equipment furnished by the Fabricator shall be new, high grade, and free from defects and imperfections.
: 3.       Ins2ector         shall       mean       an   authorized           representative of the Purchaser.
Workmanship shall be in accord with the highest standard practices.
B.       Drawings arid Sg           ecifications.                 The Purchaser- vill furnish           to the Fabricator,                 free       of charge, such numbers of drawings and specifications                             reasonably necessary for                           the execution of the work.                         The drawings accompany the specifications                   and they       are by this             reference incorporated into     and shall             become a       part       of the specifications.
Both materials and workkmanship throuyhout shall be at all times subject to the approval of the Inspectors.
C.       Tests and Inspection.                       Where tests           are required by the     specifications,                 arrangements for- the conduction of such tests       shall       be made and all               expenses in connection therewith shall       be borne by the Fabricator.                             Such tests             and inspections shall       be made by an independently qualified                                     inspection firm or agency approved by the Purchaser-.                                       All tests         shall       be witnessed by the Purchaser.                               The Fabricator shall                     review, certify           and submit to Purchaser for r eview all                                     inspection reports,           radiographs and material certifications.                                         It shall be the responsibility                       of the fabricator                   to notify           the Purchaser five                   (5) working days in advance so witnessing of tests       can be arranged without delaying the work.
E. Reference Standa ds and Specificaticns.
D.       QualitY of Work and Materials.                               All materials,               parts and equipment furnished by the Fabricator                                           shall       be new, high grade, and free                   from defects           and imperfections.                     Workmanship shall       be in accord with the highest standard practices.                                                   Both materials             and workkmanship throuyhout shall                               be at all           times subject           to the approval of the Inspectors.
The following listed standards and i-ipecifications, as applicable to the work involved, forrm a part of this specification.
E.       Reference Standa ds and Specificaticns.                                         The following listed                   standards and i-ipecifications,                           as applicable to the work involved, forrm a part                                 of this         specification.
American Society of Mechanical Engineers (ASME)TRIGA REACTOR TAN1{ T'. NER £'P'ECTFICATIONS il C-1 I Par-to of Section 1IfMaterials Specifications, Part B--Nonferrous Materials, of the 1986 edition of the ASME Boiler and Pressure Vessel Code ASME SB-209 ASME SB-211 ASME SB-221 ASME SB-241 AMSE SB-211 as follows: Specification for. Aluminum--Alloy Sheet and Plates Specification for Aluminum--Alloy Bars, Rods and Wire Specification for Aluminum- -Alloy Extruded Bars, Rods and Shapes Specification for Aluminum--Alloy Seamless Pipe and Seamless Extruded Pipe Specification for Aluminum --Alloy Bolts Parts of Section II Materials Specifications:
American Society of Mechanical Engineers (ASME)
Part C Welding Rods, Electrodes, and Filler Metals, of the 1986 edition of the ASnE Boiler and Pressure Vessel Code ASME SFA-5.10 Specification for Aluminum and Aluminum Alloy Welding Rods, Class ER 4043 Part of Section V, Nondestructive Examination, Subsection A of the 1986 edition of the ASNE Boiler- and Pressure Vessel Code as follows: Article 6 Liquid Penetrant Examination Parts of Section V, Nondestructive Examination, Subsection B, for the 1986 edition of the ASME Boiler. and Pressure Vessel Code as follows: Article 24 Liquid Penetrant Standards Parts of Section III, Division 1, of the 1986 edition of the ASME Boiler and Pressure Vessel Code as follows: Subsection NB Para. NB-5300 Acceptance Standards Subpara NB-5320 Radiographic Acceptance Standards Subpara NB-5350 Liquid Penetrant Parts of Section IX, Welding & Br.azing Qualifications, of the 1986 edition of the ASME Boiler. and TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 2 Pressure Vessel Code as followoi Part QW Welding Aerospace Material Specifications (AMS) as follows: AMS 2568A Hard Coating Treatment--Aluminum Alloys F. Packaging aýnd Shi-2 rent.1. All items shall be thoroughly cleaned of all grease, water, and other foreign matter.2. All fabricated items shall be packed for shipment and shall conform to standards of packaging requirements for the carriers.
TRIGA REACTOR             TAN1{       T'.NER   £'P'ECTFICATIONS il C-1 I
No stacking of items will be permitted where metal surfaces can come in contact with other metal surfaces.3. Seal off the open end of the tank with a wood frame, dust tight cover. A minimum of 3/4 inch plywood shall be used over opening.4. The tank shall be loaded in a secure and safe manner. Extra bracing and special handling shall be supplied by the Fabricator' as necessary to prevent deformation of the tank in shipment..
 
All aluminum surfaces shall be protected from direct contact with bracing or crating and the elements during shipping cr storagce.5. Fabricator will prepare all items for shipment and load aboard truck carrier selected by Purchaser.
Par-to of         Section     1IfMaterials             Specifications,           Part     B-
Pert 2. SaOLe.The work covered by this specification consists of furnishing all labor, materials, appliances, and equipment, and performing all coperations in connection with the fabrication, assembly, testing, bracing, shoring and loading for shipment of one aluminum reactor tank, complete, including special test fittings and cover plates, in strict accordance with this specification and the applicable drawings and subject to the terms and conditions of the contract.Pert 3. Aluminum Tank.TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 3 A. Codes. The fabrication, inspection, testing, handling, and installation shall be in strict accordance with this specification and with Section VIII and IX of the latest edition of the ASME Boiler and Pressure Vessel Code; however, a Code Stamp is not required.
-Nonferrous           Materials,         of   the     1986     edition         of   the ASME   Boiler and Pressure           Vessel         Code as follows:
In the event of conflict between this specification and the codes, the Fabr.icator' shall notify the Purchaser and secure a written clarification before proceeding with the work.B. Alternate Quotations and Deviations.
ASME SB-209                   Specification             for. Aluminum--Alloy Sheet       and   Plates ASME    SB-211                Specification             for Aluminum--Alloy Bars, Rods           and Wire ASME    SB-221                Specification             for     Aluminum- -Alloy Extruded         Bars,       Rods and Shapes ASME SB-241                    Specification             for     Aluminum--Alloy Seamless Pipe and Seamless Extruded Pipe AMSE    SB-211                Specification             for     Aluminum -- Alloy Bolts Parts     of Section         II   Materials Specifications:
The Fabricator may quote prices based on alternate construction methods when deviations from this constyruction will improve design, delivery, or decrease cost. List all such deviations and submit to the Purchaser in writing. Written approval will be required prior to putting changes into effect. If no exceptions are taken, it will be assumed that the pr-oposal is in stryict compliance with this specification.
Part     C                     Welding Rods, Electrodes, and Filler Metals, of the 1986 edition                       of the ASnE Boiler and Pressure Vessel Code ASME SFA-5.10                 Specification               for Aluminum and Aluminum Alloy Welding Rods, Class ER 4043 Part     of Section V, Nondestructive Examination, Subsection A of the 1986 edition                             of the ASNE Boiler- and Pressure Vessel Code as follows:
C. DrawingE Ly Fabricator.
Article         6             Liquid Penetrant                 Examination Parts     of Section V, Nondestructive Examination, Subsection B, for the 1986 edition                               of the ASME Boiler. and Pressure Vessel Code as follows:
The Fabricator shall submit to the Purchaser one reproducible tracing of his final fabrication drawings and any applicable standard.
Article         24             Liquid       Penetrant           Standards Parts of Section III,                   Division         1, of the 1986 edition of the ASME Boiler and Pressure Vessel                                   Code as follows:
These drawings and standards shall locate plate Joints in plan and elevations, show construction details, such as all weld joint design, welding procedures and processes to be used, lifting lugs, slings, bracing jigs, fixtures, gussets, other reinforcements, and fabrication tolerances.
Subsection NB                 Acceptance          Standards Para. NB-5300 Subpara         NB-5320       Radiographic             Acceptance         Standards Subpara         NB-5350       Liquid Penetrant Parts     of Section IX, Welding & Br.azing Qualifications,               of the 1986 edition                 of the ASME Boiler. and TRIGA       REACTOR TANK LINER SPECIFICATIONS PAGE 2
One copy will be returned to the Fabricator stamped for fabrication as noted.Fabricator shall not proceed until this stamped drawing is received unless written instr-uctions are given to the contrary.
 
Shop drawings stamped by Purchaser.
Pressure           Vessel         Code as           followoi Part         QW                         Welding Aerospace             Material             Specifications                     (AMS)       as     follows:
does not relieve the Fabricator of the responsibility for, fabrication and testing of the tank in accordance with the specification.
AMS       2568A                         Hard Coating                 Treatment--Aluminum Alloys F.       Packaging             aýnd     Shi-   2 rent.
D. Functional Re uirernents and Basi.s for Design.1. The Tank is to be a leak-tight container, for.demineralized water, filled to 3 inches below the top channel. The tank plate thiulki-esses specified on the Purchaser.'s drawings are minirmum allowable.
: 1.       All     items         shall         be     thoroughly               cleaned           of     all grease,           water,         and other               foreign           matter.
The Fabr-icator.
: 2.       All     fabricated                 items         shall       be packed for                   shipment and     shall         conform to               standards               of     packaging requirements                               for the     carriers.               No stacking                 of     items       will       be permitted                   where metal         surfaces           can come in                 contact           with other               metal         surfaces.
shall be responsible foy- desicnu of tank bracing required to suppor-t the tank during fabrication, shipping and handling, all in accordance with the basis lfor design.2. The Following Re uire ments are the basis for-design of the aluminum tank using Part UNF of Section VIII of the ASME Unfired Pressure Vessel Code, latest edition.a. Oterjatinq PreEsure:
: 3.       Seal       off     the       open end of               the       tank       with a wood frame, dust                 tight       cover.             A minimum of                 3/4       inch       plywood shall be used over                 opening.
24.5 foot static head of water.*b. ~Pec-ic Tign r.:-atures.
: 4.       The tank           shall         be loaded             in     a secure             and safe manner.               Extra       bracing           and special                 handling             shall       be supplied by the         Fabricator'             as     necessary               to     prevent           deformation                 of the tank       in     shipment..               All     aluminum surfaces                       shall         be protected from direct                 contact           with bracing                   or crating               and the           elements during         shipping           cr     storagce.
150 degrees F (maximum).
: 5.       Fabricator             will         prepare           all     items         for     shipment and     load         aboard truck               carrier             selected           by Purchaser.
TRIGA REACTOR TANK LINER SPECIFICATIONS  
Pert       2.         SaOLe.
: c. No Bracing, IntLe.L-al oi- External.d. Shell Thickness shall bie at least 1/4 inch.E. Materiale.
The work covered                       by this           specification                 consists             of furnishing               all     labor,         materials,                 appliances,               and equipment, and performing                   all       coperations in                   connection               with the fabrication,                   assembly,             testing,             bracing,           shoring           and loading for     shipment             of one aluminum reactor                               tank,         complete, including             special         test       fittings             and cover plates,                       in     strict accordance               with     this       specification                     and the           applicable drawings             and subject               to     the       terms       and conditions                   of     the contract.
: 1. Tank material shall be one of the following aluminum alloys: 5052-H32, 6061-T4 or 5154-H32, and shall conform to Specification SB-209 from the ASME Pressure Vessel Code, Section VIII, latest edition. Other- materials may be considered, but may be used only if approved in writing *by.Purchaser.
Pert     3.         Aluminum           Tank.
The first choice shall be 5052-H32 alloy.Welding filler- wire shall be as follows (or equivalent approved by Purchaser):
TRIGA       REACTOR             TANK LINER               SPECIFICATIONS PAGE 3
on the 5052 alloy use AWS-ASTI E 5154; on the 6061 alloy use AWS-ASTM E 4043; on the 5154 alloy, use AWS-ASTM E 5554; on combinations of 5000 series to 6061 alloy use AWS-ASTM E 4043.2. Bolts that weld to tank bottom shall be 6061-T6 aluminum alloy and hayrdcoat anodized per. AMS-2468, except anodize shall be clear..3. Aluminum Angle (Alcoa die 4892) shall be of alloy 6061-T6, or. equivalent as a.approved by the Purchaser.
 
F. Shop Fabrication.
A.       Codes.             The fabrication,                           inspection,                 testing, handling,               and installation                         shall           be in       strict           accordance               with this       specification                     and with               Section             VIII and IX of                     the       latest edition           of the           ASME Boiler                 and Pressure                   Vessel           Code; however, a Code Stamp is                       not     required.                   In     the     event         of conflict between this                   specification                     and the             codes, the               Fabr.icator' shall         notify           the       Purchaser               and secure                 a written               clarification before         proceeding                 with the             work.
: 1. Handling nd ForminQg.
B.       Alternate               Quotations                 and Deviations.                         The Fabricator may quote               prices           based on alternate                             construction                   methods when deviations                 from this             constyruction                     will       improve design, delivery,               or     decrease             cost.           List         all     such deviations                       and submit         to     the     Purchaser               in     writing.               Written           approval             will       be required             prior         to     putting           changes into                   effect.               If     no exceptions                 are     taken,           it     will       be assumed that                       the       pr-oposal is in   stryict           compliance               with this                 specification.
With the following exceptions, the aluminum used in the work is to be handled and formed in a normal manner.a. Aluminum to be used for the tank shall be stored in a clean place, free from dir.t, grease, etc.b. Care shall be taken not to nick, scratch, or, otherwise mar aluminum surfaces.c. All rolls and machine tools used in for-ming.
C.       DrawingE Ly Fabricator.                                       The Fabricator                     shall         submit to     the     Purchaser               one reproducible                         tracing           of     his final fabrication                 drawings             and any applicable                           standard.                 These drawings             and standards                     shall         locate           plate         Joints           in     plan       and elevations,                 show construction                           details,             such as all                 weld joint design,           welding procedures                             and processes                   to     be used, lifting lugs,         slings,           bracing             jigs,         fixtures,               gussets,             other reinforcements,                       and fabrication                       tolerances.                   One copy will                   be returned             to     the       Fabricator                 stamped for                 fabrication                   as   noted.
the aluminum parts shall lie clean arnd free from grease, dirt, shavings, turnings, etc.d. Tolerances as specified on drawings shall bie maintained.
Fabricator                 shall         not     proceed             until         this       stamped drawing is received             unless           written           instr-uctions                   are     given         to     the contrary.                 Shop drawings stamped by Purchaser.                                                 does not relieve           the       Fabricator                 of the           responsibility                     for,       fabrication and testing                 of the         tank         in     accordance               with the             specification.
Deviations shall tie subject to written approval by the Purchaser..
D.       Functional               Re       uirernents               and     Basi.s       for       Design.
: e. Suitable lifting lugs, slings and handling equipment shall be provided by the Fabricator, either- as shown on the Purtchaser's drawings or in other locations where lifting of the tank can be accomplished during fabrication and shipping.2. Special Creat.rutic, Features shall be complied with in fabrication, testing,.
: 1.       The       Tank       is     to     be     a     leak-tight               container,             for.
and preparation for shipping and field installation.
demineralized water,                             filled           to 3 inches below the top channel.               The tank plate                       thiulki-esses specified                             on the Purchaser.'s drawings are minirmum allowable.                                                               The Fabr-icator.
TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 5  
shall         be responsible                     foy- desicnu               of tank           bracing             required             to suppor-t the                 tank       during           fabrication,                   shipping             and     handling, all     in     accordance                 with         the       basis         lfor     design.
: a. Round-off all sharp corners to 1/16" r-adius minimum.b. Fabr-icato-shall Ic-cate all shell girth and longitudinal seams on shop drawificqS and identify by number-each plate or shell course.c. The tank E-hall be cormpletely fabricated and tested in the shop prior to Ehipment.3. Welding. All welds shall be full penetration welds unless otherwise specified, and shall be in conformance with this specification, Part 4..4. Testing Sequence shall be as follows: a. Penetrant inspection of all welde shall be in conformance with Part 5B of this specification.
: 2.         The Following                     Re     uire     ments       are       the       basis         for-design         of the           aluminum               tank       using         Part       UNF of           Section           VIII       of the     ASME Unfired                   Pressure             Vessel           Code,       latest           edition.
: b. Welds shall hbe radiographed in conformance with Part 5A of this specification.
: a.       Oterjatinq               PreEsure:                   24.5     foot         static           head       of water.
: c. Air. pressure test of the completed tank shall be in conformance with Part 5C of this specification.
                        *b.       ~Pec-ic       Tign r.:-atures.                       150 degrees                 F   (maximum).
: d. As an alternate to the air pressure test, a hydr-ostatic test may be performed in confo-mance with Part 5D of this specification.
TRIGA         REACTOR TANK                   LINER SPECIFICATIONS
: e. A leak test of all welds shall be performed in conformance with Part 5E of this specification.
: c.       No Bracing,                 IntLe.L-al           oi- External.
: 5. Defects found at any stage of testing shall be.repaired at that stage, and all tests shall be repeated for-the defective area.6. Responsibil1ty.
: d.       Shell       Thickness               shall         bie at       least         1/4     inch.
The Fabricator.
E.       Materiale.
shall conduct and be fully responsible for. the inspection and tests called for in these specifications, and shall maintain cC-Toplete  
: 1.       Tank material                   shall         be one of             the       following aluminum alloys:                     5052-H32, 6061-T4 or 5154-H32, and shall conform to             Specification                     SB-209 from the                   ASME Pressure                     Vessel Code, Section                 VIII,         latest           edition.               Other- materials                     may be considered,               but     may be used only if                           approved in                 writing           *by.
.-eccr-ds of all tests. Certified copies of all test and inspection reports shall be supplied to the Purchaser..
Purchaser.                 The first             choice           shall         be 5052-H32 alloy.
: 7. Finish.a. All wire brushes, welders' hammers or- scrapers used on tank must be of AISI 300 series stainless steel.When welds are to be ground, aluminum oxide disks shall be used. The disks shall be new or dressed to remove any trace of non-aluminum grindings, and of a type that does not leave abrasive particles embedded in welds.b. nsi of t:: nk shall :e 1:ept clean, free of gr-ease, di-ft., etc.TRIGA REACTOR TAN]" LINER SPECIFICATIONS PACE t c .Care r-s)ll b~e cx.-rcdEt d during fIb icatioCn not to mar the inside surfaces of the tank.d. At the conclusion of all work and testing, the..tank shall be thoroughly cleaned inside and out with a suitable solvent (Toluene, acetone, or others) to remove all grease, dirt, grime, etc.,, before packing for shipment.8. -epcrts.a. Welding Documents:
Welding filler-                 wire       shall         be as follows                   (or equivalent approved by Purchaser):                               on the           5052 alloy             use       AWS-ASTI E 5154; on the                 6061 alloy               use AWS-ASTM E 4043; on the                                     5154 alloy,       use     AWS-ASTM E 5554; on combinations                                             of     5000 series               to 6061 alloy             use AWS-ASTM E 4043.
Prior to fabrication of the tank, the Contractor shall submit to the Purchaser for review one copy of each of the following:
: 2.       Bolts       that       weld to             tank       bottom shall                 be 6061-T6 aluminum alloy                   and hayrdcoat anodized                             per. AMS-2468,                   except anodize         shall         be clear..
welding procedure specification; qualification test reaults of welding procedures; welder percformance qualification test results.The welding procedure specifications and welding personnel shall be qualified in accordance with the requirements of ASbE Section IX.b. Prior- to any production fabrications; procedures for welding, liquid penetrant inspection, x-ray inspection, leak testing and cleaning shall be submitted to the Purchaser for approval.c. Within 10 days after tank is released for" shipment, the Fabricator shall submit copies of each of the following to the Purchaser.(I) Dimensions of finished tank (5 copies).(2) Two copies of certified test reports of all material used in the fabrication of this equipment.(These are to be available to the Inspector upon request during fabrication.  
: 3.       Aluminum             Angle (Alcoa                   die     4892)         shall         be of       alloy 6061-T6,           or. equivalent                 as a.approved                   by the           Purchaser.
)(3) Two certified copies of all test and inspection reports.Part 4. Aluminum Welding.A. Code. All welds shall be full penetration welds unless otherwise specified, and in accordance with Sections VIII and IX of the ASME Boiler and Pressure Vessel Code, latest edition.B. Preiaratior, of Joints.1. Welding JointS shall be prepared so as to permit complete fusion with complete Joint penetr-ation.
F.       Shop       Fabrication.
Multipass welding from both sides is recommended to minimize distortion.
: 1.       Handling               nd ForminQg.                   With the             following exceptions,               the     aluminum used in                         the     work is to               be handled and formed             in   a normal manner.
TRIGA REACTOR TANK LINER SPECIFICATIONS FTM71 7  
: a.       Aluminum             to     be used for               the       tank       shall       be stored         in     a clean           place,           free       from dir.t,             grease,           etc.
: 2. All weld Joint edges shall be prepared either. by machining, sawing, or- grinding with tools which leave.. no r-esidue on the joint faces.3. Surfaces to be welded shall be clean and free fr-om foreign material for a distance of at least 2 inches fr-om the joint edges.4. Prior to welding, all Joints shall be thoroughly wire brushed Ior- a distance of at least one inch on each side of the joint to remove aluminurm oxide in the weld region.Only Type AISI 300 stainless steel wi-re br-ushes shall be used on this wor-k.5. Pr-ior to welding, but after wire brzushlng, all.Joints shall be wiped with methyl alcohol and air-dried' to remove any dirt of foreign material in the weld region.6. After- the weld Joints have been cleaned, the joints shall be handled only with clean cloth gloves.7. The joint edges must not. be placed in contact with any material which could contaminate the surfaces after cleaning.8. The use of welding flux of any kind is not per-mitted on this work.C. Methods and Mechanics of Welding.I. Welds shall be made by the inert-gas shielded consumable electrode welding method (nIG) or- the tungsten inert-gas shielded arc welding pr-ocess (AC-TIG or- DC-TIG).2. The inert gas used with the MIG pr-ocess shall be helium, argon, or- a mixture of these gases. The iner-t gas used with the AC-TIG process shall be argon. The inert gas used with the DC-TIG process shall be helium.3. Any inert gas used shall have a minimum pur-ity of 99.95 percent. The flow of Inert gas shall he sufficient to*pr-operly protect the weld region during welding and coollng.4. £electicro., of the welding process ahall he based on production of the bec:t quality welds with a minimum of distor-tion and residual stx--:-ss.
: b.       Care shall                 be taken             not     to     nick,         scratch,           or, otherwise           mar     aluminum             surfaces.
in the finished work.Processes other than specified may be used only with the wr-itten consent of the Purchaser.
: c.       All     rolls           and     machine tools                   used in           for-ming. the aluminum           parts         shall         lie     clean         arnd free         from grease,                   dirt, shavings,             turnings,             etc.
: 5. When a Joint requires more than one pass, the preceding pass shall bie cleaned with a stainless steel wi-re br-ush prior to deposition of the nrexct pass.TRIGA REACTORl TANI{ LINER, SPECIFICATIONS PMA C.3  
: d.       Tolerances                 as     specified             on     drawings             shall       bie maintained.                 Deviations                 shall         tie subject             to     written           approval by the       Purchaser..
: 6. When a weld joint if welded frome both sides;i.e., full penetration weldc, the ,side welded second (opposite aide) shall be gound out to sound metal and liquid penetrant inspected in accordance with Part 5 prior- to depositing metal on that side.7. When using the TIG welding process, stopping of the arc shall occur in the Joint using a gr-adual reduction of welding current to permit the molten weld puddle to 'solidify slowly. After most of the puddle has solidified, the arc will be carried back over the completed weld Joint during the final reduction of the welding current to a point where no molten metal is observed beneath the arc. At this point the arc will be broken.8. No peening of welds will be permitted.
: e.       Suitable             lifting           lugs,       slings           and handling equipment shall                   be provided                 by the         Fabricator,                 either-         as shown on the               Purtchaser's                 drawings or in                   other         locations             where lifting         of     the     tank       can be accomplished during                                     fabrication and shipping.
D. Filler' Wire.1. Only filler wire from a special marked container reserved for this work only shall hie used for- any welding, including tacks or temporaary welds.2. All filler. metal shall be clean and dry.3. All filler wires used for this work shall be stored in a separate area from other filler materials.
: 2.         Special           Creat.rutic,                   Features             shall         be complied with     in   fabrication,                   testing,.             and     preparation                 for     shipping and field           installation.
The area shall be free of dirt, gcrease, or other for-eign material.
TRIGA       REACTOR             TANK LINER               SPECIFICATIONS PAGE 5
Access to filler. wire shall be permitted only by responsible personnel supervisiong the fabrication of the work. Care must be used to assure that no unapproved wire is used on any aluminum work. The type of wire to be used is specified in Part 3, paragr-aph E.1 of this specification.
: a.       Round-off             all   sharp corners                 to 1/16"         r-adius minimum.
The wire shall be smooth, clean and free of surface defects.E. Visual Inspection shall be made during and after each weld pass. Any defects detected shall be removed and repairs made before deposition of the next weld pass.F. Qualification of Welding P:r-ocedures and Welders.1. The welding proceduxre(s) and welders shall be qualified in accor.'a-nce with the requIrements of the ASIIE Boiler and Pres-sure VeEsel Code, Section IX latest edition, with the following addltional r-equirements:
: b.       Fabr-icato- shall                 Ic-cate all           shell     girth     and longitudinal               seams on shop drawificqS and identify                                     by number-each plate             or shell           course.
: a. Aluminum alloy uoed for. the qualification test plates shall be of the same thickness, alloy and temper as used in the item to be fabricated.
: c.       The tank E-hall               be cormpletely               fabricated         and tested       in     the     shop       prior       to   Ehipment.
: b. The test plates shall receive 100 percent radiographic inspection of the welds and shall meet the I-equir-ements of UW-5! fo £'ecticn VII of the AS)IE Boiler-and Pressure Vessel Code, Fepair welding is not permitted.
: 3.       Welding.             All welds shall                 be full         penetration welds unless otherwise specified,                                       and shall           be in conformance with this           specification,                 Part 4.
TRIGA R.7.ACTO=R TAN, L1-EI-Z _P'EC.IPICATIONS 17.";:] q
              .4.       Testing Sequence                   shall         be as follows:
: c. The test plates shall be given a liquid penetrant inspection of the welds and shall meet the requirements of Part 5, paragraph B. Any evidence of cracking or. excessive pofosity shall be cause for. re-testing.
: a.       Penetrant inspection                       of all       welde shall           be in conformance with Part                         5B of this             specification.
: d. In addit-ion to the groove weld qualification test plate(s) for p(erDfIrnoricne iual.ification required by Section IX of th ASME Code, weldero shall qualify on a fillet weld test plate in accordance with the requirements of Section IX.e. At least one weld stop and start per pass shall be made near the center. of procedure and welder qualification test plates.2. All other te&t.s of weldE as required by the qualification code shall be piex for.med. and a comiplete report of the qualification resLlts shall be made.Part 5. Testing and ngpegt!ion.
: b.       Welds shall             hbe radiographed                 in   conformance with Part     5A of this               specification.
A. RadioqE!a2hiS Inspection.
: c.       Air. pressure test                   of the completed                 tank shall be in       conformance with Part                         5C of this             specification.
I.. One hundred percent of every full penetration weld Joint not specifically exempted by Purchaser in writing shall be radiographed in conformance with Subsection UW-51 of Section VIII of the ASME Boiler and Pressure Vessel Code to demonstrate that proper weld quality is attained.2. When any of the weld as repzresented by radiography contains rejectable defects as specified by UW-51, the weld shall be removed, rewelded and 100 percent radiographed.
: d.       As an alternate                 to the air             pressure test,           a hydr-ostatic test                   may be performed in confo-mance with Part                                         5D of this         specification.
: 3. Each radiograph shall bie made as soon as practicable after the completion of the increment of weld that is to be examined.4. X-ray shall be used, gamma ray is not acceptable.
: e.       A leak         test       of all       welds shall             be performed         in conformance with Part                         5E of this             specification.
: 5. Final acceptance of all radiographs shall be.obtained from the inspector.
: 5.       Defects found at any stage                             of     testing       shall   be.
: 6. Originals of the developed film of radiographs shall be properly identified and made available to the Purchaser-, and after' acceptance of the tank shall become the property of the Purchaser.
repaired         at     that       stage, and all                 tests     shall       be repeated for-the     defective             area.
B. Penetrant Inspection.
: 6.       Responsibil1ty.                   The Fabricator.                 shall     conduct and be fully         responsible               for. the inspection and                       tests     called     for in these         specifications,                   and shall           maintain         cC-Toplete .- eccr-ds of all       tests.             Certified           copies of all               test     and inspection reports       shall         be supplied to the Purchaser..
All finihed welds and the second side of a full penetration weld shall be checked for defects using a liquid penetrant test in conformance with TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 10 Appendix 8 of the ASME Doiler and Pressure Vessel Code and the following.
: 7.       Finish.
: 1. The Fabr-icato.x shall Submit a detailed wr-itten liquid penetrant inspection procedure for approval by the Purchaser.
: a.       All wire brushes, welders'                               hammers or- scrapers used on tank must be of AISI 300 series                                             stainless         steel.
: 2. Liquid Penetrant Acceptance Standards.
When welds are to be ground, aluminum oxide disks shall                                                         be used.       The disks               shall       be new or dressed to remove any trace of non-aluminum grindings, and of a type that                                                   does not leave abrasive         particles             embedded in welds.
: a. All linear indication_-
: b.         nsi         of   t:: nk shall           :e 1:ept clean,             free   of gr-ease,       di-ft.,       etc.
are unacceptable and shall be r-emoved comupletely and xepair welded.b. All non-linear (rounded) indications with any dimension which exceed2 I/,1," wice unacceptable and shall he completely removed and repair welded.3. Rejectable defe.cts shall be xepaired and retested.C. Air-Pressure Test. The alr-pressure test shall be conducted .to demonstrate adequate strength of the tank.1. The tank shall be internally pressur-ized to a pressure of 10 pounds per square inch gage using suitable cover, plates and fittings.2. After- completion of the test, the pressure can be decreased to that specified for performance of the leak test (soap bubble).3. It is the responsibility of the Fabricator for the safe per-formance of this test.D. HydgriostatIc Test (Alternate to Air-Pressure Test).1. Hydrostatic testing shall be performed on the completed tank.2. The hydrostatic test shall consist of placing the tank in a vertical position, andfilling the tank with clean water with a pH between 6. 0 and 7. 0. After 24 hours, all outside surfaces shall be visually inspected for leaks. Any trace of moisture on the outside surfaces must be traced to the sour-ce of the leaks. The leaks must bie repaix-ed and the test repeated.
TRIGA REACTOR TAN]" LINER SPECIFICATIONS PACE t
Water shall not remain in the tank longer, than. 36 hour-s; after the water is removed, all surfaces of the tank shall be wiped dry with clean, lint-free rags.E. Leak Test.1. The leak testing .shall be per-formed on the completed tank assembly.TRIGA REACTOR TANK LINER SPECIFICATIONS
 
!"ACE, 11  
c .       Care r-s)ll               b~e   cx.-rcdEt       d   during         fIb       icatioCn         not to     mar the             inside         surfaces             of the         tank.
'-2. The tanh shall Lbe I.illed wiLh ai. at a pressure of 4 pounds per square inch gaqe. The tank shall he br-aced and supported as requi:ed to TaDItain the dimensional tolerances specified.
: d.       At the           conclusion             of all         work and testing,                         the..
: 3. After- the tank has been pressurized, a soap bubble test shall be applied to all weld regions and regions where a large amount of cold work has been applied to the tank (such as at. the knuckle between the side plates and the bottom).4. The liquid used for testing shall be "Leak-Tec" No. 277-C, a product of American Gas and Chemicals, Inc., P.O. Box 101, Gracie Station, New York, NY 10021, or. an equal product.5. The "Leak-Teo" shall be s.prayed or brushed over all surfaces to be checked and the surfaces shall be carefully examined visually for white foam or live bubbles.6. Any leaks detected by this test shall be repaired, and the test shall be repeated until no leaks ar-e detected.TRIGA REACTOR TANI!,'1 LINEi" SPECFICATI CtS F..... 12}}
tank       shall           be thoroughly                   cleaned           inside         and out             with a suitable             solvent               (Toluene,             acetone,           or others)               to     remove         all grease,           dirt,           grime,           etc.,,       before         packing for                 shipment.
8.-           epcrts.
: a.       Welding Documents:                           Prior       to     fabrication                 of the tank,       the       Contractor                 shall         submit to             the     Purchaser               for     review one copy of                   each of           the     following:                 welding procedure specification;                       qualification                   test       reaults           of     welding procedures;                   welder percformance qualification                                         test         results.
The welding procedure                               specifications                   and welding personnel shall       be qualified                     in     accordance               with the           requirements                   of ASbE Section                   IX.
: b.       Prior-         to     any production                   fabrications; procedures                 for       welding, liquid                     penetrant             inspection,                 x-ray inspection,                   leak testing                   and     cleaning shall                   be submitted to the     Purchaser               for       approval.
: c.       Within 10 days after                           tank is           released for" shipment,               the Fabricator                       shall       submit copies of each of the following               to     the       Purchaser.
(I)       Dimensions of finished                             tank       (5     copies).
(2)         Two copies of certified                               test         reports         of all     material used in the fabrication                                             of this           equipment.
(These are to be available                                     to the Inspector                     upon request during         fabrication.                   )
(3)       Two     certified             copies         of     all       test       and inspection                 reports.
Part 4.             Aluminum Welding.
A.       Code.             All welds shall                     be full           penetration                 welds unless         otherwise                 specified,               and     in     accordance               with Sections VIII       and IX of               the     ASME         Boiler         and     Pressure           Vessel           Code, latest         edition.
B.       Preiaratior,                 of     Joints.
: 1.         Welding             JointS shall                 be prepared               so as to permit complete             fusion             with complete                   Joint       penetr-ation.                     Multipass welding           from both               sides         is     recommended to                   minimize distortion.
TRIGA REACTOR TANK LINER                                 SPECIFICATIONS FTM71     7
: 2. All weld Joint       edges shall be prepared either.                   by machining, sawing, or- grinding with tools                       which leave.. no r-esidue on the joint             faces.
: 3. Surfaces to be welded shall               be clean and free fr-om foreign material for a distance                       of at least     2 inches fr-om the joint           edges.
: 4. Prior to welding, all           Joints   shall   be thoroughly wire brushed Ior- a distance                 of at least       one inch on each side of the joint           to remove aluminurm oxide in the weld region.
Only Type AISI 300 stainless                   steel   wi-re br-ushes shall         be used on this       wor-k.
: 5. Pr-ior to welding, but after             wire brzushlng, all.
Joints       shall     be wiped with methyl alcohol and air-dried'                     to remove any dirt           of foreign material in the weld region.
: 6. After- the weld Joints           have been cleaned, the joints       shall     be handled only with           clean cloth       gloves.
: 7. The joint   edges must not. be placed in contact with any material which could contaminate the surfaces                                 after cleaning.
: 8. The use of welding flux of any kind is                     not per-mitted on this           work.
C.     Methods   and Mechanics         of Welding.
I. Welds shall     be made by the inert-gas               shielded consumable electrode             welding method (nIG) or- the tungsten inert-gas         shielded arc welding pr-ocess (AC-TIG or- DC-TIG).
: 2. The inert   gas used with the MIG pr-ocess shall                     be helium, argon, or- a mixture of these                       gases. The iner-t gas used with the AC-TIG process shall                     be argon.       The inert       gas used with the DC-TIG process shall                     be helium.
: 3. Any inert     gas used shall have a minimum pur-ity of 99.95 percent.             The flow of Inert         gas shall       he sufficient         to*
pr-operly protect           the weld region during welding and coollng.
: 4.     £electicro., of the welding process ahall                 he based on production of the bec:t quality                     welds with a minimum of distor-tion         and residual     stx--:-ss. in the finished         work.
Processes other than specified                     may be used only with the wr-itten consent of the Purchaser.
: 5. When a Joint     requires       more than one pass,           the preceding pass shall             bie cleaned with a stainless               steel     wi-re br-ush prior         to deposition of the nrexct pass.
TRIGA   REACTORl   TANI{ LINER, SPECIFICATIONS PMA C.3
: 6.       When     a   weld   joint     if     welded   frome   both     sides; i.e.,     full       penetration           weldc,     the ,side     welded second (opposite aide) shall                     be gound out to sound metal and liquid penetrant           inspected in           accordance with Part 5 prior-                     to depositing metal on that                         side.
: 7.       When using the TIG welding process, stopping of the arc shall               occur in the Joint                 using a gr-adual reduction of welding current                 to permit the molten weld puddle to 'solidify slowly.           After most of the puddle has solidified,                                 the arc will     be carried             back over the completed weld Joint                           during the final     reduction of the welding current                             to a point where no molten metal is                 observed beneath the arc.                   At this         point the arc will           be broken.
: 8.       No peening         of welds will           be permitted.
D.       Filler'       Wire.
: 1.       Only filler           wire from a special             marked container reserved for               this     work only shall             hie used for- any welding, including tacks or temporaary welds.
: 2.       All filler.         metal     shall       be clean     and dry.
: 3.       All filler           wires used for this             work shall           be stored       in a separate                 area from other filler               materials.             The area shall             be free         of dirt,       gcrease, or other for-eign material.             Access to filler.               wire shall       be permitted only by responsible               personnel supervisiong the fabrication                               of the work.       Care must be used to                     assure that       no unapproved wire is used on any aluminum work.                             The type of wire to be used is specified           in Part         3, paragr-aph E.1 of this                 specification.
The wire shall                 be smooth, clean and free                   of surface         defects.
E.       Visual Inspection shall                       be made during and after each weld pass.                     Any defects         detected shall           be removed and repairs         made before deposition of the next weld pass.
F.       Qualification             of Welding P:r-ocedures and Welders.
: 1.       The welding proceduxre(s) and welders shall                                 be qualified           in accor.'a-nce with the requIrements of the ASIIE Boiler and Pres-sure VeEsel Code, Section IX latest                                           edition, with the following addltional                             r-equirements:
: a.     Aluminum alloy uoed for. the qualification                                 test plates       shall       be of the same thickness, alloy                         and temper as used in the item to be fabricated.
: b.     The test         plates       shall     receive 100 percent radiographic inspection                       of the welds and shall                 meet the I-equir-ements of UW-5!                   fo £'ecticn VII           of the AS)IE Boiler-and Pressure Vessel Code,                     Fepair welding is             not permitted.
TRIGA       R.7.ACTO=R   TAN,     L1-EI-Z _P'EC.IPICATIONS q 17.";:]
: c.     The test       plates       shall       be given a liquid penetrant             inspection           of the welds and shall                   meet the requirements of Part                       5, paragraph B.                 Any evidence of cracking or. excessive pofosity                             shall       be cause for. re-testing.
: d.     In addit-ion to the groove weld qualification test       plate(s)         for p(erDfIrnoricne iual.ification                     required by Section IX of th ASME Code, weldero shall                                       qualify       on a fillet weld test           plate     in accordance with the requirements of Section IX.
: e.     At least       one weld stop and start                     per pass shall be made         near     the   center.       of   procedure         and   welder       qualification test       plates.
: 2.     All   other       te&t.s of       weldE as       required       by the qualification               code     shall       be   piex for.med.       and   a   comiplete         report of the qualification                     resLlts       shall       be made.
Part       5.       Testing and             ngpegt!ion.
A.       RadioqE!a2hiS           Inspection.
I.. One hundred percent of every full                             penetration weld Joint             not specifically               exempted by Purchaser in writing shall         be radiographed in conformance with Subsection UW-51 of Section VIII of the ASME Boiler and Pressure Vessel Code to demonstrate that                 proper weld quality                   is attained.
: 2.     When any of the weld as repzresented by radiography contains rejectable                               defects       as specified             by UW-51, the weld shall                   be removed, rewelded and 100 percent radiographed.
: 3.     Each radiograph shall                     bie made as soon as practicable             after     the completion             of the increment of weld that       is   to     be examined.
: 4.     X-ray     shall       be used,       gamma ray is           not acceptable.
: 5.     Final acceptance               of all       radiographs         shall       be
.obtained from the inspector.
: 6.     Originals         of the developed film of radiographs shall         be properly identified                     and made available               to the Purchaser-, and after'                   acceptance of the tank shall                         become the property of the Purchaser.
B.       Penetrant Inspection.                     All finihed           welds and the second side             of a full         penetration           weld shall         be checked for defects         using a liquid               penetrant         test     in conformance with TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 10
 
Appendix 8 of the ASME Doiler                               and Pressure             Vessel   Code and the following.
: 1.     The Fabr-icato.x             shall       Submit a detailed               wr-itten liquid       penetrant         inspection             procedure for approval                     by the Purchaser.
: 2.     Liquid       Penetrant Acceptance                       Standards.
: a.     All linear           indication_- are unacceptable                           and shall       be r-emoved comupletely and xepair welded.
: b.     All non-linear (rounded) indications                                   with any dimension which exceed2 I/,1," wice unacceptable                                           and shall       he completely removed and repair                               welded.
: 3.     Rejectable defe.cts                   shall       be xepaired         and retested.
C.     Air-Pressure Test.                       The alr-pressure               test     shall     be conducted .to demonstrate adequate strength                                           of the tank.
: 1.     The tank shall               be internally               pressur-ized to a pressure of 10 pounds per                         square inch               gage using suitable cover, plates             and fittings.
: 2.     After- completion of the                         test,     the pressure can be decreased to that                 specified           for performance of the leak test (soap bubble).
: 3.     It   is   the responsibility                     of the Fabricator             for the safe           per-formance of this                   test.
D.       HydgriostatIc Test               (Alternate to               Air-Pressure         Test).
: 1.     Hydrostatic           testing           shall       be performed         on the completed tank.
: 2.     The hydrostatic                 test       shall       consist     of placing the tank in a vertical                   position,             andfilling             the tank with clean water with a pH between 6. 0 and 7. 0.                                       After 24 hours, all outside         surfaces         shall       be visually               inspected for leaks.                   Any trace       of moisture on the outside                           surfaces         must be traced to the sour-ce of the leaks.                         The leaks must bie repaix-ed and the test     repeated.             Water shall             not remain in the tank longer, than. 36 hour-s; after                   the water is               removed, all           surfaces       of the tank shall               be wiped dry with clean, lint-free                                 rags.
E.       Leak Test.
: 1.     The leak testing                 . shall       be per-formed           on the completed tank assembly.
TRIGA REACTOR TANK LINER SPECIFICATIONS
                                                      !"ACE, 11
: 2.     The     tanh       shall           Lbe     I.illed       wiLh       ai.       at   a   pressure of     4   pounds         per     square         inch         gaqe.           The tank             shall       he     br-aced and     supported             as   requi:ed             to     TaDItain           the       dimensional tolerances             specified.
: 3.     After-       the     tank         has       been     pressurized,                 a   soap bubble test               shall be           applied to all weld regions                                       and regions where       a   large       amount         of     cold       work       has     been         applied           to     the tank       (such       as at. the knuckle between the side                                               plates         and the bottom).
: 4.     The liquid               used for testing shall                                 be "Leak-Tec" No. 277-C, a product                         of American Gas and Chemicals, Inc.,
P.O. Box 101, Gracie                         Station,             New York, NY 10021,                           or. an equal product.
: 5.     The "Leak-Teo"                     shall         be s.prayed             or brushed over all     surfaces           to     be checked                 and       the     surfaces             shall       be carefully             examined visually                       for white foam or                         live     bubbles.
: 6.     Any leaks             detected               by this         test       shall       be repaired,             and the         test       shall         be repeated                 until         no leaks           ar-e detected.
TRIGA REACTOR TANI!,'1 LINEi"                             SPECFICATI CtS F.....       12}}

Latest revision as of 16:01, 10 March 2020

Response to Question 1 of the Referenced RAI
ML11250A172
Person / Time
Site: U.S. Geological Survey
Issue date: 08/30/2011
From: Timothy Debey
US Dept of Interior, Geological Survey (USGS)
To:
Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML11250A172 (17)
v • d • e


Text

-USGS science for a changingworld Department of the Interior US Geological Survey PO Box 25046 MS 974 Denver, CO 80225-0046 August 30, 2011 U.S. Nuclear Regulatory Commission Document Control Desk Washington, DC 20555

Reference:

U.S. Geological Survey TRIGA Reactor (GSTR), Docket 50-274, License R-1 13 Request for Additional Information (RAI) dated September 29, 2010

Subject:

Response to Question 1 of the Referenced RAI Mr. Wertz:

Question 1: The ISG requires the NRC staff to review significant changes to the facility, including those done in accordance with the provisions of Title 10 of the Code of Federal Regulations Section (10 CFR)

Section 50.59. In 1988, changes to the GSTR were made which involved the installation of a new reactor tank liner. The details of this change are not provided in the GSTR Safety Analysis Report (SAR). As such, please provide a description of the new tank liner, the applicable design and construction criteria, and any associated additional instrumentation or equipment added as a result of the new tank liner. In addition, please describe any analyses of accidents and malfunctions associated with the new tank liner.

Response: Twenty three years ago, in 1988, corrosion and the resultant water leakage in the original, aluminum reactor tank was resolved by installing a tank liner inside the leaking tank. The tank liner has a slightly (4") smaller diameter than the original tank so it could be easily slipped into place. The tank liner is constructed of 6061-T6 aluminum with an overall height of 25' 3" and with an outer diameter of 7' 7.25". The bottom of the tank liner is supported by twelve ribs that are welded to the outer surface of the liner. These twelve ribs are welded to the liner in a spoke pattern, at a 300 spacing. The ribs are 4" tall, 1" thick, and 32" long. The floor of the liner is one inch thick, and the wall thickness varies from 3/8" near the bottom to 1/4" at 90.375" up from the bottom.

The reactor core structure is supported by a triangular base. The base connects to the floor of the tank liner at three pads that are located 30.625" from the center and separated from each other by 1200. These pads are supported by the ribs on the underside of the tank, with each pad centered directly over a rib.

The pads are 4" wide, 8.5" long, and 1" thick. The triangular base is connected to the pads through adjusting screws that allow for the base to be leveled manually. The triangular shape is reinforced by crossing support beams. The reactor core structure sits on the crossing support beams of the triangular base and is connected via nuts and bolts.

Design and Construction Criteria The ASME pressure vessel code was used as the basis for the reasonable, safe and economical design of the tank. The design included seismic, strength and thermal calculations for the mechanical and structural integrity of the tank liner and lifting lugs.

Pressure: Int:10.83 PSI EXT: 1.184 PSI Temp: Max: 150 0 F Min: 50 0 F Liquid Level: Full of water Corrosion Allowance: None Joint Efficiency: 1.0 (100% X-Ray)

Specific Gravity of Contents : 1.0 (Water)

Seismic: PER API 650, APP'E' , Zone 1 A copy of the design specifications is provided as Attachment 1.

Added instrumentation or Equipment Because of Change The only equipment that was added because of the change was a "pump tube" located at the liner's edge in the SE quadrant of the tank liner. This tube is an aluminum tube, 6" diameter at the top and 3" diameter for the lower 5 feet. This tube penetrates the bottom of the tank liner so that access can be gained into the bottom annulus between the original tank and the tank liner. This access is needed to check the annulus for water accumulation and to allow removal of any accumulated water. An eductor pump system was purchased to fit in the pump tube for the removal of accumulated water. The pump is only located in the tube when water is being removed; otherwise the pump tube is empty. A radiation shield plug is located at the top of the pump tube to prevent radiation streaming into accessible locations.

The pump tube is checked regularly, when the reactor is shutdown, for water accumulation.

Accident and/or Malfunction Analyses A copy of the design calculations for the tank liner is attached as Attachment 2. These accident/malfunction calculations include static and dynamic pressures that could result from water pressure, lifting and placement, and a design basis (0.2 G force) earthquake.

Additional Preliminary Responses Based on Information Received from the Colorado School of Mines:

Question 8. The technical parameters of the GSTR are being analyzed using the MCNP version 5 and RELAP version 5, mod 3.3. These analyses are being performed using the Oregon State University relicensing work as a starting point for the methodology. The code results will be benchmarked to the GSTR operating data. After the existing core model is finalized, the limiting core configuration will be modeled and analyzed. These models are being worked on and we expect to have final neutronic and thermal hydraulic results by October 31, 2011.

Question 9. We have a limiting core configuration determined, which will include a number of new 12 weight% fuel elements in the center of the core. However, since our neutronic and thermal hydraulic models are not completed, we do not have control rod worths or excess reactivities calculated for all configurations. Again, we expect to have these results by October 31, 2011.

Question 10. The fuel and moderator temperatures that are used are 293 K for low power operations and 600 K for full power operations. The void and power coefficients will be determined by October 31, 2011.

Question 12. The DNBR analysis will be done using RELAP version 5, mod 3.3. The model used for the GSTR was received from the Oregon State University relicensing effort and has been adapted for the GSTR conditions. These results will be available by October 31, 2011.

Question 15.1 The power density values given in our original license renewal submission are being recalculated with the MCNP version 5 model. Preliminary MCNP results are showing power peaks around 17 kW per element in the existing core. The limiting core will obviously have higher values. We expect that the peak power per element will stay below 22 kW for all core configurations. These results will be available by October 31, 2011.

Sincerely, C

Tim DeBey Qý07---

USGS Reactor Supervisor I declare under penalty of perjury that the foregoing is true and correct.

Executed on 8/30/11 : TRIGA Reactor Aluminum Tank Liner Specifications : Design Calculations for United States Geological Survey 1MW Mark I TRIGA Reactor -

Tank Liner Copy to:

Betty Adrian, Reactor Administrator, MS 975 USGS Reactor Operations Committee

TRIGA Reactor Aluminum Tank Liner Specifications TRIGA REACTOR ALUMINUM TANK LINER SPECIFICATIONS FOR UNITED STATES GEOLOGICAL SURVEY FEDERAL CENTER 6TH & KIPLING LAKEWOOD, CO BY GILLAN'S ENGINEERING, INC.

5126 W 38TH AVE DENVER, CO 80212 (303) 480-0471 (revised original tank specification) 9-25-87

Part 1. General A. Definitions. Whenever used in any part Of this specification, the following shall have the respective meanings set forth below:

1. Purchaser shall mearn an authorized representative of the organization issuing the contfact for the work contained herein.
2. Fabricator shall mean the successful bidder for the work, material, and equipment included under this specification.
3. Ins2ector shall mean an authorized representative of the Purchaser.

B. Drawings arid Sg ecifications. The Purchaser- vill furnish to the Fabricator, free of charge, such numbers of drawings and specifications reasonably necessary for the execution of the work. The drawings accompany the specifications and they are by this reference incorporated into and shall become a part of the specifications.

C. Tests and Inspection. Where tests are required by the specifications, arrangements for- the conduction of such tests shall be made and all expenses in connection therewith shall be borne by the Fabricator. Such tests and inspections shall be made by an independently qualified inspection firm or agency approved by the Purchaser-. All tests shall be witnessed by the Purchaser. The Fabricator shall review, certify and submit to Purchaser for r eview all inspection reports, radiographs and material certifications. It shall be the responsibility of the fabricator to notify the Purchaser five (5) working days in advance so witnessing of tests can be arranged without delaying the work.

D. QualitY of Work and Materials. All materials, parts and equipment furnished by the Fabricator shall be new, high grade, and free from defects and imperfections. Workmanship shall be in accord with the highest standard practices. Both materials and workkmanship throuyhout shall be at all times subject to the approval of the Inspectors.

E. Reference Standa ds and Specificaticns. The following listed standards and i-ipecifications, as applicable to the work involved, forrm a part of this specification.

American Society of Mechanical Engineers (ASME)

TRIGA REACTOR TAN1{ T'.NER £'P'ECTFICATIONS il C-1 I

Par-to of Section 1IfMaterials Specifications, Part B-

-Nonferrous Materials, of the 1986 edition of the ASME Boiler and Pressure Vessel Code as follows:

ASME SB-209 Specification for. Aluminum--Alloy Sheet and Plates ASME SB-211 Specification for Aluminum--Alloy Bars, Rods and Wire ASME SB-221 Specification for Aluminum- -Alloy Extruded Bars, Rods and Shapes ASME SB-241 Specification for Aluminum--Alloy Seamless Pipe and Seamless Extruded Pipe AMSE SB-211 Specification for Aluminum -- Alloy Bolts Parts of Section II Materials Specifications:

Part C Welding Rods, Electrodes, and Filler Metals, of the 1986 edition of the ASnE Boiler and Pressure Vessel Code ASME SFA-5.10 Specification for Aluminum and Aluminum Alloy Welding Rods, Class ER 4043 Part of Section V, Nondestructive Examination, Subsection A of the 1986 edition of the ASNE Boiler- and Pressure Vessel Code as follows:

Article 6 Liquid Penetrant Examination Parts of Section V, Nondestructive Examination, Subsection B, for the 1986 edition of the ASME Boiler. and Pressure Vessel Code as follows:

Article 24 Liquid Penetrant Standards Parts of Section III, Division 1, of the 1986 edition of the ASME Boiler and Pressure Vessel Code as follows:

Subsection NB Acceptance Standards Para. NB-5300 Subpara NB-5320 Radiographic Acceptance Standards Subpara NB-5350 Liquid Penetrant Parts of Section IX, Welding & Br.azing Qualifications, of the 1986 edition of the ASME Boiler. and TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 2

Pressure Vessel Code as followoi Part QW Welding Aerospace Material Specifications (AMS) as follows:

AMS 2568A Hard Coating Treatment--Aluminum Alloys F. Packaging aýnd Shi- 2 rent.

1. All items shall be thoroughly cleaned of all grease, water, and other foreign matter.
2. All fabricated items shall be packed for shipment and shall conform to standards of packaging requirements for the carriers. No stacking of items will be permitted where metal surfaces can come in contact with other metal surfaces.
3. Seal off the open end of the tank with a wood frame, dust tight cover. A minimum of 3/4 inch plywood shall be used over opening.
4. The tank shall be loaded in a secure and safe manner. Extra bracing and special handling shall be supplied by the Fabricator' as necessary to prevent deformation of the tank in shipment.. All aluminum surfaces shall be protected from direct contact with bracing or crating and the elements during shipping cr storagce.
5. Fabricator will prepare all items for shipment and load aboard truck carrier selected by Purchaser.

Pert 2. SaOLe.

The work covered by this specification consists of furnishing all labor, materials, appliances, and equipment, and performing all coperations in connection with the fabrication, assembly, testing, bracing, shoring and loading for shipment of one aluminum reactor tank, complete, including special test fittings and cover plates, in strict accordance with this specification and the applicable drawings and subject to the terms and conditions of the contract.

Pert 3. Aluminum Tank.

TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 3

A. Codes. The fabrication, inspection, testing, handling, and installation shall be in strict accordance with this specification and with Section VIII and IX of the latest edition of the ASME Boiler and Pressure Vessel Code; however, a Code Stamp is not required. In the event of conflict between this specification and the codes, the Fabr.icator' shall notify the Purchaser and secure a written clarification before proceeding with the work.

B. Alternate Quotations and Deviations. The Fabricator may quote prices based on alternate construction methods when deviations from this constyruction will improve design, delivery, or decrease cost. List all such deviations and submit to the Purchaser in writing. Written approval will be required prior to putting changes into effect. If no exceptions are taken, it will be assumed that the pr-oposal is in stryict compliance with this specification.

C. DrawingE Ly Fabricator. The Fabricator shall submit to the Purchaser one reproducible tracing of his final fabrication drawings and any applicable standard. These drawings and standards shall locate plate Joints in plan and elevations, show construction details, such as all weld joint design, welding procedures and processes to be used, lifting lugs, slings, bracing jigs, fixtures, gussets, other reinforcements, and fabrication tolerances. One copy will be returned to the Fabricator stamped for fabrication as noted.

Fabricator shall not proceed until this stamped drawing is received unless written instr-uctions are given to the contrary. Shop drawings stamped by Purchaser. does not relieve the Fabricator of the responsibility for, fabrication and testing of the tank in accordance with the specification.

D. Functional Re uirernents and Basi.s for Design.

1. The Tank is to be a leak-tight container, for.

demineralized water, filled to 3 inches below the top channel. The tank plate thiulki-esses specified on the Purchaser.'s drawings are minirmum allowable. The Fabr-icator.

shall be responsible foy- desicnu of tank bracing required to suppor-t the tank during fabrication, shipping and handling, all in accordance with the basis lfor design.

2. The Following Re uire ments are the basis for-design of the aluminum tank using Part UNF of Section VIII of the ASME Unfired Pressure Vessel Code, latest edition.
a. Oterjatinq PreEsure: 24.5 foot static head of water.
  • b. ~Pec-ic Tign r.:-atures. 150 degrees F (maximum).

TRIGA REACTOR TANK LINER SPECIFICATIONS

c. No Bracing, IntLe.L-al oi- External.
d. Shell Thickness shall bie at least 1/4 inch.

E. Materiale.

1. Tank material shall be one of the following aluminum alloys: 5052-H32, 6061-T4 or 5154-H32, and shall conform to Specification SB-209 from the ASME Pressure Vessel Code, Section VIII, latest edition. Other- materials may be considered, but may be used only if approved in writing *by.

Purchaser. The first choice shall be 5052-H32 alloy.

Welding filler- wire shall be as follows (or equivalent approved by Purchaser): on the 5052 alloy use AWS-ASTI E 5154; on the 6061 alloy use AWS-ASTM E 4043; on the 5154 alloy, use AWS-ASTM E 5554; on combinations of 5000 series to 6061 alloy use AWS-ASTM E 4043.

2. Bolts that weld to tank bottom shall be 6061-T6 aluminum alloy and hayrdcoat anodized per. AMS-2468, except anodize shall be clear..
3. Aluminum Angle (Alcoa die 4892) shall be of alloy 6061-T6, or. equivalent as a.approved by the Purchaser.

F. Shop Fabrication.

1. Handling nd ForminQg. With the following exceptions, the aluminum used in the work is to be handled and formed in a normal manner.
a. Aluminum to be used for the tank shall be stored in a clean place, free from dir.t, grease, etc.
b. Care shall be taken not to nick, scratch, or, otherwise mar aluminum surfaces.
c. All rolls and machine tools used in for-ming. the aluminum parts shall lie clean arnd free from grease, dirt, shavings, turnings, etc.
d. Tolerances as specified on drawings shall bie maintained. Deviations shall tie subject to written approval by the Purchaser..
e. Suitable lifting lugs, slings and handling equipment shall be provided by the Fabricator, either- as shown on the Purtchaser's drawings or in other locations where lifting of the tank can be accomplished during fabrication and shipping.
2. Special Creat.rutic, Features shall be complied with in fabrication, testing,. and preparation for shipping and field installation.

TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 5

a. Round-off all sharp corners to 1/16" r-adius minimum.
b. Fabr-icato- shall Ic-cate all shell girth and longitudinal seams on shop drawificqS and identify by number-each plate or shell course.
c. The tank E-hall be cormpletely fabricated and tested in the shop prior to Ehipment.
3. Welding. All welds shall be full penetration welds unless otherwise specified, and shall be in conformance with this specification, Part 4.

.4. Testing Sequence shall be as follows:

a. Penetrant inspection of all welde shall be in conformance with Part 5B of this specification.
b. Welds shall hbe radiographed in conformance with Part 5A of this specification.
c. Air. pressure test of the completed tank shall be in conformance with Part 5C of this specification.
d. As an alternate to the air pressure test, a hydr-ostatic test may be performed in confo-mance with Part 5D of this specification.
e. A leak test of all welds shall be performed in conformance with Part 5E of this specification.
5. Defects found at any stage of testing shall be.

repaired at that stage, and all tests shall be repeated for-the defective area.

6. Responsibil1ty. The Fabricator. shall conduct and be fully responsible for. the inspection and tests called for in these specifications, and shall maintain cC-Toplete .- eccr-ds of all tests. Certified copies of all test and inspection reports shall be supplied to the Purchaser..
7. Finish.
a. All wire brushes, welders' hammers or- scrapers used on tank must be of AISI 300 series stainless steel.

When welds are to be ground, aluminum oxide disks shall be used. The disks shall be new or dressed to remove any trace of non-aluminum grindings, and of a type that does not leave abrasive particles embedded in welds.

b. nsi of t:: nk shall :e 1:ept clean, free of gr-ease, di-ft., etc.

TRIGA REACTOR TAN]" LINER SPECIFICATIONS PACE t

c . Care r-s)ll b~e cx.-rcdEt d during fIb icatioCn not to mar the inside surfaces of the tank.

d. At the conclusion of all work and testing, the..

tank shall be thoroughly cleaned inside and out with a suitable solvent (Toluene, acetone, or others) to remove all grease, dirt, grime, etc.,, before packing for shipment.

8.- epcrts.

a. Welding Documents: Prior to fabrication of the tank, the Contractor shall submit to the Purchaser for review one copy of each of the following: welding procedure specification; qualification test reaults of welding procedures; welder percformance qualification test results.

The welding procedure specifications and welding personnel shall be qualified in accordance with the requirements of ASbE Section IX.

b. Prior- to any production fabrications; procedures for welding, liquid penetrant inspection, x-ray inspection, leak testing and cleaning shall be submitted to the Purchaser for approval.
c. Within 10 days after tank is released for" shipment, the Fabricator shall submit copies of each of the following to the Purchaser.

(I) Dimensions of finished tank (5 copies).

(2) Two copies of certified test reports of all material used in the fabrication of this equipment.

(These are to be available to the Inspector upon request during fabrication. )

(3) Two certified copies of all test and inspection reports.

Part 4. Aluminum Welding.

A. Code. All welds shall be full penetration welds unless otherwise specified, and in accordance with Sections VIII and IX of the ASME Boiler and Pressure Vessel Code, latest edition.

B. Preiaratior, of Joints.

1. Welding JointS shall be prepared so as to permit complete fusion with complete Joint penetr-ation. Multipass welding from both sides is recommended to minimize distortion.

TRIGA REACTOR TANK LINER SPECIFICATIONS FTM71 7

2. All weld Joint edges shall be prepared either. by machining, sawing, or- grinding with tools which leave.. no r-esidue on the joint faces.
3. Surfaces to be welded shall be clean and free fr-om foreign material for a distance of at least 2 inches fr-om the joint edges.
4. Prior to welding, all Joints shall be thoroughly wire brushed Ior- a distance of at least one inch on each side of the joint to remove aluminurm oxide in the weld region.

Only Type AISI 300 stainless steel wi-re br-ushes shall be used on this wor-k.

5. Pr-ior to welding, but after wire brzushlng, all.

Joints shall be wiped with methyl alcohol and air-dried' to remove any dirt of foreign material in the weld region.

6. After- the weld Joints have been cleaned, the joints shall be handled only with clean cloth gloves.
7. The joint edges must not. be placed in contact with any material which could contaminate the surfaces after cleaning.
8. The use of welding flux of any kind is not per-mitted on this work.

C. Methods and Mechanics of Welding.

I. Welds shall be made by the inert-gas shielded consumable electrode welding method (nIG) or- the tungsten inert-gas shielded arc welding pr-ocess (AC-TIG or- DC-TIG).

2. The inert gas used with the MIG pr-ocess shall be helium, argon, or- a mixture of these gases. The iner-t gas used with the AC-TIG process shall be argon. The inert gas used with the DC-TIG process shall be helium.
3. Any inert gas used shall have a minimum pur-ity of 99.95 percent. The flow of Inert gas shall he sufficient to*

pr-operly protect the weld region during welding and coollng.

4. £electicro., of the welding process ahall he based on production of the bec:t quality welds with a minimum of distor-tion and residual stx--:-ss. in the finished work.

Processes other than specified may be used only with the wr-itten consent of the Purchaser.

5. When a Joint requires more than one pass, the preceding pass shall bie cleaned with a stainless steel wi-re br-ush prior to deposition of the nrexct pass.

TRIGA REACTORl TANI{ LINER, SPECIFICATIONS PMA C.3

6. When a weld joint if welded frome both sides; i.e., full penetration weldc, the ,side welded second (opposite aide) shall be gound out to sound metal and liquid penetrant inspected in accordance with Part 5 prior- to depositing metal on that side.
7. When using the TIG welding process, stopping of the arc shall occur in the Joint using a gr-adual reduction of welding current to permit the molten weld puddle to 'solidify slowly. After most of the puddle has solidified, the arc will be carried back over the completed weld Joint during the final reduction of the welding current to a point where no molten metal is observed beneath the arc. At this point the arc will be broken.
8. No peening of welds will be permitted.

D. Filler' Wire.

1. Only filler wire from a special marked container reserved for this work only shall hie used for- any welding, including tacks or temporaary welds.
2. All filler. metal shall be clean and dry.
3. All filler wires used for this work shall be stored in a separate area from other filler materials. The area shall be free of dirt, gcrease, or other for-eign material. Access to filler. wire shall be permitted only by responsible personnel supervisiong the fabrication of the work. Care must be used to assure that no unapproved wire is used on any aluminum work. The type of wire to be used is specified in Part 3, paragr-aph E.1 of this specification.

The wire shall be smooth, clean and free of surface defects.

E. Visual Inspection shall be made during and after each weld pass. Any defects detected shall be removed and repairs made before deposition of the next weld pass.

F. Qualification of Welding P:r-ocedures and Welders.

1. The welding proceduxre(s) and welders shall be qualified in accor.'a-nce with the requIrements of the ASIIE Boiler and Pres-sure VeEsel Code,Section IX latest edition, with the following addltional r-equirements:
a. Aluminum alloy uoed for. the qualification test plates shall be of the same thickness, alloy and temper as used in the item to be fabricated.
b. The test plates shall receive 100 percent radiographic inspection of the welds and shall meet the I-equir-ements of UW-5! fo £'ecticn VII of the AS)IE Boiler-and Pressure Vessel Code, Fepair welding is not permitted.

TRIGA R.7.ACTO=R TAN, L1-EI-Z _P'EC.IPICATIONS q 17.";:]

c. The test plates shall be given a liquid penetrant inspection of the welds and shall meet the requirements of Part 5, paragraph B. Any evidence of cracking or. excessive pofosity shall be cause for. re-testing.
d. In addit-ion to the groove weld qualification test plate(s) for p(erDfIrnoricne iual.ification required by Section IX of th ASME Code, weldero shall qualify on a fillet weld test plate in accordance with the requirements of Section IX.
e. At least one weld stop and start per pass shall be made near the center. of procedure and welder qualification test plates.
2. All other te&t.s of weldE as required by the qualification code shall be piex for.med. and a comiplete report of the qualification resLlts shall be made.

Part 5. Testing and ngpegt!ion.

A. RadioqE!a2hiS Inspection.

I.. One hundred percent of every full penetration weld Joint not specifically exempted by Purchaser in writing shall be radiographed in conformance with Subsection UW-51 of Section VIII of the ASME Boiler and Pressure Vessel Code to demonstrate that proper weld quality is attained.

2. When any of the weld as repzresented by radiography contains rejectable defects as specified by UW-51, the weld shall be removed, rewelded and 100 percent radiographed.
3. Each radiograph shall bie made as soon as practicable after the completion of the increment of weld that is to be examined.
4. X-ray shall be used, gamma ray is not acceptable.
5. Final acceptance of all radiographs shall be

.obtained from the inspector.

6. Originals of the developed film of radiographs shall be properly identified and made available to the Purchaser-, and after' acceptance of the tank shall become the property of the Purchaser.

B. Penetrant Inspection. All finihed welds and the second side of a full penetration weld shall be checked for defects using a liquid penetrant test in conformance with TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 10

Appendix 8 of the ASME Doiler and Pressure Vessel Code and the following.

1. The Fabr-icato.x shall Submit a detailed wr-itten liquid penetrant inspection procedure for approval by the Purchaser.
2. Liquid Penetrant Acceptance Standards.
a. All linear indication_- are unacceptable and shall be r-emoved comupletely and xepair welded.
b. All non-linear (rounded) indications with any dimension which exceed2 I/,1," wice unacceptable and shall he completely removed and repair welded.
3. Rejectable defe.cts shall be xepaired and retested.

C. Air-Pressure Test. The alr-pressure test shall be conducted .to demonstrate adequate strength of the tank.

1. The tank shall be internally pressur-ized to a pressure of 10 pounds per square inch gage using suitable cover, plates and fittings.
2. After- completion of the test, the pressure can be decreased to that specified for performance of the leak test (soap bubble).
3. It is the responsibility of the Fabricator for the safe per-formance of this test.

D. HydgriostatIc Test (Alternate to Air-Pressure Test).

1. Hydrostatic testing shall be performed on the completed tank.
2. The hydrostatic test shall consist of placing the tank in a vertical position, andfilling the tank with clean water with a pH between 6. 0 and 7. 0. After 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, all outside surfaces shall be visually inspected for leaks. Any trace of moisture on the outside surfaces must be traced to the sour-ce of the leaks. The leaks must bie repaix-ed and the test repeated. Water shall not remain in the tank longer, than. 36 hour-s; after the water is removed, all surfaces of the tank shall be wiped dry with clean, lint-free rags.

E. Leak Test.

1. The leak testing . shall be per-formed on the completed tank assembly.

TRIGA REACTOR TANK LINER SPECIFICATIONS

!"ACE, 11

2. The tanh shall Lbe I.illed wiLh ai. at a pressure of 4 pounds per square inch gaqe. The tank shall he br-aced and supported as requi:ed to TaDItain the dimensional tolerances specified.
3. After- the tank has been pressurized, a soap bubble test shall be applied to all weld regions and regions where a large amount of cold work has been applied to the tank (such as at. the knuckle between the side plates and the bottom).
4. The liquid used for testing shall be "Leak-Tec" No. 277-C, a product of American Gas and Chemicals, Inc.,

P.O. Box 101, Gracie Station, New York, NY 10021, or. an equal product.

5. The "Leak-Teo" shall be s.prayed or brushed over all surfaces to be checked and the surfaces shall be carefully examined visually for white foam or live bubbles.
6. Any leaks detected by this test shall be repaired, and the test shall be repeated until no leaks ar-e detected.

TRIGA REACTOR TANI!,'1 LINEi" SPECFICATI CtS F..... 12

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