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Purdue University - Request for Additional Information Regarding the Purdue University Reactor License Renewal Application (TAC No. ME1594), Responses to Letter Dated August 29, 2014 (ML14115A221). Part 5 of 5
	ML15210A288
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Site:	Purdue University
Issue date:	07/24/2015
From:	Bean R S; Purdue University
To:	Montgomery C K; Office of Nuclear Reactor Regulation
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APPENDIX 2: NATCON INFORMATIONHot Channel Factors in the NATCON Code Version 1.0The NATOON code version 1.0 [Ref. ANL/RERTR/TM-12] uses three hot channel factors (FQ,FW, FH). Using the source code and documentation, the factor FH used in NATCON is found tobe the same as the factor FNUSLT used by E. E. Feldman. Table 1 shows the tolerances anduncertainties included in each of the six hot channel factors used by E. E. Feldman. Thecorrespondence between the NATCON hot channel factors and E. E. Feldman's six hot channelfactors is as follows.Feldman's Hot Channel FactorNC CNInuVariableSystem-wide Factors:FFLOW a factor to account for the uncertainty in total reactorflowFPOWER a factor to account for the uncertainty in total reactorpowerFNUSLT a factor to account for the uncertainty in Nu numbercorrelationFW (approximately)FQFHLocal Factors:FBULK a hot channel factor for local bulk coolanttemperature riseFFILM a hot channel factor for local temperature rise acrossthe coolant filmFFLUX a hot channel factor for local heat flux from claddingsurfaceFBULK (new input)FFILM (new input)FFLUX (new input)Hot Channel Factors in the NATCON Code Version 2.0PUR-1 SARAppendix 2-1PUR- SARAppndix2-1Rev 2, July 23, 2015 Sections 2.1 and 2.2 develop, for laminar natural convection, two thermal-hydraulic relationshipsthat are used in section 2.3 to obtain formulas for the hot channel factors from user-suppliedmanufacturing tolerances and measurement uncertainties. The results of section 2.3 aresummarized here for convenience. The first three are local/random hot channel factors, and thelast three are system-wide. An example of the use of these hot channel factors is given insection 4, with NATCON running instructions in section 3, and the new input description insection 5.FBULK- 1 +j{(1 + u)2a+ (1+ u2)2+-r-:U1 +u62FBULK is higher (conservative) if the temperature dependence of water viscosity is ignored.FFILM = 11u12+/-+u22+/-+u32 +u42+/-+u52FFLUX -- 12 +u22+/-+u32 +u4FQ = 1 +u-FW = 1 + u8FH = 1 +- u9whereul= Fractional uncertainty in neiitronics calculation of power in a plateu2= Fractional uncertainty in U-235 mass per plate =Am/_Mu3 Fractional uncertainty in local (at an axial position) fuel meat thicknessu4= Fractional uncertainty in U-235 local (at an axial position) homogeneityu5 = Fractional uncertainty in coolant channel thickness = (tnc -thc) / tnu6 = Fractional uncertainty in flow distribution among channelsu7= Fractional uncertainty in reactor power measurementu8= Fractional uncertainty in flow due to uncertainty in friction factorUg = Fractional uncertainty in convective heat transfer coefficient, or in the Nu numbercorrelationM = Nominal mass of U-235 per plate, gramAm = Tolerance allowed in U-235 mass per plate, gramPUR-1 SARAppendix 2-2PUR- SARAppndix2-2Rev 2, July 23, 2015 The code obtains, for an input nominal reactor power CPWR, a thermal-hydraulic solution usingthe three systematic hot channel factors FW, EQ and FH. If the user-input reactor power is zero,then the code itself chooses the nominal power from a series of power levels (10 kW, 100 kW,200 kW, and so on increasing in steps of 100 kW). This thermal-hydraulic calculation is done fora hot plate power of CPWR*FQ*(Radial power peaking factor RPEAK)/(Total number of fuelplates in standard and control assemblies). Also, the frictional resistance to flow is multiplied byFW2, and the convective heat transfer coefficient found for laminar flow in a rectangular channelis divided by FH. The random hot channel factors FBULK, FFILM and FFLUX are not used inthis solution.Having obtained the above solution, the random hot channel factors FBULK, FFILM and FFLUXare applied to the temperatures obtained, using the following equations. The temperaturescalculated with all six hot channel factors are printed after the above solution. The onset ofnucleate boiling ratio, ONBR, is computed using the temperatures with all six hot channelfactors applied (using the equation below). If the user-input nominal power is zero, then the lastnominal power for which the code prints a solution is that at which the ONBR is 1.0.Ti,6hcf = To + (Ti- To)*FBULKTwalj,i,6hcf = Ti,6hcf + (TwaiiUi- Ti)*FFILMTmax,j,6hcf = TwaII,i,6hcf + (Tmax~i -TwaIlU)*FFLUXwhereTo = Bulk water temperature at the coolant channel inlet, i.e., the pool temperature,= Bulk water temperature in node i of the channel with only systematic hotchannel factors applied, 00Twai,i Cladding surface temperature in node i with only systematic hot channel factorsapplied, °CTmax,i =Fuel meat centerline temperature in node i with only systematic hot channelfactors applied, °CTI,6hof = Bulk water temperature in node i of the channel with all six hot channel factors,°CTwaII,i,6hcf = Cladding surface temperature in node i with all six hot channel factors, 0CTmax,i,6hcf = Fuel meat centerline temperature in node i with all six hot channel factors, CT~o, = Incipient boiling temperature in node i with only systematic hot channel factorsapplied, CPUR-1 SARAppendix 2-3PuR- SARAppndix2-3Rev 2, July 23, 2015 Flow Rate in a Coolant Channel versus Power of a Fuel PlateNATCON is a laminar natural circulation code. The flow rate is calculated in the code bybalancing the buoyancy pressure force to the laminar friction pressure drop. Following thisconcept, an analytical relationship is developed here (with some approximation) for the coolantflow rate in a single coolant channel in terms of the power generated in a fuel plate and thechannel geometrical dimensions. The analytical relationship is needed for obtaining hot channelfactors.The hot channel factor FW used in the code to account for the uncertainty in coolant flow rate isactually applied to the laminar friction factor in the code, that is, the laminar friction factor ismultiplied by FW2.It is not applied directly to the flow rate. The relationship developed hereexplains how this technique works.p1 , T1 at channel outletIL = Channel height containing hot coolant (hotter than pool), mIP = Power in a single fuel plate or the two half plates, WIW=Upward flow rate in a single channel, kg/spo, To at channel inletSchematic of what the code analyses, that is, a single rectangular coolant channel heated by ahalf of a fuel plate on each side (right and left sides).The above schematic shows what the code analyses, that is, a single rectangular coolantchannel heated by a half of a fuel plate on each side (right and left sides). See Fig. 1 for details.The buoyancy pressure force is caused by the decrease in water density due to heating in thechannel. The temperature dependence of water density can be written as,p(T) =po -,p0,8 (T -To )(I)whereT1= Bulk water temperature at channel outlet, CAT = T1-To = Temperature rise in channel from inlet to outlet, CPUR-1 SARAppendix 2-4PUR- SARAppndix2-4Rev 2, July 23, 2015 p0 = Water density at channel inlet, i.e., the water density in the pool, kg/rn3I? = Volumetric expansion coefficient of water, per C,p = Average coolant density in the channel, kg/rn3L= Channel height that contains hotter coolant (hotter than pool), m. It is the sum ofheat generating length of fuel plate, non-heat generating fuel plate length at top,and the assembly duct length above the top of fuel plateg = Acceleration due to gravity, 9.8 m/s2The buoyancy pressure force is given byBuoyancyAp =(po -p)gL (2)The average coolant density p is given byp =O0.5 (po+p,) = p0 -0.5,po /J(T1 -To )= p0 -0.5,O p0 fAT (3)Buoyancy Ap = 0.5 p0 ,/1 AT g L (4)The coolant temperature rise AT can be written in terms of the input power P generated in afuel plate, as shown by Eq. (5) below, and then the buoyancy A p of Eq. (4) can be written interms of the input power P, as shown by Eq. (6).AT = P/ (W Cp) (5)_ o0/gLPBuoyancyAp -WC(6)Ignoring the minor losses at channel inlet and outlet, the laminar frictional pressure drop in thechannel is written below as Eq. (9) after using the laminar friction factor given by Eq. (7), andafter replacing the coolant velOcity by mass flow rate using Eq. (8). The parameter C in Eq. (7)is a constant for a given channel cross section, but it depends upon the channel cross sectionaspect ratio width/thickness, and varies from 57 for aspect ratio 1.0 (square channel) to 96 foran infinite aspect ratio (infinitely wide channel).f =C /Re (7)W= pAV (8)PUR-1 SARAppendix 2-5PUR- SARAppndix2-5Rev 2, July 23, 2015 Fritioal _ p 2 = C4ULcW(9Fritioal P 2D 2 p AD2 9wheref -Moody friction factor for laminar flow in the channelRe -Reynolds number in the channel = ,oVD/,uA = Flow area of the channel cross section, m2D = Equivalent hydraulic diameter of the channel cross section, mLc = Total coolant channel length causing frictional pressure drop, m.V = Coolant velocity averaged over the channel cross section, m/sW = Coolant mass flow rate in the channel, kg/s11 = Average coolant dynamic viscosity in the channel, N-s/rn2/u (T) = Temperature-dependent dynamic viscosity of water, N-s/rn2/-Uo =1 , (To) = Coolant dynamic viscosity at the channel inlet temperature ToFor the PUR-1 reactor, the temperature dependence of the dynamic viscosity of water over thetemperature range 27 00 < T < 50 °0 can be approximated as follows.pz(T)= ,p(To) (1+T-T)0)- (10)where a = 0.12, To = 2700C, , ( To) = 0.875x10 -3 N-s/in 2The average coolant dynamic viscosity ,p used in Eq. (9) can be set equal to the viscosity atthe average coolant temperature (To + 0.5AT) in the channel. Putting this temperature in Eq.(10), the average viscosity ,u is found to be= ,p(To) (1 +0.5AT)0-. (11 )Equation (11) indicates that the average viscosity 41 can be set equal to ,p ( To) if AT is just afew 00 (this is the case for the PUR-1 reactor at the operating power of 1 kW). If AT is greaterthan a few 00, i.e., 1 <<0.5AT (this is the case for the PUR-1 reactor at an ONB power of about100 kW), then Eq. (11) simplifies to the following.PUR-1 SARAppendix 2-6PUR- SARAppndix2-6Rev 2, July 23, 20i5

,u= ,u ( To) (0.5AT)-0i T 201aif AT >> 2 °C(12a)/1u /u(To) if AT<<2 °C (12b)Substituting Eq. (12a) into Eq. (9), the frictional Ap becomesFrictional Ap = C'U°LcW (-'W-p' (13)21-a p AD2 21-° 7 AD2\ /-, PEquating the frictional A p of Eq. (13) to the buoyancy A p of Eq. (6) to find the steady-statecoolant flow rate W in the channel, one obtains Eq. (14) below. Equation (14) can be rewrittenas Eq. (15).P0flgLP-_ C 'u-----°L-W-- (-W " (14)2WCp 21-a p AD2 )W -+ p0 poAD2 /3 gLPl+a 152' CltoLc 15Equation (15) relates the fuel plate power to the channel flow rate in natural circulation. It isused to find the dependence of the flow rate on the parameter C in the laminar friction factor (atconstant power). All parameters in this equation are constant is also practically constant)except the parameter C in the laminar friction factor. Based on Eq.(15), the relationship betweenthe flow rate W and the parameter C is given by Eq. (16) below.Wcc I (16)Equation (16) shows that the friction factor parameter C is multiplied by a factor (FW)2, the2coolant flow rate W will be reduced by the factor (FW)2+a,. This has been verified by actuallyrunning the NATCON code for the PUR-1 reactor. Since a is small (a = 0.12 for the PUR-1reactor), 21(2+a) is nearly 1.0, and the flow rate W is reduced approximately by the factor FW.Bulk Coolant Temperature Rise versus Power of a Fuel PlateEquation (5) expresses, for laminar natural circulation, the bulk coolant temperature rise interms of fuel plate power, coolant flow rate and specific heat. Putting the value of flow rateobtained in Eq. (15) into Eq. (5), the bulk coolant temperature rise is given by Eq. (17) below,purely in terms of power and the geometrical dimensions of the channel. The right hand side ofEq. (17) is rearranged into two factors in Eq. (18), such that the second factor is sensitive topower and channel geometrical dimensions that usually have manufacturing tolerances andPUR-1 SARAppendix 2-7PUR- SARAppndix2-7Rev 2, July 23, 2015 measurement uncertainties, and the first factor is insensitive to power and channel geometricaldimensions.AT =::" 2;Q ---j2÷ (17)'AT[C~p~po/gL .A (18)The nominal flow area and hydraulic diameter of a rectangular coolant channel are given byA = tnc Wn (1 9)P w= 2 (tnc + W ~c) (20)D = 4 A/ P~, = 2 tnc Who / (tnc + Wnc) (21)whereto = Channel thickness (spacing between fuel plates), mto = Nominal channel thickness (spacing between fuel plates), mthc = Minimum channel thickness in hot channel (spacing between fuel plates), mWc =Channel width, assumed not to change from its nominal value, mPw = Wetted perimeter of the nominal channel, mPc = Power generated in a fuel plate, without applying manufacturing tolerances, WPhc = Power generated in a fuel plate, after applying manufacturing tolerances, WBecause the channel thickness to, is much smaller than the channel width Wc in mostexperimental reactors, Eq. (21) reduces too 2 tc, (22)Using the channel area and hydraulic diameter given by Eqs. (19) and (22) into Eq. (18), thebulk coolant temperature rise can be written in terms of power, channel thickness, and channelwidth. This is the desired relationship for use in finding hot channel factors.PUR-1 SAP,Appendix 2-8PUR- SARAppndix2-8Rev 2, July 23, 2015

-- --CfOL -7--7_- 1 (23)C 4w~t3Formulas for Hot Channel FactorsFor use in the NATCON version 2.0, six hot channel factors (three global/systemic and threelocal/random) are obtained from 9 manufacturing tolerances and measurement uncertainties u1,u=,..., u9 that are defined below. These are fractional uncertainties rather than percent. Of thesenine uncertainties, those affecting a particular hot channel factor are indicated in Table 1. Thesystemic hot channel factors are given by Eqs. (24) through (26), and the random hot channelfactors are given by Eqs. (27) through (29). A utility Fortran computer program NATCON_HCFand a Microsoft spreadsheet NATCON.HotChanFactors.xls have also been developed tocompute the hot channel factors using these formulas.EQ = 1 + u7 (24)FW =1 + u8 (25)FH = 1 + u9 (26)The ratio of the power generated in hot plate to its nominal power, caused by the uncertaintiesin neutronics-computed power and in U-235 mass per plate, can be written asPh...._c (1 +u1)(1+/-+u2) (27)nPoThe ratio of bulk coolant temperature rise in hot channel to the temperature rise in the nominalChannel, caused by the uncertainties in neutronics-computed power, U-235 mass per plate, andchannel thickness, is obtained from Eq. (23). Only the quantity in the second parentheses isimportant here because the quantity in the first parentheses is insensitive to these uncertainties.~h 1 (28)The uncertainty in flow distribution is assumed to reduce the channel flow to (1- U6) times theflow without this uncertainty, and therefore the bulk coolant temperature rise is increased by thefactor (1+ u6). This uncertainty in bulk coolant temperature rise is statistically combined with thatgiven by Eq. (28) to obtain the following formula for the hot channel factor FBULK for input tothe NATOON version 2.0.FBULK= 1 +, 1. -1+u2 (29)PUR-1 SARAppendix 2-9PuR- SARAppndix2-9Rev 2, July 23, 2015 The temperature drop across coolant film on the cladding surface at an axial location is given byEq. (30). Here the heat flux q" (W/m2) on the cladding surface is replaced by tf q'"/2 in terms ofthe volumetric power density q"'" (W/m3) in the fuel meat.Aflh 2h (0The convective heat transfer coefficient h (W/m2-C) is given by Eq. (31). Here the laminarNusselt number Nu is independent of flow rate, and varies only slowly with the aspect ratio(width/thickness) of coolant channel. The main variation of the heat transfer coefficient withchannel thickness is due to the denominator of Eq. (31). The numerator of Eq. (31) isconsidered to be constant.h -NKc°° -N"IKC°°! (31)D 2tcUsing Eq. (31) for the heat transfer coefficient, the temperature drop across coolant film can bewritten as Eq. (32).fil~m -Nco (32)Equation (32) states that ATift,~ is directly proportional to the fuel meat thickness (havinguncertainty u3), the channel thickness (having uncertainty u5), and the power density in meat.The uncertainty in power density is caused by three uncertainties, that is, u1, u2 and u4.Statistically combining these five uncertainties gives the following formula for the hot channelfactor FFILM for input to the NATCON version 2.0.FFILM =1+4Ul2+/-+u22+/-+u32+/-u-/452 (33)The uncertainty in the heat flux at the cladding surface is included in the hot channel factorFFILM given by Eq. (33). A hot channel factor FFLUX for the heat flux alone can be found fromEq. (34) for heat flux in terms of the power density q"'" in the fuel meat and the thickness of themeat. The fractional uncertainty in heat flux is the sum of fractional uncertainties in powerdensity and meat thickness, as given by Eq. (35).q" t- (34)2Sq"_ Sq '" Ste__ +/- fe (35)q,, q,, tfuelIn Eq. (35), the uncertainty in power density is caused by three uncertainties, that is, u1, u2 andu4.The uncertainty in the meat thickness is given by u3.Statistically combining these fouruncertainties gives the following formula for the hot channel factor FFLUX for input to theNATCON version 2.0.PUR-1 SARAppendix 2-10PUR- SARAppedix -10Rev 2, July 23, 2015 FFLUX= 1+ u12+//2 -+/-u32+u42(6(36)The uncertainty in the temperature drop ATmetal from fuel meat centerline to cladding surface isnot important in the case of the PUR-1 reactor because ATmetai is very small compared to ATritm.For example, ATmetai is 0.05 00 and ATfilm is 34.5 00 at 100 kW without any hot channel factors.Table A2-1. Uncertainties Included in the Six Hot Channel Factors Used in NATCON Version2.0 (X implies that an uncertainty affects a hot channel factor)Uncertainty Fraction FQ FW {FH FBULK FFILM FFLUXLocal or random uncertaintiesI Neutronics calculation ofXXXpower in a plate, u12 U-235 mass per plate, u2 X X X3 Local fuel meat thickness,XXu34 U-235 axial homogeneity,XX5 Coolant channel thickness,XXu56 Flow distribution amongXXchannels, u6System-wide uncertainties7 Reactor powermeasurement uncertainty, X8 Flow uncertainty due to X___uncertainty in friction_____PUR-1 SARAppendix 2-11PUR- SARAppedix -1 1Rev 2, July 23, 2015 factor, u89 Heat transfer coefficientuncertaintydue to uncertainty inNu number correlation, u9The following information was presented as answers to Requests for Additional Information(RAIs) during the conversion process. This information is not presented in the SAR chapters onthermal hydraulics.Question 2828. Appendix 1. From the information in Appendix 1 it is not clear how insignificant are thechannel inlet and outlet losses when compared to the wall shear. Please clarify.Response:The information in Appendix 1 was used only to obtain hot channel factors for input to a moredetailed thermal-hydraulic calculation using the NATCON code [Ref. 8 of the conversionproposal]. Therefore, Appendix 1 is a simplified modeling of what is calculated in detail inNATCON, and it is used only for the purpose of obtaining closed-form equations from which hotchannel factors could be found. Appendix 1 does not include the minor losses. The minor lossescalculated by NATCON are reported below, and found to be about 16% of the total frictionalpressure drop in the HEU core, and 14% of the total frictional pressure drop in the LEU core(see Table 027-1 ).The pressure drop due to inlet and outlet losses were calculated (by the NATCON code) usingloss coefficients of 0.5 and 1.0 respectively. The pressure drop due to wall shear along thechannel length is found by summing the pressure drop for each axial mesh which is calculatedusing temperature-dependent coolant viscosity and density for the axial mesh (14 meshintervals were used over the channel length in all calculations). The pressure drops arecalculated by NATCON assuming fully developed laminar flow in a rectangular cross-sectionchannel, and then multiplied by a factor FW2 (FW squared) where FW is an input which may beused to account for the increased pressure drop due to hydrodynamically developing laminarflow. In the calculations presented in the conversion proposal, FW was always set to 1.0, andthus the increased pressure drop due to developing laminar flow was not included. It is includedin the calculations presented here (Table 027-1). The method used is described below.For the most limiting fuel plate in Table 4-27 of the conversion proposal for each core (HEU andLEU), a comparison of the pressure drops due to inlet plus outlet loss and wall shear, with andwithout the effect of developing laminar flow, are tabulated in Table 027-1.NATCON calculates the Darcy-Weisbach friction factor f = C/Re for laminar flow, using a built-intable of the parameter C for different aspect ratios of the rectangular channel cross sectionPUR-1 SARAppendix 2-12PUR- SARAppedix -12Rev 2, July 23, 2015 (values of parameter C are given in the response to Question number 29). An apparent value ofthe parameter C averaged over the channel length, called Capp, was calculated using Eq. (576)of Shah and London [Ref. 2 listed at the end of all responses] to account for the increasedpressure drop due to hydrodynamically developing laminar flow in the channel. The ratio Capp/Cwas found to be 1.1105 for the 207 mil HEU channel, 1.0985 for the 197 mil LEU channel. Sincethe NATOON code multiplies the fully developed friction factor by FW2 as mentioned above, theinput FW equals 1.054 and 1.048 for the HEU and LEU channels respectively. NATCONcalculations were done using these values of FW, and the pressure drops due to inlet plus outletloss and wall shear are compared in Table Q27-1 (column B for the HEU channel, and column Ffor the LEU channel).Table Q27-1 shows that the pressure drops due to wall shear and minor losses are 84% and16%, respectively, of the total pressure drop in the HEU channel at its ONB power; and thepressure drops due to wall shear and inlet plus outlet loss are 86% and 14%, respectively, ofthe total pressure drop in the LEU channel at its ONB power.Question 2929. Appendix 1. From the information in Appendix 1 it is not clear what is the functionaldependency of the laminar friction parameter C to the channel cross-section dimensions.Provide a reference for the evaluation of C.Response:The following values (rows 1 and 2 of Table Q29-1) of the parameter C for fully developedlaminar flow in a channel of rectangular cross section versus the width-to-thickness aspect ratio(Wc/tc) of the channel are used in the NATCON code that was used in the thermal-hydraulicscalculations. The table starts from the square cross section (aspect ratio = 1.0) and goes to theinfinite value of the aspect ratio (parallel plates). In order to find the parameter C for the aspectratio of the PUR-1 reactor, the NATCON code simply interpolates between the tabulated values.The original author of the code obtained these values from an old Reference [E. R. G. Eckertand T. F. Irvine, Heat Transfer Laboratory, University of Minnesota (1957)] but these values arealso given in a textbook by Frank Incropera [Ref. 3]. These values are obtained from the closed-form analytical solution for the fully developed laminar velocity distribution in a rectangularchannel summarized by R. K. Shah and A. L. London [Ref. 2]. Equation (341) in [Ref. 2] is afitted equation to easily find the parameter C. It should be noted that the aspect ratio used in[Ref. 2] is channel thickness-to-width ratio (the reciprocal of that used in NATOON and shownbelow in Table A2-2), and the friction factor in [Ref. 2] should be multiplied by 4 to get theDarcy-Weisbach friction factor that is used in NATCON and tabulated below.Table A2-2. Friction Parameter C Used in the NATCON Codewtc 1.0 2.0 3.0 4.0 5.0 6.3 8.0 11.0 15.0 18.0 100.0C in 58.0 63.0 69.0 72.5 77.0 80.0 83.0 85.0 88.0 89.0 96.0NATCONPUR-1 SARAppendix 2-13PUR- SARAppedix -13Rev 2, July 23, 2015 C in 57.0 62.0 69.0 73.0 82.0 96.0Ref. 3C in 56.9 62.2 68.4 72.9 76.3 79.5 82.4 85.6 88.1 89.3 94.7Ref. 2Question 3030. Appendix 1. From the information in Appendix 1 in both the calculation of the channelflow and the calculation of the bulk coolant temperature rise the ratio of the coolant kinematicviscosity to density (pip) was assumed to be insensitive to temperature. Please demonstrate thevalidity of this assumption.Response:The information in Appendix 1 was used only to obtain hot channel factors for input to a moredetailed thermal-hydraulic calculation using the NATCON code [Ref. 8 of the conversionproposal]. NATCON does account for the temperature dependence of coolant viscosity anddensity in the calculation of the channel flow and the calculation of the bulk coolant temperaturerise. Therefore, Appendix 1 is a simplified modeling of what is calculated in detail in NATCON,for the purpose of obtaining closed-form equations from which hot channel factors could befound.As suggested in the question, water viscosity is temperature-dependent, i.e., it decreases withrising temperature. Appendix 1 was revised to account for the effect of temperature dependenceof viscosity on hot channel factors, and the revised Appendix 1 is enclosed herewith. Thetemperature dependence of the dynamic viscosity of water over the temperature range 27 00 <T < 50 00 (adequate for the PUR-1 reactor) can be written as follows./()= /z(T0) (1+T-T0)-0 (Al)where a=0.12To= 27 00 = Pool temperature of PUR-1,u ( To) = 0.875x10 -3 N-s/rn 2,p (T) = Temperature-dependent dynamic viscosity of water, N-s/in2As shown in the revised Appendix 1, the revised relationship between the flow rate W in achannel and the friction parameter C is given by Eq. (A2). The revised formula for hot channelfactor FBULK for bulk coolant temperature rise is given by Eq. (A3).(A2PUR-1 SARAppendix 2-14PuR- SARAppedix -14Rev 2, July 23, 2015 FRUlLu )=+, (l+u9)2+- lJ l -1} u (A3)The exponent on the right hand side of Eq. (A2) changed from 0.5 (in the conversion proposalignoring temperature dependence of p) to the revised value 1/2.12 = 0.4717. There exponentsin Eq. (A3) for EBULK also changed, e.g., from 3/2 to 3/2.12 =1.415. As a result of this revision,the hot channel factor FBULK decreased from 1.312 (in the conversion proposal) to 1.301 forthe most limiting fuel plate 262 in the HEU core. Similarly, FBULK decreased from 1.321 (in theconversion proposal) to 1.308 for the most limiting fuel plate 1348 in the LEU core. The effect ofignoring the temperature dependence of viscosity is conservative.NATCON calculations were done with these revised values of EBULK along with a value of FW> 1.0 to account for the increased friction due to developing laminar flow (in response toQuestion number 33). The results are shown in Table Q27-1 (column C for the HEU core, andcolumn G for the LEU core).As a consequence of the two effects (i.e., increased friction due to developing laminar flow andthe temperature dependence of viscosity) on hot channel factors FW and EBULK, the ONBpower of the HEU core changes from 76.3 kW (reported in the conversion proposal) to 75.9 kW,and the ONB power of the LEU core changes from 96.1 kW (reported in the conversionproposal) to 95.8 kW. The effect is small for the PUR-1 reactor.Question 3232. Appendix 1. Equation (30) has two terms and the conversion proposal states that theexpression within the parenthesis on the right hand side of the equation varies slowly comparedto the heat flux tfuel q'"/2. Demonstrate the validity of the statement with reference to the PUR-1fuel plate.Response:Equation (30) of Appendix 1 is for finding a hot channel factor for the temperature drop from themeat mid-plane to cladding surface (ATmetai). This temperature drop is very small compared tothe temperature drop from the cladding surface to bulk coolant (ATflrn). For example, in thePUR-1 HEU fuel plate 262 without hot channel factors, Ammetai iS 0.07 °C and ATfi~m is 46.98 °C(at meat mid-height) at a high power of 100 kW. Similarly, in the PUR-1 LEU fuel plate 1348without hot channel factors, Ammetai is 0.05 °C and ATfi m is 34.5 °C at a power of 100 kW.Therefore, the hot channel factor for Ammetai iS not important for PUR-1. The important hotchannel factor is the factor FFILM for ATf, m. In the case of PUR-1, ATtim is the biggercomponent (bigger than the bulk coolant temperature rise) in the total temperature rise from theinlet temperature to the cladding surface temperature at the axial level experiencing the onset ofnucleate boiling. The hot channel factor FFILM found by Eq. (29) of Appendix 1 in theconversion proposal remains unchanged. It depends on the uncertainties in q'"tfuel and channelthickness (as shown in Eq. 28), but not on the uncertainty in [tfuel/(4KfueI) + tcdad/Kclad].In short, PUR-1 is not limited by the fuel peak temperature, but by the onset of nucleate boiling,and the uncertainty in [tfuel/(4KfueI) + tclad/Kclad] is not important for PUR-1. We believe that thehot channel factor FFILM has been determined accurately.PUR-1 SARAppendix 2-15PUR- SARAppedix -15Rev 2, July 23, 2015 Question 3333. Section 4.7.2. According to Appendix 1 the systematic uncertainty in flow rate isaccounted for by applying the hot channel factor Fw to the laminar friction factor C. Explain thereason for the value of the flow friction factor Fw being unity in Tables 4-25 and 4-26.Response:As suggested in the question, a value of FW (hot channel factor for flow) greater than 1.0 shouldbe used to account for the increased frictional pressure drop due to the hydrodynamicallydeveloping laminar flow in the entrance region of the coolant channel, otherwise the code(NATCON) accounts only for the fully developed frictional pressure drop. This has been donenow and the results are presented in Table Q27-1. Since each coolant channel creates its ownbuoyancy to drive its own coolant flow, there is no uncertainty due to redistribution of a totalreactor flow rate. The loss coefficients of 0.5 and 1.0 at channel inlet and outlet are used in thecalculations. To account for the reduction in flow rate due to the hydrodynamically developinglaminar flow in the channel, the values of FW were calculated for the most limiting channels inthe HEU and LEU cores as follows.NATOON calculates the Darcy-Weisbach friction factor f = C/Re using a built-in table of theparameter C for different aspect ratios of the rectangular channel cross section (values ofparameter C are given in the answer to Question number 29). These values of parameter C arefor the fully developed laminar flow in a rectangular cross-section channel. An apparent value ofthe parameter C averaged over the channel length, called Capp, was calculated using Eq. (576)of Shah and London [Ref. 2] to account for the increased pressure drop due tohydrodynamically developing laminar flow in the channel. The ratio Capp/C was found to be1.1105 for the 207 rail HEU channel, and 1.0985 for the 197 mil LEU channel. Since theNATCON code multiplies the fully developed frictional factor by FW2, the input FW equals 1.054and 1.048 for the HEU and LEU channels respectively. The flow reduction factor is input factorFW or more accurately FW2/(2+a) FW°'9434 (noting that a = 0.12 for the PUR-1 reactor asmentioned in the revised Appendix 1 enclosed herewith).The results of using these values of FW in NATCON calculations (excluding the effect oftemperature dependence of p on hot channel factors) are shown in Table Q27-1. The ONBpower of the HEU core changes to 75.8 kW from 76.3 kW reported in the conversion proposal.The ONB power of the LEU core changes to 95.7 kW from 96.1 kW reported in the conversionproposal.The channel flow indeed gets reduced by the factor FW0"9434 as expected. For the HEU plate262, the flow reduces from 0.02083 kg/s to 0.01 989 kg/s (see Table Q27-1) when the input hotchannel factor FW is changed from 1.0 to 1.054. The expected reduced flow should be0.02083/(1.054)0"9434 = 0.01982 kg/s which is close to the NATCON-calculated value of 0.01 989kg/s. For the LEU plate 1348, the flow reduces from 0.01 912 kg/s to 0.01834 kg/s (see TableQ27-1) when the input FW is changed from 1.0 to 1.048. The expected reduced flow should be0.01 912/(1 .048)0.9434 = 0.01 829 kg/s which is close to the NATCON-calculated value of 0.01834kg/s.Question 3636. Table 4-28. Define the parameter "margin to incipient boiling."PUR-1 SARAppendix 2-16PuR- SARAppedix -16Rev 2, July 23, 2015 Response:The margin to incipient boiling shown in Table 4-28 was calculated at the nominal operatingpower of PUR-1 (i.e., 1 kW), and it is the smallest value of the temperature difference (ToNg -Tw) over the coolant channel length in the hottest channel where Tw is cladding surfacetemperature with all hot channel factors applied, and TONB is the local onset-of-nucleate-boilingtemperature. This basically gives an idea of how far below the onset of nucleate boilingcondition the reactor is operating. This definition can be written as an equation as follows:whereT(z) = Bulk coolant temperature at axial position z in the channel heated by theplate power of PopFr EQ/N and applying the global hot channel factors forflow and Nusselt number of Fw and FhTwani(Z) = Cladding surface temperature at axial position z in the channel heated by aplate power of Pop~r EQ/N and applying the global hot channel factors forflow and Nusselt number of Fw and Fhq"(z) = Heat flux at position z for the plate power of Pop~r EQ/N and applying theglobal hot channel factors for flow and Nusselt number of Fw and Fhp(z) = Absolute pressure in the channel at axial position zT~nop(p(z), q"(z)Fnux) = Onset of nucleate boiling temperature at absolute pressure p(z) and heatflux q"(z)FfluxPop = Operating power of the reactor (e.g., 1 kW for PUR-1)N = Number of fuel plates in the core (e.g., 190 for PUR-1 LEU core)To = Coolant temperature at the channel inletFr = RPEAK = Radial power factor of the plate cooled by the channelFw = Hot channel factor for flow in the channelEQ = Hot channel factor for reactor powerFh =Hot channel factor for Nusselt numberFflrn = FFILM = Hot channel factor for temperature drop across the coolant film oncladding surfaceEFlux -FFLUX = Hot channel factor for heat fluxFbuIk = FBULK = Hot channel factor for bulk coolant temperature rise in thechannelPUR-1 SARAppendix 2-17PUR- SARAppedix -17Rev 2, July 23, 2015 APPENDIX 3: FUEL SPECIFICATIONSPages Appendix 3-2 through Appendix 3-62 are the specification document Specification forPurdue University Standard and Control Fuel Elements -Assembled for the Purdue UniversityReactor, idaho National Laboratory, SPC-382, Rev 1, January 27, 2007..Pages Appendix 3-63 through Appendix 3-84 are engineering drawings of the PUR-1 fueiassemblies.PUR-1 SARAppendix 3-1PuR- SARAppndix3-1Rev 2, July 23, 2015 Document ID: SPC-382Revision ID: IEffective Date: 01/24/07SpecificationSpecification for PurdueUniversity Standard andControl Fuel Elements -Assem bled for thePurdue UniversityReactorIdaho NationalLaboratoryThe INL is a U.S. Department of Energy National Laboratoryoperated by Battelle Energy Alliance.PUR-1 SARAppendix 3-2FUR- SARAppndix3-2Rev 2. July 23, 2015 INTENTIONALLY BLANKPUR-1 SARAppendix 3-3PUR- SARAppndix3-3Rev 2. July 23, 2015 Form 412.09Idenifir:IPCa82rU- PUNRDUE FUNIERITY00 Ideniie.r: ENGIE-RNGU N SI IMWDCNRLFESHO NIERN*ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: i of iiPURDUE UNIVERSITY REACTOR .CRe'. 09)Document Project File No. Revision1. Identifier: SPC-382 2. (optional): ________3. No.: 1Specification for Purdue University Standard and Control Fuel Elements -Assembled for the4. Document Title: Purdue University ReactorComments5. : .All review and approval signatures for this specification are located on DAR Number 511249.* :SIGNATURES. .........ii ,:6. 7.i 8.Type or Printed Name JSignature Organization!Signature I Code Date DisciplineSee DAR Number 506184.See DAR Number 511249.Document Control Release / .-.*9. Signature: ]' LE. o0710. Is this a Construction Specification? Yes [] No [] 11. NCR Related? Yes Lii No []Does document contain sensitive, unclassified information? [] Yes [] No If Yes, what12. category: __________13. Can document be externally distributed? Yes [] No LiArea Index14. Code: Area______ Type______ SSC ID)Review annually. Cutoff whenRecord superseded, obsolete orUniform File Disposition Retention cancelled. Destroy 75 years15. Code: 0250 16. Authority: ENVl-b-4-a Period: after cutoff.17. For QA Records Classification Only: Lifetime [-i, Nonpermanent LI-, Permanent LIItem or activity to which the QA Recordsapply: _____________________________Periodic Review Frequency: N/A Li, 5 years [], or18. Other___________________ ____Nuclear Engineering Building [] 400 Central Drive ta West Lafayette, IN 47907-2017PUR-I SAR (765) 494-5739 m Fax: (765) 494-9570 [] https:/lengineerin~dplj.N4ERev 2. July 23, 2015 Form 412.09 (Rev. 09)Ida ho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: ii of iiPURDUE UNIVERSITY REACTORINTENTIONALLY BLANKPUR-1 SARAppendix 3-5PUR- SARAppndix3-5Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 1 of 57PURDUE UNIVERSITY REACTOR[Purdue University Reactor [Specification [ DAR Number: 511249 [REVISION LOGRev. Date Affected Pages Revision Description0 05/31/06 All New Document.1 0 1/24/07 All Revised to add Program Anneal requirements and_____ ________ ____________update Drawing Titles-1- 1 4-I- + II- 4F + I.I. + I-PUR-1 SARAppendix 3-6FUR- SARAppndix3-6Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 2 of 57PURDUE UNIVERSITY REACTORCONTENTS1. SUMMARY............................................................................................... 51.1 General .............................................................................................. 52. APPLICABLE CODES, PROCEDURES, AND REFERENCES...................................... 52.1 Standards, Specifications, Drawings and Attachments.......................................... 52.1.1 Specifications and Standards ......................................................... 52.1.2 Drawings (INL)........................................................................ 83. TECHNICAL REQUIREMENTS.......................................................................... 93.1 Production Qualification.................. ......................................................... 93.1.1 Fuel Plate Qualification: .............................................................. 93.1.2 Fuel Element Qualification:......................................................... 103.1.3 Requalification: ...................................................................... 103.1.4 Operator Qualification:........................................... 113.2 Materials ........................................................................................... 123.2.1 Fuel Bearing Plates .................................................................. 123.2.2 Aluminum Weld Filler Metal: ...................................................... 123.2.3 Dummy (Non-Fueled) Plate:........................................................ 123.2.4 Material Requirements .............................................................. 133.3 Mechanical Requirements........................................................................ 133.3.1 Fuel Plate Requirements ............................................................ 133.3.2 Non-fueled (dummy) plates:........................................................ 153.3.3 Fuel Element Requirements......................................................... 153.4 Physical Properties................................................................................ 153.4.1 Fuel Plate Requirements ............................................................ 153.5 Surface Condition ................................................................................. 173.5.1 Surface Defects ...................................................................... 173.5.2 Cleanliness: .......................................................................... 173.5.3 Contamination: ....................................................................... 183.6 Marking............................................................................................ 183.6.1 Fuel Plate Identification: ............................................................ 183.6.2 Fuel Assembly Identification:....................................................... 183.6.3 Dummy Element Identification: .................................................... 193.7 Storage ............................................................................................. 193.8 Fuel Element Surface Treatment ................................................................ 19PUR-1 SAR Appendix 3-7 Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 3 of 57PURDUE UNIVERSITY REACTOR3.8.1............................................................................................ 193.8.2............................................................................................ 203.8.3............................................................................................ 203.9 Graphite Reflectors and Graphite Radiation Baskets .......................................... 203.9.1 Material: .............................................................................. 203.9.2 Assembly:............................................................................. 203.9.3 Welding: .............................................................................. 203.9.4 Identification: ........................................................................ 203.9.5 Dimensional Inspection:............................................................. 213.9.6 Surface Finish and Defects: ......................................................... 213.9.7 Storage: ............................................................................... 214. QUALITY ASSURANCE................................................................................. 214.1 Materials ........................................................................................... 224.2 Core Density....................................................................................... 224.3 Fuel Loading....................................................................................... 244.4 Fuel Homogeneity ................................................................................ 244.5 Core Configuration................................................................................ 264.6 Bond Integrity ..................................................................................... 264.6.1 Blister Anneal: ....................................................................... 264.6.2 Ultrasonic Scanning: ................................................................ 274.6.3 Metallographic Examination........................................................ 274.7 Internal Defects ................................................................................... 274.8 Surface Finish and Defects....................................................................... 284.9 Clad-Core-Clad Dimensions..................................................................... 284.10 Cleanliness......................................................................................... 294.11 Contamination..................................................................................... 294.12 Dimensional ....................................................................................... 294.12.1 Final Dimensional Inspection....................................................... 294.13 Reactor Components and Spare Fuel Element Parts........................................... 295. PACKAGING AND SHIPPING.......................................................................... 306. NOTES ...................................................................................................... 30PUR-1 SAR Appendix 3-8 Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY !Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 4 of 57PURDUE UNIVERSITY REACTOR6.1 Definitions......................................................................................... 306.2 Purchaser Tests.................................................................................... 336.3 Submittals.......................................................................................... 336.3.1 Preproduction:........................................................................ 336.3.2 Pre-repair:............................................................................. 346.3.3 Manufacturing Schedule: ........................................................... 346.3.4 Delivery Submittals: ................................................................. 346.3.5 Fuel Plate Radiographs:............................................................. 356.3.6 Core Compact Data Sheets: ......................................................... 356.3.7 Report of Production by Unapproved Process:.................................... 35APPENDIX A ...................................................................................................... 37APPENDIX B...................................................................................................... 39FIGURES1. Purdue University Fuel Plate Sampling Procedures For Destructive Tests....................... 36PUR-1 SARAppendix 3-9PUR- SARAppndix3-9Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 5 of 57PURDUE UNIVERSITY REACTOR1.SUMMARY1.1 GeneralThis specification (see def.) defines the materials, components, testing, inspection,certain processes, quality control (see def.) requirements and acceptance criteriafor the fabrication of standard and control fuel elements (see def.) and fuelelement containers for the Purdue University Reactor at Purdue University atWest Lafayette, Indiana.2. APPLICABLE CODES, PROCEDURES, AND REFERENCES2.1 Standards, Specifications, Drawings and AttachmentsThe applicable portions of the following documents as defined herein, form a partof this specification. Where there is a conflict between the documents cited andthe latest revision thereof, the supplier (see def.) shall notify the purchaser(see def.) of the conflict and use the latest revision in effect at the signing of thecontract, unless otherwise directed by the purchaser.2.1 .1 Specifications and StandardsNational Codes and StandardsASTM E 1742-00ASTM E 1417-99MIL-C-45 662RDT F6-2TAmerican Society for TestingASTM B 209-00ASTM B 210-04ASTM B 211-00ASTM B 214-99ASTM B 221-00Standard Practice for RadiographExaminationStandard Practice for Liquid PenetrantExaminationCalibration System RequirementsWelding of Reactor Core Components,Sections 1,2,3 and 6and Materials (ASTM)Standard Specification for Aluminumand Aluminum-Alloy Sheet and PlateAluminum and Aluminum-Alloy DrawnSeamless TubesStandard Specification for Aluminumand Aluminum-Alloy Bar, Rod and WireStandard Test Method for Sieve Analysisof Granular Metal PowdersStandard Specification for AluminumPUR-1 SARPUR-1 SAR ~~~Appendix 3-10 2 uy2,212. July 23,2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382 5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 6 of 5PURDUE UNIVERSITY REACTORand Aluminum-Alloy Extruded Bars,Rods, Wires, Profiles and TubesASTM B 24 1-02ASTM E 8-00ASTM E 29-93 a (1999)ASTM E 2016-99Aluminum and Aluminum-AlloySeamless Pipe and Seamless ExtrudedTubeMethods of Tension Testing of MetallicMaterialsRecommended Practice for IndicatingWhich Places of Figures are to beConsidered Significant in SpecifiedLimiting ValuesStandard Specification for IndustrialWoven Wire ClothAmerican Welding Society (AWS')AWS A5.10-1995Aluminum and Aluminum AlloyWelding Rod and Bare ElectrodesAmerican National Standards Institute (ANSI)ANSI B46.1-1994Surface TextureANSI Y14.5-1994 Dimensioning and Tolerancing forEngineering DrawingsAmerican Society of Mechanical Engineers (ASME)ASME Section V -2001,without addendumASME Section IX -2001ASME NQA- 1-1997Boiler and Pressure Vessel CodeSection VBoiler and Pressure Vessel CodeSection IXQuality Assurance Requirements forNuclear Facility ApplicationsPUR-1 SARPUR-1 SAR ~~~Appendix 3-11 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382 5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 7 of 5PURDUE UNIVERSITY REACTORIdaho National Laboratory (INL)TRTR- 11TRTR- 14IN-F-4-TRASTD 7022ASpecification for Low Enriched UraniumMetal in Test Reactor FuelSpecification for Reactor Grade LowEnriched Uranium Silicide Fuel PowderSpecification for Aluminum Powder forMatrix Material in Test Reactor FuelCleanliness Acceptance Levels forNuclear or Non-Nuclear ServiceComponentsAmerican Society for Nondestructive Test (ASNT)SNT-TC-lA (1996 or later) American Society For NondestructiveTesting (ASNT) Recommended PracticePUR-1 SARPUR-1 SAR ~~~Appendix 3-12 2 uy2,212. July 23,2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 8 of 57PURDUE UNIVERSITY REACTOR2.1.2 Drawings (JNL)635454635455635456635457635458635459635460635461635462635463635464635465Purdue University Test Research andTraining Reactor Graphite ReflectorAssembly and Source Drive AssemblyPurdue University Test Research andTraining Reactor Standard Fuel, Partial,& Dummy Element AssembliesPurdue University Test Research andTraining Reactor Control Fuel ElementAssembly and Dummy Control FuelElement AssemblyPurdue University Test Research andTraining Reactor Fission Chamber FuelElement AssemblyPurdue University Test Research andTraining Reactor Standard FuelContainer AssemblyPurdue University Test Research andTraining Reactor Control Fuel ContainerAssemblyPurdue University Test Research andTraining Reactor Irradiation FacilityAssemblyPurdue University Test Research and.Training Reactor Capsule Holder andCapsule Insert Assemblies and DetailsPurdue University Test Research andTraining Reactor Graphite ContainerAssembly, and Source Drive ContainerAssemblyPurdue University Test Research andTraining Reactor Fuel Plate Assemblyand Dummy Fuel Plate DetailPurdue University Test Research andTraining Reactor Container TubeAssembly and DetailsPurdue University Test Research andPUR-1 SARPUR-1 SAR ~~~Appendix 3-13 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1of5ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 9of5PURDUE UNIVERSITY REACTORTraining Reactor Graphite Block DetailAnd Graphite Capsule Holder Detail635466 Purdue University Test Research andTraining Reactor Miscellaneous Details635467 Purdue University Test Research andTraining Reactor Source Drive NozzleAssembly and Source Drive Top635468 Purdue University Test Research andTraining Reactor Nozzle PreliminaryMachined and Fission Chamber Top3. TECHNICAL REQUIREMENTS3.1 Production QualificationThe supplier is required to qualify the processes or portions of the process or beexempt from same by written approval of the purchaser. In qualifcation (seedef.), only materials that comply with this specification shall be used.Qualification processes, equipment, and operator qualificationltraining programsshall be identical to those used during production (see def.). To qualify, thesupplier must demonstrate, to the satisfaction of the purchaser, that the process iscapable of producing a product, which satisfies all the requirements of thespecifications. Assembly of production fuel elements shall not be initiated until:(1) all required data, to assure compliance with the qualification requirements, hasbeen submitted to the purchaser; (2) data and records required by Section 6.3 havebeen submitted; and (3) written approval of qualification has been received by thesupplier from the purchaser.3.1.1 Fuel Plate Qualification:Fuel plate (see def.) qualification shall be satisfied by supplierproduction of a minimum of two consecutively produced plate lots (seedef.), in lot quantities of 24 plates (see def.). The plates shall be madeusing low enriched uranium in the form of Silicide (see def.) powder,which have a yield of no less than 65% acceptable fuel plates meeting allapplicable requirements of this specification. The supplier may combinethe results of two consecutive lots into a production run in determiningthe 65% yield requirement provided that there have been no changes inthe manufacturing (see def.) procedure (see def.) between lots whichwould require requalifcation (see def.) in accordance with Section 3.1.3.PUR-1 SARPUR-1 SAR ~~~Appendix 3-14 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 10of5PURDUE UNIVERSITY REACTORIn the event that fuel plate qualification has been performed by thesupplier meeting all the requirements of this specification during the pasttwelve months, and qualified operators are performing the fabrication,fuel plate qualification requirements listed above will be waived.Fuel plates made in development (see def.) (prior to and includingqualification runs that fail to meet the 65% yield requirements) will notbe used in fabricating production fuel elements without prior approval ofthe purchaser.3.1.2 Fuel Element Qualification:The supplier shall fabricate 1 dummy standard fuel element assembly(see def.), which shall meet the requirements of this specification.3.1.3 Requalification:The supplier shall notify the purchaser of any proposed process change.A changed process may not be used in production until the supplier hasmet all the requirements of Section 3.1.3, submits the results and data ofthe requalification effort, and receives written approval from thepurchaser.Requalification for any fuel plate attribute to the requirements of thespecification will be required when the processes, materials, fuelloadings, equipment or equipment operators (welding and rolling) whichhave been previously qualified are changed, unless the supplier candemonstrate to the satisfaction of the purchaser by engineeringexplanation or proof test that such changes will have no detrimentaleffect on the product.Requalification for compacting, pack (see def.) assembly, and rollingmill operators can be less than qualification basis, since the procedurehas already been established. Candidate operators who are not qualifiedfor compacting operations, pack assembly operations, and hot/coldrolling mill operations must demonstrate their abilities in performing theindividual operations they are assigned.An operator must qualify by processing two lots of fuel plates withminimum lot size of 24, for the operation he is assigned to qualify,before performing any production operation independently. Each lot offuel plates shall be processed through final inspection, with a minimumyield rate of 90% acceptable fuel plates required for the operator to betermed qualified.PUR-1 SARPUR-1 SAR ~~~Appendix 3-15 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 11of5PURDUE UNIVERSITY REACTORNOTE: Failure of an operator to qualify', because of fuel piate deviations,must be based on deviations related to the operation being qualified.The purchaser on a case-by-case basis will determine the quantitiesand sizes of requali~fication fuel plates selected to be destructivelyexamined.3.1.4 Operator Qualification:Operator qualification will be accomplished via an approved supplierinternal qualification program for the following operations:A. Arc meltingB. CompactingC. Pack assemblyD. Hot rollingB. Cold rollingF. Final machining.3.1.4.1In addition to the operations specified above, the suppliershall also show evidence of the training and competency ofthose individuals who perform any of the following fuelelement fabrication and inspection activities:A. Powder sieving, weighing, and testingB. Compact weighing, visual and dimensionalinspectionC. Fuel plate/element and component cleaningD. Fuel plate annealing operationsB. Dimensional inspection of plates, elements, andsubcomponentsF. Metallographic sample preparation and inspection0. Visual inspection of plates, elements, andsubcomponentsH. Void volume inspectionI. Fluoroscope inspection of fuel platesPUR-1 SARPUR-1 SAR ~~~Appendix 3-16 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 12 of 57PURDUE UNIVERSITY REACTORJ. Radiography and inspection of fuel plate radiographsK. Ultrasonic testing and interpretation.The individuals performing these operations shall havespecific requirements imposed on them that willdemonstrate their knowledge and ability to perform theirrespective assignments. Documented evidence of thetraining of these individuals shall be maintained and shall bemade available to the purchaser upon request.3.2 MaterialsThe material requirements for the components comprising the fuel element are asspecified on Drawings per Section 2.1.2 and requirements of this section.3.2.1 Fuel Bearin2 Plates3.2.1.1 Fuel Cores: The fuel cores (see def.) of the fuel plates shallbe uranium silicide powder dispersed in aluminum alloypowder which meet the requirements of IN.-F-4-TRA andTRTR- 14, per Section 2.1.1 of this specification.3.2.1.2 Frames and Covers: Aluminum for the frames and coverplates shall conform to ASTM B209, Alloy 606 1-0. Thealuminum plate stock used for frame and cover plates shallbe certified by the supplier to contain less than 30 PPMboron, 80 PPM cadmium, and 80 PPM lithium.The subcontractor shall furnish certified physical propertiesand chemical analyses of ingots or plates of the 6061materials to INL.3.2.2 Aluminum Weld Filler Metal:All aluminum weld filler metal shall be ER4043 as required bySpecification AWS A5.10-1995.3.2.3 Dummy (Non-Fueled) Plate:Dummy (non-fueled) plates (see def.) shall be fabricated from aluminumType 6061-0, that meets the requirements of Section 3.2.1.2.PUR-1 SARPUR-1 SAR ~~~Appendix 3-17 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSuRU UIEST- ASSEMBLEDRECoFOR THE Effective Date: 01/24/07 Page: 13 of 573.2.4 Material ReqiuirementsAll material used or contained in the product shall comply with all therequirements of this specification and Drawings per Section 2.1.2 unlessexempted by written document by the purchaser.3.3 Mechanical Requirements3.3.1 Fuel Plate Requirements3.3.1.1 Fabrication: The supplier shall furnish the details of his fuelplate rolling schedule and component cleaning process tothe purchaser for approval prior to use in productionper 6.3.1.Compacting details shall include silicide -aluminumcompacting pressure and compacting press dwell time.After hot rolling, each fuel plate shall be blister annealed perSection 4.6.1 and then cold rolled to final thickness at roomtemperature. After cold rolling operation, the fuel platesshall be subjected to program annealing. The rollingschedule shall contain, at a minimum, the following:A. Nominal plate reductionB. Minimum number of hot roll passesC. Nominal inter-pass reduction and target thicknessD. Hot rolling furnace temperatureE. Preheat time for all hot roll passesF. Final hot roll plate thicknessG. Type and frequency of roll lubricant utilizedH. Nominal cold roll reduction.I. Final cold roll thickness.Fuel plate cladding (see def.) thickness required bySection 3.3.1.4 and fuel core homogeneity requirements ofSection 4.4 are independent requirements that must be met.PUR-I SARAppendix 3-18PUR- SARAppedix -152. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 14 of 57PURDUE UNIVERSITY REACTOR3.3.1.2 Core Configuration: No fuel particles are allowed within thefuel free zones located at the ends of the plates as shown onDrawing 635463.The nominally unfueled area of each fuel plate as defined byDrawing 635463 may contain random fuel particles definedas flaking and limited in size, location, and spacing per thisSection, as determined by Section 4.5.The presence of fuel particles detected between themaximum fuel core outline and fuel plate edges and ends isallowed provided they do not violate the followingrestrictions:-One or more fuel particles, which fit in a rectangle whosearea is not more than 4x1 0-4 in2 is acceptableAND-The fuel particle(s) are no closer than 0.080 in. to anyother particle edge to edgeAND-No particle is closer to the plate edge or end than themajor dimension of the particle.Stray fuel particles (see def.) that violate the aboverequirements may be removed from fuel plate edges byfiling, provided the following:-The filed out area is no deeper into the edge of the platethan 0.050 in., no longer than 0.250 in.ANDEach filed area is at least 1.0 in. apart3.3.1.3Filing of fuel plate ends, for the removal of stray particles, isnot allowed, unless previously approved by the purchaser.Internal Defects and Bond Integrity: Metallurgical bond, asdetermined by Section 4.6 is required at interface areas ofthe finished fuel plates, specifically fuel core-to-clad andclad-to-frame. The presence of grain growth across the fuelPUR-1 SARPUR-1 SAR ~~~Appendix 3-19 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 15 of 57PURDUE UNIVERSITY REACTORmatrix-cladding interface and across the aluminumframe-cladding interface of at least 50% is required. Fuelcore defects in excess of 0.06 in. in any dimension asdetermined by Section 4.7 are not allowed.3.3.1.4 Cladding Thickness: During production, all plates will besubjected to UT mmn-clad inspection. The standard will becalibrated at the nominal 0.008-inch scan depth. The gagewill then be adjusted to a 0.010 inch scanning depth and thefuel plates will be scanned at 0.0 10 inch. Fuel plate UTtraces, which display mmi-clad indications at the 0.010-inchdepth, shall be visually compared with the 0.008-inchStandard trace. Fuel plates for which the UT reports show acomparable density of indications, or worse, than theindications displayed on the standard UT report areunacceptable. Fuel plates, which fail the 0.010-inch UTscan, shall be rescanned at 0.008 inch. Only fuel plateswhich are acceptable when rescanned at 0.008 inch shall besubmitted to the Purchaser and User for evaluation.3.3.2 Non-fueled (dummy) plates:The supplier shall use a cold rolling method to obtain plate thickness.Non-fueled (dummy) plates shall be subjected to program anneal.3.3.3 Fuel Element Reqiuirements3.3.3.1 Weldinp: All welding shall be performed using proceduresand welding personnel qualified in accordance with ASMESection IX or the criteria defined in Appendix B. Qualityacceptance of production welds shall be in accordance withAppendix B, Section 5.3.4 Physical PropertiesFuel plates shall have a core of U3 Si2 and aluminum and completed fuel platesand fuel elements shall have fuel loadings per Sections 3.4.1.2, and 3.4.1.5.3.4.1 Fuel Plate Requirements3.4.1.1 Fuel Core: The fuel core shall consist of 19.75 "0.2 weight% enriched uranium silicide powder dispersed in aluminumpowder. The uranium silicide powder shall be -100, +325U.S. standard mesh particles. However, a blend mayPUR-1 SARPUR-1 SAR ~~~Appendix 3-20 2 uy2,212. July 23,2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 16 of 57PURDUE UNIVERSITY REACTORcontain up to 35 weight percent of -325 U.S. standard meshparticles. Any powder particles greater than 100 meshparticles shall be reground such that they will go thru the100 mesh sieve. The fuel core shall be fabricated accordingto standard powder-metallurgical and roll-bondingtechniques. The supplier shall provide to the purchaser, awritten procedure for pack assembly and the initial rollingstep which describes the method used to prevent excessiveoxidation that causes non-bond of fuel core to the cladding.3.4.1.2 Fuel Loading: By using the approved supplier's method ofassigning U-23 5 content, per a detailed description as to theweighing procedure by which the supplier proposes toassign fuel plate U-235 content. Each fuel plate shallcontain 12.5 "0.35 grams U-235. The weight of each coreshall be measured and recorded to within 0.01 gram U-235based upon weight of the final compact and chemical andisotopic analysis of the constituents.3.4.1.3 Fuel Homogeneity: Fuel homogeneity requirements arelocated in section 4.4.3.4.1.4 Void Volume: In the qualification process, all fuel platesshall be inspected for void volume using the methoddescribed in Section 4.2. The percent voids in the fuel coresof all fuel plates shall be determined by the inspectionprocedure developed by the supplier. The percent voids inthe fuel cores shall be at least 3.0% and not more than11.0%.3.4.1.5 Fuel Element Requirements3.4.1.6 Fuel Loading: Assigned fuel loading for each fuel elementshall be 175.006-4.90 grams of U-235. Each Control FuelElement shall contain 100 grams of U-235. Controllimits for the method used to measure this weight areestablished at the 95% confidence level for a significantpopulation of measurements of a particular standard. TheU-235 enrichment shall be 19.75 '-0.2 weight % of totaluranium per specification TRTR- 11.PUR-1 SARPUR-1 SAR ~~Appendix 3-212.Jl3,012. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 17of5PURDUE UNIVERSITY REACTOR3.5 Surface ConditionFuel plates and completed fuel elements must comply with the surface conditionrequirements of Section 3.5.1, 3.5.2, and 3.5.3 and drawings of Section 2.1.2, perANSI B46. 1. Sanding, or any other finishing procedure that will smear thealuminum surface, will not be allowed on fuel plates unless approved by thepurchaser.3.5.1 Surface Defects3.5.1.1 Compliance with surface finish and defect requirementsshall be established by 100% visual inspection of all fuelplates and elements. The surface of the finished fuel platesshall be smooth and free of gouges, scratches, pits, orremoval of metal in excess of 0.005 inch in depth. Dents inthe fuel plate shall not exceed 0.0 12 inch in depth or 0.25inch in diameter. If there is evidence of dogboning in theplates, surface defects in the dogbone (see def.) area shallnot exceed 0.003 inch in depth. No degradation of the fuelplates beyond these limits shall be permitted.3.5.1.2 Fuel Plates shall be free of stringiness, scabs, or cracks.Surface finish shall be as required by Drawing 635463.Compliance with requirements of this section shall beaccomplished by visual inspection of all fuel plates and fuelelements.3.5.1.3 Defects on fuel plate edges or ends are permissible providedthey are evaluated and acceptable to the requirements ofParagraph 3.3.1.2.3.5.1.4 Compliance with surface finish and defect requirementsshall be established by 100% visual inspection of all fuelelement containers. Fuel element containers shall be free ofsurface defects such as pits, dents, or scratches in excess of0.0 10 inch in depth and 0.12 inch in diameter or equivalentarea.3.5.2 Cleanliness:The suppliers fabrication, assembly, and storage areas used for theproduction of Purdue University fuel elements and/or components shallconform to the requirements of "controlled work area" (see def.) asdefined in Paragraph 1.3.6 of INL Standard 7022A. Cleanliness shall bePUR-1 SARPUR-1 SAR ~~~Appendix 3-22 2 uy2,212. July 23, 2015 Form 4l2.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 18 of 57PURDUE UNIVERSITY REACTORin compliance with INL Standard 7022A, Paragraphs 1.1, 1.2.3, 3.1, 3.2-b, d, i, 3.3 -d, e, 4.1.3, 4.2, and 4.3. Freon shall not be used to clean fuelelements or components.As determined by Section 4.10 of this specification, there shall be noforeign materials on the finished fuel plates or surfaces of the finishedfuel elements. All oil, metal chips, turnings, dusts, abrasives and spatter,scale, and other particles shall be removed from the fuel surfaces byprocedures which assure that the minimum cladding thickness has notbeen violated. All components shall be cleaned by a method approved bythe purchaser.3.5.3 Contamination:The surfaces of each fuel plate shall be counted or smeared and countedfor alpha-beta-gamma contamination. The alpha count shall be less thanfive dpm per 100 cm2, and the beta-gamma count shall be less than200 dpm per 100 cm2.Each fuel element shall be smeared and counted for radioactivecontamination. The alpha count shall be less than five dpm per 100 cm2,and the beta-gamma count shall be less than 200 dpm per 100 cm23.6 MarkingNOTE: All/fuel plates, fuel assemblies, and fuel element containers will bemarked per this section.3.6.1 Fuel Plate Identification:Each finished fuel plate shall be identified, as shown onDrawing 635463, by a combination of numbers and/or letters that willmaintain positive identification relative to the complete traceability tothe supplier fabrication history, including the basic material lots, heat ormetal, manufacturing cycle, and quality control phases. Theidentification number shall be stamped, etched or vibro-peened at thelocation specified by Drawing 635463. The depth of the identificationcharacters shall not exceed 0.010 in.3.6.2 Fuel Assembly Identification:rEach fuel assembly shall have an identifying number such as 07-XX (07signifying year of fabrication). The number shall be placed on thecontainer assembly as shown on Drawings 635455, 635456 and 635457.PUR-I EARPUR-l SAR ~~~Appendix 3-23 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 19 of 57PURDUE UNIVERSITY REACTORThe identification shall be stamped or entered by a method approved bythe purchaser, with two inch block characters not in excess of 0.010inches in depth. Standard assemblies should be labeled: E2, F2, G2,H2, F3, H3, E4, F4, G4, H4, F5, H5. Control assemblies should belabeled: E3, G3, and E5. The fission chamber assembly should belabeled as G5. The source assembly shall be labeled as C3. The spareStandard Assemblies should be labeled: SP-1, SP-2, SP-3. The spareControl Assembly should be labeled as SP-4.3.6.3 Dummy Element Identification:The dummy standard fuel element assembly shall have the identifyringnumber DUM-1. The number shall be placed on the container assemblyas shown on Drawing 635455. The identification shall be stamped orentered by a method approved by the purchaser, with two inch blockcharacters not in excess of 0.010 inches in depth.3.7 StorageAll fuel plates, fuel assemblies, and fuel element containers that have receivedfinal cleaning per Section 3.5.2 shall be protected in clean polyethylene containersor other containers approved by the purchaser while (1) awaiting final assembly,(2) being transferred into or being maintained in storage, or (3) being prepared forpackaging or shipment. Any material exposed to contamination shall bereinspected to the requirements of Section 3.5.3.8 Fuel Element Surface TreatmentIf boehnmite treatment is required during fuel element fabrication, the followingshall apply. After fuel elements are assembled and inspected they shall besubjected to an environment that will cause an evenly distributed boehmite layerof 0.00006 to 0.0003 in. thickness (averaged over the surface using eddy currentinstrumentation) to form on all surfaces of the entire assembly. The treatmentprocess shall be performed under controlled conditions, which shall require thesupplier to maintain a record of the thermal history of the autoclave. The recordsshall include heat charts of recorded time and temperature. Documented evidenceof the controls placed on the autoclave shall be maintained by the supplier.3.8.1 After the boehmite process has been qualified, one fuel element fromevery 2n autoclave run shall be inspected following a procedureapproved by the Purchaser.PUR-1 SARPUR-1 SAR ~~~Appendix 3-24 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 20of5PURDUE UNIVERSITY REACTOR3.8.2 Each fuel element shall have a corresponding aluminum plate coupon,made from fuel plate end crops, placed near the fuel element during theboehmite formation process. The aluminum plate coupon shall besubjected to the same environment as the fuel elements and each couponmeasured for boehmite thickness.3.8.3 Fuel elements and aluminum plate coupons subjected to the boehmiteformation process must be carefully handled to preclude scratches, dents,and gouges that would cause removal of boehmite.3.9 Graphite Reflectors and Graphite Radiation BasketsGraphite reflector assemblies (see def.) and irradiation facility assemblies (seedef.) shall be fabricated as per requirements contained in this section and indrawings 635454, 635460, 635461, and 635465.3.9.1 Material:All materials used shall comply with all the requirements of thisspecification and applicable drawings.3.9.2 Assembly:The assembly of the graphite reflector assemblies and irradiation facilityassemblies shall be as shown on the applicable drawings.3.9.3 Welding:All welding shall be performed using procedures and welding personnelqualified in accordance with ASME Section IX or the criteria defined inAppendix B. Quality acceptance of production welds shall be inaccordance with Appendix B, Section 5.3.9.4 Identification:The graphite reflector assemblies shall have identifying numbers such asGR-X placed on the side of the assembly as shown drawing 635454.The graphite reflector shall be labeled as follows: Dl, D2, D3, D4, D5,El, Fl, G1, Hl, I1, 12, 13, 14, and I5. The irradiation facility assembliesshall have identifying numbers such as IF-X placed on the side of theassembly as shown on drawing 635460. The irradiation facilityassemblies shall be labeled as follows: D6, E6, F6, G6, H6, and 16. Theidentification shall be stamped or entered by a method approved by thepurchaser, with two inch block not in excess of 0.0 10 inches in depth.PUR-1 SARPUR-1 SAR ~~~Appendix 3-25 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSuRU U VEST- ASSEMBLED ECoFOR THE Effective Date: 01/24/07 Page: 21 of 573.9.5 Dimensional Inspection:Verification of all external dimensions of the graphite reflectorassemblies and irradiation facility assemblies shall be by 100%inspection, in accordance with drawings 635454 and 635460. Alldimensions of this specification shall apply at a temperature of 75°F+/-5°"3.9.6 Surface Finish and Defects:The graphite reflector assemblies and irradiation facility assemblies shallbe free of surface defects such as pits, dents, scratches in excess of 0.010inch deep and 0.12 inch diameter or equivalent area.3.9.7 Storage:All graphite reflector assemblies and irradiation facility assemblies shallhave received final cleaning and shall be protected in clean polyethylenecontainers or other containers approved by the purchaser while (a) beingtransferred into storage, (b) being maintained in storage, or (c) beingprepared for shipment or packaging.4. QUALITY ASSURANCEThe supplier shall document, implement, and maintain a quality program in compliancewith ASME NQA-1-1997.The supplier shall permit the purchaser to conduct pre-award and continuing evaluationof the Quality Program.Personnel performing NDE examinations, specifically radiographic, ultrasonic, liquidpenetrant, and visual shall be certified to American Society for Nondestructive Testing(ASNT) Number SNT-TC-1A and certification documentation shall be made available tothe purchaser.Unless otherwise specified, the supplier shall be responsible for the performance of alltests and inspections required prior to submission to the purchaser of any fuel element foracceptance. Provided, however, that the performance of such tests and inspections is inaddition to, and does not limit, the right of the purchaser to conduct such other tests andinspections as the purchaser deems necessary to assure that all fuel elements are in-conformance with all requirements of this specification. Except as otherwise specified,the supplier may use for inspection purposes either his own or any commercial laboratoryacceptable to the purchaser. Records of all tests and examinations shall be kept completePUR-1 SARPUR-1 SAR ~~Appendix 3-262.Jl3,012. July 23, 2015 Forn 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 22 of 57PURDUE UNIVERSITY REACTORand available to the purchaser. All test and measuring equipment shall be calibrated perthe requirements of Standard MIL-C-45 662.The following applies to specified limits for requirements on core density perSection 3.4.1.1 and 4.2 and all dimensional requirements of this specification. Forpurposes of determining conformance with this specification an observed value or acalculated value shall be rounded off to the nearest unit in the last right hand place offigures used in expressing the limiting value in accordance with the rounding-off methodof the Recommended Practices for Designating Significant Places in Specified LimitingValues (ASTM E29).The supplier shall prepare for his use and the purchaser's approval an integratedmanufacturing and inspection test plan. The plan shall include all manufacturingoperations, equipment and tooling used, inspection requirements and gaging used, andmandatory hold points established by the purchaser.Any materials or fuel element components that are fabricated using equipment,personnel, or processes that are not in accordance with approvals as previously grantedby the purchaser are subject to rejection (see def.). A report of any such incident must besubmitted in accordance with Section 6.3.7.Fuel element inspection for shipment or rejection will be made by the on-site purchaser'srepresentative at the supplier's plant. Final fuel element acceptance will be made by thepurchaser at the User's facility.4.1 MaterialsCompliance with the material requirements of Section 3.2 shall be established bysupplier certification. A "Certification of Chemical Analysis" or a certified milltest report shall be supplied to the purchaser for each lot of material used in thefabrication of fuel elements. This certificate shall give the results of the chemicalanalysis for the material. All fuel element materials shall be traceable.4.2 Core DensityThe density of the fuel cores required in Section 3.4.1.3 shall be determined bythe Archimedes principle. During qualification of the fuel plate core void densityrequired by Section 3.4.1.3 shall be determined on all qualification fuel platessubmitted. After the particular plate type has been qualified, 100% inspection forvoid density is not required for production lots of fuel plates. For production lots,three randomly selected fuel plates from each lot shall be inspected for voidvolume density. Should any one of these plates be discrepant, the entire lot mustthen be inspected for void volume density. If void density discrepancies appearregularly in the process, the purchaser may request 100% inspection.PUR-1 SARAppendix 3-27PUR- SARAppedix -27Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 23 of 57PURDUE UNIVERSITY REACTORThe actual core volume shall be calculated by the following formula where:weight units are in grams and volumes in cubic centimeters.PALwhere:Voimmersion volume of fuel plate coreVp volume of fuel plateAL= density of aluminum used for fuel plate cladding2.715 gins/ccWp = weight of plateWc = deburred weight of fuel plate core compactPUR-1 SARAppendix 3-28PUR- SARAppedix -28Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-3 82STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 24 of 57PURDUE UNIVERSITY REACTORThe theoretical core volume shall be calculated by the following formulas:_ ( WU3Si2 + ( WA/1Vet --pA---TJwhere:Vct= calculated theoretical core volumeWU3Si2 = weight of U3Si2 powder in coreWal weight of aluminum matrix powder in corepU3Si2= density of U3Si2powder as measuredPAl= density of aluminum powder used for core matrix= 2.710 gms/ccThe void percent in the core shall be calculated using the following formula:V°%=v V-vCt(10000)Vcwhere:V% = percent voids in the fuel plate core4.3 Fuel LoadingVerification of the fuel loading as specified in Section 3.4.1.2 shall be inconformance to the supplier's procedure required in Section 6.3.1.In order to determine compliance with the fuel density requirements ofSection 4.4, the U-235 loading of the fuel plate, as determined in accordance withthe procedures of Section 6.3.1, will be divided by the core volume (Vc) ascalculated by the method described in the second paragraph of Section 4.2.4.4 Fuel HomogeneityFuel core homogeneity requirements shall be complied with by a one-pieceradiograph of all fuel plates from each fuel plate lot and evaluation of theradiograph by calibrated densitometer measurements. Purchaser approved densitystandards may be used by the supplier. Fuel plates and density standards shall bePUR-1 SARAppendix 3-29FUR- SARAppedix -29Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 25 of 57PURDUE UNIVERSITY REACTORexposed simultaneously. Fuel plate density variations shall be determined bycomparison of fuel plate areas to corresponding areas of the standard.All fuel plates shall be inspected for homogeneity. Homogeneity of the fuel platecore shall be determined by radiograph film density measurements with adensitometer having a 0.080 inch aperture.When determining fuel core density from plate radiographs, the brighter theimage on the radiograph, the more dense is the uranium and the lower the numberindicated on the densitometer. The darker the image on the radiograph, the lessdense is the uranium and the larger the number indicated on the densitometer. A+30% fuel core density and a +20% fuel core density is indicated by thedensitometer readings in the suspect area being 30% or 20% lower than theaverage densitometer readings for all core locations. A -30% or a -20% fuel coredensity is indicated by the densitometer readings in the suspect area being 30% or20% higher than the average densitometer readings for all fuel core locations.Any one-half inch diameter or greater spot in the plate fuel core area, other thanthe dogbone area shall not be less in fuel density than -20% of the average fueldensity for all fuel core locations. To determine the low density of a one-half inchdiameter area, the film is maneuvered under the densitometer in the low-densityarea until the highest number possible is obtained on the densitometer. Thisnumber is recorded. Then four readings are taken one-fourth inch from this spotand symmetrical around it. The average of these five readings is compared to theaverage densitometer readings for all fuel core locations.If density standards are used, the average densitometer readings of all fuel corelocations will be replaced by the nominal density standard and comparisons willbe determined between the suspect spot on the radiograph and the -30% and-20% standards. For the +30% and +20% homogeneity overload inspection,compare the nominal density standard to the suspect area. In this casedensitometer units from nominal of the fuel plate represent the followingpercentages: -0.15 = +30%; -0.10 = +20%. Fuel plates exceeding these limits arediscrepant.For rectangular shaped, suspected discrepant areas that are evaluated to the one-half inch criteria, orient the four symmetrical readings such that worst casereadings will be taken.Between the minimum and maximum permissible fuel core length boundary, fuelunderload condition shall not be evaluated.Any indication of un-alloyed uranium as determined by radiography shall because for rejection.PUR-1 SARAppendix 3-30PUR1 SR Apenix -30Rev2. ,July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSuRU U VEST- ASSEMBLEDRE oFOR THE Effective Date: 01/24/07 Page: 26 of 57Any 0.080 inch diameter spot in the fuel plate dogbone area (area within one inchof each fuel core end) shall not be greater in fuel density than +30% of theaverage fuel density for all core locations. Any one-half inch diameter area in thedogbone area shall not be less in fuel density than -30% of the average fueldensity for all fuel core locations. The actual dogbone shall not be more than one-half inch in the longitudinal direction.Other than the dogbone areas near ends of fuel core, any one-half inch diameterarea shall not be greater in fuel density than +20% of the average fuel density forall fuel core locations. To determine the high density of a one-half inch diameterarea, the film is maneuvered under the densitometer in the high-density area untilthe lowest number possible is obtained on the densitometer. This number isrecorded. Then four readings are taken one-fourth inch from this spot andsymmetrically around it. The average of these five readings is compared to theaverage densitometer readings for all fuel core locations.Unless otherwise specified, purchaser approval of all radiographs is required priorto assembly of fuel plates into elements.4.5 Core ConfigurationEach finish-cut flat fuel plate shall be radiographed in accordance withAppendix A and evaluated for compliance with Section 3.3.1.2.Visual radiograph inspections will be performed without magnification on a lighttable having a light intensity of 450 to 600 ft-candles at the table surface and thearea darkened to give a light range of 5 to 15 ft-candles 18 in. above the lighttable with radiograph film in place on the table.4.6 Bond Integrity4.6.1 Blister Anneal:After the fuel plate has been hot rolled, it shall be heated to 9000F+130F,held at that temperature for a period of 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br />, -15 minutes, +30 minutes,removed from furnace, and allowed to air cool.Any blisters, in the fuel core region larger than a 0.060 in. diameter or anyblister in the frame region of the fuel plate larger than 0.120 in. diametershall result in rejection of the associated fuel plate. A maximum of twoblisters less than 0.060 in. diameter is allowed in the fuel core area,provided they are more than 0.25 0 in. apart. A maximum of two blisters inany of the four sides of the picture frame (see def.)(a maximum of eight)region smaller than 0.120 in. can be tolerated providing that no blister isPUR-1 SARAppendix 3-31PUR- SARAppedix -31Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 27 of 57PURDUE UNhIVERSITY REACTORany closer to the plate edge or end or to another blister than the majordimension of the blister and no blister is closer to the plate edge or endthan 0.050 inch. When there is question as to size or location of theblisters, the acceptance or rejection of the plate shall be determined in theultrasonic inspection of Section 4.6.2.4.6.2 Ultrasonic Scanning:The finished fuel plate area shall be ultrasonically inspected incompliance with ASME Boiler and Pressure Vessel Code,Section V,Article 5, Paragraphs T-ll0, T-5 10, T-520, T-521, T-522-a, b, c, e, g, i,j, k, 1, o, T-523, T-523-1, and T-534. Any indication of discontinuity inthe fuel core region equivalent to that indicated by a 0.060 in. diameterstandard or any indication of a discontinuity in the frame region of thefuel plate equivalent to that indicated by a 0.120 in. diameter standardshall result in rejection of the associated fuel plate. Acceptance criteriafor number of blisters revealed by ultrasonic scanning are perSection 4.6.1. Any discontinuities, inside the fuel plate, other thanblisters and for which acceptance criterion is not already stated, shall bedescribed by the supplier and evaluated by the purchaser.4.6.3 Metallo~raphic Examination.During qualification, one fuel plate per lot selected for qualification perSection 3.1.1 will be sectioned per Figure 1, polished and etched, andexamined at 50x or above for bond and clad-core-clad dimensions perthe requirements of Sections 3.3.1.3 and 3.3.1.4, and Drawing 635463,respectively.If the fuel plate fails the metallographic examination for grain growth,voids, laminations, core cracking or separation, or foreign particles ormaterials, then randomly selected another plate in the lot formetallographic examination. If this plate fails the examination, reject thelot.Fuel plates selected for destruction tests may be rejected fuel plates,providing the attribute to be tested for is not affected by the cause forrejection. Reject fuel plates so used must have purchaser approval beforedestruct tests are performed.4.7 Internal DefectsAny internal defect in excess of the requirement of Section 3.3.1.3 in the fuelcore, including voids, laminations, U3Si2segregation, clumping, core cracking orPUR-1 SARAppendix 3-32PUR- SARAppedix -32Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382 5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 28 of 5PURDUE UNIVERSITY REACTORseparation, or foreign particles or materials, which is identified by anymeasurement technique, including radiography per Section 4.4, ultrasonicscanning per Section 4.6.2, or metallography per Section 4.6.3, shall be cause forrejection of the fuel plate.4.8 Surface Finish and DefectsCompliance with requirements of Section 3.5 shall be established by visualinspection of all fuel plates and fuel elements. Out-of-specification defects shallbe measured for size and depth and reported to the purchaser.4.9 Clad-Core-Clad DimensionsFuel Plate Qualification requirements of section 3.1.1 shall be established byultrasonic techniques using the purchaser-supplied, min-clad inspection gage. Allfuel plates will be subjected to ultrasonic mmn-clad inspection with the fuel coreregion scanned for each plate. Ultrasonic mmn-clad inspection shall beaccomplished by calibration of the mmn-clad gage, using the Advanced TestReactor (ATR) Standard (8E0777) scanned at the normal mode of 0.008 inches.The mmn-clad gage will then be adjusted and the fuel plates will be scanned at adepth of 0.010 inches. Ultrasonic Test (UT) traces showing fuel at the 0.010 inchdepth will be compared to the 0.008 inch standard to determine plateacceptability. If the density of indications from fuel plate exceeds the ATRstandard density of indications, the plate is rejectable.NOTE: The ATR standard is a small piece of an A TR fuel plate that has fuelparticles near the surface. It is used on the UT mmn-clad machine toindicate mmi-clad indications and compare the density of theseindications to any indications noted from a fuel plate being inspectedby UT.During the fuel plate qualification process, compliance with the requirements ofSection 3.3.1.4 shall be established by destructive analysis of one fuel plate per lotin accordance with Figure 1.After fuel plate qualification, all production plates shall be mmi-clad ultrasonicinspected at a depth of 0.010 inches. Those plates discrepant at 0.010 inches shallbe rescanned at 0.008 inches. Plates which are acceptable when re-scanned at0.008 inches shall be submitted on Information/Change Request (Form 540.33) tothe purchaser.PUR-1 SARAppendix 3-33PUR1 SR Apenix -33Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorSPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07PURDUE UNIVERSITY REACTORPage: 29 of 574.10 CleanlinessFuel plate, fuel assembly, and fuel element container cleanliness requirements ofSection 3.5.2 shall be established by visual inspection without magnification of allfuel plates, fuel assemblies, and fuel element containers.4.11 ContaminationThe surfaces of each fuel plate and fuel assembly shall be counted or smeared andcounted for alpha-beta-ganmma contamination and meet the requirements ofSection 3.5.3.4.12 DimensionalIt shall be the supplier's responsibility to assure that fabrication is performed inaccordance with all dimensions delineated in the Drawings referenced in Section2.1.2. Noncomplying design dimensions on fuel plates, fuel assemblies, and fuelelement containers (actual measurements) shall be submitted to the purchaser forreview and approval. Any discrepant component shall not be used in a fuelelement assembly unless approved.The supplier is to certify to compliance with the design dimensional requirementsdelineated in the Drawings referenced in Section 2.1.2.All dimensions of finished fuel plates, fuel assemblies and fuel element containersapply at 75°F+5°F.4.12.1 Final Dimensional Inspection.Dimensions required by this specification and drawings of Section 2.1.2shall be inspected using a purchaser approved sample plan and recordedon an inspection sheet with "in specification" dimensions recorded bycheck mark, "O, or actual measurements and out of specificationdimensions recorded as actual measurements.4.13 Reactor Components and Spare Fuel Element PartsReactor components and spare fuel element parts not assembled into fuel elementassemblies are required to be certified. The certification shall consist of materialcertification, fabrication verification, and supplier certificate of compliance to thespecification and drawing requirements. The certification documents shall besubmitted to the purchaser and user.PUR-1 SARAppendix 3-34PUR- SARAppedix -34Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 30 of 57PURDUE UNIVERSITY REACTOR5. PACKAGING AND SHIPPINGPackaging and shipping of the fuel elements shall be performed using a Purchaserapproved procedure in compliance with this section.*The purchaser shall provide shipping containers to protect the fuel elements from damage duringshipment and which conform to the applicable requirements of the Departments of Energy andTransportation, and other regulatory agencies having jurisdiction of the shipment of radioactivematerials. Re-useable shipping containers will be returned to the Supplier by the User at thePurchaser's expense.*The Supplier is responsible for loading the fuel elements into shipping containers in a sealedpolyethylene sleeve in a cleaned dry condition and free of extraneous materials.*The Supplier shall take necessary precautions during pack~aging to prevent damage to the fuelelements during shipment. Each container shall be provided with a tamper-proof seal. Loadingand shipping documents for the container shall be prepared in accordance with the applicableregulatory requirements.*The Supplier shall make arrangements for shipment to the User.6. NOTES6.1 DefinitionsFor the purpose of this specification, the following terms are identified:Batch. The amount of sulicide powder mixture which is handled as a unit ortraceable to a common step.Blended. To mix or mingle constituents of a batch.Certification. The action of determining, verifying and attesting in writing (signedby a qualified party) to the qualifications of personnel and material.Cladding. The aluminum covers bonded to the fuel core and the picture frame.Control Fuel Element Assembly. An assembly consisting of the control fuelelement container with eight fuel plates.Controlled Work Area. A work area to which access of personnel, tools, andmaterials is limited and physically controlled. Temporary enclosures may be usedwhere adjacent activities produce contamination which is detrimental to the job.PUR-1 SARAppendix 3-35PUR1 SR Apenix -35Rev2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 31 of 57PURDUE UNIVERSITY REACTORDevelopment. A determination of processes, equipment, and parameters requiredto produce a product in compliance with this specification.Dogbone Area. Thickening of the fuel core usually in the last 1/2 in. of the core,which may result in clad thinning in those areas.Dummy Fuel Element Assembly. An assembly consisting of a fuel elementcontainer with unfueled simulated dummy fuel plates.Dummy Fuel Plate. A non-fueled plate made entirely from the aluminum materialspecified in this document.Edge Clad. The distance between the edge of the fuel core and the edge of thefinished fuel plate, before any stray particles are removed, in the width directionas determined by radiography of a flat fuel plate.Failure. A condition where the fabrication process appears to be out of control ora breakdown or damage to equipment creates excessive costs and/or scheduledelays.Fuel Compact. A quantity of uranium silicide powder and aluminum powder, coldcompacted by pressing into a solid block for assembly into packs for hot roll andcold roll into fuel plates. The compacts are encased in frames and cover plates toform the pack.Fuel Assembly. An assembly of fuel plates and hardware components. Thisincludes both the standard and control fuel elements.Fuel Core. The uranium-bearing region of each Fuel Plate.Fuel Plate. The Fuel Core complete with aluminum frame and cladding.Graphite Reflector Assemblies. A component consisting of a graphite containerassembly with a graphite blockc inside.In-Process Controls. Inspections and tests made during production to ensure thatthe manufacturing processes, equipment, and personnel are producing a productmeeting specified requirements.Irradiation Facility Assemblies. A component consisting of a round tube attachedinside a graphite container assembly with graphite blocks filling the annulusbetween the tube and container. Inserted within the tube is the isotope capsuleassemblies.PUR-1 SARAppendix 3-36PUR- SARAppedix -36Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 32 of 57PURDUE UNIVERSITY REACTORLot. A group of pieces handled as a unit or material traceable to a commonprocessing step.Manufacture(ing). All fabrication, assembly, test, inspection and quality controlprocesses. Fabrication is a synonym for Manufacture.Pack. The fuel compact, picture frame, and cover plates, assembled together forhot rolling.Picture Frame. The window shaped aluminum frame, which holds the fuelcompact.Plates. See Fuel Plates.Procedure. The detailed description of the series of processes during manufactureand inspection, which follow a regular definite order (not to be construed as anoutline).Production. That phase of the program, following Qualification, during which theproduct is in Manufacture.Purchaser. Idaho National Laboratory (INL).Qualification. A demonstration that the Manufacturing process, equipment andpersonnel can produce a Product in compliance with this Specification.Quality Control. The sampling plans, inspections, tests and records required andused during Production to assure that the Product is in compliance with thisSpecification.Rejection. Materials, parts, components, or assembly products, which will not beaccepted as fulfilling the contract requirements because of noncompliance withthis Specification.Requalification. A demonstration that a single or group of manufacturingprocesses, equipment and personnel can produce a product in compliance withthis specification after the original qualification has been completed and becomesinvalid.Silicide. Uranium metal alloyed with silicon and fabricated per the requirementsof Specification TRTR-14. The word "fuel" is a synonym for Silicide.Specification. All parts and appendixes to this document, its references, drawings,and standards, as may be modified from time to time by contractual document.Standard Fuel Element Assembly. An assembly consisting of the fuel elementcontainer with fourteen (14) fuel plates.PUR-1 SARAppendix 3-37PUR- SARAppedix -37Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 33 of 57PURDUE UNIVERSITY REACTORStray Fuel Particles. Isolated fuel particles lying outside the maximum fuel coreoutline defined on Drawing 635463.Supplier. The primary vendor selected by INL to manufacture the product.User. Purdue University, at West Lafayette, Indiana.6.2 Purchaser TestsNone6.3 SubmittalsThe following data and records shall be supplied to the purchaser in the quantitiesstated. The purchaser's approval, prior to implementation, is required on thosemarked with an asterisk. All records and data shall be maintained by the supplierfor the duration of the Purdue University fuel element contract.The granting of approval by the purchaser of design, working drawings,specifications, requests, and other technical data submitted by the supplier underthe provisions of the subcontract or specification shall not affect or relieve thesupplier from such responsibility as the supplier has with respect to adequacy orcorrectness of the design, working drawings specifications, reports, and othertechnical data.6.3.1 Preproduction:Documents requiring approval must be submitted prior to productionuse. The number of copies shall be as specified by the Vendor DataSchedule. These documents include:-*A detailed description as to the weighing procedure by which thesupplier proposes to assign Plate U-235 content as required inSection 4.3.-Included in the description must be sampling, analytical, and qualitycontrol procedures; a statement as to the established accuracy andprecision of the assigned fuel plate and fuel element U-23 5 content;developmental and production data in support of the accuracy andprecision estimate; and data which at the 95% confidence level, showsthat the method used to assign U-235 values has a bias which is lessthan 0.2% relative-*A detailed description as to the manner the supplier will use to verify'the fuel Plate U-235 value as required by Section 4.3PUR-1 SARAppendix 3-38FUR- SARAppedix -38Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 34 of 57PURDUE UNIVERSITY REACTOR-*AlI fabrication, assembly, cleaning, surface treating, handling, anddecontamination procedures (not to be construed as an outline)*AlI production test, inspection, and quality control procedures,including all nondestructive and destructive tests and all standards andsampling section drawings. All data from these tests, including but notlimited to: radiographs, metallographic samples, ultrasonic testingtraces, and qualification yield rates-*All packaging, storage and shipping procedures6.3.2 Pre-repair:*All repair programs and procedures prior to use.6.3.3 Manufacturinu Schedule:*A schedule using a purchaser approved technique.6.3.3.1Reports.1. Biweekly qualifications phase summary status report. Thefirst such report shall be initiated 1 month after date ofcontract award.2. Three (3) copies of a monthly report detailing program~progress against a previously submitted schedule shall besupplied by the supplier to the purchaser. Report type,format and submittal schedule shall be as agreed uponbetween the purchaser and supplier.6.3.4 Delivery Submittals:Three copies (except as noted) of the following data and records shall besent prior to or accompany the shipments. The supplier shall maintaincopies of these records for at least 10 years and until the supplier hasreceived written approval from the purchaser for disposition or disposal:-Certification of product compliance to the requirements of thisspecification to include any test data pertaining thereto-Supplier's core compact data sheets, with individual fuel plate uraniumcomposition data including:-Serial number with batch (see def.) identificationPUR-1 SARAppendix 3-39PUR- SARAppedix -39Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSpRU UIEST- ASSEMBLEDRECoFOR THE Effective Date: 01/24/07 Page: 35 of 57Uranium contentFuel plate core weightU-23 5 enrichmentTotal quantity U-235 contentCore void density data-Individual fuel element composition data, including:Uranium contentU-235 contentSerial number of each plate in the element-Radiation count from fuel plate and fuel element exterior as required bySection 3.5.3 and 4.11. The counting period, counter, background,efficiency, and type of counter used shall be reported-List of all applicable waivers and deviations and related fuel plates orfuel elements-If performed, documented evidence of the performance and test resultsof the boehimite formation from the fuel element surface treatment perSection 3.8.6.3.5 Fuel Plate Radiographs:Fuel plate radiographs of all accepted fuel plates required by Sections 4.4and 4.5 and Appendix A shall be sent to the user.6.3.6 Core Compact Data Sheets:Supplier's fuel core compact data sheets shall be supplied to the INLQuality Assurance Representative as they are generated.6.3.7 Report of Production by Unapproved Process:Whenever the supplier's previously submitted and approved processcontrol limits are exceeded, or any material or fuel element componentsare fabricated using equipment, personnel, or processes which are notpurchaser approved, the time, nature, description, corrective action to betaken, and proposed further corrective action shall be reportedimmediately by the supplier, with a written report to the purchaser tofollow within 10 working days.PUR-1 SARAppendix 3-40PUR- SARAppedix -40Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 36 of 57PURDUE UNIVERSITY REACTOR1. T Samples. Transverse to be taken equally space along Fuel Core length.2. L Samples. Longitudinal to be taken at centerline and to include the Dogbone Area.TilT34I JLiT[- II I+/- +I IL11LL 1I I-I-I IFigure 1. Purdue University Fuel Plate Sampling Procedures For Destructive Tests.PUR-1 SARAppendix 3-41PUR- SARAppedix -41Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSpR E UIEST- ASSEMBLEDRECoFOR THE Effective Date: 01/24/07 Page: 37 of 57APPENDIX ARequirements for Radiography of Purdue University Fuel Plates1. ScopeThis specification provides requirements for radiography of Purdue University reactorfuel plates, acceptable film quality and film identification.2. RequirementsA procedure must be writt en to specify the details for achieving acceptable fuel plateradiographs. The procedure must include the requirements given in this specification.2.1 Equipment SetupThe voltage shall be 100 k.v.p. with a focal spot size of 5 mm maximum. Thedistance between the focal point and the plate shall be at least twice the length ofthe plate. The focal point shall be centered laterally and longitudinally over theplate or group of plates.2.2 Film2.2.1 The image outline shall be clear and sharp; the film shall be free of runs,streaks, scratches, blurs, and cassette defect that will affect the areacovered by the fuel plates.2.2.2 The film density of all points of the radiograph that correspond to thefuel plate border locations outside the plate core shall providedensitometer readings between 1.5 and 2.7. Film density as read over thenominal density standards shall provide densitometer readings between0.9 and 1.5.2.2.3 The film shall be extreme sensitivity, extra fine grain, high contrast,double emulsion, industrial x-ray type, (Kodak type M or equal) which isacceptable to the purchaser. Development of the film shall be inaccordance with the manufacturer's recommendation.2.2.4 Film IdentificationAppendix APUR-1 SAR Appendix 3-42 Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 38 of 57PURDUE UNIVERSITY REACTOR2.2.5 A system of identification of the film shall be provided by the supplier,which shall show as a minimum:A. Plate lot numberB. Plate type and serial numberC. Orientation of density standardD. Density standard identificationE. Date of radiography.Appendix APUR-1 SARRevA2.pJuyi23,3201PUR-1 SANRev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 39 of 57PURDUE UNIVERSITY REACTORAPPENDIX BWelding Requirements and Qualification for Purdue University FuelElements1. ScopeThe requirements for welding and for the evaluation of welds applicable to the PurdueUniversity Fuel Element Container and components are established by this Appendix.1.1 Application. This document defines requirements for the following:1.1.1 Welding procedure qualification.1.1.2 Performance qualification of welders, welding equipment, and specialfixturing.1.1.3 Information to be included in welding procedure specifications.1.1.4 Application of qualified procedures to production welding.1.1.5 Destructive testing and nondestructive examination for qualification andfor production welding.1.2 Special Limitations for Applicability. The requirements contained in thisappendix are to some degree based on RDT F6-2T. Those requirementsapplicable to Manual, GTAW, single pass, welding of Plug Joint welds, CornerJoint welds, and Partial Penetration Butt Joint welds have been included in thisappendix. The introduction of a new weld design or weld process requiring achange in these limited parameters would require an appropriate review of RDTF6-2T for requirements applicable to the new parameters.1.3 Definitions.Arc Strike. Any localized melting, heat affected zones, or change in the contour ofthe surface of the finished weld or adjacent base metal resulting from an arc orheat generated by the passage of electrical energy between the weld or base metaland a current source; such as welding electrodes, electron beams, ground clamps,high frequency arc, etc.Automatic Welding. Welding with equipment which performs the entire weldingoperation without constant observation and adjustment of controls by an operator.The equipment may or may not perform the loading and unloading of the work.Appendix BPUR-1 SAR Appendix 3-44 Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 40 of 57PURDUE UNIVERSITY REACTORFace of Weld. The exposed surface of a weld on the side from which welding wasdone.Face Reinforcement. Reinforcement of weld at the side of the joint from whichwelding was done.Heat. A single homogeneous melt of metal or alloy.Joint Penetration. The minimum depth a groove or flange weld extends from itsface into a joint, exclusive of reinforcement.Machine Welding. Welding with equipment which performs the weldingoperations under the constant observation and control of an operator. Theequipment may or may not perform the loading and unloading of the work.Position of Welding. The terms related to positions of welding for joint types andwelding processes and the position limits are defined in Section IX, ASME Boilerand Pressure Vessel Code.Repair. The process of restoring a nonconforming item characteristic to anacceptable condition, although it does not conform to a specified requirement.Rework. The process by which a nonconforming item is made to conform tospecified requirements.Root of a Joint. That portion of a joint to be welded where the members approachclosest to each other. In cross section the root of the joint may be a point, a lineor an area.Root of a Weld. The points, as shown in cross section, at which the back of theweld intersects the base metal surfaces.Root Penetration. The depth a groove weld extends into the root of a jointmeasured on the centerline of the root cross section.Root Reinforcement. Reinforcement of weld at the side opposite that from whichwelding was done.Root Surface. The exposed surface of a weld on the side opposite that from whichwelding was done.Size of a Groove Weld. The joint penetration (depth of chamfering plus rootpenetration when specified).Appendix BAppendix 3-45 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 41of5PURDUE UNIVERSITY REACTORUndercut. A groove melted into the base metal adjacent to the toe or root of aweld and left unfilled by weld metal.Underfill. A depression on the face of the weld or root surface extending belowthe surface of the adjacent base metal.Welder and Welding Operator Performance Qualification. The tests todemonstrate a welder's or welding operator's ability to produce welds meetingprescribed standards.Welder. One who is capable of performing a manual or semiautomatic weldingoperation (sometimes erroneously used to denote a welding machine).Welding Operator. One who operates machine or automatic welding equipment.Welding Procedure Qualification. The test to demonstrate that welds made by aspecified procedure can meet prescribed standards.Welding Procedure Specifcation. A written welding procedure which specifiesthe detailed methods and practices to be used in the production of a weldment andhow they shall be carried out. A specification includes all elements of aprocedure necessary to produce a satisfactory weldment. Examples of some ofthe elements included in a specification are: material used, preparation of basematerials, preheat and postheat cleaning, assembly method and sequence,fixturing, heat treatments, joint welding procedures, preweld and postweldnondestructive examinations, repair, rework, etc.Welding Procedure. The detailed methods and practices including all jointwelding procedures.2. Reference DocumentThe following documents are a part of this appendix to the extent specified herein. Theissue of a document in effect on the date of the invitation to bid, including anyamendments also in effect on that date, shall apply unless otherwise specified. Wherethis appendix appears to conflict with the requirements of a reference document, suchconflict shall be brought to the attention of the purchaser for resolution.Appendix BPUR-1 SAR Appendix 3-46 Rev 2. July 23, 2015.

Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR TILE Effective Date: 01/24/07 Page: 42 of 57PURDUE UNIVERSITY REACTOR2.1 American Society for Testing and Materials (ASTM) Standards2.1.1 ASTM E2, Preparation of Micrograplis of Metals and Alloys2.1.2 ASTM E3, Preparation of Metallographic Specimen2.2 American Society of Mechanical Engineers (ASME) Codes2.2.1 ASME Boiler and Pressure Vessel Code,Section IX, WeldingQualifications2.3 American Welding Society (AWS) Standards2.3.1 AWS A2.2, Nondestructive Testing Symbols2.3.2 AWS A3.0, Terms and Definitions3. Weld Qualification Requirements3.1 General ReqiuirementsAppendix BPUR-1 SARRevA2.pJuyi23,3201PUR-1 SARRev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 43 of 57PURDUE UNIVERSITY REACTOR3.1.1 All welding procedures, welders, or welding machine operators shall bequalified in accordance with the provisions identified in this Appendix.3.1.2 Weld Procedure and Performance Qualification Testing previouslyqualified to these requirements under other contracts may be used.Existing records to support previously qualified procedures andpersonnel are subject to review by the purchaser.3.1.3 Base materials and filler material shall comply with the requirements ofthe drawings.3.1.4 Welding processes which satisfy the specified requirements and producethe quality required by this Appendix are permissible. Weldingprocedures which utilize fluxes and coatings shall not be used.3.1.5 Fixtures: The capability of fixtures for aligning parts shall bedemonstrated before welding of production parts is initiated. If chill barsor blocks are used, the type of material and their location with respect tothe joint shall be included in the procedure specification.3.1.6 Position of Qualification Welds. All procedure and performancequalification test welds shall be made in the same positions as forproduction welds.3.1.7 Special Conditions for Qualification Welds: All procedure andperformance qualification test welds shall be made under conditionswhich simulate the actual production welding conditions. Theseconditions shall include space limitations, joint accessibility, degree ofcomfort due to heat, position and other handicaps or environmentalfactors which the welder or welding operator will endure during actualproduction welding.3.1.8 Heat Treatment. Weld preheat and postheat treatments shall not be usedwithout prior approval by the purchaser.3.1.9 Interpass Temperature. For multi-pass weld, the weld interpasstemperature shall not be less than 60° F or greater than 3500 F withoutprior approval by the purchaser.3.1.10 Records. Records of welding, associated processing, and inspectionshall be maintained for all welds. Complete records may consist ofinspection forms, routings, or reference to Operating Procedures or otherdocuments. These records shall include at least the following:Appendix BAppendix 3-48 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 44 of 57PURDUE UNIVERSITY REACTOR1. Base Material (Type, material specification, heat or lot number).2. Filler Material (Type, material specification, heat or lot number).3. Cleaning procedures.4. Joint identification and weld maps when applicable.5. Welding machine type and identification.6. Welding procedure specification.7. Welder or welding operator qualification.8. Procedure and performance qualification.9. Current-voltage data for machine or automatic welding.10. Date welds are made.11. Inert gas mixture, when applicable.12. Nondestructive examination procedure.13. Nondestructive examination personnel identification.14. Examinations and tests (nondestructive and destructive) and theresults.15. Photomacro graphs and photomicrographs.16. Metallographic specimens.17. If applicable, rework and repair of welds.18. Disposition of welds.3.2 Welding Procedure Specification3.2.1 The welding procedure specification shall meet the requirements of thisAppendix, and shall be submitted to the purchaser for information.3.2.2 The welding procedure specification shall include all essential elementsand details, as required by this section, to cover each joint to be weldedby the supplier. Each joint shall be identified in the welding procedurespecification. The specification shall include a joint design sketch forAppendix BPUR-1 SARRevA2.pJuyi23,3201PUR-1 SARRev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UN~IVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 45of5PURDUE UNIVERSITY REACTOReach joint welding procedure even if the specification references drawingnumbers.3.2.3 The following basic information and essential variables shall be includedin sufficient detail to assure that compliance with the requirements of thespecification can be verified:1. Basic Informationa. Joint Design: (the joint geometry, fit-up, and other requireddimensions of the welded j oint) tolerances and materialthickness.b. Method of arc initiationc. Electrode size (for gas tungsten arc welding)d. Gas type and flow rate (shielding and backing gas)e. Welding current range for manual weldingf. Whether tack welds or fixtures are used for assembly of thejoint for weldingg. Method and frequency of cleaningh. Number of weld layers and passesi. Whether stringer beads or weave beads are used2. Essential Variablesa. General, All Welding Processes.i.A change from a base material type or grade(materials of the same nominal chemical analysisand mechanical property range, even though adifferent product form) to any other base materialtype or grade. When joints are made between twodifferent types or grades of base material, aprocedure qualification shall be made for theapplicable combinations of materials, even thoughprocedure qualification tests have been made foreach of the two base materials welded to itself.Appendix BAppendix 3-50 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSpRU U VEST- ASSEMBLEDRE oFOR THE Effective Date: 01/24/07 Page: 46 of 57ii. A change of filler metal type or classification to anyother type of classificationiii. A change in welding position.iv. A change in vertical welding direction, i.e., fromupward to downward or vice versa.v. The addition or omission of integral backing (e.g.,"butt-lap" type joint).vi. The addition or omission of nonfusing metalretainers.vii. The addition or omission of filler metal to the joint.viii. Any change in the method by which filler is added,such as preplaced shims, preplaced wire, preplacedconsumable inserts, wire feed, or prior weld metalsurfacing ("buttering") of one or both joint faces.ix. The addition or omission or any type of preplacedconsumable inserts or joint surfacing.x. A change in the shape or size of preplacedconsumable inserts or joint surfacing.xi. A change from multiple pass welds to single passwelds.xii. The omission of inert gas backing during welding,except that requalification is not required where aqualified welding procedure is changed to omit theinert gas backing and then is used only for a singlewelded butt joint with a backing strip, or a filletweld. For multiple pass welding, the omission ofinert gas backing during welding until three layersor 3/16 of weld metal thickness has been deposited,whichever is greatest.xiii. A change from one welding process to any otherprocess or combination of welding processes.b. Manual Welding, All Welding Processes.Appendix BAppendix 3-51 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 47 of 57PURDUE UNIVERSITY REACTOR1. An increase in the standard size of filler metal fromthat stated and qualified in the procedurespecification.ii. A change in joint geometry which violates thetolerances given for the joint geometry elementslisted below:Bevel Angle: State in procedure specification.Tolerance:- Minus 5%.Groove Angle: State in procedure specification.Tolerance: Minus 5%Alignment Tolerance: Assign value inprocedure specification. Qualify procedure forsingle welded joints using maximumpermissible misalignment in a portion of thejoint.c. Gas Tungsten Arc Process.1. A change of electrode material type.ii. A change in arc starting methods.iii. A change from a single shielding gas to any othershielding gas or to a mixture of shielding gases or achange in specified composition of gas mixture.iv. A decrease in shielded gas flow rate of more thanten percent.Appendix BAppendix 3-52 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07PURDUE UNIVERSITY REACTOR3.3 Welding Procedure QualificationPage: 48 of 573.3.1 The welding procedure shall be qualified to the requirements of thissection.3.3.2 All welding used in qualifying a welding procedure shall be performedin accordance with a welding procedure specification.3.3.3 Before any welding is performed on production components, the suppliershall qualify each proposed welding procedure by:1. Recording all essential elements of the welding procedure in awelding procedure specification (see Section 3.2)2. Verifying the welding procedure specification by welding testspecimens representing each joint to be welded in production andperforming nondestructive examination and destructive tests inaccordance with the requirements of this Appendix.3. Submitting to the purchaser, for information, the weldingprocedure specification and a certified copy of the detailed resultsobtained from the tests performed on the test welds. Themetallographic sections required by this Appendix shall also besubmitted to the purchaser.Appendix BAppendix 3-53 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 49 of 57PURDUE UNIVERSITY REACTOR3.3.4 Essential Variables. The welding procedure shall be set us as a newwelding procedure specification and shall be completely re-qualifiedwhen any of the changes listed in Section 3.2.3.2 are made in theprocedure.3.3.5 Chart Recordings. Current-voltage-time charts shall be used for eachprocedure qualification weld for automatic or machine welding.Calibrated current and voltage indicating meters may be substituted fortrace chart type equipment for manual welding. The current and voltageranges shall be recorded for manual welding.3.4 Welder Performance Qualification3.4.1 Performance qualification weld tests shall meet the requirements of thissection, except that any welder used to qualify the welding procedureshall also be considered qualified and additional performance weld testsare not required.3.4.2 General.1. The performance qualification tests are intended to determine theability of welders to make sound welds.2. The performance test may be terminated at any stage of the testingprocedure whenever it becomes apparent to the supervisorconducting the tests that the welder does not have skill required toproduce satisfactory results. In this event, the welder may be re-tested at the discretion of the supplier in accordance with 3.4.3.3. Each supplier shall maintain a record of the procedures, includingthe essential variables, under which welders are examined and theresults of the examinations.3.4.3 Qualification of Welders.1. Each welder shall pass the tests prescribed for procedurequalification except that tensile tests are not required. Theessential variables and the test results obtained by each weldershall be recorded in a Performance Qualification Test Report. Anywelder who performs acceptable welding procedure qualificationtests shall be considered qualified.2. Renewal of Qualification. Requalification of a welder is requiredwhen:Appendix BAppendix 3-54 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-3 82STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 50 of 57PURDUE UNIVERSITY REACTORa. 90 or more days have elapsed since he last producedacceptable welds using the specific welding process, orb. He has not performed acceptable welds using theproduction welding procedure.c. Any time there is a specific reason to question a welder'sability to make welds meeting the requirements of thisAppendix, requalification shall be required. Only one testweld shall be required for renewal of qualification. If thistest weld fails to meet all of the original requirements, thena complete performance requalification shall be required.3.4.4 Chart Recordings. Current-voltage-time charts shall be used for eachprocedure and performance qualification weld for automatic or machinewelding. Calibrated current and voltage indicating meters may besubstituted for trace chart type equipment for manual welding. Thecurrent and voltage ranges shall be recorded for manual welding.3.5 Welding Machine Qualification3.5.1 Performance qualification weld tests shall meet the requirements of thissection, except that any welding machine used to qualify the weldingprocedure shall also be considered qualified and additional performanceweld tests are not required.1. The performance qualification tests are intended to determine theability of welding machines to make sound welds.2. Any time there is a specific reason to question a weldingmachine's ability to make welds meeting the requirements of thisAppendix, requalification shall be required. Only one test weldshall be required for renewal of qualification. If this test weld failsto meet all of the original requirements, then a completeperformance requalification shall be required. Welding machinesused for the manual welding of any successful procedure or welderqualification tests shall be considered qualified for manual weldingof all core components covered in this Appendix.Appendix BAR Appendix 3-55 Rev 2. July 2PUR-1 SI3, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382 5STANDARD AND CONTROL FUEL Revision: 1ELEMENTSpRU UIEST- ASSEMBLEDRECoFOR THE Effective Date: 01/24/07 Page: 51 of 53.5.2 Welding machines used for the manual welding of any successful welderperformance qualification tests shall be considered qualified for manualwelding of all components covered in this session.3.6 Examination & Tests3.6.1 Type of Test Required. The following tests shall be used for thequalification of welding procedures and / or welders as applicable:1. Nondestructive examination by a liquid penetrant method.2. Nondestructive examination by Visual to test for soundness andsurface characteristics of the weld.3. Destructive examination by sectioning for metallo graphicexamination of weld joints and adjacent areas to test for fusion,weld geometry, weld reinforcement, and soundness of the weld.4. When the purchaser has reason to believe that the quality of anyweldment is doubtful, he may require additional inspection.5. Nondestructive Examination and Testsa. Visual. The test weld shall be examined visually prior towelding and after welding in accordance with Section 5.1b. Liquid Penetrant. The test weld shall be examined after the.final layer in accordance with Section 3.6.2.2 using a colorcontrast method.c. Unless otherwise specified, inspection of procedure andperformance qualification welds shall be performed in thefinal surface condition.6. Destructive Examination. Each test weld shall be sectionedtransversely to metallographically examine a minimum of:a. Three section faces for welds on cylindrical componentsless than 1 'A inch in diameter or for welds that are one tofour inches long on non-cylindrical components.b. Four sections faces for welds in cylindrical componentsthat are greater than 11/4'/ inch in diameter or for welds thatare greater than four inches long on non-cylindricalcomponents.Appendix BARAppendix 3-56 Rev 2. July2PUR-1 St.33, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -. ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 52 of 57PURDUE UNIVERSITY REACTORc. One section face for plug welds, arc spot welds, and weldsthat are less than one inch long on non-cylindricalcomponents.d. The cross section shall be polished and etched to provideclear definition of the structure in the fusion zone and theheat-affected zones.e. For welds in (a) and (b) of this paragraph, one cross sectionshall be made through a weld start and a weld stop area andthe remaining sections shall be made at random. For welddescribed in (c) of this paragraph, the cross section shall bemade at the approximate centerline of the weld.Examination of the welds shall be in accordance withSection 3.6.2.3.3.6.2 Acceptance Criteria for Qualification Test Welds1. Visual Examination. Visual examination shall be in accordancewith Section 5.1.2. Liquid Penetrant Examination. Unless otherwise specified, finalweld surfaces shall be examined using a color contrast method.a. For welded joints in materials less than 1/8 inch thick thefollowing relevant indications are unacceptable.1. Any cracks.ii. Linear indications.iii. Indications with dimensions exceeding 1/64 inch.iv. Rounded indication separated by 1/44 inch or lessedge-to-edge.v. Five or more rounded indications in any six squareinches of weld surface with the maj or dimension ofthis area not to exceed six inches with the areabeing taken in the most unfavorable locationrelative to the indication being evaluated.b. For all welds in materials 1/8 inch thick or greater, thefollowing relevant indications are unacceptable. (OnlyAppendix BAppendix 3-57 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THlE Effective Date: 01/24/07 Page: 53of5PURDUE UNIVERSITY REACTORthose indications with maj or dimensions greater than 1/64inch are considered relevant for item (iii).)1. Any cracks.ii. Any linear indications.iii. Rounded indications with dimensions exceeding 10percent of the nominal weld thickness or 1/8 inch,whichever is smaller. Rounded indicationsseparated by 1/16 or less edge-to-edge shall beevaluated as a single indication.iv. Four or more rounded indications in a line separatedby 1/16 inch or less edge-to-edge.v. Six or more indications in any six square inches ofweld surface with the major dimension of this areanot to exceed six inches with the area taken in themost unfavorable location relative to the indicationsbeing evaluated.vi. Aligned indications in which the average of thecenter-to-center distance between any oneindication and the two adjacent indications in astraight line is less than 3/16 inch.3. Metallo graphic Examination Metallographic examinations shall beperformed on qualification test welds at not less than 50X on testwelds as required in this Section in accordance with ASTM E.2.Any cross section which is shown by metallographic examinationto contain any of the following relevant defects shall be cause forrejection of the test welds.a. Any cracks.b. Incomplete fusion, or insufficient joint or root penetration.c. Any tungsten inclusions, slag inclusions, or porosity havinga maximum dimension greater than 20 percent of the weldthickness or 1/32 inch, whichever is smaller.d. More than four tungsten inclusions or pores which have a~maximum dimension less than in (c) above.Appendix BAppendix 3-58 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 54 of 57PURDUE UNIVERSITY REACTORe. Any deviation from specified weld geometry or weldreinforcement.3.6.3 Test Welds.1. Procedure and / or welder performance qualification shall be madeon test welds which duplicate the production weld joint type andwhich simulate the conditions to be used in production with respectto orientation, the essential variables listed in Section 3.2.3.2, andthe dimensions of the parts to be joined to the extent that theyaffect heat requirements, relative motions, and distortions. Allwelding used in qualifying a welding procedure and / or welderperformance shall be performed in accordance with the procedurespecification.2. For manual welding, two consecutive test welds shall be madewhen the weld joint is less than six inches in length. Only one testweld shall be required when the weld joint is 6 inches or greater inlength.3. All test welds shall be tested using the required tests listed inSection 3.6.1. To qualify the procedure specification used inmaking the test welds, each Weld shall pass the required tests.4. Repair of procedure or performance qualification test weld(s) isprohibited.4. Production WeldingAll production welding shall be accomplished using approved welding procedurespecifications and qualified welders and/or welding operators.5. Quality Acceptance of Production Welds5.1 All completed production welds shall be visually examined in accordance withthe following requirements:5.1.1 General Visual Inspection Requirements. All visual examinations shallcomply with the following:1. Visual examination shall be made under direct daylight-typefluorescent lighting of at least 100 foot-candles at the workexamination area.Appendix BPUR-1 SAR Appendix 3-59 Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 55 of 57PURDUE UNIVERSITY REACTOR2. Visual examination shall be performed with the aid of a 5x(minimum) magnifying glass.3. The inspection required by this standard shall not be performed bythe welder who made the welds. However, if the welder isqualified in accordance with this standard, he may visually inspecthis own welds prior to the inspections required by this standard.4. Personnel performing visual inspection shall have 20-20 vision,natural or corrected, stereo acuity, and shall not be color-blind.5.1.2 Visual Acceptance Criteria (except for porosity). Visual examination ofweld joint preparations and welds shall be performed in accordance withthe following requirements to verify conformance to the written weldingprocedure, the design requirements, and the requirements of thisstandard:1. Prior to welding, the weld joint edges and adjacent surfaces shallbe examined for:a. Proper edge preparation, dimensions, and finish.b. Alignment and fitup of the pieces being welded.c. Verification of correct material by check of records.d. Verification of the cleanliness requirements.2. After welding, the joint shall be examined in the final surfacecondition for:a. Contour, reinforcement and surface finish of welds.b. Degree of underfill, undercut, and overlap.c. Arc strikes, weld spatter and impression marking.d. Burn-through and fuse-through3. Weld joints and surfaces which are shown by visual examination tohave any of the following defects or areas of nonconformance areunacceptable:a. Any nonconformance revealed by 5.1.2.1.Appendix BAppendix 3-60 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STAN7DARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THlE Effective Date: 01/24/07 Page: 56 of 57PURDUE UNTIVERSITY REACTORb. Any zone of incomplete fusion.c. Insufficient joint or root penetration.d. Any undercutting, underfill, or burn through.e. Any concavity on the face side of groove welds.f. Any arc strikes, weld spatter, and impression marking.g. Any visible inclusions, porosity, cracks, and unfilledcraters.4. Machined welds shall meet the drawing requirements.5. All welds shall be free from surface markings resulting frommishandling, punching, scratching, etc., which exceed the specifiedsurface requirements.6. All welds shall be fiee of dross, or slag.7. All welds shall be free of oxidation due to improper shfielding andoverheating which produce black or gray spalling or looseparticles. Iridescent temper films and the dark metallic vapordeposits which may occur adjacent to the welds are acceptable.These films and deposits shall be removed by approved cleaningprocedures when accessible.5.1.3 Visible unacceptable porosity is as follows:1. Four or more pores with a major dimension of 0.048 inches ormore randomly positioned.2. A single pore with a major dimension of 0.064 inches or more.3. Six or more pores with a major dimension of 0.016 inches orgreater in one weld.4. Four or more porosity with a major dimension of 0.016 inches orgreater, in line separated by less than 0.063 inches from edge toedge.5.2 Repair of a defective weld by welding shall be limited to two attempts.Unacceptable defects shall be removed and re-examination made using liquidpenetrant color contrast method to assure complete removal of the defect. If theAppendix BANAppendix 3-61 Rev 2. July2PUR-1 Sa3,2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -. ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 57 of 57PURDUE UNIVERSITY REACTORremoval of the defects results in reducing the thickness of the weld metal belowthe thickness of the base metal, the area shall be rewelded using a welding repairprocedure which has been approved by the Purchaser. Whenever a defect isremoved and subsequent repair by welding is not required, the excavated areashall be blended into the surrounding surface to remove any sharp notches,crevices or corners. Completed repairs shall be visually re-examined per Section5.1. Records shall be maintained on all repairs and shall include the following:5.2.1 Location ofj oint.5.2.2 Location of defect.5.2.3 Description of defect, including type and size.5.2.4 Reference to approved repair procedure.5.2.5 Inspections before and after repair and the results thereof.5.2.6 Identification of repair welders or welding operators.Appendix BPUR-1 SARRevA2.pJuyi23,3201PUR-1 SARRev2. July 23, 2015 1RA.J4I 2 I 1SNOTES:1. PROCURE. FABRICATE, AND INSPECT PER SPECIFICATION SPC-382.L2MARK ASSEMBLY ISENTFItC.BT82 PER SPECIFICATION SPO-SA2.3. REMOVE AUL BURRS HAS SHARP ESGES.2 1 SHEET REV STATUS PTA 0 PHYSIS2 E LESHEETS REVISED DESCRIPTION OF ITEM 3ASSES SHEET 2;I SEEOSAR-RADE ESS2 ,&8NY1C M ~t I1/2SA/ST2 ASSES ITEM S. CHANGES MATEREAL ITEM?CHANGES ITEMS. SEE SAA-RTA7VT A/ASSDC4 CU PAILLPS, 100" 3I6 SST OR 304SST 91 635457.5 SOURCE DRIVE TOP B .A S CU PHILUPS, T00O 315 SST 7B-SB SAC-2A S I/S LU1 635482-3 SOURCE DRIVE CONTAINERA1 5 35465-1 GRAPHITE BLOCK1 R 35462-1 GRAPHITE CONTAINER3ASSEMBLYSC .5 SOURCE ERRSE SUPPORTASSEMBLY2sc 1 GRAPHITE REFLECTORASSEMBLY1Br-1 SECTIONED ISOMETRIC REFERENCE ONLYSCALE: NONE-2 FINAL-t FINALsncsoa= REOURNTR: T, VINNOU.NHARRIK 3SIG S. MORRELL PURSUE UNIVERSITYN OUDRAM TEST RESEARCH AND TRAINING REACTORTA/SM-T S.,t PROJECT SEO. IGRAPHITE REFLECTOR ASSEMBLY ANDSPA.'USS SOURCE DRIVE ASSEMBL.YPROR I PHIRSCAAPPARH ARTUI/ES 5 A FFECTAR IVTE: A/1iO NOTES ISHEET 1 OF 2I 21 SORE0VAPURS- 1 OAR Arniendix 3-63 Rev' 2, Iulv 23, 2015[ APPLE~ATUNU/bb4 7517 2"1Y I ' I V I "." W

I V I I IIDIB (2953)AX 7I2.95(3 AXC-2 ASSEMBLYSCALE: 111BVA-2 SECTIONED ISOMETRICSCALE: NONEPUR-1 SAR Appendls* 3-64 Rev 2, July 23, 2013D OIMF3 DWG-635454 20 I i., I I CA E AII A I/I&D4:j1 8765~J74I I T INOTES:1. PROCURE. FABRICATE. AND INSPECT PER SPECIFICATION SPC-3R2./MARKE ASSEMBLY IDENT1FICATION PER SPECIFICATION SPC-TBZ/.OUANTn~f OF ITEM 5 (FUEL PlATES) ANAD ITEM N (DUMMY FUE L PLATES) USED IN -U ASSE MULY(PARTIAL FUEL ASSEMBLY) TO RE DETERMINED BY THE USER.A\CHANNE L SPACING BY SIDE PLATE GROOVE LOCATIONS AND WIDTHS. ANDFUEL PLATE THICKNESS. DIRECT MEASUREMENT IS NOT REQUIRED.S. REMOVE AU. BURRS AND SHARP EDGES.i T

c I{ LIADDED NOTE 3 A -3 ASSY; REVISED TITLES1CHANGED TO SHOW NEW FUEL PLATE DESIGN; 140SEDADD UGUUUED ITEM B. CHARGED MATERIAL ITEM A, HHDL1UICHNGE ITEM.. ,NOTEA,,SEEO ..A.... I ....___________ -(-ID%KItVAC~-1 -2 45 B-3MAMACHINE SCREW, FLAT HD.PHIWPS, 1W0'3B TO ST8-3UUNC-UA X lI2LG --3! 6 SST BMAHN HD,A 4 4 EG PHIWPU.I1DO" 31 SST OR DR4 UST H14 AH A 6.35A3-3 DUMMY FUEL PLATE BAR 14 A 35463-1 FUELPLATEASSEMBLY 51 1 1 635454-1 STANDARD FUEL CONTAINER4SC -D DUMMY FUEL ELEMENT3SC -2 PARTIAL FUEL ELEMENTSC -I STIANDARD FUEL ELEMEN'T-ASSEMMESBAT RIOLY T 1IAEATTCETK SCAT DRUESCBPT0H AG-1 SECTIONED ISOMETRIC REFERENCE ONLYSCALE: NONE..IFNAVWIRFSRRT RESSEUSTER: T. VINNOLAam~o PURDUE UNIVERSITYTEST RESEARCH AND TRAINING REACTORSTANDARD FUEL. PARTIALU DUMMY ELEMENT ASSEMBUESFUR-I SAR AppendixE 3-65 Rev 2, July 23, 2015in~i R I7 I I PLIAWT I ,TSORP -EE. OIUT21 8765431I .........NOTES:1. PROCURE, FABRICATE, AND INSPECT PER SPECIFICATION SPC-.382.L2XA ASEMLY DNIFCTO PE DRSECFID;CAINSC-B .....T ...FUEL PLATE THICKNESS. DIRECT MEASUREMENT IS NOT REOUIRED.4. REMOVE ALL BURRS AND SHARP EDGED.RAY EFRFIN DATA.CHANGED TO SHOW NEW FUEL PLATE DESION:I ADDED -2 ASSEMBLY. SECTION A-A. B ITEM 6; 1524/07SEE SAR-N3094D0CHANGED MEATERIAL ITEM?7 CHANGED MOTE 3.ICA-1 ASSEMBLY-2 ASSEMBLYBA--SE CHANNELSUPACNG .156MACAWNE SCREW. FLAT AS. O~S B CG PHILWPS, SB0 316 SET ON34SST 7S-3D UNO-DA A 5/11 LU8 5 35AA3.3 DUMMY FUEL PLATE 61 1 S 3SH6A=11I CONTROL TOP 5B 635463- I FUEL PLATE ASSEMBLY A1 I 34B CONTROL FUEL CONTAINERASSEMBSLYSC *D DUMMY CONTROL FUEL ELEMENTASSEMBLY2SC CONTROL FUEL ELEMENTS -T ASSEMBLY1CAT. BERTPYPTIOG CA 0S TESPTE0M OS EBANBAB AU-1 SECTIONED ISOMETRIC BEFERENCEONLYSCALE: NONESECTION A-ASCALE. 1/1PUR-1 SAR Appendix 3-66 Rev 2, July 23, 2015-2 FINAL-1 FINALmua= e..7 RAOLESISR: T. VINMOLAPURDUE UNIVERSrITYTEST RESEACRH AND TRAINING REACTORCONTROL FUEL ELEMENT ASSEMBLY ANDDUMMY CONATROL FUEL ELEMENT ASSEMBLYDI01MF3 DwO-635456 2~AC I 7 I I LT A,IUTOZ1 R754321NOTES:1. PROCURE, FABRICATE, AND INSPECT PER SPECIFICATION SPC-382.L~MARK ASSEMBLY IDENTIFICATION PER SPECIFICATION SPC-382,43CHANNEL SPACING IS CNROLDBY SIDE PLATE GROOVE LOCATIONS AND WIDTHS, ANDFUEL PLATE THICTINESS. DIRECT MEASUREMENT IS NOT REQUIRED.4a REMOVE ALL BURRS AND SHARP EDGES.2 SEE DA-514751 HEIVISiNS /40REVISE TO SHOW NEW FUEL PLATE DESGN;1 REMOVED iTEMS 2,4A &7REVIESEDTITLE; 1/2407BEE DAR-SURAURREVISED NOTE SB& MATERIAL ON ITEM B0A-1 ASSEMBLYSCALE: 11'BSECTION A-ASCALE. 1/MACHINE SCREW. FLAT RD.CDPHILLIPS. ITS' 316SST OR[504SST BB-32 UNC.DA X 5/16LGB* 35468-? FISSION CHAMBER TOP A635463-1 PUEL PLATE ASSEMBLY S515458-1 STANDARD FUEL CONTAINERASS EMRBLV-U REMOVED SDC -1 EEMNTFISSION CRAMBER FUEL ASMLA(DX CHANNEL SPACING .120)-ISNNEL SPACING .130(-1 SECTIONED ISOMETRICSCALE: HONEREFERENCE ONLYPUTSUSIi FINALTRRAT D*IS RHAURSTER: T. VINNOLAottaRR AESRGN a MORRELL, ,= ,WN N.OLOHAMLISTPURDUE UNISERSITYTEAT RESEARCH AND TRAINIMO REACTONFISSION CRAMBER FUEL ELEMENT ASSEMBLYAStUR- l SAR AppendixE 367 Rev 2, July 23. 2015I.!I. I APLICATMB 1 -AlA8 7 b 41 SORRY I ElF 18764I I .... .1 NOTES:1. PROCURE, FABRICATE. ANT INSPECT PER SPECIFICATION SPC-352.2r REMOVED3. REMOVED4. REMOVE ALL RIURRS AND SHARP EDGES.5. WELD PER SPECIRCEATION SPC-352 APPENODD B. USING ITEM 7 (WELDFILLER METAL).S. AUL CORNER AND FILLET RADII ,U30 UNLESS OTHERWISE NOTED.SCRUTICAL INTERFACE DIMENSIONS SHALL BE ADHERED TO.ANVERIFY RECTANGULAR CAVITY AND SLOT SIZE WITH GO-NO-GOGAUGE. DFE PROVIDED GO-NO-GO GAUGE SHALL SLIDE FREELYTHROUGHOUT ENTIRE DESIGNATED CAVITY (OR SLOT) LENGTH FORALL ULOTS HANG-UP, STICEING. OR DISENGAGEMENT FROMSLOT.-1 ASSEMBLYSCALE: 1/1-1 ISOMETRIC VIEW REFERENCE ONLYSCALE: NONEVIEW BDEALE: 4:1VIEW C AUSCALE. 4/1VIEW ASCALE: 2/1PUR-I1 SAR Appendix 3-68 Rev 2, July 23, 2015 NOTES:1. PROCURE. FABRICATE. AND INSPECT PER SPECIFICATION SPC-382.2. REMOVED3. REMOVEDB. REMOVE ALL BURRS AND SHARP EDGES.U. WlELD PER SPECIFICATION SPC.382 APPENDIX B. USING ITEM 7 (WELDFILLER METAL).THROUGHOUT ENTIRE DESIGNATED CAVITY (OR SLOT) LENGTH FORALL SLOTS WITHOUT HANG-UP, STICKING, ON DISENGAGEMENT FROMSLOT,-1 ASSEMBLYSCALE: 1/1-1 ISOMETRIC VIEW REFERENCE ONLYSCALA: NONEjz~~VIEW C 4x,SCALE: 4/lVIEW BSCALE: 4/1VIEW ASCALE: E1PUR-1 SAR Appendix 3-69 Rev 2, July 23,2015 NOTES:1. PROCURE. FABRICATE. AND INSPECT PER SPECIFICATION SPO-,3A2.2. REMOVED3. REMOVE ALL BURRS AWD SRARP EDGES.A. WELD pER SPECIFICATION SEC-UB2 APPENODIX B, USING ITEM 7(WELD FILLER METAL). _5. REMOVED.GAUGE. OFF PROVIDED GO-MO-GO GAUGE SHALL S LIIDE FREELYENTIRE DESIGNATES CAVITY (OR SLOT) tLENGTH FONALL SLOTS PATAGUT HANG-UP. STICKING. OR DISENGAGEMENTFROM SLOT.,167/-1 ASSEMBLYSEALE III-1 ISOMETRIC VIEW REFERENCE ONLYSCALE: NONEi"WIEW AUCALE: DliVIEW C AUSCALE: A/l R7S4743NOTES:1. PROCURE. TABRRCATE, AND INSPECT PER SPECIFICATION SPC-382.ASSEMRLY IDENTFIfCATION PER SPECIFICATION SPO-3E2.3. REMOVE ALL BURRS AND SHARP EDGES.2 I 1SEE DAR-514751 REVINIONS 440REVl04100 I EFECTNEATEREVISED THE DESCRIPTION SF RTEM 3 /471SEE DAR-5UH425 /402CHANGED MATERIAL ITEM 7 4AUD.4 1 F-1 ASSEMBLYSCALE: 1,1BMACHINE SCREW, FLAT HD,A CAPHILUIPS, TOO 316 SST OR3U4 SOT 7UNC-2A 0172 LU __1 8 35461.2 CAPSULE INSERT ASSEMBLY1 635451.1 CAPSULE HOLDERHASSEMBLVY1 63S462-I GRAPHITE CONTAINER3ASSEMBLYDC -1 IRRADIATION FACILITY ASSEMELY I-1 SAFETI PART OB IIOAIELtISERE UHIE RIE,/PECFECATEH ITEIT. EIEqNTEMTI ECAET.,'P' URAE,.SRMA o..510011(1SFTI-1 SECTIONED ISOMETRIC REFERENCEONLYSCALE: NONEFINALNEXT 05TN400 B EASlN U. MORRELL PURDUE UNt~fERSITYETORiroOR TNAN OLOHAM TEST RESEARCH AND TRAINING REACTORTOOT , NTA U 0 004C so IRRADIATION FACILITY ASSEMBLY.. ...... ..... 1M owG.635460 N EBOTI 505051 1FAPI16.1 C AD Ann,.HSiY 3-71 A.RT I/O/Rh 101IS~TI F STBACUB/OE7 6 4 2 1 S2EU32876'P42,1 SD8032

-712432I1I P 4, I.I.,ll I REASONSREV STATESNOTES:1. REMOVE ALL BURRS AND SHARP EDGSES.2. pROCURE. FABRICATE. AND INSPECT PER SPECIFICATION SPC-382.3. WELD PER SPECIFICATION SP0-322 APPENDIX R. USING ITEM 17 {WE LD FILLER METAL).4.ALL CORNER AND FILLET OTIIERISSE NOTED.ITITI1IREV IDESl.ETSj REVISED TOLERANCES ONl ITEM1%o?I I .............. IDI-_(2.755)........................... J-O SEE DETAIL3 SEE ASSC-1 ASSEMBLYSCALE IllAR AR AR AR SC ELILRMTL ER4043 AWDA5AD 17AR SC BAR. 01/)2 ASTM B211 INAL SON61.TNSTAR SC 0114 ASTM B2TT ISAL 6021-T05 1AR SC 002101t18 ASTM B211 14ALBAAI. TB51AR SC TUBING, 1 TI8OD X D05 WALL 12AL. DEI-TE ASTM B21DAR SC WALL IlALBAA61.TB ASTM 82121 C 10 PLGpLATE, 1127115 ASTM BUS IDAL 661 T-5I SC -B CAPSULE UPPER TUBE BAR, 01 31 ASTM 8211 9t S -8 CAPSUIE HOLDER TOP PLATE. I THE ASTI, BUSS 8tSC -7 CAPSULE BOTTOM PLATE. 54114TK P.574 8209 71 5 35405-2 GRAPHT CAPSULE HOLDER SSC *4 CAPSULE HOLDER TOP PLATE41 SC .3 CAPSULE HOLDER WELDMENT3ASSEMBLYSC -2 CAPSULE RNSERT ASSEMBLY 2SC .1 CAPSULE HIOLDER ASSEMBLYP0279 IBEREIELFATIO TO45 .D535A5\* "4-1 7F 5 THR..2753XH RU-LK5WOE/BOOtlNSSAEIOUHRNBAT-1 ISOMETRIC REFERENEONLYSCALE: NONEoDETAILSCALE: U11P4415SIL$-2 635460-I 635460-B.B,m 5y T.RINOLADEBA MORRELIBRBB IB*4,92 O IDA I0 c 9911 55095115*1 8RPURDUE USIVERSITYTEST RESEARCH 4245 TRAINING REACTORCAPSULE HOLDER AND CAPSULE INSERTASSAMBUES AND DETAILA1 I*'*PUJR- I SAR Appendix 3-72 ReP 2. July 23, 2015:_=='OF 3* -,^ b 31 '8 18701 a7654321D"4"4"1-3 ASSEMBLYSCALE: lt-02.6.0065 X45"8 ESDETA(255)SECTION A-ASCALE LISECTION B-BSCALE IIIB20 14-4-000~1'4- ABCBVVB~I[0]-4 ASSEMBLY-8 ISOMETRIC ONLSCALE: NONEADETAILSCALE: il1PUR-i SAR AppendLx 3-73 Roy 2, July 23. 201.5D O1MF3 ow3.635461 1[0 I b 4 1 008032U/t5421 J, ,lQ"7R1a -7 A0-u-iC'1-2 ASSEMBLYSCALE: Oit0110 IR2.750f-0 -01.040 -H01(.1O)C) DETAILBC) DETAILSCALE. 211A-2 ISOMETRIC FIEFNENCE OLYPUR-1 SAR AppendLx 3-74 Re'," 2. July 23.20150 IO1MF3' ow-356SCALE NONE PUR-i SAR Appendix 3-74 Rev 2. July 23. 2015B / 'P 4 :3 2874321 4,.7IVA91NOTES:1. REMOVE ALL BURRS AND SHARP EDGES.2. PROCURE. FABRICATE. AND INSPECT PER SPECIFICATION SP-32.3. WELD PER SPECIFICATION SPC-SJA2 APPENDSX B. USING ITEM B WEhLD F'iLLER METAL).A. ALL CORNER AND FILLET RADII .232 UNLESS OTHERWISE NOTED.4CRITICAL INTERFACE DRMENSIONS SHALL RE ADHERED TO,/~VERIFY ULAR CAVITY AND SLOT SIZE WITH GO-NO-GO DAUGE. DIV PROVIDEDGO-NO-GO GAUGE SHALL SLIDE FREE LY THIROUGHOUT ENTIRE DESIGNATED CAVITY (ORSLOT) LENGTH FOR ALL SLOTS WITHOUTY HANG-UP. STICKING. OR DISENGAGEMENT FROMSLOT.REMOVED PRIOR REV HISTORY IO4SEE ECR-55V8)R72/0REVIVED DIMENSIONS BSlD.---.---.J, m-1 ISOMETRIC REFERENCE ONLYSCALE: NONE-1, ASSEMBLY IsHOw-3 ASSEMBLY (SIMILR)AR AR SC WELDFILLERMETAL ER4043 AWEANS) BS1 -T* SOUIRCE DRIVE NOZZLE MK RMASU-ASSEMBLY MK RM656-I "' -H NOZZLE MANE FROGM B3SAHT-3 BIINCONTAINER MN RMBNS-1 N1 -TUNE ASSEMBLY MK RM656*SCS3.OURCE DRIVE CONTAINER3S -3 ASSEMBLY3-2 REMOVED2S -, GRAPHITE CONTAINERASSEMBLY14--HASN AG)5ANN-IA5NINEAGA* S!"EN T. VINNOLA PUDUE UNIVERSAITYHAHN) S, NORRELL TEST RESEARCH ANAD TRAINING REACTOR5)3.1 N. GIGISAM GRAPHITE CONTAINER ASSEMBLYISSAA E N AWJAN A. AND SOURCE DRIVE CONTAINER ASSEMBLYrnAO 3 OENNWA)P)NANLSNAV)NS t'NCE'PSAD6354621M3ISWVIEW ASCALE: FUR-I1 SAR Appendix 3-75 Rev 2, July 23, 2015VIEW B.1.I b 9 4/b4:J 8 I 7 I I4 I I 2 INOTES: I I I I..1. REMOVE ALL. BURRS AND SHARP EDGES.SE c.5837202. PROCURE. FABRICATE. AND INSPECT PER SPECIFICATTON SPC-382, SEE ECR.652525 811507I/3ALL GROOVE LOCATIONING DIMENSIONS ARE *8802 AND TOLERANCE SHALLNOT SE ACCUMULATIHE UNLESS OTHERWISE SPECIFIES. 8SEER53RL+/-WELD PREP AS NECESSARY.5.REMOVEDD/Z\TOLERANCEXXX 1.041-2RV8X.005 MAD 255722 .28_D -.1883 CZ-:2.AA cm.]oE0 .-.8 (Cm TNDR IEPLT HE O LTjBT 211C ETILL8THND8HW -0 EMVE 1-2284 __ __H__ET-1DEAI 098 N________-__PARPT__L,-E AT ~ -.84 __ ____ ___.21 ,, *622STANDARD SIDE PLATE SHEET OR PLATE ATMB2SC -1 ERGT SAND ALNIT 85361221T6G DEALETADSHSRI-IT REMOVES ID-3 GTOrRLSDETAIL RIGHTE ANS06 OPOSTE) SCMB21 -5 SPCRPLATED 82417(I) UT ASTIM 8209 5uSLEFT HND5Al.8881-T1-C 635STANDARD SIDE PDLN E.MEETEOR PLATE ANSVER 8221*6 3548 R/ LEFTDU HANDT RESEARC1.DTP8 GRfC-.3 REMOVED548 o~¢CONTROLSII 5 PLT SETDPAE STI 2213 21IREMOVED 7 4 9D6-C) DETAIL LEFT HANI SO VsowlDETAIL rnGHTIIANO(oPPosITEPUR- I SAR Appendix 3-77 Rev' 2, July 23, 2015I : &L. I 2i ZI- 2 1 Seib/00Z I.0fl.010J/-> 040045I/ .00420 4( 2260.9451242xx20 .,77.1701 2 1.3155.DETAILI //I nlnl l00.T 3400270F OX .255fo20 .25045 -'2~I. _______ I40, 2.0100)DETAILPUR-i SAR Appendix 1-70 Rev 2, July 23, 2015 1a"7R'I,2tI f I V I v * ! V I I iD-.355AL(TOP) (BOTTOM}A-AE PARALLEL WITHIN .005-11 ISOMETRIC ONLSCALE: NONECBA) DETAIL/ASCALE: 111OUR-I OAR Appendix 3-79 Rev 2, July 23, 2015D OJMF3 00S~ 63 46 6EA3EE ROTED OE0f l 0I .'"PR I ' i2. .../I::).Z,Z O"7'S55',,A5-111111 7NOTES:1. REMOVE Alt BURRS AND SHARP EDGES.2. PROCURE, FABRICATE, AND WNSPECT PER SPECIFICATION SPC-3BZ.3. WELD PER SPECIFICATION SPC-3B2 APPENDIX B USING ITEM 8 (WELD FILLER METALI.A ALL CORNER AND FILLET RADII .230 UNLESS OTHERWISE NOTED.S. REMOVEDATOLERANCE:A. IIAXCERNE I IR H NID FCNTIE0UE SY53.A-LL1LLLIZLIJREVXTATU 12~ ~ FSREVISED TITLE; REVISED ITEM 3; ADDED NOTE A;ADDED SHEET 2 & 3; ADDED ITEM 2:SEE DAR-SSBA4VX1/TAX?7TOTALLY REVISED SHEET 2C REMOVE D CHAMFER 440FROM DETAIL U. ADDED RADIUJS DIMENSION TO AlSITEM 3, REMOVED MOTE S. SEE DAR-D147513SEE ECX-551R72 T/2/07ADDED NOTE 7.ID-1 ISOMETRIC REFERENCEONLYSCALE: NOSESE .... SEE DETAIL(SSSTU = II2.i.IS .13..B1313 SEE DETAIL E1I~CI (2.5531-1 ASSEMBLYSALE: /1SR SC WELS FILLER METAL ER 4543 AWS A5.10 8_WOVEN WIRE CLOTH.SLUSC -V MESH TN16 B6MESH PER NACH, BAL ASTM E 2UISSC -3 NOZZLE PITEUMINA1Y MACHINED ALRXST. T6 ORAL 60A1-TN511 OR 3AL NXNI-TS5lSC -2 SOURCE DRIVE TOP AP L RUST-TENTf ASTM B20XASC -I SOURCE DRIVE NOZZLEASSEMBLY-T I/ST PAETISH NA'TURI.PXGCEEAIB( I7512CVI. REBFIPITIC UHSSCXVER XEHRANNE I2mi.7PM IS UST-XN1 635TARTEBBIa y 5 REOUENTRH. T. AINMOLAAXSIVIN D. MORRELLgqITIR DRAWN AS.LHAt IcL oEAV IPURDUE UNIVERISITYTEST RESEARCH AND TRAINING REACTORSOURCE DRIVE NOZZLE ASSEMBLYAND SOURCE DRT/E TOPn ] 4IAO) DETAILSCALE: 1It0DETAILSCALE; litruE- I TAIlS A[T~ERUIX 55V WET 1. IXJ~ 1.1, ~AIT APREARRA I I~EC~X~EIDIART j1c118 NOTES SUET 1 OF 3B / B A'S 4 1 SURESA87(5,1=4 7 R "7 4DX11/4-28 UNF *.381, .375(FOP){8OTTOMA)Ct 2.52*, 01 _" [ '-2 ISOMETRIC REFERENC.'E 084,VSCALE: NONET22 ~.... :_/t (.25).-2X .219.284BOX ROE'C) ETAIL L/\APUJR- I 04AR Appendix 3-81 Rev 2. July 23. 2015SSF41. NOTED 2d 3 2+ '5/00q.Z 7417 N17I IID-1 ISOMETRIC REFERENCEONLYSCALE: NONEB0 DETAIL/AAPUR- 1 SAR Appendix 3-82 Rev 2, July 23, 2015D OJMF3 owci-635467 4nolAn ati / b 9 4 1 ..... I 0-- 9/bb41 NOTES:1. REMOVE ALL BURRS AND SI-ARP EDGES.2. PROCURE, FABRICATE. AND INSPECT PER SPECIFICATION SPC-382.A AILLCORNER AND FILLET RADII D030 UN LESS OTHERWISE NOTED.4. REMOVED,/ TOLERANCE:.0031 ABA5-1 ISOMETRIC REFERENCE ONLYSCALE NONEo DETAILAPUR-l SAR Appendix 3-83 Rev 2, Jully 23, 2015 7,1,A,0O"t0DX1)4-28 UNF.- 3B 7.375(TOP) (BOTTOM)-2 ISOMETRICSCALE: NONE-- 2X .07BC) DETAIL A\SCALE: 11PUR- I SAP. Appendix 3-84 Rev 2, July 23, 2015O OJMF3 owe.635468 48A~EE NOTED EEl 2I 1 S08183A-a T -, "r 'I02

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+{{#Wiki_filter:APPENDIX 2: NATCON INFORMATIONHot Channel Factors in the NATCON Code Version 1.0The NATOON code version 1.0 [Ref. ANL/RERTR/TM-12] uses three hot channel factors (FQ,FW, FH). Using the source code and documentation, the factor FH used in NATCON is found tobe the same as the factor FNUSLT used by E. E. Feldman. Table 1 shows the tolerances anduncertainties included in each of the six hot channel factors used by E. E. Feldman. Thecorrespondence between the NATCON hot channel factors and E. E. Feldman's six hot channelfactors is as follows.Feldman's Hot Channel FactorNC CNInuVariableSystem-wide Factors:FFLOW a factor to account for the uncertainty in total reactorflowFPOWER a factor to account for the uncertainty in total reactorpowerFNUSLT a factor to account for the uncertainty in Nu numbercorrelationFW (approximately)FQFHLocal Factors:FBULK a hot channel factor for local bulk coolanttemperature riseFFILM a hot channel factor for local temperature rise acrossthe coolant filmFFLUX a hot channel factor for local heat flux from claddingsurfaceFBULK (new input)FFILM (new input)FFLUX (new input)Hot Channel Factors in the NATCON Code Version 2.0PUR-1 SARAppendix 2-1PUR- SARAppndix2-1Rev 2, July 23, 2015 Sections 2.1 and 2.2 develop, for laminar natural convection, two thermal-hydraulic relationshipsthat are used in section 2.3 to obtain formulas for the hot channel factors from user-suppliedmanufacturing tolerances and measurement uncertainties. The results of section 2.3 aresummarized here for convenience. The first three are local/random hot channel factors, and thelast three are system-wide. An example of the use of these hot channel factors is given insection 4, with NATCON running instructions in section 3, and the new input description insection 5.FBULK- 1 +j{(1 + u)2a+ (1+ u2)2+-r-:U1 +u62FBULK is higher (conservative) if the temperature dependence of water viscosity is ignored.FFILM = 11u12+/-+u22+/-+u32 +u42+/-+u52FFLUX -- 12 +u22+/-+u32 +u4FQ = 1 +u-FW = 1 + u8FH = 1 +- u9whereul= Fractional uncertainty in neiitronics calculation of power in a plateu2= Fractional uncertainty in U-235 mass per plate =Am/_Mu3 Fractional uncertainty in local (at an axial position) fuel meat thicknessu4= Fractional uncertainty in U-235 local (at an axial position) homogeneityu5  = Fractional uncertainty in coolant channel thickness = (tnc -thc) / tnu6  = Fractional uncertainty in flow distribution among channelsu7= Fractional uncertainty in reactor power measurementu8= Fractional uncertainty in flow due to uncertainty in friction factorUg = Fractional uncertainty in convective heat transfer coefficient, or in the Nu numbercorrelationM = Nominal mass of U-235 per plate, gramAm = Tolerance allowed in U-235 mass per plate, gramPUR-1 SARAppendix 2-2PUR- SARAppndix2-2Rev 2, July 23, 2015 The code obtains, for an input nominal reactor power CPWR, a thermal-hydraulic solution usingthe three systematic hot channel factors FW, EQ and FH. If the user-input reactor power is zero,then the code itself chooses the nominal power from a series of power levels (10 kW, 100 kW,200 kW, and so on increasing in steps of 100 kW). This thermal-hydraulic calculation is done fora hot plate power of CPWR*FQ*(Radial power peaking factor RPEAK)/(Total number of fuelplates in standard and control assemblies). Also, the frictional resistance to flow is multiplied byFW2, and the convective heat transfer coefficient found for laminar flow in a rectangular channelis divided by FH. The random hot channel factors FBULK, FFILM and FFLUX are not used inthis solution.Having obtained the above solution, the random hot channel factors FBULK, FFILM and FFLUXare applied to the temperatures obtained, using the following equations. The temperaturescalculated with all six hot channel factors are printed after the above solution. The onset ofnucleate boiling ratio, ONBR, is computed using the temperatures with all six hot channelfactors applied (using the equation below). If the user-input nominal power is zero, then the lastnominal power for which the code prints a solution is that at which the ONBR is 1.0.Ti,6hcf = To + (Ti- To)*FBULKTwalj,i,6hcf = Ti,6hcf + (TwaiiUi- Ti)*FFILMTmax,j,6hcf = TwaII,i,6hcf + (Tmax~i -TwaIlU)*FFLUXwhereTo = Bulk water temperature at the coolant channel inlet, i.e., the pool temperature,= Bulk water temperature in node i of the channel with only systematic hotchannel factors applied, 00Twai,i Cladding surface temperature in node i with only systematic hot channel factorsapplied, &deg;CTmax,i =Fuel meat centerline temperature in node i with only systematic hot channelfactors applied, &deg;CTI,6hof = Bulk water temperature in node i of the channel with all six hot channel factors,&deg;CTwaII,i,6hcf = Cladding surface temperature in node i with all six hot channel factors, 0CTmax,i,6hcf = Fuel meat centerline temperature in node i with all six hot channel factors, CT~o, = Incipient boiling temperature in node i with only systematic hot channel factorsapplied, CPUR-1 SARAppendix 2-3PuR- SARAppndix2-3Rev 2, July 23, 2015 Flow Rate in a Coolant Channel versus Power of a Fuel PlateNATCON is a laminar natural circulation code. The flow rate is calculated in the code bybalancing the buoyancy pressure force to the laminar friction pressure drop. Following thisconcept, an analytical relationship is developed here (with some approximation) for the coolantflow rate in a single coolant channel in terms of the power generated in a fuel plate and thechannel geometrical dimensions. The analytical relationship is needed for obtaining hot channelfactors.The hot channel factor FW used in the code to account for the uncertainty in coolant flow rate isactually applied to the laminar friction factor in the code, that is, the laminar friction factor ismultiplied by FW2.It is not applied directly to the flow rate. The relationship developed hereexplains how this technique works.p1 , T1 at channel outletIL = Channel height containing hot coolant (hotter than pool), mIP = Power in a single fuel plate or the two half plates, WIW=Upward flow rate in a single channel, kg/spo, To at channel inletSchematic of what the code analyses, that is, a single rectangular coolant channel heated by ahalf of a fuel plate on each side (right and left sides).The above schematic shows what the code analyses, that is, a single rectangular coolantchannel heated by a half of a fuel plate on each side (right and left sides). See Fig. 1 for details.The buoyancy pressure force is caused by the decrease in water density due to heating in thechannel. The temperature dependence of water density can be written as,p(T) =po -,p0,8 (T -To )(I)whereT1= Bulk water temperature at channel outlet, CAT = T1-To = Temperature rise in channel from inlet to outlet, CPUR-1 SARAppendix 2-4PUR- SARAppndix2-4Rev 2, July 23, 2015 p0 = Water density at channel inlet, i.e., the water density in the pool, kg/rn3I? = Volumetric expansion coefficient of water, per C,p = Average coolant density in the channel, kg/rn3L= Channel height that contains hotter coolant (hotter than pool), m. It is the sum ofheat generating length of fuel plate, non-heat generating fuel plate length at top,and the assembly duct length above the top of fuel plateg = Acceleration due to gravity, 9.8 m/s2The buoyancy pressure force is given byBuoyancyAp =(po -p)gL (2)The average coolant density p is given byp =O0.5 (po+p,) = p0 -0.5,po /J(T1 -To )= p0 -0.5,O p0 fAT (3)Buoyancy Ap = 0.5 p0 ,/1 AT g L (4)The coolant temperature rise AT can be written in terms of the input power P generated in afuel plate, as shown by Eq. (5) below, and then the buoyancy A p of Eq. (4) can be written interms of the input power P, as shown by Eq. (6).AT = P/ (W Cp) (5)_ o0/gLPBuoyancyAp -WC(6)Ignoring the minor losses at channel inlet and outlet, the laminar frictional pressure drop in thechannel is written below as Eq. (9) after using the laminar friction factor given by Eq. (7), andafter replacing the coolant velOcity by mass flow rate using Eq. (8). The parameter C in Eq. (7)is a constant for a given channel cross section, but it depends upon the channel cross sectionaspect ratio width/thickness, and varies from 57 for aspect ratio 1.0 (square channel) to 96 foran infinite aspect ratio (infinitely wide channel).f =C /Re (7)W= pAV (8)PUR-1 SARAppendix 2-5PUR- SARAppndix2-5Rev 2, July 23, 2015 Fritioal _ p 2 = C4ULcW(9Fritioal P 2D 2 p AD2  9wheref -Moody friction factor for laminar flow in the channelRe -Reynolds number in the channel = ,oVD/,uA = Flow area of the channel cross section, m2D = Equivalent hydraulic diameter of the channel cross section, mLc = Total coolant channel length causing frictional pressure drop, m.V = Coolant velocity averaged over the channel cross section, m/sW = Coolant mass flow rate in the channel, kg/s11 = Average coolant dynamic viscosity in the channel, N-s/rn2/u (T) = Temperature-dependent dynamic viscosity of water, N-s/rn2/-Uo =1 , (To) = Coolant dynamic viscosity at the channel inlet temperature ToFor the PUR-1 reactor, the temperature dependence of the dynamic viscosity of water over thetemperature range 27 00 < T < 50 &deg;0 can be approximated as follows.pz(T)= ,p(To) (1+T-T)0)- (10)where a = 0.12, To = 2700C, , ( To) = 0.875x10 -3 N-s/in 2The average coolant dynamic viscosity ,p used in Eq. (9) can be set equal to the viscosity atthe average coolant temperature (To + 0.5AT) in the channel. Putting this temperature in Eq.(10), the average viscosity ,u is found to be= ,p(To) (1 +0.5AT)0-. (11 )Equation (11) indicates that the average viscosity 41 can be set equal to ,p ( To) if AT is just afew 00 (this is the case for the PUR-1 reactor at the operating power of 1 kW). If AT is greaterthan a few 00, i.e., 1 <<0.5AT (this is the case for the PUR-1 reactor at an ONB power of about100 kW), then Eq. (11) simplifies to the following.PUR-1 SARAppendix 2-6PUR- SARAppndix2-6Rev 2, July 23, 20i5
+,u= ,u ( To) (0.5AT)-0i T 201aif AT >> 2 &deg;C(12a)/1u /u(To) if AT<<2 &deg;C (12b)Substituting Eq. (12a) into Eq. (9), the frictional Ap becomesFrictional Ap = C'U&deg;LcW (-'W-p' (13)21-a p AD2  21-&deg; 7 AD2\ /-, PEquating the frictional A p of Eq. (13) to the buoyancy A p of Eq. (6) to find the steady-statecoolant flow rate W in the channel, one obtains Eq. (14) below. Equation (14) can be rewrittenas Eq. (15).P0flgLP-_ C 'u-----&deg;L-W-- (-W " (14)2WCp 21-a p AD2  )W -+ p0 poAD2 /3 gLPl+a 152' CltoLc 15Equation (15) relates the fuel plate power to the channel flow rate in natural circulation. It isused to find the dependence of the flow rate on the parameter C in the laminar friction factor (atconstant power). All parameters in this equation are constant is also practically constant)except the parameter C in the laminar friction factor. Based on Eq.(15), the relationship betweenthe flow rate W and the parameter C is given by Eq. (16) below.Wcc I (16)Equation (16) shows that the friction factor parameter C is multiplied by a factor (FW)2, the2coolant flow rate W will be reduced by the factor (FW)2+a,. This has been verified by actuallyrunning the NATCON code for the PUR-1 reactor. Since a is small (a = 0.12 for the PUR-1reactor), 21(2+a) is nearly 1.0, and the flow rate W is reduced approximately by the factor FW.Bulk Coolant Temperature Rise versus Power of a Fuel PlateEquation (5) expresses, for laminar natural circulation, the bulk coolant temperature rise interms of fuel plate power, coolant flow rate and specific heat. Putting the value of flow rateobtained in Eq. (15) into Eq. (5), the bulk coolant temperature rise is given by Eq. (17) below,purely in terms of power and the geometrical dimensions of the channel. The right hand side ofEq. (17) is rearranged into two factors in Eq. (18), such that the second factor is sensitive topower and channel geometrical dimensions that usually have manufacturing tolerances andPUR-1 SARAppendix 2-7PUR- SARAppndix2-7Rev 2, July 23, 2015 measurement uncertainties, and the first factor is insensitive to power and channel geometricaldimensions.AT =::" 2;Q ---j2&#xf7; (17)'AT[C~p~po/gL .A (18)The nominal flow area and hydraulic diameter of a rectangular coolant channel are given byA = tnc Wn (1 9)P w= 2 (tnc + W ~c) (20)D = 4 A/ P~, = 2 tnc Who / (tnc + Wnc) (21)whereto = Channel thickness (spacing between fuel plates), mto = Nominal channel thickness (spacing between fuel plates), mthc = Minimum channel thickness in hot channel (spacing between fuel plates), mWc =Channel width, assumed not to change from its nominal value, mPw = Wetted perimeter of the nominal channel, mPc = Power generated in a fuel plate, without applying manufacturing tolerances, WPhc = Power generated in a fuel plate, after applying manufacturing tolerances, WBecause the channel thickness to, is much smaller than the channel width Wc in mostexperimental reactors, Eq. (21) reduces too 2 tc, (22)Using the channel area and hydraulic diameter given by Eqs. (19) and (22) into Eq. (18), thebulk coolant temperature rise can be written in terms of power, channel thickness, and channelwidth. This is the desired relationship for use in finding hot channel factors.PUR-1 SAP,Appendix 2-8PUR- SARAppndix2-8Rev 2, July 23, 2015
+-- --CfOL -7--7_- 1 (23)C 4w~t3Formulas for Hot Channel FactorsFor use in the NATCON version 2.0, six hot channel factors (three global/systemic and threelocal/random) are obtained from 9 manufacturing tolerances and measurement uncertainties u1,u=,..., u9 that are defined below. These are fractional uncertainties rather than percent. Of thesenine uncertainties, those affecting a particular hot channel factor are indicated in Table 1. Thesystemic hot channel factors are given by Eqs. (24) through (26), and the random hot channelfactors are given by Eqs. (27) through (29). A utility Fortran computer program NATCON_HCFand a Microsoft spreadsheet NATCON.HotChanFactors.xls have also been developed tocompute the hot channel factors using these formulas.EQ = 1 + u7  (24)FW =1 + u8  (25)FH = 1 + u9  (26)The ratio of the power generated in hot plate to its nominal power, caused by the uncertaintiesin neutronics-computed power and in U-235 mass per plate, can be written asPh...._c (1 +u1)(1+/-+u2) (27)nPoThe ratio of bulk coolant temperature rise in hot channel to the temperature rise in the nominalChannel, caused by the uncertainties in neutronics-computed power, U-235 mass per plate, andchannel thickness, is obtained from Eq. (23). Only the quantity in the second parentheses isimportant here because the quantity in the first parentheses is insensitive to these uncertainties.~h 1  (28)The uncertainty in flow distribution is assumed to reduce the channel flow to (1- U6) times theflow without this uncertainty, and therefore the bulk coolant temperature rise is increased by thefactor (1+ u6). This uncertainty in bulk coolant temperature rise is statistically combined with thatgiven by Eq. (28) to obtain the following formula for the hot channel factor FBULK for input tothe NATOON version 2.0.FBULK= 1 +, 1. -1+u2 (29)PUR-1 SARAppendix 2-9PuR- SARAppndix2-9Rev 2, July 23, 2015 The temperature drop across coolant film on the cladding surface at an axial location is given byEq. (30). Here the heat flux q" (W/m2) on the cladding surface is replaced by tf q'"/2 in terms ofthe volumetric power density q"'" (W/m3) in the fuel meat.Aflh 2h (0The convective heat transfer coefficient h (W/m2-C) is given by Eq. (31). Here the laminarNusselt number Nu is independent of flow rate, and varies only slowly with the aspect ratio(width/thickness) of coolant channel. The main variation of the heat transfer coefficient withchannel thickness is due to the denominator of Eq. (31). The numerator of Eq. (31) isconsidered to be constant.h -NKc&deg;&deg; -N"IKC&deg;&deg;! (31)D 2tcUsing Eq. (31) for the heat transfer coefficient, the temperature drop across coolant film can bewritten as Eq. (32).fil~m -Nco (32)Equation (32) states that ATift,~ is directly proportional to the fuel meat thickness (havinguncertainty u3), the channel thickness (having uncertainty u5), and the power density in meat.The uncertainty in power density is caused by three uncertainties, that is, u1, u2 and u4.Statistically combining these five uncertainties gives the following formula for the hot channelfactor FFILM for input to the NATCON version 2.0.FFILM =1+4Ul2+/-+u22+/-+u32+/-u-/452 (33)The uncertainty in the heat flux at the cladding surface is included in the hot channel factorFFILM given by Eq. (33). A hot channel factor FFLUX for the heat flux alone can be found fromEq. (34) for heat flux in terms of the power density q"'" in the fuel meat and the thickness of themeat. The fractional uncertainty in heat flux is the sum of fractional uncertainties in powerdensity and meat thickness, as given by Eq. (35).q" t- (34)2Sq"_ Sq '" Ste__ +/- fe (35)q,, q,, tfuelIn Eq. (35), the uncertainty in power density is caused by three uncertainties, that is, u1, u2 andu4.The uncertainty in the meat thickness is given by u3.Statistically combining these fouruncertainties gives the following formula for the hot channel factor FFLUX for input to theNATCON version 2.0.PUR-1 SARAppendix 2-10PUR- SARAppedix -10Rev 2, July 23, 2015 FFLUX= 1+ u12+//2 -+/-u32+u42(6(36)The uncertainty in the temperature drop ATmetal from fuel meat centerline to cladding surface isnot important in the case of the PUR-1 reactor because ATmetai is very small compared to ATritm.For example, ATmetai is 0.05 00 and ATfilm is 34.5 00 at 100 kW without any hot channel factors.Table A2-1. Uncertainties Included in the Six Hot Channel Factors Used in NATCON Version2.0 (X implies that an uncertainty affects a hot channel factor)Uncertainty Fraction FQ FW {FH FBULK FFILM FFLUXLocal or random uncertaintiesI Neutronics calculation ofXXXpower in a plate, u12 U-235 mass per plate, u2  X X X3 Local fuel meat thickness,XXu34 U-235 axial homogeneity,XX5 Coolant channel thickness,XXu56 Flow distribution amongXXchannels, u6System-wide uncertainties7 Reactor powermeasurement uncertainty, X8 Flow uncertainty due to X___uncertainty in friction_____PUR-1 SARAppendix 2-11PUR- SARAppedix -1 1Rev 2, July 23, 2015 factor, u89 Heat transfer coefficientuncertaintydue to uncertainty inNu number correlation, u9The following information was presented as answers to Requests for Additional Information(RAIs) during the conversion process. This information is not presented in the SAR chapters onthermal hydraulics.Question 2828. Appendix 1. From the information in Appendix 1 it is not clear how insignificant are thechannel inlet and outlet losses when compared to the wall shear. Please clarify.Response:The information in Appendix 1 was used only to obtain hot channel factors for input to a moredetailed thermal-hydraulic calculation using the NATCON code [Ref. 8 of the conversionproposal]. Therefore, Appendix 1 is a simplified modeling of what is calculated in detail inNATCON, and it is used only for the purpose of obtaining closed-form equations from which hotchannel factors could be found. Appendix 1 does not include the minor losses. The minor lossescalculated by NATCON are reported below, and found to be about 16% of the total frictionalpressure drop in the HEU core, and 14% of the total frictional pressure drop in the LEU core(see Table 027-1 ).The pressure drop due to inlet and outlet losses were calculated (by the NATCON code) usingloss coefficients of 0.5 and 1.0 respectively. The pressure drop due to wall shear along thechannel length is found by summing the pressure drop for each axial mesh which is calculatedusing temperature-dependent coolant viscosity and density for the axial mesh (14 meshintervals were used over the channel length in all calculations). The pressure drops arecalculated by NATCON assuming fully developed laminar flow in a rectangular cross-sectionchannel, and then multiplied by a factor FW2 (FW squared) where FW is an input which may beused to account for the increased pressure drop due to hydrodynamically developing laminarflow. In the calculations presented in the conversion proposal, FW was always set to 1.0, andthus the increased pressure drop due to developing laminar flow was not included. It is includedin the calculations presented here (Table 027-1). The method used is described below.For the most limiting fuel plate in Table 4-27 of the conversion proposal for each core (HEU andLEU), a comparison of the pressure drops due to inlet plus outlet loss and wall shear, with andwithout the effect of developing laminar flow, are tabulated in Table 027-1.NATCON calculates the Darcy-Weisbach friction factor f = C/Re for laminar flow, using a built-intable of the parameter C for different aspect ratios of the rectangular channel cross sectionPUR-1 SARAppendix 2-12PUR- SARAppedix -12Rev 2, July 23, 2015 (values of parameter C are given in the response to Question number 29). An apparent value ofthe parameter C averaged over the channel length, called Capp, was calculated using Eq. (576)of Shah and London [Ref. 2 listed at the end of all responses] to account for the increasedpressure drop due to hydrodynamically developing laminar flow in the channel. The ratio Capp/Cwas found to be 1.1105 for the 207 mil HEU channel, 1.0985 for the 197 mil LEU channel. Sincethe NATOON code multiplies the fully developed friction factor by FW2 as mentioned above, theinput FW equals 1.054 and 1.048 for the HEU and LEU channels respectively. NATCONcalculations were done using these values of FW, and the pressure drops due to inlet plus outletloss and wall shear are compared in Table Q27-1 (column B for the HEU channel, and column Ffor the LEU channel).Table Q27-1 shows that the pressure drops due to wall shear and minor losses are 84% and16%, respectively, of the total pressure drop in the HEU channel at its ONB power; and thepressure drops due to wall shear and inlet plus outlet loss are 86% and 14%, respectively, ofthe total pressure drop in the LEU channel at its ONB power.Question 2929. Appendix 1. From the information in Appendix 1 it is not clear what is the functionaldependency of the laminar friction parameter C to the channel cross-section dimensions.Provide a reference for the evaluation of C.Response:The following values (rows 1 and 2 of Table Q29-1) of the parameter C for fully developedlaminar flow in a channel of rectangular cross section versus the width-to-thickness aspect ratio(Wc/tc) of the channel are used in the NATCON code that was used in the thermal-hydraulicscalculations. The table starts from the square cross section (aspect ratio = 1.0) and goes to theinfinite value of the aspect ratio (parallel plates). In order to find the parameter C for the aspectratio of the PUR-1 reactor, the NATCON code simply interpolates between the tabulated values.The original author of the code obtained these values from an old Reference [E. R. G. Eckertand T. F. Irvine, Heat Transfer Laboratory, University of Minnesota (1957)] but these values arealso given in a textbook by Frank Incropera [Ref. 3]. These values are obtained from the closed-form analytical solution for the fully developed laminar velocity distribution in a rectangularchannel summarized by R. K. Shah and A. L. London [Ref. 2]. Equation (341) in [Ref. 2] is afitted equation to easily find the parameter C. It should be noted that the aspect ratio used in[Ref. 2] is channel thickness-to-width ratio (the reciprocal of that used in NATOON and shownbelow in Table A2-2), and the friction factor in [Ref. 2] should be multiplied by 4 to get theDarcy-Weisbach friction factor that is used in NATCON and tabulated below.Table A2-2. Friction Parameter C Used in the NATCON Codewtc 1.0 2.0 3.0 4.0 5.0 6.3 8.0 11.0 15.0 18.0 100.0C in 58.0 63.0 69.0 72.5 77.0 80.0 83.0 85.0 88.0 89.0 96.0NATCONPUR-1 SARAppendix 2-13PUR- SARAppedix -13Rev 2, July 23, 2015 C in 57.0 62.0 69.0 73.0 82.0 96.0Ref. 3C in 56.9 62.2 68.4 72.9 76.3 79.5 82.4 85.6 88.1 89.3 94.7Ref. 2Question 3030. Appendix 1. From the information in Appendix 1 in both the calculation of the channelflow and the calculation of the bulk coolant temperature rise the ratio of the coolant kinematicviscosity to density (pip) was assumed to be insensitive to temperature. Please demonstrate thevalidity of this assumption.Response:The information in Appendix 1 was used only to obtain hot channel factors for input to a moredetailed thermal-hydraulic calculation using the NATCON code [Ref. 8 of the conversionproposal]. NATCON does account for the temperature dependence of coolant viscosity anddensity in the calculation of the channel flow and the calculation of the bulk coolant temperaturerise. Therefore, Appendix 1 is a simplified modeling of what is calculated in detail in NATCON,for the purpose of obtaining closed-form equations from which hot channel factors could befound.As suggested in the question, water viscosity is temperature-dependent, i.e., it decreases withrising temperature. Appendix 1 was revised to account for the effect of temperature dependenceof viscosity on hot channel factors, and the revised Appendix 1 is enclosed herewith. Thetemperature dependence of the dynamic viscosity of water over the temperature range 27 00 <T < 50 00 (adequate for the PUR-1 reactor) can be written as follows./()= /z(T0) (1+T-T0)-0  (Al)where a=0.12To= 27 00 = Pool temperature of PUR-1,u ( To) = 0.875x10 -3 N-s/rn 2,p (T) = Temperature-dependent dynamic viscosity of water, N-s/in2As shown in the revised Appendix 1, the revised relationship between the flow rate W in achannel and the friction parameter C is given by Eq. (A2). The revised formula for hot channelfactor FBULK for bulk coolant temperature rise is given by Eq. (A3).(A2PUR-1 SARAppendix 2-14PuR- SARAppedix -14Rev 2, July 23, 2015 FRUlLu )=+, (l+u9)2+- lJ l -1} u (A3)The exponent on the right hand side of Eq. (A2) changed from 0.5 (in the conversion proposalignoring temperature dependence of p) to the revised value 1/2.12 = 0.4717. There exponentsin Eq. (A3) for EBULK also changed, e.g., from 3/2 to 3/2.12 =1.415. As a result of this revision,the hot channel factor FBULK decreased from 1.312 (in the conversion proposal) to 1.301 forthe most limiting fuel plate 262 in the HEU core. Similarly, FBULK decreased from 1.321 (in theconversion proposal) to 1.308 for the most limiting fuel plate 1348 in the LEU core. The effect ofignoring the temperature dependence of viscosity is conservative.NATCON calculations were done with these revised values of EBULK along with a value of FW> 1.0 to account for the increased friction due to developing laminar flow (in response toQuestion number 33). The results are shown in Table Q27-1 (column C for the HEU core, andcolumn G for the LEU core).As a consequence of the two effects (i.e., increased friction due to developing laminar flow andthe temperature dependence of viscosity) on hot channel factors FW and EBULK, the ONBpower of the HEU core changes from 76.3 kW (reported in the conversion proposal) to 75.9 kW,and the ONB power of the LEU core changes from 96.1 kW (reported in the conversionproposal) to 95.8 kW. The effect is small for the PUR-1 reactor.Question 3232. Appendix 1. Equation (30) has two terms and the conversion proposal states that theexpression within the parenthesis on the right hand side of the equation varies slowly comparedto the heat flux tfuel q'"/2. Demonstrate the validity of the statement with reference to the PUR-1fuel plate.Response:Equation (30) of Appendix 1 is for finding a hot channel factor for the temperature drop from themeat mid-plane to cladding surface (ATmetai). This temperature drop is very small compared tothe temperature drop from the cladding surface to bulk coolant (ATflrn). For example, in thePUR-1 HEU fuel plate 262 without hot channel factors, Ammetai iS 0.07 &deg;C and ATfi~m is 46.98 &deg;C(at meat mid-height) at a high power of 100 kW. Similarly, in the PUR-1 LEU fuel plate 1348without hot channel factors, Ammetai is 0.05 &deg;C and ATfi m is 34.5 &deg;C at a power of 100 kW.Therefore, the hot channel factor for Ammetai iS not important for PUR-1. The important hotchannel factor is the factor FFILM for ATf, m. In the case of PUR-1, ATtim is the biggercomponent (bigger than the bulk coolant temperature rise) in the total temperature rise from theinlet temperature to the cladding surface temperature at the axial level experiencing the onset ofnucleate boiling. The hot channel factor FFILM found by Eq. (29) of Appendix 1 in theconversion proposal remains unchanged. It depends on the uncertainties in q'"tfuel and channelthickness (as shown in Eq. 28), but not on the uncertainty in [tfuel/(4KfueI) + tcdad/Kclad].In short, PUR-1 is not limited by the fuel peak temperature, but by the onset of nucleate boiling,and the uncertainty in [tfuel/(4KfueI) + tclad/Kclad] is not important for PUR-1. We believe that thehot channel factor FFILM has been determined accurately.PUR-1 SARAppendix 2-15PUR- SARAppedix -15Rev 2, July 23, 2015 Question 3333. Section 4.7.2. According to Appendix 1 the systematic uncertainty in flow rate isaccounted for by applying the hot channel factor Fw to the laminar friction factor C. Explain thereason for the value of the flow friction factor Fw being unity in Tables 4-25 and 4-26.Response:As suggested in the question, a value of FW (hot channel factor for flow) greater than 1.0 shouldbe used to account for the increased frictional pressure drop due to the hydrodynamicallydeveloping laminar flow in the entrance region of the coolant channel, otherwise the code(NATCON) accounts only for the fully developed frictional pressure drop. This has been donenow and the results are presented in Table Q27-1. Since each coolant channel creates its ownbuoyancy to drive its own coolant flow, there is no uncertainty due to redistribution of a totalreactor flow rate. The loss coefficients of 0.5 and 1.0 at channel inlet and outlet are used in thecalculations. To account for the reduction in flow rate due to the hydrodynamically developinglaminar flow in the channel, the values of FW were calculated for the most limiting channels inthe HEU and LEU cores as follows.NATOON calculates the Darcy-Weisbach friction factor f = C/Re using a built-in table of theparameter C for different aspect ratios of the rectangular channel cross section (values ofparameter C are given in the answer to Question number 29). These values of parameter C arefor the fully developed laminar flow in a rectangular cross-section channel. An apparent value ofthe parameter C averaged over the channel length, called Capp, was calculated using Eq. (576)of Shah and London [Ref. 2] to account for the increased pressure drop due tohydrodynamically developing laminar flow in the channel. The ratio Capp/C was found to be1.1105 for the 207 rail HEU channel, and 1.0985 for the 197 mil LEU channel. Since theNATCON code multiplies the fully developed frictional factor by FW2, the input FW equals 1.054and 1.048 for the HEU and LEU channels respectively. The flow reduction factor is input factorFW or more accurately FW2/(2+a) FW&deg;'9434 (noting that a = 0.12 for the PUR-1 reactor asmentioned in the revised Appendix 1 enclosed herewith).The results of using these values of FW in NATCON calculations (excluding the effect oftemperature dependence of p on hot channel factors) are shown in Table Q27-1. The ONBpower of the HEU core changes to 75.8 kW from 76.3 kW reported in the conversion proposal.The ONB power of the LEU core changes to 95.7 kW from 96.1 kW reported in the conversionproposal.The channel flow indeed gets reduced by the factor FW0"9434 as expected. For the HEU plate262, the flow reduces from 0.02083 kg/s to 0.01 989 kg/s (see Table Q27-1) when the input hotchannel factor FW is changed from 1.0 to 1.054. The expected reduced flow should be0.02083/(1.054)0"9434 = 0.01982 kg/s which is close to the NATCON-calculated value of 0.01 989kg/s. For the LEU plate 1348, the flow reduces from 0.01 912 kg/s to 0.01834 kg/s (see TableQ27-1) when the input FW is changed from 1.0 to 1.048. The expected reduced flow should be0.01 912/(1 .048)0.9434 = 0.01 829 kg/s which is close to the NATCON-calculated value of 0.01834kg/s.Question 3636. Table 4-28. Define the parameter "margin to incipient boiling."PUR-1 SARAppendix 2-16PuR- SARAppedix -16Rev 2, July 23, 2015 Response:The margin to incipient boiling shown in Table 4-28 was calculated at the nominal operatingpower of PUR-1 (i.e., 1 kW), and it is the smallest value of the temperature difference (ToNg -Tw) over the coolant channel length in the hottest channel where Tw is cladding surfacetemperature with all hot channel factors applied, and TONB is the local onset-of-nucleate-boilingtemperature. This basically gives an idea of how far below the onset of nucleate boilingcondition the reactor is operating. This definition can be written as an equation as follows:whereT(z) = Bulk coolant temperature at axial position z in the channel heated by theplate power of PopFr EQ/N and applying the global hot channel factors forflow and Nusselt number of Fw and FhTwani(Z) = Cladding surface temperature at axial position z in the channel heated by aplate power of Pop~r EQ/N and applying the global hot channel factors forflow and Nusselt number of Fw and Fhq"(z) = Heat flux at position z for the plate power of Pop~r EQ/N and applying theglobal hot channel factors for flow and Nusselt number of Fw and Fhp(z) = Absolute pressure in the channel at axial position zT~nop(p(z), q"(z)Fnux) = Onset of nucleate boiling temperature at absolute pressure p(z) and heatflux q"(z)FfluxPop = Operating power of the reactor (e.g., 1 kW for PUR-1)N = Number of fuel plates in the core (e.g., 190 for PUR-1 LEU core)To = Coolant temperature at the channel inletFr = RPEAK = Radial power factor of the plate cooled by the channelFw = Hot channel factor for flow in the channelEQ = Hot channel factor for reactor powerFh =Hot channel factor for Nusselt numberFflrn = FFILM = Hot channel factor for temperature drop across the coolant film oncladding surfaceEFlux -FFLUX = Hot channel factor for heat fluxFbuIk = FBULK = Hot channel factor for bulk coolant temperature rise in thechannelPUR-1 SARAppendix 2-17PUR- SARAppedix -17Rev 2, July 23, 2015 APPENDIX 3: FUEL SPECIFICATIONSPages Appendix 3-2 through Appendix 3-62 are the specification document Specification forPurdue University Standard and Control Fuel Elements -Assembled for the Purdue UniversityReactor, idaho National Laboratory, SPC-382, Rev 1, January 27, 2007..Pages Appendix 3-63 through Appendix 3-84 are engineering drawings of the PUR-1 fueiassemblies.PUR-1 SARAppendix 3-1PuR- SARAppndix3-1Rev 2, July 23, 2015 Document ID: SPC-382Revision ID: IEffective Date: 01/24/07SpecificationSpecification for PurdueUniversity Standard andControl Fuel Elements -Assem bled for thePurdue UniversityReactorIdaho NationalLaboratoryThe INL is a U.S. Department of Energy National Laboratoryoperated by Battelle Energy Alliance.PUR-1 SARAppendix 3-2FUR- SARAppndix3-2Rev 2. July 23, 2015 INTENTIONALLY BLANKPUR-1 SARAppendix 3-3PUR- SARAppndix3-3Rev 2. July 23, 2015 Form 412.09Idenifir:IPCa82rU- PUNRDUE FUNIERITY00 Ideniie.r: ENGIE-RNGU N SI IMWDCNRLFESHO NIERN*ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: i of iiPURDUE UNIVERSITY REACTOR .CRe'. 09)Document Project File No. Revision1. Identifier: SPC-382 2. (optional): ________3. No.: 1Specification for Purdue University Standard and Control Fuel Elements -Assembled for the4. Document Title: Purdue University ReactorComments5. : .All review and approval signatures for this specification are located on DAR Number 511249.* :SIGNATURES. .........ii ,:6. 7.i 8.Type or Printed Name JSignature Organization!Signature I Code Date DisciplineSee DAR Number 506184.See DAR Number 511249.Document Control Release / .-.*9. Signature: ]' LE. o0710. Is this a Construction Specification? Yes [] No [] 11. NCR Related? Yes Lii No []Does document contain sensitive, unclassified information? [] Yes [] No If Yes, what12. category: __________13. Can document be externally distributed? Yes [] No LiArea Index14. Code: Area______ Type______ SSC ID)Review annually. Cutoff whenRecord superseded, obsolete orUniform File Disposition Retention cancelled. Destroy 75 years15. Code: 0250 16. Authority: ENVl-b-4-a Period: after cutoff.17. For QA Records Classification Only: Lifetime [-i, Nonpermanent LI-, Permanent LIItem or activity to which the QA Recordsapply: _____________________________Periodic Review Frequency: N/A Li, 5 years [], or18. Other___________________ ____Nuclear Engineering Building [] 400 Central Drive ta West Lafayette, IN 47907-2017PUR-I SAR (765) 494-5739 m Fax: (765) 494-9570 [] https:/lengineerin~dplj.N4ERev 2. July 23, 2015 Form 412.09 (Rev. 09)Ida ho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: ii of iiPURDUE UNIVERSITY REACTORINTENTIONALLY BLANKPUR-1 SARAppendix 3-5PUR- SARAppndix3-5Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 1 of 57PURDUE UNIVERSITY REACTOR[Purdue University Reactor [Specification [ DAR Number: 511249 [REVISION LOGRev. Date Affected Pages Revision Description0 05/31/06 All New Document.1 0 1/24/07 All Revised to add Program Anneal requirements and_____ ________ ____________update Drawing Titles-1- 1 4-I- + II- 4F + I.I. + I-PUR-1 SARAppendix 3-6FUR- SARAppndix3-6Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 2 of 57PURDUE UNIVERSITY REACTORCONTENTS1. SUMMARY............................................................................................... 51.1 General .............................................................................................. 52. APPLICABLE CODES, PROCEDURES, AND REFERENCES...................................... 52.1 Standards, Specifications, Drawings and Attachments.......................................... 52.1.1 Specifications and Standards ......................................................... 52.1.2 Drawings (INL)........................................................................ 83. TECHNICAL REQUIREMENTS.......................................................................... 93.1 Production Qualification.................. ......................................................... 93.1.1 Fuel Plate Qualification: .............................................................. 93.1.2 Fuel Element Qualification:......................................................... 103.1.3 Requalification: ...................................................................... 103.1.4 Operator Qualification:........................................... 113.2 Materials ........................................................................................... 123.2.1 Fuel Bearing Plates .................................................................. 123.2.2 Aluminum Weld Filler Metal: ...................................................... 123.2.3 Dummy (Non-Fueled) Plate:........................................................ 123.2.4 Material Requirements .............................................................. 133.3 Mechanical Requirements........................................................................ 133.3.1 Fuel Plate Requirements ............................................................ 133.3.2 Non-fueled (dummy) plates:........................................................ 153.3.3 Fuel Element Requirements......................................................... 153.4 Physical Properties................................................................................ 153.4.1 Fuel Plate Requirements ............................................................ 153.5 Surface Condition ................................................................................. 173.5.1 Surface Defects ...................................................................... 173.5.2 Cleanliness: .......................................................................... 173.5.3 Contamination: ....................................................................... 183.6 Marking............................................................................................ 183.6.1 Fuel Plate Identification: ............................................................ 183.6.2 Fuel Assembly Identification:....................................................... 183.6.3 Dummy Element Identification: .................................................... 193.7 Storage ............................................................................................. 193.8 Fuel Element Surface Treatment ................................................................ 19PUR-1 SAR Appendix 3-7 Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 3 of 57PURDUE UNIVERSITY REACTOR3.8.1............................................................................................ 193.8.2............................................................................................ 203.8.3............................................................................................ 203.9 Graphite Reflectors and Graphite Radiation Baskets .......................................... 203.9.1 Material: .............................................................................. 203.9.2 Assembly:............................................................................. 203.9.3 Welding: .............................................................................. 203.9.4 Identification: ........................................................................ 203.9.5 Dimensional Inspection:............................................................. 213.9.6 Surface Finish and Defects: ......................................................... 213.9.7 Storage: ............................................................................... 214. QUALITY ASSURANCE................................................................................. 214.1 Materials ........................................................................................... 224.2 Core Density....................................................................................... 224.3 Fuel Loading....................................................................................... 244.4 Fuel Homogeneity ................................................................................ 244.5 Core Configuration................................................................................ 264.6 Bond Integrity ..................................................................................... 264.6.1 Blister Anneal: ....................................................................... 264.6.2 Ultrasonic Scanning: ................................................................ 274.6.3 Metallographic Examination........................................................ 274.7 Internal Defects ................................................................................... 274.8 Surface Finish and Defects....................................................................... 284.9 Clad-Core-Clad Dimensions..................................................................... 284.10 Cleanliness......................................................................................... 294.11 Contamination..................................................................................... 294.12 Dimensional ....................................................................................... 294.12.1 Final Dimensional Inspection....................................................... 294.13 Reactor Components and Spare Fuel Element Parts........................................... 295. PACKAGING AND SHIPPING.......................................................................... 306. NOTES ...................................................................................................... 30PUR-1 SAR Appendix 3-8 Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY !Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 4 of 57PURDUE UNIVERSITY REACTOR6.1 Definitions......................................................................................... 306.2 Purchaser Tests.................................................................................... 336.3 Submittals.......................................................................................... 336.3.1 Preproduction:........................................................................ 336.3.2 Pre-repair:............................................................................. 346.3.3 Manufacturing Schedule: ........................................................... 346.3.4 Delivery Submittals: ................................................................. 346.3.5 Fuel Plate Radiographs:............................................................. 356.3.6 Core Compact Data Sheets: ......................................................... 356.3.7 Report of Production by Unapproved Process:.................................... 35APPENDIX A ...................................................................................................... 37APPENDIX B...................................................................................................... 39FIGURES1. Purdue University Fuel Plate Sampling Procedures For Destructive Tests....................... 36PUR-1 SARAppendix 3-9PUR- SARAppndix3-9Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 5 of 57PURDUE UNIVERSITY REACTOR1.SUMMARY1.1 GeneralThis specification (see def.) defines the materials, components, testing, inspection,certain processes, quality control (see def.) requirements and acceptance criteriafor the fabrication of standard and control fuel elements (see def.) and fuelelement containers for the Purdue University Reactor at Purdue University atWest Lafayette, Indiana.2. APPLICABLE CODES, PROCEDURES, AND REFERENCES2.1 Standards, Specifications, Drawings and AttachmentsThe applicable portions of the following documents as defined herein, form a partof this specification. Where there is a conflict between the documents cited andthe latest revision thereof, the supplier (see def.) shall notify the purchaser(see def.) of the conflict and use the latest revision in effect at the signing of thecontract, unless otherwise directed by the purchaser.2.1 .1 Specifications and StandardsNational Codes and StandardsASTM E 1742-00ASTM E 1417-99MIL-C-45 662RDT F6-2TAmerican Society for TestingASTM B 209-00ASTM B 210-04ASTM B 211-00ASTM B 214-99ASTM B 221-00Standard Practice for RadiographExaminationStandard Practice for Liquid PenetrantExaminationCalibration System RequirementsWelding of Reactor Core Components,Sections 1,2,3 and 6and Materials (ASTM)Standard Specification for Aluminumand Aluminum-Alloy Sheet and PlateAluminum and Aluminum-Alloy DrawnSeamless TubesStandard Specification for Aluminumand Aluminum-Alloy Bar, Rod and WireStandard Test Method for Sieve Analysisof Granular Metal PowdersStandard Specification for AluminumPUR-1 SARPUR-1 SAR ~~~Appendix 3-10 2 uy2,212. July 23,2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382 5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 6 of 5PURDUE UNIVERSITY REACTORand Aluminum-Alloy Extruded Bars,Rods, Wires, Profiles and TubesASTM B 24 1-02ASTM E 8-00ASTM E 29-93 a (1999)ASTM E 2016-99Aluminum and Aluminum-AlloySeamless Pipe and Seamless ExtrudedTubeMethods of Tension Testing of MetallicMaterialsRecommended Practice for IndicatingWhich Places of Figures are to beConsidered Significant in SpecifiedLimiting ValuesStandard Specification for IndustrialWoven Wire ClothAmerican Welding Society (AWS')AWS A5.10-1995Aluminum and Aluminum AlloyWelding Rod and Bare ElectrodesAmerican National Standards Institute (ANSI)ANSI B46.1-1994Surface TextureANSI Y14.5-1994 Dimensioning and Tolerancing forEngineering DrawingsAmerican Society of Mechanical Engineers (ASME)ASME Section V -2001,without addendumASME Section IX -2001ASME NQA- 1-1997Boiler and Pressure Vessel CodeSection VBoiler and Pressure Vessel CodeSection IXQuality Assurance Requirements forNuclear Facility ApplicationsPUR-1 SARPUR-1 SAR ~~~Appendix 3-11 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382 5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 7 of 5PURDUE UNIVERSITY REACTORIdaho National Laboratory (INL)TRTR- 11TRTR- 14IN-F-4-TRASTD 7022ASpecification for Low Enriched UraniumMetal in Test Reactor FuelSpecification for Reactor Grade LowEnriched Uranium Silicide Fuel PowderSpecification for Aluminum Powder forMatrix Material in Test Reactor FuelCleanliness Acceptance Levels forNuclear or Non-Nuclear ServiceComponentsAmerican Society for Nondestructive Test (ASNT)SNT-TC-lA (1996 or later) American Society For NondestructiveTesting (ASNT) Recommended PracticePUR-1 SARPUR-1 SAR ~~~Appendix 3-12 2 uy2,212. July 23,2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 8 of 57PURDUE UNIVERSITY REACTOR2.1.2 Drawings (JNL)635454635455635456635457635458635459635460635461635462635463635464635465Purdue University Test Research andTraining Reactor Graphite ReflectorAssembly and Source Drive AssemblyPurdue University Test Research andTraining Reactor Standard Fuel, Partial,& Dummy Element AssembliesPurdue University Test Research andTraining Reactor Control Fuel ElementAssembly and Dummy Control FuelElement AssemblyPurdue University Test Research andTraining Reactor Fission Chamber FuelElement AssemblyPurdue University Test Research andTraining Reactor Standard FuelContainer AssemblyPurdue University Test Research andTraining Reactor Control Fuel ContainerAssemblyPurdue University Test Research andTraining Reactor Irradiation FacilityAssemblyPurdue University Test Research and.Training Reactor Capsule Holder andCapsule Insert Assemblies and DetailsPurdue University Test Research andTraining Reactor Graphite ContainerAssembly, and Source Drive ContainerAssemblyPurdue University Test Research andTraining Reactor Fuel Plate Assemblyand Dummy Fuel Plate DetailPurdue University Test Research andTraining Reactor Container TubeAssembly and DetailsPurdue University Test Research andPUR-1 SARPUR-1 SAR ~~~Appendix 3-13 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1of5ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 9of5PURDUE UNIVERSITY REACTORTraining Reactor Graphite Block DetailAnd Graphite Capsule Holder Detail635466 Purdue University Test Research andTraining Reactor Miscellaneous Details635467 Purdue University Test Research andTraining Reactor Source Drive NozzleAssembly and Source Drive Top635468 Purdue University Test Research andTraining Reactor Nozzle PreliminaryMachined and Fission Chamber Top3. TECHNICAL REQUIREMENTS3.1 Production QualificationThe supplier is required to qualify the processes or portions of the process or beexempt from same by written approval of the purchaser. In qualifcation (seedef.), only materials that comply with this specification shall be used.Qualification processes, equipment, and operator qualificationltraining programsshall be identical to those used during production (see def.). To qualify, thesupplier must demonstrate, to the satisfaction of the purchaser, that the process iscapable of producing a product, which satisfies all the requirements of thespecifications. Assembly of production fuel elements shall not be initiated until:(1) all required data, to assure compliance with the qualification requirements, hasbeen submitted to the purchaser; (2) data and records required by Section 6.3 havebeen submitted; and (3) written approval of qualification has been received by thesupplier from the purchaser.3.1.1 Fuel Plate Qualification:Fuel plate (see def.) qualification shall be satisfied by supplierproduction of a minimum of two consecutively produced plate lots (seedef.), in lot quantities of 24 plates (see def.). The plates shall be madeusing low enriched uranium in the form of Silicide (see def.) powder,which have a yield of no less than 65% acceptable fuel plates meeting allapplicable requirements of this specification. The supplier may combinethe results of two consecutive lots into a production run in determiningthe 65% yield requirement provided that there have been no changes inthe manufacturing (see def.) procedure (see def.) between lots whichwould require requalifcation (see def.) in accordance with Section 3.1.3.PUR-1 SARPUR-1 SAR ~~~Appendix 3-14 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 10of5PURDUE UNIVERSITY REACTORIn the event that fuel plate qualification has been performed by thesupplier meeting all the requirements of this specification during the pasttwelve months, and qualified operators are performing the fabrication,fuel plate qualification requirements listed above will be waived.Fuel plates made in development (see def.) (prior to and includingqualification runs that fail to meet the 65% yield requirements) will notbe used in fabricating production fuel elements without prior approval ofthe purchaser.3.1.2 Fuel Element Qualification:The supplier shall fabricate 1 dummy standard fuel element assembly(see def.), which shall meet the requirements of this specification.3.1.3 Requalification:The supplier shall notify the purchaser of any proposed process change.A changed process may not be used in production until the supplier hasmet all the requirements of Section 3.1.3, submits the results and data ofthe requalification effort, and receives written approval from thepurchaser.Requalification for any fuel plate attribute to the requirements of thespecification will be required when the processes, materials, fuelloadings, equipment or equipment operators (welding and rolling) whichhave been previously qualified are changed, unless the supplier candemonstrate to the satisfaction of the purchaser by engineeringexplanation or proof test that such changes will have no detrimentaleffect on the product.Requalification for compacting, pack (see def.) assembly, and rollingmill operators can be less than qualification basis, since the procedurehas already been established. Candidate operators who are not qualifiedfor compacting operations, pack assembly operations, and hot/coldrolling mill operations must demonstrate their abilities in performing theindividual operations they are assigned.An operator must qualify by processing two lots of fuel plates withminimum lot size of 24, for the operation he is assigned to qualify,before performing any production operation independently. Each lot offuel plates shall be processed through final inspection, with a minimumyield rate of 90% acceptable fuel plates required for the operator to betermed qualified.PUR-1 SARPUR-1 SAR ~~~Appendix 3-15 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 11of5PURDUE UNIVERSITY REACTORNOTE: Failure of an operator to qualify', because of fuel piate deviations,must be based on deviations related to the operation being qualified.The purchaser on a case-by-case basis will determine the quantitiesand sizes of requali~fication fuel plates selected to be destructivelyexamined.3.1.4 Operator Qualification:Operator qualification will be accomplished via an approved supplierinternal qualification program for the following operations:A. Arc meltingB. CompactingC. Pack assemblyD. Hot rollingB. Cold rollingF. Final machining.3.1.4.1In addition to the operations specified above, the suppliershall also show evidence of the training and competency ofthose individuals who perform any of the following fuelelement fabrication and inspection activities:A. Powder sieving, weighing, and testingB. Compact weighing, visual and dimensionalinspectionC. Fuel plate/element and component cleaningD. Fuel plate annealing operationsB. Dimensional inspection of plates, elements, andsubcomponentsF. Metallographic sample preparation and inspection0. Visual inspection of plates, elements, andsubcomponentsH. Void volume inspectionI. Fluoroscope inspection of fuel platesPUR-1 SARPUR-1 SAR ~~~Appendix 3-16 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 12 of 57PURDUE UNIVERSITY REACTORJ. Radiography and inspection of fuel plate radiographsK. Ultrasonic testing and interpretation.The individuals performing these operations shall havespecific requirements imposed on them that willdemonstrate their knowledge and ability to perform theirrespective assignments. Documented evidence of thetraining of these individuals shall be maintained and shall bemade available to the purchaser upon request.3.2 MaterialsThe material requirements for the components comprising the fuel element are asspecified on Drawings per Section 2.1.2 and requirements of this section.3.2.1 Fuel Bearin2 Plates3.2.1.1 Fuel Cores: The fuel cores (see def.) of the fuel plates shallbe uranium silicide powder dispersed in aluminum alloypowder which meet the requirements of IN.-F-4-TRA andTRTR- 14, per Section 2.1.1 of this specification.3.2.1.2 Frames and Covers: Aluminum for the frames and coverplates shall conform to ASTM B209, Alloy 606 1-0. Thealuminum plate stock used for frame and cover plates shallbe certified by the supplier to contain less than 30 PPMboron, 80 PPM cadmium, and 80 PPM lithium.The subcontractor shall furnish certified physical propertiesand chemical analyses of ingots or plates of the 6061materials to INL.3.2.2 Aluminum Weld Filler Metal:All aluminum weld filler metal shall be ER4043 as required bySpecification AWS A5.10-1995.3.2.3 Dummy (Non-Fueled) Plate:Dummy (non-fueled) plates (see def.) shall be fabricated from aluminumType 6061-0, that meets the requirements of Section 3.2.1.2.PUR-1 SARPUR-1 SAR ~~~Appendix 3-17 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSuRU UIEST- ASSEMBLEDRECoFOR THE Effective Date: 01/24/07 Page: 13 of 573.2.4 Material ReqiuirementsAll material used or contained in the product shall comply with all therequirements of this specification and Drawings per Section 2.1.2 unlessexempted by written document by the purchaser.3.3 Mechanical Requirements3.3.1 Fuel Plate Requirements3.3.1.1 Fabrication: The supplier shall furnish the details of his fuelplate rolling schedule and component cleaning process tothe purchaser for approval prior to use in productionper 6.3.1.Compacting details shall include silicide -aluminumcompacting pressure and compacting press dwell time.After hot rolling, each fuel plate shall be blister annealed perSection 4.6.1 and then cold rolled to final thickness at roomtemperature. After cold rolling operation, the fuel platesshall be subjected to program annealing. The rollingschedule shall contain, at a minimum, the following:A. Nominal plate reductionB. Minimum number of hot roll passesC. Nominal inter-pass reduction and target thicknessD. Hot rolling furnace temperatureE. Preheat time for all hot roll passesF. Final hot roll plate thicknessG. Type and frequency of roll lubricant utilizedH. Nominal cold roll reduction.I. Final cold roll thickness.Fuel plate cladding (see def.) thickness required bySection 3.3.1.4 and fuel core homogeneity requirements ofSection 4.4 are independent requirements that must be met.PUR-I SARAppendix 3-18PUR- SARAppedix -152. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 14 of 57PURDUE UNIVERSITY REACTOR3.3.1.2 Core Configuration: No fuel particles are allowed within thefuel free zones located at the ends of the plates as shown onDrawing 635463.The nominally unfueled area of each fuel plate as defined byDrawing 635463 may contain random fuel particles definedas flaking and limited in size, location, and spacing per thisSection, as determined by Section 4.5.The presence of fuel particles detected between themaximum fuel core outline and fuel plate edges and ends isallowed provided they do not violate the followingrestrictions:-One or more fuel particles, which fit in a rectangle whosearea is not more than 4x1 0-4 in2 is acceptableAND-The fuel particle(s) are no closer than 0.080 in. to anyother particle edge to edgeAND-No particle is closer to the plate edge or end than themajor dimension of the particle.Stray fuel particles (see def.) that violate the aboverequirements may be removed from fuel plate edges byfiling, provided the following:-The filed out area is no deeper into the edge of the platethan 0.050 in., no longer than 0.250 in.ANDEach filed area is at least 1.0 in. apart3.3.1.3Filing of fuel plate ends, for the removal of stray particles, isnot allowed, unless previously approved by the purchaser.Internal Defects and Bond Integrity: Metallurgical bond, asdetermined by Section 4.6 is required at interface areas ofthe finished fuel plates, specifically fuel core-to-clad andclad-to-frame. The presence of grain growth across the fuelPUR-1 SARPUR-1 SAR ~~~Appendix 3-19 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 15 of 57PURDUE UNIVERSITY REACTORmatrix-cladding interface and across the aluminumframe-cladding interface of at least 50% is required. Fuelcore defects in excess of 0.06 in. in any dimension asdetermined by Section 4.7 are not allowed.3.3.1.4 Cladding Thickness: During production, all plates will besubjected to UT mmn-clad inspection. The standard will becalibrated at the nominal 0.008-inch scan depth. The gagewill then be adjusted to a 0.010 inch scanning depth and thefuel plates will be scanned at 0.0 10 inch. Fuel plate UTtraces, which display mmi-clad indications at the 0.010-inchdepth, shall be visually compared with the 0.008-inchStandard trace. Fuel plates for which the UT reports show acomparable density of indications, or worse, than theindications displayed on the standard UT report areunacceptable. Fuel plates, which fail the 0.010-inch UTscan, shall be rescanned at 0.008 inch. Only fuel plateswhich are acceptable when rescanned at 0.008 inch shall besubmitted to the Purchaser and User for evaluation.3.3.2 Non-fueled (dummy) plates:The supplier shall use a cold rolling method to obtain plate thickness.Non-fueled (dummy) plates shall be subjected to program anneal.3.3.3 Fuel Element Reqiuirements3.3.3.1 Weldinp: All welding shall be performed using proceduresand welding personnel qualified in accordance with ASMESection IX or the criteria defined in Appendix B. Qualityacceptance of production welds shall be in accordance withAppendix B, Section 5.3.4 Physical PropertiesFuel plates shall have a core of U3 Si2 and aluminum and completed fuel platesand fuel elements shall have fuel loadings per Sections 3.4.1.2, and 3.4.1.5.3.4.1 Fuel Plate Requirements3.4.1.1 Fuel Core: The fuel core shall consist of 19.75 "0.2 weight% enriched uranium silicide powder dispersed in aluminumpowder. The uranium silicide powder shall be -100, +325U.S. standard mesh particles. However, a blend mayPUR-1 SARPUR-1 SAR ~~~Appendix 3-20 2 uy2,212. July 23,2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 16 of 57PURDUE UNIVERSITY REACTORcontain up to 35 weight percent of -325 U.S. standard meshparticles. Any powder particles greater than 100 meshparticles shall be reground such that they will go thru the100 mesh sieve. The fuel core shall be fabricated accordingto standard powder-metallurgical and roll-bondingtechniques. The supplier shall provide to the purchaser, awritten procedure for pack assembly and the initial rollingstep which describes the method used to prevent excessiveoxidation that causes non-bond of fuel core to the cladding.3.4.1.2 Fuel Loading: By using the approved supplier's method ofassigning U-23 5 content, per a detailed description as to theweighing procedure by which the supplier proposes toassign fuel plate U-235 content. Each fuel plate shallcontain 12.5 "0.35 grams U-235. The weight of each coreshall be measured and recorded to within 0.01 gram U-235based upon weight of the final compact and chemical andisotopic analysis of the constituents.3.4.1.3 Fuel Homogeneity: Fuel homogeneity requirements arelocated in section 4.4.3.4.1.4 Void Volume: In the qualification process, all fuel platesshall be inspected for void volume using the methoddescribed in Section 4.2. The percent voids in the fuel coresof all fuel plates shall be determined by the inspectionprocedure developed by the supplier. The percent voids inthe fuel cores shall be at least 3.0% and not more than11.0%.3.4.1.5 Fuel Element Requirements3.4.1.6 Fuel Loading: Assigned fuel loading for each fuel elementshall be 175.006-4.90 grams of U-235. Each Control FuelElement shall contain 100 grams of U-235. Controllimits for the method used to measure this weight areestablished at the 95% confidence level for a significantpopulation of measurements of a particular standard. TheU-235 enrichment shall be 19.75 '-0.2 weight % of totaluranium per specification TRTR- 11.PUR-1 SARPUR-1 SAR ~~Appendix 3-212.Jl3,012. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 17of5PURDUE UNIVERSITY REACTOR3.5 Surface ConditionFuel plates and completed fuel elements must comply with the surface conditionrequirements of Section 3.5.1, 3.5.2, and 3.5.3 and drawings of Section 2.1.2, perANSI B46. 1. Sanding, or any other finishing procedure that will smear thealuminum surface, will not be allowed on fuel plates unless approved by thepurchaser.3.5.1 Surface Defects3.5.1.1 Compliance with surface finish and defect requirementsshall be established by 100% visual inspection of all fuelplates and elements. The surface of the finished fuel platesshall be smooth and free of gouges, scratches, pits, orremoval of metal in excess of 0.005 inch in depth. Dents inthe fuel plate shall not exceed 0.0 12 inch in depth or 0.25inch in diameter. If there is evidence of dogboning in theplates, surface defects in the dogbone (see def.) area shallnot exceed 0.003 inch in depth. No degradation of the fuelplates beyond these limits shall be permitted.3.5.1.2 Fuel Plates shall be free of stringiness, scabs, or cracks.Surface finish shall be as required by Drawing 635463.Compliance with requirements of this section shall beaccomplished by visual inspection of all fuel plates and fuelelements.3.5.1.3 Defects on fuel plate edges or ends are permissible providedthey are evaluated and acceptable to the requirements ofParagraph 3.3.1.2.3.5.1.4 Compliance with surface finish and defect requirementsshall be established by 100% visual inspection of all fuelelement containers. Fuel element containers shall be free ofsurface defects such as pits, dents, or scratches in excess of0.0 10 inch in depth and 0.12 inch in diameter or equivalentarea.3.5.2 Cleanliness:The suppliers fabrication, assembly, and storage areas used for theproduction of Purdue University fuel elements and/or components shallconform to the requirements of "controlled work area" (see def.) asdefined in Paragraph 1.3.6 of INL Standard 7022A. Cleanliness shall bePUR-1 SARPUR-1 SAR ~~~Appendix 3-22 2 uy2,212. July 23, 2015 Form 4l2.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 18 of 57PURDUE UNIVERSITY REACTORin compliance with INL Standard 7022A, Paragraphs 1.1, 1.2.3, 3.1, 3.2-b, d, i, 3.3 -d, e, 4.1.3, 4.2, and 4.3. Freon shall not be used to clean fuelelements or components.As determined by Section 4.10 of this specification, there shall be noforeign materials on the finished fuel plates or surfaces of the finishedfuel elements. All oil, metal chips, turnings, dusts, abrasives and spatter,scale, and other particles shall be removed from the fuel surfaces byprocedures which assure that the minimum cladding thickness has notbeen violated. All components shall be cleaned by a method approved bythe purchaser.3.5.3 Contamination:The surfaces of each fuel plate shall be counted or smeared and countedfor alpha-beta-gamma contamination. The alpha count shall be less thanfive dpm per 100 cm2, and the beta-gamma count shall be less than200 dpm per 100 cm2.Each fuel element shall be smeared and counted for radioactivecontamination. The alpha count shall be less than five dpm per 100 cm2,and the beta-gamma count shall be less than 200 dpm per 100 cm23.6 MarkingNOTE: All/fuel plates, fuel assemblies, and fuel element containers will bemarked per this section.3.6.1 Fuel Plate Identification:Each finished fuel plate shall be identified, as shown onDrawing 635463, by a combination of numbers and/or letters that willmaintain positive identification relative to the complete traceability tothe supplier fabrication history, including the basic material lots, heat ormetal, manufacturing cycle, and quality control phases. Theidentification number shall be stamped, etched or vibro-peened at thelocation specified by Drawing 635463. The depth of the identificationcharacters shall not exceed 0.010 in.3.6.2 Fuel Assembly Identification:rEach fuel assembly shall have an identifying number such as 07-XX (07signifying year of fabrication). The number shall be placed on thecontainer assembly as shown on Drawings 635455, 635456 and 635457.PUR-I EARPUR-l SAR ~~~Appendix 3-23 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 19 of 57PURDUE UNIVERSITY REACTORThe identification shall be stamped or entered by a method approved bythe purchaser, with two inch block characters not in excess of 0.010inches in depth. Standard assemblies should be labeled: E2, F2, G2,H2, F3, H3, E4, F4, G4, H4, F5, H5. Control assemblies should belabeled: E3, G3, and E5. The fission chamber assembly should belabeled as G5. The source assembly shall be labeled as C3. The spareStandard Assemblies should be labeled: SP-1, SP-2, SP-3. The spareControl Assembly should be labeled as SP-4.3.6.3 Dummy Element Identification:The dummy standard fuel element assembly shall have the identifyringnumber DUM-1. The number shall be placed on the container assemblyas shown on Drawing 635455. The identification shall be stamped orentered by a method approved by the purchaser, with two inch blockcharacters not in excess of 0.010 inches in depth.3.7 StorageAll fuel plates, fuel assemblies, and fuel element containers that have receivedfinal cleaning per Section 3.5.2 shall be protected in clean polyethylene containersor other containers approved by the purchaser while (1) awaiting final assembly,(2) being transferred into or being maintained in storage, or (3) being prepared forpackaging or shipment. Any material exposed to contamination shall bereinspected to the requirements of Section 3.5.3.8 Fuel Element Surface TreatmentIf boehnmite treatment is required during fuel element fabrication, the followingshall apply. After fuel elements are assembled and inspected they shall besubjected to an environment that will cause an evenly distributed boehmite layerof 0.00006 to 0.0003 in. thickness (averaged over the surface using eddy currentinstrumentation) to form on all surfaces of the entire assembly. The treatmentprocess shall be performed under controlled conditions, which shall require thesupplier to maintain a record of the thermal history of the autoclave. The recordsshall include heat charts of recorded time and temperature. Documented evidenceof the controls placed on the autoclave shall be maintained by the supplier.3.8.1 After the boehmite process has been qualified, one fuel element fromevery 2n autoclave run shall be inspected following a procedureapproved by the Purchaser.PUR-1 SARPUR-1 SAR ~~~Appendix 3-24 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 20of5PURDUE UNIVERSITY REACTOR3.8.2 Each fuel element shall have a corresponding aluminum plate coupon,made from fuel plate end crops, placed near the fuel element during theboehmite formation process. The aluminum plate coupon shall besubjected to the same environment as the fuel elements and each couponmeasured for boehmite thickness.3.8.3 Fuel elements and aluminum plate coupons subjected to the boehmiteformation process must be carefully handled to preclude scratches, dents,and gouges that would cause removal of boehmite.3.9 Graphite Reflectors and Graphite Radiation BasketsGraphite reflector assemblies (see def.) and irradiation facility assemblies (seedef.) shall be fabricated as per requirements contained in this section and indrawings 635454, 635460, 635461, and 635465.3.9.1 Material:All materials used shall comply with all the requirements of thisspecification and applicable drawings.3.9.2 Assembly:The assembly of the graphite reflector assemblies and irradiation facilityassemblies shall be as shown on the applicable drawings.3.9.3 Welding:All welding shall be performed using procedures and welding personnelqualified in accordance with ASME Section IX or the criteria defined inAppendix B. Quality acceptance of production welds shall be inaccordance with Appendix B, Section 5.3.9.4 Identification:The graphite reflector assemblies shall have identifying numbers such asGR-X placed on the side of the assembly as shown drawing 635454.The graphite reflector shall be labeled as follows: Dl, D2, D3, D4, D5,El, Fl, G1, Hl, I1, 12, 13, 14, and I5. The irradiation facility assembliesshall have identifying numbers such as IF-X placed on the side of theassembly as shown on drawing 635460. The irradiation facilityassemblies shall be labeled as follows: D6, E6, F6, G6, H6, and 16. Theidentification shall be stamped or entered by a method approved by thepurchaser, with two inch block not in excess of 0.0 10 inches in depth.PUR-1 SARPUR-1 SAR ~~~Appendix 3-25 2 uy2,212. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSuRU U VEST- ASSEMBLED ECoFOR THE Effective Date: 01/24/07 Page: 21 of 573.9.5 Dimensional Inspection:Verification of all external dimensions of the graphite reflectorassemblies and irradiation facility assemblies shall be by 100%inspection, in accordance with drawings 635454 and 635460. Alldimensions of this specification shall apply at a temperature of 75&deg;F+/-5&deg;"3.9.6 Surface Finish and Defects:The graphite reflector assemblies and irradiation facility assemblies shallbe free of surface defects such as pits, dents, scratches in excess of 0.010inch deep and 0.12 inch diameter or equivalent area.3.9.7 Storage:All graphite reflector assemblies and irradiation facility assemblies shallhave received final cleaning and shall be protected in clean polyethylenecontainers or other containers approved by the purchaser while (a) beingtransferred into storage, (b) being maintained in storage, or (c) beingprepared for shipment or packaging.4. QUALITY ASSURANCEThe supplier shall document, implement, and maintain a quality program in compliancewith ASME NQA-1-1997.The supplier shall permit the purchaser to conduct pre-award and continuing evaluationof the Quality Program.Personnel performing NDE examinations, specifically radiographic, ultrasonic, liquidpenetrant, and visual shall be certified to American Society for Nondestructive Testing(ASNT) Number SNT-TC-1A and certification documentation shall be made available tothe purchaser.Unless otherwise specified, the supplier shall be responsible for the performance of alltests and inspections required prior to submission to the purchaser of any fuel element foracceptance. Provided, however, that the performance of such tests and inspections is inaddition to, and does not limit, the right of the purchaser to conduct such other tests andinspections as the purchaser deems necessary to assure that all fuel elements are in-conformance with all requirements of this specification. Except as otherwise specified,the supplier may use for inspection purposes either his own or any commercial laboratoryacceptable to the purchaser. Records of all tests and examinations shall be kept completePUR-1 SARPUR-1 SAR ~~Appendix 3-262.Jl3,012. July 23, 2015 Forn 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 22 of 57PURDUE UNIVERSITY REACTORand available to the purchaser. All test and measuring equipment shall be calibrated perthe requirements of Standard MIL-C-45 662.The following applies to specified limits for requirements on core density perSection 3.4.1.1 and 4.2 and all dimensional requirements of this specification. Forpurposes of determining conformance with this specification an observed value or acalculated value shall be rounded off to the nearest unit in the last right hand place offigures used in expressing the limiting value in accordance with the rounding-off methodof the Recommended Practices for Designating Significant Places in Specified LimitingValues (ASTM E29).The supplier shall prepare for his use and the purchaser's approval an integratedmanufacturing and inspection test plan. The plan shall include all manufacturingoperations, equipment and tooling used, inspection requirements and gaging used, andmandatory hold points established by the purchaser.Any materials or fuel element components that are fabricated using equipment,personnel, or processes that are not in accordance with approvals as previously grantedby the purchaser are subject to rejection (see def.). A report of any such incident must besubmitted in accordance with Section 6.3.7.Fuel element inspection for shipment or rejection will be made by the on-site purchaser'srepresentative at the supplier's plant. Final fuel element acceptance will be made by thepurchaser at the User's facility.4.1 MaterialsCompliance with the material requirements of Section 3.2 shall be established bysupplier certification. A "Certification of Chemical Analysis" or a certified milltest report shall be supplied to the purchaser for each lot of material used in thefabrication of fuel elements. This certificate shall give the results of the chemicalanalysis for the material. All fuel element materials shall be traceable.4.2 Core DensityThe density of the fuel cores required in Section 3.4.1.3 shall be determined bythe Archimedes principle. During qualification of the fuel plate core void densityrequired by Section 3.4.1.3 shall be determined on all qualification fuel platessubmitted. After the particular plate type has been qualified, 100% inspection forvoid density is not required for production lots of fuel plates. For production lots,three randomly selected fuel plates from each lot shall be inspected for voidvolume density. Should any one of these plates be discrepant, the entire lot mustthen be inspected for void volume density. If void density discrepancies appearregularly in the process, the purchaser may request 100% inspection.PUR-1 SARAppendix 3-27PUR- SARAppedix -27Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 23 of 57PURDUE UNIVERSITY REACTORThe actual core volume shall be calculated by the following formula where:weight units are in grams and volumes in cubic centimeters.PALwhere:Voimmersion volume of fuel plate coreVp volume of fuel plateAL= density of aluminum used for fuel plate cladding2.715 gins/ccWp = weight of plateWc = deburred weight of fuel plate core compactPUR-1 SARAppendix 3-28PUR- SARAppedix -28Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-3 82STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 24 of 57PURDUE UNIVERSITY REACTORThe theoretical core volume shall be calculated by the following formulas:_ ( WU3Si2 + ( WA/1Vet --pA---TJwhere:Vct= calculated theoretical core volumeWU3Si2 = weight of U3Si2 powder in coreWal weight of aluminum matrix powder in corepU3Si2= density of U3Si2powder as measuredPAl= density of aluminum powder used for core matrix= 2.710 gms/ccThe void percent in the core shall be calculated using the following formula:V&deg;%=v V-vCt(10000)Vcwhere:V% = percent voids in the fuel plate core4.3 Fuel LoadingVerification of the fuel loading as specified in Section 3.4.1.2 shall be inconformance to the supplier's procedure required in Section 6.3.1.In order to determine compliance with the fuel density requirements ofSection 4.4, the U-235 loading of the fuel plate, as determined in accordance withthe procedures of Section 6.3.1, will be divided by the core volume (Vc) ascalculated by the method described in the second paragraph of Section 4.2.4.4 Fuel HomogeneityFuel core homogeneity requirements shall be complied with by a one-pieceradiograph of all fuel plates from each fuel plate lot and evaluation of theradiograph by calibrated densitometer measurements. Purchaser approved densitystandards may be used by the supplier. Fuel plates and density standards shall bePUR-1 SARAppendix 3-29FUR- SARAppedix -29Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 25 of 57PURDUE UNIVERSITY REACTORexposed simultaneously. Fuel plate density variations shall be determined bycomparison of fuel plate areas to corresponding areas of the standard.All fuel plates shall be inspected for homogeneity. Homogeneity of the fuel platecore shall be determined by radiograph film density measurements with adensitometer having a 0.080 inch aperture.When determining fuel core density from plate radiographs, the brighter theimage on the radiograph, the more dense is the uranium and the lower the numberindicated on the densitometer. The darker the image on the radiograph, the lessdense is the uranium and the larger the number indicated on the densitometer. A+30% fuel core density and a +20% fuel core density is indicated by thedensitometer readings in the suspect area being 30% or 20% lower than theaverage densitometer readings for all core locations. A -30% or a -20% fuel coredensity is indicated by the densitometer readings in the suspect area being 30% or20% higher than the average densitometer readings for all fuel core locations.Any one-half inch diameter or greater spot in the plate fuel core area, other thanthe dogbone area shall not be less in fuel density than -20% of the average fueldensity for all fuel core locations. To determine the low density of a one-half inchdiameter area, the film is maneuvered under the densitometer in the low-densityarea until the highest number possible is obtained on the densitometer. Thisnumber is recorded. Then four readings are taken one-fourth inch from this spotand symmetrical around it. The average of these five readings is compared to theaverage densitometer readings for all fuel core locations.If density standards are used, the average densitometer readings of all fuel corelocations will be replaced by the nominal density standard and comparisons willbe determined between the suspect spot on the radiograph and the -30% and-20% standards. For the +30% and +20% homogeneity overload inspection,compare the nominal density standard to the suspect area. In this casedensitometer units from nominal of the fuel plate represent the followingpercentages: -0.15 = +30%; -0.10 = +20%. Fuel plates exceeding these limits arediscrepant.For rectangular shaped, suspected discrepant areas that are evaluated to the one-half inch criteria, orient the four symmetrical readings such that worst casereadings will be taken.Between the minimum and maximum permissible fuel core length boundary, fuelunderload condition shall not be evaluated.Any indication of un-alloyed uranium as determined by radiography shall because for rejection.PUR-1 SARAppendix 3-30PUR1 SR Apenix -30Rev2. ,July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSuRU U VEST- ASSEMBLEDRE oFOR THE Effective Date: 01/24/07 Page: 26 of 57Any 0.080 inch diameter spot in the fuel plate dogbone area (area within one inchof each fuel core end) shall not be greater in fuel density than +30% of theaverage fuel density for all core locations. Any one-half inch diameter area in thedogbone area shall not be less in fuel density than -30% of the average fueldensity for all fuel core locations. The actual dogbone shall not be more than one-half inch in the longitudinal direction.Other than the dogbone areas near ends of fuel core, any one-half inch diameterarea shall not be greater in fuel density than +20% of the average fuel density forall fuel core locations. To determine the high density of a one-half inch diameterarea, the film is maneuvered under the densitometer in the high-density area untilthe lowest number possible is obtained on the densitometer. This number isrecorded. Then four readings are taken one-fourth inch from this spot andsymmetrically around it. The average of these five readings is compared to theaverage densitometer readings for all fuel core locations.Unless otherwise specified, purchaser approval of all radiographs is required priorto assembly of fuel plates into elements.4.5 Core ConfigurationEach finish-cut flat fuel plate shall be radiographed in accordance withAppendix A and evaluated for compliance with Section 3.3.1.2.Visual radiograph inspections will be performed without magnification on a lighttable having a light intensity of 450 to 600 ft-candles at the table surface and thearea darkened to give a light range of 5 to 15 ft-candles 18 in. above the lighttable with radiograph film in place on the table.4.6 Bond Integrity4.6.1 Blister Anneal:After the fuel plate has been hot rolled, it shall be heated to 9000F+130F,held at that temperature for a period of 2 hours, -15 minutes, +30 minutes,removed from furnace, and allowed to air cool.Any blisters, in the fuel core region larger than a 0.060 in. diameter or anyblister in the frame region of the fuel plate larger than 0.120 in. diametershall result in rejection of the associated fuel plate. A maximum of twoblisters less than 0.060 in. diameter is allowed in the fuel core area,provided they are more than 0.25 0 in. apart. A maximum of two blisters inany of the four sides of the picture frame (see def.)(a maximum of eight)region smaller than 0.120 in. can be tolerated providing that no blister isPUR-1 SARAppendix 3-31PUR- SARAppedix -31Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 27 of 57PURDUE UNhIVERSITY REACTORany closer to the plate edge or end or to another blister than the majordimension of the blister and no blister is closer to the plate edge or endthan 0.050 inch. When there is question as to size or location of theblisters, the acceptance or rejection of the plate shall be determined in theultrasonic inspection of Section 4.6.2.4.6.2 Ultrasonic Scanning:The finished fuel plate area shall be ultrasonically inspected incompliance with ASME Boiler and Pressure Vessel Code, Section V,Article 5, Paragraphs T-ll0, T-5 10, T-520, T-521, T-522-a, b, c, e, g, i,j, k, 1, o, T-523, T-523-1, and T-534. Any indication of discontinuity inthe fuel core region equivalent to that indicated by a 0.060 in. diameterstandard or any indication of a discontinuity in the frame region of thefuel plate equivalent to that indicated by a 0.120 in. diameter standardshall result in rejection of the associated fuel plate. Acceptance criteriafor number of blisters revealed by ultrasonic scanning are perSection 4.6.1. Any discontinuities, inside the fuel plate, other thanblisters and for which acceptance criterion is not already stated, shall bedescribed by the supplier and evaluated by the purchaser.4.6.3 Metallo~raphic Examination.During qualification, one fuel plate per lot selected for qualification perSection 3.1.1 will be sectioned per Figure 1, polished and etched, andexamined at 50x or above for bond and clad-core-clad dimensions perthe requirements of Sections 3.3.1.3 and 3.3.1.4, and Drawing 635463,respectively.If the fuel plate fails the metallographic examination for grain growth,voids, laminations, core cracking or separation, or foreign particles ormaterials, then randomly selected another plate in the lot formetallographic examination. If this plate fails the examination, reject thelot.Fuel plates selected for destruction tests may be rejected fuel plates,providing the attribute to be tested for is not affected by the cause forrejection. Reject fuel plates so used must have purchaser approval beforedestruct tests are performed.4.7 Internal DefectsAny internal defect in excess of the requirement of Section 3.3.1.3 in the fuelcore, including voids, laminations, U3Si2segregation, clumping, core cracking orPUR-1 SARAppendix 3-32PUR- SARAppedix -32Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382 5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 28 of 5PURDUE UNIVERSITY REACTORseparation, or foreign particles or materials, which is identified by anymeasurement technique, including radiography per Section 4.4, ultrasonicscanning per Section 4.6.2, or metallography per Section 4.6.3, shall be cause forrejection of the fuel plate.4.8 Surface Finish and DefectsCompliance with requirements of Section 3.5 shall be established by visualinspection of all fuel plates and fuel elements. Out-of-specification defects shallbe measured for size and depth and reported to the purchaser.4.9 Clad-Core-Clad DimensionsFuel Plate Qualification requirements of section 3.1.1 shall be established byultrasonic techniques using the purchaser-supplied, min-clad inspection gage. Allfuel plates will be subjected to ultrasonic mmn-clad inspection with the fuel coreregion scanned for each plate. Ultrasonic mmn-clad inspection shall beaccomplished by calibration of the mmn-clad gage, using the Advanced TestReactor (ATR) Standard (8E0777) scanned at the normal mode of 0.008 inches.The mmn-clad gage will then be adjusted and the fuel plates will be scanned at adepth of 0.010 inches. Ultrasonic Test (UT) traces showing fuel at the 0.010 inchdepth will be compared to the 0.008 inch standard to determine plateacceptability. If the density of indications from fuel plate exceeds the ATRstandard density of indications, the plate is rejectable.NOTE: The ATR standard is a small piece of an A TR fuel plate that has fuelparticles near the surface. It is used on the UT mmn-clad machine toindicate mmi-clad indications and compare the density of theseindications to any indications noted from a fuel plate being inspectedby UT.During the fuel plate qualification process, compliance with the requirements ofSection 3.3.1.4 shall be established by destructive analysis of one fuel plate per lotin accordance with Figure 1.After fuel plate qualification, all production plates shall be mmi-clad ultrasonicinspected at a depth of 0.010 inches. Those plates discrepant at 0.010 inches shallbe rescanned at 0.008 inches. Plates which are acceptable when re-scanned at0.008 inches shall be submitted on Information/Change Request (Form 540.33) tothe purchaser.PUR-1 SARAppendix 3-33PUR1 SR Apenix -33Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorSPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07PURDUE UNIVERSITY REACTORPage: 29 of 574.10 CleanlinessFuel plate, fuel assembly, and fuel element container cleanliness requirements ofSection 3.5.2 shall be established by visual inspection without magnification of allfuel plates, fuel assemblies, and fuel element containers.4.11 ContaminationThe surfaces of each fuel plate and fuel assembly shall be counted or smeared andcounted for alpha-beta-ganmma contamination and meet the requirements ofSection 3.5.3.4.12 DimensionalIt shall be the supplier's responsibility to assure that fabrication is performed inaccordance with all dimensions delineated in the Drawings referenced in Section2.1.2. Noncomplying design dimensions on fuel plates, fuel assemblies, and fuelelement containers (actual measurements) shall be submitted to the purchaser forreview and approval. Any discrepant component shall not be used in a fuelelement assembly unless approved.The supplier is to certify to compliance with the design dimensional requirementsdelineated in the Drawings referenced in Section 2.1.2.All dimensions of finished fuel plates, fuel assemblies and fuel element containersapply at 75&deg;F+5&deg;F.4.12.1 Final Dimensional Inspection.Dimensions required by this specification and drawings of Section 2.1.2shall be inspected using a purchaser approved sample plan and recordedon an inspection sheet with "in specification" dimensions recorded bycheck mark, "O, or actual measurements and ''out of specification''dimensions recorded as actual measurements.4.13 Reactor Components and Spare Fuel Element PartsReactor components and spare fuel element parts not assembled into fuel elementassemblies are required to be certified. The certification shall consist of materialcertification, fabrication verification, and supplier certificate of compliance to thespecification and drawing requirements. The certification documents shall besubmitted to the purchaser and user.PUR-1 SARAppendix 3-34PUR- SARAppedix -34Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 30 of 57PURDUE UNIVERSITY REACTOR5. PACKAGING AND SHIPPINGPackaging and shipping of the fuel elements shall be performed using a Purchaserapproved procedure in compliance with this section.*The purchaser shall provide shipping containers to protect the fuel elements from damage duringshipment and which conform to the applicable requirements of the Departments of Energy andTransportation, and other regulatory agencies having jurisdiction of the shipment of radioactivematerials. Re-useable shipping containers will be returned to the Supplier by the User at thePurchaser's expense.*The Supplier is responsible for loading the fuel elements into shipping containers in a sealedpolyethylene sleeve in a cleaned dry condition and free of extraneous materials.*The Supplier shall take necessary precautions during pack~aging to prevent damage to the fuelelements during shipment. Each container shall be provided with a tamper-proof seal. Loadingand shipping documents for the container shall be prepared in accordance with the applicableregulatory requirements.*The Supplier shall make arrangements for shipment to the User.6. NOTES6.1 DefinitionsFor the purpose of this specification, the following terms are identified:Batch. The amount of sulicide powder mixture which is handled as a unit ortraceable to a common step.Blended. To mix or mingle constituents of a batch.Certification. The action of determining, verifying and attesting in writing (signedby a qualified party) to the qualifications of personnel and material.Cladding. The aluminum covers bonded to the fuel core and the picture frame.Control Fuel Element Assembly. An assembly consisting of the control fuelelement container with eight fuel plates.Controlled Work Area. A work area to which access of personnel, tools, andmaterials is limited and physically controlled. Temporary enclosures may be usedwhere adjacent activities produce contamination which is detrimental to the job.PUR-1 SARAppendix 3-35PUR1 SR Apenix -35Rev2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 31 of 57PURDUE UNIVERSITY REACTORDevelopment. A determination of processes, equipment, and parameters requiredto produce a product in compliance with this specification.Dogbone Area. Thickening of the fuel core usually in the last 1/2 in. of the core,which may result in clad thinning in those areas.Dummy Fuel Element Assembly. An assembly consisting of a fuel elementcontainer with unfueled simulated dummy fuel plates.Dummy Fuel Plate. A non-fueled plate made entirely from the aluminum materialspecified in this document.Edge Clad. The distance between the edge of the fuel core and the edge of thefinished fuel plate, before any stray particles are removed, in the width directionas determined by radiography of a flat fuel plate.Failure. A condition where the fabrication process appears to be out of control ora breakdown or damage to equipment creates excessive costs and/or scheduledelays.Fuel Compact. A quantity of uranium silicide powder and aluminum powder, coldcompacted by pressing into a solid block for assembly into packs for hot roll andcold roll into fuel plates. The compacts are encased in frames and cover plates toform the pack.Fuel Assembly. An assembly of fuel plates and hardware components. Thisincludes both the standard and control fuel elements.Fuel Core. The uranium-bearing region of each Fuel Plate.Fuel Plate. The Fuel Core complete with aluminum frame and cladding.Graphite Reflector Assemblies. A component consisting of a graphite containerassembly with a graphite blockc inside.In-Process Controls. Inspections and tests made during production to ensure thatthe manufacturing processes, equipment, and personnel are producing a productmeeting specified requirements.Irradiation Facility Assemblies. A component consisting of a round tube attachedinside a graphite container assembly with graphite blocks filling the annulusbetween the tube and container. Inserted within the tube is the isotope capsuleassemblies.PUR-1 SARAppendix 3-36PUR- SARAppedix -36Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 32 of 57PURDUE UNIVERSITY REACTORLot. A group of pieces handled as a unit or material traceable to a commonprocessing step.Manufacture(ing). All fabrication, assembly, test, inspection and quality controlprocesses. Fabrication is a synonym for Manufacture.Pack. The fuel compact, picture frame, and cover plates, assembled together forhot rolling.Picture Frame. The window shaped aluminum frame, which holds the fuelcompact.Plates. See Fuel Plates.Procedure. The detailed description of the series of processes during manufactureand inspection, which follow a regular definite order (not to be construed as anoutline).Production. That phase of the program, following Qualification, during which theproduct is in Manufacture.Purchaser. Idaho National Laboratory (INL).Qualification. A demonstration that the Manufacturing process, equipment andpersonnel can produce a Product in compliance with this Specification.Quality Control. The sampling plans, inspections, tests and records required andused during Production to assure that the Product is in compliance with thisSpecification.Rejection. Materials, parts, components, or assembly products, which will not beaccepted as fulfilling the contract requirements because of noncompliance withthis Specification.Requalification. A demonstration that a single or group of manufacturingprocesses, equipment and personnel can produce a product in compliance withthis specification after the original qualification has been completed and becomesinvalid.Silicide. Uranium metal alloyed with silicon and fabricated per the requirementsof Specification TRTR-14. The word "fuel" is a synonym for Silicide.Specification. All parts and appendixes to this document, its references, drawings,and standards, as may be modified from time to time by contractual document.Standard Fuel Element Assembly. An assembly consisting of the fuel elementcontainer with fourteen (14) fuel plates.PUR-1 SARAppendix 3-37PUR- SARAppedix -37Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 33 of 57PURDUE UNIVERSITY REACTORStray Fuel Particles. Isolated fuel particles lying outside the maximum fuel coreoutline defined on Drawing 635463.Supplier. The primary vendor selected by INL to manufacture the product.User. Purdue University, at West Lafayette, Indiana.6.2 Purchaser TestsNone6.3 SubmittalsThe following data and records shall be supplied to the purchaser in the quantitiesstated. The purchaser's approval, prior to implementation, is required on thosemarked with an asterisk. All records and data shall be maintained by the supplierfor the duration of the Purdue University fuel element contract.The granting of approval by the purchaser of design, working drawings,specifications, requests, and other technical data submitted by the supplier underthe provisions of the subcontract or specification shall not affect or relieve thesupplier from such responsibility as the supplier has with respect to adequacy orcorrectness of the design, working drawings specifications, reports, and othertechnical data.6.3.1 Preproduction:Documents requiring approval must be submitted prior to productionuse. The number of copies shall be as specified by the Vendor DataSchedule. These documents include:-*A detailed description as to the weighing procedure by which thesupplier proposes to assign Plate U-235 content as required inSection 4.3.-Included in the description must be sampling, analytical, and qualitycontrol procedures; a statement as to the established accuracy andprecision of the assigned fuel plate and fuel element U-23 5 content;developmental and production data in support of the accuracy andprecision estimate; and data which at the 95% confidence level, showsthat the method used to assign U-235 values has a bias which is lessthan 0.2% relative-*A detailed description as to the manner the supplier will use to verify'the fuel Plate U-235 value as required by Section 4.3PUR-1 SARAppendix 3-38FUR- SARAppedix -38Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 34 of 57PURDUE UNIVERSITY REACTOR-*AlI fabrication, assembly, cleaning, surface treating, handling, anddecontamination procedures (not to be construed as an outline)*AlI production test, inspection, and quality control procedures,including all nondestructive and destructive tests and all standards andsampling section drawings. All data from these tests, including but notlimited to: radiographs, metallographic samples, ultrasonic testingtraces, and qualification yield rates-*All packaging, storage and shipping procedures6.3.2 Pre-repair:*All repair programs and procedures prior to use.6.3.3 Manufacturinu Schedule:*A schedule using a purchaser approved technique.6.3.3.1Reports.1. Biweekly qualifications phase summary status report. Thefirst such report shall be initiated 1 month after date ofcontract award.2. Three (3) copies of a monthly report detailing program~progress against a previously submitted schedule shall besupplied by the supplier to the purchaser. Report type,format and submittal schedule shall be as agreed uponbetween the purchaser and supplier.6.3.4 Delivery Submittals:Three copies (except as noted) of the following data and records shall besent prior to or accompany the shipments. The supplier shall maintaincopies of these records for at least 10 years and until the supplier hasreceived written approval from the purchaser for disposition or disposal:-Certification of product compliance to the requirements of thisspecification to include any test data pertaining thereto-Supplier's core compact data sheets, with individual fuel plate uraniumcomposition data including:-Serial number with batch (see def.) identificationPUR-1 SARAppendix 3-39PUR- SARAppedix -39Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSpRU UIEST- ASSEMBLEDRECoFOR THE Effective Date: 01/24/07 Page: 35 of 57Uranium contentFuel plate core weightU-23 5 enrichmentTotal quantity U-235 contentCore void density data-Individual fuel element composition data, including:Uranium contentU-235 contentSerial number of each plate in the element-Radiation count from fuel plate and fuel element exterior as required bySection 3.5.3 and 4.11. The counting period, counter, background,efficiency, and type of counter used shall be reported-List of all applicable waivers and deviations and related fuel plates orfuel elements-If performed, documented evidence of the performance and test resultsof the boehimite formation from the fuel element surface treatment perSection 3.8.6.3.5 Fuel Plate Radiographs:Fuel plate radiographs of all accepted fuel plates required by Sections 4.4and 4.5 and Appendix A shall be sent to the user.6.3.6 Core Compact Data Sheets:Supplier's fuel core compact data sheets shall be supplied to the INLQuality Assurance Representative as they are generated.6.3.7 Report of Production by Unapproved Process:Whenever the supplier's previously submitted and approved processcontrol limits are exceeded, or any material or fuel element componentsare fabricated using equipment, personnel, or processes which are notpurchaser approved, the time, nature, description, corrective action to betaken, and proposed further corrective action shall be reportedimmediately by the supplier, with a written report to the purchaser tofollow within 10 working days.PUR-1 SARAppendix 3-40PUR- SARAppedix -40Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 36 of 57PURDUE UNIVERSITY REACTOR1. T Samples. Transverse to be taken equally space along Fuel Core length.2. L Samples. Longitudinal to be taken at centerline and to include the Dogbone Area.TilT34I JLiT[- II I+/- +I IL11LL 1I I-I-I IFigure 1. Purdue University Fuel Plate Sampling Procedures For Destructive Tests.PUR-1 SARAppendix 3-41PUR- SARAppedix -41Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSpR E UIEST- ASSEMBLEDRECoFOR THE Effective Date: 01/24/07 Page: 37 of 57APPENDIX ARequirements for Radiography of Purdue University Fuel Plates1. ScopeThis specification provides requirements for radiography of Purdue University reactorfuel plates, acceptable film quality and film identification.2. RequirementsA procedure must be writt en to specify the details for achieving acceptable fuel plateradiographs. The procedure must include the requirements given in this specification.2.1 Equipment SetupThe voltage shall be 100 k.v.p. with a focal spot size of 5 mm maximum. Thedistance between the focal point and the plate shall be at least twice the length ofthe plate. The focal point shall be centered laterally and longitudinally over theplate or group of plates.2.2 Film2.2.1 The image outline shall be clear and sharp; the film shall be free of runs,streaks, scratches, blurs, and cassette defect that will affect the areacovered by the fuel plates.2.2.2 The film density of all points of the radiograph that correspond to thefuel plate border locations outside the plate core shall providedensitometer readings between 1.5 and 2.7. Film density as read over thenominal density standards shall provide densitometer readings between0.9 and 1.5.2.2.3 The film shall be extreme sensitivity, extra fine grain, high contrast,double emulsion, industrial x-ray type, (Kodak type M or equal) which isacceptable to the purchaser. Development of the film shall be inaccordance with the manufacturer's recommendation.2.2.4 Film IdentificationAppendix APUR-1 SAR Appendix 3-42 Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 38 of 57PURDUE UNIVERSITY REACTOR2.2.5 A system of identification of the film shall be provided by the supplier,which shall show as a minimum:A. Plate lot numberB. Plate type and serial numberC. Orientation of density standardD. Density standard identificationE. Date of radiography.Appendix APUR-1 SARRevA2.pJuyi23,3201PUR-1 SANRev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 39 of 57PURDUE UNIVERSITY REACTORAPPENDIX BWelding Requirements and Qualification for Purdue University FuelElements1. ScopeThe requirements for welding and for the evaluation of welds applicable to the PurdueUniversity Fuel Element Container and components are established by this Appendix.1.1 Application. This document defines requirements for the following:1.1.1 Welding procedure qualification.1.1.2 Performance qualification of welders, welding equipment, and specialfixturing.1.1.3 Information to be included in welding procedure specifications.1.1.4 Application of qualified procedures to production welding.1.1.5 Destructive testing and nondestructive examination for qualification andfor production welding.1.2 Special Limitations for Applicability. The requirements contained in thisappendix are to some degree based on RDT F6-2T. Those requirementsapplicable to Manual, GTAW, single pass, welding of Plug Joint welds, CornerJoint welds, and Partial Penetration Butt Joint welds have been included in thisappendix. The introduction of a new weld design or weld process requiring achange in these limited parameters would require an appropriate review of RDTF6-2T for requirements applicable to the new parameters.1.3 Definitions.Arc Strike. Any localized melting, heat affected zones, or change in the contour ofthe surface of the finished weld or adjacent base metal resulting from an arc orheat generated by the passage of electrical energy between the weld or base metaland a current source; such as welding electrodes, electron beams, ground clamps,high frequency arc, etc.Automatic Welding. Welding with equipment which performs the entire weldingoperation without constant observation and adjustment of controls by an operator.The equipment may or may not perform the loading and unloading of the work.Appendix BPUR-1 SAR Appendix 3-44 Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 40 of 57PURDUE UNIVERSITY REACTORFace of Weld. The exposed surface of a weld on the side from which welding wasdone.Face Reinforcement. Reinforcement of weld at the side of the joint from whichwelding was done.Heat. A single homogeneous melt of metal or alloy.Joint Penetration. The minimum depth a groove or flange weld extends from itsface into a joint, exclusive of reinforcement.Machine Welding. Welding with equipment which performs the weldingoperations under the constant observation and control of an operator. Theequipment may or may not perform the loading and unloading of the work.Position of Welding. The terms related to positions of welding for joint types andwelding processes and the position limits are defined in Section IX, ASME Boilerand Pressure Vessel Code.Repair. The process of restoring a nonconforming item characteristic to anacceptable condition, although it does not conform to a specified requirement.Rework. The process by which a nonconforming item is made to conform tospecified requirements.Root of a Joint. That portion of a joint to be welded where the members approachclosest to each other. In cross section the root of the joint may be a point, a lineor an area.Root of a Weld. The points, as shown in cross section, at which the back of theweld intersects the base metal surfaces.Root Penetration. The depth a groove weld extends into the root of a jointmeasured on the centerline of the root cross section.Root Reinforcement. Reinforcement of weld at the side opposite that from whichwelding was done.Root Surface. The exposed surface of a weld on the side opposite that from whichwelding was done.Size of a Groove Weld. The joint penetration (depth of chamfering plus rootpenetration when specified).Appendix BAppendix 3-45 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 41of5PURDUE UNIVERSITY REACTORUndercut. A groove melted into the base metal adjacent to the toe or root of aweld and left unfilled by weld metal.Underfill. A depression on the face of the weld or root surface extending belowthe surface of the adjacent base metal.Welder and Welding Operator Performance Qualification. The tests todemonstrate a welder's or welding operator's ability to produce welds meetingprescribed standards.Welder. One who is capable of performing a manual or semiautomatic weldingoperation (sometimes erroneously used to denote a welding machine).Welding Operator. One who operates machine or automatic welding equipment.Welding Procedure Qualification. The test to demonstrate that welds made by aspecified procedure can meet prescribed standards.Welding Procedure Specifcation. A written welding procedure which specifiesthe detailed methods and practices to be used in the production of a weldment andhow they shall be carried out. A specification includes all elements of aprocedure necessary to produce a satisfactory weldment. Examples of some ofthe elements included in a specification are: material used, preparation of basematerials, preheat and postheat cleaning, assembly method and sequence,fixturing, heat treatments, joint welding procedures, preweld and postweldnondestructive examinations, repair, rework, etc.Welding Procedure. The detailed methods and practices including all jointwelding procedures.2. Reference DocumentThe following documents are a part of this appendix to the extent specified herein. Theissue of a document in effect on the date of the invitation to bid, including anyamendments also in effect on that date, shall apply unless otherwise specified. Wherethis appendix appears to conflict with the requirements of a reference document, suchconflict shall be brought to the attention of the purchaser for resolution.Appendix BPUR-1 SAR Appendix 3-46 Rev 2. July 23, 2015.
+Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR TILE Effective Date: 01/24/07 Page: 42 of 57PURDUE UNIVERSITY REACTOR2.1 American Society for Testing and Materials (ASTM) Standards2.1.1 ASTM E2, Preparation of Micrograplis of Metals and Alloys2.1.2 ASTM E3, Preparation of Metallographic Specimen2.2 American Society of Mechanical Engineers (ASME) Codes2.2.1 ASME Boiler and Pressure Vessel Code, Section IX, WeldingQualifications2.3 American Welding Society (AWS) Standards2.3.1 AWS A2.2, Nondestructive Testing Symbols2.3.2 AWS A3.0, Terms and Definitions3. Weld Qualification Requirements3.1 General ReqiuirementsAppendix BPUR-1 SARRevA2.pJuyi23,3201PUR-1 SARRev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 43 of 57PURDUE UNIVERSITY REACTOR3.1.1 All welding procedures, welders, or welding machine operators shall bequalified in accordance with the provisions identified in this Appendix.3.1.2 Weld Procedure and Performance Qualification Testing previouslyqualified to these requirements under other contracts may be used.Existing records to support previously qualified procedures andpersonnel are subject to review by the purchaser.3.1.3 Base materials and filler material shall comply with the requirements ofthe drawings.3.1.4 Welding processes which satisfy the specified requirements and producethe quality required by this Appendix are permissible. Weldingprocedures which utilize fluxes and coatings shall not be used.3.1.5 Fixtures: The capability of fixtures for aligning parts shall bedemonstrated before welding of production parts is initiated. If chill barsor blocks are used, the type of material and their location with respect tothe joint shall be included in the procedure specification.3.1.6 Position of Qualification Welds. All procedure and performancequalification test welds shall be made in the same positions as forproduction welds.3.1.7 Special Conditions for Qualification Welds: All procedure andperformance qualification test welds shall be made under conditionswhich simulate the actual production welding conditions. Theseconditions shall include space limitations, joint accessibility, degree ofcomfort due to heat, position and other handicaps or environmentalfactors which the welder or welding operator will endure during actualproduction welding.3.1.8 Heat Treatment. Weld preheat and postheat treatments shall not be usedwithout prior approval by the purchaser.3.1.9 Interpass Temperature. For multi-pass weld, the weld interpasstemperature shall not be less than 60&deg; F or greater than 3500 F withoutprior approval by the purchaser.3.1.10 Records. Records of welding, associated processing, and inspectionshall be maintained for all welds. Complete records may consist ofinspection forms, routings, or reference to Operating Procedures or otherdocuments. These records shall include at least the following:Appendix BAppendix 3-48 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 44 of 57PURDUE UNIVERSITY REACTOR1. Base Material (Type, material specification, heat or lot number).2. Filler Material (Type, material specification, heat or lot number).3. Cleaning procedures.4. Joint identification and weld maps when applicable.5. Welding machine type and identification.6. Welding procedure specification.7. Welder or welding operator qualification.8. Procedure and performance qualification.9. Current-voltage data for machine or automatic welding.10. Date welds are made.11. Inert gas mixture, when applicable.12. Nondestructive examination procedure.13. Nondestructive examination personnel identification.14. Examinations and tests (nondestructive and destructive) and theresults.15. Photomacro graphs and photomicrographs.16. Metallographic specimens.17. If applicable, rework and repair of welds.18. Disposition of welds.3.2 Welding Procedure Specification3.2.1 The welding procedure specification shall meet the requirements of thisAppendix, and shall be submitted to the purchaser for information.3.2.2 The welding procedure specification shall include all essential elementsand details, as required by this section, to cover each joint to be weldedby the supplier. Each joint shall be identified in the welding procedurespecification. The specification shall include a joint design sketch forAppendix BPUR-1 SARRevA2.pJuyi23,3201PUR-1 SARRev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UN~IVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 45of5PURDUE UNIVERSITY REACTOReach joint welding procedure even if the specification references drawingnumbers.3.2.3 The following basic information and essential variables shall be includedin sufficient detail to assure that compliance with the requirements of thespecification can be verified:1. Basic Informationa. Joint Design: (the joint geometry, fit-up, and other requireddimensions of the welded j oint) tolerances and materialthickness.b. Method of arc initiationc. Electrode size (for gas tungsten arc welding)d. Gas type and flow rate (shielding and backing gas)e. Welding current range for manual weldingf. Whether tack welds or fixtures are used for assembly of thejoint for weldingg. Method and frequency of cleaningh. Number of weld layers and passesi. Whether stringer beads or weave beads are used2. Essential Variablesa. General, All Welding Processes.i.A change from a base material type or grade(materials of the same nominal chemical analysisand mechanical property range, even though adifferent product form) to any other base materialtype or grade. When joints are made between twodifferent types or grades of base material, aprocedure qualification shall be made for theapplicable combinations of materials, even thoughprocedure qualification tests have been made foreach of the two base materials welded to itself.Appendix BAppendix 3-50 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTSpRU U VEST- ASSEMBLEDRE oFOR THE Effective Date: 01/24/07 Page: 46 of 57ii. A change of filler metal type or classification to anyother type of classificationiii. A change in welding position.iv. A change in vertical welding direction, i.e., fromupward to downward or vice versa.v. The addition or omission of integral backing (e.g.,"butt-lap" type joint).vi. The addition or omission of nonfusing metalretainers.vii. The addition or omission of filler metal to the joint.viii. Any change in the method by which filler is added,such as preplaced shims, preplaced wire, preplacedconsumable inserts, wire feed, or prior weld metalsurfacing ("buttering") of one or both joint faces.ix. The addition or omission or any type of preplacedconsumable inserts or joint surfacing.x. A change in the shape or size of preplacedconsumable inserts or joint surfacing.xi. A change from multiple pass welds to single passwelds.xii. The omission of inert gas backing during welding,except that requalification is not required where aqualified welding procedure is changed to omit theinert gas backing and then is used only for a singlewelded butt joint with a backing strip, or a filletweld. For multiple pass welding, the omission ofinert gas backing during welding until three layersor 3/16 of weld metal thickness has been deposited,whichever is greatest.xiii. A change from one welding process to any otherprocess or combination of welding processes.b. Manual Welding, All Welding Processes.Appendix BAppendix 3-51 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 47 of 57PURDUE UNIVERSITY REACTOR1. An increase in the standard size of filler metal fromthat stated and qualified in the procedurespecification.ii. A change in joint geometry which violates thetolerances given for the joint geometry elementslisted below:Bevel Angle: State in procedure specification.Tolerance:- Minus 5%.Groove Angle: State in procedure specification.Tolerance: Minus 5%Alignment Tolerance: Assign value inprocedure specification. Qualify procedure forsingle welded joints using maximumpermissible misalignment in a portion of thejoint.c. Gas Tungsten Arc Process.1. A change of electrode material type.ii. A change in arc starting methods.iii. A change from a single shielding gas to any othershielding gas or to a mixture of shielding gases or achange in specified composition of gas mixture.iv. A decrease in shielded gas flow rate of more thanten percent.Appendix BAppendix 3-52 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07PURDUE UNIVERSITY REACTOR3.3 Welding Procedure QualificationPage: 48 of 573.3.1 The welding procedure shall be qualified to the requirements of thissection.3.3.2 All welding used in qualifying a welding procedure shall be performedin accordance with a welding procedure specification.3.3.3 Before any welding is performed on production components, the suppliershall qualify each proposed welding procedure by:1. Recording all essential elements of the welding procedure in awelding procedure specification (see Section 3.2)2. Verifying the welding procedure specification by welding testspecimens representing each joint to be welded in production andperforming nondestructive examination and destructive tests inaccordance with the requirements of this Appendix.3. Submitting to the purchaser, for information, the weldingprocedure specification and a certified copy of the detailed resultsobtained from the tests performed on the test welds. Themetallographic sections required by this Appendix shall also besubmitted to the purchaser.Appendix BAppendix 3-53 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 49 of 57PURDUE UNIVERSITY REACTOR3.3.4 Essential Variables. The welding procedure shall be set us as a newwelding procedure specification and shall be completely re-qualifiedwhen any of the changes listed in Section 3.2.3.2 are made in theprocedure.3.3.5 Chart Recordings. Current-voltage-time charts shall be used for eachprocedure qualification weld for automatic or machine welding.Calibrated current and voltage indicating meters may be substituted fortrace chart type equipment for manual welding. The current and voltageranges shall be recorded for manual welding.3.4 Welder Performance Qualification3.4.1 Performance qualification weld tests shall meet the requirements of thissection, except that any welder used to qualify the welding procedureshall also be considered qualified and additional performance weld testsare not required.3.4.2 General.1. The performance qualification tests are intended to determine theability of welders to make sound welds.2. The performance test may be terminated at any stage of the testingprocedure whenever it becomes apparent to the supervisorconducting the tests that the welder does not have skill required toproduce satisfactory results. In this event, the welder may be re-tested at the discretion of the supplier in accordance with 3.4.3.3. Each supplier shall maintain a record of the procedures, includingthe essential variables, under which welders are examined and theresults of the examinations.3.4.3 Qualification of Welders.1. Each welder shall pass the tests prescribed for procedurequalification except that tensile tests are not required. Theessential variables and the test results obtained by each weldershall be recorded in a Performance Qualification Test Report. Anywelder who performs acceptable welding procedure qualificationtests shall be considered qualified.2. Renewal of Qualification. Requalification of a welder is requiredwhen:Appendix BAppendix 3-54 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-3 82STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 50 of 57PURDUE UNIVERSITY REACTORa. 90 or more days have elapsed since he last producedacceptable welds using the specific welding process, orb. He has not performed acceptable welds using theproduction welding procedure.c. Any time there is a specific reason to question a welder'sability to make welds meeting the requirements of thisAppendix, requalification shall be required. Only one testweld shall be required for renewal of qualification. If thistest weld fails to meet all of the original requirements, thena complete performance requalification shall be required.3.4.4 Chart Recordings. Current-voltage-time charts shall be used for eachprocedure and performance qualification weld for automatic or machinewelding. Calibrated current and voltage indicating meters may besubstituted for trace chart type equipment for manual welding. Thecurrent and voltage ranges shall be recorded for manual welding.3.5 Welding Machine Qualification3.5.1 Performance qualification weld tests shall meet the requirements of thissection, except that any welding machine used to qualify the weldingprocedure shall also be considered qualified and additional performanceweld tests are not required.1. The performance qualification tests are intended to determine theability of welding machines to make sound welds.2. Any time there is a specific reason to question a weldingmachine's ability to make welds meeting the requirements of thisAppendix, requalification shall be required. Only one test weldshall be required for renewal of qualification. If this test weld failsto meet all of the original requirements, then a completeperformance requalification shall be required. Welding machinesused for the manual welding of any successful procedure or welderqualification tests shall be considered qualified for manual weldingof all core components covered in this Appendix.Appendix BAR Appendix 3-55 Rev 2. July 2PUR-1 SI3, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382 5STANDARD AND CONTROL FUEL Revision: 1ELEMENTSpRU UIEST- ASSEMBLEDRECoFOR THE Effective Date: 01/24/07 Page: 51 of 53.5.2 Welding machines used for the manual welding of any successful welderperformance qualification tests shall be considered qualified for manualwelding of all components covered in this session.3.6 Examination & Tests3.6.1 Type of Test Required. The following tests shall be used for thequalification of welding procedures and / or welders as applicable:1. Nondestructive examination by a liquid penetrant method.2. Nondestructive examination by Visual to test for soundness andsurface characteristics of the weld.3. Destructive examination by sectioning for metallo graphicexamination of weld joints and adjacent areas to test for fusion,weld geometry, weld reinforcement, and soundness of the weld.4. When the purchaser has reason to believe that the quality of anyweldment is doubtful, he may require additional inspection.5. Nondestructive Examination and Testsa. Visual. The test weld shall be examined visually prior towelding and after welding in accordance with Section 5.1b. Liquid Penetrant. The test weld shall be examined after the.final layer in accordance with Section 3.6.2.2 using a colorcontrast method.c. Unless otherwise specified, inspection of procedure andperformance qualification welds shall be performed in thefinal surface condition.6. Destructive Examination. Each test weld shall be sectionedtransversely to metallographically examine a minimum of:a. Three section faces for welds on cylindrical componentsless than 1 'A inch in diameter or for welds that are one tofour inches long on non-cylindrical components.b. Four sections faces for welds in cylindrical componentsthat are greater than 11/4'/ inch in diameter or for welds thatare greater than four inches long on non-cylindricalcomponents.Appendix BARAppendix 3-56 Rev 2. July2PUR-1 St.33, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -. ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 52 of 57PURDUE UNIVERSITY REACTORc. One section face for plug welds, arc spot welds, and weldsthat are less than one inch long on non-cylindricalcomponents.d. The cross section shall be polished and etched to provideclear definition of the structure in the fusion zone and theheat-affected zones.e. For welds in (a) and (b) of this paragraph, one cross sectionshall be made through a weld start and a weld stop area andthe remaining sections shall be made at random. For welddescribed in (c) of this paragraph, the cross section shall bemade at the approximate centerline of the weld.Examination of the welds shall be in accordance withSection 3.6.2.3.3.6.2 Acceptance Criteria for Qualification Test Welds1. Visual Examination. Visual examination shall be in accordancewith Section 5.1.2. Liquid Penetrant Examination. Unless otherwise specified, finalweld surfaces shall be examined using a color contrast method.a. For welded joints in materials less than 1/8 inch thick thefollowing relevant indications are unacceptable.1. Any cracks.ii. Linear indications.iii. Indications with dimensions exceeding 1/64 inch.iv. Rounded indication separated by 1/44 inch or lessedge-to-edge.v. Five or more rounded indications in any six squareinches of weld surface with the maj or dimension ofthis area not to exceed six inches with the areabeing taken in the most unfavorable locationrelative to the indication being evaluated.b. For all welds in materials 1/8 inch thick or greater, thefollowing relevant indications are unacceptable. (OnlyAppendix BAppendix 3-57 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382of5STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THlE Effective Date: 01/24/07 Page: 53of5PURDUE UNIVERSITY REACTORthose indications with maj or dimensions greater than 1/64inch are considered relevant for item (iii).)1. Any cracks.ii. Any linear indications.iii. Rounded indications with dimensions exceeding 10percent of the nominal weld thickness or 1/8 inch,whichever is smaller. Rounded indicationsseparated by 1/16 or less edge-to-edge shall beevaluated as a single indication.iv. Four or more rounded indications in a line separatedby 1/16 inch or less edge-to-edge.v. Six or more indications in any six square inches ofweld surface with the major dimension of this areanot to exceed six inches with the area taken in themost unfavorable location relative to the indicationsbeing evaluated.vi. Aligned indications in which the average of thecenter-to-center distance between any oneindication and the two adjacent indications in astraight line is less than 3/16 inch.3. Metallo graphic Examination Metallographic examinations shall beperformed on qualification test welds at not less than 50X on testwelds as required in this Section in accordance with ASTM E.2.Any cross section which is shown by metallographic examinationto contain any of the following relevant defects shall be cause forrejection of the test welds.a. Any cracks.b. Incomplete fusion, or insufficient joint or root penetration.c. Any tungsten inclusions, slag inclusions, or porosity havinga maximum dimension greater than 20 percent of the weldthickness or 1/32 inch, whichever is smaller.d. More than four tungsten inclusions or pores which have a~maximum dimension less than in (c) above.Appendix BAppendix 3-58 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 54 of 57PURDUE UNIVERSITY REACTORe. Any deviation from specified weld geometry or weldreinforcement.3.6.3 Test Welds.1. Procedure and / or welder performance qualification shall be madeon test welds which duplicate the production weld joint type andwhich simulate the conditions to be used in production with respectto orientation, the essential variables listed in Section 3.2.3.2, andthe dimensions of the parts to be joined to the extent that theyaffect heat requirements, relative motions, and distortions. Allwelding used in qualifying a welding procedure and / or welderperformance shall be performed in accordance with the procedurespecification.2. For manual welding, two consecutive test welds shall be madewhen the weld joint is less than six inches in length. Only one testweld shall be required when the weld joint is 6 inches or greater inlength.3. All test welds shall be tested using the required tests listed inSection 3.6.1. To qualify the procedure specification used inmaking the test welds, each Weld shall pass the required tests.4. Repair of procedure or performance qualification test weld(s) isprohibited.4. Production WeldingAll production welding shall be accomplished using approved welding procedurespecifications and qualified welders and/or welding operators.5. Quality Acceptance of Production Welds5.1 All completed production welds shall be visually examined in accordance withthe following requirements:5.1.1 General Visual Inspection Requirements. All visual examinations shallcomply with the following:1. Visual examination shall be made under direct daylight-typefluorescent lighting of at least 100 foot-candles at the workexamination area.Appendix BPUR-1 SAR Appendix 3-59 Rev 2. July 23, 2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 55 of 57PURDUE UNIVERSITY REACTOR2. Visual examination shall be performed with the aid of a 5x(minimum) magnifying glass.3. The inspection required by this standard shall not be performed bythe welder who made the welds. However, if the welder isqualified in accordance with this standard, he may visually inspecthis own welds prior to the inspections required by this standard.4. Personnel performing visual inspection shall have 20-20 vision,natural or corrected, stereo acuity, and shall not be color-blind.5.1.2 Visual Acceptance Criteria (except for porosity). Visual examination ofweld joint preparations and welds shall be performed in accordance withthe following requirements to verify conformance to the written weldingprocedure, the design requirements, and the requirements of thisstandard:1. Prior to welding, the weld joint edges and adjacent surfaces shallbe examined for:a. Proper edge preparation, dimensions, and finish.b. Alignment and fitup of the pieces being welded.c. Verification of correct material by check of records.d. Verification of the cleanliness requirements.2. After welding, the joint shall be examined in the final surfacecondition for:a. Contour, reinforcement and surface finish of welds.b. Degree of underfill, undercut, and overlap.c. Arc strikes, weld spatter and impression marking.d. Burn-through and fuse-through3. Weld joints and surfaces which are shown by visual examination tohave any of the following defects or areas of nonconformance areunacceptable:a. Any nonconformance revealed by 5.1.2.1.Appendix BAppendix 3-60 Rev 2. July 23, 2015PUR-1 SAR Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STAN7DARD AND CONTROL FUEL Revision: 1ELEMENTS -ASSEMBLED FOR THlE Effective Date: 01/24/07 Page: 56 of 57PURDUE UNTIVERSITY REACTORb. Any zone of incomplete fusion.c. Insufficient joint or root penetration.d. Any undercutting, underfill, or burn through.e. Any concavity on the face side of groove welds.f. Any arc strikes, weld spatter, and impression marking.g. Any visible inclusions, porosity, cracks, and unfilledcraters.4. Machined welds shall meet the drawing requirements.5. All welds shall be free from surface markings resulting frommishandling, punching, scratching, etc., which exceed the specifiedsurface requirements.6. All welds shall be fiee of dross, or slag.7. All welds shall be free of oxidation due to improper shfielding andoverheating which produce black or gray spalling or looseparticles. Iridescent temper films and the dark metallic vapordeposits which may occur adjacent to the welds are acceptable.These films and deposits shall be removed by approved cleaningprocedures when accessible.5.1.3 Visible unacceptable porosity is as follows:1. Four or more pores with a major dimension of 0.048 inches ormore randomly positioned.2. A single pore with a major dimension of 0.064 inches or more.3. Six or more pores with a major dimension of 0.016 inches orgreater in one weld.4. Four or more porosity with a major dimension of 0.016 inches orgreater, in line separated by less than 0.063 inches from edge toedge.5.2 Repair of a defective weld by welding shall be limited to two attempts.Unacceptable defects shall be removed and re-examination made using liquidpenetrant color contrast method to assure complete removal of the defect. If theAppendix BANAppendix 3-61 Rev 2. July2PUR-1 Sa3,2015 Form 412.09 (Rev. 09)Idaho National LaboratorySPECIFICATION FOR PURDUE UNIVERSITY Identifier: SPC-382STANDARD AND CONTROL FUEL Revision: 1ELEMENTS -. ASSEMBLED FOR THE Effective Date: 01/24/07 Page: 57 of 57PURDUE UNIVERSITY REACTORremoval of the defects results in reducing the thickness of the weld metal belowthe thickness of the base metal, the area shall be rewelded using a welding repairprocedure which has been approved by the Purchaser. Whenever a defect isremoved and subsequent repair by welding is not required, the excavated areashall be blended into the surrounding surface to remove any sharp notches,crevices or corners. Completed repairs shall be visually re-examined per Section5.1. Records shall be maintained on all repairs and shall include the following:5.2.1 Location ofj oint.5.2.2 Location of defect.5.2.3 Description of defect, including type and size.5.2.4 Reference to approved repair procedure.5.2.5 Inspections before and after repair and the results thereof.5.2.6 Identification of repair welders or welding operators.Appendix BPUR-1 SARRevA2.pJuyi23,3201PUR-1 SARRev2. July 23, 2015 1RA.J4I 2 I 1SNOTES:1. PROCURE. FABRICATE, AND INSPECT PER SPECIFICATION SPC-382.L2MARK ASSEMBLY ISENTFItC.BT82 PER SPECIFICATION SPO-SA2.3. REMOVE AUL BURRS HAS SHARP ESGES.2 1 SHEET REV STATUS PTA 0 PHYSIS2 E LESHEETS REVISED DESCRIPTION OF ITEM 3ASSES SHEET 2;I SEEOSAR-RADE ESS2 ,&8NY1C M ~t I1/2SA/ST2 ASSES ITEM S. CHANGES MATEREAL ITEM?CHANGES ITEMS. SEE SAA-RTA7VT A/ASSDC4 CU PAILLPS, 100" 3I6 SST OR 304SST 91 635457.5 SOURCE DRIVE TOP B .A S CU PHILUPS, T00O 315 SST 7B-SB SAC-2A S I/S LU1 635482-3 SOURCE DRIVE CONTAINERA1 5 35465-1 GRAPHITE BLOCK1 R 35462-1 GRAPHITE CONTAINER3ASSEMBLYSC .5 SOURCE ERRSE SUPPORTASSEMBLY2sc 1 GRAPHITE REFLECTORASSEMBLY1Br-1 SECTIONED ISOMETRIC REFERENCE ONLYSCALE: NONE-2 FINAL-t FINALsncsoa= REOURNTR: T, VINNOU.NHARRIK 3SIG S. MORRELL PURSUE UNIVERSITYN OUDRAM TEST RESEARCH AND TRAINING REACTORTA/SM-T S.,t PROJECT SEO. IGRAPHITE REFLECTOR ASSEMBLY ANDSPA.'USS SOURCE DRIVE ASSEMBL.YPROR I PHIRSCAAPPARH ARTUI/ES 5 A FFECTAR IVTE: A/1iO NOTES ISHEET 1 OF 2I 21 SORE0VAPURS- 1 OAR Arniendix 3-63 Rev' 2, Iulv 23, 2015[ APPLE~ATUNU/bb4 7517 ''2"1Y I ' I V I "." W
+* I V I I IIDIB (2953)AX 7I2.95(3 AXC-2 ASSEMBLYSCALE: 111BVA-2 SECTIONED ISOMETRICSCALE: NONEPUR-1 SAR Appendls* 3-64 Rev 2, July 23, 2013D OIMF3 DWG-635454 20 I i., I I CA E AII A I/I&D4:j1 8765~J74I I T INOTES:1. PROCURE. FABRICATE. AND INSPECT PER SPECIFICATION SPC-3R2./MARKE ASSEMBLY IDENT1FICATION PER SPECIFICATION SPC-TBZ/.OUANTn~f OF ITEM 5 (FUEL PlATES) ANAD ITEM N (DUMMY FUE L PLATES) USED IN -U ASSE MULY(PARTIAL FUEL ASSEMBLY) TO RE DETERMINED BY THE USER.A\CHANNE L SPACING BY SIDE PLATE GROOVE LOCATIONS AND WIDTHS. ANDFUEL PLATE THICKNESS. DIRECT MEASUREMENT IS NOT REQUIRED.S. REMOVE AU. BURRS AND SHARP EDGES.i T
+* c I{ LIADDED NOTE 3 A -3 ASSY; REVISED TITLES1CHANGED TO SHOW NEW FUEL PLATE DESIGN; 140SEDADD UGUUUED ITEM B. CHARGED MATERIAL ITEM A, HHDL1UICHNGE ITEM.. ,NOTEA,,SEEO ..A.... I ....___________ -(-ID%KItVAC~-1 -2 45 B-3MAMACHINE SCREW, FLAT HD.PHIWPS, 1W0'3B TO ST8-3UUNC-UA X lI2LG --3! 6 SST BMAHN HD,A 4 4 EG PHIWPU.I1DO" 31 SST OR DR4 UST H14 AH A 6.35A3-3 DUMMY FUEL PLATE BAR 14 A 35463-1 FUELPLATEASSEMBLY 51 1 1 635454-1 STANDARD FUEL CONTAINER4SC -D DUMMY FUEL ELEMENT3SC -2 PARTIAL FUEL ELEMENTSC -I STIANDARD FUEL ELEMEN'T-ASSEMMESBAT RIOLY T 1IAEATTCETK SCAT DRUESCBPT0H AG-1 SECTIONED ISOMETRIC REFERENCE ONLYSCALE: NONE..IFNAVWIRFSRRT RESSEUSTER: T. VINNOLAam~o PURDUE UNIVERSITYTEST RESEARCH AND TRAINING REACTORSTANDARD FUEL. PARTIALU DUMMY ELEMENT ASSEMBUESFUR-I SAR AppendixE 3-65 Rev 2, July 23, 2015in~i R I7 I I PLIAWT I ,TSORP -EE. OIUT21 8765431I .........NOTES:1. PROCURE, FABRICATE, AND INSPECT PER SPECIFICATION SPC-.382.L2XA ASEMLY DNIFCTO PE DRSECFID;CAINSC-B .....T ...FUEL PLATE THICKNESS. DIRECT MEASUREMENT IS NOT REOUIRED.4. REMOVE ALL BURRS AND SHARP EDGED.RAY EFRFIN DATA.CHANGED TO SHOW NEW FUEL PLATE DESION:I ADDED -2 ASSEMBLY. SECTION A-A. B ITEM 6; 1524/07SEE SAR-N3094D0CHANGED MEATERIAL ITEM?7 CHANGED MOTE 3.ICA-1 ASSEMBLY-2 ASSEMBLYBA--SE CHANNELSUPACNG .156MACAWNE SCREW. FLAT AS. O~S B CG PHILWPS, SB0 316 SET ON34SST 7S-3D UNO-DA A 5/11 LU8 5 35AA3.3 DUMMY FUEL PLATE 61 1 S 3SH6A=11I CONTROL TOP 5B 635463- I FUEL PLATE ASSEMBLY A1 I 34B CONTROL FUEL CONTAINERASSEMBSLYSC *D DUMMY CONTROL FUEL ELEMENTASSEMBLY2SC CONTROL FUEL ELEMENTS -T ASSEMBLY1CAT. BERTPYPTIOG CA 0S TESPTE0M OS EBANBAB AU-1 SECTIONED ISOMETRIC BEFERENCEONLYSCALE: NONESECTION A-ASCALE. 1/1PUR-1 SAR Appendix 3-66 Rev 2, July 23, 2015-2 FINAL-1 FINALmua= e..7 RAOLESISR: T. VINMOLAPURDUE UNIVERSrITYTEST RESEACRH AND TRAINING REACTORCONTROL FUEL ELEMENT ASSEMBLY ANDDUMMY CONATROL FUEL ELEMENT ASSEMBLYDI01MF3 DwO-635456 2~AC I 7 I I LT A,IUTOZ1 R754321NOTES:1. PROCURE, FABRICATE, AND INSPECT PER SPECIFICATION SPC-382.L~MARK ASSEMBLY IDENTIFICATION PER SPECIFICATION SPC-382,43CHANNEL SPACING IS CNROLDBY SIDE PLATE GROOVE LOCATIONS AND WIDTHS, ANDFUEL PLATE THICTINESS. DIRECT MEASUREMENT IS NOT REQUIRED.4a REMOVE ALL BURRS AND SHARP EDGES.2 SEE DA-514751 HEIVISiNS /40REVISE TO SHOW NEW FUEL PLATE DESGN;1 REMOVED iTEMS 2,4A &7REVIESEDTITLE; 1/2407BEE DAR-SURAURREVISED NOTE SB& MATERIAL ON ITEM B0A-1 ASSEMBLYSCALE: 11'BSECTION A-ASCALE. 1/MACHINE SCREW. FLAT RD.CDPHILLIPS. ITS' 316SST OR[504SST BB-32 UNC.DA X 5/16LGB* 35468-? FISSION CHAMBER TOP A635463-1 PUEL PLATE ASSEMBLY S515458-1 STANDARD FUEL CONTAINERASS EMRBLV-U REMOVED SDC -1 EEMNTFISSION CRAMBER FUEL ASMLA(DX CHANNEL SPACING .120)-ISNNEL SPACING .130(-1 SECTIONED ISOMETRICSCALE: HONEREFERENCE ONLYPUTSUSIi FINALTRRAT D*IS RHAURSTER: T. VINNOLAottaRR AESRGN a MORRELL, ,= ,WN N.OLOHAMLISTPURDUE UNISERSITYTEAT RESEARCH AND TRAINIMO REACTONFISSION CRAMBER FUEL ELEMENT ASSEMBLYAStUR- l SAR AppendixE 367 Rev 2, July 23. 2015I.!I. I APLICATMB 1 -AlA8 7 b 41 SORRY I ElF 18764I I .... .1 NOTES:1. PROCURE, FABRICATE. ANT INSPECT PER SPECIFICATION SPC-352.2r REMOVED3. REMOVED4. REMOVE ALL RIURRS AND SHARP EDGES.5. WELD PER SPECIRCEATION SPC-352 APPENODD B. USING ITEM 7 (WELDFILLER METAL).S. AUL CORNER AND FILLET RADII ,U30 UNLESS OTHERWISE NOTED.SCRUTICAL INTERFACE DIMENSIONS SHALL BE ADHERED TO.ANVERIFY RECTANGULAR CAVITY AND SLOT SIZE WITH GO-NO-GOGAUGE. DFE PROVIDED GO-NO-GO GAUGE SHALL SLIDE FREELYTHROUGHOUT ENTIRE DESIGNATED CAVITY (OR SLOT) LENGTH FORALL ULOTS HANG-UP, STICEING. OR DISENGAGEMENT FROMSLOT.-1 ASSEMBLYSCALE: 1/1-1 ISOMETRIC VIEW REFERENCE ONLYSCALE: NONEVIEW BDEALE: 4:1VIEW C AUSCALE. 4/1VIEW ASCALE: 2/1PUR-I1 SAR Appendix 3-68 Rev 2, July 23, 2015 NOTES:1. PROCURE. FABRICATE. AND INSPECT PER SPECIFICATION SPC-382.2. REMOVED3. REMOVEDB. REMOVE ALL BURRS AND SHARP EDGES.U. WlELD PER SPECIFICATION SPC.382 APPENDIX B. USING ITEM 7 (WELDFILLER METAL).THROUGHOUT ENTIRE DESIGNATED CAVITY (OR SLOT) LENGTH FORALL SLOTS WITHOUT HANG-UP, STICKING, ON DISENGAGEMENT FROMSLOT,-1 ASSEMBLYSCALE: 1/1-1 ISOMETRIC VIEW REFERENCE ONLYSCALA: NONEjz~~VIEW C 4x,SCALE: 4/lVIEW BSCALE: 4/1VIEW ASCALE: E1PUR-1 SAR Appendix 3-69 Rev 2, July 23,2015 NOTES:1. PROCURE. FABRICATE. AND INSPECT PER SPECIFICATION SPO-,3A2.2. REMOVED3. REMOVE ALL BURRS AWD SRARP EDGES.A. WELD pER SPECIFICATION SEC-UB2 APPENODIX B, USING ITEM 7(WELD FILLER METAL). _5. REMOVED.GAUGE. OFF PROVIDED GO-MO-GO GAUGE SHALL S LIIDE FREELYENTIRE DESIGNATES CAVITY (OR SLOT) tLENGTH FONALL SLOTS PATAGUT HANG-UP. STICKING. OR DISENGAGEMENTFROM SLOT.,167/-1 ASSEMBLYSEALE III-1 ISOMETRIC VIEW REFERENCE ONLYSCALE: NONEi"WIEW AUCALE: DliVIEW C AUSCALE: A/l R7S4743NOTES:1. PROCURE. TABRRCATE, AND INSPECT PER SPECIFICATION SPC-382.ASSEMRLY IDENTFIfCATION PER SPECIFICATION SPO-3E2.3. REMOVE ALL BURRS AND SHARP EDGES.2 I 1SEE DAR-514751 REVINIONS 440REVl04100 I EFECTNEATEREVISED THE DESCRIPTION SF RTEM 3 /471SEE DAR-5UH425 /402CHANGED MATERIAL ITEM 7 4AUD.4 1 F-1 ASSEMBLYSCALE: 1,1BMACHINE SCREW, FLAT HD,A CAPHILUIPS, TOO 316 SST OR3U4 SOT 7UNC-2A 0172 LU __1 8 35461.2 CAPSULE INSERT ASSEMBLY1 635451.1 CAPSULE HOLDERHASSEMBLVY1 63S462-I GRAPHITE CONTAINER3ASSEMBLYDC -1 IRRADIATION FACILITY ASSEMELY I-1 SAFETI PART OB IIOAIELtISERE UHIE RIE,/PECFECATEH ITEIT. EIEqNTEMTI ECAET.,'P' URAE,.SRMA o..510011(1SFTI-1 SECTIONED ISOMETRIC REFERENCEONLYSCALE: NONEFINALNEXT 05TN400 B EASlN U. MORRELL PURDUE UNt~fERSITYETORiroOR TNAN OLOHAM TEST RESEARCH AND TRAINING REACTORTOOT , NTA U 0 004C so IRRADIATION FACILITY ASSEMBLY.. ...... ..... 1M owG.635460 N EBOTI 505051 1FAPI16.1 C AD Ann,.HSiY 3-71 A.RT I/O/Rh 101IS~TI F STBACUB/OE7 6 4 2 1 S2EU32876'P42,1 SD8032
+-712432I1I P 4, I.I.,ll I REASONSREV STATESNOTES:1. REMOVE ALL BURRS AND SHARP EDGSES.2. pROCURE. FABRICATE. AND INSPECT PER SPECIFICATION SPC-382.3. WELD PER SPECIFICATION SP0-322 APPENDIX R. USING ITEM 17 {WE LD FILLER METAL).4.ALL CORNER AND FILLET OTIIERISSE NOTED.ITITI1IREV IDESl.ETSj REVISED TOLERANCES ONl ITEM1%o?I I .............. IDI-_(2.755)........................... J-O SEE DETAIL3 SEE ASSC-1 ASSEMBLYSCALE IllAR AR AR AR SC ELILRMTL ER4043 AWDA5AD 17AR SC BAR. 01/)2 ASTM B211 INAL SON61.TNSTAR SC 0114 ASTM B2TT ISAL 6021-T05 1AR SC 002101t18 ASTM B211 14ALBAAI. TB51AR SC TUBING, 1 TI8OD X D05 WALL 12AL. DEI-TE ASTM B21DAR SC WALL IlALBAA61.TB ASTM 82121 C 10 PLGpLATE, 1127115 ASTM BUS IDAL 661 T-5I SC -B CAPSULE UPPER TUBE BAR, 01 31 ASTM 8211 9t S -8 CAPSUIE HOLDER TOP PLATE. I THE ASTI, BUSS 8tSC -7 CAPSULE BOTTOM PLATE. 54114TK P.574 8209 71 5 35405-2 GRAPHT CAPSULE HOLDER SSC *4 CAPSULE HOLDER TOP PLATE41 SC .3 CAPSULE HOLDER WELDMENT3ASSEMBLYSC -2 CAPSULE RNSERT ASSEMBLY 2SC .1 CAPSULE HIOLDER ASSEMBLYP0279 IBEREIELFATIO TO45 .D535A5\* "4-1 7F 5 THR..2753XH RU-LK5WOE/BOOtlNSSAEIOUHRNBAT-1 ISOMETRIC REFERENEONLYSCALE: NONEoDETAILSCALE: U11P4415SIL$-2 635460-I 635460-B.B,m 5y T.RINOLADEBA MORRELIBRBB IB*4,92 O IDA I0 c 9911 55095115*1 8RPURDUE USIVERSITYTEST RESEARCH 4245 TRAINING REACTORCAPSULE HOLDER AND CAPSULE INSERTASSAMBUES AND DETAILA1 I*'*PUJR- I SAR Appendix 3-72 ReP 2. July 23, 2015:_=='OF 3* -,^ b 31 '8 18701 a7654321D"4"4"1-3 ASSEMBLYSCALE: lt-02.6.0065 X45"8 ESDETA(255)SECTION A-ASCALE LISECTION B-BSCALE IIIB20 14-4-000~1'4- ABCBVVB~I[0]-4 ASSEMBLY-8 ISOMETRIC ONLSCALE: NONEADETAILSCALE: il1PUR-i SAR AppendLx 3-73 Roy 2, July 23. 201.5D O1MF3 ow3.635461 1[0 I b 4 1 008032U/t5421 J, ,lQ"7R1a -7 A0-u-iC'1-2 ASSEMBLYSCALE: Oit0110 IR2.750f-0 -01.040 -H01(.1O)C) DETAILBC) DETAILSCALE. 211A-2 ISOMETRIC FIEFNENCE OLYPUR-1 SAR AppendLx 3-74 Re'," 2. July 23.20150 IO1MF3' ow-356SCALE NONE PUR-i SAR Appendix 3-74 Rev 2. July 23. 2015B / 'P 4 :3 2874321 4,.7IVA91NOTES:1. REMOVE ALL BURRS AND SHARP EDGES.2. PROCURE. FABRICATE. AND INSPECT PER SPECIFICATION SP-32.3. WELD PER SPECIFICATION SPC-SJA2 APPENDSX B. USING ITEM B WEhLD F'iLLER METAL).A. ALL CORNER AND FILLET RADII .232 UNLESS OTHERWISE NOTED.4CRITICAL INTERFACE DRMENSIONS SHALL RE ADHERED TO,/~VERIFY ULAR CAVITY AND SLOT SIZE WITH GO-NO-GO DAUGE. DIV PROVIDEDGO-NO-GO GAUGE SHALL SLIDE FREE LY THIROUGHOUT ENTIRE DESIGNATED CAVITY (ORSLOT) LENGTH FOR ALL SLOTS WITHOUTY HANG-UP. STICKING. OR DISENGAGEMENT FROMSLOT.REMOVED PRIOR REV HISTORY IO4SEE ECR-55V8)R72/0REVIVED DIMENSIONS BSlD.---.---.J, m-1 ISOMETRIC REFERENCE ONLYSCALE: NONE-1, ASSEMBLY IsHOw-3 ASSEMBLY (SIMILR)AR AR SC WELDFILLERMETAL ER4043 AWEANS) BS1 -T* SOUIRCE DRIVE NOZZLE MK RMASU-ASSEMBLY MK RM656-I "' -H NOZZLE MANE FROGM B3SAHT-3 BIINCONTAINER MN RMBNS-1 N1 -TUNE ASSEMBLY MK RM656*SCS3.OURCE DRIVE CONTAINER3S -3 ASSEMBLY3-2 REMOVED2S -, GRAPHITE CONTAINERASSEMBLY14--HASN AG)5ANN-IA5NINEAGA* S!"EN T. VINNOLA PUDUE UNIVERSAITYHAHN) S, NORRELL TEST RESEARCH ANAD TRAINING REACTOR5)3.1 N. GIGISAM GRAPHITE CONTAINER ASSEMBLYISSAA E N AWJAN A. AND SOURCE DRIVE CONTAINER ASSEMBLYrnAO 3 OENNWA)P)NANLSNAV)NS t'NCE'PSAD6354621M3ISWVIEW ASCALE: FUR-I1 SAR Appendix 3-75 Rev 2, July 23, 2015VIEW B.1.I b 9 4/b4:J 8 I 7 I I4 I I 2 INOTES: I I I I..1. REMOVE ALL. BURRS AND SHARP EDGES.SE c.5837202. PROCURE. FABRICATE. AND INSPECT PER SPECIFICATTON SPC-382, SEE ECR.652525 811507I/3ALL GROOVE LOCATIONING DIMENSIONS ARE *8802 AND TOLERANCE SHALLNOT SE ACCUMULATIHE UNLESS OTHERWISE SPECIFIES. 8SEER53RL+/-WELD PREP AS NECESSARY.5.REMOVEDD/Z\TOLERANCEXXX 1.041-2RV8X.005 MAD 255722 .28_D -.1883 CZ-:2.AA cm.]oE0 .-.8 (Cm TNDR IEPLT HE O LTjBT 211C ETILL8THND8HW -0 EMVE 1-2284 __ __H__ET-1DEAI 098 N________-__PARPT__L,-E AT ~ -.84 __ ____ ___.21 ,, *622STANDARD SIDE PLATE SHEET OR PLATE ATMB2SC -1 ERGT SAND ALNIT 85361221T6G DEALETADSHSRI-IT REMOVES ID-3 GTOrRLSDETAIL RIGHTE ANS06 OPOSTE) SCMB21 -5 SPCRPLATED 82417(I) UT ASTIM 8209 5uSLEFT HND5Al.8881-T1-C 635STANDARD SIDE PDLN E.MEETEOR PLATE ANSVER 8221*6 3548 R/ LEFTDU HANDT RESEARC1.DTP8 GRfC-.3 REMOVED548 o~&#xa2;CONTROLSII 5 PLT SETDPAE STI 2213 21IREMOVED 7 4 9D6-C) DETAIL LEFT HANI SO VsowlDETAIL rnGHTIIANO(oPPosITEPUR- I SAR Appendix 3-77 Rev' 2, July 23, 2015I : &L. I 2i ZI- 2 1 Seib/00Z I.0fl.010J/-> 040045I/ .00420 4( 2260.9451242xx20 .,77.1701 2 1.3155.DETAILI //I nlnl l00.T 3400270F OX .255fo20 .25045 -'2~I. _______ I40, 2.0100)DETAILPUR-i SAR Appendix 1-70 Rev 2, July 23, 2015 1a"7R'I,2tI f I V I v * ! V I I iD-.355AL(TOP) (BOTTOM}A-AE PARALLEL WITHIN .005-11 ISOMETRIC ONLSCALE: NONECBA) DETAIL/ASCALE: 111OUR-I OAR Appendix 3-79 Rev 2, July 23, 2015D OJMF3 00S~ 63 46 6EA3EE ROTED OE0f l 0I .'"PR I ' i2. .../I::).Z,Z O"7'S55',,A5-111111 7NOTES:1. REMOVE Alt BURRS AND SHARP EDGES.2. PROCURE, FABRICATE, AND WNSPECT PER SPECIFICATION SPC-3BZ.3. WELD PER SPECIFICATION SPC-3B2 APPENDIX B USING ITEM 8 (WELD FILLER METALI.A ALL CORNER AND FILLET RADII .230 UNLESS OTHERWISE NOTED.S. REMOVEDATOLERANCE:A. IIAXCERNE I IR H NID FCNTIE0UE SY53.A-LL1LLLIZLIJREVXTATU 12~ ~ FSREVISED TITLE; REVISED ITEM 3; ADDED NOTE A;ADDED SHEET 2 & 3; ADDED ITEM 2:SEE DAR-SSBA4VX1/TAX?7TOTALLY REVISED SHEET 2C REMOVE D CHAMFER 440FROM DETAIL U. ADDED RADIUJS DIMENSION TO AlSITEM 3, REMOVED MOTE S. SEE DAR-D147513SEE ECX-551R72 T/2/07ADDED NOTE 7.ID-1 ISOMETRIC REFERENCEONLYSCALE: NOSESE .... SEE DETAIL(SSSTU = II2.i.IS .13..B1313 SEE DETAIL E1I~CI (2.5531-1 ASSEMBLYSALE: /1SR SC WELS FILLER METAL ER 4543 AWS A5.10 8_WOVEN WIRE CLOTH.SLUSC -V MESH TN16 B6MESH PER NACH, BAL ASTM E 2UISSC -3 NOZZLE PITEUMINA1Y MACHINED ALRXST. T6 ORAL 60A1-TN511 OR 3AL NXNI-TS5lSC -2 SOURCE DRIVE TOP AP L RUST-TENTf ASTM B20XASC -I SOURCE DRIVE NOZZLEASSEMBLY-T I/ST PAETISH NA'TURI.PXGCEEAIB( I7512CVI. REBFIPITIC UHSSCXVER XEHRANNE I2mi.7PM IS UST-XN1 635TARTEBBIa y 5 REOUENTRH. T. AINMOLAAXSIVIN D. MORRELLgqITIR DRAWN AS.LHAt IcL oEAV IPURDUE UNIVERISITYTEST RESEARCH AND TRAINING REACTORSOURCE DRIVE NOZZLE ASSEMBLYAND SOURCE DRT/E TOPn ] 4IAO) DETAILSCALE: 1It0DETAILSCALE; litruE- I TAIlS A[T~ERUIX 55V WET 1. IXJ~ 1.1, ~AIT APREARRA I I~EC~X~EIDIART j1c118 NOTES SUET 1 OF 3B / B A'S 4 1 SURESA87(5,1=4 7 R "7 4DX11/4-28 UNF *.381, .375(FOP){8OTTOMA)Ct 2.52*, 01 _" [ '-2 ISOMETRIC REFERENC.'E 084,VSCALE: NONET22 ~.... :_/t (.25).-2X .219.284BOX ROE'C) ETAIL L/\APUJR- I 04AR Appendix 3-81 Rev 2. July 23. 2015SSF41. NOTED 2d 3 2+ '5/00q.Z 7417 N17I IID-1 ISOMETRIC REFERENCEONLYSCALE: NONEB0 DETAIL/AAPUR- 1 SAR Appendix 3-82 Rev 2, July 23, 2015D OJMF3 owci-635467 4nolAn ati / b 9 4 1 ..... I 0-- 9/bb41 NOTES:1. REMOVE ALL BURRS AND SI-ARP EDGES.2. PROCURE, FABRICATE. AND INSPECT PER SPECIFICATION SPC-382.A AILLCORNER AND FILLET RADII D030 UN LESS OTHERWISE NOTED.4. REMOVED,/ TOLERANCE:.0031 ABA5-1 ISOMETRIC REFERENCE ONLYSCALE NONEo DETAILAPUR-l SAR Appendix 3-83 Rev 2, Jully 23, 2015 7,1,A,0O"t0DX1)4-28 UNF.- 3B 7.375(TOP) (BOTTOM)-2 ISOMETRICSCALE: NONE-- 2X .07BC) DETAIL A\SCALE: 11PUR- I SAP. Appendix 3-84 Rev 2, July 23, 2015O OJMF3 owe.635468 48A~EE NOTED EEl 2I 1 S08183A-a T -, "r 'I02
 }}

v t e Letter Sequence Request
TAC:ME1594, (Open)
Initiation Request, Request, Request, Request, Request, Request, Request, Request, Request, Request, Request, Request, Request, Request, Request Acceptance Administration Questions 24 March 2010 6 July 2011 8 July 2011 28 December 2011 29 May 2012 29 August 2014 23 December 2015 25 July 2016 Answers 4 June 2010 15 November 2011 4 January 2012 1 June 2012 15 June 2012 29 June 2012 13 July 2012 11 August 2012 29 January 2016 26 February 2016 31 March 2016 9 May 2016 19 July 2016 19 September 2016 Results Approval... Other: ML120900571, ML16265A632, ML16277A165
MONTHYEAR2012-06-29 [Table View]

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