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


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


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


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

Revision as of 16:09, 12 November 2019

Response to Question 1 of the Referenced RAI
ML11250A172
Person / Time
Site: U.S. Geological Survey
Issue date: 08/30/2011
From: Timothy Debey
US Dept of Interior, Geological Survey (USGS)
To:
Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML11250A172 (17)
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-USGS science for a changingworld Department of the Interior US Geological Survey PO Box 25046 MS 974 Denver, CO 80225-0046 August 30, 2011 U.S. Nuclear Regulatory Commission Document Control Desk Washington, DC 20555

Reference:

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

Subject:

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

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

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

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

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

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

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

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

Specific Gravity of Contents : 1.0 (Water)

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

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

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

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

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

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

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

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

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

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

Sincerely, C

Tim DeBey Qý07---

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

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

Tank Liner Copy to:

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

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

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

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

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

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

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

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

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

American Society of Mechanical Engineers (ASME)

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

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

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

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

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

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

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

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

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

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

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

Pert 2. SaOLe.

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

Pert 3. Aluminum Tank.

TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 3

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

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

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

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

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

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

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

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

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

TRIGA REACTOR TANK LINER SPECIFICATIONS

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

E. Materiale.

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

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

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

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

F. Shop Fabrication.

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

TRIGA REACTOR TANK LINER SPECIFICATIONS PAGE 5

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

.4. Testing Sequence shall be as follows:

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

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

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

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

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

TRIGA REACTOR TAN]" LINER SPECIFICATIONS PACE t

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

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

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

8.- epcrts.

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

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

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

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

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

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

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

Part 4. Aluminum Welding.

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

B. Preiaratior, of Joints.

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

TRIGA REACTOR TANK LINER SPECIFICATIONS FTM71 7

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

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

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

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

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

C. Methods and Mechanics of Welding.

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

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

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

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

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

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

TRIGA REACTORl TANI{ LINER, SPECIFICATIONS PMA C.3

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

D. Filler' Wire.

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

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

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

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

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

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

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

Part 5. Testing and ngpegt!ion.

A. RadioqE!a2hiS Inspection.

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

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

.obtained from the inspector.

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

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

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

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

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

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

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

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

E. Leak Test.

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

TRIGA REACTOR TANK LINER SPECIFICATIONS

!"ACE, 11

'-

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

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

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

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

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